The Original Synthetic Motor Oil

Lubrication News August-December 2004

Reprinted from The Direct Line & The Action News

August-December 2004

Past issues of Auto Technology & Lubrication News

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Briefly

Strong Medium Duty Truck Sales in 2004

According to research performed by Ward's Communications, U.S. retail sales of Class 3-7 medium duty trucks are on the upswing. Through the first seven months of 2004, sales were up 19.2 percent compared to the same months in 2003. According to Peterbilt Motors Co. general manager Dan Sobic, medium-duty truck "quote and ordering activity is solid." Thomas Cellitti, vice president and general manager of Navistar International's Medium Truck Vehicle Center, predicts the overall Class 6 and 7 market will be up 15 percent this year from 2003. Class 6 trucks showed the largest growth through July, growing 48.7 percent, while Class 7 truck sales climbed 12.6 percent.

Relubricating "Packed for Life" Bearings

"Packed for life" bearings are common for many light to medium duty services. Equipped with seals, these bearings are packed at the factory with high quality grease designed to last for the life of the correctly applied bearing. According to the book "Lubrication Fundamentals," the service ranges of these bearings can sometimes be extended by making provisions for relubrication, by either removing one seal and applying grease through it with a gun or hollow needle, or carefully forcing the grease through the holes in the outer ring. The latter method requires caution because small amounts of pressure can dislodge seals.

Changes Proposed for Calculating Fuel Economy Ratings

The fuel economy ratings posted on new cars and trucks may be changing. Due to the increased cost of gasoline and complaints that the posted ratings aren't accurate, the U.S. Environmental Protection Agency (EPA) is looking into changing the way ratings are calculated.

The proposed change stems from a petition sent from the Bluewater Network to the EPA in 2002. Bluewater founder and director Russell long initiated research into the issue when he discovered discrepancies in fuel economy in his personal vehicle.

"I am an efficient driver and am concerned with false advertising on the part of the government," says Long.

Bluewater research reveals several reasons why posted ratings are inaccurate, including faster speed limits, under rated smog emissions testing, increased traffic congestion, air conditioning and aftermarket items like roof racks. According to Long, it is important to factor in actual speed of motorists rather than posted speed limits.

While some states currently have 70 mph speed limits, the current EPA fuel economy test still measures highway fuel economy at speeds of 48 mpg, based on the old national highway speed of 55 mph.

Automobile manufacturers argue that the current ratings are still reliable estimates of actual fuel economy and no change is necessary. Eron Shosteck, director of communications for the Alliance of Automobile Manufacturers, agrees that driving habits affect fuel economy, but believes any changes would be a waste of time and money when the vehicle stickers already state that mileage will vary.

"Why fix what's not broken?" asks Shosteck. "The money is better spent on advancing technology."

Before making a decision, the EPA will gather and analyze information and comments form automakers, motorists, individuals and agencies. The EPA last changed the fuel economy rating formula in 1984.

"There is a 15 percent downward change on average for both city and highway mileage," says EPA spokesperson John Millet. "The adjustments should be consistent and clear to the customer. It's about demographics and the way we drive."

The use of AMSOIL synthetic motor oils is a proven way to improve fuel economy. Independent tests show the use of synthetic lubricants can increase fuel efficiency by two to five percent, while many AMSOIL customers report even larger gains.

Simple Maintenance Yields Gas Savings

According to the Car Care Council, average fuel economy for vehicles in the U.S., including cars and light trucks, is 20 miles per gallon. A 0.7 mile fuel economy improvement (3.5 percent) sounds small, but it would add up to a nationwide fuel savings of $11 billion if the cost of fuel remains at $1.98 a gallon.

If a vehicle is running poorly, it uses more fuel. In order to achieve the same performance as a vehicle in top running condition, it is necessary to depress the gas pedal further. Simple maintenance procedures such as changing spark plugs, filters and engine sensors can easily improve a vehicle's fuel efficiency by 3.5 percent or more, but such maintenance often goes unperformed.

Fuel economy can be improved by one to two percent by simply using the manufacturer's recommended motor oil viscosity. Using a heavier viscosity oil than recommended requires more power to pump, while a restricted oil filter requires even more energy from the engine. A two percent fuel efficiency increase translates into about $25 a year in fuel savings.

Restricted air filters block incoming air, causing the engine to run too rich. Replacing a restricted air filter can improve fuel efficiency by up to 10 percent, saving the average motorist about $135 a year.

Replacing worn spark plugs usually yields a three to four percent fuel economy improvement, an average savings of between $50 and $60 per year.

Defective oxygen sensors often produce inaccurate readings that result in rich fuel mixtures. Replacing defective oxygen sensors improves fuel efficiency by about 15 percent, saving the motorist about $195 a year.

Replacing other defective sensors, such as mass air flow and throttle position sensors, can improve fuel economy between 10 and 25 percent. Although replacing these sensors can be expensive up front, the fuel savings are significant and pay for the repairs rather quickly.

AMSOIL offers premium synthetic lubricants, filters and Bosch spark plugs, all of which are proven to improve fuel efficiency.

Briefly

RV Sales Strong in 2004

Professor Richard Curtin, director of the Survey of Consumers at the University of Michigan and economic consultant for the Recreation Vehicle Industry Association (RVIA), forecasts that 347,800 motorhomes and towable RVs will be shipped from manufacturers to dealers this year, an 8.4 percent increase over 2003. However, Curtin predicts the market will pull back almost eight percent to around 320,300 units in 2005, a number consistent with the delivery totals of 1999 and 2003. According to Bruce Hertzke, chairman of the RVIA, Curtin's forecast of a new 25 year high for RV shipments in 2004 is too conservative. "Increases in interest rates will have a greater impact on RV shipments in 2005," says Hertzke. "But even then the size of the impact will be relatively small due to the offsetting impact of strong job gains as well as increases in wages."

Grease Tip

The "Rolling Bearings Handbook and Troubleshooting Guide" offers valuable advice for greasing bearings. "When greasing a new unsealed bearing at installation, pack the grease in from both sides until all of the cavity is filled. If a split pillow block is used, fill the bottom half of the housing half full." A sealed bearing is usually packed one-half to one-third full of grease. Overpacking will cause excess heat, and the excess grease will be purged out of the seal contact area. When greasing bearings, be sure to wipe off the grease fitting before injecting grease.

Proper Used Motor Oil Disposal

Efforts are increasing to reduce environmental pollution created through improperly discarded used oil.

According to the National Petrochemical & Refiners Association "2002 Report on U.S. Lubricating Oil Sales," 2.46 billion gallons of lubricants were sold in the United States in 2002. At the same time, the American Petroleum Institute (API) estimates around 1 billion gallons of used oil are properly disposed of each year. This leaves nearly 1.5 billion gallons of used oil that cannot be accounted for.

Not all of this unaccounted for used oil is improperly discarded, but according to the U.S. Environmental Protection Agency (EPA), "Improperly disposed used oil is the largest single source of oil pollution fouling our nation's waters." Although this used oil includes diesel, two-cycle, transmission, hydraulic and industrial lubricants, the biggest problem comes from improperly discarded gasoline engine oils. Just one quart of used oil can produce a two-acre oil slick, while one gallon can foul one million gallons of water.

Do-it-for-me (DIFM) centers, including quick lubes, auto dealers and other businesses that change oil, perform about 55 percent of the nation's oil changes, while the other 45 percent are performed by do-it-yourselfers (DIY). According to Stephen Christie, executive director of the Automotive Oil Change Association (AOCA), "The vast majority of our member companies and their separate oil-change facilities dispose of used oil in approved ways. Used oil is collected by installers into tanks on site, picked up by licensed used oil transporters which either recycle it on their own facilities or resell it to other recyclers. Virtually all of the used motor oil collected by the DIFM market is appropriately treated."

It's more difficult to determine where used oil from the DIY market ends up, and efforts are increasing to encourage do-it-yourselfers to properly recycle it. California currently operates one of the most active used oil programs in the country, collecting about 600 million gallons of used oil over the past decade. Utah, Maryland, Florida and Alabama also have active programs, with Utah funding its program with a small per-quart fee on new oil purchases of less than 55 gallons.

Used oil filters are also a source of oil pollution. Even after allowing a used oil filter to drain for a few minutes, six to eight ounces of oil usually remain inside. When thrown out with the trash, the oil eventually leaks out into landfills, contributing an estimated 12 million gallons of untreated oil to the environment each year. It is hoped that increased efforts encouraging used filter recycling will lessen the negative impact of use oil ion the environment.

A plethora of information is available on the Internet about used oil and filter recycling. The Earth 911 website provides do-it-yourselfers with all the information they need on recycling used oil and filters. By simply typing in their zip codes, do-it-yourselfers get a list of used oil collection sites in their area, as well as information regarding the proper disposal of other hazardous materials.

Considering that conventional motor oil companies recommend oil drain intervals of 3,000 miles, and AMSOIL recommends oil drain intervals of up to 25,000 miles, the use of AMSOIL synthetic motor oils greatly reduces the source of motor oil pollution by up to eight times. In addition, the synthetic formulations of AMSOIL motor oils effectively reduce emissions and improve fuel efficiency, further contributing to a clean, healthy environment.

Americans Driving More Despite High Gas Prices

Although motorists have not received a break on high gasoline prices, market research performed by the Automotive Aftermarket Suppliers Association (AASA) branch of the Motor and Equipment Manufacturers Association (MEMA) reveals Americans are actually driving more. Total mileage figures for June and July 2004 show Americans tallied more miles than the same months in 2003.

"As we have seen in the past, it takes an actual shortage of fuel to make mileage fall." says Frank Hampshire, AASA/MEMA director of market research. "What we may see instead is a shift in the types of vehicles Americans drive."

The fuel shortages of the 1970s led to the dramatic downsizing of popular large passenger cars of the time, including the Ford LTD, Pontiac Bonneville and Buick LeSabre, while fuel efficient Japanese compact cars quickly gained popularity.

"Today, we are seeing increased interest in diesel and hybrid vehicles," says Hampshire.

According to Hampshire, increased driving normally increases demand for service and maintenance, but without a break in gasoline prices, motorists are cutting back their spending on vehicle maintenance and repair.

AMSOIL synthetic motor oils allow motorists to save money by maximizing fuel efficiency, while providing an unsurpassed level of protection and performance for extended drain intervals.

Improper Filter Installation Puts Honda CR-Vs at Fire Risk

An October New York Times article reports that 60 model year 2003 and 2004 Honda CR-Vs have caught fire. An investigation last summer by the National Highway Transportation Safety Administration (NHTSA) revealed that many of the fires broke out shortly after an oil change.

The NHTSA concluded that the fires were caused by improperly installed oil filters that allowed oil to seep onto the vehicles' hot exhaust systems. The filter installation error can happen one of two ways: When the old filter is removed, the O-ring gasket can stick to the crankcase. If it is not removed and the new filter is installed over it, the new filter cannot create enough suction to prevent oil leakage. In addition, if the gasket on the new filter isn't lubricated properly, it may set incorrectly and cause oil to leak around it.

"We consulted with Honda," NHTSA spokesman Rae Tyson told the Washington Post. "Honda concluded it was technician's error, and they have taken steps to make sure service technicians who work on this vehicle understand that they need to be particularly diligent when they replace the oil filter."

Honda does not plan on issuing a recall of the CR-V. Rather, they will focus on improving communication and education with dealers in order to eliminate future problems.

The following steps help prevent oil leakage from filters:

1) Be sure the sealing surface on the engine is clean.

2) Be sure the 0-ring from the old filter isn't stuck to the engine block. If it is, scrape it off completely and thoroughly clean the surface.

3) Be sure the new filter's threads and 0-ring surfaces clean.

4) Lightly coat the new filter's 0-ring with clean oil to prevent shear.

5) Torque the new filter to the proper specs to properly compress the 0-ring.

I believe I echo what most readers are thinking after reading these 5 steps that this is standard for any car!

Briefly

Business and Leisure Travel on the Rise

Both business and leisure travel is on the rise in America. According to the latest annual Domestic Travel Market Report released by the Travel Industry Association of America, 68 percent of American adults took a leisure or business trip of at least 50 miles one way in 2003. The 1.14 billion person-trips taken in 2003 represent an increase of 1.2 percent from 2002, while overall domestic travel volume grew 9.8 percent mostly due to large increases in leisure travel.

Oil Analysis Tip

According to Mike Johnson, Senior Technical Consultant at Noria Corporation, proper oil sample location is extremely important when trending changing equipment conditions. Although accurate reports of lubricant condition can be determined from samples taken from a variety of locations, "sampling for evidence of mechanical problems requires a sample to be collected from a location that contains the highest concentration of 'evidence' of a problem," says Johnson. "The evidence is of course the wear metals." Samples are often taken from pressure lines after a filter or drain lines at the bottom of the reservoir due to easy access and low cost, but these locations are not ideal because evidence of a problem may be filtered of settled out. Sample ports should be configured to allow collection of lubricant close to the components in question.

Quick Lubes and Oil Monitoring Systems

Longer drain intervals have oil change facilities seeking alternate ways to increase profits.

Modern on-board oil monitoring systems are becoming increasingly common in today's automobiles, analyzing engine operational data such as temperature, revolutions, trip length and speed to calculate motor oil drain intervals. When the system determines the oil is nearing the end of its life, a dashboard light is illuminated. Oil monitoring systems are helping motorists safely extend their drain intervals, while making the standard 3,000 mile oil change obsolete.

As fixed mileage oil changes become less common, oil change facilities must re-think their marketing strategies. For example, rather than mailing regular customers an oil change reminder every three months, a good strategy to keep in touch with customers may be a monthly or quarterly newsletter.

According to Gary Goms, owner of Midland Engine Electronics & Diagnostics in Buena Vista, Colo., "When the oil change reminder light does come on, a shop must be fully prepared to use the oil change service as an opportunity to sell other needed services such as timing belt replacements, brake inspections, wheel services and safety inspections."

Extended drain intervals usually mean customers visit shops less often, neglecting other important maintenance procedures. It is important for shop owners to capitalize on opportunities to perform the following regular maintenance services:

1) Test vehicle emissions components such as oxygen sensors and EGR valves

2) Inspect and, if necessary, replace cam timing and accessory drive belts.

3) Change air, fuel and oil filters.

4) Adjust intake and exhaust valve clearances.

5) Lubricate linkages.

6) Coat rubber door and hatch moldings with silicone spray.

7) Check and, if necessary, replace lighting and wiper blades.

8) Lubricate door locks and hinges.

9) Change brake and drivetrain fluids.

For many independent automobile shops, the decision to get into the quick lube business is a big one. While specifically dedicating a service bay to oil changes can improve efficiency and productivity, technicians often overlook other scheduled maintenance and repair opportunities because they become preoccupied with maintaining a high car count. Using bays for both repair work and oil changes can affect productivity through scheduling conflicts.

Staffing can also become a problem because many skilled technicians would rather not focus exclusively on performing oil changes, while entry-level technicians often overlook needed maintenance and repair opportunities due to inexperience.

"The ideal quick-lube operation would be a fully equipped drive-on lube pit staffed by older, perhaps semi-retired technicians who can quickly spot needed maintenance and repairs," says Goms. "The ideal quick-lube bay should also have computer access to a vehicle's service history so the lube technicians can help sell scheduled maintenance and refer needed repairs to the service writer's desk for dispatch to skilled technicians. In this way, oil changes can be performed quickly and profitably without losing efficiency and productivity in the repair department."

The AMSOIL XL Oil Change Program presents shop owners with another excellent way to increase profits, while providing customers superior protection and performance for extended drain intervals. Busy quick lubes that are currently working at capacity can potentially service twice as many customers since they only need to see them half as often to make the same or greater profit.

AMSOIL XL Synthetic Motor Oils are specially formulated to deliver 7500 miles or six months between oil changes, and may be used longer when relying on factory-installed oil monitoring systems.

Briefly

Gas Prices Affect SUV Sales

As gasoline prices have remained higher than average, fullsize SUV sales have suffered. Average wholesale prices for used fullsize SUV's dropped steeply over the summer months, while sales of the Hummer H2 have fallen by more than 25 percent. In addition to high gas prices, industry analysts blame the lag in used truck sales on large cash incentives on new fullsize SUV's, while the H2 is likely experiencing a sales slump typical of vehicles that are extremely popular at launch but can't sustain high sales numbers over the long term.

Prevent Moisture Ingress

Noria Corporation offers the following tips for avoiding moisture in gearboxes that operate in humid conditions:

1) Avoid direct jetting of water at ingression points like shaft seals and breathers.

2) If water spray is unavoidable, make use of passive shields and deflectors to prevent direct water spray on shafts, dipsticks, fill-caps, breathers, etc.

3) Install high quality seals that wear less and offer improved protection against contaminants.

4) Inspect and maintain gaskets on fill-caps, hatches, etc. on a regular basis.

5) Replace dipsticks with level indicators.

6) Tightly close all hatches.

7) Replace basic vent breathers with desiccant breathers or expansion chambers.

Recreational Vehicle Market Shows Growth

Boating Industry reports large growth in motorcycle and ATV sales, while boat sales hold their own.

According to the 2004 Market Data Book published by Boating Industry, the boating industry is holding its own in today's marketplace, while sales of ATV's and motorcycles are steadily increasing each year.

"While we did see a slight decline in 2003, sales growth in the boating industry continues to outpace U.S. economic growth when you compare numbers over the last seven years," says NMMA director of market statistics Jim Petru. "Sales in the boating industry have increased an average of 8 percent annually since 1997, while the Gross Domestic Product has averaged 3.2 percent

In 1999, boat sales reached 584,979 units, exceeding sales figures for ATV's, motorcycles, snowmobiles and motorized and towable RV's. However, in the years since 1999, motorcycle sales have surged by 44 percent and ATV sales have increased 32 percent. While boat unit sales have decreased by almost 17 percent since 1999, total retail value of the new boats increased up until 2003. Boat sales hit record numbers in the beginning of 2004, leading boating insiders to be optimistic about end-of-year numbers.

In Boating Industry's 2004 survey of marine dealers, over half of respondents reported increased revenues compared to the previous season, while one-quarter reported lower revenues and one-quarter reported revenues of about the same as the previous season. Increased sales of new boats can be attributed to the success, with the majority of survey respondents reporting increased sales in this category. New boat sales produced more revenue than used boats, engines and boat accessories, and they outsold used boats by a 2 to 1 margin.

AMSOIL offers premium lubricants to meet the needs of recreational vehicle owners. AMSOIL "Fabulous Four" Synthetic 2-Cycle Oils, Synthetic Motorcycle Oils and Formula 4-Stroke Synthetic Motor Oil provide unmatched protection and performance in both modern and older equipment, including outboard motors, ATV's motorcycles, snowmobiles and personal watercraft.

Briefly

Freedonia Predicts Strong Future for Synthetics

According to a study by the Freedonia Group, lubricant demand in the United States will grow 0.9 percent per year for the next five years, reaching 2,745 billion gallons in 2008. The study predicts a two percent annual growth for general industrial oils, a 1.4 percent annual growth for transmission fluids and hydraulic oils and a 0.2 percent annual growth for automotive motor oils. Freedonia projects demand for synthetic lubricants to grow six times faster than the overall market, with synthetics accounting for 10 percent of overall demand by 2008. More rapid than average growth is also predicted for high mileage oils and oils marketed specifically for ATV's, motorcycles and scooters.

Volkswagen Extends Warranty Coverage

Due to reported problems related to oil sludge, Volkswagen of America has extended warranty coverage on approximately 425,000 Passats and Audi A4s with 1.8-liter turbocharged four-cylinder engines. The extended coverage applies to Passats built between 1998 and 2004 and Audi A4s built between 1997 and 2004. The warranty is for eight years, has no mileage limit and is fully transferable. Oil sludge problems have also been reported in Chrysler 2.7-liter V6 engines installed in vehicles built between 1998 and 2002. The Center for Auto Safety is asking DaimlerChrysler to offer owners extended warranties.

Extend Hydraulic Equipment Life

Hydraulic Equipment runs at peak efficiency when oil is kept clean and free of contaminants.

Hydraulic power is an invaluable resource, allowing heavy equipment to easily lift and scoop heavy loads. "Hydraulics are a force multiplier and are included in just about every function on every earthmoving machine," says Rudy Urbano, senior marketing consultant for Caterpillar's Hydraulic Parts Products. "In addition, a hydraulic motor converts horsepower into torque, which propels the machine's wheels or tracks."

In order to keep hydraulic equipment running efficiently, it is important to keep both the equipment and the hydraulic oil as clean as possible. "All machines tend to work in dusty conditions," explains Urbano. "Some types of dust are smaller - measured in microns - which makes it easier for the dust to enter the hydraulic system. In extremely dusty conditions, the hydraulic, fuel and engine filters may require more-frequent change intervals than the normally recommended periods."

Reducing the amount of time equipment runs at full-engine speed reduces wear and emissions. "Cat hydraulic systems operate on standby or on-demand use," says Urbano. "This is one reason why our oil change recommendations were raised form 2,000 to 4,000 hours: because the oil isn't flowing through the system all of the time. In standby system mode, the oil doesn't move until the operator asks it to perform work. Then, of course, the more oil that flows through the system, the more power the machine produces. This standby mode also reduces the engine horsepower requirement; when you're not using the horsepower, you're not emitting exhaust into the atmosphere."

Because the interior of a hydraulic system is generally warmer than the outside air, condensation often forms in hydraulic lines. "Moisture is considered an oil contaminator, just like metal particles," says Urbano. "It breaks down the oil film and zinc protection and can cause rust buildup on metal parts. This rust becomes a small, hard, raised spot that can break through the oil film separating moving parts. If water and oil mix together under pressure and water bubbles implode, this implosion puts a 'pothole' between the metal surfaces the oil's protecting. If your system has 4% moisture content, you have to change the oil. Even at less than 4%, moisture can cause problems; check the oil filter to see if moisture is present. And check the oil in the hydraulic tank. If there is water present, the oil will have a milky cream color after the machine's hydraulic system has been operated."

Leaving the hydraulic tank cap off for even a short period of time allows vapor in the air to enter the oil. Stored oil can also accumulate moisture when temperatures cause barrels to expand and contract. To Keep stored oil free from water contamination, it is best to keep it indoors and covered with a protective plastic lid.

Shop cleanliness can help keep hydraulic oil free of contaminants. "We suggest that customers clean their machine shops daily and that they should do machine maintenance at the beginning of the shift, before dust is raised on the site," says Urbano. "Once dust is in the air, it can travel into the machine shop from open doors and then get whisked all around the area by the fans used to keep workers cool.

"Our dealers have recognized the contamination problems in hydraulic systems and component rebuilds. During a shop-operations review, [we learned that] one dealer had experienced several problems when rebuilding hydraulic components. During our review of the shop, we realized dust was coming in through the building's 16-foot overhead doors. However, it was much too hot outside - 110°F - to turn off the fans. Our mutual conclusion was that it was less expensive to air-condition the repair shop than it was to rework all of the hydraulic components because of dust contamination."

Bill Leary of Southworth-Milton Inc., a Cat dealer in Milford, Mass., stresses the importance of contamination control training for all employees, explaining that simple changes can pay significant dividends. "For example, by covering your work and by using caps and plugs on hoses that are taken apart, you avoid contamination," says Leary. "We have a clean room for rebuilding pumps and motors. Components are disassembled, cleaned and inspected before they're taken in for reassembly. No tools that will generate particles or contaminants are used in there. The room is filtered, and the room has positive pressure to keep out contaminants. After pumps are assembled, we have a separate area for testing, and we filter the fluid in the test bench to ensure that pumps are being calibrated and tested with clean oil meeting Caterpillar's spec of ISO 16/13.

The rest of the service shop isn't air-conditioned, so according to Leary, they keep the doors closed as much as possible and have a sweeping program that keeps airborne dust to a minimum. "After each job, we clean the bays and sweep and scrub the floors," he says. "We also sweep the yards on a regular basis, once per week in the summer. We've also put epoxy sealers on the cement floors, which keeps dust down. To further combat dust, we don't use absorbents like Speedy Dry or kitty litter - only absorbent pads." Southworth-Milton also uses Cat hose-cleaners to clean new and repaired hoses and tubes.

Southworth-Milton uses filter carts to ensure hydraulic oil is clean. "Our 90-gallons-per-minute filter carts, which contain a bank of four or eight 10-micron filters, filter oil in the machine while we're working on it," says Leary. "We call it a 'kidney machine' because it's like a dialysis machine for oil. We measure readings on the hydraulic fluid with a portable particle counter; after measuring the contaminants, we clean the oil up to Caterpillar's cleanliness standards of ISO 18/15. This saves the customer the expense of replacing the fluid."

Southworth-Milton has filters on their bulk oil storage tanks and lube truck discharge lines, and they monitor lubricant conditions in their customers' machines to be sure they meet Caterpillar standards. They also check stored fluids for water contamination. "All bulk oil containers have 2-micron filters as breathers," says Leary. "On some of our larger tanks, we use a dessicant breather. Our lube trucks are enclosed, insulated, and heated so tanks, pumps, and reels are kept clean and oil pumps easier."

Contaminants within new equipment must be filtered out using clean oil. "If there were other particulates in the oil, that woold make matters worse," says Ed Blackford, manager of proactive maintenance and filtration at Eaton Hydraulics. "The intense pressure inside a hydraulic system can turn small particulates into big problems. As a comparison, the typical home has water pressure of about 40 to 50 pounds per square inch. Many hydraulic systems run pressure of 3,000 to 6,000 pounds per square inch. At this pressure, a small particle coursing through the system will abrade, or 'sand,' the surface inside the system, breaking down into more particulates and creating more problems."

Hydraulic systems with reservoir breathers are continuously exposed to contaminants. In these systems, a vent is necessary to ensure the reservoir doesn't implode, but it exposes the system to contamination.

"Common forms of contamination include dust and moisture," says Blackford. "Most people in our industry use breathers or vents that are little more than mesh screens. These screens keep out large items like screwdrivers or rags but do nothing to block dust and moisture. If a customer looks at oil and thinks it looks clean, looks can be deceiving. The human eye can only see objects as small as about 40 microns, but most oil contaminants are about 5 microns. The reality is that we can't see most of the things that will damage hydraulic systems.

According to Blackford, over 90 percent of hydraulic system failures are preventable, many through adequate filtration. "Some filters will reduce the number of particles in oil," he says. "Others can reduce the number of particles and take out water. The ones that take out water work like GORE-TEX fabric raincoats; they let air breathe in and out, but the water stays on the outside."

"Every operator should have a proactive maintenance program, a plan to prevent problems before they start, because, when systems fail, it costs you money," says Blackford. "It costs more to fix a problem than to prevent it."

AMSOIL Synthetic Hydraulic Oils offer superior protection and performance in severe duty applications. Formulated with top-or-the-line synthetic base oils and premium additive packages, AMSOIL Hydraulic Oils effectively prevent carbon and varnish deposits, provide outstanding wear protection and reduce maintenance costs through extended drain intervals and reduced downtime.

Briefly

RV Sales Strong

Despite recent spikes in the prices of gasoline and diesel fuel, Winnebago Industries Inc. is reporting record revenue from motorhome sales, with its profits nearly doubling in its third fiscal quarter. "We continue to believe the long-term prospects remain extremely positive for Winnebago and our industry," says company chairman, president and CEO Bruce Hertzke. "Economic factors have improved since last year at this time. Fuel prices have stabilized and it appears consumer confidence has begun to rise." According to Hertzke, Winnebago's redesigned diesel vehicles, the Winnebago Journey and Vectra and Itasca Meridian and Horizon, are largely responsible for the company's large increase in diesel-motorhome shipments.

Water Contamination Tips

Noria Corporation offers the following tips for avoiding water contamination in outside gearboxes:

1) Check for cooler leaks in gearboxes that run continuously.

2) For gearboxes that run periodically, consider installing desiccant breather. They can offset problems and costs associated with high water content.

3) Expansion chambers are a good option over water removing breathers because they allow oil to expand and contract without bringing wet air into the system.

4) Consider off-line water removal with either full-time filters of periodic use of a cart.

Synthetic Blend Oils Gain Popularity

Motor oil companies are looking toward synthetic blends to meet stricter performance standards, but how much "synthetic" should be in a synthetic blend?

Modern vehicles are requiring motor oils that meet stricter and stricter performance standards, and it's becoming apparent that lubricants formulated solely with Group I conventional base stocks will be unable to meet these increasing standards. ConocoPhillips, for example, recently made the decision to convert the majority of its passenger car motor oil line to synthetic blend formulations, and other motor oil companies will likely follow suit in the near future.

In order to meet tougher standards, many motor oil companies are quickly switching from Group I base stocks to Group II-plus base stocks. Others are blending Group I base stocks with Group III and PAO "correction" base stocks and marketing the oils as synthetic blends.

"Synthetic blend" is an ambiguous term because there are no official rules or regulations dictating how much "synthetic" must be present in the oil. It is up to the manufacturer. While some companies blend oils with a 50/50 mix of synthetic and conventional base stocks, others use only 10 to 20 percent synthetic base stocks. In addition, companies do not agree on whether the synthetic portion of the oil should consist of Group III or PAO base stocks.

Some lubricant manufacturers even go so far as to claim synthetic blends do not require the use of any synthetic base stocks, arguing that because additives comprise around 20 percent of an oil's volume, and because additives contain fully synthesized molecules, a motor oil formulated with additives is a synthetic blend. In the end, customers cannot be quite sure of the quality of the synthetic blend motor oil they buy.

With AMSOIL synthetic motor oils, customers are assured of receiving the best protection and performance on the market. AMSOIL synthetic motor oils exceed the strictest industry standards, providing second-to-none protection against friction, heat and wear, while providing maximum power, performance and fuel efficiency for extended drain intervals.

Briefly

Hybrids Experience Engine Problems

According to the JD Power & Associates 2004 Vehicle Dependability Study, diesel and gasoline electric hybrid vehicles have more engine problems than their gasoline-powered counterparts. The study surveyed over 45,000 owners of 2001 model year vehicles in the areas of malfunction, NVH (noise, vibration and harshness), drivability, dependability and safety. Owners of Toyota Prius and Honda Insight hybrid vehicles and Volkswagen diesel vehicles reported twice as many problems as owners of the corresponding gasoline models, with the most common problems related to engine computers and emission-control systems. Because hybrid vehicles weren't introduced until 1999, a JD Powers executive suggests the problems were likely due to quirks that weren't worked out yet by the 2001 model year.

Sight Gauge Tip

Dave Nestman, lube mechanic with Howe Sound Pulp And Paper, stresses the importance of periodically draining oil sight gauges to ensure they're providing proper readings. "One of our fan pumps recently lost an oil-filled bearing due to lack of oil in the sump," he says. "The oil level sight gauge used on this pump indicated that the pump was full but actually it was not. The pipe coming out of the side of the pump to the level gauge was plugged with sediment and would not let oil out of the sight gauge to give a true oil level reading."

Diesel Market Looks Toward Synthetics to Protect New Engines

New diesel engines set to debut in 2007 will require premium diesel oils.

The next wave of EPA-mandated low emission diesel engines will debut in 2007, and lubricant manufacturers will be challenged to formulate diesel oils capable of meeting increased heat and detergency demands, while also protecting emission-control systems. According to Light & Medium Truck magazine (September 2004), some suppliers are looking to synthetic diesel oils to provide the answer.

AMSOIL Executive Vice President Alan Amatuzio is quoted in the article, saying, "synthetic oil has the potential for growth as heavy-duty diesel engines [coming in 2007] put more stress on the motor oil."

Engine manufacturers will be relying on diesel particulate filters (DPF) to meet 2007 EPA regulations, which require a 90 percent reduction in particulate matter emissions. Oil manufacturers must ensure new diesel oils minimize any harmful effects on these DPF's.

Drain intervals for future diesel oils are also a concern. Fleet owners do not want to see recommended drain intervals decrease. "One of the fears is that oil-drain intervals will be reduced [with the next 2007 engine oil specification], and most maintenance practices won't be able to keep up," says Alex Bolkhovsky, technical advisor at ExxonMobil Lubricants & Specialties.

The use of synthetic diesel oils is the key to allowing extended drain intervals with new diesel engine technology. Karen Campbell, marketing manager at Castrol, believes synthetic market share in the diesel market will increase from two to six percent over the next five years as fleet owners realize "the benefits of extending drains, less oil consumption and, in some cases, improved fuel economy."

AMSOIL synthetic diesel oils provide superior protection and performance in today's diesel engines. As new diesel engine technology is introduced in the future, AMSOIL will be ready with premium, top performing synthetic lubricants.

Lubrication System Tips

Noria Corporation offers the following tips in relation to centralized and automatic lubrication systems:

1) The advantages of using oil mist lubrication include the following:

• It provides a constant supply of fresh oil.
• The slight pressurization minimizes contamination.
• The system has no moving parts or cyclic mechanism.
• Alarm systems aid the monitoring of flow rates and oil levels.
• Lubricant consumption is minimized, reducing expenses.
• Temperatures in bearing housing can be reduced up to 30 percent.

2) Chain oilers automatically lubricate at pre-determined rates, preventing problems related to over- or under-lubrication. Automatic lubrication reduces risks of under-lubrication, chain wear and chain elongation.

3) Most single point automatic lubrication devices offer mounting flexibility, mounting at any angle.

4) When high contamination levels are a problem in bearing applications, it may be beneficial to convert grease lubrication systems to oil mist lubrication. Because they're slightly pressurized, oil mist systems reduce contamination levels. Pure mist is recommended for rolling element bearings and purge mist for gearboxes and journal bearings.

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Vehicle Maintenance Becomes Bigger Priority

The Automotive Aftermarket Suppliers Association (AASA) reports that unperformed automotive maintenance dropped from $62 billion to $43.3 billion in 2003. According to AASA director of market research Frank Hampshire, the drop can be attributed to increased consumer interest in maintenance due to uncertainty about future economic conditions, as well as a high rate of new vehicle sales that took many "maintainable" vehicles off the road. "When money is the only issue, for example in the months leading up to Christmas, car owners will neglect vehicle maintenance," says Hampshire. "When their job or economic future is uncertain, on the other hand, consumers will maintain their cars to protect their investment and to make sure the vehicle remains in good running condition." Of the $43.3 billion in neglected maintenance, tires and shocks/struts represent the largest product segments.

Bombardier Name Change

In order to create a fresh look, Bombardier Recreational Products has officially changed its name to "BRP." "We have a unique opportunity to start anew without having to start over," says BRP president and CEO Jose Boisjoli. "We are determined to use it to lay claim to every playing field - snow, water, off-road, on-road, or in the air." According to Boisjoli, the company plans to make good on "a new and superior promise - the BRP 'ultimate fun' experience" for its customers.

Trucks Incorporate New Technology to Reduce Emissions

Manufacturers are preparing for the next round of EPA emissions regulations.

Manufacturers of heavy duty trucks and engines are continuously modifying their products to comply with Environmental Protection Agency (EPA) emissions regulations. While the tough October 2002 emissions control deadline has passed, even stricter rules go into effect in both 2007 and 2010.

Reviews of new engine technology have been mixed. Cummins, for example, incorporated exhaust gas recirculation (EGR) technology to comply with the 2002 regulations. By removing exhaust gas from the exhaust stream, cooling it and placing it back in the engine's intake side, the gas mixes with air and fuel and inhibits the combustion process, lowering flame temperature and NOx levels.

"Regarding Cummins' EGR, no one is crazy about the loss of fuel economy or the increased price of the engine, but I have not heard of major issues with the performance of those engines," says Frank Raney, severe service marketing manager at International Truck and Engine Corporation.

"We know of some new environmental regulations set to take effect in 2007 and 2010," says Jim Crowcroft, product marketing manager at Sterling Truck Corporation. "For all practical purposes, you won't be able to pollute at all in 2007, and for 2010, whatever's left will be gone.

"These changes force costs back into the product, drive down fuel economy, force manufacturers to provide hotter engines, and raise tare weights," says Crowcroft. "On the other hand, customers demand more power. And they want lighter tare weights, zero maintenance, and more automatic transmissions."

Some manufacturers have managed to keep their truck offerings fairly consistent. "We continue to offer the vast majority of the trucks and horsepowers that we did before," says Stephan Olsen, vocational market segment manager for Kenworth Truck Company. "We've invested heavily in designing trucks to accommodate these new engines, to handle the increased heat rejection that is inherent with the new engine technology.

"The largest impact was on the cooling system," says Olsen. "Our investment is in accommodating the turbochargers, the air piping, and cooling piping.

"Customers need to pay close attention to the new spec'ing guidelines that engine manufacturers have," he says. "That's particularly true with Caterpillar's new engines. They're bringing back an old saying: 'Gear fast, run slow.'"

To receive maximum fuel efficiency over the road, Caterpillar advises gearing its trucks to 65 mph with its big bore C15 engine turning over 1,325 rpm.

AMSOIL Synthetic Diesel Oils offer unmatched protection and performance in both older and new diesel engines, keeping wear to a minimum, maximizing engine life and reducing emissions, operating temperatures and fuel consumption.

Oil Sampling Tips

Noria Corporation offers the following oil sampling tips:

1) When planning to purchase new equipment, be sure the design includes both and optimum primary and secondary sampling port. It saves time and work at this point rather than waiting until after commissioning, when fitting the ports may be more difficult. Communicate with manufacturers to let them know your specific needs.

2) A battery-operated medical suction unit is ideal for collecting oil samples from tight or hard to reach areas. a sample bottle hand pump can be converted to work in conjunction with the suction unit, drawing the oil sample directly into the sample bottle. Simply install a new bottle and turn on the suction unit. Now both hands are free to get the tubing into the sump oil. Medical suction units are available at medical supply stores, while private ambulance services may be willing to sell a good used one.

3) Drain and return lines are ideal sampling locations in circulating systems because the oil sample can be obtained before it returns to the tank or flows through a filter.

4) Obtain oil samples during typical operating conditions, while the equipment is running and under normal applications. Do not obtain samples following an oil or filter change or any other time when the oil won't represent typical conditions.

5) Create and record specific sampling procedures for each piece of equipment to ensure samples are always obtained in a consistent manner.

Oil Analyzers Inc. (OAI) provides lubricant testing, technical support and mail, internet, fax and phone reporting for the following applications:

• Diesel Engines
• Gasoline Engines
• Automatic Transmissions
• Final Drives
• Differentials
• Hydrostatic Drives
• Mobile Hydraulics
• Compressors
• Natural Gas and Dual Fuel Engines
• Generators
• Marine Engines
• Racing

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Lubricants Addressed in Handbook 130

The National Conference on Weights and Measures has added a lubricant category to Handbook 130, a book which serves as a prototype for states that regulate consumer products. It calls for warning labels on obsolete motor oil containers, as well as documentation of performance claims upon request. "This is basically something that can serve as a model regulation for states that want to address such problems," says Dennis Johannes, chairman of the conference's Laws and Regulations Committee. The new rules automatically become law on January 1 in Pennsylvania, New Hampshire and West Virginia, while other states are expected to soon adopt the regulations or develop their own. "As issues arise, this regulation will be something that is easy for states to use, whether they adopt it as is or use it as a starting point to write their own laws," says Johannes. "But it takes someone pushing the issues for those states to deal with it."

Storage Tip

When preparing sealed case type equipment such as gearboxes for long term storage, Porter Claytor, maintenance consultant with CNS Associates, LLC, says, "After following all recommended standard lube practices, bring your inert gas tank (helium or argon) along-side and purge the interior before putting in the final plug. This will drive out remaining moisture in the air with associated contaminants and significantly increase corrosion resistance over time."

Increased Demand for Premium Quality Greases

NLGI survey reveals double digit growth in the production of lithium complex greases.

According to an annual survey conducted by NLGI, total worldwide grease production grew to nearly 1.7 billion pounds in 2003, the highest total reported since the survey began in 1957. Production of premium greases showed the most impressive growth with lithium complex grease production growing 12.5 percent and polyurea grease production climbing five percent since 2002.

According to Joseph A. Lurz Jr. president of J & A Consultants, an increasing number of companies are responding to the NLGI survey for grease production. "We're very pleased with the response, and the comparative numbers [for North America and Europe] are also good.

"The comparative totals went down a little, but grease is still a thriving business. People are buying higher quality greases that last longer. The increases [for high quality greases] are impressive."

North American grease production totaled 504.7 million pounds in 2003, representing a 0.2 percent decrease from 2002. However, lithium complex grease production grew by 10.1 percent and polyurea grease production rose 2.1 percent, showcasing increased customer demand for the improved protection and performance and longer drain intervals afforded by premium greases.

Similar numbers were submitted by European companies, with total grease production at 443 million pounds, a decrease of 0.7 percent from 2002. Lithium complex grease production increased by eight percent, while polyurea grease production increased by two percent.

Formulated with top-of-the-line synthetic oils, lithium complex thickeners and premium additives, AMSOIL synthetic greases offer unsurpassed protection and performance for all types of applications.

Bearing Lubrication Tips

Noria Corporation offers the following tips for bearing lubrication:

1) Using bearing grease of a higher consistency helps prevent water washout, bleed/separation and leakage, and it offers improved performance in high ambient temperatures.

2) In humid operating conditions, condensate can build up in rolling element bearings and lead to corrosion and reduced bearing life. High quality greases can significantly reduce the negative effects of condensed moisture. While greases with sodium soap thickeners emulsify large volumes of water, the water tends to soften the grease and cause it to flow out of the bearing. Formulated with proper additives, lithium soap greases and greases with synthetic thickeners provide valuable protection against corrosion and prolong bearing life.

3) When grease-packed bearings are run at high speeds (over 5000 rpm), grease quantity can have a significant impact on heat generation. Excessive amounts of grease hinder bearing's ability to push the excess to surrounding pockets, causing bearings to heat up quickly. A 10 percent change in grease quantity can yield as much as a 40 degree F temperature change. The optimum level of grease is often less than one expects.

4) Because the grease's base oil could separate out and get drained from the thickener, bearings should not sit idle for long periods. The thickener cannot provide adequate lubrication protection on its own.

5) Over lubrication of rolling element bearing leads to churning and excessive heat generation, especially on higher speed applications.