No.

: 07 TS - 37
June 26, 2007
TO: DDC Distributors, FLLC Dealers, G2 Members

FROM: Technical Service

SUBJECT: Interpreting High Aluminum and Potassium in Used Oil Analysis from
Detroit Diesel Engines

ISSUE
This letter is intended to provide guidance for the proper interpretation of aluminum, potassium,
and sodium levels in oil analysis reports from MY 2002 and newer Detroit Diesel Series 60 and
MBE 4000 engines to avoid unnecessary inspection and repairs.

Oil samples taken during the first two or three oil drain periods from these Detroit/MBE engines
may exhibit high levels of potassium and aluminum. The actual levels will vary by engine type,
service severity, and oil drain interval, but may be as high as 500 ppm. A possible source of
these elements is from the brazing flux used in the manufacture of the Charge Air Cooler (CAC).
This flux material is introduced into the intake air stream from condensation and enters the oil
film on the cylinder walls.

High levels of potassium are usually associated with engine coolant and may be alerted by the
oil analysis laboratory as a coolant leak. If sodium is not present, this may be a false alert. An
engine coolant leak is distinguished from CAC flux by the presence of elevated sodium and
potassium. Table 1 may be used in properly interpreting these oil analysis results.

Aluminum, Potassium, Sodium, Cause Action

ppm ppm ppm
Above 50 Above 150 5-50 CAC Brazing Flux Monitor oil analysis/
No actions required.
Any Level Above 50 Above 50 Suspected Change oil,
Coolant Leak Monitor oil analysis
Any Level Above 100 Above 100 Probable Coolant Change oil,
Leak Investigate coolant leak,
Monitor oil analysis
Note: All three elements must satisfy criteria for conditions to apply
Table 1
Nominal Values for Series 60 and MBE4000 Engines,
Below 100,000 engine miles

Detroit Diesel 13400 Outer Drive, West / Detroit, Michigan 48239-4001

 07TS37 -2- 6/26/2007

Aluminum and potassium may exhibit sporadic trends but should decrease to a more stable
level after the second or third oil drain. If coolant contamination is present, sodium and possibly
potassium levels will generally exhibit an increasing trend, and water or glycol may be detected.

If high aluminum and potassium levels persist after the third oil drain, a leaking CAC and/or air
system should be suspected. A leaking CAC will result in elevated soot levels from a loss of
turbocharger boost pressure. Table 2 should be used once potassium and aluminum have
reached stable levels.

Aluminum, Potassium,
Soot, % Cause Action
ppm ppm
Monitor, NO Actions
Normal, max 50 50 4.0 Normal
required.
Abnormal Possible
50 - 65 50 – 75 4.0 - 4.5 Change Oil, Monitor
Range CAC Leak
Probable Check CAC, Change
Critical, min 65 75 4.5
CAC Leak Oil, Monitor *
Note: Levels are based on use of engine oil approved to Power Guard® Oil Specification
(PGOS) 93K218 or 93K214 at 30,000 maximum oil drain interval (All three elements must
satisfy criteria for conditions to apply.)

* If soot exceeds 4.5% and the CAC is not leaking, a reduction in oil drain interval is required.

Table 2
Abnormal / Critical values for Series 60 and MBE 4000 Engine,
Above 100,000 engine miles

For 30,000 mile oil drain intervals the use of a DD PGOS approved oil and oil analysis by an
accredited lab is mandatory.

ADDITIONAL RECOMMENDATIONS
1. While monitoring aluminum and potassium levels for decreasing trends, also track soot, TBN
(if tested), fuel dilution, and coolant contamination for abnormal conditions taking
appropriate actions as necessary.
2. Accurately record unit miles to ascertain that unit is in break-in (under 100,000 miles).
3. Select a laboratory with A2LA accreditation to properly discern normal versus abnormal
conditions during this period. DD recommends PowerTrac oil analysis program for
best results.

Note: Under no circumstances should an engine be disassembled based on a single alerted oil
analysis without additional sampling and mechanical confirmation supporting the oil
analysis report.

CONTACT INFORMATION
Please contact the Detroit Diesel Customer Support Center at 313-592-5800 if you have
any questions.