挖掘机培训教材FOWA--Komatsu.ppt

Page 1/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSEMaintenance FOWACHECK AND CHANGE OF OILOil ManagementMaintenance FOWAUKPTE0602BUSERS TEXTMAINTENANCE COURSEPage 2/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSE1.Ingredients of lubricating oil2.Types and functions of additives3.Types and functions of oils for construction machinery4.Transition of recommendation for lubricating oils 5.Oil to be used for machines complying with Tier 3 and Stage 3A emission regulations6.Failure example due to use of oils other than Komatsu recommended7.Example of oil test result on main pump cradle8.Recommended oils9.Oil check/refill components and positions of filters to be replaced10.Factory-fill oil11.Maintenance time management with machine monitor12.12.History of engine oil standard13.Use Komatsu genuine oil DH series as engine oil14.Detergency of engine oil15.Use Komatsu genuine engine oil filter16.Combination filter for medium and large-sized engine with bore of 114 mm and above17.Use of Komatsu genuine parts extend the oil change interval to every 500 hours.18.Check the oil level before starting19.Be sure to observe the oil change interval specified in the Operation and Maintenance Manual20.Use adequate engine oilContent 1Page 3/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSE21.Be careful about foreign matter getting into the oil22.Replacement of engine oil filter23.Recheck the oil level and filter installation after replacing the engine oil24.24.Power train oil KES name is TO25.Remote drain for swing machinery case26.Oil level check and refill,and oil change of swing machinery case27.Oil level check and refill,and oil change of final drive case28.Oil level check and refill of damper case(every 1000 hours)29.29.Oil level check and refill of hydraulic tank30.Features of hydraulic filter element(ECHO-WHITE)31.Replacement of hydraulic oil filter element32.Oil change of hydraulic tank33.33.Axle with built-in brake34.Properties required for axle oil35.35.Oil storage36.Recommendation of KOWAContent 2Page 4/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSES S1.Ingredients of lubricating oilSDetergent and dispersant(Ca sulfonate)SHeat-resistant oxidation inhibitor and extreme pressure additive(ZDTP)Gear oilS SBaseoil SS/P-based(sulfur/phosphorus)extreme pressure additive for gear seizure preventionHydraulicoilEngine oil+SOxidation inhibitor,rust inhibitor and antifoamerBase oil+Additives to attain required functions=Lubricating oil-Main functions of the lubricating oil depend on the additives.+Page 5/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSE2.Types and functions of additivesOxidation inhibitorsOxidation inhibitorsTo prevent oxidation of oil and extend its lifeTo prevent oxidation of oil and extend its lifeDetergent and Detergent and dispersantdispersantTo deterge soot and dust(deterging function)To deterge soot and dust(deterging function)To disperse deterged materials,dust and water into the oil To disperse deterged materials,dust and water into the oil(dispersing function)(dispersing function)Oiliness improverOiliness improverTo aid the oil to adhere to metal surface and form strong To aid the oil to adhere to metal surface and form strong oil filmoil filmExtreme pressure Extreme pressure additive(EP)additive(EP)To prevent parts seizure when high-pressure or load is To prevent parts seizure when high-pressure or load is appliedappliedRust inhibitorRust inhibitorTo prevent iron rustTo prevent iron rustCorrosion inhibitorCorrosion inhibitorTo prevent corrosion of metals such as copper alloy,etc.To prevent corrosion of metals such as copper alloy,etc.Viscosity index Viscosity index improver(VII)improver(VII)To retain viscosity of oil against temperature change.To retain viscosity of oil against temperature change.Cold flow improverCold flow improverTo prevent solidification of oil at low temperatureTo prevent solidification of oil at low temperatureAntifoamerAntifoamerTo prevent producing bubbles and eliminate produced To prevent producing bubbles and eliminate produced bubbles instantlybubbles instantlyFriction modifier(FM)Friction modifier(FM)To aid the oil to cover the metal surface in order to reduce To aid the oil to cover the metal surface in order to reduce friction for smooth runningfriction for smooth runningPage 6/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSEEngine oilEngine oilIn addition to lubrication function,detergency and In addition to lubrication function,detergency and dispersibility,wear resistance and heat resistance dispersibility,wear resistance and heat resistance properties,etc.are requested for the engine oil.properties,etc.are requested for the engine oil.Power train oilPower train oilFor power train units such as transmission,final For power train units such as transmission,final drive,swing machinery,etc.Friction coefficient drive,swing machinery,etc.Friction coefficient retention,anti-gear pitching and wear resistance retentionanti-gear pitching and wear resistance properties,etc.are requested for the oil.properties,etc.are requested for the oil.Gear oilGear oilFor gear case,etc.For gear case,etc.For Komatsu machines,use of the oil is limited to For Komatsu machines,use of the oil is limited to some portions such as the final drive of large-sized some portions such as the final drive of large-sized bulldozers(D475A-5EO).bulldozers(D475A-5EO).Hydraulic oilHydraulic oilFor hydraulic components.Wear resistance and For hydraulic components.Wear resistance and scuffing resistance properties,etc.are requested for scuffing resistance properties,etc.are requested for the oil.the oil.Axle oilAxle oilFor axles with built-in brake.Friction coefficient For axles with built-in brake.Friction coefficient retention property,low viscosity,seizure resistance retention property,low viscosity,seizure resistance property,etc are requested.property,etc are requested.3.Types and functions of oils for construction machineryPage 7/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSEEnginePower train units(Transmission,final drive,damper,steering system,etc.)Axles of wheel loaders and articulated dump trucksHydraulic components(Hydraulic oil)Conventional usagesMajor componentsCurrent usages(From Tier2)Engine oil had been used widely by expanding its versatility.Engine oilClassification CDSAE 10W,30,10W30Special oil Axle oilKES AXO75Not available forLSDEngine oilGrade:JASO DH-1Viscosity:SAE3010W30,15W40Power train oilKES TO oilTO10,TO30Hydraulic oil HO46-HMSpecial oil Axle oil KES AXO80Available for LSD4.Transition of recommendation for lubricating oilsPage 8/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSEPage 9/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSEPage 10/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSETested oil:Komatsu genuine oils TO10 and HO46-HMOil pressure:42 MPaResult:No abnormality was found on the cradle bearing*The life of hydraulic pump and motor is extended.Tested oil:Commercially available hydraulic oil EOil pressure:35 MPaResult:Abnormal wear of cradle bearing was found.*The hydraulic pump and motor have to be replaced due to the abnormal wear of the cradle bearing.Scuffing flaw7.Example of oil test result on main pump cradlePage 11/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSETO30TO30HydraulicsystemHydraulicsystem PowertrainoilPowertrainoilTO10TO10 HydraulicoilHydraulicoilHO46-HMHO46-HM0FluidTypeFluidType10 SwingmachinerycaseSwingmachinerycase FinaldrivecaseFinaldrivecase DampercaseDampercasePowertrainoilPowertrainoilReservoirReservoir1432-30-2010AmbientTemperatureAmbientTemperature-22-450RecommendedRecommendedKomatsuFluidsKomatsuFluids2030406886104122F50C KomatsuEO10W30-DHKomatsuEO10W30-DH KomatsuEO15W40-DHKomatsuEO15W40-DH KomatsuEO30-DHKomatsuEO30-DHEngineoilpanEngineoilpanEngineoilEngineoil KomatsuEOS0W30KomatsuEOS0W30 KomatsuEOS5W40KomatsuEOS5W40Abstract from PC200-8 Operation and Maintenance Manual8.Recommended oilsPage 12/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSESwing machineryDamper caseEngine oil filterFuel pre-filterwith water separatorEngineComplying with Tier 3 and Stage 3Aemission regulationsFuel main filterFuel tankHydraulic tankCab9.Oil check/refill components and positions of filters to be replacedExample of PC200-8Final driveHydraulic oil filterPage 13/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSEUse Komatsu genuine oils when refilling.Use Komatsu genuine oils when refilling.Mixing oils of different types may produce impurities as with Mixing oils of different types may produce impurities as with human blood.human blood.10.Factory-fill oilExample of PC200-8ItemItemTypeType EngineoilpanEngineoilpan EngineoilEO15W40DH(Komatsugenuineoil)EngineoilEO15W40DH(Komatsugenuineoil)DampercaseDampercase SwingmachinerycaseSwingmachinerycase FinaldrivecaseFinaldrivecase HydraulicoilsystemHydraulicoilsystem PowertrainoilTO10(Komatsugenuineoil)PowertrainoilTO10(Komatsugenuineoil)PowertrainoilTO30(Komatsugenuineoil)PowertrainoilTO30(Komatsugenuineoil)Page 14/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSE11.Maintenance time management with machine monitorMaintenance item Engine oil replacement Engine oil filter replacement Fuel main filter replacement Fuel pre-filter replacement Hydraulic oil filter replacement Hydraulic oil tank breather replacement Damper case oil check and replenishment Final case oil replacement Hydraulic oil replacementPressing F5()function switch to move maintenance list screenMaintenance time reset screenSelect an item and press F6 switchTo reset press F6()Pressing F5 or making no operation for 30 sec restores the normal screenExample of PC200-8To return press F5Page 15/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSECheck and change of engine oilPage 16/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSEFor engine with DPFCA1940CB1949CC1961CD1955CF1994CE1983CF-41990CG-41995CH-41998CI-42002DH-12001Transition of API engine oil standardJASO standardSoot dispersibilityCJ-42006Discontinued standardsDH-22005JASO:Japanese Automobile Standards OrganizationAPI:American Petroleum InstituteDPF:Diesel Particulate Filter12.History of engine oil standardDetergency/Heat resistanceFor engine with DPF:API multi grade:JASO standard:API single gradePage 17/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSE13.Use Komatsu genuine oil DH series as engine oil Use Komatsu genuine oil when replacing and refilling engine oil Use Komatsu genuine oil when replacing and refilling engine oilDH seriesOptimum engine oil to diesel engines for construction machinery!Page 18/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSEEvaluation of detergency on piston ring grooveCarbons may adhere to the grooves,causing piston ring to stick when using poor detergency oil.High detergency oil disperses carbons finely and keeps the combustion chamber of engine clean.14.Detergency of engine oilCommercially available oil 15W40-CDPage 19/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSEComparison of conventional and new Komatsu genuine engine oil filters for PC200 series machines15.Use Komatsu genuine engine oil filterKomatsu genuine oil filter features improved filtration performance and Komatsu genuine oil filter features improved filtration performance and extended life.extended life.Be sure to use Komatsu genuine parts and replace the filter when changing Be sure to use Komatsu genuine parts and replace the filter when changing the engine oil.the engine oil.PC200-7/8:New filter material Multilayer overlapped fiber filter materialPC200-6:Conventional filter material2.Change in filter materialCELLULOSEMICROGLASSCOARSE LAYERMIDDLE LAYERFINE LAYERCellulose filter materialMicro fiberglass filter materialCoarse layerIntermediate layerMinute layer&New oil filter has three types of filtration layer and catches dust and sludge both at the surface and inside the filter material.Komatsu genuine parts!1.Comparison of conventional and new partsIdentifying bar markConventional filterConventional filterNew filterNew filter6735-51-51436735-51-51436736-51-51426736-51-5142Every 250 hoursEvery 250 hoursPC200-6PC200-6Every 500 hoursEvery 500 hoursPC200-7/8PC200-7/8Overlapped fiber filter Overlapped fiber filter material is adopted.material is adopted.Page 20/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSECombination filter is an integrated filter of full-flow filter and bypass filter.Full-flow filter portion has same function as that of normal oil filter.Bypass filter portion through which 3 to 5%of the oil passes has filter papers with finer mesh than that of full-flow filter to increase filtration performance filtering carbon particles mainly.Full-flow filterVenturiLow pressureBypass filter16.Combination filter for medium and large-sized engine with bore of 114 mm and abovePage 21/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSE17.Use of Komatsu genuine parts extend the oil change interval to every 500 hours.The oil change interval is not necessarily applied to all machine models uniformly.Carry out oil change according to the Operation and Maintenance Manual.250H500HOil change interval for conventional machinesHigh disepersibilityDH seriesKomatsu genuine oilHigh filtration performanceKomatsu genuine oil filterImprovement of combustion chamberOptimized oil pan For engines that comply with Tier 2 and Stage 2 emission regulations and later For engines that comply with Tier 2 and Stage 2 emission regulations and later engines,oil change interval has been extended from conventional every 250 engines,oil change interval has been extended from conventional every 250 hours to every 500 hours,thanks to the adoption of high quality Komatsu hours to every 500 hours,thanks to the adoption of high quality Komatsu genuine oil and oil filter,and improvement in engine.genuine oil and oil filter,and improvement in engine.Page 22/45 Maintenance FOWAOIL MANAGEMENTOIL MANAGEMENTUSERS TEXTMAINTENANCECOURSE18.Check the oil level before startingAdd oil so that the oil level is Add oil so that the oil level is always being kept between H always being kept between H and L marks of the oil level and L marks of the oil level gauge.gauge.When the oil level is too low,When the oil level is too low,the lubricating system the lubricating system becomes in short supply of oil becomes in short supply of oil and pistons and bearings may and pistons and bearings may seizure in a short period of seizure in a short period of time.When the oil level is too time.When the oil level is too high,the oil may cause high,the oi