Waukesha gas engines Fuels and Lubrication

Lube Oil Recommendations for Waukesha* gas engines

Waukesha gas engines are heavy duty industrial type engines which require heavy duty lubricating oils. The basic
requirements are high lubricating quality, high thermal stability and good control of contaminants.
Waukesha gas engines product line consists of spark ignited industrial gas engines from the VGF* through the
16V275GL+ models. The lubricating oil requirements and systems change greatly between each model and fuel type.

LUBE OIL PERFORMANCE

There are hundreds of commercial crankcase oils marketed today. Obviously, engine manufacturers or users cannot
completely evaluate the numerous commercial oils.
The performance of a lubricant, like that of any manufactured product, is the responsibility of the refiner and supplier.
The Waukesha gas engine warranty is limited to the repair or replacement of parts that fail due to defective material or
workmanship during the warranty period. The warranty does not include responsibility for satisfactory performance of
the lubricating oil.
With the exception of cogeneration, the 220GL products, and special or prototype installations, Waukesha has made it
a practice not to recommend oil by brand name.
Waukesha strongly recommends monitoring the condition of the engine oil through the use of a good oil analysis
program.

OIL DESIGNATIONS
Oil is designated in several ways: American Petroleum Institute (API), Society of Automotive Engineers (SAE),
American Society for Testing and Materials (ASTM) performance classifications and Military Designation. Since no
gas engine industry oil performance designations exist, it is the responsibility of the engine operator to verify with their
oil supplier, that the oil they select has proven field performance in their specific engine make and model. This oil
must also meet the minimum requirements specified by Waukesha as listed in the included tables.

SUPPLEMENTARY LUBE OIL ADDITIVES

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

LUBE OIL RECOMMENDATIONS

Waukesha recommends the use of oil formulated specifically for natural gas engines and meeting minimum ash
requirements based on engine model. The ash forming constituents in oil formulations provide detergency, corrosion
protection and anti-wear protection. In addition, the ash produced during combustion of these additives will provide
protection against valve face and seat recession. However, use of oils containing a higher ash level than specified in
the tables may increase engine deposits and decrease component life.

Waukesha gas engines use specifically formulated oils. Waukesha

does not recommend gasoline or diesel oil formulations for use with its
Waukesha gas engines. Use of gasoline or diesel formulations may
cause severe engine damage. The Waukesha gas engine warranty is limited to the repair or replacement of parts that
fail due to defective material or workmanship during the warranty period. The Waukesha warranty does not provide
coverage for unsatisfactory performance of lube oil.

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TABLE 1. Oil Recommendations By Engine Model

GAS ENGINE MODELS SULFATED ASH WT% (1, 2, 3)
F18, H24, L36, P48 G, GL, GLD, GLD/2 0.45 – 0.75

VGF* F18, H24, L36, P48, GSI, GSID 0.35 – 0.55

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
NOTE: (1) 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.
(2) 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.
(3) Use 1.0% ash oil for the VHP and 275GL engines only if needed due to higher than normal valve recession rates.

CATALYST CONTAMINANTS
The following contaminants are known catalyst deactivators and should be avoided when selecting lubricating oils for
installations with catalysts since they contribute to shortened catalyst life: heavy and base metals such as lead,
mercury, arsenic, antimony, zinc, copper, tin, iron, nickel, chrome, sulfur, and phosphorus. Generally these individual
elements should not exceed 1 ppm or collectively exceed 5 ppm at the catalyst inlet. Specific exceptions: phosphorus
or silicon compounds at the catalyst inlet are not to exceed 1 ppm and sulfur compounds at the catalyst inlet are not to
exceed 100 ppm. Always consult the catalyst supplier for specific recommendations for the catalyst being used.
Do not confuse the concentration of these elements in the exhaust gas flow AT THE CATALYST INLET with the
concentration of these elements in the lube oil itself.

LUBE OIL FILTRATION REQUIREMENTS

The quality of oil filtration will directly affect engine component life. Waukesha’s basic filtration requirement is 90%
efficient at 15 microns for all full flow sock and paper elements, and 98% efficient at 25 microns for fiberglass
disposable and cleanable full flow metal mesh elements. Mesh or screen sizes larger than 25 microns are not
acceptable.
Lube oil filter elements should be changed when the lube oil is changed or when the pressure drop across the lube oil
filter exceeds values stated in specific engine maintenance manuals.

EXTENDED LUBE OIL DRAIN INTERVALS

Extended oil drain intervals should be based on oil analysis. The Microspin® centrifuge, in conjunction with Waukesha
supplied oil filtration components, will remove spent additives and other by-products of combustion allowing an
increase in scheduled lube oil drain and lube oil filter element change intervals. Waukesha recommends that a lube oil
analysis program be used to determine oil change intervals when condemning limits are reached. Please reference
Table 5. See Tables 11 and 12 for the recommended maximum number of hours between normal lube oil drain and
lube oil filter element changes without a lube oil analysis program.

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WAUKESHA COGENERATION INSTALLATIONS

Waukesha does not ordinarily recommend lube oils by brand name. However, based on actual field experience, the
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 4000+ hours of experience, the lube oils listed in Table 2 are known to give satisfactory
performance in high temperature cooling systems applications.

TABLE 2. Recommended Lube Oils For Cogeneration Applications (Using Pipeline Quality Gas)
SULFATED ASH (%W) ASTM D 874
BRAND TYPE
(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, HDAX Low Ash SAE 40 0.50
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
Conoco Elmar LA4 EXD SAE 40 0.50
GS Caltex – GS Generator/Low Ash SAE 40 0.51
Mobil Pegasus 1 (Synthetic) SAE 15W40 0.5
Mobil Pegasus 1005 SAE 40 0.5
Mobil Pegasus 905 SAE 40 0.5
Mobil Pegasus 805 SAE 40 0.5
Mobil Pegasus 710 SAE 40 1.0
Mobil Pegasus SHC40 SAE 40 0.5
Mobil Pegasus 1105 SAE 40 0.5
Mobil Pegasus 805 Ultra SAE 40 0.5
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 Blend SAE 15W40 0.51
PetroChina Kunlun, KCN 7905 SAE 40 0.52
PETRONAS GEO S40 SAE 40 0.5
PETRONAS GEO SNG SAE 40 0.5
PUMA LA Natural Gas S SAE 40 0.5
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 Oil (premium) SAE 40 0.51
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 0.5
TOTAL Nateria MP 40 SAE 40 0.48
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SULFATED ASH (%W) ASTM D 874

BRAND TYPE
(TYPICAL)
Valvoline GEO LA40 SAE 40 0.58
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: Refer to Table 1 for lube oil sulfated ash recommendations for Waukesha gas engine models.
*PER ISO 3987

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).

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

TABLE 3. Recommended Lube Oils For all 220GL Applications (Using Pipeline Quality Gas)
SULFATED ASH (%W)
SUPPLIER BRAND NAME TYPE
ASTM D 874 (TYPICAL)
Nateria MH 40 SAE 40 0.45
Total Nateria P 405 SAE 40 0.42
Nateria X 405 (Synthetic) SAE 15W40 0.45
Mobil Pegasus 705 SAE 40 0.50
Mobil Pegasus 805 SAE 40 0.50
Mobil Pegasus 905 SAE 40 0.50
Exxon Mobil Mobil Pegasus 1005 SAE 40 0.50
Mobil Pegasus 1105 SAE 40 0.50
Mobil Pegasus 1 (Synthetic) SAE 15W40 0.50
Mobil Pegasus 805 Ultra SAE 40 0.50
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

*PER ISO 3987

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SOUR GAS, DIGESTER GAS, ALTERNATIVE FUEL GAS, AND LANDFILL GAS RECOMMENDATIONS
Waukesha assumes no liability or responsibility for potential damage to
the environment or any personal injury caused by using landfill gases
or sour gases as fuel. It is the engine owner’s/customer’s sole
responsibility to carefully analyze any fuel gases they choose to use. Use of these gases is at the owner’s/customer’s
own risk.
Note: Low BTU fuel gases 400-660 BTU/FT3 LHV must meet the requirements specified in the current version of
Standard S-7884-7 Gaseous Fuel Specification for Waukesha gas engines. (Always refer to the latest version).
Alternative fuel sources are attracting increasing interest today as a low cost fuel or because of their environmental
benefits. However, there are issues that arise due to the sulfur compounds (H2S, etc.), siloxanes and halide
constituents in these fuels. Hydrogen sulfide (H2S), siloxanes and total organic halide as chloride (TOH/CI) bring with
them totally different challenges for the engine and lube oil. Refer to the current version of the Gaseous Fuel
Specification for Waukesha gas engines, S-7884-7, for additional information.
The use of landfill, digester or other waste gas makes the selection of an engine lube oil, lube oil analysis, and lube oil
drain intervals far too complicated to address here because the lube oil requirements change as the TOH/CL level
increases. Anyone operating with landfill, digester or other waste gas must review the current version of Waukesha’s
Gaseous Fuel Specification, S-7884-7, to fully understand the ramifications of operating an engine with that type of
fuel gas.

RECOMMENDED LUBE OILS FOR LANDFILL GAS APPLICATIONS

Waukesha recommends lube oil specifically formulated for landfill gas applications. Always follow the lube oil
manufacturer’s instructions and do not use the oil beyond their recommendations. Some landfill gas formulated lube
oils can cause excessive build-up of abnormal ash deposits in the combustion chamber when used outside of their
recommendations. Landfill gas engine lube oils should only be used in engines applied to landfill gas operation and
not digester gas operation.

TABLE 4. Recommended Lube Oils Landfill Gas Applications

BRAND TYPE PERCENT OF SULFATED ASH
Mobil Pegasus 605 SAE 40 0.60
Mobil Pegasus 610 SAE 40 1.0 (Note 1)
Mobil Pegasus 605 Ultra 40 SAE 40 0.50
Chevron HDAX 5500 LFG
SAE 40 0.71
(HDAX LFG)
Note: (1) These lube oils have a higher sulfated ash level than specified in Table 1 for the F18, H24, L36, P48, G,
GSI, GSID,GL, GLD, and F3514, F3524, L5794, L7044, GSI, L7042GSI S4, P9394GSI, L5774, L5794, LT, F3524,
L7044G Engines. These lube oils may be used but be aware that engine life cycle may decrease due to an increase
in engine deposits.
The best approach to improving engine life cycle is to filter out or absorb contaminants in the fuel gas before they
reach the engine. There are various companies manufacturing and promoting gas filtration and absorption processes.
However, Waukesha makes no endorsement of these products or services. Their performance is solely the
responsibility of their manufacturers.
The following lube oil recommendations will minimize corrosion problems normally encountered with fuel gas
containing H2S and TOH/CI:
Recommendation # 1
Select a gas engine lube oil with a high alkalinity reserve, 7 to 13 TBN (Total Base Number). Alkalinity reserve in the
lube oil is measured in TBN. The higher the TBN, the more reserve.
Contact your lube oil supplier for an appropriate choice. Also follow the appropriate ash content percent by weight for
the specific engine model.

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Recommendation # 2
Used lube oil analysis is mandatory for alternative fuel applications. Lube oil change periods are determined by TBN,
(Total Base Number), TAN (Total Acid Number), oxidation, and nitration level in the used lube oil samples. The user
must change the oil when the TBN level falls to 30% of the new lube oil value or TAN increases by 2.5 – 3.0 above
the new oil value. The method of measuring TBN in used lube oil is shown in Table 6.
The DEXSIL® Corporation has developed the Q2000 field test kit. This kit is used to determine the chlorine
contamination of engine lube oil exposed to chlorine containing fuels such as landfill gas. This field test kit is highly
accurate and allows the operator to obtain timely test results in the field. The lube oil must be sampled every 50 hours
in order to establish an initial “trend”. Waukesha has experienced good results with this kit. Ordering information may
be obtained from the DEXSIL® Corporation, One Hamden Park Drive, Hamden, CT 06517.

TOH/CI does not affect TBN levels the same as sulfur compounds. Therefore, the 30%
TBN depletion down to 30% of new lube oil TBN (50% TBN depletion on 220 GL
engines) as an indicator of a change interval only applies to the applications where fuel
gas does not contain halides. Disregarding this information could result in product damage and/or personal injury.

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 Application Engineering Department prior to selecting a lube oil.

LUBE OIL CONDEMNING LIMITS

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 6, will help determine the used lube oil’s suitability for
continued use.

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TABLE 5. Used Lube Oil Testing And Recommended Condemnation Limits

(With natural gas fuel engine lube oil samples should be taken based on trend experience or @ 500 hours maximum)
STANDARD TEST CONDEMNING LIMITS
ANALYSIS METRICS 12V/18V 220GL
METHOD USED All Other Waukesha gas 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 analysis
Tin (Sn) 10 ppm max (Investigate source(s) of rising wear
ASTM D5185
metal(s). Change oil based upon
Chromium (Cr) 10 ppm max analysis report recommendations.)
Nickel (Ni) 10 ppm max
Silver (Ag) Wear metals by trend analysis
Change oil based upon report
Titanium (Ti) recommendations
CONTAMINANTS
Follow analysis report
Silicon (Si) 20 ppm max
recommendations
ASTM D5185
Sodium (Na) Any detectable amount Any detectable amount
Potassium (K) (>5 ppm) as coolant leak indicator (>5 ppm) as coolant leak indicator
ASTM D6443 (XRF) or
Chlorine (Cl) 900 ppm max 900 ppm max
ASTM D2622 (XRF)
Soot FTIR Above 2.5% by volume Above 2.5% by volume
Water % by IR & ASTM D1744 or
Above 0.3% by weight (3000 ppm) Above 0.1% by weight (1000 ppm)
Karl Fischer ASTM D6304-04A
(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 Report Multi-source by Analysis Report
ASTM D5185 Recommendations Recommendations
Antimony (Sb) (if contaminant) (if contaminant)
Manganese (Mn)
ADDITIVES
Magnesium (Mg)
Calcium (Ca)
Additive levels are Additive levels are
Barium (Ba) ASTM D5185
information only information only
Phosphorous (P)
Zinc (Zn)
CHARACTERISTICS
Viscosity (40°C) ASTM D445 +50% change - 20 / +30% change
Viscosity (100°C) ASTM D445 +25% change - 20 / +30% change
TAN ASTM D664 2.5 rise over new oil 3.0 rise over new oil
ASTM D2896 (new and used Drop to 30% of new oil TBN
TBN Drop to 50% of new oil TBN
oil) Not applicable to TOHCL
Oxidation ASTM E2412-04 40 Abs/cm – Peak Height 40 Abs/cm – Peak Height
Nitration ANNEX A2 (Single Point Baseline) Method (Single Point Baseline) Method

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STANDARD TEST CONDEMNING LIMITS

ANALYSIS METRICS 12V/18V 220GL
METHOD USED All Other Waukesha gas engines
25 Abs @ 1700 cm-1 25 Abs @ 1735 cm-1
Oxidation
ASTM E2412-04 Peak Area Method Peak Area Method
ANNEX A1 **2 20 Abs @ 1625 cm-1 25 Abs @ 1625 cm-1
Nitration
Peak Area Method Peak Area Method
ASTM D92
Flash Point 356°F (180°C) 356°F (180°C)
(Cleveland Open Cup)
PARTICLE COUNTS
STANDARD TEST
ANALYSIS METRICS MAXIMUM MONITORED LEVELS**3
METHOD USED
ISO Code ISO 4406 24/24/20
4 micron 160,000 particles/ml
6 micron 80,000 particles/ml
10 micron 30,000 particles/ml
14 micron 5,000 particles/ml
ISO 11500
21 micron 1,000 particles/ml
38 micron 100 particles/ml
70 micron 12 particles/ml
100 micron 8 particles/ml

**1 Sweeten the sump lube oil by adding new lube oil when characteristics fall below condemning limits.
Resample sweetened lube oil to verify proper characteristic levels. If 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 and deposit control.
**2 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 5, the oil is condemned.
**3 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 5 along with rising
particle counts in the decision to change lube oil and filters.

Actual lube oil change intervals must be determined by engine inspection and lube oil
analysis in conjunction with the condemning limits. Disregarding this information could
result in engine damage.
In order to obtain a reasonable life expectancy for Waukesha gas engines operating on fuel gas containing some level
of halogens, our experience dictates the following:
● To achieve a life expectancy equivalent to an engine operating on pipeline quality natural gas, remove all
halogen compounds and abrasives from the fuel gas.
● Reasonable life can be expected if the Total Organic Halide as Chloride (TOH/CI) concentration of the fuel
does not exceed 8.5 micrograms per BTU (µg/BTU) (150 µg/liter). Total Organic Halide as Chloride equals
the sum of all halogenated compounds expressed as chloride (Cl) in micrograms per BTU (µg/BTU) (or
µg/liter) at Standard Temperature and Pressure (STP). Refer to the most current version of the Gaseous
Fuel Specification for Waukesha gas engines S-7884-7. Reasonable life can also be expected with
increased maintenance and operating adjustments to the engine, such as:

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Typical changes in maintenance and operation at this chloride level are:

− Decreased lube oil change interval (150 hours to start)
− Condemn the lube oil when the 900 ppm chlorine limit in used lube oil is reached. This will aid in establishing
a lube oil change interval.
− Perform a lube oil analysis at least every 50 hours to start.
− Elevate the jacket water temperature to 212 – 235°F (100 – 113°C)
− Elevate the lube oil temperature to 185 – 200°F (85 – 93°C); 180°F (82°C) maximum for 275GL models, and
176°F (80°C) for 220GL models.
− Use of high TBN oil (7.0 – 13.0)
− Bypass lubrication oil filtration. Waukesha has introduced the Microspin cleanable lube oil filtering system for
Waukesha gas engines. The Microspin system utilizes the cleaning capabilities of a centrifuge coupled with
cleanable filter elements. The Microspin system utilizes Waukesha gas engines current lube oil filtration
canister for the cleanable elements. The centrifuge is installed as a bypass system working in conjunction
with the cleanable filter elements.
● A fuel gas containing a TOH/Cl concentration above 8.5 µg/BTU (150 µg/liter) requires pre-treatment of the
fuel in order to make it suitable for use in a Waukesha gas engine.

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 oil temperature is unknown add 120°F (67°C) to the ambient temperature to obtain an estimated
lube oil sump temperature.

TABLE 6. VGF/VHP Sump And Header Temperatures And SAE Number

SUMP HEADER
SAE NUMBER
TEMPERATURE TEMPERATURE
160 – 230°F (71 – 110°C) 160 – 195°F (71 – 91°C) 40
Below 160°F (71°C) Below 160°F (71°C) 30

TABLE 7. 275GL/GL+ Sump And Header Temperatures and SAE Number

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

TABLE 8. 220GL Sump And Header Temperatures And SAE Number

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

TABLE 9. 16V150LTD/APG1000 Sump And Header Temperatures And SAE Number

SUMP HEADER
SAE NUMBER
TEMPERATURE TEMPERATURE
195 – 205°F (90 – 96°C) 180 – 190°F (82 – 88°C) 40 or 30*

NOTE: Do not operate engines with an 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 6).
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MULTI-VISCOSITY LUBE OILS

Use multi-viscosity lube oils only for engines in cold starting applications. Multi-viscosity lube oil may deteriorate in
continuous operation allowing the lube oil to lose viscosity through shearing. In this state the lube oil may not supply
sufficient lubricating film and/or pressure. Therefore, utilize a lube oil analysis program to determine the lube oil
change interval.

SYNTHETIC LUBE OILS

Based on developments by lube oil manufacturers and the release of their synthetic lube oils, Waukesha now
recognizes these products as being suitable for all Waukesha stoichiometric (“rich burn”) and lean burn gas engines.
Table 2 and Table 3 include synthetic lube oils.
When synthetic lube oils are selected, Waukesha suggests contacting the Waukesha Field Service or Sales
Engineering Departments for oil change interval recommendations if lube oil analysis is not done. However a lube oil
analysis program is always recommended by Waukesha.
Actual lube oil change intervals must be established through a lube oil analysis program and visual inspection of
engine components. Typical areas to look for lube oil breakdown are exhaust valve stems, piston ring area, and piston
undercrown. Synthetic lube oil change intervals are 3 to 5 times longer than those of mineral oils. However, lube oil
filter change intervals remain at 1000 to 1500 hours of operation, so that contaminant build up does not result in
excessive lube oil filter pressure drop.
Synthetic lube oils are not recommended for alternative fuel gas applications without prior approval by Waukesha.

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 1000 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 oil and water for faster starting and load application. Waukesha
will supply information on these starting devices upon request.
For 220GL Applications
To avoid any troubles when starting under cold ambient conditions, and because of the extra pressure drop involved
by the external circuit, it is mandatory that lube oil temperature in the external circuit does not fall down below 68°F
(20°C).
This minimum temperature can be achieved by two different means:
• Either the external circuit (piping, control valve, and cooler) is located in a warm area where
temperature never falls below 68°F (20°C), such as inside engine a building rather than outside.
• Or the external circuit is fitted with a warming system (electrical resistance or preheaters and
circulation) which regulate lube oil temperature to a minimum of 68°F (20°C).

LUBE OIL CONSUMPTION GUIDELINES

Typical gross lube oil consumption rates for all Waukesha gas engines are:

TABLE 10. Typical Gross Oil Consumption Rate

MODEL LBS/ GRAMS/ GRAMS/
HP-HR HP-HR kW-HR
VGF SE 0.0002 0.091 0.121
VHP Series Four GSI 0.0002 0.091 0.121
7042GSI S5 (1500 BHP) 0.0003 0.136 0.182
7044GSI S5 (1680 BHP) 0.0003 0.136 0.182
7044GSI S5 (1900 BHP) 0.00045 0.204 0.274

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MODEL LBS/ GRAMS/ GRAMS/

HP-HR HP-HR kW-HR
9394GSI S5 (2500 BHP) 0.0005 0.227 0.304
275GL+ 0.0003 0.136 0.182
ALL OTHER 0.0002 – 0.002 0.091 – 0.910 0.121 – 1.22
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.
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.
Advancing ignition timing increases oil consumption.
Retarding ignition timing decreases oil consumption.
Under normal conditions and after engine break in period, the S4 and S5 oil consumption is assumed to be fairly consistent over the life of
the engine up to the published bottom end interval.

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FORMULAS FOR DETERMINING LUBE OIL CONSUMPTION RATE

The following formulas may be useful for determining the engine lube oil consumption rate:
LBS 7.3x Number of Gallonsof OilUsed Grams 875 x Number of Litersof OilUsed
= =
HP- HR HPx Hoursof Operation HP- HR HPx Hoursof Operation

LBS 1.82x Number of Quartsof OilUsed Grams 875 x Number of Litersof OilUsed
= =
HP- HR HPx Hoursof Operation kWb - HR kWb (corrected) x Hoursof Operation

RECOMMENDED LUBE OIL CHANGE INTERVALS

Waukesha recommends establishing lube oil change intervals using a lube oil analysis program and visual inspection
of power cylinder components for Waukesha gas engines. When lube oil analysis is not possible, the intervals listed in
Table 12 and Table 13 serve as a guideline for engines running on pipeline quality natural gas. Lube oil change intervals
may be extended beyond those listed in Table 12 and Table 13 if the following conditions are met:

• Lube oil analysis is performed per Table 6

• Waukesha factory-supplied lube oil filtration system is used.
- Filter change intervals cannot be extended. See LUBE OIL FILTRATION REQUIREMENTS on page 2.
• A factory-approved centrifugal oil filter is installed and maintained for proper function.
• A visual inspection of power cylinder components after a run time of two times the desired/extended lube oil
change interval under the expected running conditions.
- 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 installation, the internal engine condition,
and/or operation of an engine that has malfunctioning carburetion equipment. The lube oil drain should be as
complete as possible, including draining of used lube oil from low lying plumbing in the lubrication system. Waukesha
recommends that the lube oil be monitored with a professional lube oil analysis program. However, extended lube oil
change intervals may cause varnish deposits, lube oil oxidation or sludge conditions to appear in the engine which a
lube oil analysis program may not detect. Disregarding this information could result in engine damage. Contact your
local Waukesha Distributor for periodic engine maintenance recommendations.

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TAKING AN OIL SAMPLE

Engine lube oil is extremely hot and is under pressure. Use caution
when sampling engine lube oil for analysis. Personal protection
equipment (PPE) including insulated gloves and safety glasses are
required when oil samples are being taken. Failure to follow proper procedures could cause severe personal injury or
death.
Select Waukesha gas engines are equipped with oil sampling valves beneath the oil filter base. See Figure 1

Figure 1: Oil Sampling Port (P9394GSI shown)

NOTE: On models not equipped with oil sampling valves, take the oil sample before the full-flow lube oil filters.
For all oil samples, record the following on the oil sample container:
• Engine model

• Engine serial number

• Engine total hours

• Lube oil sample hours

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TABLE 11. Recommended Lube Oil Change Intervals For Engines Receiving Normal Maintenance and Using
Natural Gas Fuel without a Lube Oil Analysis Program
Table 11 is provided as a guide to engine lube oil change intervals when lube oil analysis is extremely difficult to
obtain by customers/end users of Waukesha gas engines.

ENGINES OPERATED IN EBULLIENT COOLED OR HOT WATER

ENGINE ISO STANDARD OR CONTINUOUS EXCESS OF ISO STD POWER SYSTEM WITH ENGINE WATER STANDBY
MODEL POWER RATING OR TEMPERATURE DUTY
PEAK SHAVING OF 211°F (99°C) OR ABOVE
FOR ENGINES OPERATING WITH LUBE OIL HEADER TEMPERATURE OF 195°F (91°C) OR BELOW.
VGF G, GL, GLD
500 hours or
Low Capacity Normal 1,000 hours 500 hours 500 hours
annually
Natural Gas and HD-5 Propane
VGF G, GL, GLD
500 hours or
High Capacity Normal 2,100 hours 1000 hours 1000 hours
annually
Natural Gas and HD-5 Propane
VGF GSID, GSI
500 hours or
Low Capacity Normal 720 hours 500 hours 500 hours
annually
Natural Gas and HD-5 Propane
VGF GSID, GSI, SE
500 hours or
High Capacity Normal 1,500 hours 720 hours 720 hours
annually
Natural Gas and HD-5 Propane
VHP
500 hours or
Low Capacity Normal 1,000 hours 500 hours 500 hours
annually
Natural Gas and HD-5 Propane
VHP
High Capacity
Normal 1,500 hours — —
Natural Gas With
Extender Package
500 hours or
VHP annually
Series Five GSI 3,000 hours**
High Capacity **(4,000 hours typical with — —
Natural Gas with oil analysis)
Extender Package
275GL/GL+
4000 hours
Natural Gas
APG SERIES
16V150LTD
Normal 1500 hours Not Allowed Not Allowed Not Allowed
Natural Gas
Normal 3,000 hours for engines
12V/18V 220GL 500 hours or
shipped after March 2011; Filter Not Allowed Not Allowed
Natural Gas annually
changed at 3,000 hours

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TABLE 12. Recommended Lube Oil Change Intervals For Engines Receiving Normal Maintenance And Using
Gaseous Fuel Containing H2S of 50 µg/BTU or less (refer to S-07884-7 Gaseous Fuel
Specifications for further information) based upon lube oil analysis (See Table 6). A lube oil
change is required at the TBN/TAN crossover point.

ISO STANDARD OR ENGINES OPERATED IN EXCESS OF EBULLIENT COOLED OR HOT WATER SYSTEM
STANDBY
ENGINE MODEL PRIME POWER ISO STD POWER OR PEAK WITH ENGINE WATER TEMPERATURE OF
DUTY
RATING SHAVING 211°F (99°C) OR ABOVE
FOR ENGINES OPERATING WITH ELEVATED LUBE OIL SUMP TEMPERATURE.
250 hours
VGF SERIES 360 hours 250 hours 360 hours
or annually
250 hours
VHP SERIES 360 hours 250 hours 360 hours
or annually
NOTE: 275GL/GL+ series engines are limited to a maximum of 180°F (82°C) lube oil temperature.
275GL/GL+ 500 hours or sooner by lube oil analysis.
See Table 6 for condemning limits
Natural Gas Sample every 100 hours.

TABLE 13. Duty Cycle Definitions

The highest load and speed which can be applied 24 hours a day, 7 days a week, 365 days per
ISO STANDARD OR CONTINUOUS POWER year, except for normal maintenance. It is permissible to operate the engine at up to ten percent
RATING overload, or the maximum load indicated by the intermittent rating, whichever is lower, for 2 hours
each 24 hour period.
GENERATOR STANDBY In a system used as a backup or secondary source of electrical power, this rating is the output the
engine will produce continuously (no overload), 24 hours a day, for the duration of the prime power
POWER RATING
source outage.
This rating is the highest load and speed that can be applied in variable speed mechanical system
INTERMITTENT POWER RATING
application only. Operation at this rating is limited to a maximum of 3500 hours per year.
Peak shaving is operation of an engine for a limited time to meet the short term peak power
GENERATOR PEAK SHAVING requirements. Speed, loading, and hours per year of operation will affect the recommended oil
change interval.

*Trademark of INNIO Waukesha Gas Engines. All other trademarks are the property of their respective owners.

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