The warning signs we detect
If the oil is thickening, thinning or picking up water, or if vibration is rising, a problem may be starting in the machine. We measure these changes. When a reading moves away from normal, we warn you.
Warning signs and what to do
| Warning sign | What we measure | Likely cause | What to do | Benefit |
|---|---|---|---|---|
| Oil is thickening | Viscosity ↑ | The oil has aged (oxidation) or overheated. | Plan an oil change. | The oil is changed on time, not early. |
| Oil is thinning | Viscosity ↓ | Fuel has got into the oil, or the wrong grade is in use. | Check for leaks and check the oil grade. | Lower risk of engine and bearing damage. |
| Water in the oil | Moisture (ppm) ↑ | There is a coolant leak, a worn seal or condensation. | Check the seals. | Helps protect bearing life. |
| Oil is ageing | Dielectric ↑ | Oxidation products have built up, or the oil is contaminated. | Plan the change from the trend. | Fewer unnecessary oil changes. |
| Possible coolant leak | Dielectric and water rising fast | There is a leak in the cooling system. | Inspect without delay. | Lower risk of major engine failure. |
| Vibration is rising | Vibration level (RMS velocity) ↑ | There is imbalance, looseness or bearing wear. | Plan a repair. | Lower risk of unplanned stops. |
| Oil is getting dirty | Particle count ↑ (ISO 4406 code rises) | The filter is failing, a seal is worn or dust is getting in. | Check the filter and the entry points. | Helps protect valve and pump life. |
| Metal wear is increasing | Wear-metal particle trend ↑ | A gear or bearing is wearing. | Plan a repair. | Lower risk of unplanned stops. |
| Temperature is rising | Temperature ↑ | There is a lubrication, load or cooling problem. | Check lubrication, load and cooling. | Heat damage is caught early. |
Terms: Viscosity is how thick the oil is. Dielectric is an electrical property of the oil that shifts with ageing and contamination. ISO 4406 code is a three-number cleanliness code for solid particles in oil. RMS velocity is vibration intensity (mm/s).
What we do not measure: metal identification (which metal a particle is), acid and base number (TAN/TBN) and vibration spectrum analysis (FFT). These tests need a laboratory and a specialist. DataMonitor does not replace them. It works alongside them. The system watches for warning signs and gives early warning. It does not diagnose faults.
The readings to monitor on the machine are defined on site.
Questions about warning signs
How can I tell if there is water in my oil, and why does it matter?
Oil only turns cloudy at roughly 0.1% or more suspended water (NASA RCM Guide). By the time you can see it, it may be too late. The sensor measures water as ppm and water activity. It warns you as soon as the level starts to rise. Water degrades lubrication and increases corrosion (US DOE FEMP Guide), and it can shorten bearing life. Details
What does a rise or fall in oil viscosity mean?
Viscosity is how thick the oil is. Thickening usually points to ageing (oxidation) or overheating. Thinning can point to fuel dilution or the wrong oil grade. The trend tells you whether to plan an oil change or to check for leaks and the oil type. Details
Does DataMonitor diagnose faults?
No. DataMonitor detects warning signs and gives early alerts. Examples are oil thickening, water or dirt in the oil, or rising vibration. Metal identification, acid and base number (TAN/TBN) and vibration spectrum (FFT) analysis need a lab and a specialist. DataMonitor works alongside them. Details
What is an ISO 4406 cleanliness code and how do I read it?
An ISO 4406 code describes solid particle contamination in oil with three numbers. Each number covers a different particle size. Higher numbers mean dirtier oil. An online particle counter reports the code continuously. A rising code can point to a failing filter, a worn seal or dust getting in. Details
What does wear metal in oil tell me, and can the sensor identify the metal?
A rising wear-metal particle trend can show that gear or bearing wear is increasing. That is an early signal to plan a repair. The sensor tracks the particle counts and their trend. It does not identify the metal. That needs lab analysis. Details