Engine oil overflow

[5936]

Today, my diesel engine suddenly. "discharged" engine oil from dipstick, filler cap and even from breather valve.

There was a short burst of black smoke from exhaust .

This happened after 5 minutes after started.

 

This is a stand by caterpillar V8 diesel engine with in-direct cooling.

Last year we experieced almost similar situation, and the culprit is plastic bag being sucked into and block up the engine lube oil cooler. Hope it us same problem. But this time operator reported seeing some black smoke..

 

[Good-Carbuyer]

Today, my diesel engine suddenly. "discharged" engine oil from dipstick, filler cap and even from breather valve.

There was a short burst of black smoke from exhaust .

This happened after 5 minutes after started.

 

This is a stand by caterpillar V8 diesel engine with in-direct cooling.

Last year we experieced almost similar situation, and the culprit is plastic bag being sucked into and block up the engine lube oil cooler. Hope it us same problem. But this time operator reported seeing some black smoke..

Do you meant your boat engine? How did the plastic bag get into the engine lube oil cooler (selaed)?

Do you mean the engine still running like normal with these? Anything like noiser?

[Heelntoe]

Sounds like excessive crankcase pressure. Maybe a piston ring went and caused the combustion pressure to pressurize the crankcase. Can try to do a compression/leakdown test on each cylinder?

[5936]

Engine connected to drive water pump to draw sea water.

It was running when this happened.

But was quickly shut down.

Edited March 26, 2012 by 5936

[5936]

This is possible.

I tried not to think of this scenario to happen.

Hopefully it wont be this.

Arranging for mechanics to open up lube oil cooler for inspection and already sent oil sample for laboratory analysis.

So just wait for the results of these two trouble shooting actions.

 

[5936]

No luck this time.

Oil cooler looks clean.

Also got the lab test results. Almost identical results from last sample test done 5 months ago. Very minute trace of water, flashpoint, viscosity remains the same.

Calling in agent to take a look at it.

Hope nothing serious.

[5936]

Agent mechanics came in this afternoon.

They are professional and experienced.

Provided 2 more in house mechanics to help and speed things up.

 

 

The first thing he check was oil and radiator.

He suspected that oil level has increased abnormally, with either contamination from fuel or coolant. ( Putting the latest lab test results aside, we let him continue with his probe).

 

Next he opened up the 8 individual cylinder covers to check.

 

Bingo.. found something not right.

One fuel injector had came loose. it M12 size mounting bolt broke off. upper part can pull up by hand, leaving the bottom half inside the cylinder block.

 

I got a bad feeling that the valves may be gone too as one exhaust valve spring looks slightly tilted.

 

Repair continue tomorrow when they bring in spreacial tools to remove the damaged cylinder block.

 

This engine is very old already. Hope they still have spare parts, recon or new doesn't matter. As long as can repair this engine.

 

So the engine oil overflow was caused by the increased pressure from compression of this piston through the space around the loosened injector. This created increased pressure in the crankcase, thus forcing oil out through all the dipsticks, refilling cap, and breather valve.

 

In this case, 20-30L of diesel fuel had mixed with 250L of engine oil.

That would mean new oil and oil filter change.

 

With more parts needed to be opened tomorrow, it may also mean more damages....

[Happily1986]

i recall sometime back you posted about a certain marine engine woe. Is this the same engine block you referred to then?

[5936]

That correct.

 

The same old faithful engine.

 

Last time plastic bag got suck in from sea and blocked the engine oil cooler, caused it to over heat.

That was straight forward with no damage to engine.

 

This time, it's serious.

Dont know how much is the final bill.

EO alone already costed me almost $1K.

Edited March 27, 2012 by 5936

[Happily1986]

That correct.

 

The same old faithful engine.

 

Last time plastic bag got suck in from sea and blocked the engine oil cooler, caused it to over heat.

That was straight forward with no damage to engine.

 

This time, it's serious.

Dont know how much is the final bill.

EO alone already costed me almost $1K.

 

so far engine block no crack and valves not bent right? judging from the application of the engine, is the prospect of hydrolock high?

[5936]

Progress today, only all the 8 cylinder covers opened.

For the rest of damage report, I will only know tomorrow, after they remove the affected cylinder block and check further.

 

They planned to trace downstream all the way to the turbo chargers.

Will keep you guys posted.

[Barrett625]

Nice sharing.

I think you are beating to hard on your engine as you slam the gas pedal down.

[5936]

FINALLY WE FOUND THE CULPRIT.

a broken exhaust VALVE.

but alot of damages already done by this broken exhaust valve head.

Found the head wadged in turbo charger housing.

 

The broken valve head dropped onto piston head and hammered the piston like moon craters, before breaking fuel injector mounting bolt.

Finally found its way through exhaust manifold into turbo charger.....turbocharger totally wacked, all the fins gone crushed.

 

Keeping my finges closed. Now its not a time ant how much the bill will be. But whether we can get parts, even the rebuilt parts

 

Damages done by a broken valve :

 

Piston

Cylinder liner

4 valves

injector

turbo charger

 

 

 

[5936]

Finally with both factory remade and new parts, filters cartridges, coolant additives, and 250L of engine oil, the engine is running again.

 

Total damage done by a broken exhausted valve $20,000+.

 

[5936]

 

Take a look at the damages done by this little culprit.

The broken exhaust valve head.

Still trying to come to terms with this almost impossible situation that a such tiny thing had caused such extensive damages.

Agent repair team said that we were lucky. They had seen whole engine wrecked and had to be written off because of this.

 

 

One reason is material fatique.

 

So those with old turbo engine have to be really careful.

[Happily1986]

wow broken exhaust valve head. by right your engine should have been running rich and/or quite an amount of diesel was wasted, since the diesel is injected and can straightaway exit the exhaust valve due to the unfortunate opening.

 

this old engine is direct injection right?

[5936]

thankfully, agent repair team is able to fix up the engine.

It was really a heavy duty work horse, kept running with a broken turbocharger and 1 cylinder not working.

Yes, direct fuel injection.

This engine is still considered rugged mechanical type.

The newer verson will have lots of sensors and electronics.