潤滑油培訓-英文版

VolvoConstructionEquipmentLubricantsLubricationTrainingBacktoMarketingProgramoverviewModuleOverviewLubricationPrinciplesEngineLubricationTransmissionLubricationAutomaticTransmissionFluidsGreaseLubricationBacktoMarketingProgramoverviewLubricationPrinciples-SectionOverviewRefiningProcessRefineryProductsfromCrudeOilLubricantBase-stocksKeyLubricantFunctionsKeyLubricantPropertiesViscosityViscosityClassificationSystem(SAE)Mono-gradeVs.Multi-gradePourPoint/FlashPoint/VolatilityConventionalVs.Syntheticlubricant?SyntheticLubricantsLubricantAdditivesAdditiveTypesBacktomoduleoverviewRefiningProcessTwoMainProcesses:SeparationProcessesSelectsDesirableComponentsfromtheCrudeIncludesDistillation,SolventExtraction,SolventDewaxingConversionProcessesConvertUndesirableElementsintoUsefulLubeOilComponentsAromatics,Sulfur,Wax,etc.IncludesHydrotreating,Hydrofinishing,HydrocrackingandCatalyticDewaxingToachievedesiredpropertiesBacktosectionoverviewRefineryProductsfromCrudeOilBacktosectionoverviewBASESTOCKSELECTIONADDITIVESELECTIONFINISHEDLUBRICANTLubricantBasestocksBacktosectionoverviewLubricantBasestocksMineralOilBasestocksRefinedfromCrudeOilTrueSyntheticBasestocksareDerivedfromChemicalReactionsSomecompaniesnowconsiderveryhighlyrefinedmineraloilas“Synthetics”BacktosectionoverviewKeyLubricantFunctionsSeparatemovingsurfacesCoolingSealingWearprotectionRust,corrosionandfoaminhibitionAntioxidationDispersancyDetergencyBacktosectionoverviewKeyLubricantPropertiesViscosityPourPointFlashPointVolatilityBacktosectionoverviewViscosityMeasureofafluid’sresistancetoflowChangeswithTemperature–highertemperature,lowerviscosityPressure–higherpressure,higherviscosityShearRate–highertheshearrate,lowerviscosityViscosityIndexEffectofchangeoftemperatureontheviscosityofanoilBacktosectionoverviewViscosityClassificationSystem(SAE)E.G.:SAE15W-40LowTemperatureCrankingViscosity(CCS)LowTemperaturePumpingViscosity(MRV)MINandMAXViscosityMeasuredat100°CHighTemperatureViscosityUnderHighShear(HTHS)3,500MAXat-15°C60,000MAXat-25°C12.5MINat100°C3.7MINat150°CBacktosectionoverviewMono-gradeVs.Multi-gradeMono-GradesMeetstherequirementsofoneSAEviscositygradee.g.SAE15W(WinterGrade)orSAE40(SummerGrade)Lowtemperatureviscositycriticalforwintergrades,hightemperatureviscositycriticalforsummergrades

Multi-GradesMeetstherequirementsofmorethanoneSAEviscositygrade(Bothwinter&summergrades)Combine‘summer’and‘winter’SAEgradesinoneoile.g.SAE15W-40pertiesofSAE15W&pertiesofSAE40HigherVIthanMono-GradesBacktosectionoverviewPourPoint/FlashPoint/VolatilityPourPointDefinestheTemperatureatWhichFluidnoLongerFlowsHasDirectEffectonFluidPumpingTemperatureGivesanindicationofcoldflowproperties

FlashPointTemperatureatwhichvaporfromaheatedoiligniteswhenexposedtoanakedflameIndicatesthefirehazard

VolatilityAmeasureofanengineoil’stendencytoevaporateathighenginetemperaturesBacktosectionoverviewConventionalVs.Syntheticlubricant?SyntheticLubricantProducedfromChemicalFeedstocksBasestockisEngineeredThroughaCatalyticProcess(Creatingasynthesizedmaterial)ConventionalLubricantProducedfromCrudeOilBasestocksareObtainedbyREMOVINGUndesirableComponentsSyntheticConventionalBacktosectionoverviewSyntheticLubricantsAdvantagesReplacesVolatileLightMineralOilReducedLubricantConsumptionImprovedFuelEconomyImprovesLowTemperaturePerformanceOxidationStabilityBacktosectionoverviewLubricantAdditivesChemicalCompoundsWhichareAddedtoLubeOilStockstoImproveTheirPerformancePropertiesSupplementorReinforceWell-refined,High-qualityBasestocksPerformTwoCriticalFunctions:MaximizeBeneficialPropertiesMinimizeDestructiveProcessesOxidationWearRust/CorrosionShear“Combustion”BacktosectionoverviewAdditiveTypesDispersantsDetergentsAnti-WearAgentsFrictionModifiersOxidationInhibitorsRustInhibitorsViscosityIndexImproversPourPointDepressantsFoamInhibitorsBacktosectionoverviewEngineLubrication-SectionOverviewMainEnginePartsGasolineVs.DieselDieselEngineDesignsTurbochargerEngineOilFunctionsEngineOilComponentsMajorInternationalEngineOilSpecificationsAPIClassificationAPIDieselOilQualityLevelsACEAClassificationOtherClassificationsEngineBuilderTrendsBacktomoduleoverviewMainEnginePartsFlywheelDistributorCrankshaftSparkplugsPistonsCamshaftValvesBacktosectionoverviewGasolineVs.DieselTypicalgasolineengineTypicaldieselengineSparkplugDistributorFuelpumpFuelinjectorSection2-EngineLubricationBacktosectionoverviewGasolineVs.DieselGasolineQuieterLighterFasterBetteraccelerationLowerinitialcostCatalystemissionscontrolBetterfueleconomyHeavierLongerlifeGoodreliabilityCatalystandparticulatetrapemissionscontrolBacktosectionoverviewDieselEngineDesignsDirectInjectionIndirectInjectionInjectorPre-compression

chamberPistonPistonInjectorBacktosectionoverviewTurbochargerBacktosectionoverviewEngineOilFunctionsFriction&WearReductionCoolingSealingDetergent&DispersantRust&CorrosionInhibitorDiagnosisFoamInhibitorBacktosectionoverviewEngineOilComponentsBaseOil:70%to95%offinalproductAdditives:30%to5%offinalproduct+=BaseOilAdditivesFinalProductBacktosectionoverviewMajorInternationalEngineOilSpecificationsAPI(AmericanPetroleumInstitute)ACEA(AssociationdesConstructeursEuropéensd’Automobiles)VDS(Volvo)MBMANScaniaRVI(Renault)AllisonCAT(Caterpillar)ZFBacktosectionoverviewDieselCA(Obsolete)CD(1965)CE(1988)CF(HeavyDutyOffHighway)CF-2(TwoCycle)(1994)CF-4(1990)CG-4(1994LowEmissions)CH-4(1998LowEmission)CI-4(2002LowEmission)GasolineSA(Obsolete)

SG(1989)SH(1993)SJ(1996Introduced)APIClassificationBacktosectionoverviewAPIDieselOilQualityLevelsBacktosectionoverviewACEAClassificationGasolineA1-98A2-98A398HeavyDutyDieselE1-98(obsolete)E2-98E3-98E4-98E5-99PassengerCarDieselB1-98B2-98B3-98B4-98BacktosectionoverviewOtherClassificationsVolvoVDSVDS-2VDS-3HeavyDutyDieselMAN270MAN271MAN3275MAN3277MB227.0228.1228.3228.5BacktosectionoverviewEngineBuilderTrendsHigherHorsepowerupto600HPHigherInjectionPressuresNewmetallurgyincomponentsNewtimingmaps-ExpecthighersootlevelsDevelopmentofEGREnginesGreatlyextendedserviceintervalsAlternatefiltrationsystemsNewenginedesignsBacktosectionoverviewTransmissionLubrication-SectionOverviewManualTransmissionTypesOfGearsSynchromeshGearsDifferentialLimitedSlipDifferentialFunctionsofaGearLubricantGearOilPropertiesGearOilSpecifications-APIOEMRequirements-MercedesOEMRequirements-ZFOEMRequirements-Volvo&ScaniaOEMRequirements-MANCommercialVehicleTrendsOEMDrainPeriodsComparativeViscosityClassesBacktomoduleoverviewManualTransmissionAllowsthedrivertoselectthegear,andthereforethepoweroutputoftheenginethatisneededforthespeedandcontrolofthevehicle

Asthedriveleavestheengine,it

passesthroughtheclutch

Itentersthegearbox

AndleavestothewheelsBacktosectionoverviewTypesOfGearsSpurGearsHypoidGearBacktosectionoverviewSynchromeshGearsWhenchanginggears,thegearsarerotatingatthespeedofeitherthedriveshaftsortheengineTopreventdamagethesynchromeshequalizesthespeedsofthegearshaftsbeforeengagingthegearsFatiguelifeFrictionaldurabilityGearprotectionOxidativeandthermalstabilityCorrosionprotectionBacktosectionoverviewDifferentialWhenavehicledrivesroundacornertheouterwheeltravelsfurtherthantheinnerTodothistheyneedtotravelatdifferentspeedsThisiscalleddifferentialortheequaldistributionofturningpowerBacktosectionoverviewLimitedSlipDifferentialIftractionislostononewheel,extratorqueistransmittedtotheoppositewheelFittedtooff-highwayvehiclesandsomesportcarsRequiresfrictionmodifiedlubricantBacktosectionoverviewFunctionsofaGearLubricantPreventmetal-to-metalcontactProvidegoodshiftabilityatalltemperaturesDissipateheatPreventrustingCarryawayweardebrisReducefrictionImprovefueleconomyBacktosectionoverviewGearOilPropertiesLoadcarrying/antiwearOxidationresistanceCorrosionprotectionThermalstability/cleanlinessFrictionalpropertiesFoamsuppressionSealcompatibilityBacktosectionoverviewGearOilSpecifications-APIGL-1:ForsomemanualgearboxeswhereuntreatedoilsmaybeusedGL-1:ForsomemanualgearboxeswhereuntreatedoilsmaybeusedGL-3:Formanualgearboxesandspiralbevelaxlesoperatingundermoderateconditions-MildEPAdditiveGL-4:Forspiralbevelandhypoidgearsinaxlesoperatingundermoderatelysevereconditions-MediumEPGL-5:Forhypoidgearsoperatingunderhighspeedorlowspeed/hightorqueconditions-HighEPGL-6:ObsoleteFordonlyNewAPIserviceclarificationsMT-1(PreviouslyknownasPG-1):Fornon-synchronizedbusandheavydutytruckgearboxeswithimprovedthermalstability,cleanlinessandsealcompatibilityPG-2(maybeknownasGL-7):Heavydutyrearaxleapplicationwithimprovedthermalstability,cleanlinessandspallingresistanceBacktosectionoverviewOEMRequirements-MercedesSpecification235.1235.0235.5235.6235.4235.10ApplicationHeavyDutyManualGearBoxesHeavyDutyRearAxles HeavyDutyManualGearBoxesHeavyDutyRearAxles Off-HighwayGearBoxesOnlyMediumSized‘Sprinter’VansandPassengerCarManualTransmissionsApprovedViscosityGrades80W,80-85W 80W-85W,85W-90,9080W,80-85W 80W-85W,85W-90,90 BacktosectionoverviewOEMRequirements-ZFSupplycomponentstoOEMse.g.MB,MAN,Volvo,DAFComponentsusuallysupplieddryApprovallistsforeachspecificationwhichmayhaveseveraldifferentpagesTE-ML01 ConstantMeshGearboxesTE-ML02 SynchromeshGearboxesTE-ML05 RearAxles(includeslimitedslip)TE-ML07 HydrostaticandMechanicalDrives(ReductionGears)TE-ML08 Non-PowerAssistedSteeringGearsExtendedDrain(300,000km)Sheet-TE-ML02(Page4)BacktosectionoverviewOEMRequirements-Volvo&ScaniaVolvoNewExtendedDrain(400,000km)Specifications.STD1273.07-HDManualTransmissionsSTD1273.12-HDRearAxlesProgramInitiated7YearsAgoCandidatesChosenforFieldTrialEvaluationInterim180,000kmApprovalforFieldTrialProductsScaniaNewSTO:1SpecificationIssuedforFactory&ServiceFillofGearBoxandRearAxlesAPIGL-5+OxidationTest+Shear+FilterabilityAchievablewithallmineralproductsAllowsupto180,000kmODIDependantonServiceBacktosectionoverviewOEMRequirements-MANUseEatonorZFGearboxes-IssueOwnApprovalListsBacktosectionoverviewCommercialVehicleTrendsFuelEconomyIncreasedH.P.EnginesReducedComponentSizeReducedAirFlow,NoiseAttenuationIncreasedUseofRetardersEnvironmentalSynchromeshMetallurgyExtendedDrainShiftabilityLowerViscosity/FrictionIncreasedThermal/OxidativeStabilityNeedforAlternateChemistryReducedChlorine,FuelEconomy(LessCO2)SealCompatibilityMetalCompatibilityFrictionalPropertiesIncreasedDurabilityShear/friction/wear/oxidationLowTemperatureFluidityBacktosectionoverviewOEMDrainPeriodsBacktosectionoverviewComparativeViscosityClasses2010406085115140175205240280365400450500550625700775850mm2/sat40°C62022422426283032343638404218161412108315mm2/sat100°C140W90W85W80W75W60W50W40W30W20W10W5W650N500N300N200N100NSAEGearOilViscosityNumberSAEEngineOilViscosityNumberSAEBaseOilViscosityNumberBacktosectionoverviewAutomaticTransmissionFluids-SectionOverviewAutomatictransmissionsFluidFunctionsFluidPropertiesAutomaticTransmissionTrendsAutomaticTransmissionFluidTrendsU.S.ATFSpecificationsEuropeanATFSpecificationsKeyEuropeanOEM’s-MercedesKeyEuropeanOEMsBacktomoduleoverviewAutomaticTransmissionsHowitworksDriveentersthetorqueconverterPassestothegearsetAndouttothewheelsBacktosectionoverviewFluidFunctionsLubricatethegeartrainTransmitpowerinthetorqueconverterActashydraulicmediumLubricatethefrictionclutchesActasaheattransfermediumBacktosectionoverviewFluidPropertiesAdequateloadcarryingperformanceGoodfoamingresistanceLowviscosity,buthighviscosityindexCorrectfrictionalcharacteristicstomatchclutchmaterialsanddesignCorrectseal–SwellcharacteristicsGoodoxidationstabilityGoodcorrosioninhibitionThermalstabilityLow-temperaturefluidityBacktosectionoverviewAutomaticTransmissionTrendsTransmissionswithelectroniccontrolsImprovedlowtemperaturefluidityCompactsdesigns,BetterAerodynamicsofretardersThermal/OxidativestabilityEnginepoweroutputFrictioncapacity/Durability,Shearstability,WearprotectionShear/Wear/Thermal/Oxidativestability,FrictiondurabilityExtendeddrainintervalseeeeBacktosectionoverviewAutomaticTransmissionFluidTrendsATFDexronIIIExtendedDrain

SyntheticsPart-syntheticsPart-HydrocrackedOEMspecificfluidsFill-for-lifeSpecialbasestocksMinimalservicefill

BacktosectionoverviewU.S.ATFSpecificationsGeneralMotors(PassengerCar)CurrentSpecification-DexronIII

Allison(GeneralMotors-HeavyDutyDivision)CurrentSpecification-AllisonC-4

Ford(PassengerCar)CurrentSpecification-Mercon??(1993)/Mercon??VBacktosectionoverviewEuropeanATFSpecificationsRequireDexronIIapprovalasbasisImportantOEMsMBZFOthersRenkVoithRenaultBacktosectionoverviewKeyEuropeanOEM’s-MercedesApprovedproductslist(Sheet236.X)In-HouseEvaluationRequiredSheetlistingdependantonchemistryusedMB236.1MB236.6MB236.7MB235.8(Synthetic)MB236.6(coversmostapplications)DBNoLongermanufactureHDtransmissionsBacktosectionoverviewKeyEuropeanOEMs-MAN,RenkMANApprovedProductsListMAN339A-T.A.S.A.MAN339D-DexronIID/IIEMAN339F-DexronIIILessstringentapprovalrequirementsRenkApprovedProductsListforDoromatTransmissionsT.A.S.A.Fluids-30,000kmDrainDexronIIDFluids-15,000kmDrainDonotapproveDexronIIIproductsBacktosectionoverviewGreaseLubrication-SectionOverviewWhatisaGrease?LubricatingGreasesVs.OilsKeyGreaseFunctionsWhentoLubricatewithGrease?PenetrationandNLGIClassesGreaseApplicationsSemi-FluidGreasesRe-greasingintervalsWorkingLimitsofGreasesBalanceofPropertiesGreaseTrendsSelectionChartofGreasesBacktomoduleoverviewWhatisaGrease?Asolidtosemi-fluidproductconsistingofafluidlubricantandathickenerItusuallycontainsadditivesto

enhanceperformanceTypicalgreasecontentsoil80-87%thickener8-15%additives5%OilThickenerAdditivesBacktosectionoverviewLubricatingGreasesVs.OilsOils FluidRunawayremoveheat(cool)removedebris(clean)removeparticles(clean)ClassificationViscosity(SAE)GreasesSemi-fluid/semi-solidStayinplacesealnocooling/nocleaningClassification Consistency(NLGI)BacktosectionoverviewKeyGreaseFunctionsReducesFriction,Wear,HeatAssuresaLubricantReserveSealsFromContaminationBacktosectionoverviewWhentoLubricatewithGrease?TodecreasedrippingandsplatteringoflubricantTodecreasefrequencyoflubricationTosealoutcontaminantsForintermittentoperationTosuspendsolidadditivesUnderextremeoperatingconditionshightemperaturehighpressureshockloadinglowspeed/highpressureMachinebadlywornWhennoisereductionisveryimportantBacktosectionoverviewPenetrationandNLGIClassesWorkedPenetration445to475400to430355to385310to340265to295220to250175to205130to16085to115NLGIGrade000000123456GreaseConsistencySemi-FluidSemi-FluidSoftSoftCommonSemi-HardSemi-HardHardHardGeargreasesforsmallborecentralizedsystemsApplicationCentralizedlubricationsystemsUsualbearinglubricationVeryStiff(4)toblockgreases,rarelyusedBacktosectionoverviewGreaseApplicationsAutomotiveConstantVelocityJoints,WheelBearings,AuxiliaryEquipment,Chassis,FifthWheel,etc.AgricultureTractors,Trailers,HarvestingMachines,etc.IndustryRollingElementBearings,PlainBearings,Gears,SlidingElem