Oil Contains Coolant: Troubleshooting

3512B Generator Set YAM00001-UP(SEBP5402 - 12) - Documentation Page 1 of 13
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Product: GENERATOR SET

Model: 3512B GENERATOR SET YAM07518
Configuration: 3512B Generator Set YAM00001-UP
Troubleshooting
3500B and 3500C Generator Set Engines
Media Number -RENR5059-11 Publication Date -01/04/2014 Date Updated -16/04/2014
i05711915
Oil Contains Coolant

SMCS - 1348-035; 1395-035
Evidence of the following substances in the results of engine oil analysis are indications of coolant in
the oil:
• Glycol
• Water
• Sodium (Na) when a conventional coolant is used
• Potassium (K) when Extended Life Coolant (ELC) is used
• Silicon (Si) is used in coolant as an anti-foaming agent. Si is also used as an anti-corrosion

agent for aluminum components.
Elevated levels of Na or K and Si can occur in an oil analysis without glycol or water. The glycol or
water is boiled off if the coolant is burned during engine operation.
In some cases, water or glycol can seep into the oil when the engine is not operating.
The presence of Si and glycol or water in the oil indicates direct entry of coolant.
Review the results of the oil analysis before troubleshooting.
Review the service records in order to determine the components that may be more likely to have
caused the coolant contamination.
Oil Analysis Results and Probable Causes

Table 1
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Oil Analysis Result Probable Cause Additional Notes

High Na or K
Failure of the seal in the
Elevated Si Troubleshoot the more likely jacket water
jacket water pump or
Presence of glycol or pump first
auxiliary water pump
water
The oil pressure is greater than the coolant
pressure during engine operation. The
coolant level will rise as oil enters the
High Na or K
cooling system.
Presence of glycol or Leaking oil cooler
water
Glycol and water can enter the oil if the
engine is unused for days or if the leak is
severe.
With a crack between the coolant passage
and the turbine housing, the coolant is
burned in the exhaust.
High Na or K
No glycol or water
Backpressure of the exhaust gas on the oil
or
Cracked turbocharger system seal enables contamination.
High Na or K
cartridge
Elevated Si
White smoke is in the exhaust.
Presence of glycol or
water
A crack between the coolant passage and
oil passage can allow coolant into the oil
drain.
Glycol and water can appear in the oil
sample after months of burning coolant.
Glycol and water can also appear if the

engine is unused for days.
High Na or K
Cracked cylinder head Small cracks can be hard to find.
No glycol or water
Small cracks only open when the cylinder
head is hot.
A severe crack can enable hydraulic lock,

but the condition is unlikely.
High Na or K Typically rapid progression
No glycol or water if the
engine is operated White smoke for an extended period at start
Cracked aftercooler core
Presence of glycol or -up
water if the engine is not
run for an extended For a severe leak, white smoke continues
period during operation.

High Na or K Cracked cylinder liner A cracked cylinder liner is unlikely.

No glycol or water
or A cracked cylinder liner allows coolant into
High Na or K the combustion chamber or into the
Presence of glycol or crankcase.
water
Usually, a cracked cylinder liner is
associated with piston seizure.
The crack develops quickly with little

warning or with no warning.
Failure of the lower liner seal is not
High Na or K common.
Damaged lower cylinder
Presence of glycol or
liner seal
water A failed lower seal could be due to an
installation issue or to cavitation erosion.
Sometimes a small amount of burned
coolant is detected in the oil because of a
failed cylinder head gasket.
High Na or K Failed cylinder head
No glycol or water gasket
A more common symptom of a failed
cylinder head gasket is exhaust gas in the
coolant.
A leak from a coolant passage in the air
compressor can allow coolant to flow into
the air system or the lubrication system.
High Na or K Cracked water-cooled air
If the leak occurs in an area where air
Presence of glycol or compressor head (If
pressure can enter the cooling system, the
water equipped)
cooling system can be pressurized.
Air dryers and air filters may plug quickly

if coolant leaks into the air system.
Recommended Actions

Illustration 1 g02877941
Typical water pump
(1) Weep hole
(2) Felt dust filter
Table 2
Troubleshooting Test Steps Value Result
1. Check the water pumps for leaks Failed Result: There is a
water stream of coolant from
Perform this procedure for the jacket water pump and for the pump seal the weep hole.
auxiliary water pump. Start with the jacket water pump,

which is more likely to have a leak. Repair: Replace the

water pump seal or
A. Locate weep hole (1) in the water pump housing. replace the water
Remove felt dust filter (2) (if equipped) from the weep hole. pump.
· If coolant flows from the weep hole, a failed water pump Result: No coolant
seal is probably the cause of coolant in the oil. flows from the weep
hole.
· A slightly damp dust filter is acceptable, but a stream of
coolant indicates excessive leaking of the water pump seal. Repair: Install a new
felt dust filter into the
· A visual inspection of the dust filter is not sufficient. A water pump.
dust filter may appear to be dry, but the pump may have
internally leaked coolant that appears when the filter is Proceed to Test Step 2.
removed.
Typical oil cooler
(3) End sheet
(4) Baffle
Table 3
Troubleshooting Test Step Value Result
2. Visually check for engine oil in the Leaking oil Result: There is an oil slick on top of the
coolant cooler coolant.
A. Remove the radiator cap. Use a Repair:

bright flashlight to help look for an oil 1. Drain the engine oil and change the oil
slick on top of the coolant. filters.
2. Disassemble the oil cooler. Look for

fretting or wear between the baffles and the
tubes. Look for a break of the seal at the
end sheet.
3.Repair the oil cooler or replace the oil

cooler. Refill the engine with oil.
Result: There is no oil slick on top of the

coolant.
Proceed to Test Step 3.
Table 4
Result: There is a loss of air
3. Check the turbocharger for a leak.
pressure.
A. Drain the coolant to a level that is
Repair: Replace the
below the turbocharger.
turbocharger cartridge or
Cracked replace the turbocharger.
B. Plug the coolant return line.
turbocharger
cartridge Result: The air pressure is
C. Pressurize the coolant supply side of
maintained at
the turbocharger with 100 kPa (15 psi) of
100 kPa (15 psi) with no loss of
air pressure.
pressure.
D. Monitor the pressure.

(5) Plug in the exhaust side
(6) Hole for the valve cover bolt in the intake side
(7) Inner spring on the exhaust side
Table 5
4. Check the intake side of the Cracked Result: The end of the bolt is wet or there is
cylinder head for evidence of cylinder residue from coolant on the bolt.
coolant leaks. head
Repair: The cylinder head is probably cracked.
A. Remove the valve cover bolt Replace the cylinder head.
from hole (6) .
Note: After the cylinder head is removed, inspect
Note: The bolt should be the inside of the air inlet elbow for the cylinder.
relatively dry. There may be a Look for coolant residue that is white in color or
slight buildup of carbon on the purple to red. Some residue may have swirled from
bolt, which is normal. the intake valve partly up into the elbow. If the

residue coats the entire inside of the elbow, a

B. Inspect the bolt for moisture leaking aftercooler is the problem.
and for residue from coolant.
Result: The bolt is relatively dry. There is no
evidence of coolant residue on the bolt.

5. Check the exhaust side of the
cylinder head for evidence of
coolant leaks..
A. Remove plug (5) .

Result: One or more of the following conditions
B. Examine the plug with a
are found:
spectrometer to detect the
presence of NA or K.
· NA or K was found on plug (5) .
· Wet, slimy residue was found in the exhaust port.
C. Insert a borescope into the
· Black, gelatinous residue was found on the inner
hole for plug (5) in order to Cracked
springs.
inspect the exhaust port. Look for cylinder
residue that is wet and slimy. head
Repair: The cylinder head is probably cracked.
Replace the cylinder head.
D. Remove the valve cover. Use
a bright flashlight to inspect the
Result: No evidence of coolant was found.
two inner springs (7) on the
exhaust side. Look for black,
gelatinous material.
The material is the result of

burned coolant mixed with oil
that was pushed up the valve
guide during operation.

(8) Air inlet elbow
Table 6
6. Inspect the insides of the air inlet elbows. Leaking Result: One or both of the
aftercooler elbows have residue that is
A. Remove the two air inlet elbows that are core white in color or that is a color
appropriate for the engine model: from purple to red.
- For 16 cylinder engines, the remove elbows for Repair: To locate the leak,
cylinder heads 1 and 16 pressurize the cooling system
to
- For 12 cylinder engines, the remove elbows for 103 kPa (15 psi). Use a bright
cylinder heads 1 and 12 flashlight and look through the
air inlet manifold. Repair the
- For eight cylinder engines, the remove elbows aftercooler core or replace the
for cylinder heads 1 and 8 aftercooler core.
inspect the inside of the elbows. Look for residue Result: The elbows do not
that is white in color or that is a color from purple have residue that is white in
to red. color or that is a color from
purple to red.
Note:If the intake side of the cylinder head is Proceed to Test Step 7.

cracked, some residue may have swirled from the

intake valve partly up into the elbow. If the
residue coats the entire inside of the elbow, a
leaking aftercooler is the problem.
(9) Lower edge of the cylinder liner
(10) Main bearing cap
Table 7
7. Pressurize the cylinders. Cracked Result: The cooling system becomes
cylinder liner pressurized and/or the cylinder loses
A. Pressurize each cylinder according to compression rapidly.
Special Instruction, REHS7138, "New
Cylinder Leak Test Procedure Available Repair: Replace the damaged parts.
for 3500 Engines".

Result: The cooling system does not

B. Check for pressurization of the become pressurized. The cylinder does
cooling system. Also check for a loss of not lose compression rapidly.
cylinder compression.
Repair: Proceed to Test Step 8.
Note: Usually, a cracked cylinder liner
is associated with damage to the liner
and to the piston rings. A loss of
cylinder compression begins almost
immediately.
8. Look for internal coolant leaks. Result: Coolant is dripping from the
lowest edges of the cylinder liner and
A. Remove the crankcase side covers, as from the main bearing caps.
necessary.
Damaged
Repair: Remove the cylinder liner and
lower
B. Pressurize the cooling system to replace the seals.
cylinder liner
103 kPa (15 psi).
seal
Result: Coolant is not dripping from the
C. Look for coolant dripping from the lowest edges of the cylinder liner and
lowest edges of the cylinder liners (9) from the main bearing caps.
and from the main bearing caps (10) . Proceed to Test Step 9.
9. Check for a leaking cylinder head Leaking Result: A stream of bubbles emerges
gasket. cylinder head from the hose, indicating that exhaust
gasket gas is forced into the coolant..
A. Check for combustion gas in the
coolant. Repair: Use the cylinder cutout test to
cut groups of cylinders out in order to
a. Attach one end of a hose to the isolate the problem cylinder head.
radiator and submerge the other end of Replace the head gasket.
the hose into a container of water.
Result:
b. Run the engine and observe the end
of the hose in the water. When the cylinder head is pressurized,
the level of the jacket water rises and/or
A few isolated bubbles may emerge bubbles emerge from the jacket water..
from the hose, but if a stream of bubbles
emerges. exhaust gas is being forced Repair: Replace the head gasket.
into the coolant.
Result: A stream of bubbles does not
B. Pressurize the cylinder heads. emerge from the hose. When the
cylinder head is pressurized, the level of
a. Install a dummy injector into the the jacket water does not rise. Bubbles
cylinder head. do not emerge from the jacket water.
b. Apply a maximum of Proceed to Test Step 10.

690 kPa (100 psi) of nitrogen pressure
into the cylinder.

c. Observe the jacket water for an

increase of the level and for the presence
of bubbles..
(11) Coolant supply to the compressor
(12) Coolant drain
(13) Oil drain from the compressor to the oil pan
Table 8
10. Check the air compressor head for Cracked water- Result: One or more of the
cracks. cooled air following conditions are found:
compressor head
A. Check for additional pressurization of · The pressure of the cooling
the cooling system. system rises when the air
compressor operates.
a. Operate the engine without the air ·Coolant is found in the oil
compressor operating. Monitor the drain from the air compressor.
cooling system pressure. · There is a pressure drop in the
compressor head.

b. Activate the air compressor and look

for additional pressurization of the Repair: Replace the air
cooling system. compressor.
B. Check for coolant in the oil drain from

the air compressor to the oil pan.
C. Pressurize the air compressor head.
a. Disconnect the coolant hoses from the

air compressor.
b. Plug the coolant inlet or outlet to the

air compressor. Pressurize the other
opening with
100 kPa (15 psi) of air pressure.
c. Monitor the pressure.
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3512B Generator Set YAM00001-UP(SEBP5402 - 12) - Documentation Page 1 of 13

Product: GENERATOR SET

Oil Contains Coolant

• Sodium (Na) when a conventional coolant is used

• Potassium (K) when Extended Life Coolant (ELC) is used

• Silicon (Si) is used in coolant as an anti-foaming agent. Si is also used as an anti-corrosion

Review the results of the oil analysis before troubleshooting.

Oil Analysis Results and Probable Causes

An evaluation version of novaPDF was used to create this PDF file.

Oil Analysis Result Probable Cause Additional Notes

Glycol and water can also appear if the

A severe crack can enable hydraulic lock,

An evaluation version of novaPDF was used to create this PDF file.

High Na or K Cracked cylinder liner A cracked cylinder liner is unlikely.

The crack develops quickly with little

Air dryers and air filters may plug quickly

An evaluation version of novaPDF was used to create this PDF file.

Typical water pump

(1) Weep hole

(2) Felt dust filter

An evaluation version of novaPDF was used to create this PDF file.

which is more likely to have a leak. Repair: Replace the

Typical oil cooler

(3) End sheet

A. Remove the radiator cap. Use a Repair:

An evaluation version of novaPDF was used to create this PDF file.

2. Disassemble the oil cooler. Look for

3.Repair the oil cooler or replace the oil

Result: There is no oil slick on top of the

Proceed to Test Step 3.

An evaluation version of novaPDF was used to create this PDF file.

(5) Plug in the exhaust side

(7) Inner spring on the exhaust side

An evaluation version of novaPDF was used to create this PDF file.

residue coats the entire inside of the elbow, a

Proceed to Test Step 5.

A. Remove plug (5) .

The material is the result of

An evaluation version of novaPDF was used to create this PDF file.

(8) Air inlet elbow

An evaluation version of novaPDF was used to create this PDF file.

cracked, some residue may have swirled from the

(9) Lower edge of the cylinder liner

(10) Main bearing cap

An evaluation version of novaPDF was used to create this PDF file.

Result: The cooling system does not

b. Apply a maximum of Proceed to Test Step 10.

An evaluation version of novaPDF was used to create this PDF file.

c. Observe the jacket water for an

(11) Coolant supply to the compressor

(12) Coolant drain

(13) Oil drain from the compressor to the oil pan

An evaluation version of novaPDF was used to create this PDF file.

b. Activate the air compressor and look

B. Check for coolant in the oil drain from

C. Pressurize the air compressor head.

a. Disconnect the coolant hoses from the

b. Plug the coolant inlet or outlet to the

c. Monitor the pressure.

An evaluation version of novaPDF was used to create this PDF file.

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