Filter Protection for Heavy-Duty Applications: Real-World Case Study of LiuGong's SP227518C1 Oil-Water Separation Filter Element

I. Project Background: Challenges in Equipment Maintenance and Operation Under Harsh Conditions

2024 In the third quarter of the year, a major logistics company added a new project in bulk material handling. 6  Tai Liu Gong 856H Loader. The project's operating environment is highly challenging: the average daily dust concentration in the open-air work area reaches 0.8 mg/m³ , far exceeding standard operating conditions; and the diesel fuel supplied on-site, affected by storage and transportation conditions, often exceeds the allowable water content (with measured levels as high as 0.15% ). Previously, the equipment used by this enterprise frequently experienced injector corrosion and reduced engine power due to issues with fuel impurities and moisture. As a result, the average monthly maintenance cost per unit exceeded 1.2  Tens of thousands of yuan, severely impacting project progress.

Before equipment delivery, the LiuGong technical team customized a dedicated support plan tailored to the project’s specific features: In addition to adding an oil-bath air filter to enhance intake filtration for the loaders, the core fuel system comes standard with these enhancements. SP227518C1 Original Manufacturer Oil-Water Separation Filter Cartridge . The filter cartridge 125×125×230mm The structural dimensions and 856H The Cummins engine equipped on the loader is precisely matched, effectively addressing the challenges of purification in environments with high dust levels and fuel containing significant moisture.

II. Application Process: Comprehensive Scenario Testing of Filter Cartridge Performance

(1) Installation Compatibility: Precise Fit According to Manufacturer Standards

After the equipment arrived, the LiuGong-authorized service team meticulously followed the original factory specifications to complete the task. SP227518C1 The installation process of the filter element. This filter element features a spiral-sealed interface design, ensuring a perfect fit with the fuel line. 99.8% , it fundamentally prevents fuel leaks or unfiltered fuel bypass issues commonly caused by installation gaps in aftermarket parts. After installation, it ensures 48  Hour-long no-load test verification showed that the fuel pressure at the filter element's inlet and outlet remained steadily maintained at 0.3-0.4MPa , perfectly meeting Cummins engine fuel supply pressure standards, laying the foundation for subsequent heavy-load operations.

(II) Operational Performance: The Practical Strength of Three Core Advantages Shines Through

During the为期 3 During months of continuous heavy-load operations, SP227518C1 Thanks to its structural design and advanced filter material technology, the filter cartridge demonstrates stable and reliable purification performance:

1. Efficient oil-water separation, blocking the source of corrosion : The transparent water collection cup configured at the bottom of the filter element can gather approximately per week 80ml The condensate mixture of water and impurities, combined with the built-in water level sensor, ensures that when the storage capacity reaches 50ml Automatically triggers dashboard alerts, enabling operators to instantly complete the drainage operation and fundamentally preventing moisture from entering the fuel injection system. Compared to another piece of equipment running concurrently in the same project—equipped with aftermarket filter elements—this unit features SP227518C1 The rusting degree of the filter cartridge loader's fuel injector has been reduced. 90% , completely eliminating the corrosion risks posed by highly water-containing fuel.
2. Strong anti-clogging design extends maintenance cycles. : Diameter generated by bulk material handling ≤5μm The fine particles can easily cause the filter element to become clogged, but SP227518C1 Employing a multi-layer composite filter material structure, the dust-holding capacity can reach 12g/1000ml Fuel consumption far exceeds the industry average. 8g Standard. Actual operational data shows that its replacement cycle has been extended to 500  Hours, compared to aftermarket parts 300  Hourly improvement 66.7% , reducing the frequency of downtime caused by filter cartridge replacements.
3. Stable system protection, ensuring reliable power output : Through regular fuel sampling and testing, it has been SP227518C1 Fuel impurity content after filtration by the filter element ≤0.02 mg/L , Moisture Content ≤0.01% , fully meeting the fuel purity requirements of the high-pressure common-rail system. With this assurance, the pressure in the engine's high-pressure common-rail system remains stable at 1800bar , idle speed vibration controlled within ±50 r/min Within this range, power output improves compared to using aftermarket filters. 3% , ensuring the equipment's operational efficiency under heavy-load conditions.

III. Application Outcomes: A Dual Breakthrough in Economy and Reliability

As of 2024 At the end of the year, 6  Equipped with a Taiwan SP227518C1 The filter cartridge loader has accumulated over 1.2  Over 10,000 hours, achieving significant improvements in fuel system protection and operational cost control:

• Maintenance costs significantly reduced : The frequency of failures in core fuel system components such as injectors and fuel pumps has risen to monthly levels. 2.3 Decreased to 0.2  Next, the average monthly maintenance cost per device decreased from 1.2  Ten thousand yuan drops to 2800  Yuan, with a decline of up to 76.7% ；
• Equipment availability rate significantly improved : Unplanned downtime caused by substandard fuel purification has risen to per month 12 Hours reduced to 0.8  Hours, the overall equipment availability remains stable at 98.5% The above measures effectively ensured the project's continuous operational needs.
• Fuel efficiency continues to be optimized. Precise fuel purification enhances engine combustion efficiency. 2.1% , the hourly fuel consumption decreases from 18.5L Drop to 18.1L , based on the annual operation per unit of equipment 2000  Hourly calculations show annual fuel cost savings exceeding 1600  Yuan.

During the project's quarterly review, the head of equipment management stated: “ Liugong Original Factory SP227518C1 The filter cartridge's stability far exceeded expectations, providing comprehensive protection for the equipment's fuel system even under harsh operating conditions characterized by high dust levels and poor-quality oil. It is a critical core component that ensures the continuous operation of heavy-duty equipment. ”