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8/6/2019 0009- Fuel Maintenance
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Media KME-003-06 KTPage 1 (10/06)
Maintenance FOWA
Fuel Maintenance
&
Fuel Management
USER’S TEXTMAINTENANCE COURSE
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Media KME-- KTPage 2 (/)
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$
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Media KME-- KTPage (/)
Fuel - MaintenanceFuel - Maintenance
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%
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Media KME-003-06 KTPage 4 (10/06)
Incorrect way
of
transportation
and charge
40%
Others
10%
Poor Daily
Maintenanc
e
50%
Fuel - MaintenanceFuel - Maintenance
The Statistic of Engine Trouble Caused by Fuel ProblemsThe Statistic of Engine Trouble Caused by Fuel Problems
Poor MaintenancePoor Maintenance
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Media KME-003-06 KTPage 5 (10/06)
Fuel - MaintenanceFuel - Maintenance
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
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Media KME-003-06 KTPage 6 (10/06)
Piston rings broken byPiston rings broken by
carboncarbon
1350 hours1350 hoursSlight wear Slight wear 8053 hours8053 hours
Fuel - MaintenanceFuel - Maintenance
Poor MaintenancePoor MaintenanceExamples (Discard)Examples (Discard)
Correct MaintenanceCorrect MaintenanceExamples(still usable)Examples(still usable)
8/6/2019 0009- Fuel Maintenance
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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
Fuel - MaintenanceFuel - Maintenance
Poor MaintenancePoor MaintenanceExamples (Discard)Examples (Discard)
Correct MaintenanceCorrect MaintenanceExamples(still usable)Examples(still usable)
8/6/2019 0009- Fuel Maintenance
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Fuel - MaintenanceFuel - Maintenance
Poor MaintenancePoor MaintenanceExamples (Discard)Examples (Discard)
Correct MaintenanceCorrect MaintenanceExamples(still usable)Examples(still usable)
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
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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
Fuel - MaintenanceFuel - Maintenance
8/6/2019 0009- Fuel Maintenance
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Fuel - MaintenanceFuel - Maintenance
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
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Fuel - MaintenanceFuel - Maintenance
Dirty fuel canDirty fuel can
XX
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Fuel - MaintenanceFuel - Maintenance
Fuel can notFuel can notbe putbe put
everywhereeverywhereXX
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Fuel - MaintenanceFuel - Maintenance
Water andWater and
impurity getimpurity get
in throughin through
thethe
clearanceclearance
XX
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ImpurityImpurity
on theon the
Pre-filterPre-filter
Fuel - MaintenanceFuel - Maintenance
8/6/2019 0009- Fuel Maintenance
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SedimentSediment
in the waterin the water
separatorseparator
Fuel - MaintenanceFuel - Maintenance
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Fuel - MaintenanceFuel - Maintenance
sedimentsediment
in the injectionin the injection
pumppumpPre-filterPre-filter
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Fuel - MaintenanceFuel - Maintenance
impurityimpurity
in thein the
imitationimitation
filterfilter
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Fuel - MaintenanceFuel - Maintenance
impurity in theimpurity in the
injection pumpinjection pump
filterfilter
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Fuel - MaintenanceFuel - Maintenance
Steel scrapsSteel scraps
in the fuelin the fuel
filterfilter
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Fuel - MaintenanceFuel - Maintenance
Poor fuel andPoor fuel and
sedimentsediment
l
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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
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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
Right and wrong in the fuel managementRight and wrong in the fuel management
XXOK OK
Fuel - ManagementFuel - Management
lF l M
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Media KME-003-06 KTPage 3 (10/06)
Right and wrong in the fuel managementRight and wrong in the fuel management
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
Fuel - ManagementFuel - Management
lF l M t
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Media KME-003-06 KTPage 4 (10/06)
Right and wrong in the fuel managementRight and wrong in the fuel management
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
Fuel - ManagementFuel - Management
F l MF l M t
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Media KME-003-06 KTPage 5 (10/06)
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
Right and wrong in the fuel managementRight and wrong in the fuel management
Fuel - ManagementFuel - Management
F l MF l M t
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Media KME-003-06 KTPage 6 (10/06)
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
Right and wrong in the fuel managementRight and wrong in the fuel management
XXOK OK
Fuel - ManagementFuel - Management
F l M tF l M t
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Media KME-003-06 KTPage 7 (10/06)
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
Fuel - ManagementFuel - Management
F l M tF l M t
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Media KME-003-06 KTPage 8 (10/06)
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
Correct fuel managementCorrect fuel management
Fuel - ManagementFuel - Management
F l M tF l M t
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Media KME-003-06 KTPage 9 (10/06)
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)
Correct fuel managementCorrect fuel management
Fuel - ManagementFuel - Management
F l M tF l M t
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Media KME-003-06 KTPage 30 (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
Fuel - ManagementFuel - Management
F l M tF l M t
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Media KME-003-06 KTPage 31 (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 - ?
Fuel - ManagementFuel - Management
F l M tFuel Management
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Media KME-003-06 KTPage 3 (10/06)
How to fill the fuel
Fuel - ManagementFuel - Management
F l M tFuel Management
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Media KME-003-06 KTPage 33 (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
Fuel - ManagementFuel - Management
F el ManagementFuel Management
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Media KME-003-06 KTPage 34 (10/06)
Fuel - ManagementFuel - Management
Fuel ManagementFuel Management
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Fuel - ManagementFuel - Management
Fuel ManagementFuel Management
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Media KME-003-06 KTPage 36 (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.
Fuel - ManagementFuel - Management
Fuel ManagementFuel Management
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Fuel - ManagementFuel - Management
FUEL PUMP UNIT WITH FILTERFUEL PUMP UNIT WITH FILTER
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Media KME-003-06 KTPage 38 (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
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Media KME-003-06 KTPage 39 (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 )
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Media KME-003-06 KTPage 40 (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
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Media KME-003-06 KTPage 41 (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
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Media KME-003-06 KTPage 4 (10/06)
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
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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) ))