S·O·S S·O·S Services Aler Services Aler t Level Help Sheet
Identified Measures of: Deterioration Contamination Formulation
Indicators
Increasing Wear
Compartment Status Urgent Stop Diagnose Repair Monitor Proceed with Caution Investigate Normal Continue Informational Cost Savings
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Reference Materials for SOS for SOS Services Interpretation
I
Many of the of the materials referenced in these training modules are updated on a regular basis. regular basis. The most recent versions of t these documents are available on the Cat intranet system and on the World Wide Web. The underlined portion of the of the entry indicates the best place to view the specified material. The material available on the Cat intranet system is identified by the following codes: SIS, KN, and GSL. All GSL. All of these of these Cat intranet sites require a Corporate Web Security (CWS) username and password. The following notes explain how to access this information from each location. your browser: Service Information System (SIS): Type the following address into your browser: your CWS https://sis.cat.com and press enter. The CWS page will appear; type in your CWS username and password. The SIS home page will appear ne appear ne xt. On the SIS home page, go to Media Search and type in the media number. your browser: Global Sales Library (GSL): Type the following address into your browser: https://gsl.cat.com/cda/layout?m=348519&x=7 and press enter. The CWS page will appear; type in your CWS your CWS username and password. Click on ‗SEARCH‘ at the top of the of the GSL home page; type in the media number in number in the ‗QUICK SEARCH‘ box. your browser: Knowledge Network (KN): Type the following address into your browser: https://kn.cat.com and press enter. The KN home page will appear; click the menu item labeled ―Search KN‖. In the search box, type in ―SOS Services‖ and press enter. Select ―SOS Services‖ from the list of KN of KN communities. At the SOS Services site, select the menu item labeled ―Tools/Guides‖. Click on the menu item labeled ―Data Analysis Analy sis Guides‖. Cat.com: To find fluids information on the http://www.cat.com/site, go to the ―Products‖ menu and select ―Parts‖. In the Parts menu, select ―Fluids‖. Go to the desired menu item t o obtain data sheets, fluids recommendations, and Cat specifications. General Information on Fluids SEBD0640 Oil and your engine your engine SIS SEBD0970 Coolant and your engine your engine SIS SEBD0518 Know Your Cooling Your Cooling System SEBD0717 Diesel Fuel and your engine your engine SIS PEGJ0045 Reporting Particle Count by ISO Code GSL SOS Interpretation Guides PEDP8025 Optimizing Oil Change Intervals KN PEGP9818 Coolant Analy Coolant Analysis sis KN Wear Tables Wear Tables Wear Tables Wear Tables in .pdf format .pdf format KN SOS Services Data Sheets PEGJ0046 Understanding SOS Services Tests GSL PEGJ0047 How to Take a Good Oil Sample GSL PEHP7052 Making the Most of SOS of SOS Services GSL PEHJ0191 SOS Services GSL Cat Fluid Cat Fluid Recommendations SEBU6250 Caterpillar Machine Caterpillar Machine Fluids Recommendations SIS SEBU6251 Caterpillar Commercial Caterpillar Commercial Diesel Engine Fluids Recommendations SIS SEBU6385 Caterpillar On-Highway Caterpillar On-Highway Diesel Truck Engine Fluids Recommendations SIS SEBU7003 3600 Diesel Engine Fluids Recommendations for Lubricants, for Lubricants, Fuels, and Coolants SIS SEBU6400 Caterpillar Gas Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations SIS Page 3
Cat Fluids Data Sheets PEHJ0059 Diesel Engine Oil (DEO) (Western Hemisphere excluding Brazil) GSL PPHJ0072 Diesel Engine Oil (DEO) (Brazil only) GSL PEHJ0021 Diesel Engine Oil (DEO) (Eastern Hemisphere excluding UAE, Saudi Arabia, Egypt) GSL PEHP7062 Full Synthetic DEO PEHP7506 Transmission/Drive Train Oil (TDTO) GSL PEHP8035 Synthetic Blend Transmission/Drive Train Oil (TDTO TMS) GSL PEHJ0009 Hydraulic Oil (HYDO) (North America) PEHP9544 Hydraulic Oil (HYDO) (outside of North America) GSL PEHP6047 Biodegradable Hydraulic Oil (HEES) GSL PELE0905 Hydraulic Oil Formulation Change GSL PEHP9530 Final Drive and Axle Oil (FDAO) GSL PEHP9570 Final Drive and Axle Oil Synthetic (FDAO Syn) GSL PEHP7508 Gear Oil (GO) GSL PEHJ0030 Synthetic Gear Oil (Synthetic GO) GSL PEHP0004 Natural Gas Engine Oil (NGEO) GSL PEHP9574 Natural Gas Engine Oil EL250 (NGEO EL250) GSL PEHJ0006 Natural Gas Engine Oil EL350 (NGEO EL350) GSL PEHJ0067 Extended Life Coolant (ELC) GSL PEHP9554 Diesel Engine Antifreeze/Coolan t (DEAC) GSL PEHJ0040 Natural Gas Engine Coolant Premix 50/50 (NGEC) GSL PEHJ0237 Cat Diesel Fuel System Cleaner GSL Cat Fluids Specifications & Industry Standards Cat ECF-1 Diesel Engine Oil Requirements Cat.com Cat EC-1 Extended Life Coolant available on request from Cat Fluids Engineering Cat FD-1 Final Drive & Axle Oil Cat.com Cat TO-4 Transmission and Drive Train Oil Requirements Cat.com Cat TO-4M Multigrade Transmission and Drive Train Oil Requirements Cat.com Cat BF-1 Biodegradable Hydraulic Fluid Requirements Cat.com API Oil Classifications American Petroleum Institute www.API.org Engine Oil Licensing and Certification System SAE Viscosity Grades Society of Automotive Engineers International www.SAE.org J300 Viscosity grades for engine oils J306 Viscosity grades for gear oils ASTM Standards American Society of Testing and Materials Int. www.ASTM.org D3306 Automobile and Light Duty Coolant D4985 Heavy Duty Coolant D4485 Standard Specification for Performance of Engine Oils
More Information IRM PELJ1065 Cat Diesel Fuel System Cleaner GSL IRM PELJ0525 Cat 256-4968 Diesel Fuel Conditioner GSL or SIS TIBU4910 Fuel Dilution of Engine Oil SIS TIBU5064 Elevated Amounts of Potassium and Aluminum in Oil Samples on 2007 Caterpillar Engines SIS PEGJ0042 Drive Train, Engine, Hydraulic Repair Indicator Quick Reference Guide GSL or SIS SEBF9066 Guideline for Examining Failed Parts SIS PEPJ0143 SIS Training CD through Media Logistics, see next entry SEBF1021 Improving Component Durability series available through Media Logistics by calling 1-800-566-7782 from the United States or Canada or 309-266-0942 from outside the United States or Canada. Alternatively, you may e-mail Media Logistics at
[email protected] . Page 4
13-March 2009
Caterpillar S·O·S Services Interpretation I Acronym Help Sheet API – American Petroleum Institute. This is a global organization that, along with other activities, produces standards and specifications for petroleum products. ASTM International – This is an organization that develops technical standards for materials, products, systems and services. They originated as the American Society for Testing and Materials. Cat BF-1 – A Caterpillar biodegradable fluid specification. Cat DEAC – Diesel Engine Antifreeze/Coolant Cat DEO – Diesel Engine Oil Cat DEO SYN – Synthetic Diesel Engine Oil Cat DEO-ULS – Diesel Engine Oil-Ultra Low Sulfur Cat ECF – Caterpillar Engine Crankcase Fluid. This is a series of oil specifications that CAT has developed. Cat ELC – Extended Life Coolant Cat FDAO – Final Drive and Axle Oil Cat GO – Gear Oil Cat MTO – Multipurpose Tractor Oil Cat TDTO – Transmission Drive Train Oil Cat TDTO TMS -Transmission Multi-Season Cat TO-4 – A Caterpillar transmission and drive train oil specification. TO does not specifically stand for anything. CF – A series of oil classifications from the API. These replace and update the CD and CE classifications. CGI – Clean Gas Induction. This is a proprietary Caterpillar process designed to recirculate exhaust gas to ultimately provide cleaner emissions. CG-4 – An oil classification from the API. This standard addresses oil formulations designed for engines that must comply with 1994 EPA emissions regulations. CH-4 – An oil classification from the API. This standard addresses oil formulations designed for engines that must comply with 1998 EPA emissions regulations. CI-4 – An oil classification from the API. One reason this new standard was introduced was to address oil conditions in engines utilizing EGR technology. CJ-4 – An oil classification from the API. This standard addresses oil formulations designed for engines that must comply with 2007 model year onhighway emissions standards. In addition to addressing oil conditions in EGR engines, this classification also address oils for other advanced aftertreatment and particulate filtering engine technologies. DPF – Diesel Particulate Filter ECM – Electronic Control Module EGR – Exhaust Gas Recirculation. A technology utilized by diesel engine manufacturers to produce cleaner emissions.
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HEUI – Hydraulically Actuated Electronically Controlled Unit Injector KN – Knowledge Network. A series of communities managed by Caterpillar. These contain information bulletins, guides and tools as well as discussion groups. NLGI- National Lubricating Grease Institute. This is a global organization that promotes technical advancements and improvements in lubrication. The NLGI also provides standards for lubricants. OMM – Operations and Maintenance Manual ppm – parts per million. This is a way to describe very dilute concentrations. PSSR – Parts Sales and Service Representatives PSOR – Parts and Service Operations Representative. SCA- Supplemental Coolant Additive SAE – Society of Automotive Engineers. This is a global organization that creates and manages engineering standards. These include viscosity standards for oils. SIS – Service Information System. This is a software tool produced by Caterpillar that contains product information. TC – Technical Communicator. TGA – Thermogravimetric Analysis. This analysis involves heating a sample and measuring the changes in weight as compounds decompose due to higher temperatures. UFM – Unsubtracted FTIR Method. A way to analyze oils using FTIR that does not require reference oil.
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S O SSM Services Position on Machine Profiles ·
·
Machine Profiles were documents that contained specific information on Caterpillar machine models and engines. The primary purpose of these documents was to provide the S·O·S Services interpreter with specifications and guidelines for cooled and lubricated compartments on Cat equipment. Machine Profiles were last published about fifteen years ago. At that time, this information was typically found in many different paper documents. Most of the information that was in the Machine Profiles can be gathered from a variety of accurate electronic sources. The chart on the following page shows a list of items that were covered by the Machine Profiles. For each item in the list, there are two or three sources available to obtain the desired information. All of the primary and secondary sources of information are electronic files. These files are available to Caterpillar dealer personnel. Three of these items may require additional intervention: Oil Transfer, Uncommon Contaminants, and Uncommon Wear Elements. Problems like these three are generally rare. Also, these problems are usually confined to a small population of machines or engines. If the interpreter suspects one of these unusual problems, a Community Discussion can be initiated on the S·O·S Services Knowledge Network. Community Discussion items are responded to by other dealers, and by S·O·S Services personnel at Caterpillar. Ultimately, it may be necessary to contact the dealership‘s Techni cal Communicator (TC) and request assistance. The TC can search the Dealer Solutions Network (DSN) for similar problems. If a similar problem is not found, the TC can submit a DSN request for information. This is the most efficient way to report these types of problems. If the DSN discovers a significant product problem, additional Caterpillar resources will be summoned to contain and solve the problem. The use of these information sources surpasses the support that was provided by Machine Profiles. The electronic data sources contain more information and the information has a higher degree of accuracy. Additionally, the DSN is in place to support the dealership, when new or unusual problems occur in Cat equipment. The DSN can bring these problems to the forefront. Service engineers and product engineers will then take action on these problems. Therefore, S·O·S Services will not be producing new Machine Profiles. Fifteen years ago, they met a need in the program; now these needs can be met with a variety of new and improved sources. Caterpillar S·O·S Services July 2010
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Item Primary Source Serial Number Prefixes SIMSi validate serial number Machine Description Performance Handbook Engine Power Rating Performance Handbook Powertrain Descriptions Performance Handbook Other Systems Performance Handbook Oil Change Interval SIS - OMM Coolant Change Interval SIS - OMM Filter Change Interval SIS - OMM Sampling Intervals - All SIS - OMM Sampling Procedures PEGJ0047 Oil Capacity SIS - OMM Coolant Capacity SIS - OMM Fuel Capacity SIS - OMM Recommended Fluids SEBU6250 (latest version) Oil Transfer SIS Parts Identification Common Contaminants Interpretation 1 Training Uncommon Contaminants SOS KN Knowledge Entries Common Wear Elements Interpretation 1 Training Uncommon Wear Elements SOS KN Knowledge Entries Wear Tables SOS Services Manager
Secondary Source SIS Global Sales Library TMI Web SIS - Specifications SIS - Specifications PM Checklist PM Checklist PM Checklist PM Checklist Global Sales Library-video PM Checklist PM Checklist PM Checklist SIS - OMM SIS - TIB SM SI Interp. 1 Help Sheets on KN SIS - TIB SM SI Interp. 1 Help Sheets on KN SIS - TIB SM SI SOS KN
Tertiary Source SOS Services Manager Global Sales Library Global Sales Library Global Sales Library SOS Services Manager SOS Services Manager SOS Services Manager SOS Services Manager SOS Services Manager SOS Services Manager SOS Services Manager Dealership TC and DSN SOS KN Knowledge Entries Dealership TC and DSN Dealership TC and DSN Request to SOS Services
SIS = Service Information System SIMSi = Service Information Management System TMI = Engine Technical Marketing Information (access on SIS) OMM = Operation and Maintenance Manual PM Checklist = Planned Maintenance Checklist (access on SIS) PEGJ0047 = How To Take A Good SOS Sample SEBU6250 = Caterpillar Machine Fluids Information (available on SIS, and Cat.com) TIB = Technical Information Bulletin SM = Service Magazine SI = Special Instruction TC = Technical Communicator DSN = Dealer Solutions Network KN = Knowledge Network Page 8
S·O·S Services Oil Analysis Help Sheet
The Overall Question about Wear 1. Has the wear rate increased? 2. Has the oil deteriorated? 3. Is the oil contaminated? 4. Is this the correct oil?
S·O S Services ·
Four Questions about Wear
S·O·S Services Oil Analysis Help Sheet
The Overall Question about Wear 1. Has the wear rate increased? 2. Has the oil deteriorated? 3. Is the oil contaminated? 4. Is this the correct oil?
S·O S Services Oil Tests ·
Aluminum Barium Boron Calcium Chromium Copper Iron Lead Magnesium Molybdenum Nickel Phosphorus Potassium Silicon Sodium Tin Zinc Nitration Oxidation Soot Sulfation Particle Count Fuel Glycol Water Viscosity
Four Questions about Wear 1
2
3
4
Wear Rate
Deterioration
Contamination
Formulation
X
X X
X X X
X X X X X X
X X
X X X X
X
X
X X X X X X X
X
X X X X X
X
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S·O·S Services Coolant Analysis Help Sheet
1. What type of coolant is being used? 2. Is freeze/boil protection adequate? 3. Is coolant condition acceptable? 4. Is coolant contaminated?
Four Questions about Coolant S·O·S Services Coolant Tests
Label Information Glycol Concentration Calculated Freeze Protection Calculated Boil Protection pH Conductivity Nitrite Precipitate Appearance Odor Color Foam Oil / Fuel Presence
1 Coolant T X
e
2
3
4
Freeze/Boil Protection
Condition
Contamination
X X X X X X X
X X
X X X
X
X X X
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Services Test Result Relationshi s Common Problems in Multiple Compartments Problem: Elevated Cu Compartments: All compartments with cooper core oil coolers, including most engines, powershift transmissions, hydraulic systems, steering systems, and some axles
Abnormal Results:
Cu
Problem: Elevated Ag Compartments: All compartments that contain rolling contact bearings, also referred to as antifriction bearings. Compartments included are: transmissions, hydraulic systems, steering systems, axles, differentials, and final drives.
Abnormal Results:
Ag
Problem: Dirt Entry Compartments: All Abnormal Results:
Si & Al, wih Si values 3 to 5 times higher than Al values Fe Particle Count Ca, Mg, K, & Na (from naturally occurring elements in the dirt)
Problem: Coolant Entry Compartments: All ―water‖ cooled compartments, including most engines, powershift transmissions, hydraulic systems, steering systems, and some axles
Abnormal Results:
K and / or Na Cu (if Cu oil cooler is present) Si, B, Mo, & P (elements in coolant additives) Viscosity increase
Problem: Water Entry Compartments: All Abnormal Results:
Positive water (0.5% or more) Fe Si & Al (from probable dirt entry)
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Services Test Result Relationshi s Problem: Bronze Component Wear Compartments: All Abnormal Results:
Cu & Pb Cu & Sn Cu, Pb & Sn Fe
Problems within a Specific Compartment Compartment: Diesel Engine Problem: Soot Abnormal Results:
Soot Fe, Pb, Cr, Sn Viscosity increase
Compartment: Diesel Engine Problem: Fuel Dilution Abnormal Results:
Viscosity decrease Positive fuel on Set-a-Flash (4% maximum) Fe (cylinder liners, crankshaft, camshaft, pushrods) Pb & Sn (bearing overlay) Cr & Mo (piston rings) Cu, Pb, & Sn (bronze bushings)
Compartment: Diesel or Gas Engine Problem: Coolant Entry Abnormal Results:
K and / or Na Cu (if Cu oil cooler is present) Si, B, Mo, & P (elements in coolant additives) Pb & Sn (bearing overlay) Fe (cylinder liner) Viscosity increase
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Services Test Result Relationshi s Compartment: Diesel or Gas Engine Problem: Dirt Entry Abnormal Results:
Si & Al, wih Si values 3 to 5 times higher than Al values Fe (cylinder liners, crankshaft, camshaft, pushrods) Pb & Sn (bearing overlay) Cr & Mo (piston rings) Cu, Pb, & Sn (bronze bushings)
Compartment: Gas Engine Problem: Oxidation or Nitration Abnormal Results:
Pb and Sn (bearing overlay) Viscosity increase Fe
Compartment: Powershift Transmission Problem: Friction Material Wear Abnormal Results:
Si or Cu & Pb (friction materials) Fe (separator plates) Particle Count or PQI increase Oxidation
Compartment: Powershift Transmission Problem: Bearing or Bushing Failure Abnormal Results:
Cu & Pb or Cu & Sn (bushing or thrust washer) Cr (rolling element bearing) Fe (rolling element bearing, shaft, iron housing) Particle Count or PQI increase
Compartment: Powershift Transmission Problem: Dirt Entry Abnormal Results:
Si & Al, wih Si values 3 to 5 times higher than Al values Fe (separator plates, gears) Cu & Pb or Cu & Sn (bushing or thrust washer) Particle Count or PQI increase
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Services Test Result Relationshi s Compartment: Hydraulic or Steering System Problem: Dirt Entry Abnormal Results:
Si & Al, wih Si values 3 to 5 times higher than Al values Fe, Cr, (cylinder rods, cylinders, steel pump components) Cu & Pb or Cu & Sn (bronze pump components) Particle Count increase
Compartment: Hydraulic or Steering System Problem: Incorrect Fluid Abnormal Results:
Zn red/light)
Compartment: Radiator Problem: Incomplete Fast Acting Cleaner Flush Abnormal Results:
Ammonia Odor High pH Foam
Compartment: Radiator Problem: SCA Overdosing Abnormal Results:
High nitrites, NO 2>2600ppm High conductivity
Compartment: Radiator Problem: Exhaust Gas Abnormal Results:
Low nitrites (NO 2) Low pH ( 2600ppm • Alta conductividad Compartimiento: Problema del radiador: Resultados anormales de gases de escape: • Los nitritos bajos (NO2) • Un pH bajo ( 2600ppm • Alta conductividad Compartimiento: Problema del radiador: Resultados anormales de gases de escape: • Los nitritos bajos (NO2) • Un pH bajo (250 ppm 34 max 34 max 60 1.50% +/- 3 cSt
viscosity decrease GC fuel dilution
below SAE Grade >4%
Water - Positive Water - Trace Glycol - Positive (optional)
Water - Positive Water - Trace Glycol - Positive (optional) Particle Analys is Caterpillar: Confidential Yellow
Gas Engine Oils Test Parameters Guideline Wear Elements Fe Cr Cu Si Al Sn Pb Wear Tables 1. Additive Elements Ca Mg Zn P Mo Ba B Help Sheet 2. Coolant (monitor) Na or K 25 ppm to 250 ppm Coolant (action required) Na or K >250 ppm Oxidation UFM 20 max Nitration UFM 12 max
Viscosity change
cSt @ 100 C
+/- 3 cSt
Water - Positive Water - Trace Glycol - Positive (optional)
Transmission Oils, Hydraulic Oils, & Gear Oils Test Parameters Wear Elements Fe Cr Cu Si Al Sn Pb Additive Elements Ca Mg Zn P Mo Ba B Coolant (monitor) Na or K Coolant (action required) Na or K Oxidation UFM
Viscosity change
28 April 2011
·
Guideline Wear Tables 1. Help Sheet 2. 25 ppm to 250 ppm >250 ppm 17 max
cSt @ 100 C
+/- 2 cSt
ISO code or cap image
>0.5% 0.1% to 0.5% 0.1% max Trend Analysi s
1. Wear Tables are written into SOS Services Manager, and are available on the SOS Services Knowledge Network 2. Help Sheets are available on the SOS Services Knowledge Network that provide typical ranges for additive elements 3. Confirmation of positive fuel dilution requires a viscosity decrease, and fuel dilution in excess of 4%. Specific fuel dilution guidelines are available on the SOS Services Knowledge Network These guidelines are intended for use by a trained interpreter of oil sample test results. Exceeding any of these guidelines does not indicate imminent failure of the component. Likewise, operating within all of these guidelines does not assure that component will not fail, or wear out prematurely. Page 16
Classic Wear Combinations V4
Diesel Engines Test Parameter
Source
Fe, Cr
cylinder liner, piston rings
Fe, Cr, Al
cylinder liner, piston rings, aluminum piston skirt
Pb
lower rod and main bearing overlay
Pb, Al, Fe
lower rod and main bearings, crankshaft
K and/or Na, Cu
ELC coolant contamination
Na, Si, Cu
conventional coolant or DEAC contamination
Si >Al, Fe, Cr
dirt, cylinder liner, piston rings
Si >Al, Fe, Pb, Cr
dirt, cylinder liner, bearing overlay, piston rings
Cu > Pb or Cu > Sn
bronze bushing or thrust washer
Cu > Pb, Sn
bronze bushing or thrust washer
Soot, Fe, Pb, Cr Soot, Fe, Mo, Cr
Soot wear on cylinder liner, piston rings, bearings
Cu
Cu oil cooler core leaching
Oxidation, Fe, Pb
overheated oil, overextended oil drain high sulfur fuel, overextended oil drain
Sulfation, Fe Viscosity increase, Oxidation, Fe, Pb
Soot wear on older engine with moly plasma coated top rings and on cylinder liners
overheated oil, wear on cylinder liners, bearing overlay, and piston rings
Viscosity increase, Soot, Fe, very high soot, wear on cylinder liners, bearing overlay, and piston rings Pb Viscosity decrease
multigrade oil permanent viscosity shear
Viscosity decrease, Pb Viscosity decrease, Fe,Pb
fuel dilution, wear on bearing overlay
Mo, B, Ba, Cu
possible additive elements
water
coolant entry, condensation, pressure washing
severe fuel dilution, wear on cylinder liners, crankshaft, and bearing overlay
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Classic Wear Combinations V4
Gas Engines Test Parameter
Source
Oxidation, Pb
overextended oil drain, overheated oil, A/F ratio
Oxidation, Pb, Fe, viscosity increase
overextended oil drain, overheated oil. A/F ratio
Nitration
operation on NOx peak, overextended oil drain
Si
siloxane gas in fuel
Si >Al, Fe, Cr
dirt, cylinder liner, piston rings
Si >Al, Fe, Pb, Cr
dirt, cylinder liner, bearing overlay, piston rings
K and/or Na, Cu
ELC coolant contamination
Na, Si, Cu
conventional coolant or DEAC contamination
Cu Mo, B, Ba, Cu
Cu oil cooler core leaching
water
coolant entry, condensation
possible additive elements
Differentials & Final Drives Test Parameter
Source
Positive Water, Si > Al, Fe, Na water entry, gear wear, dirt Si > Al, Fe, Cr, Ni, ISO code
dirt entry, gear wear, bearing wear
Ag Fe, Cr, Ag, ISO code
Ag leaching from antifriction bearing cages or races gear and bearing wear (possible pre-load problem)
Fe, ISO code
Gears
Cu > Pb or Cu > Sn
bronze bushing or thrust washer
Cu > Pb, Sn
bronze bushing or thrust washer
Si, Fe, ISO code
brake friction materials and separator plates
Cu, Pb, Fe, ISO code bronze brake materials and separator plates Oxidation, viscosity increase overheated oil, overextended oil drain viscosity decrease
lower viscosity top-off oil
water
worn or damaged seals, pressure washing
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Classic Wear Combinations V4
Powershift Transmissions Test Parameter Si, Fe, ISO code
Source wet clutch friction material and separator plates
Cu, Pb, Fe, ISO code
bronze friction material and separator plates
Si >Al, Fe, Cr, ISO code
dirt, wear on gears and bearings
Al
torque converter
Al, Cu, Fe, ISO code
torque converter
Cu
Cu oil cooler core leaching
Cu > Pb or Cu > Sn
bronze bushing or thrust washer
Cu > Pb, Sn
bronze bushing or thrust washer
K and/or Na, Cu
ELC coolant contamination
Na, Si, Cu
conventional coolant or DEAC contamination
Ag
Ag leaching from antifriction bearing cages or races
Fe, Cr, Ag, ISO code antifriction bearings Oxidation, viscosity increase overheated oil, overextended oil drain viscosity decrease
lower viscosity top-off oil
water
coolant entry
Hydraulic & Steering Systems Test Parameter
Source
Cu
Cu oil cooler core leaching
Fe, Cr, Si >Al, Fe, Cr, Cu, ISO code
Cylinders dirt, pump wear, cylinder & rod wear
Fe, Cr, Cu, ISO code
pump or motor wear
Fe, Cr, Cu, Pb, Sn, ISO code Fe, Al, Cu, ISO code
pump or motor wear
Ag
Ag leaching from antifriction bearing cages or races
Fe, Cr, Ag, ISO code
antifriction bearings wet brake friction material and separator plates
Si, Fe, ISO code Zn < 900 PPM K and/or Na, Cu
pump or motor wear
industrial hydraulic oil ELC coolant contamination
Na, Si, Cu conventional coolant or DEAC contamination Oxidation, viscosity increase overheated oil, overextended oil drain water
coolant entry, condensation, pressure washing
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SOS Interpretation Training Tool: Wear Table Overview Engine NAR MC 41 51 9 12 5 6 5 6 4 6 8 10 2 3
Transmission NAR MC 56 74 13 17 4 5 25 34 4 6 30 39 1 2
Hydraulic NAR MC 24 32 17 21 4 6 4 6 4 5 29 38 2 2
Differential NAR MC 105 134 19 25 3 4 4 6 4 6 22 30 1 2
Final Drive NAR MC 145 185 40 52 8 11 2 3 3 4 17 22 2 3
MAX Fe Si Al Pb Sn Cu Cr
NAR 81 13 9 10 9 14 6
NAR 213 28 7 82 7 54 1
NAR 40 46 8 14 6 68 4
NAR 186 30 5 9 6 35 2
NAR 290 90 17 4 5 58 10
min Fe Si Al Pb Sn Cu Cr
NAR MC 21 26 5 6 2 3 2 3 0 1 5 7 1 2 Engine
Average Fe Si Al Pb Sn Cu Cr
MC 101 16 11 14 12 17 8
MC 294 36 9 117 10 65 2
NAR MC 18 23 9 11 3 4 3 4 3 4 17 24 0 1 Transmission
MC 53 57 11 20 9 88 5
NAR MC 15 19 10 13 3 4 2 3 2 3 16 21 1 2 Hydraulic
MC 229 39 6 14 9 46 3
NAR MC 45 56 13 17 2 3 1 2 2 3 9 12 1 2 Differential
Average Fe Si Al Pb Sn Cu Cr
MC 366 119 22 6 8 72 12
MAX Fe Si Al Pb Sn Cu Cr
NAR MC 81 106 21 27 5 7 2 3 2 3 4 6 1 2 Final Drive
min Fe Si Al Pb Sn Cu Cr
Table was constructed using 15 Existing Wear Tables corresponding to three different product families: five Excavators (315C, 320C, 330L, 365B, 385B), five Off-Highways Trucks(769C, 775E, 777, 785, 793B) and five Track-Type Tractors (D4C, D5C, D7G, D9H, D11R). The values presented in the table correspond to the average, maximum (MAX) & minimum (min) Wear Table No Action Required (NAR) and Monitor Compartment (MC) table values. Disclaimer: This table is intended as a training tool to provide inisight to new interpreters into the general Wear Table levels. It is not intended as an interpretation guideline and it is not meant to replace any Wear Table. Page 20
UFM INTERPRETATION SYNOPSIS S O Ssm Services will now be reporting FT-IR results in a new format. The results for soot, oxidation, sulfation, and nitration will be unitless whole numbers (UFM – Unsubtracted FT-IR Method number) that no longer represent % Allowable values. Please note that this new method is still to be utilized as a trending module. There will be samples and oil types that do not fit this model. Please refer to the technical paper ―Un-Subtracted FTIR Methodology for S O Ssm Services‖ for further details. Also note that all information in this document was gathered utilizing a Perkin Elmer Oil Express FT-IR with Spectrum One software and the S O Ssm Services Manager laboratory information management software.
Shown below is a chart with comparisons for new soot values and the corresponding absorbance, %T, and % allowable values. Since soot is only the measure of light passage through a sample, there is a direct relationship between the absorbance value obtained at the instrument level and the resulting UFM, %T, and % allowable values.
UFM # 2 6 13 20
Absorbance 0.02 0.06 0.13 0.2
%T 95 87 74 63
Soot % Allow. 10 26 52 74
Component Compartment Soot Diesel Engine Oxidation Diesel Engine Oxidation Nat. Gas Engine Hydraulic &
UFM Guidelines 30 34 20
UFM INTERPRETATION SYNOPSIS S O Ssm Services will now be reporting FT-IR results in a new format. The results for soot, oxidation, sulfation, and nitration will be unitless whole numbers (UFM – Unsubtracted FT-IR Method number) that no longer represent % Allowable values. Please note that this new method is still to be utilized as a trending module. There will be samples and oil types that do not fit this model. Please refer to the technical paper ―Un-Subtracted FTIR Methodology for S O Ssm Services‖ for further details. Also note that all information in this document was gathered utilizing a Perkin Elmer Oil Express FT-IR with Spectrum One software and the S O Ssm Services Manager laboratory information management software.
Shown below is a chart with comparisons for new soot values and the corresponding absorbance, %T, and % allowable values. Since soot is only the measure of light passage through a sample, there is a direct relationship between the absorbance value obtained at the instrument level and the resulting UFM, %T, and % allowable values.
UFM # Absorbance 2 0.02 6 0.06 13 0.13 20 0.2 30 0.3 35 0.35 40 0.4 45 - 46 0.45 - 0.46 52 - 53 0.52 - 0.53 60 - 61 0.60 - 0.61 69 - 70 0.69 - 0.70 81 - 83 0.81 - 0.83 98 - 102 0.98 - 1.02 126 - 134 1.26 - 1.34 231 2.31
%T 95 87 74 63 50 45 40 35 30 25 20 15 10 5 0
Soot % Allow. 10 26 52 74 100 110 120 130 140 150 160 170 180 190 200
UFM Guidelines 30 34 20
Component Compartment Soot Diesel Engine Oxidation Diesel Engine Oxidation Nat. Gas Engine Hydraulic & Oxidation Non-engine Nitration Nat. Gas Engine Sulfate / COC Diesel Engine
17 12 34
* - Please note that this model does not include UFM guidelines for soot, nitration and sulfation in non-engine compartments. Those components do not provide crucial information for nonengine compartments.
Water Screen Possible Probable
% Water 0.10% 0.50%
UFM # 31 35
The UFM values for oxidation, sulfation, and nitration are not directly related to the absorbance value obtained at the instrument level. Absorbance is a single – point measurement, whereas our new method of FT-IR analysis actually measures the peak area in a specific wavenumber range. Because this new measurement is no longer a single point, we are not able to directly correlate previous % allowable values with the UFM values you will see on your reports. Shown above is a table summarizing the values for oxidation, sulfation, and nitration to be used as guidelines during oil interpretation. Please refer to the technical paper listed above for more details. The water screen information comes out of the Spectrum One software as Water Petroleum Lube. The value in this area is also a UFM number, and does not represent % water in the sample (see above table). Also, the % water and corresponding UFM number do not exhibit a linear relationship. Therefore, you cannot extrapolate % water data using the UFM number. A sample with a water petroleum lube UFM number of less than 31 will be negative for water screen. S O Ssm Services Manager will assign a water test to this sample and complete the test by entering a negative value. A sample with a water petroleum lube UFM number of 31 to 34 will indicate a possible f or water screen, S O Ssm Services Manager will assign a water test, and it will remain incomplete until a technician performs a physical confirmation of presence of water and enters the result. A sample with a water petroleum lube UFM number of 35 or greater will indicate a probable for water screen, S O Ssm Services Manager will assign a water test, and it will remain incomplete until a technician performs a physical
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confirmation of presence of water and enters the result.
S·O·S Services Soot Help Sheet
18 Dec 2008
Cat Soot in % Allowable vs Cat UFM number 200 180 e l b 160 a 140 w o l l 120
A 100 % 80 t 60
o o 40 S 20 0
0 10 20 30 220 230 240
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
320
340
210
UFM number TGA Soot in %Weight vs Cat UFM number 8 7
A
6
G 5 T - 4 t o o 3 S 2
1 0 0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
UFM number
Interpretation Guidelines for Fuel Dilution Results in Caterpillar OffHighway Diesel Engines Two Caterpillar service documents were released to address the subject of fuel dilution in off-highway diesel engines. These documents are a Special Instruction REHS3007, and a Technical Information Bulletin TIBU4910. These service documents provide test guidelines for the oil viscosity test and the GC fuel dilution test. These documents do not provide interpretation guidelines for S·O·S Services interpreters at the dealership. This document provides a series of interpretations that can be used when relaying fuel dilution recommendations to a customer. Use of these interpretations will provide the customer with a clear understanding of the problem, and the recommended action. These interpretations will also provide a level of commonality between Cat dealers. This is especially important to customers that use more than one dealer for their oil analysis business.
360
Interpretation Guidelines for Fuel Dilution Results in Caterpillar OffHighway Diesel Engines Two Caterpillar service documents were released to address the subject of fuel dilution in off-highway diesel engines. These documents are a Special Instruction REHS3007, and a Technical Information Bulletin TIBU4910. These service documents provide test guidelines for the oil viscosity test and the GC fuel dilution test. These documents do not provide interpretation guidelines for S·O·S Services interpreters at the dealership. This document provides a series of interpretations that can be used when relaying fuel dilution recommendations to a customer. Use of these interpretations will provide the customer with a clear understanding of the problem, and the recommended action. These interpretations will also provide a level of commonality between Cat dealers. This is especially important to customers that use more than one dealer for their oil analysis business. These example interpretations are written with the assumption that the customer is sampling at a recommended oil change interval. If the sample has very few hours of operation, or if the sample has been run for an extended period of time, the interpreter may need to adjust the recommendation and change the alert level. In other words, these interpretations may not exactly fit every scenario; however, they do provide a common framework that addresses the most common sample results. The interpreter should always use their experience and equipment history to make the best recommendation.
Registered Measured Visc. Grade Viscosity none 11.0 to 12.4
PFc
