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Story by David Sikorsky
Technical Representative, Caterpillar Forest Products

With the cost of major component overhaul and replacement, along with the expense of extended downtime, heavy equipment owners should do all they can to get as much value out of their investment as possible. Oil sampling on a regular basis is literally the cheapest insurance you can buy today.

Many owners manage their planned costs by purchasing extended warranties, often for at least 80% of the time they plan on keeping a particular unit. It is in making that new equipment acquisition, along with the extended warranty, that machine owners often are first introduced to scheduled oil sampling.

Many extended warranty plans require, or at least recommend, that owners take oil samples from all machine compartments at specific intervals. Obviously, this is done to limit the warranty company’s exposure to repair costs during the warranty period. But it is a great example to follow and a good time to get in the oil sampling habit to limit your own exposure to repair costs beyond the warranty period.

Regular oil sampling provides many benefits. It sets a baseline for what is normal wear for a specific component and what may be an indicator of a coming catastrophic failure or shorter wear out period. It may also provide indications of injection of contaminants or seal failure between components. With improvements in lubricants, it may also provide for allowed extended drain intervals, reducing routine maintenance costs. Many manufacturers approve increased engine, transmission and hydraulic oil change intervals in conjunction with scheduled oil sampling. Additionally, it provides another opportunity for an owner to inspect his machine while taking an oil sample.

Perhaps the most value provided by oil sampling is when it prevents a machine failure or significantly reduces the cost of a major repair. Many processing labs strive for same day turnaround, so the information can be shared with the dealer and owner for quick response to any changes in the sample content.

For example, an engine oil sample that has higher silica content than the previous samples would be flagged for possible dirt ingestion. A differential sample with high iron content may indicate a need to at least drain the oil and re-sample before the next regular interval. Bronze or non-metallic material in a power shift transmission could indicate that a seal failed and is causing clutch slippage. Increased iron in a hydraulic oil sample could be an indicator of a loose cylinder piston. High brass might be the beginning of a pump failure.

In my long career, I have seen many examples of catastrophic failures that required total and very expensive rebuilds of components because there was no oil sampling and the unit was simply run until it stopped moving. With the increased use of scheduled oil sampling, I have seen many documented reductions in repair costs, such as minor engine overhauls needed in the case of dirt ingestion instead of expensive major overhauls, or a simple bearing roll-in required when antifreeze was found in an oil sample, rather than a crankshaft and block replacement.

Get in the habit of regular oil sampling. It pays in the long run.