Heat Exchanger Maintenance.
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Incorrect maintenance on heat exchangers.
In the picture to the left, this heat exchanger was found to be the cause of an engine overheating on a clients site.
The brown sludge shown in the image was found to have hardened when the engine was cold and had completely blocked the coolant galleries around the engine.
This allowed the engine to be starved of fresh coolant when running.
The root cause of this was found to be that the engine had been filled with tap water and strong coolant mix and even at one point, topped up with oil!
The case resulted in the customer requiring 3 new engines to be supplied as the issue was present in all the heat exchangers on site.