Interpretacion Curso Cat

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Identified

Increasing

Increasing Wear

Wear

Compartment

_Status

__

Measures

of:

Deterioration

Contamination

Formulation

Urgent

Stop

Diagnose

Repair

Indicators

Monitor

Proceed with

Caution

Investigate

Normal

Continue

Informational

Cost Savings

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Many

Many of of thethe materialsmaterials referencedreferenced inin t thesehese trainingtraining modulesmodules areare updatedupdated onon aa regular regular basis.basis. TheThe most

most recentrecent versionsversions of of t thesehese documentsdocuments areare availableavailable onon thethe CatCat intranetintranet systemsystem andand onon thethe WorldWorld Wide

Wide Web.Web. TheThe underlinedunderlined portionportion of of thethe entryentry indicatesindicates thethe bestbest placeplace t too viewview thethe specifiedspecified material.

material. The

The materialmaterial availableavailable onon thethe CatCat intranetintranet systemsystem isis identifiedidentified byby thethe followingfollowing codes:codes: SIS, SIS, KN,KN, andand GSL.

GSL. All All of of thesethese CatCat intranetintranet sitessites requirerequire aa CorporateCorporate WebWeb SecuritySecurity (CWS)(CWS) usernameusername and password.and password. The

The followingfollowing notesnotes explainexplain howhow toto accessaccess thisthis informationinformation fromfrom eacheach location.location. Service

Service InformationInformation SystemSystem (SIS):(SIS): TypeType thethe followingfollowing addressaddress intointo your your browser:browser: https://sis.cat.com

https://sis.cat.com andand presspress enter.enter. TheThe CWSCWS pagepage willwill appear;appear; typetype inin your your CWSCWS username

username andand password.password. TheThe SIS SIS homehome pagepage willwill appear appear nenext.xt. OnOn thethe SIS SIS homehome page,page, gogo toto MediaMedia Search

Search andand typetype inin thethe mediamedia number.number. Global

Global SalesSales LibraryLibrary (GSL):(GSL): TypeType thethe followingfollowing addressaddress intointo your your browser:browser: https://gsl.cat.com/cda/layout?m=348519&x=7

https://gsl.cat.com/cda/layout?m=348519&x=7 andand presspress enter.enter. TheThe CWSCWS pagepage willwill appear; typeappear; type in

in your your CWSCWS usernameusername andand password.password. ClickClick onon ‗SEARCH‘‗SEARCH‘ _at_{at the}_{the top}_{top of}_of the_{the GSL}_{GSL home}_{home page;}_page;

type

type inin thethe mediamedia number number inin thethe ‗QUICK‗QUICK SEARCH‘SEARCH‘ _box._box.

Knowledge

Knowledge NetworkNetwork (KN):(KN): TypeType thethe followingfollowing addressaddress intointo your your browser:browser: https://kn.cat.com

https://kn.cat.comandand presspress enter.enter. TheThe KNKN homehome pagepage willwill appear;appear; clickclick thethe menumenu itemitem labeled

labeled ―S―S_earch_earch KN‖.KN‖. _In_{In the}_{the search}_{search box,}_{box, type}_{type in}_in ―SOS―SOS Services‖Services‖ _and_{and press}_{press enter.}_{enter. Select}_Select ―SOS

―SOS Services‖Services‖ _from_{from the}_{the list}_{list of}_of KN_{KN communities.}_{communities. At}_At_the_{the SOS}_{SOS Services}_{Services site,}_{site, select}_{select the}_{the menu}_{menu item}_item

labeled

labeled ―To―To_o_ols/Guides‖.ls/Guides‖. _Click_{Click on}_{on the}_{the menu}_{menu item}_{item labeled}_labeled―Data―Data_Analy_Analysis_sis Guides‖.Guides‖.

Cat.com:

Cat.com: ToTo findfind fluidsfluids informationinformation onon thethe http://www.cat.com/http://www.cat.com/ssite,ite, gogo toto thethe ―Products‖―Products‖ _menu_menu

and

and selectselect ―Parts‖.―Parts‖. _In_{In the}_{the Parts}_{Parts menu,}_{menu, select}_select ――_F_Fluids‖.luids‖. _Go_{Go to}_{to the}_{the desired}_{desired menu}_{menu item}_item t_to_{o obtain}_{obtain data}_data

sheets,

sheets, fluidsfluids recommendations,recommendations, andand CatCat specifications.specifications. General

General InformationInformation onon FluidsFluids SEBD0640

SEBD0640 OilOil andand your your engineengine SIS SIS SEBD0970

SEBD0970 CoolantCoolant andand your your engineengine SIS SIS SEBD0518

SEBD0518 KnowKnow Your Your CoolingCooling SystemSystem SEBD0717

SEBD0717 DieselDiesel FuelFuel andand your your engineengine SIS SIS PEGJ0045

PEGJ0045 ReportingReporting ParticleParticle CounCountt byby ISOISO CodeCode GSLGSL SOS

SOS InterpretationInterpretation GuidesGuides PEDP8025

PEDP8025 OptimizingOptimizing OilOil ChangeChange IntervalsIntervals KNKN PEGP9818

PEGP9818 CoolantCoolant Analy Analysissis KNKN Wear

Wear TablesTables Wear Wear TablesTables inin .pdf .pdf formatformat KNKN SOS

SOS ServicesServices DataData SheetsSheets PEGJ0046

PEGJ0046 UnderstandingUnderstanding SOSSOS ServicesServices TestsTests GSLGSL PEGJ0047

PEGJ0047 HowHow toto TakeTake aa GoodGood OilOil SampleSample GSLGSL PEHP7052

PEHP7052 MakingMaking thethe MostMost of of SOSSOS ServicesServices GSLGSL PEHJ0191

PEHJ0191 SOSSOS ServicesServices GSLGSL Cat

Cat Fluid Fluid RecommendationsRecommendations SEBU6250

SEBU6250 Caterpillar Caterpillar MachineMachine FluidsFluids RecommendationsRecommendations SISSIS SEBU6251

SEBU6251 Caterpillar Caterpillar CommercialCommercial DieselDiesel EngineEngine FluidsFluids RecommendationsRecommendations SISSIS SEBU6385

SEBU6385 Caterpillar Caterpillar On-HighwayOn-Highway DieselDiesel TruckTruck EngineEngine FluidsFluids RecommendationsRecommendations SISSIS SEBU7003

SEBU7003 36003600 DieselDiesel EngineEngine FluidsFluids RecommendationsRecommendations for for Lubricants,Lubricants, Fuels,Fuels, andand CoolantsCoolants SIS SIS SEBU6400

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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

APIOil 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

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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 on-highway 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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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

S

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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Serial Number Prefixes SIMSi validate serial number SIS SOS Services Manager Machine Description Performance Handbook Global Sales Library

Engine Power Rating Performance Handbook TMI Web Global Sales Library Powertrain Descriptions Performance Handbook SIS - Specifications Global Sales Library Other Systems Performance Handbook SIS - Specifications Global Sales Library Oil Change Interval SIS - OMM PM Checklist SOS Services Manager Coolant Change Interval SIS - OMM PM Checklist SOS Services Manager Filter Change Interval SIS - OMM PM Checklist SOS Services Manager Sampling Intervals - All SIS - OMM PM Checklist SOS Services Manager

Sampling Procedures PEGJ0047 Global Sales Library-video

Oil Capacity SIS - OMM PM Checklist SOS Services Manager Coolant Capacity SIS - OMM PM Checklist SOS Services Manager Fuel Capacity SIS - OMM PM Checklist SOS Services Manager Recommended Fluids SEBU6250 (latest version) SIS - OMM

Oil Transfer SIS Parts Identification SIS - TIB SM SI Dealership TC and DSN Common Contaminants Interpretation 1 Training Interp. 1 Help Sheets on KN SOS KN Knowledge Entries Uncommon Contaminants SOS KN Knowledge Entries SIS - TIB SM SI Dealership TC and DSN

Common Wear Elements Interpretation 1 Training Interp. 1 Help Sheets on KN

Uncommon Wear Elements SOS KN Knowledge Entries SIS - TIB SM SI Dealership TC and DSN Wear Tables SOS Services Manager SOS KN 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?

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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

Four Questions about Wear

1 2 3 4

Wear Rate Deterioration Contamination Formulation

Aluminum X X Barium X Boron X X Calcium X Chromium X Copper X Iron X Lead X Magnesium X Molybdenum X X Nickel X Phosphorus X Potassium X Silicon X X X Sodium X Tin X Zinc X Nitration X Oxidation X Soot X Sulfation X Particle Count X X Fuel X Glycol X Water X Viscosity 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?

S·O·S Services Coolant Tests

Four Questions about Coolant

1 2 3 4

Coolant T e

Freeze/Boil

Protection Condition Contamination Label Information X Glycol Concentration X Calculated Freeze Protection X Calculated Boil Protection X pH X X Conductivity X X Nitrite X Precipitate X Appearance X Odor X X Color X X Foam X

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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

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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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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

T

ransmission

Problem:

Friction Material Wear

Abnormal Results:

 Si or Cu & Pb (friction materials)  Fe (separator plates)

 Particle Count or PQI increase  Oxidation

Compartment: Powershift

T

ransmission

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

T

ransmission

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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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 <900 PPM

 Fe (pump component wear)

Compartment: Hydraulic Brake System

Problem:

Friction Material Wear

Abnormal Results:

 Si (friction materials)

 Fe (steel separator plates)  Particle Count or PQI increase

Compartment: Differentials

&

Final Drives

Problem: Dirt Entry

Abnormal Results:

 Si & Al, wih Si values 3 to 5 times higher than Al values  Fe (gears, housing)

 Cr (rolling element bearings)

 Cu & Pb or Cu & Sn (bushing or thrust washer)  Particle Count increase or PQI increase

 Particles on oil bottle cap

 Particles on magnetic drain plug  Water

Compartment: Differentials

&

Final Drives

Problem: Brake Wear (only for axles with wet brakes)

Abnormal Results:

 Si (friction material)  Fe (separator plates)  Oxidation  Viscosity increase

Compartment: Radiator

Problem: Incorrect Glycol Level

Abnormal Results:

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Compartment: Radiator

Problem: Oil/Fuel Contamination

Abnormal Results:

 Visible oil/fuel layer/drops  Odor (abnormal, fuel, solvent)

Compartment: Radiator

Problem: Overheating or Restricted Flow

Abnormal Results:

 Low nitrites (NO₂)  Low pH

 Odor (burnt, abnormal, ammonia)

 Mix of magnetic and non-magnetic black solids

Compartment: Radiator

Problem: Internal Reaction - Al

Abnormal Results:

 Low nitrites (NO₂)  High pH

 Odor (abnormal, ammonia)

 ELC color change (red->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, NO₂>2600ppm  High conductivity

Compartment: Radiator

Problem:

Exhaust

Gas Abnormal Results:

 Low nitrites (NO₂)  Low pH (<6.5)

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Problemas comunes en varios compartimentos Problema: Cu elevados

Todos los compartimentos: compartimentos con enfriadores de aceite de cobre fundamentales, incluidas la mayoría de los motores, transmisiones eléctricas, sistemas hidráulicos, sistemas de dirección, y

algunos ejes

Los resultados anormales: • Cu

Problema: La elevación de Ag

Los compartimentos: Todos los compartimentos que contienen los rodamientos de contacto, también conocidas como rodamientos. Los compartimentos que se incluyen son: transmisiones, sistemas hidráulicos, sistemas de dirección, ejes, diferenciales y mandos finales. Los resultados anormales:

• Ag

Problema: Los compartimentos de suciedad de entrada: todos los resultados anormales:

• Si y Al, wih valores de IE de 3 a 5 veces más altos que los valores de Al • Fe

• Partículas Conde

• Ca, Mg, K, Na + (a partir de elementos naturales en la tierra) Problema: Entrada del refrigerante

Todos los compartimientos: "agua" compartimentos refrigerados, incluyendo la mayoría de los motores, transmisiones eléctricas, sistemas hidráulicos, sistemas de dirección, y los ejes de algunos

Los resultados anormales: • K y / o Na

• Cu (si es fresco Cu aceite está presente)

• Si A, B, Mo, y P (elementos de aditivos de refrigerante) • aumento de la viscosidad

Problema: Los compartimientos de agua de entrada: todos los resultados anormales:

• Positivo agua (0,5% o más) • Fe

• Si y Al (a partir de la entrada de tierra probable)

Problema: desgaste de los componentes de bronce Todos los compartimientos:

Los resultados anormales: • Cu y Pb

• Cu y Sn • Cu, Pb y Sn

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• Fe

Los problemas dentro de un compartimiento específico Compartimiento: Motor Diesel

Problema: El hollín

Los resultados anormales: • El hollín

• Fe, Pb, Cr, Sn

• aumento de la viscosidad

Compartimiento: Problema de motor diesel: Los resultados anormales de combustible de dilución:

• disminuir la viscosidad

• Combustible positiva en el conjunto -a-Flash (el 4% como máximo) • Fe (camisas de cilindro, cigüeñal, árbol de levas, varillas de empuje) • Pb y Sn (superposición de rodamiento)

• Cr y Mo (aros de pistón)

• Cu, Pb, y Sn (bujes de bronce)

Compartimiento: motor diesel o de gas Problema: Entrada del refrigerante Los resultados anormales:

• K y / o Na

• Si A, B, Mo, y P (elementos de aditivos de refrigerante) • Pb y Sn (superposición de rodamiento)

• Fe (camisa)

Compartimiento: motor diesel o de gas Problema: La suciedad de entrada Los resultados anormales:

• Si y Al, wih valores de IE de 3 a 5 veces más altos que lo s valores de Al • Fe (camisas de cilindro, cigüeñal, árbol de levas, varillas de empuje) • Pb y Sn (superposición de rodamiento)

Compartimiento: Problema de gas del motor: Resultados de oxidación o nitración anormales:

• Pb y Sn (superposición de rodamiento) • aumento de la viscosidad

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Compartimiento: Transmisión Powershift

Problema: el desgaste por fricción de materiales Los resultados anormales:

• Si o Cu y Pb (materiales de fricción) • Fe (placas separadoras)

• Partículas Conde o el aumento PQI • Oxidación

Compartimiento: Problema de transmisión Powershift: Resultados de cojinetes o bujes de fallo anormales:

• Cu y Pb y Cu y Sn (lavadora buje o empuje) • Cr (cojinete de rodadura)

• Fe (cojinete de rodadura, el eje, alojamiento de hierro) • Partículas Conde o el aumento PQI

Compartimiento: Transmisión Powershift Problema: La suciedad de entrada

Los resultados anormales:

• Si y Al, wih valores de IE de 3 a 5 veces más altos que los valores d e Al • Bloqueo FE (placas separadoras, engranajes)

• Cu y Pb y Cu y Sn (lavadora buje o empuje) • Partículas Conde o el aumento PQI

Compartimiento: sistema hidráulico o de dirección Problema: La suciedad de entrada

• Si y Al, wih valores de IE de 3 a 5 veces más altos que los valores de Al

• Fe, Cr, (varillas de los cilindros, cilindros, componentes de acero de la bomba) • Cu y Pb y Cu y Sn (componentes de la bomba de bronce)

• Aumento del recuento de partículas

Compartimiento: sistema hidráulico o de dirección Problema: El fluido incorrecto

Los resultados anormales: • Zn <900 PPM

• Fe (desgaste de la bomba de componentes) Compartimiento: sistema de freno hidráulico Problema: el desgaste por fricción de materiales Los resultados anormales:

• Si (materiales de fricción)

• Fe (placas de acero de separación) • Partículas Conde o el aumento PQI

Compartimiento: Diferenciales y mandos finales Problema: La suciedad de entrada

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• Si y Al, wih valores de IE de 3 a 5 veces más altos que los valores de Al • Fe (engranajes, vivienda)

• Cr (rodamientos de elementos)

• Cu y Pb y Cu y Sn (lavadora buje o empuje) • Partículas aumento Count o PQI aumento • Partículas en la tapa envasadoras de aceite de • Partículas en tapón de drenaje magnético • Agua

Compartimiento: Diferenciales y mandos finales

Problema: Desgaste de frenos (únicamente para los ejes con frenos húmedos) de los resultados anormales:

• Si (material de fricción) • Fe (placas separadoras) • Oxidación

• aumento de la viscosidad Compartimiento: Radiador

Problema: El nivel de glicol incorrecta Los resultados anormales:

•% de glicol <30% o> 65% o inadecuado para la temperatura ambiente

Compartimiento: Radiador

Problema: Petróleo / Combustible contaminación Los resultados anormales:

• El aceite de Visible / capa de combustible / gotas • Olor (anormal, combustible, disolvente)

Problema: Flujo de sobrecalentamiento o Restringidas Los resultados anormales:

• Los nitritos bajos (NO2) • pH bajo

• Olor (quemar, amoníaco anormal)

• Mezcla de sólidos negros magnéticos y no magnéticos Compartimiento: Radiador

Problema: La reacción interna - Al Los resultados anormales:

• Los nitritos bajos (NO2) • pH alto

• Olor (amoníaco anormal)

• ELC cambio de color (rojo-> rojo / luz) Compartimiento: Radiador

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Los resultados anormales: • Amoníaco Olor

• pH alto • Espuma

Compartimiento: Problema del radiador: SCA La sobredosis de los resultados anormales:

• Los nitritos altos, NO2> 2600ppm • Alta conductividad

Compartimiento: Problema del radiador: Resultados anormales de gases de escape:

• Los nitritos bajos (NO2) • Un pH bajo (<6,5)

• Olor (combustible anormal)

Problemas comunes en varios compartimentos Problema: Cu elevados

Todos los compartimentos: compartimentos con enfriadores de aceite de cobre fundamentales, incluidas la mayoría de los motores, transmisiones eléctricas, sistemas hidráulicos, sistemas de dirección, y

algunos ejes

Los resultados anormales: • Cu

Problema: La elevación de Ag

Los compartimentos: Todos los compartimentos que contienen los rodamientos de contacto, también conocidas como rodamientos. Los compartimentos que se incluyen son: transmisiones, sistemas hidráulicos, sistemas de dirección, ejes, diferenciales y mandos finales. Los resultados anormales:

• Ag

Problema: Los compartimentos de suciedad de entrada: todos los resultados anormales:

• Si y Al, wih valores de IE de 3 a 5 veces más altos que los valores de Al • Fe

• Partículas Conde

• Ca, Mg, K, Na + (a partir de elementos naturales en la tierra) Problema: Entrada del refrigerante

Todos los compartimientos: "agua" compartimentos refrigerados, incluyendo la mayoría de los motores, transmisiones eléctricas, sistemas hidráulicos, sistemas de dirección, y los ejes de algunos

Los resultados anormales: • K y / o Na

• Si A, B, Mo, y P (elementos de aditivos de refrigerante) • aumento de la viscosidad

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Problema: Los compartimientos de agua de entrada: todos los resultados anormales:

• Positivo agua (0,5% o más) • Fe

• Si y Al (a partir de la entrada de tierra probable)

Problema: desgaste de los componentes de bronce Todos los compartimientos:

Los resultados anormales: • Cu y Pb

• Cu y Sn • Cu, Pb y Sn • Fe

Los problemas dentro de un compartimiento específico Compartimiento: Motor Diesel

Problema: El hollín

Los resultados anormales: • El hollín

• Fe, Pb, Cr, Sn

Compartimiento: Problema de motor diesel: Los resultados anormales de combustible de dilución:

• disminuir la viscosidad

• Combustible positiva en el conjunto -a-Flash (el 4% como máximo) • Fe (camisas de cilindro, cigüeñal, árbol de levas, varillas de empuje) • Pb y Sn (superposición de ro damiento)

Compartimiento: motor diesel o de gas Problema: Entrada del refrigerante Los resultados anormales:

• K y / o Na

• Si A, B, Mo, y P (elementos de aditivos de refrigerante) • Pb y Sn (superposición de rodamiento)

• Fe (camisa)

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Problema: La suciedad de entrada Los resultados anormales:

• Si y Al, wih valores de IE de 3 a 5 veces más altos que los valores de Al • Fe (camisas de cilindro, cigüeñal, árbol de levas, varillas de empuje) • Pb y Sn (superposición de rodamiento)

Compartimiento: Problema de gas del motor: Resultados de oxidación o nitración anormales:

• Pb y Sn (superposición de rodamiento) • aumento de la viscosidad

• Fe

Compartimiento: Transmisión Powershift

Problema: el desgaste por fricción de materiales Los resultados anormales:

• Si o Cu y Pb (materiales de fricción) • Fe (placas separadoras)

• Partículas Conde o el aumento PQI • Oxidación

Compartimiento: Problema de transmisión Powershift: Resultados de cojinetes o bujes de fallo anormales:

• Cu y Pb y Cu y Sn (lavadora buje o empuje) • Cr (cojinete de rod adura)

• Fe (cojinete de rodadura, el eje, alojamiento de hierro) • Partículas Conde o el aumento PQI

Compartimiento: Transmisión Powershift Problema: La suciedad de entrada

• Si y Al, wih valores de IE de 3 a 5 veces más altos que los valores de Al • Bloqueo FE (placas separadoras, engranajes)

• Cu y Pb y Cu y Sn (lavadora buje o empuje) • Partículas Conde o el aumento PQI

Compartimiento: sistema hidráulico o de dirección Problema: La suciedad de entrada

• Si y Al, wih valores de IE de 3 a 5 veces más altos que los valores de Al

• Fe, Cr, (varillas de los cilindros, cilindros, componentes de acero de la bomba) • Cu y Pb y Cu y Sn (componentes de la bomba de bronce)

• Aumento del recuento de partículas

Compartimiento: sistema hidráulico o de dirección Problema: El fluido incorrecto

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Los resultados anormales: • Zn <900 PPM

• Fe (desgaste de la bomba de componentes) Compartimiento: sistema de freno hidráulico Problema: el desgaste por fricción de materiales Los resultados anormales:

• Si (materiales de fricción)

• Fe (placas de acero de separación) • Partículas Conde o el aumento PQI

Compartimiento: Diferenciales y mandos finales Problema: La suciedad de entrada

• Si y Al, wih valores de IE de 3 a 5 veces más altos que los valores de Al • Fe (engranajes, vivienda)

• Cr (rodamientos de elementos)

• Cu y Pb y Cu y Sn (lavadora buje o empuje) • Partículas aumento Count o PQI aumento

• Partículas en la tapa envasadoras de acei te de • Partículas en tapón de drenaje magnético

• Agua

Compartimiento: Diferenciales y mandos finales

Problema: Desgaste de frenos (únicamente para los ejes con frenos húmedos) de los resultados anormales:

• Si (material de fricción) • Fe (placas separadoras) • Oxidación

• aumento de la viscosidad Compartimiento: Radiador

Problema: El nivel de glicol incorrecta Los resultados anormales:

•% de glicol <30% o> 65% o inadecuado para la temperatura ambiente

Problema: Petróleo / Combustible contaminación Los resultados anormales:

• El aceite de Visible / capa de combustible / gotas • Olor (anormal, combustible, disolvente)

Problema: Flujo de sobrecalentamiento o Restringidas Los resultados anormales:

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• pH bajo

• Olor (quemar, amoníaco anormal)

• Mezcla de sólidos negros magnéticos y no magnéticos Compartimiento: Radiador

Problema: La reacción interna - Al Los resultados anormales:

• Los nitritos bajos (NO2) • pH alto

• Olor (amoníaco anormal)

• ELC cambio de color (rojo -> rojo / luz) Compartimiento: Radiador

Problema: Incompleto Fast Flush Limpiador interino Los resultados anormales:

• Amoníaco Olor • pH alto

• Espuma

Compartimiento: Problema del radiador: SCA La sobredosis de los resultados anormales:

• Los nitritos altos, NO2> 2600ppm • Alta conductividad

Compartimiento: Problema del radiador: Resultados anormales de gases de escape:

• Los nitritos bajos (NO2) • Un pH bajo (<6,5)

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Diesel Engine Oils Gas Engine Oils

Test Parameters Guideline Test Parameters Guideline

Wear Elements Fe Cr Cu Si Al Sn Pb Wear Tables1. Wear Elements Fe Cr Cu Si Al Sn Pb Wear Tables1. Additive Elements Ca Mg Zn P Mo Ba B Help Sheet2. Additive Elements Ca Mg Zn P Mo Ba B Help Sheet2.

Coolant (monitor) Na or K 25 ppm to 250 ppm Coolant (monitor) Na or K 25 ppm to 250 ppm Coolant (action required) Na or K >250 ppm Coolant (action required) Na or K >250 ppm

Oxidation UFM 34 max Oxidation UFM 20 max

Sulfate UFM 34 max Nitration UFM 12 max

Soot UFM Absorba nce 60

Soot TGA %weight of soot 1.50%

Viscosity change cSt @ 100 C +/- 3 cSt Viscosity change cSt @ 100 C +/- 3 cSt Fuel Dilution - Positive3. viscosity decrease_{GC fuel dilution} below SAE Grade_>4%

Water - Positive Water - Positive

Water - Trace Water - Trace

Glycol - Positive (optional) Glycol - Positive (optional)

Transmission Oils, Hydraulic Oils, & Gear Oils

Test Parameters Guideline

Wear Elements Fe Cr Cu Si Al Sn Pb Wear Tables1. Additive Elements Ca Mg Zn P Mo Ba B Help Sheet2.

Coolant (monitor) Na or K 25 ppm to 250 ppm Coolant (action required) Na or K >250 ppm

Oxidation UFM 17 max

Viscosity change cSt @ 100 C +/- 2 cSt

Water - Positive >0.5%

Water - Trace 0.1% to 0.5%

Glycol - Positive (optional) 0.1% max Particle Analys is ISO code or cap image Trend Analysi s

Caterpillar: Confidential Yellow

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.

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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 wear on cylinder liner, piston rings, bearings

Soot, Fe, Mo, Cr _{Soot wear on older engine with moly plasma coated top} rings and on cylinder liners

Cu Cu oil cooler core leaching

Oxidation, Fe, Pb overheated oil, overextended oil drain Sulfation, Fe high sulfur fuel, overextended oil drain Viscosity increase,

Oxidation, Fe, Pb

overheated oil, wear on cylinder liners, bearing overlay, and piston rings

Viscosity increase, Soot, Fe, Pb

very high soot, wear on cylinder liners, bearing overlay, and piston rings

Viscosity decrease multigrade oil permanent viscosity shear Viscosity decrease, Pb fuel dilution, wear on bearing overlay

Viscosity decrease, Fe,Pb _{severe fuel dilution, wear on cylinder liners, crankshaft,} and bearing overlay

Mo, B, Ba, Cu possible additive elements

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Gas Engines

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

Mo, B, Ba, Cu possible additive elements water coolant entry, condensation

Differentials & Final Drives

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 Ag leaching from antifriction bearing cages or races Fe, Cr, Ag, ISO code 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

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Powershift Transmissions

Si, Fe, ISO code 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 > 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

Fe, Cr, Cylinders

Si >Al, Fe, Cr, Cu, ISO code dirt, pump wear, cylinder & rod wear Fe, Cr, Cu, ISO code pump or motor wear

Fe, Cr, Cu, Pb, Sn, ISO code pump or motor wear 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

Si, Fe, ISO code wet brake friction material and separator plates Zn < 900 PPM industrial hydraulic oil

K and/or Na, Cu ELC coolant contamination

Na, Si, Cu conventional coolant or DEAC contamination Oxidation, viscosity increase overheated oil, overextended oil drain

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Page 20

Engine Transmission Hydraulic Differential Final Drive

Average NAR MC NAR MC NAR MC NAR MC NAR MC Average

Fe 41 51 56 74 24 32 105 134 145 185 Fe Si 9 12 13 17 17 21 19 25 40 52 Si Al 5 6 4 5 4 6 3 4 8 11 Al Pb 5 6 25 34 4 6 4 6 2 3 Pb Sn 4 6 4 6 4 5 4 6 3 4 Sn Cu 8 10 30 39 29 38 22 30 17 22 Cu Cr 2 3 1 2 2 2 1 2 2 3 Cr

MAX NAR MC NAR MC NAR MC NAR MC NAR MC MAX

min NAR MC NAR MC NAR MC NAR MC NAR MC min

Engine Transmission Hydraulic Differential Final Drive

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.

2 0.02 95 10

6 0.06 87 26

13 0.13 74 52

20 0.2 63 74

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 %T

Soot %

Allow. Component Compartment

UFM Guidelines

Soot Diesel Engine 30

Oxidation Diesel Engine 34 Oxidation Nat. Gas Engine 20

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2 0.02 95 10 6 0.06 87 26 13 0.13 74 52 20 0.2 63 74 30 0.3 50 100 35 0.35 45 110 40 0.4 40 120 45 - 46 0.45 - 0.46 35 130 52 - 53 0.52 - 0.53 30 140 60 - 61 0.60 - 0.61 25 150 69 - 70 0.69 - 0.70 20 160 81 - 83 0.81 - 0.83 15 170 98 - 102 0.98 - 1.02 10 180 126 - 134 1.26 - 1.34 5 190 231 2.31 0 200

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 %T

Soot %

Allow. Component Compartment

UFM Guidelines

Soot Diesel Engine 30

Oxidation Diesel Engine 34 Oxidation Nat. Gas Engine 20 Oxidation

Hydraulic &

Non-engine 17

Nitration Nat. Gas Engine 12 Sulfate / COC Diesel Engine 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 non-engine compartments.

Water Screen % Water UFM #

Possible 0.10% 31

Probable 0.50% 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SsmServices

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S o o t - T G A S o o t - % A l l o w a b l e 200 180 160 140 120 100 80 60 40 20 0

S·O·S Services Soot Help Sheet

_{18 Dec 2008}

Cat Soot in % Allowable vs Cat UFM number

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240

UFM number

TGA Soot in %Weight vs Cat UFM number

8 7 6 5 4 3 2 1 0 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 UFM number

Interpretation Guidelines for Fuel Dilution Results in Caterpillar Off-Highway 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

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Highway 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.

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none 11.0 to 12.4 ≥4 P MC none 9.0 to 11.0 ≥4 P

AR

none <9.0 ≥4 P

Visc. Grade Viscosity PFc Dilution Level Interpretation for Cat Off-Highway Diesel Engines

none 11.0 to 12.4 <4 N NAR (No comment regarding viscosity or fuel dilution) Confirm the viscosity grade of the oil. Oil viscosity and the fuel test indicate fuel dilution. Confirm the viscosity grade of the oil. Intervention is not needed at this time. Consider sampling at half the normal interval. The fuel test indicates a high level of fuel dilution. Intervention is needed. At your earliest convenience, inspect engine. Possible causes of fuel dilution are: leaking injectors, injector o-rings, failed injectors, fuel transfer pump, and engine over fueling. Resample after repairs. Low oil viscosity and the fuel test indicate a high level of fuel dilution. Intervention is needed. Stop machine and inspect engine. Possible causes of fuel dilution are: leaking injectors, injector o-rings, failed injectors, fuel transfer pump, and engine overfueling.

scheduled sampling.

15W-40 11.0 to 12.4 ≥4 P Low oil viscosity and the fuel test indicate a moderate level of fuel dilution. Intervention is not needed at this time. Consider sampling at half the normal interval.

15W-40 9.0 to 11.0 ≥4 P Low oil viscosity and the fuel test indicate a high level of fuel dilution. Intervention is needed. At your earliest convenience, inspect engine. Possible causes of fuel dilution are: leaking

injectors, injector o-rings, failed injectors, fuel transfer pump, and engine over fueling.

15W-40 <9.0 ≥4 P Low oil viscosity and the fuel test indicate a high level of fuel dilution. Intervention is needed. Stop machine and inspect engine. Possible causes of fuel dilution are: leaking injectors, injector o-rings, failed injectors, fuel transfer pump, and engine over fueling.

scheduled sampling.

10W-30 8.0 to 9.2 ≥4 P Low oil viscosity and the fuel test indicate a moderate level of fuel dilution. Intervention is not needed at this time. Consider sampling at halft the noramal interval.

10W-30 7.0 to 8.0 ≥4 P Low oil viscosity and the fuel test indicate a high level of fuel dilution. Intervention is needed. At your earliest convenience, inspect engine. Possible causes of fuel dilution are: leaking

injectors, injector o-rings, failed injectors, fuel transfer pump, and engine overfueling.

10W-30 <7.0 ≥4 P Low oil viscosity and the fuel test indicate a high level of fuel dilution. Intervention is needed. Stop machine and inspect engine. Possible causes of fuel dilution are: leaking injectors, injector o-rings, failed injectors, fuel transfer pump, and engine overfueling. _{Page 24}

S·O·S

Services

Oil Viscosity Help Sheet

01Sep2008

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From SAE J300 November 2007

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Diesel Engine Oils Possible Range of Concentrations

PPM PPM Compartments Typical additive Elements

Ca 0 4000 Diesel Engine Hydraulic Systems Steering Systems Mg 0 3000 Zn 900 1500 P 800 1400 Si 0 15 Possible Additive Elements Mo 0 500 B 0 500 Ba 0 500 Cu 0 100

Gas Engine Oils Possible Range of Concentrations Compartments Typical additive Elements

Ca 0 2000 Gaseous Fuel Engines

Mg 0 500 Zn 0 400 P 0 350 Si 0 15 Possible Additive Elements Mo 0 600 B 0 300 Ba 0 2000

TO-4 Oils Possible Range of Concentrations Compartments Typical additive Elements

Ca 2500 4000 Powershift Transmission Differential & Final Drive Braking Systems Hydraulic Systems Steering Systems Zn 1100 1500 P 1000 1400 Possible Additive Elements Mg 0 100 Si 0 15

Hydraulic Oils Possible Range of Concentrations Compartments Typical additive Elements

Ca 0 4000 Hydraulic Systems Steering Systems Mg 0 3000 Zn 900 1500 P 800 1400 Si 0 15 Possible Additive Elements Mo 0 500 B 0 500 Ba 0 500 Cu 0 100

FD-1 Oils Possible Range of Concentrations Compartments Typical additive Elements

Ca 200 400 Final Drives Differentials without friction materials B 50 150 P 200 400 Zn 10 50

GL-5 Oils Possible Range of Concentrations Compartments Typical Additive Elements P 500 1500 Final Drives

Differentials in Scrapers

B 50 250

MTO Oils Possible Range of Concentrations Compartments Typical additive Elements

Ca 2700 3700 Final Drives &

Differentials in Backhoe Loaders Hydraulic Systems B 50 150 Zn 800 1400 P 900 1500

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30 3 217 -16 103 31 2 217 -17 103 32 1 217 -17 103 33 -1 218 -18 103 34 -2 218 -19 103 35 -4 219 -20 104 36 -6 219 -21 104 37 -8 219 -22 104 38 -10 220 -23 104 39 -12 220 -24 104 40 -14 220 -26 104 41 -16 221 -27 105 42 -18 221 -28 105 43 -20 221 -29 105 44 -22 222 -30 106 45 -24 222 -31 106 46 -26 223 -32 106 47 -28 223 -33 106 48 -30 224 -34 107 49 -32 224 -36 107 50 -34 225 -37 107 51 -37 225 -38 107 52 -40 226 -40 108 53 -43 226 -42 108 54 -46 227 -43 108 55 -49 227 -45 108 56 -52 227 -47 108 57 -55 228 -48 109 58 -58 228 -50 109 59 -61 229 -52 109 60 -64 229 -53 109 61 -68 230 -56 110 62 -72 231 -58 111 63 -76 232 -60 111 64 -80 233 -62 112 65 -84 234 -64 112 66 -88 235 -67 113 67 -92 236 -69 113 68 -96 237 -71 114 69 -92 238 -69 114 70 -88 239 -67 115 71 -84 240 -64 116 72 -80 241 -62 116 73 -76 243 -60 117 74 -72 244 -58 118 75 -68 245 -56 118 76 -64 246 -53 119 77 -60 248 -51 120 78 -56 249 -49 121 79 -52 251 -47 122 80 -48 253 -44 123 81 -44 255 -42 124 82 -42 257 -41 125 83 -39 259 -39 126 84 -36 261 -38 127 85 -33 263 -36 128 86 -30 264 -34 129 87 -28 268 -33 131 88 -26 270 -32 132 89 -24 272 -31 133 90 -22 275 -30 135 91 -20 279 -29 137 92 -18 283 -28 139 93 -16 287 -27 142 94 -14 291 -26 144 95 -12 295 -24 146 96 -10 299 -23 148 97 -8 303 -22 151 98 -6 307 -21 153 99 -4 311 -P2a0ge 2 155 100 -2 314 -19 157 % EG FP (oF) BP (oF) FP (oC) BP (oC) % EG FP (oF) BP (oF) FP (oC) BP (oC) % EG FP (oF) BP (oF) FP (oC) BP (oC) 1 32 212 0 100 2 31 212 -1 100 3 30 212 -1 100 4 29 212 -2 100 5 28 212 -2 100 6 27 212 -3 100 7 26 212 -3 100 8 25 213 -4 101 9 24 213 -4 101 10 23 213 -5 101 11 22 213 -6 101 12 21 213 -6 101 13 20 214 -7 101 14 19 214 -7 101 15 18 214 -8 101 16 17 214 -8 101 17 16 214 -9 101 18 15 214 -9 101 19 14 215 -10 102 20 13 215 -11 102 21 12 215 -11 102 22 11 215 -12 102 23 10 215 -12 102 24 9 215 -13 102 25 8 216 -13 102 26 7 216 -14 102 27 6 216 -14 102 28 5 216 -15 102 29 4 216 -16 102 7

Modified Stray Current Test

The standard test for stray current measures the current (AC & DC) from (a) coolant to ground of battery, (b) from top of radiator, near clamp, to battery ground, (c) the outside of the engine block to the battery ground.

This is done under the following conditions: (1) the engine and all accessories off, (2) the starter engaged – accessories off, (3) all accessories turned on.

If there is a stray current only when more than one accessory is turned on, turn off the accessories sequentially until the stray current disappears. This will indicate the source of the stray current. This test, as designed, will determine a normal stray current (positive for a negative ground system & negative for a positive ground system) where the batter ground is the system ground for all component systems.

There is no common ground in many of our power generation applications, which allows the possibility (with these floating grounds) of a positive or negative stray current (with

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The standard test for stray current measures the current (AC & DC) from (a) coolant to ground of battery, (b) from top of radiator, near clamp, to battery ground, (c) the outside of the engine block to the battery ground.

This is done under the following conditions: (1) the engine and all accessories off, (2) the starter engaged – accessories off, (3) all accessories turned on.

If there is a stray current only when more than one accessory is turned on, turn off the accessories sequentially until the stray current disappears. This will indicate the source of the stray current. This test, as designed, will determine a normal stray current (positive for a negative ground system & negative for a positive ground system) where the batter ground is the system ground for all component systems.

There is no common ground in many of our power generation applications, which allows the possibility (with these floating grounds) of a positive or negative stray current (with respect to either the engine ground, radiator ground or a true earth ground).

If a positive stray current exists (normal stray current condition), the metal acts as an anode and serious corrosion occurs at the anode (ex: high iron seen in coolant analysis report). If a negative stray current exists (if all normal negative grounds were tied together this condition would be impossible), the metal would act as a cathode and no corrosion would occur. However, the reduction of the nitrite and nitrate in the coolant could occur, which enables the production of ammonia. Ammonia can destroy the radiator, oil cooler cores, or any other copper alloy component it contacts in short order.

It is necessary to check the voltage on the coolant with respect to the battery ground, earth ground, and the block, and to determine if the current is positive or negative. It is also necessary to check for any potential difference between the block, radiator, battery ground, and the earth ground.

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Interpretation

Guide

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Coolant Analysis Interpretation Guides

Coolant Analysis Overview

Confidential

This publication is intended for the use of authorized Caterpillar dealers only. Any distribution of this form to unauthorized personnel must be avoided to maintain Caterpillar leadership in the fluids analysis field.

Index of Chapters:

Chapter 1...Coolant Analysis Overview ...3 Chapter 2...Level 1 Coolant Analysis and Interpretation ...11 Chapter 3...Level 2 Coolant Analysis and Interpretation ...31 Chapter 4...Source Water Quality and Testing ...38

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2

Coolant Analysis Overview

Foreword

The Importance of Coolant

Everyone understands the importance of oil, but another key fluid in Caterpillar engines, machine design and maintenance is the engine coolant.

How critical is it?

An estimated 50% of all engine failures or poor performance incidents are associated with cooling system problems. For this reason, Caterpillar developed the S•O•S Coolant Analysis program. S•O•S Coolant Analysis is recommended for cooling systems, regardless of type of coolant used. This includes Caterpillar Extended Life Coolant (ELC) systems or standard coolant systems, including Caterpillar Diesel Engine Antifreeze/Coolant (DEAC).

Coolant requirements for diesel engines are more severe than for automotive engines.

Diesel engines are designed to operate at higher temperatures and higher energy levels than engines in cars and small trucks. Today‘s heavy diesels produce a tremendous amount of power from a small package. Additionally, most of today ‘s Caterpillar products rely on the engine cooling system to absorb heat from the engine, transmission, and hydraulic oils. These factors increase the requirements and demands placed on the cooling system.

Used coolant disposal requirements have become more stringent and expensive. Used coolant disposal must be done in accordance with local, state, and federal laws. Customers may be extending coolant drain intervals, recycling coolants and reconditioning coolants to reduce disposal costs.

For all of the above critical reasons, S•O•S Coolant Analysis is highly recommended to achieve optimum performance and the full life designed into today ‘s machines and engines.

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3

Chapter 1 Coolant Analysis Overview

Troubleshooting with S

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Coolant Analysis

The chemistry of diesel engine coolant is complex. The chemical changes the coolant experiences in service are even more complex and variable. The objective of the S•O•S Coolant Analysis program, as with S•O•S Oil Analysis, is to help assure that Caterpillar machines achieve their full design life while providing maximum productivity with the lowest expense. To some observers, Coolant Analysis may seem to focus more on the

chemical changes within the coolant, and therefore coolant condition; whereas Oil Analysis, while considering oil condition,

appears to focus more on contamination of the oil. However, the objective is the same for both programs: to determine if a problem exists and to determine and correct the cause.

the former Diesel Engine Coolant/Antifreeze (DEAC) to a significantly superior product, Caterpillar Extended Life Coolant (ELC). The advantages of ELC over DEAC in terms of both protection to the cooling system and in cost of operation are great. However, cooling systems require periodic testing to assure that they are operating adequately.

There are two primary reasons for

deterioration of coolant in diesel engines: • Improper maintenance practices

(topping up with only water, SCA added to ELC, over/under

concentration of SCA‘s etc.)

• Cooling system problems (localized overheating, exhaust gas entry,

electrolysis, etc.)

Regardless of the type of coolant, periodic analysis of samples should be a consistent part of any maintenance program.

ELC is superior to DEAC in all respects. Although ELC is initially more expensive, its

longer life coupled with the fact that it does not require maintenance to add SCA results in a cost per operating hour that is half (or less) than that of DEAC.