Solubility Changes

with Temperature
Compound
Sodium (from salt)
Calcium Carbonate (lime)

Solubility at
Room Temp.
High Temp.
High

Low

Very High

Very Low

Mineral scale occurs where heat transfer

is greatest.

Mineral Scale in Coolant

Passage

Between the exhaust valves in a four-valve head is a notable area of high heat transfer. Therefore it is
also an area susceptible to mineral scale deposits.

Cracked Heads From Abuse

The cylinder head cracked between the exhaust valves due to overheating because
mineral scale deposits had accumulated in the water passages.
Mineral scale deposits can be prevented with proper inhibitor treatment. Cylinder heads
will not crack if good quality fill water is used, and if the cooling system is properly
treated with inhibitors.

Scaled Exhaust Guide

This water-cooled exhaust valve guide overheated due to the insulating factor
from mineral scale deposits. Eventually the valve and guide overheated, the
valve stuck in the guide, and the valve head broke off when it hit the piston.

Cooling Cylinder Head

Heat Transfer
0.12

Scale Thickness (in.)

CaCO3

CaSO4

0.1
0.08
0.06
0.04

SiO2

0.02
0

10

20

30

40

50

60

70

80

90

% Reduction in Heat Transfer

100

Failed Water Pump Seal

Corrosion
A natural, electrochemical breakdown of a
metal, by which process it returns to its native
state (its oxide form).

Batteries Work on
Principle of Corrosion
Volts

corroded

Metal
ions

protected

Electrolyte
Anode

(coolant)

Cathode

Your Cooling
System is Like
a Battery !

Crevice Corrosion
Low Oxygen
Concentration
Corrosion
Currents

High oxygen
concentration area
(dissolved in
cooling water)

Cavitation
A purely mechanical
process of erosion
through the repeated
collapse of vapor (gas)
bubbles in a liquid.

Cavitation Principle

Cavitation Concept

In the case of a cylinder liner, the coolant pressure near the outside of the liner increases
and decreases. This happens as the liner expands and contracts (vibrates) due to the
pressure fluctuation within the cylinder.

Cavitation ?
When cavitation

occurs, flow drops

off and wear occurs.

These water pump impellers have been totally destroyed by cavitations erosion. Water pumps
experience cavitations when fluctuating pressures are created inside the water pump each time a
blade passes by the housing. It is this fluctuation in pressure which creates and then collapses
the vapor bubble. Often the tips of the impeller blades will erode first, since they come closest
to the housing. When cavitations occurs at a water pump, the flow out of the pump drop off
dramatically, allowing engine overheating to occur.

Chrome Resists
Cavitation

Harder material
0.003 in (0.08mm)

Coolant
Sampling
Consistency
Clean piping
Six month intervals
or less.

Summary

Install balance lines.

Install coolant filters.
Use soft, clean fill (raw) water.
Use ethylene glycol if needed.
Use inhibitors as recommended by analysis.
Begin a coolant analysis program.
Keep the cooling system sealed.
Keep the coolant clean.

Troubleshooting

Engine High Water Temperature

Lubrication

Lubrication System

Lubrication
System

Gear Type
Oil Pump

Oil Pump & Relive Valve

Oil filter

Oil Cooler

Splash Lubrication

Oil Requirement
Oil Analysis

To understand our oil specifications,

You need to know something about oil

Lubricating oils are formulated to provide specific functions in engines.

Obviously, there is not one single oil specified to perform adequately in all
engine types or application. Therefore, as a manufacturer we have to
specify engine performance so oil manufacturers can meet these demands.
It becomes your job to select the best oil to yield the desired performance.

Oil Viscosity

Ash Composition
Calcium
Magnesium

Purpose:
Reduce valve recession
Neutralize acids

High Ash Oils

Ash Greater Than 1.0%
Some lubricating oils are designated as high ash and can reach levels over
3%. This is considered a high amount of ash for gas engines. It is
normally not recommended to run an engine with an oil designated as high
ash unless it is necessary, such as if the fuel contains H2S. Watching your
oil analysis can help determine whether high ash oils are required.
Using high ash oil in an application that does not require it, can cause ash
buildup in the combustion chamber and the valve faces.

Medium Ash Oil

Ash 0.35 - 1.0%
A more commonly specified lubricating oil is medium ash. This oil has much
less ash content as compared to high ash oils. The vast majority of engines fall
into the medium ash category. However, there are certain applications within
these engine models that medium ash oils are not recommended.

Low Ash Oil

Ash less than 0.35%
You may run engines with low ash oils, but they are restricted to naturally aspirated or
catalyst equipped engines.
Ash will accumulate in the catalytic converter which will severely reduce its operating
efficiency. The accumulating ash will prevent the exhaust from coming into direct contact
with the active catalyst material. Zinc is a known poison to the catalyst, therefore the
lubricating oil should not contain this element.
Note: Keep in mind that if you specify a lubricating oil to satisfy the requirements of the
catalytic converter, increased valve wear and sleeve/piston ring wear may result.

Ashless Oil
Less than 0.1% Ash
Engine has no recommendations for ashless oils in current production
engines today. If these oils are operated in an engine, very high valve
recession and cylinder sleeve/ring wear may result.

TAN
Total Acid Number
Indicates the amount of acid present or
suspended in the oil (Sulfur & Chlorine
compounds)

TBN
Total Base Number
Scale to indicate the reserve alkalinity
of the oil
Select oil with a high alkalinity reserve
of 7 to 13 TBN

Oil additive

 Lead sulfate on
bearing overlay layer
Early signs of
damage

 Advanced
acid attack

 Failed thrust
bearings from
acid attack

 Failed piston pin

bushing from sulfur
attack

 Piston removed from

engine operating
4,000 hours operation

Nitration
Nitrogen Dioxide is absorbed
in the oil
Heavy varnish deposits
Raises oil viscosity

Nitration
Common Causes
Lean air fuel ratios (stoichiometric engines)
Over extended oil service
Low operating oil temperatures

Oxidation
Oxygen is absorbed in the oil
Heavy varnish deposits
Hard deposits in ring area
Raises oil viscosity

Oxidation
Common causes
High operating lube oil temperatures
(195o F. Max)
Over extension of service

Base Line
Send in new oil to be tested