0009- Fuel Maintenance

8/6/2019 0009- Fuel Maintenance

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Media KME-003-06 KT (10/06)

Maintenance FOWA

Fuel Maintenance

&

Fuel Management

USER’S TEXTMAINTENANCE COURSE



Media KME-- KT (/)

Fuel - MaintenanceFuel - Maintenance

The fuel injection pump’s life and costThe fuel injection pump’s life and cost

GeneralGeneral

overhauloverhaul

Overhaul by badOverhaul by bad

management of management of

fuelfuel

Overhaul costOverhaul cost

2500025000

2000020000

1500015000

1000010000

50005000

00

8000H ～ 12000H

1500H

1910$



Media KME-- KTPage (/)


The Statistic of Engine Trouble Caused by Fuel ProblemsThe Statistic of Engine Trouble Caused by Fuel Problems

Others

20%

Too

much

impurity

45%

Too

much

water

35%



Media KME-003-06 KT (10/06)

Incorrect way

of

transportation

and charge

40%

Others

10%

Poor Daily

Maintenanc

e

50%


The Statistic of Engine Trouble Caused by Fuel ProblemsThe Statistic of Engine Trouble Caused by Fuel Problems

Poor MaintenancePoor Maintenance



Media KME-003-06 KT (10/06)


Poor MaintenancePoor Maintenance

Examples (Discard)Examples (Discard)

Correct MaintenanceCorrect Maintenance

Examples(still usable)Examples(still usable)

Much carbon roundMuch carbon round

the piston head andthe piston head and

ring groovesring grooves

15001500 HH

A few carbonA few carbon

7250 hours7250 hours



Media KME-003-06 KT (10/06)

Piston rings broken byPiston rings broken by

carboncarbon

1350 hours1350 hoursSlight wear Slight wear 8053 hours8053 hours


Poor MaintenancePoor MaintenanceExamples (Discard)Examples (Discard)

Correct MaintenanceCorrect MaintenanceExamples(still usable)Examples(still usable)


http://slidepdf.com/reader/full/0009-fuel-maintenance 7/43Media KME-003-06 KT (10/06)

The injection nozzle isThe injection nozzle is

clogged by heavy fuel oilclogged by heavy fuel oil

850 hours850 hours

The nozzle is normal withThe nozzle is normal with

only slight wear only slight wear

8135 hours8135 hours









The plunger is rusted and wornThe plunger is rusted and worn by too much water by too much water

1035 hours1035 hours 8750`hour 8750`hour

Slight wear Slight wear



Fuel sample compareFuel sample compare

Pure color,Pure color,with outwith out

impurityimpurity

and water and water

Black, withBlack, withmuchmuch

water,impuritywater,impurity

and heavy oiland heavy oil

Light color,Light color,lowlow

viscosity,withviscosity,with

much water much water

and impurityand impurity

usableusable unusableunusable unusableunusable





0.7623

1.325

0.0630.1232

00.03

0

0.3

0.6

0.9

1.2

1.5

water impurity

Special sample Fuel sample State standard

Please buy the fuel from big and reliable stationPlease buy the fuel from big and reliable station

Fuel sample statisticsFuel sample statistics[Station[Station ：： 77 ；； User User ：： 24]24]

Both water and impurity are over the standardBoth water and impurity are over the standard

Special exampleSpecial example

samplesample StandardStandard

Too much water Too much water Too much impurityToo much impurity

Special exampleSpecial example

StandardStandard

samplesample




Dirty fuel canDirty fuel can

XX


http://slidepdf.com/reader/full/0009-fuel-maintenance 12/43Media KME-003-06 KTPage 1 (10/06)


Fuel can notFuel can notbe putbe put

everywhereeverywhereXX




Water andWater and

impurity getimpurity get

in throughin through

thethe

clearanceclearance

XX



ImpurityImpurity

on theon the

Pre-filterPre-filter




SedimentSediment

in the waterin the water

separatorseparator





sedimentsediment

in the injectionin the injection

pumppumpPre-filterPre-filter




impurityimpurity

in thein the

imitationimitation

filterfilter




impurity in theimpurity in the

injection pumpinjection pump

filterfilter




Steel scrapsSteel scraps

in the fuelin the fuel

filterfilter




Poor fuel andPoor fuel and

sedimentsediment

l



Fuel - ManagementFuel - Management

Right and wrong in the fuel managementRight and wrong in the fuel management

Dust, water and yarn mayDust, water and yarn may

get in to the fuel canget in to the fuel can

Cover a plastic sheet toCover a plastic sheet to

prevent water and dust prevent water and dust

XXOK OK

l



Media KME-003-06 KTPage (10/06)

Water and sediment willWater and sediment will

be sunk into fuel tank be sunk into fuel tank

50mm50mm

Keep the suction pipeKeep the suction pipe

50mm from the fuel can50mm from the fuel can

bottom bottom


XXOK OK


lF l M



Media KME-003-06 KTPage 3 (10/06)


Clean fuel is made dirtyClean fuel is made dirty

XX

The filler and fuel canThe filler and fuel can

should be cleanshould be clean

OK OK


lF l M t





Water, impurity andWater, impurity and

fuel will mix together fuel will mix together

againagain

Settle 24 hours , send toSettle 24 hours , send to

the machine by a go-cartthe machine by a go-cart

XX OK OK


F l MF l M t




Dust gets into the fuel tank Dust gets into the fuel tank Put a silk stocking outsidePut a silk stocking outside

the clean pipe, this help tothe clean pipe, this help to

resist the impurityresist the impurity

XX OK OK



F l MF l M t




Unsafe, fuel can too dirty,Unsafe, fuel can too dirty,

the dust gets into the fuelthe dust gets into the fuel

tank by the pipetank by the pipe

It is a good way to chargeIt is a good way to charge

by a manual pumpby a manual pump

66


XXOK OK


F l M tF l M t




Drain the water and dustDrain the water and dust

from the fuel tank everyfrom the fuel tank every

morningmorning 。。

(prevent water and(prevent water and

sediment from gettingsediment from getting

into the fuel system,into the fuel system,

especially that will clogespecially that will clog

the pre-filter)the pre-filter)

1

Correct fuel managementCorrect fuel management


F l M tF l M t




2Check the water Check the water

separator everyseparator every

morning, drainmorning, drain

water andwater and

sediment if thesediment if the

float over thefloat over thered mark red mark



F l M tF l M t




3Fill the fuel tank Fill the fuel tank

after the work isafter the work is

finishedfinished 。。

(pile out the air (pile out the air

in the tank, thisin the tank, this

will prevent thewill prevent thesteam)steam)



F l M tF l M t



Media KME-003-06 KT (10/06)

●●genuine filter genuine filter ：： keep the impurity out of the meshkeep the impurity out of the mesh

Imitation filter Imitation filter ：： impurity can pass easilyimpurity can pass easily

Genuine filterGenuine filter

KomatsuKomatsu

genuine filtergenuine filter

Hole is small,Hole is small,

high filteringhigh filteringabilityability

Imitation filterImitation filter

ImitationImitationfilterfilter

Hole is big,Hole is big,

lowlow

filteringfilteringabilityability

5μ


F l M tF l M t



Media KME-003-06 KT (10/06)

• 50 Micron - Human Hair

• 40 Micron - Full Flow Cellulose Filter

• 25 Micron - White Blood Cell

• 10 Micron - FS1000 Fuel Filter

• 8 Micron - Red Blood Cell

• 2 Micron - Bacteria

• <1 Micron - ?


F l M tFuel Management




How to fill the fuel


F l M tFuel Management



Media KME-003-06 KT (10/06)

1- With cap

on, fill the

filter with

the clean

fuel.

2- After filling

the filter with

the fuel, remove

cap and dispose

it.

How to fill the fuel


F el ManagementFuel Management



Media KME-003-06 KT (10/06)


Fuel ManagementFuel Management



Media KME-003-06 KT (10/06)





Media KME-003-06 KT (10/06)

Propose Fuel Handling Method: -

INFLAMMABL

E

Mobil

e

Kiosk

x

x

x

x

Lower Ram

Upper

Ram

Primary Receiving Storage Fuel Tank

Secondar

y Storage

Fuel Tank

1.) Primary Receiving Storage Fuel Tanks : -

a.) Main function is to store dis-charged fuel from

tanker for ~ 3 days to collect sediments before

transferring to Secondary Storage Fuel Tank.

.) Secondary Storage Fuel Tanks : -

a.) To store clean fuel for consumption via kiosk.





Media KME-003-06 KT (10/06)


FUEL PUMP UNIT WITH FILTERFUEL PUMP UNIT WITH FILTER



Media KME-003-06 KT (10/06)

FUEL PUMP UNIT WITH FILTERFUEL PUMP UNIT WITH FILTER

Presentation of experimental

kit for field test

Presentation of experimental

kit for field test

「 LAST CHANCE FILTER 」！ To be Protected for



Media KME-003-06 KT (10/06)

Poor Fuel

Clean Fuel ！

↓

Reduce filter suction Load, Prevente failure

Filtering

「 LAST CHANCE FILTER 」！ To be Protected for Engine

From Dust, Rubbish contamination of Fuel when fuel refill from BarrelEasy obtainable FILTER

ELEMENT“Hyd oil Filter” use

Pump

Filter Case

Lever

handle

（ No applicable to use

this unit, in case of refilling fuel to machinefrom Special fuel tank and/or fuel supply;y truck with motoring fuel

pump ）



Media KME-003-06 KT (10/06)

BASIC USAGE METHOD

①Locate Fuel barrel near to fuel tank side of a machine

②Put Fuel Unit on that Fuel Barrel

③Connect Fuel In-Outlet hoses

④Turn hand lever of Fuel Unit

（ Need bleed air at initial stage ）

Refer to manual for

detailed

Explanation



Media KME-003-06 KT (10/06)

Presentation experimental unit and its main Specification

１、 Fuel Pump・ Manual, Portable

・ Out let Flow 1little ／ rev・ Dimension: 365×472×351mm・ Weight １３．５ kg

２、 Filter Element・ Hydraulic Filter （ Pore size: ６ μ ）（ P/No. ： 207-60-71181 ）

３、 Attachment・ Hose （ for Inlet, Outlet ）・ Suction Strainer （６０ mesh ）

＜ Special Feature ＞・ Small size, light weight Portable

・ Easy obtainable Filter Element

・ Durable Stainless Filter Case




Filtration Capacity

粒子数( / 100ml)個 NAS等級

粒子数( / 100ml)個 NAS等級

５～１５ 1,088,896 12 628,906 12 42.2

１５～２５ 219,693 12 4,096 7 98.1

２５～５０ 85,100 12 1,473 8 98.2

５０～１００9,366 12 183 8 98.0

１００～ 496 11 6 5 98.8

ろ過前ろ過後

粒子径(μ )ｍ

除去率(%)

１、 Test Result （ Element Paper ： Pore size ６ μ ）

Almost 50%

９８％

Cleaned

To be able to remove rubbish contamination in Field

Huge Effect

２、 Remarks

・ Expectable to same effect as Pre-filter （ 10μ ） for contaminated Fuel

・ Results of Fuel Supply Test ： A Barrel （２００ ltr ）／４～５ Min. Refillable

・ Can not remove Water> Water separator maintenance must be done as Usual

・ No use this for Hydraulic oil refill (Hyd. Oil has high Viscosity)

・ In the near Future, Electrical motor pump type would be developed using Field Test Results

Particle size

Before Filtration After Filtration

Particle CpountPcs/100 ml NAS Clss

Particle CpountPcs/100 ml NAS Clss

CleanRatio

Testing Field Survey



Testing, Field Survey

＜ Requested Testing Region ＞

China 、 South East Asia （ Indonesia ）Middle East 、 Africa 、 Latin-America

＜ Survey contents ＞・ Differences clogging condition of Fuel Main and Pre-filter before and

after usage of the Fuel Unit →Weight Comparison of replaced filter

elements, and appearance comparison: taking photos after cuttingelement

・ Confirmation of Manu ability○Air Bleeding, Draining fuel○Treatment of remained fuel in the Hoses○Length of Fuel Hoses

・ Other Request Testing Period Testing Period ：３：３ MonthsMonths （（ Please give your comments by Aug/End)Please give your comments by Aug/End) ））

0009- Fuel Maintenance

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Transcript of 0009- Fuel Maintenance