KOWA

1.
INTRODUCTION
When the sliding parts inside each component move, there is wear, and, as a result, wear particles are
produced. KOWA (Komatsu Oil and Wear Analysis) is a system for measuring the density of these
metal wear particles in used oil. The results of the measurement are then used to judge if the wear
condition of the parts lubricated by the oil inside each component (including the condition of corrosion)
is normal or abnormal.
The size of these wear particles is normally on a scale of only a few microns, so they cannot be seen
with the naked eye. In particular, with engine oil, these particles are so small that they can pass easily
through the oil filter, and are dispersed throughout the oil. If oil containing such small metal wear
particles or dust which has enteredfrom outside is subjected to high temperatures, it emits (or absorbs)
light of a wave length that is peculiar to that particular element. KOWA uses this property to measure
optically and analyze the density of metal elements in the oil in units of ppm.
The method of analyzing the metal content of engine oil using KOWA can detect dust and metal wear
particles of micron size which cannot be seen by the naked eye. However, it cannot measure quantita-
tively particles of a size that can be seen. And it cannot detect beforehand any problems caused by
excessive wear due to lack of oil or entry of large amounts of dust.
Therefore, with KOWA, the measurement of the density of the minute wear particles and the trend in
the changes in that value are used for estimating the condition of wear inside the component and for
making judgements regarding preventive maintenance for the component.
2. OIL SAMPLING
2-1 When using sampling pump (Oil sampling tools)

(1) Sampling pump (Part number: 799-801-1302)
Weight : 170g
Overall length: 195mm
Outer dia. : 32mm
(2) Sampling kit (Part number: 799-801-1503)

(3) Sampling Procedures
Caution
r Sample the oil while it is still warm, for exsample right after the machine is stopped.
r Try to sample under the same conditions every time.
Example (1) Example (2)

Level gauge Replace the tube with a Plug
new one after each use.
Cut the tube to the proper Cut

length if it is too long. Suc-
tion resistance will be re-
duced and smooth sam- Before remove the plug, wipe off all the
pling will be ensured. dirt from around the plug.
More than 50 mm into the oil
(Generally, insert the tube to the same length the level
gauge.)
(4) Assemble of the tube and bottle
1 Loosen the round nut. 3 Tighten the nut.
2 Extend the tube about 1.5cm

from the lower end of the pump.
4 Screw the sample

bottle in the pump.
Fill the bottle to the 80% with oil.

Do not fill the bottle to the top.
80% Tighten the cap.
2-2 When using in-line sampler
(1) Oil sampling tools
Sampling kit
No. Part name Part number Remarks

1 In-line sampler assembly 79A-851-1101 New
2 Sampling kit 799-801-1503
799-101-5230 M14 × 1.5
Quick coupler
3 799-101-5220 M10 × 1.25
(Cejn)
799-101-5160 PT1/8
Connect the adapter
Check if there is an oil pressure pick-up port nipple on the machine.
Width
Width across
across flats Width across
flats 19mm 17mm flats 17mm
M14 × 1.5 PT 1/8 M10 × 1.25
(2) Sampling Procedures
Press the check valve portion of the self-seal type quick coupler and take a sample of oil from the
circuit which is under low pressure.
The components where it is possible to sample the oil are as follows. Take a sample of the oil from
the final drive (axle, differential) using the sampling pump in the conventional way.
K : Possible to take sample ) : Impossible to take sample

Component Other units not
Power Work Final drive
Engin under hydraulic
train equipment (axle, differential)
Method pressure
sampling pump K K K K K
In-linesampler K K K ) )
When taking samples, follow the conditions below.
Component Conditions
Engine Whole speed range (mid-range speed)
Power train Neutral
Work equipment Neutral
1 Insert the tube of the sampling kit into the in-line sampler, then cut the tube to a suitable length for
use.
2 Remove the cap from the quick coupler and wipe it clean with a cloth.
3 Fit the quick coupler to the in-line sampler for measuring the oil pressure of the component to be
sampled.
Use a finger to keep the washer portion pressed and hold the bottle in your left hand. In this way,
the sample can be taken by one worker in a few seconds.
When the pushing pressure is released, the spring force of the self-seal system will automati-
cally close the quick coupler, and the flow of oil will stop.
r Precautions when sampling oil

1 Carry out the warming-up operation thoroughly for the component to be sampled in the same
way as for the sampling pump.
2 The oil can be sampled if the oil pressure at the sampling point is within a range of 0~60kg/
cm2. (If it is above 60kg/cm2, it is difficult to push the in-line sampler into the quick coupler, so
it is impossible to take the sample).
3 For machines where a quick coupler has not yet been installed, remove the oil pressure pick-
up port, check the size of the screw thread, and install a suitable quick coupler.
4 Before installing the quick coupler, use a cloth to wipe off all the dirt from around the pick-up
port.
5 After sampling the oil, dispose of the tube .
It cannot be used again.
(3) Filling Out Machine Data Sheets and Check Sheets
The check sheet should be filled out as soon as an oil sample is taken in order to accurately
record the service meter reading and various machine conditions.
For an accurate evaluation of the results of oil analysis, it is essential to carefully and continu-
ously observe the machine conditions during daily inspection and operation. The man who samples
the oil should fill out the check sheet or tell the servicemen in as much detail as possible about the
condition of the machines during operation. The servicemen should carefully observe the condi-
tions of machines which are subject to oil sampling.
(4) Sampling Interval
1 Engine
a. In case of oil change every 250 hours and 500 hours, sample oil when the oil is changed.
b. Sample oil at 10 hours after a major repair.
c. Shorten the sampling interval when any reading shows an abnormal increase.
2 Other Iubricated components
a. Sample oil every 250 hours for the first 1,000 hours, based on the KOWA program. This
rule includes new machine.
b. Sample oil every 500 hours after the first 1,000 hours in the program.
c. Sample oil between 50 and 250 hours after any major repair.
d. Shorten the sampling interval when any reading begins to show an abnormal increase.
3. EVALUATION OF ANALYZED RESULTS
This section outlines how to evaluate the trends of the oil analysis in order to estimate the internal
condition of a system. The wear rate of sliding parts in a machine will fluctuate depending on the
operating conditions, differences in environment, performance of maintenance, subtle differences
which occur during the assembly of the machine, the amount of oil which needs to be added, and
the amount of time the oil is used. Scattered values will eventually concentrate themselves into a
certain range as long as the machine is in normal condition, and can be rounded to a certain
constant value in the long run.
A key to success in this service, therefore, is to find the constant value particular to each machine
in the shortest possible time, say, between the initial oil sampling and the second or the third
sampling.
The results of analysis are evaluated in comparison with the constant value to find out how much
change occurs each time and the trend of wear. The accuracy of the constant value should im-
prove as more samples are taken.
(1) Range of judgement for KOWA
The range of judgement is as shown in the table below.
Take a sample of oil from the components that are lubricated by oil, and carry out an ICP analysis
to investigate the density of the wear particles that are contained in the oil.
ICP analysis K : Analyzed element
Element
Fe Cu Cr Al Si Pb Na
Component
Engine K K K K K K K
Power train K K K K K K -
Final drive K K K K K K -
Work equipment K K K K K K -
Other analysis K : Analysis

Component Entry of fuel Entry of water Entry of antifreeze PQ Index
Engine K K K K
Power train - K - K
Final drive - K - K
Work equipment - K - K
(2) General Precautions at Time of Evaluation

1 Do not take it for granted that a rapid increase in the analyzed value indicates a machine
failure. Rather, it is necessary to examine all conceivable causes (for examble, a sudden
change in load or operating conditions, whether or not the machine was recently overhauled)
and to eliminate the unreasonable ones. Other troubleshooting techniques should be used
simultaneously.
2 Oil changes and number of service hours have a large influence on changes in concentration.
Specifically, after an oil change the concentration will be lower, and the longer the service
hours, the higher the concentration.
3 When an oil analysis is first used after the delivery of a new machine, it is necessary to take
the initial wear into consideration.
4 The standard values for evaluation are based on 250/500 hours of oil use for the engine and
500 hours of oil use for the other systems. For engines whose oil is changed at 500-hour
intervals or systems whose oil is changed at 1000-hour intervals, the standard values should
be increased accordingly. In this case, note that the pattern of wear varies with the kind of
element and that the wear is not always proportional to the number of hours that the oil has
been used.
5 The evaluation of the analyzed results is based on a combination of the highly concentrated
elements and the rate of increase.
6 When it is difficult to evaluate fine results or when KOWA data is lacking, resampling should be
performed at shorter intervals.
7 The analyzed results should not be evaluated for every sampling. Instead, base the evaluation
on trends noticed on a continuing basis. It is also necessary to know how the trend value
compares with the standard value for the machine involved.
NOTE: Recently, large amounts of copper have been used as an additive in oil.
If the KOWA data for the copper value is abnormally high, test a sample of unused oil
to confirm the amount of copper used as an additive. Use the results of this test to
set new quidelines for use when carring out KOWA on that oil.
8 SUPPLEMENT
8-1 Standard value and converted concentration.
The standard value is provided, as shown in Fig.1.1, to divide the concentration per unit hour
into normal, caution and critical ranges. Namely, the standard values are indicated by the
minimum and the maximum value of the caution range. For example, they are indicated as
(Min. caution value) = 40 ppm or (Max. caution value) = 90 ppm.
[Explanation of standard value]

Fig. 1.1 Standard value
8-2 Unit hour and converted concentration

For comparing the analytical value we get from the Inductively Coupled Plasma with the
standard value of concentration, the analytical value has to be converted to the concentration
per unit hour (500h or 250h). The standard value indicates a permissable concentration in
ppm for each element in oil used for unit hour. Two different unit hours are employed, one for
oil used in engines and the other for oil used in units other than engines. The unit hours are
shown in Table 1.1 below.
Table 1.1 Unit hours for standard value
Oil used in engines 250/500h

Oil used in units other than engines 500h
How to convert the analytical value obtained by the Inductively Coupled Plasma to the concen-
tration per unit hour will be as follows:
An analytical value of 20 ppm was obtained from hydraulic oil used for 1000hrs. in the hy-
draulic circuit of work equipment. Since the unit hour for work equipment.
hydraulic circuit is 500 hrs, the converted concentration can be obtained as shown below.
20 ppm x 500 h (unit hrs.)

= 10 ppm
1000 h (hrs. oil wa used)
8-3 Criteria for evaluation of analytical values by Inductively Coupled Plasma Analyzer, and evalu-
ation.
We introduce here pattern control of the Inductively Coupled Plasma Analyzer values as an
example for reference to improve the accuracy of judgement based on the results of analysis
using the Inductively Coupled Plasma Analyzer.
The pattern control of the analysis values is carried out as shown in Fig. 1.2
Fig. 1.2 Example of pattrn of analytical values obtained

by Inductively Coupled Plasma Analyzer
Judgment is carried out as shown in Table 1.2 from the shape of the pattern.
Table 1.2 Criteria and evaluation
Evaluation Criteria
When converted concentra- When converted concentra-
Pattern
tion (*) of newly-obtained tion (*) of newly-obtained

analytical value is the stand- analytical value is over the
ard value (Min. caution standard value (Min.
value) or below. caution value).
A Normal Not more tha 3 times pre-
-
vious value (**)
B Caution More than 3 times but not Not more than 1.5 times
more than 5 times previous previous value (**)
value (**)
C Abnormal More than 5 times previous More than 1.5 times pre-
value (**) vious value (**)
Note: * : The converted concentration is a concentration converted to unit hour (See,
Chapter 8-1)
** : The previous value is a mean value of three preceding data. If the three data are
not available, two or one data will do.
(Note)
[Density immediately after oil]
When the oil is changed, metal wear elements in the remaining part of the old oil still remain.
Therefore, even immediately after changing the oil, the analysis value is not 0,so immediately
after changing the oil take a sample and carry out analysis, or calculated the analysis value
immedately after changing the oil from the sampling analysis value obtained immediately before
changing the oil.
< Oil change ratio >

The operation & Maintenance Manual gives the specified oil amounts and oil change amounts for
each oil filling location.
(Example) Oil filling location Specified oil amount (R) Oil change amount (R)
Hydraulic system 230 170
170
Therefore, in this example, the oil change ratio is x 100 = 74%.
230
(1) When sampling
When carrying out sampling, operate the component to be sampled thoroughly to mix the
remaining oil and new oil completely.
(2) When calculating analysis value (simple method, less accurate than method(1))
If the sampling analysis value for Fe immediately before changing the transmission oil shows
a density of 20 ppm, and the oil change ratio is 74%, the estimated analysis value immediately
after changing the oil is as follows.
74
20 ppm x (1 - ) = 5.2 ppm
100
< Example of calculating converted density >

In a case where the estimated analysis value immediately after changing the oil is 5.2 ppm, and
the sampling analysis value after 1000 hours of use shows a density of 30 ppm, the unit time for
an actuator circuit is 500 hours, so the converted density is calculated as follows.
500h (Unit time)

(30 ppm - 5.2 ppm) x = 12.4 ppm
1000h (Length of use of oil)
(3) Assuming Causes of Defects from the Combination of Highly
Concentrated Elements
Table 1 K : Rapid increase or high concentration ! : Concentration may become higher
Compo- Highly concentrated elements
Assumed location of defect
nent Fe Cu Cr Al Si Pb Na
K Liner, crankshaft, timing gear, camshaft, rocker arm, FCD
piston
K ! Timing gear thrust bearing, bushing for timing gear,
piston pin, oil pump, and camshaft, bearing metal for
crankshaft
K K Water leaks from oil cooler
Engine
K Crankshaft thrust bearing, turbo thrust bearing, aluminum

piston
K Piston rings
K K ! K Dust
(Note 1) Fresh oil contains 10 to 20 ppm of Si as an
additive, which, however, will diminish to zero
with the lapse of operating time.
K Gear, bearing
K K Brake linings
Torque converter,
transmission, and
steering controls
! K Dust
K K Clutch plate and disc
K Thrust bearing metal, retarder brake disc
K Torque converter
(Note 2) For machines with TORQFLOW
Fe : Cu = 1 : 2 to 4
(When in normal condition)
K ! Gear bearing
Final drive
K Bushing, thrust bearing metal

unit
K K ! K Dust (Floating seal)

(Note 3) Generally, Al : Si = 1 : 2 to 4
K Cylinder rod
equipment
K Cylinder wall, pump gear

Work
K Pump body
! K Dust
K Pump side plate, plain bearing, retarder brake disc
Main K K Plate and disc
Clutch
Table 2 Parts which may be cause of abnormality in KOWA analysis value for elements on SA12V140
Symbol Element Parts possibly causing problem Remarks
Fe Iron Crankshaft
Camshaft
Timing gear
Piston
Piston ring
Cylinder liner
Valve guide
Oil pump
Air compressor cylinder HD785, WA800 only
Cu Copper Main bearing
Pin bearing
Crank thrust bearing
} Appears after overlay layer is
worn
Cam bushing
Bushing at small end of
connecting rod
Cam follower roller pin
Rocker arm bushing
Timing gear bushing
Oil pump bushing
Turbocharger bearomg
Oil cooler core (corrosion)
Oil additive In this case, there is no problem.
(seizure prevention agent) Analyze fresh oil.
Cr Chromium Piston ring
Exhaust valve
(chrome plated part)
Al Aluminum Compressor piston
Compressor piston rod } HD785, WA800 only
Entry of dust Check for entry of dust
Si Silicon Entry of dust Check for entry of dust
Oil additive In this case, there is no problem.
(antifoaming agent) Analyze fresh oil.
Pb Lead Main bearing overlay
Pin bearing overlay
Cam bushing
(4) Sammary of Evaluation by System
ENGINE
r After complating a major repair, the analysis should be performed by collecting oil samples
after about 10 hours of operation. This may also serve as confirmation of successful repair.
r Take precautions to prevent the ingress of water and fuel.
r An increase or decrease of Si, Al content is important, because Si, Al content is a sensitive
monitor of abnormalities in the air intake system. Simple inspection around the air cleaner
element may often eliminate troubles. A high Si content does not occur alone. It is always
combined with the presence of Fe, Al, Cu, Pb or Cr. Note hat fresh oil contains about 10 ppm
of a Si-bases antifoam agent.
r When Fe and Al are high, it may indicate wear of the pistons and liners. Check the amount of
oil consumption, or, if nedessary, confirm the wear by means of a blow-by check and com-
pression check.
r When only the Cu content is high, it may be because Cu is set free from the oil pipes of the oil
cooler because of the reaction of ingressed water with Cu. However, a high concentration of
Cu is not likely to occur because the ingression of water is usually checked and corrected
before the water can react with the Cu.
r An excessive amount of oil tends to lower the concentration and the use of oil for longer the
specified time tends to increase the concentration. (Fe is especially sensitive to this ten-
dency.) Be careful about samples of oil to which a loarge amount of fresh oil has been added.
(A low concentration does not always prove that the machine is in normal conditions.)
r The Al content from aluminum-based bearings (including thrust earings) is apt to be over-
whelmed by the Al content coming from pistons or from dust. Be alert to symptoms of trouble,
because the former is hard to notice.
r The Pb content may exceed the normal value during break-in operation. The Pb content alone
is not significant, therefore, observe it in conjunction with the Cu content. Improper lubrication
and the ingress of dust tend to increase the Pb content.
r As can be seen from the preceding explanation, the amount of metal particles in the oil is
preduced according to the properties of each sliding part and the operating conditions, such
as the speed, load, and temperature of the sliding part. Furthermore, the amount differs for
each engine.
Therefore, the range of the density of the metal wear particles produced when the engine is
operated normally also differs for this reason for each type of engine and the way that the
machine is operated by the user. However, the present KOWA standard values are the aver-
age values for each machine without any consideration of the type of engine, and are given as
a quideline.
Fig. 1 Range for each standard value
r Action taken according to KOWA judgement standards

It is important to make economic and overall judgement of the KOWA data by comparing it with
various analyzed values.
In addition, by looking at the data together with the machine history, it is possible to judge the
operating condition of the engine, so use the method of reading the administration graph as
reference and draw a graph of the changes with the passage of time to make judgement. With
a new engine or rebuilt engine, the first few sets of KOWA data may be in the caution range,
but this is because of initial breaking in and does not indicate any abnormality, so exclude
these data when making judgement. However, if this level does not go down after the initial
period, it is necessary to take action.
r Method of reading administration graph of KOWA analysis values
When making a graph (such as shown on the left)
locally and observing the data, use the following
procedure.
1 Put Si and Al (which are common causes) at

the top, then put Cr, Fe, Pb, and Cu below
them in turn.
The reason for this is that if there is entry of
dust, Si and Al often show the same trend and
it is easier to read the graph. Next, there is a
trend for the entry of dust to show effect on the
area around the piston, and after that, to show
effects on the bearings, so it is easier to see
this if the graphs are arranged as shown on
the left.
2 If the oil change intervals are much shorter

than the standard interval (standard: 250/500
hours), convert the values to the standard in-
terval and plot them on the graph.
r If the value for each element shown in the graph exceeds the caution range three times in
succession and shows a tendency to increase ([B] and [C]) or exceeds the caution range
([D]), judge this to be an abnormality and take the action given below according to the element
that is causing the problem.
1 If there is a abnormality in the value for Si or Al

It is probable that there is dust in the oil. (If there is entry of dust, Si and Al may show the
same trend.) Check the connectors and take action, or check other parts where dust may
have been sucked in and take the necessary action.
If Si is being used as an additive in the oil (antifoaming agent) and a high level of Si is
detected, carry out analysis of fresh oil. Then subtract the value for Si in the fresh oil and
compare the result with the standard value.
2 If there is any abnormality in the value for Cr or Fe
It is probable that there is abnormal wear of the piston ring or liner. In this case, there is
probably an increase in the consumption of oil, so inspect all points and check if there is
any oil leakage. After this, carry out the checks before starting to check the oil level, then
periodically check the amount of oil that is added. If a large amount of oil must be added
and there is danger that the oil level may go down to the L level during operations, carry out
an overhaul immediately.
3 If there is any abnormality in the value for Pb or Cu
It is probable that there is abnormal wear of the bearing.
Particularly, if Pb continues to be detected in the caution range, and then abnormal amounts
of Cu appear, there has probably been seizure of the bearing, so carry out an overhaul
immediately.
r Example of following problem
Dust sucked in m excessive oil consumption m seizure of bearing
(Abnormality was detected by KOWA, but no overhaul was carried out and problem advanced
to seizure of bearing).
There was the same trend in

the increase in Si and Al, dust
was being sucked in.
r Example of situation where an overhaul was carried out after Pb and Cu entered the caution
range and abnormal wear of the bearing was found.
Example of where Pb en-

tered the caution range
and Cu also entered the
caution range after this.
(wear of bearing)
TORQFLOW TRANSMISSION (INCLUDING STEERING SYSTEM)
r The initial oil sampling and analysis should be performed beween 50 and 250 hours after
completion of a major reair. The analysis of the initial oil sample can also be used to confirm
whether or not the repair was successful.
r The TORQFLOW transmission is subjected to constant wear during ordinary operation, as it is
not much affected by the operator’s skill. Although the ratio of Fe and Cu varies from one
machine to another, it is generally Fe:Cu = 1:2 ~ 4
Any large variation from this ratio can be regarded as a symptom of trouble.
r An extraordinarily high value of Cu together with the ingress of water indicates trouble with the
cooler. (If they use antifreeze the presence of antifreeze can also be detected at the same
time.) In the case of dump trucks which equipped with retarder brakes of sintered disc and the
oil circulate from TORQFLOW system to retarder brakes, the Cu content should be higher
than in other TORQFLOW type machines, except for those equipped with fiber disc type
retarder brakes.
r Wear of brake linings may also result in a higher Si content. It is necessary to analyze the Mg
content to see if the Si content is related to the wear of brake linings. If the Mg content exceeds
the ratio of Si:Mg = 2:1, the wear of the brake linings is progressing and, If the Mg content
approaches the ratio of Si:Mg = 1:1, the wear is extensive. However, since the Al:Si ratio
brought about by dust and sand is already known, if an extremely high ratio of Si occurs, the
additional portion of Si maybe attributable to wear of the brake linings.
r Since the torque converter has no sliding parts made of Al and is a highly reliable component,
it is almost impossible for the Al content to increase because of torque conberter trouble.
Nevertheless, the Al content should be observed just in case. It is ecommended that the Al:Si
ratio for dust and dirt be observed regularly.
FINAL DRIVE UNIT
r The initial oil sampling should be analyzed between 50 and 250 hours after completion of a
major repair. The analysis of the initial oil sample can also be used to confirm whether or not
the repair was successful.
r If the Fe content is close to the abnormal value, change the oil. When draining oil, inspect the
oil for foreign matter such as metallic powder, fragments, and dirt.
r Usually Fe content increases along with Si (dirt from outside). It is often accompanied by an
increase in Cr and Cu contents and an ingress of water. The Al content also increases in
correlation with Si content. Both of these values should be recorded since they are useful
when troubleshooting other systems.
r There are many chances for dirt to get into the final drive unit, especially if taking oil samples
or checking the oil level without paying due attention. You should eliminate as many uncertain
factors as possible by cleaning the oil filler plug before removing it. This will facilitate the
evaluation because any increase in Si content may be directly releated to a trouble with the
final drive unit.
r If the Si content is gradually increasing, there is potential for oil leakege. Therefore, visual
checks in daily inspections and periodic oil level checks should be strictly observed. Look for
defective floating seals, case, gasket, etc.
r If the Si content is still increasing even though you can not find any oil leakage, leaks may be
readily located by feeding compressed air (less than 1 kg/cm2) through the oil inspection hole
while moving the vehicle body a little.
HYDRAULIC OIL
r In hydraulic oil, the content of all the elements is low. This is because of the large volume of oil
in relation to the sliding parts involved. Even if a failure occurs, the rate of increase in concen-
tration of the elements will be so small that extra care must be exercized to get an accurate
evaluation.
r If the Cr content is increasing, the cylinder rod may be warped or scratched. In this case, dust
seals and rod seals may also be defective. The presence of oil leakage is also an important
factor.
r If the Si content is increasing, it may be because of defective dust seals on the rods or
improper fitting of the hydraulic tank cap. Also, water is likely to enter the hydraulic oil together
with Si.
r An increase in Al content is caused by either Al powder coming from the pump body or dust
coming in from outside. Since the absolute amount of Al is small, however, it is difficult to
judge. Just because the analyzed value shown an increase in Al does not mean that the pump
is defective. Attention should be paid to other symptoms as well in order to locate the trouble.
r An increase in Fe content useally indicates damage inside the cylinder and wear of the pump.
Confirm this damage by checking other possible symptoms such as hydraulic drift or lack of
power.
r In general, an increase in Cu content is caused by defects on the pump side plate and plain
bearings, but its absolute value is too small to make judgement easily. Some cylinders have
metallic (Cu) piston rings. In these cases, a high Cu content may be detected even under
normal conditions.
(5) Assuming the Extent of Wear
The unit used in analysis is ppm (parts per million). For example, 250 ppm is equal to 250 out of
one million. ppm can be used to express the ratio by weight or the ratio by volume. In the OIL
ANALYSIS, however, it is used as follows:
1 gram of the element

1 ppm =
1,000,000 ml of oil
For example, let’s assume that 250 ppm of Fe was detected in the final drive unit of D155A. Since
the specified oil capacity is 55 liters,
250g
55 (or 55,000ml) x = 13.7g
1,000,000 ml
This shows that 13.7 g of Fe is suspended in the oil, assuming that the correct oil level is
maintained. To convert this into volumetric figure, the specific gravity of Fe, 7.9, is used. That is,
13.7g
= 1.73 cm3
7.9 g/cm3
Although there are some uncertain factors such as the impracticability of making a 100 per cent
complete oil change or the attraction of larger wear particles by a magnetic plug, it is possible to
estimate the gross wear by accumulating values obtained at every oil change. It is impossible to
estimate the wear of every individual part however. This same rule applies to Cu, Cr, Al, and Pb.
Before proceeding to the analysis, it is necessary to be familiar with element composition ratio
for individual parts and also the structure of the systems.
The conversion for Si is a little troublesome. As described above, the ratio of dirt:Si is expressed
by dirt:Si = 100:28. Therefore, an approximate quantity of dirt is calculated as follows:
Quantity of dirt = Calculated quantity of suspended Si a 0.28
In reality, however, the quantity of dirt is greater than the value obtained above, since the analysis
can not detect 100 per cent of the Si.
4. SUPPLEMENTARY INFORMATION FOR EVALUATION
(1) Characteristics of Elements
Fe ----- Roughly proportional to the number of hours the oil has been used. The Fe content is
influenced by the residual contamination and history of oil changes.
Cu ----- Unlike Fe, the Cu content is not proportional to the number of hours the oil has been used.
The trend of Cu content can be illustrated as shown in the graph below.
Cr ----- Concentration is usually low. Although the Cr content is roughly proportional to the number
of hours the oil has been used, this is not very significant because it is at such a low level.
The Cr value will be meaningful only after excessive wear occurs.
Al ----- Difficult to predict the location of trouble because some Al comes from dust (Al2 O3 , SiO2
, etc.) in addition to that which comes from Al parts. Pay attention to the Al content which
comes from the wear of parts, since a small amount may indicate serious trouble.
Si ----- The Si content usually comes from dust (Al2 O3 , SiO2 , etc).
Note that fresh oil contains about 10 ppm of Si-based antifoaming agent.
This is an organic Si which does not accelerate wear of parts directly and will disappear
with the lapse of operating time.
The tendency of the Si content is as follows.
Pb ----- Only the lead contained in the engine oil is analyzed. The Pb content may exceed the
normal value during the break-in period. By itself, the Pb content is not significant. It has a
close correlation to Cu content.
Na ----- This is contained in antifreeze. It applies only to engine oil.

If large amounts are detected, there is probably leakage of coolant into the engine oil.
(2) Relation between Si and Al due to Intrusion of Dust
{
The average chemical composition of rocks is generally reported as follows.
} D
SiO2 59.09% / Si 27.61%
Al : Si = 1 : 3.4
Al2O3 15.35 / Al 8.12
Fe2O3 7.29
The above ratio will vary to some extent depending on prop-
Ca 3.60
Rock erties of soil at the site where the machine is operated. ( 1 :
Na 2.97
2 to 4 )
K 2.57
If the Si content is high, you may sagely assume that some
Mg 2.11
of the Al content came from dust.
·
If Al parts are not used on the machine, the entire Al con-
·
tent comes from dust.
·
(3) Introduction of the KOWA standard values for the engine oil changing
interval of 500 hours
[ Complying with the oil changing interval of 500 hours ! ]
With recent engines, the oil changing interval is being prolonged to 500 hours. Pursuant to this
prolongation, we changed the sampling time of the KOWA to 500 hours and the standard values
have been revised as follows.
1. Standard values for the 500 hour changing interval

The standard values are being preset after conversion to 500 hours similar to the case of other
equipment and they are about 1.5 times as much as the current standard values ( after
conversion to 250 hours ). Although the interval time has been doubled from 250h to 500h, be
careful that the standard values will not be doubled like the interval time did.
Unit: ppm
Current interval of every 250H New interval of every 500H
Abnormal Abnormal
Caution range Caution range
range range
1 or more and 1 or more and
2 or more 2 or more
less than 2 less than 2
Element 1 2 Element 1 2
Fe 45 95 Fe 70 150
Cu 15 45 Cu 25 70
Cr 5 15 Cr 10 25
Al 8 16 Al 10 25
Si 20 40 Si 30 60
Pb 25 80 Pb 40 120
Na 50 100 Na 75 150
2. Applicable engines
500 hour oil change interval engines are as per the Parts sales handbook including the following
engines. Regarding the standard values for respective engine models, refer to the attached file.
SAA4D102E-2, SAA6D102E-2,
SAA6D114E-2
S6D125E-2, 3, SA6D125E-3, SAA6D125E-3
SA6D140E-3, SAA6D140E-3, SDA6D140E-3
SA6D170E-3, SAA6D170E-3
3. Ground for calculation of the new standard values
1) Standard values
The standard values of the KOWA is being set up on the premise that the metallic abrasion
chips being contained in the oil will increase in proportion to the using time of the oil.
From this theory, if the capacity of the oil pan is the same and if the oil changing interval is
2 times longer, the standard values will also become 2 times as much . However, the capacity
of the oil pan after prolongation of the oil changing interval to 500 hours has been set to, for
example, about 1.4 times as much as the capacity of the previous oil changing interval . On
the other hand. the engine is always consuming the engine oil and the total quantity of the
metallic abrasion chips being contained in the engine oil decreases together with the consump-
tion of the oil by the engine and, as the new engine oil is added to supplement the consumption,
the concentration of the metallic abrasion chips in the engine oil will also decrease. The rate
of decrease of the concentration of the metallic abrasion chips in the engine oil is in proportion
to the rate of consumption of the engine oil. (Refer to Fig. 1) With regard to the aforementioned
circumstances and in consideration of the actual oil change interval data, we shave set the new
standard values to about 1.5 times as much as the current standard value .
Progress of the concentration of the metallic abrasion chips in the engine oil in consideration
of foil consumption ( In case oil is supplemented at every 50 hours)
3.5 Fig.1
3
Oil consumption rate
2.5
2 ０.０５％
1.5
０.１％
０.２％
1
０.４％
0.5
0
0 100 200 300 400 500 600 700 800 900 1000
S ervic e m eter
2) The reason why the sampling interval was set to 500 hours
Judging from the actual oil

A ctual oil c hange interval data
change interval data, sampling Fig. 2
is being made at the time of 551 hours or more 3

changing the engine oil and,
501~550 hours or les s 31
therefore, the standard value
35
should better match the above 451~500 hours or les s
status, thus having been set to 401~450 hours or les s 0
500 hours. 250~400 hours or les s 10

(Refer to Fig. 2)
250 hours or les s 13
0 10 20 30 40
Num ber of cas es
4. Comparisons of the standard values in case of 250 hour oil change interval and the
standard values in case of 500 hour oil change interval
Shown below are comparisons of actual measurement data by each element of the case of the
HD785-3 (standard values in case of 250 hour oil change interval) and the HD785-5 (standard
values in case of 500 hour oil change interval).
[Factual measurement data in case of the [Factual measurement data in case of the
HD785-3] HD785-5]
(250 hours) (500 hours)
(Analysis results of iron) (Analysis results of iron)
Fe(Caution range: 45-95, Abnormal range: 95 or more) Fe(Caution range: 70-150, Abnormal range: 150 or more)
200
Abnormal
200
180 180
range
Abnormal
Value of analysis (ppm)
160 160

140 range 140
120 120 Caution
100 100 range
80 Caution 80
60 range 60
40 40
20 20
0 0
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 0 5,000 10,000 15,000 20,000
Service meter Service meter
(Analysis results of copper) (Analysis results of copper)

Cu(Caution range: 15-45, Abnormal range: 45 or more) Cu(Caution range: 25-70, Abnormal range: 70 or more)
150 150
135 135
120 Abnormal
120
105 105
range
90 Abnormal 90
75 range 75
60 60
45 45 Caution
30 Caution 30 range
15 range 15
0 0
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 0 5,000 10,000 15,000 20,000
[Actual measurement data in case of the [Actual measurement data in case of the
HD785-3] HD785-5]
(250 hours) ( 500 hours)
(Analysis results of chromium ) (Analysis results of chromium )
Cr(Caution range: 5-15, Abnormal range: 15 or more) Cr(Caution range: 10-25, Abnormal range: 25 or more)
30 30
Abnormal
27 27 range
Abnormal 24

24
21 21
range 18
18
15 15
Caution
12 12 range
9 Caution 9
6 range 6
3 3
0 0
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 0 5,000 10,000 15,000 20,000
(Analysis results of aluminum) (Analysis results of aluminum)

Al(Caution range: 8-16, Abnormal range: 16 or more) Al(Caution range: 10-25, Abnormal range: 25 or more)
50 50
45 45
40 40 Abnormal

35 35
30 Abnormal 30
range
25 range 25
20 20
15 15 Caution
10 Caution 10 range
5 range 5
0 0
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 0 5,000 10,000 15,000 20,000
[Actual measurement data in case of the [Actual measurement data in case of the
HD785-3] HD785-5]
(250 hours) ( 500 hours)
(Analysis results of silicon) (Analysis results of silicon)
Si(Caution range: 20-40, Abnormal range: 40 or more) Si(Caution range: 30-60, Abnormal range: 60 or more)
150 150
135 135
120 120

105 105 Abnormal
90 90
75 Abnormal range
75
60 range 60
45 45 Caution
30
Caution 30 range
15 15
0 range 0
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 0 5,000 10,000 15,000 20,000
(Analysis results of lead) (Analysis results of lead)

Pb(Caution range: 25-80, Abnormal range: 80 or more) Pb(Caution range: 40-120, Abnormal range: 120 or more)
150 150 Abnormal

135 135 range
120 Abnormal 120

105 range 105
90 90
75 75
60 60 Caution
45
Caution 45 range
30 30
15 range 15
0 0
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 0 5,000 10,000 15,000 20,000
In consideration of the above actual measurement data, we determined the standard values for
500 hour oil changing interval .
5. OTHER ANALYSIS
Besides wear analysis by INDUCTIVELY COUPLED PLASM SPECTROMETER (ICP), the KOWA
program also includes a test to detect the presence of water, fuel, and antifreeze in the oil. The
methodfor judging the analytical results obtained from such analyses is described below.
(1) Checking for Water Mixed in Lubricating Oil
1 Bad influence from water
If water is mixed in the oil, will deteriorate and emulsify, lose some of it lubricity, and possibly
cause other damage.
2 How water gets in the oil:
e Water can enter from the cooling system.
e Water can formed by the condensation of moisture in the oil pan due to change of tempera-
ture.
Very little water is produced by condensation. If you notice a sudden increase of water, it is
more reasonable to assume water leakage.
3 Method of checking for water
A hot plate is used to check to water. The existence of water is judged by seeing whether or
not bubbles of steam are produced by putting one or two drops of oil on a metal plate heated
to approx ............... 150: (300<).
The degree of bubbling is judged in comparison with a standard oil sample whose ratio of
water to oil is known beforehand (for instance, 0.2%, 0.1%).
4 Method of judgement
Applicable Water mixing

Condition of bubbles produced Measure to be taken
equipment ratio (%)
No change 0 ! None
Bubbles of approx. 0.5 mm are 0.05 ~ 0.1 ! Changing oil is advisable.
Engine e Work equipment
produced a little but soon disappear.

Bubbles of approx. 2 mm are 0.1 ~ 0.2 ! Changing oil is advisable.
produced, gather to the center, grow ! Check for water leakage.
3 ~ 4 mm but disappear soon.
Bubbles of 2 ~ 3 mm are produced 0.2 and more ! Changing oil at once.
and grow to 3 ~ 4 mm. This process ! Check for water leakage.
is repeated 2 ~ 3 mm times. If there
is too much water, violent bubbling
may occur.
No change 0 ! None
Swing machinery e Mission e Final
Bubbles of approx. 0.5 mm are 0.05 ~ 0.1 ! Changing oil is advisable.

produced a little but soon disappear.
Bubbles of approx. 2 mm are 0.1 ~ 0.5 ! Changing oil is advisable.
produced, gather to the center, grow ! Check for water leakage.
3 ~ 4 mm but disappear soon.
Bubbles of 2 ~ 3 mm are produced 0.5 and more ! Changing oil at once.
and grow to 3 ~ 4 mm. This process ! Check for water leakage.
is repeated 2 ~ 3 mm times. If there
is too much water, violent bubbling
may occur.
If excess of water is detected, you can wether it is due to cooling water or condensation. Find out if
antifreeze is used in the cooling water. If so, check the oil for antifreeze.
NOTE:
When the oil for the receiver tank of compressor (EC series) is used to lubricate the compressor, it
always absorbs the moisture contained in the air. As a result, it shows a certain amount of moisture.
For this reason, we cannot set any rules for the water cannot for receiver tank oil. Please keep to
the oil change intervals specified in the operation manual.
(2) Checking for Antifreeze (ethylene glycol) Mixed in Lubricating Oil
Antifreeze contains Na. Therefore, only the engine oil is analyzed. With the Shimazu ICP at
present used at the domestic analysis center, Na is detected, but this analysis can be used for
judging the approximate amount of antifreeze which has leaked in.
Standard value: Caution 50 ppm, Critical 100 ppm
1 Bad influence of antifreeze
As mentioned in section 8.1, water will cause the oil to lose some of its lubricity. Antifreeze
promotes the oxidation of oil. Varnish and deposits will increase, the cylinders and piston
rings will be subject to damage, and more breakdowns will occur.
2 How antifreeze gets in the oil.
If antifreeze is in the lubricating oil, it indicates that water is leaking from the cooling system.
If excess water is detected by the water checking method and if the existence of water is
confirmed by checking antifreeze, it is necessary to check the cooling system for faults.
3 Method of checking for antifreeze
A colorimetric analysis with the use of a chemical change is used to check for antifreeze.
In this method, if there is antifreeze in the oil a distinctive color will be produed by the
chemical change of the oil and the reagent. This method is only useful for checking for the
presence of antifreeze in oil, the percentage of antifreeze cannot be obtained.
Presence of antifreeze Measure to be taken

Colorless, light pink, or colors other No No need.
than the ones below.
Pink-purple in 10 minutes after Yes ! Changed oil.
reagent is added and stirred. ! Repair water leakage.
NOTE: There are two kinds of antifreeze, a permanent (ethylene glycol) and semipermanent
(mixture of ethylene glycol and alcohol).
Note the different content (%) of ethylene glycol when a sample is tested.
The content (%) of wthylene glycol is generally as follows:
Permanent type Approx. 98%
Semi-permanent type Approx. 50%
(3) Checking for Fuel Mixed in Lubrication Oil
1 Bad influence of fuel in the oil
Fuel, if a mixed in oil, will decreases the viscosity of oil and its lubricity.
2 How fuel gets in the oil
In some cases, the fuel does not burn completely in the combustion chamber.
The unburned fuel is scraped off by a piston ring and enters the oil pan. In addition, the fuel
injection pump on many of the latest models is lubricated by engine oil. There are many
opportunities for fuel to enter through this lubrication system.
3 Method of checking for presence of fuel.
Compare the flash point of new oil and sampled oil (fuel mixing oil) by means of a flash point
test. The percentage of fuel mixed in the oil can be judged from the degree of fall of the flash
point. A graph which correlates the fuel mixing ratio and flash point should be worked out
before testing.
In this connection, the flash points for various amounts of fuel mixed in SAE #10W and #30
(SAE #5 and #40 may also be needed) should be plotted.
For reference, Komatsu specifies the flash point of new oil as follows:
Specified flash point of various kinds of oil
Engine oil Specified flash point
SAE #5W Min. 180 : (356<)
SAE #10W 200 : (392<)
SAE #30W 220 : (428<)
SAE #40W 225 : (437<)
Example of fuel mixing ration - flash point

Fuel mixing ratio (%) Measure to be taken
0 None
If engine BOSCH pump is use - No particular
problem.
Less than 2%
If engine PT pump is use - Change oil.
Locate the cause of fuel mixing.
2% or more Change oil. Locate cause of fuel mixing.
NOTE: The usable limit for engine oil equivalent to SAE #30 is flash point of 180:(356<), and
fuel mixing ratio (diesel fuel) of 2 - 3%
6. INSPECTION PROCEDURE BY COMPONENTS
(1) Engine
(1)-1 Much powder from wear
When a large amount of wear powder is detected in the analysis, perform the following inspection
and take corrective actions without delay. The cause of the wear powder may be one or more of
the following: ingress of water or fuel, instrusion of dust, improper handling, or improper
maintenance. Therefore, make a thorough inspection of these potential causes.
(Note) A high concentration of wear powder may temporarily be found in some machines, even
though the analysis is performed periodically. If so, do not jump to the conclusion that it is
a sign of trouble with the engine and do not try to overhaul the engine. Instead, consider
the situation carefully by checking the oil at shorter intervals or studying the data obtained
from the following diagnosis.
r Elements and the location of defective parts (Typical examples)

Ana- Causes of excessive Combination of Assumed location
lyzed
result wear powder elements of trouble
1 Fe Timing gear, cam shaft,
rocker arm, FCD piston
2 Fe, Cr, Al Liner, piston ring, piston
Excessive wear powder
* Intake of dust (2 to 6, 8) 3 Cu, Pb Bearing metal (Main and au-

* Ingress of water (1, 3 to 7) xiliary), cam shaft bushing.
* Ingress of fuel (3, 4, 6) 4 Fe, Cu, Pb Bearing metal (Main and au-
* Improper handling xiliary), cam shaft bushing.
(1, 2, 6, 8) 5 Fe, Cr Liner, piston ring
* Improper maintenance 6 Fe, Cu, Cr, Al, Pb Bearing metal, liner,
(1, 3, 5) Piston ring, piston
7 Cu (Oil cooler)
8 Al Aluminum piston, turbo-
charger thrust bearing
* When both Al and Si are detected, dust has gotten into the engine.
When water has gotton into the engine because of a defective oil cooler, the concentration of
Cu particles may be higher.
r Diagnostic equipment required for the inspection
No. Description Part No. Remarks
1 Blow-by checker 799-201-1504
2 Compression gauge 795-502-1205
One available on the
3 Sound scope -
market
4 Filter cutter 799-801-2300
5 Hydraulic tester 799-101-5002
6 Radiator cap tester 799-202-9001
r Method of inspection
Select the appropriate inspection item for the table below according to the analyzed result and the
combination of elements, perform the inspection, and take corrective actions as needed
Inspection Equipment
No. Method of inspection
item to be used
1 Abnomal See if there is any abnormal noise. If there is locate its Sound scope
noise origin with a sound scope.
2 Foreign Drain the oil and see if it contains any foreign material Filter cutter,
material, or wear powder. Thoroughly check the wear powder visual inspec-
wear attracted by the magnet plug and, using a filter cutter. tion
powder check the foreign naterial and wear powder caught on
the inside of the filter.
Oil Accurately measure the oil pressure with an engine Hydraulic tester
3
pressure pressure measurement kit to see if the pressure is in
the normal range.
4 Blow-by Measure blow-by with blow-by checker to see if it is Blow-by
normal. checker
Compres- Measure the compression with a compression gauge Compression
5
sion and confirm that the compression is above the speci- gauge
fied value.
6 Oil con- Measure the oil consumption and confirm that the
sumption oil consumption is normal.
7 Leaks of Pressurize the inside of the radiator with a radiator Radiator cap
coling cap tester and inspect the cooling system for leakage. tester
water
r Inspection Items
Analyzed result Inspection i tems

Combination of elements 1 2 3 4 5 6 7
Fe K K
Fe, Cr, Al K K K K K
Cu, Pb K K K
Fe, Cu, Pb K K K
Fe, Cr K K K K K
Fe, Cu, Cr, Al, Pb K K K K K K
Cu K K
Al K K K
r Results of inspection and corrective actions
Result of inspection Corrective actions

No abnormalities found Continue sampling the oil and note
on any inspection item further developments. Give instruc-
tions to the customer about proper
maintenance.
Minor abnormalities Shorten the oil sampling intervals
found on one or more and analyze the samples to confirm
inspection items. that there are no abnormalities.
Teach the customers how to pre-
vent over-load operation.
Major abnormalities Thoroughly troubleshoot to locate
found on one or more the defective parts, and overhaul
inspection items. or repair as needed.
r Prevention of recurrence
Most troubles are caused by improper handling of the machine and poor oil management.
To prevent the recurrence of troubles, the customers must be given proper guidance on these
matters. Before giving guidance to customers, however, survey the items listed in the table below to
grasp the condition of the machine.
Items Survey item Method of survey

Operating Severe work Field surveys and interviews
conditions
Method of Warming up, idling before Survey of operating conditions, inter-
operation coming to a stop, over-load op- views
eration, rapid variations in load
Oil Viscosity and grade of oil Survey of operating conditions, inter-
management Ingress of foreign matter views
Maintenance Oil level, oil change intervals, Survey of operating conditions, inter-
and inspection periodic change of elements views
(1)-2 Contamination with water

The ingress of water will significantly degrade the properties of the oil, and will also result in
improper lubrication and rust. Special care must be taken to prevent serious trouble such as
burning of the bearing metal.
The oil analysis diagnosis is helpful in checking for ingress of water, but preventive measures
should be taken at an early stage by looking for symptoms of trouble in daily inspections. If the
ingress of water is detected (allowance: 0.2% or less) in the analysis, perform the inspections in
the following table and take corrective actions with out delay.
If antifreeze is being used and traces of it are found in the analysis, the water has gotten into the
engine from the cooling water system.
r Determining the location of water ingression (Inside the engine)
Location of
Classification Condition of defect
defective part
Cylinder head Body Cracks, Cavities
Cylinder head gasket
Blind plug Loose or dislocated expansion plug
Copper tubes (Sleeves) Cracks, looseness
Cylinder block, Body Cracks, cavities
liners Liner packing (O-ring) Deterioration, poor sealing effect, burn-
ing by overheating
Oil cooler Body Cracks, defective brazing
O-rings Deterioration, poor sealing effect
r Determining the location of water ingression (Outside the engine)
Location of
Classification Condition of defect
defective part
Oil management Containers for storage, Improper capping of containers, outdoor
(Storage, lubrica- location of storage storage, dirty oiler (funnel), dirty lubri-
tion) Maintenance of lubricating pump
cating equipment
Conditions of Weather Variations in temperature, long spell of
environment rain
and machines Out of service for a long Defective exhaust pipe (Defect in storage
time location)
Defective lubricating Defective cap, missing parts
system
Others When collecting samples Collecting samples in a careless manner
Vandalism when it is raining
r Diagnostic equipment required for the inspections

1 Handy hot plate 799-202-6000
2 Radiator cap tester 799-202-9001
r Method of inspection and corrective actions

Inspect as described below to determine whether the water has ingressed from the inside or
outside of the engine (if antifreeze is being used, the detection of antifreeze indicates internal
leakage). Then proceed to detailed inspections and take corrective actions if necessary.
Equipment
Method of inspection Result Judgement Corrective action
to be used
No leaks Ingress of water Change oil and check * Radiator
found from outside the for water with an oil cap tester
engine checker. Take correc-
Pressurize the inside tive actions to pre-
of the radiator with a vent recurrence.
radiator cap tester to Leaks found Leakage from Inspect as described
inspect for leakage in inside the engine in the following para-
the cooling system. (Cooling system) graph, locate the
defective part, and
take appropriate
actions.
r Preventing requrrence of water ingression from outside the engine

To prevent recurrence, perform the following inspection and give proper guidance to the customer.
Inspection items on engine body What to instruct the customer

Mounting condition and damage of ex- Proper procedure and location of storage
haust pipe
Mounting condition of oil filler cap or Item to handle lubricating equipment and
missing cap proper maintenance
r Inspections and countermeasures for leakage inside an engine
If leakage originates from inside the engine (from the cooling system), inspect as described below
and take the appropriate countermeasure.
Inspection item Method of inspection Assumed defect
lngression of oil into the Remove the radiator cap and confirm Cracks on oil cooler, poor seal-
cooling water (*) that the cooling water is not contami- ing effect of O-rings
nated with oil.
Blowing of gas back into Start the engine, remove the radiator Cracks on cylinder liners
the radiator cap, and confirm that no gas blows
back into the cooling water.
Blowing of water into ex- With the engine running, see if water Pitching cylinder liners or
haust system is being blown out from the exhaust cracks on liners.
pipe, If so, remove the exhaust mani-
fold and located the defective cylinder.
Low cool ing water level Check by the level gauge Pressure valve
* If oil has gotton into the cooling system, it must be rinsed out to prevent a secondary failure.
r Preventing recurrence
To prevent the recurrence of trouble, accurately locate the defective part and repair the defect.
After the repair, make the inspections described below and take corrective actions without delay if
any defect is predicted. In addition, give guidance to the coustomer if he is handling any items
improperly.
No. Daily inspections
Check the reverse side of the oil filler cap to see if it is damp with water or an emul-
1
sion.
2 Check the crank case breather cap to see if it is wet with water or an emulsion.
3 Does any water drain out when you loosen the drain plug to change the oil?
4 Is whitish exhaust gas visible when the engine is being started?
(1)-3 Intake of dust
The presence of dust accelerates the wear of machine parts (liners, piston, and rings wear out
quickly and bearings and crank shafts wear out later) and may lead to serious troubles.
Whenever any sign of dust intake is recognized, promptly find the cause and take corrective
actions.
The intake of dust can be identified by an increase in Si and Al content.
r Development of defects caused by intake of dust

Early stage Middle stage Later stage
intake of dust
Countermeasures Tool late (corrective actions
are possible required)
Trend of increasing Si, Al Wear powder of Fe, Cr, and Wear powder of Cu and Pb
content and wear powder Al will increase and the wear will increase and the wear of
h
(Fe, Cu, Cr, Al, and Pb) of liners, piston rings,and bearing metal and bushings
h
pistons will develop. will develop.
}
Exhaust gas has Oil pressure falls.
abnormal color Degrade-
tion of
In creased oil perform-
consumption ance
If the analyzed result indicates an intake of dust on the basis of an increase in Si, Al content,
inspect the following items so find the causes, and take proper corrective actions.
Inspection items
Method of inspection Corrective actions
(Parts)
Precleaner ! Inspect and confirm that dust deposits are ! Clean the dust cup.
below the specified level.
! Inspect and confirm that the body mount- ! Retighten the loose
ing is free from looseness and cracks. mounting.
! Inspect for looseness and damage on ! Replace or repair the
ejector pipe mounting. damaged parts.
Air cleaner * ! Inspect and confirm that elements are free ! Clean or replace the
from damage and improper fitting. elements.
! Inspect and confirm that the case mount- ! Retighten the loose
ing and cover are free from looseness and parts.
cracks. ! Install the missing
! Inspect and confirm that the dust indica- parts and replace or
tors is free from damage and missing parts. repair the damaged
parts.
Piping, joints * ! Inspect and confirm that the pipe mount- ! Retighten the loose
ings between the air cleaner and intake mounting.
monifold are securely tightened and that ! Replace or repair the
each hose is free from damage. damaged parts.
* Elaborate inspections and confirmations are required if a turbocharger is mounted. Carefully

inspect the air filter element for clogging. If the element is clogged, even slight looseness in the
piping system may cause dust to intrude.
If the intake of dust is diagnosed as a result of analysis even if there is no remarkable increase in Si, Al
content, inspect the following items and take appropriate actions, and give guidance to the customer if
any defect is found.
Inspection items Method of inspection Corrective actions

Management ! Confirm by interview or by field inspection ! While changing the oil,
and handling of that there is no fear of dust ingression based give guidance to the
oil (customers) on the conditions and location of oil storage. customer on the prop-
! Confirm by interview or by field inspec- er management and
tion that the lubricating equipment is handling of oil.
properly used and there is no fear of dust
ingression while oil is being added.
Defects in lubri- ! Inspect and confirm that the oil filler cap ! Install the missing
cating system and level gauge are properly placed in posi- parts, repair defective
tion and that there is no damage or missing parts, and change the
parts in the system. oil.
Job site and ! Confirm by interview or by field inspection ! While changing the oil,
operating con- that the job site is free from heavy dust. give guidance to the
ditions Inspect the operating conditions at the same customer on the main-
time. tenance required in
special operating con-
ditions.
To prevent recurrence, accurately locate the defective parts through inspection, and repair the
defective parts.
After completing the repair, make the above checks. Take corrective actions without delay whenever
any defect is predicted. For those items related to improper handling on the part of the customer,
give him proper guidance.
(1)-4 Contamination with fuel
Special attention must be paid to the ingress of fuel since it will lower the viscosity of the oil,
degrade the oil properties, result in poor lubrication, and cause such serious trouble as burning
of the bearing metal. If the analyzed result indicates the ingress of fuel, make the following
inspection to locate the defective parts and take corrective actions without fail.
r Determining the location of fuel ingression
Manu-
Injector Defective part (condition)
facturer
! Connection and connection gaskets
! Wear of injector body and plunger
Cummins engine
Flange type ! Broken injector cup

! Defective O-ring for injector cup
! Auxiliary starting unit
! Defective O-ring on injector mounting
Cylindrical ! Wear of injector body and plunger
type ! Broken injector cup
! Fuel injection pump
} Forced lubri-
Other than
cation type
Cummins
! Feed pump
engine
Direct injection
! Piping inside nozzle holder cylinder head
type
! Defective nozzle holder and nozzle
r Diagnostic equipment required for inspection

No. Description Part number Remarks
1 Fuel leak checker 799-203-7000
If the ingress of fuel is indicated by the analyzed results (allowable value: 2 to 3%), inspect for the
following items, locate any defective parts, and take appropriate measures.
The method of inspection described below applies to both Cummins engines with flange-type injector
and KOMATSU engines of which have fuel piping in the cylinder head.
The method of inspection also applies to other engines to check the valve opening pressure in the
nozzle and for fuel leakage.
r Inspection items and method

Classifi-
Inspection item Method of inspection
cation
Injector assembly Pressurize the injector fuel lines with a fuel leak
Cummins
engine
and connection time.

Auxiliary unit Remove the nozzles and check for leakage.
Feed pump Pressurize the inside of the pump with a fuel leak
(Forced lubrication type) checker, and check for leakage based on the leak
Non-Commins engines
time.
Nozzle holder assembly Pressurize the nozzle holder fuel lines with a fuel
and piping leak checker, and check for leakage on each
cylinder based on the leak time.
Auxiliary starting unit Remove nozzles and check for leakage.
Fuel injection pump Blind the inlet and outlet of the lubricating oil
(Forced lubrication type) pipe, and check for the ingress of fuel into the
cam chamber as the operating time lapses.
r Result of inspection and corrective actions
Result of inspection Corrective action
No leaks found on any items Change the oil and check for ingress of fuel.
Symptoms of leakage found Thoroughly check the part where leakage was
confirmed, then disassemble the part for repair.
No symptoms of leakage found on Change ths oil and check for the ingress of fuel
any items by means of an oil checker.
Symptom of leakage found Thoroughly check the part where leakage was
confirmed, and disassemble the part for repair.
* In order to perform the diagnosis efficiently, the order of inspection items should be determined
by taking into account the predicted amount of fuel injection and lapse of operating time.
After completing the repair, check the part again with a fuel leak checker to confirm that the leak
has been completely sealed.
(1)-5 Defective rear seal (engine)

If a defective rear is indicated by the analysis, confirm it by performing the following inspection,
and take corrective actions as needed. The prediction of a defective rear seal is based on the
presence of a lot of wear powder of Fe, Cu, and Si in the engine oil.
The excessive wear powder is due to entrance of oil from the main clutch and torque converter
into the engine.
r Method and location of inspection
Location of inspection Method of inspection
Engne oil Inspect carefully for variation in oil level. (If the oil
is decreasing, check the color of the exhaust gas to
see if it is related to abnormal oil consumption.)
TORQFLOW transmission oil Inspect carefully for variation in oil level.
Main clutch oil Check the oil for remarkable contamination and
abnormal odor.
r Result of inspection and corrective actions

No variation in oil level in either Continue collecting oil samples to observe future
system. No contamination or trends. Check the oil level periodically to see how
abnormal odor detected. it develops. Change the oil earlier than the normal
schedule.
Variation in oil level is observed Disassemble the engine, replace or repair the rear seal,
in both systems, and contamina- and change the oil.
tion and abnormal odor are re-
cognized.
r Actions to be taken after the repair

If inflow of engine oil into the main clutch housing or torque converter housing is indicated, drain all
the oil and flush the inside of the main clutch or torque converter to prevent secondary trouble.
The periodic oil check should be continued even after the repair in order to confirm that the defect
is completely eliminated.
Since defective rear seals are closely associated with the contamination or degradation of oil,
proper maintenance (such as periodic oil changes) must be strictly observed. Give proper guidance
on this matter to the customer.
(2) MAIN CLUTCH
If a lot of powder from wear is found in the analysis, make the inspection described below and
take appropriate measures promptly. An increase in wear powder may be caused by degraded
oil, ingression of water and dirt, or improper handling of the machine (slippage of the main
clutch). Check these items during the inspection.
r Combination of wear elements and assumed location of defective parts. (Typical examples)
Analyzed Combination
Cause of wear powder Assumed defective part
result of elements
Much ! Ingress of water Fe Pressure plate, flywheel, gear pump
wear ! Ingress of dirt Fe, Cu Clutch plate, disc (Medium and
powder ! Improper maintenance large-size machines)
! Improper handling
Fe, Cr Bearing, gears, gear pump
(slippage of clutch, etc.)
Si (Cu) Clutch disc, etc. (Small-size machines)
* If the ingress of water is caused by a defective oil cooler, a high concentration of Cu wear powder
may be detected.
r Diagnostic equipment for inspection
1 Sound scope - Available on the market
2 Push-pull scale - Available on the market 0 ~ 25 kg
4 Treading force meter - 0 ~ 80 kg
5 Stopwatch - Available on the market
r Methods of inspection
Select the inspection items from the following table according to the combination of wear elements
obtained from the analyzed results, inspect the item selected, and take corrective actions as required.
Equipment
No. Inspection items Methods of inspection
to be used
1 Abnormal noise See if there is any abnormal noise. If so, check Sound scope
its source by inspecting with a sound scope.
2 Foreign matter (1) Drain oil and closely examine the foreign Visual
Wear powder matter and wear powder in the oil. See if any inspection
wear powder is attracted by the magnet plug.
(2) Closely examine the foreign matter and wear
powder caught in the strainer.
3 Slippage of Check for slippage of the clutch in the following Stopwatch
clutch manner.
4 Operating force Measure the operating force of the main clutch Push-pull
of main clutch lever (pedal) with a push-pull scale (tread force scale, tread
lever (pedal) meter) while the engine is idling and inspect for force meter
defects such as poor performance of the main
clutch pump.
5 Boost pressure If the operating force of the main clutch lever Hydraulic
of main clutch (pedal) is greater than the specified value, tester
measure the main clutch booster pressure with
a hydraulic tester.
r Inspection items r Result of inspection and corrective actions
Combina- Inspection item Result of inspection Corrective actions
tion of No defects found on any Change the oil and continue
elements 1 2 3 4 5
inspection items. sampling the oil to observe the
Fe K K K !
future trends.
Fe, Cu K K K
Clutch slippage and wear See if there are any defective
Fe, Cr K K K !
of the plate disc are parts by adjusting or disassemb-
Si (Cu) K K K assumed. ling the clutch, and repair as
K: Rapid increase or high required.
concentration Poor pump performance Adjust the booster pressure or
!: Concentration may be- or booster pressure drop replace the pump assembly.
come higher is assumed.
Pinpoint the causes of the defects in the foregoing inspection and repair all defective parts.
Instruct the customer on the importance of daily inspections and the necessity of proper maintenance.

The properties of the oil will be remarkably degraded by the ingress of water, resulting in poor
lubrication and rust. The ingress of water will accelerate wear of discs and plates or cause
improper operation of the booster valve.
If the ingress of water is indicated, inspect in the following manner and take corrective actions
promptly. If anti-freeze is being used, the detection of antifreeze in the oil analysis may be
regarded an indication of entry of cooling water, which in turn means that the oil cooler is
defective.
r Ingress of water
Classification Location of defect Condition of defect
Inside of system Oil cooler (for Cooling water enters through a damaged or
(cooling water) water-cooled cracked cooler element or tubing, or because
type only) or defective O-rings.
Outside of Condition of oil Water gets into the oil while the oil is in storage
system management (depending on its location and condition) or
(rainwater, etc.) Handling of oil when adding oil with lubricating equipment such
(by customer) as an oiler. The inflow of the water, however, is
comparatively small in most cases.
Oil filler cap Rainwater gets into the oil because the filler cap
is missing or damaged.
Others When collecting Careless sampling in the rain.
oil samples
r Diagnostic equipment for inspection (Reference)
1 Oil leak tester 799-301-1500 To use the tester, attachments must be made.
r Inspection items r Results of inspection and corrective actions
Steps Inspection items Result of inspection Corrective action
1 Inspect for defects such as a No defective items Change oil as soon as pos-
missing or damaged oil filler found on any inspection sible (immediately if conta-
cap. items. (Temporary minated with a large amount
2 Inspect for big oil leaks. ingress of water from of water) and observe the
outside) future trend by continuing to
3 See if any oil is floating on the sample the oil.
radiator water.
(Reference) The cooling water Abnormalities found on Repair defective parts and
will be contaminated with oil if inspection items other change the oil. Confirm that
the oil cooler is defective. than the oil cooler. the ingression of water has
(Ingress of water from been completely eliminated
4 Conduct a leak test on the main outside) by continuing to take oil
clutch cooler (with an oil leak samples after the repair.
tester). The test may be
Abnormalities found on Closely inspect and repair
conducted while the main clutch
the inspection items for the oil cooler.
cooler is either mounted on or
the oil cooler. (Ingress After the repair, recheck
dismounted from the machine.
of water from inside the confirm that it is free
system) fromleaks.
After confirming that all leaks have been repaired and that there is no more ingression of water,
drain the oil and flush the system to remove the residue in order to prevent secondary trouble. If oil
has entered the cooling system because of a defective oil cooler, flush the cooling system as well.
If any troubles occur in this system, get a good understanding of the trouble before making the
repair. If water has gotten into the system from outside, clarify the cause and take corrective
actions to prevent occurrence. If the ingress of water is caused by one of the following, instruct the
customer on proper preventive actions.
e The fresh oil contains some water because of improper storage.
e Water gets into the oil while adding oil with defective lubricating equipment such as an oil
container.
(2)-3 Contamination with dust

Contamination with dust can result in significant degradation of the oil performance, leading to
improper lubrication and accelerated wear of gears, bearings, plates, and discs.
If contamination with dust is indicated by the oil analysis, thoroughly inspect the following items
and take corrective actions.
r Assumed location of dust ingression

Defective part Condition of trouble
Oil filler cap Dust enters because the filler cap is missing or damaged.
Dust enters because of a broken breather or clogged breather
Breather
element.
Dust gets into the oil while the oil is in storage (because of its
Condition of oil management
location and conditions) or when adding oil with lubricating
Handling of oil (by customer)
equipment such as an oil container.
Other
Careless oil sampling at dusty places.
(when collecting oil samples)
Steps lnspection items Result of inspection Corrective action
1 See if there are any No abnormalities found on Change the oil soon
defects such as a missing any inspection items. (immediately if contaminated
filler cap or other damage. with a lot of dust) and observe
2 See if the breather and the future trend by continuing
breather element are to collect oil samples.
damaged or clogged.
3 lnspect for big oil Ieaks. Abnormalities on some Repair the defective parts and
inspection items. change the oil. Take more oil
samples to confirm that all
defective parts are repaired.
* When the oil is drained, closely examine the foreign matter and wear powder in the oil and also the
wear powder attracted by the magnet plug. In addition, closely examine the foreign matter attached to
the strainer.

If a large amount of dust or excessive contamination of the oil is found, drain the oil and flush the
inside of the system.
repair. If the trouble was caused by poor oil management or improper handling of the oil, instruct
the customer on the proper methods of oil management and handling.
(3) Direct Transmission
If a lot of powder from wear is found in the analysis, make the inspection described below and
take corrective actions promptly. An increase in wear powder may be caused by the entry of
water or dust. Therefore, check these possible causes as well when taking corrective action.
r Combination of wear elements and assumed location of defective parts
For structural reasons, most of the wear powder detected in the analysis of the direct transmission
is Fe. Although a little Cu and Cr powder may be found in the analysis, the amount is usually so
small that it is hard to predict the wear level.
Thus it is assumed that defects are located on gears and bearings.
AnaIyzed Combination of Assumed defective
Causes of wear powder
resuIt elements parts
Much wear ! Ingress of water Fe (Cr) Gears and
powder ! Ingress of dust bearings
! Improper maintenance
Cu Bushing
! Improper handling
(improper adjustment of inertia brake)
" Diagnostic equipment for inspection
" Inspection items and methods
lnspection Method of inspection Equipment
items required
Abnormal See if there is any abnormal noise. If so, Iocate its source by Sound scope
noise inspecting with a sound scope.
Foreign Drain the oil and closely examine the foreign matter and wear powder Visual inspection
matter in the oil. See if any wear powder is attracted by the magnet plug.
Wear Check the amount of oil.
powder
" Result of inspection and corrective actions
No trouble found on any inspection items. Change the oil and continue sampling the oil to observe the
future trend.
Abnormalities found oh one or more After disassembling the system to locate defects, repair as
inspection items. needed. Find the causes of the trouble.
Pinpoint the cause of the trouble and eliminate it. The following items are considered to be factors
which accelerate the wear of parts in the system. Instruct the customer on these maters.
Items Development of accelerated wear

lmproper maintenance Failure to make the periodic oil change at the regular interval will
cause deterioration of the oil, resulting in poor lubrication and
accelerated wear of the parts.
lmproper handling Improper adjustment of the inertia brake will make ft difficult to
(daily inspection) shift speed, cause noise in the gears, and lead to accelerated
wear and damage of gears.
The properties of oil will be remarkably degraded by the ingress of water, resulting in poor
lubrication and rust, and accelerated wear of the gears and bearings. If the entry of water is
indicated by the oil analysis, inspect as described below and take corrective actions promptly.
r Assumed location of water ingression

Outside of system Condition of oil Water gets into the oil while the oil is in storage
(such as rainwater) management, handling of (because of its location and conditions) and
oil (by customer) when adding oil with lubricating equipment such
as an oil filler. The inflow of water is
comparatively small.
Oil filter cap Rain water gets into,the oil because the oil filter
cap is missing or damaged.
Others When collecting oil Careless oil sampling in the rain.
samples
Steps lnspection items Result of inspection Corrective actions
1 See if there are defects No abnormalities found on Change the oil soon
such as a missing or the inspection items. (immediately if contaminated
damaged oil filler cap. (Temporary ingress of water with a large amount of water)
2 See if there are big oil from the outside) and continue taking oil samples
leaks. to observe the future trend.
Abnormalities found on Repair the defective parts and
the inspection items. change the oil. After the repair,
continue taking oil samples to
confirm that the entry of water

is completely eliminated.
Structually, large amounts of water seldom get into the direct transmission. Nevertheless, it is
conceivable that a lot of water can temporarily get into the system under some circumstances. If
so, drain the oil, flush the inside of the system, and remove as much of the residual water as
possible to prevent secondary trouble.
The recurrence of trouble with this system can be prevented by finding the exact location of defects
and repairing the trouble completely. If the inspection shows that the ingress of water was caused
by one of the following circumstances, instruct the customer on proper management and handling
of the oil.
e The water gets into the oil while adding oil with defective lubricating equipment, such as an oil
filler.
Contamination with dust can result in significant degradation of the oil performance, leading to
poor lubrication and accelerated wear of gears and bearings. If contamination with dust is
diagnosed, inspect the location of entry and take proper corrective actions.
Since dust gets into the direct transmission in the same way as water, follow the method of
inspection and corrective actions described for contamination with water.
e When the oil is drained, closely examine the foreign matter and wear powder in the oil, and also
for wear powder attracted by the magnet plug.
(4) Steering Clutch System
If a lot of wear powder is found in the analysis, make the inspection described below and take
proper actions promptly. An increase in wear powder may be caused by entry of water, entry of
dust, poor handling, or improper maintenance. Therefore, check these items during the inspection
and take corrective actions if necessary.
r Combination of wear elements and assumed location of defective parts (Typical examples)
Analyzed resuIt Causes of wear powder Combination of elements Assumed defective parts
Much wear ' Entry of water Fe Gears and bearings
powder ' Entry of dust Fe, Cu Clutch plate, clutch disc
' Poor handling Cu* Bushing, seal ring
' Improper maintenance
Fe, Si Brake drum, brake band
Fe, Cr Gears, bearings, seal ring
* If the entry of water is caused by a defective oil cooler, a high concentration of Cu wear powder
may be detected.
3 Stop watch - Available on the market
Select the appropriate inspection item from the following table according to the combination of wear
elements obtained from the analyzed result, inspect the selected item, and take corrective actions
as required.
No. lnspection items Method of inspection Equipment to be used
1 Abnormal noise See if there is any abnormal noise. If so, check Auditory inspection or
its source by inspecting with a sound scope. sound scope
2 Foreign matter (1) Drain the oil and closely examine the Visual inspection
Wear powder foreign matter and wear powder in the oil.
See if any wear powder is attracted by the
magnet plug.
(2) Remove the filter and closely examine the
foreign matter and wear powder caught by
the filter.
No. lnspection items Method of inspection Equipment to be used
3 Slippage of clutch See if the steering clutch is slipping. With the Stopwatch
engine running at full speed, measure how long
it takes for the engine to stop.
4 Effect of brake See if the steering brake is working well. Visual inspection
With the engine running in the maximum speed
range, measure the time required for the Stopwatch
engine to stop. Inspect the wear level of the
brake linings.
5 Oil pressure Measure the steering clutch pressure with a Hydraulic tester
hydraulic tester.
Combination lnspection item Result of inspection Corrective actions
of elements 1 2 3 4 5 No defects found on any Continue taking oil samples to
Fe # # inspection items. observe the future trend. Instruct
Fe, Cu # # # # the customer in proper
# # #
maintenance .
Cu
Fe, Si # # # Minor abnormalities found on Shorten the oil sampling interval
Fe, Cr # # # at least one of the inspection and make the analysis again to
items. see if the abnormalities are still
present. Instruct the customer in
prevent overload operation.
Major abnormality found Confirm the location of the
on at least one inspection defective part by more detailed
Item. troubleshooting . Disassemble
and repair the defective part.
r Actions to be taken after the repair and preventing recurrence
After the repair, change the oil and flush the system, if necessary, to prevent secondary trouble
caused by the residual dust.
To prevent recurrence, find the exact cause of trouble, repair the defect, and instruct the customer
about daily inspections and proper maintenance.
Water contamination will significantly degrade the oil properties and will cause poor lubrication
and rust, resulting in accelerated wear of gears, bearings, plates, and discs.
Water has an especially adverse effect on the steering control valve. If the entry of water is
diagnosed, inspect as described below and take corrective actions promptly. If antifreeze is
being used, the detection of Na in the KOWA may be regarded as an indication of the entry of
cooling water, which in turn means that the oil cooler is defective.

Inside of system Oil cooler (for watercooled Cooling water enters through a damaged or cracked
(Cooling water) type only) cooler element or tube, or because of defective O-
rings.
Outside of system Condition of oil management Water gets into the oil while the oil is in storage
(rainwater, etc.) Handling of oil (by customer) (because of the location and condition of
storage) or when adding oil with lubricating
equipment such as an oil filler. The inflow of
water in this case is comparatively small .
Oil filler cap Rainwater gets into the oil because the oil filler
cap is missing or damaged.
Others When collecting oil samles Careless oil sampling in the rain.

Steps Inspection items Result of inspection Corrective actions
1 lnspect for defects such as a No abnormalities found on any Change the oil as soon as
missing or damaged oil filler inspection items (temporary possible (immediately if a lot of
cap. ingress of water from outside) water has gotten into the oil) and
2 Inspect for big oil leaks observe the future trend by
(especially on the upper part continuing to sample the oil.
of the steering case).
3 See if any oil is floating on the Abnormalities found on Repair the defective parts and
radiator water. inspection items other than change the oil. Continue to take
( Reference) If the oil cooler is the oil cooler. ( Ingress of oil samples even after the repair
defective, oil will get into the water from outside) to confirm that the ingression of
coo I ing water. water is completely eliminated.
4 Conduct a leak test on the
steering cooler with an oil leak Abnormalities found on the Closely inspect the oil cooler
tester. The test may be inspection items for the oil system and repair as required.
conducted while the steering cooler. After the repair, recheck the oil
cooler is either mounted or ( Ingress of water from outside cooler to see if it is free from
dismounted from the machine.
the system) leaks.
After the repair, confirm that the leakage of water has stopped. If the presence of a lot of oil has
caused the oil to emulsify, drain the oil and flush the inside of the system to remove as much of the
residual content as possible to prevent secondary trouble. Likewise, if oil has gotten into the cooling
system because of a defective oil cooler, flush the cooling system.
The recurrence of trouble in this system can be prevented by precisely locating the defects and
completely repairing the trouble. If water has come from outside the system, find its cause and take
appropriate action to prevent recurrence. If the ingress of water is caused by one of the following,
instruct the customer on proper management and handling of the oil.
* The fresh oil contains some water because of improper storage.
* Water gets into the oil while adding oil with defective lubricating equipment such as an oil filler.
Contamination with dust will degrade the oil properties to a considerable extent, lead to poor
lubrication, and cause accelerated wear of gears, bearings, plates, and discs. If contamination
with dust is diagnosed, inspect the following items and take corrective actions promptly.
Oil filler cap Dust enters because the oil filler cap is missing or damaged.
Breather Dust gets into the oil because of a damaged breather or
clogged breather element.
Condition of oil management Dust gets into the oil while the oil is in storage (due to the
Handling of oil location and conditions of storage) or when adding oil with
(by customer) lubricating equipment such as an oil filler.
Others (when taking an oil sample) Careless oil sampling fn a dusty area
Steps Inspection item Result of inspection Corrective actions
lnspect for defects such as a No abnormalities found on Change the oil soon
1 missing or damaged oil filler any inspection items. (immediately if contaminated by
cap. a large amount of dust) and
Inspect the breather and
observe the future trend .
2 breather element for damage
and clogging. Abnormalities found on Repair the defective part and
one of the inspection change the oil.
Inspect for big oil leaks items. Continue taking oil samples
(especially the upper part of after the repair to confirm that
3 the defective is completely
the steering case) .
repaired.
* When the oil is drained, closely examine the foreign matter and wear powder in the oil, and also
the wear powder attracted by the magnet plug. Also, examine the foreign matter caught in the
strainer.
If a large amount of dust has gotten into the oil, drain the oil and flush the system to remove as
much of the residual dust as possible to prevent secondary trouble.
repair. If the trouble was caused by poor oil management or improper handling of oil, instruct the
customer on the proper method of oil management and handling.
(5) TORQFLOW System (Torque Converter, TORQFLOW Transmission, and
Steering Clutch)
(5)-1 If a lot of wear powder is found in the analysis, make the inspection described below and take
proper actions promptly. An increase in wear powder may be caused by ingression of water and
dust, faulty operation, or improper maintenance. Therefore, check these items during the inspection
(Note) Some machines may temporarily register a high concentration of wear powder, even if the
oil is analyzed periodically. If this happens, do not disassemble the system on the
assumption that the analyzed result indicates a defect. Instead, consider the situation
carefully and recheck the oil samples at shorter intervals, or else confirm the defect with
some substantiating data obtained from the following diagnosis.
r Combination of wear elements and assumed location of defective parts (Typical examples)
Analyzed Causes of wear powder Combination of
Assumed defective part
resuIt elements
Fe, Cu Clutch plate, clutch disc (transmission,
Much ! Ingress of dust steering)
wear ! Ingress of water Fe Gears, bearings, piston housing
powder ! Improper maintenance Fe, Cr Gears, bearings, seal rings, piston
! Poor handling housing
Cu * Thrust washers, seal rings
Al Torque converter, piston (wheel loader)
Fe, Si Brake drum, brake band
* If the ingress of water is caused by a defective oil cooler, a high concentration of Cu wear powder
may be detected.
2 Multi-tachometer 799-203-9000
3 HydrauIic tester 799-101-5002
4 Filter cutter 799-801-2300
5 Stopwatch - Available on the market
elements, obtained from the analyzed result, inspect the selected item, and take corrective actions
as required.
No. lnspection item Method of inspection Equipment to be used
1 Abnormal noise See if there is any abnormal noise. If so, check its Sound scope
source with a sound scope.
2 Foreign matter, wear (1) Drain the oil and closely examine the foreign Visual inspection
powder matter and wear powder in the oil. See if any Filter cutter
wear powder is attracted by the magnet plug.
(2) Remove the filter (use a filter cutter for a
cartridge-type filter) and closely examine the
foreign matter and wear powder caught by the
filter.
(3) Drain the oil from the torque converter. Closely
examine the foreign matter and wear powder in
the oil and that caught by the torque converter
strainer.
3 Torque converter stalling Measure the engine r.p.m. with a multi-tachometer Multi-tachometer
when the torque converter is stalled and confirm
that it is in normal condition.
4 Hydraulic pressure (1) Measure the modulating pressure of the HydrauIic tester
transmission with a hydraulic tester.
(2) Measure the steering clutch pressure with a
hydraulic tester.
(3) Measure the boost pressure of the steering
brake with a hydraulic tester. Measure the
pressure at the torque converter inlet and outlet,
if necessary.
5 Slippage of clutch See if the transmission clutch or steering clutch are Visual inspection
slipping by making the torque converter stall. Stopwatch
6 Effectiveness of brakes See if the steering brake functions properly by Visua inspection
making the torque converter stall. Also, inspect for Stopwatch
wear of the brake linings.
7 Time lag Use a stop watch to measure the time lag between Stopwatch
shifting the lever from neutral position to every
speed stage of the transmission.
8 Amount of leakage from Remove the drain plug, drain the oil from the torque
torque converter converter case (oil leaked into the torque
converter), and measure the quantity.
Combination lnspection item
of elements 1 2 3 4 5 6 7 8
Fe, Cu # # # # # No defects found on Continue taking oil samples to
Fe # # # any inspection items. observe the future trend.
Fe, Cr # # # # # Instruct the customer in proper
Cu # # # # maintenance.
Al # # # # # Minor abnormalities Shorten the oil sampling interval
Fe Si # # # are found on at least and make the analysis again to
one inspection item. see if the abnormalities are still
present.
Instruct the customer in how to
prevent overload operation .
Major abnormalities Confirm the location of the
found on at least one defective part by more detailed
inspection item. troubleshooting .
Disassemble and repair the
defective part.

e After the repair, change the oil and flush the system, if necessary, to prevent secondary trouble
caused by residual foreign matter.
e To prevent recurrence, find the exact cause of trouble, repair the defect, and instruct the customer
about daily inspections and proper maintenance.
Contamination with water will significantly degrade the oil properties and will cause poor lubrication
and rust, resulting in the accelerated wear of gears, bearings, plates, and discs. Water has an
especially adverse effect on control valves. If the entry of water is diagnosed, inspect as described
below and take appropriate actions promptly. If anti-freeze is being used, the detection of anti-
freeze by the oil analysis can be regarded as an indication of the entry of cooling water, which in
turn means that the oil cooler is defective.
Classification Location of defect Condition of trouble
Inside of system (cooling Oil cooler Cooling water enters through a damaged or
water) (for water-cooled type only) cracked cooler element or tubes, or
because of defective O-rings.
Outside of system Condition of oil management Water gets into the oil while the oil is in
(rainwater, etc.) Handling of oil storage (because of the location or
(by customer) condition of storage) or when adding oil with
lubricating equipment such as an oil filler.
The inflow of water in this case is
comparatively smalI.
Oil filler cap Rain water gets into the oil because the oil
filler cap is missing or damaged.
Others When collecting oil samples Careless oil sampling in the rain.

Step Inspection item Result of inspection Corrective actions
1 lnspect for defects such as a No abnormalities found on Change the oil as soon as
missing or damaged oil filler cap. any inspection item possible (immediately if a lot
(temporary ingression of of water has gotten into the
2 Inspect for big oil leaks water from outside). oil) and continue collecting oil
(especially on the upper part of samples to observe the future
the steering case). trend.
radiator water. inspection items other than change the oil. Continue to
( Reference ) the oil cooler. take oil samples even after
If the oil cooler is defective, oil (Ingress of water from the repair to confirm that the
will get into the cooling water. outside) ingression of water is
completely eliminated .
4 Conduct a leak test on the torque Abnormalities found on the Closely inspect the oil cooler
converter cooler and steering inspection items for the oil system and repair as
cooler (with an oil leak tester). cooler. (Ingress of water from required. After the repair
The test may be conducted while inside the system) recheck the oil cooler to
the coolers are either mounted confirm that it is free from
on or dismounted from the leaks.
machine.
* After the repair, confirm that the leakage of water has stopped. If the presence of a lot of oil has
caused the oil to emulsify, drain the oil and flush the inside of the system to remove as much of the
residual content as possible to prevent secondary trouble. Likewise, if oil has gotten into the
cooling system because of a defective oil cooler, flush the cooling system.
completely repairing the trouble. If water has come from outside the system, find its source to
prevent recurrence. If the ingress of water is caused by one of the following, instruct the customer
on proper management and handling of the oil.
e Water gets into the oil while adding oil with defective lubricating equipment such as an oil filler.
Relatively little dust enters the TORQFLOW system while the vehicle is in operation.
Most dust gets into the system through carelessness during oil changes.
This is shown by the data obtained from previous analysis.
If the analysis indicates the entry of dust, closely inspect for the following items and take appropriate
measures.
Oil filler cap Dust enters because the oil filler cap is missing or damaged.
Breather Dust enters because of a damaged breather or clogged
breather element.
Oil management Dust gets into the oil while the oil is in storage (due to the
Handling of oil (by customer) location and conditions of storage) or when adding oil with
lubricating equipment such as an oil filler.
Others (when taking an oil sample) Careless oil sampling in a dusty area.

Steps Inspection item Result of inspection Corrective actions
1 lnspect for defects such as a No abnormalities found on any Change the oil soon
missing or damaged oil filler inspection items. (immediately if contaminated by
cap. a large amount of dust) and
2 Inspect the breather and observe the future trend.
breather element for
damage and clogging. Abnormalities found on one of Repair the defective part and
the inspection items. change the oil.
3 lnspect the component parts Continue taking oil samples
for big leaks (especial the after the repair to confirm that
upper part of the steering the defective is completely
case). repaired.

If a large amount of dust has gotten into the system or if the oil is very dirty, drain the oil and flush
the inside of the system if necessary.
repair. If the trouble was caused by poor oil management or improper handling of oil, instruct the
customer on the proper method of oil management and handling.
(6) Final Drive Unit
appropriate actions promptly. An increase in wear powder may be caused by the ingression of
water and dust. Therefore, check these items during the inspection and take corrective actions if
necessary.
(Note) Some machines may temporarily register a high concentration of wear powder, even if the
oil is analyzed periodically. If this happens, do not disassemble the system on the assumption
that the analyzed result indicates as defect. Instead, consider the situation carefully and
recheck the oil samples at shorter intervals, or else confirm the defect with some
substantiating data obtained from the following diagnosis.
r Combination of wear elements and location of defective parts (Typical examples)
Combination of
Analyzed resuIt Causes of wear powder Assumed defective part
elements
Much wear ! Ingress of dust Fe, Cr Gears, bearings, floating seals
powder ! Ingress of water Cr Floating seals, bearings
! Poor handling Fe, Cu, Cr Gears, bearings, plain bearings, bushing,
! Improper maintenance thrust washers, floating seals
Cu Plain bearings, bushing, thrust washers

1 Fiberscope - Available on the market
2 Oil leak tester 799-301-1500
as required.
No. lnspection item Method of inspection Equipment to be used
1 Abnormal noise Closely inspect for abnormal noise Auditory inspection
2 Foreign matter Wear Drain the oil. Closely examine the foreign Visual inspection
powder matter and wear powder in the oil, the wear
powder caught by the magnet plug, and foreign
matter and wear powder accumulated around
the drain outlet inside the case.
3 Condition of damage Closely inspect the internal gears and bearings Fiberscope
inside the case for damage by inserting a fiberscope through (Camera)
the drain hole or lubricating hole. Confirm the Visual inspection
defective parts by taking photographs of the
inside of the case, if necessary.
4 Air-tightness of floating Check for defective floating seals by Oil leak tester
seals pressurizing the inside of the case with an oil
leak tester.

Analyzed resuIts lnspection items
Combination of Resu It of inspection Corrective actions
elements 1 2 3 4
Fe, Cr # # # # No defects found on Continue taking oil samples to observe the
Cr # # # any inspection items. future trend. Instruct the customer in proper
Fe, Cu, Cr # # # # maintenance.
Cu * # # Minor abnormalities Shorten the oil sampling interval and make
are found on at least the analysis again to see if the
one inspection item. abnormalities are still present. Instruct the
customer in how to prevent overload
operation.
Major abnormalities Confirm the location of the defective part
found on at least one by more detailed troubleshooting.
inspection item. Disassemble and repair the defective part.
* (In rare cases, a lot of Cu may be present owing to the ingress of oil from the steering clutch
case.)
In most cases, an increase in wear powder is caused by external factors (ingress of water or dust)
in the initial stage. Eventually, the wear powder will increase even more. To prevent recurrence,
therefore, the ingression of dust and water must be eliminated by making periodic inspections,
changing oil at shorter intervals, finding the cause of ingression, and taking corrective actions.
Contamination with water will significantly degrade the oil properties and will cause poor lubrication
and rust, resulting in the accelerated wear of gears and bearings. If the ingress of water is
diagnosed, inspect as described below and take appropriate measures promptly. In the final
drive unit, the ingress of water is usually accompanied by that of dust and dirt.
Defective part Condition of defect
Floating seal Depending on operating conditions (such as working in water, etc.)
, water may enter through seals if the floating seals are defective.
In this case, oil will also leak.
Oil filler, inspection window Water gets into the case because of improper fitting of the oil filler
plug or inspection plug, or because of a defective O-ring. The
ingress of water often occurs when the machine is operated in the
rain or water.
Breather The dust accumulated at the breather mount forms itself into a
crucible, water comes in the form of rainfall. The ingress of dust
accompanies the water at the same time.
Oil management and handling (by Water gets into the oil while the oil is in storage (because of the
customer) location and condition of storage) or when adding oil with a
lubricators. In most cases, only a little water enters.
Others (when collecting oil samples) Careless oil sampling in the rain

1 Oil leak tester 799-301-1500
r Method of inspection r Result of inspection and corrective actions
Corrective actions
Step Method of inspection Result of inspection
1 Closely inspect the breather No abnormalities found on Change the oil and continue
mount for a large deposit of dust any inspection items taking oil samples to observe the
or looseness. See if the breather future trend . Instruct the
is clogged. customers to clean the item after
2 Visually inspect for improper work.
fitting of the oil filler plug and Minor abnormalities found Repair all defective parts except
inspection plug, and for the floating seals. Analyze oil
damaged O-rings, (These items samples taken at shorter intervals
can be inspected during the air- to see if any abnormalities
tightness test for floating seals.) remain.
3 To inspect for defective floating Major abnormalities found Confirm the defect by
seals, perform a leak check by on floating seals. disassembling, and repair as
pressurizing the inside of the needed. Examine the condition of
case with an oil leak tester. gears at the same time.
The recurrence of trouble in the final drive can be prevented by precisely locating the defects and
completely repairing the troubles. At the same time, instruct the customer to clean the system
regularly to prevent the accumulation of dust and dirt. Give special guidance for any defects or
abnormalities caused by the customers mishandling of the machine.
Contamination with dust and dirt will degrade the properties of the oil, lead to poor lubrication,
and cause accelerated wear of gears and bearings. The ingress of dust will cause a sharp
increase in the wear of gears. Therefore, if the ingress of dirt is diagnosed, make the inspection
described below and take corrective actions promptly. Dust gets into the final drive unit through
the same routes as water does. Thus the same methods of inspection and corrective actions
should be applied.
* When the oil is drained, closely inspect the foreign matter and wear powder in the oil and the
wear powder caught by the magnet plug.
(7) WORK EQUIPMENT
proper actions promptly. An increase in wear powder may be caused by entry of water, entry of
dust, poor handling, or improper maintenance.Therefore, check these items during the inspection
r Combination of wear elements and location of defective parts (Typical examples)
Analyzed Causes of wear powder Combination of
Assumed defective part
resuIt elements
Much wear ! Entry of foreign matter Fe Pump, motor, cylinder, pump gear
powder ! Entry of dust Cu * Cylinder bushing, pump side-plate
! Entry of water Cr Piston rod
! Improper maintenance
Al Pump body
! Poor handling
Fe Cu Retarder plate and disc (for dump trucks)
* 1. When copper parts are used in the pistons due to the structure of the cylinders (as in wheel
loaders), a higher concentration of Cu wear powder may appear.
2. The concentration of Cu wear powder may become higher if water gets into the system through
a defective oil cooler.
3 Contamination checker 79A-851-1000
4 Oil cleaner 790-601-4100 To be used when corrective actions are taken
5 Stopwatch Available on the market
6 Convex scale Available on the market
as required.
No. Inspection item Method of inspection Equipment to be used
1 Abnormal noise See if there is any abnormal noise. If so, check its
source by inspecting with a sound scope. Sound scope
2 Foreign matter (1) Remove the filter and closely examine the foreign Visual inspection
Wear powder matter and wear powder caught by the filter.
(2) Run the engine and let the hydraulic oil circulate Contamination checker
through the system until the oil becomes
homogenous. Take oil samples. Use the
contamination checker to check the contamination,
and examine the foreign matter and wear powder.
3 Oil pressure Measure the relief pressure of the work equipment with Hydraulic tester
a hydraulic tester.
4 Leakage of motor Measure the leakage of each motor on a hydraulic Stopwatch
excavator
5 Hydraulic drift Measure the hydraulic drift of the work equipment Stopwatch
cylinders. Convex scale
6 Work equipment Measure the operating speed of each work equipment. Stopwatch
operating speeds
7 Retarder Confirm the effectiveness of the retarder brake by
performance completely locking the retarder brake and seeing if it
( Dump truck) can hold the vehicle at a stand still in the specified
speed range.
Combination Inspection items Result of inspection Corrective actions
of elements 1 2 3 4 5 6 7 No defects found on Continue taking oil samples to
Fe " " " " " " any inspection items. observe the future trend. Instruct
Cu " " " " " the customer fn proper
Cr " " " " maintenance.
Al " " " " Minor abnormalities Shorten the oil sampling interval
Fe, Cu " " " are found on at least and make the analysis again to
one inspection item. see if the abnormalities are still
present. Instruct the customer in
how to prevent overload
* Before cleaning the oil with oil refresher, operation. Clean the oil with oil
use the contamination checker to cleaner.
Major abnormalities Conduct a more detailed
determine whether or not the oil can be found on at least one troubleshooting to confirm the
purified. inspection item. location of the defect.
If it can not be purified, change the oil. Disassemble and repair the
system. After the repair, clean the
If the oil contains more than 0.2% water,
oil with oil cleaner.
the oil must be changed.

e After the repair, periodically measure the contamination level of the oil with the contamination
checker. If the oil can be cleaned, clean it with oil cleaner.
e To prevent recurrence, find the exact cause of trouble, repair the defect, and periodically check
the oil for contamination. Instruct the customer about the importance of daily inspections and the
necessity of proper maintenance.
The entry of water into the oil will significantly degrade the performance of the oil and will cause
poor lubrication and rust, resulting in accelerated wear of pumps and motors and cavitation of
pumps. If the ingress of water is diagnosed, inspect as described below and take appropriate
measures promptly. If anti-freeze is being used, the detection of antifreeze in the oil analysis
may be regarded as an indication of the entry of cooling water, which in turn means that the oil
cooler is defective.

lnside of system Oil cooler Cooling water enters through a broken or cracked
(cool ing water) (for watercooled type only) cooler element or tube, or because of defective O-
rings.
Oil filler cap Rainwater gets into the oil because the oil filler cap is
missing or damaged.
Hydraulic cylinder Water adhering to the cylinder rod because of rainfall
will get inside the cylinder through worn-out seals and
Outside of system bushings on the cylinder head side. In this case.
(rainwater, etc.) Ieakage or oozing of oil from the head is often seen.
Condition of oil Water gets into the oil while the oil is in storage
management, handling of (because of the location and condition of storage) or
oil (by customer) when adding oil with lubricating equipment such as an
oil filler. Relatively little water enters in this case.
Others When taking oil samples Careless oil sampling in the rain.

Step Inspection item Result of inspection Corrective actions
1 Inspect for defects such as a No abnormalities found Change the oil as soon as
missing or damaged oil filler cap. on any inspection items possible (immediately if a lot of
2 Inspect for oil leaks on the (temporary, ingress of water has gotten into the oil ) and
hydraulic cylinder head and for water from outside) observe the future trend by
damage on the piston rod. continuing to sample the oil.
radiator water. (Reference) If the inspection items other change the oil. Continue to take
oil cooler is defective, oil will get than the oil cooler. oil samples even after the repair
into the cooling water. (Ingress of water from to confirm that the ingression of
outside) water is completely eliminated .
4 Conduct a leak test on the Abnormalities found on Closely inspect the oil cooler
hydraulic oil cooler with an oil the inspection items for system and repair as required.
leak tester. The test may be the oil cooler. ( Ingress of After the repair, recheck the oil
conducted while the cooler is water from inside the cooler to see if it is free from
either mounted on or dismounted system) leaks.
from the machine.

After the repair, confirn that the leakage of water has stopped. If the presence of a lot of oil has
caused oil to emulsify, drain the oil and flush the inside of the system to remove as much of the
residual content as possible to prevent secondary trouble. Likewise, if oil has gotten into the cooling
system because of a defective oil cooler, flush the cooling system.
completely repairing the trouble. If water has come from outside the system, find its cause and take
appropriate action to prevent recurrence. If the ingress of water is caused by one of the following,
instruct the customer on proper management and handling of the oil.
e Water gets into the oil while adding oil with defective lubricating equipment such as an oil filler.
Contamination with dust will degrade the oil properties to a considerable extent, lead to poor
lubrication, and cause accelerated wear of pumps, motors, and hydraulic cylinders. If dust
contamination is diagnosed, inspect the following items and take proper actions promptly.

Oil filler cap Dust enters into the oil through missing or damaged filler cap.
Breather Dust gets into the oil because of a damaged breather or clogged
breather element.
Hydraulic cylinder Dust adhering to the cylinder rods is carried into the cylinders during
operation because of the worn-out seals and bushing on the cylinder
heads. In this case. Ieakage or oozing of oil is often seen on the head.
Condition of oil management Dust gets into the oil while the oil is in storage (because of the location
and conditions of storage) or when adding oil with lubricating
equipment such as an oil container.
Others Careless oil sampling in a dusty area
(when collecting oil samples)

1 Oil cleaner 790-601-4100 to be used when corrective actions are taken.
Step Inspection item Result of inspection Corrective action
1 lnspect for defects such as a No abnormalities found on Continue taking oil samples to
missing or damaged oil filler any inspection items. observe the future trend and clean
cap. the oil with the oil cleaner.
2 lnspect the breather and
breather element for damage Abnormalities found on Repair the defective parts and
and clogging. some inspection items. clean the oil with the oil cleaner.
3 Inspect for oil leaks on the After the repair, collect oil samples
hydraulic cylinder head and again to confirm that the defective
for damaged piston rods. parts are completely repaired.
* Before cleaning the oil with the oil cleaner, use the contamination checker to determine whether
or not the oil can be purified. If it can not be purified, change the oil. After changing the oil,
closely inspect the foreign matter and wear powder in the oil and also the wear powder attracted
by the magnet plug. In addition, closely inspect the foreign matter attached to the filter.

After the repair, periodically measure the contamination level of the oil with the contamination
checker, and clean the oil with oil refresher depending on the measured contamination level.
To prevent recurrence, find the exact cause of the trouble, repair the defect, and periodically check
the oil for contamination. Instruct the customer about the importance of daily inspections and the
necessity of proper maintenance.
(8) Multiplate Oil Cooler
(8)-1 How to cope with elusion of the copper content from the multiplate oil cooler
(8)-2 The Cu content may remain at a higher level when oil analysis of on board equipment (See page
(8)-6) is conducted with machines being equipped with a multiplate coil cooler.
This document is meant to inform you the method to cope with such circumstances.
(8)-3 Causes for elusion of the copper content should include:
r Elution of cooper solder from the oil cooler.
r Wear of the main bearing of the engine.
r Wear of the thrust plate and plain bearing of the hydraulic pump.
(8)-4 How to cope with elusion of the copper content at field sites.
To find out which of the aforesaid causes is applicable, a determination can be made after
checking if metal abrasion chips are adhering to the oil filter element.
Check flow
Abrasion chips Observe the copper content

Check the were not found. levels through several times of
oil filter samplings. The copper content
element shall usually be reducing after a
few times of oil replacement.
Abrasion chips (An example: See page 61-4.)
were found.
These abrasion chips are coming from bearings and if, for
example, the subject equipment is an engine, determine the
wearing section of the equipment referring to the results of the
oil pressure with an engine pressure measurements and to
the information of the oil consumption level, before replacing
the necessary parts in the wearing section.
(8)-5 Factors accelerating elution of copper solder from the multiplate oil cooler include:
r When the oil temperature rises after over-heated operations for long hours.
r When moisture content enters into the lubricating oil.
r Some oil brands are more corrosive against copper.
r Specifically, with dump trucks, when the retarder brake is used frequently during loaded downhill
travels, the cooling oil temperature rises to possibly cause elusion into the cooling oil of copper
solder being used inside the oil cooler.
(8)-6 List of equipped oil coolers with different machine models
Legend
":Multiplate type (water cooling)
!:Shell tube type (water cooling)
!:Corrugated fin type (air cooling)
Equipment Work
Power line Rear brake
names Engine equipment Remarks
Models
":D475 With models below D41, the
D575 power line and the work
D41 - D575A " " -
!:Other equipment are of the natural
models air cooling type.
HD205 The work equipment is of
" " - "
the natural air cooling type.
Dump HD325 " ! - ! The same as above.
trucks
HD465 " " ! "
HD785 " " ! "
PC60-PC1600 " - ! -
The work equipment is of
WA200 " " - -
the natural air cooling type.
WA300 " " " -
Wheel WA450 " " " -
Ioader WA500 " " " -
WA600 " ! " -
WA700 " ! ! -
WA800 " ! ! -
The natural air cooling is being-employed for models other than the above.
(8)-7 [An example}
r Circumstances: The engine was overhauled after 1,700 hours but the abnormal wear in the
bearing section was not detected and the engine was reassembled as it was to resume operation.
The Cu content reading entered within the normal range after execution of two times of oil
replacement.
r Assumption: Since abnormal wear was not detected in the crank shaft, connecting rod, main
bearing, pin bearing, cam shaft, oil pump, turbo, etc. after overhauling the engine, the cause for
the Cu content hike is being deemed the elution of copper solder in the oil cooler.
Opinion: The field servicing in this case determined that an abnormal wear was occurring with the
drive shaft(bearing thereof) inside the engine, from the results of oil clinic analysis.
However, if the oil element was checked and the hydraulic pressure was measured at the
same time, the determination error may have been avoided.
r [For reference]
Chart of the structures and materials of different oil coolers
7. GENERAL WEAR ANALYSIS
Description of general wear level
Normal
When all readings are in the normal range, the wear of the lubricating parts is normal.
There are instances when relatively high readings are considered normal. For example, the first oil
analysis for rebuilt equipment normally shows relatively high readings. This is due to the entrance of
dirt at assembly and the wearing-in of mating parts. These higher readings are considered normal for
the first few oil changes of a rebuilt machine.
Caution
If a reading is in this range, some faulty condition in the lubricated parts is assumed.
Dipending on conditions, more frequent sampling may be required, or diagnostic checks may be
performed. Maintenance procedures should be reviewed, and minor faults should be corrected. Major
repair is not recommended at this stage.
If reading in the caution range and close to critical, shorten the sampling intervals and decrease the
load onthe unit if possible. At this stage, the machine does not need repair immediately, however, work
out a schedule for repair and recommend your customers to carry it out at their convenience.
Critical
If the reading is in this range, advanced wear is assumed.
Locate the cause and take the necessary measures immediately.
Depending on the case, it may be necessary to stop the machine and overhaul it immediately.
If the reading goes highter, do not condider it in relation to trouble in the machine. Ask you customer to
investigate the possible causes.
For instance, the following factors are possible:
e Any sudden change in operating conditioins or
e Any influence by repairs made just before operation.
KOWA Units and Their Codes
[KOWA units]
Unit Unit Unit Unit name
Unit name Unit name
symbol symbol symbol
AXL Axle H/D Hydraulic R/B Rear brake
C/M Compressor HST HST system S/M Swing machinery
D/F Deferential M/C Main clutch S/T Steering
E/N Engine P/T Power train T/D Tandem drive
F/D Final drive PTO Power take-off T/M Transmission
[KOWA unit code]
No. Applicable unit No. Applicable unit No. Applicable unit
00 Engine, overall 34 Transmission (HYDROSHIFT) 67
01 35 Power train 68
02 Engine, rear 36 69
03 Engine, left 37 70 Differential, front
04 Engine, right 38 71 Differential, rear
05 39 Torque splitter 72 Axle, front
06 40 Swing machinery 73 Axle, rear
07 41 Swing machinery (rear) 74 Differential, intermediate(HA250)
08 42 75 Crasher, motor
09 43 76 Feeder, vibrator
10 Main clutch 44 77 Screen, vibrator
11 Damper 45 Winch 78 Conveyer, motor
12 46 79
13 47 80 P.T.O.
14 48 81 P.T.O, Ieft
15 Compressor, overall 49 82 P.T.O., right
16 50 Tandem. Ieft 83 Transfer (W/L)
17 51 Tandem, right 84 Steering
18 52 F/D, Ieft intermediate 85
19 53 F/D, right intermediate 86
20 Differential, intermediate (HA300) 54 87
21 Final drive, left intermediate (HA300) 55 88 Circle gear
22 Final drive, right intermediate (HA300) 56 89
23 57 90 Hydraulic
24 58 91 Hydraulic (BK).
25 59 92 HST
26 60 F/D, Ieft front 93 Brake cooling
27 61 F/D, right front 94
28 62 F/D, Ieft rear 95
29 63 F/D, right rear 96
30 Transmission (TOROUEFLOW) 64 97
31 Transmission (direct) 65 Brake, front 98
32 Sub-mission 66 Brake, rear 99 Others
33 Rear-mission
8. HOW TO SETUP ACCEPTANCE CRITERIA FOR THE KOWA
(Manual acceptance criteria setup)
(1) Scope
This standard is applicable to the manual setup acceptance criteria for values obtained in the
KOWA.
(2) How to setup acceptance criteria

(2)-1 Number of data
At least 100 oil assay data shall be collected on the machines (*1).
If the number of data collected is in the range of 50 - 100, the acceptance criteria developed
on them shall be used as temporary one. The criteria becomes the reqular one only after the
number of data reaches 100 or more.
*1: In this case, records of the oil used (its use duration and analytical value) must be traceable.
(2)-2 Calculation of the reduced concentration per unit time

Reduced concentration per unit time shall be calculated based on the oil assay data obtained
on the machines and broken down by models, units and elements. Calculation shall be done
with the formula given in Table 1.
(*2)
Table 1 Calculation of reduced concentration per unit time
Unit name Formula Remarks
Engine Ci= Xi × 250/Ti Ci = Reduced concentration per unit time (ppm)
Other (Equipments Ci = Xi × 500/Ti Xi = Analytical value of oil assay obtained on the machine (ppm)
other than engine) Ti = Oil use duration (hour)
*2: The machine must be of the sane model or type and has same structure and is made of
the same materials.
(2)-3 Creation of the cumulative frequency distribution graph
The graph shall be prepared using the reduced concentration per unit time (ppm), Ci, obtained
for each model, unit and element in the section (2)-2 above. (Concerning the Procedures for
Creating Cumulative Frequency Graph, see the item (4)).
Figure 1 Cumulative Frequency Distribution Graph

(2)-4 Setting of the acceptance criteria
The acceptance criteria shall be set up based on the cumulative frequency distribution graphs
developed in the section (2)-3 for each model, unit and element. The acceptance criteria at
the reduced concentration per unit time of 85% is maned A and that at 95% is called B.
Table 2 How to Set Acceptance Criteria
Acceptance How to round off values:
Status 1-2 digits figures...Rounded off at units. Examples) 1.5 = 2, 87.3 = 87, etc.
criteria
Normal zone From 0 to A 3 digits figures...Rounded off at 10s. Examples) 234 = 240, 781 = 780,
etc.
Caution zone Over A to B 4 digits figures...Rounded off at 100s. Examples) 1025 = 1000, 1260 =
Warning zone Over than B 1300, etc.
(2)-5 Creation of the acceptance criteria list
Acceptance criteria prepared for each model, unit and element in the section (2)-4 shall be
entered to the attached From 1 and copy of the form shall be circulated immediately to
relevant organizations. The organization issued the document shall be responsible for
maintaining the original.
When entering the values, reasons for the setup (or the modifications) must be clearly noted
in the form.
(3) Review of the acceptance criteria
Acceptance criteria shall be reviewed on the following occasions.
(3)-1 With the temporary acceptance criteria (number of data used for developing the acceptance
criteria is 50 - 100), the criteria shall be reviewed when total number data reaches 100 or
above. (The temporary acceptance criteria shall then be the standard criteria.)
(3)-2 When another 100 or more data have been collected after the standard acceptance criteria
has been established. In this case, a new standard criteria shall be prepared by combining
data collected in the previous assay with the ones obtained in the succeeding analysis. The
number of data, however, shall not exceed 300.
Example) 118 + 154 = 272
Where, 118 = No. of data obtained in the previous assay.
154 = No. of new data.
272 = Total number of data used for revising the current accep tance
criteria.
(3)-3 The acceptance criteria set in the above section (3)-2 shall be reviewed again when another
250 to less than 300 data is collected. Current criteria developed on new data for determining
which the two is to be employed as the standard acceptance criteria.
(4) Procedures for Creating the cumulative frequency graph (Manual method)
(4)-1 Collection of oil assay data on the machines (100 or more data is required.)
When collecting the data, the followings must be identified:
1) Model, type and model number. For instance, D155A-1, #51234.
2) Service meter.
3) Oil use duration.
4) Unit name. For instance, engine, transmission, etc.
5) Element assay value (Fe, Cu, Cr, Al, Si, Pb and Na).
6) Data and place the assay conducted.
7) History of the machines, as needed.
(4)-2 Determination of the reduced concentration per unit time (ppm).

In this operation, oil assay data collected on the machine is converted to the reduced
concentration per unit time (ppm).
Table 3 Oil assay data collected on machine
Model name and Service Oil use
No. Unit Fe Cu Cr Al Si Pb Na
number hour duration (H)
1 D155A-1#51234 Engine 3945 240 23 7 0*1 16 11 6 33
2 D155A-1#52234 T/M 4780 680 39 44 0 24 31 5 -
3 D155A-1#53234 F/D·L 4169 969 102 6 4 0 37 3 -
4 D155A-1#53234 F/D·R 4169 969 110 15 4 0 44 3 -
Example) Fe reduced concentration per unit time given in Table 3.

1) Reduced concentration per unit time on the engine
Ci = Xi e 250 a Ti = 23 e 250 a 240 23.924 (ppm)
2) Reduced concentration per unit time on the final drive (L)
Ci = Xi e 500 a Ti = 102 e 500 a 969 52.653 (ppm)
*1: 0 in the on-the machine oil assay data indicates that the has not been detected and,
therefore, shall be treated as 0.
(5) Creation of the table of reduced concentration per time.
Table 4 Table of reduced concentration per unit time
Model/type: D155A-1 Element name: Fe No. of data: 118
Unit: F/D·R Overall max. value (L) = 659Overall min. value (s) = 10
(Unit = ppm)
Max. value Min. value
No. 1 2 3 4 5 6 7 8 9 10 of group of group
(marked with ") (marked with !)
Group 1 94 94 125 !53 55 "385 200 57 138 57 385 53
Group 2 144 19 "274 193 230 163 93 79 !10 152 274 10
Group 3 *4 593 38
! 38 141 46 1243 270 91 44 "593 406 74
Group 11 !49 353 343 64 50 532 314 142 88 "659 659 49

Group 12 124 162 162 "435 !26 37 360 61 51 435 26
Group 13
Remarks *4: Excluded as an abnormal value. (N=119·1 = 118)
(6) Preparation of cumulative frequency distribution table.

Determine the followings from the table of reduced concentration per unit time (Table 4):
1) Class (K) = 12 (from Table 5)
2) Class width (h) = 54
h = (L-S)/K = (659-10)/12 54.1 54
3) Central value = 27 (h/2)
Table 5 No. of classes used for creating cumulative

frequency distribution graph
No. of data (N) No. of class (*5)
50 or above - less than 100 10
100 or above - less than 250 12
250 or above 20
*5: No. of c;asses has been determined according to the Komatsu QC Handbook.
Table 6 Frequency distribution
Class Class limit values Central value Frequency (check) Total % Cumulative %
1 0 - 54 (*6) 27 42 35 35
2 55 - 109 82 35 30 65
3 110 - 164 137 14 12 77
4 165 - 219 192 6 5 82
11 540 - 594 567 1 1 98

12 595 - 649 622 1 1 99
13 650 - 677 677 1 1 100
Total - - 118 100 -
*6: The first setting must start with 0 or above (since there is no data with minus sign).
(7) Creation of cumulative frequency distribution graph

Referring to the frequency distribution table, plot the cumulative percentage of central values on the
graph to draw the distribution curve (using a curved rule).
Figure 2 Cumulative frequency distribution graph

Then, prepare cumulative frequency distribution graph of elements for each unit and determine A
and B.
Determined reference values shall be entered to the specified form (Form 1).
This standard has been prepared referencing the SAE Paper 730745 (Sep. 10 - 13, 1973).
Limited Distribution Care is required for the handling Form 1
Model group code Setup data
Applicable model
Acceptance criteria
Acceptance criteria Unit: PPM
Unit name Unit code (Oil use duration: 250 hrs for engine and 500 hrs for others)
Status Fe Cu Cr Al Si Pb Na
Normal 45 15 5 8 20 25 50 A
Engine 00 Cation - - - - - - -
Warning 95 45 15 16 40 80 100 B
Hydraulic oil Normal
90 Cation - - - - - - -
Warning
Normal
Cation - - - - - - -
Warning
Normal
Cation - - - - - - -
Warning
Normal
Cation - - - - - - -
Warning
Normal
Cation - - - - - - -
Warning
Normal
Cation - - - - - - -
Warning
Remarks
10. Effective use of KOWA
Received order for the Reman Engine for use on the HD405 dump truck of the
Serial No. 1027
1. Details of the vehicle

Delivery date: June 1998 Failure occurred in: Jan. 2000
Service Meter: 5,767 H Engine: SAA6D140-E2
2. Analysis results by the KOWA upto the time when the failure occurred and determination to
replace the engine
Oil analyses have been made ever since the delivery of the vehicle and abnormal contents of
sodium, copper and lead were detected at the time of 5,767 hours and water leakage was also
detected at that time.
However, abnormal phenomenon was not occurring with the vehicle at this stage.
Since this vehicle was the main model for the cracked stone hauling work for the using customer,
in fear of occurrence of long period of down time, they immediately determined to replace the
engine.
C o pp e r con te nt a na lyses fo r th e H D 40 5 d ump tru ck

o f the S e ria l N o. 10 27
9 00
8 00
Analyzed values (ppm)
7 00
6 00
5 00
ＣＵ
4 00
3 00 C riteria Ab no rma l: 45 pp m
C au tio n:1 5p pm
2 00
1 00
0
0 1 00 0 2 00 0 3 00 0 4 00 0 5 00 0 6 00 0 7 00 0
S e rvice me ter va lue s
S odium content analyses for the H D 405 dump truck
of the S erial N o. 1027
300
270 C riteria Abnormal: 100 ppm
C aution: 50 ppm
240
210
180
150 ＮＡ
120
90
60
30
0
0 1000 2000 3000 4000 5000 6000 7000
S ervice meter values
Lead content analyses for the H D 405 dump truck

of the S erial N o. 1027
200
180
C riteria Abnormal: 50 ppm
160
C aution : 25 ppm
140
120
100 ＰＢ
80
60
40
20
0
0 1000 2000 3000 4000 5000 6000 7000
S ervice meter values
3. Results of analyses
1) Coolant was leaking through the crevice seal of the No.1 cylinder and, as a result, the leaked water
mixed into the oil resulting in lubrication failure between the main metal bearing and the connecting
rod metal bearing causing galling, although seizure was not occurring and, therefore, the crank
shaft was usable.
2) Other main parts like the cylinder block, cylinder head, piston and piston ring, liner, air intake and
exhaust valves, cam shaft, etc. were normal.
a. Conditions of the cylinder liner

The crevice seal was damaged and water
leakage was occurring through the dam-
aged crevice seal.
b. Conditions of the main metal bearing

Wears of the sliding surface are in
progress.
c. Conditions of the connecting rod
metal bearing
Wears are in progress because of leak of
lubrication.
d. Conditions of the crank shaft

Slight scratch was occurring because of
leak of lubrication.
e. Conditions of the piston
No particular abnormality was found the
the piston was normal.
f. Conditions of other parts

Other parts like the cam shaft, cylinder liner, tappet, cylinder head, air intake and exhaust
valves, etc. were normal.
4. Effects of the KOWA

Since serious damage of the engine did not occur, the expenses shouldered by the using cus-
tomer were about 3 million yen of ordinary reman price only. If the subject vehicle did not take
the oil sampling, the engine must have gone into serious damage and, by replacement of the
cylinder head, cylinder block and crank shaft, additional expenses of about 2.3 million yen must
have become necessary.

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1.

2-1 When using sampling pump (Oil sampling tools)

(2) Sampling kit (Part number: 799-801-1503)

Example (1) Example (2)

Cut the tube to the proper Cut

1 Loosen the round nut. 3 Tighten the nut.

2 Extend the tube about 1.5cm

4 Screw the sample

Fill the bottle to the 80% with oil.

No. Part name Part number Remarks

Connect the adapter

Check if there is an oil pressure pick-up port nipple on the machine.

K : Possible to take sample ) : Impossible to take sample

r Precautions when sampling oil

Other analysis K : Analysis

(2) General Precautions at Time of Evaluation

[Explanation of standard value]

8-2 Unit hour and converted concentration

Oil used in engines 250/500h

20 ppm x 500 h (unit hrs.)

Fig. 1.2 Example of pattrn of analytical values obtained

tion (*) of newly-obtained tion (*) of newly-obtained

< Oil change ratio >

< Example of calculating converted density >

500h (Unit time)

K Crankshaft thrust bearing, turbo thrust bearing, aluminum

K Bushing, thrust bearing metal

K K ! K Dust (Floating seal)

K Cylinder wall, pump gear

r Action taken according to KOWA judgement standards

1 Put Si and Al (which are common causes) at

2 If the oil change intervals are much shorter

1 If there is a abnormality in the value for Si or Al

There was the same trend in

Example of where Pb en-

1 gram of the element

Na ----- This is contained in antifreeze. It applies only to engine oil.

(2) Relation between Si and Al due to Intrusion of Dust

1. Standard values for the 500 hour changing interval

Judging from the actual oil

is being made at the time of 551 hours or more 3

status, thus having been set to 401~450 hours or les s 0

500 hours. 250~400 hours or les s 10

Value of analysis (ppm)

(Analysis results of copper) (Analysis results of copper)

Value of analysis (ppm)

(Analysis results of aluminum) (Analysis results of aluminum)

Value of analysis (ppm)

Value of analysis (ppm)

(Analysis results of lead) (Analysis results of lead)

150 150 Abnormal

Value of analysis (ppm)

Applicable Water mixing

produced a little but soon disappear.

Bubbles of approx. 0.5 mm are 0.05 ~ 0.1 ! Changing oil is advisable.

Presence of antifreeze Measure to be taken

Example of fuel mixing ration - flash point

Fuel mixing ratio (%) Measure to be taken

r Elements and the location of defective parts (Typical examples)

tion () of newly-obtained tion () of newly-obtained