Ver.

1- 2010-03

Construction Machinery Ⅰ

Structure and Maintenance of

Internal Combustion Engine

Chapter 6
Fuel, Oil and Grease

The Construction Equipment Training Center(CETC)

Japan International Cooperation Agency
1 1
© Employment and Human Resources Development Organization of Japan
 Section 1 fuel
1.1 refinement of crude oil

table 6-1 kinds of petroleum

kinds ingredients major source
more than 2/3
1 paraffin oil of paraffin クエート ,Soudi Arabia,
hydrocarbon Iraq ,Mexico, Peru, Ohio
oil

naphtalene more than 2/3 South-California, ガリシ

of naphtalene
hydrocarbon ア , Rumania, Egypt, スマ
2 or asphalt
oil oil トラ , Japan
3 mixed oil Poland, Rumania, Borneo,
Taiwan
4 abnormal oil
1-1 2
 1.1 refinement of crude oil
(1) fractional distillation
table 6-2 kinds of petroleum
fraction
Products temperature principal specific use
ingredient gravity
gasoline 40 - 225 C2H12-C11H24 0.60-0.75 gasoline engine(direct
petroleum engine, jet
kerosine 125 - 300 C9H20-C18H38 0.75-0.83 engine, lamp, washing
high speed diesel engine,
diesel oil 250 - 350 C14H12-C11H48 0.80-0.88 hot-bulb engine
low speed diesel engine,
hot-bulb engine,gas turbine,
heavy oil > 350 C17H36 - 0.88-0.99 boiler, lubricants, paraffin,
material for cracked
gasoline
petroleum (residual (paraffin base
pitch substance) crude oil) paint, paving, materials for
briquette or medicine
petroleum (residual naphthane base
asphalt substance) crude oil
1-1 3
 1.1 refinement of crude oil

(2) cracking distillation

(3) reforming

1-1 4
 1.2 light oil
table 6-3 regulation for diesel engine
oil
kind JIS K
2203 JIS K 2205 (heavy
ASTM D975 JIS K 2204 (light oil)
(kerosen oil class ?)
e)
property 1-D 2-D 4-D S1 1 2 3 S3 2 1 2
indic ation neutral neutral neutral neutral neutral neutral neutral neutral
flash point 38< 52< 55< 50< 50< 50< 45< 45< 40< 60< 60<
distilution 90%distilution temp (deg C) 282 -
288> 360> 360> 360> 330> 330>
characteristic 338
s 95%distilution temp (deg C) 300>
pour point (deg C) (1) +5> -2.5> -7.5> -20> -30> 5> 5>
cold filter plugging point (deg C) -1> -5> -12> -19>

carbon reside mass (%) 4> 4>

content (10% reside oil ?) mass(%) 0.15> 0.35> 0.10> 0.10> 0.10> 0.10> 0.10>
cetane index 40< 40< 30< 50< 50< 45< 45< 45<
30 deg C 2.7< 2.7< 2.5< 2.0< 1.7<
kinematic 5.5 -
mm2/s (cSt) (3) 40 deg C 1.3 - 2.4 1.9 - 4.1
viscosity (2) 24.0
50 deg C 20> 20>
water (volumetric %) 0.3> 0.3>
water and residual matter (volumetric %) 0.05> 0.05> 0.5>
ash content (mass %) 0.01> 0.01> 0.01> 0.05> 0.05>
sulfur content (mass %) 0.5> 0.5> 2.0> 0.0010> 0.0010> 0.0010> 0.0010> 0.0010> 0.50> 0.50> 2.0>
copper corrosion test No.3> No.3>

note (1) cetane number can be used instead of cetane index. 1-1 5
 1.2 light oil

(1) Reaction

(2) Flash point

(3) Distillation characteristics

(4) Pour point

(5) clogging point

1-1 6
 1.2 light oil

(6) Carbon residue content

(7) Cetane value

(8) Viscosity

(9) Sulfur

1-1 7
 1.3 gasoline
table 6-4 regulation of
gasoline
distilution characteristics
vapor
octane densit copper
pressure
value y 10%dis 50%dis 90%dis corrosi oxidati
residu (38.7 real gum
(resear (15deg tilutio tilutio tilutio termin on test on
kind al oil deg C) (mg/100 color
ch C) n n n al (deg (50 stabilit
KPa ml)
metho (g/cm3 temp temp temp C) (mass deg C, y (min)
%) (Kg/cm2
d) ) (deg C) (deg C) (deg C) 3h)
)

class 1 96.0< 44 -78

0.783> 70> 125> 180> 220> 2.0> 1> (0.45 - 5> 240< orange
class 2 89.0< 0.80)

octane number
Knocking endurance matter
benzene and alcohol
1-1 8
 1.4 treatment of fuel
① clean fuel tank
② leave refilled oil at least one day and night.
③ refill after end of the work of the day to avoid mix water into the
fuel tank from cold air during night time.
④ when refilling, clean around caps before taking off, cans, hoses
and your hands in advance.
⑤ do not refill too much. the fuel may spill out of the tank due to its
expansion by heat.
⑥ when refilling the tank it will be complete if you use a filter cloth.
⑦ remove water and dust 5 – 10 min after refill or when you start
the engine.
⑧ take off a drain plug of a store tank and a fuel tank of the machine
to drain sediment.

1-1 9
 Section 2 oil and grease 2.1 engine oil
shaft

oil film a. lubricating

Journal b. sealing
no direct contact
c. cooling
compression pressure
d. cleaning(detergent)

Cylinder wall
Oil e. rust prevention
piton
helps
air tight

oil film
Fig 6-1 working of engine oil
1-1 10
 Section 2 oil and grease 2.1 engine oil
Table 6-5 characteristics and performance of engine oil
characteristics
detergent oxdation abration rust prevention,
viscosity
performance disperse stability resistance antifoaming

low temp starting O

friction loss - fuel
O O
consumption
oil consumption O
sticking or damage of piston ring O O
dirty inside engine O O
stick of oil filter O
sediment in combustion
O O
chamber
corrosion or rust O O O
oil life time O O
stick or wear of lubricated
O O O
portion
oil less by foam 1-1 O 11
 2.1 engine oil
table 6-6 SAE viscosity grade of engine oil (1993)
low temp viscosity high temp viscosity
cranking pumping kinematic viscosity, cSt(mPa*s) high shear viscosity,
SAE viscosity viscosity, cP viscosity, cP @limit temp deg C, max cP(mPs*s), @150 deg
grade (mPa*s) (mPa*s) C, 106s-1, max
@measuring @measuring
temp, max temp deg C, max min max
0W 3,250 @ -30 30,000 @ -35 3.8 - -
5W 3,500 @ -25 30,000 @ -30 3.8 - -
10W 3,500 @ -20 30,000 @ -25 4.1 - -
15W 3,500 @ -15 30,000 @ -20 5.6 - -
20W 4,500 @ -10 30,000 @ -15 5.6 - -
25W 6,000 @ - 5 30,000 @ -10 9.3 - -
20 - - 5.6 9.3> 2.6
30 - - 9.3 12.5> 2.9
2.9 (0W40, 5W40,
40 - - 12.5 16.3> 10W40)
40 - - 12.5 16.3> 3.7 (15W40, 20W40,
25W40, 40)
50 - - 16.3 21.9> 3.7
60 - - 21.9 26.1> 3.7

1-1 12
 2.1 engine oil

table 6-7 ambience temp and recommended viscosity

SAE viscosity ambience temp
season
number (deg C)
spring, autumn,
10W -30 - 40
winter
spring, summer,
30 -10 - 40
autumn
seriously hot
40 0 - 50
area
15W/40 -20 - 40 all season
1-1 13
 2.1 engine oil
table 6-6 SAE viscosity grade of engine oil (1993)
low temp viscosity high temp viscosity
kinematic viscosity, high shear viscosity,
SAE viscosity cranking viscosity, cP pumping viscosity, cP cSt(mPa*s) @limit cP(mPs*s), @150 deg
grade (mPa*s) @measuring (mPa*s) @measuring temp deg C, max C, 106s-1, max
temp, max temp deg C, max
min max
0W 3,250 @ -30 30,000 @ -35 3.8 - -
5W 3,500 @ -25 30,000 @ -30 3.8 - -
10W 3,500 @ -20 30,000 @ -25 4.1 - -
15W 3,500 @ -15 30,000 @ -20 5.6 - -
20W 4,500 @ -10 30,000 @ -15 5.6 - -
25W 6,000 @ - 5 30,000 @ -10 9.3 - -
20 - - 5.6 9.3> 2.6
30 - - 9.3 12.5> 2.9
2.9 (0W40, 5W40,
40 - - 12.5 16.3> 10W40)
3.7 (15W40, 20W40,
40 - - 12.5 16.3> 25W40, 40)
50 - - 16.3 21.9> 3.7
60 - - 21.9 26.1> 3.7

1-1 14
 1-1 combustion of gasoline engine

table 6-9 SAE viscosity grade of gear oil

max temp (deg C) visicosity at 100 deg C (cSt)
SAE viscosity when viscosity
grade number reaches 150,000 min max
cP
75W -40 4.1 -
80W -26 7.0 -
85W -12 11.0 -
90 - 13.5 24.0>
140 - 24.0 41.0>
250 - 41.0 -

1-1 15
 2.3 hydraulic oil

table 6-10 ISO viscosity grade of industrial lubrication oil

median of
ISO viscosity kinematic viscosity range of kinematic
viscosity mm2/s
grade mm2/s (cSt) (cSt) (40deg C)
(40deg C)
ISO VG 22 22 19.8 - 24.2
ISO VG 32 32 28.8 - 35.2
ISO VG 46 46 41.4 - 50.6
ISO VG 68 68 61.2 - 74.8
ISO VG 100 100 90.0 - 110

1-1 16
 2.4 grease
table 6-11 features of lubrication by grease
It can work for long time without supply of grease, as it
1 remains as it is in journals.
As grease itself works as seal, it can prevent water and dust to
invade into bearings. So, a seal structure of lubricated portions
2 can be easily designed.
merit
Good lubrication can be obtained in low rotation speed, high
3 load, high and low temperature, impact load, and on moving
portions as well.
As oil film is kept , rust and corrosion are prevented even in
4 long time work.
It is a little bit hard to deal with supplying, exchanging, cleaning
1 of grease.

2 It is hard to remove invaded water or dust if any.

deme
rit cooling effect is low, and heat generated by stiring resistance is
3 generally big.

4 It can not be used for a high rotation speed portion.

1-1 17
 1-1 combustion of gasoline engine
table 6-12 main kinds of grease
material for general
look feature main use
hardening name

Oil and soap are separated at around 80 deg C. good water- General machine. Water
calcium like butter cup grease
resistance. Fairly good mechanical atability. resitance rewuireed use

Usable till around 180 deg C due to its high melting point.
sodium like fiber Good water-resistance and fairly good mechanical stability, rolling bearing fiber grease
but water-resistance is not good.

structure does not change till melting point. Good

vibrational bearing joint, aluminum
aluminum semi-fluidity adhesion. Usable till around 80 deg C. Good water-
rubbing parts. grease
resistance. Mechanical sability is less than middle grade.

the best of soap base greases. Usable till 150 deg C. good all
lithium like butter bering which requiers all
heat-resistance, water-resistance, mecanical stability. multi
heat resitsance, water-
purpose
good next to litium. Mechanical stability is middle grade. resistance and
grease
barium like butter Not suitable for a low temperature use because of its much mechanical stability.
quantity of soap.

Worse adhesion and rust-resistance for metal surface in

mainly for a roller table heat-
comparison with soap base greases. Multi purpose type of
bentonite like butter of a high temperature resistance
this grease is almost good at water-resistance and
1-1 rolling mill. grease
18
mechanical stability.
 1-1 combustion of gasoline engine

table 6-13 classification of hardness of grease

NLGI number 兆度 (25 deg C) hardness

No.000 445 - 447 semi-fluidized

No. 00 400 - 430 semi-fluidized
No. 0 355 - 385 soft
No. 1 310 - 340 soft
No. 2 265 - 295 average
No. 3 220 - 250 average
No. 4 175 - 205 a little hard
No. 5 130 - 160 hard
No. 6 85 - 115 solid
1-1 19
 2.5 solid lubricant 2.6 cautions for oil supply

(1)General cautions

(2)Cautions during inspection and supply of oil

(3)Cautions for greasing

(4)Cautions for exchanging of oil

1-1 20
 Section 3 coolant and anti-freeze
3.1 coolant

table 6-14 condition of suitable cooling water

included material content
chlorine ion 50ppm>
sulfuric acid ion 50ppm>
total hardness 100ppm>
residue on evaporation 250ppm>
pH 6.5<
1-1 21
 3.2 anti-freeze
table 6-15 regulation of anti-freeze(JIS K2234;2006)
kind
1 2
item (usable in (usable
winter) through year)

-34.0>
freezing point (deg C) 50% volumetric aqueous solution
30% volumetric aqueous solution 7.0 - 11.0
PH (ordinary
temperature) 30% volumetric aqueous solution
metal corrosion change cast aluminium ±0.60 ±0.30
30% volumetric of metal cast iron ±0.30 ±0.15
test solution test
88±2deg C piece steel ±0.30 ±0.15
336±2h mass brass ±0.30 ±0.15
(mg/cm3) solder ±0.60 ±0.30
copper ±0.30 ±0.15
density (20 deg C) (g/cm3) 1.112<
boioling point 155<
frothing 30% volumetric 4>
aqueous
1-1 solution 22
 1-1 combustion of gasoline engine

table 6-16 usable limit temperature for antifreeze density

density (%) usable temp
0 0 deg C <
10 -4 deg C <
20 -9 deg C <
30 -15 deg C <
40 -25 deg C <
45 -30 deg C <
1-1 23
1-1 24