10056-2 275gl Packaging Guide 5-19-17 PDF

GE Power
Waukesha* gas engines
275GL Packaging Guide

*
General packaging guidelines to help meet the best recommended practices for the application and
use of Waukesha 275GL+ engines
form 10056-2
* Indicates a trademark of the General Electric Company

Disclaimer
GE’s Waukesha gas engines (“Waukesha”) is providing the following packaging guidelines to help you meet best recommended
practices for the application and use of Waukesha engines. Waukesha strongly recommends that engines not be started or operated
until all packaging guidelines are met. Operating engines in applications that do not meet packaging guidelines has the potential to
cause engine damage and/or personal injury. Waukesha will not be held liable or take any responsibility for any damage or incidents
that occur due to operation of an engine that does not meet the packaging guidelines.
TOC Chapter I
CONTENTS
Chapter 1 - Safety
Chapter 2 - General Information
Chapter 3 - Technical Data
Chapter 4 - Engine Base Design
Chapter 5 - Torsional Analysis
Chapter 6 - Installation
Chapter 7 - Mounting and Alignment
Chapter 8 - Engine Lifting
Chapter 9 - Cooling System
Chapter 10 - Lubrication System
Chapter 11 - Crankcase Breather System
Chapter 12 - Crankcase Pressure Relief Valves
Chapter 13 - Combustion Air Intake System
Chapter 14 - Exhaust System
Chapter 15 - Fuel System
Chapter 16 - Starting System
Chapter 17 - ESM Packaging
Chapter 18 - Asset Performance Management
Chapter 19 - Engine Operation
Chapter 20 - Engine Commissioning
Chapter 21 - Storage
Chapter 22 - Maintenance Considerations
Appendices
I - 1 Form 10056-2
© 5/2017 General Electric Company
Chapter I TOC
I - 2 Form 10056-2
Safety Chapter 1
CHAPTER 1 - SAFETY
SAFETY INTRODUCTION
The following safety precautions are published for your information. Waukesha does not, by
the publication of these precautions, imply or in any way represent that they are the sum of
all dangers present near industrial engines or fuel rating test units. If you are installing, oper-
ating, or servicing a Waukesha product, it is your responsibility to ensure full compliance with
all applicable safety codes and requirements. All requirements of the Federal Occupational
Safety and Health Act must be met when Waukesha products are operated in areas that are
under the jurisdiction of the United States of America. Waukesha products operated in other
countries must be installed, operated and serviced in compliance with any and all applicable
safety requirements of that country.
For details on safety rules and regulations in the United States, contact your local office of the
Occupational Safety and Health Administration (OSHA).
The words DANGER, WARNING, CAUTION and NOTICE are used throughout this manual to
highlight important information. Be certain that the meanings of these alerts are known to all
who work on or near the equipment.
Follow the safety information throughout this manual in addition to the safety policies and
procedures of your employer.
This safety alert symbol appears with most safety statements. It means atten-
tion, become alert, your safety is involved! Please read and abide by the mes-
sage that follows the safety alert symbol.
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could

result in minor or moderate injury.
Indicates a situation which can cause damage to the engine,

personal property and/or the environment, or cause the
equipment to operate improperly.
NOTE: Indicates a procedure, practice or condition that should be followed in order for the en-
gine or component to function in the manner intended.
1 - 1 Form 10056-2
Chapter 1 Safety
Symbol Description
A black graphical symbol inside a yellow triangle with a black triangular band defines
a safety sign that indicates a hazard.
A black graphical symbol inside a red circular band with a red diagonal bar defines a
safety sign that indicates that an action shall not be taken or shall be stopped.
A white graphical symbol inside a blue circle defines a safety sign that indicates that
an action that shall be taken to avoid a hazard.
Warnings
Safety Alert Symbol
Asphyxiation Hazard
Burn Hazard
Burn Hazard (Chemical)
Burn Hazard (Hot Liquid)
Burn Hazard (Steam)
Burst/Pressure Hazard
Crush Hazard (Hand)
1 - 2 Form 10056-2
Safety Chapter 1
Crush Hazard (Side)
Crush Hazard (Side Pinned)
Crush Hazard (Top)
Electrical Shock Hazard
Entanglement Hazard
Explosion Hazard
Fire Hazard
Flying Object Hazard
Hazardous Chemicals
High-Pressure Hazard
Impact Hazard
Pinch-Point Hazard
1 - 3 Form 10056-2
Chapter 1 Safety
Pressure Hazard
Puncture Hazard
Sever Hazard
Sever Hazard (Rotating Blade)
Prohibitions
Do not operate with guards removed
Do not leave tools in the area
Drugs and Alcohol Prohibited
Lifting/Transporting only by qualified personnel
Welding only by qualified personnel
1 - 4 Form 10056-2
Safety Chapter 1
Mandatory Actions
Read Manufacturer’s Instructions
Wear Eye Protection
Wear Personal Protective Equipment (PPE)
Wear Protective Gloves
Miscellaneous
Emergency Stop
Grounding Point
Physical Earth
Use Emergency Stop (E-Stop); Stop Engine
The safety messages that follow have WARNING level hazards.
1 - 5 Form 10056-2
Chapter 1 Safety
SAFETY LABELS
All safety labels must be legible to alert personnel of safety hazards. Replace any illeg-
ible or missing labels immediately. Safety labels removed during any repair work must
be replaced in their original position before the engine is placed back into service.
EQUIPMENT REPAIR AND SERVICE

Always stop the engine before cleaning, servicing or repairing the engine
or any driven equipment.
• If possible, lock all controls in the OFF position and remove the key.
• Put a sign on the control panel warning that the engine is being serviced.
• Close all manual control valves.
• Disconnect and lock out all energy sources to the engine, including all fuel, electric,
hydraulic and pneumatic connections.
• Disconnect or lock out driven equipment to prevent the possibility of the driven
equipment rotating the disabled engine.
Allow the engine to cool to room temperature before cleaning, servicing or repairing
the engine. Some engine components and fluids are extremely hot even after the en-
gine has been shut down. Allow sufficient time for all engine components and fluids to
cool to room temperature before attempting any service procedure.
Exercise extreme care when moving the engine or its components. Never walk or
stand directly under an engine or component while it is suspended. Always consider
the weight of the engine or the components involved when selecting hoisting chains
and lifting equipment. Be positive about the rated capacity of lifting equipment. Use
only properly maintained lifting equipment with a lifting capacity that exceeds the
known weight of the object to be lifted.
ACID
Always read and comply with the acid manufacturer’s recommendations for proper
use and handling of acids.
BATTERIES
Always read and comply with the battery manufacturer’s recommendations for pro-
cedures concerning proper battery use and maintenance..
Batteries contain sulfuric acid and generate explosive mixtures of hydrogen and oxy-
gen gases. Keep any device that may cause sparks or flames away from the battery
to prevent explosion.
1 - 6 Form 10056-2
Safety Chapter 1
Always wear protective glasses or goggles and protective clothing when working with
batteries. You must follow the battery manufacturer’s instructions on safety, mainte-
nance and installation procedures.
BODY PROTECTION
Always wear OSHA-approved body, sight, hearing and respiratory system protection.
Never wear loose clothing, jewelry or long hair around an engine.
CHEMICALS
GENERAL
Always read and comply with the safety labels on all containers. Do not remove or
deface the container labels.
CLEANING SOLVENTS
Always read and comply with the solvent manufacturer’s recommendations for prop-
er use and handling of solvents. Do not use gasoline, paint thinners or other highly
volatile fluids for cleaning.
LIQUID NITROGEN
Always read and comply with the liquid nitrogen manufacturer’s recommendations
for proper use and handling of liquid nitrogen.
COMPONENTS
HEATED OR FROZEN
Always wear protective equipment when installing or removing heated or frozen com-
ponents. Some components are heated or cooled to extreme temperatures for proper
installation or removal.
INTERFERENCE FIT
Always wear protective equipment when installing or removing components with an

interference fit. Installation or removal of interference components may cause flying
debris.
1 - 7 Form 10056-2
Chapter 1 Safety
COOLING SYSTEM
Always wear protective equipment when venting, flushing or blowing down
the cooling system. Operational coolant temperatures can range from
180° – 250°F (82° – 121°C).
Do not service the cooling system while the engine is operating or when the
coolant or vapor is hot. Operational coolant temperatures can range from
180° – 250°F (82° – 121°C).
ELECTRICAL
GENERAL
Equipment must be grounded by qualified personnel in accordance with IEC (Interna-

tional Electric Code) and local electrical codes.
Do not install, set up, maintain or operate any electrical components unless you are
a technically qualified individual who is familiar with the electrical elements involved.
Disconnect all electrical power supplies before making any connections or servicing
any part of the electrical system.
Always label “high voltage” on engine-mounted equipment over 24 volts nominal.
IGNITION
Avoid contact with ignition units and wiring. Ignition system components can store
electrical energy, and if contacted, can cause electrical shock.
Properly discharge any electrical component that has the capability to store electrical
energy before connecting or servicing that component.
EMERGENCY SHUTDOWN
An Emergency Shutdown must never be used for a normal engine shutdown. Doing so
may result in unburned fuel in the exhaust manifold. Failure to comply increases the
risk of an exhaust explosion.
1 - 8 Form 10056-2
Safety Chapter 1
EXHAUST
Do not inhale engine exhaust gases. Ensure that exhaust systems are leak-free and
that all exhaust gases are properly vented to the outside of the building.
Do not touch or service any heated exhaust components. Allow sufficient time for
exhaust components to cool to room temperature before attempting any service pro-
cedure.
FIRE PROTECTION
See local and federal fire regulations for guidelines for proper site fire protection.
FUELS
GENERAL
Ensure that there are no leaks in the fuel supply. Engine fuels are highly combustible
and can ignite or explode.
GASEOUS
Do not inhale gaseous fuels. Some components of fuel gas are odorless, tasteless and
highly toxic.
Shut off the fuel supply if a gaseous engine has been cranked excessively without
starting. Crank the engine to purge the cylinders and exhaust system of accumulated
unburned fuel. Failure to purge accumulated unburned fuel in the engine and exhaust
system can result in an explosion.
LIQUIDS
Use protective equipment when working with liquids and related components. Liquids
can be absorbed into the body.
1 - 9 Form 10056-2
Chapter 1 Safety
INTOXICANTS AND NARCOTICS
Do not allow anyone under the influence of intoxicants and/or narcotics to work on or
around industrial engines. Workers under the influence of intoxicants and/or narcotics
are a hazard to both themselves and other employees.
PRESSURIZED FLUIDS /GAS/AIR

Never use pressurized fluids/gas/air to clean clothing or body parts. Never use body
parts to check for leaks or flow rates. Observe all applicable local and federal regula-
tions relating to pressurized fluids/gas/air.
PROTECTIVE GUARDS
Provide guarding to protect persons or structures from rotating or heated parts. It
is the responsibility of the engine owner to specify and provide guarding. See OSHA
standards on “machine guarding” for details on safety rules and regulations concern-
ing guarding techniques.
SPRINGS
Use appropriate equipment and protective gear when servicing or using products that
contain springs. Springs, under tension or compression, can eject if improper equip-
ment or procedures are used.
TOOLS
ELECTRICAL
Do not install, set up, maintain or operate any electrical tools unless you are a techni-
cally qualified individual who is familiar with them.
HYDRAULIC
Do not install, set up, maintain or operate any hydraulic tools unless you are a techni-
cally qualified individual who is familiar with them. Hydraulic tools use extremely high
hydraulic pressure.
Always follow recommended procedures when using hydraulic tensioning devices.
1 - 10 Form 10056-2
Safety Chapter 1
PNEUMATIC
Do not install, set up, maintain or operate any pneumatic tools unless you are a tech-
nically qualified individual who is familiar with them. Pneumatic tools use pressurized
air.
WEIGHT
Always consider the weight of the item being lifted and use only properly rated lifting
equipment and approved lifting methods.
Never walk or stand under an engine or component while it is suspended.
WELDING
Comply with the welder manufacturer’s recommendations for procedures concerning
proper use of the welder.
The safety message that follows has a CAUTION level

hazard.
Ensure that all tools and other objects are removed from the unit and any driven
equipment before restarting the unit.
The safety messages that follow have NOTICE level hazards.
Ensure that the welder is properly grounded before attempting to weld on or near an
engine.
Table 1-1: Disconnect the ignition harness and electronically controlled devices before welding
with an electric arc welder on or near an engine. Failure to disconnect the harnesses and electron-
ically controlled devices could result in severe engine damage.
1 - 11 Form 10056-2
Chapter 1 Safety
1 - 12 Form 10056-2
General Information Chapter 2
CHAPTER 2 - GENERAL INFORMATION

The Waukesha 12V/16V 275GL + engine is a four stroke, prechamber, lean burn, V-configu-
ration engine. The 16V 275GL + has a total cylinder displacement of 285 L (17,398 cu. in.) and
the 12V 275GL + has a total cylinder displacement of 214 L (13,048 cu. in.). For more specifi-
cations, see the Technical Data section.
The 12V/16V 275GL + engines operate on natural gas, and are designed for low fuel con-
sumption and reduced exhaust emissions. This is accomplished through a “stratified charge”
combustion chamber in which a very lean fuel mixture is burned. The lean combustion con-
cept requires prechamber-type cylinder heads that permit the engine to run at a natural gas
air/fuel ration (AFR) of approximately 32:1.
Key components, such as the oil filters, oil cooler, pre-lube pump, and jacket water and aux-
iliary thermostats are mounted on the engine, simplifying the packaging process and skid
layout.
SCOPE OF SUPPLY
A scope of supply list for the engine is available in the Appendix.
BASIC ENGINE DESCRIPTION
CRANKCASE
The crankcase is a single-piece gray iron casting with a 54° bank angle. For assembled ri-
gidity, the main bearing caps are attached to the crankcase with both vertical studs and
lateral tie bolts. This feature makes the crankcase assembly more rigid and extends the life of
the main bearings. The 16V 275GL + has eight crankcase pressure relief doors, and the 12V
275GL + has seven crankcase pressure relief doors.
For ease of operation and overall serviceability, the sides of the engine are clear of compo-
nents and piping. The crankshaft covers can be easily removed.
The oil level in the sump is below the crankshaft covers, so the covers can be quickly removed
and the crankshaft inspected or the bearing caps positioned without draining oil.
Crankcase pressure relief valves are mounted on the side of the crankcase.
CRANKCASE VENTILATION SYSTEM

Forced ventilation with CSA Class I Groups C&D Class II Groups F&G 230V AC/1 ph blower,
restriction valve, and check valve. 4” blower outlet for customer connection per local codes.
Motor starter is shipped loose and must be mounted in a safe area for CSA Class I & II appli-
cations. The ventilation system rids the engine of harmful vapors and gases by maintaining
a negative crankcase pressure.
CRANKSHAFT
The crankshaft is a low alloy, forged, fully machined shaft. The bearings are heavy-duty, re-
placeable, precision aluminum type. There are 16 counterweights used on the 16V 275GL +
crankshaft, and 12 counterweights on the 12V 275GL + crankshaft. An enclosed, viscous
type vibration damper is included and mounted on the crankshaft to dampen torsional vi-
brations.
2 - 1 Form 10056-2
Chapter 2 General Information
CONNECTING RODS
The connecting rods are machined to ensure maximum strength, precise balance and consis-
tent weight between cylinders. They are made of a low alloy, high tensile strength forged steel
and are rifle-drilled to supply pressurized oil from the crankshaft to the piston pin bushings.
The split line of the rod and cap is at a 35° angle to allow for removal of the connecting rod
assembly up through the cylinder sleeve bore. The high-angle diagonal split also permits the
largest possible bearing diameter, especially important for heavily loaded engines.
The serrated split line ensures precise alignment and transfer of loads. The caps and rod are
also match numbered to ensure that each cap is mated with the correct rod during reassem-
bly.
The connecting rod cap fasteners are stretched, using special hydraulic tensioning tools.
PISTONS
The pistons are machined from one-piece aluminum castings. Each piston is cam-shaped.
Cam-shaped means the dimension of the piston skirt at room temperature is slightly larger
at a point 90° to the piston pin bore. This somewhat oval-shaped feature allows the piston to
expand along the pin axis when the skirt is compressed 90° to the pin axis due to thrust loads.
Piston skirts are graphite-coated to provide antiscuffing and break-in qualities.
A cooling coil is cast into the piston head. Pressurized oil flows from the piston pin bushing
area through the cooling coil to control piston temperature and dimension.
Waukesha 12V/16V 275GL + engines have four piston rings – two straight-cut, barrel-faced
top compression rings, one scraper ring and one oil control ring that provide combustion
sealing and oil control. The two top compression ring lands are cast in a Ni-Resist steel (nickel
alloy) insert to reduce wear in the top ring grooves, the areas exposed to the highest tem-
perature, pressure and abrasion.
CYLINDER SLEEVES
The cylinder sleeves are a “wet” type, since installation in the crankcase is such that the
sleeve ledge rests on a separate water guide above the crankcase deck. The water guide
allows high-velocity coolant to flow around the combustion chamber and also ensures min-
imum bore distortion.
CAMSHAFT
The design of the camshaft lobe and cam minimizes valve overlap and reduces the flow of
gases between the intake and exhaust ports. This improves fuel efficiency and lowers ex-
haust emissions.
For easy removal and replacement, the camshaft is made up of individual sections bolted
together, one section for each cylinder. This modular design allows replacement of a single
section, rather than the entire camshaft
CYLINDER HEAD AND VALVES

Each cylinder head has four valves, two intake and two exhaust, with overhead rocker and
actuator arms and a centrally located prechamber.
The cylinder head is “bore-cooled” to reduce heat deformation during the combustion pro-
cess. Bored passages direct coolant to the valve seats and prechamber. The length of the
igniter sleeve is also water-cooled.
2 - 2 Form 10056-2
General Information Chapter 2
The valve guides are cast iron. The valve stems are chrome-plated. A special coating is used
on the valve heads, a feature that provides additional strength and wear resistance. The valve
seats are hardened tool steel, water-cooled to minimize high-temperature distortion and cor-
rosion.
TURBOCHARGER
Two high-efficiency, radial flow turbochargers, one for each bank, are mounted on the front
of the engine and generate the required boost levels for the engine. Bearing housing is wa-
ter-cooled. Wastegate and compressor bypass actuators are controlled by ESM.
INTERCOOLER
A single box-type intercooler is mounted on the front of the engine. The intercooler receives
air from the turbochargers, cools it and delivers it to the carburetor.
CARBURETOR
The carburetor consists of a venturi type mixer, the throttle valve, the main adjusting screw
and the necessary tubes and elbows to connect it into the system. The carburetor and its as-
sociated parts are mounted in the crankcase vee. Governor linkage goes to the throttle valve.
INTAKE MANIFOLD
The air/fuel mixture passes through the single intake manifold, where it is distributed to the
individual cylinders.
EXHAUST MANIFOLD
The 16V 275GL+ engine manifold consists of eight individual cast-iron segments on each
side, one exhaust manifold segment per cylinder. On the 12V 275GL+ engine manifold there
are six individual cast-iron segments on each side, one exhaust manifold segment per cyl-
inder. Between each of these cast-iron segments is a bellows. All exhaust components are
covered with a form to fit hard panel insulation. This manifold is a dry manifold and does not
use water cooling.
WATER CIRCULATION SYSTEM

Auxiliary Circuit – The auxiliary circuit provides cooling to the intercooler and the oil cool-
er. System Includes mounted 130° F (54° C) auxiliary water temperature control valve with
mounted bypass, gear driven centrifugal type water pump, mounted intercooler, and mount-
ed oil cooler. Provides single customer inlet and single customer outlet connection.
Engine Jacket – The jacket circuit provides cooling to the cylinder sleeves , cylinder heads, and
the turbocharger bearings. System Includes mounted 180°F (82°C) jacket water temperature
control valve with mounted bypass and gear driven centrifugal type water pump. Provides
single customer inlet and single customer outlet connection.
2 - 3 Form 10056-2
Chapter 2 General Information
ESM
The ESM integrates spark timing control, speed governing, knock detection, start-stop con-
trol, air/fuel control, diagnostic tools, fault logging and engine safeties. ESM system automa-
tion and monitoring provides:
• Better engine performance
• Extensive system diagnostics
• Rapid troubleshooting of engines
• Local and remote monitoring capability used to trend engine performance.
• Easy integration into an extensive data acquisition system
ENGINE MONITORING DEVICES

Factory mounted Display for NOx emissions with improved ESM user interface, display sys-
tem and emissions controls. Wired sensors for NOx emissions, lube oil pressure and tempera-
ture, intake manifold temperature and pressure, overspeed; and jacket water temperature;
all accessible through ESM. Sensors meet Canadian Standards Association Class 1, Division 2,
Group A, B, C, & D (Canada & US) hazardous location requirements. ESM continually monitors
combustion performance through accelerometers to provide detonation protection. Dual
magnetic pick-ups are used for accurate engine speed monitoring. ESM provides predictive
spark plug diagnostics as well as advanced diagnostics of engine and all ESM sensors and
logs any faults into non-volatile flash memory. Ktype thermocouples for individual cylinder
exhaust temperatures, pre and post turbocharger and main bearing temperatures are wired
to a common bulkhead. Waukesha preprogrammed HMI panel for engine and AFR control
readout, which provides direct interface for AFR setup and monitoring. HMI is shipped mount-
ed on engine and can be off-engine mounted using optional HMI harness. All ESM and AFR
information with alarm and shutdown faults are displayed. All ESM and AFR parameters are
available via a MODBUS RS485 signal.
2 - 4 Form 10056-2
Technical Data Chapter 3
CHAPTER 3 - TECHNICAL DATA

WHERE TO FIND TECHNICAL DATA
Technical data for Waukesha engines can be found on the website, ge-distributedpower.com.
Please contact Waukesha Application Engineering ([email protected]) to
request access. Permission must be granted to receive a username and password, and once
access is granted, you will be able to login.
Table 3-1: Technical Data Sheets Available on www.ge-distributedpower.com
16V275GL+ 12V275GL+ SHEET NAME

S-SHEET S-SHEET
SPECIFICATIONS S-9063-27 S-9062-2 Engine Specification Sheet
RATINGS & STANDARDS S-9063-31 S-9062-13 Engine Rating and Fuel Consumption
S-9063-40 Load Acceptance Curves
HEAT REJECTION S-9052-8 S-9062-10 Heat Rejection & Emissions
COOLING SYSTEM S-6699-7 Cooling System Guidelines
S-7610-3 Water Treatment Guidelines
S-8473-2 Elevated Ambient Air Temperature and Altitude Correc-
tion to Heat Rejection
S-9001-21 Cooling System Schematic
S-9063-38 S-9063-37 Jacket and Auxiliary Water Pump Performance
S-9064-2 Water Heater Recommendations
CONTROL SYSTEM S-8382-2 Alarm and Shutdown Setpoints
S-8600 Startup and Shutdown of Engine Equipped with Deltec
Carburetion
DRIVE DATA SA-2905-H Definitions for Various Types of Duty
S-4052-13 Front End Drive Data
S-6900-3 Flywheel Information
S-8462 Maximum Unbalanced Inertia Forces and Moments
SOUND DATA S-8205-11 S-9062-6 Engine& Exhaust Sound Level Data
EMISSIONS DATA S-8483-6 Gas Engine Emissions Levels
INTAKE & EXHAUST SYS- S-8117-2 Engine Exhaust Recoverable Energy Calculations
TEMS
S-8242 Exhaust System Installation Guide
S-9063-10 S-9063-36 Engine Breather Schematic and Operating Instructions
POWER ADJUSTMENTS & S-8154-101 Power Adjustments for Altitude and Ambient Air Tem-
WKI* perature
S-9063-32 S-9062-11 Power Adjustments for Fuel Quality (WKI* Curve)
FUEL SYSTEM SA-434-D Engine Mechanical Efficiency Calculation
SA-6656-L Gas Solenoid Valve Selection
S-5806A Gas Flow Data in Piping
S-6656-23 Gas Pressure Limits to Engine Mounted Regulator
S-7032-2 Procedure for Calculating Fuel Gas SLHV
S-7884-7 Gaseous Fuel Specification
S-7898-2 Glossary of Gaseous Fuel Terms
3 - 1 Form 10056-2
Chapter 3 Technical Data
LUBRICATION SYSTEM S-1015-30 Lube Oil Recommendations
S-3549-J Allowable Engine Angle for Operation
S-7382-56 Prelube and Postlube Requirements
S-9063-33 N/A Engine Oil Pump Performance
S-9064-2 Lube Oil Heater Recommendations
STARTING SYSTEMS S-9063-23 S-9063-22 Air Volume and Pressure Guidelines for Air Starter
S-9064-4 Starting and Running Equipment Requirements
Table 3-2: Engine Specifications
Description 16V275GL+ 12V275GL+

Type 4-cycle, lean burn, prechamber
Aspiration Turbocharged, intercooled
Number of Cylinders 16 12
Bore x Stroke 275 x 300 mm (10.83 x 11.81 in.)
Displacement 285 L (17,398 cu. In.) 214 L (13,048 cu. In.)
Compression Ratio 9.0:1
Mean Piston speed @ 1000 RPM 10.0 m/sec (1,969 ft/min)
Speed Range 750 - 1,000 RPM
Low Idle 750 RPM
Firing Order 1R-1L-4R-4L-7R-7L-6R-6L 1R-1L-5R-5L-3R-3L
8R-8L-5R-5L-2R-2L-3R-3L 6R-6L-2R-2L-4R-4L
MAIN BEARINGS
Number 9 7
Diameter x Width 225 x 104 mm (8.858 x 4.094 in.)
Projected Area / bearing 234 sq. cm (36.27 sq. in.)
CRANKPIN BEARINGS
Diameter x Width 195 x 78 mm (7.677 x 3.071 in.)
Projected Area / bearing 152 sq. cm (23.58 sq. in.)
OIL SYSTEM
Sump Capacity, Including Filter & Cooler 1,041 L (275 gal) 833 L (220 gal)
Main Filter 26 micron @ 98.6% absolute efficiency
Normal Oil Pressure 415 - 450 kPa (60 - 65 psi)
Low Oil Pressure Shutdown Set point 310 kPa (45 psi)
High Oil Temperature Shutdown Set point 92°C (197°F)
Normal Flow 833 L/min. (220 gpm) 493 L/min. (130 gpm)
Prelube Duration 90 seconds before engine start
Prelube Pressure (cold) 172 kPa (25 psi)
Prelube Flow 115 L/min. (30 gpm)
Postlube (After Hot Shutdown) 1 minute (recommended)
Maximum Prelube/Postlube Pressure 620 kPa (90 psi)
Prelube/Postlube Air Consumption 307 m3/hr (181 SCFM) at 620.5 kPa (90psi)
Normal Oil Header Temperature 74° - 78°C (165° - 172°F)
3 - 2 Form 10056-2
Description 16V275GL+ 12V275GL+
CRANKCASE BREATHER SYSTEM
Volume Flow (maximum) 56.7 L/sec. (120 SCFM)
Crankcase Vacuum -25.4 to -76.2 mm-H2O (-1 to -3 inch-H2O)
COOLING SYSTEM
Jacket Coolant Capacity, Engine Only 503 L (133 gal) 379 L (100 gal)
Auxiliary Coolant Capacity, Engine Only 150 L (40 gal) 114 L (30 gal)
Normal Temperature Range Out of Engine 82°C (180°F)
High Jacket Coolant Temperature Shutdown 93°C (200°F)
Maximum Inlet Head Water Pump 15.2 m-H2O (50 ft-H2O)
Minimum Inlet Head Water Pump 4.3 m-H2O (14.1 ft-H2O)
Auxiliary Water Pipe Flange 4.0 in. ANSI
Jacket Water Pipe Flange 5.0 in. ANSI
FUEL SYSTEM
Natural Gas Pressure at Regulator 310 - 414 kPa (45-60 psi)
Natural Gas Inlet Pipe Flange 508 mm (2.0 in. ANSI)
EXHAUST SYSTEM (TURBINE OUTLET)
Maximum Permissible Back Pressure 508 mm-H2O (20.0 inch-H2O)
Turbine Outlet Pipe Flange 14.0 in. ANSI 8.0 in. ANSI
AIR INDUCTION SYSTEM (DUCTING AND FILTER)
Maximum Permissible Restriction 381 mm-H2O (15 inch-H2O)
High Intake Manifold Temperature Shutdown 74°C (165°F)
Compressor Inlet Pipe Connection 360mm (14.17 in.) 229mm (9.0 in)
Required Filtering Efficiency (Coarse Dust Per SAE 99.70%
J726/ISO 5011, Latest Version)
Minimum Combustion Air Inlet Temperature For -17.8°C (0°F)
Starting And Engine Operation
STARTING SYSTEM
Regulated Starting Air/Gas Pressure 862 - 1,034 kPa (125 - 150 psi)1
Air Inlet Pipe Flanges (Left & Right) 1.5 in. ANSI RF flange
Air Outlet Pipe Flanges (Left & Right) 3.0 in ANSI RF flange
MISCELLANEOUS
Recommended Minimum Spacing Between Engines 2,900 mm (114 in.)2
Recommended Minimum Distance to Wall 2,000 mm (78 in.)2
Recommended Minimum Overhead Clearance 2,340 mm (92 in.)2
Engine Without Shipping Skid 29,624 kg (65,320 lb) 23,541 kg (51,900 lb)
Shipping Skid (Standard) 1,878 kg (4,141 lb) 1,633 kg (3,600 lb)
Flywheel 817 kg (1,800 lb)
Heaviest Engine Part, Top Overhaul, Cylinder Head 204 kg (450 lb)
1. Pressure is based on 50F (10C) lubricating oil temperature

2. From centerline of crankshaft
3 - 3 Form 10056-2
ENGCALC
For engine data at site specific conditions and fuel, EngCalc is available to download off the
website ge-distributedpower.com. When downloaded, there will be 2 files which must be
saved in the same directory together and requires Microsoft Excel version 2003 or newer. This
program will provide site specific engine data based on a user’s input of site conditions and
a fuel analysis. The data provided by EngCalc must be used when sizing radiators, catalysts,
and other auxiliary components. Data from EngCalc can be printed out in a report format.
Figure 3-1: EngCalc Inputs Page
OUTLINE DRAWINGS
Outline drawings are available on ge-distributedpower.com using the left side menu under
Documents >> Outline Drawings. Choose the engine model from the corresponding engine
family’s drop menu and press GO. The outline drawings are broken down by engine ship
date at the top of the page, and will show dimensions, connection sizes, and component
identifications. These outline drawings are just for the base engine with no option codes. If
option codes are ordered, and they change components from the base engine, there will be
an option code outline drawing listed on the page by option code number. These option code
outline drawings should be overlaid over the base engine drawing and the changes called
out on the option code drawing should be made. (E.g. REPLACES ENGINE CONNECTIONS 14
AND 15 ON STANDARD PRICECODE INSTALLATION DRAWING.)
3 - 4 Form 10056-2
Figure 3-2: 12V275GL+ Base Engine Outline Drawing (no options)
Figure 3-3: 12V275GL+ Option Code 9209 Outline Drawing
The outline drawings page also has wiring diagrams for the ESM system, breather, HMI Har-
ness, and an overall engine electrical system schematic.
Also found on the outline drawings page are P&ID drawings for the lube oil system, cooling
system, fuel system, and air system. These are available in PDF or DWG formats.
SERVICE BULLETINS
Waukesha releases Service Bulletins to update the field on changes, retrofits or new offerings
that are applicable to existing engines. The Service Bulletin Index is available on the Wauke-
sha website www.ge-distributedpower.com. There is also a registry list for people who want
to receive an e-mail when a new Service Bulletin is released. To register for these notifications
please e-mail [email protected].
3 - 5 Form 10056-2
3D MODELS
There is a Support Central website set up that contains 3D models for the base engine. This
model is only of the base engine, and may not fully represent the engine that is ordered.
Separate access will need to be granted for these 3D models. Please contact application
engineering at [email protected].
Figure 3-4: 16V275GL+ 3D model
MANUALS
The available manuals for the engine are shown in “Table 3-3: Manuals”. Each engine will
come with one copy of the Operation and Maintenance manual shipped loose with the
engine, but if additional manuals are required please contact application engineering at
[email protected].
Table 3-3: Manuals
MANUAL FORM NUMBER DESCRIPTION
6354-2 12V/16V275GL+ Operation and Maintenance with ESM Manual

6334-3 12V/16V275GL+ Repair and Overhaul Manual
6351-3 12V275GL+ Parts Manual
6332-3 16V275GL+ Parts Manual
3 - 6 Form 10056-2
Engine Base Design Chapter 4
CHAPTER 4 - ENGINE BASE DESIGN

When a base (also referred to as a “skid”) is not supplied by Waukesha gas engines, the pack-
ager assumes responsibility for the base design. Any package being assembled outside of
the engine manufacturer should have a vibration study performed and tests completed for
assurance of installation integrity against vibration at the site. Information on engine unbal-
anced forces and moments can be found in the Waukesha gas engine technical data; vibra-
tion limits can be found in the Application and Installation section of Waukesha gas engine
service bulletins.
It is strongly recommended that the driven equipment be mounted on a common-skid with

the engine. By mounting both units on the same skid, a common plane for the engine and
driven equipment is created. The equipment is less likely to lose alignment, because the driv-
en equipment cannot shift relative to the engine.
When designing bases to be used with Waukesha gas engines, the engine base must be a
rigid design to maintain alignment between the engine and the driven equipment. Base flex-
ing due to lack of torsional rigidity is a major cause of misalignment. When designed correct-
ly, the base must offer rigidity adequate to oppose the twist due to torque reaction on drives
for driven equipment mounted on the base assembly and not bolted to the engine. The de-
sign must prevent any excessive bending forces that could be transmitted to the engine block
and any components in the drive train. A modal and torsional analysis must be performed to
validate the base design using Mass Elastic System Data (MESD) and maximum unbalanced
forces and moments data for the engine. MESD can be ordered as an option code (refer to the
Price Book). A third party engineering firm may be required to perform this analysis. “Figure
4-1: Example of genset base”, shown below, is an example of the skid used by Waukesha for
power generation packages.
Driven
equipment
Engine
Figure 4-1: Example of genset base
The base must be designed according to the following:
• The entire package must be able to withstand normal handling during transportation
without permanently distorting the base or causing misalignment of the engine or driven
equipment.
4 - 1 Form 10056-2
Chapter 4 Engine Base Design
• The base must limit torsional and bending moment forces caused by torque reaction and
flexing of the foundation substructure or vibration isolators under the base.
• The base must be free of linear and torsional vibration in the operating load and speed
range of the engine, and have a natural frequency such that resonance does not occur
during the machinery’s normal work.
• The base must maintain engine and driven equipment alignment under all operational
and environmental conditions.
Designs that rigidly mount the base to the foundation are preferred over using vibration isola-
tors. The use of isolators causes the base to react all of the transmitted torque and eliminates
the “path to ground” for the engine’s unbalanced forces.
Special consideration must be taken for bases designed for vibration isolators to ensure the
base is designed to limit torsional and bending moment forces and prevent flexing of the
base while mounted on vibration isolators. The base must maintain equipment alignment
under all conditions.
Vibration isolators between the driven equipment and skid, or engine and skid are not ac-
ceptable for use with Waukesha gas engines.
Skid designs with a step down base feature between the engine and driven is not recom-
mended and as an alternative, it is recommended that the mounting feet of the driven equip-
ment are modified to use a continuous I-beam skid design with one level plane for mounting
the engine and driven equipment.
Mounting of any ancillary components by a packager may result in unwanted vibration of

those components. Appropriate lifting capability for lifting the complete package must be
provided as part of the base design. Engine lifting eyes are not to be used for lifting of a pack-
aged unit.
4 - 2 Form 10056-2
Torsional Analysis Chapter 5
CHAPTER 5 - TORSIONAL ANALYSIS

All equipment with rotating components have inherent torsional vibrations that occur at
various speeds. Manufacturers design their equipment so these inherent vibrations are be-
low set limits and/or well outside its operating speed range. However, when equipment is
combined (i.e., engine to driven equipment, generator, compressor etc…) the combination will
have its own torsional characteristics where the torsional vibrations may exceed the limits in
the equipment’s operating range. This is why it is extremely important to perform or have a
torsional analysis performed on every unit.
Crankshaft torsional vibration refers to the angular twisting of the crankshaft relative to the
center of rotation. Since torsional vibration cannot be seen or felt by hand, it must be mea-
sured with special equipment.
The following engine situations may lead to excessive torsional vibration:
• Misalignment
• Bank to bank imbalance
• Uneven firing pressures
• Cylinder misfires
• Uneven ignition timing
• Incompatibility of the engine, couplings, and driven equipment
• Faulty vibration damper
To help limit the possibility of damage to the crankshaft, gear train, or coupling, vibration
dampers are mounted on the front of the engine to reduce torsional vibration. Dampers will
lose their ability to dampen as they age and therefore must be replaced. However, since
damper life cannot easily be determined, it is recommended that they be replaced every five
years, 35,000 to 40,000 operating hours or in the event of a crankshaft failure. Waukesha
recommends an initial sample at 2,000 hours after start-up. Then sample annually after initial
sample at 2,000 hours or sooner by damper manufacturer’s analysis and recommendations.
A torsional analysis must be performed to determine compatibility of the drive line compo-
nents when the components are used together for the first time. Waukesha can complete
a torsional analysis when supplied with the coupling and driven equipment information or
the engine mass elastic information can be supplied if another company will be doing the
torsional analysis.
Contact Waukesha’s Application Engineering department (AppEngineering.Department@
ge.com) to request either the mass elastic system data or a complete torsional analysis.
5 - 1 Form 10056-2
Chapter 5 Torsional Analysis
5 - 2 Form 10056-2
Installation Chapter 6
CHAPTER 6 - INSTALLATION
MOUNTING AND ALIGNMENT SUMMARY
• Properly designed and constructed inertia block
• Skid designed and analyzed for engine forces and vibrations
• Engine aligned per Waukesha’s procedure using correct shims and bolts
• Driven equipment aligned to the Waukesha engine
PREPARATION FOR MOUNTING

Waukesha engines should be mounted on an inertia block or a concrete pad with spring
isolators. These types of mounting are important as they help to isolate the engine and its
vibration from the surrounding structure and from other machines. The inertia block or pad
provides a level surface on which to mount the engine as well as a high level of isolation,
which reduces the noise and vibration level transmitted to surrounding buildings and ma-
chines. Waukesha recommends bolting the engine skid directly to the inertia block, without
spring isolators, to reduce the amount of vibration seen by the engine. The concrete upper
face shall be painted with hydrocarbon resistant paint to avoid concrete resistance proper-
ties alteration and/or finishing coping mortar stratification.
It is strongly recommended that the driven equipment be mounted on a common skid with
the engine (see “Figure 6-1: Engine and driven equipment on common skid”). By mounting
both units on the same skid, a common plane for the engine and driven equipment is creat-
ed. The equipment is less likely to lose alignment, because the driven equipment cannot shift
relative to the prime mover (engine).
Driven support Engine
Common skid
Inertia block
Figure 6-1: Engine and driven equipment on common skid
Waukesha strongly recommends the packager analyze skid design to determine that the
structural integrity of the skid does not incur harmful natural frequencies for constant speed
applications and throughout the speed range for variable speed applications.
To meet these demands, the inertia block or pad (spring isolated) must be of both adequate
size and mass to support the engine/driven equipment and to absorb vibration. The engine/
driven equipment common skid must rest on a surface of sufficient density to support both
the common skid and the equipment mounted on it. The inertia block or mounting pad must
have an accurately finished, level mounting surface. To secure the engine/driven equipment
to the inertia block or mounting pad, properly sized retaining bolts must be installed in the
correct spots to align with the holes in the engine base or common skid.
6 - 1 Form 10056-2
Chapter 6 Installation
DETERMINING INERTIA BLOCK OR PAD SIZE RECOMMENDED MINIMUM STANDARDS

Width of the inertia block or pad (W)
The inertia block or pad width is to be at least one foot (30.5 cm) wider than the base of the
engine or the common skid to be installed.
Length of the inertia block or pad (L)
The inertia block or pad length is to be at least one foot (30.5 cm) longer than the combined
length of the base of the engine and driven equipment to be installed.
Height of the inertia block or pad (H)
With the length and width of the inertia block controlled by the package dimensions, the
height will be controlled by the desired weight of the block. Waukesha recommends using a
foundation specialist to determine what inertia block weight and isolation will be required to
minimize vibration transmitted to the surrounding environment. Waukesha provides engine
unbalance forces and moments in the Drive Data section of the Tech Data. This information,
along with the driven machine unbalance information would be required to properly calcu-
late vibration transmission.
In the absence of calculations for the proper inertia block weight, Waukesha recommends
the weight of the inertia block equal 1.3 to 1.5 times the weight of all equipment mounted on
the inertia block or pad.
This includes accessory equipment and the weight of all liquids (coolant and oil) supported
by the inertia block.
Weights of Liquids
Water............................8.03 lb/gal (1.00 kg/liter)
Water/Glycol..............8.55 lb/gal (1.02 kg/liter)
Lube Oil........................7.60 lb/gal (0.91 kg/liter)
Engine capacities are listed in “Table 6-1: Engine liquid capacities”; any additional volumes in
customer supplied equipment or piping must be added if mounted on the inertia block.
Table 6-1: Engine liquid capacities
Jacket & Aux Water Lube Oil

gallons liters gallons liters
12V275GL+ 130 493 220 833
16V275GL+ 173 653 275 1040
6 - 2 Form 10056-2
L
W
Figure 6-2: Schematic of inertia pad
The depth of the inertia block can be found using the following:
H = (1.3 to 1.5)M
(L)(W)135
H = Depth of the inertia block
M = weight of engine in pounds
L = Length of inertia block (common skid length plus one foot)
W – Width of common inertia block (common skid width plus one foot)
135 = Density of concrete [lbs/ft3]
DETERMINING REQUIRED SOIL BEARING LOAD

The next step is to determine if the weight of an inertia block or pad of this size plus the weight
of the engine (and driven equipment, if mounted on a common skid) exceeds the safe soil
bearing load.
Sample calculations for determining the require soil bearing load can be found in the Appendix.
“Table 6-2: Soil bearing capacity” can be used to estimate if the supporting material at the
site will be sufficient to carry the required load. If the required soil bearing load exceeds sug-
gested standards, footings may have to be incorporated to give the inertia block or pad a
larger support area (see “Figure 6-3: Footing for poor bearing soil”).
Table 6-2: Soil bearing capacity
Safe Bearing Capactiy

Nature of Supporting Material
(Lbs. per square ft.) kG/m2
Hard rock – Granite, etc. 50,000 – 200,000 240,000 – 980,000
Medium rock – Shale, etc. 20,000 – 30,000 100,000 – 150,000
Hard pan 16,000 – 20,000 80,000 – 100,000
Soft rock 10,000 – 20,000 50,000 – 100,000
Compacted sand & gravel 10,000 – 12,000 50,000 – 60,000
6 - 3 Form 10056-2
Safe Bearing Capactiy
Nature of Supporting Material
(Lbs. per square ft.) kG/m2
Hard clay 8,000 – 10,000 40,000 – 50,000
Gravel & coarse sand 8,000 – 10,000 40,000 – 50,000
Loose, medium and coarse sand,
6,000 – 8,000 30,000 – 40,000
compacted fine sand
Medium clay 4,000 – 8,000 20,000 – 40,000
Loose fine sand 2,000 – 4,000 10,000 – 20,000
Soft clay 2,000 15,000
Note: This table gives approximate values for average conditions. Building code re-
quirements may vary and should be consulted for a particular locality.
Normal soil Poor bearing soil
Figure 6-3: Footing for poor bearing soil
A suggested concrete mixture of one part cement, two parts sand and three parts aggre-
gate by volume, with a maximum slump of 4 inch (100 mm) providing a 28-day compressive
strength of 3000 psi (211 kg/cm2).
INERTIA BLOCK REINFORCEMENT

The concrete reinforcing network should be a 10 in. x 10 in. (254 mm x 254 mm) steel wire
fabric or equivalent which is 0.155 in. (3.9 mm) diameter minimum. It should be placed 2 inch-
es (51 mm) from the top and bottom surfaces with each level spaced 6 in. (152 mm) apart.
Common skid
Hex nut & flat washer
Shim
Liner
Convoluted tube sleeve
Mounting bolt
Reinforcing
Figure 6-4: Common skid mounted directly
6 - 4 Form 10056-2
An alternate method of reinforcing is to place a level of 3/4 in. (19 mm) diameter reinforcing
rod, or equivalent, on 6 in. (152 mm) centers in both directions. A level should be placed 2
inches (51 mm) from the top and bottom surfaces. Rod placement should take into consider-
ation interference with inertia block or pad mounting bolts and sleeves.
VIBRATION ISOLATION
The inertia block or pad (spring isolated engine) is an important factor in isolating engine
vibration from the surrounding structure. Many times however this is not enough. There are
several additional techniques that can be used to isolate the vibration.
Isolating Liners
A liner can be fabricated and used to line the pit into which the concrete inertia block is
poured (see “Figure 6-5: Cross section of concrete inertia block”) A number of suitable liners
are available commercially. Consult the liner manufacturer for specific information. The prin-
ciple for all liners is the same – line the bottom and sides of the pit, and pour the concrete
inertia block inside of the isolator lining. The engine and/or common mounting skid will still
vibrate, but the vibration is dampened and largely confined within the liner.
Be sure to construct the liner so that no liquid concrete can flow into gaps between the liner
slabs. If concrete seeps between the inertia block and the pit, the vibration absorption value
of the liner will be greatly reduced.
Other materials such as sand or gravel may be used as isolating mediums. One foot of well
tamped, settled gravel under the inertia block will be satisfactory.
Do not bridge the gap between the inertia block and the surrounding floor with concrete or
a similar solid material. If for reasons of neatness or appearance it is necessary to close this
gap, use an expansion joint or a similar resilient material.
Isolation of inertia block from the building, convoluted tube sleeve and anchor bolt place-
ment, and a mounting pad area greater than engine base area may be noted in this illustra-
tion.
Anchor bolt
Engine mounting
surface
Inerita block
Liner
Concrete floor
Liner
Figure 6-5: Cross section of concrete inertia block
6 - 5 Form 10056-2
Spring and Rubber Mounts
Spring and rubber mounts of various sizes and resiliencies are available for installation pur-
poses. These mounts can be positioned between the common skid and the inertia block or
pad or between the inertia block and bottom of the pit (see “Figure 6-6: Schematic of spring
isolator mounting pad construction”). As with the isolating liners, we recommend contacting
the manufacturer of the mounts for specific instructions.
For units installed in basements or on ground floors (no other floors beneath), neoprene waf-
fle type pads (50% vibration reduction) or the sandwich type pad of rubber and cork (75%
vibration reduction) can be used. Where engine-generator sets are to be installed above the
ground floor, the more critical type of isolators should be used.
Larger units should use spring type vibration isolators that provide about 95% isolation. All
percentages are approximate and exact information for your particular application should
be discussed with your Waukesha Distributor to be certain that the right type of isolator is
selected.
Common skid
Leveling screw
Adapter washer
Spring type isolater
in inertia block
Liner
Floor slab
Grouting
Mounting bolt
Reinforcing
Inerita block
Figure 6-6: Schematic of spring isolator mounting pad construction
INERTIA BLOCK BOLT OR PAD MOUNTING BOLT INSTALLATION

The inertia block or pad mounting bolts should be a minimum of an SAE grade 5 bolt mate-
rial. The bolt diameter will be determined by the hole diameter in the engine mounting base
or common skid frame. The bolts should be long enough to provide a minimum embedded
length of 30 times the bolt diameter, plus 3 – 4 in. (76 – 102 mm) for a hook. (The bolt should
have a “J” or “L” shaped hook on the non-threaded end to increase its holding power.) Approx-
imately seven more inches (178 mm) are needed to protrude above the top surface of the
inertia block or pad. These seven inches (178 mm) will provide the length needed for:
• The grout, (if used), 2 inches (51 mm)
• Sole plate, (if used), 3/4 inch (19 mm)
• Chock, 1/2 inch (13 mm)
6 - 6 Form 10056-2
• Shims and engine base, 1-3/4 inches (44.5 mm)
• Washer, nut and small variations in levelness, 7/8 inch (22 mm)
Common skid
Hex nut & flat washer
Rubber washer
Pad type isolater
Shim
Liner
Floor slab

in inertia block
Mounting bolt
Reinforcing
Grouting
Inerita block
Figure 6-7: Common skid mounted on pad type vibration isolators
For a common skid mounted engine, only 7 inches (140 mm) of bolt need protrude above the
inertia block or pad surface (see “Figure 6-8: Mounting bolt”).
Bolt placement in the inertia block or pad can be determined by making a template from 1 x 6
inch (25 x 1 52 mm) boards. Consult a Waukesha installation print for template information. (A
certified installation print can be made for your engine if ordered when the engine is ordered.)
Suspend the template over the inertia block or pad and hang bolts and sleeves through the
template holes (see “Figure 6-9: Template”). Seven inches (178 mm) of bolt must extend from
the top surface of the inertia block or pad.
4” Threaded
Extend to suit mounting
30 x D
+ Sleeve
15°
3-1/2”
Approx.
Figure 6-8: Mounting bolt
6 - 7 Form 10056-2
Outboard bearing
Engine mounting Shaft centerline
mounting bolt holes
bolt holes
Figure 6-9: Template
A sleeve of convoluted plastic tubing 2 – 3 inches (51 – 76 mm) in diameter, should be placed
around the bolts before they are embedded in the concrete (see “Figure 6-10: Mounting
sleeves embedded in concrete”). This will allow the bolts to bend and conform to the dimen-
sions of the sole plate (if used) if the template was not exact. The sleeve may be 10 – 12 in.
(254 – 305 mm) long. The top end of the sleeve should be slightly above the top level of the
inertia block or pad so that the concrete will not spill into the sleeve and interfere with bolt
adjustments.
Convoluted mounting
Mounting bolt Template
sleeve (10-12”)
Foundation bolt Concrete

Liner
Forms
Figure 6-10: Mounting sleeves embedded in concrete
CURING THE INERTIA BLOCK OR PAD

Once the inertia block or pad is poured, it should be kept moist and protected until fully cured
according to the supplier’s requirements. A longer curing period may be required in adverse
weather.
Inertia blocks or pads poured in the winter must be insulated against the cold or have calcium
chloride incorporated into the mix.
Before the concrete curing advances too far, rough up the concrete surface to provide a good
bonding surface for the grout (if used).
6 - 8 Form 10056-2
SOLE PLATES
Sole plates can be used to mount the engine to the inertia block (see “Figure 6-11: Cross
section of mounting using sole plates”). The plates distribute the weight of the engine evenly
over the top of the inertia block or pad. They also make up for any variations of the concrete
from level. When selecting material stock for the sole plates, select cold rolled steel 3/4 – 1
inch (19 – 25 mm) thick, and 4 inches (102 mm) wide minimum. The plates should run the full
length of the engine.
If the engine is common skid mounted, it may be less expensive to use several shorter sole
plates (if required). The plate should be as wide as the common skid flange. Sole plate lengths
are available on Waukesha installation drawings.
The sole plates should be clean and free from rust and scale. Mounting holes in the plates
should be drilled and tapped according to the instructions provided. Jack screws are to be
used in these holes which keep the sole plates in position while pouring the grout. Before the
inertia block or pad is fully cured, the surface should be roughened up to provide for a good
bond between the concrete and the grout. Position the sole plate over the inertia block or pad
bolts, and level the plates, keeping them a minimum of 2 inches (51 mm) above the inertia
block or pad surface. Plates must be level lengthwise, and crosswise, relative to each other.
After leveling, tighten the nuts on the inertia block or pad bolts finger tight. This will help keep
the sole plates level while installing the grout.
Nut Washer
Engine base flange
Shims & chock
Grout Sole plate
2”
Convoluted tube
sleeve (10-12”)
Inertia block
Mounting bolt
6” 2”
Figure 6-11: Cross section of mounting using sole plates
6 - 9 Form 10056-2
GROUTING
Grouting can be done only after the installation of the inertia block or pad has fully cured
and the sole plates (if used) have been positioned and leveled (see “Figure 6-12: Grouting the
inertia block”). On sole plate installations, grouting is important as it anchors the sole plates
in place. Since the sole plates support the engine, it is important that the grout be installed
properly to hold the plates level.
Engines and common skids can be mounted directly to the grout without the use of sole
plates. When this is done, the engine must be mounted and leveled before the grout is poured.
Shim and level the engine as described in Chapter 7: Mounting and Alignment. Pour the grout
under the engine base or common skid. After all grout has cured, back out the jacking screws
and fill with grout.
l Level
ve
Le
l
ve
Le
Grout
2”
2” Mounting bolts
Leveling screws
Additional vibration
Inertia block
insulation
Figure 6-12: Grouting the inertia block
GROUTING PROCEDURE
Make a form around the inertia block or pad. If possible, pour the grout from one point on
the inertia block or pad only, and allow the grout to flow under the common skid or engine
base rails. This pouring procedure will help lessen the chances of air pockets being trapped
between the engine and the inertia block or pad. Air pockets will lessen the contact area
between the grouting and the engine base or common skid, reducing support for the engine.
Also, a metallic based grout will expand into these spaces and force the engine out of align-
ment. If the pour point on the engine or common skid is slightly higher than the rest of the
inertia block or pad, the grout will flow more easily under the engine or common skid.
The best way to install a concrete, metallic based grout is to form wedge shaped grout pads
(see “Figure 6-13: Rear view of mounted engine”). These pads should run the length of the en-
gine or common skid. Slope the grout outward in a wedge shape towards the inertia block or
pad to provide better support. Sole plates can be embedded in this run of grout, or the engine
base can be installed directly on it.
The advantage of this grouting technique is that it will keep grout out from under the engine.
The grout will not be able to expand up into the hollow area under the engine base and force
the engine out of alignment.
6 - 10 Form 10056-2
Grout Sole plate
Inertia block or pad
Figure 6-13: Rear view of mounted engine
Grouting should be worked into place using rods or chain lengths. Work the material gently
to avoid air entrapment.
When using sole plates, pour in enough grout to embed the plates 1/2 inch (13 mm) into the
grout. When sole plates are not used, never allow the grout to come up over the engine base
or common skid, to allow for future adjustments.
Follow the grout manufacturer’s instructions for applying the grout, and recommendations
for curing times. Concrete grouts must be sealed after curing. All metallic based grouts should
be sealed to prevent rust from destroying the grout.
If the grout is allowed to settle at a slight outward slope, oil and water will be able to run off
the inertia block or pad.
After the grout has cured, remove the leveling screws and remove any accumulation from the
common skid or engine base. Save enough grout to pour into the inertia block bolt sleeves
after the engine has been aligned.
Many epoxy grouts are also available which provide superior performance for these appli-
cations.
6 - 11 Form 10056-2
6 - 12 Form 10056-2
Mounting and Alignment Chapter 7
CHAPTER 7 - MOUNTING AND ALIGNMENT

MOUNTING SURFACE
This section discusses mounting surface requirements for Waukesha 275GL engines.
Waukesha 275GL engines require a very smooth and level mounting surface. This is to pre-
vent distortion of the main bearing bores in the crankcase and prevent movement from vi-
bration and thermal growth. Using shims to correct a rough distorted surface does not pro-
vide adequate support under the engine.
“Figure 7-1: Machined surface mounting”, illustrates a surface leveled by machining then
shimmed and a surface leveled by shims alone.
Machined mounting surface Non-machined mounting surface
Figure 7-1: Machined surface mounting
The machined surface provides a much better support.
A level mounting surface can be provided by attaching 175 mm x 175 mm x 65 mm (7” x 7”

x 2.5”) chocks to the skid by welding or grouting. The engine mounting surface of the chocks
must be flat, smooth, and their planes parallel within 0.08 mm (0.003”) with a surface finish
of 500 RMS.
Mounting bolt
Skid
Welded or
Shims grouted
Figure 7-2: Shimming an engine
Shims of 127 mm x 127 mm (5” x 5”) are then used at each mounting bolt to correct base
deflection and alignment. Appendix C ”Shimming Information” describes proper shimming
procedures and lists shims available from Waukesha.
7 - 1 Form 10056-2
Chapter 7 Mounting and Alignment
Adjustable engine shims or chocks are suitable for mounting Waukesha gas engines pro-
vided the installer follows the sizing and installation guidelines of the adjustable shim man-
ufacturer. 12V275GL+ and 16V275GL+ engines require Vibracon SM36 or equivalent size. All
original engine mounting holes must be used, and the correct size for the size of the engine
must be used. It is not acceptable to use a smaller size shim to allow for clearance around the
engine mounting pad or original jacking bolt.
Adjustable engine shims may loosen over time, and engine alignment must be checked peri-
odically to ensure engine is in correct alignment at all times.
All of the mounting bolt positions are required to properly secure the engine. The jacking bolts
are used to raise the engine to shim for final crankshaft web deflection and alignment. An
anti-seizing dry lubricant must be applied to the jacking bolts before adjusting to prevent the
threads from locking. The jacking bolts can be removed and mounting bolts installed once
the engine is aligned to provide additional clamping force. If the jacking bolts are to remain in
place, they must be backed off to allow proper forging of the mounting bolts.
Mounting bolts should not be a tight fit through the holes in the engine and skid. The bolts
should either be slightly smaller than the engine mounting hole or the thru hole in the skid
should be slightly larger than the bolt. The 275GL+ engine mounting holes have a 37mm
diameter.
Figure 7-3: Bolt locations for 16V275GL+
Figure 7-4: Bolt locations for 12V275GL+
Table 7-1: Bolt location
Engine No. of mounting Positions No. of jacking Positions

bolts bolts
12V275GL+ 8 1, 3, 5, 7 6 2, 4, 6
16V275GL+ 10 1, 3, 5, 7, 9 8 2, 4, 6, 8
7 - 2 Form 10056-2
CRANKSHAFT WEB DEFLECTION
Turn off the air/gas supply to the starters and bleed off air/gas pressure to prevent acci-
dental rotation of the crankshaft before entering the engine crankcase. Accidental rota-
tion of the crankshaft could result in severe personal injury or death.
Engine crankshaft distortion caused by mounting is determined by measuring deflection of

crankshaft webs. This procedure measures the deflection of a crankshaft during one revo-
lution. It is the most direct method of determining if the shaft is being bent by a deflected
crankcase or misalignment. Web deflection measurements are required for 275GL engines.
Equipment attached to the front stub shaft can effect engine alignment. If any side loading is
applied the front stub shaft, web deflection must be checked with this load applied.
Waukesha 275GL engines have center point marks located on the counterweights to indicate
proper web deflection gauge mounting locations (see “Figure 7-5: Checking the crankshaft
deflection”).
1. Mount a web deflection gauge, tool #A292683, into the center point marks. Carefully twirl the
gauge to make sure it is properly seated.
2. Position the crankshaft so the deflection gauge hangs freely next to the connecting rod, as
close to the rod as possible, but not touching. Zero the gauge dial.
3. Slowly rotate the crankshaft until the gauge is in position 2, on the horizontal. Record any
positive or negative reading attained.
4. Rotate the crankshaft to positions 3 and then 4, recording any readings. Now rotate the shaft
further until the gauge is as high as possible to position 5 without contacting the connecting
rod. Record this reading.
5. Remove the deflection gauge and repeat this procedure on the other crankshaft webs. Ac-
ceptable deflection figures are given in “Table 7-2: Deflection of web”.
Table 7-2: Deflection of web
NEXT TO FLYWHEEL ALL OTHER WEBS

0/-0.105 mm +0.035 mm/-0.035 mm
(+0/-0.0040”) (+0.0015”/-0.0015”)
7 - 3 Form 10056-2
POSITIONS OF WEB DEFLECTION GAUGE
Right side Left side
Gauge
Gauge
Position 1 Position 5
View of damper side

(6”)
1 5
152.5
2 4
Measuring positions
Damper side
Outer mount Inner mounts Outer mount
Enlarging of Narrowing of
distance between distance between
crank webs crank webs
Figure 7-5: Checking the crankshaft deflection
Crankshaft web deflection is corrected by adjusting the mounting foot height adjacent to the
deflected web. A web which is closed at the bottom (6:00) position is corrected by lowering
an inner mount or raising an outer mount, if it is adjacent to an outer mount. Conversely, a
web which is open at the bottom is corrected by raising an inner mount or lowering an outer
mount. After an adjustment the deflection at the other crankshaft webs must again be mea-
sured.
Tightening any v-belts on the engine stub shaft or pulley can change the engine alignment
and cause crankshaft web deflection values to change. Alignment should be checked once
all driven equipment is attached to the engine.
7 - 4 Form 10056-2
ALIGNMENT
MULTI-BEARING MACHINES
A multi-bearing machine is one which fully supports its own shaft and does not rely on the
engine shaft to support the driven end.
Three areas must be adjusted to accurately align a multi-bearing machine to an engine,

which is also a multi-bearing machine. These are: end play, angular alignment and parallel
alignment.
When aligning two multi-bearing machines, one machine must be designated as the station-
ary machine and one as the movable machine. Deciding which machine will be stationary
will depend on size, weight, and connections. All adjustments will be made on the movable
machine.
Adjusting angular and parallel alignment on multi-bearing machines requires correcting the
angular alignment first and then parallel. Once alignment is acceptable, the machines must
be shimmed to compensate for thermal growth (see “Figure 7-6: Angular alignment”).
Vertical misalignment
Engine
Horizontal misalignment
Engine
Proper alignment
Engine
Figure 7-6: Angular alignment
Waukesha offers a low cost computer program (P/N 475063) which finds adjustments for
angular and parallel alignment as well as thermal growth. The program user inputs dimen-
sional, growth, and measuring information. Using this program, only one or two adjustments
are normally required to place the units within the alignment specifications. If the alignment
program is not available, the following procedure will provide an accurate alignment.
7 - 5 Form 10056-2
END PLAY
To measure end play:
1. Roughly position the two machines and install the shaft coupling. Adjust the distance be-
tween the two machines so that there is no apparent tension or compression of the coupling.
Properly space gear type couplings per the coupling manufacturer’s specifications.
2. Set up a dial indicator on the machine with the least end play (normally the engine). Clamp
the dial indicator to the engine crankcase and read against the flywheel face.
3. Pre-lube engine until gauge reads a pressure, if oil is available.
4. Pry the crankshaft fully forward, and zero the dial indicator. (Moving the crankshaft will
require removing an oil pan door and prying between a main bearing cap and crankshaft
cheek or web.)
5. Pry the shaft rearward and read the dial indicator. Crankshaft end play should be within
0.15 – 0.45 mm (0.006 – 0.018”). The shaft must not spring back when the pry bar is removed.
6. If there is insufficient end play or if spring-back occurs, adjust the distance between the
machines until it is resolved.
ANGULAR ALIGNMENT
To measure the angular alignment, a dial indicator is mounted to the coupling half of one
machine to read against the coupling half face of the other. The coupling should be installed
or the shafts bound together so they both turn together while taking the alignment measure-
ments. The radius “R” from the center of the shaft to the dial indicator should be at least 180
mm (7”) (see “Figure 7-7: Distance from center of shaft to dial indicator”).
Driven coupling Drive coupling

“7”
half half
(180 mm)
Figure 7-7: Distance from center of shaft to dial indicator
Before taking readings, roll the shaft 45° in reverse rotation and then back 45°nin standard
rotation and zero the dial indicator. This sets the axial position for both the engine and driven
machine shafts.
To measure angular alignment, four dial indicator readings are required; one each at the
12:00, 9:00, 6:00 and 3:00 positions which are taken while turning the engine in the standard
direction of rotation (see “Figure 7-8: Dial indicator reading positions when measuring angu-
lar alignment”).
7 - 6 Form 10056-2
12:00
9:00 3:00
6:00
Figure 7-8: Dial indicator reading positions when measuring angular alignment
Readings taken at the 12:00 and 6:00 positions determine vertical angular alignment and
readings in the 3:00 and 9:00 positions determine horizontal angular alignment. A total in-
dicator reading (TIR) is the absolute difference between two readings on opposite sides of
the shaft (see “Figure 7-9: Total indicator reading (TIR)”). The horizontal TIR is (-0.009”) and
(+0.004”) which is a difference of (0.013”). Vertical TIR is (0) and (+0.005”) which is a difference
of 0.127 mm (0.005”).
-0.009 +0.004
+0.005
Figure 7-9: Total indicator reading (TIR)
“Figure 7-10: Multi-bearing driven equipment”, shows the shaft of a multi-bearing machine
with both angular and parallel misalignment.
Figure 7-10: Multi-bearing driven equipment
This could represent either vertical or horizontal misalignment since the principles are the
same for both.
Correcting this misalignment first involves correcting angular alignment, thus getting the
shaft centerline to line up on line B.
7 - 7 Form 10056-2
The amount of correction required to bring the centerline into alignment with line B, can be
determined from the dial indicator TIR, radius to the indicator “R”, and distance “L” from the
coupling to the mounts.
1 / 2 (TIR ) So Si
= =
R Lo Li
Therefore:
Lo x 1 / 2 (TIR )
So =
R
and
Li x 1 / 2 (TIR )
Si =
R
“So” is the amount of adjustment at distance “Lo” which is the distance from the center of the
coupling to the center of the outboard mount.
“Si” is then the adjustment at a mount distance of “Li” from the coupling.
The adjustment should be made to close the open side of the coupling (see “Figure 7-11:
Adjusting coupling”).
Closed side
Adjust this
direction Adjust this
direction
Open side
Open side
Figure 7-11: Adjusting coupling
Adjustment for angular alignment should then take place as follows:
1. Set up two dial indicators, one to monitor horizontal movement of the inboard mounts, one to
monitor horizontal movement of the outboard mounts. Zero the indicators (see “Figure 7-12:
Adjusting for angular alignment”).
driven equipment
Engine
Dial indicators
Figure 7-12: Adjusting for angular alignment
7 - 8 Form 10056-2
2. Going to one corner at a time, loosen the mounting bolt and shim as calculated, then tight-
en the mounting bolt. Center mounts will have to be shimmed in conjunction with corner
mounts. Note any horizontal movement that may occur on the dial indicators.
After shimming, loosen both mounts on one end and all center mounts. It may also be nec-
essary to loosen one mount on the fixed end but do not loosen both. Slide the free end the
amount calculated, then re-torque the bolts (see “Figure 7-13: Slide free end”).
driven equipment
Engine
Figure 7-13: Slide free end
Loosen both bolts on the opposite end and move as calculated. Re-torque all mounting bolts
(see “Figure 7-14: Move opposite end”).
driven equipment
Engine
Figure 7-14: Move opposite end
3. Check angular alignment again using the same procedure as used previously. Angular align-
ment is correct when total indicator runout is less than 0.127 mm (0.005”) per foot of radius
from center of shaft to where the dial indicator reads (see “Figure 7-15: Correct angular align-
ment”).
driven equipment
Engine
Figure 7-15: Correct angular alignment
7 - 9 Form 10056-2
PARALLEL ALIGNMENT
Parallel alignment can be checked and adjusted after angular alignment has been complet-
ed. It will, however, be necessary to re-check angular alignment after each adjustment (see
“Figure 7-16: Parallel alignment”).
Vertical misalignment
Engine
Horizontal
Horizontalmisalignment
alignment
Engine
Proper alignment
Engine
Figure 7-16: Parallel alignment
The following procedure can be used to measure parallel alignment.
1. Set up a dial indicator to read parallel alignment. If available, setup a second dial indicator
to read angular alignment. This will allow you to rotate the shafts only one time to get both
readings (see “Figure 7-17: Position of dial indicator”).
Read parallel
Read angular alignment
alignment
Driven coupling Drive coupling

half half
Figure 7-17: Position of dial indicator
2. Rotate both shafts to the 2:00 position (facing the flywheel) then back to the 12:00 position.
Zero the indicator(s).
7 - 10 Form 10056-2
3. Rotate the shafts to the 9:00 position and record the readings.
4. Rotate the shafts to the 6:00 and 3:00 positions and record the readings.
5. Rotate the shafts back to the 12:00 position and verify that the indicators return to zero.
The amount of parallel misalignment is one-half the TIR (total indicator reading) for each
direction.
See “Figure 7-18: Total indicator reading (TIR)”. In this example, the vertical TIR is 0.508 mm
(0.020”), thus the machines are vertically misaligned by 0.254 mm (0.010”). Horizontal TIR is
the difference between (+0.015”) and (+0.005”) which is (0.010”). Horizontal misalignment is
1/2 of the TIR which is (0.005”). All mounts should get the same amount of adjustment, 0.127
mm (0.005”) in this case, to move the machine without losing angular alignment.
-0.015 +0.005
+0.020
Figure 7-18: Total indicator reading (TIR)
Adjustment for parallel alignment is similar to that for angular and should be accomplished
as follows:
1. Set up two dial indicators; one to monitor horizontal movement of the inboard mounts, and
one to monitor horizontal movement of the outboard mounts. Zero the indicators.
2. Going to one corner at a time, loosen the mounting bolt(s) and shim as calculated, then
torque the mounting bolt. Center mounts will have to be shimmed in conjunction with corner
mounts.
3. After shimming, loosen both mounts on one end and all center mounts. It may also be nec-
essary to loosen one mount on the fixed end but do not loosen both. Slide the free end the
amount calculated then re-torque the bolts.
4. Loosen both mounts on the opposite end and move the same. Re-torque all mounting bolts.
5. Check parallel alignment again using the same procedure as used previously. Parallel align-
ment is correct when total indicator runout is less than 0.127 mm (0.005”).
THERMAL GROWTH
After angular and parallel alignment are satisfactory, it will be necessary to adjust alignment
to compensate for engine block thermal growth which affects the height of the crankshaft
centerline after the engine is hot. This will allow the machines to be in good alignment after
they reach operating temperature.
Table 03 lists the changes in crankshaft height that will occur due to the temperature change
from 21°C (70°F) to normal operating temperatures (measured from the mounting rail of the
crankcase).
7 - 11 Form 10056-2
The vertical thermal growth in the height of the 275GL crankshaft centerline from the bottom
of the crankcase pan rails are listed here in “Table 7-3: Vertical thermal growth crankshaft
centerline” (based on temperature change from 21° C (70°F) to normal operation oil tempera-
ture).
Table 7-3: Vertical thermal growth crankshaft centerline
ENGINE HEIGHT OF CRANKSHAFT VERTICAL GROWTH IN CRANKSHAFT HEIGHT

MODEL CENTERLINE TO BOTTOM OF PAN RAIL (Over Range of Normal to High Lube Oil
Temperatures)
12V/16V 480 mm (18.898”) 0.31 – 0.39 mm (0.012 – 0.015”)
Heat growth information for the driven equipment should be available from the manufactur-
er. If not, it can be calculated with the following formula:
Gm = (Tm - 70) x h x E for °F or (Tm - 20) x h x E for °C
Where:
Gm = amount of growth expected (inches or mm)
Tm = operating temperature of driven machines (°F or °C)
h = height from machine mounting surface to center of shaft (inches or mm)
E = thermal expansion coefficient for material machine is made from:
6.5 x 10-6 (0.0000065) in/in °F or 1.2 x 10-6 mm/mm °C for steel
5.8 x 10-6 (0.0000058) in/in °F or 1.1 x 10-6 mm/mm °C for cast iron
To adjust for thermal growth take the difference in machine growths and add that amount
in shims under the machine which grows least. In the case of cooling compressors, the com-
pressor gets cold when loaded and shrinks. This will require a further offset to compensate
for engine growth and compressor shrinkage. The growth formula still applies for a cold com-
pressor since the growth number will be negative.
To add the shims, loosen one side at a time and add the shims then re-torque the bolts before
moving on to the next mount. This prevents horizontal alignment from changing while add-
ing shims. Parallel dial indicator readings will now indicate the machine which grows least
is higher than the machine which grows more, but the machines will be aligned when they
reach operating temperature.
Check end play to verify that the alignment procedure did not eliminate end thrust.
HOT CHECK
Engine components and fluids are extremely hot after the engine has been shut down.
Contact with hot components or fluids can cause severe personal injury or death. Wear
protective clothing and eye protection protection during the hot check of crankshaft de-
flection.
Once the machines are aligned and offset for thermal growth, they should be checked when
hot.
1. Remove alignment measurement instruments.
2. Install safety guards over flywheel and coupling.
7 - 12 Form 10056-2
3. Start the engine and apply load.
4. Allow machines to run for one hour after reaching their operating temperatures.
Ensure that all tools and other objects are removed from the unit and any driven equip-
ment before starting the unit. Running equipment can eject objects at great force, result-
ing in severe personal injury or death.
5. Shut down and immediately check angular and parallel alignment and end play. Alignment
TIR should now be less than 0.203 mm (0.008”) both parallel and angular.
6. Adjust alignment and end play if necessary.
PERIODIC INSPECTIONS
Engine base deflection and alignment must be checked periodically, at least once a year.
Installations which are subject to settling of the concrete must be checked often (initially –
monthly) to determine if settling is causing misalignment.
ALIGNMENT WORKSHEET
1. Install and level engine or common skid.
2. Measure crankshaft web deflection.
Table 7-4: Web deflection
NEXT TO FLYWHEEL ALL OTHER WEBS

0/-0.105 mm +0.035 mm/-0.035 mm
(+0/-0.0040”)) (+0.0015”/-0.0015”)
Throw 1 2 3 4
TIR 0. 0. 0. 0.
mm (in.) mm (in.) mm (in.) mm (in.)
Throw 5 6 7 8
TIR 0. 0. 0. 0.
mm (in.) mm (in.) mm (in.) mm (in.)
3. Adjust base deflection at four corners of driven machine.
0. mm (") 0. mm (")
0. mm (") 0. mm (")
4. Check for crankshaft end play 0.________ mm (“)
7 - 13 Form 10056-2
5. Check and adjust angular alignment. Maximum 0.127 mm (0.005”) per foot of radius from
center of shaft to dial indicator read point.
0.
mm (")
0. 0.
mm (") mm (")
0.
mm (")
6. Check and adjust parallel alignment. Maximum TIR 0.127 mm (0.005”).
0.
mm (")
0. 0.
mm (") mm (")
0.
mm (")
7. Adjust for thermal growth.
Engine Growth 0._______mm (“) minus
D.M. Growth 0._______mm (“) = Cold Alignment Offset 0._______mm (“)
8. Recheck crankshaft end play 0._______mm (“)
9. Start engine, run loaded, allow to warm up 1 hour minimum 0._______
10. Shutdown and check hot angular alignment and end play.
End play (Hot) 0._______mm (“)
Alignment:
Parallel (Hot) Angular (Hot)
0. 0.
mm (") mm (")
0. 0. 0. 0.
mm (") mm (") mm (") mm (")
0. 0.
mm (") mm (")
7 - 14 Form 10056-2
Endplay before alignment______________________ End play after alignment_______________________

Engine model________________________________ Serial No.____________________________________
Driven machine make_________________________ Model No.___________________________________
Customer’s observer__________________________ Performed by________________________________
Date_______________________________________
Figure 7-19: Alignment progression chart
7 - 15 Form 10056-2
SUMMARY OF MOUNTING AND ALIGNMENT
The intent of this section is to review the step by step procedure to properly install the 275GL
engine both in the fabrication shop and at the final operating site.
FABRICATION SHOP
1. Level the prefabricated skid in the fabrication shop.
2. Prepare the mounting surfaces.
3. Install the engine on the skid. Level the engine using jacking screws (Section1). Use crankshaft
deflection measurements for engine leveling ().
4. With the engine in its leveled position, install shims.
5. Remove or loosen the jacking bolts and fasten the engine down with the mounting bolts.
Recheck crankshaft deflection and make corrections if necessary.
6. Align the driven machine.
ON SITE
1. Level the unit skid using crankshaft web deflection and alignment to verify the skid is properly
leveled (see “Figure 7-20: Adjust for minimum crankshaft web deflection per section”).
Engine
Figure 7-20: Adjust for minimum crankshaft web deflection per section
2. Shim or grout under the skid to hold its level position.
3. Fasten the skid with anchor bolts or welding, whichever is applicable.
4. Recheck alignment and crankshaft deflection to verify fastening did not cause distortion.
Correct it if necessary.
Ensure that all tools and other objects are removed from the unit and any driven equip-
ment before starting the unit. Running equipment can eject objects at great force, result-
ing in severe personal injury or death.
5. Hot Check – Operate the engine for 1 hour minimum after reaching operating temperature.
Shut down the engine and recheck crankshaft deflection and alignment.
7 - 16 Form 10056-2
Engine Lifting Chapter 8
CHAPTER 8 - ENGINE LIFTING
Exercise extreme care when moving the engine or its components.

Never walk or stand directly under a suspended engine or any ob-
ject. Always consider the total weight of the engine, the compo-
nents involved when selecting hoisting chains and lifting equip-
ment. Be positive about the rated capacity of lifting equipment.
Use only properly maintained lifting equipment with a lifting ca-
pacity that exceeds the known weight of the object to be lifted.
Always lift engine using the approved lifting eyes. The 12V/16V
275GL+ engines are equipped with two pairs of lifting eyes. Lifting
eyes are only meant for lifting the engine. Do not use to lift driven
or auxiliary equipment that may be attached to the engine.
Follow approved rigging procedures to ensure that no undue

strain is placed on the lifting eyes or hoisting chains/cable sling
when the engine is raised. Use the proper lifting device to avoid
damage o the cylinder head studs.
275GL engines will be supplied with a skid that is suitable for shipping but is not to be used
for mounting or operating the engine. GE Power introduced a new Waukesha 275GL engine
lifting lug design in 2016 to make lifting easier. Verify which lifting lug is installed before lift-
ing any 275GL+ engine. The previous lifting lug required the use of a special spreader barto
maintain a 27° angle on the lifting chains. The new lifting lugs allow vertical lifting. See Service
Bulletin 15-4066 for more information.
275GL Enginators include the generator and a skid suitable for shipping and mounting. Spe-
cific lifting instructions will be provided with each Enginator order. Depending on weight re-
quirements the generator may be shipped separate from the engine/skid to reduce the max-
imum weight to be lifted.
To identify between new lugs and old lugs, reference the part numbers and compare the
physical differences in “Figure 8-1: New and previous lifting lug comparison”. Note that the
new lug is painted yellow from the factory. When using the new lug (P/N 293303E), it is critical
that the lugs are installed on the engine in the correct orientation. The arrow must be pointing
toward the centerline of the engine (see”Figure 8-2: Lifting lug orientation”) labeled on the lug.
Figure 8-1: New and previous lifting lug comparison
8 - 1 Form 10056-2
Chapter 8 Engine Lifting
Figure 8-2: Lifting lug orientation
Figure 8-3: New four-point lifting beam (P/N 295174G)
8 - 2 Form 10056-2
The lifting eyes on the 16V275GL+ engine are to be installed between the 1R and 2L cyl-
inder heads and 7R and 8L cylinder heads on both sides of the engine. The lifting eyes on
the 12V275GL+ engine are installed between the 1R and 2L cylinder heads and 5R and 6L
cylinder heads on both sides of the engine. The engine will be shipped with a clevis, plate
and four nuts that are used in conjunction with the lifting device (see “Figure 8-4: Clevis plate
installation” through “Figure 8-5: 16V275GL+ clevis plate location”).
Figure 8-4: Clevis plate installation
Figure 8-5: 16V275GL+ clevis plate location
8 - 3 Form 10056-2
NOTE: In order to install lifting eyes, knock sensors on the 16V 275GL + cylinder heads 2L, 8L,
1R and 7R MUST be removed. On the 12V 275GL +, knock sensors on cylinder heads 2L, 6L, 1R
and 5R MUST be removed.
Before operating the engine the plates must be removed and the knock sensors reinstalled
and torqued to 20 N·m (177 in.-lb) dry.
RIGGING AND LIFTING PROCEDURE
The new vertical lifting lug (P/N 293303E) is designed to be attached to a vertical lifting device
for a straight vertical lift. The new vertical lifting lug system allows use with a standard four-
point adjustable lifting beam and is ASME- and CE-compliant.
The new vertical lifting beam (P/N 295174G) is designed to be used with new lifting lugs (P/N
293303E) (see Figure 8-Z). The new lifting beam is ASME- and CE-compliant, is adjustable, and
has the capacity to lift 12V or 16V 275GL+ engines.
The end user also has the option of obtaining other beams or other lifting means. The follow-
ing requirements apply to a lifting device to be used with the new lugs (P/N 293303E):
• It must be rated to lift a minimum of 75,000 lb (34,019 kg) for 16V275GL+ engines or
66,000 lb (29,937 kg) for 12V275GL+ engines.
• The chain angle from the lifting lug to the lifting device must not exceed 15 degrees in a
front-to-back direction or 27 degrees out from the lug (in reference to the engine’s cen-
terline)
• The lifting device must lift directly over the engine’s center of gravity to ensure the engine
is lifted level
See Service Bulletin 15-4066 for more information.
Single point lifting is prohibited. Do not use four chains or straps to one single point.
NOTE: With old style lifting lugs (P/N 293303B) use certified lifting device (Special Tool P/N
295174E) when lifting the 12V275GL+ or 16V275GL+ engine. The old style lifting device pro-
vides the required 27° lifting angle from the engine centerline. Maximum lifting capacity of
the lifting device is 38,555 kg (85,000 lb). Do not use this lifting device when temperatures are
below -17.8°C ( 0°F ).
See “Table 8-1: Lifting specifications” for lifting specifications.
8 - 4 Form 10056-2
Table 8-1: Lifting specifications
DESCRIPTION LIFTING DEVICE

Maximum Capacity 38,555 kg (85,000 lb)
Weight (Approximate) 3,175 (7,000 lb)
Crossbeam Adjustments 2,762.25 mm (108.75 in.)
Tightening Torque (Lifting eye to engine) 203 – 237 Nm (150 – 175 lb-ft)
Bail Adjustment 241.3 mm (9.5 in.) total in 120.65 mm (4.75 in.) increments
Minimum ambient temperature -17.8°C (0°F)
Acceptance Test: Sight Inspection
Test Load: Rated Load + 50% Once a Year
Figure 8-6: Lifting of 12V275GL+ using Waukesha supplied lifting device and old style lugs
8 - 5 Form 10056-2
SUPPORTING FLYWHEEL
During shipping and storage of the engine the flywheel must be properly supported to pre-
vent damage to the main bearings. Use the following procedure and supplied equipment to
properly support the flywheel.
1. Assemble the wedge blocks, threaded rod, nuts and washers on the base.
2. Temporarily attach two dial indicators to read the flywheel position as shown. The nuts on the
outside of the base beam should be tightened to hold the threaded rod in place. The threaded
rod may be cut to accommodate a narrower base width.
3. Set both dial indicators to zero. Raise the flywheel by alternately tightening the outer nuts
against the left and right wedge. (Requires less than one full rotation of the outer nuts.)
4. The final vertical flywheel position from zero should read between +0.007 and +0.008 inches
(0.178 and 0.203 mm) on the top dial indicator.
The final Horizontal flywheel position should be between -0.001 and +0.001 inches (0.025 and
-0.025 mm) on the side dial indicator.
Horizontal adjustments are made by tightening one wedge side more or less than the other.
5. When the readings are within specification lock the wedge blocks in place by tightening the
jam nuts and check that the dial indicators are still within the required specification,
6. The nuts on the inside of the wedge blocks are used (if necessary) to help lower the flywheel,
before the engine is removed from the skid.
Top dial indicator
Side dial indicator
2 1
3, 4
3, 4, 5 6
Figure 8-7: Supporting the flywheel
Table 8-2: Flywheel support
Item Quantity Name

1 2 wedge block, flywheel
2 1 rod, thrd 3/4”-10 UNC x 72”
3 8 flat washer 3/4”
4 8 hex nut 3/4”-10 UNC
5 4 jam nut 3/4”-10 UNC
6 1 shipping skid
7 1 flywheel
8 - 6 Form 10056-2
Cooling System Chapter 9
CHAPTER 9 - COOLING SYSTEM

COOLING SYSTEM REQUIREMENTS
• Radiator sized using site specific engine data from EngCalc or Special Application Approv-
al (SAA)
• Radiators installed considering prevailing winds at the site. Install radiators so they are not
adversely affected by other heat sources on site
• Static pressure lines connected to the inlet of each pump providing a static inlet pressure
between 6.5 – 22 psig (0.45 – 1.5 bar)
• Vent lines installed at high points of the engine for both JW and AW circuits
- Vent lines continuously sloping upwards to expansion tank
- Vent lines should be 1/4” in diameter on systems with vent lines less than 10 feet (3
meters) long, or 1/2” diameter with a 1/4” orifice on systems with vent lines more than
10 feet (3 m) long
• Separate expansion tank for each circuit sized for 11% of total cooling system volume
with a 7 psig (0.48 bar) pressure cap
• Flexible connections installed on all connections to the engine including static pressure
lines and vent lines
• Jacket water heater systems installed when ambient air temperature is less than 50°F
(10°C)
• Piping properly supported not to exert any additional forces on engine connections
• External cooling system restriction is less than maximum external restriction limits pub-
lished in tech data on S-9063-38 and S-9063-37
• Industrial natural gas engine coolant that meets Waukesha’s water treatment guidelines
in technical data document S-7610-3
SUPPORTING DOCUMENTS
L-08092-9 12V275GL+ outline drawing
L-08065-39 12V275GL+ flexible connection outline drawing
PC2174A Cooling system P&ID
S-6699-7 Cooling system guidelines
S-7610-3 Water treatment guidelines
S-9001-21 Cooling system schematic
S-9063-37 12V275GL+ jacket and auxiliary water pump performance
S-9063-38 16V275GL+ jacket and auxiliary water pump performance
9 - 1 Form 10056-2
Chapter 9 Cooling System
S-9064-2 Water heater recommendations
EngCalc Engine data program for site specific heat rejection
COOLING SYSTEM OVERVIEW

275GL+ engines consist of two separate cooling circuits, one circuit for the engine jacket wa-
ter, one circuit for the intercooler and oil cooler. Both circuits include engine gear driven water
pumps, mechanical thermostats, and bypass piping. The jacket water circuit consists of cool-
ing the engine cylinders, cylinder heads, and turbocharger bearing housings and maintains
an engine outlet temperature of 180°F (82°C) with the engine mounted thermostat. The aux-
iliary water circuit cools the charge air intercooler and lube oil cooler while maintaining an
engine inlet temperature of 130°F (54°C) with the engine mounted thermostat.
RADIATOR SIZING
Engine cooling is typically performed using an externally mounted radiator or cooler. For gas
compression applications, this is typically a separate core cooler that is used to cool both the
jacket water and auxiliary water circuits on the engine as well as the gas compression stages.
When sizing the cooler for the engine circuits, EngCalc or a Special Application Approval (SAA)
must be used to determine site specific engine data which is dependent on the ambient tem-
peratures, site elevation, engine operating point, and fuel composition. Engine heat rejection
data will be provided for all systems, and it is recommended to use the high end of the heat
rejection data tolerance, as well as an additional safety and fouling factor to ensure the cool-
er is sized to prevent overheating the engine.
The temperature rise across the engine will vary with operating conditions, but it is recom-
mended to maintain a fairly consistent temperature differential across the engine. Large tem-
perature differentials across the engine can cause cyclical temperature changes, or even
thermal shock the engine if extremely cold coolant suddenly enters the engine which can
cause engine damage.
Typical coolant temperatures:
• Jacket Water inlet: 165°F (74°C)
• Jacket Water outlet: 180°F (82°C) (thermostatically controlled outlet temperature)
• Auxiliary water inlet: 130°F (54°C) (thermostatically controlled inlet temperature)
• Auxiliary water outlet: 150°F – 165°F (65°C – 74°C)
COOLING SYSTEM PIPING

Cooling system piping must be sized to allow the coolant to flow without excessive restric-
tion. The piping material must be suitable for the temperatures and pressures encountered,
as well as vibration from the operating engine. Flexible connections are recommended at
all connection points to the engine. This will isolate the engine and piping components from
high stresses due to vibration. Engines mounted on spring isolators or other soft mounting
systems must have cooling system connections with flexibility sufficient to handle the mo-
tion normally encountered. Flexible connections for the Jacket and Auxiliary water circuit
inlet and outlet connections are available as an option from Waukesha for 275GL+ engines.
Cooling system piping must also be properly aligned and supported on the package to not
exert any external forces on the engine connections. Flexible connections are not designed
to accommodate for misaligned piping.
9 - 2 Form 10056-2
Optional Flexible connection specifications and alignment
Jacket Water Flexible Connections
• 5.00” ANSI 150# Raised – Face Flange
• 24 inch length
• 1.5 inch maximum offset from centerline
Auxiliary Water Flexible Connection
• 4.00” ANSI 150# Raised – Face Flange
• 24 inch length
Dresser and Flexmaster couplings have the ability to join pipes which are not closely aligned.
These couplings flex to join the pipes. However, they become very stiff when clamped in place.
Waukesha does not consider these as flexible couplings for isolating components from ex-
cessive vibration.
Piping restriction depends on the pipe diameter, pipe length, number of elbows and transi-
tions, and the piping material used. A procedure for calculating the cooling system piping
restriction is available in Appendix A in this manual. This procedure uses the EDL (Equivalent
Duct Length) Method, however there are other methods or computer based simulations that
may also be used.
Jacket Water Inlet connection: 5.00” ANSI 150# Raised – Face Flange
Jacket Water Outlet Connection: 5.00” ANSI 150# Raised – Face Flange
Auxiliary Water Inlet Connection: 4.00” ANSI 150# Raised – Face Flange
Auxiliary Water Outlet Connection: 4.00” ANSI 150# Raised – Face Flange
CIRCUIT EXTERNAL RESTRICTION, BOOSTER PUMP

If the external restriction of the cooling system is too high, an additional cooling system
booster pump is required to ensure adequate flow through the cooling system. The two pump
system, illustrated in “Figure 9-1: Two pump system”, is used in circuits where the engine
water pump has insufficient capacity to flow coolant through the engine and heat recovery
components. A system water pump is installed downstream of the engine thermostat, and a
common pipe must be installed between the inlet of both the system pump and the engine
pump. The common pipe is used to equalize the pressure at the inlet of both pumps and the
static pressure line is installed at the common pipe. The system pump is sized to deliver the
required flow through all cooling components other than the engine. The engine water pump
needs to overcome restriction of the engine, the thermostat, and the common pipe.
9 - 3 Form 10056-2
Exhaust heat
Expansion tank exchanger
Custom heat
exchanger
Engine T-stat Excess heat

dump radiator
System
WP
System
Common
Engine T-stat
pipe
Engine WP
Figure 9-1: Two pump system
EXPANSION TANK
Each cooling circuit requires an expansion tank sized to 11% of the circuit volume with a 7
psig (0.48 bar) pressure cap. The expansion tank should be mounted at the highest point in
the system, and high enough to provide at least 6.5 psig (15 feet) static head pressure to the
inlet of the engine mounted pumps. The expansion tank provides the function of de-aerating
the coolant, controlling cooling system pressures, allows for coolant expansion, and provides
coolant reserve.
An expansion tank is a single chamber tank located at the highest point in the cooling system.
Vent lines are connected from high points in the cooling system to the expansion tank below
the water line. These vent lines allow trapped air to escape to the expansion tank where the
air bubbles out of solution, thus de-aerating the coolant (see “Figure 9-2: Cooling system
schematic”).
Expansion tank
Vent line
Trapped Air
Static line
Engine Component
Cooling
component
Figure 9-2: Cooling system schematic
9 - 4 Form 10056-2
Vent lines should be 1/4” in diameter on systems with vent lines less than 10 feet (3 meters)
long, or 1/2” diameter with a 1/4” orifice on systems with vent lines more than 10 feet (3 m)
long.
Vent lines on the 275GL+ engines should be connected to the high points on the engine for
the circuit. For the Jacket Water circuit, the vent line should be connected to the two water
manifold pipes on the top of the engine and is shown on the general engine outline drawing
available on www.ge-distributedpower.com. The auxiliary water circuit vent connections are
in the piping to the oil cooler, and at the top of the intercooler near the front side of the en-
gine. These connection locations have a 0.50”-14 NPTF thread and are shipped with petcocks
installed, these should be removed to install the vent lines.
All vent lines must have flex connections, or other provisions, to prevent stress on the lines
due to engine vibration. The vent lines must also be properly supported so their weight is not
being supported by the flexible connection. Failure to properly relieve these stresses may re-
sult in a broken vent line which could cause a glycol fire. Each circuit may have multiple vent
lines and they may be combined into one common vent line. Vent lines between the individual
jacket and auxiliary water circuits may not be combined.
Automatic degassing systems or automatic bleeders are not recommended by Waukesha.

Also bladder pressurization systems are not preferred as they can be difficult to maintain
constant pressure, and they do not provide a reservoir for additional coolant if a leak were
to occur.
Figure 9-3: Jacket water vent connections on top of engine water header
Figure 9-4: Auxiliary water circuit vent connection on top of intercooler
9 - 5 Form 10056-2
A static line from the bottom of the expansion tank to the water pump inlet controls the pump
inlet pressure. The static inlet pressure must be between 6.5 - 21 psig (0.4 – 1.4 barg), or 15 –
50 feet (4.3 – 15.2 m) of H2O. The static pressure lines should be connected near the inlet of
both the Auxiliary and Jacket Water pumps. Connection points for the static lines are shown
on the general outline drawing available on www.ge-distributedpower.com.
Figure 9-5: Compressor cooling circuit connection (top arrow). Water pump static inlet connection
(bottom arrow)
COMPRESSOR COOLING CIRCUIT

It is common to use the engine auxiliary water circuit to also cool the compressor oil cool-
er and compressor packing. A provision on the engine has been provided to obtain some
of the coolant immediately after the auxiliary water pump at the low temperature of 130°F
(54°C) to be used for cooling the compressor. The compressor coolant is then returned to the
circuit at the outlet of the engine. When designing a compressor cooling circuit the pump
capacity must be considered since using some of the coolant for the compressor reduces
the allowable external restriction or pressure drop. A procedure for calculating the auxiliary
water pump capacity can be found in the Jacket and Auxiliary Water Pump Performance
document in technical data (S-9063-37 and S-9063-38). If the system restriction exceeds the
pump capacity, the system must be redesigned to reduce the restriction, such as larger di-
ameter piping or fewer elbows, or an additional booster pump must be installed to increase
the capacity of the circuit.
WATER HEATER
Starting an engine in cold conditions may require preheating of cooling and lubrication cir-
cuits. Waukesha requires jacket water and lube oil preheating for starting in temperatures
below 50°F (10°C). Heaters should be sized to maintain 70°F (21°C) in these conditions. Once
started, the engine should be allowed to warm up under a light load until water and oil tem-
peratures exceed 100°F (38°C). Emergency standby engines which are required to start and
accept load immediately must be preheated to 100°F (38°C) to 120°F (49°C). The size of the
jacket water heater will depend on the ambient temperature, refer to technical document
S-9064-2 for sizing information.
The jacket water heater inlet connections to the engine typically will use the water drains on
each side of the crankcase. A tee can be installed to still allow draining of the coolant from
the engine. Since the cooling system on the engine is split between the two banks, the water
heater inlet will need to be connected to both sides of the crankcase for effective heating. The
water heater outlet connection is in the water header elbow mounted on the jacket water
thermostat.
9 - 6 Form 10056-2
Figure 9-6: Water heater outlet connection (1.25” – 11.5 NPTF)
Figure 9-7: Water heater inlet connection (G1 – 0.5”)
ENGINE THERMAL SHOCK AT SHUTDOWN DUE TO THERMOSIPHONING

Thermosiphoning is a process where coolant will circulate in a cooling loop without any as-
sistance from a water pump. As coolant is heated, its density decreases, causing it to rise. As
the coolant is cooled, it drops below warmer coolant. These actions create flow in a circuit.
A greater difference between engine coolant temperature and radiator coolant temperature
will cause a greater flow. A radiator at a higher elevation than the engine will have a greater
thermosiphoning flow than one mounted in front of the engine. Thermosiphoning can cause
engine damage due to thermal shock when a hot engine is shutdown and effective cooling of
the engine stops. There are several methods to design the cooling system to prevent thermo-
siphoning which are detailed in Application Note app9_92 in Technical Data
Restarting shortly after shutdown should be avoided. Re-

starting can cause a cold slug of coolant from the radiator
to enter the engine because the thermostat may still be
fully opened.
9 - 7 Form 10056-2
FAN DRIVE
The 275GL+ engines are available with an optional stub shaft typically used for driving the
cooler fan. In a direct drive application, a drive shaft directly coupled to the front stub shaft
is used to drive the cooler fan. The drive shaft must be properly supported with a minimum
of 2 bearing jackshafts, and a coupling must be used between the engine stub shaft and the
drive shaft. No side loads should be applied to engine stub shaft when used in a direct drive
application. A torsional analysis should also be performed to analyze the front drive system.
Power can also be transmitted from the engine front stub shaft with a belt drive application.
A pulley must be installed on the engine front stub shaft, and connected downwards to an
additional driveshaft before driving the cooler fan. In a pulley arrangement, a side load is
applied to a front stub shaft which adds additional downward forces on the front crankshaft
main bearing. If the forces on the front stub shaft are high, the front main bearing may expe-
rience premature wear and cause engine failure. Limitations for the maximum load applied
are listed in the technical data (S-4052-13) for the 275GL+ engines.
Maximum front drive power: 200 BHP (149 kWb)
MAINTENANCE CONSIDERATIONS
After installation of the engine and cooling system piping, the piping should be cleaned be-
fore commissioning the engine. It is recommended to use a coarse screen or filter to capture
any installation debris from the system.
Coolant for the engine is filled from the bottom of the engine to the top which allows air in the
system to escape through the vent lines. When filling the engine, any component with a vent
should be opened during the initial fill until coolant reaches that level of the engine during
filling.
Periodically the coolant in the engine will need to be replaced (as needed by analysis or onsite
maintenance schedule). Drain locations on the engine (as indicated on the engine outline
drawing) should be easily accessible.
9 - 8 Form 10056-2
Lubrication System Chapter 10
CHAPTER 10 - LUBRICATION SYSTEM

SYSTEM REQUIREMENTS
Lube Oil Recommendations
• The lube oil chosen to run in the engine must be classified to be run in natural gas engines.
• The oil must meet Waukesha lube oil requirements for the particular engine as listed in
latest edition of S1015-30 or SB 12-1880
• A lube oil analysis should be set-up for the engine.
• Engine requires SAE 40 oil with a minimum of 0.35% sulfated ash by weight with both
metallic and ashless additive systems.
• A maximum of 0.10% zinc is recommended
Engine Pre/Post Lubrication System
• Prelube system has been set to run for 90 seconds before starting.
• An automatic post lube system set to run for 60 seconds after the gas valve has closed.
Engine Oil Heaters
• Lube oil heaters must be used if the engine will be operating at ambient temperatures
below 50° F (10° C).
• For a standby application in which the engine is required to pull load immediately upon
start-up, the oil must be heated to a minimum of 100° F (38° C).
• Use a circulating type heater that circulates the oil in the engine sump. Refer to heater
manufacturer for sizing requirements based on site conditions and engine size.
Angular Operating Limits
• Ensure the angular operating limits are within the defined limits for the engine model be-
ing used to assure constant supply of oil to the oil pick up screen.
STANDARD EQUIPMENT
The lubrication system consists of the following components:
• Oil sump and suction line
• Gear driven, externally mounted oil pump
• Pressure regulating valve
• Oil feedback system
• Cold oil relief valve
• Full-flow oil filters
• Centrifugal oil bypass filtration
• Filter relief valves (2)
10 - 1 Form 10056-2
Chapter 10 Lubrication System
• Lube oil temperature control valves
• Engine mounted, plate type oil cooler
• Engine mounted pre-lube pump
• External piping
OPTIONAL EQUIPMENT
Waukesha offers option code 5040 for an air driven prelube pump. The motor is engine
mounted, and is air/gas driven with a 182C frame size rated at 4.15HP @ 3000 rpm. The air
consumption at maximum HP is 181 SCFM. The design air pressure to the air/gas motor is
40 psi (2.8 bar), this will create sufficient oil flow and pressure within the engine for pre- and
post-lube activities. This air pressure will need to be supplied by the customer and should
never exceed 90 psig (6.2 bar).
CUSTOMER SUPPLIED EQUIPMENT

If option code 5040 is not selected, customer must supply a motor to operate the prelube
pump. The pump accepts common air or electric motor drives with NEMA 182C frame and
needs to be properly supported by the customer.
Customer must supply final air or gas piping for pre/postlube system along with the working
fluid (air or gas) being used when option code 5040 is selected.
Customer must supply a lube oil heater, if required, which heats and circulates the oil in the
sump.
Customer to supply a lube oil level regulator and oil make up tank, if desired.
REFERENCE DOCUMENTS
S-9063-33 16V275GL+ Oil Pump Performance
S-3549-J Allowable Engine Angles
PC2173A P&ID
S-05613-309 Lube Oil Level Regulator
S-1015-30 Lube Oil Recommendations
S-7382-56 Prelube & Postlube Requirements
S-9064-2 Lube Oil Heater Recommendations
SYSTEM DESCRIPTION
By circulating properly selected oil throughout the engine, the lubrication system performs
three main functions: lubrication, cooling and cleaning.
Lubrication systems provide a cushion of oil preventing direct metal to metal contact be-
tween engine components. Without a properly functioning lubrication system, moving metal
surfaces would come into direct contact with each other. This will create wear and heat,
leading to engine failure. If oil does not reach the cylinder sleeves and rings, piston and piston
ring scuffing will occur, leading to a loss of ring seal. Excessive blow-by and decreased power
would result, ultimately leading to engine seizure/failure.
10 - 2 Form 10056-2
Oil absorbs heat as it flows through the engine. The combustion chamber is cooled by the
jacket water in the cylinder head and around the sleeve and by lube oil on the piston. The
heat is then transferred from the lube oil to the auxiliary or jacket water system by the lube
oil cooler.
The lube oil contains many additives which enhance specific performance characteristics.
Among these additives are dispersants and detergents which suspend dirt and water parti-
cles in the oil allowing for removal by the oil filter system. This cleansing action is important
for component longevity.
OIL FLOW PATH DESCRIPTION

For a detailed look at the components and flow of the lubrication system, refer to the lube oil
P&ID on PC2173A.
The oil pump draws the oil form the sump and delivers it to the cooler and the full-flow oil
filters. After passing through the filters, the flow is directed to the internal oil distribution sys-
tem.
Oil flows from the main bearings through drillings in the crankshaft to the connecting rod
bearings. The flow passes through drillings in the connecting rods to the piston pin bushings.
Pressurized oil flows from the piston pin bushing area to an open chamber cast into the pis-
ton head.
Oil also passes from the main oil gallery through the internal distribution piping system to
individual feeder lines at each cylinder, where it is fed to the camshaft brackets, rocker arm
shafts, rocker arms and turbochargers. This oil then returns to the oil sump by gravity flow
through the clearance around the push rod tubes.
From the oil distribution pipe located at the flywheel end of the crankcase, oil is supplied by
internal piping to the spray nozzles that lubricate the camshaft drive. Oil is also supplied to
the camshaft drive gear bearings by external pipes that are connected to ports in the engine
housing. At the front of the engine, external pipes branch off the oil header to provide a sup-
ply of oil to the lubricating points of the water pump and to spray nozzles that lubricate the
auxiliary drive gears.
An anti-polish ring on the inside of the liner cleans the carbon off the piston top land, allowing
more combustion pressure down alongside the piston to seat the piston rings.
OIL SUMP AND SUCTION LINE (PICKUP/SUPPLY)

The bottom of the crankcase is enclosed by an oil sump of welded sheet steel. Perforated
plates separate the oil sump from the crankcase to prevent foreign matter from getting into
the lubricant. A suction pipe draws the oil from the lowest point in the sump. At the front end,
there are flange connections for the main oil pump, prelube oil pump, and the oil inlet and
discharge lines. In the bottom of the sump are cleaning openings sealed with blind flanges.
Sump capacity including filters and coolers:
• 220gal (833L) for the 12V275GL+
• 275gal (1041L) for the 16V275GL+
OIL PUMP AND PRESSURE REGULATING VALVE

The oil pump is externally mounted at the front of the engine and is gear-driven by the crank-
shaft. The pump contains an integral spool-type pressure regulating valve (see “Figure 10-1:
Oil pump pressure regulator”).
10 - 3 Form 10056-2
Figure 10-1: Oil pump pressure regulator
1. Oil Pump
2. Pressure Regulator Valve
When the oil pressure exceeds the valve setting, the valve opens and the excess oil is re-
turned to the sump. The valve maintains oil pressure, regardless of the engine speed or the
oil temperature.
NOTE: Oil pressure should be set at 60-65psi (415-450kPa) with the oil temperature 172°F
(78°C) and the engine operating at 900-1,000 rpm.
OIL FEEDBACK SYSTEM

The oil feedback system allows oil pressure to be set at Waukesha’s high oil pressure specifi-
cation and self-compensate for oil filter restriction.
The pressure regulating valve is adjusted on the outside of the engine through the use of an
adjustment screw. The screw is located behind the sealing plug on the pressure regulating
valve.
COLD OIL RELIEF VALVE

In addition to the Pressure Regulating Valve on the oil pump, there is a cold oil pressure relief
valve located on the oil filter housing at the flywheel end of the engine. This regulating valve
provides additional relief capacity to prevent oil pressure from exceeding 120psig (827kPa)
when starting the engine with cold oil (minimum 60°F [15.5°C]).
Figure 10-2: Pressure relief valve
10 - 4 Form 10056-2
FULL-FLOW OIL FILTERS
The 12V/16V275GL+ engine uses an oil filter system consisting of six replaceable filter car-
tridges mounted to a filter housing located on the engine flywheel end (see “Figure 10-3: Oil
filter”). The oil filters are full-flow type. Each filter cartridge contains a bypass valve that pre-
vents the loss of oil circulation due to a dirty filter.
Figure 10-3: Oil filter
FILTER RELIEF VALVES

With new filter elements, the pressure drop through the filter is minimal. However, if the el-
ements were to get clogged, the high differential pressure opens the relief valves and oil
bypasses the filter elements en route to the engine. Acting as a safety device, the relief valves
ensure that the engine receives a supply of lubrication oil, although unfiltered. The internal
relief valves are set at 30psi (208kPa). ESM will alarm on high oil pressure differential at 24psi
(165kPa).
OIL TEMPERATURE CONTROL VALVE

The oil inlet temperature as measured at the oil header typically is 172F (78C) (see “Table
10-1: Oil inlet temperature” and “Table 10-2: Oil inlet pressure”). The thermostatic valves are
enclosed in the oil filter base.
Table 10-1: Oil inlet temperature
OIL INLET TEMPERATURE AT THE OIL HEADER

Normal Alarm Shutdown
172°F (78°C) 187°F (86°C) 197°F (92°C)
Table 10-2: Oil inlet pressure
OIL HEADER PRESSURE

Normal Alarm Shutdown
60 - 80 psi 50 psi 45 psi
(415 - 450 kPa) (345 kPa) (310 kPa)
10 - 5 Form 10056-2
In operation, the thermostatic valves remain fully closed while the engine is warming up. The
flow from the oil pump enters the oil inlet port of the oil temperature control valve (see “Figure
10-4: Oil temperature control valve”). Oil that has passed through the oil cooler enters the
control valve at the oil cooler oil in port and mixes with the hot oil from the oil inlet port. This
blended oil passes through the oil outlet port to the oil filter and oil strainers en route to the
oil header.
Figure 10-4: Oil temperature control valve
1. Oil Filter Base
2. Oil Outlet to Filters
3. Oil Inlet from Oil Pump
4. Oil Cooler Oil Out
The thermostatic valves open as the engine warms up to its normal operating temperature.
The valves begin to open at 168°F (76°C) and are fully open at 180°F (82°C). The gradual
opening of the thermostatic valves diverts the flow of oil through the oil cooler.
The result of this operation is rapid warm-up when the thermostatic valves are closed and
efficient cooling once the valves open.
The temperature of the coolant passing through the oil cooler is controlled by a heat transfer
device. The oil temperature range is 160°F – 180°F (71°C – 82°C).
OIL COOLER
The oil cooler is mounted to the oil filter base at the flywheel end of the engine (see “Figure 10-
5: Oil cooler”). The cooler is a plate-type arrangement. The oil flows through the plates while
the coolant passes around the plates.
Figure 10-5: Oil cooler
10 - 6 Form 10056-2
CENTRIFUGE CLEANABLE OIL FILTERING SYSTEM

The centrifuge oil filtering system consists of a centrifuge, using a removable paper insert (see
“Figure 10-6: Engine-mounted centrifuge assembly”). The centrifuge is installed as a bypass
system, working in conjunction with the full-flow filter. The centrifuge is drive by the engine’s
oil pressure. The spinning action of the centrifuge’s internal turbine assembly develops a force
that exceeds 2,000 Gs, which compacts the contaminants against the turbine’s housing. The
centrifuge will remove oil-contaminating particles as small as 0.5 microns. The full-flow filter
elements remove remaining particles as small as 25 microns absolute.
Figure 10-6: Engine-mounted centrifuge assembly
1. Shutoff Valve
2. Filter Support
ALLOWABLE ENGINE ANGLE LIMITS

Angular operating limits must be complied with to assure a constant supply of oil to the oil
pump pickup screen. Due to its fluid nature, oil in the sump always flows to the lowest possi-
ble point. If the engine is not level, it is possible that the oil pickup screen/tube would not be
able to pick up the lubricant.
Figure 10-7: Angular measurement locale
This would mean a loss of lubrication at the bearings and other vital engine parts. Wauke-
sha strongly recommends mounting the engine on a level surface. However, Waukesha has
established permissible angles at which the engine can operate without loss of oil to the oil
pickup screen (see “Table 10-3: Engine angular limits”).
10 - 7 Form 10056-2
Table 10-3: Engine angular limits
FRONT DOWN REAR DOWN DE- LEFT DOWN DE- RIGHT DOWN
MODEL DEGREES GREES GREES DEGREES
12V275GL+ 7 7 15 15
16V275GL+ 5 5 15 15
1. Tabulated angle operation values are based on unidirectional tilt. For bi-directional tilt or
allowable intermittent tilt consult Waukesha’s Application Engineering Department.
2. Left and right are as viewed when facing the flywheel.
3. These values represent bare engine with oil leveler mounted in standard location.
LUBE OIL HEATER

Lube oil heaters are required for engines operating at ambient temperatures below 50° F (10°
C). Oil must be heated to ensure proper oil flow to ease startability and load application. For
engines required to pull load immediately upon startup (standby applications), the oil should
be heated to a minimum of 100° F (38° C). For engines that operate continuously other than
planned service shutdowns, the oil should be heated to 70 – 100° F (21 – 38° C).
Cold oil will not flow through the cooler and filter and still provide adequate supply pressure
to the engine. Waukesha requires circulating type oil heaters to be used. This prevents the
burning or oil coking that can occur with immersion style heaters.
When piping for engine oil pre/post lubrication and oil heating, refer to the installation draw-
ing for connection points and sizes. Oil is drawn directly from the engine oil sump drain, and
piped to the inlet of the pump/heater. From the heater, the oil flow should be piped back to
the engine oil sump.
Table 10-4: Lube oil heater sizing recommendations
ENGINE LUBE OIL HEATER

ENGINE MODEL 0°F TO 50°F BELOW O°F
(-18°C TO 10°C) (BELOW -18°C)
12V275GL+ 9 kW 12 kW
16V275GL+ 12 kW 15 kW
1. All heater sizing is based on circulated systems.
2. Size the system following the heater manufacturer’s recommendations based on system
volume and ambient conditions.
10 - 8 Form 10056-2
PRELUBRICATION
Engine prelube extends engine life by filling the lube oil cooler and filter prior to the engine
starting. This prevents the engine from being starved from the lack of lubricating oil upon
immediate startup. Engine prelube also purges the lubrication system of air and ensures all
moving parts subjected to friction are properly lubricated before the engine is started.
Prelubing is required on all 275GL+ engine models. For continuous duty applications, the en-
gine should run the prelube prior to each start. See the table below for prelube time, pressure,
and flow rate. For standby applications, the engine should prelube for 15 seconds every hour
to ensure the engine will be ready when it is required to start.
Pressures may drop in half with hot oil, flow is the determining factor.
The engine prelube is controlled by the ESM. The duration can be changed in the Prelube Time
field located on the [F3] Start-Stop panel in ESP. The duration can be set from 0 to 10,800
seconds.
Table 10-5: Prelube specifications
ENGINE MODEL PRELUBE TIME PRESSURE (IN FLOW MOTOR AIR

DURATION HEADER) RATE CONSUMPTION (90psi)
275GL+ 90 seconds before 25 psi1 30 gpm1 181 SCFM
starting (172 kPa ) (113 lpm) (308 m3/hr)
1. Based on 50°F oil
Excessive postlube may flood turbochargers.
POSTLUBRICATION
Waukesha recommends post lubrication for all 275GL+ models. Post lubrication ensures that
sufficient heat is removed from the engine after shutdown by providing cooling to the turbo-
charger bearings and preventing carbon coking of the oil which extends turbocharger life.
Post lube should be performed automatically upon main gas valve closure for 60 seconds
after every engine shutdown. Excessive postlube may flood turbocharger.
There must be NO postlube with any engine emergency shutdown.
LUBE OIL LEVEL REGULATOR

It is highly recommended to add a lube oil level regulator to the engine package. Lube oil level
controllers are designed to maintain the running oil level in the crankcase of stationary en-
gines. The oil controller works in conjunction with an overhead oil supply system which feeds
the oil level controller. As the oil is consumed, the oil controller supplies the required amount
of oil to maintain a proper level in the crankcase. The oil controller maintains the proper
amount of oil in the crankcase using a float controlled valve. The valve opens and closes as oil
is needed in the crankcase to provide a constant oil level. There are optional oil level switches
that can be added to trip an alarm if the oil level is too high or too low.
The oil level controller can be mounted onto the engine skid, and has a sight glass to visually
show engine lube oil level. For engine oil level, reference Oil Level section below.
10 - 9 Form 10056-2
Figure 10-8: Oil Level regulator mounting example
TYPICAL OIL CONSUMPTION

The typical lube oil consumption, at full load and 1000rpm, for a new 275GL+ engine is around
0.0003 lb/bhp-hr (0.182 g/kW-hr). For engines running at full load see “Table 10-6: 275GL+ Oil
Consumption”:
Table 10-6: 275GL+ Oil Consumption
Power Oil Consumption

ENGINE MODEL
(hp) (kW) (gal/day (L.day)
12V275GL+ 5000 3729 4.93 18.64
16V275GL+ 3750 2796 3.70 13.98
Est. Oil Consumption (gal) = 0.0007(lb/bhp-hr) x Power(bhp) x Time(hr) / 7.3(lb/gal).
Oil consumption will vary depending on site conditions, engine load, engine speed, and the
age of the engine. Excessive oil consumption is a sign that the engine may need service.
When sizing an oil makeup tank double the values above to plan for oil consumption increase
as the engine ages.
10 - 10 Form 10056-2
OIL CHANGE
Hot oil can cause severe burns. Allow oil to cool prior to working
an oil system components. Wear protective equipment and use
caution while working on oil system components.
Always consider the weight of the item being lifted and use only
properly rated lifting equipment and approved lifting methods.
Allow the engine to cool to room temperature before cleaning,

servicing or repairing the unit.
Always stop the unit before cleaning, servicing or repairing the

unit or any driven equipment.
Always place all controls in the OFF position and disconnect or

lock out starters to prevent accidental restarting. If possible, lock
all controls in the OFF position and take the key. Put a sign on the
control panel warning that the unit is being serviced.
Always close all manual control valves, and disconnect and lock
out all energy sources to the unit, including all fuel, electric, hy-
draulic, and pneumatic connections.
Always disconnect or lock out driven euipment to prevent the pos-

sibilty of the driven equipment rotating the disabled engine.
Do not put the filter or cooler near the exhaust outlet or

other places where the temperature could become exces-
sively warm. Excessive heat will speed oil deterioration. It
will also create a fire hazard in the event in the event of an oil spill or line rupture.
Change the oil, including the oil filters, every 4,000 running hours or as determined by oil anal-
ysis. Oil change intervals should never be extended beyond this recommendation because of
additive depletion and changes in the physical properties of the oil. A sample of the used oil
should be submitted for analysis after every 500 running hours at first, then can potentially
be extended based on the analysis results.
10 - 11 Form 10056-2
When operating on a fuel that contains hydrogen sulfide (H2S), the oil should be changes
every 500 hours or sooner as determined by the lube oil analysis. Samples should be taken
every 100 hours to ensure the oil is within the condemning limits given in S-1015-30.
Based on environmental and engine operating conditions, the lubrication oil may require
changes that are much more frequent than those recommended by Waukesha. Many vari-
ables are involved in determining the proper time between oil changes. The oil type, the se-
verity of the environment and the internal condition of the engine are only a few of many
variables that have a direct effect on the frequency at which the oil must be changed.
Using an incorrect oil or extending the time between oil changes may cause varnish deposits,
oil oxidation/nitration, sludge or any number of problems to appear.
To change the oil, drain the oil pan, oil cooler, and full-flow oil filters. Remove the 1.5in. drain
plug from the oil pan at the front of the engine. Remove the two 1in. drain plugs located in
each of the lower oil tube connectors at the flywheel end of the engine. Loosen or vent the
six filters to be replaced to allow complete drainage. When the oil has drained, ensure all the
drain plugs are reinstalled.
The paper element and O-rings in the centrifugal bypass filter should be replaced along with
the six spin-on full flow filters.
To fill the engine with oil, remove the plug from the oil fill hole located on the left side of the
engine shown in “Figure 10-9: Oil dipstick and fill hole”, or if using a pump, remove one of the
oil sump drain plugs.
1
2
Figure 10-9: Oil dipstick and fill hole
1. Fill hole
2. Dipstick
Insert the makeup line and add oil to the sump. Periodically remove the dipstick beside the oil
fill hole and continue to add oil until the level reaches the upper notch of the dipstick.
Figure 10-10: Oil dipstick
10 - 12 Form 10056-2
Once the oil level reaches the upper notch, stop adding oil and start the prelube pump. This
will fill the oil lines, full-flow filters, and the oil cooler. It also ensures that the bearings, tur-
bochargers, and other moving parts of the engine are properly lubricated. Run the prelube
pump until pressure is indicated on ESP. Once pressure is indicated, stop the prelube pump,
check the dipstick and add oil to the sump until the level returns to the upper notch.
Run the prelube pump a second time. Allow sufficient time for the oil to circulate throughout
the system two or three times, and then check the dipstick while the prelube pump is running.
If the level is low, add oil from the makeup line until the level is back to the upper notch.
Reinstall the oil fill plug, start the engine and run at idle speed. Check the dipstick again and
add more oil if the level is below the upper notch. Wait until the oil has warmed up to its
normal operating temperature of 176-180°F (80-82°C) and check the oil level one more time.
The level of the oil in the crankcase should be checked each day while the engine is running
and should always maintain the oil level at the upper notch. Since there is no static line on the
dipstick, it does not indicate where the level of the oil in the sump should be when the engine
is shut down.
Whenever the oil level is checked, carefully examine the condition of the oil on the dipstick.
Replace the oil any time it appears diluted, thickened by sludge or otherwise deteriorated.
OIL LEVEL
The oil level is 21.16in (537.5mm) from the crankcase centerline to the high level mark on the
lube oil dipstick and 23.05in (585.5mm) to the low level mark on the dipstick.
Crankshaft centerline
21.16” (537.5 mm)
Figure 10-11: Oil level distance
10 - 13 Form 10056-2
OIL PRESSURE ADJUSTMENT
NOTE: Before adjusting the oil pressure, always check the condition of the oil filters and re-
place if necessary. A dirty filter will cause the engine oil pressure to drop.
The pressure regulating valve is adjusted on the outside of the engine through the use of an
adjustment screw (see “Figure 10-12: Oil pressure adjustment”). Before adjustment of the oil
pressure, the oil temperature must be at normal operating temperature with the engine op-
erating at rated speed. Adjust the oil pressure to 60-65psi (415-448kPa) at 1,000rpm. Turn the
screw in to increase the oil pressure and out to decrease the oil pressure.
2
1
Figure 10-12: Oil pressure adjustment
1. Pressure Regulating Valve
2. Sealing Plug
10 - 14 Form 10056-2
Crankcase Breather System Chapter 11
CHAPTER 11 - CRANKCASE BREATHER SYSTEM

SYSTEM REQUIREMENTS
• Flexible connection used to isolate the breather components from engine vibration and to
allow for expansion or growth due to heat
• Drains installed at low spots in piping after the blower outlet to drain condensed vapors
• Adjustable restriction valve should be used to maintain a constant vacuum of 0-2in of H2O
• Maximum breather flow of 120 SCFM (204 Nm3/hr) for the 16V275GL+ and 90 SCFM (153
Nm3/hr) for the 12V275GL+
STANDARD EQUIPMENT
The standard equipment on the engine is a CSA Class I Groups C&D Class II Groups F&G 230V
AC/1 ph blower, restriction valve, and check valve. A motor starter is shipped loose and must
be mounted and wired in a safe area for CSA Class I & II applications.
OPTIONAL EQUIPMENT
There is an optional 115V AC/1 ph electric motor which replaces the standard 230V AC/1 ph
electric motor. This motor is also certified for CSA Class I Groups C&D Class II Groups F&G.
This option code also includes the restriction valve, check valve, and motor starter which is
shipped loose and must be mounted and wired in a safe area for CSA Class I & II applications.

The customer must install piping to the 4in. (10.16cm) O.D. blower motor outlet in order to
carry the crankcase vapors away from the engine. The piping should slope upward from the
engine connection to the blower to prevent trapping of oil in the low spots. Drains should be
installed at low spots in the piping, after the blower outlet, to drain condensed vapors.
A customer supplied oil separator should be installed after the flexible connection to protect
the components from oil fouling. The flexible connection is used to isolate the breather com-
ponents from engine vibration and to allow for expansion or growth due to heat.
Customer supplied - Not included
A positive Vent to atmosphere

inclination is
recommendation
to allow lube oil Rain hood and
Engines main seals allow draain back drip collector
ambient air to enter crankcase
Flex
hose Separator
Drain
Low pressure
Condensed oil
drop non- Butterfly valve/ Breather air drain traps
return valve vacuum regulator pump
set @ -2” water
Figure 11-1: Customer supplied breather system equipment
11 - 1 Form 10056-2
Chapter 11 Crankcase Breather System
REFERENCE DOCUMENTS
S-9063-10 16V275GL+ Breather Schematic and Flow
S-9063-36 12V275GL+ Breather Schematic and Flow
S-07232-398 Breather Wiring
PC2173A P&ID
SYSTEM DESCRIPTION
Industrial engines rely on a crankcase breather system to remove normal engine combustion
vapors which accumulate in the engine crankcase. These vapors, if not removed, can cause
oil contamination, component damage, crankcase oil leakage, and shortened oil life. Most
systems rely on some form of vacuum to evacuate the engine crankcase vapors.
All 275GL+ engines require a crankcase blower for maintaining a vacuum crankcase pres-
sure from zero to a negative two inch water column (0 to -0.5 kPa). The concept of a negative
crankcase pressure has the advantage of evacuating the crankcase of the blow-by vapors
in the engine and therefore keeping these vapors from mixing with the lube oil. As the vapors
mix with the lube oil, the life of the engine lube oil is greatly reduced, resulting in decreased
time between oil change intervals.
The crankcase ventilation blower should run any time the engine is in operation. The en-
gine-mounted breather pipe is intended for connection to the crankcase ventilation equip-
ment. The components consist of:
• Blower with Electric Motor
• Blower electric motor starter (in off engine mounted junction box)
• Restriction Valve
• Customer Supplied Piping and oil separator
• Check Valve
• Crankcase Pressure Relief Valves
11 - 2 Form 10056-2
3
4
5
Figure 11-2: Crankcase breather system
1. Crankcase
2. Crankcase connection
3. Check Valve
4. Restriction Valve
5. Discharge Outlet
6. Ventilation Blower
7. Blower Mounting Bracket
BLOWER WITH ELECTRIC MOTOR

The blower ventilates the crankcase to maintain a negative crankcase pressure. The cus-
tomer must connect their piping to the 4in. (10.16cm) O.D. blower motor outlet. The standard
electric motor is 0.5 hp, 230V AC, 1 phase, TEFC, with a 56C motor frame. It is also CSA class
I, DIV I, Group C&D certified.
4” O.D. Customer
connection point
Figure 11-3: Breather system connection
11 - 3 Form 10056-2
BLOWER ELECTRIC MOTOR STARTER
The motor starter is a contactor/relay which uses a 24VDC signal to allow the AC power
circuit to open and close as needed. This AC circuit opening and closing is what turns the
electric motor for the blower system on and off. The motor starter box is not CSA Class I Div II
rated and must be mounted in a safe area. This includes a surge suppression diode included
as standard.
Contactor, 3 pole,
24 VDC, 9 amp
Relay, 24 VDC, 3 pole

overload, 4 amp
4”
8.75”
Ø 0.31”
Figure 11-4: Blower electric motor starter
RESTRICTION VALVE
The restriction valve is used to adjust and maintain the crankcase pressure at the recom-
mended specification.
CHECK VALVE
The check valve prevents air from flowing back into the crankcase, while allowing air move-
ment toward the blower.
INSTALLATION
FLOW RATE
The crankcase ventilation flow rate will depend on the engine load and condition. Refer to
S-9063-36(12V) or S-9063-10(16V) for a blow-by flow vs. speed and load graph.
PIPING
When designing the system, ensure that the piping in the system has minimal bends to re-
duce the backpressure in the system. The backpressure must be low enough in order to main-
tain a constant vacuum of 0 to 2in of H2O. Backpressure calculation reference sheets can be
found in the appendix.
The maximum allowable backpressure available for the customer filter and piping assuming
an engine speed of 1000 RPM is:
• 4.8in wg (1.2kPa) @ 120 ACFM (204 m3/hr) with 60Hz electrical supply
• 2.6in wg (0.65kPa) @ 120 ACFM (204 m3/hr) with 50Hz electrical supply
*Assuming 0.075 lb/ft3 (1.2 kg/m3) density for air/oil mixture
11 - 4 Form 10056-2
WIRING DIAGRAM
A wiring diagram can be found on ge-distributedpower.com. In the Accessory Drawings, the
breather wiring schematic can be downloaded in either PDF or DWG formats of S-07232-317.
The motor starter needs to be wired to the power distribution box to provide power when the
engine is running.
The crankcase ventilation system must be maintained to ensure that a negative crankcase
pressure will rid the crankcase of harmful vapors and gases. The ventilation system compo-
nents must provide free air flow through all customer-supplied external piping, check valve,
butterfly valve, and ventilation blower. Clean and remove any restriction to air flow and any oil
that may have collected in the piping. Also verify correct operation of valves and ventilation
blower.
When this “open” type of breather system is used, the outlet may be considered a second
source of emissions for regulator enforcement.
When this “open type of breather system is used, the outlet

may be considered a second source of emissions for regu-
lator enforcement.
Measure the crankcase pressure at least once every 3 months.
11 - 5 Form 10056-2
11 - 6 Form 10056-2
Crankcase Pressure Relief Valves Chapter 12
CHAPTER 12 - CRANKCASE PRESSURE RELIEF VALVES

STANDARD EQUIPMENT
The 275GL+ series engines have been designed with crankcase pressure relief valves on the
crankcase doors. The size and number of relief valves was determined based on a calcula-
tion of the volume in the crankcase under evacuation (-2” H2O). The 16V 275GL+ engine is
equipped with eight (8) crankcase relief valves and the 12V 275GL+ engine is equipped with
seven (7) crankcase relief valves. The number of relief valves are sized based on a ratio of 1.5
square inches of relief area per cubic foot of crankcase volume.

An engine safety pressure switch should also be installed to detect positive crankcase pres-
sure. The engine should not be allowed to operate with positive crankcase pressure due to
the potential for a crankcase explosion. The pressure switch contacts can be used for alarm
and/or shutdown of the engine in the event of a positive pressure due to blower failure, power
losses or piping restrictions. Also the crankcase pressure is a good indication on the engine
condition (i.e. in event of catastrophic failure excessive blowby occurs resulting in high crank-
case pressure).
DESCRIPTION
As a safety precaution, crankcase pressure relief valves are supplied (see “Figure 12-1: Crank-
case pressure relief valves”). The valves open fully when the pressure in the crankcase ex-
ceeds 6.9kPa (1psi) and close tightly and quickly to prevent the inflow of air after the internal
pressure has been relieved. In this way, the possibility of a secondary explosion is greatly re-
duced. The valves do not prevent crankcase combustion, but only reduce the peak pressures
during combustion, thereby minimizing damage.
Since there are always flames present in any explosion, the valve incorporates an internal
flame trap to retard the emission of flame while the valve is venting. The flame trap is of an
oil-wetted wire gauze design. The cooling capacity of the gauze is doubled when it is oil-wet-
ted, a condition affected by the oil mist that normally exists in the crankcase or by an 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.
Figure 12-1: Crankcase pressure relief valves
12 - 1 Form 10056-2
Chapter 12 Crankcase Pressure Relief Valves
The seals in the explosion relief valves are intended to last for 16,000 hours before replace-
ment is necessary, depending on the operating temperatures, engine vibration, etc. If the
seals have gone over the seal life expectancy of 16,000 hours, they should be replaced to
prevent oil leakage.
Exercise and inspect the crankcase pressure relief valves annually to ensure that they are in
proper working condition.
Never operate the engine without the proper type or number of re-
lief valves on the engine. Maintenance of the pressure relief valves
must be performed annually. Failure to follow these precautions
could result in the inspection doors being blow off.
Only exercise the valve after the engine has been shut
down and allowed to cool.
Exercise and inspect the crankcase pressure relief valves annually to ensure they are in prop-
er working condition.
The number of pressure relief valves used on the engine depends

on the volume of the crankcase. Never operate the engine without
all necessary valves on the engine working properly. The ability of
the system to function is dependent upon the proper number of
relief valves. Do not operate without the proper type and number
of relief valves. Operating the engine without the proper type and
number of relief valves may result in fire and explosion.
Allow the engine to cool to room temperature before cleaning,

servicing or repairing the unit.
12 - 2 Form 10056-2
Combustion Air Intake System Chapter 13
CHAPTER 13 - COMBUSTION AIR INTAKE SYSTEM

INTAKE AIR REQUIREMENTS
• Air filter assemblies properly supported
• Air filter assemblies installed in a clean, dry location with minimal temperature variations
• Air filter assemblies installed with easy access to perform frequent air filter maintenance
• Intake air piping properly supported with no forces applied to engine turbochargers
• Intake air piping sized with minimal restriction
−− Total air induction system restriction (including air filter when dirty) less than 15 inches
(381 mm) H2O
• Intake air piping of non-collapsible construction
• Flexible connections between engine and intake air piping
• Filter restriction gauge properly installed within 10 feet (3 meters) of air filter assemblies
for Waukesha supplied filters
• Intake air temperature between 0°F (-17.8°C) and 100°F (38°C)
−− Intake air temperature less than 0°F (-17.8°C) requires additional heating
−− Intake air temperature greater than 100°F (38°C) requires engine power reduction, re-
fer to EngCalc site specific power ratings
• Intake air system designed to minimize temperature variation from hot and cold sources
• Intake air piping and air filter assemblies must be cleaned from any installation debris
before engine commissioning
• Intake air filter protective panels removed before engine commissioning
STANDARD EQUIPMENT
Combustion air inlet elbows mounted to the turbocharger. The 12V275GL+ engine includes a
flange customer connection to the elbow. The 16V275GL+ engine includes round non-flanged
customer connections to the elbow.
OPTIONAL EQUIPMENT
Shipped loose standard duty or heavy duty air filter housings (two supplied per engine) with
Waukesha supplied air filter elements.
Engine mounted stainless steel flexible connections with ANSI flanged customer connections.

• Air filter housings and filter elements (when not using the Waukesha optional equipment)
• Tubing and installation of air filter restriction gauge (when using Waukesha optional air
filter housings)
13 - 1 Form 10056-2
Chapter 13 Combustion Air Intake System
• Intake air piping between engine and air filter housings
• Flexible connection between engine and intake air piping (when not using the Waukesha
optional equipment)
• Flexible connection between air filter housings and piping (if necessary)
• Support and installation of all intake air piping and air filter housings
• Maintenance walkways for frequent changing of air filter elements (if necessary)
• Intake air heater when combustion air inlet temperature will be less than 0°F (-17.8°C)
REFERENCE DOCUMENTS
L-08063-18 Air cleaner outline drawing
L-08065-27 Heavy duty air filter outline drawing
L-08067-19 Intake air flex connections outline drawing
PC2177D Air system P&ID
EngCalc Engine data program for site specific combustion air flow rate
INTAKE AIR FILTRATION

The air intake filters used for 275GL+ engines are mounted off the engine. Optional air filter
assemblies are available from Waukesha and are shipped as a loose item with the engine.
The optional air filter assemblies include 2 air filter housing assemblies (one for each engine
bank). Each air filter assembly consists of three sets of parallel dry main air filter elements
and pre-filters. The air filter assembly housings consist of a standard cover with latches and
hinges to easily replace the air filter elements. Each filter assembly includes a filter differential
pressure gauge which must be installed by the packager. Each filter requires the customer to
provide a cover to protect rain intrusion when installed outdoors. Outline drawings of the air
filter assembly housings can be found in Waukesha’s standard engine outline drawings on
www.ge-distributedpower.com.
13 - 2 Form 10056-2
Figure 13-1: Optional Waukesha supplied heavy duty air filter housing mounted off engine, properly
supported and includes a work platform to perform maintenance of changing air filter elements.
For extremely dusty air conditions, heavy duty air filter housings are available which utilizes
inertial forces to remove a portion of the dust prior to reaching the main filter element. This
inertial type precleaner can be ordered from Waukesha as an integral part of the air cleaner
housing. It effectively filters out 70 – 90% of the large dirt particles in the first stage, there-
by reducing the dust load passed onto the second stage of the filter. Refer to “Figure 13-2:
Schematic of air filter inertia separators”, for a schematic of a typical inertial type precleaner.
As shown, the precleaner is made up of various cyclone tubes. Large dirt particles are spun
out of the air as it is drawn through the cyclone tubes and fall into a dust bin located at
the bottom of the panel. These inertial type precleaners require the large dirt particles to be
frequently emptied (based on site conditions) from the dust bin using an included discharge
valve at the bottom of the dust bin. Each filter requires the customer to provide a cover to
protect rain intrusion when installed outdoors.
Air inlets must be located away from fuel tanks, flammable vapors, tank vents, chemicals,
industrial wastes or any other material of explosive nature. An engine backfire could ig-
nite such material causing a dangerous explosion. Also, these volatile fumes could be
drawn into the engine. Disregarding this information could result in severe personal inju-
ry or death.
Waukesha supplied air filter assembly specifications with clean air

filter elements (per each assembly):
Restriction is based on standard conditions when running at full rated load. Restriction is
based on clean air filters and the restriction will increase as the filter element becomes dirty.
A reserve in restriction should be included to account for dirty air filter elements.
12V275GL+
Restriction without inertia separators: 1.5 inches (38 mm) H2O
Restriction with inertia separators: 3.5 inches (89 mm) H2O
Rear out connection to engine: 14.25 inch (397 mm) outside diameter piping
13 - 3 Form 10056-2
16V275GL+
Restriction without inertia separators: 3 inches (76.2 mm) H2O
Restriction with inertia separators: 6 inches (152 mm) H2O
Rear out connection to engine: 14.25 inch (397 mm) outside diameter piping
Figure 13-2: Schematic of air filter inertia separators
AIR TEMPERATURE
The temperature of the combustion air will vary depending on site conditions. It is preferred
to design the air intake system in a method that will reduce the amount of temperature vari-
ation as much as possible. High temperature air is less dense and has fewer molecules per
unit volume which reduces engine power output. The heat rejection to the intercooler can
increase significantly, resulting in an increase in the radiator or heat exchanger size. Refer to
the Technical Data for engine specific derate information, or the latest EngCalc program for
power ratings at elevated ambient air temperatures.
Cold intake air can also adversely affect engine operation affecting turbocharger perfor-
mance and engine stability. Cold intake air can cause turbocharger surge, delay ignition,
and create a cold combustion chamber which can make starting the engine difficult. In cold
ambient temperatures, below 0°F (-17.8°C), intake air heating is required for starting and op-
eration of the engine. Ducting air from the warm side of the radiator, utilizing engine jacket
water heat to warm ducted air through the use of a packager supplied heat exchanger, or
using warm engine room air are common methods of providing warm air in cold climates.
Water heaters for the intercooler circuit are not an effective form of heating the combustion
air because it does not heat the air upstream of the turbocharger which is required to prevent
turbo surge.
Ensure that the inlet air temperature and piping restriction is the same for both air cleaners.
One air cleaner being installed in the corner of an engine room or receiving hot air from the
radiator can cause an imbalance of temperatures/flows. This could lead to engine surging
and operational issues.
13 - 4 Form 10056-2
Figure 13-3: Air intake system showing packager supplied heat exchanger for air inlet heating
The air intake system should not be installed near hot engine parts or exhaust lines. If instal-
lation requirements demand locating air induction lines near hot engine components, insula-
tion must be used to prevent the intake air from being heated.
COMBUSTION AIR DUCTING

Air ducts have to be large enough to meet the combustion air requirements of the engine. Air
duct restriction should be kept to a minimum. Maximum air inlet restrictions including the air
filter when dirty are listed in the Waukesha Technical Data Manual and the beginning of this
chapter. PVC pipe is commonly used for air ducting due to its light weight and simple con-
struction. Seamless or welded steel pipe can be used as an alternative to PVC. Select appro-
priately sized hose clamps to ensure strong airtight connections. Oddly shaped ducting is not
recommended as it creates turbulent flow which may affect engine performance and cause
high inlet restriction. Gradual changes in piping direction should also be used to prevent tur-
bulent flow which may reduce turbocharger life. The pressure in the air ducting will be lower
than ambient, due to the suction of the engine and the restriction of the air filter, therefore the
ducting must be non-collapsible.
All pipes and fittings used to bring air into the system must
be absolutely free of dirt, scale and slag. Otherwise this
material may be drawn into the engine upon startup and
will damage engine components.
Use a flexible connection to mount the air ducting to the engine. This will isolate most engine
vibration from the ducting, thereby avoiding stress on the engine air inlets and pipes. Do not
try to support the ducts on the engine, since that would introduce stress to the ducting and
the engine. Suspend the air ducting independently, and use vibration absorbing hangers to
avoid transmitting engine vibration to the surrounding building.
Mounting of the air ducting to the engine will depend on the engine model. Options for flexible
connections are available from Waukesha, or can be provided by the packager. Turbocharg-
er air inlet silencers are not available from Waukesha, and if used they must be installed
with air filters to provide effective filtering of the air before entering the turbocharger. The
turbocharger air inlet elbows which are mounted on the engine may be rotated if needed to
accommodate the installation of the piping. If the elbows are rotated, the ambient tempera-
ture sensor must remain installed in the elbow, and the temperature sensor harness must be
free from contact with any hot surfaces and the harness must not be pulled tight which may
cause the sensor to fail.
13 - 5 Form 10056-2
Standard 12V275GL+ flanged Standard 16V275GL+ air inlet

inlet elbow connection elbow
Figure 13-4: Connections.
16V275GL+
Engine inlet connection: 14.17 inch (360 mm) outside diameter
Optional flexible connection: 12 inch ANSI flange connection
12V275GL+
Engine inlet connection: Flange, 11.02 inch (280 mm) bolt circle, 12 holes equally spaced
Optional flexible connection: 10” ANSI flange connection
The best air induction system has ducting as short and straight as possible. Use long radius
bends and low restriction fittings only where necessary. The use of pipe fittings should be kept
to a minimum. Each fitting added to a ducting system is equivalent to adding a length of pipe.
Intake air ducting restriction should be kept to a minimum. Air induction systems should be
designed with at least a 30% pressure loss reserve to minimize required air cleaner change
intervals. The maximum permissible intake air restriction for the entire air induction system
including the air cleaners are listed in the Waukesha Technical Data Manuals for each engine.
Once an air induction system design is proposed the total system restriction must be deter-
mined. The total system restriction is the total pressure loss the system experiences when the
maximum intake air is flowing through the system. A procedure for calculating the air intake
system piping restriction is available in Appendix A in this manual. This procedure uses the
EDL (Equivalent Duct Length) Method, however there are other methods or computer based
simulations that may also be used.
13 - 6 Form 10056-2
Exhaust System Chapter 14
CHAPTER 14 - EXHAUST SYSTEM

EXHAUST SYSTEM REQUIREMENTS
• Exhaust system must be properly supported with no forces applied to engine exhaust
connection
• Proper selection and placement of flexible connections, to account for thermal expansion
in both horizontal and vertical directions
• Adequate materials to be used, of sufficient strength and temperature capabilities. Rec-

ommended are listed below for guidance
−− ANSI schedule 10 stainless steel pipe
−− ANSI schedule 20 carbon steel pipe
• Exhaust piping and components sized with minimal restriction
−− Total exhaust system restriction less than 20 inches (508mm) H2O, at full rated load /
speed conditions
−− Ensure any exhaust transition sections are smooth (no abrupt transitions)
−− Exhaust elbow sections should be of the long radius type
• Piping should be sized to keep exhaust velocity less than 12,000 ft/min (60 m/sec). This will
keep exhaust restriction and exit noise low.
• Explosion relief valves, if installed, should be located in the exhaust piping near the engine
and can protect exhaust components from a damaging exhaust explosion. Explosion re-
lief valves must be vented to a safe location to prevent fires or personal injury.
• Silencer(s) should be sized using the proper exhaust flow rate, temperature, and to achieve
local/site sound attenuation requirements.
• Moisture traps and drains - during startup of a cold system, water can condense and
collect in low spots of exhaust piping. Moisture traps and drains in the low spots provide a
way to remove this water. Many silencer manufacturers include drains in their equipment.
Piping should be sloped away from engine.
• Common Exhaust Systems – the use of a single exhaust system fed by multiple engines
is discouraged
−− If an engine is not in operation, exhaust gas from other engines (s) can condense water
in the non-operating engine and result in damage.
−− The engine which is not in operation can also be a path for exhaust gas to leak.
• Maintenance considerations
−− Access to drain points
14 - 1 Form 10056-2
Chapter 14 Exhaust System
−− Access to allow for catalyst replacement, if applicable
−− Access for emissions port sampling, if applicable
−− Clearance between exhaust system components and building cranes or other site
equipment
• Layout considerations
−− Exhaust outlet location and orientation should not be in the vicinity of the engine air
intake or radiators/coolers. Prevailing winds should be considered.
−− The exhaust outlet should be designed to keep out rain, dirt, and other debris. This can
be accomplished with a rain cap.
• Emissions – local requirements may require exhaust aftertreatment to attain specific

emissions levels. If required, such equipment should be appropriately sized considering
exhaust flow, temperature, and emissions produced by the bare engine.
• Exhaust purging - To prevent explosions and personal injury the engine and the exhaust
system are purged by cranking the engine for several seconds before the ignition is turned
on and the fuel valves are opened. The purge volume of the engine is approximately its
displacement for every two revolutions. Additional purge time can be added in ESM via a
user-programmable field. Up to 20 seconds can be added while still allowing the engine
to start.
Use high temperature gasket materials and proper room ventilation. Inadequate gaskets
can break down allowing poisonous exhaust gas to leak. These fumes can cause personal
injury or death.
Never discharge engine exhaust into a brick, tile, or cement

block chimney, or a similar structure. Exhaust pulsations
could cause severe structural damage.
Legend
Growth (change in length) dee Note 1
Direction of growth (growth not allowed in
opposite direction)
Fixed (rigid) pipe mounte
Roller
Fexible connections must accomodate all
growth between rigid mounts
Figure 14-1: Example sketch of exhaust system layout
14 - 2 Form 10056-2
14 - 3 Form 10056-2
SPECIFICATIONS
Connection Sizes
Maximum
allowable Typical Temperature At turbo outlet With optional flexible With optional Wye
Engine model backpressure Range (post-turbo) (standard) connections transition
12V275GL+ 20 in. H2O 600 - 1000F (2) 8” ANSI flat faced (2) 14” ANSI flat faced (1) 22” ANSI flat faced
(315 - 540C) flange flange flange
16V275GL+ (2) 14” ANSI flat faced (2) 14” ANSI flat faced (1) 28” ANSI flat faced
flange flange flange
STANDARD SYSTEM AND COMPONENT DESCRIPTION

The exhaust system consists of the following components:
• Exhaust Manifold Segments (one per cylinder)
• Exhaust Thermocouples
−− 16V 275GL+ (20)
−− 12V 275GL+ (16)
• Exhaust System Insulation Blankets
• Flanged outlet connections - located at the turbocharger outlet. The connections are
shown in “Figure 14-2: View from rear right” and “Figure 14-3: View from rear left”.
EXHAUST MANIFOLD SEGMENTS

The 16V 275GL + manifold consists of eight individual cast-iron segments on each side, one
exhaust manifold segment per cylinder. The 12V 275GL + manifold consists of six individual
cast-iron segments on each side, one exhaust manifold segment per cylinder. Bellows are
installed between each segment. This manifold is a dry manifold and does not use water
cooling.
Customer connection points

(standard configuration)
Manifolds with insulation
Figure 14-2: View from rear right
14 - 4 Form 10056-2
Manifolds segments and

bellow assemblies
Figure 14-3: View from rear left
EXHAUST THERMOCOUPLES
Thermocouples are used to monitor engine exhaust temperatures. The 16V275GL+ engine
has 20 thermocouples and the 12V275GL+ has 16 thermocouples. One thermocouple is pro-
vided for each of the cylinders and measures the exhaust temperatures within the respective
cylinder head exhaust port. There is also one post-turbine and one pre-turbine thermocouple
for each turbocharger. The pre-turbine exhaust thermocouple is only intended to be used as
a general indication of the relative exhaust temperature.
Exhaust thermocouples are not monitored by ESM; Waukesha includes a single connection
point on the engine as well as a thermocouple harness for connection to customer-supplied
monitoring equipment. Monitoring of exhaust temperatures can be useful for troubleshoot-
ing, for example aiding to detect a cylinder which is not firing properly (this would be indicated
by a temperature significantly lower than other cylinders).
EXHAUST SYSTEM INSULATION

The exhaust manifold and turbocharger are covered with hard panel insulation. This special
high-temperature insulation is formed to fit securely onto the manifold sections and turbo-
charger tubing. Approximate surface temperature of the insulation is 300° F (150° C). Surface
temperature of exhaust manifold and turbocharger, if not insulated, is approximately 1050° F
(565° C). The insulation is not designed to be 100% air tight.
EXHAUST CONNECTIONS
Standard exhaust are shown in “Figure 14-4: 12V275GL+ standard connections” and “Figure
14-5: 16V275GL+ standard connections”. Gasket and hardware for connection to customer
piping are not included.
14 - 5 Form 10056-2
Figure 14-4: 12V275GL+ standard connections
14 - 6 Form 10056-2
Figure 14-5: 16V275GL+ standard connections
OPTIONAL COMPONENT DESCRIPTION

• Flexible Connections – vertical flexible connections as shown in figures. Gaskets are in-
cluded for both engine connection and between the flexible connection and customer
piping. Mounting hardware (bolts, nuts, washers) is included only between the engine con-
nection and flexible connection. See “Figure 14-6: Flexible connections for 12V275GL+ and
16V275GL+”.
• Exhaust Wye transition – If desired, a transition section can be purchased from Waukesha.
If not supplied by Waukesha, the customer has the option of either supplying their own
transition section, or running separate exhaust paths (one per bank). See “Figure 14-7:
Wye transition connections for 12V275GL+ and 16V275GL+”.
• Gaskets are included between the Waukesha supplied components, and also between the
wye transition and customer piping. Mounting hardware (bolts, nuts, washers) is included
only between the Waukesha supplied components.
• All items mentioned above are shipped loose for customer installation
14 - 7 Form 10056-2
14 - 8 Form 10056-2
Fuel System Chapter 15
CHAPTER 15 - FUEL SYSTEM

FUEL SYSTEM REQUIREMENTS
• Fuel pressure at inlet flange of engine mounted fuel valve between 45 – 60 psig (310 – 414
kPa)
• Fuel piping sized for maximum fuel flow with minimal piping restriction ; 3” customer pip-
ing recommended.
• Coalescing fuel filter installed as close to the engine inlet as possible when fuel contains
water vapor or heavy hydrocarbons
• Fuel meets Waukesha’s latest fuel specification S-7884-7 in technical data
• Additional pressure regulators installed upstream of engine if fuel pressure at engine ex-
ceeds 60 psig.
−− For fuels containing water vapor or heavy hydrocarbons, a coalescing fuel filter and
possibly fuel heater is installed between the high pressure regulator and engine con-
nection to remove liquids from the fuel at the engine inlet pressure.
• Flexible connection
• Fuel temperature between -20° F to 140° F (-29° C to 60° C)
• Vent fuel solenoid valves to a safe location when required
• Install piping and provide supply pressure of 40 - 80 psig (275 - 551 kPa) to solenoid valve
to operate pneumatic main fuel valve.
• Fuel H2S and sulfur less than 50 µg/BTU
• Fuel LHV variation within ±6%. Fuel variation greater than 6% requires engine adjustment.
STANDARD EQUIPMENT
Carburetor with precombustion circuit. Single fuel inlet connection, mounted main and
prechamber gas supply regulators and 24V DC pilot operated prechamber fuel valve. En-
gine-mounted 24V DC pilot operated main fuel valve. Fuel system and ESM calibration for
fuels with a LHV greater than 850 BTU/ft3 (33.4 MJ/m3) and WKI between 75 – 100.
OPTIONAL EQUIPMENT
ESM calibration for fuels between 35 – 80 WKI (automatically supplied when needed with the
engine depending on the fuel composition at the time of engine order)
Fuel system (carburetor insert) and ESM calibration for fuels between 700 – 850 BTU/ft3 (27.5
– 33.4 MJ/m3)
Fuel system (carburetor insert), ESM calibration, and turbochargers for fuels between 600 –
750 BTU/ft3 (23.6 – 29.5 MJ/m3)
Shipped loose stainless steel flexible connection for fuel inlet
15 - 1 Form 10056-2
Chapter 15 Fuel System

Fuel piping connections to engine
Flexible connection to engine (when not using Waukesha optional equipment)
Fuel filter
Fuel coalescing filter
Fuel treatment system (when needed)
Fuel vent from solenoid valve (when needed)
Supply pressure to solenoid valve of 40 - 80 psig (275 - 551 kPa)
REFERENCE DOCUMENTS
S-6656-23 Gas pressure limits to engine mounted regulator
S-7884-7 Gaseous fuel specification
PC2175B Fuel system P&ID
EngCalc Engine data program for site specific fuel consumption
FUEL SYSTEM COMPONENT DESCRIPTION

The fuel system consists of the following components:
• Main Fuel Shutoff Valve
• Main Fuel Gas Regulator
• Carburetor
• MAS Valve (Main Fuel Adjustment Screw)
• Prechamber Fuel Supply Valve
• Prechamber Fuel Regulator
• Prechamber Manifold
• Admission Valve Assembly (one assembly per cylinder)
• Prechamber (one per cylinder)
• Necessary Piping
• Stepper
15 - 2 Form 10056-2
Do not inhale gaseous fuels. Some components of fuel gas are

odorless and tasteless.
When the main gas shutoff valve is open, and the engine is not run-
ning, gas flows both into the exhaust and through the air cleaner.
The fuel system must have a positive main gas shutoff valve that
opens upon cranking and closes whenever engine rotation stops.
MAIN FUEL GAS REGULATOR

The main fuel gas regulator is mounted on the front right side of the engine. The regulator
reduces the incoming customer fuel supply pressure to the carburetor from 310 – 414 kPa
(45 – 60 psi) to approximately 0 – 508 mm-H2O (0 – 20 inch-H2O) above the carburetor air
pressure, as measured at the carburetor inlet. From the main fuel gas regulator, the fuel flows
into the carburetor, where it is mixed with air.
The 12V/16V 275GL + uses a venturi carburetion system that has a low inlet restriction for
maximum performance. The carburetor’s flat tracking provides desirable performance and
low emissions. The venturi carburetor contains no moving parts. The carburetor consists of
a main mixing body with a perforated venturi insert that allows fuel gas to be drawn into the
air stream. The size and number of the holes controls the air/fuel mixture. The main adjust-
ment screw located in the line before the mixer body controls the fuel gas to the carburetor.
The flow of air into the engine is controlled by the actuator-operated throttle valve located
downstream from the carburetor. The throttle valve is mounted to the induction elbow on the
intake manifold in the engine vee.
Exceeding the maximum inlet pressure rating of the regulator

may cause the regulator housing to burst, resulting in severe per-
sonal injury or death.
PRECHAMBER FUEL SUPPLY VALVE

The prechamber fuel supply valve is located on the left side of the engine. Opening of the
valve supplies fuel to the prechamber manifolds. The fuel supply valve is electric solenoid
operated. Solenoid operated valves are actuated by engine speed (200 – 400 rpm), the speed
being determined by the ESM.
PRECHAMBER FUEL REGULATOR

The function of the prechamber fuel regulator, located on the left front of the engine, is to
control the amount of fuel available to the prechamber.
PRECHAMBER MANIFOLD
The prechamber manifolds are located on both sides of the engine. The prechamber manifold
supplies fuel to the prechambers through the admission valve assembly. A pressure tap is
provided for checking the prechamber regulator pressure.
15 - 3 Form 10056-2
MAIN FUEL VALVE
The engine comes equipped with a pneumatic main fuel valve and solenoid valve. Both the
main valve and solenoid valve are mounted on the engine just upstream of the main fuel
gas regulator. The solenoid valve is wired and controlled by ESM through the start and stop
sequences. The main fuel valve is pneumatically operated from the electronic solenoid valve.
Both valves are shipped from Waukesha with the valve vented to atmosphere for when the
valve is opened and closed. The solenoid valve requires an inlet supply pressure of 40 - 80
psig (275 - 551 kPa) from either the inlet fuel or a separate instrument air supplied by the site.
The valve should be vented to a safe location if required by local codes and specifications
using the venting ports indicated in “Figure 15-1: Main fuel valve and solenoid valve showing
solenoid valve inlet (left arrow) and outlet vents (two right arrows)”. The inlet (left arrow) and
outlet (middle arrow) vents have a 0.5 NPT connection size. The conduit vent (right arrow) has
a 0.25 NPT connection.
Figure 15-1: Main fuel valve and solenoid valve showing solenoid valve inlet (left arrow) and outlet
vents (two right arrows)
Use extreme caution when venting gas to avoid open flames or

other ignition sources. Observe local fire and safety codes.
15 - 4 Form 10056-2
FUEL INLET PIPING
Fuel system piping must be sized to allow the fuel to flow without excessive restriction; 3”
customer piping recommended. The piping material must be suitable for the temperatures
and pressures encountered, as well as vibration from the operating engine. Flexible connec-
tions are recommended at all connection points to the engine. This will isolate the engine and
piping components from high stresses due to vibration. Engines mounted on spring isolators
or other soft mounting systems must have fuel system connections with flexibility sufficient to
handle the motion normally encountered. Flexible connections for the fuel system are avail-
able as an option from Waukesha for 275GL+ engines (not suitable for vibration isolators).
Fuel system piping must also be properly aligned and supported on the package to not exert
any external forces on the engine connection. Flexible connections are not designed to ac-
commodate for misaligned piping.
The engine mounted fuel valve has a 2.00” ANSI 150# Flat–Face Flange. It is recommended
that the fuel piping running to the engine be at least 3” in diameter. There have been instanc-
es when a 2” fuel pipe did not deliver enough fuel to the engine under full load due to restric-
tion and piping losses in the 2” customer piping.
The following description applies to the flexible inlet connection that is supplied with Option
Code 1200A. If the customer supplies their own it is recommended to meet, or exceed, these
properties:
• Fuel Inlet Flexible Connection
• 2.00” ANSI 150# Flat-Face (engine inlet)
• 3.00” ANSI 150# Raised-Face Flanges (customer connection)
• 18 inch length
Piping restriction depends on the pipe diameter, pipe length, number of elbows and transi-
tions, and the piping material used. A procedure for calculating the fuel system piping restric-
tion is available in Appendix A in this manual. This procedure uses the EDL (Equivalent Duct
Length) Method, however there are other methods or computer based simulations that may
also be used.
Fuel treatment considerations
The fuel being used in the engine must meet Waukesha’s most current fuel specification
available in technical data. The fuel specification has limitations for contaminants in the fuel
and must be treated if the fuel does not meet the specification. Methods for treating the fuel
are explained in more detail in the fuel specification in technical data.
The 275GL+ engine does not have a specific limit for CO2 content in the fuel, however CO2 in
the fuel will decrease the LHV of the fuel. The fuel LHV must fit within the requirements of the
available fuel systems provided in the standard and optional equipment in the beginning of
this section.
15 - 5 Form 10056-2
15 - 6 Form 10056-2
Starting System Chapter 16
CHAPTER 16 - STARTING SYSTEM

STARTING SYSTEM REQUIREMENTS
• Adequately sized starters for turning over the engine and driven equipment
• High pressure air or gas supply
• Piping to and from the starter, sized to reduce restriction and supply appropriate pressure
• Flex connections used at starter inlets and outlets
• Starter and solenoid valve exhausts piped to safe location if combustible gas is used
STANDARD EQUIPMENT
The 275GL+ engines will be equipped with either one or two turbine pneumatic, inertia start-
ers with Y-strainers. The starters are electronically controlled through a normally closed, CSA
Class I Div II, 24VDC solenoid valve which is actuated when it receives a signal from ESM. This
signal is programmed from the factory into the standard engine start sequence.
OPTIONAL EQUIPMENT
The 12V275GL+ has options to change the single starter to a dual starter system – this ad-
ditional torque is required for the majority of applications. High or low pressure starters are
available for either engine depending on the starting torque required or air pressure avail-
able. Refer to S-9063-23 for properly sizing the starter requirements.
CUSTOMER CONNECTION
The inlet to the air/gas starter utilizes a 1.5” ANSI 150# raised face flange and the outlet has
a 3” ANSI 150# raised face flange. Each starter requires its own inlet and outlet piping; when
two starters are mounted on the engine these connections will have to be made on both
sides of the engine. Flex connections are recommended on both the inlet and the outlet to the
air/gas starter(s), the inlet flex connection is available as part of option code 1200A. These flex
connections have two 1.5” ANSI 150# raised face flanges and are 18 inches [457.2 mm] long.
The starter solenoid vent and exhaust ports must be plumbed to a safe location if hazardous
gas is used. Regardless if there are one or two starters on the engine there will be only one so-
lenoid valve. The solenoid valve has two 0.25 NPT connection locations (one for the exhaust,
one for the vent) that would need to be vented to a safe location.
16 - 1 Form 10056-2
Chapter 16 Starting System
REFERENCE DOCUMENTS
L-08065-39 12V275GL+ optional flexible connection outline drawing
L-08067-29 16V275GL+ optional flexible connection outline drawing
L-08065-37 12V275GL+ optional starters
S-9063-23 Air volume and pressure guidelines for air starter
PC2177D Air system P&ID
S-7232-422 Battery Specification
SYSTEM DESIGN
The starter(s) for the engine must be sized so that they are capable of rotating the engine
and driven equipment; different options and pressure ranges are available. Gas compres-
sion applications usually require two starters to produce sufficient torque. Compressor by-
pass valves are typically used to unload compressors and make the package easier to start.
Documents for sizing the starter, torque output and air/gas consumption are available in
S-9063-23. These documents also contain information and equations for sizing the air receiv-
er if compressed air is being used.
Compressed air or high pressure gas can be used to spin the pneumatic starters. If a com-
bustible gas is used then the starter exhaust and solenoid exhaust/vent must be plumbed to
a safe location per applicable local codes and regulations. If compressed air is used and the
exhaust is not routed away from the engine it should be directed to prevent personal injury.
Piping must be sized to provide the appropriate flow and pressure to the starters. Pressure
loss through the piping to the starters and restriction from the exhaust piping must be taken
into consideration. It is common to see up to a 30% pressure loss due to piping restriction. Us-
ing transition pieces and piping larger than the starter flange sizes can help reduce restriction
in the system for longer piping runs. Flex connections should be used at the inlet and outlet
of any engine connections.
AIR/GAS QUALITY
The starter does not require lubrication of the drive air/gas supply. The starters incorporate
sealed, greased packed lubrication of the gearbox and bearings, designed to be maintenance
free for the life of the starter. It is recommended to use a coarse (40 mesh [420 micron]) filter
in the supply stream of the air/gas in applications where larger particulate is abundant. The
most common damaging solid contaminants found in unfiltered air/gas supply are weld slag
or steel pipe shavings generally found in new installations or when piping has been modified.
The starter includes an internal piping screen to remove some debris; however this should not
be used for gross debris removal and an additional screen should be used to clean the piping
before commissioning. These starter motors will operate reliably on field quality (wellhead)
gas and “sour natural gas” (including gas that has H2S content as high as 6000 PPM). Liquids
in the supply stream will not damage the starter motors. The only detriment to operating on
air/gas supplies with high concentrations of liquids is freeze-up. Liquids which “pool” and
then freeze around rotating elements (turbine rotors) may restrict motor rotation until the
liquids are thawed.
16 - 2 Form 10056-2
ESM Packaging Chapter 17
CHAPTER 17 - ESM PACKAGING

ESM SYSTEM REQUIREMENTS
• Proper supply power provided: – 24VDC with minimum voltage ripple
• Control panel to supply all input signals to ESM for control and operation of the engine
• Required connections to Customer Interface harness (6 wires minimum)
• Setup through ESP with laptop or local PC
• Alarm/shutdown logic through customer panel for non-ESM controlled shutdowns
• Connect to exhaust and main bearing thermocouples for temperature readings and
alarm/shutdown; these are not monitored by ESM
• Zener diode for all 4-20 mA input signals
STANDARD EQUIPMENT
The Waukesha ESM is a system designed to optimize engine performance and maximize up-
time. The ESM integrates spark timing control, speed governing, knock detection, start-stop
control, air-fuel control, turbocharger wastegate control, turbocharger compressor bypass
control, diagnostic tools, fault logging and engine safeties. In addition, the ESM system has
safety shutdowns such as low oil pressure, engine overspeed, high IMAT, high coolant outlet
temperature and uncontrolled knock.
The Engine Control Unit (ECU) is the central brain of the control system and main customer
interface. Interface with ESM is through 25 foot (7.6 m) harness to local panel, through MOD-
BUS RTU slave connection RS-485 multidrop hardware, and through the Electronic Service
Program (ESP). ESM meets Canadian Standards Association Class I, Division 2, A, B, C & D
(Canada & US) hazardous location requirements
See “Figure 17-1: ESM schematic” for a general overview of the ESM system inputs and out-
puts.
CAN
(all NCM information
ignition coils 24 VDC
personal to and from HMI) HMI
computer
ignition power power electronic service ESM MODBUS IN

module w/diagnostics distribution box program (all information)
NCM
NOx sensor AGR stepper
customer interface harness

wastegate
control
local control harness
intake manifold
bypass pressure (2) knock sensors
control exhaust thermocouples
oil pressure HT water temperature
• throttle actuator main bearing thermocouples
integrated throttle control • throttle position oil temperature
• throttle actuator
• throttle position
• power electronics barometric pressure intake manifold
temperature
camshaft & crankshaft
magnetic pickups
ambient air temperature
Customer Supplied
fuel pressure
Waukesha Supplied
HT coolant
pressure
Figure 17-1: ESM schematic
17 - 1 Form 10056-2
Chapter 17 ESM Packaging
Interface to the ESM is accomplished through ESP (Electronic Service Program) which is in-
cluded with the engine and can also be downloaded for free from the Waukesha website
(www.ge-distributedpower.com). ESP is a PC-based program which allows the user to pro-
gram settings, retrieve error codes and also includes E-Help that provides troubleshooting
information. More information about using ESP and programming the engine can be found in
the 275GL+ Operation & Maintenance manual.
REQUIRED CONNECTIONS
POWER SUPPLY
The ESM system requires a connection to a steady power source; 18 – 32 VDC and a peak-to-
peak voltage ripple of less than 2 volts. Batteries are the preferred method of supplying the
ESM system with clean, stable power (sized per S-7232-422). In addition, batteries have the
advantage of continued engine operation if there is a disruption in the source of electric pow-
er. See “Figure 17-2: Power supplied by batteries” for a wiring schematic. The 275GL+ engines
require a quantity of 2 batteries with the following characteristics as a minimum: 1000 Cold
Cranking Amps, 320 minute reserve capacity, 12 Volts and 4D size.
Do not install, set up, maintain or operate any electrical compo-

nents unless you are a technically qualified individual who is fa-
miliar with the electrical elements involved.
Disconnect all electrical power supplies before making any con-

nections or servicing any part of the electrical system.
Disconnect all engine harnesses and electronically con-

trolled devices before welding on or near an engine. Failure
to disconnect all engine harnesses and electronically con-
trolled devices will cause damage to electronic compo-
nents and void warranty.
Comply with the battery manufacturer’s recommendations for

procedures concerning proper battery use and maintenance.
Batteries contain sulfuric acid and generate explosive mixtures

of hydrogen and oxygen gases. Keep any device that may cause
sparks or flames away from the battery to prevent explosion.
Always wear protective glasses or goggles and protective clothing

when working with batteries. You must follow the battery man-
ufacturer’s instructions on safety, maintenance and installation
procedures.
17 - 2 Form 10056-2
Always turn the battery charger off first, before disconnecting
the batteries. Then disconnect the battery negative (-) cable
before beginning any repair work. Failure to turn battery
charger off before disconnecting the batteries may cause
electronic component damage and void warranty.
CHARGING
EQUIPMENT
See Power Distribution Box + -

and size lines using Maximum
ESM Current Draw
POWER
DISTRIBUTION
JUNCTION
BOX
+ - + -
M12
GROUND STUD
ENGINE CRANK CASE
EARTH GROUND
2/0 AWG MIN.
POWER (+) NOT WIRED AT WAUKESHA

GROUND (-) WIRED AT WAUKESHA
GROUND (-) NOT WIRED AT WAUKESHA
ANY CHARGING EQUIPMENT
EARTH GROUND (-) NOT WIRED AT WAUKESHA MUST BE CONNECTED DIRECTLY
TO THE BATTERIES
Figure 17-2: Power supplied by batteries
Depending on the distance from the batteries or power supply, choose appropriate cable
diameters for ground and power wiring. The 12V and 16V275GL+ engines have an average
draw of 6 amps with a maximum current draw of 29 amps. If the optional user power 24V
FOR U is used it can increase the current draw by a maximum of 5 amps. The batteries should
be wired directly to the 3/8 inch stud located in the Power Distribution Junction Box using the
largest diameter cable that is practical; 00 AWG is the largest the Power Distribution Box can
accommodate.
Disconnect all electrical power supplies and batteries before mak-

ing any connections or servicing any part of the electrical system.

Equipment must be grounded by qualified personnel in accor-

dance with IEC (International Electric Code) and local electrical
codes.
17 - 3 Form 10056-2
The customer-supplied earth ground should be connected to the front, right side of the en-
gine. There is an M12 ground stud located just left of the IPM-D and below the camshaft cover
door that is readily accessible for this requirement. See “Figure 17-3: Earth ground location”
below.
Figure 17-3: Earth ground location
CUSTOMER INTERFACE HARNESS

The electrical interference from solenoids and other electri-
cal switches will not be cyclic and can be as high as several
hundred volts. This could cause faults within the ESM that
may or may not be indicated with diagnostics. Waukesha requires a “freewheeling” diode
be added across the coils of relays and solenoids to suppress high induced voltages that
may occur when equipment is turned off. Failure to comply will void product warranty.
Customer electrical connections to the ECU are made through the Customer Interface Har-
ness. The unterminated end of the harness connects to the customer supplied panel. Some
connections of the Customer Interface Harness are required for ESM operation: Start Engine,
Normal Shutdown, Emergency Shutdown and 3 wires for speed controls. For more informa-
tion on the required connections, and the optional ones available, see Appendix A.
A 1 inch diameter harness will be shipped loose with the engine which will have unterminated
wire ends for connecting inside the customer panel. This Customer Interface harness has a
Deutsch connector for connecting to the on engine harness. On the customer connection
side there is a 1” sealing ring and gland for connection to the customer control panel and this
harness has a maximum bend radius of 6”. The Customer Interface Harness must be properly
grounded to maintain CE compliance.
Waukesha currently provides suppression diodes for the fuel valve, prelube solenoid valve
and starter solenoid valves.
A Zener diode is required to prevent the ECU from becoming disabled when a current source
is powered before the ECU. The Zener diode should be a 6.2 volt, 1.0 watt Zener diode from
(+) to (–) across all 4 – 20 mA input signals (see “Figure 17-4: Zener Diode (4-20mA Analog
Inputs)”). This diode may be applied at the signal source, such as an output card of a PLC,
or at an intermediate junction box commonly used where the Customer Interface Harness
terminates.
17 - 4 Form 10056-2
Figure 17-4: Zener Diode (4-20mA Analog Inputs)
OPTIONAL CONNECTIONS
THERMOCOUPLE CONNECTIONS
Main bearing and exhaust thermocouples are standard equipment on the 275GL+ engines.
Thermocouples can be used to monitor engine exhaust temperatures through the customer
control panel; the ESM does not monitor these temperatures. The 16V 275GL + engine has
20 thermocouples and the 12V 275GL + has 16 thermocouples. One thermocouple is provid-
ed for each of the cylinders and measures the exhaust temperatures within the respective
cylinder head exhaust port. There is also one post-turbine and one pre-turbine thermocou-
ple for each turbocharger. See “Table 17-2: Harness construction” for harness construction
information.
Main bearing temperature sensors – Type K sensors are also wired to a bulkhead so they can
be monitored through the customer control panel; these are not monitored by ESM. Alarm
and shutdown setpoints will need to be programmed into the customer logic; the recom-
mended shutdown temperature is 250F (121C). On the 12V275GL+ engine there are 7 tem-
perature sensors and on the 16V275GL+ there are 9 main bearing temperature sensors. See
“Table 17-2: Harness construction” for harness construction information.
LOCAL CONTROL CONNECTIONS

See “Table 17-1: Local control option harness loose wire identification” for the Local Control
harness wires. These connections are not required but may be helpful for certain applica-
tions. See “Table 17-2: Harness construction” for harness construction information.
HMI REMOTE MOUNTING

The HMI panel comes mounted on the engine, however there are option codes to remotely
mount the HMI panel. This allows the HMI to be mounted in a local customer panel using
one of the option codes which include a harness up to 100ft (30 m) long. See S-9043-130 for
mounting instructions; this is available through the Waukesha website Outline Drawing index.
17 - 5 Form 10056-2
Table 17-1: Local control option harness loose wire identification
CIRCUIT # WIRE LABEL SIGNAL NAME SIGNAL TYPE WIRE COLOR WIRE SIZE SOCKET SIZE
1020 +24VFOR U User Power +24 VDC nominal (5 Red 18 16
amps maximum)
1120 GND FOR U User Ground Ground Black 18 16
1802 ESTOP SW Emergency Stop Switch, Depends on hardware Tan 18 16
Normally Open wired to switch
1679 PREL CTRL Customer Prelube Control +24 VDC digital I/P Brown 18 16
1426 GOV SD+ Switch, Governor Actuator, G Shutdown input Purple 18 16
1010 GOVSD+24 Shutdown Switch Power +24 VDC nominal Red 18 16
1436 WASTEGSD+ Switch, Wastegate Actuator, G Shutdown Input Purple 20 16
Table 17-2: Harness construction
Harness Diameter Engine Side Customer Side Maximum

bend radius
Customer Interface 1” Deutsch connector Loose wires, 1” 6”
sealing gland
Local Control 0.75” Deutsch connector Loose wires, 0.75” 5”
sealing gland
Exhaust Thermocouple 1” Deutsch connector Loose wires, 1” 6”
sealing gland
Main Bearing Thermocouple 0.75” Deutsch connector Loose wires, 0.75” 5”
sealing gland
WASTEGATE AND GOVERNOR CONNECTIONS

The wastegate and governor actuators are always drawing power. If battery-powered igni-
tion is being used, power is being drawn from the battery even with the engine shut down.
To remedy this, the battery can be removed when not in use, or the ESM can be placed in
reduced power mode, limiting the amount of power that will be drawn from the battery. The
GOVSD+24V and WASTEGSD+ wires of the local control option harness can be used as a way
to reduce power demand from the battery. Connecting GOVSD+24V and WASTEGSD+ with
a 10 kΩ resistor will put the actuator in a low current draw standby mode. NEVER connect
GOVSD+24V and WASTEGSD+ with a 10 kΩ resistor while the engine is operating.
+24V FOR U AND GND FOR U

Never attempt to power the engine using the +24VFOR U wire
in the local control option harness. The +24VFOR U wire is for
customer use to provide 24 VDC power to other equipment.
Power (24 VDC, 5 amps maximum) is available for items such as a local control panel and
panel meters. The 24 VDC wires are labeled +24VFOR U and GND FOR U. DO NOT POWER THE
ENGINE THROUGH THIS CONNECTOR!
17 - 6 Form 10056-2
MODBUS
MODBUS is an industrial communication network that uses the master-slave topology.
Through this connection nearly every parameter that ESM is monitoring can be read by the
customer’s PLC. This includes temperatures, pressures, timing, engine speed, error codes etc.
See the O&M manual for more information.
Modbus RS-485 output is available through the customer interface harness as two wires
labeled RS 485A- and RS 485B+ (green and yellow, respectively).
ALARM AND SHUTDOWNS

ESM has alarm and shutdown setpoints built into its logic to help prevent engine damage or
unsafe operation. User signals can also be sent to ESM to perform a shutdown; Waukesha
recommends monitoring the main bearing and exhaust thermocouples to program alarm
and shutdowns.
“Table 17-3: Alarm and shutdown parameters” lists some of the normal operating parame-
ters as well as the respective alarm and shutdown setpoints.
Table 17-3: Alarm and shutdown parameters
Parameter Normal Alarm Shutdown

Jacket Water 180°F 190°F 200°F
Lube Oil Header Temp 172°F 187°F 197°F
Lube Oil Header Pressure 60-65 psi 40 psi 35 psi
Intake Manifold Temperature up to 140°F 160°F 165°F
Main Bearing Temperature* 250°F
Exhaust Temperature* 75°F above normal** Customer
preference**
Overspeed 1000 rpm max 10% overspeed
Fuel Pressure 45-60 psi 45 psi 38 psi
*logic supplied by customer
**Exhaust temperatures vary based on site conditions and load. Determine the average ex-
haust temperature at full load and speed, then set an alarm value 75°F above this. A shut-
down above the alarm can be used if required at the site.
17 - 7 Form 10056-2
Other shutdowns programed into ESM include the following:
• E-Stop buttons on each side of the engine
• Low oil pressure
• Engine overspeed
−− 10% overspeed instantaneous
−− Waukesha-calibrated to run no more than rated speed
−− User-calibrated driven equipment overspeed
• Customer-initiated emergency shutdown
• Engine overload (based on percentage of engine torque)
• Uncontrollable knock
• Low HT jacket water coolant pressure
• Overcrank
• Engine stall
• Failure of magnetic pickup
17 - 8 Form 10056-2
Asset Performance Management Chapter 18
CHAPTER 18 - ASSET PERFORMANCE MANAGEMENT (APM)

APM REQUIREMENTS
• Cellular network or internet connection on site to transmit data
• Access to myPlant to allow user to view APM data from laptop or smartphone
• APM Module must be located at least 3ft (1m) from the engine to avoid electro-magnetic
interference, and must be installed in an enclosure to keep safe from the environment
(rain, sunlight, dust, etc.)
• Requires 24VDC power source for APM module and optional cell router. 6VDC power re-
quired for optional cell booster
STANDARD EQUIPMENT
All 275GL+ engines with ESM will come standard with the parts shown in Kit 1 shipped loose.
Note that these are sensitive electrical components and care should be taken to not allow the
shipped loose parts box to be exposed to the elements.
Table 18-1: Kit 1 Components
Item Description Quantity Part Number

APM Module Data Collector 1 741335
APM Installation Manual 1 FORM 10000-3
and Operation
Instructions
OPTIONAL EQUIPMENT
The data that is collected with the APM Module needs to be transmitted to GE’s secure data
storage. To do this GE offers different option codes, which provides a cell router, SIM card, and
antenna. This kit is meant to connect the APM Module to the internet via a cellular connection
to allow data transmissions to the APM user interface. Check with application engineering to
ensure suitability of the cell router in the specific country that the package will be located.
This option is not needed if the site has an internet connection or an existing cellular network
is being used, refer to S-09209-1 for router performance requirements. A local area network
connection could also be used to transmit the data, but one of these options is required for
the system to function.
Item Quantity
Cell Router 1
SIM Card 1
Cellular Antenna 1
Antenna Magnetic Base 1
18 - 1 Form 10056-2
Chapter 18 Asset Performance Management
There is an additional option (code 1022) for a cellular signal booster kit that is available for
North American customers who have poor cellular coverage. This booster can be ordered
for sites where APM Kit # 2 – cell router, does not provide adequate cell connection. The cell
booster must be installed outside of a Class 1, Div. 2 area. The kit includes:
Item Quantity Part Number

Directional Antenna 1 741290
Cell Booster 1 741074
50ft Coax Cable 1 741312

The customer must supply a suitable location to mount the APM hardware to keep it safe
from exposure to the environment (rain, sunlight, dust, etc.). The APM Module and optional
cell router kit should be installed at least 3ft (1m) away from the engine in either the local
control panel or an additional junction box (NEMA 4/IP66 rated). Other miscellaneous hard-
ware for installation will be required, which may include Ethernet and/or serial cable as well
as power and ground wires for the devices as the lengths of these connections will be site
specific.
REFERENCE DOCUMENTS
Form 10000-3 APM Installation and Operation Instructions
SYSTEM DESCRIPTION
The GE Waukesha Asset Performance Management Module (APM Module) is a data collector
that allows collection of operational and site data from multiple sources. The collected data is
transferred to GE’s secure APM User Interface, called “myPlant”, for further data trending and
analysis. Collected data can be used to identify trends and fine tune maintenance actions to
reduce plant operating costs and keep assets running at optimal performance and availabil-
ity. The myPlant interface can be viewed from either a laptop or smartphone to allow users
access to their data 24/7 from anywhere, and allows trending of up to 2 years of historical
data. myPlant also offers analytics to allow better planned maintenance or a close watch on
any user defined parameter.
In addition to collecting operational data from the engine’s ESM, the APM Module can gather
operational data from the driven equipment and site balance of plant (BoP) data from the
site PLC. The APM system can aggregate data from multiple assets (compressor/generator,
ESM, AFR2, or PLCs) at the same time, using a Modbus RTU or Modbus TCP network. Up to 6
packages (engine + compressor/generator) and all related PLCs or site BoP can be connected
to one APM Module for stable data collection. One APM Module is needed for each duplicate
Modbus network that requires data collection (up to 6 packages per network).
18 - 2 Form 10056-2
Asset Performance Management Chapter 18
Figure 18-1: APM System Flow Diagram
The APM Module and optional cell router are CSA Class 1, Div. 2 rated for hazardous environ-
ments. The APM Module has an IP20 rating, and it, along with the optional cell router, must
be mounted in an enclosure so they are not exposed to the environment (rain, sunlight, dust,
etc.).
Refer to Form 10000-3 – APM System Installation and Operation Instructions manual for
more information on mounting, installation, system configuration, and specific component
details and schematics.
18 - 3 Form 10056-2
Chapter 18 Asset Performance Management
18 - 4 Form 10056-2
Engine Operation Chapter 19
CHAPTER 19 - ENGINE OPERATION

LIGHT LOAD OPERATION
The following information gives recommendations for special operation and maintenance
procedures when operating Waukesha natural gas engines at light loads or no loads for
extended periods of time.
Light load operation is typically defined as power levels less than 50% of the maximum con-
tinuous power rating. Gas engines usually have unstable combustion at light loads because
combustion chamber pressures are lower, which increases blow-by past the piston rings. This
can lead to contamination of the engine oil including an increase in oil nitration rates and
carboning of the piston ring grooves. Oil analysis is recommended to determine proper oil
change intervals. See latest edition of Service Bulletin 12-1880 for Waukesha oil recommen-
dations. Change intervals are usually not affected by periodic light loading.
If the engine is operated at less than 30% load for long periods (>300 hours), it is recommend-
ed that the engine be exercised at full load for 2 hours every 400 hours.
Engine oil and coolant temperatures should be maintained within the standard operating
ranges.
Always check thermostats for proper operation.
For further information regarding light load operation, refer to service bulletin 16-2864.
ENGINE STARTING
The following section describes the routine start-up sequence and procedure. For initial com-
missioning and pre-start procedures, refer to the Commissioning section of this manual.
STARTING REQUIREMENTS:
• Engines that are required to start at ambient temperatures below 50°F (10°C) require Lube
Oil and Jacket Water Heaters. Verify engine is warm enough before attempting to start.
Lube oil temperature range is 70°F - 100°F (21°C - 38°C). Jacket water temperature range
is 70°F - 125°F (21°C - 52°C)
• When intake air temperature is below 0°F (-17.8°C), the air must be heated. See the Air
Intake section for further details.
NOTE: The ESM is calibrated by Waukesha to both alarm and shut down on low oil pressure.
However, low oil pressure alarm and shutdowns are inhibited for a period of time after engine
start. Follow these instructions for normal start-up of the engine.
NOTE: Contact Waukesha’s Sales Engineering Department for additional information or with
questions regarding a specific engine or installation.
19 - 1 Form 10056-2
Chapter 19 Engine Operation
Always purge the engine and the exhaust system by cranking the
engine for several seconds before the ignition is turned on and the
main gas shutoff valves are opened.
The volume that is purged is several times greater than the vol-
ume of the exhaust system. This purge volume is approximately
the engine displacement for two revolutions.
In case the volume of the exhaust system is such that it will not be
purged by the cranking of the engine, the customer has to use an
alternative means to purge the exhaust system.
Only trained personnel should program the ESM.
STARTING PROCEDURE:
1. Complete all prestart activities and checks.
2. Reset all engine protection switches and devices.
3. Set operating speed to 750 rpm.
4. Confirm engine coolant and lube oil are at least 10°C (50°F) for reliable starting.
5. Open the manual gas shutoff valve, if closed. This statement refers to a customer-sup-
plied shutoff valve, located upstream of the engine. The ESM will automatically open the en-
gine-mounted shutoff valve at the appropriate time.
6. Initiate pre-lube/start cycle by activating the digital Start Signal to the ESM.
• Start Signal – a momentary “high” (8.6 – 36 volts; 24VDC nominal) input to the ECU indicat-
ing the engine should be started. The minimum duration of the signal is 1/2 second but
should not exceed 1 minute. The wire is labeled “START” and is located in the Customer
Interface Harness.
• The shutdown signals must both be “high” (8.6 – 36 volts; 24VDC nominal) in order to allow
the engine to start and run. This includes the Normal Shutdown (Run/Stop) digital input
(wire label “RUN/STOP”) and Emergency Shutdown digital input (wire label “ESD”). Both of
these wires are located in the Customer Interface Harness.
7. Engine should start in the first 7 – 8 seconds of cranking cycle. (A 5-second delay from
crank initiation to main gas shutoff valve opening is programmed into the ESM to purge un-
burned fuel from previous start attempts from the engine and fuel system.)
When the engine is started, listen carefully for any unusual noises. If a problem is suspected,
stop the engine immediately.
After the engine is started, verify that there are no gas, air, coolant or oil leaks. Pay special
attention to the gas manifolds and piping.
19 - 2 Form 10056-2
NOTICE
If the oil pressure display does not indicate sufficient oil pressure within 15 seconds, shut
the engine down immediately. Never operate the engine without the proper oil pressure
indication.
If the engine has not reached the proper operating temperature of 76° – 82°C (170° –
180°F), the oil pressure could be as high as 758 kPa (110 psi). Once the engine has reached
the proper operating temperature, the oil pressure should meet the above specifications.
Turbocharged engines should not be idled for extended periods. Accumulated carbon
may damage the turbocharger.
Never idle turbocharged engines for extended periods. Accumu-

lated carbon may damage turbocharger. Instead of idling the en-
gine, shut it down and restart when needed.
8. Warm engine by running with little or no load until oil pressure is 415 – 450 kPa (60 – 65 psi)
and intake manifold temperature exceeds 38°C (100°F). For standby units, jacket water heat-
ing to 43°C (110°F) is required.
9. Gradually apply load to avoid overloading engine. Refer to the following “Engine Loading”
section for further details.
ESM START SEQUENCE:

See “Figure 19-1: Start Flow Diagram”.
During the start sequence, the ESM performs the following steps:
• Prelubes engine (programmable from 0 – 10,800 seconds from the Prelube Time field lo-
cated on the [F3] Start-Stop panel)
• Engages starter motor (programmable rpm range using ESP software)
• Turns ignition on (after a user-calibrated purge time using ESP software)
• Turns main fuel on (programmable above a certain rpm and after a user-calibrated purge
time using ESP software)
• Turns prechamber fuel on (programmable above a certain rpm and after a user-calibrat-
ed purge time using ESP software)
When the user initiates a start from the user panel, a signal is sent to the ECU to begin the
start procedure. After receiving a start signal, and confirming the emergency stop and run/
stop signals are high, the ECU prelubes the engine for a user-calibrated period of time.
Once the prelube is complete, the starter is activated. The ignition is energized after the en-
gine has rotated through a minimum of two complete engine revolutions and a user-calibrat-
ed purge timer has expired. When the engine speed reaches an rpm determined by Wauke-
sha, the main gas shutoff valve is energized. After the engine speed exceeds a slightly higher
rpm, the prechamber main gas shutoff valve is energized at an rpm calibrated by Waukesha,
factoring in the value located in “Starter OFF RPM adj” field located on the [F3] Start-Stop
panel. The engine then increases speed until it reaches its governed rpm.
19 - 3 Form 10056-2
Once the starter is activated, a timing circuit begins. If the engine does not reach a minimum
rpm within a calibrated amount of time, the ECU will initiate a shutdown and de-energize the
starter.
Figure 19-1: Start Flow Diagram
19 - 4 Form 10056-2
ENGINE LOADING
COMPRESSION APPLICATIONS
In compression applications, a compressor bypass is used to apply the load to the engine,
which is designed to equalize the suction and discharge pressures on the compressor and
can minimize the load required from the engine for startup and warm-up. The bypass valve
must be completely open during engine startup and warm-up.
Loading of engine is accomplished by either ramping (timed) closure of bypass valve or

opening of suction valve depending on operating protocol of end-user. In either manner the
loading is continued over a period of time, while maintaining engine RPM within acceptable
drop limits. Once the unit has warmed up, load should be applied at a controlled ramp rate.
This rate is linear and should not exceed 20% of maximum rated load per minute (therefore
0-100% load can be achieved in 5 minutes).
The bypass line must be properly sized to minimize the compressor load during engine start-
up and warm-up. Typically a bypass line with a diameter equal to the discharge line is ideal
because it can accommodate all the flow from the compressor. A bypass line with a smaller
diameter will normally cause the engine to be started under a partial load. This will compro-
mise the durability of the starting system and internal components of the engine.
While a completely open bypass line will reduce the load required from the engine, there
may still be a small load applied to the engine if the compressor is not depressurized after
shutdown. While using a completely open bypass line, starting the engine does not require
depressurizing of the compressor unless otherwise required by the operating philosophy of
the customer’s compressor site.
Engine speed ramp rate is limited by ESM. The quickest speed change rate that ESM will allow
is 10 rpm per second.
POWER GENERATION APPLICATIONS

In Power Generation applications, the units are started and can be warmed up at either low
idle speed, or at synchronous speed (900 or 1000rpm). With the circuit breaker open, there is
no load applied during warmup.
For units operating in parallel with the utility grid, once the unit has warmed up, load should
be applied at a controlled ramp rate. This rate is linear and should not exceed 20% of maxi-
mum rated load per minute (therefore 0-100% load can be achieved in 5 minutes).
For units in island mode operation (also known as stand-alone mode), the loading is deter-
mined by the sequencing/starting of individual site loads. In these cases, the maximum allow-
able load steps for the 275GL+ engines are typically either 20% or 25% of rated load, depend-
ing on the engine calibration used. Refer to document S-09063-40 in Tech Data for details.
SHUTDOWN
The following section describes the routine and emergency shutdown procedures and se-
quences. A routine shutdown is the normal method use to stop the engine, whereas an emer-
gency shutdown should be used to avoid imminent personal injury or property damage.
19 - 5 Form 10056-2
ROUTINE SHUTDOWN PROCEDURE:
Allow engine to cool for at least 10 minutes after shutdown. Do

not restart an overheated engine or an engine that has been shut
down by the engine protection system until the cause has been
determined and corrected.
Always ensure that the fuel gas valve(s) are closed after engine
shutdown.
NOTICE
If the engine is being shut down for an extended period of time, cap the exhaust pipe to
prevent moisture or contaminants from entering the engine.
1. Gradually reduce engine load.
2. Operate engine at no load for 5 minutes to cool down engine temperatures.
3. Shut down engine using customer-supplied control panel.
4. Postlube engine for 60 seconds. ESM system is programmed to automatically postlube

engine.
ROUTINE SHUTDOWN SEQUENCE

See “Figure 19-2: Routine Stop Flow Diagram”.
To initiate a routine shutdown, the engine should be stopped by causing the normal stop (or
run/stop) input to go “low.” This turns off the fuel supply before ignition is halted, eliminating
unburned fuel. It runs the postlube procedure supplying oil to vital engine components. The
wire is found in the Customer Interface Harness and is labeled “RUN/STOP”. During this rou-
tine shutdown, the Emergency Shutdown input must remain active (high).
During the routine shutdown sequence, the ESM performs the following steps:
• Begins cooldown period (programmable using ESP software)
• Shuts off fuel (by closing the engine-mounted shutoff valve)
• Stops ignition when engine stops rotating.
• Postlubes engine (programmable from 0 – 10,800 seconds using the [F3] Start-Stop panel)
When the run/stop digital input to the ECU goes low (less than 3.3 volts), and a user-calibrated
cooldown period is met, the ECU stops the engine. This is accomplished by first de-energiz-
ing the main gas shutoff valve and prechamber main gas shutoff valve and then, when the
engine speed drops to zero, de-energizing the ignition. If the engine fails to stop in a prepro-
grammed period of time (typically less than 1 minute) after the main gas shutoff valve has
been de-energized, the ignition is de-energized, forcing a shutdown.
19 - 6 Form 10056-2
Figure 19-2: Routine Stop Flow Diagram
EMERGENCY SHUTDOWN SEQUENCE (ESD)

See “Figure 19-3: Emergency Stop Flow Diagram”.
Use an emergency shutdown to stop the engine to avoid imminent

personal injury or property damage. Never use an emergency
shutdown to stop the engine under normal circumstances, as this
may result in unburned fuel in the exhaust system which could
ignite.
An Emergency shutdown can be initiated in three ways:
1. An engine-mounted emergency pushbutton is activated
19 - 7 Form 10056-2
2. Activating the ESD digital input signal:
• A digital signal input to the ECU that must be connected to +24 VDC nominal (8.6 – 36
volts) for the engine to run. If ESD goes open circuit, the engine performs an emergency
shutdown. The ESD wire connection can be found in the Customer Interface Harness.
NOTE: Do not use this input for routine stopping of the engine. After an emergency shutdown
and rpm is zero, ESD input should be raised to high to reset the ESM. If ESD input remains low,
ESM reset will be delayed and engine may not start for up to 1 minute.
3. The engine will perform an ESD if one of the ESM safety shutdowns are activated (over-
speed condition, low oil pressure, etc.).
Figure 19-3: Emergency Stop Flow Diagram
19 - 8 Form 10056-2
Engine Commissioning Chapter 20
CHAPTER 20 - ENGINE COMMISSIONING

Always disconnect the clutch, circuit breaker or other main power

transmission device prior to the prestart inspection.
Slowly loosen the air bleed petcock to relieve any excess pressure.
Always wear protective clothing when bleeding the cooling sys-

tem on a heated engine.
The following section provides guidelines and steps as an overview of the com-
missioning and initial star-up process for 275GL+ Engines. Refer to the 275GL+
with ESM operation & maintenance manual for details.
PRIOR TO ENGINE STARTUP

1. Remove any temporary items from engine (i.e. air filter covers, covers/plugs for other
engine connections)
2. Ensure all engine connections are properly installed, torqued and supported
3. Verify shutoff valves, control valves are in the proper position
4. Verify drain cocks are completely closed
5. Fill oil and coolant, and check for proper level. Check for leaks.
6. Inspect air filter and restriction indicator
7. Verify protective guards and shields on both engine and driven equipment are in place
and secure
8. Remove tools, rags, fittings or any objects that may get caught by rotating parts.
20 - 1 Form 10056-2
Chapter 20 Engine Commissioning
9. Bar engine over two revolutions in a counterclockwise direction and verify nothing inter-
feres with rotation
10. Examine engine foundation for tightness of holddown bolts, and general alignment of
driven equipment.
11. Complete initial ESM programming and checks:
a. Visually inspect the ESM installation to be sure that all wiring conforms to the require-
ments of this manual, local codes and regulatory bodies
b. Apply power to the ESM
c. Using a digital voltmeter, measure the voltage between the power terminals in the
Power Distribution Junction Box. Verify that the power supply voltage is within the
specification provided in the ESM section.
d. Install ESP to the PC that will be connected to the ECU.
e. Connect PC to the ECU and start ESP
f. Reset all emergency stop buttons (E-Stops)
g. Check alarm and shutdown status LEDs located on the front of the Engine Control Unit
(ECU). Yellow and red LEDs flash codes when an alarm or shutdown occurs
h. Perform ESP setup; refer to the ESP Programming section in the 275GL+ Operation &
Maintenance manual for details.
12. Perform initial fuel system adjustment. This is accomplished by adjusting the Main Ad-
justing Screw (MAS) is between the fuel regulator and the carburetor in the Vee of the
engine.
a. The MAS valve is used to adjust fuel flow at rated speed and load, with the NOx control
functioning in Automatic, until the regulator actuator is at the proper steps.
b. The MAS valve is initially adjusted for 900 BTU/SCF LHV fuel at the Waukesha factory.
If site fuel is lower than 850, or higher than 950 BTU/SCF LHV, adjust the initial MAS
position according to recommendations in the O&M manual.
Never attempt to start an engine that has been stored without

first cranking it over with the spark plugs removed. Any oil, cool-
ant or preservative oil that might spurt from these openings must
be removed to prevent a hydraulic lock. Continue to crank the
engine with the starter until liquid is no longer ejected from the
openings. Inspect the intake passages and manifolds for thick-
ened preservative oil. Accumulations of thickened preservative oil
may thin as the engine warms up and be burned as fuel, resulting
in a runaway engine.
NOTICE
Waukesha engines should be purged of all preservative oil from the cylinder head area
prior to start-up. Failure to comply with this message may result in engine damage.
20 - 2 Form 10056-2
Engine Commissioning Chapter 20
INITIAL START-UP PROCEDURE
• Engines that are required to start at temperatures below 10°C (50°F) should be equipped
with heaters. Verify engine is warm enough before attempting to start.
• Verify ESM is in control of main fuel shutoff valve.
• Verify the ignition timing using a timing light and compare timing value to ESP [F5] ignition
panel value.
1. Complete all pre-start activities and checks including checking oil and coolant levels, ad-
justing valves (if needed), alignment and crankshaft deflection, rocker arm oiling, piping
tests, etc.
2. Set operating speed to 750 rpm.
3. Confirm engine coolant and lube oil are at least 10°C (50°F) for reliable starting.
4. With manual fuel shut-off valve closed, initiate prelube/start sequence and confirm pre-
lube oil pressure is between 35 kPa (5 psi) and 200 kPa (30 psi). Allow engine to crank for
15 seconds to verify adequate purging.
5. Open the manual gas shut-off valve.
6. Initiate pre-lube/start cycle.
7. Crank engine for 20 seconds maximum. Engine should start in the first 7 – 8 seconds of
cranking cycle. (A 5 second delay from crank initiation to main gas shutoff valve opening
is programmed into ESM to purge unburned fuel from previous start attempts from the
engine and fuel system)
8. Verify correct oil pressure at 1,000 rpm and the engine at operating temperature, in ESP
[F2] engine panel. Normal oil pressure is 415 – 450 kPa (60 – 65 psi). Note - If the engine
has not reached the proper operating temperature of 76° – 82°C (170° – 180°F), the oil
pressure could be as high as 758 kPa (110 psi). Once the engine has reached the proper
operating temperature, the oil pressure should meet the above specifications. Turbo-
charged engines should not be idled for extended periods. Accumulated carbon may
damage the turbocharger.
9. If engine fails to start, confirm fuel is reaching engine, ignition is firing. Using the HMI:
a. Reduce START position in 200-step increments and retry.
b. Raise START position in 200-step increments and retry.
c. Repeated start attempt failures may cause moisture to build on spark plugs. Crank
several times with fuel off to “dry” the spark plugs, and repeat start attempts.
10. Continue with prechamber regulator adjustment and MAS adjustment as described in
the O&M manual.
11. Engine checks during operation:
a. Observe system readings for oil pressure, oil temperature and water temperature on
ESP [F2] engine panel.
b. Verify engine status using ESP. These panels display system and component status,
current pressure and temperature readings, alarms, ignition status, governor status,
air/fuel control status and programmable adjustments.
c. Listen to the engine. Certain problems, such as occasional misfiring, turbocharger

bearing failure or water pump problems, may first be noticeable from engine sound.
20 - 3 Form 10056-2
Chapter 20 Engine Commissioning
d. Observe throttle. Engine misfire can be seen as an occasional “twitch” of the throttle.
e. Visually examine fuel, water and lubrication lines for signs of leaks, damage or cor-
rosion.
Always purge the engine and the exhaust system by cranking the
engine for several seconds before the ignition is turned on and the
main gas shutoff valves are opened.
The volume that is purged is several times greater than the vol-
ume of the exhaust system. This purge volume is approximately
the engine displacement for two revolutions.
In case the volume of the exhaust system is such that it will not be
purged by the cranking of the engine, the customer has to use an
alternative means to purge the exhaust system.
NOTICE
If the oil pressure display does not indicate sufficient oil pressure within 15 seconds,
shut the engine down immediately. Never operate the engine without the proper oil
pressure indication.
NOTICE
If the engine has not reached the proper operating temperature of 76° – 82°C (170°
– 180°F), the oil pressure could be as high as 758 kPa (110 psi). Once the engine has
reached the proper operating temperature, the oil pressure should meet the above
specifications. Turbocharged engines should not be idled for extended periods. Accu-
mulated carbon may damage the turbocharger.
.
Stop the engine immediately if the oil pressure is low or fluctuating.
Operating the engine without the proper oil pressure could result
in engine damage
NOTICE
Only trained personnel should program the ESM.
20 - 4 Form 10056-2
Storage Chapter 21
CHAPTER 21 - STORAGE
STANDARD PRESERVATION
All Waukesha engines leave the factory with preservative oil which allows the engine to be
stored up to one year after shipment from the Waukesha factory with the capability of being
re-preserved to extend the preservation period. If the engine is stored outside or in harsh or
humid conditions, it may need to be preserved more frequently. Consider the following fac-
tors before deciding how much preservation is required:
• Whether the engine was used, the length of service since the last oil change
• The period of time the engine is likely to be idle or inoperative
• The atmospheric conditions at the time and place of storage. For example, the storage
problems encountered in a tidewater warehouse will differ greatly from those that may be
experienced in a dry and dusty location.
If caps from the engine connections have been removed for packaging or the engine has
been run for testing purposes then the engine must be re-preserved according to Waukesha
standards outlined in the latest revision of Service Bulletin 16-1855H.
NOTICE
Waukesha engines should be purged of all preservative oil from the cylinder head area
prior to start-up. Failure to comply with this message may result in engine damage.
NOTICE
Engines stored outdoors or in humid environments may require more frequent preser-
vations and inspections.
21 - 1 Form 10056-2
Chapter 21 Storage
Engine preservative oils, such as Waukesha Preservative Oil, con-

tain a petroleum distillate which is harmful or fatal if swallowed.
If taken internally, do not induce vomiting. Consult a physician. If
vomiting occurs, keep head below hips to prevent aspiration of
liquid into lungs.
Avoid breathing of vapor. Vapor is harmful and may cause irrita-

tion to eyes, nose and throat. Use only with adequate ventilation.
If affected by exposure, move to fresh air immediately and get
medical help. If breathing is difficult, give oxygen.
Avoid contact with eyes, skin and clothing. Use rubber gloves to
protect hands and chemical goggles to protect eyes. A National
Institute for Occupational Safety and Health (NIOSH) approved
respirator is required where ventilation is inadequate to protect
from inhaling vapors. If skin contact occurs, immediately wash
with soap and water. If eye contact occurs, flush eyes for at least
15 minutes and get immediate medical help. Remove and wash
clothing before reuse.
Keep the preservative oil container closed and away from heat.
Always read and observe the safety labels on the container. Do
not remove or deface container labels.
Do not heat Waukesha Preservative Oil beyond 93°C (200°F). If

heating below 93°C (200°F), the container must be opened or vent-
ed to reduce the danger of explosion. Direct heating is dangerous
and must be avoided.
Do not heat preservative compounds to temperatures that exceed

93°C (200°F).
21 - 2 Form 10056-2
Storage Chapter 21
EXTENDED PRESERVATION FOR NEW ENGINES
The purpose of the deferred engine start-up is to maintain Waukesha’s Express Limited War-
ranty on an engine which will be stored longer than 12 months from the factory shipment
date. The engine may be preserved beyond the one year period by contacting an authorized
Waukesha Distributor. Waukesha gas engines will allow two (2) deferred start-up requests:
the first after one (1) year from the factory ship date and the second two (2) years after the
factory ship date. Only an authorized Waukesha Distributor can perform the deferred start-
up process. Deferred start-up inspection and preservation instructions can be found in the
most current version of Service Bulletin 16-1855.
PRESERVATIVE OIL
Waukesha preservative oil will protect the engine during storage for up to one year when
applied correctly; refer to the current version of Service Bulletin 16-1855.
If Waukesha preservative oil is not available in the region where the engine is being stored
the 275GL+ O&M Manual has a storage section which provides alternative preservative oils.
When an engine is ready to be taken out of storage and put into operation or tested the spark
plugs must be removed and the engine cranked over to evacuate the prechambers of any
preservative oil.
21 - 3 Form 10056-2
Chapter 21 Storage
21 - 4 Form 10056-2
Maintenance Considerations Chapter 22
CHAPTER 22 - MAINTENANCE CONSIDERATIONS

WORK PLATFORMS
Work platforms should be installed on both sides of the engine to allow access to compo-
nents on the top of the engine. The platforms should be made large enough to allow an indi-
vidual to easily perform any required maintenance.
Figure 22-1: Engine Work Platform
Work platforms can also be installed to allow easy access to the air filter housings and ele-
ments on both sides of the engine.
Figure 22-2: Air Filter Housing Work Platform
22 - 1 Form 10056-2
Chapter 22 Maintenance Considerations
COMPONENT WEIGHTS
Refer to Component Weights for approximate weights of engine components. Use this table
to determine the size of the overhead crane required to do maintenance on site. The heavi-
est engine part that needs to be removed for a top end overhaul is the cylinder head which
weighs approximately 450lb. (204kg). For other routine maintenance, there are heavier com-
ponents. Refer to “Table 22-1: Component Weights”.
Table 22-1: Component Weights
APPROXIMATE WEIGHT
ITEM DESCRIPTION
lb kg
Air/Gas Starter 138 63
Camshaft Cover 380 173
Camshaft Gear 60 28
Camshaft End Piece, Left 47 22
Camshaft End Piece, Right 38 18
Camshaft Idler Gear, Large Intermediate 53 24
Camshaft Idler Gear, Small Intermediate 50 23
Camshaft Section 75 44
Camshaft w/Bearing and Gear 940 426
Carburetor 300 136
Connecting Rod w/End Cap and Studs 147 67
16V: 17,421 7,902
Crankcase w/Main Bearing Caps/Studs/Nuts, Machined
12V: 13,501 6,124
16V: 2,460 1,116
Crankshaft Counterweights Total
12V: 1,836 833
16V: 4,072 1,847
Crankshaft w/o Counterweights
12V: 3,203 1,453
Crankshaft Ring Gear 44 20
Cylinder Head 450 205
Cylinder Liner (Sleeve) 173 79
16V: 789 358
Damper
12V: 541 241
16V: 69,461 31,502
Engine With Shipping Skid
12V: 55,500 25,174
16V: 65,320 29,624
Engine Without Shipping Skid
12V: 51,900 23,541
Engine Cover, Front 460 209
Engine End Plate, Rear 375 170
Extensions Shaft, Front Crankshaft 215 98
Flywheel w/Ring Gear 1,800 817
Hydraulic Tensioning Device (Four Head) 314 142
Intercooler, Without Bracket or Piping 1,049 476
Main Bearing Cap 103 47
Manifold, Exhaust w/Water Manifold 1,120 508
Manifold, Exhuast Section 100 50
Manifold, Intake 477 217
Oil Catcher, Two Part 53 25
22 - 2 Form 10056-2
APPROXIMATE WEIGHT
ITEM DESCRIPTION
lb kg
Oil Cooler 278 126
Oil Pump w/Drive Gear 381 173
16V: 1,486 674
Oil Sump
12V: 1,224 550
Piston 109 48
Piston Pin 34 15
Regulator, Main Fuel 99 45
Regulator, Prechamber Fuel 31 14
16V: 4,141 1,878
Shipping Skid
12V: 3,600 1,633
Thermostatic Valve 99 45
16V: 573 260
Turbocharger, Water Cooled
12V: 353 160
16V: 104 47
Turbocharger Feet (each)
12V: 101 46
16V: 55 25
Turbocharger Induction Elbow
12V: 18 8
Water Header Manifold 65 30
Water Guide, Cylinder 38 17
Water Pump w/Drive Gear, Main 189 86
Water Pump w/Drive Gear, Auxiliary 189 86
MAINTENANCE CLEARANCES
The recommended minimum spacing between engines is 114in. (2900mm) and between an
engine and a building wall is 78in. (2000mm). This distance allows a worker to perform re-
quired maintenance on the engines when given the required spacing between engines and
from a building wall.
The recommended minimum overhead clearance is 92in. (2340mm). This measurement is the
distance from the crankshaft centerline required to remove the power cylinder parts (cylinder
head, piston, connecting rod, and cylinder liner). Additional clearance is then required for the
lifting device and any tools or straps for connecting the crane hood to the engine component
being removed. This additional clearance will vary per the equipment being used.
PACKAGE DESIGN
Placing the engine and driven equipment underneath a roof or inside a building can help
protect the engine from the environment and give maintenance personnel a more suitable
environment for working. Buildings or walls can also be used for sound attainment if local
regulations impose limits on sound levels. Any structure erected around the engine should be
designed with consideration given to maintenance and operation tasks.
Whether a building will be constructed around the engine or the engine will be installed into
an existing building there should be easy access to remove the engine and driven equipment
for maintenance purposes and major overhauls. Having a large enough door or removable
wall will help facilitate removal of the equipment. If a removable wall design is used the
amount of piping or equipment running through, or connected to, the wall should be mini-
mized to make this process easier.
22 - 3 Form 10056-2
Building ventilation is required to maintain a suitable temperature inside the building and
provide enough air to the intake filters if they are mounted inside. Wherever they are mount-
ed there should be easy access to the filters for maintenance purposes. The engine room
temperature should not exceed 65°C and the temperature to the intake filters should be be-
low 38°C or the maximum engine output will be reduced. For these situations it is usually
beneficial to remotely mount the filters or duct air from outside the building. Precautions must
be taken so that warm air is not recirculated into the intake Common heat sources are from
engine exhaust, radiators or coolers, building ventilation and heat from generator fans.
Exhaust silencers are often mounted on top of coolers, buildings or support structures. The
building should be designed to support any auxiliary equipment that will be mounted on it.
Exhaust systems should be configured so prevailing winds do not recirculate exhaust gases
back towards the engine and so the sound level and exhaust stack emissions meet local
regulations.
TYPICAL MAINTENANCE SCHEDULE

Table 22-2: 12V/16V275GL+ Typical Maintenance Schedule
4000 HRS OR 6 MONTHS
72000 HRS (Bottom End

8000 HRS OR ANUALLY
36000 HRS (Top End

AS REQUIRED
16000 HRS
24000 HRS
Overhaul)
Overhaul)
1000 HRS
ITEM SERVICE
Air Cleaner filter element Check/Clean or
Replace •
Air starter lubricator Check/Fill •
Cooling system fluid level (Jacket and Check/Fill
auxiliary) •
Crankcase level Check/Fill •
Prechamber regulator Adjust •
Engine Oil (continuous duty) Analyze •
Waste gate linkages for freedom of Check
movement, security •
Turbo inlet and discharge bellows Check •
stepper motor for security Check •
Spark plugs Replace •
Valve clearance Adjust •
Pre-chamber pressure Check/Adjust •
Waste gates Clean •
Bypass valves for condition and security Check •
Micro-Spin Clean •
Ignition leads and coils Check •
Crankcase pressure Check/Adjust •
Oil Cooler Drain •
Oil Filter Elements Replace •
Admission valve assembly Clean or Replace •
Cooling water analysis Check •
Crankcase breather Clean •
22 - 4 Form 10056-2

8000 HRS OR ANUALLY
36000 HRS (Top End

AS REQUIRED
16000 HRS
24000 HRS
Overhaul)
Overhaul)
1000 HRS
ITEM SERVICE
Engine oil (continuous duty) Change •
Cylinder compression/Borescope Check •
Engine mounting and alignment Check •
Main & Rod bearings Inspect •
Intercooler Clean/Inspect •
Cooling system (Jacket and auxiliary) Clean and Flush •
Cooling system thermostats Remove and Test •
Exhaust backpressure Test •
Igniter sleeve O-rings Replace •
pre-chamber cups Replace •
NOx sensor Check/Replace •
Washer, Igniter Sleeve Replace •
Pre chamber washer Replace •
Crankcase pressure relief valves Inspect •
Turbocharger Inspect •
Wastegate Maintenance Inspect/Clean •
Main chamber regulator filter Replace •
Ignition coils Inspect •
Ignition primary terminals, Connections, Inspect
Harness plugs and wires •
Vibration damper fluid (see note) Sample •
Valve cover gasket Replace •
Ignition coil O-ring Replace •
Fuel regulator actuator assembly Replace •
Starter motor turbine Replace •
Extension arm Replace •
Turbocharger parts Replace •
Butterfly valve assembly Replace •
Cylinder Heads Rebuilt •
Seal, Thermostat Replace •
O-Ring Replace •
Bearing, Piston Pin Replace •
Ring, Cyl. Head Sealing Replace •
Liner, Cylinder Replace •
Sleeve, Water Guide Replace •
Rocker Arm Tappet Ball Replace •
Ring, Piston Pin Retaining Replace •
Bearing, Cam Rocker Arm Replace •
DAMPER, VIBRATION Replace •
O-Ring, Cyl Liner Replace •
22 - 5 Form 10056-2

8000 HRS OR ANUALLY
36000 HRS (Top End

AS REQUIRED
16000 HRS
24000 HRS
Overhaul)
Overhaul)
1000 HRS
ITEM SERVICE
Main Bearing Replace •
Crankshaft Replace •
Pump kit Replace •
Jacket water kit Replace •
Connecting rod Replace •
Oil Pump kit Replace •
Note : For the 16V275GL+, Waukesha recommends an initial sample at 2000 running hrs after start up. Then sample annually
after initial samples at 2000 hrs or sooner by damper manufacturer’s analysis and recommendations.
*Turbocharger maintenance to be done at 20,000 – 24,000 hrs, Only inspection at 8000 hrs
EMERGENCY SPARES
An emergency spares list is available upon request. Please contact application engineering
or local sales representative.
SPECIAL TOOLS
Waukesha has developed various special tools which have been designed to simplify per-
forming maintenance on a 275GL+ engine.
Table 22-3: Special Tools for 275GL+
275GL+ PART NUMBER DESCRIPTION

X 472082 FUEL, OIL, & WATER LINE WRENCH
X 472996 COMPRESSION TESTER ADAPTER
X 473005 GEAR BACKLASH ADJUSTMENT TOOL
X 473016 PRECHAMBER REMOVER KIT
X 473030 DAMPER PLUG REMOVAL TOOL
X 473035 VIBRATECH DAMPER TEST KIT
X 494215 COMPRESSION TESTER
X A292539 HYDRAULIC PUMP KIT
X A292693 DAMPER SAMPLE CONTAINER
X 292583 VALVE SEAT INSTALLER
X 292630 CYLINDER HEAD LIFTING EYE
X 473006 CARBON SCRAPPER KIT
X A292511 WATER GUIDE SLEEVE REMOVER
X A292669 VALVE SEAT REMOVER
X AA292579 VALVE SPRING COMPRESSOR
X AA293268 CYLINDER HEAD/MAIN BRG HYDRAULIC FIXTURE
X 292779 CONNECTING ROD NYLON GUIDE PIN
X 296492 ANTI-POLISHING RING REMOVER-CURRENT WIDE GROOVE
X 473001 PISTON LIFTING TOOL
22 - 6 Form 10056-2
275GL+ PART NUMBER DESCRIPTION
X 473002 SLEEVE PULLER INSTALLER
X 473010 STUD INSTALLER
X 473017 COMPRESSOR, PISTON RING
X 473018 EXPANDER, PISTON RING
X 473019 TOOL-ANTIPOLISH RING REMOVAL
X 473031 PLIERS-PISTON RING EXP
X 473033 TOOL-CAM GEAR ADJ
X 473034 KIT-CAM GEAR PUMP
X 494498 PISTON RING RETAINER PLIER
X A292587 MAIN BEARING TURNING DEVICE
X A292591 THRUST BEARING TURNING DEVICE
X A292683 CRANKSHAFT DEFLECTION GAUGE
X A292696A CONNECTING ROD BRG INSTALLATION TOOL
X A292704 CONNECTING ROD HYDRAULIC JACKS
X A292804 CAMSHAFT MOUNTING DEVICE
X A292848 PUMP GEAR DISASSEMBLY TOOL
X AA292699 CONNECTING ROD BUSHING REMOVING TOOL
X AA295135 MAIN BEARING CAP LIFTING TOOL
NOTE: Hand Tool Kit 473004 is recommended as the best method to obtain the needed hand
tools and torque wrenches.
22 - 7 Form 10056-2
22 - 8 Form 10056-2
Appendices
APPENDICES
APPENDIX A
CALCULATIONS FOR COOLANT PIPING RESTRICTION
1. Calculate coolant velocity (V) in pipe.
Equation 2
3
Flow(ft /min) 1000x Flow(L/sec)
V (FPM) = 2
or V(m/sec)= 2
Pipe inside area(ft ) Pipe inside area(mm )
3 3
Flow (ft /min) =Flow(GPM) * 0.1247(ft /gallon) or
3
m /hr
Flow (L/sec) =Flow
3.6
2
Pipe Area (ft )= {Diameter (inch)} * π /4*0.00694 ft /inch
2 2 2
Pipe Area (mm ) = π /4*{Diameter(mm)}

2 2
Table A-1: Pipe areas for standard pipe
PIPE SIZE ID (inch) ID (mm) AREA (inch2) AREA (mm2) AREA (ft2)
(inch)
1.5 1.61 40.894 2.04 1312.77 0.0142
2 2.067 52.502 3.36 2163.80 0.0233
2.5 2.344 59.538 4.32 2782.61 0.030
3 3.068 77.927 7.39 4767.03 0.0513
4 4.026 102.260 12.73 8208.89 0.0884
5 5.047 128.194 20.01 12900.42 0.139
6 6.065 154.051 28.89 18629.39 0.201
8 7.981 202.717 50.03 32259.06 0.347
2. Determine pressure loss (PL) per 100 ft. or meter of pipe for the velocity and pipe size from
“Figure A-1: Piping Restriction Chart”.
A - 1 Form 10056-2
©5/2017 General Electric Company
Appendices
Figure A-1: Piping Restriction Chart
3. Determine the equivalent pipe length (EPL) for all fittings:
“Figure A-2: Equivalent pipe length of fittings” gives equivalent pipe length in feet or meters
for various pipe fittings. Sum the EPL’s and add them to the total length of straight pipe to
find the total EPL.
4. Calculate the total piping restriction (RP):
Equation 3
PL (psi) PL (mbar)
RP = x EPL(ft) or x EPL(m)
100ft m
5. Calculate the total cooling circuit restriction:
Equation 4
RT = RP + RE + RR
Where
RT = total restriction (psi)
RP = piping restriction (psi)
RE = engine restriction (psi)
RR = radiator/heat exchanger restriction (psi)
A - 2 Form 10056-2
Appendices
From Crane Co. Technical Paper No. 409. Data based on the above chart are satisfactory for most applications.
REPRINTED WITH PERMISSION OF CRANE VALVE GROUP.
Figure A-2: Equivalent pipe length of fittings
A - 3 Form 10056-2
Appendices
CALCULATIONS FOR FUEL PIPING RESTRICTION
1. Determine fuel consumption (Btu/hr or kW) for the highest speed and load condition ex-
pected. This information is available in the Ratings and Standards section or Heat Rejection
section of the Waukesha Tech Data Manual. If working with the Brake Specific Fuel Con-
sumption “BSFC” (Btu/hp-hr) then multiply this figure by the maximum horsepower to get fuel
consumption in Btu/hr.
Equation 1
FuelConsumption(Btu/hr)=BSFC(Btu/hp-hr) xBHP
or
KJ kW
on(kW)=
FuelConsumptio x
kW/hr 3600
2. Determine the flow volume at standard temperature (60° F) and pressure (29.92” HG) with
the following formula:
Equation 2
3 Fuel consumption (Btu/hr)
Standard Flow (ft / min) = ÷ 60
Fuel SLHV (Btu/SCF SLHV)
or
3 Fuel consumption (kW)

StandardFlow (nm /hr)= 3
Fuel SLHV (KJ/nm )
3. Determine the flow volume at the site supply temperature and pressure:
Equation 3
o
14.7 [psia] x (460 [R] +Tsup )
Fsup =Fstd x o
(14.7 [psia] +Psup ) x 520 [R]
or
101.3 kPa x (273+Tsup )
ACTUAL FLOW (m3 /s)=
(101.3 kPa+Psup ) x 273
Table A-2: Pipe areas for schedule 40 pipe
PIPE SIZE ID (inch) ID (mm) AREA (inch2) AREA (mm2) AREA (ft2)
(inch)
1” 1.049 26.644 0.864 557.42 0.00600
1.25” 1.380 35.53 1.496 965.16 0.01039
1.5” 1.610 40.894 2.04 1312.77 0.0142
2” 2.067 52.502 3.36 2163.80 0.0233
2.5” 2.344 59.538 4.32 2782.61 0.030
3” 3.068 77.927 7.39 4767.03 0.0513
4” 4.026 102.260 12.73 8208.89 0.0884
5” 5.047 128.194 20.01 12900.42 0.139
6” 6.065 154.051 28.89 18629.39 0.201
A - 4 Form 10056-2
Appendices
Figure A-3: Restriction Vs. Velocity for pipe diameters up to 6 inches.
Where
3 3
Fstd = Flow at standard conditions (ft /min or Nm /sec)
3 3
Fsupp = Flow at supply conditions (ft /min or Nm /sec)
o o
Tsup = supply temperature ( F or C)
Psup = supply pressure (psig or kPa)
4. Calculate fuel velocity (V) based on the supply flow Fsup for each pipe size used:
Equation 4
3
Fsup (ft /min)
V (FPM)= 2
or
Pipe inside area (ft )
3
Fsup (m /sec) x 1,000,000
V (m/sec)= 2
Pipe inside area (mm )
Pipe Area (ft )=[Diameter (inch)] x π /4 x 0.00694 ft /inch
2 2 2 2
Inside diameter and area for common pipe sizes are given in “Table A-2: Pipe areas for sched-
ule 40 pipe”.
As a general rule gas velocities over 12,000 FPM (60 m/s) are unacceptable because of the
high resulting restriction.
5. Determine pressure loss PL per 10 ft or 1 meter of pipe for each velocity and pipe size from
“Figure A-3: Restriction Vs. Velocity for pipe diameters up to 6 inches.”
A - 5 Form 10056-2
Appendices
6. Determine the equivalent pipe length (EPL) for all fittings of each pipe size.
“Figure A-2: Equivalent pipe length of fittings” gives equivalent pipe length in feet for various
pipe fittings. For each pipe size, sum the EPLs and add them to the total length of straight pipe
of that size to find the total of each pipe size.
7. Calculate the fuel gas corrected specific gravity:
Equation 5
o
(14.7 [psia] +Psup ) x 520 [R]
SGC =SG x o
or
14.7 [psia] x (460 [R] +Tsup )
(101.3 [kPa] +Psup ) x (273)
SGC =SG x
(101.3 x (273+Tsup ))
Where
SGc = specific gravity corrected for pressure and temperature
SG = fuel specific gravity
Natural Gas SG ≈ 0.6
600 Btu Digester Gas SG ≈ 0.9
400 Btu Landfill Gas SG ≈ 1.1
Field Gas SG ≈ 0.6 to 1.0
HD-5 Propane SG ≈ 1.5
Tsup = supply temperature (°F or °C)
Psup = supply pressure (psig or kPa)
8. Calculate the total piping restriction RP for each pipe size:
Equation 6
RP1 = PL1 (" wc /10 ft) x SGC x EPL(ft) or PL1 (mbar/m) x SGC x EPL (m)
9. Calculate the total fuel piping restriction:
Equation 7
RT = RP1 + RP2 + RP3+ RA
Where
RT = total restriction (“ wc or mbar)
RP1,2,3 = piping restriction for various pipe sizes (“ wc or mbar)
RA = accessories (filters, solenoid valves, etc.) restriction (“ wc or mbar)
A - 6 Form 10056-2
Appendices
CALCULATIONS FOR INDUCTION AIR PIPING RESTRICTION
Determine maximum engine inlet airflow at site conditions:
Actual airflow = SCFM x (Tsite + 460 / Tstd + 460)
Determine the equivalent pressure loss using “Figure A-4: Presssure loss vs. airflow”, “Figure
A-5: Presssure loss vs. airflow”, and “Figure A-6: Presssure loss vs. airflow”.
Determine the Equivalent Duct Length (EDL) from “Table A-4: Equivalent Pipe Length Of Fit-
tings In Feet (Meter)” and Table A-5 for each applicable component from step 2.
Calculate the pressure loss (PL) for each applicable components in the air induction system
from step 2 and 3.
PL = PL/L * EDL
Determine the total pressure loss for miscellaneous components such as piping bellows, air
cleaners, etc.
Calculate the total air induction system restriction by adding the PL for each component and
miscellaneous components
Verify that the total restriction does not exceed the maximum permissible restriction, includ-
ing a 30% reserve. If the restriction is too high, redesign the system to reduce the restriction
such as using larger diameter piping, or reducing the amount of flow reducing components
such as elbows.
Table A-3: ANSI schedule 40 pipe dimensions
ANSI PIPE ID (inch) ID (mm) AREA (inch2) AREA (mm2) AREA (ft2)
DIAMETER
1.5” 1.61 40.894 2.04 1312.77 0.0142
2” 2.067 52.502 3.36 2163.80 0.0233
2.5” 2.344 59.538 4.32 2782.61 0.030
3” 3.068 77.927 7.39 4767.03 0.0513
4” 4.026 102.260 12.73 8208.89 0.0884
5” 5.047 128.194 20.01 12900.42 0.139
6” 6.065 154.051 28.89 18629.39 0.201
8” 7.981 202.717 50.03 32259.06 0.347
10” 10.02 254.508 78.85 50847.84 0.5476
12” 12 304.800 113.1 72928.89 0.7854
14” 13.25 336.550 137.9 88913.73 0.9575
16” 15.25 387.350 182.7 117781.42 1.268
18” 16.88 428.752 223.7 144305.20 1.553
20” 18.81 477.774 278.0 179190.38 1.931
22” 21.00 533.400 346.4 223344.71 2.405
24” 22.60 574.040 401.2 258674.71 2.786
A - 7 Form 10056-2
Appendices
Figure A-4: Presssure loss vs. airflow
A - 8 Form 10056-2
Appendices
Table A-4: Equivalent Pipe Length Of Fittings In Feet (Meter)
ROUND PIPE DIAMETER

FITTINGS 3” 4” 5” 6” 8” 10” 12” 14” 16” 18” 20” 24”
d/D=1/4 3.5 4.9 6.3 7.9 11.2 14.5 18.3 20.6 24.3 29.7 31.9 39
Flanged (1) (1.5) (1.9) (2.4) (3.4) (4.4) (5.6) (6.3) (7.4) (9.1) (9.7) (11.9)
d 15˚ D
d/D=1/2 2.4 3.3 4.3 5.4 7.6 9.9 12.5 14.0 16.5 20.3 21.7 27
Flanged (0.7) (1) (1.3) (1.6) (2.3) (3) (3.8) (4.3) (5) (6.2) (6.6) (8.2)
15° Diffuser*
d 15˚ D
EPL based on d/D=3/4 1.1 1.6 2.0 2.5 3.6 4.6 5.8 6.6 7.8 9.5 10.2 13
D flow at
15˚“d” d Flanged (0.3) (0.5) (0.6) (0.8) (1.1) (1.4) (1.8) (2) (2.4) (2.9) (3.1) (4)
d/D=1/4 1.3 1.8 2.4 3.1 4.3 5.5 7.0 7.7 8.8 10.7 11.9 14.4
Flanged (0.4) (0.5) (0.7) (0.9) (1.3) (1.7) (2.1) (2.3) (2.7) (3.3) (3.6) (4.4)
D 15˚ d
d/D=1/2 1.0 1.4 1.9 2.5 3.5 4.4 5.6 6.2 7.0 8.6 9.6 11.5
Flanged (0.3) (0.4) (0.6) (0.8) (1.1) (1.3) (1.7) (1.9) (2.1) (2.6) (2.9) (3.5)
15° Diffuser*
EPL based on d/D=3/4 0.6 0.8 1.1 1.4 2.0 2.5 3.3 3.6 4.1 5.0 5.6 6.7
flow at “D” Flanged (0.2) (0.2) (0.3) (0.4) (0.6) (0.8) (1) (1.1) (1.2) (1.5) (1.7) (2)
(Calculated using NTIS Handbook Of Hydraulic Assistance, Form AEC-TR-6630)
A - 9 Form 10056-2
Appendices
ROUND PIPE DIAMETER

FITTINGS 3” 4” 5” 6” 8” 10” 12” 14” 16” 18” 20” 24”
d
90˚
34.7 43.7 49.1 58.1
Flanged — — — — — — — —
d
D = 1.4 d
(10.6) (13.3) (15) (17.7)
dY-Connection
15˚ D
based on flow at “d”
D 15˚ d
Bell 0.7 1.0 1.3 1.6 2.3 2.9 3.5 4.0 4.7 5.3 6.1 7.6
mouth
inlet (0.2) (0.3) (0.4) (0.5) (0.7) (0.9) (1.1) (1.2) (1.4) (1.6) (1.9) (2.3)
15° Diffuser*
EPL based on
flow at “D”
Square 9.5 13.0 16.0 23.0 29.0 35.0 40.0 47.0 53.0 61.0 76.0
mouth 6.7 (2)
inlet (2.9) (4) (4.9) (7) (8.8) (10.7) (12.2) (14.3) (16.2) (18.6) (23)
* Minimum restriction is with a 6° diffuser. EPL with a 6° diffuser is approximately 1/2 the EPL of a 15° diffuser.
A - 10 Form 10056-2
Appendices
EXHAUST PIPING THERMAL GROWTH CALCULATION
NOTES:
1. Allow for thermal expansion of the exhaust pipe beyond the engine exhaust flex connec-
tion. The Waukesha exhaust flex (when supplied) will accommodate engine thermal expan-
sion but cannot tolerate movement imposed by external thermal growth. Insulated pipes will
run hotter and consequently expand more.
COEFFICIENT OF EXPANSION Ce
-6 in -5 mm
Steel 6.5 x10 o
(1.17 x 10 o
)
in F mm C
-6 in -5 mm
Stainless Steel 9.9 x 10 o
(1.7 x 10 o
)
in F mm C
Thermal expansion can be calculated with the following formula:
Equation 1
L e = Ce *L *(Texh -Tstnd )/100
WHERE:
L e = Length of pipe expansion (inches or meters)
o o
Ce = Coefficient of expansion for the material (in/in/ F or mm/mm C)
L = Piping length at standard conditions (inches or meters))
o o
Texh = Exhaust Temperature ( F or C)
o o
Tstnd = Standard Temperature ( F or C)
A - 11 Form 10056-2
Appendices
EXHAUST PIPING RESTRICTION CALCULATION
1. Determine exhaust volume flow rate (ft3/min or m3/hr) for the specific engine model from
the heat rejection sections in the Technical Data Manual. If exhaust flow is given in terms of
mass flow, a conversion is available in the notes section of the heat balance.
2. Calculate exhaust velocity (V) for each pipe size used:
Equation 2
3
Flow (ft /min)
V (FPM) = 2
Pipe inside area (ft )
or
3
Flow (m /hr)
V (m/sec) = 277.8 x 2
Pipe inside area (mm )
2 2 2 2
Pipe Area (ft ) =[Diameter (inch)] x �/ 4 x 0.00694 ft /inch
Inside diameter and area for common pipe sizes are given in “Table A-6: ANSI schedule 40
pipe dimensions”.
Table A-6: ANSI schedule 40 pipe dimensions
ANSI PIPE ID (inch) ID (mm) AREA (inch2) AREA (mm2) AREA (ft2)
DIAMETER
1.5” 1.61 40.894 2.04 1312.77 0.0142
2” 2.067 52.502 3.36 2163.80 0.0233
2.5” 2.344 59.538 4.32 2782.61 0.030
3” 3.068 77.927 7.39 4767.03 0.0513
4” 4.026 102.260 12.73 8208.89 0.0884
5” 5.047 128.194 20.01 12900.42 0.139
6” 6.065 154.051 28.89 18629.39 0.201
8” 7.981 202.717 50.03 32259.06 0.347
10” 10.02 254.508 78.85 50847.84 0.5476
12” 12 304.800 113.1 72928.89 0.7854
14” 13.25 336.550 137.9 88913.73 0.9575
16” 15.25 387.350 182.7 117781.42 1.268
18” 16.88 428.752 223.7 144305.20 1.553
20” 18.81 477.774 278.0 179190.38 1.931
22” 21.00 533.400 346.4 223344.71 2.405
24” 22.60 574.040 401.2 258674.71 2.786
3. Determine pressure loss (PL) per 10 ft (3m) of pipe for each velocity and pipe size from
“Figure A-8: Restriction vs. velocity for pipe diameter up to 8” (high speed)”, and “Figure A-9:
Restriction vs. velocity for pipe diameter up to 24””.
4. Determine the equivalent pipe length (EPL) for all fittings of each pipe size:
“Table A-7: Equivalent Pipe Length Of Fittings In Feet (Meter)” give equivalent pipe length in
feet for various pipe fittings. For each pipe size sum the EPLs and add them to the total length
of straight pipe of that size to find the total of each pipe size. Exit loss does not need to be
considered in these calculations.
A - 12 Form 10056-2
Appendices
Figure A-7: Restriction vs. velocity for pipe diameter up to 8”
Figure A-8: Restriction vs. velocity for pipe diameter up to 8” (high speed)
A - 13 Form 10056-2
Appendices
Figure A-9: Restriction vs. velocity for pipe diameter up to 24”

(Calculated using NTIS Handbook Of Hydraulic Assistance, Form AEC-TR-6630)
ROUND PIPE DIAMETER

FITTINGS 3” 4” 5” 6” 8” 10” 12” 14” 16” 18” 20” 24”
d/D=1/4 3.5 4.9 6.3 7.9 11.2 14.5 18.3 20.6 24.3 29.7 31.9 39
Flanged (1) (1.5) (1.9) (2.4) (3.4) (4.4) (5.6) (6.3) (7.4) (9.1) (9.7) (11.9)
d 15˚ D
d/D=1/2 2.4 3.3 4.3 5.4 7.6 9.9 12.5 14.0 16.5 20.3 21.7 27
Flanged (0.7) (1) (1.3) (1.6) (2.3) (3) (3.8) (4.3) (5) (6.2) (6.6) (8.2)
15° Diffuser*
EPL based on d/D=3/4 1.1 1.6 2.0 2.5 3.6 4.6 5.8 6.6 7.8 9.5 10.2 13
D flow at
15˚“d” d Flanged (0.3) (0.5) (0.6) (0.8) (1.1) (1.4) (1.8) (2) (2.4) (2.9) (3.1) (4)
d/D=1/4 13.2 18.7 24.3 30.1 42.7 56 70 79 93 114 122 151
Flanged (4) (5.7) (7.4) (9.2) (13) (17.1) (21.3) (24) (28) (35) (37) (46)
d D d/D=1/2 8.5 12.1 15.7 19.5 27.6 35.9 45.4 51 60 74 79 97
Flanged (2.6) (3.7) (4.8) (5.9) (8.5) (11) (14) (15.5) (18) (23) (24) (30)
Sudden expansion d/D=3/4 2.9 4.2 5.4 6.7 9.5 12.3 15.5 17.6 20.8 25.4 27.2 34
based on flow at “d” Flanged (0.9) (1.3) (1.6) (2.0) (2.9) (3.7) (4.7) (5.4) (6.3) (7.7) (8.3) (10.4)
d
90˚
34.7 43.7 49.1 58.1
Flanged — — — — — — — —
d
D = 1.4 d
(10.6) (13.3) (15) (17.7)
Y-Connection
based on flow at “d”
A - 14 Form 10056-2
Appendices
5. Calculate the exhaust gas density correction:
Equation 3
Dc = Lc * 520 / (460 + Texh) or Dc= Lc * 273 / (273 + Texh °C)
WHERE:
Dc = density correction
Lc = lambda correction,
for Lambda = 0.97 to 1.06, Lc = 0.95 (rich burn)
for Lambda = 1.53 to 2.0, Lc = 0.97 (lean burn)
Texh = exhaust temperature ° F (° C)
6. Calculate the total piping restriction RP for each pipe size:
Equation 4
PL1(psi) P (mbar)
RP1= xDC xEPL(ft) or RP1= L1 xDC xEPL(m)
10 ft. m
7. Calculate the total exhaust system restriction:
Equation 5
RT = RP1 + RP2 + RP3 + RS + RA
WHERE:
RT= total restriction (psi or mbar)
RP1,2,3 = piping restriction for various pipe sizes (psi or mbar)
RS = silencer restriction (psi or mbar)
RA = accessories (catalyst, boiler, etc.) restriction (psi or mbar)
A - 15 Form 10056-2
Appendices
APPENDIX B
SOIL BEARING LOAD
The necessary soil bearing load (S.B.L.) can be determined with the following formula:
(2.5)(M +F)
S.B.L.=
(W)(L)
2.5 = Safety constant
M = Weight of engine
W = Width of inertia block or pad
L = Length of inertia block or pad
F = Weight of engine and equipment (see Note 1)
The weight of the inertia block or pad (F) must first be determined.
The weight is determined by the following formula:
Weight of inertia block or pad = W x L x H x density of the concrete
NOTE1: The above example only takes into account the weight and size of the engine. An actu-
al installation would have to include the weight of the engine and the driven equipment, and
the weight of a common mounting skid large enough to support both the engine and driven
equipment.
Example: F3524GSI
F = 4.5 x 9.3 x 3.75 x 135 lb/ft3 F=1.37 m x 2.84 m x 1.13 m x 2162kg/mr3
F = 21187 lb. F = 9505 kg.
Now that “F” is known, the required soil bearing load can be determined using the given for-
mula.
(2.5)(M +F)
S.B.L.=
(W)(L)
(2.5)(15,000 + 21,187)
S.B.L.=
(4.5)(9.3)
Required S.B.L. = 2161.7lbs/sq.ft.
NOTE 1: The above example only takes into account the weight and size of the engine. An ac-
tual installation would have to include the weight of the engine and the driven equipment, and
the weight of a common mounting skid large enough to support both the engine and driven
equipment.
A - 16 Form 10056-2
Appendices
APPENDIX C
SHIMMING INFORMATION
Waukesha recommends using die cut stainless steel shims for final adjustment of base de-
flection and alignment when a “Machined skid” or “Sole plates leveled in grout” mounting sur-
face is used. Die cut stainless steel shims provide and accurate mounting and good corrosion
resistance. Shims should be available in thicknesses of approximately:
0.05 mm (0.002”)
0.125 mm (0.005”)
0.250 mm (0.010”)
0.750 mm (0.030”)
Die cut shims available from Waukesha are listed in “Table A-8: Die cut shims available from
Waukesha”.
Table A-8: Die cut shims available from Waukesha
PART NUMBER LENGTH WIDTH THICKNESS BOLT SLOT WIDTH

P310062 127 mm (5”) 127 mm (5”) 4.76 mm (0.1875”) 41 mm (1.625”)
P310063 127 mm (5”) 127 mm (5”) 1.52 mm (0.060”) 41 mm (1.625”)
P310064 127 mm (5”) 127 mm (5”) 0.635 mm (0.025”) 41 mm (1.625”)
P310065 127 mm (5”) 127 mm (5”) 0.254 mm (0.010”) 41 mm (1.625”)
P310066 127 mm (5”) 127 mm (5”) 0.076 mm (0.003”) 41 mm (1.625”)
Width
Length
Bolt slot width
Figure A-10: Shim schematic
Shim packs should use thick shims on the outside sandwiching the thin shims on the inside.
Adding or removing shims is accomplished by removing the complete shim pack and adding
or removing shims as required. (See “Figure A-11: Stacking Shims”)
A - 17 Form 10056-2
Appendices
Figure A-11: Stacking Shims
GROUT INFORMATION
An oil resistant and heat resistant pourable epoxy grout is required for grouting. Grouting
must be sized and applied per the grouting manufacturers recommendations. The engine
cannot be secured with the mounting bolts until the grout has had ample time to cure.
MOUNTING BOLT AND TORQUING INFORMATION

Grade 5 or 8 mounting bolts 32 mm (1-1/4”) should be utilized for engine mounting. The min-
imum bolt length allowed is 215 mm (8.25”). Spacers must be used if necessary to meet the
bolt stretch length requirement. Hardened washers are required under the nut (see”Figure
A-12: Hardened Washer”). Torque should be based on grout strength and bolt torque limits.
Waukesha recommends a minimum of 450 ft-lb.
120 mm 215 mm
(8.25”)
Minimum bolt
length for
proper stretch
Hardened washer
Figure A-12: Hardened Washer
After the engine has acceptable crankshaft web deflection and alignment and the grout has
cured or shims have been installed, the jacking bolts can be replaced with mounting bolts.
Alignment and web deflection must be measured again after the mounting bolts are properly
torqued to verify the measurements remain within acceptable limits.
Mounting bolts must be torqued in three increments (1/3 torque, 2/3 torque, and full torque)
in the pattern indicated in “Figure A-13: Belt Tightening Pattern”.
Flywheel
Coupling
Figure A-13: Belt Tightening Pattern
A - 18 Form 10056-2
Appendices
When jacking bolt positions will be used for mounting bolts a special provision must be
made to block the mounting hole during leveling. This can be accomplished by threading the
mounting hole in the skid and inserting a blocking bolt with a locking nut. (See “Figure A-14:
Jacking Using Mounting Bolt”.)
Jacking bolt against Mounting bolt

blocking bolt installed
Figure A-14: Jacking Using Mounting Bolt
SIDE JACKING BOLT INFORMATION

Side jacking bolts must not push between end mounting
bolts or crankcase. Rail damage will result.
Horizontal jacking bolts should be installed for positioning the engine horizontally and axially.
The jacking bolts must push against the area indicated in “Figure A-15: Horizontal Jacking”.
Pushing on a different area of the mounting rail will result in damage to this hollow rail.
Engine
Rail is hollow between

mounting bolts
Figure A-15: Horizontal Jacking
A - 19 Form 10056-2
Appendices
Side jacking devices should be of sufficient size and strength to slide the engine where nec-
essary. Jacking devices designed as shown in Figure 10-7 are suitable for moving the engine.
Horizontal jacking design

75 mm (3”)
38 mm (1.5”)
50 mm (2”)
Weld full length -

22 mm (7/8”) Jacking bolt diameter
4 sides
Side jacking device
Figure A-16: Jacking Devices
SKID DESIGN INFORMATION

Proper skid design varies greatly with the type of driven machine, location, skid mounting
requirements etc. For this reason, Waukesha cannot make specific skid design recommenda-
tions. However, the following general guidelines are provided to assist packagers in designing
a skid to fulfill their needs.
The Waukesha 275GL+ engines have oil sumps which are underslung below the mounting
surface of the engine. A flush mounting surface is not possible therefore, and the skid must
be designed to accommodate this. To get good support under the engine, the mounting rail
should be positioned directly over the web of the skid beam. A C-channel beam or I-beam can
be used for the beam. For wide flanged I-beams, it will be necessary to cut off the inner flange
at the top of the beam to allow the engine to mount directly above the web. (See “Figure A-17:
Engine Mounted Directly Above Web”)
I-BEAMS WITH INSIDE

FLANGES REMOVED
GUSSETS WELDED IN BEAM

AND UNDER OIL SUMP
Figure A-17: Engine Mounted Directly Above Web
A - 20 Form 10056-2
Appendices
Waukesha strongly recommends the packager analyze skid design to determine that the
structural integrity of the skid does not incur harmful natural frequencies for constant speed
applications and throughout the speed range for variable speed applications.
For more information on skid design and preparation for mounting reference Chapter 2.
Side to side support in the skid must be provided by gussets between the main beams and
in the channel or by gussets welded to a wider outside beam. There should be gussets near
each mounting bolt position, but sufficient space must be provided for tools to reach the
mounting bolts. (See “Figure A-18: Additional Gussets Added”.)
GUSSETS WELDED IN BEAM

AND UNDER OIL SUMP
GUSSETS WELDED TO
ADDITIONAL SKID
Figure A-18: Additional Gussets Added
Torque reactions between the engine and driven machine are transferred by the skid. The
skid design must have sufficient torsional rigidity to transmit the torque reactions. (See “Fig-
ure A-19: Torsional Rigidity in Skid”.)
Figure A-19: Torsional Rigidity in Skid
A - 21 Form 10056-2
Appendices
MAXIMUM UNBALANCED FORCES AND MOMENTS FOR 275GL+ ENGINES
The tabulated data are based on the possibility that engine components (pistons, rods, crank-
shaft, etc.) may be machined to maximum and/or minimum permissible weight limits, and
that assembly may occur in such a way that maximum unbalanced forces or couples may
be produced. Note that these are maximum theoretical values and that standard assembly
procedures will rarely produce such extreme conditions. Normally expected values would
not exceed 50% of the calculated values shown. Note also that an assembly that produces
a maximum unbalanced force will produce a minimum unbalanced couple and vice versa.
Table A-9: Maximum Unbalanced Inertia Force – Lb (N)
900 RPM 1000 RPM
HORIZONTAL
HORIZONTAL
VERTICAL
VERTICAL
AXIAL
AXIAL
ENGINE
12V275GL+ 917 (4079) 1550 (6894) 0 1132 (5035) 1913 (8509) 0

16V275GL+ 1277 (5680) 2027 (9016) 0 1577 (7015) 2503 (11133) 0
Table A-10: Maximum Unbalanced Inertia Force – Lb-Ft (N m)
900 RPM 1000 RPM

HORIZONTAL
HORIZONTAL
VERTICAL
VERTICAL
AXIAL
AXIAL
ENGINE
12V275GL+ 2620 (3552) 4154 (5632) 0 3235 (4386) 5128 (6952) 0

16V275GL+ 4684 (6350) 7128 (9664) 0 5783 (7840) 8800 (11931) 0
Unbalanced forces or moments at any other speed, N, may be calculated as:
ForceN (MomentN) = Force1000 (Moment1000) x (N/1000)2
A - 22 Form 10056-2
Appendices
APPENDIX D
CUSTOMER INTERFACE CONNECTIONS
Table A-11: Customer Interface Harness Loose Wire Identification
SIGNAL SIGNAL WIRE FROM WIRE SOCKET

CIRCUIT # WIRE LABEL DESCRIPTION
NAME TYPE COLOR PIN SIZE SIZE
1110 GOVAUXGND Used for compatible load sharing input. Aux. Input Ground Black 29 20 20-24
Used for power generation applications Ground
only.
1111 LOGIC GND Used as the negative connection point Customer Ground* Black 4 16 16-20
for 4 – 20 mA signals. Reference
Ground
1137 GOVAUXSHD Used as shield for compatible load Harness 44 20 20-24
sharing input. Shield Shield
Silver
1145 RS 485SHD Customer shield ground for RS485 twist- RS-485 Shield – Silver 13 20 20-24
ed shielded pair wire.
1305 RS 485A- RS485 MODBUS RS485 A- Comms Green 2 20 20-24
1306 RS485B+ RS485 MODBUS RS485 B+ Comms Yellow 23 20 20-24
1600 PROG OP1 A 4 – 20 mA output from the ECU that Average RPM 4 – 20 mA Dark 9 20 20-24
represents an engine operating param- O/P+* Green
eter.
1601 PROG OP2 A 4 – 20 mA output from the ECU that Oil Pressure 4 – 20 mA Dark 21 20 20-24
represents an engine operating param- O/P+* Green
eter.
1602 PROG OP3 A 4 – 20 mA output from the ECU that Coolant Tem- 4 – 20 mA Dark 3 20 20-24
represents an engine operating param- perature O/P+* Orange
eter.
1603 PROG OP4 A 4 – 20 mA output from the ECU that Intake Mani- 4 – 20 mA Dark Green 11 20
represents an engine operating param- fold Absolute O/P+*
eter. Pressure
1604 ENG ALM A digital output from the ECU that Engine Alarm Digital HSD White 14 20 20-24
indicates the ECU is in either alarm or O/P
shutdown mode.
1606 ESD A digital input to the ECU from the local performs an Emergency Digital Yellow 15 20
control that must be high for the engine emergency Engine I/P
to run. If ESD goes low, the engine shutdown. Shutdown
1607 ENG ESD A digital output from the ECU that Emergency Digital HSD White 42 20 20-24
indicates the ECU is in shutdown mode. Shutdown O/P
Output is NOT latched.
1608 GOVREMSEL Digital input to the ECU that switches be- Remote Digital I/P Yellow 22 20 20-24
tween either remote speed setting input Speed Select
or high/low idle input. Must be used to
enable remote speed input. Not typically
used for power generation.
1609 START Momentary digital input to the ECU that Start Engine Digital I/P Yellow 24 20 20-24
is used to begin the engine start cycle.
1611 RUN/STOP A digital input to the ECU from the local High = OK to Digital I/P Yellow 25 20 20-24
control that must be high for the engine Run
to run. If RUN/STOP goes low, the engine Low = Normal
performs a normal shutdown. Shutdown
A - 23 Form 10056-2
Appendices
1613 GOVREMSP– Input to the ECU that is used for remote Remote 4 – 20 mA Light 27 20 20-24
speed setting using 4 – 20 mA signal. Speed Setting I/P- open Blue
4 – 20 mA circuit for
Signal – 0.875 – 4.0
V operation
1614 GOVREMSP+ Input to the ECU that is used for remote Remote 4 – 20 mA Light 39 20 20-24
speed setting using 4 – 20 mA signal. Speed Setting I/P+ open Green
4 – 20 mA circuit for
Signal + 0.875 – 4.0
V operation
1615 GOVAUXSIG Used for compatible load sharing input. Aux. Input ±2.5 V I/P Red 28 20 20-24
Used for power generation applications Signal
only.
1616 GOVHL IDL Digital input to the ECU that changes Rated Speed/ Digital I/P Yellow 37 20 20-24
the operating rpm of the engine. Used Idle Speed
for power generation applications only. Select
When using GOVREMSEL, the input sta-
tus of GOVHL IDL must be checked. See
information on setting this input to a
“safe mode” in Table 5.00-5.
1617 KNK ALM A digital output from the ECU that indi- Engine Digital HSD White 47 20 20-24
cates the engine is knocking and will shut Knocking O/P
down immediately unless some action is
taken to bring the engine out of knock.
1618 GOV 40 Used for remote speed voltage input set- Remote 0.875 – 4.0 Tan 40 20 20-24
ting. Fit “jumper” between GOV 40 and Speed Setting V I/P+ Fit
GOV 41 to use 4 – 20 mA remote speed Mode Select “jumper”
input. between 40
and 41 for
4 – 20 mA
operation
1619 GOV 41 Used for remote speed voltage input set- Remote 0.875 – 4.0 Tan 41 20 20-24
ting. Fit “jumper” between GOV 40 and Speed Setting V I/PFit
GOV 41 to use 4 – 20 mA remote speed Mode Select “jumper”
input. between 40
and 41 for
4 – 20 mA
operation
1620 GOVALTSYN Alternate governor dynamics. Used for Alternate Digital I/P Yellow 10 20 20-24
power generation applications only to Governor
obtain a smooth idle for fast paralleling Dynamics
to the grid.
1621 AVL LOAD% A 4 – 20 mA output from the ECU that Available 4 – 20 mA Dark 33 20 20-24
represents the available percentage of Load + O/P+ Green
rated torque the engine is capable of
producing.
1622 WKI– A 4 – 20 mA analog input to the ECU that Fuel Quality 4–20 mA Light 31 20 20-24
represents the real-time WKI rating of the (WKI) Signal - I/ P Blue
fuel. Use not necessary for most applica-
tions.
1623 WKI+ A 4 – 20 mA analog input to the ECU that Fuel Quality 4 – 20 mA Light 30 20 20-24
represents the real-time WKI rating of the (WKI) Signal + I/P+ Green
fuel. Use not necessary for most applica-
tions.
A - 24 Form 10056-2
Appendices
1624 ACT LOAD% A 4 – 20 mA output from the ECU that Engine Load + 4 – 20 mA Dark 32 20 20-24
represents the actual percentage of rat- O/P+* Green
ed torque the engine is currently produc-
ing.
1627 USER DIP1 A digital input to the ECU that can be User Defined Digital I/P Yellow 16 20 20-24
used to indicate a customer alarm. Digital Input 1
1631 LRG LOAD Digital input to the ECU that “kicks” the Load Coming Digital I/P Yellow 20 20 20-24
governor to help the engine accept large
load additions. Mainly useful for stand-
alone power generation applications.
Use LOGIC GND “Customer Reference Ground” as the negative connection point for these 4 – 20 mA signals. Self-regulating solid
state logic can become high impedance during an overcurrent event. The overcurrent logic is rated for 1.1 A.
Table A-12: Required Connection Descriptions
DESCRIPTION WIRE LABEL PHYSICAL CONNECTION

Start Engine START Momentary (>1/2 second and <60 seconds) digital signal input to ECU to begin the starting process,
must momentarily be connected to +24 VDC nominal (8.6 – 36 volts) for the ECU to start the engine.
Normal Shutdown RUN/STOP A digital signal input to the ECU that must be connected to +24 VDC nominal (8.6 – 36 volts) for the
(Run / Stop) engine to run. If RUN/STOP goes open circuit, the engine performs a normal shutdown.
Emergency Shutdown ESD A digital signal input to the ECU that must be connected to +24 VDC nominal (8.6 – 36 volts) for the
engine to run. If ESD goes open circuit, the engine performs an emergency shutdown. NOTE: Do not use
this input for routine stopping of the engine. After an emergency shutdown and rpm is zero, ESD input
should be raised to high to reset the ESM. If ESD input remains low, ESM reset will be delayed and engine
may not start for up to 1 minute.
Rated Speed/Idle GOVHL IDL Digital signal input to ECU must be connected to +24 VDC nominal (8.6 – 36 volts) for rated speed, idle
Speed (Fixed Speed speed and remote speed setting enable (GOVREMSEL) must be open circuit. When using the Remote
Application) Speed/Load Setting, GOVHL IDL should be set to a safe mode. “Safe mode” means that if the wire that
enables remote rpm operation (GOVREMSEL) fails, the speed setpoint will default to the GOVHL IDL idle
value. Consider all process/driven equipment requirements when programming idle requirements.
Remote Speed/Load GOVREMSPGOV- Either 4 – 20 milliamp or 0.875 – 4.0 volt input to ECU. Inputs below 2 milliamps (0.45 volts) and above 22
Setting (Variable REMSP+ milliamps (4.3 volts) are invalid. Input type can be changed by fitting a jumper across pins 40 and 41 to
Speed Application) enable the 4 – 20 milliamp option. GOVREMSP- and GOVREMSP+ are used for the 4 – 20 milliamp input.
For voltage, input pin 40 is the + voltage input and pin 41 is the - voltage input. See Figure 5.00-5 for an
example showing the user 4 – 20 mA analog inputs.
Remote Speed Setting GOVREMSEL Digital signal input to ECU must be connected to +24 VDC nominal (8.6 – 36 volts) to enable remote
Enable (Variable speed/load setting. NOTE: When programming Rated Speed/Idle Speed, GOVHL IDL must be set to safe
Speed Application) mode.
A - 25 Form 10056-2
Appendices
Table A-13: Optional Connection Descriptions – Customer Interface Harness
DESCRIPTION WIRE LABEL PHYSICAL CONNECTION

Current Operating ACT LOAD% A 4 – 20 milliamp output from the ECU that represents the current engine torque output on a 0 – 125% of
Torque rated engine torque scale.
Desired Operating AVL LOAD% A 4 – 20 milliamp output from the ECU that represents the desired operating torque of the engine. Always
Torque indicates 100% of rated engine torque unless there is an engine fault such as uncontrollable knock.
Engine Alarm ENG ALM Digital signal output from ECU goes from open circuit to +24 VDC nominal (battery voltage – 1 volt) when
ECU detects engine problem. Output remains +24 VDC nominal while an alarm is active. As soon as alarm
condition is resolved, digital signal returns to open circuit.
Engine OK/Emergency ENG ESD Digital signal output from ECU goes from open circuit to +24 VDC nominal (battery voltage – 1 volt) when
Shutdown ECU performs an emergency shutdown.
Synchronizer Mode/ GOVALTSYN Digital signal input to the ECU when +24 VDC nominal (8.6 – 36 volts) allows synchronizer mode/alternate
Alternate Governor governor dynamics. User can program a small speed offset to aid in synchronization.
Dynamics
Aux. Speed Input GOVAUXSIG A ±2.5 volt input to the ECU used for compatibility to Woodward™ generator control products (or other
GOVAUXGND comparable control products).
GOVAUXSHD
Uncontrolled Knock KNK ALM Digital signal output from ECU goes from open circuit to +24 VDC nominal (battery voltage – 1 volt) when
ECU cannot control engine knock. Allows customer knock control strategy such as load reduction instead
of the ECU shutting down the engine.
Load Coming LRG LOAD Digital signal input to the ECU when +24 VDC nominal (8.6 – 36 volts) is applied, signals the ECU that a
large load will be applied to the engine. This input can be used to aid in engine load acceptance. User can
program delay time from receipt of digital signal to action by the ECU.
Four Analog Outputs PROG OP 1 4 – 20 milliamp analog outputs from the ECU that can be used to read engine parameters such as oil
through PROG pressure, coolant outlet temperature, engine speed and intake manifold pressure.
OP 4
MODBUS RS 485A– The ECU is a MODBUS RTU slave operating from 1200 to 19,200 baud on “two-wire” RS-485 hardware.
RS 485B+ Current operating values such as oil pressure and fault information are available.
RS485SHD
Four Digital Inputs USER DIP 1 Four digital signal inputs to the ECU when +24 VDC nominal (8.6 – 36 volts) is applied allows user to wire
through USER alarm and/or shutdown digital outputs of the local control into ESM. The purpose of these four digital
DIP 4 inputs to the ECU is to aid in troubleshooting problems with the driven equipment.
WKI Value WKI+ A 4 – 20 milliamp input to the ECU that allows the customer to change the input fuel quality (WKI) in real
WKI- time (4 mA = 20 WKI; 20 mA = 135 WKI).
A - 26 Form 10056-2
Appendices
LOCAL CONTROL CONNECTIONS
Table A-14: Local Control Option Harness Loose Wire Identification
CIRCUIT # WIRE LABEL SIGNAL NAME SIGNAL TYPE WIRE COLOR WIRE SIZE SOCKET SIZE
1020 +24VFOR U User Power +24 VDC nominal (5 amps Red 18 16
maximum)
1120 GND FOR U User Ground Ground Black 18 16
1679 PREL CTRL Customer Prelube Control +24 VDC digital I/P Brown 18 16
1426 GOV SD+ Switch, Governor Shutdown input Purple 18 16
Actuator, G
1010 GOVSD+24 Shutdown Switch Power +24 VDC nominal Red 18 16
1436 WASTEGSD+ Switch, Wastegate Shutdown Input Purple 20 16
Actuator, G
A - 27 Form 10056-2
Appendices
APPENDIX E
SCOPE OF SUPPLY
Table A-16: Scope of Supply
Customer Mounted/Shipped
Qty. Standard Optional
supplied Loose
STARTING SYSTEM
Air/gas starters (high pressure) 1 (12V)
 Mounted
2 (16V)
Air/gas starters (high pressure, two starters) 2 (12V) 9209
Air/gas starters (low pressure) 2 (12V) 9209A
Mounted
2 (16V) 9209B
Inlet flexible connection 1 (12V)
1200A Shipped Loose
2 (16V)
2 (16V)
Outlet flexible connection 1 (12V)

2 (16V)
Solenoid valve 1  Mounted
Solenoid valve wiring 1  Mounted
External piping to each starter 1 (12V)

2 (16V)
Air/gas supply to each starter 1 (12V)

2 (16V)
COOLING SYSTEM
AUXILIARY CIRCUIT
Water pump 1  Mounted
Thermostat 1  Mounted
Thermostat bypass 1  Mounted
Radiator / heat exchanger 1 
External piping 
Inlet flexible connection 1 1200A Shipped Loose
Outlet flexible connection 1 1200A Shipped Loose
Expansion tank 1 
Circuit vent lines to expansion tank 3 
Static pressure line to pump inlet 1 
Radiator fan drive 
JACKET CIRCUIT
Water pump 1  Mounted
Thermostat 1  Mounted
Thermostat bypass 1  Mounted
Radiator 1 
External piping 
Inlet flexible connection 1 1200A Shipped Loose
Outlet flexible connection 1 1200A Shipped Loose
Expansion tank 1 
Circuit vent lines to expansion tank 2 
Static pressure line to pump inlet 1 
Scope of supply is meant only as a guide. Always refer to the latest version of the Waukesha gas engine price book for available equipment.
A - 28 Form 10056-2
Appendices
supplied Loose
Jacket water circuit heater 1 
Radiator fan drive 
FUEL SYSTEM
850 - 2300 BTU/scf ( 33.4 – 90.5 MJ/nm3) fuel system
1  Mounted
range
700 - 850 BTU/scf ( 27.5 – 33.4 MJ/nm3) fuel system range 1 2060 Mounted
600 - 750 BTU/scf ( 23.6 – 29.5 MJ/nm3) fuel system range 1 2060A Mounted
Carburetor 1  Mounted
Main gas regulator 1  Mounted
Prechamber gas regulator 1  Mounted
Main fuel valve 1  Mounted
Pilot fuel valve 1  Mounted
Fuel valve wiring and open/close ESM control 1  Mounted
Fuel valve vent piping (if required) 
Particulate fuel filter 1 
Coalescing fuel filter 1 
Additional fuel treatment (if required) 
Fuel inlet flexible connection 1 1200A Shipped Loose
LUBRICATION SYSTEM
Oil pump 1  Mounted
Oil filter (set of spin-on filters) 1  Mounted
Oil cooler and thermostats 1  Mounted
Centrifugal oil filter 1  Mounted
Oil pressure regulator 1  Mounted
Prelube pump 1  Mounted
Prelube pump oil piping 1  Mounted
Prelube pump air/gas motor 1 5040 Mounted
Prelube pump solenoid valve, wiring and control by ESM 1  Mounted
Prelube pump air/gas supply 1 
Prelube pump air/gas piping 1 
Oil level regulator 1 
Oil sump heater (if required) 1 
EXHAUST SYSTEM
Exhaust engine flexible connections 7200A (12V)
2 Shipped Loose
7200B (16V)
Exhaust Wye transition (includes flexible connections) 7201C (12V)
1 Shipped Loose
7201B (16V)
Exhaust silencer 1 or 2 
Exhaust piping, explosion relief valves, aftertreatment (as

required)
Exhaust piping flexible connections 
Exhaust system support 
Exhaust Wye support 
CRANKCASE VENTILATION SYSTEM
Crankcase blower and motor (230 VAC) 1  Mounted
Crankcase blower and motor (115 VAC) 1 1135E Mounted
A - 29 Form 10056-2
Appendices
supplied Loose
Crankcase blower restriction valve 1  Mounted
Crankcase blower check valve 1  Mounted
Crankcase ventilation system external piping 
Crankcase ventilation system external filter / demister 
Crankcase blower motor starter 1  Shipped Loose
Crankcase blower motor/starter wiring 
AIR INDUCTION SYSTEM
Air filters - standard type with cover 2 2300A Shipped Loose
Air filters - heavy duty option with inertia separators 2 2300B Shipped Loose
Rain cover/protection (if installed outdoors) 
Air filter piping and mating hardware 2 
Air filter flexible connection at turbo inlet 2399 (12V)
2 Shipped Loose
2400 (16V)
Air filter and piping support 
Air heaters for inlet air temperatures less than 40F (4.4C) 
FLYWHEEL
Flywheel, machined for Thomas plate type coupling 1  Mounted
Flywheel, intended for power generation applications 1167A Mounted
Coupling 1 
Driven Equipment 1 
POWER TAKE-OFF
Front Stub Shaft, 200bhp maximum 1 8000B Mounted
Partial Front Stub Shaft 1 8010 Mounted
ENGINE MOUNTING
Shims for engine alignment 
Engine jacking bolts  Mounted
Engine mounting bolts 
Skid/baseplate, for engine and driven equipment 
ENGINE CONTROL
ESM 1  Mounted
25’ (7.6m) Harnesses for ESM customer interface, local
control, exhaust thermocouples, main bearing thermo- 4  Shipped Loose
couples,
50’ (15m) harnesses for items above 4 6650W Shipped Loose
100’ (30m) harnesses for items above 4 6650X Shipped Loose
HMI 1  Mounted
HMI, for off-engine mounting, with 25ft (7.6m) HMI harness 6661 Shipped Loose
HMI, for off-engine mounting, with 50ft (15m) HMI harness 6661A Shipped Loose
HMI, for off-engine mounting, with 100ft (30m) HMI
6661B Shipped Loose
harness
Cylinder exhaust thermocouples & wiring to bulkhead
 Mounted
connection
Cylinder exhaust thermocouple monitoring 
A - 30 Form 10056-2
Appendices
supplied Loose
Main bearing thermocouples & wiring to bulkhead con-
 Mounted
nection
Cylinder exhaust thermocouple monitoring 
ESM control batteries 
ESM control battery charger 
PAINTING
Oilfield orange or gray topcoat 
SHIPPING SKID
Non-returnable; not intended for lifting engine 
ENGINE LIFTING DEVICE
Lifting device, suitable for single point lift 9801 Shipped Loose
SERVICE ITEMS
Engine Test Log 9900
Torsional analysis 9965/A/B
Mass Elastic System Data (MESD) 9981
Static and modal anaylsis of genset skid or engine/com-

pressor skid
Specification Package 9972
A - 31 Form 10056-2
Appendices
A - 32 Form 10056-2
GE Power
1101 West St. Paul Avenue
Waukesha, WI USA 53188-4999
Phone: +1 (262) 547-3311
Fax: +1 (262) 549-2795
www.ge-distributedpower.com
©2017 General Electric Company

All Rights Reserved
FORM 10056-2
5/2017

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What are the main components of a Waukesha gas engine package?

What are the main components of a Waukesha gas engine package?

What safety precautions should be followed when operating a Waukesha gas engine?

What safety precautions should be followed when operating a Waukesha gas engine?

GE Power

Waukesha* gas engines

275GL Packaging Guide

* Indicates a trademark of the General Electric Company

Indicates a hazardous situation which, if not avoided, could

Indicates a situation which can cause damage to the engine,

Burn Hazard (Chemical)

Burn Hazard (Hot Liquid)

Burn Hazard (Steam)

Crush Hazard (Hand)

Crush Hazard (Side Pinned)

Crush Hazard (Top)

Electrical Shock Hazard

Flying Object Hazard

Sever Hazard (Rotating Blade)

Do not leave tools in the area

Drugs and Alcohol Prohibited

Lifting/Transporting only by qualified personnel

Welding only by qualified personnel

Wear Eye Protection

Wear Personal Protective Equipment (PPE)

Wear Protective Gloves

Use Emergency Stop (E-Stop); Stop Engine

The safety messages that follow have WARNING level hazards.

EQUIPMENT REPAIR AND SERVICE

Always wear protective equipment when installing or removing components with an

Equipment must be grounded by qualified personnel in accordance with IEC (Interna-

Always label “high voltage” on engine-mounted equipment over 24 volts nominal.

PRESSURIZED FLUIDS /GAS/AIR

Always follow recommended procedures when using hydraulic tensioning devices.

Never walk or stand under an engine or component while it is suspended.

The safety message that follows has a CAUTION level

The safety messages that follow have NOTICE level hazards.

CHAPTER 2 - GENERAL INFORMATION

BASIC ENGINE DESCRIPTION

CRANKCASE VENTILATION SYSTEM

CYLINDER HEAD AND VALVES

WATER CIRCULATION SYSTEM

• Better engine performance

• Extensive system diagnostics

• Rapid troubleshooting of engines

• Local and remote monitoring capability used to trend engine performance.

• Easy integration into an extensive data acquisition system

ENGINE MONITORING DEVICES

CHAPTER 3 - TECHNICAL DATA

Table 3-1: Technical Data Sheets Available on www.ge-distributedpower.com

16V275GL+ 12V275GL+ SHEET NAME

Table 3-2: Engine Specifications

Description 16V275GL+ 12V275GL+

1. Pressure is based on 50F (10C) lubricating oil temperature

Figure 3-1: EngCalc Inputs Page

Figure 3-2: 12V275GL+ Base Engine Outline Drawing (no options)

Figure 3-3: 12V275GL+ Option Code 9209 Outline Drawing

Figure 3-4: 16V275GL+ 3D model

Table 3-3: Manuals