Fluid Analysis
LABORATORY GUIDE
A good sample is vital for the success of any oil
analysis program, since the results can be no more
representative than the sample. For this reason the
oil should be hot and well mixed when the sample
is taken.
intervals have been at each oil change, 250 hours
for engines, or every 500 hours for all other
compartments. However, under the following
conditions a sample interval of 250 hours for all
compartments is recommended.
Severe Application
Studies have revealed, that in severe applications,
500 hours between oil samples is too long a time
lapse for timely prediction of potential failure
modes. A 250 hour sampling interval provides more
data points between oil change intervals thus
increasing the odds of detecting a potential failure.
Determining Optimal Oil Change Intervals
Sampling compartments every 250 hours also
provides oil condition/performance information
to ascertain the optimal utility of a particular oil.
Also, more data points enable close monitoring
of component wear rates while obtaining maximum
lubrication utility. (For detailed information on
extending oil change intervals, please contact
your Caterpillar dealer).
Optimizing Component Life Cycle
An increased sampling frequency also provides
better defined data trends from one oil change
interval to the next. This enables close monitoring
of component life cycle wear patterns to assure
full component life cycle value is realized.
interval for all engines remains at 250 hours. While
500 hour oil sample intervals remain acceptable for
non-engine compartments, they are not necessarily
optimal. Under the above conditions, 250 hour oil
sampling intervals are recommended.
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The two accepted methods of obtaining an oil
sample are vacuum extraction or oil valve probe.
Both methods allow sampling without draining the
compartment, eliminating the danger of being
burned by hot oil and reducing the risk of
contaminating the sample.
Oil Valve Probe
The use of an oil valve probe is the preferred
sampling method. It is the easiest, neatest and
quickest way to obtain an oil sample from
pressurized compartments such as engines,
transmissions, and hydraulic systems. The
sampling valve also allows sampling between oil
changes without shutting down the machine. The
valve locations provide oil sample integrity.
Comparative data from pressurized oil samples is
more reliable because the sample is taken from a
continuous oil flow at a known location. The oil
valve probe allows the valve to be quickly flushed
prior to taking the oil sample.
Pressurized systems on most Caterpillar machines
and engines are factory equipped with sampling
valves. Special Instruction SEHS9043 details
retrofitting some earlier models with oil sampling
valves, as well as pointing out valve locations on
models currently factory equipped with the oil
sampling valves.
Vacuum Extraction
Vacuum extraction utilizes a vacuum pump (part
number 1U5718 or equivalent), to obtain oil
samples from non-pressurized vehicle
compartments such as final drives, differential
compartments, transfer cases and axle housings.
The sampling gun (or vacuum pump) is
inexpensive, highly portable and capable of pulling
a vacuum of 25 inches of mercury. It accepts any
38M threaded plastic bottle and 1/4" O.D. or 5/16"
O.D. plastic tubes.
SAFETY NOTICE
When taking a sample from a hydraulic tank at the
filler cap, follow the Service Manual procedure for
removing the filler cap.
How to Take a Good Oil Sample...
Using Oil Valve Probe
This sampling method requires a Brass Probe
(8T9208) and approximately 15 cm (6 in) of
5/16" O.D. tubing. If you are sampling several

usually the hydraulic system, then the transmission

or steering system, and finally the engine. Step C

Use a new piece of tubing for each machine or
engine. It is especially important to discard the
tubing after sampling engine oil because soot and
oil additives may remain in the tubing and
contaminate other samples.
Insert the probe into the valve again and fill the
the top. Do not allow any dirt to enter the bottle
or bottle cap.

Step D
Step A
Withdraw the probe from the valve and the bottle
Set the engine at low idle and remove the dust cap and secure the cap on the bottle. Then place the
from the valve of the compartment you are bottle with the completed label into the shipping
sampling. cylinder.

Advantages of using sampling valves:

More reliable

a known location making comparative data more

reliable.

Step B condition because the oil has been well mixed

and circulated.
Insert the
probe into the valve and collect about 100 ml (4 fl Faster and more convenient
oz) of oil into a waste container.
Dispose of this waste oil properly. (This process prior to taking the oil sample.
clears the valve of any residual debris ensuring
a representative sample.)
gun.
NOTE: If the oil flow is slow at low idle, it may be
necessary to have someone accelerate the engine
to high idle while extracting the sample. samples because the valve method is much more
convenient than using a sampling gun.

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Using vacuum extraction
Use this method for non-pressurized systems and
pressurized systems not equipped with sampling
valves. This sampling method requires a Vacuum
Pump (1U5718 or equivalent).
Again, it is important to use a new piece of tubing
after sampling engine oil because soot and oil
additives may remain in the tubing and contaminate
Step D
other samples.
Pump the vacuum pump handle to create a

over, oil may contaminate the pump. If oil enters

the pump, disassemble and clean it with laboratory
grade kerosene before taking the sample.

the top.

Step A
Turn off the engine and measure and cut new
tubing to the length of the dipstick. If the
compartment you are sampling does not have a
dipstick, cut the tubing so that it reaches about
halfway into the oil depth of the sump.

Step E
Withdraw the tubing from the compartment.
Remove the bottle from the vacuum pump and
secure the cap on the bottle. Then place the bottle
with the completed label into the shipping cylinder.

Use Separate Vacuum Pump for Oil

Step B
Insert the tubing through the head of the vacuum
pump and tighten the retaining nut. The tubing
should extend about 4 cm (1 in) beyond the base
of the vacuum pump head.
and Coolant Samples
The vacuum pump used to take oil samples should
not be used for coolant samples. Although the fluid
does not enter the barrel of the pump, a small
residue of glycol from the coolant remains and can
contaminate the oil sample, thereby causing a

system. Train your personnel in the importance of

using separate pumps for oil and coolant samples.

Step C
Install a new sampling bottle onto the vacuum

do not allow the tubing to touch the bottom of the

compartment.

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Pump Repair Kit
The 1U5718 Vacuum Pump may be disassembled
to replace the O-ring on the pump plunger when it
becomes worn and requires replacement. The
1U5719 Seal Kit is available for this purpose.
Plastic Tubing
Either 1/4" O.D. or 5/16" O.D. tubing may be used
with the 1U5718 Vacuum Pump. The 8T9208
Purging Probe requires 5/16" tubing.
The following tubing is serviced by Caterpillar:
4C4056 5/16 inch O.D. Tube (100 foot lengths,
five rolls per box)
4C4057 Tube 5/16 inch O.D. by 7 foot length
(250 per box)
4C4055 Tube 1/4 inch O.D. by 7 foot length
(250 per box)
1U8757 1/4 inch O.D. Tube (100 foot lengths,
five rolls per box)
Bottles with Oil Valve Probe
A bottle with a tube and probe attached is used by
some customers. If a probe bottle is used follow
Taking Samples from Oil Drain Stream
Occasionally samples are taken by holding a
sample bottle under the stream of oil draining from
a crankcase or sump. This sampling method is not
recommended. This is because a stream of dirty oil
from the bottom of the compartment will
contaminate the sample resulting in a non-
representative sample.
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Also, dipping a sample from the waste oil container
has proven to provide non-representative samples.
Use only a sample valve or a vacuum pump to
obtain consistent, representative samples. Also, use
only new oil sample bottles which have remained
sealed until ready for use.
Why Requests for a Second Sample?
Occasionally an additional sample may be
necessary. The reasons for this include:
card may have been incomplete. It is particularly
important to report how many hours, miles, or
kilometers the oil has been used, the odometer or
service meter reading for the vehicle or engine,
and the amount of make-up oil added since the
last oil change. The interpreter may inquire if this
or other information is missing or if the accuracy
of the information is in doubt.
(i.e. half oil change interval) to verify a trend.
two adjacent compartments to check for possible
oil transfer.
oil and filter, run the machine for an hour or so,
then take another sample. This does two things:
It determines debris carryover and establishes
a quick baseline for future sample reference
purposes. This is usually necessary because of
sporadic oil change intervals and/or sampling, or
poor SMU/oil hour reporting.
not have been a representative sample; it could
been contaminated while being drawn.
is required, and forward the sample to Caterpillar
for additional testing.
Whenever you ask a customer to take a second
sample be certain to get back with him concerning
the results. This is important in demonstrating to the
customer your interest in his equipment and the
program.
 Oil Analysis
Take sample when oil is hot
Owner Name
Job Site
Serial No.
Application Light
Oil (brand) Type
Was oil changed at this sample time?
Oil Analysis bottle label Form Number PEEP5031
Complete and Accurate Bottle Label
A bottle label which includes adequate space for
all the necessary information is essential in serving
customers well. You will find that customer
personnel are more likely to fully report necessary
sample information on a label that is easy to write
on and attractive.
The label above is the format currently
recommended by Caterpillar. It is available through
Caterpillar literature sources form number
PEEP5031 (PESP5031 in Spanish). It is printed on
oil resistant paper which permits the information to
be read even if soaked with oil. If you wish to
substitute your own logo and company name, you
may either have them printed locally or obtain a
quote from Peoria via your Caterpillar subsidiary
This label is not gum backed to adhere to the
sample bottle. Lab personnel have found it more
efficient for sample registration to simply have the
customer personnel wrap the loose label around the
bottle and insert both into the plastic mailing tube.
Upon receipt at the lab, a daily processing code is
written on both the bottle and the label, so sample
processing and registration can begin
simultaneously and each sample can be efficiently
tracked.
Preparing for Mailing
1. Fill out the label suppling all requested
information. Pay special attention to serial
number, sample date, service meter units
on equipment, service meter units on oil,
and amount of oil added. Indicate whether
or not the oil was changed when the sample
was taken.
Sample taken from:
Date Sample Taken Oil Added
(Qts / Liters)
Meter Reading Hrs/Miles/Km on Oil
(circle which)
Model Equipment No.
Medium Heavy
Oil Wt (visc.)
yes no
2. Insert bottle and sample label into mailer and
attach shipping label. Wrap the shipping label
around the mailing tube. The postal service
prefers the plastic mailing tubes, part number
4C4600, which Caterpillar offers, since oil
cannot soak through.
3. For comparison testing using FT-IR, it is
imperative to include a sample of the new
(clean) oil, along with the used oil sample
whenever oil suppliers are changed or a new
shipment of bulk oil received.
4. Fill out as much information as possible on the
sample label before you begin taking samples
to keep the labels oil-free and easy to read.
Mailing Tubes
The plastic mailing tubes, part number 4C4600,
are reusable. The mailing labels should be removed
before reusing the mailing tube. The tube should be
cleaned, if necessary before reuse. Never clean
and reuse oil sample bottles.
Sealed Plug to Stop Leaking Valves
Occasionally, valves become damaged and may
defective valves should be replaced at the earliest
convenience, there is a plug available to provide a
temporary solution.
The 8C8456 Sealed Plug is a brass fitting which
snaps over the leaking valve and alleviates the leak
until the valve can be replaced. The 8C8456 Sealed
Cap can also be used in place of the rubber dust
cap to provide extra protection for a valve located
in positions subjected to severe elements.
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Protective Dust Caps Valve Part Numbers
Rubber dust caps should be kept on all sampling There are three oil sampling valve part numbers
valves. These are black rubber caps with embossed serviced by Caterpillar. They are different only in
symbols to indicate the system being sampled. The the type of threads. When replacing a leaking valve
part numbers are: be certain the replacement valve has the same
thread.
8C3445 Dust Cap (Engine)
8C3447 Dust Cap (Transmission) The valves and the O-rings seal required for each
are:
8C3451 Dust Cap (Hydraulic)
6V0852 Dust Cap (Blank) 8C3446 Oil Sampling Valve
(7/16-20 external thread)
3J7354 O-ring Seal

8C3345 Oil Sampling Valve

(Mid x 1 external thread)
8T7876 O-ring Seal

7X3387 Oil Sampling Valve

(1/4-18 NPTF external thread)
(No O-ring required)

Some miscellaneous fittings and adapters

commonly used for oil sampling valve installations
include:
3B7722 Reducer 3/8-18 NPTF to 1/4-18 NPTF
8C6427 Adapter 1/4-18 NPTF external to
Install Oil Sampling Valves 7/16-20 SAE internal
Most current Cat engines and machine models 6V7529 Adapter 1/8-27 NPTF external to
are equipped with sample valves for pressurized oil 7/17-20 SAE internal
compartments. Some engines and machines may 7J8611 Adapter 90 degree street elbow
not have these valves, but it is easy and 1/4-18 NPTF
inexpensive to add them.
5P9617 Adapter Reducer 9/16-18 SAE
It is important to install valves in the correct location external to 7/16-20 SAE internal
in each system and to avoid contaminating the
3J1907 O-ring seal for 5P9617 adapter
system during installation. As a rule, the valve
should be installed on the inlet side of the filter. Of 3J5390 Adapter Reducer 3/8-18 NPTF
greater importance is that they be installed in a low external to 1/8-27 NPTF internal
pressure line. The pressure should not exceed 9T6865 Adapter Plug 5/8-12 SAE external to
500 psi (3500 kPA). Also, the line should provide a 7/16-20 SAE internal
constant flow, such as a filter line, rather than a low
flow line such as a pilot valve line. 2S4078 O-ring seal for 9T6865 Adapter Plug
5P3501 Adapter 9/16-18 SAE external to
If you are installing valves on a number of machines
1/4-18 NPTF internal
or engines of the same model, be certain to place
the valve in the same location on each unit. 3J1907 O-ring seal for 5P3501 Adapter
Different valve locations will result in samples which 3L6521 Adapter Tee 1/4-18 NPT (two internal
are inconsistent with one another for trending and and one external)
compression purposes.
1P9369 Adapter Tee 1/8-27 NPT (Two internal
Special Instruction SEHS9043 covers the and one external)
recommended valve location for many machine
6V3966 Pressure Test Valve 1/4-18 NPTF
models. If you have questions concerning valve external
installation contact the Service Development
Department in Peoria. 7M8489 Adapter 90 degree elbow 9/16-18
SAE external to 1/4-18 internal
5P3413 Pipe Sealant 12/3 oz tube

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Use a Tube Cutting Device
and it allows particles that can contaminate your
sample into the tubing. To avoid these problems, we
recommend the Tube Cutter (1U7648), which
allows you to make a quick, clean cut with just one
hand. Replacement blades (1U8589) for the Tube
Cutter
are also available.
Keep Sampling Supplies Clean
Dirty supplies can contaminate your samples and
keep sampling supplies clean.
Keep new, empty oil bottles capped and store
bottles in dust-free plastic bags. The vacuum pump
and brass valve probe should also be protected
from dust. If you feel a sample is contaminated,
discard it and take another.
What Else Can I Do?
Oil analysis cannot be the sole repair indicator. Just
as a doctor uses a variety of tests, such as
checking blood pressure, looking down your throat,
listening to your chest or just asking questions,
before making a diagnosis and prescribing a plan of
action, you must also look for other indicators to
help you evaluate the problem and determine what
needs to be done. Some things you should look for
are:
A change in performance
machine performs?
A change in conditions
of oil being used?
equipment is being used? A backhoe loader
which has been working at one job site for a
long time will experience considerably greater
final drive and differential wear if it is changed
to an application which requires a lot of travel
over the road.
the equipment in a different manner?
Inspect filters - Recommend that filters be saved for
inspection. Plastic bags are convenient for retaining
the filters until they can be cut open for inspection.
The 4C5084 Filter Cutting Tool is available for this
purpose.
you can examine the filter media to see what it
has trapped. If there are metal particles
present, a magnet can be used to determine if
they are iron, aluminum or lead. Also, be alert
for pieces of synthetic friction material or rubber
seals which may indicate a problem.
Inspect magnetic plugs - Excessive or large cuttings
on a magnetic plug could point to a problem.
Perform tests - Tests can be performed to help
locate problems:
Look for leaks - If oil can escape through a leaking
seal, then dirt can also be pulled in through the
same seal.
Talk with operators - A good operator can often tell
you about a problem developing long before you
can see it.
An oil sample report should be looked at as an early
warning of a problem. Other indicators can confirm
oil test results and help determine what action is
needed. Often, unnecessary disassembly expense
and downtime can be avoided.
Note: For more information, refer to the following
Caterpillar bulletins:
Listen To Your Oil! ............................ PEDP1129-01
How To Take a Good Oil Sample ..... PEHP6001-06
Oil and Your Engine ......................... SEBD0640-01