MAINTENANCE SERVICES

Understanding S·O·S Services Tests SM

Know what the numbers mean and

maximize your investment
S·O·S Services are valuable management tools that can
maximize equipment life and productivity, and minimize
operating costs and downtime. Four types of analysis are
performed on engine, hydraulics and drivetrain oil.
• Wear Rate monitors and tracks metal wear particles,
contaminants and oil additive package elements
• Oil Condition compares used oil to new oil to see if
it is providing adequate lubrication and protection
• Oil Cleanliness determines if abrasive contaminants
are causing accelerated wear
• Additional Tests detect water, glycol or fuel in oil
You’ll get greater benefits from your S·O·S Services Take oil samples at consistent intervals to detect potential
program when you understand the tests chosen by
Caterpillar® engineers to monitor oil condition and problems early, reduce repair costs and lessen the impact
contaminants. of downtime.
S·O·S Wear Rate Analysis
Prevent problems and reduce
costs by knowing wear rates
Wear Rate Analysis is an integral part
of our S·O·S Services program that helps
you maintain equipment performance and
maximize availability. Through regularly
scheduled testing of oil samples from
your engine, hydraulics and powertrain
systems, Wear Rate Analysis detects tiny
metal particles caused by component
wear. By monitoring trends in the type
and quantity of particles, you can get
early warning of problems before major
damage occurs.

Understanding wear metals

Every oil-washed system—engines,
hydraulics, transmissions, and final drives—
produces wear metals in everyday operation.
If wear accelerates, the concentration of
wear metal particles increases, signaling a
problem. Wear Rate Analysis allows you to
find problems before they result in major
repairs or machine failure.
Wear Rate Analysis can detect particles that
range up to about 10 microns in size. Wear
metal concentrations are expressed in parts- Trending wear metals
per-million (or ppm). The S·O·S Services in your equipment The technology behind
program tests for at least nine different Two identical machines under identical Wear Rate Analysis
substances: copper, iron, chromium, lead, conditions may generate wear particles
tin, aluminum, molybdenum, silicon and at different rates. Our S·O·S interpreters We use an emission spectrometer
sodium. All are wear metals found in have access to a large database of samples to perform Wear Rate Analysis.
Caterpillar machines and engines except for comparison with samples from your The spectrometer determines wear
silicon (which generally indicates dirt) and equipment. However, your own machines elements and silicon in a sample
sodium (which indicates water or coolant). by subjecting the oil to very high
provide the best guidelines for appropriate
Certain elements in a sample may be from temperatures. At these temperatures,
levels of wear metals in each compartment. the elements in the sample are
the oil additive package rather than from That’s why trending is an essential part “atomized,” with each emitting a
wear within the system. Skilled dealer of Wear Rate Analysis. After three samples different wavelength of light energy.
interpreters can tell the difference between have been taken from a particular compart- An optical system measures and
normal elements and those that indicate ment, a trend for each wear metal is records the light energy and calculates
abnormal wear. established. Our interpreters then compare the results in parts-per-million for
subsequent samples to this trend line each element.
to quickly spot deviations as well as
monitor gradual changes in concentration
levels. This attention to trends also assists
with life cycle analysis, helping you
optimize productivity.
 MAINTENANCE SERVICES

Combinations of Classic Wear Elements

Engines–Top End Primary Element Secondary Element Potential Wear Probable Problem Area/Causes

Silicon (dirt) Iron, Chrome, Aluminum Liners, Rings, Pistons Air Induction System/Filter Dirt Contamination

Iron Chrome, Aluminum Liners, Rings, Pistons Abnormal Operating Temps., Oil Degradation,
Fuel and/or Coolant Contamination, Stuck/Broken Rings

Chrome Molybdenum, Aluminum Rings, Pistons Blowby, Oil Consumption, Oil Degradation

Iron Liners, Gears, Abnormal Operating Temps., Lack of Lubrication,

Valve Train, Crankshaft Contamination, Storage (Rust)

Engines–Bottom End Silicon (Dirt) Lead, Aluminum Bearings Dirt Contamination

Lack of Lubrication, Coolant Contamination,
Lead Aluminum Bearings Fuel Contamination

Hydraulics Silicon (Dirt) Molybdenum, Aluminum Cylinders, Rods Dirt Contamination

Copper Iron Hydraulic Pumps Oil Degradation, Contamination

Roller or needle
Transmissions Iron Aluminum, Chrome bearings Bearing fatigue/failure
Bearing wear/failure
Aluminum Iron, Copper Torque Converter allowing contact
Final Drives Silicon (Dirt) Iron, Aluminum Gears Dirt Contamination, Clay Soils Contamination

Iron Sodium, Chrome Gears, Bearings Water Entry, Preload Loss

Pinpointing the causes and

effects of component wear Silicon/aluminum ratio in
dirt varies by location
By comparing infrared (Oil Condition) test results with wear metal
buildup, we can pinpoint probable causes of elevated wear metals.
The primary constituents of dirt are
The chart above illustrates some of the most common wear metals,
minerals containing silicon and aluminum.
their source(s), and the potential problems they indicate in oil-
The ratio of these two elements varies
lubricated systems. widely from place to place. Clay soils
Spectrometry detects dirt contamination, as well as wear metals. contain nearly as much aluminum as
Silicon is the most common element indicating dirt entry, although silicon. This is one reason why local
some clay soils also produce increased aluminum readings. interpretation of your sample results is
important. We are familiar with the soils
Monitoring your components in your area, giving us the best under-
standing of the combinations of
When S·O·S oil analysis identifies an increase in the concentration of elements in your samples.
one or more metals, it can point to the wearing component most likely
causing the increase and, often, the probable cause. For example, a
sudden increase in copper and iron in a hydraulic oil sample would
probably indicate a problem with the hydraulic pump caused by either
oil degradation or contamination (see chart, above).
S·O·S Oil Condition Analysis
Maximize performance by Understanding Oil It works like this:
knowing your oil condition Condition Analysis 1 You submit a sample of new oil, called
“reference oil,” when you enroll in the
Oxygen exposure, heat and contaminants Oil Condition Analysis is similar to Wear S·O·S Services program and when you
cause all oils to degrade. Engine oil is Rate Analysis with one important exception: get new shipments of bulk oil. Reference
particularly susceptible to degradation by It evaluates chemical compounds in the oil oil samples are processed at no cost to
sulfur, nitration, by-products of combustion, rather than wear element particles. you. If you are using Cat oil, new oil
high temperatures, and water from the
Oil Condition Analysis is important for samples may not be necessary. Advise
combustion process or condensation. Oil
oil from all systems: transmissions and your S·O·S analyst of the viscosity of the
Condition Analysis, part of the comprehen-
hydraulics, as well as engines. Cat oil you use in each system; it has its
sive S·O·S Services program, helps prevent
own Cat oil reference samples.
component damage by monitoring your oil
and keeping track of its degradation. Oil 2 The new oil is scanned by a special
Condition Analysis also allows instrument using infrared light. Information
you to correct problems that affect oil is stored in the instrument’s memory.
performance. The bottom-line benefit: 3 At each scheduled interval, you submit
maximum oil performance, optimum oil a sample of used oil.
change intervals and reduced repair costs.
4 The Oil Condition Analysis instrument
focuses a beam of light through a film
of used oil and records the data.
5 The instrument uses a mathematical
formula to compare the used and new
oils and quantify any differences.

Fourier Transform
Infrared Analysis

S·O·S Oil Condition Analysis includes

an infrared instrument that uses a
mathematical method to convert raw
instrument data into meaningful terms.
This test, often called FT-IR (Fourier
Transform Infrared Analysis), identifies
and quantifies organic compound groups
by measuring their infrared absorption
at the specific wavelength of each group.
Besides identifying oxidation, soot, sulfur
products and nitration, the test is also
used to scan for oil contamination by
fuel, water or glycol (engine coolant).
 MAINTENANCE SERVICES

Identifying contaminants This chemical reaction is accelerated by oxidizes, then combines with water to
before they cause problems high oil temperatures, glycol contamination form acid. Acid corrodes all engine parts,
from engine coolant, the presence of copper, but is most dangerous to valves and valve
Oil Condition Analysis detects soot, oxidation,
and from extended oil change intervals. guides, piston rings and liners.
nitration products and sulfur products/acids.
Oxidation causes the oil to thicken, form
This test can also detect contamination
acids, and lose lubrication qualities, which
by water, fuel and glycol from coolant. If Optimizing your equipment
threatens the life of your components.
detected, specific contaminant tests are used with the S·O·S Services program
Oxidized oil will cause deposits on engine
to confirm findings. Oil Condition Analysis
pistons and valves, stuck rings, and bore
focuses on:
polishing. In hydraulic systems and Oil degradation may be the result of a
Soot transmissions, it can cause valve scuffing number of factors and conditions, including
Soot is found only in engine oil. It is the and sticking. extended oil change intervals, abnormal
insoluble residue of partially burned fuel. temperatures, or contamination by fuel,
Nitration Products
It is held in suspension by the oil additive water or coolant. Lower quality oils will
Nitration occurs in all engine oils, but is degrade more rapidly than a premium
package and causes engine oil to turn black.
generally only a problem in natural gas quality lubricant.
When soot drops out of suspension in the
engines. Nitrogen compounds from the
oil, it contributes to additive depletion and With Oil Condition Analysis, you can
combustion process thicken the oil and determine the extent to which oil has
eventually increases oil viscosity. Heavy
reduce its lubricating ability. If nitration deteriorated during use and verify whether
concentrations of soot can cause bearing
continues unchecked, it can result in filter it is performing up to specification during
damage by starving contact surfaces
plugging, heavy piston deposits, lacquering the entire oil change period. Oil Condition
of lubrication.
of valves and pistons, and eventual failure. Analysis is just one part of the S·O·S Services
Oxidation program that provides information to
Sulfur Products/Acids
Oxidation occurs in transmission, hydraulic reduce downtime and save you money
Sulfur is present in all fuels and affects
and engine oils when oxygen molecules by preventing major equipment problems.
all engines. During combustion, fuel sulfur
chemically join with oil molecules.

Glycol, Water and Fuel Detection

Fluid Contaminants Water Fuel
If infrared analysis indicates the presence of Fuel contamination is confirmed using a
When present in your engine oil or fluid
water, the approximate amount is determined flash test in which the used oil is heated to
power system, water, glycol (coolant) or
by placing a drop of oil on a plate heated to a prescribed temperature in a closed cup,
fuel can indicate a number of problems,
between 230˚ and 250˚ F. If water is present then subjected to a flame. Fuel vapors
from incorrect engine timing (fuel) to
the oil will bubble and sputter. By compar- driven off by the heat will flash if the
cooling system leaks. By detecting these
ing the amount of bubbling to laboratory dilution exceeds four percent.
problems before they cause component
control samples, experienced laboratory Fuel in the engine oil reduces its lubricating
failure, we can work with you to schedule
technicians can determine the quantity of properties. Small amounts of fuel are com-
downtime and maximize productivity.
water in the sample. Any amount over 0.5 mon as a result of the combustion process.
Glycol (Coolant) percent is considered excessive. But if fuel levels exceed recommended
Glycol causes rapid oxidation of the oil Water can contaminate a system by leaking levels, we will suggest a check for defective
and usually indicates a cooling system in from the outside or condensing in the fuel injection nozzles and other sources
leak. Severely oxidized oil becomes sticky engine’s crankcase or compartment. When of leakage. Fuel dilution is generally the
and forms sludge that plugs the filter. Any water combines with oil, it reduces the oil’s result of extended idling, incorrect timing,
amount of glycol contamination in the oil ability to lubricate and forms a sludge that or a problem with the fuel injectors,
is unacceptable. Engines, hydraulics or plugs filters. Water passing between very pumps or lines.
transmissions using water-to-oil coolers close components can create “hot spots.”
may become contaminated with coolant If the water gets hot enough, it causes tiny
if a leak develops in a cooler tube or seal. steam explosions that can fracture metal.
S·O·S Oil Cleanliness Analysis
Clean oil keeps equipment
running right
Counting the tiny particles in an oil sample
identifies harmful contaminants that shorten
component life. It can also pinpoint larger
particles that signal imminent equipment
failure. Our S·O·S Services program
finds these particles through a combination
of tests that includes Particle Count.

Fighting an unseen enemy

Even particles far too small to see can cause
damage. In fact, oil that looks clean may
contain particles that cause abrasive wear.
Particle contamination:
• Accelerates component wear
• Reduces system efficiency
• Diminishes equipment performance

Learn About ISO Cleanliness Codes

The International Standards Organization
(ISO) has developed a code system for
convenience in discussing the cleanliness
level of a fluid. The system reports on
particles at two important size catagories
(>5 micron and >15 micron). You may wish
to learn more about this system of reporting Going beyond Wear These may include silicon from dirt or
oil cleanliness to better manage the life Rate Analysis synthetic friction materials that signal
of your hydraulic and transmission deterioration in transmissions, steering
components. If you are interested ask Particle Count, which is used for
transmission and hydraulic system oil clutches and brakes. Gasket, seal, filter
us for Form No. PEJT5025 Reporting and hose material can also be detected.
Particle Count by ISO Code. samples, is one of two tests in the S·O·S
Services program that look at particles. Another benefit of Particle Count is its
The other is Wear Rate Analysis, which ability to detect particles larger than 10
The technology behind uses spectrometry to identify metal particles microns that cannot be seen by Wear
Particle Count from 8 to 10 microns in size. Unlike Rate Analysis or any other oil analysis
Wear Rate Analysis, Particle Count detects test. These larger particles are a sign
metallic and non-metallic particles from of imminent failure if the problem is
S·O·S labs use a technique called
2 to 100 microns. However, Particle not corrected.
light extinction to “count” the
Count only reports the size and number Particle Count is only used for non-engine
particles. The sample is passed
through a beam from a special of particles, not their composition. oil samples because engine oil contains soot
light source. When a particle in Particle Count is the most efficient way that cannot be distinguished from metal
the oil passes through the beam, to identify non-metallic particles in oil. particles or debris.
a sensor monitors changes in the
light, counts the particles and
records their sizes. This test
detects particle contaminants
that can lead to accelerated
wear and other costly problems.
 MAINTENANCE SERVICES

Actual Oil Analysis Results from

Transmission Progressing to Failure
A partnership of tests
identifying trends
Particle Count works with Wear Rate
Analysis to give you a more accurate picture

†
of what’s going on in your machine. Wear
Rate Analysis may indicate a sharp rise in
the concentration of a certain wear metal.
This concentration may then level off,
indicating normal wear. But Wear Rate
Analysis can only detect particles up to
about 10 microns. A Particle Count run on
the same sample could show a sharp rise in
particles over 15 microns. The two trends
together may show a failure in progress,
or an intrusion of external contaminants.

*
*Wear metals are calculated as parts per million, or PPM.
†
Particle count values are those sized >15µ per ml.
 Count on our experts.
The S·O·S Services program is just one of
many maintenance products and
services we offer to help you
maximize productivity and reduce
operating costs. For example, you may
wish to check into our maintenance
software programs. Trend Analysis
Module (TAM) permits you to receive
your S·O·S results electronically.
Maintenance Control System (MCS)
is a Windows®-based system for
maintenance and repair scheduling.
Preventive Maintenance Planner (PMP)
provides convenient checklists for
maintenance personnel at each service
interval. Talk to our experts or stop in
for a demonstration.

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