Generators, backup power & batteries
rebuildinG your industrial enGine
Diesel engines can power a variety of industrial equipment, ranging from construction apparatus like cranes to agricultural machines including combine harvesters. Preventative maintenance helps to keep these machines running as optimum performance and, when they reach the end of their lifecycles, a full engine rebuild can give them a new lease of life. Here Peter Hutyan, product manager for Energy and Transportation at Finning UK & Ireland, explains the benefits of an industrial engine rebuild and offers some tips.
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iesel engines can power various industrial machines, including agricultural apparatus like tractors,
materials handling equipment and cranes. whatever the application, it is essential that the engine can continue to provide the hydraulic and rotational power that these machines require. traditionally, an industrial engine will last
anywhere between 10,000 to 30,000 hours before requiring a major overhaul. when the engine reaches the end of its life, it may be tempting to simply replace it with a newer model. However, keeping the engine running until failure can increase costs and introduce various risks.
MaInTaInIng UPTIME while not every industrial machine is critical, most operators rely on engine uptime. For example, businesses and sites in remote communities that rely on prime gensets must ensure that the generator’s engine continues to run as it should. if operators keep their engine running until the end of its life, this can compromise performance because legacy engines are typically less productive and efficient than new machines.
take the prime generator set as an example.
this machine is designed to provide constant power for sites in remote areas with a poor grid connection, but it uses an engine nearing the end of its life. because the engine does not run efficiently, the operator may need to keep the generator running for longer to generate the required power. as well causing delays, extended runtime can increase costs, particularly if the operator faces downtime while they source a replacement from the original equipment manufacturer (oem) when the machine does eventually fail. rather than face unnecessary downtime,
operators can order a complete overhaul of their engine before it reaches the end of its life. by planning in advance, they can shut down part of the site in a controlled way without worrying about an extended period of unplanned downtime. scheduling a rebuild also gives the operator time to source a rental replacement, ensuring business runs as normal.
SElEcTIng a rEbUIlD many industrial engines are built in a similar way, with minor component variations. in
32 november 2021 | Factory&HandlinGsolutions
reality, the difference between an engine on a drill rig, a crusher or a crane can come down to its turbocharger. therefore, the repair strategy is often determined by budget and power restoration requirements, rather than by application. if operators have a limited budget and want
to save time, a basic value repair will recondition the cylinder heads, piston rings and liners. this option is ideal if a tractor or crusher, for example, is experiencing a slightly increased fuel consumption and a short-term solution is needed that will see the engine through to its next service. if the engine is experiencing a loss of power
or excessive fuel consumption, operators can go that extra mile with a mid-range top and tail recondition. this approach involves renewing all major components, including the cylinder packs and heads, the injectors and pistons. all slower-wearing parts, such as lube oil and water pumps, are also replaced. if the engine is halfway through its 30,000-hour lifecycle, this option will restore vital power and can provide an additional 15,000 hours of runtime (depending on engine model).
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