2. S·O·S Fluid Analysis

3. No Longer “Scheduled Oil Sampling”
Caterpillar Dealer Labs now perform Coolant and Fuel analysis in addition to Oil Analysis
Coolant Analysis
Level I
Level II
Fuel Analysis
Fuel Testing
Bacteria/Fungus Testing

4. Purpose
Detect problems early so minor problems can be repaired before they become major failures.
Monitor “positives” as well as “negatives” so money is not wasted on early oil changes or by repairing components needlessly.
Shorten repair time. By using S·O·S information as a guideline, troubleshooting time can often be reduced allowing the servicemen to go right to the core of the problem.

5. Purpose
Monitor maintenance schedules and practices to verify that maintenance is being done, and if it is being done on time.
Schedule downtime to fit into your workload.
Better manage budgets by forecasting the costs of repairs and downtime.
Increase used equipment value at trade-in by using S·O·S program history as proof of proper maintenance and condition.

6. Sampling and Sample Problems
How to Take a Good Sample
How to Fill in the Label

7. How to Take a Good Sample
Oil
Sample Valve
Sample Gun
Drain Plug
Fuel
It’s hard to get a representative sample
Try to mix the fuel and collect from the line or drain.
Coolant
Don’t use the same gun
Don’t get burned

8. While Draining Oil Use no tubing. Labor intensive.
High chance of external contamination.
Not a recommended method.

9. Sampling Problems Contaminated Sample Dirt from draining
Dirt in sample tubing
Dirt in sample gun
Dirt blows into bottle
Prevent problems by using new tubing for each sample and store extra tubing in a clean bag
Use a gun or probe and store in a clean bag
Keep bottle covered on windy days

10. Sampling Problems Non-Representative Sample
Water and Antifreeze settle out
Particles and Metals settle out
Sample contains bottom sediment
Bottle filled too full
Prevent problems by using taking warm samples using good “technique.”

11. Recommended Sample Intervals
Engines-250 hours or at oil change
Non-engine compartment-every 500 hours
Level I Coolant-every engine oil change
Level II Coolant-annually
Fuel-every shipment to check quality
-annually for in-ground storage tanks

12. Complete the Label! Problems No information on bottle
No oil brand or viscosity information
Wrong machine or compartment
No hours reported or inaccurate value
Not fastening the label to the bottle
Not saying if you’re looking for something
The report is only as good as the information on the label!

13. Example

14. Oil Analysis

15. Four Factors that Affect Wear
Maintenance/Application
Lubricating Oil…Type of Application.
Contamination…From Outside Sources.
Wear Particles…From the operation of the parts themselves.

16. “Physical” Tests Water Hot plate “sputter” test Fuel Dilution
Seta-Flash closed cup flash tester
Glycol Contamination
“Wet” chemistry test

17. Wear Elements Analysis
Performed on DCP Spectrometer
Direct Current Plasma Emission Spectrometer
Measures wear metals-10 microns and under
Copper, Iron, Chrome, Lead, Aluminum, Silicon, Sodium, Molybdenum, Silver, Nickel
Readings are in parts per million (PPM)

18. Direct Current Spectrometer

19. Classic Wear Metal Combinations

20. Oil Condition FT-IR Infrared Analyzer
Fourier Transformed Emission Spectrometer
Measures Soot - Sulfur - Oxidation - Nitration Water - Antifreeze* - Fuel* (*not very well!)
Provides information about oil condition
Requires a reference oil from each customer.
Results are in “percent allowable”

21. Nicolet F.T.I.R.

22. Viscosity Testing Measures how thick the oil is
Tells about oil condition and contamination
Oxidation and Soot thickens oil
Fuel and other contaminants makes oil thin

23. Particle Count Performed on Particle Counter
Measures all particles: sand/dirt, metal, non-metals(clutch material), bugs, water and air bubbles
Particles are measured in 8 size ranges and reported as counts per milliliter at 10 and 15 microns
Measures particles missed by the DCP
Cannot analyze engine oils, dark oils or heavily contaminated samples

24. Large Particle Counter

25. I.S.O. Code Quantifies particles by size.
Each I.S.O. Code represents a range of particles/ml.
The smaller the code, the fewer the particles.

26. Cat Cleanliness Targets
Hydraulic Systems…………….ISO 18/15 or less
Transmissions………………....ISO 21/17 or less
Electronic Transmissions..…….ISO 18/15 or less
Fill Oil………..………………..ISO 16/13 or less

27. Understanding I.S.O. Codes
First number represents cumulative particles from5-100 microns
Second number represents cumulative particles from microns

28. Example 5 10 15 20 25 50 75 100 2504 278 36 16 8 4 1 0 Answer:
5       
Answer:
19/12

29. How to Read the S·O·S Report

30. 3 Sections (All samples)

31. Equipment Data

32. Interpretation & Recommendation

33. Wear Metal,Physical, I.R. Results

34. 4th Section (Non-engine)

35. Large Particle Count Results

36. Reverse of Report

37. What the Analyst Looks For
Hours on the Oil
Hours on the Machine or Engine
Trends of all Elements (metals)
Evidence of Contamination
Oil Condition and Type
Product History
Application and Maintenance Practices

38. Hours on Oil The number of hours on the oil since last oil change
This information is critical for accurate interpretation of results
During interpretation, the readings are adjusted to a standard change interval before trend comparisons can be made
Without the hours on oil, our recommendations will likely be wrong!

39. Hours on Machine or Engine
Total operating hours on the machine or engine
Component age
Overhauls
Repairs
All of the above affect wear metal readings

40. Trends of all Elements
Trending is the most reliable and accurate method of interpreting results
A trend is established by repeated test of samples from a particular compartment
Three or four samples are needed to establish a trend
Large deviations from a trendline are indicators of a serious problem

41. Evidence of Contamination
Evidence of Contamination (physical FT-IR) Fuel
Water
Glycol
Sodium
Silicon/Aluminum
Particle Counts
Viscosity Changes

42. Oil Condition and Type Infrared Analysis Soot Sulfur Oxidation
Nitration
Oil Type
CG-4 multi-viscosity for engine
TO-4 straight weight for transmissions

43. Oil Condition and Type
Viscosity
Increasing
Decreasing

44. Infrared Analysis Soot Unburned Fuel Not enough air or too much fuel
Causes accelerated wear, especially iron
Makes oil thick and decreases lubricity
Sulfur
Contaminant in fuel
Forms acid with water

45. Infrared Analysis Oxidation A chemical change to oil
Makes oil thick and decreases lubricity
Temperature increases the oxidation rate
Indicator of Cooling System problems
Nitration
Similar to Oxidation
Indicator of degradation

46. Viscosity Increase Antifreeze contamination High soot levels
Oil break down
Overheating
Use of the wrong lubricant

47. Viscosity Decrease Fuel contamination
Oil transfer from another compartment
Use of wrong lubricant

48. Product History
Product history is examined to determine if any product problem patterns have developed for that specific model and compartment

49. Application and Maintenance Practices
Machine Applications/Environments
Periods of Inactivity
Type and Brand of Oil
Type and Brand of Filter
Quality of Maintenance
Sample Techniques

50. Coolant Analysis

51. Cooling System-Maintenance Management
of premature engine failures or non-performance incidences can be directly attributed to cooling system problems
40%

52. Cooling System Functions
Remove Heat generated from fuel combustion
Burn temperatures can reach 3518 F
Transfer heat from
Transmission oil coolers
Hydraulic oil coolers
Water cooled exhaust manifolds
Water cooled turbocharger shield/housings
Marine gear oil coolers
Jacket-water aftercoolers

53. Typical Cooling System Problems
Overheating
Overcooling
Loss of Coolant

54. Typical Overheating Causes
Low coolant level
Reduced airflow through radiator
Insufficient cooling system pressure
Coolant overflow
High inlet air temperature or restriction
Low heat transfer through scale build-up
Exhaust restriction
Excessive engine load
Insufficient coolant flow

55. Coolant
Function
Transfer heat from hot engine components to a radiator or a heat exchanger
Additive protection is required to improve the properties of the water base
Desired Characteristics
High boiling temperature
Freeze protection
Corrosion resistance

56. Coolant Desired Characteristics Scale & deposit protection Non-foaming
Minimum sediment
Maintain pH (acidity level)

57. New Coolant Characteristics

59. Level I Coolant Analysis
Test for:
% Glycol
pH (acidity)
Total Dissolved Solids
Inhibitor
Recommended every oil change

60. Level II Coolant Analysis
Metal Corrosion Rate
Iron
Copper
Aluminum
Lead
Scaling Potential
Total Hardness
Calcium Hardness
Mg Hardness
Silicate
Phosphate
Acid Potential
Sulfate
Glycolate
Salt (as chloride)
Nitrate
Recommended annually

61. Fuel Analysis

62. Properties and Tests Cetane Number
Ignition quality measure-affects cold starting, smoke and combustion
Sulfur Content
Affects wear, deposits and particulate emmisions
API Gravity
Related to heat content-affects power and economy

63. Properties and Tests Heating Value
Affects power output and fuel economy
Volatility
Affects ease of starting and smoke
Flash Point
Related to volatility and fire hazard in handling

64. Properties and Tests Viscosity
Affects injector lubrication and atomization
Cloud Point
Affect low-temperature operation
Water and Sediment
Affects life of fuel filters, pump and injectors

65. Properties and Tests Carbon Residue
Measures residue in fuel, can influence combustion
Ash
Measures deposit-forming inorganic residue
Corrosion
Measures possible corrosive attack on metal parts

66. API Gravity Related to heat content, affects power and economy
Lighter fuels have higher API numbers
Heavier fuels have lower API number
For Cat engines an API of 35 is optimium
Lighter fuels, like kerosene read about 44 API
Heavier fuel (below 30 API) create combustion chamber deposits which cause abnormal wear
Blending is the only way to correct density

67. Flash Point Related to volatility and fire hazard in handling
It is the temperature at which fuel vapors can be ignited when exposed to a flame
Affected by the type of fuel and the air/fuel ratio
Important for safety reasons, not engine operating characteristics
The minimum flash point for most diesel fuels is 100F

68. Water and Sediment Affects life of fuel filters, pump and injectors
Water introduced during shipment or as condensation during storage
Cause damage, especially to fuel lubricated pumps
Water separators are critical to fuel systems
Sediment (rust, scale,dirt,weld slag, etc.)
Removed by settling, straining/filtration or centrifuging

69. Water and Sediment Eliminate water by draining the fuel tank regularly
Obtain fuel from a reliable source
Water separators should be used
Primary and secondary filtering is usually required

70. Microbial Contamination
Fuels are sterilized during the refining process
Contamination occurs after leaving the refinery
Bacteria and fungi multiply and grow only when water is present
Plugs filter with a greenish-black or brown slime
Prevent growth by keeping fuel system dry
Treat with biocides when a reoccurring problem
Tanks and lines must be clean to reduce filter plugging