and your engineContents ( Foreword Understanding Of Function ‘Bate Siok Mineral Ot ‘Synthetic O15 eves [Total Base Number (TEN) [Ash or Suated Ash Vecosty —_ 'SAE Viscosity Grades for Engine Gis - SAE 900 Dec 98 ‘APL Engine Oil Classiations Diesel Engine Oi Recommendtons Caerpilar Diesel Engine Ol Commercial Lubricant Viscosy Recommendations for Dwea injection Diesel gna The API Donut Cleaniness ‘Contamination & Degradation '5045°"Wear Rate Anais Prevent Problems and Reduce Goss by Knowing Wear Rates Understanding Wear Mots “Tiending Wear Metals in Your Engine “The Technology Bohind Wear Rat Analysis Pinpointing the Causes and Efecs of Conpanent Wear ‘Montring Your Components ‘Stioon/ Aluminum Ratio Di Varios by Location 'Se0+S Oil Condon Analysis 7 MaxinizePertrmance by Knowing Vou Ol Condon ‘Understanding Oi Condon Analysis Furr Transform nfiared Anais entiving Oi Condon Before it Causes Probie ‘Soot Oxidation Nation Produ ‘Sullur Products / Acids ‘Optimizing Your Equemant wih the SeO+S™ Services Program ‘Aditonal Tests: Giycol, Water, Fuel Detection, Viscosty and TEN. {Gye (Coola) Water FeetContents —_ TaN 7 Viscosty 18 “Typical Examples of Ol Related Fares 18 “Tho Lubrication System 1° Bearings 18 ‘Crankshatis 2 Pistons Rings and Une 23 Turbochargers 25 Valves 30 m1 ‘inimiing the Occurrence of OW Ralted Engine Faure Fuel Sur 3 TAN and Fuel Sur Levels for Det injcton (O))Disel Engines "TON and Fuel Sul: Levels fr Precombuston Chamber (PC) Desel Engines Basie Martenance ofthe Lubrcaton System Summary lela] e|Foreword Foreword Bearing fare piston ring sticking, nd excessive of consumption ae dass Symptoms folate engine fais, How do you avd them? There are numerous ways tbe ot he ‘mos! important being Scheduled Ol Sampling (Se0+S") gular maintenance ofthe Iubicao system, andthe use of correct lubricants. Potowing these recommendations ‘can mean the afernce between expenencing ‘epeated ol elated engine ature and beefing {tom a productive and salstactory engine ie This bocka temps to oll the try af of: what iis composed of and what unctons are, how to identify ts contamination and degradation, 'ypcal eonsequonces, and some provenive ‘measures to hep you protet your engine. agains! he devastating flected ‘engine atureUnderstanding Oil Funetion Engine ol performs soveral base uncon in certo provide adequate ubricaton. works 0 ‘Keep he engine clean andre rom ust ane Coronen. tare as cola and cela: andi provides anol fim cushion tat keeps metal o- ell contact oa minimum, thereby reducing {ton and weer” Bul these ae onl the bam functions of otitis te pare domanis ofa ‘ven appcation andthe special condtions under Which an of is used that argo determine the humerous adatonal uncon ol must part, "Those aditonalunctons make chooung Die oes ot forthe ‘The selection ofa sutable orang ol shows be based onthe engine perormance Fecuirements 2s spect by the manufacture ‘wala the appication and he gual ofthe {raiabl uel. Diesel engines, for nstance, orally operate at ower speeds but higher temperatures than gssotne engines, making anations exceptonaly conducive oo oxidation, ‘Sepest formation and coresion of bering metas ‘Unde these condions. the os expected to functon nan expanded capac. Ths where ‘dives ar noliead. The final patormance ‘haracerisicsof he ol depend on the base ol ‘and he addives used. The amount types of ‘dives used vary according othe properties of the base os and he envionment in which he ol ‘al ction, Lutriatng ol opine with base olor base stock Base stocks are mineral (pettaum) or synthetic ‘tain, although vegetable stocks maybe used or Specialized applications, Tho base stock provides {he basic hicatng requirements ofan engine. However, unless ls supported wih atives, ‘base a will degrade ana deteriorate wory rarely In some operating condons. Depending on the ‘ype of basa stock, potloum, syne orohers, ifeentaddive chomistes are used Mineral Olle Mira stocks ace refined from patcloun crue as. The cde ol source and {he ong process wil determine the base stock haraclerts. The cde ols sed for ese! ‘Seine hibicants are primey made up of paraffin, napthone, and aroma compounds ‘Te crue os vith higher paratncontent are ‘moet reqveniy used mn Banded engine ots ‘The reting process begins wih vacuum ditaton. Vacaum iaionsoperates he oi) Info products wih ¢sinlarbotng range and ‘iar viscostis, Aer vacuum tiation, the ‘5 must be puta remove a” moaly Uoiabiesompeunds Base ol pursiation is Usual done by solvent extraction ana hytrenishing or by hycroerecking 2nd hydtnehing. Bot a! these provastes are used {oma or olminate wax, slur, and aromatics Varations in these reting process prosuce base cis with dierent characterises. Mineral base stocks are most prevalent for dese tngin ol formulation becouse Hoy ext proven ‘haraceritcs nd ae ready avaiable a2 reaconable cos. SynthaticOis Syihtic baso stocks are formed by processes that chemically react mates ca Speci comical compostion to produce a ‘Compound win plannod and predtabie. Proper, Those bare socks have viscosly Indexes much higher than HI mineral basa Stocks, whl ther pour pins are considerably tower, These charectertstics make them valuable bending components when compounding ois or ‘creme series at bath high and ow temperatures. The main dsadvantage of @ ‘Synthese the sonar higher ce and he Somewhat imted supp. The group of synnetic ‘ls known as estar couses grater eal eweling than mineral os The possible use a ester ‘Sythe ols rogues hat component design bo ‘atoily consider for seal and astro ‘Sompabilty The use of synthe base stocks lueante 9 Caterpiar engines and machines = ‘ccoptabe the of formulation meets the Spectiedviscosty and Caerpilr performance fequirements or the compartment n which wa ‘boused. For very cold ambient conditions, the ‘Use of symthebc base sock os nocastary. Additives ‘Adaives stengtnon or meaty certain ‘Saracens ofthe base oi Utimatoy, the ‘enable th oo meet requrements Beyond Me ‘Shi of he base ‘The most common aves are doorgents ‘scaton ina, clsperani,akalinty agent, ‘ni-wearagonis,pourpontdepressans and ‘ocoaty inex improve. Here i brief descripion of whet each ative and how @Understanding Oil Detergent help koop tho engine dean by chemical reacting with oxidation produto stop {he fermaton and dopast of eolble ‘compounds. The detergents nue today ae metalic ais called sulfonates, phenates, Dhosphonaies or salicylates ‘Akality agents help neuivalize acs. The ‘elegents ae also song acid notralier, hanging combustion and xideton acs to harmless nevtaized sas, Cridation inhibitors help prover increases in ‘scosy the development f organic acs nd the formation of carbonaceous matt. These ‘nt-enldants are th allowing chemicals. sine ‘ihiophospnates, phenae sates, aromate famines, suilrized ester, and hindered phenol, Depressants help prevent sludge formation by The ‘erent active four stroke cycle desl engine ol {assication designation ae API CF, APICF-4, API C64, and APL CH {API CH ots wore developed in oder to mest he ‘equeemenis ofthe new high perermance dese! ‘engines Also, tie of wes dosgned to mec ‘equromanis of thew emissions deal engi {991 Chet oe are also accepable for vse in older ‘esel engines and in dose engines that ue igh Sur dace ful A CH os may be used in Caterer engines that use API CG and APL (CF-tals. APICH.4 als wil generally excaed the pecormance of APICG-4 olin folowing ‘le doposis on pistons, canal ofa onsumpton, wear of piston ings, vale vain ‘woo, scoay con, and conesion “Trrae new engine tests were developed forthe APLCH ol. The tra tat spiel evelustes Gepests on pistons for engines wih tho two-piece ‘steel piston. This est (pston deposi also ‘measures the control of ol consumption. A ‘Seoond este conducted win modeala ost. ‘The second test meatus th folewirg err: wea’ of pat ings, weer of nda ers, an fealstancet comesion Atha new test ‘measures the folowing charactors with high (ovo of satin tb at wor of te vale wl, ‘eslstancs of the on plugin theo iter, and contol e ldo, {n acdtion tthe new ests, API CH-4 ols have tougher mts for viscosity contin applications ‘hat generate high soot. The ols aso have Improves oxidation resistance. API CH ois ‘must pass an addtional tt (piston depos for {ngines that use aluminum pistons (single ice). ‘Ot pertarmance salto estabished for ennes ‘hal operate in areas with high Sur dese We ‘Allo these improvements alow he API CH ol {o achieve optimal ol change tervals. API C4 Os are recommenced for use in extnde ol Change intovls. API CH ls are ‘ecommended for eonditons tht demand a premium ol. Your Caterpitar deal nas speciic {uielines for optimizing of change ruaral [API CG-4 ols were developed primal fr diesel tengines thal use a 0.05 percent evel of fue Suu However, API CG os can be used wih igh aurea. The TEN a he new a ‘elermins the maximum fel sur love, See ‘svatons' and 2 on pages 31 and 32. [APLC ols ar he fst ols that are required to ass industry standard tests or foam conl and "ecosty shear loss. APICG-4 ls must aso ass tots that wore developed for corrosion, tears odaton [API CF-4 ol service @ wide variety of modern ‘esel engines. API CE-4 l rovde more stable ‘i contro and reduced piston deposit n comparison to AP CF and the solo CE and (CO esiicatons of ol. API CFs ols provide Improved soot dspersancy in comparison to API (Cand absolete CO ols. The APICF-s. Classen was developed wit a 0.40 percont Sulfur dese ua. Ths represents the type of ‘hese fs tat are commontyavaabe wore, NOTE: Do not use single grade API CF olls or ‘multigrade API GF alan Caterpillar Direct Injection (0) Diesel Engines (except (Caterpillar 3600 Series Diesel engines). NOTICE: APICF i not the same classification ‘3s APICF-4. APICF alls are only Fecommended for Caterplar 3600 Series Diesel Engines and Caterpilr engines with precombustion chamber (PC) fuel systems. ‘Same commercial is that meet the APL Classfeations may equre reduced ol change intrvle. Ta determin the of change intra ‘osay moater the conten of the a ana poror a wear metal analy. Caterpilars e045 O1 Analysis Program tho profes metho. NOTICE: Failure to follow these oi ‘ecommendation can cause shortenedUnderstanding Oil Diesel Engine Oil Recommendations * Caterpillar Diesel Engine Oil Caterer Ot have boon developed and ested to row the fl performance ar save fe {hat has been designed an bul no Caterpir Engines. Caterplar Os are curonty used to fit deel engines athe factory. Thee ola ao ‘offered by Caterpilar dealers or conned use ‘nen the engine oli changed Cansut your ‘teri dese for more formation ons ‘Due to significant variation inthe quatty and porormarce af commercial avatable os, {atop reconmends + Caterpiliar Diese Engine O4 (10W20) {Caterpillar Diesel Engine O4 (1540) Caterpitir muttgrade Oise Engine Otis formulated wa he corect routs of fotegents, sepersants, and shal to provide Superer performance in Catorilar Diese! Engines Caeritar multrade Diesel Engine Os ‘avalable n2vscosy grades 1020 and 154740. For det njcton engines, so0 Table {to choose the correct vost grade fe te Ambien temperature, Murad ols provide 2 corect vacosty fora oad range of ‘operating empertures. Muligrade ols re eectiv in maintaining ow ‘of consumption alow loves piston epost, CCaterilar maltgrade Diesel Engine Ot can be ‘sed noes dese engines andin gasline fengines. See the engine manulacre’ guide forthe recommended specications. Compare the epacfeatons to thove of Caterplar tmutirede Desa! Engr Ol. The curent Industry standards for Celera Diesel Engine ‘Ota ited on tho preduct abel and ho data heats forthe product Consult your Caterpila dealer or par rabers ‘and avalable ize of eonsinors, NOTE: In adlion o passing the APICH-, C64, CFs, OF ol clasiicaon ets, Ceri 19-40 maagrade DEO (CH) aso passes adaional popitary tess that Inoue Piston ring sting, cota wear and soot fests Propratary tests help ensure that Ctarpiar muligzade provides superior cil Caer Stes De Eg perrmance in Catepitar Diesel Engines. In ‘don, Caterpiar multgrade surpasses many Othe porermance requrements of cher dose! {engine manufacturers co tis an excelent chore formany med fees. True high performance ollie produced using a combination of industry test, proprietary tests eld test, land prior experience with similar formulations. All these factors are used to ‘design and develop the high performence ‘and high quay tbricants sold by Catorpitar. Commercial Oils ‘The perlomance of commercial sisal engine ‘ls based on American Petotoum Institte (GP) casstcatons which are developed to ‘rovde commer uareants or a toed ange {t sel engines that operate a various ondtons. 1 Caterpitar mutigrade Diesel Engine Cis not ‘sed, ony use commer fs that meet he otoning assieatons: 1+ APICH muligrace al (refered os) 2 API C6-4 mutigrade ol (peered ol) 1 -APICE-4 mutigrade ol (accopable ol? NOTICE: In selecting an ll for any engine ‘aplication, both the ol viscosity and performance category as specified by the ‘Sngine menufacturer must be defined and Satisfied. Using only one ofthese parameters wil not sufficiently {or an engine application. te 1 Onratn and Morerance Man fr guanceSelect anol wih a sutsbe vscosty anda proper performance classieaton Lubricant Viscosity Recommendations for Direct Injection (01) Diesel Engines ‘The prope SAE wiscosty grade of os termined by the minum amtsent temperature during eo engine startup andthe maximum ambient temperature ding nine Speraton Refer to Tabla 1 (minimum temperature) inorder fo termine the requred ol vacant for tang old engine Fofor to Table 1 (maximum temperature} in ‘te o soc he ol viscsty Tor engine ‘peration a ihe ighest amen temperature thats antopated Generally, use the highest i viscosty hats aval io meet tho requrement forthe Temperature a star-up, oes [ean aEE EES 'S'SS;~ s~«C™ Understanding Oil The API Donut To aid customers in selecting the appropiate o the Amarcan Pevoleum istuta Mat ceveioped the API "donut symbal. The symbol (see ‘rawing below indeats the AP serdce, dase (upper ha fhe ce), SAE ‘scoaty grado (cone ofthe symbo) and pplcadte, energy conserving feature of a al (Gatto half othe sree). Energy conservation 'snotappeabo fo heavy-duty esl engine oe While any ol supper may use the AP service tasscations lo indicate the perfomance level Of any one oF her commercial ls, oly teoneed cmpanies may use the API donut symbol on thor latels. Leensees whe use this dont have cates that each feansod ol meets a ‘reserbod technical erormance standards. Some menting is cone through he SAS Ol Labotng Assessment Program (OLAP), co sponsored by API and the US. Army, wich analyzes a represeratve samp of as nthe marketplace. Therloe, forest seswance hat anol does mee! ie adverisea pertomance {asuteton, slat an ol hat hae the AP ‘Sonu ipaUnderstanding Oil Cleanliness. ‘Normal engine operation generates avait of contaminants ranging fom miroseape metal Patiis o cortosve chemicals. the engine ol Fenotkept clean trough fvation, tis Contamination would be earrad through the ‘naine va the ilies are designed to remove these hal ‘brs paris tom the haicaton sytem Use ‘offer beyond tsntanded if can resutin a lugged iter. A plugged titer wil cause the bypass valve to open, releasing uitere a ‘Any debris parle Is the owl flow dey to {he engine. When a bypass ve remains ‘open, the partces that were previously repped bythe itr may aso be Nosh rom and fon through te open bypass valve Fier plugging can aso cause ditotion of he ment. This happens won tee san Increase in he prossureatferonce between the ‘Outside and nie a the iter element Distortion can progress to cracks or loa inthe aper. This again lows debris o fw ita the lengine where ican damage components Neurite elemeni(s) shou be intated any {ime te engine sump ols anod andthe ‘engine sump ile wth new ot Spiral Roving aud Acyte Beads siti pat Stbity and spacing preset Bunling and nize Mckayss NW a — .Contamination & DegradationContamination & Degradation Proper il maintonanceis imperative to keep dlsel ‘engines operating at peak perfomance. Ot ‘manlenance includes scheduled ol changes and Cllanalyis. Ol analysis important bacause the pertomance of engine al somly degrades wit) time. This degradation takes place as the amounts cof wear melals and contaminants ease. Under Severe operating condone, he degradation process can be accelerated. Fo sel engines, $overeconditons ae defined as one ox more of the fotowng:high ad factor, excessive eying, ‘ended ol drains, igh ste, dusty a brolonged ie, gh Sulu fel, and iow Jacket ‘rater temperaives. In eer normale severe onatons, crankcase ols eventually oes the sity {o adequately uoreate and protect engine pars ftom aceelerated wear and damege, Us trefore important to anaiyze the ot at requis intrvale. Coterpir has developed a maintenance ‘management tool that avaluaes ol degradation ‘nd detects the eary sgn of noma component ‘Went. The Caterpitar tool fool analysis aod '5e0+S" Oi Analysis and t's aro he SaaS Services program. 5:05" Ol Analysis dies ‘engine ol analysis rae basi categories wear fal, ol condo, and adonal teste, Tether, thee 3 types of analysis aro used to evaluate of ‘gradation and detect potential engine problems [property administered S+OxS™" Ol Anais program wil reduce repair costs and essen the Impact of downtime. ‘S#0«S™ Wear Rate Analysis, Provent problems and reduce costs by knowing wear rates War Rate Analysis isan integra pat of ou ‘S048 Sercas program that alps you malta engine perermance and maxinze avait ‘rrough rgularyschoduld testing of samples from your engine, Wear Rat Analysis detects ny rola partcis caused by component wear. By tmontoring tends in he tpe she quanty of Daeles, you can gt eary warning of problems Before major damage ocr. Understanding wear metals Every engine produces wear metas in everyday ‘operation wear aceioate, the concentration of ‘ear melt patces increases, signaling 2 problem. Weer Rae Ana}ysis alow you find Droblems beore thoy result in major reps of fnaine ale, ‘Wear Rate Anais can detect particles that range Upto aboxt 1O morons a sze, Wear metal ‘Concentrations ae ezressedin pats pe-miton (opm). The O46" Serces progam tsi for at Teast 9 erat substances: copper en, ‘Gomis, ead tin, aluminum, motndenum, ‘eon and sods Allare wear metas found in Caterpilar engines excep sion (which goneraly Indeates dt) and sodium (whch indeales voter or Coolant). Certain elements na sample may be fom the ol adaeve package rather than tom woat wioun the sytem Sled desir intrpretrs can tothe dtference betwoen normal elements and those that indste storms wos. ‘Trending wear metals in your engine “Two identical engnes under identical condtions ‘may generate wear partcies at diferent rates. Our ‘S008 interpreters have acess toa age ‘alabase of samples for comparison wih saps {rem your engine. However, your own engines may provide the bet guidelines for appropriate evel of wear meals each compartment. Tha’ why Vending isan orcenal part of Woae Rs Analysis ‘Alter thes sarge have ben taken from 2 particular compartment a rend for each wear fatal is estabshed Our interpreters than Compare subsequent samples to is Wend tne to ‘ule spot deviatens a wel ae monitor gradual ‘anges n concentration avels. This atleiion trends also assists wih ile eye analy, helping yOU optimize preducityContamination & Degradation ‘The Technology Behind Wear Rate Analysis emission spectrometer o perform Wear Rae Analy The sectomete determines went temperatures, he elements inthe samp ‘atomized. with each emiting 8 diferent wavelorth of tght ener. An opis yet and cord the lg neeay ans the sits n partspormlion fr each | Element Blament Potantiat Wee Probable Problem ArvaiCauses. ge [Bea | tne tas tera ee =~ [thn mmc er cane |g —[ a aoe — eg = eee __| ais =a |e = = ex Pinpointing the Causes and Effects of ‘Component Wear By comparing inrared (01 Conon tet rests ‘with wear metal Duldup, we can point probable ‘causes of elevated wear melas. The char above istates some ofthe moet common wear mel, thelr source(s), andthe potential poblems they insiate, ‘Spectrometry detects dit contamination as wel as wea metas Slicon isthe most common element Inaeatng de ertry, atough some clay sats aso produce neressed aluminum readings Monitoring Your Components \Wnon $2045 analysis senifies an increase in the conceniraton of ena o more mela, ean pont tothe wearing component most ily, Eausing the increase and, often he probate Cause. For example, a sun increase In slicon {and iron nan olsarple woud prababy inate 2 probiem caused by eho a systom leaks or ‘crankcase seal oaks (99 chat above). Silicon/Aluminum Ratio in Dirt Varies by Location ‘The primary constituents of tare minerals cantaining acon an aluminum. The rao of these 2 elements vanes widely rom place to Place. Clay sls conan neary ae much Suminum as sileon. Ths sone reaton wy local interpretation of you sample resuts is important. ‘We are fami wh he sos your area. ging us te best understanding ofthe embunaions of ‘ments your amos, ‘Se0+S™ Oil Condition Analysis Maximize Performance by Knowing Your Oil Condition Oxygen exposure eat and contaminants cause ‘at ots fo degrade. Engine of parla, Susceptible to dogradaton by suit, nation, by- products of combustion, high temperatires, and Water rom the combustion processor Condensaten. Oil Condton Analyst, part ofthe Comprehensive S«OxS*" Services program, helps prvent component demage by mentoring yout ol ‘Bd Keoping Wack of ts dapradaon. OF {Condon Analisis als allows you to orectContamination & Degradation problems that affect ol pefomance. The bottom: line banett: maximum ol prtrmance, optimum ‘ol change intrate and reduced ropa cost. Understanding Oil Condition Analysis ‘4 Conon Analysis similar o Woar ato ‘Analysis wth one important excepion it ‘vauates chemical compounds Inthe of rather than wear element partes. works the thi: 1 You submita sample of now ot called refernce when you eral inthe ‘5e045™ Services program and when you get new shipmonts of tuk ol. Reference of Samplos are processed at no costo you. YOU ae using Cato nw ol samples ay ol benecessary. Advise your S«OxS" ‘natyst othe viscosity of te Ca ol you use it ach system thas ts own Cat ol reference samples, 2. Thee oi scanned bya special insrument using inared ight Irirmaton Is Storedin ie nsituments memory. 2. Ateach scheduled itera you submit a sample of used 4. Thw OI Condon Analysis insrument focuses ‘abeam of ight tough a fm of sed oa ‘cod the dat, 5 Thensrument uses a mathematica forma to compare te Used anc now als ond ‘qantly any ioronces. Fourier Transform Infrared Analysis 5404S" 01 Conton Analysis nudes an invareaistument that sos a mathematics ‘moth to convert raw instument dat meaningful terms. This os fen called FT, (FourerTrantorn inared Aras) denies ‘2pd quanti organic compound gros by ‘measuring thei ifared absorption athe specie \wavetongh ofeach group. Basdeswontiying ‘xiation, soo, sur products an nation, the {ests ito used to scan foro contamination by {tol water or gyal engine eosin), Identifying Oil Condition Before It Causes Problems (1 Condition Anaysis detects soo. oxidation ant hraton products and sult producing. Ths test can also cect contamina by wate. us and gol rom coolant. detected, spect entamirantects are used to cont ings. (G1 Condon Anata focuses. on Soot Scot's the Insobie resize of pacaly burned fol ished m suspension byte al ode Pckege and causes engine oot Back ‘Who seat erops cut of suspension in theo. ‘controls 16 advo depletion and evenly increases ol viscosity. Heavy concentrations of Soot can cause beara damage by slang ‘contact surtaens of hiicaton, Oxidation ‘xidation occurs when oxygen molecules ‘chomiaty jn wit of molecules. This chemical Feacton i accelerated by igh ol tomperatres, {yoo contamination fom engine coolant, te bresenceof copper and ram extonded ol change Intervals. Oxidation causes the oto thcken, fom ‘Sede, ad ose iatonqunins hin Treatans the fe of your components. Oxidized ‘ll cause deposits on engin sions and ‘ates, stuck rings, and bore plshing Nitration Products ication occurs in alleging os be gorraly nly pablen in natal gas engines. Nirogen ‘Compounds om tha combuston process theken the of ond reduces haeating aby I itation Continoee unchecked, bean rest iter ‘luging, heavy piston deposts, Iacquoring of ‘aves and pistons, and eventual ale. Sulfur Prodcts/Acis Sullris prosontn al foels and afects a engines. During combustion, ue sur oxtizos {hon combines with water form acd. Acid ‘omrodes all engine pars buts most dangerous to ‘valves and valve guides piston rings and ners Optimizing Your Equipment with the 'Se0S™ Services Program i degradation maybe the resut of a numer of factors and conions.itetuting exended a ‘hange nivel. abnormal temperatures, or antamination by ue water oeoolant. Lower ‘quality ol wl degrade more rapidly han @ premium qualty brea wth 0 Condon Analyse, you can determine the exentto which oles deerirated during use ‘2d vey Whether its pecorming upto Specteatondurng the ene a ehange peiod,Contamination & Degradation. (i Congtion Analysis is just one pat of the ‘S045 Services program hat provides information to reduce ove and save you ‘money by preventing maar engine preboms Additional Tests: Glycol, Water, Fuel Detection, Viscosity, and TBN ‘Adekona ol analysis ests may be reqied to bate define tho conten of used engine oI the FT-IR resis show he presence of aol, Water, or sel ue, aor sting wl be heeded to measure he quay of hase, ‘onlaminanis inthe ol. Also in some cases, Severe condtons may waren the need for ‘dotoal ol tsts Those adstonal ets fnonce the inormation aieady gathered inthe ‘War Rate Analysis and Of Condon Analysis. ‘iyco! (Coolant) (Gyeo causes api oxidation ofthe of and Usual nceates a cooking system lak. Severely ‘nied of becemes sok and forms sudge that ‘gs the itr Any amount of eo! ontamaation nthe lis unaceepable. Engines sing waterto-ol coolers may become Contaminated wth coolant a leak dovelops ina ‘ool tube o ea Water Itnrared analysis inscates the presence of ‘water, the approumato ameunt is ctermined by Pinang drop of ol on a plate led to between 230°-260"F.watris present, the owl bbe ‘and spite By comparing ve amount ot boing to iaboratory contol sampes, ‘porenced labortery technicians can determine the quaty of water inthe sample. Any aroun ‘ver 05% considered excas5ve Water can contaminate sstom by leaking in rom te outsige or condensing nthe engine's crankcase or comparment. When water ‘ombines tho reduces the os ay 6 Iieate and forms asudge that pugs fiers iter passing between vor close components Can eae "hol pots I the water ges ot noua aus iy steam erosions a can Fuel Fuel contamination i confirmed using 2 fash test {nich the used ol shoal fo presebed perature in losed cup. then subject oa flame. Fuel vapors von of bythe hea wil fash Fuel in the engine ol reduces ts ubricating ‘roperbes, Smal amounts of uel ae common as ‘result of he combustion proces. Buti fel loveleexcood 43 we wil suggest a chock for etecive fel jection nozzles and oher sources ‘of leakage. Fuel lui s general the result of ‘tended ising, incorrect ng, a prblem wth {he uenjectors, pumps ortoes ‘A dies fel contain some sutur. How much ‘epands on the ameunt of Suu in the crus8 ot ‘andor he reners sity oF dei to ramove & ‘She of he functions of lubrsting ol To rouvalize sur byqroduts (sutrous and lure aie), 8 wel ab orgrie acids frmod by ‘xiaton. In is way, the ol helps prevent omoaive damage. Ades inthe ol contin ‘akaine compounds fomulatod to reuvalze these cca" The measure of reserve akan ote of ie known as the Tota Base Numba (TEN). Generally te higher the TAN valve, the more reserve aay eapacty theo contain Sulric and oer acs signal danger to mot {engine pats, causing corrosive wear io the flrfaces of valve guides, ton ngs and ters "The typeof crroive wear atrbuted to igh sulfur ont uel ean also acslerate ot consumption Because the evel of uur ondesin a used ol inereases with aonger of change interval ‘hocking te TEN of lis important. The TBN of the ol ehoud be checked foreach ollsample. Engine jacket water out! temperature infuencas the formation of erosive ace. Even when {sig ol wth sos than 55% sul cootant temperatures below 822° C (100: F) can couse ‘ci vars lo condense inthe engine ol Syston land corosve attack curs. Low temperatures. so incase tbe amount of water condensation then otherwise might Rave evaporatag out of the (tat normal operating tomparature. This rosival ‘water depletes certan ol aves and reduces tho of abit to protect engine parts. Ts causes deposts, susp formation laoquering, ‘amish and caboning. In aplcatons where ‘humilis high, ack are me kayo fom ‘because ofthe adlitonal water inthe a. So, ‘oth ow coolant temperature an high humiity ‘an osu in preasea erosive aacContamination & Degradation Viscosity Viscosity is defined a¢ a measure ofa fis fesbtance to ow. The standard measure of his ‘rope for crankcase os steed nematic Ascoaty” Kinematic wscost is based onthe ‘ity ofan oto ow under he innce of fray through a capiary tube. The et for Kinematic viscosity is dened by ASTM DSS Crankcase ol may begin tse Its ubicating ‘ropes after experiencing a 3eSt. Change. An ‘inion has experienced a viscosity change of “Tere axe 2 most frequent causes for an increase Inerankesse ol viscosity. The frst is a0 Sceumulaton of combustion by-products (mainly Soot whieh can theken the al. Tho seconds heat whieh can cause oxisaton. Als, axa, tah reeltant of ickenng, ean occu i engine ‘lotat (ly) enters the crankcase. Weer rom ‘Sondensston oF contamination ean iso contribute tooxidaton “Tere are wo primary reason an of might experiance a cecreasenvscosty The fst is {Uatdluton, whch snl fre ofthe of bul 8 ‘Contamination problem that must be resolved fromplly. Arotber posible reason fora viscosty ‘Secrease ie shearing of th long-chain polymer motels tat comprise the vacant Improver Suiives. Insuch an inlance, tho of ean no Fonger mainain performance ai higher temperatures and migrates toward te lover \vazoay ofthe base sock mineral ol. In ether ‘Sse fue alaton or searing. he ot can Thin ‘wn tothe pont tean no engor mastain 20 ‘Sdoquate of fm at operating temperatures. ‘nen invessgatig 2 change ino viscosty be ‘it othe poset tal te wrong ol was use ‘ing an of change or as make-up a. Cael ratio FT tet resi can Rep determine ‘hs possi, ‘An ilthathas experienced 2 3 constoke change has been used beyond ts use fe. An neease Imwear metal cobs wil robaby be detected in ‘amples of when have experienced this ‘amount of vacosty change.ical Examples of Oil Related Failures ‘The Lubrication System ‘basic understanding of the engine lubrication ‘stom eno ont elpuin understanding how ol ontaminain/degradatin can damage engine ‘ormponents bul alo in understanding how 9 ack fol ean ave an equaly dbitaing eect. Most o-oatd fares ae caused eter by Contaminated of degrade 0 foming trough the {engine a by al faling to ow oa given mponant. Knowing how the ubreston system “Teeds" te engine can simpy flue anata An ‘example of ths would be a bearing fare Gust lack of uration. I the ae i covered eae, ‘he Bearings farthest rom te i supply may show the greatest damage ‘The hvication systom for each engine may iter Sight however, most pncpls are the eae, ‘The hbcation eytor forthe 3408 Engine i ‘Smiar to aer engine Morzation systema, Az own inthe schemat, te pump snd ol the ol cooler and thn trough the of fiers. The bypass valves forthe al cole oi fiers protect the system there sa reducton in tho-afew. When the engine started wi cls ‘or the cooler or itor becomes plugged, the bypass vas assure a constant few a to te engine of passage, Ci rom he tt lous into the boc of mand ‘This o then flows int he various Boek oF paseages o ubiete and cool te various engine ‘Components: hen i retus tothe ol pan, To weiinecton pues rocker am shalt toate, Z bot ot ‘Teas apten oa Ea Bearings Oirelates bearing fale is usualy attributed to one of two soutees: lack of ication or dit inthe oi Lack fusion oro starvation ers o an lnbuticen ol fly batoen the crankshaft journal ‘nd bearing. Prolonged operation ofan engine ‘nth an nsuictnt of fis wa cause damage progress quilt a smeared bear, then .a Scued bearing, and nly to 2 seized boning, The fest stage ofthis type of damage smearing. ‘This stage wil show depicoment of he lead-in overlay. normally inthe centro be bearing, In the second stage of damage, sulin, the sluminum i te cere of te bearings displaced ‘The nal tages of fature resut fb! sezue. Ina tree stages the rtatng journal cepiaces Some ofthe Bearing materia em the crown toward the mating fac of each bearng na, Tne amount cf dplaced mater wil dopond on how severe ‘hence of ubrioston Contamination in the ot eau fon and results in scratching the bearing surface by wiping ‘sway some ofthe fi. Parties of ron, ste,Typical Examples of Oil Related Failures tuminum plastic wood, cath, te. can aso attack {he ounal surface, As the Bearing and jury ‘etoces wear, clearances nerease and ol ry thickness changes euleg in uneven supp0d of Ine suraces ‘Amsjr source of dabrietaden ois a plunges far Pioged ites allow uftered ol coniing (roar prises, Gt and dost tow tothe (ectge seriching and camaging ther surfaces. {oactike a ginder Secon “Minemaing the Occurence of OF Rested Eine Faure for exampes of cankshat aamage rye :Typical Examples of Oil Related Failures a ‘ett msintoings ta wre age by et. TeTypical Examples of Oil Related F: Crankshafts “The i ha ows to the basins forms an lm tbotwoen te ranks jouma! and bearing Retain ofthe crankshaft Journal ends to frce ot Detwean te journal andthe bearing an. ing rormal operation, prevents meatal contact She pressured ol develops tormota conac,nceased con and higher temperatores tht lad ote Bearing sing tothe ‘shat in exreme cases the Desing surface ‘acho 3 gly tat the crankshat scace wil be ‘completa destoyed Contaminated ai also causes excessive wear of the crankshaft This is almost nye result of sbrasvesiconiaminatin embeded nth bearing,Typical Examples of Oil Related Failures Pistons, Rings and Liners ‘itlatod piston faire is most commonly caused bythe abrasive action of contamina of which ‘esuls in wea ofthe piston sk. Indeaions ‘nue avery dl ery plton skin, chrome facings ‘wom ef on lings ng rails worn away badly ‘wom grooves and some tner wear. Piston scufing, which appcrs in steaks on the ‘kit, parculary the pin bor area, and ite or ‘ho cuig on tho ft land, maybe caused by Inadequot ner ubeaon” Breakdown ofl fim ‘an produce setzure mars, Piston ings can show wea inthe sping groove, ‘Some sping groove woar normal, but nepleciod clichanges wl cause severe ring ook” that ‘ccurs when the sping catches ma worn roave ‘nd prevents fullexpasion Liner damage can be caused by lack of bxeston ‘ory abrasives which can polish the bore ertove {he cosshatch pattern) and leave 8 shiny ste. stn hi age by ene wat ‘Sicton yn ie.Typical Examples of Oil Related FailuresTypical Examples of Oil Related Failures Turbochargers Oi cetaad ubochargor damage is caused by ol Contamination or lack a l hat can e related ‘operating practices. The ol supplied to the Tboctarger i required o prove bearing (bth Journal and trust iiaton and alo for cooing the Deaig, particularly onthe tine an In operating tho engin. startup and shutdown practices can aggravate turocharger bearing {alres. Whon starting the engin, parity at ‘older ambient temperatures who the os more ‘Yscous, allow a shorting me Ths lene wal ‘ow th alo warm up fr proper filtration and ow Before high engine and turbocharger speeds re alaned On engine shutdown short ie at le Speed wil alow the flowing oto cool he {bocherger bearing housing. ito the cating ero, the ol il onze or coke, cresting deport ‘on bearing surfaces and nol passages which can Festt a Row on he nest operating pid, (i contamination can erode ol holes an can Scratch and wear bearing susfaces as wo as damage shat ana housing Surfaces. The lack of for proper hiicaton wil cause bearing surace ‘damage and aio ease metal disclorain die fo increased temperature Damage the urocharger bearings rom contamination lek of bration allows meton of {he shaft that permis the compressor whes! fo eontat is hausing. Typical conta! damage ‘aused by shaft motion wil bo inated by Toce ‘bing on afew Dados nea ther inducer section, (On th back ofthe whos 180 from where the foe ‘bing appears, here wil be some evidence of Contact wth he Gotor housing, Deep esa dango ahs on bearsTypical Examples of Oil Related Failures) Typical Examples of Oil Related Failures Lack of ubeant and contaminated ot both cause wear ontheast bearings, mating i dticut o Pinpoint the cause of faire. Checking journal bearing condition wi ep dtermine te exact cause ofthe falure. Heat dacoloration of tust "ings also points tack of breton. On, ‘ARtesearch uroochaigers, tortion is most ‘ommorty seen onthe inboard side ofthe trust tings. On the Schuzer models, ecorton tends tobe conned o one area of the gfe Often, bing marks ave present. Damage ‘appears on both ings,ical Examples of Oil Related Failures ea dco nbn ef rt ganaTypical Examples of Oil Related Failures Bearing damage ana excesive sha mation ‘used by lek of ubicaton o abrasives theo ‘may eventually cause the shaft to bend or break Generally, arts wor by abrasives wl lok eroded, ‘As aru, the Dearing sriaces wil ot ook ‘smeared and parts wil show no heat esenioraton, OFthemustatons, he fst pies wear fom {oroign material in he abreting oi: deep grooves ‘are warm tothe two soe rust washers, The cond shows abrasive wea onthe AResearch rbocharge deep grooves are worn inthe tut \washor. The damegei the thd histaton hater to deny. is very fe abrasive woar, which makes ha trust bearing surtace lok palshod, and here is no heat deceleration,Typical Examples of Oil Related Failures Valves os ol-elated va fares resut om deposit The usual cause of valve stem selzue is deposit Ealection between the valve stem and guide ‘deporte contamination nthe ol: Mor special, ‘poss acramulate fom the decompositon of [breatng products ino axidizad reste and the normal wastes generated rom te comtuston Drovest The progressive bubdyp of hese depos ‘ct fo acclerate be mouthing of he guise Valve stom scuffing andr seizure can also be use. Valve seat carbon deposi can crea problems it the deposits are excoesivo. Some loncaton necessary to prevent extreme wear of te valve oat andthe insert inthe head. Bu excessive ‘on the valve seat that wil then break up and flake ‘allowing combustion gas leakage. Ths hot Gesleahage (tein) als Ho emperatre ‘tbe vale ol “This typ of valve fare can exstin qu and gas fuoled engines. The carbon formation tendency of the ol andthe sulfated ash ove! of the a afer the tartbon formedon the vaive sat, aMinimizing the Occurrence of Oil Related Engine Failure Fuel Sulfur (1 contamination can ake numberof fas, but one i more apis is hale han the sui acid hat ean be produced by hgh sue fuel. In October 1955, ow slr fel was mandated in the Unite States fo antigay venice. Inthe stat of Calfomia “ALL” vehicles are requ to se low sulfur fue. Low sur fel was mvoduced ‘3 a means to moot the engine manufactur (EMA) nea for omssons conta in these fappicatons. There ae few ono negative effects ‘ow sult ues Coping wih the oft ffl sul not a se {ask, Even though te use of proper brea and orec itervas reduces the degra c corosne ‘tamago, angie wear wil incense sigicanty ‘sen fuels th high sutur content are used. Not ‘only do hese tues produce acids which chery ‘aac ne engine causing eorosive wear, Dut the (ols used tonegate the acd effets haves igher fash conient which ineeaies chances of depos formation ‘Know the ful sultur conan by perdicaly asking your supple or by having the fel analyzed. Sulfur Content can change with each bulk davery Total Base Number (TBN) and Fuel Sulfur Levels for Direct Injection (01) Diesel Engines The Toll Base Number (TBN) for anol depends ‘on the fal slr level For det injection engines thal use distat fot the minimum TEN of to now co mest be tn tes te ut sur level, “STHM 'D2896" dons the TEN, ‘The minimum TBN of he liste regardless of uel suite lve Husain 2 demonstrat the TEN, eageatan Use he folowing guidelines for fe! slur levels that exceed 15 porent + Choose ano withthe highest TBN that meets ‘one of those dssiicstion: API CH, API CG- and AP CF + Radice the ollchange interval, basing the ‘nterval on the ot anajss. Ensue hat theo analysis ines the concton of theo ard. ‘wear metal analy (i witha high TBN can produce excessive piston ‘deposts. These deposits can lead tos ose of antl ofthe of consumption and tthe polishing ofthe eyinder bore. NOTICE: Operating Direct injected (01 aise! engines with ful sulur levels over 4.0 percent ‘may requir shortened oll change interval in ‘rdor to help maintain adequate wear protection.imizing the Occurrence of Oil Related Engine Failure Total Base Number (TBN) and Fuel Sulfur Levels for Precombustion ‘Chamber (PC) Diesel Engines ‘The TAN or anew il depends onthe ue suitor level ofthe fel used, The minimum TON ofthe {ied n PC engines must be 20 tres ho fel slur level. The TEN i defined in “ASTM 02896. Regadiss of fuel sul level the mieimum TEN of ‘ew lls 5. See station 2 below. (2) ange cian te TON dnt 9 pact tea To Whenever the fel slur exceeds 1.5 percent, do he flowing tase: + Choose an ot withthe highest TBN hat meets ‘ne ofthese casiieatons: API CF, APICF-4, ‘API OG, and API CH 1+ Reduce the ol change interval, basing the interval onthe ol analyte. Ensure that the ol nays ncldes the condion othe of and a ‘wear metal analy NOTICE: Operating PC engines at fel sulfur levels over 0 porcent may require shortened ‘ilchange intervals to maltain adequate wea? protection Basic Maintenance of the Lubrication System Probab the most important step n preventing o- ‘ised e's tbeon be Stay amar “Specie, he means bing senstve the ear signe of Wouble. One way todo thsi ‘wih very base check for obvious warning Sonal. Such a chock weud best be made often ‘nd incude these 3 oy oles 1. Anexteral check of the engine for ny ‘bios sgn ofleakage rom any ‘compartment 2. check of the ol pressure gauge. A change hee eau inate anything fom a defective (pump ta stock pressure rele valve 3. -A chock ofthe olleel gauge. low ol ievel ‘ould veal excessive consumption, leakage, ‘rtalure ofa ines. Antherimporart le of thumb isto aahere to fecommended ol and ater ehange inervals. Tris IS paramount the ight against ol contamination / ‘gradation, especialy wih roars to high sult ‘het. ®‘Summary Inthe long un you ae directly responsite for your engine's performance. You can lessen the Chances of lait false by taking the Inative to protect your engine ‘Selec the corect performance category and ‘acest ofl or he application, Flow he recommended il and fir change inerais Pay atenion to «0x5 ol anayes resus,