Limit values for lubricants

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Limit values provide an initial indication as to whether analysis results point to a problem. However, this
requires detailed knowledge of the application, the lubricant used and sometimes even the lubricant analysis
itself. Important aspects of oil analysis, such as wear or oil condition, also depend signifi cantly on the
duration of use. Due to different operating conditions and times, limit values are therefore often diffi cult to
defi ne. The trend line is helpful here, in that it makes a more detailed assessment possible. But one point is
crucial; the analytical results must always be evaluated in relation to each other. The mere consideration of
individual values can lead to considerable errors in judgement. Before a tribologist can evaluate the results of
an analysis, he needs a basis for his assessment. In addition to his own experience, he makes use of
absolute limit values, fresh oil reference values and the trend line for this. The adjoining sample spreadsheet
shows the extent to which the limit values, e.g. of elements in engine oils, can vary.
Table of contents

1. Where do limit values come from?

2. Absolute limit values vs trends
3. Trends – the tool of choice?
4. The solution from OELCHECK
5. Examples for limit values
1. Typical limit values for motor oils
2. Hydraulic oils and their typical limit values
3. Gear and industrial oils and their typical limit values
4. Interpreting the values
5. Related information
6.
Where do limit values come from?

Limit values are determined by the following groups, often with very different intentions:

 Component manufacturers
 OEMs
 Oil companies
 Standards, technical groups/organisations
 Laboratories

Manufacturers of components often defi ne limit values for individual parameters which affect the
performance or the service life of the component. For example, manufacturers of hydraulic components, such
as pumps and valves, give recommendations for oil cleanliness. In particular, specifications from OEMs
relating to warranty cases should be strictly adhered to. This is because OEMs also define limit values to
identify necessary repairs and maintenance, establish general conditions for safe operation, and assist in
evaluating oil analysis values. The limit values of oil companies usually relate to the condition of the oil.
These are used to judge the point at which additive degradation or ageing has progressed too far, and the oil
can no longer reliably fulfi l its tasks. This will guarantee that the oil still meets the necessary conditions of
use at the time of the oil change. Limit values and evaluation bases can also be standardised, as is the case,
for example, with ASTM. These values issued by specific organisations relate primarily to areas of
application and must be examined on a case-by-case basis for their applicability. The limit values used by the
OELCHECK laboratory are statistically determined and validated by experienced tribologists using historical
analytical data which has been collected in the company‘s own database for more than 25 years. Special
features such as oil and machine type, manufacturer and sampling point can also be included in the
assessment in order to obtain particularly reliable and specific limit values. This is because OELCHECK asks
for detailed information about every lubricant sample in its Sample Information Forms.

Absolute limit values provide quick and easy orientation (see Fig. 1). They are, for the most part, based on
statistical analyses of machines operated under comparable conditions. As long as these operating
conditions are in agreement, the limit values used are also applicable. Under differing conditions, such as
start-and-stop versus continuous operation, the absolute limit values lose their significance. For all statistics,
limit values must always be validated by experienced experts. If they are set too high, it may be that the
lubricant has changed significantly or that the machine has been damaged without this being noticed. If they
are too low (see Fig. 2), then the accumulating alarms are eventually ignored, because they occur regularly
and often without good reason. Then, when an actual problem does arise, no one will respond quickly
enough. Analytical results often show no ideal trend such as that shown in Fig. 1. Rather, the values (see
Fig. 3) vary within a certain range, so that several samples (at least 3-4) are needed to form a trend. Only
then is it possible to predict the range of values for the next result. It may also be the case that the same
values for similar machines but differing trends lead to different recommendations. If the jump in a wear value
is too large compared to the previous sample or in relation to the duration of use, an indication will appear in
the OELCHECK diagnosis, even if the result of the analysis is below the absolute limit. Particularly when
lubricants have been in use for a very long time, limit values can also be exceeded without the necessity of a
warning (see Fig. 4). If the increase is in line with the trend and with the expected range for the duration of
use, operation may continue without difficulty. The trend supplements the absolute limits by making more in-
depth interpretations possible. This improves the predictive quality, and emerging problems are detected
even earlier. This is because the trend only takes previous analysis values from the same machine into
account, and so specific application conditions can best be considered. It works the same way with the
doctor. He compares the results of a blood analysis with their general limit values in relation to the patient‘s
personal attributes and life circumstances. The patient‘s medical history, i.e. the trend, is then used for the
final assessment.

Trends – the tool of choice?

 Trends are not always necessary for assessing analytical values. This is partly because enough previous
sample data must be available, and you have to start somewhere. On the other hand, there are also
parameters that can be comprehensively assessed with absolute limit values. Included among these are:

 Increased water content – can cause corrosion and/or cavitation, different saturation limits for the different oil
types.
 Oil impurities – can lead to increased wear and affect the operation of hydraulic systems, for example.
 Elevated silicon levels – can cause abrasive wear. When assessing silicon content, consideration must also
be given to the use of silicon as an anti-foam additive.
 Breakdown voltage – is examined, for example, for transformer and insulating oils.

The decision as to whether absolute limit values are sufficient as a basis for decision-making also depends
on the situation. If an oil sample is taken at each oil change in order to detect necessary repair measures or
emerging problems, often an assessment based on the absolute limit values is sufficient. If oil change
intervals are to be optimised, the trends must always be considered when analyzing results that are
dependent on the duration of use. However, even trends are not always reliable. This is due to the fact that
the location of the sampling point and the way in which the sampling is performed can have a significant
effect on the results of the analysis. Therefore, samples for trend analysis should always be taken in the
same place, using the same method. Changes to the conditions of use or maintenance can also affect the
trends.

The solution from OELCHECK

OELCHECK combines absolute limit values and trends in the evaluation of all analytical results. Our
experienced tribologists rely on our in-house software SampleRating for sample diagnostics. The software
displays limit values, trend curves, diagrams, photos and all the information from the information form
pertaining to the current sample and machine at a glance. Each individual value is colour coded on the basis
of often very specifi c limit values which have been validated multiple times. Our experienced tribologists can
access data from the more than three million samples we have analysed, 200,000 machine-specific limit
value tables and more than 10,000 fresh oil references. In this way, OELCHECK combines all the information
and advantages of the various assessment methods in order to make a precise diagnosis.

OELCHECK laboratory reports do not include limit values; this is for the purpose of preventing
misinterpretations, because values should never be considered individually, but always in conjunction with
the other analytical values, the application and the lubricant used. Even a doctor does not simply hand the
results of a blood test over to his patient. With their extensive expertise in the fields of mechanical
engineering and chemistry, OELCHECK tribologists always assess the status of both the machine and the
oil, taking all analysed values into account.
year and supply data that is as complete as possible if you value getting a sound diagnosis by an experienced
OELCHECK tribologist.

Gear and industrial oils and their typical limit values

Typical warning values for contaminants, additives and wear

Wear

Mostly in
Warning
Element Sign connection Possible causes
valuemobilestationary
with

Aluminium Al 45 20 Si, Cu, Mg Worm wheels (aluminium-bronze),

clutches, oil pumps, pressure or
aluminium cast parts, housings,
aluminium sealing rings

Antimony* Sb <7 <3 Sn, Pb, Cu Hard lead, zinc alloys on bearings,
white metal bearings, solder (soft
solder)

Barium Ba 2 2 - No typical wear element in gears

Beryllium* Be 3 3 Al, Cu Lightweight construction parts made

from sintered metal, beryllium-copper
alloy

Lead Pb 20 10 Cu, Zn, Sb Plain bearing running surface, lead

bronze, synchroniser rings, coats of
paint

Boron B 12 12 Fe Ceramic components, insulation

bodies, brake and clutch linings

Cadmium* Cd 2 2 - No typical wear element in gears

Chrome Cr 20 10 Fe, Ni, Mn, Roller bearings, alloy constituents of
Mo high-strength gearwheels, multiple disc
clutches

Chlorine* Cl 2 2 - No typical wear element in gears

Iron Fe 490 150 Cu, Ni, Cr, Gearwheels, rolling bearings, oil
Mn, Mo pumps, steel lamina couplings, cast
housings, shafts, radial serrations,
planetary carriers

Potassium K 2 2 - No typical wear element in gears

Calcium Ca 2 2 - Kein typisches Verschleißelement in

Getrieben

Cobalt* Co 2 2 - No typical wear element in gears

Copper Cu 75 40 Zn, Sn, Pb, Bronze worm wheels, friction bearings,

Sb roller bearing cages, oil coolers,
synchroniser rings, brass

Lithium* Li 2 2 - No typical wear element in gears

Magnesium Mg 9 4 Al Aluminium die-cast alloy

Manganese Mn 20 20 Fe, Cr, Ni, Roller bearings, pumps, general high-

Cu alloyed steels

Molybdenum Mo 14 8 Fe, Cr, Ni Constituent of high-strength alloys e.g.

for hardened gearwheels or roller
bearing steel

Sodium Na 2 2 - No typical wear element in gears

 Nickel Ni 17 5 - Constituents of high-strength alloys e.g.
for hardened gear wheels or roller
bearing steel, nickel-plated
components

Phosphorus P 2 2 - Phosphated (hardened) surfaces,

generally covering with P as additive

Sulphur S 2 2 - No typical wear element in gears

Silver* Ag 4 4 - Plain bearing, silver solder

Silicon Si 23 9 Al Aluminium die-cast parts, e.g. housings

Titanium* Ti 3 3 Fe Alloy constituent of high-strength

steels

Vanadium* V 2 2 - No typical wear element in gears

Tungsten* W 2 2 - No typical wear element in gears

Zinc Zn 41 78 Cu Roller bearing cages, coolers, zinc-

coated components (e.g. filter support
cores), brass components

Tin Sn 20 20 - Plain bearing

The „mobile“ warning values apply to vehicle gears and to oil fillings from mobile systems. The „stationary“ warning
values refer to oils from gears in stationary industrial systems. Values above or below the warning values do not
always mean that the oil should be changed. Elements marked with * appear in the standard laboratory report for
gear oils only for values above 1 mg/kg (1 ppm.)
Additive

Typical Mostly in
Element Sign Possible causes
range connection with

Aluminium Al < 50 Si Aluminium silicate-based nanoparticle additive

Antimony* Sb 2 - No typical additive components for gear oil

Barium Ba < 2000 P, Zn Friction-reducing additive (friction modifier) in

automatic gear oils, unusual for industrial gear oils

Beryllium* Be 2 - No typical additive components for gear oil

Lead Pb <3 - Reduces friction (friction modifier), (previously

used as a wear protector, no longer commonplace
today)

Boron B < 400 - Friction-reducing additive (friction modifier)

Cadmium* Cd 2 - No typical additive components for gear oil

Chrome Cr 2 - Chlorinated additives to protect against wear are

only rarely used today as cooling lubricants

Chlorine* Cl < 30 - No typical additive components for gear oil

Iron Fe 2 - No typical additive components for gear oil

Potassium K 2 - No typical additive components for gear oil

Calcium Ca < 4000 P,S Detergent (cleaning) and dispersent (for keeping
in suspension) additives, UTTO, engine oils

Cobalt* Co 2 - No typical additive components for gear oil

Copper Cu 2 - No typical additive components for gear oil

Lithium* Li 2 - No typical additive components for gear oil

Magnesium Mg < 2000 - Detergent (cleaning) and dispersent (for keeping

in suspension) additives, UTTO, engine oils

Manganese Mn <2 - No typical additive components for gear oil

Molybdenum Mo < 2000 P,S,Ca,Mg Molybdenum-organic additives, for gear oils with
PD effect, MoS2

Sodium Na < 200 - Non-ferrous metal protection, corrosion

protection

Nickel Ni <2 - No typical additive components for gear oil

Phosphorus P < 2000 S Wear and corrosion protection additive, extreme

pressure additive

Sulphur S bis 3% P Additives to protect against wear, in hypoid gear

oils, constituent of mineral base oils

Silver* Ag 2 - No typical additive components for gear oil

Silicon Si < 40 - Anti-foaming additives, nanoparticles in

combination with Al
 Titanium* Ti 2 - No typical additive components for gear oil

Vanadium* V 2 - No typical additive components for gear oil

Tungsten* W 2 - No typical additive components for gear oil

Zinc Zn < 1500 - Wear-reducing extreme pressure additive,

reduces friction (friction modifier), resistance to
ageing

Tin Sn <2 - No typical additive components for gear oil

* Element appears in standard laboratory reports for hydraulic oils only for values over 1 mg/kg (1ppm).

Contaminant

Mostly in
Warning
Element Sign connection Possible causes
value
with

Aluminium Al < 20 Si Dust from mines, e.g. bauxite

Antimony* Sb < 10 Li, Ca Contamination due to lubricating grease

Barium Ba < 15 - Contaminant due to greases and pastes containing

barium, blending with an ATF

Beryllium* Be 2 - Unusual as a contaminant

Lead Pb <3 - Blending with leaded grease, leaded paint coats

Boron B < 10 Na, K Cooling-grease and cooling-fluid supplement, fluxing

agent for solder joints, detergent supplement,
pesticide
Cadmium* Cd 3 Cu, Sn, V Dye pigments, disc brake lubricant (cadmium poses
a danger to health and has been banned in many
applications in the EU since 2011)

Chrome Cr 2 - Unusual as a contaminant

Chlorine* Cl < 30 Fe, Na, K Seawater, table salt, chlorine gas, PCB, chlorinated
refrigerants, supplement in some cutting fluids

Iron Fe 2 - Additive made from lubricant grease or assembly

paste

Potassium K - Na Gritting salt, synthetic fertiliser, from tap water, sea

salt, salty air, coolant (glycol), metal working oil

Calcium Ca < 15 Na, K, Si From hard (cooling) water, engine oils, mineral dust
(e.g. dolomite), from hydraulic oils, calcium
saponified greases

Cobalt* Co 2 - Unusual as a contaminant

Copper Cu 11 Fe, Pb, Al Abrasion of friction lining of multiple disc clutch or

brakes, from plumping pipes, sealing rings,
synchronising sealing rings, high temperature paste

Lithium* Li 20 Ca, Zn, P Thickener of multipurpose grease, assembly paste

Magnesium Mg < 15 Ca, Zn, P Blending with engine oil, tap or waste water, also
possible from hydraulic oils, or alloy component
constituents

Manganese Mn 2 - Unusual as a contaminant

Molybdenum Mo < 15 Ca, Zn, P Assembly paste, grease, blending with engine oil
 Sodium Na < 24 Al, Si, K Gritting salt, synthetic fertiliser or tap water, sea
salt, salty air, grease thickener, antifreeze (glycol)

Nickel Ni <6 - Assembly paste containing nickel

Phosphorus P < 20 Si, Ca, Al Dust, synthetic fertiliser

Sulphur S 2 - Unusual as a contaminant

Silver* Ag 2 - Unusual as a contaminant

Silicon Si 19 Al Dust or arenaceous quartz, glass dust, silicon oil,

silicon grease or silicon spray, plastic release agent,
silicon sealing compounds

Titanium* Ti < 40 - Used as a marker to prove the authenticity of the oil

by the manufacturer

Vanadium* V < 10 Nl, Al, Bi Constituent in heavy oil, dye and occasionally in
greases

Tungsten* W <4 Fe Residue from welding electrodes, TIG welding

Zinc Zn < 80 Fe, Cu, Al Coats of paint containing zinc, abrasion of sealing
compounds, blending with oils containing zinc

Tin Sn <9 - Soldering joints, coatings, as a constituent of ester

oils

* Element in standard laboratory reports for hydraulic oils only for values over 1ppm (1 mg/kg).

Interpreting the values

The experienced tribologist assesses the interplay of all of the values and also takes into account the customer‘s
specific operating conditions. The limit values and tolerances published here can therefore only serve as a general
guide for a specific usage case with a typical service life and oil fill volume.

Limit values for wear metals should be set lower:

the larger the oil quantity

the shorter the service life

for engines: the lower the engine speed;

for hydraulic systems: the higher the working pressure

for gearboxes: the higher the circumferential speed

Additives and their changes should always be scrutinised critically, particularly if they hint at being mixed with an
incompatible oil. If zinc is found in used oil which does not contain zinc as an additive in itself, its source must always
be investigated.

Contaminants, their warning values apply independent of the service life, quantity of oil and loads. Any dust is always
too much!

Our tip: With one to two yearly lubricant analyses per unit, you not only get substantiated diagnoses from an
experienced OELCHECK tribologist, but also make the course of any trends visible. This is a valuable tool, not only for
discovering wear at an early stage.