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User Manual - On-Site Analysis, Inc.

1. Ei Waste E Flush ANALYZE mover Version 5 1 Build 11 Measuted Misc Only Print Mode NumericHistory Samples 10 User TTT Analysis Mode Truck OPERATING THE DTV Operation of an OSA with the DTV is the same method used in How to Analyze a Sample The time frame is longer because of the additional DIV component Never reuse the 5 ounce sample bottles after the test is completed STANDARDIZING THE DTV Once every 6 months the DTV will need to be standardized Included with your OSA will be two viscosity standard bottles Low Viscosity Standard Pink Fluid and High Viscosity Standard Green Fluid Pour these into separate 3 ounce sample bottles and label them accordingly From the Main Menu Select ADMIN Button then Viscometer Utilities Button Revision Date 1 January 2012 56 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Manage System Configuration and Maintenance Log Logout Logan Logout Current Operator and login a New Operator Printout Format Select Format for Printed Samplo Results Current Setting Combined Select Analysis Mode Auto Truck Marine ete Analysis Mode Current Setting Auto Select Method tor Viscosity Evaluation Viscosity Mode Current Setting Measured Viscometer Utilities Set Options for Viscometer Operation Set Options f 6 Se Barcode Scan Mode gt Options for ite att Data Transfer Upload or Download Sample Data E
2. SAMPLE DATA ENTRY Information about your sample of oil must be entered prior to starting the analysis The information you provide is vitally important to the analysis The more accurate the information the better the analysis Revision Date 1 January 2012 21 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Sample data includes information about the customer the vehicle and the oil The system keeps lists of your customers and their vehicles These lists keep you from having to re enter information The lists can also be sorted by Customer Name Customer ID or right and left justified VIN number SELECT A CUSTOMER When selecting a customer you have two options Select a customer from the list or add a new customer If the Customer ID you want is not displayed in the box but it is in the customer list then highlight the customer you want by using the UP and DOWN Arrow Keys or entering the first letter s of the customer name and use the ENTER key to make your selection Press OK to continue If the customer you want is not displayed in the list of customers then you must add your customer name to the list Press the New Customer button to add your customer Each option is discussed in detail below Revision Date 1 January 2012 22 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual SELECT 4 CUSTOMER Select a Customer from the List LIST SORTED BY
3. Extended metals Low Concentration Standard is now complete Select the OK button to continue on to Extended metals High Concentration Standard Clean the electrodes thoroughly and place a clean straw into the brown High Concentration Standard and connect to the silver sipper nozzle Select OK when ready as shown below OSA OPERATIONS BEZO WELCOME TO THE Strdedr Extended Metas High TRUCK ample a Network B waste A cover E Vernon 4 Budd 2 Viecomty Mode Meansed Pint Mode Nunee Samples 131 User 2 Ansives Mode Truck Revision Date 1 January 2012 50 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual This method will last approximately 10 minutes A message will appear stating Extended Metals HCS Standardization Completed as shown below If you see otherwise CANCEL and repeat previous steps for the HCS standardization OSA OPERATIONS FEZ WELCOME TO THE StadaderEstended Metak High et 4 4 zer Sample E Network 10 Waste 8 Cover Vernon d 1 Budd 2 Viscosty Mode Mesuned Pert Mode Numero Pera Mode Truct Extended metals High Concentration Standard is now finished Select the OK button A message stating Standard is Finished will appear Select the OK button to begin automatic flushing procedure Follow screen instructions and select OK on all flushing messages that appear Extended Metal St
4. E COX A Spectro Scientific Company User Manual Includes Extended Metals Dual Temp Viscometer VIN Decoder Particle Counter MetalLab and Viscometer Only OSA4 VERSION 6 1 Original Instructions Guide to the OSA4 Analyzer certified ASTM D7417 10 PREFACE This user manual is the first part of the complete guide to the OSA4 Analyzer This manual is intended to guide operators of the Analyzer through the normal procedures associated with processing oil samples This manual is intended for mechanics technicians or anyone else who wants to learn the proper way to analyze oil samples using the OSA4 Analyzer The introductory sections of this manual orient the user with the equipment and supplies that are used The Standardization section covers the procedures that give the user confidence that the Analyzer is performing to specifications The largest section of this manual is the How To section The reader is taken through a step by step process of how to analyze an oil sample The Printing and Flushing sections complete the start to finish organization of this manual This manual includes features that are designed to aid the reader in quickly referencing helpful information The outlining is extensive so that the reader can easily find the topic of interest Useful tips are emphasized in boxes entitled Key to Successful Oil Analysis The electronic version of this document includes hyperlinks and
5. The Baseline Test is used to determine if there is contamination in the flow system or on the electrodes of the Analyzer It should be performed at the beginning of each day or any time you wish to confirm that the Auto Flush cycle has sufficiently cleaned the internal lines and electrodes after running a highly contaminated sample To run this test simply select the STANDARDIZE button from the Main Menu The Standardize Options Screen will appear as shown below Select Check Base Line from the list of options a Basic Metals Standardization AA AAA A ee ee ee A Verify the Unit has Flushed Properly and the System ts Clean Verify Metals Verity Metais are within Specifications Standardize Metals Full Standardization of the Metals Revision Date 1 January 2012 14 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual When the Baseline Test begins you will be given instructions to clean the electrodes Refer to Cleaning the Electrodes in the How to Analyze an Oil Sample section of this manual for a description of the proper technique Follow the directions on the screen to perform the Baseline Test After cleaning the electrodes press the OK key and the Analyzer will run the test Press CANCEL if you want to return to the main menu At the end of the test a message box will display informing you if there is contamination or that the System is clean OK to proceed If the
6. 40 Date Taken YIN DECODER 508 460 7779 MAY 02 2005 123456 Miles 1C3AL56R24N356459 4500 Miles MAY 02 2005 Sall DIL INFO The sample will run through and upon completion the message below will appear Selecting YES will return you to the Main Menu where you will select Analyze to run another sample for the same vehicle Transmission or Power Steering This avoids having to scan or enter the same VIN number again If you want to run another vehicle Select NO IN DECODER a a ee JCO 1 Tig J Aj h 7 A 2A 65 Revision Date 1 January 2012 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Default Customer Info Select the Default Customer Info button to fill in the data on the form below This data will be shown on the report printout w Default Customer DEFAULT CUSTOMER FOR VIN DECODER Customer Name VIN DECODER Customer Address 398 CEDAR HILL ROAD City MARLBOROUGH State MA Zip Code 8 8 Customer Phone PERO Customer Fax 508 460 7779 OOO Customer Email TCAI ON SITEANALYSIS COM OK CANCEL Revision Date 1 January 2012 66 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual ADDENDUM A for instruments equipped with a particle counter module Sample Preparation Procedure for Particle Measurement lf the sample to be measured has been standing for any period of
7. accessed The main menu is shown below Page numbers for description of the main menu features are provided Some of the items described here are elsewhere in the Users Manual U M WHEN THE ANALYZER IS BOOTED FROM THE DESKTOP THE USER ID AND PASSWORD ARE 1 AND 1 THIS MESSAGE BOX WILL APPEAR BRIEFLY AS THE UNIT WARMS UP 054 WARMING UP PLEASE WAIT OSA OPERATIONS 1 0 Disabled OSA Inc O ON ROAD T R U C KC H E E K NOUSTRIAL ON SITE OIL ANALYZER COMMERCIAL GENSET System Status OIL ANALYSIS SYSTEM T E Network 54 Waste 53 Flush E Cover Version 5 3 Build 1 Empirical Analysis on Road TRUCK Begin View Sample Analysis Help Information RAILROAD Revision Date 1 January 2012 13 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual HI STANDARDIZATION EXPLANATION Occasionally it is necessary to standardize the OSA4 Analyzer in order to compensate for minor changes affecting the Analyzer s calibration You do not have to standardize the Analyzer unless 1 you have adjusted the Electrode Gap 2 the Test Standard routine prompts you to or 3 the message box tells you to at the beginning of a sample run You should run the Test Standard routine 3 days 72 hours after a Full Standardization or whenever you question the Analyzer s performance Prior to running the Test Standard routine a Baseline Test should be performed CHECK BASELINE TEST
8. 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual SELECT A CUSTOMER IN OFF HIGHWAY MODE When selecting a customer you have three options use the default customer select a customer from the list or add a new customer lf the Customer ID for the customer you want is already displayed in the box next to Enter Customer ID then press OK to use the default customer name If the Customer ID you want is not displayed in the box but it is in the customer list then highlight the customer you want by using the UP and DOWN Arrow Keys and use the ENTER key to make your selection Press OK to continue lf the customer you want is not the default customer and is not displayed in the list of customers then you must add your customer name to the list Press the NEW CUSTOMER button to add your customer Each option is discussed in detail below Follow the instructions below for choosing a customer from the list or adding a new customer Select a Customer from the List USIT SORTED By ENTER CUSTOMER NAME CUSTOMERS Address City State ZipCode Phone Fa Revision Date 1 January 2012 38 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Listed Customer Listed customers are the names of customers that have had their oil analyzed previously Choosing from the list keeps you from having to enter the customer s information each time their oil is analyzed Using t
9. Go gauge for measuring the electrode gap The gap should b set to the distance between the flat sides of the gap tool As samples are run the gap between electrodes will increase To reset the gap loosen the upper electrode by turning the 5 32 socket head cap screw Let the upper electrode holder slide down till it is flush with the top of the white electrode gap tool Retighten 5 32 socket head cap screw Anytime the gap is changed the unit must be re standardized As described above the lower electrode will slowly decrease in size with us widening the gap between the electrodes Any time a full standardization is required it is recommended to check the height of the lower electrode Revision Date 1 January 2012 9 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual To check lower electrode height place the grooved U shaped end of the white electrode gap tool shown below around the bottom electrode If the electrode falls below the height of the U shaped tool then it is time to change the electrode To change electrodes Start by sliding the upper electrode straight up out of its holder This is done by loosening the same screw as shown on page 9 After raising the upper electrode out of its holder remove the lower electrode The lower electrode has a 05 Allen screw holding it in place Loosen the Allen screw and remove the lower electrode by turning counter clockwise Anytime y
10. N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual OIL SAMPLE INFORMATION Off road Diesel Engine Oil and Analysis Information CHECK Y Customer Name XYZ MINE AAA Street Address 123 DESERT ROAD Fax Number City State Zip MINEYILLE AZ 12222 Description CRANE Phone Number 555 888 9999 Fleet Unit ID X3456 Time on Unit 215 Vehicle Make GROVE Unit ID 976542 Vehicle Model RT518 Bay Oil Brand CH EVRON Operator Driver Name JON Oil Type RPM Heavy Duty Date Taken FEB 16 2003 All Weights C Common Weights Specific Weights Oil Weight 20W50 iy all UNIT INFO Enter Additional Special ID for sample Any text Oil Weight Selection Miles on Oil 21 5 Oil Brand Type and Weight Select the oil brand type and weight of your sample If you do not know the any of this information you may leave it as unknown Usage Units and Miles on Oil Enter the number of hours that have accumulated on the component since the last oil change User Sample ID A User Sample ID is a way of uniquely identifying a sample This ID may be a bar code that is affixed to the sample bottle and data entry sheet Operator Name Enter the name of the vehicle s driver here The information is useful when there is more than one operator on the unit After completing the Oil Sample Information screen press ANALYZE to continue Revision Date 1 January 201
11. OSA4 Analyzer User Manual Startup Check List Check Flush Please fill flush bottle and check straw position Please clean electrodes thoroughly Please empty waste bottle Fill Paper Tray Please fill printer paper tray with paper e us select the GASOLINE key on the keypad to analyze a sample of crankcase oil from gasoline powered cars and light duty trucks Select the DIESEL key to analyze a sample of crankcase oil from a diesel powered car medium or heavy duty truck Select the TRANSMISSION key to analyze a sample of transmission fluid Select the POWER STEERING FLUID key to analyze a sample of power steering fluid The Re Run Last Sample Button allows you analyze the last sample again without having to re enter all of the sample information The Main Menu page shown on page 13 is where the initial application is first selected The available modes are ON ROAD which includes Bus RV and Trucks OFF ROAD AUTO INDUSTRIAL COMMERCIAL GENSET MARINE CYCLE RAILROAD The following example is in ON ROAD Trucking Mode Revision Date 1 January 2012 20 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual w TRUCK MODE BTRUCKCHECK ON ROAD MODE SELECT A TESTING OPTION E ON SITZ OIL ANALYZER After making selection a message box will appear giving last standardization information Select OK If you have exceeded allotted time you will be asked to Standardize
12. STANDARDIZE To standardize the Analyzer select Standardize from the Standardize Options screen When the standardization process begins you will be given instructions like those shown on the screen below Press OK to continue or CANCEL to return to the main menu Standardization is comprised of two parts Low Standardization and High Standardization All the operator has to do is insert a clean sipper straw into the Test Standard fluid Blue 50 ppm standard connect to the silver sipper nozzle and follow the instructions Carefully follow all on screen instructions completely The total process will take about 15 minutes to complete Upon completion the Analyzer will display a message stating whether or not the standardization was successful If unsuccessful the software will prompt you on what to do next Revision Date 1 January 2012 17 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual COLLECTING THE OIL SAMPLE 8 SAMPLE DATA To analyze oil from an engine or transmission you must first obtain a sample There are two methods for sampling the oil You can either catch a sample during a drain or you can pull a sample through the dipstick Provisions for sampling have either been provided with the OSA4 Analyzer or you may obtain sampling kits from your retailer Refer to the Training Manual or other supporting documents for detailed instructions SAMPLE INTRODUCTION When you have a sample to analyze
13. To reduce the risk of injury do not open the instrument enclosure or remove access panels There are no user serviceable parts inside Refer servicing to qualified service personnel WARNING LABELS Special labels are placed where hazards exist This symbol warns that dangerous voltages are near that present a risk of electrical shock or personal injury This symbol warns that hazards are near which are described in instructions accompanying the equipment SPECIFIC WARNINGS Do Not Defeat the Spark Door Interlocks Defeating Spark Door Interlocks may expose the user to UV Radiation that can Cause permanent eye damage Defeating the Spark Door Interlocks may expose the user to voltages that are lethal Operate in a Well Ventilated Area The Analyzer produces ozone when high voltage is arcing across the electrodes Do Not Introduce Flammable Fluids into the Analyzer Never attempt to introduce fuels such as gasoline kerosene and diesel fuel into the Analyzer Fuels may ignite and explode causing injury Only introduce used oil samples from diesel engines gasoline engines gearboxes hydraulics and transmissions Key to Successful Oil Analysis Never attempt to introduce anti freeze water brake fluid or fuel into the Analyzer These fluids will cause irreparable damage Revision Date 1 January 2012 5 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual ANALYZER FEATURES The basic feat
14. a last name was entered or press OK to leave it blank The Analyzer s software will automatically assign a Customer ID Press OK to continue Enter the rest of the information using the Tab key to move through the fields When you are finished entering or selecting a customer name Press OK to continue to the Vehicle Data Entry portion CUSTOMER INFORMATION New Customer Information CHECK ON SITE ANALYZER Company fLast Name Company or Last name First name Customer ID Street Address City Zip Code Phone Revision Date 1 January 2012 24 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual ENTERING VEHICLE INFORMATION Unit Information screens are shown below The screens are different depending on which test you have selected The screen below is for On Road Trucking On the Unit Information screen you provide information about the vehicle If the information about this vehicle has been previously entered then the information is filled in for you when you select the vehicle from the list In this case you simply have to enter in the current Miles Hours Kilometers on the Engine or Transmission or Miles etc since the last overhaul If the vehicle is not listed then you must enter all the information manually VEHICLE UNIT INFORMATION OSAT On Road TRUCK Diesel Unit Information TRUCKCHECK Customer Name LANDSTAR SYSTEMS Phone O
15. extended metals is not required at this time Do you still wish to standardize extended metals press YES button to continue Clean the electrodes thoroughly and place a clean straw into the yellow Low Concentration Standard and connect to the silver sipper nozzle Press the OK button when ready to continue as shown in following picture Revision Date 1 January 2012 48 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual OSA OPERATIONS TRUCK CHECK j SHAKE AND INSERT LCS STANDARD FLUID LIGHT ar ad e ini a ENTER OK TO CONTINUE JR CANCEL TO ABORT STANDARDIZATION View Begin Sample Analysis Help Information a Network E Waste E Cover Version 4 1 Build 2 Viscosity Mode Measured Print Mode Numeric Samples 131 User 2 Analysis Mode Truck A message will appear on screen asking to clean the electrodes when the status bar is at 40 Do so and select the OK button when finished This method will last 10 15 minutes A message will appear stating Extended Metals LCS Standardization Stand Completed If error message appears press CANCEL and return to beginning steps for LCS Standardization Revision Date 1 January 2012 49 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual OSA OPERATIONS E Network D waste A cover Vernon 4 1 Budd 2 Vecowy Mode Mesusec Pot Mode Numere ser 2 Anata Mode Truck
16. page 18 of this manual Revision Date 1 January 2012 67 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual ADDENDUM B for instruments equipped sample bottle cap overpressure module Over Pressure Sample Bottle Cap Module When certain gear oil samples are to be measured the analyzer will prompt the user to utilize the sample bottle over pressure cap module When the instrument prompts the user should install the sample bottle over pressure cap as instructed below 1 Ensure that the inside of sample bottle cap is clean wipe with clean rag if necessary 2 Install sample bottle cap onto sample bottle a Align the sample bottle and cap then rotate bottle until cap is tight NOTE Sample bottle cap MUST be on tight A loose fit will result in an air leak preventing instrument from achieving proper air pressure within the sample bottle 3 Loosen straw fitting no need to fully remove fitting located in the center of the sample bottle pressure cap then insert straw through center fitting and finger tighten the fitting NOTE Do NOT over tighten fitting around straw Over tightening the straw input fitting may result in collapsing damaging the straw causing an air leak preventing instrument from achieving proper air pressure within the sample bottle 4 start analysis Reference section IV How to Analyze an Oil Sample page 18 of this manual 5 Follow all prompts in the order that t
17. remove the lid from the bottle and shake the sample thoroughly Select a sipper straw from the box attached to the right side of OSA by grabbing it at the bend of the straw where the ridges are located Place the straw into the bottle long side down and slide the straw onto the silver sipper nozzle as shown below Revision Date 1 January 2012 18 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Key to Successful Oil Analysis Always grab the sipper straw at the bend of the straw on the ridges The sipper must remain in the oil throughout the analysis cycle NEVER REUSE SIPPER STRAWS TEST SELECTION The analysis of your oil depends on what type of sample it is You must specify if the sample comes from a transmission gasoline diesel engine or power steering fluid Press the green ANALYZE button from the main menu and 2 message boxes will appear stating Test Baseline status and Verify Metals Status DSA User Int These messages keep track of time since last Test Baseline and last Verify Metals were run If you exceed the time limit a message will appear stating that you need to run the test s It will allow you to run 5 more samples before stopping Analysis Select OK on each A Checklist will now be shown giving you buttons to select once you perform the listed tasks Perform the tasks then select OK Revision Date 1 January 2012 19 P N 29091 32 On Site Analysis Inc Guide to the
18. standard bottle from the sipper nozzle and continue running samples X VIN DECODER SOFTWARE The VIN decoder software is an application used in Gas Engine Transmission and Power Steering applications The software uses a wireless barcode reader to capture the Vehicle Identification Number from the vehicles front window GM or driver door panel most other manufacturers The barcode reader has a range of approximately 90 feet but can also store the VIN within the reader if you go outside the range The data is automatically transferred to the OSA once you enter the range area The Main Menu will appear as pictured below Simple select Analyze button to begin sampling process Revision Date 1 January 2012 60 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual system Status OIL ANALYSIS SYSTEM 9 ver Bagin ao Sample Sample Analysis Help Information E Network el Waste Fa Cover User 1 Analysis Mode Auto The screen below will appear Select YES to run the VIN decoder software or NO to run the regular software The Customer Info button is used to enter the information for the site that is running the samples This is a one time data entry function performed by the engineer setting up your unit When the screen below is shown Scan the vehicle barcode or type in VIN manually If you scan the VIN the Vehicle data will appear automatically If you type in the VIN you will
19. time particle settlement and agglomeration will occur It is essential that the agglomerates be broken up and the contaminant particles become dispersed evenly throughout the contents of the sample bottle in an ultrasonic bath Energize the bath for 30 seconds or until no surfacing air bubbles are observed Remove the sample bottle from the ultrasonic bath and gently turn the sample bottle over five times taking care not to introduce air bubbles into the liquid prior to analyzing with the OSA Oil Analyzer particle counter function Reference sample preparation procedure outlined below 1 Fill ultrasonic bath with 3 inches of water turn on heater and energize for a minimum of two minutes to degas the system WARNING DO NOT ENERGIZE AN EMPTY ULTRASONIC BATH Energizing an empty ultrasonic bath may cause damage to the instrument 2 Vigorously shake the sample bottle by hand for 15 seconds NOTE A minimum of 3 ounces of sample is required when using the particle counting function of the OSA Oil Analyzer 3 Place the sample bottle in an ultrasonic bath and energize the bath for 30 seconds or until no surfacing bubbles are observed 4 Remove the sample bottle from the ultrasonic bath then gently turn the bottle over five times taking care not to introduce air bubbles into the oil fluid 5 Place the sample bottle under the sipper of the OSA and immediately start analysis Reference section IV How to Analyze an Oil Sample
20. trucks COMBINED REPORT The Combined Report is a printout of both the Diagnostic Report and the Numeric Report This selection is typically used when the Diagnostic Report is given to the customer and the Numeric Report is kept for reference TABULAR HISTORY The Tabular History report is a laboratory style report Like the Numeric Report the Tabular History Report states Wear Metal concentrations in parts per billion and physical properties are quantified in their appropriate units The Tabular History report includes the records of all the previous oil analysis results The Tabular History report is useful to repeat customers who routinely have their oil analyzed on a daily or hourly basis Revision Date 1 January 2012 33 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual PRINTING HISTORY REPORTS To print the report for a sample that has just been analyzed select the REPORTS button A list of all the reports for the particular customer will be displayed SELECT amp JIFFY LUBE SAMPLE Select a Sample from the List ST SORTED By AA ENTER customer name Cr E ON SITE ANALYZER JIFFY LUBE SAMPLES VIN Sample Io UntID____ Description Make Mode 569008 ABC TRUCKIh 978 569008 DIESEL ENGI FREIGHTLINE FL 1 458974D INDUSTRIAL 980 458974D DIESEL ENGI FREIGHTLINE C11 The Sort button on the right top can be used to change the sorting options from Customer Name Sample ID VIN right
21. 2 44 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual REVIEW ENTRIES The Analyzer checks the information you entered when you exit the data entry screens lf there are no data entry errors the Oil Analysis Activation Screen is displayed Your sample vehicle and oil data will be displayed on the screen Review this information for correctness lf you need to make corrections press the OIL INFO button If the information is correct you can now press START to continue with the analysis Go to How to Analyze a Sample for complete information on running an Analysis VIII Standardizing Extended Metals EXPLANATION Occasionally it is necessary to standardize the extended metals of the OSA4 Analyzer in order to compensate for minor changes affecting the Analyzer s calibration You do not have to standardize the Analyzer unless 1 you have adjusted the Electrode Gap or 2 the Test Extended Metals Standard routine prompts you to or 3 the message box tells you to at the beginning of a sample You should run the Test Extended Metals Standard routine 3 days 72 hours after a Full Standardization or whenever you question the Analyzer s performance Prior to running the Test Extended Metals Standard routine a Baseline Test should be performed The 10 Basic Metals include Iron Fe Chromium Cr Lead Pb Copper Cu Tin Sn Aluminum Al Molybdenum Mo Silicon Si Sodium Na and Potass
22. CHECK 7m ENTER CUSTOMER NAME ON SITE ANALYZER CUSTOMERS Customer ID CustomerName Address City State ZipCode Phone Fa INDOO1 INDUSTRIAL TRU 987 ELM WAY NICEVILLE 33333 555 111 2222 Listed Customer Listed customers are the names of customers that have had their oil analyzed previously Choosing from the list keeps you from having to enter the customer s information each time their oil is analyzed Using the UP and DOWN arrow keys see if the customer you want is on the list If the customer name you want is on the list then highlight the name select it by pressing SELECT If the customer s name you want is not on the list then press the NEW CUSTOMER key to enter a new customer If you want to edit the highlighted customer select the EDIT CUSTOMER key Revision Date 1 January 2012 23 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual New Customer Note Never use quotation marks in Customer Name lf a customer has not had their oil analyzed previously their name is probably not on the list The first time a customer has their oil analyzed you must enter all of their information Once you have entered the customer s information the Analyzer will keep it on the list for the next time The new customer information screen is shown below Enter the customer s last name or enter a company name and press ENTER to move to next field Enter the customer s first name if
23. Entering Vehicle Information On the Sample Data Entry screen information about the vehicle is entered along with information about the oil Enter the information as complete and accurate as possible If you are not sure about some of the information you may leave the entry as UNKNOWN but all fields must have an entry Depending on the type test selected Gasoline Diesel Engine Gearbox Hydraulic or Transmission different information is requested in the Unit Information screen Not all of the following information items will be requested on every analysis VEHICLE MAKE AND MODEL Select the vehicle make and model from the drop down list Use the drop down arrow key to view the list of vehicle makes Scroll through the list using the arrow keys and select an item Now select the vehicle model using the same keys and press down to continue You can also select makes and models by entering the first letters or numbers of the type you want for example press C to go to the beginning of the C makes If the item you want is not in the drop down list you must specify it as UNKNOWN or General or select CUSTOM and an extra field will appear for filling out custom entries ENGINE MAKE AND MODEL DIESEL ENGINE ONLY Select the engine model from the drop down box If you do not know the model or your model is not on the list you must specify unknown VEHICLE YEAR DIESEL ENGINE ONLY Enter the vehicle year information in the approp
24. K Bee En 4 Y Y lol a E z r CHECK ap Ai oe r INSERT TEST STANDARD FLUID BLUE OIL Aaa INSERT TEST STANDARD BLUE OIL ENTER UR TU LU NTI UE OR CANCEL TO ABORT STANDARDIZATION View Begin Sample Analysis Help Information ES Network E Waste fa Cover Print Mode Numeric Samples 131 User 2 Analysis Mode Truck Wersion 4 1 Build 2 Viscosity Mode Measured After 30 has elapsed on the status bar a message will appear on screen asking to again clean the electrodes Do so and press the OK button when finished This method will last 10 15 minutes A message will then appear stating Basic Metal Standardization Completed as shown in following picture If you see otherwise Select CANCEL and repeat previous extended metals standardization steps Revision Date 1 January 2012 47 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual OSA OPERATIONS j fo FE WELCOME TO THE Stawacite Bask Metas TRUCK CHECK i ON SITE ANALYTER y e i ole Help Information BD Network D waste cover Vernon 4 1 Sudd 2 Vincosty Mode Measured Pent Mode Numani Samples 131 User 2 Anasi Mode Tuck This now indicates that Basic Metal Standardization is completed Press OK button to continue on to Extended Metal Standardization A message may appear asking the following Standardization of
25. M 8 e Sample Analysis Help atA B R B was BD cover Vetumn 4 4 Duid Varmdy Mock Meausect Pret Mote Copter Sage 138 Liar 1 Ansyin Mode tuto Select the Viscosity Mode Button Revision Date 1 January 2012 53 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual owner inte Manage System Configuration and Maintenance Log S Y Logout Logan Logout Current Operator and login a New Operator Print mat Select Format for Printed Sample Results out Fo Current Setting Combined Select Analysis Mode Auto Truck Marine ete Analysis Mode Current Setting Auto Select Method tor Viscosity Evaluation Viscosity Mode Current Setting Measured Viscometer Utilities Set Options for Viscometer Operation Set Options for Barcode Scanning Current Setting Normal Data Transfer Upload or Download Sample Data En Then Select the Measured Button the measured V40 Only or Measured V100 Only Button The Measured Button runs both V40 and V100 simultaneously The V40 runs only a Viscosity at 40 C and the V100 runs only a Viscosity at 100C Press Cancel until you arrive back at the Main Menu Barcodo Scan Modo empincal Cabculated from spectral data Modeled Modated from spectral data Measured Direct measurement from wscometer Measured W40C Only Measurement for V40C ory Measured V100C ony Measurement For VI0OC only Revision Date 1 January 2012 54 P N 29091 32 On Sit
26. N Select the Visc Standardization Button ADMIN Viscometer Op ions 5 Visc Standardization Standardize the Viscometer w e Revision Date 1 January 2012 57 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual On the labels of your bottles of Viscosity Standard Low and High you will have measurements for Viscosity at 40 C and 100 C As you move through the Viscosity standardization process you will need these measurement numbers to enter in the appropriate fields for standardization Low Viscosity High Viscosity Standard Standard CHECK a High Viscosity Standard Low Viscosity Standard 138 00 ct 40 C 43 70 ct 40 C 14 50 cst 100 C 6 60 cst 100 C Lot Date APRIL 2008 Lot Date AUGUST 2008 The first message as shown below will appear Make sure that the number from your Low Viscosity Standard at 40 C on the pink fluid bottle label is entered into this field then Press OK Viscosity OF Low WEecosity Standard 40 C Input Low Standard Viscosty 40 C Revision Date 1 January 2012 58 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual The message as shown below will appear Make sure that the number from your High Viscosity Standard at 40 C on the pink fluid bottle label is entered into this field then Press OK Viscosity of High viscosity Standard 40 C Input High Standard Viscosity 40 C The m
27. N LIST INPO werd RE 200 Pe The Vehicle Identification Number is decoded and fields are filled with Make Model Year Engine Type and Fuel Type Press OK to continue Choose the system type that you will be running Revision Date 1 January 2012 63 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual i Choose System Type CHOOSE A SYSTEM TYPE Enter Odometer mileage and Mileage on Oil and Select Enter WALKUP SAMPLE INFORMATION GASOLINE SAMPLE TEST VIN i C3AL56R24N356459 Vehicle Make pas Vehicle Year 2o04 Yehicle Model eu Oil Brand CHEVRON Engine Size ve 2 7L DOHC 24 Oil Type pate 400 Odometer p Mileage On Oil Ly Fuel Type Gasoline Diesel Transmission Type Automatic Manual Standard Revision Date 1 January 2012 64 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Review Data then Select Start to begin Analysis OIL ANALYSIS ACTIVATION CHECK OM STTT AVATAR Email address Customer Name street Address City State Zip TCAM ON SITEANALYSIS Ct Phone Number Yehicle ID Unit Make Unit Model Oil Brand Oil Type Oil Weight Sample ID 13 Auto Gasoline Engine YIN DECODER 398 CEDAR HILL ROAD MARLBOROUGH MA 01852 506 460 7776 Fax Number 1C3AL56R24N356459 sample date Chrysler Sebring Usage Miles Unit ID CHEVRON Miles On Oil DELO 400 USER SAMPLE ID 15
28. N SITE OIL ANALYZER Street Address 13410 SUTTON PARK AVENUE Fax City State Zip JACKSONVILLE FL 32224 Truck Year Quarts Truck Make GEN Capacity Units C Liters RICO A e Truck Model GENERAL Gallons Sump Capacity Quarts Engine Make 9 SAL B Hour On Oil Miles Engine Model ENERAL Usage Units C Hours C Kilometers Turbo Ho Yes l Ie CUSTOMER INFO Enter ID for this Vehicle Such as VIN Customer Unit Number etc Selecting Vehicle Information from a List Each customer may have one or several vehicles A Vehicle ID is a way of identifying a specific customer s vehicle New customers will not have any vehicles listed and you will have to manually enter the vehicle information After you select the desired Customer the Select a Vehicle will flash red and all the known Vehicles will appear on the list Existing customers will have a list of Vehicle IDs associated with their name Use the UP and DOWN arrow key to view the list of Vehicle IDs or simply enter the first several numbers or letters of the Vehicle ID If the vehicle you want is on the list then highlight the desired Vehicle ID and press SELECT After selecting a vehicle from the list and pressing SELECT the Unit Information screen is re displayed with the vehicle information you selected Revision Date 1 January 2012 25 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Manually
29. O T AS E ES 38 Entering Off Road Vehicle Info oooononcnnccnnnnnnnnnnnnnnnnnonnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnss 40 DOLE CIS Macinne T E tetiitis 4 VIM Extended Metal Standardization PAINT bo 45 DCA A lo IA Pi vests 65 qpaseietsenan denies snes saneuesanserteeeatets 46 VIV Dual Temperature Viscometer Pocono or OR eren il e E oo nn enon hark A R E peed ula ias SS hoe ad e e e X VIN Decoder Software DO A A 1 XI Addendums Addendum A Particle Counter Operations amp Requirements ocoociocicncocincon con con coo coo ron O Addendum B Over Pressure Sample Intake Assist 00 0 ccc noenee ccc cae con cee cae con cono seen rro o 08 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual I INTRODUCTION OVERVIEW This is the User Manual for the OSA4 Analyzer The OSA4 oil Analyzer is a tool for evaluating the condition of engines transmissions gearboxes and hydraulics The Analyzer tests for wear debris and other contaminates in the oil The Analyzer also tests the physical properties of the oil itself By comparing test results to normal conditions the OSA4 Analyzer can recommend if any maintenance or repair actions are necessary The OSA4 Analyzer is a tandem spectrometer that integrates an Optical Emissions Spectrometer OES and an Infrared Module The OES burns a portion of the used oil sample and measures the concentration of sub microscopic metals in solution These metal
30. andardization is now complete Revision Date 1 January 2012 51 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual When running a sample if you wish to show Extended Metals on the report simply press YES when screen pops up stating Do you wish to show extended metals reports If you wish to show only Basic Metals press NO OSA OPERATIONS JL REF y WEL p TIRE KINGDOM System Status W Analyzer E Aaa oa VEA i E Sample Sample Analysis Help Information E Network E Waste a Cover EA ANZ o P y El nc ersion 4 3 Build 2 Viscosity Mode Empirical Print Mode Numeric Samples 7 User Q Analysis Mode Auto Revision Date 1 January 2012 52 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual VIV Dual Temperature Viscometer DTV EXPLANATION The Dual Temperature Viscometer DTV is a fully integrated component for the OSA that generates a 100 Centigrade Viscosity a 40 Centigrade Viscosity and a Viscosity Index This patented device works seamlessly in the background generating these measurements during the course of a normal OSA sample run If your OSA is equipped with a DTV you must first ensure that the Viscometer has been enabled Check bottom of screen and see that Viscosity Mode Measured is shown If not select the ADMIN button WELCOME TO THE Production OIL ANALYSIS SYSTE
31. bookmarks to further speed the readers access to information Copyright 2008 On Site Analysis Inc 7108 Fairway Drive Suite 130 Palm Beach Gardens FL 33418 561 775 5756 On Site Analysis Inc declares that their OSA4 Oil Analyzer with the following models MotorCheck TruckCheck MilitaryCheck 3M MetalLab and MicroLab are classified within the following directives EU Low Voltage Directive 2006 95 EC EU Electromagnetic CompatibilityDirective 2004 108 EC EN 60950 1 2006 EN55022 2006 A1 2007 EN 55024 1998 A2 2003 User Manual Outline I Introduction TW ete ced NE E E E o gn A E E 4 A EI rito b AT TE OS E e nee 6 I Getting Started POUE T I S a E A E A E E E EE RE E E EAE AE EERE S Necessary SUPPI ES i 11 TEMA MET ia 13 IH Standardization 99 6 10 10 10 APA IE E E o e 14 A TO A A 14 VOT e e PEOR o en E E AEE 16 Andador Es oidos 17 IV How to Analyze an Oil Sample Collecting the Oil Sample and DAta ooooocooonononanananannnnnnnononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 18 A A A ei UR E 18 MA AS PP A 19 Sample DATE ias 2l E A E o Co A 28 ION OLEO o OP A RE is REE OO A 29 Cledmine Me Elec dera iaa 30 ERAS AA E E 31 On Screen Reportin i cd 31 V Printing Reports PONG EDO AOS naa 33 PINGING History REDOTS lt div 34 VI Flushing PAUL OT UG AAA A A 36 Matta lla oa ea eta eo epa 36 TENIS EIN toas 36 VII Off Road MA AAA nn o E OE an oe cossieteg ndeuaueaneeneseeaen cH O E T
32. can reset and be ready for the next analysis Physical Properties Diagnostic Statements ENGINE WEAR RATES HIGHER THAN TYPICAL FOR BREAKIN OVERHAUL PERIOD POSSIBLE MINOR FUEL DILUTION OCCURRING VISCOSITY HIGHER THAN TYPICAL FOR THE GIVEN OIL TYPE CHECK FUEL SYSTEM DRAIN OIL AND E Revision Date 1 January 2012 32 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual V PRINTING REPORTS OPTIONAL REPORT FORMATS Depending on how the Analyzer has been configured the Analyzer may automatically print a hardcopy of the analysis in one of the following formats DIAGNOSTIC REPORT The Diagnostic Report is a simplified report designed for consumers This numberless style report provides information on engine components wear and oil condition This report is typically used when oil analysis is performed on cars and light duty trucks Test results are reported as normal monitor and inspect Reasons for abnormal test results are suggested and service actions are recommended NUMERIC REPORT The Numeric Report is a standard laboratory style report with wear metal concentrations reported in parts per million and physical properties are quantified in their appropriate units The results range from normal to severe A diagnostics statement is included which suggests problem sources and recommended service actions Typically the numeric report is used when oil analysis is performed on heavy duty
33. e Analysis Inc Guide to the OSA4 Analyzer User Manual DTV VISCOMETER ONLY If you purchased the DTV Visc Only package you will have the option to run a sample that only reports Viscometer readings from the DTV Select Admin and then Viscosity Mode ADMIN Viscosity Mode Empirical Calculated from spectral data Modeled Modeled trom spectral data V40C and V100C measurement from viscometer Measured V40C V40C measurement from viscometer Measured VI00C V100C measurement trom viscometer Run All Test Run all OSA test EN Pay e Selecting the Run all OSA Test will change the OSA from Visc Only to All Tests All Tests will report Elements Physical Properties and Viscometer Normal Sample Toggling back and forth from this button puts you in Visc Only and All Tests Mode Viewing the screen above the unit is in Visc Only mode and you can select Measured both V100 and V40 Measured V40C V40C only or Measured V100C 100C only Once you make your selection Select the Cancel button As shown below the OSA is now in Measured Visc only mode The bottom of Main Revision Date 1 January 2012 55 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Menu scrren bar will always show you what mode your are in OSA OPERATIONS IN SITE ANALYZER System Status OIL ANALYSIS SYSTEM El E Sample Begin View sample Analysis Help Information EJ Network
34. e analysis of every sample Residue from the previous sample can affect your results Use the proper cleaning technique that is illustrated below Close the spark box cover when you have finished cleaning the electrodes and press OK Use a cotton swab to clean the upper electrodes First wipe the outside of the upper electrode Then clean the inside of the upper electrode by inserting the swab down through the center of the electrode and turning clockwise Revision Date 1 January 2012 31 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual THE ANALYSIS CYCLE The analysis takes about 5 to 10 minutes to complete based on the components in your Analyzer after the data entry and manual tasks have been performed The status bar indicates progress as the sample is processed If you want to stop the analysis press the STOP button The stop process takes 15 30 seconds to complete ON SCREEN REPORTING When the analysis is complete an analysis report may be briefly displayed on the screen An example of the on screen report is shown below The report will include the results of the analytical tests along with a diagnostic statement Severity codes will also be printed with the test results Green indicates normal conditions After the results are displayed the Analyzer will begin the Auto Flush process and ask you to perform the task of removing the sample Remove the sample and press OK so that the alada bas
35. essage as shown below will appear Make sure that the number from your Low Viscosity Standard at 100 C on the green fluid bottle label is entered into this field then Press OK Viscosity OF Lov WEcosity standard 100 C Input Low Standard Viscosty 100C The message as shown below will appear Make sure that the number from your High Viscosity Standard at 100 C on the green fluid bottle label is entered into this field then Press OK Viscosity of High Wscosity Standard 100 Input High Standard Viscosity 100C OK Press OK and a message box as follows will appear Revision Date 1 January 2012 59 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual METHOD INFORMATION Dw ISCOSITY STANDARD PINK FLUID Bocce YF WHEN GE An a LCL QWoem OCA T A LAA ga EN Em Lr o OR CANCEL TO ABORT STANDARDIZATION Place a clean straw into the Low Viscosity Standard Pink Fluid and connect to the silver sipper nozzle and press OK Once this process has finished another message will come up asking you to insert the High Viscosity Standard Green Fluid Pull the Low Viscosity Standard out from the sipper nozzle Place a clean straw into the High Viscosity Standard Green Fluid and connect to the silver sipper nozzle after this message appears The Viscosity Standardization process will be concluded after the High Viscosity Standard has finished Once completed you can remove the
36. for over 2 minutes without printing a report then the printer needs your attention Most printing problems are easily remedied Make sure the printer has paper and is powered on Turning the printer off and back on can clear up other problems Occasionally the toner cartridge and or printer drum will need to be replaced Patches of light printing on the report page are indications that the toner cartridge needs to be replaced If the LED indicator light for a Paper Jam is blinking and you cant find a paper jam that s an indication that the drum needs to be replaced Please contact your customer service center for replacement toner cartridges or printer drums NECESSARY SUPPLIES Test Standard 29087 00 The High Standard solution is a colored base oil that contains precisely controlled amounts of each of the metals that the Analyzer tests for An analysis of the High Standard should yield around 50 parts per million of each wear metal CheckFlush Solution 29093 00 The flush solution is a non toxic environmentally friendly oil solvent The flush solution is used to purge the flow system and run low standard Sample Bottles 29002 00 Sample bottles are typically 1 to 5 ounces in capacity The Basic Analyzer usually uses less than one ounce of oil for a complete analysis The sample bottles are pre cleaned and should not be re used to avoid contamination Report Paper 29009 00 Report paper is pre printed having a logo on the fron
37. ghts O Kilometers Oil Weight 15W40 Ra Miles on Oil 14256 UNIT INFO Enter miles on oil Must be numeric ENTERING OIL SAMPLE INFORMATION Oil Brand Type and Weight Select the oil brand type and weight of your sample In the Oil Weight Selection box you can scroll between selections to designate what type of weights will be displayed in the Oil Weight field If you do not know the any of this information you may leave it as unknown Usage Units and Miles on Oil Enter the number of miles or hours that have accumulated on the engine or transmission since the last oil change If the unit has been run before the miles or hours will be automatically generated from previous history Revision Date 1 January 2012 21 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual User Sample ID A User Sample ID is a way of uniquely identifying a sample This ID may be a bar code that is affixed to the sample bottle and data entry sheet Operator Name Enter the name of the vehicle s driver here The information is useful for fleet owners who may have several drivers for each vehicle After completing the Oil Sample Information screen press Analyze to continue CUSTOMER NOTES Revision Date 1 January 2012 28 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual REVIEW ENTRIES The Analyzer checks the information you entered when you exit the data entry
38. have to select the DECODE button to show data If you want to scan more than one VIN at a time Select the Multiple Scan checkbox and the VIN s will be stored in the VIN LIST box If you want the sample data to be automatically transferred via an xml file Revision Date 1 January 2012 61 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual select the Transfer checkbox Using this transfer setting requires high speed access and special ADMIN settings to be set by your OSA representative een Automobile VIN CUTE ARAL TS RR T Multiple Scan C Transtar VEN Estar of Scae Barcode gt f If you choose the Multiple Scan checkbox and you have finished scanning your VIN barcode they will all be listed in the VIN LIST box as shown on next page Once you select a VIN from this list it will be removed from the column ELS CHOOSE A VIN FROM THE LIST VEHICLES ILNHIMS 185 664955 Revision Date 1 January 2012 62 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Once you have scanned a single VIN or picked the appropriate VIN from the list the screen below will appear a ACI E Automobile VIN CHECK ON ME AMA YES C Mu tiple Scan Transter WUE 2G2WRb44361 306393 VIN Enter or Scan Harenda Maka Pontiac Engme Typa VE 381 SFL Supercharged Model Graad Prie Year 2605 Fuel Type Gesoline a e Le CUSTOMER VI
39. he UP and DOWN arrow keys see if the customer you want is on the list If the customer name you want is on the list then highlight the name select it by pressing OK If the customer s name you want is not on the list then press the NEW CUSTOMER key to enter a new customer New Customer lf a customer has not had their oil analyzed previously their name is probably not on the list The first time a customer has their oil analyzed you must enter all of their information Once you have entered the customer s information the Analyzer will keep it on the list for the next time The new customer information screen is shown below Enter the customer s last name or enter a company name and press OK to move to next field Enter the customer s first name or press OK to leave it blank The Analyzer s software will automatically assign a Customer ID Press OK to continue Enter the rest of the information using the OK key to move through the fields CUSTOMER INFORMATION New Customer Information CHECK ON SITE ANALYZER Company Last Name PO Company or Last name First name Customer ID Street Address City Zip Code Phone When you are finished entering or selecting a customer name Press OK to continue Revision Date 1 January 2012 39 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual ENTERING OFF ROAD VEHICLE UNIT INFORMATION The Unit Information scree
40. hey appear Ensure that the straw has been inserted over the analyzer s intake nozzle prior to activating the overpressure function When overpressure function is activated contents of the sample container will be forced out through the straw Revision Date 1 January 2012 68 P N 29091 32
41. ing low standardization There is a sensor to alert you to a low level of flushing solution The waste bottle is accessed behind the Flush Waste Door Check the flush bottle regularly and replace it when it gets low If your unit Is equipped with an optional DTV the flush is located on the right side in the DTV Flush Bracket Key to Successful Oil Analysis Keep an adequate level of flushing solution in the flush bottle An inadequate level of flush will cause cross contamination between oil samples Maintaining the Electrodes The software will prompt you when required adjustments are needed If it is necessary to adjust the electrode gap then you must also standardize the Analyzer Refer to the Standardization section of this manual for details The electrodes are on a stand inside the Spark Door The upper and lower electrodes are positioned vertically one above the other The gap is the distance between the upper and lower electrodes The gap should be no more than 5 32 of an inch The flat end of the gap tool supplied with instrument can be used as a Go No Go gauge for measuring the electrode gap A 5 32 allen wrench is used to loosen the screw that holds the upper electrode and is included with the Analyzer s supplies Revision Date 1 January 2012 8 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual The flat end of the white electrode gap tool shown above is used as a Go No
42. is Inc Guide to the OSA4 Analyzer User Manual VI FLUSHING AUTO FLUSH The computer controls the Auto Flush The computer evaluates the last sample s level of contamination and determines what type of flush to perform on the system The user has no control over the duration of the Auto Flush MANUAL FLUSH The Manual Flush allows the user to perform additional cleanings This function gives the user additional tools to fight sample carry over and contamination To perform a Manual Flush press FLUSH from the main menu The Flush screen shown below will offer you various selections Select the flush you want and press SELECT The system will execute the flush selected IR NIGHT FLUSH The IR Night Flush should be selected each night when the unit will no longer be used This flush is used to soak the IR module cell windows and ensure they stay clean from soot buildup Selecting this button starts a procedure that checks the amount of sooty samples run during the day If there were any run the instructions on the screen will prompt you through an automated process ia Flush Options apo E FLUSH CHECK Flushes for time based on last sample ON SITE ANALYZER Short Short use for light contamination Medium Medium use for moderate contamination Long Long use for excessive contamination IR Night Flush IR Night Flush MY LC a Revision Date 1 January 2012 36 P N 29091 32 On Site A
43. ium K The Extended Metals package includes the 10 Basic Metals plus Titanium Ti Manganese Mn Vanadium V Boron B Magnesium Mg Calcium Ca Barium Ba Phosphorous Nickel Ni and Zinc Zn STANDARDIZATION Select the Standardize button from the Main Menu select STANDARDIZE METALS button as shown on the following screen Revision Date 1 January 2012 45 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual TEETER F ieie a _ creck Base Lino very the Unit nas ushed Properly and the System i5 Clean Verify Metals Verify Metals are within Specifications Standardize Metals Full Standardization of the Metals t Ei Clean the electrodes and place a clean straw into the blue Test Standard Fluid and connect to the silver sipper nozzle A message will appear asking the following Standardization of basic metals is not required at this time Do you still wish to standardize basic metals Select the YES button to proceed Vernon 4 1 Bult 2 Vecorty Mode Mescured 5 5 13 2 Aneiyns Mode Truck Revision Date 1 January 2012 46 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Press OK as shown on screen pictured below after cleaning electrodes and inserting Test Standard Fluid blue OSA OPERATIONS AG Ata ADMIN DIAGNOSE e TO THE T HIS ME T HOD Y ZILI Ss TANC A A DIZE TH E JESI TRUC
44. justified and VIN left Justified Once the vehicle is found select it and then the screen below is shown Revision Date 1 January 2012 34 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual ig Historical Report Options CHECK MM Displays prints component diagnostics for vehicle DISTA AAA AZAR engine or transmission Displays prints analytical results for vehicle engine or transmission Displays prints diagnostics and analytical results report Displays prints analysis history for vehicle select the style of report to be printed and a screen report will appear You can then select PRINT or CANCEL An example of a report is shown below WEST TEEAS PETERRAT Prone 806 372 5444 3000 1 49 EAST AMARILLO TA Truck Mate E TEME Fieet Une iD SAN Vile Trace Mode 15 Espina Moke ATERPALLA Test Date Engne Mode 1440 Truck Year Sump Capacity Chl Weight Mies of Unit s vil AN i EFI UN AJ Y avr a DA TL OF wat ERI Rr ENT Sr M LEY Oi AD iT ru LAN Ty HER TAHAN TIPILCAL LONG T COOLANT OA MAY TF SRPSENTIIN OL POTASA A if HIGHER Te ver AL ADVISE USE OF ADDITIONAL DIAGNOS TY LS TO ERMME COLMSE O WAECTN Al ON DRAIN OL AND CHANCE ILTER IF N Y ALREADY MIN COOLANT DONTANENATION IN 1 pn OCR CLILIPPEL LK E VA A dl ERA COOLER ALA IONAL Our E YN HEAD GASHET AND OR CRACKED HEAD OR LOCA RESIMA E NORMAL MTERVAL TO CONFIRM Revision Date 1 January 2012 35 P N 29091 32 On Site Analys
45. n is shown below The screen shown is for Diesel Unit Information Depending on which selection you use Diesel Gasoline Transmission or Gearbox will determine the differences in the screen On the Unit Information screen you provide information about the vehicle If the information about this vehicle has been previously entered then the information is filled in for you when you select the vehicle from the list If the vehicle is not listed then you must enter the information manually OFF ROAD UNIT INFORMATION Off road Diesel Unit Information CHECK Customer Name XYZ MINE Phone 555 888 9999 Street Address 123 DESERT ROAD Fax ON SITE ANALYZER f City State Zip MINEVILLE AZ 12222 ID 976542 Serial Number x3456 Job Site WEST Engine Make GROVE w Capacity Units Quarts O Liters Gallons Engine Model RT518 y Sump Capacity 38 Gallons Location FRONT Turbo No O Yes Select a Machine Description CRANE CUSTOMER INFO Enter Hours on Component Revision Date 1 January 2012 40 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Selecting Machine Information From A List Each customer may have one or several machines A Machine ID is a way of identifying a specific customer s machine New customers will not have any machines listed as shown below and you will have to manually enter the vehicle information Existing customers
46. nalysis Inc Guide to the OSA4 Analyzer User Manual VII OFF ROAD Before running a sample the Analysis mode must be changed from the current configuration Truck Auto Marine Cycle to Off Road Selecting the Admin button at the Main Menu does this Tab down to the Analysis Mode select this button and simply change to Off Road TEST SELECTION IN OFF ROAD The analysis of your oil depends on what type of sample it is You must specify if the sample comes from a diesel or gasoline engine or from a transmission or gearbox Press the ANALYZE button to bring up the Test Selection screen shown below Select the GASOLINE key on the keypad to analyze a sample of crankcase oil from gasoline powered cars and light duty trucks Select the DIESEL key to analyze a sample of crankcase oil from a diesel powered medium or heavy duty engine Select the TRANSMISSION key to analyze a sample of transmission fluid Select the GEARBOX button to sample Gearbox fluid and select the HYDRAULIC button to sample Hydraulic Fluid The Re Run Last Sample Button allows you to analyze the last sample again without having to re enter all of the sample information w OFF ROAD MODE MOTOR CHECK OFF ROAD MODE SELECT A TESTING OPTION ON SITE ANALYZER pi Sia SN Dios ea ie alia SS EN gt os N de oe gt A Sys a RE RUN LAST SAMPLE CINN 5 A A A Ver6 1 20 i 9 31 PM Revision Date 1 January 2012 37 P N 29091
47. ou change the bottom electrode change the upper electrode as well The upper electrode can be removed from its holder by loosening the screw in the upper holder The upper electrode is reversible so pull it out and if it is in good shape place it back in reversed and tighten screw Lower electrode Allen screw t i Upper electrode screw ga Replace bottom electrode by turning in new one clockwise Place upper electrode holder back in slot and re gap between the electrodes making sure to tighten down upper screw holder Anytime an upper or lower electrode are replaced the unit must be Standardized WARNING DO NOT OVER TIGHTEN SOCKET HEAD CAP SCREWS LOCATED ON ELECTRODE HOLDER socket head cap screw should be finger tight plus 1 4 turn with wrench only over tightening of screw may cause stress cracking toholder Revision Date 1 January 2012 10 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Servicing the Printer Re supplying paper is usually all you need to do for the printer Check the paper tray and add paper as necessary following the instructions included with the printer When the printer needs service it will indicate with the Light Emitting Diode LED The LED on the printer should stay steadily illuminated when not actively printing a report The LED blinks on and off while it is actively printing If the LED is not illuminated if the LED blinks rapidly or if the LED blinks
48. re is contamination then the Analyzer will give you instructions to flush clean the electrodes and try the test again Key to Successful Oil Analysis Clean the electrodes thoroughly prior to starting the Baseline test A dirty electrode will cause the test to fail Revision Date 1 January 2012 15 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual VERIFY METALS The Verify Metals function allows you to check the Analyzer s standardization To run this test choose Verify Metals from the Standardize Options screen and press ENTER When the test begins you will be given instructions like those shown on the screen below Refer to Cleaning the Electrodes in the How to Analyze an Oil Sample section of this manual for a description of the proper technique AETHOD INFORMA Press the OK key and the Analyzer will run the test or press CANCEL to return to the main menu At the end of the test a message box will display informing you if the test of the Analyzer is within specifications If the Test Standard is not within specifications then a message box will provide you with instructions to try the test again or to proceed to Standardization Key to Successful Oil Analysis Please clean the electrodes prior to starting Test Standard A dirty electrode will cause the test to fail Revision Date 1 January 2012 16 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual
49. riate box CAPACITY UNITS SUMP CAPACITY Enter in the appropriate units USAGE UNITS VEHICLE MILES Select the appropriate units using the arrow keys to designate whether the maintenance interval is measured in miles hours or kilometers then enter the miles or hours that have accumulated on the engine Key to Successful Oil Analysis A re built engine or transmission may have less miles hours on it than the vehicle does Where appropriate enter Miles Hours since last re build Revision Date 1 January 2012 26 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual ENGINE SIZE Gasoline Only AND TURBO CHARGING Enter the engine size in liters and specify whether or not the vehicle is turbocharged When the Unit Information Screen is complete Select OIL INFO to continue OIL SAMPLE INFORMA TION Truck Diesel Engine Oil and Analysis Information CHECK Customer Name ABC TRUCKING COMPANY USSR oe hess Street Address 123 MAIN STREET Fax Number City State Zip ANYWHERE GA 55555 Phone Number 555 555 1111 Fleet Unit ID A345 Time on Unit 354216 Vehicle Make FREIGHTLINER Unit ID 569008 Vehicle Model FL 106 system Make DETROIT DIESEL System Model SERIES 60 Bay 21 Oil Brand CH EVRON Operator Driver Name JIM Oil Type RPM DELO lv Date Taken FEB 14 2003 Oil Weight All Weights Usage Units Miles Selection Common Weights Hours C Specific Wei
50. rt is equipped with a female 3 8 18 NPT Revision Date 1 January 2012 6 P N 2909 1 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Keyboard Keyboard is used for entering information and operating the Analyzer Display The flat panel LCD touchscreen displays operator keyed information and Analyzer status Printer not shown Analysis reports are printed from a printer located near the Analyzer Typically the printer sits on the shelf of a cart supporting the Analyzer Modem Network not shown A computer modem connection to the Analyzer facilitates problem diagnosis and maintenance from remote customer service centers A dedicated telephone line or a network IP address connected to the Analyzer via the modem network connection on the back panel is a requirement at Analyzer placement sites Revision Date 1 January 2012 7 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Il GETTING STARTED ROUTINE TASKS Emptying the Waste Bottle The waste bottle collects the used sample oil and flushing solution that has been circulated through the flow system There is a sensor to alert you to empty the waste bottle The waste bottle is accessed behind the Flush Waste Door Check the waste bottle occasionally to be sure that the sensor is working properly Replacing the Flush Bottle The Flush Bottle contains the fluid that cleans the instrument between samples and is used dur
51. s are present due to component wear normal and abnormal inside the engine or transmission The Infrared Module scans a portion of the used oil sample to measure the physical properties of the oil and look for contaminants An onboard computer controls both spectrometers and tabulates the results gathered from each Information about the oil and the vehicle provided by the operator along with the test results are evaluated by the Analyzers proprietary software The software generates a report that includes the test results and a diagnostic statement The diagnostic statement is a summary of the test results and an evaluation of the condition of the engine or transmission being tested The diagnostic statement may also recommend maintenance for specific engine or transmission components This manual is about operating the OSA4 Analyzer The introduction will acquaint you with the features of the Analyzer and bring your attention to safety concerns The Getting Started section will instruct you on the simple tasks associated with operating the Analyzer and how to use the other items supplied with it Standardizing the Analyzer is an important first step in getting comfortable with its operation In the following sections you will be given details on how to properly analyze a sample of oil and produce useful reports Revision Date 1 January 2012 4 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual SAFETY INFORMATION
52. screens lf there are no data entry omissions the Oil Analysis Activation Screen is displayed Your sample vehicle and oil data will be shown on the screen Review this information for accuracy lf you need to make corrections press the OIL INFO button If the information is correct you can now press START to continue with the analysis OIL AMALYSIS 4ACTIVATION Sample ID 978 Truck Diesel Engine CHECK ee Customer Name ABC TRUCKING COMPANY Street Address 123 MAIN STREET City State Zip ANYWHERE GA 55555 Email address Phone Number 555 555 1111 Fax Number Fleet Unit ID 4345 sample date FEB 14 2003 Unit Make FREIGHTLINER Unit Model FL 106 Time on Unit 354216 M aystem Make DETROIT DIESEL Unit ID 569006 system Model SERIES 60 Oil Brand CHEVRON Oil Time 14256 M Oil Type RPM DELO User Sample 21 Oil Weight 15440 Date Taken FEB 14 2003 Sall OIL INFO Revision Date 1 January 2012 29 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual START ANALYSIS When the analysis starts you will be prompted to perform a few necessary tasks A message box will be displayed like the one shown below Follow the on screen instructions METHOD INFORMATION Customer Notes Revision Date 1 January 2012 30 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual CLEANING THE ELECTRODES It is necessary to clean the electrodes prior to th
53. t and an explanation of oil analysis results on the back The explanations are helpful when interpreting oil analysis results Input Sheets 29020 00 Input sheets are half sheet sized pre printed forms that are helpful to fill out when taking oil samples from vehicles When several samples are being processed it is important that the input sheets can be identified as to which sample bottle they pertain to Input sheets are available with adhesive bar codes for this purpose Revision Date 1 January 2012 11 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Cleaning Supplies e Cleaning Swabs 29033 00 Only certain sized cotton swabs will fit properly through the upper electrode Care should be taken so that the swab does not get stuck in the upper electrode e Shop Rags or Paper Towels Shop rags or paper towels are used to wipe off the top electrodes and clean up any oil spills Sipper Straws 29822 00 Box of 350 Sipper Straws are a single use sample intake straw that are swapped out with each individual sample The straw is removed from the box by holding the bend area and placed directly over the metal intake Revision Date 1 January 2012 12 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual THE MAIN MENU The main menu of the User Interface is the first screen that is displayed when the Analyzer is powered up From the main menu all of the Analyzers functions can be
54. the arrow keys and select an item using the SELECT key Now select the vehicle model using the same keys and continue to the next field The Custom selection under make and model may be used to enter units that do not appear in the drop down lists COMPONENT UNIT INFORMATION Enter the component Serial Number the Job Site and the total Hours on the component USAGE UNITS Select the appropriate units using the arrow keys to designate whether the sump capacity is measured in Quarts Gallons or Liters LOCATION SUMP CAPACITY Select the correct location of the component then the sump capacity TURBO Select yes or no using the space bar if the component is turbocharged Revision Date 1 January 2012 42 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual OFF ROAD UNIT INFORMATION Off road Diesel Unit Information CHECK Customer Name XYZ MINE Phone 555 888 9999 Street Address 123 DESERT ROAD Fax ON SITE ANALYZER City State Zip MINEVILLE AZ 12222 Serial Number X3456 Job Site WEST Engine Make GROVE v Capacity Units Quarts Liters Gallons Engine Model RT518 Ly Sump Capacity 38 Gallons Location FRONT Turbo CINE O Yes Description CRANE CUSTOMER INFO Enter Hours on Component When the Unit Information Screen is complete press OIL INFO to continue Entering Oil Sample Information Revision Date 1 January 2012 43 P
55. ures of the OSA4 Analyzer are listed here You should be familiar with these features as you will need to interact with them routinely during the normal operation of the Analyzer The photo at the end of this section illustrates the location of each of the following features of the OSA4 Oil Analyzer Spark Door This door should be closed at all times unless performing routine maintenance Sipper Straw The Oil Straw draws sample oil into the Analyzer where it is pumped through the flow system for analysis This is a consumable item and has to be replaced for every sample Waste Bottle Oil that has been analyzed and flushing solution that has been purged through the flow system drains into this container Flush Bottle The Flush Bottle contains a flushing solution CheckFlush used to clean out the flow system and is used during the low standardization process This bottle needs to be checked on a daily basis ON OFF Switch Reset Button The power switch is an illuminated rocker switch located on a recessed bulkhead along the right side of the Analyzer DTV Flush Bracket This bracket is included with units that have an optional Dual Temperature Viscometer It allows for a larger flush bottle to be attached to the side of the OSA4 Waste Port This port can be set up by an OSA engineer to allow for larger waste containers A special tube is inserted in the interior of waste door and this port becomes active The po
56. will have a list of Machine IDs associated with their name An example screen is shown below Once you select the customer the ID button will flash red and give you a list of machines available Use the UP and DOWN arrow key to view the list of Machine IDs If the name you want is on the list then highlight the desired Machine ID and press Enter If the Machine ID you want is not on the list then simply enter a machine ID in the ID box After selecting a machine from the list the Unit Information screen is re displayed with the machine information you selected If your machine is not listed then it is ready for you to manually enter the machine information SELECT 4 MACHINE UNIT Select a Machine Unit from the list CHECK IM ENTER MACHINE ON SITE ANALYZER SELECT DESIRED MACHINE rUnitID Machine ID CustomerID Customer __ Serial Number_ Make Model Revision Date 1 January 2012 41 P N 29091 32 On Site Analysis Inc Guide to the OSA4 Analyzer User Manual Manually Entering Machine Information On the Sample Data Entry screen information about the machine is entered along with information about the oil Enter the information as complete and accurate as possible If you are not sure about some of the information you may leave the entry as unknown MACHINE MAKE AND MODEL Select the vehicle make and model from the drop down list Scroll down to view the list of vehicle makes Scroll through the list using

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