Section 4 — Factors Affecting Oil Performance and Engine Wear Any good lubrication management program must maintain oil change intervals so the engine receives maximum and continual protection. If oil degrades to the point where protection is diminished, engine life cycle is shortened and costs begin to rise. A number of factors can contribute to oil degradation and accelerated wear. They can be placed into two categories: fixed factors and variable factors. Fixed Factors By establishing an oil change optimization program, you and your customer have already identified two fixed factors. 1. You will be testing a specific engine design. And, 2. You will be using one particular oil So for the purposes of this project, the engine design and branditype of oil can be considered fixed. The interaction of these two fixed factors, together with certain variables, will determine the optimal oil change interval. Engine Design ‘An engine’s design and operating characteristics dictate the need for certain oil lubircation qualities. ‘Temperatures, cylinder pressures, horsepower, type of aspiration (naturally aspirated, turbocharged or turbocharges/aftercooled), overall performance rating, sump capacity, oil consumption rate and fuel consumption rate are some of the engine design parameters that impact a lubricant’s useful life. When developing a new engine model, manufacturers consider the lubricating capability of the oil as if it were another engine part. As a result, engine features play a significant role in determining the ‘manufacturer’s recommendations for lubricant classification, viscosity ranges and oil change intervals. The useful life of the same oil used in two or more differently designed engine sin the same application will vary due to engine design and operating characteristics, Please note that two different Caterpillar ‘engine models in the same application may, therefore, have different optimal oil change intervals. Engine oil technology of the past will not provide optimum life and performance in current and future engines. Caterpillar engines have advance through the years to provide the performance and features that customers demand, These advancements have resulted in numerous improvements: * Increased horsepower, from smaller sized engines. * Smokeless combustion «Reduced emissions + Reduced fuel consumption * Reduced oil consumption+ Better response and lugging ability with electronic engine controls Alll these engine improvements have an effect on the engine oil. Increased horsepower drives up temperatures and promotes oil oxidation. Emissions reductions increase soot levels in the oil. Concurrent with higher demands on crankcase oil, engine users are pressing for longer oil drain intervals, Oil technology must keep pace with engine technology and customer needs to provide products that work together for optimum engine life and performance. Engine oil has undergone changes to meet the increasing demands on engines for emissions and performance. These changes are best tracked by the American Petroleum Institute (API) service category and the corresponding engine improvements. API and Caterpillar PC Engines Caterpillar has been active in development of diesel engine oils (DEO) since the 1930s, and Caterpillar set the standards for DEO until the early 1970s. In 1973, API introduced their oil classification system. API CD (previously called Caterpillar Series 3), was adequate for Caterpillar precombustion chamber (PC) type diesel engines. By the early 1980s, the drive was on for improved fuel economy and diesel engines were changing. New engine designs were introduced with direct injection (DI) fuel systems. In 1983, API introduced the CE oil category to address the needs of both DI and PC diesel engines. API and Caterpillar DI Engines The CF-4 category was introduced in 1990 as the first oil category totally dedicated to the modem direct injection (DI) diesel engine. Low emissions, reduced fuel consumption, and higher power ratings were all driving the designs for diesel engines. CF-4 oils tightened the limits on piston deposits to improve engine durability and reliability. By 1994, the emissions laws has changed again and low sulfur diesel fuel was common in North America. Responding to these changes, the API released CG-4 in 1995, and CH-4 in 1998, These oils are designed to operate in the latest low emissions DI diesel engine and in non-tegulated DI diesel engines. CG-4 and CH-4 are especially effective in controlling soot and wear. The following chart shows the progression of oil categories and engine performance. For up-to-date lubrication performance recommendations, refer to the Operation and Maintenance Manual Supplements listed on page 46 of this bulletin. Note: Some oil formulations in particular engine applications will form more deposits than others on engine parts over time. This starts to happen as the oil nears its breakpoint. With some oils, it takes only a few times of operation near the breakpoint for lacquering and carbon to build up enough to cause ring packing and cause an increase in oil consumption. The absence of any apparent or significant increase in wear metals (particularly iron) as the oil change period is being “walked out” in time does not necessarily mean that all is proceeding well. To the contrary, it can mean damage is occurring. Therefore, be sure to monitor the key wear metals for moderate increases normally expected to accumulate because of the increase hours on th eoil. If the ‘wear metals (especially iron) do NOT increase accordingly something is wrong...especially if iron decreases. In this case, more than likely, the wear metals are being diluted by an increased amount of‘make-up during the oil change interval. Ifso, ring packing and/or bore polishing has probably already occurred, Variable Factors The amount of wear occurring during an oil change interval is a general indication of how well a lubricant has performed during that time period. There are several variable factors that operators and maintenance engineers can control to affect a lubricant’s performance, The rate and amount of wear occurring in an engine depends on four factors, as discussed in customer bulletin PEGP7035 (Section 2). These variables are: "Maintenance "Application = External Contamination "Internal Contamination Allof these variables affect the overall condition of the oil. Oil Condition is monitored by SeO¢S oil analysis. Most CH-4 and CG-4 oils will do a satisfactory job of controlling engine wear in their early hours of usage. Engine damage and wear becomes a problem when the oil begins to deteriorate. Deterioration begins at early hours for a low quality oil and at considerably higher hours for top grade oils. However, any oil will eventually deteriorate and begin to allow engine damage and wear. In general, the objective of an oil change optimization program is to identify the usage interval at which a particular oil no longer provides sufficient protection for the engine components. The variable affecting engine oil performance are discussed in detail in the next section.