1、,Volvo Construction Equipment Lubricants,Lubrication Training,Back to Marketing Program overview,Module Overview,Lubrication Principles Engine Lubrication Transmission Lubrication Automatic Transmission Fluids Grease Lubrication,Back to Marketing Program overview,Lubrication Principles - Section Ove
2、rview,Refining Process Refinery Products from Crude Oil Lubricant Base-stocks Key Lubricant Functions Key Lubricant Properties Viscosity Viscosity Classification System (SAE) Mono-grade Vs. Multi-grade Pour Point / Flash Point / Volatility Conventional Vs. Synthetic lubricant ? Synthetic Lubricants
3、Lubricant Additives Additive Types,Back to module overview,Refining Process,Two Main Processes: Separation Processes Selects Desirable Components from the Crude Includes Distillation, Solvent Extraction, Solvent Dewaxing Conversion Processes Convert Undesirable Elements into Useful Lube Oil Componen
4、ts Aromatics, Sulfur, Wax, etc. Includes Hydrotreating, Hydrofinishing, Hydrocracking and Catalytic Dewaxing To achieve desired properties,Back to section overview,Refinery Products from Crude Oil,Back to section overview,BASESTOCK SELECTION,ADDITIVE SELECTION,FINISHED LUBRICANT,Lubricant Basestocks
5、,Back to section overview,Lubricant Basestocks,Mineral Oil Basestocks Refined from Crude OilTrue Synthetic Basestocks are Derived from Chemical ReactionsSome companies now consider very highly refined mineral oil as “Synthetics”,Back to section overview,Key Lubricant Functions,Separate moving surfac
6、es Cooling Sealing Wear protection Rust, corrosion and foam inhibition Anti oxidation Dispersancy Detergency,Back to section overview,Key Lubricant Properties,Viscosity Pour Point Flash Point Volatility,Back to section overview,Viscosity,Measure of a fluids resistance to flow Changes with Temperatur
7、e higher temperature, lower viscosity Pressure higher pressure, higher viscosity Shear Rate higher the shear rate, lower viscosityViscosity Index Effect of change of temperature on the viscosity of an oil,Back to section overview,Viscosity Classification System (SAE),Back to section overview,Mono-gr
8、ade Vs. Multi-grade,Mono-Grades Meets the requirements of one SAE viscosity grade e.g. SAE 15W (Winter Grade) or SAE 40 (Summer Grade) Low temperature viscosity critical for winter grades, high temperature viscosity critical for summer grades Multi-Grades Meets the requirements of more than one SAE
9、viscosity grade (Both winter & summer grades) Combine summer and winter SAE grades in one oil e.g. SAE 15W-40 has the low temp. properties of SAE 15W & the high temp. properties of SAE 40 Higher VI than Mono-Grades,Back to section overview,Pour Point / Flash Point / Volatility,Pour Point Defines the
10、 Temperature at Which Fluid no Longer Flows Has Direct Effect on Fluid Pumping Temperature Gives an indication of cold flow properties Flash Point Temperature at which vapor from a heated oil ignites when exposed to a naked flame Indicates the fire hazard Volatility A measure of an engine oils tende
11、ncy to evaporate at high engine temperatures,Back to section overview,Conventional Vs. Synthetic lubricant ?,Synthetic Lubricant Produced from Chemical Feedstocks Basestock is Engineered Through a Catalytic Process (Creating a synthesized material),Conventional Lubricant Produced from Crude Oil Base
12、stocks are Obtained by REMOVING Undesirable Components,Synthetic,Conventional,Back to section overview,Synthetic Lubricants,Advantages Replaces Volatile Light Mineral Oil Reduced Lubricant Consumption Improved Fuel Economy Improves Low Temperature Performance Oxidation Stability,Back to section over
13、view,Lubricant Additives,Chemical Compounds Which are Added to Lube Oil Stocks to Improve Their Performance Properties Supplement or Reinforce Well-refined, High-quality Basestocks Perform Two Critical Functions: Maximize Beneficial Properties Minimize Destructive Processes Oxidation Wear Rust/Corro
14、sion Shear “Combustion”,Back to section overview,Additive Types,Dispersants Detergents Anti-Wear Agents Friction Modifiers Oxidation Inhibitors Rust Inhibitors Viscosity Index Improvers Pour Point Depressants Foam Inhibitors,Back to section overview,Engine Lubrication - Section Overview,Main Engine
15、Parts Gasoline Vs. Diesel Diesel Engine Designs Turbocharger Engine Oil Functions Engine Oil Components Major International Engine Oil Specifications API Classification API Diesel Oil Quality Levels ACEA Classification Other Classifications Engine Builder Trends,Back to module overview,Main Engine P
16、arts,Back to section overview,Gasoline Vs. Diesel,Section 2 - Engine Lubrication,Back to section overview,Gasoline Vs. Diesel,Gasoline Quieter Lighter Faster Better acceleration Lower initial cost Catalyst emissions control,Better fuel economy Heavier Longer life Good reliability Catalyst and partic
17、ulate trap emissions control,Back to section overview,Diesel Engine Designs,Back to section overview,Turbocharger,Back to section overview,Engine Oil Functions,Friction & Wear Reduction Cooling Sealing Detergent & Dispersant Rust & Corrosion Inhibitor Diagnosis Foam Inhibitor,Back to section overvie
18、w,Engine Oil Components,Base Oil: 70% to 95% of final product Additives: 30% to 5% of final product,+,=,Base Oil,Additives,Final Product,Back to section overview,Major International Engine Oil Specifications,API (American Petroleum Institute) ACEA ( Association des Constructeurs Europens dAutomobile
19、s ) VDS (Volvo) MB MAN Scania RVI (Renault) Allison CAT (Caterpillar) ZF,Back to section overview,Diesel CA (Obsolete)CD (1965) CE (1988) CF (Heavy Duty Off Highway) CF-2 (Two Cycle) (1994) CF-4 (1990) CG-4 (1994 Low Emissions) CH-4 (1998 Low Emission) CI-4 (2002 Low Emission),Gasoline SA (Obsolete)
20、 SG (1989) SH (1993) SJ (1996 Introduced),API Classification,Back to section overview,API Diesel Oil Quality Levels,Back to section overview,ACEA Classification,Gasoline A1-98 A2-98 A398,Heavy Duty Diesel E1-98 (obsolete) E2-98 E3-98 E4-98 E5-99,Passenger Car Diesel B1-98 B2-98 B3-98 B4-98,Back to s
21、ection overview,Other Classifications,Volvo VDS VDS-2 VDS-3,Heavy Duty Diesel MAN 270 MAN 271 MAN 3275 MAN 3277,MB 227.0 228.1 228.3 228.5,Back to section overview,Engine Builder Trends,Higher Horsepower up to 600 HP Higher Injection Pressures New metallurgy in components New timing maps - Expect hi
22、gher soot levels Development of EGR Engines Greatly extended service intervals Alternate filtration systems New engine designs,Back to section overview,Transmission Lubrication - Section Overview,Manual Transmission Types Of Gears Synchromesh Gears Differential Limited Slip Differential Functions of
23、 a Gear Lubricant Gear Oil Properties Gear Oil Specifications - API,OEM Requirements - Mercedes OEM Requirements - ZF OEM Requirements - Volvo & Scania OEM Requirements - MAN Commercial Vehicle Trends OEM Drain Periods Comparative Viscosity Classes,Back to module overview,Manual Transmission,Allows
24、the driver to select the gear, and therefore the power output of the engine that is needed for the speed and control of the vehicle As the drive leaves the engine, it passes through the clutch It enters the gear box And leaves to the wheels,Back to section overview,Types Of Gears,Spur Gears,Hypoid G
25、ear,Back to section overview,Synchromesh Gears,When changing gears, the gears are rotating at the speed of either the drive shafts or the engine To prevent damage the synchromesh equalizes the speeds of the gear shafts before engaging the gears,Back to section overview,Differential,When a vehicle dr
26、ives round a corner the outer wheel travels further than the inner To do this they need to travel at different speeds This is called differential or the equal distribution of turning power,Back to section overview,Limited Slip Differential,If traction is lost on one wheel, extra torque is transmitte
27、d to the opposite wheel Fitted to off-highway vehicles and some sport cars Requires friction modified lubricant,Back to section overview,Functions of a Gear Lubricant,Prevent metal-to-metal contact Provide good shiftability at all temperatures Dissipate heat Prevent rusting Carry away wear debris Re
28、duce friction Improve fuel economy,Back to section overview,Gear Oil Properties,Load carrying / antiwear Oxidation resistance Corrosion protection Thermal stability/ cleanliness Frictional properties Foam suppression Seal compatibility,Back to section overview,Gear Oil Specifications - API,GL-1 : Fo
29、r some manual gearboxes where untreated oils may be used GL-1 : For some manual gearboxes where untreated oils may be used GL-3 : For manual gearboxes and spiral bevel axles operating under moderate conditions - Mild EP Additive GL-4 : For spiral bevel and hypoid gears in axles operating under moder
30、ately severe conditions - Medium EP GL-5 : For hypoid gears operating under high speed or low speed/high torque conditions - High EP GL-6 : Obsolete Ford only New API service clarifications MT-1 (Previously known as PG-1) : For non-synchronized bus and heavy duty truck gearboxes with improved therma
31、l stability, cleanliness and seal compatibility PG-2 (may be known as GL-7) : Heavy duty rear axle application with improved thermal stability, cleanliness and spalling resistance,Back to section overview,OEM Requirements - Mercedes,Specification235.1235.0235.5235.6235.4235.10,ApplicationHeavy Duty
32、Manual Gear BoxesHeavy Duty Rear Axles Heavy Duty Manual Gear BoxesHeavy Duty Rear Axles Off-Highway Gear Boxes OnlyMedium Sized Sprinter Vans and Passenger Car Manual Transmissions,Approved Viscosity Grades80W,80-85W 80W-85W, 85W-90, 9080W,80-85W 80W-85W, 85W-90, 90,Back to section overview,OEM Req
33、uirements - ZF,Supply components to OEMs e.g. MB, MAN, Volvo, DAF Components usually supplied dry Approval lists for each specification which may have several different pages TE-ML 01 Constant Mesh Gearboxes TE-ML 02 Synchromesh Gearboxes TE-ML 05 Rear Axles (includes limited slip) TE-ML 07 Hydrosta
34、tic and Mechanical Drives (Reduction Gears) TE-ML 08 Non-Power Assisted Steering Gears Extended Drain (300,000 km) Sheet - TE-ML 02 (Page 4),Back to section overview,OEM Requirements - Volvo & Scania,Volvo New Extended Drain (400,000 km) Specifications. STD 1273.07 - HD Manual Transmissions STD 1273
35、.12 - HD Rear Axles Program Initiated 7 Years Ago Candidates Chosen for Field Trial Evaluation Interim 180,000 km Approval for Field Trial Products,Scania New STO:1 Specification Issued for Factory & Service Fill of Gear Box and Rear Axles API GL-5 + Oxidation Test + Shear + Filterability Achievable
36、 with all mineral products Allows up to 180,000 km ODI Dependant on Service,Back to section overview,OEM Requirements - MAN,Use Eaton or ZF Gearboxes - Issue Own Approval Lists,Back to section overview,Commercial Vehicle Trends,Fuel Economy,Increased H.P. Engines Reduced Component Size Reduced Air F
37、low, Noise Attenuation Increased Use of Retarders,Environmental,Synchromesh Metallurgy,Extended Drain,Shiftability,Lower Viscosity / Friction,Increased Thermal/ Oxidative Stability Need for Alternate Chemistry,Reduced Chlorine,Fuel Economy (Less CO2) Seal Compatibility,Metal Compatibility Frictional
38、 Properties,Increased Durability Shear / friction / wear / oxidation,Low Temperature Fluidity,Back to section overview,OEM Drain Periods,Back to section overview,Comparative Viscosity Classes,Back to section overview,Automatic Transmission Fluids - Section Overview,Automatic transmissions Fluid Func
39、tions Fluid Properties Automatic Transmission Trends Automatic Transmission Fluid Trends U.S. ATF Specifications European ATF Specifications Key European OEMs - Mercedes Key European OEMs,Back to module overview,Automatic Transmissions,How it works Drive enters the torque converter Passes to the gea
40、r set And out to the wheels,Back to section overview,Fluid Functions,Lubricate the gear train Transmit power in the torque converter Act as hydraulic medium Lubricate the friction clutches Act as a heat transfer medium,Back to section overview,Fluid Properties,Adequate load carrying performance Good
41、 foaming resistance Low viscosity, but high viscosity index Correct frictional characteristics to match clutch materials and design Correct seal Swell characteristics Good oxidation stability Good corrosion inhibition Thermal stability Low-temperature fluidity,Back to section overview,Automatic Tran
42、smission Trends,Transmissions with electronic controls,Improved low temperature fluidity,Compacts designs, Better Aerodynamics of retarders,Thermal / Oxidative stability,Engine power output,Friction capacity / Durability, Shear stability, Wear protection,Shear / Wear/ Thermal/ Oxidative stability, F
43、riction durability,Extended drain intervals,Back to section overview,Automatic Transmission Fluid Trends,ATF,DexronIII Extended DrainSyntheticsPart-syntheticsPart-Hydrocracked,OEM specific fluids Fill-for-lifeSpecial base stocks Minimal service fill,Back to section overview,U.S. ATF Specifications,G
44、eneral Motors (Passenger Car) Current Specification - Dexron III Allison ( General Motors - Heavy Duty Division) Current Specification - Allison C-4 Ford (Passenger Car) Current Specification - Mercon?(1993)/ Mercon?V,Back to section overview,European ATF Specifications,Require Dexron II approval as
45、 basis Important OEMs MB ZFOthers Renk Voith Renault,Back to section overview,Key European OEMs - Mercedes,Approved products list (Sheet 236.X) In-House Evaluation Required Sheet listing dependant on chemistry used MB 236.1 MB 236.6 MB 236.7 MB 235.8 (Synthetic) MB 236.6 (covers most applications) D
46、B No Longer manufacture HD transmissions,Back to section overview,Key European OEMs - MAN, Renk,MAN Approved Products List MAN 339 A - T.A.S.A. MAN 339 D - Dexron IID / IIE MAN 339 F - Dexron III Less stringent approval requirements Renk Approved Products List for Doromat Transmissions T.A.S.A. Flui
47、ds - 30,000 km Drain Dexron IID Fluids - 15,000 km Drain Do not approve Dexron III products,Back to section overview,Grease Lubrication - Section Overview,What is a Grease? Lubricating Greases Vs. Oils Key Grease Functions When to Lubricate with Grease? Penetration and NLGI Classes Grease Applicatio
48、ns Semi-Fluid Greases Re-greasing intervals Working Limits of Greases Balance of Properties Grease Trends Selection Chart of Greases,Back to module overview,What is a Grease?,A solid to semi-fluid product consisting of a fluid lubricant and a thickenerIt usually contains additives to enhance perform
49、anceTypical grease contents oil 80-87% thickener 8-15% additives 5%,Back to section overview,Lubricating Greases Vs. Oils,Oils Fluid Run away remove heat (cool) remove debris (clean) remove particles (clean) Classification Viscosity (SAE),Greases Semi-fluid / semi-solid Stay in place seal no cooling / no cleaningClassification Consistency (NLGI),Back to section overview,Key Grease Functions,Reduces Friction, Wear, HeatAssures a Lubricant ReserveSeals From Contamination,
