HEAVY EQUIPMENT

Engine

Hydraulic System

Transmission
Differential

Grease Point

Engine Diagram :

E : Exhaust Camshaft
I : Intake Camshaft
S : Spark
P : Piston
R : Connecting Rod
C : Crankshaft
V : Valve
W : Cooling
Water/Jacket

Engines
Types of engine applications
Heavy duty diesel engines used in onroad transportation and off-road
applications
Stationary gas engines used in gas
transmissions and power generation
CNG (compressed natural gas) engines in
mobile transportation

HDEO - Highlight

Tighter emission regulations

drive new engine designs
Euro I emission standard
required in China. Singapore
implemented Euro II in Jan
1, 2001
EGR the primary approach
of many OEMs for
addressing future emission
targets Euro 3, 4 (2005 in
Europe).

EGR
Valve

EGR Recirculation Duct

Intake Manifold

Exhaust Manifold

EGR (Exhaust Gas

Re-circulation)

HDEO - Highlight
What is EGR?

Exhaust gas is re-

circulated back into

the cylinder to reduce
the amount of fresh
air intake available for
combustion

EGR
Valve

EGR Recirculation Duct

Intake Manifold

Exhaust Manifold

Combustion

temperatures and thus

NOx emissions are
reduced

EGR (Exhaust Gas

Re-circulation)

HDEO - Highlight

Impact of EGR on lubricants

Significantly increases soot level in the oil

from current 1% to as high as 3 to 5 %
Leads to higher soot-related engine wear and
increased oil viscosity.
Cooled exhaust leads to condensation and
formation of higher acid levels
Drain intervals may need to be reduced to
maintain engine durability
Specifications for EGR-capable lubricants in
API PC-9

OIL CHANGING :

VISCOSITY
WATER CONTENT
TBN
FLASH POINT
WEAR METAL

< 20% OR > 20%

> 0.2 %
< 50 %
< 200 C
20-100 ppm

Products - HDEO
MOTOLUB CS3
API CI-4

MOTOLUB CS3
API CH-4

MOTOLUB CS3
API CF-4

MOTOLUB CS3
API CF

Ultimate Performance
SAE 15W-40
TBN 10.3

Ultimate Performance
SAE 15W-40
TBN 10.2

High Performance
SAE 15W-40
TBN 11

High Performance
SAE 10W/30/40/50
TBN 11

API CI-4
ACEA E5/E3/A3/B3/B4

API CH-4
ACEA E5/E3

API CF-4
ACEA E2/A3

API CF

MB 228.3
Volvo VDS-3/VDS-2
CES 20077/20078
MAN 3275
MACK EO-M Plus
Global DHD-1

MB 228.3
Volvo VDS-2
CES 20076/20077
MAN 271/3275
Renault RVI-99
MACK EO-M Plus
Allison C-4

MB 228.1
Volvo VDS
MTU Type 2
MAN 271
VW 501/505
Allison C-4

MB 227
Allison C-3
CAT TO-2
BACK===

Hydraulic Systems
Functions of Hydraulic Systems
Transmit power
Lubricate Moving Parts
Seal Between Moving Parts
Cool and Dissipate Heat

Types of Hydraulic Pumps

Gear
pump
Vane
pump
Piston
pump

Capacity
(GPM)

Pressure
(psi)

Speed

0.2 150

250 2500 800 - 3500

0.5 250

250 2500 1200

4000

0.5 450

750 5000 600 6000

(rpm)

The hydraulic pump is the most critical

component of the hydraulic system and
usually determines the fluid requirements

Gear Pump

Vane Pump

Piston Pump

Hydraulic Fluid Reservoir

Hydraulic Fluid Requirements

Proper oil viscosity, good lubricity
No cavitation (air release, foaming)
Deposit control (oxidation, thermal
stability, hydrolytic stability)
Anti-wear and low compressibilityMotor
Corrosion and rust control

Lines
and
hoses

Anti-wear
Deposit control (oxidation, thermal stability, hydrolytic stability)
Corrosion and rust control
Flow Control
Valve

Pump

Cylinder
or Receptor

Pressure
relief
Valve

Elastomer
compatibility

Filter

Proportional
Solenoid Valve

Anti-wear
Elastomer compatibility
Reservoir

Demulsibility, air release, foaming

Oxidation, thermal stability,
hydrolytic stability
Corrosion and rust control
Low fluid volatility

Filterability
Deposit control (oxidation, thermal stability,
hydrolytic stability)

Hydraulic Fluid Trends

More reserves of
anti-wear/EP

Smaller reservoirs
Reduced Cycle Times
Higher Temperatures
Higher Pressures
Long Fluid Life
Water Tolerance
Base Oil Flexibility

Improved filtration
Extended rust
performance
Improved thermal
stability
Good multi-metal
compatibility

Better resistance
to oxidation

Good demulsibility
Good antifoam
characteristics

Improved air
release properties

Hydraulic Fluid Properties

Anti-oxidants

Rust Inhibitors

Forms protective film on metal surfaces to prevent

rusting

Anti-wear agents

Delay lubrication degradation in the presence of heat

and air, by preventing the formation of acids, varnish
and sludge. Deposits in oil passages and components
cause sluggish operation.

Provides good film strength and lubricity (slipperiness)

Forms ductile film on surfaces to prevent metal-tometal contact

Water separability

Separate from water quickly to prevent emulsion

Hydraulic Fluid Properties

Detergents and dispersants

Anti-foam agents

Weaken the surface tension of air bubbles so they are released at

the oil surface in the reservoir and not returned to the system

Filterability

Keeps surfaces clean of deposits and disperses particles

throughout the oil until they are drained

Prevent filter clogging with oil degradation products

Allows fine filtration to protect pump, valves and other components

Metal deactivator

Inhibit reaction of oil degradation products with Copper and

Aluminum alloy

Hydraulic Fluid Properties

Good anti-oxidation ability

Good filterability
Good anti-wear properties
Rust and corrosion prevention
Low fluid/water and fluid/air interaction
(demulsibility, air release, foaming)
Good seal and paint compatibility
Good thermal stability
Low reaction with non-ferrous materials

Hydraulics - Highlight

Cold temperature start up requires good fluidity and pour

point characteristics
Pump cavitation can result from low fluid level in the
reservoir, drawing air into the system. Air and foam
explode at the pump outlet and cause wear
Ideal bulk oil temperature is about 450 C (range 420 to 500
C)
Need good demulsibilty characteristics for rapid
separation of oil and water to occur
Anti-wear hydraulic fluids normally recommended (above
1000 PSI, AW hydraulic fluid must be used)
Need proper air breathers to prevent dirt and water entry
Need low volatility to prevent oil loss and viscosity changes

Hydraulic - Highlight

At high temperatures, higher viscosity oil is required

to provide adequate lubricating films.
Oil reservoir should be 2 to 3 times the pumping
capacity
Need adequate design of reservoir to allow removal
of dirt, sludge and water
Most failure are due to contamination
Milky looking oil is either water or air contamination;
crackle test can confirm presence of water
Filtration: Cleanliness targets should be set for each
hydraulic system the cleaner the better (refer to
Table Fluid Cleanliness Targets

Cleanliness VS Operating Pressure

Operating pressure

<1500 psi

1500-2500
psi

>2500 psi

Servo valve

16/14/12

15/13/11

14/12/10

Proportional valve

17/15/13

16/14/12

15/13/11

Variable volume pump

17/16/13

17/15/12

16/14/12

Cartridge valve

18/16/14

17/16/13

17/15/12

Fixed piston valve

18/16/14

17/16/13

17/15/12

Vane pump

19/17/14

18/16/14

17/16/13

Pressure/flow
control valve

19/17/14

18/16/14

17/16/13

Solenoid valve

19/17/14

18/16/14

18/16/14

Gear pump

19/17/14

18/16/14

18/16/14

Specifications

Federal Republic of Germany Lubricating oil

standards

DIN 51524 Part 1

Rust and Oxidation Protected Hydraulic oil
Grades covered are HL. ISO VG 10 to VG 100
DIN 51524 Part 2 & Part 3
Anti-wear Hydraulic oils
Grades covered under Part 2 are HLP. ISO VG
10 to VG 100
Grades covered under Part 3 are HVLP. ISO
VG 15 and VG 32 to VG 100 (high VI).

Specifications :

DENISON

HF-1 Standard covers the performance requirements

for hydraulic fluids suitable for piston pumps
HF-2 Standard covers the performance requirements
for hydraulic fluids used in vane pumps
HF-0 Standard concerns hydraulic fluids for use in
axial piston pumps and vane pumps in severe duty
applications
AFNOR NF E 48-603 (Part 2) French standard

CINCINNATI MILACRON

P-68 Light anti-wear hydraulic oil and lubricants

P-69 Heavy/medium anti-wear hydraulic oil and
lubricants
P-70 Medium anti-wear hydraulic oil and lubricant

Specifications

MANNESMANN REXROTH

Does not issue approvals. Recommendations based on

DIN 51 524 specifications
RE 07 075/07.98 and RE 90 220

HL oils meeting DIN 51 524 Part 1 - Non-additized oils for

specific pump models up to 80 bar
HLP oils meeting DIN 51 524 Part 2 - Oils with corrosion,
oxidization and wear inhibitors may be used with all
components.
HVLP oils meeting DIN 51 524 Part 3 Oils with increased VI
for wide temperature range
HLP-D oils with detergent and dispersant additives

OIL CHANGING :

VISCOSITY
WATER CONTENT
TAN
FLASH POINT
WEAR METAL

< 20% or > 20%

> 0.2 %
Max 2
< 200 C
20-100 ppm

Products - Hydraulic
Oil
HIDRAULIK EP
Anti-Wear Hydraulic Oil

Premium Quality
ISO VG 10/22/32/37*/46/68/
100/150
DIN 51524 (Part 2 HLP)
BS 4231 HSD
CETOP RP 91H HM
AFNOR NFE 48600 HM
VDMA 24318
DENISON HF-2A
Aplikasi:
Sistem hidraulik (beban berat)
Pompa hidraulik
Plain bearing
Gear (requiring non-EP)
Diecasting machines

HIDRAULIK FZ

HIDRAULIK HL

Zinc Free

R&O Hydraulic Oil

DIN 51524 (Part 2)

Denison HF-0, HF-1, HF-2
AFNOR NFE 48603 HM
Sperry Vickers I-286-S
M-2950-S
Cincinati Milacron P-68
P-67
P-70

DIN 51524 (Part 1)

DIN 51517 CL
BS 4231 HSC
Denison HF-1A
AFNOR NFE 48600 HL
CETOP RP 91H HL

Aplikasi:

Aplikasi:

Sistem hidraulik (bebas Zinc)

Pompa hidraulik
Plain bearing
Gear (requiring non-EP)
Diecasting machines

Sistem hidraulik (tidak

memerlukan aditif anti-wear)
Plain bearing
Gear (requiring non-EP)
Air Compressor (where opr.
temp. < 140oC)

Hydraulic Oil
High Performance
ISO VG 32/46/68/100

Premium Quality
ISO VG 32/46/68/100/150

BACK===

Automotive Gears - Highlight

Power shift transmissions

ATFs must have correct frictional characteristics

for clutch packs

Differentials

Hyoid gears in rear axles of motor vehicles must use

API GL-5 oil
Limited slip differentials must use oil designed with
friction modifier
Use suitable breathers to prevent ingress of water
and dirt; consider remote location for breather
away

Specifications

American Gear Manufacturers Assoc (AGMA)

United States Steel (USS) 224

Non-lead EP industrial gear oils

Deutsches Institut Fur Normung (DIN)

9005 (replacement for 250.04)

250.02

51517, Part 3 for EP gear oils

Cincinnati Milacron P-Series

API GL-4, GL-5 (automotive gears)

OIL CHANGING :

VISCOSITY
WATER CONTENT
TAN
FLASH POINT
WEAR METAL

< 20% OR > 20%

> 0.2 %
Max 2
< 200 C
20-100 ppm

Products Automotive Gear Oil

PETRONAS GL-1

PETRONAS GL-4

Automotive Hypoid Gear Oil

High Quality EP
SAE 90/140

Automotive Hypoid Gear Oil

High Quality EP
SAE 80W/85W-140/90/140

API GL-1

API GL-4
MIL-L-2105

Aplikasi:
Hypoid, Spur, Bevel, Helical,
Spiral-Bevel & Worm Gears
untuk Differential,
Manual Transmission
Final Drives

Aplikasi:
Gear Box & Axle automotive
(beban menengah)

PETRONAS GL-5
Automotive Hypoid Gear Oil
High Performance EP
SAE 80W-90/85W140/90/140
API GL-5
MIL-L-2105D (SAE 80W-90,
85W-140)
MIL-L-2105B (SAE 90, 140)

Aplikasi:
Gear Box & Axle automotive
(beban berat)
Hypoid, spur, bevel, helical,
spiral-bevel & worm gears
untuk differential
BACK===

Products - ATF
PETRONAS ATF-D

PETRONAS ATF-D3

POWERTRANS T4

Automatic Transmission Fluid

Premium Quality
Dexron-II

Automatic Transmission Fluid

Premium Quality
Dexron-III

High performance Caterpillar

TO-4 Transmission Fluid

GM Dexron IID
Allison C-4
MB 236.6
Caterpillar TO-2
Ford CJ Type Fluid
Voith Daiwa
ZF Transmission

Allison C-4
GM Dexron IIIG
Aplikasi:
Automatic Transmission
Power Steering
Hydraulic System

Caterpillar TO-4
Allison C-4
API MT-1 (CRC L-60-1)
Vickers 35VQ25 Pump Test
Aplikasi:
Transmission, Drives Trains,
Clutch and Hydraulic System

Aplikasi:
Automatic Transmission
Power Steering
Hydraulic System
BACK===

Greases - Motors

Issues in lubrication

Bearings are main components requiring

lubrication
Grease motor bearings to one third or half full.
Excessive grease on motor bearings can get on
motor windings and cause electrical failures
Oil level in a static bath should be one half up on
lowest rolling element at rest
Check potential grease incompatibility. Are
motors rebuilt? What grease has been put into
the motor bearing? What soap type or thickener
is in the new grease

Greases - Highlight
Bearings operating below 850 C in a clean
environment, re-greasing interval is once a year
Bearings operating above 850 C, re-grease at
least every 6 months, or more frequently if in
dirty environment
Grease equipment while it is running if it is safe
to do this
Greases in sealed bearings should last about 7
years

Products - Greases
GRIS EPI
Extreme Pressure Lithium
Grease Lead-Free
NLGI 0/1/2/3
Lithium Soap
Opr. range -20 to 130oC
Resist water washout
Protection against rust &
corrosion
Aplikasi:
Rolling Element Bearing
Plain Bearings
Gears
Coupling

GRIS MPI
Multipurpose Industrial
Grease
NLGI 2/3
Lithium Soap
Opr. range -20 to 130oC
Resist water washout
Protection against rusting
Aplikasi:
Plain Bearings
Swivels
Joints or other parts of
equipment in industry,
construction, agriculture

MOTOGRIS LM
Multipurpose Automotive
& Industrial Grease with
Moly
Lithium Soap
NLGI 2
Opr. range -20 to 130oC
Resist water washout
Protection against wear, rust
& corrosion
Aplikasi:
Wheel Bearings
Chasis Components

BACK===