Lubricants News and Updates

What can High Copper Levels mean?

Recently I have reviewed many Used Oil Analysis reports that indicated elevated Copper levels. Although Copper is considered a Wear Metal, there are instances or situations that can occur where higher than normal levels of copper can exist. This can also be true with other Wear Metals like iron, lead, aluminum, and chromium, where the analysis readings were raised or lower than normal.

Back to Copper. There are many reasons why copper could be high, but it usually comes down to either wear, or the copper is leaching into the oil from cooler lines or components due to new equipment break in. By looking at other wear metals and elements such as tin and/or zinc for instance, equipment wear can be rules out or confirmed. If the other wear mechanisms are not present in the oil sample analysis, then most likely the culprit for high copper levels is in fact the oil cooler and components.

The break in or leaching of copper levels into the oil can be either slowed or increased depending on Diesel Engine Oil formulations. Sometimes, converting from one brand to another these levels of copper would increase or decrease. Therefore, it is always important to look at the analysis reports and the elements in it’s entirety before drawing any conclusions.

Most often we have seen these issues with Caterpillar equipment. In 2003 CAT issued bulletin SEBD9318-00 to address this issue. It says in part “These elevated copper levels can be dramatic. Customers that observe these elevated copper levels are very concerned about excessive wear or component failure. In most cases, the customer should not be concerned about these elevated copper levels: the condition does not usually indicate excessive wear and/or component failure. However, it is important to understand the cause of the condition.”   Again, it is important to review the UOA Reports completely to have a better understanding of the oil and equipment condition.

Quality hydraulic fluids have advanced formulations, high VI and the most advance additive packages to provide operating and maintenance benefits for increased productivity and less downtime. T

wo rules of thumb for hydraulic fluid are to keep it - “Clean and Dry”, because research and testing has proven that over 80% of hydraulic pumps wear and system failures are due to particulates and water contamination. Production downtime and labor costs for repairs often outweigh the cost of replacement of hydraulic components or systems. 

A hydraulic system can be complex with very high pressures. Most hydraulic system components have very tight tolerances ranging from 0.1 to 40 microns. Particles larger then allow tolerances can weaken the lubricant film and cause premature wear. Ingression of particulates (contaminates) usually enters the hydraulic system reservoirs or tanks through the breather cap. This is because a hydraulic reservoir will “breathe” every time the fluid is pumped in and out of an actuator or cylinder. Most particulate starts off as just airborne dust or dirt, then it finds its way into hydraulic reservoirs. From the reservoirs the particulates can find their way to the hydraulic pump and out to valves, bushings, seals, bearings, and other components. It is here that premature wear begins.

Filtration and quality breather elements are key to minimizing airborne contamination. Filtration and filter elements should be specific to the hydraulic system and its tolerances. This also holds true for a reservoir/tank breather element. Like a quality filter, a quality desiccant breather is one that: achieves the target level for “cleanliness and dryness”, has the capacity to hold and filter contaminants between fluid change-outs, but also should be easily visible for routine inspection during preventive maintenance.

Preventing the ingression of contaminants and water with quality filters, breather and hydraulic fluid is easier and costs much less then downtime or labor to replace a hydraulic system or components.

To summarize: Keeping hydraulic fluid “Clean and Dry” will extend the life of the fluid and the equipment.

Final Drive Train Oil

Final drives play a crucial role within a machine’s drive train by transferring power to the tires or tracks while providing speed reduction and torque increase. Since final drives are closed components and thus hidden from view, it is easy to overlook their maintenance.

Proper Oil Use

The three main functions of oil are to provide: cleaning, cooling and lubrication. Modern drive train systems feature new metals, elastomers and paper disc materials which may have advanced lubrication needs, requiring you to change oil at the correct intervals, properly, and use the right drive train oil to achieve top performance.

Use the Right Drive Train Oil

Final drives, axles and differentials experience high gear and bearing loads and temperatures. In these conditions, it is important gears and bearings are protected.                            

Depending on the configuration of the final drive and the equipment, 1 of 2 very different fluids may be recommended, Tractor Hydraulic fluid or TDTO/CAT TO-4.  

Tractor Hydraulic Fluids – also most commonly known as – THF or UTF – which can carry all of the required additives to meet or exceed OEM specifications.

1. This fluid is typically used to lubricate transmissions, wet brakes, clutches, hydraulic systems, and of course final drive.
2. To meet the specific requirement for this fluid must have: Friction Modifiers – which help to prevent wet brake squeal and offer smoother clutch operation
3. Tractor Fluids meet or exceed API GL-4 spec.

TDTO (Transmission Drive Train Oil)/CAT TO-4 – also known as Powershift Transmissions and Drivetrain Fluid.

1. Primarily used in CAT equipment or other equipment that requires fluids without friction modifiers
2. This type of fluid is used to lubricate transmissions, brakes, clutches, hydraulic systems and of course final drive.
3. To meet the specific OEM requirements for this fluid: TDTO fluids do not contain (Friction Modifiers). TDTO fluids are available in SAE Grades of 10W, 30, 50 and 60 for specific application and temperature requirements.
4. TDTO fluids – only meet API GL-3 spec

Larger and more advanced equipment may require a heavier viscosity, synthetic fluid, which will meet the new CAT FDAO spec for Final Drive Axles. This fluid is commonly used in Differentials, Front Wheels and Final Drives for Off-Highway Trucks.

A common question amongst maintenance personnel is around the life expectancy of our Hydraulic Oils in their machines. For the most part, many maintenance personnel say that they expect a very short time because of the aggressive environment surrounding the manufacturing equipment.

And this is true if we recognize that the oil will suffer just two adverse effects in the equipment: Contamination & Degradation.

Premium hydraulic oils are capable of maintaining their initial characteristics and protect the equipment for a very long time…..even several years in a properly designed hydraulic system and with a proactive maintenance program.

6 areas to help extend the life of Hydraulic fluid while protecting equipment:

1.-Choose the Right Product:

A few Premium Hydraulic fluids characteristics:

1. Advanced Technologies in Base Oils and Additives:
1. Keep the oil and system clean
2. Have Outstanding contamination control
3. Have Exceptional protection against wear
4. Control demulsibility

2.-Prevent Contamination:

1. Keep strict housekeeping control.
2. Change from metal screen breathers to a desiccant breather.
3. Use proper Filtration and filters with an Absolute Ratio β according to your needs.
4. Segregate type of lubricants to prevent compatibility concerns.
5. Consolidate Inventory of Lubricants.
6. Fix leaks and the air intrusion in the equipment.
7. Do not use after-market additives or mix products.
8. Identify and ‘Lube Tag’ the equipment and the oil being used.

3.-Avoid Waste

1. Repair leaks
2. Use the golden rule: The right product in the right place with the right amount.

4.-Protect against deterioration:

1. Maintain proper storage and handling of hydraulic fluids.
2. In outside storage, stack drums horizontally or upside down to prevent water contamination
3. Monitor equipment operation to avoid: high temperatures, excessive air exposure, static or electric discharges.

5.-Extend Useful Life

1. Purchase Premium products to meet your equipment’s needs.
2. Determine the optimum practical drain interval.
3. Establish a system of simple checks in the field to assure the integrity of the oil and its operations – Send in routine used oil samples to a laboratory.

6.-Personnel Training on Lubricants

1. Training generates experience and this is the base of an optimum use and preservation of the lubricants and the benefits that can be achieved.
2. Do not let unauthorized/inexperienced people handle lubricants.
3. Hydraulic lube oils are the heart and soul of your equipment and maintaining a staff that can take proper oil samples and interpret the laboratory testing results will pay huge dividends back to any operation.

Maintaining Proper Oil Levels in Reservoirs, Sumps, Gearboxes and Crank case

Whether the case is Automotive – (engines, transmission, differentials), Gearboxes, Circulating Systems or Pumps; maintaining proper oil levels in reservoirs and sumps is imperative for both the equipment and oil life.

When oil levels are too low, machine wear and damage can occur very rapidly. There may be an increase in friction due to the lack of lubricating boundary film and/or viscosity changes from increased fluid temperatures. The lack of oil can lead to metal-to-metal contact which can in turn cause wear. This wear mechanism, known as spalling, pitting, smearing and seizing, all of which are forms of Adhesive Wear, are most common from metal to metal contact.

When oil levels are too high, it mainly can affect the lubricant and its properties, but can also cause damage to equipment. Oil levels that are too high for long periods of time can result in the machine or equipment aerating or churning the oil. Oil that has been aerated can change viscosity, speed up oxidation, and use up additives. When equipment or machines are run in these conditions, the lubricating film strength weakens, boundary conditions form and damage to the equipment can occur.

Implementing proper programs and procedures to continually monitor and maintain oil levels will result in longer fluid life and equipment life. Properly training personnel on how to “Monitor and Maintain Fluid Levels” through dip sticks, sight glasses or other methods determined by the OEM can produce higher productivity and less down time. Checking the oil for proper levels at regular intervals will help to ensure long life for both the equipment and the oil.

Since December of 2020, we have seen an unprecedented SIX price increases roll out on base oil, additive & finished lubricant products. Now we are additionally seeing essentially all major suppliers move to allocations on products because of increasing difficulty on supply/sourcing.

So what is going on? 

Like most things in 2021, a lot of the issue started with the Pandemic & its after effects. When shutdowns went into effect in March 2020, demand for finished products crashed and that led to cuts in production volumes by producers, and the simultaneous drop in fuel demand led to a drop in refining, which caused a drop in the ability to source products for lube production that derive from fuel refining... and so on, like dominos. 

Once things came back online, the freak ice storms in Texas that derailed refineries once again slowed the access to lube production products. 

As soon as that was sorted,  demand  in the US roared back much faster than anticipated on both fuel & lubricant products as the world began to open back up.  This essentially created a situation where production was not able to come back online fast enough to meet suddenly skyrocketing demand. 

This has led to unofficial allocation levels for nearly all distributors across the country, as companies from major suppliers to independent blenders struggle to access the supply required to service their customers properly. 

To add another layer of frustration, the labor shortage in the transportation industry (read about that here: All Eyes on the Growing Driver Shortage )  means that even in the event that product CAN be sourced adequately, it is increasingly difficult to secure delivery, even at higher than standard freight rates. 

Long story short, the Pandemic, Economic Rebound, and Labor Shortages have essentially created a "perfect storm" where the fundamentals of supply and demand are pushing lubricant, additive, and base oils skyward. Optimists in the field hope supply issues will be remedied by the end of the summer, but with talk on the horizon of yet another increase in September, it seems doubtful that will be the case. 

We will keep you apprised of any major changes in the supply and pricing picture going forward. Hang in there, everybody.  

In 2015 we moved out of our longtime corporate headquarters in Chelsea MA into our new facility in Taunton MA. In 2020 we also added another state-of-the art lubricant plant in Saco, Maine.

While current COVID protocols limit our ability to show our facilities to our customers, we thought a photo "walk through" and explanation might be helpful while we wait for things to open up in Massachusetts so we can return to the real thing (which thankfully should be soon!!) 

Below is a quick run through some of the key parts of our main facility in Taunton, Mass. 

One of the things we are most proud of about the Taunton facility, is starting again in the warehouse let us have the ability to put the same level of extra care into planning out product segregation in our facility as we have always done in our trucks. 

We have a substantial tank farm, and our Lubricant Operations team really went the extra mile in installing a segregated piping system, including separate pumps for hydraulic, motor oil, and DEF. This essentially provides extra steps to ensure product integrity, and eliminates the chances of any cross contamination by removing even the chance of slight residual product in hoses after pumping. 

Within our customized lube delivery trucks, the same principal applies, as you can see here:

For DEF, our DEF trailers are equipped with 1 micron filters, which ensures the cleanest possible product and guarantees no contamination. We run closed systems on all DEF packaging & equipment to ensure quality throughout the life of the product. 

Additionally, we added a customized tote wall setup. This setup allows us to store multiple totes in an efficient space, as well as designate each one by product and manufacturer, so each tote only carries its designated item which we can track by barcode from fill through delivery to a customers site, meaning in the event of any issues, we have full visibility into the full journey of the product and know exactly where it is and where it came from. 

The barcoded, segregated totes tie into our broader inventory tracking & product delivery platform we use to integrate product management within the warehouse with precise delivery to customers, and route optimization for our drivers, but that's a subject we will cover in another update. 

Saco to follow!

Berkebile Oil's Protection First Class (PFC) is a must for plow and snow removal equipment operators. Road treatments, added to harsh conditions of New England winters can do a number on plows and salt spreading equipment. With PFC, you can coat plow blades (polymer or metal), spreader bays, augers, and chains, and even battery terminals. You have a lot riding on your equipment functioning correctly, and remaining in peak condition to perform. Help protect it with Protection First Class. We stock PFC in our Taunton facility. For more info, contact your area rep, or simply leave a comment below and we will reach out. 

The video below explains more about PFC, particularly for use in snow removal. For additional info, visit Protection First Class

Dennis K Burke is proud to announce that we are now the Phillips 66/Kendall Lubricants distributor for the Northeast. Kendall has been on the forefront of advances in lubricant product technology since the early 1900's and we are excited to be able to offer their premium, cutting edge products to our customers.  

For more information about Phillips 66/Kendall Lubricants product offerings, please visit  https://www.kendallmotoroil.com/ or feel free to reach out to the office (800-289-2875) or your Dennis K Burke representative for more information.

Dennis K Burke is excited to announce that we are now an official distributor of Castrol automotive & heavy duty lubricants throughout the states of Massachusetts, Rhode Island, Connecticut, New Hampshire, Maine and Vermont! 

Castrol is a premium product line, and offers a range of advanced motor oils including synthetics, synthetic blends, high mileage, conventional, and diesel engine oils.  We are excited to add Castrol to our product mix!

For more information on Castrol & Castrol Lubricants, check out their website at www.castrol.com