7.

GENERAL WEAR ANALYSIS

Description of general wear level

Normal
When all readings are in the normal range, the wear of the lubricating parts is normal.
There are instances when relatively high readings are considered normal. For example, the first oil
analysis for rebuilt equipment normally shows relatively high readings. This is due to the entrance of
dirt at assembly and the wearing-in of mating parts. These higher readings are considered normal for
the first few oil changes of a rebuilt machine.

Caution
If a reading is in this range, some faulty condition in the lubricated parts is assumed.
Dipending on conditions, more frequent sampling may be required, or diagnostic checks may be
performed. Maintenance procedures should be reviewed, and minor faults should be corrected. Major
repair is not recommended at this stage.
If reading in the caution range and close to critical, shorten the sampling intervals and decrease the
load onthe unit if possible. At this stage, the machine does not need repair immediately, however, work
out a schedule for repair and recommend your customers to carry it out at their convenience.

Critical
If the reading is in this range, advanced wear is assumed.
Locate the cause and take the necessary measures immediately.
Depending on the case, it may be necessary to stop the machine and overhaul it immediately.
If the reading goes highter, do not condider it in relation to trouble in the machine. Ask you customer to
investigate the possible causes.
For instance, the following factors are possible:
e Any sudden change in operating conditioins or
e Any influence by repairs made just before operation.
KOWA Units and Their Codes
[KOWA units]
Unit Unit Unit Unit name
Unit name Unit name
symbol symbol symbol
AXL Axle H/D Hydraulic R/B Rear brake
C/M Compressor HST HST system S/M Swing machinery
D/F Deferential M/C Main clutch S/T Steering
E/N Engine P/T Power train T/D Tandem drive
F/D Final drive PTO Power take-off T/M Transmission
[KOWA unit code]
No. Applicable unit No. Applicable unit No. Applicable unit
00 Engine, overall 34 Transmission (HYDROSHIFT) 67
01 35 Power train 68
02 Engine, rear 36 69
03 Engine, left 37 70 Differential, front
04 Engine, right 38 71 Differential, rear
05 39 Torque splitter 72 Axle, front
06 40 Swing machinery 73 Axle, rear
07 41 Swing machinery (rear) 74 Differential, intermediate(HA250)
08 42 75 Crasher, motor
09 43 76 Feeder, vibrator
10 Main clutch 44 77 Screen, vibrator
11 Damper 45 Winch 78 Conveyer, motor
12 46 79
13 47 80 P.T.O.
14 48 81 P.T.O, Ieft
15 Compressor, overall 49 82 P.T.O., right
16 50 Tandem. Ieft 83 Transfer (W/L)
17 51 Tandem, right 84 Steering
18 52 F/D, Ieft intermediate 85
19 53 F/D, right intermediate 86
20 Differential, intermediate (HA300) 54 87
21 Final drive, left intermediate (HA300) 55 88 Circle gear
22 Final drive, right intermediate (HA300) 56 89
23 57 90 Hydraulic
24 58 91 Hydraulic (BK).
25 59 92 HST
26 60 F/D, Ieft front 93 Brake cooling
27 61 F/D, right front 94
28 62 F/D, Ieft rear 95
29 63 F/D, right rear 96
30 Transmission (TOROUEFLOW) 64 97
31 Transmission (direct) 65 Brake, front 98
32 Sub-mission 66 Brake, rear 99 Others
33 Rear-mission
8. HOW TO SETUP ACCEPTANCE CRITERIA FOR THE KOWA
(Manual acceptance criteria setup)

(1) Scope
This standard is applicable to the manual setup acceptance criteria for values obtained in the
KOWA.

(2) How to setup acceptance criteria

(2)-1 Number of data
At least 100 oil assay data shall be collected on the machines (*1).
If the number of data collected is in the range of 50 - 100, the acceptance criteria developed
on them shall be used as temporary one. The criteria becomes the reqular one only after the
number of data reaches 100 or more.
*1: In this case, records of the oil used (its use duration and analytical value) must be traceable.

(2)-2 Calculation of the reduced concentration per unit time

Reduced concentration per unit time shall be calculated based on the oil assay data obtained
on the machines and broken down by models, units and elements. Calculation shall be done
with the formula given in Table 1.
(*2)
Table 1 Calculation of reduced concentration per unit time
Unit name Formula Remarks
Engine Ci= Xi × 250/Ti Ci = Reduced concentration per unit time (ppm)
Other (Equipments Ci = Xi × 500/Ti Xi = Analytical value of oil assay obtained on the machine (ppm)
other than engine) Ti = Oil use duration (hour)

*2: The machine must be of the sane model or type and has same structure and is made of
the same materials.
 (2)-3 Creation of the cumulative frequency distribution graph
The graph shall be prepared using the reduced concentration per unit time (ppm), Ci, obtained
for each model, unit and element in the section (2)-2 above. (Concerning the Procedures for
Creating Cumulative Frequency Graph, see the item (4)).

Figure 1 Cumulative Frequency Distribution Graph

(2)-4 Setting of the acceptance criteria
The acceptance criteria shall be set up based on the cumulative frequency distribution graphs
developed in the section (2)-3 for each model, unit and element. The acceptance criteria at
the reduced concentration per unit time of 85% is maned A and that at 95% is called B.
Table 2 How to Set Acceptance Criteria
Acceptance How to round off values:
Status 1-2 digits figures...Rounded off at units. Examples) 1.5 = 2, 87.3 = 87, etc.
criteria
Normal zone From 0 to A 3 digits figures...Rounded off at 10s. Examples) 234 = 240, 781 = 780,
etc.
Caution zone Over A to B 4 digits figures...Rounded off at 100s. Examples) 1025 = 1000, 1260 =
Warning zone Over than B 1300, etc.
(2)-5 Creation of the acceptance criteria list
Acceptance criteria prepared for each model, unit and element in the section (2)-4 shall be
entered to the attached From 1 and copy of the form shall be circulated immediately to
relevant organizations. The organization issued the document shall be responsible for
maintaining the original.
When entering the values, reasons for the setup (or the modifications) must be clearly noted
in the form.
(3) Review of the acceptance criteria
Acceptance criteria shall be reviewed on the following occasions.

(3)-1 With the temporary acceptance criteria (number of data used for developing the acceptance
criteria is 50 - 100), the criteria shall be reviewed when total number data reaches 100 or
above. (The temporary acceptance criteria shall then be the standard criteria.)

(3)-2 When another 100 or more data have been collected after the standard acceptance criteria
has been established. In this case, a new standard criteria shall be prepared by combining
data collected in the previous assay with the ones obtained in the succeeding analysis. The
number of data, however, shall not exceed 300.
Example) 118 + 154 = 272
Where, 118 = No. of data obtained in the previous assay.
154 = No. of new data.
272 = Total number of data used for revising the current accep tance
criteria.

(3)-3 The acceptance criteria set in the above section (3)-2 shall be reviewed again when another
250 to less than 300 data is collected. Current criteria developed on new data for determining
which the two is to be employed as the standard acceptance criteria.

(4) Procedures for Creating the cumulative frequency graph (Manual method)
(4)-1 Collection of oil assay data on the machines (100 or more data is required.)
When collecting the data, the followings must be identified:
1) Model, type and model number. For instance, D155A-1, #51234.
2) Service meter.
3) Oil use duration.
4) Unit name. For instance, engine, transmission, etc.
 5) Element assay value (Fe, Cu, Cr, Al, Si, Pb and Na).
6) Data and place the assay conducted.
7) History of the machines, as needed.

(4)-2 Determination of the reduced concentration per unit time (ppm).

In this operation, oil assay data collected on the machine is converted to the reduced
concentration per unit time (ppm).
Table 3 Oil assay data collected on machine
Model name and Service Oil use
No. Unit Fe Cu Cr Al Si Pb Na
number hour duration (H)
1 D155A-1#51234 Engine 3945 240 23 7 0*1 16 11 6 33
2 D155A-1#52234 T/M 4780 680 39 44 0 24 31 5 -
3 D155A-1#53234 F/D·L 4169 969 102 6 4 0 37 3 -
4 D155A-1#53234 F/D·R 4169 969 110 15 4 0 44 3 -

Example) Fe reduced concentration per unit time given in Table 3.

1) Reduced concentration per unit time on the engine
Ci = Xi e 250 a Ti = 23 e 250 a 240 23.924 (ppm)
2) Reduced concentration per unit time on the final drive (L)
Ci = Xi e 500 a Ti = 102 e 500 a 969 52.653 (ppm)
*1: 0 in the on-the machine oil assay data indicates that the has not been detected and,
therefore, shall be treated as 0.
(5) Creation of the table of reduced concentration per time.
Table 4 Table of reduced concentration per unit time
Model/type: D155A-1 Element name: Fe No. of data: 118
Unit: F/D·R Overall max. value (L) = 659Overall min. value (s) = 10
(Unit = ppm)
Max. value Min. value
No. 1 2 3 4 5 6 7 8 9 10 of group of group
(marked with ") (marked with !)
Group 1 94 94 125 !53 55 "385 200 57 138 57 385 53
Group 2 144 19 "274 193 230 163 93 79 !10 152 274 10
Group 3 *4 593 38
! 38 141 46 1243 270 91 44 "593 406 74

Group 11 !49 353 343 64 50 532 314 142 88 "659 659 49

Group 12 124 162 162 "435 !26 37 360 61 51 435 26
Group 13
Remarks *4: Excluded as an abnormal value. (N=119·1 = 118)

(6) Preparation of cumulative frequency distribution table.

Determine the followings from the table of reduced concentration per unit time (Table 4):
1) Class (K) = 12 (from Table 5)
2) Class width (h) = 54
h = (L-S)/K = (659-10)/12 54.1 54
3) Central value = 27 (h/2)

Table 5 No. of classes used for creating cumulative

frequency distribution graph
No. of data (N) No. of class (*5)
50 or above - less than 100 10
100 or above - less than 250 12
250 or above 20

*5: No. of c;asses has been determined according to the Komatsu QC Handbook.
 Table 6 Frequency distribution
Class Class limit values Central value Frequency (check) Total % Cumulative %
1 0 - 54 (*6) 27 42 35 35
2 55 - 109 82 35 30 65
3 110 - 164 137 14 12 77
4 165 - 219 192 6 5 82

11 540 - 594 567 1 1 98

12 595 - 649 622 1 1 99
13 650 - 677 677 1 1 100
Total - - 118 100 -
*6: The first setting must start with 0 or above (since there is no data with minus sign).

(7) Creation of cumulative frequency distribution graph

Referring to the frequency distribution table, plot the cumulative percentage of central values on the
graph to draw the distribution curve (using a curved rule).

Figure 2 Cumulative frequency distribution graph

Then, prepare cumulative frequency distribution graph of elements for each unit and determine A
and B.
Determined reference values shall be entered to the specified form (Form 1).
This standard has been prepared referencing the SAE Paper 730745 (Sep. 10 - 13, 1973).
 Limited Distribution Care is required for the handling Form 1
Model group code Setup data
Applicable model

Acceptance criteria
Acceptance criteria Unit: PPM
Unit name Unit code (Oil use duration: 250 hrs for engine and 500 hrs for others)
Status Fe Cu Cr Al Si Pb Na
Normal 45 15 5 8 20 25 50 A
Engine 00 Cation - - - - - - -
Warning 95 45 15 16 40 80 100 B
Hydraulic oil Normal
90 Cation - - - - - - -
Warning
Normal
Cation - - - - - - -
Warning
Normal
Cation - - - - - - -
Warning
Normal
Cation - - - - - - -
Warning
Normal
Cation - - - - - - -
Warning
Normal
Cation - - - - - - -
Warning
Remarks
10. Effective use of KOWA
Received order for the Reman Engine for use on the HD405 dump truck of the
Serial No. 1027

1. Details of the vehicle

Delivery date: June 1998 Failure occurred in: Jan. 2000
Service Meter: 5,767 H Engine: SAA6D140-E2

2. Analysis results by the KOWA upto the time when the failure occurred and determination to
replace the engine
Oil analyses have been made ever since the delivery of the vehicle and abnormal contents of
sodium, copper and lead were detected at the time of 5,767 hours and water leakage was also
detected at that time.
However, abnormal phenomenon was not occurring with the vehicle at this stage.
Since this vehicle was the main model for the cracked stone hauling work for the using customer,
in fear of occurrence of long period of down time, they immediately determined to replace the
engine.

C o pp e r con te nt a na lyses fo r th e H D 40 5 d ump tru ck

o f the S e ria l N o. 10 27

9 00
8 00
Analyzed values (ppm)

7 00
6 00
5 00
ＣＵ
4 00
3 00 C riteria Ab no rma l: 45 pp m
C au tio n:1 5p pm
2 00
1 00
0
0 1 00 0 2 00 0 3 00 0 4 00 0 5 00 0 6 00 0 7 00 0
S e rvice me ter va lue s
 S odium content analyses for the H D 405 dump truck
of the S erial N o. 1027

300
270 C riteria Abnormal: 100 ppm
　　　　 C aution: 50 ppm
Analyzed values (ppm)

240
210
180
150 ＮＡ
120
90
60
30
0
0 1000 2000 3000 4000 5000 6000 7000
S ervice meter values

Lead content analyses for the H D 405 dump truck

of the S erial N o. 1027

200
180
C riteria Abnormal: 50 ppm
Analyzed values (ppm)

160
C aution : 25 ppm
140
120
100 ＰＢ
80
60
40
20
0
0 1000 2000 3000 4000 5000 6000 7000
S ervice meter values
3. Results of analyses
1) Coolant was leaking through the crevice seal of the No.1 cylinder and, as a result, the leaked water
mixed into the oil resulting in lubrication failure between the main metal bearing and the connecting
rod metal bearing causing galling, although seizure was not occurring and, therefore, the crank
shaft was usable.

2) Other main parts like the cylinder block, cylinder head, piston and piston ring, liner, air intake and
exhaust valves, cam shaft, etc. were normal.

a. Conditions of the cylinder liner

The crevice seal was damaged and water
leakage was occurring through the dam-
aged crevice seal.

b. Conditions of the main metal bearing

Wears of the sliding surface are in
progress.
c. Conditions of the connecting rod
metal bearing
Wears are in progress because of leak of
lubrication.

d. Conditions of the crank shaft

Slight scratch was occurring because of
leak of lubrication.
 e. Conditions of the piston
No particular abnormality was found the
the piston was normal.

f. Conditions of other parts

Other parts like the cam shaft, cylinder liner, tappet, cylinder head, air intake and exhaust
valves, etc. were normal.

4. Effects of the KOWA

Since serious damage of the engine did not occur, the expenses shouldered by the using cus-
tomer were about 3 million yen of ordinary reman price only. If the subject vehicle did not take
the oil sampling, the engine must have gone into serious damage and, by replacement of the
cylinder head, cylinder block and crank shaft, additional expenses of about 2.3 million yen must
have become necessary.