Off-Highway

Trouble Shooting

ExxonMobil Use Only

Introduction

 Find Solutions for Component Failures

 Utilize ExxonMobil Tools
Handling a Problem

 Respond Promptly
 Visit Personally
 Investigate
 Use Common Sense
 Listen
 Put Yourself in their Shoes
 Take Down History Data, Samples Photographs,...Etc
 Radiate Confidence
 Don’t Lose Customer by Winning Argument
RING-RING-RING
 Hello, this is Joe at Joe’s
construction. I just lost an engine
and CAT’s not warranting it
because your engine oil doesn’t
meet their specs.

You Owe Me an Engine!

How Would You
Reply?
Get as Much Information Over the
Phone as Possible

 What’s the engine in?

 What type of work?
 What’s the engine model?
 Which oil are you using?
 Is it new or rebuilt? (How many hours?)
 When was the last oil analysis result taken?
 What’s your oil change intervals?
 etc.
I’ll Be Right Over!!
Exercise

Failed Part Analysis

Investigation

 Obtain Background Facts

 Obtain, Identify, Protect All Parts
 Clean Parts Properly
 Photograph Parts Prior to Cleaning
 Use Good Lighting
 Use Unaided Eye
 Look at All Surfaces
 Use Magnification
 Identify and Record Facts
 If you don’t conclusively
recognize the cause, then
DON’T GUESS!
Necessary Information

 Account Name  Engine Oil Used - How Long

 Account Location  Engine Oil Consumption
 Engine Mfr.  Oil Change Interval
 Engine Model  Oil Filter - Change Interval
 Engine Serial #  Oil Pressure before Tear Down
 Type of Service  Fuel Consumption
 Load Factor  Type of Fuel (Hi Sulfur?)
 Number of Miles/Hours  Why Rebuild
Since Last Overhaul  Engine Performance
 Last Overhaul  Inspect Air Intake System
 Major or Minor
 Engine Smoking (Color?)
 Who did Last Overhaul
and Why
Engine Part Cleanliness

 Oil Quality
 Oil Change Interval
 Operating Condition
 Cold, Hot, Dusty
 Engine Design
 Type of Fuel
 Gasoline, Diesel, LPG, Etc.
Inspection Parts
 Cleanliness  Wear
 Air Intake System  Main Bearings  Fuel Injectors
 Valve Cover and Deck  Cylinder Liners  Oil Pump Gears
 Crankcase Pan  Pistons and Rings  Turbocharger
 Oil Screen and Pump  Cam (S)
 Piston and Rings  Valve Guides
 Combustion Chamber  Valve Stems
 Intake Ports (2-cycle)  Valve Seats
 Turbocharger  Rocker Arm Pads
 Valves and Valve Stems  Push Rod Ball and Socket
 Fuel Injector  Connecting Rod Bearings
Air Intake System

 Check for Leaks

 Hoses
 Clamps
 Connectors
 Cover Seals
 Filter Element
 Pleats
 Seals
Air Intake Inspections
1 Ounce of Dirt can Kill an Engine!

Secondary filter wing nut

missing seal-allows dirt to enter.

Precleaners take
out 80% Broken filter gauge allows
of dirt in air..... dirt to bypass filters and
This one is not enter engine.
connected -
plugging filters
with dirt.
Valve Cover and Valve Deck

 Dirt and Sludge

 Oil Drain Back Holes are Open
 Valve Springs are Clean (Are Any Broken?)
Crankcase Pan

 Sludge/Varnish
 Clean: If a finger can be wiped down through the dirt/oil film
on the bottom of the pan showing bear metal.
 Cleanliness is direct relationship with oil’s
detergent/dispersant package.
 Proper water temps
 No glycol leaks
Oil Pump
Oil Screen and Pump

 Clean
 Not been Exposed to:
– Cold Operation
– Stop and Go
– Glycol
 Oil Pump Gear Wear
 More Wear Less Oil Pressure
 Oil Pump Pressure Relief Valve
 Free or Sticking
Pistons

 Top of Piston
 Fuel Pattern
– Bad pattern can put a hole in the piston
 Undercrown
 Heavy Lacquer Deposits and Coked
– Insufficient Oil Supply
Pistons

Old Current
Piston Rings

 Rings Free
 Ring Sticks or Breaks
– Oil Consumption Goes up
– Power Loss
– Time to Rebuild
 Ring Prowdness
 Blow-by
 Stuck rings should have corresponding blow-by marks on
piston
– Piston removal can sometimes cause stuck rings
Piston Ring
Piston Ring
Effects of Crown Deposits on
Oil Consumption
Thrust Face
Oil throw-off from the crown carbon

Pressure buildup delay on ring

produces poor sealing at
periphery and side face

Unfavorable pressure
distribution among rings

Piston Liner
3516 liner 8383 hrs
Intake Port Deposits (2-cycle)

 Dirty Intake Air

 High Temperature Operation
 Turbocharger: Oil Bearing Leak
 Too Much Sulfated Ash in the Oil
 2-cycle Detroit Diesel wants no more than 1%
What is Sulfated Ash?

Sulfated ash is what’s left when you burn lubricating

oil.
Typically, it’s the metallic ash from your detergent
package.
Sulfated ash helps “cushion” valve face/seats in 4-
cycle diesel engines.
Sulfated ash can contribute to plugging ports in
2-cycles diesel engines.

Note: New API CJ-4 Engines require 1% sulfate ash maximum limit.
Valves and Valve Stems

 Intake valves generally have more deposits than

exhaust valves.
 Typically cooler than exhaust so deposit do not
burn off.
 More oil is pulled onto the intake valve stem
guide and deposited on the fillet.
 Incoming dirt collects in this area from a worn
valve guide.
 Worn valve stem guides or seals cause high oil
consumption.
Turbocharger

 Compressor side should be free of dirt and clean

 Blades are shiny with nicks in them (dirt has gotten in)
 Turbine blades should be relatively free from
deposits
 High oil consumption can cause deposit build-up
 Deposit build-up can cause imbalance/vibration destroying the
blade
 Oil return line
 Deposits are generally caused by immediate engine shutdown
– Oil bakes in bearing housing
Quick Shutdown
Turbocharger Schematic
7 Types of Wear

 Abrasive Wear
 Adhesive Wear
 Corrosive Wear
 Erosive Wear
 Cavitation Erosion
 Contact Stress Fatigue
 Fretting Corrosion
Abrasive Wear

Abrasive wear caused by

large foreign particles.
Adhesive Wear

Melting and adhesive wear

occurred on piston skirt.
Adhesive Wear

 Oil Quality or Quantity Problems

Bearing surfaces are “smeared” or highly polished,

they were hot enough to melt the lead-tin overlay.
Corrosive Wear
Corrosion Types

 General
 Galvanic
 High Temperature
General Corrosion

Moisture on Metal Surface Moisture on Valve Stem

Galvanic Corrosion

 Baffle plate held oil cooler tube

High Temperature Corrosion

 High temperature makes metal atoms more active

allowing oxygen to penetrate quickly and deeply
Erosive Wear

 Found at restrictions or at turns which force

moving particles to change direction

Erosive wear above and

below pin due to
foreign object
restricting its flow.
Cavitation Erosion

Piston liner has cavitation

erosion due to air
imploding on cylinder
wall.
Contact Stress Fatigue
(Sliding or Rolling)

 Load to Great
 Misalignment
 Inadequate Lubrication
Contact Stress Fatigue (Sliding)

Cracks start at surface,

progress downward, join
together, and produce surface
pitting.
Contact Stress Fatigue (Rolling)

Cracks start below the

surface on rolling loads.
These cracks progress
upwards to the surface and
break off (spalling).
Fretting Corrosion

 Occurs when two parts that are tightly held are

caused to move against each other

Connecting rod
bearing parting
face.

It’s generally high frequency, low amplitude movement, and

typically leads to, asperity microwelding, metal pull out, and pitting.
Engine Inspection of Wear

 Inspect All Surfaces

 Top
 Bottom
 Inside
 Front
 Back
 Parting Faces
 Etc.
 Especially Look for Evidence of:
 Heat
 Misalignment
 Competitive Parts
Bearing (Main, Rod, Piston Pin)

 Get Engine Serial #

 Determines bearing composition (If they are original)
 Remove Bearings from Engine
 Mark position (locking tab or back of bearing)
 Lay bearings out in order for inspection
Two Bearing Halves Failed of
Lubrication

What does the rest of the bearings look like?

Always Place the Bearings in Order
Bearing (Main, Rod, Piston Pin)
 Get Engine Serial #
 Determines bearing composition (If they are original)
 Remove Bearings from Engine
 Mark position (locking tab or back of bearing)
 Lay bearings out in order for inspection
 Inspect Condition of Bearings
 Main bearings more wear on lower half
 Con. rod bearing more wear on upper half
Bearing Structure
Bearing Installation
Bearing Crush

 Insert bearings are

held from rotating by
proper crush.
 If a bearing has
rotated, generally
there will be a shiny
mark on its backside.
 Locking tabs are used
for alignment.
Abnormal Wear on Bearings

 Abrasive Wear
Abnormal Wear on Bearings

 Abrasive Wear
Abnormal Wear on Bearings

 Electric Discharge Pitting

Shiny Chrome like Main Bearings Micro Pitting on Shaft

Backside
Black Marks
Cylinder Liners

 Discoloration
 Measure Cylinder Wear
 Micrometer
 Compare with Original Specs.
 Piston Pin Wear
 Machined Hone Cross Hatch Marks are Present
 Better Oil Retention Between the Rings and Cylinder Walls
 Outside Surface (If Taken Out)
 Rust and Cavitation
Pistons and Rings

 Number Pistons as They are Removed

 Pistons skirt wear should correspond to similar wear on liner
 Piston Pin, Bore and Slipper Bushing (If Applicable)
 Top of Piston for Condition
 Injector Spray Pattern
 Rings
 Measure by Micrometer
 Sticking
 Accelerated Ring/Cylinder Wear
– ether
Leaking Fuel Injector
Plugged/Broken Tip
Thrust Load Scuff
Running Cold
CAM

 Critical to Valve Openings and Injection Timing

 Without Roller Followers are Most Difficult to
Lubricate
 Inadequate Lubrication or Overloaded
 Wear Initially Shows up as Spalling, Progressing to Metal
“Smearing”
– Contact Stress Fatigue
Valve Guides, Stems and Seats

 Valve Guide to Stem Clearance

 High Oil Consumption
 Engine Overhaul
 Valve Guides can Break Dropping Valve into the
Combustion Chamber
 Abnormal Combustion
 Improper Fuel Injection Pattern (Overfueling)
 Over Speeding
 Incorrect Valve Adjustment
 Burnt Valves
 Stuck Open Valve
– Valve-face or Seat Deposits
– Hair Line Surface Cracks
Valve Channeling
Rocker Arm Pads

 Wear on these Pads

 Dirty Oil
 Extended Oil Drains
 Too Tight Adjustment
 Wrong Valve Lifter Spring
Push Rod Ball and Socket

 Accelerated Wear
 Dirty Oil Blocking Oil Flow
Ways to Get Dirty Oil

Dipstick and Fill Cap Left Damaged Dipstick, Allowing Dirt

Open, Allowing Dirt to Enter Engine
to Directly Enter Engine
Fuel Injectors

 Nozzle spray pattern is critical to engine performance

 Broken tips
 Plugged with deposits
 Pressure and Flow Test
 Check top of piston for correct spray pattern
 Should not be too close to the edge of the piston or it can burn the
edge away or cause cracks
 100,000-mile checks are recommended
 Nozzle problems generally cause:
 Low engine power
 Black smoke in the exhaust
Oil Pump Gears

 Abrasive wear in gear mesh

 Dirty Oil
 Worn oil pump will cause low oil pressure
 Check oil pump bearings for wear and play
Turbocharger

 Clearance of the Rotary Blades

 Damage to Impeller or Turbine
 Nicks or Broken Blades Caused by Dirt Ingestion
 Worn or Scratched Bearings
 Oil Feed/Drain Lines for Bends/Collapse
Dirt Ingestion
ExxonMobil’s Tricks of the Trade
(Tool Box)

 Use Oil Analysis

 Signum
 Filter Patch
 EMRE
 Glycol Test Kit
 Flow Stick
 Ultrasonic Sound/Air Detector
 Borescope
 Camera
EMRE

 Specialized Lab Analysis

 Information Required
 Account Information
 Specific Information about the Test
 Specific Results Wanting to Achieve
 Inform the Customer of Cost for Analysis
 Turnaround Time for Results (Long Time)
SIGNUM
 Measures Viscosity at 100°C
 Determine Permanent Viscosity Shear
 Water
 Oxidation - A/cm
 Fuel Dilution - % Vol
 Gas Chromatography
 Glycol - % Vol
 SOOT - Index
 Sodium and Potassium
 Elements Found in Anti-freeze
 PQ Index
PQ Index

• Sensitive Magnetometer that measures the mass of

ferrous debris in a sample and displays this as a PQ
index.

• The PQ index is a quantitative unitless number that

can be trended with accepted linearity over a wide
range of ferrous debris content and particle size.
 Schematic of PQ™ Magnet Assembly

Sample bottle

Measurement surface
Upper

Balance coils
Excitation coil
Lower

Ferrite core adjustment

screw

A ferrite rod passes

through the centre of
the coil assembly
PQ Index

• Since ICP/DCP is measuring Iron you would

expect a strong correlation between PQ and Iron.
• But because the ICP/DCP measures only small
particles (<5 Microns) the correlation is low.
• The PQ tells us if we have large particles or lots of
small particles.
• Most engines do not have large particles
 Low PQ High PQ Low / High PQ
High Iron Low Iron Low / High Iron
= small particles = large particles = small particles

PQ-60 Iron-286 PQ-67 Iron-15 PQ-66 Iron-64

PQ-154 Iron-407 PQ-105 Iron-52 PQ-119 Iron-164

Filter Patch
 Mobile Non-engine Components
 Transmissions
 Differentials/Final Drives
 Hydraulics
 Monitor Large Metal Particles Greater than 5 Microns
 Foreign Contamination
 Water
 Insoluble
 Viscosity
The Advantage of Filter Patch

Silicon 4
Iron Only 76 PPM
Aluminum 1
Copper 5
Lead 0
Chromium 0

Filter patch should be used on all non-engine

components!
Filter Patch
ExxonMobil Recommendations
Hydraulic
Tank Shield

Hydraulic Hose Wear Hydraulic Plastic Tie Hose

Hose to Hydraulic
Shield
ExxonMobil engineers design and recommend
how to avoid future hose damage.
Fuel Dilution
Fuel Dilution - Leaky Injector

ExxonMobil’s heat gun is used to determine which cylinder had a leaky fuel
injector. ExxonMobil’s lab analysis determined fuel dilution.
Ultrasonic Leak Detector

Leak detector is used to help find air Intake leaks quickly.

Borescope

Borescope is used to check cylinder wear through the spark

plug/fuel injector hole. Avoiding engine tear down.
QUIZ TIME