Case Studies
Rapid Turnaround – Superior Charge Air Cooler (CAC)
Background
A customer with a Volvo marine engine approached Diecon Marine after accidentally damaging their CAC core, constructed from an inferior aluminum fin material, by acid-bathing it. This rendered the fin beyond repair, leaving their boat docked and in urgent need of a high-quality replacement.
Challenge
The customer needed two CAC cores replaced immediately to return their vessel to operation. The replacements had to be durable, outperform the original OEM part, and be delivered quickly to minimize downtime.
Solution and Results
Diecon Marine’s engineering team quickly assessed the design and, within four days, designed and manufactured two high-performance replacement CAC cores. Using materials superior to the OEM’s aluminum fin, Diecon created a robust solution designed to withstand the marine environment’s demands and prevent further damage from maintenance errors.
Diecon’s fast turnaround and superior product quality allowed the client to resume operations with minimal disruption. The custom-built CAC cores not only met the customer’s needs for quick delivery but also provided a long-lasting and durable alternative to the original OEM part.
River City Ferries
Challenge
The fleet of 24 vessels were encountering overheating & performance issues with the exhaust manifold, along with difficulties in servicing, high costs, and downtime issues related to genuine Cummins heat exchangers.
Solution
After inspecting the vessels and acquiring genuine components, DIECON Marine reverse-engineered the manifold to create an efficient water-cooled version. Additionally, DIECON transformed the non-serviceable genuine heat exchangers into fully serviceable units.
Benefits
Decreased maintenance down time
Reduction in maintenance cost
Improve operating efficiency
Custom solution when required
Perkins Heat Exchanger
Client Challenge
A customer approached Diecon Marine with a Perkins heat exchanger housing that had been poorly repaired by a local engineer. The existing housing needed to be replaced, but the client struggled to find a new housing or a provider capable of manufacturing one with a new tube bundle.
Solution
The customer sent us the existing heat exchanger assembly, which is compatible with the Perkins 4108 Lowline Series (genuine part number 24865081). Our team quickly assessed the situation and designed a replacement housing and tube bundle tailored to the client's specifications.
Manufacturing Process
Material Selection: We utilised high-quality billet material to ensure durability and performance.
Coating: The housing was ceramic coated to enhance resistance to corrosion and wear.
Production Timeline: The entire process, from design to completion, was executed efficiently within a three-week timeframe.
Outcome
The client received a custom-engineered replacement heat exchanger housing that met all specifications, ensuring optimal performance and reliability for their Perkins engine. Diecon Marine demonstrated its capability to provide specialised solutions, even when standard parts were unavailable, reinforcing our commitment to exceptional service and quality.
Captain Cook Cruises/Sealink
Client Challenge
Captain Cook Cruises/Sealink, a leading marine transport provider in Sydney, faced an urgent issue with the oil cooler in one of their vessels. The original oil cooler, a Twin Disc Model MGX5114SC, was no longer functioning efficiently, risking the performance and longevity of their vessel's engine. The challenge was to redesign and manufacture a reliable replacement that could withstand the rigorous demands of daily operations, ensuring smooth service continuity for their passengers.
Solution
The customer sent us the existing heat exchanger assembly, which is compatible with the Perkins 4108 Lowline Series (genuine part number 24865081). Our team quickly assessed the situation and designed a replacement housing and tube bundle tailored to the client's specifications.
