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    12 Cylinder G Gsi GL

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    This document contains proprietary and trade secret information and is given to the receiver in confidence. The receiver agrees not to use the document or the confidential or trade secret information therein. Dresser, Inc. Disclaims any proprietary interest in these marks owned by others.

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    12 Cylinder G Gsi GL

    Uploaded by

    joshhines
    13K views750 pages
    This document contains proprietary and trade secret information and is given to the receiver in confidence. The receiver agrees not to use the document or the confidential or trade secret information therein. Dresser, Inc. Disclaims any proprietary interest in these marks owned by others.

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    12 Cylinder g Gsi Gl

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    This document contains proprietary and trade secret information and is given to the receiver in confidence. The receiver agrees not to use the document or the confidential or trade secret information therein. Dresser, Inc. Disclaims any proprietary interest in these marks owned by others.

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    13K views750 pages

    12 Cylinder G Gsi GL

    Uploaded by

    joshhines
    This document contains proprietary and trade secret information and is given to the receiver in confidence. The receiver agrees not to use the document or the confidential or trade secret information therein. Dresser, Inc. Disclaims any proprietary interest in these marks owned by others.

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    of 750

    Serial No.

    ( Specification No.

    Waukesha® M

    YHp
    12 Cylinder G/GSI/GL
    Repair & Overhaul Manual
    First Edition

    This document contains proprietary and trade secret information and


    is given to the receiver in confidence. The receiver by reception and
    retention of the document accepts the document In confidence and
    agrees that, except as with the prior expressed written permission of
    Waukesha Engine, Dresser, Inc., itwill; (1) notusethedocumentorany
    copy thereof or the confidential or trade secret information
    therein; (2) not copy or reproduce the document in whole, or in part
    without the prior written approval of Waukesha Engine, Dresser, Inc.;
    and (3) not disclose to others either the document orthe confidential or
    trade secret information contained therein.
    All sales and information herein supplied subject to Standard Terms of
    Sale, including limitation of liability.

    WAUKESHA®, DRESSER®, and WKI® are registered trademarks of


    Dresser, Inc. VHPT" and DRESSER logo are trademarks of Dresser,
    Inc. All other trademarks, service marks, logos, slogans, and trade
    names (collectively "marks~) are the properties of their respective
    owners. Dresser, Inc. disclaims any proprietary interest in these marks
    owned by others.

    m#9"*~
    Waukesha
    FORM 6248 -- Printed 4/06
    Waukesha Engine
    ) Dresser, Inc.
    Waukesha, Wisconsin 53188
    Printed in U.S.A. 1/2004
    © Copyright 1995, Dresser, Inc. All rights reserved.
    )

    )
    CONTENTS

    Warranty Welding ................................... 1.05 - 5


    General ............................. 1.05 - 5
    List Of Illustrations On Engine ........................... 1.05 - 5
    Weight .................................... 1.05 - 5
    List Of Tables
    Section 1.10 - Rigging And Lifting
    How To Use This Manual Engines
    Engine Rigging And Lifting . . . . . . . . . . . . . . . . . . 1.10 - 1
    Location Of The Lifting Eyes ................ 1.1 0 - 1
    CHAPTER 1 - SAFETY AND Correct Method Of Rigging And
    GENERAL Lifting Engine ........................ 1.1 0 - 1

    Section 1.00 - Warning Tags & Decal Section 1.15 - General Information
    Section Main Points: ....................... 1 .15 - 1
    Locations
    Overhaul/Repair Process ................... 1 .15 - 1
    Warning Tags And Decal Locations .......... t .00-1
    Preventing Engine Damage ................. 1 .15 - 1
    Section 1.05 - Safety
    Handling And Shipping ..................... 1 .15 - 1
    Safety Introduction ......................... 1.05 - 1
    Engine Removal ........................... 1 .15 - 2
    Safety Tags And Decals ..................... 1.05 - 1
    Equipment Repair And Service ............... 1.05 - 1 Serial Number And Engine Nameplate ........ 1.15 - 3

    Acids ..................................... 1.05 - 2 Engine Identification Views .................. 1 .15 - 4


    Batteries .................................. 1 .05 - 2 Right Side View ........................... 1.15 - 4
    Body Protection ............................ 1.05 - 2 Left Side View ............................. 1.15-5
    Chemicals ................................. 1.05 - 2
    RearView ................................ 1.15-6
    General ............................. 1.05 - 2
    Basic Engine Description ................... 1 .15 - 7
    Cleaning Solvents .................... 1.05 - 2
    Liquid Nitrogen/Dry Ice ................ 1.05 - 2 Service Tools List .......................... 1.15 - 8
    Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.05 - 2 Engine Standards ......................... 1 .15 - 10
    Heated Or Frozen .................... 1.05 - 2
    Component Weights ...................... 1.15 - 10
    Interference Fit ....................... 1.05 - 2
    Cooling System ............................ 1.05 - 2 Clearances .............................. 1.15 - 11
    Electrical ............ . . . . . . . . . . . . . . . . . . . . .. 1.05 - 3 Torque Specifications ..................... 1.15 - 12
    General ....... . . . . . . . . . . . . . .. . . . . . .. 1.05 - 3 General Torquing Sequence Procedure ...... 1.15 - 12
    Ignition .............................. 1.05 - 3
    Thread Lubrication For Torque
    Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.05 - 3 Fasteners .......................... 1.15 - 12
    Fire Protection ............................. 1.05 - 3
    Critical Engine Torque Values .............. 1.15 - 13
    Fuels ..................................... 1.05 - 3
    Cylinder Head Torquing Procedure .......... 1.15 - 14
    General ............................. 1.05 - 3
    Gaseous ............................ 1.05 - 3 Connecting Rod Capscrew Torquing
    Liquid ............................... 1.05 - 3 Procedure (P/N Series 205407 And
    Intoxicants And Narcotics .................... 1.05 - 4 205507) ............................ 1.15 - 14
    Pressurized Fluids/Gas/Air ................... 1.05 - 4 Main Bearing Cap Torquing Procedure ....... 1.15 - 15
    Protective Guards .......................... 1.05 - 4 General Torque Recommendations .......... 1.15 - 16
    Sodium Cooled Valve ....................... 1.05 - 4 English/Metric Conversions ................ 1 .15 - 17
    Springs ................................... 1.05 - 4
    Index Of Sealants. Adhesives And Lubricants 1.15 - 18
    Tools ..................................... 1.05 - 4
    Split Ring Washer Usability Criteria .......... 1 .15 - 19
    Electrical ............................ 1 .05 - 4
    Hydraulic ............................ 1.05 - 4
    Pneumatic ........................... 1.05 - 4

    Form 6248 First Edition iii


    CONTENTS

    Section 1.20 - Specifications CHAPTER 3 - ENGINE INSPECTION


    )
    SpecHications ............................. 1.20 - 1 AND OVERHAUL
    Gear Tooth Wear - General ................. 1.20 - 1
    Timing Gears .............................. 1.20 - 1 Section 3.00 - Cylinder Head
    Engine Timing Data ....................... 1.20 - 29 Disassembly
    Cylinder Head Disassembly ................. 3.00 - 1
    Rocker Arms .............................. 3.00 - 1

    CHAPTER 2 - ENGINE TEAR DOWN Intake And Exhaust Valves .................. 3.00 - 8
    Valve Seat Insert And Valve Guide
    Section 2.00 - Cylinder Head Removal Removal ............................ 3.00 - 9
    Cylinder Head Removal .................... 2.00 - 1 Cylinder Head Cleaning And Inspection ...... 3.00 - 10
    Cylinder Head Casting Pressure Testing ..... 3.00 - 12
    Section 2.05 - Crankcase Removal
    Cylinder Head Casting Magnaflux@ .......... 3.00 - 13
    Piston/Connecting Rod Removal ............. 2.05 - 1
    Cylinder Head Lower Deck Recondition ...... 3.00 - 14
    Cylinder Sleeve Removal ................... 2.05 - 4
    Valve Failure Analysis ......•.............. 3.00 - 14
    Vibration Damper Removal .................. 2.05 - 5
    Cylinder Head Assembly ....•.............. 3.00 - 19
    Front Gear Cover Removal .................. 2.05 - 7
    Valve Guide Installation .................... 3.00 - 19
    Magneto Drive Gear Removal ............... 2.05 - 9
    Cylinder Head Casting Plug Installation ...... 3.00 - 20
    Idler Gear Removal ....................... 2.05 - 10
    Valve Seat Insert Installation ............... 3.00 - 20
    Gamshaft Gear Removal ................... 2.05 - 10
    Valve Seat Grinding ....................... 3.00 - 21
    Front Gear Housing Removal ............... 2.05 - 11
    Valve Seat Lapping ....................... 3.00 - 22 )
    Rocker Arm Oil Header Removal ............ 2.05 - 12
    Intake And Exhaust Valve Installation ........ 3.00 - 23
    Valve LHter Housing Removal .............. 2.05 - 13
    Camshaft Removal ........................ 2.05 - 15 Section 3.05 - Crankcase Disassembly
    Barring Device Removal ................... 2.05 - 16 Crankcase ................................ 3.05 - 1
    Flywheel Removal ........................ 2.05 - 16 Crankcase Cleaning And Inspection .......... 3.05 - 1
    Oil Pickup Screen Removal ................ 2.05 - 18 Lower Sleeve Bore And Sleeve
    Projection Inspection . . . . . . . . . . . . . . . . . . 3.05 - 3
    Oil Pan Removal .......................... 2.05 - 19
    Crankcase Lower Bore Restoration .......... 3.05 - 3
    Crankshaft Removal ...................... 2.05 - 20
    Main Bearing Bore Cleaning And
    Crankcase ............................... 2.05 - 24 Inspection ........................... 3.05 - 5
    Crankshaft No.1 Main Bearing Removal In Main Bearing Running Clearance ............ 3.05 - 6
    Field Conditions ........................ 2.05 - 24
    Camshaft Bearing Bore Inspection ........... 3.05 - 9
    Crankshaft No. 1 Main Bearing Installation In
    Field Conditions ........................ 2.05 - 27 Crankshaft ................................ 3.05 - 9
    Crankshaft Main Bearings Removal In Field Crankshaft Cleaning And Inspection .......... 3.05 - 9
    Cond~ions ............................ 2.05 - 29 Crankshaft Journal Repair ..•.............. 3.05 - 11
    Crankshaft Main Bearings Installation In Field Crankshaft Polishing .......•.............. 3.05 - 11
    Cond~ions ............................ 2.05 - 30
    Crankshaft Repair ........................ 3.05 - 11
    Camshaft Bearing Removal In Field
    Conditions ............................ 2.05 - 31 Crankshaft Counterweight Retorque ......... 3.05 - 12

    Camshaft Bearing Installation In Field Camshaft ................................ 3.05 - 14


    Conditions ............................ 2.05 - 32 Camshaft Cleaning And Inspection .......... 3.05 - 14
    )

    Iv Form 6248 First Ednion


    CONTENTS

    Valve Lifters .............................. 3.05 - 15 Lower Valve Lifter Housing Cover


    Installation ........................... 4.00 - 5
    Roller Type Lifters ........................ 3.05 - 15
    Valve Lifter Housing Gasket
    Hydraulic Lifters .......................... 3.05 - 16
    Installation ........................... 4.00 - 6
    Piston ................................... 3.05 - 17
    Camshaft And Bearing Installation ........... 4.00 - 6
    Piston Disassembly ....................... 3.05 - 17
    Gear Housing Installation .................. 4.00 - 10
    Piston Cleaning And Inspection ............. 3.05 - 18
    Camshaft End Play Measurement ........... 4.00 - 11
    Piston Ring Inspection ..................... 3.05 - 23
    Cam Gear Installation ..................... 4.00 - 12
    Piston Ring Assembly ..................... 3.05 - 27
    Valve Lifter Housing Installation ............. 4.00 - 13
    8-1/2 Inch Bore G/GSI/GL (4 Ring Piston) .... 3.05 - 27
    Rocker Arm Oil Header Installation .......... 4.00 - 18
    9-3/8 Inch Bore G/GSI (4 Ring Piston) ....... 3.05 - 29
    Rear Oil Seal Retainer Installation .......... 4.00 - 18
    Previous Production 9-3/8 Inch Bore GL
    Main Bearing Installation ................... 4.00 - 20
    (4 Ring Piston) ...................... 3.05 - 30
    Crankshaft Installation ..................... 4.00 - 22
    Current Production 9-3/8 Inch Bore GL
    (3 Ring Piston) ...................... 3.05 - 31 Rear Oil Seal Retainer
    (Lower Half) Installation .............. 4.00 - 25
    Piston Pin Cleaning And Inspection ......... 3.05 - 32
    Main Bearing Caps Installation ............. 4.00 - 26
    Connecting Rod .......................... 3.05 - 33
    Crankshaft End Play Measurement .......... 4.00 - 26
    Connecting Rod Disassembly .............. 3.05 - 33
    Outside Crankshaft Thrust Ring
    Connecting Rod Cleaning And Inspection .... 3.05 - 35
    Installation .......................... 4.00 - 28
    Connecting Rod Assembly ................. 3.05 - 38
    Crankshaft Gear Installation ..•............. 4.00 - 30
    Connecting Rod Bearing Running
    Oil Pump Idler Gear ....................... 4.00 - 31
    Clearance .......................... 3.05 - 40
    Camshaft Idler Gear Installation ............ 4.00 - 32
    Connecting Rod Bearing Running
    Clearance Measurement Accessory Idler Gear Installation ............ 4.00 - 35
    With Plastigage® .................... 3.05 - 42
    Gear Backlash Measurement ............... 4.00 - 36
    Cylinder Sleeve .......................... 3.05 - 42
    Magneto Drive Assembly Installation ........ 4.00 - 37
    Cylinder Sleeve Disassembly ............... 3.05 - 42
    Magneto Drive Gear Installation ............ 4.00 - 39
    Cylinder Sleeve Cleaning And Inspection .... 3.05 - 43
    Cylinder Sleeve Installation ................ 4.00 - 41
    Cylinder Sleeve Deglazing ................. 3.05 - 47
    Piston And Connecting Rod Installation ...... 4.00 - 42
    Flywheel ................................. 3.05 - 48
    Oil Pan .................................. 4.00 - 46
    Ring Gear Removal ....................... 3.05 - 48
    Crankcase Installation ..................... 4.00 - 49
    Ring Gear Installation ..................... 3.05 - 48
    Front Flywheel Housing Installation ......... 4.00 - 50
    Timing Tape Installation .................... 4.00 - 51
    Flywheel Installation ...................... 4.00 - 52
    CHAPTER 4 - ENGINE ASSEMBLY Magnetic Pickup Sensor Installation ......... 4.00 - 53

    Section 4.00 - Crankcase Assembly Rear Flywheel Housing Installation .......... 4.00 - 54

    Crankcase Assembly ....................... 4.00 - 1 Flywheel/Flywheel Housing Bore And


    Face Runout Measure ................ 4.00 - 55
    Idler Gear Spindle Installation ............... 4.00 - 1
    Barring Device Installation ................. 4.00 - 58
    Oil Tube Installation ........................ 4.00 - 1
    Oil Filler Bracket Installation ................ 4.00 - 58
    Main Bearing Stud Installation ............... 4.00 - 2
    Gear Train Lubrication ..................... 4.00 - 59
    Dowel Installation .......................... 4.00 - 3
    Oil Slinger/Front Oil Seal/Gear Cover
    Water Header Plug Installation ............... 4.00 - 3 Installation .......................... 4.00 - 60
    Lube Oil Strainer Adapter Installation ......... 4.00 - 5 Front Gear Cover Plates Installation ......... 4.00 - 64

    Form 6248 First Ed~ion v


    CONTENTS

    Rear Gear Housing Cover Plate Governor Drive Gear/CEC Disc


    Installation .......................... 4.00 - 64 (Previous Production) Installation ....... 5.00 - 8
    Vibration Damper/Crankshaft Pulley Governor Drive Shaft ...................... 5.00 - 10
    Installation .......................... 4.00 - 65
    Governor Drive Shaft Removal ............. 5.00 - 10

    Section 4.05 - Cylinder Head Assembly Governor Drive Shaft Disassembly .......... 5.00 - 10
    Cylinder Head Installation ................... 4.05 - 1 Governor Drive Shaft
    Cleaning And Inspection .............. 5.00 - 11
    Cylinder Head Torquing Procedure ........... 4.05 - 3
    Governor Drive Shaft Assembly ............. 5.00 - 11
    Exhaust Manifolds ......................... 4.05 - 5
    Governor Drive Shaft Installation ............ 5.00 - 12
    Section 4.10 - Valve Adjustment And Governor Drive Housing ................... 5.00 - 13
    Web Deflection Governor Drive Housing Removal ......... , . 5.00 - 13
    Valve Adjustment Procedure ................ 4.10 - 1
    Governor Drive Housing Disassembly ....... 5.00 - 13
    Crankshaft Web Deflection
    Governor Drive Housing
    Measurement ........................... 4.10 - 4
    Cleaning And Inspection .............. 5.00 - 13
    Governor Drive Housing Assembly .......... 5.00 - 14
    Governor Drive Housing Installation ....... , . 5.00 - 14
    CHAPTER 5 - ENGINE SYSTEMS Governors ............................... 5.00 - 16

    Section 5.00 - Speed Governing System Woodward UG-8L Governor Linkage


    Removal ........................... 5.00 - 16
    Speed Governing System Components ....... 5.00 - 1
    Woodward UG-8L Governor Removal ....... 5.00 - 17
    Speed Governing System Description ........ 5.00 - 1
    Woodward UG-8L Governor Disassembly .,. 5.00 - 17
    Woodward UG-8L Governor ................ 5.00 - 1 )
    Woodward UG-8L Governor Assembly ...... 5.00 - 17
    Woodward UG-8 Dial Governor ............. 5.00 - 1
    Woodward UG-8L Governor Installation ..... 5.00 - 18
    Woodward EG-3P Electronic Governing
    System .............................. 5.00 - 1 UG-8L Governor Linkage Installation And
    Adjustment ......................... 5.00 - 19
    Governor Linkages ......................... 5.00 - 2
    Woodward UG-8L Governor
    Magnetic Pickup ........................... 5.00 - 2 Compensation Adjustment ............ 5.00 - 22
    Control Panel ............................. 5.00 - 2 Woodward UG-8L Governor High/Low
    Overspeed Governor ....................... 5.00 - 2 Speed Limn Adjustment .............. 5.00 - 24
    Governor Drive Gear/CEC Timing Disc ....... 5.00 - 3 Woodward UG-8L Governor Droop
    Adjustment ......................... 5.00 - 24
    Governor Drive Gear/CEC Timing Disc
    (Current Production) Removal .......... 5.00 - 3 Woodward UG-8 (Dial) Governor Linkage
    Removal ........................... 5.00 - 25
    Governor Drive Gear/CEC Timing Disc
    (Current Production) Cleaning And Woodward UG-8 (Dial) Governor Removal ... 5.00 - 26
    Inspection ........................... 5.00 - 4 Woodward UG-8 (Dial) Governor
    Governor Drive Gear/CEC Timing Disc Disassembly ........................ 5.00 - 27
    (Current Production) Installation ........ 5.00 - 4 Woodward UG-8 (Dial) Governor
    Governor Drive Gear/CEC Disc Assembly ........................... 5.00 - 27
    (Previous Production) Removal ......... 5.00 - 6 Woodward UG-8 (Dial) Governor
    Governor Drive Gear/CEC Disc Installation .......................... 5.00 - 27
    (Previous Production) Disassembly ..... 5.00 - 7 Woodward UG-8 (Dial) Governor Linkage
    Governor Drive Gear/CEC Disc Installation And Adjustment ........... 5.00 - 27
    (Previous Production) Cleaning And Woodward UG-8 Dial Governor
    Inspection ........................... 5.00 - 7 Compensation Adjustment ............ 5.00 - 29
    Governor Drive Gear/CEC Disc Woodward UG-8 Dial Governor High/Low
    (Previous Production) Assembly ........ 5.00 - 7 Speed Adjustment ................... 5.00 - 30

    vi Form 6248 First Edition


    CONTENTS

    Woodward UG-8 (Dial) Governor Droop Prechamber Gas Safety Shutdown Valve -
    Adjustment ......................... 5.00 - 31 GL .................................. 5.05 - 5
    Woodward EG-3P Electric Governor Prechamber Regulator - GL ................. 5.05 - 5
    Linkage Removal .................... 5.00 - 31
    Prechamber Manffolds - GL ................. 5.05 - 6
    Woodward EG-3P Governor Removal ....... 5.00 - 32
    Butterfly Cross Shaft - GlGSI ............... 5.05 - 6
    Woodward EG-3P Governor Disassembly ... 5.00 - 32
    Butterfly Cross Shaft Removal - GIGSI ....... 5.05 - 6
    Woodward EG-3P Governor Cleaning And
    Butterfly Cross Shaft Installation
    Inspection .......................... 5.00 - 33
    - GIGSI ............................. 5.05 - 7
    Woodward EG-3P Governor Assembly ...... 5.00 - 33
    Carburetor Cross Shaft - GL ................ 5.05 - 8
    EG-3P Governor Drive Removal ............ 5.00 - 33
    Carburetor Cross Shaft Removal - GL ........ 5.05 - 8
    EG-3P Governor Drive Disassembly ........ 5.00 - 34
    Carburetor Cross Shaft Installation - GL ...... 5.05 - 8
    EG-3P Governor Drive Cleaning And
    Prechamber Manffold Cross Pipe - GL ....... 5.05 - 9
    Inspection .......................... 5.00 - 35
    Prechamber Manffold Cross Pipe
    EG-3P Governor Drive Assembly ........... 5.00 - 35
    Removal - GL ....................... 5.05 - 9
    EG-3P Governor Drive Installation .......... 5.00 - 35
    Prechamber Manffold Cross Pipe
    Woodward EG-3P Governor Installation ..... 5.00 - 36 Installation - GL ..................... 5.05 - 10
    EG-3P Governor Linkage Cleaning And Carburetors .............................. 5.05 - 11
    Inspection .......................... 5.00 - 37
    Carburetor Removal - GIGS I ............... 5.05 - 11
    EG-3P Governor Linkage Installation And
    Carburetor Disassembly - G/GSI ............ 5.05 - 12
    Adjustment ......................... 5.00 - 38
    Carburetor Cleaning And Inspection -
    Manual Shutdown Lever - GL .............. 5.00 - 40
    GIGSI .............................. 5.05 - 12
    Manual Shutdown Lever Adjustment - GL .... 5.00 - 40
    Carburetor Assembly - GIGS I .; ............ 5.05 - 13
    Manual Shutdown Lever Removal - GIGSI ... 5.00 - 42
    Carburetor Installation - GIGSI ............. 5.05 - 13
    Manual Shutdown Lever Installation -
    Carburetor Removal - GL ..... :: ........... 5.05 - 15
    GIGSI .............................. 5.00 - 42
    Carburetor Disassembly - GL .............. 5.05 - 15
    Manual Shutdown Lever Adjustment -
    GlGSI .............................. 5.00 - 42 Carburetor Cleaning And Inspection - GL .... 5.05 - 16
    Overspeed Governor ...................... 5.00 - 42 Carburetor Assembly - GL ................. 5.05 - 17
    Overspeed Governor Removal ............. 5.00 - 42 Carburetor Installation - GL ................ 5.05 - 17
    Overspeed Governor Adjustment ........... 5.00 - 43 Butterfly Valve(s) ......................... 5.05 - 18
    Overspeed Governor Installation ............ 5.00 - 43 Butterfly Valve Removal - GIGSI ............ 5.05 - 18
    Hour Meter .............................. 5.00 - 44 Butterfly Valve Disassembly - GlGSI ........ 5.05 - 18
    Hour Meter Removal ...................... 5.00 - 44 Butterfly Valve Assembly - GIGSI ........... 5.05 - 19
    Hour Meter Installation .................... 5.00 - 44 Butterfly Valve Installation - GIGSI .......... 5.05 - 19
    Tachometer Drive ......................... 5.00 - 45 Admission Valve - GL ..................... 5.05 - 19
    Tachometer Drive Removal ................ 5.00 - 45 Admission Valve Removal - GL ............. 5.05 - 19
    Tachometer Drive Installation ............... 5.00 - 45 Admission Valve Disassembly - GL ......... 5.05 - 19
    Admission Valve Cleaning And
    Section 5.05 - Fuel System Inspection - GL ..................... 5.05 - 19
    Fuel System Components ................... 5.05 - 1 Admission Valve Assembly ................. 5.05 - 20
    Main Fuel Gas Pressure Regulators .......... 5.05 - 1 Admission Valve Installation - GL ........... 5.05 - 20
    Operation Of The Fisher 99 Main Fuel Prechamber Cup - GL ..................... 5.05 - 21
    Gas Pressure Regulator .. .. .. .. .. .. .. . 5.05 - 4
    Prechamber Cup Removal - GL ............ 5.05 - 21
    Carburetors .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.05 - 5
    Pilot Operated Prechamber Gas Valve - GL . . . 5.05 - 5

    Form 6248 First Ed~ion vII


    CONTENTS

    Prechamber Cup Cleaning And CEC Ignition Module Removal .............. 5.10 - 19 )
    Inspection - GL ..................... 5.05 - 22
    CEC Ignition Module Installation ............ 5.10 - 19
    Prechamber Cup Installation - GL .......... 5.05 - 22
    Governor Drive Gear/CEC
    Prechamber Manifold - GL ................. 5.05 - 23 Timing Disc (Current Production) ......... 5.10 - 20
    Prechamber Manifold Removal - GL ........ 5.05 - 23 Governor Drive Gear/CEC TIming Disc
    Removal (Current Production) ......... 5.10 - 20
    Prechamber Manifold Installation - GL ....... 5.05 - 24
    Governor Drive Gear/CEC TIming Disc
    Main Fuel Gas Pressure Regulator
    Cleaning And Inspection
    (Fisher 99) ............................ 5.05 - 25
    (Current Production) ................. 5.10 - 20
    Main Fuel Gas Pressure Regulator
    Governor Drive Gear/CEC TIming Disc
    (Fisher 99) Removal ................. 5.05 - 25
    Installation (Current Production) ....... 5.10 - 21
    Right Bank Installation ..................... 5.05 - 25
    CEC Ignition Module Static TIming SET
    Left Bank Installation ...................... 5.05 - 28 (Current Production) ................. 5.10 - 22
    Prechamber Regulator Selling The Air Gap Specification
    (Fisher 95L) - GL ...................... 5.05 - 29 (Current And Previous Production) ..... 5.10 - 24
    Prechamber Regulator (Fisher 95L) CEC Ignition Module TIming Set
    Removal - GL ...................... 5.05 - 29 (Current Production) ................. 5.10 - 24
    Prechamber Regulator (Fisher 95L) Steps Required To Adjust CEC Ignition
    Installation - GL ..................... 5.05 - 30 Module Timing (Current Production) .... 5.10 - 25
    Fuel System Maintenance ................. 5.05 - 33 Governor Drive Gear/CEC
    Timing Disc (Previous Production) ........ 5.10 - 26
    Fisher 99 Regulator Filter Cleaning And
    Inspection .......................... 5.05 - 33 Governor Drive Gear/CEC TIming
    Disc (Previous Production) Removal ... 5.10 - 26
    Section 5.10 - Ignition System Governor Drive Gear/CEC TIming Disc )
    Ignition System Components ................ 5.10 - 1 (Previous Production)
    CEC Ignition Module ....................... 5.10 - 1 Cleaning And Inspection .............. 5.10 - 26

    Magneto .................................. 5.10 - 1 Governor Drive gear/CEC Timing Disc


    (Previous Production) Installation ...... 5.10 - 27
    Wiring Harness ............................ 5.10 - 1
    CEC Ignition Module Ignition TIming
    Ignition Coils .............................. 5.10-1 (Previous Production) Set ............. 5.10 - 28
    Spall< Plugs ............................... 5.10 - 1 Steps Required To Adjust CEC Ignition
    Spark Plugs ............................... 5.10- 1 Module TIming (Previous Production) ... 5.10 - 30

    Spark Plug Carrier Removal - GL . . . . . . . . . . .. 5.10 - 1 Magneto ................................. 5.10 - 30

    Spark Plug Carrier Installation - GL .......... 5.10 - 3 Drive Disc Coupling Replacement ........... 5.10 - 30

    Spark Plug Carrier Removal - CSA .......... 5.10 - 3 Magneto - Static Timing Set ................ 5.10 - 32

    Spark Plug Carrier Installation - CSA ......... 5.10 - 4 Magneto - Ignition Timing Set .............. 5.10 - 37

    Spark Plug Removal ....................... 5.10 - 5 Magneto Adapter ......................... 5.10 - 39

    Spark Plug Inspection ...................... 5.10 - 7 Magneto Adapter Disassembly ............. 5.10 - 39

    Spark Plug Installation . . . . . . .. . . . . . . . . . . . . .. 5.10 - 8 Magneto Adapter Cleaning And Inspection ... 5.10 - 40

    Spark Plug Extension Repair ............... 5.1 0 - 10 Magneto Adapter Assembly ................ 5.10 - 40

    Ignition Coils ............................. 5.10 - 11 Magneto Drive ........................... 5.10 - 42

    Wiring Harness ........................... 5.10 - 13 Magneto Drive Disassembly ................ 5.10 - 42

    Wiring Harness Removal .................. 5.10 - 13 Magneto Drive Assembly .................. 5.10 - 43

    Wiring Harness Inspection ................. 5.10 - 14


    Wiring Harness Installation ................. 5.10 - 15
    CEC Ignition Module ...................... 5.10 - 19

    vIII Form 6248 First Edition


    CONTENTS

    Section 5.15 - Air Induction System Section 5.20 - Turbochargers


    Air Induction System ....................... 5.15 - 1 Turbochargers ............................. 5.20 - 1
    Air Cleaners .............................. 5.15 - 1 Turbocharger(s) Removal ................... 5.20 - 1
    Turbochargers ............................. 5.15 - 1 Turbocharger Cleaning And Inspection ....... 5.20 - 3
    Intercoolers ............................... 5.15 - 1 Turbocharger Installation ................... 5.20 - 8
    Carburetor And Intake Manifold .............. 5.15 - 1 Prelube Pressure Maintenance/Check Valve
    Inspection ............................. 5.20 - 12
    Air Induction System Specifications .......... 5.15 - 1
    Air Cleaners .............................. 5.15 - 2 Section 5.25 - Cooling System
    Precleaner Pad Removal ................... 5.15 - 2 Cooling System Components ................ 5.25 - 1
    Precleaner Pad Cleaning And Inspection ...... 5.15 - 3 Jacket Water Header/Jacket Water . . . . . . . . . . . 5.25 - 1
    Precleaner Pad Installation .................. 5.15 - 3 Exhaust Manifold .......................... 5.25 - 1
    Main Air fiRer Element Removal ............. 5.15 - 3 Water Manifold ............................ 5.25 - 1
    Main Air Filter Element Cleaning And Jacket Water Pump ........................ 5.25 - 2
    Inspection ........................... 5.15 - 3
    Cluster Thermostat Housing . . . . . . . . . . . . . . . . . 5.25 - 7
    Main Air FiRer Element Installation ........... 5.15 - 4
    Remote Heat Transfer Device ............... 5.25 - 7
    Air Restriction Indicator ..................... 5.15 - 4
    Auxiliary Water Pump ...................... 5.25 - 7
    Air Cleaner Ducts .......................... 5.15 - 5
    Intercooler ................................ 5.25 - 8
    Air Cleaner Duct Removal - G ............... 5.15 - 5
    Oil Cooler ................................. 5.25 - 8
    Air Cleaner Duct Installation - G ............. 5.15 - 7
    Auxiliary Water Temperature Control Valve .... 5.25 - 8
    Air Cleaner Duct Removal - GSI/GL .......... 5.15 - 8
    Auxiliary Water Remote Heat Transfer
    Air Cleaner Duct Installation - GSI/GL ....... 5.15 - 10 Device .............................. 5.25 - 9
    Air Tubing ............................... 5.15 -10 Cooling System Problems ................... 5.25 - 9
    Air Tubing Removal - G ................... 5.15 - 10 Scale Build-up, Cavitation Erosion And
    Air Tubing Installation - G .................. 5.15 - 11 Corrosion ............................ 5.25 - 9

    Air Tubing Removal - GSI ................. 5.15 - 11 Scale Build-up ............................ 5.25 - 9

    Air Tubing Installation - GSI ................ 5.15 - 12 CavHation Erosion ......................... 5.25 - 9

    Air Tubing Removal - GL .................. 5.15 - 12 Corrosion ................................ 5.25 - 10

    Air Tubing Installation - GL ................ 5.15 - 14 Water Treatment .......................... 5.25 - 10

    Intake ManHolds .......................... 5.15 - 14 Ethylene Glycol ........................... 5.25 - 10

    Intake Manifold Removal - G/GSI ........... 5.15 - 14 Cooling System Specifications And
    Recommendations ..................... 5.25 - 11
    Intake Manifold Installation - GlGSI ......... 5.15 - 15
    Cooling System Specifications . . . . . . . . . . . . .. 5.25 - 11
    Intake Manifold Flange Attachments ......... 5.15 - 16
    Cooling System Recommendations ......... 5.25 - 11
    Intake ManHold Flange Attachments -
    GlGSI .............................. 5.15-16 Jacket Water CircuH - InHial Fill ............. 5.25 - 12

    Left Bank ................................ 5.15-16 Auxiliary Cooling Water Circuit - Initial Fill .... 5.25 - 13

    Right Bank ............................... 5.15-17 Cooling Water System Air Bleed ............ 5.25 - 14

    Intake Manifold Removal - GL .............. 5.15 - 18 Jacket Water And Auxiliary Cooling Water
    Circuits - Drain And Flush ............... 5.25 - 14
    Intake ManHold Installation - GL ............ 5.15 - 19
    Grease Fittings ........................... 5.25 - 17
    Intake ManHold Flange Attachments - GL .... 5.15 - 20
    Idler Pulley Bearing Lubrication ............. 5.25 - 17
    Left Bank ................................ 5.15-20
    Auxiliary Water Pump Bearings Lubrication ... 5.25 - 17
    Right Bank ............................... 5.15 - 20
    Grease Recommendations ................. 5.25 - 17

    Form 6248 First EdHion Ix


    CONTENTS

    Belts .................................... 5.25 - 18 Idler Pulley Bracket Cleaning And


    Inspection .......................... 5.25 - 41
    Jacket Water Pump Drive Belts
    Replacement ....................... 5.25 - 18 Idler Pulley Bracket Assembly .............. 5.25 - 41
    Jacket Water Pump Drive Belt Tension Idler Pulley Bracket Installation ............. 5.25 - 43
    Adjustment ......................... 5.25 - 19
    Jacket Water Pump ....................... 5.25 - 44
    Auxiliary Water Pump Drive Belt
    Jacket Water Pump Removal ............... 5.25 - 44
    Replacement ....................... 5.25 - 21
    Jacket Water Pump Disassembly ........... 5.25 - 45
    Auxiliary Water Pump Drive Bett Tension
    Adjustment ......................... 5.25 - 22 Jacket Water Pump Cleaning And
    Inspection .......................... 5.25 - 46
    Jacket Water Pump Seal Inspection ......... 5.25 - 23
    Jacket Water Pump Assembly .............. 5.25 - 47
    Crankcase Water Inlet Elbows .............. 5.25 - 24
    Jacket Water Pump Installation ............. 5.25 - 54
    Crankcase Water Inlet Elbows Removal -
    Left Bank ........................... 5.25 - 24 Safety Guards ............................ 5.25 - 56
    Crankcase Water Inlet Elbows Removal - Safety Guards Removal ................... 5.25 - 56
    Right Bank ......................... 5.25 - 25 Safety Guards Installation .................. 5.25 - 57
    Crankcase Water Inlet Elbows Auxiliary Water Temperature Control Valve ... 5.25 - 58
    Installation - Left Bank ............... 5.25 - 25
    Auxiliary Water Temperature Control Valve
    Crankcase Water Inlet Elbows Installation - Removal ............•.............. 5.25 - 58
    Right Bank ......................... 5.25 - 25
    Auxiliary Water Temperature Control
    Water Pump Inlet Elbows And Water Header . 5.25 - 26 Thermostatic Valve Inspection And
    Water Pump Inlet Elbows And Water Test ............................... 5.25 - 58
    Header Removal .................... 5.25 - 26 Auxiliary Water Temperature Control Valve
    Water Pump Inlet Elbows And Water
    Header Installation ................... 5.25 - 27
    Assembly ........................... 5.25 - 59 )
    Auxiliary Water Temperature Control Valve
    Lower/Upper Bypass Tubes And Water Installation .......................... 5.25 - 60
    Bypass Elbows ........................ 5.25 - 28
    Intercooler ............................... 5.25 - 60
    Lower/Upper Bypass Tubes And Water Intercooler Removal ........•.............. 5.25 - 60
    Bypass Elbows Removal ............. 5.25 - 28
    Intercooler Disassembly ................... 5.25 - 66
    Lower/Upper Bypass Tubes And Water
    Bypass Elbows Installation ............ 5.25 - 29 Intercooler Cleaning And Inspection ......... 5.25 - 67
    Water Manifold ........................... 5.25 - 31 Intercooler Assembly ...................... 5.25 - 68
    Water Manifold Removal ........ , .......... 5.25 - 31 Intercooler Installation ..................... 5.25 - 71
    Water Manifold Installation ................. 5.25 - 32 Crankcase Vee Pipe Connection
    Installation ............................ 5.25 - 73
    Cluster Thermostat Housing And
    Thermostatic Valves .................... 5.25 - 34 Auxiliary Water Pump And Bracket .......... 5.25 - 77
    Cluster Thermostat Housing And Auxiliary Water Pump And Bracket
    Thermostatic Valves Removal ......... 5.25 - 34 Removal ........................... 5.25 - 77
    Cluster Thermostat Housing And Auxiliary Water Pump And Bracket
    Thermostatic Valves Cleaning And Installation .......................... 5.25 - 79
    Inspection .......................... 5.25 - 35
    Cluster Thermostat
    Section 5.30 - Lubrication System
    Housing/Thermostatic Valves Lubrication System Components ............. 5.30 - 1
    Installation .......................... 5.25 - 37 Description ............................... 5.30 - 1
    Idler Pulley Bracket ....................... 5.25 - 39 Internal Oil Control ......................... 5.30 - 3
    Idler Pulley Bracket Removal ............... 5.25 - 39 Lube Oil Specifications ..................... 5.30 - 4
    Idler Pulley Bracket Disassembly ........... 5.25 - 39 Oil Designations ........................... 5.30 - 4
    Oil Recommendations ...................... 5.30 - 4

    x Form 6248 First Ed~ion


    CONTENTS

    Waukesha Cogeneration Installations ......... 5.30 - 5 Oil Pickup Screen Installation ............... 5.30 - 29
    Sour Gas & Alternate Fuel Gas Lube Oil Pump ........................... 5.30 - 29
    Recommendations ...................... 5.30 - 5
    Lube Oil Pump Removal ................... 5.30 - 29
    Recommended Lube Oils For Sour Gas And
    Lube Oil Pump Disassembly ............... 5.30 - 29
    Alternate Fuel (Landfill) Gas Applications 5.30 - 5
    Lube Oil Pump Cleaning And Inspection ..... 5.30 - 31
    Fuel Coalescer Specification For
    A~ernative Fuel Application ............ 5.30 - 6 Lube Oil Pump Assembly .................. 5.30 - 32
    Lube Oil Condemning Limits ................ 5.30 - 6 Lube Oil Pump Installation ................. 5.30 - 37
    Lube Oil Analysis .......................... 5.30 - 8 Prelube Y -strainer ........................ 5.30 - 40
    Oil Viscosity Selection ...................... 5.30 - 9 Prelube Y -strainer Removal ................ 5.30 - 40
    Multi-viscosity Oils. . . . . . . . . . . . . . . . . . . . . . . . . 5.30 - 9 Prelube Y-strainer Cleaning And
    Inspection .......................... 5.30 - 40
    Synthetic Oils ............................. 5.30 - 9
    Prelube Y -strainer Installation .............. 5.30 - 40
    Low Ambient Temperature Operation ......... 5.30 - 9
    Oil Filler Pipe Removal .................... 5.30 - 41
    Lube Oil Consumption Rates ................ 5.30 - 9
    Oil Filler Pipe Removal .................... 5.30 - 41
    Formulas ................................. 5.30 - 9
    Oil Filler Pipe Installation .................. 5.30 - 41
    Recommended Oil Change Intervals ........ 5.30 - 10
    Rocker Arm Oil Header Oil Inlet
    Lube Oil Piping Purge ..................... 5.30 - 11
    Tubes/Fittings ......................... 5.30 - 42
    Oil Cooler And Lube Oil Filter
    Rocker Arm Oil Header Oil Inlet
    Installation ............................ 5.30 - 12
    Tubes/Fittings Installation ............. 5.30 - 42
    Lube Oil Change ......................... 5.30 - 12
    Turbo Oil Supply!Drain Tubes .............. 5.30 - 43
    Checking Crankcase Oil Level .............. 5.30 - 13
    Turbo Oil Supply!Drain Tubes
    Oil Cooler Maintenance .................... 5.30 - 13 Installation .......................... 5.30 - 43
    Lube Oil System Air Bleed ................. 5.30 - 13 Lube Oil Pilot Pressure/Governor. Oil Tube
    Connection ............................ 5.30 - 44
    Lube Oil Fi~er Element Replacement ........ 5.30 - 13
    Oil Pan Doors ............................ 5.30 - 45
    Lube Oil Fi~er Relief Valve Inspection ....... 5.30 - 15
    Oil Pan Doors Removal .................... 5.30 - 45
    Magnetic Plugs ........................... 5.30 - 16
    Oil Cooler Piping Removal ................. 5.30 - 16 Oil Pan Doors Installation .................. 5.30 - 46
    Lube Oil Strainer ......................... 5.30 - 46
    Oil Cooler Piping Installation ............... 5.30 - 18
    Lube Oil Strainer Removal ................. 5.30 - 46
    Oil Cooler Removal ....................... 5.30 - 18
    Lube Oil Strainer Cleaning And
    Oil Cooler Cleaning And Inspection ......... 5.30 - 19
    Inspection .......................... 5.30 - 47
    Oil Cooler Installation ..................... 5.30 - 19
    Lube Oil Strainer Installation ............... 5.30 - 47
    Lube Oil Temperature Control Valve ......... 5.30 - 21
    Troubleshooting Low Lube Oil Pressure ...... 5.30 - 24 Section 5.35 - Exhaust System
    Lube Oil Pressure Adjustment .............. 5.30 - 24 Exhaust System ........................... 5.35 - 1

    Prelube System .......................... 5.30 - 24 Components .............................. 5.35 - 1

    Prelube Pressure Maintenance ............. 5.30 - 25 Description ............................... 5.35 - 1

    Check Valve Inspection .................... 5.30 - 26 Exhaust System Specifications .............. 5.35 - 2

    In-line Lubricator ......................... 5.30 - 26 Measuring Exhaust System


    Backpressure .. . . . . . . . . . . . . . . . . . . . . .. 5.35 - 2
    Oil Pan Clean And Inspect ................. 5.30 - 28
    Checking Exhaust Gas Temperatures ........ 5.35 - 2
    Oil Pickup Screen ......................... 5.30 - 28
    Exhaust Manifold .......................... 5.35 - 3
    Oil Pickup Screen Removal ................ 5.30 - 28
    Exhaust Manifold Removal .................. 5.35 - 3
    Oil Pickup Screen Cleaning And
    Inspection .......................... 5.30 - 29 Exhaust Manifold Disassembly .............. 5.35 - 5

    Form 6248 First Edition xl


    CONTENTS

    Exhaust Manifold Assembly ................. 5.35 - 5 Venturi - GSI .............................. 5.40 - 2


    Exhaust Manifold Installation ................ 5.35 - 6 Crankcase Pressure Measurement ........... 5.40 - 3
    Turbo Exhaust Inlet Elbows ................ 5.35 - 10 Crankcase Pressure Measurement -
    G/GSI/GL ........................... 5.40 - 3
    Turbo Exhaust Inlet Elbows Removal ........ 5.35 - 10
    Crankcase Pressure Adjustment -
    Turbo Exhaust Inlet Elbows Installation ...... 5.35 - 11
    G/GSI Venturi Equipped ............... 5.40 - 3
    Exhaust Connections - G .................. 5.35 - 13
    Crankcase Pressure Adjustment
    Exhaust Connections Removal - G ......... 5.35 - 13 (Venturi ExtractorNacuum Valve
    Exhaust Connections Installation - G ........ 5.35 - 14 Assembly Equipped) - GSI/GL ......... 5.40 - 4

    Exhaust Connections Removal - GSI/GL .... 5.35 - 14 Crankcase Separator Screen ................ 5.40 - 6

    Exhaust Connections Installation - GSI/GL ... 5.35 - 15 Crankcase Separator Screen Removal ....... 5.40 - 6

    Thermocouples ........................... 5.35 - 16 Crankcase Separator Screen Cleaning And


    Inspection ...........•............... 5.40 - 6
    Thermocouple Replacement ............... 5.35 - 16
    Crankcase Separator Screen Assembly ....... 5.40 - 6
    Exhaust Thermocouples Installation ......... 5.35 - 18
    Oil Separators ............................. 5.40 - 7
    Thermocouple Clean And Inspect ........... 5.35 - 19
    Oil Separator Removal - G .................. 5.40 - 7
    Wastegates .............................. 5.35 - 20
    Oil Separator Installation - G ................ 5.40 - 8
    Wastegates - Bleeding Air ................. 5.35 - 20
    Oil Separator Removal - GSI/GL ............. 5.40 - 8
    PIN Series 208372 Wastegate Removal ..... 5.35 - 20
    Oil Separator Cleaning And Inspection -
    PIN Series 208372 Wastegate Disassembly .. 5.35 - 21 GSI/GL .............................. 5.40 - 9
    PIN Series 208372 Wastegate - Oil Separator Installation - GSI/GL ........... 5.40 - 9
    Cleaning And Inspection .............. 5.35 - 23
    PIN Series 208372 Wastegate Assembly ..... 5.35 - 24
    Crankcase Breather Regulator - GSI/GL ..... 5.40 - 10 )
    Crankcase Breather Regulator Removal -
    PIN Series 208372 Wastegate Calibration .... 5.35 - 25 GSI/GL ............................. 5.40 - 10
    PIN Series 295645 Wastegate Removal - Crankcase Breather Regulator
    Draw Thnu Only ..................... 5.35 - 28 Disassembly - GSI/GL ............... 5.40 - 10
    PIN Series 295645 Wastegate Crankcase Breather Regulator
    Disassembly - Draw Thru Only ........ 5.35 - 29 Cleaning And Inspection - GSI/GL . . . .. 5.40 - 11
    PIN Series 295645 Wastegate Calibration Crankcase Breather Regulator
    Setup - Draw Thru Only .............. 5.35 - 29 Installation - GSI/GL ................. 5.40 - 11
    PIN Series 295645 Calibration Procedure Venturi .................................. 5.40 - 12
    Test - Draw Thru Only ............... 5.35 - 30
    Venturi Removal - GSI .................... 5.40 - 12
    PIN Series 295645 Wastegate
    Installation - Draw Thru Only •......... 5.35 - 31 Venturi Cleaning And Inspection - GSI ...... 5.40 - 12

    Engine AHttude Adjustments ................ 5.35 - 32 Venturi Installation - GSI ................... 5.40 - 12
    Venturi Extractor - GSI/GL ..•.............. 5.40 - 12
    Section 5.40 - Crankcase Breather Venturi Extractor Removal - GSI/GL ......... 5.40 - 12
    System
    Venturi Extractor Cleaning And
    Crankcase Breather System ................. 5.40 - 1 Inspection - GSI/GL ................. 5.40 - 14
    Components .............................. 5.40 - 1 Venturi Extractor Assembly - GSI/GL ........ 5.40 - 15
    Description ............................... 5.40 - 1 Crankcase Pressure Relief Valves .......... 5.40 - 16
    Separator Screen .......................... 5.40 - 1 Crankcase Pressure Relief Valve Exercise ... 5.40 - 16
    Oil Separator(s) ........................... 5.40 - 1 Crankcase Pressure Relief Valve Removal ... 5.40 - 16
    Vacuum Valve/Choke Valve ................. 5.40 - 1 Crankcase Pressure Relief Valve Cleaning
    And Inspection ...................... 5.40 - 17
    )
    Breather Regulator ......................... 5.40 - 2
    Venturi Extractor - GSI/GL .................. 5.40 - 2

    xii Form 6248 First Edition


    CONTENTS

    Crankcase Pressure Relief Valve Air Starter ............................... 5.45 - 24


    Assembly ........................... 5.40 - 17
    Air Starter Removal ....................... 5.45 - 24
    Breather Tubes ........................... 5.40 - 18
    Air Starter Installation ..................... 5.45 - 25
    Breather Tube Removal - GSI .............. 5.40 - 18
    Electric Starter ........................... 5.45 - 26
    Breather Tube Installation - GSI ............ 5.40 - 19
    Electric Starter Removal ................... 5.45 - 26
    Breather Tube Removal - GL ............... 5.40 - 20
    Electric Starter Installation ................. 5.45 - 26
    Breather Tube Installation - GL ............. 5.40 - 21
    Venturi Extractor Compressor Discharge
    Tubes ................................ 5.40 - 22
    Venturi Extractor Compressor Discharge
    CHAPTER 6 - ACCESSORIES
    Tubes Removal ..................... 5.40 - 22
    Section 6.00 - Control Panel
    Venturi Extractor Compressor Discharge
    Control Panel ............................. 6.00 - 1
    Tubes Installation .................... 5.40 - 23
    Components .............................. 6.00 - 1
    Section 5.45 - Air/Gas Prelube And Start Control Panel Removal - Right Side .......... 6.00 - 1
    Systems Control Panel Installation - Right Side ........ 6.00 - 3
    Air/Gas Prelube And Start Systems .......... 5.45 - 1
    Control Panel Removal - Left Side .... . . . . . . . 6.00 - 4
    Components .............................. 5.45 - 1
    Control Panel Installation - Left Side ......... 6.00 - 5
    Prelube System ........................... 5.45 - 1
    Start System .............................. 5.45 - 4 Section 6.05 - Engine Protection
    Prelube/Start System Systems
    Removal/Installation ..................... 5.45 - 9 Engine Protection Systems .................. 6.05 - 1
    Bulkhead Bracket Assembly Removal ........ 5.45 - 9 Components .............................. 6.05 - 1
    Bulkhead Bracket Assembly "K" Type Thermocouples .......•............ 6.05 - 1
    Installation ........................... 5.45 - 9
    Thermocouple Junction Box .... " ............ 6.05 - 6
    Pilot Operated Prelube Valve Removal ....... 5.45 - 10
    Manual Shutdown Switches ................. 6.05 - 6
    Pilot Operated Prelube Valve
    Customer Supplied Control Switches ......... 6.05 - 6
    Installation .......................... 5.45 - 11
    Pressure And Temperature Switches
    Prelube Pump/Motor And Connections ....... 5.45 - 12
    Calibration ........................... 6.05 - 6
    Prelube Pump/Motor And Connections
    Alarm And Shutdown Setpoints .............. 6.05 - 7
    Removal ........................... 5.45 - 12
    Engine Gauge Panel Components
    Prelube Pump/Motor And Connections
    (Shipped Loose) ...................... 6.05 - 8
    Installation .......................... 5.45 - 13
    Remote Panel Components ................. 6.05 - 9
    Lube Oil Pressure Gauge Tubes And Fitting
    (Former Engine Mounted Panel) ......... 5.45 - 14 Custom Engine Control® Detonation
    Sensing Module System ................ 6.05 - 10
    Lube Oil Pressure Gauge Tubes And
    Fitting Removal ..................... 5.45 - 14 DSM System Operation . . . . . . . . . . . . . . . . . . . . 6.05 - 11
    Lube Oil Pressure Gauge Tube Fitting Defautt Timing Value ...................... 6.05 - 11
    Installation .......................... 5.45 - 14
    User Interface ............................ 6.05 - 13
    Bulkhead To Panel Bracket ................. 5.45 - 14
    DSM System Troubleshooting .............. 6.05 - 14
    Bulkhead To Panel Bracket Removal ........ 5.45 - 14
    Bulkhead To Panel Bracket Installation ...... 5.45 - 15 Section 6.10 - Miscellaneous Equipment
    Miscellaneous Equipment ................... 6.1 0 - 1
    Tube Clips/Clamps Installation .............. 5.45 - 17
    Components .............................. 6.10 - 1
    Prechamber Gas Valves - GL .............. 5.45 - 19
    Surge Tank ............................... 6.10 - 2
    Prechamber Gas Valves Removal (GL) ...... 5.45 - 19
    Surge Tank Removal ....................... 6.10 - 2
    Prechamber Gas Valves Installation (GL) .... 5.45 - 22

    Form 6248 First Ednion xIII


    CONTENTS

    Surge Tank Disassembly .................... 6.10 - 3 )


    Surge Tank Cleaning And Inspection ......... 6.10 - 4
    Surge Tank Assembly ...................... 6.10 - 4
    Surge Tank Installation ..................... 6.10 - 4
    Jacket Water Heater ....................... 6.10 - 5
    Jacket Water Heater Removal ............... 6.10 - 5
    Jacket Water Heater Cleaning And
    Inspection ........................... 6.10 - 6
    Jacket Water Heater Installation ............. 6.10 - 6

    CHAPTER 7 - TROUBLESHOOTING
    AND MAINTENANCE
    Section 7.00 - Troubleshooting
    Troubleshooting ........................... 7.00 - 1

    Section 7.10 - Maintenance And Storage


    Routine Maintenance ....................... 7.10 - 1
    Routine Inspection ......................... 7.10 - 4
    Engine Storage ............................ 7.10 - 5
    Preservation Equipment And Material ......... 7.10 - 5 )
    Waukesha Engine Preservative Oil ........... 7.10 - 5
    Waukesha Engine Preservative Oil Usage .... 7.10 - 5
    Use Of Other Preservative Oils And
    Materials ............................ 7.10 - 6
    Engine Storage - New ...................... 7.10 - 7
    Operational Engines ....................... 7.10 - 7
    Non-operational Engines ................... 7.10 - 7
    Engine Storage - Used ..................... 7.10 - 8
    Operational Engines ....................... 7.10 - 8
    Non-operational Engines ................... 7.10 - 8
    Engines - Return To Service After Storage .... 7.10 - 8

    Alphabetical Index . ...................... A- 1

    xlv Form 6248 First EdHion


    ILLUSTRATIONS

    LIST OF ILLUSTRATIONS
    Section 1.00 - Warning Tags & Decal Figure 1.15-7. Manifolds, Headers, etc...... 1.15 -12
    Locations Figure 1.15-8. Cylinder Head Capscrew
    TIghtening And Torquing
    Figure 1.00-1. Sample Of Warning Tag Sequence (1 - 8) .................... 1.15 -14
    Placement . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.00 - 1
    Figure 1.15-9. Connecting Rod Cap Capscrew
    Figure 1.00-2. Warning Tag (PIN 209107B) - TIghtening Sequence (Series PIN 205407
    On Regulator(s), All Naturally Aspirated and 205507) ........................ 1.15 -14
    Gas Engines ......................... 1.00 - 1
    Figure 1 .15-10. Main Bearing Cap
    Figure 1.00-3. Warning Tag (PIN 209107E) .. 1.00 - 2 TIghtening{Torquing Pallern - As Viewed
    Figure 1.00-4. Warning Tag (P/N 209107H) - From Underside Of Crankcase ........ 1.15 - 15
    On Fisher 99 Regulator(s), Turbocharged Figurel.15-11.Spl~RingWashers ........ 1.15-19
    Gas Engines . . . . . . . . . . . . . . . . . . . . . . . .. 1.00 - 2
    Figure 1.00-5. Warning Tag (PIN 209107L) - Section 1.20 - Specifications
    On Fisher 66 Regulator(s), Naturally Figure 1.20-1. Valve Sequence -
    Aspirated, Low Btu Engines ............ 1.00 - 2 Crankshaft Degrees Shown . . . . . . . . . . . 1.20 - 19
    Figure 1.00-6. Warning Tag (P/N 209107R) - Figure 1.20-2. Engine Compression
    On Fisher 99 And S211 Regulator(s), Pressures .......................... 1.20 - 28
    Turbocharged Engines ................ 1.00 - 3
    Figure 1.00-7. Warning Tag (P/N 209107U) - Section 2.00 - Cylinder Head Removal
    On IMPCO (MAXITROL) Pressure Figure 2.00-1. Rocker Arms ................ 2.00 - 2
    Reduction Valve, Used With 5 - 20,
    Figure 2.00-2. Install Rocker Arm Oil
    Water Column Gas Pressure . . . . . . . . . .. 1.00 - 3
    Supply Tubes ........................ 2.00 - 2
    Figure 1.00-8. Warning Tag (PIN 209107K) -
    Figure 2.00-3. Push Rods And Water
    On Carburetor Throttle Lever For Engines
    Outlet Elbows ........................ 2.00 - 2
    Ordered And Built Without Waukesha
    Engine Division Designed Engine Safety Figure 2.00-4. Water Outlet Elbow Gaskets .. 2.00 - 2
    Shutdown Equipment ................. 1.00 - 3 Figure 2.00-5. Exhaust Manifold ~ Rear View. 2.00 - 3
    Figure 1.00-9. Warning Tag (PIN 209107P) - Figure 2.00-6. Intake Manifold ': , ............ 2.00 - 3
    For Gas Vent On Prelube Systems That Figure 2.00-7. Eye Bolt Location -
    Use Natural Gas For Prelube Motor ..... 1.00 - 4 12 Cylinder Engines .................. 2.00 - 3
    Figure 1.00-10. Warning Tag (P/N 208840A) - Figure 2.00-8. Cylinder Heads .............. 2.00 - 3
    On High Voltage Equipment. . . . . . . . . . .. 1.00 - 4
    Figure 2.00-9. Lilting The Cylinder Head ..... 2.00 - 4
    Section 1.10 - Rigging And Lifting Section 2.05 - Crankcase Removal
    Engines Figure 2.05-1. Capscrews -
    Figure 1.10-1. Correct Method Of Lifting Connecting Rod Caps ................. 2.05 - 1
    Engine - Side Views ...... . . . . . . . . . . .. 1.10 - 1 Figure 2.05-2. Carbon Ridge ............... 2.05 - 1
    Figure 1.10-2. Correct Method of Lifting Figure 2.05-3. Install Piston Puller .......... 2.05 - 1
    Engine - Rear View ................... 1.10 - 2
    Figure 2.05-4. Remove Piston/Connecting
    Section 1.15 - General Information Rod Assembly ....................... 2.05 - 2
    Figure 2.05-5. Connecting Rod ............. 2.05 - 2
    Figure 1.15-1. Nameplate -
    Current Production ................... 1.15 - 3 Figure 2.05-6. Bearing Cap ................ 2.05 - 2
    Figure 1.15-2. Nameplate - Figure 2.05-7. Keep Connecting Rod Caps
    Previous Production .................. 1.15 - 3 And Blades Properly Mated ............ 2.05 - 3
    Figure 1.15-3. Right Side View - Figure 2.05-8. Cylinder Sleeve Puller ........ 2.05 - 4
    12CylinderVHPGL .................. 1.15-4 Figure 2.05-9. Cylinder Sleeve ............. 2.05 - 4
    Figure 1.15-4. Left Side View - Figure 2.05-10. Vibration Dampers/Crankshaft
    12CylinderVHPGL .................. 1.15-5 Pulleys .............................. 2.05 - 5
    Figure 1.15-5. RearView- Figure 2.05-11 . Crankshaft Pulley Stop
    ) 12CylinderVHPGL .................. 1.15-6 Sleeve .............................. 2.05 - 6
    Figure 1.15-6. Torque Sequence For Figure 2.05-12. Rear Vibration Damper/Rear
    MuHi-Bolt Pallerns .................. 1.15 - 12 Crankshaft Pulley ..................... 2.05 - 6

    Form 6248 First Edition xv


    ILLUSTRATIONS

    Figure 2.05-13. Gear Cover Plates - Figure 2.05-48. Bolt Holes In Engine Block .. 2.05 - 19 )
    Front Left ............................ 2.05 - 7 Figure 2.05-49. Oil Pan Cross Cuts -
    Figure 2.05-14. Rear Gear Housing - Rear Right .......................... 2.05 - 19
    Front Left ............................ 2.05 - 7 Figure 2.05-50. Oil Pump Gear ............ 2.05 - 20
    Figure 2.05-15. Ball Bearing ............... 2.05 - 7 Figure 2.05-51. Oil Pump Gear Assembly ... 2.05 - 20
    Figure 2.05-16. Gear Cover ................ 2.05 - 8 Figure 2.05-52. Crankshaft Gear Mount .... 2.05 - 21
    Figure 2.05-17. Front Oil Seal .............. 2.05 - 8 Figure 2.05-53. Lower Oil Retainer Plate .... 2.05 - 21
    Figure 2.05-18. Oil Slinger And O-Ring ...... 2.05 - 9 Figure 2.05-54. Wick Seal ................ 2.05 - 22
    Figure 2.05-19. Magneto Drive Gear ........ 2.05 - 9 Figure 2.05-55. Cross-Tie Bolts ........... 2.05 - 22
    Figure 2.05-20. Drive Shaft ................ 2.05 - 9 Figure 2.05-56. Main Bearing Cap ......... 2.05 - 22
    Figure 2.05-21. Magneto Drive ............. 2.05 - 9 Figure 2.05-57. No.1 Main Bearing Cap .... 2.05 - 22
    Figure 2.05-22. Lock Idler Gear Capscrews . 2.05 - 10 Figure 2.05-58. Thrust Bearing ............ 2.05 - 23
    Figure 2.05-23. Gamshaft Idler Gear - Figure 2.05-59. Crankshaft ............... 2.05 - 23
    Upper .............................. 2.05 - 10 Figure 2.05-60. Bearings ................. 2.05 - 23
    Figure 2.05-24. Gamshaft Cover Plate ...... 2.05 - 10 Figure 2.05-61. Oil Tubes ................. 2.05 - 24
    Figure 2.05-25. Unlocking The Camshaft Figure 2.05-62. Crankcase - Inside Front ... 2.05 - 24
    Gear Nut ........................... 2.05 - 10 Figure 2.05-63. Upper Retainer Plate ....... 2.05 - 24
    Figure 2.05-26. Oil Pan Gapscrew - Figure 2.05-64. Cross Tie Bolts ............ 2.05 - 25
    Front Left ........................... 2.05 - 11
    Figure 2.05-65. No.1 Main Bearing ........ 2.05 - 25
    Figure 2.05-27. Valve Lifter Housing - Figure 2.05-66. Bearing Rollout ........... 2.05 - 26
    Front .............................. 2.05 - 11
    Figure 2.05-67. Roll Pin Installation ........ 2.05 - 26
    Figure 2.05-28. Front Gear Housing ........ 2.05 - 11
    Figure 2.05-68. No.1 Main Bearing Cap .... 2.05 - 27
    Figure 2.05-29. Rocker Arm Oil Header ..... 2.05 - 12
    Figure 2.05-69. Main Bearing Cap Stamped
    Figure 2.05-30. Longer Capscrew Locations
    For Mounting The Rocker Arm
    Identification Numbers ............... 2.05 - 27 )
    Figure 2.05-70. Oil Pump Gear Assembly ... 2.05 - 28
    Oil Header .......................... 2.05 - 12
    Figure 2.05-71. Main Bearing Cap
    Figure 2.05-31. Valve Lifter Guides ........ 2.05 - 13
    Tightening(Torquing Pattern - As Viewed
    Figure 2.05-32. Valve Lifter Housing Cover .. 2.05 - 13 From Underside Of Crankcase ........ 2.05 - 28
    Figure 2.05-33. Raising The Valve Lifter Figure 2.05-72. Main Bearing ............. 2.05 - 29
    Housing ............................ 2.05 - 13 Figure 2.05-73. Bearing Rollout ........... 2.05 - 30
    Figure 2.05-34. Valve Lifter Housing Figure 2.05-74. Main Bearing Cap
    Assembly ........................... 2.05 - 14 Stamped Identification Numbers ....... 2.05 - 30
    Figure 2.05-35. Gamshaft Set Screw Figure 2.05-75. Cross Tie Bolts ............ 2.05 - 31
    On Valve Lifter Housing Cover ........ 2.05 - 14
    Figure 2.05-76. Main Bearing Gap
    Figure 2.05-36. Valve Lifter Housing - Tightening{Torquing Pattern - As Viewed
    Rear ............................... 2.05 - 14 From Underside Of Crankcase ........ 2.05 - 31
    Figure 2.05-37. Lower Valve Lifter Housing Figure 2.05-n. Cam Bearing Cap ......... 2.05 - 31
    Cover .............................. 2.05 - 14
    Figure 2.05-38. Thrust Washer ............ 2.05 - 15 Section 3.00 - Cylinder Head
    Figure 2.05-39. Shim Pack ................ 2.05 - 15 Disassembly
    Figure 2.05-40. Cam Bearing Cap ......... 2.05 - 15 Figure 3.00-1. Rocker Arm Assembly ........ 3.00 - 1
    Figure 2.05-41. Valve Lifter Housing Figure 3.00-2. Fixed Valve Lifter Screw ...... 3.00 - 2
    Gasket - Front ...................... 2.05 - 16 Figure 3.00-3. Rocker Arm Adjusting Screws . 3.00 - 2
    Figure 2.05-42. Front Flywheel Housing - Figure 3.00-4. Rocker Arm Shaft ............ 3.00 - 2
    Rear Left ........................... 2.05 - 16 Figure 3.00-5. Exhaust Rocker Arm Bushings 3.00 - 4
    Figure 2.05-43. Flywheel Lifting Bracket .... 2.05 - 16 Figure 3.00-6. Rocker Arm Bushings ........ 3.00 - 4
    Figure 2.05-44. Rear Flywheel Housing ..... 2.05 - 16 Figure 3.00-7. Intake Rocker Arm Bushings .. 3.00 - 5
    Figure 2.05-45. Remove Flywheel ......... 2.05 - 17 Figure 3.00-8. Intake Actuator Rocker Arm
    Figure 2.05-46. Front Flywheel Section ..... 2.05 - 17 Bushings ............................ 3.00 - 5
    Figure 2.05-47. Oil Pickup Screen Assembly- Figure 3.00-9. Rocker Arm Assembly ........ 3.00 - 6
    12 Cylinder ......................... 2.05 - 18 Figure 3.00-10. Intake Actuator Assembly .... 3.00 - 7

    xvi Form 6248 First Edition


    ILLUSTRATIONS

    Figure 3.00-11. Cylinder Head Assembly - Figure 3.05-5. Determine Bearing Thickness . 3.05 - 8
    Exploded View ....................... 3.00 - 8 Figure 3.05-6. Select Main Bearing Shells
    Figure 3.00-12. Install Valve Stem Seal ...... 3.00 - 8 For Proper Running Clearance ......... 3.05 - 8
    Figure 3.00-13. Tack Weld Valve To Figure 3.05-7. Camshaft Bearing Bore ....... 3.05 - 9
    Valve Seat ........................... 3.00 - 9 Figure 3.05-8. Crankshaft Set Screws ...... 3.05 - 10
    Figure 3.00-14. Valve Seat Insert Removal ... 3.00 - 9 Figure 3.05-9.12 Cylinder Crankshaft ...... 3.05 - 11
    Figure 3.00-15. Valve Seat Insert Removal ... 3.00 - 9 Figure 3.05-10.12 Cylinder Crankshaft ..... 3.05 - 13
    Figure 3.00-16. Core Plug Locations - Top .. 3.00 - 10 Figure 3.05-11. Camshaft Valve Lifter Body -
    Figure 3.00-17. Core Plug Locations - Front 3.00 - 10 Bottom View ........................ 3.05 - 15
    Figure 3.05-12. Camshaft Valve Lifters And
    Figure 3.00-18. Core Plug Locations - Right 3.00 - 10
    Guides ............................. 3.05 - 15
    Figure 3.00-19. Core Plug Locations - Left .. 3.00 - 11
    Figure 3.05-13. Lubricate Valve Lifter
    Figure 3.00-20. Core Plug Locations - Rollers ............................. 3.05 - 16
    Boltom ............................. 3.00 - 11 Figure 3.05-14. Hydraulic Lifter ............ 3.05 - 16
    Figure 3.00-21 . Check Cylinder Head Deck Figure 3.05-15. Push Rod ................ 3.05 - 16
    For Warpage ........................ 3.00 - 12
    Figure 3.05-16. Hydraulic Lifter -
    Figure 3.00-22. Cylinder Head Pressure Internal View ........................ 3.05 - 17
    Test Plates ......................... 3.00 - 12
    Figure 3.05-17. Hydraulic Lifter - Installation 3.05 - 17
    Figure 3.00-23. Water Outlet Hole ......... 3.00 - 13 Figure 3.05-18. Piston Assembly .......... 3.05 - 17
    Figure 3.00-24. Cylinder Head - Figure 3.05-19. Piston And Rings .......... 3.05 - 18
    Intake Port Side ..................... 3.00 - 14
    Figure 3.05-20. Piston Oil Drain Holes ...... 3.05 - 18
    Figure 3.00-25. Checking Valve Stems
    Figure 3.05-21. Check Piston Ring Groove
    For Straightness ..................... 3.00 - 15
    Clearance .............. " ........... 3.05 - 23
    Figure 3.00-26. Checking Head Figure 3.05-22. Install Piston Rings ........ 3.05 - 27
    Perpendicularity ..................... 3.00 - 16
    Figure 3.05-23. Oil Control Ring Detail -
    Figure 3.00-27. Cylinder Head Valve ....... 3.00 - 16 8-1/2 Inch Bore ...................... 3.05 - 27
    Figure 3.00-28. Margin Wear .............. 3.00 - 16 Figure 3.05-24. Compression Ring Detail ... 3.05 - 28
    Figure 3.00-29. Installing Valve Guides ..... 3.00 - 19 Figure 3.05-25. Barrel-faced C9IlIpression
    Figure 3.00-30. Valve Seat Insert .......... 3.00 - 20 Ring Detail ............ ,~ ........... 3.05 - 28
    Figure 3.00-31. Measure Valve Seat Figure 3.05-26. 9-3/8, Bore G,GSI Piston
    Concentricity ........................ 3.00 - 21 Ring Configuration ................... 3.05 - 29
    Figure 3.00-32. Valve Lapping ............. 3.00 - 22 Figure 3.05-27. Previous Production 9-3/8,
    Bore GL Piston Ring Configuration
    Figure 3.00-33. Good Valve And
    PIN 205404Z ....................... 3.05 - 30
    Seat Contact ........................ 3.00 - 23
    Figure 3.05-28. Current Production Piston
    Figure 3.00-34. Checking Valve Spring Ring Detail 9-3/8 Inch Bore GL
    Height ............................. 3.00 - 24 (3-Ring Piston) ..................... 3.05 - 31
    Figure 3.00-35. Install Valve Stem Seal ..... 3.00 - 24 Figure 3.05-29. Current Production 9-3/8 Inch
    Figure 3.00-36. Cylinder Head Assembly - Bore GL (3-Ring Piston) .............. 3.05 - 31
    Exploded View ...................... 3.00 - 25 Figure 3.05-30. Connecting Rod ........... 3.05 - 33
    Figure 3.00-37. Valve Spring Compressor ... 3.00 - 25 Figure 3.05-31. Bearing Cap .............. 3.05 - 33
    Figure 3.00-38. Valve Compressor Special Figure 3.05-32. Align Rod Pin Bushing
    BoH Installation Locations ............. 3.00 - 25 Split Line ........................... 3.05 - 33
    Figure 3.00-39. Assembled Cylinder Head - Figure 3.05-33. Clean Connecting Rod
    Cross Sectional View ................ 3.00 - 26 Lube Oil Passageways ............... 3.05 - 33
    Figure 3.05-34. Connecting Rod Twist Gap . 3.05 - 36
    Section 3.05 - Crankcase Disassembly
    Figure 3.05-35. Rod Cap Roll Pin .......... 3.05 - 36
    Figure 3.05-1. Lower Sleeve Bore .......... 3.05 - 3 Figure 3.05-36. Connecting Rod Cap
    Figure 3.05-2. Lower Bore And Restoration Capscrew Tightening Sequence -
    Sleeve Dimensions ................... 3.05 - 4 ROil Pin Equipped ................... 3.05 - 37
    Figure 3.05-3. Main Bearing Bores .......... 3.05 - 5 Figure 3.05-37. Check Rod Bearing Bore
    )
    Figure 3.05-4. Main Bearing Cap For Out-Of-Round And Taper ......... 3.05 - 37
    TIghtening{Torquing Pattern - As Viewed Figure 3.05-38. Weight Classification Stamp
    From Underside Of Crankcase ......... 3.05 - 6 Location ............................ 3.05 - 38

    Form 6248 First Edition xvII


    ILLUSTRATIONS

    Figure 3.05-39. Rod Pin Bushing .......... 3.05 - 38 Figure 4.00-22. Outside Camshaft )
    Figure 3.05-40. Verify Orientation Of Rod Pin Thrust Ring .......................... 4.00 - 9
    Bushings Oil Groove ................. 3.05 - 39 Figure 4.00-23. Shim Pack ................ 4.00 - 10
    Figure 3.05-41. Connecting Rod Bearings .. 3.05 - 40 Figure 4.00-24. Thrust Washer ............ 4.00 - 10
    Figure 3.05-42. Position Bearing Shell Above Figure 4.00-25. Gear Housing Flange ...... 4.00 - 10
    Bearing Seat ........................ 3.05 - 40 Figure 4.00-26. Rear Gear Housing Flange . 4.00 - 10
    Figure 3.05-43. Installing Bearing Shell ..... 3.05 - 40 Figure 4.00-27. Verify That Bottoms Are
    Figure 3.05-44. Keep Connecting Rod Caps Flush .............................. 4.00 - 11
    And Blades Properly Mated ........... 3.05 - 41 Figure 4.00-28. Measuring Camshaft End
    Play ............................... 4.00 -11
    Figure 3.05-45. Connecting Rod Cap
    Capscrew Figure 4.00-29. Prevent Lateral Movement
    Tightening Sequence - Roll Pin Of Camshaft ........................ 4.00 - 12
    Equipped ........................... 3.05 - 41 Figure 4.00-30. Prevent Camshaft Rotation . 4.00 - 12
    Figure 3.05-46. Cylinder Sleeve ........... 3.05 - 42 Figure 4.00-31. Cam Gear Key ............ 4.00 - 12
    Figure 3.05-47. Flexible Hone ............. 3.05 - 47 Figure 4.00-32. Locking The Camshaft
    Figure 3.05-48. Cylinder Sleeve Deglazing Gear Nut ........................... 4.00 - 13
    Cross Hatch Pattern ................. 3.05 - 47 Figure 4.00-33. Valve Lifter Housing
    Assembly ........................... 4.00 - 13
    Figure 3.05-49. Flywheel Ring Gear ........ 3.05 - 48
    Figure 4.00-34. Lowering The Valve Lifter
    Section 4.00 - Crankcase Assembly Housing ............. _.............. 4.00 - 14

    Figure 4.00-1. Crankcase - Inside Front ..... 4.00 - 1 Figure 4.00-35. Rear Gear Housing Gasket . 4.00 - 14
    Figure 4.00-36. Valve Lifter Housing - Front. 4.00 - 15
    Figure 4.00-2. Gear Train Oil Spray Tube .... 4.00 - 1
    Figure 4.00-37. Fasten Valve Lifter Housing
    Figure 4.00-3. Oil Tubes ................... 4.00 - 2
    To Rear Gear Housing ............... 4.00 - 15
    Figure 4.00-4. Main Bearing Cap Studs -
    Old And New Styles .................. 4.00 - 2
    Figure 4.00-38. Camshaft Cover Plate ...... 4.00 - 15 )
    Figure 4.00-39. Camshaft Set Screw On
    Figure 4.00-5. Main Bearing Cap Studs ...... 4.00 - 2 Valve Lifter Housing Cover ............ 4.00 - 15
    Figure 4.00-6. Water Header/Oil Outlet Plugs - Figure 4.00-40. Valve Lifter Housing - Rear . 4.00 - 16
    Rear Left ............................ 4.00 - 3
    Figure 4.00-41. Lubricate Valve
    Figure 4.00-7. Oil Outlet Plugs - Lifter Rollers ......... _.............. 4.00 - 16
    Rear Right View ...................... 4.00 - 3
    Figure 4.00-42. Install Valve Lifter Guides ... 4.00 - 16
    Figure 4.00-8. 3/4, NPT Oil Header Figure 4.00-43. Longer Capscrew Locations
    Pipe Plugs ........................... 4.00 - 4 For Mounting The Rocker Amn
    Figure 4.00-9. Crankcase - Main Oil Header - Oil Header .......................... 4.00 - 17
    Rear Right ........................... 4.00 - 5 Figure 4.00-44. Pipe Tee Magnet Plug ...... 4.00 - 18
    Figure 4.00-10. Lube Oil Strainer Adapter .... 4.00 - 5 Figure 4.00-45. Rocker Arm Oil Header -
    Figure 4.00-11. Lower Valve Lifter Housing Rear ............................... 4.00 - 18
    Cover ............................... 4.00 - 5 Figure 4.00-46. Rocker Arm Oil Header ..... 4.00 - 18
    Figure 4.00-12. Crankcase - Top Rear ...... 4.00 - 6 Figure 4.00-47. Rear Oil Seal Retainer-
    Figure 4.00-13. Valve Lifter Housing Gasket- Upper Half .......................... 4.00 - 19
    Front ............................... 4.00 - 6 Figure 4.00-48. Cut Rope Type Seal ....... 4.00 - 19
    Figure 4.00-14. Valve Lifter Housing Gasket- Figure 4.00-49. Rear Oil Seal Retainer -
    Rear ................................ 4.00 - 6 Upper Ha~ .......................... 4.00 - 19
    Figure 4.00-15. Camshaft Bearing Saddles .. 4.00 - 7 Figure 4.00-50. Rear Oil Seal Retainer -
    Upper Half ........... _.............. 4.00 - 20
    Figure 4.00-16. Install Roll Pins In Front
    Cam Bearing Cap .................... 4.00 - 7 Figure 4.00-51. Front Main Bearing Cap .... 4.00 - 20
    Figure 4.00-17. Cam Bearings ............. 4.00 - 7 Figure 4.00-52. Install Roll Pins In Front
    Main Bearing Cap ................... 4.00 - 21
    Figure 4.00-1 8. Inside Camshaft Thrust Ring . 4.00 - 8
    Figure 4.00-53. Upper Fully Grooved
    Figure 4.00-19. Front Cam Bearing Cap ..... 4.00 - 9 Main Bearing Shells - Bearing Saddles . 4.00 - 21
    Figure 4.00-20. Cam Bearing Cap .......... 4.00 - 9 Figure 4.00-54. Lower Ungrooved Main
    Figure 4.00-21. Camshaft Thrust Ring ....... 4.00 - 9 Bearing Shells - Bearing Caps ...... , . 4.00 - 22

    xviii Form 6248 First Edition


    ILLUSTRATIONS

    Figure 4.00-55. Crankshaft Set Screws ..... 4.00 - 22 Figure 4.00-89. Gear Backlash ............ 4.00 - 36
    Figure 4.00-56. Crankshaft Set Screw Figure 4.00-90. Magneto Drive Assembly ... 4.00 - 37
    Locations (6) ........................ 4.00 - 23 Figure 4.00-91 . Remove Adapter Cover
    Figure 4.00-57. Crankshaft Guiding ........ 4.00 - 23 Side Bons .......................... 4.00 - 38
    Figure 4.00-58. Crankshaft Oil Grooves .... 4.00 - 24 Figure 4.00-92. Mount Magneto Drive
    Figure 4.00-59. Crankshaft Placement ...... 4.00 - 24 Assembly ........................... 4.00 - 38
    Figure 4.00-60. Install Inside Thrust Ring ... 4.00 - 24 Figure 4.00-93. Accessory Idler Gear -
    TIming Marks ....................... 4.00 - 39
    Figure 4.00-61. Rear Oil Seal Retainer
    Assembly ........................... 4.00 - 25 Figure 4.00-94. Drive Shaft ............... 4.00 - 39

    Figure 4.00-62. Trim Rear Oil Seal Retainer Figure 4.00-95. Mount Magneto Drive Gear . 4.00 - 39
    Gasket ............................. 4.00 - 25 Figure 4.00-96. Magneto Drive Gear
    TIghtening And Torquing Pattern ....... 4.00 - 40
    Figure 4.00-63. Main Bearing Gap
    TIghtening[Torquing Pattern - As Viewed Figure 4.00-97. PIN 205130L Cylinder
    From Underside Of Crankcase ........ 4.00 - 26 Sleeve Caution Tape ................. 4.00 - 41
    Figure 4.00-64. Torque Front Main Bearing Figure 4.00-98. Cylinder Sleeve ........... 4.00 - 41
    Cap ............................... 4.00 - 26 Figure 4.00-99. Spiraling O-rings .......... 4.00 - 42
    Figure 4.00-65. Measure Crankshaft Figure 4.00-100. Sleeve Projection ........ 4.00 - 42
    End Play ........................... 4.00 - 27 Figure 4.00-101. Piston And Connecting
    Figure 4.00-66. Bump Crankshaft Towards Rod ............................... 4.00 - 42
    Rear ............................... 4.00 - 27 Figure 4.00-102. Connecting Rod Bearings . 4.00 - 43
    Figure 4.00-67. Crankshaft End Play ....... 4.00 - 27 Figure 4.00-103. Connecting Rod Bore And
    Figure 4.00-68. Roll Pins ................. 4.00 - 28 Bearing Shell ....................... 4.00 - 43
    Figure 4.00-69. Install Roll Pins In Figure 4.00-104. Installing Bearing Shell .... 4.00 - 44
    Crankshaft .......................... 4.00 - 28 Figure 4.00-105. Connecting Rod Position .. 4.00 - 44
    Figure 4.00-70. Crankshaft Thrust Ring Figure 4.00-106. Connecting Rod Position .. 4.00 - 45
    (Half) Up ........................... 4.00 - 29 Figure 4.00-107. Connecting Rod Cap
    Figure 4.00-71. Outside Thrust Ring - Gaps crew Tightening Sequence -
    Cap Side ........................... 4.00 - 29 Roll Pin Equipped ................... 4.00 - 45
    Figure 4.00-72. Outside Thrust Ring - Figure 4.00-108. Oil Pickup Screen Assembly -
    Saddle Side ........................ 4.00 - 29 12 Cylinder ......................... 4.00 - 46
    Figure 4.00-73. Crankshaft Thrust Washer .. 4.00 - 29 Figure 4.00-109. Oil Pan Seal ............. 4.00 - 47
    Figure 4.00-74. Thrust Washer ............ 4.00 - 30 Figure 4.00-110. Oil Pan Seal - Front Right . 4.00 - 47
    Figure 4.00-75. Crankshaft Gear .......... 4.00 - 30 Figure 4.00-111. Dipstick ................. 4.00 - 48
    Figure 4.00-76. Crankshaft Gear Mount .... 4.00 - 30 Figure 4.00-112. Expansion Plug Location .. 4.00 - 48
    Figure 4.00-77. Oil Pump Gear Assembly ... 4.00 - 31 Figure 4.00-113. Oil Pan Cross Cuts -
    Figure 4.00-78. Secure Spindle Screw Head 4.00 - 31 Rear Right .......................... 4.00 - 49
    Figure 4.00-79. Torque Spindle Screw Figure 4.00-114. Oil Pan Gapscrew-
    Hex Nut ............................ 4.00 - 31 Front Right ......................... 4.00 - 49
    Figure 4.00-80. Idler Gear ................ 4.00 - 32 Figure 4.00-115. Oil Pan Gapscrew-
    Front Left ........................... 4.00 - 50
    Figure 4.00-81. Idler Gear ................ 4.00 - 32
    Figure 4.00-116. Crankcase - Rear ........ 4.00 - 50
    Figure 4.00-82. Camshaft Idler Gear ....... 4.00 - 32
    Figure 4.00-117. Front Flywheel Section .... 4.00 - 50
    Figure 4.00-83. Camshaft Idler Gear -
    Upper .............................. 4.00 - 33 Figure 4.00-118. Front Flywheel Housing
    Capscrew TIghtening Pattern .......... 4.00 - 50
    Figure 4.00-84. Camshaft Idler Gear -
    TIming Marks ....................... 4.00 - 33 Figure 4.00-119. Flywheel TIming Tape
    Locations ........................... 4.00 - 51
    Figure 4.00-85. Gam Gear/Camshaft Idler
    Gear TIming ........................ 4.00 - 33 Figure 4.00-120. TIming Tape ............. 4.00 - 51
    Figure 4.00-121. Orient Crank Gear ........ 4.00 - 52
    Figure 4.00-86. Lock Idler Gear Capscrews . 4.00 - 35
    Figure 4.00-122. Ufting The Flywheel ...... 4.00 - 52
    Figure 4.00-87. Accessory Idler Gear -
    TIming Marks ....................... 4.00 - 35 Figure 4.00-123. Flywheel Mounting ....... 4.00 - 52
    Figure 4.00-88. Accessory Idler Gear - Figure 4.00-124. Mount Flywheel .......... 4.00 - 53
    Lower .............................. 4.00 - 35 Figure 4.00-125. Remove Ufting Bracket ... 4.00 - 53

    Form 6248 First Ednion xix


    ILLUSTRATIONS

    Figure 4.00-126. Ring Gear Tooth Alignment 4.00 - 53 Figure 4.05-4. Push Rod Cover ............. 4.05 - 3
    Figure 4.00-127. Install Magnetic Pickup Figure 4.05-5. Push Rods ................. 4.05 - 4
    Sensor ............................. 4.00 - 53 Figure 4.05-6. Rocker Arm Oil Supply Tube -
    Figure 4.00-128. Rear Flywheel Housing Rear Left ............................ 4.05 - 4
    Capscrew TIghtening Pattern .......... 4.00 - 54 Figure 4.05-7. Exhaust Manifold Gasket ..... 4.05 - 5
    Figure 4.00-129. Flywheel, Flywheel Housing Figure 4.05-8. Prelube Motor Air/Gas
    Bore And Face Runout ............... 4.00 - 55 Supply Tube ......... . . . . . . . . . . . . . . . . 4.05 - 5
    Figure 4.00-130. Flywheel Housing Rear Figure 4.05-9. Exhaust Manifold - Left Bank . 4.05 - 5
    Face Runout ........................ 4.00 - 55 Figure 4.05-10. Exhaust Manifold End
    Figure 4.00-131. Total Indicator Reading Sections - Left Bank .................. 4.05 - 6
    (TIR) In Inches ...................... 4.00 - 56 Figure 4.05-11. Water Outlet Elbow Gaskets . 4.05 - 6
    Figure 4.00-132. Flywheel Face Runout Figure 4.05-12. Exhaust ManHold -
    On Wheel .......................... 4.00 - 56 Right Bank .......................... 4.05 - 6
    Figure 4.00-133. Flywheel Housing Bore Figure 4.05-13. Water Outlet Elbows -
    Runout ............................. 4.00 - 56 Rear Right ........................... 4.05 - 7
    Figure 4.00-134. Horizontal Support Bar .... 4.00 - 57 Figure 4.05-14. Exhaust Manifold - Front .... 4.05 - 7
    Figure 4.00-135. Flywheel Pilot Bearing Figure 4.05-15. Exhaust Manifold - Left Bank 4.05 - 7
    Bore Runout ........................ 4.00 - 57 Figure 4.05-16. Thermocouple Connector-
    Figure 4.00-136. Front Flywheel Housing - Rear Right ...........•............... 4.05 - 7
    Rear Left ........................... 4.00 - 58
    Section 4.10 - Valve Adjustment And
    Figure 4.00-137. Mount Oil Filler Bracket-
    Rear Left ........................... 4.00 - 58 Web Deflection
    Figure 4.00-138. Oil Filler Pipe/Bracket- Figure 4.10-1. Engine Firing Order -
    Rear Left ........................... 4.00 - 58 12 Cylinder .......................... 4.10 - 1
    Figure 4.00-139. Grease Gear Train ....... 4.00 - 59 Figure 4.10-2. Rocker Arms ................ 4.10 - 2
    \
    Figure 4.00-140. Lube Gear Train .......... 4.00 - 59 Figure 4.10-3. Rocker Arm Adjusting Screws . 4.10 - 2 }
    Figure 4.10-4. Hydraulic Lifter ............ ,. 4.10 - 2
    Figure 4.00-141. Oil Slinger/O-Ring ........ 4.00 - 60
    Figure 4.10-5. Engine Shimming Procedure .. 4.10 - 5
    Figure 4.00-142. Gear Cover .............. 4.00 - 60
    Figure 4.00-143. Front Oil Seal ............ 4.00 - 60 Section 5.00 - Speed Governing System
    Figure 4.00-144. Install Front Oil Seal ...... 4.00 - 61 Figure 5.00-1. 2301 A Load Sharing And
    Figure 4.00-145. Oil Pan Cross Cuts - Speed Control ....................... 5.00 - 2
    Front Left ........................... 4.00 - 61 Figure 5.00-2. 2301A Speed Control ........ 5.00 - 3
    Figure 4.00-146. Gear Cover TIghtening Figure 5.00-3. Governor Drive Housing ...... 5.00 - 3
    Pattern (A - F) ...................... 4.00 - 62 Figure 5.00-4. Hall-Effect Pickup ........... 5.00 - 3
    Figure 4.00-147. Installing The Gear Cover. 4.00 - 63 Figure 5.00-5. Current Production CEC
    Figure 4.00-148. Gear Cover Plates- TIming Disc .......................... 5.00 - 4
    Front Left ........................... 4.00 - 64 Figure 5.00-6. Current Production Governor
    Figure 4.00-149. Rear Gear Housing - Drive Gear.. . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 - 4
    Front Left ........................... 4.00 - 64 Figure 5.00-7. Current Production Governor
    Figure 4.00-150. Vibration Damper/Crankshaft Drive Gear ........... , ............... 5.00 - 4
    Pulleys ............................. 4.00 - 65 Figure 5.00-8. Flywheel TIming Opening ..... 5.00 - 5
    Figure 4.00-151. Side Section View "5V" And Figure 5.00-9. Current Production CEC
    "C" Section Groove Pulleys ........... 4.00 - 67 TIming Disc .......................... 5.00 - 5
    Figure 4.00-152. Torquing End Plate Figure 5.00-10. Current Production CEC
    capscrews ......................... 4.00 - 68 TIming Disc .......................... 5.00 - 5
    Figure 5.00-11. Governor Drive Housing ..... 5.00 - 6
    Section 4.05 - Cylinder Head Assembly Figure 5.00-12. Hall- Effect Pickup ......... 5.00 - 6
    Figure 4.05-1. Cylinder Head Gasket ........ 4.05 - 1 Figure 5.00-13. Previous Production
    Figure 4.05-2. Lifting The Cylinder Head - CEC Disc ............................ 5.00 - 6
    12 Cylinder Engines .................. 4.05 - 2 Figure 5.00-14. Previous Production
    Figure 4.05-3. Cylinder Head Capscrew Governor Drive Gear .................. 5.00 - 6
    TIghtening And Torquing Sequence Figure 5.00-15. Previous Production
    (1 - 8) .............................. 4.05 - 3 Governor Drive Gear .................. 5.00 - 7

    xx Form 6248 First Edition


    ILLUSTRATIONS

    Figure 5.00-16. Previous Production Governor Figure 5.00-44. Governor Rod -


    Drive Gear Vibration Damper Installation. 5.00 - 7 G, GSI Engines ..................... 5.00 - 20
    Figure 5.00-17. Previous Production Governor Figure 5.00-45. Governor Rod - GL Engines
    Drive Gear ........................... 5.00 - 8 (Throttle Control Shown Installed) ...... 5.00 - 20
    Figure 5.oo-t 8. Previous Production Governor Figure 5.00-46. Governor Rod - GL Engines
    Drive Gear ........................... 5.00 - 8 (Throttle Control Shown Installed) ...... 5.00 - 21
    Figure 5.00-19. Previous Production Figure 5.00-47. Governor Rod ............. 5.00 - 21
    Timing Disc .......................... 5.00 - 9 Figure 5.00-48. Woodward UG-8L Governor 5.00 - 22
    Figure 5.00-20. Previous Production Figure 5.00-49. Woodward UG-8L Governor
    CEC Disc ............................ 5.00 - 9 - Top View ......................... 5.00 - 24
    Figure 5.00-21. Governor Drive Housing ..... 5.00 - 9 Figure 5.00-50. Governor Rod ............. 5.00 - 25
    Figure 5.00-22. Governor Drive Shaft Figure 5.00-51. Governor Rod -
    Assembly ........................... 5.00 - 10 G, GSI Engines ..................... 5.00 - 25
    Figure 5.00-23. Governor Drive Shaft ...... 5.00 - 10 Figure 5.00-52. Governor Rod - GL Engines
    (Throttle Control Shown Installed) ...... 5.00 - 25
    Figure 5.00-24. Governor Drive Shaft
    Figure 5.00-53. Governor Rod - GL Engines
    Assembly ........................... 5.00 - 11
    (Throttle Control Shown Installed) ...... 5.00 - 26
    Figure 5.00-25. Governor Drive Gear ....... 5.00 - 12
    Figure 5.00-54. Governor ................. 5.00 - 26
    Figure 5.00-26. Oil Line And Hall-Effect Figure 5.00-55. Governor Assembly ........ 5.00 - 27
    Pickup ............................. 5.00 - 13
    Figure 5.00-56. Governor Rod ............. 5.00 - 27
    Figure 5.00-27. Governor Drive Housing .... 5.00 - 13
    Figure 5.00-57. Governor Rod -
    Figure 5.00-28. Governor Drive Assembly - G, GSI Engines ..................... 5.00 - 28
    Front Right ......................... 5.00 - 13
    Figure 5.00-58. Governor Rod - GL Engines
    Figure 5.00-29. Governor Drive Housing - (Throttle Control Shown Installed) ...... 5.00 - 28
    Rear ............................... 5.00 - 14
    Figure 5.00-59. Governor Rod - GL Engines
    Figure 5.00-30. Governor Drive Housing - (Throttle Control Shown Installed) ...... 5.00 - 28
    Rear ............................... 5.00 - 14 Figure 5.00-SO. Governor Rod Assembly ... 5.00 - 28
    Figure 5.00-31. Governor Drive Assembly - Figure 5.00-61. Woodward UG-S
    Front Right ......................... 5.00 - 14 Dial Governor ....................... 5.00 - 29
    Figure 5.00-32. Govemor Drive Housing .... 5.00 - 15 Figure 5.00-62. EG-3P Governor Rod ...... 5.00 - 31
    Figure 5.00-33. Oil Line And Hall-Effect Figure 5.00-63. Governor Rod -
    Pickup ............................. 5.00 - 15 G, GSI Engines ..................... 5.00 - 31
    Figure 5.00-34. Govemor Rod ............. 5.00 - 16 Figure 5.00-64. Governor Rod - GL Engines
    Figure 5.00-35. Govemor Rod - (Throttle Control Shown Installed) ...... 5.00 - 32
    G, GSI Engines ..................... 5.00 - 16 Figure 5.00-65. Governor Rod - GL Engines
    (Throttle Control Shown Installed) ...... 5.00 - 32
    Figure 5.00-36. Governor Rod -
    GL Engines Figure 5.00-66. Splined Connector ......... 5.00 - 32
    (Throttle Control Shown Installed) ...... 5.00 - 16 Figure 5.00-67. Governor Drive ............ 5.00 - 33
    Figure 5.00-37. Governor Rod - GL Engines Figure 5.00-6S. Governor Drive
    (Throttle Control Shown Installed) ...... 5.00 - 17 Internal View ........................ 5.00 - 34
    Figure 5.00-38. UG-8L Governor Assembly. 5.00 - 17 Figure 5.00-69. Governor Drive ............ 5.00 - 35
    Figure 5.00-39. Governor Assembly ........ 5.00 - 17 Figure 5.00-70. Splined Connector ......... 5.00 - 36
    Figure 5.00-40. UG-SL Governor Linkage .. 5.00 - 18 Figure 5.00-71. Gasket ................... 5.00 - 36
    Figure 5.00-41. UG-S Govemor Linkage Figure 5.00-72. EG-3P Governor-
    Adjustment Information For 51 OSGL, Bottom View ........................ 5.00 - 36
    5790GL And 7042GL ................ 5.00 - 19 Figure 5.00-73. Ring Gear Tooth Alignment . 5.00 - 36
    Figure 5.00-42. UG-S Linkage Adjustment Figure 5.00-74. Install Magnetic Pickup
    Information For 51 OSGL, 5790GL And Sensor ............................. 5.00 - 37
    7042GL - Low Pressure Fuel, Draw Figure 5.00-75. Governor Rod Assembly ... 5.00 - 37
    I Thru Carburetion .................... 5.00 - 19 Figure 5.00-76. EG-3P Governor Linkage
    /
    Figure 5.00-43. Angle Finder In "No Fuel" Adjustment Information For 51 08GL,
    Pos~ion ............................ 5.00 - 20 5790GL And 7042GL ................ 5.00 - 38

    Form 6248 Rrst Edition xxi


    ILLUSTRATIONS

    Figure 5.00-77. EG-3P linkage Adjustment Figure 5.05-12. Prechamber Cross Pipe-
    Information For 51 08GL, 5790GL And Right Bank .......................... 5.05 - 9
    7042GL - Low Pressure Fuel, Draw Figure 5.05-13. Prechamber Cross Pipe-
    Thru Carburetion .................... 5.00 - 38 Left Bank ............................ 5.05 - 9
    Figure 5.00-78. Governor Rod ............. 5.00 - 39 Figure 5.05-14. Prechamber Cross Pipe
    Figure 5.00-79. Governor Rod - Retainer ............................ 5.05 - 10
    G, GSI Engines ..................... 5.00 - 39 Figure 5.05-15. Cross Pipe Tee ............ 5.05 - 10
    Figure 5.00-80. Governor Rod - GL Engines Figure 5.05-16. Prechamber Cross Pipe -
    (Throttle Control Shown Installed) ...... 5.00 - 40 Left Bank ............ _.............. 5.05 - 10
    Figure 5.00-81. Governor Rod - GL Engines Figure 5.05-17. Carburetor Assembly -
    (Throttle Control Shown Installed) ...... 5.00 - 40 G/GSI .............................. 5.05 - 11
    Figure 5.00-82. Orientate Manual Shutdown Figure 5.05-18. Air/Gas Valve Assembly .... 5.05 - 12
    Lever .............................. 5.00 - 41 Figure 5.05-19. Air/Gas Valve ............. 5.05 - 12
    Figure 5.00-83. Lock Manual Shutdown Figure 5.05-20. Carburetor Cross Shaft
    Lever .............................. 5.00 - 41 Assembly ........................... 5.05 - 13
    FIgure 5.00-84. Governor Rod - GL Engines Figure 5.05-21. Carburetor Assembly - GL .. 5.05 - 15
    (Throttle Control Shown Installed) ...... 5.00 - 41 Figure 5.05-22. Air/Gas Valve Assembly .... 5.05 - 16
    Figure 5.00-85. Butterfly Valve linkage Figure 5.05-23. Air/Gas Valve ............. 5.05 - 16
    Adjustment - L5108G, L5790G,
    Figure 5.05-24. Carburetor Bonnet Baffle
    L7042G Engines .................... 5.00 - 42
    Welds ............... _.............. 5.05 - 16
    Figure 5.00-86. Overspeed Pressure Swttch 5,00 - 42
    Figure 5.05-25. Carburetor - Left Bank ..... 5.05 - 17
    Figure 5.00-87. Overspeed Governor ....... 5.00 - 43
    Figure 5.05-26. Carburetor Cross Shaft
    Figure 5.00-88. Overspeed Governor ....... 5.00 - 43 Assembly ........................... 5.05 - 18
    Figure 5.00-89. Overspeed Pressure Switch 5.00 - 44 Figure 5.05-27. Butterfly Valve GlGSI ...... 5.05 - 18
    Figure 5.00-90. Tachometer/Hour Meter .... 5.00 - 44 Figure 5.05-28. Admission Valve Assembly . 5.05 - 19
    Figure 5.00-91. Hour Meter ............... 5.00 - 44 Figure 5.05-29. Spring Seats In Cold
    )
    Figure 5.00-92. Nylok Plugs ............... 5.00 - 45 Poppets ............................ 5.05 - 20
    Figure 5.00-93. Tachometer Drive Assembly 5.00 - 45 Figure 5.05-30. Install Stainless Steel Washer
    In Cylinder Head ..... _.............. 5.05 - 20
    Figure 5.00-94. Tachometer/Hour Meter .... 5.00 - 46
    Figure 5.05-31. Prechamber Puller
    Figure 5.00-95. Magneto Drive Assembly- Assembly ............ _.............. 5.05 - 21
    Front Right ......................... 5.00 - 46
    Figure 5.05-32. Prechamber Puller
    Figure 5.00-96. Nylok Plugs ............... 5.00 - 46 Assembly ........................... 5.05 - 21
    Section 5.05 - Fuel System Figure 5.05-33. Prechamber Puller
    Assembly ........................... 5.05 - 22
    Figure 5.05-1. Fuel System Diagram - G .... 5.05 - 1
    Figure 5.05-34. Install Prechamber Cup .... 5.05 - 22
    Figure 5.05-2. Fuel System Diagram - GSI .. 5.05 - 2 Figure 5.05-35. Prechamber Gas Supply -
    Figure 5.05-3. Fuel System Schematic - GL . 5.05 - 3 Left Bank ............ _.............. 5.05 - 23
    Figure 5.05-4. Fisher 99 Main Fuel Gas Figure 5.05-36. Prechamber Manifold ...... 5.05 - 23
    Pressure Regulator - Figure 5.05-37. Prechamber Manifold ...... 5.05 - 24
    Cross Sectional View ................. 5.05 - 4
    Figure 5.05-38. Fisher 99 Regulator Tube
    Figure 5.05-5. 95L Prechamber Regulator - Connections - GSI .................. 5.05 - 25
    Cross Sectional View ................. 5.05 - 6
    Figure 5.05-39. Fisher 99 Regulator Tube
    Figure 5.05-6. Butterfly Cross Shaft Connections - GL ................... 5.05 - 25
    Assembly ............................ 5.05 - 6
    Figure 5.05-40. BoR Holes In Engine Block .. 5.05 - 25
    Figure 5.05-7. Crankcase Center Bores - Figure 5.05-41. Fisher 99 Regulator
    G/GSI - Right Bank ................... 5.05 - 7 Bracket - Right Bank ................ 5.05 - 26
    Figure 5.05-8. Universal Joint Disc Spider ... 5.05 - 7 Figure 5.05-42. Fisher 99 Regulator Mounting
    Figure 5.05-9. Carburetor Cross Shaft Orientation - Right Bank - Top View ... 5.05 - 26
    Assembly ............................ 5.05 - 8 Figure 5.05-43. Main Fuel Gas Regulator -
    Figure 5.05-10. Crankcase Center Bores - Right Bank ......................... 5.05 - 26 )
    GL - Right Bank ...................... 5.05 - 8 Figure 5.05-44. Carburetor Gas Inlet -
    Figure 5.05-11. Universal Joint Disc Spider .. 5.05 - 8 Right Bank ......................... 5.05 - 27

    xxii Form 6248 First Ednion


    ILLUSTRATIONS

    Figure 5.05-45. Dresser Elbow Coupling .... 5.05 - 27 Figure 5.10-17. Triangular Ignition Coil
    Figure 5.05-46. Dresser Elbow Coupling .... 5.05 - 27 Bracket ............................ 5.10-13
    Figure 5.05-47. Fisher 99 Regulator Tube Figure 5.10-18. Wire Harness Assembly .... 5.10 - 14
    Connections - GSI .................. 5.05 - 28 Figure 5.10-19. Harness Cable Clip -
    Figure 5.05-48. Fisher 99 Regulator Tube Front Right ......................... 5.10 - 14
    Connections - GL ................... 5.05 - 28 Figure 5.10-20. Electronic Ignttion System
    Figure 5.05-49. Fisher 99 Regulator Bracket - Diagram ............................ 5.10-16
    Left Bank ........................... 5.05 - 28 Figure 5.10-21. Wire Harness - Right Bank -
    Carburetor And Intake Manifold Removed
    Figure 5.05-50. Fisher 99 Regulator Mounting
    Orientation - Left Bank - Top View ..... 5.05 - 28 For Clarity .......................... 5.10-17
    Figure 5.10-22. Wire Harness - Front Right . 5.10 - 17
    Figure 5.05-51. Prechamber Regulator -
    Front Right ......................... 5.05 - 29 Figure 5.10-23. Wire Harness Cable Clip
    Locations ........................... 5.10 - 17
    Figure 5.05-52. Prechamber Regulator - GL 5.05 - 29
    Figure 5.10-24. Retaining Clip ............. 5.10 - 18
    Figure 5.05-53. Prechamber Regulator ..... 5.05 - 30
    Figure 5.10-25. Attaching Cable Clip
    Figure 5.05-54. Prechamber Regulator
    Support Braces ..................... 5.10 - 18
    Mounting Bracket .................... 5.05 - 30
    Figure 5.10-26. Triangular Ignition Coil
    Figure 5.05-55. Intake Manifold Flange Bracket ............................ 5.10-18
    Aftachments - Right Bank ............ 5.05 - 31
    Figure 5.10-27. Magneto Pin Connector
    Figure 5.05-56. Prechamber Regulator - Cable .............................. 5.10-18
    Front Right ......................... 5.05 - 31
    Figure 5.10-28. Ignition Module ............ 5.10 - 19
    Figure 5.05-57. Prechamber Regulator/ManHold
    Figure 5.10-29. Mounting Brackets ......... 5.10 - 19
    Tube Connections - GL .............. 5.05 - 32
    Figure 5.1 0-30. Ignition Module' ............ 5.10 - 19
    Figure 5.05-58. Prechamber Gas Supply -
    Left Bank ........................... 5.05 - 33 Figure 5.1 0-31. Governor Drive Housing .... 5.10 - 20
    Figure 5.05-59. Fisher 99 Regulator Fuel Figure 5.10-32. Hall-effect Pickup ......... 5.10 - 20
    Gas Fitter ........................... 5.05 - 33 Figure 5.10-33. Current Production CEC
    Figure 5.05-60. Fisher 99 Regulator Filter ... 5.05 - 34 Timing Disc ......................... 5.10 - 20
    Figure 5.10-34. Current Produetjon Govemor
    Section 5.10 - Ignition System Drive Gear. .......................... 5.10 - 20
    Figure 5.10-1. Spark Plug Carriers .......... 5.10 - 1 Figure 5.10-35. Current Production Timing
    Tool ............................... 5.10 - 21
    Figure 5.10-2. Spark Plug Carrier Removal
    Tool ................................ 5.10 - 2 Figure 5.10-36. Flywheel Timing Opening ... 5.10 - 21
    Figure 5.10-3. Spark Plug Carrier Removal Figure 5.10-37. Current Production CEC
    Tool ................................ 5.10 - 2 Timing Disc ......................... 5.10 - 22
    Figure 5.10-4. Install Spark Plug Carrier ..... 5.10 - 2 Figure 5.10-38. Current Production CEC
    Timing Disc ......................... 5.10 - 22
    Figure 5.10-5. Spark Plug Carrier Extractor
    Tool ................................ 5.10 - 2 Figure 5.10-39. Flywheel Timing Opening ... 5.10 - 23
    Figure 5.10-6. Install Spark Plug Carrier ..... 5.10 - 3 Figure 5.10-40. Current Production Timing
    Tool ............................... 5.10 - 23
    Figure 5.10-7. CSASpark Plug ............. 5.10 - 4
    Figure 5.10-41. Current Production CEC
    Figure 5.10-8. Install Spark Plug/Connections 5.10 - 6 Timing Disc ......................... 5.10 - 23
    Figure 5.10-9. Install Spark Plug/Connections Figure 5.10-42. Current Production CEC
    PiN 211357H Extension ............... 5.10 - 6 Timing Disc ......................... 5.10 - 24
    Figure 5.10-10. VHP Spark Plug Recess Figure 5.10-43. CEC Ignttion Module Timing
    Cover ............................... 5.10 - 9 Switches ........................... 5.10 - 24
    Figure 5.10-11. VHP Spark Plug Recess Figure 5.10-44. Flywheel Timing Opening ... 5.10 - 25
    Cover Vent Cap ...................... 5.10 - 9
    Figure 5.10-45. Governor Drive Housing .... 5.10 - 26
    Figure 5.10-12. Spark Plug Connector Tube. 5.10 - 10
    Figure 5.10-46. Hall-Effect Pickup ......... 5.10 - 26
    Figure 5.10-13. Ignttion Coil Brackets ...... 5.10 - 11 Figure 5.10-47. Previous Production CEC
    Figure 5.1 0-14. Prechamber ManHold Timing Disc ......................... 5.10 - 26
    ) Bracket - Front Left .................. 5.10 - 12 Figure 5.10-48. Previous Production
    Figure 5.10-15. Ignition Coil Brackets ...... 5.10 -12 Governor Drive Gear ................. 5.1 0 - 26
    Figure 5.10-16. Coil (PIN 69694, Blue Coil) .5.10 -12 Figure 5.10-49. Governor Drive Gear ....... 5.10 - 27

    Form 6248 First Edition xxiii


    ILLUSTRATIONS

    Figure 5.10-50. Previous Production CEC Figure 5.15-10. Air Ducts - GSI/GL ......... 5.15 - 8
    TIming Disc ......................... 5.10 - 27 Figure 5.15-11. Crankcase Breather Tube .... 5.15 - 9
    Figure 5.10-51. Previous Production CEC Figure 5.15-12. Air Duct Brace - Left Bank ... 5.15 - 9
    TIming Disc ......................... 5.10 - 27 Figure 5.15-13. Air Duct Braces - Right Bank 5.15 - 9
    Figure 5.10-52. Governor Drive Housing .... 5.10 - 28 Figure 5.15-14. Air Intake Pipes - G ....... 5.15 - 10
    Figure 5.10-53. Previous Production TIming Figure 5.15-15. Air Pipe And Air Horn ...... 5.15 - 10
    Disc ............................... 5.10 - 28
    Figure 5.15-16. Intercooler Air Outlet Tube -
    Figure 5.10-54. CEC Ignnion Module GSI ................................ 5.15 - 11
    Rotary Switches A and B ............. 5.10 - 28 Figure 5.15-17. Intercooler Air Outlet Tube
    Figure 5.10-55. Magneto/Magneto Adapter And Intercooler ...................... 5.15 - 11
    Flange Bolts ........................ 5.10 - 31 Figure 5.15-18. Intercooler Air Outlet Tube .. 5.15 - 11
    Figure 5.10-56. Magneto/Magneto Adapter .. 5.10 - 31 Figure 5.15-19. Air Intake Pipe And
    Figure 5.10-57. Magneto Drive Disc Carburetor .......................... 5.15 - 12
    Coupling ........................... 5.10-31 Figure 5.15-20. Intercooler Air Outlet Tube-
    Figure 5.10-58. Magneto Drive Adapter GL .................•.............. 5.15-12
    Cover Studs ........................ 5.1 0 - 32 Figure 5.15-21. Intercooler Air OutietTube .. 5.15 - 12
    Figure 5.10-59. Engine Firing Order - Figure 5.15-22. Intercooler Air Outlet Tube
    12 Cylinder ......................... 5.10 - 32 O-ring - Carburetor End ............. 5.15 - 13
    Figure 5.10-60. Nameplate - Current Figure 5.15-23. Intercooler Air Outlet Tube -
    Production .......................... 5.10 - 33 Intercooler End .............. , ....... 5.15 - 13
    Figure 5.10-61. Nameplate - Previous Figure 5.15-24. Carburetor Air Horn And
    Production .......................... 5.10 - 33 Elbow .............................. 5.15 - 13
    Figure 5.10-62. Rotation Plate Front Figure 5.15-25. Intake Manifold - G/GSI .... 5.15 - 14
    Flywheel Housing - Right Bank ........ 5.10 - 34 Figure 5.15-26. Intake Manifold Flange
    Figure 5.10-63. TIming Pointer - Attachments ........................ 5.15 - 16
    Rear Right .......................... 5.10 - 34 Figure 5.15-27. Intake ManHold - GL ....... 5.15 - 18 )
    Figure 5.10-64. TIming Tape .............. 5.10 - 34 Figure 5.15-28. Intake ManHold Flange
    Figure 5.10-65. Magneto Drive Disc Attachments .........•.............. 5.15 - 19
    Coupling ........................... 5.10 - 35 Figure 5.15-29. Wire Harness Cable Clip
    Locations ........................... 5.15 - 21
    Figure 5.10-66. Magneto Drive Disc
    Coupling Shims ..................... 5.10 - 35 Section 5.20 - Turbochargers
    Figure 5.10-67. Magneto Static TIming ..... 5.10 - 36 Figure 5.20-1. Turbo Air Outlet Elbow -
    Figure 5.10-68. Magneto/Magneto Adapter .. 5.10 - 36 Rear Right ........................... 5.20 - 1
    Figure 5.10-69. Magneto Drive Assembly ... 5.10 - 36 Figure 5.20-2. Turbo Air Outlet Elbow -
    Figure 5.10-70. Magneto/Magneto Adapter Rear Right ........................... 5.20 - 1
    Flange Bolts ........................ 5.10 - 37 Figure 5.20-3. Turbo Air Outlet Elbow ....... 5.20 - 1
    Figure 5.10-71. Magneto Adapter Assembly. 5.10 - 39 Figure 5.20-4. Turbo Upper Oil Tube Clip .... 5.20 - 2
    Figure 5.10-72. Magneto Adapter Assembly. 5.10 - 39 Figure 5.20-5. Turbo Clamps ............... 5.20 - 2
    Figure 5.10-73. Magneto Drive Assembly ... 5.10 - 42 Figure 5.20-6. Turbocharger ............... 5.20 - 2
    Figure 5.20-7. Check Turbocharger Axial
    Section 5.15 - Air Induction System Play ................................ 5.20 - 4
    Figure 5.15-1. Air Cleaner Assembly ........ 5.15 - 2 Figure 5.20-8. Check Turbocharger Radial
    Play ................................ 5.20 - 5
    Figure 5.15-2. Air Cleaner Assembly ........ 5.15 - 2
    Figure 5.20-9. Turbo V-Band Coupling ...... 5.20 - 6
    Figure 5.15-3. Air Restriction Indicator/Filter -
    G[JGSI Models Shown ................ 5.15 - 4 Figure 5.20-10. Turbo V-Band Coupling ..... 5.20 - 6
    Figure 5.20-11. Turbocharger Torque
    Figure 5.15-4. Restriction Filter ............. 5.15 - 4
    Specifications ........................ 5.20 - 7
    Figure 5.15-5. Air Ducts - G ............... 5.15 - 5
    Figure 5.20-12. Turbocharger .............. 5.20 - 8
    Figure 5.15-6. Engine Breather ............. 5.15 - 6
    Figure 5.20-13. Turbo Exhaust Inlet Gasket .. 5.20 - 8
    Figure 5.15-7. Oil Separator Hose .......... 5.15 - 6 Figure 5.20-14. Air Duct Braces - Intercooler. 5.20 - 8 )
    Figure 5.15-8. Brace ...................... 5.15 - 6 Figure 5.20-15. Turbo/Exhaust Elbow
    Figure 5.15-9. Capscrew .................. 5.15 - 7 Connection- Left Bank ................ 5.20 - 9

    xxiv Form 6248 First Edition


    ILLUSTRATIONS

    Figure 5.20-16. V-Band Coupling ........... 5.20 - 9 Figure 5.25-18. Jacket Water Pump Drive
    Figure 5.20-17. Lower Turbo Oil Drain Tubes. 5.20 - 9 BeltTension ........................ 5.25 - 20
    Figure 5.20-18. TV94 Turbo Oil Supply/Drain Figure 5.25-19. Adjusting/Idler Lever
    Flanges ............................. 5.20 - 9 Assembly ........................... 5.25 - 21
    Figure 5.25-20. Auxiliary Water Pump Betts . 5.25 - 21
    Figure 5.20-19. Turbo Oil Supply Tubes .... 5.20 - 10
    Figure 5.25-21. Jacket And Auxiliary Water
    Figure 5.20-20. Turbo Upper Oil Supply
    Pump Belts ......................... 5.25 - 22
    Tubes .............................. 5.20 - 10 Figure 5.25-22. Jacket Water Pump Drive
    Belt Tension Tester .................. 5.25 - 22
    Figure 5.20-21. Turbocharger Alignment .... 5.20 - 10
    Figure 5.25-23. Jacket Water Pump "Weep"
    Figure 5.20-22. Turbocharger Alignment .... 5.20 - 11 Hole - Water Pump Shown Removed .. 5.25 - 23
    Figure 5.20-23. Turbo Air Outlet Elbows .... 5.20 - 11 Figure 5.25-24. Water Pump .............. 5.25 - 24
    Figure 5.20-24. Turbo Air Outlet Elbow ..... 5.20 - 11 Figure 5.25-25. Crankcase Water Inlet
    Figure 5.20-25. Turbo Air Outlet Elbow - Flange ............................. 5.25 - 25
    Rear Right. . . . . . .. . . . . . . . . . . . . . . . . .. 5.20 - 11 Figure 5.25-26. Water Pump Inlet Elbow -
    Figure 5.20-26. Turbo Air Outlet Elbow - Left Bank ........................... 5.25 - 25
    Rear Right .......................... 5.20 - 12 Figure 5.25-27. Water Header Assembly -
    Front Left ........................... 5.25 - 26
    Section 5.25 - Cooling System Figure 5.25-28. Water Header Assembly
    Figure 5.25-1. Water Outlet Hole ........... 5.25 - 1 Couplings .......................... 5.25 - 26
    Figure 5.25-2. VHP Twelve Cylinder Cooling Figure 5.25-29. Water Pump Inlet Elbows ... 5.25 - 26
    System - Cutaway View ............... 5.25 - 2 Figure 5.25-30. Dresser Coupling .......... 5.25 - 27
    Figure 5.25-3. VHP G Engine Cooling System Figure 5.25-31. Water Bypass T.tJbes ....... 5.25 - 28
    Schematic - Standard Jacket Water Figure 5.25-32. Bypass Tubes - Front Left .. 5.25 - 29
    Temperature ......................... 5.25 - 3 Figure 5.25-33. Water Bypass Elbows ...... 5.25 - 29
    Figure 5.25-4. VHP G Engine Cooling System Figure 5.25-34. Dresser Coupling .......... 5.25 - 30
    Schematic - Elevated Jacket Water Figure 5.25-35. Bypass Tubes - Front Left .. 5.25 - 30
    Temperature ......................... 5.25 - 4
    Figure 5.25-36. Exhaust Manifold Flanges -
    Figure 5.25-5. VHP GSI Engine Cooling Rear Left ............................ 5.25 - 31
    System Schematic - Standard And
    Figure 5.25-37. Water Manifold ............ 5.25 - 31
    Elevated Jacket Water Temperatures .... 5.25 - 5
    Figure 5.25-38. Water Manifold Bracket -
    Figure 5.25-6. VHP GL Engine Cooling
    Front Left ........................... 5.25 - 32
    System Schematic - Standard And
    Elevated Jacket Water Temperatures . . . . 5.25 - 6 Figure 5.25-39. Water Manifold Mounting
    Brackets ........................... 5.25 - 32
    Figure 5.25-7. 12 Cylinder Cluster
    Thermostat Housing .................. 5.25 - 7 Figure 5.25-40. Flexmaster Coupling ....... 5.25 - 32
    Figure 5.25-41. Water Manifold - Front ..... 5.25 - 33
    Figure 5.25-8. Auxiliary Cooling Water Circuit 5.25 - 7
    Figure 5.25-42. Water Outlet Elbow ........ 5.25 - 33
    Figure 5.25-9. Intercooler Flow ............. 5.25 - 8
    Figure 5.25-43. Water Manifold Connections 5.25 - 33
    Figure 5.25-10. Auxiliary Cooling Water
    Temperature Control Valve ............. 5.25 - 9 Figure 5.25-44. Water Manifold Bracket -
    Front Left ........................... 5.25 - 33
    Figure 5.25-11. Customer Supplied Ball
    Figure 5.25-45. Water Manifold Mounting
    Valve .............................. 5.25 - 12
    Brackets ........................... 5.25 - 34
    Figure 5.25-12. Idler Pulley Bearing Lube ... 5.25 - 17 Figure 5.25-46. Water Manifold Bracket -
    Figure 5.25-13. Auxiliary Water Pump Pulley Rear Left ........................... 5.25 - 34
    Lube ............................... 5.25 - 17 Figure 5.25-47.12 Cylinder Cluster
    Figure 5.25-14. Adjusting/Idler Lever Thermostat Housing ................. 5.25 - 34
    Assembly ........................... 5.25 - 18 Figure 5.25-46. Thermostat Testing ........ 5.25 - 35
    Figure 5.25-15. TIghten Idler Pulley Bracket Figure 5.25-49. Thermostat Open And
    Bolts ............................... 5.25 - 18 Closed ............................. 5.25 - 36
    Figure 5.25-16. Jacket Water Pump Drive Figure 5.25-50. Jacket Water Thermostats -
    Belt Tension Tester .................. 5.25 - 19 PIN 208627 Series .................. 5.25 - 36
    Figure 5.25-17. Jacket Water Pump Drive Figure 5.25-51. Jacket Water Thermostats -
    BeH Tensioning ...................... 5.25 - 20 PIN 208660 Series .................. 5.25 - 36

    Form 6248 First Ednion xxv


    ILLUSTRATIONS

    Figure 5.25-52. Thermostat Seal .......... 5.25 - 37 Figure 5.25-87. Install Water Pump Cover
    Figure 5.25-53. 12 Cylinder Cluster Gasket ............................. 5.25 - 55
    Thermostat Housing - Bottom View .... 5.25 - 38 Figure 5.25-88. Water Pump Cover And
    Figure 5.25-54. Idler Pulley Bracket ........ 5.25 - 39 Cover Gasket ....................... 5.25 - 55
    Figure 5.25-89. Water Drain Petcock -
    Figure 5.25-55. Idler Pulley ............... 5.25 - 39
    Front Right ......................... 5.25 - 55
    Figure 5.25-56. Idler Pulley Shaft Removal .. 5.25 - 39
    Figure 5.25-90. Lifting The Jacket Water
    Figure 5.25-57. Cover Removal ........... 5.25 - 40 Pump ...............•.............. 5.25 - 55
    Figure 5.25-58. Remove Ball Bearing/Shaft Figure 5.25-91. Front Pulley Guard ........ 5.25 - 56
    Assembly ........................... 5.25 - 40 Figure 5.25-92. Left Hand BeH Guard Panel. 5.25 - 56
    Figure 5.25-59. Grease Seal Removal ...... 5.25 - 40 Figure 5.25-93. Right Hand Belt Guard
    Figure 5.25-60. Idler Pulley Ball Bearing/Shaft Panel .............................. 5.25 - 56
    Assembly ........................... 5.25 - 41 Figure 5.25-94. Auxiliary Water Pump BeH
    Figure 5.25-61. Idler Pulley Shaft .......... 5.25 - 41 Guards ............................. 5.25 - 57
    Figure 5.25-62. Idler Pulley Ball Bearing/Shaft Figure 5.25-95. Inner Auxiliary Water Pump
    Assembly ........................... 5.25 - 42 Bett Guard .......................... 5.25 - 57
    Figure 5.25-63. Idler Pulley Bracket Vent Hole Figure 5.25-96. Auxiliary Water Temperature
    Location ............................ 5.25 - 43 Control Valve ....................... 5.25 - 58
    Figure 5.25-97. Auxiliary Cooling Water
    Figure 5.25-64. Idler Pulley Bracket ........ 5.25 - 43
    Temperature Control Valve - All Models 5.25 - 59
    Figure 5.25-65. Water Drain Petcock -
    Figure 5.25-98. Turbo Oil Supply Tube -
    Front Right ......................... 5.25 - 44
    Rear Left ........................... 5.25 - 60
    Figure 5.25-66. Lifting The Jacket Water Figure 5.25-99. Intercooler Bonnet
    Pump .............................. 5.25 - 44 Attachments - Right Bank Side . . . . . . . . 5.25 - 61
    Figure 5.25-67. Water Pump Cover And Figure 5.25-100. Turbo Clamps ............ 5.25 - 61
    Cover Gasket ....................... 5.25 - 44
    Figure 5.25-101. Intercooler Connections - )
    Figure 5.25-68. VHP Water Pump Assembly 5.25 - 45 Top ................................ 5.25 - 62
    Figure 5.25-69. Jacket Water Pump Shaft ... 5.25 - 47 Figure 5.25-102. Intercooler/Wastegate Tube
    Figure 5.25-70. Jacket Water Pump Service Connections ........................ 5.25 - 62
    Tool Kit PIN 474013 .................. 5.25 - 47 Figure 5.25-103. Intercooler Connections -
    Figure 5.25-71. Press Bearings Onto Shaft .. 5.25 - 47 Left Bank ........................... 5.25 - 63
    Figure 5.25-72. Pack Water Pump Bearings. 5.25 - 48 Figure 5.25-104. Intercooler Connections ... 5.25 - 63
    Figure 5.25-105. Compressor Discharge
    Figure 5.25-73. Open (Lipped) Side Of
    Tube ............................... 5.25 - 63
    Carriers ............................ 5.25 - 49
    Figure 5.25-106. V-Branch ............... 5.25 - 63
    Figure 5.25-74. Install Inner Grease Seal ... 5.25 - 49
    Figure 5.25-107. Flexmaster Elbow
    Figure 5.25-75. Install Shaft And Bearing Coupling ........................... 5.25 - 64
    Assembly ........................... 5.25 - 49
    Figure 5.25-108. Intercooler Mounting -
    Figure 5.25-76. Install Retaining Ring/OUier Rear Left ........................... 5.25 - 64
    Grease Seal ........................ 5.25 - 50
    Figure 5.25-109. Intercooler Removal ...... 5.25 - 64
    Figure 5.25-77. Pulley Hub Wear Sleeve .... 5.25 - 51
    Figure 5.25-110. Intercooler Connections -
    Figure 5.25-78. Install Pulley Hub Wear Left Bank ........................... 5.25 - 65
    Sleeve ............................. 5.25 - 51 Figure 5.25-111. Intercooler Connections ... 5.25 - 65
    Figure 5.25-79. Water Pump Seal Assembly 5.25 - 51 Figure 5.25-112. Support Rails ............ 5.25 - 65
    Figure 5.25-80. Install Ceramic Seal ....... 5.25 - 52 Figure 5.25-113. Intercooler Connections ... 5.25 - 65
    Figure 5.25-81. Install Carbon Seal ........ 5.25 - 52 Figure 5.25-114. Intercooler -
    Figure 5.25-82. VHP Water Pump Assembly 5.25 - 53 12 Cylinder Engines ................. 5.25 - 86
    Figure 5.25-83. Check Impeller Clearances . 5.25 - 53 Figure 5.25-115. Intercooler Connections ... 5.25 - 67
    Figure 5.25-84. Jacket Water Pump ........ 5.25 - 54 Figure 5.25-116. 455 Ell Dresser Coupling .. 5.25 - 67

    Figure 5.25-85. Water Pump Mounting Figure 5.25-117. Intercooler Piping ......... 5.25 - 67
    Flange ............................. 5.25 - 54 Figure 5.25-118. 455 Ell Dresser Coupling .. 5.25 - 68
    Figure 5.25-86. Water Pump Cover And Figure 5.25-119. Support Rails ............ 5.25 - 68
    Cover Gasket ....................... 5.25 - 54 Figure 5.25-120. Intercooler Connections ... 5.25 - 69

    xxvi Form 6248 First Edition


    ILLUSTRATIONS

    Figure 5.25-121. Intercooler Connections ... 5.25 - 69 Section 5.30 - Lubrication System
    Figure 5.25-122. Compressor Discharge Figure 5.30-1. External Lube Oil Schematic-
    Pressure Sensing Tubes Support Braces 5.25 - 69 Blending Type. . . . . . . . . . . . . . . . . . . . . . .. 5.30 - 1
    Figure 5.25-123. Intercooler/Wastegate Figure 5.30-2. Lube Oil Temperature Control
    Tube Connections ................... 5.25 - 69 Valve ............................... 5.30 - 1
    Figure 5.25-124. Wastegate Connections ... 5.25 - 70 Figure 5.30-3. Pressure Regulating Valve .... 5.30 - 2
    Figure 5.25-125. Flexmaster Elbow Figure 5.30-4. Lube Oil Strainer ............ 5.30 - 2
    Coupling ........................... 5.25 - 70 Figure 5.30-5. Intemal Oil Control ........... 5.30 - 3
    Figure 5.25-126. Lifting The Intercooler ..... 5.25 - 71 Figure 5.30-6. Petcock At Lube Filter Inlet ... 5.30 - 8
    Figure 5.25-127. Intercooler Mounting - Figure 5.30-7. VHP Oil Filler Pipe .......... 5.30 - 11
    Rear Left ........................... 5.25 - 71 Figure 5.30-8. Dipstick ................... 5.30 - 12
    Figure 5.25-128. Lower Turbo Oil Drain Figure 5.30-9. Lube Oil Fitter .............. 5.30 - 14
    Tubes .............................. 5.25 - 71 Figure 5.30-10. Full-Flow Lube Oil Fitter .... 5.30 - 14
    Figure 5.25-129. Upper Turbo Oil Drain Figure 5.30-11. Fitter Elemenl/Relief
    Tubes .............................. 5.25 - 72 Valve Configuration .................. 5.30 - 14
    Figure 5.25-130. Turbo Oil Supply Tube - Figure 5.30-12. Lube Oil Fitter Relief Valve
    Rear Left ........................... 5.25 - 72 Assembly ........................... 5.30 - 15
    Figure 5.25-131. V-Branch ............... 5.25 -73 Figure 5.30-13. Magnetic Plugs ........... 5.30 - 16
    Figure 5.25-132. Assemble Intercooler Figure 5.30-14. Oil Cooler Piping
    Water Supply/Return Pipe Clamps ..... 5.25 - 73 Connections ........................ 5.30 - 18
    Figure 5.25-133. Intercooler Water Figure 5.30-15. Oil Cooler Assembly ....... 5.30 - 20
    Supply/Return Pipes - Threaded Ends . 5.25 - 74 Figure 5.30-16. Lube Oil Temperature
    Figure 5.25-134. Install Intercooler Water Control Valve ....................... 5.30 - 21
    Supply/Return Pipe Clamps - Rear .... 5.25 - 74 Figure 5.30-17. ThermostatTesting ........ 5.30 - 21
    Figure 5.25-135. Install Intercooler Water Figure 5.30-18. Thermostat Open And
    Supply/Return Pipe Clamps - Front .... 5.25 - 74 Closed ............................. 5.30 - 22
    Figure 5.25-136. Intercooler Water Figure 5.30-19. Thermostatic Valve ........ 5.30 - 22
    Supply/Return Pipes ................. 5.25 - 75 Figure 5.30-20. Lube Oil Temperature Control
    Figure 5.25-137. Install Intercooler Water Valve - 12 And 16 Cylinder Engines ... 5.30 - 23
    Supply/Return Pipes ................. 5.25 - 75 Figure 5.30-21. Lube Oil Temperature Control
    Valve .............................. 5.30 - 23
    Figure 5.25-138. Intercooler Water Retum
    Pipe - Front Left .................... 5.25 - 75 Figure 5.30-22. Prelube Oil Pressure Relief
    Valve .............................. 5.30 - 25
    Figure 5.25-139. Intercooler Water Return
    Pipe Flange ......................... 5.25 - 75 Figure 5.30-23. Prelube Motor/Pump
    Assembly ........................... 5.30 - 26
    Figure 5.25-140. Intercooler Water Return
    Pipe Flange ......................... 5.25 - 76 Figure 5.30-24. In-Line Lubricator .......... 5.30 - 27
    Figure 5.30-25. Oil Pickup Screen
    Figure 5.25-141. Intercooler Water Supply
    Assembly - 12 Cylinder .............. 5.30 - 28
    Pipe Elbow ......................... 5.25 - 76
    Figure 5.30-26. Fastening Flange Adapter .. 5.30 - 29
    Figure 5.25-142. Intercooler Water Supply
    Pipe - Front Left .................... 5.25 - 76 Figure 5.30-27. Lube Oil Pump Manffold
    Check Valve ........................ 5.30 - 30
    Figure 5.25-143. Intercooler Water Supply
    Figure 5.30-28. Relief Valve ............... 5.30 - 30
    Pipe - Front Left .................... 5.25 - 76
    Figure 5.30-29. Drive Gears .............. 5.30 - 30
    Figure 5.25-144. Flexmaster Elbow
    Coupling ........................... 5.25 - 77 Figure 5.30-30. Oil Pump Cover Front Cover 5.30 - 30
    Figure 5.30-31. Oil Pump Intemal Gears .... 5.30 - 30
    Figure 5.25-145. Auxiliary Water Pump ..... 5.25 - 77
    Figure 5.30-32. Pump Body Bushings ...... 5.30 - 31
    Figure 5.25-146. Auxiliary Water Pump
    Idler And Adjusting Lever ............. 5.25 - 78 Figure 5.30-33. Pump Cover Bushings ..... 5.30 - 31
    Figure 5.25-147. Auxiliary Water Pump Figure 5.30-34. Adjustable Boring Tool ..... 5.30 - 32
    ) Bracket ............................ 5.25 - 78 Figure 5.30-35. Idler Gear ................ 5.30 - 33
    Figure 5.25-148. Adjusting/Idler Lever Figure 5.30-36. Woodruff Keys ............ 5.30 - 33
    Assembly ........................... 5.25 - 79 Figure 5.30-37. Checking Clearance ....... 5.30 - 34

    Form 6248 First Ednion xxvII


    ILLUSTRATIONS

    Figure 5.30-38. Oil Pump Internal Gears .... 5.30 - 34 Figure 5.35-5. Water Outlet Elbow Gaskets .. 5.35 - 4
    Figure 5.30-39. Oil Pump Cover Figure 5.35-6. Exhaust Manifold - Rear View. 5.35 - 4
    Torque Sequence .................... 5.30 - 34 Figure 5.35-7. Exhaust Manifold - GL Shown 5.35 - 5
    Figure 5.30-40. Relief Valve ............... 5.30 - 34 Figure 5.35-8. Exhaust Manifold Gasket ..... 5.35 - 6
    Figure 5.30-41. Oil Pump Mounting Stud .... 5.30 - 37 Figure 5.35-9. Exhaust Manifold - Rear View. 5.35 - 6
    Figure 5.30-42. Oil Pump Gasket .......... 5.30 - 37 Figure 5.35-1 O. Exhaust Manifold - Left Bank 5.35 - 7
    Figure 5.30-43. Oil Pump Tightening Pattern 5.30 - 37 Figure 5.35-11. Prelube Motor Air/Gas
    Figure 5.30-44. Measuring Oil Pump Drive Supply Tube ......................... 5.35 - 7
    Gear Backlash ...................... 5.30 - 38 Figure 5.35-12. Exhaust ManHold End
    Sections - Left Bank .................. 5.35 - 7
    Figure 5.30-45. Lube Oil Pump ............ 5.30 - 38
    Figure 5.35-13. Breather Tube And Intercooler
    Figure 5.30-46. Lube Oil Pump Manifold -
    Tubes ............................... 5.35 - 8
    Front View .......................... 5.30 - 39
    Figure 5.35-14. Water Outlet Elbow Gaskets . 5.35 - 8
    Figure 5.30-47. Lube Oil Pump ManHold
    Check Valve ........................ 5.30 - 39 Figure 5.35-15. Exhaust Manifold -
    Right Bank .......................... 5.35 - 8
    Figure 5.30-48. Fastening Flange Adapter .. 5.30 - 39
    Figure 5.35-16. Water Outlet Elbows -
    Figure 5.30-49. Prelube V-Strainer ......... 5.30 - 40 Rear Right ........................... 5.35 - 9
    Figure 5.30-50. Attaching Pipe Tee ........ 5.30 - 40 Figure 5.35-17. Exhaust Manifold - Front .... 5.35 - 9
    Figure 5.30-51. V-Strainer - Front Left ..... 5.30 - 40 Figure 5.35-18. Exhaust Manifold - Left Bank 5.35 - 9
    Figure 5.30-52. VHP Oil Filler Pipe ......... 5.30 - 41 Figure 5.35-19. Thermocouple Connector-
    Figure 5.30-53. Oil Filler Pipe/Bracket - Rear Right ........................... 5.35 - 9
    Rear Left ........................... 5.30 - 41 Figure 5.35-20. Turbo Exhaust Inlet Elbow -
    Figure 5.30-54. Rocker Arm Header Oil Rear Left ................... , ....... 5.35 - 10
    Supply - Rear ....................... 5.30 - 42 Figure 5.35-21. Turbo Exhaust Inlet Elbow -
    Rear Right - G/GSI Engines .......... 5.35 - 10
    Figure 5.30-55. Rocker Arm Header Oil
    Supply - Figure 5.35-22. Turbo Exhaust Inlet Elbow .. 5.35 - 10 )
    Rear Vee ........................... 5.30 - 42 Figure 5.35-23. Turbo Exhaust Inlet Elbow -
    Figure 5.30-56. Oil Supply Tube Clip - Rear Left ...... .. .. .. .. .. .. .. .. .. ... 5.35 - 11
    Rear Right .......................... 5.30 - 42 Figure 5.35-24. Turbo Exhaust Inlet Elbow
    Figure 5.30-57. Rocker Arm Header Oil Gasket ............................. 5.35 - 11
    Supply - Front ...................... 5.30 - 43 Figure 5.35-25. Turbo Exhaust Inlet Elbow .. 5.35 - 11
    Figure 5.30-58. Turbo Oil Supply - Figure 5.35-26. Turbo Exhaust Inlet Elbow -
    Rear Right .......................... 5.30 - 44 Rear Left ............•.............. 5.35 - 12
    Figure 5.30-59. Pipe Cross Magnet Plug .... 5.30 - 44 Figure 5.35-27. Exhaust Connections - G ... 5.35 - 13
    Figure 5.30-60. Rear Tube Connections .... 5.30 - 44 Figure 5.35-28. Exhaust Connections -
    GSI/GL ............................. 5.35 - 14
    Figure 5.30-61 . Main Oil Header Oil
    Outlet Ports ......................... 5.30 - 44 Figure 5.35-29. Exhaust Elbow Assembly ... 5.35 - 15
    Figure 5.35-30. Check Exhaust Elbow For
    Figure 5.30-62. Governor Drive Oil Supply -
    Front Right ......................... 5.30 - 45 Straightness ........................ 5.35 - 15
    Figure 5.35-31. Exhaust Elbow Adapter .... 5.35 - 15
    Figure 5.30-63. Oil Pan Door - Rear View .. 5.30 - 45
    Figure 5.35-32. Exhaust Thermocouple -
    Figure 5.30-64. Oil Pan Door - Side View ... 5.30 - 45 Rear Left ........................... 5.35 - 16
    Figure 5.30-65. Lube Oil Strainer - Figure 5.35-33. "K" Type Thermocouple .... 5.35 - 16
    Rear Right .......................... 5.30 - 46 Figure 5.35-34. "K" Type Thermocouple .... 5.35 - 17
    Figure 5.30-66. Lube Oil Strainer Assembly. 5.30 - 47 Figure 5.35-35. Exhaust Thermocouple
    Installation .......................... 5.35 - 17
    Section 5.35 - Exhaust System
    Figure 5.35-36. Thermocouple Conduit -
    Figure 5.35-1. Exhaust Thermocouples Rear Right .......................... 5.35 - 18
    Arrangement - 12 Cylinder ............ 5.35 - 1
    Figure 5.35-37. Exhaust Thermocouples
    Figure 5.35-2. Exhaust Thermocouple - Arrangement - 12 Cylinder ........... 5.35 - 18
    Rear Left ............................ 5.35 - 3 Figure 5.35-38. Exhaust Thermocouple
    )
    Figure 5.35-3. Thermocouple Bracket ....... 5.35 - 3 Installation .......................... 5.35 - 19
    Figure 5.35-4. Water Outlet Elbows - Figure 5.35-39. Intercooler/Wastegate Tube
    Rear Right.. .. .. .. .. .. .. . .. .. .. .. . .. . 5.35 - 3 Connections ........................ 5.35 - 20

    xxvIII Form 6248 First Edition


    ILLUSTRATIONS

    Figure 5.35-40. Wastegate Breather Vent ... 5.35 - 21 Figure 5.40-11. Crankcase Separator Screen
    Figure 5.35-41. Wastegate Disassembly .... 5.35 - 21 Assembly - 12 Cylinder Engines -
    GL Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 - 6
    Figure 5.35-42. Wastegate -
    Figure 5.40-12. Crankcase - Rear Right ..... 5.40 - 6
    PIN Series 208372 - Bottom View ..... 5.35 - 22
    Figure 5.40-13. Oil Separator - G ........... 5.40 - 7
    Figure 5.35-43. VHP Wastegate -
    PIN Series 208372 - Cutaway ........ 5.35 - 22 Figure 5.40-14. Oil Separator Assembly,
    Unthreaded Oil Inlet Pipe - GL Shown .. 5.40 - 8
    Figure 5.35-44. Wastegate Breather Vent ... 5.35 - 23
    Figure 5.40-15. Oil Separator Assembly,
    Figure 5.35-45. Wastegate Assembly ...... 5.35 - 24 Threaded Oil Inlet Pipe - GSI/GL ....... 5.40 - 9
    Figure 5.35-46. Wastegate - Figure 5.40-16. Breather Regulator
    PIN Series 208372 - Bottom View ..... 5.35 - 25 Assembly - GL Shown ............... 5.40 - 10
    Figure 5.35-47. PIN Series 208372 Figure 5.40-17. Breather Regulator
    Wastegate Calibration Tool ........... 5.35 - 25 Assembly - All Engines .............. 5.40 - 10
    Figure 5.35-48. PIN Series 208372 Figure 5.40-18. Venturi Assembly-
    Wastegate Calibration ................ 5.35 - 26 GSI Shown ......................... 5.40 - 12
    Figure 5.35-49. PIN Series 208372 Figure 5.40-19. Venturi Extractor
    Wastegate calibration Tool ........... 5.35 - 26 Assembly - GSI ..................... 5.40 - 12
    Figure 5.35-50. PIN Series 208372 Figure 5.40-20. Venturi Extractor
    Wastegate calibration Setup .......... 5.35 - 26 Assembly - GL . . . . . . . . . . . . . . . . . . . . . . 5.40 - 12
    Figure 5.40-21. Venturi Extractor Assembly . 5.40 - 13
    Figure 5.35-51. Wastegate Calibration
    Setup .............................. 5.35 - 27 Figure 5.40-22. Venturi Extractor Assembly . 5.40 - 14
    Figure 5.35-52. Intercooler/Wastegate Tube Figure 5.40-23. Venturi Extractor Assembly . 5.40 - 14
    Connections ........................ 5.35 - 28 Figure 5.40-24. Venturi Extractor Brackets .. 5.40 - 15
    Figure 5.35-53. Intercooler/Wastegate Tube Figure 5.40-25. Venturi Extracto"Assembly . 5.40 - 15
    Connections ........................ 5.35 - 28 Figure 5.40-26. Bicera Pressure Relief Valve 5.40 - 16
    Figure 5.35-54. Wastegate Adjusting ....... 5.35 - 29 Figure 5.40-27. Pressure Relief Valve -
    Cross Sectional View ................ 5.40 - 17
    Figure 5.35-55. Wastegate Gasket Removal 5.35 - 30
    Figure 5.40-28. Breather Tubes - GSI ...... 5.40 - 18
    Figure 5.35-56. Wastegate Poppet To
    Figure 5.40-29. Support Clamp ............ 5.40 - 19
    Wastegate Mounting Face
    Measurement ....................... 5.35 - 30 Figure 5.40-30. Breather Tube - Front Vee .. 5.40 - 19
    Figure 5.40-31. Breather System Tube
    Figure 5.35-57. Wastegate Adjusting -
    Connections - GL ................... 5.40 - 20
    PIN Series 295645 .................. 5.35 - 30
    Figure 5.40-32. Y -Shaped Breather Tube ... 5.40 - 21
    Figure 5.35-58. Wastegate Connections .... 5.35 - 32
    Figure 5.40-33. Install Vee Mounted
    Section 5.40 - Crankcase Breather Breather Tube Clamps ............... 5.40 - 21
    Figure 5.40-34. Breather Tube - Front Vee .. 5.40 - 21
    System
    Figure 5.40-35. Breather Tube - Rear Vee .. 5.40 - 21
    Figure 5.40-1 . Oil Separator -
    Figure 5.40-36. Venturi Extractor Compressor
    12 Cylinder Engines .................. 5.40 - 1
    Discharge Plumbing - GL Shown ...... 5.40 - 22
    Figure 5.40-2. Breather Regulator Assembly - Figure 5.40-37. Right Bank Compressor
    Current Style ......................... 5.40 - 2 Discharge Tube ..................... 5.40 - 22
    Figure 5.40-3. Venturi Extractor/Choke Valve
    Assembly - GL Shown ................ 5.40 - 2 Section 5.45 - Air/Gas Prelube And Start
    Figure 5.40-4. Venturi Assembly - Systems
    GSI Shown .......................... 5.40 - 2 Figure 5.45-1. Prelube/Start Pushbutton
    Figure 5.40-5. Install Water Manometer Valves .............................. 5.45 - 1
    Tube Connector ...................... 5.40 - 3 Figure 5.45-2. Prelube And Start Air/Gas Tube
    Figure 5.40-6. Vacuum Valve Assembly - G .. 5.40 - 3 Connections - Bulkhead (G/GSI/GL) .... 5.45 - 2
    Figure 5.45-3. Pilot Operated Prelube Valve
    Figure 5.40-7. Vacuum Valve Assembly - GSI 5.40 - 3
    Connections ......................... 5.45 - 3
    Figure 5.40-8. Venturi Extractor/Choke Valve Figure 5.45-4. Prelube Motor/Pump
    Assembly - GL ....................... 5.40 - 4 Assembly ............................ 5.45 - 3
    ) Figure 5.40-9. Venturi Extractor/Choke Valve Figure 5.45-5. Schematic - Pneumatic Control
    Assembly - GSI ...................... 5.40 - 4 System For Air Only Start And Prelube
    Figure 5.40-10. Venturi Extractor Assembly .. 5.40 - 5 (G, GSI) ............................. 5.45 - 5

    Form 6245 First Edttion xxix


    ILLUSTRATIONS

    Figure 5.45-6. Schematic - Pneumatic Figure 5.45-33. Air/Gas Plenum - )


    Control System For Air/Gas Start And Safety Shutdown Valve ............... 5.45 - 21
    Prelube (G, GSI) ..................... 5.45 - 6 Figure 5.45-34. Air/Gas Plenum -
    Figure 5.45-7. Schematic - Pneumatic Safety Shutdown Valve ............... 5.45 - 21
    Control System For Air/Gas Start And Figure 5.45-35. Prechamber Gas Valve ..... 5.45 - 22
    Prelube (GL) ......................... 5.45 - 7 Figure 5.45-36. Mount Prechamber Gas
    Figure 5.45-8. Pilot Operated Prechamber Valve .............................. 5.45 - 22
    Fuel Valves - GL ..................... 5.45 - 8 Figure 5.45-37. Lube Oil Pilot Pressure
    Figure 5.45-9. Shuttle Valve - GL ........... 5.45 - 9 Tube Connection .................... 5.45 - 23
    Figure 5.45-10. Bulkhead And Connector Figure 5.45-38. Tube Clips - Right Bank .... 5.45 - 23
    Brackets ............................ 5.45 - 9 Figure 5.45-39. Air/Gas Starter ............ 5.45 - 24
    Figure 5.45-11. Rear Flywheel Housing - Figure 5.45-40. Electric Starter ............ 5.45 - 26
    Rear Right .......................... 5.45 - 10 Figure 5.45-41. Wiring Diagram -
    Figure 5.45-12. Bulkhead/Connector Bracket DC Junction Box - CEC IgnHion With
    Assembly ........................... 5.45 - 10 Electric Start ........................ 5.45 - 27
    Figure 5.45-13. Pilot Operated Prelube Valve- Figure 5.45-42. Wiring Diagram -
    Rear Right .......................... 5.45 - 10 DC Junction Box - CEC Ignition WHh
    Figure 5.45-14. Pilot Operated Prelube Valve - Air Start ............................ 5.45 - 28
    Rear Right .......................... 5.45 - 11
    Section 6.00 - Control Panel
    Figure 5.45-15. Pilot Operated Prelube Valve
    Figure 6.00-1. Control Panel - Right Side .... 6.00 - 1
    Connections ........................ 5.45 - 12
    Figure 6.00-2. IgnHion Switch .............. 6.00 - 1
    Figure 5.45-16. Prelube Motor/Pump
    Assembly ........................... 5.45 - 12 Figure 6.00-3. Control Panel - Right Side .... 6.00 - 1
    Figure 5.45-17. Rear Gear Housing - Figure 6.00-4. Prelube And Start Air/Gas
    Front Left ........................... 5.45 - 13 Tube Connections - Bulkhead
    (G/GSI/GL) .......................... 6.00 - 2
    Figure 5.45-18. Prelube Motor/Pump
    Figure 6.00-5. Ignition SwHch Wire Harness .. 6.00 - 3
    )
    Mounting Bracket - Rear View ........ 5.45 - 13
    Figure 6.00-6. Mounting Straps ............. 6.00 - 3
    Figure 5.45-19. Lube Oil Pressure Gauge
    Connection ......................... 5.45 - 14 Figure 6.00-7. Intake ManHold - Right Bank .. 6.00 - 3
    Figure 5.45-20. Prelube/Start Pushbutton Figure 6.00-8. Pushbutton Valves ........... 6.00 - 3
    Valves ............................. 5.45 - 14 Figure 6.00-9. Bracket Strap ............... 6.00 - 4
    Figure 5.45-21. Tube Clamp - Rear Right ... 5.45 - 15 Figure 6.00-10. IgnHion SwHch Wire Harness. 6.00 - 4
    Figure 5.45-22. Tube Clamp Support Brace - Figure 6.00-11. Control Panel Cover ........ 6.00 - 4
    Rear Right .......................... 5.45 - 15 Figure 6.00-12. Ignition Wire Harness
    Figure 5.45-23. Tube Clamp - Rear Right ... 5.45 - 15 And IgnHion Switch - Left Side ......... 6.00 - 4
    Figure 6.00-13. Control Panel .............. 6.00 - 5
    Figure 5.45-24. Prelube And Start Air/Gas
    Tube Connections - Bulkhead Figure 6.00-14. IgnHion Switch Wire Harness. 6.00 - 5
    (GIGSI/GL) ......................... 5.45 - 16 Figure 6.00-15. Wiring Diagram - DC
    Figure 5.45-25. Pushbutton Valve Junction Box - CEC Ignition WHh
    Connections ........................ 5.45 - 17 Electric Start ......................... 6.00 - 6
    Figure 5.45-26. Prelube/Start Pushbutton Figure 6.00-16. Wiring Diagram - DC
    Valves ............................. 5.45 - 17 Junction Box - CEC IgnHion With
    Air Start ............. _. . . . . . . . . . . . . . . 6.00 - 7
    Figure 5.45-27. Intake Manifold Flange
    Attachments - Right Bank ............ 5.45 - 18 Section 6.05 - Engine Protection
    Figure 5.45-28. Tube Clip Brackets - Systems
    Right Bank Intake Manifold ........... 5.45 - 18
    Figure 6.05-1. Lube Oil Inlet Temperature
    Figure 5.45-29. Pilot Operated Prechamber Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 - 1
    Fuel Valves ......................... 5.45 - 19
    Figure 6.05-2. Jacket Water Temperature
    Figure 5.45-30. Lube Oil Pilot Pressure Tube Sensor .............. _. . . . . . . . . . . . . . . 6.05 - 1
    Connection ......................... 5.45 - 20 Figure 6.05-3. Intake Manifold Temperature
    Figure 5.45-31. Mount Prechamber Gas Sensor .............................. 6.05 - 1
    Valve .............................. 5.45 - 20 Figure 6.05-4. Exhaust Thermocouples
    Figure 5.45-32. Prechamber Gas Valve ..... 5.45 - 20 Arrangement ......................... 6.05 - 2

    xxx Form 6248 First Edition


    ILLUSTRATIONS

    Figure 6.05-5. Exhaust Thermocouple -


    Rear Left ............................ 6.05 - 2
    Figure 6.05-6. Main Bearing Temperature
    Thermocouples ...................... 6.05 - 2
    Figure 6.05-7. Wiring Diagram - Main Bearing
    Temperature Thermocouples ........... 6.05 - 3
    Figure 6.05-8. Wiring Diagram - Thermocouple
    Junction Box ......................... 6.05 - 4
    Figure 6.05-9. Thermocouple Junction Box ... 6.05 - 6
    Figure 6.05-10. Manual Shutdown Switch -
    Left Side ............................ 6.05 - 6
    Figure 6.05-11. Instrument Panel Gauge
    Placement ........................... 6.05 - 8
    Figure 6.05-12. Remote Mounted Panel ..... 6.05 - 9
    Figure 6.05-13. Optional Remote Instrument
    Panel ............................... 6.05 - 9
    Figure 6.05-14. CEC Detonation Sensing
    Module ............................. 6.05 - 10
    Figure 6.05-15. IgnHion Module WHh
    Expansion Port ...................... 6.05 - 10
    Figure 6.05-16. Detonation Sensor ......... 6.05 - 11
    Figure 6.05-17. Detonation Sensing Module
    System Wiring Schematic ............. 6.05 - 12
    Figure 6.05-18. Detonation Sensing Module
    Front Panel ......................... 6.05 - 13
    ) Figure 6.05-19. Detonation Sensing Module
    LCD Display ........................ 6.05 - 13
    Figure 6.05-20. Remote Instrument Panel
    Connections ........................ 6.05 - 17
    Figure 6.05-21. Remote Instrument Panel
    Connections ........................ 6.05 - 18

    Section 6.10 - Miscellaneous Equipment


    Figure 6.10-1. Surge Tank Assembly ........ 6.10 - 1
    Figure 6.10-2. Water Connection Pipe ....... 6.10 - 2
    Figure 6.10-3. Overflow Line Support Bracket 6.10 - 2
    Figure 6.10-4. Filler Cap And Plug .......... 6.1 0 - 3
    Figure 6.1 0-5. Pipe Adapter ................ 6.10 - 3
    Figure 6.10-6. Sight Gauge ................ 6.10 - 3
    Figure 6.10-7. Jacket Water Heater -
    Right Side ........................... 6.10 - 5
    Figure 6.10-8. Jacket Water Heater -
    LeftSide ............................ 6.10-6

    Form 6248 First Ednion xxxi


    ILLUSTRATIONS

    xxxii Form 6248 First Edition


    TABLES

    LIST OF TABLES

    Section 1.10 - Rigging And Lifting Table 1.20-16. Crankshaft Web Deflection
    Measurement Wfth Connecting Rods
    Engines Installed ............................ 1.20 - 18
    Table 1.10-1. Engine Dry Weights .......... 1.10 - 1 Table 1.20-17. Rocker Arm Bores And
    Shafts ............................. 1.20 - 19
    Section 1.15 - General Information
    Table 1.20-18. Rear Gear Backlash
    Table 1.15-1. Service Tools ................ 1.15-8 Specifications . . . . . . . . . . . . . . . . . . . . . . . 1.20 - 20
    Table 1.15-2. VHP 12 Cylinder Gas Engine Table 1.20-19. Oil Pump And Oil Pump
    Component Weights ................. 1.15 - 10 Drive Gears. . . . . . . . . . . . . . . . . . . . . . . . . 1.20 - 21
    Table 1.15-3. 12 Cylinder VHP Table 1.20-20. VHP Accessory Gear
    Torque Values ....................... 1.15 -13 Backlash ........................... 1.20 - 23
    Table 1.15-4. Cylinder Head Capscrews .... 1.15 - 14 Table 1.20-21. Accessory Drive Ratios ..... 1.20 - 23
    Table 1.15-5. U.S. Standard Capscrew Table 1.20-22. Flywheel And Housing ...... 1.20 - 24
    Torque Values ....................... 1.15 - 16 Table 1.20-23. Turbo Inspection ........... 1.20 - 25
    Table 1.15-6. English To Metric Formula Table 1.20-24. Lubrication System
    Conversion Table .................... 1.15 - 17 Pressures .......................... 1.20 - 25
    Table 1.15-7. Metric To English Formula Table 1.20-25. Lubrication System
    Conversion Table .................... 1.15 - 17 Temperatures ....................... 1.20 - 25
    Table 1.15-8. Sealants, Adhesives, Table 1.20-26. Lubrication System Engine
    And Lubricants ...................... 1.15 - 18 Transient Tift Angles ................. 1.20 - 25
    Table 1.20-27. Cooling System
    Section 1.20 - Specifications Temperatures ....................... 1.20 - 26
    Table 1.20-1. Wear Limits .................. 1.20 - 2 Table 1.20-28. Alarm And Shutdown
    Table 1.20-2. Cylinder Sleeve (Used With Setpoinis .. .. .. .. .. .. .. .. .. .. .. .. ... 1 .20 - 26
    Four Ring Pistons Only) - Gas ......... 1 .20 - 3 Table 1.20-29. Capacities ................. 1.20 - 27
    Table 1.20-3. Piston (Four Ring Only) - Gas . 1.20 - 4 Table 1.20-30. 1/2 Inch Reach Spark Plugs
    Table 1.20-4. Piston Rings (Used With 1/2 Inch Reach Spark Plug
    (Four Ring Piston Only) - Gas .......... 1.20 - 6 Carriers Only) .. .. .. .. .. .. .. .. .. .. ... 1 .20 - 27
    Table 1.20-5. PIN 205130L Cylinder Sleeve Table 1.20-31. VHP GL 13/16 Inch Reach
    (Sleeve Used On GL 9-3/8 Inch Spark Plugs (Used With 13/16 Inch
    Bore' Only) - Gas .................... 1.20 - 8 Reach Spark Plug Carriers Only) ...... 1 .20 - 28
    Table 1.20-6. Three Ring Piston (PIN 205504D) Table 1.20-32. Ignftion Timing Data
    (Piston Used On GL 9-3/8 Bore Wfth (Non-DSM) ......................... 1.20 - 30
    PIN 205130L Liner Only) - Gas ........ 1.20 - 9 Table 1.20-33. Ignftion Timing Data
    Table 1.20-7. Piston Rings (DSM Equipped) .................... 1.20 - 32
    (Used On GL 9-3/8 Inch Bore Wfth
    Three Ring Piston And PIN 205130L Section 3.00 - Cylinder Head
    Cylinder Sleeve Only) - Gas .......... 1.20 - 10 Disassembly
    Table 1.20-8. Crankcase - Gas ............ 1.20 - 11 Table 3.00-1. Rocker Arm Shafl ............ 3.00 - 3
    Table 1.20-9. Crankshaft Wear Limits ...... 1.20 - 12 Table 3.00-2. Rocker Arm Bushing Bore I.D. . 3.00 - 3
    Table 1.20-10. Piston Pin - Gas ........... 1.20 - 12 Table 3.00-3. Running Clearance -
    Table 1.20-11. PIN Series 205507 Rocker Arm Bushing To Shaft .......... 3.00 - 3
    Connecting Rod, Bushing And Table 3.00-4. Valve Train ................. 3.00 - 17
    Bearing SpecHications ............... 1.20 - 13
    Table 3.00-5. Valve Seat Insert Grinding
    Table 1.20-12. Valve Train Clearances - Stones ............................. 3.00 - 21
    Gas ............................... 1.20-14 Table 3.00-6. Valve Seat Width And
    Table 1.20-13. Valve Clearance ........... 1.20 - 17 Face Angle ......................... 3.00 - 22
    Table 1.20-14. Camshaft ................. 1.20 -17 Table 3.00-7. Valve Springs ............... 3.00 - 23
    Table 1.20-15. Valve Springs .............. 1.20 - 18 Table 3.00-8. Valve Spring Reference ...... 3.00 - 25

    Form 6248 First Edition xxxiii


    TABLES

    Section 3.05 - Crankcase Disassembly Table 5.00-2. Governor Speed


    Droop Settings ...................... 5.00 - 24
    Table 3.05-1. Crankcase - Gas ............. 3.05 - 2
    Table 5.00-3. Governor Speed
    Table 3.05-2. Cylinder Sleeve Gaskets ...... 3.05 - 3 Droop Settings ...................... 5.00 - 31
    Table 3.05-3. Restoration Sleeve And Table 5.00-4. EG-3P Governor Linkage
    Crankcase Lower Bore Machining Adjustment Information For LSI 08G,
    Dimensions .......................... 3.05 - 4 GSI; LS790G, GSI; L7042G, GSI ...... 5.00 - 38
    Table 3.05-4. Crankshaft Wear Limits ....... 3.05 - 7
    Table 3.05-5. Main Bearings ............... 3.05 - 8
    Section 5.10 - Ignition System
    Table 3.05-6. Camshaft ................... 3.05 - 14 Table 5.10-t. Spark Plug Tools ............. 5.10 - 5

    Table 3.05-7. Piston (Four Ring Only) - Gas 3.05 - 20 Table 5.10-2. Spark Plug Troubleshooting .... 5.10 - 7
    Table 5.10-3.112 Inch Reach Spark Plugs
    Table 3.05-8. Three Ring Piston
    (Used WHh 1/2 Inch Reach Spark Plug
    (PIN 205504D) (Piston Used On GL
    Carriers Only) ........................ 5.10 - 7
    9-3/8 Bore With PIN 205130L Liner
    Only) - Gas ......................... 3.05 - 22 Table 5.1 0-4. VHP GL 13/16 Inch Reach
    Spark Plugs (Used WHh 13/16 Inch
    Table 3.05-9. Piston Rings (Four Ring
    Reach Spark Plug Carriers Only) ....... 5.10 - 8
    Piston Only) - Gas .................. 3.05 - 24
    Table 5.10-5. Waukesha Ignition Module
    Table 3.05-10. Piston Rings
    Firing Order ......................... 5.10 - 24
    (Used On GL 9-3/8 Inch Bore With Three
    Ring Piston And PIN 205130L Cylinder Table 5.10-6. CEC Timing Disc Pin Location
    Sleeve Only) - Gas .................. 3.05 - 26 (Previous Production) ................ 5.10 - 29
    Table 3.05-11. Piston Pin - Gas ........... 3.05 - 32 Table 5.1 0-7. CEC Ignition Module Rotary
    SwHch PosHion (Previous Production) ., 5.10 - 29
    Table 3.05-12. Series PIN 205507
    Connecting Rod, Bushing And Section 5.15 - Air Induction System
    Bearing Specifications ............... 3.05 - 34
    Table 3.05-13. Connecting Rod Weight
    Classifications ...................... 3.05 - 38
    Table 5.15-1. High Intake Manifold
    Temperature Settings 0 F (0 C) .......... 5.15 - 1 )
    Table 3.05-14. Cylinder Sleeve (Used WHh Section 5.25 - Cooling System
    Four Ring Pistons Only) - Gas ........ 3.05 - 45
    Table 5.25-1. Water Versus Glycol
    Table 3.05-15. PIN 205130L Cylinder Sleeve Concentration ....................... 5.25 - 10
    (Sleeve Used On GL 9-3/8 Inch Bore' Table 5.25-2. Other Cooling System
    Only) - Gas ......................... 3.05 - 46
    Treatments ..........•.............. 5.25 - 11
    Section 4.00 - Crankcase Assembly Table 5.25-3. Jacket Water Outlet
    Temperature Settings 0 FCC) ......... 5.25 - 11
    Table 4.00-1. Crankshaft Thrust Rings ...... 4.00 - 27
    Table 5.25-4. Jacket Water Capacity -
    Table 4.00-2. Rear Gear Backlash Engine Only ........................ 5.25 - 13
    Specifications ....................... 4.00 - 34
    Table 5.25-5. Air Bleed Petcocks .......... 5.25 - 14
    Table 4.00-3. Pulleys And Spacers ......... 4.00 - 67
    Table 5.25-6. Water Drain Petcocks ........ 5.25 - 15
    Table 4.00-4. Attaching Hardware .......... 4.00 - 67
    Table 5.25-7. Jacket Water CapacHy -
    Engine Only ........................ 5.25 - 15
    Section 4.05 - Cylinder Head Assembly
    Table 5.25-8. PIN 208660 Series And
    Table 4.05-1. Cylinder Head Capscrews ..... 4.05 - 3 PIN 199221 Series Jacket Water
    Thermostats ........................ 5.25 - 37
    Section 4.10 - Valve Adjustment And
    Table 5.25-9. PIN 208627 Series -
    Web Deflection Weir Type Jacket Water Thermostats .. 5.25 - 37
    Table4.10-1.ValveSettings ............... 4.10-1 Table 5.25-10. Auxiliary Cooling Water
    Table 4.10-2. Crankshaft Web Deflection Thermostat - All Models .............. 5.25 - 58
    Measurement WHh Connecting Rods
    Installed ............................. 4.10 - 4 Section 5.30 - Lubrication System
    Table 5.30-1. Oil Recommendations By Model
    Section 5.00 - Speed Governing System And Fuel For VHP Series Gas Engines .. 5.30 - 4
    Table 5.00-1. UG-8 Governor Linkage Table 5.30-2. Recommended Lube Oils For
    Adjustment Information For LSl08G, Cogeneration Applications Using Pipeline
    GSI; LS790G, GSI; L7042G, GSI ...... 5.00 - 20 QualHy Gas . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 - 5

    xxxiv Form 6248 First Edition


    TABLES

    Table 5.30-3. Recommended Lube Oils For Table 6.05-4. DSM Diagnostic Codes
    Sour Gas And Alternate Fuel (Landfill) Troubleshooting ..................... 6.05 - 16
    Gas Applications ..................... 5.30 - 5
    Table 5.30-4. Used Oil Testing And Section 7.10 - Maintenance And Storage
    Condemnation ....................... 5.30 - 6 Table 7.00-1. Troubleshooting Table ......... 7.00 - 1
    Table 5.30-5. Recommended TBN Ratings ... 5.30 - 7 Table 7.10-1. Routine Maintenance Chart .... 7.10 - 1
    Table 5.30-6. Wear Metals ................. 5.30 - 8
    Table 7.10-2. Routine Inspection Form ...... 7.10 - 4
    Table 5.30-7. Sump Temperature And
    Table 7.10-3. Waukesha Engine Preservative
    SAE Number ......................... 5.30 - 9
    Oil Application ....................... 7.10 - 6
    Table 5.30-8. Sump And Header Temperatures
    And SAE Number ..................... 5.30 - 9 Table 7.10-4. Preservative Oils ............. 7.10 - 6
    Table 5.30-9. Oil Consumption ............. 5.30 - 9 Table 7.10-5. Protective Materials ........... 7.10 - 6
    Table 5.30-10. Duty Cycle Definitions ...... 5.30 - 10
    Table 5.30-11. Recommended Oil Change
    Intervals For Engines Receiving Normal
    Maintenance ........................ 5.30 - 10
    Table 5.30-12. Recommended Oil Change
    Intervals For Engines Receiving Normal
    Maintenance And Using Gaseous Fuel
    Containing H2S Or Liquid Fuel Containing
    Sulfur In Excess Of Published Limits .... 5.30 - 10
    Table 5.30-13. Lube Oil Filter Data ......... 5.30 - 14
    Table 5.30-14. Engine Oil Capacity ........ 5.30 - 15
    Table 5.30-15. Magnetic Plug Locations .... 5.30 - 16
    Table 5.30-16. Oil Cooler Thermostatic
    Valves - PIN 169867A Series ......... 5.30 - 22
    Table 5.30-17. Oil Pump And Oil Pump
    Drive Gears ......................... 5.30 - 35
    Table 5.30-18. Turbocharger Connections .. 5.30 - 43
    Section 5.35 - Exhaust System
    Table 5.35-1. Quick Disconnect Plug ....... 5.35 - 16
    Table 5.35-2. Air Bleed Petcocks -
    Auxiliary Cooling Water Circutt ........ 5.35 - 20
    Table 5.35--3. Nominal Pressure For
    PIN Series 208372 Wastegate
    Calibration Test ..................... 5.35 - 27
    Table 5.35-4. Adjustable Wastegate
    Settings - Draw Thru Engines Only .... 5.35 - 29
    Section 5.45 - Air/Gas Prelube And Start
    Systems
    Table 5.45-1. PIN 208569D Air Valves
    Inlet Pressures And Pilot Pressures
    To Shift ............................. 5.45 - 4
    Section 6.05 - Engine Protection
    Systems
    Table 6.05-1. Alarm And Shutdown Setpoints . 6.05 - 7
    Table 6.05-2. Remote Instrument Panel
    Annunciator Legend .................. 6.05 - 9
    Table 6.05-3. DSM Module LCD Message
    Display Diagnostic Codes ............ 6.05 - 15

    Fonn 6248 First Edition xxxv


    TABLES

    xxxvi Form 6248 First Edition


    HOW TO USE THIS MANUAL

    Your purchase of a L5108, L5790 or L7042G/GSI/GL ALWAYS BE ALERT FOR THE SPECIAL WARN-
    Series engine was a wise investment. In the industrial INGS WITHIN THE MANUAL TEXT. THESE WARN-
    engine field the name, Waukesha Engine, stands for INGS PRECEDE INFORMATION THAT IS CRUCIAL
    quality and durability. W~h normal care and mainte- TO YOUR SAFETY AS WELL AS OTHER PERSON-
    nance this engine will provide many years of reliable NEL WORKING ON OR NEAR THE ENGINE. CAU-
    service. TIONS OR NOTES IN THE MANUAL CONTAIN
    Before servicing your engine, read Chapter 1 very INFORMATION THAT RELATES TO POSSIBLE
    DAMAGE TO THE ENGINE OR ITS COMPONENTS
    carefully. This chapter covers Safety and General
    DURING ENGINE OPERATION OR MAINTENANCE
    Information.
    PROCEDURES.
    Section 1.00 - Warning Tags and Decal Location -
    This manual contains both repair and overhaul instruc-
    gives the location of all warning tags and decals and will
    tions for current L5108, L5790 or L7042G/GSI/GL
    show you a duplicate of each tag is in case the decals or
    engines. There are seven chapters w~hin the manual
    tags have been lost or damaged.
    and each chapter contains one or more sections. The
    Section 1.05 - Safety Section - Provides a list of title of each chapter or section appears at the top of
    dangers, warnings, cautions and notes to make you each page. To locate information on a specific topic,
    aware of the dangers present during operation and refer to the Table of Contents at the front of the manual
    maintenance of the engine. - READ THEM CAREFUL- or the Index at the back of the manual.
    LY AND FOLLOW THEM COMPLETELY -
    Recommendations and data contained in the manual is
    Section 1.15 - General Information - Provides basic the latest information available althe time ofthis printing
    data on all current L5108, L5790 or L7042G/GSI/GL and is subject to change w~hout notice. Since engine
    engines such as; engine plate data, component accessories may vary due to customer specifications
    weights, torque specifications and clearances. This consult your local distributor or Waukesha Engine
    section also supplies torque values of metric and Division Service Operations Department for any in-
    standard capscrews as well as conversion data. formation on subjects beyond the scope of this manual.

    FORM 6248 First Ednion xxxvii


    HOW TO USE THIS MANUAL

    xxxviii FORM 6248 First Edition


    CHAPTER 1 - SAFETY AND GENERAL

    CONTENTS

    SECTION 1.00 - WARNING TAG AND DECAL LOCATIONS

    SECTION 1.05 - SAFETY

    SECTION 1.10 - RIGGING AND LIFTING ENGINES

    SECTION 1.15 - GENERAL INFORMATION

    SECTION 1.20 - SPECIFICATIONS

    FORM 6248 First Edition


    )

    FORM 6248 First Ed~ion


    SECTION 1.00 - WARNING TAGS & DECAL LOCATIONS

    WARNING TAGS AND DECAL LOCATIONS

    A WARNING
    All warning tags and decals must be visible and
    readable to the operator when the engine Is run-
    ;J
    ~
    ~ II
    ning. Make sure all warning tags and decals remain
    legible and attached. Likewise, all warning tags and
    decals removed during any repair work must be
    replaced in their original position before the engine f ~ \
    Is placed back into service. Old or badly worn
    decals and tags should also be replaced. Failure to

    ~
    ~
    properly replace these important tags and decals
    )--
    I .J
    can result in serious personal injury or death. I~
    >-- I :a
    z
    I>--'
    Depending on the model, the VHP 12 Cylinder engines
    have warning tags located on:
    '--

    I
    I
    -
    Z
    C)
    '--

    • Each of the two starter (Air/Gas) motor inlet pipes at


    the rear of the engine.

    • The fuel gas regulators below each cylinder bank.


    Figure 1.00-1. Sample Of Warning Tag Placement
    • The fuel gas vent tube supply pipe connection
    adjacent to the flywheel.

    • On the carburetor throttle levers.

    • On the high voltage equipment.

    WARNING
    Recommended Gas Supply Pressure 5-10 PSI
    Maximum Gas Supply Pressure 12 PSI
    CUSTOMER OR END USER IS RESPONSIBLE FOR PROVISION
    OF OVERPRESSURE PROTECTION FOR GAS SUPPLY TO THIS
    REGULATOR AND FOR GAS SYSTEM COMPLIANCE WITH
    APPLICABLE CODES.
    ALL GAS VENTED FROM ENGINE COMPONENTS MUST BE PIPED
    TO A SAFE AREA IN ACCORDANCE WITH APPLICABLE CODES.
    OVerpressuring, Improper Venting Or Piping May Cause
    Gas Leakage And Possible Serious Personal Injury.
    2091078

    Figure 1.00-2. Warning Tag (PIN 2091078) - On Regulator(s), All Naturally Aspirated Gas Engines

    FORM 6248 First Edition 1.00 - 1


    WARNING TAGS & DECAL LOCATIONS

    WARNING
    This System Suitable For Air Or Clean Dry Natural Gas At A
    Maximum Supply Pressure Of 150 PSI

    CUSTOMER OR END USER IS RESPONSIBLE TO PROVIDE OVER-


    PRESSURE PROTECTION TO THIS SYSTEM
    ALL GAS VENTED FROM THIS SYSTEM SHALL BE PIPED TO A SAFE
    AREA IN ACCORDANCE WITH APPLICABLE CODES.
    Overpressuring, Improper Venting Or Piping And Possible Corrosion
    Caused By Using Natural Gas With Appreciable Amounts Of
    Hydrogen Sutfide May Cause Gas Leakage And Possible Serious
    Personal Injury.
    209107E

    Figure 1.00-3. Warning Tag (PIN 209107E)

    rn
    wa:
    ~O
    ~S
    WARNING
    RECOMMENDED GAS SUPPLY PRESSURE 25-40 PSI
    w:::l MAXIMUM GAS SUPPLY PRESSURE 50 PSI
    Del
    ~ll! CUSTOMER OR END USER IS RESPONSIBLE FOR PROVISION
    a: '"
    ..: '"
    OF OVERPRESSURE PROTECTION FOR GAS SUPPLY TO THIS
    REGULATOR AND FOR GAS SYSTEM COMPLIANCE WITH )
    i'i ffi APPLICABLE CODES.
    OI
    mrn ALL GAS VENTED FROM ENGINE COMPONENTS MUST BE PIPED
    ~ u: TO A SAFE AREA IN ACCORDANCE WITH APPLICABLE CODES.
    I-
    OVERPRESSURING, IMPROPER VENTING OR PIPING MAY CAUSE
    GAS LEAKAGE AND POSSIBLE SERIOUS PERSONAL INJURY.
    209107H

    Figure 1.00-4. Warning Tag (PIN 209107H) - On Fisher 99 Regulator(s), Turbocharged Gas Engines

    WARNING
    RECOMMENDED GAS SUPPLY PRESSURE 0.75-5 PSI
    MAXIMUM GAS SUPPLY PRESSURE B PSI
    CUSTOMER OR END USER IS RESPONSIBLE FOR PROVISION
    OF OVERPRESSURE PROTECTION FOR GAS SUPPLY TO THIS
    REGULATOR AND FOR GAS SYSTEM COMPLIANCE WITH
    APPLICABLE CODES.
    ALL GAS VENTED FROM ENGINE COMPONENTS MUST BE PIPED
    TO A SAFE AREA IN ACCORDANCE WITH APPLICABLE CODES.
    OVERPRESSURING, IMPROPER VENTING OR PIPING MAY CAUSE
    GAS LEAKAGE AND POSSIBLE SERIOUS PERSONAL INJURY.
    209107L

    Figure 1.00-5. Warning Tag (PIN 209107L) - On Fisher 66 Regulator(s), Naturally Aspirated, Low Btu Engines

    1.00 - 2 FORM 6246 First Edition


    WARNING TAGS & DECAL LOCATIONS

    A WARNING
    MAXIMUM GAS SUPPLY PRESSURE TO REGULATOR 50 PSI
    ~

    CUSTOMER OR END USER IS RESPONSIBLE FOR PROVISION


    iii OF OVERPRESSURE PROTECTION FOR GAS SUPPLY TO THIS

    '"oill REGULATOR AND FOR GAS SYSTEM COMPLIANCE WITH


    APPLICABLE CODES.

    ALL GAS VENTED FROM ENGINE COMPONENTS MUST BE PIPED

    iii'"
    w TO A SAFE AREA IN ACCORDANCE WITH APPLICABLE CODES.

    u: OVERPRESSURING, IMPROPER VENTING OR PIPING MAY CAUSE


    GAS LEAKAGE AND POSSIBLE SERIOUS PERSONAL INJURY.
    209107R

    Figure 1.00-6. Warning Tag (PIN 209107R) - On Fisher 99 And S211 Regulator(s), Turbocharged Engines

    ~
    :'l

    Bi5
    w
    WARNING
    RECOMMENDED GAS SUPPLY PRESSURE 5-20" W.C.
    ~~ MAXIMUM GAS SUPPLY PRESSURE 22" W.C.

    ~ => CUSTOMER OR END USER IS RESPONSIBLE FOR PROVISION


    ~ OF OVERPRESSURE PROTECTION FOR GAS SUPPLY TO THIS
    0'" PRESSURE REDUCTION VALVE AND FOR GAS SYSTEM
    ~M! COMPLIANCE WITH APPLICABLE CODES.

    ;;:ijl ALL GAS VENTED FROM ENGINE COMPONENTS MUST BE PIPED


    ffl TO A SAFE AREA IN ACCORDANCE WITH APPLICABLE CODES.

    'a." OVERPRESSURING, IMPROPER VENTING OR PIPING MAY CAUSE


    GAS LEAKAGE AND POSSIBLE SERIOUS PERSONAL INJURY.
    209107U

    Figure 1.00-7. Warning Tag (PIN 209107U) - On IMPCO (MAXITROL) Pressure Reduction Valve, Used With 5 - 20"
    Water Column Gas Pressure

    A WARNING

    o THIS ENGINE HAS BEEN ORDERED AND BUILT WITHOUT WAUKESHA


    ENGINE DIVISION DESIGNED ENGINE SAFETY SHUT-DOWN EQUIPMENT.

    ENGINE MUST BE PROVIDED WITH FUEL SHUT-OFF TYPE SAFETY


    EQUIPMENT TO PREVENT ENGINE DAMAGE AND POSSIBLE
    PERSONAL INJURY OR LOSS OF LIFE.

    REFER TO W.E.D. SA7232-40 FOR RECOMMENDED


    SAFETY EQUIPMENT AND SETTINGS.

    209107K

    Figure I.DO-B, Warning Tag (PIN 209107K) - On Carburetor Throttle Lever For Engines Ordered And Built Without
    Waukesha Engine Division Designed Engine Safety Shutdown Equipment

    FORM 6248 First Edition 1,00 - 3


    WARNING TAGS & DECAL LOCATIONS

    A WARNING
    GAS VENT CONNECTION

    CUSTOMER OR END USER IS RESPONSIBLE FOR VENTING OF


    GAS FROM THIS CONNECTION, AND PIPING TO A SAFE AREA
    TO MEET APPLICABLE CODES.

    IMPROPER VENTING CAN CAUSE GAS LEAKAGE AND


    POSSIBLE SERIOUS PERSONAL INJURY.

    209107-P

    Figure 1.00-9. Warning Tag (pIN 209107P) - For Gas Vent On Prelube Systems That Use Natural Gas For Prelube
    Motor

    )
    Figure 1.00-10, Warning Tag (pIN 20B840A) -
    On High Voltage Equipment

    1.00 - 4 FORM 6248 First Edition


    SECTION 1.05 - SAFETY

    SAFETY INTRODUCTION SAFETY TAGS AND DECALS


    The following safety precautions are published for your
    information. Waukesha Engine Division, Dresser Indus-
    tries, Inc., does not, by the publication of these
    A WARNING
    precautions, imply or in any way represent that they are To avoid severe personal injury or death, all
    the sum of all dangers present near industrial engines or warning tags and decals must be visible and legible
    fuel rating test units. If you are installing, operating or to the operator while the equipment is operating.
    servicing a Waukesha product, it is your responsibility to
    ensure full compliance with all applicable safety codes
    and requirements. All requirements of the Federal EQUIPMENT REPAIR AND SERVICE
    Occupational Safety and Health Act must be met when Proper maintenance, service and repair are important
    Waukesha products are operated in areas that are to the safe, reliable operation of the unit and related
    under the jurisdiction of the United States of America. equipment. Do not use any procedure not recom-
    Waukesha products operated in other countries must mended in the Waukesha Engine manuals for this
    be installed, operated and serviced in compliance with equipment.
    any and all applicable safety requirements of that
    country.
    For details on safety rules and regulations in the United
    A WARNING
    States, contact your local office of the Occupational To prevent severe personal injury or death, always
    Safety and Health Administration (OSHA). stop the unit before cleaning, servicing or repairing
    The words "danger", "warning", "caution" and "note" are the unit or any driven equipment.
    used throughout this manual to highlight important Place all controls in the OFF position and disconnect or
    information. Be certain thatthe meanings ofthese alerts lock out starters to prevent accidl\htal restarting. If
    are known to all who work on or near the equipment. possible, lock all controls in the OFF position and take
    NOTE: This symbol identifies information which is the key. Put a sign on the control parilll warning that the
    NECESSARY TO THE PROPER OPERATION, MAIN- unit is being serviced. -
    TENANCE OR REPAIR OF THE EQUIPMENT. Close all manual control valves, disconnect and lock out
    all energy sources to the unit, including all fuel, electric,
    A
    IL.
    CAUTION IThiss~mbolidentlfiesin- hydraulic, and pneumatic connections.
    • .=
    .=;.....;;..........;;....
    . ___"-----'. formation about hazards Disconnect or lock out driven equipment to prevent the
    or unsafe practices. Disregarding this information possibility of the driven equipment rotating the disabled
    could result In PRODUCT DAMAGE AND/OR PER- engine.
    SONAL INJURY.

    A WARNING
    A WARNING To avoid severe personal injury or death, ensure
    This symbol identifies information about hazards or that all tools and other objects are removed from the
    unsafe practices. Disregarding this information unit and any driven equipment before restarting the
    could result in SEVERE PERSONAL INJURY OR unit.
    DEATH.

    A WARNING
    A DANGER Allow the engine to cool to room temperature
    This symbol identifies information about immediate before cleaning, servicing or repairing the unit. Hot
    hazards. Disregarding this information will result in components or fluids can cause severe personal
    SEVERE PERSONAL INJURY OR DEATH. injury or death.

    Some engine components and fluids are extremely hot


    even after the engine has been shut down. Allow
    sufficient time for all engine components and fluids to
    ) cool to room temperature before attempting any service
    procedure.

    FORM 6248 First Edition 1.05 - 1


    SAFETY

    ACIDS LIQUID NITROGEN/DRY ICE


    )
    A WARNING A WARNING
    Comply with the acid manufacturer's recommenda- Comply with the liquid nitrogen/dry ice manufactur-
    tions for proper use and handling of acids. Improp- er's recommendations for proper use and handling
    er handling or misuse could result In severe of liquid nitrogen/dry ice. Improper handling or use
    personal Injury or death. could result in severe personal injury or death.

    BATTERIES COMPONENTS
    HEATED OR FROZEN
    A WARNING
    Comply with the battery manufacturer's recommen- A WARNING
    dations for procedures concerning proper battery Always wear protective equipment when Installing
    use and maintenance. Improper maintenance or or removing heated or frozen components. Some
    misuse could result in severe personal injury or components are heated or cooled to extreme
    death. temperatures for proper installation or removal.
    Direct contact with these parts could cause severe
    personal injury or death.
    BODY PROTECTION
    INTERFERENCE FIT
    A WARNING
    Always wear OSHA approved body, sight, hearing
    I A WARNING
    and respiratory system protection. Never wear Always wear protective equipment when installing )
    loose clothing, jewelry or long hair around an or removing components with an Interference fit.
    engine. The use of improper attire or failure to use Installation or removal of interference components
    protective equipment may result in severe personal may cause flying debris. Failure to use protective
    injury or death. equipment may result In severe personal injury or
    death.

    CHEMICALS
    COOLING SYSTEM
    GENERAL

    A WARNING
    A WARNING
    Always wear protective clothing when venting,
    Always read and comply with safety labels on all flushing or blowing down the cooling system.
    containers. Do not remove or deface the container Operational coolant temperatures can range from
    labels. Improper handling or misuse could result In 180° - 250° F (82° -121° C). Contact with hot coolant
    severe personal injury or death. or coolant vapor can cause severe personal injury
    or death.
    CLEANING SOLVENTS

    A WARNING A WARNING
    Comply with the solvent manufacturer's recom- Do not service the cooling system while the engine
    mendations for proper use and handling of sol- is operating or when the coolant is hot. Operational
    vents. Improper handling or misuse could result in coolant temperatures can range from 180° - 250° F
    severe personal injury or death. Do not use gaso- (82° - 121 ° C). Contact with hot coolant or vapor can
    line, paint thinners or other highly volatile fluids for cause severe personal injury or death.
    cleaning.

    1.05 - 2 FORM 6248 First Ednion


    SAFETY

    ELECTRICAL FIRE PROTECTION


    GENERAL
    A WARNING
    A WARNING Refer to local and federal fire regulations for
    guidelines for proper site fire protection. Fires can
    Do not install, set up, maintain or operate any
    cause severe personal injury or death.
    electrical components unless you are a technically
    qualified Individual who Is familiar wHh the electri-
    cal elements involved. Electrical shock can cause
    severe personal Injury or death. FUELS
    GENERAL
    A WARNING
    A WARNING
    Disconnect all electrical power supplies before
    making any connections or servicing any part of the Ensure that there are no leaks in the fuel supply.
    electrical system. Electrical shock can cause se- Engine fuels are highly combustible and can Ignite
    vere personal injury or death. or explode causing severe personal injury or death.

    IGNITION GASEOUS

    A WARNING A WARNING
    Avoid contact with ignition units and wiring. Igni- Do not inhale gaseous fuels. Soltl&components of
    tion system components can store electrical ener- fuel gas are odorless, tasteless, ~d highly toxic.
    gy and if contacted can cause electrical shocks. Inhalation of gaseous fuels can cause severe
    Electrical shock can cause severe personal Injury personal injury or death.
    or death.

    A WARNING
    I AWARNI~ I
    Shut off the fuel supply if a ga~us engine has
    Properly discharge any electrical component that been cranked excessively without starting. Crank
    has the capability to store electrical energy before the engine to purge the cylinders and exhaust
    connecting or servicing that component. Electrical system of accumulated unburned fuel. Failure to
    shock can cause severe personal injury or death. purge accumulated unburned fuel In the engine and
    exhaust system can result In an explosion resulting
    in severe personal Injury or death.
    EXHAUST
    LIQUID

    A WARNING A WARNING
    Do not inhale engine exhaust gases. Exhaust gases
    Do not Ingest liquid fuels or breathe In their vapors.
    are highly toxic and could cause severe personal
    Liquid fuels may be highly toxic and can result in
    injury or death.
    severe personal injury or death.
    Ensure exhaust systems are leak free and that all
    exhaust gases are properly vented.
    A WARNING
    A WARNING Use protective equipment when working with liquid
    fuels and related components. Liquid fuel can be
    Do not touch or service any heated exhaust absorbed into the body resulting In severe personal
    components. Allow sufficient time for exhaust Injury or death.
    components to cool to room temperature before
    attempting any service procedure. Contact with hot
    exhaust system components can cause severe
    personal injury or death.

    FORM 6248 First Edition 1.05 - 3


    SAFETY

    INTOXICANTS AND NARCOTICS SPRINGS


    )
    A WARNING A WARNING
    Do not allow anyone under the Influence of Intoxi- Use appropriate equipment and protective gear
    cants and/or narcotics to work on or around when servicing or using products that contains
    industrial engines. Workers under the influence of springs. Springs, under tension, can eject If im-
    intoxicants and/or narcotics are a hazard both to proper equipment or procedures are used. Failure
    themselves and other employees and can cause to take adequate precautions can result in serious
    severe personal injury or death to themselves or personal injury or death.
    others.

    TOOLS
    PRESSURIZED FLUIDS/GAS/AIR
    ELECTRICAL

    A WARNING A WARNING
    Never use pressurized fluids/gas/air to clean cloth-
    Do not install, set up, maintain or operate any
    ing or body parts. Never use body parts to check for
    electrical tools unless you are a technically quali-
    leaks or flow rates. Pressurized fluids/gas/air in-
    fied individual who is familiar with them. Electrical
    jected into the body can cause severe personal
    tools use electricity and if used improperly could
    injury or death.
    cause severe personal injury or death.
    Observe all applicable local and federal regulations
    relating to pressurized fluid/gas/air. HYDRAULIC

    PROTECTIVE GUARDS
    A WARNING
    Do not install, set up, maintain or operate any

    A WARNING
    hydraulic tools unless you are a technically quali-
    fied Individual who is familiar with them. Hydraulic
    Provide guarding to protect persons or structures tools use extremely high hydraulic pressure and if
    from rotating or heated parts. Contact with rotating used improperly could cause severe personal
    or heated parts can result in severe personal injury injury or death.
    or death.
    It is the responsibility ofthe engine owner to specify
    and provide guarding.
    IA CAUTION I
    L..
    Always follow recom-
    mended procedures
    ==-,.;;;;.;;..:...;;;;....:...;;...;:;...:...;:...J.
    when using hydraulic tensioning devices. Improper
    use of hydraulic tensioning tools can cause severe
    SODIUM COOLED VALVE engine damage.

    PNEUMATIC
    A DANGER
    Do not cut or break open sodium cooled exhaust
    valves. Contact with sodium will cause severe
    A WARNING
    Do not install, set up, maintain or operate any
    personal injury or death. pneumatic tools unless you are a technically
    Contact local waste management authorities to dispose qualified Individual who Is familiar with them.
    of sodium cooled valves per local or federal codes. Pneumatic tools use pressurized air and if used
    improperly could cause severe personal injury or
    death.

    1.05 - 4 FORM 6245 First Edilion


    SAFETY

    WELDING
    GENERAL

    A WARNING
    Comply with the welder manufacturer's recommen-
    dations for procedures concerning proper use of
    the welder. Improper welder use can result in severe
    personal injury or death.

    ON ENGINE

    IA CAUTION I Ensure that the welder Is


    ....:aa=,--,,"--_,-_-,--,. properly grounded be-
    fore attempting to weld on or near an engine. Failure
    to properly ground the welder could result in severe
    engine damage.

    A CAUTION I
    I-=aa=~=..:.::::...;;.;:..;::;..;~.
    L.
    Disconnect the ignition
    harness before welding
    on or near an engine to eliminate charging of an
    ignition system capacitor. Failure to disconnect the
    ignition harness could result in severe engine
    damage.

    WEIGHT

    A WARNING
    Always consider the weight of the item being lifted
    and use only properly rated lifting equipment and
    approved lifting methods. Failure to take adequate
    precautions can result in serious personal injury or
    death.

    A WARNING
    Never walk or stand under an engine or component
    while it is suspended. Failureto adhere to this could
    result in severe personal injury or death.

    FORM 6248 First Edttion 1.05 - 5


    SAFETY

    1.05 - 6 FORM 6248 First Ednion


    SECTION 1.10 - RIGGING AND LIFTING ENGINES

    ENGINE RIGGING AND LIFTING LOCATION OF THE LIFTING EYES

    A WARNING A WARNING
    Exercise extreme care when moving the engine or Always lift the engine using the approved lifting
    its components. Never walk or stand directly under eyes. The VHP 12 cylinder gas engines are
    an engine or component while It Is suspended. equipped with two pairs of lifting eyes, one pair on
    Always consider the weight of the engine or the each cylinder bank. Lifting eyes are only meant for
    components involved when selecting hoisting lifting the engine. Do not use to 11ft driven or
    chains and lifting equipment. Be positive about the auxiliary equipment that may be attached to the
    rated capacity of lifting equipment. Use only prop- engine. Disregarding this Information could result
    erly maintained lifting equipment with a lifting in severe personal injury or death.
    capacity which exceeds the known weight of the
    object to be lifted. Disregarding this Information The VHP 12 cylinder engine is equipped with two pairs
    of lifting eyes, one pair on each cylinder bank. A
    could resuH in severe personal injury or death.
    spreader beam (P/N 494363B), is needed for the proper
    Table 1.10-1 shows the approximate dry weight of the method of lifting the engine. The lifting eyes are only
    VHP 12 Cylinder gas engines. meantfor lifting the engine. Do not use the lifting eyes to
    lift driven equipment that may be attached to the engine.
    Table 1 10-1 Engine Dry Weights
    WEIGHT CORRECT METHOD OF RIGGING AND LIFTING
    ENGINE ENGINE
    Ibs. kg
    Lifting chains should be positioned so that they do not
    L510BG 20.500 9,300
    rub or bind against parts of the engine. A properly rigged
    L510BGSI 21,000 9,525
    engine will be able to be lifted in such a manner that the
    5108GL 21,000 9,525 chains will not damage the engine. See Figure 1 .10-1
    L5790G 20,500 9,300 and Figure 1.10-2 for examples of engine lifting.
    L5790GSI 21,000 9,525
    5790GL
    L7042G
    21,000
    20,500
    9,525
    9,300
    A WARNING
    To avoid severe personal injury or death, follow
    L7042GSI 21,000 9,525 approved rigging procedures to ensure that no
    7042GL 21,000 9,525 undue strain is placed on the lifting eyes and
    hoisting chains/cable sling when the engine is
    raised. Use the proper spreader beam to avoid
    damage to the cylinder head studs.

    Figure 1.10-1. Correct Method Of Lifting Engine - Side Views

    FORM 6248 First Ednion 1.10 -1


    RIGGING AND LIFTING ENGINES

    Figure 1.10-2. Correct Method of Lifting Engine-


    Rear View

    1.10 - 2 FORM 6248 First Edition


    SECTION 1.15 - GENERAL INFORMATION

    SECTION MAIN POINTS: • DONT check parts for precision fH if they are
    abnormally hot or cold. Temperature will greatly affect
    • Overview of the overhaul and repair process, dimensions, especially large diameters. DO measure
    including general considerations before starting the all parts at room temperature, or check composite
    work such as engine handling and removal. assembly pieces at the same temperature.
    • Engine description, details and specifications. • DONT jump from one subassembly to another. DO
    complete each subassembly from start to finish.
    • Specialized engine tool list.
    • DONT reassemble the engine in a contaminated
    • Conversion tables. parts cleaning area. DO keep the overall assembly
    OVERHAUL/REPAIR PROCESS area free from flying foreign particles which will settle
    on and contaminate the engine. Cover the exposed
    Overhaul is the complete disassembly, examination, engine with a sheet of plastic at the end of each day.
    repair or replacement of components, and reassembly When a component is removed, seal the engine
    of the entire engine. Repair deals strictly with individual opening to prevent foreign material from entering the
    engine components. When properly planned and engine.
    executed, the overhaul and repair process can be
    effectively completed in a safe and timely manner. • DO work in a safe environment. No job should be
    started if it cannot be finished safely and correctly.
    PREVENTING ENGINE DAMAGE
    Throughout this manual CAUTIONS and NOTES HANDLING AND SHIPPING
    emphasize procedural items which need to be carefully Whenever an overhaul of an VHP series engine is
    followed to avoid serious engine damage. Other points anticipated, a decision must be made to do the work on
    to remember are: site or remove the engine to a mO$"'suitable overhaul
    facility. Factors which can effect your decision are:
    • DO NT assume that procedures used for other
    engines also apply to the VHP engine series. DO be • Operational requirements of the user. What is the
    certain of procedures and information for this specific owner's turn-around time?
    engine before starting the work.
    • Adequate lifting equipment. Is the proper lifting
    • DONT remove gears, pulleys and other related parts equipment available? Can it be safely used on site?
    by prying or pounding. DO use the correct pullers or
    special tools. • Cleanliness of the site. A reasonably clean reas·
    sembly area will be required.
    • DONT throw nuts and bolts into a Single box or
    container. DO identify and store nuts and bolts • Proximity of an adequate overhaul facility.
    according to their proper assemblies. Different Realistically, most VHP series engine overhauls will be
    lengths and grades of bolts are used for specific done on site. Practicality and customer requirements
    purposes in certain applications. will be the determining factors. The VHP series engine
    was originally designed so that it could be easily
    • DONT use parts from another engine. These. parts
    serviced on site. Only the most unusual situations will
    have wear-in patterns that may not match in another
    require the removal olthe engine. lithe engine work will
    engine. DO use new parts, if replacement is
    be done on site, then some external engine connections
    necessary.
    may not need to be disconnected. Common sense,
    • DONT try to compensate for torque wrench length· practicality and safety need to be your guidelines in
    ening. DO use the correct tool and torque values. such a situation. However, if engine removal from the
    site is necessary, use the steps that follow.
    • DO NT force parts together. DO look for burrs,
    foreign material or improper fHs if an assembly is
    difficult to put together.

    • DONT inspect a part for precision fit if it is oil


    varnished, rusty or carbonized. DO clean parts first.
    ) True fits cannot be calculated until true, accurate
    measurements are taken. Keep records of the
    engine history for yourself and the customer.

    FORM 6248 First Edition 1.15·1


    GENERAL INFORMATION

    2. Disconnect driven equipment from the engine


    A WARNING flywheel. )
    Use extreme care when working on or near engine 3. Drain and properly discard coolant from the engine
    installations. Make sure all fuel supply lines are and cooling system.
    CLOSED and all electrical power is OFF. Place all
    engine controls in the OFF position to prevent 4. Disconnect coolant lines from the inlet and outlet
    accidental restarting. If possible, lock all controls engine connections.
    in the OFF position and take the key. Place a sign on
    the instrument panel advising that the engine Is 5. Drain and properly discard lubricating oil from the oil
    being serviced. Never attempt any work on an pan, filter and cooler. Disconnect the oil fi~er lines.
    engine while it is running. Disregarding this
    information could result in severe personal injury 6. Disconnect or remove air intake equipment.
    or death. 7. Disconnect engine exhaust connections.
    ENGINE REMOVAL 8. Remove any auxiliary instrument panels and sup-
    ports. Disconnect wiring cables, fuel lines, throttle
    A WARNING linkage and any other accessory controls as required.

    Fluids in the engine remain hot after the engine is


    shutdown. These hot fluids can cause severe A WARNING
    burns. Use care when working with engine fluid Never walk or stand under an engine or component
    connections. Wait until the engine and Its fluids while it is suspended. Always consider the weight
    cool down before proceeding with any service. of the engine or component and use only properly
    Disregarding this information could result in se- rated lifting equipment and approved lifting meth-
    vere personal Injury or death. ods. Make sure the transport vehicle is adequate to
    handle the weights involved and can safely move
    IA
    ..
    CAUTION IBe sure to follow the
    correct shutdown proce-
    the engine. Disregarding this information could
    result in severe personal injury or death.
    )

    dures before starting any work on the engine.


    When the engine is disconnected from its support NOTE: See Section 1.02 of this manual for correct
    equipment, be sure to seal all engine openings to lifting methods and component weights.
    prevent dirt and moisture from entering. Disregard-
    Ing this information could result in product dam- CAUTION I
    I A=:......:=...:..:;;....;;..:.=...;:...:...J.
    Follow approved rigging
    age and/or personal injury. .L .::
    .. procedures so that no
    undue strain is placed on the lifting eyes and

    IA
    ..
    CAUTION I An approved engine
    shippmg Skid, designed
    hoisting chains/cable sling when the engine is
    raised. Use the proper lifting device to avoid
    product damage and/or personal injury.
    to remain with the engine during any handling and
    shipping, should be used. This skid is available 9. USing a suitable lifting device carefully lift engine as
    from Waukesha Engine. If this skid is already required.
    attached, do not remove It. If not present, arrange
    to get the skid to the site before engine removal is
    attempted. Disregarding this information could
    result in product damage and/or personal Injury.

    NOTE: Tag al/ electrical, pneumatic, fuel, coolant and


    lubrication oi/lines to ensure correct reassembly.

    1. Check the installation for potential problems. If


    problems are found, ensure that corrections are made
    before the engine is reinstalled. Consu~ the Waukesha
    Engine Installation Manual, Form 1091-1 thru 8, and
    the VHP 12 cylinder gas engine Installation Drawings
    for installation recommendations.

    1.15 - 2 FORM 6248 First Edition


    GENERAL INFORMATION

    SERIAL NUMBER AND ENGINE When requesting information about the engine or parts,
    NAMEPLATE ~ is important to reference both the engine model
    number and serial number. If the nameplate is defaced
    The engine model, size, specification, serial, and or detached, the serial number can be obtained directly
    governing speed numbers are stamped on a nameplate from the crankcase. It is stamped on the left firing deck,
    (see Figure 1.15-1 and Figure 1.15-2). This nameplate just forward of the No. 1L cylinder head.
    is mounted on the left side of the crankcase just below
    the No. 1L cylinder head.

    Figure 1.15-1. Nameplata - Currant Production

    , Figure 1.15-2. Nameplate - Previous Production


    )

    FORM 6248 First Edition 1.15 - 3


    GENERAL INFORMATION

    ENGINE IDENTIFICATION VIEWS


    RIGHT SIDE VIEW

    1. Exhaust Manifold Assembly, (Right Bank) 12. Lube Oil Dipstick (Right Bank)
    2. Jacket Water Pump 13. Regulator, Gas (Right Bank)
    3. Governor 14. Cariburetor (Right Bank)
    4. Governor Speed Control Hand Lever 15. Manual Shutdown Lever
    5. Vibration Damper 16. Lube Oil Strainer
    6. Lube Oil Pump 17. Engine Leveling Bolts (Right Bank)
    7. Magneto Drive 18. Lube Oil Drain (Right Bank)
    8. Water Drains (Right Bank) 19. Control Panel (Right Bank)
    9. Magneto Adapter 20. ExhaustThermocouple Assembly
    10. CEC Ignition Module 21. Engine Ignition Power 24 von DC
    11. Regulator, Prechamber Manifold 22. Thermocouple Control Box!
    CEC Ignition Junction Box

    )
    Figure 1.15-3. Right Side View - 12 CylinderVHP GL

    1.15-4 FORM 6248 First Edition


    GENERAL INFORMATION

    LEFT SIDE VIEW

    1. Thermostat Cluster Housing 11. Lube Oil Pan


    2. Waler Manifold 12. Regulator, Gas (Left Bank)
    3. Venturi Extractor 13. Lube Oil Dipstick (Left Bank)
    4. Exhaust ManHold Assembly, (Left Bank) 14. Crankcase
    5. Lube Oil Filler 15. Engine Leveling Bolts (Left Bank)
    6. Flywheel and Housing 16. Prelube Pump and Motor
    7. Manual Barring Device 17. Crankcase Breather (2)
    8. Lube Oil Drain (Left Bank) 18. Safety Guarding
    9. Lube Oil Pan Access Doors (Left Bank) 19. Control Panel (Left Bank)
    10. Engine Jacket Water Drains (Left Bank)

    Figure 1.15-4. Left Side View - 12 CylinderVHP GL

    FORM 6248 First Edition 1.15 - 5


    GENERAL INFORMATION

    REAR VIEW
    )

    1. Flexible Exhaust Connection 6. Air Cleaners (2)


    2. Wastegates (2) 7. Prechamber Manifolds (2)
    3. Turbochargers (2) 8. Intake Manifolds (2)
    4. Lifting Eyes (4) (2 each front and rear) 9. Carburetors (2)
    5. Cylinder Head Assemblies (12) 10. Intercooler
    11. Auxiliary Pump Inlet

    Figure 1.15-5. Rear View -12 CylinderVHP GL

    1.15 - 6 FORM 6248 First Edition


    GENERAL INFORMATION

    BASIC ENGINE DESCRIPTION


    The Waukesha VHP 12 cylinder gas engine series has
    the following models; L5108G/GSI, 5108GL,
    L5790G/GSI, 5790GL, L7042G/GSI, and 7042GL.
    Engines designated "G", are naturally aspirated. En-
    gines designated "GSI" are turbocharged and inter-
    cooled. Engines designated "GL" are turbocharged,
    intercooled and lean combustion.
    All engines are four cycle and rotate in the standard
    counter-clockwise direction, as viewed from the rear
    (flywheel) end. The 12 cylinders are arranged in a
    V-configuration, six on each bank. The crankcase is a
    single piece, rigid gray iron casing. The main bearings
    are replaceable. The main bearing caps are held in
    place with vertical studs and lateral tie bolts. The
    counterweighted crankshaft is made of forged steel and
    has seven main bearing journals. Each engine is
    equipped with viscous vibration dampers.
    There are 12 interchangeable cylinder heads, each with
    two Stellite® faced intake and two Stellite® faced
    exhaust valves. Both exhaust and intake valve seat
    inserts are also Stellite® faced. Roller type valve lifters
    and hydraulic push rods are standard. The camshaft
    consists of two individual segments. The connecting
    rods are made from drop forged steel and are rifle
    drilled. The cylinders have replaceable wet cylinder
    sleeves. The pistons are aluminum alloy with full
    floating piston pin. The flywheel is machined and has a
    ring gear attaChed.
    The exhaust driven turbocharger compresses intake
    air. This charged air is cooled in the intercooler then
    enters the carburetor and mixes with pressurized fuel
    gas. The turbocharged air/fuel mixture enhances the
    engine's power and performance.
    The pressurized lubricating system consists of an oil
    sump, gear driven pump, piping network, filters,
    strainers and cooler. The full flow oil filter is externally
    mounted, separate from the engine. The system also
    consists of an externally mounted oil cooler.
    The cooling system has two water pumps. The main
    water pump is belt driven and circulates the jacket water
    of the engine. The other belt driven pump, the auxiliary
    water pump, circulates water for the oil cooler and the
    intercooler. The engine jacket, cylinder heads, exhaust
    manifold, turbocharger, oil and charged intake air are all
    water cooled.
    NOTE: "Stellite® is a registered trademark of Stoody
    De/oro Ste//ite, /nc."

    FORM 6248 First Edition 1.15-7


    GENERAL INFORMATION

    SERVICE TOOLS LIST some instances, substitute items may be used, but only
    Table 1.15-1 lists the available tools to perform the
    if specifically approved by Waukesha. To order these )
    special tools, contact your local Waukesha Engine
    tasks indicated on VHP 12 cylinder gas engines. In
    Distributor.
    Table 1.15-1. Service Tools
    WAUKESHA WAUKESHA
    TOOLP/N TOOL DESCRIPTION TOOL DESCRIPTION
    TOOLP/N
    1671640 Spark Plug Socket/Ext. (1 inch socket wnh 10 494235 Flexible Cylinder Hone
    inch extension, for Shielded, eSA wI EM. coils)
    494236 Flexible Cylinder Hone
    474001 Camshaft Bearing Rollout Tool
    494255 Valve Spring Compressor
    474003 Reducer
    494292 Crankshaft Deflection Gauge
    474005 Stop Sleeve
    494256 Digital Pyrometer
    474007 Prechamber Removing Collet (5108GL only)
    494257 Valve Guide Remover
    474008 Screw Extractor
    494258 Slack Tube Manometer
    474013 Water Pump Kit
    494261 VHP Hand Tool Kit
    474016 VHP V- BeitTester
    494262 Depth Gauge
    474018 Pistoo Puller (8.5 inch bore)
    494264 Adapter kn
    474019 Piston Puller
    494266 Socket
    474020 Valve Seat Installer
    494267 Extension
    474023 Spark Plug Carrier Tool (CSA)
    494268 Socket
    475000 Infrared Thermometer
    494269 Torque Multiplier
    475004 Control Display Unn
    494272 Torque Wrench
    475005 Digital Thermometer
    494273 Torque Wrench
    475006 Spark Plug Gapper
    475007 Oxygen Analyzer
    494276 Digital Tachometer )
    494277 Valve Grinder
    475015 Filter (Box Of Ten)
    494278 Dial Indicator
    475019 Torque Wrench
    494014 VaNe Seat Grinding Stone (20 0 Seat Angle Stone)
    475020 Standard Borescope Kit
    494305 Valve Seat Grinding Stone (30 0 Seat Angle
    475022 DC Battery Pack Stone, Current Wide Bridge Heads)
    475023 AC/DC Ught Source Cable 494283 Magnaflux@ Dye Penetrant Kit
    475025 Deluxe Borescope Kit 494264 Bottom Plate
    475026 Regulator Adjuster 494286 Bottom Plate
    475028 Digital Manometer/Calibrator Kit 494287 Valve Adjusting Wrench
    475032 CEe Ignition Tester 494286 Dial Indicator Kit
    Spark Plug Socket (NEW) \1/8 inch Socket 494289 Spark Plug Carrier Tool (Non CSA)
    475037 wtrubber insert) (Deeigned to fit over standard and
    CSA spark plug extension) 494290 Prechamber Remover
    494019 Piston Ring Spreader 494292 Deflection Gauge
    494023 AdapterKn 494331 Valve Guide Machining Tool
    494029 O-Ring Lube 494335 Valve Seat Installation Tool
    494085 Piston Ring Compressor (8-1/2 inch bore) 494336 Inducllon Timing Light
    494086 Piston Ring Compressor 494344 Pilot
    494087* Spark Plug Thread and Seat Cleaner (18 mm) 494345 Exhaust Probe
    494152 Piston Ring Compressor 494346 Exhaust Probe
    494208 Pistoo Ring Compressor (9-3/8 inch bore) 494357 Oxygen Analyzer
    494215 Gas Compression Gauge 494358 Carbon Monoxide Analyzer
    494217 Compression Tester Adapter (18 mm) 494360 Emissions Accessory Kit

    494227* Explosion Proof Timing Ught 494363B Spreader Beam


    494234 Cylinder Deglazing Hone 494364 Main Bearing Installation Tool
    (Continued)

    1.15 - 8 FORM 6248 First Edition


    GENERAL INFORMATION

    WAUKESHA TOOL DESCRIPTION


    TOOL PIN
    494366 Main Bearing Installation Tool
    494365 Main Bearing Installation Tool
    494365 Seal Removal Tool
    494368 Oxygen Cell
    494389 Span Gas Bottle
    494421 Spark Plug Gapping Tool
    494422 Spark Plug Gapping Tool
    494498 Piston Pin Retaining Plier
    499233 Cylinder Sleeve Puller
    499953 Valve Guide Reamer

    FORM 6248 First Edition 1.15 - 9


    GENERAL INFORMATION

    ENGINE STANDARDS
    COMPONENT WEIGHTS
    Table 1.15-2. VHP 12 Cylinder Gas Engine Component Weights

    COMPONENTS Ibs. kg COMPONENTS Ibs. kg


    Air Duct 53 24 Intercooler, Without Bracket or Piping 369 177
    Camshaft Cover 198 90 Intercooler Assembly w/Bracket 423 192
    Camshaft Gear 32 15 Magneto Drive Assembly 92 41
    Camshaft 114 52 Magneto Drive Gear 78 35
    Carburetor 24 11 Mannold, Exhausl 92 42
    Cover, Gear 157 71 Manoold, Intake 6B 39
    Connecting Rod Assembly 62 28 Mannold, WatBr 102 46
    Crankcase w/Main Bearing Caps/Studs! Manifold, Prechamber 30 14
    Nuts and Camshaft Bearing Caps 4965 2252
    Oil Cooler 8 inch 493 224
    Crankshaft Assembly 1828 829
    Oil Cooler 10 inch 664 301
    Cylinder Head 195 89
    Oil Filter 254 115
    Cylinder Liner (Sleeve) 63 28
    Oil Pump 123 56
    Front Vibration Damper 303 137
    Oil Pan 1790 812
    Rear Vibration Damper 112 51
    Piston 33 15
    Elbow. Turbo Inlet R.B. 34 15
    Piston Pin 12 6
    Elbow, Turbo Inlet L.B. 35 16
    Pulley, Rear Crankshaft 81 37
    Elbow, Turbo Exhaust 7 3
    Regulalor, Gas (Fisher 99) 78 35
    Extractor, Venturi 15 7
    Skid, Shipping 46B 211
    Housing, Gear 138 63
    Turbocharger 67 (MAX) 30
    Housing, Flywheel, Front Section 202 97
    Thermostat Housing Assembly 67 30
    Housing, Flywheel, Rear Section 107 49
    Carburetor 24 11
    Flywheel wI Ring Gear 878 39B
    Water Pump, Main 101 46
    Governor Assembly 52 24
    Waler Pump, Auxiliary 44 20
    Idler Gear, 27 12

    1.15 - 10 FORM 6246 First Edition


    GENERAL INFORMATION

    CLEARANCES
    The clearances section of the manual contains both
    new part tolerances as well as field condemning limits.
    These part tolerances are published to establish engine
    ratings and warranty limitation on liability of new
    engines and service parts.
    Wear limits are published as guidelines for engine
    overhaul and repair. These guidelines can be the basis
    for the reuse of parts which, though worn, still retain
    service life at a reduced performance rating. Waukesha
    Engine Division emphasizes that these wear limits are
    guidelines and, as such, must be used with discretion
    and with the understanding that new engine perfor-
    mance may not be achievable.

    CAUTION I
    I.=A=......;;..;;..~;...........;...."-~.
    While Waukesha Engine
    L. . does not recommend the
    reuse of pistons during engine overhauls, we
    recognize that this Is a common field practice.
    Pistons experience a combination of mechanical
    and thermal cyclic stresses during operation.
    Aluminum piston life is unknown beyond recom-
    mended overhaul. If and when end users make the
    decision to reuse pistons, inspection steps need to
    be taken to minimize failure risks. Contact your
    authorized Waukesha distributor for assistance.
    Disregarding this information could result In prod-
    uct damage and/or personal injury.

    Waukesha Engine Division's position for these wear


    limits is that the reuse of an engine part that does not
    meet the new part specifications is solely the responsi-
    bility of the person making the inspection and repair.
    Under no circumstances is the reuse of any part
    exceeding the following wear limits justified.
    Waukesha Engine Division assumes no liability for any
    damage which may occur through the reuse of engine
    parts which fall outside of the new part tolerances.

    FORM 6248 First Edition 1.15 - 11


    GENERAL INFORMATION

    TORQUE SPECIFICATIONS
    )
    GENERAL TORQUING SEQUENCE PROCEDURE
    The sequence in which capscrews, bolts and nuts are
    tightened influence the distribution of fastener clamp
    load. Parts that use several fasteners such as cylinder
    heads, flywheels, oil pans, water pumps, cover plates,
    etc. must have the fasteners tightened (or loosened)
    gradually and in a specific sequence. This is necessary
    to avoid the excessive uneven loads that can cause
    gasket leakage, or the locking and warpage that cause
    damage to the parts during assembly or disassembly.
    If a special torquing sequence diagram is not available, NON-CIRCULAR
    the following procedure should be used. CIRCULAR FOUR-BOLT MULTI-BOLT

    First, assemble all the fasteners loosely and align and


    adjust the part as required to assure proper alignment
    with mating parts and to eliminate possible interference
    with adjacent parts, then begin torquing sequence.
    o 1
    o 3
    The torquing of fasteners to their torque specifications
    should be done in a minimum of three steps, with no 4 2
    more than 50 percent of the final required torque being
    applied in the initial step. The fasteners should be o 0
    tightened in a criss-cross or diagonal pattern, as shown
    in Figure 1 .15-6 and Figure 1.15-7, to distribute the CIRCULAR MULTI-BOLT SQUARE FOUR-BOLT
    fastener load evenly throughout the part. Use the same
    Figure 1.15-6. Torque Sequence For Multi-Bolt
    sequence of torquing for each subsequent step until
    each fastener is torqued to it's torque specification. To
    Patterns )
    loosen or remove the fasteners, the procedure should
    Special thread lubricants such as Molycote® Paste G or
    be done in reverse.
    Bostik Never Seez® reduce the friction on the threads
    THREAD LUBRICATION FOR TORQUE so much that the actual torque on the fastener may
    FASTENERS exceed the actual torque wrench indication by as much
    as 41 percent. This over-torquing puts an excessive
    Use only SAE 30 engine lubricating oil as a thread
    strain on the fasteners, which could be critical on such
    lubricant on those fasteners that have been assigned
    fasteners as the capscrews and studs that attach VHP
    specific torque values.
    cylinder heads.

    IA CAUTION IDo not use Molykote- Also when working on a crankcase that has been
    hot-tank cleaned, be sure to generously apply engine
    .L .::
    . ::::::::---'--_
    . Paste G®, Bostlk Never
    _- ' - _ - ' .
    Seez® or any other special thread lubricant unless oil on all studs that were hot-tanked as part of the
    specifically instructed to do so by Waukesha Engine crankcase assembly.
    Division. Disregarding this information could result
    in product damage and/or personal InJury.

    23 17 15 9 7 3 5 11 13 19 21

    FRONT
    or,") REAR
    I
    oL...J~ \a{ \a{

    22 20 2 8 10 16 18 24
    )
    Figure 1.15-7. Manifolds, Headers, etc.

    1.15 - 12 FORM 6248 First Edition


    GENERAL INFORMATION

    CRITICAL ENGINE TORQUE VALUES


    Table 1.15-3 lists critical fastener torque specifications for current VHP 12 cylinder gas engines. Fasteners not listed
    here should be tightened according to the general torque specifications listed in this manual.
    Table 1.15-3. 12 Cylinder VHP Torque Values
    DESCRIPTION ft-lb N·m
    Cylinder Heads (see Figure 1.15-8 for special torque sequence) 1 inch capscrews 625 - 650 847 - 881
    Main Bearing caps (see Figure 1.15-10 for special torque sequence*)
    Elastic Stop Nuts 3/4-16 271 - 279 367 - 378
    Cross-tie Capscraws 3/4-10 242 - 250 328 - 339
    Main Bearing Studs (in crankcase) 50 BB
    Connecting Rod Capscraws 5/8-18 (see Figure 1.15-9 for speciai torque sequence")
    (Series 205504 and 205507) 150 - 190 244 - 257

    Camshaft Gear Nut 1-1/2-12 432 - 450 587 - 610


    Camshaft Bearing Capscrews 3/8-16 22 - 24 30-33
    Idler Gear Spindle Nut, 1-1/2-12 (in crankcase, LH thread) (use LocIfte® #271 on threads) 775 -780 1017 - 1058
    Oil pump hollow idler spindle capscrew and nut, 3/4-16 300 - 325 407 - 441
    Oil pump cover capscrews 26 - 30 35 - 41
    Vibration Damper Capscrew 1/2-13 (vibration damper 10 pulley) 87-92 118 - 125
    Crankshaft End Plate capscrews r i 410 55B
    Stub Shaft
    Plate 10 stub shaft capscrews and nut 5/8-11 157 - 160 213-217
    Plate to flywheel capscrew, 3/4-10 275 - 285 373 - 3B6
    Flywheel to crankshaft capscrews 5/8-18 171 - 175 232 - 237
    Oil Pan Capscraws
    1/2-13 (QIy 6) 52 - 56 71 -76
    5/8-11 (QIy 2) 108 - 112 146 - 152
    3/4-10 (QIy 28) 204 - 208 277 - 282
    Rocker Arm Cover Capscraws 1/2-13 55-60 75 - 81
    Rocker Arm Support capscrews 1/2-13 55- 60 75 - 81
    Valve Ufter Screw (fixed Iype only) 9/16-18 55-60 75 - 81
    Crankshaft Counterweight Capscrews-7/8-14 463 - 500 655 - 678
    Oil Filter Cover Bolts 33-37 47- 50
    Spark Plugs (18 - 1.5 mm) 40 - 45 (dry) 54 - 61 (dry)
    275 - ~80 (w~ FEL- 373 - ~ (~ FEL-
    Spark Plug Carriers- PRO C5-A ,Part PRO C5-A ,Part
    IA CAUTION IStainless stset prechamber sesl (PIN 2095620) must be u _ with the- No. 51005 anti-seize
    compound apried to
    No. 51005 anti-seize
    compound applied to
    prechamber cup when torquing the spark plug carrier to 275 - 280 1t4b threads threads)
    (373 - 380 N'm) (with FEL-PRO® C5-A®, Part No. 51005 anti-seize
    compound applied to threads) or damage to equipment will rasuH.

    Gas Admission Valve- (PIN 211587A used with stainless steel washer PIN 28357) 65 -70 88-95
    Water Pump Impeller
    Impeller Nut 1-14
    Pulley Nut 1-14
    Holding one nut, torque other nut to: 195 - 200 284 - 271
    DESCRIPTION In-Ib N'm
    CEC liming Disc Nylok Capscrews (Current Production) 43-45 4.88 - 5.08
    NOTE: All torques oiled uniBss specified.
    * Refer to following diagrams and instructions for torquing procedures for connecting rods and main bearing caps.
    ~ Torque the end plate capscrews to 410 ft-lb (556 N·m). Repeat the torque sequence as necessary. Each time the sequence is repeated, /he
    assembly is driven further up onto the tapered pulley sleeve. The assembly is properly tightened only after ful/torque is applied to each boH without
    any rotation of /he torque wrench. Check torque annually.
    - Check counterweight torque ao to 60 days after start up and then annually.
    - Previous torque values for spark plug carriers was 90 - 95 ft-Ib (41 - 43 N·m) (wfth FEL-PRO® C5-A®, Part No. 51005 anti-seize compound
    applied to threads). A copper prechamber seal (PIN 2095628) was used with /he prechamber cup.
    --. Torque values for previous admission valves are discussed in sa 9-2574A, dated February 15, 1994.

    FORM 6248 First Edition 1.15 -13


    GENERAL INFORMATION

    CYLINDER HEAD TORQUING PROCEDURE Table 1.15-4. Cylinder Head Capscrews


    When being installed, cylinder heads should always INITIAL TORQUE RETORQUING 7/8 INCH
    )
    (CAPSCREW OR (CAPSCREW OR STUD
    be torqued in the proper sequence illustrated, using 1" STUD) 1" STUD)
    new gaskets. Lubricate cap screws and washers with
    625 - 650 ft·lb 550 - 575 ft-Ib 446 - 450 ft-Ib
    SAE 30 engine oil. First, hand secure capscrews in (847 - 881 N·m) (746 - 779 N'm) (605 - 610 N·m)
    positions 1 and 2 (see Figure 1.15-8), making sure that

    CAUTION I
    the head dowels are seated. Hand start the remaining
    screws. The first time through the torque sequence use
    25 percent of the total torque value; each succeeding
    I =~;;.;;....;;..::;...;~;:;.,::....:.J.
    :A
    1..._:
    . :: .
    Do not intermix studs
    and capscrews to secure
    a cylinder head or damage to equipment will result.
    time through the torque sequence increase the torque
    setting by 25 percent of total torque value until final
    torque of 625 - 650 ft-Ib (847 - 881 N·m) is reached. In CONNECTING ROD CAPSCREW TORQUING
    order to be sure of proper torque, the torque sequence PROCEDURE (PIN SERIES 205407 AND 205507)
    should again be repeated with the torque wrench set to A. Lubricate the the threads, and under the heads,
    the total torque value. Do not overtorque. If any screws offourferry head connecting rod capscrews with
    are overtorqued by 20 ft-Ib (27 N·m), reduce torque on SAE 30 engine oil.
    all screws to 75 percent of total torque and repeat the
    entire torquing sequence. B. Locate the number "1" stamped in the connecting
    rod cap. Hand tighten a capscrew in this hole
    EXHAUST VALVE BORES first. Hand tighten the remaining capscrews in
    WATER OUTLET positions 2 thru 4 (see Figure 1.15-9).
    ELBOW CONNECTION
    C. Following the same numerical sequence, torque
    the capscrews to 50% of the final torque value.

    D. Repeating the torque sequence, torque the


    capscrews to a final torque value of 180 - 190 ft.
    Ibs. (244 - 257 N·m). )
    o

    • 1

    11
    I"'""

    A
    / INTAKE VALVE BORES
    CYUNDER HEAD

    Figure 1.15-8, Cylinder Head Capscrew Tightening


    -
    ][
    And Torquing Sequence (1 - 8)

    Retorquing after running the engine at idle or after load


    testing is not required. If retorquing for any reason, use "- RODCAP
    a value of 550 - 575 ft-Ib (746 - 779 N·m) to compensate
    for the set which the head gasket takes (see
    , ,
    Table 1.15-4).

    )
    Figure 1.15-9. Connecting Rod Cap Capscrew
    Tightening Sequence (Series PIN 205407 and 205507)

    1.15 -14 FORM 6248 First Edition


    GENERAL INFORMATION

    MAIN BEARING CAP TORQUING PROCEDURE


    This torque sequence should be used on previous
    engines as well as current production ones.

    NOTE: Generously apply engine oi/ to main bearing


    cap studs, nuts and side bolts immediately before
    installing them. Apply 3M Scotch Grip ~ Industrial
    Adhesive EC 847, or equivalent, to both sides of the
    side bolt washers to prevent lube oi/leaks.

    1. Refer to Figure 1.15-10 and torque nuts 1 through 4


    (in that order) to 75 ft-Ib (102 N·m). If installing
    replacement caps that will be align bored, torque to only
    30 ft-Ib (40 N·m). When installing more than one cap,
    torque nuts 1 through 4 to 75 ft-Ib (102 N·m) on all caps
    before torquing side bo~s.

    LEFT SIDE OF ENGINE


    5

    FRONT OF ENGINE

    6
    Figure 1.15-10. Main Bearing Cap Tlghtenlng/Torqulng
    Pattern - As Viewed From Underside Of Crankcase

    2. Torque all left side bolts (5) to 250 ft-Ib (339 N·m),
    starting from the front of the engine.

    3. Torque all right side bo~s (6) to 250 ft-Ib (339 N·m)
    starting from the front of the engine.

    4. Torque nuts 1 through 4 to 275 ft-Ib (373 N·m) to


    two steps: first 175 ft-Ib (237 N·m), and then 275 ft-Ib
    (373 N·m).

    FORM 6248 First Edition 1.15 - 15


    GENERAL INFORMATION

    GENERAL TORQUE RECOMMENDATIONS


    the values specified below are to be used only in the absence of specified torquing instructions and are not to be
    )
    construed as authority to change existing torque values. A tolerance of ±3 percent is permissible on these values,
    which are for oiled threads.
    ..
    Table 1 15-5 US Standard Capscrew Torque Values

    SAE
    GRADE
    NUMBER
    0
    Grade 1 or2
    G
    Grade 5
    @
    I'
    GradeS
    SIZEj
    TORQUE TORQUE TORQUE
    THREADS In-Ib (N·m) In-lb (N·m)
    PER INCH In-lb (N·m)

    THREADS DRY OILED PLATED DRY OILED PLATED DRY OILED PLATED
    1/4-20 62 (7) 53 (6) 44 (5) 97 (11) 60 (9) 159 (18) 142 (16) 133 (15) 124 (14)
    1/4-28 71 (8) 62 (7) 53 (6) 124 (14) 106 (12) 97 (11) 168 (19) 159 (18) 133 (15)
    5/16-18 133 (15) 124 (14) 106 (12) 203 (23) 177 (20) 168 (19) 292 (33) 265 (30) 230 (26)
    5/16-24 159 (18) 142 (16) 124 (14) 230 (26) 203 (23) 177 (20) 327 (37) 292 (33) 265 (30)
    3/8-16 212 (24) 195 (22) 168 (19) 372 (42) 336 (38) 301 (34) 531 (60) 478 (54) 416 (47)

    ft-Ib (N·m) ft-lb (N·m) ft-Ib (N·m)


    3/8-24 20 (27) 18 (24) 16 (22) 35 (47) 32 (43) 28 (38) 49 (66) 44 (60) 39 (53)
    7/16-14 28 (38) 25 (34) 22 (30) 49 (56) 44 (60) 39 (53) 70 (95) 63 (85) 56 (76)
    7/16-20 30 (41) 27 (37) 24 (33) 55 (75) 50 (68) 44 (60) 78 (106) 70 (95) 62 (84)
    1/2-13 39 (53) 35 (47) 31 (42) 75 (102) 68 (92) 60 (81) 105 (142) 95 (129) 84 (114)
    1/2-20 41 (56) . 37 (50) 33 (45) 85 (115) 77 (104) 68 (92) 120 (163) 108 (146) 96 (130)
    9/16-12 51 (69) 46 (62) 41 (56) 110 (149) 99 (134) 88 (119) 155 (210) 140(190) 124 (168)
    9/16-18 55 (75) . 50 (68) 44 (60) 120 (163) 106 (146) 96 (130) 170 (230) 153 (207) 136 (184)
    5/8-11 63 (113) 75 (102) 66 (89) 150 (203) 135 (183) 120 (163) 210 (285) 169 (256) 168 (228)
    5/8-18 95 (129r 68 (117) 76 (103) 170 (230) 153 (207) 136 (184) 240 (325) 216 (293) 192 (260)
    3/4-10 105 (142) 95 (130) 84 (114) 270 (366) 243 (329) 216 (293) 375 (508) 336 (458) 300 (407)
    3/4-16 115 (156) 104 (141) 92 (125) 295 (400) 266 (361) 236 (320) 420 (569) 378 (513) 336 (456)
    7/8-9 160 (217) 144 (195) 128 (174) 395 (535) 356 (483) 316 (428) 605 (820) 545 (739) 484 (856)
    7/8-14 175 (237) 158 (214) 140 (190) 435 (590) 392 (531) 348 (472) 675 (915) 608 (824) 540 (732)
    1.0-8 235 (319) 212 (287) 188 (255) 590 (BOO) 531 (720) 472 (640) 910 (1234) 819 (1110) 728 (987)
    1.0-14 250 (339) 225 (305) 200 (271) 660 (895) 594 (605) 528 (716) 990 (1342) 891 (1208) 792 (1074)

    NOTE: Dry torque values are based on the use of clean. dry threads.
    O;1ed torque values have been reduced by 10% when engine oil is used as a lubricant.
    Plated torque values have been reduced by 20% for new plated capscrews.
    Gapscrews which are threaded into aluminum may require a torque reduction of 30% or more.
    The conversion factor from ft-lb to in-lb is ft-Ib x 12 equals in-lb

    1.15 - 16 FORM 6248 First Edition


    GENERAL INFORMATION

    ENGLISH/METRIC CONVERSIONS
    Table 1.15-6. English To Metric Formula Conversion Table
    CONVERSION FORMULA EXAMPLE
    Inches and any fraction in decimal equivalent
    Inches to Millimeters multiplied by 25.4 equals millimeters. 2-5/8 in. = 2.625 x 25.4 = 66.7 mm

    Cubic Inches to Litres Cubic inches multiplied by 0.01639 equals litres. 93S8 cu. in. = 93S8 x 0.01639 = 153.91itres
    Ounces to Grams Ounces multiplied by 28.35 equals grams. 21 oz. = 21 x 28.35 = 595.4 grams
    Pounds to Kilograms Pounds multiplied by 0.4536 equals kilograms. 22,550 lls. = 22,550 x 0.4538 = 10.228.7 kg
    Inch pounds multiplied by 0.11298 equals
    Inch Pounds to Newton-meters Newton-meters. 360 in-Ib = 360 x 0.11298 = 40.7 N'm

    Foot pounds multiplied by 1.3558 equals


    Foot Pounds to Newton-meters Newton-meters. 145 ft-Ib = 145 x 1.3558 = 196.6 N'm

    Pounds per Square Inch to Pounds per square inch multiplied by 0.0703 equals
    Kilograms per Square Centimeter kilograms per square centimeter. 45 psi = 45 x 0.0703 = 3.2 kg/cm2

    Pounds per Square Inch to Pounds per square inch multiplied by 6.8947 equals
    Kilopascals kilopascal. 45 psi = 45 x 6.6947 = 310.3 kPa

    Fluid ounces multiplied by 29.57 equals


    Fluid Ounces to Cubic Centimeters cubic centimeters. 8 oz. = 8 x 29.57 = 236.6 cc

    Gallons to Utres Gallons multiplied by 3.7853 equals Inras. 148 gal. = 148 x 3.7853 = 580.2 litras
    Degrees Fahrenheit to Degrees Degrees Fahrenheft minus 32 divided by 1.8 equals
    Centigrade degrees Centigrade. 212" F - 32+ 1.8 = 100" C

    Table 1.15-7. Metric To English Formula Conversion Table. ..


    CONVERSION FORMULA EXAMPLE
    Millimeters to Inches Millimeters muniplied by 0.03937 equals inches. 67 mm = 67 x 0.03937 = 2.6 in.
    Utres to Cubic Inches Utres multiplied by 61.02 equals cubic Inches. 153.8 L = 153.8 x 61.02 = 9384.9 cu. in.
    Grams to Ounces Grams multiplied by 0.03527 equals ounces. 595 G = 595 x 0.03!;W = 21 oz.
    Kilograms to Pounds Kilograms muniplied by 2.205 equals pounds. 10,228 kg = 10,228 JI< .2.205 = 22,55t\lbs.
    Newton-meters multiplied by 8.85 equals
    Newton-meters to Inch Pounds inch pounds. 40.7 N·m = 40.7 x 8.85 = 360 in-Ibs.

    Newton-meters multiplied by 0.7375 equals


    Newton-meters to Foot Pounds foot pounds. 197 N'm = 197 x 0.7375 = 145ft-lb

    Bar multiplied by 14.5 equals pounds per square


    Bar to Pounds per Square Inch inch. 685 Bar = 685 x 14.5 = 9,932.5 psi

    Kilograms per Square Centimeter Kilograms multiplied by 14.22 equals pounds per
    to Pounds per Square Inch (psi) square inch. 3.2 kg = 3.2 x 14.22 = 45.5 psi

    Kilopascals to Pounds per Square Inch Kilopascals multiplied by 0.145 equals pounds per
    (psi) square inch. 310 kPa = 310 x 0.145 = 45 psi

    CubiC centimeters multiplied by 29.5 equals


    Cubic Centimeters to Fluid Ounces fluid ounces. 238 cc = 236 x 29.5 =8 oz.

    Utres to Gallons Litras muttiplied by 0.264 equals gallons. 580L = 580 x 0.284 = 147.8 gal.
    Degrees Centigrede to Degrees Fahren- Degrees Centigrede multiplied by 9/5 plus 32 equals
    hen Degrees Fahrenheft. 100" C = 100 x 9/5 + 32 = 212" F

    FORM 6248 First Edition 1.15-17


    GENERAL INFORMATION

    INDEX OF SEALANTS, ADHESIVES AND may be used to match the general description to a
    LUBRICANTS specific product or its equivalent (ie. pipe sealant = )
    Perma Lok® Heavy Duty Pipe Sealant with Teflon® or its
    The following is a list of sealants, adhesives and equivalent). Waukesha does not endorse one brand
    lubricants (see Table 1.15-8) required to perform the over another. In all cases, equivalent products may be
    tasks in this manual. Where possible, brand names are substituted for the brand name listed. All part numbers
    included with the task. When they are not, this index listed are the manufacturer's numbers.
    Table 1.15-8. Sealants, Adhesives, And Lubricanta
    NAME USED IN TEXT BRAND NAMEJDESCRIPTION
    High Temperature FEL-PRO® C5-A®, Part No. 51005 or Locti1.® Anti-Seize 767/ Copper based anti-seize compound
    Anti-seize compound
    Anti-Seize Bostik Never Seez® Anti-Seize and Lubricating Compound/Nickle based anti-seize compound
    Black Silicone G.E. Silmata .... Silicone Rubber
    Magnaflux® Products: Penetrant (SKL-HF/S) Developer (SKD-NF-ZP-98) Cleaner/Remover
    Bluing Agent (SKC-NF/ZC-7B)
    Bluing Paste Permatex® Non Drying Prussian Blue (mfg. by Loctite® Corporation)
    Ceramic bonded high temperature Lube-Lok® 1000 or equivalent
    solid film lubricant
    Cleaning Solvent/Mineral Spirits Amisol® Solvent (mfg. by Standard Oil)
    Dielectric Silicone Grease Dow Corning DC-200, G.E. G-624, GC Electronics 25
    Engine Oil See Lubricating Oil
    Scotch Weld ~ No. 270 B/A Black Epoxy Potting Compound/Adhesive, Part Nos. A and B
    Epoxy Seatant (3M 10 No. 62-3266-7430-6 (PA)
    Gasket Adhesive Scotch Grip~ 847 Rubber and Gasket Adhesive (mfg. by 3M), 3M 10 No. 62-0847-7530-3
    Heavy Lube Oil Vactra® 8OW90 Gear Oil (mfg. by Mobil)
    )
    UquidSoap Dove® Dishwashing Liquid
    Lithium Grease See Molycote® Paste G
    Locquic® Primer "T" Item No. 74756 (mfg. by Loctite® Corporaflon)
    Loctite® 242 Loctite® Item No. 24241/a blue coiorecl removable thread locking compound
    Loctite® 271 Loctite® Item No. 27141/a red colored thread locking compound
    Loctite® Compound 40 Loctite® Item No. 64041 /High Temperature Retaining Compound 40
    Loctite® Hydraulic SeaJant Loctne® Item No. 56941
    Loctne® RC ~ /809 Locti1e® ~em No. 80931
    Loctite® 620 Locti1.® Item No. 620/High Temperature Retaining Compound
    Lubricating Oil/Engine Oil New oil of the type used in the crankcase
    Magnaflux® See Bluing Agent
    Dow Coming Molycote® Paste G or CITGO Uthoplex® Grease NLGI No.2 Product Code 55-340/
    Molycote® Paste G a molybdenum-based grease
    D-ring Lubricant Parker Super O-Lube®/dry silicone lubricant
    Permatex® No. 3D Aviation Form-
    A-Gasket® Sealant Uquid Loctite® Item No. 3D

    Permatex® No.2 Form-A-Gasket®


    Sealant Loctite® Item No. 2C

    Pipe Sealant Perma Lok® Heavy Duty Pipe Sealant wtth Teflon®, Item No. LH050
    Stellne® Stellite® is a registered trademark of Stoody Deloro SteUite, Inc.
    WD-4O® WD-40® is a registered trademark of the WD-40@ Company.

    1.15 -18 FORM 6246 First Edition


    GENERAL INFORMATION

    SPLIT RING WASHER USABILITY


    CRITERIA
    Split ring washers are washers that, once compressed,
    keep an outward pressure applied on screw threads
    allowing friction to hold them in place. Depending on the
    location and application, these washers may be suitable
    for re-use. Do not re-use split ring washers that have
    flattened due to high temperatures or over-use (see
    Figure 1.15-11). If you are not sure if a split ring washer
    is suitable for re-use, replace it with a new one.

    @ @
    E::li23 E%:3
    DO NOT RE-USE RE-USE

    Figure 1.15-11. SplH Ring Washers

    During overhauls, and on all components subjected to


    high temperatures, Waukesha recommends replacing
    split ring washers.

    FORM 6248 First Edition 1.15 -19


    GENERAL INFORMATION

    1.15 - 20 FORM 6248 First Edition


    SECTION 1.20 - SPECIFICATIONS

    SPECIFICATIONS GEAR TOOTH WEAR - GENERAL


    The following tables cover the minimum and maximum After a gear train has initially worn in, it will have a long
    specifications for parts requiring inspection during and trouble free life if not overloaded and if adequately
    routine maintenance or overhauls. The tables also lubricated with clean oil.
    appear in the tasks where the inspection criteria is The first sign of a gear train in trouble is unusual gear
    required. Parts not meeting the specifications listed tooth noise and a sudden increase in gear backlash.
    should be replaced. This section does not cover all
    Gears fail because of excess wear, plastiC flow of gear
    components, but rather lists the most common wear
    material, surface fatigue, or tooth failure.
    parts and their allowable tolerances. All parts should be
    inspected for damage or wear whenever they are If a gear train shows signs of excessive abrasive wear or
    removed. Any questions on whether a part not covered scoring, it is an indication that abrasive material has
    in this section is suitable for reuse should be referred to passed through the gear train or there has been
    Waukesha Engine Division, Service Operations. inadequate lubrication or both. the problems should be
    resolved and the affected gears replaced. The lube oil
    Waukesha provides the following wear limits to assist in
    filter by-pass valves should be inspected as well as the
    deciding as to the reuse of engine parts. Many parts can
    oil passages and nozzles that provide lubrication to the
    be reused at overhaul time if wear limits do not exceed
    gears.
    those listed in Table 1.20-1. Under no circumstances
    can the use of any part exceeding the established wear If the gears in the gear train show signs of !inning,
    limits be justified. When using these wear limits, the ridging, rippling, pitting, spalling or tooth breakage,
    decision to reuse engine parts must be tempered with there is a serious problem. These types of failures are
    the consideration of: associated, in one way or another, with tooth loads that
    exceed the design of the gear. the reasons for the gear
    • Number of mating parts being reused. tooth overload should be determined and resolved and
    affected gears replaced. Bearing failures, misalign-
    • Service life expected until the next overhaul.
    ment, torsional vibrations, or failure of the driven
    • Problems that might occur in the future. equipment are some possible causes.

    • Engine application. TIMING GEARS


    The camshaft idler gear is a "hunting-tooth" design to
    E. Horsepower requirement minimize tooth wear. The fractional drive ratio between
    F. Maintenance intervals the crankshaft and camshaft gears results in the idler
    gear timing marks realigning with the crankshaft and
    G. Type of installation camshaft timing marks only once in every 154 crank-
    Waukesha Engine Division's position for these wear shaft revolutions. The most practical way to realign the
    limits is that the reuse of an engine part that does not timing marks, when timing a camshaft, is to remove the
    meet the new part specifications is solely the responsi- idler gear and reassemble to it's timed position as
    bility of the person making the inspection and repair. previously described.
    Under no circumstances is the reuse of any part
    exceeding the following wear limits justified.

    CAUTION I~hile
    I A="--.;=.;:.::....:~=-..::...::..J.
    Waukesha Engine
    .L .::
    .. does not recommend the
    reuse of pistons during engine overhauls, we
    recognize that this is a common field practice.
    Pistons experience a combination of mechanical
    and thermal cyclic stresses during operation. Alu-
    minum piston life is unknown beyond recom-
    mended overhaul. If and when end users make the
    decision to reuse pistons, inspection steps need to
    be taken to minimize failure risks. Contact your
    authorized Waukesha distributor for assistance.
    Disregarding this Information could result In prod-
    ) uct damage and/or personal injury.
    Waukesha Engine Division assumes no liability for any
    damage which may occur through the reuse of engine
    parts which fall outside of the new part tolerances.

    FORM 6248 First Ednion 1.20 - 1


    SPECIFICATIONS

    Table 1.20-1. Wear Limits


    WEAR LIMITS - GAS
    MEASUREMENT INCHES, METRIC (mm)
    Cylinder sleeve bore wear 0.001 (0.025 mm) per inch of diameter
    Cylinder sleeve bore - maximum taper 0.0005 (0.013 mm) per inch of piston travel
    (after ridge removal and honing)
    Cylinder sleeve out of round - maximum 0.005 (0.127 mm)
    Piston diameter wear 0.0005 (0.013 mm) per inch of diameter measure at skirt and above pin
    Piston pin diameter wear 0.001 (0.025 mm) total wear
    Piston pin bore wear and pin bushing wear
    (A) In piston 0.0005 (0.013 mm) per inch of diameter
    (8) In rod 0.0005 (0.013 mm) per inch of diameter
    Journal clearance
    Main and connecting rods 10.0005 (0.013 mm) per inch of diameter over high lim~
    Crankshaft
    (A) Main journal maximum out of round 0.0004 (0.010 mm) per inch of diameter
    (8) Connecting rod journal out of round 0.0004 (0.010 mm) per inch of diameter
    (C) End play 0.005 (0.13 mm) over high lim~
    Camshaft - minimum journal diameter 0.0005 (0.013 mm) per inch diameter under the low limit
    (A) Bushing 10 0.0005 (0.013 mm) per inch diameter over the high limit
    (8) End play 0.010 (0.25 mm) over high limit
    Valves
    Minimum stem diameter 0.001 (0.025 mm) total wear
    Valve guide - maximum 10 0.0015 (0.038 mm) )
    Valve seat maximum width Original width +15%

    .
    CAUTION IPiston
    I.==......;;;.;;....;;.;;;;~.:....::'-"-;..J.
    L.
    A
    .
    rings must be re-
    placed if they have been
    disturbed after 50 hours of operation. Disregarding
    this information could result In product damage.

    1.20 - 2 FORM 6248 First Edition


    SPECIFICATIONS

    Table 1.20-2. Cylinder Sleeve (Used With Four Ring Pistons Only) - Gas

    1-1_--- D -----I

    F
    it l
    C

    '\.020 -0.030 CYUNDER SLEEVE


    GASKET USED ON
    9-3!8 BORE PIN 205130C AND
    205130H CYUNDER SLEEVES
    ONLY

    MEASUREMENT INCHES . METRIC (mm)


    Sleeve type: Wet type, replaceable
    (A) Heat dam projection 0.045 - 0.049 1.143 -1.245
    (B) Flange height (current 8-1/2 in. bore sleeve used wnhout cylinder sleeve gasket) 0.5635 - 0.5655 ,,',4.3,3 - 14.364
    Flange height (sleeve used wnh cylinder sleeve gasket', 9-3/8 inch bore engines) 0.5345 - 0.5365 13.576 - 13.627
    (C) Sleeve projection above crankcase (current 8-1/2 in. bore engines) 0.0010 - 0.0055 0.025 - 0.1397
    Sleeve projection above crankcase (with cylinder sleeve gasket-' - 9-3/8 In. bore engines) 0.000 - 0.007 0.000 - 0.178
    (D) Flange 00: L5108 and L5790 10.188 -10.190 258. n5 - 258.826
    Flange 00: L7042 10.611 - 10.616 269.519 - 269.646
    (E) Sleeve 00 (below flange) L5108 and L5790 9-11/16 246.050
    Sleeve 00 (below flange) L7042 10-1/4 260.35
    (F) Sleeve length 18-5/8 473.075
    (G) Sleeve 10: L5108 and L5790 8.5003 - 8.5013 215.908 - 215.933
    Sleeve 10: L7042 9.3753 - 9.3763 239.133 - 239.158
    (H) Sleeve 00 lower seal area: L5108 and L5790 9.673 - 9.6n 245.694 - 245.796
    Sleeve 00 lower seal area: L7042 10.240 - 10.245 260.096 - 260.223
    Sleeve 10 out of round limits 0.001 0.025
    Sleeve seal area to crankcase clearance on a side 8-1/2 inch bore 0.0005 - 0.0035 0.013 - 0.069
    Sleeve seal area to crankcase clearance on a side 9-3/8 inch bore 0.0005 - 0.0040 0.013 - 0.102
    NOTE: Cylinder sleeve gasket PIN 176375D is used on 9-3/8 inch bore PIN 205130C and 205130H cylinder liners only. For use of standard or
    oversize cylinder sleeve gaskets reter to Chapter 3.

    FORM 6246 First Edition 1.20 - 3


    SPECIFICATIONS

    Table 1.20-3. Piston (Four Ring Only) - Gas


    )
    E

    -.-l
    T
    ,
    A

    @
    W NOTE: Dimensions A and B must be measured at
    the locations shown.

    D- f-
    FOUR RING PISTON - GAS
    Piston material: Tin plated aluminum alloy
    Piston type: Cam ground
    Pistons are removed from: Top of crankcase
    Permissible weight variation per set: 2 ounces (56.7 grams) )
    MEASUREMENT I INCHES I METRIC (mm)
    Piston hole center to piston crown standard compression ratio
    L5108G (8.25:15 to 1) 6.245 - 6.255 158.623 - 158.877
    L5790G/GSI (8.25:15 to 1) 5.620 - 5.630 142.748 - 143.002
    L7042G/GSI (8.0 to 1) 5.465 - 5.475 138.811 - 139.085
    10.0:1 Compression ratio
    L5108GSI 6.587 - 6.597 167.310 - 167.564
    5790GL 6.031 - 6.037 154.737 - 154.864
    10.5:1 Compression ratio
    7042GL - 4 Ring I 6.092 - 6.097 I 154.737 - 154.864
    (A) Piston skirt diameter ~op) in line with pin hole:
    All 8-1/2 inch bore models (L5108 etc .• L5108 etc.) 8.481 - 8.462 214.909 - 214.934
    All 9-3/8 inch models (L7042 etc.) - 4 Ring 9.334 - 9.335 237.084 - 237.109
    90" from pin hole:
    All 8-1/2 inch bore models 8.477 - 8.478 215.316 - 215.341
    All 9-3/8 inch models - 4 Ring 9.350 - 9.351 237.490 - 237.515
    (B) Piston skirt diameter (bottom) in line with pin hole:
    All 8-1/2 inch bore models 8.478 - 8.479 215.341 - 215.367
    All 9-3/8 inch models - 4 Ring 9.354 - 9.355 237.592 - 237.617
    90° from pin hole:
    All 8-1/2 inch bore models 8.487 - 8.488 215.570 - 215.595
    All 9-3/8 inch models - 4 Ring 9.362 - 9.363 237.795 - 237.820
    (Continued)

    1.20 - 4 FORM 6248 First EdHion


    SPECIFICATIONS

    ~
    1
    ,
    A

    &~
    ~ NOTE: Dimensions A and B must be measured at
    the locations shown.

    O- f--
    MEASUREMENT INCHES METRIC (mm)
    (e) Piston pin bore 3.0004 - 3.0009 76.210 - 76.223
    (0) Piston skirt to sleeve clearance (thrust area) --
    Ail 8-1/2 inch and 9-318 inch bore models - 4 Ring I 0.0123 - 0.0143 Q:3124 - 0.3832
    (E) Groove width;
    -
    Top, 2nd and 3rd: All 8-1/2 inch models (L5108 etc., L5790 etc.) 0.189 - 0.1S0 ::4.901 - 4.826
    Top: All 9-3/8 Inch bore models (L7042 etc.) 0.1915 - 0.1925 ~.B641 - 4.8895
    2nd and 3rd: AIIS-3/8 inch bore models (L7042 etc.) - 4 Ring 0.1S0 - 0.191 .,:4.826 - 4.851
    4th Oil ring
    Oil ring, All 8-1/2 inch bore models 0.313 - 0.314 7.950 - 7.9756
    Oil ring, All 9-3/8 inch bore models - 4 Ring 0.376 - 0.377 9.550 - 9.576

    FORM 6248 First Edition 1.20 - 5


    SPECIFICATIONS

    Table 1 20-4. Piston Rings (Four Ring Piston Only) - Gas


    )
    TANGENTIAL LOAD (Ll)
    IN-LB
    ==:l t= B (END CLEARANCE)

    A . . LOAD AT DIA. (LD)


    IN-LB
    (GAUGE DIAMETER)

    L
    E (SIDE CLEARANCE) L K (RADIAL WALL
    -.lD
    LL THICKNESS)

    T~ !iN
    T
    (WIDTH)

    PISTON RINGS (FOUR RING PISTON ONLy)- GAS


    Top ring: (L5108G/GSI/GL. L5790G/GSI/GL. L7042G/GSI/GL) Crowned plasma coated compression (top marked with notch)
    Second ring: Tapered face compression (top marked "top" and marked with notch)
    Third rinp,: (L5108G/GSI/GL. L5790G/GSI/GL. L7042G/GSI), tapered face compression ~op marked "top" and marked with notch) 7042GL,
    scraper aced compression ring (top marked with indentation)
    Fourth ring: (All VHP Gas Engines). conformable grooved oil ring with expander (top marked with notch)
    Measurement Top 2nd and 3rd 4th
    (A) Ring gauge diameter
    L5108G/GSIIGL. L579OG!GSIIGL 8.500 in. (215.9 mm) 8.500 in. (215.9 mm) 8.500 in. (215.9 mm)
    L7042G/GSI/GL 9.375 in. (238.125 mm) 9.375 in. (238.125 mm) 9.375 in. (238.125 mm)
    (B) Ring end clearanca at gauge diameter
    L5108G!GSIIGL. 0.040 - 0.055 in. 0.025 - 0.040 in. 0.023 - 0.038 in.
    L579OG!GSIIGL (1.016 - 1.397 mm) (0.635 - 1.016 mm) (0.584 - 0.965 mm)
    0.045 - 0.060 in. 0.030 - 0.045 in. 0.015 - 0.035 in.
    L7042G/GSI (1.143 -1.524mm) (0.762-1.143mm) (0.381 - 0.889 mm)
    (C) Ring redial wall thickness
    L5108G/GSIIGL. 0.300 - 0.315 in. 0.300 - 0.315 in. 0.243 - 0.258 in.
    L5790G/GSIIGL (7.62 - 8.00 mm) (7.62 - 8.00 mm) (6.172 - 6.553 mm)
    0.302 - 0.317 in. 0.302 - 0.317 in. 0.290 - 0.310 in.
    L7042G/GSI (7.671 - 8.052 mm) (7.671 - 8.052 mm) (7.386 - 7.874 mm)
    0.302 - 0.317 in. 0.302 - 0.317 in. 0.290 - 0.310 in.
    7042GL (7.671 - 8.052 mm) (7.671 - 8.052 mm) (7.386 - 7.874 mm)
    (D) Ring width
    L5108G/GSIIGL, 0.1850 - 0.1865 in. 0.1835 - 0.1850 in. 0.3085 - 0.3100 in.
    L579OG!GSIIGL (4.699 - 4.7371 mm) (4.661 - 4.699 mm) (7.838 - 7.874 mm)
    0.1850 - 0.1865 in. 0.1850 - 0.1865 in. 0.3720 - 0.3735 in.
    L7042G/GSI (4.699 - 4.737 mm) (4.699 - 4.737 mm) (9.449 - 9.487 mm)
    )
    (Continued)

    1.20 - 6 FORM 6248 First Ed~ion


    SPECIFICATIONS

    TANGENTIAL LOAD (LT)


    IN-LB
    ==:l t= B (END CLEARANCE)

    A
    (GAUGE DIAMETER)
    .. LOAD AT DIA. (LD)
    IN-LB

    .~

    E (SIDE CLEARANCE) L K (RADIAL WALL


    -..1D

    ..LL THICKNESS)

    T~
    6$iI (WIDTH)

    T
    Measurement Top 2nd and 3rd - 4th
    (D) Ring width
    0.1850 - 0.1885 in. 0.1850 - 0.1885 in. 0.3720 - 0.3735 in.
    7042GL (4.699 - 4.737 mm) (4.699 - 4.737 mm) (9.449 - 9.497 mm)
    (E) Ring, piston groove, side clearance ,
    0.0025 - 0.0050 in. 0.0040 - 0.0065 in. O.ao;ao - 0.0055 in.
    L5108G/GSIIGL. L579OG!GSI/GL (0.064 - 0.127 mm) (0.102-0.165mm) (O.~ - 0.140 mm)

    0.0050 - 0.0075 in. 0.0035 - 0.0060 in. 0.0025 - 0.0050 in.


    L7042G/GSI (0.127 - 0.1905 mm) (0.0889 - 0.1524 mm) (0.084 - 0.127 mm)
    0.0050 - 0.0075 in. 0.0035 - 0.0060 in. 0.0025 - 0.0050 in.
    7042GL (0.127 - 0.191 mm) (0.089 - 0.152 mm) (0.084 - 0.127 mm)
    (LO) Load in lb•. , a1 gauge diameter
    L5108G/GSI/GL. L5790G/GSI/GL 30 lb•. (13.6 kg) (minimum) 15 - 22 Ibs. (6.8 - 9.9 kg) -
    L7042 G/GSI 22 lb•. (13.6 kg) (minimum) 13.5 - 20.5 lb•. (6.1 - 9.3 kg) -
    7042GL 22 lb•. (13.6 kg) (minimum) 13.5 - 20.5 lb•. (6.1 - 9.3 kg) -
    (LT) Tangential load, in lb•. , a1 end clearance
    L5108G/GSI/GL, L5790G/GSI/GL - - 28.5 - 38.5 lb•. (12.9 -17.5 kg)
    L7042G/GSI - - 24.0 - 38.0 Ibs. (10.9 -17.2 kg)
    7042GL - - 24.0 - 38.0 lb•. (10.9 - 17.2 kg)

    FORM 6249 First Edftion 1,20 -7


    SPECIFICATIONS

    Table 1.20·5. PIN 205130L Cylinder Sleeve (Sleeve Used On GL 9-3/8 Inch Bore" Only) - Gas
    )
    j.IO---D - - - . . j

    c
    *
    IA CAUTION ICylinder sleeve
    F L.. gasket should NOT
    =.....;;;.:....;..;;;....;;...;;..;;;...:..:..J.
    ;:: .

    be used with this cylinder sleeve.

    MEASUREMENT INCHES METRIC (mm)


    Sleeve type: Wet type, replaceable
    (A) Heat dam projection 0.045 - 0.049 1.143 -1.245
    (8) Flange height 0.5635 - 0.5655 14.313 - 14.364
    (e) Sleeve projection above crankcase 0.0010 - 0.0060 0.0254 - 0.1524
    (D) Flange OD: 7042GL 10.611 - 10.616 269.519 - 269.646
    (E) Sleeve OD (below flange) 7042GL 10.300 - 10.305 261.620 - 261.747
    (F) Sleeve length 18.625 473.075
    (G) Sleeve ID: 7042GL 9.3753 - 9.3763 238.133 - 238.158
    (H) Sleeve OD lower seal area: 7042GL 10.240 - 10.245 260.096 - 260.223
    Sleeve 10 out of round limits (installed in crankcase) 0.002 0.0508
    Sleeve seal area to crankcase clearance 0.0005 - 0.0040 0.0127 - 0.1016
    NOTE: 'Preferred application. used with three ring pistons. Acceptable application. used with four ring piston.

    1.20 - 8 FORM 6248 First Edition


    SPECIFICATIONS

    Table 1.20-6. Three Ring Piston (PIN 2055040) (pIston Used On GL 9-3/8 Bore With PIN 205130L Liner Only) - Ges

    ~
    I
    T
    A

    ~!~
    W NOTE: Dimensions A and B must be measured at
    the locations shown.

    O- f-
    THREE RING PISTON - GAS
    Piston material: Tin plated aluminum alloy
    Piston type: Cam ground
    Pistons are removed from: Top of crankcase
    ... '

    Permissible weight variation per set: 2 ounces (56.7 grams)


    MEASUREMENT INCHES METRIC (mm)
    Piston hole center to piston crown 6.094
    - .... 154.787
    (A) Piston skirt diameter (top) in line wilh pin hole: 9.336 - 9.337 23i134 - 237.159
    goo from pin hole 9.352 - 9.353 237.541 - 237.820
    (8) Piston skirt diameter (bottom) in line with pin hole 9.354 - 9.355 237.592 - 237.617
    goo from pin hole: 9.362 - 9.363 237.795 - 237.820
    (e) Piston pin bore 3.0004 - 3.0009 76.2100 - 76.2228
    (0) Piston skirt 10 sleeve clearance ~hrust area) 0.0123 - 0.0143 0.3124 - 0.0363
    (E) Groove width
    Top 0.1920 - 0.1930 4.8768 - 4.9022
    2nd 0.189 - 0.190 4.8006 - 4.6260
    3rd 0.251 - 0.252 6.375 - 6.401

    FORM 6248 First Ed~ion 1.20 - 9


    SPECIFICATIONS

    Table 1.20·7. Piston Rings


    (Used On GL 9-3!8lnch Bore With Three Ring Piston And PIN 205130L Cylinder Sleeve Only) - Gas

    TANGENnALLOAD(Ln
    IN·LB
    ==:J t= B (END CLEARANCE)

    A
    (GAUGE DIAMETER)
    .. LOAD AT DIA. (LD)
    IN·LB

    E (SIDE CLEARANCE) L K (RADIAL WALL


    ..-1D

    LL THICKNESS)

    T~ lSi
    r
    (WIDTH)

    Top ring: Plasma coated (top marked w~h notch)


    Second ring: Scraper groove compression (top marked with indentation mark)
    Third ring: Conformable grooved oil ring with expander
    Measurement Top 2nd 3rd
    (A) Ring gauge diameter 9.375 in. (238.125 mm) 9.375 in. (238.125 mm) 9.375 in. (238.125 mm)
    0.035 - 0.047 in. 0.065 - 0.080 in. 0.Q15 - 0.035 in.
    (8) Ring end dearance at gauge diameter (0.889 - 1.194 mm) (1.651 - 2.032 mm) (0.381 - 0.889 mm)
    0.317 - 0.302 in. 0.302 - 0.317 in. 0.213 - 0.227 in.
    (C) Ring radial wall thickness (8.052 - 7.761 mm) (7.671 - 8.052 mm) (5.410 - 5.7658 mm)
    0.1850 - 0.1865 in. 0.1850 - 0.1865 in. 0.2475 - 0.2490 in.
    (D) Ring widlh (4.6990 - 4.7371 mm) (4.6990 - 4.7371 mm) (6.2865 - 6.3246 mm)
    0.0055 - 0.008 in. 0.0025 - 0.0050 in. 0.002 - 0.0045 in.
    (E) Ring, piston groove, side clearance (0.1143 - 0.2032 mm) (0.0635 - 0.127 mm) (0.0508 - 0.1143 mm)
    13.5 - 20.5Ibs.
    (LD) Load in Ibs., at gauge diameter 20.4Ibs. (9.2 kg) -
    (6.1 - 9.3 kg)
    45.4 - 86.1 Ibs.
    (Ln Tangenlialload, in Ibs., at end clearance - - (20.6 - 30.9 kg)

    1.20 - 10 FORM 6246 Firsl Ed~ion


    SPECIFICATIONS

    Table 1.20-8. Crankcase - Gas

    ·1

    JACKET

    MEASUREMENT INCHES METRIC (mm)


    (A) Sleeve counterbore diameter L51 08 and L5790 10.199 -10.202 259.055 - 259.130
    Sleeve cQunterbore diameter l7042 10.625 - 10.628 269.875 - 269.951
    (8) Sleeve counter bore depth 8-1/2 inch bore 0.5600 - 0.5625 14.224 - 14.288
    Sleeve counter bore depth 9-3/8 inch bore 0.5595 - 0.5625 14.211 - 14.288
    (C) Crankcase upper bore: L5108 and L5790 9.750 - 9.760 247.850 - 247.904
    Crankcase upper bore: L7042 10.317 -10.322 262.051 - 262.178
    (D) Crankcase lower bore: L5108 and L5790 9.678 - 9.660 245.821 - 245.872
    Crankcase lower bore: L7042 10.245 - 10.248 260.248 - 260.299
    Crankcase main bearing journal bore 6.6630 - 6.6615 169.240 - 169.202
    Crankcase camshaft bearing bore 3.752 - 3.753 95.301 - 95.326

    FORM 6248 Rrst Ednion 1.20 - 11


    SPECIFICATIONS

    Table 1.20-9. Crankshaft Wear Limits


    )

    MEASUREMENT INCHES METRIC (mm)


    Crankshaft
    Crankshaft end play (end play adjustment - 0.003 in. (0.076 mm) shims) 0.005 - 0.Q16 0.127 - 0.406
    Thrust ring thickness (standard) 0.215 - 0.217 5.461 - 5.512
    Connecting rod bearing running clearance* (diametral clearance'*) 0.0042 - 0.0081 0.1069 - 0.2057
    (A) Connecting rod bearing journal diameter 6.2485 - 6.2500 158.712 -156.750
    (8) Main bearing journal diameter 6.2485 - 6.250 158.712 -156.750
    Main bearing running clearance* (diamatral clearance*) 0.0045 - 0.0089 0.1143 - 0.2260
    (e) Connecting rod end play 0.029 - 0.041 0.7366 -1.041
    NOTE: *Main and connecting rod bearing running clearance* (diametral clearance*) = calculated bearing 1.0. minus journal 00.

    Table 1 20-10 Piston Pin - Gas

    t
    r-----------------------

    r-----------------------
    (0
    f
    MEASUREMENT INCHES METRIC (mm)
    (Al Piston pin diameter 8-1/2 inch bore 2.9987 - 2.9992 76.1670 - 76.1797
    Piston pin diameter 9-3/8 inch bore 2.9989 - 2.9994 76.1720 -76.1847
    Piston pin length L5108G,L5790G 7-11/32 186
    L7042G 8-11/32 212 )
    Piston pin fit 8-1/2 inch bore 0.0012 - 0.0022 0.0305 - 0.0559
    Piston pin fit 9-3/8 inch bore 0.001 - 0.002 0.0254 - 0.0508

    1.20 - 12 FORM 6248 First Edftion


    SPECIFICATIONS

    Table 1.20-11. PIN Series 205507 Connecting Rod, Bushing And Bearing Specifications

    ~-----------------A----------------~

    -+-
    I

    ~C­

    I--B--o

    ; - - - - - - D ------I

    MEASUREMENT I INCHES I ' METRIC (mm)


    Rod material: Heat treated steel forging
    Pennisslble connecting rocl weight variation in an engine, within weight class A, B, or C
    Connecting rod weight, Class A 60.0 ±0.12Ibs. ' 27.21 .0.054 kg
    Connecting rod weight, Class B 62.0.0.12Ibs. '28.12.0.054 Kg
    Connecting rod weight, Class C 64.0.0.12Ibs. "29.03 .0.054 Kg
    (A) Connecting rod length, center to center 18.001 - 18.002 ~457.225 - 457.251
    (B) Bore diameter for piston pin bushing 3.250 - 3.251 82.550 - 82.575
    (C) Bushing bore diameter (diamond bored),
    (assemble 2 bushings with open ends of grooves toward inside) 3.0015 - 3.0020 76.238 - 76.508

    Bushing press fit into connecting rod 0.0035 - 0.0065 0.0889 - 0.1651
    Piston pin clearance in bushing
    8.500 bore engines 0.0023 - 0.0033 0.0584 - 0.0838
    9.375 bore engines 0.0021 - 0.0031 0.0533 - 0.0787
    (0) Bore for crankpin bearing 6.625 - 6,626 168.275 - 166.300
    Crankpin bearing diametral clearance (calculated bearing inside diameter minus
    connecting rocl journal diameter). 0.0042 - 0.0081 0.1067 - 0.2057

    Width of connecting rod on bearing cap end 2.905 - 2.908 73.787 - 73.883
    Connecting rod side clearance 0.029 - 0.041 0.736 -1.041
    Parallelism and twist limit between piston pin bushing bore and crankpin bore 0.001 0.0254

    FORM 6248 First Edition 1.20 - 13


    SPECIFICATIONS

    Table 1.20-12. Valve Train Clearances - Gas


    )

    ..1I--H--/

    t'I-!1'~

    EXHAUST INTAKE

    INTAKE AND EXHAUST


    MEASUREMENT INCHES METRIC (mm)
    (A) Valve overall length
    GIGSI engines Ontake end exhaust) 10.883 276.428

    GL engines 10.883 276.428


    Ontake) 10.837 275.260
    (exhaust)
    (8) Valve stem diameter
    GIGSI engines
    (intake) 0.557 - 0.558 14.148 -14.173
    (exhaust) (top) 0.5591 - 0.5598 14.2011 - 14.2189
    (exhaust) (bottom) taper 0.5573 - 0.5580 14.1554 -14.1732
    GL engines ~ntake and exhaust) 0.557 - 0.558 14.148 -14.173
    (e) Valve head diameter (intake and exhaust) 2.825 - 2.835 71.755 - 72.009
    (D) Valve face angle
    GIGSI engines Ontake end exhaust)
    30" :!:15'

    GL engines
    Ontake) 30" :!:15'
    (exhaust) 20" ±15'
    (Il") Valve seat width
    GlGSI engines 300 0.265 6.731
    Ontake end exhaust)
    (Continued)

    1.20 -'4 FORM 6248 First Edition


    SPECIFICATIONS

    -IG~

    1- f--- H -----I
    t "f---- !-=lIS 1 E

    -IF~
    1
    B

    EXHAUST INTAKE

    INTAKE AND EXHAUST


    MEASUREMENT INCHES METRIC (mm)
    GLengines
    (intake) 300 0.265 6.731
    (exhaust) 200 0.281 7.137
    (E) valve guide length (intake and exhaust) 5.188 131.775
    (F) Valve guide outside diameter (intake and lower exhaust) 1.0015 -1.0025 25.4381 - 25.4635
    (F') Exhaust guide upper outside diameter (exhaust) 0.997 - 0.996 25.324 - 25.350
    (G) Guide inside diameter
    (reamed in assembly, except hardened guides in landfill applications) 0.5608 - 0.5615 14.244 - 14.262

    (G) Valve guide to valve stem clearance


    GIGSI engines
    (intake) 0.0029 - 0.0045 0.0711 - 0.1143
    (exhaustj (top) 0.0010 - 0.0027 0.0254 - 0.0696
    (exhaust (bottom) 0.0029 - 0.0045 0.0711 - 0.1143
    GL engines Qntake and exhaust) 0.0028 - 0.0045 0.0711 - 0.1143
    (H) Valve seat insert outside diameter Qntake and exhaust) 3.002 - 3.003 76.251 - 76.276
    (I) Valve seat insert inside diameter (intake and exhaust) 2.441 - 2.451 62.001 - 62.255
    ) (J) Valve seat insert height (intake and exhaust) 0.550 - 0.555 13.970 - 14.097
    (K) Valve seal insert seat angle 30° ±15'
    GIGSI engines Ontake and exhaust) 30° ±15'

    (Continued)

    FORM 6248 First Edijion 1.20 - 15


    SPECIFICATIONS

    -/Gi- -/Gi- )

    ~ J--H--/
    t'~!~IS T
    E
    F* 1 E

    1
    -/Ff-- -/Ff--
    1
    B

    EXHAUST INTAKE

    INTAKE AND EXHAUST


    MEASUREMENT INCHES METRIC (mm)
    GL engines
    Ontake) 30 0 +30' -0' 30 0 +30' -0'
    (exhaust) 20 0 +30' -0' 20° +30' -0'
    (K*) Valve sea! Insert sea! width
    0.172 - 0.203 4.370 - 5.160
    GlGSI engines 300 Ontake ..xl exhaust)
    GLengi nes 0.172 - 0.203 4.365 - 5.159
    (intake) 300
    0.188 - 0.250 4.780 - 6.350
    (exhaust) 200
    (L) Valve guide extension above boss 1.75.0.03 44.25.0.76
    (M) Valve guide bore in head Ontake and lower exhaust) 1.000 - 1.001 25.400 - 25.425
    (M*) Valve guide bore in head (upper exhaust) 0.995 - 0.996 25.273 - 25.298
    (NJ Valve seat insert counterbore depth Ontake and exhaust) 0.8245 - 0.8285 20.9423 - 21.0439
    (0) Valve seat insert counterbore diameter 3.000 - 3.001 76.20 - 76.23

    1.20 -16 FORM 6248 First Edition


    SPECIFICATIONS

    Table 1.20-13. Valve Clearance


    MEASUREMENT I INCHES METRIC (mm)
    Valve clearance (hydraulic lifters)
    Cam lift (see camshaft)
    Intake valve lifter travel at piston TOG 0.039 (+0.018 -0.014) 0.9906 (+0.4572 -0.3556)
    0.229 (Piston travel from TOG) 5.8166 (Piston travel from TOG)
    Intake lifter travel at 17° BTDC (0.0105 Nominal) (0.2667 Nominal)
    0.315 (Piston travel from TOC) 8.001 (Piston travel from TDC)
    Exhaust lifter travel at 20° ATDC (0.0210 Nominal) (0.5334 Nominal)
    VALVE LIFTERS
    MEASUREMENT INCHES METRIC (mm)
    Valve lifter body 00 1.4965 - 1.4975 38.0111 - 38.0365
    Valve lifter guide 10 1.4995 - 1.5005 38.0873 - 38.1127
    Valve lifter body to valve lifter guide clearance 0.002 - 0.004 0.051-0.101

    Table 1.20-14. Camshaft

    B1111- II!I8IutI 81[3EmllIllIll EiIId" I{JIIIIIIIlI + A

    II .1lI [J II

    MEASUREMENT INCHES METRIC (mm)


    (A) Camshaft journal diameter 3.498 - 3.499 66.849 - 66.875
    Camshaft journal running clearance (theoretical) 0.003 - 0.0056 0.076 - 0.142
    Camshaft end play 0.005 - 0.008 0.127 - 0.203
    End Play Adjustment 0.002 shims
    Thrust rtng thickness (standard) 0.154 - 0.156 3.911 - 3.962
    Cam lift (intake) 0.6435 16.345
    cam lift (exhaust) 0.6735 17.107
    Rocker arm ratio 1.0926 to 1
    NOTE: camshaft coupling must never be loose.

    FORM 6248 First Ednion 1.20 - 17


    SPECIFICATIONS

    Table 1.20-15. Valve Springs


    )

    I~ A J
    \. J

    MEASUREMENT
    Lt INCHES
    J
    )
    "")

    METRIC (mm)
    (A) Intake and exhaust valve spring free length:
    204035 and 204035A ~nner) 3·25/16.1/16 96mm:!:1.6mm
    204135 (outer) 4·9/32.1/16 108.7 mm .1.6 mm
    204135A (outer) 4-5/32 .1/16 105.56 mm .1.52mm
    Intake valve closed spring length:
    204035A (inner) 3.0 @ 66.4Ibs . .JIbs. 76.2 [email protected]
    204135A (outer) 3·27/64@ 120 Ibs.•5Ibs. 86.91 mm @ 54.43 kg .2.27 kg
    Exhaust valve closed spring length:
    204035 ~nner) 3 @ 56.7 Ibs.•2.5 Ibs. 76.2 mm @25.72 kg .1.36 kg
    204135 (outer) 3·27/64 @ 111 Ibs.•5 Ibs. 86.9 mm @ 50.35 kg .2.27 kg
    Intake valve open spring length:
    204035A ~nner) 2·19/64 @ 126.2 Ibs.•5 Ibs. 58.34 mm @ 57.24 kg .2.27 kg
    )
    204135A (outer) 2·23/32 @ 235 Ibs.•10 Ibs. 69.06 mm @ 106.60 kg .4.54 kg
    Exhaust valve open spring length:
    204035 (inner) 2·17/64@ 110 Ibs.•5Ibs. 57.5 mm @ 49.8 kg .2.27 kg
    204135 (outer) 2·11/16@ 2051bs .•10 Ibs. 68.3 mm @ 92.99 kg .4.54 kg

    Table 1.20-16. Crankshaft Web Deflection Measurement With Connecting Rods Installed
    VIEW FROM FLYWHEEL END

    DIAL GAUGE POSITION


    FOR MEASUREMENT 3

    CRANKSHAFT WEB DEFLECTION SPECIFICATIONS


    Total ot 0.001" (0.0254 mm) deflection from pos~ive to negative.
    Except rear: Total of 0.0015" (0.0361 mm) from positive to negative.

    1.20 - 18 FORM 6248 First Edition


    SPECIFICATIONS

    INTAKE
    OPENS
    mc EXHAUST
    CLOSES

    ~SEQUENCE
    OF EVENTS

    '\

    EXHAUST INTAKE
    FULL FULL
    OPEN OPEN

    Figure 1.20-1. Valve Sequence - Crankshaft Degrees


    Shown

    Table 1.20-17. Rocker Arm Bores And Shafts

    1=t·",""I~·=r- - - - - --

    f
    A

    ~-~----------------------~
    - ..:..og:::..:..==.:..==.:.== -=-==.:..==.:..-=:. ~~- -
    f B

    MEASUREMENT INCHES METRIC (mm)


    (A) Rocker arm bushing bore 1.0. (machined in assembly) 1.375 - 1.376 34.925 - 34.950
    (B) Rocker arm shaft 0.0. 1.3735 - 1.3745 34.8869 - 34.9123
    Running clearance, rocker arm bushing to shaft 0.0005 - 0.0025 0.0127 - 0.0835

    I
    /

    FORM 6248 First Ed~ion 1.20 - 19


    SPECIFICATIONS

    Table 1.20-18. Rear Gear Backlash Specifications


    )

    1 - CAM GEAR
    \
    2 - CAM IDLER GEAR
    3 - CRANK GEAR )
    4 - OIL PUMP IDLER GEAR
    5 - ACCESSORY IDLER GEAR
    6 - ACCESSORY (MAGNETO) DRIVE GEAR

    MEASUREMENT INCHES METRIC (mm)


    (A) liming gears (helical gears)
    Normal to tooth 0.008 - 0.012 0.203 - 0.305
    In plane of rotation 0.0082 - 0.0122 0.2083 - 0.3099
    Governor drive gears
    Magneto shaft to intermediate shaft (spur gears)
    60 and 72 tooth gears 0.005 - 0.007 0.127 - 0.178
    42 and 90 tooth gears 0.003 - 0.005 0.076 - 0.127
    Intermediate shaft to governor (spiral gears)
    Normal to tooth 0.004 - 0.006 0.102 - 0.152
    In plane of rotation (governor gear) 0.0057 - 0.0085 0.1448 - 0.2159
    NOTE: The engine camshaft idler gear is a "Hunting- Tooth" design, to minimize tooth wear. The fractional drive ratio between the crankshaft
    and camshaft gears results in the idler gear timing marks re-aligning with the crankshaft and camshaft timing marks only once in evel}' 154
    crankshaft revolutions. The most practical way to realign the timing marks, when timing B camshaft, is to remove the idlergear and re-assembJe
    to it's timed position as previously described.

    1.20-20 FORM 6248 First Edition


    SPECIFICATIONS

    Table 1.20-19. Oil Pump And Oil Pump Drive Gears

    l-CAMGEAR
    2 - CAM IDLER GEAR
    3 - CRANK GEAR
    4 - OIL PUMP IDLER GEAR
    5 - ACCESSORY IDLER GEAR
    6 - ACCESSORY (MAGNETO) DRIVE GEAR
    7 - OIL PUMP DRIVE GEAR
    8 - OIL PUMP DRIVE GEAR

    MEASUREMENT INCHES METRIC (mm)


    Idler gear between crankshaft gear and oil pump drive gear
    (A) Backlash with crankshaft gear
    Normal to tooth 0.008 - 0.012 0.203 - 0.305
    In plane of rotafton 0.0082 - 0.0122 0.2083 - 0.3099
    (B) Backlash wnh 011 pump drive gear
    Normal to tooth 0.015 - 0.020 0.381 - 0.508
    In plane of rotation 0.0153 - 0.0204 0.3888 - 0.5182
    (C) End play Qncluding clamp load compression of spindle) 0.008 - 0.025 0.203 - 0.835
    (0) Bushing inside diameter (machined in assembly) 1.5005 - 1.5015 38.1127 - 38.1381
    (E) Idler spindle (hollow) outside diameter (free state)- 1.4985 - 1.4970 38.0111 - 38.0238
    (F) Running clearance be1ween spindle (free state) and bushing* 0.0035 - 0.005- 0.0889 - 0.127*
    Oil pump drive gears
    (G) Backlash between external oil pump drive gears
    Backlash, normal to tooth 0.008 - 0.010 0.203 - 0.254
    Backlash in plane of rotation 0.0082 - 0.010 0.2083 - 0.254
    (Continuad)

    I
    /

    FORM 8249 First Ednion 1.20-21


    SPECIFICATIONS

    MEASUREMENT
    Oil Pump Clearances
    (H) Hub clearance with oil pump body
    Drive shaft bushing inside diameter
    (Q In body
    (I') In cover
    Drive shaft diameter
    (J) Body section
    (J') Cover section
    Running clearance between shaft and bushing
    (K) In cover
    (1<') In body
    Oil pump pumping gears
    (L) Backlash between pumping gears
    Backlash normal to tooth 0.015 - 0.020 0.381 - 0.508
    Backlash in plane of rotation 0.016 - 0.021 0.408 - 0.533
    (M) End play 0.005 (minimum) 0.127 (minimum)
    (N) Pumping gear (idler) bushing inside diameter 1.0005 - 1.0015 25.4127 - 25.4381
    (0) Pumping gear (idler) shaft diameter 0.9980 - 0.9985 25.3492 - 25.3619
    (P) Pumping gear (idler) running clearance 0.002 - 0.0035 0.051 - 0.0889
    (Q) Radial clearance between outside diameter of pumping gears and oil pump body bores 0.002 - 0.008 0.051 - 0.203
    * Outside diameter will be slightly larger and running clearance will be slightly smaller, because of idler spindle capscrew clamp load.

    1.20 - 22 FORM 6248 First Edition


    SPECIFICATIONS

    Table 1.20-20. VHP Accessory Gear Backlash


    MEASUREMENT I INCHES I METRIC (mm)
    Tachometer (spiral gears)
    Normal to tooth 0.002 - 0.003 0.051 - 0.076
    In plane of rotation (driven gear) 0.0021 - 0.0032 0.0533 - 0.0813
    Mechanical hourrneter (spiral gears)
    Normal to tooth 0.002 - 0.003 0.051 - 0.076
    In plane of rotation (driven gear) 0.0021 - 0.0031 0.0533 - 0.079
    Mechanical overspeed governor (spiral gears)
    Normal to tooth 0.002 - 0.004 0.051 - 0.102
    In plane of rotation (driven gear) 0.0024 - 0.0049 0.0610 - .0.1245
    Speed switch drive (spiral gears)
    Normal to tooth 0.002 - 0.004 0.051 - 0.102
    In plane of rotation (driven gear) 0.0023 - 0.0047 0.0584 - 0.1194
    Magneto drive (spur gears) 0.002 - 0.003 0.051 - 0.076

    Magneto coupling end clearance 0.0310 (nominal) 0.7874 (nOmlnall


    0.015 (minimum) 0.381 (minimum
    Magneto pickup clearance with ring gear 0.015 .0.005 0.381 .0.127
    Ring gear and starting motor (spur gears - stub tooth) 0.015 - 0.035 0.381 - 0.889
    Jacket water pump
    Impellor to body clearance I 0.015 - 0.045 I 0,381-1.143
    NOTE: These backlash limits are based on gear tooth thIckness Bnd center distance design tolerances. Actual backlash may vary slightly
    because of inherent secondary tolerances, but must not be less than 75% of the minimum backlash value listed.

    Table 1.20-21. Accessory Drive Ratios


    MEASUREMENT DRIVE RATIO DIRECTION OF ROTATION
    Gamshaft 0.5 CW Oookin.!l. at front of engine)
    Injection pump/main magneto drive 0.5 CW (looking at rear of engine)
    On gear cover (2) 1.74 CCW
    0.79, 0.975, 1.22, 1.50,
    Governor drive ratios 1.80, 2.31, 2.94, 3.52 CCW

    OVerspeed governor 1.0 CCW


    Tachometer 0.5 CCW
    Hourmeter 0.1 CCW
    Speed switch 1.0 CCW
    Oil pump (main drive shaft) 1.52 CW Oooking at front of engine)
    Ring gear/starting mota.. (Cranking Ratio)*18.9:1 CW (looking at drive end of motor)
    Magneto drive** 1.5 CW
    Allowable Speed Range For Various Woodward Governors
    VG8- 900 - 1550 RPM
    EGB2P*'" 2000 - 4000 RPM
    EGB lOP*'" 900 - 1100 RPM
    PG - PL- 250 - 1200 RPM

    NOTE: * Cranking ratio = Ring Gear Teeth + Starting Motor Pinion Teeth
    ** The magneto direction ofrotation designated is determined bylooking at the drive endofthe magneto. Therefore the magneto rotation
    designation is opposite to the rotation of the engine drive. A CWengine drive requires a magneto designated as CCWand vice versa.
    *** When normal engine operating speed is changed it may be necessary to change the governor drive gears to obtain a drive ratio that
    ) will maintain allowable governor speed. PG-PL governors are set at Woodward for air pressure verses engine speed. Re-adjusting
    PG-PL speed settings should not be attempted without thorough knowledge of the procedure.

    FORM 6248 First Edition 1.20 - 23


    SPECIFICATIONS

    Table 1.20-22. Flywheel And Housing

    MEASUREMENT (TIR) INCHES METRIC (mm)


    (A) Flywheel pilot bearing bore run-ou1 0.005 0.130
    (8) Flywheel face runout on wheel 0.Q16 0.406
    (C) Flywheel housing bore run-ou1 0.012 0.305
    (D) Rywheel housing rear face run-out 0.012 0.305
    (E) Rywheel clu1ch or coupling mounting face run-ou1 0.016 0.406
    (F) Flywheel clutch or coupling pilot diameter run-ou1 0.005 0.130
    (G) Flywheel housing rear face to crankshaft flange 5.219 - 5.281 132.563 - 134.137
    Flywheel housing
    SAE Size: #00
    Starting motor flange size: #3
    Starting motor pinion data: 6/8 pitch

    1.20 - 24 FORM 6248 First Edition


    SPECIFICATIONS

    Table 1.20-23. Turbo Inspection

    AOAPTER
    PLATE
    MAGNETIC COMPRESSOR
    BASE WHEEL

    - •
    BEARINGS

    TURBOCHARGER AXIAL PLAY TURBOCHARGER RADIAL PLAY

    TURBO INSPECTION
    Model Axial Measurement Radial Measurement
    TV 94 (Airesearch) 0.004 - 0.009 in. (0.102 - 0.229 mm) 0.003 - 0.006 in. (0.076 - 0.152 mm)

    Table 1.20-24. Lubrication System Pressures


    MEASUREMENT U.S. METRIC
    Normal stabilized oil pressure at idle speeds. 15 to 40 psi 103 - 276 kPa
    Normal stabilized oil pressure with engine loaded 55 %5 psi 380.34 kPa
    Low oil pressure (alarm) 30 psi 207 kPa
    Low oil pressure (shutdown) 20 psi 138 kPa
    Minimum oil pressure at the turbocharger 10 psi 6BKPa

    Table 1.20-25. Lubrication System Temperatures


    MEASUREMENT U.S. METRIC
    Minimum stabilized low oil temperature 160° F 70° C
    Normal stabilized oil temperature 160° F 82° C
    High oil temperature (alarm) 195° F 91° C
    High oil temperature (shutdown) 205°F 96° C

    Table 1.20-26. lubrication System Engine Transient Tilt Angles


    ATTITUDE DEGREE
    Front down 2°
    Rear down 2°
    Left side down 7°
    Right side down .,.
    NOTE: Permissible continuous duty engine tilt angles at low oil mark, based on keeping suction screen submerged.

    FORM 6248 First Edition 1.20 - 25


    SPECIFICATIONS

    Table 1.20-27. Cooling System Temperatures


    Standard Cooling System: )
    Normal:
    0
    180 F (82
    0
    Clfor continuous rating
    2000 F (930 C for intermittent rating
    JACKET WATER OUTLET Elevated Temperature Solid Water Cooling System:
    TEMPERATUREI :
    Normal: 2100 - 235 0 F (820 - 1130 C) solid water
    Ebullient Cooling System
    Normal:
    NOTE: 1 See Table 1.20·28 for alarm and shutclown temperatures.

    A CAUTION !
    !~.=.a.==~~~~~~~~.ues Alarm and shutdown val-
    are based on dry
    natural gas (900 BTU/cu. ft. SLHV). Refer to Gas-
    eous Fuel Specification Sheet S7884C and Lube Oil
    Recommendations Sheet S1015Y or latest revi-
    sions for typical changes in operation temperatures
    for jacket water and lube oil when running on
    landfill or digester gas fuels. Disregarding this
    information could result in product damage.
    Table 1.20-28. Alarm And Shutdown Setpoints
    Standard Cooling System:
    1800 F (820 C) for continuous rating
    Normal: 200 0 F (930 C) for intermittent rating
    Alarm: 100 F (5S C) above normal/design temperature
    Shutdown: 20° F (11 0 C) above normal/design temperature
    )
    Elevated Temperature Solid Water Cooling System:
    JACKET WATER OUTLET Normal: 2100 - 235 0 F (820 - 1130 C) solid water
    TEMPERATURE
    Alarm: 5° F (30 C) above normal/design temperature 1
    Shutdown: 10° F (5.5° C) above normal/design operating temperature
    Ebullient Cooling System
    Normal: 212 0 - 2500 F (1000 -1210 C)
    Alarm: See Note 2 below
    Shutdown: See Note 2 below
    Normal: 1800 F (820 C)
    LUBE OIL HEADER TEMPERATURE Alarm: 1950 F (W C)
    Shutdown: 2050 F (960 C)
    Normal: 40 - 55 psi (275 - 380 kPa)
    LUBE OIL HEADER PRESSURE Alarm: 30 psi (207 kPa)
    Shutdown: 20 psi (138 kPa)
    Normal: Up to 100 F (5.5° C) above design intercooter water inlet temperature
    INTAKE MANIFOLD TEMPERATURE Alarm: 15° F (8 0 C) above design intercooler water inlet temperature
    (GSI AND GL ENGINES)
    Shutdown: 20° F (11 0 C) above design intercooler water inlet temperature
    INTAKE MANIFOLD PRESSURE Contact Waukesha Engine Application Engineering Department
    MAIN BEARING TEMPERATURE Shutdown: 250 F (121 0 C)
    OVERSPEED Shutdown: 10% over governed speed
    NOTE: 1 Waukesha Power Systems Gode 1105, 110SA, or equivalent shutdown system is recommended when jacket water temperature
    exceeds 210 0 F (99" C).
    2 Waukesha Power Systems Code 1106, 1106A, or equivalent shutdown system is recommended for ebulliently cooled engines.

    1.20 - 26 FORM 6248 First Edition


    SPECIFICATIONS

    Table 1.20-29 Capacities


    MEASUREMENT U.S. METRIC
    Lubrication System Capacities
    Oil pan ~ow level mark) 35 gal 132.5 Litre
    Oil pan high level mark)' 45 gal 170.3 Litre
    Lube oil filter 36 gal 136.3 Lnre
    Oil cooler (8 inch) 6.9 gal 26.1 Litre
    Oil cooler (10 inch)' 10 gal 37.8 Litre
    Lube oil strainer 0.75 gal 2.8 Litre
    *Total capacity of lube oil system. Fill oil pan, filter, cooler, etc., run engine, then add oil as required to bring all level in oil pan back to high
    mark.
    Record total amount for future reference.
    Governor - Air Starter Capacities
    UG8 governor oil reservoir 1.5 qt 1.1 Litre
    EGB10P governor oil reservoir 1.5 qt 1.1 Litre
    PG-PL governor oil reservoir 1.6 qt 1.1 Litre
    Air starter all reservoir for one shot lubricator 2.0 Pint 0.9 Litre
    Air motorized pre-lube motor ~n-line lubricator 0.5 Pint 0.2 Litre
    Jacket Water Capacities
    8-1/2 inch bore 107 gal 405 Litre
    9-3/8 inch bore 100 gal 367 Litre
    Surge tank 45.5 gal 183 Litre
    Oil cooler water (6 inch diameter) 3.4 gal 12 Litre
    Oil cooler water (8 inch diameter) 5.5 gal 20 Litre
    Oil cooler water ( 10 inch diameter) 9.4 gal 34 Litre
    Intercooler water capacity 5.50 gal 20 Litre

    CAUTION 11/2 inch reach sp~rk


    I =:......::::..:.....;;.,;;:;....;;,..;;..;:;".;~.
    A
    .L .::
    .. plugs must be used with
    1/2 inch reach spark plug carriers. Mixing spark
    plug carrier and spark plug components will cause
    damage to equipment.

    Table 1.20-30. 1/2 Inch Reach Spark Plugs (Used With 1/2 Inch Reach Spark Plug Carriers Only)
    SPARK
    THRB HEX REACH GAP GASKET APPUCATION
    PLUG
    0.020 in
    PIN 60999F 18mm 0.875 1/2 in (O.508mm) Yes Standard for GIGSI model used wnh: CEC, A~ III, FM9000

    0.020 in
    PIN 60999G 18mm 1.000 1/2 in (0.508 mm) Yes GlGSI Provisioo for spM< plug mounted coil, FM9000 - GSA

    0.020 in
    P/N60999H 18mm 0.875 1/2 in (0.508 mm) Yes GIGSI - Shielded CEC - CSA

    0.010 in
    P/N60999M 18mm 0.875 1/2 in (0.254 mm) Yes Standard for GL CEC ignition

    0.010 in
    P/N60999N 18mm 1.000 1/2 in (0.254mm) Yes GL Provision for spark plug mounted coil, FM9000 - eSA
    0.010 in
    P/N60999R 18mm 0.875 1/2 In (0.254mm) Yes GL Provision for spark plug mounted coil, Alt III -CSA

    Spark plug size 18 mm with 1/2 inch reach


    NOTE: ' Torque to 40 - 45 ft-lb dry (54 - 61 N·m) Use steel gasket PIN 499865.
    ** When B shielded Ignition system is used, tighten allconnector nuts and spark plug extensions finger tight plus 1/8 to 1/4 tum. Do not
    ) touch terminal connectors with bare fingers and make sure all parts are clean before assembling them. All knurled connecffons on
    shielded magnetos and coil should be finger tightened only.

    FORM 6248 First Ednion 1.20 - 27


    SPECIFICATIONS

    CAUTION I~HP
    I.=A=,---,~,---,;;....;..;;...::;..;~.
    GL 13/16 inch reach
    L.. . spark plugs must be )
    used with 13/16 inch reach spark plug carriers.
    Mixing spark plug carrier and spark plug compo-
    nents will cause damage to equipment.

    Table 1.20-31. VHP GL 13/16 Inch Reach Spark Plugs (Used With 13/16 Inch Reach Spark Plug Carriers Only)
    SPARK THRB HEX REACH GAP GASKET APPLICATION
    PLUG
    0.010 in Non-shielded GL (Used w~h PIN 69694 "Blue Coil")
    PIN 60999S 18mm 0.875 13/16 Yes
    (0.254 mm) (4 ground) (nickel)

    P/N60999W 18mm 0.875 13/16


    0.010 in
    Yes Non-shielded GLJUsed ~h PIN 69684 "Blue Coil")
    (0.254 mm) (" "type) (platinum)
    0.010 in Yes Non-shielded GL (Used with PIN 69684 'Blue Coil')
    PIN 60998T 18mm 0.875 13/16 (0.254 mm) ("J" type) (iridium/platinum)
    0.Q10 in
    PIN 60999U 18mm 0.875 13/16 Yes Shielded GL (Used ~h PIN 696840 coil)
    (0.254mm)
    PIN APPLICATION
    13/16 INCH SPARK PLUG CARRIERS 209567M Used on 5108GL only
    209567K Used on 5790GL and 7042GL
    NOTE:· Torque to 40 - 45 ft~b dry (54 - 61 N·m). Use steel gasket PIN 499865.
    ** When B shielded ignition system is used, tighten all connector nuts and spark plug extensions finger tight plus 1/8 to 1/4 tum. Do not
    touch terminal connectors with bare fingers and make sure all parts are clean before assembling them. All knurled connections on
    shielded magnetos and coil should be finger tightened only.
    -Refer to SB 11-2636 for additional GL spark plug information.

    GAS ENGINE COMPRESSION PRESSURE

    Q
    W
    W
    11.
    UJ
    CI
    z 280
    iii ,/
    g 270
    260
    ,/
    250

    Iz
    Ie
    240
    230
    220 ./
    ./
    ;'
    ./

    /"
    ./
    ./

    210
    ~ 200
    ,/ ./
    ../I V
    190 ,; -..... I
    ll!
    :> 180 ./
    UJ ./ /' USUAL RANGE
    170
    . /
    iz
    160
    150
    ,/
    ./
    ./
    ./
    140

    i
    ,/
    130
    120 ./ ./
    ::IE 110 ~./
    8 100 ;..-
    I
    90
    5 6 7 8 9 10 11
    COMPRESSION RATIO
    NOTE: use these compression values during troubleshooting to assist in determining engine condition.

    Figure 1.20-2. Engine Compression Pressures

    1.20 - 28 FORM 6248 First Ed~ion


    SPECIFICATIONS

    \
    ENGINE TIMING DATA
    CAUTION I
    I-=.A=--,,;.;;...;;.;;;;...;;.~...;;.,,-,.
    This information does usually calculated from a component analysis. On the
    L. . NOT supercede Special motor method scale used by Waukesha, the octane
    Application Approval data found on the engine number ranges from 120 for methane (best) to 0 for
    nameplate. Disregarding this Information could normal heptane (worst).
    result In product damage.
    PROPANE, HD-S: A fuel gas made of carbon (C3 ), and
    NOTE: Changing the engine timing will also change the hydrogen (Ha) with 97.1 octane rating. Often used as a
    exhaust emissions and fuel economy. backup fuel.

    Table 1.20-32 and Table 1.20·33 list the correct ignition LOW BTU FUEL: Fuel having less than 700 Btu!ft3
    timing for VHP 12 Cylinder engines from January 1, (26.08 J/cm3 ), such as landfill gas.
    1980. Refer to Service Bulletin 11-1520A for the timing
    specifications for older engines. IA..
    CAUTION I Detonation is NOT al-
    lowed at any time during
    Both Table 1.20-32 and Table 1.20-33 list the engines engine operation, regardless of the specified tim-
    by models and fuel types. Table 1.20·32 provides data ing. H detonation occurs at the specified timing, a
    for engines that are not DSM equipped and timing adjustment must be made to retard the
    Table 1.20-33 provides data for engines that are DSM ignition timing until NO audible detonation extsts.
    equipped. The fuel types are defined in the following Engine damage may result If detonation occurs.
    paragraphs.

    COMMERCIAL QUALITY NATURAL GAS: A natu-


    rally occurring mixture of hydrocarbon and other
    gases found beneath the earth's surface, often in
    connection with liquid petroleum. The principle com-
    ponent is usually methane (CH4). Minor components
    ) are heavier hydrocarbons and other gases such as
    nitrogen (N2), carbon dioxide (C02), helium (He),
    argon (Ar) , oxygen (02)' and hydrogen sulfide (H2S).
    The heat value normally ranges from 900 - 1000
    Btu/ft3 SLHV (33.54 - 37.26 J/cm3 ). Octane rating of
    118 - 120. Holland's pipeline gas has a heat value of
    820 Btu!ft3 SLHV (30.5 J/cm3)

    DIGESTER GAS: A fuel gas formed by the anaerobic


    decomposition of organiC matter in a digester. It is
    composed primarily of methane (CH 4) and carbon
    dioxide (C02). The heat value normally ranges from
    500 - 600 Btu!ft3 SLHV (18.63 - 22.36 J/cm3). Octane
    rating of 120. Hydrogen sulfide (H2S) is a typical trace
    component.

    FIELD GAS: The heat value normally ranges from


    900 - 1500 Btu/ft3 SLHV (33.54 - 55.898 J/cm 3 ).
    Octane rating of 115 - 118.

    LANDFILL GAS: A fuel gas formed by the decomposi-


    tion of landfill refuse. It is composed primarily of
    methane (CH4) and carbon dioxide. (C02). The heat
    value normally ranges from 450 - 550 Btu!ft3 SLHV
    (16.77 - 20.39 J/cm3). Octane rating of 118 - 120.
    Chlorine and fluorine bearing compounds are typical
    ) trace components.

    OCTANE NUMBER: The octane number of a fuel is a


    measure of if its ability to resist detonation (knock). It
    may be measured or calculated. For gas mixtures it is
    FORM 6248 Rrst Edition 1.20 - 29
    SPECIFICATIONS

    Table 1.20-32. Ignition Timing Data (Non-DSM)


    OPERATING RPM
    600 1 700 1 800 1 900 1000 11100 1200
    COMPRESSION
    MODEL RATIO:1 DUTY FUEL TYPE IGNITION TIMING CO BTDC)
    L5108G 8.25:1 Cont. Low Btu 2t O 21 0 21 0 240 240 240 240
    L5108G 8.25:1 All HD-5 LPG 180 18 0 18 0 150 150 150 150
    L5108G 8.25:1 All Nat. Gas 21 0 21 0 21 0 240 240 240 240
    L5108G* 8.25:1 All Nat. Gas - - - - - - 21 0
    L5108G 10:1 Cant. Low Btu 20 0 20 0
    22 0
    220 240 240 240
    L5108G 10:1 All HD-5LPG 12 0
    12 0
    12 0
    12 0
    12 0
    12 0
    12 0
    L5108G 10:1 All Nat. Gas 20 0 20 0
    22 0
    22 0 240 24 0 240
    L5108G* 10:1 Cant. Nat. Gas - - - - - - 21 0

    L5108GSI 8.25:1 Cant. Low Btu 22" 22" 22" 22 0


    22 0
    22 0
    22 0

    L5108GSI** 8.25:1 Cant. HD-5 LPG go go go go go go go


    0
    L5108GSI- 8.25:1 Cant. HD-5 LPG 12 0
    12 12 0 120 120 120 120
    L5108GSI 8.25:1 Cant. Nat. Gas 22 0
    22 0 22 0
    220 22 0
    22 0 220
    0 0
    L5108GSI 8.25:1 Intr. Nat. Gas 18 0
    18 18 0
    18 0
    18 18 0
    180
    L5108GSI* 8.25:1 Cont. Nat. Gas - - - - - - 22 0
    L5108GSI* 8.25:1 Intr. Nat. Gas - - - - - - 18 0
    L5108GSI 10:1 Cant. Low Btu 180 180 180 18 0 18 0 150 15 0
    0 0 0 0 0 0
    L5108GSI 10:1 Cant. Nat. Gas 18 18 18 18 18 15 15 0
    L5108GSI 10:1 Intr. Nat. Gas - - - - - - 150
    L5108GSI* 10:1 All Nat. Gas - - - - - - 150

    5108GL 10.5:1 All Low Btu 20 0


    20 0 20 0
    200 200 20 0 200
    5108GL 10.5:1 All Low Octane, 115 Min. 6" 6" 6" 60 6" 6" 60
    5108GL 10.5:1 All Low Octane, 117 Min. 10 0
    10 0
    10 0
    10 0
    10 0
    10 0
    10 0
    5108GL 10.5:1 All Nat. Gas 14 14 0
    14 0
    14 0
    14 0
    14 0
    14 0

    L5790G 8.25:1 Cant. Low Btu 22 0


    220 22 0 240 240 240 240
    L5790G 8.25:1 All HD-5 LPG 180 18 0 180 150 150 15 0 150
    L5790G 8.25:1 All Nat. Gas 22 0
    22 0
    22 0
    24 0
    24 0
    24 0
    240
    L5790G 10:1 Cant. Low Btu 20 0
    20 0
    20 0
    20 0 20 0 20 0 20 0
    L5790G 10:1 All HD-5 LPG 12 0
    12 0
    12 0
    12 0
    12 0
    12 0
    12 0
    L5790G 10:1 All Nat. Gas 200 20 0
    200 200 200 20 0
    200
    L5790G* 10:1 All Nat. Gas - - - - - - 160

    L5790GSI 8.25:1 Cant. Low Btu 21 0 21 0 21 0 21 0 21 0 21 0 21 0


    L5790GSI** 8.25:1 Cont. HD-5 LPG go go go go 9" 9" 9"
    0 0 0
    L5790GSI- 8.25:1 Cant. HD-5 LPG 12 12 12 120 12 0 120 12 0
    L5790GSI 8.25:1 Cant. Nat. Gas 21 0 21 0 21 0 21 0 21 0 21 0 21 0
    L5790GSI 8.25:1 Intr. Nat. Gas 22 0
    22 0
    22 0
    20 0
    20 0
    18 0
    180
    L579OGSI* 8.25:1 Cont. Nat. Gas - - - - - - 21 0
    )
    L5790GSI* 8.25:1 Intr. Nat. Gas - - - - - - 180

    1.20 - 30 FORM 6248 First Edition


    SPECIFICATIONS

    OPERATING RPM
    600 700 800 900 1000 1100 1200
    COMPRESSION
    MODEL RATIO:1 DUTY FUEL TYPE IGNITION TIMING r BTDC)
    5790GL 10:1 All Low Btu 160 160 160 160 160 160 160
    5790GL 10:1 All Low Octane, 115 Min. 60 60 60 60 60 60 60
    5790GL 10:1 All Low Octane, 117 Min. 100 100 100 100 100 100 100
    5790GL 10:1 All Nat. Gas 100 100 100 100 100 11 0 11 0

    L7042G 8:1 Cont. Low Btu 20 0 200 200 240 240 240 240
    L7042G 8:1 All HD-5 LPG 180 180 180 150 150 150 150
    L7042G 8:1 All Nat. Gas 20 0 200 200 240 240 240 240
    L7042G 10:1 Cont. Low Btu 20 0 200 200 220 220 240 240
    L7042G 10:1 All HD-5 LPG 120 120 120 100 100 go go

    L7042G 10:1 All Nat. Gas 20 0 200 200 220 220 240 240
    L7042G" 10:1 All Nat. Gas - - - - - - 21 0

    L7042GSI 8:1 Cont. Low Btu 21 0 21 0 21 0 240 240 240 240


    L7042GSI- 8:1 Cont. HD-5 LPG go go go go go go go

    L7042GSI 8:1 Cont. HD-5 LPG 120 120 120 120 120 120 120
    L7042GSI 8:1 Cont. Nat. Gas 21 0 21 0 21 0 24~..., . 24
    0 240 240
    L7042GSI 8:1 InlT. Nat. Gas 150 150 150 15" _. 150 150 150
    L7042GSI" 8:1 Cont. Nat. Gas - - - - - - 21 0
    L7042GSI" 8:1 InlT. Nat. Gas - - - - - - 150
    "

    7042GL 10.5:1 Cont. Low Btu - 160 160 16°.,. ~" 16" 160 160
    7042GL 10.5:1 All Low Octane,115 Min. - 60 60 60 60 60 6"
    7042GL 10.5:1 All Low Octane, 117 Min. - 100 100 100 100 100 100
    7042GL 10.5:1 All Nat. Gas 100 100 100 100 100 100 100
    7042GL 10.5:1 Cont. HD-5 LPG - - - 40 40 40 40
    NOTE: "These enQlnes run wnh an elevated jacket water temperature between 2100 and 250 0 F (990 -1210 C). It is neeessaryto adjust the
    ignition timing to allow for a greater margin of protection from detonation. Changing the engine timing will also change the exhaust
    emissions and fuel economy.
    **1. W. Temperature 1300 F (540 C)
    -I. W. Temperature 850 F (2go C)

    FORM 6248 First Edition 1.20 - 31


    SPECIFICATIONS

    Table 1.20-33. DSM Timing Data (DSM Equipped)


    OPERATING RPM
    600 700 800 900 1000 1100 1200
    COMPRESSION
    MODEL RATIO:l DUTY FUEL TYPE DSM TIMING (" BTDC)
    L5108G 8.25:1 Cont. Low Btu 15-21 0 15-21 0 15-21 0 18 - 24° 18 - 240 18 - 240 18 - 240
    L5108G 8.25:1 All HD-5 LPG 12 - 180 12 - 180 12 - 180 9 - 150 9 _15 0 9 _15 0 9 _15 0
    L5108G 8.25:1 All Nat. Gas 15 - 21 0 15-21° 15 - 21 0 18 - 240 18 - 240 18 - 24 0 18 - 240
    L5108G* 8.25:1 All Nat. Gas - - - - - - 15-21 0
    L5108G 10:1 Cont. Low Btu 14 _ 200 14 - 20 0 16-22° 16 - 220 18 - 240 18 - 24° 18 - 240
    L5108G 10:1 All HD-5 LPG 6 _12 0 6 - 120 6 _120 6 _120 6 _120 6 - 120 6 _12 0
    L5108G 10:1 All Nat. Gas 14 - 20° 14 - 200 16 - 220 16 - 22 0 18 - 240 18 - 24
    0 18 - 24°

    L5108G* 10:1 Cont. Nat. Gas - - - - - - 15-21 0

    L5108GSI 8.25:1 Cont., Low Btu 16 - 22° 16 - 22 0 16 - 220 16 - 22" 16 - 220 16 - 22 0 16 - 22°
    L5108GSI- 8.25:1 Con!. HD-5 LPG 3 - go 3 _ g" 3 - g" 3 - g" 3 _ go 3 _ g" 3 - g"
    L5108GSI- 8.25:1 Cont. HD-5 LPG 6 _12" 6 _120 6 - 120 6 _12" 6 _120 6 _120 6 - 120
    L5108GSI 8.25:1 Cont. Nat. Gas 16 _ 22 0 16 _ 22 0 16 - 220 16 - 220 16 - 220 16 _ 22 0 16 - 220
    L5108GSI 8.25:1 Intr. Nat. Gas 12 - 180 12 - 180 12 - 180 12 - 180 12 - 180 12 _18 0 12 - 180

    L5108GSI* 8.25:1 Cont. Nat. Gas - - - - - - 16 - 220


    L5108GSI* 8.25:1 Intr. Nat. Gas - - - - - - 12 - 180
    L5108GSI 10:1 Cont. Low Btu 12 - 180 12 - 180 12 - 180 12 - 180 12 - 18" 9 _15 0 9 _15 0
    L5108GSI 10:1 Cant. Nat. Gas 12 - 180 12 _18 0 12 _18 0 12 _ 180 12 - 18° 9 _15 0 9 _15 0
    L5108GSI 10:1 Intr. Nat. Gas - - - - - - 9 _15 0
    )
    L5108GSI* 10:1 All Nat. Gas - - - - - - 9 - 15"

    5108GL 10.5:1 All Low Btu 14-20° 14 _ 200 14 _ 200 14 - 20 0 14-200 14_200 14 - 200
    Low Octane, 0_60 0_60
    5108GL 10.5:1 All 115 Min.
    0-6" 0-6° 0-6° 0-6" 0-6"

    Low Octane, 4 _10 0 4 _10 0 4 _10 0 4 _10 0 4 _10 0


    5108GL 10.5:1 All 117 Min. 4 - 10° 4 - 100

    5108GL 10.5:1 All Nat. Gas 8 -14 8 - 140 8 _14 0 8 _14 0 8 _14 0 8 _14 0 8 - 140

    L5790G 8.25:1 Cont. Low Btu 16 _ 22 0 16 - 220 16 - 220 18 - 24° 18 - 240 18 - 240 18 - 240
    L5790G 8.25:1 All HD-5 LPG 12 _18 0 12 - 180 12 _18 0 9 - 150 9 - 150 9 _15 0 9 _15 0
    0 16 - 22° 0
    L5790G 8.25:1 All Nat. Gas 16 - 22 16 - 22 18 - 240 18 - 240 18 - 24" 18-240
    Low Btu 0 14 _ 200 14-20 0 14_200 14 - 20 0 14 _ 200 14 - 20"
    L5790G 10:1 Cont. 14 - 20
    L5790G 10:1 All HD-5 LPG 6 _12 0 6 _120 6 _120 6 _120 6 _120 6 _120 6 - 120
    10:1 All Nat. Gas 14 - 20 0 14 - 20° 14 - 200 14 - 200 14 - 200 14-200 14 - 200
    L5790G
    L5790G* 10:1 All Nat. Gas - - - - - - 10 - 160

    1.20-32 FORM 6248 First EdHion


    SPECIFICATIONS

    OPERATING RPM
    600 700 800 900 1000 1100 1200
    COMPRESSION
    MODEL RATIO:1 DUTY FUEL TYPE DSM TIMING (' BTDC)
    L5790GSI 8.25:1 Cant. Low Btu 15 - 21' 15-21' 15-21° 15 - 21° 15-21' 15-21' 15-21'
    L5790GSlti 8.25:1 Cant. HD-5LPG 3 _ go 3 _ go 3 _ go 3 _ go 3 _ go 3 - go 3 _ go
    L5790GSI- 8.25:1 Cant. HD-5 LPG 6 _12' 6 _12' 6 _12' 6 _12' 6 _12' 6 - 12' 6 _12'
    L5790GSI 8.25:1 Cont. Nat. Gas 15-21' 15-21' 15-21' 15-21' 15-21' 15-21° 15-21'
    L5790GSI 8.25:1 In!r. Nat. Gas 16 - 22° 16 - 22' 16 - 22' 14 - 20' 14 - 20' 12 - 18' 12 - 18°
    L5790GSI* 8.25:1 Cont. Nat. Gas - - - - - - 15-21°
    L5790GSI* 8.25:1 In!r. Nat. Gas - - - - - - 12 - 18'
    5790GL 10:1 All Low Btu 10 - 16' 10 - 16' 10 - 16' 10 - 16' 10 _16' 10 - 160 10 - 16'
    Low Octane, 0_6 0_6 0_6
    5790GL 10:1 All 115 Min. 0-6° 0 0 0
    0_6 0
    0_6 0
    0_60

    Low Octane, 4 _10' 4 _10' 4 _10' 4 _10'


    5790GL 10:1 All 117 Min. 4 - 10' 4 - 100 4 _10'

    5790GL 10:1 All Nat. Gas 4 - 10' 4 _10' 4 _10' 4 _10' 4 _10' 5 - 11' 5 - 11°

    L7042G 8:1 Cont. Low Btu 14-20° 14 _ 20' 14 _ 20' 18 - 24' 18 - 24' 18 - 24' 18 - 24°
    L7042G 8:1 All HD-5 LPG 12 _18' 12 - 18 0
    12 - 18' 9 _15' 9 _15 0
    9 - 15' 9 _15'
    L7042G 8:1 All Nat. Gas 14-20° 14 - 20° 14 _ 20' 18 - 24' 18 - 24' 18 - 24' 18 - 24°
    L7042G 10:1 Cont. Low Btu 14-20° 14 - 200 14 - 20' 16 _ 22' 16 - 22"' 18 - 24' 18 - 24'
    L7042G 10:1 All HD-5 LPG 6 - 12° 6 _12' 6 _12' 4 _10' 4 - 10'. 3 _ go 3 - go
    L7042G 10:1 All Nat. Gas 14-20° 14 - 20' 14 - 20' 16 _ 22' 16 - 22°, 18 - 24' 18 - 24°
    L7042G* 10:1 All Nat. Gas - - - - - - 15-21'

    L7042GSI 8:1 Cont. Low Btu 15-21' 15 - 21' 15 - 21' 18 - 24' 18 - 24". 18 - 24° 18 - 24'
    L7042GSlti 8:1 Cont. HD-5 LPG 3 _ go 3 _ go 3 _ go 3 _ go 3 _ go 3 - go 3 _ go
    L7042GSI 8:1 Cont. HD-5 LPG 6 - 12' 6 _12' 6 _12' 6 _12' 6 _12' 6 - 12' 6 _120
    L7042GSI 8:1 Cont. Nat. Gas 15-21' 15-21' 15-21' 18 - 24' 18 - 24' 18 - 24' 18 - 24'
    L7042GSI 8:1 Intr. Nat. Gas 9 - 15' 9 _15' 9 _15' 9 _15' 9 _15' 9 - 15' 9 _15'
    L7042GSI* 8:1 Cont. Nat. Gas - - - - - - 15-21'
    L7042GSI* 8:1 Intr. Nat. Gas - - - - - - 9 _15'

    7042GL 10.5:1 Cont. Low Btu - 10 _16' 10 - 16' 10 - 16' 10 - 160 10 - 16' 10 - 16'
    Low Octane,
    7042GL 10.5:1 All 115 Min. - 0_6 0
    0_60 0-60 0-6 0 0_60 0_60

    Low Octane,
    7042GL 10.5:1 All 117 Min. - 4 - 10' 4 _10 0 4 _10 0 4 _10 0 4 - 10' 4 _10'

    7042GL 10.5:1 All Nat. Gas 4 -10' 4 - 10' 4 _10' 4 _10' 4 _10' 4 - 10° 4 _10'
    NOTE: * These en9ines run with an elevated jacket water temperature between 210 and 250 F (99° - 121 C). It is necessary to adjust the
    0 0 0

    ignition timing to allow for a greater margin of protection from detonation. Changing the engine timing will also change the exhaust
    emissions and fuel economy.
    ti I. W. Temperature 130' F (54' C)
    - I. W. Temperature 85' F (29' C)

    FORM 6248 First Edition 1.20 - 33


    SPECIFICATIONS

    1.20 - 34 FORM 6248 First Edition


    CHAPTER 2 - ENGINE TEAR DOWN

    CONTENTS

    SECTION 2.00 - CYLINDER HEAD REMOVAL

    SECTION 2.05 - CRANKCASE REMOVAL

    FORM 6248 Rrst Edition


    )

    FORM 6248 First Edition


    SECTION 2.00 - CYLINDER HEAD REMOVAL

    CYLINDER HEAD REMOVAL


    IL• .:
    A CAUTION Ilf repair work requires
    . =:.....;:;.;;...;;.;;;....;;...;;...;;:..--1.
    . removal of the cylinder
    NOTE: Be sure that you have read and understood the heads from one or both banks while the exhaust
    safety and waming information in Section 1.01, Safety, manifold stays in place, care must be taken so that
    and Section 1.02 Rigging and Lifting Engines. before proper support is maintained for the exhaust
    proceeding. manifold. To provide this support, only a limited
    number of cylinder heads can be removed at any
    A WARNING one time. This specific technique provides the
    proper support to the exhaust manifold. If sufficient
    Failure to take adequate precautions when servic- support is not provided to the exhaust manifold and
    ing this product can result in severe personal injury associated components, severe damage can occur
    or death. to these parts.

    Leave the exhaust manifold secured to cylinder heads


    A WARNING 1L, 1R, 3L, 3R, 5L and 5R on Left and Right cylinder
    banks while cylinder heads 2L, 2R, 4L, 4R, 6L and 6R
    Never walk or stand under an engine or component
    are removed. When the removed cylinder heads are
    while it is suspended. Always consider the weight
    replaced and secured to the exhaust manifold, then
    of the item being lifted. Use properly rated lifting
    cylinder heads 1 L, 1 R, 3L, 3R, 5L and 5R on Left and
    equipment and approved lifting methods. H not
    Right cylinder banks can be removed.
    supported by a properly rated lifting device, some
    heavy parts may fall when loosened. Failure to take
    adequate precautions can resuH in severe personal I A CAUTION I Before disassembly,
    .. drain all coolant com-
    injury or death.
    pletely from the engine. Prevent dirt or water from
    entering the 011 sump when removing' the cylinder
    NOTE: As part of the overhaul process, the exhaust
    heads and liners.
    manifold, intake manifold and water manifold should
    already be removed. If not, refer to Chapter 5 of this
    manual, for removal procedures for those particular
    items. Chapter 5 covers the removal of all the extemal
    A WARNING
    components of the engine. Procedures have been This procedure is a two person operation. To do this
    included in this section to allow cylinder heads to be procedure alone is dangerous and can result In
    removed in field conditions, when the manifolds may not severe personal injury or death.
    normally be removed.
    1. Refer to Chapter 5 and remove spark plug assembly.
    NOTE: Service Bulletin 15-2oo7B, Exhaust Manifold
    Support Bracket, describes how to fabricate and use
    exhaust manifold support brackets, when it is desired to A WARNING
    remove cylinder heads without removing the exhaust Ensure that the fuel source Is completely shut off
    manifolds. If support brackets are not available, an prior to working on fuel system components Clear
    altemative method is to remove six cylinder heads the engine supply lines and piping of accumulated
    (three from each cylinder bank) in a pattem that allows gas before performing any maintenance work on the
    for full support of the exhaust manifolds as outlined in fuel system or severe personal InJury or death could
    the following. resuH.

    2. Refer to Chapter 5 and disconnect the fuel supply


    tube from the admission valve body (GL).

    3. Refer to Chapter 5 and remove the admission valve


    assembly from the cylinder head (GL).

    4. Remove the rocker arm covers and gaskets from the


    cylinder heads.

    FORM 6248 First EdHion 2.00 -1


    CYLINDER HEAD REMOVAL

    NOTE: Do not mix parts between rocker arm assem- 7. Pull out the hydraulic push rods (2 rods per cylinder
    blies, lift both sides of the rocker arm assemblies off head) (see Figure 2.00-3). Tag the push rods as they )
    together. are removed, so that they can be installed in their
    original locations. Place the pushrods in clean plastiC
    5. Remove the rocker arm support capscrews and bags to keep dirt and debris out of the hydraulic lifters.
    washers (8 capscrews per head, 1/2 x 4-3/4 inches).
    Move the rocker arm assemblies to a suitable work-
    bench (See Figure 2.00-1).

    Figure 2.00-3. Push Rods And Water Outlet Elbows

    8. Remove the water outlet elbows (2 ferry head, 2 hex


    head capscrews per elbow, 1/2x 1-3/4 inches, with lock
    washers) (see Figure 2.00-3). Remove and discard the
    Figure 2.00-1. Rocker Arms rectangular rubber seals from the ends of each elbow
    (see Figure 2.00-4).
    8. Remove the rocker arm oil supply tubes from the
    cylinder heads (see Figure 2.00-2). Remove the male )
    connector tube fittings from the cylinder head castings.

    ROCKER ARM OIL


    SUPPLY TUBE ~ ~
    ~
    _

    FERRULE
    Nut

    FERRULE~~lI"'''.f I

    Figure 2.00-4. Water Outlet Elbow Gaskets

    ~_MALE CONNECTOR
    ~ TUBE FITTING

    Figure 2.00-2. Install Rocker Arm 011 Supply Tubes

    IA CAUTION IHydraulic push rods


    .L .::
    . . must be stored I n the
    =:.......;::..;;,...;;,,;:...-.;:.,..:.-.;;;...0...:...1. )
    vertical position to prevent the oil from leaking out
    of the hydraulic valve lifters. Disregarding this
    information could result In product damage.

    2.00 - 2 FORM 6248 First Edition


    CYLINDER HEAD REMOVAL

    9. Remove two capscrews (2 hex head 1/2 x 5-1/2


    inches, with washers and 2 hex head 1/2 x 8-1/2", with A WARNING
    washers) from the exhaust manifold (see Each cylinder head weighs approximately 195 Ibs.
    Figure 2.00-5). (89 Kg). Use a suitable lifting device and exercise
    caution to avoid severe personal injury or death.

    13. Thread an eye bolt (1/2"-13) into the rocker arm


    cover capscrew bore closest to the water oUOet elbow
    connection. Install a suitable lifting chain, (see
    Figure 2.00-7).

    Figure 2.00-5. Exhaust Manifold - Rear VIew

    10. Loosen the gasket seal where the exhaust manifold


    joins the cylinder head.

    11. Remove four capscrews (GL models, hex head,


    1/2 x 1-3/8" with washers and lockwashers)
    (G/GSI models, hex head, 1/2 x 1-1/4" with washers and
    lockwashers) from the intake manifold (see
    ) Figure 2.00-6).

    NOTE: Loosen the intake manifold capscrews on all Figure 2.00-7. Eye Bolt Location -
    cylinder heads to to allow the intake manifold to be 12 Cylinder Engines· ..
    moved back.
    14. Remove the capscrews and washers securing the
    heads to the engine block (8 capscrews per head; 2
    short, 6 long) (see Figure 2.00-8).

    Figure 2.00-6. Intake Manifold

    12. Loosen the gasket seal where the intake manifold


    joins the cylinder head. Figure 2.0IHI. Cylinder Heads

    FORM 6248 First Edition 2.00 - 3


    CYLINDER HEAD REMOVAL

    CYLINDER HEAD

    WEIGHT
    UNBALANCED
    )

    CRANKCASE

    Figure 2.00-9. Lifting The Cylinder Head

    CAUTION I
    I=.A=:........;~...;..;;;;....:c...:...;;;...;:....:...J.
    To avoid damage to the 16. Remove the head gaskets from the engine block.
    L. . deck surface or the dowel Scrape any gasket material from the cylinder head and
    locating pins, raise the cylinder head at an angle that engine block.
    closely approximates the angle of the crankcase.

    15. Lift the head off the engine using an overhead lifting
    device (see Figure 2.00-9).

    NOTE: A pry bar may be needed to free the cylinder


    head from the head gasket.

    NOTE: The push rod cover assemblies may lift off with
    the cylinder head or remain attached to the valve lifter
    housing. In any case, remove the push rod cover
    assemblies from either the cylinder head or valve lifter
    housing.

    CAUTION I
    I=.A=:........;~---''-c...:...;;;...;:....:...J.
    Position the cylinder
    L. . heads on a wooden
    board or pallet. Place each head on its side to avoid
    damage to the nozzle of the prechamber cup on GL
    models.

    2.00 - 4 FORM 6245 First Ed~ion


    SECTION 2.05 - CRANKCASE REMOVAL

    PISTON/CONNECTING ROD REMOVAL

    A WARNING
    This procedure Is a two person operation. To do this
    procedure alone is dangerous and can result In
    severe personal injury or death.

    A CAUTION I ~emove only. one piston


    IL• .:
    . =:.......;;;;.;;....;;..;;....;~.;;...~.
    . and connecting rod as·
    sembly at one time. Removing more than one
    cylinder may cause damage to equipment.

    NOTE: Drain all engine oil before proceeding. Engine


    coolant should already be drained. Figure 2.05·2. Carbon Ridge
    1. Remove the connecting rod cap (4 ferry head
    3. Install a piston puller (PiN 474018, for 8-1/2 in. bore,
    capscrews) (see Figure 2.05-1).
    PiN 474019, for 9-3/8 in. bore) into the two threaded holes
    in the piston crown (see Figure 2.05-3). Use a suitable
    refacing tool to unplug the holes and clean hardened
    carbon from the threads without causing damage to the
    bore. Install a lifting chain to the piston puller.

    PISTON
    ) PULLER

    Figure 2.05-1. Capscrews - Connecting Rod Caps

    A CAUTION IToensureremo~alofthe
    I = ' - ' -_ _ _ _--'. entire carbon ridge and
    L...
    : .

    to avoid nicking or scratching the piston with the


    carbon scraper, bar the engine over to move each
    piston to its lowest point of travel.
    Figure 2.05-3. Install Piston Puller
    'A CAUTION I~onotcutdownlntothe
    =
    ..
    IL. =:.......;;;;.;;....:.:=-.;:;..;;..;:;..;~. ring travel zone when
    removing the carbon ridge from the cylinder sleeve
    bore. Disregarding this information could result In
    A WARNING
    product damage. Each piston and connecting rod assembly weighs
    approximately 90 Ibs. (41 Kg). Use a suitable lifting
    2. Use a suitable carbon scraper to remove the carbon device and exercise caution during removal or
    ridge from the cylinder sleeve bore (see Figure 2.05-2). Installation to avoid severe personal injury or
    The ridge is confined to the area above the upper range death.
    of top piston ring travel.
    ) NOTE: The piston and connecting rod assembly con-
    sists of the piston, piston rings, piston pin and two
    retaining rings, piston pin bushings, connecting rod and
    connecting rod bearing.

    FORM 6248 First Edition 2.05 - 1


    CRANKCASE REMOVAL

    IA
    :..
    CAUTION I Do not allow the con-
    necting rod to contact
    I.A. CAUTION IConnecting rods and
    caps are matched sets. )
    the crankshaft after the bearing halves have been Do not mix connecting rods and caps. Do not mix
    removed. Insure that plastic is wrapped around the bearing halves. Tag bearing halves to identify them
    end ofthe connecting rod to preventthe connecting during wear analysis. Disregarding this information
    rod end end from damaging the cylinder sleeve could result in product damage.
    bore.
    5. Remove bearing haives from the connecting rod cap
    NOTE: The piston slides out of the cylinder block with and connecting rod (see Figure 2.05-5 and Figure 2.05-6).
    relative ease until the lower part of the skirt reaches the
    upper portion of the sleeve. At this point, the piston may
    become cocked, causing it to bind in the sleeve. To
    prevent this from happening, lightly jiggle the piston
    back and forth as it is raised.

    4. Pull the piston and connecting rod assembly out of


    the cylinder block at an angle that closely approximates
    the angle of the crankcase (see Figure 2.05-4).

    Figure 2.05-5. Connecting Rod

    Figure 2.05-6. Bearing Cap


    CORRECT

    Figure 2.05-4. Remove Piston/Connecting Rod


    Assembly

    2.05 - 2 FORM 6248 First Ed~ion


    CRANKCASE REMOVAL

    WAUKESHA
    PART NUMBER

    ,L IljIY
    IR

    .-
    ---- -
    --
    CAP AND BLADE
    MATCH NUMBERS

    WEIGHT CLASSIFICATION
    "A", "B", OR "c"

    Figure 2.05-7. Keep Connecting Rod Caps And Blades Properly Mated
    6. Temporarily install the connecting rod cap to the
    connecting rod. To keep the parts properly mated, verify
    IA
    . ..
    CAUTION I Do not barthe crankshaft
    . over more than neces-
    that the rod and cap are marked with the same match or sary to remove each piston and connecting rod
    cylinder location numbers (see Figure 2.05-7). assembly while a piston and connecting rod are
    loose in the cylinder liner. Completely remove the
    piston and connecting rod assembly before barring
    ) over the engine. Disregarding this Information
    could result In product damage.

    FORM 6248 First Edition 2.05 - 3


    CRANKCASE REMOVAL

    7. Repeat the procedure to remove any other pistons


    BAU
    and connecting rods. Using the manual engine barring BEARING
    device, reposition the crankshaft as necessary to aid in
    further piston and connecting rod removal.

    S. Be sure to remove any connecting rod bearings


    which may have fallen into the oil sump during the
    removal process. Note their original location and tag
    each bearing.

    CYLINDER SLEEVE REMOVAL

    A WARNING
    The cylinder sleeve weighs approximately 63 Ibs.
    (28 kg). Use the aid of an assistant, and exercise
    caution during removal or installation avoid severe
    personal injury or death.

    IA CAUTION IInsure that all. engine


    coolant was drained be-
    '-'...==-...;;;..;;....;;..;;;."...;;;..--::,...;;;..;..J.
    fore proceeding. Use proper procedures to insure
    that the oil sump is not contaminated with coolant.
    Protect all electrical components to insure coolant Figure 2.05-8. Cylinder Sleeve Puller
    does not enter. Disregarding this information could
    result in product damage. 5. Remove the upper and middle O-rings, and lower
    NOTE: Piston and connecting rods should already be O-ring from cylinder sleeve (see Figure 2.05-9).
    removed from the engine.
    )
    1. With a grease pencil, mark the cylinder liners parallel
    and perpendicular to the crankshaft. Use different colors or
    markings, so that you can differentiate between the two.
    The marks will be helpful later when measuring the cylinder
    liners for wear.

    NOTE: The bottom plate of the Waukesha supplied


    screw-type cylinder sleeve remover must be sized for the
    liner as follows: 8-1/2 inch bore (PIN 4942840); 9-318 inch
    bore (PIN 494286).
    2. Install a screw-type cylinder sleeve remover
    (PIN 499233) and pull the sleeve upward about 2 - 3
    inches (51 - 76 mm) (see Figure 2.05-8). The puller and
    sleeve can be lifted out by hand once the sleeve seals
    clear the lower bore of the crankcase.

    IA CAUTION INEVER reuse a cylinder


    .. sleeve which has been
    dropped. A dropped cylinder sleeve can have
    unseen damage resulting in severe engine damage.
    3. If the cylinder sleeves are to be reused, mark each
    cylinder sleeve with the position tt carne from on the engine;
    for example, 2LB, 3RB, etc. During reassembly, a reused )
    sleeve must be installed in the sarne cylinder position.

    4. Repeat this procedure for each cylinder sleeve being


    removed. Figure 2.05-9. Cylinder Sleeve

    2.05 - 4 FORM 6248 First Edition


    CRANKCASE REMOVAL

    I.a
    A CAUTION I Do NOT use a cylinder
    sleeve gasket with a PIN
    2. Install three guide pins in the 12, 9 and 3 o'clock
    positions (guide pins may be fabricated from 1/2 x 6-1/2 in.
    205130L sleeve. Using the cylinder sleeve gasket (12.7 x 165.1 mm) capscrews. Capscrews must be
    will cause the sleeve to project too far above the threaded approximately 2 in. (50.8 mm) on one end).
    crankcase deck for proper head gasket sealing,
    causing severe engine damage.
    A WARNING
    6. On 9-3/8 inch bore models using the PIN 205130C and The vibration damper weighs approximately 3031bs.
    205130H cylinder sleeve, remove the cylinder sleeve (137 kg). Use a suitable lifting device and exercise
    gasket from the cylinder sleeve. The PIN 205130L cylinder caution during removal or installation to avoid
    sleeve does not use a cylinder sleeve gasket. severe personal injury or death.

    7. Store the cylinder liners upright on end.

    VIBRATION DAMPER REMOVAL


    A WARNING
    Do not pull the vibration damper past the ends of
    A WARNING the guide pins when installing lifting straps and
    lifting device. Allowing the vibration damper to
    This procedure Is a two person operation. To do this slide past the ends of the guide pins without proper
    procedure alone Is dangerous and can result in lifting devices attached could cause severe person-
    severe personal injury or death. al injury or death.

    Different combinations of pulleys, vibration dampers, 3. Attach a lifting eyes to the two threaded holes in the
    and spacers are installed on the the front of the engine. vibration damper and a suitable lifting device to the
    Figure 2.05-10, shows the engine with two vibration lifting eyes.
    dampers installed. Refer to Table 4.00-3 and
    Table 4.00-4 in Chapter 4 for combinations of pulleys, 4. Insuring that the vibration damper stays back
    spacers and attaching hardware. Current engines may against the rear crankshaft pulley, remove the remain-
    have eITher "C" section or 5V section groove pulleys ing eight capscrews washers and front drive pulley, and
    (see Figure 4.00-151). . spacer (if present) from front vibration damper.
    1. Remove three of the capscrews from the 12, 9 and 3 5. Using a suitable lifting device, and:with the aid of an
    o'clock positions on the front drive pulley (see assistant, remove front vibration damper from the
    Figure 2.05-10). crankshaft.

    REAR VIBRATION
    / DAMPER

    FRONT PULLEY SPACER

    )
    Figure 2.05-10. Vibration Dampers/Crankshaft Pulleys

    FORM 6248 First Edition 2.05 - 5


    CRANKCASE REMOVAL

    6. Remove three capscrews, 7/8 x 2-1 12" lock washers,


    washers, crankshaft end plate and crankshaft front
    pulley sleeve from the crankshaft.

    7. Remove ten ferry head capscrews, 1/2 x 1-1/2" and REAR VIBRATION
    washers from the rear crankshaft pulley and rear / DAMPER
    vibration damper.

    A WARNING
    The special removal tool (stop sleeve) must be
    used, and the crankshaft end plate re-installed,
    when removing the rear crankshaft pulley. This will
    keep the crankshaft pulley from springing off the
    tapered sleeve during the removal process and also
    separates the tapered sleeve from the pulley.
    Failure to follow this procedure could cause severe Figure 2.05-12. Rear Vibration Damper/Rear
    personal injury or death. Crankshaft Pulley

    8. Install stop sleeve (PIN 474005) on the crankshaft


    end (see Figure 2.05-11). A WARNING
    The rear vibration damper weighs approximately
    STOP SU,I:Vlc. TAPER SU,cVI:, 112 Ibs. (SO kg). Insure that the rear vibration
    damper does not slide off crankshaft while remov-
    ing the rear crankshaft pulley to avoid severe
    personal injury or death.
    )
    1/4" CLEARANCE '"1i--++- 10. Using a puller and a portable hydraulic press,
    MINIMUM_IL~:+-t remove the rear crankshaft pulley from the crankshaft.

    A WARNING
    The rear vibration damper weighs approximately
    1121bs. (SO kg). Use a suitable lifting device and use
    caution during removal or installation to avoid
    severe personal injury or death.
    Figure 2.05-11. Crankshaft Pulley Stop Sleeve

    9. Re-install the crankshaft end plate and three IA..


    CAUTION I The rear vibration damper
    will tilt during removal
    capscrews (see Figure 2.05-12).
    from crankshaft end, use aid of an assistant to steady
    vibration damper and prevent damage to equipment

    11. Install two lifting eyes and lifting straps to the rear
    vibration damper.

    12. Using a suitable lifting device, remove the rear


    vibration damper from the crankshaft.

    13. Remove tapered crankshaft pulley sleeve from crank-


    shaft.

    14. Remove the crankshaft rear pulley spacer from the


    crankshaft. )

    2.05 - 6 FORM 6248 First Ed~ion


    CRANKCASE REMOVAL

    FRONT GEAR COVER REMOVAL

    A WARNING
    This procedure is a two person operation. To do this
    procedure alone is dangerous. Failure to use at
    least two people for this operation can result in
    serious personal injury or death. See other warn-
    Ings and cautions at the beginning of this section.

    NOTE: Engine oil and coolant should already be


    drained.
    1. Remove capscrews, lock washers two circular
    cover plates and gaskets from gear housing cover (six
    capscrews per plate, 3/8 x 7/8") (see Figure 2.05-13).

    Figure 2.05-14. Reer Gear Housing - Front Left

    A WARNING
    Always wear proper eye protection when removing
    retaining rings. Slippage may propel the retaining
    ring with enough force to cause serious eye injury.
    use the correct retaining ring pliers. Verify that the
    \ tips of the pliers are not exC4!$Sively worn or
    damaged to prevent severe personal injury or death.

    3. Remove retaining ring and ball bearing from acces-


    sory (magneto) drive shaft (see Figure 2.05-15).

    Figure 2.05-13. Gear Cover Plates - Front Left

    2. Remove six nuts, lock washers cover plate and


    gasket from rear left side of gear housing (see
    Figure 2.05-14).

    Figure 2.05-15. Ball Bearing

    FORM 6248 First Edttion 2.05 - 7


    CRANKCASE REMOVAL

    ,--,,0«-...,..,0 •

    \ CAPSCREWS ALREADY REMOVED (5)

    1"'1 OIL PAN TO GEAR COVER - 6 CAPS CREWS

    fO\ REAR HOUSING TO GEAR COVER - 15 CAPSCREWS

    @ GEAR COVER TO REAR HOUSING - 13 CAPSCREWS

    e DOWEL PIN HOLES - 2

    Figure 2.05-16. Gear Cover )


    4. Remove eighteen capscrews (1/2 x 3") from the rear 10. Remove the oil seal from the front gear cover (see
    right and rear left gear housing cover. Figure 2.05-17).

    5. Remove six capscrews, (1/2 x 1-3/4") and washers


    from the bottom flange of the gear housing cover and oil
    sump (see Figure 2.05-16).

    6. Remove fifteen capscrews, (1/2 x 1-3/4") and lock


    washers from perimeter of gear housing cover.

    A WARNING
    Front gear housing cover weighs approximately
    157 Ibs. (71 kg). Use a suitable lifting device and
    exercise caution during removal or Installation to
    avoid severe personal injury or death.

    7. Place lifting straps through upper right and left


    inspection holes and attach lifting device.
    Figure 2.05-17. Front 011 Seal
    NOTE: There are dowel pins between the gear housing
    and gear housing cover, these pins do not have to be
    removed.

    8. Using a pry bar, gently pry apart the seal between


    gear housing and gear housing cover.

    9. Using a lifting device, carefully remove the gear


    housing cover from gear housing.

    2.05 - 8 FORM 6248 First Edition


    CRANKCASE REMOVAL

    11. Remove O-ring and oil slinger from crankshaft end 3. Remove the drive gear from the shaft (see
    (see Figure 2.05-18). Figure 2.05-20).

    Figure 2.05-20. Drive Shaft


    Figure 2.05-18.011 Slinger And O-Ring
    4. Remove six nuts, lock washers and magneto drive
    MAGNETO DRIVE GEAR REMOVAL from the front gear housing (see Figure 2.05-21).

    1. Remove the key from the shaft keyway.

    2. Remove six capscrews and lock washers from the


    drive gear (see Figure 2.05-19).

    Figure 2.05-21. Magneto Drive

    Figure 2.05-19. Magneto Drive Gear

    FORM 6248 First Edition 2.05 - 9


    CRANKCASE REMOVAL

    IDLER GEAR REMOVAL CAMSHAFT GEAR REMOVAL


    )
    1. Bend back tabs on capscrew locks on idler gears 1. At the back of the engine, loosen the lock nut, and
    (see Figure 2.05-22). turn the camshaft set screw in to contact the camshaft,
    then back it out about 1/4 turn so cam is free to r01ate
    (see Figure 2.05-24).

    Figure 2.05-22. Lock Idler Gear Capscrews


    Figure 2.05-24. Camshaft Cover Plate
    2. Remove two capscrews, (1/2 x 1-1/4") capscrew
    locks and idler gear washers from each idler gear. 2. Bend back the 1ab on the camshaft gear nut lock (see
    Figure 2.05-25). )
    3. Remove the idler gears from the idler gear spindles.

    NOTE: Perform Step 4, only if required.

    4. Remove six Nyloc capscrews, (3/B x 1 ") ball bearing


    re1ainer, front ball bearing, spacer and rear ball bearing
    from the idler gear (see Figure 2.05-23).

    Figure 2.05-25. Unlocking The Camshaft Gear Nut

    NOTE: The engine may be prevented from rotating by


    placing a clean shop rag between the camshaft and idler
    gear teeth.

    3. Remove the camshaft gear nut from the camshaft.


    Figure 2.05-23. Camshaft Idler Gear - Upper

    2.05 - 10 FORM 6248 First Ednion


    CRANKCASE REMOVAL

    4. Using the two threaded holes in camshaft gear, 3. Remove capscrews and lock washers from the front
    mount a bar-type gear puller to the camshaft gear. of the valve lifter housing and front gear housing (see
    Figure 2.05-27).

    & WARNING
    Heated parts can cause serious bums. Use caution
    when heating parts to prevent severe personal injury
    or death.

    CAUTION I
    I A="---==...:..:::....:~=:;..;~.
    1...
    • .::..
    Use caution when using
    the torch to prevent
    damage to the camshaft or camshaft gear.
    5. The camshaft gear is a shrink fit to the camshaft. If
    required, apply heat to the camshaft gear to assist in
    removal of the gear, and remove gear using the puller.

    6. Remove the key from the keyway in shaft end.

    FRONT GEAR HOUSING REMOVAL


    NOTE: The gears, with the exception of the crankshaft
    and oil pump gear must be removed before removing
    the front gear housing. Figure 2.05-27. Valve Llftar Housing - Front

    1. Remove two capscrews and washers from the 4. Remove sixteen capscrews and lock washers,
    bottom flange of the front gear housing cover and oil (1/2 x 1-1/2" with lock washers) from the front gear
    sump (see Figure 2.05-26). housing cover (see Figure 2.05-2Sj.
    \
    I

    Figure 2.05-2B. Front Gear Housing

    Figure 2.05-26. 011 Pan Capscrew - Front Left


    I& CAUTION I
    L..
    Be careful not to bend or
    ==--.;:;..;;;....;;.;:;...;;;....;;...;:;...;~.
    damage the oil tubes
    when removing the front gear housing cover.

    & WARNING 5. Carefully pry the front gear housing cover from the
    Gear housing weighs approximately 138lbs. (63 kg) crankcase and the dowel pins.
    use a suitable lifting device and exercise caution 6. Using a suitable lifting device, carefully remove gear
    during removal or installation to avoid severe housing from crankcase.
    ,I personal injury or death.
    2. Attach lifting straps and lifting device to the front gear 7. Remove gasket from crankcase and front gear
    housing. housing.

    FORM 6248 First Edition 2.05 - 11


    CRANKCASE REMOVAL

    ROCKER ARM OIL HEADER REMOVAL


    FRONT )
    1. Remove four long bolts (3/8 x 1-1/2 inches), 1/4 inch (GEAR TRAIN SIDE)
    spacers, and the rocker arm oil header (see
    Figure 2.05-29 and Figure 2.05-30).

    LEFT BANK

    Figure 2.05-29. Rocker Arm Oil Header

    RIGHT BANK

    REAR
    (FLYWHEEL SIDE)

    Figure 2.05-30. Longer Capscrew Locations For


    Mounting The Rocker Arm Oil Header

    2.05 -12 FORM 6248 First Edition


    CRANKCASE REMOVAL

    VALVE LIFTER HOUSING REMOVAL


    NOTE: Retum each valve lifter to its original location
    facing in the proper direction. Always retain the
    established wear pattems to minimize roller and cam
    lobe wear.

    I.A. CAUTION IofValve lifters may fall out


    the valve lifter guides
    during removal. Use caution during removal to
    prevent damage to the valve lifters.

    1. Remove 44 short bolts (3/8 x 1·1/8 inches, with lock


    washers) and valve lifter guides from the valve lifter
    housing (see Figure 2.05·31).

    2. Remove the valve lifters (cam followers) from slotted


    lower bore of the valve lifter guides (see Figure 2.05-32. Valve Lifter Housing Cover
    Figure 2.05·31). Remove lifter guide gaskets.
    5. Remove twenty-eight capscrews, 3/8 x 1·1/2" and
    NOTE: Replace all valve lifters if a new camshaft is lock washers from the valve lifter housing cover (see
    needed. Waukesha will not wa"antthe new shaft if used Figure 2.05·33).
    followers are installed.

    Figure 2.05-33. Raising The Valve Lifter HOllslng


    Figure 2.Q5.31. valve Lifter Guides
    6. Carefully pry the valve lifter housing from the
    NOTE: The five ferry head capscrews and lock wash·
    crankcase.
    ers attaching the front flange of the valve lifter housing to
    the rear of the front gear housing, should have been
    removed with the front gear housing. A WARNING
    3. If not already removed, remove the five ferry head Valve lifter housing weighs approximately 198 Ibs.
    capscrews and lock washers from the front flange of the (90 kg). Use a suitable lifting device and exercise
    valve lifter housing (see Figure 2.05·27). caution during removal or installation to avoid
    severe personal InJury or death.
    4. Remove two ferry head capscrews, (3/8 x 1·1/2")
    and lock washers from the flanges of the upper and 7. Attach lifting eyes, lifting straps and a suitable lifting
    lower valve lifter housing covers (see Figure 2.05·32). device to the valve lifter housing.

    A CAUTION I~alve
    I..
    ==-=:..:..=:....:...:....:=-=~.
    L.
    lifter guides and
    lifters must be removed
    prior to Step 8, or severe engine damage may occur.

    FORM 6248 First Edition 2.05 -13


    CRANKCASE REMOVAL

    8. Using a suitable lifting device, remove the valve lifter 14. If required, remove two male connector tube fittings
    housing from the crankcase. (7/8 inch tube OD). Using the 1-1/4 inch hex on the )
    connector body. Remove the tube fittings in the 3/4 inch
    9. Clean the gasket material from the valve lifter pipe taps at the rear of the valve lifter housing (for
    housing and crankcase mating surfaces. connection of the turbo oil drain tubes) (see
    Figure 2.05-36).
    10. Remove five capscrews and lock washers (3 ferry
    head capscrews, 3/8 x 1-1/2 inches, with lock washers
    and hex nuts; 2 ferry head capscrews, 3/8 x 1-1/4 inches,
    with lock washers) and separate the front and rear
    sections of the valve lifter housing (see Figure 2.05-34).

    THREADED
    LEFT BANK FURROW FRONT SECTION

    ~.~
    I[ 1 ' - - [-

    Figure 2.05-36. Valve Lifter Housing - Rear

    o 15. Remove four capscrews, lock washers, lower valve


    lifter housing cover and gasket from the crankcase (see
    REAR SECTION RIGHT BANK Figure 2.05-37).
    Figure 2.05-34. Valve Lifter Housing Assembly
    )
    11. Clean the gasket material from the valve lifter
    housing front and rear sections.

    12. Finger tighten the cover to the rear face olthe valve
    lifter housing (5 ferry head capscrews, 3/8 x 1-1/2
    inches, with lock washers and hex nuts).

    13. If required, loosen the hex jam nu1 and remove the
    jam nut and set screw from the rear face of the valve
    lifter housing (see Figure 2.05-35).

    Figure 2.05-37. Lower Valve Lifter Housing Cover

    Figure 2.05-35. Camshaft Set Screw On Valve Lifter


    Housing Cover )

    2.05 -14 FORM 6248 First Edition


    CRANKCASE REMOVAL

    CAMSHAFT REMOVAL I.A. CAUTION Ithe


    Do not mix or cross mate
    camshaft bearing
    NOTE: Each thrust ring is located by a roll pin. shells. Bearings are matched sets. Mixing the cam-
    shaft bearings may cause damage to equipment
    1. Remove the thrust washer, shims and outer thrust
    ring from the camshaft end (see Figure 2.05-38 and
    1. Remove sixteen ferry head capscrews and lock
    Figure 2.05-39).
    washers from the camshaft bearing caps (see
    Figure 2.05-40).

    FIgure 2.05-38. Thrust Washer

    Figure 2.05-40. Cam Bearing Cap

    2. Remove the camshaft bearing caps and bearings


    from the camshaft.

    3. Remove and discard the O-rings from the top of the


    camshaft bearing caps.

    4. Tag bearing shells to aid in assembly.

    A WARNING
    Camshaft weighs approximately 114 Ibs. (52 kg).
    Use a suitable lifting device and exercise caution
    during removal or installation to avoid severe
    personal injury or death.

    Figure 2.05-39. Shim Pack 5. Attach a suitable lifting device to the camshaft.

    6. Using a suitable lifting device, remove the camshaft


    I.A. CAUTION IDo not mix camshaft
    bearing caps, camshaft
    from the camshaft bearing saddles.

    bearing caps are marked for their proper location 1


    thru 7 (front to rear). The camshaft bearing saddles
    are precision align bored with all camshaft bearing
    caps torqued In place. Installing the camshaft
    bearing caps in the wrong positions will result In
    camshaft bearing and/or camshaft failure.

    FORM 6248 First Edition 2.05 -15


    CRANKCASE REMOVAL

    7. Remove the lower camshaft bearing shells and tag 1. Attach a suitable lifting bracket, lifting straps and
    them to aid in assembly (see Figure 2.0541). lifting device to the rear flywheel housing section. A )
    lifting bracket (see Figure 2.05-43) should be devised to
    properly handle the flywheel. With this device, the
    flywheel can be safely handled.

    Figure 2.0541. Valve Lifter Housing Gasket - Front

    BARRING DEVICE REMOVAL


    1. Remove the barring device from the starter bore on
    the left bank side of the front flywheel housing (3
    capscrews, 5/8 x 1-1/4 inches, with lock washers) (see
    Figure 2.05-42). Figure 2.0543. Flywheel Lifting Bracket
    )
    2. Remove sixteen capscrews, (1/2 x 1-1/2" and lock
    washers) from the rear flywheel housing section (see
    Figure 2.05-44).

    BARRING
    DEVICE

    Figure 2.0542. Front Flywheel Housing - Rear Left

    FLYWHEEL REMOVAL

    A WARNING
    Rear flywheel housing section weighs approximately Figure 2.0544. Rear Flywheel Housing
    107 Ibs. (49 kg). Use a suitable lifting device and
    3. Carefully pry the rear flywheel housing section from
    exercise caution during removal or Installation to
    the front flywheel housing section and the dowel pins.
    )
    avoid severe personal injury or death.

    2.05 -16 FORM 6248 First Ednion


    CRANKCASE REMOVAL

    4. Using a suitable lifting device, remove the rear


    flywheel housing section from the front flywheel housing A WARNING
    section. Front flywheel housing section weighs approxi-
    mately 202 Ibs. (97 kg). Use a suitable lifting
    A WARNING device and exercise caution during removal or
    installation to avoid severe personal injury or
    Flywheel weighs approximately 878 Ibs. (398 kg). death.
    Use a suitable lifting device and lifting bracket, and
    exercise caution during removal or installation to 11. Attach suitable lifting eyes, chains and lifting device
    avoid severe personal injury or death. to the front flywheel housing section.

    5. Attach the flywheel lifting bracket, chains and a 12. Remove fourteen capscrews, 5/8 x 1-1/2" and lock
    suitable lifting device, to the flywheel. washers from the front flywheel housing section (see
    Figure 2.05-46).
    6. From the nine o'clock and three o'clock positions,
    remove two capscrews and lock washers (see
    Figure 2.05-45).

    Figure 2.05-45. Remove Flywheel Figure 2.05-46. Front Flywheel Section

    7. Fabricate two guide pins approximately 6 in. 13. Carefully pry the front flywheel housing section
    (152.4 mm) long the same diameter as the flywheel from the crankcase and dowel pins.
    bolts, threaded approximately 1/2 in. (12.7 mm) on
    one end. Install two guide pins at the nine o'clock and 14. Using a suitable lifting device, remove the front
    three o'clock positions. flywheel housing section from the crankcase.

    8. Remove the remaining ten flywheel bolts and


    washers from the flywheel.

    9. Using a suitable lifting device, remove the flywheel


    from the crankshaft end.

    10. Remove the guide pins.

    FORM 6248 First Ednion 2.05 -17


    CRANKCASE REMOVAL

    OIL PICKUP SCREEN REMOVAL 2. Remove capscrews and lock washers from oil elbow
    outlet flanges (2 capscrews per elbow, 3/8 x 1-1/8 )
    CAUTION I D? not bar o~er e.ngine
    I A=:.....;=..:..::.....;~=...;:....:.J.
    inches, with lock washers) and the front of the oil pan.
    .L..:
    .. with the 011 pickup 3. Remove the oil pickup screen assembly and elbows
    screen assembly loose in the crankcase. Failure to from the oil pan. Replace the baffle if damaged.
    remove the oil pickup screen assembly prior to
    barring the engine over will cause damage to the 4. Separate the baffle and oil pickup screen.
    connecting rods and crankshaft.
    5. Remove oil tubes from screening element.
    1. Remove capscrews and lock washers from oil elbow
    inletflanges (2 capscrews per elbow, 3/8 x 2 inches, with NOTE: Gasket material may stick to the oil pan surface
    lock washers) and the pickup screen assembly (see and oil pickup screen assembly as weI/ as the oil elbow
    Figure 2.05-47). The inlet flange is on the shorter end of flanges.
    the elbow.
    6. Remove gaskets from the oil elbow inlet and outlet
    flanges.

    7. Remove gaskets from oil tube flanges.

    Figure 2.05-47. Oil Pickup Screen Assembly -


    12 Cylinder

    2.05 -18 FORM 6248 Firsl Edition


    CRANKCASE REMOVAL

    OIL PAN REMOVAL capscrew heads are located inside the crankcase,
    along each side of the engine. They are accessible
    1. Insure the engine is positioned upright with the oil
    through the side access plates (see Figure 2.05-48).
    pan supported on suitable blocks or cribbing.

    A WARNING
    The oil pan weighs approximately1790 Ibs. (813 kg).
    Use extreme caution when removing this compo-
    nent. Plan ahead on how this piece, as well as the
    crankcase, will be handled. Make sure that the 011
    pan is properly supported by blocks or cribbing.
    Also make sure that properly rated lifting equip-
    ment and rigging are used. The crankcase weighs
    approximately 6793 Ibs. (3081 kg) with the crank-
    shaft installed, but completely stripped of all other
    components. If ANY components are stili attached,
    the crankcase will be heavier by the amount of the
    components weight. Failure to take adequate pre-
    cautions can result In severe personal injury or
    death.
    Figure 2.~B. Bolt Holes In Engine Block

    A WARNING A WARNING
    Always 11ft the engine using the approved lifting eyes. Make sure that the crankcase lifts 'away from the oil
    The 12 Cylinder VHP engine is equipped with two pan. Do not raise the crankcase ifthe oil pan does
    pairs of lifting eyes, one pair at the front, the other pair not separate from the crankcase Immediately as it is
    at the rear. Lifting eyes are meant for lifting the engine raised. The 011 pan must stay in contact with the
    only. They must not be used to 11ft driven or auxiliary supporting blocks or cribbing at all times. Failureto
    equipment that may be attached to the engine. Follow take adequate precautions can result in severe
    approved rigging procedures. Always use the proper personal injury or death.
    spreader bar to ensure that no undue strain is placed
    on the lifting eyes and hoisting chains. Disregarding 3. Carefully lift crankcase away from the oil pan.
    this information could result in severe personal
    injury or death. 4. Install the crankcase on a suitable engine rollover
    stand.

    A WARNING 5. Remove the oil pan seal from the grooves along the
    edges of oil pan and crankcase (see Figure 2.05-49).
    Never raise the crankcase more than an inch or two
    off the floor (except to remove It from the hot tank,
    install it in the rollover stand or position It on the oil
    pan). While the block Is suspended, do not put hands,
    arms, feet or any other body paris beneath it. Stand
    back as far as possible and exercise extreme caution.
    Disregarding this Information could result in severe
    personal injury or death.
    1. Attach a suitable lifting device to the lifting eyes ofthe
    crankcase.
    NOTE: The front gear housing, along with two capscrews
    and washers that connect the bottom flanges of the front
    gear housing to the crankcase should already be removed.
    2. Remove twenty-eight capscrews, 3/4 x 2-1/2" and Figure 2.05-49. 011 Pan Cross Cuts - Rear Right
    / washers holding the oil pan to the crankcase. These

    FORM 6248 First Edition 2.05 -19


    CRANKCASE REMOVAL

    CRANKSHAFT REMOVAL 1. Install the crankcase in a suitable rollover stand with


    the crankcase oriented so that the crankshaft is on top.
    A WARNING (see Figure 2.05-50).

    This procedure is a two person operation. To dothis


    procedure alone is dangerous. The only recom-
    mended way to remove the crankshaft from the
    crankcase is with an engine rollover stand with the
    crankcase oriented so that the crankshaft is on top.
    Use the proper attachment fixtures certified to
    handle the weights involved with the VHP engine.
    Failure to use at least two people for this operation
    and a proper engine rollover stand, and properly
    rated lifting and moving equipment can result in
    severe personal InJury or death. See otherwarnings
    and cautions at the beginning of this section.

    A WARNING
    The crankcase weighs approximately 6793 Ibs.
    (3081 kg) with the crankshaft installed, but com-
    pletely stripped of all other components. If ANY Figure 2.05-50. 011 Pump Gear
    components are still attached, the crankcase will be
    heavier by the amount of the components weight. 2. Remove the nut and washer from the oil pump gear
    Failure to take adequate precautions can result in bolt (see Figure 2.05-50).
    severe personal injury or death. 3. Remove the oil pump gear capscrew, gear and the
    idler gear spindle from the front main housing (see )
    Figure 2.05-51) Separate the capscrew. front washer
    A WARNING and idler gear spindle. If required. press out bushing
    from idler gear spindle. Note position of the recess on
    Always lift the engine using the approved lifting eyes. the front washer.
    The 12 Cylinder VHP engine is equipped with two
    pairs of lifting eyes, one pair at the front, the other pair
    at the rear. Ufting eyes are meant for lifting the engine
    only. They must not be used to lift driven or auxiliary
    equipment that may be attached to the engine. Follow
    approved rigging procedures. Always use the proper
    spreader bar to ensure that no undue strain is placed
    on the lifting eyes and hoisting chains. Disregarding
    this information could result in severe personal
    injury or death.

    A WARNING
    Never raise the crankcase more than an inch or two
    off the floor (except to remove It from the hot tank,
    Figure 2.05-51. Oil Pump Gear Assembly
    install it in the rollover stand or position It on the oil
    pan). While the block Is suspended, do not put hands,
    arms, feet or any other body parts beneath it. Stand
    back as far as possible and exercise extreme caution.
    Disregarding this information could result in severe
    personal injury or death.
    )

    2.05 - 20 FORM 6248 First Edition


    CRANKCASE REMOVAL

    A WARNING A WARNING
    Heated parts can cause serious bums. Use caution The crankcase weighs approximately 6793 Ibs.
    when heating parts to prevent severe personal injury (3081 kg) with the crankshaft Installed, but
    or death. completely stripped of all other components. If
    ANY components are still attached, the crank-
    CAUTION I
    I A=~=...:;.;::;...;;..;;..;::;..;~.
    Use caution when using
    case will be heavier by the amount of the compo-
    nents weight. The crankshaft weighs
    1..
    • .::
    .. the torch to prevent dam-
    approximately 1828 Ibs. (829 kg) with the coun-
    age to the crankshaft or crankshaft gear.
    terweights attached. Each main bearing cap
    4. The crankshaft gear is a shrink fit to the crankshaft. weighs 461bs. (21 kg). Use extreme caution when
    Apply heat to the crankshaft gear to assist in removal of removing this component. Plan ahead on how
    the gear, and remove gear using a puller. this piece, as well as the crankcase it Is attached
    to, will be handled. Make sure that the crankcase
    NOTE: Previous design crankshaft gears had threaded and the crankshaft are properly supported and
    holes. that properly rated lifting equipment and rigging
    5. Attach a bar type puller to the threaded holes in the are used. Failure to take adequate precautions
    thrust washer (see Figure 2.05-52). can result In severe personal Injury or death.

    8. Remove the four capscrews and lock washers from


    the rear of lower oil retainer plate at the rear of the
    engine (see Figure 2.05-53).

    Figure 2.05-52. Crankshaft Gear Mount


    6. Remove the crankshaft gear from the crankshaft.
    7. Remove the thrust washer, shims (if present) and
    outer thrust rings from the crankshaft end (see
    Figure 2.05-52).

    NOTE: The pistons, connecting rods, and the oil pan


    should already be removed.

    Figure 2.05-53. Lower 011 Retainer Plate

    9. Remove the two capscrews and lock washers from


    the flanges between the upper and lower shells olthe oil
    retainer plates.
    10. Remove the lower oil retainer plate from the
    crankcase.

    FORM 6248 Rrs! EdHion 2.05 - 21


    CRANKCASE REMOVAL

    11. Remove and discard the wick type seal from the
    lower oil retainer plate (see Figure 2.05-54).
    IA
    ..
    CAUTION I Do not mix or cross mate
    crankshaft bearing caps. )
    The crankshaft bearing saddles are precision
    matched with the caps (numbered 1 thru 7, front to
    rear). Installing the crankshaft bearing caps in the
    wrong positions will result in crankshaft bearing
    and/or crankshaft failure.

    CAUTION I
    I A=~=..:..;:;....;;;..::..::;..;~.
    While it is not recom-
    .L .::
    .. mended to reuse bear-
    ings, do not mix or cross mate the crankshaft bearing
    shells if they are to be reused. Tag bearings to Insure
    they are installed In the same position. Note the
    difference between upper and lower bearings and
    differences in bearing width. Mixing the crankshaft
    bearings may cause damage to equipment.
    13. Remove four lock nuts and washers from each
    main bearing cap (see Figure 2.05-56).

    Figure 2.05-54. Wick Seal


    12. Remove two cross-tie bolts and washers from
    each main bearing cap (see Figure 2.05-55).

    Figure 2.05-56. Main Bearing Cap


    Figure 2.05-55. Cross-Tie Bolts
    14. Using the small "ears" on each end of the bearing
    caps, pry up alternately on each side, and remove the
    A WARNING main bearing caps and the upper main bearing shells
    from the crankcase.
    Once the main bearing caps are removed, the engine
    rollover stand cannot be moved. If the rollover stand 15. Remove the thrust ring from the No.1 main bearing
    is moved the crankshaft may fall from the crankcase, cap (see Figure 2.05-57). Tag the thrust ring for
    causing severe personal Injury or death. identification.

    A WARNING
    Main bearing caps weigh approximately 46 Ibs.
    (21 kg). Use the aid of an assistant and use
    suitable lifting devices when removing or instal-
    ling the main bearing caps or severe personal
    injury or death may result.

    Figure 2.05-57. No.1 Main Bearing Cap

    2.05 - 22 FORM 6248 First Ednion


    CRANKCASE REMOVAL

    NOTE: The lower thrust bearing segment will be 19. Using suitable lifting devices, remove the crank-
    removed with the No. 1 main bearing cap. shaft from the crankcase and lower it to a suitable cradle
    (see Figure 2.05-59).
    16. Remove the remaining inner thrust bearing ring
    segment from the crankshaft (see Figure 2.05-58). Tag
    the inner thrust ring for identification.

    rooo -
    0
    0 0
    0
    ~o
    THRUST BEARING
    t-'"
    Ll Figure 2.05-59. CrankSflaft
    Figure 2.05-58. Thrust Bearing
    20. Remove the main bearing shelf$'from the bearing
    saddles (see Figure 2.05-60). Tag"the main bearing
    17. Remove the bearing shells from each main bear-
    shells for identification.
    ing. Tag the bearing shells for identification.

    A WARNING
    Crankshaft weighs 1828 Ibs. (829 kg). Use the aid of
    an assistant and use suitable lifting devices when
    removing or installing the crankshaft or severe
    personal injury or death may resuH.

    1 A CAUTION 1When removing the


    ;.. crankshaft, be sure the
    lifting straps distribute the weight of the crankshaft
    evenly. the crankshaft should not be subjected to
    any excessive bending or flexing. Use care during
    handling and prevent scratching or marring the
    machined surfaces, especially the connecting rod
    and main bearing Journals.

    -A CAUTION 1Insure that the lifting de-


    I=..
    L. =~::.:....:..:=-=~::;..:~. vices used, do not
    scratch or damage the crankshaft.
    Figure 2.05-60. Bearings
    18. Attach suitable lifting devices to the crankshaft.

    FORM 6248 First Edition 2.05 - 23


    CRANKCASE REMOVAL

    CRANKCASE
    1. If required, matchmark position, and remove oil
    A WARNING )
    tubes from the front of the crankcase (see Heated parts can cause serious burns. Use caution
    Figure 2.05-61). when heating parts to prevent severe personal
    injury or death.

    A CAUTION I
    I'!!!"!!:!!!!~::':'''':':::''''::'''':''=:..:..J.
    L.
    Use caution when heat-
    ing the area around the
    idler gear spindles. Applying too much heat could
    cause damage to the crankcase or idler gear
    spindle.

    4. Apply heat to the area around the idler gear spindle.

    5. Remove the idler gear spindles from the crankcase.

    6. Remove five capscrews, lock washers and upper


    retainer plate from crankcase.

    7. Remove the wick type seal from retainer plate (see


    Figure 2.05-63).

    Figure 2.05-61. Oil Tubes

    NOTE: A collet type stud driver grips the threads of the


    studs. This will prevent scratching and gouging of the
    studs, causing weak spots to be created. )
    2. Using a collet type stud driver, remove the main
    bearing studs from the crankcase (see Figure 2.05-62).

    Figure 2.05-63. Upper Retainer Plate

    CRANKSHAFT NO.1 MAIN BEARING


    REMOVAL IN FIELD CONDITIONS
    NOTE: This procedure applies to the No. 1 main bearing
    Figure 2.05-62. Crankcase - Inside Front with current 'T' Drilled crankshaft. Procedures for the
    remaining main bearings are similar, with the exception
    NOTE: The idler gear spindle nut is a left-hand thread. that Steps to remove the oil pump, oil pickup screen and
    The idler gear spindle is a shrink fit to the crankcase. oil pump drive gear, do not apply. Refer to Main Bearing,
    Removal for procedures to remove the other main
    3. If required, remove the nut and washer from the idler
    bearings. Refer to Service Bulletin 5-2328D for all
    gear spindles.
    previous crankshaft and bearing configurations. )

    2.05 - 24 FORM 6245 First Edition


    CRANKCASE REMOVAL

    3. Remove the two cross tie bolts from the No. 1 main
    A WARNING bearing (see Figure 2.05-64).
    Each main bearing cap weighs 46 Ibs. (21 kg). The
    bearing must be supported from underneath while
    removing or installing to avoid severe personal
    injury or death.

    CAUTION I
    I.=A=---''----'_...;...;.;....~.
    Do not subject the crank-
    L. . shaft to any excessive
    bending or flexing. Keep high heat sources, such as
    cutting torches and welders, away from the crank-
    Shaft. use care during handling. prevent scratching
    or marring the machined surfaces, especially the
    rod and main bearing Journals. Disregarding this
    information could result In product damage.

    A CAUTION IT~e
    I..
    L.
    main bearings con-
    ==....;;;;.;;...~....:..:...;;;....:..:..J.
    SISt of two half shells,
    fitted in the bearing saddle and bearing cap,
    Figure 2.05-64. Cross Tie Bolts

    4. Loosen the four lock nuts on the bottom of the


    respectively. The shells are precision machined. Do bearing cap (see Figure 2.05-65).
    not file the joint faces, and do not scrape the
    running layer in anyway. Disregarding this Informa-
    tion could result in product damage.

    A WARNING
    The crankshaft weighs 1828Ibs. (829 kg). to provide
    the crankshaft with adequate support, never re-
    move more than two main bearing caps at the same
    time. the only exception to this is when the
    crankshaft Is removed from the crankcase and both
    are properly supported with adequate lifting de-
    vices. Failure to take adequate precautions can
    result in severe personal injury or death.
    NOTE: The oil pan doors should already be off. If not, Figure 2.05-65. No.1 Main Bearing
    remove the doors adjacent to the main bearing to be
    replaced. 5. To assist in the removal, install an eye screw in the
    center drilling of the No.1. main bearing cap (see
    1. Refer to Chapter 5, and remove the oil pump
    Figure 2.05-65).
    assembly.
    6. Protect the idler gear by placing a block of wood
    IA
    ..
    CAUTION IDo not leave an unat-
    tached 011 pickup screen
    under the oil pump idler gear so that when the bearing
    cap and oil pump gear drop down, the gear will rest on
    beneath any rod journals If the engine Is to be the block of wood.
    barred over. Disregarding this Information could
    result in product damage. 7. Carefully pry with pipe in eye screw to loosen cap
    (see Figure 2.05-65). Mark thrust bearing position.
    2. Refer to Chapter 5, and remove the oil pickup screen
    8. Using a socket to secure the oil pump bolt, remove
    from the oil sump.
    the self-locking marsden nut and washer from the
    spindle (see Figure 2.05-65).
    )
    9. Remove the oil pump bolt and washer from the oil
    pump gear.

    FORM 6248 Rrsl Edition 2.05 - 25


    CRANKCASE REMOVAL

    10. Mark the gear spindle front side and remove the BEARING SHELL
    spindle through the oil pump opening.

    11. While supporting the lower bearing cap, remove the


    #1 MAIN BEARING
    JOURNAL
    ~0 0 0 r-
    four lock nuts and washers from the lower bearing cap. BEARING
    ROLLOUT TOOL
    ~
    12. Slide the cap out from under the studs. '\:1 0
    IA
    ..
    CAUTION I The eye screw is not
    required for installation.
    The eye screw must be removed from the bearing
    0
    "'. I I
    0
    cap prior to installation, or damage to equipment
    will result. 1- 0
    13. Remove the eye screw from the bearing cap. GEAR
    ~~
    0 ~ '"'
    14. Mark the position ofthe thrust bearings if they are to
    be reused.
    .00",
    FRONT MAIN~
    BEARING SADDLE COUNTERWEIGHT
    !
    CAUTION I~atch for the p~sition of
    I.==,--,~..;;.;;;......_...;....---,.
    A
    LOCATING TANG

    L.. . the upper bearmg tang Figure 2.05-66. Bearing Rollout


    before rolling out the upper bearing. The bearing
    must be rolled in the proper direction. H the tang Is 16. Inspect the roll pins on the front of the bearing cap,
    accidently rolled through the upper bearing seat, insure that the split of the roll pins is assembled as
    damage to the seat and crankshaft will result. shown (see Figure 2.05-67).
    15. Using a bearing rollout tool (PIN 494366), roll out 17. Thoroughly clean all parts as required.
    the upper main bearing and thrust bearing (see )
    Figure 2.05-66). Tag them for identification.

    l~
    ROLL PINS AND HOLES IN CAP 0.188.0.015"
    MUST BE CLEANED BEFORE (4.775.0.381 mm)
    ASSEMBLING ROLL PINS BOTH SIDES

    MAIN BEARING CAP


    12 eYL - FRONT

    SPLIT OF ROLL PINS (4) TO BE


    ASSEMBLED AS SHOWN )
    Figure 2.05-67. Roll Pin Installation

    2.05 - 26 FORM 6248 Firs! Edilion


    CRANKCASE REMOVAL

    CRANKSHAFT NO.1 MAIN BEARING 4. Apply a small amount of grease to the thrust bearing
    INSTALLATION IN FIELD CONDITIONS roll pins (see Figure 2.05-68) to help hold the thrust
    bearing on the bearing cap.
    NOTE: This procedure applies to the No. 1 main
    bearing with current "T' Drilled crankshaft. Procedures
    for all other main bearings are similar, with the exception
    that steps to remove the oil pump, oil pickup screen and
    oil pump drive gear, do not apply. Refer to Main Bearing,
    Installation, for procedures to remove the other main
    bearings. Refer to Service Bulletin 5-23280 for all
    previous crankshaft and bearing configurations.

    IA CAUTION IThrust bearings come in


    .1...= . matched sets. Always
    .=.....;::...:..=:;..:....:....;:;..::..=...1.
    Install the thrust bearings in the same position.
    Failure to Install thrust bearings in the correct
    position can cause damage to equipment.

    1. Lubricate the running side of the upper main bearing Figure 2.05-68. No.1 Main Bearing Cap
    shell.
    5. Install the lower bearing shell and and thrust bearing
    on the bearing cap (see Figure 2.05-66) .
    A CAUTION IWatchforthep~sitionof
    ==-=:;..:.=....:....:=..:...::..J.
    I•L.;. . the upper bearing tang
    before roiling In the upper bearing. The bearing
    must be rolled In the proper direction. If the tang is
    A WARNING
    accidently rolled through the upper bearing seat, Each main bearing cap weighs 461bs. (21 kg). The
    ) damage to the bearing seat and crankshaft will bearing must be supported from underneath while
    result. removing or installing to avoid severe personal
    injury or death.
    2. Using the bearing rollout tool (PIN 494366) (see
    Figure 2.05-66), install the upper bearing shell (grooved NOTE: Each main bearing cap is matched to a main
    with elongated oil hole) and thrust bearing (Grease the bearing saddle. Check the stamped number on the
    thrust bearing to help hold it in place). bearing cap before installing the cap (see
    Figure 2.05-69).

    I A CAUTION I Insure the ungrooved


    ;.. lower bearing shell is
    Installed on the bearing cap. Failure to follow
    proper procedures could cause damage to equip-
    ment.

    3. Lubricate the running surface of the lower bearing.

    Figure 2.05-69. Main Bearing Cap Stamped


    Identilication Numbers
    )
    6. Place the bearing cap on 2 inch x 6 inch (51 x 152 mm)
    wood blocks on edge, with the bearing cap just started
    on the studs.

    FORM 6248 First Edition 2.05 - 27


    CRANKCASE REMOVAL

    7. Refer to reference mark on the oil pump gear and 11. Torque the bearing cap in the proper sequence
    install the gear on the lower main bearing cap with outer listed below (see Figure 2.05-71): )
    washer, oil pump bolt, inner washer and self-locking
    marsden nut (see Figure 2.05-70). Torque the nut to
    LEFT SIDE OF ENGINE
    175 ft-Ib (237N·m).
    5

    FRONT OF ENGINE

    Figure 2.05-70. 011 Pump Gear Assembly


    6
    8. Generously apply engine oil to main bearing cap
    studs, nuts and washers before installing them. Figure 2.05-71. Main Bearing Cap Tightening(Torqulng
    Pattern - As Viewed From Underside Of Crankcase
    9. Apply 3M Scotch-Grip'· 847, Rubber and Gasket
    Adhesive, to both sides of each cross tie bolt washer to
    • Torque the bearing cap nuts one through four (in that )
    prevent oil leaks. Install one washer on each cross tie
    bolt. order) to 75 ft-Ib (102 N·m). If installing replacement
    caps that will be align bored, torque to only 30 ft-Ib
    10. Install the main bearing cap with the four washers, (40 N·m). When installing more than one cap, torque
    lock nuts, cross tie bolts and washers (see Figure 2.05-64 nuts one through four to 75 ft-Ib (102 N·m) on all caps
    and Figure 2.05-65). before torquing side bolts.

    • Torque all left side bolts (five) to 250 ft-Ib (339 N'm)
    starting from the front of the engine.

    • Torque all right side bolts (six) to 250 ft-Ib (339 N'm)
    starting from the front of the engine.

    • Torque nuts one through four to 275 ft-Ib (373 N'm) to


    two steps: first 175 ft-Ib (237 N'm), and then 275 ft-Ib
    (373 N·m).

    12. Check the crankshaft for free rotation after the


    bearing cap is torqued.

    13. Refer to Chapter 5 and install the oil pump


    assembly.

    14. Refer to Chapter 5 and install the oil pickup screen.

    2.05 - 28 FORM 6248 Rrst Edition


    CRANKCASE REMOVAL

    CRANKSHAFT MAIN BEARINGS 2. Loosen the four lock nuts (see Figure 2.05-72) on
    REMOVAL IN FIELD CONDITIONS the bottom of the bearing cap.

    NOTE: This procedure applies to the main bearings


    with current 'T' Drilled crankshaft, with the exception of
    the No. 1 Main bearing. For procedures for the No. 1
    main bearing refer to Crankshaft, No. 1 Main Bearing,
    Removal In Field Conditions.

    A WARNING
    Each main bearing cap weighs 46 Ibs. (21 kg). The
    bearing must be supporled from underneath while
    removing or installing to avoid severe personal
    injury or death.

    IA
    ..
    CAUTION I Do not subject the crank-
    shaft to any excessive Figure 2.05-72. Main Bearing
    bending or flexing. Keep high heat sources, such as
    cutting torches and welders, away from the crank- 3. To assist in the removal, install an eye screw in the
    shaft. use care during handling. prevent scratching center drilling of the main bearing cap (see
    or marring the machined surfaces, especially the Figure 2.05-72).
    rod and main bearing journals. Disregarding this
    Information could result in product damage 4. Carefully pry with pipe in eye screw to loosen cap.

    IA;..
    CAUTION I The main bearings con-
    sist of two half shells,
    A WARNING
    fitted in the bearing saddle and bearing cap, Each main bearing cap weighs 46 Ibs. (21 kg). The
    respectively. The shells are precision machined. Do bearing must be supported from underneath while
    not file the joint faces, and do not scrape the removing or Installing avoid seV8lie personal injury.
    running layer in any way. Disregarding this Informa-
    tion could result in product damage 5. While supporting the lower main bearing cap,
    remove the four lock nuts and washers from the lower
    bearing cap (see Figure 2.05-72).
    A WARNING NOTE: Do not handle the bearing running surfaces
    The crankshaft weighs 1828Ibs. (829 kg). to provide with bare hands.
    the crankshaft with adequate support, never re-
    move more than two main bearing caps at the same 6. Slide the main bearing cap and lower bearing shell
    time. the only exception to this is when the out from under the studs.
    crankshaft Is removed from the crankcase and both
    are properly supported with adequate lifting de-
    vices. Failure to take adequate precautions can
    IA
    ..
    CAUTION I The eye screw Is not
    required for installation.
    result in severe personal injury or death. The eye screw must be removed from the bearing
    cap prior to installation, or damage to equipment
    NOTE: The oil pan doors should already be off. If not, will result.
    remove the doors adjacent to the main bearing to be
    replaced. 7. Remove the eye screw from the main bearing cap.

    1. Remove the two cross tie bolts from the main bearing
    (see Figure 2.05-64). IA
    ..
    CAUTION I Watch for the position of
    the upper bearmg tang
    before rolling out the upper bearing. The bearing
    must be rolled in the proper direction. If the tang Is
    accidently rolled through the upper bearing seat,
    damage to the bearing seat and crankshaft will result

    FORM 6248 First Edition 2.05 - 29


    CRANKCASE REMOVAL

    8. Using a bearing rollouttool, roll outthe upper bearing 1 A CAUTION 1Insure the ungrooved
    )
    shell (see Figure 2.05-73). .. lower bearing shell Is
    Installed on the bearing cap. Failure to follow
    proper procedures could cause damage to equip-
    BEARING SHELL
    ment.
    MAIN BEARING
    JOURNAL
    ~0 0 0 4. Install the lower bearing shell on the main bearing
    BEARING ""-.l:::::::!===s==:::!.1 cap.
    ROLLOUTTOOL~
    o A WARNING
    CI:=:::J o Each main bearing cap weighs 46 Ibs. (21 kg). The
    bearing must be supported from underneath while
    removing or installing to avoid severe personal

    GEAR
    I 0 injury or death.

    NOTE: Each main bearing cap is matched to a main


    %~f-~ bearing saddle. Check the stamped number on the

    I
    MOUNT
    bearing cap before installing the cap (see
    BEARING SADDLE"" Figure 2.05-74).
    COUNTERWEIGHT

    LOCATING TANG

    Figure 2.05-73. Bearing Rollout

    9. Thoroughly clean all parts as required.

    CRANKSHAFT MAIN BEARINGS


    )
    INSTALLATION IN FIELD CONDITIONS
    NOTE: This procedure applies to the main bearings
    with current "T" Drilled crankshaft, with the exception of
    the No. 1 Main bearing. For procedures for the No. 1
    main bearing refer to Crankshaft, No. 1 Main Bearing,
    Installation In Field Conditions.

    1. Lubricate the running side of the upper main bearing


    Figure 2.05-74. Main Bearing Cap Stamped
    shell.
    Identification Numbers

    -A CAUTION 1Watch for the p~sition of 5. Place the bearing cap on 2 inch x 6 inch (51 x 152 mm)
    1~="-=::..:....:..:=--=~;;;;...;~. the upper bearing tang
    L.. . wood blocks on edge, with the bearing cap just started
    before rolling in the upper bearing. The bearing on the studs.
    must be rolled In the proper direction. Ifthe tang Is
    accidently rolled through the upper bearing seat, 6. Apply 3M Scotch-Grip~ 847, Rubber and Gasket
    damage to the bearing seat and crankshaft will Adhesive, to both sides of each cross tie bolt washer to
    result. prevent oil leaks. Install one washer on each cross tie
    bolt.
    2. Using the bearing rollout tool, install the upper
    bearing shell (grooved with elongated oil hole) (see
    Figure 2.05-73).

    3. Lubricate the running surface of the lower bearing


    shell.
    )

    2.05 - 30 FORM 6248 First Edition


    CRANKCASE REMOVAL

    7. Install the main bearing cap with the four washers, • Torque all right side bolts (six) to 250 ft-Ib (339 N'm)
    lock nuts, cross tie bolts and washers (see starting from the front of the engine.
    Figure 2.05-75).
    • Torque nuts one through four to 275 f1-lb (373 N'm) to
    two steps: first t75 ft-Ib (237 N'm), and then 275 ft-Ib
    (373 N·m).

    9. Check the crankshaft for free rotation after each


    bearing cap is torqued.

    CAMSHAFT BEARING REMOVAL IN


    FIELD CONDITIONS
    NOTE: Replace one bearing at a time.

    1. Remove the capscrews and lock washers from the


    bearing cap (see Figure 2.05-77).

    Figure 2.05-75. Cross Tie Bolts

    8. Torque the bearing cap in the proper sequence listed


    below (see Figure 2.05-76):

    LEFT SIDE OF ENGINE


    5

    Figure 2.05-77. Cam Bearing Cap

    FRONT OF ENGINE 2. Remove the bearing cap and upper bearing shell.

    3. Remove and discard the O-ring from the cam


    bearing cap.

    A CAUTION I The ~amshaft bearings


    I'!!"!!:!!!!~=':':::""::"':"=-';:..:...J.
    L. consist of two half
    shells, fitted in the bearing saddle and bearing cap,
    respectively. The shells are precision machined. Do
    6
    not file the joint faces, and do not scrape the
    running layer in any way. Disregarding this informa-
    Figure 2.05-76. Main Bearing Cap Tightening(Torqulng tion could result in product damage.
    Pattern - As Viewed From Underside Of Crankcase

    A CAUTION l~atchforthep~SitionOf
    • Torque the bearing cap nuts one through four (in that
    order) to 75ft-Ib (102 N·m). If installing replacement
    I'!!"!!:!!!!~=':':::""::"':"=-';:..:...J.
    L. the lower bearing tang
    before r0111ng out the lower bearing. The bearing
    caps that will be align bored, torque to only 30 ft-Ib must be rolled In the proper direction. If the tang Is
    (40 N·m). When installing more than one cap, torque accidently rolled through the lower bearing seat,
    nuts one through four to 75 ft-Ib (1 02 N'm) on all caps damage to the bearing seat and camshaft will result.
    ) before torquing side bolts.
    4. Using the proper bearing rollout tool, PIN 474001,
    • Torque all left side bolts (five) to 250 ft-Ib (339 N·m)
    carefully roll out the lower camshaft bearing in the
    starting from the front of the engine.
    proper direction.
    FORM 6248 Rrst Ed~ion 2.05 - 31
    CRANKCASE REMOVAL

    CAMSHAFT BEARING INSTALLATION IN


    FIELD CONDITIONS

    A CAUTION IWatchforthep~sitionof
    ..
    =
    IL. ='---''----''--_-''-----1. the lower bearmg tang
    before roiling in the lower bearing. The bearing
    must be rolled in the proper direction. If the tang is
    accidently rolled through the lower bearing seat,
    damage to the bearing seat and camshaft will result.

    1. Lubricate the bearing shells.

    2. Using the bearing rollout tool, PIN 474001, carefully


    roll in the lower bearing shell.

    3. Install a new O-ring in the bearing cap.

    4. Install the bearing cap and upper bearing shell, wtth


    the ferry head capscrews and lock washers.

    5. Refer to Chapter 4 for procedures on replacing the


    valve lifter cover.

    2.05 - 32 FORM 6248 First Ednion


    CHAPTER 3 - ENGINE INSPECTION AND OVERHAUL

    CONTENTS

    SECTION 3.00 - CYLINDER HEAD DISASSEMBLY

    SECTION 3.05 - CRANKCASE DISASSEMBLY

    FORM 6248 First Ednion


    )

    FORM 6248 First Ednion


    SECTION 3.00 - CYLINDER HEAD DISASSEMBLY

    CYLINDER HEAD DISASSEMBLY NOTE: Perform Steps 5 thru 9 only as necessary. If


    parts are serviceable, only cleaning is required.
    Refer to Chapter 5 for procedures to remove and install
    the admission valve, spark plug carrier and prechamber 5. Remove the fixed valve lifter screws (3/4 inch) from
    cup. Service of these components is also covered in the intake actuator and exhaust rocker arm.
    Chapter 5.
    6. Remove and discard the tappet ball insert from the
    ROCKER ARMS intake actuator.
    Rocker Arms Disassembly
    7. Remove the two hex jam nu1s (15/16 inch) and
    1. Remove the crossover oil tube between the rocker rocker arm adjusting screws from the intake and
    arm supports on the intake actuator side of the rocker exhaust rocker arms.
    arm assembly (see Figure 3.00-1).
    8. Remove the steel pop rivets (3/16 inch) from the
    2. Remove and discard the O-rings from the crossover intake actuator and exhaust rocker arm. The intake
    oil tube. actuator has two rivets, the exhaust rocker arm has one.

    3. Remove the rocker arm supports from the shafts. 9. Press out the old rocker arm bushings and discard.
    Remove the shafts from the rocker arms and rocker arm The intake actuator has one bushing, the intake and
    supports. exhaust rocker arms have two.

    4. Remove the allen head pipe plugs (1/8 inch) from the
    ends of the rocker arm shafts.

    HEX JAM NUT

    ~Ii ® I ADJUSTING SCREW

    ROCKER ARM/
    SUPPORT /
    i, EXHAUST

    ,1
    I
    FIXED VALVE
    /UFTER SCREW

    ,
    INTAKE
    ACTUATOR
    ROCKER ARM SHAFT

    ALLEN HEAD PIPE /


    \I~
    ROCKER ARM BUSHING

    INTAKE ROCKER

    STEEL POP RIVET

    TAPPET BALL INSERT--[J " CROSSOVER


    OIL TUBE

    Figure 3.()()'1. Rocker Arm Assembly

    I
    /

    FORM 6248 First Edition 3.00 - 1


    CYLINDER HEAD DISASSEMBLY

    Rocker Arm Cleaning and Inspection 2. Inspect the rocker arm adjusting screws for dam-
    aged threads. Look for cracks or breakage around the
    A WARNING ball tappet insert. Verify that the ball rotates freely in all
    directions without binding. Direct compressed air
    Compressed air can pierce the skin and cause through the lube oil passage to ensure its cleanliness
    severe personal injury or death. Never use your (see Figure 3.00-3). Replace the adjusting screw if
    hand to check for leaks or to determine air flow damaged.
    rates. Wear safety glasses to shield your eyes from
    flying dirt and debris.
    LUBE OIL

    1. Inspect the fixed valve lifter screws for damaged


    threads. Look for cracks or breakage around the oil
    holes and excessive wear from contact with the
    hydraulic lifter socket. Direct compressed air through
    the lube oil passage to ensure its cleanliness (see
    Figure 3.00-2). Replace the fixed screw if damaged or
    excessively worn.

    TAPPET INSERT

    Figure 3.00-3. Rocker Arm Adjusting Screws

    Figure 3.00-2. Fixed Valve Lifter Screw 3. Carefully inspect the rocker arm shafts for damage )
    (see Figure 3.00-4). Replace the shafts if they are
    scratched, pitted, galled or seized.

    !fl ii
    _..J....J.... ________________________ ....J...J...._ ii Yj\
    -F
    ~
    - --------- - - - - - ------ - - - - - - - - - ---
    -r1"""------------------------r1"""-
    +-:-
    ~_I=
    t-

    \i.J II II lJ;
    Figure 3.00-4. Rocker Arm Shaft

    3.00 - 2 FORM 6248 First Edition


    CYLINDER HEAD DISASSEMBLY

    4. Check the rocker arm shafts for excessive wear. Rocker Arm Assembly
    Refer to Table 3.00-1 for new part tolerances for the
    rocker arm shaft. Refer to Table 3.00-1 to calculate the NOTE: If it was not necessary to totally disassemble
    wear limits. Discard the shafts that are not within the rocker arm assemblies, perform only those steps in
    allowable limits. this procedure that apply.

    Table 3 00-1 Rocker Arm Shaft


    INCHES MILLIMETERS
    IA
    ..
    CAUTION I Insure that the 011
    grooves of the rocker
    8-1/2 INCH BORE arm bushings are positioned at the bottom of the
    rocker arm with the open ends ofthe grooves facing
    L5108, L5790 1.3735 - 1.3745 34.8869 - 34.9123
    the center. If the grooves are not positioned
    9-3/8 INCH BORE correctly, the rocker arms will not be adequately
    L7042 1.3735 - 1.3745 34.8869 - 34.9123 lubricated, causing damage to equipment.

    5. Polish the rocker arm shafts with fine grit crocus cloth 1. Press in the two bushings in the exhaust rocker arm.
    to remove minor scuff marks and scratches. The bearings must be flush with the ends of the rocker
    arm and the bearing oil grooves must be positioned at
    6. Inspect the 10 (see Table 3.00-2) of the rocker arm
    the bottom ofthe rocker arm with the open ends ofthe oil
    bore to verify that it is clean and smooth, free of burrs
    grooves facing the center, (see Figure 3.00-5 and
    and high spots. Check the bore diameter to verify that
    Figure 3.00-6).
    there is proper bushing press interference (see
    Table 3.00-3). 2. Press in the two bushings in the intake rocker arm.
    Table 3 00-2 Rocker Arm Bushing Bore I D .. The bearings must be flush with the ends of the rocker
    arm and the bearing oil grooves must be positioned at
    INCHES MILLIMETERS the bottom of the rocker arm with the oPen ends of the oil
    8-1/2 INCH BORE grooves facing the center, (see Figure 3.00-6 and
    L51OS,L5790 1.375 - .376 34.925 - 34.950 Figure 3.00-7).
    9-3/8 INCH BORE
    L7042 1.375 - 1.376 34.925 - 34.950

    Table 3.00-3. Running Clearence -


    Rocker Arm Bushing To Shaft
    INCHES MILLIMETERS
    8-1/2 INCH BORE
    L51OS, L5790 0.0008 - 0.0025 0.0127 - 0.0635
    9-3/B INCH BORE
    L7042 0.0008 - 0.0025 0.0127 - 0.0635

    A WARNING
    Always use approved cleaning solvents in a well
    ventilated area. Contact with skin could result in
    severe personal Injury or death.

    A WARNING
    Compressed air can pierce the skin and cause
    severe personal injury or death. Never use your
    hand to check for leaks or to determine air flow
    rates. Wear safety glasses to shield your eyes from
    flying dirt and debris.
    )
    7. Thoroughly clean all parts of the rocker arm assem-
    blies in a non-volatile cleaning solution or solvent. Dry
    with moisture free compressed air.

    FORM 6248 First Edition 3.00- 3


    CYLINDER HEAD DISASSEMBLY

    LUBE OIL HOLE 11IROUGH BUSHING,


    #11 DRILL (.191")(4.86 mm)
    ON

    BUSHING
    FLUSH

    BUSHING
    FLUSH

    DRILL LUBE OIL HOLE


    THROUGH BUSHING,
    1/8 DRILL (.125") (3.05 mm)
    LUBE OIL
    PASSAGE

    Figure 3.00-5. Exhaust Rocker Arm Bushings


    )
    OPEN CLOSED
    GROOVES GROOVES
    (INSIDE)

    INTAKE & EXHAUST INTAKE ACTUATOR


    ROCKER ARMS

    OUTSIDE END OUTSIDE END

    GROOVES ON BonOM

    Figure 3.00-6. Rocker Arm Bushings

    3.00 - 4 FORM 6248 First Ed~ion


    CYLINDER HEAD DISASSEMBLY

    ~,:;.oo'--=r---------------

    ~I. ~O':'I~~~:be:~:::::::--t-j~
    BEARING/'
    FLUSH
    CAUTION Wi I
    lower Circumference, open
    DIA.
    faCing In.

    BEARING
    FLUSH

    LUBE OIL
    PASSAGES

    Figure 3.00-7. Intake Rocker Arm Bushings

    3. Press in the bushing in the intake actuator rocker arm. 6. Drill one lube oil hole (0.191 inch or 4.851 mm)
    The bearing must be flush with the ends of the rocker arm through the intake actuator rocker arm bushing by
    and the bearing oil grooves must be positioned at the inserting a #11 drill bit into the pop rivet hole behind the
    bottom of the rocker arm (see Figure 3.00-8 and fixed valve lifter screw bore (see Figure 3.00-8).
    Figure 3.00-6). Remove any burrs left by drilling.

    4. Drill one lube oil hole (0.191 inch or 4.851 mm) 7. Drill one lube oil hole (0.191 inch or 4.851 mm)
    through the exhaust rocker arm bushing by inserting a through the intake actuator rocker arm bushing by
    #11 drill bit into the pop rivet hole behind the fixed screw inserting a #11 drill bit into the pop rivet hole behind the
    bore (see Figure 3.00-5). Remove any burrs left by tappet ball insert bore (see Figure 3.00-8). Remove any
    drilling. burrs left by drilling.

    5. Drill a smaller oil hole through the other exhaust


    rocker arm bushing by inserting a 1/8 inch (3.2 mm) drill
    bit into the hole in each adjusting screw bore. Remove
    any burrs left by drilling.

    1.376" 134.95 mml


    1.375" (34.93 mm) DIA.

    )
    Figure 3.00-8. Inteke Actuator Rocker Arm Bushings

    FORM 6248 First Edition 3.00 - 5


    CYLINDER HEAD DISASSEMBLY

    10. Direct compressed air into the lube oil passages and
    A WARNING around the bushings to remove all metal debris. Lightly oil
    Compressed air can pierce the skin and cause a good rocker arm shaft and insert H into the rocker arm
    severe personal injury or death. Never use your bore to feel for the proper interference ffl. The shaft should
    hand to check for leaks or to determine air flow slide in and out of the rocker arm bushing without binding.
    rates. Wear safety glasses to shield your eyes from pivoting or rocking. The proper rocker arm bushing to
    flying dirt and debris. shaft running clearance should be 0.0005 - 0.0025 inch
    (0.0127 - 0.0635 mm) (see Figure 3.00-9).
    8. Direct compressed air into the lube oil passages and 11. Tap in new 3/16 inch steel pop rivets to plug the
    around the bushings to remove all metal debris. exterior lube oil holes in the intake actuator and exhaust
    NOTE: If the rocker arm shaft OD is within the new rocker arm castings. The intake actuator requires two
    parts specification at 1.3735 - 1.3745 inches rivets. the exhaust rocker arm requires one.
    (34.8869 - 34.9123 mm), then the final bushing bore 12. Install the two rocker arm adjusting screws and hex
    ID will be 1.375 - 1.376 inches (34.925 - 34.950 mm). jam nuts (15/16 inch) on the intake and exhaust rocker
    (NOTE: Bushing to shaft running clearance is arms.
    0.0005 - 0.0025 inch (0.0127 - 0.0635 mm).

    9. Diamond bore the rocker arm bushings to a diameter


    0.0005 - 0.0025 inch (0.0127 - 0.0635 mm) larger than
    the rocker arm shaft, to aRMS 24 MAX, finish.

    HEX JAM NUT

    ROCKER ARM
    /
    ~
    1,1, ADJUSTING SCREW

    f
    /
    FIXED VALVE
    LIFTER SCREW

    SUPPORT
    ROCKER ARM SHAFT
    /
    ALLEN HEAD PIPE
    ROCKER ARM BUiSHII~G·

    INTAKE ROCKER ARM


    /
    I

    ~~
    STEEL POP

    TAPPET BALL INSERT


    -1!
    L@
    ~~CROSSOVER
    ;
    O-RING OIL TUBE

    Figure 3.00-9. Rocker Arm Assembly

    3.00 - 6 FORM 6248 First Edition


    CYLINDER HEAD DISASSEMBLY

    A CAUTION I
    NOTE: Install new ball tappet inserts in the intake
    actuators. Each insert consists of a seat, collar and ball
    tappet.
    I=..
    L..
    Do not Install the allen
    =---'_---'-_......;;_....... head pipe plugs too deep
    in the rocker arm shafts. The allen heads pipe plugs
    must not block more than half of the diameter of the
    13. Install the cup-shaped seat into the intake actuator 011 passages in the ends of the rocker arm shafts.
    ball tappet insert bore with the rounded side facing Also the allen head pipe plugs must be Installed
    inward (see Figure 3.00-10). completely into the rocker arm shafts. Failure to
    follow proper procedures could cause damage to
    POP equipment.

    16. Install and tighten the allen head pipe plugs (1/8 inch)
    in the ends of the rocker arm shafts.

    17. Look through the oil passages in the rocker arm


    shafts to insure that the allen head pipe plugs are not
    blocking more than half of the diameter of the oil
    COLlAR
    passages at each end of the rocker arm shafts
    FIXED VALVE
    SCREW 18. Install the rocker arm supports on the ends of the
    rocker arm shafts.

    19. Install the capscrews and washers on the rocker arm


    supports (8 capscrews per head, 1/2 x 4-3/4 inches).

    NOTE: The fixed valve lifter screws must torqued to


    55 - 60 ft-Ib (75 - 81 N'm) after installation 01 the
    POP rocker arm assemblies on the cylinder heads and
    RIVET adjustment of the valves.
    Figure 3.00-10. Intake Actuator Assembly
    20. Install the fixed valve lifter screws. (3/4 inch) on the
    exhaust rocker arm and intake actuator (see
    IA
    ..
    CAUTION I Insure that the tabs on
    the collar are parallel to
    Figure 3.00-10). See note above.

    21. Lubricate the rocker arm shafts and bushings.


    the shaft, with the split side of the collar facing the
    pop rivet, to avoid contact with the ball tappet 22. Slide the exhaust rocker arm and intake actuator
    during operation. Disregarding this Information over the rocker arm shaft. Slide the second shaft into the
    could result in product damage. intake rocker arm (see Figure 3.00-9).

    14. Compress the collar with a channel lock and slide it 23. Install a new O-ring in the groove at each end 01 the
    into the ball tappet insert bore, insuring that the tabs on crossover oil tube. Apply Parker Super O-Lube® to
    the collar are parallel to the shaft with the split side of the each O-ring and instail the oil tube between the rocker
    collar facing the pop rivet. Lightly tap the collar until it is arm supports on the intake actuator side of the rocker
    fully seated. arm assembly.

    IA
    ..
    CAUTION ICrimping the tabs too
    tightly will prevent the
    24. Lightly brush the rocker arm assemblies with clean
    engine oil. Cover the rocker arm assemblies with a
    clean plastic sheet to protect them from dust and dirt.
    ball from rotating properly. If the tabs are not
    crimped enough, the ball could fall out, causing
    damage to equipment.

    15. Tap in the ball tappet insert, and bend the two tabs
    in equally to secure the bail. Verify that the ball rotates
    freely in all directions without binding and is secured
    ) sufficiently by the tabs.

    FORM 6248 First Ednion 3.00 - 7


    CYLINDER HEAD DISASSEMBLY

    INTAKE AND EXHAUST VALVES


    ~ )
    ((J!!!J).'TAPERED Intake and Exhaust Valve Removal
    ~,KEEPERS

    A
    I
    SPRING
    RETAINER WARNING
    Use caution when removing or installing the valve
    'OUTER VALVE springs. They are under tension and can eject from
    SPRING the cylinder head during the removal process. Use

    I _
    __
    'INNER VALVE
    SPRING
    the special valve spring compressor tool for this
    procedure. Wear safety goggles. Failure to take
    adequate precautions can result In severe personal
    o> WASHERS
    injury.

    8, 1. Compress the valve springs using a Valve Spring


    Compressor (PIN 494255). Remove the tapered keep-

    ,
    VALVE STEM
    SEAL ers from each valve stem and slide off the spring
    INTAKE
    retainer, inner and outer valve springs and washers (2).
    VALVE Slide out the two intake and two exhaust valves (see
    EXHAUST
    GUIDE", Figure 3.00-11).

    2. Inspectthe intake and exhaust valves for wear. Refer


    to Table 3.00-4 for specifications of the valves. Discard
    any valve that is not within allowable limits.

    3. Remove and discard the white Teflon® valve stem


    seal from the valve guides (see Figure 3.00-12).
    )

    VALVE SEAT
    INSERT

    EXHAUST
    INTAKE VALVE
    VALVE",
    /

    Figure 3.00·11. Cylinder Head Assembly - Exploded


    View Figure 3.00-12. Install Valve Stem Seal

    3.00 - 8 FORM 6248 First Ednion


    CYLINDER HEAD DISASSEMBLY

    VALVE SEAT INSERT AND VALVE GUIDE


    REMOVAL A WARNING
    1. Move the cylinder head to a suitable workbench. Use a soft faced hammer and wear proper eye
    protection, to avoid severe personal injury or death
    2. Grind or machine the head diameter of several while removing the valve seat insert.
    discarded valves until they fit within the valve seat
    inserts. 7. Tap the valve stem tip with a soft faced hammer to
    remove the valve seat insert (see Figure 3.00-14 and
    3. Apply anti-spatter compound to protect the cylinder Figure 3.00-15).
    head deck surface and to facilitate the removal of weld
    spatter.

    4. Insert the ground down valves into the cylinder head


    until the valve head makes contact with the valve seat
    insert bore.

    A WARNING
    Always wear protective eye shields when welding,
    cutting or watching a welding operation. Protective
    clothing and face shields must be worn. Never weld
    or cut near combustible materials. Disregarding
    this Information could result in severe personal
    injury or death.

    5. Using a mild steel rod, weld a series of tack welds


    around the perimeter of each valve head where it
    contacts the valve seat bore (see Figure 3.00-13).

    TACK WELD
    THREE PLACES

    --..,-,..~/
    VALVE SEAT INSERTS

    Figure 3.00-14. Valve Seat Insert Removal

    SPOT WELD 3 PLACES


    TO REMOVE INSERT
    Figure 3.00-13. Tack Weld Valve To Valve Seat

    A. CAUTION Ilf a cracked weld breaks


    ~=~:..:.....:..::....:...:...;=~.
    IL.. . during removal of the
    insert, the seat may turn causing It to break or
    become lodged in the counterbore. A crooked or
    broken seat makes removal more difficult and can
    cause damage to the seat counterbore.

    6. Tap on the welds to check for cracks.


    Figure 3.00-15. Valve Seat Insert Removal

    FORM 6248 First Edition 3.00 - 9


    CYLINDER HEAD DISASSEMBLY

    8. Wipe off the anti-spatter compound. Use crocus


    cloth to remove all dirt, slag, weld spatter and debris
    from the lower deck surface and the valve seat insert
    counterbore.

    IA
    ...
    CAUTION I The exhaust valve
    guides are machined
    with two outside diameters and can only be re-
    moved in one direction. Failure to press out the
    valve guides through the bottom of the cylinder
    head (piston side) can cause damage to equipment.

    9. Using a Valve Guide Remover (PIN 494257) press


    out the valve guides. Guides must be pressed out
    through the bottom of the cylinder head towards the
    (piston side).

    CYLINDER HEAD CLEANING AND INSPECTION


    Generally the cylinder head casting does not require
    any unusual maintenance other than resurfacing of the Figure 3.00-16. Core Plug Locations - Top
    lower deck if required, (see Cylinder Head, Lower Deck
    Reconditioning). Items needing replacement within the
    casting, are removable fittings, such as valve guides
    and valve seats. All water plugs and removable fittings
    must be removed to adequately clean the casting.
    lJ
    Scale buildup in a cylinder head can cause it to fail. An V 0 0
    "-
    0
    accumulation of scale deposits within the cylinder head ,.........
    )
    '-
    inhibits the proper transfer of heat around critical engine
    parts, causing overheating. This overheating and
    expansion cause the casting to crack. Preventing scale
    buildup will help prevent a cracked cylinder head.
    During an engine overhaul, hot tank the component to
    o @ 0
    remove any scale. 8~
    When the cylinder head is cleaned and air dried, check
    thoroughly for cracks. Magna-Flux® products can Figure 3.00-17. Core Plug Locations - Front
    assist with such an inspection. When checking for
    cracks, special attention must be paid to the combustion
    side of the cylinder head. The area between the valve
    inserts must be inspected carefully. Only after the
    cylinder head casting is found to be free of cracks can
    the removable fittings be replaced. These fittings must
    ,>--
    t- Un) ~
    lJ-
    also meet the required specifications. If they do not
    meet the specifications or guidelines for the reuse of ~
    used parts, replace with new genuine Waukesha parts.

    1. Remove the eleven countersunk headless core


    plugs from each cylinder head (eight 3/4 inch NPT, .... I~l 10::::::
    three 1 inch NPT) (see Figure 3.00-16, Figure 3.00-17, 9
    Figure 3.00-18, Figure 3.00-19 and Figure 3.00-20).
    Figure 3.00-18. Core Plug Locations - Right

    3.00 -10 FORM 6248 First Edition


    CYLINDER HEAD DISASSEMBLY

    A WARNING
    Use of caustic solutions should be restricted to a
    well ventilated area. Contact with skin, clothing and
    eyes could result In severe personal InJury or death.

    A WARNING
    ~_--1..-_©)~----1..._---L::r Compressed air can pierce the skin and cause
    severe personal injury or death. Never use your
    11 hand to check for leaks or to determine air flow
    rates. Wear safety glasses to shield your eyes from
    Figure 3.00-19. Core Plug Locations - Left
    flying dirt and debris.

    2. Submerse the cylinder heads in the caustic hot tank


    7 to remove all paint, dirt, grease, oil, carbon and varnish
    deposits. Follow up with a thorough hot rinse. Dry the
    heads with moisture free compressed air.

    3. Inspect the cylinder head through a water passage


    opening for an accumulation of lime and mineral scale
    deposits. If use of an untested water supply or the lack of
    a suitable water treatment program resulted in a

    o o accumulation of deposits, then speciEll cleaning may be


    required.

    4. Buff the gasket surfaces to ensure a tight seal at the


    o o crankcase, rocker arm cover and intake and exhaust
    ports.

    o 5. With the valve seat side facing upward, position a


    straight edge diagonally across the length of the
    cylinder head intersecting the seats of one intake and
    one exhaust valve (see Figure 3.00-21). Slide a feeler
    o0 ,..=r:;r gauge beneath the straight edge to check the head for
    warpage. Place the straight edge across the other
    intake and exhaust valve seats and repeat the
    Figure 3.00-20. Core Plug Locations - Bottom procedure. If the gap between the straight edge and
    the lower deck surface exceeds 0.002 inch (0.051 mm)
    refer to Cylinder Head Lower Deck Recondition.

    FORM 6248 First Edition 3.00 - 11


    CYLINDER HEAD DISASSEMBLY

    CYLINDER HEAD CASTING PRESSURE TESTING


    METAL
    EXHAUST STRAIGHT EDGE Water test the cylinder head casting for leaks.
    )
    VALVE
    1. Using the correct cylinder head gasket as a stencil ,
    make a steel plate 3/4 to 1 inch thick (19 to 25 mm)
    (see Figure 3.00-22). To ensure a tightfit, cut holes in
    the plate to match all eight cylinder head capscrew
    holes in the head gasket. Cut the plate open at the
    valve area, so any leakage around the exhaust valve
    guides or between the valve seat inserts can be
    observed. Do not drill holesforthetwo locating dowels

    o or the seven water passage openings. The rubber


    grommets in the head gasket point out the location of
    the water passage openings.
    o o

    St······
    ~ .........
    ~'"

    INTAKE
    VALVE SEAT
    .....
    METAL
    STRAIGHT EDGE
    )
    \
    Figure 3.00-22. Cylinder Head Pressure Test Plates

    2. Fabricate a steel plate 3/4 to 1 inch thick (19 to 25 mm)


    to cover the water outlet elbow connection at the top of the
    cylinder head. Drill and tap the plate to accept a 3/8 or 1/2
    inch pipe fitting. Fit the pipe fitting with a male air line fitting.

    3. Using the plates as a stencil, cut rubber gaskets to


    seal the plates onto the cylinder head.

    4. Bolt the plates onto the cylinder head.

    5. Fabricate a small plate or plug to close off the water


    CYLINDER HEAD
    / outlet hole centered below the exhaust outlet port (see
    Figure 3.00-23).
    Figure 3.00-21. Check Cylinder Head Deck For
    Warpage

    3.00 - 12 FORM 6248 First Ednion


    CYLINDER HEAD DISASSEMBLY

    CYLINDER HEAD CASTING MAGNAFLU)(®


    WATER OUTLET
    ELBOW CONNECTION
    A WARNING
    Always carefully read the manufacturer's instruc-
    tions to avoid severe personal injury or death.

    Using the Magnaflux@ Dye Penetrant Test Kit


    (Tool PIN 494283), inspect the cylinder head for surface
    cracks. The small area between the exhaust seat
    inserts is the location where most cracks occur.
    1. To remove oily residues, apply the Magnaflux@
    Spotcheck@ Cleaner/Remover (SKC-S) directly to the
    test area. Thoroughly wipe the area with a clean cloth.
    Repeat the procedure as necessary. Final wiping
    should result in a clean cloth. Allow the test area to dry.
    NOTE: Wear rubber gloves to avoid hard-to-remove
    stains on hands.
    2. Spray the test area with the Magnaflux@ Spotcheck@
    Penetrant (SKL-SP). Wait 1 to 30 minutes.
    WATER HOLE
    TO EXHAUST 3. Spray the Magnaflux@ Spotcheck@ Cleaner/Re-
    MANIFOLD CYLINDER mover (SKC-S) on a clean cloth (not on the test area).
    HEAD
    Wiping in one direction, remove all surface penetrant.
    Figure 3.00-23. Water Outlet Hole Repeat as necessary.

    4. Spray the test area with the MagnafluX®


    A DANGER Spotcheck@ Developer (SKD-S2). Apply a thin even
    film. Allow the film to dry completely. The proper
    Never use air pressure alone to test a cylinder head application dries to an even white layer.
    casting. The cylinder head must be filled with water
    prior to applying air pressure or the casting will 5. Carefully inspect the test area for cracks. A bright
    break, hurling fragments In all directions. Air colored solid or dotted line marks a crack. Fine cracks
    pressure cannot exceed 50 psi (345 kPa). Failure to may take up to 15 minutes to appear. Large cracks can be
    follow proper procedures will result in severe seen almost immediately. If the crack is wide and deep,
    personal injury or death. the indication will grow and spread.

    6. Wipe the test area clean if cracks are not found.


    6. Fill the cylinder head with water.

    7. Attach an air source to the male air fitting and apply


    50 psi (345 kPa) air pressure on top of the water. IA
    .L..=
    CAUTION not weld cracked cyl-
    mder heads. Welding
    I~o
    .=c..-.;;;;.;;....;;.;::.....:;....:....::....::....:..J.
    .
    has been found to be an unsuccessful repair.
    8. Inspect the cylinder head for leaks. Carefully check Disregarding this information could result in prod-
    the lower deck surface between the two exhaust seats uct damage and/or personal injury.
    and between the intake and exhaust seats. Look for
    leakage at both ends of the exhaust guides. On rare 7. Discard the cylinder head if cracks are found.
    occasions, leaks may be found around the core plugs or
    inside the spark plug carrier bore.

    9. Carefully release air pressure.

    10. Drain water from cylinder head.

    FORM 6248 First Edition 3.00 -13


    CYLINDER HEAD DISASSEMBLY

    CYLINDER HEAD LOWER DECK RECONDITION VALVE FAILURE ANALYSIS


    If it is determined that the lower deck needs to be The major causes for valve failures include:
    reconditioned by milling, this reconditioning should be
    done prior to any other cylinder head reconditioning. • Valve recession
    The lower deck should be reconditioned until the
    • Wear
    surface is clean. Remove only sufficient material to
    clean up the lower deck surface. • Scuffing of the valve stem

    A
    I ..
    CAUTION Ilf the lower deck of the • Excessive deposits on the valve
    cylinder head is recondI-
    tioned, the valve seat insert counterbore depth will • Carbon buildup in the guide
    have to be recut as required, to maintain the proper • Distortion of the valve seat
    depth of the valve heads In the cylinder head.
    Failure to recut the valve seat insert counterbore • Incorrect valve adjustment
    depth could cause damage to equipment.
    • Torching
    The height of a new cylinder head is 8.469 inch,
    (215.113 mm) (see Figure 3.00-24). During recondition- • Heat fatigue/cracking
    ing, not more than 0.020 inch, (0.508 mm) may be
    removed from the lower deck. If more material is • Valve erosion
    removed from the lower deck, the casting strength will
    • Other
    be reduced, making it incapable of withstanding the
    firing pressure of rated horsepower, in addition to Valve Recession
    causing misalignment problems. These misalignment
    Valve recession is a normal process, and is expected
    problems include misalignment between the exhaust
    over time. Typically, 0.0015 to 0.002 in. (0.0381 to
    manifold and intake manifold. The cylinder head must
    0.0508 mm) of wear (per 1000 hours of operation on the
    be marked to indicate it has been reconditioned.
    valve and seat faces is acceptable and will result in a )
    normal top end overhaul life.
    Valve and Guide Wear
    J Abnormal component wear leads to excessive valve

    \0 recession. Wear can occur on the valve face, valve stems,


    valve guides, and valve seats. Valve guides typically wear
    from poor valve-to-seat contact, causing a side thrust on
    8.469" the guide. Out-of-round valve seats can also cause the
    /:,215.11 3mm)
    HEI HT(NEWHEAD) same type of guide wear. In addition, combustion air or
    fuel gas can contain abrasives which can also wear the
    valve face, seat, and the lower end of the guide.
    Worn guides can cause the valves to meet the valve
    frO seat at a variety of angles, causing a sliding motion
    which will further wear the valve and its seat. This
    improper seating leads to blowby of combustion gases
    and seat burning, or torching. Other reasons for worn
    Figure 3.00-24. Cylinder Head - Intake Port Side valve guides are:

    lithe lower deck is reconditioned, it may be necessary to • Improperly adjusted valves which cause excessive
    recut the valve seat insert counterbore depth to side thrust on the valve stems.
    maintain the proper depth of the valve heads in the
    cylinder head (see Figure 3.00-24). The valve seat • Poor lubrication in the guide, either too much or too
    insert counterbore depth will have to be recut to the little.
    amount as was taken off the cylinder head.
    • Carbon deposits on the valve stem which cause the
    valve guide to wear into a bell-mouthed shape at the )
    lower end.

    • Incorrect valve or seat angle due to grinding during


    rebuilding.

    3.00 - 14 FORM 6245 First Edition


    CYLINDER HEAD DISASSEMBLY

    Valve Stem Scuffing Valve Breaks


    Scuffing of the valve stem can result from a lack of When a valve breaks, it generally is from a bending
    lubrication and too much or too little stem to guide fatigue or impact w~h the piston. Fatigue occurs usually
    clearance. Poor disassembly or assembly practices can from mechanical damage where the valve and piston
    cause damage to the surface finish of the valve stem or have made contact, bending the valve slightly, and over
    valve guide, which will scuff the valve or guide. a period of time the flexing at the stem-head interfaces,
    breaks the valve stem. Impact with the piston, if severe
    Valve Deposits enough, will break the valve immediately or induce the
    Valve deposits are normal. Deposits on exhaust valves cond~ion that causes a bending fatigue type failure.
    should be dry and white, to tan in color. Depos~s typically
    occur on the head of the valve and the blended area Valve Erosion
    between the valve head and stem. The seating surface of Erosion of the valve stem under the valve head can
    the valve will typically exhibit a matted appearance ~h cause valve breakage. Causes of valve erosion include
    some small pot marks due to deposits being caught fuel gas with high hydrogen sulfide levels, faulty combus-
    between the valve and the seat. This is also considered tion, or excessively high valve temperatures. Improper
    normal unless the p~ng allows gas leakage. airlfuel mixture ratios which overheat and erode valves,
    Deposits will also build up on intake valves, however can cause such high temperature valve failure as well.
    they are typically darker in color, and on the blended
    area between the head and the valve stem, they will be Other
    black and carbonaceous with some oil present. We have listed only a few of the reasons why valves fail,
    The major~ of combustion chamber depos~ are made there are, obviously, many others. In the list above we
    up of burnt lube oil and lube oil additives. These deposits have identified ten most common causes, however they
    are commonly called ash, and the proper amount of ash are not necessarily in any prior~ of probable occurrence.
    is desirable to to retard valve recession, or wear. Ash
    Valve Inspection
    depos~ should be seen on the valve face and seat.
    At overhaul, it is recommended tnat all valves be
    Valve Guide Deposits replaced. If the valves are to be reused, they must be
    Deposits (carbon or lacquering) in the valve guide can inspected before grinding. The valve .[Tlust be cleaned
    cause the valve to stick in the guide, causing the valve to thoroughly prior to inspection. The following checks
    be held in the open position. Inspect the valve guides for should be made for each valve.
    deposits or wear. See Clearances in Table 3.00-4 ofthis
    manual. Replace worn guides. 1. The diameter should be measured in three locations
    along the wear area length. In addition, each location
    Valve Seat Distortion should consist of two measurements, one at 90° to the
    Distortion of a valve seat can lead to burnt valves. This is other to check for roundness of the stem.
    usually caused by:
    2. Valve stem straightness. Valve stem straightness can
    • Poor grinding practice be examined using two V -blocks and a dial indicator
    • Loose or improperly seated valve seats which may (see Figure 3.00-25). total indicator reading must not
    reduce or stop the transfer of heat between the valve exceed 0.002 inch, (0.050 mm). Never attempt to
    seat insert and the cylinder head. straighten a bent valve. Bent valves must be discarded.

    • Failure of the cooling system

    Torching
    Burnt or torched valves are always caused by combus-
    tion gases leaking between the valve and seat. This
    leakage occurs when the valve is supposed to be ROTATE
    closed, but is, in fact, held open due to excessive
    deposits, improper adjustment, or sticking valves. It can
    also be caused by improper valve grinding practices or
    valve adjustment procedures.
    Valve Heat Fatigue/Cracking
    )
    Heat fatigue, caused by overheating, can lead to valve
    head cracking, burning, or breakage. Heat fatigue can
    Figure 3.00·25. Checking Valve Stems For Straightness
    include worn valve guides, distorted valve seats,
    excessive deposits, and/or improper air/fuel ratios.

    FORM 6248 First Edition 3.00 - 15


    CYLINDER HEAD DISASSEMBLY

    3. Head perpendicularity. The head must be perpen- become distorted. The grooves are machined with a
    dicularto the valve stem or improper seating will result 0.094 inch (2.388 mm) radius. Any valve with distorted )
    (see Figure 3.00-26). Total runout must be within grooves must be discarded (see Figure 3.00-27).
    0.002 inch, (0.050 mm).
    NOTE: "Ste/lite® is a registered trademark of Stoody
    De/oro Ste/lite, Inc."
    -
    HARDENED STEM END IS PERPENDICULAR
    TO STEM CENTERLINE
    /
    C:I

    \/ I
    RETAINER GROOVES

    -
    C:I

    ~ b
    C:I STELLITE"
    FACE

    SEAT )
    ~ C:~==F=~~)==~rARGIN
    ANGLE /

    \
    V/ \ \ HEAD PERPENDICULAR
    t
    ( "l HEAD STAMPED FOR
    INTAKE/EXHAUST PLUS PIN
    TO STEM CENTERUNE

    Figure 3.00-26. Checking Head Perpendicularity


    Figure 3.00-27. Cylinder Head Valve

    4. Stem end perpendicularity. It is important that this


    surface be flat and perpendicular to prolong the life of
    the valve and tappet ball (see Figure 3.00-27). t 13.69
    0.156" mml NEW VALVE
    0.128" 3.25 mm MINIMUM AFTER GRINDING

    5. Margin wear. After the valve face is ground until all


    wear marks are removed, it is important to inspect the
    margin (see Figure 3.00-28). The valve is Stellite®
    faced, and it is important that there is enough Stellite®
    left on the valve face. A margin 0.128 inch (3.25 mm) or
    fMARGIN - -
    less, indicates that too much Stellite® has been
    removed and the valve will have a tendency to burn.
    This valve should be discarded.

    6. Cracks. The valves must be inspected for hairline


    cracks which cannot be readily seen under convention-
    al light. They must be inspected using a dye penetrant
    process. Ordinary Magnetic particle inspection will not
    locate fissures or cracks in non-ferrous materials. Figure 3.00-28. Margin Wear
    7. Valve stem retainer groove wear. The two retainer
    grooves must be examined to determined if they have

    3.00 - 16 FORM 6248 First Ednion


    CYLINDER HEAD DISASSEMBLY

    Table 3.00-4. Valve Train

    ~ I---- ---l
    H

    t'~!-=l'~

    EXHAUST INTAKE
    INTAKE AND EXHAUST
    MEASUREMENT INCHES METRIC (mm) .
    (A) Valve overailleng1h 10.883
    GlGSI engines (Intake and Exhaus1) 276.428

    GLengines 10.883 276.428


    Qmake)
    10.837 275.260
    (exhaust)
    (8) Valve stem diame1er
    GIGSI engines
    (intake) 0.557 - 0.558 14.148 -14.173
    (exhaust) (top) 0.5591 - 0.5588 14.2011 - 14.2189
    (exhaust) (bottom) taper 0.5573 - 0.5580 14.1554 -14.1732
    GL engines (I make and Exhaust) 0.557 - 0.558 14.148 -14.173
    (C) Valve head diame1er (Intake and Exhaust) 2.825 - 2.835 71.755 - 72.009
    (0) Valve face angle
    GlGSI engines Ontake and Exhaust) 300 ±15' 300 :!:15'

    GLengines
    (intake)
    (exhaust)
    (Continued)

    FORM 6248 First Edition 3.00 -17


    CYLINDER HEAD DISASSEMBLY

    INTAKE AND EXHAUST


    MEASUREMENT INCHES METRIC (mm)
    )
    (D') Valve seat width
    GlGSI engines :30' 0.265 6.731
    Qntake and exhaust)
    GLengines
    (intake) 30' 0.265 6.731
    (exhaust) 20' 0.281 7.137
    (E) Valve guide length (intake and exhaust) 5.188 131.775
    (F) Valve guide outside Diameter (intake and lower exhaust) 1.0015 - 1.0025 25.4381 - 25.4635
    (F') Exhaust guide upper outside diameter (exhaust) 0.997 - 0.996 25.324 - 25.350
    (G) Guide inside diameter (reamed in assembly, except hardened
    gUides in landfill applications) 0.5608 - 0.5615 14.244 - 14.262

    (G) Valve guide to valve stem clearance


    GIGSI entes
    (intake 0.0028 - 0.0045 0.0711 - 0.1143
    (eXhaust! ~) 0.0010 - 0.0027 0.0254 - 0.0886
    (exhaust bottom) 0.0028 - 0.0045 0.0711 - 0.1143
    GL engines (intake and exhaust) 0.0028 - 0.0045 0.0711 - 0.1143
    (H) Valve seat insert outside diameter (intake and exhaust) 3.002 - 3.003 76.251 - 76.276
    (I) Valve seat insert inside diameter (intake and exhaust) 2.441 - 2.451 62.001 - 62.255
    (J) Valve seat insert height Qntake and exhaust) 0.550 - 0.555 13.970 - 14.097
    (I<) Valve seat insert seat angle
    GiGSI engines Qntake and exhaust) 30° ±15' 30" ±15'

    GLengines
    Qntake) :30' +30' -0' 30° +30' -0'
    (exhaust) 20" +30' -0' 20° +30' -0'
    (K., Valve seat insert seat width
    0.172 - 0.203 4.370 - 5.160
    )
    GiGSI engines :30' Qntake and exhaust)
    GL engines 0.172 - 0.203 4.365 - 5.159
    (intake) 30'
    0.188 - 0.250 4.780 - 6.350
    (exhaust) 20'
    (l) Valve guide extension above boss 1.75.0.03 44.25.0.76
    eM) Valve guide bore in head (intake and lower exhaust) 1.000 - 1.001 25.400 - 25.425
    (M') Valve guide bore in head (upper exhaust) 0.995 - 0.996 25.273 - 25.298
    (N) Valve seat insert counterbore depth (Intake and Exhaust) 0.6245 - 0.8285 20.9423 - 21.0439
    (0) Valve seat insert counterbore diameter 3.000 - 3.001 76.20 - 76.23

    3.00 - 18 FORM 6248 First Edition


    CYLINDER HEAD DISASSEMBLY

    Valve Seat Bore and Insert Inspection 3. Start the new valve guides in their respective bores.
    Always press in the valve guides from the valve seat
    NOTE: Before inspection, all parts must be thoroughly insert side of the cylinder head. Use a 20-ton hydraulic
    cleaned. press and the Valve Guide Removerllnstaller
    1. Inspect the cylinder head valve seat bores for (PIN 494257) (see Figure 3.00-29). Any contact be-
    cracks, pits, wear or any deformations. The bores must tween the press and the lower deck ofthe cylinder head
    be perfectly smooth. must be avoided.

    2. Refer to Table 3.00-4 for the proper measurements


    of the valve seat bore.

    CYLINDER HEAD ASSEMBLY


    The correct order of assembly for a cylinder head is:
    • Valve guides

    • Water Plugs
    o
    • Valve seat inserts

    • Valves with springs


    PRESS TOOL
    • Prechamber assembly
    VALVE GUID~I
    • Spark plug carrier assembly
    CYUNDER(
    HEAD" [
    -............:(~~==iii()t
    • Rocker arm assemblies

    A WARNING PRESS~IC==!Il
    GAUGE
    The cylinder head weighs approximately 195 Ibs.
    (89 kg). Use a suitable lifting device and exercise
    caution during removal or installation to prevent Figure 3.00-29. Installing Valve Guides
    severe personal InJury or death.

    VALVE GUIDE INSTALLATION


    IA CAUTION I Always start the reamer
    .. from the valve seat Insert
    CAUTION I Only a ~mall amount of
    I A!:!!c...::::::....:.:::....:~=.::..:..J. side of the cylinder head and never tum the reamer
    backwards. Failure to follow these procedures will
    .L.!
    .. grease IS req u I red, do
    not apply grease to necked-down portion of the cause damage to equipment.
    exhaust guide. Disregarding this information could
    resuh in product damage.
    IA
    ..
    CAUTION I The valve guides
    P/N204109G (Intake) and
    1. Apply a small amount of grease to the outside 204109F (Exhaust) used in landfill applications
    surface of the new intake and exhaust valve guides. (Cylinder Head assemblies PIN AF204802C,
    CF204802C and AC204702N) are specially hard-
    IA;..
    CAUTION I Insure that the exhaust
    valve guide is pressed in
    ened. These guides are pre-sized, and should not
    be reamed, to preserve the hardened surface.
    from the valve seat insert side of the cylinder head. Disregarding this information could result in prod-
    Insure that the correct end of the guides are uctdamage.
    Inserted first. Failure to follow these procedures
    will cause damage to equipment. 4. Using a Carboloy-tip Reamer, (PIN 499953), ream
    the valve guides, starting from the valve seat insert side
    2. Position a shop towel to prevent metal chips and of the cylinder head.
    debris from falling into the cylinder heads.
    5. Carefully remove the shop towel to prevent metal
    chips and debris from falling into the cylinder head.

    FORM 6248 First Ednion 3.00 -19


    CYLINDER HEAD DISASSEMBLY

    -_____---'.I
    I. . "'A.-.='-CAUTION
    CYLINDER HEAD CASTING PLUG INSTALLATION Install the valve seat in-
    sert with the beveled )
    1. Apply a removable pipe sealant (Loctite® Remov- side facing outwards. Disregarding this information
    able Threadlocker 242) to the threads of the counter- could result in product damage.
    sunk headless core plugs (see Figure 3.00-16,
    Figure 3.00-17, Figure 3.00-18, Figure 3.00-19 and NOTE: The insert warms up rapidly, and must be
    Figure 3.00-20). properly installed before its diameter increases to the
    2. Install eleven core plugs in each cylinder head point where installation becomes difficult.
    (eight 3/4 inch NPT, three 1 inch NPT). TIghten the core 5. Using a wire bent in the shape of a hook, pick up Ihe
    plugs to 600 in-Ib (68 N·m). valve seat insert and position it into the counterbore with
    VALVE SEAT INSERT INSTALLATION the beveled side facing outward (see Figure 3.00-30).

    A WARNING
    Always wear safety gloves and safety glasses when
    handling liquid nitrogen. Comply with the liquid
    nitrogen/dry ice manufacturer's recommendations
    for proper use and handling of liquid nitrogen/dry
    ice. Improper handling or use could result in severe
    personal InJury or death .

    IA
    .-.
    CAUTION I Do not drive the valve
    seat insert into the cylin-
    der head at room temperature. The valve seat
    inserts are a shrink fit In the valve seat counterbore
    and must be cooled with liquid nitrogen/dry ice )
    before Installation. Disregarding this information
    could result in product damage.

    3. Chill each valve seat insert prior to installation.


    Chilling decreases the diameter of the insert to ensure
    an easy fit. Submerse the valve seat insert in liquid
    nitrogen or a solution of dry ice and alcohol.

    NOTE: Liquid nitrogen is recommended for shrink


    fitting valve seat inserts and is the method used in the
    factory for seat installation. The low temperatures
    provided by liquid nitrogen guarantee maximum shrink-
    age, thereby reducing the risk of damage to the
    counterbore or improper seating of the valve seat insert. Figure 3.00-30. Valve Seat Insert

    4. Allow the insert to remain submersed until the


    6. Wait for several minutes for the valve seat insert to
    solution stops boiling. At this point, the temperature of
    warm to the temperature of the cylinder head. As the
    the insert will not drop any further.
    insert warms, it expands to form a metal-to-metal
    contact with the counterbore. Use a 0.001 inch (0.0254
    A WARNING mm) feeler gauge to verify that the insert is properly set
    in the bottom ofthe counterbore. Verify that the insert frts
    Always wear safety gloves and safety glasses when tightly around its circumference.
    handling liquid nitrogen. Comply with the liquid
    nitrogen/dry Ice manufacturer's recommendations
    for proper use and handling of liquid nitrogen/dry
    ice. Improper handling or use could result in severe )
    personal injury or death.

    3.00 - 20 FORM 6248 First Ed~ion


    CYLINDER HEAD DISASSEMBLY

    VALVE SEAT GRINDING


    NOTE: Use of the Hall-Toledo EDP Valve Seat Grinder
    (PIN. 494277) is the only factory approved service
    method of grinding valve seats (an eccentric grinder,
    diamond dresser, stand and necessary wrenches are
    ~TIGHTEN PILOT
    MANDREL
    included).

    A CAUTION I~aChining
    I~.a=~=..:..;:;...:....:...;:;..:~.
    L.
    accuracy de-
    pends upon the fit of the
    pilot mandrel. The pilot mandrel should fit snugly In
    the guide and in the hub of the grinder stone. Be
    sure that the upper end of the mandrel does not
    wobble during the grinding procedure. Upper end
    movement will produce a seat that is not ground
    true, causing damage to equipment.

    NOTE: The pilot mandrel allows each valve seat to be •


    ground concentric with the valve guide. The Waukesha
    supplied pilot mandrels (PIN 494344) are made only for ' " REMOVE HANDLE
    use with the Hall- Toledo EDP Valve Seat Grinder.

    1. Install the handle on the pilot mandrel. Insert the


    mandrel (0.564 inch) into the intake or exhaust valve
    guide. Turn the round knob until the mandrel is snug
    (see Figure 3.00-31).

    2. Remove the handle from the pilot mandrel (see


    Figure 3.00-31). Slide on a dial indicator gauge gra-
    duated in thousandths of an inch (PIN 494278).

    3. Measure the valve seat concentrici1y to determine INSTALL DIAL


    the amount of valve seat grinding required (see /INDICATOR GAUGE
    Figure 3.00-31).

    I;A. . CAUTION Iseats


    Do not grind the valve
    ~
    too long and do not
    apply too much pressure to the grinding stone.
    Disregarding this information could resuH in prod-
    uctdamage.

    I~
    A CAUTION IAlways dress the stone
    before grinding, failure
    to dress the stone could cause damage to equip- Figure 3.00-31. Measure Valve Seat Concentricity
    ment. The stone should be dressed to the proper
    angle after each seat is ground.
    5. Install a finer dressed stone or fine dress the stone
    4. Refer to Table 3.00-5 to select the proper degree for a final cut. A highly polished seat with a total indicator
    angle grinding stone, Rough grind the valve seat insert runout less than 0.001 inch (0.0254 mm) is deSirable.
    to obtain a total indicator runout of 0.002 inch
    6. Repeat the grinding procedure as necessary.
    (0.0508 mm) maximum.
    Table 3.00-5. Valve See! Insert Grinding Stones
    TYPE STONE ANGLE WEDTOOLP/N
    Seat Angle 20 Degrees 494014
    Seat Angle 30 Degrees
    494305
    (current wide bridge heeds)

    ..
    FORM 6248 First Edition 3.00 - 21
    CYLINDER HEAD DISASSEMBLY

    2. Install a light lifting spring over the valve stem, apply


    A WARNING a small amount of Iubricating oil into the valve guide
    Compressed air can pierce the skin and cause bore and slide the valve into the cylinder head. The
    severe personal injury or death. Never use your spring should just barely hold the valve off its seat.
    hand to check for leaks or to determine air flow rates. 3. Press down until the valve is seated. Rotate the
    Wear safety glasses to shield your eyes from flying valve a quarter turn, first in one direction, then in the
    dirt and debris. other. Do this three or four times (see Figure 3.00-32).

    A WARNING
    4. Release the pressure on the valve stem, so that the
    spring lifts the valve straight off its seat. Turn the valve
    Always use approved cleaning solvents in a well about 10 to 15 degrees clockwise and repeat the
    ventilated area. Contact with skin could result in grinding procedure. Continue this operation until the
    severe personal injury or death. valve has been rotated a complete 360 degrees and all
    grinding compound has been rubbed off the valve seat.
    7. Use compressed air to blow away all loose dust.
    Wipe down the valve seat and seat insert surfaces with
    a non-volatile cleaning solution or solvent and dry with a IA CAUTION I Insure that all lapping
    ==-.;;..;;;....;;..;;;....;....;;...;:;..;~_
    L. compound Is completely
    clean cloth. removed from tihe valve and valve seat. Failure to
    completely clean all lapping compound from tihe valve
    VALVE SEAT LAPPING and valve seat could cause damage to equipment.
    1. Apply a good fine grinding compound sparingly
    around the entire valve face (see Figure 3.00-32). 5. Remove the valve and spring from the cylinder head
    and thoroughly clean the valve and valve seat insert of
    any lapping compound.

    6. Carefully inspect the mating surfaces. A proper1y


    lapped valve will show a gray, frosly seating surface )
    located either near the center of the valve face for 30'
    valves, or near the valve head end for 20' valves. If
    proper1y lapped, the lapped surface width will equal the
    valve seat width values listed in Table 3.00-6.

    7. Repeat the lapping procedure if necessary. Regrind


    the valve seat insert if the results are not acceptable.

    8. Apply Prussian blue dye sparingly around the entire


    Figure 3.00-32. Valve Lapping circumference of the valve seat surface.

    NOTE: Lap the va/ves in the locations in which they will 9. Install the valve in the cylinder head. Gently push
    be installed. The va/ve type, whether (INT)ake or down on the valve stem until the valve face just contacts
    (EXH)aust, is stamped on the head at the va/ve. the valve seat. Do not rotate or turn the valve. Carefully
    pull the valve straight out of the head.
    Table 3 DO-6. Valve Seat Width And Face Angle
    INTAKE AND EXHAUST
    MEASUREMENT INCHES METRIC (mm)
    Valve seat width
    GlGSI engines 30' 0.265 6.731
    (Intake ,.,d Exhaust)
    GLengines
    (Intake) 30' 0.265 6.731
    (Exhaust) 20' 0.281 7.137
    Valve face angle
    GIGSI engines (Intake and Exhaust)
    30 0 ±15' 30° :1::15'

    GLengines
    )
    (Intake) 30° ±15' 30 0 :!:15'
    (Exhaust) 20° ±15' 20° :1::15'

    3.00 - 22 FORM 6248 First Edition


    CYLINDER HEAD DISASSEMBLY

    10. Inspect the valve face for Prussian blue transfer INTAKE AND EXHAUST VALVE INSTALLATION
    (see Figure 3.00-33). The dye transfers from the valve
    seat to the valve face wherever a good face-to-seat 1. Apply a small amount of lubricating oil into the valve
    contact exists. A definite Prussian blue transfer around guide bores and install the valves in the cylinder head, in
    the entire valve face circumference is desirable. the locations from which they were removed. To
    distribute the lubricating oil around the valve stem, hand
    spin the valves as they are installed. Work the valves
    VALVE back and forth to verify that they slide smoothly and seat
    properly.

    A WARNING
    Always use approved cleaning solvents in a well
    ventilated area. Avoid contact with skin. Failure to
    WIDTH OF
    PRUSSIAN BLUE follow proper procedures could cause severe per-
    TRANSFER sonal injury or death.
    Figure 3.00-33. Good Valve And Seat Contact
    2. Clean the inner and outer valve springs, washers,
    retainers and tapered keepers in a non-volatile cleaning
    11. Repeat the lapping procedure if necessary. If the solution or solvent. Although replacement of these parts
    results are not acceptable, regrind the valve seat insert is uncommon, they should be inspected for damage, rust
    before relapping. pits or excessive wear. Replace as necessary (see
    Table 3.00-7).
    Table 3 00-7 Valve Springs

    I~
    A
    ~ )
    )

    t )

    L~
    )
    )
    )

    MEASUREMENT INCHES I METRIC (mm)


    (A) Intake and Exhaust Valve Spring Free Length:
    204035 and 204035A (Inner) 3-25/16.1/16 96mm ±1.6 mm
    204135 (Outer) 4·9/32 .1/16 108.7 mm ±1.6 mm
    204135A (Outer) 4·5/32 .1/16 105.56 mm .1.52 mm
    Intake Valve Closed Spring Length:
    204035A (Inner) 3.0 @ 66.4 Ibs.•3 Ibs. 76.2 [email protected]
    204135A (Outer) 3-27/64 @ 120 Ibs.•5 Ibs. 66.91 mm @ 54.43 kg .2.27 kg
    Exhaust Valve Closed Spring Length:
    204035 (Inner) 3 @ 56.7 Ibs.•2.5 Ibs. 76.2 mm @ 25.72 kg .1.36 kg
    204135 (Outer) 3-27/64@ 111 Ibs.•5Ibs. 66.9 mm @ 50.35 kg .2.27 kg
    Intake Valve Open Spring Length:
    204035A (Inner) 2-19/64 @ 126.2 Ibs.•5 Ibs. 58.34 mm @ 57.24 kg .2.27 kg
    204135A (Outer) 2-23/32 @ 235 Ibs.•10 Ibs. 69.06 mm @ 106.60 kg 04.54 kg
    ) Exhaust Valve Open Spring Length:
    204035 (Inner) 2-17/64@ 110 Ibs .•5Ibs. 57.5 mm @ 49.8 kg .2.27 kg
    204135 (Outer) 2-11/16@205Ibs.•10 Ibs. 66.3 mm @ 92.99 kg 04.54 kg

    FORM 6248 First Edition 3.00-23


    CYLINDER HEAD DISASSEMBLY

    3. Position the intake and exhaust valve springs on a


    level surface and use a straight edge to check for proper )
    squareness and height (see Figure 3.00-34). Too much
    height corresponds to a reduction in spring pressure
    which results in sluggish valve action. Load test the
    springs in a valve spring tester.

    Figure 3.011-34. Checking Valve Spring Height


    Figure 3.00-35. Install Valve Stem Seal
    IA
    ..
    CAUTION I To avoid cracking the
    white Teflon® valve stem 5. Position the valve stem seal installation tool
    seals, always use the proper valve stem seal (PIN 494335) over the valve stem and seal. The tool )
    installation tool (Tool PIN 494335). Use of an bore allows insertion of the valve stem, while the
    ordinary socket may damage the seals, resulting In counterbore fits over the valve stem seal.
    leakage around the valve stem and excessive oil
    consumption. 6. With the palm of your hand, lightly strike the end of
    the tool to seat the seal evenly on the valve guide.
    4. Position the new valve stem seal on top of each valve
    guide with the outer band facing downward (see 7. Install two washers over the valve guide shoulders
    Figure 3.00-35). The outer band holds the seal in place until they come to rest on the cylinder head casting. The
    on the guide, while the spring maintains even tension on washers are needed to retain proper tension on the
    the valve stem. inner spring (see Figure 3.00-36).

    3.00 - 24 FORM 6248 First Edition


    CYLINDER HEAD DISASSEMBLY

    NOTE: Do not intennix the intake and exhaust valve


    till, springs. Since the orange dye may eventually wear off, the
    ~ TAPERED intake valve springs can be distinguished from the exhaust
    ~, KEEPERS
    valve springs by the direction in which they wind from the

    I
    SPRING
    RETAINER top down (see Table 3.00-8 Valve Spring Reference).
    Table 3 00-8 Valve Spring Reference
    'OUTER VALVE DIRECTION OF HEUX
    SPRING VALVE COLOR
    (TOP TO BOTTOM)

    I
    . - 'INNER VALVE
    __ SPRING
    INTAKE
    Inner
    Outer
    Orange
    Orange
    Right

    <=::> WASHERS EXHAUST


    Left

    ,) Inner Black Left


    ( Outer Black Right
    I
    9. Install the spring retainer on top of the inner and
    outer valve springs. The smaller diameter flange fits
    inside the inner valve spring. The larger diameter flange
    separates the inner and outer springs.

    10. Install the special boR supplied with the Valve Spring
    Compressor (PIN 494255) (see Figure 3.00-37), in the
    bolt holes shown (see Figure 3.00-38).

    Figure 3.00-37. Valve Spring Compressor

    INSTALL WATER OUTLET


    SPECIAL BOLT ELBOW CONNECTION

    ~~o
    EXHAUST
    INTAKE
    /VALVE
    VALVE~

    O~~''-
    o
    Figure 3.00-36. Cylinder Head Assembly -
    Exploded View a
    A WARNING
    Use caution when removing or installing the valve
    springs. They are under tension and can eject from
    the cylinder head during the removal process. Use
    the special valve spring compressor tool for this
    procedure. Wear safety goggles. Failure to take
    edequate precautions can result in severe personal
    injury or death
    i
    8. Install the inner and outer valve springs on the intake
    Figure 3.00-38. Valve Compressor SpeCial Bolt
    and exhaust valve guides. The intake valve springs are
    Installation Locations
    dyed orange.

    FORM 6248 Firs! Edition 3.00 - 25


    CYLINDER HEAD DISASSEMBLY

    11. Position the grooved end of the Valve Spring springs. Fit the halves of the tapered keepers together
    Compressor below the head of the special bolt. on the valve stem recess. The taper of the keepers )
    should point downward. Release the compression on
    12. Position the open center of the Valve Spring the valve springs to center the tapered keepers in the
    Compressor around the valve stem end and on the spring retainer bore (see Figure 3.00-39).
    spring retainer. Press down to compress the valve

    RETAINER

    VALVE STEM SEAL


    OUTER VALVE SPI~IN'G~
    VALVE SPRING

    CVUNDER HEAD

    WATER PASSAGES

    )
    VALVE GUIDE

    EXHAUST SEAT INSERT

    Figure 3.00-39. Assembled Cylinder Head - Cross Sectional View

    3.00 - 26 FORM 6248 Firsl Edition


    SECTION 3.05 - CRANKCASE DISASSEMBLY

    CRANKCASE INSPECTION
    NOTE: The crankshaft should already be removed
    A WARNING
    from the crankcase. Refer to Chapter 2, Engine The crankcase weighs 4965 Ibs. (2252 kg) with its
    main bearing and camshaft caps attached, but
    Teardown for the removal procedure.
    completely stripped of all other components. If ANY
    The crankcase is gray cast iron. Its partitions and webs components are still attached, the crankcase will be
    hold the bearing saddles and contain drillways, through heavier by the amount of the components weight.
    which lube oil is supplied to the bearings. The crankcase Make sure that the crankcase Is properly supported
    is open to the bottom once the oil pan is removed, so and that properly rated lifting equipment and
    fitting the crankshaft is easier. Each main bearing cap is rigging are used. Failure to take adequate precau-
    fitted to the crankcase with four vertical studs. Two tions can result in severe personal injury or death.
    cross-tie bolts are fitted horizontally, one from each
    side, to provide positive positioning between the CRANKCASE CLEANING AND INSPECTION
    crankcase and each bearing cap. This gives the
    necessary stiffening to the lower part of the crankcase. Crankcase Cleaning
    Routine access to the crankcase is through inspection Crankcases are most effectively cleaned by the hot tank
    openings located in both sides of the oil pan. The method. Alternative methods may be used. Lime and
    camshaft and bearings are located in the "Vee" between scale deposits found, must be removed. A caustic
    the cylinder banks. the bottom of the crankcase is is solution will attack and break the lime down into
    enclosed by the oil pan. solution. Steam cleaning will not be effective on lime
    deposits, although it will break down oil deposits.
    A WARNING Precision machined surfaces must be cleaned to allow
    for accurate measuring. All cylinder sleeve bores must
    Be sure you have read and under stood the safety be cleaned down to bare metal for proper cylinder
    and warning Information in Section 1.01 - Safety, sleeve sealing.
    and Section 1.02 - Rigging and Lifting Engines,
    before proceeding. Failure to take adequate precau- Crankcase inspection
    ) tions when servicing this product can result In The crankcase should be thoroughly checked for
    severe personal Injury or death. cracks. Special attention should be paid to the area
    between the cylinders. Cracked crankcases should not
    A WARNING be reused. Cracks may be detected with dye penetrant
    process. The lower sleeve seal area in the cylinder
    Never walk or stand under an engine or component block must be checked. See Table 3.05-1 for specifica-
    while it is suspended. Use properly rated lifting tions of the crankcase.
    equipment and approved lifting methods. Failure to
    take adequate precautions can result in severe
    personal injury or death.

    FORM 6248 First Ednion 3.05 - 1


    CRANKCASE DISASSEMBLY

    Table 3.05·1. Crankcase - Gas

    MEASUREMENT INCHES METRIC (mm)


    (A) Sleeve counterbore diameter L5108 and L5790 10.199-10.202 259.055 - 259.130
    Sleeve counterbore diameter L7042 10.825 - 10.628 269.875 - 269.951
    (8) Sleeve counter bore depth 8-1/2 inch bore 0.5600 - 0.5625 14.224 - 14.288
    Sleeve counter bore depth 9-3/8 inch bore 0.5595 - 0.5825 14.211 - 14.288
    (C) Crankcase upper bore: L5108 and L5790 9.750 - 9.780 247.650 - 247.904
    Crankcase upper bore: L7042 10.317 -10.322 262.051 - 282.178
    (0) Crankcase lower bore: L5106 and L5790 9.678 - 9.680 245.821 - 245.872
    Crankcase lower bore: L7042 10.246 - 10.246 280.246 - 260.299
    Crankcase main bearing journal bore 6.6630 - 6.6615 169.240 - 169.202
    Crankcase camshaft bearing bore 3.752 - 3.753 95.301 - 95.326

    3.06 - 2 FORM 8248 First Edition


    CRANKCASE DISASSEMBLY

    LOWER SLEEVE BORE AND SLEEVE Table 3 05-2 Cylinder Sleeve Gaskets
    PROJECTION INSPECTION PIN INCHES MILLIMETERS
    Cavitation and erosion can affect the lower sleeve area 1763750* 0.028 - 0.000 0.711 - 0.762
    (see Figure 3.05·1) and prevent the sleeve packing 176375E* 0.032 - 0.034 0.813 - 0.864
    rings from sealing. This area must be in good condition. 176375F* 0.038 - 0.042 0.965 - 1.067
    if grooves or pockmarks have affected the area, or
    NOTE: Used on 9.375 inch (238 mm) bore with PIN 205130H and
    fretting can be seen or felt, the bore must be machined 205130C cylinder sleeves.
    and fitted with a steel sleeve to restore it to standard

    IA CAUTION I
    size. This operation should only be performed by
    service shops that have experience in this type of repair. The PIN 205130L cylin-
    der sleeve does NOT use
    ...=:=-....;;.._....;;......;...;;....;;....;...;;..J.
    a cylinder sleeve gasket. Disregarding this informa-
    tion could result In product damage and/or person·
    al injury.

    IA CAUTION I Refer to Fits an~ Clear·


    1...==....;::~=:.....:..:...:::;..;~.
    ances to determine cor·
    rect sleeve projection. It is necessary to maintain
    proper sleeve projection after the gaskets and
    sleeves are Installed. The sleeve projection dimen·
    sion will be reduced by 0.001 inch (0.0254 mm) due
    to gasket (seal ring) crush when the cylinder head Is
    torqued, so you must reduce the measured projec-
    tion by this amount. Disregarding this information
    could resuH in product damage and/or personal injury.
    Figure 3.05·1. Lower Sleeve Bore
    CRANKCASE LOWER BORE RESTORATION

    CAUTION IDo not machine material


    I =:......;=...:..=-.:...:~..:...::..J.
    'A
    The crankcase lower bore cylinder sleeve sealing areas
    are subject to deterioration if cooling system mainte·
    1..
    • .:.. from the lower seal area
    nance is neglected. Deterioration, such as grooves,
    to clean up the surface. While this may provide a
    pockmarks or fretting, if not detected in the earliest
    good surface for sleeve sealing, there will not be a
    possible stages, could become severe enough to
    correct fit to hold the sleeve In place.
    prevent proper sealing. Evidence of sealing area
    Sleeve side play cannot be tolerated. Any lateral deterioration includes engine coolant in the oil due to
    motion, no matter how slight, will cause the sleeve to leakage past the seal rings.
    crack and separate from the top flange. (The top flange If deterioration should occur, the crankcase lower bore
    will remain in place due to the cylinder head/flange sealing areas (see Figure 3.05·2) must be restored by
    mounting. being machined oversize and fitted with restoration
    The sleeve counter bore depth must be checked (see sleeves.
    Chapter 1 - Table 1.20·2 and Table 1.20·5, and Restoration Sleeve Machining
    Table 3.05·1). The correct depth will provide proper
    sleeve projection and gasket crush. If this surface is in The sleeve should be machined to a depth of 1.75 inch
    poor condition it will be necessary to machine the (44.45 mm), which is the same as the depth of the
    counterbore deeper and install an iron ring. crankcase lower bore. A 15° chamfer must be machined
    on the inner diameter at one edge of the sleeve.
    The GL 9.375 inch (238 mm) bore with PIN 205130H
    and 205130C cylinder sleeves are assembled with a The restoration sleeve should be machined to the same
    cylinder sleeve gasket (see Table 3.05·2). Cylinder inner diameter as the original crankcase lower bore
    sleeve gaskets are available in two oversize thick· diameter. The outer diameter should be machined
    nesses which may be used in the place of a standard 0.250 inch (6.340 mm) larger than the inner diameter to
    cylinder sleeve gasket, if the sleeve counterbore needs provide a 0.125 inch (3.170 mm) sleeve wall thickness.
    to be machined deeper.

    FORM 6248 First Edition 3.05 - 3


    CRANKCASE DISASSEMBLY

    15...LJ0~ /
    RESTORATION
    SLEEVE

    1.75' I~=======ll
    1.7
    T
    i==: ==J
    RESTORAnONSLEEViE
    UPPER
    BORE

    A. SLEEVE INNER DIAMETER


    (SAME AS CRANKCASE
    ORIGINAL
    LOWER BORE DIAMETER)

    B. SLEEVE OUTER DIAMETER

    A. ORIGINAL LOWER BORE DIAMETER


    (SAME AS RESTORATION SLEEVE
    INNER DIAMETER)
    C. MACHINED LOWER BORE DIAMETER
    )
    Figure 3.05-2. Lower Bore And Restoration Sleeve Dimensions

    Typical. readily available. materials used to make The crankcase lower bore must be machined concen-
    restoration sleeves are mild seamless steel tubing, tric with the upper bore within 0.003 inch (0.08 mm). A
    Grade 1021, DaM (drawn over mandrel) seamless vertical boring machine large enough to accommodate
    steel tubing and cast iron. Old cylinder sleeves. if the VHP series crankcases is required.
    appropriate size is available, may also be used.
    The crankcase lower bore should be machined to
    provide an interference fit for the restoration sleeve. I~ CAUTION I
    -A Never machine the
    crankcase lower bore be-
    The correct interference fit can be determined by yond the determined machining dimension, just to
    multiplying the outer diameter of the restoration sleeve clean up the bore. Machining beyond the estab-
    by 0.001 inch (0.02 mm). Table 3.05-3 gives examples lished machining dimension will result in a loose
    for calculating restoration sleeve and crankcase lower restoration sleeve fit. Disregarding this information
    bore machining dimensions. could result in product damage and/or personal
    injury.
    Table 3 05-3 Restoration Sleeve And Crankcase Lower Bore Machining Dimensions
    MEASUREMENT L5108. L5790G/GSI/GL L7042G/GSI/GL
    Restoration Sleeve 10
    (Same as original lower bore diameter) 9.678 - 9.680" (245.82 - 245.87 mm) 10.246 - 10.248" (260.25 - 260.30 mm)
    Step 1
    + Restoration sleeve wall thickness + 0.250" (6.35 mm) + 0.250" (6.35 mm)
    (0.125" (3.17 mm) x 2)
    Restoration sleeve 00 9.928 - 9.930" (252.17 - 252.22 mm) 10.496 -10.499" (266.60 - 266.65 mm)
    Step 2 - Interference fit • - 0.010" (0.25 mm)
    (0.001" (0.025mm) x sleeve 00) - 0.010" (0.25 mm)
    )
    Step 3 Lower bore machined dimension 9.918 - 9.920" (251.92 - 251.97 mm) 10.499 - 10.488" (266.35 - 266.40 mm)
    NOTE: • RestoratIon sleeve dIameter OD x 0.001 inch (0.025 mm) to three (3) _imal plaoes.

    3.05 - 4 FORM 6248 First Edilion


    CRANKCASE DISASSEMBLY

    Restoration Sleeve Installation


    NOTE: The machined surfaces of the restoration
    A WARNING
    sleeve and the machined surface of the crankcase Compressed air can pierce the skin and cause
    lower bore must be clean and dry before installation of severe personal injury or death. Never use your
    the restoration sleeve. hand to check for leaks or to determine air flow
    rates. Wear safety glasses to shield your eyes from
    1. The restoration sleeve must be installed with the flying dirt and debris.
    chamfered end facing upward in the crankcase (see
    Figure 3.05-2). The chamler will prevent damage to the 2. Air dry bearing caps and oil passages.
    cylinder sleeve packing rings when the cylinder sleeves
    are lowered into position. NOTE: Main Bearing caps must be secured in their
    proper positions and torqued in their proper sequence
    before making these checks.
    A WARNING
    • Out-ol-round: A maximum measurement 01 0.001
    Always wear safety gloves and safety glasses when inch (0.0254 mm) is allowed il the horizontal dimen-
    handling liquid nitrogen. Comply with the liquid sion exceeds the vertical dimension. The bore should
    nitrogen/dry Ice manufacturer's recommendations
    be measured at lour locations (see Figure 3.05-3).
    for proper use and handling of liquid nitrogen/dry
    ice. Improper handling or use could result in severe
    personal injury or death.

    2. Chill the restoration sleeve in liquid nitrogen or a dry


    ice and alcohol solution to reduce its size.

    NOTE: Locktite ~ may be applied to the mating


    surfaces of the restoration sleeve and the crankcase
    lower bore. This will help prevent leakage behind the
    .i
    sleeve and eliminate possible callbacks. However, if the
    mating surfaces have been properly machined and
    cleaned, and the restoration sleeve is properly installed,
    there is little chance of leakage.

    3. Slip the restoration sleeve into position on the


    machined lower bore and hold it in position until it warms
    enough to expand and secure itself in the crankcase.

    NOTE: If at some future time the sealing surface of the


    restoration sleeve bore deteriorates, a new restoration ~~
    OIL PUMP IDLER
    sleeve may be installed without the need of further GEAR SPINDLE BORE
    crankcase machining. The deteriorated restoration
    BEARING TEMPERATURE
    sleeve must be cut for removal. Replacing the sleeve SENSOR BORE
    may be accomplished time after time without any (SENSOR OPTIONAL)
    adverse affects to the crankcase.
    Figure 3.05-3. Main Bearing Bores
    MAIN BEARING BORE CLEANING AND
    INSPECTION • Taper: Maximum taper in any bearing bore is
    The main bearing bore must be checked lor wear and/or 0.0005 inch (0.0127 mm).
    distortion, including out-ol-round, taper, surface condi-
    tion, and bore size. • Surface condition: Main bearing borelinish should be
    80 micro-inches. Bearing cap parting surfaces must
    1. Thoroughly clean all oil passages 01 sludge. be flat, free from burrs and nicks, and must match
    evenly when torqued in position.

    • Bore size: Bore diameter should be 6.6615 - 6.6630


    inches (169.202 - 169.240 mm) measured at lour
    locations.

    FORM 6248 First Ed~ion 3.05 - 5


    CRANKCASE DISASSEMBLY

    Normally main bearing bores are found in alignment. • Torque all right side bolts (six) to 250 ft-Ib (339 N'm)
    Misalignment could occur if the engine had not been starting from the front of the engine. )
    properly installed.
    • Torque nuts one through four to 275 ft-Ib (373 N'm) to
    It bearing bores are not worn or damaged, or it all
    two steps: first 175 ft-Ib (237 N'm), and then 275 ft-Ib
    damaged caps(s) have been replaced, the bore may be (373 N·m).
    considered properly aligned if a standard size crank-
    shaft can be rotated freely with the main bearings
    installed and lubricated, and with the bearing caps LEFT SIDE OF ENGINE
    properly torqued. Replacement bearing caps are only 5
    furnished semi-finished. They must be torqued in
    position and align-bored to size.

    MAIN BEARING RUNNING CLEARANCE

    A CAUTION I
    I. .=.. The use of Plastigage®ls
    =:.......;~--';......_.;;;.....---'.
    an acceptable method of
    determining bearing running clearance, if used FRONT OF ENGINE
    properly. The Improper use of Plastigage® can
    result in false measurements that may lead to
    bearing and/or crankshaft failure. 4@@ 2
    n
    CAUTION I
    I...=.A=:.......;~--':......:....:....;;;.....~.
    Do not mill: or cross mate
    . main bearing caps. The
    bottom of each cap is stamped with a number to
    identify its location. Disregarding this information
    could result in product damage and/or personal 6
    injury.
    Figure 3.05-4. Main Bearing Cap TlghtenlngfTorquing
    1. Position the engine with the engine rollover stand so Pattern - As Viewed From Underside Of Crankcase
    that the engine is upside down.
    6. Using an inside micrometer, measure the inside
    2. Starting at the front of the engine and moving diameter of each main bearing bore at several locations
    towards the rear, install main bearing caps 1 through 7. (see Figure 3.05-3). Write down both the minimum and
    Position each cap so that the pin hole in the foot is maximum diameters.
    aligned with the dowel on the deck of the main bearing
    saddle. Carefully slide the cap onto the four studs until it
    comes to rest on the bearing saddle. Use a rubber
    mallet to seat the cap, if necessary.

    3. Lubricate the main bearing cap studs and nuts with


    clean engine oil.

    4. Install the washers and nuts on the studs of the main


    bearing caps.

    5. Torque the bearing caps in the proper sequence


    listed below (see Figure 3.05-4):

    • Torque the bearing cap nuts one through four On that


    order) to 75 ft-Ib (102 N·m). If installing replacement
    caps that will be align bored, torque to only 30 ft-Ib
    (40 N·m). When installing more than one cap, torque
    nuts one through tour to 75 ft-Ib (1 02 N·m) on all caps
    before torquing side bolts.

    • Torque all left side bolts (five) to 250 ft-Ib (339 N'm)
    starting from the front of the engine.

    3.05 - 6 FORM 6248 First Ed~ion


    CRANKCASE DISASSEMBLY

    Table 3.05-4. Crankshaft Wear Limits

    MEASUREMENT INCHES METRIC (mm)


    Crankshaft end play (end play adjustmen1-0.003 (0.076 mm) shims) 0.005 - 0.016 0.127 - 0.406
    Thrust ring thickness (standard) 0.215 - 0.217 5.461 - 5.512
    Connecting red bearing running clearance*(diametral clearance') 0.0042 - 0.0081 0..1.069 - 0.2057
    (A) Ccnnecting rod bearing journal diameter 6.2465 - 6.2500 158;712 - 158.750
    (8) Main bearing journal diameter 6.2465 - 6.250 158.712 - 158.750
    Main bearing running clearance* (diametraJ clearance*) 0.0045 - 0.0089 0.1143 - 0.2280
    (C) Connecting rod end play 0.029 - 0.041 0.7366 -1.041
    NOTE: *Main and connecting rod bearing running clearance* (diametral clearance*) = calculated bearing 1.0. minus joumal 00.
    7. Use an outside micrometer to measure the outside
    diameter of the associated crank pin at several locations
    (see Table 3.05-4) Write down both the minimum and
    maximum diameters.

    8. Insert the min./max. diameters of the bearing bore


    and crank journal into the following formulas (see
    Figure 3.05-5). The results will determine the required
    thickness of the bearing shell.

    .!

    FORM 6248 First Edition 3.05 -7


    CRANKCASE DISASSEMBLY

    Determining Bearing Thickness


    See Figure 3.05-5 to determine bearing thickness.
    )

    (Min. Bore 10) - (Max. journal 00) - (Max. running/oil clearance)


    Min. bearing thickness = 2

    (Max. Bore 10) - (Min. journal 00) - (Min. running/oil clearance)


    Max. bearing thickness
    2

    Figure 3.05-5. Determine Bearing Thickness

    Table 3.05-5. Main Bearings

    DESCRIPTION WALL THICKNESS AT CRANKSHAFT DIAMETER


    PIN CROWN
    Front, Center, Rear
    200025U Standard 0.2035 - 0.2028 6.250/6.249
    200025U2 0.020 Undersize 0.2135 - 0.2128 6.230/6.229
    Intermediate
    2OO022U Standard 0.2035 - 0.2028 6.250/6.249
    2OO022U2 0.020 Undersize 0.2135 - 0.2128 6.230/6.229

    9. Using a micrometer with a ball adapter (for measur- 10. Remove the cross tie bolts and main bearing cap
    ing spherical surfaces), check the thickness of each stud nuts. Remove the main bearing caps.
    bearing shell to be sure that it is suitable for use (see
    Table 3.05-5 and Figure 3.05-6).

    WAll. AT CROWN (SEE TABLE)

    I
    - - - - - ----
    I

    WALL THICKNESS TO BE 0.0000 - O.llOO7 LESS


    THAN MEASURED WALL AT CROWN (BOTH SIDES)

    Figure 3.05-6. Select Main Bearing Shells For Proper


    Running Clearance

    3.05 - 8 FORM 6248 First Edition


    CRANKCASE DISASSEMBLY

    CAMSHAFT BEARING BORE INSPECTION CRANKSHAFT


    The camshaft bearing bore must be checked for wear CRANKSHAFT CLEANING AND INSPECTION
    and/or distortion.
    Crankshaft Cleaning
    NOTE: Camshaft bearing caps must be secured in
    their proper positions and torqued before making these
    checks. IA CAUTION I The crankshaft counter-
    =:....-"---'''-_"''----'. weights should never be
    L.."
    . ' ..

    • Surface condition: Camshaft bearing parting sur- removed from the crankshaft unless grinding is
    faces must be flat, free from burrs and nicks, and necessary. The crankshaft is balanced at the
    match evenly when torqued in position. factory with the counterweights attached. The
    counterweight mounting holes are oversize, and It
    • Bore size: Camshaft bore diameter should be is impossible to attach the weights back In the
    3.752 - 3.753 inches (95.301 - 95.326 mm) original positions. Disregarding this information
    measured at four locations (see Figure 3.05-7). could result In product damage

    Once the crankshaft is removed from the engine it


    .should be thoroughly cleaned. All VHP crankshafts
    have internal oil passages. Drilling of these passages
    results in six openings in the crankshaft cheeks.
    These openings are plugged with set screws to prevent
    loss of engine oil pressure. Prior to hot tank cleaning,
    these set screws should be removed from the crankshaft.

    A CAUTION I
    I==--.;:;..;;-"-;;....;....;;....;:.....;~
    .
    '-'. . .
    The set Screws must be
    .. removed
    from the crank-
    shaft for proper cleaning of the oil passages. If the set
    screws are not removed, they will make flushing of the
    oil passages diflicuh and will prevent inspection of the
    oil passages for debris. Cleaning solution can easily
    be trapped in these passages and bearing faOure can
    Figure 3.05-7. Camshaft Bearing Bore resuh upon engine startup. h will be necessary to
    insert a high pressure air line into the passageways to
    The process of checking longitudinal alignment of the
    camshaft bores must be made with all bearing caps in blow out cleaning solution. You should be certain all
    cleaning solution is thoroughly removed from the oil
    place and properly torqued.
    passageways. THE SET SCREWS MUST BE
    Normally the camshaft bore will be found in alignment. INSTALLED PRIOR TO INSTALLING THE CRANK-
    If bearing bores are not worn or damaged, or if all SHAFT IN THE ENGINE. Failure to follow proper
    damaged camshaft bearing caps have been replaced, procedures may cause damage to equipment
    the bore may be considered properly aligned if a
    standard size camshaft can be rotated freely with
    camshaft bearing caps properly torqued.
    Replacement camshaft bearing caps are only supplied
    semi-finished. they must be torqued in position and
    align-bored to size.

    FORM 6248 First Edijion 3.05 - 9


    CRANKCASE DISASSEMBLY

    1. Remove the set screws from the crankshaft cheeks NOTE: Wedge a pointed punch between the set
    (see Figure 3.05-8). screws and crankshaft threads and sharply strike the )
    punch a single blow to securely stake the set screws in
    place. This operation distorts the threads to lock the set
    screws in place.

    6. Carefully examine the entire crankshaft to be certain


    all cheek openings are plugged with set screws.

    7. In addition, check the area for metal chips resulting


    from the staking operation.

    Figure 3.05-8. Crankshaft Set Screws


    2. Flush the cleaning solution through all of the drilled
    oil passages. Run a stiff wire brush through the oil
    passages to loosen deposits.

    A WARNING )
    Compressed air can pierce the skin and cause
    severe personal injury. Never use your hand to
    check for leaks or to determine air flow rates. Wear
    safety glasses to shield your eyes from flying dirt
    and debris.

    3. Blow the crankshaft dry after it is removed from the


    hot tank, paying special attention to the drilled oil
    passages. insert a stiff, clean wire through all of the
    passages to be certain they are clear of any obstruction.

    4. Lightly coat the crankshaft with a thin coat of oil to


    prevent surface oxidation.

    A CAUTION I
    I=...
    L.
    THE CRANKSHAFT SET
    =.--::._..::..----'-.;;;,..,:....:..J. SCREWS MUST BE
    INSTALLED PRIOR TO INSTALLING THE CRANK-
    SHAFT IN THE ENGINE. A crankshaft installed and
    operated with one or more missing set screws will
    cause bearing seizure and piston/sleeve damage
    due to low oil pressure.

    5. Coat the threads of the set screw plugs with Loctite®


    271. Install set screw plugs approximately three threads
    below the cheek surface. Peen or stake these set
    )
    screws into place as described in the Note below.

    3.05 - 10 FORM 6248 First Edition


    CRANKCASE DISASSEMBLY

    Figure 3.05-9. 12 Cylinder Crankshaft

    Crankshaft Inspection CRANKSHAFT JOURNAL REPAIR


    The crankshaft should be Magnafluxed® before it is NOTE: Repairs to the crankshaft journals and pins
    remachined, since cracked crankshafts cannot be reused. should only be performed by a firm specializing in such
    However, surface cracks a tew thousandths of an inch worle Contact your distributor or Waukesha Engine
    deep in bearing surface areas can be sometimes ground Division's Service Operations Department for the latest
    oul. A shaft with surface cracks may be reused, but only IT information regarding this process.
    the shaft reveals no cracks alter the grinding operation.
    It is recommended to send crankshafts which require CRANKSHAFT POLISHING
    remachining to a crankshaft reconditioning shop. Re· A crankshaft journal or pin with a roughened surface,
    machined crankshaft main and rod journals should be but with the dimensions still within limits, should be
    finished to a 12 RMS finish. polished. However, do not polish by haM with emery or
    polishing paper. Polishing the crankshaft where critical
    1. Inspect the crank pin and main bearing fillets. these tolerances are involved, requires great skill and special-
    areas are most likely to develop cracks, IT cracks are ized equipment. Waukesha Engine Division recom-
    found (see Figure 3.0S-9). mends contacting a company which specializes in
    2. Inspect the crank pins for wear. It is this inspection polishing such highly machined surfaces.
    step that will usually determine how much material will CRANKSHAFT REPAIR
    be ground off.
    NOTE: Rebuilding the crankshaft (straightening, grind-
    3. Inspect the end play thrust surface. If it is in poor ing, polishing and rebalancing) must be done by a firm
    condition, the surface must be reground. specializing in such work. Diameter tolerance limits
    must not exceed those listed in Table 3.05-4.
    4. Inspect the thrust washer thrust surface. If the thrust
    surface is in poor condition the washer must be replaced. NOTE: All crankshafts must be shot -peen stress
    relieved around all of the joumals prior to grinding.
    NOTE: The crankshaft may have some deflection
    under its own weight, when supported between centers. There are two options when machining the crankshaft;
    Deflection usually follows a symmetrical pattern.
    • If it is desired to maintain the crankshaft to standard
    S. Inspect the crankshaft for straightness. The shaft size, the crankshaft may be chrome plated to bring it
    must be inspected for straightness before it can be to oversize and then machined to standard size. The
    ground. engine can then be rebuilt with standard size
    bearings. Chrome plating must be kept off of the fillet
    surfaces. Since the chrome used for crankshaft
    plating has a hardness of SO Rockwell. After the
    crankshaft is ground back to standard size, there
    should be approximately 0.060 inch (I.S24 mm) of
    plating thickness remaining.
    FORM 6248 First Edition 3.05 - 11
    CRANKCASE DISASSEMBLY

    • If the engine will be rebuilt with undersized bearings, CRANKSHAFT COUNTERWEIGHT RETORQUE
    the machine operator will have to machine to )
    crankshaft to accept 0.020 inch (0.508 mm) under-
    sized bearings.
    A WARNING
    Improperly torqued fasteners can cause the coun-
    CAUTION I
    I A.=:........:;;.;;......;:,,:::....:~=-.;:....:..J.
    If there is any doubt as to terweights to become loose resulting in catastroph-
    ic engine damage and possible severe personal
    .L .::
    .. the condition of a
    chromed shaft, or verification of a possible crack injury or death.
    under the chrome, the chrome plating must be
    ground off and the shaft reinspected. Disregarding To prevent possible loosening of the counterweights,
    this information could result in product damage verify the torque on the fasteners after serviCing or
    and/or personal injury. reconditioning of the crankshaft or prior to installation
    after each bottom end overhaul. Retorque the counter-
    When the shafts are rebalanced, they must be balanced weight capscrews 30 to 60 days after startup. Retorque
    with the counterweights attached. Any metal removed the counterweight capscrews once a year afterwards.
    to bring the shaft into balance should be removed from
    the counterweights, not from the crankshaft. 1. Retorque each counterweight capscrew to
    510 - 525 ft-Ib (691 - 712 N·m).
    Precision balancing of the crankshaft can increase
    bearing life from 25 to 100 percent. Static balancing NOTE: For 6 and 12 cylinder engines, fully counter-
    (shaft is placed on knife edges and will come to rest with weighted crankshafts are defined as those having
    the heaviest part of the shaft on the bottom) is not 12 counterweights (with a total of 24 fasteners, 2 per
    adequate to balance crankshafts from these high speed counterweight). Sixteen cylinder fully counterweighted
    engines. The shaft must be placed in a spin balancer to crankshafts have 8 counterweights (16 fasteners, 2 per
    locate kinetic and dynamic unbalance. This type of counterweight) .
    unbalance will create forces which will cause the shaft to
    rock and twist on an axis perpendicular to the axis of 2. If any fastener is found to be loose or not torqued to
    rotation. Rotating the shaft is the only method capable of
    identifying this type of balance problem.
    specification, remove the capscrew and hardened
    washer for inspection.
    )

    CAUTION IAft~r a crankshaft is re-


    I =:........:=....;:,,:::....:~:::...::....:..J.
    A.
    3. Carefully check the capscrew for nicks, cracks,
    galled or stretched threads and other damage. Inspect
    .L .::
    .. bUilt and before It Is
    the washer for nicks and abrasive wear. Replace the
    installed Into the engine, check and verify that all
    counterweight capscrew (P/N 199168A) and/or hard-
    tolerances are correct. Disregarding this informa-
    ened washer (P/N 209667) if any defects are found.
    tion could result in product damage and/or person-
    al injury. 4. If removed, place the counterweight on the crank-
    shaft flat with the part number facing the main bearing
    journal.

    5. Always verify that the counterweight and the crank-


    shaft cheek are stamped with the same location number
    (see Figure 3.05-10). Starting at the front of the
    crankshaft (crank gear side) and moving towards the
    rear (hub side), the counterweights and crankshaft
    cheeks are numbered 1 through 12 (6 and 12 cylinder
    engines).

    A WARNING
    Installing the counterweights In the wrong location
    will cause the crankshaft to be unbalanCed. Opera-
    tion with an unbalanced crankshaft will result In
    catastrophic engine damage and possible severe
    personal Injury or death. )

    6. Verify that the Side of the counterweight is flush with


    or slightly set back from the wall of the crankshaft on the

    3.05 - 12 FORM 6248 First Edijion


    CRANKCASE DISASSEMBLY

    main bearing side. The counterweight may overlap the 9. Install the screws in the counterweight capscrew
    wall slightly on the rod bearing side. bores. Snug the counterweight to the crankshaft.

    NOTE: Overlapping the wall on the main bearing side 10. Alternately torque the two counterweight caps-
    will interfere with installation of the main bearing cap. crews to 255 - 262 ft-Ib (346 - 355 N·m), which is 50% of
    the final torque value.
    7. Lubricate the first few threads of the counterweight
    capscrew, the underside of the bolt head and one side of 11. Torque the counterweight capscrews to 510 - 525ft-lb
    the hardened washer with a quality high viscosity oil, (691 - 712 N·m).
    such as Slide Rite® 220.

    8. Slide the hardened washer on the capscrew with the


    lubricated side facing the bolt head.

    COUNTERWEIGHT

    ""'-=--, J:>.
    ""'A'"

    ..."-/CAPSCREW

    HARDENED
    WASHER

    Figure 3.05-10.12 Cylinder Crankshaft

    FORM 6248 First Edition 3.05 - 13


    CRANKCASE DISASSEMBLY

    Table 3 05-6 Camshaft


    )
    A

    DID 1--:1 tJI8IuIllf[lftlaIHIJ].i~j2j. []JIdm{JIlH!~lll • •gIS-1i


    ..... t
    MEASUREMENT INCHES METRIC (mm)
    (A) Camshaft journal diameter 3,498 - 3.499 88,849 - 88,875
    Camshaft journal running clearance (theoretical) 0,003 - 0,0056 0,076 - 0,142
    Camshaft end play 0,005 - 0,008 0,127 - 0,203
    End Play Adjustment 0,002 shims
    Thrust ring thickness (standard) 0,154 - 0,156 3,911 - 3,962
    Cam lift (Intake) 0,6435 16,345
    Cam lift (Exhaust) 0,6735 17,107
    Rocker arm ratio 1,0926 to 1
    NOTE: Camshaft coupling must never be loose.
    CAMSHAFT Since camshafts rotate at one half engine speed and
    are liberally lubricated, camshaft bearing surfaces are
    CAMSHAFT CLEANING AND INSPECTION usually found in good condition. If after inspection (see
    Camshaft, Inspection) the camshaft or its journais are
    I A CAUTION I When a new camshaft is not in satisfactory condition, it will be necessary to
    .. to be Installed, all valve chrome plate the camshaft and grind it back to size,
    lifter assemblies must also be replaced. Wear )
    patterns on used lifters can result in early failure of
    a new camshaft.
    A
    I ..
    CAUTION I Keep all chrome from
    fillet areas. Camshaft
    journals should be polished after the camshaft is
    -A CAUTION Icams~aft ground back to standard size. Disregarding this
    I'!!!"~~::::''':'::::''::'':'=-:.:.J.
    L.
    bearing caps
    are alig ned bored and
    matched to the camshaft bearing saddles. Cam-
    information could result In product damage and/or
    personal Injury.
    shaft bearing caps are marked 1 thru 7, frontlo rear.
    After removing the camshaft from the engine, all
    Install them in their original position. Changing
    camshaft lobes and bearing journals should be thor-
    camshaft bearing cap pOSition will cause damage to
    oughly inspected. The camshaft may be varnished from
    equipment.
    engine oil, butthe bearing and lobe running surfaces will
    normally be clean enough to allow a close and accurate
    NOTE: If any of the camshaft drive gears exceed the
    inspection.
    gear lash tolerances, they MUST be replaced. with a
    new gear. See Chapter 1, Clearances, and Chapter 4, 1. Inspect the camshaft lobes and bearing journals to
    Camshaft Installation, for the correct tolerances and be certain they are in useable condition, Normally,
    installation procedures. under good lighting, a slight wear pattern will be viSible.
    Camshaft lobes will show a wear pattern as wide as the
    NOTE: The camshaft bearings should be replaced at valve lifter roller, These light wear patterns may be
    engine overhaul. polished by spinning in a lathe,
    Normally the camshaft needs no special maintenance,
    other than regular inspections of its bearings, journais,
    and cam lobes when other routine maintenance is
    performed (see Table 3.05-6).
    Camshafts are of two piece construction, permanently
    )
    joined to form a single shaft. Camshafts are supplied as
    an assembly only. Waukesha Engine Division will not
    furnish a single section of the camshaft The camshaft
    bearings should be replaced at engine overhaul.

    3.05 -14 FORM 6248 First Edition


    CRANKCASE DISASSEMBLY

    NOTE: The body of the valve lifter roller has a 7. Inspect the camshaft for cracks or fissures using a
    machined flat side with an oil passage hole drilled (see dye penetrant process. Since the camshaft is of two
    Figure 3.05·11). On 12 cylinder engines only. this flat piece construction, the Magnaflux© process cannot be
    side may be oriented in either direction, once the roller is used.
    seated in the groove.
    VALVE LIFTERS
    ROLLER TYPE LIFTERS

    A CAUTION I Valve Ii~ers should nev·


    I..
    ==.....;:==:;....;:....:...;=~.
    1.... er be disassembled for
    Inspection or repair. Only complete lifters are
    FLAT SIDE available for replacement. Disregarding this in·
    formation could resub in product damage and/or
    personal injury.

    BOTTOM VIEW OF VALVE LIFTER BODY A WARNING


    Figure 3.05·11. Camshaft Valve lifter Body- Cleaning solvents may be toxic or flammable. Keep
    Bottom View away from heat or flame. Read the manufacture's
    warnings on the container. Always use approved
    2. Inspect the valve lifter rollers (see Figure 3.05·12). If cleaning solvents In a well ventilated area. Contact
    the lifters have caused any wear on the cam lobes, the with skin could resub in severe personal injury or
    camshaft must be reconditioned or replaced. death.

    A CAUTION I~oller
    I..
    ==.....;:==:;....;:....:...;=~.
    1....
    type lifters used
    for replacement are
    shipped from the factory coated with a light rust
    preventative coating. the coating may be removed
    from the lifters by wiping them with a dry cloth or a
    cioth dampened in cleaning solvent. Roller type
    lifters should not be immersed in cleaning solvent,
    since this would not only remove the outer rust
    preventative coating but would also remove the
    lubricant from the lifter roller bushing and pin,
    which can result in lifter failure.

    Figure 3.05-12. Camshaft Valve Ufters And Guides

    3. Inspect the camshaft for heavily pitted areas.


    Replace camshafts that have pitting that cannot be
    polished out.

    4. Inspect the camshaft for straightness. Support the


    camshaft on blocks at the camshaft end bearing
    journals. Using a dial indicator, check for straightness
    while rotating the camshaft. The camshaft must be
    straight within 0.001 inch (0.0254 mm).

    5. Using a dial indicator, inspect the camshaft journals


    (this check should be repeated after polishing, before
    assembly).
    ) 6. Inspect the camshaft coupling for tightness. the
    coupling should never be loose. A camshaft with a loose
    coupling should be replaced.

    FORM 6248 First Ed~ion 3.05 - 15


    CRANKCASE DISASSEMBLY

    1. Clean valve lifters of varnish and buildup (insure that 1. Inspect the hydraulic lifters for damage and dirt
    the lubricant is not removed from the bushing and pin particles (see Figure 3.05-14). )
    area (see Figure 3.05-13).

    PLUNGER~~C-CUP

    HYDRAULIC
    LIFTER",
    "-~/

    PUSH
    /
    Figure 3.05-13. Lubricate Valve Lifter Rollers ROD
    TUBE
    1'-
    2. Inspect the outside diameter of the roller for scuffing
    or chips.

    3. Inspect the roller for smooth rotation (insure that the


    "
    Figure 3.05-14. Hydraulic Lifter )
    roller is properly lubricated during this step). Insure that
    2. Inspect the push rod for straightness, kinks or other
    the roller is free and does not have tight or loose spots
    damage. Replace any bent or damaged push rods. The
    during its rotation.
    push rod must be straight to within 0.020 in (0.508 mm)
    4. Inspect the valve lifter body for scratches and galled T.I.R. (see Figure 3.05-15).
    areas.

    IA
    ..
    CAUTION I Dry valve lifters should
    never be installed In the
    engine. Disregarding this information could result
    in product damage and/or personal injury.

    5. After inspection and cleaning, the lifters should be


    stored in a container of S.A.E. 20 or 30 lube oil. New
    replacement lifters should be stored in the same
    container of lube oil (do not wipe the oil from the lifters
    when installing them).

    HYDRAULIC LIFTERS
    Servicing hydraulic lifters requires a clean service shop.
    Because of the delicate procedures required to service Figure 3.05-15. Push Rod
    hydraulic lifters, many service agencies replace all
    lifters at engine overhaul. 3. Inspect the ball and socket fittings for signs of wear

    IA..
    CAUTION I Hydraulic lifters must be
    filled with the proper oil
    beyond the case hardening. Push rods with worn socket
    and ball assemblies must be replaced.

    prior to installation in the engine. Failure to fill the NOTE: Since testing of the hydraulic lifters requires a
    lifters with oil will cause damage to equipment. special viscosity fluid and test equipment, Waukesha
    Engine Division does not recommend testing in the field.

    3.05 - 16 FORM 6248 First Ed~ion


    CRANKCASE DISASSEMBLY

    4. Inspect the hydraulic lifter to insure that the spring PISTON


    and check valve are not broken (see Figure 3.05-16).
    PISTON DISASSEMBLY

    A WARNING
    Always wear proper eye protection when removing
    piston pin retaining rings. Slippage may propel the
    ring with enough force to cause severe personal
    injury or death. Use the correct retaining ring pliers.
    Verify that the tips of the pliers are not excessively
    worn or damaged.
    CHECK VALVE
    Figure 3.05-16. HydrauliC Lifter - Internal View A WARNING
    The connecting rod weighs 62 Ibs. (28 kg). Use a
    5. If it is determined that the hydraulic lifter is to be suitable lifting device and use caution during
    replaced, insure that the push rod is not damaged when removal or Installation to prevent serious personal
    removing the hydraulic lifter. injury or death.

    6. Use a suitable fixture and press, to properly install 1. Remove the piston pin retaining rings. Slide out the
    the hydraulic lifter on the push rod (see Figure 3.05-17). piston pin and remove the connecting rod (see
    Figure 3.05-18).

    Figure 3.05·17. Hydraulic Lifter - Installation

    ) Figure 3.05-18. Piston Assembly

    FORM 6248 First Edition 3.05 -17


    CRANKCASE DISASSEMBLY

    2. Remove and discard the piston rings. Piston rings 3. Thoroughly clean the oil drain holes leading from the
    take a definite set and must not be reused if the engine oil control ring groove (bottom) to the underside of the )
    has been operated in excess of 50 hours (see piston crown (see Figure 3.05-20). Run a small bristle
    Figure 3.05-19). brush through the passageways to ensure their cleanli-
    ness, but be careful not to damage or enlarge the holes.
    Do not use a wire brush.

    ~
    "'" ~OILDRAIN
    HOLES

    \: j
    Figure 3.05-19. Piston And Rings
    -
    PISTON CLEANING AND INSPECTION

    I A CAUTION IDo not sand blast or


    Figure 3.05-20. Piston 011 Drain Holes
    )
    .. glass bead blast pistons.
    Sand and glass bead blasting removes the tin
    plating and rounds off the ring lands. Disregarding I.A. CAUTION Iscratching
    Exercise care to avoid
    the sides of
    this information could result in product damage
    and/or personal Injury. the piston ring grooves.

    4. Thoroughly clean the piston ring grooves of all

    I A CAUTION IDo not place pistons in carbon deposits. A broken piston ring properly ground to
    .. the caustic hot bath. The a sharp chisel-like edge may be used for this purpose.
    caustic solution attacks aluminum and the tin
    plating may blister or warp if heated to tempera- 5. Carefully inspect the pistons for excessive damage.
    tures above 212' F (100' C). Discard pistons with cracked, broken or bent ring lands.
    Check the piston skirt for cracks, gouges, deep
    1. To remove all carbon and combustion deposits, soak scratches or heavy scoring (displaced metal formed into
    the pistons in a special detergent that will not corrode patches or crowns). Check the piston heads for
    aluminum. Maintain the temperature of the cleaning evidence of burning, etching or melting. Look for marks
    solution well below 212' F (100' C). or imprints caused by contact with valves. Pistons with
    superficial wear marks, minor scratching or mild scoring

    A WARNING
    may continue to be used.

    6. Run your index finger around the edge of the piston


    Compressed air can pierce the skin and cause
    crown to feel for dings, nicks or burrs. lightly file the
    severe personal Injury. Never use your hand to
    edge of the crown to remove any defects.
    check for leaks or to determine air flow rates. Wear
    safety glasses to shield your eyes from flying dirt 7. Check under crown and pin tower bosses for any
    and debris. cracks.

    2. Thoroughly rinse the pistons and dry with moisture


    free compressed air.

    3.05 - 18 FORM 6248 First Edition


    CRANKCASE DISASSEMBLY

    A WARNING IA
    ..
    CAUTION I Waukesha assumes ab-
    solutely no liability for
    Always carefully read the manufacturer's instruc- any damage that may occur through the reuse of
    tions to avoid severe personal injury or death. engine parts failing within published wear limit
    guidelines. Reuse of engine parts that do not meet
    Using the Magnaflux® Dye Penetrant Test Kit the new part speCifications listed In the Fits and
    (Tool PIN 494283), inspect the piston for surface cracks. Clearances section of this manual are the sole
    Pay special attention to the area around the pin bores, responsibility of the user. Under no circumstances
    ring lands and oil drain holes beneath the piston crown. is the reuse of any part exceeding the published
    wear IimHs Justified.
    8. To remove oily residues, apply the Magnaflux®
    Spotcheck® Cleaner/Remover (SKC-S) directly to the 14. Weigh the pistons to verify that all are within
    test area. Thoroughly wipe the area with a clean cloth. 2 ounces (56.7grams) of one another.
    Repeat the procedure as necessary. Final wiping
    should result in a clean cloth. Allow the test area to dry. 15. Measure the piston skirt diameter (top), in line with
    NOTE: Wear rubber gloves to avoid hard-to-remove and at 90 degrees from the pin hole (A inTable 3.05-7
    stains on hands. and Table 3.05-8). Discard the piston if the measure-
    ment does not fall within allowable limits.
    9. Spray the test area with the Magnaflux®
    Spotcheck® Penetrant (SKL-SP). Wait 1 to 30 minutes.

    10. Spray the Magnaflux® Spotcheck® Cleaner/Re-


    I~
    A CAUTION I Use the published wear
    limits with discretion. Al-
    mover (SKC-S) on a clean cloth (not on the test area). though Waukesha recognizes that many used parts
    Wiping in one direction, remove all surface penetrant. are suitable for continued service, there is almost
    Repeat as necessary. always a corresponding reductlon.ln performance.
    Carefully consider the following items before reus-
    11. Spray the test area with the Magnaflux® Ing any particular part: (a.) The number of mating
    Spotcheck® Developer (SKD-S2). Apply a thin even parts being reused. (b.) The extent of the repair
    film. Allow the film to dry completely. The proper relative to the expected service life prior to the next
    application dries to an even white layer. major overhaul. (c.) The engine application, such as
    horsepower requirement, maintenance Intervals
    12. Carefully inspect the test area for cracks. A bright and type of installation. (d.) The problems that may
    colored solid or dotted line marks a crack. Fine cracks occur through reuse.
    may take up to 15 minutes to appear. Large cracks can
    be seen almost immediately. If the crack is wide and 16. Measure the piston skirt diameter (bottom), in line
    deep, the indication will grow and spread. Discard the with and at 90 degrees from the pin hole (8 in Table 3.05-7
    piston if any cracks are found. and Table 3.05-8). Discard the piston if the measurement
    does not fall within allowable limits.
    A WARNING 17. Measure the inside diameter of the piston pin bore
    Operating an engine with a cracked piston could at four locations (C in Table 3.05-7 and Table 3.05-8).
    resuH In severe engine damage and possible severe Discard the piston if any measurement does not fall
    personal Injury or death. within allowable limits.

    18. Check the piston pin bores for excessive wear.


    13. Wipe the test area clean if no cracks are found.
    Insert a good piston pin into the pin bore. The pin should
    Thoroughly wash the piston in a non-caustic cleaner to
    slide in and out without binding, pivoting or rocking.
    remove any traces of dye penetrant.
    Carefully inspect the pistons for excessive wear. The 19. Measure the inside diameter of the cylinder sleeve
    following checks and measurements are helpful in at right angles to the crankshaft in the lower or most
    determining whether the pistons are fit for reuse. worn area of the sleeve. Measure the outSide diameter
    of the piston skirt across the thrust faces (at right angles
    to the piston pin bore). The difference in these two
    measurements is the piston skirt to cylinder sleeve
    clearance (0 in Table 3.05-7 and Table 3.05-8).

    NOTE: Check piston clearance in the sleeve in which


    the piston will run. The sleeve must be deglazed before
    it is suitable for further service.

    FORM 6248 First Edition 3.05 -19


    CRANKCASE DISASSEMBLY

    Table 3.05-7. Piston (Four Ring Only) - Gas

    -.l
    T
    •
    A

    W
    vIS; NOTE: Dimensions A and B must be measured at
    the locations shown.
    '-=/

    .B

    D- ~
    FOUR RING PISTON - GAS
    Piston material: Tin plated aluminum alloy
    Piston type: Cam ground
    Pistons are removed from: Top of crankcase
    Permissible weight variation per set: 2 ounces (56.7 grams)
    Measurement I Inches I Metric (mm)
    Piston hole center to piston crown standard compression ratio
    L5108G (8.25:15101) 6.245 - 6.255 158.623 - 158.877
    L5790G,GSI (8.25:15101) 5.620 - 5.630 142.748 - 143.002
    L7042G/GSI (8.0 to 1) 5.465 - 5.475 138.811 - 139.065
    10.0:1 Compression ratio
    L5108GSI 6.587 - 6.597 167.310 - 167.564
    5790GL 6.031 - 6.037 154.737 - 154.864
    10.5:1 Compression ratio
    7042GL - 4 Ring I 6.092 - 6.097 I 154.737 - 154.864
    (A) Piston skirt diameter ~op) in line wnh pin hole:
    All 8-112 inch bore models (L5108 etc., L5108 etc.) 8.461 - 8.462 214.909 - 214.934
    All 9-3/8 inch models (L7042 etc.) - 4 Ring 9.334 - 9.335 237.064 - 237.109
    90° from pin hole:
    All 8-1/2 inch bore models 8.477 - 8.478 215.316 - 215.341
    All 9-3/8 inch models - 4 Ring 9.350 - 9.351 237.490 - 237.515
    (8) Piston skirt diameter (bottom) in line with pin hole:
    All 8-112 inch bore models 8.478 - 8.479 215.341 - 215.387
    All 9-3/8 inch models - 4 Ring 9.354 - 9.355 237.592 - 237.617
    90° from pin hole:
    All 8--1/2 inch bore models 8.487 - 8.488 215.570 - 215.595
    All 9-3/8 inch models - 4 Ring 9.382 - 9.363 237.795 - 237.820 )
    (Continued)

    3.08-20 FORM 6248 First Edition


    CRANKCASE DISASSEMBLY

    ~
    T
    ,
    A
    ~

    es!~
    W NOTE: Dimensions A and B must be measured at
    the locations shown.

    D- f-
    Measurement Inches Metric (mm)
    (e) Piston pin bore 3.0004 - 3.0009 76.210 - 76.223
    (D) Piston skirt to sleeve clearance (thrust area) ."
    All 8-1/2 inch and 9-3/8 inch bore models - 4 Ring 0.0123 - 0.0143 I 0.~1.24 - 0.3632

    (E) Groove width;


    Top, 2nd and 3rd: All 8-1/2 inch models (L5108 etc., L5790 etc.) 0.189 - 0.190 4.801 - 4.826
    Top: All 9-3/8 inch bore models (L7042 etc.) 0.1915 - 0.1925 4.8641 - 4.8995
    2nd and 3rd: All 9-3/8 Inch bore models (L7042 etc.) - 4 Ring 0.190 - 0.191 4,~26 - 4.851

    4th Oil Ring


    Oil Ring, All 8-1/2 inch bore models 0.313 - 0.314 7.950 - 7.9756
    Oil Ring, All 9-3/8 inch bore models - 4 Ring 0.376 - 0.377 9.550 - 9.576

    FORM 6248 First Edition 3,05 - 21


    CRANKCASE DISASSEMBLY

    Table 3.05-8. Three Ring Piston (PIN 2055040) (pIston Used On GL 9-3/8 Bore With PIN 205130L Liner Only) - Gas
    )
    E

    -.-1
    I
    T A

    6!~
    ~ NOTE: Dimensions A and B must be measured at
    the locations shown.

    D_
    ~
    THREE RING PISTON - GAS
    Piston material: lin plated aluminum alloy
    Piston type: Cam ground
    Pistons are removed from: Top of crankcase
    Pennissible weight variation per set: 2 ounces (56.7 grams)
    Measurement Inches Metric (mm)
    Piston hole center to piston crown 6.094 154.787
    (A) Piston skirt diameter (top) in line wtth pin hole: 9.336 - 9.337 237.134 - 237.159
    go.;l from pin hole 9.352 - 9.353 237.541 - 237.820
    (8) Piston skirt diameter (bottom) in line with pin hole 9.354 - 9.355 237.592 - 237.617
    0
    90 from pin hole: 9.362 - 9.363 237.795 - 237.820
    (e) Piston pin bore 3.0004 - 3.0009 76.2100 - 76.2228
    (D) Piston skirt to sleeve clearance (thrust area) 0.0123 - 0.0143 0.3124 - 0.0363
    (E) Groove width
    Top 0.1920 - 0.1930 4.8768 - 4.9022
    2nd 0.189 - 0.190 4.8006 - 4.8260
    3rd 0.251 - 0.252 6.375 - 6.401

    3.05-22 FORM 6248 First Edition


    CRANKCASE DISASSEMBLY

    CAUTION I~or~ rin9. grooves re~ult


    I=.-A='-;;;..;;....;;.;::..~..;::.-'---'. NOTE: The weights of the pistons installed in the
    L. . high 011 consumption
    In engine must not vary by more than 2 ounces. For
    and blow-by of exhaust gases. Blow-by of exhaust example, if the piston weights are stamped 500, 501
    gases contaminates the engine 011 supply with and 502 ounces, then the variance would be within the
    acids and leaves sludge in the crankcase. It also acceptable range. But if the weights are 499-1/4, 500
    reduces engine efficiency by weakening the com- and 501-1/2, then the variance exceeds specification,
    bustion seal necessary for efficient transfer of and the piston set, as constituted, would be unaccept-
    energy to the piston. able.

    20. Measure the piston ring groove widths 23. Cover the pistons with a clean plastic sheet to
    (D in Table 3.05-9 and Table 3.05-10).lnserttheedgeof protect them from dust and dirt.
    a new ring into the piston ring groove (see
    Figure 3.05-21). Insert a feeler gauge between the PISTON RING INSPECTION
    upper surface of the ring and the ring land to measure Before placing each ring on the piston, perform the
    the ring groove side clearance. Since the grooves wear following checks.
    unevenly, repeat this check at several locations around
    A CAUTION IExces~ive
    the piston groove circumference. Discard the piston if
    any ring groove clearance does not fall within allowable
    limits (see Table 3.05-9 and Table 3.05-10).
    I. . =..
    ='-'----''-_,;;,...--1. suits In high oil con-
    .'ing gap re-

    sumption and blow-by of exhaust gases. Blow-by


    of exhaust gases contaminates the engine oil
    supply with acids and leaves sludge in the crank-
    case. It also reduces engine efficiency by weaken-
    ing the combustion seal necessary for efficient
    transfer of energy to the piston.

    I. . =.A. CAUTION I Insufficient ring gap may


    cause the ends to abut at
    ='-;..;;....;;.;;;....;;....;;.;::..;....;;..J.
    engine operating temperatures, resulting in ring
    breakage, sleeve scuffing and/or piston seizure.

    1. Insert the new ring into the cylinder sleeve, square it


    in the lower end of the bore and measure the ring gap
    with a feeler gauge (see Figure 3.05-21). Do not use the
    ring if the gap exceeds the specifications listed in
    Table 3.05-9 and Table 3.05-10. Discard the ring if any
    Figure 3.05-21. Check Piston Ring Groove Clearance clearance does not fall within allowable limits.

    NOTE: The top compression ring groove is exposed to


    the highest temperature, pressure and abrasion. To
    prolong piston and ring life, a cast iron ni-resist insert is
    installed to slow groove and ring side wear. The
    extended service life realized by the ni-resist insert may
    result in a condition where the greatest wear is found in
    the second compression ring groove.

    21. Polish the pistons and pin bosses with fine grit
    crocus cloth to remove minor scuff marks and
    scratches.

    22. Replace pistons that do not conform to specifica-


    tions.

    FORM 6248 First Edition 3.05 - 23


    CRANKCASE DISASSEMBLY

    Table 3.05-9. Piston Rings (Four Ring Piston Only) - Gas


    )

    TANGENTIAL LOAD (LT)


    =:::I C B (END CLEARANCE)

    A . . . LOAD AT DIA. (LD)

    (GAUGE DIAMETER)

    E (SIDE CLEARANCE) L K (RADIAL WAlL


    ...10
    .LL THICKNESS)

    T~
    NSI (WIDTH)

    "T
    PISTON RINGS (FOUR RING PISTON ONLy) - GAS
    Top ring: (L51OSG/GSI/GL, L5790G/GSI/GL, L7042G/GSI/GL) Crowned plasma coaled compression (top marked with notch)
    Second ring: (All VHP gas engines), Tapered face compression (top marked "top" and marked with notch) )
    Thirdrin~: (L5108G/GSI/GL, L579OG/GSI/GL, L7042G/GSI) Tapered face compression ~op marked "top' and marked with notch} 7042GL,
    Scraper aced compression ring (top marked with indentation)
    Fourth ring: (All VHP Gas Engines) Conformable grooved oil ring with expander ~op marked w~h notch)
    Measurement Top 2nd and 3rd 4th
    (A) Ring gauge diameter
    L51OBG/GSI/GL, L579OG/GSI/GL 8.500 in. (215.9 mm) 8.500 in. (215.9 mm) 8.500 in. (215.9 mm)
    L7042G/GSI/GL 9.375 in. (238.125 mm) 9.375 in. (238.125 mm) 9.375 in. (238.125 mm)
    (8) Ring end clearance at gauge diameter
    L51OSG/GSI/GL, 0.040 - 0.055 in. 0.025 - 0.040 in. 0.023 - 0.038 in.
    L5790G/GSI/GL (1.016 -1.397 mm) (0.635 - 1.016 mm) (0.584 - 0.965 mm)
    0.045 - 0.060 in. 0.030 - 0.045 in. 0.Q15 - 0.035 in.
    L7042G/GSI (1.143 -1.524 mm) (0.762 -1.143 mm) (0.381 - 0.889 mm)
    (C) Ring radial wall thickness
    L5108G/GSI/GL, 0.300 - 0.315 in. 0.300 - 0.315 in. 0.243 - 0.258 in.
    L579OG/GSI/GL (7.62 - 8.00 mm) (7.62 - 8.00 mm) (6.172 - 6.553 mm)
    0.302 - 0.317 in. 0.302 - 0.317 in. 0.290 - 0.310 In.
    L7042G/GSI (7.671 - 8.052 mm) (7.671 - 8.052 mm) (7.366 - 7.874 mm)
    0.302 - 0.317 in. 0.302 - 0.317 in. 0.290 - 0.310 in.
    7042GL (7.671 - 8.052 mm) (7.671 - 8.052 mm) (7.366 - 7.874 mm)
    (D) Ring width
    L51OSG/GSI/GL, 0.1850 - 0.1865 in. 0.1835 - 0.1850 in. 0.3085 - 0.3100 in.
    L5790G/GSI/GL (4.699 - 4.7371 mm) (4.661 - 4.689 mm) (7.836 - 7.874 mm)
    0.1850 - 0.1865 in. 0.1650 - 0.1865 in. 0.03720 - 0.03735 in.
    L7042G/GSI (4.699 - 4.737 mm) (4.899 - 4.737 mm) (9.449 - 9.487 mm)
    (Continued)

    3.05 - 24 FORM 6248 First Ed~ion


    CRANKCASE DISASSEMBLY

    TANGENTlAL LOAD (LT)


    =:I t=: B (END CLEARANCE)

    ~ LOAD AT DIA. (LD)


    A
    (GAUGE DIAMETER)

    J
    E (SIDE CLEARANCE) L K (RADIAL WALL
    -1
    D

    LL THICKNESS)

    T~ fi:!i:!
    T
    (WIDTH)

    Measurement Top 2nd and 3rd :.Ath


    (D) Ring width
    0.1850 - 0.1865 in. 0.1850 - 0.1865 in. 0.03720. - 0.03735 in.
    7042GL (4.699 - 4.737 mm) (4.699 - 4.737 mm) (9.449 - 9.487 mm)
    .
    (E) Ring, piston groove, side clearance
    0.0025 - 0.0050 in. 0.0040 - 0.0065 in. 0.0030:- 0.0055 in.
    L5108G/GSIIGL, L579OG/GSIIGL (0.064 - 0.127 mm) (0.102 - 0.165 mm) (0.076:' 0.140 mm)
    0.0050 - 0.0075 in. 0.0035 - 0.0060 in. 0.0025 - 0.0050 in.
    L7042GIGSI (0.127 - 0.1905 mm) (0.0689 - 0.1524 mm) (0.064 - 0.127 mm)
    0.0050 - 0.0075 in. 0.0035 - 0.0060 in. 0.0025 - 0.0050 in.
    7042GL (0.127 - 0.191 mm) (0.069 - 0.152 mm) (0.064 - 0.127 mm)
    (LD) Load in Ibs. at gauge diameter
    L5106GIGSIIGL, L5790GIGSIIGL 30 Ibs. (13.6 kg) (minimum) 15 - 22 Ibs. (6.8 - 9.9 kg) -
    L7042GJGSI 22 Ibs. (13.6 kg) (minimum) 13.5 - 20.5 Ibs. (6.1 - 9.3 kg) -
    7042GL 22lbs. (13.6 kg) (minimum) 13.5 - 20.5Ibs. (6.1 - 9.3 kg) -
    (LT) Tangenlialload, in Ibs. at end clearance
    L510SGIGSIIGL, L5790GIGSIIGL - - 28.5 - 3S.Slbs. (12.9 - 17.5 kg)
    L7042GIGSI - - 24.0 - 3S.0 Ibs. (10.9 - 17.2 kg)
    7042GL - - 24.0 - 3S.0 Ibs. (10.9 - 17.2 kg)

    FORM 6248 Firs! Ed~ion 3.06 - 25


    CRANKCASE DISASSEMBLY

    Table 3.05-10. Piston Rings


    (Used On GL 9-3/8 Inch Bore With Three Ring Piston And PIN 205130L Cylinder Sleeve Only) - Gas )

    TANGENTIAL LOAD (LT) ==:I t= 8 (END CLEARANCE)

    A ~ LOAD AT DIA. (LD)

    (GAUGE DIAMETER)

    E (SIDE CLEARANCE) LK (RADIAL WALL


    ...1
    D

    .LL THICKNESS)

    Tr-: I~ r(WIDTH)

    PISTON RINGS
    (USED ON GL 9-3/8 INCH BORE THREE RING PISTON AND PiN 205130L CYUNDER SLEEVE ONLY) - GAS
    Top ring: Plasma ooated (top marked wnh nelch)
    Second ring: Scraper groove compression (top marked with indentation mark)
    Third ring: Conformable grooved oil ring with expander
    Measurement Top 2nd 3rd
    (A) Ring gauge diameter 9.375 in. (238.125 mm) 9.375 in. (238.125 mm) 9.375 in. (238.125 mm)
    0.035 - 0.047 in. 0.065 - 0.060 in. 0.015 - 0.035 in.
    (8) Ring end clearance at gage diameter (0.889 -1.194 mm) (1.651 - 2.032 mm) (0.381 - 0.889 mm)
    0.317 - 0.302 in. 0.302 - 0.317 in. 0.213 - 0.227 in.
    (C) Ring radial wall thickness (8.052 - 7.761 mm) (7.671 - 8.052 mm) (5.410 - 5.7658 mm)
    0.1850 - 0.1865 in. 0.1850 - 0.1865 in. 0.2475 - 0.2490 in.
    (D) Ring widlh (4.6990 - 4.7371 mm) (4.6990 - 4.7371 mm) (6.2865 - 6.3246 mm)
    0.0055 - 0.008 in. 0.0025 - 0.0050 in. 0.002 - 0.0045 in.
    (E) Ring, piston groove, side clearance (0.1143 - 0.2032 mm) (0.0635 - 0.127 mm) (0.0506 - 0.1143 mm)
    13.5 - 20.5 Ibs.
    (LD) Load in lb•. at gauge diameter 20.4 lb•. (9.2 kg)
    (6.1 - 9.3 kg)
    -

    45.4 - 68.1 lb•.


    (LT) Tangential load, in lb•. at end clearance - - (20.6 - 30.9 kg)

    3.05 - 26 FORM 6248 First Edition


    CRANKCASE DISASSEMBLY

    PISTON RING ASSEMBLY NI·RESIST


    INSERT
    8-1/2 INCH BORE G/GSI/GL (4 RING PISTON)

    A CAUTION IAIWaYS~nstalinewPiston
    .
    =.
    I =----'=..;;..;;;....;;....;;...;;;..;~. rings. Piston rings take a
    L..

    definite set and must not be reused If the engine has


    been operated In excess of 50 hours. Deglaze the
    cylinder sleeve before installing new rings. Disre-
    garding this information could result in product
    damage and/or personal injury.

    I.
    A CAUTION 1~lngdeSignSandmateri­
    ==----'=..;;..;;;....;;....;;...;;;..;~.
    L.. . als vary between engine
    models. Be sure that the replacement ring set is the Figure 3.05-22. Install Piston Rings
    one specified for the engine. Disregarding this
    information could result in product damage and/or
    personal injury.
    .. CAUTION
    A
    = I Use the proper piston
    I =--=:...::..-::..::;...:...:....;:;..:..:.J. ring spreader (Tool
    1...

    PIN 494019) to prevent excessive ring twist and


    A WARNING expansion. Over expansion may cause the ring to
    crack opposite the ring gap. Defective or distorted
    Compressed air can pierce the skin and cause rings result in blow-by of exhaust gases, increased
    severe personal injury or death. Never use your hand oil consumption and lower service life on compo-
    to check for leaks or to determine air flow rates. Wear nents.
    safety glasses to shield your eyes from flying dirt
    and debris.
    A CAUTION I ~o avoid stre~ching the
    IL.=
    .=:........;=...;..;;....;;....;;...;;;..;~.
    . expander spring, Install
    1. Use compressed air to remove any dirt or dust that
    may have settled in the oil drain holes and piston ring
    the spring and 011 control ring separately. Excessive
    stretching may adversely affect spring tension and
    grooves (see Figure 3.05·22).
    reduce ring performance.

    2. Remove the expander spring from the slotted


    spring-loaded oil control ring (see Figure 3.05-23).
    Carefully inspect the ring for burrs or metal fragments
    that may remain from the machining process.

    DIRECTIONAL
    NOTCH

    )
    Figure 3.05-23.011 Control Ring Detail - 8-1/2 Inch Bore

    FORM 6248 First Edition 3.05-ZT


    CRANKCASE DISASSEMBLY

    3. Pull apart the ends of the expander spring. Wrap 6. Install the top crowned plasma-coated compression
    the spring around the bottom ring groove. Insert the ring. The notch on center of the ring gap must face up )
    1-1/2 inch (38.1 mm) wire pin at one end of the spring (see Figure 3.05-25). Verify that the ring rotates freely
    into the coil loop on the other end. on the piston.

    4. Install the slotted oil control ring with ring gap


    opposite mated ends of the expander spring. Be sure
    that the notches on the ring gap face upward (see
    Figure 3.05-23). Verify ring rotates freely on the piston.

    CAUTION I
    I A=:.....:=.:..;::;.....;:~=-.::..:..J.
    Do not Install th.e 2nd and
    L..
    : .. 3rd compression rings
    upside down. Upside down rings will scrape 011 up
    Into the combustion chamber, resulting in high oil
    consumption and sticking valves.

    5. Install the two tapered compression rings with the


    word "Top" facing the piston crown. The top olthe ring is
    also identified by the inside bevel and the notch in the
    center of the ring gap (see Figure 3.05-24). Verify that
    the ring rotates freely on the piston.
    Figure 3.05-25. Barrel-faced Compression Ring Detail

    7. Rotate the four piston rings using the palms of both


    hands. The rings must rotate freely without sticking.

    8. Stagger the ring gaps around the piston. Rotate each


    ring to position the gap 90 degrees from the gap in the )
    ring above it.

    Figure 3.05--24. Compression Ring Detail

    3.05-28 FORM 6248 First Ed~ion


    CRANKCASE DISASSEMBLY

    9-3/8 INCH BORE GIGSI (4 RING PISTON) 5. Install the 3rd and 2nd compression rings with the
    sides marked "TOP" up, this side is also marked with a
    A WARNING notch. Verify that the ring rotates freely on the piston
    (see Figure 3.05-26).
    Compressed air can pierce the skin and cause
    severe personal Inlury or death. Never use your
    hand to check for leaks or to determine air flow
    rates. Wear safety glasses to shield your eyes from
    flying dirt and debris.

    1. Use compressed air to remove any dirt or dust that


    may have settled in the oil drain holes and piston ring
    grooves. TOP COIWPRESSIION

    IA
    ...
    CAUTION I To avoid stretching the
    expander spring, Install
    NOTCH

    the spring and oil control ring separately. Excessive


    stretching may adversely affect spring tension and
    reduce ring performance. NOTCH

    2. Remove the expander spring from the slotted


    spring-loaded oil control ring. Carefully inspect the ring
    for burrs or metal fragments that may remain from the
    machining process.

    3. Pull apart the ends of the expander spring. Wrap the CONTOURED
    _--FACE
    spring around the bottom ring groove. Insert the 1-1/2
    inch (38.1 mm) wire pin at one end of the spring into the
    coil loop on the other end.

    IA
    ...
    CAUTION I Use the proper piston
    ring spreader (Tool PIN Figure 3.05-26. 9-3/8" Bore G,GSI Piston Ring
    494019) to prevent excessive ring twist and expan- Configuration
    sion. Over expansion may cause the ring to crack
    opposite the ring gap. Defective or distorted rings 6. Install the top crowned plasma coated compression
    result in blow-by of exhaust gases, increased oil ring with the notch on the ring gap facing the piston
    consumption and lower service life on valves and crown. Verify that the ring rotates freely on the piston.
    other components.
    7. Rotate the four piston rings using the palms of both
    4. Install the slotted oil control ring with the ring gap hands. The rings must rotate freely without sticking.
    opposite the mated ends of the expander spring. The
    ring must be installed with the notched side up. Verify 8. Stagger the ring gaps around the piston. Rotate each
    that the ring rotates freely on the piston. ring to position the gap 90 degrees from the gap in the
    ring above it.

    IA
    ...
    CAUTION I Do not install the 2nd and
    3rd compression rings
    upside down. Upside down rings will scrape 011 up
    into the combustion chamber, resulting in high oil
    consumption and sticking valves.

    FORM 6248 First Edition 3.05 - 29


    CRANKCASE DISASSEMBLY

    PREVIOUS PRODUCTION 9-3/8 INCH BORE GL 5. Install the 3rd compression ring with the scraper
    (4 RING PISTON) groove on the outer lower corner facing down toward the
    piston skirt. Verify that the ring rotates freely on the
    A WARNING piston (see Figure 3.05-27).

    Compressed air can pierce the skin and cause


    NOTCH IN RING GAP
    severe personal in/ury or death. Never use your FACES CROWN
    hand to check for leaks or to determine air flow
    rates. Wear safety glasses to shield your eyes from
    flying dirt and debris.

    1. Use compressed air to remove any dirt or dust that


    may have settled in the oil drain holes and piston ring
    grooves.
    NI-RESIST
    INSERT

    A CAUTION I
    I=..
    L.
    To avoid stretching the
    ='-"---''"---_.;;...---J. expander spring, Install
    the spring and oil control ring separately. Excessive
    stretching may adversely affect spring tension and
    reduce ring performance.
    GROOVE
    2. Remove the expander spring from the slotted
    spring-loaded oil control ring. Carefully inspect the ring
    for burrs or metal fragments that may remain from the
    machining process.

    3. Pull apart the ends of the expander spring. Wrap the ,


    spring around the bottom ring groove. Insert the 1-1/2 )
    DRAIN HOLE
    inch (38.1 mm) wire pin at one end of the spring into the
    coil loop on the other end. Figure 3.05-27. Previous Production 9-3/8" Bore GL
    Piston Ring Configuration PIN 205404Z
    IA
    ..
    CAUTION I Use the proper piston
    ring spreader (Tool PIN 6, Install the 2nd compression ring with the word "Top"
    494019) to prevent excessive ring twist and expan- facing the piston crown. The top of the ring is also
    sion. Over expansion may cause the ring to crack identified by the inside bevel and the notch in the center
    opposite the ring gap. Defective or distorted rings olthe ring gap (see Figure 3.05-27). Verify that the ring
    result In blow-by of exhaust gases, increased 011 rotates freely on the piston.
    consumption and lower service life on valves and
    other components. 7. Install the rectangular Plasma-faced top compres-
    sion ring with the notch on the ring gap facing the piston
    4. Install the slotted oil control ring with the ring gap crown. Verify that the ring rotates freely on the piston.
    opposite the mated ends of the expander spring. The
    8. Rotate the four piston rings using the palms of both
    ring may be installed with either side up. Verify that the
    hands. The rings must rotate freely without sticking.
    ring rotates freely on the piston.
    9. Stagger the ring gaps around the piston. Rotate each
    CAUTION I
    I.=A='-"-..;-::....;.....;;...;;;;....;~.
    Do not install the 2nd and ring to position the gap 90 degrees from the gap in the
    L. . 3rd compression rings ring above it.
    upside down. Upside down rings will scrape oil up
    into the combustion chamber, resulting in high 011
    consumption and sticking valves.

    3.05-30 FORM 6248 First Edition


    CRANKCASE DISASSEMBLY

    CURRENT PRODUCTION 9-3/8 INCH BORE GL 2. Install the second ring (see Figure 3.05-28 and
    (3 RING PISTON) Figure 3.05-29). Position the piston with the ring gap
    located toward the rear of the engine. The ring must be
    IA
    :..
    CAUTION I To avoid stretching the
    expander spring, install
    installed with the scraper edge down. The top of the ring
    is identified with a machined mark.
    the spring and 011 control ring separately. Excessive
    stretching may adversely affect spring tension and 3. Install the top compression ring (see Figure 3.05-28
    reduce ring performance. and Figure 3.05-29). Position the end gap toward the
    front of the engine. Do not put the ring gap toward the

    I~ CAUTION I
    exhaust side of the engine. Carbon usually forms on the
    -A Do not shorten the ex-
    pander spring for any exhaust side early in the operation of the engine. Ring
    reason. Shortening the expander spring will cause gaps located on the exhaust side enhance the formation
    high oil consumption. of carbon. The top of the ring is marked "TOP".

    1. Install oil control ring on the piston with the ring gap
    located to the intake side of the engine (see
    Figure 3.05-28 and Figure 3.05-29). Install spring in the
    oil control ring groove with joint 180 degrees away from
    oil control ring gap.

    TOP RING
    CENTERLINE
    /. RING
    ~~~~~ __________~Ic=J

    '" CENTERLINE
    BARREL
    -..j I-- ~:~:
    SECOND RING
    GAP

    "'>--____________--'1 c=J
    -----I '------ 0.080"
    ----, , - - 0.065" GAP

    OIL CONTROL RING 0.250"

    IECI}§~~~I-.r B
    1
    Figure 3.05-28. Current Production Piston Ring Detail
    9-3/8 Inch 80re GL (3-Rlng Piston)

    Figure 3.05-29. Current Production 9-3/8 Inch Bore GL


    (3-Ring Piston)

    FORM 6248 First Ed~ion 3.05 - 31


    CRANKCASE DISASSEMBLY

    PISTON PIN CLEANING AND NOTE: A/ways rep/ace the pin when a new piston is
    INSPECTION instal/ed.

    3. Visually inspect the pin for etching, scoring, damage


    A WARNING or excessive wear. Any surface wear or detect that may
    be felt is cause for replacement.
    Always use approved cleaning solvents in a well
    ventilated area. Contact with skin could result in 4. Measure the outside diameter of the piston pin in all
    severe personal injury or death. wear areas. Wear is usually concentrated on those
    surfaces that run in the pin bosses and rod bushings.
    1. Wash the piston pins in a non-volatile cleaning Measure the pin diameter 90 degrees to the wear area.
    solution or solvent. Refer to Table 3.05-11 for the new part tolerances olthe
    piston pin. Discard the pin if the measurement is not
    A WARNING within allowable limits.

    Compressed air can pierce the skin and cause 5. Polish the piston pins with fine gr~ crocus cloth to
    severe personal Injury or death. Never use your remove minor scuff marks and scratches. Rotate each
    hand to check for leaks or to determine air flow pin in a lathe to avoid an out-ot-round condition.
    rates. Wear safety glasses to shield your eyes from
    6. Replace pins that do not conform to specifications.
    flying dirt and debris.
    7. Cover the piston pins with a clean plastic sheet to
    2. Thoroughly dry the pins w~h moisture free com· protect them from dust and dirt.
    pressed air.

    Table 3.05·11. Piston Pin - Gas

    t )

    ------------------------
    ------------------------
    [)
    T
    MEASUREMENT INCHES METRIC (mm)
    (A) Piston pin diameter 8-1/2 inch bore 2.9987 - 2.9992 76.1670 - 76.1797
    Piston pin diameter 9-3/8 inch bore 2.9989 - 2.9994 76.1720 -76.1647
    Piston pin length L5108G,L5790G 7-11/32 186
    L7042G 8-11/32 212
    Piston pin fit 8-1/2 inch bore 0.0012 - 0.0022 0.0305 - 0.0559
    Piston pin fit 9-3/8 inch bore 0.001 - 0.002 0.0254 - 0.0508

    3.05 - 32 FORM 6248 First Edilion


    CRANKCASE DISASSEMBLY

    CONNECTING ROD
    I. ... CAUTION I
    CONNECTING ROD DISASSEMBLY
    =A= __---'___---'. Adequately support the
    upper end of the con-
    necting rod to avoid unnecessary stress when
    1. Remove and discard the connecting rod bearings pressing out old piston pin bushings.
    (see Figure 3.05-30 and Figure 3.05-31).
    2. Refer to Table 3.05-12 and measure the piston pin
    bushings for wear. If the piston pin bushings are to be
    replaced, press the old piston pin bushings from the
    upper connecting rod bore and discard (see
    Figure 3.05-32).

    SPLIT LINE OF BUSHING


    (NEARSIDE)

    Figure 3.05-30. Connecting Rod

    SPLIT LINE OF BUSHING


    (FAR SIDE)

    Figure 3.05-32. Align Rod Pin Bushing Split Line

    3. Remove the allen head pipe plug (1/8 inch) above


    the pin bore (see Figure 3.05-33).
    Figure 3.05-31. Bearing Cap

    lro~~~ __::::-
    ----
    ----
    --
    ---- ----
    ----
    --~~-:::--\~~~=-==-===--=-=-==--:..:--~-------~
    =~ --",,: ... -
    PISTON PIN
    BUSHING
    LUBE OIL
    PASSAGEWAYS
    ROD BEARING
    '-_
    - _==_
    .....

    Figure 3.05-33. Clean Connecting Rod Lube 011 Passageways

    FORM 6248 First EdHion 3.05 - 33


    CRANKCASE DISASSEMBLY

    Table 3.05-12. Series PIN 205507 Connecting Rod, Bushing And Bearing Specifications
    )
    A

    ~
    rt~~J~ ~
    r"'\
    ~-I
    ~~~~
    -+- \!
    ~ ~~-- I

    [-] ~ ~~ ~ ~
    !--C_

    -B_
    ~
    D

    MEASUREMENT INCHES METRIC (mm)


    Rod material: Heat treated steel forging
    Permissible connecting rod weight variation in an engine, within weigrt class A, B, or C
    Connecting rod weight, Class A 60.0 ±O.12Ibs. 27.21 .0.054 kg
    Connecting rod weight, Class B 62.0 ±O.12Ibs. 28.12.0.054 Kg )
    Connecting rod weight, Class C 64.0 ±O.12Ibs. 29.03.0.054 Kg
    (A) Connecting rod length, center to center 18.001 - 18.002 457.225 - 457.251
    (8) Bore diameter for piston pin bushing 3.250 - 3.251 82.550 - 82.575
    (C) Bushing bore diameter (diamond bored)
    (Assemble 2 bushings with open ends of grooves toward inside) 3.0015 - 3.0020 76.238 - 76.508

    Bushing press fit into connecting rod 0.0035 - 0.0085 0.0889 - 0.1651
    Piston pin clearance in bushing
    8.500 bore engines 0.0023 - 0.0033 0.0584 - 0.0838
    9.375 bore engines 0.0021 - 0.0031 0.0533 - 0.0787
    (D) Bore for crankpin bearing 6.625 - 6.626 168.275 - 168.300
    Crankpin bearing diametral clearance (calculated bearing inside diameter minus
    connecting rod journal diameter).
    0.0042 - 0.0081 0.1067 - 0.2057

    Width of connecting rod on bearing cap end 2.905 - 2.908 73.787 - 73.863
    Connecting rod side clearance 0.029 - 0.041 0.736 - 1.041
    Parallelism and twist limit between piston pin bushing bore and crankpin bore 0.001 0.0254

    3.05 - 34 FORM 6248 First Ed~ion


    CRANKCASE DISASSEMBLY

    CONNECTING ROD CLEANING AND INSPECTION Connecting Rod - MagnafluX® Application


    Connecting Rod Cleaning
    A WARNING
    A WARNING Always carefully read the manufacturer's instruc-
    tions to avoid severe personal injury or death.
    Use of caustic solutions should be restricted to a Using the Magnaflux® Dye Penetrant Test Kit (Tool
    well ventilated area. Contact with skin, clothing and PIN 494283), inspect the connecting rods for surface
    eyes could result In severe personal InJury or death.
    cracks and defects. Look around high stress areas,
    1. Submerse the connecting rods in the caustic hot tank such as the pin bushing and rod bearing bores.
    (or flush with a non-volatile cleaning solution and steam Proceed as follows:
    clean) to remove all dirt, grease, oil, carbon and varnish
    deposits. 1. Remove the rod caps from the blades.

    2. Rush out the rifle drilled oil passageways with cleaning 2. To remove oily residues, apply the Magnaflux®
    solution (see Figure 3.05-33). Run a stiff bristle brush Spotcheck® Cleaner/Remover (SKC-S) directly to the
    through the passageways to ensure their cleanliness. test area. Thoroughly wipe the area with a clean cloth.
    Repeat the procedure as necessary. Final wiping
    should result in a clean cloth. Allow the test area to dry.
    A WARNING NOTE: Wear rubber gloves to avoid hard-to-remove
    Compressed air can pierce the skin and cause stains on hands.
    severe personal injury or death. Never use your
    3. Spray the test area with the Magnaflux®
    hand to check for leaks or to determine air flow
    Spotcheck® Penetrant (SKL-SP). Wait 1 to 30 minutes.
    rates. Wear safety glasses to shield your eyes from
    flying dirt and debris. 4. Spray the MagnafluX® Spotcheck®'Cleaner/Remov-
    3. Thoroughly rinse the rods and dry with moisture free er (SKC-S) on a clean cloth (not on the test area).
    compressed air. Wiping in one direction, remove all surface penetrant.
    Repeat as necessary.

    A WARNING 5. Spray the test area with the MagnafluX®


    Spotcheck® Developer (SKD-S2). Apply a thin even
    Always use approved cleaning solvents in a well
    film. Allow the film to dry completely. The proper
    ventilated area. Contact with skin could result in
    severe personal injury or death. application dries to an even white layer.

    4. Clean the connecting rod capscrews in solvent. 6. Carefully inspect the test area for cracks. A bright
    Inspect the capscrews for nicks, cracks, galled or colored solid or dotted line marks a crack. Fine cracks
    stretched threads and other obvious damage. Replace may take up to 15 minutes to appear. Large cracks can
    as necessary. be seen almost immediately. If the crack is wide and
    deep, the indication will grow and spread.
    A CAUTION I Any ~Ick, dent or ding in
    I..=~.::;.::....:..::;...;:....:..,;;;,.;~.
    1.,;. the SIde of the rod shank
    is a potential problem. Stress focused at these points
    7. Wipe the test area clean if cracks are not found.
    Thoroughly wash the rod to remove any traces of dye
    penetrant.
    may result in metal fatigue and eventual failure.
    Disregarding this Information could result in prod-
    uct damage and/or personal InJury.

    FORM 6248 First Edition 3.05 - 35


    CRANKCASE DISASSEMBLY

    Connecting Rod Inspection A CAUTION 'Install a ~alrofbra.ssjaw


    L =~=..:..::;...:~.;;....;~. inserts In the vise to
    . .::
    ..
    1. Perform a careful visual inspection of the connecting
    avoid damage to the rod shanks.
    rods. Verify that the rod shank is free of sharp nicks, '
    dents and gouges.
    4. Place the rod blade in a vise with the serrated split
    NOTE: All grinding to remove defects must be longitu- facing upward.
    dinal and blend in smoothly with the surrounding areas.
    5. Use Prussian blue to check the mating surfaces of the
    Do not transverse grind.
    rod cap and blade for proper contact. Proceed as follows:

    , -A CAUTION , Do not try .to straighten A. Apply the dye sparingly to the rod blade serrations.
    '!!"!!:!!!~::'::''':':::''''::''':'':=''::..:..J. bent or twisted rods. A
    L.
    B. Install the rod cap and torque each capscrew
    straightened rod will revert to its bent condition after equally to 45 ft-Ib (61 N·m) or less.
    several hours of engine operation. Disregarding this
    Information could result in product damage. C. Remove the connecting rod capscrews and careful-
    ly pull cap straight back off the rod blade. Inspeclthe
    2. Position the rod in a fixture suitable for measuring cap serrations for Prussian blue transfer. The blue
    parallelism and length. dye transfers from the blade to the cap wherever
    good contact exists. The flanks of the cap serrations
    A. Connecting rods are twisted when the sides of must show at least 50% surface contact Non-con-
    the bearing bore (large) and pin bushing bore tact areas must be discontinuous with no more than
    (small) are not parallel (see Figure 3.05-34). The 10% of the void concentrated in any area.
    connecting rod bores must be parallel (see
    Table 3.05-12) within 0.001 inch (0.0254 mm) 6. If the transfer of Prussian blue does not meet the
    per inch of bushing diameter. Discard any above speCification, proceed as follows:
    connecting rods that are bent or twisted.
    A. Using a needle nose pliers, remove the 1/8 x 1/2
    inch hollow roll pin from the rod cap (see
    Figure 3.05-35). )

    INDICATOR

    Figure 3.05-34. Connecting Rod Twist Gap


    B. Measure the rod length. The center of the bearing
    bore to the center of the pin bushing bore (see
    Table 3.05-12) must be 18.001 - 18.002 inches
    (457.225 - 457.251 mm). Discard any rod that
    does not conform to this specification.
    3. The difference between the bearing bore diameter
    measurements on one side of the rod and the other is
    the bore taper. Discard the connecting rod (see Figure 3.05-35. Rod Cap Roll Pin
    Table 3.05-12) if the taper exceeds 0.0003 inch B. Slide the cap back and forth on the blade. If the
    (0.00762 mm). cap sticks, use a fine triangular pattern file
    between the serrations to lightly dress down any
    burrs and high spots or to straighten any teeth
    that may be bent slightly.

    3.05-36 FORM 6248 First Edijion


    CRANKCASE DISASSEMBLY

    C. Slide the cap back and forth on the blade. If the D. Repeating the torque sequence, torque the caps-
    cap sticks again, repeat the procedure until the crews to a final torque value of 180 - 190 ft-Ib
    cap slides smoothly without sticking. (244 - 257 N·m).
    D. Use Prussian blue to recheck the mating surfaces 9. Inspect the connecting rod bore to verify that it is
    for proper contact. Discard the rod if the transfer is clean and smooth.
    still unacceptable. If the transfer is within specifica-
    tion, install the roll pin with the longitudinal groove
    A CAUTION! Do not use a flexible ball
    facing the cap and the end of the pin flush with the
    finished surface.
    =
    ...
    !L. =~=..:..;::;..;:....:...;=-=~. type hone to recondition
    the rod bearing bore. The rod bearing bore is shot
    Check the rod bearing bore for out-of-round and taper. peened and stress relieved. Honing degrades the
    bearing seat by removing the shot peened finish.
    A CAUTIO N !Install a pair of brass Jaw
    !L.="'='--';";"'---''-''';'''';;;''''---1. Inserts In the vise to
    Disregarding this information could resuH In prod-
    uctdamage.
    avoid damage to the rod shanks.
    10. Using an inside micrometer or dial bore gauge,
    7. Place the rod blade in a vise with the serrated split measure the diameter of one side of the connecting rod
    facing upward. bearing bore at four locations (see Figure 3.05-37). Write
    8. Torque the connecting rod cap to the blade, as down the diameter readings for reference purposes. The
    difference between the largest and smallest diameter is the
    follows:
    out-of-round condition.
    A. Lubricate the threads and under the heads of four
    ferry head connecting rod capscrews with SAE
    30 engine oil.
    B. Locate the number "1" stamped in the connecting
    rod cap. Hand tighten a capscrew in this hole
    first. Hand tighten the remaining capscrews in
    positions 2 thru 4 (see Figure 3.05-36).

    STAMP
    /~o OV 3

    lJ
    I"'"

    A
    -
    ,
    ][ ,
    "- ROD CAP

    ~\.O 0--2 Figure 3.05-37. Check Rod Bearing Bore For


    Out-Of-Round And Taper
    Figure 3.05-36. Connecting Rod Cap Capscrew 11. Repeat the measurements on the other side of the
    Tightening Sequence - Roll Pin Equipped rod bearing bore (see Figure 3.05-37).
    C. Following the same numerical sequence, torque
    12. Discard the connecting rod if the variation between
    the capscrews to 50% of the total torque value.
    the four out-of-round measurements on either side of
    the bore exceeds 0.001 inch (0.0254 mm).

    FORM 6248 First Ed~ion 3.05 - 37


    CRANKCASE DISASSEMBLY

    CONNECTING ROD ASSEMBLY NOTE: Total weight is not the most important consider-
    Replace connecting rods as necessary. The letters"A," ation in matching connecting rods. Connecting rods are )
    "8" or "C" are stamped on the cap of A205507A and classified by matching unbalanced weight distribution.
    A205507C series connecting rods to identify its weight
    classification (see Figure 3.05-38). Only rods from the CAUTION I
    I A=~=...;;..;:::....:~.;:;..;;....;;.J.
    Carefully inspect new
    same weight class may be used in any engine (see 1....;
    . :: . connecting rods before
    Table 3.05-13). use. Damage may occur from careless handling.
    Verify that the rod shank is free of sharp nicks,
    dents, gouges, etc.

    All grinding to remove damages must be longitudinal


    and blend smoothly with the surrounding areas. Do not
    transverse grind.

    1. Obtain a set of new piston pin bushings. Rotate one


    of the bushings to take note of the split line (see
    Figure 3.05-39).

    ROD PIN
    /BUSHING

    WEIGHT
    CLASSIFICATION
    STAMP
    )
    Figure 3.05-38. Weight Classification Stamp Location

    IA
    ;...
    CAUTION I Never intermix rods of
    different weight classifi-
    cations. Disregarding this information could result
    in product damage.
    Figure 3.05-39. Rod Pin Bushing
    Table 3 05-13 Connecting Rod Weight Classifications
    A205507A SERIES
    Large End Small End Total Rod
    Weight Weight
    Class Weight Weight
    ~O.06lbs. ~ 0.06Ibs. ~0.13Ibs.

    A 42.5Ibs. 2O.0Ibs. 62.5Ibs.


    B 43.5Ibs. 21.0Ibs. 64.5Ibs.
    C 44.5Ibs. 22.0Ibs. 66.5Ibs.
    A205507C SERIES

    Weight ~eEnd Small End Total Rod


    Class
    eight Weight Weight
    ~ O.06lbs. ~ 0.06Ibs. ~0.12Ibs.

    A 4O.3Ibs. 19.7Ibs. 6Olbs.


    B 41.3Ibs. 2O.7Ibs. 621bs.
    C 42.3Ibs. 21.7Ibs. 64lbs.

    3.05-38 FORM 6248 First Edition


    CRANKCASE DISASSEMBLY

    2. Position the bushing over the rod pin bore so thatthe 6. Diamond bore the upper connecting rod bushings
    split line is 45 degrees off the rod centerline with the (see B in Table 3.05·12) to a diameter
    open ends of the two lateral oil grooves facing inward 3.0015 - 3.0020 inch (76.238 - 76.508 mm) and a
    (see Figure 3.05-32 and Figure 3.05-40). RMS 24 MAX finish.

    A WARNING
    Compressed air can pierce the skin and cause
    OIL
    severe personal injury or death. Never use your
    GROOVES hand to check for leaks or to determine air flow rates.
    Wear safety glasses to shield your eyes from flying
    dirt and debris.

    7. Direct compressed air into the lube oil drillings and


    around the surface of the bushings to remove all metal
    debris.

    8. Ughtly oil a good piston pin and insert it into the


    upper connecting rod bore to feel for the proper
    interference fit. The pin should slide in and out of the pin
    bushing without binding. but also without pivoting or
    rocking.

    9. Apply a drop of Loctite@ 271 Adhesive Sealant


    (High Strength) to the leading threads of the pipe plug.
    Install a new 1/8 inch allen head pipe plug in the oil hole
    above the pin bore (see Figure 3.05-40). Wrench
    LINE
    tighten.
    Figure 3.05-40. Verify Orientation Of Rod Pin
    Bushings Oil Groove 10. Wedge a pointed punch between the plug and
    connecting rod threads. Strike the punch sharply with a
    single blow. Staking distorts the threads of the plug and
    3. Press the piston pin bushing into the rod pin bore locks it in place.
    (see Figure 3.05-40).
    11. Place a second stake 180 degrees from the first.
    4. Turn the connecting rod over and repeat steps 2 and
    3 to install the second bushing. 12. Remove any metal chips or fragments that may
    have been produced by the staking operation.
    5. Note that proper installation of the bushings puts the
    oil grooves at the bottom of the bore with the closed end
    of each groove pointing to opposite sides of the rod
    shank (see Figure 3.05-40). The outside edge of each
    bushing must be flush with the connecting rod.

    IA
    ..
    CAUTION I Clamp the connecting
    rod In a suitable fixture
    that references off the center of the crankshaft bore_
    A loose boring setup will produce an oblong hole.
    Disregarding this information could result in prod-
    uct damage.

    I=.A. CAUTION I
    L.
    Do not r~am the upper
    connectmg rod bush-
    =:.....;;..;;....;;..::;.........:...;;;...;;...;;..J.
    ings. The reamer will merely follow the existing
    bushing bore. Diamond bore the bushings to
    maintain rod centerline tolerances. Disregarding
    this information could result in product damage.

    FORM 6248 First Edition 3.05 - 39


    CRANKCASE DISASSEMBLY

    CONNECTING ROD BEARING RUNNING 3. Position the fully grooved bearing shell above the
    CLEARANCE bearing seat on the rod cap. The shell diameter is slightly
    larger than the connecting rod bore, so the bearing ends
    1. Obtain a set of new connecting rod bearings. Each protrude approximately 1/4 inch (6.35 mm) above the
    set consists of two shells. The shell installed in the cap, bearing seat (see Figure 3.05-42).
    which is the unloaded side of the rod, is fully grooved
    with no oil holes. The bearing installed in the blade is
    partially grooved, the groove extending from the parting / PARTING EDGES ~
    edges ofthe shell to each oil hole (see Figure 3.05-41).

    LATERAL LOCATING
    / TANG
    ROD CAP
    (LOWER)

    Figure 3.05-42. Position Bearing Shell Above Bearing


    Seat

    4. Apply even pressure on the edges of the bearing to


    press it into place. The locating tang on the parting edge
    CENTERED ofthe shell must fit squarely in the notch machined in the
    / LOCATING TANG
    roll pin side of the cap (see Figure 3.05-43). )
    ROD BLADE
    (UPPER)

    L OIL HOLES

    Figure 3.05-41. Connecting Rod Bearings

    I It.
    ..
    CAUTION I Do not touch the rod
    bearing running surface.
    Acidic skin secretions promote the start of surface BEARING SHELL
    corrosion and wear in the affected area.
    Figure 3.05-43. Installing Bearing Shell

    It. CAUTION I
    I..:"~!.....:=...:..:=-.;:...;;....;:..:....:..J.
    .L
    The bearing shells and
    rod bore must be com-
    pletely free of oil, dirt or other foreign material. Any dirt
    5. Position the partially grooved bearing shell above
    the bearing seat on the rod blade. The locating tang
    centered on the parting edge of the bearing shell
    or debris caught between the bearing shell and bore (opposite the bearing running surface) must be directly )
    results in bearing distortion and reduced service life. above the notch centered in the roll pin side ofthe blade.
    Apply even pressure on the edges of the bearing to
    2. Wipe the rod bearing bore and bearing shells clean. press it into place.

    3.05 - 40 FORM 6248 First Edition


    CRANKCASE DISASSEMBLY

    -----
    --

    WEIGHT CLASSIFICAnON
    "A", "S"', OR "c"

    Figure 3.05-44. Keep Connecting Rod Caps And Blades Properly Mated

    6. Verify that the two oil holes in the shell match up with B. Locate the number 'I" stamped in the connecting
    the supply holes in the rod bearing bore. rod cap. Hand tighten a capscrew in this hole
    first. Hand tighten the remaining capscrews in

    IL.
    A CAUTION Ilf the bearing shells fit
    positions 2 thru 4 (see Figure 3.05-45).
    • .::
    . =;....'-.....;'-_"'----'.
    . loosely in the rod bear-
    ing bore, poor heat transfer will result in excessive
    temperatures that shorten bearing service life. A
    spun bearing may damage the crankshaft journal. 1

    7. Verify that the bearing shells fit tightly in the bearing


    bore. 11
    A WARNING
    Both the connecting rod blades and caps are
    punched to Identify their location in the engine. For A
    example, 12 cylinder rods are stamped 1R, 1L, 2R, 2L,
    etc. The blade and cap also have mating numbers. Do
    not crossmate connecting rod blades and caps.
    Disregarding this Information could result in severe -
    ][
    personal Injury or death.

    8. Install the connecting rod caps. Verify that the rod


    blade and cap are marked with the same number (see
    "- RODCAP

    Figure 3.05-44). , \

    9. Torque the four connecting rod capscrews in the


    proper numerical sequence, as follows:

    A. Lubricate the threads and under the heads offour


    ferry head connecting rod capscrews with SAE Figure 3.05-45. Connecting Rod Cap Capscrew
    30 engine oil. TIghtening Sequence - Roll Pin Equipped

    FORM 6248 First Ed~ion 3.05 - 41


    CRANKCASE DISASSEMBLY

    C. Following the same numerical sequence, torque CYLINDER SLEEVE


    the capscrews to 50",(, of the total torque value.
    CYLINDER SLEEVE DISASSEMBLY
    D. Repeating the torque sequence, torque the
    capscrews to a final torque value of 180 - 190
    ft-Ib (244 - 257 N·m). A WARNING
    10. Use an inside micrometer to measure the inside Cylinder sleeve weighs approximately 63 Ibs. (28 kg).
    diameter of the connecting rod bearing bore. Use a suitable lifting device and exercise caution
    during removal or installation to prevent severe
    11. Use an outside micrometer to measure the outside personal injury or death.
    diameter of the crankshaft connecting rod journal.
    1. Remove the lower, middle and upper O-rings from
    12. Subtract the results of Step 11 from those of Step
    the cylinder sleeve (see Figure 3.05-46).
    10 to find the connecting rod bearing running clearance.
    If the clearance exceeds specification, then the rod
    must be replaced.
    INCHES MILLIMETERS
    8-1/2 Inch Bore
    L5108. L5790 0.0042 - 0.0081 0.10668 - 0.20574
    9-3/8 Inch Bore
    L7042 0.0042 - 0.0081 0.10668 - 0.20574

    13. Remove the caps from the connecting rods.

    14. Cover the connecting rods and caps with a clean


    plastic sheet to protect them from dust and dirt.

    CONNECTING ROD BEARING RUNNING CLEAR-


    ANCE MEASUREMENT WITH PLASTIGAGE®
    Plastigage® provides an easy and accurate way to check
    rod bearing running clearances. Plastigage® is a special
    plastic thread with ex1remely accurate crush properties.

    1. Remove the connecting rod cap. Wipe all oil from the
    bearing shell and crankshaft journal, if necessary.

    2. Place a string of Plastigage® across the full width of


    the bearing shell (parallel to the crankshaft) about 1/4
    inch off the centerline.

    3. Install the rod cap. Tighten the connecting rod


    capscrews to the specified torque.

    4. Remove the bearing cap without rotating the crank- Figure 3.05-46. Cylinder Sleeve
    shaft. The flattened Plastigage® will be found adhering
    to the rod bearing shell or the crankshaft journal.
    CAUTION I~o
    I A=:-..;=....:..:::.....::....:...;:;...;:..:..J.
    Not use a cylinder
    5. Compare the width of the Plastigage® strip with the .L .::
    .. sleeve gasket with
    graduated scale on the envelope. The scale indicates PiN 205130L sleeve. Using the sleeve gasket will
    the bearing running clearance in thousandths of an inch cause the sleeve to project too far above the
    (or millimeters). crankcase deck for proper head gasket sealing,
    causing severe engine damage.
    NOTE: Measure both ends of the Plastigage® strip. If
    the bearing bore or crankshaft journal is tapered, then 2. On 9-3/8 inch bore models, remove and discard the
    one end of the flattened Plastigage® strip will be wider cylinder sleeve gasket from the cylinder sleeve. Cylinder )
    than the other. sleeve gaskets are NOT used with the PIN 205130L
    cylinder sleeve.
    6. Remove the Plastigage® material from the engine
    and discard.
    3.05 - 42 FORM 6248 First Edition
    CRANKCASE DISASSEMBLY

    CYLINDER SLEEVE CLEANING AND INSPECTION 6. Wipe the test area clean if cracks are not found.
    Thoroughly wash the sleeve to remove any traces of
    Cylinder Sleeve Cleaning dye penetrant.
    1. Thoroughly clean the cylinder sleeve.
    Cylinder Sleeve Cleaning

    A WARNING 1. Inspect the cylinder sleeve bore for defects or


    damage in the ring travel area. Replace sleeves that are
    Compressed air can pierce the skin and cause severely scored, scuffed or scratched.
    severe personal injury or death. Never use your
    hand to check for leaks or to determine air flow 2. Inspect the outside surfaces of the cylinder sleeve
    rates. Wear safety glasses to shield your eyes from for corrosion and cavitation damage. Pay particular
    flying dirt and debris. attention to the upper sleeve flange and lower sleeve
    seal areas. Replace sleeves that are severely pitted.
    2. Hot rinse the sleeves and dry with moisture free
    NOTE: The cylinder sleeves of 9-3/8 inch bore engines
    compressed air.
    are chrome plated to better withstand corrosion and
    Cylinder Sleeve MagnafluX® Application cavitation erosion.

    3. Using an inside micrometer or dial bore gauge,


    A WARNING check for excessive sleeve bore wear and taper (see
    Table 3.05-14 and Table 3.05-15).
    Always carefully read the manufacturer's instruc-
    tions to avoid severe personal injury or death.

    Using the Magnaflux® Dye Penetrant Test Kit (Tool


    IA
    ...
    CAUTION I Waukesha assumes ab-
    solutely no liability for
    PIN 494283), inspect the sleeves for surface cracks. any damage that may occur through the reuse of
    Pay particular attention to the area in or around the three engine parts falling within published wear limit
    sleeve seal grooves and beneath the upper sleeve guidelines. Reuse of engine parts that do not meet
    flange. the new part specifications listed In the Fits and
    Clearances section of this manual are the sole
    1. To remove oily residues, apply the Magnaflux® responsibility of the user. Under no circumstances
    Spotcheck® Cleaner/Remover (SKC-S) directly to the is the reuse of any part exceeding the published
    test area. Thoroughly wipe the area with a clean cloth. wear limits justified.
    Repeat the procedure as necessary. Final wiping
    should result in a clean cloth. Allow the test area to dry.
    NOTE: Wear rubber gloves to avoid hard-to-remove IA
    ...
    CAUTION I Use the published wear
    limits With discretion. Al-
    stains on hands.
    though Waukesha recognizes that many used parts
    2. Spray the test area with the Magnaflux® are suitable for continued service, there is almost
    Spotcheck® Penetrant (SKL-SP). Wait 1 to 30 minutes. always a corresponding reduction in performance.
    Carefully consider the following Items before reus-
    3. Spray the Magnaflux® Spotcheck® Cleaner/Remov- Ing any particular part: (a.)The number of mating
    er (SKC-S) on a clean cloth (not on the test area). parts being reused. (b.) The extent of the repair
    Wiping in one direction, remove all surface penetrant. relative to the expected service life prior to the next
    Repeat as necessary. major overhaul. (c.) The engine application, such as
    horsepower requirement, maintenance Intervals
    4. Spray the test area with the Magnaflux®
    and type of Installation. (d.) The problems that may
    Spotcheck® Developer (SKD-S2). Apply a thin even
    occur through reuse.
    film. Allow the film to dry completely. The proper
    application dries to an even white layer.

    5. Carefully inspect the test area for cracks. A bright


    I~
    A CAUTION I Maximum sleeve wear
    occurs at the very top of
    colored solid or dotted line marks a crack. Fine cracks top ring travel. Minimum wear occurs below ring
    may take up to 15 minutes to appear. Large cracks can travel. Failure to measure the sleeve diameter at
    be seen almost immediately. If the crack is wide and these points may result In a faulty decision regard-
    deep, the indication will grow and spread. ing the suitability of the sleeve for continued use.

    FORM 6248 First Edition 3.05 - 43


    CRANKCASE DISASSEMBLY

    4. At the top of the piston ring travel area Oust below the
    cylinder ridge), measure the cylinder sleeve diameter at
    two locations-parallel and perpendicular to the crank-
    shaft. Mark the readings on the outside of the cylinder
    sleeve for reference purposes.

    5. Repeat the procedure below the piston ring travel


    area at the bottom of the bore.

    6. Refer to Table 3.05-14 and Table 3.05-15 for the


    new part tolerances ofthe cylinder sleeve bore. Discard
    the cylinder sleeve if any single measurement is not
    within allowable limits.

    I.A. CAUTION IInCheck piston clearance


    the sleeve in which the
    piston will run. Disregarding this information could
    result in product damage and/or personal injury.

    7. Measure the piston skirtto cylinder sleeve clearance


    (see Piston, Measuring for Wear).

    3.05 -44 FORM 6248 First Edition


    CRANKCASE DISASSEMBLY

    Table 3.05-14. Cylinder Sleeve (Used With Four Ring Pistons Only) - Gas

    j.1'--- D ---..-I

    C
    F

    " 0.020 - 0.030 CYLINDER SLEEVE


    GASKET USED ON
    9-318 BORE PIN 205130C AND
    205130H CYLINDER SLEEVES
    ONLY

    MEASUREMENT INCHES METRIC (mm)


    Sleeve type: Wet type, replaceable
    (A) Heat dam projection 0.045 - 0.049 1.143 -1.245
    (B) Flange height
    (current 8-1/2 in. bore sleeve used without cylinder sleeve gasket) 0.5635 - 0.5655 14.313 - 14.364

    Flange height
    (sleeve used with cylinder sleeve gasket*, 9-3/8 inch bore engines) 0.5345 - 0.5365 13.576 - 13.627

    (C) Sleeve projection ebove crankcase (current 8-1/2 In. bore engines) 0.0010 - 0.0055 0.025 - 0.1397
    SleE,W8 projection above crankcase (with cylinder sleeve gasket* - 9-3/8 in. bore
    engines) 0.000 - 0.007 0.000 - 0.178

    (D) Flange 00: l5108 and l5790 10.188 -10.190 258.775 - 256.826
    Flange 00: L7042 10.611 - 10.616 269.519 - 269.646
    (E) Sleeve 00 (below flange) l5108 and l5790 9-11/16 246.050
    Sleeve 00 (below flange) L7042 10-1/4 260.35
    (F) Sleeve length 18-5/8 473.075
    (G) Sleeve 10: l5108 and l5790 8.5003 - 8.5013 215.908 - 215.933
    Sleeve 10: L7042 9.3753 - 9.3763 238.133 - 238.158
    (H) Sleeve 00 lower seal area: l5108 and l5790 9.673 - 9.677 245.694 - 245.796
    Sleeve 00 lower seal area: L7042 10.240 - 10.245 260.096 - 260.223
    Sleeve 10 out of round limits 0.001 0.025
    Sleeve seal area to crankcase clearance on a side 8-1/2 inch bore 0.0005 - 0.0035 0.013 - 0.089
    Sleeve seal area to crankcase clearance on a side 9-3/8 inch bore 0.0005 - 0.0040 0.013 - 0.102
    NOTE: Cylinder sleeve gasket PIN 176375D is used on 9-3/8 inch bore PIN 205130C and 205130H cylinder liners only. For use of standard or
    oversize cylinder sleeve gaskets refer to Chapter 3.

    FORM 6248 First Edition 3.05-45


    CRANKCASE DISASSEMBLY

    Table 3.05-15. PIN 205130L Cylinder Sleeve (Sleeve Used On GL 9-3/8 Inch Bore" Only) - Gas
    )
    I~'---- 0 ----I

    it!c

    CAUTION Cylinder sleeve


    F L..:="--'_-:-:-:----'-::--:-' gasket should NOT
    be used with this cylinder sleeve.

    MEASUREMENT INCHES METRIC (mm) )


    Sleeve type: Wei type, replaceable
    (A) Heat dam projeclion 0.045 - 0.049 1.143 -1.245
    (B) Flange heighl 0.5635 - 0.5655 14.313 - 14.364
    (C) Sleeve projection above crankcase 0.0010 - 0.0060 0.0254 - 0.1524
    (0) Flange OD: 7042GL 10.611 - 10.616 269.519 - 269.646
    (E) Sleeve OD (below flange) 7042GL 10.300 - 10.305 261.620 - 261.747
    (F) Sleeve lenglh 18.625 473.075
    (G) Sleeve ID: 7042GL 9.3753 - 9.3763 238.133 - 238.156
    (H) Sleeve OD lower seal area: 7042GL 10.240 - 10.245 260.096 - 260.223
    Sleeve ID out of round limns (Installed in crankcase) 0.002 0.0508
    Sleeve seal area to crankcase clearance 0.0005 - 0.0040 0.0127 - 0.1016
    NOTE: ·Preferred application, used wah three ring pistons. Acceptable application, used with four ring piston.

    3.05- 46 FORM 6248 Firsl Ednion


    CRANKCASE DISASSEMBLY

    CYLINDER SLEEVE DEGLAZING 6. Thoroughly wash the cylinder sleeve bore with liquid
    dishwashing soap and warm water to remove all
    CAUTION I~yllnder
    I~"A=~=:..:.=.:..:;.;:;..:.;:.J. sleeve honing abrasive particles and residual grit. Continue cleaning
    until a clean cloth shows no evidence of dirt or debris.
    L. . . IS not recommended as a
    sleeve reconditioning method. Disregarding this
    information could result in product damage and/or
    personal injury.
    Deglaze the cylinder sleeve bore. Deglazing removes
    wear patterns, minor scuff marks and scratches without
    enlarging the sleeve bore diameter.
    1. Lightly swab the sleeve bore with a cloth dipped in
    clean engine oil.

    CAUTION I A uni-directional hon~ng


    I~A=~=:..:.=.:..:;.;:;..:.;:.J.
    L. . . pattern does not provide
    optimum lubrication and may result in severe
    piston scuffing.
    2. Use a flexible ball-type deglazing tool (see
    Figure 3.05-47), (8-1/2 inch bore - Tool PIN 494236;
    9-3/8 inch bore - Tool PIN 494234). The bristle tip or
    finishing stone arrangement (180 to 250 grit) is able to
    produce a 60 degree cross hatch pattern (see
    Figure 3.05-48). The angular cross hatch pattern ensur-
    es an even flow of oil onto the cylinder walls and
    promotes longer sleeve, piston and ring life.

    i;22222221

    Figure 3.05-47. Flexible Hone

    3. Install the deglazing tool in a slow-speed drill. The


    speed at which the tool rotates determines the speed at Figure 3.05-48. Cylinder Sleeve Deglazing Cross
    Hatch Pattern
    which it must be stroked up and down the bore to
    produce the desired cross hatch pattern.

    4. Move the deglazing tool up and down the entire


    length of the sleeve bore for IOta 12 complete strokes.
    A WARNING
    Compressed air can pierce the skin and cause
    NOTE: Make the transition between the naturally worn severe personal Injury or death. Never use your
    surface and the area cut with the ridge reamer as hand to check for leaks or to determine air flow
    smooth as possible. rates. Wear safety glasses to shield your eyes from
    flying dirt and debris.
    5. Stop to examine the sleeve bore and/or take
    measurements. A precise cross hatch pattern in the 7. Hot rinse the sleeve and dry with moisture free
    piston travel area is the most important. compressed air.

    I.A. CAUTION IabraSive


    Failure to remove all
    particles may
    8. Oil the inside olthe cylinder sleeve with a light coat of
    clean engine oiL
    result in premature sleeve, piston and ring wear and 9. Cover the cylinder sleeves with a clean plastic sheet
    possible engine failure. to protect them from dust and dirt.

    FORM 6248 First Edition 3.05-47


    CRANKCASE DISASSEMBLY

    FLYWHEEL 3. Clean the outer circumference of the flywheel to be


    certain the new ring gear will seat properly. Dress down )
    RING GEAR REMOVAL any burrs or raised spots.

    A WARNING RING GEAR INSTALLATION

    1. Position the flywheel on a flat surface.


    Always wear protective equipment when installing
    or removing components with an interference fit.
    Installation or removal of interference components
    may cause flying debris. Failure to use protective
    A WARNING
    equipment may result in severe personal injury or Always wear protective equipment when Installing or
    death. removing components with an interference fII. Instal-
    lation or removal of interference components may

    IA..
    CAUTION I Do not try to pry or tap
    the rmg gear from the
    cause flying debris. Failure to use protective equip-
    ment may result in severe personal injury or death.

    flywheel. The shrink fit holds the ring gear with


    sufficient bond that damage to the gear will result if
    these methods are used.
    A WARNING
    Heated components can cause severe bums. Do
    not handle heated paris with bare hands. Failure to
    A CAUTION I
    I~"!!:!!!!!""":=:"':':::""::"":'=:....:..J.
    L.
    When cutting the ring
    gear from the flywheel,
    use protective equipment may result in severe
    personal injury or death.
    use caution to avoid damage to the flywheel.
    NOTE: If the shop oven is not large enough, a torch
    1. Using a hacksaw, cut into the ring gear between two may be used to heat the ring gear. If the torch is used,
    teeth (see Figure 3.05·49). Use caution to avoid cutting make sure to heat the ring gear evenly to insure the ring
    into the flywheel. gear will not bind during installation.
    )
    2. Heat the new ring gear to approximately 350' F
    (176' C).

    3. Install the ring gear evenly on the flywheel. Once


    cooled, the flywheel ring gear will be held to the flywheel
    by the shrink fit.

    4. Check flywheel balance. Balance must be within


    4 inch-ounces (0.028 N·m). Any metal removed must
    be removed from the outer rim.

    BLOCKS

    Figure 3.05-49. Flywheel Ring Gear

    2. After a cut is established, wedge a cold chisel into it


    and tap the chisel until the ring gear slits open.
    )

    3.05 - 48 FORM 6248 First Ed~ion


    CHAPTER 4 - ENGINE ASSEMBLY

    CONTENTS

    SECTION 4.00 - CRANKCASE ASSEMBLY

    SECTION 4.05 - CYLINDER HEAD ASSEMBLY

    SECTION 4.10 - VALVE ADJUSTMENT AND WEB DEFLECTION

    FORM 6248 First Edition


    )

    FORM 6248 First Edition


    SECTION 4.00 - CRANKCASE ASSEMBLY

    CRANKCASE ASSEMBLY while the case is still hot. The spindles are more difficult
    to install after the block has cooled.
    A WARNING 2. Slide the washer onto the threaded end of each idler
    gear spindle.
    The bare engine crankcase may weigh as much as
    4965Ibs. (2252 Kg). Use a suitable lifting device and 3. Apply a small amount of Loctite® 271 Adhesive
    exercise caution during removal or installation to Sealant (High Strength) on the threads of the spindle.
    avoid severe personal Injury or death.
    4. Install the idler gear spindle nut (see Figure 4.00-1).

    A WARNING
    Turn the reverse threaded nut counter-clockwise to
    tighten.
    Always lift the engine using the approved lifting
    eyes. The 12 CylinderVHP engine is equipped with
    two pairs of lifting eyes, one pair at the front, the
    other pair at the rear. Lifting eyes are meant for
    lifting the engine only. They must not be used to 11ft
    driven or auxiliary equipment that may be attached
    to the engine. Follow approved rigging proce-
    dures. Always use the proper spreader bar to
    ensure that no undue strain is placed on the lifting
    eyes and hoisting chains. Disregarding this in-
    formation could result in severe personal injury or
    death.

    A WARNING
    Neverraise the crankcase more than an inch or two Figure 4.00-1. Crankcase - Inside Front
    off the floor (except to remove it from the hot tank,
    install it In the rollover stand or position it on the 011 5. Torque the idler gear spindle nlill to 775 - 780 ft-Ib
    pan). While the block is suspended, do not put (1051 - 1058 N·m).
    hands, arms, feet or any other body parts beneath
    it. Stand back as far as possible and exercise OIL TUBE INSTALLATION
    extreme caution. Disregarding this information
    could result in severe personal injury or death. A
    I.....
    CAUTION Ilfthe~lotintheo~l.spray
    ;:=.__----'_...:.."----'. tube IS not positioned
    correctly, or If the Internal oil passage is ob-
    A WARNING structed, Insufficient lubrication of the gear train
    will result in premature wear and gear failure.
    The engine crankcase depicted In the accompany-
    ing photographs is mounted in a rollover stand. A 1. Verify thatthe oil passage within the oil tubes are free
    rollover stand is necessary to ensure maximum of dirt, grit or other obstructions (see Figure 4.00-2).
    safety and ease of assembly. Tipping or flipping the Replace the tubes if bent or damaged.
    engine block using dual chains and lifting devices
    is a tricky and extremely dangerous maneuver that
    INTERNAL OIL PASSAGE~
    is not recommended. Disregarding this informa-
    tion could result in severe personal injury or death.

    IDLER GEAR SPINDLE INSTALLATION


    NOTE: Install idler gears prior to installation of the
    LiF~========---~~1-
    ,
    crankshaft. SLOT

    1. Install the two idler gear spindles, if removed (see Figure 4.00-2. Gear Train 011 Spray Tube
    Figure 4.00-1). Using a rubber mallet, drive the shafts
    into the spindle bores until their collars are seated
    solidly against the front face of the engine block. For
    best results, install the spindles at the hot tank area

    FORM 6248 FirS! Edition 4.00 -1


    CRANKCASE ASSEMBLY

    IA..
    CAUTION I Do not use Loctite® on
    the threads of the oil )
    spray nozzles. Loctite® or any similar substance
    may obstruct the oil passage and deprive the gear
    train of proper lubrication. Disregarding this In- =
    formation could result in product damage and/or /NEWSTYLE
    personal injury.

    2. Refer to the matchmarks and install the two oil tubes


    on each side of the camshaft idler gear spindle (see
    Figure 4.00-3). Thread the tubes into the block until
    snug. Position each tube so that the center of the slot
    points toward the center of the crank bore.

    == STRAIGHT
    THREADS

    Figure 4.00-4. Main Bearing Cap Studs -


    Old And New Styles )
    1. Check all main bearing cap studs (28) for nicks,
    cracks, burrs, galled or stretched threads and other
    obvious damage. Replace as necessary.
    Figure 4.00-3. 011 Tubes
    2. Apply Loctite® 271 Adhesive Sealant (High
    MAIN BEARING STUD INSTALLATION Strength) into the two stud holes on each side of the
    New and improved studs (better retention) are currently seven main bearing saddles (see Figure 4.00-5).
    being installed in VHP production engines. The new
    stud uses straight threads with a 31/32 inch lead (see
    Figure 4.004). Do not intermix old and new style studs
    on the same engine.

    )
    Figure 4.00-5. Main Bearing Cap Studs

    4.00 - 2 FORM 6248 First Ednion


    CRANKCASE ASSEMBLY

    A CAUTION I~o
    I-="=-=:.:...=:...:;...:...;::;..;;..~.lng
    L.
    not install main bear-
    studs with a pipe
    wrench or similar device, since these devices may
    scratch or gouge the studs, causing weak points.
    Use a collet type stud driver that grips the 00 ofthe
    threads without causing damage, to properly
    Install the main bearing studs. Disregarding this
    information could result in product damage and/or
    personal injury.

    3. Using a collet type stud driver, turn each main


    bearing cap stud until the lead bottoms out in the bore.

    4. Torque the studs to 50 ft-Ib (68 N·m).

    DOWEL INSTALLATION
    1. Inspect the dowel pins on the cylinder head deck (24). Figure 4.00-6. Waler Header/Oil OuUel Plugs -
    Replace if damaged or missing. Rear Left

    2. Inspect the dowel pins on each side of the cam


    Oil Header - Right Bank
    bearing saddle (14). Replace, if damaged or missing.
    1. Apply Loctite® 271 Adhesive Sealant (High
    3. Inspect the dowel pins on the inside deck ofthe main Strength) to the threads of two 1-1/4 inch NPT
    bearing saddle (7). Replace if damaged or missing. countersunk headless pipe plugs..>
    .......
    '-,-
    WATER HEADER PLUG INSTALLATION 2. Install the plugs where the right I:IIJnk main oil tleader
    1. Apply Loctite® 271 Adhesive Sealant (High opens at the front and rear cie the block (see
    Strength) to the threads of two 1·1/2 inch NPT square Figure 4.00·7) Torque the plugs to 453 ft·lb (316 N·m).
    .. ' .
    head pipe plugs. Install the plugs where the right and left
    bank water headers open at the rear of the block (see
    Figure 4.00-6). Torque the plugs to 50 ft-Ib (68 N·m).

    2. Apply Loctite® 271 Adhesive Sealant (High


    Strength) to the threads of twelve 1-1/2 inch NPT
    countersunk headless pipe plugs. Install the plugs in the
    right and left bank water headers (see Figure 4.00-6).
    Torque the plugs to 50 ft·lb (68 N·m).

    3. Apply Perma Lok® Heavy Duty Pipe Sealant with


    Teflon® to the threads of four 3/4 inch NPT countersunk
    headless pipe plugs. Install the plugs in the drain holes
    just below the water header on both the right and left
    bank sides (front and rear) (see Figure 4.oo-6). Torque
    the plugs to 50 ft·lb (68 N·m).

    Figure 4.00·7. Oil Outlet Plugs - Rear Righi View

    IA
    ..
    CAUTION I The oil header plugs
    must be Installed so that
    they are recessed 0.015 to 0.062 Inches
    (0.38 to 1.58 mm) below the machined surface ofthe
    crankcase, to prevent Interference with the fly·
    wheel. Failure to properly install these plugs may
    cause damage to equipment.

    FORM 6248 First Edition 4.00 - 3


    CRANKCASE ASSEMBLY

    3. Verify that the oil header plugs are 6. Apply Loctite® 271 Adhesive Sealant (High
    0.015 to 0.062 inches (0.38 to 1.58 mm) below the Strength) to the threads of three 3/4 inch NPT square )
    machined surface of the block. head pipe plugs. Install the plugs in the remaining ports
    of the right bank main oil header (ports 1, 4 and 5).
    I.A. CAUTION IThe rear face of the
    crankcase Is machined
    Torque the plugs to 50 ft-Ib (68 N·m).

    7. Apply Loctite® Removable Threadlocker 242 to the


    to mate with the front flywheel housing. Traces of
    threads of a single 1/4 inch NPT hex head pipe plug.
    Loctite® left on the machined surface may result In
    Install the plug adjacent to the farthest rearward square
    a rear flywheel housing face runout that exceeds
    head in the right bank main oil header (see
    specification. Traces of Loctlte® left on the ma-
    Figure 4.00-8). Torque the plug to 50 ft-Ib (68 N·m).
    chined surface at the front of the crankcase may
    result in 011 leakage from beneath the rear gear Oil Outlet Ports - Left Bank
    housing. Disregarding this information could re-
    sult In product damage and/or personal Injury. 1. Apply Loctite® 271 Adhesive Sealant (High
    Strength) to the threads of a 3/4 inch NPT square head
    4. Remove all traces of Loctite® from the machined pipe plug. Install the plug in the rear oil outlet port on the
    surfaces at the front and rear of the block. left bank side olthe engine (atthe level olthe right bank
    main oil header) (see Figure 4.00-6). Torque the plug to
    5. Install five 3/4 inch NPT square head pipe plugs in 50 ft-Ib (68 N·m).
    the right bank main oil header (from front to rear, ports 2,
    3, 6, 7 and 8) (see Figure 4.00-8). These plugs will be 2. Install a 3/4 inch NPT square head pipe plug in the
    removed for connection of external oil supply lines. front oil outlet port. This plug will be removed for
    connection of an external oil supply line.

    PORTS: II • • ONLY
    LOCnTE® 3/4" NPT SQUARE HEADS

    PORTS: ®@ <DC?> 18
    FINGER TIGHTEN 3/4" NPT SQUARE HEADS

    Figure 4.00-8. 3/4' NPT 011 Header Pipe Plugs

    4.00 - 4 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    LUBE OIL STRAINER ADAPTER INSTALLATION 4. Place masking tape over the adapter opening to
    keep out dust and dirt while the engine is being
    CAUTION I
    I.=A=~=..;;.;;:;...;;-=-;:;..;~.
    Deposits left on gasket assembled.
    L. . surfaces will cause
    LOWER VALVE LIFTER HOUSING COVER
    leaks. Verify that the gasket and gasket mating
    surfaces are clean and completely free of grease INSTALLATION

    CAUTION I
    and 011. Disregarding this information could result
    in product damage.
    I-=.A=~=..:.;::;....;-=-;:;..;~.
    L. .
    Deposits left on gasket
    surfaces will cause
    1. Locate the 2 inch diameter hole in the rear right side leaks. Verify that all gaskets and gasket mating
    of the main oil header (see Figure 4.00-9). surfaces are clean and completely free of grease
    and oil. Disregarding this information could result
    in product damage.

    1. Apply 3M Scotch Grip ~ Rubber and Gasket Adhe-


    sive 847 to the rear portion of the block that mates with
    the camshaft cover plate (see Figure 4.00-11).

    Figure 4.00-9. Crankcase - Main 011 Header -


    Rear Right

    2. Slide the fasteners through the flange holes in the


    lube oil strainer adapter (4 capscrews, 1/2 x 1-1/2
    inches, with lock washers). Install a new gasket on the
    capscrews.
    Figure 4.00-11. Lower Valve Lifter Housing Cover
    3. With the strainer adapter pointing upward (see
    Figure 4.00-10), fasten the flange to the block. 2. Place a new gasket on the contact cement. Gently
    push down on the gasket to verify that it is properly
    seated.

    3. Install the camshaft cover plate (4 capscrews, 3/8 x


    3/4 inch and lock washers).

    Figure 4.00-10. Lube 011 Strainer Adapter

    FORM 6248 First Edition 4.00 - 5


    CRANKCASE ASSEMBLY

    VALVE LIFTER HOUSING GASKET 5. Apply Permatex® Aviation Form-A-Gasket Sealant


    INSTALLATION to the exposed side of the entire rear section olthe valve )
    lifter housing gasket (see Figure 4.00-14). Apply Avi-
    A. CAUTION I
    I,:-.="=:=~;:.......;....;,"---:,:-,,-~:-,-:,.
    Deposits left .on gasket
    surfaces will cause
    leaks. Disregarding this information could result in
    ation Form-A-Gasket Sealanttothose areas where the
    four dovetails interlock.

    product damage.
    1. Verify that all gaskets and gasket mating surfaces
    are clean and completely free of grease and oil.

    2. Apply 3M Scotch Grip~ Rubber and Gasket Adhe-


    sive 847 to the area of the block around the camshaft
    recess (that mates with the bottom flange of the valve
    lifter housing) (see Figure 4.00-12).

    Figure 4.00-14. Valve Lifter Housing Gasket - Rear

    CAMSHAFT AND BEARING INSTALLATION

    A WARNING
    Compressed air can pierce the skin and cause
    Figure 4.00-12. Crankcase - Top Rear severe personal injury. Never use your hand to
    3. Carefully place the gasket strips on the contact check for leaks or to determine air flow rates. Wear
    cement. The gasket is made up of five separate pieces safety glasses to shield your eyes from flying dirt
    (two sets of side gaskets and one rear). Fit the and debris.
    dovetailed sections together to interlock the gasket
    strips. 1. Verify that the internal lube oil passages leading from
    the main oil header to the cam bearing saddles are
    4. Remove the excess gasket material that overlaps completely free of dirt, grit and other accumulations.
    the block at the front of the engine, (see Check the oil passage in the cam bearing caps for
    Figure 4.00-13). cleanliness. Visually inspect the passageways wherev-
    er possible or insert a piece of drill welding rod to feel for
    obstructions. Use compressed air to blowout all dirt and
    debris.

    I A.
    ..
    CAUTION I The cam bearing
    saddles and caps must
    be completely free of oil, dirt or other foreign
    material. Any dirt or debris caught between the
    bearing shell and cam bore can result in bearing
    distortion and reduced service life.

    Figure 4.00-13. Valve Lifter Housing Gasket - Front

    4.00 - 6 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    2. Thoroughly clean the cam bearing saddles (see 7. Obtain a set of new cam bearings.
    Figure 4.00-15) and caps. Inspect the bearing running
    surfaces for burrs, nicks, minor scuff marks or scratches.
    Use compressed air to blow away all dust and debris.
    IA
    ...
    CAUTION I Do not touch the cam
    bearing running surface.
    Acidic skin secretions can promote the start of
    surface corrosion and wear.

    8. Wipe the cam bearing shells clean. Inspect the


    bearing surfaces for burrs, nicks, minor scuff marks or
    scratches. Use compressed air to blow away all dust
    and debriS.

    9. Locate the two front cam bearing shells. An oil


    groove distinguishes the front cam bearing shells from
    the others (see Figure 4.00-17). The twelve intermedi-
    ate, center and rear cam bearing shells are ungrooved
    Figure 4.00-15. Camshaft Bearing Saddles
    and about 1/2 inch thinner.

    3. Verify thatthe roll pins in the front and rear face ofthe
    front cam bearing cap are clean and straight. r-- 2-5/16" ---1
    OIL
    r- 14"-I
    13
    -

    4. Remove and discard the pins if bent or damaged. I I GROOVE

    1..
    • .::
    ...
    CAUTION I~f
    I A=:......::=...:..::.....::...:...=-..::...:..J.
    installed incorrect!y,
    mternal stress may dIS-
    tort or damage the roll pins, resulting in dislocation
    ~ ~;'
    L-----IHOLE~ .
    of the thrust ring. Disregarding this information
    could rasult in product damage. .• 0
    ~ ".,-
    5. Verify that the pin holes in the front and rear face of the
    front cam bearing cap are completely free of dirt and gr~.
    ,·r:
    6. Install new roll pins with the split opposite the bearing

    -- --
    seat (see Figure 4.00-16). Measure the length of each
    pin to verify that it protrudes 0.125 inch (±0.015 inch) ::I ::I
    from the face of the cam cap. LOCATING TANG
    FRONT INTERMEDIATE
    SPLIT OF ROLL PINS (2) TO BE (UPPER & LOWER) REAR
    ASSEMBLED AS SHOWN (UPPER & LOWER)

    Figure 4.00-17. Cam Bearings

    1O. Position one of the fully grooved Shells above the


    bearing seat of the front cam saddle. The two halves of
    the front cam bearing are interchangeable.

    11. Position the narrow, ungrooved shells above the six


    remaining cam bearing saddles. The intermediate,
    o center and rear cam bearings shells (both upper and

    UJ •125" ± .015" BOTH SIDES


    lower) are also interchangeable.

    12. Verify that the locating tang on the parting edge of


    each shell (opposite the bearing running surface) is
    directly above the notch machined on the inSide edge of
    the bearing saddle .

    13. Apply even pressure to the parting edges of each


    Figure 4.oo-16.ln81811 Roll Pins In Front Cam Bearing bearing shell to snap it into place.
    Cap

    FORM 6248 First Edition 4.00 -7


    CRANKCASE ASSEMBLY

    A CAUTION I While ~oose fitting shells


    I-=.a=~=..:.;:::....:~;::..;~.
    L. are nOIsy, they also can
    NOTE: Install the wider fully grooved bearing in the
    front cam bearing cap (stamped with the number 1). )
    have an adverse affect on the bearing's ability to Instal/ the narrow ungrooved bearing shells in the
    transfer heat. Excessive temperatures shorten bear- intermediate, center and rear cam bearing caps
    ing service life and may lead to camshaft damage. (stamped with the numbers 2 through 7).

    14. Verify that the bearing shells fit tightly in the cam 19. Install the second half of the bearing shells in the
    bearing bore. cam bearing caps. The locating tang on the parting
    edge of each shell must fit squarely in the notch

    I.a
    A CAUTION I 011 starvation results In
    rapid bearing failure and
    machined on the inside edge of the cap .

    20. Verify that the bearing shells fit tightly in the cam
    possible damage to the cam journal. bearing caps.

    A CAUTION IOil starv~tlon


    15. Verify that the oil hole in each shell matches up with
    the supply hole in the center of the cam bearing bore. I-=.a=~;.:=.....;.;:::-::...:...::..:=-:..J.
    1:-.
    results in
    rapid fall u re of the af-
    16. Apply oil to the running surface of the lower cam fected valve lifter and possible damage to the cam
    bearing shells. Use a quality high viscosity oil. Evenly lobe.
    spread the oil up over the entire bearing surface. 21. Verify that the oil hole in each shell matches up with
    the exit hole in the center of the cam bearing cap.
    A WARNING 22. Apply a quality high viscosity oil to the upper cam
    The camshaft weighs approximately 115 pounds bearing shells. Evenly spread the oil up over the entire
    (52 Kg). Use a suitable lifting device and exercise bearing surface.
    caution during removal or installation to avoid
    severe personal injury or death. 23. Be sure that the dowels on the deck of the cam
    bearing saddles and the pin holes in the cam bearing
    17. While the camshaft is suspended, slide a new thrust caps are free of dirt and grit. )
    ring over the cam end. Move the ring down the shaft until

    -"-_"-_--'.I~onotml~orcrossmate
    A CAUTION
    I. . ==-__
    the flat side (with the oil grooves) is flush against the
    circular plate attached to the rear face of the front cam cam beanng caps. The
    bearing journal (see Figure 4.00-18). Rotate the ring so cam bearing saddles are precision align bored with
    that the notch on the outside edge faces upward. all cam bearing caps torqued in place. The caps are
    stamped 1 thru 7, for easy identification. Installing
    the caps in the wrong positions will result In cam
    bearing and/or camshaft failure.
    24. Install the cam bearing caps. The top of each cap is
    stamped to identify its location. Starting at the front of
    the engine and moving towards the rear, install cam
    bearing caps 1 through 7.

    Cam Bearing Cap location Numbers


    #1 - Front (Gear Train Side)
    #2 - Intermediate
    #3 - Intermediate
    #4 - Center
    Figure 4.00-18. Inside Camshaft Thrust Ring #5 - Intermediate
    18. Install the camshaft in the cam bearing bore. The #6 - Intermediate
    front of the camshaft is easily identified by the cam gear
    #7 - Rear (Flywheel Side)
    mount and the wider front bearing journal.
    Position each cap so that the dowel pin holes in the feet
    are aligned with the two dowels on the deck of the cam
    bearing saddle. The dowels are offset, so the caps can
    only be installed one way. If necessary, use a rubber
    mallet to ensure that the caps are fully seated.

    4.00 - 8 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    NOTE: Rotate the installed thrust ring, so that the notch 28. Slide a new thrust ring over the camshaft end, w~h
    on the outside edge fits over the roll pin centered on the the lipped side facing inward (see Figure 4.00-21).
    rear face of the front cam bearing cap. The lip on the inside Position the ring flush against the front face of the front
    diameter of the thrust ring seats in the groove where the cam bearing cap. Fit the notch on the outside edge of
    cam journal, shell and bearing bore converge. the thrust ring, over the roll pin centered on the face of
    the cap (see Figure 4.00-22). The lip on the inside
    25. Starting at the front of the engine (see diameter of the thrust ring, seats in the groove where
    Figure 4.00-19) and moving towards the rear, install the the cam journal, shell and bearing bore converge.
    capscrews in the cam bearing caps (16 capscrews, 3/8
    x 2-1/2 inches, w~h lock washers). Wrench tighten.

    UP~

    OIL GROOVE

    Figure 4.00-21. Camshaft T'hrust Ring

    Figure 4.00-19. Front Cam Bearing Cap

    26. Following the same sequence, torque the capscrews


    of each cam bearing cap to 22 - 24 Ib-ft (30 - 33 N·m).

    A CAUTION I
    I=..
    L..=~=..:.;:~~~~.
    Aged or missing O-rings
    may cause leakage and
    loss of pressure around the oil hole, resulting in
    insufficient lubrication of the affected valve lifter
    roller and possible damage to the cam lobe.

    27. Install new O-rings in the circular recess around


    the oil exit holes at the top ofthe cam bearing caps (see
    Figure 4.00-20).

    Figure 4.00-22. Outside Camshaft Thrust Ring

    Figure 4.00-20_ Cam Bearing Cap

    FORM 6248 First Edition 4.00 - 9


    CRANKCASE ASSEMBLY

    29. Move 8 shims (0.002 thickness each) down the 4. Aligning the holes in the gasket with those at the
    camshaft end until they contact the thrust ring (see back of the housing, assemble a new gasket on the
    Figure 4.00-23). Replace any shims that are missing, flange. The gasket is made up of five separate pieces
    torn or otherwise damaged. (two sets of side gaskets and one top). Fitthe dovetailed
    sections together to interlock the gasket strips (see
    Figure 4.00-25). If necessary, trim the dovetails to find
    the best fit.

    Figure 4.00-23. Shim Pack Figure 4.00-25. Gear Housing Flange

    GEAR HOUSING INSTALLATION 5. Remove the assembled gasket from the rear gear
    housing flange.
    A. CAUTION I Deposits I~ft on gasket
    I~"=:""";:;,,;;,,,;;,,;~;;,,,,;:,~,,-,-,_
    L. surfaces will cause leaks.
    Disregarding this information could result in prod-
    6. Apply 3M Scotch Grip Rubber and Gasket Adhe·
    N

    sive 847 to the rear gear housing cover flange. )


    uctdamage.
    7. Install the gasket on the flange. Gently pull each leg
    1. Verify that the mating flanges are completely ofthe gasket (on each side ofthe crankshaft recess), so
    smooth. Use a fine toothed pattern file to lightly dress that the material extends past the bottom edge of the
    down any burrs or high spots. cover approximately 1/32 inch (0.79 mm).
    2. Slide a new thrust washer down the cam shaft end 8. Push down on the gaskets to verify that the strips are
    until it contacts the shim pack (see Figure 4.00-24). properly seated. Using a ball peen hammer, lightly tap
    Install the thrust washer with the small inside bevel (and the dovetails to flatten the tabs, if necessary.
    smooth machined surface) facing inward.
    9. Apply Permatex® Aviation Form-A-Gasket Sealant
    to those four areas where the dovetails interlock (see
    Figure 4.00-26).

    Figure 4.00-24. Thrust Washer

    3. Verify that all gaskets and gasket mating surfaces


    are clean and free of grease and oil. Figure 4.00-26. Rear Gear Housing Flange

    4.00 - 10 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    10. Inspect the dowel pins on the frontface ofthe block CAMSHAFT END PLAY MEASUREMENT
    (2). Replace the dowels if damaged or missing.
    NOTE: Fabricate a sleeve to simulate a cam gear, for
    11. Be sure that the dowels and the pin holes in the rear measuring cam gear end play.
    gear housing are free of dirt and grit.
    1. To measure the lateral movement of the camshaft,
    A WARNING install a pin in the bo~ hole in front of the camshaft cover
    plate. Mount a dial indicator to the pin. Position the
    The rear gear housing weighs approximately 140 Ibs. indicator button against the face of the rear cam journal
    (64 Kg). Use a suitable lifting device and exercise (see Figure 4.00-28).
    caution during removal or installation to avoid severe
    personal injury or death.
    12. Install the rear gear housing on the dowel pins.
    13. Holding the rear gear housing in position, tighten the
    two capscrews in the botIom comers of the block, one on
    each side of the crankshaft recess (1/2 x 1-1/2 inches,
    with lock washers).
    14. Remove the lifting strap.
    15. Install the remaining fasteners in the rear gear
    housing (14 capscrews, 1/2 x 1-1/2 inches, with lock
    washers). Wrench tighten.

    A CAUTION Ilf the r~ar gear housing


    IL.=.a=---::..:.....:..;;"--"...:....:;:....;'-"-I. gasket IS left uncut, the
    excess material will dig into the oil pan seal.
    Figure 4.00-28. Measuring Camthaft End Play
    Damage to the oil pan seal will result in oil leakage. -:;:~

    16. Using a sharp knife or razor, carefully cut the rear 2. Install the sleeve and cam gear nut on the camshaft.
    gear housing gasket, so that the legs (on each side of the
    3. Holding the camshaft in the_~jarthest rearward
    crankshaft reoess) are flush with the bottom of the block.
    position, zero the dial indicator on the face of the rear
    cam journal.
    A CAUTION I ~f the rear ge?r housing
    IL.=.a=---'=..:..;::;....:...:....=-=~. IS not flush With the bot- 4. Hand push the camshaft forward as far as it will go.
    tom of the block, a faulty seal with the 011 pan will
    result in oil leakage. 5. Holding the camshaft in the farthest forward posi-
    tion, take note of the dial indicator reading. Verify that
    17. Verify that the bottom of the rear gear housing is the camshaft end play is between 0.005 and 0.008 inch
    flush with the bottom of the block. Slide a metal straight (0.127 and 0.203 mm).
    edge across both surfaces to detect if there is a drop
    between one plane and the other (see Figure 4.00-27). If the end play is too small, add additional shims
    Check the block on each side of the crankshaft bore. between the thrust ring and washer. Shims come in
    standard thicknesses of 0.002 inch (PIN 153029). If the
    end play is too great, remove shims as necessary.

    6. Remove the cam gear nut and sleeve from the


    camshaft.

    Figure 4.00-27. Verify The! Bottoms Are Flush

    FORM 6248 Firsl Edition 4.00 -11


    CRANKCASE ASSEMBLY

    CAM GEAR INSTALLATION 4. Verify that the keyway on the camshaft end is clean
    and undamaged. Install the Woodruff key (see )
    1. Move the camshaft forward. To keep the camshaft Figure 4.00-31). Ughtly tap the key to properly seat it in
    from moving backward, place a wooden block between the keyway. Verify that the key is level.
    the camshaft cover plate and the face of the rear cam
    journal. Insert the blade of a screwdriver between the
    camshaft and the block, so that the block fits snugly in
    the recess (see Figure 4.00-29).

    Figure 4.00-31. Cam Gear Key

    A WARNING
    Always wear suitable Insulated gloves when han-
    dling the cam gear. Ifthe gear slips from your grasp
    Figure 4.00-29. Prevent Lateral Movement Of Camshaft and drops, do not attempt to catch it. The sharp )
    teeth of the gear combined with its weight 30 Ibs.
    2. To prevent the camshaft from turning, wedge the (14 Kg) and momentum may cause severe lacera-
    rubber handle of a mallet between one of the front cam tions. Heating the gear during assembly can cause
    lobes and the camshaft recess (see Figure 4.00-30). burns If Insulated gloves are not worn.

    A CAUTION I
    I=..
    L..=-.:___
    Do not drive a cold cam
    gear onto the end of the
    .;;....;_...J.
    camshaft. Driving the cam gear onto the shaft may
    gall the inside diameter of the gear, resulting in
    Improper installation and gear or camshaft damage.

    IA CAUTION I:a~.~~~~t~:gth:n~~
    gear will not withstand the excessive heat generated
    by the torch. Penetration of the case-hardening will
    also resuh in brittle teeth leading to premature gear
    failure. Uneven expansion also can lead to gear or
    camshaft damage during installation.

    Figure 4.00-30. Prevent Camshaft Rotation

    3. Inspect the Woodruff key for damage and distortion.


    Replace the key if necessary.

    4.00 - 12 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    5. Heat the cam gear (see Figure 4.00-32). Place the feel for obstructions. Use compressed air to blowout all
    gear in an oven for a period of 1-1/2 to 2 hours. Maintain dirt and debris.
    the oven temperature at 500 - 550 0 F (260 - 288 0 C).
    3. Apply 3M Scotch Grip ~ Rubber and Gasket Adhe-
    sive 847 where the front section mates with the rear.
    The mating flange of each section can be identified by
    the threaded furrow adjacent to one of the capscrew
    holes (see Figure 4.00-33).

    THREADED
    LEFT BANK FURROW FRONT SECTION

    ~.~
    I[ 1 ' - - [-

    r
    o po~C
    o
    Figure 4.00.;32. Locking The Camshaft Gear Nut
    REAR SECTION R/GIf/{(BANK
    6. Install key in the camshaft end. Figure 4.00.;33. Valve Lifter Ho~ng Assembly
    ·.t..

    7. Install the camshaft gear on the camshaft with


    camshaft gear nut lock and camshaft gear nut. 4. Place a new gasket on the contact cement. Gently
    push down on the gasket to verify that it is properly
    8. Torque camshaft gear nut to 433 - 450 Ib-ft seated. 'C
    (587 - 610 N·m). $:!'.

    5. Apply Permatex® Aviation Form-A-Gasket Sealant


    9. Bend camshaft gear nut lock against the camshaft to the exposed side of the valve lifter housing gasket.
    gear nut.
    6. Fasten together the front and rear sections of the
    VALVE LIFTER HOUSING INSTALLATION valve lifter housing (3 ferry head capscrews, 3/8 x 1·1/2
    inches, with lock washers and hex nuts; 2 ferry head
    A WARNING capscrews, 3/8 x 1·1/4 inches, with lock washers).
    Install the two short capscrews in the holes leading to
    Compressed air can pierce the skin and cause the threaded furrows.
    severe personal injury. Never use your hand to
    check for leaks or to determine air flow rates. Wear 7. Verify that the bottom of the front section is flush with
    safety glasses to shield your eyes from flying dirt the bottom of the rear section. Slide a straight edge
    and debris. across both surfaces to detect if there is a drop between
    one section and the other. Check each side of the valve
    1. Refer to Valve utter Housing Gasket, Installation, lifter housing recess.
    and install the valve lifter housing gasket on the engine
    block. 8. Apply PermateX® Aviation Form-A-Gasket Sealant
    to the exposed portion of the gear housing gasket that
    2. The valve lifter housing consists of a front and rear mates with the front face of the valve lifter housing.
    section. Be sure that the internal lube oil passages in
    both sections are completely free of dirt, grit and other 9. Apply PermateX® Aviation Form-A-Gasket Sealant
    accumulations. Visually inspect the passageways to both legs of the valve lifter housing gasket (where it
    wherever possible or insert a piece of drill welding rod to approaches the rear face of the gear housing).

    FORM 6248 Rrst Edition 4.00 -13


    CRANKCASE ASSEMBLY

    10. Apply a bead of RTV Silicone Rubber Adhesive 13. Verify that the tip of the rear gear housing gasket
    Sealant along the seam in the bottom flange where the (the portion that mates with the valve Ilfter housing
    front and rear sections are joined. above the top center capscrew hole) was not folded
    over or pulled down when the valve lifter housing was

    A WARNING installed (see Figure 4.00-35).

    The valve lifter housing assembly weighs approxi-


    mately 400 Ibs. (181 Kg). Use a suitable lifting device
    and exercise caution during removal or installation to
    avoid severe personal injury or death.

    11. Fasten lifting brackets to the valve lifter guide bolt


    holes on opposite sides of the valve lifter housing
    assembly (see Figure 4.00-34). Install lifting chains of o o
    equal length and raise the valve lifter housing using an
    overhead hoist.
    o o
    DAMAGED OR
    CREASED GASKET

    I
    o o

    o o

    Figure 4.00-34. Lowering The Valve Lifter Housing


    Figure 4.00-35. Rear Gear Housing Gasket
    I.A. CAUTION Iwill
    Excessive oil leakage
    occur if the tip of the 14. Remove the lifting device.
    rear gear housing gasket is creased or folded.
    15. Install the fasteners in the valve lifter housing
    12. With the 3/4 inch pipe taps (or male connector tube (28 capscrews, 3/8 x 3-1/4 inches, with lock washers).
    fittings) atthe rear olthe engine block, position the valve

    IA CAUTION I
    lifter housing in the center of the crankcase vee.
    The ends of the longer
    ....==--....:........;._---':....::.__...... capscrews may contact
    the rear face of the cam gear If installed in the holes
    closest to the block. Contact will gouge the gear
    when the camshaft is rotated.

    4.00 -14 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    16. Fasten the valve lifter housing to the gear housing 21. Wrench tighten the seven capscrews (see
    (3 ferry head capscrews, 3/8 x 1-1/2 inches; 2 ferry head Figure 4.00-38).
    capscrews, 3/8 x 1-1/4 inches, all with lock washers)
    (see Figure 4.00-36). Always install the two shorter
    capscrews in the holes closest to the crankcase (see
    Figure 4.00-37).

    Figure 4.00-38. Camshaft Cover Plate

    22. I nstall the camshaft set screw in the valve lifter


    housing cover, if necessary. The set screw consists of a
    slotted headless capscrew (3/8 x 2-1/2 inches), washer
    Figure 4.00-36. Valve Lifter Housing - Front
    and hex jam nut (see Figure 4.00-39).

    LUBE OIL PASSAGE VALVE LIFTER

    Xoo /HOUSING

    Figure 4.00-37. Fasten valve Lifter Housing To Rear Figure 4.00-39. Camshaft Set Screw On Valve Ufter
    Gear Housing Housing Cover

    =A CAUTION I
    17. Apply 3M Scotch Grip ~ Rubber and Gasket
    Adhesive 847 to the rear face of the valve lifter housing. I..
    L. =--';..;;....;;..;;;....;;...;;...;;....:c..:...J.
    Overti,ghtening the jam
    nut Will cause the head
    of the set screw to break.
    18. Place a new gasket on the contact cement. Gently
    push down on the gasket to verify that it is properly 23. Loosen the hex jam nut and turn the set screw in
    seated. until it just contacts the camshaft. Turn the set screw out
    2 full turns. Tighten the hex jam nut to lock the position of
    19. Finger tighten the cover to the rear face of the valve
    the set screw. As the jam nut is tightened, verify that the
    lifter housing (5 ferry head capscrews, 3/8 x 1-1/2 inches,
    set screw does not rotate more than 1/2 turn.
    with lock washers and hex nuts).

    20. Finger tighten the valve lifter housing cover to the


    camshaft cover plate (2 ferry head capscrews, 3/8 x
    1-1/2 inches, with lock washers).

    FORM 6248 First Ednion 4.00 - 15


    CRANKCASE ASSEMBLY

    24. Apply Loctite® 271 Adhesive Sealant (High


    Strength) to the threads of two male connector tube IA CAUTION II~staliarubbertiPonthe
    ~~":::':""::":::'''':''';=-=:'':'''::..J_ 011 nozzle or spout to
    L..
    )
    fittings (7/8 inch tube OD). Using the 1-1/4 inch hex on avoid scratching the valve lifter rollers.
    the connector body, install the tube fittings in the 3/4
    inch pipe taps at the rear of the valve lifter housing (for 28. Lubricate the valve lifter rollers (see
    connection of the turbo oil drain tubes) (see Figure 4.00-41). Use SAE 40 engine oil. Also apply a
    Figure 4.00-40). bead of oil between the valve lifter body OD (roller side)
    and the guide bore sidewall (see Figure 4.00-41).

    Figure 4.00-40. Valve Lifter Housing - Rear

    25. Apply Loctite® 271 Adhesive Sealant (High


    Strength) to the threads of two 1/2 inch square head
    pipe plugs. Install the plugs in the pipe taps althe front of Figure 4.00-41. Lubricate Valve Lifter Rollers
    the valve lifter housing. Wrench tighten.
    29. Ensuring that the valve lifter rollers do not slide out,

    A WARNING
    slide the valve lifter guide assemblies into the valve lifter
    housing bores. For best results, insert the guide with the
    Compressed air can pierce the skin and cause right angle of the mounting flange facing the center of
    severe personal injury. Never use your hand to the vee and then rotate the assembly 180 degrees (see
    check for leaks or to determine air flow rates_ Wear Figure 4.00-42). Align the holes in the valve lifter guide
    safety glasses to shield your eyes from flying dirt gaskets with those in the mounting flange.
    and debris.

    26. Be sure that the internal lube oil passages in the


    valve lifter guides are completely free of dirt, grit and
    other accumulations. Visually inspect the passageways
    wherever possible or insert a piece of drill welding rod to
    feel for obstructions. Use compressed air to blowout all
    dirt and debris.

    27. Insert the valve lifters (cam followers) into the


    slotted lower bore of the valve lifter guides (see
    Figure 4.00-41). Slide on new valve lifter guide gaskets.

    NOTE: Return each valve lifter to its original location


    facing in the proper direction. Always retain the
    established wear patterns to minimize roller and cam
    lobe wear.
    Figure 4.00-42. Install Valve Lifter Guides )
    NOTE: Replace all valve lifters if a new camshaft is
    needed. Waukesha will not warrant the new shaft if
    used followers are installed.

    4.00 -16 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    30. Four long bolts (3/8 x 1-1/2 inches) with 1/4 inch FRONT
    spacers are used to secure the rocker arm oil header to (GEAR TRAIN SIDE)
    the valve lifter guides. Install the 44 short bolts (3/8 x
    1-1/8 inches, with lock washers) to secure the guides to
    the valve lifter housing, leaving the holes for the longer
    bolts open (see Figure 4.00-43).

    31. Lubricate the inside diameter of the upper valve


    lifter guide bores, to a depth of approximately 1/4 to 1/2
    inch (6.35 to 12.70 mm) with Parker Super O-Lube®.

    LEFT BANK

    RIGHT BANK

    REAR
    (FLYWHEEL SIDE)

    Figure 4.00-43. Longer Capscrew Locations For


    Mounting The Rocker Arm 011 Header

    FORM 6248 First Ednion 4.00 - 17


    CRANKCASE ASSEMBLY

    ROCKER ARM OIL HEADER INSTALLATION 3. Slide the fasteners (1 capscrew per clamp, 3/8 x
    1-1/2 inches, with lock washer) through the slotted )
    1. To verify cleanliness, remove the magnet plug from holes in the tube clamps. Install 1/4 inch spacers and
    the center port ofthe pipe tees on each end ofthe rocker thread the capscrews into the empty valve lifter guide
    arm oil header (see Figure 4.00-44). Clean the plugs in bolt holes (see Figure 4.00-46). Wrench tighten.
    solvent, if necessary. Wipe the plugs clean to ensure
    that all ferrous metal debris is removed. APP~ Perma
    Lok® Heavy Duty Pipe Sealant with Teflon to the
    threads of each plug. Install the plugs back in the pipe
    tees.

    Figure 4.00-44. Pipe Tee Magnet Plug

    2. Position the rocker arm oil header assembly in the


    center of the crankcase vee. Verify that the free end of
    the front male elbow tube fitting points horizontally
    toward the left bank, while the rear male elbow points to Figure 4.00-46. Rocker Arm Oil Header
    the right (See Figure 4.00-45).
    REAR OIL SEAL RETAINER INSTALLATION
    )
    IA
    ..
    CAUTION IThe two piece rope-type
    seal In the rear oil seal
    retainer must be correctly installed to prevent oil
    leakage and keep out dirt and dust. 011 leakage will
    occur if the ends of the wick-type seal are not
    slightly above flush on both the upper and lower
    halves of the retainer. If the ends of the seal
    protrude too far, then the seal will bunch up upon
    Installation and 011 leakage will also occur.

    1. Secure the upper half ofthe rear oil seal retainer in a


    vise with the inside groove facing upward.

    2. Roll a new rope-type seal into the groove of the


    retainer, leaving a half inch of material on each side.

    Figure 4.00-45. Rocker Arm Oil Header - Rear

    4.00 - 18 FORM 6248 First Ed.ion


    CRANKCASE ASSEMBLY

    3. Work the smooth rounded handle of a hammer back 6. Repeat Steps one thru five to install the rope-type
    and forth along the full length of the seal until the seal in the lower half of the retainer assembly.
    material is pressed tightly into the groove (see
    Figure 4.00-47). While the inside of the seal should be 7. Thoroughly wipe the machined areas where the rear
    firmly seated against the bottom of the groove, the oil seal retainer assembly mates with the rear face of the
    material on ihe worked Side spreads out to overlap the crankcase (see Figure 4.00-49). Dirt, grit or other debris
    flat edge on the retainer 10. will prevent proper seating. Verify that the mating
    flanges are completely smooth. Use a fine toothed
    pattern file to lightly dress down any burrs or high spots.

    Figure 4.110-47. Rear 011 Seal Retelner - Upper Half

    4. To trim the ends of the seal, start from the crankshaft


    side and make the first cut so that ij would be flush wijh
    the top of the gasket (if one were installed) (see
    Figure 4.00-48). Using a sharp knife, saw the seal at a Figure 4.00-49. Rear 011 Seal R~ner - Upper Half
    slight downward angle leaving the low end of the cut '. \.'
    slightly above flush with the foot of the retainer. 8. Apply 3M Scotch Grip ~ Rubber and Gasket Adhe-
    sive 847 to the portion of the crankcase that mates with
    the upper and lower halves of the rear oil seal retainer.

    9. Place a new gasket on the contact cement. Push


    down on the gasket to verify that the strip is properly
    seated. Gently pull each leg of the gasket (on each side
    of the crankshaft bore), so that the material extends
    past the bottom edge of the crankcase approximately
    1/32 inch (0.79 mm).

    10. Posijion the upper half of the rear oil seal retainer
    against the gasket and start the fasteners (5 capscrews,
    3/8 x 1 inch, with lock washers).

    11. I nsert a dowel pin into the two smaller holes on each
    side of the upper retainer. Use a hammer and a blunt
    tipped center punch to ensure that the pins are fully
    seated in the crankcase.

    Figure 4.00-411. Cut Rope Type Seal

    5. Use the side of the blade to form the cut ends of the
    seal into a square shape (so that the material does not
    interfere wijh proper placement of the gasket).

    FORM 6248 First Edition 4.00 -19


    CRANKCASE ASSEMBLY

    12. Apply 3M Scotch Grip ~ Rubber and Gasket I A CAUTION I This publication ad-
    Adhesive 847 to the two feet of the upper retainer (those .. dresses current produc- )
    that mate with the lower half of the retainer assembly). If tion configurations only. Refer to Service Bulletin
    necessary, use the side of a knife blade to form the cut 5-23280, Crankshaft, Main Bearing and Connect-
    ends of the seal into a square shape (so that the Ing Rod Identification and Replacement for in-
    material does not interfere with proper placement of the formation regarding previous production
    gasket) (see Figure 4.00-50). configurations, to avoid damage to equipment.

    A
    I ..
    CAUTION IThe main bearing
    saddles and caps must
    be completely free of oil, dirt or other foreign
    material. Any dirt or debris caught between the
    bearing shell and crankshaft bore results in bear-
    ing distortion, reduced service life and product
    damage.
    1. Thoroughly clean the main bearing saddles and
    caps. Inspect the bearing running surface for burrs,
    nicks, minor scuff marks or scratches, remove as
    necessary. Use compressed air to blow away all dust
    and debris.

    2. Check the oil passage in the front main bearing cap


    for cleanliness. Insert a piece of drill welding rod into the
    passageway to feel for obstructions. The front main
    bearing cap, stamped with the number I, is easily
    Figure 4.00-50. Rear Oil Seal Retainer - Upper Half identified by the oil pump idler gear spindle bore (see
    Figure 4.00-51). )
    13. Place two new gaskets on the contact cement.

    14. Apply Permatex® Aviation Form-A-Gasket Seal- BEARING TEMPERATURE SENSOR BORE

    l~
    ant to the exposed side of each gasket piece (see
    Figure 4.00-49).

    15. Apply Permatex® Aviation Form-A-Gasket Seal-


    ant to the exposed portions of the rear oil seal retainer
    gasket (the legs on each side of the crankshaft bore)
    (see Figure 4.00-49).

    NOTE: The lower half of the rear oil seal retainer is


    installed after the crankshaft is in place. See Rear Oil
    Seal Retainer (Lower Half).

    MAIN BEARING INSTALLATION


    ~~
    OIL PUMP IDLER
    A WARNING GEAR SPINDLE BORE

    Figure 4.00-51. Front Main Bearing Cap


    Compressed air can pierce the skin and cause
    severe personal injury. Never use your hand to
    check for leaks or to determine air flow rates. Wear 3. Verify that the four roll pins in the front main bearing
    safety glasses to shield your eyes from flying dirt cap are clean and straight.
    and debris.

    4.00 - 20 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    SPLIT OF ROLL PINS (4) TO BE ASSEMBLED AS SHOWN

    Figure 4.00-52. Install Roll Pins In Front Main Bearing Cap

    4. Remove and discard the pins if bent or damaged.


    WIDE SHELL
    (FRONT, CENTER
    A CAUTION Ilf installed incorrect~y,
    AND REAR)

    ~
    I.....
    "'='-___
    . ....0..._--0. Internal stress may dis-
    tort or damage the roll pins, resulting in dislocation
    of the thrust ring.

    5. Verify thatthe four pin holes in the front main bearing


    cap are completely free of dirt and grit.

    6. Install new roll pins with the split opposite the bearing
    seat approximately 15 degrees below horizontal (see
    Figure 4.00-52). Measure the length of each pin to
    verify that it protrudes 0.188 inch (±O. 015 inch) from the
    face of the main bearing cap. NARROW SHELL
    (INTERMEDIATE)

    I A CAUTION I Do not touch the main Figure 4.00-53. Upper Fully Grooved Main Bearing
    .. bearing runmng surface. Shells - Bearing Saddles
    Acidic skin secretions can promote the start of
    surface corrosion and wear.
    NOTE: The words "UPPER" and ''LOWER" are marked
    7. Wipe the main bearing shells clean. Inspect the on the back of each shell to indicate its location.
    bearing surfaces for burrs, nicks, minor scuff marks or
    9. Position the fully grooved shells above the bearing
    scratches, remove as necessary. Use compressed air
    seats of the seven main bearing saddles. The front,
    to blowout all dust and debris.
    center and rear bearing shells are about 1-1/8 inches
    8. Locate the seven upper main bearing shells. All (28.575 mm) wider than the four intermediate shells
    upper main bearing shells are fully grooved with a (see Figure 4.00-53).
    slotted oil hole towards the center (see Figure 4.00-53).

    FORM 6248 First Edition 4.00 - 21


    CRANKCASE ASSEMBLY

    10. Verify that the locating tang on the parting edge of 16. Apply even pressure to the parting edges of each
    each shell (opposite the bearing running surface) is bearing shell to snap it into place.
    directly above the notch machined on the inside edge of
    lin ~ddition to making
    the bearing saddle.
    :11.. CAUTION
    11. Apply even pressure to the parting edges of each
    1=.=......;:==::.....:...::..;;.....:~.
    L.. . nOIse, loose fitting
    shells can adversely affect the bearing's ability to
    bearing shell to snap it into place.
    transfer heat. Excessive temperatures shorten
    bearing service life and may cause damage to the
    A CAUTION lin ~ddltlon to m~k~ng
    I..
    ==......;:=..:...:::.....:....:...;;;.....:~.
    L.. nOIse, loose fItting
    crankshaft.
    shells can adversely affect the bearing's ability to 17. Verify that the bearing shell fits tightly in each main
    transfer heat. Excessive temperatures shorten bearing cap.
    bearing service life and may cause damage to the
    crankshaft.
    :11.. CAUTION I ~iI ~arvatlon results In
    12. Verify that the bearing shells fit tightly in the main
    =
    ..
    1L.. =......;:;..;;....;;...;'--...::....:....;~. rapId wear of the oil
    pump idler gear bushing and spindle.
    bearing bore.

    IA
    ..
    CAUTION IOil starvation results in
    rapid bearing failure and
    18. Verify that the oil hole in the shell of the front main
    bearing cap matches up with the supply hole to the oil
    pump idler gear spindle bore.
    possible crankshaft damage.
    CRANKSHAFT INSTALLATION
    13. Verify that the slotted oil hole in each shell matches
    up with the oil supply hole centered in each main
    Crankshaft Set Screws

    A CAUTION I
    bearing saddle.

    14. Position the ungrooved bearing shells above the I.="='--':-_


    L.
    • _
    A missing crankshaft set
    screw causes a loss of
    "'::"'_--1.
    engine oil pressure resulting in bearing seizure and )
    bearing seats of the seven main bearing caps (see
    Figure 4.00-54). piston/sleeve damage.

    1. Six drillings can be found in the crankshaft cheeks of


    current production tee-drilled crankshafts. Since Wau-
    UNGROOVED
    kesha recommends that the set screws (see
    Figure 4.00-55) be removed for proper cleaning, in-
    spect the cheeks to verify that all openings are plugged
    and staked (see Figure 4.00-56).

    NARROW SHELL
    (INTERMEDIATE)

    Figure 4.00-54. Lower Ungrooved Main Bearing Shells


    - Bearing Caps

    15. Verify that the two locating tangs on the parting


    edges of each shell (opposite the bearing running
    surface) are directly above the notches machined on
    the inside edge of each main bearing cap.

    FIgure 4.00-55. Crankshaft Set Screws

    4.00 - 22 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    Figure 4.00-56. Crankshaft Set Screw Locations (6)

    IA CAUTION I~~~~~~NK~~~'i S:~ I A. CAUTION ISlide plastic or rubber


    =,---,;,.;;"...;;..;;.,.,;;;,..;;.,,;;;,,,,;~. tubes over the main
    L.,;:
    ..

    INSTALLED PRIOR TO INSTALLING THE CRANK- bearing cap studs to avoid damage to the crank-
    SHAFT IN THE ENGINE. A crankshaft installed and shaft and/or studs during Installation.
    operated with one or more missing set screws will
    cause bearing seizure and piston/sleeve damage 3. Slide protective plastic or rubber tubes over the main
    due to low oil pressure. bearing cap studs.

    2. Carefully examine the entire crankshaft to be certain


    all cheek openings are plugged with set screws. A WARNING
    The crankshaft weighs approximately 1,850 Ibs.
    3. In addition, check the area for metal chips resulting (839 kg). Use a suitable lifting device and exercise
    from the staking operation. caution during removal or installation to avoid
    4. If a set screw is missing, proceed as follows: Coat severe personal injury or death.
    the threads of the set screw plugs with Loctite® 271.
    Install set screw plugs approximately three threads 4. Gently position the crankshaft iri the main bearing
    below the cheek surface. Peen or stake these set bore. While the crankshaft is suspended, wrap a clean
    screws into place as described in the Note below. cloth around the end of the crankshaft (see
    Figure 4.00(57). Interlock the fingers iii both handis over
    NOTE: Wedge a painted punch between the set the top of the cloth to guide the crankshaft as ~ is lowered
    screws and crankshaft threads and sharply strike the into position. Position the crankshaft so that the oil
    punch a Single blow to securely stake the set screws in grooves behind the oil slinger (see Figure 4.Q0(58) are
    place. This operation distorts the threads to lock the set centered on the rope-type seal of the rear oil seal retainer
    screws in place. (upper hall) (see Figure 4.CJO.59).

    5. Carefully check the surface area of the cheek for


    metal chips that may have been produced from the
    staking operation.

    1. Apply oil to the upper bearing halves in the main


    bearing bore. Use SAE 40 engine oil, and evenly spread
    the oil up over the entire bearing surface.

    2. Before installing crankshaft in crankcase, use a


    clean cloth to clean the main and rod bearing journals.

    Figure 4.00-57. Crankshaft Guiding


    )

    FORM 6248 First Edition 4.00 - 23


    CRANKCASE ASSEMBLY

    Inside Crankshaft Thrust Ring Installation


    )
    I~ CAUTION I
    -A Do not mix or match
    thrust rings. If reinstal-
    ling thrust rings, insure that the thrust rings are
    installed in their original position. Mixing thrust
    rings may affect the crankshaft end play. Disregard-
    ing this information could result in product dam-
    age andlor personal injury.
    1. Install one half of a new thrust ring into the space
    between the bearing saddle .and the cheek of the #1
    main bearing journal. The lip on the inside diameter of
    the thrust ring seats in the groove where the crankshaft
    journal, shell and bearing bore converge (see
    Figure 4.00-60).

    Figure 4.00-58. Crankshaft 011 Grooves BEARING SHELL

    #1 MAIN BEARING
    JOURNAL
    BEARING CRANKSHAFT
    OIL HUB
    SLINGER

    )
    ROPE-TYPE
    SEAL
    o o

    OIL
    GROOVES GEAR
    o
    MOUNT 0 0
    FRONT MAIN.---'
    BEARING SADDLE COUNTERWEIGHT
    7
    o o Figure 4.00-60. Install Inside Thrust Ring

    CAUTION I
    ROPE-TYPE
    SEAL
    IA..
    To avoid damage to a
    crankshaft Journal or fil-
    let, always position the pry bar against a non-criti-
    MAIN BEARING UPPER REAR OIL cal surface, such as the crankshaft cheek,
    SADDLE SEAL RETAINER
    counterweight, or main bearing cap.
    Figure 4.00-59. Crankshaft Placement 2. Use a pry bar to bump the crankshaft towards the rear
    if the gap is too narrow to accommodate the thrust ring.
    5. Remove the protective tubes from the main bearing
    3. Place one half of a new thrust ring (PIN 153031 B)
    cap studs.
    flush against the front face of the #1 main bearing
    saddle. The lip on the inside diameter of the thrust ring
    fits in the groove where the crankshaft journal, shell and
    bearing bore converge.

    NOTE: The upper and lower halves of the thrust ring


    are interchangeable.

    4.00 - 24 FORM 6248 First Ed~ion


    CRANKCASE ASSEMBLY

    REAR OIL SEAL RETAINER (LOWER HALF) 6. Fasten the lower half of the retainer to the crankcase
    INSTALLATION (4 capscrews, 3/8 x 1 inch, with lock washers).
    1. If not already accomplished, see Rear Oil Seal
    Retainer (Upper Half) for installing a new rope-type A CAUTION Ilfther~roilsealretainer
    seal. .:!!!!!!!!~=..:..:::....::...:..=...;~.
    I.L . . gasket IS left uncut, the
    excess material will dig into the oil pan seal.
    Damage to the oil pan seal will result in oil leakage.
    A CAUTION I Pinning the lower half of
    .!!!!!!~=..:..:::....::...:..=...;~.
    I.L .:!! . the rear 011 seal retainer 7. Using a sharp knife or razor, carefully cut the rear oil
    to an upper retainer that is already tightened to the seal retainer gasket, so that the legs (on each side of the
    crankcase will pinch or crack the legs of the crankshaft bore) are flush with the bottom of the
    retainer gasket. Damage to the rear oil seal retainer crankcase (see Figure 4.00-62).
    gasket will result in oil leakage.

    2. Be sure that the five capscrews of the upper rear oil


    seal retainer are loose (see Figure 4.00-61).

    UPPER HALF
    OF RETAINER

    Figure 4.00-62. Trim Rear Oil Seal Re1alner Gasket

    I A CAUTION Ilf the lower half of the


    .. rear oil seal retainer Is
    not flush with the bottom of the crankcase, a faulty
    seal with the 011 pan will result in 011 leakage.

    8. Verify that the bottom of the lower rear oil seal


    retainer is flush with the bottom of the crankcase. Slide
    a metal straight edge across both surfaces to detect if
    there is a drop between one plane and the other. Check
    each side of the seal retainer bore.
    Figure 4.00-61. Rear Oil Seal Retainer Assembly

    3. Align the dowels in the lower half of the rear oil seal
    retainer with the two pin holes in the upper half. If
    necessary, use a rubber mallet to bring the mating
    flanges together.

    4. Fasten the lower retainer to the upper half


    (2 capscrews, 7/16 x 1-1/4 inches, with lock washers).

    5. Fasten the upper half ofthe retainer to the crankcase


    (5 capscrews, 3/8 x 1 inch, with lock washers).

    FORM 6248 First Edition 4.00 - 25


    CRANKCASE ASSEMBLY

    MAIN BEARING CAPS INSTALLATION CRANKSHAFT END PLAY MEASUREMENT


    )
    This torquing sequence should be used on previous
    engines as well as current production ones. IA
    ..
    CAUTION I The crankshaft gear
    should not be installed
    NOTE: Generously apply engine oil to main bearing prior to checking the crankshaft end play. Disre-
    cap studs, nuts and side bolts immediately before garding this Information could result In product
    installing them. Apply 3M Scotch Grip ~ Industrial damage and/or personal Injury.
    Adhesive EC 847, or equivalent, to both sides of the
    side bolt washers to prevent lube oil leaks. NOTE: Fabricate a sleeve to the same dimensions as
    the crankshaft gear, leaving enough inside diameter
    1. Apply engine oil to the lower bearing halves in the
    that the gear fits over the crankshaft easily. A second
    main bearing caps and to the crankshaft main bearings.
    longer sleeve with a closed end should be fabricated to
    2. Refer to the stamped marks on the main bearing fit over the end of the crankshaft, with enough length to
    caps and install them on their corresponding main reach the sleeve positioned against the thrust washer
    bearing seat on the crankcase. (see Figure 4.00-64). The longer sleeve should be
    fabricated to allow capscrews to be threaded through
    3. Refer to Figure 4.00-63 and torque nuts 1 through 4 the closed end, and into the threaded holes in the
    (in that order) to 75 ft-Ib (102 N·m). If installing crankshaft end. This will allow the sleeves to be
    replacement caps that will be align bored, torque to only tightened against the thrust washer.
    30 ft-Ib (40 N·m). When installing more than one cap,
    torque nuts 1 through 4 to 75 ft-Ib (102 N·m) on all caps
    before torquing side bolts.

    LEFT SIDE OF ENGINE


    5

    LOCATING
    DOWEL I I
    )

    ~"
    FRONT OF
    ENGINE

    Figure 4.00-64. Torque Front Main Bearing Cap

    1. Position temporary sleeves against the thrust thrust


    as described in the Note above, and tighten.

    2. Remove the capscrew (3/8 x 1 inch, with lock


    6 washer) from the lower right corner of the rear oil seal
    retainer assembly. Install a pin in the bo~ hole.
    Figure 4.00-63. Main Bearing Cap Tightening(Torqulng
    Pattem - As Viewed From Underside Of Crankcase

    4. Torque all left side bo~s (5) to 250 ft-Ib (339 N·m),
    starting from the front of the engine.

    5. Torque all right side bolts (6) to 250 ft-Ib (339 N·m)
    starting from the front of the engine.

    6. Torque nuts 1 through 4 to 275 ft-Ib (373 N·m) to two


    steps: first 175 ft-Ib (237 N'm), and then 275 ft-Ib
    (373 N·m).

    7. Check the crankshaft for free rotation after each


    bearing cap is torqued.

    4.00 - 26 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    3. To measure the lateral movement of the crankshaft, 5. Holding the crankshaft in the farthest rearward
    mount a dial indicator on the pin. Position the indicator posHion, zero the dial indicator on the crankshaft hub.
    button against the crankshaft hub (see Figure 4.00-65).
    6. Insert a pry bar between the main bearing cap and
    the crankshaft cheek. Push on the cheek to bump the
    crankshaft forward as far as it will go.

    7. Holding the crankshaft in the farthest forward position,


    take note of the dial indicalor reading. Verify that the
    crankshaft end play is between 0.005 and 0.016 inch
    (0.127 and 0.406 mm).
    If the end play is too small, add addHional shims between
    the thrust ring and washer. Shims (PIN 153043A) come in
    standard thickness of 0.003 inch (0.076 mm). If the end
    play is too great, then remove shims as necessary (see
    Figure 4.00-67). Table 4.00-1 lists the standard thrust ring
    measurements.

    LJ
    ~~*
    BEARING CRANKCASE

    Figure 4.00-65. Measure Crankshaft End Play


    D
    CAUTION ITo
    #1 MAIN

    I...
    A avoid damage to a
    crankshaft journal or fil-
    let, always position the pry bar against a non-criti-
    CRANKSHAFT
    JOURNAL

    . -. ADDING
    SHIMS
    W ILL
    cal surface, such as the crankshaft cheek, INC REASE
    counterweight or main bearing cap. PLAY
    ENI

    -~-'~D
    4. Insert a pry bar between the counterweight and the
    CRANK GEAR"""'-
    D
    main bearing cap (see Figure 4.00-66). Push on the
    counterweight to bump the crankshaft back as far as H
    will go.
    THRUST RING
    (BEARING)

    Figure 4.00-67. Crankshaft End Play

    Table 4.00-1. Crankshaft Thrust Rings


    PIN A B
    0.215 0.268
    Standard 1530318 0.217 0.263

    Figure 4.00-66. Bump Crankshaft Towards Rear

    FORM 6248 First Edition 4.00 - 'Z1


    CRANKCASE ASSEMBLY

    8. Remove the dial indicator from the crankshaft hub. A CAUTION Ilf installed incorrect!y,
    .
    =.
    IL. =~;;.;;....:..:;;.....;....:...;;;...;~. Internal stress may dis-
    9. Remove the pin from the rear oil seal retainer and tort or damage the roll pins, resulting In dislocation
    install the capscrew (3/8 x 1 inch, with lock washer) in of the thrust ring.
    the bolt hole.
    3. Verify that the pin holes are completely free of dirt
    1O. Remove the fabricated sleeves from the crankshaft
    and grit.
    end.
    4. Install new roll pins (PIN 26800) with the split
    OUTSIDE CRANKSHAFT THRUST RING
    opposite the crankshaft end. Measure the length of
    INSTALLATION
    each pin to verify that it protrudes 0.312 inch (±0.015
    1. Verify that the two roll pins in the front face of the #1 inch) from the face of the crankshaft journal (see
    main bearing journal are clean and straight (see Figure 4.00-69).
    Figure 4.00-68).

    Figure 4.00-68. Roll Pins

    2. Remove and discard the pins if bent or damaged.

    / #1 MAIN BEARING JOURNAL

    --lI-- -<I>--h-I;.-2 ~q
    'v
    ----
    SPLIT OF ROLL PINS (2)
    .312" •.015.J TO BE ASSEMBLED AS
    (BOTH SIDES) SHOWN

    Figure 4.00-69. Install Roll Pins In Crankshaft

    4.00 - 28 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    5. Position the other half of the thrust ring flush against


    the machined flange on the front face of the front main
    bearing cap (see FlQure 4.00-70, Figure 4.00-71 and
    Figure 4.00-72). The two roll pins in the cap fit into pin
    holes on opposite sides of the thrust ring. The lip on the
    inside diameter of the ring seats in the groove where the
    crankshaft journal, shell and bearing bore converge. If
    necessary, place a little grease on the roll pins to help hold
    the thrust ring in place.

    Figure 4.00-72. Outside Thrust Ring - Saddle Side

    6. Slide the thrust washer onto the end of the crankshaft


    ROLL PIN HOLES
    with the inside bevel facing the thrust ring (see
    Figure 4.00-70. Crankshaft Thrust Ring (Half) Up Figure 4.00-73). Position the washer so thai the notch on
    the inside diameter slides past ttJe< "dowel pin on the
    crankshaft circumfererce (see Figure".<\.00-74). Move the
    washer down the crankshaft until tt, Contacts the thrust
    ring, fitting the two roll pins on the fiice of the #1 main
    bearing journal into the pin holes on opPosite sides of the
    thrust washer.

    Figure 4.00-71. Outside Thrust Ring - Cap Side

    Figure 4.00-73. Crankshaft Thrust Washer

    FORM 6248 Firs! Edition 4.00 - 29


    CRANKCASE ASSEMBLY

    A WARNING
    Always wear insulated gloves when handling
    heated gears. Use of bare hands will result In
    severe bums.
    NOTE: Do not delay installation of the crankshaft gear
    after it is removed from the oven. The gear shrinks as it
    cools, so it must be properly installed before its inside
    diameter decreases to the paint where installation
    becomes difficult. Any difficulty associated with installa-
    tion of the crankshaft gear increases the risk of
    improper installation or damage to the crankshaft gear
    and/or crankshaft.

    2. Align the notch on the inside diameter of the heated


    crankshaft gear with the dowel pin on the crankshaft
    end (see Figure 4.00-76). Verify that the timing marks
    Figure 4.00·74. Thrust Washer
    (the letters "X· and "0") face outward. Slide the gear
    down the crankshaft end until Rseats solidly against the
    CRANKSHAFT GEAR INSTALLATION
    thrust washer.

    CAUTION I~notdriveacoldcrank­
    I~A!!:!!!!~~....:..:::....::....:..:::..:~.
    L. . . shaft gear onto the crank-
    shaft. Driving the gear onto the shaft may gall the
    Inside diameter of the gear, resulting In Improper
    installation and gear or crankshaft damage.
    )
    I A CAUTION IDo not torch heat the
    .. crankshaft gear. The ni-
    trating on the gear will not withstand the excessive
    heat generated by the torch. Penetration of the
    case-hardening will also result in brittle teeth
    leading to premature gear failure. Uneven expan-
    sion also can lead to gear or crankshaft damage
    during installation.
    1. Heat the crankshaft gear (see Figure 4.00-75). Figure 4.00-76. Crankshaft Gear Mount
    Place the gear in an oven for a period of 1·1/2 to 2
    hours. Maintain the oven temperature at 500 0 - 550 0 F 3. WaR for the gear to cool to the temperature of the
    (260 0 - 288 0 C). crankshaft. Occasionally tap on the gear face with a soft
    hammerto ensure that it remains tight against the thrust
    washer. As the gear cools, it shrinks to form a
    metal-to-metal contact with the crankshaft.

    4. Verify that the gear fRs snugly on the crankshaft


    without rocking or sliding.

    Figure 4.00-75. Crankshaft Gear

    4.00 - 30 FORM 6248 First Edttion


    CRANKCASE ASSEMBLY

    OIL PUMP IDLER GEAR 8. Install the spindle screw hex nut (Grade 8, 3/4" -16)
    w~h the large chamfer facing outside, the smaller
    1. Lubricate the exterior surface of the oil pump idler chamfer in toward the bearing cap. Secure the head of
    gear spindle (see Figure 4.00-77). Use a quality high the spindle screw w~h a wrench (see Figure 4.00-78)
    viscosity oil. and tighten the hex nut.

    Figure 4.00-77. 011 Pump Gear Assembly

    2. Slide the spindle into the hole at the bottom of the


    front main bearing cap until ~ is seated solidly against
    the inside counterbore. Verify that the WED part
    number faces outside toward the front of the engine. Figure 4.00-78. Secure Spind!i$crew Head

    3. Install the oil pump idler gear onto the spindle with 9. Leaving the wrench in place to keep the oil pump
    the tapered end facing inward. idler gear from turning, torque the sPindle screw hex nut

    4. W~h the recessed side facing the screw head, move •.


    to 300 - 325ft-lb (407 - 441 N·m) (~Figure 4.00-79).

    the thick washer down the spindle screw.

    5. Insert the screw into the oil pump idler gear spindle
    until ~ exits the bore at the rear of the front main bearing
    cap.

    6. Install the thin washer on the end of the spindle


    screw.

    7. Apply a small amount of Loctite@ 271 Adhesive


    Sealant (High Strength) to the threads of the spindle
    screw.

    Figure 4.00-79. Torque Spindle Screw Hex Nut

    FORM 6248 First Edition 4.00 - 31


    CRANKCASE ASSEMBLY

    CAMSHAFT IDLER GEAR INSTALLATION 5. Position a new bearing above the gear hub. Exert
    uniform pressure against the outer race of the bearing )
    A WARNING until it makes solid contact with the counterbore (see
    Figure 4.00-81). The bearing is a slight interference fit,
    Always wear suitable safety gloves when handling so minimum pressure is required to press the bearing
    the idler gears. The edges of the gear teeth are into place.
    sharp enough to cut flesh if mishandled. If the gear
    slips from your grasp and drops, do not attempt to
    NYLOK
    catch It. The sharp edges of the gear teeth CAPSCREW
    WIDE
    combined with its weight 30 Ibs. (14 kg) and BORE
    momentum may cause severe lacerations.

    1. Position the camshaft idler gear in a suitable press


    with the shallow CQunterbore in the gear hub facing
    upward (see Figure 4.00-80). Position a new ball
    bearing above the hub.

    ,5HALL.UW COUNlERBORE

    THIN

    Figure 4.00-111. Idler Gear

    6. Position the gear on a suitable workbench with the


    threaded holes around the hub facing upward.

    7. With the beveled inside diameter of the bearing


    DEEP
    retainer plate facing outward, align the holes in the plate )
    with the holes in the gear.
    Figure 4.00-80. Idler Gear
    8. Start six new 3/8 x 1 inch Nylok capscrews in the
    gear hub (see Figure 4.00-82). Aijernately wrench
    2. Exert uniform pressure against the outer race until tighten the capscrews.
    the bearing makes solid contact with the counterbore.
    Since the bearing is a slight interference fit in the gear
    bore, minimum pressure is required to press the bearing
    into place.

    3. Turn the idler gear over so that the deeper counter-


    bore in the gear hub faces upward.

    4. Position the spacer in the gear hub.

    Figure 4.00-112. Camshaft Idler Gear

    4.00 - 32 FORM 6248 First Ed~ion


    CRANKCASE ASSEMBLY

    9. Use a piece of white chalk to highlight the timing


    marks ("X's" and "0'5") on the faces of the cam, crank AUGN VERTICAL "X" BELOW TOOTH
    and idler gears (see Table 4.00-2) (the oil pump idler WITH "X" ON CAM GEAR ROOT
    gear is not timed). The chalk enables the technician to
    quickly focus on the timing marks, which facilitates
    installation olthe gears and provides for quick confirma-
    tion of correct timing.

    NOTE: Install both idler gears cold.

    10. With the timing marks facing outward, push the


    idler gear onto the spindle until the rear ball bearing race
    is fully seated. The spacer separating the front and rear
    ball bearings drops down to halt complete installation of
    the idler gear (see Figure 4.00-83).

    ALIGN HORIZONTAL "X" BELOW ROOT


    WITH "X" ON CRANK GEAR TOOTH

    Figura 4.00-84. Camshaft Idler Gear - Timing MlIrks

    13. Align the camshaft idler gear so that the vertical "X"
    on the tooth lines up with the "X" on the cam gear root
    (see Figure 4.00-85), and the horizontal "X" on the root
    lines up with the "X" on the crank gear tooth.
    Figure 4.00-83. Camshaft Idler Gear - Upper

    11. When the end of the spindle contacts the spacer,


    rotate the idler gear to align the timing marks.

    12. Two "X's," positioned 180 degrees apart, are


    stamped on the camshaft idler gear. One "X" (vertical) is
    stamped at the base of a tooth, the other (horizontal) is
    directly below a root (see Figure 4.00-84).

    ,I Figure 4.00-85. Cam GearlCamshaft Idler Gear Timing

    FORM 6248 First Ed~ion 4.00 - 33


    CRANKCASE ASSEMBLY

    Table 4.00-2. Rear Gear Backlash Specifications


    )

    1- CAM GEAR
    2 - CAM IDLER GEAR
    3 - CRANK GEAR
    4 - OIL PUMP IDLER GEAR
    )
    5 - ACCESSORY IDLER GEAR
    6 - ACCESSORY (MAGNETO) DRIVE GEAR

    MEASUREMENT INCHES METRIC (mm)


    (A) TIming Gears (Helical Gears)
    Normal to tooth 0.005 - 0.012 0.203 - 0.305
    In plane of rotation 0.0052 - 0.0122 0.2063 - 0.3099
    Governor Drive Gears
    Magneto shalt to Intermediate Shalt (Spur Gears)
    60 and 72 Tooth Gears 0.005 - 0.007 0.127 - 0.178
    42 and 90 tooth gears 0.003 - 0.005 0.076 - 0.127
    Intermediate shalt to governor (Spiral Gears)
    Normal to tooth 0.004 - 0.006 0.102 - O.t52
    In plane of rotation (Governor Gear) 0.0057 - 0.0085 0.1448 - 0.2159
    NOTE: The engine camshaft idler gear is a "Hunting - Tooth" design, to minimize tooth wear. The fractional drive ratio between the crankshaft and
    camshaft gears results in the idler gear timing marks re - aligning with the crankshaft and camshaft timing marks only once in Bvel}' 154 crankshaft
    revolutions. The most practical way to realign the timing marks, when timing a camshaft, is to remove the idler gear and re - assemble to it's timed
    position as previously described.

    4.00 - 34 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    14. With the timing marks correctly aligned, pull up on ACCESSORY IDLER GEAR INSTALLATION
    the ball bearing spacer and slide the idler gear down the
    spindle until the rear face contacts the spindle shoulder. 1. Follow steps 1 - 11 under Camshaft Idler Gear.
    Lightly tap the gear face with a soft rubber mallet to
    2. Align the accessory idler gear so that the "0"
    ensure that it is completely seated. stamped at the base of the tooth lines up with the "0"
    below the crank gear root (see Figure 4.00-87).
    15. Align the holes in the idler gear washer and lock
    washer with those in the idler gear spindle. (Use a new
    lock washer) Verify that the tapered hole in the center of
    the idler gear washer faces inward. Finger tighten the AUGN "0" BELOW TOOTH
    WITH "0' ON CRANK
    two capscrews (1/2 x 1-1/4 inches), so that the flat of GEAR ROOT
    one is parallel with the flat of the other (see
    Figure 4.00-86).

    "12" BELOW TOOTKTP~BE


    ALIGNED WITH "12" BELOW
    MAG DRIVE GEAR ROOT
    Figure 4.00-86. Lock Idler Gear Capscrews
    Figure 4.00-87. Accessory Idler Gear - Timing Marks
    16. With the facing flats parallel, use a thin wall socket
    to tighten the first capscrew. If the socket cannot be 3. Follow steps 13 - 17 under Camshaft Idler Gear (see
    removed, then make the capscrew a little tighter to bring Figure 4.00-88).
    the flats parallel again. TIghten the second capscrew in
    the same manner. The socket can only be removed
    when the facing flats of the two capscrews are parallel.

    17. Torque the two idler gear capscrews to 87 ft-Ib


    (118 N·m). Using a thin wall socket, follow the "parallel
    flats" tightening procedure described in step 15.

    NOTE: It may be necessary to exceed the torque value


    slightly in order to make the facing flats of the two
    capscrews parallel. The flats must be parallel to install
    or remove the thin wall socket.

    18. Use a chisel and hammer to bend the rounded tab


    on each end of the idler gear lock washer toward the
    head of the adjacent capscrew. Bend each tab forward
    until it rests tightly against the flat of the capscrew (see
    )
    Figure 4.00-86).

    Figure 4.00-88. Accessory Idler Gear - Lower

    FORM 6248 First Ednion 4.00 - 35


    CRANKCASE ASSEMBLY

    GEAR BACKLASH MEASUREMENT Camshaft Idler Gear to Cam Gear


    Backlash is the distance or the amount of "play" 1. Mount a dial indicator with a magnetic base next to
    between the teeth of two meshed gears (see the camshaft idler gear. Position the indicator point
    Figure 4.00-89). Always check the backlash, regard- against the inside face of any idler gear tooth.
    less of whether the gear is new or used. Refer to
    Chapter 1 for backlash values. 2. Secure the cam gear against movement.

    GEAR BACKLASH 3. Turn the idler gear until contact with the stationary
    cam gear prevents further movement.

    4. Holding the idler gear in position, zero the dial


    indicator.

    5. Turn the idler gear in the opposite direction until


    movement is again ha~ed by contact with the stationary
    cam gear.

    6. Take note of the dial indicator reading. Verify that the


    camshaft idler gear to cam gear backlash is between
    0.008 and 0.012 inch (0.203 and 0.305 mm).

    Figure 4.00-89. Gear Backlash


    A CAUTION I Severe engine damage
    ,":,
    I ="=-:-:-~-:--:- __-" may result from opera-

    I ..
    A CAUTION Ilf the backlash on a new tion with "tight" or excessively worn gears.
    gear is not within speci-
    fication, recheck the part number to be sure that the 7. Back off the point ofthe dial indicator, rotate the idler
    correct gear was installed. Use of tight or "bound" gear 180 degrees and recheck the backlash.
    gears or use of excessively worn gears, can lead to
    Accessory Idler Gear to Crank Gear
    )
    severe engine damage.
    If the backlash is not within specification, then the gear, 1. Mount a dial indicator with a magnetic base next to
    and/or the gear with which it mates, must be replaced. the accessory idler gear. Position the indicator point
    against the inside face of any idler gear tooth.
    Camshaft Idler Gear to Crank Gear
    2. Turn the accessory idler gear until contact with the
    1. Mount a dial indicator with a magnetic base next to
    stationary crank gear prevents further movement.
    the camshaft idler gear (see Figure 4.00-88). Position
    the indicator point against the inside face of any idler 3. Holding the idler gear in position, zero the dial
    gear tooth. indicator.
    2. Turn the camshaft idler gear until contact with the 4. Turn the accessory idler gear in the opposite
    stationary crank gear prevents further movement. direction until movement is again ha~ed by contact with
    the crank gear.
    3. Holding the idler gear in position, zero the dial
    indicator. 5. Take note ofthe dial indicator reading. Verify thatthe
    accessory idler gear to crank gear backlash is between
    4. Turn the camshaft idler gear in the opposite direction
    0.008 and 0.012 inch (0.203 and 0.305 mm).
    until movement is again halted by contact with the crank
    gear.
    A CAUTION I ~evere engine damage
    5. Take note of the dial indicatorreading. Verify thatthe ..
    =
    IL. =-==..:...::.....:~::;..:~. may result from opera-
    camshaft idler gear to crank gear backlash is between tion with "tight" or excessively worn gears.
    0.008 and 0.012 inch (0.203 and 0.305 mm).
    6. Back off the point of the dial indicator, rotate the

    I.L .:
    A CAUTION I Severe engine damage
    accessory idler gear 180 degrees and recheck the
    backlash.
    .=:.-...:=...:...;::;...::....:..=;..;;.J.
    . may result from opera-
    tion with "tight" or excessively worn gears.
    6. Back off the point of the dial indicator, rotate the idler
    gear 180 degrees and recheck the backlash.

    4.00-36 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    011 Pump Idler Gear to Crank Gear I.A. CAUTION Idrive


    Do not install magneto
    mounting studs
    1. Mount a dial indicator w~h a magnetic base next to with a pipe wrench or similar device. Use a collet
    the oil pump idler gear. Position the indicator point style stud driver to prevent damage to studs.
    against the inside face of any idler gear tooth.

    2. Turn the oil pump idler gear until contact w~h the 6. Install the six studs in the rear right bank side of the
    stationary crank gear prevents further movement. rear gear housing. Drive each stud into the flange until
    the last coarse thread is turned into the casting.
    3. Holding the idler gear in pos~ion, zero the dial
    indicator. IA
    ..
    CAUTION IDeposits left on gasket
    surfaces will cause
    4. Turn the oil pump idler gear in the opposite direction leaks.
    until movement is again halted by contact with the crank
    gear. 7. Verify that all gaskets and gasket mating surfaces
    5. Take note ofthe dial indicator reading. Verifythatthe are clean and completely free of grease and oil.
    oil pump idler gear to crank gear backlash is between 8. Slide a new gasket on the mounting studs.
    0.008 and 0.012 inch (0.203 and 0.305 mm).

    CAUTION I A WARNING
    I..
    =A= ______
    L..
    Severe engine damage
    ....;;.._~. may result from opera-
    tion with "tight" or excessively worn gears.
    The magneto drive assembly weighs approximate-
    ly 70 Ibs. (32 Kg). Use a suitable lifting device and
    exercise caution during removal or installation to
    6. Back off the point of the dial indicator, rotate the oil avoid severe personal injury or death.
    pump idler gear 180 degrees and recheck the backlash.
    9. Locate the bolt hole between the'tWo rounded cuts in
    MAGNETO DRIVE ASSEMBLY INSTALLATION
    the flange of the magneto drive housing (see
    1. Remove the 3/4 inch NPT square head pipe plugs Figure 4.00-90). With the bolt hole at the 10 o'clock
    from taps 2 and 3 in the right bank main oil header. Oil position and the overspeed governor mounting pad
    header tap number 1 is at the front of the engine, while facing upward (but tilting toward the right), move the
    tap number 8 is at the rear. magneto drive down the mounting"Studs until the outer
    lip on the spindle side fits squarely in the hole in the rear
    2. Apply Perma Lok® Heavy Duty Pipe Sealant with gear housing.
    Teflon® to the threads of a 1/2 to 1/8 inch reducing
    bushing. Install the bushing in oil header tap number 2
    (for connection of the oil header pressure tube to the
    prechamber safety fuel shutdown valve).

    3. Apply Perma Lok® Heavy Duty Pipe Sealant with


    Teflon® to the threads of a 1/2 to 1/4 inch reducing
    bushing. Install the bushing in oil header tap number 3
    (for connection of the governor drive oil supply and
    overspeed governor oil header pressure tube connec-
    tions).

    4. Check the six magneto drive mounting studs for


    nicks, cracks, galled or stretched threads and other
    obvious damage. Replace as necessary (P/N B839).

    5. Each magneto drive mounting stud has both fine and Figure 4.00-90. Magneto Drive Assembly
    coarse threads separated by a smooth boss. Apply
    Loctite® Removable Threadlocker 242 to the coarsely 10. Install the fasteners (1/2 inch hex nuts with lock
    threaded side. washers) on the six mounting studs. Alternately wrench
    tighten.

    FORM 6248 First Edition 4.00 - 37


    CRANKCASE ASSEMBLY

    11. Remove the two side bolts (3/8 x 1 inch, with lock 14. Alternately wrench tighten the capscrews (5) to
    washers) from the magneto drive adapter cover, if secure the magneto drive support bracket to the block )
    installed (see Figure 4.00-91). and to the magneto drive adapter cover (see
    Figure 4.00-92).

    Figure 4.00-91. Remove Adapter Cover Side Bolts

    12. Leaving the fasteners loose, attach the magneto


    Figure 4.00-92. Mount Magneto Drive Assembly
    drive support bracket to the front right side of the engine
    block (3 capscrews, 1/2 x 1-1/8 inches, with both lock
    and flat washers). Slide the bracket forward until it
    contacts the magneto drive adapter cover.
    )
    NOTE: The round hole in the center of the bracket, as
    well as the rounded open-ended cut at the back,
    provides access to the second and third taps in the main
    oil header.

    13. Slide two longer fasteners (3/8 x 1-1/2 inches,


    with lock washers and flat washers) through the slots
    in the magneto drive support bracket. Install spacers
    (5/32 inch) on the capscrews and thread them into the
    magneto drive adapter cover.

    4.00 - 38 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    MAGNETO DRIVE GEAR INSTALLATION 4. With the timing marks facing outward, slide the
    magneto drive gear onto the drive shaft (see
    1. Use a piece of white chalk to highlight the timing Figure 4.00-94). Align the magneto drive gear so that
    marks (the number "12") on the face of the magneto the "A" marked on the magneto drive shaft and the" A"
    drive and accessory idler gears. The chalk enables the marked on the magneto drive gear lines up, and the
    technician to quickly focus on the timing marks, which number "12" stamped below the magneto drive gear
    facilitates installation and provides for easy confirma- root lines up with the "12" at the base of the accessory
    tion of correct timing. idler gear tooth (see Figure 4.00-93, Figure 4.00-94
    2. Bar the engine over, so that the "12" on the and Figure 4.00-95).
    accessory idler gear is facing the mag drive gear shaft
    (see Figure 4.00-93).

    ALIGN "0" BELOW TOOTH


    WITH '0" ON CRANK
    GEAR ROOT

    Figure 4.00-94. Drive Shaft

    5. Install the six magneto drive gearcapscrews (7/16 x


    3 inches, with lock washers) (see Figure 4.00-95).
    lighten the capscrews in an alterilating pattern (see
    Figure 4.00-96).

    LINE UP "A"
    "12" BELOW TOOTH TO BE ON
    ALIGNED WITH "12" BELOW MAGNETO
    MAG DRIVE GEAR ROOT DRIVE GEAR
    wrTH "A" ON
    Figure 4.00-93. Accessory Idler Gear - Timing Marks MAGNETO
    DRIVE SHAFT

    A WARNING
    Always wear suitable safety gloves when handling
    the magneto drive gear. The edges ofthe gear teeth
    are sharp enough to cm flesh If mishandled. If the
    gear slips from your grasp and drops, do not
    attempt to catch it. The sharp edges of the gear
    teeth combined with its weight 80 Ibs. (36 Kg) and
    momentum may cause severe lacerations.

    3. Rotate the magneto drive shaft so that the keyway


    slot and the "N marked on the shoulder face of the
    shaft, (marked between threaded holes) are at the top
    (see Figure 4.00-94 and Figure 4.00-95). Figure 4.00-95. Mount Magneto Drive Gear

    NOTE: An "A" is marked on both the front and rear of


    the magneto drive gear.
    FORM 6248 First Edition 4.00 - 39
    CRANKCASE ASSEMBLY

    Magneto Drive Gear to Accessory Idler Gear


    Backlash, Measure )
    1. Mount a dial indicator with a magnetic base on the
    rear gear housing flange next to the magneto drive gear.
    Position the indicator point againstthe inside face of any
    drive gear tooth.

    2. Secure the accessory idler gear against movement.

    3. Turn the magneto drive gear until contact with the


    stationary idler gear prevents further movement.

    4. Holding the magneto drive gear in position, zero the


    dial indicator.

    5. Turn the drive gear in the opposite direction until


    movement is again halted by contact with the stationary
    idler gear.

    6. Take note of the dial indicator reading. Verify that the


    magneto drive gear to accessory idler gear backlash is
    between 0.008 and 0.012 inch (0.203 and 0.305 mm).

    7. Back off the point of the dial indicator, rotate the


    magneto drive gear 180 degrees and recheck the
    backlash.

    CAUTION I
    I.=A=,---,;;..;;..~:......;;...;;..;;;....:~.
    Severe engine damage )
    Figure 4.00-96. Magneto Drive Gear TIghtening And L. . may result from opera-
    Torquing Pattern tion with "tight" or excessively worn gears.

    NOTE: If the backlash on a new gear is not within


    6. Torque the magneto drive gear capscrews to 60 ft-Ib
    specification, recheck the part number to be sure that
    (8t N·m).
    the correct gear was installed. If the gear is used, then
    7. To verify proper torque, retorque the capscrews the distance between the teeth gradually increases as
    moving clockwise around the mag drive gear hub. the gear wears, eventually resulting in excessive
    backlash. If the backlash is not within specification on a
    new or used gear, then the gear, and/or the gear with
    which it mates, must be replaced.

    4.00 - 40 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    A CAUTION I
    CYLINDER SLEEVE INSTALLATION
    I=...
    L. = ______.;;...;-...1.
    Do NOT use a cylinder
    sleeve gasket PIN
    A WARNING 1763750 with PIN 205130L sleeve. Using the
    cylinder sleeve gasket will cause the sleeve to
    Cylinder sleeve weighs approXimately 63lbs. (28 kg). project too far above the crankcase deck for
    Use a suitable lifting device and exercise caution proper head gasket sealing, causing severe
    during removal or installation to avoid severe per- engine damage.
    sonal injury or death.
    3. On 9-3/8 inch bore GL models with PIN 205130C
    1. Make sure that the crankcase counterbore is clean, and 205130H cylinder sleeves only (see
    as the new sleeve pilots in the upper crankcase bore Figure 4.00-98) Install cylinder sleeve gasket to the
    provide rigidity and support. cylinder sleeve.

    IA
    ...
    CAUTION I Remove caution tape
    "Do not use a cylinder
    sleeve gasket #1763750 with this sleeve as severe
    damage will occur", from the circumference of the
    PIN 205130L cylinder sleeve priorto installation, or
    severe engine damage will result.

    2. On PIN 205130L cylinder sleeves, (see


    Figure 4.00·97) remove the caution tape from the
    circumference ofthe cylinder sleeve. Clean any residue
    from the cylinder sleeve.

    Figure 4.00-98. Cylinder Sleeve

    4. Lubricate the a-rings and the crankcase a-ring


    bores with Parker Super-O-Lube® silicone lubricant,
    prior to installing the sleeve into the crankcase.

    NOTE: Prior to assembling the D-rings into the sleeve


    grooves, the grooves should be cleaned of any
    preservative oil. Remove all traces of the oil from the
    grooves. Failure to remove petroleum based oils will
    cause the ethylene propylene rings to swell when they
    come in contact with the oil.
    Figure 4.00-97. PIN 205130L Cylinder Sleeve Caution 5. Install the a-rings into the sleeve grooves by hand.
    Tape The red a-ring is silicone and is installed on the oil side

    FORM 6248 First Ednion 4.00 - 41


    CRANKCASE ASSEMBLY

    olthe sleeve. The two black O-rings are installed on the 10. Measure the bore diameter 2 and 8 inches
    water side of the sleeve. (51 and 203 mm) down from the top of the sleeve. The
    sleeve must be round within the tolerances listed in
    6. With the O-rings installed in the grooves, spiral the Table 3.05-14 and Table 3.05-15. lithe sleeve bore is out
    O-rings, using a pencil to remove the twists in the of round, reposition the sleeve and recheck tolerance.
    O-rings and properly seat the rings in the sleeve
    grooves (see Figure 4.00-99). 11. Repeat Steps 1 thru 10 for the remaining cylinder
    sleeves.

    PISTON AND CONNECTING ROD INSTALLATION

    A WARNING
    Always wear proper eye protection when removing
    piston pin retaining rings. Slippage may propel the
    ring with enough force to cause severe personal
    injury or death. Use the correct retaining ring
    pliers. Verify that the tips of the pliers are not
    excessively worn or damaged.
    NOTE: Refer to Chapter 3 for procedures to install
    piston rings.

    NOTE: The rounded edge of the retaining rings should


    Figure 4.00-99. Spiraling O-rings
    be oriented towards the piston pin.

    NOTE: Pull the pencil around the sleeve circumference 1. Install one piston pin retaining ring into the piston
    at least twice. (see Figure 4.00-101).

    7. Install the sleeve into the crankcase. The fit will be )


    snug. If the sleeve will not fit with a good push, pick up
    the sleeve, rotate and try again.

    NOTE: It is only necessary to snug the screws down in


    Step 8 to allow the sleeve to fully seat down against the
    crankcase counterbore.

    8. Using the crossbar from the sleeve puller (PIN


    499233), clamp the cylinder sleeve down against the
    crankcase counterbore.

    9. Measure the sleeve projection (see Figure 4.00-100


    above the crankcase deck. Refer to Table 3.05-14 and
    Table 3.05-15 for the proper sleeve projection value.

    MEASURE SLEEVE PROJECTION


    _ _ _ _ _ABOVE CRANKCASE DECK J
    1

    Figure 4.00-100. Sleeve Projection

    NOTE: If the O-rings become twisted during installa-


    tion of the sleeve, this may be enough to cause the
    cylinder sleeve to exceed out of round tolerance. When
    cylinder sleeve is repositioned, insure thai the O-rings Figure 4.00-101. Piston And Connecting Rod
    are not twisted.

    4.00-42 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    2. Lubricate a piston pin and insert it part way into the LATERAL LOCATING
    opposite piston pin boss. / TANG
    ROD CAP

    A WARNING
    (UNLOADED SIDE)

    Connecting rod weighs 62 Ibs. (28 kg). Use a


    suitable lifting device and the aid of an assistant
    when removing or installing the connecting rod to
    prevent severe personal injury or death.

    3. Position connecting rod between the piston pin


    bosses. Push the pin through the connecting rod and
    into position against the retaining ring.

    4. Install the second retaining ring into the piston.

    I.a
    A CAUTION I Do not touch the rod
    bearing runmng surface. /
    CENTERED
    LOCATING TANG
    Acidic skin secretions promote the start of surface ROD BLADE
    corrosion and wear in the affected area. (LOADED SIDE)

    A CAUTION I
    I=.a=
    L. __:...;......;...:__
    The bearing shells and
    ....::..:.;;...;~. rod bore must be com-
    pletelyfree of oil, dirt or other foreign material. Any
    dirt or debris caught between the bearing shell and
    bore results in bearing distortion and reduced
    service life.

    5. Wipe the rod bearing bore and bearing shells clean.

    6. Obtain a set of new connecting rod bearings. Each


    set consists of two shells. The shell installed in the cap, Figure 4.00-102. Connecting Rod Bearings
    which is the unloaded side of the rod, is fully grooved
    with no oil holes. The bearing installed in the blade is
    7. Position the fully grooved bearing shell above the
    partially grooved, the groove extending from the parting bearing seat on the rod cap. The shell diameter is
    edges of the shell to each oil hole (See slightly larger than the connecting rod bore (see
    Figure 4.00-102).
    Figure 4.00-103).

    / PARTING EDGES ~

    Figure 4.00-103. Connecting Rod Bore And Bearing


    Shell

    FORM 6248 First Ednion 4.00 - 43


    CRANKCASE ASSEMBLY

    8. Apply even pressure on the edges of the bearing to A. CAUTION II~sure that the piston
    press ~ into place. The locating tang on the parting edge I.L .=.a=~;;.;;....;;.::.......;;;..;;..;;;;..;;..:...J. ring compressor is prop- )
    ofthe shell mustftt squarely in the notch machined inthe erly installed on the piston, to prevent it from falling
    roll pin side of the cap (see Figure 4.00-104). off and causing damage to equipment and/or
    personal injury.
    NOTE: Stagger the piston ring openings 120 degrees,
    prior to installing the ring compressor on the piston.
    NOTE: Proper use of the piston ring compressor is
    especially important when installing the three ring
    piston, due to piston ring tangential load.

    14. Install the piston ring compressor (P/N 494085 for


    8-1/2 inch bore or PIN 494206 for 9-3/8 inch bore) on the
    BEARING RUNNING piston (see Figure 4.00-105).
    SURFACE
    ">( ROD CAP

    ~OILGROVE

    " BEARING SHELL

    Figure 4.00-1 04. Installing Bearing Shell

    9. Position the ungrooved bearing shell above the


    bearing seat on the rod blade. The locating tang
    centered on the parting edge of the bearing shell must
    be directly above the notch centered in the roll pin side
    PISTON RING
    of the blade. Apply even pressure on the edges of the COMPRESSOR
    bearing to press ~ into place.

    10. Verify that the two oil holes in the shell match up
    w~h the supply holes in the rod bearing bore.

    A. CAUTION Ilf the b!aring shells fit


    I.L .=.a='--:........;..;;;....;;..;;.._--I. loosely In the rod bear-
    ing bore, poor heat transfer will result In excessive CORRECT
    temperatures that shorten bearing service life. A
    spun bearing may damage the crankshaft journal.
    11. Verify thatthe bearing shells f~ tightly in the bearing
    PISTON RING
    bore. COMPRESSOR

    12. Lubricate the piston, piston rings, cylinder sleeve,


    crankshaft and bearings w~h clean engine oil.

    13. Using the engine barring device, bar the engine


    over until the crankshaft connecting rod journal is
    oriented towards the midpoint of the crankcase door Figure 4.00-105. Install Piston And Connecting Rod
    Assembly
    opening, on the same side of the engine as the piston
    being installed. 15. Install a piston puller (P/N 474018 for 8-1/2 inch
    bore or PIN 474019 for 9-3/8 inch bore) to the two
    threaded holes in the piston pin crown. )

    4.00 - 44 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    NOTE: Looking at the rod centerline, note that one 17. Install the connecting rod cap. Verify that the rod
    "leg" of the rod bore is longer than the other (see blade and cap are marked with the same cylinder
    Figure 4.00-106). The long "leg" olthe rod bearing bore location number (see Figure 4.00-107).
    must face inside toward the camshaft during installa-
    tion.

    1J
    THIS SIDE TOWARDS
    THE CAMSHAFT

    00'.' ~\mI.N"I-_-"''-----''''-_~\ A

    I
    ][ " \
    ROD CAP

    Figure 4.00-106. Connecting Rod Position

    16. Using a su~able lifting device and the aid of an


    assistant, slowly lower the piston into the cylinder bore. Figure 4.00-107. Connecting RoctCap Capscrew
    As the piston ring compressor touches the top circum- TIghtening Sequence - Roll Pih Equipped
    ference of the cylinder sleeve, the piston must be
    pushed down through the piston ring compressor and 18. Torque the four connecting rod capscrews in the
    into the cylinder sleeve. Hold the piston ring compressor proper numerical sequence, as follows:
    against the crankcase to prevent the rings from slipping
    out between the piston ring compressor and the A. Lubricate the the threads, and under the threads,
    crankcase. of four ferry head connecting rod capscrews with
    engine oil.
    A WARNING B. Locate the number "1" stamped in the connecting
    Both the connecting rod blades and caps are rod cap. Hand tighten a capscrew in this hole
    marked to Identify their location in the engine. For first. Hand tighten the remaining capscrews in
    example, 12 cylinder rods are marked 1R, 1L, 2R, pos~ions 2 thru 4 (see Figure Figure 4.00-107).

    2L, etc. Do not crossmate connecting rod blades


    C. Following the same numerical sequence, torque
    and caps. Disregarding this information could
    the capscrews to 50% of the final torque value.
    result in severe personal injury or death.
    D. Repeating the torque sequence, torque the
    A CAUTION I
    capscrews to a final torque value of 180 - 190
    Use the aid of a~ assis-
    I=..
    L. ='--''--'--''--....;;..~:--'.
    tant when lowering the
    piston and connecting rod assembly into the
    ft-Ib (244 - 257 N·m).

    19. Repeat Steps 1 thru 18 for each piston assembly.


    cylinder sleeve, to prevent damage to the cylinder
    sleeve, crankshaft, connecting rod journal and/or 20. Refer to Table 1.20-9 and verify thatthe connecting
    personal Injury. rod end play is 0.029 - 0.041 in. (0.7366 - 1.044 mm).

    FORM 6248 First Edition 4.00-45


    CRANKCASE ASSEMBLY

    OIL PAN 2. Inspect the baffle box for broken welds, split seams
    or cracks around the oil tube holes. Replace the baffle if )
    Oil Pickup Screen Installation damaged.
    1. Inspect the pickup screen for tears or holes (see
    3. Apply a fast setting gasket adhesive, such as 3M
    Figure 4.00-108). Replace the screen if damaged.
    Scotch Grip~ Rubber and Gasket Adhesive 847, on the
    oil tube flanges. Place new gaskets on the flanges.

    4. Install the oil tubes in the screening element. Place


    the baffle over the screen aligning the holes with those
    in the flange gaskets.

    5. Obtain two new gaskets for the oil elbow inletflanges


    and apply gasket adhesive to one side. Press the sticky
    side of the gasket onto the baffle aligning the holes with
    those in the box.

    6. Verify that the oil elbow inlet and outlet flanges are
    clean. Old gasket material or adhesive left on the mating
    surfaces may cause air or unfiltered oil to leak into the
    elbows.

    7. Finger tighten the oil elbow inlet flanges (2 caps-


    crews per elbow, 3/8 x 2 inches, with lock washers) to
    the pickup screen assembly. The inlet flange is on the
    shorter end of the elbow.

    8. Position the pickup screen assembly in the oil pan.

    9. Apply 3M Scotch Grip ~ Rubber and Gasket Adhe-


    sive 847 to the oil elbow outlet flanges. Place new
    gaskets on the flanges.

    10. Finger tighten the oil elbow outlet flanges (2


    capscrews per elbow, 3/8 x 1-1/8 inches, with lock
    washers) to the front of the oil pan.

    11. Alternately wrench tighten all capscrews.

    Figure 4.00-108. 011 Pickup Screen Assembly-


    12 Cylinder

    4.00 - 46 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    Figure 4.00-109. Oil Pan Seal

    Oil Pan Seal Installation 5. Apply a small amount of RTV Silicone Rubber
    Adhesive Sealant to one end of the seal. Press the ends
    I. Verify that the oil pan flange and seal groove are together. Use two oil pan bolts to hold the seal in place
    clean. until the adhesive is dry (see Figure 4.00-110).
    2. Place a new silicon rubber seal in the groove. Locate
    the break in the seal material along the right front side of
    the oil pan where the groove is straight (in the area
    between the first and second oil pan doors) (see
    Figure 4.00-109).

    3. Back the seal up slightly in the groove to obtain a little


    slack. This step ensures that both ends meet without
    any stretching of the material once the seal is cut.

    4. Hold both ends of the seal side-by-side and cut


    them diagonally at a 45 - 60 degree angle. Since each
    end must be cut althe same angleto provideforthe best
    fit, always cut both ends simultaneously.

    Figure 4.00-110. Oil Pan Seal - Front Right

    FORM 6248 First Edition 4.00 - 47


    CRANKCASE ASSEMBLY

    011 Level Dipsticks Installation Expansion Plug Instsllatlon


    )
    CAUTION I~posits
    1. Apply Loctite® Hydraulic Sealant around the edge of
    I=.A.="-==..;;..;;;...;;..:..~~.
    1... .
    left .on gasket
    surfaces will cause
    a new expansion plug (see Figure 4.00-112).
    leaks. Verify that the gasket and gasket mating
    surfaces are clean and completely free of grease
    and 011.

    1. Slide two new NyIok capscrews through the holes in


    the oil gauge support. Position a new gasket on the
    capscrews.
    2. Install the gauge support on the right side of the
    engine between the second and third oil pan doors.

    3. Install a new a-ring on the neck of the oil level gauge


    (see Figure 4.00-111). Apply Parker Super-O-Lube®
    silicone lubricant, to the a-ring. Install the gauge in the
    oil gauge support. Repeatthe procedure on the left side.

    IlO'N IFUU.
    i> 0 0 1I1If===::::l
    --------~2~~~\J~ EXPANSION
    PLUG
    I
    OoRlNG Figure 4.00-112. Expansion Plug Location
    Figure 4.00-111. Dipstick
    2. With the concave side facing inward, pos~ion the
    plug against the opening in the oil pump mounting
    flange. The correct opening (lower left corner) is easily
    identified by the counterbore.

    3. Using a suitably sized brass drift and a brass faced


    hammer, seat the plug squarely in the opening.

    4. Reach into the oil pan and push against the back of
    the plug to verify that it is tightly and squarely seated
    against the counterbore.

    Oil Pan Cover Plate Installation

    I.. CAUTION I
    =A.= ____
    L..
    Deposits left .on gasket
    ....;;.."'---'.
    surfaces Will cause
    leaks. Verify that the gasket and gasket mating
    surfaces are clean and completely free of grease
    and oil.

    1. Slide two fasteners through the holes in the


    diamond-shaped cover plate (1/2 x 1-1/2 inches, with
    lock washers). Hang a new gasket on the capscrews.

    2. Position the cover plate over the flange on the rear


    right corner of the oil pan. Tighten the capscrews. )
    Repeat the procedure on the rear left corner.

    4.00 - 48 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    CRANKCASE INSTALLATION to ensure that no dirt, grit or debris is caught between


    the block and the oil pan.
    1. Fill in the cross cuts at the rear corners of the oil pan
    with RTV Silicone Rubber Adhesive Sealant (see 5. Apply a bead of RTV Silicone Rubber Adhesive
    Figure 4.00-113). Sealant along the bottom seam formed where the front
    of the block mates with the rear gear housing cover.
    Apply another bead of RTV along the seam formed
    where the rear of the block mates with the lower half of
    the rear oil seal retainer.

    A WARNING
    While the crankcase Is suspended, do not put hands,
    arms, feet or any other body part beneath it. Stand
    back as far as possible and exercise extreme caution.
    Disregarding this Information could result in severe
    personal Injury or death.

    Figure 4.00-113.011 Pan Cross Cuts - Rear Right 6. Using a suitable lifting device, raise the crankcase.

    7. The upper flange of the oil pan has two locating


    2. Inspect the area where the oil pan seal bends around
    dowels, one at the front left corner, the other at the rear
    the rear corners ofthe oil pan. Use RTV Silicone Rubber
    right corner. With the crank shaft gear end of the
    Adhesive Sealantto fill any small gaps between the seal
    installed crankshaft on the same side as the lube oil
    and the inside wall of the groove.
    pump mounting pad on the oil pan, carefully lower the
    3. From the center of the second oil pan door up to the crankcase down on the locating dowels and the oil pan.
    first bolt hole on the right bank side, lay a bead of RTV
    8. Install the 28 capscrews (3/4 x~2-1/2 inches, with
    Silicone Rubber Adhesive Sealant in the gap between
    washers) around the perimeter oftheoil pan, 12 on each
    the oil pan seal and the inside wall of the groove. Repeat
    side and 4 in the rear. Torque the 28 capscrews ofthe oil
    this step on the left bank side.
    pan to 215 ft-Ib (292 N·m).

    A WARNING 9. Install the two smaller oil pan capscrews (5/8 x 2-1/4
    inches, with washers) in the bottom of the rear gear
    The crankcase at this point in assembly may weigh as housing at the front of the engine, one on each Side of the
    much as 13,000 Ibs. (5897 kg). To avoid serious crankshaft bore (see Figure 4.00-114 and
    personal injury or death, always consider the weight Figure 4.00-115). Torque the 2 smaller capscrews
    of the engine when selecting hoisting chains and threaded into the rear gear housing to 150 ft-Ib (203 N·m).
    lifting equipment. Never exceed the maximum capac-
    ity rating of the lifting device. Inspect the lifting
    equipment for physical damage or defects before
    use. Remain alert to potential hazards.

    A WARNING
    Always lift the crankcase using the approved lifting
    eyes. The 12 Cylinder VHP engine Is equipped with
    two pairs of lifting eyes, one pair at the front, the
    other pair at the rear. Follow approved rigging
    procedures. Always use the proper spreader bar to
    ensure that no undue strain Is placed on the lifting
    eyes and hoisting chains. Disregarding this In-
    formation could result in severe personal injury or
    death.

    4. While the crankcase still installed in the engine


    stand, thoroughly clean the bottom of the cylinder block Figure 4.00-114.011 Pan Capscrew - Front Right

    FORM 6248 First Edition 4.00-49


    CRANKCASE ASSEMBLY

    A WARNING
    The front flywheel housing weighs approximately
    205 Ibs. (93 kg). Use a suitable lifting device and
    exercise caution during removal or installation to
    avoid severe personal injury or death.
    3. Attach a suitable lifting device to the front flywheel
    housing (see Figure 4.00-117).

    Figure 4.00-115. Oil Pan Capscrew - Front Left

    10. Remove the hoisting chains from the lifting eyes.

    FRONT FLYWHEEL HOUSING INSTALLATION

    NOTE: Insure that the camshaft rear cover plate is


    installed prior to installing the front flywheel section.

    1. Install two 1-1/2 inch dowel pins into the rear face of
    the engine block to a depth of 3/4 inch.

    2. Thoroughly wipe the flanges where the front flywheel


    Figure 4.00-117. Front Flywheel Sectlon
    housing mates with the rear face of the block (see
    Figure 4.00-116). Dirt, grit or other debris will prevent 4. Position the front flywheel housing on the dowel pins
    proper seating. Verify that the mating flanges are (see Figure 4.00-117 and Figure 4.00-118). Note that
    completely smooth. Use a fine toothed pattern file to the bore resembles the shape of the rear oil seal retainer
    lightly dress down any burrs or high spots. assembly.

    Figure 4.00-116. Crankcase - Rear Figure 4.00-11 B. Front Flywheel Housing Capscrew
    TIghtening Pattern

    4.00 - 50 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    5. Start two capscrews (5/8 x 1-1/2 inches, with lock NOTE: Disregard the 7DC" marking on the rim of the
    washers) in the top center segment of the front flywheel flywheel, which is the reference mark for 6 cylinder models.
    housing (see Figure 4.00-118).

    6. Start the remaining twelve capscrews (5/8 x 1-1/2


    inches, with lock washers) in the frontflywheel housing.

    7. Alternately tighten the four capscrews (5/8 x 1-1/2


    inches, with lock washers) around each dowel pin (see
    Figure 4.00-118). Tighten the remaining capscrews.

    8. Remove the lifting device.


    ATTACH
    TIMING TAPE INSTALLATION THIS TAPE
    Gheck the condition of the timing tapes. Replace the
    tapes if torn, deteriorated or peeling.

    1. Remove the old timing tapes and discard.

    2. Thoroughly clean the rim of the flywheel to remove


    all oil, grease and dirt.

    3. Peel the adhesive backing off a new timing tape. Avoid


    kinking the tape when the protective paper is removed.

    A CAUTION I~o not touch the ~dhe­


    I=.a=:........;=~~~~:..:..J.
    L. Slve surface on the timing
    tape or its bonding ability will be adversely affected.

    4. Carefully align the "TOG" mark on the timing tape (see


    Figure 4.00-120) with the "#1 RB TOG" mark on the rim of
    the flywheel (see Figure 4.00-119). Be sure the tape is
    readable when facing the flywheel from the rear. Place
    the top of the tape (the inside edge) directly behind the
    letter 'T' in "TOG" on the rim of the flywheel. To get the
    tape on straight, use the machining lines for reference.

    ALIGN TDC MARKS ON


    TWO TAPES AT THESE
    LOCATIONS
    ATTACH THIS
    SECOND TAPE
    OVER THE
    FIRST TAPE

    mc

    #6 LB mc

    PAINTED MARK
    AT50'CLOCK
    POSITION

    Figure 4.00-119. Flywheel Timing Tape Locations


    Figure 4.00-120. Timing Tape

    FORM 6248 First Edition 4.00 - 51


    CRANKCASE ASSEMBLY

    5. Use a smooth roller or another blunt object to tightly


    press the tape into place. )
    6. Align the "TDC" mark on a second timing tape (same
    part number) with the "#6LB TDC" mark on the rim ofthe
    flywheel (see Figure 4.00-119). Press the tape into
    place, overlapping a portion of the first tape with the end
    of the second.

    FLYWHEEL INSTALLATION
    1. Rotate the crankshaft until the keyway in the crank
    gear is at the top (see Figure 4.00-121).

    Figure 4.00-122. Llftl ng The Flywheel

    3. Thread two guide pins into the crank hub in the 3


    o'clock and 9 o'clock positions (see Figure 4.00-123).

    LIFTING BRACKET BOLT HOLES


    )
    Figure 4.00-121. Orient Crank Gear

    A WARNING
    The flywheel weighs approximately 900 Ibs. (408 kg).
    Use a suitable lifting device and exercise caution
    during removal or installation to avoid severe
    personal Injury or death.

    IA CAUTION IHandle the flvw.h~1 with CRANK HUB


    .L .:: care. As a precision ma-
    .=:.......::=....;;..;:;....;;..:..=...;:.:...J.
    . GUIOEPIN
    chined component, the condition of the flywheel is HOLES
    critical to satisfactory engine performance. Disre-
    garding this information could result in product Figure 4.00-123. Flywheel Mounting
    damage and/or personal Injury.
    4. Thoroughly wipe the face and rim of the crankshaft
    2. Mount the lifting bracket to the flywheel using the
    hub. Thoroughly wipe the counterbore at the back of the
    three outside bolts holes shown (see Figure 4.00-122).
    flywheel. Dirt, grit or other debris will prevent proper
    Be sure that suspension of the flywheel places the
    seating. Verify that all mating surfaces are completely
    painted marked at the 5 o'clock position.
    smooth. Use a fine toothed pattern file to lightly dress
    down any burrs or high spots.

    5. Attach a suitable lifting device to the flywheel lifting )


    bracket.

    NOTE: The painted mark indicates an offset hole. This


    offset hole insures the correct installation of the flywheel.

    4.00 - 52 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    6. With the painted mark at the 5 o'clock position, slide 12. Alternately torque the flywheel capscrews to
    the flywheel down the guide pins until it makes solid 171 - 175 ft-Ib (232 - 237 N·m).
    contact with the crankshaft hub (see Figure 4.00-124).
    MAGNETIC PICKUP SENSOR INSTALLATION
    1. Position a new copper washer on the 5/8 inch hex
    head plug.

    2. Locate the two holes in the lower right side of the front
    flywheel housing. Install the plug in the selected hole.

    3. Rotate the flywheel until the tooth of the ring gear is


    centered in the unplugged hole (see Figure 4.00-126).

    FRONT FLYWHEEL
    SPOT FAC~6=:::::::::,," HOUSING
    ,... (UPPER HOLE)

    Figure 4.00-124. Mount Flywheel

    7. Ughtly lubricate the flywheel capscrews. Use a


    ~
    RING GEAR TOOTH

    Figure 4.00-126. Ring Gear Tooth Alignment


    .
    quality high viscosity oil.
    A CAUTION I Be su~1!: that the top of
    8. Tighten the four lower capscrews (5/8 x 2 inches,
    with hardened washers) to hold the flywheel flat against
    I....~":=7""';;'-~-::-~-:-::-"
    thetO<if!ls paralleito the
    pole face, or rotation of the flywheel will damage the
    the hub of the crankshaft. pickup sensor. .
    9. Remove the lifting bracket from the flywheel (see 4. Thread the magnetic pickup inlet the hole until the
    Figure 4.00-125). pole face bottoms out on the flat head of the ring gear
    tooth (see Figure 4.00-127). ._.

    NOTE: If the rear flywheel housing is installed, the


    feeler gauge cannot be used.
    5. Back out the pickup one turn.

    6. Use a feeler gauge to verify that the gap between the


    pole face and the top of the tooth is 0.040 ±0.010 inch
    (1.0 ±0.25 mm) (see Figure 4.00-127).

    Figure 4.00-125. Remove Lifting Bracket --0.(140".0.010" GAP


    (1.0 • 0.25 mm)
    10. Remove the two guide pins from the crankshaft
    hub. Figure 4.00-127. Install Magnetic Pickup Sensor
    11. Install the eight remaining flywheel capscrews 7. Tighten the jam nut (7/8 inch hex) against the spot
    (5/8 x 2 inches, with hardened washers). face on the flywheel housing.

    FORM 6248 First Edition 4.00 - 53


    CRANKCASE ASSEMBLY

    REAR FLYWHEEL HOUSING INSTALLATION 7. Start the remaining twelve capscrews in the rear
    flywheel housing. Wrench tighten using the pattern )
    1. Install two 1-1/8 inch dowel pins into the rear face of shown (see Figure 4.00-128).
    the front flywheel housing (at the 2 o'clock and 7 o'clock
    positions) to a depth of 1/2 inch. 8. Remove the lifting device.
    2. Thoroughly wipe the mating flanges of the front and
    9. Remove the two capscrews between the dowel pin
    rear flywheel housings. Dirt, grit or other debris will and the starter bore on the left bank side (for mounting of
    prevent proper seating. Verify that the mating flanges the oil filler bracket). Remove the single capscrew
    are completely smooth. Use a fine toothed pattern file to between the timing pointer and the dowel pin on the right
    lightly dress down any burrs or high spots. bank side (for mounting of the bulkhead connector
    bracket).
    A WARNING
    The rear flywheel housing weighs approximately
    110 Ibs. (50 kg). Use a suitable lifting device and
    exercise caution during removal or installation to
    avoid severe personal injury or death.
    3. Attach a suitable lifting device to the rear flywheel
    housing.
    4. With the straight edge down, hang the rear flywheel
    housing on the dowel pins.
    5. Release the tension on the lifting chain, so that the
    full weight of the housing is supported by the dowels.

    A CAUTION I
    ILte.::n=s=io:....n...;:;.o~n....;t:-;he"--re-a-r"'::fI:-yw-:-'heel
    . ..
    Be sure the lifting device
    . does not place too much
    housing as it is bolted
    )
    down. Too much tension on the lifting chain will pull
    the housing into an egg shape, resulting in a bore
    runout that exceeds specification.
    6. Tighten the two capscrews (1/2 x 1-1/2 inches, with
    lock washers) on each side of the dowel pins (see
    Figure 4.00-128).

    9 10
    o
    o 0

    DOWEL PINS (2)

    o
    16 / 15 )
    STRAIGHT EDGE

    Figure 4.oo-12B. Rear Flywheel Housing Capscrew


    Tightening Pattern

    4.00 - 54 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    FLYWHEEl./FLYWHEEL HOUSING BORE AND Flywheel Housing Rear Face Runout Measure
    FACE RUNOUT MEASURE
    1. Mount a dial indicator with a magnetic base on the
    1. Verify that the flywheel and rear flywheel housing flat face of the flywheel (top center) (see
    (bore and face) are clean and free of dirt, grit or other Figure 4.00-130). Position the indicator button against
    foreign matter. Figure 4.00-129 shows the measure- the face of the flywheel housing. Zero the dial indicator
    ments that are required for proper flywheel mounting. gauge.

    -+-+- B

    C Figure 4.00-130. Flywheel HouslngReer Face Runout

    2. Apply pressure to the front of the crankshaft to


    remove crankshaft endplay, and rotate the crankshaft
    counter-clockwise a full 360 degr~es. Jot down the
    indicator reading every 90 degrees.'

    3. Note the four dial indicator readings. Verify that the


    • •-'--:--:-- E flywheel housing face runout does not exceed 0.012 inch
    (0.305 mm) total indicator reading.

    A PILOT BEARING BORE RUNOUT


    B FACE RUNOUT ON WHEEL
    C HOUSING BORE RUNOUT
    D HOUSING FACE RUNOUT
    E= FLYWHEEL CLUTCH OR COUPUNG MOUNTING
    FACE RUNOUT
    F = FLYWHEEL CLUTCH OR COUPUNG
    PILOT DIAMETER RUNOUT
    G= FLYWHEEL HOUSING REAR FACE TO
    CRANKSHAFT FLANGE

    Figure 4.00-129. Flywheel, Flywheel Housing Bore


    And Face Runout

    )
    2. Dress down any burrs or high spots using a fine
    toothed pattern file. Surface imperfections may result in
    false indicator readings.

    FORM 6248 First Edition 4.00- 55


    CRANKCASE ASSEMBLY

    In examples A and B of Figure 4.00-131, the total 2. Apply pressure to the front of the crankshaft to
    indicator reading is 0.002 inch (0.051 mm), indicating remove crankshaft endplay, and rotate the crankshaft )
    that the flywheel housing face runout is well within counter-clockwise a full 360 degrees. Jot down the
    specification. indicator reading every 90 degrees.

    3. Note the four dial indicator readings. Verify that the


    EXAMPLE A EXAMPLEB flywheel housing face runout does not exceed 0.01 0 inch
    (0.254 mm) total indicator reading.

    Flywheel Clutch Or Coupling Mounting Face


    Runout Measure
    Procedures to measure the flywheel clutch or coupling
    mounting face runout are the same as in Flywheel Face
    +.002 -.002
    Runout On Wheel (above). Refer to Figure 4.00-129 (E) for
    location of the dial indicator. Total indicator reading must not
    exceed 0.016 inch (0.406 mm)
    EXAMPLE C EXAMPLED
    Flywheel Housing Bore Runout Measure
    .000 .000

    -ElJ- --ElJ--
    1. Mount a dial indicator with a magnetic base on the flat
    face of the flywheel (see Figure 4.00-133). Position the
    indicator button against the flywheel housing bore ID. Zero
    the dial indicator gauge.

    +.002 +.006

    Figure 4.00-131. Total Indicator Reading (TIR) In DIAL


    (FLYWHEEL
    Inches

    In examples C and D of Figure 4.00-131, the flywheel


    )
    housing is out of specification with a total indicator
    reading of 0.014 inch (0.356 mm) and 0.013 inch
    (0.330 mm), respectively.
    Flywheel Face Runout On Wheel Measure

    1. Mount a dial indicator with a magnetic base on the


    face of the flywheel housing (top center) (see
    Figure 4.00-132). Position the indicator button against
    the flat face of the flywheel. Zero the dial indicator gauge.

    Figure 4.00-133. Flywheel Housing Bore Runout

    2. Apply pressure to the front of the crankshaft to


    remove crankshaft endplay, and rotate the crankshaft
    counter-clockwise a full 360 degrees. Jot down the
    indicator reading every 90 degrees.

    3. Note the four dial indicator readings. Verify that the


    flywheel housing bore runout does not exceed 0.012 inch
    (0.305 mm) total indicator reading.

    Figure 4.00-132. Flywheel Face Runout On Wheel

    4.00 - 56 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    Flywheel Clutch Or Coupling Pilot Diameter 2. Mount a dial indicator with a magnetic base on the
    Runout Measure bar directly over the flywheel bearing bore. Position the
    indicator button against the flywheel bore ID (see
    1. Refer to Figure 4.00-129 (F) for location of the dial Figure 4.00-135). Zero the dial indicator gauge.
    indicator.

    2. Mount a dial indicator with a magnetic base on the


    face of the flywheel housing (top center). Position the
    indicator button against the clutch or coupling pilot
    diameter ID. Zero the dial indicator gauge.

    3. Apply pressure to the front of the crankshaft to


    remove crankshaft endplay, and rotate the crankshaft
    counter-clockwise a full 360 degrees. Jot down the
    indicator reading every 90 degrees.

    4. Note the four dial indicator readings. Total indicator


    reading must not exceed 0.005 inch (0.130 mm).

    Flywheel pilot bearing Bore Runout Measure

    1. Remove one capscrew from the side of the flywheel


    housing and mount a solid horizontal bar that crosses
    the flywheel bore (see Figure 4.00-134).
    Figure 4.00-135. Flywheel Pilot Bearing Bore Runout

    3. Apply pressure to the front at the crankshaft to


    remove crankshaft endplay, and rotate the crankshaft
    counter-clockwise a full 360 degrees. Jot down the
    indicator reading every 90 degrees,.

    4. Note the four dial indicator readings. Verify that the


    flywheel bore runout does not exceed 0.005 inch (0.127
    mm) total indicator reading.

    Figure 4.00-134. Horizontal Support Bar

    ,
    )

    FORM 6248 First Edition 4.00 - 57


    CRANKCASE ASSEMBLY

    BARRING DEVICE INSTALLATION OIL FILLER BRACKET INSTALLATION


    )
    1. With the straight edge facing the block, fasten the 1. Fasten the oil filler bracket to the left bank side of the
    barring device to the starter bore on the left bank side of rear flywheel housing (2 capscrews, 1/2 x 1-3/4 inches,
    the front flywheel housing (3 capscrews, 5/8 x 1-1/4 with lock washers). Use the two open bolt holes
    inches, with lock washers) (see Figure 4.00-136). between the starter bore and the lower dowel pin (see
    Figure 4.00-137). The rounded cut in the bracket
    accommodates the rib in the rear flywheel housing.

    BARRING
    DEVICE

    Figure 4.00-136. Front Flywheel Housing - Rear Left

    Figure 4.00-137. Mount Oil Filler Bracket - Rear Left )


    2. Wrap the U-bolt around the oil filler pipe and fasten it
    to the oil filler bracket (3/8 inch flat washers, lock
    washers and hex nuts) (see Figure 4.00-138).

    Figure 4.00-138.011 Filler Pipe/Bracket - Rear Left

    3. Fasten the chain ofthe oil filler cap to the bracket and
    screw the cap on the inlet pipe.

    4.00 - 58 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    GEAR TRAIN LUBRICATION


    1. Using a small paintbrush, apply Lithoplex® Grease
    No.2 (Multipurpose Lithium Complex Formula Contain-
    ing Molybdenum Disulfide) to the teeth of each gear in
    the gear train: cam, camshaft idler, accessory idler,
    accessory (magneto) drive, crank and oil pump idler
    gears (see Figure 4.00-139). Restrict the application to
    those teeth that are easily accessed (see
    Figure 4.00-140).

    Figure 4.00-139. Grease Gear Train

    1 - CAM GEAR
    2 - CAM IDLER GEAR
    3 - CRANK GEAR
    4 - OIL PUMP IDLER GEAR 4 I
    "..... _.....
    5 - ACCESSORY IDLER GEAR \ /
    6 - ACCESSORY (MAGNETO) DRIVE GEAR
    /

    Figure 4.00-140. Lube Gear Train

    FORM 6246 Firs1 Ednion 4.00- 59


    CRANKCASE ASSEMBLY

    OIL SLINGER/FRONT OIL SEAL/GEAR COVER 4. Apply an even coat of Permatex® Aviation Form-A-
    INSTALLATION Gasket Sealant over the width of the machined area. )
    1. With the concave side facing outward, position the oil 5. Thoroughly wipe the new front oil seal with a clean
    slinger down the front of the crankshaft until it contacts cloth. Verify that the expander spring is in place behind
    the crankshaft gear (see Figure 4.00-141). the seal lip. Carefully check the seal for defects.
    Replace if damaged.

    6. With the Waukesha PIN facing upward (the lipped


    side inward). position the front oil seal over the gear
    cover crankshaft bore (see Figure 4.00-143).

    Figure 4.00-141. 011 Slinger/O-Rlng

    2. Position a new O-ring down the shaft until it contacts Figure 4.00-143. Front 011 Seal )
    the slinger (see Figure 4.00-141).

    I A. CAUTION I Oil leakage will occur.if


    .==---..:=....;;..;::;...;;....:...=:....:....:;..J.
    .L.:: . the front 011 seal .s
    Installed Incorrectly.
    3. Position the gear cover on a flat surface with the
    concave side facing down. Be sure that the machined
    area within the gear cover crankshaft bore is clean and
    smooth (see Figure 4.00-142). Use compressed air to
    blowout all dust and debris.

    Figure 4.00-142. Gear Cover

    4.00 - 60 FORM 6248 First Edrtion


    CRANKCASE ASSEMBLY

    EXPANDER
    MACHINED SUI~FA,CE!><~

    COVER
    CRANKSHAFT __ .._,

    FRONT OIL

    MACHINED SUI~FACE!;--

    Figure 4.00-144. Install Front 011 Seal

    7. Press the seal into the bore to a depth of 3/8 inch (9.5 16. Apply Permatex® Aviation Form-A-Gasket Seal-
    mm) (see Figure 4.00-144). Use the large end of the ant to the six areas where the dovetails interlock.
    tapered crankshaft pulley sleeve as a seal installation
    tool. 17. Fill in the cross cuts (see Figure 4.00-145) at the
    front corners of the oil pan with RTV Silicone Rubber
    8. Verify that the front oil seal is squarely seated in the Adhesive Sealant.
    bore.

    CAUTION I
    I A=~=...;;.;:;...;;...;;..;:;...;;....;..J.
    Deposits left on gasket
    .L .::
    .. surfaces will cause leaks.

    9. Be sure thatthe mating flanges olthe gear cover and


    rear gear housing are clean and smooth.

    10. Lay the gear cover on a flat surface with the


    concave side facing up.

    11. Aligning the holes in the gasket with those in the


    gear cover, assemble a new gasket on the flange
    around the outside edge of the gear cover. The gasket is
    made up of seven separate pieces. Fit the dovetailed
    sections together to interlock the gasket strips. If
    necessary, trim the dovetails to find the best fit.
    Figure 4.00-145.011 Pan Croas Cuts - Front Left
    12. Remove the assembled gasket from the gear cover
    flange.
    18. Inspect the area where the silicon oil pan seal
    13. Apply 3M Scotch Grip" Rubber and Gasket bends around the front corners of the oil pan. Use RTV
    Adhesive 847 to the gear cover flange. Silicone Rubber Adhesive Sealant to fill any small gaps
    between the oil pan seal and the inside wall of the
    14. Reassemble the gasket on the flange. Gentty push groove.
    down on the gaskets to verify that the strips are properly
    ) seated.

    15. Using a ball peen hammer, lightty tap the dovetails


    to flatten the tabs. Upraised tabs may cause the gasket
    to be pulled loose when the cover is slid into place.

    FORM 6248 First Edition 4.00 - 61


    CRANKCASE ASSEMBLY

    IA
    ..
    CAUTION I With the locating dowels
    in place, installation re- A WARNING )
    quires that the gear cover be slid horizontally along The gear cover weighs approximately 160 Ibs.
    the top of the oil pan. Sliding the cover in this (73 kg). Use a suitable lifting device and use caution
    manner will pull up and damage the silicon oil pan during removal or installation to avoid severe
    seal. personal injury or death.
    19. Remove the two dowel pins from the gear cover, if 20. Attach a suitable lifting device to the gear cover.
    installed (see Figure 4.00-146).
    21. Position the gear cover against the flange of the
    rear gear housing. Lower the cover into position so that
    it does not slide along the top of the oil pan.

    E D

    A ___ ---'t
    ~ OIL PAN TO GEAR COVER - 6 CAPSCREWS

    fO\ REAR HOUSING TO GEAR COVER - 15 CAPSCREWS

    @ GEAR COVER TO REAR HOUSING - 13 CAPSCREWS

    • DOWEL PIN HOLES - 2

    Figure 4.00-146. Gear Cover Tightening Pattern (A - F)

    4.00 - 62 FORM 6248 First Edition


    CRANKCASE ASSEMBLY

    /GUIDE PIN LOCATION

    • 0 0

    SNUG CAPS CREWS (4)

    Figure 4.00-147. Installing The Gear Cover

    22. Insert two guide pins in the dowel pin holes (see E. Install 5 capscrews (1/2 x 1-3{8 inches, with lock
    Figure 4.00-147). The guide pins ensure that the gear washers) in the right bank side of the front gear
    cover is properly situated before the fasteners are cover. Leave one bolt hole oPen for mounting of
    installed. the safety guard and the water pump drain pipe
    bracket (see Figure 4.00-146). Wrench tighten.
    23. Snug four capscrews (1/2 x 1-3/8 inches, with lock
    washers) in the locations shown (see Figure 4.00-147). F. Install 3 capscrews (1/2 x 1-3/8 inches, with lock
    Remove the lifting chain. washers) at the top of the front gear cover.
    Wrench tighten.
    24. Install 34 gear cover capscrews in the following
    pattern (see Figure 4.00-146). 25. Remove the two guide pins and install the dowel
    pins. Use a hammer and a blunt tipped center punch to
    A. Secure the bottom flange of the gear cover to the ensure that the pins are fully seated in the rear gear
    front of the oil pan (6 capscrews, 1/2 x 1-3/4 housing flange.
    inches, with flat washers). Torque the capscrews
    to 125 ft-Ib (170 N·m). 26. Remove lifting device.

    B. Install 9 capscrews (1/2 x 3 inches, with lock


    washers) in the right bank side of the rear gear
    housing. Wrench tighten.

    C. Install 6 capscrews (1/2 x 3 inches, with lock


    washers) in the left bank side of the rear gear
    housing. Leave three bolt holes open for mount-
    ing of the prelube pump/motor mounting bracket
    (see Figure 4.00-146). Wrench tighten.

    D. Install 5 capscrews (1/2 x 1-3/8 inches, with lock


    washers) in the left bank side of the front gear
    cover. Leave one bolt hole open for mounting of
    the safety guard (see Figure 4.00-146). Wrench
    tighten.

    FORM 6245 First Edttion 4.00 - 63


    CRANKCASE ASSEMBLY

    FRONT GEAR COVER PLATES INSTALLATION REAR GEAR HOUSING COVER PLATE INSTALLA-
    TION )
    1. With the WED PIN facing outside, install two
    fasteners (3/8 x 7/8 inch, with lock washers) in the 6 inch 1. Check the six rear gear housing cover plate mount-
    diameter cover plate. Position a new gasket on the ing studs for nicks, cracks, burrs, galled or stretched
    capscrews. Finger tighten the cover plate over the threads and other obvious damage. Replace as neces-
    upper left hole in the gear cover (see Figure 4.00-148). sary.
    Install the remaining four capscrews. Wrench tighten in
    an alternating pattern. 2. Each cover plate stud has fine and coarse threads
    separated by a smooth center boss. Apply Loctite®
    Removable Threadlocker 242 to the first three threads
    on the coarsely threaded side.

    I.. CAUTION IDonoti~stallcoverplate


    =A=,-,,,-,--,,-,,--,-,,,-,~.
    L.. studs With a pipe wrench
    or similar device. Use a collet type stud driver for
    installing studs, to avoid damage to the studs and
    threads.

    3. Install the studs in the flange on the rear left bank


    side of the rear gear housing. Install each stud into the
    flange until the last coarse thread is turned into the
    casting. Use a collet type stud driver for best results.

    CAUTION I
    I=.A=,-=-.:.",-=-.:.-,-,-,. Deposits left .on gasket
    L.. . surfaces Will cause
    leaks.
    )
    4. Verify that the gasket and gasket mating surfaces
    Figure 4.00-148. Gear Cover Plates - Front Left are clean and completely free of grease and oil.

    5. POSition a new gasket on the mounting studs.


    2. With the WED PIN facing outside, install two
    fasteners (3/8 x 7/8 inch, with lock washers) in the 5-1/4 6. Position the cover plate on the mounting studs and
    inch diameter cover plate. Position a new gasket on the install the fasteners (1/2 inch lock washers and hex
    capscrews. Fingertighten the cover plate over the lower nuts) (see Figure 4.00·149).
    left hole in the gear cover. Install the remaining four
    capscrews. Wrench tighten in an alternating pattern.

    Figure 4.00·149. Rear Gear Housing - Front Left

    4.00 - 64 FORM 6248 First Ed~ion


    CRANKCASE ASSEMBLY

    REAR
    VIBRATION
    /DAMPER

    FRONT
    PULLEY
    I SPACER

    FRONT/"
    VIBRATION
    DAMPER

    Figure 4.00·150. VIbration Damper/Crankshaft Pulleys

    VIBRATION DAMPER/CRANKSHAFT PULLEY


    INSTALLATION AWARN~G
    I.A. CAUTION Icrankshaft
    The rear crankshaft pulley wetg'hs approximately
    Do not machine the rear 85 Ibs. (39 kg). Use a suitable lifting device and
    pulley spacer exercise caution during removal or Installation to
    to remove the wear groove. Reducing the outside avoid severe personal InJury or..death.
    diameter of the spacer will adversely affect the
    sealing performance of the front 011 seal. 5. Attach a suitable lifting device to. the rear crankshaft
    pulley.
    1. Inspect the rear pulley spacer where the smooth
    surface made contact with the front oil seal. Install a new 6. With the wide rim facing downward, place the rear
    spacer if a wear groove can be seen or felt. crankshaft pulley (10 inch) on a clean floor mat. The rear
    crankshaft pulley is easily distinguished from the front
    2. With the tapered end facing toward the block, move pulley by the ten holes and the protruding lip on both the
    the rear pulley spacer down the crank until it contacts front and rear faces.
    the oil slinger. The inside bevel on the tapered end
    prevents damage to the O-ring (see Figure 4.00-150). NOTE: Since the normal service life of vibration
    dampers is approximately 40,000 running hours, it is

    I..
    1...
    CAUTION I
    =A= ______ The front 011 seal must
    seat on the smooth sur-
    --1.
    recommended that they be replaced at the time of
    overhaul.
    face ofthe pulley spacer or oil sealing and seal wear
    qualities will be adversely affected. A WARNING
    3. Verify that the front oil seal is completely seated on The rear vibration damper weighs approximately
    the smooth surface of the pulley spacer. 115 Ibs. (52 kg). Use a suHable lifting device and
    exercise caution during removal or Installation to
    4. Install the crankshaft pulley sleeve with the large end avoid severe personal Injury or death.
    facing inward, the smaller tapered end facing outward.

    FORM 6248 First Ednion 4.00- 65


    CRANKCASE ASSEMBLY

    CAUTION I
    I.=A=--===..:..;::....:...:...;=-=~.
    Carefully inspect the A CAUTION I
    I.. Carefully Inspect the
    L. . new damper before use. ==--===..:..;::....:...:...;=-=~_
    L. new damper before use.
    Damage may occur from careless handling. Verify Damage may occur from careless handling. Verify
    that the damper case is free of dents or bulges. that the damper case Is free of dents or bulges.
    Damage to the case may restrict the movement of Damage to the case may restrict the movement of
    the internal iron weight resulting in gear train clatter the Internal iron weight resulting in gear train clatter
    and excessive vibration. and excessive vibration.

    7. Attach a suitable lifting device to the rear vibration 12. Attach a suitable lifting device to the front vibration
    damper. damper.

    8. With the recessed side facing upward, place a new 13. With the WED PIN and the cautionary message
    rear vibration damper on top of the rear crankshaft ("Handle Damper With Care") facing outward (and the
    pulley (the end closest to the two wide pulley sheaves). inside bevel facing the block), slide a new front vibration
    The lip on the pulley seats in the damper hub. Align the damper onto the crankshaft. Move the damper down the
    holes in the damper with those in the pulley and install guide studs until it contacts the rear pulley. Be sure that
    the fasteners (10 ferry head capscrews, 1/2 x 1-1/2 inch, the lip on the pulley is evenly seated in the damper hub.
    with lock washers). Torque the capscrews to 86 ft-Ib
    (117 N·m).

    A WARNING
    The pulley/damper assembly weighs approximately
    200 Ibs. (91 kg). Use a suitable lifting device and
    exercise caution to avoid severe personal injury or
    death.

    9. Attach a suitable lifting device to the pulley/Vibration )


    damper assembly.

    10. With the damper-side facing inward, slide the


    assembly down the crankshaft. The bore of the rear
    pulley is made to fit the tapered pulley sleeve.

    11. Thread three guide studs (minimum) into the front


    face of the rear pulley. Position the studs so that there is
    equal space between them. The studs are needed to
    keep the capscrew holes aligned and to help support the
    weight of the remaining components.

    NOTE: Since the normal service life of vibration


    dampers is approximately 40,000 running hours, it is
    recommended that they be replaced at the time of
    overhaul.

    A WARNING
    The front vibration damper weighs approximately
    310 Ibs. (141 kg). Use a suitable lifting device and
    exercise caution during removal or installation to
    avoid severe personal injury or death.

    4.00 - 66 FORM 6248 First Ed~ion


    CRANKCASE ASSEMBLY

    Table 4.00-3. Pulleys And Spacers


    "C" "e" "SV" "sv" "5V"
    MODEL SECTION SPACER' SPACER*" SECTION SECTION SECTION SECTION
    PIN 2002958 PIN 199B08A PIN 19980BC PIN 200795 PIN 2OO795A PIN 2OO295H PIN 2OO295J
    L5108G Optional Optional· - - - - Optional
    L5108GSI/GL Optional - Optional**' - - Optional -
    L5790G Optional Optional· - - - - Optional
    L5790GSI/GL Optional - Optional" - - Optional -
    L7042G Optional Optional· - - - - Optional
    L7042GSI/GL Optional - Optional" - - Optional -
    * Required when uSing ~C~ section groove pulley PIN 2002958 on all d naturally aspirated twelve cylinder engines.
    (Not used with "5V'section groove pulleys.)
    ** Required when using "e" section groove pulley PIN 2002958 on all turbocharged twelve cylinder engines.
    (Not used with "5V" section groove pulleys.)

    Table 4.00-4. Attaching Hardware


    "C" SECTION "5V" SECTION "SV" SECTION
    PIN 2002958 PIN 2OO295H PIN 200295J
    MODEL CAPSCREW& "C"SECTION "SV" SECTION CAPSCREW& CAPSCREW&
    WASHER PIN 200795 PIN 2OO795A WASHER WASHER
    L5108G PIN 28627 & B355 - - - PIN 28618 & 6355
    L5108GSI/GL PIN 28627 & B355 - - PIN 28607 & B355 -
    L5790G PIN 28627 & B355 - - - PIN 28618 & 6355
    L57908GSI/GL PIN 28627 & B355 - - PIN 28607 & B355 ~,,,:,~
    -
    L7042G PIN 28627 & B355 - - - PIN 28618 & B355
    L7042GSI/GL PIN 28627 & B355 - - PIN 28607 & B355 -
    "SV" SECTION GROOVE HC" SECTION GROOVE
    ;..

    H, IH I I--_'~I 1.00 In
    H
    O.69ln O.59in O.887ln
    (17.53mm)
    (14.99mm) (25.4mm) (25.53mm)
    ,

    Figure 4.00-151. Side Section VIew "5V" And "C" Section Groove Pulleys

    NOTE: The front pulley spacer is used only when the 15. With the lipped side facing inward, slide the front
    "C" section pulley is to be installed. If the 5V section crankshaft pulley (10 inch) down the guide studs. Be
    groove pulley is installed, the front pulley spacer is not sure that the pulley lip is seated solidly against the
    used. Refer to Table 4.00-3 and Table 4.00-4 for details counterbore on the inside diameter of the front pulley
    ofpulley, spacer and attaching hardware combinations. spacer.
    Figure 4.00-151 shows a side section view of the ':5'V
    and "C" section pulley. 16. With the ten holes in the front pulley, pulley spacer
    and front damper aligned with those in the rear pulley,
    14. With the flat side facing outward, slide the front tighten seven of the fasteners (10 ferry head capscrews,
    pulley spacer (front pulley spacer is used with "CO 1/2 x 4 inches, with washers). Remove the three guide
    section pulley only refer to Table 4.00-3 and studs and wrench tighten the remaining three fasteners.
    Table 4.00-4) down the guide studs until it contacts the
    ,
    ,
    damper. Be sure that the lipped side of the spacer is 17. Slide the front spacer ring down the crankshaft until
    evenly seated in the damper hub. it contacts the small end of the tapered crankshaft pulley
    sleeve.

    FORM 6245 First Edition 4.00 - 67


    CRANKCASE ASSEMBLY

    18. With the large depression in the center of the


    crankshaft end plate facing outward, align the three holes )
    in the plate with those in the crankshaft end. Wrench
    tighten the fasteners (3 capscrews, 7/8 x 2-1/2 inches,
    with washers and lock washers).

    NOTE: The end plate depression is needed for proper


    mounting of the puller tool necessary for safe and
    effective removal of the front crankshaft pulley assembly.

    19. Torque the end plate capscrews to 410 ft-Ib (556 N·m)
    (see Figure 4.00-152). Repeat the torque sequence as
    necessary. Each time the sequence is repeated, the
    assembly is driven further up onto the tapered pulley
    sleeve. The assembly is properly tightened only after full
    torque is applied to each bo~ without any rotation of the
    torque wrench.

    Figure 4.00-152. Torquing End Plate Capscrews

    20. Torque the ten ferry head capscrews (1/2 x 4 inches)


    in the front crankshaft pulley to 86 ft-Ib (117 N·m) (see
    Figure 4.0()'152).

    4.00 - 68 FORM 6248 First Edition


    SECTION 4.05 - CYLINDER HEAD ASSEMBLY

    CYLINDER HEAD INSTALLATION

    I~A CAUTION IPlace the cylinder heads


    =--=:...:..;;...;:;....;:..;;;...:=:....::...:..J. on a wooden board or
    1..... .

    pallet. Place each head on its side to avoid damage


    to the nozzle of the prechamber cup.

    1. Refer to Chapter 5, Spark Plug Carrier and Pre-


    chamber Cup Installation, and install the prechamber
    cups and spark plug carriers in the cylinder heads.

    2. Install head gasket to crankcase (see


    Figure 4.05-1).

    I,
    ------~------
    I
    I,
    I

    o = WATER PASSAGE OPENINGS (7)

    ® = CAPSCREW HOLES (8)

    © = DOWEL PIN HOLES (2)

    Figure 4.05-1. Cylinder Head Gasket

    FORM 6248 First Ednion 4.05 -1


    CYLINDER HEAD ASSEMBLY

    CYUNDER HEAD

    WEIGHT
    UNBALANCED
    )

    CRANKCASE

    Figure 4.OS-2. LIfting The Cylinder Head - 12 Cylinder Engines

    A WARNING
    Each cylinder head weighs approximately 195 Ibs.
    (89 kg). Use a suitable lifting device and exercise
    caution during removal or installation to avoid
    severe personal Injury or death.

    3. Thread an eye bolt (1/2"-13) into the rocker arm


    cover capscrew bore closest to the water outlet elbow
    connection. Install a suitable lifting chain, (see
    Figure 4.05-2).

    NOTE: Uft the cylinder head with the weight unbal-


    anced, so that the tilt of the cylinder head matches the
    angle of the crankcase.

    4. Using a suitable lifting device, install the cylinder


    head to the crankcase. )

    4.05 - 2 FORM 6245 First EdHion


    CYLINDER HEAD ASSEMBLY

    CYLINDER HEAD TORQUING PROCEDURE 5. If the prechamber cup and spark plug carrier were
    When being installed, cylinder heads should always be not installed previously, refer to Chapter 3 and install
    torqued in the proper sequence illustrated, using new them at this time.
    gaskets. Lubricate cap screws and washers with
    A CAUTION 10il~eakSmaYOCCUrifall
    engine oil. First, hand secure cap screws in positions 1
    and 2 (see Figure 4.05-3), making sure that the head I!!!"~~::':"":':~~:::"::..:...J.
    L. O-ring contact surfaces
    dowels are seated. Hand start the remaining screws. are not completely clean. Disregarding this in-
    The first time through the torque sequence use 25 formation could result in product damage.
    percent ofthe total torque value; each succeeding time
    through the torque sequence increase the torque 6. Verify that all old paint is removed from the push rod
    setting by 25 percent of total torque value until final covers. Verify that the O-ring grooves and contact
    torque of 625 - 650 ft-Ib (847 - 881 N·m) is reached surfaces are thoroughly clean (see Figure 4.05-4).
    (see Table 4.05-1). In order to be sure of propertorque,
    the torque sequence should again be repeated with the
    UPPER O-RING
    torque wrench set to the total torque value. Do not
    overtorque. If any screws are overtorqued by 20 ft-Ib
    (27 N'm), reduce torque on all screws to 75 percent of
    total torque and repeat the entire torquing sequence.
    1/ UPPER COVER

    .........SPRING SEAT

    EXHAUST VALVE BORES T


    WATER OUTLET
    ELBOW CONNECTION ~/SPRING
    'T
    i l
    'T l
    WASHER
    -r .L

    o
    /
    ~ INTERMEDIATE O-RING
    / ' LOWER COVER

    / LOWER O-RING

    Figure 4.05-4. Push Rod Cover

    / INTAKE VALVE BORES


    I.A. CAUTION 10Id push rod cover 0-
    rings swell or become
    CYUNDER HEAD
    hard and brlHle with age. Oil leaks will occur ifthe
    Figure 4.05-3. Cylinder Head Capscrew Tightening O-rings break or crack. Disregarding this informa-
    And Torquing Sequence (1 - 8) tion could result In product damage.

    Table 4 05-1 Cylinder Head Capscrews 7. Install a new O-ring in the groove at the top of the
    INITIAL TORQUE RETORQUING 7/8 INCH upper push rod cover.
    (CAPSCREW OR (CAPSCREW OR STUD
    1" STUD) 1" STUD) 8. Slide the spring onto the body of the upper push rod
    625 - 650 ft-Ib 550 - 575 ft-Ib 446 - 450 ft-Ib cover until it contacts the spring seat.
    (847 - 881 N'm) (746 - 779 N·m) (605 - 610 N·m)
    9. Slide the washer onto the upper push rod cover until
    \ Retorquing after running the engine at idle or after load it seats against the spring.
    / testing is not required. If retorquing for any reason, use a
    value of 550 - 575 ft-Ib (746 - 779 N'm) to compensate 10. Slide a new O-ring onto the bottom of the upper
    for the set which the head gasket takes. push rod cover until it contacts the washer.

    FORM 6248 First Edition 4.05 - 3


    CYLINDER HEAD ASSEMBLY

    11. Install a new a-ring in the groove opposite the 19. Connect the fuel supply tube to the admission
    flared end of the lower push rod cover. valve. )
    12. Using a small paintbrush, apply Parker Super-O- 20. Inspect the rocker arm oil supply tubes (1/4 inch
    Lube® silicone lubricant, the upper, intermediate and 00) for cracks, cuts, holes, dents or other damage (see
    lower push rod cover a-rings. Figure 4.05-6). Inspect the male connector tube fittings
    for galled or stretched threads. If necessary, replace the
    13. Apply Parker Super-O-Lube® silicone lubricant, to tubes or fittings.
    the cylinder head and valve lifter guide bores. Grease
    the inside diameter of the bores to a depth of approxi-
    mately 1/4 to 1/2 inch (6.35 to 12.70 mm).

    14. Fit the straight end (without a-ring groove) of the


    upper push rod cover into the flared end of the lower
    push rod cover.

    15. Hand compress the push rod cover assembly.


    Insert the upper cover into the cylinder head bore, the
    lower cover into the valve lifter guide bore. Release the
    compression on the push rod covers. Verify that the
    push rod covers fit snugly in the upper and lower bores.

    NOTE: The hydraulic lifters on the push rods must be


    filled with engine oil prior to installation. Depress the
    center of the lifter to allow oil to be applied.

    16. Install the hydraulic push rods (2 tubes per cylinder


    head) (see Figure 4.05-5).

    Figure 4.05-6. Rocker Arm 011 Supply Tube -


    Rear Left

    21. Apply Loctite® 271 Adhesive Sealant (High


    Strength) to the large end of each male connector.
    Using the 9/16 inch hex on the connector body, install
    the fittings in the rear right side of each cylinder head.

    22. Finger tighten the ferrule nuts (9/16 inch hex) to


    install the oil supply tubes between the rocker arm oil
    header (male branch tee tube fittings) and the cylinder
    heads (male connectors) (see Figure 4.05-6). Reattach
    both ends of each tube before tightening.
    Figure 4.05-5. Push Rods
    23. Wrench tighten both ends of each tube, before
    17. Install the rocker arm assemblies and supports tightening.
    with capscrews and washers (8 capscrews per head,
    NOTE: The rocker arm covers will be installed after the
    1/2 x 4-3/4 inches) (see Figure 4.05-6).
    valves are adjusted in Section 4. 10.

    I.=A. CAUTION I
    L..
    Insure that the proper
    =-''---'_ _''--'-J. washer and and torque
    are used when Installing the admission valve
    assembly. Chapter 5 provides detailed information
    on the installation of admiSSion valves. Failure to
    use the proper torque, or the wrong washer could
    cause damage to equipment.

    18. Refer to Chapter 5 and install the admission valve


    assembly.

    4.05 - 4 FORM 6248 First Edition


    CYLINDER HEAD ASSEMBLY

    EXHAUST MANIFOLDS (see Figure 4.05-9). The end section with the exhaust
    outlet port is number 6.
    NOTE: Detailed exhaust manifold disassembly is cov-
    ered in Chapter 5. 6. Attach the air/gas supply tube retaining clips and
    insert the capscrews back into the lower bosses of the
    1. Remove the protective masking tape from the exhaust left bank exhaust manifold (see Figure 4.05-8).
    ouHet port and the water outlet elbow flange on each
    cylinder head.
    2. With the lip on the inside diameter olthe gasket facing
    upward, position new exhaust manifold gaskets on the
    cylinder head exhaust outlet ports (see Figure 4.05-7).
    Be sure that the hole with the copper grommet lines up
    with the water hole in the casting. Do not use the gasket if
    the grommet is missing or damaged.

    '0 0"

    LlP~

    Figure 4.05-8. Prelube Motor AlrlGas Supply Tube


    ,0 -r© 0. . .
    COPPER
    GROMMET A WARNING
    Figure 4.05-7. Exhaust Manifold Gasket Do not attempt to lift the exhaust manifold without
    providing adequate support for eIIch section. Disre-
    3. Install two long capscrews (1/2 x 8-1/2 inches, with
    garding this information could result in severe
    flat washers) into the upper bosses of each exhaust
    personal inJury or death.
    manifold section. Install two short bolts (1/2 x 5-1/2
    inches, with flat washers) into all the lower bosses.
    4. Attach three retaining clips (0.048 inch gauge, 1/2
    A WARNING
    inch clamping diameter) to the prelube motor air/gas The exhaust manifold weighs approximately 5151bs.
    supply tube (37.5 inches long, 1/2 inch tube 00). (234 kg). Use a suitable lifting device and exercise
    caution during removal or Installation to avoid
    5. Pull the 5-1/2 inch capscrews from three sections severe personal injury or death.
    (numbers 1, 3 and 6) of the left bank exhaust manifold

    REAR FRONT

    ATTACH AIR/GAS SUPPLY TUBE RETAINING CLIPS

    Figure 4.05-9. Exhaust Manifold - left Bank

    FORM 6248 First Edition 4.05-5


    CYLINDER HEAD ASSEMBLY

    CAUTION IExer~ise
    I.=A=--,~--,~_:;....;...;..J. care to avoid 8. Tighten the outside short bolt in each end section
    )
    L... . bending or denting the (front and rear) (see Figure 4.05-12). Remove the lifting
    rocker arm oil supply tubes. Disregarding this device. Wrench tighten the remaining capscrews.
    information could result In product damage and/or
    personal injury. NOTE: Leave the upper inside capscrews loose on
    each end section of the right bank exhaust manifold (for
    7. Position the exhaust manifold on the cylinder bank. attachment of the vee mounted breather tube) (see
    Be sure that the end section with the exhaust outlet port Figure 4.05-12).
    (for mounting of the turbo exhaust inlet elbow) is
    9. Apply 3M Scotch Grip~ Rubber and Gasket Adhe-
    positioned at the rear of the engine (see
    sive 847 to the rectangular grooves on both sides of the
    Figure 4.05·10).
    water outlet elbows. Install new rubber seals in the
    grooves (see Figure 4.05-11).
    WATER
    WATER MANIFOLD
    MOUNTING BRACKET
    BOLT HOLES

    FRONT END )
    SECTION
    Figure 4.05·10. Exhaust ManifOld End Sections -
    Left Bank Figure 4.05-11. Water Outlet Elbow Gaskets

    LEAVE LOOSE FOR


    ATTACHMENT OF BREATHER
    TUBE PIPE CLAMPS

    OUTSIDE SHORT BOLTS

    Figure 4.05-12. Exhaust Manifold - Right Bank

    4.05 - 6 FORM 6248 First Ednion


    CYLINDER HEAD ASSEMBLY

    10. Finger tighten the water outlet elbows to the


    cylinder heads (2 ferry head capscrews per elbow,
    1/2x 1-3/4 inches, with lock washers). Fingertighten
    the elbows to each exhaust manifold section (2 hex
    head capscrews per elbow, 1/2 x 1-3/4 inches, with
    lock washers). Alternately wrench tighten the four
    capscrews (see Figure 4.05-13).

    Figure 4.05-15. Exhaust Manifold - Left Bank

    14. Inspect the twelve stainless steel male connector


    tube fittings (1/4 inch thermocouple aD) for galled or
    stretched threads. Replace the fittings if necessary.

    15. Apply Bostik Never Seez® Anti-Seize and lubri-


    Figure 4.05-13. Water Outlet Elbows - Rear Right cating Compound (capable of withstanding tempera-
    tures up to 1800° F/982° C) to the large end of each
    11. Use a rubber mallet to seat the manifold caps in the male connector lube fitting. Using the 9/16 inch hex on
    front end sections of the right and left bank exhaust the connector body, thread the fitting into the exhaust
    manifolds. port of each segment of the exhaust manifold (see
    Figure 4.05-16).
    12. Install the fasteners to secure the end cap to the right
    bank exhaust manifold end section (see Figure 4.05-14)
    (2 capscrews, 1/2 x 1-5/8 inches, with flat washers).

    Figure 4.05-14. Exhaust ManHold - Front

    Figure 4.05-16. Thermocouple Connector-


    13. Install the fasteners in the auxiliary cooling water Rear Right
    outlet pipe support bracket (2 capscrews, 1/2 x 2 inches,
    I with lock washers and 1/4 inch spacers). Position the
    / 16. Repeat the procedure on the other bank.
    bracket over the end cap of the left bank exhaust
    manifold end section (see Figure 4.05-15). Wrench
    tighten the capscrews.

    FORM 6248 First EdHion 4.05-7


    CYLINDER HEAD ASSEMBLY

    4.05 - 8 FORM 6248 First Edition


    SECTION 4.10 - VALVE ADJUSTMENT AND WEB DEFLECTION

    VALVE ADJUSTMENT PROCEDURE To set the valves on a 12 cylinder engine, roll the engine
    crankshaft over until the valves ofthe first cylinder in the
    To compensate for slight differences in wear between
    firing order, which is the #1 R cylinder (see Table 4.10-1
    the valves and valve seats, adjust the valve clearance
    and Figure 4.10-1), are at top dead center (compres-
    every 2 months (1440 hours). Install new rocker arm
    sion stroke). At this point, all four valves will be fully
    cover gaskets when the valve adjustments are per-
    closed. To determine when this condition exists, watch
    formed.
    the valves on its mating cylinder, #6R.

    I A CAUTION I Shut the engine down


    FRONT
    .. and allow it to cool for at
    least one hour before adjusting the valves. Disre- (GEAR SIDE}
    garding this Information could result in product
    damage and/or personal injury.

    1. Remove the spark plug cables from the ignition coils


    and pull out the spark plug extension rods and rubber
    GG
    recess covers.

    2. Remove the rocker arm cover capscrews, washers


    88
    and spark plug cable clips (2 capscrews per cover).

    NOTE: A special tool (Tool PIN 494287) may be used


    LEFT
    SIDE 88 RIGHT
    SIDE

    for removing the rocker arm cover capscrews. The


    same tool can also be used for loosening the valve lifter
    capscrews and rocker arm adjusting screws, enabling
    88
    88 DIRECTION OF
    the operator to perform multiple operations without FLYWHEEL ROTATION
    switching tools.
    COUNTERCLOCKWISE
    3. Remove the rocker anm covers. Use a rubber mallet
    to loosen the covers, if necessary.
    Set the valves (see Table 4.10-1) in the order that the
    8_
    engine fires. The cylinder firing order appears on the FIRING ORDER:
    1R, 6L, 5R,2L, 3R, 4L,
    nameplate on the left front side of the engine below the 6R, 1 L, 2R,5L, 4R, 3L
    intake manifold (see NO TAG and Figure 1.15-2).
    Table 410·1 Valve Settings REAR (FLYWHEEL SIDE)
    12 CYLINDER ENGINE
    SET VALVES ON WHEN VALVES OVERLAP
    CYUNDER ON MATING CYUNDER - = MATING CYLINDER OF THE FIRST CYLINDER
    • IN THE FIRING ORDER
    ColumnA ColumnB
    NOTE: When the mating cylinder is in vaNe overlap, the fiJst
    lR 6R cylinder in the firing Older is at top deatJ center (comp!BSSion sIroi<eJ.
    6L lL
    2R Figure 4.10-1. Engine Firing Order - 12 Cylinder
    5R
    2L 5L
    Both exhaust valves on #6R cylinder begin to open
    3R 4R simultaneously. As the exhaust valves are closing, the
    4L 3L intake valves begin to open. At this point, the #6R
    6R lR cylinder is in valve overlap (all four valves partially
    lL 6L open). This means that all four valves on the #1 R
    2R 5R cylinder are fully closed. The valves on #1 R must be
    closed before any adjustments are performed. All
    5L 2L
    tension is removed from the valve stems and push rod
    4R 3R tubes when the valves are closed.
    3L 4L
    Column A shows the cylinder flrln~ order. Value In
    Column A added to value In Column alwa~ equals 7.

    FORM 6246 First Edition 4.10 -1


    VALVE ADJUSTMENT AND WEB DEFLECTION

    NOTE: Right bank and left bank are determined by hydraulic lifters. Verify that the hydraulic lifter plunger is
    standing at the flywheel end of the engine facing the fully extended up against the C-clip (see )
    flywheel. The cylinders farthest from the flywheel on the Figure 4.10-4).
    left and right side are the # 1Land # 1R cylinders,
    respectively. Those closest to the flywheel are the #6L
    and #6R cylinders. PLUNGER~-yC-CLIP

    ~
    4. Loosen the hex jam nut at the four valve stem tips
    (see Figure 4.10-2).
    HYDRAULIC
    LlFTER~

    PUSH
    /
    ROD
    TUBE
    Figure 4.10-2. Rocker Arms v
    '--
    5. Loosen the adjusting screw at the four valve stem Figure 4.10-4. Hydraulic Lifter
    tips.

    6. Look for cracks or breakage around the ball and 8. Raise the intake rocker arm until it just contacts the
    tappet insert of the rocker arm adjusting screws (see intake actuator. Turn the intake rocker arm adjusting
    Figure 4.10-3). Verify that the ball rotates freely in all screw (closest to the actuator arm) down until the ball
    directions without binding. Replace the adjusting screw, and tappet contacts the valve stem. Snugly center the
    if necessary. "elephants foot" tappet on the valve stem tip.

    NOTE: Use finger pressure only when turning the


    rocker arm adjusting screws.

    9. Verify that the fixed valve lifter screw just contacts,


    but does not depress, the hydraulic lifter plunger.

    10. Using a valve adjusting wrench (PIN 494287) and


    screwdriver, tighten the hex jam nut to lock the setting of
    the first intake rocker arm adjusting screw.

    NOTE: When tightening the hex jam nut, hold the


    rocker arm adjusting screw with a screwdriver. The
    screwdriver will keep the adjusting screw from turning
    while the jam nut is being tightened.

    Figure 4.10-3. Rocker Arm Adjusting Screws )

    7. Mark the two fixed valve lifter screws. Back out the
    fixed screws 1/2 turn to remove the preload from the

    4.10 - 2 FORM 6248 First Ednion


    VALVE ADJUSTMENT AND WEB DEFLECTION

    11. Holding the tappet of the adjusting screw against procedures for each cylinder in the firing order (see
    the valve stem tip, turn the other intake rocker arm Table4.10-1 and Figure 4.10-1). Watch each mating
    adjusting screw down until the tappet contacts the valve cylinder for valve overlap.
    stem. Eliminate any play.
    23. Scrape the old gasket material from the rocker arm
    NOTE: The "elephants foof'tappets should be cen- covers.
    tered on the valve stem tips. If the tappets are not
    properly centered, loosen the two hex head capscrews
    and slightly shift the rocker arm support. After the best
    I.A. CAUTION Igasket
    Exercise care to keep the
    material out ofthe
    position is obtained, torque the rocker arm support cylinder head. Disregarding this information could
    capscrews to 60 ft-Ib (81 N·m). resuH in product damage and/or personal injury.
    12. Tighten the hex jam nut, to lock the setting of the
    24. Scrape the old gasket material from the cylinder
    second intake rocker arm adjusting screw.
    heads.
    13. Rotate the tappets of the two intake rocker arm
    25. Verify that the rocker arm cover and cylinder head
    adjusting screws to feel for equal contact with the valve
    gasket surfaces are clean and completely free of grease
    stem tips. If a tappet cannot be rotated, or if it rotates too
    and oil.
    freely, loosen the jam nut and readjust the screw.
    26. Apply a fast setting contact-type gasket shellac,
    14. Turn the exhaust rocker arm adjusting screw down
    such as 3M Weather Strip Cement, Permatex® High-
    until the "elephants foot" tappet contacts the valve stem.
    Tac or equivalent, on the rocker arm covers.
    Snugly center the tappet on the valve stem tip.
    27. Place new gaskets on the rocker arm covers.
    15. Verify that the fixed valve lifter screw just contacts,
    but does not depress, the hydraulic lifter plunger. NOTE: To prevent the gaskets from sliding, allow the
    gasket shellac to cure before installing the rocker arm
    16. Tighten the hex jam nullo lock the setting ofthefirst
    covers on the engine. Follow the manufacturer's
    exhaust rocker arm adjusting screw.
    recommendations.
    17. Holding the tappet of the adjusting screw against
    the valve stem tip, turn the other exhaust rocker arm CAUTION I~aretully
    I.=A=~:..:...;;..;:;;...:--=...;:::....:~.
    check the cyl-
    adjusting screw down until the tappet contacts the valve L. . Inder head for any old
    stem. Eliminate any play. gasket debris before installing the rocker arm
    covers. Disregarding this information could result
    NOTE: The "elephants foof' tappets should be cen- in product damage and/or personal injury.
    tered on the valve stem tips. If the tappets are not
    properly centered, loosen the two hex head capscrews 28. Position the rocker arm covers on the cylinder
    and slightly shift the rocker arm support. heads. Install the washers, spark plug cable clips and
    rocker arm cover capscrews (2 capscrews per cover).
    18. Tighten the hex jam nut to lock the setting of the
    second exhaust rocker arm adjusting screw.
    CAUTION I~ndertl~htening
    I=.A='---':..:...;;..;:;;...:....:....:::....:~.
    or over-
    19. Rotate the tappets of the two exhaust rocker arm L. . tightening the rocker
    adjusting screws to feel for equal contact with the valve arm covers may cause the gaskets to leak. Disre-
    stem tips. Readjust, if necessary. garding this information could result in product
    damage and/or personal injury.
    20. Turn the two fixed valve lifter screws clockwise 1/2
    turn to their original setting. Preloading the hydraulic 29. Torque the rocker arm cover capscrews to 30 - 35 ft-Ib
    lifter backs the plunger off the C-clip and moves it into (41 - 47 N'm) oiled.
    the upper range of lifter travel. Torque each valve lifter
    screw to 60 ft-Ib (81 N'm) oiled. 30. Install the spark plug extension rods. Fit the rubber
    recess cover into the top of each spark plug carrier.
    21. Rotate the tappets of the two intake and two
    exhaust rocker arm adjusting screws to feel for equal
    contact with the valve stem tips.

    22. Rotate the engine counter clockwise to the next


    cylinder in the firing order, top dead center (compres-
    sion stroke). Return to Step 4, and repeat the above

    FORM 6248 First Ed~ion 4.10 - 3


    VALVE ADJUSTMENT AND WEB DEFLECTION

    CRANKSHAFT WEB DEFLECTION NOTE: Cu"ent production VHP engines are punched
    MEASUREMENT to locate the web deflection gauge exactly. )
    Check crankshaft web deflection when the engine is 1. Remove the engine access covers from both sides of
    commissioned, annually, or when crankshaft bear- the engine.
    ings are replaced, or the engine mounting is dis-
    turbed. Check the crankshaft web deflection by 2. Install a web deflection tool (PIN 494292) in the
    measuring crank web deflections with a dial gauge, center point marks in a crank throw location (spin the
    (PIN 494292). See Table 4.10-2 for points of mea- gauge in position to insure it is fully seated (see
    surementwith the dial gauge. Electronic type gauges, Table 4.10-2).
    (PIN 494424) are also available.
    3. Position the crankshaft so the gauge hangs next to
    When checking the crank web deflection, pay special the rod, but not touching.
    attention to these points.
    4. Zero the gauge.
    • The dial gauge must rest on the same point on all the
    cranks. There is a small milled recess on the inside of NOTE: A crank throw which opens at the bottom is a
    each counterweight for this purpose.' positive reading. A crank throw which is closed at the
    bottom is a positive reading.
    • So that comparisons are accurate, it is very important
    to take the measurements at the same engine 5. Slowly rotate the crankshafl to the No.1 position and
    temperature. A cold engine is one that is at normal record the positive or negative gauge reading (see
    room temperature; approximately 70· F (21· C). Table 4.1 0-2).

    • When measuring, the crankshaft should always be 6. Slowly rotate the crankshaft to the No.2 position and
    rotated in a counter clockwise direction as viewed record the positive or negative reading.
    from the rear (flywheel) end.
    7. Slowly rotate the crankshaft, stopping and recording
    NOTE: Start measurements at one end of the crank- the dial readings for positions No.3, 4 and 5.
    shaft. Proceed along the length of the shaft to the )
    opposite end. Record the measurements. 8. Repeat the procedure for each of the crankshaft
    webs.
    NOTE: On spring isolated units, the spring isolators
    should first be adjusted to insure that all the isolators are
    bearing equal weight. Refer to the Installation Manual,
    Form 1091, for procedures on how to adjust the spring
    isolators.
    Table 4.10-2. Crankshaft Web Deflection Measurement With Connecting Rods Installed
    VIEW FROM FLYWHEEL END

    DIAL GAUGE PosmON


    FOR MEJUlUIRENIEN1r ~

    GAUGE

    CRANKSHAFT WEB DEFLECTION SPECIFICATIONS


    Total of 0.001" (0.0254 mm) deflection from positive to negative. )
    Except Rear: Total of 0.0015" (0.0381 mm) from positive to negative.

    4.10 - 4 FORM 6248 First Edition


    VALVE ADJUSTMENT AND WEB DEFLECTION

    9. Correct the crankshaft web deflection by adjusting as much as 0.0015 inch (0.0381 mm) deflection due to
    the mounting foot height adjacent to the deflected web. the effects of the flywheel weight.
    A web which is closed at the bottom (6:00) is corrected
    by raising an outer mount, if it is adjacent to an outer 10. Using the jack screws to provide the necessary
    mount (see Figure 4.10-5). Conversely, a web which is clearance, install shims as required althe engine corner
    open at the bottom is corrected by raising an inner and center mounting points.
    mount or lowering an outer mount. After an adjustment,
    11. Refer to the Installation Manual, Form 1091 for
    the deflection at the other crankshaft webs must again
    additional information on crankshaft web deflection.
    be measured. A total of 0.001 inch (0.0254 mm)
    deflection, from positive to negative, is allowable on all 12. Install engine access doors.
    but the rear crankshaft throw. The rear throw may have

    2" (50.8 mm)

    6" (152.4 mm) 1---1----1 6" (152.4 mm)

    JACKSCREW JACKSCREW
    BOSSES BOSSES
    NOTE: Use two separate shim pads under the center mounts.

    Figure 4.10-5. Engine Shimming Procedure

    FORM 6248 First Edition 4.10 - 5


    VALVE ADJUSTMENT AND WEB DEFLECTION

    4.10 - 6 FORM 6246 First Edition


    CHAPTER 5 - ENGINE SYSTEMS

    CONTENTS

    SECTION 5.00 - SPEED GOVERNING SYSTEM

    SECTION 5.05 - FUEL SYSTEM

    SECTION 5.10 - IGNITION SYSTEM

    SECTION 5.15 - AIR INDUCTION SYSTEM

    SECTION 5.20 - TURBOCHARGERS

    SECTION 5.25 - COOLING SYSTEM

    SECTION 5.30 - LUBRICATION SYSTEM

    SECTION 5.35 - EXHAUST SYSTEM

    SECTION 5.40 - CRANKCASE BREATHER

    SECTION 5.45 - AIR/GAS PRELUBE AND START SYSTEMS

    FORM 6248 First Edition


    )

    FORM 6248 First Edition


    SECTION 5.00 - SPEED GOVERNING SYSTEM

    SPEED GOVERNING SYSTEM Alternating current generating units tied in with other
    COMPONENTS units should have droop set sufficiently high (30 to 50 on
    the dial) to prevent interchange of load between the units.
    The engine speed governing system consists of the If one unit in the plant, or system has enough capacity, its
    following components: governor may be set on zero droop and ~ will regulate the
    . frequency of the entire system. This un~ will take all the
    • Governor
    - Woodward UG-SL Governor load changes within the limits of its capac~ and will
    - Woodward UG-S Dial Governor control frequency if its capac~ is not exceeded.
    - Woodward EG-3P Electronic Governing System The system frequency is adjusted by operating the
    synchronizer of the governor having zero droop. the
    • Governor Linkage
    distribution of load between units is accomplished by
    • Magnetic Pickup (electronic systems) operating the synchronizers of the governors having
    speed droop.
    • Control Panel (electronic systems)
    • Overspeed Governor
    IA CAUTION I Do not manually force the
    ... engine linkage to in-
    SPEED GOVERNING SYSTEM crease fuel without first turning load limit knob to 10.
    DESCRIPTION Failure to follow proper procedures could cause
    damage to equipment.
    WOODWARD UG-SL GOVERNOR
    The load limit control hydraulically limits the load that
    The Woodward UG-SL Govemor, capable of isochronous can be put on the engine by restricting the terminal
    operation (will maintain the same engine speed regardless output shaft rotation of the governor, and consequently,
    of engine load) is a mechanicai-hydraulic device. The the quant~ of fuel supplied to the engine. The control
    governor is located on the mounting pad of the govemor may also be used for shutting down the engine by
    drive housing on the front right side of the engine. The turning it to zero.
    govemor is driven from the accessory drive gear.
    An optional synchronizing motor may be mounted on a
    WOODWARD UG-S DIAL GOVERNOR special cover for the governor to provide remote speed
    control. Its use enables the operator to to match the
    The Woodward UG-S Dial Governor, is a mechanical-
    output of an engine driven machine with that of other
    hydraulic device mechanically linked to the fuel system.
    units. The motor is that of the split field, series wound,
    The governor operates isochronously (will maintain the
    reversible type. It can be used on either direct current or
    same engine speed regardless of engine load), except
    alternating current at its specified voltage. A slip
    during transient load conditions. Located on the mount-
    coupling is provided between the motor shaft and the
    ing pad of the governor drive housing on the front right
    synchronizer control knob on the governor. This cou-
    side of the engine, the governor is driven from the
    pling is a friction type.
    accessory drive gear. The UG-S Dial Governor has dial
    adjustments on the face of the gear. These dials are the WOODWARD EG-3P ELECTRONIC GOVERNING
    Speed Droop control knob, the Load Limit control knob, SYSTEM
    the Synchronizer, and the Syn. Indicator. The speed
    The Woodward EG-3P electronic governing system
    droop control can be set to automatically divide and
    consists of three components, the magnetic pickup, the
    balance the load between engines driving the same
    control unit and the actuator. The system is capable of
    shaft, or paralleled in an electrical system.
    isochronous operation (will maintain the same engine
    Droop is incorporated in the governor through a linkage speed regardless of engine load). The control unit is
    which varies the compression of the speeder (speed oft-engine mounted and is usually in the control room. It
    adjusting spring) as the output shaft rotates. Increased is the device that interrupts the signal that is sent from the
    fuel reduces spring compression, reduces the governor magnetic pickup. The control unit then compares the the
    setting accordingly, and the unit will gradually reduce its magnetic signal through circuitry and makes the proper
    speed as load is applied. This relationship between load adjustments through the actuator. The governor actuator
    and speed, acts as a resistance to load changes when is engine mounted, and is the mechanical device that
    the unit is interconnected with other units either physically moves the carburetor butterflies. Located on
    mechanically or electrically. the mounting pad of the governor drive housing on the
    As droop is reduced toward zero, the unit becomes able front right side of the engine, the governor actuator is
    ) to change load without changing speed. As a general driven from the accessory drive gear.
    rule, units running alone should be set on zero droop,
    interconnected units should be run at the lowest droop
    setting that will give satisfactory load division.
    FORM 6248 First EdHion 5.00 - 1
    SPEED GOVERNING SYSTEM

    GOVERNOR LINKAGES engine RPM is set with the rated speed potentiometer
    located on the control unit, or by the optional external )
    The governor linkage connects the governor output shaft
    with the carburetor butterfly shaft. On G and GSI engines, speed trim potentiometer. The RPM setting voltage is
    a hand lever on the governor side is used to manually set compared at the control unit between the control
    the engine to the desired speed. All engines have a amplifier voltage and the RPM voltage. The control
    Manual Shutdown Lever added to the linkage on the amplifier sends an appropriate voltage to the actuator.
    carburetor side, that enalbles the operator to manually For example, if the speed was greater than the speed
    close the fuel valves in the event of an emergency. setting, the control amplifier would decrease its output
    and the actuator would decrease fuel to the engine. Load
    MAGNETIC PICKUP sharing between two or more engine-generator sets is
    The engine speed is detected by a magnetic pickup accomplished via the load sensing circuitry. Each
    threaded into the flywheel housing aIbove the flywheel generator's load is electronically measured continuously
    ring gear. Each tooth passing by the magnetic pickup to other units on the same bus via parallel lines.
    generates an AC voltage whose frequency is propor- Continuous correction to control loop gives load sharing.
    tional to engine speed. this AC voltage is then converted OVERS PEED GOVERNOR
    into a DC voltage through internal circuitry.
    The overs peed governor is a safety device that protects
    CONTROL PANEL the engine from overspeed damage. The overspeed
    The control unit (see Figure 5.00-1 and Figure 5.00-2), governor is activated when the engine speed rises
    used with electric units, is off-engine mounted, usually in approximately 10 percent aIbove the maximum high idle
    the control room, and is the device that receives the speed. The maximum high idle speed for all VHP
    signal that is sent from the magnetic pickup. The control engines is 1200 rpm. Therefore, the setpoint allows
    unit then compares the magnetic pickup signal to the engine speeds up to 1300 - 1325 rpm before the
    predetermined engine RPM signal through circuitry and overspeed governor trips. The overspeed governor
    makes the proper adjustments through the actuator. The functions only if the regular governor fails to operate.

    """"'~
    =,~ RATED ~'ffi
    '""" COMPENSATION ~, ~, FuaUMT
    DROOP

    00
    o 10
    00 00 00 iJ 00
    o 10 o 10 o 10 o 10 o 10

    00
    o
    00
    10
    RAMPUIE
    o
    ~~
    10
    2301A LOAD SHARING & SPEED CONTROL

    -
    ,~,

    ~
    ~ =ro

    1 sEi'¥l S~L I
    CLOSEro

    [ ~c ~E
    ~= ~R
    s~
    ~~
    ~ SP£EO
    ~=-
    w' w
    ....._ _ _ _---'" 1-+"1

    ,..!!-, ~ ~ ~ 'u.., j'T I I 'b~--m..


    01234567891011121314151617181920212223242526272829

    Figure 5.00-1. 2301A Load Sharing And Speed Control

    5.00 - 2 FORM 6248 First Ed~ion


    SPEED GOVERNING SYSTEM

    0 ® ® 0

    ~~ ~~
    ~"~ COMPENSA110tl
    -~
    ~,

    00 00 00 00
    o 10 010 o 10 o 10

    2301 A SPEED CONTROL j} j} jj


    ~,

    FOR
    M~
    ~
    RATED
    -
    o 10

    SPEED
    o
    ~
    ,~
    10

    SPM
    INPUT
    M>ro
    ~~

    AUX
    ItlM
    I~VDC SPEED TRIM ~

    r~i 'I ii:~~~:S r~J=k


    1 2 3 4 S 6 7 6 9 10 11 12 13 M 1S 16 17

    Figure 5.00-2. 2301 A Speed Control

    GOVERNOR DRIVE GEAR/CEC TIMING 2. Remove the CEC Hall-effect Pickup from the
    DISC REMOVAL/INSTALLATION Governor Drive Housing (see Figure 5.00-4)

    GOVERNOR DRIVE GEAR/CEC TIMING DISC


    REMOVAL (CURRENT PRODUCTION)
    NOTE: Magneto equipped engines will not have a GEG
    disc.
    1. Place a small oil pan beneath the governor drive
    housing and remove the governor drive cover plate (4
    capscrews, 3/8 x 3/4 inch, with lock washers; 10
    capscrews, 3/8 x 1 inch, with lock washers) and gasket
    (see Figure 5.00-3).

    Figure 5.00-4. Hall-effect Pickup

    Figure 5.00-3. Governor Drive Housing

    FORM 6248 First Edition 5.00 - 3


    SPEED GOVERNING SYSTEM

    3. On CEC equipped engines, remove the four nylok GOVERNOR DRIVE GEAR/CEC TIMING DISC
    allen head screws, washers and the CEC timing disc (see INSTALLATION (CURRENT PRODUCTION) )
    Figure 5.00-5). Discard the nylok allen head screws.
    NOTE: If the engine is GEG equipped, perform Steps 1
    thru 16. If not GEG equipped, perform Steps 1 thru 3 and
    Steps 14 thru 16.

    1. Install the No. 8 Woodruff key in the slot on the


    accessory drive gear shaft, if removed. Ughtly tap the key
    to properly seat it in the keyway. Verify that the key is level.

    2. Position the notch in governor drive gear assembly


    with the key on the shaft. Install the governor drive gear
    assembly onto the accessory drive gear shaft with flex
    lock nut (see Figure 5.00-7).

    Figure 5.00-5. Current Production CEC Timing Disc

    4. Refer to Governor Drive Shaft Assembly, Removal,


    and remove the governor drive shaft from the governor
    drive housing.

    5. Remove flex nut and governor drive gear assembly


    from the accessory drive gear shaft (see Figure 5.00·6).
    Use a rubber mallet to loosen the drive gear assembly, if )
    necessary. Move the assembly to a suitable workbench.

    Figure 5.00-7. Current Production Governor Drive


    Gear

    3. Refer to Governor Drive Shaft Assembly, Installa-


    tion, and install the governor drive shaft on the governor
    drive housing.

    NOTE: Insure that the directional arrow and the


    stamped word "ROTATION" are positioned towards the
    front of the engine, so they are visible.

    4. Loosely install the CEC timing disc on the governor


    drive gear with four new nylok allen head screws, and
    washers. Roughly align timing mark on disc with the
    threaded hole used for the Hall-effect Pickup in the
    Figure 5.00-6. Current Production Governor Drive magneto housing.
    Gear
    5. Locate the first cylinder to fire in the firing order
    GOVERNOR DRIVE GEAR/CEC TIMING DISC sequence. Refer to the engine's nameplate for firing
    CLEANING AND INSPECTION order sequence.
    (CURRENT PRODUCTION)
    6. Check the engine's nameplate to determine the
    1. Using a soft cloth, remove all dirt, grime, grease and exact timing (or most advanced) for the primary fuel.
    oil deposits, from the gear and CEC disc. )
    7. Bar the engine crankshaft over in a counter-clock-
    2. Inspect the gear teeth for chips, cracks and exces· wise direction until the valves of the first cylinder in the
    sivewear. Replacethe governor drive gear if necessary. firing order, which is the #1 R cylinder, are at top dead
    center (compression stroke).

    5.00 - 4 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    To determine when this condHion exists, watch the rocker 10. Thread the timing disc alignment tool into the
    arms and valves on Hs mating cylinder, #SA. As the magneto housing (see Figure 5.00-9).
    exhaust valves on #6R cylinder are closing, the intake
    valves begin to open. At this point, the #SR cylinder is in
    TIMING DISC
    valve overlap (all four valves partially open). This means ALIGNMENT TOOL
    that all four valves on the #1 R cylinder are fully closed. TIMING DISC }I'
    The cylinder is now at top dead center (compression REFERENCE POINT

    ~
    stroke).

    NOTE: Timing marks on the flywheel timing tape .----"""7'---J 0 0

    :@;
    should be visible through the timing opening located in
    the flywheel housing when approaching top dead center
    (TDC) of the first firing cylinder on the compression
    stroke (see Figure 5.00-8). ©
    NYLOKALLEN HEAD
    o~
    ~'\
    SCREW AND WASHER TIMING DISC

    Figure 5.00-9. Current Production CEC Timing Disc

    11. Loosen the allen head screws, and rotate the timing
    disc so the timing disc reference mark aligns with the
    point of the alignment tool.

    12. Once aligned, torque the nylok aUen head screws


    on the timing disc to 43 - 45 in-Ib (4.86 - 5.08 N·m).

    Figure 5.00-8. Flywheel Timing Opening 13. Remove the alignment tool and install the Hall-effect
    pickup sensor, Set the gap betweenjfie pickup and the
    timing disc to 0.040 in. ± 0.010 in. (1.016 mm ± 0.254 mm)
    8. Bar the engine over in the direction opposite normal (see Figure 5.(J().1 0).
    engine rotation to a point at least 30' prior to the point of
    desired timing.

    9. Slowly bar the engine in the direction of normal


    engine rotation, carefully observing the flywheel timing
    tape and pointer. Stop rotating the flywheel exactly at
    the nameplate timing for primary fuel (see Figure 5.00-8
    and Figure 1.15-2).

    CAUTION I
    I~A=-.::::...:.....:..;::...:....:...;:;..:..:..J.
    By rotating the crankshaft
    L.. . too fast and then backing
    up to the desired timing, the disc drive gear backlash
    will be on the wrong side of the gear teeth. The timing
    could therefore be incorrect by several degrees.
    Disregarding this information could result in prod-
    uct damage and/or personal InJury.

    Figure 5.00-10. Current Production CEC TIming Disc

    FORM 6248 First Ednion 5.00- 5


    SPEED GOVERNING SYSTEM

    IA
    ...
    CAUTION I DO NOT tum on the fuel
    until the Ignition timing Is
    2. Remove the CEC Hall-effect Pickup from the
    Governor Drive Housing (see Figure 5.00-12). )
    verified to be at an acceptable setting, to prevent
    possible engine damage. Use a timing light to check
    the ignition timing while the engine is cranking in a
    NO-FUEL state. Disregarding this Information could
    result in product damage and/or personal InJury.

    14. Apply a fast setting contact-type gasket shellac,


    such as 3M Weather Strip Cement, PermateX® High-
    Tac or equivalent, on the gasket surfaces of the
    governor drive cover plate. Install a new governor drive
    cover gasket.

    NOTE: During Step 15, the governor drive cover must


    first be installed on the ball bearing retainer, four
    capscrews and lock washers To prevent the gaskets
    from sliding during installation of the governor drive
    assembly, allow the gasket shellac to cure. Follow the Figure 5.00-12. Hall-effect Pickup
    manufacturer's recommendations. 3. On CEC equipped engines, remove the lock nut and
    the CEC timing disc (see Figure 5.00-13).
    15. With the WED part number facing outside, install
    the governor drive cover to the ball bearing retainer (4
    capscrews, 3/8 x 3/4 inch, with lock washers). Install the
    remaining fasteners (10 capscrews, 3/8 x 1 inch, with
    lock washers) (see Figure 5.00-11).

    Figure 5.00-13. Previous Production CEC Disc


    4. Remove the governor drive gear assembly from the
    accessory drive gear shaft (see Figure 5.00-14). Use a
    rubber mallet to loosen the drive gear assembly, if
    necessary. Move the assembly to a suitable workbench.
    Figure 5.00-11. Governor Drive Housing

    16. On CEC equipped models, refer to CEC Ignition


    Module Ignition Timing Set (Current Production) and set
    engine ignition timing. On Magneto equipped modelS,
    refer to Magneto Static Timing Set, and Magneto
    Ignition Timing Set, and set engine timing.

    GOVERNOR DRIVE GEAR/CEC DISC REMOVAL


    REMOVAL (PREVIOUS PRODUCTION)

    1. Place a small oil pan beneath the governor drive


    housing and remove the governor drive cover plate (4 )
    capscrews, 3/8 x 3/4 inch, with lock washers; 10
    capscrews, 3/8 x 1 inch, with lock washers) and gasket
    (see Figure 5.00·11). Figure 5.00-14. Previous Production Governor Drive
    Gear

    5.00 - 6 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    GOVERNOR DRIVE GEAR/CEC DISC GOVERNOR DRIVE GEAR/CEC DISC ASSEMBLY


    DISASSEMBLY (PREVIOUS PRODUCTION) (PREVIOUS PRODUCTION)
    1. Lubricate four new vibration dampers with clean
    A WARNING engine oil.

    Always wear proper eye protection when removing 2. Start the drive gear hub in the governor drive gear bore
    retaining rings. Slippage may propel the ring with (see Figure 5.00-16). Position the hub so that the roll pin
    enough force to cause severe personal injury or drilling faces the front of the gear and the hub wings are
    death. Use the correct retaining ring pliers. Verify centered above the recess at the back of the gear.
    thatthe tips ofthe pliers are not excessively worn or
    damaged.

    1. Remove the rear retaining ring and the governor


    drive gear retainer from the drive gear hub (see
    Figure 5.00-15).

    FRONT
    RETAINING
    RING

    ROLL
    PIN

    HUB WINGS
    GEAR
    HUB

    HUB
    WING

    VIBRATION
    DAMPER

    Figure 5.00-15. Previous Production Governor Drive


    Gear

    VIBRATION DAI.PER
    2. Remove the front retaining ring and the governor
    (4) ~~p.p.F~:;,.....
    drive gear from the drive gear hub.

    3. Remove and discard the four rubber vibration


    dampers.

    GOVERNOR DRIVE GEAR/CEC DISC CLEANING


    AND INSPECTION (PREVIOUS PRODUCTION)

    1. Using a soft cloth, remove all dirt, grime, grease and


    oil deposits, from the gear and CEC disc.

    2. Inspect the gear teeth for chips, cracks and exces-


    sive wear. Replace the governor drive gear if necessary.

    Figure 5.00-16. Previous Production Governor Drive


    Gear Vibration Damper Installation

    FORM 6248 First EdHlon 5.00 -7


    SPEED GOVERNING SYSTEM

    NOTE: On those engines equipped with the Waukesha 8. Determine from the engine nameplate and
    GEG ignition module, the front of the gear hub is also Table 5.10-6 which hole number was used to position
    distinguished by the holes needed for mounting of the the CEC timing disc (see Figure 5.00-19).
    magnet disc.
    9. Install the timing pin on the gear hUb.
    3. Place the vibration dampers in an upright position on
    each side of the two hub wings (see Figure 5.00-16). GOVERNOR DRIVE GEAR/CEC DISC
    Place the dampers in position just before the hub wings INSTALLATION (PREVIOUS PRODUCTION)
    enter the drive gear recess. 1. Install the No. 8 Woodruff key in the slot on the
    4. Alternately press on the hub and the four vibration accessory drive gear shaft, if removed. Lightly tap the
    dampers, until the hub is centered on the gear and the key to properly seat it in the keyway. Verify that the key is
    dampers are fully seated in the cavities. Verify that the level.
    top of the dampers are flush with the gear face. 2. Slide the governor drive gear assembly onto the
    accessory drive gear shaft aligning the notch in the hub
    A WARNING with the key on the shaft. Solidly seat the assembly
    against the shoulder of the accessory drive gear shaft
    Always wear proper eye protection when Installing (see Figure 5.00-18).
    retaining rings. Slippage may propel the ring with
    enough force to cause severe personal injury or
    death. Use the correct retaining ring pliers. Verify
    that the tips ofthe pliers are not excessively worn or
    damaged.

    5. Install the governor drive gear retainer on the drive


    gear hub (see Figure 5.00-17).

    FRONT
    RETAINING
    RING
    Figure 5.00-18. Previous Production Governor Drive
    Gear
    ROLL
    PIN
    3. Verify that the governor drive gear assembly fits
    snugly on the accessory drive gear shaft without rocking
    GEAR or sliding.
    HUB
    4. Refer to Governor Drive Shaft, Installation and install
    the governor drive shaft (see Figure 5.00-18).
    HUB
    WING NOTE: If the engine is GEG equipped, perform Steps 5
    thru 11. If not GEG equipped, perform Steps 7, and 9
    VIBRATION thru 11.
    DAMPER

    Figure 5.00-17. Previous Production Governor Drive


    Gear
    IA
    ...
    CAUTION I DO NOT turn on the fuel
    until the Ignition timing IS
    verified to be at an acceptable satting, to prevent
    6. With the rounded edge towards the gear, install the possible engine damage. Use a timing light to check
    rear retaining ring on the drive gear hub. the Ignition timing while the engine is cranking In a
    NO-FUEL state. Disregarding this Information could
    7. With the rounded edge towards the gear, install the result in product damage and/or personal Injury. )
    front retaining ring on the drive gear hub.
    NOTE: It is recommended that the timing pin be
    installed on the gear hub prior to installation of the gear.

    5.00 - 8 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    5. Determine from the engine nameplate and 8. Install the CEC Hall-effect Pickup on the Governor
    Table 5.10-6 which hole number is used to position the Drive Housing see Figure 5.00-20. Setthe gap between
    CEC timing disc (see Figure 5.00-19). the pickup and the timing disc to 0.040 in. ±0.010 in.
    (1.016 mm ±0.254 mm)

    9. Apply a fast setting contact-type gasket shellac,


    such as 3M Weather Strip Cement, Permatex® High-
    Tac or equivalent, on the gasket surfaces of the
    governor drive cover plate. Install a new governor drive
    cover gasket.
    \
    \ NOTE: During Step 10, the governor drive cover must
    \ first be installed on the ball bearing retainer, four

    ~
    capscrews and lock washers To prevent the gaskets
    from sliding during installation of the governor drive
    assembly, allow the gasket shellac to cure. Follow the

    ~
    manufacturer's recommendations.

    10. With the WED part number facing outside, install


    the governor drive cover to the ball bearing retainer
    (4 capscrews, 3/8 x 3/4 inch, with lock washers) (see
    Figure 5.00-21). Install the remaining fasteners
    (10 capscrews, 3/8 x 1 inch, with lock washers).
    HOLE #1 - 1/8" PIN
    HOLE #2 - 5/32" PIN
    HOLE #3 - 3/16" PIN
    HOLE #4 - 1/4" PIN

    Figure 5.00-19. Previous Production Timing Disc

    6. Install the timing disc, and pin on the gear hub and
    pin it in position.

    7. Apply Loctite® 242 to threads and install the flex lock


    nut on the shaft and wrench tighten (see
    Figure 5.00-20).

    Figure 5.00-21. Governor Drive Housing

    11. On CEC equipped models, refer to CEC Ignition


    Module Ignition Timing Set (Previous Production) and
    set engine ignition timing. On Magneto equipped
    models, refer to Magneto Static Timing Set, and
    Magneto Ignition Timing Set, and set engine timing.

    Figure 5.00-20. Previous Production CEC Disc

    FORM 6248 First Edition 5.00 - 9


    SPEED GOVERNING SYSTEM

    GOVERNOR DRIVE )
    GEAR (HELICAL)

    REAR BALL
    BALL
    BEARING

    RETAINING
    RING

    COUNTERBORE

    BALL BEARING
    RETAINER

    Figure 5.00-22. Governor Drive Shaft Assembly


    GOVERNOR DRIVE SHAFT GOVERNOR DRIVE SHAFT DISASSEMBLY

    GOVERNOR DRIVE SHAFT REMOVAL


    A WARNING
    )
    I.A. CAUTION IThe CEC disc must be
    removed prior to remov-
    Always wear proper eye protection when removing
    retaining rings. Slippage may propel the ring with
    Ing the governor drive shaft assembly or damage to enough force to cause severe personal Injury or death.
    the CEC disc will result. Disregarding this Informa- Use the correct retaining ring pliers. Verify that the tips
    tion could result in product damage and/or person- of the pliers are not excessively worn or damaged.
    al injury. 1. Remove the retaining ring from the first groove on
    the governor drive shaft (in front of the ball bearing
    1. Refer to Governor Drive Gear, Removal, and retainer (see Figure 5.00-23).
    remove the governor drive housing cover plate and
    CECdisc. 2. Remove the retaining ring from the second groove
    on the governor drive shaft.
    2. Remove the governor drive shaft assembly from the
    3. Using a suitable press, push on the governor drive
    governor housing (see Figure 5.00-20 and
    shaft to remove the ball bearing retainer.
    Figure 5.00-22). Move the assembly to a suitable
    workbench. 4. Remove the large retaining ring from the groove in
    the ball bearing retainer. Press on the inner race to
    remove the ball bearing from the retainer.
    GOVERNOR DRIVE GEAR
    REAR BALL BEARING
    SHOULDER \ -.L
    KEYW.-""_:t_ _
    SHOULDER
    KE:vWAY
    RETAINING RING
    2ND GROOVE

    Ef] ~d]~t·~
    1
    INTERMEDIAT/ RETAINING RING! RETAINING RING
    GEAR SHOULDER 3RD GROOVE 1ST GROOVE

    Figure 5.00-23. Governor Drive Shaft

    5.00 -10 FORM 6248 Firs1 Edition


    SPEED GOVERNING SYSTEM

    5. Press on the opposite end of the governor drive shaft NOTE: The gear sizes of the governor drive shaft
    to remove the rear ball bearing, and the spur-type assembly mayv8l)ldepending upon the governor speed.
    intermediate gear. For the correct part numbers of replacement gears,
    consult the specifications provided with the engine.
    6. Remove the woodruff key from the shaft.
    7. Remove the retaining ring from the third groove on 3. Inspect the No. 9 Woodruff keys for damage and
    the governor drive shaft. Press on the end of the shaft to distortion. Replace the keys if necessary.
    remove the helical governor drive gear and woodruff 4. Inspect the governor drive shaft (see
    key from the shaft. Figure 5.00·23) for damage and wear. If a Woodruff key
    must be replaced, verify that the keyway is clean and
    GOVERNOR DRIVE SHAFT
    undamaged. Inspect the ball bearing seating surfaces
    CLEANING AND INSPECTION
    for scoring, scuffing, excessive wear and cleanliness.
    Replace the governor drive shaft if necessary.
    A WARNING 5. Inspect the three drive shaft retaining rings for damage
    Always use approved cleaning solvents in a well or distortion. Replace the retaining rings if necessary.
    ventilated area. Contact with skin could result In
    severe personallnlury or death. 6. Inspect the ball bearing retainer for cracks, chips or
    other damage. Replace the ball bearing retainer if

    A WARNING necessary.
    7. Inspect the large ball bearing retainer retaining ring
    Compressed air can pierce the skin and could for damage or distortion. Replace the retaining ring if
    result In severe personal injury or death. Never use necessary.
    your hand to check tor leaks or to determine air flow
    rates. Wear safety glasses to shield your eyes from GOVERNOR DRIVE SHAFT ASSEMBLY
    flying dirt and debris.
    1. Remove all dirt, grime, grease, oil and varnish
    deposits, from the intermediate and governor drive
    A WARNING
    To avoid severe personal injury or death, always
    gears, drive shaft and ball bearing retainer. Thoroughly wear protective gloves when heating gears.
    clean all parts of the assembly in suitable solvent. Dry
    with moisture free compressed air. 1. Preheat the helical governor drli/e gear to 350 0 F
    (1760 C). Install the No.9 Woodruff I\,~, if removed, and
    2. Inspect the gear teeth for chips, cracks and exces· slide the gear down the shaft until it contacts the shaft
    sive wear. Replace the governor drive gear or the shoulder (see Figure 5.00·24).
    intermediate gear if necessary.

    GOVERNOR DRIVE
    GEAR (HELICAL)

    REAR BALL
    BEARING BALL
    BEARING

    RETAINING
    RING

    COUNTERBORE

    /
    BALL IIEj~II~G'
    RETAINER

    Figure 5.00·24. Governor Drive Shaft Assembly

    FORM 6248 First Edition 5.00 - 11


    SPEED GOVERNING SYSTEM

    GOVERNOR DRIVE SHAFT INSTALLATION


    A WARNING
    1. Hand pack Lithoplex® Grease No.2 (Multipurpose
    )
    Always wear proper eye protection when installing Lithium Complex Formula Containing Molybdenum
    retaining rings. Slippage may propel the ring with Disulfide) into the front and rear ball bearings of the
    enough force to cause severe personal injury or governor drive shaft assembly. Apply the same grease
    death. Use the correct retaining ring pliers. Verify to the teeth of the two gears on the drive shaft.
    that the tips of the pliers are not excessively worn or
    damaged. 2. Apply engine oil to the bearing bore opposite the
    expansion plug.
    2. With the rounded edge facing the gear, install the
    retaining ring in the third groove (see Figure 5.00-23) on 3. Install the governor drive shaft assembly into the
    the governor drive shaft to lock the governor drive gear governor drive housing (see Figure 5.00-25). The rear
    in position. Verify that the gear fits snugly on the drive ball bearing on the drive shaft is slip fitted into the
    shaft without rocking or sliding. bearing bore at the back. Use a rubber mallet to properly
    seat the drive shaft assembly, if necessary. Be sure that
    3. Press a new front ball bearing into the ball bearing the rear ball bearing is squarely seated in the bore.
    retainer. Exert pressure against the outer race of the ball
    bearing until it is seated against the bearing retainer
    counterbore. Install the large retaining ring in the ball
    bearing retainer groove.

    4. With the rounded edge faCing the gear, install the


    retaining ring in the second groove on the governor
    drive shaft. Exert pressure on the inner race of the ball
    bearing insert to press the bearing retainer onto the
    drive shaft. Press the bearing retainer assembly down
    the shaft until it seats against the retaining ring.

    5. With the rounded edge facing the gear, install the


    retaining ring in the first groove on the governor drive
    shaft (in front of the ball bearing retainer) to lock the
    bearing retainer assembly into position. Verify that the Figure 5.00-25. Governor Drive Gear
    assembly rotates freely on the drive shaft without
    binding or catching.
    4. Refer to "Governor Drive Gear, Assembly", and instail
    the Governor Drive Gear and CEC disc, (see
    A WARNING Figure 5.00-20). Set the gap between the pickup and the
    timing disc to 0.040 in. ±0.010 in. (1.016 mm ±D.254 mm).
    To avoid severe personal injury or death, always
    wear protective gloves when heating gears. 5. Refer to "Governor Drive Gear, Assembly", and
    install the governor drive housing cover plate.
    6. Preheat the spur-type intermediate gear to 350" F
    (176" C). Install the No.9 Woodruff key, if removed, and 6. Refer to Ignition Systems, and set engine timing.
    slide the gear down the governor drive shaft until it
    contacts the rear shoulder. Verify that the gear fits
    snugly on the drive shaft without rocking or sliding.

    7. Press a new rear ball bearing onto the end of the


    governor drive shaft. Exert pressure against the inner
    race of the ball bearing until it becomes seated against
    the rear drive shaft shoulder. Verify that the ball bearing
    rotates freely on the drive shaft without binding or
    catching.

    5.00 -12 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    GOVERNOR DRIVE HOUSING 5. If required, remove retaining ring and ball bearing
    from the magneto drive shaft (see Figure 5.00-28).
    GOVERNOR DRIVE HOUSING REMOVAL

    1. Refer to "Governor Drive Gear, Removal", "Gover-


    nor Drive Shaft, Removal" and "Governor, Removal" to
    remove these components.

    2. Disconnect the oil line from the upper governor drive


    housing (see Figure 5.00-26).

    3. Remove the Hall-effect pickup from the housing


    (see Figure 5.00-26).

    Figure 5.00-28. Governor Drive Assembly -


    Front Right

    GOVERNOR DRIVE HOUSING DISASSEMBLY


    1. If required, remove the plug and copper washer from
    the governor drive housing.
    2. If required, remove the plug from the side of the
    governor drive housing.
    3. If required, remove the elbow and fitting from the
    governor drive housing.
    GOVERNOR DRIVE HOUSING
    CLEANING AND INSPECTION
    1. Inspect governor drive housing for cracks.
    2. Inspect the expansion plug to insure it is fitted
    properly in the counterbore.
    Figure 5.00-26. 011 Una And Hall-effect Pickup
    3. Remove and discard the expansion plug.
    4. Remove eight capscrews (3/8 x 1 inch, with lock
    washers) governor drive housing and gasket, from the
    gear cover (see Figure 5.00-27).

    /
    !

    Figure 5.00-27. Governor Drive Housing

    FORM 6248 First EdHion 5.00 - 13


    SPEED GOVERNING SYSTEM

    GOVERNOR DRIVE HOUSING ASSEMBLY GOVERNOR DRIVE HOUSING INSTALLATION


    )
    1. If removed, apply Perma Lok® Heavy Duty Pipe 1. Apply a fast settin9". contact-type gasket shellac,
    Sealant with Teflon® to the pipe plug square head, 1 such as 3M Scotch Grip Rubber and Gasket Adhesive
    inch NPT) and install it on the governor drive housing 847, to the rear gasket surfaces.
    side (see Figure 5.00-29).
    2. Install a new gasket at the rear of the governor drive
    housing (see Figure 5.00-30).

    Figure 5.00-29. Governor Drive Housing - Rear

    2. If removed, apply Perma Lok® Heavy Duty Pipe Figure 5.00-30. Governor Drive Housing - Rear
    Sealant with Teflon® to the pipe plug and install the plug
    and copper washer on the upper governor drive housing.
    3. If removed, press a new rear ball bearing onto the end
    of the accessory (magneto) drive gear shafl (see
    3. If removed, apply Perma Lok® Heavy Duty Pipe
    Sealant with Teflon®, to the fitting and elbow and install Figure 5.00-31). Exert unHorm pressure against the inner
    them on the upper governor drive housing. race of the ball bearing until Hbecomes seated against the
    drive shaft shoulder. Verify that the bali bearing rotates
    4. If removed, apply 3M Scotch Grip'· Rubber and freely on the drive shafl without binding or catching.
    Gasket Adhesive 847 around the edge of a new
    expansion plug.

    5. With the concave Side facing inward, position the


    plug against the opening in the governor drive housing
    (see Figure 5.00-29).

    6. Using a soft hammer and a brass drift, strike the


    center of the plug a solid blow.

    7. Reach into the governor drive housing and push


    against the back of the expansion plug to verify that it is
    tightly and squarely seated against the counterbore.

    Figure 5.00-31. Governor Drive Assembly -


    Front Right

    5.00 -14 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    9. Apply Perma Lok® Heavy Duty Pipe Sealant with


    A WARNING Teflon®, to the threads of fitting and elbow (see
    Always wear proper eye protection when installing Figure 5.00-33).
    retaining rings. Slippage may propel the ring with
    enough force to cause severe personal injury or
    death. Use the correct retaining ring pliers. Verify
    that the tips ofthe pliers are not excessively worn or
    damaged.

    4. Install the retaining ring in the ball bearing retainer


    groove. Rotate the retaining ring to verify that it is fully
    seated.

    5. Apply Uthoplex® Grease No.2 (Multipurpose Uthi-


    urn Complex Formula Containing Molybdenum Disul-
    fide) between the inner and outer races of the rear ball
    bearing (see Figure 5.00-31).

    6. Apply engine oil to the inside of the sleeve at the back


    of the governor drive housing.

    7. With the governor mounting pad facing upward on


    the right bank side, slide the sleeve over the ball bearing
    on the magneto drive gear shaft. Use a rubber malletio
    properly seat the housing against the gear cover.

    8. Install the governor drive housing to the gear cover


    (8 capscrews, 3/8 x 1 inch, with lock washers) (see
    Figure 5.00-32). Figure 5.00-33. Oil Une And Hall-effect Pickup

    10. Connect oil line to the governoroove housing.

    11. Install the Hall-effect Pickup on the governor drive


    housing, (see Figure 5.00-20). Set the gap between
    the pickup and the timing disc to 0.040 in. ±0.010 in.
    (1.016 mm ±0.254 mm).

    12. Refer to Governor Drive Gear/CEC Disc, Governor


    Drive Shaft Assembly, and Governor Assembly, and
    install these components.

    13. Refer to Ignition Systems, set engine timing.


    Figure 5.00-32. Governor Drive Housing

    I
    ./

    FORM 6248 First Edition 5.00 -15


    SPEED GOVERNING SYSTEM

    WOODWARD UG-SL GOVERNOR 2. Remove the lock nut, two washers, capscrew, and
    governor rod from the butterfly valve on the carburetor
    WOODWARD UG-8L GOVERNOR LINKAGE (see Figure 5.00-35, Figure 5.00-36 and
    REMOVAL Figure 5.00-37).
    NOTE: Mark the hole in the governor output lever that
    the governor rod is attached to for reference during
    assembly.

    1. Remove the lock nut, two washers, capscrew, and


    governor rod from the governor output lever (see
    Figure 5.00-34).

    Figure 5.00-35. Governor Rod - GIGSI Engines

    Figure 5.00-36. Governor Rod - GL Engines


    (Throttle Control Shown Installed)

    3. Remove the rod end bearings and nuts if necessary.

    4. Remove lock nut and two spacers, and disconnect


    Figure 5.00-34. Governor Rod
    the rod from the governor speed control handle (see
    Figure 5.00-34).

    NOTE: On GL engines, refer to Throttle Control Handle


    Removal, and remove the throttle control handle to
    expose the butterfly on the carburetor.

    5.00 - 16 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    WOODWARD UG-SL GOVERNOR REMOVAL

    t. Remove two nuts, lock washers, screws and the


    governor speed control assembly from the governor
    and housing (see Figure 5.00-38).

    2. Remove two nylok capscrews, lock washers, gover-


    nor assembly and gasket, from the governor housing
    (see Figure 5.00-38).

    WOODWARD UG-SL GOVERNOR DISASSEMBLY

    IA CAUTION IDo not remove the gover-


    nor output lever or speed
    L-==--'------';......
    . .. _ _--'.
    control lever from the serrated shafts, unless required.
    H the levers must be removed, carefully mark their
    radial position on the shafts. Indexing levers to the
    wrong splines on the shafts may lead to an overspeed
    condition resulting in catastrophic engine damage.

    1. If required, remove cotter pin, nut and gear from


    the governor shaft (see Figure 5.00-39). Discard the
    cotter pin.

    Figure 5.00-37. Governor Rod - GL Engines


    (Throttle Control Shown Installed)

    5. Remove lock nut and two spacers, and disconnect


    the rod from the governor speed adjustment lever (see
    Figure 5.00-34 and Figure 5.00-38).

    GEAR .............. ~
    NUT~ til
    ---@
    Figure 5.00-39. Governor Assembly

    WOODWARD UG-SL GOVERNOR ASSEMBLY

    1. if removed, install a new cotter pin, nut and gear on


    the governor shaft (see Figure 5.00-39).
    Figure 5.00-38. UG-SL Governor Assembly

    FORM 6248 First Ednion 5.00 - 17


    SPEED GOVERNING SYSTEM

    WOODWARD UG-BL GOVERNOR INSTALLATION 5. Connect governor rod to the side away from the
    governor speed lever with two washers and lock nut. )
    1. Apply 3M Scotch Grip'· Rubber and Gasket Adhe-
    sive 847 to the housing gasket surface and install 6. Refer to Governor Speed Control Lever adjustment
    gasket on the governor housing (see Figure 5.00-39). and adjust the governor speed control rod.
    Install two nylok capscrews, lock washers, governor
    assembly and gasket, on the governor housing. 7. Check oil level and fill to proper level.

    2. Install governor to the governor housing with the two 8. Refer to Rod Adjustment, to adjust the governor rod.
    nylok capscrews and lock washers (see
    Figure 5.00-38). 9. Refer to Governor Compensation Adjustment, to
    adjust compensation.
    3. Install the throttle control handle assembly and the
    governor to the governor housing with two capscrews,
    lock washers and nuts.

    NOTE: The washers on the control rod are positioned


    to either side of the control rod ends. The lock nuts are
    positioned on the govemor side of the control rod.

    4. Connect rod to the side away from the governor


    governor speed control with two washers and lock nuts
    (see Figure 5.00-40).

    Figure 5.00-40. UG-SL Governor Linkage

    5.00 -18 FORM 6248 First Ed~ion


    SPEED GOVERNING SYSTEM

    80° CLOSED 142° MAX. FUEL

    ---- ----
    (INSTALL AT 80°
    FROM HORIZONTAL)
    / 40° MAX. TRAVEL
    / -~-

    NOTE: Governor Data 184° NO FUEL


    • reference rod length - 51.900 (INSTALL LEVER 4°
    • travel - 42° BELOW HORIZONTAL)
    • shaft - 0.500-36
    -lever length - 2.625

    Figure 5.00-41. UG-8 Governor linkage Adjustment Information For 5108GL, 5790GL And 7042GL

    NOTE: Governor Data


    • reference rod length - 50.610 MAXIMUM
    • travel - 42" FUEL POSITION
    • shaft - 0.375-36 '"

    • /ever le{n~gt~h~-~4~'~~90~_:_~==_=_==:::=:_::-3~-;~~~:~=~~~1-t8~. 00

    / 5.28
    NO FUEL POSmON 'I
    _ - - _ - - _ - - _ - - _ - - __ ~NSTALLLEVER1° ~
    BELOW HORIZONTAL)
    NOTE: Butlerflr Valve Data
    • trave - 72"

    cu~~~~~~__~·:Ie=ve:r~le~ngth::~-~I:.2:50~___
    54.28 -------------,----1
    Figure 5.00-42. UG-8 linkage Adjustment Information For 51 OBGL, 5790GL And 7042GL
    - Low Pressure Fuel, Draw Thru Carburetion .

    A CAUTION I
    UG-SL GOVERNOR LINKAGE INSTALLATION
    AND ADJUSTMENT I.::-="--.::=.;:";::;",,;;,..:...;:;,,,;~.
    .L
    Be sure the governor le-
    ver and butterfly valves
    properly close and open at the same time. governor
    A WARNING linkage travel must not be limited by the butterfly
    valve striking the housing, this imposes unneces-
    Before making any adjustments to an operating sary loads on the linkage. Failure to follow the proper
    governor on an engine, check that you have hand procedures can cause damage to equipment.
    throttle control over the engine speed to avoid
    severe personal injury or death. NOTE: Refer to Figure 5.00-41, Figure 5.00-42 and
    Table 5.00-1 for the correct adjustment angles listed by
    engine type.

    FORM 6248 First Edition 5.00 -19


    SPEED GOVERNING SYSTEM

    Table 5.00-1. UG-S Governor Linkage Adjustment Information For L5108G/GSI; L5790G/GSI; L7042G/GSI

    NOTE: These chart values


    are approXImate.
    I OPEN '-'" •
    _....
    <\
    . _~. _ CLOSED / ' ' ' - .M

    H~L ':;x __ ~ONm~L


    !: ROD rC") _l.. ±
    --t- '-- -4-
    K .\ I

    .
    LENGTH ("D")
    ~G OPEN
    f \J I
    CLOSED E .... _ F L

    BUTTERFLY SHAFT LEVER ("S") GOVERNOR LEVER ("A")

    A B C D E F G H J K L M N
    LEVER LEVER ROD NO.
    50.5 in. 0.53 in. 1.0 in. 0.17 in. 3.25 in. REo
    156339A 153267C AA209615B (1308.1 mm) 32' 38' (13.462 mm) (25.4mm) 3' 42' (4.318 mm) (82.55 mm)
    50.75 in.
    60' 0.26 in. 1.0in.
    206564F** 153267C AA209615J (1288.05 mm) 15' (6.604 mm) (25.4mm) 0' 42' 0 0 RE

    NOTE: .. Name plate towards rear.


    .. For L7042GSI (with EGR option) ano double butterfly housing.

    NOTE: On GL engines, refer to Throttle Control Handle


    Removal, and remove the throttle control handle.
    1. If removed, install the governor output lever on the
    near side governor output shaft at the proper angle, with
    the output shaft in the NO FUEL position (see
    Figure 5.00-43). Tighten the capscrew on governor
    output lever to 14 ft-Ib (18.98 N·m).

    Figure 5.00-44. Governor Rod - G/GSI Engines

    Figure 5.00-43. Angle Finder In "No Fuel" Position

    2. Install the governor rod to the lever on the butterfly


    valve with capscrew, two washers, and lock nut (see
    Figure 5.00-44, Figure 5.00-45 and Figure 5.00-46).

    Figure 5.00-45. Governor Rod - GL Engines


    (Throttle Control Shown Installed)

    5.00 - 20 FORM 6248 First Ed~ion


    SPEED GOVERNING SYSTEM

    4. Install the governor rod to the near side on the


    governor lever with capscrew, two washers, and lock
    nut.
    5. Center the angle finder on the top of the governor
    lever. Refer to Figure 5.00-41, Figure 5.00-42 and
    Table 5.00-1 for the correct adjustment angles listed by
    engine type. Verify that the angle is at the proper value.

    6. Move the governor lever up to the "full fuel" position.


    Refer to Figure 5.00-41, Figure 5.00-42 and
    Table 5.00-1 for the correct adjustment angles listed by
    engine type. Verify that the angle is at the proper value.

    7. Measure the length of the governor rod. Refer to


    Figure 5.00-41 , Figure 5.00-42 and Table 5.00-4 for the
    correct distance from the centerline of one rod end
    bearing to the other.

    8. To adjust the rod length, loosen the governor rod jam


    nuts on each side of the governor rod (see
    Figure 5.00-47). Screw the threaded studs in or out of
    the governor rod, as necessary. Adjustlhe studs on both
    ends of the rod, so that their length (external to the
    governor rod) is as equal as possible. When the
    governor rod assembly is at the correct length, wrench
    tighten both governor rod jam nuts (CW).
    Figure 5.00-46. Governor Rod - GL Engines
    (Throttle Control Shown Installed) 9. Check all fasteners on the rod for tightness. thread
    engagement on all rod ends must be a minimum of
    seven threads.
    3. With the governor output shaft in the NO FUEL
    position, and with the butterfly valve held closed, adjust
    the governor rod for length so that a capscrew will pass
    through the rod end and the hole in the lever (see
    Figure 5.00-43).

    Figure 5.00-47. Governor Rod

    FORM 6248 First Ed~ion 5.00 - 21


    SPEED GOVERNING SYSTEM

    WOODWARD UG-SL GOVERNOR


    COMPENSATION ADJUSTMENT A WARNING )
    Adjust the governor compensation as required. High When starting the engine, be prepared to use the
    overspeeds and underspeeds or a slow return to normal hand throttle control and or manual shutdown lever
    speed after load changes may be the result of improper- to shut down the engine to protect against runaway
    ly adjusted governor compensation. or overspeed should the electro-hydraulic actua-
    torts), or electric control(s), fuel control(s), the
    NOTE: Large, permanent changes in ambient air driving mechanism(s), Iinkage(s) or the controlled
    temperature affecting govemor oil viscosity may require device(s) fall. Failure to take use the proper proce-
    compensation adjustments. dures can cause severe personal injury or death.
    The compensation pointer (coarse adjustment) and
    compensation needle valve (fine adjustment) are ad- NOTE: Steps 1 thru 3 refer to initial operation.
    justable parts of the engine speed control system (see
    Figure 5.00-48). Governor stability and response are 1. Fill the governor with oil.
    directly affected by adjustment of these components. 2. Remove the slotted plug and washer from the base
    The amount of adjustment required is based on the of the governor to access the compensating needle
    individual operating characteristics (speed and load) of valve. Using a #2 Phillips screwdriver or a 3/16 inch
    each engine. regular screwdriver, turn the compensating needle
    valve (CW) to close. When the valve just touches its
    OIL FILLER CUP seat, open the valve (CCW) 1/2 to 3/4 turn.

    3. Loosen the nut holding the compensation pointer


    and move the pointer to the midpoint. (see
    SIGHT Figure 5.00-48). Tighten the nut to secure the com-
    GLASS
    pensation pointer.

    WOODWARD 4. At a reduced speed, run the engine without load until


    the lube oil reaches normal operating temperature.

    t
    OUTPUT
    SHAFT
    5. Loosen the nut holding the compensation pointer
    and move the pointer all the way up for maximum
    compensation (see Figure 5.OO-4S). Tighten the nut to
    secure the compensation pointer.

    '"
    COMPENSATION
    POINTER
    6. Remove the slotted plug and washer from the base of
    the governor to access the compensating needle valve.

    J------:;;;;o-----:i-. 011: DRAIN


    PLUG

    DRIVE SHAFT

    Figure 5.00-48. Woodward UG-SL Governor

    5.00 - 22 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    A CAUTION I If a regular screwdriver Is


    I.L .=.a='--':;...:....:..::....---'-"'---"-'. used for compensation
    needle valve more than necessary makes the governor
    slow to return to normal speed after a load change. It is
    adjustments, fit the tip into the shallow slot on the also desirable to have as little compensation as
    compensating needle valve (at right angles to the possible.
    deep slot). Use of the deep slot may cause the
    screwdriver to bind or otherwise damage the needle NOTE: Once the needle valve adjustment is CO"ect, it
    valve. The purpose of the deep slot is to allow the is not necessary to change the setting except for large
    head ofthe needle valve to expand during governor changes in temperature, which affect governor oil
    operation. The increased friction resulting from temperature and viscosity.
    expansion of the head prevents vibration from
    NOTE: As a general rule, always adjust the governor to
    altering the setting of the needle valve. Disregard-
    provide as little compensation as possible. Adjustment
    ing this infonnatlon could result In product damage
    of the compensation pointer too far toward the maxi-
    and/or personal injury.
    mum position, provides stable, steady state operation,
    but causes excessive offspeed, which is the amount by
    A CAUTION INevertig~entheneedle
    I.L .::.a=~:;.;;....;;..;::;....;;--,-;;;...;~. valve against Its seat.
    which the governor overshoots and undershoots the
    desired speed upon load changes. Closing the needle
    Damage to the needle valve could result. valve too far, makes the governor slow to return
    (recover) to speed after load changes. Opening the
    7. Using a #2 Phillips screwdriver or a 3/16 inch regular needle valve too far, makes the governor too respon·
    screwdriver, turn the compensating needle valve (CW) sive, a condition which adversely affects governor
    to close. When the valve just touches its seat, open the stability and can cause the engine to hunt.
    valve (CCW) 2 full turns.
    14. When the compensation adjustment is correct,
    8. To bleed trapped air from the governor oil passages, tighten the nut to secure the position·~f the compensa·
    allow the engine to "hunt" for one-half minute. "Hunting" tion pointer.
    is a fluctuation in engine speed above and below the
    desired rpm. 15. Install the needle valve access plug and washer in
    the base of the governor. The plug prevents oil seepage
    NOTE: During Step 9, the engine speed will vary. around the needle valve as well as unauthorized
    tampering with the compensation adjustment.
    9. Loosen the nut just enough to move the compensa-
    tion pointer all the way down for minimum compensa-
    tion. Retighten the nut to secure the pointer. I A CAUTION I Do not tamper with the
    .a internal adjustment of
    NOTE: The objective of the compensation adjustment the governor unless thoroughly familiar with the
    procedure is to find the particular settings for the proper procedures. Normally, the only require-
    compensation needle valve and compensation adjust- ments for putting a new or overhauled governor
    ment pointer at which the engine will return quickly to into service are bleeding trapped air and adjusting
    speed (needle valve adjustment), after a speed distur· compensation to obtain good response with maxi-
    bance, with only a slight over or undershoot (compensa· mum stability. All other operating adjustments are
    tion pointer adjustment). made at the factory in accordance with Waukesha
    specifications and should not require further ad-
    10. Gradually close the needle valve until the hunting justment. Disregarding this infonnatlon could re-
    just stops. If the hunting does not stop, open the sult in product damage and/or personal injury.
    compensating needle valve three to five turns from the
    closed position and move the compensation pointer up
    by two marks on the front panel indicator scale. Again,
    gradually close the needle valve until hunting stops.

    11. If hunting does not stop, repeat Step 7.

    12. Check governor stability by manually disturbing the


    governor setting. The compensation adjustment is
    satisfactory when the governor returns to speed with
    only a slight undershoot or overshoot.

    13. The needle valve must not be closed completely,


    normal position is from 1/2 to 3/4 turn open. Closing the

    FORM 6248 First Edition 5.00 - 23


    SPEED GOVERNING SYSTEM

    WOODWARD UG-8L GOVERNOR HIGH/LOW NOTE: Turning the high speed stop screw (CCW) will
    SPEED LIMIT ADJUSTMENT increase engine speed. Turning the high speed stop
    screw (CW) will decrease engine speed.
    CAUTION I
    I~A=~=....:..;::.....::..:;..;:;...;:....:..J.
    Do.not adjust the internal 5. Loosen the locking nut and turn the high speed stop
    L.. . adlustment of the gover-
    screw to make fine adjustments to the high speed setting.
    nor unless thoroughly familiar with the proper
    procedures. Normally. the only requirements for 6. Lock the high speed stop screw in position by
    putting a new or overhauled governor into service tightening the locking nut.
    are bleeding trapped air and adjusting compensa-
    tion to obtain good response with maximum stabil- WOODWARD UG-8L GOVERNOR DROOP
    ity. All other operating adjustments are made at the ADJUSTMENT
    factory in accordance with Waukesha specifica-
    Speed droop. or "droop" is one method of creating
    tions and should not require further adjustment.
    stability in a governor.
    Disregarding this Information could result in prod-
    uct damage and/or personal injury. Droop is also used to divide and balance load between
    two or more prime movers operating in parallel or
    1. Position the governor speed control to the minimum connected to a single shaft.
    speed setting (see Figure 5.00-49).
    Droop is the decrease in speed taking place when the
    LEFT BANK SIDE governor output shaft moves from the minimum to the
    maximum fuel position in response to a load increase,
    expressed as a percentage of rated speed.
    OIL SIGHT 'GUISS. Speed droop is expressed as a percent of rated speed.
    ;;~~iEW.
    HIGH ...
    The following formula can be used to calculate droop.
    STOP
    Speed Droop % ~ (NO load RPM-Ratedload RPM) x 100
    Rated load RPM

    1. Refer to High/Low Speed Stop Adjustment and )


    adjust the governor at no load, for 600 RPM low idle
    speed.

    2. Run engine at rated load, and position governor high


    speed stop (see Figure 5.00-49) for rated speed.
    Remove load and check high idle speed and record.
    LOW
    STOP 3. To adjust droop (see Table 5.00-2):

    • On 1200 RPM industrial engines, if high idle speed is


    more than 60 RPM above rated speed, adjust droop
    of the governor to give a high idle speed of 20 - 60
    RPM above rated speed.

    • On industrial engines rated at 1100 RPM and lower, a


    RIGHT BANK SIDE high idle speed of up to 10% above rated speed is
    Figure 5.1JO.49. Woodward UG-8L Governor acceptable.
    - Top View
    Table 5.00-2. Governor Speed Droop Settings
    NOTE: Turning the low speed stop screw (CCW) will GOVERNOR SPEED DROOP
    SETTING (%)
    decrease engine speed. Turning the low speed stop
    Woodward UG-8L (Lever)" **5 to 10
    screw (CW) will increase engine speed.
    Woodward UG-8 Dial 0
    2. Loosen the locking nut and turn the low speed stop Woodward Eleclrie EG-3P 0
    screw to make fine adjustments to the low speed setting. NOTE: * VHP Marine engines have isochronous governors without
    any means for adding droop.
    3. Lock the low speed stop screw in position by ** VHP engines with rated speed above 1100 RPM must have the )
    tightening the locking nut. droop set to provide a No-load speed of 20 - 60 RPM above rated
    speed.
    4. Pos~ion the governor speed control to the maximum
    speed setting.
    5.00 - 24 FORM 6248 First Edition
    SPEED GOVERNING SYSTEM

    WOODWARD UG-8 (DIAL) GOVERNOR


    WOODWARD UG-8 (DIAL) GOVERNOR LINKAGE
    REMOVAL
    NOTE: Mark the hole in the governor output lever that
    the governor rod is attached to, for reference during
    assembly.

    1. Remove the lock nut, two washers, capscrew, and


    governor rod from the governor output lever (see
    Figure 5.00-50).

    Figure 5.00-51. Governor Rod - GIGSI Engines

    Figure 5.00-52. Governor Rod - GL Engines


    (Throttle Control Shown Installed)

    Figure 5.00-50. Govemor Rod

    NOTE: On GL engines, refer to Throttle Control Handle


    Removal, and remove the throttle control handle to
    expose the carburetor butterfly.

    2. Remove the lock nut, two washers, capscrew, and


    governor rod from the butterfly valve (see
    Figure 5.00-51, Figure 5.00-52 and Figure 5.00-53).

    FORM 6248 First Edition 5.00 - 25


    SPEED GOVERNING SYSTEM

    WOODWARD UG-8 (DIAL) GOVERNOR REMOVAL

    1. Remove two nuts, lock washers, and screws from


    the the output lever side of the governor and governor
    housing (see Figure 5.00-54).

    Figure 5.00-53. Governor Rod - GL Engines


    (Throttle Control Shown Installed)

    3. Remove the rod end bearings and nuts if necessary.

    Figure 5.00-54_ Governor

    2. Remove two nylok capscrews, lock washers, gover-


    nor assembly and gasket, from the governor and
    governor housing.

    5.00 - 26 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    WOODWARD UG-8 (DIAL) GOVERNOR WOODWARD UG-8 (DIAL) GOVERNOR LINKAGE


    DISASSEMBLY INSTALLATION AND ADJUSTMENT

    IA CAUTION I Do not remove the gover- A WARNING


    .. nor output lever or speed
    control lever from the serrated shafts. H the levers Before making any adjustments to an operating
    must be removed, carefully mark their radial posi- governor on an engine, check that you have hand
    tion on the shafts. Indexing levers to the wrong throttle control over the engine speed to avoid
    splines on the shafts may lead to an overspeed severe personal InJury or death.

    CAUTION I
    condition resulting in catastrophic engine damage
    and/or personal injury.
    1. If required. remove cotter pin and nut from the governor
    IA Be sure the governor le-
    ....="=7'-:---''---':-''----'' ver and butterfly valves
    properly close and open at the same time. governor
    shaft (see Figure 5.00-55). Discard the cotter pin. linkage travel must not be limited by the butterfly
    valve striking the housing, this Imposes unneces-
    sary loads on the linkage. Failure to follow the proper
    procedures can cause damage to equipment and/or
    personal injury.
    NOTE: Refer to Figure 5.00-41. Figure 5.00-42 and
    Table 5.00-1 for the correct adjustment angles listed by
    engine type.
    NOTE: On GL engines, refer to Throttle Control Handle
    Removal, and remove the throttle control handle.
    1. If removed, install the governor QIltput lever on the
    near side governor output shaft attheiiroper angle, with
    the output shaft in the NO FUEL position (see
    Figure 5.00-56). Tighten the capscrew on governor
    output lever to 14 ft-Ib (18.98 N·m).

    Figure 5.00-55. Governor Assembly

    2. If required. remove gear from the governor shaft.

    WOODWARD UG-8 (DIAL) GOVERNOR


    ASSEMBLY
    1. If removed. install a new cotter pin. nut and gear on
    the governor shaft (see Figure 5.00-55).

    WOODWARD UG-8 (DIAL) GOVERNOR


    INSTALLATION
    1. Apply 3M Scotch Grip Rubber and Gasket Adhe-
    N

    sive 847 to the housing gasket surface and install


    gasket on the governor housing (see Figure 5.00-55).

    2. Install two nylok capscrews. lock washers. governor


    assembly and gasket. on the governor housing (see
    Figure 5.00-54).

    3. Install the remaining two capscrews. lock washers


    and nuts on the governor and housing.

    ) 4. Check oil level and fill to proper level.

    5. Refer to Rod Adjustment. to adjust the governor rod.

    6. Refer to Governor Adjustment. to adjust the Governor. Figure 5.00-56. Governor Rod
    FORM 6248 First Ednion 5.00-27
    SPEED GOVERNING SYSTEM

    2. Install the governor rod to the lever on the butterfly Table 5.00-1, for the correct adjustment angles listed by
    valve with capscrew, two washers, and lock nut (see engine type. Verify that the angle is at the proper value. )
    Figure 5.00-57, Figure 5.00-58 and Figure 5.00-59).

    Figure 5.00-57. Governor Rod - GIGSI Engines

    )
    Figure 5.00-59. Governor Rod - GL Engines
    (Throttle Control Shown Installed)
    8. Measure the length of the governor rod. Refer to
    Figure 5.00-41, Figure 5.00-42 and Table 5.00-1, for
    the correct distance from the centerline of one rod end
    bearing to the other.
    Figure 5.00-58. Governor Rod - GL Engines
    (Throttle Control Shown Installed) 9. To adjust the rod length, loosen the governor rod jam
    nuts on each side of the governor rod (see
    3. With the governor output shaft in the NO FUEL Figure 5.00-60). Screw the threaded studs in or out of
    position, and with the butterfly valve held closed, adjust the governor rod, as necessary. Adjustthe studs on both
    the governor rod for length so that a capscrew will pass ends of the rod, so that their length (external to the
    through the rod end and the hole in the lever (see governor rod) is as equal as possible. When the
    Figure 5.00-56 and Figure 5.00-60). governor rod assembly is at the correct length, wrench
    tighten both governor rod jam nuts (CW).
    4. Refer to reference marks, and install the governor
    rod to the near side on the governor lever with capscrew, GOVERNOR ROD END BEARING
    two washers, and lock nut (see Figure 5.00-56). ROD JAM NUT
    GOVERNOR ROD / ROD END
    5. Check all fasteners on the rod for tightness. thread JAM NUT BEARING

    ~ I~T~..u---,:~
    engagement on all rod ends must be a minimum of \
    seven threads.
    6. Center the angle finder on the top of the governor
    lever. Refer to Figure 5.00-41, Figure 5.00-42 and
    Table 5.00-1, for the correct adjustment angles listed by
    engine type. Verify that the angle is at the proper value. RIGHT LEFT \
    )
    HAND HAND GREASE
    7. Move the govemor lever up to the "full fuel" position. THREADS THREADS FlmNG
    Refer to Figure 5.00-41, Figure 5.00-42 and
    Figure 5.00-60. Governor Rod Assembly

    5.00 - 28 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    WOODWARD UG-8 DIAL GOVERNOR


    COMPENSATION ADJUSTMENT A WARNING
    Adjust the governor compensation daily or as required. When starting the engine, be prepared to make an
    High overspeeds and underspeeds or a slow return to emergency shut down to protect against runaway
    normal speed after load changes may be the result of or overspeed should the electro-hydraulic actua-
    improperly adjusted governor compensation. tor(s), or electric control(s), fuel control(s), the
    driving mechanlsm(s), IInkage(s) or the controlled
    NOTE: Large, permanent changes in ambient air device(s) fall, Failure to take use the proper proce-
    temperature affecting governor oil viscosity may require dures can cause severe personal injury or death.
    compensation adjustments.
    The compensation pointer (coarse adjustment) and NOTE: Steps 1 thru 3 refer to initial operation.
    compensation needle valve (fine adjustment) are ad-
    justable parts of the engine speed control system (see 1. Fill the governor with oil.
    Figure 5.00-61). Governor stability and response are 2. Remove the slotted plug and washer from the base
    directly affected by adjustment of these components. of the governor to access the compensating needle
    The amount of adjustment required is based on the valve. Using a #2 Phillips screwdriver or a 3/16 inch
    individual operating characteristics (speed and load) of regular screwdriver, turn the compensating needle
    each engine. valve (eW) to close. When the valve just touches its
    seat, open the valve (CCW) 1/2 to 3/4 turn.
    OIL FILLER CUP
    3. Loosen the nut holding the compensation pointer
    and move the pointer to the midpoint. (see
    Figure 5.00-61). Tighten the nut to secure the com-
    SIGHT pensation p o i n t e r . . , .
    GLASS

    4. At a reduced speed, run the engine without load until


    the lube oil reaches normal operating temperature.

    -'~-:..
    - -
    5. Loosen the nut holding the compensation pointer

    -WI
    and move the pointer all the way,up for maximum
    " ....
    compensation (see Figure 5.00-61). lighten the nut to
    secure the compensation pointer.
    ~~~~
    - - I \
    6. Remove the slotted plug and washer from the base
    of the governor to access the compensating needle
    valve.

    CAUTION I
    I A=:.....;=-=-=-.:....:=...:...;:..J.
    If a regular screwdriver Is
    .L .::
    .. used for compensation
    adjustments, fit the tip into the shallow slot on the
    compensating needle valve (at right angles to the
    deep slot). Use of the deep slot may cause the
    screwdriver to bind or otherwise damage the needle
    .i-----,;;:o-----:!.- OIL DRAIN valve. The purpose of the deep slot is to allow the
    PLUG head ofthe needle valve to expand during governor
    operation. The increased friction resulting from
    expansion of the head prevents vibration from
    altering the setting of the needle valve. Disregard-
    ing this Information could result In product damage
    COMPENSATION
    NEEDLE VALVE and/or personal injury.
    (BEHIND PLUG)

    Figure 5,00-61, Woodward UG-B Dial Governor CAUTION I Never tigh~en t~e needle
    I A=:.....;=-=-=-.:....:-=-...:...;:..J.
    ) L
    . .::
    .. valve agamst Its seat.
    Damage to the needle valve could resuh.

    FORM 6248 First Edilion 5.00 - 29


    SPEED GOVERNING SYSTEM

    7. Using a #2 Phillips screwdriver or a 3/16 inch regular NOTE: As a general rule, always adjust the governor to
    screwdriver, turn the compensating needle valve (CW) provide as little compensation as possible. Adjustment
    to close. When the valve just touches its seat, open the of the compensation pointer too far toward the maxi-
    valve (CCW) 2 full turns. mum position, provides stable, steady state operation,
    but causes excessive offspeed, which is the amount by
    8. To bleed trapped air from the governor oil passages, which the governor overshoots and undershoots the
    allow the engine to "hunt" for one-half minute. "Hunting" desired speed upon load changes. Closing the needle
    is a fluctuation in engine speed above and below the valve too far, makes the governor slow to return
    desired rpm. (recover) to speed after load changes. Opening the
    needle valve too far, makes the governor too respon-
    NOTE: During Step 9, the engine speed will vary.
    sive, a condition which adversely affects governor
    9. Loosen the nut just enough to move the compensa- stability and can cause the engine to hunt.
    tion pointer all the way down for minimum compensa-
    14. When the compensation adjustment is correct,
    tion. Retighten the nut to secure the pointer.
    tighten the nut to secure the position of the compensa-
    NOTE: The objective of the compensation adjustment tion pointer.
    procedure is to find the particular settings for the
    15. Install the needle valve access plug and washer in
    compensation needle valve and compensation adjust-
    the base of the governor. The plug prevents oil seepage
    ment pointer at which the engine will return quickly to
    around the needle valve as well as unauthorized
    speed (needle valve adjustment), after a speed distur-
    tampering with the compensation adjustment.
    bance, with only a slight over or undershoot (compensa-
    tion pointer adjustment). WOODWARD UG-8 DIAL GOVERNOR HIGH/LOW
    SPEED ADJUSTMENT
    10. Gradually close the needle valve until the hunting
    just stops. If the hunting does not stop, open the The synchronizer is the speed adjusting control and is used
    compensating needle valve three to five turns from the to change engine speed for a single unit. On engines
    closed position and move the compensation pointer up paralleled with other units, ~ is used to change engine load.
    by two marks on the front panel indicator scale. Again, The upper knob, "SYNCHRONIZER" is the control knob, )
    gradually close the needle valve until hunting stops. while the lower knob, "SYN. INDICATOR", indicates the
    number of revolutions of the synchronizer control knob.
    11. If hunting does not stop, repeat Step 7.
    A CAUTION I
    12. Check governor stability by manually disturbing the
    governor setting. The compensation adjustment is
    I=..
    L.
    Do not adjust the Internal
    ='--:';..;;.....:;..;:......;...;;..~~.
    adjustment of the gover-
    nor unless thoroughly familiar with the proper
    satisfactory when the governor returns to speed with procedures. Normally, the only requirements for
    only a slight undershoot or overshoot. putting a new or overhauled governor into service
    are bleeding trapped air and adjusting compensa-
    13. The needle valve must not be closed completely,
    tion to obtain good response with maximum stabil-
    normal position is from 1/2 to 3/4 turn open. Closing the Ity. All other operating adjustments are made at the
    needle valve more than necessary makes the governor factory in accordance with Waukesha specifica-
    slow to return to normal speed after a load change. It is tions and should not require further adjustment.
    also desirable to have as little compensation as Disregarding this information could result in prod-
    possible. uct damage and/or personal injury.
    NOTE: Once the needle valve adjustment is correct, it
    is not necessary to change the setting except for large
    changes in temperature, which affect governor oil
    A WARNING
    Adjusting the governor speed settings beyond the
    viscosity.
    specified minimum and/or maximum speed ratings
    of the engine can cause damage to equipment and
    severe personal injury or death.

    5.00-30 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    WOODWARD UG-8 (DIAL) GOVERNOR DROOP


    ADJUSTMENT
    Speed droop, or "droop" is one method of creating
    stability in a govemor. Droop is also used to dMde and
    balance load between two or more prime movers operating
    in parallel or connected to a single shaft.
    Droop is the decrease in speed laking place when the
    governor output shaft moves from the minimum to the
    maximum fuel position in response to a load increase,
    expressed as a percenIage of rated speed.
    Speed Droop is expressed as a percent of rated speed
    (see Table 5.00-3). The following formula can be used
    to calculate droop.
    Speed Droop % = (NO load RPM - Rated load RPM) x 100
    Rated load RPM

    Table 5.00-3. Govemor Speed Droop Settings


    SPEED DROOP
    GOVERNOR
    SETTING (%)
    Woodward UG-8L (Lever)· * 5 to 10
    Woodward UG-8 Dial 0
    Woodward Electric Actuators 0
    NOTE: ·VHPengines with rated speedabove 1100 RPM must have
    the droop set to provide a NO-load speed at 20 - 60 RPM above
    rated speed.
    Marks on the adjustment scale are reference numbers
    only, and do not represent droop percentages. Therefore,
    the 100 mark does not represent 100% droop. It represents
    the maximum droop percentage available on on that UG-8
    Dial govemor.
    Reducing droop to zero allows the unit to change load
    without changing speed. Normally set zero droop on uni1B
    running alone. On interconnected uni1B, set the least
    amount of droop possible to provide satisfactory load
    division.
    For AC generating uni1B tied in with other uni1B, set droop
    sufficiently high to (reference numbers 30 to 50 on the dial)
    to prevent interchange of load between uni1B. If one unit in
    the system has enough capacity, set i1B governor on zero
    droop and it will regulate the frequency of the prime mover
    system. If i1B capacity is not exceeded, this unit will
    handle all load changes.
    Operate the SYNCHRONIZER of the governor with
    zero droop, to adjust the systems frequency. Operate
    the SYNCHRONIZERS, of the governors that have
    speed droop, to distribute load between units.
    1. To adjust droop: Rotate the speed droop knob and
    set zero droop on units running alone. On intercon-
    nected units, set the least amount of droop possible to
    provide satisfactory load division.
    j

    FORM 6248 First Edition 5.00 - 31


    SPEED GOVERNING SYSTEM

    WOODWARD EG-3P ELECTRIC


    GOVERNOR
    WOODWARD EG-3P ELECTRIC GOVERNOR
    LINKAGE REMOVAL

    NOTE: Mark hole in the governor output /ever that the


    governor rod is attached to for reference during assembly.

    1. Remove the lock nut, two washers, capscrew, and


    governor rod from the governor lever (see
    Figure 5.00-62).

    Figure 5.00-63. Governor Rod - GIGSI Engines

    Figure.5.oo-64. Governor Rod - GL Engines


    (Throttle Control Shown Installed)

    Figure 5.00-62. EG-3P Governor Rod

    NOTE: On GL engines, refer to manual shutdown lever


    Handle Removal, and remove the manual shutdown
    lever handle.

    2. Remove the lock nut, two washers, capscrew, and


    governor rod from the butterfly valve (see
    Figure 5.00-63, Figure 5.00-64 and Figure 5.00-65).

    5.00 - 32 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    WOODWARD EG-3P GOVERNOR DISASSEMBLY

    1. Remove the splined connector from the governor


    shaft (see Figure 5.00·66). The splined connector may
    stay with the governor drive housing shaft.

    Figure 5.00-65. Governor Rod - GL Engines


    (Throttle Control Shown Installed)

    3. Remove the rod end bearings and nuts if necessary. Figure 5.00-66. Spllned Cpnnector

    A. CAUTION I
    WOODWARD EG-3P GOVERNOR REMOVAL

    1. Disconnect the oil line from the governor (see


    I.::.-='
    L.
    • --_____---'. Do not remove the gover-
    nor lever from the ser-
    rated governor output shaft. If the governor lever
    Figure 5.00-62). must be removed, carefully mark Its radial position
    2. Disconnect pickup harness from the governor. on the output shaft. Indexing the governor lever to
    the wrong splines on the output shaft may lead to an
    3. Remove two nuts, lock washers and governor from overspeed condition resulting In catastrophic en-
    the governor drive. gine damage.

    4. Remove and discard the gasket. WOODWARD EG-3P GOVERNOR CLEANING AND
    INSPECTION

    A WARNING
    Comply with the solvent manufacturer's recom-
    mendations for proper use and handling of sol-
    vents. Do not use gasoline, paint thinners or other
    highly volatile fluids for cleaning. Improper han-
    dling or misuse could resuH in severe personal
    injury or death.

    ) I A.
    .-
    CAUTION I Do not submerge the
    governor during the
    cleaning process. Submerging the governor will
    cause damage to equipment.

    FORM 6248 First Ed~ion 5.00 - 33


    SPEED GOVERNING SYSTEM

    1. Clean all parts in an approved cleaning solvent. WOODWARD EG-3P GOVERNOR DRIVE
    REMOVAL )
    2. Inspect the governor gear for damaged teeth.
    1. Refer to Governor Removal, and remove the gover-
    3. Inspect the control rod and rod end bearings for nor.
    damage or wear. If damage is noted, replace the parts
    as necessary. 2. Remove two nuts, lock washers, and capscrews
    from the governor drive (see Figure 5.00-67).
    4. Inspect all attaching hardware for stripped or dam-
    aged threads. replace if damage is noted.

    5. Inspect the oil lines for kinks or breaks. Replace if


    damaged.

    6. Inspect the fittings for stripped threads. Replace if


    damaged.

    WOODWARD EG-3P GOVERNOR ASSEMBLY


    There is no assembly required for the governor
    assembly.

    Figure 5.00-67. Governor Drive

    3. Remove two capscrews, lock washers and governor


    drive from the governor housing.

    4. Remove and discard the gasket.

    5.00 - 34 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    /GOVERNOR DRIVE ADAPTER


    RETAINING

    RETAINING

    _WOIOD~IUFF KEY

    Figure 5.00-68. Governor Drive Internal View

    WOODWARD EG_3P GOVERNOR DRIVE 4. Remove the shaft assembly from the governor drive
    DISASSEMBLY adapter.

    1. Secure the governor drive assembly in a brass jawed 5. Remove the small retaining ring from the splined end
    vise. of the shaft.

    2. Remove the lock nut from the end of the shaft (see 6. Remove the bearing from the splined end.
    Figure 5.00-68).
    7. Remove the spacer and roller bearing from the shaft.

    A WARNING 8. Remove the gear and woodruff key from the shaft.
    Always wear proper eye protection when removing
    retaining rings. Slippage may propel the ring with
    enough force to cause severe personal Injury or
    death. Use the correct retaining ring pliers. Verify
    that the tips of the pliers are not excessively worn or
    damaged.

    NOTE: All drive components will come out with the


    shaft.
    )
    3. Remove the retaining ring from the governor drive
    adapter.

    FORM 6248 First EdHion 5.00- 35


    SPEED GOVERNING SYSTEM

    WOODWARD EG-3P GOVERNOR DRIVE WOODWARD EG-3P GOVERNOR DRIVE


    CLEANING AND INSPECTION INSTALLATION
    1. Install the gasket on the governor drive housing (see
    A WARNING Figure 5.00-69).
    Comply with the solvent manufacturer's recommen- 2. Install the governor drive to the governor drive
    dations for proper use and handling of solvents. Do
    housing with two lock washers and capscrews.
    not use gasoline, paint thinners or other highly
    volatile fluids for cleaning. Improper handling or 3. Install the remaining two capscrews, lock washers
    misuse could result In severe personal Injury or and nuts.
    death.
    1. Clean all parts in an approved cleaning solvent.

    2. Inspect the gear for damaged teeth. Replace the


    gear if damage is noted.

    3. Inspect the splined shaft and coupling for damaged


    splines or teeth. Replace if damage is noted.

    4. Inspect the bearings for signs of wear or looseness


    on the shaft. Replace worn or loose bearings.

    5. Inspect the shaft for wear in bearing mounting areas


    and check thread condition. Replace if damaged or wom.

    WOODWARD EG~3P GOVERNOR DRIVE


    ASSEMBLY
    1. Press the center roller bearing on the shaft (see
    Figure 5.00·68).
    )
    2. Install the spacer on the shaft.

    3. Press the bearing on the splined end of the shaft.

    A WARNING
    Always wear proper eye protection when removing
    retaining rings. Slippage may propel the ring with Figure 5.00-69. Governor Drive
    enough force to cause severe personal Injury or
    death. Use the correct retaining ring pliers. Verify
    that the tips ofthe pliers are not excessively worn or
    damaged.
    4. Install the small retaining ring on the shaft.

    5. Install the shaft assembly in the governor drive


    adapter.

    6. Install the large retaining ring on the governor drive


    adapter and shaft.

    7. Press the gear on the shaft end and install lock nut.

    5.00-36 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    WOODWARD EG-3P GOVERNOR INSTALLATION


    BOTTOM VIEW
    1. Install the splined connector to the splined top end of
    the governor drive shaft (see Figure 5.00-70).

    ~@ ALIGN OIL HOLE IN


    GASKET WITH THIS HOLE
    ENGINE SlOE

    Figure 5.00-72. EG-3P Governor - Bottom View

    2. Install the gasket on the governor drive adapter,


    insure that the gasket does not block the oil hole on the
    bottom of the governor (see Figure 5.00-71 and
    Figure 5.00-72).

    3. Ensuring that the bottom shaft of the governor is


    ) engaging the splined connector, Install the governor to
    the governor drive with two lock washers and nuts.
    Figure 5.00-70. Spllned Connector

    I I
    A CAUTION Insure that the oil hole on
    .!!:!!!!!c....:::::.:....:.:::....:~=...:~.
    .L .!! .. the bottom of the gover-
    4. Apply Perma Lok® Heavy Duty Pipe Sealant with
    Teflon® to the threads offiltings and connect the oil lines
    to the governor.
    nor is not blocked by the gasket. Disregarding this
    information could result In product damage and/or 5. Slide a new copper washer on a 5/8 inch hex head
    personal injury. plug.
    NOTE: The larger 13/32 in (0.4062 mm) diameter cut 6. Locate the two holes in the lower right side of the front
    out oil hole is positioned over the oil drain on the flywheel housing. Install the plug in the selected hole.
    govemor (see Figure 5.00-71 and Figure 5.00-72).
    7. Rotate the flywheel until the tooth of the ring gear is
    centered in the unplugged hole (see Figure 5.00-73).
    13/32 (10.3 mm) OIA. OIL HOLE

    o o SPOTFAC~
    FRONT FLYWHEEL
    HOUSING
    ..,......(UPPER HOLE)

    )
    o o
    ~
    RING GEAR TOOTH

    Figure 5.00-73. Ring Gear Tooth Alignment

    ENGINE SlOE

    Figure 5.00-71. Gasket

    FORM 6248 First Ednlon 5.00 - 37


    SPEED GOVERNING SYSTEM

    IA
    :..
    CAUTION I Be sure that the top of
    the tooth is parallel to the
    WOODWARD EG-3P GOVERNOR LINKAGE
    CLEANING AND INSPECTION I
    pole face or rotation ofthe flywheel will damage the
    pickup sensor.
    A WARNING
    8. Thread the magnetic pickup into the hole until the pole Comply with the solvent manufacturer's recommen-
    face bottoms out on the flat head of the ring gear tooth. dations for proper use and handling of solvents. Do
    not use gasoline, paint thinners or other highly
    9. Back out the pickup 1/4 turn. volatile fluids for cleaning. Improper handling or
    misuse could result in severe personal injury or
    NOTE: A feeler gauge can only be used, if the rear
    death.
    flywheel housing is removed.

    10. Use a feeler gauge to verify that the gap between 1. Clean all parts in an approved cleaning solvent.
    the pole face and the top of the tooth is 0.040 ± 0.010
    2. Inspect all threaded parts for damage to the threads
    inch (1.0 ± 0.25 mm) (see Figure 5.00-74).
    (see Figure 5.00-75). Replace parts if damage is noted.

    PICKUP SENSOR
    BODY GOVERNOR ROD END BEARING
    ROD JAM NUT
    \ FACE

    \ GOVERNOR ROD /
    JAM NUT
    ROD END
    BEARING

    FRONT
    JAM
    FLYWHEEL RING
    GEAR TOOTH

    ,0.010" GAP
    ,O.25mm)
    ~ I¥T~: -
    RIGHT
    HAND
    THREADS
    LEFT
    HAND
    \ GREASE
    FlmNG
    )
    THREADS

    Figure 5.00-74. Install Magnetic Pickup Sensor Figure 5.00-75. Governor Rod Assembly

    11. Tighten the jam nut (7/8 inch hex) against the spot 3. Inspect the governor rod and rod ends for damage or
    face on the flywheel housing. wear. Replace if damaged.

    12. Connect pickup harness to the governor.

    5.00 - 38 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    WOODWARD EG-3P GOVERNOR LINKAGE NOTE: Refer to Figure 5.00-76, Figure 5.00-77 and
    INSTALLATION AND ADJUSTMENT Table 5.00-4 for the correct adjustment angles listed by
    engine type.
    A WARNING
    Before making any adjustments to an operating
    governor on an engine, check that you have hand
    throttle control over the engine speed to avoid
    severe personal injury or death.

    800 CLOSED
    (INSTALL AT 800 0
    142 MAX. FUEL"
    FROM HORIZONTAL)
    400 MAX. TRAVEL __ ------:r-IS=:::I

    NOTE: Governor Data


    • reference rod length - 52.340 1840 NO FUEL
    • travel - 42° (INSTALL LEVER 4 0
    • shaft - 0.375-36 BELOW HORIZONTAL)
    • lever length - 2.625

    Figure 5.00-76. EG-3P Governor Linkage Adjustment Information For 51 OSGL, 5790GL And 7042GL

    NOTE: Govemor Data


    • reference rod length - 49.410 MAXIMUM
    • travel - 42° FUEL POSITION
    BUTTERFLY VALVE
    MAX. OPEN POSmON
    • shaft - 0.375-36
    • /ever length - 4.290

    -------- '"
    -- NO FUEL POSmON
    ~~
    ONSTALL LEVER 10 UP
    FROM HORIZONTAL)
    NOTE: Butterfly Valve Data
    • travel - 72"
    BUTTERFLY VALVE • lever length - 1.250
    CLOSED POSITION

    Figure 5.00-77. EG-3P Linkage Adjustment Information For 51OSGL, 5790GL And 7042GL
    - Low Pressure Fuel, Draw Thru Carburetion

    Table 5.00.... EG-3P Governor Linkage Adjustment Information For L5108G/GSI; L5790GlGSI; L7042G/GSI

    NOTE: These chart values


    are approximate.
    I OPEN ..,./ •
    . ~\
    <
    . _~. _ CLOSED ;' ; "M

    H~L~- _~NTRqLRODf'C") ~ I
    L LENGTH ("D")
    _
    =t: L
    '_ K
    -~
    .\

    CLOSED
    • .(
    E
    ~ i--G F
    -r-
    OPEN ! \ I
    BUTTERFLY SHAFT LEVER iB") GOVERNOR LEVER iAU)

    A B C D E F H J K L
    LEVER LEVER ROD PIN G M N
    )
    50.160 in. 0.53 in. 1.0 in. 0.32 in. 3.62 in.
    208564A 153267C AA209615 (1274.064 mm) 32 0 380 (13.462 mm) (25.4 mm)
    50 420 (8.128 mm) (91.948 mm) RE

    NOTE: • Name plate towards rear.


    .. For L7042GSI (with EGR option) and double butterfly housing.

    FORM 6248 First Edition 5.00 - 39


    SPEED GOVERNING SYSTEM

    1. Install the governor output lever on the near side the output shaft in the NO FUEL position (see
    governor output shaft at the proper angle shown, with Figure 5.00-78). Tighten the capscrew on governor )
    the output shaft in the NO FUEL position. output lever to 14 ft-Ib (18.98 N·m).

    2. Install the lever on the near side butterfly shaft to the


    angle shown, with the butterfly shaft in the NO FUEL
    position.

    3. Install the governor rod to the lever on the butterfly


    valve with capscrew, two washers, and lock nut.

    4. With the governor output shaft in the NO FUEL


    position, and with the butterfly valve held closed, adjust
    the governor rod for length so that a capscrew will pass
    through the rod end and the hole in the lever.

    5. Refer to reference marks, and install the governor


    rod to the near side governor lever with capscrew, two
    washers, and lock nut.

    6. Check all fasteners on the rod for tightness. thread


    engagement on all rod ends must be a minimum of
    seven threads. After test, pin lever and spiders.

    7. Refer to EG-3P Governor Adjustment for proce-


    dures on adjusting the linkage.

    A WARNING
    Before making any adjustments to an operating
    governor on an engine, check that you have hand Figure 5.00-78. Governor Rod
    throttle control over the engine speed to avoid
    severe personal injury or death. 2. Install the governor rod to the lever on the butterfly
    valve with capscrew, two washers, and lock nut (see
    CAUTION I Figure 5.00-79, Figure 5.00-80 and Figure 5.00-81).
    I~fit..=:.....:=....:..;:::;,..,;:....:..=~.
    L.. .
    Be sure the governor le-
    ver and butterfly valves
    properly close and open at the same time. Governor
    linkage travel must not be limited by the butterfly
    valve striking the housing, this imposes unneces-
    sary loads on the linkage. Failure to follow the proper
    procedures can cause damage to equipment.

    NOTE: Refer to Figure 5.00-76, Figure 5.00-77 and


    Table 5.00-4 for the correct adjustment angles listed by
    engine type.

    NOTE: On GL engines, refer to Manual Shutdown


    Lever Handle Removal, and remove the manual
    shutdown lever handle.

    1. If removed, install the governor output lever on the


    near Side governor output shaft at the proper angle, with Figure 5.00-79. Governor Rod - GIGSI Engines

    5.00 - 40 FORM 6248 First Edi~on


    SPEED GOVERNING SYSTEM

    5. Check all fasteners on the rod for tightness. Thread


    engagement on all rod ends must be a minimum of
    seven threads.

    6. Center the angle finder on the top of the governor


    lever. Refer to Figure 5.00-76, Figure 5.00-77 and
    Table 5.00-4 for the correct adjustment angles listed by
    engine type. Verify that the angle is at the proper value.

    7. Move the governor lever up to the "full fuel" position.


    Refer to Figure 5.00-76, Figure 5.00-77 and
    Table 5.00-4 for the correct adjustment angles listed by
    engine type. Verify that the angle is at the proper value.

    8. Measure the length of the governor rod. Refer to


    Figure 5.00-76, Figure 5.00-77 and Table 5.00-4 for the
    Figure 5.00-80. Governor Rod - GL Engines correct distance from the centerline of one rod end
    (Throttle Control Shown Installed) bearing to the other.

    9. To adjust the rod length, loosen the governor rod jam


    nuts on each side of the governor rod (see
    Figure 5.00-75). Screw the threaded studs in or out of
    the governor rod, as necessary. Adjustthe studs on both
    ends of the rod, so that their length (external to the
    governor rod) is as equal as possible. When the
    governor rod assembly is at the correct length, wrench
    tighten both governor rod jam nuts/pW).

    10. Remove and discard the gasket.

    MANUAL SHUTDOWN LEVER


    MANUAL SHUTDOWN LEVER ADJUSTMENT - GL

    1. Remove the 2 capscrews, four washers, and the


    friction handle bracket from the intake manifold adapter
    (see Figure 5.00-81). Remove the elastic stop lock nut
    and remove the bracket, washers and handle, from the
    friction handle hub.

    2. Position the angle finder on the flat surface of the


    butterfly valve (see Figure 5.00-82). Verifythatthe lever
    is installed at the proper angle in the "fully closed"
    position (see Figure 5.00-41, Figure 5.00-42,
    Figure 5.00-76, and Figure 5.00-77).

    3. Pull up on the governor rod to simulate wide open


    Figure 5.0Q.81. Governor Rod - GL Engines throttle. Verify that the lever is installed at the proper
    (Throttle Control Shown Installed) angle (see Figure 5.00-41, Figure 5.00-42,
    Figure 5.00-76, and Figure 5.00-77).
    3. With the governor output shaft in the NO FUEL 4. If adjustment is necessary, proceed as follows:
    position, and with the butterfly valve held closed, adjust
    the governor rod for length so that a capscrew will pass A. Remove the governor rod end bearing from the
    through the rod end and the hole in the lever (see manual shutdown lever (see Figure 5.00-81)
    Figure 5.00-76). (1 capscrew, 3/8 x 1-3/4 inches, with 2 flat
    ) washers and an elastic stop lock nut).
    4. Install the governor rod to the near side on the
    governor lever with capscrew, two washers, and lock nut.

    FORM 6248 First Ednion 5.00 - 41


    SPEED GOVERNING SYSTEM

    B. Loosen the No. 10x7/8 inch allen head setscrew F. Tighten the No. lOx 7/8 inch allen head setscrew
    (see Figure 5.00-83) to unlock the position of the to lock the position olthe manual shutdown lever
    manual shutdown lever on the right bank butter- on the butterfly valve shaft (see Figure 5.00-63).
    fly valve shaft (see Figure 5.00-82).
    G. Secure the governor rod end bearing to the open
    hole in the manual shutdown lever (see
    Figure 5.00-84) (1 capscrew, 3/8 x 1-3/4 inches,
    with 2 flat washers and an elastic stop lock nut).

    Figure 5.00-82. Orientate Manual Shutdown Lever

    C. Close the left and right bank throWe plates (which


    are now synchronized to open and close together).

    D. Position an angle finder with a magnetic base on


    the flat side of the butterfly valve (where the WED
    logo and part number are stamped).

    E. Holding the cross shaft to prevent rotation of the


    throttle plates, turn the butterfly valve until the Figure 5.00-84. Governor Rod - GL Engines
    angle finder reads the proper angle (Throttle Control Shown Installed)
    (see Figure 5.00-83). See Figure 5.00-41,
    Figure 5.00-42, Figure 5.00-76, and 5. Slide the handle, bracket and washers on the friction
    Figure 5.00-77 for the proper angles. handle hub and tighten the elastic stop lock nut (see
    Figure 5.00-84). Fasten the friction handle bracket to
    the intake manifold adapter with two capscrews and four
    washers.

    6. Verify thatthe linkage from the governor output shaft


    to the butterfly shaft is clean and free of friction or lost
    motion.

    Figure 5.00-83. Lock Manual Shutdown Lever

    5.00-42 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    MANUAL SHUTDOWN LEVER REMOVAL - GIGSI MANUAL SHUTDOWN LEVER ADJUSTMENT -


    GIGSI
    1. Remove two lock nuts from carburetor linkage (see
    Figure 5.00-85). Discard lock nuts. 1. Move the manual shutdown lever to the fully closed
    position. Refer to Figure 5.00-41, Figure 5.00-42 and
    Table 5.00-1 and verify that the butterfly valve is at the
    correct angle.

    2. Move the manual adjustment lever to the fully open


    position. Refer to Figure 5.00-41, Figure 5.00-42 and
    Table 5.00-1 and verify that the butterfly valve is at the
    correct angle.

    OVERSPEED GOVERNOR
    OVERSPEED GOVERNOR REMOVAL

    NOTE: The lube oil header pressure inlet side is


    marked "IN".

    1. Disconnect the lube oil header pressure inlet tube


    Figure 5.00-85. Butterfly Valve Linkage Adjustment - from the fitting (see Figure 5.00-86).
    L5108G, L5790G, L7042G Engines

    2. Remove linkage from the butterfly valve and lever.

    3. Remove nuts and shaft ends from linkage, if


    required.

    4. Remove two screws, lock washers, washers, and


    lever assembly from the bracket.

    MANUA~SET
    5. Remove two screws, lock washers, washers and
    bracket from intake manifold.
    BUTTON
    MANUAL SHUTDOWN LEVER INSTALLATION - DEPRESSED
    (NORMAL MODE)
    GIGSI
    1. Install two screws, lock washers, washers and
    bracket on intake manifold.

    2. Install two screws, lock washers, washers, and lever


    assembly on the bracket.
    Figure 5.00-86. Overspeed Pressure Switch
    3. Install nuts and shaft ends on linkage, if required.

    4. Move the butterfly valve to the fully closed position. 2. Tag all wires, and disconnect the three leads to the
    overspeed pressure switch.
    5. Move the manual Shutdown lever to the Closed
    position. 3. Remove the overspeed pressure switch from the
    overs peed governor.
    6. Install linkage on the butterfly valve and lever with
    two new lock nuts. 4. Remove 4 capscrews, (5/16 x 2-3/4 inches, with lock
    washers) overspeed governor, and gasket from the
    magneto drive assembly.

    5. Remove the fitting from the inlet port.


    )

    FORM 6248 First Edition 5.00 - 43


    SPEED GOVERNING SYSTEM

    OVERS PEED GOVERNOR ADJUSTMENT 2. Turn the adjusting screw outward (CCW) to lower the
    overspeed setting that will trigger a shutdown. )
    1. Loosen the jam nut to unlock the position of the
    adjusting screw (see Figure 5.00-87). 3. Turn the adjusting screw inward (CW) to raise the
    overspeed setting necessary to trigger a shutdown.

    4. Using a screwdriver to hold the setting of the


    adjusting screw, tighten the jam nut to lock its position.

    OVERSPEED GOVERNOR INSTALLATION


    1. Apply Perma Lok® Heavy Duty Pipe Sealant with
    Teflon® to the threads of the fitting.

    2. Install the fitting in the inlet port marked "IN" of the


    overspeed governor housing cover, so that the free end
    of the male elbow points horizontally toward the block.

    3. Apply 3M Scotch Grip Rubber and Gasket Adhe-


    N

    sive 847 to one Side of a new overspeed governor


    gasket. Place the gasket on the mounting pad at the top
    of the magneto drive assembly.

    4. Using a small paintbrush, apply Lithoplex® Grease


    No.2 (Multipurpose Lithium Complex Formula Contain-
    ing Molybdenum Disulfide) to the teeth ofthe overspeed
    governor drive gear (see Figure 5.00-88).

    )
    Figure 5.00-a7. Overs peed Governor

    IA
    ..
    CAUTION I Overspeeds that exceed
    specification may result
    in catastrophic engine damage. The overs peed
    governor is factory adjusted to the maximum
    allowable setpoint and establishes the acceptable
    amount of overspeed for VHP engines. Do not
    perform any adjustments that may allow the over-
    speed to exceed 1300 -1325 rpm (approximately 10
    percent of the maximum high idle speed of 1200
    rpm). Disregarding this information could result
    in product damage and/or personal Injury.

    IA
    ..
    CAUTION IThe overspeed governor
    IS only provided as an
    Figure 5.110-88. Overspeed Governor
    ENGINE protection device. H Is not to be used as
    overspeed protection for driven equipment_ If the
    speed of the driven equipment must remain below 5. With the "IN" port on the cover towards the front of
    1300 - 1325 rpm, or less than 10 percent overspeed the engine, set the overspeed governor on the mounting
    protection, then It is the responsibility ofthe user or pad of the magneto drive assembly. Fit the collar on the
    packager to adjust the overspeed governor or gear side squarely in the hole in the mounting pad.
    provide separate overspeed protection. Disregard-
    Ing this information could result in product damage 6. Fasten the overspeed governor to the magneto drive
    )
    and/or personal inJury_ assembly (4 capscrews, 5/16 x 2-3/4 inches, with lock
    washers).

    5.00 - 44 FORM 6248 First Edition


    SPEED GOVERNING SYSTEM

    7. Rotate the tube fitting in the inlet port of the HOUR METER
    overspeed governor housing cover. so that the free end
    of the male elbow points horizontally toward the HOUR METER REMOVAL
    crankcase. 1. Remove four screws. lock washers hourmeter and
    8. Apply Perma Lok® Heavy Duty Pipe Sealant with gasket from the magneto drive assembly (see
    Teflon® to the threads of the overspeed pressure Figure 5.00-SO).
    switch. Using the pressure port hex. thread the switch
    into the rear port of the overs peed governor housing
    cover (marked "OUr). Position the pressure switch. so
    that the red reset button is facing downward. (see
    Figure 5.00-89) to prevent against the entrance of
    moisture and dirt.

    OVERSPEED

    ftlu°ii;vsiEuRii:ESPEED
    .. , SWITCH
    L;;;U~B"iiSE
    .. , SOlul}LiHeEADER
    INLET

    MANUAL
    BUTTON
    DEPRESSED
    (NORMAL MODE) Figure 5.00-90. TachometeriHour Meter
    )
    HOUR METER, INSTALLATION

    1. Using a paintbrush. apply a small quantity of


    Lithoplex® Grease No. 2 (Multipurpose Lithium Com·
    plex Formula Containing Molybdenum Disulfide) to the
    Figure 5.00-89. Overspeed Pressure Switch gear at the end of the hour meter drive shaft (see
    Figure 5.00·91).

    9. Verify that the reset button is pushed in. Ifthe button


    is not depressed (reset). grounding of the magneto will NYLON WASHER
    prevent the engine from starting.

    10. Refer to tags and connect the three overspeed


    pressure switch leads.

    11. Apply Perma Lok® Heavy Duty Pipe Sealant with


    Teflon® to the threads of the fitting.

    12. Install the lube oil header pressure inlet tube to the
    fitting and inlet port marked "IN" on the overspeed
    governor.

    DIGITAL READOUT

    Figure 5.00-91. Hour Meter


    )
    2. Position a new gasket against the square hole at the
    front of the magneto drive housing (below the tachome-
    ter drive set screw).

    FORM 6248 First Edition 5.00 - 45


    SPEED GOVERNING SYSTEM

    3. With the digital reading facing upward, fasten the


    hour meter flange to the pad (4 No. 10 round head PROTECTIVE
    CAP
    machine screws, with Nylon washers) (see
    Figure 5.00-90). Use new Nylon washers if damaged or
    flattened. ~
    NOTE: To calculate the actual number of running hours
    on the engine, multiply the digital reading by 1667 and
    divide by the engine rpm.
    I I
    4. If an hour meter is not provided: Position a new
    gasket against the square hole at the front of the II I O-RING I
    J~I
    magneto drive housing (below the front tachometer
    drive plug). Fasten the cover plate to the housing (4 No. I I
    10 round head machine screws, with Nylon washers) I I I I
    (see Figure 5.00-92). Use new Nylon washers if dam-
    Ir~:=lJI~ -y I
    aged or flattened.

    I SPLASH I
    PORT

    HOURMETER
    ~~ MATING
    GEAR
    T

    .. ~. ;.

    ~~ 1
    '"
    MAG

    ~~ ~~
    MATING
    GEAR

    ~' ~ ~
    Figure 5.00-92. Nylok Plugs

    I
    11.
    I
    ~
    TACHOMETER DRIVE
    Figure 5.0D-93. Tachometer Drive Assembly
    TACHOMETER DRIVE REMOVAL

    1. Loosen the thin hex nut on the set screw and remove TACHOMETER DRIVE INSTALLATION
    the set screw from the magneto drive housing (see
    Figure 5.00-90). 1. Install a new O-ring in the middle groove of the
    tachometer drive assembly (see Figure 5.00-93).
    2. Remove the copper washer and thin hex nutfrom the
    square head set screw (see Figure 5.00-90). 2. Note the two gears on the tachometer drive shaft. The
    wider gear at the bottom mates with the front tachometer
    3. Remove the tachometer drive from the magneto drive gear on the magneto drive shaft, the thinner gear
    drive. mates with the gear on the hour meter shaft. Using a
    small paintbrush, apply Lithoplex® Grease No.2 (MuHi-
    4. Remove and discard the O-ring from the tachometer purpose Lithium Complex Formula Containing Molybde-
    drive (see Figure 5.00-93). num Disulfide) to both tachometer gears.

    A CAUTION Iincor~ect orientation of


    I ==-""-'-"-.0..---'-""-'-'-'. the 011 splash port will
    L...

    result in Insufficient lubrication of the drive shaft


    leading to premature failure of the tachometer drive
    assembly.

    5.00 - 46 FORM 6248 Firsl Ednion


    SPEED GOVERNING SYSTEM

    3. Locate the oil splash port in the groove below the 8. If a tachometer is not installed, apply 3M Scotch
    O-ring (third groove from shoulder). Note the flat on the Grip~ Rubber and Gasket Adhesive 847 to the exterior
    collar opposite the oil splash port. sleeve of two new tachometer drive plugs. Position the
    plugs in the round openings in the upper pad of the
    4. With the flat facing outside and the splash port magneto drive housing (directly below and on each side
    inward toward the mag drive shaft, slide the tachometer ofthe overspeed governor) (see Figure 5.00-95). Using
    drive into the front hole (right) in the mounting pad ofthe a ball peen hammer, strike the center of each cap so that
    magneto drive housing (see Figure 5.00-94). If poor the bottom lip is seated solidly against the counterbore.
    contact with the mag gear stops the tachometer drive
    before the shoulder seats against the counterbore, turn
    the mag drive spindle shaft slightly to drop the unit into
    place.

    )
    Figure 5.00-95. Magneto Drive Assembly -
    Front Right i

    Figure 5.00-94. Tachometer/Hour Meter 9. Install new Nylok plugs in the set screw holes below
    each tachometer drive plug. (see Figure 5.00-96).
    5. Install the thin hex nut on the square head set screw
    (see Figure 5.00-94). Using a new copper washer,
    install the set screw in the hole between the tachometer
    drive and the hour meter mounting pad.

    6. When the set screw is tight against the tachometer


    drive (third groove from shoulder), turn the thin hex nut
    until it is snug against the magneto drive housing.

    7. To keep out dust and dirt, verifythatthe plastic cap at


    the top of the tachometer drive is tight.

    Figure 5.00-96. Nylok Plugs

    \ )

    FORM 6248 First Edition 5.00-47


    SPEED GOVERNING SYSTEM

    5.00-48 FORM 6248 First Edition


    EXHAUST GAS

    WAUKESHA GAS ENGINE EMISSIONS LEVELS

    VHP: GRAMS/HP-HR "OBSERVED EXCESS


    CARBURETOR DRY MASS VOWM AIR
    AFR·· AFR·· RAn
    MODEL

    G.GSI
    SETTING

    Lowest Manifold
    NO.·

    7
    CO

    28
    NMHC

    .3
    CO

    1.15
    °2
    .30 15.5:1 9.3:1 .97
    °
    (Best Power)

    G.GSI Equal No,. a. CO 10 10 .3 .45 .30 15.9:1 9.6:1 .99

    Catalytic Conv. 11 .30 15.95:1 9.6:1 .99


    G.GSI
    Input (3-way"·)
    8 .25.
    ~

    G.GSI Normal (Best 18 1 .2 .02 1.35 17:1 10.2:1 1.06


    Economy)

    GL Normal 1.5 2.65 1.0 .06 9.8 28:1 16.8:1 1.74

    • NOx is measured as (NO + N0 , and hPl esse;d as N0 "


    2 2
    •• Based on a natural gas fuel With a stoighiodietrtc mass air fuel ratio of , 6.05:1 and a HIe ratio of 3.85.
    ... cOnsult with individual catalyst manufacturers for their preferred carburetor set point and post-catalyst
    emission values.

    FORMULAE
    .
    (5.9)
    PPMV 0 15% O. PPMV_X 792.1X!O X BHP
    8
    (20.9-%02)
    BMEP = Rpm X CJ.o.

    GRAMS X
    BHP-HR
    lBS
    LB
    453.6 grams
    s lBS
    BHP-HR
    BHP
    - BMEP X C.I.D_ X Rpm
    7lI2.1X!O
    X BHP = lBS HP = leW
    (Gel! Ell) X 0.7457
    BHP-HR HR
    lBS X 24 HAS X 36S PAYS X TON = TONS
    HR DAY YEAR 2IXXl lBS YEAR
    Inches of _ r X 0.03606 = PSI
    PSI X 27.73 = Inches of water
    Inches of Men:ury X 0-4912 PSI =
    PS) X 2.036 = Inches 01 Mercury
    =
    Gauge Pressure + AImospherIc prassure AbsoIuIe pressure
    Example: Inlake Mannold pressure r Hg) + SiIe IIatome1er r Hg) =' HgA

    METRIC CONVERsiONS
    MeIric Conversions
    Millimeter (mm) X 0.0394 = Inches
    =
    kglcm2 X 14.223 PSI

    FORM 515 Second editiOn

    6-5
    )

    )
    EXHAUST GAS

    EMISSION ANALYSIS

    The most common rich bum AirlFuel Ratios used by


    THIS CURVE 'PLOTTED FOR LABORATORY FUEL.
    Waukesha are: ACTUAL AlRlFUEL RATIO VALUES WILL DEPEND
    UPON FUEL CDMPosmON, BUT RELATIONSHIPS
    Best Power (lowest manifold pressure) 15.5:1 FDR CO ANO CIz WILL REMAIN CONSTANT.
    Nominal Catalyst Setting 15.95:1
    N
    Best Economy (1.5 Hg) 17.0:1
    ! i. !i ii
    NOTE: The Best Economy /evel of 17:1 airlfuel ratio
    may not be obtainable depending upon engine COnd/~ !' !'; j Y
    tion, ignition system capability, load, and fuel quality !\ 1 CARBON MONOXIDE i ; I: OXYGEN
    (detonation resistance). i \;
    3' '
    j l ' i. /
    ;/
    ,

    The Waukesha preferred and most accurate method of


    setting an engine is by the use of exhaust gas analysis.
    For example, if an engine is to be set to the Best
    Economy setting, the carburetor screw is simply
    adjusted to obtain the observed oxygen (~) and carbon
    monoxide (CO) readings for the engine model being
    used. Figure 1.05-3 shows the relationship between
    pereant of oxygen (~ and carbon -:nonoxide (CO) in
    the exhaust and their associated airlfuel ratio.

    1\ i A i
    .'I i . i, Ii!
    . i !
    j ,
    .I
    .38:--: -;- t- V STOICHIOMETRIC AIF = 1&.09

    oI!. Ii\. 1 I Ii
    14 15 16 17 18 18 aD Z1
    RICH SPlNDTAIF LEAN

    EMISSION LEVELS ARE GIVEN FOR


    PRE-CATALYST MEASUREMENTS.

    figure 1.115-3. Standard Natural Gas Oxygen And


    Carbon Monoxide

    )
    FORM 515 Second Edition 1.05-3

    6-3
    )

    )
    SECTION 5.05 - FUEL SYSTEM

    FUEL SYSTEM COMPONENTS MAIN FUEL GAS PRESSURE REGULATORS


    The function of the fuel system is to maintain a constant To ensure a steady fuel supply to each carburetor, 12
    air/fuel ratio throughout the load range ofthe engine and cylinder engines have a regulator on both the right and
    to deliver the air/fuel mixture in the proper quantities. left banks.
    The fuel system consists of the following components The main fuel gas pressure regulators reduce the
    (see Figure 5.05-1, Figure 5.05-2 and Figure 5.05-3): incoming fuel supply pressure to the carburetors from
    45 - 50 psi (310 - 345 kPa) to approximately 10 inches
    • Main Fuel Gas Pressure Regulators
    (254 mm) of water above the carburetor air pressure, as
    • Carburetors measured at the carburetor inlet.

    • Prechamber Gas Safely Shutdown Valve - GL NOTE: The actual carburetor inlet fuel pressure will
    depend on the heating value of the fuel.
    • Prechamber Regulator - GL
    From the main fuel gas pressure regulators the fuel
    • Prechamber Manifolds - GL flows into the carburetors where it is mixed with air to
    provide a very lean mixture to the combustion cham-
    • Cylinder Head Admission Valves bers.
    (one assembly per cylinder) - GL

    D=I

    CARBURETOR

    ~fiI"----lJ
    I
    I
    r..J
    I
    L ~ / ----,

    ~~~'1:=
    BALANCE LINE BALANCE LINE

    ~i~i~~~·'SENSING LINE SENSING LINE


    ----------c:r
    I
    I
    FUEL REGULATOR FUEL REGULATOR ~~-
    0

    CI
    a
    .•
    ....

    Gtu'------'~ Q~DD
    "'-GAS SAFETY VALVES GAS SAFETY VALVES
    LEFT SIDE RIGHT SIDE
    Figure 5.05-1. Fuel System Diagram - G

    FORM 6248 First Ednion 5.05 -1


    FUEL SYSTEM

    1=1 )

    " BALANCE LINE

    / --""1 CI
    BALANCE LINE
    ~DJ
    C::~MI
    I

    bJ~~3~SENSING LINE SENSING LINE/""

    I FUEL REGULATOR FUEL REGULATOR


    -----c:r 0

    I I:] a
    •
    ~,-----,PD Q~DD
    "-
    LEFT SIDE GAS SAFETY VALVES GAS SAFETY VALVES RIGHT SIDE
    )
    Figure 5.05-2. Fuel System Diagram - GSI

    5.05 - 2 FORM 6248 First Edition


    '-

    2l
    "
    ;;:

    ~
    NOTES:
    J?. CUSTOMER OR END USER IS RESPONSIBLE
    ~FOR VENTING GAS FROM THIS SYSTEM
    AND PIPING TO ASAFEAREA TO MEET
    - -
    =
    _
    - FURNISHED BY CUSTOMER
    AIR
    AIR/FUEL
    ,- 'N
    ;N~E-
    OIL HEADER
    -,
    APPICABLE CODES.

    ~ 2. THIS SHEET DEPICTS ENGINE CONTROL POSITIONS


    - - - FUEL
    BAlANCE OR CONTROL LINE
    !l' WHEN OPERATING IN THE FOLLOWING MODE.
    FUEL: STANDARD NATURAL GAS
    o JUNCTION FDA STARTING OPTIONS
    VOLUME
    CHAMBER r - .,
    ~
    ENGINE: RUNNING
    (SEE INSERT FOR START CYCLE) ~
    L:":'...J) I
    --------------------~ I~ I
    ~ - - ~N;E~ I STARTS'GNAL
    - - "G" CARBURETOR I
    TURBO AIR AIR PRESSURE SAMPLE POINT DOWNSTREAM I I

    ".rPRESSURETAP

    ~
    I OXYGEN SAMPLE POINT
    I
    c-, ...., ...\
    CONTROL LINE
    GAS PRESSURE
    REGULATOR
    J i FUEL: NATURAL GAS {HIG H BTU} I
    I ENGINE MODE: STARilNG
    L: ___________ _
    .-J
    ."
    i!i
    c
    \ - ----,
    I

    iii "\... _ "F" CARBURETOR INL£T I


    ~AS PRESSURE SAMPLE POINT L ~ .J

    ~
    CARBURETOR
    GOVERNOR CONTROLLED

    ."

    Ii

    i L ~ L'r-'r-'Er-'
    ~
    - i -- -'::.':'~~ __ .-J
    __- - ::-::::-"'C r;~ ____
    - ----'
    I
    ENGINE LUBE
    LbJ
    ~ ..
    a-WAY N. C. ELECTRIC
    SOLENOID VALVE FOR AIR
    START WITHOUT PNEUMATIC
    CONTROL PANEL
    DILHEADER

    I
    n AIR
    SUPPLY
    I
    ~ _ _ _ STANDARD NATURAL GAS
    I
    ...
    Gl
    AIRiGAS
    SUPPLY
    I
    35-50 PSI

    . I I
    ~~I PUSH BUTTON VALVE FOR
    PNEUMATIC START WITH
    I PNEUMATIC CONTROL PANEL
    I
    "J" PRESSURE TAP
    "0" I
    OXYGEN SAM~POINT \
    "E"A
    ill \ I "TI
    c-~ ., ~ W\LVt: ...J C
    \ I, m
    r
    EXHAUST MANIFOL/1.
    RIGHT BANK I I "F" CARBURETOR INLET
    *
    ~
    L. _ , AS PRESSURE SAMPLE POINT PREC~~~~~JJF UP
    "A" MIX ADJUST
    -------t>-------.J
    l............itESTRICTOR PLATE I GAS PRESSURE (OE ENERGIZED ELECmlC START ONLy)

    ~,
    SCREW REGULATOR - ,
    "0" CARBURETOR
    INto~O 'AIR PRESSURE SAMPLE POINT
    3:
    '"
    FUEL SYSTEM

    UPPER PILOT
    GAS OUTLET
    CHAMBER DIAPHRAGM
    (TO CARBURETOR)

    MAIN

    FUEL
    GAS
    INLET
    BALANCE LINE PILOT
    (TO CARBURETOR CHAMBER
    AIR INLEl) SUPPLY
    TUBE

    Figure 5.05-4. Fisher 99 Main Fuel Gas Pressure Regulator - Cross Sectional View
    OPERATION OF THE FISHER 99 MAIN FUEL GAS farther from its seat - the flow of gas to the outlet system
    PRESSURE REGULATOR increases.
    Changes in gas consumption cause the pressure in the When the pressure pushing down on the upper pilot
    gas outlet system to rise and fall. Pressure changes are chamber diaphragm exceeds the setting of the pilot
    transmitted to the main orifice chamber through the spring, the valve assembly moves down to close the gas
    downstream sensing line (see Figure 5.05-4). inlet orifice. The pressure in the upper chamber bleeds
    When the pressure pushing down on the upper pilot into the main chamber allOwing the main spring to pull
    chamber diaphragm is lower than the force of the pilot up the main diaphragm rod and move the disc valve
    spring, the valve assembly is forced upward and the gas towards its seat - the gas flow to the outlet system
    inlet orifice is opened. High pressure gas flows into the decreases.
    pilot chamber and then on through a supply line to a A balance line connects the carburetor air inlet to a vent
    chamber above the main diaphragm. in the pilot spring chamber (see Figure 5.05-4). This
    Higher pressure in the upper chamber opposes the ensures that a constant gas-aver-air pressure differen- )
    main spring to push the main diaphragm down. The tial is maintained regardless of changes in air filter
    downward motion causes a lever to pull the disc valve restriction and turbo boost.

    5.05 -4 FORM 6248 First Edition


    FUEL SYSTEM

    CARBURETORS plenum bleeds down, the shuttle valve shifts position


    12 cylinder engines have two carburetors, one mounted and the downstream gas pressure assumes the task of
    just below the center of the intake manifold on the left holding the pilot gas valve open.
    side of the engine, the other at the same location on the The time delay provided by the check valve and air/gas
    right side. plenum keeps pilot pressure on the gas valve long
    The carburetor produces a combustible mixture by enough for lube oil pressure to rise and shift the shuttle
    automatically mixing air and fuel in the proper propor- valve. Lube oil pressure continues to admit gas to the
    tions. It consists of an air inlet housing, a gas inlet, two prechamber regulator as long as the engine is running.
    air flow measuring valves, two diaphragm-operated If the engine stops, loss of engine lube oil pressure
    gas metering valves and a butterfly valve. automatically causes the prechamber gas safety shut-
    The amount of air going to the engine is sensed by the down valve to stop the flow of downstream gas to the
    airflow measuring valves, which rise in direct proportion prechamber gas valve, which effectively shuts off the
    to the volume of air passing through them. Each gas supply of high pressure gas to the prechamber regula-
    metering valve is mechanically fixed to an air flow tor. If the engine fails to start, insufficient lube oil
    measuring valve, so the gas passages are opened by pressure prevents the downstream gas from passing to
    an amount that is proportional to the amount of air the prechamber gas valve, so the gas supply shuts off
    entering the engine. The tapered gas metering valve is as soon as the pilot pressure in the air/gas plenum is
    shaped to admit the correct amount of gas at any height exhausted. In both cases, any gas in the downstream
    to which the air flow measuring valve rises. This line passes to the vent tube and is exhausted at the
    operation allows the engine to maintain a specific customer's bulkhead connection.
    airlfuel ratio throughout its operating range. PRECHAMBER REGULATOR - GL
    The amount of air/fUel mixture flowing out of the The prechamber fuel system uses one Fisher 95L
    carburetor is controlled by the position of the butterfly regulator. On 12 cylinder engines,the prechamber
    valve in the carburetor throat. regulator is mounted on the right side of the engine in
    The air/fUel mixture passes from the carburetor to the front of the carburetor.
    intake manifold. The prechamber regulator controls the amount of fuel
    PILOT OPERATED PRECHAMBER GAS VALVE - available to the prechamber manifolds. The flow to the
    GL prechamber manifolds is fuel only. AII..of the air needed
    for combustion is pushed into the pr.echamber by the
    The air/gas supply from the bulkhead is connected to piston on its compression stroke.
    the Prelube and Start pushbutton valves. The normally
    open port of each valve vents the downstream side Fed by high pressure fuel (35 - 50 psi, 241 - 345 kPa)
    when the pushbutton valve is not depressed. The from the Fisher 99 main fuel gas pressure regulator
    vented air/gas supply is directed back to the bulkhead supply line, the prechamber regulator is set to maintain
    where it is piped to a safe location. a specific prechamber manifold over intake manifold
    pressure differential (measured in inches of mercury).
    Depressing the Start pushbutton causes the pilot air
    pressure to be directed to the pilot operated starter
    pre-engage valve. Enroute to the starter pre-engage
    valve, a portion is diverted to the pilot operated
    prechamber gas valve. Before reaching the gas valve,
    the pilot pressure passes through an orifice check valve,
    air/gas plenum (volume tank) and shuttle valve. When
    the pilot pressure opens the prechamber gas valve, a
    line off the Fisher 99 main fuel gas pressure regulator
    gas inlet admits high pressure gas to the prechamber
    fuel regulator. The orifice check valve and air/gas
    plenum act as a pneumatic timer to retard the blow down
    of pilot pressure when the Start pushbutton is released.
    PRECHAMBER GAS SAFETY SHUTDOWN VALVE
    -GL
    ) The prechamber gas safety shutdown valve admits
    downstream gas pressure to the opposite side of the
    shuttle valve once engine lube oil pressure reaches or
    exceeds 20 psi. When the pressure in the air/gas
    FORM 6248 First Edition 5.05 - 5
    FUEL SYSTEM

    If the force of the pilot spring exceeds the force of the With two cylinder banks, 12 cylinder engines have two
    outlet pressure (as exerted against the bottom of the prechamber manifolds, one on each side of the
    diaphragm), the guide stem is held down (see crankcase vee.
    Figure 5.05-5). Pilot spring pressure, as plus compres- A pressure tap at the end of each prechamber manifold
    sion of the valve spring holds the valve plug away from is provided to measure prechamber regulator pressure.
    the gas inlet orifice allowing flow to the outlet system (via
    the prechamber gas valve). BUTTERFLY CROSS SHAFT - G/GSI
    BUTTERFLY CROSS SHAFT REMOVAL - GIGSI

    SQUARE
    ADJUSTING SC~IEW A WARNING
    Ensure that the fuel source is completely shut off
    PILOT prior to working on fuel system components. Clear
    the engine supply lines and piping of accumulated
    gas before perfonning any maintenance work on the
    fuel system or severe injury or death could result.
    1. Turn off fuel supply.
    2. Turn the butterfly shaft on to the fully closed position.

    NOTE: Mark the spider assembly halves, disks, and


    shafts to aid in assembly.

    3. Remove four capscrews 5/16 x 1/2" with external


    shakeproof washers from the two rear spider assem-
    STEM blies, (see Figure 5.05-6).
    )
    BUTTERFLY
    CROSS SHAFT
    SPRING
    VALVE

    Figure 5.05-5. 95L Prechamber Regulator -


    Cross Sectional View
    "
    REAR
    During engine operation, changes in gas consumption SPIDER ~~ I CROSS SHAFT
    cause the pressure in the gas outlet system to rise and FRONT \ GI""/~- COVER
    SPIDER ~'
    fall. A decrease in gas consumption causes the
    pressure in the regulator outlet system to increase. This
    J~~",,~
    ~ ~~ ~
    increase counteracts the tension of the pilot spring. • ROLL
    Compression of the pilot spring allows the regulator > DISC - PIN
    diaphragm to rise. When the guide stem is pulled up, the (!J'0,
    valve spring pushes up the valve plug. Restriction of the
    SHAKEPROOF
    gas inlet orifice causes the gas flow to the outlet system WASHER
    to decrease.
    A balance line connects a vent in the prechamber Figure 5.05-6. Butterfly Cross Shaft Assembly
    regulator pilot spring chamber to the intake manifold. 4. Refer to Butterfly Removal, to remove one of the
    Through pressurization of the pilot spring chamber, a butterfly valves.
    constant prechamber manifold over intake manifold
    pressure differential is maintained. 5. Drive out roll pins, loosen the capscrews on the
    spider clamps and remove the rear spiders from the
    PRECHAMBER MANIFOLDS - GL cross shaft ends.
    The prechamber manifolds supply fuel only to the
    6. Remove two capscrews 3/8 x 3/4" with lock washers
    prechambers. From the prechamber manifold, fuel
    and washers and the cross shaft covers from the
    passes to each admission valve assembly through a
    crankcase.
    fuel inlet tube.
    7. Remove the butterfly cross shaft from the crank-
    case.

    5.05 - 6 FORM 6248 First Edition


    FUEL SYSTEM

    BUTTERFLY CROSS SHAFT INSTALLATION 4. Position the universal joint spider assembly down
    - GIGSI the cross shaft (see Figure 5.05-6).
    1. Position the butterfly cross shaft through the upper 5. With the wings in the horizontal position, align the pin
    center bore in the crankcase until it exits the opposite holes in the rear spider (1/2 inch bore size) with those in
    side (see Figure 5.05-7). the cross shaft. Install a new 118 x 1-1/8 inch roll pin.

    6. Tighten the capscrew in the shaft clamp portion of


    the rear spider (5/16 x 1-1/8 inches, with external
    shakeproof washer). Start the shaft clamp capscrew in
    the front spider.

    NOTE: Only one side of the spider shaft clamp fastener


    bore is threaded. Start the fastener by inserting it into
    the thru hole. Use the threaded side of the bore to
    tighten.

    7. Repeat Steps 2 thru 6 on the other bank.

    8. Refer to Butterfly Installation, and install the Butterfly.

    9. Verify that both butterfly valves are in the closed


    Figure 5.05-7. Crankcase Center Bores - GIGSI - position.
    Right Bank
    10. TIghten the clamp capscrew (5/16 x 1-1/8 inches,
    2. Position the cross shaft cover down the cross shaft until with external shakeproof washer) on the front spiders.
    it contacls the block. Finger tighten the cross shaft cover to
    the block flange with 2 capscrews, 3/8 x 3/4 inches, with 11. Install a new 1/8 x 1-1/8 inch roll pin in the front
    lock washers and flat washers. spiders.

    3. Align the two parallel holes in the wings of the


    universal joint spider with those in the disc and tighten
    the fasteners 2 capscrews, 5/16 x 1/2 inches, with
    external shakeproof washers. Using the remaining two
    holes on the opposite side ofthe disk, install the second
    spider perpendicular to the first.
    NOTE: The left bank universal joint disc assembly uses
    two spiders with different diameter bores (1/2 inch and
    5/8 inch) (see Figure 5.05-8). The spider with the 5/8
    inch bore fits on the inside butterfly valve shaft, which
    has a larger diameter than the carburetor cross shaft.
    The right bank universal joint disc assembly uses two
    identical spiders (1/2 inch bore size).

    Figure 5.05-6. Universal Joint Disc Spider

    FORM 6248 First Edition 5.05 -7


    FUEL SYSTEM

    CARBURETOR CROSS SHAFT - GL CARBURETOR CROSS SHAFT INSTALLATION -


    GL
    CARBURETOR CROSS SHAFT REMOVAL - GL
    1. Position the carburetor cross shaft through the lower

    A WARNING
    center bore in the crankcase until it exits the opposite
    side (see Figure 5.05-10).
    Ensure that the fuel source is completely shut off
    prior to working on fuel system components. Clear
    the engine supply lines and piping of accumulated
    gas before perfonning any maintenance work on the
    fuel system or severe injury or death could resuH.

    1. Turn off fuel supply.

    2. Turn the carburetor shafts on both carburetors to the


    fully closed position.

    NOTE: Mark the spider assembly halves, disks, and


    shafts to aid in assembly.

    3. Remove four capscrews 5/16 x 1/2" with external


    shakeproof washers from the two rear spider assem-
    Figure 5.05-10. Crankcase Center Bores - GL-
    blies (see Figure 5.05-9).
    Right Bank
    CARBURETOR 2. Position the cross shaft cover down the cross shaft
    CROSS SHAFT
    until it contacts the crankcase. Finger tighten the cross
    "'" shaft cover to the block flange with 2 capscrews, 3/8 x
    3/4 inches, with lock washers and flat washers. )
    REAR 3. Align the two parallel holes in the wings of the
    SPIDER ~~ I CROSS SHAFT universal jOint spider with those in the disc and tighten
    FRONT \ GI""/~-- COVER the fasteners 2 capscrews, 5/16 x 1/2 inches, with

    ST~~~'~
    external shakeproof washers. Using the remaining two
    holes on the opposite side olthe disk, install the second
    ~~~ ~ ROLL
    spider perpendicular to the first.
    ~ :> DISC - PIN NOTE: The left bank universal joint disc assembly uses
    (!j'f!J, two spiders with different diameter bores (1/2 inch and
    SHAKEPROOF 5/8 inch) (see Figure 5.05-11). The spider with the 5/8
    WASHER inch bore fits on the inside butterfly valve shaft, which
    has a larger diameter than the carburetor cross shaft.
    Figure 5.05-9. carburetor Cross Shaft Assembly
    The right bank universal joint disc assembly uses two
    identical spiders (1/2 inch bore size).
    4. Refer to Carburetor Removal, to remove one of the
    carburetors.

    5. Drive out roll pins, loosen the capscrews on the


    spider clamps and remove the rear spiders from the
    cross shaft ends.

    6. Remove two capscrews 3/8 x 3/4" with lock washers


    and washers and the cross shaft covers from the
    crankcase.

    7. Remove the carburetor cross shaft from the crank-


    case.

    Figure 5.05-11. Universal Joint Disc Spider

    5.05 - 8 FORM 6248 First Edition


    FUEL SYSTEM

    PRECHAMBER MANIFOLD CROSS PIPE 2. Remove two capscrews (3/8 x 1-3/8 inches, with lock
    -GL washers) retainer, and flange from the right hand side of
    the crankcase.
    PRECHAMBER MANIFOLD CROSS PIPE
    REMOVAL-GL 3. Remove two capscrews (3/8 x 1-3/8 inches, with lock
    washers) retainer, flange and cross pipe from the right

    A WARNING hand side of the crankcase as one assembly (see


    Figure 5.05-13).
    Ensure that the fuel source is completely shut off
    prior to working on fuel system components. Clear
    the engine supply lines and piping of accumulated
    gas before performing any maintenance work on the
    fuel system or severe injury or death could result.
    1. Remove male elbow tube fitting, male connector
    tube fitting, and pipe tee from the cross pipe (see
    Figure 5.05-12).

    Figure 5.05-13. Prechamber Cross Pipe - Left Bank

    4. Remove male connector tube fitting, pipe elbow,


    flange and retainer from the cross pipe.

    5. Remove and discard the retainer hose gaskets from


    the retainers.

    Figure 5.05-12. Prechamber Cross Pipe - Right Bank

    FORM 6248 First Editlon 5.05 - 9


    FUEL SYSTEM

    PRECHAMBER MANIFOLD CROSS PIPE 7. Apply Perma Lok® Heavy Duty Pipe Sealant with
    INSTALLATION - GL Teflon® to the threads of a male connector and male )
    elbow tube fitting (3/4 inch tube 00).
    1. Using the thumb of each hand, press a hose into
    each retainer until it makes solid contact with the 8. Thread the male connector tube fitting into the center
    counterbore (see Figure 5.05-14). port of the pipe tee. Thread the male elbow tube fitting
    into the remaining port. Be sure that both the male elbow
    and male connector tube fittings face the front of the
    engine (see Figure 5.05-12).

    9. Position the gasket on the free end of the cross pipe


    (see Figure 5.05-16). With the hose insert facing the
    block, slide on the retainer until it contacts the flange.

    Figure 5.05-14. Prechamber Cross Pipe Retainer

    2. Install flange on the cross pipe.

    3. With the hose insert facing inside, install the retainer


    on the cross pipe.

    4. Apply Perma Lok® Heavy Duty Pipe Sealant with


    Teflon® to the cross pipe threads. Thread the pipe tee
    onto the cross pipe leaving the center port open (see
    Figure 5.05-15).
    )
    PIPE TEE
    Figure 5.05-16. Prechamber Cross Pipe - Left Bank

    MANIFOLD
    CROSS PIPE 10. Apply Perma Lo~ Heavy Duty Pipe Sealant with
    Teflon® to the cross pipe threads. Holding the cross pipe
    Figure 5.05-15. Cross Pipe Tee to prevent movement, install the pipe elbow with the
    open port facing the rear of the engine.
    5. Standing next to the right bank, insert the end of the 11. Move the flange and retainer down the cross pipe
    cross pipe into the upper center bore of the crankcase. until it contacts the block. Rotate the retainer and and
    I nstall the pipe through the crankcase until it exits the left flange so that the flat edge faces upward. Tighten the
    bank side. retainer and flange to the block (2 capscrews, 3/8 x
    1-3/8 inches, with lock washers).
    6. Move the flange and retainer down the cross pipe until
    they contact the block. Holding the cross pipe with the 12. Apply Perma Lok® Heavy Duty Pipe Sealant with
    center port of the pipe tee facing the front of the engine, Teflon® to the threads of a male connector tube fitting
    rotate the flange and retainer until the flat edge faces (3/4 inch tube 00). Thread the fitting into the open port
    upward. Tighten the retainer and flange to the block with of the pipe elbow (facing the rear of the engine) (see
    2 capscrews (3/8 x 1-3/8 inches, with lock washers). Figure 5.05-13).

    5.05 -10 FORM 6248 First Edition


    FUEL SYSTEM

    )
    ITEM NUMBER AND DESCRIPTION
    1 Ferry Head Screw 7 Carburetor 13 Spring 19 Nut
    2 Air Hom Flange 8 Air Hom 14 Capscrew 20 Nipple
    3 Pipe 9 Gapscrew 15 Backup Plate 21 Reducing Elbow
    4 O-ring 10 Gasket 16 Diaphragm 22 Pipe Plug
    5 Capscrew 11 Capscrew 17 Valve, Air/Gas 23 Nipple
    6 Gasket 12 Cover 18 Lock washer 24 Ccupllng
    Figure 5.05-17. Carburetor Assembly - GIGSI
    CARBURETORS 2. Refer to Governor Linkage Removal and remove the
    governor linkage.
    CARBURETOR REMOVAL - G/GSI
    Clean and inspect the carburetor diaphragms and 3. Refer to Carburetor Cross Shaft Removal, and
    air/gas valves every 6 months (4320 hours). Replace disconnect the carburetor cross shaft from the carbure-
    the carburetor diaphragm(s) once each year. tor.

    4. Disconnect the main fuel line and balance line from


    A WARNING the carburetor and air horn.

    Ensure that the fuel source is completely shut off 5. Remove four capscrews, lock washers, air horn
    prior to working on fuel system components. Clear flange, air intake pipe and gasket from the carburetor air
    the engine supply lines and piping of accumulated horn (see Figure 5.05-17).
    gas before performing any maintenance work on the

    ./' fuel system or severe Injury or death could result.

    1. Turn off fuel supply.


    6. Remove four nuts lock washers, capscrews, gasket
    and carburetor assembly from the butterfly assembly.

    7. Remove four capscrews, gasket, and air horn from


    the carburetor.

    FORM 6248 First Edition 5.05 - 11


    FUELSVSTEM

    CARBURETOR DISASSEMBLY - G/GSI 2. Remove the spring inside the center shaft of the
    air/gas valve. Inspect the spring for corrosion. Any )
    1. Remove six machine screws with lock washers from damage to the spring requires replacement.
    the edge of the valve cover. Remove the valve cover
    and slide out the air/gas valve (see Figure 5.05-18). 3. Remove four machine screws with lock washers,
    backup plate and diaphragm from the air/gas valve. Any
    damage to the diaphragm requires replacement.

    o .....
    I I
    ..... -./
    CARBURETOR CLEANING AND INSPECTION -
    G/GSI

    1. Inspect the center shaft of the air/gas valve for wear,


    especially the area around the tapered gas metering
    valve (see Figure 5.05-19). This area may contact
    o metal as the gas inlet orifice is opened and closed.
    Scratches or wear results in sloppy action affecting gas

    BACKUP
    SPRING

    'xl i
    metering preCision. Any damage to the center shaft
    requires replacement of the air/gas valve.

    X@)",
    PLATE •
    '\. 1'..... I
    GAS METERING IIMPCO PART NUMBER
    o c!. VALVE ~\
    ~
    o
    o 0

    1/
    0

    DIAPHRAGM
    (~_ A CENTER
    SHAFT

    Figure 5.05-19. Air/Gas Valve

    2. Check the tapered gas metering valve for wear.


    Inspect the 0- ring for nicks or tears. Any damage to the
    gas metering valve or O-ring requires replacement.

    3. Inspect the backup plate for warpage, distortion or


    other damage.

    4. Inspect the diaphragm for dryness, stiffness or loss


    of elasticity. Hold the diaphragm up to the light and
    carefully check for pin holes. Gently stretch the material
    Figure 5.05-18. Air/Gas Valve Assembly
    to look for cracks and tears. Look for charring from
    excessive heat or backfiring. Excessive heat from the

    A WARNING
    exhaust manifold or improperly cooled turbocharged air
    can greatly reduce service life. Any damage to the
    Always wear proper eye protection when removing diaphragm requires replacement.
    the spring. Slippage may propel the spring with 5. Before installing the carburetors, inspect the air horn
    enough force to cause severe personal injury or for cracks.
    death.
    )

    5.05 - 12 FORM 6248 First Edition


    FUEL SYSTEM

    CARBURETOR ASSEMBLY - G/GSI 4. Identify the left and right bank carburetors. The two
    carburetors are not interchangeable.
    I A CAUTION I Thevarielyoffuelsystem 5. With the air/gas inlet port facing the rear of the
    .. designs, site operating
    conditions and fuel types used has made it neces- engine, install the carburetor on the butterfly assembly
    sary for Waukesha to custom design gas metering with gasket, four capscrews, lock washers, and nuts.
    valves at some installations. Han Impco part number 6. With the wings in the vertical pOSition, fit the front
    is not stamped on the tapered end of the gas valve, spider on the carburetor cross shaft to the inside
    please contact the Waukesha Product Support butterfly shaft of the left bank carburetor. Leave the
    Department before ordering replacements. Disre- spider shaft clamp fastener loose.
    garding this information could result in product
    damage and/or personal injury. 7. With the air/gas inlet port facing the rear of the
    engine, position a new gasket on the carburetor and
    1. Position the backup plate in the center of the install the right bank carburetor (6 capscrews, 1/2 x
    diaphragm (see Figure 5.05-18). Slide the four machine 1-1/2 inches, with lock washers).
    screws with lock washers through the plate and
    diaphragm. Thread the screws into the center shaft of 8. With the wings in the vertical position, fit the front
    the air/gas valve and tighten. spider on the carburetor cross shaft to the inside
    butterfly shaft of the right bank carburetor; Leave the
    2. Insert the air/gas valve into the vaive housing until front spider shaft clamp fastener loose (see
    the tapered gas metering valve slides into the gas inlet Figure 5.05-20).
    orifice. Align the air/gas valve, so that the holes on the
    edge of the diaphragm rest over the holes in the valve
    housing. CARBURETOR
    CROSS SHAFT
    ...........
    A WARNING
    Always wear proper eye protection when removing REAR
    the spring. Slippage may propel the spring with SPIDER ~~ I CROSS SHAFT
    enough force to cause severe personal Injury or FRONT \ ~./~- COVER
    death.

    3. Insert the spring into the center shaft of the air/gas


    SPt~~~~
    valve. Jil~~ ~ ROLL
    ~ :> DISC - PIN
    4. Place the valve cover over the air/gas valve assem- (!?0,
    bly, so that the projection fits inside the spring. Align the SHAKEPROOF
    cover, so that the holes on the edge rest over the holes WASHER
    in the diaphragm.
    Figure 5.05-20. Carburetor Cross Shaft Assembly
    5. Slide the six machine screws with lock washers
    through the valve cover and diaphragm. Thread the
    screws into the valve housing and tighten. A CAUTION I~he t~rottle plate must
    I1...
    • .=.=....;;;..:....:....:;..:...:....:;:....:...:...J.
    . be adjusted so that it Just
    6. Raise the center shaft of the air/gas valve several touches the housing. Failure to properly adjust the
    times to check if it is free to travel. Verify that the valve throttle plate will cause the plate to bind against the
    closes tightly when released. housing. Disregarding this information could result
    in product damage and/or personal InJury.
    CARBURETOR INSTALLATION - G/GSI
    NOTE: If the throttle plate cannot be heard contacting
    1. Install the air horn on the carburetor with gasket, and
    the rear casing, then back off the idle stop screw.
    four capscrews (see Figure 5.05-17).
    2. Position a new gasket on the upper flange of the 9. On the left bank, turn the outside butterfly shaft
    carburetor assembly. towards the rear of the engine (clockwise) until the
    ) throttle plate inside the butterfly valve housing contacts
    3. Raise the center shaft of the air/gas valve assem- the casting, indicating that the valve is in the fully ciosed
    blies in the carburetor. Verifythatthe valve closes tightly position.
    when released.

    FORM 6248 First Edition 5.05 - 13


    FUELSVSTEM

    10. Holding the outside butterfly shaft to keep the


    throttle plate in the fully closed position, tighten the front )
    spider shaft clamp to lock it on the inside butterfly shaft.

    11. Pin the front spider to the cross shaft using a new
    1/8 x 1-1/8 inch roll pin.

    12. On the right bank, turn the outside butterfly shaft


    towards the rear of the engine (counterclockwise) until
    the throttle plate contacts the casting, indicating that the
    valve is in the fully closed position.

    13. Try to turn the cross shaft to the left (counterclock-


    wise). If the shaft cannot be moved, then the left bank
    carburetor throttle plate is also in the fully closed
    position. Holding the cross shaft to prevent clockwise
    rotation, tighten the front spider shaft clamp to lock it on
    the inside butterfly shaft.

    14. Pin the front spider to the cross shaft using a new
    1/8 x 1-1/8 inch roll pin.

    15. Check all fasteners on both banks for tightness.

    16. Open and close the throttle plates to verify move-


    ment. Usten for throttle plate contact with the rear side
    of the butterfly valve housing (both banks).

    17. Verify that the cross shaft does not strike or rub
    against the cross shaft cover when the throttle plate is
    )
    opened and closed (both banks). Tighten the fasteners
    securing the cross shaft covers to the block (2 capscrews
    per cover, 3/8 x 3/4 inches, with lock washers and flat
    washers).

    18. Install carburetor gasket and carburetor elbow to


    the air horn with twelve capscrews and lock washers.

    19. Refer to Governor Unkage Installation and install


    and adjust the governor linkage.

    20. Connect the main fuel line and balance line to the
    carburetor and air horn.

    21. Remove four capscrews, lock washers butterfly


    valve housing and gasket from the intake manifold.

    5.05 -14 FORM 6248 First Edition


    FUEL SYSTEM

    BUTTERFLY VALVE HOUSiNG .........

    AIR/GAS VALVE
    ASSEMBLY
    e~~IR/GASVALVE
    ~
    "VALVE HOUSING

    ="
    q:D ~"DIAPHRAGM
    ((i!}j
    ,I I ~ BACKUP PLATE

    CARBURETOR AIR/ ~SPRING


    ~ ."-
    INLET ELBOW

    I VALVE COVER
    I

    'CARBURETOR AIR
    INLET HOUSING -

    Figure 5.05-21. Carburetor Assembly - GL

    CARBURETOR REMOVAL - GL 5. Remove twelve capscrews, lock washers carburetor


    Clean and inspect the carburetor diaphragms and gasket and carburetor elbow from the air horn (see
    air/gas valves every 6 months (4320 hours). Replace Figure 5.05-21).
    the carburetor diaphragm(s) once each year. 6. Remove six capscrews, lock washers, gasket and
    carburetor assembly from the manifold inlet adapter.
    A WARNING 7. Remove six capscrews, gasket, and air horn from
    Ensure that the fuel source is completely shut off the carburetor.
    prior to working on fuel system components. Clear
    the engine supply lines and piping of accumulated CARBURETOR DISASSEMBLY - GL
    gas before performing any maintenance work on the
    1. Remove six machine screws with lock washers from
    fuel system or severe Injury or death could result.
    the edge of the valve cover. Remove the valve cover
    and slide out the air/gas valve.
    1. Turn off fuel supply.

    2. Refer to Governor Linkage Removal and remove the


    governor linkage.
    • WARNING
    Always wear proper eye protection when removing
    3. Refer to Carburetor Cross Shaft Removal, and the spring. Slippage may propel the spring with
    disconnect the carburetor cross shaft from the carburetor. enough force to cause severe personal injury or
    death.
    ) 4. Disconnect the main fuel line and balance line from
    the carburetor and air horn. 2. Remove the spring inside the center shaft of the
    air/gas valve. Inspect the spring for corrosion. Any
    damage to the spring requires replacement.
    FORM 6248 Firs! Edition 5.05 -15
    FUEL SYSTEM

    3. Remove four machine screws with lock washers,


    backup plate and diaphragm from the air/gas valve (see GAS METERING 11MPCO PART NUMBER
    Figure 5.05-22). Any damage to the diaphragm re- VALVE~--""'"
    quires replacement. ( ..............

    1""===0" A \ CENTER

    SHAFT

    o
    o
    SPRING
    Figure 5.05-23. Air/Gas Valve

    BACKUP
    PLATE
    ~I I
    •
    2. Check the tapered gas metering valve for wear.
    Inspect the 0- ring for nicks or tears. Any damage to the

    X@)"
    "\.. 1', I
    gas metering valve or O-ring requires replacement.
    o c!.
    o 0 3. Inspect the backup plate for warpage, distortion or
    o 0 DIAPHRAGM other damage.
    1/ 4. Inspect the diaphragm for dryness, stiffness or loss
    of elasticity. Hold the diaphragm up to the light and
    carefully check for pin holes. Gently stretch the material
    to look for cracks and tears. Look for charring from
    excessive heat or backfiring. Excessive heat from the )
    exhaust manifold or improperly cooled turbocharged air
    can greatly reduce service life. Any damage to the
    diaphragm requires replacement.

    5. Before installing the carburetors, inspect the baffle


    plate in the carburetor bonnets for cracked welds (see
    Figure 5.05-24). Ifthe welds are cracked or the baffle is
    loose, then the carburetor must be repaired (see
    Carburetor Baffle, Inspecting/Repairing under Fuel
    System).

    Figure 5.05-22. Air/Gas Valve Assembly

    CARBURETOR CLEANING AND INSPECTION - GL

    1. Inspect the center shaft of the air/gas valve for wear,


    especially the area around the tapered gas metering
    valve (see Figure 5.05-23). This area may contact
    metal as the gas inlet orifice is opened and closed.
    Scratches or wear results in sloppy action affecting gas CARBURETOR
    metering precision. Any damage to the center shaft BONNET WELD
    )
    requires replacement of the air/gas valve.
    Figure 5.05-24. Carburetor Bonnet Baffle Welds

    5.05 -16 FORM 6248 First Edition


    FUEL SYSTEM

    CARBURETOR ASSEMBLY - GL 4. Identify the left and right bank carburetors. The two
    carburetors are not interchangeable. The left bank
    I.A. CAUTION IThe variety of fuel system
    designs, site operating
    carburetor has an idle stop screw attached to a larger
    diameter butterfly shaft.
    conditions and fuel types used has made It neces-
    sary for Waukesha to custom design gas metering 5. With the air/gas inlet port facing the rear of the
    valves at some installations. If an Impco part number engine, install the two center capscrews (1/2 x 1-1/2
    is not stamped on the tapered end of the gas valve, inches, with lock washers) in the butterfly valve housing
    please contact the Waukesha Product Support to install the left bank carburetor on the intake manifold
    Department before ordering replacements. Disre- inlet adapter (see Figure 5.05-25). Wrench tighten the
    garding this Information could result in product capscrews. Install the four remaining fasteners.
    damage and/or personal injury.
    INSTALL CAPSCREWS IDLE STOP
    1. Position the backup plate in the center of the HERE TO HANG SCREW
    CARBURETOR
    diaphragm (see Figure 5.05-22). Slide the four machine
    screws with lock washers through the plate and
    diaphragm. Thread the screws into the center shaft of
    the air/gas valve and tighten.

    2. Insert the air/gas valve into the valve housing until


    the tapered gas metering valve slides into the gas inlet
    orifice. Align the air/gas valve, so that the holes on the
    edge of the diaphragm rest over the holes in the valve
    housing.

    A WARNING
    BUTTERFLY ' \ AIR INTAKE
    Always wear proper eye protection when removing VALVE ELBOW FLANGE
    the spring. Slippage may propel the spring with
    enough force to cause severe personal Injury or Figure 5.05-25. Carburetor - Left Bank
    deeth.
    6. With the wings in the vertical position, fit the front
    3. Insert the spring into the center shaft of the air/gas
    spider on the carburetor cross shaft to the inside
    valve.
    butterfly shaft of the left bank carburetor. Leave the
    4. Place the valve cover over the air/gas valve assem- spider shaft clamp fastener loose.
    bly, so that the projection fits inside the spring. Align the
    cover, so that the holes on the edge rest over the holes 7. With the air/gas inlet port facing the rear of the
    engine, position a new gasket on the carburetor and
    in the diaphragm.
    install the right bank carburetor (6 capscrews, 1/2 x
    5. Slide the six machine screws with lock washers 1-1/2 inches, with lock washers).
    through the valve cover and diaphragm. Thread the
    8. With the wings in the vertical position, fit the front
    screws into the valve housing and tighten.
    spider on the carburetor cross shaft to the inside
    6. Raise the center shaft of the air/gas valve several bullerfly shaft of the right bank carburetor. Leave the
    times to check if it is free to travel. Verify that the valve front spider shaft clamp fastener loose.
    closes tightly when released.
    9. On the left bank, turn the outside bullerfly shaft
    CARBURETOR INSTALLATION - GL towards the rear of the engine (clockwise) until the
    throttle plate inside the butterfly valve housing contacts
    1. Install the air horn on the carburetor with six the casting, indicating that the valve is in the fully closed
    capscrews and lock washers. position.
    2. Position a new gasket on the upper flange of the NOTE: If /he throttle plate cannot be heard contacting
    ) carburetor bullerfly valve housing. /he rear casing, then back off /he idle stop screw.
    3. Raise the center shaft of the two air/gas valve
    assemblies in each carburetor. Verify that the valve
    closes tightly when released.
    FORM 6248 First Edition 5.05 - 17
    FUEL SYSTEM

    10. Holding the outside butterfly shaft to keep the (2 capscrews per cover, 3/8 x 3/4 inches, with lock
    throttle plate in the fully closed position, tighten the front washers and flat washers).
    spider shaft clamp to lock it on the inside butterfly shaft
    (see Figure 5.05-26). 18. Install carburetor gasket and carburetor elbow to
    the air horn with twelve capscrews and lock washers.
    CARBURETOR
    CROSS SHAFT 19. Refer to Governor Linkage Installation and install
    ~ and adjust the governor linkage.

    20. Connect the main fuel line and balance line to the
    REAR carburetor and air horn.
    SPIDER ~~ , CROSS SHAFT
    FRONT \ (If'''/~- COVER
    BUTTERFLY VALVE(S)
    SPIDER ~'

    J~~~~
    BUTTERFLY VALVE REMOVAL - G/GSI

    ~ • ~~ ~
    ~(!J,
    :> DISC -
    ROLL
    PIN
    A WARNING
    Ensure that the fuel source Is completely shut off
    SHAKEPROOF prior to working on fuel system components. Clear
    WASHER the engine supply lines and piping of accumulated
    gas before performing any maintenance work on the
    Figure 5.05-26. Carburetor Cross Shaft Assembly
    fuel system or severe Injury or death could result.
    11. Pin the front spider to the cross shaft using a new
    1. Refer to Carburetor Removal and remove the
    1/8 x 1-1/8 inch roll pin.
    carburetor.
    12. On the right bank, turn the outside butterfly shaft
    2. Refer to Butterfly Cross Shaft Removal and discon-
    towards the rear of the engine (counterclockwise) until
    the throttle plate contacts the casting, indicating that the
    nect the butterfly cross shaft. )
    valve is in the fully closed position. 3. Remove four capscrews, lock washers, butterfly
    valve and gasket from the intake manifold (see
    13. Try to turn the cross shaft to the left (counterclock-
    Figure 5.05-27).
    wise). If the shaft cannot be moved, then the left bank
    carburetor throttle plate is also in the fully closed
    position. Holding the cross shaft to prevent clockwise
    rotation, tighten the front spider shaft clamp to lock it on
    the inside butterfly shaft.

    14. Pin the front spider to the cross shaft using a new
    1/8 x 1-1/8 inch roll pin.

    15. Check all fasteners on both banks for tightness.

    IA
    ;...
    CAUTION I The throttle plate must
    be adjusted SO thatit just Figure 5.05-27. Butterfly Valve GIGSI
    touches the housing. Failure to properly adjust the
    BUTTERFLY VALVE DISASSEMBLY - G/GSI
    throttle plate will cause the plate to bind against the
    housing resulting In product damage and/or per- NOTE: Matchmark the spiders to aid in assembly.
    sonallnjury.
    1. Remove the roll pins from the spiders (see
    16. Open and close the throttle plates to verify move- Figure 5.05-27).
    ment. Listen for throttle plate contact with the rear side
    of the butterfly valve housing (both banks). 2. Remove capscrews, lock washers and spiders from
    the butterfly shaft.
    17. Verify that the cross shaft does not strike or rub
    against the cross shaft cover when the throttle plate 3. Remove two capscrews, lock washers, and the
    is opened and closed (both banks). Tighten the butterfly valve from the butterfly housing.
    fasteners securing the cross shaft covers to the block
    4. Remove the butterfly shaft from the butterfly housing.

    5.05 - 18 FORM 6248 First Edilion


    FUEL SYSTEM

    5. Remove and discard the butterfly shaft seals from 2. Remove the admission valve from the engine.
    the butterfly housing. Remove and discard the O-ring from the valve body
    (see Figure 5.05-28).
    6. Remove and discard the two bushings from the
    butterfly housing. 3. Remove the stainless steel washer at the bottom of
    the admission valve bore using the Seal Remover (Tool
    BUTTERFLY VALVE ASSEMBLY - GIGSI PIN 494385) or an O-ring pick. Discard this washer.
    1. Install two new bushings in the butterfly housing.
    ADMISSION VALVE DISASSEMBLY - GL
    2. Install the butterfly shaft through the butterfly housing.
    A CAUTION I Intermixing components
    3. Install the butterfly valve on the flat of the shaft with ..
    =
    IL. =-.::::..:....:..::;....;;..;;..;::....;;..;.J. with those of oth er
    two screws and lock washers. valves is not permitted. Admission valves (and
    rebuild kits) are Inspected as assemblies during
    4. Install the two spiders on the butterfly shaft with roll manufacture. Disregarding this Information could
    pins capscrews and lock washers. result in product damage andlor personal InJury.
    BUTTERFLY VALVE INSTALLATION - GIGSI
    1. Remove the lock nut from the end of the admission
    1. Install the butterfly valve on the intake manifold, with valve body using a 1/4 inch Allen wrench.
    new gasket, four capscrews, and lock washers (see
    Figure 5.05-27).
    I.....
    A CAUTION Ilf a vise Is needed to
    "'=---''----'
    . _ _''---1. remove the lock nut,
    2. Refer to Butterfly Cross Shaft Installation and
    install a pair of brass Jaw Inserts to avoid damaging
    connect the butterfly cross shaft.
    the assembly.
    3. Refer to Carburetor Installation and install the
    carburetor. 2. Remove the tube assembly. Remove the tube seat.
    Strike the admission valve body sharply against a piece
    ADMISSION VALVE - GL of wood to free the tube and tube seat, if necessary.

    ADMISSION VALVE REMOVAL - GL 3. Remove the contents olthe tube. Remove the spring
    and cold poppet from one end. Remove the hot poppet
    A WARNING from the other.

    Ensure that the fuel source is completely shut off 4. Remove and discard the O-ring from the admission
    prior to working on fuel system components. Clear valve body.
    the engine supply lines and piping of accumulated
    ADMISSION VALVE CLEANING AND INSPECTION
    gas before performing any maintenance work on the
    -GL
    fuel system or severe injury or death could result
    1. Remove any loose carbon using a rag or soft
    NOTE: This procedure applies only to the PIN 211587A nonmetallic bristle brush.
    admission valve. Refer to Service Bul/etin 9-2574A for
    information on previous admission valves. 2. Boil all parts in a solution of one cup laundry
    detergent to one gallon of water for 30 - 45 minutes.
    1. Disconnect the fuel supply tube from the admission
    valve body. 3. After boiling, rinse the parts in cold water and wipe dry.

    STAINLESS ,ACIMISiSICIN VALVE BODY


    STEEL WASHER HOT POPPET COLD POPPET

    @
    "LOCKNUT~
    (IDe (
    ,TUBE

    Ce)O
    I
    .SPRII~G

    OO(@
    /EAT~___

    Figure 5.05-28. Admission Valve Assembly

    FORM 6248 First Ed~ion 5.05 - 19


    FUEL SYSTEM

    ADMISSION VALVE ASSEMBLY 8. Install the hot poppet into the opposite end of the
    tube. The flat side of the poppet must face toward the

    IA CAUTION I The service kit parts may open end of the tube, so that the tip of the poppet seats
    inside the counterbore.
    .. separate after the pack-
    aging is removed. There are internal differences
    between the hot and cold poppets, as well as the hot 9. Hold the tube assembly upright in one hand with the
    (flame trap) and cold (check valve) sides ofthe tube. tip of the cold poppet pointing upward. Use a finger to
    The valve will not function properly if incorrectly keep the hot poppet in the other end of the tube.
    assembled. Disregarding this Information could
    result In product damage and/or personal injury. 10. Place the tube seat over the tip of the cold poppet,
    so that the lip on the seat fits within the tube ID.

    IA CAUTION I Do not mix part~ from 11. With the long hex on top, slide the admission valve
    ....=
    .:=='""--'''---';;........;;,.c:....--I.
    . varl ou s ad m I ssi on
    body over the cold poppet end of the tube until the entire
    valves, components are in matched sets. Disre-
    assembly fits easily within the valve body.
    garding this information could result in product
    damage and/or personal injury. 12. Finger tighten the lock nut into the end of the
    NOTE: Before assembling, all parts must be dry and oil admission valve body.
    free.
    4. Look into both poppets. Note that the bore of the hot IA
    ..
    CAUTION I Do not over torque the
    lock nut or the tube may
    poppet is approximately 1/8 inch deeper than the cold be permanently damaged_ Disregarding this in-
    poppet. formation could result in product damage and/or
    NOTE: The parts in the service kit are assembled in the personal injury.
    proper oreier for installation in the valve body (see 13. Use an inch pound torque wrench and Allen socket
    Figure 5.05-29). The service kit parts may separate after to tighten the lock nut to 70 - 90 in-Ib (8 - 10 N·m).
    the packaging is removed. If the parts become sepa-
    rated, an easy way to identify the hot and cold poppets is 14. Install a new a-ring on the admission valve body.
    to visually inspect the inside of the poppets (see To prevent tears when the assembly is inserted into the )
    Figure 5.05-29). Another way to identify the poppets is to cylinder head admission valve bore, lubricate the
    install the spring. The spring will extend farther out of the a-ring with Parker Super O-Lube®.
    cold poppet (see Figure 5.05-29). The cold poppet and
    spring are installed in the end of the tube that is marked ADMISSION VALVE INSTALLATION - GL
    with the WED label. Proper assembly is required. 1. Clean the washer seat at the bottom of the cylinder
    head admission valve bore.
    HOT COLD
    POPPET POPPET NOTE: Previous production admission valves use a
    copper washer.

    2. Install a new stainless steel washer at the bottom of


    the cylinder head admission valve bore (see
    Figure 5.05-30).

    Figure 5.05-29. Spring Seats In Cold Poppets


    ADMISSION
    5. Install the spring in the open end of the cold poppet. VALVE

    ~£t~?1.c~
    (see Figure 5.05-29).
    6. Look into each end ofthetube. Note that one end has
    a larger diameter counter bore (to fit the tip of the hot
    poppet), while the other end of the tube has a small
    opening encircled with a lip (spring seat). !
    STAINLESS STEEL
    7. Insert the cold poppet (spring end first) into the tube WASHER
    until the end of the spring contacts the spring seat. Verify
    that the tip of the poppet sticks out slightly.
    Figure 5.05-30. Install Stainless Steel Washer In
    )
    NOTE: If the entire poppet fits within the tube, then the Cylinder Head
    wrong (hot) end of the tube has been selected. Fit the
    cold poppet into the other end of the tube.

    5.05 - 20 FORM 6248 First Edition


    FUEL SYSTEM

    A CAUTION I
    I-="'=:...;::-:-..;;.:~+-,,-~.
    L.
    When Installing the ad·
    mission valve, make
    sure only a stainless steel washer Is used and Is
    ASSEMBLED
    PRECHAMBER
    PULLER~
    seated flat against the seating surface In the
    cylinder head. If the stainless steel washer is
    damaged, fuel leaks will occur.

    IA CAUTION I~onotusecopperwash.
    .
    L;. .. er PIN 16409 with PIN
    ==--;:;.:;...:.;::;..:...:..;:;;..:.:.J.
    211587A admission valve or with a PIN 211587 valve
    o SLtDE
    that has been upgraded by machining the lock nut. .........--'I/HAMMER
    If the copper washer Is used, the new assembly
    torque will drive the admission valve through the
    washer, causing damage.

    3. Install the admission valve in the cylinder head bore.

    A CAUTION I~o
    I=...
    L.
    not over tighten the
    =,--,;..;;...;;..;;;..;;..;;..,,-~.
    admission valve or the
    TAPERED
    /POST
    valve may become damaged.

    4. TIghten the valve to a torque of 65 - 70 ft-Ib


    (88 - 95 N'm) dry.

    5. Reattach both ends of the prechamber fuel inlet tube


    on the prechamber manifold and the admission valve
    assembly. Finger tighten the ferrule nuts. Use a wrench
    to tighten the ferrule nuts. Inspect for fuel leaks.

    PRECHAMBER CUP - GL COLLET~


    PRECHAMBER CUP REMOVAL - GL

    1. Refer to Section 5.10, Ignition System and remove


    the the spark plug and spark plug carrier from the
    cylinder head.

    A WARNING Figure 5.05-31. Prechamber Puller Assembly

    Take care when using the assembled prechamber


    puller tool. The slide hammer moves freely up and 3. Insert the puller tool into the cylinder head bore with
    down the rod and may cause severe personal injury the welded extension of the collet inside the cylinder
    if it contacts your fingers. head recess (see Figure 5.05-32). With the collet
    flange, carefully locate the groove inside the top of the
    2. Assemble the Prechamber Puller (Tool PIN 494290). prechamber cup.
    The tool consists of a rod, slide hammer, tapered post
    and collet (see Figure 5.05-31). Slide the hammer on
    the threaded end of the rod and screw on the tapered
    post. Thread the collet on the tapered post.

    NOTE: Model 510BGL requires a smaller size collet


    (Tool PIN 474007) that is used with the prechamber
    puller parts supplied under Tool PIN 494290.

    )
    Figure 5.05-32. Prechamber Puller Assembly

    FORM 6248 First Edition 5.05 - 21


    FUELSVSTEM

    NOTE: While expanding the col/et, be sure that it is PRECHAMBER CUP CLEANING AND INSPECTION
    centered in the pul/er groove of the prechamber cup. -GL )
    4. Slide a 3/4 inch drive handle through the hole in the
    puller handle and turn the puller tool clockwise. The A WARNING
    welded extension on the collet will come to rest against Always use approved cleaning solvents In a well
    the cylinder head recess. With the collet unable to ventilated area. Contact with skin could result In
    rotate, turning the puller handle causes the post on the severe personal injury or death.
    tapered end of the rod to push on the bearing within the
    collet, which forces the three ears outward. 1. Soak the prechamber cup in a non-volatile cleaning
    solution or solvent (see Figure 5.05-34).
    5. Pull up on the puller tool to remove the prechamber
    cup (see Figure 5.05-33). Since the bottom of the cup

    ~,
    resides in the combustion chamber, it may accumulate
    deposits causing i110 stick. If pulling up on the puller tool
    does not free the cup, grasp the slide hammer and raise IS' PRECHAMBER
    with sufficient force to contact the plate below the /Y CUP
    STAINLESS
    handle of the puller tool. Repeat this action until the STEEL SEAL
    prechamber is free.
    ~e

    Figure 5.05-33. Prechamber Puller Assembly Figure 5.05-34. Install Prechamber Cup

    6. Remove the old stainless steel seal from the bottom 2. Thoroughly clean the spark plug carrier bore. If
    of the cylinder head spark plug carrier bore using the necessary, use the Spark Plug Carrier Refacing tool
    Seal Remover (Tool PIN 494385) or an O-ring pick. (Tool PIN 494087) to clean hardened carbon from the
    threads and seat without causing damage to the bore.

    A WARNING
    Compressed air can pierce the skin and cause
    severe personal injury or death. Never use your hand
    to check for leaks or to determine air flow rates.

    3. Use compressed air to remove all moisture and


    debris.

    PRECHAMBER CUP INSTALLATION - GL


    NOTE: Previous production prechamber cups used a
    copper prechamber cup seal.

    1. Place a new stainless steel seal at the bottom of the


    cylinder head spark plug carrier bore. The stainless )
    steel seals are manufactured to take a definite crush
    and must be replaced after each disassembly (see
    Figure 5.05-34).

    5.05 - 22 FORM 6248 First Edition


    FUEL SYSTEM

    CAUTION I
    I-=.A=...;::..:...~;..:...:..:::..::..:..J.
    Do not apply FEL-PRO® 3. Disconnect the prechamber fuel inlet tubes from the
    L. . C5-A®, Part No. 51005 admission valves and prechamber manifolds.
    anti-seize compound to any holes in the precham-
    ber. 4. Remove two nuts, lock washers, washers and
    U-bolts from the prechamber manifold brackets (see
    2. Apply FEL-PRO® C5-A®, Part No. 51005 anti- Figure 5.05-36).
    seize compound to the 0.0. of the prechamber (at
    prechamber to cylinder head interfaces).

    3. Position the prechamber cup into the cylinder head


    bore making sure that it is properly seated on the
    stainless steel seal.

    PRECHAMBER MANIFOLD - GL
    PRECHAMBER MANIFOLD REMOVAL - GL

    A WARNING
    Ensure that the fuel source is completely shut off
    prior to working on fuel system components. Clear
    the engine supply lines and piping of accumulated
    gas before performing any maintenance work on the
    fuel system or severe Injury or death could result.

    1. Shut off fuel supply. Figure 5.05-36. Prechamber'Manlfold

    2. Disconnect the prechamber inlet pipe from the 5. Removetwocapscrews lock washers, four washers,
    ) and remove the prechamber manifold brackets from the
    bottom of the prechamber (see Figure 5.05-35).
    engine.

    6. Remove hex head pipe plug, plug, and copper


    gasket from the ends of the prechamber manifold.

    Figure 5.05-35. Prechamber Gas Supply - Left Bank

    FORM 6248 First Ednion 5.05 - 23


    FUELSVSTEM

    7 12
    10 ......
    . ~fl!;®
    '11

    ITEM NUMBER AND DESCRIPTION


    1 Elbow 5 Prechamber Mannold 9 U-Bo~ 13 Tube

    2 Tee 6 Plug 10 Washer 14 Connector )


    3 Connection 7 Bracket 11 Lock washer 15 Gasket
    4 Tube 8 Capscrew 12 Nut 16 Plug
    Figure 5.05-37. Prechamber Manifold
    PRECHAMBER MANIFOLD INSTALLATION - GL 8. Rotate the manifold so that the male elbow tube
    1. Install the prechamber manifold brackets on the fitting is at the bottom and each male connector is
    engine with two capscrews lock washers, four washers. pointing toward a section of the exhaust manifold.

    2. Apply Perma Lok® Heavy Duty Pipe Sealant with 9. Hold the other prechamber manifold up against the
    Teflon® to the threads of twelve male connector tube right bank prechamber manifold brackets. Be sure that
    fittings (3/8 inch tube OD). the free end of the male elbow tube fitting points toward
    the front of the engine.
    3. Install the fittings in the six pipe taps in each
    prechamber manifold. 10. Finger tighten the U-bolts to fasten the manifold to
    4. Apply Perma Lok® Heavy Duty Pipe Sealant with the two manifold brackets. Rotate the manifold so that
    Teflon® to the threads of two male elbow tube fittings the male elbow tube fitting is at the bottom and each
    (3/4 inch tube OD). male connector is pointing toward a section of the
    exhaust manifold.
    5. Install the male elbows into the pipe tap in the center
    of each prechamber manifold. 11. Install the prechamber fuel inlet tubes between the
    prechamber manifolds (male connector tube fittings)
    6. Hold one ofthe prechamber manifolds up againstthe and the admission valve assemblies.
    two left bank prechamber manifold brackets. Be sure
    that the free end of the male elbow tube fitting points NOTE: Reattach both ends of each tube before tighten-
    toward the rear of the engine. ing.
    7. Install the prechamber manifold on the brackets with )
    12. Tighten the prechamber manifold bracket U-bolt
    two lock washers, washers and nuts (see hex nuts (5/16 inch).
    Figure 5.05-37). Leave the nuts loose enough to allow
    movement of the manifold.

    5.05 - 24 FORM 6248 First Edition


    FUELSVSTEM

    MAIN FUEL GAS PRESSURE 3. Disconnect the Dressor coupling from the carburetor.
    REGULATOR (FISHER 99)
    MAIN FUEL GAS PRESSURE REGULATOR A WARNING
    (FISHER 99) REMOVAL The Fisher 99 main fuel gas pressure regulator
    weighs approximately 80 Ibs. (36 kg). Use a suitable
    A WARNING lifting device and exercise caution during removal
    or Installation to avoid severe personal injury or
    Ensure that the fuel source is completely shut off death.
    prior to working on fuel system components. Clear
    the engine supply lines and piping of accumulated 4. Attach a suitable lifting device to the regulator.
    gas before performing any maintenance work on
    the fuel system or severe personal Injury or death 5. Remove four nuts, lock washers, washers from the
    could result. regulator and mounting bracket.
    1. Shut off fuel supply.
    6. Using a suitable lifting device, remove the regulator
    2. Disconnect the balance line from the regulator (see from the mounting bracket.
    Figure 5.05-1, Figure 5.05-38 and Figure 5.05-39).
    7. Remove five capscrews, lock washers, washers and
    mounting bracket from the crankcase

    RIGHT BANK INSTALLATION


    NOTE: A slotted open-ended cut at the bottom of the
    bracket provides access to the #3 main bearing cap
    cross tie bolt (directly above the oil level gauge).

    1. Fasten the right bank regulator r'lounting bracket to


    the bolt holes (see Figure 5.05-40) in the engine block
    with five capscrews, lock washers and washers.

    Figure 5.05-38. Fisher 99 Regulator TUbe Connections


    -GSI

    DOWNSTREAM SENSING

    Figure 5.05-40. Bolt Holes In Engine Block

    )
    Figure 5.05-39. Fisher 99 Regulator Tube Connections
    - GL

    FORM 6248 First Edition 5.05 - 25


    FUEL SYSTEM

    NOTE: The right bank regulator mounting bracket can


    UPPER CHAMBER FUEL SUPPLY TUBE
    be distinguished from the left bank bracket by the two (ALIGN WITH SLOTTED CUT IN BRACKET)
    slotted holes on the front edge (for mounting of the
    LONG BOLTS WITH SPACERS
    prechamber air/gas valve and bracket) (see (ALIGN WITH SLOTTED
    Figure 5.05-41). HOLES IN BRACKET)

    FRONT OF ENGINE \ ~
    BOLT HOLES FOR
    MOUNTING PRECHAMBER

    ~1~
    REAR FRONT
    OF OF
    ENGINE ENGINE

    LONG BOLTS WITH SPACERS


    (ALIGN WITH SLOTTED HOLES
    IN BRACKET)
    SLOTTED CUT FOR #3 MAIN
    BEARING CAP CROSS TIE BOLT

    REAR OF ENGINE
    Figure 5.05-42. Fisher 99 Regulator Mounting
    Figure 5.05-41. Fisher 99 Regulator Bracket - Right Orientation - Right Bank - Top View
    Bank )
    2. Remove the four short bolts {l/16 x 1-1/2 inches) from
    the regulator housing (see Figure 5.05-42). Install four
    long bolts (l/16 x 4-1/2 inches) in the empty bolt holes.

    3. Place spacers (2-5/8inch) over the four slotted holes


    in the regulator mounting bracket (see Figure 5.05-41).

    A WARNING
    The Fisher 99 main fuel gas pressure regulator
    weighs approximately 80 Ibs. (36 kg). Use a suitable
    lifting device and exercise caution during removal
    or Installation to avoid severe personal Injury or
    death.

    4. Position the regulator, so that the fuel supply tube


    (leading from the pilot chamber to the chamber above
    the main diaphragm) is directly above the slotted Figure 5.05-43. Main Fuel Gas Regulator - Right Bank
    open-ended cut in the top of the mounting bracket (see
    Figure 5.05-43). Be sure that the four long bolts slide
    through the spacers and the bracket holes as the
    regulator is lowered. Alternately tighten the fasteners
    (washers, lock washers and hex nuts).

    5.05 - 26 FORM 6248 First Edition


    FUEL SYSTEM

    5. Rotate the pipe elbow so that the carburetor inlet 8. With the concave side facing the pipe ends, slide the
    pipe nipple is approximately 15 degrees above horizon- coupling hex nuts onto the regulator outlet and carbure-
    tal (see Figure 5.05-44). tor inlet pipe nipples.

    9. Wipe the rubber seals clean and fit the tapered end
    into the hollowed side of the seal retainers.

    10. Install the seals in the ends of the coupling elbow,


    so that the rubber face seats against the beveled
    counterbore.

    11. Position the coupling between the regulator outlet


    and carburetor inlet pipe nipples and alternately tighten
    the hex nuts (see Figure 5.05-46).

    Figure 5.05-44. Carburetor Gas Inlat - Right Bank

    6. Verily that the ends of the regulator outlet and


    carburetor inlet pipe nipples are clean and completely
    free of dirt and oil. Check the surfaces where the
    coupling seals contact the pipe ends to ensure that
    there are no gouges, grooves, burrs, nicks or dents.

    7. Disassemble both sides of the Dresser elbow


    coupling (see Figure 5.05-45). Remove and discard the
    old armored gaskets, if still in place. Obtain two new Figure 5~05-46. Dresser Elbow Coupling
    armored gaskets.
    NOTE: Based on the height of the Fisher 99 regulator
    bracket, it may be necessary to drop the free end of the
    COUPLING CLt.UWl!... carburetor inlet pipe a few degrees.

    12. Inspect the Fisher 99 main fuel gas pressure


    regulator filter for cleanliness.

    NOTE: See Fisher 99 Regulator Filter, Cleaning and


    Inspection.

    Figure 5.05-45. Dresser Elbow Coupling

    \ )

    FORM 6248 First Edition 5.05 - 27


    FUEL SYSTEM

    13. Install the gas supply tube between the gas inlet tee 17. Connect the balance line between the Fisher 99
    (male elbow tube fitting) and the Fisher99 regulator pilot regulator pilot spring chamber (male connector) and the
    chamber gas inlet port (male elbow) (see Figure 5.05-1, carburetor air horn, on G or the air inlet tube, on GSI
    Figure 5.05-47, and Figure 5.05-48). (see Figure 5.05-1 and Figure 5.05-47).

    LEFT BANK INSTALLATION


    1. Follow steps in Right Bank to install the left bank
    Fisher 99 regulator. The pattern of the regulator
    mounting bracket to cylinder block bolt holes (see
    Figure 5.05-49), as well as the installation of the long
    bolts in the regulator housing (see Figure 5.05-50), are
    the reverse of the left bank configuration.

    Figure 5.05-47. Fisher 99 Regulator Tube Connections


    - GSI

    DOWNsmEAM SENSING LINE


    SLOTTED CUT FOR #3 MAIN SLOTTED CUT FOR
    BEARING CAP CROSS TIE BOLT FUEL SUPPLY TUBE
    (pILOT CHAMBER TO
    FRONT OF UPPER CHAMBER)
    ENGINE
    )
    Figure 5.05-49. Fisher 99 Regulator Bracket - Left
    Bank

    UPPER CHAMBER FUEL SUPPLY TUBE

    LONG BOLTS WITH SPACERS


    (ALIGN WITH SLOTTED
    j
    (ALIGN WITH SLOTTED CUT IN BRACKET)

    HOLES IN BRAC~K;.-A
    _ _ _~

    Figure 5.05-48. Fisher 99 Regulator Tube Connections


    - GL

    NOTE: For best results, reattach both ends of each REAR


    tube before tightening. OF
    ENGINE
    14. On G/GSI, install the down stream sensing line (see
    Figure 5.05-1 and Figure 5.05-47).

    15. On GL, install the downstream sensing line (5/8


    inch tube OD) between the gas outlet system (male
    elbow tube fitting) and the Fisher 99 regulator main LONG BOLTS WITH SPACERS
    (ALIGN WITH SLOTTED HOLES
    orifice chamber (male connector) (see Figure 5.05-48). IN BRACKET)

    16. On GL, connect the balance line between the )


    carburetor air inlet housing (male elbow tube fitting) and
    the Fisher 99 regulator pilot spring chamber (male
    connector) (see Figure 5.05-48). Figure 5.05-50. Fisher 99 Regulator Mounting
    Orientation - Left Bank - Top View

    5.05 - 28 FORM 6248 First Ed~ion


    FUEL SYSTEM

    PRECHAMBER REGULATOR
    (FISHER 95L) - GL
    PRECHAMBER REGULATOR (FISHER 95L)
    REMOVAL-GL

    1. Disconnect balance line tube from elbow on intake


    manifold.

    2. Disconnect balance line tube from fitting on pre-


    chamber regulator.

    3. Disconnect the gas inlet tube from the bottom gas


    inlet tube connection on the prechamber regulator (see
    Figure 5.05-51).

    4. Disconnect the flex elbow from the gas outlet tube.

    5. Remove four capscrews, lock washers, washer, Figure 5.05-51. Prechamber Regulator - Front Right
    spacers, and the prechamber regulator from the
    regulator bracket (see Figure 5.05-52).
    7. Remove capscrew, lock washer, washer, regulator
    6. Remove capscrew, lock washer, two washers, nut brace, and spacer from the crankcase.
    and spacer from the regulator bracket and regulator
    8. Remove two capscrews, lock washers, spacers, and
    brace.
    regulator bracket from the crankcase.

    "-
    ~
    ~f) ~~"
    12
    I I~ 15" 8 16
    14

    ITEM NUMBER AND DESCRIPTION


    1 Regulator 7 Capscrew 13 lock washer 19 Elbow
    2 Gapscrew 8 lock washer 14 Nut 20 Washer
    3 Spacer 9 Brace 15 Capscrew 21 Lock washer
    4 Bracket 10 Spacer 16 Washer
    5 Spacer 11 Capscrew 17 Pipe
    6 Spacer 12 Washer 18 Coupling
    )
    / Figure 5.05-52. Prechamber Regulator - GL

    FORM 6246 First Edition 5.05 - 29


    FUEL SYSTEM

    PRECHAMBER REGULATOR (FISHER 95L)


    INSTALLATION - GL
    NOTE: If longer mounting capscrews are already
    installed, Step 1 is not required.
    1. Position the prechamber regulator on a workbench
    with the adjusting screw facing upward (see
    Figure 5.05-53). Rotate the regulator, so that the gas PRECHAMBER
    inlet tube connection is at the bottom. Starting at the 11 REGULATOR

    ///~I
    o'clock position and moving counter-clockwise, re-
    move four bolts from the regulator housing.
    o all I /
    o I II
    o ~( \ \\
    0' '
    °t~~
    MOUNTING
    BRACKET

    REMOVE
    BOLTS BRACKET SUPPORT BRACE
    (TO BLOCK)

    Figure 5.05-54. Prechamber Regulator Mounting


    Bracket

    7. Slide two longer (1/2 x 2-1/4 inches, with both lock and )
    washers) through the two slotted holes in the upper rim of
    the regulator mounting bracket (see Figure 5.05-55).

    8. Install 3/8 inch spacers on the ends of the caps-


    crews. Attach the harness cable clip(s) and thread the
    capscrews back into the lower intake manifold flanges.
    Wrench tighten.
    Figure 5.05-53. Prechamber Regulator 9. Slide a capscrew (1/2 x 1-1/2 inches, with lock
    washer and flat washer) through the large end of the
    2. Position four longer capscrews (5/16 x 1-1/2 inches,
    bracket support brace. Install a 1/2 inch spacer on the
    with lock washers and flat washers) through the slotted
    end of the capscrew. With the foot of the brace pointing
    holes in the prechamber regulator mounting bracket
    downward, thread the capscrew into the crankcase
    (see Figure 5.05-54).
    directly above the open-ended cut at the back of the
    3. Position the mounting bracket over the prechamber magneto drive support bracket. Wrench tighten.
    regulator aligning the capscrews in the bracket with the
    four empty bolt holes in the prechamber regulator 10. Slide a capscrew (3/8 x 2-1/4 inches, with lock
    housing. The rounded cut in the mounting bracket washer and flat washer) through the horizontal slot in
    accommodates the male elbow tube fitting in the gas the center of the regulator mounting bracket (see
    outlet port of the prechamber regulator. Figure 5.05-54).

    4. Position 1/4 inch spacers on the capscrews and 11. Remove the 1/4 inch square head pipe plug from
    thread them into the regulator housing. Wrench tighten. the front of the right bank intake manifold (bottom).
    5. Install the 1-1/8 inch spacer and the free end of the 12. Apply Perma Lok® Heavy Duty Pipe Sealant with
    bracket support brace on the end of the capscrew.lnstall Teflon® to the threads of a male elbow tube fitting (1/4
    a 3/8 inch flat washer and hex nut. Wrench tighten. inch tube 00). Install the elbow leaving the free end )
    6. Remove two capscrews (1/2 x 2 inches) from the pointing towards the front of the engine.
    lower intake manifold flanges at the front right side of the
    engine (see Figure 5.05-55).

    5.05-30 FORM 6248 First EdHion


    FUEL SYSTEM

    PRECHAMBER FUEL
    SUPPLY TUBE BRACKET
    (1/2 X 2" CAPSCREW)

    INTAKE
    MANIFOLD\

    AIR/GAS SYSTEM TUBE PRECHAMBER REGULATOR


    CLIP BRACKETS MOUNTING BRACKET
    (1/2 X 1-3/4" CAPSCREW) (1/2 X 2-1/4" CAPSCREW)

    Figure 5.05-55. Intake Manifold Flange Attachments - Right Bank

    13. Install the balance line (1/4 inch tube 00) between NOTE: Reattach both ends of each tube before tighten-
    the intake manifold (male elbow tube fitting) and the ing.
    prechamber regulator pressure port (male connector)
    (see Figure 5.05-56).

    i
    / Figure 5.05-56. Prechamber Regulator - Front Right

    FORM 6248 First Edition 5.05 - 31


    FUEL SYSTEM

    14. Install the fuel supply tube (3/4 inch tube aD) to the 16. Install a retaining clip to the fuel supply tube
    prechamber regulator gas outlet port (male elbow) (see downstream (rear) of the union tube fitting. Fasten the
    Figure 5.05-57). Tighten the ferrule nut (1-1/8 inch hex) clip to the tube support bracket (1 capscrew, 3/8 x 3/4
    to install the union tube fitting on the free end ofthe tube. inch, with flat washer, lock washer and hex nut).

    15. Install the fuel supply tube (3/4 inch tube aD)
    between the union tube fitting and the cross pipe tee
    (male elbow).

    PRECHAMBER MANIFOLD
    / (LEFT BANK)

    PRECHAMBER MANIFOLD
    (RIGHT BANK)

    ~ '(>
    ~ "'-CROSS PIPE ELBOW

    CROSS PIPE
    CROSS PIPE TEE I

    ~~ ~1lJBESUPPORTBRACKET
    )

    ~/ ~
    1lJBECUP
    UNION 1lJBE FITTING
    I I
    FUEL SUPPLY 1lJBE

    PRECHAMBER
    ~ REGULATOR

    )
    Figure 5.05-57. Prechamber Regulator/Manifold Tube Connections - GL

    5.05 - 32 FORM 6248 First Ednion


    FUEL SYSTEM

    17. Remove the lower capscrew (1/2 x 2 inches, with


    both lock and flat washers) from the intake manifold A WARNING
    flange (see Figure 5.05-55). Slide the capscrew Gas vented from engine components must be piped
    through the round hole in the bracket. Install the to a safe area In compliance with all applicable
    capscrew back in the intake manifold flange. codes. Disregarding this information could result In
    severe personal Injury or death.
    18. Finger tighten the ferrule nuts (1-1/8 inch hex) to
    attach the fuel supply tube (3/4 inch tube 00) between 6. Open the bleed valve between the Fisher 99
    the cross pipe tee (male connector tube fitting) and the regulator(s) and the downstream shutoff valve(s).
    right bank prechamber manifold (male elbow).
    NOTE: Do not change the Fisher 99 main fuel gas
    19. Finger tighten the ferrule nuts (1-1/8 inch hex) to pressure regulator spring adjustment. The regulator
    attach the fuel supply tube (3/4 inch tube 00) between opens in response to decreased outlet pressure, so al/
    the cross pipe elbow (male connector tube fitting) and pressure between the upstream and downstream
    the left bank prechamber manifold (male elbow) (see shutoff valves is released through the bleed valve.
    Figure 5.05-58). FISHER 99 REGULATOR FILTER CLEANING AND
    INSPECTION
    Clean or replace the filter of the Fisher 99 main fuel gas
    pressure regulator(s) annually. If clogging is suspected
    in the upstream regulator passages, more frequent
    cleaning may be required.
    Filter Element Removal
    1. Loosen the hex nut (5/8 inch) on each end ofthe pilot
    chamber supply tube (see Figure 5.05-59). Detach the
    pilot supply tube from the brass fitting threaded into the
    body of the filter assembly.

    Figure 5.05-58. Prechamber Gas Supply - Left Bank

    FUEL SYSTEM MAINTENANCE

    A WARNING
    Ensure that the fuel source is completely shut off
    prior to working on fuel system components. Clear
    the engine supply lines and piping of accumulated
    gas before performing any maintenance work on
    the fuel system or severe personal injury or death
    could result.

    1. Run the engine at idle with no load. PILOT CHAMBER GAS SUPPLY

    2. Close the gas shutoff valve(s) upstream from the Figure 5.05-59. Fisher 99 Regulator Fuel Gas Filter
    Fisher 99 main fuel gas pressure regulator(s).
    2. Remove the 1-1/8 inch filter head hex nut from the
    3. Let the engine run. The supply lines are clear when pilot chamber orifice pipe nipple.
    the engine stops.
    3. Remove the filter assembly. Disassemble as follows:
    If provision has been made for downstream shutoff and
    bleed valves: A. Remove the 1-1/8 inch filter head hex nut from
    the filter body.
    4. Close the gas shutoff valve(s) upstream from the
    ) Fisher 99 main fuel gas pressure regulator(s). B. Remove the machine screw securing the filter
    element to the filter head.
    5. Close the downstream shutoff valve(s).
    C. Remove the two flat washers and the filter
    element.

    FORM 6248 First Edilion 5.05-33


    FUELSVSTEM

    Cleaning/lnspection/Replacement
    )
    1. Thoroughly wash all parts of the assembly in a
    non-volatile cleaning solution or solvent. Blow dry with
    low pressure compressed air.
    FILTER HEAD
    HEX NUT
    2. Inspect the filter element for stubborn deposits,
    peeling or flaking. Replace as necessary.

    Filter Element Installation


    1. Reassemble the filter assembly as follows (see
    Figure 5.05-60):
    FLAT
    WASHERS
    A. Place the flat washer on the support flange inside
    the filter head.

    B. Center the filter element on top of the washer.

    C. Center the second flat washer on top of the filter


    element.

    D. Slide the machine screw through the center ofthe


    filter element. Thread the screw into the filter
    head.
    MACHINE
    /
    SCREW
    E. Thread the filter head hex nut onto the filter body.

    ~/
    2. Thread the other end of the filter head hex nut onto
    the pilot chamber orifice pipe nipple.
    FILTER
    BODY
    )

    ~
    3. Attach the pilot supply tube to the brass fitting
    threaded into the body of the filter assembly. Tighten the
    hex nut (5/8 inch) on each end of the pilot chamber
    supply tube.
    /

    \... V
    Figure 5.05-60. Fisher 99 Regulator Filter

    5.05 - 34 FORM 6248 First Ednion


    SECTION 5.10 - IGNITION SYSTEM

    IGNITION SYSTEM COMPONENTS SPARK PLUGS

    CAUTION I~3/16
    The ignttion system consists of the following components:
    inch reach sp~rk
    • CEC Ignition Module/Hall-effect Pickup I. . ...
    ;::A= ______ plugs must be used with
    --1.

    13/16 inch reach carriers, and 1/2 Inch reach spark


    • Magneto plugs must be used with 1/2 Inch reach carriers.
    Mixing carrier and spark plug components will
    • Wiring Harness
    cause damage to equipment and/or personal injury.
    • Ignition Coils Service Bulletin 11-2636 announced the release of longer
    • Spark Plug Carriers - GL Engines reach spark plugs (13/16 inch) and longer reach spark plug
    carriers (13/16 inch) as a service option on GL engines.
    • Spark Plugs Carriers are marked with the spark plug reach (thread
    length) (see Figure5.10-1). Carrier and spark plug size
    CEC IGNITION MODULE must be verified prior to installation.
    The ignition module functions by using a Hall-effect Pickup One spark plug is provided for each cylinder. on GL
    to read magnetic reference marks on a disc attached to the engines, each spark plug is housed within a spark plug
    governor drive gear hub. this method of timing determines carrier and fires the rich fuel mixture in the respective
    the exact position of the crankshaft. The microcircutt- prechamber. The flame torch ignites the lean mixture in the
    based, electronic ignition module interprets the sensor's main combustion chamber. Spark plug life will depend on
    impulses to set the optimum ignition timing. The electronic the site experience. Table 5.10-3, Table 5.10-4, and Ser-
    ignition module directs a precisely timed voltage to the vice Bulletin 11-2636, list spark plug options available.
    appropriate coil. Form 6253, Custom Engine Control®
    Ignition Module, provides information on the installation, SPARK PLUGS
    operation and maintenance of the CEC ignition module.
    SPARK PLUG CARRIER REMOVAL - GL
    MAGNETO
    The magneto is located at the front right side of the -A CAUTION 113/ 16 inch reach sp~rk
    engine and is driven from the accessory (magneto) I=
    .=~:;.::....;;.;:::......::~;::;....:~.
    L. . plugs must be used With
    drive gear. The magneto uses solid state electronic 13/16 inch reach carriers, and 1/2 inch reach spark
    components. Self-generated alternating current is plugs must be used with 1/2 inch reach carriers.
    rectified to direct current and stored within a capacitor. Mixing carrier and spark plug components will
    Silicon controlled rectifiers (SeR's) function as switches cause damage to equipment and/or personal injury.
    to release the stored energy to the ignition coils. A
    13/16 inch reach carriers PIN 209567M (5108GL only) and
    trigger coil arrangement produces the voltage needed
    209567K (used on all other GL) have been designed to
    to turn the SCR on.
    accommodate the 13/16 inch reach spark plugs. The
    WIRING HARNESS carriers are stamped on the upper circumference with part
    number and the plug reach size (see Figure5.1Q-1). An
    A flexible wiring harness is used to connect the CEC and
    unmarked Waukesha spark plug carrier indicates 1/2 inch
    magneto and CEC Ignition Module to the ignition coils. The
    reach.
    wiring hamess uses solder less connectors on the coil
    terminals and a multiple pin connector at the CEC and
    magneto connections.

    IGNITION COILS
    One ignition coil is provided for each cylinder. Each coil
    is attached to a bracket that is securely mounted to the
    upper intake manifold flanges.

    FORM 6248 First Edition 5.10 - 1


    IGNITION SYSTEM

    METAL STAMP METAL STAMP


    P/N\.: ___
    P/N\.:~-.....
    SPARK PLUG
    AN UNMARKED WAUKESHA CARRIER

    ,
    SPARK PLUG CARRIER
    INDICATES 1/2 INCH REACH
    /
    METAL STAMP SPARK
    PLUG REACH

    Figure 5.10-1. Spark Plug Carriers

    5.10 - 2 FORM 6248 First Edttion


    IGNITION SYSTEM

    5. Remove two O-rings from the spark plug carrier (see


    A WARNING Figure 5.10·4).
    Ensure that the fuel source is completely shut off
    prior to working on fuel system components. Clear
    the engine supply lines and piping of accumulated
    gas before performing any maintenance work on the
    fuel system or severe Injury or death could result.

    -A CAUTION 1 ~park plug carrier re- Q-RINGS


    =
    ..
    I =~=..;..;;;;....;...:;..;;;;..;~. moval without the spe-
    ~Q
    L.

    cial tool may result In damage to the tangs of the


    spark plug carrier. Disregarding this information ~
    could result in product damage and/or personal
    injury

    A WARNING
    The spark plug carrier becomes extremely hot
    during engine operation. Allow the spark plug
    carrier to cool prior to handling, to prevent severe
    personal Injury.

    4. Using the spark plug carrier removal tool (Tool


    PIN 494289 for Non eSA, and PIN 474023 for eSA,
    (see Figure 5.10-2 and Figure 5.10-3), remove the
    spark plug carrier.
    Figure 5.10-4. Install Spark Plug Carrier

    NOTE: Whether through corrosion, stress or use of


    the incorrect tool, the tangs of the spark plug carrier
    may break, rendering the Spark Plug Garrier Remover
    (Tools PIN 494289 for Non GSA, and PIN 474023 for
    GSA) ineffective. Therefore, a Spark Plug Carrier
    Extractor has been made available to remove broken
    spark plug carriers (Tool PIN 474008) (see
    Figure 5. 10-5). The special tool has a tapered, fluted
    OD allowing it to be screwed counter-clockwise into
    Figure 5.10·2. Spark Plug Carrier Removal Tool
    the carrier ID. Tightening the tool locks it in the carrier
    bore and then turns the carrier to free it from the
    cylinder head.

    Figure 5.10-5. Spark Plug Carrier Extractor Tool

    Figure 5.10-3. Spark Plug Carrier Removal Tool

    FORM 6248 First Edilion 5.10 - 3


    IGNITION SYSTEM

    A CAUTION I
    SPARK PLUG CARRIER INSTALLATION - GL
    NOTE: Excessive lubrication of the spark plug carrier
    I..
    L.
    Stainless steel precham-
    ==.....;:;..:....:~..:....:-=-.:....:.J.
    ber seal (PIN 2095620) )
    must be used with the prechamber cup when
    O-rings may cause the spark plug to foul. torquing the spark plug carrier to 275 - 280 ft-Ib (373
    1. Apply Parker Super O-Lube® to two new O-rings - 380 N·m) (with FEL-PRO® C5-A®, Part No. 51005
    and install them to the outside of the spark plug carrier anti-seize compound applied to threads) or dam-
    (see Figure 5.10-6). age to equipment will result.

    4. Fit the bottom notch of the spark plug carrier


    removal tool (PIN 494289 for Non CSA and PIN
    474023 for CSA) into the upper groove of the spark
    SPARK PLUG
    plug carrier and turn clockwise). Torque the spark plug
    / CARRIER carrier to 275 - 280 ft-Ib (373 - 380 N'm) (with
    FEL-PRO® C5-A®, Part No. 51005 anti-seize com-
    pound applied to threads).

    NOTE: Previous torque values for spark plug carriers


    was90-95ft-lb (41 -43N-m) (with FEL-PRO® C5-A®,
    Part No. 51005 anti-seize compound applied to
    threads). A copper prechamber seal (PIN 2095628)
    was used with the prechamber cup.

    SPARK PLUG CARRIER REMOVAL - CSA

    I'":... CAUTION I
    =A= ______ Do not pull on the spark
    plug cables to remove
    --1.
    the spark plug connectors. Pulling on the cable may
    loosen or detach the terminal connection within the )
    Teflon® tube.

    Figure S.10-6.lnstaU Spark Plug Carrier 1. Disconnect the spark plug connector from the coil.

    2. Remove three capscrews, lock washers and coil

    I.=A. CAUTION I
    from the coil adapter.
    Do not apply FEL-PR~®
    L. C5-A® to any holes In
    ='---'=...;;..;;:;....;;.;;...;;;..;;...;;..J. 3. Remove three capscrews, washers and coil adapter
    the spark plug carrier or damage to equipment will from the spark plug carrier.
    result.
    4. Remove spark plug extension from the spark plug
    2. Apply FEL-PRo® C5-A®, Part No. 51005 anti- carrier.
    seize compound to entire O.D.of the threads of the
    spark plug carrier.

    3. Thread the spark plug carrier into the cylinder head


    bore. The spark plug carrier and prechamber cup must
    make metal-to-metal contact.

    A CAUTION I
    I=..
    L.
    Spark plug carrier instal-
    lation without the special
    =......;_-0._ _ _......
    tool may result in damage to the tangs of the spark
    plug carrier.

    5.10 - 4 FORM 6248 First Edition


    IGNITION SYSTEM

    5. Remove the spark plug from the spark plug carrier SPARK PLUG CARRIER INSTALLATION - CSA
    (see Figure 5.10-7).
    A CAUTION 1 ~o not apply FEL-PRO®
    =~=..;...;:;.....;;...;;...;:;...;~.

    D
    1 C5-A® to any holes In

    PLUG/~ ~
    .L .::
    . .
    the spark plug carrier or damage to equipment will
    SPARK resuh.
    CONNECTOR
    1. Apply FEL-PRO® C5-A®, Part No. 51005 anti-
    ~ 1'-'-.' seize compound to entire O.D.of the threads of the
    COIL ii spark plug carrier.
    c:::> -',1

    O-RIN/ [J SPARK PLUG


    EXTENSION
    2. Thread the spark plug carrier into the cylinder head
    bore. The spark plug carrier and prechamber cup must
    make metal-to-metal contact.

    / A CAUTION
    o
    1 1Spark plug carrier instal-
    .. latlon whhout the special
    tool may result In damage to the tangs of the spark
    plug carrier.
    I /SPARK PLUG

    A CAUTION 1 Stainless steel precham-


    , COIL 1 ..
    =
    L. =~..:.....::..;:;...:....::..;:;.~. ber seal (PIN 2095620)

    ~/ADAPTER must be used with the prechamber cup when


    torquing the spark plug carrier to 275 - 280 ft-lb (373
    - 380 N·m) (with FEL-PRO® C5-A®, Part No. 51005
    8-- , anti-seize compound applied to threads) or dam-

    [j ~~
    age to equipment will result.

    3. Fit the bottom notch of the spark plug carrier


    removal tool (PIN 474023 for CSA) into the upper
    ~/CARRIER groove of the spark plug carrier and turn clockwise ).
    Torque the spark plug carrier to 275 - 280 ft-Ib (373 -

    ~~O-RINGS
    380 N·m) (with FEL-PRO® C5-A®, Part No. 51005
    anti-seize compound applied to threads).
    c::>
    NOTE: Previous torque values for spark plug carriers
    was 90 - 95ft-lb (41 - 43 N'm) (with FEL -PRo® C5-A®,
    Figure 5.10-7. CSA Spark Plug
    Part No. 51005 anti-seize compound applied to
    6. Fit the bottom notch of the spark plug carrier threads). A copper prechamber seal (PIN 2095628)
    removal tool (PIN 474023 for CSA) into the upper was used with the prechamber cup.
    groove of the spark plug carrier and remove the spark
    plug carrier.
    A CAUTION 113/16 inch reach sp~rk
    1 ==--.;;;;.;;....;;..;;;...;;...;;.;:;...;~. plugs must be used With
    .
    L..; . .

    13/16 Inch reach carriers. Mixing carrier and spark


    plug components will cause damage to equipment.

    4. Obtain a set of new spark plugs.

    1.
    A CAUTION 1The spark plug gasket
    ==---"_....::._:....::_--'.
    L.. . must be properly seated
    to seal the combustion chamber and transfer heat
    from the plug.
    )
    5. Install the steel gasket on the spark plug. Use only
    new steel gaskets. Verify that the gasket is flat against
    the gasket seat.

    FORM 6248 First Ednion 5.10 - 5


    IGNITION SYSTEM

    6. Install the terminal nut. 10. Apply Dow Corning-4 electrical insulating com-
    pound on boot I.D. Install spark plug extension assem-
    7. Set the spark plug gap to 0.010 - 0.013 inch bly to spark plug.
    (O.254 - 0.330 mm).
    11. Install the coil adapter on the spark plug carrier with
    NOTE: A standard wire gauge should be used for "J" three capscrews and washers.
    type spark plugs.
    12. Install a new gasket on the coil adapter.
    A CAUTION I
    I=.a=~=...:..;::.....::....:..=~.
    L.
    Do not use oil or antl-
    seize compound on the
    13. Install the coil on the coil adapter with new gasket,
    three screws, and lock washers.
    spark plug threads. The spark plug may be overtor-
    qued If oiled. Overtorqulng distorts the spark plug 14. Connect the spark plug connector to the coil.
    and may crack the ceramic construction. Anti-seize
    compound may foul the firing tip, resulting in a plug SPARK PLUG REMOVAL
    shorted to ground.
    1. Detach the spark plug cable from the cable clip
    mounted on the rocker arm cover. Remove the rubber
    A CAUTION I
    I=.a=~=-::-::.....::....:..=~.
    L.
    The presence of oil or
    grease on the ceramic
    insulator of the spark plug can cause flashover.
    boot from the coil terminal connection (see
    Figure 5.10-8 and Figure 5.10-9). Remove the spark
    plug cable from the ignition coil.
    Flashover, a condition where the spark fails to jump
    the gap because of an easier path to ground, resuHs 2. Remove the rubber recess cover from the spark plug
    in misfire. carrier bore.

    A CAUTION I~o
    8. Verifythatthe spark plug is clean. If necessary, use a
    Dielectric solvent to remove any grease or oily finger-
    prints.
    I'":.=.a=----' not pull on the spark
    ;.....----';.....__---'.
    plug cables to remove
    the spark plug connectors. Pulling on the cable may
    loosen or detach the terminal connection within the )
    A CAUTION IIf the spark plug is under
    I.a Teflon® tube. Disregarding this Information could
    tightened, sufficient heat result in product damage and/or personal Injury
    may not be transferred to the water jacket, resulting
    in an overheated plug. overtorqueing can distort 3. Holding onto the Teflon® tube, remove the spark
    the spark plug, stretch the thread area, crack the plug connector from the spark plug terminal nut.
    ceramic construction or increase the point gap,
    resulting in misfire, hard starting and/or poor 4. Refer to Table 1.15-1 and select the proper spark
    engine operation under load. plug tools. Remove the spark plug from the spark plug
    carrier bore.
    9. Torque the spark plug to 40 - 45 ft-Ib (54 - 61 N'm) Table 5 10-1 Spark Plug Tools
    dry.
    TOOLP/N TOOL DESCRIPTION
    Spark Plug Socket/Ext. (1 inch socket with 10
    A CAUTION IBy ml~slng the threaded
    I=.a='---''-'-.;;..;;;....;;...;;....;;;...;;...;..,. 1671640 inch extension. for Shielded, eSA wi F.M. coils)
    L. hoi e In the spa rk plug
    Spa\< Plug Socket (NEW)~nch Socket 15-1/2
    carrier bore, the spark plug gap may be Inadvertent- 475037 inch long wjrubber insert) . ned to fit CM3I"
    ly closed or altered. Exercise caution to avoid siandl'nl and spark and plug extension)
    bumping the electrodes into the spark plug carrier
    counterbore.

    5.10 - 6 FORM 6248 First Edition


    IGNITION SYSTEM

    SPARK PLUG CABLE SPARK PLUG CABLE


    ~ ~CLIP

    ~
    ~CLlP

    ~~
    CABLE CABLE

    " ~ COIL " COIL

    ~BOOT
    TERMINAL
    ,.
    TERMINAL
    BOOT

    I. I
    I
    I I

    RUBBER
    ,IGNITION
    COIL

    RUBBER
    -'_
    ,
    IGNITION
    COIL

    RECESS RECESS
    COVER COVER

    " "
    TEFLON® TEFLON®
    SPARK PLUG SPARK PLUG
    CONNECTOR", CONNECTOR",

    SPARK
    PLUG
    BOOT

    /
    e/ TERMINAL
    NUT
    e/ TERMINAL
    NUT

    STEEL
    GASKET
    STEEL
    GASKET
    0/
    0/
    Figure 5.10-9. Install Spark Plug/Connections PIN
    Figure 5.10-11. Install Spark Plug/Connections 211357H Extension

    ,
    )

    FORM 6248 First EdHion 5.10 - 7


    IGNITION SYSTEM

    Table 5.10-2. Spark Plug Troubleshooting


    FIRING TIP CONDITION REMEDY
    APPEARANCE
    Ught castinR of whitish ash, Normal with medium to high ash lube oils
    uniform y deposited No change; reflects a healthy operating cylinder

    High oil consumption Change engine lube oil type


    Excessive ash build-up
    Wrong lube oil; ash content too high Change engine lube oil type
    Excessive ash build-up Poor oil control around valve guides and piston rings Inspect and replace wom parts as necessary
    Poor oil control around valve guides and piston rings Replace worn parts as necessary
    Black oil fouling depOSits
    Engine 100 lightly loaded Adjust engine load
    Add fuel filter
    Gap bridging Contaminated or "dirty" fuel gas
    Use more "open" electrode type plug
    Spark plug firing tip temperature too low Change plug heat range
    Carbon fouling Engine too lightly loaded Adjust engine load
    High oil consumption Inspect and replace worn parts as necessary
    Electrode burning Spark plug firing tip temperature 100 high Change plug heat range
    Wear on side electrodes Reverse polarity Reverse ignition coil wiring
    Inspect piston crowns with borescope; replace
    worn parts as necessary
    Engine operated with severe detonation resutting in
    Aluminum contamination piston damage Check ignition timing, fuel gas octane
    Reduce engine load
    Oxide of cobalt fouling from burning of Stellite® on
    Bright blue or green deposits valves and seats Replace valves and seats

    NOTE: 1. If any ofJ!1ze above conditions exist, be sure to correct the cause before installing new spark plugs.
    2. "Stellite is a registered trademark of Stoody Deloro Stellite, Inc. n )
    SPARK PLUG INSPECTION
    .-:-------,
    A. CAUTION 11/2 inch reach spark
    1. . plugs must be used with
    Inspect the condition of the spark plugs paying particu-
    lar attention to the firing tip. Spark plugs often yield 1/2 inch reach spark plug carriers. Mixing spark
    visual clues to abnormal conditions existing in the plug carrier and spark plug components will cause
    engine's power cylinders. Your observations also can damage to equipment. Disregarding this informa-
    be used as a guide in establishing the proper service tion could result in product damage and/or person-
    interval. See Table 5.10-2. al injury

    Table 5.10-3.1!2lnch Reach Spark Plugs (Used With l!2lnch Reach Spark Plug Carriers Only)
    SPARK THRB HEX REACH GAP GASKET APPUCATION
    PLUG
    0.020 in
    PiN 60999F 18mm 0.875 1/2 in (0.508 mm) Yes Standard for GIGSI model used wtth: CEC. A~ III, FM9000

    0.020 in
    P/N60999G 18mm 1.000 1/2 In (0.508 mm) Yes GiGSI Provisior for spa1< plug mounted coil. FM9000 - GSA

    18mm 1/2 in 0.020 in Yes


    P/N60999H 0.875 (0.508 mm) GIGSI - Shielded CEC - GSA

    0.010 in Yes
    P/N60999M 18mm 0.875 1/2 in (0.254mm) Standard for GL CEC ignttion

    0.010 in
    PIN 60999N 18mm 1.000 1/2 in (0.254mm) Yes GL Provision for spark plug mounted coil, FM9000 - CSA

    0.010 in
    PIN 60999R 18mm 0.875 1/2 in (0.254 mm) Yes GL ProviSion for spark plug mounted coil, Alt III -CSA

    Spark plug size 18 mm with 1/2 inch reach


    NOTE:' Torque to 40 - 45 ft~b dry (54 - 61 N·m) Use steel gasket PIN 499865.
    ** When a shielded ignition system is used, tighten aIrconnector nuts and spark plug extensions finger tight plus 1/8 to 1/4 tum. Do not
    touch terminal connectors with bare fingers and make sure all paJts are clean before assembling them. AJI knurled connections on
    shielded magnetos and coif should be finger tightened only.

    5.10 - 8 FORM 6248 First Edttion


    IGNITION SYSTEM

    A CAUTION 1~HP GL 13/16 Inch reach


    1 ==-.;;;;.;;....;;.;;:;...;;..;:....::...c~. spark plugs must be
    L..

    used with 13/16 inch reach spark plug carriers.


    Mixing spark plug carrier and spark plug compo-
    nents will cause damage to equipment and/or
    personal injury.
    Table 5 10-4 VHP GL 13/16 Inch Reach Spark Plugs (Used With 13/16 Inch Reach Spark Plug Carriers Only)
    SPARK THRB HEX REACH GAP GASKET APPLICATION
    PLUG
    0.010 in Non-shielded GL (Used with PIN 69694 "Btue Coil")
    P/N60999S 18mm 0.875 13/16 (0.254mm) Yes (4 ground) (nickel)
    0.010 in Non-shielded GLJ.USed with PIN 69694 "Blue Coil")
    P/N60999W 18mm 0.875 13/16 (0.254 mm) Yes (" type) (platinum)
    0.010 in Non-shielded GL (Used with PIN 69694 "Blue Coil")
    PIN 60999T 18mm 0.875 13/16 (0.254mm) Yes ("J" type) Qridium/platinum)
    0.010 in
    PIN 60999U 18mm 0.875 13/16 (0.254 mm) Yes Shielded GL (Used wnh PIN 696940 coil)

    PIN APPLICATION
    13/16 INCH SPARK PLUG CARRIERS 209567M Used on 51 08GL only
    209567K Used on 5790GL and 7042GL
    NOTE: * Torque 10 40 - 45 ft-lb dry (54 - 61 N·m). Use steel gasket PjN 499865.
    .. When a s,hie/dec/ ignition s~m is used, tighten all connector nuts and spark plug extensions finger light plus 1/8 to 1/4 tum. Do not
    touch termInal connectors With bare fingers and make sure all parts are clean before assembling them. All knurled connections on
    shIelded magnelos and coil should be finger tightened only. .
    -Refer to S8 11-2636 for additional GL spark plug information. .

    SPARK PLUG INSTALLATION 5. Set the spark plug gap to 0.010 - 0.013 inch
    (0.254 - 0.330 mm).
    A CAUTION 113/ 16 inch reach sp~rk
    1=
    ..
    =c...::..:;....:..::.....:....;;..;;::;..;~. plugs must be used with
    L..
    NOTE: A Spark Plug Gapping tool (Tool PIN 494421) is
    13/16 inch reach carriers, and 1/2 inch reach spark available to facilitate the gapping of Champion plugs
    plugs must be used with 1/2 Inch reach carriers. with 4 side electrodes. Slide the hollow tip of the tool
    Mixing carrier and spark plug components will over the center electrode and bend the side electrodes
    cause damage to equipment and/or personal injury. to contact the sleeve. A standard wire gauge should be
    used for "J" type spark plugs.
    1. Obtain a set of new spark plugs (see Table 5.10-3
    and Table 5.10-4) verify which size carrier is present
    and use the correct size spark plug, see Caution above A CAUTION 1D~ not use oil or antl-
    1==-...;::..:...:..;::....;:...:....:::....:~. seIZe compound on the
    L.
    and Figure 5.10-1. spark plug threads. The spark plug may be overtor-
    2. Before installing the spark plugs, verify spark plug qued if oiled. distorts the spark plug and may crack
    carrier torque is 275 - 280 ft-Ib (373 - 380 N·m) (with the ceramic construction. Anti-seize compound
    FEL-PRO® CS-A®, Part No. 51005 anti-seize com- may foul the firing tip, resuHing in a plug shorted to
    pound applied to threads). The required torque is ground. Disregarding this information could result
    necessary for proper grounding and maximum heat in product damage and/or personal injury
    transfer.
    A CAUTION 1The presence of oil ~r
    A CAUTION 1The spark plug gasket
    1==-...;;;.:.....:=....;;..;:....::....;;..;:..J. must be properly seated
    L.
    1==---=..:...=-=:....;:..:..:::....:~. grease on the ceramic
    L.

    insulator of the spark plug can cause flashover.


    to seal the combustion chamber and transfer heat Flashover, a condition where the spark fails to jump
    from the plug_ Disregarding this Information could the gap because of an easier path to ground, results
    result In product damage and/or personal InJury in misfire. Disregarding this information could
    resuH in product damage and/or personal injury
    I 3. Install the steel gasket on the spark plug (see
    /
    Figure 5.10-8). Use only new steel gaskets. Verify that 6. Verify that the spark plug is clean. If necessary, use a
    the gasket is flat against the gasket seat. Dielectric solvent to remove any grease or oily finger-
    4. Install the terminal nut. prints.

    FORM 6248 First Ed~ion 5.10 - 9


    IGNITION SYSTEM

    =A CAUTION I
    I.. I! the spark plug.is under 9. Position the spark plug recess cover as shown in
    L... ='--'-_.;;.........;;....::..--'....1. tightened, sufficient heat Figure 5.10-10.
    may not be transferred to the water jacket, resulting
    in an overheated plug. Exceeding the torque value 10. Do not pull the rubber vent cap on the spark plug
    can distort the spark plug, stretch the thread area, recess cover, back too far. If the rubber vent cap is
    crack the ceramic construction or increase the pulled back too far, it will tear off completely.
    pOint gap, resulting in misfire, hard starting and/or
    poor engine operation under load. Disregarding 11. The rubber vent cap is pre-cut at the factory, but
    this information could result in product damage needs to be pulled back initially, to insure proper
    and/or personal injury operation. About half of the rubber vent cap circumfer-
    ence is cut, the remaining half acts as a rubber hinge.
    7. Torque the spark plug to 40 - 45f1-lb (54 - 61 N'm) dry.

    CAUTION IBy mi~sing the threaded


    12. Using your thumb, gently pull the rubber vent cap

    I==--=....:..;::....::....:..:::...;~.
    A
    .L..;. . hole In the spark plug
    carrier bore, the spark plug gap may be inadvertent-
    towards the center hole of the spark plug recess cover
    until the vent hole is exposed (see Figure 5.10-11).

    ly closed or altered. Exercise caution to avoid


    bumping the electrodes into the spark plug carrier
    counterbore. Disregarding this information could RUBBER
    VENT CAP
    result In product damage and/or personal InJury
    NOTE: The rubber boots must be installed on the spark
    plug extensions. These boots prevent flashover from
    the spark plug insulators.
    8. On P/N211357H extensions, apply Dow Corning-4
    Dielectric grease on boot 1.0. Install cable assembly to
    spark plug (see Figure 5.10-9).
    NOTE: The rubber recess cover keeps dirt and debris
    out of the spark plug well and functions as a rain shield
    )
    for those engines that are outside. Any accumulation of
    rain water in the spark plug well can short out the spark
    plug, resulting in a misfire or a stalled engine. Figure 5.10-11. VHP Spark Plug Recess Cover Vent
    Cap
    NOTE: Before installing VHP spark plug recess covers,
    (see Figure 5.10-10), check to be sure that the rubber
    vent caps are opened. If the rubber vent caps are not 13. During normal operation, pressures generated in
    opened, the spark plug recess covers and spark plug the spark plug recess will vent through the vent hole in
    extensions, may pop off the spark plugs, due to the spark plug recess cover. During venting of pressure,
    pressure build up. This condition may cause engine the upper half of the rubber vent cap will pop up, and
    misfire. Proper installation will insure that the spark plug then return to the closed position
    recess covers remain in place, preventing dirt and
    moisture from entering the spark plug recess. The NOTE: Release the upper half of the rubber vent cap.
    following procedure will insure proper installation. the cap should return to the closed position.

    NOTE: If the rubber vent cap is torn off, the spark plug
    recess cover should be replaced, when it is to be used in
    outdoor environments.

    14. Attach the spark plug cable to the ignition coil. Make
    sure that the cable terminal connection bottoms out in
    the coil contact well. Fit the rubber boot over the coil
    terminal connection. On PIN 211357H extensions,
    insure the rubber boot is fitted over the upper end of the
    spark plug extension. Secure the cable by snapping it
    into the cable clip mounted on the rocker arm cover.

    Figure 5.10-10. VHP Spark Plug Recess Cover

    5.10 -10 FORM 6248 Firs! Ed~ion


    IGNITION SYSTEM

    SPARK PLUG EXTENSION REPAIR connector. Remove the spark plug cable from the
    connector, if attached.

    I LIt. CAUTION IPulling on the spark plug NOTE: To install a new spark plug cable, peel back the
    .L .:
    . =:........;=...;;.;;;....::....:;...;;;...;~.
    . cable may loosen or de-
    tach the cable terminal connection within the insulation on one end 5/16 inch (7.9 mm). Remove any
    Teflon® flashover protector tube. Disregarding this
    excess material. Twist the ends of the wires together to
    information could result In product damage and/or
    form a tight prong. Slide the Teflon® sealing plug on the
    personal injury spark plug cable.

    To repair a loosened or detached terminal connection or 4. Insert the stripped end of the cable into the top of the
    to install a new spark plug cable, proceed as follows: spark plug connector tube (see Figure 5.10-12). Slide
    the wire prong through the hole in the center of the tube
    1. Move the rubber recess cover about half way down insert. Verify that all wires can be seen on the spark plug
    the spark plug connector tube (see Figure 5.10-12). side of the connector tube.

    5. With a firm grip on the cable, thread the terminal

    SPARK PLUGJlGNmON
    COIL CABLE
    /0 screw into the tube insert using a 3/8 inch (10 mm) deep
    well socket or a #2 x 4 inch Phillips screwdriver.

    6. Seat the Teflon® sealing plug in the recess at the top


    of the connector tube. Verify that the plug is tight.

    7. Exert several pounds of pulling force on the cable to


    verify that the wire is locked in place.
    PLUG
    8. Move the rubber recess cover to tAe top of the spark
    plug connector tube. Attach the connector to the spark
    plug. The spark plug connector should snap onto the
    terminal nut. A good friction fit is required. Replace the
    TEFLON® SPARK PLUG
    CONNECTOR TUBE", spark plug connector if the condition of the terminal nut
    connection socket results in a loose fit.

    9. F~ the rubber recess cover into the top of the spark plug
    carrier. Replace the recess cover if damaged or missing.

    NOTE: The rubber recess cover keeps dirt and debris


    out of the spark plug well and functions as a rain shield
    for those engines that are outside. Any accumulation of
    rain water in the spark plug well can short out the spark
    plug, resulting in a misfire or a stalled engine.

    10. Attach the spark plug cable to the ignition coil. Make
    sure that the cable terminal connection bottoms out in the
    coil contact well. Fit the rubber boot over the coil terminal
    WIRE
    PRONG connection. Secure the cable by snapping it into the
    cable clip attached to the rocker arm cover capscrew.
    TERMINAL
    SCREW~a
    TERMINAL NUT ___
    CONNECTION SOCKET

    Figure 5.10-12. Spark Plug Connector Tube

    2. Remove the sealing plug from the end of the


    connector tube and slide it about 9 inches (229 mm)
    down the spark plug cable.

    3. Using a 3/8 inch (10 mm) deep well socket, remove


    the terminal screw from the spark plug side of the

    FORM 6248 First Edition 5.10-11


    IGNITION SYSTEM

    IGNITION COILS
    )
    Inspect and test the ignition coils once each year.

    1. Detach the spark plug cable from the cable clip


    mounted on the rocker arm cover. Remove the rubber
    boot from the coil terminal connection. Remove the
    spark plug cable from the ignition coil.

    2. Remove the ignition coils from the mounting brack-


    ets attached to the upper intake manifold flanges (2
    capscrews per bracket, 5/16 x 5/8 inch, with shakeproof
    washers and hex nuts) (see Figure 5.10-13).

    3. Remove all oil, grease and dirt from the ignition coils.
    Pay particular attention to the area around the primary
    terminals.
    TRIANGULAR SHAPED
    BRACKET
    4. Carefully inspect the ignition coils for cracks or other
    obvious damage. Replace as necessary.
    o
    5. Thoroughly clean the ignition coil contacts. Use a
    soft brass wire brush if corrosion or an accumulation of
    dirt is present. Inspect the contacts for damage.

    6. Check the ignition coils with reliable test equipment.


    Replace the coil if its serviceability is in doubt.

    9"RAlL

    10-1/8" RAIL

    Figure S.1o-13.lgnition Coli Brackets

    5.10 -12 FORM 6248 Rrst Edition


    IGNITION SYSTEM

    CAUTION I
    I A=......;;;.;;...~_.:....::_--'.
    Do. not mix long duration 8. Use a 3/8 inch socket to attach the wire harness
    L.
    • .:
    .. cOils (red) and standard leads to the ignition coil. The lead with the yellow collar
    Ignition coils (blue). Substitute the standard igni- is negative (-), the lead with the blue collar is positive
    tion coils for the long duration colis in complete (+). To find the location of the negative and positive
    sets only. Disregarding this Information could terminals on the coil, look for the stamp on the side of the
    result in product damage and/or personal injury. bottom lip (see Figure 5.10-16). A tag on each positive
    lead identifies the cylinder to which the leads are to be
    7. Fasten the ignition coils to the mounting brackets (2 attached.
    capscrews per bracket, 5/16 x 5/8 inch, with shakeproof
    washers and hex nuts) (see Figure 5.10-14 and
    Figure 5.10-15). Check each coil and bracket for
    mounting security.

    ;---~:-----------~+.-~

    Figure 5.10-14. Prechamber Manifold Bracket- Figure 5.10-16. Call (PIN 69694, Blue Call)
    Front Left

    IA
    ..
    CAUTION I Do not reverse the polar-
    ity of the ignition colis.
    The spark plugs will not fire and fouling or missing
    will occur. Disregarding this information could
    result in product damage and/or personal injury.

    9. Verify that the wiring to each ignition coil is properly


    installed.

    10. To help seal out moisture and prevent corrosion,


    Dow Corning-4 Dielectric grease on the high tension
    connectors between the coils and the spark plug
    connectors.

    Figure 5.10-15. Ignition Call Brackets

    FORM 6248 First Ed~ion 5.10 -13


    IGNITION SYSTEM

    IA
    ..
    CAUTION I A poor common ground
    for the Ignition coils can
    WIRING HARNESS
    )
    cause misfiring. Disregarding this information WIRING HARNESS REMOVAL
    could result in product damage and/or personal Replace the ignition wiring harness once each year. If
    injury. the engine is installed indoors, this time frame may be
    extended provided that no defects are found after a
    11. Verify that the four ground wires leading from the careful examination.
    #1 L. #6L, #1 Rand #6R negative coil leads are properly
    grounded to the coil mounting bracket capscrews (see NOTE: GEG ignition is now standard. This task refer-
    ences both GEG and magneto systems.
    Figure 5.10-17).
    1. Verify that the ignition switch is turned to the "OFF"
    position.

    A WARNING
    Ifthe ignition switch is left in the ON position when a
    CEC ignition module is disconnected, then the
    spark plugs may fire when the ignition system
    harness Is reconnected, and could cause severe
    personal injury or death.

    A WARNING
    If the "G" lead is not grounded, the magneto
    remains "hot," which means that the capacitor(s)
    will have a stored voltage. Depending upon where
    the voltage is released during assembly, and )
    whether the engine has been purged of unburned
    gas, the risk of personal injury or death exists in the
    Figure 5.10-17. Triangular Ignition Coil Bracket form of electrical shock, unexpected rotation of the
    crankshaft and/or an exhaust gas explosion.
    12. Inspect the condition of the spark plug cable. Before connecting the ignition harness (to the coils) to
    Obtain a new spark plug connector assembly if the the CEC ignition module, discharge the storage capaci-
    cable is damaged. tor to ground. Attach one end of a wire lead to the
    crankcase and then touch the other end to the harness
    13. Attach the spark plug cable to the ignition coil. Make connector pins on the CEC, one at a time. A snap is
    sure that the cable terminal connection bottoms out in heard when a capacitor discharges.
    the coil contact well. Fit the rubber boot over the coil
    terminal connection. Secure the cable by snapping it
    into the cable clip attached to the rocker arm cover
    A WARNING
    capscrew. As a safety measure, ground all the pins. Some
    breakerless Ignition systems have more than one
    storage capacitor. Severe personal injury or death
    could result.
    NOTE: If the ignition switch is in the OFF position, the
    capacitor is immediately grounded when the ignition
    harness is reconnected to the GEG ignition module.

    2. Detach the wire harness "G" lead from the #9


    terminal on the terminal block in the junction box. Note
    the location and mark wire prior to removal.

    3. Loosen the sleeve and detach the ignition wiring


    harness from the mag pin connector.

    4. Use a 3/8 inch socket to remove the wire harness


    leads from the ignition coils.

    5.10 -14 FORM 6248 First Edition


    IGNITION SYSTEM

    5. Remove the four ground wires leading from the #1 L, 6. Remove the lower intake manifold flange capscrews
    #6L, #1 Rand #6R negative coil leads from the coil to detach the wire harness cable retaining clips (see
    mounting bracket capscrews (see Figure 5.10-17 and Figure 5.10-19).
    Figure 5.10-18).

    5R

    4R
    +
    "
    GROUND
    TO COIL
    BRACKET

    RIGHT 3R
    BANK

    2R Figure 5.10-19. Harness Cable Clip - Front Right

    7. Remove the ignition wiring harness from the engine.

    flO 8. Spread out the harness on a clean flat surface.

    L __ \R
    PIN CONNECTOR PLUG
    (TO CEC OR MAGNETO) \
    WIRING HARNESS INSPECTION

    1. Inspect the wiring harness for burned, chafed, frayed


    or cracked insulation. Look for cracks, cuts, tears, oil
    contamination or any other damage that can cause a
    short to ground.
    GROUND TO
    COIL BRACKET
    1---- 2. Inspect the harness for pinched, broken or frayed
    I lL
    ~:;;iIIi~
    I wires.

    3. Look for loose, damaged or corroded ignition coil


    contacts. Use a soft brass wire brush if corrosion or an
    2L
    accumulation of dirt is present.

    4. Check the condition and security of the harness


    3L 3 +
    cable plug and receptacle connection.

    LEFT 5. Replace the harness if damaged or deteriorated.


    BANK

    4L
    6. If the wiring harness can be reused, verify that all
    wire exits and sleeve junctions are securely taped to
    keep out moisture and dirt. Thoroughly seal or plug all
    wire exits with Dow Corning RlV #734 or equivalent.
    5L +
    GROUND
    TO COIL

    )
    L ---- ~~I::+~~7CKET
    6L

    Figure 5.10-18. Wire Harness Assembly

    FORM 6248 Firs! Edition 5.10-15


    IGNITION SYSTEM

    WIRING HARNESS INSTALLATION NOTE: If the ignition switch is in the OFF position, the
    capacitor is immediately grounded when the ignition )
    NOTE: GEG ignition is now standard. This task refer- harness is reconnected to the GEG ignition module.
    ences both GEG and magneto systems.
    1. Verify that the ignition switch is turned to the "OFF"
    A WARNING position.

    Ifthe Ignition switch is left in the ON position when a


    CEC Ignition module is disconnected, then the A WARNING
    spark plugs may fire when the ignition system If the "G" lead is not grounded, the magneto
    harness is reconnected, and could cause severe remains "hot," which means that the capacitor(s)
    personal Injury or death. will have a stored voltage. Depending upon where
    Before connecting the ignition harness (to the coils) to the voltage is released during assembly, and
    the GEG ignition module, discharge the storage capaci- whether the engine has been purged of unburned
    tor to ground. Attach one end of a wire lead to the gas, the risk of personal injury or death exists in the
    crankcase and then touch the other end to the harness form of electrical shock, unexpected rotation of the
    connector pins on the GEG, one at a time. A snap is crankshaft and/or an exhaust gas explosion.
    heard when a capacitor discharges.
    2. Move to the rear right side of the engine and lay the
    end of the ignition wiring harness over the lube oil
    A WARNING strainer adapter. The right bank section of the harness
    As a safety measure, ground all the pins. Some can be distinguished from the left by the pin connector
    breakerless ignition systems have more than one plug (for hook up to the GEG or magneto) and the long
    storage capacitor. Severe personal injury or death "G" lead (see Figure 5.10-18 and Figure 5.10-20).
    could result.

    5.10 -16 FORM 6248 First Edition


    IGNITION SYSTEM

    LEFT BANK GROUND TO COIL


    B N F R D L MOUNTING BRACKET
    4 PLACES

    SWITCH"S" WIRE MUST BE


    ATTACHED BETWEEN
    THE NEGATIVE
    TERMINALS OF THE
    SWITCH "A" #1 COILS ON BOTH
    ENGINE BANKS

    K C P E M J A
    RIGHT BANK

    * SWITCH - 10 AMP MIN.'


    r _______ ~STOM~UPPLIED)
    J
    DC POWER
    JUNCnONBOX

    - - -
    I 24 VDC NOMINAL
    POWER SOURCE
    ---JL ____________ -o MIN. WIRE SIZE 14AWG

    -~~~~====:[P~) ~~ HALL-EFFE
    PICKUP
    • MAGNETS

    1£ CAUTION 1
    1. All wires Including "ground" wires muS1 be PIN CONNECTORS' A B C D E F K L M N P R
    connected to the specific coils as shown.
    2. The ground wires should be connected between CYLINDERS 1 6 5 2 3 4 6 1 2 5 4 3
    the negative terminal of the coli and one of the coli R L R L R L R L R L R L
    bracket mounting capscrews.
    3. Ignition wires muS1 not be bundled together with NOTE:' G = Shutdown - J = Ground
    product protsctlon syS1em wiring. The left bank
    Ignition wiring must be routed around the front of
    the engine.

    * IF SWITCH IS LEFT CLOSED WITH THE


    ENGINE SHUTDOWN, THE IGNmON UNIT WILL
    DRAIN ABOUT 0.1 AMP FROM POWER SOURCE.
    I
    /
    Figure 5.10-20. Electronic Ignition System Diagram

    FORM 6248 Firs! EdHion 5.10-17


    IGNITION SYSTEM

    A WARNING
    Do not attach the harness pin connector plug to the
    magneto. Rapid rotation of the crankshaft will
    generate an electrical charge at the coil connec-
    tions, which may result in electrical shock and/or
    personal injury or death.
    3. Moving towards the front of the engine, Position the
    cable over the prechamber manifold cross pipe tee,
    placing the harness pin connector plug and "G" lead
    near the top of the magneto drive assembly (see
    Figure 5.10-21 and Figure 5.10-22).

    Figure 5.10-22. Wire Harness - Front Right

    4. Laying the cable behind the right and left bank lifting
    eyes, draw the free end of the harness around the front
    ofthe engine over to the left bank side (below the level of
    the intake manifold).

    5. Attach the cable retaining clips to the wiring harness.


    Since the diameter ofthe harness varies, eight light clips
    (0.032 inch gauge, 3/8 inch clamping diameter) and 5
    heavy clips are used (0.048 inch gauge, 7/16 inch )
    clamping diameter) (see Figure 5.10-23).

    Figure 5.10-21. Wire Harness - Right Bank -


    Carburetor And Intake Manifold Removed For Clarity
    LEFT BANK
    1L 2L 3L 4L 5L 6L

    REAR

    HEAVY CLIPS LIGHT CLIPS


    (0.048" GAUGE) (0.032" GAUGE)

    RIGHT BANK
    6R 5R 4R 3R 2R lR

    REAR FRONT

    LIGHT CLIPS HEAVY CLIPS


    (0.032" GAUGE) (0.048" GAUGE)

    Figure 5.10-23. Wire Harness Cable Clip Locations

    5.10-18 FORM 6248 First Edrtion


    IGNITION SYSTEM

    6. Attach the harness cable clips to the lower intake terminals on the coil, look for the stamp on the side ofthe
    manifold flange capscrews (see Figure 5.10-23 and bottom lip. A tag on each positive lead identifies the
    Figure 5.10-24). cylinder to which the leads are to be attached.

    9. Attach the four ground wires leading from the #1 L,


    ~\GAUGE #6L, #1 Rand #SR negative coil leads to one of the coil
    n mounting bracket capscrews (see Figure 5.10-26).
    II
    II
    II
    II
    II
    --,d)
    -
    CLAMPING DIAMETER

    Figure 5.10-24. Retaining Clip

    NOTE: The shorter intake manifold flange capscrews


    (1/2x 1-3/4 inches) are used with the light gauge clips.
    Use the longer capscrews (1/2 x 2 inches) wherever the
    heavy gauge hamess cable clips are mounted (see
    Figure 5. 10-23). Figure 5.10-26. Triangular Ignition Coli Brackat

    7. Attach two heavy gauge cable clips (0.048 inch 10. Install the harness cable plug on the magneto pin
    gauge, 1/2 inch clamping diameter) to the wiring connector. The notch in the connector mates with a
    harness where it straddles the vee. Secure the clips to groove in the plug to prevent improper installation.
    the two 3-1/4 inch support braces fastened to the lifting
    11. Tie wrap the magneto pin connector cable into a
    eye mounting pads at the front ofthe block (1 capscrew
    permanent drip loop (see Figure 5.10-27). The drip loop
    per clip, 1/2 xl- 1/4 inches, with lock washer and hex
    prevents moisture or rain from entering the magneto.
    nut) (see Figure 5.10-25).

    TIE WRAP
    Figure 5.111-25. Attaching Cable Clip Support Braces
    CABLE
    ) DRIP LOOP
    8. Use a 3/8 inch socket to attach the wire harness
    leads to the ignition coil. The lead with the yellow collar
    is negative (-), the lead with the blue collar is positive (+) Figure 5.10-27. Magnato Pin Connector Cable
    To find the location of the negative and positive

    FORM 6248 First Edition 5.10 - 19


    IGNITION SYSTEM

    CEC IGNITION MODULE CEC IGNITION MODULE INSTALLATION

    CEC IGNITION MODULE REMOVAL 1. Verify that the ignition switch is turned to the "OFF"
    position.
    1. Verify that the ignition switch is turned to the "OFF"
    position.
    A WARNING
    A WARNING Ifthe ignition switch is left In the ON position when a
    CEC ignition module Is disconnected, then the
    Hthe ignition switch is left in the ON position when a spark plugs may fire when the ignition system
    CEC ignition module is disconnected, then the harness Is reconnected, and could cause severe
    spark plugs may fire when the Ignition system personal injury or death.
    harness is reconnected, and could cause severe
    personal injury or death. . Before connecting the ignition harness (to the coils) to
    the CEC ignition module, discharge the storage capaci-
    NOTE: If the ignition switch is in the OFF position, the tor to ground. Attach one end of a wire lead to the
    capacitor is immediately grounded when the ignition crankcase and then touch the other end to the harness
    harness is reconnected to the GEG ignition module. connector pins on the CEC, one at a time. A snap is
    heard when a capacitor discharges.
    1. Disconnect the wiring harnesses from the ignition
    module (see Figure 5.10-20 and Figure 5.10-28).
    A WARNING
    As a safety measure, ground all the pins. Some
    breakerless ignition systems have more than one
    storage capacitor. Severe personal Injury or death
    could result.
    NOTE: If the ignition switch is in the OFF position, the
    capacitor is immediately grounded when the ignition
    harness is reconnected to the GEG ignition module.

    1. I nstall the mounting brackets to the crankcase and


    gear cover.

    2. Install the ignition module to the mounting brackets


    with four screws, lock nuts, and rubber mounts (see
    Figure 5.10-29).

    Figure 5.10-2B.lgnition Module 3. Connect the ground wire from the ignition module.
    2. Disconnect the ground wire from the ignition module. 4. Connect the wiring harnesses to the ignition module
    (see Figure 5.10-20 and Figure 5.10-30).
    3. Remove four screws, lock nuts, rubber mounts, and
    the ignition module from the mounting bracket (see
    Figure 5.10-29).

    Figure 5.10-29. Mounting Brackets

    4. Remove the mounting bracket from the gear cover. Figure 5.10-30. Ignition Module

    5.10 - 20 FORM 6248 First Edition


    IGNITION SYSTEM

    GOVERNOR DRIVE GEAR/CEC 4. Refer to Governor Drive Shaft, Removal and remove
    TIMING DISC (CURRENT PRODUCTION) the governor drive shaft from the governor drive
    housing (see Figure 5.10-33).
    GOVERNOR DRIVE GEAR/CEC TIMING DISC
    REMOVAL (CURRENT PRODUCTION)

    NOTE: Magneto equipped engines will not have a GEG


    disc.
    1. Place a small oil pan beneath the governor drive
    housing and remove the governor drive cover plate (4
    capscrews, 3/8 x 3/4 inch, with lock washers; 10
    capscrews, 3/8 x 1 inch, with lock washers) and gasket
    (see Figure 5.10-31).

    Figure 5.10-33. Current Production CEC TIming Disc

    5. Remove flex nut and governor drive gear assembly


    from the accessory drive gear shaft (see
    Figure 5.10-34). Use a rubber mallet. to loosen the drive
    gear assembly, if necessary. Move'the assembly to a
    suitable workbench.

    Figure 5.10-31. Governor Drive Housing

    2. Remove the GEG Hall-effect Pickup from the


    Governor Drive Housing (see Figure 5.10-32)

    Figure 5.10-34. Current Production Governor Drive


    Gear

    GOVERNOR DRIVE GEAR/CEC TIMING DISC


    CLEANING AND INSPECTION
    Figure 5.10-32_ Hall-effect Pickup
    (CURRENT PRODUCTION)

    3. On GEG equipped engines, remove the four nylok 1. Using a soft cloth, remove all dirt, grime, grease and
    allen head screws, washers and the GEG timing disc oil deposits, from the gear and GEG disc.
    (see Figure 5.10-33). Discard the nylok allen head
    2. Inspect the gear teeth for chips, cracks and exces-
    screws.
    sive wear. Replace the governor drive gear if necessary.

    FORM 6248 First Ed~ion 5.10-21


    IGNITION SYSTEM

    GOVERNOR DRIVE GEAR/CEC TIMING DISC To determine when this condition exists, watch the rocker
    INSTALLATION (CURRENT PRODUCTION) arms and valves on its mating cylinder, #6R. As the
    exhaust valves on #6R cylinder are closing, the intake
    NOTE: If the engine is GEG equipped, perform Steps 1 valves begin to open. At this point, the #6R cylinder is in
    thru 16. If not GEG equipped, perform Steps 1 thru 3 and valve overlap (all four valves partially open). This means
    Steps 14 thru 16. that all four valves on the #1 R cylinder are fully closed.
    1. Install the No. 8 Woodruff key in the slot on the The cylinder is now at top dead center (compression
    accessory drive gear shaft, if removed. Lightly tap the stroke).
    key to properly seat it in the keyway. Verify that the key is NOTE: Timing marks on the flywheel timing tape
    level. should be visible through the timing opening located in
    the flywheel housing when approaching top dead center
    2. Position the notch in governor drive gear assembly
    (TDG) of the first firing cylinder on the compression
    with the key on the shaft. Install the governor drive gear
    stroke (see Figure 5.10-36).
    assembly onto the accessory drive gear shaft with flex
    lock nut (see Figure 5.10-34).

    3. Refer to Governor Drive Shaft, Installation, and


    install the governor drive shaft on the governor drive
    housing (see Figure 5.10-35).

    )
    Figure 5.10-36. Flywheel Timing Opening

    8. Bar the engine over in the direction opposite normal


    engine rotation to a pOint at least 30° prior to the point of
    desired timing.

    9. Slowly bar the engine in the direction of normal


    engine rotation, carefully observing the flywheel timing
    Figure 5.10-35. Current Production Timing Tool tape and pointer. Stop rotating the flywheel exactly at
    the correct timing desired.
    NOTE: Insure that the directional arrow and the
    A CAUTION I
    stamped word "ROTATION" on the face of the GEG
    timing disc are positioned towards the front of the I=....
    L.
    By rotating the crank-
    =~:..:;...;;...;;;....;;;...;:...=-.::...:...J.
    shaft too fast and then
    engine, so they are visible. backing up to the desired timing, the disc drive gear
    backlash will be on the wrong side olthe gear teeth.
    4. Loosely install the CEC timing disc on the governor The timing could therefore be incorrect by several
    drive gear with four new nylok allen head screws, and degrees. Disregarding this information could result
    washers (see Figure 5.10-35). In product damage and/or personal Injury.
    5. Locate the first cylinder to fire in the firing order
    sequence. Refer to the engine's nameplate for firing
    order sequence.

    6. Check the engine's nameplate to determine the


    exact timing (or most advanced) for the primary fuel.

    7. Bar the engine crankshaft over in a counter-clock-


    wise direction until the valves of the first cylinder in the
    firing order, which is the #1 R cylinder, are at top dead
    center (compression stroke).

    5.10-22 FORM 6248 First Ednion


    IGNITION SYSTEM

    10. Thread the timing disc alignment tool into the


    magneto housing (see Figure 5.10-37).
    IA
    ...
    CAUTION I DO NOT turn on the fuel
    until the ignition timing
    is verified to be at an acceptable setting, to prevent
    TIMING DISC possible engine damage. Use a timing IIghtto check
    ALIGNMENT TOOL
    the ignition timing while the engine is cranking in a
    TIMING DISC /
    REFERENCE POINT NO-FUEL state. Disregarding this Information

    ~e=O:::::::::"
    could result in product damage and/or personal
    injury.
    ...-----;l........u 0

    :@;
    14. Apply a fast setting contact-type gasket shellac,
    such as 3M Weather Strip Cement, Permatex® High-
    © Tac or equivalent, on the gasket surfaces of the
    governor drive cover plate. Install a new governor drive

    o~
    cover gasket.

    NOTE: During Step 15, the governor drive cover must

    ~\
    first be installed on the ball bearing retainer, four
    NVLOKALLEN HEAD capscrews and lock washers To prevent the gaskets
    SCREW AND WASHER TIMING DISC from sliding during installation of the governor drive
    Figure 5.10-37. Current Production CEC Timing Disc assembly, allow the gasket shellac to cure. Follow the
    manufacturer's recommendations.
    11. Loosen the allen head screws, and rotate the timing
    disc so the timing disc reference point aligns with the 15. With the WED partnumberfacing outside, install
    point of the alignment tool. the governor drive cover to the ball bearing retainer
    (4 capscrews, 3/8 x 3/4 inch, with lock washers) (see
    12. Once aligned, torque the nylok allen head screws
    Figure 5.00-21). Install the remaining fasteners (10
    on the timing disc to 43 - 45 in-Ib (4.86 - 5.08 N·m).
    capscrews, 3/8 x 1 inch, with lock washers) (see
    13. Remove the alignment tool and install the Figure 5.10-31).
    Hall-effect Pickup sensor, Set the gap between the
    16. On CEC equipped models, refer to eEe Ignition
    pickup and the timing disc to 0.040 in. ±0.010 in.
    Module Timing Set (Current Production) and set engine
    (1.016 mm ±0.254 mm) (see Figure 5.10-38).
    timing. On Magneto equipped models, refer to Magneto
    Static Timing Set, and Magneto Ignition Timing Set, and
    set engine timing.

    CEC IGNITION MODULE STATIC TIMING SET


    (CURRENT PRODUCTION)
    1. Locate the first cylinder to fire in the firing order
    sequence. Refer to the engine's nameplate for firing
    order sequence.

    2. Check the engine's nameplate to determine the


    exact timing (or most advanced) for the primary fuel.

    3. Bar the engine crankshaft over in a counter-clock-


    wise direction until the valves of the first cylinder in the
    firing order, which is the #1 R cylinder, are at top dead
    center (compression stroke).
    Figure 5.10-38. Current Production CEC TIming Disc To determine when this condition exists, watch the rocker
    arms and valves on its mating cylinder, #6R. As the
    exhaust valves on #6R cylinder are closing, the intake
    valves begin to open. At this point, the #6R cylinder is in
    valve overlap (all four valves partially open). This means
    ) that all four valves on the #1 R cylinder are fully closed.
    The cylinder is now at top dead center (compression
    stroke).

    FORM 6248 First Edition 5.10 - 23


    IGNITION SYSTEM

    NOTE: Timing marks on the flywheel timing tape 8. Thread the timing disc alignment tool into the
    should be visible through the timing opening located in magneto housing (see Figure 5.10-40 and
    the flywheel housing when approaching top dead center Figure 5.10-41).
    (TDC) of the first firing cylinder on the compression
    stroke (see Figure 5.10-39).

    Figure 5.10-40. Current Production TIming Tool


    Figure 5.10-39. Flywheel Timing Opening

    4. Bar the engine over in the direction opposite normal TIMING DISC
    ALIGNMENT TOOL
    engine rotation to a point at least 30' prior to the point of
    TIMING DISC /
    desired timing. REFERENCE POINT

    5. Slowly bar the engine in the direction of normal


    engine rotation, carefully observing the flywheel timing
    tape and pointer. Stop rotating the flywheel exactly at
    o~O )

    the correct timing desired.


    ~ ~
    I.A. CAUTION Itoo
    By rotating the crankshaft © ~@cf
    o~
    fast and then backing
    up to the desired timing, the disc drive gear backlash
    will be on the wrong side of the gear teeth. The timing
    could therefore be incorrect by several degrees.
    Disregarding this information could result in prod- NYLOKALLEN HEAD
    SCREW AND WASHER
    ~\ TIMING DISC
    uct damage and/or personal injury.
    Figure 5.10-41. Current Production CEC Timing Disc
    6. Remcve the magneto adaptor housing cover.

    7. Remove the Hall-eIIect Pickup sensor from the 9. Loosen the allen head screws, and rotate the timing
    magneto housing. disc so the timing disc reference point aligns with the
    point of the alignment tool.
    NOTE: If you are replacing the timing disc, remove the
    old timing disc and replace it with a new one. 10. Once aligned, tighten the allen head screws on the
    timing disc to 43 - 45 in-Ib (4.86 - 5.08 N·m).

    11. Remove the alignment tool and install the Hail-ef-


    fect Pickup sensor as explained in the next section,
    "Setting the Air Gap Specification."

    12. Refer to CEC Ignition Module Ignition Timing


    (Current Production) Set, and set engine timing.

    5.10-24 FORM 6248 Firsl Edilion


    IGNITION SYSTEM

    SETTING THE AIR GAP SPECIFICATION CEC IGNITION MODULE TIMING SET
    (CURRENT AND PREVIOUS PRODUCTION) (CURRENT PRODUCTION)
    The correct air gap specification for the Hall-effect The ignition module has two 16-position timing switches
    Pickup sensor is 0.040 in. ± 0.01 0 in. (1.016 mm ± 0.254 located under white plastic caps at one end of the box, one
    mm) (see Figure 5.10-42). Follow the steps below to set marked "A" and another marked "9" (see Figure 5.10-43).
    the air gap specification between the Hall-effect Pickup Grounding lead "0" in the 7-pin connector to the engine
    sensor and timing disc. crankcase gives the timing selected by switch A Open-cir-
    cuiting lead "0" gives the timing selected by switch "9". This
    feature gives the engine operator the ability to switch
    between two different timing settings to accommodate
    automatic changeover between two fuels.

    CEC
    ROTARY

    Figure 5.10-42. Current Production CEC Timing Disc


    NOTE: Timing selection is made by the dot on the switch,
    not the screwdriver slot.
    1. Remove the magneto adaptor housing cover.
    Figure 5.10-43. CEC IgnHion Module Timing SwHches
    2. Using a feeler gauge (see Figure 5.10-42), thread Each timing adjust switch has 16 switch positions (0 - 15)
    the Hall-effect Pickup sensor into the magneto housing with a 10 timing variation per position. SwiIch position 15
    until it comes in contact with the feeler gauge. gives the most advanced timing, while switch position 0 is
    full retard. A 60 overlap between timing adjust switch "A"
    3. Thread the Hall-effect Pickup sensor as necessary and timing adjust switch "9" gives the ignition module a
    to set the air gap specification of 0.040 in. ±0.010 in. combined timing range of 25.
    (1.016 mm ±0.254 mm) (see Figure 5.10-42).

    4. Once the air gap is set, tighten the locking nut


    against the magneto adaptor housing. I:A=~=..:..;:::....::...:..;::...:~.
    L..
    : .
    CAUTION I~o not switch !"om posi-
    tlon 15 to pOSition 0, or
    from position 0 to 15 while the engine is running.
    5. Remove the feeler gauge after locking nut is The timing change Is so large that It may damaga
    tightened. the engine and/or cause it to shut down. Disregard-
    ing this information could result in product damage
    6. Replace the magneto housing cover. and/or personal injury.
    The initial ignition timing is established by the location of
    the Hall-effect Pickup sensor and the location of the
    magnets on the rotating disc. Final ignition timing is set
    with switch "9" on the ignition module with engine running.
    Table 5.1 Q-5 lists the ignition module firing order.
    NOTE: The outside temperature of ignition module
    casing should not exceed 1500 F (650 C) in operation.
    Table 5.10-5. Waukesha Ignition Module Firing Order
    PIN
    ) CONNECTORS· A B C D E F K L M N P R
    1 6 5 2 3 4 6 1 2 5 4 3
    CYLINDERS R L R L R L R L R L R L
    NOTE: • G=Shuldown - J=Grounc!

    FORM 6248 First Ednion 5.10-25


    IGNITION SYSTEM

    STEPS REQUIRED TO ADJUST CEC IGNITION NOTE: Increasing the timing switch position by one will
    MODULE TIMING (CURRENT PRODUCTION) advance the timing one degree. Decreasing the timing )
    switch position by one will retard the timing one degree.
    1. Set both timing switches on the side of the CEC

    CAUTION I
    ignition module to 10 (see Figure 5.10-43).
    To prev~nt the timing
    2. Check the engine's nameplate to determine the I.=A=:......:;=..;;":;;;.,.,,;~;::,,,,:~.
    L. . from being altered, al-
    exact timing (or most advanced) of the primary and ways replace the white caps over the timing
    secondary (if equipped) fuels. switches once the desired setting has been
    selected. Disregarding this Information could re-
    3. Run the engine on primary fuel with the "D" lead sult in product damage and/or personal InJury.
    (found in the 7 pin connector from box) grounded to the
    engine block and the detonation sensing module
    deactivated. A WARNING
    NOTE: VHP gas engines are to be run with no load on If a gas engine has been cranked excessively
    fuels other than natural gas fuel. With natural gas fuel, without starting, shut off the gas fuel supply and
    the engines may be run at any load. ignition, and then crank the engine to purge the
    cylinders and exhaust system of accumulated
    4. Check engine timing at the flywheel using a timing unburned gas. If this is not done a spark could
    light (see Figure 5.10-44). Ignite the gas and cause an exhaust explosion.
    Failure to comply could cause severe personal
    Injury or death.

    A WARNING
    If the Ignition switch Is left In the ON position when a
    CEC Ignition module is disconnected, then the )
    spark plugs may fire when the ignition system
    harness is reconnected, and could cause severe
    personal injury or death.

    Before connecting the ignition harness (to the coils) to


    the CEC ignition module, discharge the storage capaci-
    tor to ground. Attach one end of a wire lead to the
    crankcase and then touch the other end to the harness
    Figure 5.10-44. Flywheel Timing Opening connector pins on the CEC, one at a time. A snap is
    heard when a capacitor discharges.
    5. Adjust the "A" switch as required to achieve correct
    timing. Single fuel ignition adjustments are now com-
    plete.
    A WARNING
    As a safety measure, ground all the pins. Some
    NOTE: Increasing the timing switch position by one will breakerless ignition systems have more than one
    advance the timing one degree. Decreasing the timing storage capacitor. Severe personal injury or death
    switch position by one will retard the timing one degree. could result.

    6. Run the engine on secondary fuel with the "D" lead NOTE: If the ignition switch is in the OFF position, the
    (found in the 7 pin connector from box) open and the capaCitor is immediately grounded when the ignition
    detonation sensing module deactivated. harness is reconnected to the GEG ignition module.

    NOTE: VHP gas engines are to be run with no load on


    fuels other than natural gas fuel. With natural gas fuel,
    the engines may be run at any load.

    7. Check engine timing at the flywheel using a timing


    light (see Figure 5.10-44).

    8. Adjust the "B" switch as required to achieve correct


    timing. Dual fuel ignition adjustments are now complete.
    5.10-26 FORM 6248 First Edition
    IGNITION SYSTEM

    GOVERNOR DRIVE GEAR/CEC


    TIMING DISC (PREVIOUS PRODUCTION)
    GOVERNOR DRIVE GEARICEC TIMING DISC
    (PREVIOUS PRODUCTION) REMOVAL

    NOTE: Magneto equipped engines will not have a GEG


    disc.

    1. Place a small oil pan beneath the governor drive


    housing and remove the governor drive cover plate
    (4 capscrews, 3/8 x 3/4 inch, with lock washers;
    10 capscrews, 3/8 x 1 inch, with lock washers) and
    gasket (see Figure 5.10-45).

    Figure 5.10-47. Previous Production CEC Timing Disc

    4. Refer to Governor Drive Shaft Removal, and remove


    the governor drive shaft assembly (see Figure 5.10-47).

    5. Remove the governor drive gear assembly from the


    accessory drive gear shaft (see Figure 5.10-48). Use a
    rubber mallet to loosen the drive gear assembly, if
    necessary. Move the assembly to a suitable workbench.

    Figure 5.10-45. Governor Drive Housing

    2. Remove the CEC Hall-effect Pickup from the


    Governor Drive Housing (see Figure 5.10-46)

    Figure 5.10-411. Previous Production Governor Drive


    Gear

    GOVERNOR DRIVE GEARICEC TIMING DISC


    (PREVIOUS PRODUCTION)
    CLEANING AND INSPECTION

    1. Using a soft cloth, remove all dirt, grime, grease and


    oil deposits, from the gear and CEC disc.

    2. Inspect the gear teeth for chips, cracks and exces-


    Figure 5.10-46. Hall-effect Pickup sive wear. Replace the governor drive gear if necessary.

    3. On CEC equipped engines, remove the flex lock nut


    and the CEC timing disc (see Figure 5.10-47).

    FORM 6248 First Edition 5.10 - Z7


    IGNITION SYSTEM

    GOVERNOR DRIVE GEAR/CEC TIMING DISC


    (pREVIOUS PRODUCTION) INSTALLATION )
    1. Install the No. 8 Woodruff key in the slot on the
    accessory drive gear shaft, if removed. Lightly tap the
    key to properly seat it in the keyway. Verify that the key is
    level. \
    \
    2. Slide the governor drive gear assembly onto the \

    ~
    accessory drive gear shaft aligning the notch in the hub
    with the key on the shaft. Solidly seat the assembly
    against the shoulder of the accessory drive gear shaft
    (see Figure 5.10-49).
    ~
    HOLE #1 - 1/8" PIN
    HOLE #2 - 5/32" PIN
    HOLE #3 - 3/16" PIN
    HOLE #4 -1/4" PIN

    Figure 5.10-50. Previous Production CEC Timing Disc

    7. Apply Loctite® 242 to threads and install the flex lock


    nut on the shaft and wrench tighten (see
    Figure 5.10-51).

    Figure 5.1049. Governor Drive Gear

    3. Verify that the governor drive gear assembly fits


    snugly on the accessory drive gear shaft without rocking
    or sliding.

    4. Refer to Governor Drive Shaft Installation, and install


    the governor drive shaft assembly (see Figure 5.10-49).

    NOTE: If the engine is CEC equipped, perform Steps 5


    thru 11. If not CEC equipped, perform Step 7 and Steps
    9thru 11.

    IA
    ..
    CAUTION I DO NOT turn on the fuel
    until the Ignition timing Figure 5.10-51. Previous Production CEC Timing Disc
    is verified to be at an acceptable setting to prevent
    possible engine damage and/or personal injury.
    Use a timing light to check the ignition timing while 8. Install the CEC Hall-effect Pickup on the Governor
    the engine is cranking in a NO-FUEL state. Drive Housing (see Figure 5.10-50). Set the gap between
    the pickup and the timing disc to 0.040 in. ±0.010 in.
    5. Determine from the engine nameplate and (1.016 mm ±0.254 mm).
    Table 5.10-6 which hole number was used to position
    9. Apply a fast setting contact-type gasket shellac,
    the CEC timing disc (see Figure 5.10-50).
    such as 3M Weather Strip Cement, Permatex® High-
    6. Install the timing disc, and pin on the gear hub and Tac or equivalent, on the gasket surfaces of the
    pin it in position. governor drive cover plate. Install a new governor drive
    cover gasket.

    5.10-28 FORM 6248 First Ednion


    IGNITION SYSTEM

    NOTE: During Step 10, the governor drive cover must CEC IGNITION MODULE IGNITION TIMING
    first be installed on the ball bearing retainer, four (PREVIOUS PRODUCTION) SET
    capscrews and lock washers To prevent the gaskets The previous production version of the GEG ignition system
    from sliding during installation of the governor drive contains a timing disc with four holes, which allows for four
    assembly, allow the gasket shellac to cure. Follow the different static timing settings (see Figure 5.10-53). These
    manufacturer's recommendations. four settings allow the engine to reach a variety of ignition
    10. With the WED part numberfacing outside, install timings for various fuel applications.
    the governor drive cover to the ball bearing retainer
    (4 capscrews, 3/8 x 3/4 inch, with lock washers) (see
    Figure 5.10-52). Install the remaining fasteners
    (10 capscrews, 3/8 x 1 inch, with lock washers).

    \
    \
    \

    ~
    ~
    HOLE #1 - 1/8" PIN
    HOLE #2 - 5/32" PIN
    Figure 5.10-52. Govemor Drive Housing HOLE /13 - 3/16" PIN
    HOLE #4 - 1/4" PIN

    Figure 5.10-53. Previous Production Timing Disc


    11. On GEG equipped models, refer to CEC Ignition
    Module Timing Set (Previous Production) and set
    engine timing. On Magneto equipped models, refer to Specific ignition timings can be achieved by changing
    Magneto Static Timing Set, and Magneto Ignition the GEG ignition module rotary switch position (see
    Timing Set, and set engine timing. Figure 5.10-54).

    CEC IGNITION MODULE


    ROTARY A AND B

    NOTE: TIming selection is made by the dot on the switch.


    not the screwdriver slot.

    Figure 5.10-54. CEC IgnHlon Module


    Rotary Switches A and B

    FORM 6248 First Edition 5.10-29


    IGNITION SYSTEM

    Table 5.10-6 lists the correct pin location in the timing Table 5.10-7 lists the CEC rotary switch position for the
    disc for VHP12 cylinder engines. range of VHP ignition timing.
    Table 5.11Hi. CEC Timing Disc Pin Location (previous Production)
    FUEL
    LPG LBTU
    NATURAL NATURAL LPG
    NATURAL GAS AND LOW AND AND
    MODEL GAS AND LPG AND LBTU
    GAS OCTANE LOW LOW
    LPG* LBTU" LBTU
    OCTANE OCTANE
    L5108G 3 3 4 3 3 4
    L5108GSI 2 2 4 2 3 4
    5108GL 1 1 2 2 2 2 2 2
    L5790G 3 3 4 3 3 4
    L5790GSI 2 2 4 2 3 4
    5790GL 1 1 1 1 1 1 1 1
    L7042G 3 3 4 3 3 4
    L7042GSI 2 2 4 2 3 4
    7042GL 1 1 1 1 1 1 1 1
    NOTE: Pin #1 - PIN 87978 Pin #2 - PIN 44831 Pin #3 - PIN B350 PIN #4 - 78878
    * LPG is HO-5 Propane
    ** LBTU is Low BTU Fuel

    Table 5.10-7. CEC Ignition Module Rotary Switch Position (previous Production)
    DEGREES BEFORE TOP DEAD CENTER
    HOLE SWITCH
    0 1 2 3 4 5 6 7 B 9 10 11 12 13 14 15 16 17 lB
    )
    A AO AI A2 A3 A4 A5 A6 A7 AS AS
    1
    B Bl B2 B3 B4 B5 B6 B7 BB B9 Bl0 Bl1 B12 B13 B14 B15
    A AO AI A2 A3 A4 A5
    2
    B BO Bl B2 B3 B4 B5 B6 B7 BB B9 Bl0 Bll B12 B13 B14 B15
    A AO AI
    3
    B BO Bl B2 B3 B4 B5 B6 B7 BB B9 Bl0 Bl1
    4 A
    4 8 BO Bl B2 B3 B4 B5 B6 B7
    DEGREES BEFORE TOP DEAD CENTER
    HOLE SWITCH
    19 20 21 22 23 24 25 26 27 2B 29 30 31 32 33 34 35 36
    A Al0 All A12 A13 A14 A15
    1
    B
    A AS A7 AS AS Al0 All A12 A13 A14 A15
    2
    B
    A A2 A3 A4 A5 A6 A7 AS AS Al0 All A12 A13 A14 A15
    3
    B B12 B13 B14 B15
    A AO AI A2 A3 A4 A5 A6 A7 AS AS Al0 All A12 A13 A14 A15
    4
    B BB B9 Bl0 Bll B12 B13 B14 B15

    5.10-30 FORM 624B Firsl Edition


    IGNITION SYSTEM

    STEPS REQUIRED TO ADJUST CEC IGNITION DUAL FUEL ENGINES


    MODULE TIMING
    (PREVIOUS PRODUCTION) 1. Switches "A" and "B" must be set for both fuels
    before engine startup.

    IA CAUTION I DO NOT turn on the fuel 2. Engine must be run on both switch settings to verify
    .. until the ignition timing correct engine timing. Engine should be run at no load
    is verified to be at an acceptable setting, to prevent when verifying timing for fuels other than natural gas.
    possible engine damage and/or personal injury.
    Use a timing light to check the ignition timing while 3. If the ignition module switch setting is changed to
    the engine is cranking in a NO-FUEL state. obtain the correcttiming on natural gas, the other switch
    must also be adjusted the same number of clicks in the
    1. Determine from the engine nameplate which hole same direction.
    number was used to position the CEC timing disc (see
    Example: Dual fuel engine - natural gas/landfill gas
    (see Figure 5.10-60 and Figure 5.10-61).
    engine timing
    2. Determine the specified engine timing from the Natural Gas - B8
    engine nameplate. Landfill Gas - A7
    The engine is run on natural gas and, due to manufac-
    3. Locate the proper switch setting by intersecting the turing tolerances, switch "B" must be changed from B8
    specified hole row (Step 1) with the specified engine to Bl0 to obtain the correct engine timing. Since switch
    timing column (Step 2) and select the switch position "B" was adjusted 2 positions (2 clicks) higher, switch "A"
    that is given for that timing (see Table 5.10-7). must also be adjusted 2 positions higher, A7 to A9.
    NOTE: Due to manufacturing tolerances, the engine NOTE: The engine should be run at no load to verify the
    may not be timed at the exact timing. Adjust the engine engine timing at switch position A9.
    to the timing specified on the engine nameplate by
    rotating the specified switch to a different position to set MAGNETO
    the correct engine timing.
    Check the ignition timing every 2 months (1440 hours).
    NOTE: Rotating either switch A or B one switch See Magneto Ignition Timing Set.
    position (one click) changes the engine timing 1°. For DRIVE DISC COUPLING REPLACEMENT
    example, changing the switch position from AS to A9 will

    CAUTION IDo not advance the mag-


    advance engine timing 10. Changing the switch position
    from AS to A7 will retard engine timing 1°. IA
    .L .=
    .=:.....;=..:...;;:;.....;;...;;....;;;...;;..;..J.
    . neto to compensate for a

    CAUTION I
    worn drive disc coupling. Disregarding this In-

    I A=~=..:...;;:;.....;;...;;...=;..;..J.
    .L .!!!
    ..
    Do not switch from posi-
    tlon 15 to 0, 0 to 15 or
    make other large timing changes quickly while the
    formation could resun in product damage and/or
    personal injury.

    engine is running. The large timing change may Replace the free-floating drive disc coupling between
    cause engine damage or shutdown. Disregarding the magneto and the magneto adapter every 3 or 4
    this information could result In product damage months. Worn drive discs can retard the timing by as
    and/or personal InJury. much as 10 - 15 degrees.
    1. Close the gas shutoff valves.
    4. Run engine. Use the ignition module's active rotary
    switch, either switch "A" ("D" lead grounded) or "B" ("D" 2. Bump the starter or barr the engine over manually 5
    lead ungrounded) to adjust the ignition timing to the revolutions to purge the cylinders and exhaust system
    specified setting. of unburned gas.
    5. Verify the engine timing with a timing light. 3. Verify that the ignition switch is turned to the "Off"
    position.

    4. Verify that the wire harness "G" lead is grounded.

    FORM 6248 Rrst Edition 5.10-31


    IGNITION SYSTEM

    7. Remove the capscrews (with flat washers), shims


    A WARNING and magneto from the magneto adapter flanges (see )
    If the "G" lead is not grounded, the magneto Figure 5.10-56). Count and record the number of shims
    remains "hot," which means that the capacitor(s) removed (normally 2 to 5) to ensure the correct drive
    will have a stored voltage. Depending upon where disc end clearance when the unit is reinstalled (see
    the voltage Is released during assembly, and Figure 5.10-56).
    whether the engine has been purged of unburned
    gas, the risk of personal injury or death exists in the
    form of electrical shock, unexpected rotation of the
    crankshaft and/or an exhaust gas explosion.

    NOTE: In the engine mounted junction boxes supplied


    by Waukesha, the wire harness "G" lead is normally
    grounded to the #9 terminal on the terminal block in the
    junction box of the ignition switch, so that turning the
    switch to the "Off' position automatically discharges the
    storage capacitors to ground.

    5. Loosen the sleeve and detach the ignition wiring


    harness from the mag pin connector.

    6. Remove the hex nuts, lock washers and flat washers Figure 5.10-56. Magneto/Magneto Adapter
    from the two magneto/magneto adapter flange caps-
    crews (3/8 x 1-3/4 inches) (see Figure 5.10-55).
    8. Remove the drive disc coupling from the magneto or
    magneto adapter drive hub lugs (see Figure 5.10-57).
    Discard the drive disc.

    Figure 5.10-55. Magneto/Magneto Adapter Flange


    Bolts

    Figure 5.10-57. Magneto Drive Disc Coupling

    9. Clean the outSide of the magneto with a clean cloth


    dampened in solvent or cleaning agent.

    NOTE: Proceed to Magneto, Static and Ignition Timing.

    5.10 - 32 FORM 6248 First Ed~ion


    IGNITION SYSTEM

    MAGNETO - STATIC TIMING SET 5. Position two new gaskets on the adapter cover
    studs. The rounded side of each gasket goes toward the
    1. Check the ten magneto drive adapter cover studs for outside, the straight edges in towards the block.
    nicks, cracks, galled or stretched threads and other
    obvious damage (see Figure 5.10-58). Replace as 6. Position the cover plate on the studs around the
    necessary. lower bore. The rounded side ofthe plate goes toward
    the outside, while the straight edges face the block.
    Wrench tighten the fasteners (3/8 inch hex nuts with
    lock washers) in an alternating pattern.

    7. Refer to Valve Adjustment for detailed instructions,


    and set the valves in the order that the engine fires. The
    cylinder firing order appears on the nameplate on the
    front left side of the block Oust below the intake
    manifold) (see Figure 5.10-59, Figure 5.10-60 and
    Figure 5.10-61).

    FRONT
    (GEAR SIDE)

    88
    88
    Figure 5.10-58. Magneto Drive Adapter Cover Studs
    LEFT
    SIDE 88 RIGHT
    SIDE

    2. Each adapter cover stud has both fine and coarse


    threads separated by a smooth boss. Apply Loctite®
    271 Adhesive Sealant (High Strength) to the coarse
    88
    threaded side.

    I
    88 DIRECTION OF
    FLYWHEEL ROTATION

    COUNTERCLOCKWISE

    I
    L.:
    .
    A CAUTION Do not install adapter
    :=~=..:..;:;...;;~=~.
    . cover studs with a pipe
    wrench or similar device. Use collet type stud
    driver, to avoid damage to equipment and/or per-
    8_
    sonal injury. FIRING ORDER:
    1 R, 6L, SR, 2L, 3R, 4L,
    6R, 1L, 2R, 5L, 4R, 3L
    3. Using a collet type stud driver, install the studs
    around the upper and lower bores of the adapter cover. REAR
    Drive the coarsely threaded side of each stud into the (FLYWHEEL SIDE)
    casting leaving 2 to 3 threads exposed.

    IA
    ..
    CAUTION IDeposits left on gasket
    surfaces will cause leaks.
    . . = MATING CYLINDER OF THE FIRST CYLINDER
    ., IN THE FIRING ORDER

    NOTE: When the mating cylinder is in valve overlap, the first


    Disregarding this information could result In prod- cylinder in the firing order is at top dead center
    uct damage and/or personal Injury. (compression stroke).

    4. Verify that all gaskets and gasket mating surfaces Figure 5.10-59. Engine Firing Order - 12 Cylinder
    are clean and completely free of grease and oil.

    FORM 6248 First Edition 5.10-33


    IGNITION SYSTEM

    Figure 5.1 ().60. Nameplate - Current Production

    Figure 5.10-61. Nameplate - Previous Production


    8. After all valves have been properly set, check the
    ignition timing specification on the engine nameplate.
    The correct timing will vary between engines. Factors
    affecting ignition timing include engine speed (RPM),
    fuel type, octane level and heating value.

    5.10 - 34 FORM 6248 First Edition


    IGNITION SYSTEM

    NOTE: Right bank and left bank, and direction of rotation,


    are determined by standing at the flywheel end of the
    engine facing the flywheel (see Fl[Jure 5. 10-62). The
    cylinders farthest from the flywheel on the left and right side
    are the #1 L and #1 R cylinders, respectively. Those closest
    /0 the flywheel are the #6L and #6R cylinders.

    w--
    z
    O'~
    ..
    REAR OF
    ENGINE
    i=~
    ;; DIRECTION OF NORMAL
    ENGINE ROTATION
    0
    a:
    lJoL
    Figure 5.10-62. Rotation Plate Front Flywheel Housing
    - Right Bank
    9. Bar the engine crankshaft over in a counter-clock-
    wise direction until the valves of the first cylinder in the
    firing order, which is the #1 R cylinder, are at top dead
    center (compression stroke).
    To determine when this condition exists, watch the rocker
    arms and valves on its mating cylinder, #6R. As the
    exhaust valves on #6R cylinder are closing, the intake
    valves begin to open. At this point, the #6R cylinder is in
    valve overlap (all four valves partially open). This means
    that all four valves on the #1 R cylinder are fully closed.
    The cylinder is now at top dead center (compression
    stroke).
    10. Turn up the timing pointer cover on the upper right
    side of the rear flywheel housing to view the timing tape
    (see Figure 5.10-63). The tape indicates the position of
    the flywheel (see Figure 5.10-64).

    Figure 5.10-64. Timing Tape

    Figure 5.10-63. Timing Pointer - Rear Right

    FORM 6248 First Edition 5.10-35


    IGNITION SYSTEM

    IA
    ..
    CAUTION I Do not back up to the
    exact desired timing. The
    18. Using a depth micrometer, measure the distance
    from the magneto adapter flange to the base of the
    magneto drive gear backlash will be on the wrong magneto adapter drive hub lugs (see Figure 5.10-66). To
    side ofthe gear teeth, resulting in timing that may be obtain the correct drive disc end clearance, the measure-
    incorrect by several degrees. Disregarding this ment must be 1.027 - 1.037 in. (26.08 - 26.34 mm) Add
    information could result in product damage and/or 0.010 in. (0.25 mm) shims (PIN 208842), as necessary.
    personal Injury. Normally, 2 to 5 shims are needed.

    11. Watching the marks on the timing tape, bar the


    0.010" (0.25 mm) SHIM
    engine over in the direction opposite normal engine (USE AS REQUIRED)
    rotation (CW) to a point at least 30 degrees before the
    desired timing.

    12. Slowly turn the engine in the direction of normal


    engine rotation (CCW) until the pointer indicates the
    exact desired timing.

    13. If the crankshaft is rotated too far, do not back up to


    the desired timing. Repeat steps 12 and 13.

    14. When the timing pOinter indicates the exact timing


    desired, mark the timing tape with a paint stick, grease
    pencil or other marker. Due to the wide variety of
    applications, speeds and fuels, the factory does not
    place a permanent mark on the timing tape.
    . M~,GNIETO ADAPTOR
    15. Apply 3M Scotch Grip ~ Rubber and Gasket
    TO
    Adhesive 847 to the magneto flange. Place a new
    gasket on the adhesive.
    Figure 5.10-66. Magneto Drive Disc Coupling Shims
    16. With the nameplate facing upward, position the
    magneto in a vise. Be sure to install a pair of brass jaw
    19. Install a flat washer on two capscrews (3/8 x 1-3/4
    inserts to avoid damaging the unit.
    inches). Insert the capscrews through the slotted holes
    17. Center a new drive disc coupling on the magneto in the magneto adapter flanges.
    drive hub. The wider grooves on one side of the
    20. Position the shims on the capscrews.
    free-floating disc fit the magneto drive hub lugs, the
    thinner grooves on the other side mate with the hub of 21. Fit the magneto adapter drive hub lugs into the
    the magneto adapter (see Figure 5.10-65). grooves of the mag drive disc coupling. Rotate the
    magneto adapter to align the slotted flanges with those
    NOTE: See Ignition System, Magneto Adapter, Over-
    on the magneto. When facing the timing window of the
    hauling.
    magneto, verify that the rounded side of the mag
    adapter flange (gear side) is on the right, the two straight
    edges on the left.

    MAGNETO DRIVE 22. Install 3/8 inch flat washers, lock washers and hex

    HUBLUG~__-J-1
    nuts on the flange capscrews. Wrench tighten the hex
    nuts evenly.

    MAGNETO ADAPTER
    DRIVE HUB LUGS
    (THIN) ---....:~---L

    Figure 5.10-65. Magneto Drive Disc Coupling

    5.10 - 36 FORM 6248 Firs! Edrtion


    IGNITION SYSTEM

    23. Rotate the magneto adapter drive shaft while 25. With the nameplate of the magneto facing upward,
    watching the timing window of the magneto. Align the slide the rear magneto adapter flange onto the studs
    red mark on the end of the magneto shaft (as seen around the upper bore of the magneto drive adapter
    through the timing window) with the "CCW" mark on the cover. Be sure that the ball bearing on the mag adapter
    timing plate (see Figure 5.10-67). The magneto is now drive shaft seats squarely in the circular recess within
    set to fire the first cylinder in the firing order. the magneto drive assembly (see Figure 5.10-69).

    NAMEPLATE \ ~nMING
    .t=:====~1 WINDOW

    o
    ~=~~
    o
    HARNESS PLUG
    A CONNECTOR Figure 5.10-69. Magneto Drive Assembly
    / 01 (14 PIN)
    O® .~. 0 26. Verify that the red line on the magneto shaft stays
    o~o aligned with the "CCW" mark on the timing plate. If the
    mark moves out of alignment during installation, then
    Figure 5.10-67. Magneto Static Timing the assembly must be removed and reset.

    27. Finger tighten the fasteners (six 3/8 inch hex nuts
    24. Using a small paintbrush, apply Uthoplex@ Grease with lock washers) on the magneto adapter cover studs.
    No.2 (Multipurpose Uthium Complex Formula Contain- Wrench tighten in an alternating pattern.
    ing Molybdenum Disulfide) to the magneto adapter
    drive gear and ball bearing (see Figure 5.10-68).
    • WARNING
    If the "G" lead was not grounded when the magneto
    was removed, then the magneto will be "hot," which
    means that the capacitor(s) have a stored voltage.
    Depending upon where the voltage Is released
    during assembly, and whether the engine has been
    purged of unburned gas, the risk of personal injury
    or death exists In the form of electrical shock,
    unexpected rotation of the crankshaft and/or an
    exhaust gas explosion.

    Figure 5.10-68. Magneto/Magneto Adapter

    FORM 6248 First Edition 5.10-37


    IGNITION SYSTEM

    MAGNETO - IGNITION TIMING SET


    A WARNING
    Remember that the magneto storage capacitor(s)
    can be charged by simply hand-turning the drive
    IA CAUTION IC?v~rlyadvancedlgnition
    L.~~"::;':""::'=:"':"'=-=:":";:..J.
    timing can result in deto-
    shaft after the unit has been removed from the nation which may severely damage pistons and
    engine. If there are any doubts as to whether the rings. Retarded timing will resun in loss of power
    magneto is "hot," discharge the storage capaci- and poor fuel economy. Disregarding this informa-
    tor(s) to ground before reconnecting the wiring tion could result In product damage and/or person-
    harness. Clip one end of a wire lead to the magneto al injury.
    housing and then touch the other end to the
    harness connector pins at the back of the magneto, 1. If tightened, loosen and then snug the hex nuts on
    one at a time. A snap Is heard if a capacitor the two magneto/magneto adapter flange capscrews
    discharges. As a safety measure, ground all the (see Figure 5.10-68 and Figure 5.10·70).
    pins. Some breakerless magnetos have more than
    one storage capacitor. Disregarding this informa-
    tion could resun in severe personal injury or death.

    28. Connect the harness cable plug to the mag pin


    connector. The notch in the connector mates with a
    groove in the plug to prevent improper installation.
    Finger tighten the connector sleeve.

    29. Open the gas shutoff valve(s).


    NOTE: Although the engine is now statically timed,
    verify the ignition timing with a properly connected
    timing light (Tool PIN 494338) once the engine is
    running. See Ignition Timing. )

    Figure 5.10-70. Magneto/Magneto Adapter Flange


    Bolls
    2. Start the engine and run at rated speed (with or
    without load).

    3. Connect a stroboscopic type timing light to the


    ignition cable of the #1 R cylinder.

    4. Turn up the timing pointer cover on the upper right


    side of the rear flywheel housing.

    5. Align the beam of the timing light with the timing


    pointer. The timing light will flash at the instant the spark
    occurs, making the tape on the rim of the flywheel
    visible.

    6. Place a pencil mark straight across the magneto


    adapter/magneto mating flanges to mark the current
    position. Note the timing next to the mark on the
    magneto flange.

    5.10-38 FORM 6248 First Edition


    IGNITION SYSTEM

    7. For example, to retard the timing, from 10 to 18 degrees


    BTDC, loosen the hex nuts on the two magneto/magneto
    adapter flange capscrews and tum the magneto in the
    direction of normal rotation. Since the mag drive shaft (as
    seen through the timing window) tums in a counter-clock-
    wise direction (as does the flywheel), slightiy rotate the
    magneto counter-clockwise to retard the timing. Snug the
    flange capscrew hex nuts.

    8. Check the timing again with the timing light.

    9. In line with the mark on the magneto adapter flange,


    place a second pencil mark on the magneto flange to
    indicate the new position. Note the new timing next to the
    mark. The two pencil marks on the magneto flange provide
    a relative indication of the amount of rotation necessary to
    achieve the correct timing.

    10. If ~ is necessary to advance the timing a 1ew degrees,


    loosen the flange capscrew hex nuts and slightiy tum the
    magneto in the direction op~ normal rotation of the
    magneto drive shaft (clockwise when facing the magneto
    timing window). Snug the flange capscrew hex nuts.

    11. Use the timing light to check the timing again.

    12. If the timing is still not correct, make a third pencil


    mark on the magneto flange (in line with the stationary
    mark on the magneto adapter). Loosen the flange
    capscrew hex nuts and slightly rotate the magneto
    again.

    13. Snug the flange capscrew hex nuts and check the
    timing with the timing light. When the correct timing is
    obtained, the timing pointer will be aligned with the
    painted mark placed on the timing tape at the precise
    moment the timing light flashes.

    14. Alternately wrench tighten the hex nuts on the two


    magneto/magneto adapter flange capscrews.

    FORM 6248 First Ed~ion 5.10 - 39


    IGNITION SYSTEM

    MAGNETO ADAPTER 1. Remove the retaining ring from the drive hub side of
    the mag adapter drive shaft (see Figure 5.10-72). )
    MAGNETO ADAPTER DISASSEMBLY
    Disassemble the mag adapter assembly for cleaning, PRESS
    EXTENSION
    inspection and/or repair (see Figure 5.10-71).

    DRIVE SHAFT

    MAGNETO
    ADAPTER
    FRONT BALL
    HOUSING \ BEARING

    SHIMS

    Figure 5.10-72. Magneto Adapter Assembly

    2. Remove the retaining ring from the groove in the


    DRIVE mag adapter housing (gear side).

    3. Press the drive shaft through the drive coupling and


    out of the housing.

    4. Remove the No.3 Woodruff key from the drive hub


    RETAINING Side of the shaft.
    RING #5 W011>DRUFF KEY )
    #3 WOODRUFF 5. Remove the oil seal from the shaft and discard.

    Figure 5.10-71. Magneto Adapter Assembly 6. Remove the retaining ring from the middle groove on
    the drive shaft (behind the rear ball bearing).
    A WARNING 7. Remove the retaining ring next to the gear.
    Always wear proper eye protection when removing
    8. Press the shaft out of the ball bearings and and the
    retaining rings. Slippage may propel the ring with
    drive gear. Remove the woodruff key from the shaft.
    enough force to cause severe personal injury or
    death. Use the correct retaining ring pliers. Verify 9. Press the oil seal out of the adapter housing.
    that the tips ofthe pliers are not excessively worn or
    damaged.

    5.10 - 40 FORM 6248 Firsl Edition


    IGNITION SYSTEM

    MAGNETO ADAPTER CLEANING AND MAGNETO ADAPTER ASSEMBLY


    INSPECTION

    A WARNING
    A WARNING
    Always wear proper eye protection when installing
    Use of caustic solutions should be restricted to a retaining rings. Slippage may propel the ring with
    well ventilated area. Contact with skin, clothing and enough force to cause severe personal injury or death.
    eyes could result in severe personal injury or death. Use the correct retaining ring pliers. Verify that the tips
    of the pliers are not excessively worn or damaged.

    A WARNING
    A CAUTION I Verify that the rou.n~ed
    Always use approved cleaning solvents in a well
    ventilated area. Contact with skin could result in
    I..
    ==.....::..:..=;;...;;..:...;=-=~.
    1... edge of each retaining
    ring abuts the adjoining part. If installed incorrectly,
    severe personal InJury or death. the adjoining part may be scored or scratched by
    the straight edge of the retaining ring. Disregarding

    A WARNING
    this information could result in product damage
    and/or personal Injury.
    Compressed air can pierce the skin and cause
    severe injury or death. Never use your hand to 1. Press the rear ball bearing into the housing, exerting
    check for leaks or to determine air flow rates. forces on the outer race. Install the retaining ring.

    1. To remove all dirt, grime, grease and gasket debris,


    clean the mag adapter housing in the caustic hot tank.
    A WARNING
    Thoroughly clean all other parts of the assembly in To avoid bums, always wear protective gloves
    naphtha or other suitable solvent. Dry with moisture free when heating gears. Disregarding this information
    compressed air. could result in severe personal injury or death.

    2. Inspect the mag adapter housing for cracks. Re· 2. Preheat the adapter gear to 3500 F (1760 C).
    place the mag adapter assembly or just the housing, if
    damaged. 3. Install the No.5 woodruff key, if removed, and slide
    the gear down the shaft until it contacts the raised
    3. Inspect the teeth of the drive gear for chips, cracks shoulder on the shaft.
    and excessive wear. Replace the gear, if necessary.
    4. Install the retaining ring in the groove next to the gear
    4. Inspect the No.3 Woodruff key (drive hub side) for on the drive hub side of the shaft.
    damage and distortion. Replace the key if necessary.
    5. Press the drive shaft into the ball bearing and
    housing. A pipe of sufficient diameter to support the
    inner race must be used to allow press forces to be
    placed on the inner race only. The shaft shoulder will
    seat against the inner bearing race.

    6. Install the retaining ring in the groove next to the ball


    bearing on the drive hub side of the shaft.

    7. Install the retaining ring in the groove in the magneto


    adapter housing, behind the rear ball bearing.

    FORM 6248 First Ednion 5.10 - 41


    IGNITION SYSTEM

    , -A CAUTION , Use caution when instal-


    =
    ..
    L..=,--,~--,,--...:....::....---,. ling the seal. Make cer-
    tain there are no sharp edges or burrs around the
    retaining ring groove, shaft shoulder, and the
    woodruff key slot. Lightly lubricate the drive shaft
    with engine oil to protect the seal during Installation
    and lubrication when the engine Is first started.
    Disregarding this information could result in prod-
    uct damage and/or personal injury.

    8. Using the press, install the oil seal on the shaft with
    the seal lips facing towards the drive hub.

    9. Preheat the drive hub to 350 0 F (1760 e).

    10. Install the No. 3 woodruff key on the shaft, and


    press the drive hub on the shaft.

    11. Install the retaining ring on the drive hub end of the
    shaft.

    12. Press the rear ball bearing onto the drive shaft.
    Apply pressure only to the inner race. Support the
    opposite end of the shaft. Do not allow the inner ball
    bearing to support the drive shaft during this operation
    as the press forces may damage the bearing.

    5.10 - 42 FORM 6248 First Edition


    IGNITION SYSTEM

    OVERSPEED GOVERNOR

    • REITAIININIG RING

    FLATHEAD
    CAPSCREW

    FOR MAGNETO
    DRIVE ADAPTER
    ASSEMBLY

    Figure 5.10-73. Magneto Drive Assembly

    MAGNETO DRIVE 4. Remove the woodruff key and the retaining ring
    located behind the drive gear.
    MAGNETO DRIVE DISASSEMBLY
    NOTE: The front ball bearing, tachometer gears and
    1. Remove eight capscrews, lock washers, cover and overspeed governor gear will remain on the shaft as it is
    gasket from the magneto drive adapter (see removed. The rear ball bearing will stay in the housing.
    Figure 5.10-73).

    2. Remove lock nut and washer from the drive shaft. CAUTION I
    I-=.A=:.....;;=...:..;::.....;~;:;.;:..:..I.
    The shaft should be re-
    L. . moved In the manner de-
    3. Using a three jawed puller, remove the magneto scribed below. Do not remove the magneto drive
    drive gear from the shaft. adapter from the housing with the rear bearing in
    place before the shaft Is removed. This procedure
    A WARNING will leave the drive shaft supported by only the front
    bearing. The front bearing could become misa-
    Always wear proper eye protection when Installing ligned during shaft removal, causing damage to the
    retaining rings. Slippage may propel the ring with bearing bore In the housing. Disregarding this
    enough force to cause severe personal injury or information could result In product damage and/or
    death. Use the correct retaining ring pliers. Verify personal Injury.
    that the tips ofthe pliers are not excessively worn or
    damaged. 5. Mark the gears to aid in assembly, and remove
    retaining ring, tachometer gears, spacer, and over-
    speed governor gear from the shaft.

    FORM 6248 First Ed~ion 5.10-43


    IGNITION SYSTEM

    6. Remove the retaining ring and bearing from the 12. Install the washer and gear lock nut.
    shaft. )
    13. Install the cover with gasket, eight capscrews and
    7. Remove five capscrews and lock washers from the lock washers.
    magneto adapter assembly.

    8. Remove one flat head screw, magneto adapter


    assembly, and gasket from the magneto drive assembly
    housing.

    9. Remove the retaining ring and press the bearing


    from the magneto drive adapter housing.

    MAGNETO DRIVE ASSEMBLY

    A WARNING
    Always wear proper eye protection when installing
    retaining rings. Slippage may propel the ring with
    enough force to cause severe personal injury or
    death. Use the correct retaining ring pliers. Verify
    that the tips ofthe pliers are not excessively worn or
    damaged.

    1. Install the large front ball bearing on the shaft,


    pressing ij to the shaft shoulder. Install the bearing
    retaining ring on the shaft.

    2. Preheat the overs peed and two tachometer gears to )


    3500 F (176 0 C).

    3. Install the woodruff key, PIN 153181 tachometer


    drive gear, and overspeed governor drive gear on the
    shaft with the tachometer gear on the ball bearing end.
    Position the gears against the shaft shoulder.

    4. Install the spacer, woodruff key, and remaining


    tachometer gear on the shaft.

    5. Install the rear bearing and its retaining ring in the


    magneto drive adapter.

    6. Install the drive shaft assembly in the housing.

    7. Install a new gasket on the drive housing.

    8. Exerting force only on the inner bearing race, press


    the magneto drive adapter, with the bearing installed, on
    the shaft.

    9. Install five capscrews, lock washers and one flat


    head screw and secure the magneto drive adapter to
    the housing.

    10. Preheatthe magneto drive gear to 350 0 F (1760 C).

    11. Install the woodruff key and the magneto drive gear )
    on the shaft.

    5.10 - 44 FORM 6248 First Edrtion


    IGNITION SYSTEM

    FORM 6248 First Edijion 5.10-45


    )

    ,
    )
    SECTION 5.15 - AIR INDUCTION SYSTEM

    AIR INDUCTION SYSTEM Each intercooler is a box-type tube and fin assembly.
    Heated compressed air from the turbocharger(s) enters
    NOTE: Draw Thru equipped models are beyond the the intercooler and flows over a series of tubes through
    scope of this manual. For information concerning Draw which the engine coolant is circulated. The temperature
    Thru models, refer to Catalog Form 6220. of the compressed air is reduced, which makes it
    The air intake system consists of the following compo- denser.
    nents: CARBURETOR AND INTAKE MANIFOLD
    • Air Cleaners Twelve cylinder engines have a carburetor on both the
    right and left side, one for each cylinder bank. The
    • Turbochargers (see Turbochargers) carburetor produces a combustible mixture byautomat-
    ically mixing air and fuel in the proper proportions.
    • Intercoolers (see Cooling System)
    Twelve cylinder engines have two intake manifolds, one
    • Carburetors (see Fuel System) for each bank, mounted on opposite sides of the
    crankcase vee. The intake manifold connects the
    • Intake Manifolds carburetor to the intake ports of the cylinders and
    AIR CLEANERS equally distributes the air/fuel mixture to each.

    The air cleaner removes dirt and dust from the air AIR INDUCTION SYSTEM
    admitted to the engine. SPECIFICATIONS
    Twelve cylinder engines have two air cleaners, one for The efficiency rating ofthe air filtration system is 99.6%,
    each bank. The air cleaners are side-mounted at the based on SAE J726b test procedure. The maximum
    rear of the engine. permissible air intake restriction for 12 cylinder engines
    TURBOCHARGERS is 15 inches (381 mm) H20 through the main air filter
    element.
    Twelve cylinder engines have two turbochargers, one
    for each bank. The turbochargers are side-mounted at Based on the temperature rating of the specified
    the rear. auxiliary cooling water thermostat (determined by
    engine application), the maximum intake manifold
    The turbine side of each turbocharger is part of the alarm and safety shutdown setpoint temperatures are
    exhaust system, the compressor side is part of the air as follows. (See Table 5.15-1)
    induction system. A shaft connects the two. When the
    turbine spins through the expansion of exhaust gases Table 5.15-1. High Intake Manifold Temperature
    exiting the engine, the movement of the compressor SetUngs 0 F e C)
    wheel causes the air passing through the air cleaner, INTERCOOLER COOLING 130 (54) 85 (29)
    WATER INLET TEMPERATURE
    en route to the carburetor, to be compressed.
    140 - 145 100-105
    ALARM (60 - 63) (38 - 41)
    INTERCOOLERS
    The 12 cylinder engine has two intercoolers, one for SHUTDOWN* (MAXIMUM) 150 (66) 110 (43)
    each turbocharger, also mounted at the rear. *Fuel shutoff type safety equipment must be provided to prevent
    engine damage and possible personal injury.

    FORM 6248 First Edition 5.15 - 1


    AIR INDUCTION SYSTEM

    MAIN AIR FILTER ......~..


    ELEMENT~

    PRECLEANER
    PAD
    "'-...

    FILTER ELEMENT
    FRAME

    .
    !,
    RAIN SHIELD

    Figure 5.15-1. Air Cleaner Assembly

    AIR CLEANERS )
    The 12 cylinder engine has left bank and right bank air
    cleaners. "G" engine air cleaners are rear mounted.
    "GSI" and "GL" engine air cleaners are side-mounted at
    the rear. Each air cleaner consists of the air filter frame,
    main air filter element, prefilter pad, air intake restriction
    indicator and rain shield. (See Figure 5.15-1)
    PRECLEANER PAD REMOVAL
    The precleaner is a foam rubber pad that increases the
    life of the main air filter element. Inspect and clean the
    precleaner pad daily or as required. This can be done
    while the engine is running. Replace the precleaner pad
    every 4000 running hours, or more often if necessary.

    1. Locate the four threaded mounting studs on the


    air cleaner assembly and loosen the front lock nut
    (5/16 inch) on each (see Figure 5.15-2). (The rear
    lock nut is loosened only for removal of the main air
    filter frame and element.)

    2. Raise up and remove the rain shield.

    3. Peel the precleaner pad off the main air filter REAR
    element. LOCKNUT
    I
    Figure 5.15-2. Air Cleaner Assembly

    5.15 - 2 FORM 6248 First Edition


    AIR INDUCTION SYSTEM

    PRECLEANER PAD CLEANING AND INSPECTION MAIN AIR FILTER ELEMENT CLEANING AND
    INSPECTION
    1. Wash the precleaner pad with soap and water.
    1. Clean the main air filter element using one of the
    CAUTION I~ompressed
    I A=~::..;;....:..;;:......;,-,,-;;;....;,--,.
    air can eas-
    following methods.
    .L .::
    ... ily damage the foam rub-
    A. Gently tap the element on a flat surface with the
    ber pad. Disregarding this information could result
    dirty side of the element down.
    in product damage and/or personal injury.
    2. Air dry the pad. Do not use compressed air.
    A WARNING
    PRECLEANER PAD INSTALLATION Compressed air can pierce the skin and cause
    severe personal injury or death. Never use your
    A CAUTION I~n ne~
    I,!!"'!!:!!!~:::':"":':::"'::"':"=:..:.J.
    L.
    engines, a card-
    board Insert between the
    ralnshleld and precleaner pad must be removed
    hand to check for leaks or to determine air flow
    rates. Wear safety glasses to shield your eyes from
    flying dirt and debriS.
    before the engine Is started. Disregarding this
    information could result In product damage and/or B. Direct compressed air through the element
    personal injury. opposite the direction of the air flow, as indi-
    cated by the orange arrow on the instruction
    1. Reinstall the precleaner pad between the rain shield label. The air pressure should be a maximum of
    and the main air filter element. If necessary; use a drop 30 psi (2.1 Kg/cm2).
    of adhesive on the corners to keep it from falling.
    C. Soak the element in a solution of lukewarm water
    2. Do not clean and reuse the precleaner pad more and nonfoaming detergent for about 10 minutes.
    than three times. Replace with a new precleaner pad. The outlet side of element must be held above
    the water level. Rinse the element with a gentle
    NOTE: Use only Waukesha supplied prec/eaner pads.
    spray of water.
    3. Lower the rain shield on the four mounting studs of
    the air cleaner assembly. Alternately re-tighten the front
    lock nuts (5/16 inch). IA
    ...
    CAUTION I Compressed air can eas-
    ily damage the pleated
    4. Clean or replace the main air filter element if the air paper of the main air filter element. Disregarding
    intake restriction indicator "pops" red after installation of this Information could result in product damage
    a new or cleaned precleaner pad. andlor personal injury.

    MAIN AIR FILTER ELEMENT REMOVAL D. Air dry the element. Do not use compressed air.
    Inspect and clean the main air filter element every 30 2. Carefully examine the element after cleaning. If
    days or as required. Replace the main air filter element damaged, replace.
    every 6 months, or more often if necessary.
    NOTE: Use only Waukesha supplied air filter elements.
    1. Locate the four threaded mounting studs on the
    air cleaner assembly and loosen the front lock nut 3. Do not clean and reuse the main air filter element
    (5/16 inch) on each (see Figure 5.15-2). more than three times. Replace with a new element.
    2. Raise up and remove the rain shield. 4. Inspect the air duct for cracks. All of the combustion
    air must pass through the main air filter element, not
    3. Peel the precleaner pad off the main air filter
    through cracks or defects in the air cleaner assembly. If
    element. inspection of the and intake manifold yields an accu-
    4. Loosen the rear lock nut (5/16 inch) on each mulation of dust and grit, it is an indication that the main
    mounting stud until the flat washer behind it can be air filter element is not properly maintained or that air is
    brought forward far enough to clear the step in the getting into the system around or behind the element.
    welded bracket of the main air filter frame (see
    5. Inspect all air duct hoses. Replace any hose that is
    Figure 5.15-2). cracked or aged.
    5. Swing the four mounting studs to the outside in a
    horizontal motion.

    6. Remove the main air filter frame and element.

    FORM 6248 First Edition 5.15 - 3


    AIR INDUCTION SYSTEM

    MAIN AIR FILTER ELEMENT INSTALLATION NOTE: The operating temperature of the air intake
    restriction indicator is -65" to 200° F (-54° to 93" C). )
    NOTE: The orange flow arrow on the instruction label
    shows the direction of air flow. Always store the NOTE: Always check the signal of the air restriction
    elements with the air outlet side down. Dirt and dust on indicator before and after shutdown.
    the out/et side will pass into the engine when the Refer to Precleaner Pad and Main Air Filter Element
    element is installed. Cleaning if the air intake restriction exceeds the
    recommended specification.
    1. Install the main air filter element with the instruction
    label facing up. Fit the deflection brace on the outlet side NOTE: After the restriction problem is corrected, reset
    of the filter element over the horizontal bar running the indicator by depressing the black button on the
    across the front of the air duct chamber. plastic housing.

    2. Place the frame over the main air filter element. A WARNING
    3. Swing the four mounting studs to the inside in a The location of the air restriction Indicator relative
    horizontal motion so that they fit within the welded brackets to the Intake manifold causes it to be subjected to
    on the air filter frame. Move the flat washer behind the rear high pressure If the engine backfires. An Indicator
    lock nut back into the step in the welded bracket. filter must be installed in the Indicator air passage
    to dampen high pressure surges which would
    4. Install the precleaner pad between the rain shield otherwise damage the indicator. Through the pro-
    and the main air filter element. If necessary, use a drop jection of broken material, damage to the indicator
    of adhesive on the corners to keep it from falling. could result in severe personal injury or death. The
    restriction filter also protects against the entrance
    5. Lower the rain shield on the four mounting studs. of dust and dirt in the event that the restriction
    Indicator is broken off or removed.
    6. Alternately tighten the rear lock nuts (5/16 inch). Verify that the restriction filter is in place between the
    clean air tap and indicator.
    7. Alternately tighten the front lock nuts (5/16 inch) on
    )
    the four mounting studs.

    8. Check the frame of the main air filter elementto verify


    A WARNING
    Do not grasp the indicator housing; the plastic may
    that its perimeter is sealed tightly. Damage to the frame
    crack or break resulting in severe personal injury or
    may result in improper element sealing.
    death.
    AIR RESTRICTION INDICATOR 1. Turn the hex nut (7/16 inch) on the brass fitting to
    Each indicator is externally mounted on the air cleaner remove the restriction indicator and filter.
    housing (behind each air cleaner on "G" engines and on 2. Verify that the filter element is staked in place inside
    the end on "GSI" and "GL" engines) (see Figure 5.15-3). the fitting (see Figure 5.15-4). Replace the filter fitting if
    any damage is apparent.

    FILTER
    INDICATOR ELEMENT
    FILTER

    .~
    \
    AIR RESTRICTION
    INDICATOR

    Figure 5.15-4. Restriction Filter


    3. Inspect the plastiC restriction indicator for cracks.
    Figure 5.15-3. Air Restriction Indicator/Filter - Replace the indicator if damaged or defective. Finger
    GL/GSI Models Shown tighten the indicator to the filter fitting. No tools are
    necessary.
    The air restriction indicator will "pop" red when the air
    intake restriction through the main air filter element 4. Tum the hex nut (l/16 inch) on the brass fitting to install
    reaches or exceeds 15 inches (381 mm) of H20. the restriction indicator and filter in the air cleaner housing.

    5.15 - 4 FORM 6248 First Edition


    AIR INDUCTION SYSTEM

    2
    ~/

    ITEM NUMBER AND DESCRIPTION


    1 Duct 5 Duct 9 Hose 13 Lockwasher
    2 Nut 6 Gapscrew 10 Clamp 14 Washer
    3 Elbow 7 Lockwasher 11 Brace 15 Restriction Indicator
    4 Screw 8 Tube 12 Capscrew 16 Restriction Element
    Figure 5.15-5. Air Ducts - G

    AIR CLEANER DUCTS 3. Loosen the hose clamp attaching the hose to the air
    duct, and disconnect it.
    AIR CLEANER DUCT REMOVAL - G

    A WARNING A WARNING
    Do not grasp the Indicator housing; the plastic may The air duct weighs approximately 53 Ibs. (24 kg).
    crack or break resulting In severe personal injury or Use a suitable lifting device and exercise caution
    death. during removal or Installation to avoid severe
    personal injury or death.
    1. Refer to Precleaner Pad Removal and Main Air Filter
    Element Removal, and remove these components. 4. Attach a suitable lifting device to the air cleaner duct.

    2. Turn the hex nut (7/16 inch) on the brass fitting to


    remove the restriction indicator and filter from the air
    cleaner housing (see Figure 5.15-5).

    FORM 6248 First Edition 5.15 - 5


    AIR INDUCTION SYSTEM

    5. If removing the right bank air duct, refer to Crankcase 7. Remove the cross brace between the air duct flange
    Ventilation System, and remove the engine breather and engine. See Figure 5.15-8. )
    assembly from the air duct (see Figure 5.15-6).

    Figure 5.15-6. Engine Breather

    6. If removing the right bank air duct, loosen clamp, and


    disconnect the oil separator hose from the elbow at the
    rear of the air duct (see Figure 5.15-7).
    )

    Figure 5.15-6. Brace

    8. Remove two capscrews, lock washers and air duct


    from the engine (see Figure 5.15-5).

    Figure 5.15-7.011 Separator Hose

    5.15 - 6 FORM 6248 First Edition


    AIR INDUCTION SYSTEM

    AIR CLEANER DUCT INSTALLATION - G 8. Install the support bracket between the air duct and
    the intake manifold (see Figure 5.15-8).
    A WARNING 9. Turn the hex nut (7/16 inch) on the brass fitting to
    Do not grasp the indicator housing; the plastic may install the restriction indicator and filter in the air cleaner
    crack or break resulting severe personal Injury or housing (see Figure 5.15-5).
    death.
    10. Tighten the hose clamp on the air duct.
    1. Position the clamp on the air hose.
    11. Turn capscrew until it takes up all movement of the
    air duct (see Figure 5.15-9).
    A WARNING
    The air duct weighs approximately 53 Ibs. (24 kg)
    Use a suitable lifting device and exercise caution
    during removal or Installation to avoid severe
    personal InJury or death.

    2. Attach a suitable lifting device to the air cleaner duct.

    3. Using a suitable lifting device, position the air duct on


    the engine, connect the air hose to the air duct with the
    clamp (do not tighten).

    4. Install the air duct on the engine with two lock


    washers and capscrews (see Figure 5.15-5).

    5. Install the cross brace between the air duct flange


    and engine (see Figure 5.15-8).

    6. If installing the right bank air duct, refer to Crankcase


    Figure 5.15-9. Capscrew
    Ventilation System, and install the engine breather
    assembly on the air duct (see Figure 5.15-7).
    12. Refer to Precleaner Pad Installation and Main Air
    7. If installing the right bank air duct, refer to Crankcase Filter Element Installation, and install these components.
    Ventilation System and connect the oil separator hose
    (see Figure 5.15-7).

    FORM 6248 First Edition 5.15 -7


    AIR INDUCTION SYSTEM

    10
    9 ......
    ......@ @(' )
    ~25

    ITEM NUMBER AND DESCRIPTION


    1 Air Duct 9 Lockwasher 17 Brace 25 Capscrew
    2 Plate 10 Washer 18 Brace 26 capscrew
    3 Gasket 11 Gapscrew 19 Brace 27 Lockwasher
    4 Capscrew 12 Nut 20 Brace 28 Washer
    5 Lockwasher 13 Air Restriction Indicator 21 Gapscrew 29 Spacer
    6 Air Duct 14 Filter 22 Hump Hose
    7 Clamp 15 Bracket 23 Brace

    8 Capscrew 16 Bracket 24 Capscrew


    Figure 5.15-10. Air Ducts - GSI/GL
    AIR CLEANER DUCT REMOVAL - GSI/GL 1. Refer to Precleaner Pad Removal and Main Air Filter
    Element Removal, and remove these components.
    A WARNING 2. Turn the hex nut (7/16 inch) on the brass fitting to
    Do not grasp the indicator housing; the plastic may remove the restriction indicator and filter from the air
    crack or break resulting in severe personal injury or cleaner housing (see Figure 5.15-10).
    death.

    5.15 - 8 FORM 6248 First Ednion


    AIR INDUCTION SYSTEM

    3. Loosen the hose clamp attaching the hump hose to


    the turbocharger air inlet and disconnect it from the
    turbocharger inlet.

    4. Remove six capscrews, lock washers, circular cover


    plate and gasket from the air cleaner duct.

    A WARNING
    The air duct weighs approximately 53 Ibs. (24 kg).
    Use a suitable lifting device and exercise caution
    during removal or installation to avoid severe
    personal injury or death.

    5. Attach a suitable lifting device to the air cleaner duct.


    Figure 5.15-12. Air Duct Brace - Left Bank
    6. If removing the right bank air duct, remove the "U"
    bolt that holds the crankcase breather tube to the
    support bracket flange mounted on the right bank air
    duct (see Figure 5.15·11).

    Figure 5.15-11. Crankcase Breather Tube

    7. Remove the cross braces between the air duct


    flange and intercooler mounted support bracket. See
    Figure 5.20-14.

    8. Remove the support braces between the bottom air


    duct flange and the flywheel housing (see Figure 5.15-13. Air Duct Braces - Right Bank
    Figure 5.15·12).

    9. Remove the support braces between the air duct and 11. Using a suitable lifting device, remove the air duct
    the exhaust manifold water outlet elbow (see from the engine.
    Figure 5.15-13).
    12. Loosen the rematnlng clamp, and remove the
    10. Remove the support brackets between the air duct hump hose from the air duct.
    and the intake manifold (see Figure 5.15-11).

    FORM 6248 First Edition 5.15 - 9


    AIR INDUCTION SYSTEM

    AIR CLEANER DUCT INSTALLATION - GSI/GL AIR TUBING


    )
    A WARNING AIR TUBING REMOVAL - G

    Do not grasp the indicator housing; the plastic may 1. Loosen the four hose clamps on the air tube (see
    crack or break resulting in severe personal injury or Figure 5.15-14).
    death.

    1. Install the hump hose on the air duct with one clamp.

    2. Install the hose clamp on the turbocharger inlet, do


    not tighten.

    A WARNING
    The air duct weighs approximately 53 Ibs. (24 kg).
    Use a suitable lifting device and exercise caution
    during removal or installation to avoid severe
    personal injury or death.

    3. Attach a suitable lifting device to the air cleaner duct.

    4. Using a suitable lifting device, position the air duct on Figure 5.15-14. Air Intake Pipes - G
    the engine, connect the hump hose to the turbocharger
    air inlet with the remaining clamp (do not tighten). 2. Remove the four capscrews, lock washers, air horn
    flange, and the air intake pipe from the carburetor air
    5. Install the cross braces between the air duct flange
    horn and air tube.
    and intercooler mounted support bracket (see
    Figure 5.20-14). 3. Remove the air tube from the air duct.
    )
    6. Install the support brace between the bottom air duct 4. Remove hose clamps and hoses from the air tube.
    flange and the flywheel housing (see Figure 5.15-12).
    5. Remove the O-ring from the groove in the end ofthe
    7. Install the support brace between the air duct and the air intake pipe (see Figure 5.15-15).
    exhaust manifold water outlet elbow (see
    Figure 5.15·13).

    a. Install the support bracket between the air duct and


    the intake manifold (see Figure 5.15-11).

    9. TIghten the clamp to secure the hump hose on the


    turbocharger (see Figure 5.15-10). AIR INTAKE
    / PIPE
    10. Install six capscrews, lock washers, circular cover
    plate and gasket on the air cleaner duct.

    11. If installing the right bank air duct, install the "U" bolt
    that holds the crankcase breather tube to the support
    bracket flange mounted on the right bank air duct (see
    Figure 5.15-11).

    12. Turn the hex nut (7/16 inch) on the brass fitting to
    install the restriction indicator and filter in the air cleaner
    housing (Figure 5.15-3).

    13. Refer to Precleaner Pad Removal and Main Air


    Filter Element Removal, and install these components.

    Figure 5.15-15. Air Pipe And Air Horn

    5.15 - 10 FORM 6248 First Edition


    AIR INDUCTION SYSTEM

    AIR TUBING INSTALLATION - G 3. Remove two capscrews, lock washers and intercool-
    er air outlet tube from the intercooler (see
    1. Install the O-ring on the air intake pipe (see Figure 5.15-17).
    Figure 5.15-15).

    2. Install the air intake pipe on the carburetor air horn


    with air horn flange, four capscrews, and lock washers.

    3. Position two hoses and four clamps on the air tube


    with the ends of the hoses even with the air tube ends.

    4. Position the air tube on the air cleaner duct and the
    carburetor air pipe.

    5. Install the air tube on the air duct and the carburetor
    air pipe by sliding the hoses out and tightening the
    clamps on the air duct and carburetor air pipe.

    AIR TUBING REMOVAL - GSI

    1. Loosen the two hose clamps on the air hose between Figure 5.15-17. Intercooler Air Outlet Tube And
    the intercooler air outlet tube and the air intake pipe (see Intercooler
    Figure 5.15-16).

    4. Remove the intercooler air outlet tube from the air


    intake pipe.

    5. Remove the two hose clamps, air hose and support-


    ing clamp from the intercooler air outlet tube (see
    Figure 5.15-16).

    6. Remove the O-ring from the groove in the intercool-


    er air outlet tube (see Figure 5.15-18).

    Figure 5.15-16. Intercooler Air Outlet Tube - GSI

    2. Remove nut, lock washer, capscrew, and supporting


    clamp from the intercooler air ouUet tube.

    Figure 5.15-18. Intercooler Air Outlet Tube


    )

    FORM 6248 First Edition 5.15 - 11


    AIR INDUCTION SYSTEM

    7. Remove four capscrews, lock washers, air horn AIR TUBING REMOVAL - GL
    flange, and air intake pipe from the carburetor air horn. )
    See Figure 5.15-19. 1. Remove two capscrews, lock washers and retainers
    from the intercooler air outlet tube and carburetor elbow
    (see Figure 5.15-20).

    AIR INTAKE
    #" PIPE

    Figure 5.15-20. Intercooler Air Outlet Tube - GL

    2. Remove two capscrews, lock washers and intercool-


    Figure 5.15-19. Air Intake Pipe And Carburetor er air outlet tube from the intercooler (see
    Figure 5.15-21). )
    8. Remove the O-ring from the groove on the air intake
    pipe.

    AIR TUBING INSTALLATION - GSI


    1. Install the O-ring on the air intake pipe (see
    Figure 5.15-19).

    2. Insta" the air intake pipe on the carburetor air horn


    with air horn flange, four capscrews, and lock washers.

    3. Insta" a new O-ring in the groove on the intercooler


    air outlet tube (see Figure 5.15-17).

    4. Position supporting clamp, hose, and two hose


    clamps on the intercooler air outlet tube (see
    Figure 5.15-16).
    Figure 5.15-21. Intercooler Air Outlet Tube
    5. Position the intercooler air outlet tube on the
    intercooler and air intake pipe. 3. Remove the intercooler air outlet tube from the
    engine.
    6. Insta" the air outlet tube on the intercooler air oudet
    port with two capscrews and lock washers (see
    Figure 5.15-18).

    7. Insta" the intercooler air outlet tube on the engine


    with supporting clamp, capscrew, lock washer and nut
    (see Figure 5.15-16).

    8. Secure the intercooler air outlettube on the air intake


    pipe with the two hose clamps (see Figure 5.15-16).

    5.15-12 FORM 6248 First Ed~ion


    AIR INDUCTION SYSTEM

    4. Remove the O-ring from the groove on the carbure- 5. Remove the O-ring from the groove on the intercool-
    tor elbow end of the intercooler air outlet tube (see er end of the air intake pipe (see Figure 5.15-23).
    Figure 5.15-22).

    Figure 5.15-22. Intercooler Air Outlet Tube 0- ring -


    Carburetor End

    Figure 5.15-23. Intercooler Air Outlet Tube -


    Intercooler End

    6. Remove six capscrews, lock washers, carburetor


    elbow, and gasket from the carburetor air horn (see
    Figure 5.15-24).

    /~,
    CAPSCREW /" ~
    LOCK /
    WASHER
    RETAINER

    /~, ....
    CAPSCREW ~ ....

    LOCK /
    WASHER

    CARBURETOR ELBOW

    Figure 5.15-24. Carburetor Air Horn And Elbow

    FORM 6248 First Edilion 5.15 -13


    AIR INDUCTION SYSTEM

    AIR TUBING INSTALLATION - GL INTAKE MANIFOLDS


    1. Install the carburetor elbow and gasket on the
    )
    INTAKE MANIFOLD REMOVAL - GIGSI
    carburetor air horn with six capscrews and lock washers
    (see Figure 5.15-24). 1. Refer to Air Duct Removal, and remove the air duct
    support bracket from the manifold.
    2. Install the O-ring in the groove on the carburetor 2. Refer to Throttle Control Valve Removal, and
    elbow end of the intercooler air outlet tube (see remove the throttle control lever (right bank).
    Figure 5.15-22).
    3. Refer to Control Panel Removal, and remove the
    3. Install the O-ring in the groove on the intercooler end control panel from the manifold.
    of the air intake pipe (see Figure 5.15-23).
    NOTE: During the removal at the intake manifold, the
    4. Position the intercooler air outlet tube on the coils, coillHackets, tubing brackets and wire harness will be
    intercooler air outlet port and the carburetor elbow. removed when the capscrews lock washers and washers
    holding the intake manifold are removed. Refer to Intake
    5. Install the intercooler-to-carburetor air tube on the
    Manifold Attaching Hardware (GIGSI) for infonnation on
    intercooler air outlet port with two capscrews and lock
    the mounting location at these componenJs.
    washers (see Figure 5.15-21).
    4. Tag wires, and disconnect the ignition wires from the
    6. Instail the intercooler-to-carburetor air tube on the coils.
    carburetor elbow with two capscrews, lock washers and
    retainers (see Figure 5.15-24). 5. Remove four capscrews and lock washers from the
    upper flange of the butterfly valve housing (see
    Figure 5.15-25).

    )
    INTAKE MANIFOLD
    /
    PLUG. BRASS

    ,./

    ~ .
    WASHER
    ';Pf)
    /
    PLUG

    Figure 5.15-25. Intake Manifold - GlGSI

    5.15 -14 FORM 6248 First Edition


    AIR INDUCTION SYSTEM

    6. As required, refer to Ignition System Installation, and


    A WARNING install the coil brackets and coils.
    The Intake manifold weighs approximately 86 Ibs. 7. As required, on GL refer to Prechamber Manifold
    (39 kg). Use a suitable lifting device and exercise Installation, and install the prechamber brackets and
    caution during removal or Installation to avoid prechamber manifolds.
    severe personal injury or death.
    8. As required, refer to Air Duct Installation and install
    6. Attach a suitable lifting device to the intake manifold. the air duct brackets.

    7. Remove twenty-four capscrews, lock washers and 9. Refer to Throttle Control Lever Installation and install
    washers from the intake manifold. the throttle control lever.

    8. Remove the intake manifold from the cylinder heads. 10. Refer to Control Panel Installation and install the
    control panel.
    9. Remove six intake manifold gaskets from the intake
    manifold. 11. Refer to tags, and connect the ignition wires to the
    coils.
    10. Remove the gasket from the upper flange of the
    butterfly valve housing. 12. Refer to Figure 5.15-26 and torque the twenty-four
    capscrews, lock washers and washers on the intake
    11. If required, remove the small slotted brass plug and manifold in the sequence shown.
    and the headless countersunk pipe plug from the intake
    manifold. 13. Install the gasket, four capscrews and lock washers
    on the upper flange of the butterfly valve housing.
    12. If required, remove the large plugs and washers
    from the intake manifold.

    INTAKE MANIFOLD INSTALLATION - GIGSI

    1. If removed, apply pipe sealant to threads and install


    the small slotted brass plug and and the headless
    countersunk pipe plug on the intake manifold.

    2. If removed, install the large plugs and washers on


    the intake manifold.

    A WARNING
    The intake manifold weighs approximately 86 Ibs.
    (39 kg) use a suitable lifting device and exercise
    caution during removal or Installation to avoid
    severe personal InJury or death.

    3. Attach a suitable lifting device to the intake manifold.

    4. Position the intake manifold on the cylinder heads.

    NOTE: The coils, coil brackets, wire harness, and other


    brackets and accessories are secured by the intake
    manifold attaching hardware. Refer to Intake Manifold
    Attaching Hardware (G/GSI) for information on the
    mounting location of these components. Install these
    components as the intake manifold is installed.

    5. Install the gaskets washers, lock washers and


    capscrews on the intake manifold. Do nottighten until all
    the accessories and attaching hardware are installed as
    noted.

    FORM 6248 First Ed~ion 5.15 -15


    AIR INDUCTION SYSTEM

    RIGHT BANK )
    REAR 6R 5R 4R 3R 2R lR FRONT

    iriiV LAf.rffilO)a{ ·r--11 ·r,·


    l!.L.J.!l .... ~L J.
    I
    l!.L.J.!l l!.L.J. 6. j==:=--_=:=..--=----===
    FRONT 3L 4L 5L 6L REAR

    LEFT BANK

    :0:
    Figure 5.15-26. Intake Manifold Flange Attachments

    INTAKE MANIFOLD FLANGE lock washer and capscrew.


    ATTACHMENTS 4) Washer, lock washer and capscrew.
    2L
    INTAKE MANIFOLD FLANGE ATIACHMENTS -
    GIGSI 1) 9 inch coil rail (2 of 2 holes); lock washer and
    capscrew.
    Each intake manifold flange can be identified by the 2) 9 inch coil rail (1 of 2 holes); lock washer and )
    cylinder head to which it is attached. Right bank and left capscrew.
    bank cylinders are determined by standing at the 3) Wire harness cable retaining clip (heavy gauge)
    flywheel end of the engine facing the flywheel. The washer, lock washer and capscrew.
    cylinders farthest from the flywheel on the left and right 4) Washer, lock washer and capscrew.
    side are the #1 Land #1 R cylinders, respectively. Those
    3L
    closest to the flywheel are the #6L and #6R cylinders.
    1) 9 inch coil rail (2 of 2 holes) lock washer and
    NOTE: Facing the manifold, the numbers 1 and 2 are
    capscrew.
    the upper holes in the intake manifold flange, from left to 2) 10-1/8 inch coil rail (1 of 2 holes) lock washer and
    right. The numbers 3 and 4 are the lower flange holes, capscrew.
    left to right (see Figure 5.15-26).
    3) Wire harness cable retaining clip (light gauge) wire
    LEFT BANK harness cable retaining clip (heavy gauge, "G" engines
    cable from control box); washer, lock washer and
    NOTE: Use the shorter capscrews (1/2 x 1-3/4 inches) capscrew.
    wherever the light gauge harness cable clips and coil 4) Wire harness cable retaining clip (light gauge) lock
    rails are fastened to the intake manifold flanges. Use the washer and capscrew.
    longer intake manifold flange capscrews (1/2 x 2 inches) 4L
    wherever the heavy gauge harness cable clips or
    prechamber manifold brackets are installed. 1) 10-1/8 inch coil rail (2 of 2 holes) lock washer and
    capscrew.
    NOTE: Items in brackets ( ) are attached to the intake 2) 9 inch coil rail (1 of 2 holes) lock washers and
    manifold flanges later in the assembly procedure. capscrew.
    3) Washer, lock washer and capscrew.
    1L 4) Wire harness cable retaining clip (light gauge)
    1) Triangular shaped coil bracket (1 of 2 holes) lock washer, lock washer and capscrew.
    washer and capscrew.
    2) 9 inch ignition coil rail (1 of 2 holes) lock washer and
    capscrew.
    3) Wire harness cable retaining clip (heavy
    gauge);Triangular coil bracket (2 of 2 holes) washer,

    5.15 - 16 FORM 6248 First Edition


    AIR INDUCTION SYSTEM

    5L 5R
    1) 9 inch coil rail (2 of 2 holes) lock washer and 1) 9 inch coil rail (2 of 2 holes); lock washer and
    capscrew. capscrew.
    2) 9 inch coil rail (1 of 2 holes) lock washer and 2) 9 inch coil rail (1 of 2 holes); lock washer and
    capscrew. capscrew.
    3) Washer, lock washer and capscrew. 3) Wire harness cable retaining clip (light gauge);
    4) Wire harness cable retaining clip (light gauge) spacer, lube oil strainer support strap, lock washer and
    washer, lock washer and capscrew. capscrew.
    6L 4) (4-way tube clip bracket with clips for air/gas supply,
    vent, start and prelube tubes) washer, lock washer and
    1) 9 inch coil rail (2 of 2 holes); lock washer and capscrew.
    capscrew.
    2) Washer, lock washer and capscrew. 4R
    3) Washer, lock washer and capscrew. 1) 9 inch coil rail (2 of 2 holes) lock washer and
    4) Washer, lock washer and capscrew. capscrew.
    2) 10-1/8 inch coil rail (1 of 2 holes) lock washer and
    RIGHT BANK
    capscrew.
    NOTE: Use the shorter capscrews (1/2 x 1-3/4 inches) 3) Wire harness cable retaining clip (light gauge);
    wherever the light gauge harness cable clips and coil (retaining clip for the lube oil pressure tube between the
    rails are fastened to the intake manifold flanges. Use the main oil header and the instrument panel) lock washer
    longer intake manifold flange capscrews (1/2 x 2 inches) and capscrew.
    wherever the heavy gauge harness cable clips or 4) Washer, lock washer and capscrew.
    prechamber manifold brackets are installed. 3R
    NOTE: At the #5R cylinder, use a 1/2 x 2-3/4 inch 1) 10-1/8 inch coil rail (2 of 2 holes) lock washer and
    capscrew (with lock washer, flat washer and 1-1/4 inch capscrew.
    spacer) to secure the strainer head support strap to the 2) 9 inch coil rail (1 of 2 holes); lock washer and
    lower rear flange hole. capscrew.
    3) Wire harness cable retaining clip (light gauge)
    NOTE: Items in brackets ( ) are attached to the intake washer, lock washer and capscrew.
    manifold flanges later in the assembly procedure. 4) Wire harness cable retaining clip (light gauge)
    6R washer, lock washer and capscrew.

    1) Triangular shaped coil bracket (1 of 2 holes) lock 2R


    washer and capscrew. 1) 9 inch coil rail (2 of 2 holes) lock washer and
    2) 9 inch ignition coil rail (1 of 2 holes) lock washer and capscrew.
    capscrew. 2) 9 inch coil rail (1 of 2 holes); lock washer and
    3) Triangular coil bracket (2 of 2 holes); wire harness capscrew.
    cable retaining clip (light gauge) washer, lock washer 3) Washer, lock washer and capscrew.
    and capscrew. 4) Wire harness cable retaining clip (heavy gauge);
    4) (4-way tube clip bracket with clips for air/gas supply, washer, lock washer and capscrew.
    vent, start and prelube tubes) washer, lock washer and 1R
    capscrew.
    1) 9 inch coil rail (2 of 2 holes); lock washer and
    capscrew.
    2) Washer, lock washer and capscrew.
    3) Wire harness cable retaining clip (heavy gauge);
    washer, lock washer and capscrew.
    4) Wire harness cable retaining clip (heavy gauge);
    washer, lock washer and capscrew.

    FORM 6248 First Edition 5.15 - 17


    AIR INDUCTION SYSTEM

    I )

    e=
    1/@
    16/
    18/

    ITEM NUMBER AND DESCRIPTION


    1 Intake ManHold 6 Washer 11 Capscrew 16 Lockwasher
    2 Plug 7 Lockwasher 12 Plug 17 Stud

    3 Plug 8 Cover 13 Adapter 18 Nut

    4 Gasket 9 Cover 14 Gasket 19 Plug

    5 Capscrew 10 Gasket 15 Capscrew


    Figure 5.15-27. Intake Manifold - GL
    INTAKE MANIFOLD REMOVAL - GL 3. Tag wires, and disconnect the ignition wires from the
    coils.
    1. Refer to Air Duct Removal, and remove the air duct
    support bracket from the manifold. 4. Remove four nuts and lock washers from the upper
    flange of the manifold inlet adapter (see
    2. Refer to Control Panel Removal, and remove the Figure 5.15-27).
    control panel from the manifold.

    NOTE: During the removal of the intake manifold, the


    coils, coil brackets, tube brackets, wire harness,
    A WARNING
    prechamber manifold and prechamber bracket will be The intake manifold weighs approximately 86 Ibs.
    removed when thecapscrews and lock washers holding (39 kg). Use a suitable lifting device and exercise )
    the intake manifold are removed. Refer to Intake caution during removal or installation to avoid
    Manifold Attaching Hardware (GL) for information on severe personal injury or death.
    the mounting location of these components 5. Attach a suitable lifting device to the intake manifold.

    5.15 -18 FORM 6248 Rrst Edition


    AIR INDUCTION SYSTEM

    6. Remove twenty-four capscrews, lock washers and 4. Position the intake manifold on the cylinder heads.
    washers from the intake manifold.
    NOTE: The coils, coil brackets, wire harness, tube
    7. Remove the intake manifold from the cylinder heads. brackets, prechamber manifold, prechamber bracket
    and other brackets and accessories are secured by the
    8. Remove six intake manifold gaskets from the intake
    intake manifold attaching hardware. Refer to Intake
    manifold. Manifold Attaching Hardware (GL) for information on
    9. Remove the gasket from the upper flange of the the mounting location of these components. Install
    manifold inlet adapter. these components as the intake manifold is installed.

    10. If required, remove the four capscrews, lock 5. Install the gaskets washers, lock washers and
    washers, flange cover, and gasket from each end of the capscrews on the intake manifold. Do nottighten until all
    intake manifold. Remove the two square head pipe of the attaching hardware is installed. Refer to Manffold
    plugs from the flange cover. Flange Attachments for details on the installation of
    attaching hardware
    11. If required, remove the two square head pipe plugs
    and the countersunk headless pipe plug from the intake 6. As required, refer to Ignition System Installation, and
    manifold. install the coil brackets and coils.

    INTAKE MANIFOLD INSTALLATION - GL 7. As required, on GL refer to Prechamber Manifold


    Installation, and install the prechamber brackets and
    1. If removed, install the four capscrews, lock washers, prechamber manifolds.
    flange cover, and gasket on each end of the intake
    manifold. Apply pipe sealant to threads and install the 8. As required, refer to Air Duct Installation and install
    two square head pipe plugs on the flange cover (see the air duct brackets.
    Figure 5.15-27). 9. Refer to Throttle Control Lever Installation and install
    2. If removed, apply pipe sealant to threads and install the throttle control lever.
    the two square head pipe plugs and the countersunk 10. Refer to Control Panel Installation and install the
    headless pipe plug on the intake manifold. control panel.

    A WARNING
    11. Refer to tags, and connect the ignition wires to the
    coils.
    The intake manifold weighs approximately 86 Ibs. 12. Referto Figure 5.15-28 and torque the twenty-four
    (39 kg). Use a suitable lifting device and exercise capscrews, lock washers and washers on the intake
    caution during removal or installation to prevent manifold in the sequence shown.
    severe personal injury or death.
    13. Install the butterfly valve housing to the intake
    3. Attach a suitable lifting device to the intake manifold. manifold with gasket, four capscrews and lock washers.

    RIGHT BANK
    REAR 6R 5R 4R 3R 2R lR FRONT

    ["riP LAf."r&l0} IOr,o


    w ~~~ ~~o~F=~__~~~w~~=~=J=o
    FRONT 3L 4L 5L 6L REAR

    LEFT BANK

    :0:
    Figure 5.15·28. Inlake Manifold Flange Attachments

    FORM 6248 First Ednion 5.15 - 19


    AIR INDUCTION SYSTEM

    INTAKE MANIFOLD FLANGE ATTACHMENTS - GL 4L


    Each intake manifold flange can be identified by the 1) 10-1/8 inch coil rail (2 of 2 holes) lock washer and
    cylinder head to which it is attached. Right bank and left capscrew.
    bank cylinders are determined by standing at the 2) 9 inch coil rail (1 of 2 holes) lock washers and
    flywheel end of the engine facing the flywheel. The capscrew.
    cylinders farthest from the flywheel on the left and right 3) Washer, lock washer and capscrew.
    side are the #1 Land #1 R cylinders, respectively. Those 4) Wire harness cable retaining clip (light gauge)
    closest to the flywheel are the #6L and #6R cylinders. washer, lock washer and capscrew.

    NOTE: Facing the manifold, the numbers 1 and 2 are 5L


    the upper holes in the intake manifold flange, from left to 1) 9 inch coil rail (2 of 2 holes) lock washer and
    right. The numbers 3 and 4 are the lower flange holes, capscrew.
    left to right (see Figure 5. 15-28). 2) 9 inch coil rail (1 of 2 holes) lock washer and
    capscrew.
    LEFT BANK 3) Washer, lock washer and capscrew.
    NOTE: Use the shorter capscrews (1/2 x 1-3/4 inches) 4) Wire harness cable retaining clip (light gauge)
    wherever the light gauge hamess cable clips and coil washer, lock washer and capscrew.
    rails are fastened to the intake manifold flanges. Use the 6L
    longer intake manifold flange capscrews (1/2 x 2 inches)
    1) 9 inch coil rail (2 of 2 holes); prechamber manifold
    wherever the heavy gauge harness cable clips or
    bracket (1 of 2 holes) lock washer and capscrew.
    prechamber manifold brackets are installed.
    2) Prechamber manifold bracket (2 of 2 holes) washer,
    NOTE: Items in brackets ( ) are attached to the intake lock washer and capscrew.
    manifold flanges later in the assembly procedure. 3) Washer, lock washer and capscrew.
    4) Washer, lock washer and capscrew.
    lL
    RIGHT BANK
    1) Triangular shaped coil bracket (1 of 2 holes) lock
    washer and capscrew. NOTE: Use the shorter capscrews (1/2 x 1-3/4 inches) )
    2) 9 inch ignition coil rail (1 of 2 holes) lock washer and wherever the light gauge harness cable clips (see
    capscrew. Figure 5. 15-29) and coil rails are fastened to the intake
    3) Wire harness cable retaining clip (heavy manifold flanges. Use the longer intake manifold flange
    gauge);Triangular coil bracket (2 of 2 holes) (flexible capscrews (1/2 x 2 inches) wherever the heavy gauge
    hose (auxiliary water pump to intercooler cooling water harness cable clips or prechamber manifold brackets
    supply pipe support brace) washer, lock washer and are installed.
    capscrew.
    4) Washer, lock washer and capscrew. NOTE: At the #5R cylinder, use a 1/2 x 2-3/4 inch
    capscrew (with lock washer, flat washer and 1-1/4 inch
    2L
    spacer) to secure the strainer head support strap to the
    1) 9 inch coil rail (2 of 2 holes); prechamber manifold lower rear flange hole.
    support bracket (1 of 2 holes); lock washer and
    capscrew. NOTE: Items in brackets ( ) are attached to the intake
    2) 9 inch coil rail (1 of 2 holes); prechamber manifold manifold flanges later in the assembly procedure.
    support bracket (2 of 2 holes);lock washer and caps- 6R
    crew.
    3) Wire harness cable retaining clip (heavy gauge) 1) Triangular shaped coil bracket (1 of 2 holes) lock
    washer, lock washer and capscrew. washer and capscrew.
    4) Washer, lock washer and capscrew. 2) 9 inch ignition coil rail (1 of 2 holes) lock washer and
    capscrew.
    3L 3) Triangular coil bracket (2 of 2 holes); wire harness
    1) 9 inch coil rail (2 of 2 holes) lock washer and cable retaining clip (light gauge) washer, lock washer
    capscrew. and capscrew.
    2) 10-1/8 inch coil rail (1 of 2 holes) lock washer and 4) (4-way tube clip bracket with clips for air/gas supply,
    capscrew. vent, start and prelube tubes) washer, lock washer and
    3) Wire harness cable retaining clip (light gauge) capscrew. )
    washer, lock washer and capscrew.
    4) Wire harness cable retaining clip (light gauge) lock
    washer and capscrew.

    5.15 - 20 FORM 6248 First Ed~ion


    AIR INDUCTION SYSTEM

    5R 3) Wire harness cable retaining clip (light gauge)


    1) 9 inch coil rail (2 of 2 holes); prechamber manifold washer, lock washer and capscrew.
    bracket (1 of 2 holes) lock washer and capscrew. 4) Wire harness cable retaining clip (light gauge)
    2) 9 inch coil rail (1 of 2 holes); prechamber manifold washer, lock washer and capscrew.
    bracket (2 of 2 holes) lock washer and capscrew. 2R
    3) Wire harness cable retaining clip (light gauge); 1) 9 inch coil rail (2 of 2 holes) lock washer and
    spacer, lube oil strainer support strap, lock washer and capscrew.
    capscrew. 2) 9 inch coil rail (1 of 2 holes); lock washer and
    4) (4-way tube clip bracket with clips for air/gas supply, capscrew.
    vent, start and prelube tubes) washer, lock washer and 3) Wire harness cable retaining clip (heavy gauge);
    capscrew. (prechamber regulator gas outlet tube bracket with
    4R retaining clip) washer, lock washer and capscrew.
    1) 9 inch coil rail (2 of 2 holes) lock washer and 4) Wire harness cable retaining clip (heavy gauge);
    capscrew. (prechamber regulator mounting bracket) washer, lock
    2) 10-1/8 inch coil rail (1 of 2 holes) lock washer and washer and capscrew.
    capscrew. 1R
    3) Wire harness cable retaining clip (light gauge); 1) 9 inch coil rail (2 of 2 holes); prechamber manifold
    (retaining clip for the lube oil pressure tube between the support bracket (1 of 2 holes) lock washer and
    main oil header and the instrument panel) lock washer capscrew.
    and capscrew. 2) Prechamber manifold support bracket (2 of 2 holes);
    4) Washer, lock washer and capscrew. Washer, lock washer and capscrew.
    3R 3) (Prechamber regulator mounting bracket), wire
    1) 10-1/8 inch coil rail (2 of 2 holes) lock washer and harness cable retaining clip (heavy gauge); washer,
    capscrew. lock washer and capscrew.
    2) 9 inch coil rail (1 of 2 holes); lock washer and 4) Wire harness cable retaining clip (heavy gauge);
    capscrew. washer, lock washer and capscrew.

    LEFT BANK
    lL 2L 3L 4L 5L 6L

    REAR

    HEAVY CLIPS LIGHT CLIPS


    (0.048" GAUGE) (0.032" GAUGE)

    RIGHT BANK
    6R 5R 4R 3R 2R lR

    REAR

    LIGHT CLIPS HEAVY CLIPS


    (0.032" GAUGE) (0.048" GAUGE)

    Figure 5.15-29. Wire Harness Cable Clip Locations

    FORM 6248 First Edition 5.15 - 21


    AIR INDUCTION SYSTEM

    5.15-22 FORM 6248 First Edition


    SECTION 5.20 TURBOCHARGERS

    TURBOCHARGERS 3. loosen the hose clamps to detach the turbo air outlet
    elbow from the turbo compressor air outlet (see
    TURBOCHARGER(S) REMOVAL Figure 5.20-2).

    A WARNING
    Operation ofthe turbocharger(s) without all air inlet
    and exhaust outlet connections In place can result
    In serious personal injury or death as well as severe
    damage to the turbocharger(s) and/or engine.

    A WARNING
    Insure that the turbochargers have cooled before
    performing any maintenance procedures. Failure to
    allow the turbochargers to cool could resuH In
    severe personal Injury or death.

    1. loosen the ferrule nut (1-1/8 inch hex) to detach the


    compressor discharge tube (3/4 inch tube aD) from the
    turbo air outlet elbow (male elbow or male connector
    tube fitting) (see Figure 5.20-1).
    Figure 5.20-2. Turbo Air Outlet Elbow - Rear Right

    4. Remove the turbo air outlet elbow from the engine.

    5. Remove and discard the a-ring from the outlet side


    of the turbo air outlet elbow (see Figure 5.20-3).

    Flgurl> 5.20-1. Turbo Air Outlet Elbow - Rear Right

    2. Remove two capscrews, washers and the turbo air


    outlet elbow from the intercooler air inlet port.
    Figure 5.20-3. Turbo Air Outlet Elbow

    6. Repeat Steps 1 - 5 on the other bank.

    FORM 6248 First Ednion 5.20 -1


    TURBOCHARGERS

    7. Remove the tube clip securing the upper turbo oil 11. Remove the upper section ofthe lower oil drain tube
    supply tube to the intercooler air inlet/outlet bonnet (see from the bottom flange of the turbo center housing.
    Figure 5.20-4).
    12. Loosen the union tube fitting ferrule nut to separate the
    upper and lower sections of the lower turbo oil drain tubes.

    13. Repeat Steps 11 - 12 on the other bank.

    14. Loosen the V-band coupling securing the rim ofthe


    exhaust elbow adapter to the rim of the turbo exhaust
    outlet.

    15. Loosen the hose clamp and remove the hump hose
    from the lip of the turbo compressor air inlet.

    A WARNING
    Each turbocharger weighs approximately 70 Ibs.
    (32 kg). Use a suitable lifting device and exercise
    caution during removal or Installation to avoid
    severe personal Injury or death.
    16. Remove four thin stainless steel nuts, four thick
    stainless steel nuts, eight stainless steel lock washers,
    four stainless steel capscrews gasket and the turbo-
    charger from the turbo exhaust inlet elbow. On models
    requiring a turbocharger adapter, remove gasket, four
    thin stainless steel nuts, four thick stainless steel nuts, )
    and four stainless steel lock washers from the stainless
    steel studs (see Figure 5.20-6).
    Figure 5.20-4. Turbo Upper 011 TUbe Clip

    8. Remove the upper oil supply tube from the top flange
    of the turbo center housing (see Figure 5.20-5).

    Figure 5.20-5. Turbo Clamps

    9. Loosen the union tube fitting ferrule nut to separate


    the lower turbo oil supply tubes sections (see Figure 5.20-6. Turbocharger
    )
    Figure 5.20-5).
    17. Move the turbocharger to a suitable workbench.
    10. Repeat Steps 7 - 9 on the other bank.
    18. Repeat Steps 14 - 17 on the other bank.

    5.20 - 2 FORM 6248 First Edition


    TURBOCHARGERS

    TURBOCHARGER CLEANING AND INSPECTION apparent, inspect the oil drain tubes for damage or
    Clean and inspect the turbocharger(s) every 6 months internal restrictions.
    (4320 hours). 4. Replace the turbocharger if any damage, sludge or

    I:A=~=..:..;;;;;....;~;:;...;~.
    CAUTION I
    carbon coking is found.
    Exercise care during in-
    .L..::
    ... spection of the turbo- 5. Look into the exhaust outlet to inspect the condition
    chargers to prevent the entrance of dirt or other of the turbine wheel. Loose material from the engine,
    foreign matter through the oil, air and exhaust such as small pieces of valves or rings, can cause
    openings. Disregarding this information could re- severe damage to the tips or leading edges of the
    sult in product damage and/or personal injury. turbine blades. Focus the beam of a flashlight between
    the turbine blades to the inside of the turbine housing in
    1. Look into the compressor air inlet to inspect the order to perform a proper inspection.
    condition of the compressor wheel (see Figure 5.20-7).
    Inspect the tips or leading edges of the blades to see if 6. Examine the outer contoured edges of the blades for
    they are pitted, nicked or chipped. Dust, dirt, sand or metal loss. Also check the housing wall adjacent to the
    other foreign material entering the compressor housing turbine for rub marks. Carbon coking or bearing failure
    from a leaking air inlet system will cause the leading can cause the blades to contact the turbine housing
    edges of the compressor wheel blades to erode. wall.

    2. Examine the outer contoured edges of the blades for 7. Inspect the inside of the turbine housing for carbon
    metal loss. Also check the compressor housing wall coking or signs of oil leakage. If any oil leakage is
    adjacent to the wheel for rub marks or dirt. Bearing observed, remove the upper turbo oil drain tube. Look
    failure or an excessive accumulation of dirt will cause for sludge buildup on the shaft between the bearing
    the blades to contact the compressor housing wall. journals and on the inner walls of the turbo center
    housing from the oil drain opening back to the turbine

    IA
    ...
    CAUTION I Thorough inspection
    and cleaning of the air
    end. If no sludge is apparent, inspectthe oil drain tubes
    for damage or internal restrictions.
    induction system is essential following compres- 8. Replace the turbocharger if any damage, sludge or
    sor wheel damage. Metal pieces from the compres- carbon coking is found.
    sor wheel may become imbedded in the air cleaner
    element. If the eiement is not changed, these pieces 9. Push inward on the compressor ~eel while rotating
    can be drawn Into the replacement turbocharger the shaft assembly by hand. Feel for drag, rubbing or
    and cause It to fail in the same manner as the binding. Verify that the wheels turn freely, without
    original unit. Disregarding this information could contacting the housings, backplate or shroud. Listen for
    result in product damage and/or personal injury. unusual noises. Repeat the procedure on the turbine
    side.
    3. Inspect the inside of the compressor housing for
    signs of oil leakage. If any oil leakage is observed, 10. Rotate the assembly by hand while pushing the
    remove the upper turbo oil drain tube. Look for sludge shaft up and down (sideways). Verify that the shaft turns
    buildup on the shaft between the bearing journals and smoothly without wheel rub.
    on the inner walls ofthe turbo center housing from the oil
    11. Replace the turbocharger if any drag, rubbing,
    drain opening back to the turbine end. If no sludge is
    binding or unusual noises are noted.

    FORM 6248 First Edition 5.20 - 3


    TURBOCHARGERS

    )
    THI<USiT BEARING

    MAGNETIC BASE

    MOUNTING
    ;ADAPTER

    - DIAL
    INDICATOR

    Figure 5.20·7. Check Turbocharger Axial Play

    Check the journal bearings for axial clearance as 17. Hand push the shaft assembly away from the )
    follows: turbine end of the turbocharger as far as it will go.
    Holding the shaft in position. note that the indicator
    12. Mount a dial indicator with a magnetic base on the pointer returns exactly to zero.
    exhaust outlet flange althe turbine end of the turbochar-
    ger. Set the dial indicator point on the flat end of the 18. Repeat Steps 12 - 17 to verify the first dial indicator
    turbine wheel assembly (see Figure 5.20-7). reading.

    I. ..=A. CAUTION I
    13. Hand push the shaft assembly away from the
    turbine end of the turbocharger as far as it will go. Continued operati.on ofa
    =c.....::..:.....:;..;;;....;;..;;..::....;;..;;..J. turbocharger haVing ex-
    14. Holding the shaft in position. zero the dial indicator cessive axial play will result in irreparable damage
    on the turbine end of the shaft. to the compressor wheel and housIng or to the
    turbine wheel assembly. DisregardIng this informa-
    15. Push on the compressor wheel to move the shaft tIon could result in product damage and/or person-
    assembly toward the turbine end olthe turbocharger as al injury.
    far as it will go.
    19. Replace the turbocharger if the maximum axial
    16. Holding the shaft in position. note the maximum play is less than 0.004 inch (0.102 mm) or greater than
    travel of the turbine wheel as shown on the indicator O.OOg inch (0.229 mm).
    dial.

    5.20 - 4 FORM 6248 First Edition


    TURBOCHARGERS

    DIAL
    OFFSET EXTENSION

    TURBINE WHEEL

    JOURNAL B~\RI~IGS·

    Figure 5.20-8. Check Turbocharger Radial Play

    Check the journal bearings for radial clearance as NOTE: Make sure that the dial indicator reading is the
    follows: maximum obtainable, which can be verified by rolling the
    wheels slightly in both directions while applying pressure.
    20. Attach a rack and pinion type dial indicator with a
    two inch long, 3/4 to 1 inch offset extension rod to the 24. Simultaneously apply equal hand pressure to both
    center housing so that the indicator plunger extends the compressor and turbine wheels to move the shaft
    through the oil outlet port (larger diameter hole in center assembly away from the dial indicator plunger as far as
    housing) and contacts the shaft of the turbine wheel it will go. Holding the shaft in position, note that the
    assembly. If required, a dial indicator mounting adapter indicator pointer returns exactly to zero.
    can be used (see Figure 5.20-8).
    25. Repeat Steps 20 - 24 to verify the first dial indicator
    21. Simultaneously apply equal hand pressure to both reading.
    the compressor and turbine wheels to move the shaft
    assembly away from the dial indicator plunger as far as
    it will gO. IA
    ..
    CAUTION Iturbocharger
    Continued operation of a
    haVing ex-
    22. Holding the shaft in position, set the dial indicator to cessive radial play will resuH in irreparable damage to
    zero. the compressor wheel and housing or to the turbine
    wheel and housing. Disregarding this infonnation
    23. Simultaneously apply equal hand pressure to both could resuH in product damage and/or personal injury.
    the compressor and turbine wheels to move the shaft
    assembly toward the dial indicator plunger as far as it 26. Replace the turbocharger if the maximum radial
    will go. Holding the shaft in position, note the maximum play is less than 0.003 inch (0.076 mm) or greater than
    movement of the shaft as shown on the indicator dial. 0.006 inch (0.152 mm).

    FORM 6248 Firs! Edilion 5.20 - 5


    TURBOCHARGERS

    NOTE: As long as the turbocharger passes all inspec- COMPRESSOR


    tion, an accumulation of dirt may be cleaned from the AIR OUTLET
    compressor wheel or housing wall.
    V-BAND COUPLING

    I.A. CAUTION IAny accumulation of dirt


    Indicates that the system
    INLET

    is not closed to foreign material. Carefully Inspect


    all turbocharger connections for air leaks. Damage
    to the turbocharger will occur if the source of the
    problem is not located and corrected. Disregarding
    this information could result in product damage
    and/or personal Injury.

    27. Mark the compressor and center housings with a


    paint stick, grease pencil or other marker to facilitate
    proper orientation of the compressor housing during
    assembly.

    IA CAUTION I~xe~cise care when re-


    .L .::
    . =:......=.-;;.;:;.....;;....;;..;:;....;;..~.
    . moving the compressor
    AIR INLET
    housing to avoid damage to the compressor wheel
    blades and/or personal Injury.
    Figure 5.20-10. Turbo V-Band Coupling
    28. Remove the V-band coupling between the com-
    pressor and center housings. Lift off the compressor
    A CAUTION I D~notuseascrewdrlver,
    housing (see Figure 5.20-9 and Figure 5.20-10).
    I=..
    =:......"-_ _ _....;.._..J. dirty rags, sandpaper,
    L..

    )
    emery cloth or steel wool to clean the compressor
    wheel or housing. Use of abrasive materials or
    caustic solutions will result In damage. Disregard-
    Ing this information could result in product damage
    and/or personal injury.

    I=.A. CAUTION I
    L.
    Use care to. prevent dirt
    or contaminants from
    =:......=....;...;:....;;....;;....;;;....;;..;;..J.
    entering the turbocharger. Disregarding this in-
    formation could resuh in product damage and/or
    personal injury.

    A WARNING
    Compressed air can pierce the skin and cause
    severe personal InJury or death. Never use your hand
    to check for leaks or to determine air flow rates. Wear
    Figure 5.20-9. Turbo V-Band Coupling safety glasses to shield your eyes from flying dirt
    and debris.

    29. Clean the compressor wheel and housing with a


    non-caustic cleaning solution. Use a soft hog bristle or
    nylon brush and a plastic blade scraper to completely
    remove all accumulated surface matter.

    30. Dry the compressor wheel and housing with


    moisture free compressed air.

    5.20 - 6 FORM 6248 First Edition


    TURBOCHARGERS

    31. Slide the V-band coupling over the turbo center housing. Center the inside groove of the V-band
    housing. coupling over the mated rims and finger tighten the lock
    nut.
    IA
    ..
    CAUTION I Exercise care when
    installing the compres-
    34. Match the painted marks on the compressor and
    center housings for proper orientation of the compres-
    sor housing to avoid damage to the compressor
    sor air outiet port.
    wheel blades and/or personal InJury.
    35. Torque the V-band coupling to 60 in-Ib (7 N·m). See
    32. Mate the rims of the compressor and center Figure 5.20-11.
    housings.

    33. Verify that the rim of the compressor housing is


    seated squarely against the rim of the turbo center

    ® ORIENTATE COMPRESSOR AIR OUTLET


    AND V-BAND TO 60 IN·LB (7

    o
    \ EXHAUST ELBOW

    G) TOROUE TURBO LOCK CAPSCREWS (8) TO


    160 IN·LB (18 N'M) AND BEND UP LOCKING TABS

    Figure 5.20-11. Turbocharger Torque Specifications

    FORM 6248 First Ed~ion 5.20 -7


    TURBOCHARGERS

    TURBOCHARGER INSTALLATION

    IA
    ..
    CAUTION I Exercise care during
    installation of the turbo-
    o ~==.... o
    chargers to prevent the entrance of dirt or other
    foreign matter through the oil, air and exhaust
    openings. Disregarding this Information could re-
    sult in product damage and/or personal Injury.
    O '=7==="'" 0
    1. Position a loosened V-band coupling on the exhaust
    elbow adapter.
    "'===~=~
    LIP
    2. Slide a loosened hose clamp onto the free end of the Figure 5.20-13. Turbo Exhaust Inlet Gasket
    hump hose connection.

    NOTE: Position the gasket with the lip on the inside


    A WARNING diameter facing the exhaust inlet elbow.
    Each turbocharger weighs approximately 70 Ibs. 4. Install the hump hose onto the lip of the turbo
    (32 kg). Use a suitable lifting device and exercise compressor air inlet. See Figure 5.20-14.
    caution during removal or installation to avoid
    severe personal injury or death.

    3. Install the turbocharger on the turbo exhaust inlet


    elbow with gasket, four stainless steel capscrews, eight
    stainless steel lock washers, four thick stainless steel
    nuts, and four thin stainless steel nuts (see
    Figure 5.20-12 and Figure 5.20-13). On models requir-
    ing a turbocharger adapter, Install gasket, four stainless )
    steel washers, four thick stainless steel nuts and four
    thin stainless steel nuts and four stainless steel lock
    washers on the stainless steel studs.

    Figure 5.20-14. Air Duct Braces - Intercooler

    Figure 5.20-12. Turbocharger

    5.20 - 8 FORM 6248 First Edijion


    TURBOCHARGERS

    5. Verify that the rim of the exhaust elbow adapter is 6. Torque the V-band coupling bolt to 60 in-Ib (7 N·m).
    seated squarely against the rim of the turbo exhaust
    outlet. Center the inside groove olthe V-band coupling 7. Tighten the hose clamp to secure the hump hose
    over the mated rims. See Figure 5.20-15 and connection to the turbo compressor air inlet.
    Figure 5.20-16.
    8. Repeat steps 1 - lOon the other bank.
    COMPRESSOR
    AIR OUTLET 9. Apply 3M Scotch-Grip ~ Rubber and Gasket Adhe-
    sive 847 to the flanges of the upper and lower turbo oil
    \ EXHAUST ELBOW
    supply tubes (see Figure 5.20-17 and Figure 5.20-18).

    ---~~~\

    TURBO OIL
    DRAIN TUBES
    ,,,
    UNI0:lllN
    TUBE
    EXHAUST
    FlmNG
    ,
    OUTLET
    "

    Figure 5.20-15. Turbo/Exhaust Elbow Connection Figure 5.20-17. Lower Turbo Oll'Drain Tubes
    - Left Bank

    OIL SUPPLY FLANGE OIL DRAIN FLANGE


    (TOP) (BOTTOM)

    Figure 5.20-1 B. TV94 Turbo 011 Supply/Draln Flanges

    10. Place new gaskets on the contact cement. Allow


    the gasket shellac to cure. See the manufacturer's
    recommendations.

    11. Finger tighten the ferrule nuts (union tube frtting) to


    join the upper and lower sections of the lower turbo oil
    supply tubes (both banks).

    Figure 5.20-16. V-Band Coupling

    FORM 6248 First Edition 5.20 - 9


    TURBOCHARGERS

    12. Fasten the upper section of the lower oil drain tubes
    to the bottom flange of the turbo center housings with 2 )
    allen head capscrews and lock washers (see
    Figure 5.20-19).

    Figure 5.20-19. Turbo 011 Supply Tubes

    13. Fasten the upper oil supply tubes to the top flange
    of the turbo center housings with 2 allen head caps-
    crews and lock washers).

    14. If it is necessary to re-orientate the center housing


    for attachment of the turbo oil supply/drain tubes, flatten )
    the tabs to free the eight turbo lock capscrews on the
    turbine side. Loosen each capscrew 1/4 turn to allow Figure 5.20-20. Turbo Upper 011 Supply Tubes
    rotation of the center housing.

    15. Attach the tube clips to the upper turbo oil supply
    tubes (above the union tube fitting). Fasten the clips to
    the intercooler air inlet/outlet bonnets (1 capscrew per
    clip, 3/8 x 2-1/2 inches, with lock washer, flat washer and
    1 inch spacer) (see Figure 5.20-20 and Figure 5.20-21).

    Figure 5.20-21. TUrbocharger Alignment

    5.20 - 10 FORM 6248 First Edrtion


    TURBOCHARGERS

    16. If loosened, torque the eight turbo lock capscrews 18. Slide two loosened hose clamps over the free end
    to 160 in-Ib (18 N·m) (see Figure 5.20-11 and of the turbo air outlet elbow hose connections (see
    Figure 5.20-22). Bend the rounded tabs on the end of Figure 5.20-23).
    each lock washer inward toward the head of the
    adjacent capscrew. Bend each tab forward until it rests 19. Apply Parker Super O-Lube® to the a-ring.
    tightly against the flat.
    20. Install a new a-ring in the groove on the outlet side
    (see Figure 5.20-24).

    Figure 5.20-22. Turbocharger Alignment Figura 5.20-24. TUrbo Air OuJIet Elbow

    17. If necessary, place a new rubber hose connection 21. Apply Loctite® Removable Threa:dlocker 242 to the
    on the tapered inlet end of the turbo air outlet elbows. threads of capscrews and position the 2 capscrews and
    Install two clamps towards the inside edge of each hose washers on the turbo air outlet elbow (see
    (see Figure 5.20-23). Figure 5.20-25).

    Figura 5.20-25. Turbo Air Outlet Elbow - Rear Right


    Figure 5.20-23. TUrbo Air Outlet Elbows

    FORM 6248 First Edition 5.20 -11


    TURBOCHARGERS

    22. With the free end of the male elbow tube fitting PRELUBE PRESSURE
    pointing horizontally toward the intercooler, insert the MAINTENANCE/CHECK VALVE )
    large end of the left bank turbo air outlet elbow into the
    INSPECTION
    intercooler air inlet port (7 inch 00). Align the holes in
    the winged flanges with those in the intercooler flange To ensure quick lubrication of the turbocharger(s) at
    and finger tighten the two fasteners. startup, the external supply line is provided with a check
    valve to keep the oil from draining back into the oil pan
    23. With the male connector tube fitting facing the rear, when the engine is shut down. The check valve also
    insert the large end of the right bank turbo air outlet prevents excessive lubrication of the turbochargers
    elbow into the intercooler air inlet port (7 inch 00). Align during continuous or intermittent prelube.
    the holes in the winged flanges with those in the
    intercooler flange and finger tighten the two fasteners.
    A WARNING
    24. Install the hose on the tapered inlet end olthe turbo If the prelube oil pressure reaches or exceeds 5 psi
    air outlet elbows, (see Figure 5.20-23) onto the lip of (35 kPa), oil flows through the supply line check
    each turbo compressor air outlet (see Figure 5.20-26). valve into the turbocharger housings. Startup ofthe
    TIghten the two hose clamps. engine may blow accumulated oil Into the intake
    manifold and carburetor, resuhing in oily depOSits
    that gum up internal surfaces. On the turbine side,
    oil leakage around the turbine housing poses a
    potential fire hazard. Disregarding this information
    could result in severe personal injury or death.

    Check the prelube oil pressure at least once each year.


    Also inspect the operation of the check valves.

    NOTE: For additional information, see Prelube and


    Starting Systems, and Lubrication System. )

    Figure 5.20-26. Turbo Air Outlet Elbow - Rear Right

    NOTE: If adjustment of the turbo compressor air outlet


    is necessary, loosen the V -band coupling on the
    compressor side of the turbo center housing. Rotate the
    compressor air outlet until it is aligned with the turbo air
    outlet elbow. Tighten the coupling.

    25. TIghten the capscrews to secure the turbo air outlet


    elbows to the intercooler air inlet ports. Loosen the
    capscrews slowly until the washers can be spun (see
    Figure 5.20-25).

    26. If loosened, torque the V-band coupling on the


    compressor side of the turbo center housing to 60 in-Ib
    (7 N·m).

    27. TIghten the ferrule nuts (1-1/8 inch hex) to attach )


    the compressor discharge tubes (3/4 inch tube 00) to
    the right and left bank turbo air outlet elbows (see
    Figure 5.20-24).

    5.20 - 12 FORM 6248 First Edition


    SECTION 5.25 - COOLING SYSTEM

    COOLING SYSTEM COMPONENTS EXHAUST MANIFOLD


    The cooling system consists of the following compo- From each cylinder head, water passes up through the
    nents: water outlet elbow connection to one segment of the
    water-jacketed exhaust manifold. A portion of the
    Jacket Water Circuit cooling water also exits the head through a hole
    • Jacket Water Header/Jacket Water centered below the exhaust port (see Figure 5.25-1).
    Each exhaust manifold assembly is comprised of six
    • Exhaust Manifold individual water-cooled segments.

    • Jacket Water Pump


    WATER OUTLET
    • Water Manifold ELBOW CONNECTION

    • Jacket Water Temperature Control Valve

    • Remote Heat Transfer Device

    Auxiliary Cooling Water Circuit


    • Auxiliary Water Pump

    • Intercooler

    • Oil Cooler

    • Auxiliary Water Temperature Control Valve

    • Auxiliary Water Heat Transfer Device

    JACKET WATER HEADER/JACKET WATER


    The cooling water passageways in both the crankcase EXHAUST
    PORT
    ~'
    ) _
    and cylinder head comprise the jacket water system.
    From the jacket water header, integrally cast within the WATER HOLE
    crankcase, cooling water circulates around the cylinder TO EXHAUST
    MANIFOLD CYLINDER
    sleeves. Three external sleeve seals ensure separation HEAD
    of the cooling water and lube oil inside the cylinder
    block. Passing up through seven water passage Figure 5.25-1. Water Outlet Hole
    openings in the deck of each cylinder head (see
    Figure 5.25-1, the cooling water flows around the valve WATER MANIFOLD
    seats, and exhaust guides en route to the water-cooled
    exhaust manifolds. See Figure 5.25-2 thru The water manifold receives the cooling water flowing
    Figure 5.25-6 for the cooling system arrangements out of each segment of the exhaust manifold and routes
    found on the engine. it to a thermostatically controlled water outlet header.

    FORM 6248 First Ednion 5.25 -1


    COOLING SYSTEM

    WATER OUTLET
    )

    WATER INLET
    FROM HEAT
    EXCHANGER
    )

    AUXILIARY
    WATER PUMP

    FROM HEAT
    EXCHANGER

    FROM INTERCOOLER
    SHIPPE,D LOOSE

    Figure 5.25-2. VHP Twelve Cylinder Cooling System - Cutaway View

    JACKET WATER PUMP center olthe gear cover. Cooling water exiting the pump
    A single centrifugal-type water pump, driven by two is piped to the jacket water headers (see Figure 5.25-2).
    belts from the crankshaft pulley, is mounted at the
    5.25 - 2 FORM 6248 First Edilion
    COOLING SYSTEM

    9"

    LEGEND NOTE:
    1. ENGINE JACKET COOLANT PUMP All connections to unit must be flexible.
    2. AUXILIARY COOLANT PUMP * Customer supplied component and piping.
    3. LUBE OIL COOLER (SHIPPED LOOSE - 12 & 16 CYL) - - Deaeration vent lines.
    4. TOP ENGINE WATER MANIFOLD 1/4" tubing or 1/2" tubing with 1/4" ormce at the engine.
    5. ENGINE JACKET THERMOSTATS
    6. ENGINE JACKET BYPASS
    7. ENGINE JACKET EXPANSION TANK
    8. ENGINE JACKET COOLER
    9. OPTIONAL COMPRESSOR COOLER
    (REQUIRES EXTRA CAPACITY AUX. PUMP)

    Figure 5.25-3. VHP G Engine Cooling System Schematic - Standard Jacket Water Temperature

    FORM 6248 First Edition 5.25 - 3


    COOLING SYSTEM

    8* )

    I
    I
    4 I
    I
    9* I
    I
    O·"'-_ _-'U"'---' I
    I
    __ ...1I

    2
    10*

    11*

    LEGEND NOTE:
    All connections to unit must be flexible.
    1. ENGINE JACKET COOLANT PUMP * Customer supplied component and piping.
    2. AUXILIARY COOLANT PUMP - - Deaeration vent lines.
    3. LUBE OIL COOLER (SHIPPED LOOSE - 12 & 16 CYL.)
    4. TOP ENGINE WATER MANIFOLD
    1/4" tubing or 1/2" tubing with 1/4" orifice at the engine. )
    5. ENGINE JACKET THERMOSTATS
    6. ENGINE JACKET BYPASS
    7. ENGINE JACKET EXPANSION TANK
    8. AUXILIARY EXPANSION TANK
    9. ENGINE JACKET COOLER
    10. AUXILIARY COOLER
    11. OPTIONAL COMPRESSOR COOLER
    (REQUIRES EXTRA CAPACITY AUX. PUMP)

    Figure 5.25-4. VHP G Engine Cooling System Schematic - Elevated Jackat Water Temperature

    5.25 - 4 FORM 6248 First Edilion


    COOLING SYSTEM

    ':::-:=- __________ ...f r------


    L _____ -'
    5
    I
    I
    4
    I
    I
    I
    I
    I
    I
    I
    --~

    2
    10"

    ".

    NOTE:
    LEGEND All connections to unit must be flexible.
    1. ENGINE JACKET COOLANT PUMP * Customer supplied component and piping.
    2. AUXILIARY COOLANT PUMP - - DeBeration vent Jines.
    3. LUBE OIL COOLER (SHIPPED LOOSE -12 & 16 CYL.) 1/4" tubing or 1/2" tubing with 1/4" orifice·at the engine.
    4. TOP ENGINE WATER MANIFOLD
    5. ENGINE JACKET THERMOSTATS
    6. ENGINE JACKET BYPASS
    7. ENGINE JACKET EXPANSION TANK
    8. AUXIUARY EXPANSION TANK
    9. ENGINE JACKET COOLER
    10. AUXILIARY COOLER
    11. OPTIONAL COMPRESSOR COOLER
    (REQUIRES EXTRA CAPACITY AUX. PUMP)

    Figure 5.25-5. VHP GSI Engine Cooling System Schematic - Standard And Elevated Jacket Water Temperatures

    FORM 6248 First Ednion 5.25 - 5


    COOLING SYSTEM

    ~~i..\....J0'i
    )
    ~ r------ ~
    i---t ----------~ 5-----' V

    '"I ill • HE- ~~:


    II 6 1
    "':'11
    i
    I
    9*

    0 ~
    ~~ - __ .Ji
    12*

    2'\::7

    1 10*

    3( I 1 '-
    J
    I 11"
    I
    I

    LEGEND NOTE:
    All connections to unit must be flexible,
    1. ENGINE JACKET COOLANT PUMP
    2. AUXILIARY COOLANT PUMP * Customer supplied component and piping.
    3. LUBE OIL COOLER ~SHIPPED LOOSE - 12 & 16 CYL) - - Deaeration vent lines.
    4. TOP ENGINE WATE MANIFOLD
    5. ENGINE JACKET THERMOSTATS
    1/4" tubing or 1/2" tubing wfth 1/4" orifice at the engine. )
    6. ENGINE JACKET BYPASS
    7. ENGINE JACKET EXPANSION TANK
    8. AUXILIARY EXPANSION TANK
    9. ENGINE JACKET COOLER
    10. AUXILIARY COOLER
    11. OPTIONAL COMPRESSOR COOLER
    (REQUIRES EXTRA CAPACITY AUX. PUMP)
    12. AUXILIARY CIRCUIT THERMOSTAT

    Figure 5.25-6. VHP GL Engine CoDling System Schematic - Standard And Elevated Jacket Water Temperatures

    5.25 - 6 FORM 6248 First Edition


    COOLING SYSTEM

    CLUSTER THERMOSTAT HOUSING warm up when the thermostatic valves are fully closed
    By regulating the circulation of coolant, multiple thermo- and efficient cooling once the valves open.
    static valves control the jacket water temperature
    normally at 180° F (83° C). A variety of other control
    temperatures are available. The thermostatic valves
    are enclosed in the cluster thermostat housing at the
    outlet end (front) of the water manifold.
    The thermostatic valves remain closed while the engine
    is warming up, so cooling water is circulated through the
    engine water jacket only. Water passes from the water
    manifold to the thermostat housing and back to the
    jacket water pump through the bypass tube(s) (see
    Figure 5.25-7).

    NOTE: Landfill gas and high temperature application


    engines use a weir notched seal thermostat design for a
    gradual transition of coolant flow. This thermostat
    series, does not require a "lead thermostaf' because of
    the weir notch seal design. Figure 5.25-7.12 Cylinder Cluster Thermostat
    The lead thermostat in the cluster thermostat housing Housing
    starts to open as the engine warms up to its normal
    operating temperature. A portion of the coolant is REMOTE HEAT TRANSFER DEVICE
    diverted to the remote heat transfer device, which The remote heat transfer devicemay be a radiator, cooling
    absorbs the heat and directs the coolant back to the fan, cooling tower, heat exchanger or other devices.
    jacket water pump. The supply from the heat transfer
    device mixes with that portion of the coolant that AUXILIARY WATER PUMP
    continues to flow down the bypass tube(s) to provide a The auxiliary water pump, driven by two belts from the
    blend that is within the normal range. crankshaft pulley, is mounted at the front of the oil pan.
    When the cooling water temperature rises 5° F (2.8° C) The suction side of the auxiliary water pump is
    above the Start to Open rating of the lead thermostat, connected to the outlet port of the auxiliary water
    the remaining thermostatic valves begin to open. temperature control valve (see Figure 5.25-8). The
    Opening of the secondary thermostats allows an even discharge of the pump is directed to the intercooler inlet
    greater portion of the cooling water to be directed to the through external piping.
    heat transfer device. This operation results in rapid

    ~~, WASTEGATE

    AUXILIARY WATER PUMP

    o 0
    o 0

    ~ INTERCOOLER~ ~~:d~ TEMPERATURE CONTROL VALVE


    o 0
    o 0

    FROM HEAT EXCHANGER

    OIL COOLER
    1-------'-----1---- TO HEAT EXCHANGER
    Figure 5.25-8. Auxiliary Cooling Water Circuit

    FORM 6248 First Ednion 5.25 -7


    COOLING SYSTEM

    INTERCOOLER
    Each intercooler is a box-type tube and fin assembly
    mounted at the rear of the engine. The flow of air
    between the aluminum cooling fins runs perpendicular
    to the vertical flow of cooling water in the copper tubes.
    The configuration of the upper and lower bonnets create
    a U-shaped path that enables the cooling water to pass
    through the core assembly four times before exiting the
    unit at the top (see Figure 5.25-9). Header plates
    separate the air passing through the casing from the
    cooling water in the upper and lower bonnets.
    A supply tube connected to the intercooler cooling water
    inlet, provides a continuous supply of cooling water to
    the wastegate(s). The cooling water enters the lower
    housing of the wastegate and passes through a cavity
    that encircles the valve guide. Exiting the outlet port on
    the opposite side of the lower housing, the water passes
    to the intercooler cooling water outlet through a water
    return tube (see Figure 5.25-8).

    OIL COOLER
    Exiting the outlet port of the intercooler, the coolant
    flows to the remote or ofI eng ine mounted oil cooler.
    The oil cooler is a tube and baffle type assembly. While
    the coolant flows through a bundle of tubes in the oil
    cooler, the lube oil circulates around them. Heat from )
    the oil passes through the tubes to the coolant which
    carries it to a heat transfer device for dissipation. From
    the heat transfer device, the coolant passes back to the
    auxiliary water pump to repeat the circuit.

    AUXILIARY WATER TEMPERATURE CONTROL


    VALVE
    One thermostatic valve controls the temperature of the
    auxiliary cooling water. To maintain the correct tempera-
    ture, the valve controls the flow of cooling water from the
    heat transfer device.
    The thermostatic valve is enclosed in a housing on the
    suction side of the auxiliary water pump.

    • Operational Description
    • Makes Four Passes Thru Intercooler
    • Configuration Of Water Inlel/OUllet Plate
    • Configuration Of Water Return Plate
    • Location Of End Casts
    • Configuration Of Tubing
    • AirSldes

    Figure 5.25~. Intercooler Flow

    5.25 - 8 FORM 6248 First Ed~ion


    COOLING SYSTEM

    The thermostat housing has one outlet port stamped A COOLING SYSTEM PROBLEMS
    and two inlet ports stamped B (oil cooler) and C (heat
    transfer device) (see Figure 5.25-10). The casting ofthe SCALE BUILD-UP, CAVITATION EROSION AND
    thermostat housing prevents the flow of cooling water CORROSION
    through inlet port C when the thermostat is fully closed. In frequency of occurrence, the three major cooling
    The flow from the oil cooler enters bypass port Band system problems are scale deposits, cavitation erosion
    exits outlet port A enroute to the auxiliary water pump. and system corrosion. Although these problems can
    cause considerable damage to the engine, each is
    OUTLET PORT A preventable.
    AUXILIARY WATER PUMP)
    SCALE BUILD-UP
    Scale build-up is by far the most common cooling
    THERMOSTATIC system problem and may lead to cracked cylinder
    VALVE
    heads and sticking valves.
    To allow for efficient heat absorption by the cooling
    water, coolant passageways must be kept clean and
    free of scale. Scale is a solid formed when the impurity
    concentration in water exceeds its solubility limit.
    Buildup of scale and minerals can completely plug
    coolant passageways. Even if just the walls of cooling
    passageways are coated, the ability of the engine to
    transfer heat is greatly reduced. Only 0.012 of an inch of
    scale (0.305 mm) may cut the transfer of heat by as
    much as 40%.
    The growth of scale deposits are affected by a number
    of variables, the most important of which are raw water
    chemistry, system operating temperatures, cooling
    water chemistry and make-up water usage.
    Waukesha recommends that all potential water sources
    be tested before use. Never use an untested water
    supply. Be sure that the manner in which the water is
    transferred to the engine does not contribute to the
    growth of scale deposits. Transporting cooling water in
    COOLING WATER INLET PORT C oily or rusty barrels will introduce contaminants that will
    (FROM HEAT TRANSFER DEVICE)
    foul the engine cooling system.
    Figure 5.25-10. Auxiliary Cooling Water Temperature Even engines with a high degree of scale buildup can be
    Control Valve cleaned. Acids are no longer recommended for clean-
    ing. Biodegradable products that emulsify oil and
    The thermostatic valve begins to open as the engine
    grease, loosen scale deposits and hold solid deposits in
    warms up to its normal operating temperature. The
    suspension are readily available on the market. Use of
    casting ofthethermostat housing is such that inlet port B
    biodegradable products also prevent the loss of metal in
    becomes restricted as outlet port C starts to open.
    the engine and do not damage gaskets and seals.
    Therefore, a smaller portion of the coolant is received
    from the oil cooler, while a greater portion of the cooling CAVITATION EROSION
    water comes from the heat transfer device. Cool water Cavitation erosion is a mechanical process of metal loss
    passing out the heat transfer device enters port C of the caused by the collapse of vapor bubbles against a
    thermostat housing and combines with hot water spinning or vibrating metal surface. The force exerted
    passing through bypass port B. The cooling water by the bursting vapor bubble is such that a very small
    exiting outlet port A is a blend that falls within the normal particle of metal can be removed. When this process
    range. occurs with great frequency over a period of time, large
    AUXILIARY WATER REMOTE HEAT TRANSFER cavities or pits can form.
    DEVICE In advanced stages, cavitation erosion may cause
    The auxiliary or secondary heat transfer device may be cooling water to seep into the lube oil, a condition which
    a radiator, cooling fan, cooling tower, heat exchanger or compounds existing problems. Coolant mixed with
    some other device.
    FORM 6248 First Edition 5.25 - 9
    COOLING SYSTEM

    engine oil forms a thick sludge that causes piston pins, ETHYLENE GLYCOL
    piston rings, valves and valve lifters to stick.
    The most common cooling water additive is ethylene
    Inhibitor additives raise the water vapor "flash point," glycol. The required proportion normally depends on
    which eliminates or at least reduces the formation of the lowest ambient temperature levels from which the
    damaging vapor bubbles. Water PH must be main- system must be protected. A fifty-fifty mix of water and
    tained within an acceptable range for the inhibitors to be ethylene glycol will produce the best results for freezing
    effective. and boiling protection, but cooling water efficiency is
    While water in motion erodes metal, greater system reduced by as much as 15%. Since the radiator cooling
    pressure reduces the formation of vapor bubbles by system effectiveness drops by approximately 2 - 3% for
    raising the temperature at which water boils or vapor- each 10% of glycol concentration, the radiator sizing for
    izes. the specified heat rejection value must be taken into
    account to accommodate this relationship.
    Harder metals, such as chrome, are much more
    resistant to cavitation erosion than softer metals, like A minimum of 30% ethylene glycol is generally recom-
    cast iron. mended for adequate antifreeze and corrosion protec-
    tion. The amount should not exceed 67% to avoid
    CORROSION impairing the heat transfer processes. A concentration
    Corrosion is a chemical process of metal loss. Cooling beyond this percentage does not tend to lower the
    water in a closed system is similar to the electrolyte freezing point any further and may result in engine
    solution in a battery. As the electric potential becomes damage.
    stronger, the rate of corrosion increases. Since it effectively raises the boiling point of the water,
    The rate at which the cooling system corrodes is the use of ethylene glycol is also beneficial in hot
    affected by a number of variables. Trapped air, water temperatures. Therefore, ethylene glycol treated water
    PH, the type of metals in the system and both the type is still recommended in those climates where antifreeze
    and amount of inhibitor additives all affect the corrosion is not normally required (see Table 5.25-1).
    rate. Table 5.25-1. Water Versus Concentration
    In order for corrosion inhibitors to be effective (and to PERCENT COMMENTS
    )
    neutralize any blow-by gases), the jacket water PH of WATER/GLYCOL
    the standard radiator cooled engine must be kept 100/0
    Best Cooling System Efficiency; No
    Antifreeze/Corrosion Protection
    between 8.5 and 9.5.
    Different system metals, such as iron, copper, alumi-
    num, etc., corrode at different rates. An acidic coolant
    with a PH of less than 7 will speed the corrosion of cast
    iron, aluminum and steel, while a PH of 11 or higher will
    accelerate the corrosion of aluminum and solder.

    WATER TREATMENT
    Standard closed heat exchanger or radiator cooled
    cooling systems operating up to 250· F (121· C) must be
    treated with industrial grade inhibited antifreeze or with With heat exchanger cooling systems, it should be
    some other effective commercial cooling water treat- remembered that the circulation of ethylene glycol
    ment product. These products usually provide corrosion solution only protects the closed system coolant.
    protection by forming a film on the surfaces of the Therefore, the heat exchanger water supply, as well as
    cooling system and also act as a scale suppressant by the auxiliary cooling water circuit, must also be pro-
    modifying or conditioning the dissolved scale-forming tected.
    minerals. To work effectively, all antifreeze and water
    treatment products require a clean system, free of dirt, Other treatments the engine operator should consider
    are listed in Table 5.25-2.
    oil, scale and rust.

    5.25 - 10 FORM 6248 First Edition


    COOLING SYSTEM

    Table 5.25-2. Other Cooling System Treatments • faulty temperature gauge


    TREATMENT COMMENTS
    • low coolant level
    Although a maximum hardness of 200 PPM is
    Deionized, acceptable for initial fill and make-up, use only
    Distilled or • overloaded engine
    Softened Waler softened water, where the insolubles may be
    as low as 0.5 PPM.
    Sodium Nitrate Iron and steel corrosion inhibitor. • air bound system
    Molybdale Slows the growth 01 bacteria. • insufficient air circulation
    Toly~riazole Copper corrosion inhibitor.
    • exhaust recirculation
    ~nthetic Prevents hard scale build-up.
    oIymer
    COOLING SYSTEM RECOMMENDATIONS
    Borax Buffer Corrects the water PH to B.S.
    General corrosion inhibitor; over 0.1 % 1. Ensure that the rise in coolant temperature does not
    concentration is not recommended for exceed 10" F (5.6" C).
    industrial engines. A concentration that is too
    Silicates high can cause the cooling water in the
    radiator to ~ell resulting in solid deposits. High 2. Maintain the drop in system pressure at 8 - 15 psi
    silicate inhi itor concentration is used primanly (55 - 103 kPa). While pressure that is too low promotes
    for high speed aluminum engines.
    cavitation erosion, pressure that is too high may cause
    NOTE: Refer to Service Bulletin 4-2429C for more the water pump seals to leak.
    detai/ed coo/ant treatment information.
    3. Analyze the raw water chemistry to verify that it does not
    COOLING SYSTEM SPECIFICATIONS contain contaminants and that it is not too hard. Use only
    AND RECOMMENDATIONS soft water, where the insolubles are as low as 0.5 PPM.
    Hard water accelerates the formation of scale deposils.
    COOLING SYSTEM SPECIFICATIONS
    Ensure thatthe temperature ofthe cooling water leaving 4. Analyze the cooling water chemistry every 3 - 6
    the engine (as indicated by the temperature gauge) months to verify that it contains the proper inhibitor and
    does not exceed the temperatures listed Table 5.25-3. additive concentrations.
    Refer to Table 1.20-28 for Alarm and Shutdown setpoint
    5. Measure antifreeze content according to the lowest
    temperatures.
    anticipated temperature and refill as needed with the
    Engine overheating. as evidenced by high jacket water same brand.
    temperatures, may be caused by one or more of the
    following conditions: 6. Maintain cooling water PH between 8.5 and 10.5; an
    acidic coolant with a PH of less than 7 will speed the
    • inadequate sizing of the radiator corrosion of cast iron, aluminum and steel, while a PH of
    • defective thermostats 11 or higher will accelerate the corrosion of aluminum
    and solder.
    • worn jacket water pump
    7. Check the cooling system level each day or consider
    • excessive jacket water pump suction the installation of a coolant low level shutdown switch.
    Even if a high coolant temperature switch is provided, it
    • loose drive belts will not shut the engine down if the system runs low on
    cooling water.
    • blown head gasket
    Table 5 25-3 Jacket Water Outlet Temperature Settings" F e C)
    Standard Cooling System:
    Normal" 11800 F ~82° c~ for continuous rating
    • 200° F 93" C for intermittent rating
    JACKET WATER OUTLET Elevated Temperature Solid Water Cooling System:
    TEMPERATURE1:
    Normal: 1210" - 235" F (82" - 113" C) solid water
    Ebullient Cooling System
    Normal: 1212" - 250" F (100" - 121" C)
    NOTE: 1Customer supplied fuel shutoff type safety eqUipment must be provided to prevent engine damage and possible personal injury. See
    Table 1.20-28 for alarm and shutdown temperatures.

    FORM 6248 First Edition 5.25 - 11


    COOLING SYSTEM

    8. Check the cooling system for rust, sludge or other JACKET WATER CIRCUIT - INITIAL FILL
    foreign matter. Clean and flush the entire cooling
    system once each year, unless evidence of corrosion or NOTE: The following description is not applicable to
    sediment build-up demonstrates the need for more permanent vent systems.
    frequent changes. Use only clean, soft water.
    1. Remove the 3/4 inch NPT countersunk headless
    9. To eliminate the recirculation of particles and con- pipe plugs from the drain hole just below the level of the
    taminants in the cooling water circuit, install a cleanable jacket water header (see Figure 5.25-11).
    filter (sized at approximately 10 microns) in the coolant
    flow. Inspect and clean the filter on a regular basis.
    NOTE: To facilitate draining and flushing of the engine
    jacket water, replace one of the 3/4 inch NPT countersunk
    10. Frequently inspect hoses and all cooling system headless pipe plugs with a customer supplied ball va/ve
    connections for cracks and leaks. Do this when the (see Figure 5.25-11). The ball valve must be threaded to
    engine is operating at normal pressure. accept both a hose connection and pipe plug.

    11. Examine belts and pulleys of the jacket and


    auxiliary water pump drives, and if the engine is WATER
    HEADER .......
    radiator-cooled, on the cooling fan drive.

    12. On a radiator, check for damaged fan blades, a


    poorly fitting shroud, sticking shutters or dirt in the
    radiator core. Repair or clean as needed.

    13. Check the radiator cap gasket for proper seal.


    ~--
    14. If a heat exchanger is used, inspect it for scale or
    corrosion, and when necessary, clean the inside of the
    tubes with a round, soft-wire brush. Flush with cleaning
    solvent.
    \ PLUG

    15. Periodically remove the intercooler, and rod-out CRANKCASE


    the tubes with a soft-wire brush or circulate a suitable
    cleaning solution. Figure 5.25-11. Customer Supplied Ball Valve

    16. Consider the installation of the following cooling


    2. Open the jacket water pump air bleed petcock (or
    system safety accessories:
    needle valve) in the outlet port to the jacket water
    • a high water temperature shutdown device header.

    • a low water level shutdown device 3. Open the air bleed petcock(s) on top of the cluster
    thermostat hOUSing.
    • a coolant level sight glass
    4. Attach the make-up line to the ball valve and add
    To avoid scored pistons and other serious problems, a treated cooling water to the crankcase (see Water
    high water temperature shutdown device will stop the Treatment in this section).
    engine if the coolant gets too hot. A low water level
    device will shut down the engine if the coolant level NOTE: Always fill the engine from the bottom up to
    drops excessively, preventing cracked or warped cylin- minimize the formation of damaging air pockets. As the
    der heads, exhaust manifolds and water manifolds. A engine fills, air is pushed up and out.
    sight glass is a quick and easy method of visually
    checking the coolant level. 5. Close the jacket water pump air bleed petcock (or
    needle valve) when water begins to flow out in a solid
    steady stream.

    5-25 - 12 FORM 6248 First Ednion


    COOLING SYSTEM

    6. Add coolant to the engine until the level causes it to AUXILIARY COOLING WATER CIRCUIT -
    escape from the petcock(s) on top of the cluster INITIAL FILL
    thermostat housing (see Table 5.25-4).
    NOTE: The following description is not applicable to
    Table 5 25-4 Jacket Water Capacity - Engine Only permanent vent systems.
    ENGINE MODEL GALLONS (LITRES)
    L5108
    1. Open the air bleed petcock(s) in the intercooler
    107 (405) cooling water inlet/outlet bonnet(s).
    L5790
    L7042 100 (379) 2. Open the air bleed petcocks in the inlet side of the
    wastegate water return tubes.
    7. Close the cluster thermostat housing petcock(s) and
    continue filling the system until the level of the coolant 3. From the top of the surge tank or radiator, add
    reaches the top of the surge tank or radiator. treated cooling water (see Water Treatment in this
    section) to the auxiliary cooling water circuit.
    8. Close the ball valve and unthread the hose connec-
    tion. 4. Continue filling the circuit until the level causes it
    escape from the air bleed petcock(s) in the intercooler

    A WARNING
    cooling water inlet/outlet bonnet(s). Close the pet-
    cock(s) when water begins to flow out in a solid steady
    Always install a pipe plug in the ball valve when the stream.
    hose connection Is removed. If the lever of the ball
    5. Continue filling the auxiliary cooling water circuit until
    valve Is inadvertently bumped open, the absence of
    the level causes it to escape from the petcocks in the
    a plug will cause the coolant to drain. During
    intercooler cooling water supply and the inlet side ofthe
    operation, loss of any coolant may result In cata- wastegate water return tubes. Close the petcocks when
    strophic engine damage. Escaping steam and/or
    water begins to flow out in a solid steady stream.
    hot water can cause severe burns. Disregarding
    this Information could result In severe personal 6. Continue filling the auxiliary cooling water circuit until
    injury or death. the level ofthe coolant reaches the top ofthe surge tank
    or radiator.
    9. Apply Perma Lok® Heavy Duty Pipe Sealant with
    Teflon® to the threads of the pipe plug. Install the plug in
    the ball valve.
    =A CAUTION IAlrlnthecOOlingsyst~m
    ..
    IL. =......;;_....;;;._......;;_-1. speeds up the formation
    of rust, Increases corrosion and produces hot
    CAUTION l~irinthecOOlingsyst~m
    I A=:......;=...:;..;;;....;;~:::....:~. spots within the engine. Disregarding this Informa-
    .L .::
    .. speeds up the formation tion could result in product damage and/or person-
    of rust, increases corrosion and produces hot allnJury.
    spots within the engine. Disregarding this informa-
    tion could result In product damage and/or person- 7. Bleed trapped air (see Cooling Water System Air
    al injury. Bleed).

    10. Bleed trapped air (see Cooling Water System Air 8. Top off the surge tank or radiator.
    Bleed).

    11. Top off the surge tank or radiator.

    FORM 6248 Firs! Edition 5.25 -13


    COOLING SYSTEM

    Table 5 25-5 Air Bleed Petcocks


    COOLING WATER NUMBER OF
    LOCATION
    CIRCUIT PETCOCKS
    1 Jacket water pump housing (front center); outlet port to left bank jacket water header
    Jacket Water
    2 Cluster thermostat housing (above bypass outlet ports at front)
    2 Intercooler water inlet/outlet bonnets (upper rear)
    Auxiliary
    2 Wastegate water return tube (rear right and left bank)

    COOLING WATER SYSTEM AIR BLEED JACKET WATER AND AUXILIARY


    Air bleed the jacket water and auxiliary cooling water COOLING WATER CIRCUITS -
    circuits at least once each day. Open and close the air DRAIN AND FLUSH
    bleed petcocks in the order that they are listed below, Unless evidence of corrosion or sediment build-up
    starting at the lowest petcock in the system and ending demonstrates the need for more frequent maintenance,
    at the highest. Bleed one petcock at a time. The number clean and flush both the jacket water and auxiliary
    of air bleed petcocks and their locations are as follows cooling water circuits at least once each year.
    (see Table 5.25-5).
    1. Start the engine. Lelthe engine run about 10 minutes
    1. Initial Bleed: open each air bleed petcock prior to to stir up any rust or sediment.
    engine startup. A hissing sound often accompanies the
    escape of trapped air. Close the petcock when the
    hissing stops and water begins to flow out in a solid
    steady stream.
    A WARNING
    Always wear protective clothing when draining the
    cooling systems on a heated engine. Slowly loosen
    A WARNING the air bleed petcocks to relieve any excess
    pressure. Escaping steam and/or hot water could
    Always wear protective clothing when bleeding the
    cooling system on a heated engine. Slowly loosen
    result in severe personal injury or death. )
    the air bleed petcock to relieve any excess pres- 2. Shut down the engine. Open the air bleed petcocks
    sure. Escaping steam and/or hot water could result at the highest point in both the jacket water and auxiliary
    In severe personal injury or death. cooling water circuits, whether it be on top of the surge
    tank, radiator or other heat transfer device.
    2. Check Bleed: start the engine and reopen each
    petcock. Close the petcock when the hissing stops and NOTE: To facilitate draining and flushing of the engine
    waler begins to flow out in a solid steady stream. jacket water, replace one of the 3/4 inch NPT counter-
    sunk headless pipe plugs (just below the level of the
    3. Final Bleed: once the temperature of the jacket jacket water header) with a customer supplied ball
    water circuit has stabilized (as indicated by the panel valve. The ball va/ve must be threaded to accept both a
    mounted temperature gauge), reopen each petcock. hose connection and pipe plug.
    Close the petcock when the water begins to flow out in a
    solid steady stream. 3. Verify that the customer supplied ball valve is in the
    closed position. Remove the pipe plug and attach the
    A. CAUTION IAir~anbedrawnintothe drainage line.
    IL.!!!"~:"":=':";::;"':~::"";:....:;.J. engine through small
    4. Drain the coolant from the jacket water and auxiliary
    leaks In the Jacket water system. The problem is
    cooling water circuits. Avoid delay, so that the water is
    compounded when the void created by the loss of
    drained before the rust and sediment has a chance to
    coolant Is filled by more air. If aeration causes the
    settle.
    coolant to foam, the probability of engine damage
    due to overheating is greatly increased. Disregard- 5. Open all air bleed petcocks (see Table 5.25-5).
    ing this information could result in product damage
    and/or personal injury.

    4. Carefully inspect the jacket water system for coolant


    )
    leaks while the engine is running.

    5.25 - 14 FORM 6248 First Edition


    COOLING SYSTEM

    6. Open all water drain petcocks. Remove all drain 16. Continue filling the auxiliary cooling water circuit
    plugs. Place a small catch pan beneath each petcock until the level reaches the top of the surge tank or
    before opening (see Table 5.25-6). radiator.

    Table 5.25-6. Water Drain Petcocks 17. Bleed trapped air. Begin at the lowest petcock and
    COOLING NUMBER finish at the highest. Bleed one petcock at a time. Close
    WATER OF LOCATION the petcock when the hissing stops and water begins to
    CIRCUIT PETCOCKS flow out in a solid steady stream.
    2 Water mannold (front and rear)
    Jacket Jacket water pump housing 18. Top off the surge tank or radiator of the auxiliary
    Water 1 (see exit hole in side panel of cooling water circuit.
    safety guard assembly)

    Auxiliary
    2
    1
    Intercooler (rear, left and right)
    Auxiliary water pump (bottom)
    A WARNING
    Water return pipe (pipe end at Always wear protective clothing when venting the
    1 crankcase Vee, engine front) cooling system on a heated engine. Slowly loosen
    the air bleed petcock to relieve any excess pres-
    7. Close all water drain petcocks. Install all drain plugs. sure. Escaping steam and/or hot water could result
    in severe personal injury or death.
    8. Select and inspect an internal surface that is suitable
    for gauging the effectiveness of the cleaning and
    19. Start the engine and slowly reopen each air bleed
    descaling solution. If necessary, insert a piece of drill
    petcock. Close the petcock when the hissing stops and
    welding rod into the water passage opening to feel for an
    water begins to flow out in a solid steady stream.
    accumulation of lime and mineral scale deposits.
    20. Slowly reopen each air bleed petccek when the
    9. Attach the make-up line to the ball valve and add
    engine jacket water temperature has stabilized (as
    clean, soft water to the crankcase. Always fill the engine
    indicated by the panel mounted temperature gauge).
    from the bottom up to minimize the formation of air
    \ Close the petccek when the water begins to flow out in a
    pockets. As the engine fills, air is pushed up and out
    solid steady stream.
    (see Table 5.25-7).
    Table 5 25-7 Jacket Water Capacity - Engine Only 21. Let the engine run about 10 minutes to stir up any
    rust or sediment in the cooling water system.
    ENGINE MODEL GALLONS (LiTRES)
    L5108
    L5790
    107 (405) A WARNING
    L7042 100 (379) Always wear protective clothing when draining the
    cooling systems on a heated engine. Slowly loosen
    10. Successively close each air bleed petcock when the drain petcocks to relieve any excess pressure.
    water begins to flow out in a solid steady stream. Begin Escaping steam and/or hot water could result in
    at the lowest petcock and finish at the highest. severe personal injury or death.

    11. Close the cluster thermostat housing petcock(s) NOTE: Contaminants left in the cooling water systems
    and continue filling the jacket water system until the will reduce or deplete the effectiveness of the cleaning
    level reaches the top of the surge tank or radiator. solution.
    12. Bleed trapped air. Begin at the lowest petcock and 22. Stop the engine. Drain the crankcase and all
    finish at the highest. Bleed one petcock at a time. Close cooling system accessories. Drain the auxiliary cooling
    the petcock when the hissing stops and water begins to water circuit. Avoid delay, so that the water is completely
    flow out in a solid steady stream. drained while the rust and sediment are still in suspen-
    sion.
    13. Top off the surge tank or radiator ofthe jacket water
    circuit. 23. Attach the make-up line and fill the jacket water
    and auxiliary cooling water circuits with a suitable
    14. Attach the make-up line and add clean, soft water
    cleaning solution. Use a non-acidic, non-corrosive,
    to the surge tank or radiator of the auxiliary cooling
    biodegradable compound that prevents the loss of
    water circuit.
    metal in the engine and avoids damage to internal
    15. Successively close each air bleed petcock when gaskets and seals.
    water begins to flow out in a solid steady stream.

    FORM 6248 First Ed~ion 5.25 -15


    COOLING SYSTEM

    NOTE: Follow the manufacturer's recommendations


    for the proper concentration of cleaning solution and
    A CAUTION I
    I==-:...;:;.:....;=-=-:...:::...:...:..J.
    L.
    Air can be drawn Into the
    system through small
    length of cleaning time. leaks in the cooling water circuit. The problem Is
    compounded when the void created by any loss of
    24. Bleed trapped air. coolant Is filled by more air. Air in the cooling
    system speeds up the formation of rust, Increases
    25. Top off the surge tank or radiator of the jacket water
    corrosion and produces hot spots within the
    and auxiliary cooling water circuits.
    engine. If aeration causes the coolant to foam, the
    26. Start the engine. Let it run for at least 10 minutes or probability of engine damage due to overheating Is
    until the cleaning solution is depleted. greatly increased. Disregarding this information
    could result In product damage and/or personal
    27. To ensure thatthe contaminants remain in suspen- Injury.
    sion, drain the cooling systems as quickly as possible.
    32. Carefully inspect the jacket water and auxiliary
    28. Inspect internal surfaces. If the results are not cooling water circuits for leaks.
    satisfactory, refill the engine with cleaning solution.
    Repeat Steps 23 thru 27 as necessary.

    29. To flush the systems of cleaning solution and any


    residual contaminants, fill the jacket water and auxiliary
    cooling water circuits with clean, soft water. Drain
    immediately.

    CAUTION I
    I A=:......;=....:..:::...::....::...;:;....:...;:..J.
    .L .
    .:: .
    All antifreeze and water
    treatment products re-
    quire a clean system In order to work effectively. If
    contaminants, such as dirt, rust, scale, lime,
    grease, oil and/or cleaning agents, are not com- )
    pletely flushed out, they can destroy the corrosion
    inhibitors and scale suppressants intended to keep
    freshly filled cooling systems clean. Disregarding
    this information could result In product damage
    and/or personallnlury.

    30. Inspect the drain water for cleanliness. Fill and flush
    the systems again, if necessary. The best results are
    obtained when the drain water runs clear.

    31. Fill the jacket water and auxiliary cooling water


    circuits with coolant. Be sure that the coolant has the
    proper inhibitor and additive concentrations (See Water
    Treatment). Bleed the system of trapped air.

    A WARNING
    Always install a pipe plug in the ball valve when the
    hose connection is removed from the jacket water
    header. If the lever of the ball valve is Inadvertently
    bumped open, the absence of a plug will cause the
    coolant to drain. During operation, loss of any
    coolant may result in catastrophic engine damage.
    Escaping steam and/or hot water could resuh in
    severe personallnlury or death.
    )

    5.25 - 16 FORM 6248 First Edition


    COOLING SYSTEM

    CAUTION I Do not over greas~ the


    GREASE FmlNGS
    IDLER PULLEY BEARING LUBRICATION
    I A=:....;=....;;..;:;....;~.;;;....;---'.
    .L .::
    .. water pump bearmgs.
    Over greasing causes high bearing temperatures
    Grease the ball bearing in the jacket water pump idler that shorten bearing service life. Disregarding this
    pulley bracket every 720 running hours. information could result in product damage and/or
    personal Injury.
    1. Locate the idler pulley bracket grease fitting
    mounted above the drain cock in the upper panel of the 2. Using a hand held grease gun, apply two or three
    safety guard assembly (right bank side) (see strokes of Lithoplex® Grease No. 2 (Multipurpose
    Figure 5.25-12). Lithium Complex Formula Containing Molybdenum
    Disulfide) to the grease fittings.

    Figure 5.25-12. Idler Pulley Bearing Lube

    CAUTION IDo not over grease the


    Figure 5.25-13. Auxiliary Water Pump Pulley Lube
    I..
    A
    idler pulley bearing. Over
    greasing causes high bearing temperatures that GREASE RECOMMENDATIONS
    shorten bearing service life. Disregarding this A Lithium complex type grease is now recommended
    information could result In product damage and/or over the Lithium soap base grease because of its ability
    personal Injury. to resist water. Lithium complex type grease also
    provides superior rust protection qualities (especially
    2. Using a hand held grease gun, apply one stroke of steel surfaces), as well as its thermal and mechanical
    Lithoplex® Grease No. 2 (Multipurpose Lithium Com- stability at high operating temperatures. The Lithium
    plex Formula Containing Molybdenum Disulfide) to the complex grease has a continuous operating tempera-
    grease fitting. ture of approximately 3500 F (177 0 C), whereas the
    Lithium soap base grease has an upper operating
    AUXILIARY WATER PUMP BEARINGS LUBRICA-
    temperature limit of approximately 225 0 F (1070 C).
    TION
    Grease the two ball bearings in the auxiliary water pump
    every 720 running hours. The pump is mounted to a
    IA..
    CAUTION I Always install the safety
    guards after completing
    bracket at the front left corner of the oil pan. the service operation (see Safety Guards, Instal-
    1. Locate the two grease fittings on the auxiliary water ling). Never operate the engine with the safety
    pump support head (see Figure 5.25-13). The front ball guards removed. Disregarding this information
    bearing grease fitting (pulley end) is reached through an could result in product damage and/or personal
    access hole in the belt guard cover. The rear ball injury.
    bearing grease fitting is uncovered.

    FORM 6248 First Ednion 5.25 -17


    COOLING SYSTEM

    BELTS
    JACKET WATER PUMP DRIVE BELTS
    REPLACEMENT
    1. See Safety Guards Removal.

    IA CAUTION IAn accumulation of dirt


    ADJUSTING
    LEVER

    \
    .L.:=......;:..;;.,..:..;::;...:...;;..;=~. In the sheave grooves
    impairs traction and accelerates belt wear. Disre-
    garding this information could result in product
    damage and/or personal injury. "" LOCK WASHER

    2. Verify that the pulley sheaves are clean and com-


    pletely free of grease, oil, dirt and grit.

    3. Inspect the drive belts for fraying, cracks or wear.


    Belts must not be glazed, split, peeled or greasy.
    Replace as necessary.

    CAUTION I~elts
    I~A.=......;=..:..;:::....:...;;..;=-.:~.
    are matched and
    L.. . tied in sets of two. Al-
    ways replace the drive belts in pairs. Never replace PLAIN WASHER ...........
    just one drive belt even if only one belt Is worn. Since
    the older belts are stretched during hours of engine
    STUD ANCHOR/' II
    PLAIN WASHER /
    operation, the circumference of new belts is slightly
    smaller. A difference in belt size will cause the new ELASTIC STOP LOCK NUT
    belt to carry the full load, resulting in rapid belt Figure 5.25-14. Adjusting/Idler Lever Assembly
    )
    failure and possible damage to driven equipment.
    Disregarding this information could result in prod-
    uct damage and/or personal inJury. 6. Loosen the pivot bolt on which the idler pulley
    bracket turns (see Figure 5.25-15). Loosen the slotted
    4. Inspect the condition of the new jacket water pump lock bolt to unlock the position of the bracket. The belt
    drive belts (set of two matched belts for 10 inch tension is released as the idler pulley bracket rotates
    crankshaft pulley). Replace as necessary. upward in a counter-clockwise direction.

    5. Remove the auxiliary water pump drive belts. Back


    the upper thin hex lock nut on the threaded rod away
    from the adjusting lever (see Figure 5.25-14). The pivot
    point of the idler lever follows the adjusting lever in a
    counter-clockwise direction. The downward movement
    ofthe idler pulley releases the drive belttension. Slip the
    drive belts off the auxiliary water pump and idler pulleys.

    Figure 5.25-15. Tighten Idler Pulley Bracket Bolts

    5.25 - 18 FORM 6248 First Ed~ion


    COOLING SYSTEM

    7. Slip the old drive belts off the jacket water pump and 2. Using V-Belt Tension Tester (Tool PIN 474016),
    idler pulleys. Remove the belts from the rear crankshaft check the drive belt tension.
    pulley and discard.
    A. Align the bottom of the large O-ring on the
    S. Place a new drive belt in the rear groove of the rear "Inches of Span" scale at 19, which is the
    crankshaft pulley. The rear groove is the one closest to measured belt span between the center lines of
    the gear cover. Slip the belt into the rear groove of the the crankshaft and jacket water pump pulleys.
    jacket water pump pulley.
    B. Align the bottom of the small O-ring on the
    9. Place a new drive belt into the second last groove of "Deflection Force" scale with the zero mark.
    the rear crankshaft and jacket water pump pulleys.
    C. Place the tension tester squarely on the front
    10. Rotate the idler pulley bracket clockwise to seatthe drive belt at the center of the longest unsup-
    jacket water pump drive belts in the two pulley grooves. ported span (between the jacket water pump
    pulley and the crankshaft pulley). Apply inward
    11. Refer to Jacket Water Pump Drive Belt Tension force on the plunger perpendicular to the belt
    Adjustment, and adjust the belts. span until the bottom of the large O-ring is even
    with the top of the rear drive belt (see
    JACKET WATER PUMP DRIVE BELT TENSION
    Figure 5.25-16).
    ADJUSTMENT
    Check the tension and condition of the two jacket water D. Remove the tension tester and read the force
    pump drive belts weekly. Replace the drive belts every applied from the bottom of the small O-ring on
    SOOO running hours or as necessary. the deflection force scale. The tension of used
    belts must be between 11.9 and 17.5Ibs.
    1. See Safety Guards, Removal.
    E. Check the rear belt tension!n the same manner.
    IA
    ..
    CAUTION I Be sure that the belts are
    cool when the tension is NOTE: If the tension tester is not available, moderate
    hand pressure should deflect the long part of the belt
    checked or adjusted. The thermal expansion of
    approximately 1/4 to 1/2 inch (6 to 13 mm).
    warm belts will result in a false tension reading.
    Disregarding this information could result in prod-
    uct damage and/or personal injury.

    /FRONT DRIVE BELT


    REAR DRIVE BELT

    I I I I
    .
    ,
    I I

    DEFLECTION
    FORCE SCALE

    Figure 5.25-16. Jacket Water Pump Drive Belt Tension Tester

    FORM 6248 First Edition 5.25 - 19


    COOLING SYSTEM

    3. If belt tension adjustment is necessary, loosen the


    pivot bolt on which the idler pulley bracket turns (see )
    Figure 5.25-17). Loosen the slotted bolt to unlock the
    position of the bracket. The belt tension is released as
    the idler pulley bracket rotates upward in a counter-
    clockwise direction.

    J JACKET WATER
    PUMP PULLEY

    DRIVE BELT
    / (FRONl)

    Figure 5.25-18. Jacket Water Pump Drive Belt Tension

    5. Holding the pry bar in position, use the tension tester


    to apply inward pressure to the center of the longest
    unsupported span on the front drive belt (between the
    jacket water pump pulley and the crankshaft pulley).
    Figure 5.25-17. Jacket Water Pump Drive Belt
    Tensioning 6. Tension used belts between 11.9 and 17.5Ibs.

    CAUTION IBelts th~t are too tight


    NOTE: If the tension tester is not available, moderate

    I=.='--'''--''--'....;;..;;;;...;~.
    L. .
    A
    result In excessive
    stretching and overheating. Too much tension may
    hand pressure should deflect the long part of the belt
    approximately 1/4 to 1/2 inch (6 to 13 mm).
    )
    also damage drive components, such as sheaves 7. Tighten the slotted lock bolt on the idler pulley
    and shafts, and lead to premature failure of the idler bracket when the proper belt tension is obtained (see
    pulley and/or water pump bearings. Disregarding Figure 5.25-17). Tighten the pivot bolt.
    this information could result in product damage
    and/or personal injury. 8. Inspect the belts for proper seating. V-belts should
    ride on the sides of the pulley sheaves, not on the

    A CAUTION I
    bottom of the groove.
    Belts t~at are to~ loose
    I=..
    L. =~=..;;..::....:....;;..=-.:~.
    result In belt slippage.
    Slippage causes burn spots, overheating, rapid
    9. Verify that the tension of the front drive beit is
    between 11.9 and 17.5Ibs. Verify the tension ofthe rear
    wear and breakage. The vibration created by loose drive belt.
    belts may also be sufficient to cause unnecessary
    wear of the pulley grooves. Disregarding this 10. See Auxiliary Water Pump Drive Belts Tension
    information could result in product damage and/or Adjustment
    personal injury.

    4. To reset the be~ tension, insert a pry bar between the


    I~
    A CAUTION I Always install the safety
    guards after checking or
    upper edge of the idler pulley bracket and the untapped adjusting the jacket/auxiliary water pump drive belt
    boss on the lett bank side of the water pump housing (see tension. Never operate the engine with the safety
    Figure 5.25-18). To tighten the drive be~, use the pad guards removed. Disregarding this information
    above the untapped boss for leverage and push up on the could result in product damage and/or personal
    pry bar to move the idler pulley bracket downward (ON). injury.

    11. See Safety Guards, Installation.

    5.25 - 20 FORM 6248 First Ed~ion


    COOLING SYSTEM

    AUXILIARY WATER PUMP DRIVE BELT 4. Remove the drive belts from the auxiliary water
    REPLACEMENT pump and idler pulleys (see Figure 5.25-20). Remove
    the belts from the rear crankshaft pulley and discard.
    CAUTION I~n
    I-=.A=~=-=-::::;....:....:=...:...:..J.
    accumulation of dirt
    L. . the sheave grooves
    In
    impairs traction and accelerates belt wear. Disre-
    garding this Information could result in product
    damage and/or personal injury.

    1. Verify that the pulley sheaves are clean and com-


    pletely free of grease, oil, dirt and grit.

    2. Inspect the drive belts for fraying, cracks or wear.


    Belts must not be glazed, split, peeled or greasy.
    Replace as necessary.

    3. If replacement is necessary, back the upper thin hex


    lock nut on the threaded rod away from the adjusting
    lever (see Figure 5.25-19). The pivot point of the idler
    lever follows the adjusting lever in a counter-clockwise
    direction. The downward movement of the idler pulley
    releases the drive belt tension. Figure 5.25-20. Auxiliary Water Pump Belts

    I=.A. CAUTION I
    L.
    Belts are matched and
    tied in sets of two. Al-
    =.....;:;.;;...;;.;:;.....;;...;;..;:;....;;...:..J.
    ways replace the drive belts In pairs. Neyer replace
    lust one drive belt even if only one belt is worn.
    Since the older belts are stretched during hours of
    engine operation, the circumference of new belts Is
    ADJUSTING slightly smaller. A difference in belt size will cause
    LEVER the new belt to carry the full load, resulting in rapid

    '" \
    LOCK WASHER
    belt failure and possible damage to drrven equip-
    ment. Disregarding this information could result In
    product damage and/or personal Injury.

    5. Inspect the condition ofthe new auxiliary water pump


    drive belts. Replace as necessary.

    PLAIN WASHER ............., /

    STUD ANCHOR !I
    PLAIN WASHER /
    ELASTIC STOP LOCK NUT

    Figure 5.25·19. Adjusting/Idler Lever Assembly

    FORM 6248 First Edition 5.25 - 21


    COOLING SYSTEM

    6. Place the new drive belt in the smaller groove of the AUXILIARY WATER PUMP DRIVE BELT TENSION
    rear crankshaft pulley (directly in front of the first jacket ADJUSTMENT
    water pump drive belt) (see Figure 5.25-21). Slip the
    belt into the rear grooves of both the auxiliary water 1. See Safety Guards, Removal.
    pump and idler lever pulleys.
    CAUTION IBesurethatthebe~sa~e
    I.:=A:::::::---'7-"---''-::----:'''-::--=.
    L.. . cool when the tension IS
    checked or adjusted. The thermal expansion of
    warm belts will result in a false tension reading.
    Disregarding this information could result In prod-
    uct damage andlor personal injury.
    2. Using V-Belt Tension Tester (Tool PIN 474016),
    check the drive belt tension.
    A. Align the bottom of the large O-ring on the
    'Inches of Span" scale at 19, which is the
    measured belt span between the center lines of
    the crankshaft and jacket water pump pulleys.

    B. Align the bottom of the small O-ring on the


    "Deflection Force" scale with the zero mark.
    Figure 5.25-21. Jacket And Auxiliary Water Pump
    Belts C. Place the tension tester squarely on the front
    drive belt at the center of the longest unsup-
    7. Using the grooves directly in front ofthe first auxiliary
    ported span (between the jacket water pump
    water pump drive belt, slide a second drive belt around pulley and the crankshaft pulley). Apply inward
    the rear crankshaft, auxiliary water pump and idler lever
    force on the plunger perpendicular to the belt
    pulleys.
    span until the bottom of the large O-ring is even
    with the top of the rear drive belt (see
    )
    8. To tighten the drive belts, thread the upper thin hex
    lock nuttoward the adjusting lever. The pivot point ofthe Figure 5.25-22).
    idler lever follows the adjusting lever in a clockwise
    D. Remove the tension tester and read the force
    direction. The upward movement of the idler pulley
    applied from the bottom of the small O-ring on
    increases the drive belt tension. the deflection force scale. The tension of used
    9. Refer to Auxiliary Water Pump Drive Belt Tension belts must be between 11.9 and 17.5Ibs.
    Adjustment to adjust the belts. E. Check the rear belt tension in the same manner.

    NOTE: If the tension tester is not available, moderate


    hand pressure should deflect the long part of the belt
    approximately 1/4 to 1/2 inch (6 to 13 mm).

    ,....FRONT DRIVE BELT


    REAR DRIVE BELT

    J ~.n~'~ O-RING

    DEFLECTION
    FORCE SCALE

    Figure 5.25~. Jacket Water Pump Drive Belt Tension Tester

    5.25 - 22 FORM 6248 First Edition


    COOLING SYSTEM

    CAUTION I
    I-=.A='-"----'''-_.;;...~. Belts th~t are too ti~ht CAUTION I~lwayS
    I-=.A=:........;=..;;.;;~;...;;..;;;;..;~.
    install the safety
    L. . result In excessive L. . guards after checking or
    stretching and overheating. Too much tension may replacing the auxiliary water pump drive belts (see
    also damage drive components, such as sheaves Safety Guards, Installing). Never operate the engine
    and shafts, and lead to premature failure of the idler with the safety guards removed. Disregarding this
    pulley and/or water pump bearings. Disregarding information could result in product damage and/or
    this Information could result in product damage personal injury.
    and/or personal injury.
    JACKET WATER PUMP SEAL
    NOTE: Since the circumference of new belts is some- INSPECTION
    what smaller, reuse of the setting established for the
    Even with proper cooling system maintenance, all
    discarded drive belts will result in belts that are too tight.
    jacket water pumps require periodic overhaul.
    3. To loosen the drive belts, back the upper thin hex 1. Inspect the "weep hole" in the casting directly below
    lock nut on the threaded rod away from the adjusting the water pump pulley (see Figure 5.25-23). The "weep
    lever. The pivot point of the idler lever follows the hole" drains any coolant that leaks past the ceramic
    adjusting lever in a counter-clockwise direction. The water pump seal.
    downward movement of the idler pulley releases the
    drive belt tension.

    4. When the correct tension is obtained, thread the 3/8


    I.A. CAUTION IatThethepresence of coolant
    "weep hole" indi-
    inch elastic stop lock on the upper end of the threaded cates that the Jacket water pump must be rebuilt. A
    rod toward the adjusting lever. Be sure that the lock nuts defective water pump seal results in coolant loss
    (thin hex and elastic stop) on each side of the adjusting and contamination ofthe inner ball bearing grease.
    lever are properly tightened. Disregarding this information could result in prod-
    uct damage and/or personal injury.
    5. Inspect the belts for proper seating. V-belts should
    2. Overhaul the jacket water pump ifany leakage atthe
    ride on the sides of the pulley sheaves, not on the
    "weep hole" is observed (see Jacket Water Pump).
    bottom of the groove.

    6. Because of initial stretching, recheck the belttension


    after 10 minutes run time. Check the belt tension again
    after the first 30 minutes run time and then every 250
    hours thereafter.

    I.A. CAUTION Iresult


    Belts that are too loose
    in belt slippage.
    Slippage causes burn spots, overheating, rapid
    wear and breakage. The vibration created by loose
    belts may also be sufficient to cause unnecessary
    wear of the pulley grooves. Disregarding this
    information could result In product damage and/or
    personal injury.
    7. To tighten the drive belts, back the elastic stop lock
    nut on the upper end of the threaded rod away from the
    adjusting lever. Use a 3/8 inch deepwell socket for best
    results.

    8. Thread the upper thin hex lock nut toward the adjusting
    lever. The pivot point of the idler lever follows the adjusting
    lever in a clockwise direction. The upward movement of
    the idler pulley increases the drive belt tension.

    9. When the correct tension is obtained, thread the


    elastic stop lock nut on the upper end of the threaded
    rod toward the adjusting lever. Be sure thatthe lock nuts
    (thin hex and elastic stop) on each side of the adjusting Figure 5.25-23. Jacket Weter Pump "Weep" Hole -
    lever are properly tightened. Water Pump Shown Removed

    FORM 6248 First Edition 5.25 - 23


    COOLING SYSTEM

    ITEM NUMBER AND DESCRIPTION


    1 Water Pump 5 Elbow 9 Nut 13 Capscrew
    2 O-ring 6 Capscrew 10 Gasket 14 Washer
    3 Flange 7 Capscrew 11 Elbow
    4 Flange 8 lock washer 12 Plug
    Figure 5.25-24. Waler Pump

    CRANKCASE WATER INLET ELBOWS 3. Remove two capscrews, lock washers gasket and
    lower crankcase water inlet elbow from the crankcase.
    CRANKCASE WATER INLET ELBOWS REMOVAL
    - LEFT BANK
    1. Remove two nuts, lock washers, capscrews, and
    washers from left crankcase water inlet flange on the
    water pump (see Figure 5.25-24).

    2. Remove two nuts, lock washers, washers and


    capscrews and remove the upper crankcase water inlet
    )
    elbow from the lower elbow. Remove the two O-rings
    and crankcase water inlet flanges from each end of the
    upper elbow. Discard the O-rings.

    5.25 - 24 FORM 6248 First Ednion


    COOLING SYSTEM

    CRANKCASE WATER INLET ELBOWS REMOVAL 6. With the 1/4 inch NPT allen head pipe plug facing
    -RIGHT BANK frontward, align the flange holes on the skewed end of
    the elbow with the holes in the beveled end of the inlet
    1. Remove two nuts, lock washers, capscrews, and adapter. Finger tighten the fasteners (2 capscrews,
    washers from right crankcase water inlet flange on the 1/2 x 2-1/4 inches, with washers, lock washers and
    water pump. hex nuts).
    2. Remove two capscrews, lock washers, washers, 7. Align the holes in the crankcase water inletflange on
    right bank crankcase water inlet elbow, crankcase water the other end of the elbow with those in the nearest
    inlet flange, and gasket from the crankcase.
    water pump outlet port and finger tighten the fasteners
    3. Remove two crankcase water inlet flanges and (2 capscrews, 1/2 x 2-1/4 inches, with washers, lock
    O-rings from the ends of the crankcase water inlet washers and hex nuts).
    elbow. 8. Install the fasteners in the flat side of the crankcase
    CRANKCASE WATER INLET ELBOWS water inlet adapter (2 capscrews, 1/2 x 2-1/4 inches,
    INSTALLATION - LEFT BANK with lock washers).

    1. Look at the part numbers stamped on the crank- 9. Position a new gasket on the ends of the capscrews.
    case water inlet elbows to separate the left bank Finger tighten the adapter to the left bank crankcase
    (letter "r suffix) from the right (letter "U"). water inlet header.

    2. Inspect the ends of the left bank water inlet elbow. 10. Alternately wrench tighten the six crankcase water
    Note that one end is slightly skewed. inlet flange and crankcase water inlet adapter capscrews.

    3. Position a crankcase water inlet flange (diamond NOTE: The left bank water pump inlet elbow has an
    shaped) on each end of the water inlet elbow. Be sure indentation in the back to accommodate the left bank
    that the inside counterbore of both flanges faces crankcase water inlet elbow (see Figure 5.25-26).
    outward toward the ends of the elbow (see
    Figure 5.25-25).

    INDENTATION (IN REAR~

    o
    Figure 5.25-26. Weier Pump Inlet Elbow - Left Bank

    CRANKCASE WATER INLET ELBOWS INSTALLA-


    TION - RIGHT BANK

    1. Position an O-ring flange (diamond shaped) on


    each end of the right bank crankcase water inlet elbow.
    Be sure that the inside counterbore of both flanges
    faces outward toward the ends of the elbow (see
    Figure 5.25-25).
    Figure 5.25-25. Crankcase Water Inlet Flange
    2. Place a new O-ring on each end olthe elbow.
    4. Place a new O-ring on each end of the elbow.
    3. With the 1/4 inch NPT allen head pipe plug in the elbow
    5. Inspectthe ports olthe water inlet adapter. Note that facing upward, align the holes in the crankcase water inlet
    one side has a beveled counterbore, while the other is flange with those in the nearest water pump outlet port.
    flat. Finger tighten the fasteners (2 capscrews, 1/2 x 2-1/4
    inches, with washers, lock washers and hex nuts).

    FORM 6248 First Edition 5.25 - 25


    COOLING SYSTEM

    4. Install the fasteners in the crankcase water inlet 4. Remove the coupling sleeve and two seals from the
    flange on the other end of the water inlet elbow water pump inlet elbows (see Figure 5.25-28). Discard
    (2 capscrews, 1/2 x 2-1/4 inches, with washers and lock the seals.
    washers). Slide the crankcase water inlet flange (no
    counterbore, both sides flat) down the capscrews until it
    contacts the crankcase water inlet flange. Position a
    new gasket on the ends of the crankcase water inlet
    flange capscrews. Finger tighten the assembly to the
    right bank crankcase water header.

    5. Alternately wrench tighten the four crankcase water


    inlet flange capscrews.

    WATER PUMP INLET ELBOWS AND


    WATER HEADER
    WATER PUMP INLET ELBOWS AND WATER
    HEADER REMOVAL

    A WARNING
    The water header weighs approximately 56 Ibs. Figure 5.25-28. Water Header Assembly Couplings
    (25 kg). Use a suitable lifting device and exercise
    caution during removal or installation to avoid 5. Remove four capscrews, lock washers water pump
    severe personal injury or death. inlet flange, and flange gasket from each water pump
    inlet elbow and remove them from the water pump (see
    1. Attach a suitable lifting device to the water header Figure 5.25-29).
    (see Figure 5.25-27). )

    Figure 5.25-29. Water Pump Inlet Elbows

    Figure 5.25-27. Water Header Assembly - Front Left

    2. Remove four nuts and disconnect the two halves of


    the seal retainer connecting the water pump elbows to
    the water header assembly.

    3. Using a suitable lifting device, remove the water


    header from the water pump inlet elbows. )

    5.25 - 26 FORM 6248 First Edition


    COOLING SYSTEM

    WATER PUMP INLET ELBOWS AND WATER 4. With the tapered end facing opposite the retainer,
    HEADER INSTALLATION position a seal on the water pump inlet elbow (see
    Figure 5.25-28).
    1. Verify that the pipe ends of the water pump inlet
    elbows and water header ouilet pipes are clean and free 5. Insert the unflanged end of the water pump inlet
    of dirt and oil. Check the surfaces where the rubber elbows into the sleeves on the water header outlet
    seals contact the pipe to ensure that there are no pipes. The left bank elbow has an indentation in the
    gouges, grooves, burrs, nicks or dents. Surface back to accommodate the crankcase water inlet elbow
    imperfections will adversely affect sealing performance. (see Figure 5.25-26). Start the three clamp bolts in each
    coupling.
    2. Position the seal retainer onto the water pump inlet
    elbows, so that the concave side faces toward the pipe
    end (see Figure 5.25-28 and Figure 5.25-30). A WARNING
    The water header weighs approximately 56 Ibs.
    (25 kg). Use a suitable lifting device and exercise
    caution during removal or installation to avoid
    severe personal injury or death.

    6. Attach a suitable lifting device to the water header


    and raise the water header into position (see
    Figure 5.25-27).

    7. Position the fasteners through the square-shaped


    flange of the water pump inlet elbow (4 capscrews,
    1/2 x 1-1/2 inches, with lock washers) (see
    Figure 5.25-29). Position a new gasket on the caps-
    crews. Thread the capscrews into the water pump inlet
    flange. Wrench tighten in an alternating pattern.
    Repeat the procedure on the other bank.
    Figure 5.25-30. Dresser Coupling
    8. Alternately tighten the three clamp bolts on the
    water pump inlet elbow couplings (see Figure 5.25-28
    3. Using a small paintbrush, lubricate the seals, pipe and Figure 5.25-30). Torque the clamp bolts to 35 ft-Ib
    ends and sleeve flares with Parker Super O-Lube®. (47 N·m).

    FORM 6248 First Edition 5.25 - 27


    COOLING SYSTEM

    ,
    )

    ITEM NUMBER AND DESCRIPTION


    1 Cluster Thermostat Hsg. 5 Gasket 9 Plug 13 Lock washer

    2 Gasket 6 Lock washer 10 Elbow


    3 Upper Bypass Tube 7 Coupling 11 Gasket

    4 Lower Bypass Tube 8 Ferry head Capscrew 12 Ferry head Capscrew

    Figure 5.25-31. Water Bypass Tubes

    LOWER/UPPER BYPASS TUBES AND


    WATER BYPASS ELBOWS
    LOWER/UPPER BYPASS TUBES AND WATER
    BYPASS ELBOWS REMOVAL )
    1. Remove four capscrews and lock washers and
    gasket, from the upper bypass tube and cluster
    thermostat housing (see Figure 5.25·31).

    5.25 - 28 FORM 6248 First Edition


    COOLING SYSTEM

    2. Loosen three nuts and remove the upper bypass grooves, burrs, nicks or dents. Surface imperfec-
    tube from the lower bypass tube (see Figure 5.25-32). tions will adversely affect sealing performance.

    B. Measure back on each pipe end one-half of the


    sleeve length plus two inches and place a chalk
    mark.

    C. Slide the seal retainer onto the lower bypass


    tube, so that the concave side faces upward
    toward the pipe end.

    D. Using a small paintbrush, lubricate the seals,


    pipe ends and sleeve flares with Parker Super
    O-Lube®.

    E. With tapered end facing opposite the relainer, install


    seal onto the lower bypass tube. The pipe end must
    extend past end of the seal a minimum of one inch.
    Slide on the sleeve until it contacts rubber seal.

    Figure 5.25-32. Bypass Tubes - Front Left

    3. Remove three nuts and disassemble both sides of


    the Dresser coupling (see Figure 5.25-30).

    4. Remove two ferry head capscrews, lock washers


    lower bypass tube and gasket from the water bypass
    elbow (see Figure 5.25-33).

    5. Remove four ferry head capscrews, lock washers


    gasket and water bypass elbow from the water pump
    (see Figure 5.25-33).

    6. If required, remove the square head pipe plug from


    the water bypass elbow.

    7. Perform Steps 1 thru 6 for the opposite side of lhe


    engine.

    LOWER/UPPER BYPASS TUBES AND WATER


    BYPASS ELBOWS INSTALLATION

    1. If removed, apply pipe sealant to threads, and install


    the square head pipe plug on the water bypass elbow.

    2. Install the water bypass elbow on the water pump


    with gasket, four ferry head capscrews, and lock
    washers (see Figure 5.25-33).

    3. Fasten the lower bypass tube to the water bypass


    elbow with gasket, two ferry head capscrews and lock
    washers.

    4. Install the Dresser couplings between the lower and


    upper bypass tube as follows:

    A. Verily that the pipe ends are clean and free of dirt
    and oil. Check the surfaces where the rubber seals Figure 5.25-33. Water Bypass Elbows
    contact the pipe to ensure that there are no gouges,

    FORM 6248 First Ednion 5.25 - 29


    COOLING SYSTEM

    5. Install the second seal retainer and seal on the 7. Fasten the flange of the upper bypass tube to the
    unflanged end of the upper bypass tube (see cluster thermostat housing bypass outlet port with two )
    Figure 5.25-34). capscrews and lock washers.

    8. Alternately tighten the three clamp bolts to evenly


    draw up the seal retainers.

    9. Torque the clamp bolts to 35 ft-Ib (47 N·m).

    10. Position the upper water bypass tube over the


    outlet port on the cluster thermostat housing.

    11. Install the upper water bypass tube to the cluster


    thermostat housing with gasket, four capscrews, and
    lock washers.

    12. Perform Steps 1 thru 11 for the opposite side olthe


    engine.
    SEAL
    RETAINER"

    Figure 5.25-34. Dresser Coupling

    6. Insert the upper bypass tube into the coupling sleeve


    (see Figure 5.25-35).

    Figure 5.25-35. Bypass Tubes - Front Left

    5.25 - 30 FORM 6248 First Edition


    COOLING SYSTEM

    WATER MANIFOLD
    WATER MANIFOLD REMOVAL

    1. Refer to Coolant Drain, and drain coolant from water


    manifold and cluster thermostat housing.

    2. Refer to Cluster Thermostat Housing Removal, and


    remove the cluster thermostat housing.

    3. Refer to Engine Breather Systems, and remove the


    venturi assembly.

    4. Refer to Engine Protection Systems, and remove the


    thermocouple conduit assembly.

    5. Remove four capscrews, lock washer and gasket


    from each water outlet elbow (see Figure 5.25-36 and
    Figure 5.25-37).

    6. Remove two capscrews and lock washers from the Figure 5.25-36. Exhaust Manifold Flanges - Rear Left
    four water manifold support brackets.

    I
    I

    /'
    ~ I
    I
    j.
    t'iii
    10

    12
    /'

    ITEM NUMBER AND DESCRIPTION


    1 Water Manifold 4 Plug 7 Gasket 10 Reducing Bushing
    2 Lock washer 5 Plug 8 Gapscrew 11 Reducing Bushing
    3 Plug 6 Cover Plate 9 Plug 12 Drain Cock
    Figure 5.25-37. Water Manifold

    FORM 6248 First Edition 5.25 - 31


    COOLING SYSTEM

    12. Remove two capscrews, lock washers cover plate


    A WARNING and gasket from the water manifold (see )
    The water manifold weighs approximately 102 Ibs. Figure 5.25-37).
    (46 kg). Use a suitable lifting device and exercise
    13. If required, remove two drain cocks and reducing
    caution during removal or installation to avoid
    bushings from the bottom of the water manifold.
    severe personal injury or death.
    7. Attach a suitable lifting device to the water manifold. 14. If required, note the location and remove the seven
    square head pipe plugs from the water manifold.
    8. Using a suitable lifting device, remove the water
    manifold from the exhaust manifolds. WATER MANIFOLD INSTALLATION

    9. Position the water manifold on wooden blocks (to 1. Apply Perma Lok® Heavy Duty Pipe Sealant with
    avoid damage to the drain cocks and to keep the casting Teflon® to the threads of two drain cocks and reducer
    from rocking on the pipe plugs). bushings. Install the drain cocks and the reducing
    bushings at the bottom of the water manifold (front and
    10. Loosen the twelve flexmaster couplings from the rear).
    water manifold (see Figure 5.25·38).
    CAUTION I
    I A=~=.:::....:.=-.:..::..:=:.:..;:.J.
    Deposits left .on gasket
    .L .:
    .. surfaces will cause
    leaks. Verify that the gasket and gasket mating
    surfaces are clean and completely free of grease
    and oil. Disregarding this information could result
    in product damage and/or personal Injury.

    2. Install the cover plate on the manifold with two


    capscrews, lock washers and gasket.

    3. Disassemble both sides of twelve Flexmaster cou- )


    plings (see Figure 5.25-40).

    '~~~
    Figure 5.25-38. Water Manifold Bracket - Front Left
    11. Remove four support brackets from the exhaust
    manifold flanges (capscrew, two washers, lock washer .~ ~ S~E~
    'COUPLING
    , RUBBER
    and nut per support bracket) (see Figure 5.25·38 and
    SEAL SEAL
    Figure 5.25-39). , RETAINER
    CLAMP

    WATER MANIFOLD Figure 5.25-40. Flexmaster Coupling


    FLANGE

    \ 4. With the concave side facing outward toward the


    pipe end, position a seal retainer on the water inlet
    pipes.

    5. POSition the seals in the hollowed portion of each


    retainer. Slide on the coupling sleeves. j
    -'
    LOCK WASHER -'''---I!i==~J
    \ SUPpORT
    HEX NUT BRACKET 6. Wrap the open clamps around the seal retainers and
    the flared end of each sleeve, finger tighten the clamp
    Figure 5.25-39. Water Manifold Mounting Brackets bolt hex nuts.

    5.25- 32 FORM 6248 First Edition


    COOLING SYSTEM

    7. Verify that the pipes of each water outlet elbow and 10. Slide the pipe of each water outlet elbow into the
    water inlet pipes (see Figure 5.25-41 and free end of the Flexmaster coupling sleeves.
    Figure 5.25-42) are clean and completely free of dirt and
    oil. Check the surfaces where the coupling seal contacts 11. Wrap an open clamp around each seal retainer and
    the elbow outlet pipe and water inlet pipes to verify that the flared end of the sleeve. Leave the clamp boH hex nuts
    there are no gouges, burrs, nicks or dents. Surface loose until the water manifold is positioned on the engine.
    imperfections will adversely affect sealing performance.
    12. Position four capscrews and lock washers on each
    water outlet elbow (see Figure 5.25-43).

    Figure 5.25-43. Water Manifold Connections


    Figure 5.25-41. Water Manifold - Front
    13. Using the round hole, install the right and left bank
    support brackets to the welded flange 'at the front of the
    water manifold (see Figure 5.25-44) With capscrew two
    ELBOW OUTLET
    PIPE I I washers, lock washer and hex nut. Inslall the second flat

    1'0
    ---- i
    I
    I
    I
    I
    I
    I
    i
    washer between the welded flange and the support
    bracket (see Figure 5.25-45). Position each bracket so
    that the foot faces the rear of the engine.
    0'
    \
    "
    I .... --.... \

    I'd'\
    I
    \
    I
    I

    ~~-·-v
    ,0 '-O~ O~
    Figure 5.25-42. Water Outlet Elbow

    8. With the concave side facing toward the pipe ends,


    slide the seal retainers on the water outlet elbows.

    9. Position the seals in the hollowed portion of each


    retainer. Figure 5.25-44. Water Manifold Bracket - Front Left

    FORM 6248 First Edition 5.25 - 33


    COOLING SYSTEM

    CAPSCREW
    18. TIghten the four capscrews and lock washers on
    each of the twelve water outlet elbows.
    WATER MANIFOLD I"""''i' ' ' '.......:;.......
    / FLAT

    FLArN_G_\..L---L:====~~"~ 19. TIghten the clamp bolts and nuts on the twelve
    flexmaster couplings.

    20. TIghten the support brackets to the exhaust man-


    ifolds with two capscrews and lock washers per support
    bracket.

    /
    LOCK WASHER /"--t!===-...
    \ SUPPORT CLUSTER THERMOSTAT HOUSING AND
    HEX NUT BRACKET
    THERMOSTATIC VALVES

    Figure 5.25-45. Water Manifold Mounting Brackets CLUSTER THERMOSTAT HOUSING AND
    THERMOSTATIC VALVES REMOVAL

    14. Install the right and left bank support brackets to the NOTE: Drain the jacket water system until the level of
    side flanges welded at the rear of the water manifold (see the coolant drops below the cluster thermostat housing.
    Figure 5.25-46) with capscrew two washers, lock washer
    1. Remove the ferrule nut to detach the air venting tube
    and hex nut. Be sure to install the second flat washer
    from the bottom of the cluster thermostat housing (male
    between the welded flange and the support bracket.
    connector tube fitting) (see Figure 5.25-47).

    Figure 5.25-46. Water Manifold Bracket - Rear Left


    Figure 5.25-47.12 Cylinder Cluster Thermostat
    Housing

    A WARNING 2. Remove the two brass air bleed petcocks at the top
    The water manifold weighs approximately 102 Ibs. of the cluster thermostat housing.
    (46 kg). Use a suhable lifting device and exercise
    caution during removal or installation to avoid 3. Remove the cooling water outlet flange adapter
    severe personal injury or death. from the cluster thermostat housing (4 capscrews,
    1/2 x 1-1/2 inches, with lock washers).
    15. Attach a suitable lifting device to the water man-
    ifold. 4. Remove the upper bypass tube flanges from the cluster
    thermostat housing bypass outlet ports (4 capscrews per
    16. Position twelve gaskets on the water outlet open- flange, 1/2 x 1-1/4 inches, with lock washers).
    ings on the exhaust manifolds.

    17. Position the water manifold on the exhaust man-


    ifolds. Loosely install the support brackets to the
    exhaust manifolds with two capscrews and lock wash-
    ers per support bracket.

    5.25 - 34 FORM 6248 First Ednion


    COOLING SYSTEM

    2. Verifythatthe valves are in the fully closed position. If


    A WARNING any valve is frozen open or if there is any obvious
    The cluster thermostat housing weighs approxi- distortion, discard it. If the valve appears in good
    mately 70 Ibs. (32 kg). Use a suitable lifting device condition, test as follows:
    during removal or installation. Disregarding this A. Suspend the thermostatic valve in a container of
    information could result in severe personal injury water. Do not let the thermostat rest against the
    or death. sides or bottom.
    5. Remove the cluster thermostat housing from the
    front end of the water manifold (10 capscrews, 3/8 x
    1-1/8 inches, with lock washers).
    IA
    ..
    CAUTION I Do not boil the thermo-
    static valve. Excessive
    temperatures will force the valve to exceed its
    6. Position the thermostat housing on a suitable normal operating travel and may resuH in perma-
    workbench with the expansion elements of the thermo- nent product damage and/or personal injury.
    static valves facing upward.
    B. Gradually heat the water while stirring with a
    7. Remove the six thermostatic valves. Take note olthe quality glass laboratory thermometer (see
    nominal temperature ratings of the lead and following Figure 5.25-48). Observe the action ofthe valve.
    thermostats. The lead thermostat is located in the right
    front port of the cluster thermostat housing.The temper-
    ature rating is stamped at the bottom of the expansion
    element (bulb). The Waukesha part number is stamped
    on the valve sleeve.

    8. Remove the lip seals. Use a rolling head pry bar for
    best results.

    CLUSTER THERMOSTAT HOUSING AND


    THERMOSTATIC VALVES CLEANING AND
    INSPECTION

    A WARNING
    Use of caustic solutions should be restricted to a
    well ventilated area. Contact with skin, clothing and
    eyes could result in severe personal injury or death.

    A WARNING
    Compressed air can pierce the skin and cause
    severe personal injury or death. Never use your
    hand to check for leaks or to determine air flow
    rates. Wear safety glasses to shield your eyes from
    flying dirt and debris.

    1. Submerse the thermostat housing in the caustic hot Figure 5.25-48. Thermostat Testing
    tank to remove all paint, dirt, grease and oil. Follow up
    with a thorough hot rinse. Dry the parts with moisture C. The valve should begin to open at the Start to
    free compressed air. Open temperature rating listed in Table 5.25-8
    and be completely open at the Full Open
    temperature, plus or minus 5° F (2.8° C).

    FORM 6248 First Ednion 5.25 - 35


    COOLING SYSTEM

    D. Remove the valve and observe its closing action.


    The valve should seal evenly and tightly (see
    Figure 5.25-49). TOP VIEW

    WED
    PART
    NUMBER~
    RUBBER
    I SEAT
    FULLY CLOSED FULLY OPEN
    I
    Figure 5.25-49. Thermostat Open And Closed L
    I~
    E. If the thermostatic valve is defective, replace it.
    ""'[ -'" J""'"
    3. Take note of the temperature ratings and part
    numbers stamped on the old thermostatic valves. The SIDE VIEW
    temperature rating is stamped at the bottom of the
    expansion element (bulb) (see Figure 5.25-50 and /
    Figure 5.25-51). The Waukesha part number is VENDOR IDENTIFICATION AND
    NOMINAL TEMPERATURE RATING
    stamped on the valve sleeve.
    Figure 5.25-51. Jacket Water Thermostats -
    PIN 208660 Series )
    The colored dot centered at the top of the thermostatic
    valve is also used to readily identify its temperature
    rating. With the exception of the lead thermostat, all
    valves should have the same color code.

    NOTE: If the old thermostatic valves are not available,


    check the engine specification pack to be sure that the
    new valves are correct.

    PIN 208627 Series thermostats use a weir notched seal


    design for a gradual transition of coolant flow. This
    thermostat series, does not require a "lead thermostat"
    VENDOR
    IDENTIFICATION
    because of the weir notch seal design. All thermostats
    will be of the same part number. The PIN 208627C
    thermostat is used in landfill gas and high temperature
    applications.

    PIN ............

    Figure 5.25-50. Jacket Water Thermostats - )


    PIN 208627 Series

    5.25 - 36 FORM 6248 First Edition


    COOLING SYSTEM

    Table 5 25-8 PIN 208660 Series And PIN 199221 Series Jacket Water Thermostets
    NOMINAL START TO OPEN FULL 208660 SERIES .1
    STD. QTY. TEMP. OPEN 199221
    IOPT TYPE 'FiC) 'F('C)
    CURRENT PRODUCTION SERIES'"",,",
    'FiC)
    PIN COLOR CODE PIN
    12 CYUNDER ENGINES - CLUSTER THERMOSTAT HOUSING PIN 204478
    Lead 1 165 (74) 162 - 167 (72 - 75) 182 (83) 2086600 Yellow 1992210
    Std,
    Follow 5 170 (77) 167 - 172 (75 - 78) 187 (86) 208660 White 199221C

    Lead 1 180 (82) 177 - 182 (81 - 83) 197 (92) 208660A Red 199221 A
    Std.
    Follow 5 190 (88) 187 - 192 (86 - 89) 212 (100) 208660B None 208660B"

    Lead 1 160 (71) 157 - 162 (69 - 72) 177(81) 208660C Blue 199221E
    Opt.
    Follow 5 180 (82) 177 - 182 (81 - 83) 197 (92) 208660A Red 199221 A

    Opt. Weir 6 220 (104) 217 - 222 (103 -106) 237 (114) 208627C" Red 208627C .. (Red)
    NOTE: *1 The 208660 series thermostat is current production and uses a rubber seal for posffive coolant control. This is the first choice for
    service.
    *2 The 208627 series thermostat (see Table 5.25-9), uses a weir notched seal design for a gradual transition of coolant flow. This is the
    second choice for service.
    ~ The 199221 series thermostat uses a metal to metal seal. This is the third choice for service.
    oM These thermostats, while not of the same series, should be used in these temperature applications.

    Table 5.25-9. PIN 208627 Series - Weir Type Jacket Water Thermostats
    NOMINAL TEMP. START TO OPEN FULL OPEN
    208627 SERIES'
    'F('C) 'F('C) 'F('C)
    PIN COLOR CODE
    12 CYLINDER ENGINES OPTIONAL PIN 208627 SERIES THERMOSTATS
    160 (71) 157 -162 (69 -72) 177 (81) 208627 Blue
    170 (77) 167 - 172 (75 - 78) 187 (86) 208627A White
    190 (88) 187 - 192 (86 - 69) 212 (100) 2086276 None
    220 (104) 217 - 222 (103 - 106) 237 (114) 208627C Red
    NOTE: * The 208627 series thermostat uses a weir notched seal design for a gradual transition of coolant flow. This is the second choice for
    service. This thermostat series, does not require a "/ead thermostat" because of the weir notch sea/ design.

    CLUSTER THERMOSTAT 3, Verify that all gaskets and gasket mating surfaces
    HOUSING/THERMOSTATIC VALVES are clean and completely free of grease and oil.
    INSTALLATION
    4. With the open side facing inward, press fit new lip

    CAUTION I Deposits I~ft on gasket


    I~A="-..::=..:.;::;...;~;:;;..;:...;..J.
    seals into the cluster thermostat housing (see
    Figure 5.25-52).
    L.. . surfaces Will cause leaks.

    CAUTION I
    I~A=--=:.:...=-=-=-;:..:::..:..;;.J.
    Exercise care to keep the t j
    L.. . gasket debris out of the
    cluster thermostat housing. THIS StDE INTO
    THERMOSTAT HOUSING
    .n.V
    1, Scrape the old gasket material from the bottom of the
    Figure 5.25-52. Thermostet Seal
    cluster thermostat housing, if necessary. Scrape the
    bypass tube and cooling water outlet flanges of the
    cluster thermostat housing.

    2. Scrape the gasket mating surfaces at the top of the


    water manifold, the two upper bypass tubes flanges and
    the cooling water outlet flange, if necessary,

    FORM 6248 First Edition 5.25 - 37


    COOLING SYSTEM

    5. For best results, use a pipe or tube of equal diameter.


    Verify that each seal is square in the bore and A WARNING )
    completely seated around its circumference) (see The cluster thermostat housing weighs approxi-
    Figure 5.25-53). mately 70 Ibs. (32 kg). Use a suitable lifting device
    and exercise caution during removal or installation
    to avoid severe personal injury or death.

    12. With the water outlet flange facing the front of the
    engine, install the cluster thermostat housing althefront
    olthe water manifold (10 capscrews, 3/8 x 1-1/8 inches,
    with lock washers). Tighten the capscrews in an
    alternating pattern.

    13. Apply 3M Scotch Grip ~ Rubber and Gasket


    Adhesive 847 to the two bypass outlet port flanges olthe
    cluster thermostat housing. Position new gaskets on the
    contact cement.

    e e 14. Fasten the upper bypass tubes to the cluster


    thermostat housing bypass outlet ports (4 capscrews
    per flange, 1/2 x 1-1/4 inches, with lock washers).
    THERMOSTATIC
    VALVES 15. Slide the fasteners through the holes in the cluster

    -
    7
    -.. thermostat housing water outlet flange adapter (4
    capscrews, 1/2 x 1-1/2 inches, with lock washers).
    Position a new gasket on the capscrews.
    LEFT BANK BYPASS
    OUTLET PORT 16. Position the flange adapter over the outlet port. )
    Figure 5.25-53.12 Cylinder Cluster Thermostat Tighten the capscrews.
    Housing - Bottom View
    17. Apply Perma Lok® Heavy Duty Pipe Sealant with
    Teflon® to the threads of the two air bleed petcocks.
    6. Using a small paintbrush, lubricate the lip seals with Install the petcocks in the holes above the bypass outlet
    clean ethylene glycol (antifreeze). ports on each side of the cluster thermostat housing.
    7. Take note of the temperature ratings and part 18. Tighten the ferrule nulto attach the water header air
    numbers stamped on the old thermostatic valves. venting tube to the bottom of the cluster thermostat
    housing (male connector tube fitting).
    8. With the bulb of the expansion element facing
    outward, place the lead thermostat in the right front port 19. Refill the jacket water system and bleed trapped air.
    of the cluster thermostat housing (see Figure 5.25-53).
    The lead thermostat has a nominal temperature rating
    lower than the others, normally 5° F (2.8° C).

    9. Install thermostatic valves in the five remaining


    ports.

    10. Apply 3M Scotch Grip~ Rubber and Gasket


    Adhesive 847 to the top of the thermostat housing at the
    front of the water manifold.

    11. Place a new gasket ( on the contact cement. Allow


    the gasket adhesive to cure. See the manufacturer's
    recommendations.

    5.25 - 38 FORM 6248 First Edrtion


    COOLING SYSTEM

    IDLER PULLEY BRACKET 2. Loosen the two nylok socket head set screws in the
    idler pulley.
    IDLER PULLEY BRACKET REMOVAL
    3. Using a jaw type gear puller, remove the pulley from
    1. Remove the capscrew, lock washer and washer the idler pulley shaft (see Figure 5.25-56).
    from the adjusting groove on the idler pulley bracket
    (Figure 5.25-54).

    Figure 5.25-54. Idler Pulley Bracket

    2. Remove the V-belts from the idler pulley.

    3. Remove capscrew, lock washer and idler pulley


    bracket from the water pump.

    IDLER PULLEY BRACKET DISASSEMBLY

    1. Remove the grease fitting from the idler pulley


    bracket (see Figure 5.25-55).
    Figure 5.25-56. Idler Pulley Shaft Removal

    Figure 5.25-55. Idler Pulley

    FORM 6248 First Edition 5.25 - 39


    COOLING SYSTEM

    6. Remove the ball bearing/shaft assembly from the


    A WARNING idler pulley bracket (see Figure 5.25-58).
    Always wear proper eye protection when removing
    tack welds. failure to wear eye protection could
    result In severe personal injury or death.

    4. Using a cold chisel and hammer, break the three tack


    welds securing the cover to the back of the idler pulley
    bracket (see Figure 5.25-57).

    Figure 5.25-58. Remove Ball Bearing/Shaft Assembly


    )
    7. Remove the grease seal from the bore ofthe bracket
    (see Figure 5.25-59). Discard the seal.

    Figure 5.25-57. Cover Removal

    A WARNING
    Always wear proper eye protection when removing
    retaining rings. Slippage may propel the ring with
    enough force to result in severe personal injury or
    death. Use the correct retaining ring pliers. Verify
    that the tips of the pliers are not excessively worn or
    damaged.

    5. Remove the large retaining ring from the bore at the


    back of the idler pulley bracket.

    Figure 5.25-59. Grease Seal Removal


    )
    8. Remove the small retaining ring from the idler pulley
    shaft.

    5.25 - 40 FORM 6245 First Edition


    COOLING SYSTEM

    9. Center the ball bearing support under the ram of the 3. Inspect the pulley sheave groove sidewalls for
    arbor press. Center the ball bearing on the bearing excessive wear. Replace the pulley if the groove walls
    support. Center the driver on the idler pulley shaft. are dished out or if the sheaves are chipped or bent.

    10. Lower the ram until it makes contact with the driver. 4. Inspect the idler pulley shaft for damage and wear.
    The shaft must be straight and free of nicks and burrs.
    11. Lower the ram until the idler pulley shaft drops out of Inspect the ball bearing seating surface for scoring,
    the ball bearing (see Figure 5.25-60). Release the ram scuffing and excessive wear. Replace the shaft if
    pressure. Discard the ball bearing. necessary.

    IDLER PULLEY BRACKET ASSEMBLY


    ;SHAFT
    1. Center the ball bearing support under the ram of the

    V~
    arbor press.

    ~~
    PRESS

    S[
    I
    l'- OUT
    IA
    ..
    CAUTION I To avoid damage to the
    ball bearing, be sure that
    J:?~ ~~ -.. ~i the inner race is properly supported. Disregarding
    this information could result in product damage
    and/or personal inJury.

    BALL 2. Center a new ball bearing on the bearing support.


    BEARING
    3. Position the idler pulley shaft upright in the ball
    bearing 10 so that the retaining ring groove is at the
    bottom (see Figure 5.25-61). a
    Figure 5.25-60. Idler Pulley Ball Bearlng!Shaft
    Assembly

    IDLER PULLEY BRACKET CLEANING AND


    INSPECTION "
    I .\
    A WARNING I I
    Cleaning solvents may be toxic or flammable. Keep
    away from heat or flame. Read the manufacture's
    "- SHAFT
    SHOULDER
    warnings on the container. Always use approved
    RETAINING RING
    cleaning solvents in a well ventilated area. Avoid GROOVE"
    contact with skin. Disregarding this information
    could result in severe personal inJury or death.
    Figure 5.25-61. Idler Pulley Shaft
    A WARNING
    4. Center the driver over the idler pulley shaft. Verify
    Compressed air can pierce the skin and could result
    that the shaft is not cocked in the bearing 10.
    in severe personal inJury or death. Never use your
    hand to check for leaks or to determine air flow rates. 5. Lower the ram until it makes contact with the driver.
    Wear safety glasses to shield your eyes from flying
    dirt and debris.

    1. Thoroughly clean the internal parts of the assembly


    with solvent to remove all grease and dirt. Hot tank the
    idler pulley and bracket. Blow dry the parts with moisture
    free compressed air.

    2. Inspect the two retaining rings for damage or


    distortion. Replace the rings if necessary.

    FORM 6248 First Edition 5.25 - 41


    COOLING SYSTEM

    I .A. CAUTION ITo avoid damage, use


    only enough ram force to
    10. Pack Uthoplex® Grease No. 2 (Multipurpose
    Uthium Complex Formula Containing Molybdenum
    seat the ball bearing. Disregarding this information Disulfide) between the inner and outer races of the ball
    could result in product damage and/or personal bearing.
    Injury.
    11. With the pulley side facing the press table, center
    6. Press the idler pulley shaft into the ball bearing until the bore of the idler pulley bracket under the ram.
    the shoulder makes solid contact with the inner race
    12. With the retaining ring at the top, position the ball
    (see Figure 5.25-62).
    bearing/shaft assembly upright in the bracket bore.
    Center the bearing driver over the outer race of the ball
    bearing.

    13. Verify that the ball bearing/shaft assembly is


    aligned in the bracket bore. Lower the ram until it makes
    contact with the bearing driver.
    BALL
    BEARING\ 14. Press the ball bearing/shaft assembly into the bore.
    I Exert uniform pressure against the outer race of the
    y ~jj bearing until it makes solid contact with the inside
    counterbore.
    i~ ];:
    15. Install the large retaining ring in the bracket bore.

    ~~~ !/
    I
    ~c)
    Rotate the ring to verify that it is fully seated in the
    groove.
    RETAINING 16. Ughtly lubricate a new grease seallD with a lithium
    GROOVE
    complex type grease.
    Figure 5.25-62. Idler Pulley Ball Bearing/Shaft
    17. With the pulley side facing upward on the press
    )
    Assembly
    table, center the bore of the idler pulley bracket under
    the ram.
    7. Release the ram and remove the driver.
    18. With the lipped side facing inward towards the ball
    8. Verify that the ball bearing rotates freely on the idler
    bearing, position the grease seal over the bracket bore.
    pulley shaft, without any drag.
    19. Center the driver over the grease seal. Lower the
    A WARNING ram until it makes contact with the driver.

    Always wear proper eye protection when installing 20. Press the grease seal into the bracket bore until the
    retaining rings. Slippage may propel the ring with closed side of the carrier is flush with the top of the
    enough force to cause severe personal injury or casting.
    death. Use the correct retaining ring pliers. Verify
    21. Press the pulley on the idler pulley shaft until it
    that the tips of the pliers are not excessively worn or
    makes solid contact with the shaft shoulder.
    damaged.
    22. Install two new nylok socket head set screws in the
    9. Install the small retaining ring in the groove on the idler pulley. Tighten the set screws to secure the pulley
    idler pulley shaft. Rotate the ring to verify that it is fully to the idler pulley shaft.
    seated.

    5.25 - 42 FORM 6248 Firsl Edilion


    COOLING SYSTEM

    IDLER PULLEY wBR:A=C=K=ET~'-...)~_ _--7(~


    PIVOT BOLT HOLE~_

    +
    CENTERLINE~

    -~~~~~~
    IDLER PULLEY SHAFT /~ __

    Figure 5.25-63. Idler PUlley Bracket Vent Hole Location


    23. Position the rear cover in the back of the idler pulley 27. Using Lithoplex® Grease No. 2 (Multipurpose
    bracket. Rotate the cover so thatthe 1/8 inch vent hole is Lithium Complex Formula Containing Molybdenum
    within 1/2 inch ofthe centerline between the idler pulley Disulfide), slowly fill the bearing cavity until grease
    shaft and the pivot bolt hole (see Figure 5.25-63). extrudes from the vent hole in the rear cover.

    IDLER PULLEY BRACKET INSTALLATION


    -A CAUTION 1Ball bearing ~rease pres-
    I
    L.=
    ..
    =~=..;:.;::....:~=-=~. sure may dislocate the 1. Install the pivot bolt and lock washer through the hole
    rear cover if it is not properly secured to the idler in the idler pulley bracket. Position the idler pulley
    pulley bracket. Disregarding this infonnation could bracket assembly against the face of the water pump
    rasult in product damage and/or personal injury. and install the pivot bolt in the threaded boss above the
    right bank water pump outlet port (see Figure 5.25-64).

    A WARNING
    Always wear protective eye shields when welding,
    cutting or watching a welding operation. Protective
    clothing and face shields must be worn. Never weld
    or cut near combustible materials. Disregarding
    this Information could result in severe personal
    injury or death.

    24. Using a mild steel rod, place three tack welds (of
    equal distance) where the edge of the cover contacts
    the back of the bracket.

    25. Lightly tap on the welds to check for cracks. Use


    crocus cloth to remove any weld spatter.

    26. Install the grease fitting in the idler pulley bracket. Figure 5.25-64. Idler Pulley Bracket

    FORM 6248 First Ed~ion 5.25-43


    COOLING SYSTEM

    2. Install the lock bolt lock washer and washer through 5. Install an eye bolt 5/16 inch threads, in the threaded
    the slot in the idler pulley bracket. Install the bolt in the hole at the base of the upper center boss (see )
    threaded boss below the right bank water pump outlet Figure 5.25-66). Attach a suitable lifting device to the
    port (see Figure 5.25-64). eye bolt.

    3. Position the V -belts on the idler pulley.

    4. Refer to Jacket Water Pump Drive Belt Tension


    Adjustment and adjust the water pump drive belts.

    JACKET WATER PUMP


    JACKET WATER PUMP REMOVAL

    1. Refer to Crankcase Water Inlet Pipe Removal,


    Water Pump Inlet Elbow Removal, and Water Bypass
    Tube Removal, and remove these components.

    2. Remove capscrew, lock washer, washer, bracket


    and spacer, from the upper gear cover flange (see
    Figure 5.25-65).

    3. Remove nut, capscrew, lock washer and bracket


    from the water drain pipe.
    Figure 5.25-65. Lifting The Jacket Water Pump
    4. Remove the pipe plugs from the left and right bank
    water bypass elbows. 6. Remove ten nuts and lock washers from the water
    pump and carefully remove the pump using a suitable
    lifting device.
    )
    7. Remove the water pump cover gasket and water
    pump cover from the gear cover.

    8. Remove the water pump cover to gear cover gasket


    from the gear cover (see Figure 5.25-67).

    Figure 5.25-65. Water Drain Petcock - Front Right

    A WARNING
    The water pump weighs approximately 105 Ibs. Figure 5.25-67. Water Pump Cover And Cover Gasket
    (48 kg). Use a suitable lifting device and exercise
    caution during removal or Installation to avoid
    9. Remove the drain cock, pipe coupling, two pipe
    severe personal injury or death.
    nipples, and elbow from the bottom of the water pump.
    )

    5.25 - 44 FORM 6248 First Edition


    COOLING SYSTEM

    INNER
    GREASE SEAL

    THIN

    THIN NUT

    •• M'• ...," PUMP

    SEAL ASSEMBLY

    IMPELLER
    SHAFT AND BE~IRI~IG
    ASSEMBLY

    Figure 5.25-68. VHP Water Pump Assembly

    JACKET WATER PUMP DISASSEMBLY capscrews into the impeller puller holes (3/8-16 inch
    threads) and use a bar to keep the shaft from turning.
    A WARNING 3. Loosen the thin nut on the impeller side. Use the
    The water pump weighs approximately 105 Ibs. pulley puller holes (3/8-16 inch threads) to hold the
    (48 kg). Use a suitable lifting device and exercise shaft if necessary.
    caution during removal or installation to avoid
    4. Remove the thin nut and flat washer on both the
    severe personal injury or death.
    pulley and impeller ends of the shaft.
    1. Remove the water drain petcock from the pipe nipple 5. Turn the pump over, impeller side up.
    assembly. Remove the air bleed petcock from the water
    pump housing. 6. Remove the impeller from the shaft. The two
    threaded holes in the impeller (3/8-16 inch threads)
    2. Using an air impact wrench, loosen the thin nut on may be used with aT-type gear puller and air impact
    the pulley end of the water pump shaft (see wrench, if necessary.
    Figure 5.25·68). If necessary, thread two hardened

    FORM 6248 First Edition 5.25-45


    COOLING SYSTEM

    JACKET WATER PUMP CLEANING AND


    A WARNING INSPECTION
    Always wear proper eye protection when removing 1. Inspect the pulley sheave groove sidewalls for
    the spring. Slippage may propel the spring with excessive wear. Replace the pulley if the groove walls
    enough force to cause severe personal injury or are dished out or if the sheaves are bent, chipped or
    death. pitted.

    7. Remove the spring from the shaft. Remove the brass


    retainerlcarbon seal assembly. Use a small puller tool if A WARNING
    necessary. Discard the seal assembly. Always wear Insulated gloves when handling
    8. Remove the ceramic seal and rubber seat from the heated parts. Use of bare hands will result in burns.
    counterbore. Discard the seal and seat. Disregarding this information could result in severe
    personal InJury or death.
    9. Turn the water pump over, pulley Side up.
    2. Remove the pulley hub wear sleeve. Briefly heat the
    10. Remove the pulley from the water pump shaft. The sleeve around its circumference using a propane torch.
    two threaded holes in the pulley (3/8-16 inch threads) Expansion ofthe sleeve will cause ilto slip off the pulley
    may be used with aT-type gear puller and air impact hub.
    wrench, if necessary.
    3. Inspect the water pump housing for cracks or
    11. Remove the outer grease seal from the water pump corrosion. Look for signs of cavitation where the
    housing. Discard the seal. impeller vanes pass the volute just inside the water
    pump housing. Replace the housing if necessary.
    A WARNING
    Always wear proper eye protection when removing A WARNING
    the retaining ring. Slippage may propel the ring with Compressed air can pierce the skin and cause )
    enough force to cause severe personal injury or severe personal Injury or death. Never use your
    death. Use the correct retaining ring pliers. Verify hand to check for leaks or to determine air flow
    thatthetips ofthe pliers are not excessively worn or rates. Wear safety glasses to shield your eyes from
    damaged. flying dirt and debris.

    12. Remove the retaining ring from the groove in the 4. Hot tank the water pump housing and pulley to
    water pump housing. remove old gasket material, grease and dirt. Blow dry
    the parts with moisture free compressed air.
    13. Place the pump in an arbor press, impeller side up.
    Press on the impeller side of the shaft to remove the
    bearing and shaft assembly.

    14. Remove the inner grease seal from the water pump
    housing. Discard the seal.

    5.25 - 46 FORM 6248 First Edition


    COOLING SYSTEM

    JACKET WATER PUMP ASSEMBLY 3. Position the smaller diameter ball bearing over the
    Assemble the jacket water pump using the appropriate impeller end of the shaft. Slide the bearing driver (see
    rebuild kit. Figure 5.25-70 - Tool #2) over the shaft until it contacts
    the inner race of the smaller diameter ball bearing (see
    NOTE: Installation of the new jacket water pump Figure 5.25-71).
    assembly requires use of the new water pump cover
    plate (PIN 2OO1618). The previous cover plate (PIN
    2oo161) cannot be used with the current water pumps BALL
    (double row ball bearings). BEARING
    DRIVER
    1. Position the larger diameter ball bearing down the
    pulley end of the water pump shaft (see
    Figure 5.25-69).

    PRESSON
    PULLEY END IMPELLER END

    ---I---G- -+ -- -Fl.
    INNER RACE
    OF BEARING

    Figure 5.25~. Jacket Water Pump Shaft


    2. Place the bearing sleeve base (see Figure 5.25-70 -
    Tool #1) on the deck of the arbor press. With the larger
    diameter ball bearing positioned over the pulley end of
    the water pump shaft, insert the pulley end of the shaft
    into the sleeve base until the inner race of the larger
    diameter ball bearing contacts the top of the sleeve. BEARING
    SLEEVE
    BASE TOOL

    PRESSON
    INNER RACE
    OF BEARING

    2 3

    5 6/
    Figure 5.25-71. Press Bearings Onto Shaft

    4. Center the bearing sleeve base tool under the ram.


    4 Verify that the water pump shaft is completely vertical
    and that the ball bearings are positioned correctly on the
    shaft.

    9 5. Lower the ram until it makes contact with the bearing


    driver.

    IA
    ..
    CAUTION I Use only enough ram
    force to Install the bear-
    1. BEARING SLEEVE BASE ings, 150 Ibs. minimum (667 N), 1500 Ibs. maximum
    2. BEARING DRIVER (6672 N). To avoid use of excessive force, fit the ram
    3. GREASE PACKING FIXTURE with the proper size load cell. Damage to the ball
    4. INNER GREASE SEAL DRIVER
    5. SEAL PROTECTOR SLEEVE bearings will result in premature water pump
    6. BEARING SHAFT DRIVER failure. Disregarding this information could result
    7. OUTER GREASE SEAL DRIVER
    8. PULLEY WEAR SLEEVE DRIVER in product damage andlor personal injury.
    9. CERAMIC SEAL DRIVER
    10. BRASS RETAINER/CARBON SEAL DRIVER
    6. Lower the ram until both ball bearings are seated
    Figure 5.25-70. Jacket Water Pump Service Tool solidly against the shoulders on the water pump shaft.
    Kit PIN 474013
    7. Release the ram and remove the bearing driver.

    FORM 6248 First Edition 5.25 - 47


    COOLING SYSTEM

    8. Remove the ball bearing shaft assembly from the


    bearing sleeve base tool. Verify that the bearings are A WARNING )
    completely seated against the shaft shoulders. Verify Do not operate the valve of the pneumatic greaser
    that the bearings rotate freely without drag. unless connected to the grease fitting on the
    9. Position a new a-ring down the pulley end of the packing fixture. The pneumatic greaser produces a
    water pump shaft until it makes contact with the inner high velocity discharge that can cause severe
    race of the larger diameter ball bearing. personal Injury. Disregarding this Information
    could result in severe personal injury or death.
    NOTE: Previous shaft assemblies using PIN 2004568
    shafts, use a woodruff key to hold the water pump pulley 13. Using the grease fitting on the side of the packing
    in place. Current shafts, PIN 2OO456C, are blaok in fixture, apply a pressurized lithium complex type grease
    color, and do not use a woodruff key to hold the water (see Grease Recommendations). Hold the top of the
    pump pulley in place. The impellor and pulley are held in water pump shaft to keep the assembly stationary and
    place by the olamp load resulting from torquing the shaft fill the cavity between the two bearings until the grease
    nuts on each end. extrudes from the outside row of the upper ball bearing
    (pulley side). Verify that the grease also extrudes
    10. If using the previous PIN 2004568 shaft, position a through the outer row of the lower ball bearing (impeller
    new Woodruff key in the slot on the pulley end of the side).
    water pump shaft. Using a brass hammer or punch, tap
    the key to properly seat it in the keyway. Verify that the NOTE: A pneumatio greaser is recommended to ensure
    key is level. a fully paoked oavity and to protect against grease
    contamination. To fill the cavity with a hand held grease
    11. Clamp the arm of the grease packing fixture (see gun, as many as 130 strokes may be necessary. "a
    Figure 5.25-70 - Tool #3) in a vise with the open end of pneumatio greaser is not available, hand paok the cavity
    the cup facing upward. before plaoing the bearing shaft assembly in the packing
    fixture. Use the grease gun to oomplete the task.
    12. Insert the impeller end of the bearing shaft assem-
    bly into the packing fixture (see Figure 5.25-72). 14. Remove the grease supply line from the packing
    )
    fixture grease fitting.

    15. Lift out the bearing shaft assembly to verify that the
    grease fills the entire space between the ball bearings
    OUTSIDE (from the shaft to the bearing 00).
    ROW
    16. Remove any excess grease from the impeller and
    pulley ends of the shaft (external to the grease cavity).
    GREASE Remove the excess grease extruding from the outSide
    FmlNG row of each ball bearing. Wipe the excess grease from
    the outside diameter of each ball bearing.

    17. Insert the bearing assembly back into the packer


    until it is ready to be installed in the water pump housing.
    FILL SPACE
    WITH GREASE Lay a clean shop cloth over the top olthe packing fixture
    to keep out dust and dirt.

    18. Place the water pump casting on the press table


    ROW
    with the pulley side up.

    19. Thoroughly wipe the water pump housing seal bore


    with a clean cloth. Use compressed air to blowout all
    dust and debris.

    20. Thoroughly wipe the new inner grease seal with a


    clean cloth. Verify that the seal lip garter spring is in
    Figure 5.25-72. Pack Water Pump Bearings place. Carefully check the seal for defects. Replace if )
    damaged.

    5.25 - 48 FORM 6248 First EdHion


    COOLING SYSTEM

    21. Fit the inner grease seal (2-1/16 inch diameter) 24. Lower the ram until the shoulder olthe driver makes
    onto the seal driver (see Figure 5.25-70 - Tool #4) with solid contact with the inside counterbore.
    the open (lipped) side olthe carrier (see Figure 5.25-73)
    facing the collar of the tool. Lower the inner grease seal 25. Release the ram and remove the inner grease seal
    into the pulley bearing bore (see Figure 5.25-74). driver.

    IA CAUTION I The shoulders and


    .. threads on the water
    pump shaft can damage the sealing surface of the
    inner grease seal ifthe protector sleeve is not used.
    Disregarding this information could result In prod-
    uct damage and/or personal injury.
    26. Slide the black plastic seal protector sleeve (see
    Figure 5.25-70 - Tool #5) over the threads on the impeller
    end of the shaft until tt seats against the shaft shoulder.

    ~~.f-----SEAL LIP 27. Lightly lubricate the seal protector sleeve wtth a
    GARTER SPRING lithium complex type grease. Lightly lubricate the
    (BENEATH LIP) exposed portion of the water pump shaft (from the
    OUTER GREASE SEAL
    protective sleeve to the ball bearing).
    Figure 5.25-73. Open (Lipped) Side Of Carriers
    28. Carefully insert the impeller end ofthe bearing shaft
    assembly into the water pump housing (see
    INNER GREASE Figure 5.25-75). The posttion of the shaft is critical for a
    SEAL DRIVER straight press. Guide the end of the shaft so as not to
    damage or disturb the inner grease seal or the lip garter
    spring.

    BEARING SHAFT

    COUNTER BORE

    COUNTER BORE

    Figure 5.25-74. Install Inner Grease Seal

    22. Center the inner grease seal driver under the ram.

    23. Lower the ram until it makes contact with the driver.

    IA
    ..
    CAUTION I Minimal ram force Is re-
    quired to install the inner
    grease seal. The object of the ram is to ensure a
    straight press. To avoid product damage and/or PLASTIC SEAL PROTECTOR SLEEVE
    personal Injury, use only enough ram force to
    Figure 5.25-75. Install Shaft And Bearing Assembly
    complete the task.

    FORM 6248 First Edition 5.25 - 49


    COOLING SYSTEM

    29. Position the bearing shaft driver (see


    Figure 5.25-70 - Tool #6) over the top ofthe waler pump OUTER GREASE
    shaft (pulley side) aligning the notch on the inside SEAL DRIVER
    diameter of the tool with the installed Woodruff key.

    30. Lower the ram until it makes contact with the


    bearing shaft driver.

    IA:..
    CAUTION I To avoid damage to the
    smaller diameter ball
    bearing (impeller side), use only enough ram force to
    complete the task. Do not exceed 250 Ibs. (1112 N). RETAINING
    Damage to the ball bearing will result In premature RING
    water pump failure. Disregarding this Information
    could result in product damage and/or personal
    injury.

    31. Lower the ram until the outer race of the larger
    diameter ball bearing (pulley side) makes solid contact
    with the inside counterbore.

    NOTE: The outer race of the smaller diameter ball


    bearing (impeller side) is not supported during the
    assembly procedure. To prevent damage to the ball
    Figure 5.25-76. Install Retaining Ring/Outer Grease
    bearing, do not exceed a forceof250lbs. (1112N).lfa Seal
    greater force is required to press the bearing/shaft
    assembly into the water pump housing, then the bearing 36. Slide the outer grease seal (3-1/4 inch diameter) onto
    bore and/or the OD of the smaller diameter ball bearing the seal driver tool (see Figure 5.25-70 - Tool #7) with the )
    is not within specification. Since an accurate measure- open (lipped) Side of the carrier (see Figure 5.25-73)
    ment determines whether the parts are properly fitted facing opposite the collar on the tool. Lower the outer
    and also prevents damage to the inner race of the grease seal into the water pump housing.
    smaller diameter ball bearing, fit the ram of the press
    with the proper size load cell. 37. Center the outer grease seal driver under the ram.

    32. Release the ram and remove the bearing shaft 38. Lower the ram until it makes contact with the driver.
    driver.

    33. Remove the plastic seal protector sleeve from the IA


    ..
    CAUTION I Minimal ram force Is re-
    quired to install the outer
    impeller end of the water pump shaft.
    grease seal. The object of the ram Is to ensure a
    straight press. To avoid product damage and/or
    A WARNING personal Injury, use only enough ram force to
    complete the task.
    Always wear proper eye protection when installing
    the retaining ring. Slippage may propel the ring with
    39. Lower the ram until the shoulder ofthe driver makes
    enough force to cause severe personal injury or
    solid contact with the edge of the casting (see
    death. Use the correct retaining ring pliers. Verify
    Figure 5.25-76).
    that the tips ofthe pliers are not excessively worn or
    damaged. 40. Release the ram and remove the outer grease seal
    driver from the water pump housing.
    34. With the beveled edge on the OD facing upward,
    install the retaining ring in the groove on the pulley side 41. Lightly lubricate the ID of the installed outer grease
    of the water pump housing (see Figure 5.25-76). Verify seal with a lithium complex type grease. Also apply some
    that the ring is fully seated in the groove. grease around the face of the seal. Wipe off any excess.
    )
    35. Thoroughly wipe the new outer grease seal with a 42. With the concave side up, place the water pump
    clean cloth. Verify that the seal lip garter spring is in pulley on the press table. Thoroughly wipe the pulley
    place. Carefully check the seal for defects. Replace ij hub OD with a clean cloth. Use compressed air to blow
    damaged. out all dust and debris.

    5.25 - 50 FORM 6248 First Ednion


    COOLING SYSTEM

    43. With the lipped side down (see Figure 5.25-77),


    position a new stainless steel wear sleeve over the
    pulley hub. Be sure that the sleeve is square on the hub.

    Figure 5.25-77. Pulley Hub Wear Sleeve

    44. Center the pulley under the ram of the arbor press.
    Center the sleeve driver (see Figure 5.25-70 - Tool #8)
    over the pulley hub, so that the bottom of the shroud
    makes complete contact with the lip of the wear sleeve.
    Verify that the driver is completely vertical and that the
    wear sleeve is not cocked on the hub.

    45. Lower the ram until it makes contact with the sleeve Figure 5.25-78. Install Pulley Hub Wear Sleeve
    driver.
    50. Lubricate the threads on the pulley end of the water

    IA CAUTION IMI~lmal
    pump shaft with clean engine oil (SAE 30).
    ram force is re-
    L.~~-=':""::'="':":"::;":";:.J. qUI red
    to seat the wear 51. Install the flat washer and finger tighten the thin nut.
    sleeve. The object of the ram is to ensure a straight
    press. To avoid product damage and/or personal 52. Turn the water pump over to access the impeller
    Injury, use only enough ram force to complete the side of the shaft.
    task.
    53. Obtain a new water pump seal.
    46. Lower the ram until the lip of the wear sleeve makes
    54. Remove the spring from the brass seal retainer
    solid contact with the machined surface at the bottom of
    (carbon seal half of water pump seal).
    the pulley hub OD (see Figure 5.25-78).
    55. Carefully check the carbon ring (primary seal) for
    47. Release the ram and remove the sleeve driver.
    cracks, nicks or other defects. Replace the water pump
    48. Lubricate the wear sleeve with a lithium complex seal assembly if damaged.
    type grease. Wipe off any excess.
    56. Remove the ceramic ring (mating seal) from its
    49. Align the keyway in the pulley hub with the Woodruff rubber seat (see Figure 5.25-79). Carefully check the
    key in the water pump shaft. Inserting the hub into the ceramic material for cracks or nicks. Inspect the rubber
    outer grease seal, hand push the pulley onto the shaft. seat for tears or cuts. Replace the water pump seal
    Do not run the pulley in using the thin nut. assembly if damaged.

    Figure 5.25-79. Water Pump Seal Assembly

    FORM 6248 First Edftion 5.25 - 51


    COOLING SYSTEM

    IA..
    CAUTION lOllY deposits left on the
    sealing faces will cause
    62. Use the seal driver (see Figure 5.25-70 - Tool #10)
    to hand press the brass retainer/carbon seal assembly )
    traces of carbon to adhere to the ceramic seat, flat against the ceramic seal (see Figure 5.25-81).
    resulting In premature failure of the water pump seal.
    Disregarding this information could result In prod-
    uct damage and/or personal injury CARBON SEAL CARBON HALF
    OF SEAL
    57. Verify that the sealing faces of the carbon and
    ceramic seals are free of oily, greasy or waxy deposits.
    Use a clean solvent to clean the sealing surfaces. if
    necessary. Wipe the surfaces clean and dry with
    absorbent paper or a soft cloth.

    58. With the flat highly polished surface facing outward,


    squarely seat the ceramic seal ring in the rubber seat.
    The rear face of the seal can be easily identified by a
    groove that runs perpendicular to the seallD.

    59. Using a 50/50 mix of clean ethylene glycol and


    water, lubricate the outside diameter of the rubber seat. Figure 5.25-81. Install Carbon Seal
    Slide the ring over the shaft with the ceramic material
    facing outside. Move the ring down the shaft until it NOTE: Previous shaft assemblies using PIN 2004568
    contacts the casting bore. Use the seal driver (see shafts, use a woodruff key to hold the impeller in place.
    Figure 5.25-70 - Tool #9) to hand press the ceramic Current shafts, PIN 200456C, are black in color, and do
    seal ring against the counterbore in the water pump not use a woodruff key to hold the impeller in place. The
    housing (see Rgure 5.25-80). impellor and pulley are held in place by the clamp load
    resulting from torquing the shaft nuts on each end.
    CERAMIC DRIVER
    )
    63. If using the previous PIN 2004566 shaft, position a
    new Woodruff key in the slot on the impeller end of the
    water pump shaft. Using a brass hammer or punch, tap
    the key to properly seat it in the keyway. Verify that the
    key is level.

    A WARNING
    Always wear proper eye protection when removing
    the spring. Slippage may propel the spring with
    enough force to cause severe personal injury or
    death.

    64. Position the spring down the water pump shaft until
    Figure 5.25-80. Install Ceramic Seal it contacts the spring seat around the edge of the brass
    seal retainer.
    60. Using a 50/50 mix of clean ethylene glycol and
    65. With the blades facing inward, position a new
    water, lubricate the rubber insert and carbon seal ID
    impeller on the shaft. Do not run the impeller in using the
    within the seal retainer. Using the same solution, lightly
    thin nut.
    lubricate the lipped side of the carbon seal.
    NOTE: Although the clearance fit of the impeller should
    61. With the lipped side of the carbon seal facing
    make it relatively easy to install, there may be some
    inward, slide the brass seal retainer assembly over the
    difficulty in aligning the notch in the hub with the key on
    water pump shaft.
    the shaft. Use a grease pencil to mark the center of the
    keyway on the end of the shaft if necessary. )
    66. Lubricate the threads on the impeller end of the
    shaft with clean engine oil (SAE 30). Install the flat
    washer and finger tighten the thin nut.

    5.25 - 52 FORM 6248 First Edition


    COOLING SYSTEM

    INNER
    GREASE SEAL

    RETAINING
    OUTER
    GREASE

    THIN NUT

    THIN NUT

    PUMP
    SEAL ASSEMBLY

    \ IMPELLER
    SHAFT AND BElIRINIG
    ASSEMBLY

    Figure 5.25-82. VHP Waler Pump Assembly


    67. Tighten the pulley and impeller thin nuts to draw the ....---M-E-AS-U-RE-A-:r-T-H-R-E-E-P-LA-C-E-S--------,
    water pump assembly together (see Figure 5.25-82). - 0.045" (0.38 - 1.15 mm)
    SPRING
    68. Use the reaction torque technique to torque both
    the impeller and pulley thin nuts simultaneously.
    Attach a 1-1/2 inch socket to a breaker bar. Lock the
    socket in a vise with the opening facing upward. To
    prevent the socket from turning, verify that the handle of
    the breaker bar is in contact with the base of the vise.
    Holding the pump so that the impeller is parallel to the
    table top, fit the pulley nut in the socket. Some
    assistance will be required to hold the pump. Torque the
    impeller nut to 195 - 200 ft-Ib (265 - 270 N·m).
    69. Using a feeler gauge, check the impeller vane to
    water pump housing clearance at three equally spaced Figure 5.25-83. Check Impeller Clearances
    locations (see Figure 5.25-83). Verify thatthe clearance
    is between 0.015 - 0.045 in. (0.38 - 1.15 mm).

    FORM 6248 First Ed~ion 5.25 - 53


    COOLING SYSTEM

    70. Apply Perma Lok® Heavy Duty Pipe Sealant with 3. Install the ten studs around the perimeter of the gear
    Teflon® to the threads of two brass petcocks. Screw the cover water pump mounting flange. Drive the coarsely
    water drain petcock into the pipe nipple assembly (see threaded side of the first stud into the flange in the 11
    Figure 5.25-84). Screw the air bleed petcock into the o'clock position (see Figure 5.25-85). Thread the stud
    water pump housing. until the last coarse thread is turned into the casting.

    AIR BLEED PETCOCK"

    OUTLET

    INLET INLET

    OUTLET

    WATER PUMP
    1
    MOUNTING FLANGE
    Figure 5.25-84. Jacket Weter Pump
    Figure 5.25-65. Water Pump Mounting Flange
    71. Pressure test the water pump at 15 psig air
    pressure. 4. Moving counter-clockwise around the perimeter of
    the gear cover flange, install studs in holes 2 through 5,
    72. Check for leakage at the "weep hole" below the )
    (see Figure 5.25-85 and Figure 5.25-86). Skipping hole
    drive belt pulley. The presence of water indicates that
    number 6, install studs in holes 7 through 11. Skip hole
    the water pump seal is defective and that the jacket
    number 12.
    water pump must be rebuilt.

    73. Inspect the water pump housing for leaks. Discard


    the casting if any cracks are found.

    JACKET WATER PUMP INSTALLATION

    1. Check the ten water pump mounting studs for nicks,


    cracks, burrs, galled or stretched threads and other
    obvious damage. Replace as necessary.

    2. Each water pump stud has both fine and coarse


    threads. Using a small paintbrush, apply Bostik Never
    Seez® Anti-Seize and Lubricating Compound to all
    threads on the coarse side.

    I.=A. CAUTION I
    L.
    Do not Inst~1I wa~er
    ='--''------''--_''-----'_ pump studs With a pipe
    wrench or similar device. Use collet style stud
    Figure 5.25-86. Water Pump Cover And Cover Gasket
    driver to Install studs. Disregarding this informa-
    tion could result in product damage and/or person- CAUTION I Deposits I~ft on gasket
    I=.A=~=...;;..;:~~;::...;;.,:;..,J.
    al injury. L. . surfaces will cause leaks.
    Disregarding this Information could result in prod-
    uct damage and/or personal injury.

    5. Verify that all gaskets and gasket mating surfaces


    are clean and completely free of grease and oil.

    5.25 - 54 FORM 6245 Rrst Ed~ion


    COOLING SYSTEM

    IL.=
    A CAUTION Ilf the water pump cover 9. Apply Perma Lok® Heavy Duty Pipe Sealant with
    .=.....;;_....;;._-----'_--'.
    . gasket is installed Incor- Teflon® to threads, and install the drain cock, pipe
    rectly, rotation ofthe impeller will shear off the ears, coupling, two pipe nipples, and elbow on the bottom of
    a condition which may adversely affect sealing the water pump (see Figure 5.25-89).
    effectiveness. Disregarding this information could
    result in product damage and/or personal injury.
    6. Position a new gear cover gasket onto the ten studs
    around the perimeter of the gear cover water pump
    mounting flange (see Figure 5.25-87).

    STRAIGHT EDGE OF
    EARS ANGULAR
    ~~

    y~
    STRAIGHT EDGE OF
    EARS VERTICAL

    Figure 5.25-87. Install Water Pump Cover Gaske! Figure 5.25-89. Water Drain Pe!eock - Front Right

    7. Position the water pump cover plate with the center 10. Apply Perma Lok® Heavy Duty Pipe Sealant with
    hump (and WED part number) facing inside towards the Teflon® to threads, and install the pipe plugs on the left
    block (see Figure 5.25-88). and right bank water bypass elbows.

    A WARNING
    The water pump weighs approximately 105 Ibs.
    (48 kg). Use a suitable lifting device and exercise
    caution during removal or installation to avoid
    severe personal InJury or death.
    11. Install an eye bolt 5/16 inch, in the threaded hole at
    the base of the upper center boss (see Figure 5.25-90).
    Attach a suitable lifting chain or sling and carefully raise
    the pump using an overhead hoist.

    Figure 5.25-88. Water Pump Cover And Cover Gaske!

    A
    I ..
    CAUTION Ilf the water pump cover
    gasket Is installed incor-
    rectly, rotation ofthe impeller will shear off the ears,
    a condition which may adversely affect sealing
    effectiveness. Disregarding this Information could
    result In product damage and/or personal InJury.
    8. Position a new water pump cover gasket on the
    water pump cover. Be sure that the lettering on the
    gasket faces the cover plate and that the straight edge
    of each ear is vertical, not angular (see Figure 5.25-88). Figure 5.25-90. Lifting The Jacket Water Pump

    FORM 6248 Firs! Edition 5.25 - 55


    COOLING SYSTEM

    12. Install the water pump on the mounting studs.


    Remove the lifting device. Wrench tighten the fasteners )
    (ten 3/8 inch hex nuts with lock washers) in an
    alternating pattern.

    13. Install the pipe brackettothe 8-1/2 inch pipe nipple


    on the water drain petcock assembly. Secure the
    assembly to the open bolt hole in the upper gear cover
    flange (1 capscrew, 1/2 x 4-1/2 inches, with lock washer,
    flat washer and 3 inch spacer) (see Figure 5.25-89).

    14. Refer to Crankcase Water Inlet Pipe Installation,


    Water Pump Inlet Elbow Installation, and Water Bypass
    Tube Installation, and install these components.

    SAFETY GUARDS
    SAFETY GUARDS REMOVAL

    1. Remove eight capscrews and the front pulley guard


    from the two front belt guard panels (see
    Figure 5.25-91).

    Figure 5.25-92. Left Hand Belt Guard Panel )


    6. Remove capscrew, spacer, and the left hand belt
    guard panel from the front engine cover.

    7. Remove two capscrews and grease fitting, from the


    right hand belt guard panel (see Figure 5.25-93).

    Figure 5.25-91. Front Pulley Guard

    2. Remove thirteen capscrews and the upper and


    lower halves of the two front belt guard panels.

    3. Remove twelve capscrews and the two water pump


    belt guard panels.

    4. Remove capscrew, lock washer and support bracket


    from the center boss of the water pump.

    5. Remove two capscrews from the left hand belt guard


    panel (see Figure 5.25-92). )

    Figure 525-93. Right Hand Belt Guard Panel

    5.25 - 56 FORM 6248 First Ed~ion


    COOLING SYSTEM

    8. Remove capscrew, spacer, and the right hand belt SAFETY GUARDS INSTALLATION
    guard panel from the front engine cover.
    1. Install the inner auxiliary water pump belt guard
    9. Remove two screws and the right hand belt cover panel wtth capscrew, washer, lock washer, and spacer
    from the support bracket on the oil pan. (see Figure 5.25-95).

    10. Remove capscrew, washer, lock washer and 2. Install two capscrews in the slots on the inner
    bracket from the oil pan. auxiliary water pump belt guard panel.

    11. Remove three capscrews and the outer halve of the 3. Install the the outer halve of the auxiliary water pump
    auxiliary water pump belt guard panel (wtth grill) from belt guard panel (with grill) to the inner half of the
    the inner ha~ of the auxiliary water pump belt guard auxiliary water pump belt guard panel and bracket with
    panel (see Figure 5.25-94). three capscrews (see Figure 5.25-94).

    4. Install capscrew, spacer, and the left hand belt guard


    panel on the front engine cover (see Figure 5.25-92).

    5. Install two capscrews on the left hand belt guard


    panel.

    6. Install the right hand belt guard panel on the front


    engine cover with capscrew and spacer.

    7. Install the right hand belt cover on the support


    bracket and the oil pan with two capscrews (see
    Figure 5.25-93).

    8. Install the right hand belt guard panel on the front


    engine cover wtth capscrew and spacer.

    9. Install two capscrews and grease fitting, on the right


    hand belt guard panel.

    10. Install the support bracket on the center boss of the


    Figure 5.25-94. Auxiliary Watar Pump Belt Guards water pump with capscrew and lock washer (see
    12. Remove two capscrews from the slots on the inner Figure 5.25-91).
    auxiliary water pump belt guard panel (see
    11. Install the two water pump belt guard panels with
    Figure 5.25-95).
    twelve capscrews.

    12. Install the front pulley guard on the two front belt
    guard panels wtth eight capscrews.

    Figure 5.25-95. Inner Auxiliary Water Pump Belt Guard

    13. Remove capscrew, washer, lock washer, spacer


    and inner auxiliary water pump belt guard panel.

    FORM 6248 First Edition 5.25 - 57


    COOLING SYSTEM

    AUXILIARY WATER TEMPERATURE


    CONTROL VALVE A WARNING )
    The thermostat housing assembly weighs approxi-
    AUXILIARY WATER TEMPERATURE CONTROL
    mately 50 Ibs. (23 kg). Use a suitable lIfting device
    VALVE REMOVAL
    and exercise caution during removal or installation
    Remove and test the thermostat in the auxiliary cooling to avoid severe personal injury or death.
    water circuit annually. Inspect the thermostat sooner if
    an increase or decrease in water temperature cannot be 4. Install a lifting strap to support the thermostat
    traced to a malfunctioning water pump, loose belts, housing assembly. The assembly consists of the
    excessive engine load or other cooling system related thermostat housing and the cooling water inlet pipe
    problems. The cooling water temperature at the inter- fittings and flanges.
    cooler cooling water inlet is either 85° For 130° F (29° C
    or 54° C), depending upon application. 5. Remove the U-bolt securing the cooling water inlet
    pipe nipple to the oil pan support bracket (5/16 inch flat
    NOTE: Drain the auxiliary cooling water circuit. washers, lock washers and hex nuts).
    1. Remove the flange connection from cooling water 6. Move the thermostat housing assembly to a suitable
    inlet port C (from the heat transfer device) workbench.
    (Figure 5.25-96).
    AUXILIARY WATER TEMPERATURE CONTROL
    AUXILIARY THERMOSTATIC VALVE INSPECTION AND TEST
    PUMP THERMOSTAT
    HOUSING
    1. Pull out the thermostatic valve. Remove and discard
    the rubber O-ring seal.

    2. Verify that the valve is in the fully closed position. If


    the valve is frozen open or if there is any obvious
    distortion, discard it. If the valve appears in good )
    condition, test as follows:

    A. Suspend the thermostatic valve in a container of


    water. Do not let the thermostat rest against the
    sides or bottom.

    TO INLET
    PORTC
    (FROM HEAT
    IA
    ;..
    CAUTION I Do not boll the thermo-
    static valve. Excessive
    TRANSFER DEVICE)
    temperatures will force the valve to exceed its
    normal operating travel and may result in perma-
    Figure 5.25-96. Auxiliary Water Temperature Control nent damage. Disregarding this information could
    Valve result in product damage and/or personal injury.
    2. Remove the flange connection from bypass inlet port
    B (from the oil cooler). B. Gradually heat the water while stirring with a
    quality glass laboratory thermometer. Observe
    3. Remove the cooling water outlet port flange the action of the valve.
    (stamped A) from the thermostat housing (4 capscrews,
    with flat washers). C. The valve should begin to open at the Start to
    Open temperature rating listed (see
    Table 5.25-10) and be completely open at the Full
    Open temperature, plus or minus 5° F (2.8° C).

    -
    Table 5 25 10 Auxiliary Cooling Water Thermostat - A" Models

    STD./OPT. NUMBER NOMINAL TEMPERATURE START TO OPEN FULL OPEN PIN


    ° F (" C) ° F ("C) °F("C)
    Std. 1 120 (49) 111 (44) 130 (54) 496873
    Std. 1 75 (24) 70 (21) 85 (29) 496867 )

    5.25 - 58 FORM 6248 First Ednion


    COOLING SYSTEM

    D. Remove the valve and observe its closing action. AUXILIARY WATER TEMPERATURE CONTROL
    The valve should seal evenly and tightly (see VALVE ASSEMBLY
    Figure 5.25-97).
    1. Pull the lip seal out of the thermostat housing. Use a
    rolling head pry bar for best results.
    OUTLET PORT A
    (TO AUXILIARY WATER PUMP)
    / A WARNING
    THERMOSTATIC Use of caustic solutions should be restricted to a
    VALVE well ventilated area. Avoid contact with skin, cloth-
    ing and eyes. Disregarding this information could
    result In severe personal injury or death.

    A WARNING
    Compressed air can pierce the skin and cause
    severe personal injury or death. Never use your
    hand to check for leaks or to determine air flow
    rates. Wear safety glasses to shield your eyes from
    flying dirt and debris.

    2. Submerse the thermostat housing and pipe flange


    connections in the caustic hot tank to remove all paint,
    dirt, grease and oil. Follow up with a thorough hot rinse.
    Dry the parts with moisture free compressed air.

    3. Press fit a new lip seal of the same diameter (see


    Figure 5.25-97). Make sure that the seal is completely
    seated around its circumference.

    4. Using a small paintbrush, lubricate the lip seal with


    -:="~TTRAit<iiIN;iL;EE:RT DEVICE)
    .. PORT C clean glycol.

    Figure 5.25-97. Auxiliary Cooling Water Temperature 5. Take note of the temperature rating and part number
    Control Valve - All Models stamped on the old thermostatic valve. The part number
    and nominal temperature rating are stamped on the
    metal spring frame. If the old valve is not available,
    E. If the thermostatic valve is defective, discard it.
    check the engine spec pack to be sure that the new
    valve is correct.

    6. Install the new thermostatic valve with the expansion


    element facing outward.

    7. Place a new O-ring in the thermostat housing outlet


    port flange. Lubricate the O-ring with clean glycol.

    FORM 6248 First Ednion 5.25 - 59


    COOLING SYSTEM

    AUXILIARY WATER TEMPERATURE CONTROL INTERCOOLER


    VALVE INSTALLATION )
    INTERCOOLER REMOVAL

    A WARNING NOTE: Drain the auxiliary cooling water circuit.

    The thermostat housing assembly weighs approxi- 1. Refer to Turbocharger(s} Removal, and remove the
    mately 50 Ibs. (23 Kg). Use a suitable lifting device turbochargers, turbo air outlet elbows and compressor
    and exercise caution during removal or installation discharge tubes.
    to avoid severe personal injury or death.
    2. Refer to Exhaust Systems, and remove the turbo air
    1. Install a lifting strap to support the thermostat inlet elbows exhaust tube, and support brackets.
    housing assembly. Move the assembly to the location of
    the oil pan pipe support bracket. 3. Refer to Air Induction Systems, Air Tubing Removal,
    and remove the intercooler air outlet tubes.
    2. Fasten the cooling water outlet port flange (stamped
    A) to the thermostat housing with 4 capscrews and Turbo Oil Supply/Drain Tube Connections
    washers. Tighten the capscrews evenly and securely. Removal
    1. Loosen the union tube fitting ferrule nuts to separate
    3. Install the U-bolt securing the inlet port pipe nipple to
    the upper and lower turbo oil supply tubes (both banks)
    the oil pan support bracket with washers, lock washers
    (see Figure 5.25-98).
    and hex nuts.

    4. Remove the lifting device.

    5. Fasten the cooling water inlet flange connection


    (from the heat transfer device) to inlet port C of the
    thermostat housing.

    6. Fasten the cooling water inlet flange connection )


    (from the oil cooler) to bypass inlet port B of the
    thermostat housing.

    7. Refill the auxiliary cooling water system and bleed


    trapped air.

    Figure 5.25-98. Turbo 011 Supply Tube - Rear Left

    5.25 - 60 FORM 6248 First Edition


    COOLING SYSTEM

    WASTEGATE COMPRESSOR
    DISCHARGE TUBE
    .00 (3/8" X 1-1/4" CAPSCREWS)
    COMPRESSOR DISCHARGE TUBE .....~ BOTH SIDES
    FROM TURBO AIR OUTLET ELBOW TURBO OIL SUPPLY TUBE
    (3/8" X 1-3/8" CAPSCREWS)
    @~~ (3/8" X 2 1/2" CAPSCREWS)
    BOTH SIDES
    V ~,,@~
    ~
    ~
    ~ D~~\ll.~
    ~~ ~~~~~-trw-\
    ; I~~O~~~~

    00
    00
    o 00
    NOTE: * regular bonnet capscrews are 318" x 1-1/4"

    Figure 5.25-99. Intercooler Bonnet Attachments - Right Bank Side

    2. Detach the turbo oil supply tubes from the intercooler 4. Remove the tube clip securing the left bank turbo oil
    air inlet/outlet bonnets (4 capscrews, 3/8 X 2-1/2 inches, supply tube to the front slot in the rail support bracket.
    with lock washers, washers and 1 inch spacers) (see
    5. Remove the union tube fitting ferrule nuts to separate
    Figure 5.25-99).
    the upper and lower turbo oil drain tubes (both banks).
    3. Remove the upper oil supply tubes from the top
    6. Remove the oil drain tubes from the bottom flange of
    flange of the turbo center housing (2 allen head
    the turbo center housing (2 allen head capscrews, 3/8 x
    capscrews, 3/8 X 1 inch, with lock washers) (see
    1 inch, with lock washers).
    Figure 5.25-100).

    Figure 5.25-100. Turbo Clamps

    FORM 6248 First EdHion 5.25 - 61


    COOLING SYSTEM

    Wastegate Tube Connections Removal 2. Remove the ferrule nuts (11/16 inch hex) to remove
    1. Remove the tube retaining clips joining the right bank the water supply tubes between the wastegates (male
    wastegate water supply tube to the left bank water return elbow tube fitting - right bank; male connector tube
    tube. The clips are positioned between the 45° Dresser fitting - left bank) and the male branch tee tube fitting in
    couplings connecting the cooling water inlel/outlet piping the supply pipe tee. The supply pipe tee is on the left
    of the two core assemblies. (see Figure 5.25-101). bank side of the rear intercooler core assembly (see
    Figure 5.25-102).

    WASTEGATE WATER
    SUPPLY TUBE (RB)

    Figure 5.25-101. Intercooler Connections - Top

    WATER )
    SUPPLY
    PIPE TEE

    Figure 5.25-102. IntercoolerlWastegate Tube


    Connections

    5.25 - 62 FORM 6248 First Edition


    COOLING SYSTEM

    Compressor Discharge Tube Connections between the left bank turbo air outlet elbow (male elbow
    Removal tube fitting) and the angular port on the Y -branch (male
    connector) (see Figure 5.25-106).
    1. Remove the ferrule nuts (9/16 inch hex) to detach the
    compressor discharge pressure sensing tubes from the
    "Air" port at the side of each wastegate (male elbow tube
    fitting) (see Figure 5.25-102 and Figure 5.25-103) and
    the air outlet ports on the intercooler (see
    Figure 5.25-104).

    Figure 5.25-103. Intercooler Connections - Left Bank

    Figure 5.25-105. Compressor Discharge TUbe

    LEFT BANK
    COMPRESSOR
    45' V-BRANCH
    / FITTING
    RIGHT BANK
    COMPRESSOR
    , / ' DISCHARGE
    "~3E:=;I.~~~~' lUBE

    Figure 5.25-104. Intercooler Connections

    2. To free the right bank compressor discharge tube,


    remove the tube clip from the support bracket on the
    upper rear right side of the intercooler.
    3. Remove the ferrule nuts (1-I/Binch hex) to detach the
    compressor discharge tube (3/4 inch tube 00) between
    the right bank turbo air outlet elbow (male connector tube
    ) fitting) and the bottom port of the Y -branch (male
    connector) (see Figure 5.25-105 and Figure 5.25-106).
    RIGHT BANK
    lURBO OUTLET
    ELBOW INTERCOOLER
    / LEFT BANK
    TURBO OUTLET
    ELBOW
    4. Remove the ferrule nuts (1-I/B inch hex) to remove
    Figure 5.25-106. Y - Branch
    the compressor discharge tube (3/4 inch tube aD)

    FORM 6248 First Edition 5.25 - 63


    COOLING SYSTEM

    Intercooler Removal
    1. Loosen the Flexmaster elbow coupling clamp bolts
    A WARNING )
    (see Figure 5.25-107) on the rear end of the vee- The intercooler assembly weighs approximately
    mounted intercooler cooling water return (upper) and 423 Ibs. (192 kg). Use a suitable lifting device and
    supply pipes (lower). exercise caution during removal or Installation to
    avoid severe personal Injury or death.

    3. Wrap one lifting strap around the intercooler assem-


    bly, so thatthe material is positioned in the recess below
    the rail support bracket flanges (both sides) (see
    Figure 5.25-109).

    " ELBOW COUPLING

    Figure 5.25-107. Flexmaster Elbow Coupling

    2. Remove the bottom 3/4 inch hex nuts and washers


    on the four intercooler mounting studs (see
    Figure 5.25-109. Intercooler Removal
    Figure 5.25-108).
    4. Raise the intercooler until the mounting studs are free )
    of the slots on the mounting brackets. Remove the four 3/4
    inch washers from the mounting bracket platforms.

    I-A CAUTION I Do not move the upper


    ~ 3/4 inch hex nuts on the
    intercooler mounting studs. The position of these
    nuts holds the correct height of the Intercooler in
    relation to the top of the exhaust manifold. Disre-
    garding this Information could result in product
    damage and/or personal Injury.
    5. Install the 3/4 inch hex nuts removed from the bottom
    of the intercooler mounting studs. Run each nut up the
    stud until it makes solid contact with the upper nut.

    Figure 5.25-108. Intercooler Mounting - Rear Left

    5.25 - 64 FORM 6248 First Edition


    COOLING SYSTEM

    Intercooler Connection Removal 3. Using the 5/8 inch hex on the connector body,
    remove the male connector tube fitting from the air
    1. Remove the tube cli ps to free the right and left outlet port flange (both sides).
    bank compressor discharge pressure sensing tubes
    from the intercooler mounted 2 inch tube support 4. Remove the support rails from the air inlet/outlet
    braces (see Figure 5.25-110) (1 capscrew per clip, bonnetflanges (see Figure 5.25-112) (4 capscrews per
    3/8x 1/2 inch, with lock washer, washer and hex nut). rail, 1/2 x 1 inch, with lock washers).
    Remove 2 capscrews, lock washers and the tube
    support braces from the intercooler.

    Figure 5.25-112. Support Rails


    Figure 5.25-110. Intercooler Connecttons - Left Bank

    5. Remove the right bank compressor discharge


    2. Remove the ferrule nut (11/16 inch hex) to detach the tube support bracket (and tube clip) from the inter-
    compressor discharge pressure sensing tube (3/8 inch cooler (2 capscrews, 3/8 x 1-3/8 inches, with lock
    tube OD) from the flange above the air outlet port of washers) (see Figure 5.25-113).
    each intercooler bonnet (both sides) (see
    Figure 5.25-111).

    WASTEGATE
    COMPRESSOR
    DISCHARGE TUBE
    ¥i!l:p:: :P::

    Figure 5.25-113. Intercooler Connections


    Figure 5.25-111. Intercooler Connections

    FORM 6248 Firs! Ed~ion 5.25 - 65


    COOLING SYSTEM

    PAINTED MARK

    WATER INLET/OUTLET / -
    BONNET ~
    :sc i
    INLET/ OUTLET
    ~BONNET GASKET )

    -..........;.~-
    t
    WATERHEADERPLATE~========~======~===I
    (UPPER) ~---,;=:;;r....L--==-\
    END CASTING

    END CASTING GASKET


    (NOT AVAILABLE)

    PAINTED MARK

    END CASTING GASKET ~


    .......,y-~====I====7\=\E ::~::EADER
    ~
    "'" • /ND PLATE

    "..-
    GASKET
    RETURN BONNET
    X-
    ~ 7'
    ~
    J WATER RETURN
    BONNET

    Figure 5.25-114. Intercooler - 12 Cylinder Engines

    INTERCOOLER DISASSEMBLY 1. Make a painted mark on the edge of each water


    Each intercooler consists of two air inlet/outlet bonnets inlet/outlet bonnet (top), water return bonnet (bottom)
    and two water box core assemblies. Each core assem- and corresponding header plate (see Figure 5.25-114).
    bly consists of a water inlet/outlet bonnet (top), water Water leakage will occur ifthe bonnets are inadvertently
    return bonnet (bottom), a tube and fin assembly, two reversed in assembly.
    end castings and associated gaskets.
    2. Repeat Step 1 on the second water box. Use a )
    different color paint, so that the disassembled water
    bonnets can be easily associated with the correct core
    during assembly.

    5.25 - 66 FORM 6248 First Ed~ion


    COOLING SYSTEM

    3. Remove the end nuts on each side of the two 45' ell 7. Remove the brass drain petcock/pipe nipple assem-
    Dresser couplings to disconnect the cooling water blies from the water return bonnets (2 petcocks per
    inlet/outlet piping between the core assemblies (see bonnet).
    Figure 5.25-115 and Figure 5.25-116). Remove and
    discard the armored gaskets. 8. If required, remove the piping from the top of both
    intercoolers (see Figure 5.25-117).
    INTERCOOLER
    WATER OUTLET PIPE INTERCOOLER
    WATER INLET PIPE
    ....,\
    -=
    -
    -
    ~I·11 .."'I II II

    JF~
    1\
    ~~
    ~
    1==

    ~
    0
    JA 00
    J
    ....
    r

    (' ~ 00
    £)
    ~
    I

    REAR

    ~ ~ 00 ~....
    l 00 1) O. . . f-
    c 11
    c
    -w
    Ot;
    .... 'W .... Figure 5.25-117. Intercooler Piping

    INTERCOOLER CLEANING AND INSPECTION


    Figure 5.25-115. Intercooler ConnecUons

    COUPLING I:L..UW,
    IA
    ..
    CAUTION I When handling or clean-
    ing the intercooler core
    assemblies, exercise caution to avoid bending the
    aluminum cooling fins. Fins should be straightened
    by using the proper size fin straightening tool.
    Damaged fins obstruct the flow of air through the
    intercooler and reduce cooling efficiency. Disre-
    garding this information could result in product
    damage and/or personal injury.

    IA
    ..
    CAUTION I Do not submerge the in-
    tercooler core or outlet
    bonnets in the caustic hot tank. While the treatment
    may effectively remove lime and mineral scale
    Figure 5.25·116. 45' Ell Dresser Coupling deposits from within the copper tubes, it may also
    dissolve and warp the aluminum cooling fins and
    damage the end casting gaskets. Disregarding this
    IA CAUTION I Do not bump, bend or information could result in product damage and/or
    .. otherwise damage the personal injury.
    corrugated aluminum fins of the core assemblies.
    Damaged fins obstruct the flow of air through the
    Intercooler core and reduce cooling efficiency.
    Disregarding this information could result In prod-
    I.=A. CAUTION I
    L.
    Caustic solutions can
    =c....::..:....:...::.....:....:....::....:;...::..J. cause severe burns.
    Wear approved eye protection and safety equip-
    uct damage and/or personal injury. ment to avoid severe personal injury. Disregarding
    4. Remove the air inlet/outlet bonnets and gaskets from this Information could result in product damage
    the air sides of the intercooler core assemblies (36 and/or personal injury.
    capscrews per bonnet, 3/8 x 7/8 inch, with lock washers). 1. The intercooler may be cleaned by circulating a
    caustic solution such as Oaklite 32® through the core.
    5. Separate the two box-type core assemblies.
    Be sure and rinse and neutralize with Oaklite 162®.
    6. Remove the brass air bleed petcock/pipe nipple
    2. Fins should be straightened by using the proper size
    assembly from the water inlet/outlet bonnets (1 petcock
    fin straightening tool.
    per bonnet).

    FORM 6248 First Ed~ion 5.25 - 67


    COOLING SYSTEM

    INTERCOOLER ASSEMBLY COUPLING CL",V ....


    1. Position the core assemblies side by side approxi-
    mately 1/4 inch apart so that the nameplates and the
    port holes of the water inlet/outlet bonnets are on the
    outside (see Figure 5.25-114).

    2. Install the air inlet/outlet bonnets and gaskets on the


    air sides of the intercooler core assemblies (36 caps-
    crews per bonnet, 3/8 x 7/8 inch, with lock washers).

    3. Alternately tighten the water inlet/outlet bonnet


    capscrews. Torque the capscrews to 17 ft-Ib (23 N·m).

    4. Apply Perma Lok® Heavy Duty Pipe Sealant with


    Teflon® to the threads of the two brass air bleed Figure 5.25-118. 45° Ell Dresser Coupling
    petcock/pipe nipple assemblies. Install the petcock/
    pipe nipple assemblies in the water inlet/outlet bonnets 11. Fit the tapered end of the rubber seals into the
    (1 air bleed petcock per bonnet). hollowed Side of the seal retainers. Install the seals in
    5. Apply Perma Lok® Heavy Duty Pipe Sealant with the ends of the coupling, so that the rubber face seats
    against the beveled counterbore.
    Teflon® to the threads of the drain petcock/pipe nipple
    assemblies. Install the petcock/pipe nipple assemblies 12. Position the coupling between the cooling water
    in the water return bonnet (2 drain petcocks per bonnet) outlet pipes. Alternately tighten the end nuts.
    of the rear core assembly. The rear core assembly can
    be identified by the water supply and return pipe tees in 13. Repeat Steps 7 thru 12 to install the 45° ell Dresser
    the water inlet/outlet bonnet. Leave the free end of the coupling between the cooling water inlet pipes.
    petcock/pipe nipple assemblies pointing sideways to-
    ward the air sides. Intercooler Connection Installation

    6. Apply Perma Lok® Heavy Duty Pipe Sealant with 1. Fasten the support rail to the flanges above the air
    Teflon® to the threads of two brass drain petcocks. inlet and outlet bonnets (see Figure 5.25-119) on each
    Install the petcocks in the water return bonnet of the side of the intercooler assembly (4 capscrews per rail,
    front core assembly. 1/2 x 1 inch, with lock washers).

    7. If removed, apply Perma Lok® Heavy Duty Pipe


    Sealant with Teflon® to threads of fittings and install the
    intercooler piping on the intercoolers (see
    Figure 5.25-117).

    8. Verify that the ends of the cooling water outlet pipes


    (between the two core assemblies at the top of the
    intercooler) are clean and completely free of dirt and oil.
    Check the surfaces where the rubber seals contact the
    pipe ends to ensure that there are no gouges, grooves,
    burrs, nicks or dents. Surface imperfections will ad-
    versely affect sealing performance.

    9. Obtain new armored gaskets for the 45° ell Dresser


    coupling.

    10. With the concave side facing the pipe ends, slide
    the coupling end nuts onto the two ends of the cooling
    water outlet pipes (see Figure 5.25-118). Figure 5.25-119. Support Ralls

    2. Install the exhaust elbow support brackets to the )


    support rails (see Figure 5.25-119) with 2 capscrews
    per bracket, lock washers, washers and hex nuts.

    5.25 - 68 FORM 6248 First Edition


    COOLING SYSTEM

    3. Install the right bank compressor discharge tube


    support bracket to the intercooler with 2 capscrews and
    lock washers) (see Figure 5.25-120).

    Figure 5.25-122. Compressor Discharge Pressure


    Sensing Tubes Support Braces

    8. Apply Perma-Iok® Heavy Duty Pipe Sealant with


    Figure 5.25-120. Intercooler Connections Teflon® to the threads of two reducing bushings (2 inch
    to 1/4 inch). Install the bushings in the two pipe tees
    4. Install the tube clip (0.048 inch gauge, 3/4 inch threaded into the water inlet/outlet bonnet (top) of the
    clamping diameter) to the bracket. rear intercooler core assembly.
    5. Apply Perma Lok® Heavy Duty Pipe Sealant with
    Teflon® to the large end of two male connector tube 9. Apply Perma-Iok® Heavy Duty Pipe Sealant with
    fittings (3/8 inch tube 00). Using the 5/8 inch hex on the Teflon® to the threads of two male branch tee tube
    connector body, install the fittings in the flange above fittings. Install the fittings in each reducing bushing, so
    the air outlet port of each intercooler bonnet (both sides) that the two ferrule nuts are lined up in a horizontal
    (see Figure 5.25-121). position (see Figure 5.25-123 and Figure 5.25:124).

    COMPRESSOR
    WASTEGATE WATER DISCHARGE
    SUPPLY TUBE (RB) TUBE

    Figure 5.25-121. Intercooler Connections


    6. Install to the male connector tube fittings (both sides)
    (see Figure 5.25-121).
    7. Attach a tube clip (0.032 inch gauge, 3/8 inch
    Figure 5.25-123. Intercooler/Wastegate TUbe
    clamping diameter) to the right and left bank wastegate
    Connections
    compressor discharge pressure sensing tubes. Fasten
    the clips to the tube support braces (see
    Figure 5.25-122) (1 capscrew per clip, 3/8 x 1/2 inch,
    with lock washer, washer and hex nut).
    FORM 6248 First Edition 5.25 - 69
    COOLING SYSTEM

    LEFT BANK

    r----~----~==~
    1
    I

    "\...----+-,__.--- ~----J
    I • [[]k TO OIL COOLER

    1
    r;:l[]r
    I
    FROM AUXILIARY
    WATER PUMP
    1
    \ J
    INTERCOOLER
    1-00-
    1
    1 I t
    L~J
    I
    1
    L __ + __
    RIGHT BANK )

    ---I..
    - - - . . . COMPRESSOR DISCHARGE PRESSURE SENSING TUBES

    ---11>
    WATER SUPPLY TUBES
    WATER RETURN TUBES

    Figure 5.25-124. Wastegate Connections


    10. Install the right bank wastegate water supply tube 13. Disassemble the free ends olthe Flexmaster elbow
    to the male branch in the supply pipe tee (see couplings on the intercooler cooling water supply and
    Figure 5.25-123). The supply pipe tee is on the left bank return pipes. Fit new rubber seals into the concave Side
    side of the rear intercooler core assembly. of each retainer. Slide the assemblies up onto the
    cooling water inlet and outlet pipes at the front of the
    11. Install the left bank wastegate water return tube to intercooler (see Figure 5.25-125). The seals will hold
    the male branch in the return pipe tee (see the retainers in place until the intercooler is installed.
    Figure 5.25-123). The return pipe tee is on the right
    bank side of the rear intercooler core assembly.

    12. Join two tube retaining clips (0.032 inch gauge, 3/8
    inch clamping diameter) to fasten the right bank
    wastegate water supply tube to the left bank water
    return tube. Position the clips between the 45° ell
    Dresser couplings connecting the cooling water inlet/
    outlet piping of the two intercooler core assemblies.
    (see Figure 5.25-123).

    NOTE: Delay installation of the left bank water supply


    and right bank water return tubes until after mounting of
    the turbo assembly. , ELBOW COUPLING
    )

    Figure 5.25-125. Flexmaster Elbow Coupling

    5.25 -70 FORM 6248 First Edition


    COOLING SYSTEM

    INTERCOOLER INSTALLATION inch washers). Be sure the water inlet and outlet pipes at
    the front of the intercooler assembly slip into the sleeves
    1. Wrap one lifting strap around the intercooler assem- of the Flexmaster elbow couplings on the cooling water
    bly, so that the material is positioned in the recess below supply and return pipes (see Figure 5.25-125).
    the rail support bracket flanges (on both sides) (see
    Figure 5.25-126). 5. Install 3/4 inch washers and hex nuts on the four
    intercooler mounting studs. Run the nuts upward
    towards the bottom of the mounting brackets.

    6. Install the front clamps on the Flexmaster elbow


    couplings attached to the cooling water supply and
    return pipes (see Figure 5.25-125). Tighten all clamp
    bolt hex nuts.

    Turbo Oil Supply/Drain Tube Connection


    Installation

    1. Apply 3M Scotch Grip ~ Rubber and Gasket Adhe-


    sive 847 to the flanges of the upper turbo oil drain tubes.

    2. Position new gaskets on the contact cement (see


    Figure 5.25-126. Lifting The Intercooler Figure 5.25-128). Allow the gasket adhesive to cure.
    See the manufacturer's recommendations .

    • WARNING
    The intercooler assembly weighs approximately
    423 Ibs. (192 kg). Use a suitable lifting device and
    exercise caution during removal or installation to
    avoid severe personal injury or death.

    2. Raise the intercooler slightly. Install 3/4 inch hex nuts


    on the four mounting studs. Run each nut up the stud
    until the bottom of the nut is 1-3/4 inches from the upper
    boss (see Figure 5.25-127). ,
    TURBO OIL
    DRAIN TUBES

    ~"

    UNION:.TUBE
    ,
    FlmNG

    ~
    ..
    Figure 5.25-128. Lower TUrbo 011 Drain TUbes

    Figure 5.25-127. Intercooler Mounting - Rear Left

    3. Position a 3/4 inch washer over the two slots in each


    intercooler mounting bracket.

    4. Gently lower the intercooler, so that the four studs


    slide through the mounting bracket slots (and the 3/4

    FORM 6248 First Ednion 5.25 - 71


    COOLING SYSTEM

    3. Install the upper oil drain tubes to the bottom flange


    of the turbo center housing with two allen head )
    capscrews and lock washers) (see Figure 5.25-129).

    Figure 5.25-130. Turbo on Supply Tube - Rear Left

    Figure 5.25-129. Upper Turbo on Drain TUbes


    Wastegate Tube Connection Installation

    4. Apply 3M Scotch GripN Rubber and Gasket Adhe- 1. Install the wastegate water supply tube to the empty
    sive 847 to the flanges of the upper turbo oil supply port of the male branch tee tube fitting (left bank side of
    tubes. the rear intercooler core assembly) (see
    Figure 5.25-124).
    5. Position new gaskets on the contact cement. Allow
    the gasket adhesive to cure. See the manufacturer's 2. Install the wastegate water return tube to the empty
    recommendations. port olthe male branch tee tube fitting (right bank side of )
    the rear intercooler core assembly) (see
    6. Fasten the upper oil supply tubes to the top flange of Figure 5.25-124).
    the turbo center housing with two allen head capscrews,
    and lock washers). 3. Install the two water supply tubes to the wastegate
    water inlet ports (male elbow tube fitting - right bank;
    7. Tighten the fitting between the upper and lower oil male connector tube fitting - left bank) (see
    supply tubes. Figure 5.25-124).

    8. Attach two tube clips (0.048 inch gauge, 1/2 inch NOTE: The word 'Water" appears just above the
    clamping diameter) to the turbo oil supply tubes (one wastegate base flange between the water inlet and outlet
    above and another below the union tube fitting). ports, the side with the petcock being the outlet port.
    Remove two capscrews (3/8 x 1-1/4 inches) from each
    intercooler air inlet/outlet bonnet (see Figure 5.25-130). 4. Install the two water return tubes to the wastegate
    Using longer capscrews (3/8 x 2-1/2 inches), with lock water outlet ports (male connector tube fitting - right
    washers, washers and 1 inch spacers, fasten the turbo bank; male elbow tube fitting - left bank).
    oil supply tubes to the intercooler.
    5. Install the free end of the compressor discharge
    9. Tube clip the lefl bank turbo oil supply tube to the pressure sensing tubes to the "Air" port at the side of
    front slot in the rail support bracket. each wastegate (male elbow tube fitting - both banks).

    5.25 -72 FORM 6248 First Ed~ion


    COOLING SYSTEM

    Compressor Discharge Tube Connection CRANKCASE VEE PIPE CONNECTION


    Installation INSTALLATION
    1. Positioning the tube across the top of the intercooler, 1. Locate the six pipe clamps (2-3/8 inch clamping
    and install the compressor discharge tube (3/4 inch tube diameter) for mounting of the intercooler cooling water
    aD) to the right bank turbo air outlet elbow (male supply and return pipes. The arm on the supply pipe
    connector tube fitting). clamps is straight. The arm on the return pipe clamps is
    slightly bent to conform to the curvature of the exhaust
    2. Install the opposite end ofthe right bank compressor
    manifold.
    discharge tube to the bottom port of the V -branch (male
    connector tube fitting) (see Figure 5.25-131). 2. Bolt the clamps together as shown (see
    Figure 5.25-132), but leave the fasteners loose (one
    BRACE AND capscrew per clamp, 3/8 x 1 inch, with washer, lock
    TUBE CLIP", washer and hex nut).
    45° V-BRANCH
    / FmlNG
    RIGHT BANK WATER RETURN
    COMPRESSOR PIPE CLAMP
    , . / DISCHARGE (UPPER)
    ;";~3E:#~~~t:I¥ TUBE
    /
    WASHER
    \ :rct
    ~-=<;;.,

    '{ "\\ \'i\


    'J~==l=Ii\\ V) /I
    't)r~ ~~~
    =~
    NUT

    RIGHT BANK /
    TURBO OUTLET LEFT BANK
    ELBOW TURBO OUTLET
    INTERCOOLER ELBOW

    Figure 5.25-131. V-Branch WATER SUPPLV


    PIPE CLAMP
    (LOWER)
    3. Remove the tube clip (0.048 inch gauge, 3/4 inch
    clamping diameter) from the support bracket on the /
    upper rear right side of the intercooler. Attach the right
    bank compressor discharge tube and fasten the clip to
    the bracket (see Figure 5.25-131).

    4. Install the compressor discharge tube (3/4 inch


    tube aD) between the left bank turbo air outlet elbow
    (male elbow tube fitting) and the angular port on the Figure 5.25-132. Assemble Intercooler Water
    V-branch (male connector) (see Figure 5.25-131). Supply/Return Pipe Clamps

    3. The cooling water supply and return pipes are


    threaded on one end only. A single pipe elbow is
    connected to the threaded end of the supply pipe. The
    return pipe has a series of pipe fittings ending with the
    same size pipe elbow (remove the pipe and pipe flange
    connection if attached).

    FORM 6248 First Edition 5.25 -73


    COOLING SYSTEM

    Position the supply pipe on a workbench with the 9. Using a grease pencil make two marks, one 3 inches
    removed end to the right and the opening in the pipe and the other 8-1/4 inches, from the removed end of the )
    elbow facing upward. Oriented in the same manner, supply pipe (lower) (see Figure 5.25-134). Bring the
    position the return pipe directly above the supply pipe, removed end of the return pipe (upper) flush with the 3
    so that the pipe tee petcock is to the left of the supply inch mark. Slide the rear pipe clamp assembly to the
    pipe elbow (see Figure 5.25-133). 8-1/4 inch mark and tighten.

    WATER PIPE CLAMP TO RIGHT BANK


    RETURN PIPE EXHAUST MANIFOLD
    '0 END SECTION (REAR)
    \ / COOUNGWATER
    /RETURNPIPE
    '6
    COOLING WATER
    PPLYPIPE
    b /SU

    "- WATER
    SUPPLY
    PIPE b
    "- PIPE TEE PETCOCK
    I- 3"

    Figure 5.25-133. Intercooler Water Supply/Return


    Pipes - Threaded Ends

    4. Verify that the removed ends of the cooling water Figure 5.25-134. Install Intercooler Water
    supply and return pipes are clean and completely free of Supply/Return Pipe Clamps - Rear
    dirt and oil. Check the surfaces where the coupling seals )
    contact the pipe ends to ensure that there are no 10. Make two marks on the threaded end of the supply
    gouges, grooves, burrs, nicks or dents. Surface pipe (lower), one 2 inches and the other 5 inches from
    imperfections will adversely affect sealing performance. the shoulder of the pipe elbow (see Figure 5.25-135).
    Slide the front pipe clamp assembly to the 2 inch mark
    5. Slide one double pipe clamp assembly onto the
    and tighten the clamp assembly on the supply and
    removed ends of the supply and return pipes (with the
    return pipes. Slide the remaining clamp assembly to the
    flat side of the clamp assembly facing the workbench
    5 inch mark and tighten.
    and the angled arm on the upper clamp positioned
    above the return pipe).
    PIPE CLAMP TO PIPE CLAMP TO LEFT
    RIGHT BANK BANK EXHAUST
    6. Install the second pipe clamp assembly in the same EXHAUST MANIFOLD MANIFOLD
    manner, but with the back of the clamp facing the END SECTION END SECTION
    opposite direction (upward away from the surface of the (FRONT}"", o /(FRONT)
    workbench).
    o
    7. Slide the two pipe clamp assemblies down to the COOLING WATER
    RETURN PIPE\
    threaded ends of the pipes (see Figure 5.25-133).

    8. Install the third pipe clamp assembly like the first,


    ~-t-0"1-_-I0
    with the flat side of the clamps facing the workbench.
    Leave the assembly at the removed end of the supply
    and return pipes.

    2" I
    5" --I COOLING WATER
    SUPPLY PIPE )
    Figure 5.25-135. Install Intercooler Water
    Supply/Return Pipe Clamps - Front

    5.25 - 74 FORM 6248 First Ed~ion


    COOLING SYSTEM

    11. Slide the cooling water supply (lower) and return 13. Apply Perma Lok® Heavy Duty Pipe Sealant with
    (upper) pipe assembly down the crankcase vee with the Teflon® to the threads of the cooling water outlet pipe
    removed ends at the rear of the engine (see flange connection.
    Figure 5.25-136).
    14. Thread the pipe flange into the elbow of the return
    pipe (upper) (see Figure 5.25-138).

    WATER
    SUPPLY PIPE

    "'1i
    Figure 5.25-136. Intercooler Water SupplylReturn
    Pipes
    12. Using the front and rear clamp assemblies, secure
    the supply and return pipes to the threaded center boss
    of each end section of the right bank exhaust manifold. Figure 5.25-138. Intercooler Water Return Pipe-
    Attach the remaining pipe clamp assembly to the center Front Left
    boss of the front end section of the left bank exhaust
    manifold (see Figure 5.25-137). 15. Position an angle finder with a magnetic base on
    the flat face of the pipe flange (see Figure 5.25-139).
    EXHAUST MANIFOLD END SECTION Verify that the flange is vertical. Slightly rotate the
    (LEFT BANK) vee-mounted return pipe to adjust the orientation of the

    . . . .F:::~~ flange, if necessary.

    -....... PIGGYBACKED PIPE


    --t1~t-1l CLAMP ASSEMBLY
    Figure 5.25-139. Intercooler Water Return Pipe Flange

    Figure 5.25-137. Instellintercooler Water


    Supply/Return Pipes

    FORM 6248 First Ed~ion 5.25 -75


    COOLING SYSTEM

    16. Install the U-bolt on the flanged pipe. Slide the 20. Apply Perma Lok® Heavy Duty Pipe Sealant with
    ends of the U-bolt into the holes in the pipe support Teflon® to the threads of the union adapter. Thread the )
    bracket mounted to the left bank exhaust manifold union adapter into the auxiliary water pump outlet port
    end cap (see Figure 5.25-140). Tighten the fasten- pipe elbow (see Figure 5.25-142).
    ers (two 5/16 inch washers, lock washers and hex
    nuts).

    Figure 5.25-142. Intercooler Water Supply Plpe-


    Front Left

    Figure 5.25-140. Intercooler Water Return Pipe Flange CAUTION I Do notturn ~h.e hose hex
    I A=:......;=...;;.;::;...;:...::...:=....;~.
    .L .:
    .. on the auxIliary water
    17. To keep out dust and dirt while the engine is being pump side. Turning the hex will twist the hose and
    may result in damage to the hose fitting or seal
    )
    assembled, tape over the opening in the outlet pipe
    flange. and/or personal injury.

    18. Apply Perma Lok® Heavy Duty Pipe Sealant with 21. Hold the flexible hose hex nut (auxiliary water pump
    Teflon® to the threads of the flexible hose filling (the end side) and turn the hex nut on the union adapter to thread
    without the union adapter). the free end of the hose into the auxiliary water pump
    outlet port pipe elbow (see Figure 5.25-143).
    19. Thread the flexible hose fitting into the supply pipe
    elbow (see Figure 5.25-141).

    )
    Figure 5.25-143. Intercooler Water Supply Pipe -
    Front Left
    Figure 5.25-141. Intercooler Weter Supply Pipe Elbow

    5.25 - 76 FORM 6248 First Edition


    COOLING SYSTEM

    22. Remove the lower outside capscrew from the AUXILIARY WATER PUMP AND
    intake manifold flange (1/2 x 2 inches, with both lock and BRACKET
    washers) at the front left corner of the engine. Slide the
    capscrew through the round hole in the hose support AUXILIARY WATER PUMP AND BRACKET
    brace. Reinstall the capscrew. Attach the hose clip to REMOVAL
    the flexible hose. Fasten the clip to the slotted hole in the
    support brace (1 capscrew, 1/2 x 3/4 inch, with lock
    washer, washer and hex nut).
    A WARNING
    Always wear protective clothing when draining the
    23. Disassemble one side of a Flexmaster elbow cooling systems on a heated engine. Slowly loosen
    coupling (see Figure 5.25-144). With the concave side the air bleed petcocks to relieve any excess
    facing outward, slide the seal retainer onto the removed pressure. Escaping steam and/or hot water can
    end of the return pipe (upper). result In severe personal Injury or death.
    1. Refer to Jacket Water and Auxiliary Cooling Water
    Circuits, Drain and Flush, and drain the cooling system.

    2. Refer to Auxiliary Water Pump Belt Replacement,


    and remove the auxiliary water pump belts.

    3. Refer to Safety Guards Removal, and remove the


    safety guards from the auxiliary water pump.

    4. Disconnect the water lines to the water pump.

    NOTE: Matchmark all parts during removal to aid in the


    installation procedure. .

    ) "- ELBOW COUPLING


    5. Remove four nuts, lock washers, washers, caps-
    crews, and the auxiliary water pump from the auxiliary
    water pump bracket (see Figure 5.25-145).
    Figure 5.25-144. Flexmaster Elbow Coupling

    24. Seat a new rubber seal in the hollowed face of the


    PIPE
    retainer. Install the sleeve with the free (assembled) end
    FlmNG\
    of the elbow facing upward, but tilted slightly toward the
    left bank. Wrapping the open clamp around the seal
    retainer and the flared end of the elbow, install the clamp e
    i)/
    bolt. Leave the clamp bolt hex nut finger tight until the Ie
    intercooler is installed.

    25. Repeat the procedure on the supply pipe (lower).


    Install the sleeve with the free (assembled) end of the
    AUXILIARY
    WATER PUMP
    BRACKET
    , DRAIN
    'j, COCK
    elbow pointing upward, buttilted slightly toward the right
    bank. \ AUXILIARY
    WATER PUMP

    Figure 5.25-145. Auxiliary Water Pump

    6. Loosen two socket head set screws and remove the


    auxiliary water pump pulley and woodrufl key from the
    pump shaft.

    7. Remove the drain cock from the auxiliary water


    ) pump.

    8. If required, remove the grease fitting and instruction


    plate from the auxiliary water pump.

    FORM 6248 First Edition 5.25 -77


    COOLING SYSTEM

    SHAFT/BEARING
    )
    IDLER /
    PULLEY
    " 0 I
    IDLER

    ~
    LEVER

    LOCKNUT
    //1
    / I
    ~
    04lIII0 I
    I
    I
    IDLER
    ".~<
    ~~"/
    ,...//.:::;;.............
    :'='// ';"::;"
    // h,
    ,// ,
    "
    ) PULLEY ....-: ~)')'~ // ~ :
    / SHAFT cY...... : //~: :
    ( I
    ,..
    l~1.i
    :::
    ::
    I ,,' ,
    ~ I )f:)
    .."0,,, ( :i ~; //
    .//." I ~~(/
    LOCK NUT ~..,,' I L-- A)
    ADJUSTIN~t~?~~O I "
    ROD PIVor /~~\
    SPACE~ )
    )1 WASHER
    /
    THIN NUTS ~ //

    f~,
    J,/';. ANCHOR
    WASHERS ' / STUD
    LOCKNUT )
    Figure 5.25·146. Auxiliary Water Pump Idler And Adjusting Lever
    9. Remove lock nut and washer from the anchor stud 16. Remove adjusting lever and woodruff key from the
    and idler pulley bracket (see Figure 5.25-146). idler pulley shaft.

    10. Remove lock nut and washer from the rear of the 17. Remove the elastic stop nut, washer, anchor stud
    idler pulley shaft. and washer from the threaded rod.

    11. Remove the idler lever and adjusting lever assem- 18. Remove the two thin hex nuts from the threaded rod.
    blies with the idler pulley shaft as one piece from the
    auxiliary water pump bracket. 19. Remove elastic stop nut, two spacers and pivot rod
    and threaded rod from the idler lever.

    A WARNING 20. Remove four capscrews, lock washers, washers


    and auxiliary water pump bracket from the crankcase
    Always wear proper eye protection when removing (see Figure 5.25-147).
    retaining rings. Slippage may propel the ring with
    enough force to cause severe personal injury or death.
    Use the correct retaining ring pliers. Verify that the tips
    of the pDers are not excessively wom or damaged.
    12. Remove the retaining ring from the idler pulley shaft.
    1J
    13. If required, remove the idler pulley and shaft
    bearing from the idler lever. (!#'
    ," ~)

    ()
    ()
    14. Remove idler lever and woodruff key from the idler
    pulley shaft.
    Figure 5.25·147. Auxiliary Water Pump Bracket
    15. Remove capscrew and lock washer from the
    adjusting lever. 21. If required, press out the two bushings from the
    auxiliary water pump bracket.

    5.25 -78 FORM 6248 First Ednion


    COOLING SYSTEM

    AUXILIARY WATER PUMP AND BRACKET


    INSTALLATION A WARNING
    NOTE: Matchmark all parts during removal to aid in the Always wear proper eye protection when removing
    installation procedure. retaining rings. Slippage may propel the ring with
    enough force to cause severe personal injury or
    1. If removed, press the two bushings into the auxiliary death. Use the correct retaining ring pliers. Verify
    water pump bracket (see Figure 5.25-147). that the tips of the pliers are not excessively worn or
    damaged_
    2. Install the auxiliary water pump bracket on the crank-
    case with four capscrews, washers and lock washers. 9. Install retaining ring on the idler shaft.
    3. Install pivot rod, two spacers, elastic stop nut, 10. Install the idler shaft, adjusting lever, and idler lever
    threaded rod and thin nut on the adjusting lever (see as one assembly on the auxiliary water pump bracket,
    Figure 5.25-148). with washer and lock nut.

    11. Install the auxiliary water pump bracket on the


    crankcase with four washers, lock washers and caps-
    crews.

    12. Install the stud anchor to the auxiliary water pump


    bracket with lock nut and washer (see Figure 5.25-146).

    ADJUSTING 13. If removed, install the grease fitting and instruction


    LEVER
    plate on the water pump.
    '\.. 14. Install the drain cock on the auxiliary water pump.

    15. Install the auxiliary water pump pulley and woodruff


    key on the auxiliary water pump shaft. Tighten the two
    socket head set screws on the auxiliary water pump
    pulley (see Figure 5.25-145).

    16. Install the auxiliary water pump on the auxiliary


    water pump bracket with four capscrews, washers, lock
    washers and nuts.

    17. Connect water lines to the auxiliary water pump.

    PLAIN WASHER .............)"


    18. Refer to Auxiliary Water Pump Belt Replacement,
    and replace the auxiliary water pump belts.
    STUD ANCHOR II 19. Refer to Safety Guards Installation, and install the
    PLAIN WASHER!
    safety guards on the auxiliary water pump.
    ELASTIC STOP LOCK NUT

    Figure 5.25-148. AdJusUng/ldler Lever Assembly 20. Refer to Jacket Water and Auxiliary Water Cooling
    Circuits and refill the cooling systems.

    4. Remove capscrew and lock washer from the idler shaft.

    5. Install thin nut, washer stud anchor, washer and


    elastic stop nut on the threaded rod.

    6. Install adjusting lever on the idler shaft with woodruff


    key, lock washer and capscrew.

    7. If removed, install the idler pulley and shaft bearing


    on the idler lever.

    8. Install idler lever on the idler shaft with capscrewand


    lock washer.

    FORM 6248 Rrst Ed~ion 5.25 -79


    COOLING SYSTEM

    5.25 - 80 FORM 6248 First Edition


    SECTION 5.30 - LUBRICATION SYSTEM

    LUBRICATION SYSTEM COMPONENTS DESCRIPTION


    The lubrication system consists of the following compo- The bottom of the crankcase is enclosed by an oil pan.
    nents (see Figure 5.30-1): The lube oil pump, gear-driven off the crankshaft, is
    externally mounted at the front. The pump draws oil
    • Oil Pan and Pickup Screen from the lowest point in the oil pan and delivers it to the
    oil cooler. The lube oil pump has an pressure relief valve
    • Oil Pump pre-set at the factory to 75 psi (517 kPa). This relief
    • Oil Cooler valve protects the oil pump from high initial oil pressures
    at start up prior to the engine oil reaching normal
    • Temperature Control Valve operating temperatures. A box-shaped pickup screen
    prevents foreign material in the oil pan from entering the
    • Pressure Regulating Valve lube oil circuit.
    • Full-Flow Lube Oil Filter NOTE: The oil cooler assembly is shipped loose and
    must be either skid or remote mounted by the customer.
    • Filter Relief Valve(s) The assembly consists of the oil cooler, temperature
    control valve and pressure regulating valve.
    • Oil Strainer
    The oil cooler is a tube and baffle type assembly.
    • External Piping (customer supplied) Coolant is pumped through the cooler by the auxiliary
    water pump. While the coolantflows through a bundle of

    -1
    , ENGINE OR REMOTE MOUNTED tubes in the oil cooler, the lube oil circulates around
    OIL SUMP r----------, them. Heat from the oil passes through the tubes to the

    LUBE OIL
    :I ------t--..JI:
    L~
    LUBE OIL COOLER
    coolant which carries it to a heat transfer device for
    dissipation.
    PUMP The lube oil temperature control is maintained by the
    C thermostat housing which contains two thermostatic
    OIL valves (see Figure 5.30-2).
    BYPASS TEMPERATURE
    PIPE CONTROL
    B VALVE

    ~
    OILOUTLET
    A COVER _________ PORT
    PLATE , SPRING
    PRESSURE
    REGULATING
    ~8~t-------
    VALVE

    FULL-FLOW
    ~ ....
    LUBE OIL
    FILTER

    BYPASS
    RELIEF
    VALVE

    BYPASS
    RELIEF
    VALVE

    I MAIN OIL HEADER


    I
    Figure 5.30-1. External Lube 011 SchemaUc - SPRING
    Blending Type
    OIL COOLER
    INLET PORT

    ) Figure 5.30-2. Lube 011 Temperature Control Valve

    When the oil cooler inlet port thermostat Oead) starts to


    open the flow of oil from the oil cooler is enabled. This

    FORM 6248 First Edition 5.30 -1


    LUBRICATION SYSTEM

    supply mixes with the flow from the bypass port to NOTE: Adjust the pressure regulating valve to maintain
    provide a blend of hot and cool oil. When the oil an oil header pressure of 55 ±5 psi (380 0>34 kPa) with
    temperature rises 5' F (2.8' C) above the Start to Open the lube oil pressure stabilized at normal operating
    rating of the lead thermostat, the bypass inlet port temperature and the engine fully loaded.
    thermostat begins to open. Opening of the thermostat
    The elements of the full-flow lube oil filter, have a
    restricts the bypass inlet port passage, thereby allowing
    nominal filter rating of 5 microns. Due to their anti-chan-
    a greater portion of the oil supply to come from the oil
    neling deSign, the elements operate at 90% plus
    cooler. The result of this type of operation is rapid warm
    efficiency throughout their recommended use cycle.
    up when the thermostatic valves are fully closed and
    efficient cooling once the valves open. The oil filter housing also contains one or two bypass
    relief valves. A pressure differential of 32 psi (221 kPa)
    A pressure regulating valve maintains the correct oil
    opens the relief valves and allows the flow of oil to bypass
    pressure regardless of engine speed or oil temperature.
    the filter elements enroute to the lube oil strainer. If the
    The pressure regulating valve is mounted to the
    filter elements get clogged, the bypass relief valves act
    temperature control valve at the oil cooler outlet (see
    as a safety device to ensure that the engine receives a
    and Figure 5.30-3). When the oil pressure exceeds the
    supply of lubrication oil, although unfiltered.
    setting of the valve spring, an orifice opens to return
    excess oil to the oil pan. Oil not returned to the pan NOTE: The lube oil filter assembly is shipped loose and
    passes to the full-flow lube oil filter. must be either skid or remote mounted by the customer.
    A lube oil strainer is mounted to the main oil header on
    the left side of the engine. The strainer is downstream
    NUT
    from the full-flow lube oil filter and represents the last
    ADJUSTING .....-"':&'TI~, attempt at catching dirt and foreign material before it
    SCREW
    =~=tt,.,."."" enters the engine. The strainer contains a cleanable,
    stainless steel mesh element with a nominal filter rating
    of 74 microns. Two magnet rods are externally mounted
    on the element to catch any ferrous metal debris
    suspended in the lube oil. )
    The lube oil strainer contains one bypass pressure relief
    valve. A pressure differential of 15 psi (103 kPa) opens the
    valve and allows the oil flow to bypass the strainer element
    enroute to the main oil header (see Figure 5.30-4).

    RELIEF VALVE

    LUBE
    OIL
    OUTLET

    RUBBER
    BAND
    SEAL
    RETAINER

    ROD

    HOUSING

    STAINLESS
    STEEL )
    Figure 5.30-3. Pressure Regulating Valve ELEMENT

    Figure 5.30-4. Lube Oil Strainer

    5.30 - 2 FORM 6248 Rrsl Edition


    LUBRICATION SYSTEM

    CORED
    PASSAGE

    PUSHROD
    TUBE

    I
    ~
    TO SUMP
    ROCKER ARM
    OIL HEADER

    +
    TO SUMP

    MAGNETIC
    PLUG

    + + + + + +
    + + + + + + + + ../'.. ~.
    OIL SUPPLY
    TUBES

    .. GEAR
    .. ... TRAIN

    ;:----;;RONT MAIN
    BEARING CAP
    LUBE OIL ~lj":b.-=::::;-
    STRAINER

    INTERNAL
    OIL HEADER
    / MAIN
    I
    CRANKSHAFT BEARING OIL PUMP IDLER
    GEAR SPINDLE

    Figure 5.30-5. Internal Oil Control

    INTERNAL OIL CONTROL Internal passages in the crankcase casting also direct
    The main oil header is an integral part of the crankcase the flow of pressurized oil to the camshaft bearing
    casting (see Figure 5.30-5). Internal passages in the saddles to provide lubrication of the main camshaft
    crankcase direct the flow of pressurized oil to the main bearings (bushings). Oil passing through holes in the
    bearings via drillings in the main bearing saddles. cam bearing caps travels down passageways in the
    valve lifter housing to lubricate the roller followers and
    The flow of oil passes from the main bearing journals cam lobes, after which it drops back to the oil pan.
    into the T -drilled crankshaft and then up through drilled
    passages in the connecting rods. After lubricating the An external oil supply line off the main oil header carries
    connecting rod bearing, piston pin bushing and piston oil to a separate rocker arm oil header. Supply tubes
    pin, the pressurized oil passes through an opening in from the rocker arm oil header direct the flow of oil to the
    the top of the rod. The oil spray exiting the rod cools the rocker arm assemblies and valves.
    underside of the piston crown and drains back to the oil Excess oil drains down a cored passage in the cylinder
    pan. head and runs down the outside of the push rod tubes to
    Oil supply tubes tapped off the internal oil passage a drainage passage in the valve lifter guides. The
    leading to the front main bearing supplies a continuous passage directs the flow of oil to a drainage hole in the
    spray of oil to the gear train. The lube oil hole in the lower valve lifter housing where it drops back to the oil pan via
    front main bearing allows pressurized oil to flow down a the camshaft recess.
    ) drilled passageway in the main bearing cap to lubricate The flow of pressurized oil through the fixed valve lifter
    the oil pump idler gear spindle. screws olthe rocker arm assemblies also supplies oil to
    the hydraulic lifters, where the excess oil joins the flow
    from the cored passage in the cylinder head.
    FORM 6248 First Edilion 5.30 - 3
    LUBRICATION SYSTEM

    The turbochargers receive oil from the main oil header Since there is no generally accepted industry classifica-
    via an externally mounted oil supply line. A drain line tion system for gas engine oils, reference is made to API
    connected to the valve lifter housing returns the oil to the and Military performance levels as well as certain
    pan after lubrication of the turbocharger bearings. needed characteristics to help select an oil for a
    To ensure quick lubrication of the rocker arm assem- particular gas engine application.
    blies and turbochargers at startup, each external supply OIL RECOMMENDATIONS
    line is provided with a check valve to keep the oil from
    draining back into the oil pan when the engine is shut Waukesha has recommended high ash oil for use in
    down. The check valves also prevent excessive lubrica- VHP gas engines for many years.
    tion of the rocker arm assemblies, valves and turbochar- These high ash oils (2 - 3.4% by weight) have provided
    gers during continuous or intermittent prelube. proper lubrication and resistance to valve recession
    since 1968. However, with the new modified engine
    LUBE OIL SPECIFICATIONS combustion systems or the use of exhaust emissions
    There are hundreds of commercial crankcase oils controls, a reduction of ash-containing additives and/or
    marketed today. Obviously, engine manufacturers or those which poison or mask the catalyst is necessary.
    users cannot completely evaluate the numerous com- Engines utilizing high ash oils which have had good
    mercial oils. operating experience on these oils may continue with
    The Waukesha Engine Warranty is limited to the repair Waukesha's previous oil recommendations.
    or replacement of parts that fail due to defective material This publication provides Waukesha's current lubricat-
    or workmanship during the warranty period. The ing oil recommendations as a guideline (see
    Waukesha Warranty does not include responsibility for Table 5.30-1).
    satisfactory performance of the lubricating oil. A tabula-
    tion of lubricant producers and marketers, together with Low ash oils are formulated with an additive package
    the performance classification for which the producers which contains a maximum of 0.5% sulfated ash, using
    have indicated their products are qualified, is available ASTM Method D-874. The additive package should be
    from Engine Manufacturers' Association, 401 North composed of ash less dispersants and/or metallic deter-
    Michigan Ave, Suite 2400, Chicago, IL 60611-4267, gents with organometallic or ashless oxidation inhibi- )
    Phone (312) 644-6610, Fax (312) 321-6865. Edition tors.
    eight (8) of the EMA Lubricating Oil Data Book is The following contaminants are known catalyst deacti-
    available for purchase for $50.00. Refer to Service vators and should be avoided when selecting lubricat-
    Bulletin No. 12-1880S, or most current revision, for ing oils for installations with catalysts since they
    further information on Waukesha Lube Oil Recommen- contribute to shortened catalyst life: heavy and base
    dations. metals such as lead, mercury, arsenic, antimony, zinc,
    With the exception of cogeneration and special or copper, tin, iron, nickel, chrome, sulfur and phosphorus.
    prototype installations, Waukesha Engine Division has These individual elements should not exceed 1 ppm or
    made it a practice not to recommend oil by brand name. collectively exceed 5 ppm at the catalyst inlet. Specific
    exceptions: phosphorus or silicon compounds in the
    OIL DESIGNATIONS exhaust are notto exceed 1 ppm and sulfur compounds
    Oil is designated in several ways: American Petroleum in the exhaust are not to exceed 100 ppm.
    Institute (API), Society of Automotive Engineers (SAE), Do not confuse the concentration of these elements AT
    American Society for Testing and Materials (ASTM) THE CATALYST INLET with the concentration of these
    performance classifications and Military Designation. elements in the lube oil itself.

    Table 5.30-1. 011 Recommendations By Model And Fuel For VHP Series Gas Engines
    MODEL/FUEL API PERFORMANCE LEVEL.
    VHP 51 OS, 5790, 7042 NATURAL GAS - MEDIUM ASH 0.35% minimum gas engine oil meeting CC or CD
    G/GSI/GL performance level using highly refined mineral oil based stocks, with a minimum of 0.35%
    Naturally Aspirated and Turbocharged/ sulfated ash by weight with both metallic and ashless additive systems. A maximum of
    Natural Gas/HD-5 Propane (1) (2) (3) 0.10% zinc is recommended.

    NOTE: (1) See Recommended Oil Change Intervals.


    (2) See Lube Oil Condemning Limits.
    (3) Low ash oils may be used in naturally aspirated and catalyst equipped naturally aspirated or turlJocharged engines with the )
    understanding that valve recession may occur, thus shortening the normally expected valve and seat life.

    5.30 - 4 FORM 6248 Rrst Ed~ion


    LUBRICATION SYSTEM

    WAUKESHA COGENERATION percentages of sulfur bearing compounds (H 2S, etc.).


    INSTALLATIONS Gas exceeding 0.1 % sulfur bearing compounds must
    be treated.
    Waukesha Engine Division does not ordinarily recom-
    mend lube oils by brand name. However, based on When dealing with halogens or halogen compounds in
    actual field experience, the oils listed in Table 5.30-2 are landfill gas, the subject becomes far too complicated to
    specified for cogeneration installations with forced hot address here as it relates to the selection of a lubricating
    water cooling systems 235 0 F - 265 0 F (113 0 C - 129 0 C) oil, used oil analysis, and drain interval. It follows that
    or ebullient cooling 2500 F (121 0 C). those customers operating on landfill gas review
    Waukesha Engine's Fuel Specification SA7884C and
    Table 5.30-2. Recommended Lube Oils For Service Department Broadcast SDBC 1100 to fully
    CogeneraUon Applications Using Pipeline Quality Gas understand the ramifications of operating an engine on
    BRAND TYPE APPLICATION landfill gas. Fuel specification SA7884C and SDBC
    Chevron HOAX Low Ash SAE40 ALL 1100 prescribe specific fuel gas sampling techniques,
    Essolube P40 fuel gas analysis, handling of abrasive fuel constituents,
    (European) SAE40 Naturally Aspirated and limitations on total organic halide as chloride to
    Exxon Estor Super SAE40 ALL achieve reasonable engine life. Lubricating oil require-
    ments change as the TOHCI increases.
    Mobil Pegasus 1 SAE40 ALL
    Mobil Pegasus 80 SAE40 ALL RECOMMENDED LUBE OILS FOR SOUR GAS
    Mobil Pegasus 89 SAE40 ALL AND ALTERNATE FUEL (LANDFILL) GAS
    Mobil Pegasus 485 SAE40 ALL APPLICATIONS
    Shell Gas Oil S-9858 Waukesha recommends lubricating oils speCifically
    (European) SAE40 Naturally Aspirated
    formulated for sour gas and a1temate fuel (landfill) (see
    Table 5.30-3). However, care must i)e taken that oils
    It is especially important that the lube oils used in
    formulated for a particular fuel type not be used beyond
    cogeneration applications utilize base stocks with good
    their recommendations. Some landfill gas formulated
    thermal stability. With 10,000 to 12,000 hours of
    lube oils can cause excessive build-up of additives
    experience, the lube oils listed in Table 5.30-2 are
    when used outside of their recommendations. Landfill
    known to give satisfactory performance in high temper-
    gas engine oils should only be used for engines applied
    ature cooling systems' applications.
    to landfill gas service, not digester gas service.
    Additions to the list of approved oils will be made if
    Table 5.30-3. Recommended Lube Oils For Sour Gas
    substantiating data is provided for an oil meeting the
    And Alternate Fuel (Landfill) Gas Applications
    following criteria:
    BRAND TYPE APPLICATION
    0 0 0
    • Used in similar applications 235 F (113 C) to 250 F Mobil Pegasus 446 SAE40 ALL
    (121 0 C) jacket water temperatures.
    The best approach would be to filter or absorb
    • Minimum of one year service. Documented with corrosives in the fuel gas before they reach the engine.
    engine inspection data. There are increasing claims for filtration and absorption
    by various companies manufacturing and promoting
    • No signs of oil degradation or lacquering problems.
    these types of product. Waukesha makes no endorse-
    SOUR GAS & ALTERNATE FUEL GAS ment of these products or service. Their performance is
    solely the responsibility of their manufacturers.
    RECOMMENDATIONS
    Alternate fuel sources are attracting increasing interest
    today as a low cost fuel or because of environmental
    concerns. Waukesha, being one of the leaders in
    developing engine systems to accommodate these
    alternate fuels, is aware of problems due to sulfur
    compounds (H2S, etc.) and halide constituents in these
    fuels. Hydrogen sulfide (H2S) and total organic halide as
    chloride (TOHCI) bring with them totally different
    problems to the engine and lubricating oils.
    ) Waukesha has limited sulfur bearing compounds
    (H2S, etc.) content in fuel gas to 0.1 %, or 63 grains per
    100 cu. ft. (2.83 m3 ). However, it is not unusual to
    encounter biomass gas, or field gas, with much higher

    FORM 6248 First Edition 5.30 - 5


    LUBRICATION SYSTEM

    FUEL COALESCER SPECIFICATION FOR CAUTION I


    I A='--__ TOHCI does not affect
    )
    ALTERNATIVE FUEL APPLICATION .L .:;;
    .. '--__--'. TBN levels the same as
    sulfur compounds. Therefore, the 50% depletion as
    Solid Particulate Removal: an indicator of a change interval only applies to the
    Coalescer shall have an absolute rating of 0.3 microns applications where fuel gas does not contain
    for solid particulate removal, OR halides. Disregarding this information could result
    Have a Beta Rating of 10,000 for 0.3 micron solid in product damage and/or personal injury.
    particles, OR
    Have a 99.99% removal efficiency of 0.3 micron solid Recommendation #3
    particles. Increase the jacket water temperature to 212' - 235' F
    Liquid and Aerosol Removal: (1 ~O' - 113' C) and lube oil temperatures to
    185' - 200' F (85' - 93' C). Increased temperatures
    Coalescer shall remove entrained liquid aerosol con- will reduce the condensation, therefore, reduce the
    taminants to a minimum of 0.003 parts per million (by
    concentration of acids within the crankcase. High
    weight) downstream concentration, OR temperature thermostats are available for most models.
    Have an aerosol removal efficiency of no less than
    99.5% for aerosols of 0.3 micron or larger. If you have any question on lubricants to be used with
    alternate fuel gases, contact the Service Operations
    Design Criteria: Department or Application Engineering Department
    Coalescer Filter Housing to be of the cylindrical type, prior to selecting a lubricating oil.
    vertically mounted. The housing shall contain two sump
    chambers, such that the lower sump collects heavier
    LUBE OIL CONDEMNING LIMITS
    liquid dropouts immediately downstream of the gas Lubricating oil condemning limits are established by the
    inlet, while the upper sump collects liquids draining off engine manufacturer's experience and/or used oil
    the coalescer cartridge(s). testing.
    The coalescer design shall utilize an inside to outside Laboratory testing will determine the used oil's suitabil-
    gas flow path through the coalescer cartridge. ity for continued use. Used oil testing should cover the
    data shown in Table 5.30-4.
    )
    Recommended Coalescing Filter:
    Table 5.30-4 Used 011 Testing And Condemnation
    Pall Process Filtration Company
    Model CC3LG7A TEST CONDEMNING LIMIT
    Viscosity -20/+30% Change
    The following recommendations will minimize corrosion
    problems normally encountered with fuel gas contain- Flash Point Below 356' F (180' C)
    ing H2S and TOHCI: Total Base Number (TBN) 50% of New Oil Value
    Total Acid Number (TAN)
    Recommendation #1 (ASTM-D2896) 2.0 Rise Above New Oil Value
    Select a gas engine lubricating oil with a high alkalinity Oxidation (Abs/Cm) 25
    reserve, 7 to 13 TBN (Total Base Number). Alkalinity
    Nitration (AbsfCm) 25
    reserve in the lube oil is measured in TBN. The higher
    Insolubles Above 1.0% (Gas Enginel
    the TBN, the more reserve. Above 3% (Diesel Engine
    Contact your oil supplier or consult the EMA Lubricating Water Content Above 0.20% WI.
    Oils Data Book for an appropriate choice. Also follow the Glycol Any Detectable Amount
    appropriate ash content percent by weight for the
    Wear Metals Trend Analysis
    specific engine model.
    Chlorine 750 ppm
    Recommendation #2
    Used oil analysis is mandatory for alternate fuel
    applications. Lube oil change periods are determined
    by TBN, TAN (Total Acid Number), oxidation and
    nitration level in the used oil samples. The user must
    change the oil when the TBN level falls to 50% of the
    new oil value or TAN increases by 2.0 above the new oil
    value. The method of measuring TBN in used oil must
    be ASTM-D2896.

    5.30 - 6 FORM 6248 First Edition


    LUBRICATION SYSTEM

    Nitration: An oil analysis should be regularly performed to


    Nitration of the lube oil is one of the most common oil determine the TBN rating of oils in service. The TBN
    degradation problems. rating will not only give the engine operator some
    information regarding the condition of the oil, and
    While oil often begins to nitrate when exposed to whether an oil change is required, but it will put this
    nitrogen dioxide through blow-by, oil also nitrates when information in his hands before the lubricant actually
    exposed to nitrogen dioxide on the cylinder sleeve becomes corrosive (see Table 5.30-5).
    walls. When the nitrated oil is scrapped off the wall and
    allowed to drain into the crankcase, it causes highly Table 5 30-5 Recommended TBN Ratings
    nitrated materials to become deposited in the lube oil. NATURAL GAS TYPE MINIMUMTBN
    Nitration is the chemical reaction that occurs when the Clean, Sweet 2-4
    nitrogen dioxide acts like an adhesive to bind the oil Minimal Traces of SuHur 5-7
    molecules together. This is the reason why the viscosity Maximum Sulfur Concentration
    10
    of the oil actually increases. These molecular chains Allowable - 0.01%
    continue to grow until they become so large and heavy
    that they can no longer remain suspended in the lube oil. Total Acid Number:
    At this point, they attach themselves to internal surfaces Total Acid Number (TAN) indicates the total amount of
    to become varnish deposits, particularly around the acids present in the lube oil. Acids, which are natural
    piston skirt and ring area, or they physically drop out to by-products of internal combustion engines, are highly
    become sludge in the crankcase. corrosive substances that accelerate engine wear.
    Nitration rates increase at lower oil temperatures. Most acids are formed from sulphur or chlorine in the fuel.
    Since oil temperatures of 150' F (66' C) or below Sulfur is commonly found in many types of fuel and leads
    cause the nitration rate to increase dramatically, to the production of sulfuric acid in the crankcase. The
    maintain oil header temperatures between 165' F presence of chlorine, which is typically found only in
    (74' C) and 195' F (91' C). landfill gas, results in the production of a number of highly
    corrosive substances, hydrochloric acid among them.
    Oxidation:
    The level of acids in the lube oil, as reflected by the TAN
    Oxidation is very similar to nitration, with the exception
    number, usually rises slowly because of the neutralizing
    that oxygen (02)' rather than nitrogen, causes the oil
    effect of sulfated ash, a required lube oil additive (see
    molecules to be bound together into chains. Another
    Initial Fill). The TAN number stays low until the additive
    difference is that the rate of oxidation increases at
    package is depleted, at which point the acid level rises
    higher engine temperatures, especially temperatures
    dramatically.
    above 200' F (93' C), so oxidation is very common in
    gas engines because of the tendency to run at elevated Do not be surprised if lube oil straight from the drum is
    temperatures. found to have a TAN number. Even though some lube oil
    The damage caused by oxidation is virtually identical to additives are slightly acidic, acids from this source will
    not harm the engine.
    that of nitration. It is not uncommon for the lube oil to be
    oxidizing and nitrating in the same engine. The exis- Water Content:
    tence of one condition does not preclude the other.
    Contact with water causes the lube oil to degrade. A
    Total Base Numbers: maximum of 0.2% by weight is allowable. Water often
    Total Base Numbers (TBN) is a way of determining the forms in the crankcase through condensation. This is
    reserve alkalinity of a lube oil. Oils are formulated with especially common if the engine is running too cold, that
    different degrees of alkalinity in order to neutralize is, if it is loaded too lightly or if it has been run for only
    different concentrations of acids. Generally, the higher short periods.
    the concentration of sulphur in the fuel, the higher the Sodium and Boron:
    TBN of the lube oil must be.
    A coolant leak also brings the lube oil into contact with
    water. Remember thatthe water may vaporize ifthe leak
    is relatively minor, so a specific test for water might
    come up negative even though a coolant leak does in
    fact exist. Therefore, always test for the presence of
    ) Sodium and Boron, two compounds found in water
    treatment additives. Even if the cooling water has
    evaporated, the additives remain to serve as evidence
    of a coolant leak.

    FORM 6245 First Edition 5.30 -7


    LUBRICATION SYSTEM

    Wear Metals: for analysis after 250 running hours. Submit a second
    Moving parts of the engine will start to wear out as it sample just before the scheduled oil change. Oil quality )
    gains running hours. When clearances become larger can degrade rapidly and unexpectedly; oxidation and
    and components fall out of tolerance, bits of metal that nitration rates increase exponentially.
    have been broken or sheared off become suspended in 2. Do not draw the oil sample from the oil pan. Touching
    the lube oil. Concentrations of certain metals in the lube the sides or bottom of the oil pan with the sampling tube
    oil will increase as more and more wear occurs.
    picks up sludge and dirt that contaminates the sample.
    The existence of wear metals will normally be highest
    when the engine is new or when it is time for an 3. Draw the oil sample with the engine running.
    overhaul. Therefore, the engine operator should not be Particles suspended in the oil will settie out after the
    alarmed if there is a high concentration of wear metals engine is shut down. The sample must capture oil-
    when the engine is first installed. High concentrations of borne particles to detect signs of engine wear.
    wear metals early in the life ofthe engine are normal and
    4. Since filtration also removes particulates from the
    are due to the break -in of moving parts. The concentra-
    oil, install a petcock at the full-flow lube oil filter inlet to
    tion of wear metals should then fall dramatically and
    obtain a good sample quickly and easily (see
    only continue to rise at the point where the engine is
    Figure 5.30-6).
    approaching the time for an overhaul. On the other
    hand, always be alert for any sudden increase in the
    concentration of wear metals, this may indicate that
    some condition is accelerating the wear rate (see
    Table 5.30-6).
    Table 5 ~ Wear Metals
    / '
    METAL TYPE POTENTIAL SOURCE FILTER ~
    HOUSING / '
    Iron Cylinder Sleeves, Piston Rings
    PETCOCK
    Copper Bearings (Inner Layer) LOCATION
    Aluminum Pistons, Bearings
    )
    Figure 5.30-6. Petcock At Lube Filter Inlet
    Nickel Bearings
    Tin Piston Flashing, Bearings
    5. Follow the same sampling procedures every time to
    Viscosity: guarantee the quality of the sample and the integrity of
    the analysis. The samples are not comparable if
    If the viscosity changes, the lube oil analysis should be different sampling procedures are used.
    studied to determine the cause. A change in viscosity
    usually points to a high rate of oxidation or nitration, but 6. Always retain the last five lube oil analysis reports for
    some other form of contamination may also exist. comparison purposes. Remember that lube oil analysis
    is a study of "trends." No conclusions can be drawn from
    Insolubles:
    a single report. Each analysis must be compared to
    The concentration of insolubles or total solids sus- others if anything is to be learned.
    pended in the lube oil is a reflection of the level of
    oxidation or nitration contamination. These solids can NOTE: The original composition of the lube oil is also
    drop out of the lube oil to coat internal surfaces and plug an important consideration. In order to fully understand
    oil passages. a lube oil analysis, one must know what was in the lube
    oil to begin with. Whenever a new oil type is considered,
    LUBE OIL ANALYSIS have it analyzed to establish a ''base line." Since all lube
    Testing by qualified professionals is necessary to oils degrade with service, later samples can be
    determine whether a particular oil is suitable for compared to the "base line" to determine the suitability
    continued use. Oil analysis can be a valuable diagnos- of the oil for continued use.
    tics tool, but improper oil sampling techniques can
    render the test useless. To ensure the accuracy of any
    oil analysis:

    1. Submit a sample of the lube oil for laboratory )


    analysis after half the recommended oil change interval
    has elapsed. For example, if the oil should be changed
    every 500 running hours, submit a sample of the used oil

    5.30 - 8 FORM 6248 First Edition


    LUBRICATION SYSTEM

    OIL VISCOSITY SELECTION those of mineral oils. Oil filter change intervals remain at
    1000 to 1500 hours of operation.
    The operating temperature of the oil in the sump or
    header is the best guide for selecting the proper SAE SynthetiC oils are not recommended for alternate fuel
    grade of oil (see Table 5.30-7 and Table 5.30-8). When gas applications without prior approval by Waukesha
    the oil temperature is unknown, add 120° F (67° C) to Engine Division.
    the ambient temperature to obtain the estimated sump
    oil temperature.
    LOW AMBIENT TEMPERATURE
    OPERATION
    Table 5 30-7 Sump Temperature And SAE Number
    At low ambient temperatures, use an oil which will
    1000 CU. IN. (16.4 L) DISPLACEMENT AND SMALLER provide proper lubrication when the engine is hot and
    SUMP TEMPERATURES SAE NUMBER working. For engines of 1000 cu. in. (16.4 L) and above,
    210° - 250° F (99° - 121° C) 40 operating at ambients below 50° F (10° C) lube oil and
    jacket water heaters are required to warm oil and water
    160° - 210° F (71 ° - 99° C) 30
    for fast starting and loading of engines. Waukesha
    Table 5.30-8. Sump And Header Temperatures And Engine Division will supply information on these starting
    SAE Number devices upon request.
    1000 CU. IN. (16.4 L) DISPLACEMENT AND LARGER LUBE OIL CONSUMPTION RATES
    SUMP HEADER SAE Typical lube oil consumption rates have been updated
    TEMPERATURES TEMPERATURE NUMBER
    for all Waukesha engines (see Table 5.30-9).
    160° - 230° F 160° - 210° F
    40
    (71 ° - 110° C) (71° - 99° C) Table 5 30-9 011 Consumption
    Below 160° (71°) Below 160° (71°) 30 MODEL LBS! GRAMS! GRAMS!
    HP-HR HP-HR KW-HR
    NOTE: NOTE: Engines of 1000 cu. in. (16.4 L) dis- VHP 0.0003 - 0.001 0.14 - 0.4l1 0.18 - 0.60
    placement and above should not be operated with
    header oil temperature below 140° F (60° C). Engines of NOTE: Lube oil consumption rates given above are a
    this type which exceed 195° F (91° C) header tempera- general guide and not meant fo be used for Condemn-
    ture or 215° F (102° C) sump temperature should have ing Limits or determining overhaul requirements.
    reduced oil change intervals.
    FORMULAS
    MULTI-VISCOSITY OILS
    LBS 7.3 x Number of Gallons of Oil Used
    Use multi-viscosity oils only for engines in cold starting
    HP HR HP x Hours of Operation
    applications. Multi-viscosity oil may deteriorate in
    continuous service, allowing the oil to revert to its
    original low viscosity base. In this state, the oil may not LBS 1.62 x Number of Quarts of Oil Used
    supply sufficient lubricating films and/or pressure. HP - HR HP x Hours of Operation
    Therefore, utilize an oil analysis program to determine
    the oil change intervals. Grams 675 x Number of Litres of Oil Used
    SYNTHETIC OILS HP - HR HP x Hours of Operation

    Based on developments by Mobil Oil Corporation and


    the release of their Pegasus 1 synthetic lubricating oil, Grams 675 x Number of Litres of Oil Used
    Waukesha Engine Division now recognizes this product kW - HR kW(corrected) x Hours of Operation
    as being suitable for all Waukesha stoichiometric and
    lean burn gas engines. Mobil Pegasus 1 has been field
    proven over the last six years in a multitude of
    applications. Mobil Pegasus 1 has also been added to
    the approved lubricating oil list for co-generation
    installations. This product is an SAE 15W - 40 which
    provides good cold start capabilities that are natural to
    the synthetic base stock without the use of VI improvers.
    ) When Pegasus 1 synthetic lubricating oil is selected, it is
    suggested that you contact Waukesha Engine Division
    for change interval recommendations. Typically, syn-
    thetic oil change intervals are 3 to 5 times longer than

    FORM 6248 First Edition 5.30 - 9


    LUBRICATION SYSTEM

    RECOMMENDED OIL CHANGE


    INTERVALS )

    IA CAUTION I The use of some types of


    .. oil, as well as dusty envI-
    ronment, marginal installation, internal engine con-
    dition and/or operating the engine with
    malfunctioning carburetion or injection equipment
    may require more frequent oil changes. Waukesha
    Engine recommends the lubricating oil be moni-
    tored with a professional 011 analysis program.
    Extended oil change Intervals may cause varnish
    deposits, oil oxidation, or sludge conditions to
    appear in the engine, which an 011 analysis cannot
    detect. Contact your local Waukesha Distributor for
    periodic engine maintenance. Disregarding this
    information could result in product damage and/or
    personal injury.
    Table 5.30·10. Duty Cycle Definitions
    CONTINUOUS OR PRIME The ,hast load and T'heed which can be applied 24 hours per day, 7 days per week, except for
    norm maintenance. e rating can include operation of the engine at up to ten percent overload for
    POWER SERVICE RATING: two hours in each 24 hour period,
    STANDBY SERVICE In a system used as a backup or secondary source of electrical power, this rating is the output the
    RATING: system will produce continuously, 24 hours a day, for the duration of the prime power source outage.
    INTERMITTENT SERVICE This rat~ is the hi~est load and speed that can be applied in special applications. Operation should
    RATING: be limit to a maximum of 1500 hours per year.

    Peak shaving is operation of an engine for a limited time to meet short term peak ~ower reqUirements.
    PEAK SHAVING: Speed, loading, and hours per year of operation will affect the recommended oil c ange interval. )
    LIGHT LOAD OPERATION: 25% or less of the continuous duty rating.

    Table 5.30·11. Recommended 011 Change Intervals For Engines Receiving Normal Maintenance

    CONTINUOUS ENGINES OPERATED EBULUENT COOLED OR


    ENGINE OR PRIME IN EXCESS OF LIGHT LOAD HOT WATER SYSTEM WITH STANDBY
    MODEL POWER CONTINUOUS OPERATION ENGINE WATER
    TEMPERATURE 200°F SERVICE
    SERVICE RATING SERVICE (93° C) OR ABOVE
    VHPSERIES 500 hours or
    Natural Gas, 1500 hours 500 hours 1500 hours 500 hours
    HD-5 Propane annually

    NOTE: Change lube oil and fuel niter elements when lube oil is changed.

    CAUTION I
    I.=.A=:......;=...;;.;:-.::....:....::....~.
    Actual oil change inter- CAUTION I~andfi" .gas fuele~ en-
    I.=.-A;=:.......;;:;.;;:....:....::.....;;.".;;.,.;:;.,;;,.;:...J_
    .L . vals to be determined by .L . gines' 011 change inter-
    engine inspection or 011 analysis in conjunction vals are outlined In Waukesha Engine Division's
    with oil condemning limits. Disregarding this in- Tech Data SA7884C and Service Department Broad-
    formation could result in product damage and/or cast 1100. Disregarding this information could
    personal injury. result in product damage and/or personal injury.
    NOTE: Oil condemning limits are listed in Table 5.30-4.
    Table 5.30-12. Recommended 011 Change Intervals For Engines Receiving Normal Maintenance And Using Gaseous
    Fuel Containing H:zS Or Uquid Fuel Containing Sulfur In Excess Of Published Umits.

    CONTINUOUS ENGINES OPERATED EBULUENT COOLED OR HOT


    OR PRIME IN EXCESS OF LIGHT WATER SYSTEM WITH
    ENGINE LOAD ENGINE WATER STANDBY
    MODEL POWER CONTINUOUS OPERATION TEMPERATURE 200° F SERVICE
    SERVICE RATING SERVICE (93° C) OR ABOVE
    VHPSERIES hours hours hours 250 hours or
    360 250 360 360 hours annually
    NOTE: Change lube oil and fuel Mer elements when lube oil is changed.

    5.30 -10 FORM 6248 First Edition


    LUBRICATION SYSTEM

    In the interest of developing a reasonable life expectan- - elevated lube oil temperature to
    cy for Waukesha Engines operating on fuel gas laden 1850 F - 200 0 F (85 0 C - 93 0 C)
    with some level of halogenated VOC's (Volatile Organic
    Compounds) our experience dictates the following: - use of high TBN oil (7.0 - 13.0)

    • To achieve the life expectancy of an engine operating - bypass lubrication oil filtration
    on pipeline quality natural gas, remove all haloge-
    nated VOC's (as well as abrasives) from the fuel gas. • TOHCI at a level of between 161 micrograms
    chlorideMer and 240 micrograms chloride/liter may
    • Reasonable life can be expected if Total Organic require substantial changes to the engine wearing
    Halide as Chloride Concentration (TOHCI) of the fuel components. No guarantees of operating life or
    does not exceed 60 micrograms chloride/litre. Total operating costs are reasonable at this level.
    Organic Halide as Chloride (TOHCI) equals the sum
    of all halogenated compounds expressed as chloride • TOHCI above 240 micrograms chloride/litre require
    in micrograms/litre as chloride (uCI-/L) at STP pre-treatment of the fuel in order to make it suitable
    (Standard Temperature and Pressure). for use in a reciprocating engine.

    • Reasonable life can also be expected with increased LUBE OIL PIPING PURGE
    maintenance and operating adjustments to the
    engine if TOHCI is above 61 micrograms chloride/
    litre but does not exceed 160 micrograms chloride/
    IA CAUTION I
    L.
    The lube 011 piping must
    ==--=..;;....:.;:;,...:....:.-=..:..:..J. be purged of all slag and
    litre. debris before the engine is started. Before proceed-
    Ing with the 011 fill procedure, refer to the purging
    Typical changes in maintenance and operation at this
    Instructions In this section. Disregarding this in-
    level are: formation could result In product,damage and/or
    - decreased oil change interval personal Injury.
    (150 hours to start)
    Fill Procedure
    - condemn oil when 750 ppm chlorine level in
    used oil is reached. This will aid in establishing 1. Remove the cap from the oil filler pipe on the lower
    an oil change interval. rear left side of the engine (see Figure 5.30-7).

    - lubricating oil analysis each 50 hours minimum 2. Insert the make-up line and add lube oil to the oil
    pan. Periodically remove the dipstick and take note of
    - elevated jacket water temperature the reading. For convenience, a dipstick is located on
    212 0 F - 240 0 F (1000 C - 1130 C) both the right and left side of the oil pan.

    REAR FLYWHEEL
    / HOUSING

    OIL FILLER""""""'"
    PIPE
    o

    INSTRUCTIONft~~~~=:::::!..--,----
    DECAL \
    OIL FILLER PIPE BRACKET

    )
    Figure 5.30-7. VHP Oil Filler Pipe

    FORM 6248 First Ednion 5.30 -11


    LUBRICATION SYSTEM

    3. Continue to add oil to the oil pan until the level engine by flexible connections. Use only positive (flanged,
    reaches the "full" mark on the dipstick (see threaded or welded) connections. Both the flexible
    Figure 5.30-8). connections and fittings must be suitable for lube oil
    pressurized up to 125 psi (862 kPa) at 2500 F (121 0 C).

    ( HOW !FULL i> 0 0 1I1Ir===::::l 2. Verify that all lines between the engine and the lube
    oil filter and lube oil cooler assemblies are clean and

    2: )I] o
    free from scale.

    LUBE OIL CHANGE


    O-RING
    To change the oil, drain the oil pan and all lube oil system
    Figure 5.30-11. Dipstick accessories: oil cooler, full-flow oil filter and lube oil
    strainer. Proceed as follows:

    4. Stop the oil addition and start the prelube suction NOTE: Drain oil when warm.
    pump. The prelube pump must be run to fill the oil lines,
    oil cooler, the full-flow lube oil filter and oil strainer. It 1. Oil pan: remove the 2 inch square head drain plug.
    also ensures that the bearings, turbochargers and other For convenience, four drain plugs are provided, one at
    moving parts of the engine are properly lubricated. each corner of the oil pan.

    5. While the prelube suction pump is running, open the NOTE: Installation of a customer supplied ball valve
    full-flow lube oil filter cover petcock to bleed off any air and pump facilitates draining of the oil pan.
    that may be trapped in the lube oil system.
    2. Oil Cooler: remove the drain plug atthe bottom olthe
    6. Run the prelube pump until pressure is indicated on oil cooler shell midway between the inlet and rear
    the panel mounted oil pressure gauge. Once pressure is bonnets.
    indicated, stop the prelube pump, wait a few minutes for
    3. Full-Flow Lube Oil Filter: remove the upper drain
    the oil to drain back into the crankcase, check the
    dipstick and add oil to the oil pan until the level returns to
    plug from the oil fitter housing to drain sludge and dirty )
    oil from the filter element chamber. Remove the lower
    the "full" mark.
    plug to drain oil from the clean oil chamber.
    NOTE: Normal operating temperature is approximate-
    4. Lube Oil Strainer: remove the drain plug (3/8 inch) at
    ly ten degrees higher than the nominal rating of the
    the bottom of the strainer element housing.
    temperature control valve.
    5. When the oil has drained, reinstall the drain plugs.
    7. Thread on the oil filler cap, start the engine and wait
    until the lube oil has warmed up to its normal operating Refer to Table 5.30-12, Table 5.30-11 and
    temperature. Shut the engine dOwn, wait for the oil to Table 5.30-1 Ofar information on oil change intervals. Oil
    drain back into the pan and then check the level one change intervals should never be extended beyond
    more time. Add oil if the level is below the "full" mark. these recommendations because of additive depletion
    and changes in the physical properties of the oil.
    8. Check the crankcase oil level daily before the engine
    is started. The blade of the dipstick is marked "low" and NOTE: Submit a sample of the lube oil for laboratory
    "full." Always maintain the oil level atthe '1ull" mark. Both analysis after half the recommended oil change interval
    marks on the dipstick are "static lines." The dipstick has elapsed. If the oil should be changed every 500
    does not indicate where the level of the oil should be running hours, submit a sample of the used oil for
    when the engine is running. analysis after 250 running hours. Depending upon the
    results, more frequent oil changes may be necessary.
    OIL COOLER AND LUBE OIL FILTER
    INSTALLATION I;A. . CAUTION IOil change intervals for
    engines fueled on landfill
    1. All piping connections to and from the engine and gas are outlined in WED Tech, Data SA7884C and
    between lubrication system accessories are to be sup- Service Department Broadcast 1100. Disregarding
    plied by the customer. Place the lube oil fitter and lube oil this information could result in product damage
    cooler assemblies as close to the engine as possible. If and/or personal injury. )
    they must be over 8 feet away, use a pipe one size larger
    than the 2 inch requirement. Do not use street elbows or
    fittings with a reduced inside diameter. The lube oil fitter
    and lube oil cooier assemblies must be isolated from the

    5.30 -12 FORM 6248 First Edition


    LUBRICATION SYSTEM

    CHECKING CRANKCASE OIL LEVEL LUBE OIL SYSTEM AIR BLEED


    Check the crankcase oil level daily before the engine is Air bleed the lube oil system at least once each day.
    started. For convenience, a dipstick is located on both Proceed as follows:
    the right and left side of the oil pan. The blade of the
    dipstick is marked "low" and "full." Always maintain the NOTE: The petcock on the full-flow oil filter cover is the
    oil level at the "full" mark. Both marks on the dipstick are only air bleed through which the lube oil system may be
    "static lines." The dipstick does not indicate where the purged of air pockets.
    level of the oil should be when the engine is running. 1. Initial Bleed: start the prelube pump and open the
    When checking the oil level, carefully examine the filter cover petcock.
    condition of the oil on the dipstick. Replace the oil any
    time it appears diluted, thickened by sludge or otherwise 2. Close the petcock when oil begins to flow out in a
    deteriorated. The useful life of the oil depends on a steady stream.
    number of factors, which include the engine load,
    3. Check Bleed: start the engine and reopen the filter
    temperature, fuel quality, atmospheric dirt, moisture
    cover petcock.
    and the level of maintenance. If oil performance
    problems arise, consult your oil supplier. 4. Close the petcock when oil begins to flow out in a
    Always pay close attention to engine operating temper- steady stream.
    atures. If engine jacket water and oil temperatures are
    maintained according to engine specifications, particu- 5. Final Bleed: once the engine is running at normal
    larly during periods of light load operation, the problems operating temperature, reopen the filter cover petcock.
    resulting from condensation of corrosive vapors in the
    6. Close the petcock when oil begins to flow out in a
    crankcase can be minimized. This in turn reduces the
    steady stream.
    rate at which the TBN is depleted and extends the useful
    life of the oil. LUBE OIL FILTER ELEMENT
    When using an engine oil for which there is no previous REPLACEMENT
    operating experience, a detailed oil analysis by qualified
    Full-flow lube oil filter elements should be replaced
    professionals is strongly recommended. A well monHored
    whenever the lube oil is changed and may often require
    maintenance program also should be established for the
    more frequent replacement.
    first year of usage and the performance of the engine
    should be carefully observed against all extemal operat- When the filter is new, the drop in oil pressure through the
    ing conditions. This procedure will help to determine if the filter is around 2 - 3 psi (14 - 21 kPa) under normal
    selected oil is really suHable for your particular operation. operating temperatures. To determine the pressure
    differential, subtract the reading of the oil filter outiet
    OIL COOLER MAINTENANCE pressure gauge from the reading of the inlet pressure
    Drain the oil from the oil cooler at each oil change. gauge. When the pressure differential rises to 12 - 15 psi
    (83 - 103 kPa) , the filter elements are clogged and must
    Clean and inspect the oil cooler annually. Inspect the oil be replaced.
    cooler sooner if an increase in oil temperature cannot be
    traced to a malfunctioning auxiliary water pump, loose 1. Drain both chambers of the full-flow oil filter. Two
    belts, a faulty thermostat or excessive engine load. drain plugs are provided in the oil filter housing (see
    Plugged tubes or scale deposits inhibit the flow of Figure 5.30-9). Remove the upper plug to drain sludge
    coolant which reduces oil cooling effectiveness. and dirty oil from the filter element chamber. Remove
    the lower plug to drain oil from the clean oil chamber.
    NOTE: Schedule the oil cooler cleaning during a
    regular oil change interval, since it is necessary to drain
    the oil pan and lube oil system accessories. For oil
    cooler cleaning procedures, refer to Auxiliary Water
    A WARNING
    Always wear proper eye protection when removing
    Cooling System.
    the spring. Slippage may propel the spring with
    enough force to cause severe personal Injury or
    death.

    )
    /

    FORM 6248 First Edition 5.30 -13


    LUBRICATION SYSTEM

    A WARNING
    procedure will cause the cover to spring up from the filter
    body causing personal injury and property damage.
    To avoid personal injury, use special care to remove 5. Remove the lube oil filter elements (see
    the oil fiHer cover. Follow the proper disassembly Figure 5.30-10). Inspect each bypass relief valve for
    sequence listed. The cover compresses powerful wear. The oil filter has one relief valve. Refer to Lube Oil
    springs on the fiHer element posts. Failure to use Filter Relief Valve Inspection for more information.
    the proper sequence could cause severe personal
    injury or death.

    RELIEF
    VALVE
    ASSEMBLY

    o 0

    I,
    I, 0
    o o o
    I, 0 o o o
    I, Figure 5.30-10. FUll-Flow Lube Oil Filter )
    I 6. Install the new lube oil filter elements over each filter
    element post (see Figure 5.30-11).
    OIL
    OUTLET
    /'

    12 CYLINDER
    Figure 5.30-9. Lube 011 Filter

    2. To remove the oil filter cover safely, locate the


    longest bolts. While the long bolts extend about 1-1/4
    inches below the flange at the top ofthe oil filter housing,
    the short bolts are flush with the bottom of the flange
    (see Table 5.30·13).
    o = ELEMENT @ = REUEF VALVE

    Table 5 30-13 Lube 011 Filter Da1a Figure 5.30-11. Filter ElementlAelief
    OIL NUMBER NUMBER DISTANCE Valve Connguratlon
    FILTER OF OF BETWEEN
    ENGINE SHELL SHORT LONG LONG

    12 Cylinder
    1.0.
    16"
    BOLTS
    9
    BOLTS
    3
    BOLTS
    1200 IA CAUTION IThose filter ele~ents
    =:.......;::..;;,....:....;"---'-_---'. that are stamped With an
    L.,.
    : .

    arrow must be installed with the arrow pointing


    3. Leaving the longest bolts in place, remove the short down_ Elements that have a band around the center
    bolts working in a clockwise direction. may be installed with either end pointing down.
    Disregarding this information could result In prod-
    4. Loosen the long bolts giving each an equal amount
    of turn. Alternately loosen each of the long bolts to uct damage and/or personal injury.
    slowly ease the filter cover up. Failure to follow this

    5.30 - 14 FORM 6246 First Edition


    LUBRICATION SYSTEM

    7. Replace the drain plugs in the oil filter housing. LUBE OIL FILTER RELIEF VALVE
    S. Fill the filter assembly with clean lubricating oil (see
    INSPECTION
    Table 5.30-14). The full-flow lube oil filter housing contains one bypass
    relief valve.
    Table 5.30-14. Engine Oil Capacity
    When the elements are new, the drop in oil pressure
    OIL CAPACIlY
    ENGINE through the fiRer is minimal, around 2 - 3 psi (14 - 21 kPa)
    GALLONS LITRES under normal operating temperatures. If the pressure
    12 Cylinder 36 136.3 differential reaches 32 psi (221 kPa) , the relief valve
    begins to open and oil bypasses the fiRer elements
    9. Allow air to escape by depressing the bypass relief enroute to the lube oil strainer. The relief valve is fully open
    valve piston(s). at approximately 40 psi (276 kPa).

    10. Re-install the lube oil filter cover. The fiijer cover Inspect the relief valve(s) for wear at least once each
    a-ring should be replaced every 720 hours, any time it year or after every 8,000 hours of operation, whichever
    has taken a permanent set or if it appears damaged, comes first.
    whichever comes first. Torque the filter cover capscrews 1. Remove the relief valve assembly from the bypass
    to 35 - 37 ft-Ib (47 - 50 N·m) in a crisscross pattem. tube.
    11. To release the remaining air, start the prelube pump 2. Remove the reducing bushing from the relief valve
    and open the filter cover petcock. Close the petcock body, if provided.
    when oil flows out in a steady stream.
    3. Remove the retaining ring, washer, spring and piston
    NOTE: Air bleed the lube oil circuit at least once each from the relief valve body (see Figure 5.30-12).
    day. The petcock on the full-flow oil filter cover is the
    only location through which the lube oil system may be
    purged of air pockets (see Lube ail Filter Air Bleed in
    this section for more information).

    NOTE: Waukesha highly recommends adding a by-


    pass filtration system to the standard full-flow lube oil
    filter, especially for those engines operating in harsh VAlVE
    environments. In operation, a small portion of the lube
    oil is routed from the pump through special bypass filters
    and then back to the oil sump. Particles as small as one
    micron are effectively removed as the oil flows through
    the bypass filter elements. An orifice in the filter housing
    inlet controls the flow to approximately 10 percent of the
    rated flow to the engine. In an hour, this operation filters
    a quantity of oil equal to roughly five times the system
    capacity. Use of the bypass filtration unit does not alter
    the recommended oil change interval, since the filter is
    designed to reduce engine wear, not prolong lube oil life.
    WASHER

    RING

    Figure 5.30-12. Lube Oil Filter Relief Valve Assembly

    4. Remove the a-ring from the relief valve piston.


    Inspect the area above the a-ring for excessive wear.
    Replace if gouged or deeply scratched.

    FORM 6248 First Edition 5.30 - 15


    LUBRICATION SYSTEM

    5. Install a new O-ring on the relief valve piston. Table 5 30-15 Magnetic Plug Locations
    MAGNETIC SPECIFIC ENGINE LOCATION
    6. Install the piston, spring, washer and retaining ring in PLUGS
    the relief valve body. Rocker arm oil header supply line
    1 (3/8" pipe tee) front vee
    7. Test the relief valve as follows:
    Rocker arm oil header supply line
    1 (3/8" pipe tee) rear vee
    A. With the open end down, put the relief valve
    Turbocharger oil supply line
    assembly in a valve spring tester. 1 (3/8" pipe cross) rear right

    B. Press down on the top of the piston.


    2. Clean the magnetic plug in solvent, if necessary.
    C. Note the scale reading when the piston just Wipe the plug clean to ensure that all ferrous metal
    begins to move. The reading should be approxi- debris is removed.
    mately 41.5 pounds. If the reading does not
    3. Install the magnetic plug back into the oil supply line
    conform to this specification, then replacement
    and wrench tighten.
    of the relief valve spring is necessary.

    NOTE: A lube oil filter pressure differential of 32 psi OIL COOLER PIPING REMOVAL
    (221 kPa) exerts approximately 41.5 pounds afforce on
    top of the relief valve piston. A WARNING
    a. Install the reducing bushing onto the relief valve Allow the oil to cool, prior to removing oil system
    body. components, to prevent burns from hot oil. Disre-
    garding this information could result in severe
    9. Install the relief valve assembly onto the bypass personal injury or death.
    tube.
    NOTE: The oil cooler piping is not normally disas-
    MAGNETIC PLUGS sembled. This assembly is normally removed from the )
    Inspect and clean the magnetic plugs at each oil engine as one assembly, along with the oil cooler
    change. Proceed as follows: assembly.

    1. Remove the magnetic plug (see Figure 5.30-13). 1. Disconnect all piping from the engine. Tag all pipe
    The number of magnetic plugs and their locations are as ends for reference during assembly.
    follows (see Table 5.30-15).
    2. Refer to Figure 5.30-14 and disassemble piping only
    as required. Discard all old gaskets and seals.

    3. Refer to Lube Oil Temperature Control Valve for


    disassembly of this component.

    Figure 5.30-13. Magnetic Plugs

    5.30 - 16 FORM 6248 First Ed~ion


    LUBRICATION SYSTEM

    1
    20
    61~~~ ~

    221 1 '®
    23
    22
    1

    (Continued)

    i
    /

    FORM 6248 First Edition 5.30 -17


    LUBRICATION SYSTEM

    ITEM NUMBER AND DESCRIPTION


    )
    1 Range 12 O-ring Flange 23 Plate 34 Gasket
    2 Gasket 13 Relief Valve 24 Tee 35 Cover
    3 Hexhead Caps crew 14 Adjusting Screw 25 Lockwasher 36 Lockwasher
    4 Gasket 15 Lock Nut 26 Hexhead Capscrew 37 Hexhead Gapscrew
    5 Hexhead Capscrew 16 Washer 27 Pipe Nipple 38 Square Head Pipe Plug
    6 Lockwasher 17 Plug 28 Tube 39 Pipe
    7 Tee 18 Washer 29 Elbow 40 Hexhead Capscrew
    8 Hexhead Capscrew 19 Spring 30 Valve 41 Reducing Bushing
    9 Hex Nut 20 80dy 31 Thermostat Seal 42 Flexible Connection
    10 Pipe Flange 21 Plunger 32 Thermostat 43 Flexible Connection
    11 Gasket 22 Tee Gasket 33 Spring
    Figure 5.30-14. Oil Cooler Piping Connections

    OIL COOLER PIPING INSTALLATION 1. Remove the oil drain plug at the bottom of the oil
    cooler shell midway between the inlet and rear bonnets.
    NOTE: The oil cooler piping is not normally disas- Drain all oil.
    sembled. This assembly is normally installed on the
    engine as one assembly, along with the oil cooler 2. Drain or shut off the auxiliary water supply. Open the
    assembly. drain cock on the rear bonnet. Drain all water.

    1. Connect all piping from to the engine. Refer to tags 3. Disconnect all piping from the engine. Tag all pipe
    for reference during assembly. ends for reference during assembly.
    )
    2. Refer to Figure 5.30-14, apply pipe sealant to 4. To ensure proper reassembly, mark the flanges on
    threads of fittings, and assemble piping as required with the inlet and rear bonnets, both ends of the shell and the
    new gaskets and seals. fixed tube sheet before disassembly.

    3. Refer to Lube Oil Temperature Control Valve for 5. Refer to Figure 5.30-14 and disassemble oil cooler
    assembly of this component. piping only as required. Discard all old gaskets and
    seals.
    4. Refer to Lube Oil Pressure Adjustment and adjust
    the lube oil pressure. 6. Remove nuts, lock washers and brackets from the oil
    cooler shell.
    OIL COOLER REMOVAL
    7. Remove capscrews, nuts, inlet bonnet and gasket

    A WARNING from the oil cooler shell (see Figure 5.30-15). Discard
    gasket.
    Allow the oil to cool, prior to removing all system
    8. Remove capscrews, nuts, rear bonnet and two seals
    components, to prevent bums from hot all. Disre-
    from the oil cooler shell. Discard seals.
    garding this information could result in severe
    personal injury or death. NOTE: Be careful to avoid damage to the tube bundle
    assembly when removing it from the shell. Protect the
    A WARNING ends of the tubes from damage. After removal from the
    shell, support the tube bundle on the tubesheets to
    Do not remove the bonnets until all pressure is prevent damage to the tubes.
    relieved and both oil and coolant are completely
    drained. Failure to follow proper procedures could 9. Remove tube and baffle assembly and gasket from
    cause severe personal Injury or death. the oil cooler shell. Discard gasket.

    NOTE: Since the other lube oil accessories may also


    have to be drained, schedule the oil cooler cleaning
    during a regular oil change interval.

    5.30 - 18 FORM 6248 First Edition


    LUBRICATION SYSTEM

    OIL COOLER CLEANING AND 5. Use a suitable roller type tube expander to tighten
    INSPECTION loose tube joints. Do not roll tubes that are not leaking,
    otherwise the tube wall will be unnecessarily thinned.
    Drain the oil from the oil cooler at each oil change. Clean
    the oil cooler annually. 6. Do not blow steam through individual tubes; local-
    ized overheating can result in expansion strain.
    NOTE: Inspect the oil cooler regularly. Plugged tubes
    or scale deposits inhibit the flow of coolant which 7. Fractured tubes or those that cannot be sealed on
    reduces oil cooling effectiveness. Clean the oil cooler if the ends may be plugged, although some cooling
    an increase in oil temperature cannot be traced to a performance will be lost.
    malfunctioning auxiliary water pump, loose belts, a
    faulty thermostat or excessive engine load. OIL COOLER INSTALLATION
    The tube bundle assembly fits inside the outer shell of NOTE: This assembly is normally installed on the
    the oil cooler. The tubes are water passageways engine as one assembly, along with the oil cooler piping.
    secured to a fixed tubesheet althe inlet bonnet end. The
    tubesheet is held in place between the inlet bonnet and NOTE: When reassembling the oil cooler, use new flat
    a protruding flange on the oil cooler shell at the inlet gaskets on the inlet bonnet end and new packing seals
    bonnet end. The opposite end ofthe tube bundle is held on the rear bonnet side. Be sure that the gaskets and
    in place by pressure between the rear bonnet and the seals are properly positioned before any attempt is
    packing seals, which encircle the rear tubesheet. made to retighten the bonnet bolts.

    t. Protect all gasket and seal surfaces. 1. Install new gasket, and tube and baffle assembly in
    the oil cooler shell (see Figure 5.30-15).
    2. Clean the oil cooler by eHher mechanical or chemical
    means. The selected method largely depends upon the NOTE: All external bolting may require retightening
    type of deposit and the materials available. Any of the after installation and when the oil cooler first reaches its
    following methods may be considered: normal operating temperature. The bolted joints should
    be tightened uniformly and in a diametrically staggered
    A. Backflushing. pattern (see Figure 1.15-6).
    B. Circulate hot wash oil or light distillate to remove 2. Install the rear bonnet on the oil cooler shell with
    sludge or other soft deposits. capscrews, nuts and two new seals. Torque the rear
    bonnet bolts to18 ft-Ib (24 N'm) lubricated. Apply only
    C. Circulate hot fresh water to remove soft salt
    sufficient torque to stop weepage. Over tightening may
    deposits.
    damage the packing seals.
    D. Commercial cleaning compounds may be used
    3. Install inlet bonnet on the oil cooler shell with new
    to remove sludge or scale not removed by the
    above methods. If such compounds are used, gasket, capscrews and nuts. Torque the bolts on the
    then check material compatibility to avoid pos- inlet bonnet side to 60 ft-Ib (81 N'm) lubricated. Apply
    only sufficient torque to stop weepage. Over tightening
    sible damage.
    may damage the packing seals.
    E. Use of a high pressure water jet.
    4. Install the brackets on the oil cooler shell with nuts
    F. Scrapers, rotating brushes or other mechanical and lock washers.
    means. Nylon brushes are preferred over wire
    5. Refer to Figure 5.30-14, apply pipe sealant to
    brushes if mechanically cleaning copper alloy
    tubes. threads of fittings, and connect all piping as required
    with new gaskets and seals.
    3. If drills are used to open up tubes that are completely
    plugged, use extreme caution to avoid drilling into the 6. Close the drain cock on the rear bonnet and fill or turn
    on the auxiliary water supply.
    wall ofthe tube.
    7. Install the oil drain plug and fill the engine oil pan and
    4. Use only cold fluid for pressure testing. Hydraulic
    lube oil system accessories with the proper amount and
    pressure may be used to locate split tubes or leaking
    grade of lubrication oil (see Oil Fill Procedure).
    ) tubesheet joints. Test rings are required on removable
    tube bundles in order to locate leaks. 8. Refer to Lube Oil Pressure Adjustment and adjust
    the lube oil pressure.

    FORM 6248 First Edition 5.30 -19


    LUBRICATION SYSTEM

    10
    _<e

    21
    /~

    ITEM NUMBER AND DESCRIPTION


    1 Inlet Bonnet 7 Rear Bonnet 13 NamePIa1e 19 Pipe Nipple

    2 Gasket 8 Hexhead Capscrew 14 Name Plate Pin 20 Drain Cock

    3 Tube And Baffle 9 Hexhead Capscrew 15 Bracket 21 Name Plate

    4 Gasket 10 Hex Nut 16 Pipe Flange 22 Drain Decal )


    5 Oil Cooler Shell 11 Squarehead Pipe Plug 17 Pipe Nipple 23 Pipe Elbow

    6 Seal 12 Squarehead Pipe Plug 18 Pipe Nipple

    Figure 5.30-15. Oil Cooler Assembly

    5.30 - 20 FORM 6248 First Edition


    LUBRICATION SYSTEM

    LUBE OIL TEMPERATURE CONTROL up, remove the remaining two capscrews and lock
    VALVE washers. Remove the plate.
    Remove and test the thermostat(s) in the lube oil 3. Pull out the spring and the thermostatic valve.
    temperature control valve annually. Inspect the
    thermostat(s) sooner if an increase in oil tempera- 4. Verify that the valve is in the fully closed position. If
    ture cannot be traced to a malfunctioning auxiliary the valve is frozen open or if there is any obvious
    water pump, loose belts or excessive engine load. distortion, discard it. If the valve appears in good
    condition, test as follows:
    NOTE: Drain the lube oil system.
    A. Suspend the thermostatic valve in a container of
    NOTE: The thermostat housing contains two thermo- water. Do not let the thermostat rest against the
    static valves. Each cover plate compresses a spring to sides or bottom.
    hold a thermostatic valve in place (see Figure 5.30-16).
    IA
    ;..
    CAUTION I Do not boll the thermo-
    static valve. Excessive
    OIL OUTLET
    PORT temperatures will force the valve to exceed Its
    normal operating travel and may result in perma-

    ~"
    nent damage. Disregarding this information could
    result in product damage and/or personal Injury.

    B. Gradually heat the water while stirring with a


    'S~~~~~~~COVERPLATE quality glass laboratory thermometer (see
    Figure 5.30-17). Observe the action of the valve.

    THERMOSTAT~
    HOUSING

    Figure 5.30-16. Lube 011 Temperature Control Valve

    1. Remove three of the five capscrews and lock washers


    from the cover plate. Loosen the remaining two capscrews. Figure 5.30-17. Thermostat Testing

    2. Ifthe spring does not push up the cover plate, tap the
    edge of the plate with a hammer. When the plate pops

    FORM 6248 First Edition 5.30 - 21


    LUBRICATION SYSTEM

    Table 5.30-16 Oil Cooler Thermostatic Valves - PIN 169867A Series


    PIN NOMINAL TEMPERATURE - 0 F e C) START TO OPEN - 0 F e C) FULL OPEN - 0 F e C) )
    199221E 160 (71) 157 - 162 (69 - 72) 177(81)
    199221D 165 (74) 162 - 167 (72 - 75) 182 (83)
    199221C 170 (77) 167 - 172 (75 - 78) 187 (86)
    1992218 175 (79) 172 - 177 (78 - 81) 192 (89)
    199221 A 190 (88) 187 - 192 (86 - 89) 207 (97)
    153610 Up Seal
    169869A Gaske1

    C. The valve should begin to open within the Start to 9. Remove the cover plate gasket from the thermostat
    Open temperature range (±2° F) listed above housing. Scrape off any gasket material that remains.
    (see Table 5.30-16). The valve should be com- Verify that the gasket surface is clean and completely
    pletely open at the Full Open temperature rating free of grease and oil. Install a new gasket.
    (±2° F).
    10. Install the new thermostatic valve with the expan-
    D. Remove the valve and observe its closing action. sion element facing outward. The part number of the
    The valve should seal evenly and tightly (see valve is stamped on the metal spring frame (see
    Figure 5.30-18). Figure 5.30-19).

    )
    SPRING FRAME.......... L
    I WAUKESHA
    PART NUMBER

    FULLY CLOSED FULLY OPEN Figure 5.30-19. Thermostatic Valve

    Figure 5.30-18. Thermostat Open And Closed

    E. If the thermostatic valve is defective, discard it.


    5. Pull out the lip seal. Use a rolling head pry bar for
    best results.

    6. Apply Loctite® 271 Adhesive Sealant (High


    Strength) to the lip seal bore.

    7. With the open side facing inward, press fit a new lip
    seal into the bore with a pipe or tube 2-1/2 inches in
    diameter. Verify that the seal is square in the bore and
    completely seated around its circumference.

    8. Using a small paintbrush, lubricate the lip seal with


    clean engine oil.

    IA
    ..
    CAUTION I Exercise care to keep the
    gasket material out ofthe
    thermostat housing. Old gasket material left on the
    mating surtaces will cause leaks. Disregarding this
    information could result in product damage and/or
    personal InJury.

    5.30 - 22 FORM 6248 First Edition


    LUBRICATION SYSTEM

    NOTE: The thermostatic valve with the lower nominal 12. Compress the spring with the cover plate (see
    temperature rating (lead stat) is always installed in the Figure 5.30-21) and install the five capscrews (5/16 x
    oil cooler port. The valve with the higher rating (normal 7/8 inch) and lock washers. Tighten the capscrews
    stat) goes in the bypass port (see Figure 5.30-20). evenly and securely. Torque the capscrews to 17 fHb
    (23 N·m) in an alternating pattern.
    _ _ _ _ _ _~OILOUTLET
    COVER
    PLATE ; r I- PORT SPRING COVER
    ~e~ PLATE
    \
    ~ ~
    I
    '.--.\'""- I
    I
    )

    SEAL

    Figure 5.30-21. Lube Oil Temperature Control Valve

    OIL COOLER
    INLET PORT

    Figure 5.30-20. Lube Oil Temperature Control Valve -


    12 And 16 Cylinder Engines

    11. Seat the spring in the groove between the valve and
    the thermostat housing.

    FORM 6248 First EdUion 5.30 - 23


    LUBRICATION SYSTEM

    TROUBLESHOOTING LOW LUBE OIL PRELUBE SYSTEM


    PRESSURE )
    A CAUTION IOildrainSbaCki~otheoil
    When troubleshooting low lube oil pressure, consider
    the following checks before adjusting the pressure
    . .=
    ..
    I ='--''-..;;..;;'-....:....~~. sump after engine shut-
    down leaving a minimal amount of oil at key wear
    regulating valve.
    points. Since the crankshaft starts to tum before the
    • Defective Gauge 011 pump begins to circulate 011, "dry" starts result in
    bearing damage, and accelerated wear rate. Disre-
    • Oil Level in Crankcase Too Low garding this information could result in product
    damage and/or personal injury.
    • Oil Filter Element Plugged
    The function of the prelube system is to purge the
    • Oil Strainer Plugged lubrication system of air and to ensure that all moving
    parts are properly lubricated before the engine is started.
    • Oil Viscosity Incorrect

    • Broken or Weak Spring in Pressure Regulating Valve A


    I ..
    CAUTION Ilf high pressure gas is
    used to drive the air/gas
    • Pressure Regulating Valve Needs Adjustment prelube pump motor, be sure to vent the motor
    exhaust outside If the engine is indoors. Disregard-
    • Engine Bearings Worn ing this information couid result in product damage
    and/or personal injury.
    • Oil Pump or Drive Damaged
    1. An air/gas driven prelube pump motor is standard in
    • Oil Pump or Filters Leak continuous duty applications where high pressure air or
    gas is available. To prelube the engine, hold down the
    LUBE OIL PRESSURE ADJUSTMENT prelube pushbutton on the instrument panel for a full 30
    seconds before each engine start. Additional prelubing
    1. Run the engine until the lube oil reaches normal
    is required if a positive indication is not seen on the
    stabilized operating temperature. Take note of the oil
    panel mounted oil pressure gauge. )
    header pressure as indicated by the panel mounted oil
    pressure gauge. 2. In stand-by applications, the prelube pump is driven
    by an electric motor, usually for the purpose of remote
    2. Locate the pressure regulating valve at the oil cooler
    starting. Run the prelube system continuously when the
    outlet (see Figure 5.30-16). Loosen and back off the jam
    engine is not running. Continuous prelubing may also
    nut (1/2 inch) on the adjusting screw.
    be required in cold weather applications where oil
    3. Adjust the pressure regulating valve to maintain an heating elements are used.
    oil header pressure of 55 ±5 psi (380 ±34 kPa) with the
    3. In intermittent and peak shaving applications, the
    lube oil pressure stabilized at normal operating temper-
    prelube pump is driven by an electric motor run
    ature and the engine fully loaded, as indicated by the
    intermittently. A timing device is used to automatically
    panel mounted oil pressure gauge. Turn the adjusting
    start and stop the prelube motor. Set the timer to
    screw in to increase the oil pressure. To decrease the oil
    activate the prelube system for a full 5 minutes every
    pressure, turn the adjusting screw out.
    hour that the engine is not running.
    4. Tighten the jam nut (1/2 inch) to lock the setting of the
    adjusting screw.

    5.30 - 24 FORM 6248 First Edition


    LUBRICATION SYSTEM

    PRELUBE PRESSURE MAINTENANCE Check the prelube oil pressure annually. Proceed as
    follows:
    Care must be taken to avoid excessive oiling during
    continuous or intermittent prelube. The main cause of 1. The scale range of the panel mounted oil pressure
    excessive prelube is sustained high oil pressure. gauge (0 - 100 psi, graduated in 10 psi increments)
    When the prelube oil pressure is within specification, makes it inadequate for low pressure measurements.
    1 - 3 psi (7 - 21 kPa), a check valve in the turbo oil Remove the oil header plug closest to the turbocharger
    supply line prevents too much oil flowtothe turbochar- oil supply line and temporarily install a gauge of greater
    gers. A check valve mounted at the rocker arm oil sensitivity (0 - 15 psi, graduated in 0.5 psi increments).
    header inlet performs the same function for the rocker
    2. Activate the prelube pump. Read the oil pressure
    arm assemblies. When the engine oil pressure
    gauge with the oil at room temperature.
    reaches 5 psi (35 kPa) at startup, the check valves
    open and the flow of oil is enabled. 3. If necessary, adjust the prelube pressure regulating
    NOTE: The check valves also prevent the oil in the valve to obtain an oil pressure of 1 - 3 psi (7 - 21 kPa).
    turbo oil supply line and rocker arm oil header from Proceed as follows:
    draining back into the oil pan when the engine is shut A. Remove the cap from the prelube oil pressure
    down. This ensures quick lubrication of the turbochar- regulating valve (see Figure 5.30-22).
    gers, rocker arm assemblies and valves when the
    engine is started.
    PRELUBE PRESSURE
    ....J.-- ADJUSTING SCREW CAP
    A WARNING
    TT
    If the prelube oil pressu re reaches or exceeds 5 psi
    (35 kPa) during continuous or intermittent prelube,
    OIL
    oil flows through the supply line check valve into
    FILLER
    the turbocharger housings. Startup of the engine - f
    may blow accumulated oil into the intake manifold 11 II /PIPE

    and carburetor resulting In oily deposits that gum 'r- \ P.


    up internal surfaces. On the turbine side, 011 leakage OIL INLET

    ~
    around the turbine housing poses a potential fire
    hazard. Disregarding this information could result
    in severe personal injury or death.

    I
    A CAUTION Excessive oiling of ~he
    .i-\j OIL OUTLET

    I
    L.=
    .='---':...:....:...::.....;;..;;.,.:;:,..,:~.
    .
    can cause 011 to leak past the valve stem seals
    rocker arm assemblies
    TO OIL PAN

    resulting in the formation of carbon deposits in the Figure 5.30-22. Prelube 011 Pressure Relief Valve
    combustion chamber. A buildup of oily deposits on
    the valve guides and stems can lead to stuck B. Loosen and back oft the hex jam nut on the
    valves. Disregarding this information could resuh adjusting screw.
    in product damage and/or personal InJury.
    C. Turn the adjusting screw in to increase the oil
    An adjustable valve on the rear left side of the engine pressure. Turn the screw out to decrease it.
    regulates prelube oil pressure. External piping connects
    the discharge side of the prelube pump to the pressure D. When the correct oil pressure is obtained, tighten
    regulating valve. The valve opens when the oil pressure the hex jam nut to lock the setting of the adjusting
    exceeds the setting of the relief valve spring. Excess oil screw. Thread on the pressure regulating valve cap.
    passes into the oil filler pipe where it flows back to the oil 4. Remove the oil pressure gauge and reinstall the oil
    pan. header plug. Engine oil pressures after startup will result
    NOTE: With the air/gas prelube system, prelube is in permanent damage to the gauge.
    accomplished by manually depressing the panel
    mounted pushbutton valve. The engine prelube stops
    when the pushbutton is released (usually after a period of
    30 seconds). Since it is only the "sustained" high prelube
    pressure that poses the potential safety hazard, the
    prelube pressure relief/regulating valve is not provided.

    FORM 6248 First Ednion 5.30 - 25


    LUBRICATION SYSTEM

    CHECK VALVE INSPECTION 4. Fasten the upper oil drain tubes to the bottom flange
    of the turbo center housing with two allen head )
    Periodically inspect the operation of the check valves.
    capscrews and lock washers.
    Proceed as follows:
    Rocker Arm Oil Supply{Turbo 011 Drain Tubes, IN-LINE LUBRICATOR
    Removal For Check Valve Inspection The in-line lubricator injects oil into a stream of
    compressed air/gas to automatically provide the proper
    Rocker Arm
    internal lubrication for the vanes of the air/gas operated
    1. Holding the hex on the body of the male connector prelube pump motor (see Figure 5.30-23).
    tube fitting, unthread the ferrule nut (9/16 inch hex) to
    remove the rocker arm oil supply tube from the selected MOUNTING........
    cylinder head. BRACKET ....
    IN-LINE
    2. Position a receptacle to catch the oil in the event that PRELUBE , LUBRICATOR
    the check valve is defective. PUM\
    ~--4IL,
    Turbocharger
    1. Remove the two allen head capscrews (3/B x 1 inch,
    with lock washers) from the oil drain tube flange at the
    AIR/GAS VENT
    bottom of the turbo center housing. (CUSTOMER
    CONNECTION)
    2. Unthread the ferrule nut (union tube fitting) to
    remove the upper section of the turbo oil drain tube.

    3. Position a funnel between the turbo oil drain hole and


    the free end of the lower turbo oil drain tube. Figure 5.30-23. Prelube Motor/Pump Assembly

    Prelube )
    1. Activate the prelube system. IA CAUTION I The lubricator is In-
    ==-';:::':"':';:::'''':''';:'''=:''':''::..J. tended for systems us-
    1...

    ing dry, clean natural gas. Any appreciable amount


    2. Look for evidence of oil flow at the turbo and rocker
    arm oil supply areas. of hydrogen sulfide (H2S), particularly when com-
    bined with moisture, will cause corrosion and
    3. Deactivate the prelube system. adversely effect the lubricator and its operation.
    Disregarding this information could result In prod-
    4. Replace the check valves if oil flow was observed. uct damage and/or personal injury.
    Repeat the test to verify operation.

    Rocker Arm Oil Supply{Turbo Oil Drain Tube,


    Installation After Check Valve Inspection
    IA
    ..
    CAUTION I The maximum operating
    temperature of the lubri-
    cator Is 175' F (79' C). Disregarding this information
    Rocker Arm could result In product damage and/or personal
    1. Holding the hex on the body of the male connector, injury.
    tighten the ferrule nut (9/16 inch hex).

    Turbocharger IA CAUTION I
    L..
    From the .polnt of use,
    ==-...::.......;;...;;.....::...;:....::...::...;~.
    some 011 mist may escape
    1. Apply 3M Scotch-Grip ~ Rubber and Gasket Adhe- Into the surrounding atmosphere. Users are referred
    sive 847 to the flange of the upper turbo oil drain tube. to OSHA safety and health standards for limiting 011
    mist contamination and use of protecting equipment.
    2. Place a new gasket on the contact cement. Allow the Disregarding this Information could result in prod-
    gasket shellac to cure. See the manufacturer's recom- uct damage and/or personal injury.
    mendations.

    3. TIghten the ferrule nut (union tube fitting) to join the


    upper and lower sections of the turbo oil drain tube.

    5.30 - 26 FORM 6248 First Ednion


    LUBRICATION SYSTEM

    011 Fill 2. Pull the lock ring on the adjusting screw upward to
    Check the level of the in-line lubricator daily. The oil level release the drip rate setting.
    must always be visible in the sight glass. Refill as follows:
    3. Adjust the drip rate only when there is a constant rate
    1. With the inlet pressure shut off, slowly loosen the oil of air/gas flow through the lubricator. Oil drops are
    fill plug in the lubricator housing cover (see atomized by the air/gas flowing through the lubricator
    Figure 5.30-24). Loosening the plug exposes a bleed throat. Monitor the drip rate through the sight feed
    orifice that reduces pressure in the oil reservoir. dome. All of the drops visible in the dome are delivered
    to the prelube pump motor.
    OILER ADJUSTING
    I 4. Adjust the lubricator to provide a light oil vapor at the

    o
    SCREW
    prelube motor exhaust (about 4 to 5 drops per minute).
    Turn the adjusting screw clockwise to decrease the drip
    SIGHT FEED DOME
    AIR/GAS L,. .,..J / rate, turn the screw counterclockwise to increase it.
    OUTLET ,...J!I IL, / ' FILL PLUG
    rrTI AIR/GAS 5. Push the lock ring on the adjusting screw downward
    f-- f-- / INLET to lock the drip rate setting.
    \
    6. Monitor the prelube pump motor for a few days
    following the adjustment. Readjust the drip rate if
    necessary.

    Cleaning
    BOZ.

    RESE~ m r Clean the in-line lubricator monthly.


    m\...---1 RESERVOIR LEVEL
    SIGHT GLASS 1. With the inlet pressure shut off, slowly loosen the oil
    fill plug in the lubricator housing cover. Loosening the
    plug exposes a bleed orifice that reduces pressure in
    ) the oil reservoir. Remove the oil fill plug.
    DRAIN PLUG
    ~'- 2. Remove the drain plug althe bottom of the reservoir.
    Drain the oil.
    Figure 5.30-24_ In-Line Lubricator
    3. Unthread the reservoir from the lubricator housing
    cover.
    A. CAUTION Ilnsuret~attheoi~leVel?f
    IL• .:
    . =:....:=....:;,;~:.;;.=:....:..J.
    . the In-Line Lubricator IS 4. Inspect the O-ring on the upper lip of the reservoir for
    always visible in the sight glass. DO NOT OVERFILL tears, cuts or general deterioration. Replace as necessary.
    the reservoir. Failure to follow proper procedures
    could result in product damage and/or personal
    Injury. A WARNING
    Compressed air can pierce the skin and cause
    2. Remove the plug and fill the reservoir to the proper severe injury. Never use your hand to check for leaks
    level. DO NOT OVERFILL. The oil level must always be or to determine air flow rates. Wear safety glasses to
    visible in the sight glass. Use the proper grade of oil. Add shield your eyes from flying dirt and debris. Disre-
    SAE 1OW oil at 32° F (0° C) and above. Use No.2 Diesel garding this information could result in severe
    Oil when ambient temperatures fall below 32° F (0° C). personsllnjury or death.

    3. Inspect the O-ring on the neck of the oil fill plug for tears, 5. Clean the reservoir using soap and water. Dry parts
    cuts or general deterioration. Replace as necessary. and blowout internal body passages using clean, dry
    compressed air.
    4. Install the plug in the lubricator housing cover.
    6. Inspect all parts carefully. Replace any parts that
    Adjustments appear damaged.
    Periodically check the lubricator drip rate. If the prelube
    pump motor exhaust is oil-free or contains an excessive 7. Install the reservoir onto the lubricator housing cover
    amount of oil, manual adjustment is necessary. and fully tighten the reservoir until it stops (approximate-
    ly 5 turns). Unscrew the reservoir no more than one full
    1. Locate the oiler adjusti ng screw althe top olthe sight turn to position the sight glass for best visibility.
    feed dome on the lubricator housing cover.

    FORM 6248 First Ed~ion 5.30 - 'Z1


    LUBRICATION SYSTEM

    8. Inspect the O-ring on the neck of the oil fill plug for OIL PICKUP SCREEN
    tears, cuts or general deterioration. Replace as neces- )
    sary. Install the plug in the lubricator housing cover. OIL PICKUP SCREEN REMOVAL

    9. Apply install the drain plug at the bottom of the 1. Remove the four capscrews and lock washers to
    lubricator reservoir. detach the pickup screen assembly from the two oil
    elbows (see Figure 5.30-25).
    10. Fill the lubricator reservoir with the proper grade
    and amount of oil (See Oil Fill).

    11. Periodically check the drip rate. Readjust if neces-


    sary (see Adjustments).

    OIL PAN CLEAN AND INSPECT


    NOTE: Since it is necessary to drain the oil pan and
    lube oil system accessories, schedule the cleaning
    during a regular oil change inteNal.

    NOTE: Drain oil when warm.

    1. Drain the oil pan, oil cooler, full-flow oil filter and lube
    oil strainer (see Lube Oil Change for more information).

    2. Loosen the oil pan door clamp capscrews. A roll pin


    holds each door clamp in position. Rotate the assembly
    about 45 degrees to remove the door from the access
    hole.

    3. A small pool of oil about 3/4 inch deep will normally )


    accumulate on each end olthe oil pan where the casting
    is recessed. Only a thin film will cover the other internal
    surfaces. Using absorbant cloths, wipe the oil pan
    clean. Thoroughly clean the channel that connects the
    two recessed areas.

    4. Clean the oil pickup screen (see Oil Pickup Screen


    below).

    5. Install the oil pan doors. Hold each door so that the
    rear clamp is 45 degrees from the vertical position.
    Insert the clamp into the oil pan access hole. Holding the
    door against the face of the access hole, rotate the door
    until the clamp is in the horizontal position. TIghten the
    door clamp capscrew.

    6. Refill the engine with the proper quantity and grade


    of lubrication oil. Figure 5.30-25. 011 Pickup Screen Assembly -
    12 Cylinder

    2. Remove the pickup screen assembly from the oil


    pan.

    3. Remove the baffle and oil tubes from the pickup


    screen.

    4. Scrape the old gasket material from the oil tube


    flanges and baffle box. Old gasket material left on the
    mating surfaces may cause air or unfiltered oil to leak
    into the oil tubes.

    5.30 - 28 FORM 6248 First Edition


    LUBRICATION SYSTEM

    OIL PICKUP SCREEN CLEANING AND LUBE OIL PUMP


    INSPECTION
    LUBE OIL PUMP REMOVAL
    1. Clean all parts of the assembly in a non-volatile
    cleaning solution or solvent. Flush the screen from the 1. Disconnect all oil lines.
    inside out for best results.
    2. Attach a suitable lifting device to the oil pump.

    A WARNING A WARNING
    Compressed air can pierce the skin and cause
    severe injury. Never use your hand to check for leaks The oil pump weighs approximately 1231bs. (56 kg).
    or to determine air flow rates. Wear safety glasses to Use a suitable lifting device and exercise caution
    shield your eyes from flying dirt and debris. Disre- during removal or Installation to avoid severe
    garding this Information could resuh in severe personal injury or death.
    personal injury or death. 3. Remove ten stud nuts and using a suitable lifting
    device, remove the oil pump from the oil pan (see
    2. Thoroughly dry all parts with low pressure com-
    Figure 5.30-26).
    pressed air.

    3. Inspect the pickup screen for tears or holes. Replace


    the screen if damaged.

    4. Inspect the baffle box for broken welds, split seams


    or cracks around the oil tu be holes. Replace the baffle if
    damaged.

    OIL PICKUP SCREEN INSTALLATION


    1. Apply a fast setting gasket adhesive, such as 3M
    Scotch-Grip Rubber and Gasket Adhesive, on the oil
    N

    tube flanges. Position new gaskets on the flanges.

    2. Scrape the old gasket material from the oil tube


    flanges and baffle box. Old gasket material Iefl on the
    mating surfaces may cause air or unfiltered oil to leak
    into the oil tubes.

    3. Install the oil tubes in the screening element. Place


    the baffle over the screen aligning the holes with those
    in the flange gaskets. Figure 5.30-26. Fastening Flange Adapter

    4. Obtain two new gaskets for the elbows and apply


    gasket adhesive to one side. Press the sticky side of the 4. Remove and discard the gasket from the rear of the
    gasket onto the baffle aligning the holes with those in the oil pump.
    box. LUBE OIL PUMP DISASSEMBLY
    5. Verify that the two elbow flanges are clean. Old NOTE: Note the location and tag gears before removal.
    gasket material or adhesive left on the mating surfaces Instal/ serviceable gears in the same running position.
    may cause air or unfiltered oil to leak into the elbows.
    NOTE: The new lube oil pump manifold replaces the
    6. To ensure proper alignment, install the four caps- multiple prelube oil pump connections seen on earlier
    crews and lock washers to hold the pickup screen production engines (check valves, 4-way fitting, flex
    assembly together. After the unit is positioned in the oil connectors, oil tube, adapter flange and assorted pipe
    pan, remove one capscrew. Slide the capscrew through nipples and elbows). Use of the new manifold requires
    the elbow and thread it back into the pickup screen the new style lube oil pump. Since the old style pump
    assembly. Follow this procedure with the remaining has been discontinued, service kits have been made
    ) three capscrews. Wrench tighten only after all caps- available to facilitate the conversion.
    crews are in place.
    1. Remove four capscrews, lock washers and the oil
    pump manifold from the oil pump (see Figure 5.30-26).

    FORM 6248 First Edition 5.30 - 29


    LUBRICATION SYSTEM

    2. Remove the gaskets from the oil pump manifold


    flanges. DRIVE GEARS )

    3. Remove check valve, O-ring, and wave spring from


    the oil pump manifold (see Figure 5.30-27). Discard the
    O-ring.

    Figure 5.30-29. Drive Gears

    8. Remove fourteen capscrews, lock washers, front


    cover, and gasket from the oil pump body (see
    Figure 5.30-30).

    Figure 5.30-27. Lube Oil Pump Manifold Check Valve

    A WARNING
    ~
    0': V ,
    FRONT COVER
    PUMP BODY

    Always wear proper eye protection when removing


    or installing the spring. Slippage may propel the
    spring with enough force to cause severe personal )
    injury or death.
    4. Remove lock nut and washer from the relief valve
    assembly (see Figure 5.30-28).

    Figure 5.30-30. 011 Pump Cover Front Cover

    9. Remove the two oil pump driven gears from the oil
    pump body.
    10. Remove the two oil pump idler gears and shafts
    from the oil pump body (see Figure 5.30-31).

    Figure 5.30·28. Relief Valve

    5. Disassemble the relief valve sleeve screw, spring,


    plunger and sleeve of the relief valve.

    6. Remove the roll pins from the drive gears.

    7. Using a gear puller, remove the drive gears and


    woodruff keys from the shafts of the oil pump driven
    gears (Figure 5.30-29).

    Figure 5.30-31. Oil Pump Internal Gears

    5.30 - 30 FORM 6248 First Ed~ion


    LUBRICATION SYSTEM

    11. Remove two capscrews, lock washers, gasket and NOTE: There is approximately 1/8 in. (3.175 mm)
    cover plate from the oil pump body. clearance be1ween the bottom of the oil pump cover
    bushings and the bottom of the bushing bores. A slide
    12. Remove the countersunk pipe plugs from the oil hammer and blind hole bearing puller should be used to
    pump body. remove the bushings from the oil pump cover.

    I A. CAUTION IWhenever a new 011


    15. If required, remove the bushings from the oil pump
    front cover (see Figure 5.30-33).
    .. pump body and/or body
    bushings are installed, such as In a new or rebuilt oil
    pump, use ofthe old dowel pin locations may result
    in improper 011 pump idler to drive gear backlash.
    Disregarding this information could result In prod-
    uct damage and/or personal inlury.
    13. Remove the two oil pump locating dowels from the
    mounting flange at the front ofthe oil pan, if still in place.

    CAUTION IRepl~cing
    I-=.A.=:......;=....;:.;:;;....;;...;;..=~.
    the oil pump
    L. . bushings is a complex
    operation that requires precision machining. Do not
    remove the oil pump bushings unless during the
    inspection procedure, It Is determined that the
    bushings must be removed. Disregarding this
    information could result in product damage and/or
    personal Injury. Figure 5.30-33. Pump Cover Bushings

    NOTE: The bushings in the oil pump body are closest


    to the oil pump drive gears. It is possible that these A. . CAUTION I
    bushings could wear out before the cover bushings will
    need replacement. In this case, only the oil pump body
    I'!!!"~-=:':":'=:"":"':"=:":";:..J.
    L.
    Previous engine 011
    pumps had a I u be 011
    hole in the bushing. The hole In the bushing must
    bushings will need to be replaced. lineup with the lubrication hole in the casting.
    Failure to do so will cause a lack of lubrication and
    NOTE: The bushings in the oil pump body are pressed
    seizure of the shaft and bushing will occur. Disre-
    out in a manner similar to the valve guides in the cylinder
    garding this information could result In product
    head. The bushing driver should have a shoulder to
    damage and/or personallnlury.
    catch the bushing, but not gall the bore of the pump
    body. The new bushing is installed using the same tool.
    LUBE OIL PUMP CLEANING AND INSPECTION
    14. If required, press out the bushings from the oil 1. Visually inspect the gears for severe wear patterns,
    pump body (see Figure 5.30-32). broken, chipped, or galled teeth. Damaged gears
    should be replaced.

    2. Inspect the condition of the pump gear, housing and


    cover faces. These must be smooth and flat. Wear or
    damage on any of these surfaces will impair oil pump
    output and is cause for rebuilding with new parts.

    3. Check oil pumping gear backlash. Accuracy of


    readings is dependent on good shafts and bushings. If
    bushings or shafts are to be replaced, then check
    backlash only after new shafts and/or bushings are
    installed and machined. The gears must be slipped
    back into the pump body for this check.

    !
    I 4. Inspect pump shafts for annular scoring, galling or
    Figure 5.30-32. Pump Body Bushings bends. Replace shafts with any of these conditions.

    FORM 6248 First Ed~ion 5.30 - 31


    LUBRICATION SYSTEM

    5. Measure shafts outer diameters at several locations NOTE: The oil pump bushings are not only machined to
    along their lengths, and at 90 degrees of each measured precise size for correct shaft running clearance, but the
    location. Shafts worn beyond tolerance must be replaced. bushings must be centered within the pumping gear
    chamber. A vertical mill, or any piece of machine shop
    NOTE: Radial clearance cannot be measured accu- equipment that can produce similar work is necessary to
    rately unless the bushings, gears, and shafts are in machine these bushings.
    good condition.

    6. Measure radial clearance between pumping gear


    IA CAUTION I~revlous engine oil
    teeth and the pump chamber wall (see Table 5.30-17). L.
    • .:: .. pumps had a lube 011
    .=....;::...:....=;...:...:....;:::....;;..;..1.
    Clearances may be checked with feeler gauges. hole in the bushing. This hole must line up with the
    lubrication hole in the casting. failure to do so will
    7. Inspect the pump cover for warpage by placing a cause lack of lubrication and seizure of the shaft
    straight edge over the interior flat surface. A measure- and bushing will occur. Disregarding this Informa-
    ment may be taken by placing a feeler gauge in any gap tion could result in product damage and/or person-
    that is noted. Maximum allowable warpage is 0.002 in. al injury.
    (0.05t mm).
    1. If removed, press in new bushings in the oil pump
    8. Inspect the pump cover for undue wear or score body.
    marks.
    2. If removed, press new bushings in the oil pump front
    9. Inspect the flat machined surfaces on the suction side of cover.
    the pump (mating surface to the engine). These surfaces
    must be kept flat to insure proper gasket sealing and to NOTE: The proper position for bushing machining is
    prevent the pump from sucking air. This can be checked the center line of the pumping gear bore. Find this
    with a straight edge. Dress down any raised surfaces. location by making three measurements off the pump-
    ing gear chamber wal/.
    10. Inspect bushings for annular scoring, out-of round-
    ness, taper and excessive wear. Bushing 10 should be 3. Position the pump body (with the replacement )
    measured with a dial bore gauge. In the absence of a bushings already installed) onto the mill. The bushing
    dial bore gauge, a telescopic gauge and a micrometer bores must be concentric to the pump body gear bore to
    may be used. Measuring the bushings with straight within 0.0015 in. (0.0381 mm) TIR. The pump must be
    pilots is impractical, since a round pilot will not measure leveled and positioned.
    an oblong hole with accuracy. Severe annular scoring
    can be felt, and should be obvious. If new shafts are 4. Once the pump body is positioned, the bushings may
    being installed, the bushings should also be changed. be bored. A boring unit, or "fly cutter" is needed. The
    vernier micrometer precision boring unit (see
    Figure 5.30-34) works well and allows for versatility.
    A WARNING The insert cutting tool must be of a design to produce a
    Compressed air can pierce the skin and cause smooth micro finish.
    severe personal Injury or death. Never use your
    hand to check for leaks or to determine air flow
    rates. Wear safety glasses to shield your eyes from /PUMPBODY
    flying dirt and debris.

    11. Wash all parts prior to assembly. Blow dry with


    compressed air. Inspect that all oil passages are clear of
    foreign material.

    LUBE OIL PUMP ASSEMBLY

    IA
    ...
    CAUTION I DO NOT ream 011 pump
    bushings. The reamer
    will follow the original bushing hole. These bushings
    must be machined. Normally it will be necessary to
    machine the bushing bore Slightly off to one side.
    This will maintain bushing center line tolerances. Figure 5.30-34. Adjustable Boring Tool
    Disregarding this information could result in prod-
    uct damage and/or personal injury.

    5.30 - 32 FORM 6248 First Edition


    LUBRICATION SYSTEM

    NOTE: The most expedient method of machining the NOTE: Drive gear, PIN 200251 C is installed on the left
    oil pump cover bushings, is with the cover installed on side (facing the engine front, nearest the relief valve,
    the pump body. Be certain the dowel pins are in place see Table 5.30-17) and will mesh with the oil pump idler
    Install and tighten all cover-to-body mounting bolts. gear once the pump is installed on the engine. Drive
    gear PIN 200351A is installed on the right side (facing
    5. Mount the pump on the mill to allow entry through the the engine front, nearest the flat side of the pump with
    finished bores ofthe pump body bushings. By using the the two large pipe plugs) this gear does NOT mesh with
    body bushings as a guide, blind cover bushings may be the oil pump idler gear once the engine is installed (see
    machined with perfect alignment. Table 5.30-17).
    NOTE: Driver gears are supplied only as shaft and gear NOTE: Use a feeler gauge while installing the two drive
    assemblies. Idler gears have two bushings, one gears on the shafts. Hub clearance with pump body
    pressed flush with each gear face (see Figure 5.30-35). must be 0.022 - 0.040 in. (0.559 - 1.016 mm).
    The bushings installed in idler gears must be machined
    to size, however the bushings in new replacement idler
    gears are machined at the factory. Machining the
    bushings non-concentrically to the pitch diameter will
    cause the teeth to bind within the pump.

    LUBE OIL PASSAGE",

    II
    BUSHIN, II

    _~ro'~
    MUST BE CONCENTRIC
    WITH PITCH DIAMETER
    J
    Figure 5.30-35. Idler Gear

    NOTE: Prelube gears, shafts, and bushings with SAE


    40 motor oil.

    6. Install the oil pump driven gears in the pump body.

    NOTE: The oil pump idler gear shafts have a tapered


    end. The tapered end is installed into the oil pump body.

    7. Press the oil pump idler gear shafts into the oil pump
    body.
    Figure 5.30-36. Woodruff Keys
    8. Install the woodruff keys on the driven gear shafts
    (see Figure 5.30-36). 9. Install the PIN 200251 C drive gear on the left side
    (facing the engine front, nearest the relief valve) on the

    I.A. . CAUTION IThe drive gears must be


    installed In the correct
    driven gear shaft until the proper hub clearance with the
    pump body is obtained (see Figure 5.30-37 and
    Table 5.30-17).
    position. Failure to install the drive gears In the
    correct position will cause damage to product
    and/or personal Injury.

    FORM 6248 Firs! Ednion 5.30-33


    LUBRICATION SYSTEM

    10. Align 1I1e gear 1eeIh, and press 1I1e PIN 200351A drive
    gear on 1I1e right side (facing 1he engine front, nearest 1I1e )
    flat side of 1I1e pump with 1I1e two large pipe plugs) driven
    gear shaft until 1he proper hub clearance with 1I1e pump 07 03 Os 10 0
    body is obtained (see Figure 5.30-37 and Table 5.30-17).
    0 11 01 14 0

    0 13 O2 12 0
    gO 50 08

    Figure 5.30-39. 011 Pump Cover Torque Sequence

    A WARNING
    Always wear proper eye protection when removing
    or installing the spring. Slippage may propel the
    spring with enough force to cause severe personal
    Figure 5.30-37. Checking Clearance
    injury or death_
    11. Install roll pins in the drive gears.
    18. Install the sleeve, plunger and spring in 1I1e oil pump
    12. Install the oil pump idler gears in the pump body. body (see Figure 5.30-40).

    13. Apply an even coat of PermateX® Aviation Form-


    A-Gasket Sealant to gasket surfaces.

    14. Install 1I1e cover plate on the oil pump body with
    )
    gasket, two capscrews and lock washers.

    15. Apply Loctite® 271 to 1I1e 1I1reads of the pipe plugs,


    and install the pipe plugs on 1I1e pump body.

    16. Apply an even coat of Permatex® Aviation Form-


    A-Gasket Sealant to gasket surfaces (see
    Figure 5.30-38).

    Figure 5.30-40. Relief Valve

    19. Screw in the relief valve sleeve screw on the pump


    body approximately 0.50 in. (12.7 mm).

    20. Apply Iwo continuous beads (spaced 180 degrees


    apart) of Loctite® 271 down the exposed threads of the
    relief valve sleeve screw.

    21. Screw the relief valve sleeve screw into 1I1e pump
    body until it bottoms out.

    22. Install1l1e washer and locking nut on 1I1e relief valve


    Figure 5.30-38. Oil Pump Internal Gears sleeve screw and tighten against the oil pump body.

    17. Install the oil pump cover with gasket, fourteen )


    capscrews and lock washers (see Figure 5.30-39).
    Torque the front cover to 26 - 30ft-lb (35 - 41 N·m) in the
    sequence shown.

    5-30-34 FORM 6248 First Edition


    LUBRICATION SYSTEM

    Table 5.30-17. Oil Pump And Oil Pump Drive Gears

    1 - CAMGEAR
    2 - CAM IDLER GEAR
    3 - CRANK GEAR
    4 - OIL PUMP IDLER GEAR
    5 - ACCESSORY IDLER GEAR
    6 - ACCESSORY (MAGNETO) DRIVE GEAR
    7 - OIL PUMP ORNE GEAR PIN 200251 C
    8 - OIL PUMP DRIVE GEAR PIN 200351 A

    MEASUREMENT INCHES METRIC (mm)


    Idler gear between crankshaft gear and oil pump drive gear
    (A) Backlash with crankshaft gear
    Normal to tooth 0.008 - 0.012 0.203 - 0.305
    In plane of rotation 0.0082 - 0.0122 0.2083 - 0.3099
    (8) Backlash with oil pump drive gear
    Normal to tooth 0.Q15 - 0.020 0.381 - 0.508
    In plane of rotation 0.0153 - 0.0204 0.3886 - 0.5182
    (C) End play (including clamp load compression of spindle) 0.008 - 0.025 0.203 - 0.635
    (0) Bushing inside diameter (machined in assembly) 1 .5005 - 1.5015 38.1127 - 38.1381
    (E) Idler spindle (hollow) outside diameter (free state)" 1.4965 - 1.4970 38.0111 - 38.0238
    (F) Running clearance between spindle (free state) and bushing* 0.0038 - 0.005* 0.0899 - 0.127*
    Oil pump drive gears
    (G) Backlash between external oil pump drive gears
    Backlash, normal to tooth 0.008 - 0.010 0.203 - 0.254
    Backlash in plane of rotation 0.0082 - 0.010 0.2083 - 0.254
    (Continued)

    I
    I

    FORM 6249 First EdHion 5.30 - 38


    LUBRICATION SYSTEM

    MEASUREMENT
    Oil Pump Clearances
    (H) Hub clearance with oil pump body
    Drive shaft bushing inside diameter
    (0 In body
    (I') In cover
    Drive shaft diameter
    (J) Body section
    (J) Cover section
    Running clearance between shaft and bushing
    (K) In cover
    (K') In body
    Oil pump pumping gears
    (L) Backlash between pumping gears
    Backlash nonma! to tooth 0.Q15 - 0.020 0.381 - 0.508
    Backlash in plane of rotation 0.Q16 - 0.021 0.406 - 0.533
    (M) End play 0.005 (minimum) 0.127 (minimum)
    (N) Pumping gear (idler) bushing inside diameter 1.0005 - 1.0015 25.4127 - 25.4381
    (0) Pumping gear (idler) shaft diameter 0.9980 - 0.9985 25.3492 - 25.3619
    (P) Pumping gear (idler) running clearance 0.002 - 0.0035 0.051 - 0.0889
    (Q) Radial clearance between outside diameter of pumping gears and oil pump
    body bores
    0.002 - 0.008 0.051 - 0.203

    • Outside diameter will be slightly larger and running clearance will be slightly smaller, because of idler spindle capscrew clamp load.

    5.30 - 36 FORM 6248 First Edition


    LUBRICATION SYSTEM

    LUBE OIL PUMP INSTALLATION 6. Position a new gasket on the mounting studs with the
    dowel pin hole centered on the edge of the gasket facing
    IA
    ..
    CAUTION I Whenever a new oil
    pump body and/or body
    upward (see Figure 5.30-42).

    bushings are installed, such as in a new or rebuih oil I- DOWEL PIN HOLE
    pump, use ofthe old dowel pin locations may resuh
    In Improper 011 pump Idler to drive gear backlash.
    Disregarding this Information could result in prod-
    '---0--0 0 0 0
    uct damage and/or personal injury.
    o
    1. Install the two oil pump locating dowels on the
    mounting flange at the front of the oil pan.

    2. Check the ten oil pump mounting studs for nicks,


    cracks, galled or stretched threads and other obvious o o
    damage. Replace as necessary.

    3. Each oil pump mounting stud has fine and coarse Figure 5.30-42. Oil Pump Gasket
    threads separated by a smooth center boss (see
    Figure 5.30-41). Apply Loctite® Removable Thread-
    7. Attach a suitable lifting device to the oil pump.
    locker 242 to the first three threads on the coarsely
    threaded side.
    A WARNING
    The 011 pump weighs approximately 1231bs. (56 kg).
    COARSE CENTER FINE Use a suitable lifting device and exercise caution
    lliREADS BOSS lliREADS during removal or installation to avoid severe
    ) \ I I personal Injury or death.

    8. Using a suitable lifting device, install the oil pump on


    I the mounting studs. Start the fasteners on the studs
    (1/2 inch hex nuts with lock washers).

    \
    TAPERED END ........... OILPAN
    /
    ROUNDED
    9. Snug, but do not tighten, the center fasteners on
    each side of the pump (studs 1 and 2) (see
    END
    Figure 5.30-43). The fasteners must be loose enough to
    allow the pump to be moved several thousandths of an
    Figure 5.30-41. Oil Pump Mounting Stud
    inch, but tight enough to prevent slippage.

    -A CAUTION I~o not !nstal~ 011 pump


    I..
    ==......;;=..:...::.....;;....:...c::....:~.
    L... studs with a pipe wrench
    or similar device. Use a collet style stud driver to
    Install studs. Disregarding this information could
    result In product damage and/or personal injury. 0
    1
    4. Using a collet type stud driver, install the studs in the
    oil pan oil pump mounting flange until a single coarse
    thread is exposed (see Figure 5.30-41). 8
    o 0
    I.. CAUTION I
    =A='--':.....'--''--_''-~.
    L...
    Deposits left .on gasket
    surfaces Will cause
    Figure 5.30-43. 011 Pump TIghtening Pattem
    leaks. Disregarding this information could result in
    product damage and/or personal injury.
    )
    5. Verify that all gaskets and gasket mating surfaces
    are clean and completely free of grease and oil.

    FORM 6248 First Ed~ion 5.30 -37


    LUBRICATION SYSTEM

    10. Position the magnetic base of a dial indicator on top If the backlash is too great, push down on the punch to
    of the oil pickup screen baffle inside the oil pan. Position move the pump down slightly. If the lash is too small, pull )
    the instrument toward the oil pump drive gear on the up on the punch to move the pump up slightly. Repeat as
    right bank side. Place the indicator point against the necessary until the backlash is within specification.
    inside face of any drive gear tooth (see Figure 5.30-44).
    17. Tighten the center fasteners on each side of the
    / OIL PUMP IDLER GEAR
    pump (studs 1 and 2). Snug the four corner fasteners
    (studs 3 thru 6).
    INDICATOR
    TUBE 18. Recheck the backlash. If the backlash is not within
    specification, loosen the fasteners and return to step 7.

    19. Back off the point of the dial indicator, rotate the oil
    pump drive gear 180 degrees and recheck the back-
    lash. If not within specification, loosen the fasteners and
    return to step 7.
    PICK-UP
    SCREEN 20. Tighten the four corner fasteners (studs 3 thru 6).
    BAFFLE Tighten the four inside fasteners (studs 7 thru 10).
    TUBE
    IDLER GEAR
    21. Recheck the backlash to be sure that the pump did not
    Figure 5.30-44. Measuring Oil Pump Drive Gear move when the remaining fasteners were tightened.
    Backlash Remove dial indicator if the backlash is within specification.
    11. Secure the oil pump idler gear (in the front main
    22. Drill and ream both the upper and lower pin holes to
    bearing cap) against movement.
    fit the next larger size dowel.
    12. Turn the oil pump drive gear until contact with the
    23. Install the two dowel pins to lock the oil pump in
    stationary idler gear prevents further movement.
    position. Use a hammer and a blunt tipped center punch
    to ensure that the pins are fully seated in the pan (see
    )
    13. Holding the oil pump drive gear in position, zero the
    dial indicator. Figure 5.30-45).

    14. Turn the oil pump drive gear in the opposite NOTE: The new lube oil pump manifold replaces the
    direction until movement is again halted by contact with multiple prelube oil pump connections seen on earlier
    the stationary oil pump idler gear. prod.Jction engines (check valves, 4-way fitting, flex
    connectors, oil tube, adapter flange and assorted pipe
    15. Take note of the dial indicator reading. Verify that nipples and elbows). Use of the new manifold requires the
    the oil pump drive gear to oil pump idler gear backlash is new style lube oil pump. Since the old style pump has been
    between 0.015 and 0.020 inch (0.381 and 0.508 mm). discontinued, service kits have been made available to
    facilitate the conversion.
    16. If the backlash is not within specification, back off
    the point of the dial indicator and insert a blunt tipped
    center punch in the upper dowel pin hole of the lube oil
    pump (see Figure 5.30-45). Using the tool for leverage,
    move the oil pump in the appropriate direction.

    Figure 5.30-45. Lube Oil Pump

    5.30 - 38 FORM 6248 First Edition


    LUBRICATION SYSTEM

    SHORT DU'_' ,,_ .CHI:CKVAlVE

    ..
    FROM
    PRElUBE
    PUMP
    ..
    TO Oil
    COOLER

    lONG BOLTS /
    []LT<LET FLANGE ADAPTER (SQUARE) INLET PIPE FLANGE (DIAMOND SHAPED)

    Figure 5.30-46. Lube Oil Pump Manifold - Front View


    24. Install a new wave spring in the prelube oil inlet port 32. Install the short bolts with lock washers, into the
    of the oil pump manifold (see Figure 5.30-46 and upper holes of the two manifold flanges. Install the long
    Figure 5.30-47). Be sure that the wave spring is laying bolts with lock washers, in the lower flange holes (see
    flat on the inside counterbore. Figure 5.30-46). In addition to mounting ofthe manifold,
    the longer capscrews thread into the oil pump body and
    serve as part of the oil pump cover assembly. Alternate-
    ly wrench tighten the flange capscrews.

    33. Apply Loctite® Hydraulic Sealant to the threads of


    the two 1/2 inch hex head manifold pipe plugs. Install the
    plugs in the oil pump manifold (leaving about 2 - 3
    threads exposed).

    34. With the part number facing outside, position a new


    gasket against the oil pump manifold outlet flange
    (square). Look althe chamfers on the ID ofthe threaded
    flange adapter. With the larger chamfer facing inward,
    fasten the flange adapter to the manifold outlet flange
    with four capscrews, and lock washers (see
    Figure 5.30-48).
    Figure 5.30-47. lube Oil Pump Manifold Check Valve

    25. Press a finger against the plunger on the inlet side


    of the check valve to verify operation. Replace the check
    valve if damaged or defective.
    26. Apply Parker Super O-Lube® to a new O-ring.
    27. Install a new O-ring on the outlet side of the check
    valve.
    28. Look at the check valve housing. The words "Free
    Flow" within a hollow arrow point out the direction of
    flow. Insert the check valve into the manifold with the
    arrow pointing inward. Slide the check valve down the
    bore until it bottoms out against the inside counterbore.
    29. Apply 3M Scotch Grip ~ Rubber and Gasket
    Adhesive 847 to the two front manifold flanges (dia-
    mond-shaped).
    ) 30. Place new gaskets on the contact cement.
    31. Position the manifold against the oil pump cover
    flanges, the check valve on the Iell bank side. Figure 5.30-48. Fastening Flange Adapter

    FORM 6248 First Ed~ion 5.30 - 39


    LUBRICATION SYSTEM

    PRELUBE Y-STRAINER 9. Apply Perma Loc® heavy duty pipe sealant or the
    equivalent onto the male threads of the plug and the
    PRELUBE V-STRAINER REMOVAL
    female threads of the Y-strainer body.
    1. Remove the prelube Y-strainer from the pipe tee. 10. Thread the plug into the Y-strainer and wrench
    2. Remove the pipe tee from the oil pan. tighten.

    3. Remove the pipe nipple. square head pipe plug and PRELUBE V-STRAINER INSTALLATION
    reducing bushing from the pipe tee.
    1. Apply Perma Lok® Heavy Duty Pipe Sealant with
    PRELUBE V-STRAINER CLEANING AND TefIon® to the threads of the 2 inch pipe tee pipe nipple.
    INSPECTION reducing bushing (2 to 1 inch) and square head pipe plug.
    Clean the Y -strainer screen at each oil change. 2. Thread the pipe tee pipe nipple into the lower front
    Proceed as follows: left corner of the oil pan leaving the reducing bushing
    facing the front of the engine (see Figure 5.30-50).
    1. Drain the oil pan and all lube oil system accessories.
    oil cooler. full-flow oil filter and lube oil strainer.
    2. Locate the Y-strainer in the oil pan to prelube pump
    oil line.
    3. Remove the plug from the Y -strainer (see
    Figure 5.30-49).

    TOPRELUBE
    ¥ PUMP

    )
    STRAINER
    / Figure 5.30-50. Attaching Pipe Tee
    BODY
    3. Apply Perma Lok® Heavy Duty Pipe Sealant with
    Figure 5.30-49. Prelube Y-Strainer Teflon® to the threads of the pipe nipple on the inlet side
    of the prelube Y - strainer.
    4. Pull out the cylindrical steel mesh screen.
    4. Thread the Y -strainer pipe nipple into the pipe tee
    5. Flush the screening element in a non-volatile reducing bushing. Leave the male elbow tube fitting on
    cleaning solution or solvent. the outlet end facing horizontally toward the left bank
    side of the engine (see Figure 5.30-51).
    A WARNING
    Compressed air can pierce the skin and cause
    severe personal InJury or death. Never use your hand
    to check for leaks or to determine air flow rates. Wear
    safety glasses to shield your eyes from flying dirt
    and debris.

    CAUTION I
    I -A,
    ,..
    High pressure com-
    pressed air may damage
    the screening element. Disregarding this informa-
    tion could result in product damage and/or pers
    onallnjury.
    6. Drip dry the screen or use low pressure compressed
    air.
    )
    7. Inspect the screen for tears or holes. Replace if
    damaged.
    8. Slide the screen back into the Y -strainer. Figure 5.30-51. Y-Strainer - Front Left

    5.30 - 40 FORM 6248 First Ed~lon


    LUBRICATION SYSTEM

    REAR FLYWHEEL
    / HOUSING

    OIL FILLER"""--:
    PIPE
    o

    INsmucnoNft~~~~:~--\----
    DECALr \ OIL FILLER PIPE BRACKET

    Figure 5.30-52. VHP 011 Filler Pipe


    OIL FILLER PIPE REMOVAL 5. Install the oil filler pipe bracket on the rear flywheel
    housing with two washers, lock washers and capscrews
    OIL FILLER PIPE REMOVAL (see Figure 5.30-53).
    1. Remove two nuts, washers, lock washers and U-bolt
    from the oil filler pipe bracket (see Figure 5.30-52).

    2. Remove two capscrews, lock washers, washers and


    oil filler pipe bracket from the rear flywheel housing.

    3. Remove the oil filler pipe and cap from the pipe elbow.

    4. Remove the pipe elbow and threaded pipe adapter


    from the pipe tee fitting.

    5. Remove the pipe tee fitting and pipe nipple from the
    oil pan.

    6. Remove two square head pipe plugs from the pipe


    tee fitting.

    7. Remove pipe tee fitting from the pipe nipple.

    OIL FILLER PIPE INSTALLATION


    1. Apply Perma Lok® Heavy Duty Pipe Sealant with
    Teflon® to the threads of the pipe nipple and install the
    pipe nipple on the oil pan. Figure 5.30-53. Oil Filler Pipe!Bracket - Rear Left

    2. Apply Perma Lok) Heavy Duty Pipe Sealant with


    Teflon® to the threads of the square head pipe plugs and 6. Install the oil filler pipe to the oil filler pipe bracket with
    install the plugs on the pipe tee fitting. U-bolt, two washers, lock washers and nuts.

    3. Apply Perma Lok® Heavy Duty Pipe Sealant with


    Teflon® to the threads of the threaded pipe adapter, and
    install the threaded pipe adapter and elbow on the pipe
    tee fitting.

    4. Apply Perma Lok® Heavy Duty Pipe Sealant with


    Teflon® to the threads of the oil filler pipe and install the
    oil filler pipe and cap on the elbow.

    FORM 6248 First Edition 5.30 - 41


    LUBRICATION SYSTEM

    ROCKER ARM OIL HEADER OIL INLET 5. Attach a tube clip to the rear rocker arm oil header oil
    TUBES/FITTINGS supply tube. Secure the clip to the rear right corner of the )
    engine block with capscrew, lock washer, flat washer
    ROCKER ARM OIL HEADER OIL INLET TUBES! and spacer just above the farthest rearward plug in the
    FITTINGS INSTALLATION main oil header (see Figure 5.30-56).
    Rear Right
    1. Inspect the rear rocker arm oil header oil supply tube
    for cracks, cuts, dents, holes or other damage. Inspect
    the male elbow tube fitting for galled or stretched
    threads. If necessary, replace the tube.
    2. Apply Perma Lok® Heavy Duty Pipe Sealant with
    Teflon® to the threads of the male elbow tube fitting.
    3. I nstallthe tube fitting inthe right bank main oil header
    with the free end of the elbow facing straight up (see
    Figure 5.30-54).

    Figure 5.30-56. Oil Supply Tube Clip - Rear Right

    Front Left

    1. Locate the reducing pipe tee. The three ports of the


    pipe tee are fitted with a pipe nipple, a male connector )
    tube fitting and a pipe plug.

    2. Inspect the pipe tee male connector tube fitting for


    galled or stretched threads. Inspect the front rocker arm
    oil header oil supply tube for cracks, cuts, dents, holes
    or other damage. If necessary, replace the fitting.
    Figure 5.30-54. Rocker Arm Header 011 Supply - Rear
    NOTE: Attach both ends of the tube before tightening. 3. Remove the square head pipe plug from the oil outlet
    port at the front left side of the engine.
    4. Install the supply tube between the main oil header
    (male elbow tube fitting) and the rear end of the vee 4. Apply Perma Lok® Heavy Duty Pipe Sealant with
    mounted rocker arm oil header (male elbow) (see Teflon® to the threads of the pipe tee pipe nipple.
    Figure 5.30-55).

    Figure 5.30-55. Rocker Arm Header 011 Supply -


    Rear Vee

    5.30 - 42 FORM 6248 First Edition


    LUBRICATION SYSTEM

    5. Install the nipple into the oil outlet port leaving the TURBO OIL SUPPLY/DRAIN TUBES
    free end of the male connector tube fitting facing
    diagonally towards the rear gear housing cover flange TURBO OIL SUPPLY/DRAIN TUBES
    (see Figure 5.30-57). INSTALLATION
    1. Inspect the turbo oil supply and drain tubes for
    NOTE: Attach both ends of the tube before tightening. cracks, cuts, dents, holes or other damage. Replace the
    tubes, if necessary (see Table 5.30-18).

    2. Apply Perma Lok® Heavy Duty Pipe Sealant with


    Teflon® to the threads of reducing bushing. Install the
    bushing in the oil header tap (the farthest rearward tap
    (number 8) in the right bank main oil header).

    3. Locate the pipe cross. The four ports of the pipe


    cross are fitted with a check valve (with pipe nipple), a
    magnet plug, a male elbow tube fitting and a male
    connector tube fitting (with pipe nipple and elbow).

    4. Apply Perma Lok® Heavy Duty Pipe Sealant with


    Teflon® to the threads ofthe pipe cross check valve pipe
    nipple.

    Figure 5.30-57. Rocker Ann Header 011 Supply - Front

    6. Install the oil supply tube between the main oil


    header reducing pipe tee (male connector tube fitting)
    and the front end of the vee mounted rocker arm oil
    header (male elbow).

    Table 5.30-18. TUrbocharger Connections


    TURBOCHARGER OIL TUBE CONNECTIONS
    RIGHT BANK
    Supply Lower - Oil Header to Union Tube Fitting
    (1/2 Inch 00) Upper - Union Tube Fitting to Turbo Center Housing

    Drain Upper - Turbo Center Housing to Union Tube Fitting


    (7/8 Inch 00) Lower - Union Tube Fitting to Valve Lifter Housing
    LEFT BANK
    Supply Lower - Oil Header to Union Tube Fitting
    (1/2 Inch 00) Upper - Union Tube Fitting to Turbo Center Housing

    Drain Upper - Turbo Center Housing to Union Tube Fitting


    (7/8 Inch 00) Lower - Union Tube Fitting to Valve Utter Housing

    FORM 6248 First Ednion 5.30 - 43


    LUBRICATION SYSTEM

    5. With the openings in the male connector and male


    elbow tube fittings facing upward, thread the pipe cross )
    check valve pipe nipple into the reducing bushing (see
    Figure 5.30-58).

    AIR/GAS TUBE

    Figure 5.~. Rear Tube Connections

    9. TIghten all fittings.

    Figure 5.30-58. TUrbo Oil Supply - Rear Right LUBE OIL PILOT PRESSURE/GOVERNOR
    OIL TUBE CONNECTION
    6. Remove the magnet plug from the pipe cross to verify
    cleanliness (see Figure 5.30-59). Clean the plug in 1. Apply Perma Lok® Heavy Duty Pipe Sealant with
    solvent, if necessary. Wipe the plug clean to ensure that Teflon® to the threads of a male elbow tube fitting (1/4
    all ferrous metal debris is removed. Apply Perma Lok® inch tube 00). )
    Heavy Duty Pipe Sealant with Teflon® to the threads of
    the plug. Install the plug back in the pipe cross. 2. With the free end pointing straight down, thread the
    elbow (or slraightfitting) into the reducing bushing in the
    right bank main oil header (see Figure 5.30-61).

    3. Connect the tube between the fitting and the


    prechamber gas safety shutdown valve (GL) (see
    Figure 5.45-8).

    4. Connect the tube between the governor drive and


    the main oil header pipe tee (see Figure 5.30-61).
    Figure 5.30-59. Pipe Cross Magnet Plug

    7. Finger tighten the ferrule nuts to attach the lower


    turbo oil supply tubes (up to the union tube fittings) to the
    main oil header pipe cross. Attach the shorter right bank
    oil supply tube to the male elbow, the longer left bank
    supply tube to the male connector.

    NOTE: Attach the right bank turbo oil drain tube to the
    male connector on the right side of the valve lifter
    housing centerline. Attach the left bank tube to the left
    side connector.

    8. TIghten the turbo oil drain tubes (up to the union tube
    fitting) to the two male connector tube fittings at the rear
    )
    of the valve lifter housing (see Figure 5.30-60).

    Figure 5.30-61. Main Oil Header 011 Outlet Ports

    5.30- 44 FORM 6248 First Edition


    LUBRICATION SYSTEM

    5. Apply Perma Lok® Heavy Duty Pipe Sealant with SQUARE NUT
    Teflon® to the threads of a male elbow tube fitting (1/4
    inch tube 00). Install the fitting in the top of the governor
    drive housing (see Figure 5.30-62) with the free end
    facing the right bank main oil header.

    NOTE: Attach both ends of the tube before tightening.

    6. Install the oil supply tube (1/4 inch tube 00) between
    the top of the governor drive housing (see
    Figure 5.30-62) and the main oil header pipe tee (rear
    male elbow tube fitting) (see Figure 5.30-61).

    7. Install the tube clip securing the governor drive oil


    supply line to the gear cover (see Figure 5.30-62).

    TAB ROLL PIN

    Figure 5.3O~3. 011 Pan Door - Rear View

    CLAMP

    ROLL \
    PIN

    SPRING
    / WASHER
    Figure 5.30-62. Govemor Drive 011 Supply -
    Front Right

    SEAL
    OIL PAN DOORS
    OIL PAN DOORS REMOVAL
    Figure 5.3O~. 011 Pan Door - Side View
    A WARNING
    2. Slide the door clamp and spring off the end of the
    Always wear proper eye protection when removing capscrew.
    the spring. Slippage may propel the spring with
    enough force to cause severe personal injury or 3. Pull out the door clamp capscrew. Remove the
    death. rubber O-ring and washer from the capscrew. Discard
    the O-ring.
    1. Remove the roll pin from the threaded end of the
    door clamp capscrew. Since a tab prevents the square 4. Submerse the aluminum doors in the caustic cold
    nut atthe back of the door clamp from turning, rotate the tank to remove all paint, dirt, grease and oil. Dry the
    capscrew to unthread it from the nut (see doors with moisture free compressed air.
    . Figure 5.30-63 and Figure 5.30-64) .
    " 5. Clean the remaining parts of the assembly in a
    non-volatile cleaning solution or solvent. Although
    replacement of these parts is uncommon, they should
    be inspected for damage. Replace as necessary.
    FORM 6248 First Edition 5.30-45
    LUBRICATION SYSTEM

    OIL PAN DOORS INSTALLATION LUBE OIL STRAINER


    )
    1. Apply Parker Super O-Lube®to a new O-ring. Slide LUBE OIL STRAINER REMOVAL
    the washer and O-ring onto the door clamp capscrew.
    1. Remove capscrew, washer, lock washer support
    strap and nut from the support bracket.
    A WARNING
    2. Remove capscrew, washer, lock washer, bracket
    Always wear proper eye protection when installing and spacer from the crankcase.
    the spring. Slippage may propel the spring with
    enough force to cause severe personal injury or 3. Remove two capscrews, lock washers, spacers and
    death. support bracket from the inlet port of the strainer head.

    2. Insert the capscrew in the front ofthe oil pan door, so 4. Remove four capscrews, lock washers, and the lube
    that the O-ring seats in the round depression at the top oil strainer from the strainer adapter,
    of the capscrew bore. Turn the door over and slide the
    spring over the end of the capscrew. 5. Remove four capscrews, lock washers, strainer
    adapter and gasket, from the crankcase.
    3. With the recessed side facing the door, slide the
    6. Place masking tape over the lube oil strainer inlet to
    clamp onto the capscrew fitting the free end of the roll
    keep out dust and dirt (see Figure 5.30-65).
    pin into the pin hole in the clamp. A hole in both sides of
    the clamp facilitates assembly.

    4. Position the square nut over the center hole in the


    clamp with the flat parallel to the face ofthe tab. Turn the
    capscrewto thread it into the nut. Install the roll pin in the
    threaded end of the capscrew.

    5. Apply 3M Scotch Grip'· Rubber and Gasket Adhe-


    sive 847 in the groove at the back of the door. Install a
    )
    new seal in the groove.

    6. I nstall the oil pan doors with the U -shaped indenta-


    tion at the top. Hold each door so that the rear clamp is
    45 degrees from the vertical position. Insert the clamp
    into the oil pan access hole. Holding the door against the
    face of the access hole, rotate the door until the clamp is
    in the horizontal position. Tighten the door clamp
    capscrew.

    NOTE: Install the oil pan door with the 3/4 inch NPT
    square head pipe plug in the farthest rearward access
    hole on the right bank side. Position the door so that the
    plug is on the lower haff. Figure 5.30~5. Lube Oil Strainer - Rear Right

    5.30 - 46 FORM 6248 First Edition


    LUBRICATION SYSTEM

    LUBE OIL STRAINER CLEANING AND


    INSPECTION A WARNING
    Clean the lube oil strainer element at each oil change. Compressed air can pierce the skin and cause
    Proceed as follows: severe personal injury or death. Never use your
    hand to check for leaks or to determine air flow
    1. Remove the plug at the bottom of the element rates. Wear safety glasses to shield your eyes from
    housing to drain the strainer assembly of oil (see flying dirt and debris.
    Figure 5.30-66).
    IA
    ...
    CAUTION I High pressure com-
    pressed air may damage
    the strainer element. Disregarding this Information
    could result in product damage and/or personal
    Injury.

    9. Drip dry the element or air blow dry from the inside
    STRAINER" 0 out using low pressure compressed air.
    HEAD ~
    10. Inspect the element for tears or holes. Replace the
    O-RING /'1i!!~ BAND
    RETAINER
    element if damaged.

    11. Position a new a-ring in the inside groove at the top


    of the wire mesh element. Using a small paintbrush,
    ELEMENT lubricate the a-ring with clean engine oil.
    MAGNET ROD
    12. Position the two magnet rods in the element
    grooves and install the two band retainers.

    13. Slide the element up onto the inside flange of the


    strainer head.
    ELEMENT
    HOUSING 14. Install a new seal inside the groove althe top olthe
    /' element housing. Lubricate the a-ring with clean
    DRAIN PLUG-......:;;;:
    engine oil.

    15. Screw the drain plug into the bottom of the element
    Figure 5.30-66. Lube 011 Strainer Assembly housing.

    16. Install the four capscrews and washers to secure


    2. Remove the four capscrews and washers from the the element housing to the strainer head.
    strainer head to detach the element housing.
    LUBE OIL STRAINER INSTALLATION
    3. Remove and discard the rubber seal from the inside
    groove at the top of the element housing. 1. Install the strainer adapter to the crankcase with
    gasket, four lock washers and capscrews.
    4. Pull down on the stainless steel wire mesh element
    to detach it from the head. 2. Install new square cut a-rings in the grooves around
    the inlet and outlet ports of the strainer head.
    5. Remove the two band retainers and the two magnet
    rods externally mounted on the element. 3. Apply Parker Super O-Lube® to the a-rings.

    6. Clean the magnet rods in solvent. Wipe the magnets 4. Fasten the lube oil strainer to the strainer adapter on
    clean to ensure that all ferrous metal debris is removed. the rear right side of the main oil header with four
    capscrews and lock washers. Be sure to mate the outlet
    7. Remove the rubber a-ring from the inside groove at side olthe strainer with the strainer adapter. An arrow on
    the top of the wire mesh element. top of the strainer head paints to the outlet port. The
    words "Inlet" and "Outlet" also appear below the
    8. Clean the element in solvent. Flushing the element
    respective port hole.
    from the inside out produces the best results.

    FORM 6248 First Edition 5.30 - 47

    l
    LUBRICATION SYSTEM

    5. If masking tape was placed over the lube oil strainer


    inlet to keep out dust and dirt (see Figure 5.30-65) )
    remove if at this time.

    6. Install the support bracket on the inlet port of the


    strainer head with two capscrews, lock washers, and
    spacers.

    7. Install the strainer support bracket to the support


    bracket, if necessary with capscrew, washer, lock
    washer and nut.

    B. Fasten the support bracket above the inlet port of the


    strainer head with two capscrews, lock washers and
    spacers.

    5.30-48 FORM 6248 First Edition


    SECTION 5.35 - EXHAUST SYSTEM

    EXHAUST SYSTEM temperature of the cylinder bank (an average of the


    exhaust temperatures of each individual cylinder).
    COMPONENTS
    The leads from the exhaust thermocouples enter a
    The exhaust system consists of the following compo- thermocouple conduit. Exiting the conduit through a
    nents: flexible cable, the wires lead into the back of the
    instrument panel where they are connected to the
    • Exhaust Manifold(s)
    exhaust pyrometer selector switch. The pyrometer
    • Exhaust Thermocouples selector switch is used with the portable pyrometer to
    monitor engine exhaust temperatures.
    • Turbocharger(s)
    A wastegate-controlled turbocharger is provided for
    • Exhaust Wastegate(s) each cylinder bank. The compressor side of the
    turbocharger is part of the air induction system; the
    • Exhaust Piping and Flexible Connections turbine side is part of the exhaust system. When the
    (customer supplied) turbine spins through the expansion of exhaust gases
    exiting the engine, the movement of the compressor
    DESCRIPTION wheel causes the air passing through the air cleaner
    The exhaust port of each cylinder is connected to one enroute to the carburetor to be compressed.
    water-jacketed segment of the exhaust manifold. Each A water -cooled exhaust wastegate is mounted at the
    water-cooled exhaust manifold assembly is comprised outlet of each exhaust manifold. The wastegate is a load
    of six individual segments. One exhaust manifold limiting device. At a predetermined pOint, intake man-
    segment is joined to the next by a manifold pilot. ifold pressure counteracts the tension of a spring and a
    Thermocouples are used to monitor engine exhaust valve opens to bypass a portion of the engine exhaust
    temperatures. High exhaust temperatures greatly in- pressure around the turbocharger turbine. In this way,
    crease the potential for detonation and have a direct the air intake boost pressure is held within an accept-
    impact on the life of many engine components. able range.
    One thermocouple is mounted in the exhaust port of Exhaust gases driving (or bypassing) the turbine exit the
    each exhaust manifold segment to measure the tem- engine through the exhaust stack. Exhaust gases
    perature of the exhaust exiting the respective cylinder passing the flexible exhaust connection are directed
    head (see Figure 5.35-1). One thermocouple is also into the atmosphere through customer supplied ex-
    mounted before each exhaust elbow (G models) or haust piping.
    turbocharger (GSI/GL models) and reflects the exhaust

    LEFT BANK EXHAUST


    MANIFOLD
    /SEcnON
    TURBO EXHAUST
    INLET ELBOW t.":\

    ""'® y EXHAUST
    THERMOCOUPLE

    ® ~®~),:;::::0~ FRONT
    REAR

    '~Yn~~r---~nrr-~r-'-T--+,,~---+~~-r~THERMOCOUPLE
    THERMOCOUPLE / CONDUIT
    LEADS 14 1312 11 10 98 7 6 54 32 1

    ) RIGHT BANK
    Figure 5.35-1. Exhaust Thermocouples Arrangement - 12 Cylinder

    FORM 6248 First Edition 5.35 - 1


    EXHAUST SYSTEM

    EXHAUST SYSTEM SPECIFICATIONS D. pipe obstructions


    The maximum exhaust system backpressure for all E. exit losses
    engine models is 12 inches (305 mm) of water column at
    1200 rpm, 145 BMEP (full load). Subtract 1 inch CHECKING EXHAUST GAS TEMPERATURES
    (25 mm) of water column for each 100 rpm reduction.
    Exhaust temperatures can be an important diagnostics
    Subtract 1 inch (25 mm) of water column for each 10
    tool. A very high exhaust temperature might indicate
    BMEP reduction. Do not apply these reductions beyond
    that the air/fuel ratio is too rich. A very low temperature
    a minimum exhaust system backpressure of 4 inches
    may mean that a cylinder is not firing.
    (102 mm) of water column.
    Check engine exhaust temperatures for each cylinder
    Based upon production test data in general, the
    daily. Monitor the exhaust temperatures when the
    maximum exhaust temperature variation (on an engine
    engine is running at rated speed and load.
    running at 1000 and 1200 rpm @ 138 BMEP on natural
    gas fuel) between cylinders on the same bank is One exhaust thermocouple is mounted in each exhaust
    approximately 100' F (38' C). The maximum exhaust manifold segment. A thermocouple is also mounted
    temperature variation between respective cylinders on before each turbocharger. 12 cylinder engines have 14
    different banks (1 R versus 1L, 2R versus 2L, etc.) is thermocouples.
    approximately 50' F (23.5' C). Be on the alert for wide differences between cylinders or
    between cylinder banks. The actual exhaust tempera-
    NOTE: Since air/fuel ratio, ambient air temperature
    ture readings are not as important as the variations that
    and many other factors may affect exhaust gas
    may occur.
    temperatures, call the Waukesha Engine Division, Field
    Service Department if additional information is required. 1. Rotate the pyrometer selector switch to select the
    cylinder to be monitored.
    MEASURING EXHAUST SYSTEM
    BACKPRESSURE NOTE: Right bank and left bank are determined by
    Monitor the exhaust system backpressure daily. The standing at the flywheel end of the engine facing the
    maximum backpressure must not exceed speCification. flywheel. The cylinders farthest from the flywheel on the
    left and right side are the #1L and #1R cylinders,
    )
    1. Drill and tap a hole (1/4 inch NPD in the customer respectively. Those closest to the flywheel are the #6L
    supplied exhaust piping. Place the hole 12 inches (305 and #6R cylinders (12 cylinder engines).
    mm) downstream from the mating flange of the
    Waukesha supplied flexible exhaust connection. The 2. Record the temperature value for each cylinder.
    measurement must be taken before the silencer or
    catalytic converter, if provided, and should be away from
    any bend or elbow in the exhaust piping.

    2. Install a tubing connector in the hole. Use only


    non-corroding stainless steel fittings.

    3. Connect one end of a water manometer to the


    connector and vent the free end to the atmosphere. The
    manometer line fitting must not protrude beyond the
    inner surface of the exhaust pipe or an inaccurate
    reading may result.

    4. Measure the exhaust backpressure at rated speed


    and load. Corrective action must be taken if the
    backpressure exceeds the specified limit.

    5. Excessive exhaust backpressure may be due to one


    or more of the following conditions:

    A. undersized piping

    B. elbows, bends or sudden enlargements in the )


    piping

    C. plugged catalytic converter

    5.35 - 2 FORM 6248 First Edition


    EXHAUST SYSTEM

    EXHAUST MANIFOLD
    EXHAUST MANIFOLD REMOVAL

    CAUTION I~xer~lse care t~ avoid


    I=.='----';;.;;..;;.;;;...;;..;;..;;;..;~.
    "A
    L. . bending or denting the
    rocker arm 011 supply tubes. Disregarding this
    information could result in product damage and/or
    personal Injury.

    1. Refer to Water Manifold Removal, and remove the


    water manifold and water outlet elbows from the
    exhaust manifold.

    2. Refer to Turbocharger Inlet Elbow Removal and


    remove the turbocharger inlet elbow from the end
    exhaust manifold section.

    3. Remove thermocouples from the exhaust manifold Figure 5.35-3. Thermocouple Bracket
    sections (see Figure 5.35-2).
    5. Attach a suitable lifting device to the exhaust
    manifold.

    6. Remove two capscrews and lock washers from each


    water outlet elbow on the exhaust manifold sections
    (see Figure 5.35-4).

    Figure 5.35-2. Exhaust Thermocouple - Rear Left

    4. Remove capscrews, lock washers thermocouple


    brackets and thermocou pie conduit from the exhaust
    manifolds (see Figure 5.35-3).
    Figure 5.35-4. Water Outlet Elbows - Rear Right

    7. Remove capscrews (2 ferry head capscrews per


    elbow, 1/2 x 1-3/4 inches, with lock washers) and water
    outlet elbows from the cylinder heads

    FORM 6248 First Ed~ion 5.35" 3


    EXHAUST SYSTEM

    8. Remove and discard the water outlet elbow gaskets


    from the upper and lower flanges of the water outlet A WARNING )
    elbows (see Figure 5.35-5). Do not attempt to lift the exhaust manifold without
    providing adequate support for each section. Disre-
    garding this information could result in severe
    personal injury or death.

    A WARNING
    The exhaust manifold weighs approximately 5151bs.
    (234 kg)_ Use a suitable lifting device and exercise
    caution during removal or installation to avoid
    severe personal injury or death.

    12. Using a suitable lifting device and insuring that


    each manifold section is properly supported, remove
    the exhaust manifold assembly from the engine.

    13. Remove and discard the exhaust manifold gaskets


    from the cylinder heads or exhaust manifold sections
    Figure 5.35-5. Water Outlat Elbow Gaskets (see Figure 5.35-7).

    14. Use masking tape to cover the exhaust outlet port


    NOTE: Record the positions of the three prelube motor and the water outlet elbow flange on each cylinder head
    air/gas supply tube retaining clips. to protect against dirt.
    9. From the back side of each manifold section, remove 15. Remove and discard the two water outlet elbow
    two upper long capscrews (1/2 x 8-1/2 inches, with flat gaskets from the upper and lower flanges of the water )
    washers) and two lower short capscrews (1/2 x 5-1/2 outlet elbows. See Figure 5.35-5.
    inches, with flat washers). See Figure 5.35-6.

    Figure 5.35-6. Exhaust Manifold - Rear View

    10. Remove the three prelube motor air/gas supply


    tube retaining clips.

    11. On GSI and GL note the location and remove the


    breather tube brackets and intercooler water pipe
    brackets from the exhaust manifold sections.
    )

    5.35 - 4 FORM 6248 First Edition


    EXHAUST SYSTEM

    ITEM NUMBER AND DESCRIPTION


    1 Manifold 6 Mannold Pilot 11 Washer 16 Capscrew
    2 Manifold 7 Insulating Ring 12 Capscrew 17 Capscrew
    3 Plug 8 Clamp 13 Capscrew 18 lock washer
    4 Insulating Ring 9 MannoldCap 14 Gasket 19 Elbow
    5 Mannold Pilot 10 Capscrew 15 Ring Seal
    Figure 5.35·7. Exhaust Manifold - GL Shown

    EXHAUST MANIFOLD DISASSEMBLY EXHAUST MANIFOLD ASSEMBLY

    NOTE: The manifold pilots between the center sec- 1. If removed, apply pipe sealant to threads, and install
    tions are wider than the ones between the outer the countersunk pipe plugs on the exhaust manifold
    sections. The insulating ring used with the center sections (two plugs per section)
    manifolds pilots are also wider.
    2. Install the manifold caps in on the end exhaust
    1. Separate the exhaust manifold sections and remove manifold sections with two capscrews and washers.
    the manifold pilots (see Figure 5.35-7).
    NOTE: On GSI/GL models insure that the NO.6 RB and
    2. Remove the hose clamps and insulating rings from No. 6 LB are positioned on the correct end of the
    the pilots. assembled manifold assembly.

    3. Remove two capscrews, washers and manifold caps 3. Line up the exhaust manifold sections.
    from the end manifold sections.
    4. Position the insulating strips and hose clamps on the
    4. If required, remove the countersunk pipe plugs from manifold pilots.
    the exhaust manifold sections.

    FORM 6248 First Edition 5.35 - 5


    EXHAUST SYSTEM

    L.
    • .::
    ..
    CAUTION
    I A='--__ I~Uring assem~ly
    '-__----'.
    of the
    manifold sections, use
    3. Install two long capscrews (1/2 x 8-1/2 inches, with
    flat washers) into the upper bosses of each exhaust
    caution to avoid pinching the insulating strips or manifold section. Install two short bolts (1/2 x 5-1/2
    hose clamps between the manifold pilots and inches, with flat washers) into all the lower bosses (see
    exhaust manifold sections. Disregarding this In- Figure 5.35-9).
    formation could result in product damage and/or
    personal Injury.

    5. Install the manifold pilots, insulating strips and hose


    clamps between the manifold sections.

    6. Press the manifold sections together.

    NOTE: Align the screws on the hose clamps on a line


    parallel with the countersunk pipe plugs. The seams of
    the insulating strips should be aligned on a line parallel
    with the upper holes for the longer (1/2 x 8·1/2 inch
    capscrews) The open end of the seam should be
    oriented downwards.

    7. Tighten the hose clamps on the insulating strips. Figure 5.35-9. Exhaust Manifold - Rear View

    EXHAUST MANIFOLD INSTALLATION


    4. Attach three retaining clips (0.048 inch gauge, 1/2
    1. Remove the protective masking tape from the inch clamping diameter) to the prelube motor air/gas
    exhaust outlet port and the water outlet elbow flange on supply tube (37.5 inches long, 1/2 inch tube 00).
    each cylinder head.

    2. With the lip on the inside diameter of the gasket


    facing upward, position new exhaust manifold gaskets
    )
    on the cylinder head exhaust outlet ports (see
    Figure 5.35-8). Be sure that the hole with the copper
    grommet lines up with the water hole in the casting. Do
    not use the gasket if the grommet is missing or
    damaged.

    /""0 0'
    /F==~

    LlP~

    ,...0 7"-©=O__O-"
    COPPER
    GROMMET

    Figure 5.35-8. Exhaust Manifold Gasket

    5.35 - 6 FORM 6248 Firs! Edilion


    EXHAUST SYSTEM

    REAR FRONT

    ATTACH AIR/GAS SUPPLY ruBE RETAINING CLIPS

    Figure 5.35-10. Exhaust Manifold - Left Bank

    5. Pull the 5-1/2 inch capscrews from three sections


    (numbers 1, 3 and 6) of the left bank exhaust manifold A WARNING
    (see Figure 5.35-10). The end section with the exhaust The exhaust menlfold weighs approximately 5151bs.
    outlet port is number 6. (234 kg). Use a suitable lifting device and exercise
    6. Attach the air/gas supply tube retaining clips and caution during removal or installation to avoid
    insert the capscrews back into the lower bosses of the severe personal Injury or death.
    left bank exhaust manifold (see Figure 5.35-10 and
    Figure 5.35-11). CAUTION I
    I=.A=~:..:....;;.;::;....;~;:;..;~.
    Exercis.e care to avoid
    L.. . bending or denting the
    rocker arm oil supply tubes. Disregarding this
    information could resuh In product damage and/or
    personal injury.

    7. Position the exhaust manifold on the cylinder bank.


    Be sure that the end section with the exhaust outlet port
    (for mounting of the turbo exhaust inlet elbow, GL
    models) is positioned at the rear of the engine (see
    Figure 5.35-12).

    WATER
    WATER MANIFOLD
    MOUNTING BRACKET
    BOLT HOLES

    Figure 5.35-11. Prelube Motor Air/Gas Supply Tube

    A WARNING
    Do not attempt to 11ft the exhaust manifold without
    providing adequate support for each section. Disre-
    garding this Information could resuh in severe FRONT END
    SECTION
    personal InJury or death.
    Figure 5.35-12. Exhaust Manifold End Sections -
    Left Bank

    FORM 6248 First Ednion 5.35 -7


    EXHAUST SYSTEM

    NOTE: Leave the upper inside capscrews loose on 9. Install the breather- tube on the outside sections of
    each end section of the right bank exhaust manifold (for the right bank manifold with capscrew and bracket (see
    attachment of the vee mounted breather tube) (see Figure 5.35-13).
    Figure 5.35-13).
    10. Install the intercooler tubes on the exhaust man-
    ifold sections with brackets washers and lock washers
    (see Figure 5.35-13).

    11. Apply 3M Scotch Grip Rubber and Gasket Adhe-


    N

    sive 847 to the rectangular grooves on both sides of the


    water outlet elbows. Install new rubber seals in the
    grooves (see Figure 5.35-14).

    Figure 5.35-13. Breather TUbe And Intercooler Tubes

    8. Install the outside short bolt and washer in each end )


    section (front and rear) (see Figure 5.35-15). Remove
    the lifting device. Tighten the remaining capscrews
    (four per section). Figure 5.35-14. Water Outlet Elbow Gaskets

    LEAVE LOOSE FOR


    ATTACHMENT OF BREATHER
    TUBE PIPE CLAMPS
    FRONT REAR

    OUTSIDE SHORT BOLTS

    Figure 5.35-15. Exhaust Manifold - Right Bank

    5.35 - 8 FORM 6248 First Edition


    EXHAUST SYSTEM

    12. Finger tighten the water outlet elbows to the manifold end section (see Figure 5.35-18). Wrench
    cylinder heads (2 ferry head capscrews per elbow, tighten the capscrews.
    1/2 x 1-3/4 inches, with lock washers). Finger tighten
    the elbows to each exhaust manifold section (2 hex
    head capscrews per elbow, 1/2 x 1-3/4 inches, with
    lock washers). Alternately wrench tighten the four
    capscrews (see Figure 5.35-16).

    Figure 5.35-18. Exhaust Manifold - Left Bank

    16. Inspect the twelve stainless steel male connector


    Figure 5.35-16. Water Outlet Elbows - Rear Right tube fittings (1/4 inch thermocouplaOD) for galled or
    stretched threads. Replace the fittings if necessary.
    13. Use a rubber mallet to seat the manifold caps in the 17. Apply Bostik Never Seez® Anti~Seize and Lubri-
    front end sections of the right and left bank exhaust cating Compound (capable of withstanding tempera-
    manifolds. tures up to 1800' F (982' C) to the large end of each
    male connector tube fitting. Using the 9/16 inch hex on
    14. Install the fasteners to secure the end cap to the the connector body, thread the fitting into the exhaust
    right bank exhaust manifold end section (see port of each segment of the exhaust manifold (see
    Figure 5.35-17) (2 capscrews, 1/2 x 1-5/8 inches, with Figure 5.35-19).
    flat washers).

    Figure 5.35-17. Exhaust Manifold - Front

    15. Install the fasteners in the auxiliary cooling water


    outlet pipe support bracket (2 capscrews, 1/2 x 2 inches, Figure 5.35-19. Thermocouple Connector -
    with lock washers and 1/4 inch spacers). Position the Rear Right
    bracket over the end cap of the left bank exhaust
    18. Repeat the procedure on the other bank.

    FORM 6248 First Ednion 5.35 - 9


    EXHAUST SYSTEM

    TURBO EXHAUST INLET ELBOWS


    )
    TURBO EXHAUST INLET ELBOWS REMOVAL

    1. Refer to Wastegate Removal, and remove the


    wastegate assemblies from the left and right turbo
    exhaust inlet elbows.

    2. Refer to Turbocharger Removal and remove the


    turbocharger assembly from the exhaust inlet elbow.

    NOTE: GIGSI engines have a heat shield mounted


    using the attaching hardware between the right turbo-
    charger and the exhaust inlet elbow, and the flange that
    mounts the turbo exhaust inlet elbow to the exhaust
    manifold.

    3. Remove four stainless steel capscrews and stain- Figure 5.35-21. TUrbo Exhausllnlst Elbow -
    less steel lock washers and elbow gasket from the turbo Rear Righi - GIGSI Engines
    exhaust inlet elbow and exhaust manifold (see
    Figure 5.35-20).

    Figure 5.35-22. Turbo Exhausllnlst Elbow

    Figure 5.35-20. TUrbo Exhausllnlet Elbow - Rear Laft

    4. With the aid of an assistant, support the turbo


    exhaust inlet elbow and remove four stainless steel
    capscrews, stainless steel lock washers, turbo exhaust
    inlet elbow, exhaust bypass flange, and bypass flange
    gasket, from the exhaust manifold section and exhaust
    bypass tee (see Figure 5.35-21 and Figure 5.35-22).
    Discard the bypass flange gasket (on GIGSI, the heat
    shield and two spacers will have to be removed from the
    right side).

    5.35 -10 FORM 6248 First Edition


    EXHAUST SYSTEM

    TURBO EXHAUST INLET ELBOWS INSTALLATION 6. With the lip on the inside diameter facing upward
    (see Figure 5.35-24), position a new stainless steel
    1. Install a new compression gasket on the two plug gasket over the exhaust outlet port in the rear end
    hole adapters. Apply Bostik Never Seez® Anti-Seize section of each exhaust manifold.
    and Lubricating Compound to the plug threads. Install a
    plug in each turbo exhaust inlet elbow (see
    Figure 5.35-23). LIP (FACING UPWARD)

    'o:::::~,cy

    o o
    Figure 5.35-24. Turbo Exhaust Inlet Elbow Gasket

    NOTE: GIGSI engines have a he,at shield mounted


    Figure 5.35-23. Turbo Exhaust Inlet Elbow - Rear Left
    using the attaching hardware between the right turbo-
    charger and the exhaust inlet elbow, and the flange that
    2. Check the four stainless steel wastegate mounting mounts the right turbo exhaust inlet elbow to the
    studs for burrs, nicks, cracks, galled or stretched threads exhaust manifold.
    and other obvious damage. Replace as necessary.
    7. Position the turbo exhaust inlet elbow on the exhaust
    3. Each wastegate mounting stud has fine and coarse manifold sections and exhaust bypass tee and loosely
    threads separated by a smooth center boss. Using a install four stainless steel capscrews, stainless steel
    small paintbrush, apply Bostik Never Seez® Anti-Seize lock washers (see Figure 5.35-25) (on GIGSI, the heat
    and Lubricating Compound to the coarsely threaded shield and two spacers will have to be installed on the
    side. right side).

    A CAUTION I
    I'!!"~~="':":~:"':"'="';:...:..J.
    L.
    Do not install wastegate
    mounting studs with a
    pipe wrench or similar device. Use a collet type stud
    driver to prevent damage to stud threads. Disre-
    garding this Information could result in product
    damage andlor personal injury.

    4. Using a collet type stud driver, install each stud into


    the turbo exhaust inlet elbow until the last coarse thread
    is turned into the casting.

    5. With the exhaust bypass port facing the crankcase


    vee, position the turbo exhaust inlet elbow over the
    exhaust outlet port.

    Figure 5.35-25. Turbo Exhaust Inlet Elbow

    FORM 6248 First Edition 5.35 - 11


    EXHAUST SYSTEM

    8. Install the turbo exhaust inlet elbow on the exhaust


    manifold with four stainless steel capscrews, stainless )
    steel lock washers and elbow gasket (see
    Figure 5.35-26).

    Figure 5.35-26. Turbo Exhaust Inlel Elbow - Rear Left

    9. Wrench tighten the turbo exhaust inlet elbow on the


    exhaust manifold sections and exhaust bypass tee with
    four stainless steel capscrews, stainless steel lock )
    washers (see Figure 5.35-25).

    5.35 -12 FORM 6248 First Edttion


    EXHAUST SYSTEM

    ITEM NUMBER AND DESCRIPTION


    1 Elbow 5 Bracket 9 Washer 13 Plug

    2 Plug 6 Capscrew 10 Capscrew 14 Exhaust Connection

    3 Gasket 7 lock washer 11 Washer 15 Gasket

    4 Exhaust Connection B Capscrew 12 Bracket


    Figure 5.35-27. Exhaust Connections - G
    EXHAUST CONNECTIONS - G 4. Remove the exhaust elbows from the exhaust
    manifolds.
    EXHAUST CONNECTIONS REMOVAL - G
    NOTE: A thermocouple may be installed at this location
    1. Remove flexible exhaust connection and gasket instead of an exhaust plug.
    from the exhaust connection (see Figure 5.35-27).
    Discard the gasket. 5. If required, remove exhaust plug and gasket from the
    exhaust elbow. Discard the gasket.
    2. Disconnect the exhaust connection from the sup-
    porting brackets. 6. If required, remove the hex head pipe plug from the
    exhaust elbow.
    3. Lift the exhaust connection off the two exhaust
    elbows and supporting brackets.

    FORM 6248 First Edition 5.35 -13


    EXHAUST SYSTEM

    EXHAUST CONNECTIONS INSTALLATION - G EXHAUST CONNECTIONS REMOVAL - GSI/GL


    )
    1. If removed, apply pipe sealant to threads and install 1. Refer to Turbo Exhaust Inlet Elbow/Exhaust Bypass
    the hex head pipe plugs on the exhaust elbows. Removal, and Turbocharger Removal, and remove
    these components.
    2. If removed, install a new gasket and exhaust plug on
    the elbows. 2. Remove V-Band coupling and flexible exhaust
    connection from the venturi (GSI models) or exhaust
    3. Install the exhaust elbows on the exhaust manifolds. elbow (GL models Figure 5.35-28).
    4. Position the exhaust connection on the elbows and 3. Remove V -Band and the venturi (GSI models) from
    supporting brackets. the exhaust elbow.
    5. Install the exhaust connection to the supporting 4. Remove the exhaust bypass tee and sleeve from the
    brackets. exhaust elbow.
    6. Install a new gasket and the flexible exhaust
    connection on the exhaust connection.

    •
    ~o
    - "FlEXIBLE EXHAUST
    -= CONNECTION

    EXHAUST
    BYPASS

    TEE",'..c-.......-.--->-
    )

    EXHAUST ELBOW
    ~~/

    I'
    a
    9 I
    I

    EXHAUST CONNECTIONS - GSI


    i
    .,
    I
    !~~~~~""'"""''''''.'~
    ........
    ~,
    ~
    .....". 'It

    (!jP
    x
    //
    u
    I . . . .:" I'
    . .!. /'l
    )
    .
    Figure 5.35-28. Exhaust Connections - GSI/GL

    5.35 -14 FORM 6248 First Ed~ion


    EXHAUST SYSTEM

    5. Remove the exhaust elbow adapters from the


    exhaust elbow (see Figure 5.35-29).

    Figure 5.35-30. Check Exhaust Elbow For


    Straightness

    4. Install the exhaust bypass sleeve and exhaust


    Figure 5.35-29. Exhaust Elbow Assembly bypass tee on the exhaust elbow.

    5. Install two exhaust elbow adapters (larger 00) into


    6. Remove four nuts, lock washers capscrews and the inlet ports of the exhaust elbow (see Figure 5.35-29
    exhaust elbow from the supporting brackets. and Figure 5.35-31).

    7. Remove four nuts, lock washers, washers, caps-


    crews and two support brackets from the supporting
    rails.

    8. If required, remove eight capscrews, lock washers


    and two support rails.

    EXHAUST CONNECTIONS INSTALLATION -


    GSI/GL
    1. If removed, install two support rails with eight
    capscrews and lock washers.

    2. Install two support rails with four nuts, lock washers,


    washers and capscrews.

    3. Install the exhaust elbow on the supporting rails with


    four capscrews, lock washers and nuts (see
    Figure 5.35-30). Use an angle finder to insure that the
    exhaust elbow is straight. Figure 5.35-31. Exhaust Elbow Adapter

    NOTE: If realignment of the exhaust elbow is neces-


    6. Install the venturi (GSI models) with V-Band on the
    sary, loosen the slotted bolts to free the exhaust elbow
    exhaust elbow.
    support brackets from the intercooler-mounted support
    rails and make the necessary adjustments. 7. Install flexible exhaust connection on the exhaust
    elbow (GL models - Figure 5.35-28) or venturi (GSI
    models - Figure 5.35-28) with V-Band coupling.

    FORM 6248 First Edition 5.35 -15


    EXHAUST SYSTEM

    THERMOCOUPLES tor is red. Peel back the insulation of each conductor 3/8
    inch to expose the bare wire. Remove any excess
    THERMOCOUPLE REPLACEMENT material.
    Waukesha recommends that the thermocouple leads
    be fitted with quick disconnect plugs and that spare 6. Separate the male and female ends of the quick
    thermocouples (those with the disconnect plugs disconnect plug.
    installed) be kept in stock (see Table 5.35-1). Use ofthe 7. Locate the two machine screws on the male plug.
    quick disconnect plug allows the thermocouple to be Unthread the screw farthest from the prongs and
    changed without disassembling the thermocouple con- remove that quarter of the connector.
    duit or running the lead over the top of the engine.
    Table 5.35-1. Quick Disconnect Plug 8. Loosen the retaining screw from the side of each
    prong.
    THERMOCOUPLE TYPE TEMPERATURE RANGE
    K 32 - 2282° F 9. Slide the red negative (-) conductor into the larger
    diameter prong until contact is made with the pinhole
    1. Loosen the ferrule nuts (9/16 inch hex) (see (see Figure 5.35-33). Slide the black positive (+)
    Figure 5.35-32) to remove the thermocouple from the conductor into the smaller diameter prong until contact
    exhaust manifold. is made with the pinhole. Tighten the retaining screws to
    hold the conductors in place.

    MACHINE
    ,SCREW

    /~ '

    INSULATlO~
    I
    JACKET
    )
    ~ I NEGATIVE
    ....-.@__ ! ___CONDUCTOR
    ¥- (RED)
    I·
    IJr"-''''

    RETAINING.>"!:
    SCREW
    Figure 5.35-32. Exhaust Thermocouple - Rear Left

    When replacing "K" type thermocouple, install the quick -STAINLESS STEEL \
    BRAID
    disconnect plug as follows:
    QUICK DISCONNECT
    PLUG (MALE END)
    2. Cut the lead 12 inches after the faulty thermocouple.

    NOTE: The length of wire of each circuit should be the


    same. Variations in thermocouple wire length adversely
    affect pyrometer readings. Errors will not usually
    exceed ± 1% of the total reading if the variations in wire
    length do not exceed 22 feet.
    Figure 5.35-33. "K" Type Thermocouple
    3. Peel back the stainless steel braid 1-1/4 inches.
    Remove any excess material. 1O. Assemble the male end of the plug. Tighten the
    machine screw.
    4. Peel back the insulation beneath the braid 3/4 inch.
    Remove any excess material. 11. Snap the male end of the plug to the female end. )
    The different size prongs prevent the plug from being
    5. Separate the positive and negative conductors. The
    improperly hooked up after assembly.
    positive (+) conductor is black, the negative (-) conduc-

    5.35 -16 FORM 6248 First Edition


    EXHAUST SYSTEM

    Thermocouple Stem - "K" Type Plug 4. Inspect the thermocouple connector for galled or
    stretched threads. Remove and discard the fitting, if
    1. Unthread the ferrule nut (9/16 inch hex) from the damaged. Apply Bostik Never-Seez® Anti-Seize and
    thermocouple connector. The thermocouple connector Lubricating Compound {which can withstand tempera-
    is mounted in the exhaust port of the exhaust manifold tures up to 1800· F (982· C) to the large end of the new
    or the turbocharger exhaust inlet elbow. connector. Using the 9/16 inch hex on the connector
    2. Pull the faulty thermocouple out of the exhaust body, thread the connector into the exhaust port.
    passage and discard. 5. Insert the stem of the thermocouple into the connec-
    3. Insert a new ferrule nut and a new back and front tor and finger tighten the ferrule nut.
    ferrule onto the stem of the new thermocouple (see 6. Center the tip of the stem in the exhaust passage.
    Figure 5.35-34). The lip on the back ferrule must face The thermocouple must not contact the metal casting or
    the large end ofthe frontferrule, while the tapered end of an inaccurate pyrometer reading will result. The dis-
    the front ferrule faces the connector body. tance from the exterior casting of the exhaust manifold
    exhaust port to that portion of the thermocouple that is
    perpendicular to the tip of the stem should be 3-1/16
    inches ±1/4 inch (see Figure 5.35-35).

    7. Tighten the ferrule nut.

    8. Connect the male and female ends of the plug. The


    different size prongs prevent the plug from being
    llIERMOCOUPLE
    CONNECTOR improperly hooked up.

    Figure 5.35-34. "K" TYpe Thermocouple

    CONNECTOR TUBE FITTING


    (STAINLESS STEEL)

    Figure 5.35-35. Exhaust Thermocouple Installa1ion

    FORM 6248 First Ednion 5.35 - 17


    EXHAUST SYSTEM

    EXHAUST THERMOCOUPLES INSTALLATION 2. Position the thermocouple conduit cable down


    between cylinder heads #3R and #4R (below the )
    1. Position the thermocouple conduit between the right prechamber fuel inlet and rocker arm oil supply tubes)
    bank water outlet elbows and the fixed valve lifter and then run the free end under the coil rail over to the
    screws of the rocker arm assemblies. Be sure that the right bank intake manifold.
    four closely spaced leads exiting the bottom of the
    conduit are positioned at the rear of the engine (see 3. Route the thermocouple leads to each section of the
    Figure 5.35-36). right and left bank exhaust manifold (12) (see
    Figure 5.35-37).

    4. Route the leads (2) to the turbo inlet elbows at the top
    of the two exhaust manifold end sections (rear).

    5. Position a new ferrule nut and a new back and front


    ferrule "K" Type. The lip on the back ferrule must face
    the large end of the front ferrule, while the tapered end of
    the front ferrule faces the connector body.

    6. Insert the thermocouples into the male connector


    tube fittings in each section of the exhaust manifold.

    I.A. CAUTION IThe thermocouple must


    not contact the exhaust
    manifold casting or an inaccurate pyrometer read-
    ing will result. Disregarding this information could
    Figure 5.35-36. Thermocouple Conduit - Rear Right
    result in product damage and/or personal Injury.

    7. Center the tip of the stem in the exhaust passage. )


    The distance from the exterior casting of the exhaust
    manifold exhaust port to that portion of the thermocou-
    ple perpendicular to the tip of the stem should be 3-1/16
    inches ±1/4 inch (see Figure 5.35-38).

    LEFT BANK EXHAUST


    MANIFOLD
    /SECTION
    TURBO EXHAUST
    INLET ELBOW C-:\ EXHAUST
    "",1/31 Y THERMOCOUPLE

    @ ~@~\,~<D~ FRONT
    REAR

    /' '~vn~~r---~nrr-~v-~~~~rt--~,w~"V~THERMOCOUPLE
    THERMOCOUPLE CONDurr
    LEADS 14 13 12 11 10 98 7 6 54 32 1

    RIGHT BANK

    Figure 5.35-37. Exhaust Thermocouples Arrangement - 12 Cylinder

    5.35 - 18 FORM 6248 First Edition


    EXHAUST SYSTEM

    CONNECTOR TUBE FmlNG


    (STAINLESS STEEL)

    Figure 5.35-38. Exhaust Thermocouple Installation

    THERMOCOUPLE CLEAN AND INSPECT 3. Turn the panel mounted pyrometer selector to the
    A wide variation between one cylinder and another, or "Off' position. The pyrometer temperature reading
    one bank and another, may indicate a dirty or faulty should be equivalent to the ambient air temperature.
    thermocouple. Clean or replace the thermocouples as The thermocouple assembly consists of two wires of
    required. dissimilar metals connected within a protecting tube or
    stem. A portable pyrometer measures the small electric
    IA
    ..
    CAUTION I Do not use a battery pow-
    ered test light or similar
    current generated by the thermocouple and translates
    the voltage into a temperature reading.
    device to check the thennocouple circuit without
    completely disconnecting the pyrometer. Applying 4. Unthread the ferrule nut (9/16 inch hex) from the
    body of the thermocouple connector. A thermocouple
    uncontrolled voltage to the pyrometer will damage
    the instrument. Disregarding this Information could connector is mounted in the exhaust port of each
    section of the exhaust manifold and in the turbocharger
    result in product damage and/or personal Injury.
    exhaust inlet elbow(s).
    1. Since a very small voltage is generated at the 5. Pull the thermocouple out of the exhaust passage.
    thermocouple, verify that all electrical connections are
    in good condition. All wire ends and terminal connec- 6. Check the thermocouple stem for carbon buildup. If
    tions must be clean and dry. necessary, thoroughly clean the thermocouple using
    solvent and a soft wire brush.
    2. Check the reading of the thermocouple when
    heated. The pyrometer dial should read up scale. The 7. Insert the stem of the thermocouple back into the
    reading will be in the opposite direction if the wiring was exhaust passage.
    inadvertently reversed during installation.
    8. Wrench tighten the ferrule nut.

    FORM 6248 First Edition 5.35 - 19


    EXHAUST SYSTEM

    WASTEGATES WASTEGATES - PIN SERIES 208372


    )
    WASTEGATES - BLEEDING AIR PIN SERIES 208372 WASTEGATE REMOVAL
    1. Drain enough coolant from the auxiliary cooling
    -A. CAUTION ITrappe~airintheauxilia- water circuilto drop the water level below the level olthe
    I ~=~=..:..::.....:~;:;..;:....:..J. ry cooling water circuit
    1.... .

    wastegate(s). It is not necessary to drain the entire


    leads to overheating that can result in wastegate
    cooling system.
    damage and premature engine failure. Disregarding
    this information could result in product damage 2. Loosen the ferrule nuts (9/16 inch hex) to detach the
    and/or personal Injury. compressor discharge pressure sensing tubes from the
    "Air" port althe side of each wastegate (male elbow tube
    Air bleed the auxiliary cooling water circuit at least once
    fitting - both banks) (see Figure 5.35-39).
    each day. Always air bleed the circuit after refilling or
    topping off the cooling system. Open and close the four
    air bleed petcocks in the order listed below, starting at WASTEGATE WATER
    the lowest petcock in the system and ending at the RETURN TUBE (RB)
    highest. Bleed one petcock at a time. The number of air
    bleed petcocks and their locations are as follows in
    Table 5.35-2:
    Table 5.35-2. Air Bleed Petcocks -
    Auxiliary Cooling Water Circuit
    NUMBER OF LOCATION
    PETCOCKS
    Intercooler water inlet/outlet bonnets
    2 (upper rear)
    Wastegate water return tube
    2 (rear right and left bank)
    I

    A WARNING
    Always wear protective clothing when bleeding the
    cooling system on a heated engine. Slowly loosen
    the air bleed petcock to relieve any excess pres-
    sure. Escaping steam and/or hot water could result
    in severe personal injury or death. Figure 5.35-39. Intercooler/Wastegate Tube
    Connections
    1. Initial Bleed: open the air bleed petcock prior to
    engine startup. A hissing sound often accompanies the
    3. Loosen the ferrule nuts (11/16 inch hex) to detach
    escape of trapped air. Close the petcock when the
    the two water return tubes from the wastegate water
    hissing stops and water begins to flow out in a solid
    outlet ports (male connector tube fitting - right bank;
    steady stream.
    male elbow tube fitting - left bank).
    2. Check Bleed: start the engine and reopen the
    NOTE: The word 'Water" appears just above the
    petcock. Close the petcock when the hissing stops and
    wastegate base flange between the water inlet and
    water begins to flow out in a solid steady stream.
    outlet ports, the side with the peteoek being the out/et
    3. Final Bleed: once the temperature of the jacket port.
    water circuit has stabilized (as indicated by the tempera-
    4. Loosen the ferrule nuts (11/16 inch hex) to detach
    ture gauge), reopen the petcock. Close the petcock
    the two water supply tubes from the wastegate water
    when the water begins to flow out in a solid steady
    inlet ports (male elbow tube fitting - right bank; male
    stream.
    connector tube fitting - left bank) (see Figure 5.35-39).

    5. Alternately loosen and remove the four 3/8 inch


    stainless steel lock nuts (thin) from the wastegate
    mounting studs.

    5.35 - 20 FORM 6248 First Edition


    EXHAUST SYSTEM

    6. Alternately loosen and remove the four 3/8 inch 2. Position the wastegate in a suitable press. Use two
    stainless steel hex nuts (thick) from the mounting studs. rest blocks to properly support the base flange (see
    Remove the stainless steel lock washers. Figure 5.35-41).

    7. Remove the wastegates from the mounting studs.

    IA
    ,..
    CAUTION I Exercise care to keep the
    gasket material out ofthe
    turbo exhaust inlet elbow. Allowing gasket material
    to enter the turbo exhaust inlet elbow could result in
    product damage and/or personal injury.

    8. Remove the gaskets from the turbo exhaust inlet


    elbows or wastegate base flanges.

    PIN SERIES 208372 WASTEGATE DISASSEMBLY


    1. On PIN Series 208372 Wastegates, remove the
    breather vent plug from the center of the wastegate
    cover (see Figure 5.35-40).

    A WARNING
    The wastegate cover compresses a powerful
    spring. Wear proper eye protection. Exercise cau-
    tion to avoid severe personal Injury or death.

    ,- BRONZE FILTER Figure 5.35-41. Wastegate Disassembly

    3. Center a piece of flat stock on the wastegate cover to


    @'BREATHER
    VENT PLUG
    evenly distribute the pressing force on
    the cover surface
    area.

    WASTEGATE
    COVER
    ~
    IA CAUTION I To avoid damage to the
    waste gate cover, use
    L.==-...::.:....:...::....:..:....::....:~.

    just enough ram pressure to hold the cover while


    relaxing the valve spring(s). Disregarding this
    information could resuH in product damage and/or
    personal injury_

    4. Lower the ram until it makes contact with the flat


    stock on the wastegate cover.
    'WASTEGATE
    BASE 5. Remove the five wastegate cover capscrews
    (1/4 x 3 inches, with lock washers).

    Figure 5.35-40. Wastegate Breather Vent

    FORM 6248 First EdHion 5.35 - 21


    EXHAUST SYSTEM

    NOTE: If a press is not readily available, remove only 6. Slowly raise the ram. The wastegate cover will
    two of the five wastegate cover capscrews (see separate from the base assembly as the internal springs )
    Figure 5.35-42). Leave three capscrews in place, so become completely extended. Remove the wastegate
    that the cover does not cock as it is raised. Alternately from the press.
    loosen each remaining capscrew 1/4 inch until the valve
    spring is completely relaxed. 7. On PIN Series 208372 Wastegates, remove the
    wastegate cover from the base assembly. Remove the
    spacers, spring(s) and shims (see Figure 5.35-43).
    REMOVE Count and record the number of spacers, springs and
    CAPSCREWS
    shims to ensure proper assembly.

    8. Remove the castle nut from the tip of the poppet


    valve stem.

    9. Remove the diaphragm retainer, plate and flat


    washer from the end of the poppet valve stem. Remove
    the diaphragm from the retainer and discard.

    10. Slide the poppet valve from the base assembly.

    POPPET

    )
    Figure 5.35-42. Wastegate - PIN Series 208372 -
    Bottom View

    (MAY HAVE TWO SPRINGS DEPENDING ON APPLICATION)

    COMPRESSOR DISCHARGE CONNECTION .DI,~PtIRA,GM RETAINER

    VALVE
    POPPET

    mn(]
    "-BREATHER
    VENT PLUG

    MOUNTING r,4!OKIOT'

    SPACER )
    Figure 5.35-43. VHP Wastegate - PIN Series 208372 - Cutaway

    5.35-22 FORM 6248 First Ed~ion


    EXHAUST SYSTEM

    PIN SERIES 208372 WASTEGATE - CLEANING BRONZE FILTER


    AND INSPECTION

    A WARNING
    Compressed air can pierce the skin and could result
    in severe personal injury or death. Never use your
    hand to check for leaks or to determine air flow WASTEGATE
    rates. Wear safety glasses to shield your eyes from COVER
    flying dirt and debris.

    1. Clean all parts of the assembly in a non-volatile


    cleaning solution or solvent. Dry with moisture free
    compressed air.

    2. Replace the breather vent plug if damaged or


    missing. ""- WASTEGATE
    BASE
    3. Inspect the valve stem nut, flat washer, diaphragm
    retainer and plate. Inspectthe spring(s), spacers, shims
    and cover (see Figure 5.35-43). Replace any part that is
    damaged or excessively worn.
    Figure 5.35-44. Wastegate Breather Vent
    4. Inspect the valve guide bore to verify that it is smooth
    and not worn. The bore ID must measure between
    0.456 and 0.459 inch (11.58 - 11.66 mm).lfthe ID is out 3. Soak the plug in a non-volatile cleaning solution or
    of specification, press the old guide out in a downward solvent. Dry with low pressure compressed air.
    direction. Press in a new guide from the top until the top
    of the guide is flush with the top of the base. 4. Replace the breather vent plug if damaged or
    missing.
    5. Inspect the valve stem for straightness, scoring or
    excessive wear. Check the valve shoulder for wear.
    Check the valve face for pitting, scoring or scuffing. I "
    A CAUTION 1
    Do note operate the en-
    glne without a breather
    Clean the poppet valve. Measure the outside diameter vent plug Installed or with a clogged breather vent.
    ofthe stem to verify that it is within specification, 0.4485 Air must pass through the vent to maintain atmo-
    inches (11.39 mm) and 0.451 inches (11.45 mm). spheric pressure at the top of the wastegate
    diaphragm. The filter element in the plug prevents
    Replace the poppet valve if damaged, excessively worn dirt and dust from entering the upper wastegate
    or out of specification. assembly. Any accumulation of dirt may damage
    Breather Vent Cleaning the diaphragm or reduce Its service life. Operating
    the engine without a breather plug could result in
    Clean and inspect the filter in the wastegate breather product damage and/or personal Injury.
    vent once each year.
    1. Remove the brass vent plug in the center of the 5. Install the vent piug in the center of the wastegate cover.
    wastegate cover (see See Figure 5.35-44).
    Tube Connections Inspection
    2. Carefully inspect the sintered bronze filter for any 1. Inspect the wastegate compressor discharge pres-
    accumUlation of dirt. sure sensing tubes and the water supply/return tubes.
    Look for cracks, cuts, dents, holes or other damage.
    A WARNING Replace the tubes, if necessary.

    Compressed air can pierce the skin and could result 2. Inspect the tube connections for tightness. If loose,
    in severe personal injury or death. Never use your advance the ferrule nut to obtain a leak-tight seal.
    hand to check for leaks or to determine air flow
    rates. Wear safety glasses to shield your eyes from
    flying dirt and debris.

    FORM 6248 First Edition 5.35 - 23


    EXHAUST SYSTEM

    PIN SERIES 208372 WASTEGATE ASSEMBLY number removed at the time of disassembly. If any
    shims are replaced, be sure to use the correct size
    1. Insert the threaded end olthe poppet valve stem into (either 0.040 inch or 0.060 inch).
    the valve guide bore at the bottom of the base assembly
    (see Figure 5.35-45). 10. Place the valve springes) over the valve spring seat
    inside the wastegate cover.
    DIAPHRAGM

    /
    RETAINER
    A WARNING
    To avoid severe personal Injury or death, exercise
    caution when compressing the valve springes).
    Wear proper eye protection.

    11. Position the wastegate base assembly in a suitable


    press. Use two rest blocks to properly support the base
    flange.

    12. Align the holes in the diaphragm with those in the


    flange of the base assembly.

    13. Position the spacers on the flange of the base


    assembly. Align the holes in the spacers with those in
    the diaphragm. Be sure the number of spacers installed
    equals the number of spacers removed.
    Figure 5.35-45. Wastegate Assembly

    2. Slide the flat washer over the threaded end of the


    A WARNING
    valve stem until it contacts the valve shoulder.
    The wastegate cover compresses a powerful )
    spring. Wear proper eye protection. exercise cau-
    3. Slide the recessed side of the diaphragm plate over tion to avoid severe personal injury or death.
    the valve stem until the upraised area around the valve
    stem hole contacts the washer. 14. Position the wastegate cover over the base assem-
    bly. Holding the spring against the wastegate cover to
    4. Place the diaphragm retainer (open side up) into the retain the shims, slide the free end olthe spring over the
    hollowed side of a new diaphragm. valve stem nut until it rests against the spring seat in the
    diaphragm retainer.
    5. With the bowl facing upward opposite the base
    assembly, slide the diaphragm retainer over the valve 15. Center a piece of flat stock on the wastegate cover
    stem until it contacts the plate. to evenly distribute the pressing force on the cover
    surface area. Rotate the cover to align the holes with
    6. Finger tighten the valve stem nut. those in the base assembly.

    . CAUTION ____ I~nstall


    16. Lower the ram until it makes contact with the flat
    I. .,:.A==--...;.... a pair of b",:ss jaw
    :---'.'"serts In the vise to
    avoid damage to the valve. Disregarding this
    stock on the wastegate cover.

    Information could result in product damage and/or CAUTION I


    I=.A=:......:;..;.-'-...;.........;;-'-~:...J.
    To avoid damage to the
    personal injury. L.. . wastegate cover, use
    only enough ram pressure to compress the valve
    7. Place the base assembly upright in the vise and springes). Disregarding this information could re-
    apply enough pressure to the valve face to prevent the sult in product damage and/or personal injury.
    stem from turning.
    17. Lower the ram until the wastegate cover makes
    8. Torque the valve stem nut to 100 - 120 in-Ib contact with the spacers on the upper flange of the base
    (11.5 - 13.5 N·m). assembly.
    9. Place the shims over the valve spring seat centered 18. Install and tighten the five wastegate cover
    inside the wastegate cover (see Figure 5.35-43). Be capscrews (1/4 x 3 inches, with lock washers).
    sure the number of shims installed is the same as the

    5.35 - 24 FORM 6245 First Edition


    EXHAUST SYSTEM

    NOTE: If a press is not readily available, start only three PIN SERIES 208372 WASTEGATE CALIBRATION
    of the five wastegate cover capscrews (see Test the wastegate before installation. If the test results
    Figure 5.35-46). To prevent the cover from cocking, do not conform to specification, then the wastegate
    alternately tighten each capscrew 1/4 inch until the must be recalibrated and then retested.
    internal valve spring is compressed and the wastegate
    cover is tight. Install the two remaining capscrews. Wastegate Calibration Test Preparation
    Obtain the following equipment see Figure 5.35-47 and
    INSTALL Figure 5.35-48:
    CAPSCREWS
    o Air supply pressure, 50 psi minimum.

    o Air Pressure Regulator, range 0 psi to the shop


    supplied air pressure maximum.

    o Air Pressure Gauge, range 0 - 30 psi in 0.1 psi


    increments. The best gauge will include measure-
    ment in inches of mercury ("Hg).

    o Tubes and fittings (1/4 inch minimum) pressure rated


    at or above the shop air supply pressure maximum.

    o Dial indicator, 0.001 inch accuracy, 1 inch of travel.

    o Wastegate calibration Tool.

    Figure 5.35-46. Wastegata - PIN Series 208372 -


    Bottom View
    TOP
    VIEW
    19. Alternately torque the wastegate cover capscrews
    to 40 - 70 in-Ib (4.5 - 8.0 N·m).

    20. Release the ram pressure and remove the waste-


    gate from the press.

    IA
    ..
    CAUTION I Do not operate the engine
    without a breather vent '--- -----.I 0.50"
    plug installed. The filter element in the plug prevents ,3.50" ----; ~
    dirt and dust from entering the upper wastegate
    assembly. Any accumulation of dirt may damage the SIDE
    diaphragm or reduce Its service life. A plugged or VIEW
    clogged breather vent could result in product
    damage and/or personal InJury.

    21. Install the breather vent plug in the center of the --' 1.876" l.-
    wastegate cover. I I

    BOTTOM
    VIEW

    Figure 5.35-47. PIN Series 208372 Wastagate


    Calibration Tool

    FORM 6248 First Edition 5.35 - 25


    EXHAUST SYSTEM

    REGULATOR

    PLANT AIR SOURCE

    GAUGE-PSIG
    (0.1 PSI INCREMENTS)

    Figure 5.35-48. PIN Series 208372 Wastegate Calibration

    22. Loosen the set screw and slide the gauge block
    "'-.- t:::::I n-I
    DIAL INDICATOR DIAL INDICATOR
    beneath the dial indicator (see Figure 5.35-49). Tighten STANO
    the set screw.

    GAUGEBLOCK

    '"
    WASTEGATE
    CALIBRATION TOOL WASTEGATE
    )
    / f
    2.46"
    JJ_ T
    CALIBRATION
    /TO
    OL

    ~
    NOMINAL /
    WASTEGATE HEIGHT

    PLACE THIS END IN VISE

    Figure 5.35-50. PIN Series 208372 Wastegate


    Calibration Setup

    Figure 5.35-49. PIN Series 208372 Wastegate 24. Loosen the set screw, return the gauge block to the
    Calibration Tool side of the calibration tool and tighten the set screw.

    25. Place the extension at the bottom of the calibration


    23. Zero the outer dial (hundredths) on the dial tool in a vise (see Figure 5.35-49). Verify that the unit is
    indicator. Record the reading of the tenths indicator with level and tighten the vise to secure the calibration tool
    the gauge block in place. The preload indicated by the against movement.
    tenths indicator gives you the nominal wastegate test
    height (see Figure 5.35-50).

    5.35 - 26 FORM 6248 First Edition


    EXHAUST SYSTEM

    26. Bolt the wastegate in the calibration tool using an height." The "zero height" is the value that was recorded
    alternating pattern (see Figure 5.35-51). Verify that the on the tenths indicator when the outer dial (hundredths)
    tip of the dial indicator is placed near the center of the was zeroed under step #5 of Wastegate Calibration,
    poppet valve face. Setting Up.

    3. Record the reading of the air pressure gauge while


    DIAL INDICATOR the poppet valve is at the "zero height."
    STAND
    PIN Series 208372 Wastegate Calibration Adjust-
    ment
    Aiter the size of the shim pack to bring the nominal
    pressure within specification. Shims are available in
    WASTEGATE
    CALIBRATION 0.040 inch (1.02 mm) and 0.060 inch (1.52 mm)
    TOOL thicknesses.
    1. If the reading of the air pressure gauge is below the
    lower limit listed in the Wastegate Calibration Chart,
    then the pressure must be increased. Remove the
    wastegate cover and add the correct number of shims to
    the shim pack. Repeat the test procedure.
    ~-,~
    BOLT WASTEGATE 2. If the air pressure gauge reading is greater than the
    TO CALIBRATION
    TOOL upper limit listed in the Wastegate Calibration Chart
    (see Table 5.35-3), then the pressure must be reduced.
    Remove shims from the shim pack as necessary.
    Repeat the test procedure.

    NOTE: The calibration procedure is only intended for


    those wastegates using original components or the
    specified replacement parts.
    Figure 5.35-51. Wastegate Calibration Setup

    A CAUTION I
    PIN Series 208372 Wastegate Calibration Testing I!!!!"'!!!!!!'-=:":"'=~:"':::"':";:..J.
    L..
    Do not modify waste-
    gates. Any type of waste-
    gate conversion can result in serious engine
    1. To ensure that the test produces the correct valve
    damage. Do not rebuild wastegates using spare
    height measurement, tap on the wastegate housing
    parts of unknown origin. Disregarding this informa-
    with a wrench to prevent the poppet valve from sticking.
    tion could result In product damage and/or person-
    2. Slowly increase the air supply pressure to the al injury.
    wastegate until the dial indicator reaches the "zero
    Table 5.35-3. Nominal Pressure For PIN Series 208372 Wastegate Calibration Test
    WASTEGATE PIN NOMINAL CALIBRATION PRESSURE ("HG) SPACER(S) SHIMS*
    208372-A 11.8-12.1 2 0.140
    208372-B 14.0 - 14.4 1 0.060
    2OB372-C 13.0 - 13.3 2 0.240
    208372-0 23.4 - 23.8 2 0.040
    208372-J 25.1 - 25.6 1 0.188
    208372-5 21.6 - 22.0 1 0.206
    20B372-U 47.0 - 48.7 2 0.206
    208372-V 45.4 - 46.8 2 0.065
    208372-W 42.0 - 43.4 3 0.065

    ) 20B372-X 15.0 - 15.3 1 -


    20B372-Y 19.5 - 19.8 1 0.080

    FORM 6248 First Edition 5.35 - 27


    EXHAUST SYSTEM

    WASTEGATES - PIN SERIES 295645 4. Loosen the ferrule nuts (11/16 inch hex) to detach
    the two water supply tubes from the wastegate water
    PIN SERIES 295645 WASTEGATE REMOVAL - inlet ports (male elbow tube fitting - right bank; male
    DRAW THRU ONLY connector tube fitting - left bank) (see Figure 5.35-53).
    1. Drain enough coolant from the auxiliary cooling
    water circuit to drop the water level below the level of the WASTEGATE WATER WASTEGATE WATER
    wastegate(s). It is not necessary to drain the entire SUPPLY TUBE (LB) RETURN TUBE (RB)
    cooling system.

    2. Loosen the ferrule nuts (9/16 inch hex) to detach the


    compressor discharge pressure sensing tubes from the
    "Air" port althe side of each wastegate (male elbow tube
    fitting - both banks) (see Figure 5.35-52).

    WASTEGATE WATER
    RETURN TUBE (RB)

    Figure 5.35-53. Intercooler/Wastegale Tube


    Connections )
    5. Alternately loosen and remove the four 3/8 inch
    stainless steel lock nuts (thin) from the wastegate
    mounting studs.

    6. Alternately loosen and remove the four 3/8 inch


    stainless steel hex nuts (thick) from the mounting studs.
    Figure 5.35-52. Intercooler/Wastegale Tube Remove the stainless steel lock washers.
    Connections
    7. Remove the wastegates from the mounting studs.

    3. Loosen the ferrule nuts (11/16 inch hex) to detach


    the two water return tubes from the wastegate water IA
    ..
    CAUTION I Exercise care to keep the
    gasket material out of the
    outlet ports (male connector tube fitting - right bank;
    turbo exhaust Inlet elbow. Allowing gasket material
    male elbow tube fitting - left bank). to enter the turbo exhaust inlet elbow will result In
    NOTE: The word "Water" appears just above the product damage and/or personal injury.
    wastegate base flange between the water inlet and
    outlet ports, the side with the petcock being the out/et 8. Remove the gaskets from the turbo exhaust inlet
    port. elbows or wastegate base flanges.

    5.35 - 28 FORM 6248 Forst Edition


    EXHAUST SYSTEM

    PIN SERIES 295645 WASTEGATE DISASSEMBLY 1. Compare the reading of the air pressure gauge with
    - DRAW THRU ONLY the nominal calibration pressures listed in the chart (see
    The wastegates have a diaphragm that may require Table 5.35-4). The wastegate must be adjusted ilthe air
    replacing. Servicing the wastegate is beyond the scope pressure reading does not fall within the established
    of this manual. For detailed servicing instructions and a range. The nameplate pinned to the wastegate cover
    list of parts, consult your local distributor. identifies the wastegate part number.

    PIN SERIES 295645 WASTEGATE CALIBRATION 2. To test the wastegates, the following equipment is
    SETUP - DRAW THRU ONLY needed:

    • Air source with a minimum air pressure of 50 psi


    A WARNING (345 kPa).

    Wastegate adjusting may only be performed by • One air regulator 0 - 50 psi (0 - 345 kPa). Regulator
    factory technicians or authorized distributor repre- must have range from 0 psi (0 kPa) to maximum of
    sentatives. Improper wastegate adjustment may shop air supplied.
    resuH in violent component failure resulting in
    severe personal InJury or death. • One gauge with a range of 0 - 30 psi (0 - 206 kPa)
    with increments of 0.1 psi (0.7 kPa). A preferable
    A WARNING gauge will include measurement in inches of mercury
    ("HG) in addition to psi.
    Do not install the PIN 295645A wastegate in the
    UNSET condition. The PIN 295645A wastegate must • Tubing and fittings (1/4" minimum) to connect the
    be set to the proper setting before installation on related components together (see Figure 5.35-54).
    the engine. Installing the PIN 295645A wastegate in Tubing and fittings must have pressure ratings at or
    the UNSET condition may resuH in violent compo- above the supplied air pressure.
    nent failure resulting in serious personal injury or
    REGULATOR
    \
    , death.
    ....y_ _ _ _~
    /AIR-SUPPI:
    Table 5.35-4 lists the Waukesha Engine PIN and
    wastegate nominal control pressure setting required PLANT AIR
    for each engine application. Note that each waste- SOURCE
    gate is selfor a specific value with the exception olthe
    PIN 295645Awastegate. Wastegate PIN 295645A is
    sold as a general service part and is not set to any - - - GAUGE-PSIG
    (0.1 PSI INCREMENTS)
    specific control pressure. The PIN 295645A waste-
    gate must always be set with the proper setting forthe Figure 5.35-54. Wastegate Adjusting
    engine application before installation.

    Table 5.35-4. Adjustable Wastegate Settings - Draw Thru Engines Only


    PIN ENGINE MODEL NOMINAL CONTROL PRESSURE (IN. HG)
    295645A N/A UNSET
    295645D 5790GL Draw - thru 1000 RPM 51.8 - 52.2
    295645E 7042GL Draw - thru 1000 RPM 50.2 - 50.5
    295645F 7042GL Draw - thru 1200 RPM 47.8 - 48.2
    295645G L7042GSI Draw - thru for 1200 RPM - (ConI. Duty) 17.5 -17.8
    NOTE: Always calibrate both wastegates as a set when replacing or recaJibrating one wastegate on Vee engines. Failure to do this will cause
    an imbalance between engine banks.

    FORM 6248 First Edition 5.35 - 29


    EXHAUST SYSTEM

    3. Remove the gasket from the wastegate mounting 3. Loosen the jam nut and turn the adjustment screw
    face (see Figure 5.35-55). until the distance from the face of the poppet to the
    wastegate mounting face (without gasket) is 2.46 inches
    / (62.484 mm) (see Figure 5.35-56 and Figure 5.35-57).

    REMOVE
    GASKET",
    j 1(
    \ f
    2.46;n

    -. -.....
    j lr
    ±
    \ -=rmm

    Figure 5.35-55. Wastegste Gasket Removal


    ~

    4. Mount the wastegate in a vise with the axis/center- Figure 5.35-56. Wastegate Poppet To Wastegate
    line vertical and the valve poppet up. Mounting Face Measurement

    NOTE: Connect the gauge at the compressor dis- NOTE: Insure that the adjustment screw is not turned
    charge connection to insure accurate gauge readings. while tightening the jam nut.
    5. Connect the air source. regulator and gauge to the 4. Tighten the jam nut to lock the adjustment screw in
    compressor discharge pressure sensing connection position (see Figure 5.35-57).
    with the necessary tubing.
    I
    6. Slowly increase the air pressure to the wastegate by
    adjusting the regulator. Use minimal air pressure
    (dependent on specific wastegate) to force the poppet
    tr(=~~
    valve through its entire range of travel. When the valve
    )
    is moving. watch the valve for smooth operation through
    --L- Ie -n: \
    its range of motion. If the valve sticks. the related
    components must be checked.
    ~I' f--

    PIN SERIES 295645 CALIBRATION PROCEDURE


    TEST - DRAW THRU ONLY

    NOTE: Always calibrate both wastegates as a set


    when replacing or recalibrating one wastegate on Vee
    engines. Failure to do this will cause an imbalance
    between engine banks.
    \ >--LI ~
    f.LJJ
    t
    .L.!!
    ..
    CAUTION I
    I A!!:!!!!!.....::::....:.:::....::...:..:::::..::.:..J.
    Insure the gasket is re-
    moved from the waste-
    gate mounting face. Failure to remove the gasket j'- •
    COMPRESSO~ Jl~COOLAIfr
    from the wastegate mounting face will result in an
    inaccurate reading causing damage to equipment
    and/or personal Injury. CONNECTIONS
    DISCHARGE 0
    CONNECTION ON B TH SIDES OF
    1. Use a wrench to tap on the wastegate housing to 0.250-18 NPTF WASTEGATE
    prevent the valve from sticking during the test. to insure "- .I
    a proper valve height measurement.
    Figure 5.35-57. Wastegate Adjusting -
    2. Slowly apply air to the wastegate until the pressure PIN Series 295645
    reading agrees with the nominal control pressure range
    specified for that part number (see Table 5.35-4).

    5.35 - 30 FORM 6248 First Edition


    EXHAUST SYSTEM

    5. Release the pressure from the wastegate complete- PIN SERIES 295645 WASTEGATE INSTALLATION
    ly and let the valve return to its seated position. Apply - DRAWTHRU ONLY
    pressure per Step 2 above and confirm that the valve
    travels to the same 2.46 inch (62.484 mm) dimension.
    IA CAUTION IDeposits left on gasket
    Readjust if necessary and tighten the jam nut. 1..
    • .:: . surfaces will cause
    .="--..;=,.;.;;:.....;:....:....::............
    leaks. Exercise care to keep the gasket material out
    6. If the valve does not retum to the 2.46 inch (62.484 mm) of the turbo exhaust Inlet elbows. Verify that the
    dimension, it is an indication that the valve is sticking and gasket and gasket mating surfaces are clean and
    not working freely. If slight vibration or tapping of the completely free of grease and oil. Disregarding this
    assembly retums the valve to the 2.46 inch (62.484 mm) Information could result in product damage and/or
    dimension, the wastegate can be used. If slight tapping or personal Injury.
    vibration does not return the valve to the 2.46 inch
    (62.484 mm) height, the wastegate is not operational and 1. Scrape the old gasket material from the wastegate
    should be repaired or returned to the supplier. mounting pad at the top of the turbo exhaust inlet
    7. Stamp the proper wastegate WED PIN on the elbows.
    wastegate name plate per Table 5.35-4, after the 2. Position a new gasket on the wastegate mounting
    control pressure has been set. studs.
    8. Install the gasket to the wastegate mounting face 3. With the compressor discharge air connection
    (see Figure 5.35-55). opposite the crankcase vee, the male elbow tube fitting
    pointing to the rear of the engine. position the waste-
    gates on the mounting studs.

    4. Position 3/8 inch stainless steel lock washers over


    the mounting studs.

    5. Using a small paintbrush. apply Bostik Never-


    Seez® Anti-Seize and Lubricating Compound to the
    threads of the mounting studs.

    6. Thread the 3/8 inch stainless steel hex nuts (thick)


    onto the mounting studs. Install the nuts down until they
    contact the lock washers. Alternately tighten the nuts to
    ensure that the wastegate does not tilt.

    7. Thread stainless steel lock nuts (thin) onto the


    mounting studs. Secure the thick stainless steel nuts
    with a wrench and tighten the thin lock nuts against the
    thick stainless steel nuts in an alternating pattern.

    FORM 6248 First Ednion 5.35 - 31


    EXHAUST SYSTEM

    LEFT BANK
    I----~----~==~
    I
    I

    ,-'+-- ----r-- ~ ____

    • ar:::nk
    J
    TO OIL COOLER

    r;l(]]~ FROM AUXIUARY


    I I WATER PUMP
    I
    \ I
    INTERCOOLER
    Ilr
    I
    I I t
    I

    L.. J I
    L __ ....... __
    RIGHT BANK

    ---+ COMPRESSOR DISCHARGE PRESSURE SENSING TUBES


    )
    ---l.~ WATER SUPPLY TUBES
    --....,1> WATER RETURN TUBES

    Figure 5.35-58. Wastegate Connections

    8. Finger tighten the ferrule nuts (11/16 inch hex) to CAUTION ITrappe~alrlntheauxiIi~­
    I...-=.A=;......;:........;;...;'-_.::....;~.
    attach the two water supply tubes to the wastegate . ry cooling water cirCUit
    water inlet ports (male elbow tube fitting - right bank; leads to overheating that can result in wastegate
    male connector tube fitting - left bank) (see damage and premature engine failure. Disregarding
    Figure 5.35-58). this Information could result in product damage
    and/or personal injury.
    NOTE: The word 'Water" appears just above the
    wastegate base flange between the water inlet and outlet 13. Bleed trapped air. See Wastegates, Bleeding Air.
    ports, the side with the petcock being the outlet port.
    ENGINE ALTITUDE ADJUSTMENTS
    9. Finger tighten the ferrule nuts (11/16 inch hex) to

    CAUTION I
    attach the two water return tubes to the wastegate water
    outlet ports (male connector tube fitting - right bank;
    male elbow tube fitting - left bank).
    IA
    ..
    Engines must be derated
    for altitude. Adjusting
    wastegates to obtain rated load at high altitudes
    10. Finger tighten the ferrule nuts (9/16 inch hex) to can result in turbocharger overspeed and failure.
    attach the free end of the compressor discharge Disregarding this information could result in prod-
    pressure sensing tubes to the "Air" port at the side of uct damage and/or personal injury.
    each wastegate (male elbow tube fitting - both banks).
    Wastegates on VHP GL engines are set to produce
    11. Wrench tighten all ferrule nuts. rated load at Sea Level upto 1500 ft. (457 m). Apply the
    standard derate to all intermittent and continuous duty )
    12. Refill or top off the auxiliary cooling water circuit. engines: deduct 2% for each 1000 ft. (305 m) above
    1500 ft. (457 m).

    5.35 - 32 FORM 6248 First Ed~ion


    SECTION 5.40 - CRANKCASE BREATHER SYSTEM

    CRANKCASE BREATHER SYSTEM CRANKCASE


    VAPOR OUTLET
    COMPONENTS
    The components of the crankcase breather system are SEPARATOR
    / CELLULAR
    as follows: LID

    • Separator Screen

    • Oil Separator(s)

    • Vacuum Valve/Choke Valve

    • Breather Regulator

    • Venturi Extractor - GSl/GL


    o
    • Venturi - GSI

    DESCRIPTION
    The purpose of the crankcase breather system is to MESH
    ELEMENT
    maintain a slight negative pressure in the crankcase.
    The negative pressure rids the crankcase of harmful
    water vapors and combustion gases (blowby), and
    helps to prevent sludge buildup and oil contamination.
    CRANKCASE
    The breather system is also designed to separate the oil AND OIL INLET
    from the vapors before the discharge is released into the
    atmosphere. Figura 5.40-1. Oil Separator - 12 Cylinder Engines
    The crankcase vapors are drawn through the cellular
    SEPARATOR SCREEN
    foam contained in the outlet side of the separator and
    12 cylinder engines have one crankcase separator pass through breather tubes to the venturi extractor,
    screen. The separator screen is on top of the cylinder where they are discharged into the atmosphere through
    block on the rear right side. the exhaust stack.
    The crankcase separator screen allows vapors to be As the crankcase vapors pass into the oil separator, the
    vented from the crankcase. It also serves to stop a flow of oil is restricted by a removable corrugated steel
    portion of the oil carried by these vapors from reaching mesh element. The condensed oil returns to the oil pan
    the oil separator. As the oil mist and vapors pass out of through a drain tube in the base of the separator
    the crankcase, the expanded metal elements in the housing. The crankcase vapors pass into the venturi
    separator screen restrict the flow of much of the oil, extractor, where they are drawn into the exhaust stack
    dropping the surplus back into the oil pan. and discharged into the atmosphere.
    OIL SEPARATOR(S) VACUUM VALVE/CHOKE VALVE
    The 12 cylinder engine has two oil separators. One is The vacuum valves allow the crankcase pressure to be
    mounted above the cylinder block at the rear right side adjusted externally. On G engines, the vacuum valve is
    of the engine. The oil separator is connected by a located on top of the oil separator. On GSI engines the
    breather tube to the crankcase separator screen in the vacuum valve is located on the breather tube leading to
    top of the cylinder block. the venturi. On GL engines and some GSI engines (if
    The second oil separator is connected by an elbow to venturi extractor equipped), the choke valve is located
    the vent in the gear housing cover althe front left side of at the front of the venturi extractor.
    the engine.
    As the crankcase vapors and oil mist pass through the
    oil separator, much of the oil adheres to the steel mesh
    element contained in the inlet side of the separator
    housing. This surplus oil condenses, drops into the base
    of the separator and returns to the oil pan (see
    Figure 5.40-1).

    FORM 6248 First Edition 5.40 -1


    CRANKCASE BREATHER

    BREATHER REGULATOR VENTURI EXTRACTOR - GSI/GL


    The crankcase breather regulator assembly is con- The crankcase breather system uses exhaust gas
    nected to the ejector breather or venturi extractor velocity to create a negative pressure in the crankcase.
    through a tee and pipe nipple arrangement. The crankcase vapors are drawn through the oil
    The breather regulator is above the water manifold in separators to the venturi extractor see Figure 5.40-3.
    the center of the crankcase vee. The venturi extractor creates a vacuum at the exhaust
    pipe connection to draw the crankcase vapors from the
    While the manual crankcase pressure adjustment oil separators into the exhaust stack.
    procedures represent coarse adjustments to the
    breather system, the crankcase vacuum regulator
    automatically performs the fine adjustments that are
    necessary to compensate for variations in speed and
    load. Maintaining a negative crankcase pressure is
    important to prevent oil leaks and vacate harmful
    vapors, but too much pressure pulls in environmental
    dust and dirt.
    With less load, less vacuum is required to vacate
    crankcase vapors. When the turbocharger compressor
    discharge air is reduced, a floating disc or plate within
    the crankcase breather regulator assembly drops down
    to restrict the amount of outside air pulled in (see
    Figure 5.40-2).

    Figure 5.40-3. Venturi Extractor/Choke Valve


    Assembly - GL Shown
    )
    NOTE: Some GSI engines may be equipped with a
    venturi extractor.
    E-CLIP The venturi extractor is mounted in a horizontal position
    at the top of the water manifold in the center of the
    crankcase vee.
    VENTURI - GSI
    GSI engines use a venturi configured as shown in figure
    Figure 5.40-4.

    UPPER VENTURI---........9
    \CREEN

    NUT
    ~-~ij
    Figure 5.40-2. Breather Regulator Assembly - Current
    LOWER VENTURI I
    ~
    Style

    With an increase in load, the amount of compressor V-BAND COUPLING ~


    ~
    discharge air from the turbochargers increases and the
    plate within the regulator floats up. More outside air is
    sucked in as the plate rises, which allows the breather
    system to draw a greater vacuum. Figure 5.40-4. Venturi Assembly - GSI Shown )

    5.40 - 2 FORM 6248 Firsl Edition


    CRANKCASE BREATHER

    CRANKCASE PRESSURE CRANKCASE PRESSURE ADJUSTMENT - GIGSI


    MEASUREMENT VENTURI EQUIPPED

    CRANKCASE PRESSURE MEASUREMENT - 1. Run the engine at rated speed and load.
    G/GSI/GL NOTE: A negative pressure of 0 - 1 inch (25.4 mm)
    NOTE: Measure the crankcase pressure at least once H20 is desirable at all speeds and loads.
    evel}' 3 months (2160 hours).
    2. Locate the vacuum valve (on G models, located on
    A negative crankcase pressure of 0 - 1 in. (25.4 mm) top of the oil separator, on GSI models, located on the
    H20 must be maintained. Proceed as follows: breather tube leading to the venturi) (see Figure 5.40-6
    and Figure 5.40-7).
    1. Remove the pipe plug from the oil level gauge support
    and install a tube connector in the hole (1/8 inch NPT)
    (see Figure 5.40-5). BUTTERFLY VALVE
    I HEX NUT

    h
    ~ ~
    '='1lib,
    J
    ADJUSTING
    SCREW
    1+o
    V
    I BREATHER TUBE

    Figure 5.40.0. Vacuum Valve ~ssembly - G

    BUTTERFLY VALVE

    I HEX NUT

    ~~~---ill BREATHER TUBE

    Figure 5.40-7. Vacuum Valve Assembly - GSI


    Figure 5.40-5. Install Water Manometer Tube
    Connector 3. Loosen the upper and lower hex nuts.

    4. Slowly turn the slotted screw to adjust the internal


    2. Connect one end of a water manometer to the
    butterfly valve, to restrict or open the the air flow until
    connector and vent the free end to the atmosphere; the
    proper pressure is attained.
    manometer line must not protrude beyond the inner
    surface of the gauge support or an inaccurate reading 5. Remove the engine load.
    may result.
    6. Measure the crankcase pressure again. Readjust
    3. Measure the crankcase pressure and perform all the vacuum valve if it is not within specification.
    pressure adjustments while the engine is operating at
    rated speed and load. (See Crankcase Pressure 7. Retest at rated speed and load. If the crankcase
    Adjustment.) pressure is within specification, use a screwdriver to
    hold the slotted screw in position and tighten the lower
    4. Remove the manometer line and tube connector. hex nut. Using a wrench to hold the lower hex nut in
    Install the pipe plug (see Figure 5.40-5). position, lock the lower hex nut by tightening the upper
    hex nut down on the lower hex nut.

    FORM 6248 First Edition 5.40 - 3


    CRANKCASE BREATHER

    8. If adjustment of manual control devices fails to NOTE: GSI engines may be equipped with either a
    properly regulate crankcase pressure: (venturi extractor/choke valve assembly, see )
    Figure 5.40-8 and Figure 5.40-9, or vacuum valve
    A. Clean the crankcase separator screen. assembly, see Figure 5.40-6 and Figure 5.40-7)
    B. Clean the crankcase oil separators (lor 2).

    C. Clean all breather tubes.

    D. Clean and inspect the venturi extractor assem-


    bly.

    E. Inspect the air cleaner prefilter pads and main


    filter elements. Clean or replace as necessary.

    F. Measure the exhaust backpressure. Excessive


    backpressure reduces breather system effec-
    tiveness.

    NOTE: After cleaning, servicing or replacing any com-


    ponent of the crankcase breather system, recheck the
    crankcase pressure to verify that it is within specification
    Figure 5.40-8. Venturt Extractor/Choke Valve
    and that all system components are functioning properly.
    Assembly - GL
    CRANKCASE PRESSURE ADJUSTMENT
    (VENTURI EXTRACTORNACUUM VALVE
    ASSEMBLY EQUIPPED) - GSI/GL
    The venturi extractor assembly employs turbocharger
    compressor discharge air to create a vacuum to pull )
    vapors out of the crankcase. The vapors are pulled
    through the oil separators and discharged into the
    atmosphere through the exhaust stack.
    The amount of air forced through the venturi extractor
    controls the amount of vacuum drawn. The more air, the
    greater the vacuum. The greater the vacuum, the higher
    the negative pressure in the crankcase.
    Figure 5.40-9. Venturt Extractor/Choke Valve
    All engines are provided with manual crankcase
    Assembly - GSI
    pressure adjustment. The adjustment is accomplished
    by admitting more or less outside air into the breather
    Crankcase pressure is manually adjusted by turning the
    system. All manual adjustment devices are externally
    choke valve on GSI (venturi extractor/vacuum valve
    controlled and easily accessible.
    assembly equipped) and GL engines (Figure 5.40-8
    and Figure 5.40-9) or by adjusting the vacuum valve on
    G and GSI (choke valve equipped) engines.

    NOTE: A negative pressure of 0 - 1 inch (25.4 mm)


    H20 is required at all speeds and loads.

    5.40 - 4 FORM 6248 First Edition


    CRANKCASE BREATHER

    1. Run the engine at rated speed and load.

    2. Locate the choke valve in the venturi extractor


    assembly (see Figure 5.40-10). The choke valve is
    threaded into a hole in the bottom ofthe venturi extractor
    pressure housing and is locked in place with a hex nut.

    3. Loosen the hex nut and seat the choke valve by


    turning it clockwise into the pressure housing.

    4. Slowly back the choke valve out of the pressure


    housing until the recommended negative crankcase
    pressure is obtained.

    5. Remove the engine load.

    6. Measure the crankcase pressure again. Readjust


    the choke valve if it is not within specification. Adjust the
    choke valve by turning it into or out of the pressure
    housing.

    7. Turn the choke valve out of the pressure housing


    (CCW) to increase the negative pressure. This action
    decreases the restriction in the venturi to increase the
    amount of air passing through.

    8. Turn the valve into the pressure housing (CW) to


    reduce the negative pressure. This action increases the
    restriction in the venturi to decrease the amount of air
    passing through.

    9. Retest at rated speed and load. If the crankcase


    pressure is within specification, tighten the hex nut to
    hold the choke valve setting.

    10. If adjustment of manual control devices fails to


    properly regulate crankcase pressure:

    A. Clean the crankcase separator screen.

    B. Clean the crankcase oil separators (lor 2).

    C. Clean all breather tubes.

    D. Clean and inspect the crankcase vacuum regula-


    tor assembly.

    E. Clean and inspecttheventuri extractor assembly.


    F. Inspect the air cleaner prefilter pads and main
    filter elements. Clean or replace as necessary.

    G. Measure the exhaust backpressure. Excessive


    backpressure reduces breather system effec-
    tiveness. Figure 5.40-10. Venturi Extractor Assembly
    NOTE: After cleaning, seNicing or replacing any com-
    ponent of the crankcase breather system, recheck the
    crankcase pressure to verify that it is within specification
    and that all system components are functioning properly.

    FORM 6248 First Edition 5.40 - 5


    CRANKCASE BREATHER

    CRANKCASE SEPARATOR SCREEN


    CRANKCASE SEPARATOR SCREEN REMOVAL
    A WARNING
    Compressed air can pierce the skin and cause
    12 cylinder engines have one crankcase separator severe personal Injury or death. Never use your
    screen. The separator screen is on top of the cylinder hand to check for leaks or to determine air flow
    block on the rear right side. Since obstruction of the rates. Wear safety glasses to shield your eyes from
    elements can affect the ability of the crankcase breather flying dirt and debris.
    system to draw a negative vacuum, the separator
    2. Dry the screening element from the inside out using
    screen should be inspected annually. (The engine has
    low pressure compressed air.
    another vent in the gear cover at the front left side of the
    engine, but it does not contain a screening element.) CRANKCASE SEPARATOR SCREEN ASSEMBLY
    1. On G engines, loosen the hose clamp and detach the 1. Position a new gasket over the rectangular hole on
    connecting hose from the oil separator flange. On GSI the top of the cylinder block (rear right corner) (see
    and GL engines disconnect the breather tube from the Figure 5.40-12). Verify that the gasket surfaces are
    oil separator (see Figure 5.40-11). clean and completely free of grease and oil.

    BREATHER
    / TUBE

    Figure 5.40-12. Crankcase - Rear Right

    2. Install the separator screen in the cylinder block.

    3. POSition a new gasket on the upper flange of the


    separator screen ( (see Figure 5.40-11). Verify that the
    gasket surfaces are clean and completely free of grease
    and oil.

    4. Fasten the breather tube and separator screen to the


    top of the cylinder block (2 ferry head capscrews, 3/8 x
    1-1/4 inches, with lock washers).
    Figure 5.40-11. Crankcase Separator Screen
    Assembly - 12 Cylinder Engines - GL Shown 5. Slide a loosened hose clamp over the top of the
    breather tube.
    2. Remove the two ferry head capscrews securing the
    breather tube and separator screen to the top of the 6. Insert the oil separator inlet pipe into the breather
    cylinder block. tube. Tighten the hose clamp.
    3. Remove the breather tube. 7. Install the U-bolt to secure the breather tube to the
    4. Raise and remove the separator screen. right bank air duct support bracket.
    CRANKCASE SEPARATOR SCREEN CLEANING
    NOTE: After cleaning, servicing or replacing any com- )
    AND INSPECTION
    ponent of the crankcase breather system, recheck the
    1. Wash the screen in a non-volatile cleaning solution crankcase pressure to verify that it is within specification
    or solvent, if necessary. and that all system components are functioning properly.

    5.40 - 6 FORM 6246 First Edition


    CRANKCASE BREATHER

    , 10

    ITEM NUMBER AND DESCRIPTION


    1 Breather Flange 4 Oil Separator 7 Hose 10 Breather Tube
    2 Capscrew 5 Gasket 8 Clamp 11 Vacuum Valve
    3 Lock washer 6 Hose 9 Breather
    Figure 5.40-13. 011 Separator - G

    OIL SEPARATORS 4. Remove the breather from the air cleaner duct.

    OIL SEPARATOR REMOVAL - G 5. Loosen hose clamp and remove the crankcase
    vacuum tube assembly from the breather.
    1. Loosen two hose clamps and disconnect the hose
    6. Loosen two hose clamps and remove the connecting
    from the crankcase vacuum valve assembly tube.
    hose between the air cleaner duct and the oil separator.
    ) 2. Loosen two hose clamps and disconnect the breath-
    7. Remove two ferry head capscrews, lock washers,
    er tube from the air cleaner duct.
    breather flange, gasket, and oil separator from the
    3. Loosen hose clamp and remove the crankcase crankcase (see Figure 5.40-13).
    vacuum valve assembly from the breather.
    FORM 6248 First Edition 5.40 -7
    CRANKCASE BREATHER

    OIL SEPARATOR INSTALLATION - G

    1. Install the oil separator on the crankcase with two


    ferry head capscrews, lock washers, breather flange,
    and gasket. m,~ l,_~ ELBOW
    2. Connect the oil separator assembly to the air duct OIL
    tube with hose and two hose clamps. SEPARATOR
    " __'l...~r---_
    3. Apply pipe sealant to threads, and install the
    breather to the air cleaner duct.

    4. Install the crankcase vacuum valve assembly to the


    breather with hose clamp.

    5. Install breather tube on the air cleaner duct with two


    hose clamps.

    6. Install the connecting hose between the air breather HOSE U-BOLT
    tube and crankcase vacuum valve assembly with two CLAMP J
    hose clamps.

    7. Loosen hose clamp and remove the crankcase


    ~Q,,?
    vacuum tube assembly from the breather.

    OIL SEPARATOR REMOVAL - GSI/GL


    One oil separator is mounted althe rear right side ofthe
    engine. A breather tube (unthreaded oil inlet pipe)
    connects this oil separator to the crankcase separator
    screen in the top of the cylinder block.
    /
    AIR DUCT
    )
    BRACKET
    A second oil separator is mounted at the front left side of
    the engine. A threaded oil inlet pipe connects this oil
    separator to a vent in the gear housing cover.
    Disassemble and clean the oil separators every 720
    BREATHER
    /
    hours. TUBE
    The oil separator must be completely removed from the
    engine for proper cleaning.
    Unthreaded Oil Inlet Pipe Figure 5.40-14. 011 Separator Assembly,
    Unthreaded Oil Inlet Pipe - GL Shown
    1. Loosen the hose clamps from the oil separator inlet
    and outlet pipes (see Figure 5.40-14).

    2. If necessary, loosen the U-bolt that holds the


    breather tube to the right bank air duct support bracket.

    3. Detach the oil separator outlet pipe from the breather


    elbow (top).

    4. Detach the oil separator inlet pipe from the breather


    tube (bottom).

    5.40 - 8 FORM 6248 First Edition


    CRANKCASE BREATHER

    Threaded Oil Inlet Pipe OIL SEPARATOR CLEANING AND INSPECTION -


    GSI/GL
    1. Loosen the hose clamp and detach the breather tube
    from the oil separator outlet pipe (see Figure 5.40-15). 1. Snap down the two retaining clips. Remove the lid
    from the body of the oil separator.

    2. Remove the rubber O-ring seal from the inside rim of


    the lid. Inspectthe seal for cuts, tears or loss of elasticity.
    Replace when necessary.
    "- BREATHER
    TUBE 3. Thoroughly wash the lid containing the permanent
    filter of cellular foam in common detergent.

    4. Thoroughly wash the body containing the perma-

    HOSE CLAMP
    /~ nent steel mesh element in a non-volatile cleaning
    solution or solvent.

    IA..
    CAUTION I High pressure com-
    pressed air can easily
    damage the cellular foam and light metal filter mesh
    element causing breather system restriction and
    the resultant excessive crankcase pressure condi-
    tion. Disregarding this information could resub In
    product damage and/or personal injury_
    5. Dry the lid and body with low pressure compressed
    air.

    6. Place the rubber O-ring seal on the inside rim of the


    lid.

    7. Hook the end of each retaining cUp under the flange


    atthe top of the separator body and snap up the hinge to
    secure the lid.

    OIL SEPARATOR INSTALLATION - GSI/GL


    Figure 5.40-15. 011 Separator Assembly, Unthreaded Oil Inlet Pipe
    Threaded 011 Inlet Pipe - GSI/GL
    1. Attach the oil separator outlet pipe to the breather
    elbow (top) (see Figure 5.40-14). Tighten the hose clamp.
    2. Unthread the oil separator inlet pipe from the oil filler
    elbow. Use a 4 inch channel lock wrench or slip pliers to 2. Attach the oil separator inlet pipe to the breather tube
    grasp the tube just above the pipe threads. (bottom). Tighten the hose clamp.
    3. Tighten the U-bolt to secure the breather tube to the
    right bank air duct support bracket.
    Threaded 011 Inlet Pipe
    1. Apply Perma Lok® Heavy Duty Pipe Sealant with
    Teflon® to the inlet pipe threads(see Figure 5.40-15).
    Thread the oil separator onto the oil filler elbow
    (bottom). Use a 4 inch channel lock wrench or slip pliers
    to grasp the tube just above the pipe threads.
    2. Attach the breather tube to the oil separator outlet
    pipe. Tighten the hose clamp.
    NOTE: After cleaning, servicing or replacing any com-
    ponent of the crankcase breather system, recheck the
    crankcase pressure to verify that it is within specification
    and that all system components are functioning proper/y.

    FORM 6248 First Edition 5.40 - 9


    CRANKCASE BREATHER

    CRANKCASE BREATHER REGULATOR - CRANKCASE BREATHER REGULATOR


    GSI/GL DISASSEMBLY - GSI/GL )
    1. Remove the elastic stop lock nut (5116 inch hex) from
    CRANKCASE BREATHER REGULATOR REMOVAL
    the end of the regulator rod (Figure 5.40-17).
    - GSI/GL
    The breather regulator assembly is connected to the
    ejector breather or venturi extractor through a tee and
    . pipe nipple arrangement. The vacuum regulator is above
    the water manifold in the center of the crankcase vee.
    While there is no manual adjustment of the crankcase HOUSING
    breather regulator, it should be inspected annually for
    an accumulation of dirt or grit. Harsh environments may
    dictate more frequent attention.
    1. To free the breather regulator assembly, back off the
    conduit lock nut on the tapered pipe nipple (see
    Figure 5.40-16).

    E-CLIP
    /'
    ~
    C VALVE
    PLATE

    ~/'

    i
    VALVE
    HUB
    ~/ \
    ~ O-RING
    }

    Figure S.40-16. Breather Regulator Assembly-


    GLShown ~/LOCKNUT
    2. Remove the breather regulator assembly from the
    pipe nipple.
    Figure SAO-17. Breather Regulator Assembly-
    3. Inspect the regulator screen for tears, dents or holes. All Engines

    2. Slide the screen off the regulator rod.


    3. Remove the O-ring from the groove in the regulator
    housing 10.
    4. Slide the valve plate off the rod.

    5.40 - 10 FORM 6248 First Edition


    CRANKCASE BREATHER

    CRANKCASE BREATHER REGULATOR 4. Lightly lubricate the regulator rod with a light oil.
    CLEANING AND INSPECTION - GSI/GL Apply a thin even film.

    A WARNING
    5. Slide on the valve plate with the weighted (threaded)
    side of the hub toward the free end of the rod.
    Compressed air can pierce the skin and cause
    NOTE: Verify that the valve plate moves freely on the
    severe personal InJury or death. Never use your hand
    rod without cocking or sticking.
    to check for leaks or to detennine air flow rates. Wear
    safety glasses to shield your eyes from flying dirt 6. Slide the O-ring over the rod and into the groove in
    and debris. the regulator housing ID.

    1. Thoroughly wash all parts in a non-volatile cleaning 7. Turn the breather regulator right side up. The outer
    solution or solvent to remove accumulations of dust, dirt, edge of the valve plate should make complete contact
    grease and grit. Dry with low pressure compressed air. with the O-ring.

    2. Inspect the regulator housing for cracks. 8. Slide the screen over the rod until it seats against the
    step machined into the regulator housing OD.
    3. Inspect the regulator rod for scratches or burrs.
    9. Install the elastic stop lock nut (5/16 inch hex) on the
    4. Inspect the O-ring for cuts, tears or loss of elasticity. end of the rod. Replace the lock nut after it is removed
    the second time.
    5. Inspectthe regulator screen for tears, dents or holes.
    CRANKCASE BREATHER REGULATOR
    6. Inspect the valve plate for nicks, cracks or other
    INSTALLATION - GSI/GL
    damage.
    1. Thread the vacuum regulator onto the tapered pipe
    nipple until snug (3 or 4 threads) (s~Figure 5.40-16).
    A CAUTION IlfrePlaceme~tofthereg­
    .=~=..:..:::;...;~=;.;:.J.
    IL.!: . ulator hOUSing or valve 2. To lock the vacuum regulator in place, tighten the
    assembly is necessary, be sure to order the correct conduit lock nut against the regulator flange.
    part numbers. Since air flow requirements vary
    between engine models and applications, the hous- NOTE: After cleaning, servicing or replacing any com·
    ings and valves are sized or weighted differently ponent of the crankcase breather syStem, recheck the
    and are not interchangeable. Disregarding this crankcase pressure to verify that it is within specfflcation
    information could result in product damage and/or and that all system components are functioning properly.
    personel Injury.

    7. Replace any parts of the assembly that are damaged


    or worn.

    Assembling
    1. Insert the unthreaded end of the hub through the
    hole in the center of the valve plate (see
    Figure 5.40·17).

    2. Install the E-clip in the groove of the hub with the


    concave side facing the valve plate. Verify that the hub is
    tightly locked to the plate.

    3. If removed, use a small paintbrush to apply


    Lithoplex® Grease No. 2 (Multipurpose Lithium
    Complex Formula Containing Molybdenum DiSUl-
    fide) to the coarsely threaded end of the regulator
    rod. Drive the rod into the regulator housing until it
    bottoms out in the bore. Use a collet type stud driver
    for best results. If necessary, tap the end of the rod
    with a rubber mallet to center it in the bore.

    FORM 6248 First Edttion 5.40 -11


    CRANKCASE BREATHER

    VENTURI VENTURI EXTRACTOR - GSI/GL


    VENTURI REMOVAL - GSI VENTURI EXTRACTOR REMOVAL - GSI/GL

    1. Loosen the upper V-band coupling and remove the Crankcase vapors are drawn through the oil separators
    flexible exhaust connection from the venturi assembly to the venturi extractor. While most of the surplus oil
    (see Figure 5.40-18). drawn out of the crankcase is returned to the oil pan, a
    portion of the oil mist may pass through the separators

    UPPER VENTlJRI '---...9 into the venturi extractor assembly. Oil drawn into these
    the extractor can affect its ability to draw a negative
    vacuum over a period of time.

    NOTE: Venturi extractor assembly is similar for GSI/GL

    ~~~~ models.

    1. Loosen the hose clamp to remove the 3-1/2 inch


    flexible hose connection between the vacuum regulator
    LOWERVENTURI~I~ and the Y -shaped breather tube (see Figure 5.40-19,
    Figure 5.40-20 and Figure 5.40-21).
    V-BAND COUPUNG 'l.J
    ~
    Figure 5.40-18. Venturi Assembly - GSI Shown

    2. Remove the upper venturi from the venturi body.

    3. Loosen the lower V-band and remove the lower )


    venturi and venturi body from the exhaust elbow.

    VENTURI CLEANING AND INSPECTION - GSI


    Figure 5.40-19. Venturi Extractor Assembly - GSI
    1. Wipe off any deposits on the upper and lower venturi.

    2. Inspect the upper, and lower venturi and the venturi


    body for cracks holes or dents.

    VENTURI INSTALLATION - GSI

    1. Install the venturi body and lower venturi on the


    exhaust elbow with V-band coupling.

    2. Install the upper venturi over the tabs on the lower


    venturi.

    3. Install the flexible exhaust connection on the venturi


    body with V-band coupling.

    Figure 5.40-20. Venturi Extractor Assembly - GL

    5.40 -12 FORM 6248 First Edition


    CRANKCASE BREATHER

    9
    f',~ /8
    ~

    ~V15
    12

    ITEM NUMBER AND DESCRIPTION


    1 Venturi Extractor 9 Choke Valve 17 Gasket 25 Coupling
    2 Nozzle 10 Rear Bracket 18 Flange 26 Extractor Tube
    3 Gasket 11 Capscrew 19 Capscrew 27 Gasket
    4 Pressure Housing 12 Washer 20 Elbow 28 Capscrew
    5 Capscrew 13 Lock washer 21 Air Supply Tube 29 Washer
    6 Lock washer 14 Front Bracket 22 Pipe
    7 Nut 15 Gapscrew 23 Flange
    8 Nut 16 Capscrew 24 O-ring
    Figure 5.40-21. Venturi Extractor Assembly

    FORM 6248 First Edition 5.40 - 13


    CRANKCASE BREATHER

    2. Unthread the ferrule nut (1-5/16 inch hex) to remove 7. Remove the venturi extractor assembly from the
    the turbocharger compressor discharge line from the engine.
    venturi extractor pressure housing (male elbow tube
    fitting). 8. Unthread the hex jam nut on the choke valve in the
    center of the venturi extractor pressure housing (see
    3. Remove the brass coupling between the two venturi Figure 5.40-21).
    extractor tubes. Remove the two rubber gaskets from
    the coupling (see Figure 5.40-22). 9. Unthread the choke valve from the pressure hous-
    ing.

    10. Remove the two remaining capscrews securing the


    venturi extractor pressure housing to the extractor body.

    11. Remove the gasket between the pressure housing


    and the extractor body.

    VENTURI EXTRACTOR CLEANING AND


    INSPECTION - GSI/GL
    NOTE: Some GSI models may have a venturi extractor
    instal/ed as an option. In this application the venturi
    extractor is installed with the choke valve oriented
    towards the rear of the engine.

    NOTE: Leave the venturi extractor nozzle in place;


    removal may result in nozzle damage.

    1. Using a solvent soaked cloth and/or wire brush,


    thoroughly clean the choke valve, pressure housing and
    Figure 5.40-22. Venturi Extractor Assembly
    venturi extractor nozzle. Rod the nozzle out, if neces- )
    sary.
    4. Remove the two capscrews securing the venturi
    extractor pressure housing to the front extractor bracket
    (see Figure 5.40-23). A WARNING
    Compressed air can pierce the skin and cause
    severe personal injury or death. Never use your
    hand to check for leaks or to determine air flow
    rates. Wear safety glasses to shield your eyes from
    flying dirt and debris.

    2. Dry all parts with low pressure compressed air.

    Figure 5.40-23. Venturi Extractor Assembly

    5. Remove the two capscrews securing the venturi


    extractor to the rear extractor bracket. )
    6. Remove the venturi flange adapter, short extractor
    tube and venturi flange O-ring from the extractor body.

    5.40 -14 FORM 6248 First Edition


    CRANKCASE BREATHER

    VENTURI EXTRACTOR ASSEMBLY - GSI/GL 9. Inspect the rubber coupling gaskets for tears, cuts or
    general deterioration. Replace as necessary.
    1. Thread the choke valve into the center of the venturi
    extractor pressure housing. Install the hex jam nut on to. Install the brass coupling between the short venturi
    the choke valve (see Figure 5.40-21). flange adapter tube and the extractor tube.

    2. Install a new gasket between the venturi extractor 11. Attach the turbocharger compressor discharge line
    pressure housing and the extractor body. Verify that the to the venturi extractor pressure housing (male elbow
    gasket surfaces are clean and completely free of grease tube fitting) (see Figure 5.40-25).
    and oil.

    3. Using the two threaded holes closest to the com-


    pressor discharge air supply tube flange, fasten the
    venturi extractor pressure housing to the extractor body
    (2 capscrews, 3/8 x 1-1/2 inches, with lock washers and
    hex nuts).

    NOTE: In addition to securing the venturi extractor


    pressure housing to the extractor body, the other two
    holes are used with longer capscrews to fasten the
    assembly to the front extractor bracket.

    4. Move the venturi extractor assembly to the engine.

    5. Slide the venturi flange adapter onto the end of the


    short extractor tube. Be sure that the inside counterbore ,
    faces outward toward the tube end. Figure 5.40-25. Venturi ExtractOr Assembly

    6. Slide a new O-ring down the tube until it seats


    against the inside counterbore of the flange adapter. 12. Scribe or ink the ferrule nut and wrench tighten
    Apply Parker O-Iube® to the O-ring. 1-1/4 turns. After several remakes, it may be necessary
    to advance the ferrule nut 1/3 of a hex flat to obtain a
    7. Install two capscrews (3/8 x t-l/2 inches, with lock leak-tight seal.
    washers and plain washers) through the slotted holes in
    13. Inspect the 3-1/2 inch flexible hose connection for
    the rear extractor bracket. Thread the capscrews
    through the venturi flange adapter (with extractor tube) tears, cuts or cracks. Also check for hardening,
    into the extractor body (see Figure 5.40-24). Wrench softening or swelling.
    tighten. 14. Install the flexible hose connection between the
    vacuum regulator and the Y -shaped breather tube.
    Tighten the hose clamps.

    NOTE: After cleaning, servicing or replacing any com-


    ponent of the crankcase breather system, recheck the
    crankcase pressure to verify that it is within specification
    and that all system components are functioning properly.

    FRONT REAR
    Figure 5.40-24. Venturi Extractor Brackets

    , 8. Fasten the venturi extractor pressure housing to the


    ) front extractor bracket (2 capscrews, 3/8 x 2 inches, with
    plain washers, lock washers and hex nuts).

    FORM 6248 First Edition 5.40 -15


    CRANKCASE BREATHER

    CRANKCASE PRESSURE RELIEF


    VALVES A WARNING )
    Crankcase pressure relief valves may be supplied as a The number of pressure relief valves used on the
    safety precaution in lieu of the standard oil pan door engine depends on the volume of the crankcase.
    (see Figure 5.40-26). The valves open fully when the Never operate the engine without all valves on the
    pressure in the crankcase exceeds one pound per engine. The ability of the system to function is
    square inch and close tightly and quickly to prevent the dependent upon the proper number of relief valves.
    inflow of air after the internal pressure has been Operation without the proper type and number of
    relieved. The possibility of combustion is prevented, relief valves, or If the relief valves are not properly
    since no oxygen is allowed to enter the crankcase to maintained, can result In severe personal Injury or
    support new combustion. The valves do not prevent death.
    crankcase combustion, but only reduce the peak
    pressures, thereby minimizing damage. NOTE: Placement of the pressure relief valves may
    val)l due to other engine mounted accessories.

    CRANKCASE PRESSURE RELIEF VALVE


    EXERCISE
    To ensure that they are in proper working condition, the
    crankcase pressure relief valves should be exercised
    and inspected annually.
    1. Shut down the engine and allow it to cool.

    2. Lift the valve off its seat to verify that the plate is free
    to move and the gaskets are serviceable.

    CRANKCASE PRESSURE RELIEF VALVE


    REMOVAL )
    NOTE: Since it is necessal)l to drain the oil pan to
    remove the oil pan doors, schedule the inspection
    Figure 5.40-26. Bicera Pressure Relief Valve procedure during a regular oil change interval.

    The valve incorporates an internal flame trap to retard 1. Loosen the oil pan door clamp capscrew(s). Roll pins
    the emission of flame while the valve is venting. The will hold the door clamp in position.
    flame trap is of an oil-wetted wire gauze design. The
    cooling capacity of the gauze is doubled when oil- 2. Rotate the assembly about 45 degrees to remove
    wetted, a condition effected by the oil mist that normally the door from the access hole.
    exists in the crankcase or by oil spray from the
    connecting rod bearings. The valve incorporates the
    flame trap as a single unit and the O-ring construction
    eliminates oil leakage.
    The crankcase pressure relief valves are an important
    part of the engine safety system and must be properly
    maintained. Combustion may occur in the crankcase
    when a localized hot spot brings the oil mist above the
    flash point temperature (approximately 375 - 480' F,
    191 - 249' C). If the crankcase is not fitted with the
    proper type and number of relief valves, or if these relief
    valves are not properly maintained, the oil pan doors
    may be blown off and a secondary explosion of greater
    intensity might take place, resulting in death and
    damage to property.
    )

    5.40 - 16 FORM 6246 First Edition


    CRANKCASE BREATHER

    CRANKCASE PRESSURE RELIEF VALVE UPPER SPRING


    CLEANING AND INSPECTION CAP
    A service kit, PIN 489162, is available for servicing the
    crankcase pressure relief valves. See Figure 5.40-27.

    A WARNING
    Always use approved cleaning solvents In a well
    ventilated area. Avoid contact with skin. Disregard-
    ing this Information could result in severe personal
    injury or death.

    1. Thoroughly clean all parts of the assembly in a


    non-volatile cleaning solution or solvent. ROLL PIN
    \
    IA
    ..
    CAUTION I High pressure com-
    pressed air may damage
    the wire gauze design and adversely affect the
    operation of the flame trap. Disregarding this
    information could result in product damage and/or
    personal injury.

    2. Drip dry the screen or air blow dry using low pressure
    compressed air.

    3. Carefully inspect the screen for tears or holes.


    Figure 5.40-27. Pressure Relief Valve -
    Replace if damaged.
    Cross Sectional View
    4. Inspect the the valve to insure that all nuts, bolts and
    covers are in place and secure. CRANKCASE PRESSURE RELIEF VALVE
    ASSEMBLY
    5. Inspect the spindle for rust and lightly grease it.
    1. Check the seal at the back of the oil pan door for
    6. Inspect the large and small spindle screw O-rings for tears, cuts or general deterioration.
    cuts, tears or loss of elasticity. Replace the large and
    small O-rings every two years, or more frequently if 2. If replacement is necessary, remove the old seal
    necessary. from the groove and discard. Verify that the groove is
    clean and free of dirt, grit and other debris.
    7. Inspect the rubber sealing surface on the valve plate
    for scratches, cuts, nicks, pits or other damage. replace 3. Apply 3M Scotch Grip" Rubber and Gasket Adhe-
    the plate if damaged. sive 847 to the groove. Install a new seal.

    4. Install the oil pan doors. Hold each door so that the
    rear clamp is 45 degrees from the vertical pOSition.
    Insert the clamp into the oil pan access hole. Holding the
    door against the face of the access hole, rotate the door
    until the clamp is in the horizontal position. Tighten the
    door clamp capscrew(s).

    FORM 6248 First Edition 5.40 -17


    CRANKCASE BREATHER

    1
    /
    3

    cl6
    ~3 16
    ' \ ...-- 15
    0/ 5 7
    /
    «lib.... 14
    / 11 ~ /9 <....> /

    .~ ~ .. ~ I'
    \4 ~........ If'"?~ ~

    ~
    9....................
    . . .e "
    2
    11/
    f}
    12
    /~f}
    11
    ./'
    /"
    I'
    .... ,
    /"
    /"
    /"

    /"
    /"
    /"
    )
    /"

    /6:? :0l
    /"
    /"

    /"

    /"
    /"
    /" ....
    .... .... .... /"/"/"
    /"
    11
    10
    '\
    /"
    /"
    ........ '\
    .... ....
    /"
    12 ~
    .... 1\ ~
    ~~~
    ITEM NUMBER AND DESCRIPTION
    1 Tube 5 "L" Shaped Tube 9 Washer 13 Lower Tube
    2 Breather Regulator 6 Vacuum Valve 10 Tube 14 Clamp
    3 Clamp 7 Capscrew 11 Clamp 15 Gapscrew
    4 lock washer 8 Nut 12 Hose 16 Rear Tube
    Figure 5.40-28. Breather Tubes - GSI

    BREATHER TUBES 2. Loosen two hose clamps and remove the lower
    breather tube and connecting hose from the rear
    BREATHER TUBE REMOVAL - GSI breather tube.
    1. Remove two hose clamps and connecting hose 3. Remove the lower breather tube from between the
    between the left side oil separator breather tube and exhaust manifolds.
    lower breather tube routed between the exhaust )
    manifolds (see Figure 5.40-28).

    5.40 -18 FORM 6248 First Ednion


    CRANKCASE BREATHER

    4. Remove two hose clamps and connecting hose BREATHER TUBE INSTALLATION - GSI
    between the exhaust manifolds and the rear breather
    tube leading to the "L" shaped breather tube on the oil
    1. Apply GE Red RTV 106 Silicone Rubber Adhesive
    Sealant, High Temperature, to threads and install
    separator.
    breather pipe to the venturi (see Figure 5.40-28).
    5. Remove nut, lock washer, capscrew and rear
    2. Apply GE Red RTV 106 Silicone Rubber Adhesive
    breather tube from supporting clamp.
    Sealant, High Temperature,1 to the ends of the vacuum
    6. If required, remove nut, lock washer, two washers, valve and install the vacuum valve on the breather pipe
    capscrew and supporting clamp from the turbocharger and "L" shaped breather tube with two hose clamps.
    elbow (see Figure 5.40-29).
    3. Install the rear breather tube to the "L" shaped
    breather tube with connecting hose and two hose
    clamps.

    4. If removed, install the rear breather tube supporting


    clamp on the bracket with capscrew, two washers, lock
    washer and nut.

    5. Install the supporting clamp on the rear breather


    tube with capscrew, lock washer and nut.

    6. Install the lower breather tube to the rear breather


    tube with connecting hose and two hose clamps.

    7. Install the curved end of the lower breather tube to


    the left side air breather assembly with connecting hose
    and two hose clamps (see Figure 5.40-30).

    Figure 5.40-29. Support Clamp

    7. Loosen two hose clamps and remove the vacuum


    valve tube from the "L" shaped breather tube on the oil
    separator and the breather tube to the venturi.

    8. Remove the breather tube from the venturi.

    Figure 5.40-30. Breather Tube - Front Vee

    8. Install the supporting clamps and lower breather


    tube to the exhaust manifold with capscrew lock washer
    and nut.

    ,
    !

    FORM 6248 First Ednion 5.40 -19


    CRANKCASE BREATHER

    ...,
    ... ...
    ... "-
    "-

    .",,/
    ... r'-
    "-
    "-,,-
    ....
    ... '" I

    ~
    (J~
    -........0 A ' "
    U~ ... '"
    :> \ ,.""..
    .....
    OIL SEPARATOR
    OUTLETPIPEELBOW
    (REAR RIGHT)
    U-SHAPED TUBE ~~

    ~~~
    (1'~ 6J OIL SEPARATOR
    OUTLET PIPE
    (FRONT LEFl)

    "
    )

    Figure 5.40-31. Breather System Tube Connections - GL

    BREATHER TUBE REMOVAL - GL tube upper air breather assembly and the breather
    regulator assembly.
    1. Remove two hose clamps and connecting hose
    between the left side oil separator breather tube and 7. Remove pipe tee from the venturi extractor. If
    lower breather tube routed between the exhaust required, remove the pipe nipples from the elbow.
    manifolds (see Figure 5.40-31).

    2. Remove two hose clamps and connecting hose


    between the lower breather tube between the exhaust
    manifolds and the rear breather tube leading to the "Y'
    shaped breather tube.

    3. Remove nut, lock washer, two washers, capscrew


    and supporting clamp from support bracket.

    4. Remove two nuts, lock washers, capscrews sup-


    porting clamps and lower breather tube from between
    the exhaust manifolds.

    5. Loosen two hose clamps and remove the rear


    breather tube and connecting hose from the"Y' shaped
    breather tube. )
    6. Loosen four hose clamps and remove the two
    connecting hoses between the "Y' shaped breather

    5.40-20 FORM 6248 First Ednion


    CRANKCASE BREATHER

    BREATHER TUBE INSTALLATION - GL 8. Install the lower breather tube to the rear breather
    tube with connecting hose and two hose clamps.
    1. If removed, apply pipe sealant to threads and install
    the pipe nipples on the tee fitting (see Figure 5.40-31). 9. Install the curved end of the lower breather tube to
    the left side oil separator assembly breather tube, with
    2. Install the pipe fitting on the venturi extractor.
    connecting hose and two hose clamps (see
    3. Install the Y' shaped breather tube to the upper oil Figure 5.40-31 and Figure 5.40-34).
    separator assembly air breather assembly and the
    breather control regulator assembly with two hoses and
    four hose clamps (see Figure 5.40-32).

    Figure 5.40-34. Breather Tube - Front Vee

    1O. Install the supporting clamps and lower breather


    Figure 5.40-32. V-Shaped Breather Tube tube to the exhaust manifold with capscrew lock washer
    and nut (see Figure 5.40-35).
    4. Install the rear breather tube to the straight stem of
    the Y' shaped breather tube with connecting hose and
    two hose clamps.

    5. Position supporting clamp on the rear breather tube.

    6. Install the rear breather tube supporting clamp on the


    bracket with capscrew, two washers, lock washer and nut.

    7. Position two supporting clamps on the lower breath-


    er tube (see Figure 5.40-33).

    5"

    \ -."of----- 71" -----<>"'11 Figure 5.40-35. Breather Tube - Rear Vee

    Figure 5.40-33. Install Vee Mounted Breather Tube


    Clamps

    FORM 6248 First Ednion 5.40 - 21


    CRANKCASE BREATHER

    VENTURI
    PRESSURE
    )
    EXHAUST EXTRACTOR~ HOUSi
    ELBOW

    '" ~
    450 Y-BRANCH
    / FITTING

    RIGHT BANK
    COMPRESSOR

    ~:::E:::;~~E:::l
    ~ DISCHARGE TUBE

    RIGHT BANK VIEW


    , WATER
    MANIFOLD

    / INTERCOOLER

    RIGHT BANK TURBO


    OUTLET ELBOW
    LEFT BANK TURBO
    OUTLET ELBOW
    )

    Figure 5A0-36. Venturi Extractor Compressor Discharge Plumbing - GL Shown

    VENTURI EXTRACTOR COMPRESSOR


    DISCHARGE TUBES
    VENTURI EXTRACTOR COMPRESSOR OIS-
    CHARGE TUBES REMOVAL

    1. Loosen the ferrule nut and disconnect the upper tube


    from the choke valve pressure housing (see
    Figure 5.40-36).

    2. Remove nut, lock washer, washer, support clip and


    capscrew from the rear venturi extractor support
    bracket.

    3. Remove nut, lock washer, two washers, support clip


    and capscrew from support bracket on the exhaust
    elbow.

    4. Loosen ferrule nuts and disconnect the upper tube


    Figure 5.40-37. Right Bank Compressor Discharge
    and the right bank and left bank compressor tubes from
    Tube
    the 45 degree V-branch fitting.

    5. Remove nut, lock washer, two washers, support clip 6. Loosen ferrule nuts and disconnect the left and right )
    and capscrew from support bracket on the intercooler bank compressor discharge tu bes from the left and right
    (see Figure 5.40-37). bank turbo outlet elbows.

    5.40 - 22 FORM 6248 First Edition


    CRANKCASE BREATHER

    VENTURI EXTRACTOR COMPRESSOR DIS-


    CHARGE TUBES INSTALLATION

    1. Connect the left and right bank compressor dis-


    charge tubes to the left and right bank turbo outlet
    elbows (see Figure 5.40-36).

    2. Install nut, lock washer, two washers, support clip


    and capscrew on support bracket on the intercooler to
    support the right bank compressor discharge tube (see
    Figure 5.40-37).

    3. Apply pipe sealant to threads and connect the upper


    tube and the right bank and left bank compressor tubes
    on the 45 degree Y -branch fitting.

    4. Apply pipe sealant to threads and connect the upper


    tube on the choke valve pressure housing.

    5. Install nut, lock washer, two washers, support clip


    and capscrew to connect the upper tube to the support
    bracket on the exhaust elbow.

    6. Install the nut, lock washer, washer, support clip and


    capscrew to support the upper tube on the rear venturi
    extractor support bracket.

    FORM 6248 First Edition 5.40 - 23


    CRANKCASE BREATHER

    5.40 - 24 FORM 6248 First Ednion


    SECTION 5.45 - AIR/GAS PRELUBE AND START SYSTEMS

    AIR/GAS PRE LUBE AND START PRELUBE SYSTEM


    SYSTEMS Prelube Pushbutton Valve
    COMPONENTS The ports of the three-way Prelube pushbutton valve
    Refer to Figure 5.45-5, Figure 5.45-6, and (see Figure 5.45-1) are stamped "SUP(PLy),"
    Figure 5.45-7 for schematic representations of the "EXH(AUST)" and "DEL(IVERY)." The air/gas supply
    air/gas prelube and start systems. The air/gas prelube from the bulkhead (see Figure 5.45-2) is connected to
    and start systems consist of the following components: the normally closed "SUP(PLY)" port of the pushbutton
    valve. The normally open port of the valve, stamped
    Prelube System "EXH(AUST)," vents the downstream side when the
    pushbutton valve is not depressed. The vented air/gas
    • Prelube Pushbutton Valve supply is directed back to the bulkhead via the Vent
    • Pilot-Operated Prelube Valve tube.

    • In-line Lubricator AIR/GAS SUPPLY INLET PORT


    PRELUBE/START PILOT (TEE OR MALE ELBOW)
    • Prelube Pump/Motor AIR/GAS DELIVERY PORT
    (MALE ELBOW) ",,- __ =I-C:::n
    • Oil Pressure Gauge (Customer Supplied)

    Start System

    • Start Pushbutton Valve

    • Pilot Operated Starter Pre-engage Valve/Starter


    Motor (Customer Supplied)
    c
    • Pilot-Operated Prechamber Gas Valve (GL)
    "-PUSH
    • Prechamber Gas Safety Shutdown Valve (GL)

    NOTE: The main air/gas supply has branch lines


    BUTTON
    c , VENT AIR/GAS
    EXHAUST OUTLET PORT
    (customer supplied) leading to the the pilot operated (TEE OR MALE ELBOW)
    prelube valve, the pilot operated starter pre-engage
    valve(s) and the pilot operated starter valve(s). Figure 5.45-1. PrelubeiStart Pushbutton Valves

    A WARNING
    From the bulkhead, all gas vented from the system
    must be piped to a safe area in conformance with all
    applicable codes. Disregarding this information
    could result In severe personal injury or death.

    Depressing the Prelube pushbutton causes the


    "EXH(AUST)" port to close as the "DEL(IVERY)" port is
    opened. The pilot air pressure is directed back to the
    bulkhead (via the Prelube tube) where it passes to the
    pilot operated prelube valve.

    FORM 6248 First Ed~ion 5.45 - 1


    AIR/GAS PRELUBE AND START SYSTEMS

    ITEM NUMBER AND DESCRIPTION


    1 Vent Common Tube 10 Pipe Tee 19 Hexhead Screw 28 Hexhead Screw
    *
    2 Supply Common Tube 11 Hexhead Screw 20 Lock washer 29 Strap
    3 Prelube Common Tube 12 Nut 21 Flat Washer 30 Bulkhead Bracket
    4 Start Common Tube 13 Lock washer 22 Control Tube Brace 31 Union Bulkhead
    *
    5 Vent Panel Tube 14 Flat Washer 23 Hexhead Screw 32 Fillisterhead Screw
    6 Supply Panel Tube 15 Control Tube Brace 24 Control Panel Assembly 33 Lock washer
    7 Prelube Panel Tube 16 Injection Tube Clamp 25 Hexhead Screw 34 Control Panel Cover
    8 Start Panel Tube 17 Injection Clamp Insert 26 Hexhead Screw 35 Hexhead Screw
    9 Union Connector 18 Spacer
    ** 27 Lock washer *=GL **=G/GSI
    Figure 5.45-2. Prelube And Start Air/Gas Tube Connections - Bulkhead (G/GSI/GL)

    I
    )

    5.45-2 FORM 6248 First Edition


    AIR/GAS PRELUBE AND START SYSTEMS

    --
    PILOT AIR/GAS SUPPLY
    (FROM PRELUBE PUSHBUTTON VALVE)
    BRANCH OF
    MAIN AIR/GAS
    _/
    SUPPLY UNION ELBOW

    I
    ~~)II ,-
    r,;~~======~t:~~==~;===~~~TUBEFlrnNG
    BULKHEAD

    II TUBE CLIPS TO LEFT BANK


    II VEE MOUNTED EXHAUST MANIFOLD SECTIONS
    II PRELUBE TUBE~
    (CYUNDERS #6, #3 AND #1)

    AIR/GAS EXHAUST
    (CUSTOMER CONNECTION)

    L...,-w-I ~ ±--L.......;o' \ ~ PRELUBE MOTOR


    (FRONT LEFT)

    I AIR VALVE
    BRACKET IN-UNE
    LUBRICATOR
    \
    r'--\-.,

    "
    PILOT OPERATED UNION ELBOW
    PRELUBE VALVE ~TUBEFITTING
    (REAR RIGH1)

    TUBE BRACE
    / I \
    (TO LEFT BANK UFTING TUBE CLIP PRELUBE MOTOR
    EYE MOUNTING PAD) (TO GEAR HOUSING) BRACKET

    Figure 5.45-3. Pilot Operated Prelube Valve Connections

    Pilot-Operated Prelube Valve


    MOUNTING........
    The pilot operated prelube valve opens to admit air from BRACKET ....
    a branch of the main air/gas supply line, which turns the IN-LINE
    prelube pump air motor to activate the prelube pump PRELUBE LUBRICATOR
    PUMP ¥
    (see Figure 5.45-3).
    \
    In-Line Lubricator

    A WARNING AIR/GAS VENT


    If high pressure gas is used to drive the air/gas (CUSTOMER
    prelube pump motor, be sure to vent the motor
    exhaust to a safe area in conformance with all
    applicable codes. Disregarding this information
    PRELUBE
    MOTOR
    / CONNECTION)

    could result in severe personal injury or death.


    Figure 5.45-4. Prelube Motor/Pump Assembly
    The in-line lubricator injects oil into a stream of
    compressed air/gas to automatically provide the proper
    internal lubrication for the vanes of the air/gas operated
    prelube pump motor (see Figure 5.45-4).

    FORM 6248 First Ednion 5.45 - 3


    AIR/GAS PRELUBE AND START SYSTEMS

    Prelube Pump/Motor
    The function of the prelube pump/motor is to purge the
    A WARNING
    lubrication system of air and to ensure that all moving From the bulkhead, all gas vented from the system
    parts are properly lubricated before the engine is must be piped to a safe area in conformance with all
    started. applicable codes. Disregarding this information
    could result In severe personal injury or death.

    IA CAUTION 10!1 drains back Into ~he Depressing the Start pushbutton causes the
    .L .::
    . . 011 sump after eng me
    =:......;::..:...;;.;;;;..;;...;;...;;:....:..;:...J.
    shutdown leaving a minimal amount of 011 at key "EXH(AUST)" port to close as the "DEL(IVERY)" port is
    wear points. Since the crankshaft starts to turn opened. The pilot air pressure is directed back to the
    before the 011 pump begins to circulate oil, "dry" bulkhead (via the Start tube) where it passes to the pilot
    starts result in bearing damage and an accelerated operated starter pre-engage valve.
    wear rate. Disregarding this information could Pilot Operated Starter Pre-engage Valve/Starter
    result in product damage and/or personal Injury. Motor - Customer Supplied

    Oil Pressure Gauge The pilot operated starter pre-engage valve opens to
    admit air from a branch of the main air/gas supply line.
    When the lubrication system is properly primed, pres- The air/gas pressure causes the starter pinion to shift
    sure begins to register on the lube oil pressure gauge. into engagement with the flywheel ring gear. Movement
    Generally, about 30 seconds prelube is recommended of the pinion to the engage position opens a passage-
    before the engine is cranked. More time may be wayfor air pressure to pass through to the pilot operated
    required after the oil filter is serviced or if the oil cooler starter valve(s). The pilot operated starter valve(s) open
    has been drained. to admit air from another branch of the main air/gas
    NOTE: For more information on the prelube system, supply line, which activates the starter motor to crank
    refer to Lubrication System. the engine (see Table 5.45-1).
    NOTE: On dual starter arrangements, the pre-engage
    START SYSTEM
    connections are in series, so that the pinions of both )
    Start Pushbutton Valve starters are engaged with the ring gear before the pilot
    operated va/ves admit air to the starter motors.
    NOTE: See Figure 5.45-41 and Figure 5.45-42 electri-
    cal schematics for air starting and electrical starting Table 5.45-1. PIN 2085690 Air Valves Inlet Pressures
    systems. And Pilot Pressures To Shift
    INLET PSI (KPA) PILOT PSI (KPA) TO SHIFT
    The ports of the three-way Start pushbutton valve (see
    Figure 5.45-1) are stamped "SUP(PLy)," "EXH(AUST)" 35 psi (241 kPa) 23 psi (159 kPa)
    and "DEL(IVERY)." The air/gas supply from the bulk- 50 psi (345 kPa) 25 psi (172 kPa)
    head (see Figure 5.45-6 and Figure 5.45-7) is con- 95 psi (655 kPa) 34 psi (234 kPa)
    nected to the normally closed "SUP(PLY)" port of the 105 psi (724 kPa) 36 psi (248 kPa)
    pushbutton valve. The normally open port of the valve,
    145 psi (1000 kPa) 43 psi (296 kPa)
    stamped "EXH(AUST)," vents the downstream side
    155 psi (1069 kPa) 45 psi (310 kPa)
    when the pushbutton valve is not depressed. The
    vented air/gas supply is directed back to the bulkhead
    NOTE: Pilot pressure must be sufficient in order for the
    via the Vent tube.
    valve to function pilot operated prelube valve and pilot
    operated prechamber gas valve.

    5.45 - 4 FORM 6248 First Ed~ion


    "T1
    0
    II
    ;:
    Rl
    ~

    ~
    m
    ."
    Ei
    SOLENOID VALVES
    FOR AUTOMATIC OR REMOTE ELECTRIC CONTROLS
    AIR UNE LUBRICATOR
    c:: (WITHOUT PNEUMATIC CONTROL PANEl..)
    ~
    0
    Cil PRE-LUBE STAAT
    :J 01 (ALlENAlR) (MAC)

    ~ NOTES: [{] ru
    in
    111
    g.
    1. SYMBOLS CONFORM TO ANSI Y32-10
    STANDARD.
    2. ALLSYMBOLSARE SHOWN IN A
    r€:k--,
    I I C
    ~-,
    I 3 I
    CD DE-ENERGIZED STATE.
    3 I I -, I
    ~
    ,
    n
    / } HEAVY PHANTOM LINES INDICATE
    ~ILOT LINES FOR DUALSTART. tI 'i".... Y
    _..A._~
    'i"
    4. EQUIPMENT FURNISHED BY W.E.D. AS
    ." OPTIONAL PRICE CODE ITEMS ARE L I I
    ::I
    CD
    c::
    INDICATED BY PHANTOM LINES.
    --I>- --'j'- --'1'- - - -to--, CHECK
    VALVE
    3
    ~ + ~It t
    r
    V
    n
    0 ~I wi STRAtNER
    FILTER
    OIL COOLER

    0 It
    =>
    I '"
    I>-' "ll
    ~I
    a '" I I "'g: L - _ -I> _ _ _ _ _ _
    I
    ~PILOTOPERATEDPRELUBE
    VALVE (SHRADER)
    ~ I
    111 I
    II
    I3 ---r-
    I _ III - f
    •elp
    I
    0375-18 NPTAIR SUPPLVWHEN
    AIR STARTER IS NOT SUPPLIED
    BYWE.D
    l>

    ." I I 1 - - ~
    r-----~----, i
    0
    ~

    ~ I 11;
    ~

    0
    ::I
    .:c PILOT OPERATED
    *
    r _
    PILOT OPERATED VALVE
    -,
    L- -
    I
    - -.!..-
    I FOR GL ENGINES
    "tI
    ::tI
    m

    r' ~-=:..~ --~t r


    R~SERVOIIR ~
    ~ c:
    W
    ::l.
    I>
    VALVE (STARTER) A

    RE-;';;";;- - - - - - - - -,--1>---1 I:D


    m
    r.'~
    ::I
    C.
    ."
    1,_--1
    ... "~n
    I
    .fl. },.
    .. 'ft. ''i' I L_t'
    I I l>
    z

    (
    L(~~~7?~~~~ou~~0~<,
    ic:: c
    ... en
    y\ \"Y"STRAINE~~X L8~~I~-?JA ~
    CD
    'i5 "Y"STRAINER
    i5
    111 PRE-ENGAGED PRE-ENGAGED ~
    .:::> ~

    ~
    ONE SHOT AIR STARTER AIR STARTER
    LUBRICATOR '" AIR SUPPLY 1.500-11 NPT
    AIR EXHAUST 60 TO 150 PSI STD. AIR EXHAUST
    2.50-8 NPT 2.50-8 NPT
    \II
    ~ m
    , i:
    en en
    !" J>
    t;
    ., IIII-j
    ~
    on~'i!lJj

    I ." AIR LINE LUBRICATOR


    l;;
    "tI

    ~
    Iii" ::tI
    c PNEUMATIC PILOT VALVES m
    iil r
    l::
    PRE-LUBE STAAT
    c
    LJ LJ ID
    ~ L'"3
    -, L'"3
    -I
    m
    W J>
    ::r I I z
    c
    .
    CD
    :I
    C!:
    I
    I
    I
    I en
    ""II, I I ~
    "
    CD
    -"'--, 'CHECK
    ::tI
    -r
    I
    ~
    C

    -
    Vf>J..VE
    ~
    n-
    I
    srJNER t OIL COOLER
    O
    0
    a
    +I FILTER
    PILOT OPERATED PRELUBE
    m
    iii:
    VALVE (SHRADER) en
    ~
    ,+___.1..,.375 - 18 NPSF
    j
    :I
    7J
    ~

    l>
    .s:
    .
    C)
    &
    . .
    CUSTOMER:
    AIAIGAS VENT
    CONNECTION
    VENT

    Lct1~4--
    SUPPLY

    PILOT OPERATED

    r!:.
    !II • ~ PRE-ENGAGE VALVE NOTES:
    ~ --,
    r!::I. PILOT OPERATED
    VALVE (STARTER) II
    1'. . ----------.J
    I 1. SYSTEM FOR USE WITH AIR/GAS

    ...~
    RESERVOIR
    I I
    " _ _ _ -<I
    t RESERVOIR
    2. SYMBOLS COMFORM TO ANSI 32 -10
    STANDARD.
    s. eQUIPMENT FURNISHED BY W.E.D. AS
    OPTIONAL PAICE CODE ITEMS ARE
    "II INDICATED BY PHANTOM LINES.
    ~

    Ie.
    c /} ~EAVY PHANTOM LINES INDICATE
    g- ~ILOT LINES FOR DUAL START.

    ~
    "T1
    oJl Ci .(~ " I
    " yo STRAINER
    \ .Y" STRAINER
    -"}
    /' ~ J ONE SHOT
    LUBRICATOR 5. ALL SYMBOLS ARE SHOWN IN A
    ;:; Gl
    til
    DE-ENERGIZED STATE.

    ~
    PRE-ENGAGED PRE-ENGAGED ';,
    ...
    I\'l
    ex>
    .:::0 ONE SHOT
    LUBRICATOR
    AIR/GAS STARTER
    2.50-8 NPT
    AIR/GAS STARTER
    CUSTOMERS SUPPLY
    2.50-8 NPT
    I\.
    see so 6143 - 49 FOR CUSTOMER
    ~CONNECTIONS LOCATION
    I\. 1.500 - 11 NRT. CONNECTIONS f...!!:).
    [ f...!!:). 60 TO 150 PSI AIR/GAS STD.

    g' &
    ~

    --
    ."
    0
    JJ
    ;;:
    NOTES:
    1. SYMBOLS CONFORM TO ANSI 32-10
    ."..
    Rl STANDARD.
    & A. CUSTOMER VENT CONNECTION MUST PUSH BUTTON VALVES
    :!! L2J.BE PIPED TO MEET APPLICABLE PRE-LUBE START
    CODES.

    il
    ."
    3. eQUIPMENT FUANISHED BY W.E.D. AS
    Ci OPTIONAL PRICE CODe ITEMS ARE

    ..
    c
    iii
    U1
    INDICATED BY PHANTOM LINES.

    4. ALL COMPONENTS FURNISHED BY


    W.E.D. ARE COMPATIBLE FOR USE
    :.
    III
    WlTH NON-CORROSIVE COMBUSTIBLE
    GAS. EXCEPT AS NOTED.
    "Y" STRAINER
    n 5. ALl SYMBOLS ARE SHOWN IN A
    ". DE-ENERGIZED STATE.

    .
    CD
    3 ~ ~EAVY PHANTOM LINES INDICATE
    ~ILOT LINES FOR DUAL START. MAIN LUBE

    '"n 7. AlL EQUIPMENT FURNISHED BY w.e.c.


    OIL PUMP

    'a IS ENGINE MOUNTED UNLESS


    ::I OTHERWISE SPECIFIED. 'CHECK
    II VI>J..VE
    C ~ TUBING ANO PIPING FURNISHED BY
    3 ~CUSTOMER, INDICATED BY:
    ~
    n
    -.--.-- STRAtNER t OIL COOLER
    FILTER

    [
    0
    0
    ::I !1.
    9
    CUSTOMER CONNECTIONS WHEN AIR
    STARTER IS NOT SUPPLIED BY W.E.D.
    12 CYLINDER 0.25 DIA. TUBE CONNECTION
    1
    PILOT OPERATED
    VALVE (PRE-LUBE)

    ...;
    III
    ~" rY--<l-_.J 12VB\~ ~ r-, _ ... :1
    ~ ~ 1- -+=====
    ...... 0.375-18 NPTAIR SUPPLY WHEN
    AIR STARTER IS NOT SUPPLIED
    BYW.E.D.
    »
    -==-11- -I- - "';"'1
    ~

    ~
    3 /\3B lBNPT A I PILOT OPERATED VALVE 1
    ~ - ¥ PRE-ENGAGED pOATS TO PRECHAMBER
    ."
    0
    ~ e PILOT OPERATED r -, _____ _
    -1'":-
    1
    ENGINE OIL PRESSURE
    20 PSI MANIFOLD
    1;;
    .-.J
    t
    J> VI>J..VE (STARTER) - - -
    ,."
    r SAFETY SHUT-DOWN "tI
    ..
    15 RESERVOIR • - - - -<I RESERVOIR PILOT OPERATED VALVE :II

    71z
    I I t-~- I m
    to ~~ I , L_ I
    E
    t:~-t~J>~t· tt~~f~
    --.J I
    i .LYJ.. ,~I
    ~
    .LYJ..
    -,

    (
    ::I- III
    J> PRECHAMBER m
    ::I
    a. ONE SHOT
    PILOT OPERATED
    VALVE »z

    ~
    'a
    !.
    "Y" STRAINER "Y" STRAINER LUBRICATOR
    c
    ...
    c PRE-ENGAGED TYPE • • PRE-ENGAGED TYPE
    AlR/GAS START~EAlR/GAS STARTER
    SHUTTLE
    en
    II ONE SHOT VALVE FUel
    FUEL IN (GAS) ~
    "i5
    ~
    LUBRICATOR _" "
    5O-8NPT~ ~25O-8NPT
    .c

    ~
    ~
    ~
    I SHUT-OFF VALVE
    (CUSTOMER SUPPLIED)
    CUSTOMERS SUPPlY 1.500-11 NPTCONNECTIONS
    60 TO 150 PSI STD. AIR/GAS ~

    ,
    In
    i!:
    ... en
    AIR/GAS PRELUBE AND START SYSTEMS

    Pilot-Operated Prechamber Gas Valve - GL plenum (volume tank) and shuttle valve. When the pilot
    Enroute to the starter pre-engage valve, the air/gas pressure opens the prechamber gas valve, a line off the )
    supply passes through a tee fitting (just in front of the 99 regulator gas inlet pipe tee admits high pressure gas
    lube oil strainer) where a portion is diverted to the pilot to the prechamberfuel regulator. The orifice check valve
    operated prechamber gas valve (see Figure 5.45-6 and and air/gas plenum act as a pneumatic timer to retard
    Figure 5.45-7). Before reaching the gas valve, the pilot the blow down of pilot pressure when the Start
    pressure passes through an orifice check valve, air/gas pushbutton is released (see Figure 5.45-8).

    PRECHAMBER
    REGULATOR ~.
    AIR/GAS SUPPLY ~ .
    (FROM TEE OF "START TUBE")

    I
    t I
    '..J
    I~ j
    ~ / ORIFICE CHECK VALVE

    GAS VENTI ~. /AIRIGAS PLENUM


    (TO TEE OF "VENT TUBE")

    PRECHAMBER GAS

    '-LUBE OIL
    PRESSURE TUBE
    (FROM MAIN OIL HEAOER)

    GAS INLET

    Figure 5.45-8. Pilot Operated Prechamber Fuel Valves - GL )

    5.45 - 8 FORM 6248 Firsl Ednion


    AIR/GAS PRELUBE AND START SYSTEMS

    Prechamber Gas Safety Shutdown Valve - GL PRELUBE/START SYSTEM


    The prechamber gas safety shutdown valve admits REMOVAUINSTALLATION
    downstream gas pressure to the opposite side of the
    BULKHEAD BRACKET ASSEMBLY REMOVAL
    shuttle valve once engine lube oil pressure reaches or
    exceeds 20 psi. When the pressure in the air/gas
    plenum bleeds down, the shuttle valve shifts position
    and the downstream gas pressure holds the pilot gas
    A WARNING
    valve open (see Figure 5.45-9). The time delay pro- Ensure that the fuel source is completely shut off
    vided by the check valve and air/gas plenum keeps pilot prior to working on fuel system components Clear
    pressure on the gas valve long enough for lube oil the engine supply lines and piping of accumulated
    pressure to rise and shift the shuttle valve. Lube oil gas before perfonning any maintenance work on the
    pressure continues to admit gas to the prechamber fuel system or severe personal injury or death could
    resuh.
    regulator as long as the engine is running.
    NOTE: Tag al/ tubes and lines before removal to aid
    PILOT INLET PORT STAINLESS during assembly.
    (DOWNSTREAM GAS FROM STEEL BALL
    PRECHAMBER GAS SAFETY
    SHUTDOWN VALVE) 1. Remove the four union bulkhead fittings from the
    PILOT INLET PORT
    (PILOT SUPPLY FROM bulkhead bracket (see Figure 5.45-10).
    AIR/GAS PLENUM)
    2. Remove the bulkhead bracket from the connector
    bracket.

    3. Remove the connector bracket from the rear fly-


    wheel housing (see Figure 5.45-2 and Figure 5.45-12).

    BULKHEAD BRACKET ASSEMBLY


    INSTALLATION
    1. Attach four union bulkhead tube fittings to the
    bulkhead bracket, if necessary (see Figure 5.45-10).
    PILOT OUTLET PORT
    (TO PILOT OPERATED PRECHAMBER GAS VALVE)

    Figure 5.45-9. Shuttle valve - GL

    If the engine stops, loss of engine lube oil pressure


    automatically causes the prechamber gas safety shut-
    down valve to stop the flow of downstream gas to the
    prechamber gas valve, which effectively shuts off the
    supply of high pressure gas to the prechamber regula-
    tor. If the engine fails to start, insufficient lube oil
    pressure prevents the downstream gas from passing to
    the prechamber gas valve, so the gas supply shuts off
    as soon as the pilot pressure in the air/gas plenum is
    exhausted. In both cases, any gas in the downstream
    line passes to the vent tube (from the exhaust port of the
    prechamber gas safety shutdown valve) and is ex-
    hausted at the customer's bulkhead connection.

    CONNECTOR BRACKET
    (TO REAR FLYWHEEL HOUSING)

    Figure 5.45-10. Bulkhead And Connector Brackets

    FORM 6248 First Edition 5.48 - 9


    AIR/GAS PRELUBE AND START SYSTEMS

    2. If detached, fasten the bulkhead bracket to the PILOT OPERATED PRELUBE VALVE REMOVAL
    connector bracket with two fillister head machine )
    screws, and lock washers.
    A WARNING
    3. Using the bolt hole between the timing pointer and Ensure that the fuel source is completely shut off
    the nearest dowel pin (see Figure 5.45-11), fasten the prior to working on fuel system components Clear
    bulkhead connector bracket assembly to the rear the engine supply lines and piping of accumulated
    flywheel housing with capscrew, lock washer and flat gas before performing any maintenance work on the
    washer). fuel system or severe injury or death could result.

    NOTE: Tag al/ tubes and lines before removal to aid


    during assembly.

    1. Remove the pilot air/gas tube between the bulkhead


    bracket (bulkhead union connector) and the "Pilot A"
    port ofthe pilot operated prelube valve (male connector)
    (see Figure 5.45-13).

    )
    Figure 5.45-11. Rear Flywheel Housing - Rear Right

    4. Apply Perma Lok® Heavy Duty Pipe Sealant with


    Teflon® to the threads of two male connector tube
    fittings and install on each side of the connector bracket
    bore (see Figure 5.45-12).
    Figure 5.45-13. Pilot Operated Prelube Valve -
    Rear Right

    2. Remove the tube between the bulkhead connector


    bracket (lower male connector tube fitting) and the "A"
    oullet port of the pilot operated prelube valve (male
    elbow) (see Figure 5.45-13).

    3. Remove the tube between the rear end of the


    vee-mounted prelube motor air/gas supply tube (union
    elbow tube fitting) and the bulkhead connector bracket
    (upper male connector).

    4. Remove the union elbow tube fitting to the rear end


    ofthe prelube motor air/gas supply tube (attached to the
    inside left bank exhaust manifold). Install the fitting with
    Figure 5.45-12. Bulkhead/Connector Bracket the free end pointing straight down towards the oil pan.
    Assembly
    5. Remove the pilot operated air valve from the rear
    face of the bracket.
    )
    6. Remove the prelube air valve bracket from the starter
    pad (right bank side of the front flywheel housing).

    5.45 - 10 FORM 6248 First Edijion


    AIR/GAS PRELUBE AND START SYSTEMS

    PILOT OPERATED PRELUBE VALVE 4. Install the union elbow tube fitting to the rear end of
    INSTALLATION the prelube motor air/gas supply tube (attached to the
    inside left bank exhaust manifold). Install the fitting with
    1. Slide lock washers on 2 capscrews. Install the the free end pointing straight down towards the oil pan.
    capscrews in the prelube air valve bracket. Slide
    spacers on the ends of the capscrews. 5. Install the tube between the rear end of the
    vee-mounted prelube motor air/gas supply tube (union
    2. Using the two lower bolt holes, install the prelube air elbow tube fitting) and the bulkhead connector bracket
    valve bracket to the starter pad (right bank side of the (upper male connector).
    front flywheel housing). The rounded cut in the bracket
    accommodates the starter bore. 6. Install the tube between the bulkhead connector
    bracket (lower male connector tube fitting) and the "A"
    3. With the label facing outward, align the holes in the outlet port of the pilot operated prelube valve (male
    pilot operated air valve with those in the rear face of the elbow) (see Figure 5.45-13).
    bracket. Fasten the valve to the bracket with three
    capscrews, lock washers and hex nuts (see 7. Install the pilot air/gas tube between the bulkhead
    Figure 5.45-14). bracket (bulkhead union connector) and the "Pilot A"
    port ofthe pilot operated prelube valve (male connector)
    (see Figure 5.45-13).

    NOTE: The ·Pilot B" and "EXH(AUST)" ports of the pilot


    operated prelube valve are plugged. The "Intake" port is
    also plugged when a starter is not specified.

    Figure 5.45-14. Pilot Operated Prelube Valve -


    Rear Right

    FORM 6248 Rrst Edition 5.45 - 11


    AIR/GAS PRELUBE AND START SYSTEMS

    PILOT AIR/GAS SUPPLY


    PRELUBE PUSHBUTTON VALVE)
    BRANCH OF
    MAIN AIR/GAS
    SUPPLY UNION ELBOW

    I TUBEFITIING

    ~=j)
    II
    II TUBE CLIPS TO LEFT BANK
    II EXHAUST MANIFOLD SECTIONS
    II (CYLINDERS #6, #3 AND #1)

    AIR VALVE
    BRACKET

    PILOT OPERATED UNION ELBOW


    PRELUBE VALVE ,TUBE FITTING
    (REAR RIGHT)

    TUBE
    'WYE MOUNTING PAD) (TO GEAR HOUSING)

    Figure 5.45-15. Pilot Operated Prelube Valve Connections

    PRE LUBE PUMP/MOTOR AND


    )
    MOUNTING .......
    CONNECTIONS BRACKET .....
    IN-LINE
    PRELUBE PUMP/MOTOR AND CONNECTIONS PRELUBE LUBRICATOR
    REMOVAL PUMP ¥
    \
    A WARNING
    Ensure that the fuel source is completely shut off
    prior to working on fuel system components Clear AIR/GAS VENT
    the engine supply lines and piping of accumulated (CUSTOMER
    gas before performing any maintenance work on the
    fuel system or severe personal injury or death could
    result.
    PRELUBE
    MOTOR
    ! CONNECTION)

    NOTE: Tag all tubes and lines before removal to aid Figure 5.45-16. Prelube Motor/Pump Assembly
    during assembly.
    5. Remove the prelube motor rotor from the hub of the
    1. Remove the tube clip from the air/gas iniettubetothe
    prelube pump, and remove the key from the shaft.
    rear gear housing (see Figure 5.45-15).

    2. Remove the supply tube between the union elbow 6. Remove the prelube pump/motor mounting bracket
    from the gear housing.
    tube fitting and the air/gas inlet port of the in-line
    lubricator (male elbow).

    3. Remove the union elbow tube fitting from the front


    end of the prelube motor air/gas supply tube (attached )
    to the inside left bank exhaust manifold).

    4. Remove three bracket capscrews from the prelube


    motor flange holes (see Figure 5.45-16).
    5.45 -12 FORM 6248 First Edition
    AIR/GAS PRELUBE AND START SYSTEMS

    PRELUBE PUMP/MOTOR AND CONNECTIONS bracket. The round prelube pump flange should be at
    INSTALLATION the rear of the bracket, the body of the pump at the front.

    1. Using the bolt holes shown in Figure 5.45-17, fasten 5. Install the capscrews in the bracket through the thru
    the prelube pump/motor mounting bracket to the left holes in the prelube pump flange.
    bank side of the rear gear housing with three caps-
    crews, lock washers and washers. Be sure the welded 6. Rotate the hub of the prelube pump until the keyway
    brace in the bracket faces the rear of the engine (see is at top center.
    Figure 5.45-18).
    A CAUTION I
    I~"'~-=:'::"'=-=:"":"':";::"':"':..J.
    L.
    Dirt, grit or other debris
    caught between the mat-
    ing flanges of the prelube pump and motor may
    result in air/gas leakage. Disregarding this Informa-
    tion could result in product damage and/or person-
    al injury.

    7. Thoroughly wipe the mating flanges of the prelube


    pump and prelube motor. Verify that the mating flanges
    are completely smooth. If necessary, use fine grit crocus
    cloth to lightly dress down any burrs or high spots.

    8. Inspectthe prelube motor rotor shaft key (square) for


    damage and distortion. Replace the key if necessary.

    9. Install the key in the slot on the rotor shaft. Ughtly tap
    the key to properly seat it in the keY'l!@Y. Verify that the
    key is level. -

    10. Rotate the rotor shaft until the key is at top center.
    Figure 5.45-17. Rear Gear Housing - Front Left
    The top of the motor can be identified by the air/gas inlet
    and outlet connections.

    11. Insert the prelube motor rotor shaft into the hub of
    the prelube pump, aligning the key on the shaft with the
    notch in the hub.

    12. Start the bracket capscrews into the prelube motor


    flange holes. Alternately wrench tighten the three
    capscrews to evenly draw the prelube pump/motor
    flanges together (see Figure 5.45-16).
    REAR GEAR HOUSING
    BOLT HOLES
    13. Install the single short bolt with lock washer where
    the prelube pump/motor flange is not attached to the
    mounting bracket.

    14. Install the union elbow tube fitting to the front end of
    the prelube motor air/gas supply tube (attached to the
    Figure 5.45-1B. Prelube Motor/Pump Mounting inside left bank exhaust manifold). Install the fitting with
    Bracket - Rear View the free end pointing diagonally towards the cylinder
    head deck (left bank side).
    2. Install the three prelube pump/motor mounting
    capscrews, lock washers and washers through the 15. Install the supply tube between the union elbow
    other holes in the bracket. tube fitting and the air/gas inlet port of the in-line
    lubricator (male elbow).
    3. Install spacers on the ends of the capscrews.
    16. Tube clip the air/gas inlet tube to the rear gear
    4. With the two square head pipe plugs at the bottom housing (see Figure 5.45-15).
    (and the flange mounted nameplate althe top), position
    the neck of the prelube pump in the recess of the

    FORM 6248 First EdHion 5.45 -13


    AIR/GAS PRELUBE AND START SYSTEMS

    LUBE OIL PRESSURE GAUGE TUBES LUBE OIL PRESSURE GAUGE TUBE FITTINGS
    AND FITTINGS INSTALLATION )
    (FORMER ENGINE MOUNTED PANEL) 1. Apply Perma Lok® Heavy Duty Pipe Sealant with
    Teflon® to the threads of the reducing bushing. Install
    LUBE OIL PRESSURE GAUGE TUBES AND
    the bushing in crankcase oil header tap number 6.
    FITTINGS REMOVAL
    2. Apply Perma Lok® Heavy Duty Pipe Sealant with
    A WARNING Teflon® to the threads of a male elbow tube fitting.

    Ensure that the fuel source is completely shut off 3. With the free end pointing horizontally towards the
    prior to working on fuel system components Clear front of the block, install the male elbow tube fitting into
    the engine supply lines and piping of accumulated the reducing bushing.
    gas before performing any maintenance work on the
    fuel system or severe personallnlury or death could 4. Install the lube oil pressure tube to the male elbow
    result. tube fitting (see Figure 5.45-19) and to the back of the
    panel bracket.
    NOTE: Tag all tubes and lines before removal to aid
    during assembly. BULKHEAD TO PANEL BRACKET
    BULKHEAD TO PANEL BRACKET REMOVAL
    1. Remove the lube oil pressure tube from the main oil
    header (male elbow tube fitting) (see Figure 5.45·19)
    and from the back of the panel bracket. A WARNING
    Ensure that the fuel source is completely shut off prior
    to working on fuel system components Clear the
    engine supply lines and piping of accumulated gas
    before perfonning any maintenance work on the fuel
    system or severe personal injury or death could result. )
    NOTE: Tag all tubes and lines before removal to aid
    during assembly.

    1. Remove the Prelube tube from the "DEL(IVERY)"


    port of the Prelube Pushbutton Valve (male elbow tube
    fitting). (see Figure 5.45-20).

    AIR/GAS SUPPLY INLET PORT


    PRELUBE/START PILOT (TEE OR MALE ELBOW)
    AIR/GAS DELIVERY PORT
    (MALE ELBOW) rr=tf=h
    .........

    Figure 5.45-19. Lube Oil Pressure Gauge Connection

    2. Remove the reducing bushing from the elbow

    3. Remove the male elbow tube fitting from the


    crankcase.
    c
    " PUSH
    BUTTON

    Figure 5A5-20. Prelube/Start Pushbutton Valves

    2. Remove the Start tube to the "DEL(IVERY)" port of


    the Start Pushbutton Valve (male elbow tube fitting)
    (see Figure 5.45-20).

    5.45 - 14 FORM 6248 First Edition


    AIR/GAS PRELUBE AND START SYSTEMS

    3. Remove the tube clamp assembly from the four BULKHEAD TO PANEL BRACKET INSTALLATION
    tubes (see Figure 5.45-21).
    1. Install the tube clamp support brace to the lifting eye
    mounting pad at the rear right corner of the block with
    capscrew, lock washer and washer (see
    Figure 5.45-22).

    2. Position the four tubes over the top of the tube clamp
    support brace, and install the angled ends of the vent,
    supply, prelube and start tubes to the bulkhead union
    connectors (see Figure 5.45-24).

    3. Position the tube clamp insert in the tube clamp.


    Position the assembly between the clamp support
    brace and the supply tubes, fitting the tubes in the four
    grooves of the insert. Position the second insert on top
    Figure 5.45-21_ Tube Clamp - Reer Right
    of the tubes followed by the second half of the tube
    4. Remove the Vent tube to the line exiting the clamp. Install the two capscrews, and lock hex nuts) to
    "EXH(AUST)" ports of the Prelube and Start Pushbutton secure the tubes to the clamp support brace (see
    Valves (see Figure 5.45-20). Figure 5.45-23).

    5. Remove the Air/Gas Supply tube to the line feeding


    the "SUP(PLY)" ports of the Prelube and Start Pushbut-
    ton Valves (see Figure 5.45-20).

    6. Remove the control panel (with Start and Prelube


    pushbutton valves) to the left side of the panel bracket.

    ) 7. Remove the second length of the Air/Gas Supply,


    Vent, Start and Prelube tubes.

    8. Remove the tube clamp support brace from the lifting


    eye mounting pad at the rear right corner of the block
    (see Figure 5.45-22).
    Figure 5.45-23. Tube Clamp - Rear Right

    Figure 5.45-22. Tube Clamp Support Brace -


    Reer Right

    FORM 6248 First Edition 5.45 - 15


    AIR/GAS PRELUBE AND START SYSTEMS

    ITEM NUMBER AND DESCRIPTION


    1 Vent Common Tube 10 Pipe Tee 19 28
    2 Supply Common Tube 11
    *
    Hexhead Screw 20
    Hexhead Screw
    Lock washer 29
    Hexhead Screw

    Strap
    3 Prelube Common Tube 12 Nut 21 Flat Washer 30 Bulkhead Bracket
    Start Common Tube Control Tube Brace Union Bulkhead
    4
    5 Supply Panel Tube
    13
    14
    Lock washer
    Flat Washer
    * 22
    23 Hexhead Screw
    31
    32 FilUsterhead Screw
    6 Vent Panel Tube 15 Control Tube Brace 24 Control Panel Assembly 33 Lock washer
    7 Prelube Panel Tube 16 Injection Tube Clamp 25 Hexhead Screw 34 Control Panel Cover
    8 Start Panel Tube 17 Injection Clamp Insert 26 Hexheacl Screw 35 Hexhead Screw
    9 Union Connector 18 Spacer ** 27 lock washer *= GL ** = GlGSI
    Figure 5.45-24. Prelube And Start Air/Gas Tube Connections - Bulkhead (GIGSI/GL)

    4. Position the second length of the Air/Gas Supply, 5. Install the control panel (with Start and Prelube
    Vent, Start and Prelube tubes up to the panel bracket pushbutton valves) to the left side of the panel bracket
    (see Figure 5.45-24). Install the tubes to the free ends of with sjx hex head drive screws (see Figure 5.45-24 and
    the union and union tee tube fittings. Figure 5.45-25).

    5.45 -16 FORM 6248 First Edition


    AIR/GAS PRELUBE AND START SYSTEMS

    / AIR/GAS SUPPLY LINE

    "- AIR/GAS VENT LINE

    SLOT FOR COMPOUND


    GAUGE SELECTOR

    \
    AIR/GAS
    DELIVERY PORT
    o o o

    u u
    AIR/GAS
    /UPPLY LINE,
    "
    D ~ 1"-.: /' 1"-.: /'
    1===:tJO

    0: : ~_o_~_---JO 'AIR/GAS/'
    VENT LINE

    START PRELUBE
    PUSHBUTTON VALVE PUSHBUTTON VALVE

    Figure 5.45-25. Pushbutton Valve Connections

    6. Install the free end of the Air/Gas Supply tube to the 7. Install the free end of the Vent tube to the line exiting
    line feeding the "SUP(PLY)" ports of the Prelube and the "EXH (AUST)" ports of the Prelube and Start Push-
    Start Pushbutton Valves (see Figure 5.45-25 and button Valves (see Figure 5.45-25 and Figure 5.45-26).
    Figure 5.45-26).
    8. Install the free end of the Start tube to the 'DELOVERY)"
    AIR/GAS SUPPLY INLET PORT port of the Start Pushbutton Valve (male elbow tube filling)
    PRELUBE/START PILOT (TEE OR MALE ELBOW) (see Figure 5.45-25 and Figure 5.45-26).
    AIR/GAS DELIVERY PORT
    (MALE ELBOW) "'r=.=H==l1 9. Install the free end of the Prelube tube to the
    'DEL(IVERY)" port of the Prelube Pushbutton Valve
    (male elbow tube fitting).

    TUBE CLIPS/CLAMPS INSTALLATION


    c 1. Attach two tube clips to the Prelube tube at the rear of
    the union tube fitting. Attach two tube clips to the parallel
    Start tube althe rear of the union tee tube fitting. line up

    "' PUSH
    BlITTON
    the holes in the Prelube and Start tube clips. Fasten the
    clips to the lower slot of two tube clip brackets.

    2. Attach two tube clips to the Air/Gas Supply tube at the


    rear of the union tube fitting. Attach two tube clips to the
    parallel Vent tube at the rear of the union tee tube fitting.
    Figure 5.45-26. PrelubejStart Pushbutton Valves line up the holes in the Supply and Vent tube clips.
    Fasten the clips to the upper slot of the tube clip brackets.

    FORM 6248 First Edition 5.45 - 17


    AIR/GAS PRELUBE AND START SYSTEMS

    PRECHAMBER FUEL
    SUPPLY TUBE BRACKET
    (1/2 X 2" CAPS CREW)

    AIR/GAS SYSTEM TUBE PRECHAMBER REGULATOR


    CLIP BRACKETS MOUNTING BRACKET
    (1/2 X 1-3/4" CAPSCREW) (1/2 X 2-1/4" CAPSCREW)

    )
    Figure 5.45-27. Intake Manifold Flange Attachments - Right Bank
    3. Remove two capscrews from the lower intake 4. Using the round hole, slide the tube clip brackets on
    manifold flanges (see Figure 5.45-27). the capscrews. Install the capscrews back in the intake
    manifold flanges (see Figure 5.45-28).

    ,---f:I"::J~_A_:~_F~::LD=:t,~j:tt::l
    AIR/GAS SUPPLY TUBE
    VENT TUBE

    REAR
    rr===ik7
    I II 5R II I
    \---r--..JL
    o -
    _..J

    ~ruJ/
    PRE LUBE TUBE
    TUBE CLIP
    BRACKET
    TUBE
    CLIPS
    \
    "GL"PRECHAMBER
    FUEL VALVES
    UNION AND UNION TEE
    TUBE FITTINGS

    Figure 5.45-28. Tube Clip Brackets - Right Bank Intake Manifold

    5.45 - 18 FORM 6248 First Edrtion


    AIR/GAS PRELUBE AND START SYSTEMS

    PRECHAMBER ,~.

    I
    AIR/GAS SUPPLY
    (FROM TEE OF "START TUBE")
    ~~
    t ~
    '-J
    I~I
    ,-"'--/"/A
    ~ / ORIFICE CHECK VALVE

    GAS VENT/ ~. /AIR/GAS PLENUM


    (TO TEE OF "VENT TUBE")

    /~'

    /
    ~ "-
    PRECHAMBER GAS

    6f
    SAFETY SHUTDOWN """
    VALVE

    '~, ~/
    W

    ) SHUTTLE
    VALVE ,rB,
    I
    ~=" .&
    I
    I

    GAS OUT TO
    PRECHAMBER
    "~,I ®
    ~~ ~_~o-;
    - ,__ '~UBEOIL
    PRESSURE TUBE
    REGULATOR If (FROM MAIN OIL HEADER)

    ~t'p ~ ~
    GAS INLET " '\. DOWNcilTEAM

    (FROM 99 REGULATOR) .& ""


    \ ~ V" PILOT OPERATED
    PRECHAMBER GAS VALVE

    ~~
    Figure 5A5-29. Pilot Operated Prechamber Fuel Valves
    PRECHAMBER GAS VALVES - GL NOTE: Tag all tubes and lines before removal to aid
    during assembly.
    PRECHAMBER GAS VALVES REMOVAL (GL)
    1. Remove the gas supply tube between the" A" ouUet
    A WARNING port of the prechamber gas valve (male connector tube
    fitting to service tee) and the inlet port of the prechamber
    Ensure that the fuel source Is completely shut off prior regulator (male connector to pipe tee) (see
    j to working on fuel system components Clear the Figure 5.45-29).
    engine supply lines and piping of accumulated gas
    before performing any maintenance work on the fuel
    system or severe personal injury or death could result.

    FORM 6248 First Edition 5.45 - 19


    AIR/GAS PRELUBE AND START SYSTEMS

    2. Remove the gas supply tube between the 99 9. Remove two capscrews, washers, lock washers and
    regulator gas inlet (male elbow to reducing tee) and the washers and the gas valve bracket from the top of the
    "P" inlet port of the prechamber gas valve (male right bank 99 regulator mounting bracket (see
    connector to service tee). Figure 5.45-31).

    3. Remove the downstream gas tube between the "A"


    outlet port of the prechamber gas valve (male elbow
    tube fitting to service tee) and the "IN(LET)" port of the
    safety shutdown valve (male elbow).

    4. Remove the downstream gas tube between the


    second inlet port of the shuttle valve (male connector
    tube fitting) and the "A" outlet port of the safety
    shutdown valve (male elbow) (see Figure 5.45-29).

    5. Remove the pilot supply tube between the outlet side


    of the air/gas plenum and the "IN(LET)" port of the
    shuttle valve.

    6. Remove the lube oil pilot pressure tube between the


    main oil header male elbow (round cut in magneto drive
    support bracket) (see Figure 5.45-30) and the pilot inlet
    port ofthe prechamber gas safety shutdown valve (male
    elbow).

    Figure 5.45-31. Mount Prechamber Gas Valve


    )
    10. Remove three capscrews, washers, lock washers,
    hex nuts and the pilot operated prechamber gas valve
    (see Figure 5.45-32) from the gas valve bracket.

    Figure 5.45-30. Lube Oil Pilot Pressure Tube


    Connection

    7. Remove the vent tube between the vent tube union


    tee and the "EXH(AUST)" port of the prechamber gas
    safety shutdown valve (male elbow) (see
    Figure 5.45-29).

    8. Remove the vent tube between the vent tube union


    tee and the "EXH(AUST)" port of the prechamber gas
    safety shutdown valve (male elbow).
    Figure 5.45-32. Prechamber Gas Valve

    11. Remove the lower front corner capscrew, with lock


    \
    washer from the 99 regulator mounting bracket (right /
    bank).

    5.45 - 20 FORM 6248 First Edition


    AIR/GAS PRELUBE AND START SYSTEMS

    12. Remove capscrew, lock washer and spacer from 14. Remove two socket head machine screws, wash-
    the lower rear bolt hole of the plenum bracket (see ers, lock washers, and the prechamber gas safety
    Figure 5.45-33). shutdown valve from the plenum bracket (see
    Figure 5.45-34).

    Figure 5.45-33. Air/Gas Plenum - Safety Shutdown


    Valve

    Figure 5.45-34. Air/Gas Plenum - Safety Shutdown


    13. Remove two capscrews, lock washers, spacers,
    Valve
    and the plenum bracket from the crankcase.

    15. Remove U-bolt, two washers, lock washers, and


    hex nuts from around the air/gas plenum and remove it
    from the plenum bracket (see Figure 5.45-34).

    FORM 6248 First Edition 5.45 - 21


    AIR/GAS PRE LUBE AND START SYSTEMS

    PRECHAMBER GAS VALVES INSTALLATION (GL) 7. Using the two slotted holes on the front edge, finger
    tighten the gas valve bracketto the top of the right bank
    1. Center the U-bolt around the air/gas plenum and 99 regulator mounting bracket with two capscrews,
    fasten it to the plenum bracket with washers, lock each with two washers, lock washer and hex nut (see
    washers and hex nuts (see Figure 5.45-34). Figure 5.45-36).
    2. Fasten the prechamber gas safety shutdown valve
    to the plenum bracket with two socket head machine
    screws, flat washers, lock washers and hex nuts (see
    Figure 5.45-34).

    3. Remove the lower front corner capscrew and lock


    washer from the 99 regulator mounting bracket (right
    bank).

    4. Hold the bracket so that the plenum is at the top in a


    horizontal position. Slide the longer capscrew and lock
    washer) in the lower rear bolt hole of the plenum
    bracket. Slide a inch spacer on the end of the capscrew.
    Start the capscrew in the 99 regulator mounting bracket
    (see Figure 5.45-33).

    5. Align the two vertical holes in the plenum bracket


    with those in the engine block. Fasten the bracket to the
    block with two capscrews, lock washers and spacers.
    Wrench tighten all fasteners.

    6. With the label facing outward, fasten the pilot


    operated prechamber gas valve (see Figure 5.45-35) to Figure 5.45-36. Mount Prechamber Gas Valve )
    the gas valve bracket three capscrews, flat washers,
    lock washers and hex nuts. NOTE: Reattach both ends of each tube before tighten-
    ing.
    8. Install the air/gas supply tube between the union tee
    of the pilot air start tube and the inlet side of the air/gas
    plenum (male elbow) (see Figure 5.45-29).

    9. Install the vent tube between the vent tube union tee
    and the "EXH(AUST)" port olthe prechamber gas safety
    shutdown valve (male elbow).

    Figure 5.45-35. Prechamber Gas Valve

    ,I

    5.45 - 22 FORM 6248 First Ednion


    AIR/GAS PRELUBE AND START SYSTEMS

    10. Install the lube oil pilot pressure tube between the main 15. Install the gas supply tube between the "A" outlet
    oil header male elbow (round cut in magneto drive support port of the prechamber gas valve (male connector tube
    bracket) (see Figure 5.45-37) and the pilot inlet port of the fitting to service tee) and the inlet port olthe prechamber
    prechamber gas safety shutdown valve (male elbow). regulator (male connector to pipe tee) (see
    Figure 5.45-29).

    16. Tighten the capscrews securing the air valve


    bracket to the 99 regulator mounting bracket.

    17. Locate the square head pipe plugs in the #4 and #5


    oil header taps (right bank main oil header). Attach two
    tube clips to the pilot air/gas start tube (upper) at these
    locations. Fasten each clip to the block using the
    threaded holes below the square head pipe plugs with
    capscrew and washer.

    18. Attach two smaller clips to the pilot air/gas start tube
    (upper). Attach two smaller clips to the parallel venttube
    (lower). Line up the holes in the start and venttube clips
    and install with capscrew and washer (see
    Figure 5.45-37. Lube Oil Pilot Pressure Tube Figure 5.45-38).
    Connection

    11. Install the outlet side of the air/gas plenum (male


    elbow tube fitting) and the "IN (LET)" port of the shuttle
    valve (male elbow).

    12. Install the downstream gas tube between the


    second inlet port of the shuttle valve (male connector
    tube fitting) and the "A" outlet port of the safety
    shutdown valve (male elbow) (see Figure 5.45-29).

    13. Install the downstream gas tube between the "A"


    outlet port of the prechamber gas valve (male elbow
    tube fitting to service tee) and the "IN(LET)" port of the
    safety shutdown valve (male elbow).

    14. Install the gas supply tube between the 99 regulator


    gas inlet (male elbow to reducing tee) and the "P" inlet
    port of the prechamber gas valve (male connector to Figure 5.45-38. Tube Clips - Right Bank
    service tee).

    FORM 6248 First Edition 5.45 - 23


    AIR/GAS PRELUBE AND START SYSTEMS

    VEN",

    -,,>,----<"-.---<-,..._LO'L RESERVOIR

    ftl ~n

    AIRINLETG/

    PRELUBE VALVE
    / 1..oF:=!:;-I
    I'----,'AIRIGAS STARTER

    , CAPSCREW AND
    LOCKWASHERS
    VIEW IN DIRECT/ON
    OF ARROW "A"

    VIEW IN DIRECT/ON
    OF ARROW "B"
    Figure 5.45-39. Air/Gas Starter

    AIR STARTER NOTE: Tag al/ tubes and lines before removal to aid
    during assembly.
    AIR STARTER REMOVAL
    1. Disconnect the air/gas tubes from the bulkhead
    A WARNING fittings (see Figure 5.45-2, and Figure 5.45-39).

    Ensure that the fuel source is completely shut off 2. Disconnect the air inlet pipe from the air starter.
    prior to working on fuel system components Clear
    3. Disconnect the air/gas exhaust pipe from the air
    the engine supply lines and piping of accumulated
    starter.
    gas before performing any maintenance work on the
    fuel system or severe personal injury or death could 4. Refer to Pilot Operated Prelube Valve, Removal and
    result. remove the pilot operated prelube valve.

    5.45-24 FORM 6245 First Edition


    AIR/GAS PRELUBE AND START SYSTEMS

    A WARNING
    The air starter weighs approximately 1031bs (48 kg).
    Use a suitable lifting device and exercise caution
    during removal or installation to avoid severe
    personal Injury or death.

    5. Using a suitable lilting device remove three capscrews,


    lock washers and the air starter from the flywheel housing.

    AIR STARTER INSTALLATION

    A WARNING
    The air starter weighs approximately 103lbs. (48 kg).
    Use a suitable lifting device and exercise caution
    during removal or Installation to avoid severe
    personal injury or death.

    1. Using a suitable lifting device, install the air starter on


    the flywheel housing with three capscrews and lock
    washers.

    2. Refer to Pilot Operated Prelube Valve, Installation


    and install the pilot operated prelube valve.

    3. Apply Perma Lok® Heavy Duty Pipe Sealant with


    Teflon® to the threads and connect the air/gas exhaust
    pipe to the air starter.

    4. Apply Perma Lok® Heavy Duty Pipe Sealant with


    Teflon® to the threads and connect the air inlet pipe to
    the air starter.

    5. Connect the air/gas tubes to the bulkhead fillings


    (see Figure 5.45-2, and Figure 5.45-39).

    FORM 6248 First Edition 5.45 - 25


    AIR/GAS PRELUBE AND START SYSTEMS

    ELECTRIC STARTER ELECTRIC STARTER INSTALLATION


    )
    ELECTRIC STARTER REMOVAL
    A WARNING
    A WARNING Disconnect all electrical power supplies before
    making any connections or servicing any part ofthe
    Disconnect all electrical power supplies before electrical system. Electrical shock can cause se-
    making any connections or servicing any part ofthe vere personal injury or death.
    electrical system. Electrical shock can cause se-
    vere personal injury or death. 1. Disconnect all electrical power supplies.

    1. Disconnect all electrical power supplies. 2. Position the starter on the flywheel housing and
    install the starter on the flywheel housing with three
    NOTE: Tag all electrical wires before removal, to aid capscrews and lock washers.
    during installation.
    3. Refer to tags and connect aU wires to the starter (see
    2. Tag and disconnect all wires from the starter (see Figure 5.45-40 and Figure 5.45-41).
    Figure 5.45-40).

    Figure 5.45-40. Electric Starter

    3. Remove three capscrews, lock washers and the


    starter from the flywheel housing.

    5.45 - 26 FORM 6248 First Edition


    AIR/GAS PRELUBE AND START SYSTEMS

    -----------1
    ---~~" ! I'
    ,~ -jil-h ! j~
    ,_ -=r l
    , il I i
    ----~

    '--- ......- ..,

    Figure 5.45-41. Wiring Diagram - DC Junction Box - CEC Ignition With Electric Start

    FORM 6248 First Ed~ion 5.45 - 27


    AIR/GAS PRE LUBE AND START SYSTEMS

    ,8,1," 0
    !I
    ~~
    h! =>w
    Oz
    :'0
    !
    wa.
    z"
    !
    -0 i
    li!o
    w !
    !

    1
    l<a
    ,I 1
    Ii 1 1 I
    I" 1 1

    _____ !Il.j'~'=-----A
    i ;iI.liii
    Figure 5.45-42. Wiring Diagram - DC Junction Box - CEC Ignition With Air Start

    5.45 - 28 FORM 6248 First Edition


    CHAPTER 6 - ACCESSORIES

    CONTENTS

    SECTION 6.00 - CONTROL PANEL

    SECTION 6.05 - ENGINE PROTECTION SYSTEMS

    SECTION 6.10 - MISCELLANEOUS EQUIPMENT

    FORM 6248 First Edition


    )

    FORM 6248 First Edijion


    SECTION 6.00 - CONTROL PANEL

    CONTROL PANEL 2. Tag and disconnect the wires from the ignition switch
    (see Figure 6.00-2).
    COMPONENTS
    The control panels consist of the following components.

    • Prelube Pushbutton Valve

    • Starter Pushbutton Valve

    • Ignition Pushbutton Switches

    • Control Panel Housings

    CONTROL PANEL REMOVAL - RIGHT SIDE

    A WARNING
    Disconnect all electrical power supplies before
    making any connections or servicing any part ofthe
    Figure 6.00-2. Ignition Switch
    electrical system. Electrical shock can cause se·
    vere personal injury or death.
    3. Remove nut, locking ring, switch and foam gasket
    NOTE: Tag all tubes, lines and wires before removal, to from control panel (see Figure 6.00-2).
    aid during assembly.

    1. Remove four capscrews, lock washers, and control A WARNING


    panel cover from the control panel (see Figure 6.00-1). Ensure that the fuel source is completely shut off
    prior to working on fuel system components_ Clear
    ) the engine supply lines and piping of accumulated
    gas before performing any maintenance work on the
    fuel system or severe Injury or death could result.

    4. Tag and disconnect the start, prelube, vent, and


    supply tubes from the control panel (see Figure 6.00-3
    and Figure 6.00-4).

    Figure 6.00-1. Control Panel - Right Side

    Figure 6.D0-3. Control Panel - Right Side

    FORM 6248 First Edition 6.00 -1


    CONTROL PANEL

    I
    I
    I
    I
    I
    I
    I
    <,,
    ,,
    ,,
    ,
    )

    ITEM NUMBER AND DESCRIPTION


    1 Vent Common Tube 10 Pipe Tee 19 Hexhead Screw 28 Hexhead Screw
    2 Supply Common Tube 11
    *
    Hexhead Screw 20 Lock washer 29 Strap
    3 Prelube Common Tube 12 Nut 21 Flat Washer 30 Bulkhead Bracket
    4 Start Common Tube 13 Lock washer 22 Control Tube Brace 31 Union Bulkhead
    5 Supply Panel Tube 14 Flat Washer
    * 23 Hexhead Screw 32 Fillisterhead Screw
    6 Vent Panel Tube 15 Control Tube Brace 24 Control Panel Assembly 33 Lock washer
    7 Prelube Panel Tube 16 Injection Tube Clamp 25 Hexhead Screw 34 Control Panel Cover
    8 Start Panel Tube 17 Injection Clamp Insert 26 Hexhead Screw 35 Hexhead Screw
    9 Union Connector 18 Spacer
    ** 27 Lock washer * =GL ** =G/GSI
    Figure 6.00-4. Prelube And Start Air/Gas Tube Connections - Bulkhead (G/GSI/GL)

    6.00 - 2 FORM 6248 First Edition


    CONTROL PANEL

    5. Remove conduit lock nut and remove the ignition 7. Remove two capscrews, lock washers and straps
    wire harness from the control panel (see Figure 6.00-5). from the intake manifold (see Figure 6.00-6 and
    Figure 6.00-7).

    Figure 6.00-5. Ignition Switch Wire Harness

    Figure 6.00-7. Intake Manifold - Right Bank


    6. Remove four capscrews, lock washers, washers
    and control panel from the two mounting straps (see
    Figure 6.00-6). 8. If pushbutton valves are to be removed, loosen the
    locking nuts on the back of each pushbutton, and
    remove the pushbuttons from each valve (see
    Figure 6.00-8).

    Figure 6.0006. Pushbutton Valves

    9. Remove the two mounting nuts from the valves and


    remove the valves and connecting tubes from the
    mounting bracket.

    INTAKE 10. Tag and disconnect the connecting tubes from the
    MANIFOLD valves.

    CONTROL PANEL INSTALLATION - RIGHT SIDE


    Figure 6.00-6. Mounting Straps
    1. Refer to tags and connect the connecting tubes to
    the valves (see Figure 6.00-4 and Figure 6.00-8).

    2. Install the valves and connecting tubes to the


    mounting bracket with the two mounting nuts.

    3. Install the push buttons to the valves and tighten the


    )
    lock nuts against the pushbuttons.

    FORM 6248 First Edition 6.00 - 3


    CONTROL PANEL

    4. Install mounting straps on the intake manifold with CONTROL PANEL REMOVAL - LEFT SIDE
    two capscrews and lock washers (see Figure 6.00-6, )
    Figure 6.00-7 and Figure 6.00-9). 1. Remove four capscrews, lock washers, and control
    panel cover from the control panel (see Figure 6.00-11).

    C
    HOLE CLOSEST TO THE E N D y t f
    ALIGNED WITH INSIDE FLANGE
    HOLE OF INTAKE MANIFOLD
    0

    Figure 6.00-9. Bracket Strap

    5. Install the control panel on the straps with four


    capscrews lock washers and washers.

    A WARNING Figure 6.00-11. Control Panel Cover


    Disconnect all electrical power supplies before
    making any connections or servicing any part ofthe )
    electrical system. Electrical shock can cause se-
    vere personal Injury or death.
    A WARNING
    Disconnect all electrical power supplies before
    6. Install the ignition wire harness on the control panel making any connections or servicing any part of the
    and tighten conduit lock nut (see Figure 6.00-10). electrical system. Electrical shock can cause se-
    vere personal InJury or death.
    NOTE: Tag a/l wires before removal to aid during
    assembly.

    2. Tag and disconnect the wires from the ignition Switch


    (see Figure 6.00-12).

    Figure 6.00-10. Ignition Switch Wire Harness

    7. Connect the wires to the ignition switch (see


    Figure 6.00-15 and Figure 6.00-16).

    a. Connect the start, prelube, vent, and supply tubes to


    the control panel.
    Figure 6.00-12. Ignition Wire Harness And Ignition
    9. Install panel cover on the control panel with four
    Switch - Left Side
    capscrews and lock washers.
    6.00 - 4 FORM 6248 First Edition
    CONTROL PANEL

    3. Remove conduit lock nut and remove the ignition CONTROL PANEL INSTALLATION - LEFT SIDE
    wire harness from the control panel.
    1. Install straps on intake manifold with two capscrews
    4. Remove four capscrews, lock washers, washers and lock washers (see Figure 6.00-7 and
    and control panel from the mounting straps (see Figure 6.00-13).
    Figure 6.00-13).
    2. Install the control panel on the straps with four
    capscrews and lock washers.

    A WARNING
    Disconnect all electrical power supplies before
    making any connections or servicing any part ofthe
    electrical system. Electrical shock can cause se-
    vere personal injury or death.

    3. Install the ignition wire harness on the control panel


    and tighten conduit lock nu1 (see Figure 6.00-14).

    INTAKE
    MANIFOLD

    Figure 6.00-13. Control Panel

    5. Remove two capscrews, lock washers and straps


    from the intake manifold (see Figure 6.00-13).

    Figure 6.00-14. IgnHion Switch Wire Harness

    4. Connect the wires to the ignition switch (see


    Figure 6.00-15 and Figure 6.00-16).

    5. Install the ignition switch on the control panel with


    foam gasket, locking ring and nut.

    6. Install panel cover on the control panel with four


    capscrews and lock washers.

    FORM 6248 First Ednion 6.00 - 5


    CONTROL PANEL

    -----------1
    11:-81 ----joOol'-="1

    !
    I!
    i'
    I!" )
    "
    Figure 6.00-15. Wiring Diagram - DC Junction Box - CEC Ignition With Electric Start

    6.00 - 6 FORM 6248 First Edition


    CONTROL PANEL

    !!
    !
    Ii'."'
    ~I
    "

    Figure 6.00-16. Wiring Diagram - DC Junction Box - CEC Ignition With Air Start

    FORM 6248 First Ednion 6.00 -7


    CONTROL PANEL

    6.00 - 8 FORM 6248 First Ed~ion


    SECTION 6.05 - ENGINE PROTECTION SYSTEMS

    ENGINE PROTECTION SYSTEMS


    COMPONENTS
    On current VHP 12 Cylinder Engines, the control switches
    that make up the engine protection shutdown system
    must be supplied by the customer. Waukesha provides
    the following standard and optional components:

    A WARNING
    Switches for alarms and automatic engine shut·
    down must be supplied by the customer. The
    sensors provided are for measuring and monitoring
    temperatures and WILL NOT shut the engine down
    if potentially harmful temperatures are reached.
    Disregarding this information could result in severe
    personal injury or death.

    A WARNING
    Figure 6.05-1. Lube 011 Inlet Temperature Sensor

    To prevent engine damage and severe personal injury


    or death, it is the customer's responsibility to provide
    engine protection swiitches and fuel shutoff valves
    wired to simultaneously shut off the ignition and the
    fuel for the following conditions: normal shutdown,
    overspeed, low lube 011 pressure, high jacket water
    temperature and high Intake manifold pressure on
    GSI and GL engines. See SA 8382 for recommended
    engine protection equipment shutdown points.
    • Sensors and Thermocouples (Standard)

    • Thermocouple Junction Box


    (Standard and Optional) Figure 6.05-2. Jacket Water Temperature Sensor
    • Manual Shutdown Switches (2) (Standard)

    • Gauges
    (Optional, Engine Mounted or Remote Panel) , NOTE: Intake manifold tempe_ S8IlS0IS are located
    behind each butterfly vaJve assembly below the intake
    manifolds.
    • Detonation Sensing Module
    (Standard on selected models)

    UK" TYPE THERMOCOUPLES


    Four thermocouples are used to measure lube oil (see
    Figure 6.05-1), jacket water (see Figure 6.05-2 ), and
    intake manifold (left and right bank) air temperature (see
    Figure 6.05-3). These thermocouples are wired through
    the thermocouple junction box to a remote mounted
    instrument panel (customer supplied or as a Waukesha
    option). The thermocouple junction box is located on the
    right front side of the engine next to the main junction box.
    Fourteen additional thermocouples (see Figure 6.05-4
    and Figure 6.05-5) are used to measure exhaust temper-
    j ature and turbined inlet temperature.

    Figure 6.05-3. Intake Manifold Temperature Sensor

    FORM 6248 First Ednion 6.05 - 1


    ENGINE PROTECTION SYSTEMS

    LEFT BANK EXHAUST )


    MANIFOLD
    /SECTION
    TURBO EXHAUST
    INLET ELBOW r.::.
    "'131 Y EXHAUST
    THERMOCOUPLE

    REAR FRONT

    ~~~nr~~-+~~~H-~~··~·····"
    /" THERMOCOUPLE
    THERMOCOUPLE CONDUIT
    LEADS 14131211 10 98 7 6 54 32

    RIGHT BANK
    Figure 6.05-4. Exhaust Thermocouples Arrangement

    Figure 6.05-6. Main Bearing Temperature

    ~ ..... "-
    Thermocouples

    Figure 6.05-5. Exhaust Thermocouple - Rear Left • One"K" Type thermocouple used to monitor the oil
    sump temperature.
    Optional "K" Type thermocouples that may be found on
    the engine, are: • Two oxygen sensors mounted in the exhaust system.

    • Seven thermocouples used to monitor the main • Twelve detonation sensors are used to detect
    bearing temperatures (see Figure 6.05-6 and detonation in the combustion chambers. Refer to
    Figure 6.05-7). All thermocouples end atthethermo- Detonation Sensing Module, for information con-
    couple junction box when shipped (see cerning the detonation sensors.
    Figure 6.05-8). It is the customer's responsibility to
    connect the wiring to the remote-mounted instru-
    ment panel. Main bearing sensor logic must be
    supplied by the customer.
    )

    &.05 - 2 FORM 6248 First Edition


    ENGINE PROTECTION SYSTEMS

    LEFT SIDE VIEW REAR VIEW

    TERMINAL
    NUMBER DESCRIPTION

    21 MAIN BEARING #1
    22 MAIN BEARING #2
    23 MAIN BEARING #3
    24 MAIN BEARING #4
    25 MAIN BEARING #5
    26 MAIN BEARING #6
    27 MAIN BEARING #7

    THERMOCOUPLE JUNCTION BOX


    RIGHT SIDE

    Figure 6.05-7. Wiring Diagram - Main Bearing Temperature Thermocouples

    FORM 6248 First Edition 6.05 - 3


    ENGINE PROTECTION SYSTEMS

    THERMOCOUPLE JUNCTION BOX

    JACKET WATER OUT INTAKE MANIFOLD MAIN BEARING lHERMOCOUPLES JACKET WATER INLET LUBE OIL SUMP
    (LB. & R.B.) LUBE OIL THERMOCOUPLES TERMINAL BLOCKS: 21 - 27 THERMOCOUPLES

    J~-
    TERMINAL BLOCKS: 17 - 20

    I
    ~\ \
    EXHAUSTTHERMOCOUPLES
    TERMINAL BLOCKS: 1 - 16""
    ®
    I ®
    \
    r-
    0 '" \ /
    ---....
    0

    ®
    0 b b 6 (l)
    " , , 4 5 • , 8 9 10 11 121314151 1 161 92021222324252627 29

    f-

    ~-~
    ,.
    V
    0
    SECONDARY CUSTOMER
    STEPPING MOTOR STEPPING MOTOR
    ~ CONNEcnONS
    LEFTBANK
    TERMINAL BLOCKS:
    ~ RIGHT BANK
    TERMINAL BLOCKS: THIS SIDE )
    56 - 62 63-69

    .-
    J
    , ~ '.! ,
    ·1 1
    ~

    --
    -- .... "'"
    (l)
    3031
    - -
    I-
    '23'"
    ""
    4042444648505254 5658606264

    4143 4547 49 51 5355 ~ 61


    8877274

    65 fil 6971
    "
    , 80"

    81" ... "" 96 981101

    "99 '01 ®
    f--

    0 I
    \
    9 QQ 0
    ==~ ..~=
    0 ..... J 0
    '-- - --"

    OXYGEN SENSORS
    .I \ \
    DETONAll0N SENSORS
    TERMINAL BLOCKS: 3O,31,B2 - 87 TERMINAL BLOCKS: 88 - 102

    PRIMARY STEPPING MOTOR PRIMARY STEPPING MOTOR INTAKE MANIFOLD PRESSURE


    RIGHT BANK TERMINAL BLOCKS: LEFT BANK TERMINAL BLOCKS: TERMINAL BLOCKS: 70 - 72
    39 - 45,53 - !H5 32-38,50-52

    Figure 6.05-8. Wiring Diagram - Thermocouple Junction Box

    6.05 - 4 FORM 6248 Firsl Edition


    ENGINE PROTECTION SYSTEMS

    TERMINAL DESCRIPTION TERMINAL DESCRIPTION


    NUMBER NUMBER

    •• 1
    2
    Exhaust, CyI. #1 - Left Bank
    ExhausI, CyI. '2 - Left Bank
    0
    0
    50
    51
    Red
    Clear
    STEPPING MOTOR FEED-
    BACK

    •• 3
    4
    Exhaust. CyI. #3 - Left Bank
    Exhaust, Cyl. #4 - Left Bank
    0
    0
    52
    53
    Black
    Red
    LEFT BANK

    STEPPING MOTOR FEED-

    •• 5
    6
    Exhaust, Cyl. #5 - Left Bank
    Exhaust, Cyl. #6 - Left Bank
    0
    0
    54
    55
    Clear
    Black
    BACK
    RIGHT BANK
    0 56 Yellow
    • 7 Exhaust Common G E~ine QrTurbine
    Inlet GSI/GL Engines - eft Bank 0 57 Green

    •• 8
    9
    Exhaust, CyI. " - Rlgh1 Bank
    Exhaust, CyI. '2 - Righ1 Bank
    0
    o
    56
    59
    Blue
    Red
    SECONDARY STEPPING MO-
    TOR
    LEFT BANK
    •• 10
    11
    Exhaust, Cyl. #3 - Righ1 Bank
    Exhaust, CyI. #4 - Righ1 Bank
    0
    0
    60
    61
    White
    Black
    OPTIONAL-DUAL FUEL

    • 12 Exhaust, Cyl. #5 - Righ1 Bank 0 62 Drain

    • 13 Exhaust, Cyl. #6 - Righ1 Bank 0 63


    64
    Yellow
    Green
    •
    0
    Exha~ Common G E~ne Or Turbine
    14 Inlet G I/GL Engines - ight Bank 0 65 Blue SECONDARY STEPPING MO-
    15 Turbine Outlet - Left Bank o TOR
    0 66 Red RIGHT BANK
    0 16 Turbine Outlet - Right Bank 0 67 White OPTIONAL-DUAL FUEL
    T 17 Jacket Water Out 0 68 Black
    T 18 Intake Manifold - Left Bank 0 69 Drain
    T 19 Intake Manifold - Right Bank 0 70 Red (+) ANALOG 1
    T 20 Lube Oil Header 0 71 Black (-) INTAKE MANIFOUD
    0 72 Clear PRESSURE
    0 21 Main Bearing #1
    22 Main Bearing #2 0 73 Red (+)
    0 ANALOG 2
    23 Main Bearing #3 0 74 Black (-) UNDEDICATED
    0
    24 Main Bearing #4
    0 75 Clear
    0
    Main Bearing #5
    0 76 Red (+)
    0 25 ANALOG 3
    0 77 Black (-) UNDEDICATED
    0 26 Main Bearing He
    0 78 Clear
    0 27 Main Bearing #7
    0 78 Open
    0 28 Jacket Water In (Reserved For)
    0 60 DSM VARIABLE IGNITION
    0 29 Lube Oil Sump (Reserved For)
    0 81 DSM TiMING UNIT
    0 30 Oxygen Sensor
    0 62 Black
    0 31 Oxygen Sensor OXYGEN SENSOR HEATER
    0 63 Red LEFT BANK
    THERMOCOUPLES
    TERMINAL NUMBERS 1 - 29 0 94 Drain
    0 85 BlacI<
    OXYGEN SENSOR HEATER
    Terminal 0 66 Red RIGHT BANK
    DESCRIPTION
    Number 0 87 Drain
    .,. 32 Drain 0" 68 Cyl. #1 L.B .
    .,. 33 Yellow 0" 68 Cyl. #2 L.B.
    .,. 34 Green 0" 90 Cyl. #3 L.B.
    .,. 35 Blue
    PRIMARY STEPPING MOTOR
    LEFT BANK O· 91 Cyl. #4 L.B.
    .,. 36 Red O· 92 Cyl. #5 L.B.
    .,. 37 White
    .,. 38 BlacI<
    0"
    0"
    93
    94
    Cyl. #6 L.B.
    I CyI. #1R.B .
    .,. 39 Drain 0" 85 CyI. #2 R.B.
    DETONATION
    SENSORS
    .,. 40 Yellow 0" 96 CyI. #3 RB. (*Standard on 7042 GSI/GL)
    .,. 41 Green 0" 97 CyI. #4 RB.
    .,. 42 Blue
    PRIMARY STEPPING MOTOR
    RIGHT BANK 0" 96 CyI. #5 RB.
    .,. 43 Red 0" 99 CyI. #6 RB.
    .,. 44 White 0 100 Ground 1
    .,. 45 Black 0 101 Ground 2
    0 46 A Green OXYGEN SENSOR 0 102 Ground 3
    0 47 BWhile LEFT BANK
    103 Open
    0 46 A Green OXYGEN SENSOR
    49 BWhite RIGHT BANK
    0
    OXYGEN SENSOR CONNECTIONS FOR cec AND CAFC

    SYMBOLS • 62 White/Clear
    OXYGEN SENSOR
    ) T STANDARD ALL ENGINES • 63 Drain LEFT BANK
    •
    o
    o
    STANDARD GL ENGINE, OPTIONAL G,GSI
    OPTIONAL
    CUSTOM LEAN BURN CONTROL® (CLBC)
    •
    •
    94
    85
    Black
    White/Clear
    OXYGEN SENSOR
    • CUSTOM CATALYST CONTRO~® (CCCI • 86 Drain RIGHT BANK
    CUSTOM AIRIFUEL CONTROL (CAFC • 87 Black

    FORM 6248 First Edition 6.05 - 5


    ENGINE PROTECTION SYSTEMS

    THERMOCOUPLE JUNCTION BOX MANUAL SHUTDOWN SWITCHES


    )
    The thermocouple junction box (see Figure 6.05-9) is Two manual shutdown switches are located on left and
    located at the front right of the engine. The function of the right sides olthe engine (see Figure 6.05-10). Depress-
    thermocouple junction box is to serve as the main junction ing the manual shutdown switch will stop the engine by
    point for the wiring of engine profection shutdowns. de-energizing the ignition and electrical fuel supply
    solenoid valves. To restart the engine after depressing
    the shutdown switch, simply pull the depressed shut-
    down switch back out to its original position. The manual
    shutdown switches are wired to the main junction box.

    Figure 6.05-10. Manual Shutdown Switch - Left Side

    CUSTOMER SUPPLIED CONTROL SWITCHES )


    Control switches must be supplied by the customer.
    Control switches must include, but are not limited to; low
    oil pressure, high coolant temperature, high lube oil
    Figure 6.05-9. Thermocouple Junction Box temperature, high intake manifold air temperature, and
    an overspeed switch. Switches should be wired to an
    NOTE: The customer supplied control switches must be alarm to warn of high temperatures and low pressure as
    incorporated into the remote engine control panel logic. well as provide for automatic engine shutdown if
    potentially harmful temperatures, pressure, or over-
    speed conditions exist.
    PRESSURE AND TEMPERATURE SWITCHES
    CALIBRATION
    Calibrating and testing pressure and temperature
    switches should be performed by qualified service
    technicians every 90 days.

    6.05 - 6 FORM 6248 First Edition


    ENGINE PROTECTION SYSTEMS

    ALARM AND SHUTDOWN SETPOINTS CAUTION I


    I.=A=.."..::..:.....:..,::.....:..,:,,~~.
    Alarm and shutdown val-
    By using controls which simultaneously shut off the fuel L.. . ues are based on dry
    natural gas (900 BTU/cu. ft. SLHV). Refer to Gas-
    supply and ignition system upon reaching a "shutdown
    eous Fuel Specification Sheet S7884C and Lube Oil
    value", the potential for engine damage is reduced. See
    Recommendations Sheet S1015Y or latest revi-
    Table 6.05-1. sions fortypical changes in operation temperatures
    for jacket water and lube 011 when running on
    landfill or digester gas fuels. Disregarding this
    information could result in product damage and/or
    personal injury.
    Table 6 05-1 Alarm And Shutdown Setpolnts
    Stsndard Cooling System:
    Normal: 1800 F (820 C) for continuos rating
    200° F (93° C) for intermittent rating
    Alarm: 10° F (5.5° C) above nOrmal!desl~n temperature
    Shutdown: 20° F (11 0 C) above normal! esign temperature
    Elevated Tempereture Solid Water Cooling System:
    Jacket Water Outlet Temperature: Normal: 210 - 235° F (82 - 1130 C) solid water
    Alarm: 5° F (3° C) above normal/design temperature'
    Shutdown: 10° F (5.50 C) above normal! design operating temperature
    Ebullient Coaling System
    Normal: 212 - 2500 F (100 - 121 0 C)
    Alarm: See Note 2 below
    Shutdown: See Note 2 below
    Normal: 1800 F (82° C)
    Lube Oil Header Temperature: Alarm: 195° F (91 ° C)
    Shutdown: 2050 F (96° C)
    Normal: 40 - 55 psi (275 - 380 kPa)
    Lube Oil Header Pressure: Alarm: 30 psi (207 kPa)
    Shutdown: 20 psi (138 kPa)
    Normal: Up to 10 0 F (5.5° C) above design intercooler water inlet temperature
    Intake Manifold Temperature Alarm: 15° F (80 C) above design intercooler water inlet temperature
    (GSI And GL Engines): Shutdown: 200 F (11 0 C) above design intercooler water inlet temperature
    Intake Manifold Pressure: Contact Waukesha Engine Application Engineering Department
    Main Bearing Temperature: Shutdown: 250° F (121° C)
    Overspeed: Shutdown: 10% over governed speed
    NOTE: 1 Waukesha Power Systems Code 1105, 11asA, or equivalent shutdown system is recommended when jacket water temperature
    exceeds 210 0 F (W C).
    2 Waukesha Power Systems Code 1106, 1106A, or equivalent shutdown system is recommended for ebulliently cooled engines.

    FORM 6248 First Ed~ion 6.05-7


    ENGINE PROTECTION SYSTEMS

    ENGINE GAUGE PANEL COMPONENTS • Water Temperature SWitchgage


    (SHIPPED LOOSE) )
    • Digital Tachometer
    The optional engine mounted gauge panel (see
    Figure 6.05-11) has the following gauges mounted on it. • Intake Manifold Temperature SWitchgages
    (L.H. and R.H.)
    • Oil Temperature Gauge
    • Intake Manifold Pressure Gauge
    • Oil Pressure Switchgage

    INTAKE MANIFOLD HIGH WATER LOW OIL

    d
    VACUUM PRESSURE DIGITAL TEMPERATURE PRESSURE
    (LH, RH, OFF) GAUGE TACHOMETER SWITCHGAGE SWlTCHGAGE

    b,--=----\:::::==::::---f
    0+
    +\+
    +0
    + +~-+-+-t
    0+ +0 +
    HIGH INTAKE MANIFOLD HIGH INTAKE MANIFOLD LUBE OIL (INLET)
    TEMPERATURE SWITCHGAGE TEMPERATURE SWITCHGAGE TEMPERATURE
    (LEFT BANK) (RIGHT BANK) GAUGE

    Figure 6.05-11. Instrument Panel Gauge Placement


    )

    6.05- 8 FORM 6248 First Edition


    ENGINE PROTECTION SYSTEMS

    REMOTE PANEL COMPONENTS The following guidelines must be followed during


    The optional remote mounted gauge panel is shipped installation of the remote instrument panel.
    loose and requires 24VDC power (see Figure 6.05-t 2 • The instrument panel should not be mounted more
    and Figure 6.05-13). The remote mounted gauge panel is than 25 ft. (7.62 m) from the engine.
    equipped with an annunciator that provides display codes
    (see Table 6.05-2) to alert the operator to the status of the • To insure accurate temperature readings, the wires
    engine. Refer to Figure 6.05-20 and Figure 6.05-21 for used to connect the panel to the engine mounted
    schematic details of the remote panel. The remote panel thermocouple blocks must be "K" type thermocouple
    has the following gauges mounted on it. wire.

    • Engine Oil Pressure Gauge • Tubing used to connect the panel to the engine
    mounted pressure block should be 0.250 0.0.
    • Intake Manifold Gauge stainless steel tubing.
    • Tachometer/Hourmeter • Tubing connections to the instrument panel are to be
    • Engine Oil/Water Temperature made from the pressure block located on the right
    side of the engine.
    • Left Bank Exhaust Temperatures

    • Right Bank Exhaust Temperatures

    • Intake Manifold Temperature

    LB ~ RBI
    INTAKE MANIFOLD

    ANNUNCIATOR
    Figure 6.05-13. Optional Remote Instrument Panel

    Figure 6.05-12. Remote Mounted Panel

    Table 6.05-2. Remote Instrument Panel Annunciator Legend


    DISPLAY LOCKED OUT BY TIMER POINTS NOT LOCKED OUT BY TIMER
    10/40 Shutdown Functions 10 20 High Turbo Inlet Temperature #1 30
    00 Reset Ready To Start 11 Low Engine Oil Pressure 21 High Turbo Inlet Temperature #2 31
    80 Battery Ok 12 High Engine Oil Temperature 22 32
    00 Running Timer Active 13 High Engine Water Temperature 23 40 Overspeed
    01 Normal Run 14 Intake Manifold Temperature 24
    )
    89 Power Ok 15 25
    09 Test 16 26
    60 Stop 17 27

    .. 6.05- 9
    FORM 6248 FIrst EdItIon
    ENGINE PROTECTION SYSTEMS

    CUSTOM ENGINE CONTROL®


    DETONATION SENSING MODULE )
    SYSTEM
    Detonation is the autoignition of end gas that has not
    been consumed in normal flame-front reaction in a
    combustion chamber. When this happens in a combus-
    tion chamber of an engine, two pressure waves, created
    by the two flame-fronts, slam against the cylinder walls
    and cause an audible "ping" or "knock" known as
    detonation. Avoiding detonation conditions is critical
    since detonation is normally detrimental to engine
    components.
    To prevent detonation from occurring, Waukesha En-
    gine has developed an electronic Custom Engine
    Control® Detonation Sensing Module (DSM) system
    that is standard equipment on selected engine models
    (see Figure 6.05-14). The DSM protects Waukesha
    spark ignited gas engines from damage due to detona- Figure 6.05-14. CEC Detonation Sensing Module
    tion on an individual cylinder basis. The DSM, and its
    related system, must function with a CEC Ignition
    module with a 14 pin DSM expansion port (see
    Figure 6.05-15). The DSM System also includes a
    Waukesha designed filter, a detonation sensor mounted
    at each engine cylinder, and a number of interconnect-
    ing cables and harnesses that may vary depending on
    the application.
    )

    Figure 6.05-15. Ignition Module With Expansion Port

    6.05 - 10 FORM 6248 First Edition


    ENGINE PROTECTION SYSTEMS

    DSM SYSTEM OPERATION "0" lead is ungrounded. However these two separate
    ranges of adjustment overlap by 15 crankshaft degrees.

    IA CAUTION IRef~r to DSM Custom


    L.~~-=:""::=":"::'::':"::.J. Engine Control® Detona-
    tion Sensing Module Installation, Operation And
    Thus a total span of 35 degrees is available. At speeds
    of 1200 rpm and below, the system is capable of
    adjusting the ignition timing to within three degrees of
    Maintenance, Form 6268 and contact your WED the position of the ignition timing disc reference. For
    distributor for complete instructions on engines example, if the ignition Timing Disc Reference is at 30
    equipped with DSM. Disregarding this information degrees before top dead center (BTDC), the DSM
    could result in product damage and/or personal system is capable of adjusting ignition timing up to
    injury. approximately 27 degrees BTDC.
    During normal operation, the DSM will advance spark
    The DSM. in conjunction with the Ignition Module,
    timing to the programmed most advanced timing set
    monitors individual cylinder output by means of detona·
    point. In the event that the DSM system senses
    tion sensors mounted on the crankcase at each of the
    detonation, the ignition timing will be retarded at a
    cylinders. (see Figure 6.05·16). The output of each
    programmalble rate until either the signal from the sensor
    individual sensor is routed through a Waukesha de·
    falls below the "detonation threshold" or a most retarded
    signed electronic filter. This filter removes the signal
    timing poSition is reached. Should detonation continue
    frequencies that are not associated with detonation.
    once the most retarded timing is reached, the DSM
    When the filtered signal exceeds a predetermined limit
    system provides an output that can be used to shut the
    (detonation threshold). the DSM system, in conjunction
    engine down or activate other warning devices. As soon
    with the Ignition Module, retards the ignition timing for
    as conditions permit, the DSM system will advance spark
    the cylinder associated with that sensor.
    timing at a programmable rate to the original set point.
    The wiring schematic in Figure 6.05-17 illustrates the
    electronic route of the DSM and Ignition Module.

    A WARNING
    For maximum engine protection, the DSM system
    must be connected to a safety shutdown. The DSM
    system Is considered a safety system and, as such,
    must be connected to shutdown the engine if the
    engine cannot be brought out of detonation. Disre-
    garding this information could result In severe
    personal injury or death.

    NOTE: The most advanced timing and most retarded


    timing are programmed using a personal computer and
    Figure 6.05-16. Detonation Sensor
    DSM software at initial installation. These timings can
    only be reprogrammed by a Waukesha Engine qualified
    The sensors are calibrated through a DSM computer
    technician.
    program at initial installation. This calibration is referred to
    as the AutoCaI routine. The AutoCal routine can only be DEFAULT TIMING VALUE
    performed by a Waukesha Engine qualified technician.
    The DSM system also has a predetermined default

    IA CAUTION I After doing any


    =~-=:""::="':"'::":::':"::..J. replacement of engine
    L.
    repai~ or
    timing value which is used during engine warm-up
    periods. During engine warm-up, the DSM system is
    disabled and is not protecting the engine. The purpose
    cylinder heads, cylinder liners, pistons, or knock
    of this delay is to prevent misleading vibration signals
    sensors, the DSM must be AutoCaled. Contact your
    from being incorrectly sensed as detonation by the DSM
    local Waukesha Engine Distributor for assistance.
    system.
    Disregarding this information could result in prod-
    uct damage and/or personal injury. Default timing is 2 degrees less than nameplate timing.
    When a sensor fails, or when a sensor's automatic
    The DSM, in conjunction with the Ignition Module, is control timing is disabled, default timing is used.
    ) capable of varying engine timing a total of 35 crankshaft
    degrees. Twenty-five degrees of authority is available
    when the "0" lead of the ignition is grounded, and
    another 25 degrees of authority is available when the

    FORM 6248 First Ed~ion 6.05 -11


    ENGINE PROTECTION SYSTEMS

    )
    IGNITION
    PRIMARY

    CEC IGNITION
    DSM MODULE 14PIN
    MODULE ENGINE MOUNTED CONNECTION

    ON OR OFF
    ENGINE
    MOUNTED

    FILTER

    ON OR OFF
    ENGINE
    THROUGH MOUNTED
    )
    ABC

    GROUND MUST
    RUN TO ENGINE
    CRANKCASE
    _SEINSCIR HARNESS

    DETONATION SENSORS 1 PER CYLINDER

    Figure 6.05-17. Detonation Sensing Module System Wiring Schematic

    6.05 - 12 FORM 6248 First Edition


    ENGINE PROTECTION SYSTEMS

    USER INTERFACE
    The DSM system is equipped with several features to
    inform site personnel of system status. These features
    include:
    • "Power", "Alarm", and "Shutdown" lights (LED dis-
    play) on the front panel of the DSM module (see
    Figure 6.05-18)

    • a liquid crystal display (LCD) located inside the DSM


    module which continually shows the current status of
    the system through diagnostic codes (see
    Figure 6.05-19)

    • the capability to drive remote alarms or lights


    For example, the DSM system can detect Ha sensor has
    been damaged or disconnected. In eilher event, the defautt
    timing value is imposed for the cylinder associated with the
    lost signal. In addition to imposing the defautt timing, the
    DSM system will also illuminate the yellow alarm LED on
    the front cover, provide a signal for a remote alarm, and will
    display the error code on the LCD within the DSM module. Figure 6_05-18_ Detonation Sensing Module Front
    Panel

    INSIDE THE DSM MODULE

    -
    ~

    ~,.

    ~oo
    ~,

    ~,

    ""
    []
    -
    in
    ~_oo

    ~,~
    ~-~ ,~
    ~_oo
    ~_oo

    SENSOR07
    "=
    ,~

    ..
    ~_oo
    .,~

    I-
    ~~
    SENSOA09 ~
    SENSOR 10
    6ENSOR1t
    ~"
    CATAS
    SENSOR 12 IlATA2
    SENSOR 13 DATAl
    SENSOR 14 OATAO
    SENSOR1~
    SENSORIa -~,
    '--

    o o
    Figure 6.05-19. Detonation Sensing Module
    LCD Display

    >

    FORM 6248 First Edition 6.05 -13


    ENGINE PROTECTION SYSTEMS

    DSM SYSTEM TROUBLESHOOTING A CAUTION


    I==-..=.:.....:=....:...;=;.:..:..J.
    I After doing any repair or
    replacement of engine )
    This section is provided to determine diagnostic codes L.

    of the DSM system, as well as, possible corrective cylinder heads, cylinder liners, or pistons, or knock
    actions that may remedy diagnostic problems. sensors, the DSM must be re-AutoCaled. Contact
    your local Waukesha Engine distributor for assis-

    CAUTION I~roubleshooting
    tance. Disregarding this Information could result In
    I~-A.=~=..:..::.....:;.:..;:;...;~.
    L.. .
    the
    DSM system can include
    some disassembly of electronic equipment, wiring
    product damage and/or personal Injury.

    modification, programming, and other work of


    similar nature. Only "qualified technicians" should
    undertake these activities. Improper handling of
    electronic components can cause damage making
    the components unusable. Disregarding this in-
    formation could result in product damage and/or
    personal injury.

    If only the "Power" (green) LED is lit on the front panel of


    the DSM module, the engine is running free of any
    problems. The LCD display inside the DSM module will
    show the diagnostic code 91 .
    If the "Alarm" (yellow) or "Shutdown" (red) LED is lit on the
    front panel of the DSM module, the DSM system is sensing
    detonation in the engine or an improperly working sensor.
    Refer to the LCD display inside the DSM module for the
    diagnostic code (see Figure 6.05-19). Table 6.05-3 pro-
    vides a description of the condition based on the diagnostic
    code the DSM system is sensing. Table 6.05-4 provides )
    troubleshooting suggestions to remedy the situation.

    IL.
    A. CAUTION Ilf a DSM sensor is re-
    • .
    .=='-:...;;.....;;..;;....;;;.....-'--1.
    . moved, do not mishan-
    dle or drop the sensor. Improper handling of the
    sensor could result in permanent damage to the
    sensor crystal.

    NOTE: To install a sensor, the sensor must be free of oil


    and torqued to a value of 20 - 25 ft-/b (27 - 34 N·m). The
    mounting surface for the sensor must be smooth
    (RMS125) and flat

    A. CAUTION I Drilled and tapped hole


    IL.
    • .
    .=='-'--......:'--_-'--1.
    . (sensor surface) must be
    flat, smooth (RMS 125), and be perpendicular to the
    drilled hole. A knock sensor that Is not mounted
    flush with the surface or If the surface is not within
    RMS 125, WILL provide incorrect Signals to the DSM
    system. Disregarding this information could result
    in product damage and/or personal injury.

    6.05 -14 FORM 6248 First Edition


    ENGINE PROTECTION SYSTEMS

    Table 6 05-3 DSM Module LCD Message Display Diagnostic Codes


    LCD LED IGNITION TIMING
    DESCRIPTION OF CONDITIONS
    READ-OUT STATUS IN USE
    - - -- No Power: System Not Operating CEC Ign~ion Switch Timing
    - GYR No Program: System Has Power But Is Not Executing Gode CEC Ign~ion Switch Timing
    00 GY- No Rotation: Engine Stopped Running (Not Due to Shutdown Mode) CEC Ign~ion Switch Timing
    01 GY- Sensor #1: Failed Diagnostic Test Cylinder Defeutt Timing
    02 GY- Sensor #2: Failed Diagnostic Test Cylinder Defautt Timing
    03 GY- Sensor #3: Failed Diagnostic Test Cylinder Defautt Timing
    04 GY- Sensor #4: Failed Diagnostic Test Cylinder Defeutt Timing
    05 GY- Sensor #5: Failed Diagnostic Test Cylinder Defeutt Timing
    06 GY - Sensor #6: Failed Diagnostic Test Cylinder Defeutt Timing
    07 GY- Sensor #7: Failed Diagnostic Test Cylinder Defautt Timing
    06 GY- Sensor #6: Failed Diagnostic Test Cylinder Defautt Timing
    09 GY - Sensor #9: Failed Diagnostic Test Cylinder Defautt Timing
    10 GY- Sensor #10: Failed Diagnostic Test Cylinder Defautt Timing
    11 GY- Sensor #11: Failed Diagnostic Test Cylinder Defautt Timing
    12 GY- Sensor #12: Failed Diagnostic Test Cylinder Defeult Timing
    21 GY - Sensor #1: Uncontrolled Detonation Cylinder Maximum Retard
    22 GY - Sensor #2: Uncontrolled Detonation Cylinder Maximum Retard
    23 GY - Sensor #3: Uncontrolled Detonation Cylinder Maximum Retard
    24 GY - Sensor #4: Uncontrolled Detonation Cylinder Maximum Retard
    25 GY - Sensor #5: Uncontrolled Detonation Cylinder Maximum Retard
    ) 26 GY - Sensor #6: Uncontrolled Detonation Cylinder Maximum Retard
    27 GY - Sensor #7: Uncontrolled Detonation Cylinder Maximum Retard
    28 GY- Sensor #8: Uncontrolled Detonation Cylinder Maximum Retard
    29 GY- Sensor #9: Uncontrolled Detonation Cylinder Maximum Retard
    30 GY- Sensor #10: Uncontrolled Detonation Cylinder Maximum Retard
    31 GY- Sensor #11: Uncontrolled Detonation Cylinder Maximum Retard
    32 GY- Sensor #12: Uncontrolled Detonation Cylinder Maximum Retard
    41 G -- Sensor #1: Automatic Timing Control Disabled Cylinder Default Timing
    42 G -- Sensor #2: Automatic Timing Control Disabled Cylinder Default Timing
    43 G -- Sensor #3: Automatic Timing Control Disabled Cylinder Default Timing
    44 G -- Sensor #4: Automatic Timing Control Disabled Cylinder Defeult Timing
    45 G -- Sensor #5: Automatic liming Control Disabled Cylinder Default Timing
    46 G -- Sensor #6: Automatic liming Control Disabled Cylinder Defau~ Timing
    47 G -- Sensor #7: Automatic liming Control Disabled Cylinder Dafautt Timing
    48 G -- Sensor #8: Automatic liming Control Disabled Cylinder Dafeutt Timing
    49 G -- Sensor #9: Automatic liming Control Disabled Cylinder Defeutt Timing
    50 G -- Sensor #10: Automatic liming Control Disabled Cylinder Defautt Timing
    51 G -- Sensor #11: Automatic Timing Control Disabled Cylinder Defautt Timing
    52 G -- Sensor #12: Automatic Timing Control Disabled Cytinder Default Timing
    66 GY- Sample Error: Configuration Data or Application Problem Cylinder Default Timing
    75 GyR Shutdown: Uncontrolled Detonation Present Shutdown Activated Timing Control
    75 GY- Shutdown: Engine Has Stopped Running Due to Datonation/Shutdown Cylinder Default Timing
    ) 81 GY- System Error: Some Cylinders Are OK-Wait for Sensor Error Code liming Control
    86 G -- Autocal: Executing AutoCai Routine AutoCal Timing
    (Continued)

    FORM 6246 First Edition 6.05 - 15


    ENGINE PROTECTION SYSTEMS

    LCD LED IGNITION TIMING


    READ-OUT STATUS DESCRIPTION OF CONDITIONS IN USE )
    90 G -- System OK: Ready and Waiting for Engine to Start Cylinder Default Timing
    91 G -- System OK: Normal Operation - Controlling Detonation Timing Control
    95 G -- System OK: Delaying Engine Warm-Up Cylinder Default TIming
    97 G-- Serial Mode: Communication Transfer Mode Last Active Timing
    30° Retard from TOR
    99 GY- No Data: Configuration Data Must Be Down Loaded
    (liming Disc Reference)
    NOTE: The diagnostic cedes given in the LCO READ-OUT column are shewn on the LCD display inside the DSM module.
    Letters in the LED STATUS column represent the LED lights on the DSM module front pane/that are Iff under the given condition:
    = = =
    G = Green/Power, Y Yellow/Alarm, y Yellow/Alarm Flashing, R Red/Shutdown

    Table 6.05-4. DSM Diagnostic Codes Troubleshooting


    IF DIAGNOSTIC CODE ON THEN
    LED DISPLAY READS
    Code 00 a. Engine is not running (not due to shutdown mode).
    a. Check wiring from sensor to DSM for damage. Repair/replace wiring as required.
    b. Check Spark plug for misfiring. Replace as required.
    Codes 1 - 12 c. Check admission valves in cylinder head for correct operation. Replace or clean as required.
    d. Replace sensor.
    e. Contact your Waukesha Engine Distributor for assistance.
    a. Shutdown engine.
    b. Determine if any "hot" or unprocessed gas has gone through engine that could cause detonation.
    Codes 21 - 32 c. Check gas/air supply. )
    d. Bore scope the cylinder to check for detonation.
    e. Contact your Waukesha Engine Distributor for assistance.
    a. Check to see if the program was disabled through the electronics,
    Codes 41-52
    b. Contact your Waukesha Engine Distributor for assistance.
    Code 91 a, Engine is running normally.
    Code 99 a. Contact your Waukesha Engine Distributor for assistance.
    All Other Codes a. Contact your Waukesha Engine Distributor for assistance.

    6.05 -16 FORM 6248 First Edition


    ENGINE PROTECTION SYSTEMS

    RIGHT BANK INTAKE MANIFOLD _ _ _~L:.:::;-;:::::::'",____ LEFT BANK INTAKE MANIFOLD


    TEMPERATURE TERMINAL BLOCK #19 (-) TEMPERATURE TERMINAL BLOCK #18 (-)

    RIGHT BANK INTAKE MANIFOLD ---+-----' L..-----,f----- LEFT BANK INTAKE MANIFOLD
    TEMPERATURE TERMINAL BLOCK #19 (+) TEMPERATURE TERMINAL BLOCK #18 (+)

    PYROMETER INTAKE MANIFOLD TEMPERATURES

    ENGINE LUBE OIL ENGINE WATER TEMPERATURE


    TEMPERATURE TERMINAL BLOCK #20 (-) TERMINAL BLOCK #17 (-)

    ENGINE LUBE O I L - - - - - - + - - - - - ' '------+------ ENGINE WATER TEMPERATURE


    TEMPERATURE TERMINAL BLOCK #20 (+) TERMINAL BLOCK #17 (+)

    PYROMETER ENGINE OILJWATER TEMPERATURES

    CYLiNDER#4
    CYLINDER #3 TERMI NAL BLOCK '10 (-)
    TERMINAL BLOCK #9 (-) CYLINDER.5
    CYLI NDERII2 TERMINAL BLOCK '11(-)
    TERMINAL BLOCK'8(-)
    CYLINDER #6
    CYLINDER #1 TERMI NAL BLOCK '12 (-)
    TERMINAL BLOCK #7 (-) 1
    URBOOUTLET
    1 o
    TURB INLET
    I TERMINAL BLOCK #16 (-)

    -~
    -.
    TERMINAL BLOCK #14 (-) OPEN
    I
    I OPEN
    I
    o
    TURB INLET
    TERMINAL BLOCK #14 (+) II URBOOUTLET
    TERMINAL BLOCK #16 (+)
    CYLINDER #1
    TERMINAL BLOCK '7 (+)
    II \[ II;!;!!- IU' CYLINDER #6
    TERM INAL BLOCK #12 (+)
    CYLI NDER CYLINDER.5
    TERMINAL BLOCK #9 (+)
    CYLINDER'3
    TERMINAL BLOCK #9 (+)
    IPYROMETER EXHAUST
    TEMPERATURES RIGHT BANK
    l TERMINAL BLOCK '11 (+)
    CYLINDER'4
    TERMINAL BLOCK '10 (+)

    CYLINDER #4
    CYLINDER #3 TERMINAL BLOCK #4 (-)
    TERMINAL BLOCK #3 (-) CYLINDER.5
    CYLINDERII2 TERMINAL BLOCK #5(-)
    TERMINAL BLOCK 112 (-)
    CYLINDER #6
    CYLINDER #1 TERMINAL BLOCK #6 (-)
    TERMINAL BLOCK '1 (-) 1
    I"'-.. ~~!lBOOUTLET
    o
    TURB INLET TERMINAL BLOCK #15 (-)
    TERMINALBLOCK.13 (-)
    'IA I~
    I_a
    I OPEN
    / .1 ••••• 7.
    1 I I 1-" OPEN
    I
    o
    TURB INLET II II ~~!'IBOOUTLET

    IU/
    TERMINAL BLOCK.13 (+) TERMiNAL BLOCK #15 (+)
    CYLiNDER'l
    TERMINAL BLOCK #1 (+)
    I I \j1l;!::;.!:E1 CYLINDER #6
    TER MINAL BLOCK #6 (+)
    CYLINDER CYLINDER.5
    TERMINAL BLOCK 112 (+)
    CYLINDER.3
    I PYROMETER EXHAUST
    I TERMINAL BLOCK #5 (+)
    CYLINDER #4
    TERMINAL BLOCK #3 (+) TERMINAL BLOCK.4 (+)
    TEMPERATURES LEFT BANK
    )
    Figure 6.05-20. Remote Instrument Panel Connections

    FORM 6248 First Edttion 6.05 -17


    ENGINE PROTECTION SYSTEMS

    ELECTRICAL DETAIL )

    12

    I •
    ,3
    WARNING '~ 4
    \
    .J.
    Sensors are normally
    switches which must be retumed
    open
    8
    ...r
    Ls
    5

    to ground potential to actuate an-


    nunciator•
    • WARNING
    Any power applied to sensor wires NOTE: Terminals are shown
    10 through 40 may destroy annun· away from instrument and
    ciator circuits. modlfiedforpurposes ofpanel
    wiring clarity only.

    GROUND FOR ENCLOSURE,


    PANEL INSERT, AND ALL
    INSmUMENTATION

    CUSTOMER WIRING

    BACK VIEW OF PANEL


    1T.13

    ~
    1T.10
    INPUT.

    11

    i\iE."
    -=.
    ITEM
    & TERM.
    NO.
    READ
    OUT
    ANNUNCIATOR
    CHANNEL FUNCTION ! CLASS

    B
    40
    8 )

    14
    1T.5,SW2
    1'[6, SWI 14
    ~
    INTAKE I !TEMP,
    15 15 B
    16 B
    1T.10 1T.10
    17 ~
    'TEMP, #1
    -"- INPUT. INPUT.
    20 ! IT,7, SW. 20 ~
    21 ' IT,8, SW. 21 !, INLET TEMP, 112 A
    22 22 A
    23 23 A IT.g

    25 ~ ~
    2S 26 ~
    _27 27 A
    30 30 A

    "
    40 II4,S
    31
    32
    A
    A
    ~
    1T.10
    INPUT. 0 IT.II

    IGNmON POWER
    (TACHOMETER SIGNAL
    1~sl
    ~
    c=J 1T.12 II II
    BULKHEAD FmlNGS TO GAUGES

    AUX. CONTACTS ENGINE GROUND TO SENSORS


    (IF USED) & THERMOCOUPLES
    .24 VDC POWER

    Figure 6.05·21. Remote Instrument Panel Connections

    6.05 -18 FORM 6248 First Ed~ion


    SECTION 6.10 - MISCELLANEOUS EQUIPMENT

    MISCELLANEOUS EQUIPMENT The following miscellaneous equipment may be


    installed on the engine:
    COMPONENTS
    • Surge Tank

    • Jacket Water Heater

    FILLER CAP

    -i!
    ~-J
    ~
    I "-. FILLER NECK
    ¢t
    HOS~ n ifilf" /
    OVERFLOW PLUG (INITIAL FILL)

    UF11NG EYE

    U i ~

    )
    I

    ••
    \
    •
    /'
    SIGHT GAUGE

    I ~I
    y/ I
    I /~I
    1../ I

    )
    Figure 6.10-1. Surge Tank Assembly

    FORM 6248 Rrst Edition 6.10 -1


    MISCELLANEOUS EQUIPMENT

    SURGE TANK 7. Remove capscrew, lock washer and the overflow


    line support bracket from the front flange of the water
    SURGE TANK REMOVAL connection pipe (see Figure 6.10-3).

    A WARNING
    Always wear protective clothing when draining the
    cooling system on a heated engine. Slowly loosen
    the air bleed petcock to relieve any excess pres-
    sure. Do not remove the filler cap on the surge tank
    until pressure is released. Escaping steam and/or
    hot water can result In severe personal injury or
    death.

    1. Refer to Cooling Systems, and drain the cooling


    system and surge tank.

    2. Remove two lock nuts, spacer nuts, capscrews, and


    connecting bracket from the brackets on the water
    connection pipe (see Figure 6.10-1 and Figure 6.10-2). Figure 6.10-3. Overnow Line Support Bracket

    8. Remove the remaining five capscrews, lock wash-


    ers, water connection pipe from the surge tank (see
    Figure 6.10-1 and Figure 6.10-2).

    9. Remove the square and round gaskets from the


    ends of the water connection pipe.
    )
    A WARNING
    The surge tank weighs approximately 400 Ibs.
    (181 kg). Use a suitable lifting device and exercise
    caution during removal or Installation to avoid
    severe personal injury or death.
    Figure 6.10-2. Water Connection Pipe
    10. Attach a suitable lifting device to the surge tank.

    3. Remove two socket head capscrews, lock washers, 11. Remove eight nuts, washers, lock washers, caps-
    and the rear bracket from the water connection pipe. crews, and washers from the support brackets and
    surge tank mounting flanges.
    4. Remove two capscrews, lock washers, and the front
    bracket from the water connection pipe, 12. Using a suitable lifting device, remove the surge
    tank from the support brackets.
    5. Remove the two lower capscrews and lock washers
    from the lower two holes in the rear flange of the water
    connection pipe.

    6. Remove nut, lock washer, support clip, and caps-


    crew from the lower overflow line.

    6.10 - 2 FORM 6248 First Edition


    MISCELLANEOUS EQUIPMENT

    SURGE TANK DISASSEMBLY s. Remove pipe adapter from the bottom of the surge
    tank (see Figure 6.10-S).
    1. Remove the drain cock from the surge tank (see
    Figure 6.10-1).

    2. Remove the filler cap from the filler neck (see


    Figure 6.10-4).

    Figure 6.10-5. Pipe Adapter

    6. Remove the sight gauge from the surge tank (see


    Figure 6.10-6).

    Figure 6.1~. Filler Cap And Plug

    3. Remove four capscrews, lock washers, filler neck,


    and gasket from the surge tank.

    4. Remove upper plug from the surge tank.

    I Figure 6.10-6. Sight Gauge


    I

    FORM 6248 First Edttion 6-10 - 3


    MISCELLANEOUS EQUIPMENT

    SURGE TANK CLEANING AND INSPECTION SURGE TANK INSTALLATION

    1. Inspect the surge tank for developing cracks around 1. Attach a suitable lifting device to the surge tank.
    hose fittings, pipe couplings, mounting brackets and
    corners.

    NOTE: Usually it is not advisable to repair that is


    A WARNING
    The surge tank weighs approximately 400 Ibs.
    extensively rusted. It is better to replace an extensively (181 kg). Use a suitable lifting device and exercise
    rusted tank.
    caution during removal or Installation to avoid
    2. Inspect the tank for internal rusting that has affected severe personal Injury or death.
    the sides, top or bottom. this may be detected by paint
    that appears to be lifting off. 2. Using a suitable lifting device, install the surge tank
    on the support brackets.
    3. Flush the tank to remove any accumulated sedi-
    ment. Probe the tank through the openings to dislodge 3. Install the surge tank on the support brackets with
    material that was not removed from back washing. eight washers, capscrews, washers, lock washers and
    nuts (see Figure 6.10-1 and Figure 6.10-2).
    4. Repair any fittings that indicate leakage, such as
    plug, sight gauge and drain cock. Seal fittings with 4. Apply Permatex® Aviation Form-A-Gasket Sealant
    Perma Lok® Heavy Duty Pipe Sealant with Teflon®. Use to the gasket surfaces and install the gaskets on the
    Permatex® Aviation Form-A-Gasket Sealant to seal square and round gaskets from the ends of the water
    the filler neck gasket. connection pipe.

    5. Inspect the pressure relief filler cap. Be certain the 5. Install the water connection pipe on the cluster
    cap is properly sealing against its filler neck. Make thermostat with the two lower capscrews and lock
    certain that the pressure cap spring is pressurizing the washers.
    the cooling system correctly. This value is related to
    6. Install rear bracket on the water connection pipe with
    operating elevation. Be certain the correct cap is used. A two socket head capscrews and lock washers. )
    radiator pressure tester may be used to to determine cap
    requirements. The tester will also check the cap seal. 7. Connectthe front flange ofthe water connection pipe
    to the surge tank with the lower five capscrews and lock
    6. Inspect the overflow hose. Replace the hose if it washers.
    shows signs of cracking.
    8. Install the overflow line support bracket on the front
    7. Inspect the bleed hole. The bleed hole must not be
    flange of the water connection pipe with capscrew and
    plugged or obstructed in any way. lock washer (see Figure 6.10-3).
    SURGE TANK ASSEMBLY
    9. Install the lower overflow line on the support bracket
    1. Apply Perma Lok® Heavy Duty Pipe Sealant with with nut, lock washer, support clip, and capscrew (see
    Teflon® to threads, and install the drain cock on the Figure 6.10-1 and Figure 6.10-2)
    surge tank (see Figure 6.10-1).
    10. Install the front bracket on the water connection
    2. Apply PermateX® Aviation Form-A-Gasket Sealant pipe with two capscrews and lock washers.
    to filler neck gasket (see Figure 6.10-4).
    NOTE: AfterperformingSteps11 and 12, the connect-
    3. Install the filler neck gasket and filler neck on the ing bracket should be able to be moved by hand. This
    surge tank with four lock washers and capscrews. will allow for expansion during operation.

    4. Apply Perma Lok® Heavy Duty Pipe Sealant with 11. Install the connecting bracket on the front bracket
    Teflon® to threads, and install upper plug on the surge with lock nut, spacer nut and capscrew. Tighten the
    tank. spacer nut and locknut against the connecting bracket,
    leaving 0.031 in. (0.787 mm) space under the head of
    5. Apply Perma Lok® Heavy Duty Pipe Sealant with the capscrew. Check the distance by inserting a feeler
    Teflon® to threads, and install the pipe adapter on the gauge under the head of the capscrew.
    bottom of the surge tank (see Figure 6.10-5).
    12. Install the conl)ecting bracket on the rear bracket
    6. Apply Perma Lok® Heavy Duty Pipe Sealant with with lock nut, spacer nut and capscrew. Tighten the
    Teflon® to threads, and install the sight gauge on the spacer nut and locknut against the rear bracket, leaving
    surge tank (see Figure 6.10-6). 0.031 in. (0.787 mm) space between the top of the

    6.10 - 4 FORM 6248 First Edition


    MISCELLANEOUS EQUIPMENT

    spacer nut and the bottom surface of the connecting 1. Disconnect the power supply to the jacket water
    bracket. Check the distance by inserting a feeler gauge heater and thermostat.
    between the top of the spacer nut and the bottom
    surface of the connecting bracket.
    A WARNING
    13. Refer to Cooling Systems, and fill the cooling Always wear protective clothing when draining the
    system and surge tank. cooling system on a heated engine. Slowly loosen
    the air bleed petcock to relieve any excess pres-
    JACKET WATER HEATER
    sure. Do not remove the filler cap on the surge tank
    JACKET WATER HEATER REMOVAL until pressure is released. Escaping steam and/or
    hot water can result in In severe personal injury or
    The optional thermostatically controlled jacket water
    death.
    heater improves starting in cold temperatures and
    warms the jacket water for standby applications.
    2. Refer to Cooling System and drain the cooling
    system.
    A WARNING
    3. Loosen the hex fittings and disconnect the inlet and
    Do not install, set up, maintain or operate any oullet tubes from the jacket water heater (see
    electrical components unless you are a technically Figure 6.10-7 and Figure 6.10-8).
    qualified Individual who is familiar with the electri-
    cal components Involved. Electrical shock can NOTE: Left and right side jacket water heaters are
    cause severe personal injury or death. removed in a similar fashion.

    4. Remove four nuts, lock washers, spacers brackets


    A WARNING and the jacket water heater from the mounting bracket.
    Disconnect all electrical power supplies before
    making any connections or servicing any part ofthe
    electrical system, Electrical shock can cause se-
    vere personal injury or death.

    )
    REAR VIEW RIGHT SIDE
    Figure 6.10-7. Jacket Water Heater - Right Side

    FORM 6248 First Edttion 6.10 - 5


    MISCELLANEOUS EQUIPMENT

    hrnJHI~ )

    ~
    lot?::: ~
    -::::::::;:::::

    o
    o
    BRACKETS~
    INSERT PROBE INTO THE
    ~~~
    FIRST PIPE TAP BEHIND THE
    LEFT SIDE I THERMOSTAT HOUSING

    MOUNT TEMPERATURE REAR VIEW


    CONTROL ON LEFT BANK
    INTAKE MANIFOLD ON
    THE 2ND AND 3RD PAD
    FROM FRONT OF ENGINE
    FRONT END AND LEFT SIDE
    VIEW OF ENGINE

    Figure 6.10-11. Jacket Water Heater - Left Side


    JACKET WATER HEATER CLEANING AND r------:A~W-A-R-N-IN-G---.....,
    INSPECTION
    Properly discharge any electrical component that )
    A WARNING has the ability to store electrical energy before
    connecting or servicing that component. Electrical
    Comply with the solvent manufacturers recommen-
    shock can cause severe personal injury or death.
    dations for proper use and handling of solvents.
    Improper handling or misuse could result In severe
    personal injury or death. Do not use gasoline, paint
    thinners or other highly volatile fluids for cleaning.
    A WARNING
    Disconnect all electrical power supplies before
    1. Wipe all metal parts with a clean shop cloth
    making any connections or servicing any part olthe
    dampened in an approved cleaning solvent.
    electrical system, Electrical shock can cause se-
    2. Inspect the jacket water heater for cracks, broken vere personal injury or death.
    wires, or other damage.
    1. Mount the jacket water heaters in a vertical position
    3. Inspect all wiring for cracked insulation, broken wires as shown (see Figure 6.10-7 and Figure 6.10-8).
    or damage. Replace if necessary. 2. Install the jacket water heater on the mounting bracket
    4. Inspect all threaded parts for stripped or damaged with four nuts, lock washers, spacers and brackets.
    threads. replace parts if damage is apparent. 3. Apply Perma Lok® Heavy Duty Pipe Sealant with
    Teflon® to threads, and connect the inlet and outlet
    5. Inspect tubes for cracks, kinks, breaks or wear. tubes on the jacket water heater.
    replace tubes if necessary.
    4. Connect the power supply to the jacket water heater
    JACKET WATER HEATER INSTALLATION and thermostat.

    A WARNING
    Do not install, set up, maintain or operate any )
    electrical components unless you are a technically
    qualified individual who Is familiar with the electri-
    cal components involved. Electrical shock can
    cause severe personal injury or death.
    6.10 - 6 FORM 6248 First Edition
    CHAPTER 7 - TROUBLESHOOTING AND MAINTENANCE

    CONTENTS

    SECTION 7.00 - TROUBLESHOOTING

    SECTION 7.10 - MAINTENANCE AND STORAGE

    FOAM 6248 First Edition


    )

    FORM 6248 First Edition


    SECTION 7.00 - TROUBLESHOOTING

    TROUBLESHOOTING current readings from the engine instrument panel can


    be combined with this information to provide a frame-
    The following table is provided to assist the user in
    work for resolving actual or potential problems.
    determining the possible causes of unsatisfactory
    engine operation, as well as point out the corrective NOTE: This chart is only provided as a service to our
    action that may be undertaken to remedy the problem. customers. It should not be viewed as a reflection of
    Knowledge of how the engine operates along with the Waukesha Engine's actual experience with this product.
    Table 7 00-1 Troubleshooting Table
    SYMPTOM PROBABLE CAUSE REMEDY
    Engine crankshaft cannot be barred Load not disengaged from engine. Disengage load.
    over.
    IA CAUTION I Do not attempt to Coolant or obstruction in cylinder: NOTE: Remove spark plugs to vent cylinders of
    accumulated coolant.
    rotate crankshaft
    with starter.
    a. Cracked exhaust manifold. a. Replace.
    b. Cracked head. b. Replace.
    c. Cracked sleeve. c. Replace.
    Seized piston. Determine cause of seizure: insuffiCient
    lubrication, inadequate cooling, overload, etc.
    Replace piston assembly and sleeve, as
    required.
    Main bearings too tight:
    a. Main bearing caps installed out of loca- a. Check each bearing cap; place in proper
    tion. location,
    b. Improper bolt torque. b. Adjust bearing caps. Torque to specifica-
    tions.
    c. High spots on bearings. c. Replace.
    )
    Engine will crank but will not start. On-oft switch in OFF position or defective ~f Place switch in the ON position or replace if
    (50 F minimum ambient Tempera- used). defective.
    ture)
    Fuel throttle or manual shut -off control in OFF Place fuel throttle or manuat shut-off control in
    position. ON pOSition.
    Insufficient cranking speed:
    a. Low starting air/gas pressure. a. Build up air/gas pressure. 100 - 125 rpm
    required to start engine.
    b. Lube oil temperature too low or viscosity b. Change lube oil or raise the oil tempera-
    too high. ture.
    Fuel system Inoperative:
    a. Insufficient fuel supply or fuel pressure. a. Check gas pressure.
    b. Fuel system settings incorrect. b. Reset regulators.
    c. Stiff carburetor diaphragm. c. Replace diaphragm.
    d. Worn carburetor mixing valve assembly. d. Replace assembly.
    e. Ruptured line pressure regulator dia- e. Replace diaphragm.
    phragm.
    I. Bent pressure regulator control rod. f. Replace control rod.
    g. Prechamber regulator valve stuck open. g. Replace or repair regulator valve.
    h. Main gas valve stuck closed. h Replace or repair main gas valve.
    Faulty ignition system:
    a. Low or no output from ignition module. a. Replace ignition module as required.

    v
    b. Hall-effect Pickup not p::f.ert gapped,
    disconneded, or damag .
    b. ChS?~ap, reconned, or replace as
    requlr .
    c. Incorrect ignition timing. c. Reset the timing.
    )
    d. Broken or damaged wiring. d. Repair or replace.
    e. Magneto drive assembly broken. e. Replace drive.
    f. Spark plug(s) not firing. I. Check gap/replace as required.

    FORM 6248 First Ed~lon 7.00 - 1


    TROUBLESHOOTING

    SYMPTOM PROBABLE CAUSE REMEDY


    )
    Engine will crank but will not start Insufficient or no air intake: NOTE: Bar the engine over by hand to verify that
    (cont'd). cylinders are clear. Inspect the intake manito/dfor
    accumulations of lube oil.
    a. Clogged intake air filters. a. Remove and clean,
    b. Clogged/dirty intercooler (air side). b. Remove and clean.
    Governor inoperative:
    a. Insufficient oil:
    1. UG-8 low oil level. 1. Add oil.
    2. Gasket blocks off oil supply hole (affer 2. Re-position or replace gasket.
    repair).
    3. Water/sludge in oil passages. 3. Clean or replace governor.
    b. Binding control linkage:
    1. Linkage dirty. 1. Clean.
    2. Unkage broken. 2. Repair.
    3. Linkage pivot points tight. 3. Re-adjust or replace pivot point bear-
    ing surfaces.
    c. Electric governor actuator not opening. c. Check wiring and correct.
    d. Governor geometry incorrect. d. Correct as necessary.
    Poor compression:
    a. Worn rings. a. Replace.
    b. Leaking valves. b. Recondition seats and valves.
    c. Leaking head gaskets. c. Replace.
    Camshaft gear not in time with crankshaft gear. Set crankshaft at T.O.C. #1 RB. Align the
    camshaft, idler and crankshaft gear match
    marks.
    )
    Engine stops suddenly. Insufficient fuel supply. Check gas pressure.
    Low oil pressure causes engine protection Inspect lubricating oil system and components;
    control to shut down engine. correct cause.
    High coolant temperature causes engine Inspect cooling system and components; correct
    protection control to shut engine down. cause.
    Faulty ignition system. Repair or replace components as required.
    High intake manifold temperature. Correct cause.
    High lube oil temperature. Correct cause.
    Engine overspeed causes engine protection Determine and correct cause.
    control to shut down engine.
    Excessive load causes engine to stall. Determine and correct cause of overload.
    Insufficient intake air:
    a Clogged intake air filter(s). a. Remove and clean.
    b. Clogged intercooler (air side). b. Remove and clean.
    Obstructed exhaust manifold. Locate and remove obstruction.
    Piston seizure:
    B. Insufficient cooling. a. Replace scoredtMiston, sleeve and rings.
    Clean and/or II the cooling system,
    including the heat exchangers.
    b. Insufficient lubrication. b. Replace scored piston, sleeve and rin~s.
    Clean oil passages, and/or determine
    cause.
    c. Insufficient ring gap (ap~licable only im- c. Replace scored piston, sleeve and rings.
    mediately after overhau). Adlust ring gap.
    )
    Obstruction in cylinder. Replace parts.

    7.00 - 2 FORM 6248 First Ed~ion


    TROUBLESHOOTING

    SYMPTOM PROBABLE CAUSE REMEDY


    Engine stops suddenly (cont'd). Seizure of bearings main, connecting rod, piston Replace bearings - clean up or replace crank-
    pin or camshaft. shaft, camshaft or piston pins, as required.
    a. Lack of lubrication. a. Check lube oil system; correct cause.
    b. Dirt in lube oil. b. Check lube oil filters.
    Engine loses power. Insufficient fuel:
    a. Low gas pressure. a Check gas fuel system.
    b. Mlsadjustad wastegate(s) (altitude cem- b. Consult Waukesha factory representa-
    pensation). tive for correct setting.

    Air intake system maHunction:


    a. Dirty intake air filters. a. Remove and clean.
    b. Clogged Interceoler. b. Remove and clean.

    14 CAUTION 1Bartheenglneover by hand


    to verily that the cylinders
    are claar, Inspect the Intake
    manifold for accumulations
    of lube 011.

    Air leaks In intake system. Find and correct as required.


    Turbocharger malfunction or failure:
    a. Lack of lubrication. a. Determine cause; repair or replace turbo-
    charger.
    b. Foreign material. b. Repair or replace turbocharger.
    c. Excessive backpressure. c. Determine and correct cause.
    Engine misfiring:
    a. Incorrect main chamber and/or precham- a. Readjust.
    ) bar regulator adjustment.
    b. Faulty ignition system. b. Repair or replace components as re-
    quired.
    c. Sticky gas admission valve. c. Repair or replace gas admission valve.
    Ignition system timing incorrect. Re-time.
    Low compression pressure:
    a. Leaking head gasket. a. Replace head gasket - inspect for warped
    cylinder head and/or """kcase.
    Replace if necessary.
    b. Leaking exhaust/intake valve. b. Recondition seats and valves.
    c. Misadjusted intake and exhaust valves (if c. Readjust.
    recently overhauled).
    d. Wom rings (excessive blow-by). d. Replace.
    e. Wom pistons/liner. e. Replace as necessary.
    f. Cracked piston. f. Replace.
    g. Cracked cylinder head. g. Replace.
    Excessive exhaust system backpressure. Correct as required.
    Engine will not shut down using Defective ON-OFF swnch. Replace.
    normal stopping procedures.

    I A WARNING I Overheated combustion chamber deposits


    cause the engine to run on - auto ignition.
    Allow engine to cool down before attempting to
    stop.
    Shut off the gas supply for posi-
    tive shutdown of gaa englnas, In-
    spectthe Intake manifold for accu-
    mulations of lube oil.
    Engine will not reach rated speed. Engine overloaded. Determine and correct cause.
    ) Insufficient fuel supply. Check fuel supply system.
    Restricted air intake. Correct cause.

    FORM 6248 First Ednion 7.00 - 3


    TROUBLESHOOTING

    SYMPTOM PROBABLE CAUSE REMEDY


    )
    Engine will not reach rated speed Governor misadjusted. Rearljust.
    (cont'd).
    Ignition not properly timed. Re-time.
    Tachometer inaccurate. Calibrate or replace tachometer.
    Engine will start but will not reach idle No fuel to the prechamber manifold during start Repair or replace regulator valve.
    rpm. sequence. Prechamber regulator valve stuck
    shut.
    Engine cannot make rapid load Engine misfiring:
    changes.
    a. Fuel system settings incorrect. a. Readjust per fuel system specifications.
    b. Faulty ignition system. b. Repair or replace components as re-
    quired.
    Sensing line to the prechamber regulator Clean or replace.
    restricted or plugged.
    Engine misfires at light load. FauHy ignition system. Repair or replace components as required.
    Prechamber gas admission valves sticking. Clean or replace.
    Fuel system setting incorrect. Readjust per fuel system specifications.
    a. Fuel regulator valve stuck shut. a. Repair or replace regulator.
    b. Admission valve plugged. b. Clean or replace.
    Individual cylinders misfire. Prechamber gas admission valve stuck shut. Clean or replace valve.
    Faulty ignition system. Repair or replace components as required.
    Engine will not run at maximum Engine misfiring:
    power.
    a. Fuel system setting incorrect. a. Readjust per fuel system specifications.
    b. Faulty ignition system. b. Repair or replace components as re-
    quired.
    )
    Engine detonates. Engine overloaded. Determine and correct cause of overload.
    Incorrect ignition timing. Reset to specification.
    Air/fUel ratio too rich. Reset to specification.
    Engine misfiring:
    a. Faulty ignition system. a. Repair or replace components as re-
    quired.
    b. Prechamber fuel system incorrectly set. b. Reset per fuel system specifications.
    c. Sticking gas admission valve. c. Clean or replace valve.
    Emission levels too high. Advanced ignition timing. Reset to specification.
    Airffuel ratio incorrect. Reset to specification.
    Engine misfiring:
    a. Faulty ignition system. a Repair or replace components as re-
    quired.
    b. Prechamber fuel system incorrectly set. b. Reset per fuel system specification.
    c. Sticking gas admission valve. c. Clean or replace valve.
    Low or fluctuating lube oil pressure. Insufficient oil. Add oil as required.
    Shutdown Lube oil pressure gauge inaccurate. Compare to master gauge. Replace gauge ~
    IACAUTIONI necessary.
    the engine
    immediately.
    Oil gauge line plugged or valve shut. Renew gauge line; open valve.
    Lube oil filters plugged. Change elements; clean filter.
    Lube oil pressure regulating valve stuck in open Clean and polish valve.
    position. )
    Oil pressure regulating valve set too low. Readjust oil~ressure regulating valve to
    309 - 345 k a (45 - 50 psi) at governed speed.

    7.00 - 4 FORM 6248 First Edition


    TROUBLESHOOTING

    SYMPTOM PROBABLE CAUSE REMEDY


    Low or fluctuating lube oil pressure Lube oil dilution. Change oil and filter elements. Determine and
    (conl'd). correct source of dilution.

    Shutdown Lube oil of low viscosity. Change to higher viscosity oil as recommended.
    IAcAUTIONI
    the engine
    Lube oil foaming. Use oil grade recommended. Check for water
    Immediately. leaks into oil.
    Clogged oil inlet screen(s). Remove and clean screen(s).
    Engine is operated at angles that exceed the Operate within maximum safe tilt angles (see
    maximum safe tilt specification. Specifications).
    Dirty all cooler. Clean.
    Worn lube oil pump. Repair or replace pump.
    Worn bearings (main, connecting rod and Replace worn bearings.
    camshaft).
    Cracked or leaking lube oil piping. Repair or replace piping.
    Low gas/air pressure. Incorrectly adjusted gas regulator. Readjust.
    Insufficient line pressure. Increase line pressure.
    Incorrect orifice and/or spring in gas regulator. Replace orifice and/or spring.
    Undersize gas regulators. Replace with gas regulators of adequate size.
    Undersize piping. Replace with piping of adequate size.
    Gas regulators mounted too far from engine. Remount gas regulators as close to carburetors
    as possible.
    High gas/air pressure. Incorrectly adjustad gas regulator. Readjust.
    Incorrect spring in gas regulator. Replace spring.
    Excessive line pressure. Reduce line pressure.
    Low jacket water pressure. Low water level. Fill cooling system.
    Air is entering the system through the suction Repair leak; purge air from the system.
    side of the jacket water pump.
    Wrong pressure cap. Raplace.
    Gauge inaccurate. Compare to master gauge; replace gauge if
    necessary.
    Gauge line clogged or valve shut. Replace line; open valve.
    Leaking pump seels. Repair pump.
    Cracked water-cooled exhaust manifold. Replace manifold.
    Incorrectly sized outlet water orifice. Resize per specification.
    High lube oil pressure. Misadjusted oil pressure regulating valve. Readjust oil ~ressure regulating valve to
    309 - 345 k a (45 - 50 psi).
    Lubricating oil temperature too low. Check/replace lube oil thennostats.
    Lubricating oil of high viscosity. Change to lower viscosity oil as recommended.
    Lubricating oil pressure regulating valve stuck in Clean and pOlish valve.
    closed position.
    Low jacket water temperature. Gauge inaccurate. Compare to master gauge; replace gauge if
    necessary.
    Inoperative or malfunctioning thennostat(s). Replace thermostatic element or thennostat(s)
    (as applicable).
    High jacket water temperature. 14 CAUTION 1Allow engine to cool.
    Gauge inaccurate. Compare to master gauge; replace gauge if
    necessary.
    Low coolant level. Fill cooling system.
    Inoperative or malfunctioning thermostat(s). Replace thennostatic element or thermostats
    ) (as applicable).
    Air bound cooling system. Purge air from cooling system.

    FORM 6248 First Edition 7.00 - 5


    TROUBLESHOOTING

    SYMPTOM PROBABLE CAUSE REMEDY


    )
    High Jacket water temperature Engine overloaded. Determine and correct cause.
    (eontd).
    Poor coolant circulation. Check the entire cooling system, including outlet
    water orifice plate sizing.
    Worn jacket water pump or seals. Overhaul or replace pump.
    Frozen coolant. Completely thaw cooling system before
    restarting engine.
    Cracked exhaust manifold. Replace manifold.
    Incorrect ignition timing. Reset ignition timing.
    Cracked heed. Replace heed.
    Cracked sleeve. Replace sleeve.
    Low auxiliary water pressure. Gauge inaccurate, Compare to master gauge; replace gauge if
    necessary.
    Clogged gauge line or the gauge line valve is Replace line or open valve.
    shut.
    Air is entering the system through the suction Repair leak; purge the system of all air.
    side of the water pump.
    Worn water pump. Repair or replace.
    Clogged heat exchanger or intercooler. Clean heat exchanger/intercooler.
    Incorrectly sized auxiliary water circuit orifice Resize per specification.
    plate.
    High lube oil consumption. Oil leaks in lube oil system. Locate and repair leaks.
    Improper viscosity. Change to a viscosity recommended for
    operating temperatures.
    Leaking crankshaft oil seals rear and/or front. Change seals.
    Worn valve guides; improperly installed, worn Change head; renew guides, or valve guide
    )
    valve stem seals. internal seals.
    Stuck/WOrn piston rings. Renew rings.
    Lube oil contamination. Lube oil contaminated with water: NOTE: Change oil.
    a. Cylinder sleeve cracked or seals leaking. a. Replace sleeve O-rings.
    b. Oil cooler leaking. b. Repair or replace oil cooler.
    Lube oil contaminated with dirt:
    a. Lube oil filter bypass valves opening a. Replace elements.
    because elements are plugged.
    b. Lube oil filter elements punctured. b. Replace elements.
    c. Air intake filters punctured. e. Replace air intake filters.
    Excessive vibration. Foundation bolts:
    a. Loose. a. Torque to specification.
    IACAUTIONI Stop engine at
    once; Invasti· b. Cracked. b. Replace and torque all bolts to specifica·
    gate cause. tion.

    Unbalanced cylinders; misfiring ignition system. Repair or replace components as required.

    Vibration damper:
    a. Loose. a. Replace all securing bolts; torque to
    specifications.
    b. Malfunctioning. b. Replace damper.

    7.00 - 6 FORM 6248 First Ed~ion


    TROUBLESHOOTING

    SYMPTOM PROBABLE CAUSE REMEDY


    Excessive vibration. Crankshaft:
    a. Broken. a. Conduct a com~lete investigation of en-
    lAcAUTIONl Stop engine at tire engine for amaga.
    once; investi-
    gate cause. b. Main bearing nuts loose. b. Determine the reason for loosening; in-
    vestigate the entire lower crankcase
    before torquing the bolts to specification
    and running the engine.
    b. Crankshaft nut loose. b. Determine the reason for loosening; In-
    vestigate the entire lower crankcase
    before torquing the nut to specification
    and running the engine.
    b. Crankshaft Counter-weight loose. b. Determine the reason for loosening; In-
    vestigate the entire lower crankcase
    before torquing the counter -weight to
    specification and running the engine.
    Loose flywheel. Determine cause and correct.
    High lube oil temperature. Gauge inaccurate. Compare to master gauge; replace gauge if
    necessary.
    Engine overloaded. Determine and correct cause.
    Insufficient cooling:
    a. Low auxiliary water pressure. a. See Low Auxiliary Water Pressure
    causes.
    b. Dirty lube oil cooler. b. Clean or replace.
    c. Defective lube all cooler thermostatic c. Repair or replace.
    control.
    Dirty jacket water heat exchanger or radiator. Clean or replace.
    Low lubricating oil pressure. See Low Lubricating Oil Pressure causes.
    Knocking or unusual noises. Low octane fuel. Adjust timing for the fuel used.
    Engine overloaded. Determine and correct cause.
    Overly advanced ignition timing. Re-tlme.
    Excessive valve clearance. Adjust to specification.
    Sticking valves or rocker arms. Free up or replace.
    Damaged or excessively worn accessory drives. Repair or replace components as required.
    Loose bearings ~ailed). Replace bearings.
    Loose piston pins (failed). Replace piston pins and/or pin bushings as
    required.
    Excessive crankshaft end play. Replace main bearing thrust rings.
    Misfitted or excessively worn timing gears. Replace.
    Excessive fuel consumption. Leaks in fuel system. Repair as required.
    Faulty ignition system. Repair or replace components.
    Retarded ignition timing. Set timing to specifications.
    Engine overloaded. Determine and correct cause.
    Lean air/fuel ratio. Set to specifications.
    Poor compression. Determine cause(s) and repair.
    TURBOCHARGER: Excessive noise Low lube oil pressure. Improper bearinQ Provide required oil pressure. Clean or re~lace
    or vibration. lubrication. Load engine before warm all is oil line. If trouble persists, overhaul turboc arger.
    supplied to the turbocharger.
    Dirty impeller/lurbine. Clean.
    Damaged impeller/turbine. Replace as necessary.
    Leak in engine intake or exhaust manifoid. Tighten loose connections or replace manifold
    gaskets as necessary.
    )
    GOVERNOR: UG-8 Engine hunts or Compensation adjustments incorrect. Adjust needle valve to specification.
    surges.
    Dirty oil in governor. Drain oil, clean governor and refill.

    FORM 6248 First Edition 7.00 -7


    TROUBLESHOOTING

    SYMPTOM PROBABLE CAUSE REMEDY


    )
    Foamy oil in governor. Drain oil and refill.
    GOVERNOR: UG-8 Engine hunts or Low oil level. Add oil to correct level on gauge glass. Check
    surges (cont'd). for leaks, especially at drive shaft.
    Lost motion in engine linkage. Repair linkage.
    Binding In engine linkage. Repair and realign linkage.
    Governor worn or not correctly adjusted. Repair and adjust governor.
    Engine misfiring. See Engine Misfires.
    GOVERNOR: UG-8 Terminal shaft! Rough engine drive. a. Inspect for rough gear teeth.
    engine linkage jiggles.
    b. Check backlash of gears.
    Speed droop (rt used) at cr~ical setting. Increase droop to eliminate critical setting. Load
    division will be affected if this is done. Readjust
    droop on units affected.
    Governor base not bolted down evenly. Loosen botts, realign and secure.
    GOVERNOR: UG-8 Engine is slow to Compensation adjustment incorrect. Readjust compensation.
    respond to speed or load changes.
    Engine overloaded. Reduce load.
    Restricted fuel supply. Clean fuel supply line and filters.
    GOVERNOR: UG-8 Engine will not Butterfly valves will not open far enough. a. Adjust engine-to-governor fuel linkage.
    pick up rated load.
    b. Adjust load limiting device.
    Restricted fuel supply. Clean fuel supply line and filters.
    Engine misfiring. See Engine Misfires.
    Speed adjustment of the govemor is restricted. a. Check the maximum speed limit adjust-
    ment on dial control governor.
    b. Inspect speed adjusting linkage for inter-
    ference on lever control govemor. )

    7.00 - 8 FORM 6248 First Edition


    SECTION 7.10 - MAINTENANCE AND STORAGE

    ROUTINE MAINTENANCE extreme cold or very dirty conditions. Pick the shortest
    time listed when given a choice.
    A CAUTION I Failure to ade~uat~ly in-
    I'!!"~~=="':;=-':":~:":";:.J.
    L. spect and maintain the
    engine can lead to severe engine damage.
    Regularly inspect the engine in operation (see
    Table 7.10-1). Duplicate the Routine Inspection Form
    (see Table 7.10-2) and use it to record the results of
    regular inspections. By maintaining trend information
    The following maintenance schedule has been deter- on the general condition of the engine, the necessary
    mined for normal operating conditions. It may be corrective action can be taken when a problem first
    necessary to change some of the intervals of mainte- becomes apparent. An early diagnosis will save money
    nance to meet abnormal operating conditions such as and reduce down time, by preventing the development
    of more serious problems.

    -
    Table 7 10 1 Routine Maintenance Chart
    c
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    ::IE
    ITEM SERVICE ~ :::I
    "8 "51 "~ "~ "! "§ §".,;
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    Air Cleaner Filter Element Check/Clean or Replace •
    Air Starter Lubricator Check/Fill •
    Control Rod Ends/Governor Rod Ends and
    Unkage Clean/Lubricale •
    Cooling Systems Fluid Level
    ) (Jackel and Auxiliary) Check/Fill •
    Crankcase Oil Level Check/Fill •
    Governor Oil Level Check/Fill •
    Governor Synchronizer or Speed Control Adjust •
    Oil FiHer Release Trapped Air •
    Pre-Cleaner Element Check/Clean or Replace •
    Prelube Motor Reservoir Check/Fill •
    Power Take-Off Lubricate •
    Battery Electrolyle Check/Fill •
    BeHTenslon Check •
    Cooling Water Analysis (Ebullient) Check •
    ~nition
    Cables, Primary and
    econdary Connect Inspect •
    Water Temperature Gauge Test •
    Carburetor Adjust •
    Crankcase Pressure Check •
    Oil Pressure Safety Test •
    99 Regulator(s) Adjust •
    Prechamber Regulator* Adjust •
    Safety Controls/Engine Protection Devices Test/Calibrate •
    ) Valve Clearance Adjust •
    Valve Cover Gaskel Replace •
    (Continued)

    FORM 6248 First Ednion 7.10 -1


    MAINTENANCE AND STORAGE

    Q
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    " "li! "~ "I:! "::I "~ "§,,;
    -.
    ITEM SERVICE
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    Admission Valve Assembly'" Clean or Replace •


    Admission Valve Gasket* Replace •
    Admission Valve D-Ring* Replace •
    Cylinder Compression Check •
    Electric Starter Bearings Lubricate •
    Governor-Synchronizer Motor Bearings Lubricate •
    99 Regulator Filter Clean/Replace •
    Turbocharger Clean and Inspect •
    Main and Rod Bearings Inspect •
    Cooling System
    (Jacket and Auxiliary)
    Clean and Flush •
    Cooling System Thermostats Remove and Test •
    Cooling System Tube Bundle Clean •
    Crankcase Oil Pickup Screen Clean •
    Engine Mounting and Alignment Check • )
    Exhaust Back Pressure Check •
    Fuel Flow Filter Relief Valve Inspect •
    High TenSion Wires Replace •
    ~nitiOnPrimary Terminals,
    amess Plug Inspect •
    CEe Ignition Timing Disc Magnets Clean/Inspect •
    Governor-Synchronizer Motor Reduction
    Gears
    Lubricate •
    Intercooler Clean and Inspect •
    Jacket Water Hoses Replace •
    Lube Oil Hoses Replace •
    DilPan Clean •
    Vibration Damper Capscrews Retorque •
    Engine Oil & Filter **
    (Stand-By Service)
    Change Oil and Fmer •
    Engine Oil .. (Excess of Continuous Duty) Change Oil and Filter •
    Engine Oil ~ (Ebullient Cooled) Change Oil and Filter •
    Air Actuator Lubricate •
    Alternator Bearings Lubricate •
    Auxiliary Water Pump Inspect/Lubricate •
    Engine Oil ~ (Non Ebullient) Analysis •
    Fan Hub and Idler Pulley Bearings Lubricate •
    (Continued)

    7.10 - 2 FORM 6248 First Edition


    MAINTENANCE AND STORAGE

    Q
    W
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    5
    a
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    ~w .... .., 0:IE
    oj oj a:
    a: :z: 0 ..J
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    ITEM :IE C :z: :z: :z: :z: :z: :z: :z:
    SERVICE
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    Generator Bearings Lubricate •


    Tachometer Drive Clean •
    Spark Plugs Clean and Regap •
    Water Pump Idler Puller Bearings Lubricate •
    Water Pump Inspect •
    Engine Oil .. (Ught Load) Change Oil and Fitter •
    Crankcase Breather Clean •
    Engine Oil .. (Continuous Duty) Change Oil and Filter •
    Ignition Timing Check •
    Lube all Strainer Element Clean •
    Magnetic Plugs Clean •
    all Cooler (Oil Side) Drain •
    Oil Filter Elements Replace •
    \ Oil Separators Oean •
    Spark Plugs Replace •
    Oil Fitter Seai Replace •
    Carburetor Air/Gas Valves Clean •
    Carburetor Diaphragm Inspect •
    Governor Compensation Adjust •
    Magneto Drive Disc Replace •
    Precleaner Element Replace •
    Hydraulic Governor Oil Change •
    Cooling Water Analysis Check •
    Carburetor Gasket Replace •
    Carburetor Air-Gas Valve Replace •
    Betts (Engine) Replace •
    Carburetor Diaphragm Replace •
    Crankcase Pressure Relief Valves Inspect •
    Wastegate Vent Plug Inspect/Clean •
    Ignition Coils Inspect •
    Ignition Magneto Clean •
    Ignition Primary Terminals, Connections,
    Harness Plug, and Wires Inspect •
    NOTE: * Indicates GL engines
    ) *II Refer to sa 12-18808 or latest revision.

    FORM 6248 First Edition 7.10 - 3


    MAINTENANCE AND STORAGE

    ROUTINE INSPECTION
    )
    I.=A. CAUTION I
    L.
    Failure to adequat~ly in-
    spect and maintain the
    ='--.::..;;....;;.;;;...;;_;:...;....;;.J.
    engine can lead to severe engine damage.
    Table 7.10-2. Routine Inspection Form
    DATE ENGINE PERFORMANCE RECORD
    ITEM READING REMARKS
    Hourmater Reading
    Tachometer (RPM)
    Fuel Mater Reading
    Engine Temperature
    011 Temperature
    Coolant Temperature
    Intercooler Water Temp.
    011 Cooler Water Temp.
    Gas/Air Pressure
    Manifold Pressure Pos/Neg
    Crankcase Pressure Pos/Neg
    Unusual Noise(s) Vibration
    011 Leaks
    coolant leaks
    )
    Prechamber 0:1"
    Exhaust 0:1"
    Prechamber/lntake Pressure
    S':ide Open Throttle)
    er Manifold Pressure
    Exhaust Back Pressure
    Ignition nming
    Detonation Sensors

    7.10 - 4 FORM 6248 First Edition


    MAINTENANCE AND STORAGE

    ENGINE STORAGE
    Consider the following factors before deciding how
    A WARNING
    much preservation is required: Waukesha Preservative Oil contains a petroleum
    distillate which is harmful or fatal If swallowed. If
    1. Whether the engine was used, the length of service taken internally, do not induce vomiting. Remove
    since the last oil change. Ingested material by gastric lavage with 2 to 4
    quarts or IItres oftap water or milk. Follow with fruit
    2. The period of time the engine is likely to be idle or
    juice or vinegar to neutralize the alkali. Failure to
    inoperative.
    follow these precautions could cause severe per-
    3. The atmospheric conditions at the time and place of sonal injury or death.
    storage. For example, the storage problems encoun-
    tered in a tidewater warehouse will differ greatly from
    those that may be experienced in a dry and dusty A WARNING
    location. Avoid prolonged or repeated breathing of vapor.
    Vapor Is harmful and may cause Irritation to eyes,
    4. The hostility of the environment and the accessibility nose and throat. Use only with adequate ventilation.
    of the equipmentfor periodic inspection. An engine on a If affected by exposure, move to fresh air immedi-
    showroom floor that is turned over and oiled occasional- ately and get medical help. Failure to follow these
    ly requires less treatment than an engine stored precautions could cause severe personal InJury or
    indefinitely abandoned in a warehouse. death.
    PRESERVATION EQUIPMENT AND MATERIAL
    Sprays and Atomizers A WARNING
    Often it is necessary to apply a protective compound Avoid contact with eyes, skin and<clothing. If skin
    under difficult field conditions. Several simple tools may contact occurs, immediately flush the affected area
    be used to atomize preservative oil and force it into the with plenty of water. If eye contact occurs, flush for
    ) manifolds and combustion chambers. One of these is a at least 15 minutes and seek medical attention. If
    manually operated atomizing gun used ordinarily to clothing is contaminated, remove and wash before
    lubricate inaccessible points on cars and truck chassis. using again. Failure to follow these precautions
    Another is a hand-operated pump-type sprayer with a could cause severe personal injury or death.
    pOinted discharge nozzle commonly used with insecti-
    cides. If desired, small oil pumps may be rigged with a
    motor drive to make a convenient spray unit of the
    mechanical pressure type. In almost all cases, the air
    A WARNING
    Keep container closed and away from heat. Always
    available from shop compressor lines carries too much
    read and observe the CAUTION labels on the
    moisture to be safe for this purpose. Do not use high
    containers. Do not remove or deface the container
    pressure air from this source.
    labels. Failure to follow these precautions could
    WAUKESHA ENGINE PRESERVATIVE OIL cause severe personal injury or death.
    During storage, protect internal metal surfaces from the WAUKESHA ENGINE PRESERVATIVE OIL USAGE
    effects of dampness, salt and other corrosive sub-
    stances. Waukesha Engine Preservative Oil offers a 1. Verify that the engine temperature is below 100· F
    practical and economical solution to these storage (3S· C).
    problems. It contains volatile corrosion-inhibiting
    chemicals that slowly vaporize and diffuse throughout 2. Verify that both the oil and oil filter elements are
    any closed void. The chemicals form an invisible clean. The preservative oil will do an effective job only if
    protective layer on all surfaces contacted and allow the added to the engine oil in a clean condition. If a high
    engine to be safely stored for one year. sulfur fuel was used or if improper control of oil condition
    left a highly corrosive oil in the bearings and other close
    contact surfaces, then the vapors cannot form a good
    protective layer. In these circumstances, change the oil
    I
    and then run the engine long enough to ensure
    ) complete circulation of the clean oil.

    FORM 6248 First Edijion 7.10 - 5


    MAINTENANCE AND STORAGE

    Table 710-3 Waukesha Engine Preservative 011 Application


    UPPER CYLINDER CRANKCASE
    Ounces Of Ounces Of Standard Oil Pan Quantity of Total Quantity
    NUMBER OF Preservative Preservative Preservative Of Engine
    CYLINDERS Oil Per Oil All C'1f.:lCity Preservative
    In allons 011
    Cylinder Cylinders Oil Required
    Twelve 3-1/20z (103.5 cc) 42 oz (1242 cc) 43 gal. (162.8 IItres) 1100z (3253 cc) 152 oz (4495 cc)

    3. Add Waukesha Engine Preservative Oil to the NOTE: Waukesha Engine Preservative Oil is not
    existing crankcase oil in an amount equivalent to 2% of formulated as a protective coating for external surfaces.
    the total oil capacity. Excellent products for polished and machined surfaces
    are available on the market and should be used when
    4. If possible, crank the engine for at least 20 seconds needed. Refer to Table 7.10-5.
    to ensure adequate circulation of the preservative oil.
    Table 7.10-5 Protective Materials
    5. Add the required amount of preservative oil to each INTERNAL SURFACES EXTERNAL SURFACES
    cylinder through the spark plug hole or prechamber
    U. S. Arm~ src. 2-126 U.S. Army Spec. 2-121
    admission valve opening. Install the plugs or admission (Available as A 10 or SAE 30) ~axy Coating)
    valves.
    WED Preservative Oil, U. S. Army Ordinance Spec.
    Mil Spec. MIL-L46002 Grade 2 AXS673
    6. Apply the preservative oil to the rocker arm area (Harder Black Coating)
    through light brushing or pouring. Replace the rocker
    arm covers.

    7. While it may not be practical to completely seal an


    A WARNING
    engine in the field, try to block the paths through which Do not heat preservative compounds to tempera-
    the vaporized chemicals may escape. tures that exceed 93° C (200° FJ. This temperature

    8. The engine may be stored for one year. If storage is


    may be inadvertently reached by placing the con-
    tainer in boiling water. Direct heating always pres-
    )
    to exceed this period, inspect the engine annually and ents a dangerous and unnecessary fire hazard.
    repeat the preservation routine. Failure to follow these precautions could cause
    severe personal injury or death.
    USE OF OTHER PRESERVATIVE OILS AND
    MATERIALS
    In addition to Waukesha Engine Preservative Oil, the
    following preservative oils have been found satisfactory
    for the internal protection of engines (see Table 7.10-4).
    Other equally good oils are also available. In general,
    the properties that make an oil suitable for preservative
    requirements are good aging stability; high resistance
    to gumming, oxidation and polymerization; low pour
    point and viscosity; freedom from acids, asphalts,
    resins, tars, water and other contaminants.
    Table 7.10-4. Preservative Oils
    SUPPLIER BRAND NAME
    American Oil Company Amoco Anti-Rust Oil4-V
    Gulf 011 Corporation No rust Engine Oil Grade 1
    Mobil Oil Company Mobil Anna 522
    Shell Oil Company DonaxT-6
    Atlantic Richfield Company Dexron
    Texaco, Inc. #800 Regal 011 A (R 0)
    )

    7.10 - 6 FORM 6248 First Edition


    MAINTENANCE AND STORAGE

    ENGINE STORAGE - NEW NON-OPERATIONAL ENGINES

    OPERATIONAL ENGINES 1. Open drains, as required, to remove oil, water and


    fuel.
    Internal Component Protection
    2. Remove the spark plugs and add 100 cc (3-1/2 oz.)
    1. Mix an inhibitive type preservative oil with the engine of preservative oil to each cylinder/combustion cham-
    lubricating oil in the proportions recommended by the ber. Crank the engine in the normal direction about
    manufacturer. Operate the engine until the oil is hot. one-quarter turn, then spray each cylinder again.
    Treat the cooling water used in this run with the proper Repeat this procedure at least eight times or until the
    inhibitors based on the instructions of the manufacturer. engine has been turned through two complete revolu-
    2. Drain both the oil and cooling water while they are tions, so that each valve is exposed to a coating of
    still hot. For extra protection, remove the rocker arm preservative oil.
    covers and pour a quantity of preservative oil over the 3. Depending upon storage conditions, open the crank-
    rocker arm and valve mechanisms. shaft and camshaft inspection doors, valve rocker
    3. Remove the spark plugs and add 100 cc (3-1/2 oz.) covers, gear cover plates and as many points as
    of preservative oil to each cylinder/combustion cham- possible to spray, squirt or pour oil over the interior
    ber (see Table 7.10-4). engine parts. Replace all plugs and covers.

    4. Refill the crankcase with proper grade lube oil to 4. Refer to Operational New Engines, Storing, External
    which an inhibitive type preservative oil has been added Components, Protecting, in this chapter.
    in the recommended proportion.

    External Component Protection

    1. Wipe the engine clean and dry.

    ) 2. Protect all engine openings against the entrance of


    dirt and other foreign matter. Apply a wax type masking
    tape or similar type of material over the intake openings
    of air cleaners, exhaust outlets, breathers, magneto
    vents, open line fittings, etc.

    3. Relieve the tension on all belts to avoid deterioration


    of the rubber.

    4. Use a brush to apply a coating of heavy preservative


    compound to all exposed machined surfaces, such as
    flywheels.

    5. Protect all accessory equipment (such as carbure-


    tors, gas regulators, starters, generators, etc.) against
    corrosion, dirt, moisture saturation and progressive
    deterioration.

    6. Protect the cooling system and intercoolers against


    freezing, rusting or seizure of water pump seals.

    7. Protect against rain, snow and temperature ex-


    tremes.

    8. Disconnect the batteries and remove them to a slow


    charging station where they can be kept fully charged.

    NOTE: Engines stored according to these instructions


    } using Waukesha Engine Preservative Oil will normally
    ./
    be protected for one year. If storage is to exceed this
    period, inspect the engine annually and repeat the
    preservation routine.

    FORM 6248 First Edition 7.10 -7


    MAINTENANCE AND STORAGE

    ENGINE STORAGE - USED ENGINES - RETURN TO SERVICE AFTER


    STORAGE
    OPERATIONAL ENGINES
    During normal engine operation, residues of various
    combustion products accumulate in the combustion A WARNING
    area and in the lubricating oil. Portions of these residues Remove all accumulations of oil, water or preserva-
    combine with atmospheric moisture to form acids and tive compounds. These accumulations may thin out
    other corrosive compounds. The following treatment as the engine warms up and be burned as fuel,
    will help reduce damage from this source: resulting in a runaway engine. Disregarding this
    1. Run the engine until the original oil is hot. Drain oil.
    information could result In severe personal injury
    or death.
    2. For best results, refill the engine with a good flushing
    oil. Run the engine until the flushing oil is hot. Drain both
    the oil and cooling water while still hot. A
    I.L..:
    CAUTION I~ev~rattempttostartan
    . =:......:=....:..:;;....;;..:;...;:::..:...;;.J.
    . engine that has been
    3. Refill the crankcase with proper grade lube oil to
    stored without first cranking It over with the spark
    which an inhibitive type preservative oil has been added
    plugs removed. Any oil, water or preservative
    in the recommended proportion.
    compound that might spurt from these openings
    must be removed to prevent a hydraulic lock.
    4. Remove the spark plugs and add 100 cc (3-1/2 oz.) Disregarding this Information could result in prod-
    of preservative oil to each cylinder/combustion cham- uct damage and/or personal injury.
    ber (see Table 7.10-4). Replace the spark plugs.
    1. Remove the old spark plugs and crank the engine
    5. Refer to Operational New Engines, Storing, External over to remove any accumulation of oil, water or
    Components, Protecting, in this chapter. preservative compounds.

    NON-OPERATIONAL ENGINES 2. Crank the engine with the starter until liquid is no
    1. Refer to Non-operational New Engines, Storing.
    longer ejected from the openings. )
    3. Inspect the intake passages and manifolds for
    2. Protect the fuel system against the gumming effects
    thickened preservative oil.
    of gas reSidues.
    4. Install new spark plugs.
    3. In those cases where fuels with high sulfur concen-
    trations have been used or where extremely harsh NOTE: Refer to the Prestart Inspection and Start-up
    climatic or environmental conditions prevail, the engine Procedures in the applicable Operation And Mainte-
    may need to be disassembled, thoroughly cleaned and nance Manual for complete instructions to bring an
    then reassembled for treatment as a new engine. engine into active seNice. The steps needed are about
    the same as those normally carried out on a new engine.

    7.10 - 8 FORM 6248 First Edition


    APPENDIX A

    ALPHABETICAL INDEX

    A B
    Admission Valve - GL ................... 5.05 - 19 Barring Device Removal ................. 2.05 - 16
    Assembly ............................ 5.05 - 20 Basic Engine Description ................. 1.15 - 7
    Cleaning And Inspection ............... 5.05 - 19
    Belts .................................. 5.25 - 18
    Disassembly ......................... 5.05 - 19
    Auxiliary Water Pump Drive Belt
    Installation ........................... 5.05 - 20 Replacement ..................... 5.25 - 21
    Removal ............................ 5.05 - 19 Auxiliary Water Pump Drive Bett
    Air Cleaner Ducts ....................... 5.15 - 5 Tension Adjustment ............... 5.25 - 22
    Installation - G ........................ 5.15 - 7 Jacket Water Pump Betts Replacement .. 5.25 - 18
    Installation - GSI/GL .................. 5.15 - 10 Jacket Water Pump Betts Tension
    Removal- G .......................... 5.15 - 5 Adjustment ....................... 5.25 - 19
    Removal- GSI/GL .................... 5.15 - 8 Breather Tubes ........................ 5.40 - 18
    Air Cleaners ............................ 5.15 - 2 Installation - GL ...................... 5.40 - 21
    Main Air Fi~er Element Cleaning And Installation - GSI ..................... 5.40 - 19
    Inspection ......................... 5.15 - 3 Removal - GL ....................... 5.40 - 20
    Main Air Fi~er Element Installation ....... 5.15 - 4 Removal - GSI ....................... 5.40 - 18
    Main Air Fitter Element Removal ......... 5.15 - 3 Bulkhead To Panel Bracket .............. 5.45 - 14
    Precleaner Pad Cleaning And Inspection . 5.15 - 3 Installation ........................... 5.45 - 15
    Precleaner Pad Removal ............... 5.15 - 2 Removal ............................ 5.45 - 14
    Air Induction System Components ......... 5.15 - 1 Butterfly Cross Shaft - GIGSI ............. 5.05 - 6
    Air Cleaners .......................... 5.15 - 1 Installation ............................ 5.05 - 7
    Carburetor And Intake Manrrold .......... 5.15 - 1 Removal ............................. 5.05 - 6
    ) Intercoolers ........................... 5.15 - 1 Butterfly Valves - G/GSI ................ 5.05 - 18
    Turbochargers ........................ 5.15 - 1 Assembly ............................ 5.05 - 19
    Air Induction System Specrrications ........ 5.15 - 1 Disassembly ......................... 5.05 - 18
    Air Restriction Indicator .................. 5.15 - 4 Installation ........................... 5.05 - 19
    Removal ............................ 5.05 - 18
    Air Starter ............................. 5.45 - 24
    Installation ........................... 5.45 - 25
    Removal ............................ 5.45 - 24
    Air Tubing ............................. 5.15 - 10
    c
    Installation - G ....................... 5.15 - 11 Camshaft ............................. 3.05 - 14
    Installation - GL ...................... 5.15 - 14 Cleaning And Inspection ............... 3.05 - 14
    Installation - GSI ..................... 5.15 - 12 Camshaft Bearing Installation In Field
    Removal - G ......................... 5.15 - 10 Conditions ......................... 2.05 - 32
    Removal - GL ....................... 5.15 - 12 Camshaft Bearing Removal In Field
    Removal - GSI ....................... 5.15 - 11 Conditions ......................... 2.05 - 31
    Air/Gas Prelube And Start Systems ........ 5.45 - 1 Camshaft Gear Removal ................ 2.05 - 10
    Components .......................... 5.45 - 1 Camshaft Removal ..................... 2.05 - 15
    Prelube System ....................... 5.45 - 1
    Carburetor Cross Shaft - GL .............. 5.05 - 8
    Start System .......................... 5.45 - 4
    Installation ............................ 5.05 - 8
    Auxiliary Cooling Water Circuit - Removal ............................. 5.05 - 8
    Initial Fill ........................... 5.25 - 13
    Carburetors ............................ 5.05 - 11
    Auxiliary Water Pump And Bracket ........ 5.25 - 77 Assembly - G/GSI .................... 5.05 - 13
    Installation ........................... 5.25 - 79 Assembly - GL ....................... 5.05 - 17
    Removal ............................ 5.25 - 77 Cleaning And Inspection - G/GSI ....... 5.05 - 12
    Auxiliary Water Temperature Cleaning And Inspection - GL .......... 5.05 - 16
    Control Valve ....................... 5.25 - 58 Disassembly - G/GSI ................. 5.05 - 12
    ) Assembly ............................ 5.25 - 59 Disassembly - GL .................... 5.05 - 15
    Inspection And Test ................... 5.25 - 58 Installation - G/GSI ................... 5.05 - 13
    Installation ........................... 5.25 - 60 Installation - GL ...................... 5.05 - 17
    Removal ............................ 5.25 - 58 Removal - G/GSI ..................... 5.05 - 11
    FORM 6248 First Edition A-I
    APPENDIX A

    Removal - GL ....................... 5.05 - 15 Barring Device Installation ............. 4.00 - 58


    CEC Ignition Module .................... 5.10 - 19 Cam Gear Installation ................. 4.00 - 12 )
    Installation ........................... 5.10 - 19 Camshaft And Bearing Installation ....... 4.00 - 6
    Removal ............................ 5.10 - 19 Camshaft End Play Measurement ...... 4.00 - 11
    Camshaft Idler Gear Installation ........ 4.00 - 32
    Check Valve Inspection ................. 5.30 - 26 Crankcase Installation ................. 4.00 - 49
    Checking Crankcase Oil Level ........... 5.30 - 13 Crankshaft End Play Measurement ..... 4.00 - 26
    Clearances ..... . . . . . . . . . . . . . . . . . . . . . . . 1.15 - 11 Crankshaft Gear Installation ............ 4.00 - 30
    Crankshaft Installation ................. 4.00 - 22
    Cluster Thermostat Housing And Cylinder Sleeve Installation ............ 4.00 - 41
    Thermostatic Valves ................. 5.25 - 34 Dowel Installation ...................... 4.00 - 3
    Cleaning And Inspection ............... 5.25 - 35 Flywheel Installation .................. 4.00 - 52
    Installation ........................... 5.25 - 37 Flywheel/Flywheel Housing Bore And
    Removal ............................ 5.25 - 34 Face Runout Measure ............. 4.00 - 55
    Connecting Rod ........................ 3.05 - 33 Flywheel Clutch Or Coupling Mounting
    Assembly ............................ 3.05 - 38 Face Runout Measure ........... 4.00 - 56
    Bearing Running Clearance ............ 3.05 - 40 Flywheel Clutch Or Coupling Pilot
    Bearing Running Clearance Diameter Runout Measure ........ 4.00 - 57
    Measurement .................... 3.05 - 42 Flywheel Face Runout On Wheel ..... 4.00 - 56
    Cleaning And Inspection ............... 3.05 - 35 Flywheel Housing Bore Runout
    Disassembly ......................... 3.05 - 33 Measure ....................... 4.00 - 56
    Flywheel Housing Rear Face Runout .. 4.00 - 55
    Control Panel ........................... 6.00 - 1
    Flywheel Pilot Bearing Bore Runout
    Components .......................... 6.00 - 1 Measure ....................... 4.00 - 57
    Installation - Left Side .................. 6.00 - 5 Front Flywheel Housing Installation ..... 4.00 - 50
    Installation - Right Side ................ 6.00 - 3 Front Gear Cover Plates Installation ..... 4.00 - 64
    Removal - Left Side ................... 6.00 - 4 Gear Backlash Measurement .......... 4.00 - 36
    Removal - Right Side .................. 6.00 - 1 Gear Housing Installation .............. 4.00 - 10
    Cooling System Components ............. 5.25 - 1 Gear Train Lubrication ................. 4.00 - 59 )
    Auxiliary Water Pump .................. 5.25 - 7 Idler Gear Spindle Installation ........... 4.00 - 1
    Auxiliary Water Remote Heat Lower Valve Lifter Housing Cover
    Transfer Device .................... 5.25 - 9 Installation ........................ 4.00 - 5
    Auxiliary Water Temperature Lube Oil Strainer Adapter Installation ..... 4.00 - 5
    Control Valve ...................... 5.25 - 8 Magnetic Pickup Sensor Installation ..... 4.00 - 53
    Cluster Thermostat Housing ............ 5.25 - 7 Magneto Drive Assembly Installation .... 4.00 - 37
    Exhaust Manifold ...................... 5.25 - 1 Magneto Drive Gear Installation ........ 4.00 - 39
    Intercooler ............................ 5.25 - 8 Main Bearing Caps Installation ......... 4.00 - 26
    Jacket Water Header/Jacket Water ...... 5.25 - 1 Main Bearing Installation .............. 4.00 - 20
    Jacket Water Pump .................... 5.25 - 2 Main Bearing Stud Installation ........... 4.00 - 2
    Oil Cooler ............................ 5.25 - 8 Oil Filler Bracket Installation ............ 4.00 - 58
    Remote Heat Transfer Device ........... 5.25 - 7 Oil Pan Installation .................... 4.00 - 46
    Water Manifold ........................ 5.25 - 1 Cover Plate Installation .............. 4.00 - 48
    Expansion Plug Installation ........... 4.00 - 48
    Cooling System Problems ................ 5.25 - 9
    Cavitation Erosion ..................... 5.25 - 9 Oil Level Dipsticks Installation ........ 4.00 - 48
    Corrosion ............................ 5.25 - 10 Oil Pan Seal Installation ............. 4.00 - 47
    Ethylene Glycol ...................... 5.25 - 10 Oil Pickup Screen Installation ......... 4.00 - 46
    Scale Buildup ......................... 5.25 - 9 Oil Pump Idler Gear ................... 4.00 - 31
    Scale Buildup, Cavitation Erosion And Oil Slinger/Front Oil Seal/Gear Cover
    Installation ....................... 4.00 - 60
    Corrosion ......................... 5.25 - 9
    Oil Tube Installation .................... 4.00 - 1
    Water Treatment ..................... 5.25 - 10
    Outside Crankshaft Thrust Ring
    Cooling System Specifications ........... 5.25 - 11 Installation ....................... 4.00 - 28
    Recommendations .................... 5.25 - 11 Piston And Connecting Rod Installation .. 4.00 - 42
    Specifications ., ...................... 5.25 - 11 Rear Flywheel Housing Installation ...... 4.00 - 54
    Cooling Water System Air Bleed .......... 5.25 - 14 Rear Gear Housing Cover Plate )
    Installation ....................... 4.00 - 64
    Crankcase ............................. 2.05 - 24 Rear Oil Seal Retainer (Lower Half)
    Crankcase Assembly .................... 4.00 - 1 Installation ....................... 4.00 - 25
    Accessory Idler Gear Installation ........ 4.00 - 35 Rear Oil Seal Retainer Installation ...... 4.00 - 18
    A-2 FORM 6248 First Ednion
    APPENDIX A

    Rocker Arm Oil Header Installation ...... 4.00 - 18 Counterweight Retorque ............... 3.05 - 12
    Timing Tape Installation ............... 4.00 - 51 Crankshaft Polishing .................. 3.05 - 11
    Valve Lifter Housing Gasket Installation ... 4.00 - 6 Crankshaft Repair .................... 3.05 - 11
    Valve Lifter Housing Installation ......... 4.00 - 13 Journal Repair ....................... 3.05 - 11
    Vibration Damper/Crankshaft Pulley Crankshaft Main Bearings Installation In
    Installation ....................... 4.00 - 65 Field Conditions .................... 2.05 - 30
    Water Header Plug Installation .......... 4.00 - 3
    Crankshaft Main Bearings Removal In
    Crankcase Breather Regulator - GSI/GL .. 5.40 - 10 Field Conditions .................... 2.05 - 29
    Cleaning And Inspection ............... 5.40 - 11
    Crankshaft No. 1 Main Bearings Removal
    Disassembly ......................... 5.40 - 10 In Field Conditions .................. 2.05 - 24
    Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 - 11
    Removal ............................ 5.40 - 10 Crankshaft No.1 Main Bearing Installation
    In Field Conditions .................. 2.05 - 27
    Crankcase Breather System .............. 5.40 - 1
    Breather Regulator .................... 5.40 - 2 Crankshaft Removal .................... 2.05 - 20
    Components .......................... 5.40 - 1 Crankshaft Web Deflection Measurement ... 4.10 - 4
    Description ........................... 5.40 - 1 Cylinder Head Assembly ................ 3.00 - 19
    Oil Separators(s) ...................... 5.40 - 1 Intake And Exhaust Valve Installation ... 3.00 - 23
    Separator Screen ...................... 5.40 - 1 Plug Installation ...................... 3.00 - 20
    Vacuum Valve/Choke Valve ............. 5.40 - 1 Valve Guide Installation ............... 3.00 - 19
    Venturi - GSI ......................... 5.40 - 2 Valve Seat Grinding ................... 3.00 - 21
    Venturi Extractor - GSI/GL ............. 5.40 - 2 Valve Seat Insert Installation ........... 3.00 - 20
    Crankcase Inspection .................... 3.05 - 1 Valve Seat Lapping ................... 3.00 - 22
    Camshaft Bearing Bore Inspection ....... 3.05 - 9 Cylinder Head Disassembly ............... 3.00 - 1
    Cleaning And Inspection ................ 3.05 - 1 Cleaning And Inspection ............... 3.00 - 10
    Lower Bore Restoration ................ 3.05 - 3 Intake And Exhaust Valves
    Lower Sleeve Bore And Sleeve Assembly ........................... 3.00 - 8
    Projection Inspection ............... 3.05 - 3
    Removal ............................ 3.00 - 8
    Main Bearing Bore Cleaning And Lower Deck Recondition ............... 3.00 - 14
    Inspection ......................... 3.05 - 5
    MagnafluX® .......................... 3.00 - 13
    Main Bearing Running Clearance ........ 3.05 - 6
    Pressure Testing ..................... 3.00 - 12
    Crankcase Pressure Measurement ........ 5.40 - 3 Rocker Arms .......................... 3.00 - 1
    Pressure Adjustment Assembly ........................... 3.00 - 3
    (Venturi ExtractorNacuum Valve
    Equipped) - GSI/GL ................ 5.40 - 4 Cleaning And Inspection .............. 3.00 - 2
    Pressure Adjustment - G/GSI Disassembly ........................ 3.00 - 1
    (Venturi Equipped) ................. 5.40 - 3 Valve Failure Analysis ................. 3.00 - 14
    Pressure Measurement - G/GSI/GL ..... 5.40 - 3 Valve Seat Insert And Valve Guide
    Removal .......................... 3.00 - 9
    Crankcase Pressure Relief Valves ........ 5.40 - 16
    Assembly ............................ 5.40 - 17 Cylinder Head Installation ................ 4.05 - 1
    Cylinder Head Torquing Procedure ....... 4.05 - 3
    Cleaning And Inspection ............... 5.40 - 17
    Exhaust Manifolds Installation ........... 4.05 - 5
    Exercise ............................. 5.40 - 16
    Removal ............................ 5.40 - 16 Cylinder Head Removal .................. 2.00 - 1
    Crankcase Separator Screen ............. 5.40 - 6 Cylinder Sleeve ........................ 3.05 - 42
    Assembly ............................. 5.40 - 6 Cleaning And Inspection ............... 3.05 - 43
    Cleaning And Inspection ................ 5.40 - 6 Deglazing ........................... 3.05 - 47
    Removal ............................. 5.40 - 6 Disassembly ......................... 3.05 - 42
    Crankcase Vee Pipe Connection Cylinder Sleeve Removal ................. 2.05 - 4
    Installation ......................... 5.25 - 73
    Crankcase Water Inlet Elbows ...........
    Installation - Left Bank ................
    5.25 -
    5.25 -
    24
    25 o
    Installation - Right Bank ............... 5.25 - 25 Detonation Sensing Module .............. 6.05 - 10
    ) Removal - Left Bank .................. 5.25 - 24 Default Timing Value .................. 6.05 - 11
    Removal - Right Bank ................ 5.25 - 25 DSM Troubleshooting ................. 6.05 - 14
    Crankshaft ............................. 3.05 - 9 Operation ........................... 6.05 - 11
    Cleaning And Inspection ................ 3.05 - 9 User Interface ........................ 6.05 - 13
    FORM 6248 First Edition A-3
    APPENDIX A

    E Components ..........................
    Description ...........................
    5.35
    5.35
    -
    -
    1
    1 )
    Electric Starter ......................... 5.45 - 26 Specifications .... . . . . . . . . . . . . . . . . . . . . . 5.35 - 2
    Installation ........................... 5.45 - 26 Temperature Check .................... 5.35 - 2
    Removal ............................ 5.45 - 26
    Engine Altitude Adjustments ............. 5.35 - 32 F
    Engine Identification Views ............... 1.15 - 4 Flywheel .............................. 3.05 - 48
    Left Side View ......................... 1.15 - 5 Ring Gear Removal ................... 3.05 - 48
    Rear View ............................ 1.15 - 6 Ring Gear Replacement ............... 3.05 - 48
    Right Side View ....................... 1.15 - 4
    Flywheel Removal ...................... 2.05 - 16
    Engine Protection Systems ............... 6.05 - 1
    Front Gear Cover Removal ............... 2.05 - 7
    "K" Type Thermocouples ............... 6.05 - 1
    Alarm And Shutdown Setpoints .......... 6.05 - 7 Front Gear Housing Removal ............ 2.05 - 11
    Components .......................... 6.05 - 1 Fuel System Components ................ 5.05 - 1
    Customer Supplied Control Switches ..... 6.05 - 6 Carburetors ........................... 5.05 - 5
    Engine Gauge Panel Components ....... 6.05 - 8 Main Fuel Gas Pressure Regulators ...... 5.05 - 1
    Manual Shutdown Swttches ............. 6.05 - 6 Operation Of The Fisher 99 Main Fuel
    Pressure and Temperature Switches Gas Pressure Regulator ............ 5.05 - 4
    Calibration ........................ 6.05 - 6 Pilot Operated Prechamber Gas
    Remote Panel Components ............. 6.05 - 9 Valve - GL ........................ 5.05 - 5
    Thermocouple Junction Box ............. 6.05 - 6 Prechamber Gas Safety Shutdown
    Valve - GL ........................ 5.05 - 5
    Engine Rating Standards ................ 1.15 - 10 Prechamber Manifolds - GL ............ 5.05 - 6
    Component Weights .................. 1.15 - 10 Prechamber Regulator - GL ............ 5.05 - 5
    Engine Removal ........................ 1.15 - 2 Fuel System Maintenance ............... 5.05 - 33
    Engine Rigging And Lifting ................ 1.10 - 1 Fisher 99 Regulator Filter Cleaning And
    Correct Method ....................... 1.10 - 1
    Location OfThe Lifting Eyes ............ 1.10 - 1
    Inspection ........................ 5.05 - 33
    )
    Engine Storage ......................... 7.10 - 5 G
    Preservation Equipment And Material .... 7.10 - 5
    General Information Main Points .......... 1.15 - 1
    Engine Storage - New ................... 7.10 - 7
    Non-Operational Engines ............... 7.10 - 7 Governor - Woodward EG-3P Electric .... 5.00 - 32
    Assembly ............................ 5.00 - 34
    Operational Engines ................... 7.10 - 7
    Cleaning And Inspection ............... 5.00 - 33
    External Component Protection ........ 7.10 - 7 Disassembly ......................... 5.00 - 33
    Internal Component Protection ........ 7.10 - 7 Drive Assembly ...................... 5.00 - 36
    Engine Storage - Used .................. 7.10 - 8 Drive Cleaning And Inspection .......... 5.00 - 36
    Non-Operational Engines ............... 7.10 - 8 Drive Disassembly .................... 5.00 - 35
    Operational Engines ................... 7.10 - 8 Drive Installation ...................... 5.00 - 36
    Engines - Return To Service After Storage .7.10 - 8 Drive Removal ....................... 5.00 - 34
    Installation ........................... 5.00 - 37
    Engine Timing Data ..................... 1.20 - 29 Linkage Cleaning And Inspection ....... 5.00 - 38
    English Metric Conversions .............. 1.15 - 17 Linkage Installation And Adjustment ..... 5.00 - 39
    Exhaust Connections Linkage Removal ..................... 5.00 - 32
    Installation - G ....................... 5.35 - 14 Removal ............................ 5.00 - 33
    Installation - GSI/GL .................. 5.35 - 15 Governor - Woodward UG-8 (Dial) ....... 5.00 - 25
    Removal- GSI/GL ................... 5.35 - 14 Assembly ............................ 5.00 - 27
    Compensation Adjustment ............. 5.00 - 29
    Exhaust Connections ................... 5.35 - 13
    Disassembly ......................... 5.00 - 27
    Removal - G ......................... 5.35 - 13
    Droop Adjustment .................... 5.00 - 31
    Exhaust Manifold ........................ 5.35 - 3 High/Low Speed Adjustment ........... 5.00 - 30
    Assembly ............................. 5.35 - 5 Installation ........................... 5.00 - 27
    Disassembly .......................... 5.35 - 5 Linkage Installation And Adjustment ..... 5.00 - 27
    Installation ............................ 5.35 - 6 Linkage Removal ..................... 5.00 - 25
    Removal ............................. 5.35 - 3 Removal ............................ 5.00 - 26
    Exhaust System ......................... 5.35 - 1 Governor - Woodward UG-8L ........... 5.00 - 16
    Backpressure Measurement ............ 5.35 - 2 Assembly ............................ 5.00 - 17
    A-4 FORM 6248 First Edition
    APPENDIX A

    Compensation Adjustment ............. 5.00 - 22 Idler Pulley Bearing Lubrication ......... 5.25 - 17
    Disassembly ......................... 5.00 - 17 Grease Recommendations .............. 5.25 - 17
    Droop Adjustment .................... 5.00 - 24
    High/Low Speed Limit Adjustment ...... 5.00 - 24
    Installation ........................... 5.00 - 18
    Linkage Installation And Adjustment ..... 5.00 - 19 H
    Linkage Removal ..................... 5.00 - 16
    Removal ............................ 5.00 - 17 Handling And Shipping ................... 1.15 - 1
    Hour Meter ............................ 5.00 - 45
    Governor Drive Gear/CEC Timing Disc
    Removal ............................ 5.00 - 45
    (Current Production) ................ 5.10 - 20
    CEC Ignition Timing Adjustment ........ 5.10 - 25
    Cleaning And Inspection ............... 5.10 - 20
    Ignition Module Static Timing ........... 5.10 - 22 I
    Ignition Timing Adjustment ............. 5.10 - 24
    Installation ........................... 5.10 - 21 Idler Gear Removal ..................... 2.05 - 10
    Removal ............................ 5.10 - 20 Idler Pulley Bracket ..................... 5.25 - 39
    Setting Air Gap Specification Assembly ............................ 5.25 - 41
    (Current And Previous Production) .. 5.10 - 24 Cleaning And Inspection ............... 5.25 - 41
    Governor Drive Gear/CEC Timing Disc Disassembly ......................... 5.25 - 39
    (Previous Production) ............... 5.10 - 26 Installation ........................... 5.25 - 43
    Cleaning And Inspection ............... 5.10 - 26 Removal ............................ 5.25 - 39
    Dual Fuel ............................ 5.10 - 30 Ignition Coils ........................... 5.10 - 11
    Ignition Timing Adjustment ............. 5.10 - 28
    Ignition System Components .............. 5.10 - 1
    Installation ........................... 5.10 - 27
    CEC Ignition Module ................... 5.10 - 1
    Removal ............................ 5.10 - 26
    Ignition Coils .......................... 5.10 - 1
    Steps Required ....................... 5.10 - 30
    Magneto ............................. 5.10 - 1
    Governor Drive Gear/CEC Timing Disc Spark Plugs .......................... 5.1 0 - 1
    RemovaVlnstaliation .................. 5.00 - 3 Wiring Harness ........................ 5.10 - 1
    Assembly (Previous Production) ......... 5.00 - 7 In-Line Lubricator ...................... 5.30 - 26
    Cleaning And Inspection
    (Current Production) ................ 5.00 - 4 Index Of Sealants Adhesives And
    Cleaning And Inspection Lubricants ......................... 1.15 - 18
    (Previous Production) ............... 5.00 - 7 Inspection - Routine ..................... 7.10 - 4
    Disassembly (Previous Production) ...... 5.00 - 7
    Intake Manifold Flange Attachments ...... 5.15 - 16
    Installation (Current Production) ......... 5.00 - 4
    Intake Manifold Flange
    Installation (Previous Production) ........ 5.00 - 8
    Attachments - G/GSI .............. 5.15 - 16
    Removal (Current Production) ........... 5.00 - 3
    Removal (Previous Production) .......... 5.00 - 6 Left Bank .......................... 5.15 - 16
    Right Bank ......................... 5.15 - 17
    Governor Drive Housing ................. 5.00 - 13 Intake Manifold Flange
    Assembly ............................ 5.00 - 14 Attachments - GL ................. 5.15 - 20
    Cleaning And Inspection ............... 5.00 - 13 Left Bank .......................... 5.15 - 20
    Disassembly ......................... 5.00 - 13
    Right Bank ......................... 5.15 - 20
    Installation ........................... 5.00 - 14
    Removal ............................ 5.00 - 13 Intake Manifolds ........................ 5.15 - 14
    Installation - G/GSI ................... 5.15 - 15
    Governor Drive Shaft ................... 5.00 - 10 Installation - GL ...................... 5.15 - 19
    Assembly ............................ 5.00 - 11 Removal - G/GSI ..................... 5.15 - 14
    Cleaning And Inspection ............... 5.00 - 11 Removal- GL ....................... 5.15 - 18
    Disassembly ......................... 5.00 - 10
    Intercooler ............................. 5.25 - 60
    Installation ........................... 5.00 - 12
    Assembly ............................ 5.25 - 68
    ) Removal ............................ 5.00 - 10
    Cleaning And Inspection ............... 5.25 - 67
    Grease Fittings ........................ 5.25 - 17 Disassembly ......................... 5.25 - 66
    Auxiliary Water Pump Bearings Installation ........................... 5.25 - 71
    Lubrication ....................... 5.25 - 17 Removal ............................ 5.25 - 60
    FORM 6248 First Edition A-5
    APPENDIX A

    Lube Oil System Air Bleed ............... 5.30 - 13


    J )
    Lube Oil Temperature Control Valve ....... 5.30 - 21
    Jacket Water - Initial Fill ................ 5.25 - 12 Lubrication System Components .......... 5.30 - 1
    Jacket Water And Auxiliary Cooling Description ........................... 5.30 - 1
    Water Circuits Drain And Flush ....... 5.25 - 14 Internal Oil Control ..................... 5.30 - 3
    Jacket Water Heater ..................... 6.10 - 5
    Cleaning And Inspection ................ 6.10 - 6
    Installation ............................ 6.10 - 6 M
    Removal ............................. 6.10 - 5 Magnetic Plugs ........................ 5.30 - 16
    Jacket Water Pump ..................... 5.25 - 44 Magneto .............................. 5.1 0 - 30
    Assembly ............................ 5.25 - 47 Magneto Disc Coupling Replacement ... 5.10 - 30
    Cleaning And Inspection ............... 5.25 - 46 Magneto Ignition Timing Adjustment ..... 5.10 - 37
    Disassembly ......................... 5.25 - 45 Magneto Static Timing Adjustment ...... 5.10 - 32
    Installation ........................... 5.25 - 54 Magneto Adapter ....................... 5.10 - 39
    Removal ............................ 5.25 - 44 Assembly ............................ 5.10 - 40
    Jacket Water Pump Seal Inspection ....... 5.25 - 23 Cleaning And Inspection ............... 5.10 - 40
    Disassembly ......................... 5.10 - 39
    Magneto Drive ......................... 5.1 0 - 42
    L Assembly ............................ 5.10 - 43
    Disassembly ......................... 5.10 - 42
    Low Ambient Temperature Operation ....... 5.30 - 9
    Magneto Drive Gear Removal ............. 2.05 - 9
    Lower/Upper Bypass Tubes And Water Main Fuel Gas Regulator ................ 5.05 - 25
    Bypass Elbows ..................... 5.25 - 28 Left Bank Installation .................. 5.05 - 28
    Installation ........................... 5.25 - 29 Removal ............................ 5.05 - 25
    Removal ............................ 5.25 - 28
    Lube Oil Analysis ........................ 5.30 - 8
    Right Bank Installation ................ 5.05 - 25
    )
    Maintenance - Routine ................... 7.10 - 1
    Lube Oil Change ....................... 5.30 - 12 Manual Shutdown Lever ................. 5.00 - 41
    Lube Oil Condemning Limits .............. 5.30 - 6 Adjustment - GL ..................... 5.00 - 41
    Installation - G/GSI ................... 5.00 - 43
    Lube Oil Consumption Rates .............. 5.30 - 9
    Lever Adjustment - G/GSI ............. 5.00 - 43
    Oil Consumption Rate Formulas ......... 5.30 - 9
    Removal - G/GSI ..................... 5.00 - 43
    Lube Oil Filter Element Replacement ...... 5.30 - 13 Miscellaneous Equipment ................ 6.10 - 1
    Lube Oil FiHer Relief Valve Inspection ..... 5.30 - 15 Components .......................... 6.1 0 - 1
    Lube Oil Piping Purge ................... 5.30 - 11
    Lube Oil Pressure Adjustment ............ 5.30 - 24
    Lube Oil Pressure Gauge Tubes And
    o
    Fittings ............................ 5.45 - 14 Oil Cooler And Lube Oil FiHer Installation .. 5.30 - 12
    Installation ........................... 5.45 - 14 Oil Cooler Cleaning And Inspection ....... 5.30 - 19
    Removal ............................ 5.45 - 14 Oil Cooler Installation ................... 5.30 - 19
    Lube Oil Pressure/Governor Oil Tubes Oil Cooler Maintenance ................. 5.30 - 13
    Connection ........................ 5.30 - 44
    Oil Cooler Piping Installation ............. 5.30 - 18
    Lube Oil Pump ......................... 5.30 - 29 Oil Cooler Piping Removal ............... 5.30 - 16
    Assembly ............................ 5.30 - 32
    Cleaning And Inspection ............... 5.30 - 31 Oil Cooler Removal ..................... 5.30 - 18
    Disassembly ......................... 5.30 - 29 Oil Designations ......................... 5.30 - 4
    Installation ........................... 5.30 - 37 Oil Filler Pipe Removal .................. 5.30 - 41
    Removal ............................ 5.30 - 29 Installation ........................... 5.30 - 41
    Lube Oil Specifications ................... 5.30 - 4 Removal ............................ 5.30 - 41
    Lube Oil Strainer ....................... 5.30 - 46 Oil Pan Clean And Inspect ............... 5.30 - 28
    Cleaning And Inspection ............... 5.30 - 47 Oil Pan Doors .......................... 5.30 - 45
    Installation ........................... 5.30 - 47 Installation ........................... 5.30 - 46
    Removal ............................ 5.30 - 46 Removal ............................ 5.30 - 45
    A-6 FORM 6248 First Edition
    APPENDIX A

    Oil Pan Removal ......•................ 2.05 - 19 Prechamber Regulator (Fisher 95L) - GL .. 5.05 - 29
    Oil Pickup Screen ...................... 5.30 - 28 Installation ........................... 5.05 - 30
    Cleaning And Inspection ............... 5.30 - 29 Removal ............................ 5.05 - 29
    Installation ........................... 5.30 - 29 Prelube Pressure Maintenance ........... 5.30 - 25
    Removal ............................ 5.30 - 28 Prelube Pressure Maintenance/Check
    Oil Pickup Screen Removal .............. 2.05 - 18 Valve Inspection .................... 5.20 - 12
    Prelube Pump/Motor And Connections .... 5.45 - 12
    Oil Recommendations ................... 5.30 - 4
    Installation ........................... 5.45 - 13
    Oil Separators Removal ............................ 5.45 - 12
    Cleaning And Inspection - GSI/GL ....... 5.40 - 9
    Prelube System ........................ 5.30 - 24
    Installation - G ........................ 5.40 - 8
    Installation - GSI/GL ................... 5.40 - 9 Prelube Y -Strainer ..................... 5.30 - 40
    Removal - G .......................... 5.40 - 7 Cleaning And Inspection ............... 5.30 - 40
    Removal - GSI/GL .................... 5.40 - 8 Installation ........................... 5.30 - 40
    Removal ............................ 5.30 - 40
    Oil Viscosity Selection ................... 5.30 - 9
    Prelube/Start System Removal/Installation .. 5.45 - 9
    MuHi-Viscosity Oils .................... 5.30 - 9
    Bulkhead Bracket Installation ............ 5.45 - 9
    Synthetic Oils ......................... 5.30 - 9
    Bulkhead Bracket Removal ............. 5.45 - 9
    Overhaul/Repair Process ................. 1.15 - 1 Pilot Operated Prelube
    Overspeed Governor ................... 5.00 - 43 Valve Installation . . . . . . . . . . . . . . . . . . 5.45 - 11
    Adjustment .......................... 5.00 - 44 Pilot Operated Prelube Valve Removal .. 5.45 - 10
    Installation ........................... 5.00 - 44 Preventing Engine Damage ............... 1.15 - 1
    Removal ............................ 5.00 - 43

    R
    p Recommended Oil Change Intervals ...... 5.30 - 10
    ) Piston ................................ 3.05 - 17
    Rocker Arm Oil Header Oil Inlet
    Tubes/Fittings ...................... 5.30 - 42
    Piston Assembly ....................... 3.05 - 27 Installation ........................... 5.30 - 42
    Piston Cleaning And Inspection .......... 3.05 - 18 Rocker Arm Oil Header Removal ......... 2.05 - 12
    Piston Disassembly ..................... 3.05 - 17
    Piston Pin Cleaning And Inspection ....... 3.05 - 32
    Piston Ring Assembly
    s
    Safety Guards ......................... 5.25 - 56
    8-1/2 Inch Bore G/GSIfGL Installation ........................... 5.25 - 57
    (4 Ring Piston) ................... 3.05 - 27 Removal ............................ 5.25 - 56
    9-3/8 Inch Bore G/GSI (4 Ring Piston) ... 3.05 - 29
    Safety Introduction ...................... 1.05 - 1
    9-3/8 Inch Bore GL (4 Ring Piston) ...... 3.05 - 30
    Acids ................................ 1.05 - 2
    9-3/8 Inch Bore GL (3 Ring Piston) -
    Current Production ................ 3.05 - 31 Batteries ............................. 1.05 - 2
    Body Protection ....................... 1.05 - 2
    Piston Ring Inspection .................. 3.05 - 23 Chemicals ............................ 1.05 - 2
    Piston/Connecting Rod Removal .......... 2.05 - 1 Cleaning Solvents ................... 1.05 - 2
    Prechamber Cup - GL .................. 5.05 - 21 General ............................ 1.05 - 2
    Cleaning And Inspection ............... 5.05 - 22 Liquid Nitrogen/Dry Ice ............... 1.05 - 2
    Installation ........................... 5.05 - 22 Components .......................... 1.05 - 2
    Removal ............................ 5.05 - 21 Heated Or Frozen ................... 1.05 - 2
    Prechamber Gas Valves - GL ............ 5.45 - 19 Interference Fit ...................... 1.05 - 2
    COOling System ....................... 1.05 - 2
    Installation ........................... 5.45 - 22
    Electrical ............................. 1.05 - 3
    Removal ............................ 5.45 - 19
    General ............................ 1.05 - 3
    Prechamber Manifold - GL .............. 5.05 - 23 Ignition ............................. 1.05 - 3
    Installation ........................... 5.05 - 24 Equipment Repair And Service .......... 1.05 - 1
    ) Removal ............................ 5.05 - 23 Exhaust .............................. 1.05 - 3
    Prechamber Manifold Cross Pipe - GL ..... 5.05 - 9 Fire Protection ........................ 1.05 - 3
    Installation ........................... 5.05 - 10 Fuels ................................ 1.05-3
    Removal ............................. 5.05 - 9 Gaseous ........................... 1.05 - 3
    FORM 6248 First Ednion A-7
    APPENDIX A

    General ............................ 1.05 - 3


    Liquid .............................. 1.05 - 3
    T
    Intoxicants And Narcotics ............... 1.05 - 4 Thermocouples ........................ 5.35 - 16
    Pressurized Fluids/Gas/Air .............. 1.05 - 4 Cleaning And Inspection ............... 5.35 - 19
    Protective Guards ..................... 1.05 - 4 Exhaust Installation ................... 5.35 - 18
    Replacement. ........................ 5.35 - 16
    Safety Tags And Decals ................ 1.05 - 1
    Sodium Cooled Valve .................. 1.05 - 4 Torque Specifications ................... 1.15 - 12
    Springs .............................. 1.05 - 4 Connecting Rod Capscrew Torquing
    Procedure (P/N Series 205407 And
    Tools ................................. 1.05 - 4
    205507) ......................... 1.15 - 14
    Electrical ........................... 1.05 - 4 Critical Engine Torque Values .......... 1.15 - 13
    Hydraulic ........................... 1.05 - 4 Cylinder Head Torquing Procedure ...... 1.15 - 14
    General Torque Recommendations ..... 1.15 - 16
    Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 4
    General Torquing Sequence Procedure .. 1.15 - 12
    Weight ............................... 1.05 - 5
    Main Bearing Cap Torquing Procedure .. 1.15 - 15
    Welding .............................. 1.05 - 5 Thread Lubrication For
    General ............................ 1.05 - 5 Torque Fasteners ................. 1.15 - 12
    On Engine .......................... 1.05 - 5 Troubleshooting ......................... 7.00 - 1
    Troubleshooting Low Lube Oil Pressure ... 5.30 - 24
    Serial Number And Engine Data Plate ...... 1.15 - 3
    Tube Clips And Clamps Installation ....... 5.45 - 17
    Service Tools List ........................ 1.15 - 8 Turbo Exhaust Inlet Elbows .............. 5.35 - 10
    Sour Gas & Alternate Fuel Gas Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 - 11
    Recommendations ................... 5.30 - 5 Removal ............................ 5.35 - 10
    Fuel Coalescer Recommendations ....... 5.30 - 6 Turbo Oil Supply/Drain Tubes ............ 5.30 - 43
    Recommended Lube Oils ............... 5.30 - 5 Installation ........................... 5.30 - 43
    Spark Plugs ............................ 5.10 - 1 Turbochargers .......................... 5.20 - 1
    Carrier Installation - GL ................ 5.1 0 - 3
    Cleaning And Inspection ................ 5.20 - 3
    Installation ............................ 5.20 - 8
    )
    Carrier Installation - CSA ............... 5.10 - 4
    Removal ............................. 5.20 - 1
    Carrier Removal - CSA ................ 5.10 - 3
    Carrier Removal - GL . . . . . . . . . . . . . . . . . . 5.10 - 1
    Extension Repair ..................... 5.10 - 10
    Inspection ............................ 5.10 - 7
    v
    Valve Adjustment Procedure .............. 4.10 - 1
    Installation ............................ 5.10 - 8
    Valve Lifter Housing Removal ............ 2.05 - 13
    Removal ............................. 5.10 - 5
    Valve Lifters ........................... 3.05 - 15
    Specifications ........................... 1.20 - 1 Hydraulic Lifters ...................... 3.05 - 16
    Gear Tooth Wear - General ............. 1.20 - 1 Roller Type Lifters .................... 3.05 - 15
    Timing Gears ......................... 1.20 - 1 Venturi - GSI .......................... 5.40 - 12
    Cleaning And Inspection ............... 5.40 - 12
    Speed Governing System Components ..... 5.00 - 1
    Installation ........................... 5.40 - 12
    Speed Governing System Description . . . . . . 5.00 - 1 Removal ............................ 5.40 - 12
    Control Panel ......................... 5.00 - 2 Venturi Extractor - GSI/GL .............. 5.40 - 12
    Governor Linkages .................... 5.00 - 2 Assembly ............................ 5.40 - 15
    Magnetic Pickup ....................... 5.00 - 2 Cleaning And Inspection ............... 5.40 - 14
    Overspeed Governor ................... 5.00 - 2 Removal ............................ 5.40 - 12
    Woodward EG-3P Electronic Governor ... 5.00 - 1 Venturi Extractor Compressor
    Woodward UG-8 Dial Governor ......... 5.00 - 1 Discharge Tubes .................... 5.40 - 22
    Woodward UG-8L Governor ............ 5.00 - 1 Installation ........................... 5.40 - 23
    Removal ............................ 5.40 - 22
    Split Ring Washer Usability Criteria ....... 1.15 - 19
    Vibration Damper Removal ............... 2.05 - 5
    Surge Tank ............................. 6.10 - 2
    Assembly .............................
    Cleaning And Inspection ................
    6.10
    6.10
    -
    -
    4
    4
    w
    Disassembly .......................... 6.10 - 3 Warning Tags And Decal Locations ........ 1.00 - 1
    Installation ............................ 6.10 - 4 Wastegates ............................ 5.35 - 20
    Removal ............................. 6.10 - 2 Bleeding Air .......................... 5.35 - 20
    A-B FORM 6248 First Edition
    APPENDIX A

    Wastegates - PIN Series 208372 ......... 5.35 - 20 Removal ............................ 5.25 - 31


    Assembly ............................ 5.35 - 24 Water Pump Inlet Elbows And
    Calibration ........................... 5.35 - 25 Water Header ...................... 5.25 - 26
    Cleaning And Inspection ............... 5.35 - 23 Installation ........................... 5.25 - 27
    Disassembly ......................... 5.35 - 21 Removal ............................ 5.25 - 26
    Removal ............................ 5.35 - 20
    Waukesha Cogeneration Installations ...... 5.30 - 5
    Wastegates - PIN Series 295645
    (Draw Thru Only) ................... 5.35 - 28 Waukesha Engine Preservative Oil ........ 7.10 - 5
    Calibration Procedure Test ............. 5.35 - 30 Preservative Oil Usage . . . . . . . . . . . . . . . . . 7.10 - 5
    Calibration Setup ..................... 5.35 - 29 Use Of Other Preservative Oils And
    Disassembly ......................... 5.35 - 29 Materials .......................... 7.10 - 6
    Installation ........................... 5.35 - 31 Wiring Harness ........................ 5.10 - 13
    Removal ............................ 5.35 - 28 Inspection ........................... 5.10 - 14
    Water Manifold ......................... 5.25 - 31 Installation ........................... 5.10 - 15
    Installation ........................... 5.25 - 32 Removal ............................ 5.10-13

    FORM 6248 First Edition A-9


    APPENDIX A

    A-l0 FORM 6248 First Edition


    WAUKESHA ENGINE, DRESSER INC. - EXPRESS LIMITED WARRANTY COVERING
    PRODUCTS USED IN CONTINUOUS DUTY APPLICATIONS
    INTRODUCTION

    jCONTINUOUS DUTY DEFINITION: The highest load and speed which can be applied, subject to Waukesha's approved ratings in effect at time of sale.

    I. TERMS OF EXPRESS LIMITED WARRANTY


    A. Waukesha Engine warrants that it will repair or replace, AT ITS ELECTION AND EXPENSE, any Genuine Waukesha Service Part installed on an engine. or
    Enginator®, or product (hereinafter referred to as "Products-) manufactured by Waukesha, which proves to have had a defect in material or workmanship.
    B. Waukesha Engine further warrants that it will repair or replace, AT ITS ELECTION AND EXPENSE, any component of the Waukesha Product damaged as the direct
    result of a warrantable defect in a Product during the tenn of coverage.

    II. T1ERM LIMITATIONS OF EXPRESS LlMITlED WARRANTY


    A. This coverage shall commence upon initial new Products start-up date and shall expire upon the earlier of the following:
    1. 12 months after the initial new Products start~up date; or
    2. 24 months after the original shipment date of the covered Products by Waukesha Engine.
    B. Notwithstanding the foregoing, Waukesha further warrants that the cylinder block casting, cylinder head castings, connecting rod forgings, and crankshaft forging will
    be free from defects in material or workmanship. This additional warranty only covers failures of the specific items noted within this subparagraph.
    This coverage shall expire upon the earlier of the following:
    1. 60 months after the Initial new Products start·up date; or
    2. 25,000 hours of operation of the covered Products; or
    3. 72 months after the original shipment date of the covered Products by Waukesha Engine.
    NOTE: No damage from other sources, such as damage from the loss of a crankshaft bearing, shall be considered as a forging defect.

    III. WAUKESHA'S RESPONSIBILITIES UNDER THE EXPRESS LIMITED WARRANTY


    Waukesha shall be responsible for:
    A. The repair or replacement, at Waukesha's election, of covered defective parts and all reasonable labor required regarding a warranted failure during the express
    limited warranty term. All such labor shall be provided by Waukesha's authorized contractor or distributor.
    B. Reasonable and necessary travel and expenses incurred by Waukesha's authorized contractor or distributor.
    C. Replacement of lubricating oil, coolant. filter elements, or other normal maintenance items that are contaminated and/or damaged as a direct result of a warranted
    failure.

    IV. OWNER'S RESPONSIBILITIES UNDER THE EXPRESS LlMITlED WARRANTY


    Owner shall be responsible for:
    A. The operation and maintenance of the Products within the guidelines established by Waukesha.
    B. Making the Products available to Waukesha or Waukesha's authorized contractors or distribu~tors for any warranty repair, during normal business hours.
    C. All additional costs incurred for premium or overtime labor, should owner request that repairs be made on a premium or overtime schedule.
    D. All costs incurred as the result of removal or reinstallation of the Products as may be required to effect any warranted repair.
    E. All administrative costs and expenses resulting from a warranted failure.
    F. Any costs of transportation, towing, repair facilities, or associated costs.
    G. All labor, travel, mileage, and other related costs and expenses associated with a claim made pursuant to subparagraph II (8) above.
    H. Loss of revenue and loss oflor damage to real and/or personal property.

    LIMITATION OF WAUKESHA'S OBLIGATIONS


    The obligations of Waukesha under this express limited warranty shall be waived and voided, and Waukesha shall not, thereafter, be responsible for:
    A. Any failure resulting from owner or operator abuse or neglect, including but not by way of limitation, any operation, installation, application, or maintenance practice
    not in accordance with guidelines or specifications established by Waukesha; or
    B. Any failure resuhing from unauthorized modifications or repairs of the Products; or
    C. Any failure resuhing from overload, overspeed, overheat, accident, improper storage; or
    D. Failure of owner to promptly provide notice of a claimed defect; or
    E. Failure of Products for which Waukesha did not receive properly completed start·up reports; or
    F. Repairs of a covered failure perfonned with non~genuine Waukesha parts; or
    G. Repairs of a covered failure perlonned by non-authorized contractors or distributors; or
    H. Failure to make Products available to Waukesha or its authorized representatives; or
    I. Failure to supply documents such as drawings and specifications relating to the specific application of the Products.

    VI. APPLICABILITY AND EXPIRATION


    The warranties set out above are extended to all owners in the original chain of distribution. The warranties and obligations of Waukesha shall expire and be of no further
    effect upon the dates of eXpiration of the applicable warranty periods.

    THE FOREGOING SETS FORTH WAUKESHA'S ONLY OBLIGATIONS AND OWNERS'EXCLUSIVE REMEDY FOR BREACH OF WARRANTY, WHETHER SUCH
    CLAIMS ARE BASEDON BREACH OF CONTRACT. TORT (INCLUDING NEGUGENCE AND STRICT LlABILITY),OR OTHER THEORIES, AND THE FOREGOING IS
    EXPRESSLY IN LIEU OF OTHER WARRANTIES WHATSOEVER EXPRESSED. IMPLIED. AND STATUTORY, INCLUDING WITHOUT LIMITATION, THE IMPLIED
    WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

    Notwithstanding the preceding, In no event shall Waukesha be liable for any direct, special, incidental, or consequential damages (whether denominated in
    contract, tort strict liability, negligence, or other theories) arising out of this Agreement or the use of any Products provided under this Agreement

    Any action arlslng hereunder or relating hereto, whether baeed on breach of contract, tort (Including negligence and strict liability), or other theories must be
    commenced within two (2) years after the cause of action accrues or it shall be barred.

    BINDING ARBITRATION
    (a) Buyer and Seller shall attempt, in good faith, to resolve any dispute arising out of or relating to this agreement, or the products andlor services provided
    hereunder, promptly by negotiation between executives. If the matter has not been resolved within sixty (60) days of a party's request for negotiation,
    either party may initiate arbitration as herein after provided.
    (b) Any dispute arising out of or related to this agreement or the products anellor services provided hereunder which has not been resolved by the
    negotiation procedure described above, shall be settled by binding arbitration administered by the American Arbltratton Association in accordance with
    its Commercial Arbitration Rules and judgment on the award rendered by the arbitrator(s) may be entered in any court having Jurisdiction thereof.
    (c) Unless Buyer and Seller otherwise agree in writing, the arbitration panel shall coneist of three arbitrators. The arbhrator(8) shall have no authority to
    award punitive or other damages not measured by the prevailing party's actual damages and may not, in any ewnt, make any ruling, finding or award that
    does not conform to the terms and condl..f:1on 01 this agreement The law of Texas shall govern.
    )
    ,,(d) The arbhration proceeding shall be conducted in English. in Dallas, Texas.

    See form M464 for the most current warranty terms. EffectIve February 22, 2006

    W-l
    WAUKESHA ENGINE, DRESSER, INC. EXPRESS LIMITED WARRANTY
    FOR PRODUCTS OPERATED INEXCESS OF CONTINUOUS DUTY RATINGS

    INTRODUCTION
    This warranty only applies to engines which Waukesha Engine has approved to operate in excess of the continuous duty rating.
    APPLICATIONS COVERED BY THIS WARRANTY
    Standby Service Applications: This rating applies to those systems used as a secondary or backup source of electrical power. This rating is the output the system will
    produce continuously (no overload), 24 hours per day for the duration of the prime power source outage.
    Intermittent Service Applications: This rating is the highest load and speed that can be applied in variable speed mechanical system applications only (i.e., blowers, pumps,
    compressors, etc.). Operation at this rating is limited to a maximum of 3500 hours/year. For continuous operation tor any length of time between the continuous and
    intermittent ratings, see the Peak Shaving Application rating procedure.
    Peak Shaving Applications: The rating for a peak shaving application is based on the number of horsepower-hours available per year at site specific conditions. All
    applications using a peak shaving rating require a signed Special Application Approval (SAA) from Waukesha'S APplication Engineering Department.
    I. TERMS OF EXPRESS LIMITED WARRANTY
    A. Waukesha Engine warrants that it will repair or replace, AT ITS ELECTION AND EXPENSE, any Genuine Waukesha Service Part installed on an engine, or
    Enginatol®, or product (hereinafter referred to as ·Products") manufactured by Waukesha, which proves to have had a defect in material or workmanship.
    B. Waukesha Engine Division further warrants that it will repair or replace, AT ITS ELECTION AND EXPENSE, any component of the Waukesha Product damaged
    as the direct result of a warrantable defect in a Product during the term of coverage.
    II. TERM LIMITATIONS OF EXPRESS LIMITED WARRANTY
    A. .This coverage shall commence upon initial new Products start-up date and shall expire upon the earlier of the following:
    1. 60 months or 3500 hours, whichever occurs first, after the initial new Products start-up date; or
    2. 72 months after the original shipment date of the covered Products by Waukesha Engine.
    B. Notwithstanding the foregoing, Waukesha further warrants that the cylinder block casting, cylinder head castings, connecting rod forgings, and crankshaft
    forging will be free from defects in material or workmanship. This additional warranty only covers failure of the specific items noted within this subparagraph.
    This coverage shall expire upon the earlier of the following:
    1. 60 months after the initial new Products start-up date; or
    2. 25,000 hours of operation of the covered Products; or
    3. 2 months after the original shipment date of the covered Products by Waukesha Engine.
    NOTE: No damage from other sources, such liS damage from the loss of II crankshaft bearing. shillI be
    III. WAUKESHA'S RESPONSIBILInES UNDER THE EXPRESS UMITED WARRANTY
    Waukesha shall be responsible for:
    A. The repair or replacement, at Waukesha's election. of covered defective parts and all reasonable laborrequlred regarding a warranted failure during the express
    limited warranty term. All such labor shall be provided by Waukesha's authorized contractor or distributor.
    B. Reasonable and necessary travel and expenses incurred by Waukesha's authorized contractors or distributor.
    C. Replacement of lubricating oil, coolant, filter elements, or other normal maintenance items that arecontaminated and/or damaged as a direct result of a warranted
    failure.
    NOTWITHSTANDING THE FOREGOING, WAUKESHA SHALL NOT BE RESPONSIBLE FOR LABOR COSTS ASSOCIATED WITH WARRANTY CLAIMS BROUGHT
    PURSUANT TO SUBPARAGRAPH II (B).
    IY. OWNER·S RESPONSIBILITIES UNDER THE EXPRESS LIMITED WARRANTY
    Owner shall be responsible for:
    A. The operation of the product within the allowable HP-HRlYR rating granted by the specific SpecialApplication Approval for the product.
    B. The operation and maintenance of the Products within the guidelines established by Waukesha.
    C.
    D.
    Making the Products available to Waukesha or Waukesha's authorized contractors or distributors forany warranty repair, during normal busineSS hours.
    All additional costs incurred for premium or overtime labor, should owner request that repairs be made on a premium or overtime schedule. )
    E. All costs incurred as the result of removal or reinstallation of the Products as may be required to effectany warranted repair.
    F. All administrative costs and expenses resulting from a warranted failure.
    G. Any costs of transportation, tOWing, repair facilities, or associated costs.
    H. All labor, travel, mileage. and other related costs and expenses associated with a claim made pursuantto subparagraph II (8) above.
    I. Loss of revenue and loss oflor damage to real and/or personal property.
    V. LIMITATION OF WAUKESHA·S OBLIGATIONS
    The obligations of Waukesha under this express limited warranty shall be waived and voided, and Waukesha shall not, thereafter, be responsible for:
    A. Any failure resulting from owner or operator abuse or neglect, including but not by way of limitation, any operation, instatiation, application, or maintenance practice
    not in accordance with guidelines or specifications established by Waukesha; or
    B. Any failure resulting from unauthorized modifications or repairs of the Products: or
    C. Any failure resulting from overload, overspeed, overheat, accident, improper storage; or
    D. Failure of owner to promptly provide notice of a claimed defect; or
    E. Failure of Products for which Waukesha did not receive properly completed start-up reports; or
    F. Repairs of a covered failure performed with non-genuine Waukesha parts; or
    G. Repairs of a covered failure performed by non-authorized contractors or distributors; or
    H. Failure to make Products available to Waukesha or its authorized representatives; or
    1. Failure to supply documents such as drawings and specifications relating to the specific application of the Products.
    VI. APPLICABILITY AND EXPIRATION
    The warranties set out above are extended to all owners in the original chain of distribution. The warranties and obligations of Waukesha snail expire and be of no
    further effect upon the dates of expiration of the applicable warranty periods.
    THE FOREGOING SETS FORTH WAUKESHA·S ONLY OBLIGATIONS AND OWNERS· EXCLUSIVE REMEDY FOR BREACH OF WARRANTY. WHETHER SUCH
    CLAIMS ARE BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGUGENCE AND STRICT UABIUTY), OR OTHER THEORIES, AND THE FOREGOING IS
    EXPRESSLY IN LIEU OF OTHER WARRANTIES WHATSOEVER EXPRESSED, IMPLIED, AND STATUTORY, INCLUDING WITHOUT LIMITATION, THE IMPLIED
    WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

    Notwithstanding the preceding, in no event shall Waukesha be liable for any direct, special, incidental, or consequential damages (whether denominated in
    contract, tort strict liability, negligence, or other theories) arising out of this Agreement or the use of any Products provided under this Agreement

    Any action arising hereunder or relating hereto, whether based on breach of contract, tort including negligence and strict liability), or other theories must be
    commenced within two (2) years after the cause of action accrues or it shall be barred.

    BINDING ARBITRATION
    (a) Buyer and Seller shall attempt, in good faith, to resolve any dispute arising out of or relating to this agreement, or the products and/or services provided
    hereunder, promptly by negotiation between executives. If the matter has not been resolved within sixty (60) days of a party's request for negotiation, either
    party may initiate arbitration as herein after provided.
    (b) Any dispute ariSing out of or related to this agreement or the products and/or services provided hereunder which has not been resolved by the negotiation
    procedure described above, shall be settled by binding arbitration administered by the American Arbitration Association in accordance with its Commercial
    Arbtb'atlon Rules and judgment on the award rendered by the arbitrator(s) may be entered In any court having jurisdiction thereof.
    (c) Unless Buyer and Seller otherwise agree in writing, the arbitration panel shall consist of three arbitrators. The arbltrator(s) shall have no authority to award
    punitive or other damages not measured by the prevailing party's actual damages and may not, In any event, make any ruling. finding or award that does not
    conform to the terms and condition of this agreement The law of Texas shall govern.
    (d) The arbitration proceeding shall be conducted In English, in Dallas, Texas.
    See Form 467 for the most current warranty terms. Effectiw February 22, 2006

    W-2
    WAUKESHA ENGINE, DRESSER INC. - EXPRESS LIMITED WARRANTY FOR GENUINE WAUKESHA SERVICE PARTS AND
    WAUKESHA FACTORY REMANUFACTURED SERVICE PARTS USED IN A CERTIFIED OVERHAUL OF A WAUKESHA PRODUCT

    INTRODUcnON
    This warranty only applies to Genuine Waukesha Service Parts and Waukesha Factory Remanufactured Service Parts (to include assemblies and short blocks) (hereinafter
    referred to as 'Service Parts") sold by Waukesha Engine and used for a certified overhaul of Waukesha Product
    I. TERMS OF EXPRESS UMITED WARRANY
    A. Waukeshii.Engine warrants that it will repair or replace, AT ITS ELECTION AND EXPENSE, any Genuine Waukesha Service Part installed on an engine, or
    Enginato(6" or product (hereinafter referred to as 'Products") manufactured by Waukesha, which proves to have had a defect in material or workmanship.
    B. Waukesha Engine further warrants that it will repair or replace AT ITS ELECTION AND EXPENSE, any component of the Waukesha product damaged as the direct
    result of a warrantable defect in a Genuine Waukesha Service Part during the term of coverage.
    II. TERM UMITA110NS OF EXPRESS UMITED WARRANTY
    A. This coverage shall commence upon the initial start-up date of the overhauled Product and shall expire upon the earlier of the following:
    1. 12 months after the overhauled Product start-up date; or
    2. 24 months after the purchase date.
    B. Notwithstanding the foregoing, Waukesha further warrants that the intake valves, exhaust valves, intake valve seats, exhaust valve seats, Intake valve guides,
    exhaust valve guides, piston rings, cylinder liners, pistons, main bearings, and connecting rod bearings used in the certified overhaul will be free from defects in
    material or workmanship. This additional warranty term only covers failures of the specific items noted within this sub-paragraph.
    This coverage shall expire the earlier of the following:
    1. 18 months after the overhauled Product start-up date; or
    2. 24 months after the purchase date.
    III. WAUKESHA'S RESPONSIBILITIES UNDER THE EXPRESS LIMITED WARRANTY
    Waukesha shall be responsible for:
    A. The repair or replacement, at Waukesha's election, of covered defective Service Parts and progressive damage as explained in Paragraph 1B of this warranty.
    B. Labor time to repair or replace the defective part as established by the Waukesha Labor Guide Manual. All reimbursable labor costs shall be provided by
    Waukesha's authorized distributor.
    C. The reimbursement of documented Distributor expenses covering Freight, Customs, Brokers Fees, and Import Duties to obtain the replacement Service Part from
    Waukesha.
    D. Reimbursable travel time and mileage coverage shall expire the earlier of 6 months after the overhauled Product start-up date or 24 months after the purchase date.
    IV. OWNER'S RESPONSIBIUTIES UNDER THE EXPRESS LIMITED WARRANTY
    Owner shall be responsible tor.
    A. The operation and maintenance of the Products/Service Parts within the guidelines estabUshed by Waukesha.
    B. Making the Products/Service Parts available to Waukesha or Waukesha's authorized distributors for any warranty repair, during normal business hours.
    C. All additional costs incurred for premium or overtime labor should owner request that repairs be made on a premium or overtime schedule.
    D. All costs incurred as the result of removal or reinstallation of the Products as may be required to effect any warranted repair.
    E. All administrative costs and expenses resulting from a warranted failure.
    F. Any costs of transportation, towing, repair facilities, or associated costs.
    G. All additional labor time in excess of Waukesha's Labor Guide for the warrantable repair.
    H. Loss of revenue and loss of/or damage to real and/or personal property.
    V. UMITA110N OF WAUKESHA'S OBLIGATIONS
    The obligations of Waukesha under this express limited warranty shall be waived and voided, and Waukesha shall not, thereafter, be responsible for:
    A. Any failure resulting from owner or operator abuse or neglect, including but not by way of limitation, any operation, installation, application, maintenance, or assembly
    practice not in accordance with guidelines or specHications established by Waukesha; or
    B. Any failure resulting from unauthorized modifications or repairs of the Products or Service Parts; or
    C. Any failure resulting from overload, overspeed, overheat, accident; or
    D. Failure of owner to prompUy provide notice of a claimed defect; or
    E. Failure of Service Parts for which Waukesha did not receive proper documentation conceming the certified overhaul delivery and the start up date of the Product
    from an Authorized Waukesha Engine Distributor, or
    F. Repairs of a covered failure performed with non-genuine Waukesha parts; or
    G. Repairs of a covered failure performed by non-.authorized contractors or distributors; or
    H. Failure to make Products and Service Parts available to Waukesha or its authorized representatives; or
    I. Failure to supply documents such as drawings and specifications relating to the specific application of the Products; or
    J. Any failure of Service Parts resulting from misapplication or improper repair procedures; or
    K. Any failure or damage resulting from the improper or extended storage of a Service Part; or
    A. Freight, Customs, Brokers Fees, and Import Duties if appropriate documentation is not provided.
    B. Normal wear items or consumable parts such as belts, spark plugs, lubricating oil filters, air filters, etc. These items are not considered defective if in need of routine
    replacement, rebuild or maintenance during the term of the warranty.
    VI. APPLICABIUTY AND EXPIRA110N
    The warranty set out above is extended to the original purchaser of the Genuine Waukesha Service Parts. The warranty and obligations of Waukesha shall expire and be
    of no further effect upon the dates of expiration of the applicable warranty periods.
    VII. WARRANTY ADMINISTRATION
    This warranty is administered exclusively by an Authorized Waukesha Distributor. The certified overhaul invoice and/or start-up report must be provided to the Distributor
    to determine whether the warranty is applicable.
    Contact the nearest Authorized Waukesha Distributor for assistance with warranty matters or questions. The location of the nearest Authorized Distributor is available by
    contacting Waukesha Engine at (262) 547-3311.
    THE FOREGOING SETS FORTH WAUKESHA'S ONLY OBLlGA110NS AND OWNERS' EXCLUSIVE REMEDY FOR BREACH OF WARRANTY, WHETHER SUCH
    CLAIMS ARE BASED ON BREACH OF CONTRACT. TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY), OR OTHER THEORIES, AND THE FOREGOING IS
    EXPRESSLY IN UEU OF OTHER WARRANTIES WHATSOEVER EXPRESSED,IMPLlED, AND STATUTORY, INCLUDING WITHOUT LIMITA110N, THE IMPUED
    WARRANTIES OF MERCHANTABIUTY AND FITNESS FOR A PARTICULAR PURPOSE.
    Notwithstanding the preceding, In no event shall Waukesha be liable for any direct. special, incidental, or consequential damages (whether denominated in
    contract, tort sb'ict liability, negligence, or other theories) arising out of this agreement or the use of any Products provided under this Agreement
    Any action arising hereunder or relating hereto, whether based on breach of contract, tort (Including negligence and strict liability), or other theorias must be
    commanced within two (2) years after the cause of action accrues or R shall be barred.
    BINDING ARBITRA110N
    a) Buyer and Sellar shall attempt, in good faith, to resolve any dispute arising out of or relating to this agreement, or the Products and/or services provided
    hereunder, promptly by negotiation between aX8Cutivas. H the mattar has not been resolved within sixty (60) days of a party's request for negotiation, aRher
    party may initiate arbitration as heretn after provided.
    b) Any dispute arising out of or related to this agreement or the ProduC18 anellor services provided hereunder which has not been resolvad by the negotiation
    procedure described above, shall be aetlled by binding arbitration administered by the American Arbitration Associatton In accordance with Its Commercial
    Arbitration Rules and Judgment on the award rendered by the arbitrator(s) may be entered In any court having jurisdiction thereof.
    c) Unless Buyer and Seller otherwise agree in writing, the arbRratlon panel shall consist of three arbitrators. The arbitrator(s) shall have no authority to award
    ) punitive or other damages not measured by the prevailing party's actual damages and may not, in any evant, make any ruling, finding or award that does not
    conform to the terms and condition of this agreement. The law of Texas shall govern.
    d) The arbHration proceeding shall be conducted in English, in Dallas, Texas.
    Enginator® is registered trademark of Dresser. Inc. Copyright © 2001 Dresser, Inc.
    See Form 3245 for the most current warranty terms; Effective June 25, 2003.

    W-3
    WAUKESHA ENGINE, DRESSER, INC. - EXPRESS LIMITED WARRANTY FOR
    GENUINE WAUKESHA SERVICE PARTS AND WAUKESHA FACTORY REMANUFACTURED SERVICE PARTS
    INTRODUCTION
    This warranty only applies to Genuine Waukesha ServICe Parts and Waukesha Factory Remanufactured Service Parts (to include assemblies and short blocks) (hereinafierrefened to
    as "Service parts') sold by Waukesha Engine and used for repair, maintenance, or overhaul of Waukesha Products.
    I. TERMS OF EXPRESS LIMITED WARRANTY
    A. Waukesha Engine warrants that it will repairer replace. AT ITS ELECTION AND EXPENSE, any Genuine Waukesha Service Part installed on an engine, or Enginatol®, or
    product (hereinafter referred to as 'Products") manufactured by Waukesha, which proves to have had a defect in material or workmanship.
    B. Waukesha Engine Division further warrants that it will repair or replace, AT ITS ELECTION AND EXPENSE, any component of the Waukesha Product damaged as the
    direct result of a warrantable defect in a Product during the term of coverage.
    II. TERM LIMITATIONS OF EXPRESS LIMITED WARRANTY
    This coverage shall commence upon the date the Service Part is installed and shall expire upon the earlier of the following:
    A. 12 months after the date the part is installed; or
    B. 24 months after the purchase date from an authorized Waukesha Distributor.
    III. WAUKESHA·S RESPONSIBILITIES UNDER THE EXPRESS LIMITED WARRANTY
    Waukesha shall be responsible for:
    A. The repair or replacement, at Waukesha's election, ot covered detective Service Parts and progressive damage as explained in Paragraph 1B of this warranty.
    B. Labor time to repair or replace the defective part as established by the Waukesha labor Guide Manual. All reimbursable labor costs shall be provided by Waukesha's
    authorized Distributor.
    C. The reimbursement of documented Distributor expenses covering Freight, Customs, Brokers Fees, and Import Duties to obtain the replacement Service Part from
    Waukesha.
    IV. OWNER'S RESPONSIBILITIES UNDER THE EXPRESS LIMITED WARRANTY
    Owner shall be responsible for:
    A. The operation and maintenance of the ProductslService Parts within the guidelines established by Waukesha.
    B. Making the ProductslService Parts available to Waukesha or Waukesha's authorized Distributors for any warranty repair, during normal business hours.
    C. All additional costs incurred for premium or overtime labor, should owner request that repairs be made on a premium or overtime schedule.
    D. All costs incurred as the result of removal or reinstallation of the Products as may be required to effect any warranted repairs.
    E. All administrative costs and expenses resulting from a warranted failure.
    F. Any costs of transportation, towing, repair facilities, or associated costs.
    G. All travel, mileage, and other related Distributor costs and expenses associated with repair under the terms of this Service Parts Warranty.
    H. All additional labor time in excess of Waukesha's labor Guide for the warrantable repair.
    I. Loss of revenue and loss oflor damage to real andlor personal property.
    V. LIMITATION OF WAUKESHA·S OBLIGATIONS
    The obligations of Waukesha under this elqlress limited warranty shall be waived and voided, and Waukesha shall not, thereafter, be responsible for:
    A. Anyfailure resulting from owner or operator abuse or neglect, including but not by wayof limitation, any operation, installation, ap~ication, maintenance, or assembly practice
    not in accordance with guidelines or specifications established by Waukesha; or
    B. Any failure resulting from unauthorized modifications or repairs of the Products or Service Parts; or
    C. Any failure resulting from overload, overspeed, overheat, accident; or
    D. Failure of owner to promptly provide notice of a claimed defect; or
    E. Failure of Service Parts for which Waukesha did not receive proper documentation conceming the Service Parts purchase date from an authorized Waukesha Engine )
    Distributor; or
    F. Repairs of a covered failure performed with non-genuine Waukesha parts; or
    G. Repairs of a covered failure performed by non-authorized contractors or distributors; or
    H. Failure to make Products and Service Parts available to Waukesha or its authorized representative; or
    I. Failure to supply documents such as drawings and specifications relating to the specific application at the Products; or
    J. Any failure of Service Parts resulting from misapplication or improper repair procedures; or
    K. Any failure or damage resulting from the improper or extended storage of a Service Part; or
    L. Freight, Customs, Broker Fees, and Import Duties if appropriate documentation is not provided; or
    M. Normal wear items or consumable parts such as belts, spark plugs, lubricating oil filters,airfilters, etc. are not considered defective if in need of routine replacement, rebuild,
    or maintenance during the term of the warranty.
    VI. APPLICABILITY AND EXPIRATION
    The warranty set out above is extended to the original purchaser of the Genuine Waukesha Service Parts. The warranty and obligations of Waukesha shall expire and be of no
    further effect upon the date of expiration of the applicable warranty period.
    VII. WARRANTY ADMINISTRATION
    This warranty is administered exclusively by an authorized Waukesha Distributor. The invoice for the failed Service Parts must be provided to the distributorto determine whether
    the warranty is applicable.
    Contact the nearest authorized Waukesha Distributor for assistance with warranty matters or questions. The location of the nearest authorized Distributor is available by contacting
    Waukesha Engine at (262) 547-3311.
    THE FOREGOING SETS FORTH WAUKESHA·S ONLY OBLIGATIONS AND OWNERS· EXCLUSIVE REMEDY FOR BREACH OF WARRANTY, WHETHER
    SUCH CLAIMS ARE BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY), OR OTHER THEORIES, AND THE
    FOREGOING IS EXPRESSLY IN LIEU OF OTHER WARRANTIES WHATSOEVER EXPRESSED, IMPLIED, AND STATUTORY, INCLUDING WITHOUT
    LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
    Notwithstanding the preceding, in noevent shall Waukesha be liable for any direct. special, incidental, orconsequential damages. (whether denominated in contract, tort
    strict liability, negligence, or other theories) arising out of this Agreement or the use of any Products provided under this Agreement.
    Any action arising hereunder or relating hereto, whether based on breach of.contract, tort (including negligence and strict liability), orothertheories must becommencad
    within two (2) years aflerthe cause of action accrues or it Bhall be barred.
    BINDING ARBITRATION
    (a) Buyer and Seller shall attempt, in good faith, to resolve any dispute arising out of or relating to this agreement, or the products and/Or services provided
    hereunder, promptly by negotiation between executives. H the matter has not been resolved within sixty (60) days of a party's request for negotiation, either
    party may Initiate arbitration as hereinafter provided.
    (b) Any dispute arising out of or related to this agreement or the products and/or services provided hereunder wh;ch has not been resolved by the negotiation
    procedure described above, shall be settted by binding arbitration adminiatered by the American Arbitration Association in accordance with Its Commercial
    Arbitration Rules and judgment on the award rendered by the arbitrator{s) may be entered In any court having jurisdiction thereof.
    (c) Unless Buyer and Seller otherwise agree In writing, the arbitration panel shall consist of three arbitrators. The arbitrator(s) shall have no authority to award
    punitive or other damages not measured by the prevailing party's actual damages and may not, In any event, make any ruling, finding or award that does not
    conform to the terms and conditions of this agreement. The law of Texas shall govem.
    (d) The arbitration proceeding shall be conducted in English, in Dallas, Texas.
    See Form M..463 for the most current warranty termsj effective February 22, 2006.

    W-4

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