Prediction of Failure of Starting Motors
Prediction of Failure of Starting Motors
Prediction of Failure of Starting Motors
Prediction of Failure of
Starting Motors on D11R
Machines
Maintenance and Component Life Component MARC
Application Renewal (CRC)
Repair Management Management
DISCLAIMER: The information and potential benefits included in this document are based upon information provided by
®
one or more Cat dealers, and such dealer(s) opinion of “Best Practices.” Caterpillar makes no representation or warranty
about the information contained in this document or the products referenced herein. Caterpillar welcomes additional “Best
Practice” recommendations from our dealer network.
March 2014
1401-1.02-1330
300 Hamilton Blvd., Ste. 300, Peoria, IL 61629-3810, U.S.A.
MINING DEALER BEST PRACTICE
1.0 Introduction
This Best Practice provides an overview of one strategy in order to predict failures in starting motors of
3508B engines used on D11R machines. These faults widely impact the reliability and availability of the
machine.
These failures are related to internal problems of the component or external problems in the electrical
starting system. In both cases, these events require maintenance intervention not programmed,
increasing the operating costs due to unexpected down of the machine, and the maintenance costs due
to investment of resources, manpower, spares, etc.
One of most important issues in the maintenance of electrical systems is the preventive maintenance of
the starting system. This is managed only through corrective approach, which can have negative effects
in electrical starting system performance and can cause electrical components to not achieve the
expected life, especially the starting motors (pre-lube and electrical motor). This preventive maintenance
process includes several tasks to provide a reliable way to predict future failures in the starting motors.
Due to repetitive reports of starting problems which had root cause in the starting motors and there was
no information how to predict this failure, an improvement program was conceived in order to identify a
mode before failure to avoid unexpected machine downtime.
As a result of this program, a procedure was generated in which it was possible to establish a range of
energy consumption (in Amps) during the ignition process.
The first step was to develop a form of the procedure in which one may take the information in a logical
sequence of execution. As a result, the attached procedure (see 6.0 supporting attachments) was
generated.
After we developed the procedure, the second step was based on the data collection to establish a safe
range according to the trends in each case. Thus, these data were plotted and analyzed finding the
trends and safe operating ranges for the pre-lube motor and electrical motor consumption in starting
cycle, and Pre-lubrication consumption. The following graphs show these trends and values.
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MINING DEALER BEST PRACTICE
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MINING DEALER BEST PRACTICE
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MINING DEALER BEST PRACTICE
SUMMARY CHART
Consumption
Description Condition Action Required
(Amp)
No action Required. Execute
Up to 450
Preventive Maintenance
Starting Motors Starting Follow Up. Check Starting system
450 - 550
(each one) Cycle components for anomalies
550 - Up Change
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MINING DEALER BEST PRACTICE
This Best Practice is applied to the following starter motors in engine 3508B
STARTING
STARTING
ENGINE MOTOR
MOTOR
PRELUBRICATION
6V-0889 123-8689
6V-0513 123-8686
3508B
338-3455
338-3456
4.0 Benefits
• Saving in man power (technicians and tools transporting costs to field are not included) and saving
in reduction of machine down time in field equivalent to 54%; total Saving $91,490 USD/year. (see
chart)
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MINING DEALER BEST PRACTICE
* These failures were detected simultaneously to PM jobs and not represent a call
Failures detected at
Description Failures in Field
Shop
Calls in 2009 13 15
Calls in 2010 0 25
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MINING DEALER BEST PRACTICE
The estimated investment related to this project is approximately US $1,255. This is the cost of a Clamp-On
Multimeter P/N 329-9303 which will be invested only once. Besides 2 man hrs per machine of preventive
maintenance that can be executed in parallel to others major tasks to avoid additional downtime.
• Procedure of measurement
• None.
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MINING DEALER BEST PRACTICE
8.0 Acknowledgements
William Lopez
Technical Communicator
Mine Pribbenow – GECOLSA
Checked by:
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