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Product: TRUCK
Model: 789C TRUCK 2BW
Configuration: 3516B Custom Engine For 789C Off-Highway Truck 2BW00001-UP (MACHINE)
Special Instruction
Engine Oil Contains Elevated Lead (Pb){1348}
Media Number -REHS8653-00 Publication Date -19/11/2013 Date Updated -19/11/2013
i05374366
Engine Oil Contains Elevated Lead (Pb){1348}

SMCS - 1348
Caterpillar Products:Machine Engines All 3500 Series
Introduction
This Special Instruction provides guidance for when levels of lead (Pb) in engine oil samples are elevated to a
point of Action Required according to S·O·S wear tables.
Lead in engine oil does not always come from main or rod bearings. However this Special Instruction
presumes that the bearings are the most likely source. Lead from other sources, such as excessive thrust
washer or bronze bushing wear, most commonly is accompanied by highly elevated levels of copper (Cu).
Note: This publication is to be used to explore the root cause of elevated lead in oil samples. Due to the risk
of debris introduction from physical bearing inspections or replacements, investigate the root cause
thoroughly prior to disassembling the engine.
Additional Resources
Professional classroom instruction on oil sampling, analysis, and interpretation is available, course 08E1017
S·O·S Services Interpretation Training I. Course information, help sheets, wear tables, and community
discussion is available under S·O·S Services on the Knowledge Network (https://kn.cat.com). Other helpful
resources:
• Operation and Maintenance Manual, SEBU6250, "Caterpillar Machine Fluids Recommendations"
• Special Instruction, SEBD0640, "Oil and Your Engine"
Action Required : Example
https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 05/08/2017
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Illustration 1 g03403230
Typical example wear table. Values subject to change.
Example of a trend chart with lead level elevated to Action Required
If an oil analysis returns from the lab with an elevated level of lead and action is required, follow the steps
listed below.
1. Review and Validate the Sample
2. Determine the Root Cause - Wear or Chemistry
3. Resolve and Proceed
Review and Validate the Sample
Sample Collection, Age, and Analysis
Verify that the sample was collected and delivered correctly. Verify that the lab has been used in the past.
Verify the hours of the oil. Was an oil change missed?
Compare to Trend
Has the lead level in the oil from this engine been steady or trending upward in recent samples? If the lead
level is trending up, has the rate of increase been gradual or rapid? Has a follow-up sample been taken and
analyzed to confirm a rapidly increasing trend? If the trend is indeed increasing rapidly, the engine should be
shut down and action taken immediately to investigate and resolve the problem.
Service Records
Carefully consider service records including recent component changes, modifications to lubrication, cooling
or fuel systems, or any adjustments to the oil renewal system if equipped. Do service records reflect any
change of suppliers or formulations of oil, coolant, or fuel? Lead is common in various greases sometimes
used as assembly aids.
Operation Records
Consider operational changes including major changes in haul cycle, profile, shift, operator, and so on. Is the
operator noting anything unusual? Has the fuel burn rate changed or have there been any changes to the rate
of oil consumption or frequency/volume of oil additions?
Consider Collecting Another Sample
Has resampling been considered after changing oil and filters? Has this sample been collected early due to
elevated lead in the previous sample?
Table 1
Review and Validation Checklist
Points to Consider Notes
Correctly Collected?
Correctly Analyzed?
Sample Collection, Age, Analysis
Reported Hours Correct?
Oil Change Interval (OCI) Correct?
Steady?
Compare to Trend from this engine Gradually Increasing?
Rapidly Increasing? (1)
Major Component Replacements?
Modifications to lubrication, cooling, or fuel system?
Service Records
Changes in Oil, Coolant, of Fuel Suppliers?
Changes in Oil, Coolant, or Fuel Formulations?
Changes to haul cycle or profile?
Changes in shift or operator?
Operation Records
Noteworthy operator comments?
Rate changes in fuel burn or oil additions?
Is it safe to change oil and filters and resample?
Consider Resample
Has the engine been resampled?
(1)
Shutdown and resolve, if rapidly increasing trend is confirmed.
Determine Root Cause

Lead is most often removed from bearings by mechanical wear or chemical wear.
Mechanical Wear
Mechanical wear of main and connecting rod bearings most commonly originates from one or more of the
sources listed below:
• Dirt/Debris Introduction from Service or Operation
• Dirt Ingestion Through the Air System
• Abnormal Operating Conditions
• Out of Specification or Damaged Components
Dirt/Debris Introduction from Service or Operation
Dirt and debris can be introduced into the lubrication system anytime the engine is opened for service, repair,
or oil additions. Review service and operation records to understand when the engine has been opened and to
identify other possible sources for dirt or debris entry, including changes in personnel. Routine inspection of
oil filter media and magnetic drain plugs for signs of debris is encouraged.
Note: The first few samples from new or newly rebuilt engines often contain elevated levels of silicon from
seal materials. Elevated levels of silicon in new or newly rebuilt engines can be normal.
Dirt Ingestion Through the Air System
The chemical makeup of dirt is regionally unique, but generally dirt contains at least silicon and aluminum in
a ratio close to Si:Al = 3:1. Dirt ingestion through the air system often generates elevated levels of iron and
chromium first from liners, pistons and rings via abrasive wear. Levels of lead often rise shortly thereafter as
dirt enters the lubrication system. Regular testing to find and fix leaks in the air system is encouraged. Refer
to the following for additional information for testing the air system:
• Testing and Adjusting, RENR8327, "Air Inlet System - Test and Inspect"
• Testing and Adjusting, SENR1450, "Air Inlet System - Test and Inspect"
• Service Magazine, SEPD0712, "Procedure to Test the Air Induction System"
Abnormal Operating Conditions
Review records for evidence of overspeed, low oil level, low oil pressure, high coolant temperatures, and
other abnormal operating conditions. If the product is equipped with an overspeed protection system, the
operator should enable the system and leave the system engaged. Disabling or overriding overspeed
protection systems can rapidly accelerate bearing wear and increase risk of component breakage. Pumping
small quantities of oil and usage of oil with incorrect chemistry can aerate the oil and accelerate bearing wear.
High coolant temperatures can also increase bearing wear and lead loss by reducing oil viscosity and
accelerating oxidation. Lead levels can rise rapidly when operating in abnormal conditions. Extra diligence
with a quality oil sampling and analysis program is encouraged.
Out of Specification or Damaged Components
When lead levels are elevated alone, without contaminants such as water, glycol, or fuel, deterioration
indicators (oxidation, nitration, sulfation), or other wear elements (Fe, Cr, Ni, Cu, Sn, Si, Al), crankshaft and
connecting rod history becomes a common area of focus. How many hours are on the crankshaft and
connecting rods? Has the crankshaft been polished, or ground and polished? Did the salvage procedure follow
best practices as published in Reuse and Salvage Guidelines, SEBF8041, "Specifications for Crankshafts in
3500 Engines" and Reuse and Salvage Guidelines, SEBF8042, "Procedure for Grinding and Polishing the
Crankshaft" Were correctly sized bearings installed if the crankshaft has been ground? Over-polishing of
crankshaft journals often creates journal inconsistencies which can accelerate bearing wear and lead loss.
End of Life Components
Wear metal concentrations tend to rise as components reach the end of the components service life. If the
engine components are approaching targeted replacement points, a gradual increase in wear metal
concentration can be normal. Pay close attention to oil analysis results. Slight reductions in oil change
interval, changes to the usage profile, or similar adjustments may be required to reach the targeted
replacement points.
Chemical Wear
Problems with oil chemistry that contribute to loss of lead from bearings most commonly originate from one
or more of the sources listed below:
• Extended Usage of Old Oil
• Fuel Contamination (Dilution)
• Coolant Contamination
• Oil Deterioration and Soot Contamination
Extended Usage of Old Oil
There is no other maintenance procedure as important as regularly changing oil and filters.
Operation and Maintenance Manuals specify a maximum oil change interval (OCI) based on close monitoring
of wear metals/oil condition and the following targeted milestones: service hours or calendar time, whichever
comes first. Products that operate in severe conditions, or that have high fuel burn rates, may require more
frequent oil changes. Refer to Special Instruction, SEBD0640, "Oil and Your Engine" for additional
information.
Fuel Contamination (Dilution)
Raw fuel can enter the lubrication system directly from leaking injector seals, transfer pump seals, and
cracked fuel supply manifolds. Unburned fuel can also enter the lubrication system indirectly through leaking
injector seals, injectors with poor spray patterns, by frequent cold starting and by misguided efforts to alter
fuel or timing profiles. Unburned fuel in the combustion chamber can wash the oil film from the liners,
pistons and rings resulting in increasing levels of iron and chromium in engine oil samples.
As oil becomes contaminated (diluted) with fuel, the oil viscosity drops, which reduces the thickness of the
oil film that separates the crank journals from the bearings. The loss of viscosity can rapidly accelerate
bearing wear.
Dropping viscosity is a far better indicator of fuel dilution than wear metal levels. A viscosity decrease of 2
cSt or more is usually a sign of fuel dilution. Careful attention to viscosity trends is encouraged.
The levels of lead and other wear metals in oil samples may not increase significantly as a result of fuel
dilution, however bearing damage from fuel dilution can be very swift.
Fuel in engine oil also dilutes important oil additives, reducing effectiveness. Refer to Troubleshooting,
RENR5622, "Fuel Dilution of Engine Oil". The first few oil samples from new, or newly rebuilt engines
often contain elevated concentrations of fuel. The elevated concentration of fuel in early oil samples can be
normal.
Coolant Contamination
Coolant can contaminate engine oil through leaking cylinder head gaskets, water ferrules, cracked cylinder
heads, leaking water pump seals, cracked liners, leaking heat exchangers, leaking fuel injector seals and other
sources. Coolant in the engine oil can create a thick sludge capable of blocking oil passages and clogging oil
filters. Such substances can also reduce oil lubricating properties and act as oxidation catalysts. Oil
contaminated with coolant tends to undergo an increase in oil viscosity and levels of K, Na, Cu, Si, Mo, B,
Fe, and Al are often elevated along with Pb. Refer to Troubleshooting, RENR5622, "Oil Contains Coolant".
Oil Deterioration and Soot Contamination
Oil oxidizes naturally with time in service and the oxidation process accelerates with high temperatures. For
these reasons, oxidation is often associated with long OCIs and/or high temperature operation. Oxidation
results in oil thickening, formation of resins, piston deposits, loss of lubricating qualities, and accelerated
wear. Highly oxidized oil can leave a honey-colored residue on crankshaft journals. Likelihood of oil filter
plugging, filter bypass, and exposure of engine bearings to debris increases with increasing oxidation.
As acids of nitrogen and sulfur form in the engine oil, these acids break down the additives in the oil and
accelerate the oxidation process. These acids also create a corrosive environment where lead from engine
bearings can leach into the oil.
Table 2
Common Chemical Wear Factors
Item No Action Required Monitor Action Required
Oxidation ≤ 23 UFM 24-33 UFM ≥ 34 UFM
Sulfation ≤ 27 UFM 28-33 UFM ≥ 34 UFM
Viscosity < ± 2 cSt ± 2 cSt ≥ ± 3 cSt
Table 2 lists factors related to the proper chemistry of diesel engine oil and certain guidelines for monitoring
those factors.
Soot is a product of unburned fuel and is produced by all diesel engines. Soot is an abrasive that becomes
more damaging to engine components if soot particles are allowed to agglomerate to form larger particles. All
diesel engine oils contain dispersants to keep soot particles from sticking together. When engine oil is
contaminated with soot, abrasive mechanical wear accelerates. Soot tends to be produced more readily in
engines operating at high altitudes and/or having lower than optimal boost pressure. Soot is one of the reasons
that recommended oil change intervals for products operating at high altitudes are reduced relative to the oil
change intervals of similar products operating at low altitudes.
Oil deterioration and accumulation of soot often results from broken rings and/or worn liners that allow
excessive blowby. Refer to Special Instruction, REHS7857, "Testing for Excessive Cylinder Blowby in 3500
Engines" for guidance in identifying cylinders plagued with broken rings and/or worn liners.
Resolve and Proceed

Table 3
Quick Reference Troubleshooting Guide
Oil Analysis Probable Cause Notes and References Recommended Action
Result
Alter service or maintenance
practices to eliminate dirt/debris
introduction. Resample oil to
Review service and
confirm wear metal concentrations
Mechanical Wear : maintenance practices.
return to acceptable levels.
High Pb and Dirt/Debris Introduced Inspection of magnetic
Consider bearing replacement if
high Si, Al Through Service or plugs and oil filter
the dirt/debris introduction was
Operations elements are
severe (high concentration, long
recommended.
duration, and so on) and/or if the
engine is not close to PCR target.
Repair source of dirt ingestion and

resample oil to confirm wear metal
concentrations return to acceptable
Refer to Service
High Pb and Mechanical Wear : Dirt levels. Consider bearing
Magazine, SEPD0712,
high Si, Al, Ingestion Through the Air replacement if the dirt ingestion
"Procedure to Test Air
Fe, Cr System was severe (high concentration,
Induction System".
long duration, and so on) and/or if
the engine is not close to PCR
target.
3516B Custom Engine For 789C Off-Highway Truck 2BW00001-UP (MACHIN... Página 10 de 11
High Pb and Mechanical Wear : Thrust Bushings, bearings, and Check filter media and magnetic
high Cu Bearings or Bushings thrust washers in rear plugs for presence of larger
gear train and air particles. Replace worn
compressors are components and resample oil to
common sources. confirm wear metal concentrations
Larger particles can have returned to acceptable levels.
often be observed in
filter media.
Reduce oil change interval, alter
operations or maintenance
practices that created abnormal
conditions, and consider hours
Mechanical and/or remaining to make PCR target.
Missed oil changes are
Chemical Wear : Resample oil as needed to confirm
one of the most
Extended Oil Change wear metals concentrations return
High Pb Only common sources of
Interval, Abnormal to acceptable levels. Consider
elevated Pb alone.
Operating Conditions, Out bearing replacement if extended oil
Review operations and
of Specification or End of change interval, abnormal
service records.
Life Components operation, or out of specification
was severe (high concentration,
long duration, and so on) and/or if
the engine is not close to PCR
target.
Watch for viscosity
Repair source of fuel dilution.
Low viscosity decrease of > 2cSt
Consider bearing replacement if
or presence of versus trend. Refer to
Chemical Wear : Fuel the fuel dilution was severe (high
fuel and Troubleshooting,
Dilution concentration, long duration, and
occasionally RENR5622, "Fuel
so on) and/or if the engine is not
high Pb Dilution of Engine Oil".
close to PCR target.
Repair the coolant leak. Resample

oil to confirm that wear metal
Watch for
concentrations return to acceptable
concentrations of Na or
High Pb and levels. Consider bearing
Chemical Wear : Coolant K ≥ 25 ppm. Refer to
high Na or K replacement if the coolant leak was
Leak Troubleshooting,
severe (high concentration, long
RENR5622, "Oil
Contains Coolant".
Watch for Repair the coolant leak. Resample

concentrations of Na or oil to confirm that wear metal
K ≥ 25 ppm. Watch for concentrations return to acceptable
High Pb and
viscosity increase of levels. Consider bearing
high Na or K Chemical Wear : Coolant
greater than 2 cSt replacement if the coolant leak was
and high Leak
versus trend. Refer to severe (high concentration, long
viscosity
Troubleshooting, duration, and so on) and/or if the
RENR5622, "Oil engine is not close to PCR target.
Contains Coolant".
High Pb and Chemical Wear : Coolant Watch for Repair the coolant leak. Resample
high Na or K Leak concentrations of Na or oil to confirm that wear metal
and presence K ≥ 25 ppm. Refer to concentrations return to acceptable
of glycol or Troubleshooting, levels. Consider bearing
water RENR5622, "Oil replacement if the coolant leak was
Contains Coolant". severe (high concentration, long
3516B Custom Engine For 789C Off-Highway Truck 2BW00001-UP (MACHIN... Página 11 de 11
Refer to product
High Pb, high Operation and Reduce oil change interval and
oxidation, and Chemical Wear : Maintenance Manual or resample oil to confirm that wear
high viscosity Degraded Oil Special Instruction, metal concentrations return to
SEBD0640, "Oil and acceptable levels.
Your Engine".
Refer to product
High Pb and
Operation and Reduce oil change interval and
high soot,
Chemical Wear : Maintenance Manual or resample oil to confirm that wear
high iron, and
Degraded Oil Special Instruction, metal concentrations return to
high viscosity
SEBD0640, "Oil and acceptable levels.
Your Engine".
Replace cylinder pack/s for
cylinder/s with blowby or
Refer to REHS7857
High Pb and Chemical Wear : likelihood of broken rings.
"Testing for Excessive
high oxidation Incomplete Resample oil to confirm that
Cylinder Blowby in
and iron Combustion/Blowby combustion product and wear
3500 Engines".
metal concentrations return to
acceptable levels.
Operator complaints of
low power are often Repair the source of the boost leak
High Pb and Chemical Wear : reported. Faulty and resample oil to confirm wear
high soot Incomplete Combustion turbochargers and/or metal concentrations return to
boost leaks are often acceptable levels.
found.
Copyright 1993 - 2017 Caterpillar Inc. Sat Aug 5 22:13:57 EST 2017
All Rights Reserved. r461ah
Private Network For SIS Licensees.

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3516B Custom Engine For 789C Off-Highway Truck 2BW00001-UP (MACHINE)...

Engine Oil Contains Elevated Lead (Pb){1348}

Caterpillar Products:Machine Engines All 3500 Series

• Operation and Maintenance Manual, SEBU6250, "Caterpillar Machine Fluids Recommendations"

• Special Instruction, SEBD0640, "Oil and Your Engine"

Action Required : Example

Typical example wear table. Values subject to change.

Example of a trend chart with lead level elevated to Action Required

1. Review and Validate the Sample

2. Determine the Root Cause - Wear or Chemistry

3. Resolve and Proceed

Review and Validate the Sample

Sample Collection, Age, and Analysis

Consider Collecting Another Sample

Determine Root Cause

• Dirt/Debris Introduction from Service or Operation

• Dirt Ingestion Through the Air System

• Abnormal Operating Conditions

• Out of Specification or Damaged Components

Dirt/Debris Introduction from Service or Operation

Dirt Ingestion Through the Air System

• Service Magazine, SEPD0712, "Procedure to Test the Air Induction System"

Abnormal Operating Conditions

Out of Specification or Damaged Components

End of Life Components

• Extended Usage of Old Oil

• Fuel Contamination (Dilution)

• Oil Deterioration and Soot Contamination

Extended Usage of Old Oil

Fuel Contamination (Dilution)

Oil Deterioration and Soot Contamination

Resolve and Proceed

Repair source of dirt ingestion and

Repair the coolant leak. Resample

Watch for Repair the coolant leak. Resample

engine is not close to PCR target.

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