COMPONENT CODE [AO PARTS & SERVICE ‘AS10077 Mar 29, 1991 NEWS Tugel ot ‘SUBJECT: PREVENTIVE CHECK OF SA12V140 ENG. BY OIL ANALYSIS & BLOW-BY PURPOSE: To introduce the method of preventive checking of SA12V140 engine APPLICATION: | SA12V140-1 Engines DESCRIPTION: 1. Introduction ‘The following is a checking method effective to prevent the SA12V140 engine from becoming faulty due to deterioration of oil, Note: The values used in this PARTS & SERVICE NEWS apply to only the SA12V140 engine. 2, Items to be measured 1) Oilanalysis Sample 200 ce of fresh oil and 200 cc of used oil. Analyze each sample for total basic number (T.B.N.), total acid number (T.A.N.), insoluble matter, and kinematic viscosity. For details of analysis methods of those items, refer to the following: i) TBI: Perchloric acid method (ASTM D2896) ii) TAN: ASTM D664 iii) Insoluble matter: ASTM D893 (B method) ‘Mutual relation to the soot index method is shown in Fig. iv) Kinematic viscosity: ASTM D445, 446 When sampling the used oil, clearly record the reading of machine service meter (or engine operating hours if the engine on the test machine has already been replaced) and the time spent after the oil change which was made lately. To ensure proper judgment based on highly accurate analysis, used oil should be sampled after at least 150 hrs operation ‘since the late time oil was changed. 200 | @ 10 1 i | = 100 | V | ° | ° 10 20 30 Insoluble matter (%) Fig. 1 Insoluble Matter to Soot Index Printed in Japan : 91007 “on2e0 ee KOMATSUPage 2 of 6 2) Blow-by measurement SA12V140 engine (on WA800-2) blow-by measuring procedure (for Pm-clinic, Tool No. 799-201-1100) @® Since the right and left banks have the respective breathers, measure blow-by pressure for both banks separate from each other. RH bank LH bank Rubber hoses on engine side (inside dia. $19) Blow-by tool @i) Blowby tool as Blow by toot @, (1000 mmAq) G4 Bow byiod @ (wo sonore NEW soem (699-20 ert) ene @ When measuring blow-by pressure of the LH bank, plug the end of hose on the RH bank side. RH bank LH bank BB lug the hose end A910077Page 3 of 6 12V140 engine (on HD785-3) blow-by measuring procedure (for Pm-clinic) @®_ Since the right and left banks have the respective breathers, measure blow-by pressure for both banks separate from each other. Rubber hoses on engine side (inside dia, ¢19) Biow-by tool @ 797-20 LS9O, GAUGE (100 mm Aq) Blow oot @ Blow-by toot Blow-by toot @ ea 2 coe @® When measuring blow-by pressure of the LH bank, plug the end of hose on the RH bank side. RH bank LH bank Be Plug the hose end A910077Page 4 of 6 12V140 engine (on D475 A-2) blow-by measuring procedure (for Pra-clinic) @® Since the right and left banks have the respective breathers, measure blow-by pressure for both banks separate from each other. Biow-by tot @ Cut out the straight part of tube by 90 mm, [Cat out he straight part of fue by 100 TE] Sxenoes tote Gand D> -ERemove bolts Le) I Bolt D and B> Bolt B Detail @ Detail P @ After blow-by measurement, connect the cut ends of the tube (which has been cut out as shown in details Q and P) to each other with a hose (160 mm long -— hose 07287-01912 out down to this length may be used) and fasten the joint at each end of the hose with clamp (07285-00220). @ When measuring blow-by pressure of the LH bank, Plug the end of hose on the RH bank side. GAUGE RH bank LH bank A @ ‘ Engine & & 7 GAS GAS Plug the hose end 4910077Page 5 of 6 3, Judgment standard 3-1 Compensation of measurement data v 2) Ol analysis value Since deterioration of oil progresses with time, convert the measurements into the values corresponding to 250 hrs. of operation (oil change interval specified for this engine using class CD engine oil). Use the following equations for conversion: i) TBN. i) TAN, iii) Insoluble matter r=Ix 250 iv) Kinematic viscosity No conversion needed. Here, To, Ta, Irepresent the values (uncorrected) measured after ’t” hours of operation; ‘Teo and Tao represent the values of fresh oil analysis; and Tw’, Tx’, I’ represent the corrected values. Blow-by gas pressure Since engine output set value and measurement point are dependent on machine models, the following correction should be made: i) HD785-3 : Actual measurement (torque-converter stall point) X 0.5 fi) WA800-2: Actual measurement (full stall point) X 1.0 iii) D475-2 : Actual measurement (torque-converter stall point) X 1.0 3-2. Deterioration evaluation Evaluate the corrected measurements and give them marks, making reference to the table below. Table 1 Deterioration evaluation marks Item Unit ° 1 2 4 8 @ Biowry | mmaa | 0—100 | 101 —200 | 201 — 900 [301 or more @® TBN. (Ts)| mgkoH/g | 100rmore | 80—99 | 60-79 | 30-59 | 29orless @ TAN (tH] maKot/g | Boriess | 31—50 | 51—80 [81 ormore @ Insoluble so {3 mare oo] o~10 | 11-20 | 2130 | 3.1 ormore 4910077Page 6 of 6 3-3. Measures to be taken ‘Total the deterioration evaluation marks for 4 items. Depending on the result, take necessary measures such as shown in the table below. Table 2 ‘Total of marks Judgment ‘Measures to be taken Liormore | Disassembly needed | Disassemble and check. Replace parts if necessary. 6—10 Attention needed Continue oil analysis, giving attention to results. Bor less No problem. ‘Analyze oil again after 1000 hrs. of operation. For kinematic viscosity, a 70% or more drop from the initial value involves a suspicion of fuel leak. Check for fuel leak from the injection pump or injection nozzles. If no blow-by is measured, use the table below for making a judgment. Evaluation | Judgment Measures to taken or mor Check blow-by pressure and take the measures shown in Table 4 e Check 2, If there is no problem, continue oil analysis. Bor less No problem | Analyze oil again after 1000 hrs. of operation. 4910077