Reference Guidelines For Wear Metals, Contaminants, Lubricants, Coolant and Fuel Version 12 January 2010 Changes on this and Previous Versions The following tables contain general information and are system focused rather than machine family specific with few exceptions indicated by footnotes. Use these tables only as a guideline . ALS Staveley lab has complete and detailed guidelines by component and model that sometimes may trigger alarms at different levels than indicated on tables within this document. Also keep in mind that application, environment, filtration and type of lubricants, and attachments, could produce different readings that may not be indicative of malfunction or contamination. Time Dependant Elements: Certain elements tend to increase with time with regard to others and independently from filtration. These tables identify those elements and suggest the hours for these readings. Units of Measure PPM (Part Per Million) is used to indicate relative concentration of wear metals, water, contaminants and additives measured in weight in relation to the fluid sample volume weight. Percentage (%) of concentration represents the relative water and fuel contamination. Particle Counts indicate different groupings of particle concentrations. They are typically measured in 4 micron and higher, 6 micron and higher, 14 micron and higher, 23 micron and higher and 50 microns and higher concentrations per milliliter. These numbers correlate with an ISO chart to obtain a three number cleanliness code. See explanation in page 4. ISO Cleanliness Codes is the standard method to classify fluid cleanliness measurements more easily. Until 1999 the ISO 1944 particle size classification was used to measure 5 and 15-micron particle concentration expressed in a two number code. After 1999, a revision to this standard came into effect, which measures 4/6/14 micron particle concentrations. The older two numbers for 5/15-micron measurement closely correlate to 6/ 14-micron current measurements. Absorbance, abs/cm is a unit to report oxidation, nitration and sulfation. This unit is a direct reading from the FTIR instrument (Fourier Transform Infrared Spectroscopy) and expresses the wavelengths of certain chemical compounds of interest representative of the required tests. Recent adopted figures shown in bold On this Edition • New Cool Gard II guidelines • New table for hydraulic fluids (Forestry factory fill) • Disclaimer on guidelines added on first page Changes on previous edition • New signature tables with new products added • New table for 350D/400D ADT transmission • Improved wording on Metal and Contaminants section Service Marketing John Deere Construction and Forestry
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Reference Guidelines
For Wear Metals, Contaminants, Lubricants, Coolant and Fuel Version 12 January 2010
Changes on this and Previous Versions
Wear Metals and Contaminant Guidelines The following tables contain general information and are system focused rather than machine family specific with few exceptions indicated by footnotes. Use these tables only as a guideline. ALS Staveley lab has complete and detailed guidelines by component and model that sometimes may trigger alarms at different levels than indicated on tables within this document. Also keep in mind that application, environment, filtration and type of lubricants, and attachments, could produce different readings that may not be indicative of malfunction or contamination. Time Dependant Elements: Certain elements tend to increase with time with regard to others and independently from filtration. These tables identify those elements and suggest the hours for these readings.
Units of Measure PPM (Part Per Million) is used to indicate relative concentration of wear metals, water, contaminants and additives measured in weight in relation to the fluid sample volume weight. Percentage (%) of concentration represents the relative water and fuel contamination. Particle Counts indicate different groupings of particle concentrations. They are typically measured in 4 micron and higher, 6 micron and higher, 14 micron and higher, 23 micron and higher and 50 microns and higher concentrations per milliliter. These numbers correlate with an ISO chart to obtain a three number cleanliness code. See explanation in page 4. ISO Cleanliness Codes is the standard method to classify fluid cleanliness measurements more easily. Until 1999 the ISO 1944 particle size classification was used to measure 5 and 15-micron particle concentration expressed in a two number code. After 1999, a revision to this standard came into effect, which measures 4/6/14 micron particle concentrations. The older two numbers for 5/15-micron measurement closely correlate to 6/ 14-micron current measurements. Absorbance, abs/cm is a unit to report oxidation, nitration and sulfation. This unit is a direct reading from the FTIR instrument (Fourier Transform Infrared Spectroscopy) and expresses the wavelengths of certain chemical compounds of interest representative of the required tests.
Recent adopted figures shown in boldOn this Edition
• New Cool Gard II guidelines • New table for hydraulic fluids (Forestry factory fill) • Disclaimer on guidelines added on first page
Changes on previous edition • New signature tables with new products added • New table for 350D/400D ADT transmission • Improved wording on Metal and Contaminants section
Service Marketing John Deere Construction and Forestry
2Sealed Hydraulics 1000 H Readings Except Hydrostatics
Normal Lower Limits Upper Limits Abnormal Critical
Water (Gear Oils) GL-5 <500 (<0.05%) 501-750 (0.05-0.075%)
751-1000 (0.075-0.10% >1000 (>0.10%)
Water (Hy-Gard) GL-4 & Engine oil <750 (<0.0750%)
751-1000 (0.075-0.10%)
1001-1500 (0.10-0.15%) >1500 (>0.15%)
*Time dependant elements.
6Tandems *500 H Readings Motor Graders, Skid Steer Loaders
Normal Lower Limits Upper Limits Abnormal Critical
Silicon * 0-20 21-30 31-60 >60 Iron * 0-125 126-250 300-600 >600 Copper 0-10 11-25 25-50 >50 Copper - SSL 0 NA NA NA Sodium 0-10 11-20 21-40 >40 Aluminum * 0-10 11-20 21-30 >30 Lead 0-5 6-10 11-20 >21 Lead SS Loaders 0 NA NA NA Chromium 0-4 5-10 11-15 >15
Water (Hy-Gard) GL-4 <750 (<0.0750%) 751-1000 (0.075-0.10%)
1001-1500 (0.10-0.15%) >1500 (>0.15%)
*Time dependant elements.
Physical Properties
Viscosity is the internal resistance of a lubricant or fluid to flow. The most common viscosity measurement is Kinematic viscosity and it is expressed in an ISO unit called centistokes (cSt). Hydraulic fluid viscosity is measured at 40 degrees C while engine oils are measured at 100 degrees C. Viscosity variation of more than 10% or 15% up or down need attention, see table in page 6 for guidelines. Oxidation of an oil or fluid represents the remaining life of the antioxidant additive. When a fluid is totally oxidized there is no additive left to protect the system. The additive depletes over time and its depletion is accelerated by high temperatures, water and contaminants. TBN or total base number is the alkaline reserve of that oil to neutralize acid formation. TAN or total acid number is an opposing corresponding number to TBN and represents the total acidic level of the oil.
Physical Properties Normal Abnormal Critical
Oxidation <20 abs/cm 20-25abs/cm >25 abs/cm
TBN Engines >5 2.6 - 4.9 <2.5
Sulfation Engines <25 >25 - 40 >40
TAN Hy-Gard/Engine oil <5 5-6 >7
TAN HN46/AW <1 1.1-2 >2
TAN Transynd <1.5 1.6 – 2.0 >2.1
TAN Gear oils <3.0 3.1-4.4 >4.5 TAN Gear Oil JDM J11F (844J/ADT’s) 3.5 -5.9 6 – 7 >7
7
Hours → 0 300 500 1000 2000 3000 4000Hitachi HN46 Japan (160, 450-850) 46-48 46 45 44 43 41.7 40Hitachi HN46 USA (200-350) 44-46 43-46 43-45 42-44 41-43 40-42 40-41Engine Oil 10W-30 Hydrost. 67.4 60 52.8 50.8 50 NA NAEngine Oil 10W-30 Digging 67.4 50.5 46 43.9 42.6 40 39Torq Gard 0W-40 85.7 44 43.5 42.5 42 NA NAHy-Gard Hydraulics 57 52 48 40 39.9 NA NAHy-Gard Loader Transmissions 57 50 45 39 37 NA NAShell Tellus S 46 44.1 41.8 40.57 39.7 38.8 NA NAOther AW46 46 43 41 38 37 NA NA
APPROXIMATE VISCOSITY CHANGES WITH HOURS cSt @ 40 Degrees C - HYDRAULIC FLUIDS, UNMIXED
Sealed Hydrostatics. Assumes use of engine oil. Mixed oils
≤X/21/16** *Report Only
>X/21/16 *Report Only Not established
Unsealed Hydraulics –BHL, Skidders, MG, 4WDL, US tracked or wheel feller bunchers. Engine oil/Hy-Gard
20~21/16/13 to 21~22/18/15
22~23/19/16 to 23~24/20/17 ≥X/21/18
Unsealed Hydraulics –BHL, Skidders, MG, 4WDL, US tracked and wheel feller bunchers. Mixed Engine oil/Hy-Gard
≤X/21/16** *Report Only
>X/21/16 *Report Only Not established
*New Harvesters/Forwarders Series E & Series D with by-pass filtration – up to 100 hours With AW46.
18~19/15/12 to 19~20/16/13 Not established Not established
*Harvesters/Forwarders Series E & Series D with by-pass filtration – over 100 hours With AW46.
16~17/13/10 to 18~19/15/12
19~20/16/13 to 21~22/17/14 ≥X/18/15
*Harvesters/Forwarders Series D W/O by-pass filtration - With AW46.
17~18/15/12 to 18~19/17/14
19~20/18/15 to 20~21/19/16 ≥X/20/17
Power Shift Transmissions 17~18/15/12 to 21~22/20/17
22~23/20/17 to 23~24/21/18 ≥X/22/19
Axles and final drives (Non-Filtered) 22~23/19/16 to 23~24/20/17
24~25/21/18 to 25~26/22/19 ≥X/23/20
** If silicon, aluminum, copper, iron, water and TAN are within normal values.
Please note that the values in pink boxes are only for reference. Criticality has not been established.
Note: Obtaining accurate ISO particle count readings in the 4 micron size is more challenging. In such cases where the normal distribution of the codes does not match the table, the 6 and 14 size codes will indicate cleanliness levels. If samples valves are not available on the equipment the use of the baggy method for sample collection is highly recommended.
9
Life Extension Tables For Closed Hydraulic Systems
Note: By choosing to run a system from current cleanliness (left column) to a cleaner level, life extensions are possible as indicated in the bottom row. Keep in mind that water content and temperatures also play a role in achieving those goals.
Hydraulic Fluid and Oil Compatibility Chart
*Some zinc free fluids use TCP (Tri-Cresyl Phosphate) as anti wear additive and are not compatible with ZDDP (Zinc Dialkyl-Dithiophosphate) zinc-calcium based fluids.
♪ Torq-Gard Supreme 15W-40 marketed in Europe is API CH-4 / ACEA E5, but not CJ-4. ♫ Torq-Gard Supreme 10W-30 marketed in Canada is API CJ-4 / SM.
Coolant Guidelines Cool Gard I (No longer available)
Test Min Max
Freezing Point -70 °F 0°F % Antifreeze - Coolant Report only pH level 7.0 11.0 Reserve Alkalinity 1.0 N/A Nitrite 300ppm N/A Molibdates Report Only Silicate Report Only Corrosion Metals 0 30 Visual Assessment Clear or Sediment
(New) Coolant Guidelines Cool Gard II (Nitrite free)
Test Min Max
Freezing Point -70 °F 0°F % Antifreeze - Coolant Report only pH level 7.0 11.0 Reserve Alkalinity 1.0 N/A Nitrite 10ppm N/A Molibdates Report Only Silicate Report Only Corrosion Metals 0 30 Visual Assessment Clear or Sediment
13
Fuel Guidelines
Wear elements
Iron can be present as a fine particle produced by abrasion or wear, but also as iron oxides generally associated with the presence of water or a corrosive reaction to additives. Iron generally comes from the liners in engines or from hydraulic cylinders, gear pumps with cast iron bodies, piston pumps without sleeves, lines and reservoirs in hydraulic systems, and from planetary carriers in final drives and differentials. Chromium is a very hard metal wear particle produced by engine piston rings. Chromium readings indicate that something harder than it is present, namely silica or alumina. New engines produce could produce chromium during the break-in period, especially with break-in oils purposely lacking molybdenum. Chromium in hydraulic systems is typically from valve spools or cylinder rods; harder abrasives also trigger chromium generation. Chromium also comes from final drive and differential bearings. Copper is a soft metal from bronze alloys that are present in engines, hydraulic pumps, differentials, final drives, power shift transmissions, and in cooler cores. In engines, its presence of copper could indicate a cooler core or water pump leak, but also from thrust washers in the camshaft, rocker arm or piston wrist bushings. When present with Glycol (potassium and sodium) it could be coming from oil cooler. When it is associated with lead and/or tin, but without glycol traces, it is an indication that it is coming from the bearings/bushings. New oil like CI-4 or CJ-4’s will promote high copper generation during passivation of the oil cooler. Constant changes of type of oil will trigger copper generation from the cooler. Some copper generation, ranging from 10 to 100 PPM or more, can sometimes be present in hydraulic systems. Larger generation of copper is typically triggered by water, silica, high temperature operation and most importantly, by additive incompatibility from fluid mixing or by etching. Copper also comes from final drives equipped with park brakes and slip spin/diff lock differentials, or from thrust washers.
Test Min Max
API Gravity Report Only Water and Sediment N/A 0.05% Sulfur (Low Sulfur) N/A 0.05% Sulfur (High Sulfur) N/A 0.50% Cetane Index, Calculated 40.0 Distillation 90% recovery, #2 DF 540-640 Max Temp Bacteria Any Positive Result is Critical Cold Filter Plugging Point Report Only
IRO
N
CH
RO
MIU
M
CO
PPER
ALU
MIN
UM
TIN
LEA
D
NIC
KEL
SI
LVER
TITA
NIU
M
14Aluminum is a wear element that generally comes from pistons in engines. High aluminum associated with silica is probably dirt. Aluminum in hydraulic systems generally is from dirt ingestion. Aluminum in final drives is unequivocally from dirt. Tin is a metal used in soft alloys of bronze in combination with lead. It is generally present in small amounts in hydraulic pumps. However, when tin is present in engines, it is generally associated with lead and copper to indicate high bearing wear. Tin could also be present in coolers solder that leach back to the coolant or oil. Lead is a very soft metal used in alloys in combination with tin for engine bearings and bushings. Lead is present in hydraulic pump alloys as well. Lead presence in engines in more that 10 PPM indicates some bearing wear. Low TBN and /or high sulfation in engines correlate with high lead production. Glycol or fuel contamination can produce high lead readings. Nickel it is seldom present in oil analysis but when it shows up it is an indication of turbocharger cam plate wear or valve guide wear. There is also some nickel in valve guides and valves themselves. Silver is not typical in construction equipment oil analysis but when present in engines it could come from accessory drive, turbocharger bearings or wrist pin bushings Titanium is not a typical wear metal present in oil analysis from construction equipment. Some traces are possible from some alloys. Titanium in the form of titanium oxides could be present as contamination from paint or from operation in certain bauxite mines.
Contamination elements
SILI
CO
N
ALU
MIN
UM
POTA
SSIU
M
SOD
IUM
FUEL
GLY
CO
L
WA
TER
SOO
T
SULF
ATI
ON
NIT
RA
TIO
N
Silicon is the principal component of dirt and it is present in its natural and oxidative form as silica. It is harder than any metal used in mobile equipment and can scratch hard surfaces easily. In new engines, its presence could indicate liquid silicon material used as sealant during assembly. It typically washes out after several oil changes. Silica (the oxidative form of silicone) appears in nature associated with alumina in a typical of 4 to 1 and 6 to 1 ratios. Silicon is also present in oils and fluids as a constituent of foam inhibitor additive Polydimethylsiloxane or Polyacrylate. Expect to find between 1 to 4 PPM in new engine oils or some tractor fluids. Aluminum is generally present in association with silica in a 1 to 5 ratio and enters together with dirt. It enters the system in its oxidative form as alumina, and it is extremely hard. Aluminum is the most abundant metal in the world. Potassium is present in Glycol and it is not an additive for engine oils as such, although some small readings of about 2 to 3 PPM could be present. When combined with sodium and sometimes with boron, it is a confirmation of glycol contamination.
15 Sodium is also present in glycol but also in many salts, or seawater. Sodium in small amounts could be an additive, however, if its presence is associated with potassium and/or boron it is a confirmation of glycol contamination. Sodium in association with silica and alumina (dirt) is very typical. Fuel could be present in diesel engine oils as a by-product of incomplete combustion or leaks. The allowable limit is <2% of volume. Fuel is responsible for sulfation in engines oils. See sulfation below. Fuel in large quantities can cause a drop in viscosity of engine oils. Glycol is a coolant for engines and its presence in engine oils cause a rapid increase in oil viscosity. It also causes disruption to oil film and bearing failure. Typically glycol contains potassium, sodium and boron. Some organic acid coolants may not show increase numbers in sodium. Water is the enemy number two of hydraulic fluid additives. It causes additive depletion, corrosion, and generates copper and iron. Water is present as free water, emulsified or saturated. The Karl Fisher test provides total water content. Free and emulsified water is easy to remove with water absorbent filters. Saturated (Dissolved) water in fluids at a level of more than 75% probably requires a change of fluid. Soot is a term used to describe fine carbon particles suspended in engine oils. Soot is a by-product of incomplete combustion of fuel. Over time soot sludge causes an increase in viscosity and carbon deposits that could clog lubrication galleries in engines. Sulfation describes the amount of sulfur in engine oil introduced by combustion blow-by in diesel engines. Sulfation increases with hours and fuel contamination. Too much sulfation can deplete the alkaline reserve, create corrosive acids and increase iron and lead readings. Nitration is a phenomenon that occurs more frequently in engine oils. Nitration is a by-product of combustion. It comes as nitrous oxides that cause oxidation and leads to the formation of varnish deposits and sludge, thus increasing oil viscosity.
Additive elements
BO
RO
N
BA
RIU
M
CA
LCIU
M
MA
GN
ESIU
M
MO
LYB
DEN
UM
SOD
IUM
PHO
SPH
OR
US
SULF
UR
ZIN
C
Boron is an EP (extreme pressure) additive but it is also a constituent of coolants. A small amount of boron without the presence of potassium is an indication of Boron as an additive. Barium is an additive present in sulfonates. Sulfonates in turn are additives that act as detergents and corrosion inhibitors. Calcium is a detergent and it comes in sulfonates as well. It cleans carbon deposits from engines and acts as a corrosion inhibitor and dispersant.
16 Magnesium is also part of a detergent additive as magnesium alkyl benzene sulfonate. It reacts with sludge and varnish precursors to neutralize them and keep them soluble. Molybdenum is present in an anti-wear additive as molybdenum disulfide, typical in engine oils. Sodium is found in small amounts as part of some additives in dirt as salt. Phosphorus is present in extreme pressure (EP) as well as anti-wear /anti-oxidant additives like ZZDP and TCP and friction modifiers in engine oils, hydraulic fluids and gear oils. Sulfur is present in extreme pressure additives in combination with phosphorus. Zinc is part of ZDDP additive that acts as an anti-wear, anti-corrosive, anti-oxidant and detergent additive and in some hydraulic systems from zinc-phosphate coating leaching.