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REFERENCE
GUIDE
ENGINE, DRIVE TRAIN AND
HYDRAULIC REPAIR INDICATORS
 TABLE OF
CONTENTS

PLANNED INDICATORS......................................................5

ENGINE INDICATORS..........................................................6

FINAL DRIVE & BRAKE INDICATORS............................12

TRANSMISSION INDICATORS........................................16

DIFFERENTIAL INDICATORS........................................... 20

HYDRAULIC INDICATORS............................................... 24

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PLANNED
INDICATORS
PLANNED INDICATORS DESCRIPTION

SOSSM Services SOS Services provide the best

insight into internal component
wear and potential failure.

Service Meter Hours Operating and Maintenance

Manual gives general guidelines
for servicing based on service
meter hours.

Experience Talking with your machines

Observation & Discussion operator can reveal many potential
component problems.

Service History Service history indicates how

frequently routine maintenance
is performed.

Fuel Consumption Indicates when a piece

of equipment is operating
at less than optimum efficiency.

Site Operations SOMA is a software that

Maintenance Advisor assesses customers operating
(SOMA) and maintenance practices
and provides component
life estimates.

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 ENGINE INDICATORS

PROBLEM INDICATOR POSSIBLE CAUSES OPTIONS SOS INDICATOR POSSIBLE CAUSES

Excess Black Smoke Dirty primary/secondary FaultyTurbocharger Soot, Fe, Cr, Al Dirtyair filter
at Full Load air cleaner Technical Analysis Piston rings
(Hot, Unburned Fuel) Operating in too high Inspection Liners
a gear Customer/Dealer
Overfueling Discussion
Overloading

Increased Fuel Malfunctioning fuel Technical Analysis Positive fuel contamination, Fuel leaking into oil from injectors
Consumption nozzles/injectors Inspection decreased viscosity Shearing of the oil additives
Malfunctioning Customer/Dealer
turbocharger Discussion
Dirty air cleaner Tune-up
Improper set point
Fuel leak

Blue Smoke Worn turbocharger SOS Fluid Analysis Fe, Cr Broken or stuck piston rings
(Oil Consumption) seals Component Ether start-up
Worn rings/liners Inspection/Repair Running too cold or hot
Worn valve guides RepairDetermination Oil jet broken
Hours on engine Inspection
Customer/Dealer
Discussion

White Smoke Cracked head Technical

Analysis Positive coolant Coolant entry
(Steam: Water in and/or liners Inspection contamination, Na, K, Si, Cu
Combustion Chamber) Leaking head gasket

White Smoke Incorrect starting Customer/Dealer Positive fuel contamination, Fuel leaking into oil from injectors
(On Start-Up: procedure Discussion decreased viscosity Shearing of the oil additives
Unburned Fuel) Incorrect fuel injector Tune-up
timing
Faulty injector

6 7
 ENGINE INDICATORS

PROBLEM INDICATOR POSSIBLE CAUSES OPTIONS SOS INDICATOR POSSIBLE CAUSES

Increased Oil Worn or broken SOSFluid Analysis Fe, Cr Broken or stuck piston rings
Consumption rings/liners Component Inspection/ Ether start-up
(Excess Blow-By) Worn turbocharger Repair Running too cold or hot
seals Repair Determination Oil jet broken
Worn valve guides Inspection
Hours on engine Technical Analysis
Inspection
Customer/Dealer
Discussion

Unusual Noises Malfunctioning fuel Technical Analysis Positive fuel contamination, Fuel leaking into oil from injectors
nozzles/injectors Inspection decreased viscosity, Cu, Shearing of the oil additives
Malfunctioning Repair Determination Pb, Al Rod eye bushing
turbocharger Discussion Piston pin bushing
Worn piston pin Customer/Dealer Lower rod bearings
bushings Discussion
Worn rod/main bearings Tune-up
Too much valve lash Component Inspection
Repair

Lack of Power Incorrect adjustment Technical Analysis Soot, Fe, Cr Dirtyair filter
of governor linkage Inspection Low quality fuel
Malfunctioning fuel Customer/Dealer Piston rings and liners
nozzles/injectors Discussion
Slipping torque Tune-up
converter
Improper set point
Dirty fuel filter
Dirty air cleaner
Low quality fuel

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 ENGINE INDICATORS

PROBLEM INDICATOR POSSIBLE CAUSES OPTIONS SOS INDICATOR POSSIBLE CAUSES

Overheating Malfunctioning Technical Analysis Oxidation increases, Liner

temperature regulator Inspection Fe, Pb, Al, Cu, soot Gears
Incorrect adjustment Customer/Dealer Valve train wear
or worn belts/pulleys Discussion Bearings
Incorrect operator Cooling system Cooler core leaching
technique maintenance Dirty air filter
Plugged radiator core
(external and internal)
Low coolant level
Dirty air cleaner

Hard Starting Malfunctioning fuel Customer/Dealer Soot, Fe, Cr Dirtyair filter

(Engine Missing) nozzles/injectors Discussion Low quality fuel
Improper starting Tune-up Piston rings and liners
technique
Worn fuel injector pump
Low cranking speed
Low quality fuel
(low cetane rating
or water in fuel)

Oil Level Over Full Coolant/fuel leak SOS Fluid Analysis Positive coolant Coolant Entry
into crankcase Customer/Dealer contamination, Na, K, Si, Cu
Improper oil fills Discussion

Debris In Oil Filter Coolant/fuel leakage SOS Fluid Analysis Positive coolant Coolant entry
into crankcase Customer/Dealer contamination, positive fuel Fuel leaking into oil from injectors
Extended oil change Discussion contamination, oxidation Overheating
period increases, Si, Al Dirt contamination
Damaged bearings
Wrong oil used
Dirt entry

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 FINAL DRIVE INDICATORS

PROBLEM INDICATOR POSSIBLE CAUSES OPTIONS SOS INDICATOR POSSIBLE CAUSES

Brake Slippage Worn plates and discs Technical Analysis Si increases, Fe increases, Worndisc
Wrong oil used Inspection (Ca, P, Zn) levels change Wornplate
Linkage out Repair Determination from trend Wrong oil used
of adjustment Discussion
Customer/Dealer
Discussion

Unusual Noises Worn plates and discs Technical Analysis Si, Al, Fe Dirt
entry
Dirt
entry Inspection Worn disc
Low fluid level Repair Determination Worn plate
Discussion
Customer/Dealer
Discussion

Overheating Wrong oil used Technical Analysis Oxidation increasing, Water, Wrong oil used
Lowfluid level Inspection Fe, Na, viscosity increasing Low fluid level
Worn or damaged seals Repair Determination Water entry
Discussion
SOS Services
Customer/Dealer
Discussion

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 FINAL DRIVE INDICATORS

PROBLEM INDICATOR POSSIBLE CAUSES OPTIONS SOS INDICATOR POSSIBLE CAUSES

Debris on Dirtentry SOS Services (Si, Al), Fe, Cr, oxidation, Dirtentry
Magnetic Plug Wrong oil used Customer/Dealer viscosity increase, (Al, Cu, Fe) Worn gears/bearings
Extended oil change Discussion Sleeve bushing wear
period
Disc disintegration
Worn gears/bearings

Vibration Gear failure Technical Analysis Fe, Cr, (Si, Al), (Cu, Pb) Gear failure
Sprocket failure Inspection Bearing failure
Bearing failure Repair Determination Dirt entry
Discussion Thrust washer failure
SOS Services
Customer/Dealer
Discussion

Leaks Worn, hard, cracked RepairDetermination Si, Al, Cr Dirt entry from worn seals
seals Discussion Bearing failure
Sprocket failure Customer/Dealer
Bearing failure Discussion

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 TRANSMISSION INDICATORS

PROBLEM INDICATOR POSSIBLE CAUSES OPTIONS SOS INDICATOR POSSIBLE CAUSES

Hesitation/Slippage Worn plates and discs Technical Analysis Si increases, Fe increases, Worndisc
Linkage out Inspection (Ca, P, Zn) levels change Wornplate
of adjustment Repair Determination from trend Wrong oil used
Low fluid level Discussion
Linkage not free SOS Services
Incorrect pressure Customer/Dealer
settings Discussion
Wrong oil used

Unusual Noises Worn gears/bearings Technical Analysis Fe, Cr, (Si, Al), (Ca, P, Zn) Gears
Dirt
entry Inspection levels changed from trend, Bearings
Aeration/cavitation Repair Determination oxidation increases, viscosity Dirt entry from breather
Low fluid levels Discussion increases Low fluid levels
SOS Services
Customer/Dealer
Discussion

Vibration Bent/damaged Technical Analysis Fe, Cr Bent drive shaft

drive shaft Inspection Gear failure
Gear failure Repair Determination Bearing failure
Bearing failure Discussion
SOS Services
Customer/Dealer
Discussion

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 TRANSMISSION INDICATORS

PROBLEM INDICATOR POSSIBLE CAUSES OPTIONS SOS INDICATOR POSSIBLE CAUSES

Overheating Wrong oil used Technical Analysis Oxidation increase, coolant Extended drain interval
Plugged radiator Inspection contamination (Na,K, Si, Cu) Coolant entry
Worn pump/pressure Repair Determination viscosity increase, (Si, Al), Dirt entry
relief valve Discussion (Ca, P, Zn) levels changed Wrong oil used
Worn or damaged seals SOS Services from trend, Fe, Cr Worn gears/bearings
Low fluid level Customer/Dealer
Worn or dirty control Discussion
valve

Debris in Filter and/or Dirtentry SOS Services (Si, Al), (Ca, P. Zn) levels Dirt
entry
on Magnetic Screen Wrong oil used Customer/Dealer changed from trend, Fe, Cr Wrong oil used
Extended oil change Discussion Worn gears/bearings
period
Worn gears/bearings
Disc disintegration

Leaks Worn, hard, cracked RepairDetermination (Si, Al) Dirt entry from seals
seals Discussion
Customer/Dealer
Discussion

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DIFFERENTIAL INDICATORS

PROBLEM INDICATOR POSSIBLE CAUSES OPTIONS SOS INDICATOR POSSIBLE CAUSES

Bent or Damaged Lines External damage Technical Analysis N/A N/A

Inspection
Repair Determination
Discussion
Customer/Dealer
Discussion

Unusual Noises Worn gears/bearings Technical Analysis Fe, Cr, (Si, Al), oxidation, Worn gears/bearings
(when traveling Ring and pinion need Inspection viscosity increase Dirt
entry
straight) adjustment Repair Determination Low fluid level
Dirt entry Discussion
Low fluid level Customer/Dealer
Discussion

Unusual Noises Worn differential case Technical Analysis Fe Worn gears

(when turning) assembly Inspection Worn spider gears
Worn spider gears Repair Determination
Discussion
Customer/Dealer
Discussion

Vibration Gear failure Technical Analysis Fe, Cr Gear failure

Spider gear failure Inspection Spider gear failure
Differential failure Repair Determination Bearing failure
Bearing failure Discussion
Bent/damaged SOS Services
drive shaft

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DIFFERENTIAL INDICATORS

PROBLEM INDICATOR POSSIBLE CAUSES OPTIONS SOS INDICATOR POSSIBLE CAUSES

Debris on Contamination entry SOS Services (Si, Al), Fe, Cr, oxidation, Dirtentry
Magnetic Plug (dirt/debris) Customer/Dealer viscosity increase Worn gears/bearings
Extended oil change Discussion Extended oil change period
period
Wrong oil used
Worn gears/bearings

Leaks Worn/damaged seals RepairDetermination (Si, Al), Cr Dirt entry from seals
(pinion/differential) Discussion Worn bearings
Worn bearings Customer/Dealer
Discussion

Overheating Wrong oil used Technical Analysis Oxidation increasing, Wrong oil used
Lowfluid level Inspection (Ca, P. Zn) levels changed Low fluid level
Worn or damaged seals Repair Determination from trend, Water, Fe, Na, Water entry
Discussion viscosity increasing
SOS Services
Customer/Dealer
Discussion

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HYDRAULIC INDICATORS

PROBLEM INDICATOR POSSIBLE CAUSES OPTIONS SOS INDICATOR POSSIBLE CAUSES

Leaks System pressure Technical Analysis Cr, (Si, Al) Scored cylinder rods
too high Inspection II Dirt entry from wiper seals
Scored/bent SOS Services
cylinder rod Hose Service
Failed or incorrect seals
Improperly torqued hose
connection
Worn or damaged
hoses, tubes and fittings
Missing guards

Excessive Valve adjustment Measure Drift Cr, (Si, Al) Scored cylinder rods
cylinder drift needed Technical Analysis Dirt entry from wiper seals
Scored cylinder Inspection II
Failed seal or seals SOS Services
Scored valve
Contaminated oil

Slow cycle times Engine performance Technical Analysis Oxidation increases, Low fluid level
Faultyvalve Inspection II (Si, Al) Dirt entry
Low fluid level SOS Services
Worn system
components
Contaminated oil

Noisy operation Engine performance Technical Analysis Oxidation increases, Low fluid level
Low fluid level Inspection I (Cu, Cr, Fe), (Cu, Fe, Al) Vane pump
Restriction in system SOS Services Piston pump
Aeration Pump Cavitation
Worn system Loose or failed bearing
components
Faulty relief valve

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HYDRAULIC INDICATORS

PROBLEM INDICATOR POSSIBLE CAUSES OPTIONS SOS INDICATOR POSSIBLE CAUSES

System overheating Faulty oil cooler Technical Analysis Positive coolant Coolant entry from cooler core
Low fluid level Inspection I contamination (Na, K, Cu), Dirt
entry
Plugged filter SOS Services (Si, Al), Oxidation increases, Wrong viscosity oil
Worn system viscosity change from trend Low fluid level
components
Faulty relief valve
Wrong viscosity
or contaminated oil
Restriction in system
Poor operator habits

Loose cylinder joints Worn rod or cylinder Component Inspection/ N/A N/A
eye/trunnion Repair
Poor lubrication
Improper PM schedule

Blisters or abrasions Pinhole leaks in liner Technical Analysis N/A N/A

in hose material Inspection I
Poor hose routing Replace Hose
External damage

Excessive hose Improperclamping Use

proper clips and N/A N/A
movement or routing of hose wire ties

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when and where you need them.
The Cat Dealer Network of highly trained experts
keeps your equipment up and running to maximize
your equipment investment.

For more information, contact your local

Cat dealer or visit www.cat.com
For more information regarding SOS,
refer to PEGJ0046

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