TOPIC: Lubrication System

IDENT NO: 12-1880AR

DATE: December 2019

ALL
SUBJECT: Lube Oil Recommendations
SUPERSEDES: 12-1880AQ

MODELS AFFECTED: All INNIO Waukesha Engines

SUMMARY TABLE OF CONTENTS

The organization and content of this bulletin has TOPIC ....................................................................................... PAGE
changed significantly. Change bars have been Summary .......................................................................................................................... 1
added to the margin to highlight some of the Table of Contents ................................................................................................... 1
changes. Be sure to read and understand this bulletin Information and Instructions................................................................... 2
in its entirety. Lube Oil Performance ....................................................................................... 2
Lube Oil Designations............................................................................ 2
Use this service bulletin to identify the lube oil needs
Supplementary Lube Oil Additives .................................................... 2
and specifications of all INNIO Waukesha engines.
Catalyst Contaminants.................................................................................. 2
Listing is by current production model and fuel type.
Lube Oil Recommendations...................................................................... 2
This bulletin revision provides current lube oil Cogeneration Installations............................................................. 3
recommendations as a guideline for the selection of 12V/18V220GL Installations................................................................ 5
an appropriate lube oil only. It is the responsibility of Sour Gas, Digester Gas, Alternative Fuel
the person(s) in charge of maintenance to choose Gas and Landfill Gas Recommendations ..................... 6
the appropriate lube oil for the engine and conditions Recommended Lube Oils for Landfill Gas
that it is operating under. Applications...................................................................................................... 6
To obtain lube oil recommendations for INNIO Lube Oil Selection.................................................................................................. 8
Waukesha engines not listed in this bulletin, please Lube Oil Viscosity Selection........................................................... 8
contact the INNIO Waukesha gas engine service Multi-viscosity Lube Oils ..................................................................... 9
department. Synthetic Lube Oils.................................................................................... 9
Low Ambient Temperature Operation.......................................... 9
220GL Engines................................................................................................. 9
Lube Oil Filtration Requirements ...........................................................9
Recommended Lube Oil Change Intervals........................... 10
Taking an Oil Sample........................................................................................ 10
Lube Oil Condemning Limits ................................................................... 12
Lube Oil Consumption Guidelines.................................................... 15
Formulas for Determining Lube Oil
Consumption Rate.................................................................................. 15

* Trademark of INNIO Waukesha Gas Engines, Inc.

All other trademarks are the property of their respective owners.

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Service Bulletin No. 12-1880AR

INFORMATION AND INSTRUCTIONS CATALYST CONTAMINANTS

INNIO Waukesha engines are heavy-duty industrial- The following contaminants are known catalyst
type engines which require heavy-duty lube oils. The deactivators and should be avoided when selecting
basic requirements are high lubricating quality, high lube oils for installations with catalysts since they
thermal stability and good control of contaminants. contribute to shortened catalyst life: heavy and base
metals such as lead, mercury, arsenic, antimony, zinc,
The INNIO Waukesha product line consists of
copper, tin, iron, nickel, chrome, sulfur and
spark-ignited industrial gas engines from the VGF
phosphorus. Generally these individual elements
through the 16V 275GL + models. The lube oil
should not exceed 1 ppm or collectively exceed 5 ppm
requirements and systems change greatly between
at the catalyst inlet. Specific exceptions: phosphorus
each model and fuel type.
or silicon compounds at the catalyst inlet are not to
exceed 1 ppm and sulfur compounds at the catalyst
LUBE OIL PERFORMANCE
inlet are not to exceed 100 ppm. Always consult the
There are hundreds of commercial crankcase lube catalyst supplier for specific recommendations for
oils marketed today. Obviously, engine the catalyst being used.
manufacturers or users cannot completely evaluate Do not confuse the concentration of these elements
the numerous commercial lube oils. The performance in the exhaust gas flow AT THE CATALYST INLET with the
of a lubricant, like that of any manufactured product, concentration of these elements in the lube oil itself.
is the responsibility of the refiner and supplier. The
standard express limited warranty that accompanies LUBE OIL RECOMMENDATIONS
an INNIO Waukesha engine does not include
coverage for the performance of any lube oil. The INNIO Waukesha requires the use of lube oil
INNIO Waukesha warranty is limited to the repair or formulated specifically for natural gas engines that
replacement of parts that are found to be defective in meet minimum ash requirements based on engine
material or workmanship during the warranty period. model. The ash-forming constituents in lube oil
formulations provide detergency, corrosion
With the exception of cogeneration, the 220GL
protection and anti-wear protection. In addition, the
products and special or prototype installations, INNIO
ash produced during combustion of these additives
Waukesha has made it a practice not to recommend
will provide protection against valve face and seat
lube oil by brand name.
recession. However, use of lube oils containing a
INNIO Waukesha strongly recommends monitoring higher ash level than specified in the tables may
the condition of the lube oil through the use of a good increase engine deposits and decrease component
lube oil analysis program. life.
LUBE OIL DESIGNATIONS
NOTICE
Lube oil is designated in several ways: American
Petroleum Institute (API), Society of Automotive INNIO Waukesha requires lube oils formulated specifically
for natural gas engines. INNIO Waukesha does not
Engineers (SAE), American Society for Testing and recommend gasoline or diesel lube oil formulations for use
Materials (ASTM) performance classifications and with its engines. Use of gasoline or diesel formulations
Military Designation. Since no gas engine industry may cause severe engine damage. The standard express
lube oil performance designations exist, it is the limited warranty that accompanies an INNIO Waukesha
responsibility of the engine operator to verify with engine does not include coverage for the performance of
any lube oil. The INNIO Waukesha warranty is limited to
their lube oil supplier that the lube oil they select has the repair or replacement of parts that are found to be
proven field performance in their specific engine defective in material or workmanship during the warranty
make and model. This lube oil must also meet the period.
minimum requirements specified by INNIO Waukesha
as listed in the included tables.

SUPPLEMENTARY LUBE OIL ADDITIVES

Quality lube oils formulated specifically for natural
gas engines have sufficient additives to meet
requirements. INNIO Waukesha does not recommend
the addition of lube oil additives to these lube oils.

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 Service Bulletin No. 12-1880AR

Table 1: Lube Oil Recommendations by Engine Model

GAS ENGINE MODELS SULFATED ASH WT% *, **, ***
F18, H24, L36, P48 G, GL, GLD 0.45 – 0.75
F18, H24, L36, P48, GSI, GSID 0.35 – 0.55
VGF SERIES
ANY ENGINE MODEL WITH WAUKESHA FACTORY- 0.35 – 0.55
SUPPLIED CATALYST
F3521, L5790, L7042, P9390 G, GSI, GL 0.35 – 1.0
ALL SERIES 4 AND SERIES 5 MODELS WITHOUT 0.45 – 0.75
VHP SERIES WAUKESHA FACTORY-SUPPLIED CATALYST
ALL SERIES 4 AND SERIES 5 MODELS WITH 0.45 – 0.50
WAUKESHA FACTORY-SUPPLIED CATALYST
275GL/GL+ SERIES 12V, 16V 0.35 – 1.0
16V150LTD 0.4 – 0.55
APG SERIES
12V220GL, 18V220GL See Table 3
* Lube oils must be specifically formulated for gas engines using highly refined mineral oil base stocks. The ash
requirements are a percentage by weight with both metallic and ashless additive systems. A maximum of 0.10%
zinc is recommended.

** Lube oil with 0.35% ash or less may be used in naturally aspirated and catalyst-equipped naturally aspirated or
turbocharged engines with the understanding that valve recession may occur, thus shortening the normally
expected valve and seat life.

*** Use 1.0% ash lube oil for the VHP and 275GL engines only if needed due to higher than normal valve recession
rates.
COGENERATION INSTALLATIONS
INNIO Waukesha does not ordinarily recommend lube
oils by brand name. However, based on actual field
experience, the lube oils listed in Table 2 are specified
for cogeneration installations with forced hot water
cooling systems at 212° – 265°F (100° – 129°C) or
ebullient cooling at 250°F (121°C).
It is especially important that the lube oils used in
cogeneration applications utilize base stocks with
good thermal stability. With a minimum of 4,000+
hours of experience, the lube oils listed in Table 2 are
known to give satisfactory performance in high-
temperature cooling systems applications.
NOTE: See Table 1 for lube oil sulfated ash
recommendations for gas engine models.
Additions to the list of approved lube oils may be
made with substantiating data for a lube oil meeting
the following criteria:
• Used in similar applications with 212° – 265°F (100° –
129°C) jacket water temperatures.
• A minimum of 6 months operation with
documented engine inspection data.
• No signs of lube oil degradation, carbon or
lacquering problems (based on normal lube oil
change intervals, the engine should be clean).

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Service Bulletin No. 12-1880AR

Table 2: Recommended Lube Oils for Cogeneration / Gas Compression Applications (Using Pipeline Quality
Gas)
SULFATED ASH (%W)
BRAND TYPE ASTM D 874 (TYPICAL)
American Refining Group Brad Penn® SAE 40 0.58
Supreme DDO LA
Castrol Duratec LFG SAE 40 0.50
Chevron HDAX 5200 Low Ash SAE 40 0.50
HDAX Low Ash
Chevron HDAX 7200 Low Ash SAE 40 0.50
Chevron HDAX 9200 Low Ash SAE 40 0.50
CITGO Pacemaker GEO 1940 XL SAE 40 0.51
CITGO Pacemaker GEO 1640 SAE 40 0.50
CITGO Pacemaker 1640 AE SAE 40 0.50
Conoco Elmar LA4 EXD SAE 40 0.50
GS Caltex – GS Generator Low Ash SAE 40 0.51
Mobil Pegasus 1 (Synthetic) SAE 15W40 0.50
Mobil Pegasus 1005 SAE 40 0.50
Mobil Pegasus 905 SAE 40 0.50
Mobil Pegasus 805 SAE 40 0.50
Mobil Pegasus 710 SAE 40 1.00
Mobil Pegasus SHC40 SAE 40 0.50
Mobil Pegasus 1105 SAE 40 0.50
Mobil Pegasus 805 Ultra SAE 40 0.50
Peak Navitus LA SAE 40 0.50
Peak Navitus HA SAE 40 0.90
Pertamina NG Lube Long Life (LL) SAE 40 0.53
PETROBRAS Lubrax Gas LDI 40 SAE 40 0.50
Petro Canada, Sentron CG40 SAE 40 0.92
Petro Canada, Sentron LD 3000 SAE 40 0.47
Petro Canada Sentron LD 5000 SAE 40 0.57
Petro Canada Sentron LD 8000 SAE 40 0.52
Petro-Canada Sentron LD Synthetic SAE 15W40 0.51
Blend
PetroChina Kunlun KCN 7905 SAE 40 0.52
PETRONAS GEO S40 SAE 40 0.50
PETRONAS GEO SNG SAE 40 0.50
Puma LA Natural Gas SAE 40 0.50
Q8 Mahler MA SAE 40 0.50
Q8 Mahler HA SAE 40 0.90
Roloil Mogas (Italy) SAE 40 0.50
Roloil Mogas-AC (Italy) SAE 40 0.90
Sinopec GS200-L Stationary Gas Engine SAE 40 0.51
Oil (Premium)
Shell Mysella S3 S (was Mysella MA) SAE 40 0.90*
Shell Mysella S5 N (was Mysella XL) SAE 40 0.48*
Tongyi Hephaestus SGO LA40 SAE 40 0.50
TOTAL Nateria MP 40 SAE 40 0.48
Valvoline GEO LA40 SAE 40 0.58

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 Service Bulletin No. 12-1880AR

Table 2: Recommended Lube Oils for Cogeneration / Gas Compression Applications (Using Pipeline Quality
Gas)
SULFATED ASH (%W)
BRAND TYPE ASTM D 874 (TYPICAL)
Valvoline Premium Blue GEO LA ES 40 SAE 40 0.51
YPF Vectis LA-540 SAE 40 0.50
YPF Vectis G 40LA SAE 40 0.51
76 Triton 5005 EXD SAE 40 0.50

NOTE: See Table 1 for sulfated ash recommendations for INNIO Waukesha gas engine models.
* PER ISO 3987
12V/18V220GL INSTALLATIONS It is especially important that the lube oils used in
cogeneration applications utilize virgin base stocks
INNIO Waukesha does not ordinarily recommend lube
with good thermal stability. The lube oils listed in
oils by brand name for specific products. However,
Table 3 are known to give satisfactory performance in
based on actual field experience, the lube oils listed in
high-temperature cooling system applications.
Table 3 are specified for all 220GL installations.

Table 3: Recommended Lube Oils for All 220GL Applications (Using Pipeline Quality Gas)
SULFATED ASH (%W)
SUPPLIER BRAND NAME TYPE ASTM D 874
Mobil Pegasus 705 SAE 40 0.50
Mobil Pegasus 805* SAE 40 0.50
Mobil Pegasus 805 Ultra SAE 40 0.50
Exxon Mobil Mobil Pegasus 905 SAE 40 0.50
Mobil Pegasus 1005 SAE 40 0.50
Mobil Pegasus 1105 SAE 40 0.50
Mobil Pegasus 1 (Synthetic) SAE 15W40 0.50
Nateria MH 40 SAE 40 0.45
Total Nateria P 405 SAE 40 0.42
Nateria X 405 (Synthetic) SAE 15W40 0.45
Mysella S3 N (was Mysella LA) SAE 40 0.45**
Shell Mysella S5 N (was Mysella XL) SAE 40 0.48**
Texaco Geotex LA SAE 40 0.45
HDAX 5200 Low Ash
Chevron SAE 40 0.50
(HDAX Low Ash)
Castrol Duratec L SAE 40 0.45
BP Energas NGL SAE 40 0.45
Idemitsu Appolloil GHP 40L SAE 40 0.45
Petro-Canada Sentron LD 5000 SAE 40 0.57

* For use outside Americas

** PER ISO 3987

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Service Bulletin No. 12-1880AR

SOUR GAS, DIGESTER GAS, ALTERNATIVE FUEL Table 4: Recommended Lube Oils – Landfill Gas
GAS AND LANDFILL GAS RECOMMENDATIONS Applications
PERCENT OF
! WARNING BRAND TYPE SULFATED
ASH
INNIO Waukesha assumes no
SAE
Mobil Pegasus 610 1.00*

!
liability or responsibility for 40
potential damage to the
environment or any personal injury SAE
Mobil Pegasus 605 0.60
or death caused by using landfill 40
gases or sour gases as fuel. It is SAE
Mobil Pegasus 605 Ultra 40 0.50
solely the engine owner’s/ 40
customer’s responsibility to Chevron HDAX 5500 LFG SAE
carefully analyze any fuel gases 0.71
(HDAX LFG) 40
they choose to use. Use of these
gases is at the owner’s/customer’s * These lube oils have a higher sulfated ash level than
own risk. specified in Table 1 for the F18, H24, L36, P48, G, GSI,
GSID, GL, GLD and F3514, F3524, L5794, L7044, GSI, L5774,
NOTE: Low BTU fuel gases 400-660 BTU/FT3 LHV must L5794, LT engines. These lube oils may be used but be
meet the requirements specified in the latest edition aware that engine life cycle may decrease due to an
of Service Bulletin 9-2702, Gaseous Fuel Specification. increase in engine deposits.
Alternative fuel sources are attracting increasing The best approach to improving engine life cycle is to
interest today as a low-cost fuel or because of their filter out or absorb contaminants in the fuel gas
environmental benefits. However, there are issues before they reach the engine. There are various
that arise due to the sulfur compounds (H2S, etc.), companies manufacturing and promoting gas
siloxanes and halide constituents in these fuels. filtration and absorption processes. However, INNIO
Hydrogen sulfide (H2S), siloxanes and total organic Waukesha makes no endorsement of these products
halide as chloride (TOH/CI) bring with them totally or services. Their performance is solely the
different challenges for the engine and lube oil. See responsibility of their respective manufacturers.
the latest edition of Service Bulletin 9-2702, Gaseous The following lube oil recommendations will minimize
Fuel Specification, for additional information. corrosion problems normally encountered with fuel
The use of landfill, digester or other waste gas makes gas containing H2S and TOH/CI:
the selection of an engine lube oil, lube oil analysis
Recommendation #1
and lube oil drain intervals far too complicated to
address completely here because the lube oil Contact your lube oil supplier for an appropriate
requirements change as the TOH/Cl level increases. choice. Also follow the appropriate ash content
Anyone operating with landfill, digester or other waste percent by weight for the specific engine model.
gas must review the latest edition of Service Bulletin
9-2702, Gaseous Fuel Specification, to fully understand
Recommendation #2
the ramifications of operating an engine with that Used lube oil analysis is mandatory for alternative fuel
type of fuel gas. applications. Lube oil change periods are determined
by TBN (Total Base Number), TAN (Total Acid Number),
RECOMMENDED LUBE OILS FOR LANDFILL GAS
oxidation and nitration level in the used lube oil
APPLICATIONS samples. The user must change the lube oil when the
INNIO Waukesha recommends lube oil specifically TBN level falls to 30% of the new lube oil value or TAN
formulated for landfill gas applications. Always follow increases by 2.5 – 3.0 above the new lube oil value.
the lube oil manufacturer’s instructions and do not The method of measuring TBN in used lube oil is
use the lube oil beyond their recommendations. shown in Table 12.
Some landfill gas formulated lube oils can cause The DEXSIL® Corporation has developed the Q2000
excessive buildup of abnormal ash deposits in the field test kit. This kit is used to determine the chlorine
combustion chamber when used outside of their contamination of engine lube oil exposed to chlorine
recommendations. Landfill gas engine lube oils containing fuels such as landfill gas. This field test kit is
should only be used in engines applied to landfill gas highly accurate and allows the operator to obtain
operation and not digester gas operation. timely test results in the field. The lube oil must be
sampled every 50 hours in order to establish an initial
“trend.” Ordering information may be obtained from
the DEXSIL Corporation, One Hamden Park Drive,
Hamden, CT 06517.

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 Service Bulletin No. 12-1880AR

NOTICE
TOH/CI does not affect TBN levels the same as sulfur
compounds. Therefore, the 30% TBN depletion (50% TBN
depletion on 220GL engines) as an indicator of a change
interval only applies to the applications where fuel gas
does not contain halides.

Recommendation #3
Increase the jacket water temperature to 210° – 235°F
(99° – 113°C) and lube oil temperature to 185° – 200°F
(85° – 93°C). 275GL/GL+ series engines are limited to a
maximum of 180°F (82°C) lube oil temperature. 220GL
series engines are limited to a maximum of 212°F
(100°C) jacket water outlet temperature, and 176°F
(80°C) lube oil inlet temperature. Increased
temperatures will reduce condensation which will
reduce the concentration of acids within the
crankcase. High-temperature thermostats are
available for most models.
Any question on lubricants to be used with alternative
fuel gases should be directed to the Field Service
Department or Sales Engineering Department prior to
selecting a lube oil.

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Service Bulletin No. 12-1880AR

LUBE OIL SELECTION

LUBE OIL VISCOSITY SELECTION
The operating temperature of the lube oil in the sump
or header is the best guide for selecting the proper
SAE grade of lube oil. When the lube oil temperature is
unknown, add 120°F (67°C) to the ambient
temperature to obtain an estimated lube oil sump
temperature.

Table 5: VGF / VHP Sump and Header Temperatures and SAE Number
SUMP TEMPERATURE HEADER TEMPERATURE SAE NUMBER
160° – 230°F 160° – 195°F 40
(71° – 110°C) (71° – 91°C)
Below 160°F (71°C) Below 160°F (71°C) 30

Table 6: 275GL/GL+ Sump and Header Temperatures and SAE Number

SUMP TEMPERATURE HEADER TEMPERATURE SAE NUMBER
160° – 230F 160° – 180F 40
(71° – 110C) (71° – 82C)

Table 7: 220GL Sump and Header Temperatures and SAE Number

SUMP TEMPERATURE HEADER TEMPERATURE SAE NUMBER
194° – 203F 167° – 176F
(90° – 95C) (75° – 80C) 40

Table 8: 16V150LTD / APG 1000 Sump and Header Temperatures and SAE Number
SUMP TEMPERATURE HEADER TEMPERATURE SAE NUMBER
195° – 205F 180° – 190F 40 or 30
(90° – 96C) (82° – 88C)

NOTE: Do not operate engines with a lube oil header temperature below 140°F (60°C). Engines that exceed 195°F
(91°C) header temperature or 215°F (102°C) sump temperature should have reduced lube oil change intervals
based upon lube oil analysis (see Table 12).

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 Service Bulletin No. 12-1880AR

MULTI-VISCOSITY LUBE OILS 220GL ENGINES

Use multi-viscosity lube oils only for engines in cold To avoid any troubles when starting under cold
starting applications. Multi-viscosity lube oil may ambient conditions, and because of the extra
deteriorate in continuous operation, allowing the lube pressure drop involved by the external circuit, it is
oil to lose viscosity through shearing. In this state, the mandatory that lube oil temperature in the external
lube oil may not supply sufficient lubricating film and/ circuit does not fall down below 68°F (20°C).
or pressure. Therefore, utilize a lube oil analysis
This minimum temperature can be achieved by two
program to determine the lube oil change interval.
different means:
SYNTHETIC LUBE OILS • Either the external circuit (piping, control valve and
Based on developments by lube oil manufacturers cooler) is located in a warm area where
and the release of their synthetic lube oils, INNIO temperature never falls below 68°F (20°C), such as
inside a building rather than outside.
Waukesha now recognizes these products as being
suitable for all INNIO Waukesha engines including • Or the external circuit is fitted with a warming
stoichiometric (“rich burn”) and lean burn gas system (electrical resistance or preheaters and
engines. Table 2 and Table 3 include synthetic lube circulation) which regulates lube oil temperature to
oils. a minimum of 68°F (20°C).

When synthetic lube oils are selected, INNIO LUBE OIL FILTRATION REQUIREMENTS
Waukesha suggests contacting its Field Service or
Sales Engineering Departments for lube oil change The quality of lube oil filtration will directly affect
interval recommendations if lube oil analysis is not engine component life. The basic filtration
done. However, a lube oil analysis program is always requirement for INNIO Waukesha engines is 90%
recommended. Actual lube oil change intervals must efficient at 15 microns for all full-flow sock and paper
be established through a lube oil analysis program elements, and 98% efficient at 25 microns for
and visual inspection of engine components. Typical fiberglass disposable and cleanable full-flow metal
areas to look for lube oil breakdown are exhaust valve mesh elements. Mesh or screen sizes larger than 25
stems, piston ring area and piston undercrown. microns are not acceptable.
Synthetic lube oil change intervals are 3 to 5 times
Lube oil filter elements are to be changed based on
longer than those of mineral oils. However, lube oil
the lube oil change intervals listed in Table 9 or when
filter change intervals remain at 1,000 to 1,500 hours of
the maximum pressure drop listed in the in the
operation, so that contaminant buildup does not
Operation & Maintenance manual for that engine is
result in excessive lube oil filter pressure drop.
reached – whichever comes first. It is also
Synthetic lube oils are not recommended for recommended to change lube oil filters whenever the
alternative fuel gas applications. INNIO Waukesha lube oil is changed. This will prevent the used lube oil
suggests obtaining prior approval before using a in the filters from contaminating the fresh lube oil.
synthetic.

LOW AMBIENT TEMPERATURE

OPERATION
At low ambient temperatures, use a lube oil which will
provide proper lubrication when the engine is hot and
working. For engines of 1,000 cu. in. (16.4 L)
displacement and above, operating at ambient
temperatures below 50°F (10°C), lube oil and jacket
water heaters are required to warm lube oil and
water for faster starting and load application.
Information on these starting devices is available
upon request.

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Service Bulletin No. 12-1880AR

RECOMMENDED LUBE OIL CHANGE TAKING AN OIL SAMPLE

INTERVALS
INNIO Waukesha recommends establishing lube oil ! WARNING
change intervals using a lube oil analysis program
Engine lube oil is extremely hot and
and visual inspection of power cylinder components.

!
is under pressure. Use caution when
When lube oil analysis is not possible, the intervals sampling engine lube oil for
listed in Table 9 and Table 10 serve as a guideline for analysis. Personal protection
engines running on pipeline quality natural gas. Lube equipment (PPE) including insulated
oil change intervals may be extended beyond those gloves and safety glasses are
listed in Table 9 and Table 10 if the following conditions required when oil samples are being
are met: taken. Failure to follow proper
procedures could cause severe
• Lube oil analysis is performed per Table 12. personal injury or death.
• INNIO Waukesha factory-supplied lube oil filtration
system is used. Select INNIO Waukesha gas engines are equipped
– See “LUBE OIL FILTRATION REQUIREMENTS” on with oil sampling valves.
page 9.
• A factory-supplied centrifugal oil filter is installed
and maintained for proper function.
• A visual inspection of power cylinder components
after two oil change intervals of run time under the
expected running conditions and the desired/
extended lube oil change interval.
– Part deposit inspection pass/fail criteria must
hinge on acceptable industry standards of
deposit evaluation of varnish, lacquer and
carbon on valve stems, piston ring grooves and
piston undercrown.
– Inspections are to be performed on 2 cylinders.
NOTE: More frequent lube oil changes may be
necessary with some types of lube oil as well as with
the presence of other factors including, but not
limited to, a dusty environment, a marginal Figure 1: Oil Sample Port
installation, the internal engine condition and/or
operation of an engine that has malfunctioning On models equipped with an oil sampling valve,
carburetion equipment. The lube oil drain should be before taking a lube oil sample, clean the sample
as complete as possible, including draining of used outlet valve. This prevents any debris in the sample
lube oil from low-lying plumbing in the lubrication outlet valve from contaminating the lube oil sample.
system. INNIO Waukesha recommends that the lube Draw the lube oil sample at engine operating
oil be monitored with a professional lube oil analysis temperature.
program. However, extended lube oil change intervals
may cause varnish deposits, lube oil oxidation or On models not equipped with oil sampling valves,
sludge conditions to appear in the engine which a take the oil sample before the full-flow lube oil filters.
lube oil analysis program may not detect. Contact
your local INNIO Waukesha Distributor for periodic For all oil samples, record the following information on
engine maintenance recommendations. the oil sample container:
• Engine model
• Engine serial number
• Engine total hours
• Lube oil sample hours

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 Service Bulletin No. 12-1880AR

Table 9: Lube Oil Change Intervals for Engines Receiving Normal Maintenance and Using Commercial Quality
Natural Gas Fuel When Lube Oil Analysis Is Not Possible

ENGINES EBULLIENT COOLED

OPERATED IN OR HOT WATER
ISO STANDARD OR EXCESS OF SYSTEM WITH
ENGINE MODEL CONTINUOUS ISO STD ENGINE WATER STANDBY DUTY
POWER RATING POWER OR TEMPERATURE OF
PEAK 211°F (99°C) OR
SHAVING ABOVE
FOR ENGINES OPERATING WITH LUBE OIL HEADER TEMPERATURE OF 195°F (91°C) OR BELOW
VGF G, GL, GLD
LOW CAPACITY 500 hours or
1,000 hours 500 hours 500 hours
Natural Gas and HD-5 annually
Propane
VGF G, GL, GLD
HIGH CAPACITY 500 hours or
2,100 hours 1,000 hours 1,000 hours
Natural Gas and HD-5 annually
Propane
VGF GSID, GSI
LOW CAPACITY 500 hours or
720 hours 500 hours 500 hours
Natural Gas and HD-5 annually
Propane
VGF GSID, GSI
HIGH CAPACITY 500 hours or
1,500 hours 720 hours 720 hours
Natural Gas and HD-5 annually
Propane
VGF SE
500 hours or
Natural Gas and HD-5 1,500 hours – annually
Propane
VHP SERIES
LOW CAPACITY 500 hours or
1,000 hours 500 hours 500 hours
Natural Gas and HD-5 annually
Propane
VHP SERIES
HIGH CAPACITY 3,000 hours1 – – 500 hours or
Natural Gas with Extender 1,500 hours2
Package annually
VHP SERIES FIVE 4,000 hours – –
275GL/GL+ SERIES
4,000 hours
Natural Gas
APG SERIES
16V150LTD Normal 1,500 hours Not Allowed Not Allowed Not Allowed
Natural Gas
3,000 hours for early
engines – 1,500
hours for filters only
12V/18V220GL 500 hours or
For WEDA 460 Not Allowed Not Allowed
Natural Gas annually
engines after March
2011 –
filters changed at
3,000 hours
1 Oil change interval requires that oil analysis not exceed INNIO-specified condemning limits, listed in Table 12.
2 Oil change interval without oil analysis

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Service Bulletin No. 12-1880AR

Table 10: Recommended Lube Oil Change Intervals for Engines Receiving Normal Maintenance and Using
Gaseous Fuel Containing H2S of 50 µg/BTU or Less (see the latest edition of Service Bulletin 9-2702, Gaseous Fuel
Specification)

EBULLIENT COOLED
OR HOT WATER
ENGINES OPERATED IN SYSTEM WITH ENGINE
ENGINE ISO STANDARD OR EXCESS OF ISO STD WATER STANDBY DUTY
MODEL PRIME POWER RATING POWER OR PEAK TEMPERATURE OF
SHAVING 211°F (99°C) OR
ABOVE
FOR ENGINES OPERATING WITH ELEVATED LUBE OIL SUMP TEMPERATURE
VGF SERIES 360 hours 250 hours 360 hours 250 hours or annually
VHP SERIES 360 hours 250 hours 360 hours 250 hours or annually
NOTE: 275GL series engines are limited to a maximum of 180F (82C) lube oil temperature.
275GL/GL+
SERIES 500 hours or sooner by lube oil analysis. See Table 12 for condemning limits.
Natural Sample every 100 hours.
Gas

Table 11: Duty Cycle Definitions

The highest load and speed which can be applied 24 hours a day, 7 days a week, 365
ISO STANDARD OR days per year, except for normal maintenance. It is permissible to operate the engine
CONTINUOUS POWER at up to 10 percent overload, or the maximum load indicated by the intermittent
RATING: rating, whichever is lower, for two hours each 24-hour period.
In a system used as backup or secondary source of electrical power, this rating is the
GENERATOR STANDBY output the engine will produce continuously (no overload), 24 hours a day, for the
POWER RATING: duration of the prime power source outage.
This rating is the highest load and speed that can be applied in variable speed
INTERMITTENT POWER mechanical system application only. Operation at this rating is limited to a maximum
RATING: of 3,500 hours per year.
Peak shaving is operation of an engine for a limited time to meet the short-term peak
GENERATOR PEAK power requirements. Speed, loading and hours per year of operation will affect the
SHAVING: recommended lube oil change interval.

LUBE OIL CONDEMNING LIMITS

! CAUTION
Engine lube oil is extremely hot and
is under pressure. Use caution when
sampling engine lube oil for
analysis. Failure to take adequate
precautions may result in personal
injury.

Lube oil condemning limits are established by the

engine manufacturer’s experience and/or used lube
oil testing. Laboratory testing, using the parameters
shown in Table 12, will help determine the used lube
oil’s suitability for continued use.

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 Service Bulletin No. 12-1880AR

Table 12: Used Lube Oil Testing and Recommended Condemnation Limits
Natural gas fuel engine lube oil samples should be taken based on trend experience or @ 500 hours maximum.
CONDEMNING LIMITS
STANDARD TEST METHOD
ANALYSIS METRICS USED ALL OTHER
12V/18V220GL
INNIO WAUKESHA ENGINES
WEAR METALS:
Iron (Fe) 30 ppm max
Aluminum (Al) 10 ppm max
Copper (Cu) 15 ppm max
Lead (Pb) 20 ppm max Wear metals by trend analy-
sis.
Tin (Sn) 10 ppm max (Investigate source(s) of ris-
ASTM D5185 ing wear metal(s). Change
Chromium (Cr) 10 ppm max
lube oil based upon analysis
Nickel (Ni) 10 ppm max report recommendations.)
Silver (Ag) Wear metals by trend analy-
sis.
Titanium (Ti) Change lube oil based upon
Report recommendations.
CONTAMINANTS:
Follow analysis report rec-
Silicon (Si) 20 ppm max
ommendations
Sodium (Na) ASTM D5185 Any detectable amount (> 5 Any detectable amount (> 5
ppm) as coolant leak indi- ppm) as coolant leak indi-
Potassium (K) cator cator
ASTM D6443 (XRF) or ASTM
Chlorine (Cl) 900 ppm max 900 ppm max
D2622 (XRF)
Soot FTIR Above 2.5% by volume Above 2.5% by volume
ASTM D1744 or Above 0.3% by weight Above 0.1% by weight
Water % by IR & Karl Fischer
ASTM D6304-04A (3,000 ppm) (1,000 ppm)
(Na & K) Any detectable (Na & K) Any detectable
Glycol (pos/neg) ASTM D2982 amount (> 5 ppm) amount (> 5 ppm)
MULTI-SOURCE:
Boron (B)
Molybdenum (Mo) Multi-source by Analysis Multi-source by Analysis
ASTM D5185 Report Recommendations Report Recommendations
Antimony (Sb) (if contaminant) (if contaminant)
Manganese (Mn)
ADDITIVES:
Magnesium (Mg)
Calcium (Ca)
Barium (Ba) ASTM D5185 Additive levels are Additive levels are informa-
information only tion only
Phosphorous (P)
Zinc (Zn)
CHARACTERISTICS:
Viscosity (40°C) +50% change
ASTM D445 -20/+30% change
Viscosity (100°C) +25% change
TAN ASTM D664 2.5 rise over new lube oil ** 3.0 rise over new lube oil **
ASTM D2896 (new & used Drop to 30% of new TBN **
TBN Drop to 50% of new TBN **
lube oil) Not applicable to TOH/Cl
Oxidation 40 Abs/cm Peak Height (Sin- 40 Abs/cm Peak Height (Sin-
ASTM E2412-04 ANNEX A2 gle Point Baseline) Method gle Point Baseline) Method
Nitration
25 Abs @ 1700 cm¯ ¹ Peak 25 Abs @ 1735 cm¯ ¹ Peak
Oxidation Area Method Area Method
ASTM E2412-04 ANNEX A1 *
Nitration 20 Abs @ 1625 cm¯ ¹ Peak 25 Abs @ 1625 cm¯ ¹ Peak
Area Method Area Method
ASTM D92
Flash Point 356°F (180°C) 356°F (180°C)
(Cleveland Open Cup)
Continued on next page

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Service Bulletin No. 12-1880AR

Table 12: Used Lube Oil Testing and Recommended Condemnation Limits (Continued)
Natural gas fuel engine lube oil samples should be taken based on trend experience or @ 500 hours maximum.
CONDEMNING LIMITS
ANALYSIS METRICS STANDARD TEST METHOD
USED ALL OTHER
12V/18V220GL INNIO WAUKESHA ENGINES

PARTICLE COUNTS: MAXIMUM MONITORED MAXIMUM MONITORED

LEVELS *** LEVELS ***
ISO Code ISO 4406 24/24/20 24/24/20
4 micron 160,000 particles/ml 160,000 particles/ml
6 micron 80,000 80,000
10 micron 30,000 30,000
14 micron 5,000 5,000
ISO 11500
21 micron 1,000 1,000
38 micron 100 100
70 micron 12 12
100 micron 8 8

* Specified condemning limit (abs/cm) is the allowed change compared to unused oil of the same formulation.
Measure values in both used and new oil. Subtract the value of the used oil from the value of new oil. If the
differential value is greater than the value shown in Table 12, the oil is condemned.
** Sweeten the sump lube oil by adding new lube oil when TBN and/or TAN level falls below condemning limits.
Resample sweetened lube oil to verify proper TAN/TBN levels. If TAN/TBN condemning limits are reached and sump
sweetening is not done, the lube oil must be changed to re-establish proper lube oil alkalinity protection from
acid formation.

*** Do not condemn the lube oil based solely on particle count levels unless a severe rise in any micron level
occurs in the 500 hour lube oil sample analysis. Inspect the engine filtration system (improperly seated elements,
holes in elements, a stuck open filter bypass valve, a non-functional centrifuge, etc.) if an early hour excessive rise
is seen in particle counts. Longer term, consider other lube oil condemning limits in Table 12 along with rising
particle counts in the decision to change lube oil and filters.

In order to obtain a reasonable life expectancy for – Perform a lube oil analysis at least every 50
INNIO Waukesha engines operating on gas containing hours to start.
some level of halogens, our experience dictates the
– Elevate the jacket water temperature to
following:
212° – 235°F (100° – 113°C).
• To achieve a life expectancy equivalent to an
– Elevate the lube oil temperature to 185° – 200°F
engine operating on pipeline quality natural gas,
remove all halogen compounds and abrasives (85° – 93°C), 180°F (82°C) maximum for 275GL
from the fuel gas. models, and 176°F (80°C) for 220GL models.
• Reasonable life can be expected if the Total – Use of high TBN oil (7.0 – 13.0)
Organic Halide as Chloride (TOH/CI) concentration – Bypass lube oil filtration. INNIO Waukesha has
of the fuel does not exceed 8.5 micrograms per BTU
introduced the factory-supplied centrifugal oil
(µg/BTU) (150 µg/liter). Total Organic Halide as
Chloride equals the sum of all halogenated filter cleanable lube oil filtering system. The
compounds expressed as chloride (Cl) in factory-supplied centrifugal oil filter system
micrograms per BTU (µg/BTU) (or µg/liter) at utilizes the cleaning capabilities of a centrifuge
Standard Temperature and Pressure (STP). See the coupled with cleanable filter elements. The
latest edition of Service Bulletin 9-2702, Gaseous factory-supplied centrifugal oil filter system
Fuel Specification. Reasonable life can also be utilizes INNIO Waukesha’s current lube oil
expected with increased maintenance and filtration canister for the cleanable elements.
operating adjustments to the engine, such as: The centrifuge is installed as a bypass system
working in conjunction with the cleanable filter
Typical changes in maintenance and operation at
elements.
this chloride level are:
– Decreased lube oil change interval (150 hours to • A fuel gas containing a TOH/CI concentration
above 8.5 µg/BTU (150 µg/liter) requires pre-
start)
treatment of the fuel in order to make it suitable for
– Condemn the lube oil when the 900 ppm use in an INNIO Waukesha engine.
chlorine limit in used lube oil is reached. This will
aid in establishing a lube oil change interval.

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 Service Bulletin No. 12-1880AR

LUBE OIL CONSUMPTION GUIDELINES

Typical gross lube oil consumption rates for INNIO
Waukesha engines are:
Table 13: Typical Gross Lube Oil Consumption Rate
LBS/ GRAMS/ GRAMS/
MODEL HP-HR HP-HR KW-HR
VGF SE 0.0002 0.091 0.121
VHP
Series 0.0002 0.091 0.121
Four
GSI
VHP
Series 0.0005 0.227 0.302
Five
275GL+ 0.0003 0.137 0.182
All 0.0002 – 0.091 – 0.910 0.121 – 1.22
other 0.002

NOTE: Lube oil consumption rates given above are a

general guide and not meant to be used as
condemning limits or for determining overhaul
requirements. Lube oil treatment, losses and changes
not included.
NOTE: Oil consumption will vary depending on site
conditions, engine load, engine speed, and the age of
the engine. When sizing an oil makeup tank double
the values above to plan for oil consumption increase
as the engine ages.
FORMULAS FOR DETERMINING LUBE OIL
CONSUMPTION RATE
The following formulas may be useful for determining
the engine lube oil consumption rate.

LBS 7.3 x Number of Gallons of Lube Oil Used

=
HP-HR HP x Hours of Operation

LBS 1.82 x Number of Quarts of Lube Oil Used

=
HP-HR HP x Hours of Operation

Grams 875 x Number of Liters of Lube Oil Used

=
HP-HR HP x Hours of Operation

Grams 875 x Number of Liters of Lube Oil Used

=
kWb-HR kWb (corrected) x Hours of Operation

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Service Bulletin No. 12-1880AR

ESM2 ENGINE RUNTIME HOURS FEATURE If S005xxxx or later software is present, proceed to the
“Engine Runtime” user calibration hours update.
The following features are available on ESM2 Engines
and can assist in determining engine operating hours
between oil changes.
During the life of an ECU or engine it may be desirable
to change or reset the displayed engine hours. After
events such as an engine rebuild or an ECU
replacement, an update of the “Engine Runtime”
parameter, which is based off of the “Engine Hours
Update” user calibration, may be needed.
The “Engine Runtime” feature is handled slightly
different than other user calibrations and requires a
unique procedure. This is to help protect against
accidental changes.
Before starting procedure, verify the “Software ID” Figure 2: Verify Software ID
version is S005xxxx or later. Go to the “Systems” tab,
then the “Controller” table and verify the “Software ID.”

Figure 3: Trip Hours Reset

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 Service Bulletin No. 12-1880AR

ENGINE RUNTIME HOURS UPDATE

Use the following procedure to properly set the
starting value of “Engine Runtime” on ESM2-equipped
engines.
1. Shut down engine.
2. Login to the HMI as Customer. Go to User,
Customer and Login.
3. Set all parameters to desired values (if changes
are needed) by going to the “Parameters” tab.
After setting any needed parameters go to ADV,
Advanced Settings.

Figure 6: Save Parameters

6. Power cycle ECU.

7. Set “Engine Hours Update” to the desired value.

Figure 7: Set Engine Hours Update

8. Power cycle ECU.

The “Engine Hours Update” user calibration will read
Figure 4: Advanced Settings “0” after the power cycle.
“Engine Runtime” will now update to the value set in
4. Set “Engine Hours Update” to 0 (zero).
Step 7 and continue to increment while the engine is
running.

Figure 5: Set Engine Hours Update to Zero

5. Save parameters.

Figure 8: Engine Runtime

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