Castrol Canada Gps 2019 PDF

GUIDE TO HEAVY DUTY PRODUCTS AND SERVICES
®
A .Lubricant Basics
B .Engine Oils
C .Hydraulic Fluids
D .Transmission Fluids
E .Gear Lubricants
F . Greases
G . Other Fluids
H .Services
.
A
Lubricant Basics
(Background and Properties)
A
Lubricant Basics
Background & Properties
Industry Specifications
History........................................................................A2
API CK-4 and FA-4 Background...................................A3
API CK-4 and FA-4 Engine Tests..................................A4
API CK-4 and FA-4 Bench Tests...................................A8
Other OEM Specifications.........................................A12
The API Service Symbol.............................................A14
SAE Engine Oil Viscosity Grades

Physical Requirements...............................................A15
Comparative Viscosity Classifications.........................A16
Important Engine Oil Properties

Role of Engine Oil.....................................................A17
Base Oil....................................................................A18
Base Oil Groups........................................................A20
Base Oil Groups: Characteristics................................A21
Refining Techniques..................................................A22
Additives...................................................................A23
Viscosity Index – A Measure of Performance.............A24
Lubricant Basics 1 800 255 4417
A2
Background & Properties www.castrol.com/GPS
History
Over the years, the drivers for change in diesel engine oils have been based upon the U.S. Environmental Protection
Agency (EPA) regulations for exhaust gas emissions. These changes occur every few years. To be able to meet ever-
tightening limits, engine manufacturers must change engine designs; these design changes almost always put
additional stresses on the oil, therefore calling for new engine oil service categories. With particulate matter (PM) and
nitrogen oxide gases (NOx) already at very low levels, the newer exhaust emission regulations address the reduction of
greenhouse gases (GHG), especially carbon dioxide (CO2). The CO2 limit has led to the development of the next
generation heavy duty (HD) engine oil for low GHG engines. The first licensing of the new American Petroleum
Institute (API) specifications, CK-4 and FA-4, began on December 1, 2016.
API CK-4
The current engine oil specification, API CK-4, was released into the marketplace on December 1, 2016, replacing the
previous API CJ-4 engine oils specification. API CK-4 is backward compatible with most applications where engine
manufacturers recommended CJ-4.
CK-4 was developed to better protect new and older engines, improve engine oil performance, and help engine
manufacturers meet 2017 U.S. government emissions standards. The new CK-4 oils provide a number of API CK-4
A3
API CK-4
The current engine oil specification, API CK-4, was released into the marketplace on December 1, 2016, replacing the
previous API CJ-4 engine oils specification. API CK-4 is backward compatible with most applications where engine
manufacturers recommended CJ-4.
CK-4 was developed to better protect new and older engines, improve engine oil performance, and help engine
manufacturers meet 2017 U.S. government emissions standards. The new CK-4 oils provide a number of
improvements over CJ-4 standards such as improved shear stability and aeration control; they also offer enhanced
protection against oil oxidation and engine wear, catalyst contamination, particulate filter blocking, piston deposits,
soot-related viscosity increase, and degradation of low- and high-temperature properties.
The CK-4 category addresses diesel engine changes that have occurred since the 2006 introduction of CJ-4, thus
meeting the needs of today’s more fuel-efficient engines with their increased power and use of such hardware as high
pressure, common-rail injection systems and advanced turbocharger technology. CK-4 is the result of EPA and National
Highway Traffic Safety Administration (NHTSA) emission legislation for diesel-powered commercial transport vehicles. It
requires significant improvements in fuel consumption to help reduce carbon dioxide emissions. CK-4 is specified for
high-speed four-stroke cycle diesel engines designed to meet the 2017 model year on-highway and Tier 4 non-road
exhaust emission standards, and for use in all applications with diesel fuels ranging in sulfur content up to 500 ppm.
CK-4 exceeds performance criteria of API CJ-4, CI-4 PLUS, CI-4, and CH-4. While this category was under
development, it was referred to as American Society for Testing and Materials’ (ASTM) Proposed Category (PC) 11A.
The API CK-4 Donut looks the same as the previous CJ-4 Donut.
API FA-4
Like CK-4, API FA-4 also launched on December 1, 2016. API FA-4 oils provide similar improvements over CJ-4 oils, but
are intended for use only in newer on-highway diesel engines. FA-4 oils have limited or no backward compatibility
with on- and off-highway diesel engines where engine manufacturers recommended CJ-4. However, FA-4 oils are
expected to play an important role in some current and new diesel engines by protecting those engines while also
helping them meet more stringent emissions requirements.
FA-4 was created for certain XW-30 oils that are specifically formulated for use in select high-speed four-stroke cycle
diesel engines designed to meet 2017 model year on-highway GHG emission standards and on-highway applications
with diesel fuel sulfur content up to 15 ppm. FA-4 offers enhanced protection against oil oxidation, viscosity loss due
to shear, and oil aeration as well as protection against catalyst poisoning, particulate filter blocking, engine wear,
piston deposits, degradation of low- and high-temperature properties, and soot related viscosity increase.
FA-4 is not interchangeable or backward compatible with API CK-4, CJ-4, CI-4 PLUS, CI-4, and CH-4 oils, nor is it
recommended for use with fuels having greater than 15 ppm sulfur. While FA-4 was under development, it was
referred to as the ASTM Proposed Category (PC) 11B. The API FA-4 Donut features a shaded section to differentiate
API FA-4 oils from CK-4 oils.
CK-4 and FA-4 oils are designed for different applications, making it important that technicians consult a
vehicle’s owner’s manual or the engine manufacturer to determine whether CK-4 or FA-4 is recommended.
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API CJ-4: The Previous Spec
The previous API CJ-4 engine oil specification was released into the marketplace on October 15, 2006 as a result of
the EPA’s mandate to further control exhaust emissions from on-road truck diesel engines. This previous regulation,
known as US EPA 07, required that all 2007 model year vehicles emit lower levels of NOx and PM. Changes in engine
design alone were not sufficient to reduce emissions to the EPA 07 required levels. Therefore, original equipment
manufacturers (OEMs) had to use supplementary technologies such as Exhaust Gas Recirculation (EGR) and Diesel
Particulate Filters (DPFs), often known as exhaust aftertreatment. EGR has been used on many diesel engines since
EPA 02 and often had the effect of introducing more soot into the oil, decreasing engine efficiency, and increasing
fuel consumption.
At that time, DPFs were new to the diesel engine; they work by trapping the soot particles from the exhaust and were
sensitive to certain performance-enhancing additives in API CI-4 oils. The combination of these two extra demands
upon the lubricant led to the introduction of the API CJ-4 lubricant performance category. New technology was
employed when developing CJ-4 lubricants because 2007 and newer engine components were sensitive to sulfated
ash, phosphorus and sulfur (SAPS). API CJ-4 lubricants had to be low SAPS engine oils, while still delivering the same
or in many aspects, better performance than their predecessors. CJ-4 lubricants could be used in place of CI-4 Plus,
CI-4, CH-4, CG-4, and CF-4 lubricants.
Wear Protection in the Presence of Soot

Maintaining wear protection and engine durability in the presence of heavily sooted engine oil is a primary performance
criterion for API CK-4 oils. Mack had had long-standing interest in proper control of soot, with tests in each category
since CF-4. Other OEMs joined in, starting with the Cummins M-11 in CH-4, M-11 EGR in CI-4, and the ISM and ISB
in CJ-4. All major OEMs share the concern of soot-related wear and corrosion that can result from high percentages
of EGR, promoting an environment in which acids are created.
API CK-4 Engine Tests

Caterpillar C-13 ASTM D7549
Scope:
The test method defines a heavy-duty diesel engine test procedure conducted under high output conditions to
evaluate engine oil performance with regard to piston deposit formation, piston ring sticking and oil consumption
control in a combustion environment designed to minimize exhaust emissions. This test method uses a Caterpillar
production C-13 diesel engine. Test operation includes a 60-minute warm-up and break-in, followed by a 4-hour cool
down and a valve lash adjustment. Following the valve lash adjustment and any other needed adjustments, a
500-hour test is begun. The engine is operated under steady-state, rated power conditions known to generate
excessive piston deposits and/or oil consumption.
Test Conditions:
Engine speed: 1800 rpm
Test length: 500 hours
API CK-4 Pass/Fail Criteria:
1000 merits
A5
Caterpillar 1N ASTM D6750
Scope:
The 1N test is run in the Caterpillar 1Y5400 SCOTE (Single Cylinder Oil Test Engine) utilizing a one-piece aluminum
piston and 0.05 wt. percent sulfur fuel. This test was originally developed to replace the 1K test as part of the upgrade
requirements to move from API CF- 4 to API CG-4. The Caterpillar 1N uses the exact same hardware and test
conditions as the 1K, but with low sulfur diesel fuel. It was added to API CI-4 Plus as an adjunct to the Caterpillar
1R test to insure that oils developed for this new category also protect engines that use one-piece aluminum pistons.
The Caterpillar 1N is designed to determine the ability of an oil to provide minimal piston deposits; ring sticking; low
oil consumption; and piston, ring and liner scuffing resistance. The test is intended to simulate on-highway, heavy-
duty diesel service prior to 1998 with low sulfur fuel.
Test Conditions:
Fuel flow rate: 8000 BTU/min
Approximate power output: 70 HP

Top Groove Fill: 20% max
Top Land Heavy Carbon: 3% max
Weighted Demerits: 286.2 max
Avg. Oil Consumption, gm/Kw-hr: 0.15
Ring/Liner Scuffing: none
Caterpillar Oil Aeration Test (COAT) ASTM D8047

Scope:
The COAT utilizes a Caterpillar C-13 6-cylinder engine to measure entrained gas or foam. A micro-motion meter
measures oil density to calculate % aeration. Air is entrained in the lubricant during the test and reaches a maximum
value toward the end of the test.
Test Conditions:
Fuel flow rate: 1.5 L/min

11.5% max amount of air in oil in last 10 hours of the test
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Mack T-11 ASTM D7156
Scope:
The Mack T-11 is a procedure that evaluates the soot handling performance, as measured by viscosity increase, of
lubricating oils operating in diesel engines equipped with cooled exhaust gas recirculation. The Mack T-11 evaluation
procedure simulates stop-and-go operation and high-soot loading. It is run on a Mack E-TECH V-MAC III engine.
Test Conditions:
Oil samples are taken every 12 hours and analyzed for soot content and viscosity. Test duration is 180 hours.

The main parameter is the kinematic viscosity increase limit within soot “windows”:
3.5% minimum soot for 4 cSt viscosity increase

Scope:
The Mack T-12 test involves the use of a Mack E-TECH V-MAC III diesel engine with Exhaust Gas Recirculation (EGR).
This test method was developed to evaluate the wear performance of engine oils in turbocharged and intercooled
four-cycle diesel engines equipped with EGR and running on ultra-low sulfur diesel fuel (ULSD).
Test Conditions:
A warm-up and a 1-hour break-in are followed by a two phase test consisting of 100 hours at 1800 r/min and 200
hours at 1200 r/min, both at constant speed and load conditions.

Total Merits: 1000

Scope:
Mack T13 uses a 2010 Volvo/Mack D13 6-cylinder diesel engine with electronically controlled fuel injection, six
electronic unit injectors, VGT (variable geometry turbocharger), and cooled EGR (exhaust gas recirculation). The test
measures Kinematic viscosity increase at 40°C (300-360 hours), % max. Oil filter adapter is a modified 2007 housing.
Test Conditions:
The 360-hour test is conducted at 1500 RPM steady state conditions at a given fuel flow to evaluate the oxidation
stability performance of engine oils at an elevated oil temperature. ULSD fuel is used.

75% max. from 300 - 360 hours
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Cummins ISM ASTM D7468
Scope:
Cummins ISM is a replacement for Cummins M-11 EGR. It is used to evaluate a lubricant’s effectiveness at reducing
soot-related wear of overhead components, sludge and oil filter plugging. High-load, heavy-duty field conditions with
high soot and EGR flow rates using a 2004 emission-compliant engine are simulated.
Test Conditions:
This 200-hour procedure uses a Cummins ISM engine equipped with EGR and is intended as a replacement procedure
for the M-11 EGR, using newer hardware. The Cummins ISM procedure uses ultra low sulfur diesel fuel.

Total Merits: 1000
Cummins ISB ASTM D7484

Scope:
The Cummins ISB test method is a 350-hour test developed to evaluate the durability and reliability of the camshaft
and tappet interface when run with different lubricating oils. Oil performance is determined by assessing crosshead
wear, tappet weight loss, and cam profile wear at 3.25% soot.
Test Conditions:
The test method uses a 2007 EPA emission compliant Cummins 5.9L ISB diesel engine. Test duration is 350 hours in
two stages. During the 100-hour stage A, the engine is operated with retarded fuel injection timing to generate
excess soot. During the 250-hour stage B, the engine is operated at cyclic conditions to induce valve train wear.

Average cam wear, microns: 55 max
Average tappet wear, mg: 100 max
Sequence IIIF ASTM D6984

Scope:
This test evaluates high temperature oil thickening characteristics, sludge and varnish deposits and overall engine
wear in unleaded gasoline engines. The test engine is a six-cylinder, four stroke, 3.8 liter 1996 Buick. The test was
designed to simulate high speed driving conditions during high ambient temperatures found typically in the Southern
regions of the United States. Note: Criteria for this test is based upon the CJ-4 specification.
Test Conditions:
The test is operated on a four-hour break-in schedule after which the oil is sampled. The engine is then run for 80
hours under conditions of high speed, load and temperature.
API CJ-4 Pass/Fail Criteria:
Viscosity Increase @ 80 hour: % max 275
A8
Sequence IIIG (alternative to IIIF) ASTM D7320
Scope:
The objective of this test is to measure oil thickening and piston deposits under high temperature conditions and to
provide information about valve train wear. At the end of the test, all six pistons are inspected for deposits and
varnish; cam lobes and lifters are measured for wear and oil screen plugging is evaluated. Note: Criteria for this test is
based upon the CJ-4 specification.
Test Conditions:
A 1996/1997 231 C.I.D. (3800 CC) Series II General Motors (GM) V-6 fuel-injected gasoline engine is used. Using
unleaded gasoline, the engine runs a 10-minute initial oil leveling procedure followed by a 15-minute slow ramp up
to speed and load conditions. It then operates at 125 bhp, 3600 rpm, and 150°C oil temperature for 100 hours,
interrupted at 20-hour intervals for oil level checks.
Viscosity Increase: 150%
GM 6.5 Roller Follower Wear Test (RFWT) ASTM D5966

Scope:
The RFWT or GM 6.5L measures an oil’s ability to prevent wear of the pin in an engine equipped with needle bearings
in the roller cam followers.
Test Conditions:
Fuel flow rate: 9.0 kg/hour
Approximate power output: 30-34 kW
Average Pin Wear, microns max: 7.6
API CK-4 Bench Tests

A bench test differs from an engine test in that it is performed in a laboratory, not on a full engine. Bench tests are
less expensive to run and help round out the performance measurement for the API CK-4 category.
Noack or Volatility Bench Test ASTM D5800

Scope:
The Noack test measures oil volatility at high temperatures. As temperatures rise, any fluid, even engine oil, has a
tendency to evaporate. This test ensures that API CK-4 oils will experience only minimal evaporation due to
temperature.
A9
During the Noack Volatility Test, a sample of oil is placed in the test machine and held at elevated temperatures with a
slight vacuum for one hour. The oil sample’s weight is noted at the beginning and end of the bench test. The Noack
Volatility Test measures oil volume to assure that the oil experiences only minimal evaporation at high temperatures.
Test Conditions:
The test oil is heated for one hour at 250° C. The sample is under vacuum with resulting oil vapors drawn off by an air
stream. The amount of vapor indicates volatility of oil and oil consumption.

Loss @ 250°C, percent max volatility: 13.0%
Kinematic Viscosity/SAE J300 ASTM D445

Scope:
This simple test describes the viscosity of the oil at various temperatures.
Test Conditions:
The flow of the oil against gravity is measured using a calibrated glass tube immersed in a heated bath.

@ 100° C: 9.5 to <12.5 cSt for XW-30
12.5 to <16.3 cSt for 15W-40
High Temperature Corrosion Bench Test (HTCBT) ASTM D6594

Scope:
HTCBT was first used by API for CG-4. This test measures a diesel engine oil’s tendency to corrode various metals,
specifically alloys of lead and copper, which are commonly used in cam followers and bearings.
Test Conditions:
Four metal specimens of copper, lead, tin and phosphor bronze are immersed in a measured amount of engine oil.
The oil, at an elevated temperature, is blown with air for a period of time.
When the test is completed, the copper specimen and the stressed oil are examined to detect corrosion and corrosion
products, respectively. The corrosion process under investigation is believed to be induced primarily by inappropriate
lubricant chemistry rather than lubricant degradation or contamination.

Copper (Cu) 20 mg, Max
Lead (Pb) 120 mg, Max
Tin (Sn) 50 mg, Max
Copper Discoloration 3 Max
A10
Kurt Orbahn Shear Stability Test ASTM D7109
Scope:
The Kurt Orbahn test was first used by API for API CH-4. This test method covers the evaluation of the shear stability
of polymer-containing fluids (e.g., multi-viscosity engine oil). It measures the percent viscosity loss at 100° C when
evaluated by a diesel fuel injector apparatus procedure. The viscosity loss reflects permanent shear loss (chain
breakage). Shear stability is a critical test for hydraulic/electronic unit injector (HEUI) equipped engines. Engine oils that
shear down from their original viscosity cause injection pressures to drop, which decreases overall engine efficiency.
Wear protection is also diminished as an oil shears.
Test Conditions:
Test procedure: 90 passes for both CJ-4 and CK-4
Test temperature: 100° C

Test oil is sent through the test apparatus either 30 or 90 times at pressures of 1,900 to 2,600 psi, as defined by
instrument calibration. The final viscosity is measured and the percent loss from the beginning viscosity is recorded.

Kinematic Viscosity after 90 passes: 9.3 cSt min for XW30
12.5 cSt min for 0W40
12.8 cSt min for other XW-40 grades
High Temperature High Shear (HTHS) Viscosity Test ASTM D4683

Scope:
The HTHS test gives an indication of temporary shear stability of the viscosity index improver used in multi-grade oils.
Test Conditions:
Unlike Kinematic Viscosity, HTHS viscosity is measured under conditions similar to those of an operating engine. The
test is conducted at 150° C under shear stress conditions similar to those found in very thin film lubrication areas. An
example is the piston ring-to-cylinder wall interface. The value obtained from this test provides an indication of the
ability of the oil to maintain fluid film strength in an engine.

Non-Critical Limit: 3.5 cP min
API FA-4 Pass/Fail Criteria:

Non-Critical Limit: 2.9 - 3.2 cSt
A11
Foaming ASTM D892
This test is the standard test method for foaming characteristics of lubricating oils.
Scope:
The tendency of oils to foam can be a serious problem in systems such as high-speed gearing, high-volume pumping,
and splash lubrication. Inadequate lubrication and cavitation can lead to component failure. This test method is used
in the evaluation of oils for such operating conditions.
Test Conditions:
The sample, maintained at a temperature of 24° C (75° F), is blown with air at a constant rate for 5 minutes and then
allowed to settle for 10 minutes. The volume of foam is measured at the end of both periods. The test is repeated on
a second sample at 93.5° C (200° F), and then, after collapsing the foam, at 24° C (75° F).
Sequence I: 10 minutes/ 0 max
Sequence II: 20 minutes/ 0 max
Sequence III: 10 minutes/ 0 max
Sooted Oil Mini-Rotary Viscometer (MRV) ASTM D6896

Scope:
This test utilizes an MRV that consists of one or more viscometric cells in a temperature-controlled aluminum block.
Each cell contains a calibrated rotor-stator set. The rotation is achieved by applied load acting through a specified
pulley mechanism.
Test Conditions:
A used engine oil sample is heated at 80° C and then vigorously agitated. The sample is then cooled at a programmed
cooling rate to a final test temperature. A low torque is applied to the rotor shaft to measure yield stress and a high
torque is applied to determine apparent viscosity of the oil.
180-hour sample from Mack T-11 or T-11A
Viscosity @ -20° C, max: 25,000 mPA-S
Yield Stress: <35 Pa
Elastomer Compatibility Test ASTM D7216

Scope:
This seal compatibility test method evaluates the compatibility of API CK-4 oils with typical elastomeric compounds
used in heavy-duty engines. These include nitrile, silicone, polyacrylic, and fluoroelastomers.
Test Conditions:
Test procedure: Variation of gear lube test
A12
Test length: 20 days (336 hours)

Test temperature: 100° C for Nitrile Seals
150° C for Silicone, Polyacrylic, and Fluoroelastomer seals
Seal measurements: Volume swell
Hardness change
Tensile strength change
Elongation change

Volume Hardness Tensile Elongation
Strength
Nitrile +5/-3 +7/-5 +10/-R +10/-R

Polyacrylate +5/-3 +8/-5 +18/-15 +10/-35
Fluoroelastomer +5/-2 +7/-5 +10/-R +10/-R
Silicone +R/-3 +5/-R +10/-45 +20/-30
R = TMC 1006
Other OEM Specifications

Often, API performance categories do not meet the additional performance requirements sought by every engine
manufacturer. For this reason and others, OEMs may elect to issue their own engine oil classifications. These
classifications typically apply to specified engine models and/or operating conditions. Over the years, these
classifications have included the following:
Cummins CES 20086

The Cummins specifications for CK-4 tend to have the CJ-4 test criteria, but with some tighter limits.
Cummins 20087
These specifications for FA-4 tend to have the CJ-4 test criteria, but with some tighter limits.
Cummins CES 20081
This specification was similar to API CJ-4 but with some tighter test limits. Designed for Cummins 2007-compliant
engines equipped with diesel particulate filters (DPFs), it can be used with diesel fuel containing up to 500 ppm of
sulphur.
Cummins CES 20078
On 12/04/01, Cummins issued Cummins Engineering Standard 20078 (CES 20078). The intent of CES 20078 was to
ensure that high quality engine oils, suitable for Cummins EGR-equipped engines, would be available by the 2nd
quarter of 2002. API CI-4 Plus wasn’t officially required until August 2002; however, Cummins was planning to sell
EGR engines by April. This specification made sure that these engines would be lubricated with approved oil.
This specification is very similar to API CI-4 Plus but has a few test limits that are more severe.
A13
Detroit Diesel Power Guard 93K222
This specification for CK-4 tends to have the CJ-4 test criteria as 93K218 (below), but with some tighter limits.

This specification for FA-4 tends to have the CJ-4 test criteria, but with some tighter limits.
This specification is intended for all four-stroke cycle series engines with an aftertreatment system, EPA 07 and older
(including legacy engines), operating on ULSD fuel. These oils are similar to API CJ-4.
This specification is for engine oils used in the Detroit Diesel engines model year 2002 and newer Series 50 and 60
and Mercedes Benz MBE 400 and MBE 900 engines. This specification was needed to address the rapidly changing
requirements for emission-controlled engines. API CI-4 Plus tests formed the core of the category with additional tests
to assure lubricant performance for newer emission-controlled engines, particularly those using cooled EGR. Another
key purpose behind this specification is to extend drain intervals up to 50 percent in some engines.
Mack VDS 4.5

This specification for CK-4 tends to have the CJ-4 test criteria, but with some tighter limits.
Mack EO-O Premium Plus ‘07
This specification exceeded API CJ-4 with tighter pass limits in the Mack T-12, Cummins ISM and Cummins ISB engine
tests plus the addition of the Volvo D12D test. It can be used with diesel fuel containing up to 500 ppm of sulphur.
Mack EO-N Premium Plus
In 2002, EO-N Premium Plus oil performance specification was made mandatory for usage in ASET™ AI and AC
engine models and was recommended for all MACK engine models (E-Tech™, E7, E6, etc.) regardless of vintage.
EO-N Premium Plus engine oil promotes longer engine life and reduced component wear, providing a higher oil film
thickness, better wear performance and improved oxidation control at higher oil temperatures.
Cat ECF-3
Recommended for Caterpillar 2007 engines, this specification is the same as API CJ-4.
Cat ECF-1
Engine Crankcase Fluid Specification 1 (ECF-1) was issued in response to Caterpillar’s concern regarding the potentially
negative side effects of industry standard API CI-4 oil formulations. CI-4 oils with high sulfated ash had demonstrated
unacceptably high piston and ring groove deposits in Caterpillar engines.
A14
The API Service Symbol

The API Service Symbol “Donut” is divided into three parts:
• The top half describes the oil’s performance level.
• The center identifies the oil’s viscosity.
• The bottom half tells whether the oil has demonstrated energy-conserving properties in a standard test in
comparison to a reference oil.
Performance Levels
The top of the Donut shows the oil’s performance level for gasoline and/or diesel engines. The letter “S” followed by
another letter (for example, SM) refers to oil suitable for certain gasoline engines. The letter “C” followed by another
letter and/or number (for example, CK-4) refers to oil suitable for certain diesel engines. These letters officially stand
for “Service” and “Commercial.”
SAE Viscosity Grade

The center of the Donut shows the oil’s SAE viscosity grade. Viscosity is a measure of an oil’s flow characteristics, or
thickness, at certain temperatures.
A multi-grade oil (for example, SAE 5W-30) provides good flow capability for cold weather but still retains thickness
for high-temperature lubrication.
A single grade oil (a single number in the center of the Donut) is recommended for use under a much narrower set
of temperature conditions than multi-grade oils.
A15

Physical Requirements
The following chart contains the physical requirements for SAE viscosity grades as described in SAE J300*. Additional
requirements are imposed by the U.S. military.
Low-Temperature Viscosity High-Temperature Viscosity
Low Shear Rate max. at High Shear Rate (cP)

Pumping (cP)
SAE Cranking (cP) max. with no Kinematic (cSt) 100°C at 150°C
Grade max. at °C yield stress at °C min. max. min.
0W 6200 at -35 60,000 at -40 3.8 ---- ----
5W 6200 at -30 60,000 at -35 3.8 ---- ----
10W 7000 at -25 60,000 at -30 4.1 ---- ----
15W 7000 at -20 60,000 at -35 5.6 ---- ----
20W 9500 at -15 60,000 at -20 5.6 ---- ----
25W 13,000 at -10 60,000 at -15 9.3 ---- ----
20 ---- ---- 5.6 <9.3 2.6
30 ---- ---- 9.3 <12.5 2.9

2.9
40 ---- ---- 12.5 <16.3 (0W-40, 5W-40,
10W-40)
3.7
40 ---- ---- 12.5 <16.3 (15W-40, 20W-40,
25W-40, 40 grades)
50 ---- ---- 16.3 <21.9 3.7
60 ---- ---- 21.9 <26.1 3.7

*
All values are critical specifications as defined by ASTM D 3244 b ASTM D 5293 c ASTM D 4684 The presence of any yield stress detectable by this method constitutes a
failure regardless of viscosity. d ASTM D 455 e STM D 4683, ASTM D 4741, CEC-L-36-A-90 or ASTM D 5481 See SAE J300 for full formulation.
A16

Comparative Viscosity Classifications
Lubricant Basics A17
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Role of Engine Oil
A high quality engine oil is formulated to perform a number of roles within an engine:
• Reduce frictional resistance
• Protect against corrosion and wear
• Assist in sealing
• Contribute to cooling the engine
• Facilitate the suspension of harmful combustion by-products
The key to choosing an engine oil that can effectively accomplish the above tasks is to choose a fluid with good base
stocks and properly blended, premium additives. Below is a quick reference of base stock characteristics and how
each can influence the finished engine oil:
Key Base Stock Property Engine Oil Performance Criteria
Viscosity and Viscosity Index High Temp Viscosity
Viscosity, Viscosity Index, Low Temp Viscosity
Pour Point, and Amount of Wax
Amount of Saturates Oxidation Control
and Sulfur
Amount of Saturates Seal Swell Control and
Additive Compatibility
Volatility* and Viscosity Index Oil Consumption Control
In addition to meeting or exceeding industry specifications and accomplishing the duties described above, there are
several desirable engine oil properties that can impact the performance of today’s equipment. Typically, these
properties can be enhanced when an engine oil is blended with high quality base stocks and a premium additive
package using cutting-edge technology. Some oil properties and their importance are shown on the following pages.
*Low volatility is especially important in engine oils because the high operating temperatures in today’s diesel engines
can lead to excessive oil consumption.
Total Base Number or TBN
Modern diesel engine oils have a characteristic referred to as alkalinity (or Reserve Alkalinity) as part of their
formulation. This alkalinity — commonly called detergency, or “TBN” — describes an oil’s ability to neutralize acids as
they are formed in the crankcase. These acids are a normal by-product of the combustion process when diesel fuel is
burned because the fuel itself contains sulfur compounds. TBN levels in North American CK-4 engine oils typically
range from 8 to as high as 11.
Research suggests that TBN should never be the sole indicator for calculating drain intervals. Factors such as the
lubricant’s viscosity, soot content, and low temperature flow are critical factors in evaluating its drain limit.
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High Temperature/High Shear (HT/HS)
An oil’s resistance to permanent viscosity loss due to shear is called shear stability. Forces inside an engine — such as
high temperature, heavy loads and outside contaminants — can cause an oil to shear down, or thin. Oil thinning can
cause increased oil consumption and reduced oil film strength. Once the oil film strength is compromised, engine
components are exposed to wear and premature failure is possible. Increased oil consumption can also elevate
maintenance costs.
Oils that are shear stable maintain their oil film thickness, protecting critical moving parts like rings, bearings, and
other engine components while extending engine life. Temporary viscosity loss in high-speed, heavy-load applications
can result in metal-to-metal contact, which causes premature engine wear. Oils that offer excellent high temperature/
high shear protection give users an increased margin of protection against viscosity loss.
Viscosity Index (VI)
Viscosity index is a measure of an oil’s change in viscosity based on changes in operating temperatures. Oils with a
high viscosity index (over 100) experience relatively little change in viscosity as a result of temperature changes. High
VI oils do not experience thinning at high temperatures or thickenening at low temperatures. Viscosity index is a
performance benefit that is a result of high-quality base oils and premium additives.
Base Oil
Building a Lubricant from the Base Up
Base oil comprises 80 to 98 percent of finished lubricants used in engines, transmissions, hydraulics, and gear
housings. Base oil contributes to a number of properties in a finished lubricant; these properties can be further
enhanced with additives. A lubricant manufacturer’s goal is to accentuate the base oil’s positive properties while
decreasing or removing any unwanted characteristics. Some of the most important properties influenced by a base oil
are listed and defined below:
Viscosity and Viscosity Index (VI)

Viscosity is a measure of a fluid’s resistance to flow; viscosity index (VI) is the relationship of a fluid’s viscosity to
temperature. High VI fluids experience less change in viscosity relative to temperature than low VI fluids do. Base oils
have natural tendencies toward high, medium or low VIs, but VI can be enhanced through refining techniques and
with additives in the blending process.
Volatility
Volatility refers to how readily a base oil and resulting finished lubricant will evaporate as temperatures rise. Volatility is
especially important in engine oils where compartment temperatures are extremely high; high volatility can result in
increased oil consumption.
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Pour Point
Pour point is the temperature at which an oil “gels.” Pour point directly influences a finished lubricant’s ability to flow to
critical components during low ambient temperatures. In a base oil, the amount of wax in the fluid can make pour points
higher, but refining techniques can remove the wax so that the pour point is lowered. It is recommended that a finished
lubricant’s pour point be approximately 15 degrees below the expected ambient temperature.
Pour point is a relatively crude measure of cold temperature performance and should not be used as the sole indicator
of a fluid’s cold temperature properties. It should be viewed in conjunction with more precise testing methods such as
pumpability via TP-1 coding, D-4684 and end Brookfield viscosity measurements.
Demulsibility
The ability of an oil to separate from water that has contaminated a system is called “demulsification.” A lubricant’s
ability to separate from water is a necessity for applications where water can attack metal parts or even cause additives
to drop out of the finished lubricant. Demulsibility is especially important in hydraulic fluids.
Oxidation
Chemically, oxidation occurs when hydrocarbon molecules react with oxygen molecules at elevated temperatures. An
oxidized oil thickens excessively, jeopardizing pumpability to critical parts, and can become acidic and eventually
corrode metal surfaces. Good oxidation performance in a base oil relates directly to how “saturated” the base oil is.
Saturation refers to the amount of base oil molecules that have no chemically active double bonds. This creates a
situation where there is less chance for oxygen to bond with any molecules, which would eventually lead to oxidation.
Mineral base oils treated during refining with hydrogen are more saturated, and therefore have better oxidation
stability than mineral base oils not treated with hydrogen.
H H H H
H–C = C – C – C = C – C – H Non-Saturated Base Oil
H H H H
O H O H
=
=
H–C – C – C – C – C – C – H Oxidized Oil

=
O H O H
H H H H H H
H–C – C – C – C – C – C – H Saturated Base Oil
H H H H H H
Thermal Stability
Base oils that can withstand high temperatures for long time periods without oxidizing are termed “thermally stable.”
In applications that experience high operating temperatures for extended lengths of time, thermal stability cannot be
compromised. Thermal stability is achieved by good base stocks and additives.
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Base Oil Groups
There are several major types of base oil groupings. Each base Group V
oil group has specific characteristics that relate to the
application of the finished lubricant. As illustrated, progressing >99%
Group IV
from aromatics up to synthetic base oils increases the oxidative
stability, viscosity index and amount of saturation typically Group III
found in the base oil. It is important to note that these base
% Saturates
>90%
Better Oxidation Stability

stocks are not always interchangeable. Additive packages that Group II
Improved Soot Control

Higher Viscosity Index
produce approval with Group I base stocks in finished
lubricants may not replicate that approval in a Group II Group I
finished lubricant. Additives can react differently with each
category of base oil. Naphthenics
Aromatics
Three easily discernible characteristics in base stocks are sulfur 0%
content, saturation, and viscosity index. The measurement of
API Base Oil Groups
these features gives insight into ultimate finished product
benefits.
Sulfur Content
Sulfur content relates directly to many performance characteristics of the base stock. Sulfur negatively impacts
catalysts in aftertreatment systems and can impact seal compatibility, oxidation, and deposit performance. Total sulfur
in CK-4 oils Is limited to 4000 ppm max. Advanced refining and finishing processes remove nearly all of the sulfur in a
base oil.
Saturation
Saturation refers to the amount of base oil molecules that have no chemically active double bonds. This is an
important characteristic in a base oil because these double bonds can be easily broken to allow hydrocarbon
molecules to react with one another or oxygen or nitro-oxidized molecules. The result is oxidation in the base oil,
which leads to oil thickening, deposits, and breakdown in finished lubricants.
Highly saturated base oils, like Group II stocks, have been treated with hydrogen gas during refining. This process
forces hydrogen through the oil and causes it to react with the double bonds. This saturates the molecule with
hydrogen, thus eliminating opportunities for oxygen to attach and making the base oil more oxidation resistant.
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Viscosity index
Viscosity index (VI) may be one of the single most important performance measures in both a base oil and finished
lubricant. VI is the measure of a change in viscosity relative to a change in temperature. Base oils with high VIs (over 100)
experience less change in viscosity due to temperature. High VI finished lubricants, such as multi-viscosity engine oils,
offer improved protection, pumpability, efficiency, and oil consumption benefits over lower VI lubricants.
Base Oil Groups: Characteristics

Currently, the media, the industry, and oil marketers are playing up the benefits of Group II and higher base stocks.
Here is a review of the characteristics of each base oil group:
• Group I base oils have VIs of 80 to 120 and were the original, traditional engine oil base stock, but are not
common in modern engine lubricants. Group I base oils have more sulfur and less saturates than Group II, III, or IV
fluids. The performance of finished lubricants blended with Group I base oils is largely dependent upon the quality
of the additive package.
• Group II base oils are known for their excellent deposit control and high level of saturates, which makes them
more oxidation resistant. They typically have VIs of 95 up to 120 and rely heavily on additives to enhance finished
lubricant characteristics. Different refining techniques work to remove unwanted characteristics and improve upon
desired ones, like viscosity index and oxidation control. Most of Castrol’s finished lubricants are blended with
Group II base oils and a premium-performing additive package.
• Two other categories of fluids are common—synthetics or Group III/Group IV and specialized fluids, or Group V.
For engine oils, synthetic fluids fall into two categories: refined and polyalphaolephins.
• Refined Group III base oils are petroleum fluids that undergo extreme refining techniques, producing a base
fluid with characteristics of a man-made synthetic. Group III refined base oils are typically found in partial to full
synthetic finished lubricants, since they have greater than 90% saturates (usually 99%+) and VIs over 120. They
have low pour points, good oxidation resistance, and low volatility.
• Group IV base oils are known as polyalphaolefins (PAO). PAOs, the most widely used of the engineered base
stocks, consist of all saturated hydrocarbon structures and contain no unwanted sulfur or other metals. Free
of wax, PAOs have very low pour points and typically have VIs of 140. PAOs have good thermal stability, but
are sometimes difficult to blend with additives. Despite their noted performance features, PAOs are sometimes
cost-prohibitive for users.
• Group V base fluids consist of other fluids that are not typically derived from oil refining or PAO synthesis,
predominately esters and polyolesters. There are also aromatic and naphthenic base oils that are not suitable for
use in heavy-duty engine lubricants due to their poor oxidation stability and low VIs. Aromatics contain
elevated levels of sulfur (which lead to deposit formation) and sometimes nitrogen (which contributes to oxidation
and deposit formation). Aromatics are typically used as solvents, cleaners, and process oils, and in further chemical
reactions for industrial products.
• Naphthenic fluids, typically, have low to medium VIs of up to 60. They exhibit very low pour points, high
solubility, and excellent cold flow in long term storage. Naphthenics are commonly used in refrigeration lubricants,
metalworking oils, greases, and as extreme cold temperature fluids, such as snowplow oils.
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Refining Techniques
Group I and II mineral-based fluids are all refined from crude oil, and the way that crude oil is refined determines its
place in the base oil groupings.
Solvent refining is older technology that is often used to create Group I base stocks. A solvent refined crude oil is
dissolved in solvent, then chilled and filtered to remove wax. The resulting base fluid will still have poor low
temperature fluidity and a typical VI of 90 to 100. To further influence a base oil’s performance characteristics,
additional refining using hydrogen may be performed. There are basically three types of hydrogen refining, each more
potent than its predecessor:
Hydrofinishing forces pressurized hydrogen into a solvent extracted base oil. The hydrogen molecule fills some of
the active double bonds in the hydrocarbon molecule so these molecules cannot react with oxygen molecules to begin
the process of oxidation. Hydrofinishing also removes some of the sulfur, nitrogen, oxygen, and color impurities
present in the solvent-refined base oil.
A more severe process called hydrotreating forces hydrogen gas through the base oil, at higher pressures than
hydrofinishing, which further saturates the oil with hydrogen molecules. Hydrotreating boosts oxidation stability,
increases pour point, and removes even more sulfur and nitrogen from the base oil. A finished lubricant that has been
hydrotreated has lower carbon-forming tendencies than hydrofinished or solvent-refined fluids.
Hydrocracking, or hydrorefining, is another severe form of hydrogen processing whereby larger, waxy molecules
are cut into smaller, lighter weight ones. Hydro de-waxing reduces the wax content and increases pour point. Group II
Hydrocracked base stocks contain over 90 percent saturated molecules and typically have VIs of 95 to 115. They
exhibit strong oxidation stability and excellent demulsibility. Castrol uses hydrocracked, Group II base fluids in most of
their engine, transmission, hydraulic, and gear oils. Group III base stocks are generally hydro-isomerized during the
hydrorefining process, improving the VI to 120 or higher by rearranging the branching of basestock molecules. Group
III base stocks also exhibit other improved qualities compared to Group II oils such as reduced volatility and improved
oxidation and deposit resistance.
A properly balanced additive package is the critical link to bringing out the best performance in a high quality base oil
and, ultimately, in the user’s equipment. Castrol has been one of the largest users of Group II base stocks for many
years. Castrol also focuses on balancing premium-performing additives with base oil for lubricants that exceed
manufacturers’ recommendations and customer expectations.
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Additives
In today’s marketplace, there is very little conventional oil that does not contain additives. Especially prevalent in the
heavy-duty industry, diesel engines with high rates of soot and contamination demand a top performing additive
package in an engine oil. Generally, additives are used to perform one or more of the following functions within a
finished lubricant:
• Protect metal surfaces

• Extend range of lubricant applicability
• Extend lubricant life
The different types of additives on the market can be categorized according to functionality as surface protectors,
performance oriented, and protection based. A brief overview of the additives within each of these categories gives
insight into the benefits of lubricants containing such additives.
Surface Protecting Additives
Although grouped together under surface protectors, each of the additives below has a very specific job within the
finished lubricant. The largest group of additives, surface protectors, can be found in almost every type of lubricant on
the market today.
• Considered a cleaning agent, detergents prevent deposit formation by either combining with solid combustion
debris or changing combustion and oxidation acids into inactive, neutral salts. Total Base Number, or TBN, is a
measure of the detergent’s ability to neutralize acid. The stronger the TBN, the better an oil’s acid neutralizing
effects. For more information on TBN, see page A-15.
• Dispersants, another cleaning agent, control sludge and varnish by keeping particulates from grouping together
to form larger deposits, which become sludge and varnish over time. A lack of dispersants can increase oil viscosity
due to the agglomeration of soot and combustion by-products.
• Anti-wear agents prevent metal-to-metal contact by adhering to metal surfaces and forming a protective film.
Anti-wear agents must be selected carefully because they can affect hydrolytic and frictional stability, as well as
become corrosive to yellow metals.
• Rust and corrosion inhibitors protect metal surfaces from water-related wear. Improper rust protection can
result in significant corrosion in transmission or final drive gear. Rust and corrosion inhibitors protect components
by forming a protective layer on the component or by neutralizing harmful acids.
• Found primarily in heavy-duty transmission fluids, greases, and gear lubricants, extreme pressure (EP) agents are
a special type of anti-wear agent in that they protect against metal-to-metal contact but under extreme loads and
temperatures. EP agents must be monitored carefully because they may have compatibility issues with other active
chemicals in the lubricant and with yellow metals, such as copper and bronze. Other trade-offs include hydrolytic
stability and frictional characteristics.
• Friction modifiers work to improve the overall efficiency of a lubricant by decreasing friction, preventing scoring,
and reducing wear and noise while adding some fuel economy.
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Performance Additives
Specific to temperature performance, these additives are essential in lubricants whose applications are subject to wide
temperature ranges. Lubricants with improper tolerance for temperature, both environmental and operational, can
cause a host of problems with pumpability, cold starts, and wear.
• Viscosity modifiers boost a base oil’s natural viscosity index (VI) as well as extend lubricant performance over
varying temperatures. Viscosity modifiers work through a unique method of selective oil thickening. High
temperatures result in more thickening, which reduces the likelihood of wear; and low temperatures result in
less thickening so a lubricant can maintain pumpability.
• Pour point depressants are targeted specifically toward enhancing low temperature flow characteristics.
Oils tend to form wax crystals during low temperatures. A pour point depressant prevents oil molecules from
“sticking” to wax crystals, which would inhibit flow. Some viscosity modifiers also function as pour point
depressants and vice versa.
Protective Additives
Different from surface protecting additives, protective additives focus on preventing breakdown from foam, oxygen,
or water. Due to the severe duty endured by most diesel applications, protective additive packages are a distinguishing
factor among finished lubricants.
• Anti-oxidants protect against oil breakdown due to oxidation. Under conditions of high temperature and severe
service, oxygen can mix with the churning lubricant at high temperatures and oxidation occurs. Anti-oxidants or
oxidation inhibitors act like a sponge to extract oxygen from the oil and slow the oxidation process. Anti-oxidants
are used in almost every heavy-duty and automotive lubricant.
• Foam is the result of air getting trapped in the oil. Anti-foam agents repress foaming by lowering surface tension
and allowing trapped air to escape. Excessive foam can lead to a breakdown in an oil’s film strength and eventually
causes extensive wear. Like anti-oxidants, anti-foam agents are found in almost every commercial lubricant.
• Metal deactivators are actually a class of oxidation inhibitors. Primarily used in transmission fluids, metal
deactivators protect metal surfaces from additives that may be corrosive.
• Emulsifiers and demulsifiers are engineered to handle water contamination in a lubricant sump. Emulsifiers
eliminate any free-circulating water by enabling oil and water to mix. Demulsifiers separate water from oil. If
maintenance practices call for water removal, then demulsifiers are the additive of choice. When there is no
opportunity to remove water, emulsifiers are added to the lubricant.
Viscosity Index (VI) – A Measure of Performance

Viscosity is one of the single most important characteristics of an engine oil. By definition, viscosity is the measure of a
lubricant’s resistance to flow. Flow characteristics and temperature are directly related. For example, the higher the
temperature, the more freely an oil flows; the lower the temperature, the more flow is inhibited. This relationship
results in oil thinning as temperature increases and oil thickening as temperature decreases.
B
Engine Oils
B
Engine Oils
Product Data
Castrol® Vecton® 10W-30 FA-4 B2
Castrol® Vecton® Long Drain 10W-30 CK-4 B4
Castrol® Vecton® 15W-40 CK-4 B6
Castrol® CRB® Multi 15W-40 CK-4 B8
Castrol® Elixion® 5W-30 CJ-4 B9
Castrol® Assuron™ (straight grades) B13
Castrol® Duratec™ ES 15W-40 B14
Castrol® Duratec™ NG 15W-40 B17

Engine Oils B2
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Product Data www.castrol.com/GPS
Castrol® Vecton® 10W-30 FA-4

Castrol Vecton 10W-30 FA-4 with unique System Pro Technology™ is a part-synthetic diesel engine oil that
represents the latest technology heavy-duty engine oil engineered specifically for fuel economy in select 2017 and
beyond model year diesel engines. It is targeted exclusively at today’s low emission, low fuel consumption trucks and
buses where API FA-4 is required.
Fuel Savings and Increased Productivity

Pumping oil around the engine creates drag, which saps engine power and
increases the consumption of diesel fuel. Castrol Vecton 10W-30 FA-4 delivers a 1.5% Fuel Saving* and extended
drain intervals of up to 96,000 kilometers or 770 hours.**
In addition, Castrol Vecton 10W-30 FA-4 has lower viscosity under high temperature and high shear forces. These
characteristics reduce drag and save fuel, thus improving the productivity of the engine.
Adapting to Lower Emissions

New technology developments in diesel engines have led to lower emissions in heavy-duty vehicles. In turn, these
advances in technology also result in increasing levels of torque within the engine, which leads to higher pressures
and temperatures.
Castrol Vecton 10W-30 FA-4 with unique System Pro Technology™ adapts to increased pressure and temperature
with proven shear stability and oxidation performance.
Features/Benefits
Castrol Vecton 10W-30 FA-4 offers the following benefits in support of modern diesel engine technology:
• Excels under high pressure. Engine combustion pressures are increasing, which puts increased pressure on
key engine parts. Castrol Vecton 10W-30 FA-4 with unique System Pro Technology™ is formulated to hold its
viscosity under high shear contacts to extend oil life.
• Performs at high temperature. In modern engines, engine oil is subjected to areas of very high temperature; this
causes oxidation and oil thickening. Castrol Vecton 10W-30 FA-4 is formulated to fight oxidation to extend oil life.
Industry Approvals and OEM Specifications

• API FA-4
• Cummins CES 20087
• DDC DFS 93K223
* In independent testing versus SAE 15W-40 CJ-4 oil using SAE J1321 test method for class 8 trucks
**In combination with and following a proper used oil analysis program like Castrol Labcheck®
Engine Oils B3
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Castrol® Vecton® 10W-30 FA-4

Typical Properties
Name Method Units Vecton 10W-30 FA-4
Appearance Visual - Clear & Bright
Viscosity, Kinematic 100C ASTM D874 % wt 1.0
Viscosity, Kinematic 40C ASTM D2896 mg KOH/g 10
Viscosity Index ASTM D97 °C -42
Sulfated Ash Content ASTM D445 cSt 67
Total Base Number ASTM D445 cSt 10.2
Pour Point ASTM D2270 137
Engine Oils B4
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Castrol® Vecton® Long Drain

Castrol Vecton Long Drain 10W-30 CK-4 with unique System Pro Technology™ is an advanced part-synthetic
heavy-duty diesel engine oil that conforms to the requirements of PC-11 engine oil technology. Specifically engineered
to deliver longer oil life and enable longer service intervals even under severe operating conditions, Castrol Vecton
Long Drain 10W-30 CK-4 can be used in diesel engines where API CK-4 or CJ-4 and previous diesel engine oil
categories are required.
Extended Oil Life and Extended Drain Intervals

and temperatures.
Castrol Vecton Long Drain 10W-30 CK-4 with unique System Pro Technology™ adapts to increased pressure and
temperature with its proven shear stability and oxidation performance, extending useful life of the oil for longer
service intervals and higher productivity.
In addition, Castrol Vecton Long Drain 10W-30 CK-4 delivers extended drain intervals of up to 113,000
kilometerss or 900 hours.*
Features/Benefits
Castrol Vecton Long Drain 10W-30 CK-4 offers the following benefits in support of modern diesel engine technology:
key engine parts. Castrol Vecton Long Drain 10W-30 CK-4 with unique System Pro Technology™ is formulated to
hold its viscosity under high shear contacts to extend oil life.
causes oxidation and oil thickening. Castrol Vecton Long Drain 10W-30 CK-4 is formulated to fight oxidation to
extend oil life.
• Neutralizes harmful acids and combustion by-products that cause bearing corrosion. Castrol Vecton Long
Drain 10W-30 CK-4 maintains outstanding TBN level even while operating at maximum drain intervals.

• API CK-4, CJ-4, CI-4 Plus
• CAT ECF-3
*In combination with and following a proper used oil analysis program like Castrol Labcheck©
Engine Oils B5
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Castrol® Vecton® Long Drain

Typical Properties
Name Method Units Vecton Long Drain 10W-30 CK-4
Viscosity, Kinematic 100C ASTM D445 cSt 12.16
Viscosity Index ASTM D2270 143
Ash, Sulphated ASTM D874 % wt 0.95
Total Base Number, TBN ASTM D2896 mg KOH/g 10.69
Pour Point ASTM D97 °C -39
Engine Oils B6
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Castrol® Vecton® 15W-40 CK-4

Castrol Vecton 15W-40 CK-4 with unique System Pro Technology™ is an advanced part-synthetic heavy-duty diesel
engine oil that conforms to the requirements of PC-11 engine oil technology. Castrol Vecton 15W-40 CK-4 can be
used in diesel engines where API CK-4 or CJ-4 and below is required.
Castrol Vecton 15W-40 CK-4 is engineered specifically to deliver longer oil life, thus enabling longer service intervals
even under severe operating conditions. In fact, it delivers extended drain intervals of up to 97,000 kilometers
or 770 hours*.
Adapting to Lower Emissions

and temperatures.
Castrol Vecton 15W-40 CK-4 adapts to increased pressure and temperature with proven shear stability and
oxidation performance, extending useful life of the
oil for longer service intervals and higher productivity.
Features/Benefits
Castrol Vecton 15W-40 CK-4 offers the following benefits in support of modern diesel engine technology:
key engine parts. Castrol Vecton 15W-40 CK-4 with unique System Pro Technology™ is formulated to hold its
viscosity under high shear contacts to extend oil life.
causes oxidation and oil thickening. Castrol Vecton 15W-40 CK-4 is formulated to fight oxidation to extend oil life.

• CAT ECF-3
• Mack EOS-4.5
• Volvo VDS-4.5
• DDC DFS 93K222
• RVI RLD-4
*In combination with and following a proper used oil analysis program like Castrol Labcheck®
Engine Oils B7
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Castrol® Vecton® 15W-40 CK-4

Typical Properties
Name Method Units Vecton 15W-40 CK-4
Viscosity, Kinematic 40C ASTM D445 cSt 116
Ash, Sulphated ASTM D874 % wt 0.99
Total Base Number, TBN ASTM D2896 mg KOH/g 10
Engine Oils B8
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Castrol® CRB® Multi 15W-40

Castrol CRB Multi 15W-40 CK-4 is a multi-purpose, heavy-duty engine oil designed to provide superior protection to
diesel engines. It is engineered to promote long and healthy engine life, offering protection to diesel engines in a
variety of applications and duty cycles. Castrol CRB Multi 15W-40 CK-4 conforms to the strict requirements of PC-11
engine oil technology and can be used in diesel engines where API CK-4, CJ-4 and below is required.
Versatility for Heavy Duty and Commercial Vehicles

Castrol CRB Multi 15W-40 CK-4 can be used in a wide range of heavy duty and commercial vehicles; this versatility
makes it ideal for use in mixed fleets. Its special formulation helps to keep diesel engines cleaner and gives
more reliable engine protection. This, in turn, prolongs engine life to various vehicles fleet-wide.
Features/Benefits
Castrol CRB Multi 15W-40 CK-4 offers the following benefits:
• Protection against oil thickening and deposit build-up in critical engine parts
• Protection from wear and deposits
• Protection against viscosity loss for reliable engine protection
• Better shear stability
Castrol CRB Multi 15W-40 CK-4’s versatility makes it a highly practical solution for workshops and mixed fleets.
Industry Approvals and OEM Specifications:

• CAT ECF-3
Typical Properties
Name Method Units CRB Multi 15W-40
Total Base Number ASTM D2896 mg/g KOH 10
Sulfated Ash Content ASTM D874 % wt. 1.0
Pour Point ASTM D97 C -42
Viscosity, Kinematic 100C ASTM D445 mm²/s 15.5
Viscosity, Kinematic 40C ASTM D445 mm²/s 116
Viscosity Index ASTM D2270 None 140
Engine Oils B9
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Castrol® Elixion® 5W-30 CJ-4

Castrol Elixion, a revolutionary SAE 5W-30 synthetic engine oil, is formulated with high quality synthetic base fluids.
• Synthetic based fluids are known for their extremely low pour points and high viscosity indexes of 140 or better.
• A high viscosity index gives the finished lubricant outstanding viscosity over a range of temperatures, as well as
wear protection during extreme high and low temperatures.
Castrol Elixion is a technologically advanced fully synthetic diesel engine oil engineered to reduce operating costs
while providing outstanding engine protection. Castrol Elixion offers the fuel economy benefits of a 5W-30 engine oil
and combines it with certified API CJ-4 performance. It is formulated with synthetic base oils, which allow for easy
cold-weather starting and provide added protection against the intense heat of today’s newest diesel engines. Castrol
Elixion utilizes a high performance additive package that provides excellent protection against wear, oxidation, soot
and deposits to deliver outstanding engine life.
Castrol Elixion has been engineered to provide users with the following benefits:
Operational Cost Savings

Castrol Elixion has been specially designed to give fuel economy savings while protecting the engine and allowing
extended service intervals. Reviewing the total operating costs of a fleet, it is easy to see where most dollars are spent.
Fuel is the biggest variable operating cost for truck fleets today. The combined cost of lubricants, maintenance and
tires does not equal the cost to fuel a fleet’s vehicles.
Fleet Operating Costs
1%
6% Lubricants
Tires
36%
28% Fuel
Maintenance
13% 16%
Overhead Depreciation
Engine Oils B10
1 800 255 4417

Castrol Elixion is proven to give fleet fuel economy savings of up to 4% over conventional 15W-40 oils.
Use Less Fuel

Elixion 5W-30 vs. Conventional 15W-40
4
% improvement
0
Hill City Urban Overall
Hot
Cold
* the data reflects Castrol testing from either field tests or engine dynamometer testing, whichever is pertinent to this data.
By using Castrol Elixion, a fleet can lower fuel bills by reducing fuel consumption.
Enhanced Engine Durability

Castrol Elixion was the first SAE 5W-30 engine oil to meet the latest industry specification, API CJ-4. In fact, it exceeds
API CJ-4 limits with outstanding wear protection as evidenced by the wear chart below. In the industry’s toughest
wear tests, Castrol Elixion falls well below API CJ-4 limits, proving that this 5W-30 engine oil can control soot and
deposits in heavy-duty engines and promote long engine life.
* the parameters asterisked are statistically better than the CJ-4 limit at 95% confidence. Results on other parameters are not statistically better
than the respective CJ-4 limits.
Engine Oils B11
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All-Temperature Engine Protection
Castrol Elixion offers all-temperature protection for engines. Its base oils have very low pour points and excellent
pumpability for cold temperature flow and wear protection, while safeguarding the engine against excessive oil
thinning or thickening during very high operating temperatures and pressures.
Proven Reduced Emissions

Using Castrol Elixion, your engine will emit less carbon dioxide (CO2) as a result of decreased fuel consumption. For
example, running a fleet of 100 trucks with Castrol Elixion and gaining just a 2% improvement in fuel economy can
reduce CO2 emissions by up to 342 tons per year as compared to using a conventional 15W-40 engine oil.**
Furthermore, Castrol Elixion has been proven to produce significantly less ash forming deposits. This ensures that
Diesel Particulate Filters (DPFs) remain cleaner and more efficient, which can help lengthen regeneration cycles and
prevent early and costly replacement.
**Based on a fleet of 100 trucks, each covering 100,000 miles a year with average fuel consumption of 6.5 mpg and 2% fuel savings
Features/Benefits:
• Up to 4% fuel economy improvement vs. a 15W-40 oil.
• Highly advanced chemistry provides extra protection against wear, soot, oxidation and deposits.
• Synthetic base oils help enable extended drain capability beyond that of conventional mineral-based engine oils.
• Low volatility minimizes oil consumption.
• Helps maintain protection for the diesel particulate filters on newer engines.
Industry Specifications and OEM Approvals:

• API CJ-4, CI-4 Plus, CI-4, CH-4
• CAT ECF-3
• Volvo VDS-4
• Mack EO-O Premium Plus
• MB Sheet 228.31
Engine Oils B12
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Typical Properties
Test Method Typical
Viscosity @40°C, cSt ASTM D445 68.0

Specific Gravity @60°F ASTM D1298 0.853
Pour Point, °C(°F) ASTM D97 -42 (-44)
Flash Point, °C (°F) ASTM D92 207 (404)
Low Temp Pumping Viscosity @-35°C ASTM D4684 17,800
Noack Volatility, %loss ASTM D5800 10.3
Sulfated Ash Content, %wt. ASTM D874 1.0
Total Base Number ASTM D2896 11
Due to continual product research and development, the information contained herein is based on products
purchased in the U.S. and subject to change without notification. Typical properties may vary slightly.
Engine Oils B13
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Castrol® Assuron™
Castrol Assuron (SAE 10W, 30, 40, and 50) are high performance, heavy-duty engine oils that couple selected
base stocks with a carefully balanced additive package. Castrol Assuron has proven performance in various on- and
off-highway heavy-duty diesel engines, particularly in applications requiring API CF-2.
Castrol Assuron (SAE 10W, 30, 40, and 50) are extremely resistant to the formation of high temperature deposits.
The higher dispersant package also works to keep the cooler areas of the engine from sludge and other harmful
deposits.
Features/Benefits
• Enhances engine performance
• Protects engine parts for extended life
• Reduces maintenance costs
Industry Specifications and OEM Approvals by Grade:

Castrol Assuron (10W, 30, 40, and 50) exceeds the requirements of the following API categories:
• SAE 10W (CF)
• 30 (CF-2, CF)
• 40 (CF-2, CF)
Typical Properties
SAE Grade 10W 30 40 50
Viscosity 40° C, cSt ASTM D-445 43.9 92.2 150.1 208
100° C, cSt ASTM D-445 7 11 14.8 19.3
210° F, SUS ASTM D-2161 48.9 63 79 94.9
Viscosity Index ASTM D-2270 108 104 98 99
Sulfated Ash % wt ASTM D-874 0.95 0.95 0.95 0.95
Total Base Number
mg KOH/g ASTM D-2896 7.5 7.4 7.4 7.5
Pour Point °C ASTM D-97 -30 -30 -27 -24
Specific Gravity
@60F g/ml ASTM D-1298 0.874 0.8854 0.8911 0.895
Pounds per gallon 7.28 7.38 7.42 7.46
Due to continual product research and development, the information contained herein is based on products purchased in the U.S. and subject to
change without notification. Typical properties may vary slightly.
Engine Oils B14
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Castrol® Duratec™ ES 15W-40

Low Ash Synthetic Natural Gas Engine Oil (NGEO) for
On Road Trucks
Castrol Duratec ES 15W-40 is a synthetic lubricant formulated for use in natural gas fueled engines where minimal
thermal degradation and good deposit control is expected. Castrol Duratec ES 15W-40 provides outstanding
resistance to nitration and oxidation compared to mineral on road NGEO and meets the performance requirements of
many of today’s mobile natural gas fueled engines. Castrol Duratec ES 15W-40 provides improved cold temperature
engine starting and reduced oil consumption relative to single grade natural gas fueled engine oils.
Real World Testing

Castrol Duratec ES 15W-40 has been formulated to provide extended performance in on-road natural gas fleets to
maximize uptime and optimize operational efficiency. After thousands of hours of field trials, Duratec ES 15W-40
has delivered extreme drain intervals up to 1,200 hours (with used oil analysis).
Advanced Acid Neutralization for Extreme Extended Drain

Castrol Duratec ES 15W-40 has outstanding combustion acid neutralization capability throughout extended drain
intervals, preventing damage to engine surfaces from corrosive wear.
TAN & TBN vs. Oil Age

8
7
TAN/TBN, mg/g KOH
5
TBN
TAN
4
0
0 200 400 600 800 1000 1200 1400
Oil Age, Hours

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Exceptional Performance Against Oxidation and Nitration
Natural gas engines have higher combustion temperatures than their diesel counterparts, which leads to increased
oxidation and nitrogen oxide formation. Duratec ES 15W-40 suppresses and controls oxidation and nitration
throughout extended drain intervals, preventing sludge, varnish, plugged filters and deposits.
Oxidation & Nitration vs. Oil Age

30
25
Oxidation
20
Condemning Limit Nitration
Index
15
10
0
0 200 400 600 800 1000 1200 1400
Oil Age, Hours
Outstanding Wear Control

In natural gas engines, ash deposits (rather than soot, as in diesel engines) are a primary contributor to wear on key
metal surfaces like cams and cylinders. Castrol Duratec ES provides excellent ash wear protection across extended
drain intervals. Cummins C8.3G test results show that not only does the additive chemistry in Duratec ES easily pass
the test at the standard 200 hours; it also has outstanding performance when extended to 400 hours. This cutting
edge technology is the key to extended drain performance.
Cummins C8.3G Cylinder Wear Test

6
5
Average Liner Wear, Microns
4
CES 20074 Pass/Fail Limit for
200 Hour test, 5 Microns
3
0
Duratec ES Duratec ES
200 Hours 400 Hours
Engine Oils B16
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Features/Benefits
Castrol Duratec ES 15W-40 enables “extreme” extended drain intervals while maintaining outstanding protection and
delivers an advanced detergent/dispersant system that has been designed to reduce deposit formation and improve
oxidation characteristics while offering excellent corrosion control, TBN retention and outstanding wear control. User
benefits include:
• Exceptional nitration and oxidation control compared to conventional on road NGEO
• Specially designed for on road trucks
• Exceptional anti-wear and extreme pressure protection
• Reduces deposits & maintains engine cleanliness
• Wide range of operating temperatures
Castrol Duratec ES 15W-40 is designed for use in a wide range of natural gas equipment including Cummins, Mack,
Volvo, and other on road engines requiring a low ash natural gas engine oil.
Typical Properties
SAE Grade Method Units Typical

Kinematic Viscosity @100°C, cSt ASTM D445 mm /s
2
15
Kinematic Viscosity @40°C, cSt ASTM D445 mm /s 106 2
Viscosity Index ASTM D2270 -- 146

Sulfated Ash, %wt ASTM D874 % wt. 0.82
Total Base Number, Mg KOH/g ASTM D2896 mg/g KOH 5.5
Pour Point, °C ASTM D97 °C -33
Appearance Visual Clear and Bright
Engine Oils B17
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Castrol® Duratec™ NG 15W-40

Low Ash Natural Gas Engine Oil for On-Road Trucks
Castrol Duratec NG 15W-40 is formulated for use in natural gas fueled engines where minimal thermal degradation
and good deposit control is expected. Castrol Duratec NG 15W-40 provides outstanding resistance to nitration and
oxidation and meets the performance requirements of many of today’s mobile natural gas fueled engines. Castrol
Duratec NG 15W-40 provides improved cold temperature engine starting and reduced oil consumption relative to
single grade natural gas fueled engine oils.
Real World Testing

Castrol Duratec NG 15W-40 was developed to deliver real world results in on-road fleets looking to safely extend
service and improve operational efficiency. With countless hours of field experience, Duratec NG 15W-40 has been
proven to extended drain intervals up to 600 hours (with used oil analysis).
Outstanding Acid Neutralization

Castrol Duratec NG 15W-40 protects engine surfaces from corrosive wear with advanced combustion acid
neutralization capability throughout extended drain intervals.
TAN & TBN vs. Oil Age

8
7
TAN/TBN, mg/g KOH
5
TBN
TAN
4
0
0 100 200 300 400 500 600 700
Oil Age, Hours

Engine Oils B18
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Excellent Oxidation and Nitration Protection
Castrol Duratec NG 15W-40 prevents sludge, varnish, plugged filters and deposits that occur in natural gas engines as
a result of oxidation and nitration.
Outstanding Wear Control

Duratec NG 15W-40 prevents cylinder liner and cam tappet wear by providing excellent protection against ash
deposits over an extended drain interval. Duratec NG easily passes the Cummins C8.3G test at the standard 200
hours, and also passes when extended out to 400 hours.
Cummins C8.3G Cam Tappet Height Loss
12
CES 20074 Pass/Fail Limit for
Cam Tappet Face Wear, Microns
200 Hour test, 10 Microns

10
0
Duratec NG Duratec NG
200 Hours 400 Hours
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Features/Benefits
Castrol Duratec NG 15W-40 delivers an advanced detergent/dispersant system that has been designed to reduce
deposit formation and improve oxidation characteristics while offering excellent corrosion control, TBN retention and
outstanding wear control. User benefits include:
• Formulation exhibits excellent thermal and oxidative stability
• Provides excellent resistance to acid corrosion
• Specially designed for on-road trucks
• Exceptional anti-wear and extreme pressure protection
• Reduces deposits & maintains engine cleanliness
• Wide range of operating temperatures
Castrol Duratec NG 15W-40 is designed for use in a wide range of natural gas equipment including Cummins, Mack,
Volvo, and other on road engines requiring a low ash natural gas engine oil.
Industry Approvals and OEM Specifications by Grade

Typical Properties
SAE Grade Method 15W-40
Kinematic Viscosity @100°C, cSt ASTM D445 15
Kinematic Viscosity @40°C, cSt ASTM D445 115
Sulfated Ash, %wt ASTM D874 0.82
Total Base Number, Mg KOH/g ASTM D2896 5.5
Pour Point, °C ASTM D97 -18
Appearance Visual Clear and Bright
C
Hydraulic Fluids
C
Hydraulic Fluids
Industry Specifications C2
Important Anti-wear
Hydraulic Fluid Properties C9
Product Data
Castrol® Dual Range HV™ C14
Castrol® Blue Hydraulic Plus™ C19
Castrol® Paradene™ AW C24
Castrol® Anvol® SWX 46 C26
Castrol® Performance™ Bio HE C29

[PREVIOUSLY Castrol Carelube HTG]
Castrol® Aerial Lift Fluid C33

Hydraulic Fluids C2
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Performance standards for anti-wear hydraulic fluids are set primarily by original equipment manufacturers. Unlike
engine oils, anti-wear hydraulic oils do not have an industry licensing procedure. Therefore, anti-wear hydraulic fluid
users must seek out information on test results from the oil manufacturer itself. Without a standard industry licensing
program, it is worthwhile for users to research hydraulic fluid choices carefully.
Castrol’s Liquid Engineers have developed a range of hydraulic flueds to meet performance standards required by
Original Equipment Manufacturers (OEMs). These include products that meet recent changes in hydraulic fluid
formulation, driven by industry trends and OEMs:
• Improved oxidation stability to accommodate higher operating temperatures.
• Improved air release, foam control and water separation to handle smaller reservoirs and reduced cycle times.
• Improved dry/wet filterability due to reduced filter pore size and tolerance to water contamination.
• Better hydrolytic stability to handle water contamination.
• Extended pump life to meet Denison T6HZOC pump performance.
• Increased drain intervals requiring the lubricants to retain original performance longer.
Importance of Oxidation Tests

When selecting a hydraulic fluid, resistance to oxidation is a key component of performance. The ability to protect
against oxidation in the oil prevents premature oil thickening, sludging and other critical lubrication failures. Good
oxidation protection comes from the combination of base oil selection and quality of the additives.
Types of oxidation tests include:
Turbine Oil Oxidation Test (ASTM D 943)

This test measures the oil’s ability to prevent oxidation and the formation of destructive acids. To pass HF-O, the oil’s
acidity level must not exceed 2.0 mgKOH/g after 1500 hours.
Test Criteria
Time to 2.0 TAN, hours 1,500 min
Rotary Pressure Vessel Oxidation (ASTM D 2272)

This test utilities an oxygen pressurized vessel to evaluate oxidation stability of lubricants in the presence of water and
copper @150°C.
Test Criteria
Time to 25-psi loss in minutes HF-O, HF-2 1500
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Thermal Stability: Cincinnati Milacron
This test evaluates whether an oil will cause a reaction to steel and copper components. Run for 168 hours at 275°F.
Test Criteria P-68, P-69 HF-O

and P-70
Viscosity change, (%), max 5
Neutralization number, (%), max ±50
Sludge (mg/100 ml), max 25 100
Copper wt loss (mg), max 10
Copper rod appearance 5 Report
Iron rod appearance No discoloration
1000-h Sludge (ASTM D 4310)

This test measures the build-up of sludge and increase of iron and copper particulate in the oil.
Test Criteria Denison HF-O HF-1 HF-2

TAN (mg KOH), max 1.0 .2 1.0
Insoluble Sludge, mg max 100 100 400
Total Cooper, mg max 200 - 200
Total Iron, mg max 50 - 100
TAN (ASTM D 974-07)

Standard Test Method for Acid and Base Number by Color-Indicator Titration
Importance of Wear and Load Tests

Load performance and wear protection are crucial components when selecting a hydraulic fluid. Hydraulic fluids are
designed to handle important shock loads and other various types of loads during operation. The ability to prevent
metal to metal contact also results in lowering component wear, such as in hydraulic pumps. Proper viscosities and
excellent anti-wear additives play a pivotal in protecting against wear.
Types of Wear and Load Tests include:

Vickers 35VQ-25 Vane Pump Test
This test measures wear to the cam ring and the vane pump. It is run for three, 50-hour segments at 200°F, 3,000 psi
and 2400 rpm.
Test Criteria
Ring 75-mg max
Vane 15 mg max
Total 90 mg max
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Denison T6H2OC Hybrid Pump Test
Denison’s more stringent pump test is known as the T6H2OC. This incorporated both vane and piston pump in a
single housing, thereby replacing the need to run separate T6 and P46 pump tests, as previously required by HF-O.
The test contains both wet and dry hydraulic phases. When testing multigrade oils, this test is known to provide a
high level of shear and is able to effectively discriminate between different types of viscosity modifiers.
Test Criteria
less than or equal to 300 mg piston valve wear
less than or equal to 15 mg vane and pin wear
Denison T-6C Vane Pump Test

This test measures the oil’s ability to prevent wear on cam ring, side plate and vanes. It is run for 60 hours at 160°F
and 40 hours at 210°F both at 2400 rpm and 2500 psi.
Test Criteria
Vane Contour Increase
Denison P-46 Piston Pump Test

This evaluates the oil’s ability to withstand high pressures and temperatures in piston pumps. This test is the same as
the Denison T-5D Vane Pump Test, except it is performed on a piston pump.
Test Criteria
Piston Shoe Wear Plate, Port Plate Appearance
Denison T5D42
Vane pump test used to evaluate hydraulic fluids for wear in vane pumps.
Denison T6-C
Vane pump test used to evaluate hydraulic fluids for wear in vane pumps.
Denison T6H20C
Hybrid pump test used to evaluate oils for antiwear and working in presence of water contamination, part of HF-O
qualification.
Sundstrand Pump Test

Old test used to evaluate ability of fluid to continue to function in presence of water contamination.
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Hydrolytic Stability and Anti-wear Additives
Whether the customer uses a hydraulic fluid that emulsifies or demulsifies, the fluid must still be hydrolytically stable.
Hydrolytic stability refers to the oil’s ability to maintain performance during water contamination. Unstable wet
hydraulic oils under high operating temperatures can cause anti-wear compounds to break down. Once this occurs,
the zinc compound is no longer providing anti-wear protection and other chemicals can cause wear to hydraulic
components. As a result, component life can be decreased by 50% or more.
Hydrolytic Stability (ASTM D 2619)

This test measures the oil’s ability to protect against wear in the presence of water. It is run at 2030 psi for 250 hours
at 1440 RPM.
Test Criteria:
Copper Weight Loss, mg maximum 0.2
Acidity of Water, mg KOH, maximum 4.0
Load Test FZG (DIN 51354, Part 2)

This test evaluates a hydraulic fluid’s ability to withstand heavy shock loads.
Test Criteria Damage Load Stage, min

US Steel 136 10
DIN 51524 Part 2 10
GM (LS-2) LH, 03, 04, 06 10
HF-O Report
Hydraulic fluids containing extreme pressure additives are better equipped to handle heavy shock loads.
4-Ball Wear (ASTM D 2266)

This test measures an oil’s anti-wear and anti-weld properties. It is run for 1 hour at 54°C, 1800 rpm and 20 kg.
Test Criteria Scar Diameter, mm max

US Steel 127 0.5 (40 kg)
US Steel 136 0.5 (20 kg)
4-Ball EP (ASTM D 2783)

This test evaluates extreme pressure and anti-weld properties of the oil.
Test Criteria US Steel 136

Weld Load (kg), min 150
LWI (kg), (min) 30
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Cold Start (Up ASTM D2983)
Used to evalute ability of oil to be pumped or flow in cold temperatures.
KRL Shear Test (20 hours)

Bench test method that compares the permanent shear loss of multigrade hydraulic oils. Recent tests have shown that
the 20-hour test provides excellent correlation to actual field and pump test performance. During this test, the
lubricant is tested in a tapered bearing fitted to a four-ball EP test machine.
Test Criteria
% viscosity loss @100°C 15% max
Filterability, Demulsibility and Foam Tests

Water Tolerance: Demulsify or Emulsify?
Two major concerns for maintenance managers are keeping water out of a hydraulic system, and then dealing with it
once it inevitably enters the system. Water can enter a hydraulic system in a number of ways: loose fill caps, poor
seals, loose tolerances on the suction side of components, use of a pressure washer, condensation in the sump and
even by contaminated top-off fluid that has been compromised during storage or delivery. Once in the system, water
is to blame for problems like wear, power fluctuations, rust and the overall destruction of sensitive components.
Knowing how a hydraulic fluid handles water can inevitably save your customer time and money in maintenance.
Separating Water from Oil

The best way to handle water contamination is with proper maintenance practices and an excellent hydraulic oil. AW
hydraulic oils demulsify, or separate water from oil. This allows for the water to be drained from the sump, preferably
at the beginning of each work shift. There should be a clear delineation between the water and oil. A white, creamy
cuff between the water and oil or cloudy hydraulic fluid means the oil is not properly demulsifying and additive dropout
may be occurring.
Mixing Oil with Water

If maintenance practices or system design do not allow for the daily removal of water, a fluid that emulsifies is the next
best choice. Fluids that emulsify oil and water are ones that mix with the water to create an emulsion, fully enveloping
the water. This eliminates free-circulating water, but must be weighed against possible tradeoffs like wear protection
and proper viscosity grade selection.
How a hydraulic fluid deals with water contamination is one of the vital questions that needs to be answered when
determining the hydraulic fluid for a customer. At the same time, internal maintenance practices need to be evaluated
to assure that system maintenance coincides with the fluid’s handleability to water (emulsify or demulsify).
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Importance of Filterability, Demulsibility and Foam Tests
In hydraulic systems, air can be treated as a contaminant and lead to failures in the hydraulic pumps, including
cavitation and air bubbles. The ability to demulsify air and disperse foam improves filterability, leading to longer
component life.
Types of Filterability, Demulsibility, and Foam Tests include:
Filterability (Denison TP 02100)

This test measures how quickly an oil will filter when dry and how quickly it will filter when contaminated with 2% water.
Test Criteria
A. Dry 600 seconds maximum
to 75 ml
B. Wet (2%) 2xA seconds maximum
to 75 ml
Demulsibility (ASTM D 1401)

This test measures the oil:water cuff and the time it takes for the oil and water to separate. Equal amounts of oil and
water are agitated at 130°F and left to separate over a timed interval. It is run at 130°F with ISO VG 32/46.
Test Criteria
Oil-water-cuff (ml) 40-37-3
Separation time (min) 30
This test is very important to hydraulic fluid users. A good AW hydraulic fluid must separate oil and water effectively
and leave no creamy white cuff between the two fluids.
Foam (ASTM D 892)

This test measures an oil’s ability to prevent excessive foaming in the presence of entrained air.
Test Criteria
No foam allowed after 10 minutes
Air Separation (DIN 51381)

Test Criteria
Separation Time, min ISO VG 46/68 ISOVG 32
DIN 51524 Part 2 10 max 5 max
GM (LS-2) LH,03, 04, 06) 10 max 5 max
Denison HF-O 7/10 NR
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Environmental Tests
OECD 301B
Biodegradability test that measures how long it takes for a substance to totally biodegrade into carbon dioxide gas
and water. More severe than CEC L-33 T 82.
CEC L-33-T-82
Biodegradability test that measures only the first step in the biodegradation process. Is an alternative to OECD 301B.
Importance of Corrosion and Rust Tests

Keeping hydraulic systems clean is important to an efficient operation. Corrosion and rust can occur from the presence
of oxygen or water. Hydraulic fluids need to protect against these contaminants with rust and corrosion inhibitors
formulated in the fluid, and protect metallic surfaces. Rust and corrosion will affect pump performance and can lead
to hydraulic pump failures.
Types of Corrosion and Rust Tests include:
Rust Prevention (D665 -06 A & B)

Standard test method for rust-preventing characteristics of lubricants in the presence of water. Method A uses distilled
water, Method B uses salt water, so method B is more severe.
Steel Corrosion (ASTM D 665)

This test is performed with distilled water and synthetic seawater. It measures the hydraulic fluid’s ability to protect
against rust and corrosion when contaminated with water.
Test Criteria
Distilled Water Pass/Fail
Synthetic Sea Water Pass/Fail
Once again, this is a very important test for hydraulic fluids that must protect equipment in the presence of water.
Some additives in lesser quality hydraulic fluids may become corrosive when exposed to water.
Copper Strip (ASTM D 130)

Test Criteria
DIN 51524 Part 2 2 max
GM (LS-2) LH, 03, 04, 06 1b max
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Important Anti-wear Hydraulic Fluid Properties

By definition, any fluid whose pressure and flow is used to produce work is considered a hydraulic fluid. For this and
reasons of convenience, a multitude of different lubricants have found their way into the hydraulic sump. Without a
formal industry specification, it can be difficult to decide on the best fluid for hydraulic equipment.
A hydraulic fluid must be able to perform the following tasks:

• Transmit power;
• Provide a viscous seal;
• Maintain system pressure;
• Transfer heat to cool the system;
• Prevent rust and corrosion;
• Guard against foaming;
• Separate water from oil for easy removal;
• Be thermally and hydrolytically stable;
• Lubricate components; and
• Maintain long service life.
Selecting a hydraulic fluid that can meet the above criteria centers on determining the following fluid properties:
What is the base stock used in the fluid?

Does the oil separate from or combine with water?
How does the oil deal with water contamination?
How does the anti-wear additive react with water?
H H H H
What is the viscosity index of the fluid?
H–C = C – C – C = C – C – H Non-Saturated Base Oil
H H H H
Base Fluid
Base fluid selection and its inherent performance O H O H
=
=
characteristics are important to the formulation of a H–C – C – C – C – C – C – H Oxidized Oil

premium-performing AW hydraulic fluid. Although
=
O H O H
base oil must be enhanced with additives of varying
treat rates, they are expensive. It can be tempting for
H H H H H H
oil marketers to choose lower cost base stocks and
standard treat levels to create a lower priced fluid. H–C – C – C – C – C – C – H Saturated Base Oil
Consequently, decreased performance will result from H H H H H H
these choices.
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Viscosity Index
Viscosity Index, or VI, is one of the single most important performance indicators in both a base stock and finished
hydraulic fluid. Viscosity is a measure of a fluid’s resistance to flow. Flow characteristics and temperature are related:
oil thins at higher temperatures, making it flow more freely; oil thickens at lower temperatures, inhibiting flow.
Viscosity Index is a quick way to tell whether an oil can withstand extreme high and low temperatures. VI is a measure
of change in an oil’s viscosity relative to a change in temperature. Oils with higher VIs experience less change in
viscosity due to temperature. Higher VI oils guard against wear at high temperatures and maintain pumpability at
lower temperatures. This offers customers a more reliable hydraulic fluid during all temperature ranges.
Base oils that exhibit natural VIs over 95 experience less change in flow characteristics as the temperature fluctuates.
In a hydraulic system, where pressure and power are partly reliant on the hydraulic fluid’s viscosity, oil that is too thin
or too thick will ultimately shorten component life.
Saturation Levels
A base oil’s saturation level can also impact finished product performance. When a base fluid is highly saturated, there
are less chemical opportunities for oxygen to bond with hydrocarbon molecules—a process that results in oxidation or
oil breakdown. Refining techniques, such as hydrocracking and hydrotreatment, can boost the base stock’s saturation
levels by forcing hydrogen through the oil, saturating oil molecules with hydrogen and eliminating the oxygen
molecule’s ability to bond with those molecules. In essence, the base oil is now more oxidation resistant. In addition,
hydrotreated base oils have a longer working life and can endure higher sump temperatures than non-treated stocks.
Key Base Hydraulic Oil

Stock Property Performance Criteria
Viscosity Index High Temp Viscosity Control
Viscosity Index and Pour Point Low Temperature Fluidity
Volatility Oil Consumption Control
Amount of Saturates Oxidation Stability, Seal Swell and Additive Compatibility

A note on base stocks: Hydrocracked Group II base stocks provide higher VIs and higher saturation levels than Group I
or napthenetic base stocks.
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Base Oil Types
Mineral Group I and II
Group I base oils have VIs of 80 to 120 and were the original, traditional hydraulic fluids base stock. Group I base oils
have more sulfur and less saturates than Group II, III or IV fluids. The performance of finished lubricants blended with
Group I base oils is largely dependent upon the quality of the additive package.
Group II base oils are known for their excellent deposit control and high level of saturates, which makes them more
oxidation resistant. They typically have VIs of 105 up to 120 and rely heavily on additives to enhance finished lubricant
characteristics. Different refining techniques work to remove unwanted characteristics and improve upon desired ones,
like viscosity index and oxidation control. Most of Castrol’s hydraulic fluids are blended with Group II base oils and a
premium-performing additive package.
Synthetic Group III

Refined Group III base oils are petroleum fluids that undergo extreme refining techniques that produce a base fluid
with characteristics similar to a man-made synthetic. Group III refined base oils are typically found in partial to full
synthetic finished lubricants since they have greater than 90% saturates (usually 99%+) and VIs over 120. They have
low pour points, good oxidation resistance and can solubilize additive systems better than their man-made
counterparts.
Synthetic PAO Group IV

Group IV base oils are known as polyalphaolefins (PAO). PAOs, the most widely used of the engineered base stocks,
consist of all saturated hydrocarbon structures and contain no unwanted sulfur or other metals. Free of wax, PAOs
enjoy very low pour points and have VIs typically of 140. PAOs have good thermal stability but are sometimes difficult
to blend with additives. Despite their noted performance features, PAOs are sometimes cost prohibitive for users.
Group V: All Others

Group V base fluids consist of “all others,” predominately esters and polyolesters, along with aromatic and
naphthenic.
• Aromatic base oils are not suitable for use in heavy-duty lubricants due to their poor oxidation stability and low
VIs of 0 to 45. Aromatics also contain elevated levels of sulfur (which leads to deposit formation) and sometimes
nitrogen (which contributes to oxidation and deposit formation). Aromatics are typically used as solvents, cleaners
and process oils, and in further chemical reactions for industrial products.
• Naphthenic fluids have low to medium VIs of up to 60 typically and they exhibit very low pour points, high solubili-
ty and excellent cold flow in long term storage.
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Group V base fluids are commonly used in refrigeration lubricants, metalworking oils, greases and as extreme cold
temperature fluids, such as snowplow oils. These include:
Vegetable Oils  
Vegetable oils are derived from plants with the most common being canola oil. Vegetable oils are esters of fatty (long
chain) acids and are about as stable as group I mineral oils. The most desirable property of these oils is that they are
environmentally friendly in three ways:
1. The process to create the oil is growing a plant.

2. The oils themselves are non-toxic and, in some cases, edible (canola oil’s biggest use is salad oil), but including
additives to make a suitable lubricant increases the toxicity.
3. Vegetable oils are 100% biodegradable. (However, the oil plus additives are less than 100% as most of the
additives will not readily biodegrade.)
Ester base fluids  

Ester base fluids are synthetic base fluids containing oxygen in the molecule instead of just carbon and hydrogen like
typical mineral oils. Most esters are readily (highly) biodegradable, and some have a high degree of oxidative stability
as well. Thus, one can create an ester, which has the desirable combination of being highly biodegradable and
oxidative stable. Their disadvantage is being significantly more expensive than mineral oils.
PolyAlkaline Glycols  
PolyAlkaline glycols are used as synthetic lubricants in many diverse applications where petroleum oil-based products
do not provide the desired performance – and because they are fire-resistant and will not harm workers or the
environment. Other benefits of using PAG lubricants over petroleum, animal and vegetable oils is reduced energy
usage, reduced machine wear and overall operational efficiency.
Common Hydraulic Fluid Choices

The following are the most common fluid choices for hydraulic equipment and some of the performance features
of each:
Anti-Wear (AW) Hydraulic Fluid

Still the number one recommended fluid by pump manufacturers, a premium-performing AW hydraulic fluid should
demulsify or clearly separate water from oil, protect against wear in the presence of water, maintain fluid viscosity and
guard against oxidation. Fluids with a natural VI of 100 or more are better equipped to handle the extreme
temperatures and pressures found in a hydraulic system. Properly formulated AW fluids usually provide excellent
protection for hydraulic systems.
It is important to note that hydraulic fluids with anti-wear additives that are not hydrolytically stable can become
aggressive to yellow metal and cause premature failure in piston pumps. Excess water not removed from a hydraulic
system will also accelerate vane and piston pump wear.
1 800 255 4417

Engine Oil
Convenience has sometimes dictated the use of motor oils in the hydraulic sump. Motor oils emulsify or combine with
water that has contaminated the system and may provide some protection from rust in wet, undrained systems. But,
the anti-wear additives in motor oil are typically NOT hydrolytically stable when exposed to water. This can cause
additive dropout in wet motor oil that can result in viscosity gain, pumpability problems and poor wear protection.
Motor oil is designed for use in engine compartments where minor amounts of water are boiled off each day. A
hydraulic system’s operating temperature does not normally get high enough to boil off the water and the zinc
compounds in the anti-wear additives can cause corrosive wear.
Automatic Transmission Fluid (ATF)

Like motor oils, ATFs emulsify or combine with water but are less aggressive when wet than motor oils. As a rule, the
friction modifiers used in ATFs are not sensitive to water and tend to be thermally stable. In the past, ATFs have been
a better hydraulic fluid choice than motor oil because of their oxidation resistance and solid wear protection. But, the
latet passenger car specification, ATF Dexron®-VI, must meet performance specifications for extremely low
temperature flow, which results in viscosities that are far too low for use in heavy-duty applications.
Tractor Hydraulic Fluid (THF)

When formulated to meet OEM specifications, THFs are designed to operate in the presence of water. Good hydraulic
pump and wear protection result from a GL-4 level of gear wear protection. OEMs do not monitor THFs and low-cost
marginal base oils and incomplete additive systems can sometimes show up in low-priced fluids. THF’s viscosity grades
may be too high for some hydraulic applications but are the best choice for consistently water-contaminated systems.
Biodegradable Fluids  
Biodegradability simply means a chemical breakdown of the material by living organisms in the environment. The
biodegradable portions of the fluid biodegrade to carbon dioxide and water.
The definitions in the oil industry are:

Inherently biodegradable: An oil that degrades >20% in an extended period of time. (By that definition, all oil
products are inherently biodegradable.) 
Readily biodegradable: >60% of the oil is converted/biodegraded in 28 days.
N.B. No oil fluids will completely break down and return to nature within one year.
Non Toxic Fluids  

Fluids which have a low level of toxicity to living organisms. White mineral oil and vegetable oil would be common
examples.
R & O Fluids
Lubricant where the only additives are antioxidants and corrosion inhibitors (most rust inhibitors). There are no
anti-wear or EP additives present. Such a lubricant is appropriate for air compressors, non anti-wear hydraulic and
circulating systems, as well as non-EP gear oil applications.
Hydraulic Fluids 1 800 255 4417
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Castrol® Dual Range HV™

Stay-in-Grade Performance
The shear stable polymers in Castrol Dual Range HV keep the fluid’s viscosity consistent over a wide range of
temperatures. High operating temperatures, which may break down other hydraulic oils leading to damage to metal
parts and increased oxidation, are easily managed by Castrol Dual Range HV.
Also contributing to Castrol Dual Range HV’s excellent viscosity performance is its extra high viscosity index. The high
viscosity index of Castrol Dual Range HV (at least 140) indicates that as the temperature dramatically rises or falls,
Castrol Dual Range HV will not excessively thin or thicken. This protects your customer’s equipment from premature
wear or oil breakdown and leads to decreased maintenance costs.
Water Tolerance
In environments with high risk of water contamination, Castrol Dual Range HV delivers excellent demulsibility and
hydrolytic stability. When water penetrates a hydraulic system, Castrol Dual Range HV protects sensitive hydraulic
components from damaging rust and corrosion. At the end of the day, Castrol Dual Range HV easily separates water
from the oil for removal at the beginning of the next work shift. The creamy cuff that sometimes forms between the
water and other hydraulic oils shows that the hydraulic oil is not completely demulsifying and that cuff can encourage
oil thickening and foam. Castrol Dual Range HV separates from water cleanly and consistently protecting equipment
from damaging foam and thickened oil.
Filterability is another major concern for hydraulic equipment once water has entered the system. In tests where
uncontaminated oils were compared with water-contaminated Castrol Dual Range HV in the Denision TP 02100 test,
oil filtration time was quicker than the allowable limit. Because of this filtration, Castrol Dual Range HV provides better
lubrication protection for pumps and cylinders and helps to avoid dramatic pressure surges that could blow seals or
split hoses.
Thermal Stability
Thermal stability refers to an oil’s ability to withstand breakdown during periods of high operating temperatures. Oils
that are not thermally stable experience breakdown, which leads to damaged metal parts and oxidation of the oil.
Castrol Dual Range HV maintains its chemical stability during high temperatures and protects critical hydraulic parts
from wear.
Oxidation Control
Oxidation is a degenerative process that is accelerated by a combination of air, catalyzing metals and heat that
culminates in excessive oil thickening which leads to the formation of sludge and corrosive acids. The by-products of
oxidation cause pumpability problems, compromised wear protection and eventual downtime. Castrol Dual Range HV
easily surpasses industry test limits for oxidation control in the Turbine Oil Oxidation Test (D 943). Exceeding limits in
this test proves that Castrol Dual Range HV resists the formation of sludge and protects against wear on iron and
copper components.
C15

Performance in Industry Test Results
ASTM D 2983 Cold Temperature Startup
In ASTM D 2983, Castrol Dual Range HV exhibited better cold temperature performance than an ISO 32 and ISO 46
fluid. Castrol Dual Range HV flows even in colder temperatures, allowing it to reach critical components before
hazardous startup wear can occur.
Load-carrying Ability
Castrol Dual Range HV is recommended for heavily loaded applications like hydrostatic transmissions and high speed/
high pressure hydraulic circuits. It surpasses the load-carrying ability of economy and premium-performing hydraulic
fluids.
Cold Temperature Startup Comparison

ASTM D2983
20,000
15,000
Viscosity (cPs)
10,000
5,000
0
-20
-10
10
20
30
Temperature (F)
Castrol Dual Range HV ISO 46

ISO 32 AW
ISO 46 AW
Leak Detection
Castrol Dual Range HV is dyed to facilitate leak detection.
C16

Thermal Stability
Cincinnati Milacron Thermal Stability
Castrol Dual Range HV far exceeds the acceptable limits for sludge in the Cincinnati Milacron Thermal Stability test.
Castrol took the thermal stability test one step further. Even after being run through 3 vigorous industry tests, Castrol
Dual Range HV still far exceeded sludge limits, proving its use for severe service applications.
Thermal Stability
CMMCo Specification Maximum

New
After
Vickers 300-Hour
35VQ Test
After
Denison T-5D
Standard Test
After
Sunstrand
Stressed Test
(JDQ-84@250ºF)
0
10
20
30
40
50
60
70
80
90
100
Sludge (mg/100mL)
FZG Load Carrying Test

Castrol Dual Range HV passes the rigorous FZG Load Carrying Test at Stage 12, easily surpassing a premium HF-O
hydraulic fluid and an economy hydraulic fluid. The Stage 12 pass represents the exceptional load carrying ability of
Castrol Dual Range HV. Your customers can be assured of extra protection during high loads, especially with hydrostatic
transmissions and high speed/high pressure hydraulic circuits.
Load Carrying Capability

FZG Load Test
Castrol Dual Range HV
Premium
HF(O)–Passing
Hydraulic Fluid
Economy
Hydraulic Fluid
0
10
11
12
FZG Stage Pass Level (Load Carried Levels)

C17

KRL Shear
In the severe 20 hour test, Castrol Dual Range HV easily exceeds the major OEM requirements with the ISO 32 grade
having over 50% viscosity reserve.
Castrol Dual Range HV 32, % viscosity loss is 7.3% (limit 15%)
Castrol Dual Range HV 46, % viscosity loss is 9.0% (limit 15%)
Demulsibility Test (ASTM D 1401)

After the Turbine Oil Demulsibility Test, Castrol Dual Range HV separated all the oil from water and left no creamy
white cuff.
This line includes exceptional multi-viscosity hydraulic fluids that provide proven anti-wear protection coupled with
very shear-stable polymers and anti-foam additives for a balanced package. An extreme load carrying capability is
indicated where Castrol Dual Range HV Hydraulic Fluids pass the FZG Load carrying test at Stage 12. This outstanding
performance provides the extra measure of protection required in high load applications such as hydrostatic
transmissions and high speed/high pressure hydraulic circuits.
Castrol Dual Range HV Hydraulic Fluids’ high viscosity indexes and their low pour points ensure extra pump protection
and efficiency in cold weather starts and provide needed viscosity protection at higher operating temperatures. The
products are dyed purple to facilitate leak detection.
Features Advantages Benefits

Very shear stable polymers. Universal applications under Less wear.
a wide range of ambient conditions. Longer equipment life.
Excellent viscosity at operating Better productivity through outstanding
temperatures (particularly under extreme hydraulic system efficiency.
conditions).
Excellent vane and piston Meets major hydraulic pump Less failure of hydraulic circuits.
pump performance. manufacturers’ requirements. Less equipment repair.
Long term trouble-free service.
Outstanding hydrolytic Additional protection against corrosion in Systems operate more efficiently.
stability. the presence of water. Less maintenance costs.
C18

Industry Specifications and OEM Approvals by Grade
• Denison HF-O, HF-1, HF-2 Approved

• Vickers 35VQ25A - meets performance requirements
• Vickers M-2950-S Mobile Hydraulic Systems and I-286-S Industrial Hydraulic Systems
• Cincinnati Machine P-68 (ISO 32), P-70 (ISO 46) and P-69 (ISO 68) approved
• Meets Racine S106
• Meets Joy Mining Machinery HO-T (AW 46), HO-S (AW 68)
• Meets DIN 51524 Requirements
Typical Analysis
ISO Grade Method 32 46 68 100

Viscosity @40°C, cSt ASTM D445 32.6 46.5 68 100.3
Viscosity @100°C, cSt ASTM D445 6.2 7.9 10.6 13.9
Viscosity @100°F, SUS ASTM D2161 153 216 314 459.0
Viscosity @210°F, SUS ASTM D2161 47 52 61 73
Viscosity Index (Min.) ASTM D2270 141 143 146 141
Dielectric Breakdown ASTM 877 -- -- -- --
Voltage, kV/0.1 inch -- 35 -- --
Flash Point, ºC ASTM D92 210 232 240 251
(ºF.) (410) (450) (464) (484)
Pour Point, ºC ASTM D97 -51 -45 -39 -36
(ºF.) (-60) (-49) (-38) (-33)
Gravity, API ASTM 287 31.3 34 30 29
Pounds per Gallon 7.24 7.12 7.3 7.34
Specific Gravity @60 °F, g/ml ASTM D1298 0.869 0.859 0.874 0.88
(1) At the point of manufacture.

C19
Castrol® Blue Hydraulic Plus™

Castrol Blue Hydraulic Plus meets the most severe industry requirements including the new “hybrid” test from
Denison (T6H2OC), which incorporates both vane and piston pumps under wet and dry conditions over 600 hours.
Formulated with up to 50% more performance additive than some competitors, Castrol Blue Hydraulic Plus gives a
larger margin of safety in key areas of corrosion, oxidation and wear protection.
Water Tolerance
Castrol Blue Hydraulic Plus deals with water contamination in a number of ways. First, when water enters the system,
Castrol Blue Hydraulic Plus’ hydrolytic stability keeps the water from causing damaging rust and corrosion to sensitive
hydraulic components. Second, after hydraulic equipment has been shut down for the day, Castrol Blue Hydraulic Plus
will effectively demulsify or separate the water and oil. Water can then be drained from the system before the start of
the workday. And third, Castrol Blue Hydraulic Plus is able to remain filterable even after water invasion. Water
contamination
tends to slow down the filter time of a hydraulic oil. Castrol Blue Hydraulic Plus exhibits
excellent filterability after 2% water has been introduced into the oil.
In recent years, many original equipment manufacturers have reported that some commercial hydraulic fluids have
caused field failures when contaminated with water. It is important to note that these fluids had previously met the
severe performance standards of many pump manufacturers. Castrol Blue Hydraulic Plus Lubricants, which had
outstanding performance in many severe OEM pump tests, was subsequently run in modified tests contaminated with
1% water. Results: Still a pass against the standard pass fail criteria.
Thermal Stability Oxidation and Control

Extended high operating temperatures, commonly encountered in hydraulic equipment, can create corrosive acids,
allow sludge and varnish to form and excessively thicken oil until its breakdown is inevitable. Castrol Blue Hydraulic
Plus has an outstanding additive package that boosts its oxidation resistance. Castrol Blue Hydraulic Plus prevents the
formation of harmful deposits and guards against thermal breakdown due to high operating temperatures. As a
result, hydraulic equipment runs longer, more efficiently and with less downtime.
Safe for Vane, Gear and Piston Pumps

Castrol Blue Hydraulic Plus is formulated to meet or exceed the industry standards for vane, gear and piston pumps.
Castrol Blue Hydraulic Plus is specially suited for use in mobile hydraulic equipment, like excavators, bulldozers and
drilling equipment, that have various types of pumps and a common sump in the same hydraulic circuit.
C20

Industry Test Results
All test results are for Castrol Blue Hydraulic Plus ISO 32.
Denison T6H2OC Pump Test
Castrol Blue Hydraulic Plus passed under Denison HF-O requirements.
Denison T6-C Pump Test
Denison T5D42 Vane Pump Test
Denison P-46 Piston Pump Test
Vickers 35VQ25 Vane Pump Test
With an allowable total weight loss for ring and vane at 90 Mg, Castrol Blue Hydraulic Plus exceeded the test limits
with total weight loss of 23.3 Mg.
Turbine Oil Rust Prevention Test (ASTM D 665)
Using distilled water (D 665A), Castrol Blue Hydraulic Plus passed this test under both Cincinnati Milacron and
Denison HF-O requirements. Using synthetic sea water (D 665B), Castrol Blue Hydraulic Plus passed under Denison
HF-O requirements. There is no requirement for Cincinnati Milacron.
Foam Inhibition (ASTM D892)
Castrol Blue Hydraulic Plus left no foam after this 10 minute test.
Filterability (Denison TP 02100)
Castrol Blue Hydraulic Plus filtered in 150 seconds when dry and only 220 when contaminated with 2% water. The limit
was 600 seconds dry and 2 times the dry figure when wet.
C21

Hydrolytic Stability (ASTM D 2619)
Castrol Blue Hydraulic Plus performed exceptionally well in ASTM D 2619. With an allowable copper weight loss of
.2 mg maximum, Castrol Blue Hydraulic Plus 46 had only .09 mg copper weight loss. For water acidity, Castrol Blue
Hydraulic Plus had an acidic reading of 0, mg KOH while the test limit was 4.0 maximum.
Cincinnati Milacron Thermal Stability

Castrol Blue Hydraulic Plus received a copper rod rating of 1.5, a steel rod rating of 1 and a sludge rating of 7.2 mg
per 100 ml.
Thermal Stability
(per Cincinnati Milacron Thermal Stability Test)
1st Margin
Test of Safety
Pass Fail
2nd Margin
Test of Safety
0
10
20
30
40
50
60
70
80
90
100
Sludge (mg/100ml)
FZG
Castrol Blue Hydraulic Plus 46 passes load stage 12 in the FZG test, where as many Dension HF-O grades only meet
FZG levels of 10. This ensures that Castrol Blue Hydraulic Plus protects equipment under the most rigorous conditions.
Castrol Blue Hydraulic Plus

Castrol Blue Hydraulic Plus provides excellent pump life and trouble free service in construction and mining mobile
hydraulic applications. Castrol Blue Hydraulic Plus possesses proven anti-wear protection, a high viscosity index to
enhance performance over a wide temperature range, and excellent water separation properties.
Castrol Blue Hydraulic Plus is formulated with carefully selected premium base oils, coupled with rust, oxidation and
foam inhibitors. Castrol Blue Hydraulic Plus meets or exceeds the equipment manufacturers’ requirements for Vane,
Gear and Piston Pumps. The fluid has been dyed a medium blue to facilitate leak detection by the equipment user.
Castrol Blue Hydraulic Plus is approved or recommended for the Cincinnati Lamb P-68 and P-70 specifications. In
today’s mobile hydraulic equipment, such as excavators, bulldozers and drilling equipment, pumps of different types
have been incorporated into the same hydraulic circuit in order to achieve outstanding cost effectiveness and
efficiency.
Castrol Blue Hydraulic Plus will meet the challenge where a common fluid has to be used, which allows vane, gear
and piston pumps to work at their maximum rated output.
C22

Performance Summary
Cincinnati Denison Castrol Blue
Lamb Requirements Hydraulic Plus
Requirements HF-0 Oil ISO 32
Grades 32 46 68
Cincinnati Lamb P- 70 Pass - Pass
Pump Test
Denison T5D42 NR Pass Pass
Vane Pump Test
Denison P-46 Series NR Pass Pass
Piston Pump Test
Vickers 35VQ25 NR 23.3 Mg.
Vane Pump Test
(Total Wt. Loss 90 Mg. Max.)
Rust Prevention, ASTM D665
D665A Pass Pass Pass
(Distilled water) Pass Pass Pass
D665B NR Pass Pass
(Synthetic sea water)
Foam Inhibition, ASTM D892 NR None None
Volume of Foam
after 10 min.
Denison Filterability (HF-O)
A. Dry NR 600 Max. 51
(sec. to 75 ml)
B. Wet NR 2xA 63
(sec. to 75 ml)
Hydrolytic Stability, D2619
Copper Wt. Loss, NR 0.2 Max. 0.09
mg/cm2
Acidity of Water, NR 4.0 Max. 0.27
mg KOH
1000 Hours Sludge (D-4310)
Insoluble sludge, mg NR 200 Max. 15.8
TAN, mg KOH NR 2.0 Max. 0.09
Copper Appearance 1B
Oxidation Life, ASTM D943
Hours to TAN 2.0 NR 1500 Min. 6000+
Cincinnati Milacron Thermal
Stability
Sludge, mg per 25.0 Max. 19.6
100 ml
Copper Rod Rating 5 Max. 2
Steel Rod Rating 1 Max. 1
Cincinnati Milacron Assessment Approved
C23

Special Performance Summery
Sundstrand Pump Test (Double Length Stress Test)
A. Conditions: Test run for 450 hours at 180° F. with water (Standard test is run for 225 hours at 180° F.)
B. E.O.T. Inspection:
1-Bearing plate - Good Condition
2-Thrust plate - Good Condition
3-Piston Shoes - Good Condition
4-Distress on other parts - None
C. Assessment: Pass double length stress test.
Industry Specifications and OEM Approvals by Grade:

• Denison HF-O, HF-1, HF-2 approved
• Vickers 35VQ25A meets performance requirements
• Vickers M-2950-S Mobile Hydraulic Systems and I-286-S Industrial Hydraulic Systems
• Cincinnati Machine P-68 (ISO 32), P-70 (ISO 46) and P-69 (ISO 68) approved
Typical Analysis
ISO Grade Method 32 46 68 100
Former Grade (Light) (10) (20) (30)
Viscosity @100° F, SUS ASTM D2161 160 215 319 551
Viscosity @210° F, SUS ASTM D2161 44 48 54 65
Viscosity Index ASTM D2270 103 103 105 102
Flash Point, °C (°F) ASTM D92 210 (411) 215 (420) 226 (440) 226 (440)
Pour Point, °C (°F) ASTM D97 -32 (-26) -26 (-15) -26 (-15) -15 (+5)
Oxidation Life, ASTM D943 6000+ 5000+ 5000+ 4000+
(Hours to TAN 2.0)
Gravity, API ASTM D287 34 32 29.5 28
Pounds per Gallon ASTM D287 7.12 7.21 7.32 7.39
Specific Gravity ASTM D-1298 0.857 0.863 0.879 0.88
@60F g/ml
C24
Castrol® Paradene™ AW
Castrol Paradene AW is a premium industrial anti-wear hydraulic oil line suitable for
hydraulically activated equipment that utilizes high-performance pumps. The fluids contain
very effective anti-wear additives that allow them to meet or exceed industry OEM vane,
gear and piston pump specifications. These fluids are highly dependable, peak efficiency
oils that meet the lubricant demands of precision industrial equipment. Castrol Paradene
AW will remain very stable and clean in today’s machine tool equipment where increasingly
sophisticated control systems are used.

Effective antiwear Minimizes wear in Long, dependable equipment
performance. industrial pump life.
applications.
Special non-silicone Rapid release of System response is dependable for
anti-foam additive. entrained air. consistent work yield.
Careful selection of base Hydraulic components Long fluid life and equipment
stock coupled with yield excellent life savings.
outstanding additive performance.
selection.
Industry Specifications and OEM Approvals by Grade

• Denison HF-O, HF-1, HF-2 Approved
• Vickers 35VQ25A - meets performance requirements
• Vickers M-2950-S Mobile Hydraulic Systems and I-286-S
Industrial Hydraulic Systems
• Cincinnati Machine P-68 (ISO 32), P-70 (ISO 46) and P-69
(ISO 68) approved
C25
Castrol® Paradene™ AW
Typical Analysis
ISO Grade Method 22AW 32AW 46AW
Viscosity @40°C, cSt ASTM D445 22 33.2 46
Viscosity @100°C, cSt ASTM D445 4.3 5.5 6.7
Viscosity @100°F, SUS ASTM D2161 114 143 214
Viscosity @210°F, SUS ASTM D2162 40 44 47
Viscosity Index ASTM D2270 102 100 98
Flash Point, °C ASTM D92 205 211 215
(°F) (401) (412) (419)
Pour Point, °C ASTM D97 -32 -32 -27
(°F) (-26) (-26) (-17)
Gravity, °API ASTM D287 33.5 32.9 30
Spec. Gravity, API @60°F ASTM D1298 0.8591 0.861 0.877
Pounds per Gallon ASTM D287 7.14 7.17 7.3
Oxidation Life, ASTM D943 -- 4000 3500
(Hours to TAN 2.0)
ISO Grade 68AW 100AW 150AW 320AW

Viscosity @40°C, cSt 68.5 100 150 321
Viscosity @100°C, cSt 8.8 11.1 13.9 24.8
Viscosity @100°F, SUS 315 480 708 1489.0
Viscosity @210°F, SUS 55 62 73 120
Viscosity Index 101 96 88 99
Flash Point, °C 226 226 232 245
(°F) (429) (439) (450) (473)
Pour Point, °C -26 -15 -15 -10
(°F) (-15) (+5) (+5) (+14)
Gravity, °API 28.8 27.5 27.3 25.5
Spec. Gravity, API @60°F 0.884 0.89 0.8912 0.9015
Pounds per Gallon 7.35 7.4 7.45 7.5
Oxidation Life, 3000 -- -- --
(Hours to TAN 2.0)
C26
Castrol® Anvol® SWX 46 [PREVIOUSLY Castrol Anvol SWX FM]
Fire Resistant Hydraulic Fluids

Castrol Anvol SWX 46 products are HFDU Polyolester type hydraulic fluids as defined by ISO 6743/4 and ISO 12922(1).
They meet the requirements for Factory Mutual Category 1 Classification. Castrol Anvol SWX 46 products are
outstanding in their category in providing a safe working environment, improved system reliability and ready
biodegradability.
Formulated to work in high-pressure hydraulic systems up to 7500 psi, Castrol Anvol SWX 46 provides gear, vane and
piston pumps with protection against wear equivalent to that of mineral oils.
Castrol Anvol SWX 46 is designed to combine fire resistance with outstanding system reliability and a reduced
tendency to form varnish or sludge in valves, pipes and reservoirs. It also provides greater resistance to water by
offering high levels of corrosion protection and ease of separation.
Even in the harshest steel mill environment, Castrol Anvol SWX 46 provides safety, protection and reliability. This has
the added value of reducing failures and minimizing unscheduled downtime.
Application
Castrol Anvol SWX 46 is used in areas of the manufacturing industry where there is high risk of fire such as hot strip
mills, coil handling facilities, pipe mills and continuous casters. The risk is minimized by Castrol Anvol SWX 46’s high
fire point and a low heat of combustion.
Performance Benefits
• Greater fire protection
With a high fire point and shear stability, Castrol Anvol SWX 46 provides excellent fire suppression characteristics,
thereby creating a safer working environment and greater equipment protection.
• System protection from water
Castrol Anvol SWX 46 is designed to separate water to allow it to be removed from the system. Advanced
corrosion inhibition protects ferrous components from any residual water. This reduces rust and leads to extended
equipment life and a reduction in downtime.
• Stability in harsh operating environments
– Resistance to oxidation and thermal degradation and improved filter tolerance.
– Reduces sludge/varnish formation and the potential for valve sticking/failure.
– Ensures that product life is extended with greater drain intervals.
– Maintains fire protection characteristics with use.
per ISO 6743 / 4 and ISO 12922:1999 / Corrigendum 1:2001 (E), these are classified as synthetic fluids free of
(1)
water, but of other composition than HFDR (Phosphate Ester)].

C27
• Readily biodegradable
– Conforms to highest standards of biodegradability and has low toxicity.
– Environmentally friendly hydraulic fluids providing pump performance that is equivalent to mineral oil.
– Well suited for applications where inadvertent environmental contamination might occur due to leakage.
– Easily exceeds the 60% bioconversion of CH2/CH3 to CO2 within 28 days as per OECD 301 B.
• Outstanding equipment performance
– Extended pump and component life and reduction in replacement/maintenance costs.
– Longer life.
Compatibility with Seal Materials

Castrol Anvol SWX fluids are compatible with Acrylonitrile-butadiene rubbers (NBR), hydrogenated NBR and fluoro-
carbon rubbers (FKM). The Seal Compatibility Index (IP278) for Castrol Anvol SWX 46 is comparable to mineral oils.
System Changeover
Mineral Oil or Polyolester-based Fluids
Castrol Anvol SWX 46 fluids are miscible and compatible with nearly all mineral oil and polyolester type hydraulic
fluids. To convert a system using these types of fluids, simply drain and recharge with Castrol Anvol SWX 46. For
proper fire resistance, at least 95% of the mineral oil-based fluid should be removed. See “Topping Up an Existing
System” (below) for more detailed changeover information.
Water Glycol and Emulsions

Castrol Anvol SWX 46 fluids are not miscible or compatible with water-containing fluids and these fluids must be
removed from the system. Remove most of the fluid by draining the reservoir and lines. Remove residual fluid by
circulating Castrol Anvol SWX 46 and draining. Refill with fresh fluid. Repeat until residual fluid is less than 1% of the
system volume. The lower the residual the better, as water can cause hydrolysis and acid increase/breakdown of the
ester in Castrol Anvol SWX 46.
Phosphate Ester
Some but not all phosphate esters are compatible with Castrol Anvol SWX 46. Testing prior to conversion is
recommended. Please contact Castrol for testing and conversion recommendations.
Topping Up an Existing System

If the two products to be mixed have been compatibility checked and are deemed compatible, then simply add fresh
Castrol Anvol SWX 46 on top of the existing system. If, however, you are required by Factory Mutual to completely
change out the system, we suggest the following:
1. Heat hydraulic system to operating temperature.
2. Drain the warm oil.
3. Change existing filters.
4. Flush with new fluid. Run all cylinders, if possible, to remove old fluid. Check the Castrol Anvol SWX 46 content
of the system. If greater than 95%, go no further with flushing.
5. If Castrol Anvol SWX 46 is present at less then 95%, then drain the system again and fill with fresh Castrol
Anvol SWX 46.
C28
6. Take a sample after one hour of running, if necessary, to check for Castrol Anvol SWX 46 levels. A fire point may
need to be done to confirm Factory Mutual rating.
Property Method Units Anvol SWX 46

Appearance Visual Clear & Bright
Kinematic Viscosity at 40°C ASTM D445 mmÇ/s 48.4
Kinematic Viscosity at 100°C ASTM D445 mmÇ/s 9.56
Relative Density at 15°C ASTM D4052 g/ml 0.89
Flash Point, COC ASTM D92 °C 280
Fire Point, COC ASTM D92 °C 360
Autoignition Temperature ASTM E659 °C 430
Total Acid Number (Potentiometric) ASTM D664 mg KOH/g 1.3
Foam Sequence I, Tendency ASTM D892 ml 10
Foam Sequence I, Stability ASTM D892 ml 0
Copper Corrosion, 3hrs at 100°C ASTM D130 1A
Rust Test, Procedure B ASTM D665B Pass
RPVOT ASTM D2272 mins 230
FZG Gear Failure Load Stage ( A/8.3/90 ) DIN 51354 >12
Air Release to 0.2%volume at 50°C IP 313 mins 2
Health and Safety

Castrol Anvol SWX 46 is classified as non-hazardous and presents no significant risks to operators. However, it is good safety
procedure to minimize skin contact and inhalation of oil mist.
Storage
To ensure that your product reaches your hydraulic system in excellent condition, it is important to store your drums of
product correctly. Where practical, place drums under cover out of direct contact with sunlight and weather. Store the
drums on their side or use a drum cover to prevent water contacting the drum bung. When decanting product from
the drum, ensure that the bung area is cleaned with a lint free cloth before transfer.
All reasonable care has been taken to ensure that this information is accurate as of the date of printing. Nevertheless,
such information may be affected by changes in the blend formulation occurring subsequent to the date of printing.
Material Safety Data Sheets are available for all Castrol products. The MSDS must be consulted for appropriate
information regarding storage, safe handling and disposal of product.
C29
Castrol® Performance™ Bio HE [PREVIOUSLY Castrol Carelube HTG]

Castrol Performance Bio HE is formulated from vegetable oils to be more environmentally acceptable than
traditional mineral-based hydraulic fluids. Since hydraulic systems are prone to leakage due to high pressures,
Castrol Performance Bio HE is an excellent hydraulic fluid in applications where leakage could cause water or soil
contamination.
Biodegradability
Formulated from natural vegetable oils, Castrol Performance Bio HE is more than 95% biodegradable as measured in
the CEC L-33-T-82 tests. Tests indicate that it is capable of being decomposed by biological agents within 120 hours,
unlike mineral oil, which may remain intact for much longer, polluting water and soil. Castrol Performance Bio HE is
recommended for outdoor applications where leakage could result in soil or ground water contamination and
substantial fines or claims for damage on the responsible operator. (Spills, however, must be handled the same as for
mineral-based fluids.)
Low Toxicity
In addition to its biodegradability, Castrol Performance Bio HE has a very low toxicity before, during and after
breakdown. This reduces the threat to bacteria, fish and humans coming in contact with contaminated water.
Stay-in-Grade Performance
Castrol Performance Bio HE has a very high viscosity index (VI) of 200. Standard mineral hydraulic oils have VIs of
around 100. This extra-high VI means that Castrol Performance Bio HE experiences little change in viscosity during its
recommended operating range of 0°F to 175°F. Castrol Performance Bio HE is also very shear stable, which means
that it resists breakdown during high shear applications.
Anti-wear Performance and High Lubricity

Due to its special formulation, Castrol Performance Bio HE is inherently a better lubricant than its standard mineral-
based counterparts. This high lubricity accounts for reduced wear and less fuel consumption due to more efficient
operations. Castrol Performance Bio HE also contains an anti-wear package that increases its load-carrying abilities.
C30

CEC L-33-T-82
This test measures the biodegradability of a fluid over a period of 120 hours. Castrol Performance Bio HE is more than
95% biodegradable during the allotted time frame.
Castrol Performance Bio HE

Biodegradable Properties
100
Conventional Mineral Oil
Undegraded Product (%)
80
60
40
20
Castrol Performance Bio HE
0
24 48 72 120
Hours Hours Hours Hours
FZG Gear Test
The FZG gear tests rates the load-carrying ability of gear oils. Castrol Performance Bio HE out-performed its mineral-
based counterparts, which testifies to its excellent anti-wear performance.
FZG Test Results

14
12
Margin
of Safety
10
0
Typical Castrol
Mineral-Based Performance Bio HE
Hydraulic Fluid
C31

Important Information about Castrol Performance Bio HE
Storage and Handling
Castrol Performance Bio HE should be stored and handled as if it were a conventional mineral oil. It is recommended
that Castrol Performance Bio HE be stored indoors at temperatures above freezing to avoid any appearance of
clouding during extended storage periods. This clouding tendency is in the nature of vegetable oils but does not affect
their performance. The cloudiness will disappear when the chilled oil warms to 50-60°F.
It is also very important that Castrol Performance Bio HE be stored in a manner that prevents water contamination.
While Castrol Performance Bio HE rejects water just like mineral-based fluids do, as a regular gross contaminant,
water has greater potential for shortening service life of a vegetable oil as compared to a mineral oil. Traces of water
present under normal conditions do not present a problem.
Converting to Castrol Performance Bio HE

Drain the system while hot as completely as possible from all drain points. Small quantities of oil left in the system are
not significant. Replace the filter and clean the filter housing. Refill system with Castrol Performance Bio HE. After
start-up, change the filter after 50 and 100 hours of operation. Consult OEM for recommended drain schedule for
biodegradable, vegetable-based hydraulic oils and use routine used oil analysis to help determine drains.
Spills, Clean-Up and Disposal

Although biodegradable, Castrol Performance Bio HE must still be cleaned up when spilled. Spill prevention and clean
up efforts are the same for Castrol Performance Bio HE as for other mineral hydraulic fluids. All oil spills are reportable
to the National Response Center and/or state and local government agencies.
From a disposal standpoint, it is advisable to segregate waste Castrol Performance Bio HE from other waste oils,
which, if mixed with Castrol Performance Bio HE, could render it hazardous and eliminate less costly disposal options.
Castrol Carelube HTG

Castrol Performance Bio HE is a biodegradable hydraulic fluid that is formulated using a natural renewable fluid. The
environmentally acceptable hydraulic fluid is based on a natural fatty oil, which has a special affinity to metal surfaces
affording exceptional boundary lubrication. Castrol Performance Bio HE has also been carefully formulated to provide
excellent anti-wear and anti-corrosion properties.
Castrol Performance Bio HE is based on a specially selected natural vegetable oil that is much friendlier to the
environment than conventional mineral based hydraulic oils. (The 200 VI [viscosity index] is a property of the vegetable
oil, which means the fluid will experience very little viscosity change with temperature.)
Castrol Performance Bio HE is designed for use in applications where the risk of environmental damage through
leakage/spillage from hydraulic equipment is high: agriculture, construction, mining, forestry and marine industries.
Castrol Performance Bio HE offers a wide range of performance features similar to mineral oil based formulations.
C32

Typical Analysis
Product Appearance Clear Green Fluid
Odor Bland
Application Environmentally friendly hydraulic fluid with
similar mineral oil level performance.
Performance Method Units Typical Results

Profile Test
Viscosity @40°C ASTM D445 cSt 37
Viscosity @100°C ASTM D445 cSt 8.5
Pour Point ASTM D97 °F -25 (-13)
Flash Point ASTM D92 °C (°F) 285°C (545 °F)
Demulsification ASTM D1401 mins 20
Rust Test ASTM D665A No Rust
Rust Test ASTM D665B No Rust
Copper Corrosion, 3 hrs at 100°C ASTM D130 1b
FZG Gear Test, Pass Stage Din 51354 11
4-Ball Wear Test, 1 hr, 30kg, 1460 rpm MWSD mm 0.4
Vickers Vane, weight loss ASTM D2882 < 5 mg
Biodegradability CEC-L-33-T-82 % 95
C33
Castrol® Aerial Lift Fluid

Castrol Aerial Lift Fluid is a specially formulated multi-viscosity high performance hydraulic fluid. It is designed to
provide outstanding performance in mobile lift applications where ambient temperatures vary widely and system
operation, reliability and protection are mandatory.

Very shear stable polymers. Universal applications under severe Less wear/longer equipment life.
ambient conditions. Better productivity through excellent
Excellent viscosity at operating hydraulic system efficiency.
temperatures (particularly under extreme Reduces equipment wear and repair.
conditions).
Pour Point of -46° C (-50° F.)
Thermally stable Zinc Good thermal stability. Less failure of hydraulic circuits.
Dialkyldithio-phosphate Less equipment repair.
(ZDDP).
Long term trouble-free service.
Excellent vane and piston Meets all hydraulic pump manufacturers’ Reduced inventory.
pump performance. requirements.
Outstanding hydrolytic Additional protection against corrosion in Longer pump life.

stability. the presence of water. Less wear.
C34
Castrol® Aerial Lift Fluid

Typical Physical Characteristics
Test Method Typical Results

Viscosity at 40°C, cSt ASTM D445 24.5
Viscosity @ 100° F., SUS ASTM D2161 127.1
Appearance Visual Red
Brookfield Viscosity at -18°C (0ºF), cP ASTM D2983 660
Brookfield Viscosity at -23°C (-10ºF), cP ASTM D2983 1,290
Pour Point, ºC (ºF) ASTM D97 -46 (-50)
API Gravity ASTM D287 30.1
Specific Gravity, 60°F ASTM D1298 0.858
Pounds per Gallon ASTM D287 7.291
Aniline Point, ºC (ºF) ASTM D611 92 (198)
Turbine Oil Oxidation (D-943), ASTM D 943 2800
Hrs to 2.0 TAN
Dielectric Breakdown, ASTM D287 30
voltage KV/0.1 inch
D
Transmission Fluids
D
Transmission Fluids
Important Transmission Fluid Properties D2
Types of Transmissions and Diagnosing Problems D6
Product Data
Castrol® Trans-C™ HT D9
Castrol® Trans-C™ D12
Castrol® Syntrans™ 75W-85 D13
Castrol® UTF D14
Castrol® Heavy Duty Multi-Purpose ATF D19

Transmission Fluids D2
1 800 255 4417
Important Transmission Fluid Properties

Getting power from the engine to the drive track or wheels is the job of the transmission. The key to effective
power transmission performance and long component life is proper transmission fluid selection. An understanding
of transmission types, transmission fluids and OEM recommendations is important for maximizing transmission
performance.
Transmissions can be grouped into the following types: automatic, powershift, hydrostatic and manual. Each
transmission requires uniqiue lubricant properties.
Transmission Fluids and Friction

Each type of transmission fluid has specialized formulations to create frictional properties that ensure proper
operation of the automatic, powershift or hydrostatic transmission it is protecting. In some instances, friction
modifying additives are added to a base stock to make a lubricant more slippery. Of these fluids, the most friction-
modified fluid is engine oil. As the evolution of transmission and transmission fluids progresses, some transmissions
lubricated by engine oils may result in relatively poor transmission performance and holding capabilities, as well as
increased wear.
With automatic transmission fluids, TO-4 fluids and tractor hydraulic fluids, there is both dynamic and static friction
measurements. Static friction refers to how well the transmission fluid will hold once lock-up has been achieved.
Dynamic friction refers to the amount of slippage a transmission fluid allows before lock-up occurs.
A balanced base oil and additive package for a transmission fluid is dependent upon the role the finished lubricant
must play in the transmission.
A typical transmission fluid must perform several critical functions:

• Lubricate gears, bushings and bearings;
• Provide anti-wear performance;
• Displace heat efficiently;
• Ensure seal performance; and
• Modify frictional characteristics in transmission clutches and wet brake systems.
Formulating a premium transmission fluid begins with a high quality base oil. The base oils must provide oxidative
resistance and high and low temperature performance in order to ensure transmission fluid performance. The
measure of a base oil’s ability to resist oxidation or breakdown due to high temperature and severe service is related
to the amount of saturated hydrocarbon molecules it contains.
Group II and Group III base oils are treated with hydrogen to saturate the molecules and eliminate opportunities for
oxygen to attack and break down these molecules. This process fills spaces in the hydrocarbon molecule that might
otherwise fill with oxygen, with hydrogen atoms. This makes the base oil oxidation resistant, which is important to
transmission fluid performance.
1 800 255 4417

Viscosity index (VI), or the measure of change in an oil’s viscosity relative to a change in temperature, is another critical
factor in base oil and finished lubricant performance. Transmission fluids undergo fluctuations in temperature and are
responsible for removing heat from the system. Base oils with high VIs (over 100) experience less change in viscosity
related to temperature. In addition to stay-in-grade performance, high VI base oils offer excellent pumpability and
lower oil consumption.
An exceptional additive package is just as important as a high quality base oil. Differing friction characteristics of
transmission clutch surfaces require a delicate balance of friction modifiers and other additives. Additives typically
found in a premium-performing transmission fluid are:
• Dispersants for sludge and varnish control;
• Anti-oxidants to control oil thickening and breakdown;
• Anti-wear agents to protect planetary gears, bushings, thrust washers, sprags and pumps;
• Seal swell agents to control swelling, hardness and tensile strength of elastomers;
• Corrosion inhibitors to prevent corrosion of bushings and thrust washers;
• VI improvers to minimize viscosity change due to temperature and control sludge and varnish; and
• Friction modifiers to help clutch plate/band friction engage properly and promote
smooth shifts.
Hydrostatic Transmission Fluids (HTFs)

HTFs are charged with protecting not only the transmission and final drives but the wet brake system as well. On the
transmission side, HTFs have a higher coefficient of friction to handle heavy loads, but some friction modifier has been
added to the fluid to prevent squawk and shudder in the wet brake systems. HTFs have a low static coefficient of
friction because the fluids must have some slippery characteristics in order to protect the wet brake system. The chart
illustrates this fact.
Torque, Nm
Hydrostatic Transmission Fluids
Sliding Speed Decreasing

1 800 255 4417

Automatic Transmission Fluids (ATFs)
ATFs must be able to hold loads and encourage smooth shifts. Therefore, ATFs have a high dynamic coefficient of
friction with a moderate static coefficient of friction. ATFs do contain friction modifiers, which translate to moderate
static friction to avoid harsh shifts.
Automatic Transmission
Torque, Nm
Fluids
TES-389
TO-4 Fluids
The most dramatic friction characteristics are found in the TO-4 fluids for powershift transmissions. TO-4 fluids have
the highest static coefficient of friction for fast lock-up and outstanding holding capacity. The chart depicts this fact
with its sharp upward point illustrating a tight, firm lock-up.
Powershift Transmission
Fluids
Torque, Nm
TO-4

1 800 255 4417

Reviewing the different friction characteristics of transmission fluids makes it clear how the incorrect fluid choice could
be a serious detriment to equipment and its operation. Proper transmission fluids are a wise investment that provide
return in the long run.
TRANSMISSION FLUIDS: A CHARACTERISTIC COMPARISON

FLUID FEATURES TO-4 FLUID THF Dexron III HD/
TES-389
Friction Grabby Most Slippery
Slippery
EP/AW Very Good Best Good
Oxidation Good Good Best
Low Temperature Poor Good Best
Water Sensitivity Wet Anti-foam Test Very Good Not Tested
Color Dyed (some) ___ Dyed

Viscosity Grade Kv at 100 Various (6-26) 10W-30 0W-20
degrees C (9.5-10.5) (7.0-7.5)
1 800 255 4417
Types of Transmissions and Diagnosing Problems

Automatic Transmissions
An automatic transmission uses electronically- or hydraulically-controlled friction clutches to select gears. Although
easier to operate, automatic transmissions sometimes require more maintenance. Automatic transmissions typically
require an automatic transmission fluid.
Premium automatic transmission fluids (ATFs) are designed to:

• Prevent metal-to-metal contact and wear;
• Promote efficiency in vane pumps, planetary gear sets and bushings;
• Maximize fuel economy;
• Allow low temperature operation;
• Control oxidation to guard against oil thickening;
• Provide correct frictional properties for shifting clutches;
• Be compatible with seals; and
• Protect against thermal degradation.
Diagnosing Automatic Transmission Problems
Problems associated with automatic transmissions can sometimes be traced back to the fluid. Using a TO-4 fluid in an
automatic transmission will result in harsh shifts, poor low temperature performance, mediocre transmission response,
sludge and deposit formation and copper and bronze corrosion. Using a tractor fluid in an automatic transmission
will often cause burnt shifting clutches, elongated shifts, inadequate holding capabilities and sludge and deposit
formation. An automatic transmission operating with an improper fluid will increase the likelihood of shortened
component life, unscheduled downtime and elevated maintenance costs.
Fluid choices for automatic transmissions should take into account severity of service, ambient and operating
temperatures, which will influence viscosity grade selection, and any OEM-required approvals. For example, Allison
prefers a TES-295 fluid for severe or extended service automatic transmissions, a TES-353 fluid for its more severe,
off-highway automatic transmissions and a TES-389 fluid for its lighter duty and standard service, on-highway
automatic transmissions. Once the fluid type and grade is established, choosing a quality ATF will enhance
transmission performance and component life while decreasing costly downtime.
Powershift Transmissions
The powershift transmission has some internal components similar to that of the automatic transmission, but with
some key additions. The control of the powershift transmission is manual and allows for a wide range of speed ratios
with an almost instant shift from forward to reverse.
Most powershift transmission fluids have evolved from motor oil and multi-viscosity recommendations to straight
weight TO-4 transmission fluids. This fundamental shift in fluid type was prompted by the design of the powershift
transmission itself. Today’s powershift transmissions have highly sensitive friction-based components that require a
“grabby,” not slippery, fluid to achieve a tight lock-up.
1 800 255 4417

A premium TO-4 powershift transmission fluid should:
• P rovide control over the 7 different frictional elements, both metallic and non-metallic, commonly found in a
powershift transmission;
• Eliminate brake noise;
• Reduce wear of elastomeric material;
• Prevent slippage;
• Encourage stable performance over the life of the fluid;
• Inhibit metal-to-metal contact while protecting vane pumps, planetary gear sets, final drive gears and bearings
from premature wear;
• Offer foam protection to guard against fluid loss;
• Promote low temperature performance to reduce start-up wear;
•C ontrol oxidation to prevent deposit formation that can restrict lubrication; and
•M aintain excellent shear stability to ensure consistant protection from wear.
Diagnosing TO-4 Type Powershift Transmission Problems
Improper use of an ATF or tractor fluid in most powershift transmissions will produce burnt and/or slipping clutches,
inadequate holding capacity for both brakes and clutches and insufficient wear protection for gears.
Caterpillar pioneered the TO-4 specification for its off-highway powershift transmissions. Fluids meeting this
specification have been factory fill on all CAT powershift transmissions since 1991, and there is little comparison
between the TO-2 and TO-4 specifications. The TO-4 specification defines frictional capabilities in-depth and
combined with the anti-wear properties and added gear protection, a premium TO-4 fluid maximizes powershift
transmission life and operating efficiency.
Some agricultural equipment such as medium and large size tractors also employ powershift transmissions. The
friction material of the shifting clutches in this application are selected to function properly with tractor hydraulic
fluids, which have a low static coefficient of friction to prevent chatter or squawk in the wet brakes used in these
machines.
Hydrostatic Transmissions
A hydrostatic transmission uses fluid to transfer power from the engine to the drivetrain through a hydraulic pump
and motor. A transmission of this type consists of a pump connected to the engine generating fluid power to drive a
hydraulic motor, which is connected to the axle and/or driving wheels. If the displacement of the pump and motor
were fixed, the transmission would merely act as a gearbox to transmit power. Most hydrostatic transmissions use a
variable displacement pump or motor in order to vary speed, torque or power and provide transmission function.
Therefore, the fluid used in a hydrostatic transmission only needs to function as a hydraulic fluid, as there are no
clutches or gears to lubricate. Fluids commonly used in hydrostatic transmissions include hydraulic fluids, automatic
transmission fluids and tractor hydraulic fluids. The owner’s manual of the specific equipment should be consulted for
the manufacturer’s preferred fluid.
1 800 255 4417

A premium-performing hydrostatic transmission/hydraulic fluid must:
• Protect against metal-to-metal contact;
• P revent wear in vane and piston pumps, transmission spur gears, final drive spur, and spiral bevel gears and axle
and transmission bearings;
• P rovide proper frictional characteristics for wet brakes and clutches;
•H ave exceptional water tolerance to maintain function and prevent corrosion in the presence of 1-2% water,
which may be found in these machines;
• Offer excellent extreme pressure protection for gears;
• Provide antiwear protection for hydraulic pumps; and
• Provide adequate lubrication over a wide range of temperatures.
Diagnosing Hydrostatic Transmission Problems
Improper fluid usage in a hydrostatic transmission typically causes brake squawk, harsh shifts, poor low temperature
performance and inadequate water tolerance. An ATF used in some transmissions will result in brake squawk,
inadequate water tolerance and insufficient film strength for gear protection.
Manual Transmissions
Unlike automatic, power shift and hydrostatic transmissions, manual transmissions do not use fluid to transfer power.
Power from the engine is distributed through the transmission by engaging and disengaging gears through the clutch
and collars. Gears will move freely unless engaged by a collar.
Premium manual transmission fluids are designed to:
• Prevent metal-to-metal contact and wear;
• Provide cold flow characteristics and maintain proper viscosity over a wide
temperature range;
• Be compatible with seals;
• Maintain thermal stability throughout drain interval; and
• Control oxidation.
Diagnosing Manual Transmission Problems
The use of an inadequate fluid in most manual transmissions will produce burnt and/or slipping clutches, insufficient
wear protection for gears, harsh shifts, premature thermal degradation, poor low temperature performance, mediocre
transmission response, sludge and deposit formation and copper and bronze corrosion.
Friction Characteristics:
Similar to a gear oil, manual transmission fluids need to protect gears from metal to metal contact, disperse heat, and
seal the component. Friction modifiers are utilized in manual transmissions and are needed for proper synchronizer
friction. These friction modifiers utilize a low static coefficient of friction to allow smooth shifting between collar and
gears. Typically, manual transmission fluids will require a 50 weight or a 75W-85 transmission fluid. Newer ones are
moving toward lower viscosity.
1 800 255 4417
Castrol® Trans-C™ HT
Castrol Trans-C HT is a full synthetic transmission/hydraulic fluid that balances high-temperature wear protection
for gears and bearings with low temperature flow properties for positive shifting in transmissions. Its full synthetic
formulation allows for extended drain intervals with regular used oil analysis. It is a multi-functional fluid that can be
used for both hydraulic systems and transmissions, which helps business owners consolidate inventory and simplify
maintenance practices.
Extends Service Intervals

In field tests on various types of earthmoving equipment, Castrol Trans-C HT stretched service intervals to more than
5,000 hours in hydraulic systems and more than 2,500 hours in powershift transmissions without problems.
Trans-C HT Field Test

6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic
Transmissions
5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Hours
3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0 .........................................................................................
KOM CAT KOM CAT CAT KOM CAT KOM
605-5a 775E-1 4653 988G 775E-2 WA600 988E 605-5b
Machine Type
Exceptional Gear Wear Protection

The excellent gear protection offered by Castrol Trans-C HT is further demonstrated during a D 4998 gear wear
test and FZG D 5132 Load Test. The FZG is a heavily loaded spur gear test commonly used to evaluate gear oil
performance. The gear wear directly correlates to weight loss, with less weight loss being equal to less wear. Castrol
Trans-C HT was tested versus other TO-4 type fluids and showed the least gear weight loss. Trans-C HT achieved a
11 load stage pass delivering wear protection at high loads.
1 800 255 4417
D 4998 FZG Gear Wear Test
60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight Loss (mg) 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0 ........................................
Trans-C HT TO-4 A TO-4 B
Fluid Identity
Excellent Pump Protection

The outstanding anti-wear hydraulic performance of Castrol Trans-C HT is illustrated in a Vickers D 2882 Modified
Pump test. Castrol Trans-C HT showed only 9 milligrams weight loss on the parts, which is well below the passing
limit. The pump part photos show them to be in excellent condition with very little evidence of wear on the rings and
vanes.
Vickers D 2882 Vickers D 2882 Ring
OEM Specifications
• Meets or exceeds Caterpillar TO-4 requirements
• Vickers 35VQ25 Vane Pump Performance
1 800 255 4417
Typical Analysis
Test Method Results
Kinematic Viscosity @ 40° C, cSt ASTM D445 84.6
100° C, cSt ASTM D445 11.8
Viscosity Index ASTM D-2270 134
Flash Point °C (°F) ASTM D92 240(464)
Pour Point ºC (ºF) ASTM D97 -36(-33)
Brookfield Viscosity -35°C, cP ASTM D2983 138,000
20 Hours KRL (Shear Test)
After Shear cSt @ 100°C CEC-L45-20 11.63
% Viscosity Loss -1.61
FZG Gear Scuffing - Pass Load Stage ASTM D5182 11
FZG Gear Wear - mg wt. Loss ASTM D4998 48
Gravity, API ASTM D287 32
Specific Gravity @60F, g/ml ASTM D1298 0.8654
1 800 255 4417
Castrol® Trans-C™
Low Temperature Fluidity
Castrol Trans-C provides excellent cold weather pumpability and decreases wear typically associated with cold
weather starts. Less wear can mean longer transmission life.
Gear Protection
Castrol Trans-C passes the 35VQ25 Vickers pump test ensuring protection for high pressure hydraulic systems.
Because of this added gear protection, customers can consolidate fluids in on- and off-highway equipment.
Castrol Trans-C Transmission Drive Train Oil meets the stringent Caterpillar TO-4 fluid requirements, particularly
important where paper and elastomer disc materials are utilized and friction retention must be optimized for
extended clutch life and slippage control under severe high load operations. While commercial engine oil technology
excelled in the previous Caterpillar required CD/TO-2 specification where the bronze clutches prevailed, Castrol
Trans-C provides field-tested technology to ensure durability under today’s strenuous operating conditions and where
significant clutch material changes have taken place.
Castrol Trans-C will also provide Detroit Diesel Allison C-4 performance. Castrol Trans-C excels in many on and
off-highway hydraulic oil applications.
Castrol Heavy Duty’s traditional quality approach prevails in Castrol Trans-C by having premium base oil selection (high
viscosity indexes) coupled with select additives for noted oxidation stability, rust and corrosion protection, foaming
inhibition, anti-wear protection, mild “EP” and assured excellent pumpability in the “SAE 10W” or ISO 32 grade.
Applications and Recommendations:
• Exceeds Caterpillar TO-4 specifications/requirements
• Approved Allison C-4
• Vickers 35VQ25 Vane Pump performance
• Many on and off-highway transmissions, drive trains and hydraulic systems
Typical Analysis
SAE Grade Method 10W 30 50 60
Viscosity @40°C, cSt ASTM D445 47 97 221 351
Viscosity @100°C, cSt ASTM D445 7.19 11 19 25
Viscosity Index ASTM D2270 113 99 96 91
Flash Point, °C (°F) ASTM D92 203 (397) 220 (428) 228 (442) 229 (444)
Pour Point, °C (°F) ASTM D97 -42 (-44) -39 (-38) -24 (11) -24 (11)
FZG Gear Scuffing, ASTM D5182 10 pass 11 pass 11 pass 11 pass
Load Stage
Gravity, °API ASTM D287 29.5 27.9 24.2 24.0
Specific Gravity @60°F ASTM D1298 0.879 0.889 0.907 0.91
Pounds per Gallon ASTM D287 7.32 7.4 7.56 7.58
1 800 255 4417
Castrol® Syntrans™ 75W-85

Castrol Syntrans 75W-85 is a full synthetic transmission fluid recommended for most commercial vehicle manual
transmissions (truck, bus, light commercial vehicle) where API GL-4 lubricants are required. These transmissions are
generally larger and subjected to higher loads and temperatures than those in passenger cars; this product was
developed for these particular requirements and is approved by a number of manufacturers.
Features and Benefits

• Excellent thermal and oxidative stability maintains transmission cleanliness and lubricant performance, allowing
extended drain capability.
• Synthetic formulation provides a reduction in operating temperatures, giving longer component and lubricant life.
• Superb cold flow characteristics give smoother gear shifts at low temperatures.
• High shear stability maintains lubricant performance throughout the drain interval.
• Good wear and EP performance ensures component protection under high load conditions, reducing downtime
and service costs.
Industry Specifications and OEM Approvals:
• API GL4
• MAN 341 E4
• MB approval 235.4
• Volvo 97307
• Eaton 500,000km drain Europe (service bulletin 2273)
Typical Properties*
Brookfield Viscosity at -40 C, cP ASTM D2983 18,000
Pour Point, °C (°F) ASTM D97 -60 (-76)
API Gravity ASTM D287 37.5
* Due to continual product research and development, the information contained herein is based on components purchased in the U.S. and
subject to change without notification. Typical properties may vary slightly.
1 800 255 4417
Castrol® UTF
Castrol UTF, Universal Tractor Fluid, is a premium hydraulic/ transmission fluid that exceeds the refill and service topup
needs of farm and industrial tractor transmission, differentials and immersed disc brakes. Castrol UTF is compounded
with anti-wear, extreme pressure, anti-oxidant and friction control additives and foam and corrosion inhibitors. Castrol
UTF couples this superb additive package with highly refined base oils and a shear stable viscosity index improver for a
balanced package.
Excellent Water Tolerance and Pump Life

Water contamination in off-highway equipment poses a threat to productivity and the health of the equipment.
Castrol UTF was designed to operate in the presence of 1% water contamination. During the Gear Wear Test, Castrol
UTF protected up to four times better than the competition against wear and corrosion with water contamination up
to 1%.
Gear Wear Protection

In several OEM gear tests, Castrol UTF demonstrated its ability to withstand system pressures while showing no signs
of pitting, ridging, scoring and corrosion. On a sensitive gear surface or tooth, the slightest amount of wear can cause
maintenance problems.
Smooth Transmission Performance

Castrol UTF provides just the right balance of smooth engagement and minimum slippage, which is ideal for power
transmission performance. Due to its smooth performance characteristics, Castrol UTF reduces heat-associated wear in
power transmissions.
Thermally Stable
Castrol UTF’s excellent thermal stability provides wear protection in high temperatures. Castrol UTF protects against
the excessive deposit build-up that results from overheating, which can cause wear on clutch plates, control valves
and pressure regulators.
Low Temperature Performance

Castrol UTF’s extremely low pour point of -37°F gives it exceptional low temperature performance. Castrol UTF can
maintain flow characteristics during a cold-start, which means the oil reaches pumps, cylinders and hydraulic
components quickly, dramatically reducing start-up wear.
Compatibility
Castrol UTF maintains the size, hardness and strength of elastomers, seals and gaskets, which helps to reduce
downtime and maintenance costs.
Friction Control
Castrol UTF uses friction modifying additives to ensure the smooth, quiet operation of multi-disc clutches and
oil-immersed disc brakes. In industry tests, Castrol UTF consistently provided quiet brake operation with no loss
in capacity.
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Castrol® UTF
Water Tolerance Wear Test
The Water Tolerance Wear Test measures a fluid’s ability to protect against corrosive wear when contaminated with
water. Castrol UTF, pitted against a competitive fluid during 0.4% and 1.0% water contamination, showed that it
guarded against wear four times better than the competitive fluid.
Water Tolerance Test

Wear and Corrosion In Contaminated Fluids
600
500
Extra Margin
Weight Loss (mg)
of Safety
Extra Margin
400
of Safety
300
200
100
0
Castrol Competitive Castrol Competitive
UTF Fluid UTF Fluid
0.4% Water 1.0% Water
Sunstrand Hydraulic Pump Performance Test

During the Sunstrand Hydraulic Pump Performance Test, a fluid is contaminated with water and the flow of the
fluid is then measured. The loss of flow from the pump is measured and reported in flow degradation and is an
indicator of how well the fluid would flow and protect when contaminated with water. Castrol UTF showed only
0.6% flow rate degradation on a Sunstrand Piston Pump Model 22-2132. The maximum allowable flow rate
degradation is 10%.
Maximum allowable
flow rate degradation
10
8
6
Margin Sunstrand Model 22-2132
Variable Displacement
of Piston Pump
(5,000 psi, 3,100 rpm,
4 Safety 180˚F. [82.2˚C] with
1.0% water contamination)
2
0.6%
0
Sunstrand Hydraulic Pump
Performance
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Castrol® UTF
Plessey-Sunstrand Ford M3C134-D Test
The Plessey-Sunstrand Ford M3C134-D Test also measures the flow characteristics of a fluid once it is contaminated
with water. Castrol UTF showed no flow rate degradation during this test. The maximum allowable flow rate
degradation is 5%.
Ford 3000 Axle Test

The Ford 3000 Axle Test subjects gear tooth surfaces to pressures of 400,000 psi for 100 hours at almost 200°F.
During this test, gears protected with Castrol UTF showed practically no wear due to pitting, scoring, ridging or
corrosion.
Brake Chatter Test

Castrol UTF was compared with a competitive fluid on a Massey Ferguson 275 Agricultural Tractor to measure brake
chatter. In all gears, Castrol UTF provided consistently quieter brake performance than the competitor.
Brake Chatter Comparison

Massey Ferguson 275 Agricultural Tractor
110
100
dBA
90
80
Gear 1 Gear 2 Gear 3 Gear 1 Gear 3
Low Low Low High High
Castrol UTF
Competitive Fluid
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Castrol® UTF
Additives that provide quality Assured proper and decisive Chatter-free power transfer for
friction modifiers. functioning of multi-disc clutches used wet brakes for longer equipment
in power shift type transmissions and life.
in oil-immersed disc brakes. Excellent
control over brake chatter (shudder,
squawk, etc.)
Balanced chemistry to control Water tolerance with minimal loss of Better productivity and longer
water contamination. performance. equipment life.
Seal swell and protection. Maintain size, hardness and strength of Excellent system performance for
elastomers, seals and gaskets. better productivity.
Low pour point. Mobility and prompt lubrication at low Better productivity through year
ambient temperatures. round operation. Less repair costs.
Longer equipment life.
Excellent anti-wear package. Prevent scoring and gear wear. Longer equipment life and less
Provides excellent load carrying maintenance.
capacity and wear protection under all
load conditions.
Shear stable viscosity index Minimal viscosity change in such Longer equipment life. Less wear
improver. applications as torque converts and under severe conditions.
hydrostatic drives under very high
temperatures.
Balanced formulation. Compatibility with all seal materials. Less inventory for reduced costs.
Assured miscibility with other tractor
fluids.
Excellent rust and corrosion Protects susceptible parts against rust. Less maintenance costs.
inhibitors, anti-foam additives Excellent resistance to oil degradation
and oxidation inhibitors. due to oxidation at high temperatures.
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Applications & Approvals
Allis Chalmers Power Fluid 821
Case/New Holland(IH) MS-1207/Hy-Tran Plus, MS-1210/TCH, MS-1204/TFD Fluid, MS-1205/TFD-II
Fluid, MS-1206/PTF Fluid, JIC-145, JIC-185, B-6/Hy-Tran, CNH MAT 3505
(MS-1209 Hy-Tran Ultra Fluid), Ambra Mastertrans Fluid CNH MAT 3525
(M2C134D), Multi G & Multi G 134, Nexplore Fluid
Caterpillar TO-2
John Deere J20A, J20C, JD303, J14B, J14C
Deutz-Allis AC Power Fluid 821XL
Ford Tractor M2C53A, M2C53C, M2C41A/B, M2C86B/C, M2C134A/B/C/D,
M2C77A
Kubota Universal Transdraulic Fluid, UDT Fluid
Massey Ferguson M-1110, M-1127 A/B, M-1129-A, M-1135, M-1141 (Permatran III)
Oliver/White Q-1766B, UHTF Type 55, Q-1722, 102082, Q-1826
Sperry Vickers Pass on Pump Tests ASTM D-2882 and 35VQ25
Volvo WB-101
ZF 03E, 05F
Typical Analysis
Test Method Results
Viscosity @40°C, cSt ASTM D445 56
Viscosity @100°F, SUS ASTM D2161 285
Viscosity @210°F, SUS ASTM D2162 58
Flash Point, °C(°F) ASTM D92 215(419)
Pour Point, °C(°F) ASTM D97 -37(-35)
Cold Crank Vis, -25C, cP ASTM D5293 6272
Gravity, °API ASTM D287 29
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Castrol® Heavy Duty Multi-Purpose ATF

Castrol Heavy Duty Multi-Purpose Automatic Transmission Fluid (ATF) is a multipurpose power transmission fluid that
is designed for most power transmission and hydraulic systems to include passenger car and truck automatic
transmission, powershift transmissions in off-highway construction equipment, hydrostatic drives and industrial,
agricultural, mining and marine hydraulics.
Castrol Heavy Duty Multi-Purpose ATF has excellent anti-wear, corrosion resistance, friction retention, and oxidation
and thermal stability. In addition, it is inhibited against foaming, and the high viscosity index helps assure sufficient
body for proper lubrication in severe hot weather service, without excessive thickening low temperatures.

High viscosity index. Maintains viscosity in severe hot Longer transmission, torque
weather service. converter, hydraulic system
life.
Low pour point (low temperature Less wear in cold weather starts and Longer transmission, torque
fluidity). operation. converter, hydraulic system
life.
Controlled frictional properties. Transmission of power is smooth and Better productivity through
Maintains excellent frictional efficient and a noted long term efficient equipment
properties (smooth shifting) for the retention of these properties. performance.
life of the fluid, a prime benefit of
the Dexron®III specification.
Oxidation stability Resists chemical deterioration over long Longer equipment life under
is excellent. service periods. severe service conditions.
Excellent anti-wear performance Reduced metal-to-metal contact in Less maintenance. Keeps
when the application demands the such applications as torque converters, downtime to a minimum.
need for boundary lubrication. transmissions, vane pumps, etc.
Compatibility with rubber and Not harmful to synthetic rubber seal Longer life for vital
various friction materials, etc. materials, compatible with such components.
material as sintered bronze and
graphitic surfaces.
Minimal lock-up shudder. Smooth, consistent shift feel. Fewer operator complaints.
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Castrol® Heavy Duty Multi-Purpose ATF

Warranty and Protection Requirements
• Meets or exceeds all truck and passenger car manufacturer’s warranty requirements for vehicles, transmissions,
transaxles, power steering systems or hydraulic systems where an Allison C4, Allison TES-389, Dexron-IIIH,
Mercon or Vickers 35VQ25 fluid is specified.
• Meets or exceeds Allison transmission warranty requirements where an approved and licensed Allison TES-389
ATF is specified.
Industry Specifications and OEM Approvals

• Allison TES-389 approved and licensed (AA-32252007, AA-32362007)
• Allison C4 Approved
• Meets or Exceeds General Motors DEXRON®-IIIH Requirements
• Meets or Exceeds Ford MERCON® Requirements
• Meets or Exceeds the performance requirements of high pressure vane and piston pumps: Vickers (35VQ25, V-
• 104C) and Denison (T-6C, P-46)
Benefits
• Considerable savings through vastly reduced inventory.
• Minimal chance of costly application errors.
Typical Analysis
Test Method Results
Viscosity @ 100° F., SUS ASTM D2161 171
Color, Typical ASTM D1500 6.0 - 8.0
Appearance Visual Red
Brookfield Viscosity at -40 C, cP ASTM D2983 12,100
Pour Point, ºC (ºF) ASTM D97 -51 (-60)
API Gravity ASTM D287 34
E
Gear Lubricants
E
Gear Lubricants
Types of Gears E2
Industry Specifications E4
Important Gear Oil Properties E9
Product Data
Castrol® Gear Lubricants E11
Castrol® Alpha® HC E12

[PREVIOUSLY Castrol Isolube]
Castrol® Alpha® HC EP E16

[PREVIOUSLY Castrol Isolube EP]
Castrol® Alphasyn T™ E 17
[REPLACES Castrol SHL Lubricant 150, 220, 460]
Castrol® AP Gear Lubricant E19
Castrol® EP Gear Lubricant E21
Castrol® Syngear™ Lubricant E23

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Types of Gears
Gears are the most common way to transmit power from one revolving shaft to another. Different combinations of
gears are responsible for increasing speed, decreasing speed and changing the direction of the shaft. Gears are usually
found in meshed pairs; the smaller gear is called the pinion and is responsible for speed reduction, and the larger gear
is called the ring gear and is used to increase speed.
Due to varying needs and applications, there are several different types of gears. A basic knowledge of the most
common types of gears, their components and method of operation is helpful in understanding which lubricants will
enhance gear performance. Below are some of the types of gears encountered in today’s equipment. Each gear is
typically named for its general shape or by the arrangement of its teeth.
Spur Gears
A spur gear is a toothed wheel whose teeth run parallel to the gear shaft or axle. Spur gears are simple to
manufacture, limited in their load-carrying ability and known for their noisy operation. A variation of the spur gear can
be found in planetary gear sets.
Helical Gears
Helical gears transmit motion between non-intersecting parallel and nonparallel shafts. Similar in design to the spur
gear, the teeth of the helical gear are angled or twisted to allow several teeth to be in mesh at the same time. Because
the gear teeth engagement area is larger, helical gears can carry greater loads and tend to be much quieter and
smoother in operation than spur gears.
Herringbone Gears
A double helical gear is commonly called a herringbone gear based on the opposing angles of the gear teeth.
Herringbone gears can carry heavy loads at high speeds.
Bevel Gears
Bevel gears employ two intersecting shafts with meshing teeth cut straight across the face of a cone-shaped gear
blank. Bevel gears are commonly used when a 90-degree change in direction of shaft power is required. A special
grouping of bevel gears in automotive applications are known as differential gear sets. These gears are used to divide
power between two variable speed shafts.
Spiral Bevel Gears
The teeth of an ordinary bevel gear can be twisted to form a spiral bevel gear. The “spiral” look results from cutting
angled teeth into a cone-shaped gear. The angled teeth allow for a quiet, smooth transfer of power and a strong gear
system. Spiral bevel gears are typically found in off-highway equipment.
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Types of Gears
Hypoid Gears
A modification of the spiral bevel gear, hypoid gears transmit motion between non-intersecting shafts that cross at right
angles. Hypoid gears have inherently strong teeth, excellent load-carrying ability and offer noiseless operation. The
sliding motion of the hypoid gear requires lubricants with EP additives to maintain film strength. Hypoid gears can be
used for the most severe applications.
Worm Gears
When shafts are intersecting at right angles and the driving gear is much smaller in diameter than the driven gear, this
is called a worm gear. The two most common types of worm gears are throated and non-throated. The throated
worm gear has angled teeth that increase the number of teeth in mesh at any given time. As with spiral bevel gears
and helical gears, this feature increases load-carrying ability and quiets operation. On the contrary, the non-throated
worm gear has only one tooth at a time in mesh, thus decreasing the gear’s ability to carry loads. Due to the sliding
nature of the worm gear, lubricants employing special additives are necessary. Worm gears are typically found where
great velocity reductions are required.
Rack and Pinion Gears
A rack and pinion gear set is commonly found in automotive steering applications. Motion is transferred from the
circular motion of the pinion gear to a linear gear alignment called the rack, or bar. Gear teeth are more tolerable,
giving drivers a better feel while steering.
Gear System Lubrication Problems

The sensitive gears described above can experience problems for a number of reasons. Below are some of the more
common ones:
• Inadequate lubrication or low gear oil level;
• Incorrect type of gear lubricant;
• Wrong lubricant viscosity;
• Poor-performing lubricant;
• Dirty/contaminated gear lubricant; and
• Misalignment of gear sets.
Any or several of the above factors can contribute to gear wear. The most common types of gear wear are micro-
pitting, spalling, scoring and ridging. Basically, these different types of wear cause small pieces of metal to be removed
from the system, which eventually causes tooth failure and severe system contamination.
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Formulation of quality gear lubricants takes a delicate balance of additive chemistry. One of the best ways to
determine lubricant quality is to review service specifications and mechanical test requirements with a fluid’s results.
Finding gear oils that meet, or more importantly exceed, the API test standards is the first step to choosing a quality
gear oil.
The most widely used gear lubricants in North America are of API GL-4 (for manual transmission) and API GL-5 for
axles. Since many equipment builders’ specifications exceeded that of the above classifications, a new gear oil
classification, API MT-1, was introduced. API MT-1 contains upgraded performance requirements for oils used in
heavy-duty truck and bus nonsynchronized manual transmissions. This specification does not address oils for
synchronized manual transmissions in passenger cars and heavy-duty vehicles.
Physical Requirements for Gear Lubricants Intended for

Axle and Manual Transmission Applications
SAE Viscosity Max Temperature for Viscosity of Kinematics Viscosity at 100°C (cSt)3
Grade 150,000 cP (°C)1,2 min4 max
70W -555 4.1 --
75W -40 4.1 --
80W -26 7.0 --
85W -12 11.0 --
80 -- 7.0 <11.0
85 -- 11.0 <13.5
90 -- 13.5 <18.5
110 -- 18.5 <24.00
140 -- 24.0 <32.5
190 -- 32.5 <41.0
250 -- 41.0 --
1
Using ASTM D2983
2
Additional low temperature viscosity requirements may be appropriate for fluids intended for use in light-duty synchronized manual transmissions.
3
Using ASTM D 455
4
Limit must also be met after testing in CEC L-45-T-99, Method C (20 hours).
5
The precision of ASTM Method D 2983 has not been established for determinations made at temperatures below -40°C. This fact should be taken
into consideration in any producer-consumer relationship.
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API Gear Oil Classifications
Service Designations in Current Use:
Classification Description Uses
API GL-1 Straight Mineral Oil Manual transmissions operating under
mild conditions.
API GL-4 Equivalent to Manual transmissions, axles with spiral
MIL-L-2105 bevel gears operating under moderate to
severe conditions of speed or load, hypoid
gears operating under moderate to
severe speeds and loads and transaxle
applications where API MT-1 lubricants
are unsuitable.
API GL-5 Virtually equivalent Gears, particularly hypoid gears, in axles
to MIL-L-2105E operating under various combinations of
high-speed shock loads and low speed,
high-torque conditions.
API MT-1 Thermally stable Nonsynchronized manual transmissions used
and contains EP in buses and heavy-duty trucks.
additives

Service Designations Not in Current Use:

Classification Description Uses
API GL-2 Usually contain Automotive worm gear axles.
fatty materials
API GL-3 Mild EP additives Manual transmissions operating under moderate
to severe conditions and spiral-bevel axles
operating under mild to moderate conditions of
speed and load.
API GL-6 Obsolete Gears with very high pinion offsets.
Reprinted from Lubrizol’s Ready Reference for Lubricant and Fuel Performance.
Due to obsolescence or inability to verify test requirements from unavailable equipment, this manual will not discuss
API GL-1 through API GL-4 and API GL-6.
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API GL-5
The mechanical tests required for API GL-5 gear lubricants are as follows:
Load Carrying (ASTM L-37)
This low speed/high torque test determines the load-carrying ability of the lubricant. Extreme pressure additives are
needed to pass this test.
Test Limit
No tooth disturbance, such as pitting, ridging, rippling or severe wear
Corrosion Resistance (ASTM L-33-1)
Corrosion resistance in the presence of water is determined by this test. The gear lubricant must protect a surface
against rust after 7 days of water exposure.
Test Limit
No rusting after 7 days on any working surface Max .5 in rust on cover plate
(1% of surface area)
High-Speed Shock Loads (ASTM L-42)
The ability to prevent scoring under high-speed shock load conditions is measured by ASTM L-42.
Test Limit
Gear/pinion scoring must be equal to or better than RGO-110
Thermal and Oxidative Stability (L-60-1)
L-60-1 measures base oil quality, additive component and thermal and oxidative stability.
Test Limit
100% max viscosity increase
3% max pentane insolubles
2% max toluene insolubles
Anti-foam Properties (ASTM D 892)
The oil’s ability to resist foam is determined after 5 minutes of aeration during the ASTM D 892.
Test Limit
Sequence I 20 ml, max
Sequence II 50 ml, max
Sequence III 20 ml, max
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Copper Corrosion (ASTM D 130)
Corrosion levels are taken on copper components after a specified time interval and under strict temperature
conditions in ASTM D 130.
Test Limit
3 max after 3 h at 121.1°C
Oil Compatibility and Solubility (FTM 3430 & FTM 3440)
Evaluated by FTM 3430 and FTM 3440 respectively, an oil must show minimal separation of material and continue to
maintain solubility after being mixed with different reference oils.
Test Limit
FTM 3430: 0.25% wt max or original nonpetroleum material in sample
FTM 3440: 0.50% wt max of original nonpetroleum material in sample
API MT-1
API MT-1 was designed as a specification for transmissions apart from API GL-4. It provides additional protection against
thermal degradation, component wear and oil-seal deterioration versus API GL-4 and API GL-5 lubricants. The test
requirements for API MT-1 lubricants are as follows:
Copper Compatibility (ASTM D 130)
Measured by ASTM D 130, API MT-1 lubricants have a stricter corrosion limit than API GL-5 lubricants.
Test Limits
2A max after 3 h at 121.1°C
Foam Resistance (ASTM D 892)
Same test and limits as API GL-5 lubricants.
Thermal and Oxidative Stability (L-60-1)
Same test and limits as API GL-5 but with added measurements for component cleanliness as shown by carbon and
sludge deposits.
Test Limits
7.5 min carbon/varnish rating on large gear
9.4 min sludge rating on all gears
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Oil Compatibility and Solubility (FTM 3430 and FTM 3440)
Same test and limits as API GL-5 gear lubricants.
Oil Seal Compatibility (Similar to ASTM D 471)
A test not required for API GL-5 gear lubricants. Measures the change in volume, hardness and elongation of oil seals
for API MT-1 lubricants.
Test Limits
Polyacrylate
Elongation change -60 to 0%
Hardness change -20 to +5 pts
Volume change -5 to +30%
Fluoroelastomer
Elongation change -75 to 0%
Hardness change -5 to +10 pts
Volume change -5 to +15%
Anti-wear Characteristics (ASTM FZG D 5182)
Another test not performed on API GL-5 lubricants, ASTM FZG D-5182 determines a lubricant’s anti-wear strength.
Test Limit
Min 10 stage pass
High Temperature Stability (Mack Transmission Test T2180)
Performed only on API MT-1 lubricants, the Mack Transmission Test T-2180 evaluates the oil’s thermal stability during
extreme high temperatures.
Test Limit
Equal to or better than reference oil
There is increasing concern from OEMs regarding the operating temperatures API GL-5 lubricants must consistently
face. API MT-1 was the result of an update to the API GL-5 category as spurred by heavy-duty equipment builders.
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Important Gear Lubricant Properties

Gear lubricants perform a number of duties within a gear set including preventing metal-to-metal contact, providing
good shiftability in all temperatures, dissipating heat, preventing rust, removing wear debris and reducing friction.
Specially formulated gear lubricants work to optimize performance and preserve the gear itself. When choosing a
gear lubricant, several factors should help to determine final lubricant choice, including:
Extreme Pressure
Extreme pressure characteristics are especially important to gear lubricants. In some cases, EP additives account for up
to 80% of a gear oil’s additive package. EP additives work to protect the gear face from high temperatures and
prevent metals from welding together and tearing apart.
Gear Type
Wear resistance is especially important with spur and bevel gear lubrication since only one tooth carries the entire
load. With spiral bevel, helical and herringbone gears, the sliding action tends to wipe away the lubricant, which
dictates the need for a slightly higher viscosity lubricant. The lubricant for these gears must provide good film
protection but not excessive so that friction is increased.
Worm gears also employ sliding motion and therefore require a higher viscosity lubricant. Lubricants that are
compounded are usually specified for these gears. Hypoid gears by design require lubricants with EP additives to
combat the changing boundary and film conditions.
Gear Speed
Low viscosity oils can be used in higher speed gear operations because speed reduces the metal-to-metal contact and
actually assists in forming fluid films. High viscosity oils are typically used in low speed gear assemblies because there
is ample time for fluid films to deteriorate.
Reduction Ratio
The reduction ratio is a vital piece of information because it usually foretells of multiple reduction gears. Each
reduction set operates at a different speed; the first set being the highest speed and the last set being the lowest. The
inverse relationship between gear speed and oil viscosity holds true for multiple reduction sets. Two ways to lubricate
multiple gear reducers are to use a dual viscosity oil system, or to try circulating the cool oil to low speed gears and
then transferring it to the higher speed gears after its temperature is increased and viscosity decreased.
Operating Temperature
Ambient and operating temperatures affect an oil’s viscosity and oxidation resistance and are therefore critical pieces
of information in selecting a lubricant. To determine the operating temperature of a gear set, take the rise in
operating temperature and add it to the ambient temperature. Choose the appropriate lubricant for the calculated
temperature range.
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Important Gear Lubricant Properties

Transmitted Power
Based on the type of gear and amount of power and load that it is expected to handle, lubricant choice should take
into account the appropriate increase in temperature. Gear sets that transmit more power tend to run hotter than
their smaller counterparts. This additional heat should not be a problem if the operating temperature was properly
calculated and an adequate viscosity was chosen based on that temperature.
Surface Finish
The relative roughness of the gear surface is another determinate of gear lubricant viscosity. Rougher surfaces need
heavier viscosities to maintain adequate film strength. It is sometimes recommended to choose a viscosity based on
the average smoothing that can take place as the gear is operated.
Load Characteristics
Before choosing a gear lubricant, it is necessary to evaluate the type of loads the gear will be expected to handle.
Excessive loading and/or shock loads require the use of extreme pressure lubricants. In cases of severe loading, as with
automotive hypoid gears, metal-to-metal contact cannot be avoided and special extreme pressure lubricants are
needed to prevent welding.
Drive Type
Engines that produce varying amounts of torque typically require a higher viscosity lubricant to assure film strength.
Application Method
How the lubricant comes in contact with the gear set affects the lubricant choice. Splash-lubricated units require a
higher viscosity lubricant to help the oil stay in the gear and maintain film thickness. A pressure-applied lubricant tends
to distribute the oil uniformly, removing more heat than a splash-applied lubricant. A heavier viscosity lubricant is not
typically necessary in a pressure system.
Water Contamination
Steam, condensation or cooling effects can result in water contamination in an enclosed gear set. In cases where
water contamination is probable, a lubricant with good demulsibility (the ability to separate water and oil) is required.
It is of critical importance that the oil’s demulsibility characteristics do not fade after the oil is in service or has become
oxidized. Water in dirty oil that can no longer demulsify can cause excessive wear to gears and bearings. A lubricant
with good rust and corrosion inhibitors is also necessary to prevent gear and bearing surfaces from rusting in the
presence of water.
Other Qualities
In gears that experience heavy leakage, a special lubricant that resists leakage may be specified. Other desirable
lubricant qualities include foam resistance and oxidation resistance. These qualities help to assure oil quality during
periods of extreme service.
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Castrol® Gear Lubricants

The demand for increased equipment and vehicle productivity requires more frequent and prolonged high-load
operation. The thermal stress this creates in the gear box results in tough challenges in performance, fuel economy
and durability for the lubricant. Castrol gear lubricants meet these real world challenges and exceed the highest
industry standards. Castrol gear oils offer the following performance benefits:
Thermal Stability
Castrol gear oils are engineered to deliver high-temperature performance and protection from deposit buildup under
the stress caused by hauling extra-heavy loads, driving on-highway at high speeds and operating on severe grades.
Wear Protection
The advanced extreme pressure performance of Castrol gear oils reduces wear under severe conditions and permits
longer equipment life.
Seal Compatibility
Castrol gear oils reduce the loss of fluid due to leakage from seals that have become too soft, too brittle or damaged
by deposits.
Hydrolytic Stability
Water contamination of gear lubricants can promote rust and reduce equipment performance. Castrol gear oils have
excellent demulsibility to effectively separate water from oil for easy removal from the system. Residual water is not a
problem, since Castrol gear lubricants maintain their performance in up to 1% water-contaminated oil. Further
equipment safeguards are provided by excellent anti-rust protection.
Clean Parts
Particulate matter can also contaminate gear oils and cause accelerated wear or deposit buildup. The detergent/
dispersant properties of Castrol gear lubricants keep parts cleaner by keeping particulates suspended in the fluid until
they can be removed when the oil is changed. As a result, parts stay cleaner even during extended service intervals.
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Castrol® Alpha® HC [PREVIOUSLY Castrol Isolube]

Castrol Alpha HC Lubricants are a series of ISO grade, technically advanced chemistries that exceed the performance
levels historically attributed to the traditional synthetic products that are available today. Castrol Alpha HC Lubricants
excel in applications requiring excellent oxidation control and thermal stability, consistent anti-wear performance,
and low carbon forming tendencies, with chosen synthetic components that provide the potential for extended drain
intervals and reduced maintenance costs. Castrol Alpha HC Lubricants have noted viscosity range properties for low
temperature fluidity and controlled volatility. Other exceptional benefits of this innovative formulation include rust
protection, consistent demulsibility and hydrolytic stability.
Castrol Alpha HC Lubricants excel in circulating oil and gear set applications, and pass a 12 stage minimum in the
demanding FZG spur gear test, which provides an additional margin of safety in the noted applications. (Please note
that the Castrol Alpha HC Lubricants series should not be used for heavily loaded gear sets and where the OEM
requires an AGMA [American Gear Manufacturers Association] EP lubricant.)
Oxidation Control
Castrol Alpha HC has increased oxidation resistance as evidenced by field test results in the RBOT Oxidation Life
Test. This test showed that even after 835 hours in use, Castrol Alpha HC’s minutes to oxidation still exceeded that
of new commercial mineral and synthetic fluids. This increased oxidation control contributes to outstanding deposit
protection and extended compartment life. Castrol Alpha HC’s oxidation resistance is also important for users who
want to extend drain intervals in conjunction with a used oil analysis program.
Wear Protection
Castrol Alpha HC’s anti-wear additives give it outstanding wear protection that ensures long component life and less
maintenance and downtime.

Castrol Alpha HC’s proven low temperature pumpability ensures that critical parts remain protected, even during
extreme low temperatures. The added benefits of pumpability include more efficient operations and reduced energy
consumption.
Seal Compatibility
Castrol Alpha HC is considered elastomer compatible and showed no damaging seal swell or increase in seal hardness.
Other Qualities
Castrol Alpha HC provides outstanding rust protection, consistent demulsibility and excellent hydrolytic stability.
Field Test Results

Castrol Alpha HC was field tested at two national heavy-duty construction companies. The field test was designed to
test the following criteria: oxidation resistance, wear protection, low temperature performance and seal compatibility.
In compressor units at one of the sites, several candidate fluids were tested. Castrol Isolube was pitted against a
commercial mineral fluid and a commercial synthetic (PAO) fluid in most of these tests. The results are as follows:
Gear Lubricants E13
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RPVOT Oxidation Life Test
In the RPVOT Oxidation Life Test, a fluid is heated in pure compressed oxygen to determine how long it would take
for the fluid to fail. As shown in the chart below, Castrol Alpha HC was tested at field test intervals from 8 to 835
hours. Even after 835 hours of use, Castrol Alpha HC’s minutes to oxidation still exceeded that of a new commercial
mineral and synthetic fluid.
RPVOT Oxidation Life Test ASTM 2272
Castrol Alpha HC
835 hours
Synthetic Oil (New)
641 hours Mineral Oil (New)
435 hours
141 hours
8 hours
0
hrs
new
oil
0 hours
0
500
1000
1500
Minutes to Oxidation
ASTM D 2272 (Rotating Bomb) Procedure
In another test for oxidation resistance, Castrol Alpha HC outperformed several test fluids, showing exceptionally long
fluid life.
Oxidation Resistance Mineral Oil

ASTM D 2272 (Rotating Bomb) Procedure Commercial Synthetic
2500 PAO Diester

Experimental 1
2000 Experimental 2
Minutes to Failure
Castrol Alpha HC
1500
1000
500
0
Gear Lubricants E14
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Wear Metals and Ferrographic Analysis
Castrol Alpha HC’s outstanding anti-wear performance showed minimal wear in a field test compared to a
commercial PAO-based alternative. Ferrographic analysis also showed only trace levels of normal wear, whereas the
competitive PAO gear oil showed low to moderate levels of wear and a moderate level of dark oxides.
Commercial Synthetic (New)

Field Test
(Oxidation Resistance) Commercial Mineral Oil (New)
1500 Castrol Alpha HC
1250
(min. per ASTM D 2272)
RBOT Oxidation Life
1000
750
500
250
0
0 8 141 435 641 835
Field Test Hours
ASTM D 2983 Air Bath Procedure
Castrol Alpha HC displayed characteristics of outstanding low temperature performance in the ASTM D 2983 test for cold
temperature performance.
Mineral Oil
Cold Temperature Performance
ASTM D 2983 (Air Bath) Procedure Commercial Synthetic
100,000 Castrol Alpha HC
Brookfield Viscosity (cP)
80,000
60,000
40,000
20,000
0
-38
-20
-2
14
32
Temperature (ϒF)
Gear Lubricants E15
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ISO Grade Method Unit
Viscosity @40°C, cSt ASTM D445 mm2/s
Viscosity @100°C, cSt ASTM D445 mm2/s
Viscosity @100°F ASTM D2161 SUS
Viscosity @210°F ASTM D2161 SUS
Viscosity Index ASTM D2270 --
FZG Gear Test, load stage ASTM D5182 Stages
Pour Point ASTM D97 °C (°F)
Flash Point, open cup method ASTM D92 °C (°F)
API Gravity ASTM D287 --
Specific Gravity @16°C/60°F ASTM D1298 --
Pounds per Gallon ASTM D287 --
150 220
Viscosity @40°C, cSt 149.2 220.8
Viscosity @100°C, cSt 18.9 25.6
Viscosity @100°F, SUS 691 1,021
Viscosity @210°F, SUS 93.8 122.8
Viscosity Index 143 148
FZG Gear Test, load stage >12 >12
Pour Point, °C (°F) -45(-49) -45(-49)
Flash Point, open cup method 227(441) 227(441)
APO Gravity 33.4 33.0
Specific Gravity @16°C/60°F 0.858 0.860
Pounds per Gallon 7.14 7.16
Gear Lubricants E16
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Castrol® Alpha® HC EP [PREVIOUSLY Castrol Isolube EP]

Castrol Alpha HC EP Lubricants are a series of ISO graded, technically advanced chemistries that exceed the
performance levels historically attributed to the traditional synthetic products that are available today. Castrol
Isolube EP Lubricants have been formulated with carefully chosen synthetic components for excellent performance
in applications requiring AGMA (American Gear Manufacturers Association) EP gear oils. The product has coupled
multiple components in a formulation that provides outstanding wear protection in industrial gear sets, off-highway
construction, and mining applications where consistent performance is critical.
Castrol Alpha HC EP Lubricants provide exceptional oxidative and thermal stability in selected applications. Castrol
Alpha HC EP Lubricants offer a unique approach to gear and system component lubrication through a focused
formulation that will provide the end user with true confidence in the selected application.

• ANSI/AGMA Standard 9005-E02
• DIN 51517 Part 3
• AIST 224
Typical Analysis
Test Method Unit 68 150 220
Kinematic Viscosity ASTM D445 mmÇ/s 67.8 149.2 220.8
@40°C/100°F
Kinematic Viscosity ASTM D445 mmÇ/s 10.4 18.9 25.6
@100°C / 210°F
Viscosity Index ASTM D2270 -- 140 143 148
Timken OK Load test ASTM D2509 kg/lb 34/75 34/75 34/75
FZG Gear Scuffing ASTM D5182 Failure >12 >12 >12
test -A/8.3/90 Load Stage
Pour Point ASTM D97 °C/°F -45/-49 -36/-32 -36/-32
Flash Point ASTM D92 °C/°F 227/441 228/442 228/442
- open cup method
API Gravity ASTM D287 -- 35.4 33.4 33.0
Specific Gravity ASTM D1298 -- 0.848 0.858 0.860
@ 16°C /60°F
Pounds per Gallon ASTM D287 -- 7.06 7.14 7.16
Gear Lubricants E17
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Castrol® Alphasyn T™ [REPLACES Castrol SHL Lubricant 150, 220, 460]

The Castrol Alphasyn T gear oil range of synthetic lubricants are based on polyalpha-olefin (PAO) fluids and sulphur/
phosphorus anti-wear additive technology providing outstanding thermal stability and good load carrying capacity.
Application
Alphasyn T is suitable for various applications where a lubricating oil is used under high temperatures, e.g. from
hydraulic systems through to large, slow moving gears. All products in the Alphasyn T range have very low pour
points and excellent viscosity and temperature characteristics,
allowing their use in both low and high temperature applications.
The Alphasyn T range is fully compatible with nitrile, silicone and fluropolymer seal materials. Alphasyn T is also
suitable for bearings and circulatory systems operating at high temperatures.
The Alphasyn T range has been formulated for use in most types of light to medium duty enclosed gear systems, but
should not be used for heavy or shock loaded systems.

Castrol Alphasyn T is a PAO based lubricant that provides good compatibility with seals, paints and mineral oil based
lubricant. Castrol AlphasynT offers the following benefits:
• Good thermal and oxidative stability, providing reliable operation and extended operating life when compared to
mineral oil based products.
• Inherently high viscosity index (VI), making the product suitable for operations operating over a wide
temperature range.
• Good anti-wear and load carrying abilities, minimizing gear wear and prolongs gear tooth life.
• Reduced down time through water separation and demulsification characteristics, resulting in prolonged
lubricant life and increased equipment reliability.
Classifications
Alphasyn T is classified as follows:
• DIN Classification is CL
Alphasyn T grades meet the requirements of:

• DIN 51517 Parts 2
• David Brown Type A
Gear Lubricants E18
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Castrol® Alphasyn T™ [REPLACES Castrol SHL Lubricant 150, 220, 460]

Typical Characteristics
Test Method Units 150 220 320 460

Density @ 15°C ASTM D4052 g/ml 0.87 0.87 0.87 0.87
Kinematic Visc. @40°C ASTM D445 mm2/s 150 220 320 460
Kinematic Visc. @ 100°C ASTM D445 mm2/s 17.8 23.9 31.7 41.8
Viscosity Index ASTM 2270 -- 131 135 138 141
Pour Point ASTM D97 °C/°F -42/-44 -42/-44 -30/-22 -30/-22
Flash Point, COC ASTM D92 °C/°F 271/520 277/531 282/540 285/545
Foam Seq I ASTM D892 mls/mls 10/0 10/0 10/0 20/0
Rust Test ASTM D665B -- Pass Pass Pass Pass
(24 hrs/synthetic
sea water)
FZG fail stage (A8.3/90) DIN 51354 -- 12 12 12 12
Gear Lubricants E19
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Castrol® AP Gear Lubricant

Multi-purpose Lubricant
Castrol AP (all purpose) Gear Lubricant is formulated with high-quality base oils and additives that provide excellent
load-carrying ability, EP properties, wear resistance, oxidation stability and anti-rust, anti-corrosion and anti-foam
properties.
Thermally Stable
Castrol AP Gear Lubricants are multi-purpose, extreme pressure gear oils that are thermally stable and will provide
transmission, differential and other application protection beyond that specified for the current MIL-PRF-2105E and
API GL-5 requirements. This thermal stability extends oil service life and reduces critical component wear.
Castrol AP Gear Lubricants meet the requirements of API (American Petroleum Institute) gear oil classification GL-5
and SAE J2360 (Formerly MIL-PRF-2105E). These multi-purpose gear oils are formulated with high quality base oils
and additives to provide excellent load carrying ability, EP properties, wear resistance, oxidation stability, anti-rust and
anti-corrosion qualities and anti-foam protection.
Castrol AP Gear Lubricants are recommended for make-up and complete refill of most passenger car and light truck
conventional differentials, transmission and steering gears.These multi-purpose, extreme pressure gear oils are now
considered thermally stable and will provide transmission, differential, and other application protection beyond that
specified for SAE J2360 (Formerly MIL-PRF-2105E) requirements. This thermal stability extends oil service life and
reduces critical component wear.
Castrol AP Gear Lubricants are recommended for the following applications:

• SAE J2360
• MIL-PRF-2105E • API Service GL-5
• API MT-1 (80W-90) • American Motors
• Mack Truck GO-J • Chrysler Corporation
• BMW • Clark Equipment Company
• General Motors • John Deere Company
• Dodge • Eaton
• Euclid • Nissan
• Ford Motor Company • Renault
• Volkswagen • Rockwell International
• Navistar
Note: Castrol AP Gear Lubricants meet or exceed other automotive, construction and other heavy duty applications.
Gear Lubricants E20
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Castrol® AP Gear Lubricant

Typical Analysis
Kinematic Viscosity at 40° C, cSt ASTM D445 326
Kinematic Viscosity at 100° C, cSt ASTM D445 31.6
Flash Point, °C (°F) ASTM D92 240(464)
Pour Point, °C (°F) ASTM D97 -27(-17)
Brookfield Viscosity, -20°C, cP ASTM D2983 44,600
20 Hr KRL Shear Test After Shear cSt @ 100°C CEC-L45-20 31.4
% Viscosity Loss -0.66
FZG Gear Scuffing, Pass Load Stage ASTM D5182 12
FZG Gear Wear, mg wt Loss ASTM D4998 13
Gravity, API ASTM D287 31.4
Gear Lubricants E21
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Castrol® EP Gear Lubricant

Castrol EP Gear Lubricants are exceptional quality gear oils that are designed for severe duty applications. Castrol
EP Gear Lubricants offer excellent gear protection and possible extended lubricant usage with periodic checks by
Castrol’s Oil Analysis Program. Castrol EP Gear Lubricants are formulated with selected base oils that are coupled
with an extremely stable sulfur/phosphorous additive package that make them the ideal choice where AGMA EP
type gear oils are recommended.
Castrol EP Gear Lubricants excel in applications demanding outstanding U.S. Steel 224 performance.

Excellent thermal and Enhanced lubricant stability under Longer equipment life.
oxidation stability. all operating conditions. Efficient gear operation.
Minimal viscosity increase. Reduced maintenance cost.
Sulfur/phosphorous package Longer lubricant life.
remains stable at high
temperatures.
Minimal sludge formation.
Excellent Will separate water readily where Reduced maintenance costs.
demulsibility. water contamination is present. Longer equipment life.
Less downtime.
Good corrosion, rust and Reduce catalytic effects of Longer lubricant and equipment
anti-foam protection. corrosion and wear on various life.
system metals. Less maintenance.

• ANSI/AGMA Standard 9005-E02
• DIN 51517 Part 3
• U.S. Steel 224
Gear Lubricants E22
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Castrol® EP Gear Lubricant

Typical Analysis
Test Method 150 (4 EP)

Viscosity @100°F, SUS ASTM D2161 837.4
Viscosity @210°F, SUS ASTM D2161 80.8
Flash Point, °C (°F) ASTM D92 223(435)
Pour Point, °C (°F) ASTM D97 18(-2)
Gravity, °API ASTM D287 26.5
Timken OK Load ASTM D2509 75

Gear Lubricants E23
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Castrol® Syngear™ Lubricant

Castrol Syngear is a premium, synthetic, heavy duty, multi-grade gear lubricant that meets API GL-5 service. Castrol
Syngear provides excellent cold weather performance, outstanding stability under higher than normal operating
temperatures, and substantial load carrying ability for cooler operation and longer equipment life. Castrol Syngear is
ideal for severe service environments and customers who want to extend service intervals.Castrol Syngear Lubricants
will meet or exceed all performance requirements of the following applications:
• API GS-5 • Dana SHAES 429 Rev. A.
• API MT-1 • Dana SHAES 256 Rev. C
• MIL-PRF-2105E • Mack Truck GO-J Plus
• SAE J2360 • International TMS 6816
Castrol Syngear contains 100% synthetic base stocks for outstanding oxidation control and thermal stability for
improved fuel economy and longer equipment life. A premium additive package inhibits rust, corrosion, and wear to
protect against premature bearing failure and gear tooth wear. Excellent shear stability protects against viscosity loss
to safely extend service intervals. Castrol Syngear lubricants are accepted and approved by the Eaton Corporation as
alternatives to their Eaton Roadranger gear oils and acceptable for use in conjunction with the Eaton Roadranger
Extended Warranties.

100% synthetic base stocks. Faster start ups, greater load carrying ability and Longer equipment life.
cooler operation. Fuel economy.
Oxidation minimized through excellent thermal
stability.
Shear, stable base stocks. Viscometric stability under all operating Fuel economy.
conditions. Longer equipment life.
Lower operating temperatures due to increased
efficiency and reduced viscosity loss.
SAE J2360 (Formerly Protection against premature bearing failure. Less down time.
MIL-PRF-2105E). Minimal gear tooth wear under severe operating Longer gear box and axle life.
Certified API GL-5 quality. conditions.
Anti-rust, corrosion, and Further protection for bearings and gears. Longer equipment life.
anti-foam additives and Less down time.
excellent demulsibility.
Gear Lubricants E24
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Castrol® Syngear™ Lubricant

Typical Analysis
Test Method 75W-90 80W-140
Viscosity @40°C, cSt ASTM D445 117 29.2
Viscosity @100°C, cSt ASTM D445 15.0 312
Viscosity, cP @-40°C ASTM D2161 109,000 --
Viscosity Index ASTM 2270 139 139
Flash Point, °C (°F) ASTM D92 204 (399) 218 (424)
Pour Point °C (°F) ASTM D97 -45(-49) -33(-27)
Gravity, ° API ASTM D287 33.4 31.3
Specific Gravity @60°F ASTM D1298 0.8581 0.8692
Pounds per Gallon ASTM D287 7.15 7.24
F
Greases
F
Greases
General Information F2
Important Properties F4
Industry Specifications F5
Product Data
Castrol® Pyroplex® Gold F8
Castrol® Pyroplex® Blue F12
Castrol® Pyroplex® Red F17
Castrol® Pyroplex® Protection ES F20
Castrol® Spheerol® SHL 00 F22

[PREVIOUSLY Castrol SHL 00]
Castrol® Contractor Special F 25
Castrol HD Lithium F 27
Castrol HD Lithium 00 F 28
Castrol Fifth Wheel Grease F 29

Greases F2
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General Information
When heavy-duty equipment requires a lubricant that has staying power, thickness and the ability to provide a seal
between moving parts, a grease is typically recommended.
The National Lubricating Grease Institute (NLGI) defines grease as: “A solid to semi-solid dispersion of a thickening
agent in a liquid lubricant. Additives imparting special properties may be included.” This means that grease is mainly
base oil plus soap or thickener and additives. Each of these grease components is reviewed in depth below:
Thickeners
Grease is usually identified by the type of thickener or soap used in its formulation. Each thickener has several inherent
characteristics that enhance the finished grease product. The following is an explanation of the most common grease
thickeners and their properties.
Note: The temperatures quoted below represent the suggested maximum service temperature for each type of
thickener. This is not the same as the thickener’s dropping point, which is, on average, 100°F higher.
In practice, upper end service temperatures are limited by flash point and oxidation of base oil.
• Sodium Soap: A fibrous thickener that provides natural rust resistance but has poor water resistance. It is
generally associated with poor low temperature properties. A sodium soap is recommended for use in a maximum
temperature range of 200-275°F. This thickener is basically obsolete.
• Calcium Soap (Simple): Calcium soap is known for its smooth structure and excellent water resistance. Its
maximum service temperature is 250°F.
• Calcium Soap (Complex): Calcium complex is still smooth in texture but contains inherent extreme pressure
load-carrying abilities and good water resistance. Its maximum service temperature is 300°F.
• Calcium Sulfonate: This thickener is noted for its excellent rust protection and service temperature that tops
400°F. Its texture is smooth.
• Lithium Soap (Simple): Another smooth-textured thickener, a lithium soap boasts good water resistance and
mechanical stability. Its maximum service temperature is 325°F.
• Lithium Soap (Complex): Like its simple counterpart, lithium complex soap has good water resistance and
mechanical stability but a higher service temperature of 400+°F. Its texture is smooth but slightly stringy.
• Aluminum Complex: A smooth gel with excellent water resistance, shear stability and pumpability. Its maximum
service temperature is 400+°F.
• Clay: A smooth-structured thickener known for its ability to resist melting and excellent water resistance.
• Polyurea: An opaque, slightly mealy thickener, Polyurea has good oxidation and water resistance. Its maximum
service temperature is 350°F.
Greases F3
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General Information
Base Stock
The liquid lubricant portion of a grease can be composed of almost any base oil. A base oil is usually selected for its
low and high temperature performance, oxidation stability and elastomer compatibility. In addition to these
performance characteristics, a base fluid is chosen for the service level and application in which it will work.
The base stock makes up the largest portion of the finished grease and can be a mineral, vegetable, re-refined, partial
synthetic or full synthetic. High viscosity index and oxidation resistance are generally desirable characteristics in a
grease’s base fluid.
Additives
Additives enhance the performance of a finished grease. Additives in grease may be either chemically active or
chemically inert. Chemically active additives are ones that chemically affect the grease’s performance, such as extreme
pressure agents or rust inhibitors. Chemically inert additives affect a grease’s physical properties, like structure or water
tolerance. The most common additives found in grease are anti-oxidants, rust inhibitors, anti-wear agents, extreme
pressure agents and solids.
A premium-performing grease is one that uses top quality additives, a premium base oil and a good thickener. Low
quality grease can seriously impact equipment performance and bottom line results. Research regarding the correct
grease for critical equipment may save money in maintenance and labor in the long run.
Greases F4
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Important Properties
The NLGI has initiated two grease performance areas that define where and how grease can be used. The first relates
to where grease can be used and is outlined below:
• LA and LB: Indicates the grease’s suitability for use in chassis bearings and applications
• GA, GB, GC: Shows the grease’s suitability for wheel bearing applications and the
temperature at which the grease can operate successfully.
A NLGI GC/LB grease meets the highest performance specifications for both chassis and wheel bearing applications.
Category Service Performance

LA chassis Frequent relubrication intervals Oxidation resistant, shear stable and
(>3200 km). corrosion and wear protective.
Mild duty (non-critical
applications).
LB chassis Prolonged relubrication intervals Oxidation resistant, shear stable, and
(<3200 km). corrosion and wear protective, even
Mild to severe duty, high loads, under heavy loads and in presence of
vibration, exposure to water. aqueous contamination.
Temperature range -40 to 120°C.
These specifications are largely directed toward automotive products, and in some instances may not be adequate for
heavy-duty equipment.
NLGI Grades-Greases
NLGI Grade Penetration Description and Typical Use
Number ASTM
000 445-475 Semifluid: Centralized Systems
1 310-340 Very Soft: Grease guns or Centralized Systems
2 265-295 Soft: Grease guns or Centralized Systems
3 220-250 Light: Grease guns
4 175-205 Medium: Pressure guns
5 130-160 Heavy: Grease guns
6 85-115 Bloc: Open Grease Collars
The second performance area relates to the “body” or consistency of the grease. The consistency of the grease is
similar to the viscosity of an oil. Grease consistency is graded from 6 to 000 and is usually found next to the NLGI
indicator. For example, the most widely used grease is a NLGI GC/LB 2.
Greases F5
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There is little standardization for grease testing in the industry, but there are several industry tests that rate a grease’s
performance characteristics. To determine whether a grease can offer extreme pressure (EP) protection, pumpability,
mobility and stay-in-place performance, review the results of these critical industry tests:
Grease Tests
Penetration
The test for penetration is one of the primary quality control tests for the grease industry. Many grease suppliers quote
penetration test results as a performance indicator for their product. Unfortunately, penetration alone simply measures
the consistency of a grease and does not indicate how a grease will perform in a component.
The penetration test involves a one pound cup of grease, held at a controlled temperature, with the air bubbles
removed from it. A weighted cone is dropped into the grease. The depth of the cone immersed in the grease is
measured in millimeters. A range of penetration in millimeters determines the NLGI grade of the grease. The farther
the cone penetrates the grease, the lower the NLGI grade. A grease’s pumpability or mobility characteristics cannot be
predicted from penetration test results.
Timken OK Load
The Timken test measures a grease’s ability to withstand extremes of load and pressure. It is performed under
line-to-line contact with a specific amount of pressure applied to a greased block. The test is run for ten minutes,
and at the end of the test, the block is rated in terms of how much it is scored. A little scoring is considered a pass;
a significant amount of scoring is a fail.
The Timken test is performed with different weighted loads, usually between 10 and 70 pounds. A typical value for
the Timken test is a 40-pound pass. An excellent value for the Timken test is a 70-pound pass. The latter grease
exhibits outstanding extreme pressure protection over standard greases. Greases able to pass the Timken OK Load test
have balanced additive packages containing extreme pressure agents. Maintenance managers using a grease in high
load applications should research Timken test results.
4-Ball Weld
Another test designed to measure extreme pressure properties, the 4-Ball Weld, evaluates point-to-point contact using
ball bearings for better reproducibility and more consistent data. Three greased, rotating balls are placed in a cup and
one stationary ball is on top.
A load of up to 800 kilograms is added to the ball bearings. The test runs for one minute (under load for 10 seconds)
and if the balls keep rotating for the full minute, the grease has passed. If the balls weld together before one minute
has passed, the test shuts down and the grease fails. A typical EP grease will usually weld around 250 kilograms.
Grease with excellent extreme pressure properties can handle a load of 800 kilograms—the highest test load.
Greases F6
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Water Washout
Water Washout, like Penetration, is another widely quoted industry test. But the results are not always valid. In the
Water Washout test, an open-faced bearing is doused with a steady stream of water. However, test results can be
difficult to replicate from different grease suppliers. Water Washout results are quoted in terms of percentage of
grease washout.
Water Spray Off
A much better test for stayability in wet environments is the Water Spray Off test. During this test, a 2- by 4-inch
metal panel is sprayed with a light coating of grease and weighed. Water at 100°F is then sprayed onto the panel at
40 psi. Once the test is complete, the grease that remains on the panel is weighed and results are quoted in terms of
percentage of grease sprayed off.
This is a much more realistic test for heavy-duty grease users for two reasons. First, there is less chance to manipulate
data; therefore, it is a much more reproducible and repeatable test. And second, the test conditions—water being
sprayed at 40 psi— is what many maintenance managers actually face on the job.
US Steel Mobility
Mobility is another test that, in and of itself, does not give grease users a lot of usable information. Its purpose is to
predict pumping ease or difficulty at various temperatures. The US Steel Mobility test uses a packed grease cylinder
with a small capillary at the bottom of the cylinder. Grease is packed into the cylinder and allowed to flow through the
capillary with gravity behind it. Mobility is generally tested at 60°F and measured in grams per minute.
It is safe to assume that grease with good mobility will also have acceptable pumpability, since pressure, not gravity,
will be forcing the grease from the drum to final application. But for a grease to be effective, mobility/pumpability
must be balanced with stay-in-place capabilities. Most greases sacrifice tack and adhesion to have good mobility and
pumpability. Mobility and pumpability information alone will not relay how well the grease will stay in place once in
use or in the presence of water. Mobility numbers should always be quoted alongside water spray off results. As a
norm, mobility of 200 grams/minute at 60°F and water spray off of less than 20 percent is considered very good for
grease. The ultimate grease is one that offers the pumpability of an NLGI 1 grease with the tack and adhesion of an
NLGI 3 grease.
To take the mobility information one step further, it is helpful to have mobility numbers for a full range of ambient
temperatures. For example, a grease can flow at 1,000 grams/minute at 60°F and 0 grams/minute at 20°F. Look for
mobility information on temperatures of 0, 20, 40, 60 and 77°F to get a complete understanding of how a grease will
flow and pump during all temperatures and seasons.
Dropping Point
A grease’s dropping point is the temperature at which the grease changes from a semi-solid to a liquid state. The
dropping point is not the grease’s operating temperature. As a rule of thumb, a grease’s operating temperature is
approximately 100°F to 150°F lower than the published dropping point.
Dropping point is noted when a grease becomes so hot that the oil separates from the soap and runs out of the cup.
Greases F7
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A Note on Compatibility
For years, the heavy-duty industry believed that grease incompatibility resulted primarily from mixing the thickeners in
finished greases. But the additive package, not solely the thickener, is responsible for most incompatibility problems in
a finished grease. If you have ever seen grease run out of a component, the cause is usually not the grease’s thickener,
but the additive chemistry. Certain additives in one grease can chemically attack the soap in another grease, causing it
to soften excessively or “go to soup.” This occurrence is often easily excused as incompatibility due to the type of
thickener with which each grease is formulated, when in reality, it is influenced more by the additive package.
To avoid compatibility problems when switching greases, purge the system completely, if possible, with the new
grease. Once the grease is pumped into the component, monitor it closely. Any compatibility problem will become
apparent very quickly.
There are laboratory tests available that can analyze grease compatibility by measuring the penetration of the mixed
grease at 0, 60 and 10,000 strokes. Compatible greases should experience only minor softening—about one grade on
average. Softening above one grade is not acceptable and the greases should be labeled incompatible. But if greases
have been labeled incompatible, it does not mean that they cannot be used. Thoroughly purge the component with
the new grease. Once the component has been purged with the new grease, continue to monitor it closely and
increase grease service intervals gradually to ensure complete removal of the previous grease.
BINARY GREASE
MIXTURE COMPATIBIL*TY
y
ex
y
ox
te
ox
ex
pl
ex
na
dr
dr
m
pl
pl
)
Hy
lfo
Hy
ay
Co
m
m
Cl
Co
Su
Co
12
12
m
e(
a
inu
um
um
um
re
um
um
m
m
on
hiu
hiu
lyu
hiu
um
riu
lci
lci
lci
lci
di
nt
Lit
Po
Lit
Ca
Ca
So
Lit
Ca
Ba
Ca
Be
Al
Aluminum Complex
Barium
Bentone (Clay)
Calcium
Calcium 12 Hydroxy
Calcium Complex
Calcium Sulfonate
Lithium
Lithium 12 Hydroxy
Lithium Complex
Polyurea
Sodium
COMPATIBLE
BORDERL*NE - Monitor for softening
INCOMPATIBLE - Do not mix!
Please Note:

GENERAL Guideline.

Greases F8
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Castrol® Pyroplex® Gold

Castrol Pyroplex Gold provides the ultimate protection against wear for critical equipment. A semi-synthetic, extreme
pressure grease, Castrol Pyroplex Gold contains more than 20% solids, including 6% molybdenum disulfide, to give
equipment a protective lubricant barrier against wear, even during conditions of high load.
High Loads/Heavy Loads Performance

Castrol Pyroplex Gold is recommended for heavily-loaded pin joints and other components routinely subjected to high
shock loads in extreme conditions. Castrol Pyroplex Gold demonstrates protection against extreme loading, in both
“point” and “line” contact modes. It carries a 70-pound OK load in the Timken Test Method, without the use of
heavy metals such as antimony, lead, barium or chlorinated compounds. Additionally, Castrol Pyroplex Gold’s
outstanding wear protection was further validated after it received the highest possible score (800 kg) in the Four-Ball
Weld Test (ASTM D 2596).

Castrol Pyroplex Gold’s semi-synthetic base stock and specially chosen thickeners allow it to maintain pumpability in
low temperature environments. This ensures that Castrol Pyroplex Gold will reach critical parts at temperatures that
would make other greases too thick to pump. Other greases with high solid content may not be as mobile, subjecting
equipment to accelerated wear and possibly premature failure. US Steel Method results prove that Castrol Pyroplex
Gold easily surpasses competitive greases in mobility during low temperatures. This confirmed mobility makes Castrol
Pyroplex Gold an ideal choice for most equipment with central lubricating systems.
Stayability
Castrol Pyroplex Gold uses Castrol’s trademarked Hydro-Activation™ technology to guard against water spray off.
When exposed to moisture, Castrol Pyroplex Gold’s hydro-activated additive actually causes an increase in tack and
adhesion rather than a softening with eventual washout. The Water Spray Off (ASTM D 4049) test results show that
in comparison to other premium greases, Castrol Pyroplex Gold has outstanding adherence to metal surfaces, which
lowers grease consumption and maintenance costs.
Mobility
Castrol Pyroplex Gold combines the mobility of a typical NLGI grade 1 grease with the staying power and extreme
pressure performance of a NLGI grade 3 grease.
Applications and Recommendations:
• Castrol Pyroplex Gold will excel in multiple bearing applications, sliding applications and high pounding and
loading environments.
Greases F9
1 800 255 4417

Timken OK Load (ASTM D 2509)
Castrol Pyroplex Gold proves its excellent load-carrying capacity by passing the Timken load test with a 70-pound
load. The ability to withstand this load is testimony to Castrol Pyroplex Gold’s ability to maintain a substantial
protective film around critical components, even during high load conditions.
4-Ball Weld Test (ASTM D 2596)

Castrol Pyroplex Gold easily passes the 4-Ball Weld test under the highest load possible (800 kg), which is testimony to
its outstanding extreme pressure performance.
Extreme Pressure Protection Comparison

Four-Ball Weld Method
800
700
Four-Ball Weld Point (kg)
600
500
400
300
200
100
0
Castrol Competitor Competitor Competitor
Pyroplex A B C
Gold
Mobility and Water Spray Off

Castrol Pyroplex Gold boasts excellent mobility through a wide temperature range and still has excellent staying
power as evidenced by this chart. Castrol Pyroplex Gold combines the staying power of a NLGI grade 3 grease with
the mobility of a NLGI grade 1 grease.
ASTM D 4049
Water Spray Off
Test Results
12% 18% 34% 74%

Castrol Competitor Competitor Competitor
Pyroplex A B C
Gold
Greases F10
1 800 255 4417

Field Test Results
Concrete Company
Castrol Pyroplex Gold was used on a front end loader at a concrete company in Pennsylvania. Testing confirmed an
extended grease interval of 100 hours on track/roller applications. In relationship to the amount of work performed,
the truck moved over 400 tons of concrete during ten-hour shifts without having to re-grease. The customer was able
to double grease intervals in roller applications using Castrol Pyroplex Gold. Per ton of concrete and at previous
intervals, the volume and cost of grease are lower than the competitive product at this facility.
Castrol Pyroplex Gold successfully eliminated the dry spots on the rollers, which were a serious complaint and safety
issue. As a result, it is now used on the rollers of every vehicle.
Industrial Company
An industrial customer was chosen as a test site for Castrol Pyroplex Gold due to the severity of the test environment.
Castrol Pyroplex Gold was used to lubricate the most severe, four-bearing applications on a Nitrate Roaster. Ambient
temperatures on two of the trunnion bearings are close to 800°F; they are extremely wet; and all four are in a very
dusty, abrasive environment under heavy loads. The company’s main objectives for testing Castrol Pyroplex Gold was
to reduce operating temperatures and minimize water washout and bleeding.
Lubricating at normal intervals, temperatures were taken prior to lubricating the equipment. Castrol Pyroplex Gold,
with over 20% lubricating solids, can effectively increase tack and adhesion and increase load bearing area, which
reduces unit pressures, operating temperatures and wear.
Castrol Pyroplex Gold successfully lowered operating temperatures by an average of 115°F in 48 hours and 300°F in
six weeks with no bleeding or water washout. In the very harsh environment of battery acid and component
production, Castrol Pyroplex Gold is now being used on the entire Roaster and is being implemented in other
applications.
Castrol Pyroplex Gold is a uniquely formulated, semi-synthetic, aluminum complex grease that excels in heavily loaded
construction, mining, and industrial equipment where extreme operating conditions prevail. Castrol Pyroplex Gold
contains a high level of synergistic solids, including 6% molybdenum disulfide, for outstanding surface adhesion and
added extreme pressure characteristics. Its tough, durable lubricating film will protect all lubricated parts in high shock
loads and boundary conditions.
Castrol Pyroplex Gold’s Hydro-ActivatedTM polymers coupled with the aluminum complex thickener and carefully
selected semi-synthetic base fluids provide excellent “stay-in-place” ability and performance in the presence of very
wet and or high humidity environments. The advanced formulation couples extreme pressure performance and
“stay-in-place” ability in selected applications with outstanding mobility through all seasons. Castrol Pyroplex Gold
(NLGI 2) has assured pumpability in most cold environments, thus eliminating the traditional approach of changing to
a NLGI 1 grade in winter.
Castrol Pyroplex Gold has exceptional extreme pressure and high temperature performance as demonstrated through field
test conditions and the Timken and Four-Ball Weld tests on page F9. In noting the performance characteristics, Castrol
Pyroplex Gold will excel in multiple bearing applications, sliding applications and high loading and pounding
environments.
Greases F11
1 800 255 4417

Typical Analysis
NLGI Grade 1 2
Thickener Type Aluminum Complex Aluminum Complex
Color Gold Gold
Appearance Smooth-Tacky Smooth-Tacky
Test Method Results

1 2
Penetration W60 ASTM D217 330 272

Dropping Point °F. ASTM D2265 500 500
Base Oil Viscosity ASTM D445
SSU @100°F. 700 1,214
SSU @210°F. 78 114.5
cSt @40°C 134.2 232
cSt @100°C 14.6 23
Four Ball Weld ASTM D2596 800 kg 800 kg

LWI ASTM D2596 115 120.2
Scar-mm ASTM D2266 0.40 mm 0.39 mm
Timken OK Load ASTM D2509 70 70
Water Spray-off ASTM D4049 30 11.7
Mobility g/min USS
@77°F. 1810 624
@60°F. 908 305
@40°F. 421 85.2
@20° F. 91 20.8
@0°F. 12.1 1.6
Wheel Bearing Life ASTM D3527 140 hrs. 140 hrs.
Copper Corrosion ASTM D4048 1A 1A
Rust Prevention ASTM D1742 Pass Pass

Greases F12
1 800 255 4417
Castrol® Pyroplex® Blue

Stayability
Castrol Pyroplex Blue maintains mobility while building tack and adhesion when faced with water contamination.
This Hydro-Activated™ technology helps Castrol Pyroplex Blue resist softening and washout when exposed to wet
conditions on a continued basis. Castrol Pyroplex Blue users can expect excellent equipment performance when using
this grease.
Long Bearing Life

The extreme pressure and anti-wear additives in Castrol Pyroplex Blue promote extremely long bearing life. This
translates to less downtime and more profitable operations for users.
Outstanding Lubricant Film Strength

Castrol Pyroplex Blue, in high temperature environments, adheres to metal surfaces and provides a strong barrier of
protection for critical components.
Extended Service Intervals

Because Castrol Pyroplex Blue stays in place, there is less need to add grease, which equals less grease usage and
extended lubrication intervals.

Water Spray Off Test (ASTM D 4049)
Castrol Pyroplex Blue 2 experiences a low 15 percent water spray off as tested in ASTM D 4049. Competitive greases
have as much as 96 percent spray off.
ASTM D-4049 Water Spray Off Test

100
90
80
Percent of Spray Off
70
60
50
40
30
20
10
0
Competitor Competitor Competitor Castrol
A B C Pyroplex
Blue #2
Greases F13
1 800 255 4417

Wheel Bearing Life Test (ASTM D 3527)
The ASTM D 3527 measures the high-temperature performance of a grease in wheel bearings. Castrol Pyroplex Blue
shows exceptionally long bearing life as evidenced by this chart.
ASTM D 3527 Wheel Bearing Life Test

300
270
240
210
180
Hours
150
120
90
60
30
0
A B C Pyroplex
Blue #2
Load Wear Index Test (ASTM D 2596)

Castrol Pyroplex Blue delivers almost twice the level of anti-wear performance when compared to a typical multi-
purpose EP grease as measured by the ASTM D 2596 test.
ASTM D-2596 Load Wear Index Test

100
90
80
Load Wear Index
70
60
50
40
30
20
10
0
A B C Pyroplex
Blue #2
Greases F14
1 800 255 4417

Field Test Results
Construction Company
Castrol Pyroplex Blue was put to the test at a New Jersey construction company. Two new zero-hour front end loaders
were selected for the test. Similar workloads, lubrication intervals, shift changes and ambient temperature ranges
helped to facilitate an equal comparison.
Each grease was reviewed on several key characteristics: grease consumption, pumpability, adhesion, cohesiveness, water
washout, extreme pressure capability, anti-wear protection and service duration. The grease was used to lubricate the
entire machine with special attention given to bucket pins. The front-end loaders were performing high volume stock
piling/loading with normal lubrication intervals. The first phase of the test ran for over 2,000 hours.
At the end of this phase, a second test phase was launched that measured extended service capabilities. The
lubrication interval on each machine was extended one operating shift and grease consumption was compared to the
baseline established in the previous test phase. Castrol Pyroplex Blue emerged as the winner of both test phases for
several reasons. Compared to the premium competitive grease, it took less Castrol Pyroplex Blue to lubricant the
machine. The loader with the competitive grease experienced pin squealing, as a result of no lubrication at 85 hours.
Castrol Pyroplex Blue, at 88 hours, was going strong with no squealing. After breaking down the loader with Castrol
Pyroplex Blue, the bucket pins showed no visible signs of wear after over 2,000 hours of service—a testament to Castrol
Pyroplex Blue’s ability to withstand the most severe operating conditions and seal out dirt and water.
This company is now a firm believer and user of Castrol Pyroplex Blue. They save money using Castrol Pyroplex Blue
because it takes less Castrol Pyroplex Blue to lubricate their machines. Overall, the switch to Castrol Pyroplex Blue has
increased revenue per ton for this company due to a reduction in grease and maintenance costs.
14
Castrol Pyroplex Blue
Competitive Grease
12
10
Pumps of Grease
0
8 24 48 72 88
Lubrication Hours
Greases F15
1 800 255 4417

Castrol Pyroplex Blue is the ultimate lubricant for very wet and performance-challenging on- and off-highway
environments. Castrol Pyroplex Blue’s unique multifunctional solid lubricant additive builds tack and adhesion when
exposed to water saturated environments. When performance is challenged in the presence of water and humidity,
Castrol Pyroplex Blue not only resists softening and washing out, but grows in tack and adhesion with continued
exposure. In high temperature environments, film strength is increased between metal surfaces, and the affinity for
metal surfaces is enhanced. This produces a slippery physical barrier of protection.
Castrol Pyroplex Blue’s enhanced load-carrying ability is coupled with dramatic oxidative characteristics and
high-temperature structural stability for exceptional performance in heavily loaded bearings.

Unique multifunctional, non Better adhesion with Optimal off/on highway and
staining solid film lubricant. improved mobility. industrial performance for
Increased tack in the equipment durability.
presence of water.
Enhanced extreme pressure Bearing life greatly Extended equipment life.
and anti-wear performance. improved.
Lithium complex. Excellent shear stability and Dependable performance
very stable at high under varying conditions for
temperatures. (Note: Drop reduced maintenance costs.
Point.)
Castrol Pyroplex Blue’s environmental impact is reduced through the non-utilization of antimony, barium, lead or
chlorinated compounds.
Greases F16
1 800 255 4417

Typical Analysis
NLGI Grade 1 2
Thickener-Type Lithium Lithium
Complex Complex
Color Blue Blue
Appearance Smooth- Smooth-
Tacky Tacky
/Stringy /Stringy
Test Method Results

1 2
Penetration W60 ASTM D217 325 280
Dropping Point °F ASTM D2265 530 550
4 Ball EP ASTM D2596
Weld Point 500 kg 500 kg
LWI 90 93
4 Ball Scar-mm ASTM D2266 0.33 mm 0.39 mm
Mobility - gsm/min
@77°F 660 410
@60°F 300 170
@40°F 82 55
@20°F 27 14
@0°F 6 2
Water Spray Off ASTM D4049 40.0 18.0
SSU @100°F 750 1150
SSU @210°F 75 115
cSt @40°C 114 247
cSt @100°C 60 24
Wheel Bearing Life ASTM D3527 225 240
Wheel Bearing Leakage ASTM D4290 9.3 1.9
Oxidation Stability ASTM D942 2 2
(psi loss)
Copper Corrosion ASTM D4048 1B 1B
Greases F17
1 800 255 4417
Castrol® Pyroplex® Red

High Temperature Performance
Castrol Pyroplex Red is a high temperature EP lithium complex grease that meets the highest performance standards
of automotive GC-LB (particularly disc brake wheel bearings), fleet, industrial and off-highway applications. Its ability
to withstand extreme high temperatures makes it a particularly good grease for use with disc brake wheel bearings. It
is highly dependable in a variety of machines and applications.
Formulated from selected base stock and containing unique oxidation inhibitors, this grease possesses outstanding
thermal stability. In selecting the extreme pressure and anti-wear package, great care was exercised in choosing only
additives that had temperature characteristics similar to the grease itself. Castrol Pyroplex Red has excellent rust
protection, mechanical stability and compatibility with other greases.
Shear Stability
Castrol Pyroplex Red has the shear stability to stay in grade and in place over long periods of use.
Additive Package
Castrol Pyroplex Red employs top-quality extreme pressure and anti-wear additives. As a result, Castrol Pyroplex Red
can withstand conditions of severe shock and high loads.
Compatibility
Castrol Pyroplex Red has demonstrated excellent compatibility with other greases.

4-Ball Weld (ASTM D 2596)
Castrol Pyroplex Red passes the 4-Ball Weld test with a load of 400 kg.
Timken OK Load
Castrol Pyroplex Red passed the Timken OK Load test with a 60 lb. load.
Mobility (in grams per minute) 1 2

@60°F 600 470
@40°F 378 280
@20°F 120 65
@0°F 16 9
Water Spray Off (D 4049) 75% 55%
Greases F18
1 800 255 4417

Lithium complex Versatility for all types of machinery in Longer equipment life through noted
almost any industry. Versatility of dependability in these applications.
application: i.e., bearings of all kinds,
coupling, gears, etc.
Excellent shear stability No breakdown or run out over long Maintenance cost savings through
(or ability to stay put in a periods of use. dependable lubrication.
bearing).
Storage characteristics are Retains all of its properties in storage, Longer equipment life.
good over long periods of in packing for pre-lubricated bearings, Less overall maintenance costs through
time when required. etc. noted dependability.
Excellent extreme pressure Outstanding service under conditions Less equipment downtime. Longer
and anti-wear package. of high loading and severe shock equipment life and less maintenance
loading. cost.
Typical Analysis
NLGI Grade 1 2
Thickener-Type Lithium Complex Lithium Complex
Color Red Red
Appearance Tacky Tacky
Test Method Results

1 2
Penetration, ASTM D217 314 270
worked @ 77 °F.
Dropping Point, °F. ASTM D2265 502 538
4 Ball EP ASTM D2596
Weld Point 400 400
LWI 53 60
4 Ball Scar - mm ASTM D2266 0.43 0.43
Mobility - gms/min
@60°F. 600 470
@40°F. 378 280
@20°F. 120 65
@0°F. 16 9
Water Spray Off ASTM D4049 75 55
Greases F19
1 800 255 4417

Test Method Results
1 2
SSU @100°F. 900 900
SSU @210°F. 101 101
cSt @40°C 194 194
cSt @100°C 21 21
Viscosity Index 125 125
Water Washout, ASTM D1264 5.1 3.2
% Loss @175°F.
Oil Separation % ASTM D1742 5.3 2.8
Wheel Bearing Life - hrs ASTM D3527 85 100
Wheel Bearing ASTM D4290 3 1.5
Leakage, g
Oxidation Stability ASTM D942 2 1
@ 100 hr, psi loss
Copper Corrosion ASTM D4048 1b 1b
Greases F20
1 800 255 4417
Castrol® Pyroplex® Protection ES

Castrol Pyroplex Protection ES is a specially formulated synthetic lithium complex grease designed for extended service
performance in challenging on-highway applications. Its unique inhibitor additive system provides excellent protection
against rust, oxidation and corrosion. When performance is challenged in severe corrosive environments, Castrol
Pyroplex Protection ES not only resists rust and corrosion, but provides unmatched protection for moving parts,
reducing component wear and promoting longer equipment and lubricant life. Its inherent flow properties across
wide temperature ranges make Pyroplex Protection ES ideal for automatic lubrication systems on mobile equipment.
Castrol Pyroplex Protection ES is an extension of Castrol’s exclusive Hydro-ActivationTM technology coupled with a
lithium complex thickener, tackifiers, corrosion inhibitors, proprietary additives and carefully selected synthetic base
fluids that provides corrosion resistance, extreme pressure performance, and “stay-in-place” ability with outstanding
mobility through all seasons.

Full synthetic. Provides excellent low and high In most climates, the NLGI #2 can
temperature performance. be used year round due to
Oxidation minimized through exceptional pumpability.
excellent thermal stability. Cooler operation carrying ability.
Noted load carrying ability. Longer equipment life.
Longer lubricant life.
Unique inhibitor Provides excellent protection Field corrosion protection assured
additive system. against rust, oxidation and for longer component life.
corrosion in extreme Extended service protection.
environments.
Castrol’s exclusive Better adhesion with outstanding Excellent on-highway
Hydro-ActivationTM mobility. performance for equipment
technology. Increased tack in the presence of durability and extended service.
water.
Extreme pressure Bearing life greatly improved. Extended equipment life.
and anti-wear
performance.
Castrol Pyroplex Protection ES‘ environmental impact is reduced through the elmination of antimony, barium, lead or
chlorinated compounds.
Greases F21
1 800 255 4417
Castrol® Pyroplex® Protection ES

Typical Analysis
NLGI Grade 1 2
Thickener Type Lithium Complex Lithium Complex
Color Light Purple Light Purple
Appearance Smooth-Tacky Smooth-Tacky
Test Method Results

1 2
Penetration ASTM D217 325 280
Worked at 77 °F.
Dropping Point °F. ASTM D2265 550 550
SSU @100°F 1480 1480
SSU @210°F 144 144
cSt @40°C 320 320
cSt @100°C 30 40
Four Ball:
Weld, kg ASTM D2596 400 400
Scar, mm ASTM D2266 0.50 0.40
Water Washout ASTM D1264 10% 3%
Mobillity, g/min USS
@60°F 550 475
@40°F 296 146
@20°F 74 25
@0°F 10 3
Emcor Corrosion ASTM D6138
5% NaCl, 7 days 0,0 0,0
Copper Corrosion ASTM D4048 1B 1A
Oxidation Test ASTM D5483 Greater than 30 Greater than 35
@210°C, min
Wheel Bearing Life, hrs. ASTM D3527 160 160
Wheel Bearling ASTM D4290 3 1.5
Leakage, g
Greases F22
1 800 255 4417
Castrol® Spheerol® SHL 00 [PREVIOUSLY Castrol SHL 00]

Synthetic NLGI 00 Lubricant
Castrol Spheerol SHL 00 is a semi-fluid synthetic (PAO) lubricant that can be used for the lubrication of truck wheel
hub assemblies where minimal leakage is desired and long service life is essential. Castrol Spheerol SHL 00 can help
alleviate oil leakage from wheel seals that can damage brake shoes, increase maintenance costs and affect the overall
safety of the unit. Castrol Spheerol SHL 00 can be utilized in many types of wheel end systems designed for oil and
many systems using conventional greases.
Castrol Spheerol SHL 00 is formulated with a lithium complex thickener for exceptional service life, synthetic (PAO)
base stocks for low and high temperature performance and stability, and is fortified with extreme pressure and
anti-wear additives for extended bearing life. Castrol Spheerol SHL 00 can also be used in certain industrial, quarry,
mining or construction applications where a semi-fluid synthetic lubricant is recommended.
Extended Service Protection

With Castrol Spheerol SHL 00’s incredible staying power, maintenance managers can safely extend lubricant life and
service intervals. Its high/low temperature performance characteristics work to keep the lubricant in service longer,
protecting equipment during extreme temperature conditions.
Wear Protection
Castrol Spheerol SHL 00 contains an additive package that promotes long bearing life and guards against wear, rust
and corrosion. It is fortified with anti-wear and extreme pressure agents that contribute to extended bearing life.

Worked Strokes Worked Penetration mm
1 429
ASTM D 217 Extended Working Test 60 425
10000 406
Castrol Spheerol SHL 00 shows incredible stability due to its formulation. As demonstrated by the test below, even
after 10,000 strokes worked, Castrol Spheerol SHL 00 experiences little softening or change in its physical makeup.
ASTM D217 Spheerol SHL 00

1000
900
Worked Penetra0on (mm)
800
700
600
500
400
NLGI Minimum for 00 grade
300
1 10 100 1000 10000
Worked Strokes
Greases F23
1 800 255 4417

US Steel Mobility
Castrol Spheerol SHL 00 displays good mobility at a wide range of temperatures.
Mobility
US Steel Procedure
200
Mobility (grams/minutes)
150
100
50
0
-20 0 20 40
Temperature (Degrees C)
Castrol Sheerol SHL 00

Mineral Oil Lithium Complex #2
4-Ball Weld
Castrol Spheerol SHL 00 passes the 4-Ball Weld test under a 500 kg load, testimony to its extreme pressure protection.
Load Carrying Ability

ASTM D-2596
500
400
Kilograms
300
200
100
0
4-Ball Weld 4-Ball LWI
Castrol Spheerol SHL 00

Competitive Wheel End Grease
Greases F24
1 800 255 4417

NLGI 00 consistency. Couples the lube advantages of a fluid with Less gear case and wheel seal
the “stay put” characteristics of a grease. leakage.
Synthetic (PAO) base stocks Low temperature mobility and high Extended service protection.
temperature stability.
Lithium complex thickener. Good water resistance, excellent shear stability Assured performance over the life
and very stable at high temperatures. of the lubricant.
High performance additive Bearing life protection against wear, rust, Longer component life.
package. corrosion and high temperatures.
Typical Analysis
NLGI Grade 00
Thickener Type Lithium Complex
Color Blue
Test Method Results

Penetration, ASTM D217 425
worked at 77 °F.
Dropping Point, °F. ASTM D2265 400
@40°C, cSt 460
@100° C, cSt 42.3
Four Ball EP ASTM D2596
Weld Point, kg 500
LWI 110
Four Ball Wear Scar, mm. ASTM D2266 0.40
Rust Prevention ASTM D1743 Pass
Greases F25
1 800 255 4417
Castrol® Contractor Special

Castrol Contractor Special is a lithium complex extreme pressure lubricant containing 3% molybdenum disulfide.
Castrol Contractor Special is formulated to offer high temperature and heavy-duty performance coupled with good
pumpability for applications where a tough, durable lubricating film is needed.
Applications:
• For heavily loaded equipment such as bulldozers, shovels, loaders & off-highway trucks.
• Plain and anti-friction bearings, ball joints, king pins, hinge and bucket pins, heavy-duty chassis lubrication.

Lithium complex Provides lubrication at Extended lubricant usage, longer
elevated temperatures equipment life, reduced
without breakdown or lubrication frequency.
“run out.”
3% molybdenum Offers an outstanding Better productivity and less
disulfide lubricating film that reduces downtime where “boundary
wear. Enhanced retention on lubrication” exists.
lubricated parts.
Excellent film strength Exceptional performance Reduced downtime.
and anti-wear package. under conditions of high Longer equipment life.
loading, severe shock &
Lower maintenance costs.
oscillating motion.
Pumpability plus Readily dispensed from Reduces time and effort to
manual pumps as well as grease the bearings, especially in
automatic systems. cold winter months.
Greases F26
1 800 255 4417
Castrol® Contractor Special

Typical Analysis
NLGI Grade 1 2
Thickener-Type Lithium Lithium
Complex Complex
Color Gray Gray
Appearance Smooth Smooth
Tacky/Stringy Tacky/Stringy
Test Method Results
1 2
Penetration ASTM D217 329 285
Worked @ 77 °F.
Dropping Point, °F. ASTM D2265 530 550
4 Ball EP Weld Point ASTM D2596 400 400
Load Wear Index ASTM D2596 55 54
4-Ball Wear Scar, mm. ASTM 2266 0.4 0.39
Mobility - g/min USS
@77°F. 696 552
@60°F. 400 300
@40°F. 180 110
@20°F. 71 41
@0°F. 15 6
Water Spray Off ASTM D4049 45 27
@ 100 °F., % Loss
SSU @100°F. 700 2,710
SSU @ 210°F. 70 188
cSt @40°C 151 511
cSt @100°C 13 39
Copper Corrosion ASTM D4048 1B 1B
Greases F27
1 800 255 4417
Castrol® HD Lithium
Castrol HD Lithium is a smooth, dark brown lithium 12-hydroxy stearate EP grease formulated in
NLGI 0, 1 and 2 consistencies. It is intended for use on ball and roller anti-friction bearings as well as
conventional sleeve bearings.
Castrol HD Lithium is rust inhibited and has good water resistance and long storage life. The base oils
utilized in the Castrol HD Lithium grease, coupled with an oxidation inhibitor and EP additives, enable
the grease to withstand continuous heavy loads and shock loads.
Typical Analysis
Name HD Lithium HD Lithium

NLGI 0 2
Thickener-Type Lithium 12 Lithium 12
Color Dark Brown Dark Brown
Texture Smooth Smooth
Test Method Results

0 2
Penetration, ASTM D217 370 280
Worked @ 77 °F
Dropping Point °F ASTM D2265 340 370
Base Oil Viscosity
SUS @100°F 2521 1250
SUS @210°F 151 120
cSt @40°C 470 239
cSt @100°C 31 24
Greases F28
1 800 255 4417
Castrol® HD Lithium 00
Castrol HD Lithium 00 grease is a smooth, dark amber colored, lithium 12-hydroxy stearate grease. Castrol HD
Lithium 00 Grease is intended for service where an NLGI 00 grade lithium grease is required, including some
automatic grease systems.
[For Castol HD Lithium 000, CONTACT Castrol tech support at 630-961-6562]
Typical Analysis
Test Method Results
Color Visual Dark Brown

Penetration, Worked @ 77°F ASTM D217 415
Dropping Point °F ASTM D2265 300
SUS @100°F 2630
SUS @210°F 154
cSt @40°C 490
cSt @100°C 32
Greases F29
1 800 255 4417
Castrol® Fifth Wheel Grease

Castrol Fifth Wheel Grease has been designed specifically for fifth wheel applications where stay-in-place performance
is critical under all weather and application conditions.
Fifth wheels typically experience extreme fretting, which is defined as the removal of finely divided metal particles
from rubbing surfaces due to oscillation, sliding or vibration. Castrol Fifth Wheel Grease’s graphite/moly formulation
and high percent of tackifiers give it a true affinity for metal surfaces. The tacky tenacious properties of Castrol Fifth
Wheel Grease, coupled with 10% lubricating solids, further enables this grease to provide outstanding adhesion to
fifth wheels in even the toughest of operating conditions.
Typical Analysis
Test Method Results
Appearance Visual Black/Very Tacky
Penetration, Worked @ 77°F ASTM D217 270
Water Spray Off @ 100°F, % ASTM D4049 <10%
Copper Corrosion ASTM D4048 1B
Mobility, g/min @60°F USS 100
G
Other Fluids
G
Other Fluids
Product Data
Castrol® Aircol® SR G2
[REPLACES Castrol SHL Lubricant 32, 46, 68]
Castrol® Magna® RD G4
[PREVIOUSLY Castrol Rock Drill Oil]
Castrol® Magna® SW D G6
[REPLACES Castrol Way Lubricant]
Other Fluids G2
1 800 255 4417
Castrol® Aircol® SR [REPLACES Castrol SHL Lubricant 32, 46, 68]

The Castrol Aircol SR compressor oil range of premium lubricants are designed for use in rotary screw compressors
and are based on polyalphaolefin (PAO) fluids.
Application
Castrol Aircol SR is suitable for use in oil flooded rotary screw compressors operating under extreme climatic
conditions, harsh environments and severe operating conditions where very high air discharge temperatures (> 100°C)
are experienced.
These oils are also suitable for use in compressor units operating at normal operating conditions, with the maximum
air discharge temperature =/< 100°C, as defined by ISO 6743-3:2003.
For normal operating conditions, these products can be used for extended drain intervals up to 8000 hours.
The Castrol Aircol SR range is fully compatible with nitrile, silicone, polyurethane and fluropolymer seal materials
typically used in compressor units. It is not compatible with butadiene styrene (SBR) or ethylene propylene (EPDM)
seals.

Castrol Aircol SR is a PAO based lubricant offering good compatibility with seals and mineral oil based lubricants and
allowing changeover to Aircol SR without compatibility issues. Castrol Aircol SR offers the following benefits:
• Increased oil service life of typically up to 8000 hours in most systems, depending on the
operating environment.
• Very low deposit-forming tendency, thus extending the service life of filters and separators.
• Outstanding oxidation stability and antiwear performance, providing long lubricant and equipment life.
• Ester-free formulation that eliminates the formation of corrosive acids leading to longer equipment life.
• Excellent water separation characteristics, allowing condensation to readily separate from the oil.This minimizes
the risk of emulsions, which could block the oil separator element.
Classifications
Aircol SR is classified as follows:
• DIN 51506 classification - VDL
• ISO 6743/3 - DAG, DAH and DAJ for rotary air compressors
Aircol SR grades meet the requirements of:

• Atlas Copco 8000 hour oil drain interval
• Kaeser
Other Fluids G3
1 800 255 4417
Castrol® Aircol® SR [REPLACES Castrol SHL Lubricant 32, 46, 68]

Test Method Units 32 46 68 100

Density @ 15.6°C ASTM D4052 g/ml 0.83 0.84 0.84 0.84
Kinematic Visc. @ 40°C ASTM D445 mm /s 32 46 68 100
2
Kinematic Visc. @100°C ASTM D445 mm2/s 6.1 7.8 10.7 14.0
Viscosity Index ASTM 2270 -- 137 137 142 142
Pour Point ASTM D97 °C/°F -54/-65 -54/-65 -54/-65 -48/-51
Flash Point, COC ASTM D92 °C/°F 264/507 264/507 264/507 280/536
Foam Seq I ASTM D892 mls/mls 10/0 10/0 10/0 10/0
Rust Test ASTM D665B -- Pass Pass Pass Pass
(24 hrs synthetic sea water)
RPVOT ASTM D2272 mins 4,500 3,000 3,000 3,000
FZG fail stage (A8.3/90) DIN 51354 -- 8 8 9 9
Other Fluids G4
1 800 255 4417
Castrol® Magna® RD [PREVIOUSLY Castrol Rock Drill Oil]

Castrol Magna RD Range Oils consist of selected mineral oils specially compounded with lubricity fortifiers, corrosion
inhibitors and tackiness additives.
Extreme Pressure Requirements:

Rock drill splines are subject to sliding action under intense pressure. To prevent metal-to-metal contact, a lubricant
must have outstanding extreme pressure characteristics. Exceptionally high extreme pressure ratio of 300,000 pounds
per square inch is one of the many reasons that Castrol Magna RD is so effective in reducing wear.
Tackiness:
Castrol Magna RD contains a tackiness agent that provides excellent adhesive characteristics to drill surfaces.
Rust and Corrosion Protection:

Castrol Magna RD provides rust and corrosion protection of all internal parts of the drills, even during extended idle
periods. Serious rust and corrosion is also prevented in the presence of heavily moisture-laden compressed air. Castrol
Magna RD has a balanced additive package that provides good oxidation stability to minimize oxidation and
gumming of any parts exposed to high temperatures.
Design features and benefits of the Castrol range of high quality rock drill oils include:
• High film strength
• Reduced friction
• Provide a suitable seal between piston and cylinder
• Reduced wear
• Helps maintain maximum percussion efficiency
• Preferentially adhere to metal surfaces and resist blow-off
• Improved protection wear against wear caused by poor lubrication
• Helps maintain operating speed
• Reduced wear, allowing operation in conditions of high or low temperatures
Other Fluids G5
1 800 255 4417
Castrol® Magna® RD [PREVIOUSLY Castrol Rock Drill Oil]

Applications
• Mining
• Quarry
• Construction
• Road work
• Tunneling
• Excavation
Magna RD oils are recommended for companies including Gardner-Denver, Atlas Copco and SIG. However, the
correct grade should be selected against specific equipment and for local operating conditions. Most manufacturers
include selection charts in their handbooks to assist in the selection of the correct grade.
Name Method Units RD46 RD100 RD150 RD220 RD320 RD460

ISO Viscosity Grade 46 100 150 220 320 460
Density @ 15°C/59°F ASTM D4052 g/cm3 0.88 0.89 0.89 0.89 0.90 0.90
Kinematic Viscosity ASTM mm2 46 100 150 220 320 460
@ 40°C/104°F
Kinematic Viscosity ASTM D445 mm2 6.8 11.2 14.7 18.7 24.2 30.5
@ 100°C/212°F
Pour Point ASTM D97 °C/°F -21/-6 -18/0 -15/ 5 -15/ 5 -12/10 -9/16
Flash Point, ASTM D92 °C/°F 220/428 230/446 240/464 260/500 255/491 255/491
- open cup method
[For Castol Magna RD 68, CONTACT Castrol tech support at 630-961-6562]

Other Fluids G6
1 800 255 4417
Castrol® Magna® SW D [Replaces Castrol Way Lubricant]

Castrol Magna SW D is specially formulated for the lubrication of slideways on machine tools. These oils are fortified
with selected oiliness, extreme pressure additives and a special material to impart tackiness and adhesiveness.
Magna SW D lubricants are noted for their ability to overcome the stick-slip motion ordinarily associated with slow
moving tool parts. They reduce machine tool carriage chatter and possess the necessary adhesive characteristics to
prevent squeezing out of the lubricant.

Castrol Magna SW D offers the following user benefits:
• Outstanding demulsifying properties to help prevent soluble oil emulsions on plastic slideway surfaces.
• Avoids downtime and expensive slideway repair or replacement.
• Exceptional resistance to stick slip – helps to ensure highly accurate and repeatable machining.
• High quality output is maintained.
• Protects metals against staining and corrosion.
• Oil-wetted surfaces remain in good condition.
• Avoids downtime and expensive slideway repair or replacement.
• Highly filterable – filters in oil supply remain unblocked
Typical Analysis
Name Method Units 32 68 100 150 220
Density @ 15°C / 59°F ASTM D4052 kg/m³ 870 880 890 890 890
Kinematic Viscosity ASTM D445 mm²/s
@ 40°C/104°F 32 68 100 150 220
@ 100°C / 212°F 5.4 8.7 11.1 14.5 19.2
Viscosity Index ASTM D2270 -- 102 99 98 98 98
Flash Point ASTM D92 °C/°F 206/403 232/450 232/450 232/450 249/480
- open cup method
Rust test ASTM D665A pass pass pass pass pass
- distilled water (24 hrs)
Rust test ASTM D665B pass pass pass pass pass
- synthetic seawater (24 hrs)
Copper corrosion ASTM D130 Rating 1b 1b 1b 1b 1b
(3 hrs@100°C/ 212°F)
Brugger test DIN 51347 N/mm2 -- 44 -- -- --
Four Ball Wear test ASTM D2266 mm 0.3 0.3 0.3 0.3 0.32
Wear Scar Diameter (40 kgf/75°C/1200 rpm/1 hr)
Four Ball Weld Load test ASTM D2783 kgf 170 180 180 190 200
- Weld Point
Stick-slip ratio Cincinnati Ratio 0.74 0.74 0.74 0.74 0.74
Lamb test
Cincinnati Lamb -- -- P-53 P-47 -- -- P-50
Specification
H
Services
H
Services
Castrol® Labcheck® Next Generation H2
Castol® HD Focus Newsletter H6
Castrol® Training Video:

Truck Lubrication “Best Practices” H7
Castol®/Des-Case Partnership H8
Castol® Oil Dispensing Containers by Oil Safe ® H9
Castrol® Equipment Program H10

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The Future of Oil Analysis Technology Convenient Online

Functionality
For generations, used oil analysis has helped enhance the performance and extend the
lifespan of critical machinery around the globe. Today, it’s the most widely used form of Directly from the Castrol
proactive maintenance technology in the world. In fact, monitoring lubricant conditions Labcheck Next Generation
within the internal environment of machinery is the single-most cost-effective method home page, you can:
for extending lubricant drain intervals, preventing catastrophic failure and increasing the • Locate sample information
lifespan of vital equipment. using simple “search”
functions
Castrol® Labcheck® Next Generation represents the future of oil analysis technology. At the • Spot items that require
heart of this new program is a cloud-based application that provides the tools and technology immediate attention
needed to get accurate test results and actionable data faster and easier than ever before.
• Chart samples by severity
Castrol’s mission is to provide the most comprehensive, responsive and intuitive oil analysis • Track the samples from
service in the industry. This innovative program — and the service representatives behind it each worksite
— embody a renewed commitment to each and every Castrol customer: Labcheck Next • Review turnaround times
Generation is designed to help you streamline your workload … and simplify your job.
• Monitor first signs of
critical wear
Virtually any piece of equipment that has a lubricating system is a candidate for oil analysis.
In fact, all service and maintenance managers in construction and mining, as well as
on-road and off-road fleet managers, will see substantial benefits from the tools and
features engineered into Castrol’s Labcheck Next Generation.
By offering clear, analytical data and professional recommendations, Castrol Labcheck
Next Generation oil analysis program saves time and effort, enabling users to:
• Identify and measure lubricant contamination
• Assess equipment conditions
• Prevent breakdowns and minimize downtime
• Maximize component lifespan
• Reduce fuel and oil consumption and decrease operational costs
• Eliminate unnecessary overhauls, in-service failures and field repairs
• Establish optimal service schedules
Redesigned with easy-to-use features and helpful shortcuts, Labcheck Next Generation is
the most advanced, intuitive used oil analysis program in the industry. It performs a variety
of measurements, helping to save real dollars in maintenance, repairs and unscheduled
downtime. Sample analysis is completed within 24-48 hours of sample receipt at the
laboratory, and critical fleet information is available online 24 hours a day.
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A Closer Look at Tests

Core Tests
Along with identifying fluid properties and detecting contaminants, our core tests provide an
overall picture of the health of your equipment. The seven core tests include:
1. Wear Metals
Wear metals are tested to help locate premature wear and component risk. Labcheck Next Generation wear metal tests look
for an abnormally high presence of:
• Silver (Ag) • Copper (Cu) • Nickel (Ni) • Other metallic elements,
• Aluminum (Al) • Iron (Fe) • Lead (Pb) monitoring a total of
• Chromium (Cr) • Molybdenum (Mo) • Tin (Sn) 21 distinct metals
2. Contaminant Metals
Contaminant metals are monitored in each sample to detect contamination of the fluid in specific compartments. Fluid
contamination can cause components to lose efficiency.
3. Viscosity
Viscosity is tested to detect a change in the oil’s fluid properties. High viscosity promotes overheating in equipment, restricted
oil flow, accelerated wear, impeded low temperature operation and increased friction. Low viscosity promotes overheating,
metal-to-metal contact, accelerated wear and increased lubricant leakage. Changes in viscosity can be the result of other
problems in the sampled compartment.
4. Fuel Dilution
Used oil is tested for the presence of unburned fuel. Using oil diluted by fuel can lead to rapid and catastrophic component failure
due to reduced viscosity and film strength, as well as increased wear/ and the possibility of a fire hazard.
5. Soot
Soot can cause a host of problems, including:
• poor engine performance • increased wear • deposit and sludge • clogged filters
• decreased fuel economy • shortened fluid life formation • increased operating costs
This test measures the soot content of used engine oils and flags every sample containing 5% soot or higher.
6. Glycol (Antifreeze)
Antifreeze in any compartment other than the cooling system is a critical problem and can lead to rapid and catastrophic
component failure. This test looks for and reports the presence of glycol in components.
7. Water
This test looks for the presence of water, performing moisture checks for coolant leaks or condensation formation. Water
contamination can promote acid formation, which can cause components to lose efficiency.
Services H4
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A Closer Look at Tests

Optional Tests
When specific problems are detected, more detailed information may be required. Labcheck
Next Generation “Optional” tests provide these details. These tests include:
1. Oxidation & Nitration

Excessive oxidation can cause increased wear, decreased engine performance, shortened
equipment life, deposits, oil-filter plugging, increased oil viscosity, corrosion of metal parts,
increased acidity in oil and restricted oil flow. Heat and oxygen in oil can cause it to break
down. Low crankcase oil temperatures accelerate the rate of nitration. By-products cause
accelerated oil thickening, formation of acidic by-products, increased cylinder and valve train
wear, combustion-area deposits, increased acidity in oil and accelerated sludge formation.
Our oxidation & nitration test looks for evidence of all these elements, including the presence
of nitrogen by-products, which can accelerate oil breakdown.
2. Acid Number
Increases in the acid number of a fluid may be caused by oxidation, nitration or contamination.
The acid number can determine the serviceability of a lubricant in specific applications. A high
acid number may indicate corrosion of metallic components, oxidation, oil degradation and
additive depletion.
3. Base Number
Engine oil usually begins with a relatively high base number that decreases during use — this is an
important factor in establishing oil drain intervals. By monitoring the base number, the potential for
oil degradation, increased wear and corrosion of metal parts can be detected.
4. Particle Counting (hydraulic, turbine, and transmission fluids)

This test measures the cleanliness of an oil by determining the level of contaminants. Utilizing two extremely accurate
methods, particles over two microns in size can be detected. By closely monitoring the particle counts in a fluid,
maintenance professionals can detect wear-causing abrasion at the onset and correct conditions that can cause the
level of particulate matter to increase.
5. Ferrography
This test quantifies larger particles that cannot be seen by standard used oil analysis equipment and can correlate
them to a problem in the system. Ferrography is typically run for forensic investigative measures to identify the origin
and nature of wear or failure mode.
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Test Packages
Labcheck Next Generation also offers standardized “packages” or combinations of Reduce your costs and
routinely performed tests. These consist of tests that the lab can perform in volume, maximize your equipment
so significant savings are realized when a test “package” is selected. Your Castrol sales life with Castrol Labcheck
rep can assist you in selecting the appropriate combination of tests when you begin Next Generation.
your program. The following chart outlines Labcheck Next Generation test packages. Make Labcheck Next
Generation part of your
ENGINE TESTS long-term maintenance
PACK AGE DESCR IPTION METALS FD SOOT OX NTR V100 V GRADE W% GLY TBN 4739 LEMS program. If you manage
9904EB Engine Basic • • • • • • • • •
a maintenance operation
9904ES Engine Standard • • • • • • • • • •
9904EP Engine Premium • • • • • • • • • • or a fleet of heavy-duty
NON-ENGINE TESTS equipment, large or small,
PACK AGE DESCR IPTION METALS V100 V40 V GRADE W% GLY TAN PQI the Labcheck Next
9904NEB Non-Engine Basic • •* •* • • •
9904NES Non-Engine Standard • •* •* • • • •
Status:
Analysis Report
on Apr 11 2014
Generation used oil analysis
9904NEP Non-Engine Premium • •* •* • • • • •
Analysts, Inc. | ISO 17025 Accredited |
Phone: 800-241-6315
BP Lubricants USA Inc.
John Gebhard
3385 Martin Farm Road, Suwanee, GA, 30024
Page: 1
program can save you time,
energy and money — lots of
1500 Valley Rd
Wayne, NJ, 07470
HYDR AULIC TESTS

Unit ID: M01-0142 Unit Worksite: FAIRFAX MOBILE Comp. Ref. NO.: 4593731
Component Type: ENGINE Component: ENGINE
money. If you’re ready to

Unit Manufacturer and Model: Caterpillar 773B Oil Type: CASTROL HYPURON 15W40
PACK AGE DESCR IPTION METALS V100 V40 V GRADE W% TAN PC KF

Component Manufacturer and Model: Caterpillar 773B Component Serial Number: 63W02153
Maintenance Recommendations for Lab No. 201404220531 Reported On: Apr 23 2014
From: Luck Stone - FAIRFAX MOBILE
9904HYB Hydraulic Basic • •* •* • •

unleash the power of
Test results are acceptable. No corrective action indicated.Resample at normal interval.
9904HYS Hydraulic Standard • •* •* • • • Sample Frequency Report
9904HYP Hydraulic Premium • •* •* • • • • Analysts, Inc. 3385 Martin Farm Road, Suwanee, GA, Atlanta, 30024
Page 1 of 15
Labcheck Next Generation,
give us a call and we’ll help
Phone: 800-241-6315 Web: analystsinc.com
BP Lubricants USA Inc. - John Gebhard Report Date: May 07, 2014
NATUR AL GAS ENGINE TESTS

1500 Valley Rd, Wayne, NJ, 07470
SPECTROCHEMICAL ANALYSIS IN PARTS PER MILLION
you get started.

EVAL ID Luck Stone - FAIRFAX MOBILE
RMASTER
Molybdenum
Phosphorus
Magnesium
CENTREVILLE, VA
Potassium
Chromium
Aluminum
Vanadium
Antimony
Sample
DESCR IPTION METALS OX NTR V100 V GRADE W% GLY TAN TBN 2896
Titanium
PACK AGE
Calcium
Sodium
Copper
Barium
Silicon
Nickel
Boron
Silver
Lead
Drawn
Zinc
Iron
LAB NO.
Unit Component Manufacturer Model Interval Last Spld
Tin
0531 20 <1 1 2 M01-0125

3 5 <1 <0.1 <1 BACK 103
21 DIFFERENTIAL
8 <10 <5 1025 1256 Caterpillar
2457 <10 11 <30 <1 775D
04/11/14 90 07/11/2013
M01-0125 COOLING
59 SYSTEM 1357 Caterpillar 775D 90 01/16/2014
• • • • • • •
0684 28 <1 1 <1 2 16 <1 0.1 <1 19 5 <10 <5 1122 2628 <10 9 <30 <1 06/17/13
9904NGB NGE Basic 6518 10 <1 <1 <1 M01-0125

1 11 <1 <0.1 <1 17ENGINE
B 75
HYDRAULIC
4 <10 <5 1121 1294 Caterpillar
2516 <10 9 <30 <1 3412
06/21/12
775D
90
90
01/16/2014
07/11/2013
5101 50 1 1 1 M01-0125
3 324 C 1 0.2 <1 5 29 7 <10 <5 900 1122 Caterpillar
2173 <10 11 <30 <1 11/28/11
LEFT FRONT WHEEL 775D 90 01/16/2014
• • • • • • • •
M01-0125 1077 Caterpillar 07/19/11
NGE Standard
0506 24 1 1 1 2 294 D 1 0.8 <1 5 45 7 <10 <5 881 2051 <10 11 <30 <1
9904NGS 0690 30 <1 1 3 M01-0125

7 416 D <1 0.1 <1 17LEFT
B REAR
49 PLANETARY
12 <10 <5 925 1082 Caterpillar
2039 <10 44 <30 <1 775D
02/21/11 90 07/11/2013
M01-0125 RIGHT FRONT WHEEL Caterpillar 775D 90 01/16/2014

SAMPLE INFORMATION PHYSICAL TEST RIGHT
RESULTS
• • • • • • • • •
M01-0125 REAR PLANETARY Caterpillar 775D 90 07/11/2013
9904NGP NGE Premium LAB NO.

MI/HR
Unit
MI/HR
Oil
Oil
Add
M01-0125
FLTR
CHG
Oil
CHG
Viscosity
100 °C
Visc
Grade
Soot
STEERINGOX NTR GLY
Test
WaterCaterpillar
%
Fuel
%
TBN
D4739
775D 90 01/16/2014
M01-0125 TRANS-AUTO Caterpillar 775D 90 01/16/2014

0531 28248 314 0 Y S 14.4 40 0.2 19 10 NEG <0.1 <1.0 5.05
M01-0126 BACK DIFFERENTIAL Caterpillar 775D 90 08/09/2013
0684 27934 560 0 Y C 15.2 40 0.3 22 11 NEG <0.1 <1.0 5.16
M01-0126 COOLING SYSTEM Caterpillar 775D 90 05/03/2013
Labcheck Next Generation

6518 27632 258 0 yM01-0126
S 15.0 40 0.1 13
DIFFERENTIAL 7 NEG <0.1Caterpillar
<1.0 775D 90 01/13/2003
5101 27374 579 yM01-0126

C 11.7 B 30 ENGINE
0.4 18 10 NEG <0.1Caterpillar
>10.0 C 775D 90 12/20/2013
0506 27086 291 yM01-0126

S 12.7 40 HYDRAULIC
0.3 19 10 NEG <0.1Caterpillar
<1.0 775D 90 08/09/2013
yM01-0126 LEFT FRONT

18 WHEEL10 <0.1Caterpillar 775D 90 08/09/2013
Test Packages
0690 26795 281 C 13.0 40 0.3 NEG <1.0
M01-0126
Notice: This analysis is intended as an aid in predicting mechanical LEFT REAR
wear. Test results, maintenance recommendations PLANETARY
and accuracy are affected by customer-provided samples, Caterpillar
equipment identification and maintenance history. No 775D 90 08/09/2013
guarantee, expressed or implied, is made against failure of this piece of equipment or a component thereof. The ultimate responsibility for the maintenance of this piece of equipment and all of its components is the responsibility of the
equipment owner. M01-0126 REAR AXLE Mack DM690 90 01/14/2003
N/R = Test not performed © Copyright 2012, Analysts, Inc.
M01-0126 RIGHT FRONT WHEEL Caterpillar 775D 90 08/09/2013
M01-0126 RIGHT REAR PLANETARY Caterpillar 775D 90 08/09/2013
M01-0126 STEERING Caterpillar 775D 90 08/09/2013
M01-0126 TRANS-AUTO Caterpillar 775D 0 02/23/2007
Sample UOA Report M01-0126
M01-0128
M01-0128
M01-0128
TRANSMISSION - AUTOMATIC
BACK DIFFERENTIAL
COOLING SYSTEM
ENGINE
Caterpillar
Caterpillar
Caterpillar
Caterpillar
775D
773B
773B
773B
0
90
90
08/09/2013
01/06/2014
03/27/2014
03/27/2014
M01-0128 HYDRAULIC Caterpillar 773B 90 03/27/2014
M01-0128 LEFT FRONT WHEEL Caterpillar 773B 90 01/06/2014
M01-0128 LEFT REAR PLANETARY Caterpillar 773B 90 01/06/2014
M01-0128 RIGHT FRONT WHEEL Caterpillar 773B 90 01/06/2014
M01-0128 RIGHT REAR PLANETARY Caterpillar 773B 90 01/06/2014
M01-0128 STEERING Caterpillar 773B 90 01/06/2014
Sample Management Report
Getting Started Is Easy

Reach one of our knowledgeable sales representatives by contacting
Castrol toll-free at 1-888-CASTROL (1-888-227-8765).
For Technical Support

The Castrol Labcheck Support Desk provides industry-leading program
and technical support. The support desk can be reached toll-free at
1-866-LABCHECK (1-866-522-2432) from 7:00 am - 6:30 pm CST.

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GUIDE TO HEAVY DUTY PRODUCTS AND SERVICES

SAE Engine Oil Viscosity Grades

Important Engine Oil Properties

Background & Properties www.castrol.com/GPS

Background & Properties www.castrol.com/GPS

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Wear Protection in the Presence of Soot

API CK-4 Engine Tests

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API CK-4 Pass/Fail Criteria:

Caterpillar Oil Aeration Test (COAT) ASTM D8047

API CK-4 Pass/Fail Criteria:

Background & Properties www.castrol.com/GPS

API CK-4 Pass/Fail Criteria:

Mack T-12 ASTM D7422

API CK-4 Pass/Fail Criteria:

Mack T-13 ASTM D8048

API CK-4 Pass/Fail Criteria:

Background & Properties www.castrol.com/GPS

API CK-4 Pass/Fail Criteria:

Cummins ISB ASTM D7484

API CK-4 Pass/Fail Criteria:

Sequence IIIF ASTM D6984

Background & Properties www.castrol.com/GPS

GM 6.5 Roller Follower Wear Test (RFWT) ASTM D5966

API CK-4 Bench Tests

Noack or Volatility Bench Test ASTM D5800

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API CK-4 Pass/Fail Criteria:

Kinematic Viscosity/SAE J300 ASTM D445

API CK-4 Pass/Fail Criteria:

High Temperature Corrosion Bench Test (HTCBT) ASTM D6594

API CK-4 Pass/Fail Criteria:

Background & Properties www.castrol.com/GPS

Test temperature: 100° C

API CK-4 Pass/Fail Criteria:

High Temperature High Shear (HTHS) Viscosity Test ASTM D4683

API CK-4 Pass/Fail Criteria:

API FA-4 Pass/Fail Criteria:

Background & Properties www.castrol.com/GPS

Sooted Oil Mini-Rotary Viscometer (MRV) ASTM D6896

Elastomer Compatibility Test ASTM D7216

Background & Properties www.castrol.com/GPS

Test length: 20 days (336 hours)

API CJ-4 Pass/Fail Criteria:

Nitrile +5/-3 +7/-5 +10/-R +10/-R

Other OEM Specifications

Cummins CES 20086

Cummins CES 20081

Cummins CES 20078

Background & Properties www.castrol.com/GPS

Detroit Diesel Power Guard 93K223

Detroit Diesel Power Guard 93K218

Detroit Diesel Power Guard 93K214

Mack VDS 4.5

Mack EO-O Premium Plus ‘07

Mack EO-N Premium Plus

Background & Properties www.castrol.com/GPS

The API Service Symbol