MAINTENANCE COURSE
INTENANCE FOW
MA A
Engine
Air System Handling
Contents 1. Do you know that ...................................................................... 3
2. Air cleaner element ................................................................... 4
3. Symptoms of failure due to dust sucking in from air cleaner .................. 5
4. Sample failures on engine (caused by dust sucking in from air cleaner) .... 6
5. Symptoms of failure air cleaner clogging ......................................... 7
6. Sample failures on engine (caused by air cleaner clogging) .................. 8
Five (5) points about cleaning and changing intervals of
“Air cleaner elements” also to prevent dust from entering engine cylinder
Point 1 Before starting daily operation .............................................. 10
Point 2 Cleaning outer element ...................................................... 11
Point 3 When to clean outer element ............................................... 12
Point 4 When to change elements (with machines using 2-stage dust indicator) ........... 13
Point 4 When to change elements (with machines using 5-stage dust indicator) ........... 14
Point 5 Checking hoses and clamps ................................................. 15
Conclusion ............................................................................... 16
1 Do you know that
Dust contains hard particles such as Silicon and Iron Oxides
These hard particles
have sharp edge too
When these particles gather
inside cylinder, it causes wear
3
4
2 Air cleaner element
Air cleaner element is placed
to prevent these particles
from entering cylinders.
Improper cleaning of “Air cleaner element”
will cause these particles to get into cylinders
On the other hand
Clogged “Air cleaner element” would cause the air
intake to be disrupted and engine can not breath
3 Symptoms of failure due to dust sucking in from air cleaner
- Drop in output
Symptoms
{ - Improper exhaust color
- Excessive consumption of oil
- Premature deterioration of oil
Dust sucking in from air cleaner
Filter paper damaged Defective sealing
Causes
Improper cleaning method Imitation element
/ Interval of element
5
6
4 Sample failures on engine (caused by dust sucking in from air cleaner)
Wear of valve
stem, guide
and seat
Accumulation
of carbon,
formation of
sludge
Breakage of turbocharger
impeller
Wear or seizure of
piston and liner
5 Symptoms of failure air cleaner clogging
Symptoms
{ - Excessive blow-by gas
- Excessive heat in turbocharger, exhaust manifold
Clogging of air cleaner
Improper cleaning Defective
Causes method / intervals pre-cleaner
of element
7
8
6 Sample failures on engine (caused by air cleaner clogging)
Accumulation of carbon,
formation of sludge
Oil leakage from
turbocharger
Wear of bearing and
shaft on turbocharger
5 points
about cleaning and changing intervals
of “Air cleaner elements”
also to prevent dust from
entering engine cylinder
10
Point 1 Before starting daily operation
Before beginning work, check to make sure that the blockage signal is not
on, dust indicator is not red (or yellow in new type).
With New 5-Stage dust indicator, gradual change of air cleaner
clogging status can be seen. It is possible to check the dust
accumulation condition and know next cleaning easily.
Point 2 Cleaning outer element
If the air filter blockage signal goes on, or dust indicator
becomes red (or yellow), clean the outer element.
Never remove the inner
element when cleaning
the air filter. This can
allow dust to enter the
engine and cause a
malfunction.
Do not try to remove the
dust by hitting the filter
element or knocking it
Remove the outer element, and blow the against something else.
dust off the inside of the element with
compressed air.
11
12
Point 3 When to clean outer element
When the dust indicator becomes red or yellow
the following procedure should be taken.
1. Stop the engine. 3. Clean outer element 4. Remove one of the 1 - 6 Tags.
2. Remove outer element. with compressed air.
5. Clean inside the 6. install outer element 7. install cover. 8. Press reset button.
housing. back, be sure that the
air filter is firmly and
Inner element securely attached.
does not require
cleaning
Point 4 When to change elements (with machines using )
After 6 times cleaning and no tags left on the air cleaner cover (or on the
inner element), it is time to change both inner and outer element at the same
time.
When replacing the inner element, attach the new one right
after removing the old one.
If you leave the inner element off for any length of time, dust
will get into the engine.
13
14
Point 4 When to change elements (with machines using )
When the yellow piston reaches to “5 kpa or higher” short time after cleaning
the outer element, it is time to change both outer and inner element.
Short time
usage after
element
cleaning
1. Time to clean 2. Cleaned and button 3. Change both inner
pressed and outer element
When replacing the inner element, attach the
new one right after removing the old one.
Point 5 Checking hoses and clamps
Old and Clamp deteriorates by too much tightening
Inelastic
hose
Heat changes Clamp loosened
hose shape by vibration
Sucking
air Boosted
air
Air
Air Leaks
Dust Leaks
enters
In-Take Exhaust
Dust
enters
Checking the condition of hoses and clamps is highly recommended.
15
16
Conclusion
1- Before beginning work, check to make sure that the blockage signal is not
ON or dust indicator is not on RED (YELLOW in new type) position.
2- When the air filter is clogged, clean the outer element.
3- Never clean the inner element.
4- When cleaning the outer element, never remove the inner element.
5- Clean inside the housing before placing in the outer element.
6- When replacing the inner element, attach the new one immediately after
removing the old one to avoid a chance for dust entering.
7- Too much cleaning (everyday cleaning) of elements is wrong and can
damage the filters' media, also it may void warranty.
8- Checking the condition of hoses and clamps is highly recommended.
Always use Komatsu genuine parts
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HEN00016-00 Materials and specifications are subject to change without notice.
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