Stop ferrous contamination in its tracks
Avoiding downtime; extending component life; improving operating costs; and maximising productivity of your high value heavy equipment and trucks is a constant priority. Whilst there are many factors that get in the way of you achieving these goals, fluid contamination control – in particular ferrous contamination – is a well-recognised, ongoing challenge.
Now, there’s a new, enhanced, and complementary solution and prevention to ferrous contamination.
MagShield – NEXT GENERATION BEST PRACTICE for fluid contamination control.
MagShield are experts in magnetic filtration for key fluid operating systems in heavy trucks, equipment, and machinery. We offer a range of high-quality asset protection and diagnostic solutions to capture iron contaminants not captured by existing OEM media filters.
Our solutions are now considered best practice by notable clients and equipment makers worldwide, including:
…amongst other leading companies and equipment providers.
THE MAGSHIELD DIFFERENCE
- Up to 80% reduction in equipment downtime post
- 18+% component life improvement.
- Up to 10% mechanical availability through reduction
of secondary failures post-component repair.
- 4000-hour Oil life Improvement.
Rear Wheel Group
Front Wheel Group
Client: Oil sands operation in North America
This business was losing over $1 million and 1,000 hours of downtime per year due to hydraulic system failures across a fleet of over 70 Caterpillar 797 haul trucks. Each failure cost $350,000 to repair on average.
The business installed Mag-Shields on each of their fleet vehicles to prevent hydraulic system failure wherever possible. They later reported that doing so had saved them over $6 million in just five years.
Client: Mining Company In Australia
A CAT 797F off-road truck experienced a brake failure. From past experience the operator knew follow-on failure was a risk, due to the difficulty in completely removing all contamination from the system during repairs.
After the installation of a Mag-Shield® filter, oil samples showed an immediate and significant drop in iron particulates and PQ levels. The secondary pump failure was avoided entirely, preventing expensive repair costs.
Client: Coal Mine In Alberta, Canada
This business had an average of three failures per year across a fleet of 35 Caterpillar 777 trucks. Frequent follow-on failures led to the replacement of brake components each time a pump failed, at a cost of $96,000 plus labour.
Mag-Shield® was installed to keep the system clean and prevent the brake damage. Since installation, there have been no system wide failures. Down time for repairs has been cut in half or less and ROI took less than one year.
Client: Diamond Mine In Canada
Komatsu 830E haul trucks were suffering unpredictable, expensive failures in wheel motors and front spindle bearings. The design of the GE wheel motor does not include filtration, so ferrous contamination was only controlled by oil changes.
Mag-Probe® were installed in the wheel motor filler caps and front wheel hubs to provide a baseline reading and easy diagnosis. Mag-Shield® were installed in the wheel motor sumps, extending oil life and component service life.
Client: Australian Mine
In successive failures in a number of Hitachi EX5600 excavators, contaminated fluid was entering pumps from the suction side and causing damage. False contamination sensor alarms were leading to premature component replacement.
The customer installed Mag-Shield® on a problematic excavator, and contamination was captured and prevented from spreading through the systems. Damage was avoided and frequency of contamination alarms reduced by 75%.
Client: North American Construction Group
This business was experiencing secondary failures in excavators following cylinder failures and repairs. Uncontained contamination would pass into pumps, causing pump cavitation, pump damage and costly downtime.
This client saw a ROI in just one year and large savings by installing Mag-Shields. Over five years of having these filters installed, hydraulic failure rate fell 45%, repair costs fell 52% and downtime per event fell 48%.
Client: Alberta Mine Site
Contaminated oil also causes extensive damage throughout the hydraulic and brake systems. leading to ‘Safety-critical’ hydraulic systems on Komatsu 930E.
Installation of Mag-Shield® magnetic filters provides an extra margin of safety for the steering system and significantly reduces the costs and frequency of brake and hydraulic failures.
Client: Northern Alberta Oil Sands Mine
A CAT 777D operating at a northern Alberta oil sands mine suffered a torque converter failure. This failure can be particularly catastrophic because the torque converter, braking and hoisting systems share the same hydraulic oil.
Use of Mag-Shield® resulted in reduced downtime, repair costs, premature component wear and maintenance costs.Mag-Shield® effectively captured ferrous debris from the fluid returning to the reservoir before it reached the inlet side of the system, without causing aeration, cavitation, or a restriction to fluid flow.
As professional engineer, consultant, educator and mining equipment performance researcher, I view BAY6 Solutions’ Mag-Shield® system as a major step forward in striving for best practice in mining tools hydraulic systems maintenance.
Tim Joseph, Ph.D., P.Eng., FCIM
Keeping nearly a thousand pieces of mining machinery operating requires the best reliability strategies available. Here’s why we made MagShield an integral part of our mobile equipment fleets.
Mike Hynes, Superintendent of Reliability, North American Construction Group
Our Trusted Clients
: +1 780 984 8647
Business Development Manager
: +1 780 966 8647
Neil Cropper – Australia
: +61 409 269 873
: +61 437 072 396