M.I. 1752 Rev. M
MAINTENANCE INSTRUCTION
Lubricating Oil For Domestic 567, 645 and 710 Locomotive Engines
SAFETY PRECAUTIONS Please refer to the EMD Safety Precautions section in the applicable Locomotive Running Maintenance Manual or Locomotive Service Manual whenever routine service or maintenance work is to be preformed. WARNING: Running the engine with oil that has HIGH fuel dilution may result in a crankcase explosion and/or severe engine damage. _______________________________________________________ ___________________________ ____________________________________________. ________________.
© Copyright 2004 General Motors Electro-Motive. All rights reserved. Neither this document, document, nor any part thereof, may be reprinted without the expressed written consent of General Motors Electro-Motive. Contact GM EMD Service Publications Office.
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TABLE OF CONTENTS
1.0
Introduction Introduction ............................................ ................................................................... .............................................. .............................. ....... 4
2.0
Oil Quality .............................................. ...................................................................... ................................................ .............................. ...... 4
3.0
Oil Type......................... Type .................................................. .................................................. .................................................. ............................. .... 5
3.1 3.2
Introduction............ ................................................... ............................................. 5 Fuel Efficient Oils.................. .................................................... ................................................................................ ............................ 6
4.0
Qualification Qualification Tests for Oil...................................................... Oil........................................................................... ..................... 6
5.0
Development Development Program Requirements Requirements for New Oil Formulations............ Formulations............ 6
5.1 5.2 5.3 5.4
6.0 6.1 6.2 6.3 6.4 6.5 6.6 6.7
Laboratory Evaluations............................................ Evaluations ............................................ .............................................. 6 2-567 Silver Lubricity Test................................................... Test ................................................... ................................. 7 Full Scale Field Test .............................................. ................................................ 7 Summary ..................................................... ............................................................................................................. ........................................................... ... 7
Specific Recommendations Recommendations .............................................. ..................................................................... ......................... .. 7 Use of One Oil ........................................................ ....................................................................................................... ............................................... 7 Mixing of Oils........................ ................................................... ............................. 8 Re-Refined Oils .................................................. ................................................... 8 Reclaimed Oils.................................................................... Oils................ ....................................................................................... ................................... 8 Filter Changes ..................................................... ........................................................................................................ ................................................... 9 Oil Changes............................. ........................................................ ............................................................................... ....................... 9 Fuel Dilution ......................................................... ............................................... 10
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1.0 Introduction This Maintenance Instruction (MI) is reissued for the following reasons: • Add multigrade oil information to Table 1 • Add recommendations on re- refined oil • Add recommendations on fuel dilution in Table 2 • And new information to Table 3 This MI provides recommendations, suggestions, and comments for the selection of a suitable engine lubricating oil. In this document, the word oil refers to engine lubricating oil unless otherwise noted. The following topics are covered: Oil Quality • Oil Type • Qualification Tests for Oil • Development Program Requirements for New Oil Formulations • Specific Recommendations •
2.0 Oil Quality Actual performance performance in the d iesel iese l eng ine i s the only only real real measure measure of quality quality in oil. This is beca be cause use of the imp oss ibilit ibi lit y of estab est ablis lis hing hi ng limit lim itss o n all al l physi ph ysi cal ca l a nd chem ch emic ical al prop pr opert ert ies ie s o f oil s, whi ch can ca n affec af fec t their performance in the engine over a broad range of environmental influences. Oil quality is defined as consistent compliance with oil specifications and is the responsibility of the oil supplier, a term applicable to refiners, blenders, and rebranders of oil. oil. Because there are a substantial number of commercial oils marketed today, engine manufacturers and consumers cannot completely evaluate the entire spectrum of products available. As a resu lt, the s electio n of suita ble, heavy duty duty oil oil must must be be made in consultation with a reliable oil supplier capable of making product recomme ndatio ns commen surate with the engine engine builde builder’s r’s speci specific ficati ations ons and specific and specific envi enviro ronmental nmental influences, as well as furnishing such a product on a consistent quality level.
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3.0 Oil Type 3.1
Introduction
General Motors Electro-Motive (EMD) requires the use of an SAE 40 or SAE 20W40 heavyth e specifications speci fications in Table 1 in all engine applications applications.. duty additive type oil conforming to the In addition to the properties described in Table 1, the oil formulation should have a high resistance to oxidation, and a low tendency toward the formation of harmful carbonaceous and/or additive ash deposits. Additionally, it must be non-corrosive to silver metal at 285° F (140° C) (EMD L.O. 201 test). Oils with sufficient alkaline reserve (TBN) (T BN) and highly effective detergent-dispersant systems should b e employed employe d in line with fuel quality quality and and service demands.
Table 1. SAE 40 and SAE 20W40 Oil Specifications Property
ASTM Test Designation
New, Unused Oil Limits SAE 40 SAE 20W40
Viscosity: D88 or D445 Saybolt Universal Seconds at 690-1100 (149-237.5 cSt) 580-890 (125-192 cSt) 100° F (37.8° C) 70-85 (12.9-16.8 cSt) 72-85 (13.6-16.8 cSt) Seconds at 210° F (98.9 ° C) 132 – 206 112 – 170 cSt at 40° C (104° F) 12.5 – 16.3 13.2 – 16.3 cSt at 100 ° C (212° F) Viscosity Index D2270 60– 105 105– 125 Low Temperature Cranking D5293 (20W) 9500 cP max @ -15 °C Viscosity Flash Point D92 420° F Min. (216° C) Fire Point D92 475° F Min. (246° C) Pour Point D97 40° F Max. (4.5° C) Zinc Content (Note 1) 10 ppm Max. Total Base Number ( N o t e 2 ) D2896 7 – 20 Zinc additive compounds, such as zinc dithio-phosphate, must not be present in oil for EMD Note 1: engines. Oils containing more than 10 ppm zinc may be contaminated with zinc dithio-phosphate or similar similar additive compounds, which will not satisfactorily satisfactorily lubricate the silver bearings bearings in some EMD engines. Note that oil analysis on new or rebuilt engines may show initial elemental zinc content which exceeds the 10 ppm limit. This can be due to to the use of a recommended thread thread compound that contains contains zinc metal. metal. Zinc metal is harmless to silver bearings and its concentration in the oil will dissipate in time through normal oil addition. Note 2: The use of oils with Total Base Numbers over 13 (ASTM D-2896) are generally not required unless fuel s ulfur levels exceed 0.5% o r the higher levels levels of detergency detergency and/or dispersancy dispersancy associat associated ed with these higher base number products is demanded.
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3.2
Fuel Efficient Oils
Future oil products may have associated claims relating to improved fuel economy due to the use of multigrading, friction modifiers, or combinations of both. bot h. EMD policy requires that the diesel engine oil o il satisfactorily lubricate the entire engine and does not address the fuel economy aspects of such products. As a result, result, the responsibility for any such claims must rest with the oil/additive supplier.
4.0 Qualification Tests for Oil The diesel engine oil must satisfactorily lubricate the entire engine under all conditions expected to be encountered. While the condition and performance of the engine in actual service provides the criteria in reaching a final judgment of oil suitability, there are several laboratory tests that are useful in making preliminary evaluations of a product, as follows: 1. Physical and chemical profiles 2. Corrosion of metals: a. Silver and copper - EMD No. L.O. 201 method. b. Lea d - S.O.D S.O .D Method Met hod No. 5321-1 532 1-1 (modifi (mo dified) ed).. 3. Overall evaluation of oxidation stability by the EMD L.O. 201 method, method, including: a. Viscosity increase characteristics b. Retent Ret ention ion of alkali alk alinit nity y (add ( add itiv e conc c oncent entrat rate) e) c. Development of insolubles.
5.0 Development Program Requirements for New Oil Formulations 5.1
Laboratory Evaluations
The supplier of the lubricant base stock and the supplier of the additive concentrate are expected to conduct complete laboratory and bench test qualifications by ASTM and EMD methods. EMD will review and monitor monitor such tests and, if all results are in good agreement and within acceptable limits, the oil formulation will be considered worthy of 2-567 engine e ngine evaluation to determine its silver lubricity characteristics.
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5.2
2-567 Silver Lubricity Lubricit y Test
The purpose of this test is to determine that tha t the laboratory qualified oil formulation will satisfactorily lubricate the silver wrist pin bearing. This test evaluation is also expected to be cond co nduc ucte ted d or cont co ntra ract cted ed by the th e oil or additive addit ive supplie su pplierr with review revie w and monitoring monito ring of the results by EMD.
5.3
Full Scale Field Test
Upon successful completion of the laboratory and silver lubricity tests, an oil formulation will be considered worthy of full scale field test evaluation. Field tests should be conducted in a minimum of three EMD engines, preferably in heavy duty service, for at least one year. During the field evaluation and its conclusion, EMD will review the oil and eng ine performance data generated by the supplier(s). After successful completion of the field test program, the oil will be considered satisfactory for limited use, but should be should be closely monitored during the following two years of commercial introduction.
5.4
Summary
Oil formulations established and proven by this development program must remain exactly the same with no sub sequent seque nt changes chan ges in their mak e-up. Changes in additive additive component component manufacture or blending process following completion of the development program must be disclosed and reviewed with EMD. If an oil or additive improvement program is desirable or necessary, the revised formulation must be evaluated by going through the complete development program.
6.0 Specific Recommendations 6.1
Use of One Oil
The use of a single brand name lubricant is recommended for locomotive locomotive fleets. This recommendati recommendation on of long long standing standing is substantial substantially ly supported by obse rvations rvat ions of the perfo pe rforma rmance nce of fle ets lubricated with mixed oil products.
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6.2
Mixing of Oils
EMD recommendeds that oils are not mixed. The combining of lubricants with with different additive and base stock components creates a chemical mixture that cannot be readily evaluated in the laboratory, and its field performance cannot be reliably predicted. If mixing of oils is mandatory, the following approach is suggested in an effort to minimize potential risk factors associated with this practice: 1. The oils considered for mixing should contain the same additive concentrate. 2. The viscosity and viscosity index properties should be identical. 3. The number of oils oils to be mixed should be limited limited to no more than three for a given fleet fleet operation. 4. The brand name oil, which is the parent of the common additive selected, should, because beca use of its it s full qualification and fleet experience, be the primary component of the mixture. 5. Only premium premium base stocks should be considered for for the other two components. Each base stock and common additive formulation are to be evaluated by the standard procedures of laboratory analysis and laboratory engine testing. 6. After the three common additive oils are selected, an equally proportioned proportioned mixture of these oils oils should should undergo undergo the same same laborator laboratory y and test engine engin e evalua e valuations. tions. Upon satisfactory completion completion of these these tests, the the mixture mixture should then be evaluated in at least three EMD engines in heavy duty service for a period of at least one year.
6.3
Re-Refined Oils
Oil formulations containing re-refined base stocks may be acceptable for qualification through the test program detailed in this MI if the level of processing and quality of the rerefined base stocks is judged as acceptable to EMD. The oil re-refining process should include suitable screening of used oil feedstocks followed by a multistage process to remove water, light ends, and fuel fuel prior to distillation. distillation. A hydrotreating stage is required after the distillation process to remove any impurities carried over by the distillation process. Finally, the supplier must demonstrate that the re-refined re-refined stocks pass rigorous statistical control standards to assure product consistency and quality.
6.4
Reclaimed Oils
Considered as a general category, reclaimed oils are not recommended for lubrication of EMD engin e ngin es. If reclaimed reclai med oils are to be use d, their use requires requires a maximum maximum of evaluat evaluation ion and and control, an d the following sugge stions are offered: 1. The reclaimed oil must have the same additive package as the name brand brand oils with which it will be mixed. 2. The reclaimed oil must pass all analysis and quality control requirements requirements of brand name oils.
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3. The reclaimed oil should be introduced into the main supply tank of the railroad railroad facility at a rate not to exceed a 20% ratio. 4. Reclaimed oil should never be used as a full engine charge.
6.5
Filter Changes
Regular monitoring of oil filter tank pressure should be used to determine filter condition. Replacement of oil filter elements should be made according to the Scheduled Maintenance Program, unless pressure monitoring or laboratory analysis of the oil dictates earlier replacement. Replacement elements elemen ts must be of the EMD type or equivalent in all respects. Elements intended intended for use with other o ther type t ypess of engine eng iness are not no t suita ble. ble . Where highly dispersant dispersant oils are employed, carbonaceous matter may be suspended so finely in the oil that it is essentially essentially unfilterabl unfilterable. e. In such situations situations,, it might mig ht ap pear pea r that tha t an exten ex tension sion o f the fil ter replacement interval may be justified. justified. However, caution should be exercised when contemplating such action since filter materials have not yet been developed that will tolerate prolonged exposure to lubricants at high temperature without deterioration and/or possi po ssibl blee disin di sin tegra te gra tion ti on of the filte fil terr m edia ed ia..
6.6
Oil Changes
Oil change intervals prescribed in the applicable Scheduled Maintenance Program are based on average operating o perating conditions cond itions with quality fuels of o f less than 0.5% sulfur content. When oil change intervals are overextended, serious and costly engine problems may result. This can occur if the additive concentrate is depleted beyond acceptable limits, and the oil loses essential properties properties including alkalinity, detergency, and dispersan dispe rsancy. cy. In the absence a bsence of vital vit al reserves re serves of the se properties, properties, the oil oil no longer provides provides satisfact satisfactory ory protection of the engine in limiting harmful deposit formations from oxidized oil and other contaminants, or adequate control of the corrosive products of combustion. Oils that have experienced severe additive depletion will result in accelerated engine wear, stuck or broken piston rings, liner scuffing, and corrosive attack and/or frictional failure of vital bearing surfaces. Regular laboratory analysis of the oil is a valuable means of judging the condition of the oil, and is of equal value in in reflecting the condition of the engine. Both engine andoil and oil condition must be given careful consideratio n whe n planning planning to to extend extend oil oil change change intervals beyond those recommended. Table 3 provides detailed information on analysis.
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6.7
Fuel Dilution
EMD guidelines for fuel fuel dilution are covered in Tables 2 and 3. Oil draining is mandatory for whichever event occurs first: exceeding the fuel dilution limit (HIGH or above), or dropping below the minimum viscosity limit. WARNING: Running the engine with oil that has HIGH fuel dilution may result in a crankcase explosion and/or severe engine damage.
Figure 1 shows fuel dilution dilution effects on viscosity and flash point up to 5%. The SAE 20W40 fuel dilution limit is 1% less than the maximum maximum limit allowed for SAE 40 oil. This limit was established to allow for permanent and temporary shear effects associated with multigrade oils. Field experience has shown that new oil starting viscosity is reduced by about 0.75 cSt @ 100 °C in EMD engines due to permanent shear of the multigrade VI improver. This phenomenon coupled with viscosity reduction due to to temporary shear has resulted in minimum viscosity limits of 13.0 cSt @ 100 °C for multigrade oils. EMD recommends that customers develop a fuel dilution chart on their fleet oil to establish the relationship between viscosity and flash point change as a function of percent fuel dilution.
Fuel Dilution Chart 105
60
C 0 100 0 1 @ 95 y t i s o c 90 s i V % l 85 a n i m o 80 N
50
40
30
20
10
75
g e d , p o r D t n i o P F h s a l F . x o r p p A
0 0
1
2
3
4
5
% Fuel Dilution (vol.)
Figure 1. Fuel Dilution
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Table 2. Fuel Dilution Action Required Fuel Dilution %
0–2 2–5 (SAE 40) 2–4 (SAE 20W40)
Condition
Change Filters
Change Oil
Engine Inspection Required
Additional Action Required None
None
Find and fix fuel leak
None
Normal
Borderline
5 – 10 (SAE 40) 4 – 10 (SAE 20W40)
High
X
X
X
DO NOT RUN ENGINE None Find and fix fuel leak Check oil sample for wear metals per M.I. 1752 and follow recommended action DO NOT RUN ENGINE
10 – 20
Very High
20 – 30
X
X
X
Perform crankcase inspection, visually inspect Find and fix fuel leak all upper connecting rod Check oil sample for wear bearing fishback surfaces surfaces metals per M.I. 1752 and for accelerated wear per follow recommended EMM action
X
DO NOT RUN ENGINE Find and fix fuel leak Check oil sample for wear metals per M.I. 1752 and follow recommended action
Remove one connecting rod bearing and visually inspect bearing surfaces per EMM *
DO NOT RUN ENGINE Find and fix fuel leak Check oil sample for wear metals per M.I. 1752 and follow recommended action
Remove one connecting rod bearing and visually inspect bearing surfaces per EMM * Do an airbox inspection per EMM
Extremely High
30 – 40
X
X
* If abnormal wear conditions are found, a main bearing inspection must be done per Engine Maintenance Manual (EMM) or Running Maintenance Manual Also reference: Inspection reference: Inspection & Qualification Qualification Guide Guide – Engine Main Main & Connecting Connecting Rod Bearings (Doc Bearings (Doc MM003003)
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Table 3. Interpretation of Oil Sample Analysis NOTE: Shaded areas indicate the following following recommended action: shut down engine, drain oil, and change filters. Nonshaded areas indicate the following recommendation: change filters only. Oil Analysis Basis for NORMAL BORDERLINE HIGH Recommended Action Analysis No Action Take Extra Oil Correct Required Samples Condition Flash Point & Viscosity – Check for dilution if Flash Point less than 420 F (216 C) See Table 2 for SAE 40 0 to 2% 2 to 5% Above 5% Fuel Leak recommendations. SAE 20W40 0 to 2% 2 to 4% Above 4%
SAE 40 Vis limit @ 100 C, Min. SAE 20W40 Vis limit @ 100 C, Min.
Water Leak
12.5 cSt
13.0 cSt
Free Water
None
Any
Chromate Inhibitor Boron Inhibitor Silicon
0 to 20 ppm
20 to 40 ppm
0 to 10 ppm
10 to 20 ppm
0 to 5 ppm
5 to 10 ppm
Air Filtration
Excessive Oxidation
Contaminated fuel (cracking catalyst)
TBN (D-4739) Min. TAN (D664) Max. Viscosity Rise, Max. @ 100 F, SUS Viscosity Rise, Max. @ 100 C, cSt PH Min. Pentane Insolubles, Max. (D893 modified) Aluminum, Silicon, and/or Magnesium
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Above 40 ppm Above 20 ppm Above 10 ppm
Resample with dry container. Find and fix leak. Check main bearings per Maintenance Manual. Find and fix water leak. Check oil filter tank pressure Improved air filter maintenance required. Antifoam agent present in new oil.
2.5 4.5 30%
12%
5.0 2.0%
Above 5 ppm
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Change Oil. If short oil life persists, check lube lube oil quality, fuel sulfur content, oil cooler efficiency, engine temperature controls, power output (governor and rack settings, EUI injector cal), engine condition (worn rings, cracked pistons, poor combustion), oil filtration, or oil pump suction leak .
Check fuel cleanliness. Notify fuel supplier. If engine smokes, check injector calibration and tip erosion. Check if piston rings are excessively worn
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following recommended action: shut down engine, drain oil, and change filters. NonNOTE: Shaded areas indicate the following shaded areas indicate the following recommendation: change filters only. Oil Analysis Basis for NORMAL BORDERLINE HIGH Recommended Action Analysis No Action Take Extra Oil Correct Required Samples Condition Check if oil is contacting galvanized or zinc painted surfaces. Check if new power assemblies were installed using zinc containing thread Above 10 ppm becomes more Zinc 0 to 10 ppm compound. Check if make make dangerous with increasing values up oil in stock is stock is within specifications. Notify lube oil supplier. Check for silver silver bearing failures if engine is equipped with this bearing Oil type. Contamination Check if oil contains zinc or Silver 0 to 1 ppm 1 to 2 ppm Above 2 ppm is corrosive corros ive to silver. silver. Check Check for broken piston cooling tubes, inefficient oil cooler, or improper temperature control. Feel loaded areas of piston pin p in s for signs signs of distres distress. s. Measure piston to head clearance with lead readings. Oil draining is not mandatory. Check strainers and bottom of oil pan for debris. Abnormal Wear Chromium Above 20 Or Corrosion (Not ppm 0 to 10 ppm Check for rapid wear of rings 10 to 20 ppm (Rapid increases applicable if & liners. within normal chromate range should be coolant considered inhibitor is borderline used) condition) 0 to 75 ppm Measure piston to head Copper 75 to 150 ppm Above 150 clearance with lead readings ppm to locate worn piston thrust washers. Check connecting rod bearing blade thrust faces for distress. (See Note 1) High iron and copper increase oxidation rates. Iron
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0 to 75 ppm
75 to 125 ppm
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Above 125 ppm
Check for rapid wear of rings & liners.
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following recommended action: shut down engine, drain oil, and change filters. NonNOTE: Shaded areas indicate the following shaded areas indicate the following recommendation: change filters only. Oil Analysis Basis for NORMAL BORDERLINE HIGH Recommended Action Analysis No Action Take Extra Oil Correct Required Samples Condition Lead 0 to 50 ppm 50 to 75 ppm Above 75 Most likely lead flash is ppm dissolving off bearings. Premature lead removal, before bearings are broken in, can lead to bearing distress; inspect and replace upper con rod bearings in service less than 6 months if lead flash has been removed from the unloaded area of the fishback bearing surface on turbocharged engines. If con rod bearings require replacement, wrist pin bearings should also also be checked and replaced if lead flash has been removed. If TAN > TBN, corrosive attack of lead can occur. Draining oil is mandatory if oil analysis shows rapid rise of lead ppm has occurred Check for debris under crankshaft gear indicative of gear train bushing distress. Copper Two out of three elements in Check idler gear bearing In Combination Iron borderline or high range clearances. Check main and Lead con rod bearings per Maintenance Manual. Oil draining is not mandatory. Above 1. When in combination 40 with iron or chrome rise, Tin 0 to 20 ppm 20 to 40 ppm ppm check for piston distress. 2. When in combination with lead or copper rise, In Combination check for bearing distress
Note 1: Due to carbon buildup on both the fire face of the cylinder head and the crown of the piston during service life, lead wire readings should not be used as a basis for power assembly change out. Lead wire readings may continue to be used to indicate indicate wear trends. Significant clearance increases should be investigated as possible component failures.
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(D-L) General Motors Electro-Motive La Grange, Illinois 60525 USA Telephone: 708-387-6000 Website: www.gmemd.com ©2004 General Motors Electro-Motive. All rights reserved. Neither this document, nor any part thereof, may be reprinted without the expressed written consent of General Motors Electro-Motive. Contact GM EMD Customer Publications Office.
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