Case Studies
Equipment:CAT 994K Client: Gold Mine USA
Challenges:
A CAT 994K loader at a US Gold Mine experienced a hydraulic cylinder failure which led to total contamination of the hydraulic system. The cylinder was replaced and the hydraulic system cleaned before returning the machine to service.
Due to the inherent difficulty of cleaning the hydraulic system after the initial failure, ferrous debris smaller than the micron rating of the OEM media filter continued to circulate. The resultant impact was a secondary failure of the hydraulic pump.
Solution:
After spending considerable time exploring different potential solutions, the Gold Miner decided to install a Mag-Shield® kit in the main hydraulic tank.
After a quick turnaround in delivery and easy installation, there was renewed hope that this solution would provide ongoing filtration, effectively addressing residual ferrous material from the failure and routine wear debris generated during standard operation.
Equipment:CAT 994H Client: Coal Mine Australia
Challenges:
An Australian coal miner operating CAT 994H loaders was continually experiencing a high frequency of component failures due to heavily contaminated oil, resulting from contaminants not captured by standard media filters.
After experiencing first-hand the benefits of fitting Mag-Shield® products to their hydraulic tanks, they chose to fit Mag-Shield® to the steering & brake tank. Like the main hydraulic circuit, the goals were to keep the steering & brake fluid clean, reduce frequency of failure and extend component life.
Solution:
A Mag-Shield® kit was fitted in the steering and brake tank to provide additional and complementary filtration. As contaminated fluid circulates and returns to tank, ferrous material is captured by the Mag-Shield® preventing contamination of the entire system. This becomes even more consequential post failure as Mag-Shield® stop very large amounts of generated debris circulating and damaging system components.
Equipment:CAT 994H Client: Coal Mine Australia
Challenges:
An Australian coal miner operating CAT 994H loaders was continually experiencing a high frequency of component failures due to heavily contaminated oil. Compounding the problem, was all main hydraulic circuits which shared a common reservoir and hydraulic fluid, which meant component failures in one circuit produced contaminants that circulated throughout the entire system, causing additional damage and accelerated wear on components that were otherwise in good condition.
Solution:
A Mag-Shield® kit was fitted in the main hydraulic tank to provide additional and complementary filtration of the hydraulic system. As contaminated fluid circulated and returned to the tank, ferrous material was captured by Mag-Shield® preventing contamination of the entire system. This becomes even more consequential post failure as Mag-Shield® stops very large amounts of generated debris circulating and damaging system components.
Equipment:HITACHI EX8000 EXCAVATOR Client: Western Australia Mine
Challenges:
Repeated hydraulic main pump failures in the EX8000 excavator at a Western Australia mine have disrupted operations and productivity. Additionally, false alarms from the contamination alarm system have caused unnecessary operational pauses, questioning its effectiveness.
Solution:
To address these challenges, the MagShield® team installed a Mag-Shield® magnetic filter solution in the excavator’s main hydraulic tank. This innovative solution captures iron contamination, preventing recirculation and reducing false alarms. The state-of-the-art Mag-Shield® filtration system proves to be the next generation best practice for fluid contamination control, enhancing the excavator’s performance.
Equipment:MOBILE DRILL Client: United States - Operator
Challenges:
A drill operator in the United States faced challenges with iron contamination affecting the hydraulic system of their Cubex drill. The presence of excessive iron contamination can lead to accelerated wear and heightened failure rates for critical hydraulic components like motors and pumps.
Solution:
The MagShield® Team reached out to the drill operator and proposed a trial of our innovative solution, MagShield® X in-line filtration product. The drill operator accepted the trial and installed a single unit between the hydraulic oil cooler and the hydraulic return filter on the drill. Throughout the trial period of approximately 500 hours, the drill operated seamlessly without any failures.
Equipment: CAT 797 TRUCKS Client: Oil Sands Operation In North America
Challenges:
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.
Solution:
The business installed Mag-Shield® 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.
Equipment: CAT 797F HAUL TRUCK Client: Mining Company In Australia
Challenges:
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.
Solution:
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.
Equipment: CAT 777 TRUCKS Client: Coal Mine In Alberta, Canada
Challenges:
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.
Solution:
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.
Equipment: KOMATSU 830E Client: Diamond Mine In Canada
Challenges:
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.
Solution:
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.
Equipment: HITACHI EX5600 EXCAVATOR Client: Australian Mine
Challenges:
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.
Solution:
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%.
Equipment: EX850 EXCAVATOR Client: North American Construction Group
Challenges:
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.
Solution:
This client saw a ROI in just one year and large savings by installing Mag-Shield®. Over five years of having these filters installed, hydraulic failure rate fell 45%, repair costs fell 52% and downtime per event fell 48
Equipment: KOMATSU 930E Client:Alberta Mine Site
Challenges:
Contaminated oil also causes extensive damage throughout the hydraulic and brake systems. leading to ‘Safety-critical’ hydraulic systems on Komatsu 930E.
Solution:
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.
Equipment: CAT 777D Client: Northern Alberta Oil Sands Mine
Challenges:
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.
Solution:
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.
Dean Cryer
Business Development Manager
: +1 780 966 8647
: dean.cryer@magshield.com
Jorge Infanta
Sales Account Manager
: +1 780 909 8232
: jorge.infanta@magshield.com
Stacy Dukart
Sales Account Manager
: +1 780 984 8647
: stacy.dukart@magshield.com
Neil Cropper – Australia
General Manager
: +61 409 269 873
: neil.cropper@magshield.com
Murray Laidlaw
Sales Manager
: +61 437 072 396
: murray.laidlaw@magshield.com