As a heavy equipment operator, you know the importance of keeping your equipment running smoothly. A breakdown can cause delays and missed deadlines, ultimately impacting your bottom line. One of the most effective ways to prevent breakdowns and extend the life of your equipment is through scheduled oil sampling.
At Milton CAT, we offer Scheduled Oil Sampling (S•O•S) as part of our maintenance programs. S•O•S is a proactive approach to maintenance that allows you to detect small issues before they become major problems. By analyzing the oil in your equipment, we can determine the condition of your engine, hydraulic system, gears, and bearings.
The S•O•S process involves collecting a small sample of your machine's oil, which is sent to a lab for analysis. The lab looks for indicators of wear, contamination, and other issues that may be affecting the performance of your machine. The lab then provides a detailed analysis and recommendations for any necessary corrective actions.
Some of the benefits of S•O•S include:
Understanding the significance of the numbers generated from S•O•S fluid analysis can maximize the value of your investment. The process involves three types of analysis performed on engine, hydraulic, and drive train oils.
The first type of analysis is wear element rates. This tracks metal wear particles, oil additives, and contaminants over time. Monitoring these elements closely can identify potential problems before they cause major damage, optimizing the lifespan of your equipment.
Lead (Pb) – used as an overlay on main and rod bearings. Possible problem areas include lack of lubrication, coolant contamination, or fuel contamination.
Iron (Fe) – present in cylinder liners, pistons and piston rings, valve guides, anti-friction bearing rollers and races, gears, and gear teeth. Possible problem areas include abnormal operating temperatures, oil degradation, fuel/coolant contamination, stuck /broken rings, or bearing fatigue/failure.
Molybdenum (Mo) – used in some diesel engines to plate upper piston rings. Present naturally in crude oils and used as an anti-friction additive in some lubricants. This may appear due to a coolant leak from Molybdates present in some extended-life coolants.
Chromium (Cr) – plating material for machinery components such as shafts, seals, piston rings, bearing cages and some bearings. Possible problem areas include blow-by, oil consumption, oil degradation, or hydraulic cylinder rod wear.
Silicon (Si) – Silica debris or cleaning fluids. Possible problem areas include dirt entry through the engine’s air induction system, hydraulic cylinder wiper seals, or suction lines in the hydraulic system. Used as an anti-foam additive in some oils.
Aluminum (Al) – enters oil primarily from wear. Found in pistons, journal bearings, shims, washers, accessory casings, bearing cages of planetary gears, and some engine blocks. Possible problem areas are bearing or piston wear. Aluminum is also present in some clay soils.
Copper (Cu) – found in oil cooler cores, journal bearings, thrust bearings, cam and rocker arm bushings, piston pin bushings, gears, valves, turbocharger bearings, and hydraulic pump pressure plates. Possible problem areas include oil degradation and contamination.
Sodium (Na) – naturally present in some crude oils. Usually present in oil as a consequence of a coolant leak.
Tin (Sn) – present in bearing alloys, brass, oil seals, and solder.
Phosphorus (P) – naturally present in crude oils and as an anti-wear additive in some lubricants. Its presence can also be the result of a coolant leak.
Calcium (Ca), Barium (Ba), and Magnesium (Mg) – sometimes used as detergent, dispersing and/or anti-oxidant additives for lubricants.
Zinc (Zn) – present in brass components. Also, an oxidation inhibitor that helps prevent viscosity increases and acid development.
Potassium (K) – naturally present in some crude oils. Usually present in oil as a consequence of a coolant leak.
The second type is oil condition and contaminants analysis. This compares new oil to used oil, evaluating if it provides adequate lubrication and protection. Additionally, it detects the presence of water, glycol, or fuel contamination in the oil. Catching these contaminants early can prevent costly damage to your equipment.
Soot (ST) – Reported in terms of % allowable. Only found in engine oil. Heavy concentration of soot can cause bearing damage. Indication of lugging; over fueling; air inlet restriction; or extended engine idling. This can lead to filter plugging.
Oxidation (OX I) – Reported in terms of % allowable. Occurs in all compartments. It is accelerated by heat, extended oil drain intervals, and contaminants such as water and antifreeze. Oxidation causes the oil to thicken and lose lubrication qualities.
Sulfation (SUL) – Reported in terms of % allowable. During combustion, fuel sulfur oxidizes, then combines with water to form sulfuric acid. Acid corrodes all engine parts, but is most dangerous to valves and valve guides, piston rings, and liners.
Nitration (NIT) – Reported in terms of % allowable. Occurs in all engine oils, but is generally only a problem in natural gas engines. Nitrogen compounds from the combustion process react with water to form nitric acid, thickening the oil and reducing its lubricating ability. It can lead to filter plugging and heavy piston deposits if it continues unchecked.
Fuel Contamination (F) – Reported either negative (N) or positive (P). Tests for more than 4% diesel fuel in oil. Fuel contamination generally results from extended idling, incorrect timing, or a problem with the fuel injectors, pumps, or lines.
Antifreeze Contamination (A) – Reported either negative (N) or positive (P). Tests for more than .01% by volume ethylene glycol antifreeze in oil. Any amount of contamination in the oil is unacceptable. Usually, a positive result indicates a cooling system leak.
Water Contamination (W) – Reported either negative (N) or positive (P). Tests for more than .1% water by volume in oil. Possible problem areas and causes are coolant leaks and condensation (due to low operating temperature).
Viscosity (V100) – Reported in centistokes (cSt @ 100°C). Measures a lubricant’s resistance to flow. Viscosity changes indicate improper servicing, dilution, contamination, or lubrication breakdown.
Glycol Concentration
Level too Low: Loss of freeze/boil control
Level too High: Loss of heat transfer capability
Conductivity
Probable cause: Poor source water, combustion gasses in coolant, stray electrical current
Potential damage: Metal pitting
Nitrite Concentration
Level too Low: Loss of corrosion/cavitation control. Liner pitting, corrosion of system metals, and deposit formation.
Level too High: Possible overdosing of SCA. Maintenance chemicals will precipitate out of the coolant resulting in deposits.
pH Level
Level too Low: Coolant will attack ferrous metals and solder.
Level too High: Coolant will attack aluminum.
The third type of analysis is particle count. This analysis is used for transmission and hydraulic system oil samples to determine the level of wear particles and whether contaminants are causing accelerated wear on your equipment. This knowledge can help you proactively address any issues and ultimately improve the performance and longevity of your equipment.
Reported in the number and size (in microns) of particles in a volume of fluid. Particle counts are divided into size ranges based on a specific size particle. The ISO code is a kind of cleanliness “shorthand” that provides an instant identifier that sums up oil cleanliness in three numbers (X/Y/Z).
The first factor (X) represents the number of particles larger than 4 microns, the second factor (Y) represents the number of particles greater than 6 microns, and the third factor (Z) represents the number of particles greater than 14 microns. When establishing cleanliness standards, only the Y & Z channels are considered. As numbers change between tests of samples from the same compartment, they can be the first indication of a problem.
S•O•S fluid analysis generates valuable insight into the condition of your equipment, enabling you to take proactive steps to maximize its lifespan and minimize operational costs. Knowing the significance of the numbers generated from the analysis is key to unlocking the full potential of your heavy equipment investment.
The S•O•S program at Milton CAT is designed to provide flexible options for all types of equipment and industries. Our trained technicians can work with you to establish a sampling schedule that suits your specific needs and goals. Contact us today to get started.
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