Training Presentation

Supercal and Eurapac

1
FOWA
FOWA

2
Fuel

Oil, lubrication & hydraulic

Water

Air

3
 MACHINE MALFUNCTION STATISTICS

5% 5%
Over load Other
10%
Mechanical Malfunction

10% This figure shows

Wrong Operation that 70% of
70% machine’s
Incorrect FOWA
malfunction is
from FOWA
factors

4
Correct Maintenance Can Reduce Repair Costs

incorrect maintenance

correct maintenance

Working Hours

bad fuel and oil, or poor maintenance will lead to repair

costs rising sharply.
5
Chapter One

Management of
Diesel Fuel

6
Management of FUEL

When choosing fuel, we must ensure

its quality, it’s very important.

7
 If the fuel management is not correct

Don’t Change Fuel filter on time

Or Using bad Fuel

The pressure of Rust Pump and Fuel efficiency

pump will reduce injectors will Will be reduced
be damaged

Reduced Engine Power

8
 Fuel System

Fuel Tank --- Filter --- fuel Pump --- Fuel/Water Separator
--- Filter --- Injector Pump --- Injector

9
The Problems of bad Fuel
 contains water
 contains impurities
 Contains Heavy oil
 Contains wax
 Contains sulfur

10
The problems of water in fuel
 Accelerated Injector pump wear.
 Reduced Injector pump flow and injector pressure.
 Atomization poor, emits black smoke, and loss of Engine
power.

Worn piston of Injector pump

11
The problems of grit and impurities

 Grit and impurities will wear injector pump’s pistons, piston

covers and valves. Then lead to spray pressure reduction,
poor atomization, emit black smoke, loss of engine power.

 the fuel output va

lve is worn out by b
ad fuel.

12
 The problems of heavy oil in fuel
The heavy oil will not burn completely in cylinders, it
results in more carbon then that blocks injectors.

The blocked injector, it’s spray pattern isn’t correct.

13
The problems of wax in fuel

If there is wax in fuel, when the

temperature falls, it will freeze,
blocking the fuel piping and
filters, making the engine start
difficult.

14
The problems of sulfur in fuel
The sulfur will become acid, leading to:
1 、 accelerated contamination of oil
2 、 cause rust interally in engine

A rusted inlet valve

15
The problems of over injecting fuel

Piston Sintered The cracked cylinder head Failed valves

16
〈 Example 〉

One operator’s SD16 dozer just done 1000 hours, t

he engine exhausting black smoke, the power output
was down. After checking, we found that injector pu
mp pistons were worn badly.

Reasons:

The operator was using contaminated fuel, the

fuel containing many impurities.

17
The maintenance and management of fuel

1 、 Use high quality fuel.

2 、 Change filters on time (every 250 working hours).
3 、 Checking fuel before and after working

Before start up: drain the water and sediment by opening the valve on t
he bottom of fuel tank, also drain water from bottom of fuel filter bowl.
After shut down: top up fuel tank to eliminate any water in fuel overnig
ht a good quality diesel fuel additive will eliminate moisture and tank fu
ngus in fuel.

18
Fuel storage management

Control the fuel storage, manage the stock well

Impure fuel with water and grit

Prevent condensation Prevent aeration 19

Fuel management
Choose fuel from environment temperature

The highest temp. above 0OC one day ：

use 0# Diesel Oil
The lowest temp. in -10OC - 0OC one day ：
O O

use -10# Diesel Oil

O O
The lowest temp. in -20OC - -10OC one day
use -20# Diesel Oil
The lowest temp. in -20OC - -30OC ：
use -35# Diesel Oil
The lowest temp. below -30OC ：
use -50# Diesel Oil

20
More fuel management
After a full day working, top up fuel tank
Before start up, drain the water in tank and filter/separator

Full fuel will exhaust the Discharge the water in separator Drain the water and
air in tank, or air will sediment in the bottom of
produce condensation tank
water in it.
21
Fuel filter management

Change SHANTUI fuel filters at scheduled time

SHANTUI FILTER
22
Chapter Two

Management of OIL

23
Management of OIL
(Lubrication & Hydraulic Oil)

1 ） The functions of Oil

a 、 Lubrication
b 、 Cooling
c 、 Cleaning
d 、 Eliminate Rust
e 、 Maintenance Seals
2 ） Consisting of
Mineral Oil + Additives

24
Lubrication System of Engine

25
 Lubricant quality factors
Fuel
Fuel Lubricant
Lubricant Dust
Dust

Oxidation
Oxidation Sulfur
Sulfur Oxide
Oxide
Dust
Dust
Water
Water
Oxide
Oxide Sulfate
Sulfate Sulfuration
Sulfuration

Additive
Additive consuming
consuming

Deposition
Deposition

Lubricant
Lubricant unserviceable
unserviceable 26
Contamination of Engine Oil

27
 Oil index

SAE Viscosity Grade API Quality Grade

5W CA
10W CB
Temperatur
15W -15OC CC
20W CD
25W CD-Ⅱ
e

20 CE
30 CF
40 +40OC CF-2
50 CF-4
60 * CC for the engine without Turbo
* Environment engine use above CE
28
 The relation between Viscosity and Temperature

Viscosity
SAE40

SAE15W-40
SAE15W

Temperature

29
 The problems of oil Contamination

This liner & piston is damaged by over heating, because of ：

1 、 there has been water in oil for a long time, viscosity is down.
2 、 there is grit in oil, injectors are damaged, the compression is low.

30
 The problems of oil Contamination

This crankshaft and bearing are damaged by over heating, because of:

There is water in oil for a long time, the oil viscosity is down.

31
 Turbo problems of oil
Contamination

Due to lack lubricant, the Due to lack lubricant, the The turbo shaft is worn
bearing is worn. bearing is worn and badly by shortage of
cracked lubricant

32
〈 Example 〉
One operator using a SD22 dozer, one day the
no.3 cylinder liner cracked. After changing liner an
d piston, after working several hours, it cracked ag
ain.

Reason:
this operator didn’t change blocked oil injector,
leading to no.3 cylinder liner seizing, causing th
e cylinder to crack.

33
〈 Example 〉
One operator used a SD22 dozer in cool place. When he
had a difficult start next morning, he started engine at idle sp
eed intermittently several times, then the turbo leaked oil.

Before working warm-up Before shut down engine, run

engine, so to not damage the it at idle speed, to reduced
turbo heat in turbo

34
〈 Test 〉

One operator asked: his engine oil is very dirty, he

wants to use diesel fuel instead of oil to clean
piping at idle speed, then change new oil.
Is he right?

35
The points of oil maintenance and management 1
Choose oil base environment temperature
Check oil quantity every day
Change oil and filter every 250 working hours
Environment temperature Capacity
-22 -4 14 32 50 68 86 104℉
-30 -20 -10 0 10 20 30 40℃

SAE 30
Engine o
SAE 10W
il

SAE 10W -30

SAE 15W-40

36
The points of oil maintenance and management 2

Change oil on time strictly Remark:

1. Sulfur’s effect to oil changed time:

250 h a. normally sulfur content below 0.5%
500 h
b. sulfur content in 0.5%~1%, oil changed
time reduce half
c. sulfur content above 1%, oil changed time
is ¼ of normal time
2. If the oil corrupted, the oil and filter must be
change immediately
3. If use CC lubricant, oil changed time reduce
Without turbo With turbo half

37
The points of oil maintenance and management 3

Pure Filter Bad Filter

SHANTUI Pure Filter Poor Filter

Large filtration area Small
Small filtration hole Big
Can bear high pressure Can’t

38
Hydraulic Oil for Bulldozer

The dust in Oil after long term in service

The picture under microscope

39
the problems of impurities in hydraulic oil

Serious damage to Cylinder bores

40
Hydraulic oil maintenance and management

Use high quality oil and filters

41
Chapter Three

Management of
Coolant System

42
Circulation of cooling water
Dirty water lead 75℃ or below: water flow to pump
Thermostat 75℃-95℃: double direction flow
Running Badly
Adjust water temp. 95℃ or above: all the water flow to radiator
low Water level
Water temp. meter
Water pump
Some bubble
Broken by tremble

Air bubble Due to tremble,

Around liner form many hole on liner,
Then water come into cylinder

Block Cylinder
Fan

Using dirty water, bu

ild furring, block flow, Using dirty water, bu
water heating, engi ild furring, block flow,
ne blocked leavings water heating, engi
ne blocked
Oil cooler

Radiator Water pump Cylinder Block Cylinder Head Thermostat

If the water temp. high
Pump make Cooling water from
Cool the water, Cooling water It lead water to radiator;
Water through Firebox and air valves
Cooled water flow to From Liner to
Oil cooler Through manifold

43
Engine again Cylinder head If the water temp. low
Go to engine Flow to thermostat
It lead water to pump
 Corrosion Inhibitor

Incorrect Correct
Corrosion inhibitor Corrosion
inhibitor 44
 To Radiator

From Cylinder head

Thermostat

To Pump
Big Circle:
Super cooling running ：
Radiator→Pump →Oil cooler →Cylinder block The water long term runni
ng below 60℃
Thermostat ←Cylinder head
Super heating running ：
The water long term runni
Small Circle:
ng above 95℃

Pump→ Oil cooler → Cylinder block

Thermostat ←Cylinder head 45

(Example)
One operator using a SD22 dozer, water temp. meter
always in alarm mode, finally the engine cylinder head
cracked.

(Reason)
long term use of river water, build up of many deposits in
water piping, resulting in poor engine cooling, then the
cylinder head cracked.

46
Cooling water system

These cylinder liner, piston and cylinder block are

damaged by poor quality cooling water

47
Coolant maintenance & management 1

Replace filter and antifreeze to schedule on time

Cleaning water piping, replace proper antifreeze

48
Coolant maintenance & management 2

Perform daily checks, operate correctly

Check water level Warm up Engine Idle speed before

before start up After start shut down to cool
turbo.

49
Coolant maintenance & management 3

Use clean water, don’t use river water

50
Chapter Four

Management of AIR

51
Air induction system

Pre-filter → Air Filter → Turbo → After Cooler

→ Cylinder → Turbo → Silencer
52
Air Fuel Balance

Air → Fuel → Power

Black exhaust ？
Blue exhaust ？
White exhaust ？

53
 Pre-filter and Air filter
Clear air can
through the
hole of paper
Pre-filter Paper element

The large impu

rities will be thr
ow by To cylinder
r I n put eccentricity
ai ted
o ta
rcu mr
ci Due to double layer filter 99.9%
air dust will be rejected

54
 Turbocharger

Exhaust

Air enters

Increase engine power 30%-50% 。

55
 The problems of air system malfunctions

Due to air filter blockage, the Due to the grit in

engine power will reduce and induction air, the
emit black smoke impeller of turbo is
damaged
56
 More problems of air system malfunctions

Piston ring is scraped Piston is damaged Cylinder is damaged

by grit in air by grit in air by grit in air

57
Valve problems of air system contamination

Inlet valve is damaged by grit in induction air

58
Valve seat problems of air system contamination

Inlet and exhaust valve seat is damaged by grit in air

59
Air input and output system management 1

Use SHANTUI air filter element

60
Air input and output system management 2

Checking daily, and cleaning filter in time

Check indicator every day Prevent impurities Air cleaning and Checking
entering housing

61
Chapter Five

Problems for Diesel

Maitenance & Operation

we must prevent them

62
1. Add Excessive Engine Oil X

Facts are: if the oil is overfilled, the crankshaft and

connect rods ‘ resistance will increase. And splash
more oil to cylinders, it will build up more carbon in
the combustion chamber. Then the power will
decrease, the component wear will increase, and
emissions will be excessive.

63
2. Air Valve Clearance excessive more power X

Facts are: if the valve clearance is wide, the valve

travel will reduce, so the air intake is reduced, and
will decrease engine power, and increase engine
wear.

64
3. Water temperature is low – No Problem X

Facts are: if cooling water temperature is low, the

fuel isn’t burned completely, and lubrication is not
good. Engine power is down, emissions are
excessive.

65
4. Working on low load, low speed, the machine life is long X
Facts are: this situation will make engine over heat,
turbo damaged. Because:
1. Low speed, the radiator’s fan rotates slowly, the
cylinders discharge heat not well, engine will be
over heating.
2. Engine rotate slowly, turbo rotate slowly too, so
air intake is low, and the fuel isn’t burned compl
etely.
3. Turbo’s axial clearance is very narrow, but the r
otation speed is very high, near 10,0000 RPM. If
the rotation speed is low, the lubrication is not g
ood, it will fail. So if the dozer works at idle spee
d, the limited time is 5 minutes.

66
5. The crankshaft fan belts More tight More Powerful X

Facts are: if the belts are over tight, the resistance will
increase, and the water pump, fan, alternator shafts, will
be damaged as well.

67
6. Use Antifreeze in Winter and use water in Summer , X
it’s economic

Facts are: because there is much mineral in normal water, it

will scale on the radiator and water temperature sensor, the
engine will be over heat, the cylinders will be damaged.

So, there are many advantages using antifreeze in summer:

a. Anti boiling, the boiling point will reach above 110℃.
b. Anti freezing, the freezing point will teach below -25~-5℃
c. Anti Corrosive
d. Anti Scale

68
7. Turbo engine heating is slow,
need long time idle speed heating after start X
Facts are: this is the main reason that make turbo can
be damaged.

It’s necessary that warm up machine 3~5min at idle

speed,
speed before increase speed and load. But if warm up
machine at idle speed longer time, it will quicken up
wearing of pistons, piston rings and cylinders, at the
same time turbo will be worn even damaged due to low
oil press and bad lubrication.

In addition, at idle speed over time, the turbo will be build

low pressure or negative pressure, and lead to oil in mid
housing flow to air-compacting chamber, then flow to
cylinders to be burned and produce carbon.

69
8. At repair time Add More Grease More Good for X
ball Bearings

Facts are: if the lubricant is over applied, it will waste the

lubricant, and affect dispelling heat, it will damage
bearings.

70
9. Original bolts are high quality, use them repeatedly X

Facts are: every time you need to replace with new

bolts.

71
10. Bolts More Tension better job X

Facts are: every bolt have a standard torque data, it’s

not good to be under the torque, but it’s not good too that
be over the data torque. If the screw toque is over the
standard data, the bolt will be distorted and elongated.

72
11. To disassemble engine,
it is best way to maintain engine X
Facts are: disassembling engine will reduce it’s working
life, so don’t disassemble it randomly without finding any
assured malfunction or damage.

73
12. Washer material is not important X

Facts are: there are different purposes for every kind of

material washer. Different purposes need different
washer, don’t change it randomly, or the engine will be
damaged.

74
13. All the bearings must be lubricated
with same method X
Facts are: There are heavy loads and light load Bearing,
different bearings use different lub. Light load bearing us
e grease, but heavy load bearing must use gear oil to lub.

If heavy load bearing uses grease, when the temperature

over 100℃ the lub will be not be effective.

75
14. Turbo Engine may Stops at High Speed X

Facts are: if turbocharged engine stops at high speed,

the turbo bearing can’t be lubricated and dispelled heat
that produce at high speed, the bearing will be block or
be damaged, O-ring will be ablated.

So, before the engine stop, it must unload and run

3~5min on idle speed, to make turbo cool the heat by oil flow.

76
End
End of
of this
this Training
Training Module
Module
Thanks
Thanks Your
Your Cooperation
Cooperation !!!
!!!

77