A national contract miner approached Geographe after finding that when rebuilding CAT 3500 engines for their fleet, the OEM engine spacers were only lasting up to 6000 hours. The corrosion from the OEM coolant was causing them to become unusable. This resulted in the engine having to be pulled out of service prematurely and our client was looking for a solution which allowed greater machine uptime.
Geographe reversed engineered the sample provided and after a spectrographic analysis, it was suggested a material change should allow the spacer to work longer with the correct engine coolant. After manufacturing some trial items and running them on a freshly rebuilt engine, the results far exceeded our client’s expectations lasting well over 3 times that of the OEM item.
The results and savings achieved:
|CAT 3500 Engine Spacer – Client Trial results||OEM||GEOGRAPHE|
|Hours lasted before removal||6000||20,000|
|Part causing leakage of coolant when removed?||Yes||No|
|Reported by client as reusable?||No – too corroded||Yes – in good condition|
|Approximate cost per spacer||$300.00 AUD||$355.00 AUD|
|Total spacer costs per engine||$4800.00 AUD||$5680.00 AUD|
|Cost per 6000hrs used||$4800.00 AUD||$1704.00 AUD|
For every engine rebuild carried out, a direct cost saving on parts alone of over $3000 AUD is achievable.
The saving is considerably larger when taking in to account the minimum of 3 x saving achieved on labour change out costs and downtime!
These spacers should be compatible with the following Caterpillar machines with a 3500 Series V16 engine:
OFF HIGHWAY TRUCKS
776D, 777, 777D, 793C, 785D, 789D, 785D, 785C, 789B, 777C, MT4400DAC, 793D, 785, 797B, 789, 797, 785B, 789C, 776C, 777B, 777DHAA, 784C
994F, 992G, 994H
D11R, D11RCD, D11N
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