Castrol provides you with the the tools to
help make your business more successful
Big Honkin’ Truck
Makeover Contest Winner
Castrol Grease Keeps
Trucks On the Road
into your lubricants,
and the heavy-duty
Synthetic Transmission Fluid Proof Positive for marketplace
Lowers Operating Temperatures Castrol Trans-C 30 Volume 1 • 2009
Fuel Economy Solutions Castrol Tection Extra Helps
Stretch Maintenance Dollars
Castrol Lube Advisor
iT’S MORE THAn juST OiL. iT’S LiquiD EnGinEERinG. TM
Latest Big Honkin’ Truck Makeover Contest Winner
BP Autran Syn 295 Lowers Operating Temperatures
Information Tool Helps With Lubricant Recommendations
Fuel for Thought
Hit the Road With Castrol Grease
9 Castrol Trans-C 30
Stretch Maintenance Dollars With Castrol Tection Extra
VA Students Get Rocked
16 News & Events
About BP Lubricants USA Inc.
BP Lubricants USA Inc. markets premium Castrol lubricants and business-building programs directly and through distributors to
independent lube operators, service providers, on- and off-road fleets, new car dealers and leading retailers. Our line of diesel
engine oils includes Castrol® Elixion®, Castrol® Hypuron™ and Castrol® Tection™ Extra, as well as Castrol® Fifth Wheel Grease.
To find out more about Castrol products and programs, please call 1-800-777-1466 or log onto www.castrol.com/us.
A Little Creativity Lands W
hen Don Wolford
of Greencastle, Penn.
bought his 1977 900A
Kenworth truck more than a year
ago, his intent was for the truck
Driver Top Prize to be his “fixer upper”. Never have
truer words been spoken; however,
Wolford could never have foreseen
2008 Big Honkin’ Truck Makeover Contest Winner Selected the course of events that led to his
A man with truck driving in his blood,
Wolford has been in the driver’s seat of
a big rig for more than 2 decades, and
he has logged more than 3 million
miles in his career. He covers
approximately 140,000 miles a year,
mainly hauling general freight up and
down the East coast.
“My Grandfather drove the big trucks,
and for me it was the only thing I ever
wanted to do,” said Wolford.
Wolford is one of the fortunate people
who loves his job enough to make it
his hobby as well. Not only does he
drive a truck Sunday to Friday as part
of his business; he purchased a 30-year
old model to fix up in his free time.
At least that was his plan, until he
spotted an advertisement for Castrol
Tection Extra’s Big Honkin’ Truck
volume 2 • 2008 1
“I saw an ad for a contest to win a $50,000 truck makeover Wolford received a letter in early December 2007 stating
and decided to enter,” explained Wolford. “I wrote an essay, that he was chosen as one of the contest’s three finalists.
submitted it with pictures, and did not think much more Wolford decided at that point that he was in this contest
about it. About a month and a half later, I received a letter to win it.
stating my Kenworth was one of the top three finalists for
“Part of the final judging was determined from online
the makeover. I couldn’t believe it!”
votes,” said Wolford. “My wife Maria contacted our local
Wolford entered Castrol Tection Extra’s Big Honkin’ Truck newspaper, which did a story about the contest, our truck,
Makeover contest which advertised a grand prize of a and the need for votes. The article told people how and
$50,000 truck makeover. The makeover was performed where to vote online.”
by The Chrome Shop Mafia and 4 States Trucks and
Wolford then packed up his two daughters and his wife and
included an overhaul to the interior, exterior, and
made the trip to Louisville, KY for the Mid-America Truck
communication system of the truck. The contest was
Show, March 27-29. Once again, the family showed their
open to owner/operators of Class 6-8 trucks. A contestant
intense desire to win the contest. They wore matching
must submit an essay of no more than 150 words describing
T-shirts and distributed pencils, flyers, and Kenworth
the dire condition of his or her truck, the need for its
giveaways in an effort to solicit votes for Wolford’s truck.
makeover, and why he or she is worthy of the top prize.
Wolford and his daughters even made a YouTube video
A color photograph must accompany the entry and could
that asked the public to help improve his life and business
be sent online or by mail. Entries were reviewed and scored
with a vote for his truck. In the end, the family’s hard work
by an independent panel of judges on the following
was rewarded when Wolford was named the winner at
criteria: Originality and creativity of the essay, relevance
show’s closing. It was a dream come true.
of the essay to the contest’s theme, and photographic
evidence of the truck. Three finalists were chosen from “We went to the show to win, and we wanted to win,”
all the qualified entries received by the contest deadline. stated Wolford.
The Grand Prize winner was chosen from votes received
Now the real fun began. Wolford was put in touch with the
online and at the Mid-America Trucking Show.
truck makeover specialists from 4 States Trucks, Inc., home
Wolford’s essay was unique because it used titles of old of the Chrome Shop Mafia. Castrol has teamed with “The
country songs to describe the condition of his big rig. Boyz” from the Mafia for its last two makeovers and the
The song titles were mostly from the 1960s and 1970s results were nothing short of amazing.
and were ones with which truck drivers would be familiar.
“King of the Road”, “That Endless Black Ribbon”, and
“Movin’ On” were some of the titles used to describe
Wolford’s Kenworth and why it was worthy of a makeover.
“Although we are involved in the makeover planning Wolford’s upgraded Kenworth was unveiled to him this
process, we like to give the Chrome Shop Mafia a summer, and seen by the public for the first time at the
great deal of creative license to do what they do best,” Great American Trucking Show in Dallas, TX in late August.
said Tracy Drelich, Assistant Promotions Manager for the Wolford’s first impression of the truck was how much
contest’s sponsor BP Lubricants USA, Inc. “Their “badder” it looked.
transformations always exceed our expectations and
“My favorite part of the makeover is the extended hood. I
Don Wolford’s Kenworth was no exception.”
was surprised by the blue color, but really like it. My wife
Wolford spoke with Chrome Shop Mafia’s Don Bryan and I have nick named it ‘Red, Hot & Blue’ in a tribute to its
Martin about his truck’s renovations and asked him to colors and a restaurant we visited in Missouri. This is a truly
incorporate his love of 1970s muscle cars into the makeover. one-of-a-kind Mafia creation, and it was all made possible
The Boyz got to work on the rig by dismantling it and by the folks at Castrol,” said Wolford.
cleaning up more than 30 years of rust and wear. It was
Wolford wanted to showcase his upgraded truck and thank
given a custom paint job that featured racing stripes that
the people of his community that voted for him. He and his
extended from the hood to the fenders. The hood was
family worked in conjunction with his local Travel Centers of
extended more than 8 inches to make the overall look long
America truck shop to set up their own “truck show” for
and low. The Mafia added lighting accessories including:
Red, Hot & Blue. Castrol donated some giveaways,
stainless battery and tool boxes, 6” chrome exhaust pipes, a
Wolford’s daughters received Castrol T-shirts, and several
drop visor, 22” chrome bumper, and stainless air filters from
hundred people stopped by to see the prize-winning truck.
sponsors Grote Industries and Your Truck Shop. They even
For a self-proclaimed 100% truck driver, this has been one
fabricated some parts in the 4 States Truck shop.
Continental Tire North America supplied new tires and
wheels, made available by Alcoa Wheels. Go Green Fuel “Castrol has been wonderful to me and my family. This has
Systems provided a hydrogen enrichment system that will been an amazing experience, and we have had a lot of fun.
help the environment by decreasing emissions and improve We are so excited about the upgraded truck, and I look
Wolford’s bottom line by increasing MPG. Plush leather seats forward to driving it in my free time.”
from National Seating were installed, and the dash, floor,
A gallery of pictures, video of the makeover, updated contest
headline, and sound system also received a complete
information, and Castrol Tection Extra product information is
upgrade. For the ultimate in comfort, his sleeper was
available at www.castroltruckmakeover.com.
converted to a walk-through from crawl access.
volume 2 • 2008 3
BP Autran Syn 295
Controlled Field Tests
Proof positive that synthetic ATF prolongs component
life and saves maintenance dollars
ynthetic fluids have long been touted for their ability to remain
stable at high operating temperatures. This means that as operating
or ambient temperature rises, the synthetic fluid will not breakdown
or excessively thin, which would expose the component to damaging
wear. In theory, the superior chemical make-up of a synthetic lubricant
should allow a component to run at a cooler temperature than one using
a mineral-based fluid. BP Lubricants USA Inc. recently put this theory to
the test in a city transit bus and refuse truck fleet with the synthetic
automatic transmission fluid (ATF) BP Autran Syn 295.
“We have felt that synthetic lubricants should allow transmissions to run
cooler than ones using mineral based products should,” said Rich Gapinski,
BP Lubricants Driveline & Ancillaries Technical Services Manager. “There have
been some experiments to prove this in the laboratory, but we decided to do
a field study to generate data to support this theory.”
FiELD TEST #1, CiTy TRAnSiT BuSES
BP Lubricants began its test with a 40-foot long city transit bus that was
equipped with an Allison B400R automatic transmission and Cummins diesel
engine. Two thermocouples were added to the bus to measure fluid
temperatures. A data-logging unit with interface to vehicle data recorded
transmission temperatures, engine speed, gear position, miles per hour, and
ambient temperatures. The bus was operated for 4 hours, or until it reached
its highest transmission temperature, whichever occurred first.
Three lubricants were used in this field test: BP Autran Syn 295 synthetic ATF,
a mineral-based TES-389-approved ATF, and a mineral-based C-4-approved
diesel engine oil. After a driving cycle with one of the test lubricants, the data
was downloaded and a flush machine was used to prepare for the next test
fluid. The flush machine saved time and assured purity of the candidate
lubricants. Three flushes were necessary to achieve the goal of less than
1% volume of previous fluid in the sump. During the first phase of the field
test, the transmission oil cooler was connected and operational. The bus was
driven on a relatively traffic-free road according to the Environmental Protection
Agency (EPA) Central Business District cycle. The cycle consists of 15 segments,
each 0 to 20 miles per hour.
In the second phase of testing, BP Lubricants want to examine the effects
f higher operating temperatures on the three candidate lubricants.
To accomplish this, the transmission oil cooler was bypassed to force
an increase in system and fluid temperature.
RESULTS: In phase one of this moderate duty cycle, the RESULTS: BP Autran Syn 295 allowed the transmissions to
synthetic fluid BP Autran Syn 295 kept the transmission run cooler than the mineral ATFs and diesel engine oils used
and torque converter operating at a lower temperature in the field test. This data further validated BP Lubricant’s
than both the mineral-based fluids. In phase two, even with belief that a synthetic automatic transmission fluid such as
bypassing the transmission oil cooler, the transmission using BP Autran Syn 295 would produce lower operating
BP Autran Syn 295 still had lower operating temperatures in temperatures in a transmission.
both the transmission and torque converter than the
LOWER TEMPERATuRES, LOWER MAinTEnAnCE COSTS
transmission using mineral-based lubricants. There was a
BP Lubricant’s test results are significant for several reasons.
greater degree of difference in temperature between the
Higher operating temperatures increase the likelihood of oil
fluids during phase two, which lead engineers to some
oxidation or breakdown. It is generally believed that for
each 10° increase in temperature, the oxidation rate is
Gapinski was encouraged by these two phases of test doubled. Transmission components are exposed to critical
results. “This field test did confirm our theory that synthetic wear as oil oxidizes. Any measures a fleet owner can take
lubricants would allow a transmission to operate at a cooler to lower operating temperatures prolongs the life of the
temperature than conventional transmission fluids would,” transmission and the fluid, both of which save real
he explained. “However, phase 2 of our test showed that maintenance dollars.
as the temperature in the transmission sump increases, the
Bearings and seals receive better wear protection and last
temperature gap between synthetic and mineral-based
longer if operating temperatures are lower. Fleet owners can
fluids gets larger. Equipment running at high operating
significantly reduce downtime with the use of BP Autran Syn
temperatures would get better wear protection, longer
295. Although not the focus of this study, it is important to
component life, and longer lubricant life from using a
remember that BP Autran Syn 295 is approved for use under
synthetic ATF like BP Autran Syn 295.”
the Allison TES 295 specification. This specification allows
FiELD TEST #2, REFuSE TRuCKS for fleet owners to extended drain intervals up to 150,000
To further investigate the synthetic fluid’s effect on miles in severe duty applications and 300,000 miles in
temperature, Gapinski conducted another field test. Refuse moderate duty applications. That is almost 12 times the
trucks were chosen as the application because they drain interval of a mineral-based ATF.
experience significant stop and go conditions. Two 2003
Although this study focused on high operating and ambient
Mack refuse trucks with Mack diesel engines and Allison
temperatures, BP Autran Syn 295 provides low temperature
HD4560 automatic transmissions and two Autocar refuse
protection too. Start-up wear is a real concern for fleet
trucks with Cummins ISM engines and Allison 4500 RDS
managers as temperatures drop. BP Autran Syn 295 is able
automatic transmissions were used in the study.
to remain viscous so critical transmission components
As in the first field test, the transmissions of the test receive protection as soon as a driver turns the key. All these
trucks were outfitted with thermocouples to record benefits of BP Autran Syn 295 produce lower maintenance
torque converter out temperature and ambient temperature. costs and lower a fleet’s cost-per-mile.
Modifications were made to allow the use of a high capacity
BP Autran Syn 295 can be used in a variety of applications
automatic transmission fluid flush machine. A data logger
including inter-city buses and school buses, delivery trucks
was installed in the cab to record temperatures as each
and vans, refuse vehicles, emergency vehicles, light-duty
vehicle completed its customer pick-up route.
pick-up trucks, passenger cars (where Dexron®-III is
One notable difference between the refuse truck test and recommended), some recreational vehicles, and motor
the city bus test was that the city bus was driven on a homes. It is exceeds the performance requirements for
planned, lightly traveled EPA fuel economy route; it was in Allison TES-295, Allison C-4 and Dexron®-III specifications.
test mode, not actual service. The refuse trucks were driven For more information on BP Autran Syn 295, contact a sales
by their usual drivers in actual refuse pick-up service. The representative at 800-255-4417 or visit the BP Lubricants
data from the refuse trucks was collected for one week. web site at www.bp.com.
volume 1 • 2008 5
Powerful Information Tool Makes
Lubricant Recommendations a Snap
ne of the easiest ways to safeguard and extend the life of heavy-duty trucks and equipment is to use
the correct lubricant for a specified component. Sounds simple on paper, but in reality it can be very
complicated. Choosing the proper lubricant goes beyond engine oils, transmission fluids, hydraulic fluids,
and gear lubricants. There are single and multi-weight viscosity fluids. There are multi-purpose fluids that can
perform in both a hydraulic pump and transmissions. There are specialty fluids that address high operating
temperatures or environmental restrictions. And of course there are conventional and synthetic choices to
consider. It would take a fleet manager hours of valuable time and energy to research and specify lubricants
for his entire fleet. A Castrol sales representative or distributor can do it with a few clicks of a mouse.
“Castrol’s field engineers have been known in the industry for providing extensive
and thorough lube surveys to our customers,” says Tejuana Edmond, HD/OEM
Market Space Manager. BP Lubricants USA, Inc. “In the past, we used a system
called OATS Lubrication Reference System to aid our engineers with completing
comprehensive surveys. We polled our internal sales force and distributors on
how to enhance this program. We recently completed upgrades to the system
and rebranded this tool as Castrol Lube Advisor, powered by OATS. The Castrol
Lube Advisor is easier to use and allows for more flexibility for our field engineers,
sales people, and distributors.”
Castrol Lube Advisor is a secure, interactive, internet-based program that allows
Castrol representatives and distributors to perform a number of valuable services
when doing lube surveys for customers. First and foremost, Castrol sales and
distributor representatives can make product recommendations based on
equipment make and model types. Makes and models can be easily chosen
from comprehensive lists contained within the program, and searches can be
performed on single or multiple units. Recommendations are summarized in an
easy-to-read chart that contains a vehicle’s sump capacity and good, better, best
choices where applicable. By clicking on a Castrol fluid, the user is linked to the
product data sheet for that lubricant. The user can print or e-mail this information
to his or her customer.
Castrol Lube Advisor gives Castrol representatives and distributors the ability to
input all a customer’s vehicles and/or equipment on one screen. The program will
then generate a detailed recommendation report for the entire fleet in minutes.
Other information available through Castrol Lube Advisor includes competitive
product cross references, The Castrol Heavy Duty Green Book, viscosity charts,
product data sheets, and lubricant specifications. Reports can be saved, printed
or sent via e-mail to the customer.
Overall, Castrol Lube Advisor helps Castrol representatives ensure that their
customers are using the specified lubricants for each piece of equipment in
their fleet. This comprehensive tool also takes the guesswork out of making
lubricant recommendations for busy fleet or equipment managers. For more
information on how a Castrol representative or distributor can perform a
lubricant survey for your fleet, visit the Castrol web site at www.castrol.com/us
or call 800-888-4448.
volume 2 • 2008 7
Fuel For Thought
BP plans to track and record fuel efficiency with
new information-gathering tool.
ccording to the Energy Information Administration’s diesel fuel price comparison,
diesel fuel prices are up an average 84 cents a gallon across the country, compared
to one year ago. For trucking companies, even slight increases in diesel fuel prices cut
directly into their margins and increase their cost-per-mile. For on-highway fleets large and
small, getting the most mileage from each tank of gas has become priority one.
A LOOK AT FuEL ECOnOMy vS. FuEL EFFiCiEnCy
Fuel economy by definition is simply the amount of fuel required to move a vehicle from point A to
point B. It is typically quoted in miles per gallon (MPG) and has received more attention recently due
to skyrocketing fuel prices. Fuel efficiency is the amount of energy released by fuel combustion that
is changed into working energy. A fuel efficient engine, or one that converts the most amount of fuel
combustion energy into working energy, would get better fuel economy. Technically, it will take less
fuel to move a fuel-efficient truck a certain distance. Depending on the nature of a trucking business
(number of vehicles, distance traveled, etc.) even small increases in fuel efficiency can save a trucking
company thousands of dollars a year.
It sounds fairly simple; increase fuel efficiency, save money. However, there are many variables that
contribute to the fuel efficiency of an engine that go beyond its internal components. And measuring
the resulting fuel economy presents another challenge.
FACTORS THAT AFFECT FuEL EFFiCiEnCy
The biggest variable in determining fuel efficiency is probably the one over which fleet owners have
the least control—the driver. BP Lubricants USA Inc. has estimated that 30% of a truck’s fuel efficiency
can be traced back to its driver. Other variables that contribute to a vehicle’s fuel efficiency include fuel
type, tires, truck aerodynamics, seasonal changes, service, lubricants, and geography. Whether the role
of each of these variables is large or small, any positive change in fuel efficiency positively affects the
So now that a fleet owner knows what contributes to his vehicle’s fuel efficiency, how does he convert
this information into something useful for his business? First he must look at both traditional and
non-traditional ways to increase a vehicle’s fuel economy.
volume 1 • 2008 9
• Take a breather. Car and truck drivers alike tend to • Follow OEM preventive maintenance standards. Well-
accelerate and brake hard. The harder a driver pushes maintained vehicles are more fuel-efficient and generally
on the gas pedal, the more gas (energy) it takes to move experience less downtime. Using the correct type of fuel
the truck. One strategy for combating this problem is to and proper grade of diesel engine oil help the engine
simply take a deep breath and relax before hitting the operate more efficiently.
accelerator. A driver should ease into starting and
• Avoid useless idling. Whenever possible, avoid idling
accelerating to save fuel.
for long periods of time. When a truck idles, it is going
• Maintain a steady speed. When possible, drivers nowhere yet consuming fuel. Therefore, that truck is
should keep their trucks at a steady pace. On flat roads, getting 0 MPG, while it idles.
cruise control can provide a fuel-efficient driving option.
• Consider fuel-efficient lubricants. Many motor oils,
However, hilly terrain is not the ideal situation for cruise
transmission fluids, and gear lubricants tout fuel
control. Drivers can achieve more efficiency by driving
efficiency benefits. Lubricants that can support fuel
through the hills, accelerating up the hill when necessary
efficiency claims may seem to cost more initially, but
and letting off the gas to go downhill.
even minor fuel savings will more than cover the
• Put the truck into high gear. Drivers should strive to stay increase in the cost of the lubricants.
in the highest gear possible to maximize fuel efficiency.
Lower gears do give the truck more power, however they Crunching the numbers
are a bigger drain on fuel consumption. Higher gears, Tracking fuel efficiency for fleets is a challenge because
especially in on-highway driving, use the least amount there are so many variables that contribute to it. BP
of energy. Lubricants is in the final stages of development for a
fuel economy meter designed to capture data from many
• Check tires and tire pressure. According to the components that comprise fuel economy. The fuel economy
Department of Energy, a vehicle can increase its fuel meter consists of a small datalogger, which is connected to
economy by more than 3% simply by inflating its tires a vehicle’s systems. Using various data collection methods,
properly. Underinflated tires require the vehicle to use information is sent to a central computer, sorted and stored.
more energy to operate. BP then publishes the sorted data on a web site for the
operator or fleet manager to view. This is not a product BP
plans to sell, but to use in conjunction with its fuel-efficient
engine oil, gear lubricants, and transmission fluids.
“The way we plan to use the fuel economy meter is to
install it on 10 trucks for a 2-month time period,” explains
Steve Goodier, Technology Manager for BP Lubricants USA,
Inc. “The data we collect will be our baseline. Then we plan
to change the engine oil to our fuel efficient Castrol Elixion
and re-run the same 10 trucks for 2 more months. This data
should give us a good idea of fuel economy and the fleet’s
savings when using Castrol Elixion.”
Look for more information on BP’s fuel economy meter and
its fuel-efficient lubricants in future issues of Dimensions or
on the company’s web site at www.castrol.com/us.
THE FiRST GREASE SPECiFiCALLy
DESiGnED TO GivE yOu TOTAL
COnTROL OF yOuR LOAD, REGARDLESS
OF THE COnDiTiOnS AROunD yOu.
Castrol was the first to market a grease
specifically designed for fifth wheel plates. 3
Its unique formulation has up to twice the Easy to use steps.
adhesive properties of our competitor’s fifth No tools needed.
• Peel off tab
wheel grease, and exceptional adhesion that
guards against fretting and other types of • Grease 5th wheel
metal to metal wear. Castrol Fifth Wheel Grease • Use end of tube to
comes in a convenient eight ounce squeeze spread evenly on wheel
tube, ideal for a one-time application.
For more information, call 1-800-255-4417 or visit www.castrol.com/us
Hit the Road with Castrol Grease
When it comes to your truck’s grease needs, Castrol has got you covered.
very business owner, fleet manager, and owner/operator is singing the same tune these days. In an effort to
minimize the effects of higher fuel prices and economic uncertainty now, more than ever, you are vigilantly
trying to contain costs, reduce waste, and increase efficiency in your fleet. One product that could make a
difference in your cost-per-mile is grease. You may be surprised to learn that grease, and the proper application
of it, can save your fleet time, money, and reduce safety and environmental risks. Castrol has a dedicated grease
formulation team that technically analyzes, updates, and tests its grease offerings to keep its products on the
cutting edge. This article will review the features and benefits of Castrol’s primary on-highway greases, explain
why each is superior in its scope, examine proper grease techniques, and show the grease’s uses and applications.
The Grease Line Up
There are three primary greases that can effectively fulfill most of a fleet’s lubrication needs. These products are the most
commonly used products for on-highway fleets and provide a good sampling of the Castrol grease products that are
available. Your Castrol representative has information on the entire line of Castrol greases that address specialty needs
beyond those discussed here.
Proper Grease Techniques
Once you have chosen a high quality grease, it is important to apply the correct amount to each component. Below is a
brief look at the most common grease points on a Class 8 truck and some best practices for maintaining them.
• Kingpin Lubrication. • Front Spring Lubrication. • Steering Component • Throw Out Bearing
The technician may need The front pin shackle has Lubrication. Lubricate the Lubrication. This
to turn the wheels to fully 1 grease zerk. Apply grease drag link ends and tie rods component requires
lubricate the kingpins. until fresh grease purges enough to partially inflate only minimal lubrication.
There are 2 kingpins with the component. There are or fill the boot. Be careful One shot of grease should
upper and lower grease 2 grease fittings on the rear not to overgrease, which be enough. Overgreasing
points. The kingpin is of each front spring. Fresh leads to seal or boot causes erratic clutch
properly greased when grease should be visible at failure and may allow operation or failure.
fresh grease is visible at 4 points when lubrication contaminates or water
all 4 grease points. is complete. to enter the cavity.
Castrol Pyroplex Red is a multi-purpose, extreme
pressure grease for fleets carrying moderate to
heavy loads. This is Castrol’s standard grease
product with endurance that goes well beyond
standard expectations. It is a lithium complex grease
that boasts high temperature performance, long
term stability, and dependable wear protection.
These benefits are supported by industry test results
as shown in the chart here.
High temperature operation, a common occurrence
in heavy-duty trucks, can shorten both grease and
component life. Grease that cannot withstand high
temperatures will separate and leak out of the
component. Castrol Pyroplex Red has a high dropping
point, which reflects its ability to maintain thermal
stability and protection during elevated temperatures.
Castrol Pyroplex Red uses a high quality base oil and
thickener to achieve excellent shear stability. Its shear
stability works hand-in-hand with its thermal stability
to keep the grease in place during heavy load conditions.
You can feel confident maximizing service intervals with
Castrol Pyroplex Red because it does not compromise
wear protection and performance during extended
service. It is also highly compatible with other greases,
which greatly reduces the likelihood of problems when
switching to Castrol Pyroplex Red.
Bottom line: Castrol Pyroplex Red can save your
fleet money by reducing grease intervals and
lengthening component life.
Castrol Pyroplex Blue is a multi-purpose grease
designed for use in more severe service environments
for both on- and off-highway equipment. It is a lithium
complex grease that employs hydro-activated technology,
which keeps the grease from washing out during
wet conditions. It is an excellent choice for fleets
that undergo prolonged water contamination. Castrol
Pyroplex Blue combines a proprietary additive package
with a high quality base oil, which give it enhanced
anti-wear performance and allow it to prolong
component life. Castrol Pyroplex Blue provides almost
double the bearing life and anti-wear performance of
competitive greases, as shown in the test results below.
Bottom line: Castrol Pyroplex Blue resists water
washout and offers excellent wear protection
which helps you increase uptime, extend lubrication
intervals, and save maintenance dollars.
volume 2 • 2008 13
Castrol Pyroplex Protection ES is a full synthetic, lithium complex grease that extends service
intervals in all seasons, but especially during harsh winter conditions. Despite exposure to highly
corrosive and abrasive chemicals used to safeguard roads during winter storms, Castrol Pyroplex
Protection ES maintains wear protection against rust, oxidation, and corrosion. It routinely outperforms
competitive grease products in extreme pressure and temperature environments and resists breakdown
with excellent oxidative stability. It is an ideal choice for trucks, buses, salt-spreaders, and other
Bottom line: Castrol Pyroplex Protection ES lengthens service intervals and component life,
which keeps your trucks on the road longer.
ApplicAtions – on-HigHwAy
GOOD BETTER BEST
castrol pyroplex Red castrol pyroplex Blue castrol pyroplex
lithium complex lithium complex protection Es synthetic
light-Moderate Duty •
Heavy Duty •
Enhanced corrosion protection
wheel Bearings • • •
U-Joints • • •
Ball Joints • • •
King pins • • •
spring pins • • •
slack Adjusters • •
gc-lB • •* •
*note: only pp Blue#1 is gc-lB rated. Bold
•indicates maximum performance.
• Transmission Thru-Shaft Lubrication. Be sure to grease Applications/uses
the top-side and front of this component. Castrol greases can be used in a variety
• Front Brake Slake Adjuster and S Cam Shaft of on-highway components engaged in
Lubrication. Grease the S Cam tube lightly until grease is various service levels. Use the chart
visible from the slack adjusters and tube. Overgreasing in below as a guide to choosing the
this area leads to brake contamination. The slack adjuster type of performance you want to
should be lubricated until fresh grease shows on the side incorporate into your maintenance
away from the tube. plan. It is important to note that as
you move from good to better to best
• Rear Axle Slack Adjuster and S Cam Lubrication. in the grease line-up, the potential for
Lubricate components until fresh grease is evident. cost and time savings significantly
increases. For more information on
• U-Joint Lubrication. Before greasing, inspect each U-joint
Castrol’s grease products, proper
for play or wear and ensure that the driveline is not loose.
lubrication techniques, or other
If driveline is loose, service as necessary. There are 2
Castrol lubricants, contact your
grease zerks that must be cleaned and used for proper
Castrol representative at
lubrication. All 4 of the cups must show fresh grease
800-255-4417 or visit the web site
before the U-joint is sufficiently lubricated. It is important
that fresh grease be visible from all 4 seals. If new grease
does not purge, loosen the problem bearing cap bolt and
regrease until all 4 cups purge. If new grease still does not
purge, replace the U-joint.
Proof Positive: Castrol Trans-C 30
Construction Company Reports Superior Transmission Life
lenn O. Hawbaker, Inc., a Pennsylvania-based Castrol Trans-C 30 is a Caterpillar TO-4 transmission
heavy construction, paving, and asphalt/ fluid. The TO-4 specification defines frictional
concrete production company recently capabilities that combined with anti-wear properties
completed a teardown inspection of a Caterpillar 970F
and gear wear protection, maximize powershift
wheel loader that was in service for more than 24,000
hours. Caterpillar, BP Lubricants, and Lubrizol worked transmission life and operating efficiency. An
in conjunction with Hawbaker to report on the results. automatic transmission fluid or tractor fluid that is
Castrol Trans-C 30 was used in the CAT powershift used in a powershift transmission can lead to
transmission for the life of the component. The equipment burnt and slipping clutches, inadequate holding
was routinely engaged in light to medium duty operation. capacity for both brakes and clutches, and
Routine preventive maintenance and service repair was insufficient wear protection for gears. Castrol
performed, along with regular fluid analysis at defined
Trans-C 30 powershift transmission fluid is able to
service intervals. Throughout the life of this transmission,
used oil analysis acceptability rates were at 100% with no perform the following critical performance functions
wear alerts. And, the average wear rate was well below in a powershift transmission:
OEM-recommended limits. The component demonstrated
• Frictional control for maximum holding capacity,
this stable wear rate and exceptional wear control of copper
and iron throughout its life. • Eliminate brake noise,
Upon inspection, the transmission components were • Reduce wear,
reported to be and in very good condition. The transmission
housing and other hard parts were free from any varnish • Prevent slippage,
deposits, bearings and gears were shown to be in excellent • Encourage stable performance over the life
condition, and clutch plates and pressure discs showed only
of the fluid,
minimal wear. Inspection parameters recorded average or
below average wear and most of the parts were acceptable • Inhibit metal-to-metal contact while protecting
to be placed back into service under typical transmission vane pumps, planetary gear sets, final drive gears
rebuild criteria. and bearings from premature wear,
This success story is proof positive that Castrol Trans-C 30 • Anti-foam protection to guard against fluid loss,
delivers excellent bearing and gear wear protection,
optimizes frictional performance to reduce slippage that • Promote low temperature fluidity to reduce
causes wear, and minimizes deposit formation throughout start-up wear,
the life of the component. Castrol Trans-C 30 promotes
• Control oxidation to prevent deposit formation
trouble-free transmission operation and saves users time
that can restrict lubrication, and
and money in both labor and maintenance costs.
There is also a full synthetic transmission fluid, Castrol
• Maintain excellent shear stability for consistent
Trans-C HT, that offers extended drains for use where a stay-in-grade performance.
TO-4 or TO-4M fluid is required. For more information on
Castrol Trans-C 30 or Castrol Trans-C HT, contact a Castrol
representative or visit www.castrol.com/us.
volume 2 • 2008 15
Castrol Tection Extra Helps Fleet Owners
Stretch Their Maintenance Dollars
very fleet owner knows that subjected to intense heat of more than 400° F, and it is assaulted by acid, dirt,
engine conditions are harsh. and soot. Exhaust Gas Recirculation (EGR), an engine modification many OEMs
Reduced emissions, increased use to reduce meet government-mandated emission restrictions, forces additional
power demands, and long, pollutants back into the engine oil, contributing to its already difficult job of
demanding work hours put engine lubrication. All these pollutants must be suspended in the oil, so as not
severe stress on your equipment. to form harmful deposits.
Every fleet owner also knows that
As your engine runs, its internal metal surfaces are being forced together. The
today’s economic conditions are
engine oil must stop these surfaces from touching, reducing engine friction and
just as harsh. Rising costs, economic
preventing irreversible engine damage. Oil does this by forming a film that acts
uncertainty, and limited resources
as a buffer between the moving parts in your engine. The stronger the film, the
put severe stress on you and your
bigger the buffer, the more your engine components are protected.
business. As a savvy fleet owner,
it may be time to revisit your
maintenance program to maximize Wear Test
your equipment’s performance and (Cameron Plint, Higher Numbers Indicate More Wear)
stretch your maintenance dollar. A 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
good place to start is with your 390 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
equipment’s engine oil.
380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball Wear Scar (µM)
THE DiRTy TRuTH 370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABOuT EnGinE OiL
360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
An engine oil is expected to perform
these 5 basic functions within your 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
engine: reduce frictional resistance, 340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
protect against corrosion and wear, 330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
assist in sealing, cool the engine, and 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
eliminate harmful combustion by- Castrol Leading Leading Leading
products. Oil circulates through your Tection Extra Competitor A Competitor B Competitor C
engine at a rate of up to 100 times a
minute. All the while it is being New Oil used Oil (210 Shear)
The extreme stresses present in an engine gradually break down the oil, dispersancy additives, delivering
weakening its structure and causing it to lose its viscosity. This means that superior performance in managing
with every passing mile the oil is less effective at protecting your engine. Once soot and dirt and their damaging
viscosity is lost, a catastrophic chain of events is set into motion. The engine oil effect. This takes Castrol Tection Extra’s
is unable to perform its 5 basic functions, which ultimately results in increased performance beyond the limits of
wear, decreased engine efficiency, and premature component failure. The best ordinary API CJ-4 oils in off road
way to guard against oil breakdown is to choose an engine oil that can withstand engines.
tough engine conditions, during both its regular service interval and in periods of
Castrol Tection Extra is formulated to
exceed the requirements of API CJ-4,
THE CASTROL TECTiOn ExTRA ADvAnTAGE which means it delivers the following
Castrol Tection Extra has undergone numerous industry and field tests to benefits:
underscore its ability to provide the best protection for your engine throughout
• Generates fewer deposits and
the entire service interval, not just the first few thousand miles. Castrol Tection
reduces engine wear through
Extra’s advanced formula utilizes Castrol’s unique radial polymer technology to
deliver second-to-none protection against permanent viscosity loss. Tests have
shown that many engine oils actually fall out of grade between oil changes. • Counters sludge build-up and
That means that the 15W-40 engine oil that you put into your truck is no increases engine efficiency with
longer 15W-40 when the oil is drained. The thinned engine oil compromises excellent oxidation control
your engine protection. Castrol Tection Extra’s advanced formula utilizes Castrol’s
• Exceed the demands of OEM specs
unique Active Molecule Technology to deliver second-to-none protection against
from Caterpillar, Cummins, Detroit
permanent viscosity loss. No leading engine oil protects against viscosity loss
Diesel, Mack, Volvo and others.
better than Castrol Tection Extra does.
Better engine protection helps save
During normal use, fuel gets mixed in with the oil, diluting it and causing it to
your company money in the short term
lose viscosity. As shown by the chart below, Castrol Tection Extra still stays in
and over the life of your equipment.
grade despite being affected by normal levels of fuel dilution.
Continued use of Castrol Tection Extra
Castrol Tection Extra allows the least amount of wear from the time you first pour can contribute additional bottom line
it into your engine, until the time that you drain it out. As shown by the wear savings through maximized service
test, Castrol Tection Extra engine oil that has already been in service still protects intervals and used oil analysis with
better than fresh oil from leading competitors. In fact, Castrol Tection Extra that Castrol Labcheck. For more information
has already been subjected to the stresses and strains typical of the harsh engine on stretching your maintenance dollars
environment still protects better than the leading diesel engine oil fresh from the with Castrol Tection Extra, contact your
bottle. Even after hours of running in tough conditions, Castrol Tection Extra Castrol representative at 800-888-4448
provides more protection to your critical engine components than any other or visit the Castrol Web site at www.
leading diesel engine oil. This is especially important in those high stress, high castrol.com/tectionextra.
wear parts of the engine, such as the valvetrain and the camshaft.
Castrol Tection Extra provides the same protection benefits in off road usage as
it does for on highway engines: unsurpassed viscosity protection, long lasting
protection from metal to metal contact, and superior wear protection throughout
the entire drain interval. Castrol Tection Extra is boosted with more active
Conventional Radial Polymers
volume 1 • 2008 17
Construction and Aggregate
Companies Rock the
Education of Virginia Students
iddle school students in the State of Virginia
get a hands-on education of the unique
minerals that are mined there, thanks to
the efforts of aggregate companies and associations
in the area. The Virginia Transportation and
Construction Alliance (VTCA) spearheads a program,
now in its eighth year, whereby members collect
unique rock samples from a dozen quarry/aggregate
companies in the state. These minerals are sorted,
bagged, and distributed to science teachers across
the state at the Virginia Association of Science
Teachers (VAST) conference held every year in
November. The program’s goal is to educate students
about minerals particular to Virginia, and how those
minerals impact society.
“Part of VTCA’s mission is to provide education about the
aggregate and mining industry,” said Sam Hollins, VTCA
Aggregates Program Manager. “What better place to start
than at the ground level with students.”
Sam Hollins, VTCA Aggregates VTCA is dedicated to serving the specific needs of businesses involved in
Program Manager, mans a Virginia’s transportation construction and aggregate industries. It serves
booth at the VAST conference,
contractors, aggregate producers, materials suppliers, consulting engineers,
where minerals unique to
Virginia are distributed to and other professional service firms. It is the industry’s forum for open
elementary school teachers. communication with the Virginia Department of Transportation, Virginia
Department of Environmental Quality, Virginia Department of Mines, Minerals
and Energy, Mine Safety and Health Administration, and other agencies.
“VTCA’s Aggregate Operations Committee, under oversight from the Aggregate
Producer Leadership Committee, provides support for the VAST and coordinates
the rock collection. This is no small feat considering more than 6,000 bags were
distributed this year. The entire process begins months before the conference,
when quarries and mines are asked to donate their unique rock samples.
“Virginia’s geographic make-up drives the type of mining that is done in a
particular area,” explained Hollins. “We have a list of 12 specialty minerals
mined in our state, and ask the companies that mine them to provide us with
enough samples for schools throughout the entire state. They do so free of
charge and many of these companies show up to help us bag the samples
for the conference.”
quarry. This mineral has several uses,
most notably in green clay tennis
courts. According to Jim Van Ness,
Luck Stone Vice President of Central
Services, participation in the VAST
conference allows Luck Stone to
make a connection with the
“As we hand out the rock kits at the
conference, we get a chance to talk
with science teachers about the mining
industry and our own unique rock
samples,” said Van Ness. “We can see
that they love the program, and we get
a lot out of our participation too. It’s a
great educational tool for all of us.”
Jack McCarthy, Boxley Materials, and Sam Hollins, VTCA, spend a Friday
This year, Hollins was glad to report
morning bagging rock samples for Virginia students.
that VTCA was given the opportunity
Hollins and his staff compile a list of the minerals that are supplied each year. to be a presenter at the conference.
They map out where every mineral is mined, the company that mines it, and Tom Roller from Boxley Materials
how it is used in finished products. BP Lubricants supplies each company with spoke about the global importance
pails to collect its rock samples. Volunteers from the VTCA, supplier companies, and impact of mining.
and BP Lubricants get together a few weeks before the conference to make up
rock kits for the teachers. Hollins joked that it is “mine” numbing morning of “The VAST conference is an excellent
bagging rock samples. forum to promote our industry, and we
are excited to be involved at this level,”
“It takes us about 4 hours to stuff 6,000 rock kits for the teachers,” declares stated Hollins. “Several members of
Joe Fidd, sales representative for BP Lubricants. “We usually assemble the kits our organization have a geological
on a Friday morning and have a good time sorting through rocks and catching background, which allows us to share
up with colleagues and friends.” common interests with teachers. The
Several of the aggregate companies supplying rock samples are BP Lubricants entire program really epitomizes VTCA’s
customers. Luck Stone, long-time BP customer and program participant since concept of networking and marketing
its inception, provides the mineral Catoctin Greenstone from its Charlottesville the aggregates industry.”
Below is a list of the rock samples contained in this year’s kit for Virginia students. Fifth
graders across the state are able to see and touch minerals mined right from the soil of
their home state, while learning about how the minerals are used.
volume 2 • 2008 19
BIodEGradaBlE FlUId ChoICES ShEar STaBIlITy loW For CaSTrol ISolUBE
When fluid leaks could pose a potential health or All lubricants will experience some shear during service.
environmental problem, a biodegradable lubricant may Shear is when a lubricant loses viscosity, and based on the
be a possible solution. There are two Castrol biodegradable amount of shear the lubricant experiences, could lead to
hydraulic fluids that pose many of the same, and in some damaging wear, additional maintenance concerns, and
cases better, lubrication characteristics as conventional premature component failure. In the industry, fluids with
biodegradable fluids. It is important to note that the OEM shear levels of less than 10% are considered to demonstrate
should be contacted prior to using a biodegradable fluid in excellent shear stability. BP Lubricants USA Inc recently
a particular application. The OEM requirements for product performed a 20-hour KRL bearing shear stability test on one
specifications, changeover recommendations, drain intervals, of its leading gear lubricants Castrol Isolube. Castrol Isolube
and component protection standards need to be determined 220, 320, and 460 experienced very little viscosity loss
before a final choice is made. (approximately 6% to 7% based on the grade) at operating
temperatures of 100 degrees C. These results confirm that
If a biodegradable hydraulic fluid is needed for a sensitive
Castrol Isolube is an excellent choice for gears engaged
job, you can choose from these Castrol products:
in severe service prolonged elevated temperatures. For
- Castrol Carelube HTG. Formulated from vegetable oil to more information on Castrol gear lubricants or to view the
have a natural viscosity index of 200, Castrol Carelube HTG product data sheet for Castrol Isolube, visit the Web site at
can be used where either an ISO 32 or 46 grade is requited. www.castrol.com/us.
Its high viscosity index is indicative of its ability to stay in
grade regardless of high or low operating or ambient
temperatures. Its recommended temperature limits are
0 to 175 degrees F. To convert Castrol Carelube HTG from
a mineral oil hydraulic fluid (after OEM approval), simply
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. After start up, change the filter after 50 and 100
hours of operation.
- Castrol Anvol SWX FM is a synthetic polyolester hydraulic
fluid available in ISO 46 and ISO 68 grades. It is an
environmentally friendly fluid that provides pump
performance equivalent to mineral oil. For converting to
Castrol Anvol SWX FM from mineral hydraulic oil (after
OEM approval), simply 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. After
start-up, change the filter after 50 and 100 hours of
OTHER COMPANy NEWS
aSk ThE ExPErT STIll a hoT SPoT oNlINE
Ask the Expert is Castrol’s online 24-hour knowledge center that doles out answers to your most pressing lubricant and
maintenance questions. Manned by the BP Global Lubricant Technology team, more than 600 questions are posted weekly
and the question/answer database now totals more than 350 and counting. The two hottest topics are the use of synthetic
lubricants and Castrol SYNTEC products, but questions span the gamut of topics including ones on viscosity grade, coolant
maintenance, recommended lubricants, specific Castrol products, and specialty fluids. To have your lubricant questions
answered, visit the Web site at www.castrol.com/asktheexpert.
NEW BroChUrES aVaIlaBlE aT ThE CaSTrol STorE
Visit the Castrol store at www.
castrolstore.com or access the store
through the Customer Portal at www.
castrolcustomer.com to order copies of
the latest Castrol brochures, sell sheets,
and product testimonials. Some of the
most recent additions to the store
include the following:
• Castrol Fifth Wheel Grease sell sheet
• Castrol Hypuron brochure
and updated testimonials
• Castrol Product Catalog
• Castrol Pyroplex Blue sell sheet
• Castrol Pyroplex Gold sell sheet
• Castrol Pyroplex Protection ES sell sheet
• Castrol Pyroplex Red sell sheet
• Grease Comparison Reference Card
volume 2 • 2008 21
GrEaSE ProdUCTS SPorT UPdaTEd laBElS
For several months, BP Lubricants USA Inc has been phasing
in new labels for Castrol grease products. In 2009, all grease
products will sport the updated look. The labels are color
coordinated and clearly display marketing information and
graphics to differentiate each product. Castrol has a complete
line of grease products that meet the needs of on-highway,
off-highway, and specialty applications. For more information
on the Castrol greases or to view the new labels, visit the
Web site at www.castrol.com/greases.
REPAINTING IT SHOULD
BE yOUR BIGGEST WORRy.
MAxiMizE yOuR BOTTOM LinE WiTH
A CuSTOMizED SOLuTiOn FROM CASTROL.
Decreasing your overall maintenance costs can be key to driving your profitability. That’s why Castrol’s
experienced sales force will work closely with you to examine the way you use lubricants. Our experts will
recommend a mix of superior products and tools geared just for your company. You’ll have a customized
plan that optimizes your equipment while maximizing your bottom line, so now the only thing you have
to worry about may be a little rust. To find out how a customized plan from Castrol can save you money,
call 1-800-255-4417 or visit www.Castrolheavyduty.com/ ET.