User Manual - On-Site Analysis, Inc.
Contents
1. 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 Customer Notes Revision Date 21 December 2002 24 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual CLEANING THE ELECTRODES It is necessary to clean the electrodes prior to the 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 swap dipped in cleaning solution 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 Revision Date 21 December 2002 25 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual THE ANALYSIS CYCLE The analysis takes about 5 to 7 minutes to complete 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 of2. 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 21 December 2002 22 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual REVIEW ENTRIES The analyzer checks the information you entered when you exit the data entry screens If 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 accuracy If 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 CTIVATION Sample ID 978 Truck Diesel Engine ES 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 A345 Sample date FEB 14 2003 Unit Make FREIGHTLINER Unit Model FL 106 Time on Unit 354216 M System Make DETROIT DIESEL Unit ID 569008 System Model SERIES 60 Oil Brand CHEVRON Oil Time 14256 M Oil Type RPM DELO User Sample 21 Oil Weight 15W40 Date Taken FEB 14 2003 l DIL INFO Revision Date 21 December 2002 23 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual START ANALYSIS
3. Revision Date 21 December 2002 15 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual 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 Sample data includes information about the customer the vehicle and the oil The MotorCheck tm system keeps lists of your customers and their vehicles 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 three options use the default customer select a customer from the list or add a new customer If 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 If 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 Default Customer The default
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5. Street Address 123 DESERT ROAD Fax ON SITE ANALYZER A f City State Zip MINEVILLE AZ 12222 ID 976542 Serial Number x3456 Job Site WEST Engine Make E ROVE E Capacity Units Quarts Liters Gallons Engine Model RT518 Ly Sump Capacity 38 Gallons Location FRONT Ly Turbo No Yes Description CRANE lt a CUSTOMER INFO Enter Hours on Component Revision Date 21 December 2002 34 P N 29091 31 Guide to the MotorCheck Oil 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 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 ente
6. customer name is setup by your MotorCheck tm service representative If a default customer has been setup the default customers Customer ID will always appear in the box next to Enter Customer ID Having a default customer name is useful when the majority of samples analyzed are for one particular customer To use the default customer name press OK To use a customer other than the default follow the instructions below for choosing a customer from the list or adding a new customer Revision Date 21 December 2002 16 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual SELECT A CUSTOMER Select a Customer fromthe List UST SORTED By CHECK fm ENTERCUSTOMERNAME ON SITE ANALYZER CUSTOMERS CustomerID Customer Name Address City State Zip Code Phone Fal 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 21 December 2002 17
7. differences will be stated This manual includes features that are designed to aid the reader in quickly referencing helpful information The outlining is extensive so that 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 bookmarks to further speed the readers access to information Copyright 2001 On Site Analysis LubeTrak com 866 582 3872 Guide to the MotorCheck Oil Analyzer User Manual User Manual Outline I Introduction OTAU A eeh deiere riet 2 Safety EE 3 Analyzer Fea tres ee 4 I Getting Started Routine Tasks eer EE eieiei 6 EE 8 Th Main M Ee 9 IM Standardization Explanatio essene ni hus aN E E Eaa AREE E anaes 10 B s eline Test eege 10 Test Standard irr EASE E ER 12 Standardize eene EeeEEe 13 IV How to Analyze an Oil Sample Collecting the Oil Sample and Data ss iscisasecoxiaderannrien oeaoonvnaamnowienninaaynseainasts 14 GE 14 EE ees 14 Sample Data Ent 16 dE 23 EE 24 Cleaning the eege Eege Geen 25 TheAnalysis e socis e aA EA a EO 26 On Screen TOTTI ee eege 26 V Printing Reports Optional Report Formats 5 covaaascsnasieiensunzsenrsuruswwcennesicamuan ocoutua ureerrswnceaasdmmbe omni eeee 27 Printing History TOC IONS eege eren 28 VI Flushing E eg ob nana cunt imiateonld saa pi tesa eo muuantie pea earcuaentaune een 30 Manual Flush sisenesime a 30 VII Off Road Tes
8. main menu Standardization is comprised of two parts Low Standardization and High Standardization However these processes are seamless and will run straight through without any user intervention All the operator has to do is put a Test Standard fluid Blue 50 ppm standard under the sipper 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 21 December 2002 13 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual IV HOWTO ANALYZE AN OIL SAMPLE COLLECTING THE OIL SAMPLE amp SAMPLE DATA To analyze oil from an engine or transmission you must first obtain a sample There are two methods for sampling the oil from an engine or transmission 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 MotorCheck analyzer or you may obtain sampling kits from your retailer Refer to the Training Manual or other supporting documents for detailed instructions on the proper method of drawing oil samples from engines and transmissions SAMPLE INTRODUCTION When you have a sample to analyze remove the lid from the sample bottle and place the bottle under
9. the sipper as shown in the picture below Key to Successful Oil Analysis Use a rag to wipe off any oil left on the sipper from a previous sample Lower the sipper all the way into the oil in the sample bottle The sipper must remain in the oil throughout the analysis cycle Revision Date 21 December 2002 14 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual 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 or diesel engine Press the ANALYZE button from the main menu 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 truck Select the TRANSMISSION key to analyze a sample of transmission fluid Select the GEARBOX key to analyze a sample of gearbox fluid The Re Run Last Sample Button allows you analyze the last sample again without having to re enter all of the sample information There is a selection for PREVIOUSLY ENTERED SAMPLES that allows barcode use for samples already entered in the system or PREVIOUSLY ENTERED SAMPLES that can be selected from a list After making selection a Customer Selection List will be shown TRUCK CHECK ON SITE ANALYZER Ver 3 1 100
10. 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 analyzer can reset and be ready for the next analysis r Wear Metal Data Physical Properties Chromium Potassium Diagnostic Statements ENGINE WEAR RATES HIGHER THAN TYPICAL FOR BREAK IN OVERHAUL PERIOD POSSIBLE MINOR FUEL DILUTION OCCURRING VISCOSITY HIGHER THAN TYPICAL FOR THE GIVEN OIL TYPE CHECK FUEL SYSTEM DRAIN OIL AND a Revision Date 21 December 2002 26 P N 29091 31 Guide to the MotorCheck Oil 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 Th
11. 0 D Mil Oil 215 iles on Oll La all E UNIT INFO Enter Additional Special ID for sample Any text 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 21 December 2002 38 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual REVIEW ENTRIES The analyzer checks the information you entered when you exit the data entry screens If 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 If 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 Customer Notes Revision Date 21 December 2002
12. CK s ENTER CUSTOMER NAME fo ON SITE ANALYZER JIFFY LUBE SAMPLES Sample ID UnitID Description Make DIESEL ENGI FREIGHTLINE FL 1 458974D INDUSTRIAL 980 458974D DIESEL ENGI FREIGHTLINE C114 569008 ABC TRUCKIh 978 569008 The Sort button on the right top can be used to change the sorting options from Customer Name Sample ID VIN right justified and VIN left Justified Once the vehicle is found select it and then the screen below is shown Revision Date 21 December 2002 28 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual Displays prints component diagnostics for vehicle engine or transmission DEST AVAIYZHE 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 Revision Date 21 December 2002 29 P N 29091 31 Guide to the MotorCheck Oil 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 a
13. Manual U M Hill OIL ANALYSIS SYSTEM Sv Begin View EI sample Sample Analysis Help Information Camm waste Version 3 1 Build 71 Present fal Print Mode Combined Samples 886 User 1 1 Analysis Mode Auto Revision Date 21 December 2002 9 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual HI STANDARDIZATION EXPLANATION Occasionally it is necessary to standardize the MotorCheck 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 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 at least twice a week or whenever you question the analyzer s performance Prior to running the Test Standard routine it is good practice to perform the Baseline Test BASELINE TEST The Baseline Test is used to determine if there is contamination in the flow system or on the electrodes of the analyzer To ru
14. On Site Analysis LubeTrak Inc www lubetrak com MotorCheck User Manual VERSION 3 12 Guide to the Motor Check Analyzer PREFACE This user manual is the first part of the complete guide to the MotorCheck analyzer This manual is intended to guide operators of the analyzer through the normal procedures associated with processing oil samples Setup procedures analyzer configuration changes and problem diagnoses are topics covered in the Owner s Supplement and in other supporting documents This manual is intended for mechanics technicians or anyone else who wants to learn the proper way to analyze oil samples using the MotorCheck 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 On Site Analysis manufactures the MotorCheck oil analyzer On Site Analysis also manufactures the TruckCheck oil analyzer The information in this manual applies to both the MotorCheck and TruckCheck analyzers In other manuals where there are differences in the MotorCheck and TruckCheck applications the
15. P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual New Customer If 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 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 When you are finished entering or selecting a customer name Press OK to continue CUSTOMER INFORMATION New Customer Information CHECK ON SITE ANALYZER CompanyitastName Company or Last name First name Customer ID il Street Address City Zip Code Phone Fax Revision Date 21 December 2002 18 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual ENTERING VEHICLE INFORMATION Unit Information screens are shown below The screens are different depending on which test you have selected On the Unit Information screen you provide information about the vehicle If the information about this vehicle has been previously enter
16. PECIFIC WARNINGS e 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 e Operate in a Well Ventilated Area The analyzer produces ozone when high voltage is arcing across the electrodes e 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 and transmissions Key to Successful Oil Analysis Never attempt to introduce anti freeze water brake fluid or power steering fluid into the analyzer These fluids will cause irreparable damage Revision Date 21 December 2002 3 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual ANALYZER FEATURES The basic features of the MotorCheck 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 Please refer to the Owner s Supplement for a more comprehensive description of the analyzer s features The photo at the end of this section illustrates the location of each of the following features of the MotorCheck Oil Analyzer Spark Door This door should be closed at all ti
17. ce bar if the component is turbocharged Revision Date 21 December 2002 36 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual OFF ROAD UNIT INFORMATION Off road Diesel Unit Information CHECK Customer Name XYZ MINE Phone 555 888 9999 e Street Address 123 DESERT ROAD Fax City State Zip MINEVILLE AZ 12222 ON SITE ANALYZER Serial Number x3456 Job Site WEST Engine Make E ROVE x Capacity Units Quarts Liters Gallons Engine Model RT518 el Sump Capacity E Gallons Location FRONT x Turbo e No Yes Description CRANE ECH A GG SS CUSTOMER mc INFO J Enter Hours on Component When the Unit Information Screen is complete press OIL INFO to continue Revision Date 21 December 2002 37 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual Entering Oil Sample Information OIL SAMPLE INFORMATION Off road Diesel Engine Oil and Analysis Information CHECK DR Customer Name XYZ MINE AE eer CGGA Street Address 123 DESERT ROAD Fax Number City State Zip MINEVILLE 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 Bays Oil Brand CH EVRON Operator Driver Name JON Oil Type RPM Heavy Duty gt Date Taken FEB 16 2003 Oil Weight Al Weights Selection Common Weights Specific Weights Oil Weight 20W5
18. dditional tools to fight sample carry over and contamination To perform a Manual Flush press FLUSH from the main menu The Flush screen show below will offer you various selections Select the flush you want and press SELECT The system will execute the flush selected ia Flush Options For cleaning system Short use for light contamination Medium use for moderate contamination Long use for excessive contamination Revision Date 21 December 2002 30 P N 29091 31 Guide to the MotorCheck Oil 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
19. e 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 severity of 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 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 Revision Date 21 December 2002 27 P N 29091 31 Guide to the MotorCheck Oil 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 A JIFFY LUBE SAMPLE Select a Sample fromthe List HSLSORTED BY CHE
20. e test to fail Revision Date 21 December 2002 11 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual TEST STANDARD The Test Standard function allows you to check the analyzer s standardization To run this test choose Test Standard from the Standardize Options screen and press ENTER When Test Standard 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 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 and sipper thoroughly prior to starting Test Standard A dirty electrode or sipper will cause the test to fail Revision Date 21 December 2002 12 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual 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
21. ed 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 p i S 5 S TRUCK Truck Diesel Unit Information a Gasoline Unit Information Customer Name ABC TRUCKING COMPANY Phone 555 555 1111 Company Neme OIL LUBE AND ANALYSIS em ae Street Address 123 MAIN STREET Fax SteotAddress 25 MAPLE AVE Phono Number 088 234 9911 S City Stota Zip ANYWHERE GA 55555 Cry Sate Zip GREENVILLE OR 99923 _Solect a Truck VIN 569008 Fleet Unit ID A345 Select Vehicle CAL 455 Sooo Vehicle Make FREIGHTLINER v Vehicle Year 1996 Vehicle Make Chevrolet F Usage Units Miles Capacity Units Quarts C Hours Liters Kilometers Vehicle Model 11 106 el C Gallons Vehicle Model S10 be Vehicle Miles 85000 Sump Capacity be Quarts Engine Size 2 5 Ules System Make DETROIT DIESEL iy Miles 354216 fa Miles Usage Units Hours System Model SERIES 60 iy Kilometers No Yos Turbo CUSTOMER mn Select Capacity Units for Engine Oil Use arrow keys 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 kno
22. fluid The Re Run Last Sample Button allows you analyze the last sample again without having to re enter all of the sample information aw OFF ROAD MODE MOTOR CHECK ON SITE ANALYZER Ver 3 1 100 Revision Date 21 December 2002 31 P N 29091 31 Guide to the MotorCheck Oil 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 If 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 If 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 Default Customer The default customer name is setup by your MotorCheck service representative If a default customer has been setup the default customer s Customer ID will always appear in the box next to Enter Customer ID Having a default customer name is useful when the majority of samples analyzed are for one particula
23. i EE 31 Select EE 32 Entering Off Road eet eieiei Dee ege e 34 Selecting Machine Info cccccccccccccccececececeesceeseesceseaeeeeceeseecseeceseceeeeeseecsseeneeenseensees 35 Revision Date 21 December 2002 1 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual l INTRODUCTION OVERVIEW This is the User Manual for the MotorCheck oil analyzer The MotorCheck oil analyzer is a tool for evaluating the condition of engines or transmissions 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 MotorCheck oil analyzer can recommend if any maintenance or repair actions are necessary The MotorCheck 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 metals are present due to component wear 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 soft
24. mes unless performing routine maintenance Oil Sipper The Oil Sipper draws sample oil into the analyzer where it is pumped through the flow system for analysis 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 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 The power switch is an illuminated rocker switch located on a recessed bulkhead along the right side of the analyzer Key to Successful Oil Analysis The analyzer should remain on at all times to maintain a constant temperature inside the unit Temperature variations may cause errors in analysis Revision Date 21 December 2002 4 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual e Keypad or Keyboard application dependent The Keypad is used for entering information and operating the analyzer e Computer Screen The flat panel LCD screen displays operator keyed information and analyzer status e 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 e Modem not shown A computer modem connection to the analyzer facilitates problem diagnosis and maintenance from remote customer service ce
25. n 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 Revision Date 21 December 2002 7 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual Occasionally the toner cartridge will need to be replaced Patches of light printing on the report page are indications that the toner cartridge needs to be replaced Please contact your customer service center for replacement toner cartridges NECESSARY SUPPLIES e 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 e Baseline Test Standard 29088 00 The Low Standard solution is a clear base oil that contains no metals An analysis of the Low Standard should yield less than 10 parts per million of each wear metal e Flush Solution 29093 00 The flush solution is a non toxic environmentally friendly oil solvent The flush solution is used to purge the flow system run low standardization and can also be used to clean the electrodes e Sample Bottles 29002 00 Sample bottles are typically 1 to 4 ounces in capacity The analyzer usually uses less than one ounce of oil for a complete analysis The sample bottles are pre cleaned a
26. n this test simply press the STANDARDIZE button on the keypad or select the STANDARDIZE button from the Main Menu The Standardize Options Screen will appear as shown below Select BASELINE TEST from the list of options Standardize Options CHECK Check for contamination ON SITE ANALYZER Check standardization Restandardize system takes 15 minutes Run Baseline Test Test Standard first Revision Date 21 December 2002 10 P N 29091 31 Guide to the MotorCheck Oil 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 The Baseline Test will start immediately without prompting you to insert a sample That is because this test uses the solution from the flush bottle to run this test After cleaning the electrodes 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 there is contamination or that the System is clean OK to proceed If there 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 and sipper thoroughly prior to starting the Baseline test A dirty electrode or sipper will cause th
27. nalysis Information CHECK ER Customer Name ABC TRUCKING COMPANY co ee ores SY 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 Ly Operator Driver Name DU Oil Type RPM DELO v Date Taken FEB 14 2003 Oil Weight Al Weights Usage Units Miles Selection P Common Weights Hours C Specific Weights Kilometers Oil Weight 15W40 Ly Miles on Oil fi 4256 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 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 Revision Date 21 December 2002 21 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual
28. nd should not be re used to avoid contamination e Report Paper 29009 00 Report paper is pre printed having a logo on the front and an explanation of oil analysis results on the back The explanations are helpful when interpreting oil analysis results e 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 Some input sheets have adhesive bar codes for this purpose e Cleaning Supplies e Q Tips 29033 00 Only certain sized cotton swabs will fit properly through the upper electrode Care should be taken so that the swap does not get stuck in the electrode e Electrode Cleaning Solution 29093 00 The flush solution can be used to clean the electrodes e Shop Rags or Paper Towels Shop rags or paper towels are used to wipe off the sipper and clean up any oil spills Revision Date 21 December 2002 8 P N 29091 31 Guide to the MotorCheck Oil 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 accessed The main menu is shown below Page numbers for description of the main menu features are provided Some items are described here elsewhere in the Users
29. nd models by entering the first letter 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 appropriate 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 or transmission 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 21 December 2002 20 P N 29091 31 Guide to the MotorCheck Oil 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 INFORMATION Truck Diesel Engine Oil and A
30. nters Keep a dedicated telephone line connected to the analyzer via the modem connection on the back panel Display Flush Bottle Screen Spark Door Waste Bottle Keyboard On Off Switch Revision Date 21 December 2002 5 P N 29091 31 Il Guide to the MotorCheck Oil Analyzer User Manual 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 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 during low standardization There is no sensor to alert you to a low level of flushing solution Check the flush bottle regularly and replace it when it gets low 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 box The electrodes are made of silver held by brass fi
31. r customer To use the default customer name press OK To use a customer other than the default follow the instructions below for choosing a customer from the list or adding a new customer SELECT A CUSTOMER LIST SORTED BY Select a Customer from the List MOTOR CHECK 9 ENTERCUSTOMERNAME ON SITE ANALYZER CUSTOMERS Customer ID Customer Name Address Ciy ste ZipCode Phone JS INDOO1 INDUSTRIAL TRU 987 ELM WAY NICEVILLE FL 33333 555 111 2222 Revision Date 21 December 2002 32 P N 29091 31 Guide to the MotorCheck Oil 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 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 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 If 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
32. r the machine information SELECT amp MACHINE UNIT Select a Machine Unit from the list CHECK fim ENTER MACHINE ON SITE ANALYZER SELECT DESIRED MACHINE rUnkiD Machine ID Customer Customer Serial Number Wake Modei Revision Date 21 December 2002 35 P N 29091 31 Guide to the MotorCheck Oil 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 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 spa
33. 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 IW ON SITE ANALYZER Company Last Name PO Company or Last name First name Cooney ee Street Address zi S i ce City Ct EE Sic o so fe Fax When you are finished entering or selecting a customer name Press OK to continue Revision Date 21 December 2002 33 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual ENTERING OFF ROAD VEHICLE UNIT INFORMATION The Unit Information screen 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 Wb
34. trode is reversible If the other end of the electrode is in good shape replace the electrode with the other end out The lower electrode is not reversible To check the lower electrode view it from eye level A brand new electrode is approximately 0 50 inches long with 0 25 inches of the electrode slotted like a pizza If there is less than 0 10 inches of the slots visible then the electrode needs to be changed The lower electrode unscrews from its holder with the aid of a single edge razor blade Change electrodes if necessary and replace the upper electrode holder in the spark stand Set the electrode gap with the Allen wrench and tighten the 5 32 socket head cap screw Key to Successful Oil Analysis Always test the analyzer s standardization after making any adjustment to the electrodes Adjusting the electrode gap without testing the standardization may cause analysis errors e 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 for over 2 minutes without printing a report the
35. ttings The upper electrode and lower electrode are positioned vertically one above the other The electrode gap is the distance between the upper and lower The gap should be no more than the width of a 5 32 Allen wrench A 5 32 Allen wrench is the same tool used to loosen the screw that holds the upper electrode and is included with the analyzer s supplies Revision Date 21 December 2002 6 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual The Allen wrench is used as a Go No Go gage for measuring the electrode gap The electrode gap should be set to 5 32 which is the distance between the flat sides of the Allen wrench The electrode gap will increase with use The Electrode gap should not exceed 3 16 which is the distance diagonally across the points of the Allen wrench So when the wrench will pass through the gap in any orientation it is time to adjust the gap To reset the gap first remove the upper electrode holder completely and closely inspect both electrodes Remove the upper electrode holder by loosening the 5 32 socket head cap screws and sliding the holder out over the top of the spark stand Check the electrodes to see if they need to be changed Change the upper electrode if you can see that it has been burning on an angle The upper electrode can be removed from its holder by using a 3 32 Allen wrench Remove the setscrew and slide the electrode out of the holder The upper elec
36. ware 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 MotorCheck 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 21 December 2002 2 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual SAFETY INFORMATION 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 S
37. wn Vehicles will appear on the list Existing customers will have a list of Vehicle IDs associated with their name An example screen listing Vehicle IDs is shown below Use the UP and DOWN arrow key to view the list of Vehicle IDs If the name 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 21 December 2002 19 P N 29091 31 Guide to the MotorCheck Oil Analyzer User Manual Manually 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 Gasoline Diesel Engine Gearbox or Transmission selected 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 a
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