USER’S TEXT

MAINTENANCE COURSE

Maintenance FOWA

Fuel Maintenance
&
Fuel Management

Page 1 (10/06) Media KME-003-06 KT

 Fuel - Maintenance

The fuel injection pump’s life and cost

25000
1910$
20000
8000H ～ 12000H
15000

10000
1500H
5000

0 General Overhaul by bad Overhaul cost

overhaul management of
fuel

Page 2 (10/06) Media KME-003-06 KT

 Fuel - Maintenance
The Statistic of Engine Trouble Caused by Fuel Problems

Others
20%

Too
Too much
much water
impurity 35%
45%

Page 3 (10/06) Media KME-003-06 KT

 Fuel - Maintenance
The Statistic of Engine Trouble Caused by Fuel Problems

Poor Maintenance
Incorrect way Others
of 10%
transportation
and charge Poor Daily
Maintenanc
40% e
50%

Page 4 (10/06) Media KME-003-06 KT

 Fuel - Maintenance
Poor Maintenance Correct Maintenance
Examples (Discard) Examples(still usable)

1500 H 7250 hours

Much carbon round A few carbon
the piston head and
ring grooves
Page 5 (10/06) Media KME-003-06 KT
 Fuel - Maintenance

Poor Maintenance Correct Maintenance

Examples (Discard) Examples(still usable)

1350 hours 8053 hours

Piston rings broken by Slight wear
carbon

Page 6 (10/06) Media KME-003-06 KT

 Fuel - Maintenance

Poor Maintenance Correct Maintenance

Examples (Discard) Examples(still usable)

850 hours 8135 hours

The injection nozzle is The nozzle is normal with
clogged by heavy fuel oil only slight wear

Page 7 (10/06) Media KME-003-06 KT

 Fuel - Maintenance

Poor Maintenance Correct Maintenance

Examples (Discard) Examples(still usable)

1035 hours 8750`hour

The plunger is rusted and worn Slight wear
by too much water

Page 8 (10/06) Media KME-003-06 KT

 Fuel - Maintenance
Fuel sample compare
usable unusable unusable

Pure color, Black, with Light color,

with out much low
impurity water,impurity viscosity,with
and water and heavy oil much water
and impurity
Page 9 (10/06) Media KME-003-06 KT
 Fuel - Maintenance
Please buy the fuel from big and reliable station
Fuel sample statistics
[Station ： 7 ； User ： 24]
Both water and impurity are over the standard
Special example
1.5 1.325
1.2 Special example

0.9 0.7623 Too much impurity

Too much water
0.6 sample sample
Standard 0.063 Standard
0.3 0.1232 0.03
0
0
water impurity

Special sample Fuel sample State standard

Page 10 (10/06) Media KME-003-06 KT
 Fuel - Maintenance

X
Dirty fuel can

Page 11 (10/06) Media KME-003-06 KT

 Fuel - Maintenance

Fuel can not

X
be put
everywhere

Page 12 (10/06) Media KME-003-06 KT

 Fuel - Maintenance

Water and
impurity get
in through
the
X
clearance

Page 13 (10/06) Media KME-003-06 KT

 Fuel - Maintenance

Impurity
on the
Pre-filter

Page 14 (10/06) Media KME-003-06 KT

 Fuel - Maintenance

Sediment
in the water
separator

Page 15 (10/06) Media KME-003-06 KT

 Fuel - Maintenance

sediment
in the injection
pump
Pre-filter

Page 16 (10/06) Media KME-003-06 KT

 Fuel - Maintenance

impurity
in the
imitation
filter

Page 17 (10/06) Media KME-003-06 KT

 Fuel - Maintenance

impurity in the
injection pump
filter

Page 18 (10/06) Media KME-003-06 KT

 Fuel - Maintenance

Steel scraps
in the fuel
filter

Page 19 (10/06) Media KME-003-06 KT

 Fuel - Maintenance

Poor fuel and

sediment

Page 20 (10/06) Media KME-003-06 KT

 Fuel - Management
Right and wrong in the fuel management

X OK

Dust, water and yarn may Cover a plastic sheet to

get in to the fuel can prevent water and dust
Page 21 (10/06) Media KME-003-06 KT
 Fuel - Management
Right and wrong in the fuel management

OK
X
50mm

Water and sediment will Keep the suction pipe

be sunk into fuel tank 50mm from the fuel can
bottom
Page 22 (10/06) Media KME-003-06 KT
 Fuel - Management
Right and wrong in the fuel management

OK
X
Clean fuel is made dirty The filler and fuel can
should be clean

Page 23 (10/06) Media KME-003-06 KT

 Fuel - Management
Right and wrong in the fuel management

OK
X
Water, impurity and Settle 24 hours , send to
fuel will mix together the machine by a go-cart
again
Page 24 (10/06) Media KME-003-06 KT
 Fuel - Management
Right and wrong in the fuel management

OK
X
Dust gets into the fuel tank Put a silk stocking outside
the clean pipe, this help to
resist the impurity
Page 25 (10/06) Media KME-003-06 KT
 Fuel - Management
Right and wrong in the fuel management

OK
X
Unsafe, fuel can too dirty, It is a good way to charge
the dust gets into the fuel by a manual pump
tank by the pipe
6

Page 26 (10/06) Media KME-003-06 KT

 Fuel - Management
Correct fuel management
1
Drain the water and dust
from the fuel tank every
morning 。
(prevent water and
sediment from getting
into the fuel system,
especially that will clog
the pre-filter)

Page 27 (10/06) Media KME-003-06 KT

 Fuel - Management
Correct fuel management
2
Check the water
separator every
morning, drain
water and
sediment if the
float over the
red mark

Page 28 (10/06) Media KME-003-06 KT

 Fuel - Management
Correct fuel management
3
Fill the fuel tank
after the work is
finished 。
(pile out the air
in the tank, this
will prevent the
steam)

Page 29 (10/06) Media KME-003-06 KT

 Fuel - Management
Genuine filter Imitation filter
Imitation
Komatsu filter
genuine filter Hole is big,
Hole is small, low
high filtering filtering
ability ability

5μ

●genuine filter ： keep the impurity out of the mesh

Imitation filter ： impurity can pass easily
Page 30 (10/06) Media KME-003-06 KT
 Fuel - Management

• 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 - ?

Page 31 (10/06) Media KME-003-06 KT

 Fuel - Management
How to fill the fuel

Page 32 (10/06) Media KME-003-06 KT

 Fuel - Management
How to fill the fuel

1- With cap
on, fill the 2- After filling
filter with the filter with
the clean the fuel, remove
fuel. cap and dispose
it.

Page 33 (10/06) Media KME-003-06 KT

 Fuel - Management

Page 34 (10/06) Media KME-003-06 KT

 Fuel - Management

Page 35 (10/06) Media KME-003-06 KT

 Fuel - Management
Propose Fuel Handling Method: -
Primary Receiving Storage Fuel Tank

INFLAMMABL
x
E Upper
Ram

x
Secondar
y Storage
x

Fuel Tank
Lower Ram

1.) Primary Receiving Storage Fuel Tanks : - Mobil

e
a.) Main function is to store dis-charged fuel from
tanker for 2 ~ 3 days to collect sediments before
transferring to Secondary Storage Fuel Tank.
Kiosk

2.) Secondary Storage Fuel Tanks : -

a.) To store clean fuel for consumption via kiosk.
x
Page 36 (10/06) Media KME-003-06 KT
 Fuel - Management

Page 37 (10/06) Media KME-003-06 KT

FUEL PUMP UNIT WITH FILTER

Presentation of experimental
kit for field test

Page 38 (10/06) Media KME-003-06 KT

 「 LAST CHANCE FILTER 」！ To be Protected for
Engine

From Dust, Rubbish contamination of Fuel when fuel refill from Barrel
Easy obtainable FILTER
ELEMENT
Filtering “Hyd oil Filter” use
Filter Case

Poor Fuel （ No applicable to use

this unit, in case of
refilling fuel to machine
Pump from Special fuel tank
and/or fuel supply;y truck
Lever with motoring fuel
handle pump ）

Clean Fuel ！
↓
Reduce filter suction Load, Prevente failure

Page 39 (10/06) Media KME-003-06 KT

 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

Page 40 (10/06) Media KME-003-06 KT

 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
Page 41 (10/06) Media KME-003-06 KT
 Filtration Capacity
１、 Test Result （ Element Paper ： Pore size ６ μ ）

ろ過前
Before Filtration ろ過後
After Filtration
Clean
粒子径
Particle size 粒子数
Particle Cpount 粒子数
Particle Cpount 除去率
Ratio
(μ ｍ) (個Pcs/100
/ 100m ml l) NAS等級
NAS Clss (個 / 100m
Pcs/100 ml l) NAS等級
NAS Clss (%)
５～１５ 1,088,896 12 628,906 12 42.2 Almost 50%
１５～２５ 219,693 12 4,096 7 98.1
２５～５０ 85,100 12 1,473 8 98.2 ９８％
５０～１００ 9,366 12 183 8 98.0 Cleaned
１００～ 496 11 6 5 98.8
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

Page 42 (10/06) Media KME-003-06 KT

 Testing, Field Survey

＜ Requested Testing Region ＞

China 、 South East Asia （ Indonesia ）
Middle East 、 Africa 、 Latin-America
＜ Survey contents ＞
・ Differences clogging condition of Fuel Main andPre-filter before and
after usage of the Fuel Unit →Weight Comparison of replaced filter
elements, and appearance comparison: taking photos after cutting
element
・ Confirmation of Manu ability
○Air Bleeding, Draining fuel
○Treatment of remained fuel in the Hoses
○Length of Fuel Hoses
・ Other Request
Testing Period ：３ Months （ Please give your comments by Aug/End) ）

Page 43 (10/06) Media KME-003-06 KT