Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.

html

Service Bulletin
Service Bulletin Number: 4022060 Released Date: 04-Oct-2012
Oil Analysis Techniques for High Horsepower Diesel Engines

Oil Analysis Techniques for High Horsepower

Diesel Engines
Product Affected

This document applies to all versions of the following engines:

K19
K38
K50
QSK19
QSK23
QSK38
QSK45
QSK50
QSK60
QSK78
QSK95
QST30
V28

This service bulletin outlines the proper use of oil analysis techniques to collect an oil sample, to
set oil analysis flag limits, and to identify and take appropriate corrective action based on oil
analysis results.

Used oil analysis can be employed to monitor engine oil contaminant levels, which can provide
evidence of system weaknesses or malfunctions, such as faulty air filtration, coolant leaks, fuel
dilution, and wear metals that can suggest engine damage or unusual wear. Oil analysis can be
used to proactively identify and address these issues.

Standard oil analysis has limitations, which include the inability to detect large particles and the
inability to identify rapidly developing failures. Because of the method used to detect wear
metals for standard oil analysis, particles greater than 5 microns (µm) in size can not be
detected. However, if large particles are suspected, oil analysis labs can perform a ferrographic
analysis to quantify individual particles in the sample. Properties like magnetism, heat treatment,
shape, and size can be identified to help determine the source of the particles and the

1 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

associated wear mechanism.

The second limitation to oil analysis is the inability to detect rapidly developing failures. In order
to identify a potential problem, a failure would have had to be in progress at the time the last oil
sample was taken. Some failure modes progress so quickly that they will not be identified in oil
analysis.

The guidelines outlined in this bulletin are not to be used to establish oil drain intervals. The use
of these guidelines for the purpose of extending oil drain intervals may result in the continued
use of oil that no longer provides the intended protection. Oil analysis trends can be charted
over a period of time and can provide significant information concerning oil change intervals. For
more information on this topic, refer to Cummins® Engine Oil and Oil Analysis
Recommendations, Bulletin 3810340, or the Operation and Maintenance manual for the specific
engine model for other oil related information.

Table 1 lists those wear metals, oil contaminants, and oil properties that provide the most
reliable indicators to detect a potential problem. This list provides both a minimum set of items
that should be checked during oil analysis and a list of recommended items to monitor for
extended testing. Extended testing is recommended when a problem with the oil condition is
suspected, either from the results of the minimum testing or some other indicator in engine
operation.

Table 1: Elements to Monitor for High Horsepower Engine Oil Analysis

Oil Property Abbreviation Minimum Testing Extended Testing
Aluminum (ASTM
Al X X
D5185)
Copper (ASTM
Cu X X
D5185)
Fuel dilution (ASTM
Fuel X X
D7593)
Iron (ASTM D5185) Fe X X
Lead (ASTM D5185) Pb X X
Potassium (ASTM
K X X
D5185)
Silicon (ASTM
Si X X
D5185)
Sodium (ASTM
Na X X
D5185)
Viscosity at 100°C
[212°F] (ASTM Visc X X
D445)

2 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Table 1: Elements to Monitor for High Horsepower Engine Oil Analysis

Oil Property Abbreviation Minimum Testing Extended Testing
Total base number
TBN X
(ASTM D4739)1
Total acid number
TAN X
(ASTM D664)
Soot (ASTM E11312) Soot X
Nitration (ASTM
Nit X
E2412)
Oxidation (ASTM
Ox X
E24123 or D74143)
1ASTM method D2896 is not be used. TBN number can be falsely exaggerated for used engine
oil.
2
Labs may report a value from E2412 (FTIR) calibrated to E1131.
3Fouriertransform infrared spectroscopy (FTIR) data can use either ASTM method but should
report whether trending or subtraction

ISO 17025 is an international standard for testing and calibration laboratories that covers both
the methodology and testing equipment of a lab. This standard uses an accreditation body to
test if the lab consistently produces valid results. Choosing an oil analysis lab that meets the ISO
17025 certification for the particular oil analysis tests listed above is recommended.

OIL SAMPLE COLLECTION

Oil sample collection intervals must be set in such a manner that trend comparisons can be
made. As oil circulates in an engine during normal operation, wear metals and contaminants
accumulate at a steady rate. The amount of contaminants in the oil at the time of sampling
generally depends on the length of time since the last oil change. In order to be able to detect
changes in the wear pattern of an engine, the sample must be collected in consistent hour
intervals. Background data is required if oil analysis is to be used correctly. Such data must
include:

Information to provide with each sample:

Engine model/serial number

Miles/hours of oil use
Miles/hours on engine since new or rebuild
Oil used (brand name, performance category and viscosity grade)
Date sample was collected
Engine application
Amount of new oil added since previous oil change.

Information to investigate potential issues:

3 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Any recent engine maintenance

Analysis of new (unused) oil.

It is important to conduct oil analysis on new (unused) oil to establish a baseline. New (unused)
oil analysis samples should be taken each time the oil type or oil supplier is changed or, at a
minimum, twice a year. Samples should be taken from the bulk supply tanks to determine the
makeup of the oil and also to confirm that no contaminants are being introduced by the storage
system.

The sample to be used for analysis must be representative of the oil in the engine. Use the
following guidelines when collecting oil samples:

Bring the engine to operating temperature prior to sampling. This will make sure
representative contaminant levels are in the sampled increment.
Successive samples must be taken in the same manner and from the same location.
Take the oil sample before adding any new oil to the engine.
Always collect oil in a clean, dry container.
Collect a minimum of 118 ml [4 oz] of oil.

Two methods can be used to collect oil samples:

The recommended method for collecting an oil sample is to take the sample from a pressurized
port while the engine is idling and warm. This method will make sure the oil sample is not
stagnant and represents the actual homogeneous oil mixture that is flowing through the engine.

1. Clean the outside of the valve by wiping with a clean, dry rag.
2. Idle the engine and bring to warm temperature.
3. Purge the sample fitting by allowing a small amount of oil to flow through the valve.
4. Collect the sample into a clean, dry bottle from the oil stream being pumped by the idling
engine.
Note : A recommended location for sampling is a port that allows oil to be collected
before the oil is filtered. Reference the Operation and Maintenance Manual for
component locations.
In cases where the engine is not operational, an alternative method may be used. This method
uses a vacuum to draw oil out of the sump. The sample should be obtained as soon after
stopping the engine as possible so the oil is still warm and stratification has not occurred.

1. Use the dipstick to determine the oil level in the pan.

2. Hold a new, clean piece of tubing against the dipstick and mark, on the tube, the location
where the dipstick seats.
3. Cut the tubing so it reaches 25 to 50 mm (1 to 2 inches) below the oil level in the pan.
4. Insert the tubing into the dipstick tube so that the mark previously made on the tubing is
aligned with the top of the opening for the dipstick tube.
5. Use a hand operated vacuum pump to pump the sample into a clean dry bottle.
Note : Do not allow the tube to draw oil from the bottom of the oil pan, because

4 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

excess debris will be included that could bias the sampling results. Do not reuse the
sampling tube.
SETTING OIL ANALYSIS FLAG LIMITS

Understanding the oil system is crucial to identifying when an oil sample is indicating a problem.
Large oil system capacity, use of Centinel™ oil replenishment systems, and use of eliminator or
centrifuge filtration systems will result in overall lower contamination levels, compared to an
engine that has a standard sump capacity, no replenishment system, and standard oil filters.

System capacity can be determined by knowing the volume of the oil required to touch the high-
level mark on the dipstick and the volume of any remote oil tanks on the machine in which oil is
continuously circulated. Oil sump capacities are listed in the operation and maintenance
manuals for all Cummins® engines. If the machine is equipped with an oil reserve system with a
reservoir remote from the engine oil sump, the reservoir volume must be added to the engine
sump volume to determine the total system capacity. This is only true for remote tanks in which
the oil is continuously circulated. The Centinel™ make-up tank volume does not add to system
capacity, since the engine oil is not continuously circulated through this tank.

The addition of new oil will also decrease the overall level of contaminants. In all cases, oil
consumption should be documented by the amount of oil added prior to each service interval.
Trending oil consumption is important, as any rising trend or step change in oil consumption can
indicate possible power cylinder wear, system leaks, or other system malfunction.

One way to compensate for the differences in oil systems between units is to look at the normal
wear rates for each engine individually. This method establishes a baseline specific to that
particular engine. Provided the oil usage remains fairly constant and other systems are
functioning consistently, the trends in wear metals should remain consistent.

For example, setting up statistical flag limits based on a large group will normalize the data. If an
engine historically had very low rates of wear, but suddenly jumps to a higher wear rate that is
consistent with the average wear rate for the group of engines being analyzed, no flag would be
triggered. In comparison, looking at historical readings on a particular unit may cause action to
be taken at a lower contaminant level.

Cummins Inc. recommends working with an oil analysis lab to establish warning and critical flag
limits using ASTM method D7720-11. If samples are taken periodically throughout the oil drain
interval, the oil parameter value can be converted into a rate of increase over new oil. For
example, parts per million (ppm) per hour.

As a guideline, engines should be grouped in the following ways for statistical limit comparison:

Engine Model
Application
Similar Duty Cycles
With Centinel™ and without Centinel™
With Eliminator™ or Centrifuge type filtration and with standard filter configurations

5 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Common oil system capacities

If all engines are grouped together regardless of oil systems, the engines with Centinel™,
Eliminator™/Centrifuge type filtration, and higher oil system capacities will experience a higher
degree of engine wear before the flag limit is reached.

Table 2 lists condemnation limits for oil. If these limits are reached, the oil must be changed.

Table 2: Condemnation Limits for High Horsepower Engine Oil Analysis

Condemnation
Oil Property Abbreviation Units
Limit
Fuel dilution Fuel percent (%) 5%
For xW-40 - MIN:
Viscosity change at 12.5, MAX: 16.3
Visc centistokes (cSt)
100°C [212°F] For xW-30 - MIN:
9.3, MAX: 12.5
milligrams potassium
2.5 number minimum
hydroxide per gram
Total base number TBN or equal to total acid
of sample (mg
number (TAN)
KOH/g)
milligrams potassium 2.5 increase over
hydroxide per gram new oil or equal to
Total acid number TAN
of sample (mg total base number
KOH/g) (TBN)
Soot Soot percent (%) 5% 2
absorbance units per
Nitration Nit 25
centimeter (abs/cm)
absorbance units per
Oxidation Ox 151
centimeter (abs/cm)
1
Increase over new (unused) oil sample.
2 Oils meeting API CH-4 (CES 20071) represent a minimum quality standard for Cummins® high
horsepower engines. Oils meeting older API requirements (C F-4, CG-4) are not formulated to
tolerate greater than 1.5 percent soot.

Table 3 is to be used only as a reference if flag limits are not able to be established through
statistical analysis.

Table 3: Flag Guidelines for High Horsepower Engine Oil Analysis

Caution Flag Critical Flag
Oil Property Abbreviation Units
Limit Limit

6 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Table 3: Flag Guidelines for High Horsepower Engine Oil Analysis

Caution Flag Critical Flag
Oil Property Abbreviation Units
Limit Limit
parts per million
Aluminum Al 15 30
(ppm)
parts per million
Copper Cu 60 180
(ppm)
parts per million
Iron Fe 50 130
(ppm)
parts per million
Lead Pb 20 50
(ppm)
parts per million
Potassium K 201 1101
(ppm)
parts per million
Silicon Si 151 1101
(ppm)
parts per million
Sodium Na 201 110 1
(ppm)
1
Increase over new (unused) oil sample.

INVESTIGATION BASED ON FLAG LIMITS

The troubleshooting trees listed below are intended to serve as a guide for investigating
instances of high wear metals or oil contaminants. Some of the trees are set up to direct
investigation based on the severity level of the flag.

The caution severity level indicates that an abnormal wear condition exists, and the investigation
may require minor maintenance to be performed.

The critical severity level indicates that major wear or contamination exists that requires
immediate attention, and the investigation may require partial engine disassembly.

These troubleshooting trees are organized so that a problem can be located and corrected by
doing the easiest and most logical things first. Complete all steps in the sequence shown from
top to bottom.

Some of the steps in the troubleshooting trees require information on oil drain intervals, recent
repairs, coolant makeup or oil makeup. This information is used to verify that the engine is
experiencing a true incident of high wear or contamination and not an abnormal oil condition
due to some other factor.

Many of the troubleshooting trees use combinations of wear metals or contamination indicators
to increase confidence in determining where the problem is originating. See the list below to
become familiar with sources of wear metals or contaminants.

7 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Sources of Wear Metals or Contaminants

Pistons (some applications), crankshaft and
(Al) Aluminum camshaft thrust bearings, camshaft bushings,
dirt.
Connecting rod and main bearings,
turbocharger bearings, connecting rod
bushings, camshaft bushings, idler gear and
(Cu) Copper accessory drive bushings and thrust washers,
cam follower pins, rocker lever bushings, lube
pump bushings and thrust washers, oil
coolers.
Unburned fuel in lubricating oil, injectors or
fuel pump can be source of contamination.
Fuel Engine operation, such as frequent starts,
excessive idling, and cold weather operation
can also lead to fuel dilution.
Cylinder liner, pistons (some applications),
(Fe) Iron gears, crankshaft, camshaft and camshaft
follower rollers and shafts.
Rod and main bearings, turbocharger
bearings, camshaft bushings, idler gear and
(Pb) Lead
accessory drive bushings and thrust washers,
lube pump bushings and thrust washers.
Element contained in some coolant additive
(K) Potassium packages, which indicates coolant
contamination of oil.
Sand, dirt, silicon sealants and gasket
(Si) Silicon materials, oil additives, cooling system
inhibitor.
Element contained in some coolant additive
packages which indicates coolant
(Na) Sodium
contamination of oil, salt from detergent or
road, oil additive.
The property of a fluid measured at a certain
Viscosity temperature that resists the force to cause
the fluid to flow.
A measure of oil's acidity. New oil has a
(TAN) Total Acid Number certain level, or starting TAN, due to the type
and amount of additives.

8 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Sources of Wear Metals or Contaminants

A measure of the oil's ability to neutralize
acid. New oil has a certain level in the oil
(TBN) Total Base Number
formula that is depleted over time due to
contact with acid generated by blowby gases.
Soot Combustion by-products in oil.
A generic measure of the breakdown of a
lubricant due to age and exposure to high
Oxidation
temperature. High oxidation numbers indicate
oil is beyond its useful life.
A generic indicator of excessive "blowby" and
also indicates the presence of nitric acid
formed by nitric oxide, which is a combustion
Nitration by-product when the engine operates too
lean. Nitric acid can attack metal surfaces in
the engine and result in corrosive wear. Nitric
acid can accelerate oil oxidation.
Oil Analysis Flags for Common Failure Modes:

Additional information can be obtained when looking at combinations of wear metals and/or
contaminants. Listed below are some engine problems that may result in oil analysis flags and
an explanation of what combination of elevated wear metals and/or contaminants to look for if
suspected.

Engine Problems That Result in Oil Analysis Flags

The best indicators of fuel dilution are an
increased percentage of fuel in the oil and a
Fuel Dilution decrease in viscosity. In cases of high fuel
dilution, the oil may smell like fuel and the
engine oil level may increase.

9 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Engine Problems That Result in Oil Analysis Flags

The best method to detect coolant
contamination of oil is to look for traces of
elements, such as sodium and potassium,
which are contained in the coolant additive
package. These elements can be detected at
very low levels, so they can serve as an early
warning. Sodium is occasionally found in
lubricant additive packages; therefore, it is
important to compare the level of sodium with
that measured in the baseline (unused) oil
sample and to be aware of the coolant

additive package formulation. A water content

test is not a reliable indicator of a coolant
Coolant Contamination leak because oil temperatures are generally
higher than the boiling point of water, which
allows the water to boil out during normal
engine operation, leaving only the elements
that make up the coolant additive package
behind. Glycol tests can also be inaccurate.
Small amounts of glycol may not be
measurable, and high oil temperatures can
break down glycol to a state where it will not
be detected. In addition to identifying the
source of coolant contamination, it is
important to determine if progressive damage
has occurred. Coolant contamination of the
lubricating oil can damage bearings and
bushings.
Dirt is composed primarily of silica and
alumina, so elevated levels of silicon and
aluminum in a 2:1 to 10:1 Silicon:Aluminum
ratio indicate dirt intrusion. In addition to
identifying the source of dirt entry, it is
Dust Out important to determine if progressive damage
has occurred. A dust out can cause piston
ring/cylinder liner wear, which can lead to
lubricating oil contamination or a breakdown
of the lubricating oil properties and
bearing/bushing failures.

10 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Engine Problems That Result in Oil Analysis Flags

Increased levels of iron indicate cylinder liner
wear. Additionally, wear of the rings and/or
liner may allow blowby gases to pass by the
rings and contaminate the oil. Elevated levels
of soot, oxidation, and nitration along with an
increase in viscosity may be observed.
Piston Ring/Cylinder Liner Wear Contamination of the oil will also increase
total acid number and decrease total base
number. In addition to identifying the source
of coolant contamination, it is important to
determine if progressive damage has
occurred. Contaminated lubricating oil can
damage bearings and bushings.
Bearings are made up primarily of lead and
copper. An increased level of both of these
metals at the same time indicates failure of a
bearing and/or bushing. An increase of lead
with no increase in copper typically
Bearing/Bushing Failure
corresponds to a degradation of oil condition
that results in attack of the top layer of the
bearing. Some other indications may include
increases in oxidation, nitration, TAN and/or a
decrease in TBN.

Note : In order to be alerted to a problem, a failure would have had to be in progress

at the time the last oil sample was taken. Some failure modes progress so quickly that
they will not be identified in oil analysis.
Note : When oil is changed on an engine with a remote oil tank in which oil is
continuously circulated (not a Centinel™ make up tank), the oil in the remote tank
must be changed, in addition to the oil in the engine sump. If the oil in the remote
tank is not changed, it will act as a source of contamination for the next oil sample.
The troubleshooting trees listed below are intended to direct the user to troubleshooting and
repair procedures that can be found in the appropriate set of manuals on Quickserve™ Online
for the engine being investigated.
Note : If the troubleshooting trees listed below recommend further analysis from an
oil lab, Cummins Inc. will not pay for this additional analysis. Cummins Inc. does not
pay for oil analysis work and will not reimburse for the testing required for an oil
analysis program.
Aluminum parts per million (PPM) level exceeds caution or critical aluminum flag limit
based on oil lab results or Cummins Inc. limits

11 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Cause Explanation Correction

Check whether hours on oil
If oil hours at time of sample
at time of sample is more
are greater than oil hours for
Extended oil sample interval than 25 percent longer than
past samples, wear metals
previous sample hours. If so,
may be elevated.
resample at regular interval.
Remote oil tank circulation, Oil is not being replenished Repair remote oil circulation,
makeup oil or Centinel™ or oil capacity is reduced, makeup oil, or Centinel™
systems are not functioning causing an elevated level of system. Resample at regular
properly wear metals. interval.
Engine has aluminum pistons
Resample at regular interval.
and has had at least one
Repair to power cylinder Aluminum should return to
power cylinder (piston)
resulting in break-in wear. normal level within 1,000
replaced within the last 1000
hours of operation.
hours
Engine has aluminum pistons Resample at regular interval.
Power cylinder break-in
and is new or recently rebuilt Aluminum should return to
results in elevated wear
with less than 1000 hours or normal level within 1,000
metal levels.
operation hours of operation.
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
Check ECM image for
blowby faults and increased
Aluminum piston skirt Aluminum piston skirt oil consumption or excessive
scuffing scuffing. engine noise. Follow the
respective troubleshooting
trees.

12 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Check whether silicon is also

at elevated level. If so, check
if dipstick tube and/or oil fill
cap is missing, loose, or has
a missing seal. Inspect the
intake system for holes and
sources of leaks. Check for
collapsed air filters and
proper sealing around air
Dirt is made up of Silica and
Alumina. Silicon and cleaners. Repair as
Dirt intrusion Aluminum in 2:1 to 10:1 necessary. Check for
Silicon:Aluminum ratio increased oil consumption
indicates dirt. and high blowby. Reference
the Lubricating Oil
Consumption Excessive or
Crankcase Gases (Blowby)
Excessive Troubleshooting
Tree. Check whether iron,
copper and/or lead are also
at an elevated level. If so,
reference the respective
troubleshooting tree.
Check if crankshaft end
Increased wear rate of thrust Increased wear rate of thrust clearance is within
bearings bearings. specification. If not, inspect
or repair thrust bearings.
Copper parts per million (PPM) level exceeds copper caution flag limit based on oil lab
results or Cummins Inc. limits
Cause Explanation Correction
Check whether hours on oil
If oil hours at time of sample
at time of sample is more
are greater than oil hours for
Extended oil sample interval than 25 percent longer than
past samples, wear metals
previous sample hours. If so,
may be elevated.
resample at regular interval.
Remote oil tank circulation, Oil is not being replenished Repair remote oil circulation,
makeup oil or Centinel™ or oil capacity is reduced, makeup oil, or Centinel™
systems are not functioning causing an elevated level of system. Resample at regular
properly wear metals. interval.

13 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Copper parts per million (PPM) level exceeds copper caution flag limit based on oil lab
results or Cummins Inc. limits
Cause Explanation Correction
Resample at regular interval.
Engine has had at least one
Copper should return to
oil cooler replaced within the Oil cooler passivation.
normal level within 1,000
last 1000 hours
hours.
Resample at regular interval.
Engine is new or recently
Copper should return to
rebuilt with less than 1000 Oil cooler passivation.
normal level within 1,000
hours of operation
hours .
Resample at regular interval.
Oil formulation has recently Copper should return to
Oil cooler passivation.
been changed normal level within 1,000
hours.
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
Check if lead is also at an
elevated level. If so, cut oil
filters open or open
Oil acidity is attacking Oil acidity is attacking centrifuge and check for
bearing material due to low bearing material due to low debris. If bearing debris in
Total Base Number (TBN) in Total Base Number (TBN) in filter/centrifuge, inspect
oil oil. bearings. If no debris,
change oil, reassess oil drain
interval, resample at regular
interval.

14 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Copper parts per million (PPM) level exceeds copper caution flag limit based on oil lab
results or Cummins Inc. limits
Cause Explanation Correction
Check if lead is also at an
elevated level. If so, cut oil
filters open or open
centrifuge and check for
debris. If bearing debris in
Corrosive attack of engine Oil acidity is attacking filter/centrifuge, inspect
bearing material due to bearing material due to bearings. Check whether
coolant contamination coolant contamination. sodium and/or potassium are
also at elevated levels. If so,

reference sodium and/or

potassium troubleshooting
trees.
Check whether lead is also at
an elevated level. If so,
check for oil temperature or
High temperature, low oil
pressure faults and cut oil
Wear of bearing material due pressure, or low viscosity
filters open or open
to reduced oil film thickness compromise oil film thickness
centrifuge and check for
.
debris. If bearing debris in
filter/centrifuge, inspect
bearings.
Copper parts per million (PPM) level exceeds critical copper flag limit based on oil lab
results or Cummins Inc. limits
Cause Explanation Correction
If a sudden high reading,
perform the steps in the
copper exceeds caution flag
limit tree. If lead also has a
Possible lab testing error, sudden high reading, cut oil
Possible lab error, sample
recording error, sample filters open or open
contamination, or other
contamination, or other centrifuge and check for
reasons causing a single
reasons for a single high debris. If no debris, resample
high reading
reading. at half interval (including TBN
measurement) and request
ferrography analysis on oil
sample that produced
elevated copper level.

15 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Copper parts per million (PPM) level exceeds critical copper flag limit based on oil lab
results or Cummins Inc. limits
Cause Explanation Correction
Resample at regular interval.
Engine has had at least one
Copper should return to
oil cooler replaced within the Oil cooler passivation.
normal level within 1,000
last 1000 hours
hours of operation.
Resample at regular interval.
Engine is new or recently
Copper should return to
rebuilt with less than 1000 Oil cooler passivation.
normal level within 1,000
hours of operation
hours of operation
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
If Total Base Number (TBN)
level is low, evaluate oil drain
interval and oil type. If lead is
also at an elevated level, cut
filters open or open
Oil acidity is attacking Oil acidity is attacking centrifuge and check for
bearing material due to low bearing material due to low debris. If no debris found,
Total Base Number (TBN) in Total Base Number (TBN) in request ferrography analysis
oil. oil. on oil sample that produced
elevated copper level. If
debris in filter/centrifuge or
ferrographic analysis
indicates bearing debris,
inspect bearings.

16 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Copper parts per million (PPM) level exceeds critical copper flag limit based on oil lab
results or Cummins Inc. limits
Cause Explanation Correction
Check whether sodium
and/or potassium are also at
critical levels. If so, reference
Coolant Loss - Internal
troubleshooting tree. Check
whether lead is also at
elevated level, if so, cut filters
open or open centrifuge and
Corrosive attack of bearing Oil acidity is attacking
check for debris. If no debris
material due to coolant bearing material due to
contamination coolant contamination.
found, request ferrography
analysis on oil sample that
produced elevated copper
level. If debris in
filter/centrifuge or
ferrographic analysis
indicates bearing debris,
inspect bearings.
Check for oil temperature or
pressure faults. Check
whether viscosity is low. If so,
reference low viscosity
troubleshooting tree. Check
whether lead is also at
elevated level, if so, cut filters
High temperature, low oil
open or open centrifuge and
Wear of bearing material due pressure, or low viscosity
check for debris. If no debris
to reduced oil film thickness compromise oil film
found, request ferrography
thickness.
analysis on oil sample that
produced elevated copper
level. If debris in
filter/centrifuge or
ferrographic analysis
indicates bearing debris,
inspect bearings.

17 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Copper parts per million (PPM) level exceeds critical copper flag limit based on oil lab
results or Cummins Inc. limits
Cause Explanation Correction
Check for oil temperature or
pressure faults. Check
whether viscosity is low. If so,

reference low viscosity

troubleshooting tree. Cut
filters open or open
Connecting rod bushing, centrifuge and check for
Wear of bushings not debris. If no debris found in
gear bushing, cam follower
containing lead filters/centrifuge, request
bushings.
ferrography analysis on oil
sample that produced
elevated copper level. If
debris in filter/centrifuge or
ferrographic analysis
indicates bushing debris,
inspect bushings.
Fuel dilution exceeds flag limit based on oil lab results or Cummins Inc. limits
Cause Explanation Correction
Fuel does not burn
completely at low combustion
Change oil in engine sump
Frequent Starts chamber temperatures and
and remote oil tank.
can seep past the piston
rings and into the crankcase.
Fuel does not burn Change oil in engine sump
completely at low combustion and remote oil tank. If
Excessive Idling chamber temperatures and possible, shut off the engine
can seep past the piston rather than idling or raise the
rings and into the crankcase. idle speed.
Fuel does not burn
completely at low combustion
Change oil in engine sump
Cold Weather Operation chamber temperatures and
and remote oil tank.
can seep past the piston
rings and into the crankcase.

18 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Fuel dilution exceeds flag limit based on oil lab results or Cummins Inc. limits
Cause Explanation Correction
Fuel does not burn Change oil in engine sump
Frequent starts, completely at low combustion and remote oil tank. If
excessiveidling, or cold chamber temperatures and possible, shut off the engine
weatheroperation can seep past the piston rather than idling or raise the
rings and into the crankcase. idle speed.
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
Injector o-rings cut or blown,
Engine has had at least one Dye fuel and inspect area
injector hold down mis-
injector removed within the around injector with black
torqued, injector seal mis-
last 1000 hours light. Repair as necessary.
installed.
Excessive fuel getting in lube Confirm that viscosity has
Oil contaminated by fuel due oil reduced viscosity of lube also dropped below limit. If
to fuel pump failure or oil. Oil will have fuel smell so, follow Fuel in the
injector malfunction only at high fuel dilution Lubricating Oil
levels. Troubleshooting Tree.
Iron parts per million (PPM) level exceeds iron caution flag limit based on oil lab results
or Cummins Inc. limits
Cause Explanation Correction
Check whether hours on oil
If oil hours at time of sample
at time of sample is more
are greater than oil hours for
Extended oil sample interval than 25 percent longer than
past samples, wear metals
previous sample hours. If so,
may be elevated.
resample at regular interval.
Remote oil tank circulation, Oil is not being replenished Repair remote oil circulation,
makeup oil or Centinel™ or oil capacity is reduced, makeup oil, or Centinel™
systems are not functioning causing an elevated level of system. Resample at regular
properly wear metals. interval.
Engine has had at least one Resample at regular interval.
power cylinder (rings and/or Repair to power cylinder Iron should return to normal
liner) replaced within the last resulting in break-in wear. level within 1,000 hours of
1000 hours operation.

19 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Iron parts per million (PPM) level exceeds iron caution flag limit based on oil lab results
or Cummins Inc. limits
Cause Explanation Correction
Resample at regular interval.
Engine is new or recently
Power cylinder break-in Iron should return to normal
rebuilt with less than 1000
wear. level within 1,000 hours of
hours of operation
operation.
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
Check whether lead and
Wear of interface between High iron and copper and/or copper are also at elevated
steel and bushing/bearing lead indicates bearing levels. If so, reference
material damage. copper and/or lead
troubleshooting trees.
Check for evidence of low
Increased wear rate of rings Injector failed, causing
viscosity or fuel dilution. If so,
and/or liners due to fuel cylinder wash down with fuel,
reference fuel dilution or low
washing lubrication from which caused liner wear,
viscosity troubleshooting
liners resulting in higher iron.
tree.
Check for increased oil
Increased wear rate of rings High cylinder wear due to consumption. Reference
and/or liners due to dusting dusting, broken ring, or worn Lubricating Oil Consumption
or worn rings rings. Excessive Troubleshooting
Tree.
Check for smoke or low
High cylinder temperatures
Increased wear rate of rings power. If engine smokes or
caused by excessive fuel or
and/or liners due to does not pull power, follow
restricted air flow can
overfueling Engine Performance
accelerate cylinder wear.
Troubleshooting Trees.

20 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Iron parts per million (PPM) level exceeds iron caution flag limit based on oil lab results
or Cummins Inc. limits
Cause Explanation Correction
Request ferrography analysis
on oil sample that produced
elevated iron level. Cut oil
filters open or open
centrifuge and check for
debris. If debris in
Iron to iron wear surfaces in Camshaft, roller, or gear filter/centrifuge or
engine failure generating debris.
ferrographic analysis
indicates gear, camshaft or
roller debris, inspect
accordingly. If no debris,
change oil, and resample at
regular interval.
Iron parts per million (PPM) level exceeds critical iron flag limit based on oil lab results
or Cummins Inc. limits
Cause Explanation Correction
If a sudden high reading,
Possible lab testing error, perform the steps in the iron
Possible lab error, sample
recording error, sample exceeds caution flag limit
contamination, or other
contamination, or other tree. If other metals also
reasons causing a single
reasons for a single high have a sudden high reading,
high reading
reading. continue with this
troubleshooting tree.
Engine has had at least one Resample at regular interval.
power cylinder (rings and/or Repair to power cylinder Iron should return to normal
liner) replaced within the last resulting in break-in wear. level within 1,000 hours of
1000 hours operation.
Resample at regular interval.
Engine is new or recently
Power cylinder break-in Iron should return to normal
rebuilt with less than 1000
wear. level within 1,000 hours of
hours of operation
operation.
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.

21 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Iron parts per million (PPM) level exceeds critical iron flag limit based on oil lab results
or Cummins Inc. limits
Cause Explanation Correction
Check whether lead and
Wear of interface between High iron and copper and/or copper are also at elevated
steel and bushing/bearing lead indicates bearing levels. If so, reference
material damage. copper and/or lead
troubleshooting trees.
Check for evidence of lower
Increased wear rate of rings Injector failure causing
viscosity or fuel dilution. If so,
and/or liners due to fuel cylinder wash down with fuel
see fuel dilution and/or low
washing lubrication from can cause liner wear
viscosity troubleshooting
liners resulting in higher iron.
tree.
Check for smoke or low
High cylinder temperatures
Increased wear rate of rings power. If engine smokes or
caused by excessive fuel or
and/or liners due to does not pull power, follow
restricted air flow can
overfueling Engine Performance
accelerate cylinder wear.
Troubleshooting Trees.
Check for increased oil
Increased wear rate of rings High cylinder wear due to consumption. If so, see
and/or liners due to broken or broken ring, worn rings Lubricating Oil Consumption
worn rings causing higher iron. Excessive troubleshooting
tree.
Verify if silicon is also at an
elevated level. If so, check if
dipstick tube and/or oil fill cap
is missing, loose, or has a
missing seal. Inspect the
intake system for holes and
Increased wear rate of rings High cylinder wear due to sources of leaks. Check for
and/or liners due to dust dusting, broken ring, or worn collapsed air filters and
intrusion rings. proper sealing around air
cleaners. Repair the intake
system if necessary. Check
blowby. If high, follow the
Crankcase Gases (Blowby)
Excessive troubleshooting
tree.

22 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Iron parts per million (PPM) level exceeds critical iron flag limit based on oil lab results
or Cummins Inc. limits
Cause Explanation Correction
Request ferrography analysis
on oil sample that produced

elevated iron level. Cut oil

filters open or open
centrifuge and check for
Iron to iron wear surfaces in Camshaft, roller, or gear debris. If debris in
engine failure generating debris. filter/centrifuge or
ferrographic analysis
indicates gear, camshaft or
roller debris, inspect
accordingly. If no debris,
change oil, and resample at
regular interval.
Lead parts per million (PPM) level exceeds lead caution flag limit based on oil lab
results or Cummins Inc. limits
Cause Explanation Correction
Check whether hours on oil
If oil hours at time of sample
at time of sample is more
are greater than oil hours for
Extended oil sample interval than 25 percent longer than
past samples, wear metals
previous sample hours. If so,
may be elevated.
resample at regular interval.
Remote oil tank circulation, Oil is not being replenished Repair remote oil circulation,
makeup oil or Centinel™ or oil capacity is reduced, makeup oil, or Centinel™
systems are not functioning causing an elevated level of system. Resample at regular
properly wear metals. interval.
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.

23 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Lead parts per million (PPM) level exceeds lead caution flag limit based on oil lab
results or Cummins Inc. limits
Cause Explanation Correction
Cut oil filters open or open
centrifuge and check for
debris. If bearing debris in
Oil acidity is attacking Oil acidity is attacking
filter/centrifuge, inspect
bearing material due to low bearing material due to low
bearings. If no debris,
Total Base Number (TBN) in Total Base Number (TBN) in
oil. oil.
change oil, reassess oil drain
interval, resample at regular
interval.
Check if copper is also at an
elevated level. If so, cut oil
filters open or open
centrifuge and check for
debris. If bearing debris in
Corrosive attack of bearing Oil acidity is attacking
filter/centrifuge, inspect
material due to coolant bearing material due to
bearings. Check whether
contamination coolant contamination.
sodium and/or potassium are
also at elevated levels. If so,
reference sodium and/or
potassium troubleshooting
trees.
Check whether copper is
also at an elevated level. If
so, check for oil temperature
High temperature, low oil
or pressure faults and cut oil
Wear of bearing material due pressure, or low viscosity
filters open or open
to reduced oil film thickness compromise oil film
centrifuge and check for
thickness.
debris. If bearing debris in
filter/centrifuge, inspect
bearings.
Lead parts per million (PPM) level exceeds critical lead flag limit based on oil lab results
or Cummins Inc. limits
Cause Explanation Correction

24 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Lead parts per million (PPM) level exceeds critical lead flag limit based on oil lab results
or Cummins Inc. limits
Cause Explanation Correction
If a sudden high reading,
perform the steps in the lead
exceeds caution flag limit
tree. If copper also has a
Possible lab testing error, sudden high reading, cut oil
Possible lab error, sample
recording error, sample filters open or open
contamination, or other
contamination, or other centrifuge and check for
reasons causing a single
reasons for a single high debris. If no debris, resample
high reading
reading. at half interval (including TBN
measurement) and request
ferrography analysis on oil
sample that produced
elevated lead level.
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
If Total Base Number (TBN)
level is low, evaluate oil drain
interval and oil type. Cut
filters open or open
centrifuge and inspect for
Oil acidity is attacking Oil acidity is attacking
debris. If no debris found,
bearing material due to low bearing material due to low
request ferrography analysis
Total Base Number (TBN) in Total Base Number (TBN) in
on oil sample that produced
oil. oil.
elevated lead level. If debris
in filter/centrifuge or
ferrographic analysis
indicates bearing debris,
inspect bearings.

25 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Lead parts per million (PPM) level exceeds critical lead flag limit based on oil lab results
or Cummins Inc. limits
Cause Explanation Correction
Check whether sodium
and/or potassium are also at
critical levels. If so, reference
Coolant Loss - Internal
troubleshooting tree. Check
whether copper is also at
elevated level, if so, cut filters
Corrosive attack of bearing Oil acidity is attacking
open or open centrifuge and
material due to coolant bearing material due to
check for debris. If no debris
contamination coolant contamination.
found, request ferrography
analysis on oil sample that
produced elevated lead level.
If debris in filter/centrifuge or
ferrographic analysis
indicates bearing debris,
inspect bearings.
Check for oil temperature or
pressure faults. Check
whether viscosity is low. If so,
reference low viscosity
troubleshooting tree. Check
whether copper is also at
High temperature, low oil elevated level, if so, cut filters
Wear of bearing material due pressure, or low viscosity open or open centrifuge. If no
to reduced oil film thickness compromise oil film debris found, request
thickness. ferrography analysis on oil
sample that produced
elevated lead level. If debris
in filter/centrifuge or
ferrographic analysis
indicates bearing debris,
inspect bearings.
Potassium parts per million (PPM) level exceeds caution potassium flag limit based on
oil lab results or Cummins Inc. limits
Cause Explanation Correction

26 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Potassium parts per million (PPM) level exceeds caution potassium flag limit based on
oil lab results or Cummins Inc. limits
Cause Explanation Correction
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
Verify that coolant used in
this engine contains
potassium. Check whether
sodium and/or silicon are
also at elevated levels if
Potassium is commonly used there are also contained in
Oil contaminated by coolant
as a cooling system inhibitor. coolant. If so, monitor coolant
consumption, check for and
repair any head gasket and
water pump weep hole leaks
and resample at half of
normal interval.
Potassium parts per million (PPM) level exceeds critical potassium flag limit based on
oil lab results or Cummins Inc. limits
Cause Explanation Correction
If a sudden high reading,
verify that coolant used in
this engine contains
potassium. Check if there is
an elevated reading in silicon
Possible lab testing error, or sodium, if these are
Possible lab error, sample
recording error, sample contained in coolant. Check
contamination, or other
contamination, or other for elevated levels of lead or
reasons causing a single
reasons for a single high copper. If these combinations
high reading
reading. also have a sudden high
reading, or if oil tests positive
for glycol, continue with tree.
If only potassium is elevated,
follow the potassium exceeds
caution flag limit tree.

27 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Potassium parts per million (PPM) level exceeds critical potassium flag limit based on
oil lab results or Cummins Inc. limits
Cause Explanation Correction
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
Check for and repair any
head gasket and water pump
weep hole leaks. If no
Potassium is commonly used external leaks or problem
Oil contaminated by coolant
as a cooling system inhibitor. persists, follow Coolant Loss
- Internal Troubleshooting
Tree. Check turbocharger
axial and radial clearance.
Silicon parts per million (PPM) level exceeds the caution or critical silicon flag limit
based on oil lab results or Cummins Inc. limits
Cause Explanation Correction
Check whether hours on oil
If oil hours at time of sample
at time of sample is more
are greater than oil hours for
Extended oil sample interval than 25 percent longer than
past samples, wear metals
previous sample hours. If so,
may be elevated.
resample at regular interval.
Remote oil tank circulation, Oil is not being replenished Repair remote oil circulation,
makeup oil or Centinel™ or oil capacity is reduced, makeup oil, or Centinel™
systems are not functioning causing an elevated level of system. Resample at regular
properly wear metals. interval.
Engine has had a repair
Repair to engine resulting in Resample at regular interval.
where silicone gaskets have
replacement of silicone Silicon should return to
been replaced or silicone
gasket or silicone sealant normal level within 1,000
sealant has been applied
that is reacting with oil. hours of operation.
within the last 1000 hours
Repair to engine resulting in Resample at regular interval.
Engine is new or recently
replacement of silicone Silicon should return to
rebuilt with less than 1000
gasket or silicone sealant normal level within 1,000
hours of operation
that is reacting with oil. hours of operation.

28 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Silicon parts per million (PPM) level exceeds the caution or critical silicon flag limit
based on oil lab results or Cummins Inc. limits
Cause Explanation Correction
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
Check whether aluminum is
also at elevated level. If so,
check if dipstick tube and/or
oil fill cap is missing, loose,
or has a missing seal.
Inspect the intake system for
holes and sources of leaks.
Check for collapsed air filters
and proper sealing around air
Dirt is made up of Silica and
cleaners. Repair as
Alumina. Silicon and
necessary. Check for
Dirt intrusion Aluminum in 2:1 to 10:1
increased oil consumption
Silicon:Aluminum ratio
and high blowby. Reference
indicates dirt.
Lubricating Oil Consumption
Excessive or Crankcase
Gases (Blowby) Excessive
Troubleshooting Tree. Check
whether iron, copper and/or
lead are also at an elevated
level. If so, reference the
respective troubleshooting
tree.
Verify that coolant used in
this engine contains silicon.
Check whether sodium
Silicon is commonly used as and/or potassium are also at
Coolant contamination
a cooling system inhibitor. elevated levels. If so,
reference sodium and/or
potassium troubleshooting
trees.
Sodium Parts per million (PPM) level exceeds sodium caution flag limit based on oil lab
results or Cummins Inc. limits

29 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Cause Explanation Correction

Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
Sodium is sometimes Compare parts per million
Oil formulation has recently
contained in the oil additive (ppm) of sodium with unused
been changed
package. oil sample.
Determine if engine could
have recently been
Wash water entered engine Salts (sodium) are contained contaminated with high
contaminating oil in detergents. pressure wash water. If so,
change oil and resample at
normal interval.
Verify that coolant used in
this engine contains sodium.
Check whether silicon and/or
potassium are also at
elevated levels, if these are
Sodium is commonly used as also contained in coolant. If
Oil contaminated by coolant
a cooling system inhibitor. so, monitor coolant
consumption, check for and
repair any head gasket and
water pump weep hole leaks
and resample at half of
normal interval.
Sodium Parts per million (PPM) level exceeds critical sodium flag limit based on oil lab
results or Cummins Inc. limits
Cause Explanation Correction

30 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Sodium Parts per million (PPM) level exceeds critical sodium flag limit based on oil lab
results or Cummins Inc. limits
Cause Explanation Correction
If a sudden high reading,
verify that coolant used in
this engine contains sodium.
Check if there is an elevated
reading in silicon or
potassium, if these are
Possible lab error, sample Possible lab error, sample
contained in coolant. Check
contamination, or other contamination, or other
for elevated levels of lead or
reasons causing a single reasons causing a single
copper. If these combinations
high reading high reading.
also have a sudden high
reading, or if oil tests positive
for glycol, continue with tree.
If only sodium is elevated,
follow the sodium exceeds
caution flag limit tree.
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
Check for and repair any
head gasket and water pump
weep hole leaks. If no
Sodium is commonly used as external leaks or problem
Oil contaminated by coolant
a cooling system inhibitor. persists, follow Coolant Loss
- Internal Troubleshooting
Tree. Check turbocharger
axial and radial clearance.
Viscosity is higher than limit based on oil lab results or Cummins Inc. limits
Cause Explanation Correction
Check whether hours on oil
If oil hours at time of sample
at time of sample is more
are greater than oil hours for
Extended oil sample interval than 25 percent longer than
past samples, viscosity may
previous sample hours. If so,
be elevated.
resample at regular interval.

31 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Viscosity is higher than limit based on oil lab results or Cummins Inc. limits
Cause Explanation Correction
Remote oil tank circulation, Repair remote oil circulation,
Oil is not being replenished
makeup oil or Centinel™ makeup oil, or Centinel™
or oil capacity is reduced,
systems are not functioning system. Resample at regular
causing increased viscosity.
properly interval.
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
Confirm viscosity is within
Oil formulation and/or
Change in oil viscosity due to specification of oil
viscosity grade has recently
difference in oil specification. formulation. Resample at
been changed
regular interval.
Check whether sodium
and/or potassium are also at
elevated levels. If so,
Coolant emulsion with oil Oil contaminated by coolant.
reference sodium and/or
potassium troubleshooting
trees.
Change oil. Increase oil
Combustion by-product temperature by running
condensation occurs with engine at higher loads or
Water emulsion with oil
extended light load running using other means and
and cold weather conditions. reduce operation at light
loads.
Check blowby. If high, follow
Oil contaminated by
Contamination of oil causing the Crankcase Gases
combustion by-products or
higher viscosity. (Blowby) Excessive
dust intrusion
troubleshooting tree.

32 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

Viscosity is higher than limit based on oil lab results or Cummins Inc. limits
Cause Explanation Correction
Check for increase in
oxidation of oil. Check for
high oil temperature. If high,
High oil temperature due to follow high oil temperature
localized component failure troubleshooting tree. Check
Excessive oil temperature causes oil oxidation and for elevated levels of iron,
increases viscosity. May also copper, lead, and/or
see elevation in wear metals. aluminum. If high, follow

troubleshooting trees for

respective metals.
Viscosity is lower than limit based on oil lab results or Cummins Inc. limits
Cause Explanation Correction
Change oil in engine sump
and remote oil tank. Check
Engine has recently been Previous repair caused oil
external oil circuitry (i.e.
repaired, causing oil contamination and oil system
remote filter head/remote oil
contamination was not purged.
tank) for contamination.
Resample at regular interval.
Oil formulation and/or
Change in oil viscosity due to
viscosity grade has recently Resample at regular interval.
difference in oil specification.
been changed
Verify that fuel dilution is also
Fuel contamination reduces flagged on oil sample. If so,
Oil contaminated by fuel
oil viscosity. follow Fuel in the Lubricating
Oil Troubleshooting Tree.

Document History
Date Details
xxxx-xx-xx Module Created

2012-10-4 Update causes and troubleshooting steps for fuel dilution.

2017-6-5 Updated Table 1 and Table 2. Added Product Affected section.

Last Modified: 10-Jul-2017

33 of 34 7/31/2019, 9:52 AM
Oil Analysis Techniques for High Horsepower Diesel Engines https://quickserve.cummins.com/qs3/pubsys2/xml/en/bulletin/4022060.html

34 of 34 7/31/2019, 9:52 AM