SERIAL NO. SPECIFICATION NO. VHP 5108/5790/7042 G/GSI/GL ENGINES REPAIR & OVERHAUL MANUAL First EditionCONTENTS Warranty List Of illustrations List Of Tables How To Use This Manual CHAPTER 1 —-SAFETY AND GENERAL Section 1.00 - Warning Tags & Decal Locations Warning Tags And Decal Locations Section 1.05 - Safety Salety Introduction Salety Tags And Decals Equipment Repair And Service dias Batteries Body Protection Chemicals General Cleaning Solvents Liquid Nirogen/Dry Ice Components Heated Or Frozen Interference Fit Coating System Etectical General Ignition Exhaust Fite Protection Fuels General Gaseous guid tntoxicants And Narcotics Pressurized Fluids/Gas/Ait.. Protective Guards ‘Sodium Cooled Vawve Springs Tools electrical Hydraulic Pneumatic 1.00-1 105-1 105-1 1.05 ~ 1 1.05 -2 1.05 ~ 2 105-2 1.05 -2 1.05 ~2 1.05 -2 105-2 105-2 1.05 ~2 1.05 ~2 105-2 405-3 105-3 1.05 -3 1.05 -3 105-3 105-3 105-3 1.05 -3 105-3 105-4 1.05 ~4 105-4 1.05 = 4 = 105-4 105-4 1.05 -4 105-4 105-4 Weiding General On Engine Weight Section 1.10 - Rigging And Lifting Engines Engine Rigging And Litng Location OF The Liting Eyes Correct Method OF Rigging And Ling Engine a Section 1.15 — General Information Seation Main Points: OvernauRepair Process Preventing Engine Damage Handling And Shipping Engine Removal Serial Number And Engine Nameplate Engine Identiication Views Right Side View Lett Side View Rear View Basi Engine Description Service Tools List Engine Stangards Component Weights Clearances Torque Specifications Genera Torquing Sequence Procedure Thread Lubrication For Torque Fasteners Critical Engine Torque Values Cylinder Head Torquing Procedure Connecting Rod Capscrew Torquing Procedure (PIN Series 205407 And 205507) Main Bearing Cap Torquing Procedure General Torque Recommendations. EnglistvMetric Conversions Index Of Sealants, Adhesives And Lubricants ‘Spit Ring Washer Usabilty Criteria 105-5 108-5 405-5 105-5 110-1 1.10-1 140-4 115-1 115-1 ANS -1 415-1 118-2 115-3 1415-4 115-4 115-5 115-6 415-7 115-8 115-10 118—10 118-11 115-12 115-12 118=12 115-13 118-14 118 ~ 14 1.15 =15 138-16 118-17 115-18 118-19 Form 6248 First GattonCONTENTS Section 1.20 - Specifications Specifications 120-1 Gear Tooth Wear -General . 120-1 Timing Gears 420-1 Engine Timing Data 1.20~28 CHAPTER 2 - ENGINE TEARDOWN Section 2,00 — Cylinder Head Removal Cylinder Head Removal 200-1 Section 2.05 — Crankcase Removal Piston/Connecting Rod Removal 205-1 Cylinder Sieeve Removal 205-4 Vibration Damper Removal 205-5 Front Gear Cover Removal 205-7 Magneto Drive Gear Removal 2.05 -9 Idler Gear Removal 2.05 -10 Camshaft Gear Removal 205-10 Front Gear Housing Removal 205-11 Rocker Arm Oil Header Removal 2.05 ~ 12 Valve Litter Housing Removal 205-13, ‘Camshaft Removal 205-15 Barring Device Removal 205-16 Flyuheel Removal 205-16 il Pickup Screen Removal 2.05 - 18 il Pan Removal 208-19 Crankshaft Removal 2.05 -20, Crankcase . 205-24 Crankshaft No. 1 Main Bearing Removal In Field Conditions 205-24 Crankshaft No, 1 Main Beaving Installation in Field Conditions 208-27 Crankshatt Main Bearings Removal In Field Conditions 2.05 -20 CCrankshatt Main Bearings installation In Field Conditions 2.05 ~90 Camshalt Bearing Removal In Field Conditions 205-31 Camshaft Bearing Installation In Field Conditions 2.05 32 CHAPTER 3 ~ ENGINE INSPECTION AND OVERHAUL Section 3.00 - Cylinder Head Disassembly Cylinder Head Disassembly 300-1 Rocker Arms 300-1 Intake And Exhaust Valves 300-8 Valve Seat insert And Vaive Guide Removal 300-9 Cylinder Head Cleaning And Inspection ... 3.0010 Oylinder Head Casting Pressure Testing ... 3.00 ~12 Cylinder Head Casting Magnatiux® 3.00-13 Cylinder Head Lower Deck Recondition... 3.00-14 Valve Failure Analysis - 300-14 Cylinder Head Assembly 300-19 Valve Guide Installation 3.00~19 Gylinder Head Casting Plug Installation... 3.00~20 \Valve Seat insert Installation 3.00 -20 Valve Seat Grinding 3.00-21 Valve Seat Lapping 300-22 Intake And Exhaust Valve Installation ..... 3.00 -23, Section 3.05 — Crankcase Disassembly Crankoase 305-1 ‘Crankcase Cleaning And Inspection 3.05 - Lower Sleeve Bore And Sleeve Projection Inspection 308-3 Grankcase Lower Bore Restoration 308-3 Main Bearing Bore Cleaning And Inspection 305-5 Main Bearing Running Clearance 308-6 Camshaft Bearing Bore inspection 3.05 -9 Crankshatt 3.05-9 Crankshaft Cleaning And Inspection 305-9 Crankshaft Journal Repair 308-11 Crankshaft Polishing... 3.05 - 11 Crankshaft Repair 305-11 Crankshaft Counterweight Retorque 05-12 Camshatt 305-14 Camshaft Cleaning And Inspection 3.05 - 14 Form 6248 Frat EatonCONTENTS Valve Litters 3.05 ~ 15, Roller Type Litters 305-15 Hydraulic Liters 805-16 Piston 305-17 Piston Disassembly 305-17 Piston Cleaning And Inspection 305-18 Piston Ring Inspection 3.05 -23 Piston Ring Assembly ........- 3.05 -27 6:17 Inch Bore GIGSUGL (4 Ring Piston) . 308 -27 9-4/8 Inch Bore G/GSI (4 Ring Piston) .... 3.05 ~29, Previous Production 9-3/8 Inch Bore GL. (4 Fing Piston) «oe... 3.05 -90 Current Production 9-9/8 Inch Bore GL. (Ring Piston) 3.05 -31 Piston Pin Cleaning And inspection 3.05 -92 Connecting Rod 3105-33 Connecting Rod Disassembly see, 805-33 Connecting Rod Cleaning And Inspection . 3.05 ~ 35, Connecting Rod Assembly 3.05 38 Connecting Rod Bestng Rurring Clearance 3.05 ~ 40 Connecting Rod Bearing Running Clearance Measurement With Piastigage® ...... 3.05 - 42 Cylinder Sleeve 105 - 42 Cylinder Sleeve Disassembly ... 805 ~ 42, Cylinder Sieve Cleaning And Inspection .. 8.05 ~ 43, Cylinder Sleeve Daglazing 3.08 -47, Flywheel : 3.05 ~ 48 Ring Gear Removal 3.05 - 48 Ring Gear installation 3.05 ~48 CHAPTER 4-ENGINE ASSEMBLY Section 4.00 - Crankcase Assembly Crankcase Assembly severe 400-1 Idler Gear Spindle instalation 400-1 Tube Installation 400-1 Main Bearing Stud Installation 400-2 Dowel installation 400-3 Water Header Plug Installation 400-3 Lube Oil Strainer Adapter Installation 400-5 Lower Valve Litter Housing Cover Installation Valve Liter Housing Gasket Installation ‘Camshaft And Bearing Installation Gear Housing Installation ‘Camshaft End Play Measurement Cam Gear Installation Valve Lifter Housing Installation Rocker Arm Oil Header instalation Rear Oil Seal Retainer installation Main Bearing Installation Crankshaft Installation Rear Oil Seal Retainer (Lower Halt) instalation Main Bearing Caps Installation Crankshatt End Piay Measurement Outside Crankshaft Thrust Ring Installation Crankshatt Gear Installation (011 Pump loler Gear Camshatt Idler Gear Installation Accessory Idler Gear Installation Gear Backlash Measurement Magneto Drive Assembly Installation Magneto Drive Gear Installation Cylinder Sleeve Installation Piston And Connecting Rod Installation Ol Pan Crankcase Installation Front Fiywhee! Housing Installation Timing Tape Installation Flywheel Installation Magnetic Pickup Sensor Installation Roar Flywheel Housing Installation Flywheel Fiywhee! Housing Bore And Face Runout Measure Batting Device Installation (Oil Filler Bracket installation ‘Gear Train Lubrication i Stinger/Front Oil Seal/Gear Cover Installation Front Gear Cover Plates installation 400-5 400-6 400-6 4.00 - 10 400-11 -12 400-13 4.00-18 400-18 4.00 -20 4.00 -22 4.00 -25 - 4.0026 4.00 26 - 400-28 4.00 -30 400-31 400-32 4.00 ~35, 4.00 -36 400-37 4.00 -39 400-44 4.00 - 42 4.00 - 46 4.00 -49 4.00 - 50 400-51 400-52 4.00 ~53 4.00 ~ 400-55 4.00 ~58 4.00 ~ 58 4.00 ~59 400-60 4.00 -64 Form 6248 First EanCONTENTS Rear Gear Housing Cover Plate Installation 4.00 -64 Vibration Damper/Crankshatt Pulley Installation 4.00 - 65 Section 4.05 — Cylinder Head Assembly Cylinder Head Installation 4.05 Cylinder Head Torquing Procedure 405-3 Exhaust Manifolds 405-5 Section 4.10 - Valve Adjustment And Web Deflection Valve Adjustment Procedure 440-1 Crankshaft Web Deflection Measurement 410-4 CHAPTER 5 —- ENGINE SYSTEMS Section 5.00 - Speed Governing System ‘Spoed Governing System Components 500-1 ‘Speed Governing System Description 500-1 Woodward UG-BL Governor 500-1 Woodward UG-8 Dial Governor 500-1 Woodward EG-3P Electronic Governing ‘Systern 500-1 Governor Linkages 5.00 -2 Magnetic Pickup 500-2 Control Pane! 5.00 -2 Overspeed Governor soe 500-2 Governor Drive Gear/CEC Timing Dise ....,.. §.00-3 Governor Drive Gear/CEC Timing Disc (Current Production) Removal 500-3 Governor Drive GearlCEC Timing Disc (Current Production) Cleaning And Ingpection sees 600-4 Governor Drive GearlCEC Timing Disc (Current Production} installation 500-4 ‘Governor Drive Gear/OEC Disc (Previous Production) Removal 500-6 ‘Governor Drive Gear/CEC Disc (Previous Production) Disassembly 500-7 Governor Drive GearlCEC Dise (Previous Production) Cleaning And Inspection 7 500-7 Governor Drive GeariCEC Dise (Previous Production) Assembly 500-7 Governor Drive Gear/CEC Disc {Previous Production) Installation 500-8 Governor Drive Shatt 5,00 ~10 Governar Drive Shaft Removal 5,00 - 10 Governor Drive Shaft Disassembly 5.00 ~10 Governor Drive Shaft Cleaning And inspection 500-11 Govemor Drive Shaft Assembly 500-11 Governor Drive Shaft Installation 5.00~12 Governor Drive Housing - 5.00~13 Governor Drive Housing Removal 5.00 ~13 Governor Drive Housing Disassembly ..... 5.00~13 Governor Drive Housing Cleaning And inspection 5.00~13 Governor Drive Housing Assembly 5.00~14 Governor Drive Housing Installation 500-14 Govemors 5.00 ~ 16 Woodard UG-8L. Governor Linkage Removal pee 5.00~16 Woodward UG-BL Governor Removal .... 5.00~17 Woodward UG-BL Governor Disassembly . 5.00 ~17 Woodward UG-BL Governor Assembly ... 5.00~17 Woodward UG-8L Governor Installation ... 5.00~ 18 UG-AL. Governor Linkage Installation And ‘Adjustment Woodward UG-8L. Governor ‘Compensation Adjustment 5.00~18 5.00~22 Woodward UG-8L Governor High’Low ‘Speed Limit Adjustment 500-26 Woodward UG-8L Governor Droop ‘Adjustment Woodward UG-8 (Dial) Governor Removal 5.00~28 Linkage 500-25 Woodward UG-8 (Dial) Governor Removal 5.00-26 Woodward UG-8 (Dial) Governor Disassembly 5.00-27 Woodward UG-8 (Dial) Governor ‘Assembly. 500-27 Woodward UG-8 (Dial) Governor Installation 500-27 Woodward UG-8 (Dial) Governor Linkage Installation And Adjustment 8.00 -27 Woodward UG-8 Dial Governor ‘Compensation Adjustment 5,00 -29 Woodward UG-8 Dial Governor HighvLow ‘Speed Adjustment 5.00 -30 wi Form 6248 Fst EatonCONTENTS Woodward UG-8 (Dial) Governor Droop ‘Adjustment Woodward EG-P Electric Governor Linkage Removal Wooaward EG-SP Governor Removal Woodward EG-3P Governor Disassembly Wooaward EG-3P Governor Cleaning And Inspection Woodward EG-3P Governor Assembly EG-3P Governor Drive Removal £G-AP Governor Drive Disassembly £6-9P Govemor Ove Cleaning And Inspection, E6-3P Governor Dive Assembiy EG-GP Governor Drive Instaliation Woodward EG-aP Governor Installation EG-3P Governor Linkage Cleaning And Inspection 6-9P Governor Linkage nsalation Ard ‘Adjustment Manual Shutdown Lever - GL. Manual Shutdown Lever Adjustment GL Gigs! Manual Shutdown Lever Installation ~ GIGS! Manual Shutdown Lever Adjustment GIGS ‘Overspeed Governor .. Manual Shutdown Lever Removal ~ Overspeed Governor Removal (Overspeed Governor Adjustment (Overspeed Governor Installation Hour Meter Hour Meter Removal Hour Meter installation Tachometer Drive “Tachometer Drive Flemoval Tachometer Drive instalation Section 5.05 — Fuel System Ful System Components Main Fuel Gas Pressure Regulators Operation Of The Fisher 99 Main Fuel Gas Pressure Regulator Carburetors Pilot Operated Prochamber Gas Valve - GL 500-31 500-31 500-32 5,00 - 92 5.00 -39 5.00 -33 500-33 5,00 -34 5.00 ~ 35 5,00 - 35 8.00 - 35 5.00 -36 5.00 -37 5.00 -38 5.00 -40 5.00 - 40 5.00 -42 5,00 - 42 5,00 - 42 5,00 - 42 8.00 - 42 500-43 5,00 - 43 5,00 -44 8.00 - 44 5.00 - 44 5.00 - 45 5.00 ~ 45 5,00 - 45 505-1 5.05 - 505-4 505-5 5.08 -5 Prechamber Gas Safety Shutdown Valve ~ Gu Prechamber Regulator ~ GL Prechamber Manifolds ~ GL. Buttery Cross Shat - G/GSI utterly Cross Shaft Removal - G/GSt Butterfly Cross Shaft Installation ~ GIGS! Carburetor Gross Shaft - GL Carburetor Cross Shaft Removal - GL. Carburetor Gross Shalt Installation ~ GL Prechamber Manifold Cross Pipe - GL Prechamber Manifold Cross Pipe Removal ~ Gl. Prechamber Manifold Cross Pipe Installation - GL Carburetors Carburetor Removal - G/GS! Carburetor Disassembly - G/GS! Career Gearing And inspection - GiGs!. Carburetor Assembly ~ G/GSI Carburetor Installation ~ G/GSI Carburetor Removal - GL. Carburetor Disassembly - GL. Carburetor Cleaning And inspection ~ GL Carburetor Assembly ~ GL Carburetor Installation ~ GL Buttery Valves) utterly Valve Removal - GIGS! Buttenly Valve Disassembly - G/GSI utterly Valve Assembly - GIGS! utterly Vaive Installation - G/GSI ‘Admission Valve - GL ‘Admission Valve Removal - GL. ‘Admission Valve Disassembly - GL. ‘Admigsion Valve Cleaning And Ingpection - GL : ‘Admission Valve Assembly ‘Admission Valve Installation ~ GL Prechamber Cup ~ Gl. Prechamber Cup Removal - GL 505-5 505-5 505-6 505-6 505-6 505-7 505-8 505-8 505-8 505-9 505-9 5.05~10 505-11 505-11 5.05 -12 5.05 ~ 5.05 -13 505-13 505-15 5.05~15 5.05 - 16 5.08 -17 5.08 - 17 5.05 ~18 505-18 505-18 505-19 505-19 5.05 19 505-19 5.05 -19 5.05 ~20 505-20 5.0521 505-21 Form 6248 Fist EatonCONTENTS. Prechamber Cup Cleaning And Inspection - GL Prechamber Cup Installation ~ GL. Prechamber Manifold ~ GL Prechamber Manifold Removal ~ GL Prechamber Manifold Installation - GL. Main Fuel Gas Pressure Regulator (Fisher 99) 5 Main Fuel Gas Pressure Reguiator (Fisher 99) Removal Right Bank Installation Loft Bank Installation Prechamber Regulator (Fisher 951) ~ GL Prechamber Regulator (Fisher 961) Removal ~ GL. Prechamber Regulator Fisher 951) Installation GL... : Fuel Systm Maintenance Fisher 99 Regulator Fiter Cleaning And Inspection Section 5.10 ~ Ignition System Ignition System Components CEC Ignion Module Magneto Wing Harness Ignition Cots Spork Plugs Spark Pugs Spark Plug Carer Removal ~ GL. Spark Plug Carter instalation = GL. Spark Plug Carrier Removal ~CSA Spark Pug Carter Instalaion = CSA Spark Plug Removal Spark Plug inspection Spark Plug Instaiation Spark Plug Extension Repair Ignition Cols Wiring Harness Wing Harness Removal Wing Hamess Inspection Wiring Harness Insalaton CEC Ignition Module 5.05 -22 5.05 -22 5.05 23 505-23, 5.05 -24 5.08 - 25 5.05 -25 5.05 ~25 5.05 -28 5.05 29 5.05 -28 5.05 -30 5.05 93 5.05 ~33 810-1 510-1 5.0 510-1 510-1 510-1 B10-1 510-1 510-3 510-3 510-4 510-5 510-7 510-8 510-10 510-11 510-13 510-13, 510-14 510-15 5.10 -19 CEC Ignition Module Removal CEC Ignition Module Installation. . Governor Drive GearlCEC Timing Dise (Current Production) Governor Drive Gear/CEC Timing Disc emaval (Current Production) Governor Drive Gear/CEC Timing Disc Cleaning And Inspection (Current Production) Governor Drive GeariCEC Timing Dise {nstalation (Current Production) CEC Ignition Module Static Timing SET (Cutrent Production) Setting The Air Gap Specification (Current And Previous Production) CEC Ignition Modute Tining Set (Current Production) ‘Steps Required To Adjust CEC lgntion Module Timing (Current Production) Governor Drive Gear!CEC Timing Dise (Previous Production) Governor Drive GeariCEC Timing Dise (Previous Production) Removal Governor Drive GeariCEC Timing Disc (Previous Production) Cleaning And inspection Govemor Drive geariCEC Timing Dise (Previous Production) installation CEC Ignition Module Ignition Timing (Previous Production) Set Steps Required To Adjust CEC ignition ‘Module Timing (Previous Production) Magneto Drive Dise Coupling Replacement Magneto - Static Timing Set Magneto — Ignition Timing Set Magneto Adapter Magneto Adapter Disassembly . Magneto Adapter Cleaning And Inspection ‘Magneto Adapter Assembly Magneto Orive Magneto Drive Disassembiy Magneto Drive Assembly 610-18 510-19 5.10 -20 510-20 510-20 510-21 510-22 510-24 510-24 610-25 510-26 5.10 -26 5.10 -26 510-27 5.10 ~28 5.10 ~90 510-20 5.1030 510-32 610-37 5.10 ~39 5.10 ~39 5.10 ~ 40 5.10 ~ 40 5.10 ~42 510-42 5.10-43 vi Form 6248 Fret EdoCONTENTS, Section 5.15 — Air Induction System Air Induction System Ar Cleaners Turbochargers Interooolers é Carburetor And intake Manifold Ar induction System Specifications Air Cleaners Precleaner Pad Removal Precleaner Pad Cleaning And Inspection Precleaner Pad Installation Main Air Filter Element Removal Main Air Filter Element Cleaning And Inspection, ‘Main Air Filter Element Installation .... Air Restriction Indicator Air Cleaner Ducts 7 Air Cleaner Duct Removal - G Air Cleaner Duct Installation - G Air Cleaner Duct Removal - GSVGL Ar Cleaner Duct Installation - GSUGL Air Tubing Air Tubing Removal ~ G Ai Tubing Installation - G Air Tubing Removal - GS} Air Tubing instalation - GSI Air Tubing Removal ~ GL Air Tubing Installation ~ GL. Intake Manifolés Intake Manifold Removal - G/GS! Intake Manifold Installation - G/GSI Intake Manifold Flange Attachments Intake Manifold Flange Attachments ~ Gest Lett Bank Right Bank : Intake Manifold Removal ~ GL. Intake Manifold Instaliation ~ GL Intake Manifold Flange Attachments ~ GL Left Bank ight Bank 815-1 515-1 515-1 515-1 515-1 515-1 515-2 515-2 518-3 518-3 518-3 515-3 515-4 515-4 515-5 515-5 515-7 515-8 515-10 515-10 515-10 515-11 8.15-11 5.18 ~12 815-12 5.15 -14 515-14 515-14 515-15 515-16 6.15 -16 5.18 - 16 515-17 515-18 515-19 6.15 -20 5.18 -20 5.1520 Section 5.20 - Turbochargers Tubochargers ‘Turbocharger(s) Removal ‘Turbocharger Cleaning Ang inspection “Turbocharger Installation Prelube Pressure MaintonancelCheck Valve Inspection : Section 5.25 ~ Cooling System Cooling System Components Jacket Water Header/Jacket Water Exhaust Maniold Water Manifold Jacket Water Pump Cluster Thermostat Housing Remote Heat Transter Device ‘Auxiliary Water Pump Intercooler 0 Cooler ‘Auxitary Water Temperature Control Valve ‘Auxillary Water Remote Heat Transfer Device Cooling System Problems ‘Scale Build-up, Cavitation Erosion And Corrosion Scale Build-up Cavitation Erosion Corrosion Water Treatment Ethylene Giyco! Cooling System Specifications And Recommendations Cooling System Specifications Cooling System Recommendations Jacket Water Circuit ~ Initial Fil. ‘Auxiary Cooling Water Circuit Cooling Water System Air Bleod Jacket Water And Auxilary Cooling Water Circuits ~ Drain And Flush Grease Fittings rit Fil Idler Pulley Bearing Lubrication Auxiliary Water Pump Bearings Lubrication Grease Recommendations 5.20 820-1 520-3 520-8 620-12 525-1 525-1 525-1 525-1 525-2 525-7 525-7 525-7 528-8 525-8 525-8 525-9 525-9 525-9 525-9 525-9 525-10 525-10 5.25~10 525-11 525-11 525-11 525-12 5.25~13 525-14 525 ~14 825-17 525-17 525-17 525-47 Form 6208 Frei EatonCONTENTS Belts Jacket Water Pump Drive Batts Replacement ‘Jacket Water Pump Drive Belt Tension ‘Adjustment ‘Auxiliary Water Pump Drive Belt Replacement ‘Auxiliary Water Pump Drive Belt Tension ‘Adjustment Jacket Water Pump Seal inspection Crankcase Water Inlet Elbows Crankcase Water Inlet Elbows Removal — Ler Bank Crankcase Water Inlot Elbows Removal - ight Bank Crankcase Water inlet Elbows, Installation ~ Left Bank. Crankcase Water Inlet Elbows Installation — Right Bank Water Pump Inlet Elbows And Water Header Water Pump Inlot Elbows And Water Header Removal ‘Water Pump inlet Elbows And Water Header Installation Lower/Upper Bypass Tubes And Water Bypass Elbows, LowerlUpper Bypass Tubes And Water ‘Bypass Elbows Removal LowerUpper Bypass Tubes And Water ‘Bypass Elbows Installation Water Manifold Water Manifold Removal Water Manifoid Installation (Cluster Thermostat Housing And Thermostatic Valves. Cluster Thermostat Housing And ‘Thermostatic Valves Fremovai Cluster Thermostat Housing And ‘Thermostatic Valves Cleaning And Inspection Cluster Thermostat Housing/Thermost Instaation Idler Pulley Bracket ic Valves Idler Pulley Bracket Removal Inter Pulley Bracket Disassembly 525-18 525-18 525-19 525-21 525-22 525-23, 525-24 525-24 525-25 525-25 525-25 525-26 5.25 -26 828-27 525-28 5.25 -28 - 825-29 525-31 525-31 525-32 525-94 525-34 5.25 ~95 525-37 525-39 525-39 525-38 Idler Pulley Bracket Cleaning And Inspection Idler Pulley Bracket Assembly Idler Pulley Bracket installation . Jacket Water Pump Jacket Water Pump Removal Jacket Water Pump Disassembiy Jacket Water Pump Cleaning And Inspection Jacket Water Pump Assembly ‘Jacket Water Pump Installation Safety Guards .. Safety Guards Removal Safety Guards Installation . ‘Auxiliary Water Temperature Control Valve ‘Auxiliary Water Temperature Control Valve Removal ‘Auxiliary Water Temperature Control Thermostat ate Inepecton And Test ‘Auxiliary Water Temperature Control Vaive ‘Assembly ‘Auxiliary Water Temperature Control Valve Installation Intercooler . Intercooler Removal Intercooler Disassembly Intercooler Cleaning And Inspection Intercooler Assembly Intercooler Installation Crankcase Vee Pipe Connection Installation Auxiliary Water Pump And Bracket Auxiliary Water Pump And Bracket Removal Auxiliary Water Pump And Bracket Installation Section 5.30 - Lubrication System Lubrication Systom Components Description Internal Ot Contot Lube Oi Specitcations Oil Designations .. Ol Recommendations 6.25 ~41 525-41 5.25 ~43 5.25 ~44 525-44 525 ~45, 5.25 ~ 46 525-47 - 525 ~54 525-56 5.25 ~56 525-87 525-58 525-58 525-58 6.25 ~59 5.25 ~ 60 5.25 ~ 60 525-60 5.25 - 66 525-67 525-68 525-71 5825-73 525-77 525-77 525-79 530 - 5.30- 530-3 530-4 5.0-4 50-4 Fo 28 Firat EaionCONTENTS Waukesha Cogeneration installations 530-5 il Pickup Screen Installation 530-29 Sour Gas & Altemate Fuel Gas Lube O11 Pump 530-29 Sao! covael Lube Oil Pump Removal... 530-29 Recommended Lube Oils For Sour Gas And Alternate Fuel (Landfill) Gas Applications 5.30 ~ 5 Le eee eae eaa 530-29 Pace aoaeeare Lube Ol Pump Cleaning And Inspection ... 530-31 ‘Alternative Fue! Application 520-6 Lube Oi Pump Assembly 520-22 be Oi Condemning Limits 530-6 Lube Oi Pump Installation... 520-37 Lube Oi Analysis cesses 590-8 Prelude Y-strainer 5.20 ~40 011 Visoosity Selection 500-9 Prelube Y-strainer Removal 5.0 -40 Muti-viscosiy Ois 50-9 Prelube Y-strainer Cleaning And ‘Synthetic Oils os 530-9 roe 530-40 Low Ambient Temperature Operation 530-9 eee eee 580-40 Lube Oil Consumption Rates 530-9 Carer Glbe Geoval mee omulas 300-9 G1 Fier Pipe Removal 530-41 Recommended Oil Change Intervals 530-10 ee eee cae a Rocker Atm Oi Header Oi Inlat Lube Oi Piping Purge : 530-11 epdaalkels Ene (it Cooler And Lube Oi Fiter Rocker Arm Oit Header Oi inlet be ae ‘Tubes/Fittings Installation 530-42 eld + 890-12 ‘Turbo Oil Supply/Drain Tubes 5.90-43, Checking Crankcase Oil Level 530-13 Sane Oil Cooler Maintenance ........ 590-19 lastalaion 520-43 Lube Oi System Air Bleed 590-13 Lube Oil Plot Pressure/Governor Oi Tube Lube Oil Filter Element Replacement 5.30 -13 pene . eee Lube Oil Filter Relief Valve Inspection . 530-15 Or ear coor) ae meer ae aa Pan Doors Removal 5.30~ 45 eaceree ee 011 Pan Doors Installation 5.20 - 46 Oil Cooler Piping Installation 530-18 cae Lee . cae Ol Cooler Removal 520-18 Lube Oi Strainer Removal... » 830-46 Lube Oi Strainer Cleaning And 11 Cooler Cleaning And Inspection : Cook 2 eet 580-18 Inspection 580-47 it Cooierinstaition 4 Cooler Instataior 590-19 Lube Oil Strainer installation 50-47 Lube Oi! Temperature Conta! Valve 590-21 ‘Troubleshooting Low Lube Oil Pressure sa0-24 Section 5.35- Exhaust System Lube Oil Pressure Adjustment 530-24 Exhaust System 535-1 Prelube System . 5.90 ~24 ‘Components . Bs-1 Prelube Pressure Maintenance 5.90 ~ 25, (Description 525-1 Seen anes Exhaust System Specifications 525-2 ares : anaes Measuring Exhaust System Backpressure 535-2 Oil Pan Clean And Inspect 500-28 Checking Exhaust Gas Temperatures ...... 5:35 -2 Oil Pickup Screen 520-28 Exhaust Manifold : 535-3 i Pickup Sereen Removal 520-28 ee Exhaust Maniold Removal 535-3 Irspoction ss panes Exhaust Manifold Disassembly 535-8 Form 6248 Fst Eaton xCONTENTS Exhaust Manifold Assembly + 5.358 Exhaust Manifold Installation 595-6 Turbo Exhaust Inlet Elbows. 8.35 -10 Turbo Exhaust Inlet Elbows Removal ...,. 5:35~10 Turbo Exhaust inlet Elbows installation... §.35 — 11 Exhaust Connections -5.95-18 Exhaust Connections Removal ~ 535-13 Exhaust Connections Installation -@ ...,. 535-14 Exhaust Connections Removal -GSIGL .. 535-14 Exhaust Connections Installation -GSUGL_ 6.35 ~ 15 Thermocouples 525-16 Thermocouple Replacement 5.35 - 16 Exhaust Thermocouples Installation 535-18 ‘Thermocouple Clean And Inspect 535-19 Wastegates 5.35 -20 Wastegates — Bleoding Air 5.35 - 20 PIN Series 208372 Wastegate Removal ... 5:35 ~ 20 PIN Series 208372 Wastegate Disassembly 5.95 ~ 21 PIN Series 208372 Wastogate ~ Cleaning And Inspection . 535-23, PIN Sories 208372 Wastogate Assombly .. 6.3524 PIN Series 208372 Wastegate Calibration . 5:36 ~ 25 PIN Series 295645 Waslegate Removal — Draw Tana Only 835-28 PIN Series 295645 Wastegato Disassembly — Draw Thru Only 535-29 PIN Series 295645 Wastogate Calibration Selup ~ Draw Thru Only 535-29 PIN Series 295645 Calibration Procedure “Test =Draw Thru Only 535-90 IN Series 295645 Wastogato instalation = Draw Thr Only 535-31 Engine Altude Adjustments 535-32 Section 5.40 - Crankcase Breather System CCrankcase Breather System 540-1 Components 540-1 Description 540-1 Separator Sereen 540-1 Oi Separators) 540-1 Vacuum Valve/Cnoke Valve. 540-1 Breather Regulator 540-2 Ventun Extractor =GSUGL «.... 540-2 Venturi ~ GSI : 540-2 Crankcase Pressure Measurement 540-3 rankcase Pressure Measurement ~ GiGsvGL 540-3 Grankcase Prossure Adjustment ~ G/GSI Venturi Equipped 540-3 Crankcase Pressure Adjustment (Venturi Extractor/Vacuum Valve Assembly Equipped) - GSVGL 640-4 Crankcase Separator Screen 540-6 Crankcase Separator Screen Removal ..... 5.406 Crankcase Separator Screen Cleaning And Inspection ... . 540-6 Crankcase Separator Screen Assembly .... 5.40 -6 (Ol Separators 540-7 Oil Separator Removal ~G 540-7 it Separator instalation ~G.. 540-8 il Separator Removal ~ GSUGL 540-8 il Separator Cleaning And Inspection ~ @si@t : 540-9 Oil Separator Instalation ~ GSUGL 540-9 Crankcase Breather Regulator ~ GSIIGL Cranage Bresthor Regus Removal — GSUGL . 540 ~10 Crankcase Breather Regulator Disassembly ~ GSUGL Crankcase Breather Regulator ‘Cleaning And Inspection -GSUGL ..... 540~11 Crankcase Breather Regulator 540-10 5.40 ~10 Installation - GSUGL 540-11 Venturi 5.40 ~12 Venturi Removal ~ GSI 5.40 ~12 Venturi Cleaning And Inspection - GSI .... 840-12 Venturi Installation - GSI 5.40 ~12 Venturi Extractor - GSVGL . 540-12 Venturi Extractor Removal - GSWGL 540-12 Venturi Extractor Cleaning And Inspection ~ GSUGL 540-14 Venturi Extractor Assembly ~GSUGL ..... 540~15 Crankcase Pressure Relist Valves 5.40 ~16 Grankcase Pressure Relic! Valve Exercise . .40~ 16 Crankcase Pressure Reliet Valve Removal 540-16 Crankcase Pressure Relie! Valve Cleaning ‘And inspection 540-17 a Form G246 Fst EahionCONTENTS: Crankcase Pressure Reliet Valve Assembiy Breather Tubes Breather Tube Removal - GS! Breather Tubs installation - GSI Breather Tube Removal ~ Breather Tube Installation - GL. Venturi Extractor Compressor Discharge Tubes ‘Venturi Extractor Compressor Discharge ‘Tubes Removal Venu Exrator Compressor Oiscarge Tubes Installation 840-17 540-18 540-18 540-18 540-20 540-21 540-22 5.40 -22 540-23, Section 5.45 — Air/Gas Prelube And Start Systems AifGas Prelube And Stan Systems Components Prelube System Star System Prolube/Stant System Removal/instalation Bulkhead Bracket Assembly Removal Bulkhead Bracket Assembly Installation Plot Operated Prelube Valve Removal Pilot Operated Prelube Valve Installation Prelube PumpiMotor And Connections .. Prelube Pump/Motor And Connections Removal Prelube Pump/Motor And Connections Installation Lube Oil Pressure Gauge Tubes And Fiting (Former Engine Mounted Panel) Lube Oil Pressure Gauge Tubes And Fiting Removal Lube Oil Pressure Gauge Tube Fitting Installation Bulkhead To Panel Bracket Bulkhead To Panel Bracket Removal Bulkhead To Panel Bracket Installation Tube Clips/Clamps Installation Prechamber Gas Valves - GL Prechamber Gas Valves Removal (GL) Prechamber Gas Valves Installation (GL) 545-1 545-1 545-1 545-4 545-9 545-9 545-9 545-10 545 - 545-12 545-12 545-13 - 545 = 18 545-14 545-14 545-14 545-14 545-15 545-17 545-19 545-19 545-22 Air Starter Air Starter Removal Air Starter Installation Elecire Starter Electric Starter Removal Electric Starter Instalition CHAPTER 6 - ACCESSORIES Section 6.00 - Control Panel Control Panel Components, Control Panel Remaval - Right Side Control Pane! Installation ~ Right Side Loft Side Control Panel installation - Left Side Control Panel Removal Section 6.05 — Engine Protection Systems Engine Protection Systems Components "K" Type Thermocouples “Thermocouple Junction Box Manual Shutdown Switches Customer Supplied Control Switches Pressure And Temperature Switches Calibration Alarm And Shutdown Satpoints Engine Gauge Panel Components (Shipped Loose) Remote Panel Components Custom Engine Controt” Detonation Sensing Module System DSM System Operation Defaut Timing Value User Interface DSM Systom Troubleshooting 5.45 24 5.45 -24 5.45 ~28 5.45 -26 600-1 600-1 600-1 600-3 600-4 6.00-5 605-1 605-1 605-1 605-6 605-6 6.05 -6 605-6 605-7 605-8 605-9 6.05 - 605-11 605-11 605-13 605-14 Section 6.10 — Miscellaneous Equipment Miscellaneous Equipment Components ‘Surge Tanic ‘Surge Tank Removal 610-1 610-1 610-2 610-2 Form 6248 Fret EditonCONTENTS Surge Tank Disassembly ...... ses 610-3 ‘Surge Tank Cleaning And Inspection ....... 610-4 Surge Tank Assembly 610-4 ‘Surge Tank Installation 610-4 Jacket Water Heater 610-5 Jacket Water Heater Removal 610-5 shat Wo Hester leaning And Ingpection . ecw Jacket Water Heater Installation ... 610-6 CHAPTER 7 — TROUBLESHOOTING AND MAINTENANCE Section 7.00 - Troubleshooting ‘Troubleshooting . cece 70004 Section 7.10 - Maintenance And Storage Routine Maintenance .... oe THO-1 Routine inspection 710-4 Engine Storage ceeeeceseereseeree TAO= 5 Preservation Equipment And Material 710-5 Waukesha Engine Preservative Oil 710-5 ‘Waukesha Engine Preservative Oil Usage .. 7.10 -5 Use Of Other Preservative Oils And Materials . 710-6 Engine Storage ~ New 740-7 Operational Engines 710-7 Non-operational Engines 740-7 Engine Storage ~ Used 710-8 Operational Engines 710-8 Non-operational Engines 710-8 Engines — Retum To Service Alter Storage .... 7.10-8 Alphabetical Index : send iw Form 6246 Fist EatonILLUSTRATIONS LIST OF ILLUSTRATIONS Section 1.00 — Warning Tags & Decal Figure 1.15-7. Manitolds, Headers, ete... 1.18~ 12 Locations Figute .15-8. Cylinder Head Capserew Tightening And Torquing Fue 190-1.SampleO1WamegTag Benes trea} 118-14 eee . Po Figure 1.18-9, Connecting Rod Cap Capscrew Figure 1.00.2. Waming Tag (PIN 2091078) ~ Tightening Sequence (Series PIN 208407 ‘On Regulators), All Naturally Aspirated and 205507) 115-14 Gas Engines et Figure 1.15-10. Main Bearing Cap Figure 1.00-3. Warning Tag (P/N 209107E) -. 1,00-2 Tightening/Torquing Pattern ~ As Viewed Figute .00-4. Warning Tag (PIN 209107H) - From Underside Of Crankcase 118-16 On Fisher 99 Reguators), Turbocharged Figure 1.15-11. Split Ring Washers 115-19 Gas Engines 100-2 oe Figure 1.00-5. Warning Tag (PIN 209107L) - Section 1.20 - Specifications On Fisher 66 Paguators), Naturally Figure 120-1. Valve Sequence - Asprated, Low Btu Engines 100-2 Crankshaft Degrees Shown 120-19 Figure 1.00-6. Waming Tag (P/N 209107R) - Figure 1.20-2. Engine Compression On Fisher 99 And S211 Regulators), Proseuies 120-28 Turbocharged Engines 100-3 : Figure 100-7, Waring Tag (PN 2081074) Section 2.00 - Cylinder Head Removal On iMPCO (MAXITROL) Pressure Figute 2.00-1. Rocker Arms 200-2 Reduction Valve, Used With 5 ~ 20, . . Figure 2.002. install Rocker Arm Oi Water Column Gas Pressure 100-3 cheatin pa Figuee 1,00-8. Waming Tag (PIN 209107K) — Ce ACr yen ‘On Carburetor Throtte Lever For Engines es ea Ordered And Built Without Waukesha : Engine Division Designed engine Satety Figure 2.00-4, Water Outlet Elbow Gaskels .. 200-2 Shutdown Equipment 100-9 Figure 2.005. Exhaust Manifold -Reat View . 2.009 Figure 1.00.9. Waming Tag (PIN 209107P) — Figure 2.005. intake Maniold 200-3 For Gas Vent On Prelude Systems That Figure 2.00-7, Eye Bot Location ~ Use Natural Gas For Prelube Motor ..... 1.004 12 Cylinder Engines 200-3 Figure 100-10. Warming Tag (P/N 208840) — Figure 2.00-8, Cylinder Heads 200-3 On High Voltage Equipment ee Figure 2.00-9. Lifting The Cylinder Head 2.00 -4 Section 1.10 - pasing And Lifting Section 2.05 - Crankcase Removal ‘ngines Figure 2.05-1. Capscrews Figure 110-1, Correct Method OF Liting Connecting Rod Gaps 205-1 Engine ~ Side Views 110- Figure 2.05-2. Carbon Ridge 205-1 Figure 1.10-2. Cortect Method of Liting Figure 2.05-9, insta Pleton Pur eo Engine - Rear View 410-2 _ ° tall Piston Pule a Figure 2.05-6. Remove PistowConnecting Section 1.15 — General Information od Assombiy 205-2 haa Figuee 205-5, Connecting Rod 205-2 Current Production 115-3 Figure 2.05-6. Bearing Cap 2.05 -2 Figur 1.15:2. Nameplate - Figute 2.05-7. Keep Connecting Rod Gaps Previous Production 115-3 ‘And Blades Properly Mates 205-3 Figure 1,15-3. ight Side View Figure 2.05-8. Cylinder Sleeve Puller 205-4 12 Gyinder VHP GL 115-4 Figute 205-9. Cynder Steeve vs 205—4 Figute 1,15-4. Left Side View — Figure 205-10. Vibration DampersCrankshat 12 Gyinder VHP GL 115-5 Pulleys 205-5 Figure 1.15:5. Rear View ~ Figute 205-11, Crankshatt Pulley Stop 12 Gyliner VHP GL 115-6 ‘Sloove 205-6 Figure 1.15.6. Torque Sequence For Figure 205-12, Rear Vibraion Damperlear ‘uli-Bolt Patterns 115-12 Crankshatt Pulley 205-6 Form 6008 Fret Ean WwILLUSTRATIONS Figure 2.05-13, Gear Cover Plates ~ Front Left Figure 2.05-14 Front Lett... Figure 2.05-15. Ball Bearing . Figure 2.05-16. Gear Cover Figure 2.05-17. Front Oi! Seal Figure 2.05-18. Oil Sliger And O-Ring .. Figure 2.05-19. Magneto Drive Gear Figure 2.05-20. Drive Shaft Figure 2.05-21. Magneto Drive Figure 2.05-22. Lock Idler Gear Capscrews. Figure 2.05-28. Camshatt Idler Gear ~ Upper Figure 2.05-24. Camshaft Cover Plate Figure 2.05-25, Unlocking The Camshatt Gear Nut Figure 2.05-28. Oil Pan Capscrow — Front Left Figure 2.05-27, Valve Lifter Housing ~ Front Figure 2.05-28, Front Gear Housing Figure 2.05-28, Rocker Arm Oil Header Figure 2.05-30. Longer Capscrew Locations For Mounting The Rocker Arm il Header Figure 2.05-31. Valve Lifter Guides Figure 2.05-32, Valve Litter Housing Cover Figure 2.05-83, Raising The Valve Liter Housing : Figure 2.05-34. Valve Litter Housing ‘Assembly Figure 2.05-35, Camshatt Set Screw ‘On VaWve Litter Housing Cover Figure 2.05-96. Valve Lifter Housing ~ Rear Figure 2.05-37. Lower Valve Litter Housing ‘Cover Figure 2.05-38, Thrust Washer Figure 2.05-38. Shim Pack Figure 2.05-40, Cam Bearing Cap Figure 2.05-41. Valve Lifter Housing Gasket — Front Figure 2.08-42. Front Flywheel Housing ~ Rear Left Figure 2.05-49. Flywheel Litting Bracket Figure 2.05-44, Rear Flywheel Housing Figure 2.05-45, Remove Fiywhee! Figure 2.05-46, Front Flywheel Section Figure 2.05-47. Oi Pickup Screen Assembly ~ 12 Gylinder Rear Gear Housing - 208-7 205-7 208-7 205-8 205-8 205-9 205-3 205-9 205-9 2.05 - 10 2.05 - 10 2.05 - 10 205-10 208-11 205-11 205-11 205-12 2.05 -12 205-13 205-13 205-13 - 205-14 208-14 205-14 205-14 2.05 ~15 205-15 205-15 2.05 16 - 208-16 2.05 - 16 2.05 - 16 205-17 2005-17 2.05 - 18 Figure 2.05-48. Bolt Holes In Engine Block Figure 2.05-49, O11 Pan Cross Cuts ~ oar Right Figure 2.05-50, Oil Pump Gear Figure 2.05-51. Oil Pump Gear Assembiy Figure 2.05-52. Crankshaft Gear Mount Figure 2.05-53, Lower Ol Retainer Plate Figure 2.05-54, Wick Seal Figure 2.05-55. Cross-Tie Bolts Figure 2.05-56. Main Bearing Cap Figure 2.05-57. No. 1 Main Bearing Cap Figure 2.05-58, Thrust Bearing Figure 2.05-59. Crankshatt Figure 2,05-60. Bearings Figure 2,05-61. Oi! Tubes Figure 2,05-62. Crankcase ~ Inside Front Figure 2.05-63. Upper Retainer Plato Figure 2.05-64. Cross Tie Bolts, Figure 2.08-65. No. 1 Main Bearing Figure 2.05-66. Bearing Rollout Figure 2.05-67. Roll Pin Installation Figure 2.05+68. No, 1 Main Bearing Cap Figure 2.05-69, Main Searing Cap Stamped Identification Numbers Figure 2.05-70, Oil Pump Gear Assembly Figure 2.05-71. Main Bearing Cap ‘Tightening/Torquing Pattern ~ As Viewed From Underside Of Crankcase Figure 2.05-72, Main Bearing Figure 2.05-73, Bearing Rotout Figure 2.05-74, Main Bearing Cap ‘Stamped Identification Numbers Figure 2.05-75, Cross Tie Bolts Figure 2.05-76. Main Bearing Cap Tightening/Torquing Pattern ~ As Viewed From Underside Of Crankcase Figure 2.05-77. Cam Bearing Cap Section 3.00 - Cylinder Head Disassembly Figure 3.00-1. Rocker Arm Assombly Figure 300-2, Fixed Vave Liter Screw Figure 300-3, Rocker Arm Adjusting Screws Figure 8.00-4, Rocker Arm Shatt Figure 8.00-5, Exhaust Rocker Arm Bushings Figure 3.00-6. Rocker Arm Bushings Figure 3,00-7. Intake Rocker Arm Bushings Figure ,00-8, Intake Actuator Rocker Arn Bushings Figure 2.00.9. Rocker Arm Assembly Figure 9.00-10. intake Actuator Ascombly 2.05 ~19 205-19 2.05 ~20 2.05 ~20 205-21 205-21 2.05 ~22 2.05 ~22 2.05 ~22 2.05 -22 2.05 ~23, 205-23, 205-23 2.05 ~24 2,05 24 2.05 ~24 2.05 ~25 2.05 ~25 2.08 ~26 2.05 ~26 205-27 205-27 2.05 ~28 2.05 ~ 28 2.05 -29 2.05 -90 2.05 - 90 2,05 -31 2.08 -31 2.05 -31 300-1 300-2 300-2 300-2 300-4 300-4 300-5 300-5 300-6 300-7 ww Form 6248 Fist EatonFigure 3.00-11, Cylinder Head Assembly ~ Exploded View Figure 3,00-12, Install Valve Stem Seal Figure 3.00-13, Tack Weld Valve To Valve Seat Figure 3.00-14. Valve Seat insert Removal Figure 3.00-18. Valve Seat inser Removal . Figure 3.00-16. Core Plug Locations - Top Figure 3.00-17. Core Plug Locations ~ Front Figure 3.00-18. Core Plug Locations ~ Right Figure 3.00-19. Core Plug Locations ~ Left Figure 3.00-20, Core Plug Locations ~ Bottom Figure 8.00-21. Check Cylinder Head Deck For Warpage Figure 3.00-22. Cylinder Head Pressure Test Plates Figure 8.00-23. Water Outlet Hole Figure 3.00-24, Cylinder Head ~ Intake Port Side Figure 300-2. Checking Vahe Stems For Straightness: Figure 3.00-26. Checking Head Perpendicular Figure 3.00-27, Cylinder Head Valve Figure 3.00-28, Margin Wear Figure 3.00-29. Instaling Valve Guides Figure 3,00-30, Valve Seat Insert Figure 3.00-31. Measure Valve Seat Concentricity Figure 3.00-92. Valve Lapping Figure 3.00-33, Good Valve And ‘Seat Contact Figur 9,008. Checking Valve Spring Height Figure 3.00-36. Install Valve Stem Seal Figure 3.00-96. Cylinder Head Assembly ~ Exploded View Figure 3,00-37. Valve Spring Compressor Figure 3.00-38. Valve Compressor Special Bolt Installation Locations Figure 3.00-39. Assembled Cylinder Head ~ Cross Sectional View Figure 3.05-1. Lower Sleeve Bore Figure 3.05-2. Lower Bore And Restoration Sleeve Dimensions Figure 3.05-3. Main Bearing Boras Figure 3.05-4. Main Bearing Cap Tightoning/Torquing Pattern - As Viewed From Underside Of Grankcase 300-8 300-8 300-9 300-9 3.00 -9 3.00 - 10 3.00 - 10 3,00 - 10 300-11 300-11 300-12 300-12 300-13 300-14 300-18 3,00 - 16 3.00 -16 3.00 - 16 3.00 - 19 3.0020 3.0021 300-22 3.00 -28 3:00 -24 3.00 -24 3.00 ~25 3,00 ~25 3,00 -25 3,00 -26 Section 3.05 - Crankcase Disassembly 05-3 305-4 3.05 -5 3.05 -6 ILLUSTRATIONS, Figure 3.05-5. Determine Bearing Thickness Figure 3.05-6, Select Main Bearing Shel's For Propar Flunning Clearance Figure 3.05-7, Camshaft Bearing Bore Figure 3.05-8, Crankshaft Set Screws Figure 3.05-9. 12 Cylinder Crankshaft Figure 3.05-10. 12 Cylinder Crankshaft Figure 3.05-11. Camshaft Vale Lifter Body ~ Bottom View Figure 3.05-12. Camshaft Valve Liters And Guides Figure 3.05-13. Lubricate Valve Liter Rollers Figure 3.05-14. Hydraulic Liter Figure 3.05-15. Push Rod Figure 3.05-16. Hydraulic Litter — Internal View Figure 3.05-17. Hydraulic Litter — installation Figure 3.05-18, Piston Assembly Figure 8.05-19. Piston And Rings Figure 3.05-20, Piston Oi Drain Holes Figure 3.05.21. Chack Piston Ring Groove Clearance Figure 3.05-22. Install Piston Rings Figure 3.05-23. Of Controt Ring Detail ~ 8.4/2 Inch Bore Figure 3.05-24. Compression Ring Detail Figure 3.05-25. Barrel-faced Compression Ring Detail Figure 305-28. 9-3/8, Bore G,GSI Fiston Fing Configuration Figure 3.05.27. Previous Production 9-3 Bore GL Piston Ring Configuration PIN 2054042 Figure 3.05-28, Current Production Piston Ring Detail 9-3/8 Inch Bore GL (3-ing Piston) Figure 3.05.29, Current Production 9-9/8 Inch Bore GL (3-Ring Piston) Figure 3.05-30. Connecting Rod Figure 3.05-31. Bearing Cap Figure 3.05-92. Align Rod Pin Bushing Split Line Figure 3.05-33. Clean Connecting Rod Lube Oil Passageways Figure 3.05-34. Connecting Rod Twist Gap Figure 3.05-35. Rod Cap Rall Pin Figure 3.05-86. Connecting Rod Cap CCapscrew Tightening Sequence ~ oll Pin Equipped Figure 3.05-37. Check Rod Bearing Bore For Out-Of-Round And Taper Figure 3.05-38. Weight Classification Stamp Location 305-8 305-8 305-9 3.05 ~ 10 305-11 3.05 - 13 305-15 3.05 - 15 3.05 - 16 3.05 - 16 3.05 - 16 3.05 17 305-17 305-17 3.05 -18 3.05 -18 3.05 23 305-27 305-27 3.05 - 28 3.05 -28 305-23 3.05 ~90 305-31 305-31 3.05 -33 305-93 305-33 305-33 3.08 - 36 3.05 - 36 308-37 305-37 3.05 38 Form 6240 iri EatonILLUSTRATIONS Figure 3.05-39, Rod Pin Bushing 3.05 - 38 Figure 3.05-40. Verily Orientation Of Rod Pin Bushings Oil Groove 3.05 -39 Figure 3.05-41. Connecting Rod Bearings .. 3.05 - 40, Figure 05-42, Position Bearing Shell Above Bearing Seat 3.05 - 40 Figure 3.05-43, Installing Bearing Shell ..... 305-40 Figure 3.05-44. Keep Connecting Rod Caps ‘And Blades Properly Mated 3.05 -41 Figure 3.05-48, Connecting Rod Cap Capscrew Tightening Sequence — Roll Pin Equioped 305-41 Figure 3.05-48. Cylinder Sleeve 3,05 ~42 Figure 3.05-47. Flexible Hone 3.05 -47 Figure 3.05-48, Cylinder Sleeve Deglazing Cross Hatch Patiern 305-47 Figure 3.05-49. Fiywhee! Ring Gear 3.05 ~48 Figure 4.00-1. Crankcase — Inside Front Figure 4.00-2. Gear Train Oil Spray Tube Figure 4.003. Oil Tubes Figure 4,09-4, Main Bearing Cap Studs ~ ‘Old And New Styles Figure 4.00-5, Main Bearing Cap Studs Figure 4,00-6, Water Header/Oil Outlet Plugs ~ Rear Lett Figure 4,00-7. Oil Outlet Plugs — Rear Right View Figure 4.00-8, 3/4, NPT Oil Header Pipe Plugs Figuee 4.00-9. Crankcase ~ Main Oil Header ~ Rear Right Figure 4,00-10, Lube Ol Strainer Adapter Figure 4.00-11. Lower Valve Lifter Housing Cover Figure 4,00-12. Crankcase ~ Top Rear Figure 4,00-13, Valve Lifter Housing Gasket - Front Figure 4.00-14, Valve Litter Housing Gasket Rear Figure 4.00-15. Camshatt Bearing Saddles Figure 4,00-16. install Roll Pins In Front Cam Bearing Cap Figure 4.00-17. Cam Bearings. Figure 4.00-18, Inside Camehat Thrust Ring Figure 4,00-19, Front Gam Bearing Cap Figure 4.00-20. Gam Bearing Cap (00-21. Camshaft Thrust Fing Figure Section 4.00 - Crankcase Assembly 400-1 400-1 400-2 400-2 400-2 4.00-3 400-3 400-4 400-5 400-5 400-5 400-6 400-6 400-6 400-7 400-7 400-7 400-8 400-9 400-9 400-9 Figure 4.00-22, Outside Camshatt Thrust Ring Figure 4.00-28. Shim Pack Figure 4.00-24, Thrust Washer Figure 4,00-25, Gear Housing Flange Figure 4.00-26. Reae Gear Housing Flange Figure 4.0027. Verity That Bottoms Are Flush Figure 4.00-28, Measuring Camshaft End Play 7 Figure 4.00-29. Prevent Lateral Movement Of Camshaft : G Figure 4.00-0. Prevent Camshalt Retation Figure 4.00-31, Cam Gear Key Figure 4.00-92. Locking The Camshatt Gear Nut Figure 4.00.93. Valve Liter Housing ‘Assembly Figure 4.0024. Lowering The Valve Lifter Housing Figure 4.00-35, Rear Gear Housing Gasket Figure 4.00-36. Valve Liter Housing ~ Front Figure 4.00-37. Fasten Valve Lifter Housing To Rear Gear Housing Figure 4.00-98. Camshaft Cover Plate Figure 4.00-39. Camshaft Set Screw On Valve Litter Housing Cover Figure 4.00-40. Valve Liter Housing - lear Figure 4.00-41. Lubricate Valve Liter Rollers Figure 4.00-42. Install Valve Liter Guides Figure 4.00-43. Longer Capscrew Locations For Mounting The Rocker Arm ll Header Figure 4.00.44. Pipe Tee Magnet Plug Figure 4.00-45, Rocker Arm Oi Header ~ Rear Figure 4.00-46, Rocker Arm Oil Header Figure 4.00.47. Rear Oil Seal Retainer — Upper Hatt Figure 4.00-48, Cut Rope Type Seal Figure 4.00-49. Rear Oil Seal Retainer Upper Hatt. Figure 4,00-50, Rear Oil Seal Retainer — Upper Half Figure 4.00-51. Front Main Bearing Cap Figure 4.0052. install Rol Pins In Front Main Bearing Cap Figure 4.00-53. Upper Fully Grooved Main Bearing Shells ~ Bearing Saddles Figure 4.00-84, Lower Ungrooved Main Bearing Shells ~ Bearing Caps 400-9 400-10 400-10 4.00-10 4.00 - 10 4000-11 400-11 400-12 4900-12 400-12 4.0013 400-13 400-14 400-14 400-15 400-15 400-15 400-15 400-16 400-16 400-16 4.00~17 4.00~18 400-18 400-18 400-19 400-19 400-19 4,00 -20 4,00 ~20 400-21 4.00~24 4.00~22 Form G8 Fst FanonFigure 4.0055. Crankshatt Set Screws Figure 4.0056. Crankshatt Set Screw Locations (6) Figure 400457, Crankshatt Guiding Figure 400-58, Crankshatt Oi Grooves Figure 4,009, Crankshatt Placement Figure 4.0060. Install Inside Thaust Ring Figure 4.00-61. Rear Oi! Seal Retainer Assembly Figure 4.0062. Trim Rear Oil Seal Retainer Gasket Figure 4,00-63. Main Bearing Cap Tightening/Torquing Pattern ~ As Viewed Fram Underside Of Ceankcase Figure 4,00-64. Torque Front Main Bearing Cap Figure 4.00-65, Measure Crankshaft End Play Figure 4,00-66. Bump Crankshaft Towards Rear Figure 4.00-67. Crankshaft End Play Figure 4.00-68, Roll Pins Figure 4.00-69, install Rol Pins In Crankshatt Figure 4.00-70, Crankshaft Thrust Fing (Halt) Lip Figure 4.00-71. Outside Thrust Ring — Cap Side Figure 4.00-72. Outside Thrust Ring — Saddle Side Figure 4.00-73. Crankshaft Thrust Washer Figure 4.00-74, Thrust Washer Figure 4,00-75, Crankshaft Gear Figure 4.00-76. Crankshaft Gear Mount Figure 4.00-77. Ol Pump Gear Assembly Figure 4.00-78. Secure Spindle Screw Head Figure 4.00-78, Torque Spindle Screw Hex Nut Figure 4.00-80. Idler Gear Figure 4.00-81. Idler Gear Figure 4.00-82. Camshaft idler Gear Figure 4,00-83, Camshatt Idler Gear — Upper Figure 4.00-84, Camshalt idler Gear ~ Timing Marks Figure 4,00-85. Cam GeariCamshat Idler ‘Gear Timing Figure 4,00-88. Lock idler Gear Capscrews Figure 4.00-87. Accessory Idler Gear ~ “Timing Marks Figure 4.00-88. Accessory Idler Gear ~ Lower 4.00 -22 400-23, 4.00 -23 4.00 -24 4,00 -24 4,00 -24 4.00 -25, 4.0025 400-26 4.0026 400-27 4.00 -27 4.00 -27 4.00 ~28 4.00 ~28 4.00 -29 400-29 4.00 -29 4.00 -29 4.00 - 30 4,00 -30 4.90 -30 400-31 400-31 4.00 -31 4.00 - 32 4.00 ~92 4.00 -32 4.00 -33, 4.00 ~33, 400-33, 4.00 - 35 400-95, 4.00 -35 ILLUSTRATIONS Figure 4,00-89. Gear Backlash 4.00 ~96 Figure 4.00-90. Magneto Drive Assembly ... 4.00 -37 Figure 4,00-91. Remove Adapter Cover Side Bolts 400-38, Figure 4,00-92. Mount Magneto Drive ‘Assembly 4.00-38 Figure 4.00.93. Accessory Idler Gear — Timing Marks 4.00 -39 Figure 4.00.94, Drive Shatt 4.0038 Figure 4.00-95. Mount Magneto Drive Gear . 4.00 ~39 Figure 4.00.96. Magneto Drive Gear “Tightening And Torquing Paitern 400-40 Figure 4.00.97. P/N 2051301 Cylinder ‘Sleeve Caution Tape s. 400~41 Figure 4.00-98, Cylinder Sleeve 4.00 ~41 Figure 4.00-99. Spiraling O-rings 4.00 ~42 Figure 4.00-100. Sleeve Projection 4.00 ~42 Figure 4.00-101, Piston And Connecting Rod 4.00 ~ 42 Figure 4.00-102. Connecting Rod Bearings . 4.00 - 43, Figure 4.00-103. Connecting Rod Bore And Bearing Shell 4.00 -43 Figure 4,00-104. Instaling Bearing Shell... 4,00 - 44 Figure 4.00-108. Connacting Rod Position .. 4.00 ~ 44 Figure 4,00-106, Connecting Rod Position .. 4.00 - 45, Figure 4.00-107. Connecting Rod Gap Capsorew Tightening Sequence oll Pin Equipped 400-45, Figure 4,00-108. Oil Pickup Sereen Assembly — 12 Cylinder 4.00 - 48, Figure 4.00-109. Oil Pan Seal 4.0047 Figure 4.00-110, Oil Pan Seal Front Right . 4.00 ~47 Figure 4.00-111. Dipstick 4.00 48, Figure 4.00-112. Expansion Plug Location .. 4.00 ~ 48 Figure 4.00-113. Oil Pan Cross Cuts - Rear Right 400-49 Figure 4.00-114. Oil Pan Capscrew ~ Front Right 400-49 Figure 4.00-115. Oil Pan Capscrew — Front Lett 4.00-50 Figure 4.00-116. Crankcase ~ Rear 4.00 -50 Figure 4.00-117. Front Flywheel Section .... 4.00~ 50 Figure 4.00-118. Front Flywheel! Housing Capscrew Tightening Pattern 400-50 Figure 4.00-119. Flywheel Timing Tape Locations 4.00-51 Figure 4.00-120. Timing Tape 4.00-51 Figure 4.00-121, Orient Crank Gear 4.00 - 52 Figure 4.00-122. Lifting The Flywhee! 4.00 -52 Figure 4.00-123. Flywheet Mounting 4.00 -52 Figure 4.00-128, Mount Flywhee! 4.00 - 5a Figure 4.00-125. Remove Lifting Bracket... 4.00~53 Form 6248 Frat EatonILLUSTRATIONS Figure 4.00-126. Ring Gear Tooth Alignment Figure 4,00-127, Install Magnetic Pickup Sensor Figure 4.00-128, Rear Flywhee! Housing Capscrew Tightening Pattern Figure 4.00-129. Flywheel, Flywheo! Housing Bore And Face Funout Figure 4.00-130. Flywheel Housing Rear Face Funout Figure 4,00-131. Total Indicator Reading (TIR} In inches Figure 4.00-132. Flywheel Face Runout ‘On Wheel Figure 4,00-133. Flywheel Housing Bore Runout Figure 4,00-134, Horizontal Support Bar Figure 4.00-188. Flywheel Pilot Bearing Bore Runout Fare 4.0188 Front Fy Housing - Rear Left Figur 4.00-197. Mount Oil Filer Bracket ~ Rear Left Figure 4,00-138, Ol Filer Pipe/Bracket — Rear Lett Figure 4,00-139, Grease Gear Train Figure 4.00-140. Lube Gear Train Figure 4,00-141, Oil Singer/O-Ring Figure 4.00-142. Gear Cover Figure 4.00-143. Front Oil Seal Figure 4.00-144, Install Front Ol Seal Figure 4.00-145, Oil Pan Cross Cuts — Front Lett, Figure 4.00-146. Gear Cover Tightening Pattern (A~F) Figure 4.00-147. Instalng The Gear Cover Figure 4.00-148. Gear Cover Plates ~ Front Left, Figure 4.00-149, Rear Gear Housing ~ Front Le 400-53 400-53 4.00 -54 400-55 4.00 -55 4.00 - 56 4.00 -56 4.00 -56 400-57 400-87 4.00 -58 4.00 -58 4,00 -58 4.00 -59 400-59 4.00 -60 4.00 -60 4.00 - 60 400-61 400-61 4.00 62. 4.0063, 4.0064 4.0064 Figure 4.00-150. Vibration Damper/Crankshaft Pulleys Figur 400-151. Side Section View ‘8V" And “C Section Groove Pulleys Figure 4.00-182. Torquing End Plate Capscrews Figure 4.05-1, Cylinder Head Gasket Figure 4.05-2. Lifting The Cylinder Head ~ 12 Cylinder Engines Figure 405-3. Cylinder Head Capscrew Tightening And Torquing Sequence (8) 4.00 - 65, 4000-67 4.00 -68 Section 4,05 — Cylinder Head Assembly 405-1 405-2 405-3 Figure 4.05.4. Push Rod Cover Figure 4.05-5. Push Rods Figure 4.05-6, Rocker Arm Oil Supply Tube — Rear Lett Figure 4.05-7. Exhaust Manifold Gasket Figure 4.05-8, Prelube Motor AiriGas Supply Tube Figure 4.05-9. Exhaust Manifold ~ Lett Bank Figure 4.05-10, Exhaust Manifold Ead Sections ~ Left Bank Figure 4.05-11. Water Outlet Elbow Gaskets Figure 4.05-12. Exhaust Manifold ~ Right Bank Figure 4.05-13. Water Oulet Elbows ~ Rear Right Figure 4.05-14. Exhaust Manifold - Front Figuee 4.05-15. Exhaust Manifold ~ Lett Bank Figure 4.05-16, Thermocouple Connector Rear Right Web Deflection Figure 4.10-1. Engine Firing Order - 12 Cylinder Figure 4,10:2, Rocker Ams Figure 4.10-3, Rocker Arm Adjusting Screws. Figure 4.10-4, Hydraulic Litter Figure 4.10-5, Engine Shimming Procedure Figure .00-1. 2301A Load Sharing And ‘Speed Contro! Figure 5.00-2, 2901A Speed Control Figure 5.00-3. Governor Drive Housing Figure 5.00-4, Hall-Effect Pickup Figure 5.00-5. Current Production CEC Timing Dise| Figure 6,00-8. Current Production Governor Drive Gear Figure §.00-7. Current Production Governor Drive Gear Figure 5.00-8. Fiywhee! Timing Opening Figure §.00-9. Current Production GEC. Timing Oise Figure 5.00-10. Current Production CEC Timing Disc Figure §.00-11. Governar Drive Housing Figure 5.00-12, Hall- Etfect Pickup Figure 5.00-13, Previous Production ‘CEC Disc Figure §.00-14, Previous Production Governor Drive Gear Figure 5.00-15, Previous Produ Governor Drive Gear 405-3 405-4 405-4 405-5 405-5 405-5 408-6 408-6 405-6 408-7 405-7 405-7 405-7 Section 4.10 - Valve Adjustment And 440-1 40-2 410-2 410-2 4.10 - Section 5.00 - Speed Governing System 500-2 500-3 5.00-3 500-3 500-4 500-4 500-4 500-5 500-5 500-5 500-6 5.00 -6 5.00-6 500-6 500-7 Form 6240 Fret EaionILLUSTRATIONS. Figure 5.00-16. Previous Production Governor Drive Gear Vibration Damper Installation . §.00-7 Figure 5.00-17. Previous Production Governor Drive Gear 500-8 Figure §.00-18, Previous Production Governor Drive Gear 500-8 Figure 5.00-19, Previous Production Timing Disc 500-9 Figure §.00-20. Previous Production CEC Disc 500-9 Figure 5.00-21. Governor Drive Housing ..... 5.00~9 Figure 5,00-22. Governor Drive Shaft ‘Assembly 500-10 Figure 5.00-23, Governor Drive Shatt 500-10 Figure 5,00-24. Governor Drive Shaft ‘Assembly .00-11 Figure 5.00-25, Governor Drive Gear 500-12 Figure 5.00-26. Oil Line And Hall-Eifect Pickup 500-13 Figure 5,00-27, Governor Drive Housing .... 5.00 - 13, Figure 5.00-28. Governor Drive Assembly — Front Right 5.00 -13 Figure 5.00-29. Governor Drive Housing Rear 500-14 Figure 5.00-30. Governor Drive Housing ~ Rear pene 500-14 Figure 5,00-31. Govemar Drive Assembly ~ Front Right 5.00 ~14 Figure 5,00-32. Governor Drive Housing .... 5.00 ~ 15 Figure 5.00-38, Oi! Line And Hall-Etfect Pickup 500-15 Figure 5.00-34. Governor Rod 500-16 Figure 5,00-35, Governor Rod ~ G, GS! Engines 5.0016 Figure 5.00-36. Governor Rod ~ GL Engines (Throttle Control Shown Instaliea) 5.00 16 Figure §,00-37. Governor Rod - GL Engines (Throttle Control Shown Installed) 500-17 Figure §.00-38. UG-8L Governor Assembly . 6.00 - 17 Figure 5.00-99. Governor Assembly 500-17 Figure 5.00-40. UG-8L Govemor Linkage .. 5.00 - 18 Figure 5.00-41. UG-8 Governor Linkage ‘Adjustment Information For §108GL, 5790GL And 7042GL 500-19 Figure 5.00-42. UG-8 Linkage Adjustment Information For 5108GL, 5790GL And 7042GL ~ Low Pressure Fuel, Draw Thru Carburetion 8.00-19 Figure 5.00-43, Angle Finder In “No Fuel Position 5.0020 Figure 5.00-44. Governor Rood ~ G, GSI Engines Figure 5.00-45, Governor Rod - GL Engines, (Throttle Controt Shown Installed) Figure 5.00-48. Govemor Rod - GL Engines ‘(Throttle Control Shown installed) Figure 5.00-47, Governor lod Figure §.00-48. Woodward UG-8L Governor Figure 5.00-49, Woodward UG-8L Governor ~Top View Figure §.00-50. Governor Rod Figure 5.00-51. Governor od ~ G, GSI Engines Figure §.00-52. Gevernor Red ~ GL Engines (Throttle Control Shown installed) Figure 5.00-53. Governor Rod ~ GL Engines (Tarotie Control Showa Installed) Figure 5.00-54. Governor Figure 5.00-58. Governor Assembly Figure 5.00-56. Governor Rod Figure 5.00-57. Governor Rad ~ G, GSI Engines Figure 5.00-58. Governor Rad ~ GL Engines {Throttle Controi Shown Installed) Figure 5.00-59. Governor Rod - GL Engines (Throttle Contro! Shown installed) Figure 5.00-60. Governor Rod Assembly Figure 5.00-61. Woodward UG-8 Dial Govamor Figure 5.00-62, EG-3P Governor Rod Figure 5.00-63. Governor Rod ~ G, GSIEngnes Figure §.00-64, Governor Rod ~ GL Engines (Throtle Control Shown Installea) Figure 5.00465, Governor Fiod - Gl (Throttle Control Shown installed) Figure 5.0066. Splined Connector Figure 5.00-67. Governor Drive Figure 5.00-68, Governor Drive Internal View Figure §.00-69. Governor Drive Figure 5.00-70. Spiined Connector Figure 5.00-71. Gasket Figure 5.00-72. EG-3P Governor Bottom View Figure 5.00-73. Ring Gear Tooth Alignment Figure 5.00-74. Install Magnetic Pickup ‘Sensor Figure 5.00-75, Governor Fiod Assembly Figure 5.00-76, EG-S° Govemor Linkage ‘Adjustment Information For STOBGL, 5790GL And 7042GL, aines 500-20 5.00 -20 500-21 500-21 500-22 5.00 -24 5.00 ~25 5.00 -25 500-25 5.00 - 26 5.00 -26 5.00 -27 5.00 -27, 5.0028 500-28 5.00-28 5.00 -28 5.00 -29 500-31 500-31 500-32 500-92 5.00 -32 5.00 ~33 500-34 5.00 -35 5,00 -36 5.00 - 36 5.00 -36 5.00 -36 5.00 -37 500-37 6.00 - 98 Form 6248 iret EatonILLUSTRATIONS Figure 5.00-77, EG-GP Linkage Adjustment Information For 5108GL, 5790GL And 7042GL. ~ Low Pressure Fuel, Draw Thru Carburation Figure 5.00-78. Governor Rod Figure 5.00-79, Governor rod ~ G, GSI Engines . Figure 5.00-80. Governor Rod ~ GL Engines (Throtle Control Shown Installed) Figure §.00-81. Governor Rod ~ GL Engines (Throttle Control Shown Installed) Figure 5.00-82, Orientate Manual Shutdown Lever Figure 5.00-83. Lock Manual Shutdown Lever Figure 5.00-64. Governor Rod ~ GL Engines (Throttle Control Shown Installed) Figure 5.00-85, Butterly Valve Linkage Adjustment ~ L5108G, LS730G, 70426 Engines Figure 5.00-88. Overspeed Pressure Switch Figure 5.00-87. Overspeed Governor Figure 5.00-88. Overspeed Governor Figure 5.00-89. Overspeed Pressure Switch Figure §.00-80. Tachometer/Hour Meter Figure 5.00-91. Hour Meter Figure 5.00-92. Nylok Plugs Figure 5.00-93, Tachometer Drive Assembly Figure 5.00-94, Tachometer/Hour Meter Figure 5.00.88. Magneto Drive Assembly ~ Front Right Figure 5.00-96, Nylok Plugs Section 5.05 — Fuel System Figure 5.05-1, Fuel System Diagram - G Figure 5.052, Fuel System Diagram ~ GSI Figute 6.05-3. Fuel System Schematic ~ GL Figure 5.05-4, Fisher 99 Main Fuel Gas Prossure Regulator ~ Coss Sectional View Figure 5.05-5. 95. Prechamber Regulator — Cross Sectional View Figure §.05-6. Butterfly Cross Shaft ‘Assembly Figure 5.05-7, Crankcase Center Bores — GIGSI — Right Bank Figure 5.05-8, Universal Joint Dise Spider Figute 5.05-9. Carburetor Cross Shaft ‘Assembly Figure 5.05-10, Crankcase Center Bores — GL ~ Right Bank Figure 5.05-11, Universal Joint Disc Spicer 5.00 -38, 5.00-38 500-39 5.00 ~ 40 5.00 - 40 500-41 500-41 500-41 5.00 - 42 5.00 -42 5.0043 5,00 -43 500-44 5.00 - 44 5.00 - 44 5.00 - 45 5.00 - 45 5,00 ~ 46 5.00 46 5.00 - 46 808-1 505-2 505-3 505-4 505-6 505-6 505-7 505-7 505-8 505-8 505-8 Figure §.05-12. Prechamber Cross Pipe ~ Right Bank Figure 5.05-13. Prechamber Cross Pipe — Left Bank Figure 5.05-14, Prechamber Cross Pipe Retainer Figure 5.05-15. Cross Pipe Tee Figure 5.05-16. Prechamber Cross Pipe — Lett Bank Figure 5.05-17. Carburetor Assembly — Gicsi Figure 5.05-18, Ai/Gas Valve Assembly Figure 5.05-19. AivGas Valve Figure 5.05.20. Carburetor Cross Shaft Assembly Figure 5.05.21. Carburetor Assembly - GL Figure 5.05-22. Air/Gas Valve Assembly Figure 5.05-23. AifGas Valve Figure 5.05-24, Carburetor Bonnet Battle Welds Figure 5.05.25. Carburetor ~ Left Bank Figure 5.0526. Carburetor Cross Shaft ‘Assembly Figure 5.05.27. Buttery Valve G/GSI Figure 5.05-28, Admission Valve Assembly Figure 5.05-29. Spring Seats in Cold Poppets : Figure 5,05-20. Instal Stainless Steel Washer In Cylinder Head Figure 5.05-31. Precnamber Pullor Assembly ..seeceos- Figure 5.05-92. Precnamber Puller ‘Assembly Figure 5.05-33. Prechamber Puller ‘Assembly Figure 5.05-34. Install Prechamber Cup Figure 5.05-86. Prechamber Gas Supply ~ Left Bank on Figure .05-36. Prechamber Manifold Figure 5.05-97. Prechamber Manila Figure 5.05-38. Fisher 99 Regulator Tube Connections - GS! Figure 5.08.39. Fisher 99 Regulator Tube ‘Connections ~ GL. Figure 5.05-40, Balt Holes In Engine Block 1. Fisher 99 legulator = Right Bank Figure 5.05-42, Fisher 99 Regulator Mounting ‘Orientation ~ Right Bank ~ Top View Figure 5.05-43, Main Fuel Gas Regulator ~ Fight Bank Figure 5.05-44. Carburetor Gas Init Right Bank 505-9 505-9 5.05 ~ 10 5.05 ~10 5,05 ~10 505-11 5.05 ~12 5.05 ~ 12 5.05 ~13 505-15 505-16 5.05 -16 5.05 ~ 16 5.05 ~17 5.05 18 5,05 ~ 18 5.0519 5.05 ~20 6.0520 505-21 505-21 5.05 -22 5.05 ~22 505-23 5.05 -23 = 5.0524 5.05 - 25 505-25 5.05 25 5.05 26 5.05 26 5.08 -26 5.05 -27 Form 6246 Fret EatonILLUSTRATIONS Figure 5.05-45, Dresser Elbow Coupling .... 5,05 - 27 Figure 5.05-46. Dresser Elbow Coupling .... 5.05 - 27 Figure 5.05-47. Fisher 99 Regulator Tube Connections - GSI 5.05 - 28 Figure 5.05.48, Fisher 99 Regulator Tube Connections ~ GL ...... 5.05 - 28 Figure §.05-49, Fisher 99 Regulator Bracket — Loft Bani 5.05 ~28 Figure 5.05-50, Fisher 89 Regulator Mounting ‘Orientation ~ Left Bank = Top View ..... 5.05~ 28 Figure 5.05-51, Prechamber Regulator ~ Front Right 5.05 -29 Figure 5.05-52. Prechamber Regulator - GL 5,05 -29 Figure 5.05-53. Prechambor Regulator ..... 5.05 -30 Figure 5.05-54. Prechamber Regulator ‘Mounting Bracket 5.05 -90 Figure 5.05-55. Intake Manifold Flange ‘Attachments ~ Fight Bank 5.05 -31 Figure 5.05-56. Prechamber Regulator - Front Right 505 -31 Figure 5.05-57. Prechamber Regulator/Manifold Tue Connections ~ GL. 5.05 - Figure 5.05-58. Prechamber Gas Supply ~ Lett Bank 5.05 -93 Figure 5.05-59. Fisher 99 Regulator Fue! Gas Fiter + 505-33 Figure 5.05-60, Fisher 08 Regulator Fiter ... 5.05 - 34 Section 5.10 ~ Ignition System Figure 5.10-1. Spark Plug Carriers 510-1 Figure 5.10-2, Spark Plug Carrier Removal Too! 510-2 Figur §.10°. Spark Pl Cartier Removal Too! 510-2 Figure 5.10-4. install Spark Plug Carrier ..... 5.102 Figure 5.10-5. Spark Plug Cartier Extractor Tool : 510-2 Figure 5.10-6. install Spark Plug Cartier ..... 510-3 Figure §.10-7. CSA Spark Plug 510-4 Figure 5.10-8. instal Spark Plug/Connections 5.106 Figure 5.10-9. Install Spark Plug/Connections PIN 211357H Extension 510-6 Figure 5.10-10. VHP Spark Plug Recess Cover 510-9 Figure 5.10-11. VHP Spark Plug Recess | Cover Vent Cap 510-9 Figure 5.10-12. Spark Plug Connector Tube . 6.10 - 10 Figure 5.10-13, ignition Coll Brackets 510-11 Figure 5.10-14, Prochamber Manifold Bracket - Front Lett 510-12 Figure 5.10-15, ignition Coil Brackets 510-12 Figure 5.10-16. Coil (PIN 69694, Blue Goll) . 5.10 - 12 gue 10-17. rangle ion Co Bracket Figure 5.10-18. Wire Harness Ascomoly Figure 5.10-19, Hames Cable Clip — Front Right Figure 5,10-20, Electronic Ignition System Diagram Figure 5.10-21. Wire Hamess ~ Right Bank ~ 510-13 510-14 810-14 510-16 Carburetor And Intake Manifold Removed For Clarity Figure §.10-22. Wire Hames — Front Right Figure 5.10-23, Wire Hamess Cable Clip Locations Figure 5.10-24. Retaining Ciip Figure 8.10-25. Attaching Cable Clip Suppor Braces Figure 5.10-26, Triangular Ignition Coit Bracket Figure 5.10-27. Magneto Pin Connector Cable Figure 5.10-28. ignition Modula Figure 5.10-29. Mounting Brackets Figure 5.10-30. ignition Module Figure 5.10-31. Governor Drive Housing Figure §.10-92, Hall-etfect Pickup Figure §.10-93. Current Production CEC “Timing Dise Figure 5.10.94. Current Production Governor Drive Gear Figure §.10-95. Current Production Tering Too! Figure 5.10-36. Fiywhee! Timing Opening Figure 5.10-97. Current Production CEC Timing Dise Figure 5.10-98. Current Production CEC. Timing Dise Figure 5.10-38. Flywheel Timing Opening Figure 5.10-40. Current Production Timing Too! Figure 5.10-41. Current Production CEC Timing Dise| Figure 5.10-42. Current Production CEC Timing Dise Figure 5.10-48. CEC Ignition Module Timing Switches Figure 5.10-24. Flywhee! Timing Opening Figure 5.10-45, Governor Drive Housing Figure 510-46, Hall-Ellect Pickup Figure 5.10-47. Previous Production GEC Timing Dise Figure 5.10-48, Previous Production Governor Drive Gear Figure 5.10-49. Governor Drive Gear 510-17 5810-17, 510-17 5.10-16 510-18 510-18 510-18 510-19 510-19 510-19 5.1020, 5.1020 8.10 -20 5.10 -20 5.10 -21 510-21 810-22 510-22 510-23 5.10 -23 510-23 510-24 510-26 5.10 ~25 510-26 510-26 5.10 ~26 510-26 510-27 Form 6248 Firs EatonILLUSTRATIONS Figure §.10-80. Previous Production CEC Timing Dise Foure 5.1051, Previous Prodicton CEC Timing Disc Figure 5.10-52. Governor Drive Housing Figure 5.10-58, Previous Production Timing Disc Figure 5.10-54. CEC Igniton Module Rotary Switches A and B Fique 510-55, MagnetaNagneto Adapter Flange Bolts Figure 5.1058. MagnetonMagneto Adapter Figure 5.10-57. Magneto Drive Disc Coupling Figure 5.10-58, Magneto Drive Adapter Cover Studs Figur 5.1059, Engine Fng Order - 12 Cylinder Figure §.10-60. Nameplate - Current Production Figure §.10-61. Nameplate - Previous Production Figure 510-62. Rotation Plate Front Flywheel Housing ~ Right Bank Figure 5.10°63. Timing Pointer — ear Right Figure §.10-64, Timing Tape Figure 5.1065, Magneto Drive Disc Coupling Figure 6.10-68, Magneto Drive Disc Coupling Shims . Figure 5.10-67. Magneto Stat Ting Figure 5.10-68, Magneto/Magneto Adapter Figure 5.10-69, Magneto Drive Assembly Figure 5.10-70. Magneto/Magneto Adapter Flange Bolts Figute 6.10-71, Magneto Adapter Assembly Figute 510-72, Magneto Adaptor Assembly Figure 5.10-73, Magneto Drive Assembly . 510-27 510-27 510-28 510-28 510-28 510-31 510-31 510-31 510-92 5.1092 510-33 510-33 510-34 510-34 - 810-34 510-35 510-35 510-36 5.1036 510-96 510-37 510-39 510-38 510-42 Section 5.15 - Air Induction System Figure 5.15-1, Air Cleaner Assembly Figure 5.15-2. Air Cleaner Assembly Figure 5.15-2, Air Restriction Indicator/Fiter — GLIGSI Mode's Shown Figure 5.15-4, Restriction Fiter Figure 5,15:5. Air Ducts ~G Figure 5.15-6. Engine Breather Figure 5.187. Oil Separator Hose Figure 5.15-8, Brace Figue 6.15-9, Capscrew 515-2 515-2 515-4 515-4 515-5 515-6 515-6 515-6 515-7 Figure 5.15-10. Air Ducts - GSVGL Figure §.15-11. Crankcase Breather Tube Figure 5.15+12. Air Duct Brace ~ Left Bank Figure 5.15-13, Air Duct Braces - Right Bank Figure 5.15-14, Air Intake Pipes - G Figure 5.15-15, Air Pipe And Alc Horn Figure 5.15-16. Intercooler Air Outlet Tube ~ si Figure 5.15-17, Intercooler Air Outlet Tube ‘And Intercooler Figure 5.15-18. Intercooler Air Outlet Tube Figure §.15-19. Air Intake Pipe And Carburetor Figure 6.15-20. Intercooler Air Outlet Tube ~ GL Figure 5.15.21. Intercooler Air Oullet Tube Figure 5,15:22, Intercooler Air Outlet Tube (O-ring — Carburetor End Figure 5.15.23. Intercooler Air Outlet Tube ~ Intercooler End Figure §.15-24. Carburetor Air Homn And Elbow Figure 5.15-25. Intake Manifold - G/GSi qu 6.1526 take Maio Flange Attachments Figure 5.15.27 Intake Manifold ~ GL Figure 5,15-28, Intake Manifold Flange ‘Attachments Figure 5.15-29. Wire Harness Cable Clip Locations. Section 5.20 - Turbochargers Figure §.20-1. Turbo Air Outlet Elbow ~ Rear Right Figure 5.20-2. Turbo Air Outlet Elbow ~ Rear Right Figure 5,20-3. Turbo Air Outlet Elbow Figure 5,20-4. Turbo Upper Oil Tube Clip Figure §.20-8. Turbo Clamps .. Figure §.20-6. Turbocharger Figure 6.207. Chock Turbocharger Axa Pay. Figur § 20.8. Chock Turbocharger Racial Play Figure §.20-9, Turbo V-Band Couping Figure 5.20-10. Turbo V-Band Coupling Figure 5.20-11. Turbocharger Torque Specifications Figure §.20-12. Turbocharger Figure §.20-13, Turbo Exhaust Inlot Gasket Figure 5.20-14. Air Duct Braces - Intercooler Figure 5.20-15. Turbo/Exhaust Elbow ‘Connection~ Left Bank 515-8 515-9 515-9 515-9 5.15 - 10 515-10 515-11 815-11 515-11 515-12 5.15 ~12 515 ~12 - 815 ~13 515-13 515-13 515-14 5.15 -16 515-18 515-19 515-21 5.20 - 520-1 520-1 520-2 520-2 520-2 520-4 5.20- 520-6 520-6 520-7 520-8 520-8 520-8 520-9 Form 6248 Fist ationILLUSTRATIONS Figure 5.20-16, V-Band Coupling 520-9 Figure 5.20-17. Lower Turbo Oil Drain Tubes . 620-9 Figure 5.20-18, TV94 Turbo Oil Suppiy/Drain Flanges . 520-9 Figure 5.20-19, Turbo Oil Supply Tubes .... 5.20-10 Figure §.20-20, Turbo Upper Oil Supply Tubes 520-10 Figure §.20-21. Turbocharger Alignment .... 520-10 Figure 520-22. Turbocharger Alignment .... §.20-11 Figure §.20-23, Turbo Air Outlet Elbows .... 5.20— 11 Figute 5.20:24, Turbo Air Outlet Elbow ..... 5.2011 Figure 5:20-25, Turbo Air Outlet Elbow ~ Rear Fight 520-1 Figute 520-26, Turbo Air Outlet Elbow — Fear Right 520-12 Section 5.25 - Cooling System Figure 525-1, Water Outet Hole 525-1 Figute 625-2. VHP Twelve Cylinder Cooling ‘System ~ Cutaway View 525-2 Figure 5.25-8. VHP G Engine Cooling System ‘Schematic - Standard Jacket Water Temperature 525-3 Figure 5.25-4. VHP G Engine Cooling System ‘Schematic - Elevated Jacket Water Temperature Figure 5.25-5. VHP GSI Engine Cooling ‘System Schematic - Standard And Elevated Jackel Water Temperatures Figure 5.25-6. VHP GL Engine Cooling ‘System Schematic ~ Standard And Elevated Jacket Water Temperatures Figure 5.25-7. 12 Cylinder Cluster ‘Thermostat Housing «525-7 Figure 5.25-8. Auxliary Cooling Water Circuit 6.25 -7 525-4 525-5 525-6 Figure 5.25-9, Intercooler Flow 525-8 Figure §.25-10. Auxiliary Cooling Water ‘Tomperature Control Valve 525-9 Figure 5 25-11. Customer Supplied Ball Valve 525-12 Figure 5.25-12.luler Pulley Bearing Lube... 525-17 Figure 5,25-13. Auxiliary Water Pump Pulley Lube 525-17 Figure 5.25-14. Agjusting/dler Lever Assembly 525-18 Figure 5.25-15, Tighten Idler Pulley Bracket Bolts 525-18 Figure 5.25-16. Jacket Water Pump Drive Belt Tension Tester 525-19 Figure 5-25-17. Jacket Water Pump Drive Belt Tensioning 525-20 Figure 5.25-18, Jacket Water Pump Drive Belt Tension Figure 5.25-19. Adjusting/dler Lever ‘Assembly Figure 5.25-20. Auxiliary Water Pump Belts Figure 5.25-21. Jacket And Auxilary Water Pump Belts : Figure 5.25-22. Jacket Water Pump Drive Belt Tension Tester Figure 5.25-23. Jacket Water Pump "Weep" Hole ~ Water Pump Shown Removed Figure 5.25-24, Water Pump Figure 5.25-28. Crankcase Welter Inlet Flange 7 Figure 5.25-26. Water Pump Iniet Elbow ~ Left Bank Figure 5.25-27. Water Header Assembly ~ Front Left Figure 5.25-28. Water Heador Assembly Couplings Figure §.25-29. Water Pump Inlet Elbows Figure 5.25-90. Dresser Coupling Figure 5.25-31. Water Bypass Tubes, Figure 5.25-92. Bypass Tubes ~ Front Left Figure 5.25.93, Water Bypass Elbows . Figure 5.25-34, Dresser Coupling Figure 5.25-95, Bypass Tubes ~ Front Lelt Figure §.25-98. Exhaust Manifold Flanges — Rear Left Figure § 25-37. Water Manifold Figure 5.25-98, Water Manifold Bracket ~ Front Lett Figure 525-39. Water Manifold Mounting Brackets Figure 5.26.40. Flexmaster Coupling Figure 5.25-41. Water Manifold ~ Front Figure §.25-42. Water Outlet Eloow Figure 5.25-48. Water Manifold Connections Figure 525-44, Water Manifold Bracket — Front Lett, Figure 5.25-45. Water Manifold Mounting Brackets Figure §.25-46. Water Manitold Bracket — Rear Lett Figure 5.25-87. 12 Cylinder Cluster Thermostat Housing Figure 5.25-48. Thermostat Testing Figure 5.25-48. Thermostat Open And Closed Figure §.25-60. Jacket Water Thermostats — PIN 208627 Series Figure 5.25.51. Jacket Water Thermostats — PIN 208680 Serios 525-20 525-21 525-21 525-22 525-22 525-23 525-24 525-25 525-25 5.25 ~26 525-26 5.25 ~26 525-27 525-28 525-29 525-29 525-30 5.2530 525-31 525-31 525-34 525-34 5.25 ~35 525-96 525-96 5.25 96 Form 6248 First EatonILLUSTRATIONS Figure §.25-52. Thermostat Seal Figure 5.25-53. 12 Cylinder Cluster Thermostat Housing ~ Bottom View Figure 5.25-84. (die Pulley Bracket Figure §.25-58. Idler Pulley : Figure 5.25-66. ldler Pulley Shaft Removal Figure 5.25-57, Cover Removal Figure 5.25-58, Remove Bal! Bearing/Shatt Assembly Figute 5.25-59, Grease Seal Removal Figure 5.25-60, Idler Pulley Ball Bearing/Shaft Assembly Figure 5.25-61. idler Pulley Shaft Figure §.25-62. idler Pulley Ball BearingiShatt ‘Assembly Figure 5.25-69. ldler Pulley Bracket Vent Hole Location Figure 5:25-64,laler Pulley Brackot Figure §.25-65, Water Drain Petcock Front Right Figure 5.25-66. Lifting The Jacket Water Pump Figure 5.25-67. Water Pump Cover And Cover Gasket Figure 5.25+68. VHP Water Pump Assembly Figure 5.25-69, Jacket Water Pump Shatt Figute §.25-70. Jacket Water Pump Service “Too! Kit PIN 474013 Figure §.25-71. Press Bearings Onto Shatt Figuie 5.25-72. Pack Water Pump Bearings Figure 5.25-73, Open (Lipped) Side Of Carriers Figure 5.25-74. Install Inner Grease Seal Figure 5.25-75. Install Shaft And Bearing ‘Assembly Figure 5.25-76, Install Retaining Ring/Outer Grease Seal Figure 5.25.77. Pulley Hub Wear Sleeve Figure 5.25-78, Install Pulley Hub Wear ‘Sleeve 5 Figure §.25-79. Water Pump Seal Assembly Figuee 6.25-80. Install Ceramic Seal Figure 5.25481, Install Carbon Seal Figure 5.25-82. VHP Water Pump Assembly Figure 5.25-89. Check Impeller Clearances. Figure 5.25-64, Jacket Water Pump Figure 5.25-85. Water Pump Mounting Flange Figure 5.25-86. Water Pump Cover And Cover Gasket 525-97 525-38 5.25 -39 525-99 525-39 525-40 525-40 525-40 525-41 525-41 525-42 25-43 525-43 525-44 525-44 525-44 5.25 ~45 525-47 525-47 525-47 525-48 5.25 -49 525-49 525-49 525-50 525-51 525-51 525-51 525 525-52 525-53 525-53 525-54 52 525-54 525-54 Figure $.25-87. Install Water Pump Cover Gasket Figure 5.25-88. Water Pump Cover And ‘Cover Gasket . Figure §.25-89. Water Drain Petcock ~ Front Right Figure 5.25-90. Lifting The Jacket Water Pump Figure 5.2591, Front Pulley Guard Figure 5.25-92. Left Hand Belt Guard Panel Figure 5.25-93. Right Mand Bolt Guard Panel . . Figure §.25.94, Auxiliary Water Pump Belt Guards Figure 5.25.96. Inner Auxliary Water Pump Bolt Guard 7 Figure 5.25-96. Auxiliary Water Temperature Control Valve Figure 5,25-97. Auxiliary Cooling Water ‘Temperature Controt Valve ~ All Models, Figure 5,25-08. Turbo Oil Supply Tube ~ Roar Lett ..... Figure 5.25.99. Intercooler Bonnet ‘Allachments ~ Right Bank Side Figure §.25-100, Turbo Clamps Figure 6.25-101. Intercooler Connections ~ Top : Figure 5.25-102, Intercooler Wastegate Tube Connections Figure 5.25-103. Intercooler Connections ~ Left Bank. Figure §.25-104. intercooler Connections Figure §.25-105. Compressor Discharge Tube Figure 5.25-108. Y-Branch Figure §.25-107. Flexmaster Elbow Coupling Figure 6.25-108. Intercooler Mounting ~ Rear Lett Figute 5:25-109. Intercooler Removal Figure §.25-10. Intercooler Connections ~ Lett Bank Figure 5.25-111. Intercooler Connections Figure 5.25-112. Support Rails Figure 5,25-113. Intercooler Connections. Figure 5.25-114, Inter ooter ~ 12 Cylinder Engines Figure §.25-115, Intercooler Connections Figure 5.25-116, 455 Ell Dresser Coupling Figure §.25-117. intercooler Piping Figure §.25-118, 455 Ell Dresser Coupling Figure 5.25-119, Suppor Rails Figure §.25-120, Intercooler Connections 5.25 ~55 5.25~55 525-55 525-55 5.25 ~56 5.25 ~56 5.25 ~56 525-57 525-57 5.2558 5.25 -59 5.25 ~60 525-61 525-61 525-62 5.25 ~62 525-63 5.25 - 63 5.25 -63 5.25 -63 525-64 525-64 5.25 -64 525-65 525-65 525-65, 5.25 -65 525-66 525-67 5.25 -67 5.25 -67 - 825-68 5.25 -68 5.25 -69 Form 628 Fret EonFigure 5.25-121. Intercooler Connections Figure 5.25-122. Compressor Discharge 525-69 ILLUSTRATIONS Section 5.30 - Lubrication System Figure §.90-1. External Lube Oli Schematic ~ Pressure Sensing Tubes Support Braces 5.25 ~ 69 Blencng Tyee on Figur 5 25-123. ntrcoolerWastegate Figure 5.202. Lube Ol Temperature Control “Tube Connections 525-69 Vave 590-1 Figure 5.25-124, Wastegate Connections ... 5.25 -70 Figure 6.0.3. Prossure Regulating Vale... 5.20 ~2 Figure 5.25-105.Flexmaster Elbow Figute §.30-4. Lube Oi Strainer 590-2 Coupling 525-70 Figure §:305. internal Oi Cont! 530-3 Figure 5:25-126. iting The Intercooler... 6:25 71 Figute 5.006, Petcock At Lube Fier inlet ... 5.208 Flute 5,25-127 Intercoolor Mounting ~ Figute 5.207. VHP Ol Filer Pipe 590-11 Rear Left 525-71 Figure 5.30-8. Dipstick 5.30 - 12 Figure 5.25-128. Lower Turbo Oi Drain Figute 5.20-9. Lube Oi Fier 590-14 Tubes . $25-71 Figure 5.30-10, Full-Flow Lube Oil Fiter 530-14 Figure 5.25-129. Upper Turbo Oil Drain Figure 5.30-11. Filter ElemenvRelief Tubes 525-72 Valve Coniiguration 590-14 Figure 5.25-130. Turbo Oil Supply Tube ~ Figure 5.30-12. Lube Oil Filter Relief Valve Rear Left 525-72 ‘Ascombly 590-15 Figure 5:26-191, Y-Branch 525-73 Figure 590-13, Magnetic Pugs 5.20-16 Figure 5.25-192. Assemble Intercooler Figure 6.20-14, Ol Cooler Ping Water SuppiyFiowrn Pipe Clamps ..... 6.2573 Connections 520-18 Figure 5 25-193. intercooler Water Figue 5.30-18. Ok Cooler Assembly 520-20 ‘SuppiyRetum Pipes - Tiveaded Ends . 6.25 ~74 Fae 52046 Le Oi Temperate Figure 5.25-134, Install Intercooler Water Control Valve 530-21 ‘Supply/Return Pipe Clamps - Rear 5.25 -74 Figure 5.30-17. Thermostat “Testing 5.30-21 Figure 5 25-195. nstal Intercooler Water Figute 5.30-18, Thermostat Open And SupplyiRetum Pipe Carpe Front... 525-74 Closed 590-22 Figuio 5.25-436 niereocer Water Figure $.00-18. Thermostatic Valve 590-22 ‘SupplyiRelura Pipes 525-75 Figure 5:30:20 Lube Oi Temperature Control Figure §.25-197. Insal Intercooler Water Valve 12 And 16 Cylinder Engines... 530-23 ‘Supplyietur Pipes 525-75 Figure 5:20:21. Lube Oi Temperature Control Figure 5.25-138. Intercooler Water Return ian) 530-23 Pipe ~ Front Loh 525-75 Figure 5.3022, Prelube Oi Pressure Relct Figure 5.25-139, Intercooler Water Retun Moll a Pies Flange oe Powe 3.3023 Pree MaerPump ‘Assombly 530-26 Figure 5 25-140. ntercoolor Wator Return, ips Flange pone Figure 5.90-24. In-Line Lubricator 5.30-27 eee ears Figure 5 0-25. 04 Pickup Sereen oe ‘Assembly 12 Cynder 520-28 Es Figure 5.20-26. Fastening Flange Adapter .. §30~29 Figure 5.25-142 nlercooler Water Su Sips - Front Left belo Figure 5.30-27. Lube Oil Pump Manifold Figure 5.25-143. Intercooler We creck Vee re Se a ene Figure 5.0.28, Rit Valve 520-30 Figure 5:20:29, Drve Gears 5.00 -30 Figure 525-144. Flexmastor Elbow Couping Figure 5.30-30. Oil Pump Cover Front Gover 5.30 ~ 30 pe Fique 5.20:35, Ol Pump internal Gears .... 50-20 Figee 88106 Ascher Water Pano Figue 5.20-92. Pump Body Bushings ...... §.20-31 Idler And Adjusting Lever 525-78 Faure 50-39. Pump Cover Bushings ..... §.90 -31 Poet nee Figure 5:90-34, Acjustable Boring Tool... 6.30 -32 Bracket 525-78 Figure 5.905, ior Gear 520-09 Figure §.25-149, Adjustingidler Lever Figure 5.30-38, Woodrutt Keys 530-33 ‘Assembly 525-79 Figure 5.30-97. Checking Clearance 520-34 Fam 6008 Frain aILLUSTRATIONS Figure 6.30-38, O11 Pump Internal Gears Figure 6.30-99, Oil Pump Cover Torque Sequence Figure §.30-40, Reliel Valve Figure 5.90-41. Oil Pump Mounting Stud Figure 5.30-42. Oil Pump Gasket Figure §.90-43. Oil Pump Tightening Pattem Figure 5.30-44. Measuring Oil Pump Drive Gear Backlash . Figure 680-48, Lube Oi| Pump Figure 5:30-46, Lube Oil Pump Manifold — Front View Figure 5.30-47, Lube Oi! Pump Manifold Check Valve Figure 6.30-48, Fastening Flange Adapter Figure 5.30-49, Prelube Y-Strainer Figure 5.90-50. Attaching Pipe Tee Figure 5,30-51. Y-Strainer - Front Lett Figure 5.30-52, VHP Oi Filler Pipe Figure 5.30-53. Ol Fler Pipe/Bracket ~ Rear Left Figure 5.3054. Rocker Arm Header Oil ‘Supply ~ Rear Figure 5.30-55, Rocker Arm Header Oil ‘Supply — Rear Veo Figure §.90-86. Oil Supply Tube Clip ~ Rear Right Figure 5.90-87. Rocker Arm Header Oil ‘Supply ~ Front Figure 590-8, Turbo Ot Supp — Rear Right Figuce 5.3058, Pipe Cross Magnet Plug Figure 5.3060. Rear Tube Connections Figure 5.30-61. Main Oil Header Oil Outlet Ports Figure 5.30-62. Governor Drive Oil Supply Front Right Figure 5.30-63. Oil Pan Door - Rear View Figure 5.30-64, 01 Pan Door - Side View Figure 5.30-65. Lube Oil Strainer ~ Rear Rignt Figure 5.9066. Lube Oil Strainer Assembly . Section 5.35 — Exhaust System Figure 5.35-1. Exhaust Thermocouples “Arrangement ~ 12 Cylinder Foue 836-2 Erhaust Themocoue~ Rear Lett gute 5.358. Thermocouple Brackat Figure 5.35-4. Water Outlet Elbows ~ Rar Fight 530-34 - 530-34 530-34 530-37 530-87 530-37 50-38 530-98 530-39 50-39 530-99 530-40 530-40 530-40 530-41 530-41 530-42 8.90 -42 5.0 - 42 5.2043 5.30 -44 530-44 - 530-44 530-44 530-45 530-45 5.20 - 45 8.30 ~46 530-47 595-1 535-9 - 605-3 625-3 Figure 5.95-5, Water Outlet Elbow Gaskets Figure 5:35-6, Exhaust Manifold - Rear View Figure 5.95-7, Exhaust Manifold ~ GL Shown Figure 5.35-8, Exhaust Manifold Gasket Figure 5.35-9, Exhaust Manifold ~ Rear View Figure §.35-10. Exhaust Manifold — Leff Bank Figure § 35-11, Prolube Motor Air/Gas Supoly Tube Figure §:36-12. Exhaust Manifold End Sections ~ Left Bank 525-4 535-4 535-5 535-6 535-6 535-7 535-7 938-7 Figure §.95-13, Breather Tube And Intercooler Tubes Figure 5.35-14, Water Outlet Elbow Gaskets Figure 5.35-18, Exhaust Manifold — ight Bank Figure 5.35-16. Water Outlet Elbows ~ ear Right Figure 5.95-17, Exhaust Manifold — Front Figure 5.35-18, Exhaust Manifold ~ Let Bank Figure 5.35-19. Thermocouple Connector ~ Rear Right. Figure 5.35-20. Turbo Exhaust Roar Lett Figure 5.36-21, Turbo Exhaust niet Elbow ~ ear Right ~ G/GSI Engines Figure 5.35-22. Turbo Exhaust inlet Elbow Figure §.35-23. Turbo Exhaust iniet Elbow Roca anes Figure §.35-24. Turbo Exhaust Inlet Elbow Caceres Figure 5.95-25. Turbo Exhaust Inlet Elbow Figure 5.95-26. Turbo Exhaust Inlet Eloow ~ Rear Left : Figure 5.35-27. Exhaust Connections - G Figure §.35-28, Exhaust Connections ~ @sieL : Figure 5.95-28. Exhaust Elbow Assembly Figure §.35-30. Check Exnaust Elbow For Straightness Figure §.35-31. Exhaust Elbow Adapter Figure §.35-2. Exhaust Thermocouple ~ Rear Lett Figure §.95-3. °K" Type Thermocouple Figure §.35-34. °K’ Type Thermocouple Figure 5,95-35, Exhaust Thermocouple Installation . Figure 5.95-36. Thermocouple Conduit Fear Right Figure 5.35-37. Exhaust Thermocouples ‘Arrangement - 12 Cylinder Figure §:35-98. Exhaust Thermocouple Installation Figute 535-09. itercooier"Wastegate Tube ‘Connections Elbow — 525-8 535-8 535-8 535-9 535-9 535-9 535-9 535-10 5.35 ~ 5.35~10 535-11 535-11 835-11 535-12 5.35 13, 535-14 - 835-15. 5.35 -15 5.35 = 15 5.35 -16 5.35 - 535-17 595-17 535-18 5.35 ~18 5.25 -19 535-20 Form 6248 Fret EatonILLUSTRATIONS =. TOTO eer S Figure 5.95-40. Wastegate Breathor Vent Figure 5.95-41. Wastegate Disassembly Figure 5.35-42, Wastegate - IN Series 208372 ~ Bottom View Figure 5.95-49. VHP Wastegate ~ PIN Series 208372 ~ Cutaway Figure 6.95-44. Wastegate Breather Vent Figure 5.35-45, Wastegate Assembly Figure 5.95-46. Wastegate — PIN Series 208372 ~ Bottom View Figure 5.35-47, PIN Series 208972 ‘Wastegate Calibration Too} Figure §.35-48. P/N Series 208372 Wastegate Calibration Figure 5.95-49, P/N Series 208372 Wastegate Calibration Too! Figute 5.95-50. PIN Series 208372 Wastegate Calibration Setup Figure 5.35-51. Wastegate Calibration ‘Setup Figure 5.35-52. Inlercooler/Wastegate Tube Connections Figure 6.3553. Intercooler/Wastegate Tube Connections Figure 5.35-54, Wastegate Adjusting Figure 5.9555, Wastegate Gasket Removal Figure 5.35-56, Wastegate Poppet To Wastegate Mounting Face Measurement Figure 5.35-57. Wastegate Adjusting — PIN Series 295645 Figure 5.95-58. Wastegate Connections ‘Section 5.40 ~ Crankcase Breather System Figure .40-1.01 Separator— 12 Cynder Engines Figure 5.40-2. Breather Regulator Assembly ~ Current Style Figure §.40-9. Venturi Extractor/Choke Valve ‘Assembly ~ GL Shown Figure 5.40-4. Venturi Assembly — GSI Shown Figure 5.40-5. Install Water Manometer Tube Connector Figure 5.40-6. Vacuum Valve Assembly ~G Figure 5.40-7. Vacuum Valve Assembly ~ GSI Figure 5.40-8. Venturi Exractor/Choke Vaive ‘Assembly — GL Figure 5.40-9. Venturi Extractor/Choke Valve ‘Assembly ~ GSI : Figure 5.40-10. Venturi Extractor Assembly - 835-21 595-21 595-22 8.38 -22 595-23 5.35 -24 595-25 5.95 ~25 536-26 535-26 5.3526 535-27 595-28 535-26 535-28 5.35 30 535-90 535-30 5.35 ~92 540-1 540-2 540-2 540-2 540-3 540-3 540-3 540-4 540-4 540-5 Figure 5.40-11, Crankcase Separator Seren ‘Assembly ~ 12 Cylinder Engines ~ GL Shown 540-6 Figute 540-12. Grankcase — Rear ight .... 540-6 Figure 5:40-13, Ol Separator - G 540-7 Figure 5.40.14. Oi Separator Ascombiy Unthreaded Oi inet Pipe -GL Snown .. 540-6 Figure 5.40-15, Ol Separator Assombly, ‘Threaded OitIniot Pipe ~ GSUGL 540-9 Figure 5.40-16. Breather Regulator ‘Assembly ~ GL Shown 540-10 Figute 5.40-17. Breather Regulator Assembly ~All Engines 540-10 Figute 540-18. Venturi Assembly — GSIStown 540-12 Figure 5 40-19. Venturi Extractor ‘Assembly - GSI 540-12 Figute 5.40.20. Venturi Extractor ‘Assembly ~ GL 540-12 Figure $.40-21. Venturi Extractor Assembly . 6.40- 13 Figure 5.40-22. Ventun Extractor Assembly . 5.40 14 Figure 5.40-23, Venturi Extractor Assembly . 5.40- 14 Figure 5.40-24, Venturi Extractor Brackets .. 5.40 ~15 Figure 5 40:26. Venturi Extractor Assembly . 5.40 — 15 Figure 5.40-26. Bicora Pressure Relil Valve 5.40 ~16 Figure § 40:27. Pressure Reet Valve ~ Cross Sectional View 540-17 Figure 5.40-28, Breather Tubes -GS!...... 540-18 Figure 540-29. Suppor Giamp 540-19 Figure 540-90. Breather Tube - Front Veo .. 5.40 ~ 19 Figure 5.40-31. Breather Systom Tube Connectioas ~ GL 540-20 Figure 540-32. Y-Shaped Breather Tube ... 5.40 ~21 Figure 5.40-83, Install Vee Mounted Breather Tube Clamps 540-21 Figure §.40-34, Breather Tube - Front Veo .. 5.40-21 Figute 5 40:98. Breather Tube - Rear Vee .. 540-21 Figute §.40-36. Vontur Extractor Compressor Discharge Plumbing - Gt Shown ...... 540-22 Figure 540-37. Right Bank Compressor Discharge Tube 540-22 Section 5.45 - Air/Gas Prelube And Start Systems Figure 545-1. Prolube/Start Pushbutton Valves 545- Figute 546-2 Prolube And Start AiGas Tube Connections ~ Bulkheas (G/GSUGL) .... 545-2 Figuie 545-3. Plot Operated Pretube Valve Connections 545-3 Figure 545-4, Prelube Motor Pump ‘Assombly 545-9 Figure 545-5, Schematic - Pneumatic Contot ‘System For Air Only Start And Prelube (6.65) 545-5 Form 6248 Frat Eaton eeILLUSTRATIONS Figure §.45-6. Schematic - Pneumatic ‘Control System For AirGas Start And Prolube (G, GS!) Figute §.45-7. Schematic - Pneumatic Control Systom For Air/Gas Start And Prelube (GL) Figure 545-8, Pilot Operated Prechamber Fuel Valves - GL Figure 5.48-9. Shuttle Valve ~ GL Figure 5 45-10. Bulkhead And Connector Brackets Figure 5 45-11. Rear Flywhee! fesse . Reear Right Figure 545-12. BukhneadiConnector Bracket ‘Assembly Figure 5.45-13, Pilot Operated Prelube Valve Rear Right 545-6 = 845-7 545-8 545-9 545-9 545-10 5.48 - 545-10 Figure 5.45-14. Pilot Operated Prelube Valve ~ ear Right Figure 5.45-15, Plot Operated Prelibe Vave Connections Figure 5.45-16, Prelube Motor/Pump Assembly Figue 545-17 Rear Gear Housing - Front Left Figure 545-18, Prlibe MotorPump ‘Mounting Bracket - Rear View Figure §.45-19, Lube Oil Pressure Gauge ‘Connection Figure §.45-20. Prelube/Start Pushbutton Valves Figute §.45:21, Tube Clamp ~ Rear Right Figure 6.45-22, Tube Clamp Support Brace ~ Rear Right : Figure 5.45-23. Tube Clamp ~ Rear Right Figure 6.45-24, Prelube And Start AisiGas ‘Tube Connections ~ Bulkhead (aiasieL) Figure 5.45-25, Pushbutton Valve ‘Connections Figure 5.45-26. Prelube/Start Pushbutton Valves Figure §.45:27 Inka Manitoid Flange ‘Atlachments ~ Right Bank Figure § 45-28. Tube Clip Brackets Fight Bank Intake Manifold Figure 5.45-29, Plot Operated Prechamber Fuel Valves Figure 5.45-30. Lube Oil Pilot Pressure Tube Connection Figure §.45-31, Mount Prechamber Gas valve Figure 5.45.32. Prechamber Gas Valve 545-11 5.45 - 12 545-12 545-13 545-13 5.45 - 14 545-14 545-15 545-15 545-15 5.45 -16 545-17 545-17 545-18 = 8.45 ~ 18 545-19 5.45 -20 5.45 -20, 5.45 20 Figure §.45-33. Ai/Gas Plenum ~ Safety Shutdown Valve + 545-21 Figure 5.4534, AirGas Plenum ~ Safety Shutdown Valve 5.45 21 Figure §,45-95. Prechamber Gas Valve ..... 5.4522 Figure §.45-36. Mount Prechamber Gas Valve 545-22 Figure 5.45.37, Lube Oi Pilot Pressure ‘Tube Connection 5.45 -23 Figure 645-38. Tudo Cp - Right Bank... 545-23 Figure §.45-39. AivGas Starter, 845-24 Figure 5.45-40. Electic Slarter ...- 5.45 -26 Figure §.45-41. Wiring Diagram ~ '0C Junction Box ~ CEC Ignition With Electric Start... 5.45 -27 Figure §.45-42. Wiring Diagram ~ ¢ Junction Box CEC Iition win Air Start 545-28 Section 6.00 - Control Panel Figure 6,00-1, Control Panel ~ Right Side .... 6.001 Figure 6.00-2. Ignition Switch cose 800-1 Figure 6.00-3, Control Panel - Right Side .... 6.00 -1 Figure 6.00-4. Protube And Start AidGas “Tube Connections ~ Bulkhead (GIGSiGL) 6.00-2 Figure 6.00-5, Ignition Switch Wire Hames .. 6.00-9 Figure 6.00-6. Mounting Straps 600-3 Figure 6,00-7. Intake Manifold ~ Right Bank .. 6.00-3 Figure 6.00-8. Pushbutton Valves 600-3 Figure 6,009, Bracket Strap sss 800-4 Figure 6.00-10. Ignition Switch Wire Hamess . 6.00 - 4 Figure 6.00-11. Control Panel Cover 800-4 Figure 6.00-12. ignition Wire Hamess ‘And jgntion Switch ~ Left Side 600-4 Figure 6.00-13. Control Panel 600-5 Figure 6.00-14, Ignition Switch Wire Harness . 6.00 -5 Figure 6.00-18, Wiring Diagram ~ DC Junction Box -CEC Ignition With Electric Start... 6.00 -6 Figure 6.00-16. Wiring Diagram ~ DC ‘Junction Box - CEC Ignition With AirStart 600-7 Section 6.05 - Engine Protection Systems Figure 6.05-1, Lube Oil Inlet Temperature Sensor 6.05 -1 Figure 6.05-2. Jacket Water Temperature ‘Sensor = 605-1 Figure 605-3. Intake Manifold Temperature Sensor 605-1 Figure 6.05-4. Exhaust Thermocouples ‘Arangement 6.05 -2 wx Form 6245 Frei EaiionILLUSTRATIONS Figure 6 05-5. Exhaust Thermocouple — Rear Left 605-2 Figure 6.05-6. Main Bearing Temperature Thermocouples... 605-2 Figure 6.05-7. Wiring Diagram ~ Main Bearing Temperature Thermocouples 605-3 Figure 6.05-8. Wiring Diagram - Thermocouple Junction Box 605-4 Figure 6.05-9. Thermocouple Junction Box ... 6.05 ~6 Figure 6.05-10. Manual Shutdown Switeh ~ Left Side 605-6 Figure 6 05-11. Instrument Panel Gauge Placement 605-8 Figure 6.05-12. Remote Mounted Panel ..... 605-9 Figure 6.05-13. Optional Remote Instrument Panel 605-9 Figure 6.05-14. CEC Detonation Sensing Module 6.05 - 10 Figure 6.05-18. ignition Module With Expansion Port... 6.05 - 10 Figure 6.05-16. Detonation Sensor... 605-11 Figure 6.05-17. Detonation Sensing Module ‘System Wiring Schematic 6.05 ~ 12 Figure 6.05-18, Detonation Sensing Module Front Panel 6.05 -13 Figure 6.05-19. Detonation Sensing Moauie LOD Display : 6.05 ~13 Figure 6.05-20. Remote instrument Panet Connections 605-17 Figure 6.05-21. Remote Instrument Panel Connections 605-18 Section 6.10 — Miscellaneous Equipment Figure 6.10-1, Surge Tank Assembly 610-1 Figure 6.10-2, Water Connection Pipe 610-2 Figure 6.10-3. Overflow Line Support Bracket 6.102 Figure 6.10-4. Filer Cap And Plug 610-3 Figure 6.10-5. Pipe Adapter 610-3 Figure 6.10-6. Sight Gauge fe geo) Figure 6.10-7. Jacket Water Heater ~ Right Side 610-5 Figure 6.108, Jacket Water Heater Left Sige... 610-6 Form 6248 Fret Eaton xiILLUSTRATIONS ox Form 6245 Fiat EatonTABLES LIST OF TABLES Section 1.10 - Rigging And Lifting Engines Table 1.10-1. Engine Ory Weights 410-1 Section 1.15 — General Information Table 1.15-1, Service Tools Table 1.15-2, VHP 12 Cylinder Gas Engine Component Weights Table 1.15:3. 12 Cylinder VHP Torque Values Table 1.15-4. Cylinder Head Capscrows Table 1.15-5. US. Standard Capscrow Torque Values Table 1.15-6. English To Metric Formula Conversion Table Table 1.15-7, Metric To English Formula ‘Conversion Table. Table 1.15-8. Sealants, Adhesives, ‘And Lubricants Section 1.20 ~ Specifications Table 1.20-1, Wear Limits, ‘Table 1.20-2. Cylinder Sleeve (Used With Four Ring Pistons Only) - Gas Table 1.20-3, Piston (Four Ring Only) ~ Gas Table 1.20-4, Piston Pings (Four Fing Piston Only) ~ Gas Table 1.205. PIN 205130L Cylinder Sleeve (Sleeve Used On GL 9-3/8 inch Bore" Only) ~ Gas 115-8 145-10 115-13 115~14 115-16 145-17 45-17 145-18 120-2 120-3 120-4 120-6 120-8 Table 1.20-6. Three Ping Piston (P/N 2055040) (Piston Used On GL 9.318 Bore With PIN 2051301 Liner Only) - Gas Table 1.20-7. Piston Rings (Used On GL 9-3/8 Inch Bore With Three Ring Piston And PIN 205130L Cylinder Sleeve Oniy) - Gas Table 1.20-8, Crankcase ~ Gas Table 1.20-9. Crankshatt Wear Limits Table 1.20-10, Piston Pin ~ Gas Table 1.20-11, PIN Series 205507 Connecting Rod, Bushing And Bearing Specifications, ‘Table 1.20-12. Valve Train Clearances Gas Table 1.20-13. Valve Clearance Table 1.20-14, Camshatt “Table 1.20-15, Valve Springs Form 6248 First Eaton 120-9 120-10 1.20-11 120-12 120-12 120-13 120-16 120-17 120-17 120-18 Table 1.20-16, Crankshaft Web Detlection Measurement With Connecting Rods Installed Table 1.20-17. Rocker Arm Boros And Shafts Table 1.20-18, Rear Gear Backlash ‘Spectications Table 1.20-19. Oil Pump And Ol Pump Drive Gears Table 1.20-20. VHP Accessory Gear Backlash Table 1.20-21, Accessory Drive Ratios Table 1.20-22. Flywheel And Housing Table 1.20-23. Turbo Inspection Table 1.20-24. Lubrication System Pressures Table 1.20-25, Lubrication System Temperatures Table 1.20-26. Lubrication System Engine “Transient Tit Angles Table 1.20-27. Cooling System Temperatures Table 1.20-28, Alarm And Shutdown Setpoints Table 1.20-29. Capacities Table 1-20-90. 1/2 inch Reach Spark Plugs (Used With 1/2 Inch Reach Spark Plug Carriers Only) Table 1.20-91. VHP GL 13/16 Inch Reach Spark Plugs (Used With 13/16 Inch Reach Spark Plug Carriors Oni) Table 1.20-92. Ignition Timing Data (Non-08M) Table 1.20.9. lgniton Timing Data (OSM Equipped) Section 3.00 - Cylinder Head Disassembly Table 3.0041, Rocker Arm Shat Table 3.00-2. Rocker Arm Bushing Bore LO. Table 3.0033. Running Clearance ~ Rocker Arm Bushing To Shalt “Table 300-4 Valve Train Table 2.00.5. Valve Seat inser Grinding Siones “Table 3.06 Valve Seat Win And Face Angle Table 2.00-7, Valve Springs Table 3.00.8. Valve Spring Reterence 120-18 120-19 1.2020 4.20-21 1.2023 120-23 1.20-24 1.20-25 1.20-25 1.20-25 120-25 120-26 120-26 1.2027 120-27 120-28 1.20-20 120-32 300-21 300-22 300-23 3.00 -25TABLES Section 3.05 - Crankcase Disassembly Table 3.05-1. Crankcase ~ Gas 308-2 Table 3.05-2. Cylinder Sleeve Gaskets 305-3 Table 3.05-3. Restoration Sleeve And ‘Crankcase Lower Bore Machining Dimensions .. 305-4 ‘Table 3.05-4, Grankshatt Wear Limits 3.05 -7 Table 3.05-5. Main Bearings 305-8 Table 3.05-6. Camshatt 305-14 Table 3.05-7. Piston (Four Ring Only) ~Gas 9.05~20 Table 3.05-8. Three Ring Piston (PIN 208804D) (Piston Used On GL 9-3/8 Bore With PIN 2051301 Liner Oniy) ~ Gas Table 3.05-9. Piston Rings (Four Fing Piston Only) - Gas, ‘Table 3.05-10. Piston Rings (Used On GL. 9-3/8 Inch Bore With Three Ring Piston And P/N 2051801. Cylinder Sleeve Only) ~ Gas Table 3.05-11, Piston Pin - Gas Table 3.05-12. Series P/N 205507 Connecting Red, Bushing And Bearing Speciications Table 3.05-13. Connecting Rod Weight Classifications: Table 3.05-14, Cylinder Sleove (Used With Four Ring Pistons Oniy) - Gas ‘Table 3.05-15, PIN 2051301 Cylinder Sleeve (Gleeve Used On GL 9-3/8 Inch Bore Oniy) = Gas Section 4.00 - Crankcase Assembly 305-22 3.08 ~28 3.05 ~26 3.08 92 305-34 - 3.05 -98 3.05 ~45 3.05 - 46 Table 4,00-1. Crankshaft Thrust Rings 4.00-27 Table 4.00-2, Rear Gear Backlash Specifications 400-34 ‘Table 4.00-3, Pulleys And Spacers. 4.0087 ‘Table 4.00-4, Attaching Hardware 400-67 Section 4,05 - Cylinder Head Assembly Table 4.05-1. Cylinder Head Capscrews ..... 4.05 -3 Section 4.10 - Valve Adjustment And Web Deflection Table 4.10-1. Valve Settings 410-1 Table 4.10-2. Crankshatt Web Detlection Measurement With Connecting Flods Installed 410-4 Section 5.00 - Speed Governing System Table 5.00-1. UG-8 Governor Linkage ‘Adjustment Information For L5108G, GSI; L5790G, GSI; 170426, GSI 500-20 Table 5.00-2. Governor Speed Droop Setings 500-24 Table 5.00.3, Governor Speed Droop Settings 500-31 Table 5:00-4, EG-3P Governor Linkage ‘Adjustment Information For LSt08G, GS}; L57906, GSI; L70426, Gs 500-98 Section 5.10 - Ignition System Table 5.101. Spark Pug Tools 510-5 Table 5.10.2. Spark Ptug Troubleshooting .... 510-7 Table 5.10. 1/2 inch Reach Spark Plugs (Used with 1/2 Inen Reach Spark Plug Carers Only) 510-7 Table 5.10-4. VHP GL 13/16 inch Reach ‘Spark Plugs (Used Win 13/16 Inch Reach Spark Plug Carriers Only) 510-8 Table 5.10-5, Waukesha Ignition Medule Firing Order 510-24 Table 6.1046. CEC Timing Dise Pin Location (Previous Production) 510-29 ‘Table §.10-7. CEC lgnition Module Rotary Switch Position (Previous Production) .. 610-29 Section 5.15 - Air Induction System Table 5.15-1. High intake Manifold Temperature Settings ° F (°C) 5.18 - Section 5.25 - Cooling System Table 5.25-1. Water Versus Glycol Concentration ...... 7 525-10 ‘Table §.25-2, Other Cooling System Treatments 525-11 ‘Table 5.25-3. Jackot Water Outlet Temperature Settings ° F (°C) 525-11 Table 5.25-4, Jacket Water Capacity Engine Only 525-13 Table 5.25-5. Air Bleed Petcocks 525-14 Table 5.25-6. Water Drain Petcacks 525-15 Table 5.25-7, Jacket Water Capacity ~ Engine Only 525-15 ‘Table 5.25-8. PIN 208660 Series And PIN 199224 Series Jacket Water Thermostats cesses 825-97 Table 5.25-9, PIN 208627 Series ~ Weir Type Jacket Water Thermostats .. 5.25 -97 ‘Table 5.25-10. Auxiliary Cooling Water ‘Thermostat - All Models 525-58 Section 5,30 - Lubrication System ‘Table 5.30-1. Oil Recommendations By Model ‘And Fuel For VHP Series Gas Engines ., 5.30-4 ‘Table 5.30.2, Recommencied Lube Olls For ‘Cogeneration Applications Using Pipeline Quaity Gas 530-5 Form 6240 Fst EatonTABLES Table §.30-3. Recommended Lube Oils For ‘Sour Gas And Allernate Fuel (Lanai) Gas Applications 5.30 Table 5.30-4, Used Oil Testing And ‘Condemnation 530-6 Table §.30-5. Recommended TEN Ratings ... 530-7 Table 5.30-6. Wear Metals 530-8 ‘able §.30-7. Sump Temperature And SAE Number 520-9 ‘Table 5.20-8. Sump And Header Temperatures ‘And SAE Number 530-9 ‘Table 5.20-9. Oil Consumption 530-9 Table 5.20-10. Duty Cycle Definitions 5.30 - 10 Table 5.30-11. Recommended Oil Change Intervals For Engines Receiving Normal Maintenance 530-10 Table 5.30-12. Recommended Oil Change Intervals For Enginas Receiving Normal Maintenance And Using Gaseous Fuel Containing HS Or Liquid Fue! Containing Suifur In Excess Of Published Limits, ... 5.90 - 10 Table 5.90-13, Lube Oil Filter Data 520-14 ‘able 5.30-14. Engine Oil Capacity 590-16 Table 5.30-15. Magnetic Plug Locations .... §:30- 16 Table 5.30-16. Oil Cooler Thermostatic Valves ~ PIN 163867A Series 5.0 Table 5.20-17. Oil Pump And Oil Pump, 2 Drive Gears 5.0 ~35 Table 830-18. Turbocharger Connections... 6.20 = 43 Section 5.35 - Exhaust System “able 5.35-1. Quick Disconnect Plug 5.35 -16 Table 5.35.2. Air Bleed Petcocks ‘Auxiliary Cooling Water Circuit 595-20 Table 55-9, Nominal Pressure For PIN Series 208372 Wastegale Caliraton Test 595-27 Table 525-4, Adjustable Wastegate Settings - Draw Thru Engines Only .... 5:95 - 29 Section 5.45 — Air/Gas Prelube And Start Systems “able 5.45-1, PIN 2085690 ir Valvas Inlet Pressures Ang Plt Pressures To snitt Section 6.05 - Engine Protection Systems “Table 605-1. Alarm And Shutdown Setpoints . 605-7 Table 6.05-2. Remote instrument Panel 545-4 ‘Annunciator Legend 605-9 Table 6.05-3. DSM Module LCD Message Display Diagnostic Codes 605-15, Table 6.05-4, DSM Diagnostic Codes Troubleshooting 6.05 ~16 Section 7.10 - Maintenance And Storage Table 7.00-1. Troubleshooting Table 700-1 Table 7.10-1. Routine Maintenance Chart .... 7.101 Table 7.10-2. Routine Inspection Form 710-4 Table 7.10-3. Waukesha Engine Preservative il Application 710-6 Table 7.10-4. Preservative Oils 710-6 Table 7.10-5. Protective Materials 740-6 Form 6288 Fret EatonHOW TO USE THIS MANUAL Your purchase of a L5108, L5790 or L7042G/GSVGL Series engine was a wise investment. In the industrial engine field the name, Waukesha Engine, stands for quality and durability. With normal care and mainte- nance this engine will provide many years of reliable service, Before servicing your engine, read Chapter 1 very carefully. This chapter covers Safety and General Information. Section 1.00 ~ Warning Tags and Decal Location ~ gives the location of all warning tags and decals and will ‘show you a duplicate of each tagis in case the decals or tags have been lost or damaged. Section 1.05 ~ Safety Section ~ Provides a list of dangers, warnings, cautions and notes to make you aware of the dangers present during operation and, ‘maintenance of the engine, - READ THEM CAREFUL- LY AND FOLLOW THEM COMPLETELY - Section 1.15 - General Information ~ Provides basic data on all current 15108, L5790 or L7042G/GSVGL engines such as; engine plate data, component ‘weights, torque specifications and clearances, This section also supplies torque values of metric and standard capscrews as well as conversion data. ALWAYS BE ALERT FOR THE SPECIAL WARN- INGS WITHIN THE MANUAL TEXT. THESE WARN- INGS PRECEDE INFORMATION THAT IS CRUCIAL, TO YOUR SAFETY AS WELL AS OTHER PERSON- NEL WORKING ON OR NEAR THE ENGINE. CAU- TIONS OR NOTES IN THE MANUAL CONTAIN INFORMATION THAT RELATES TO POSSIBLE DAMAGE TO THE ENGINE OR ITS COMPONENTS DURING ENGINE OPERATION OR MAINTENANCE PROCEDURES. This manual contains both repair and overhaul instruc- tions for current 15108, L5790 or L7042G/GSVGL engines. There are seven chapters within the manual and each chapter contains one or more sections. The title of each chapter or section appears at the top of each page. To locate information on a specific topic, refer to the Table of Contents at the front of the manual ‘or the Index at the back of the manual, Recommendations and data contained in the manual is the latest information available atthe time of this printing land is subject to change without notice. Since engine accessories may vary due to customer specifications consult your local distributor or Waukesha Engine Division Service Operations Department for any in: formation on subjects beyond the scope of this manual. FORM G2a6 Fiat EasHOW TO USE THIS MANUAL eee sav FORM 6248 Frei EatonCHAPTER 1 ~ SAFETY AND GENERAL FORM 6246 Fist Eanon CONTENTS SECTION 1.00 - WARNING TAG AND DECAL LOCATIONS SECTION 1.05 - SAFETY SECTION 1.10 - RIGGING AND LIFTING ENGINES SECTION 1.15 - GENERAL INFORMATION SECTION 1.20 - SPECIFICATIONSSECTION 1.00 - WARNING TAGS & DECAL LOCATIONS WARNING TAGS AND DECAL LOCATIONS, A WARNING All warning tags and decals must be visible and readable to the operator when the engine is run- ning. Make sure all warning tags and decals remain legible and attached. Likewise, all warning tags and decals removed during any repair work must be replaced in their original position before the engine is placed back into service. Old or badly worn decals and tags should also be replaced. Failure to properly replace these important tags and decals can result in serious personal injury or death. Depending on the model, the VHP 12 Cylinder engines have warning tags located on SNINYVM + Each of the two starter (Air/Gas) motor inlet pipes at the rear of the engine. + The fuel gas regulators below each cylinder bank. Figure 1.00-1. Sample Of Warning Tag Placement * The fuel gas vent tube supply pipe connection adjacent to the flywheel. ‘© On the carburetor throttle levers, = On the high voltage equipment. Recommended Gas Supply Pressure 5-10 PSI ‘Maximum Gas Supply Pressure 12 PSI LO) |% —cusrowen on eno uses nesronsia.e ron enowsion ENGINES NATURALLY ASPIRATED ALL GAS VENTED FROM ENGINE COMPONENTS MUST BE PIPED JOA SAFE AREA IN ACCORDANCE WITH APPLICABLE CODES. COverpressuing, Improper Venting Or ing May Cause ‘Gas Leakage And Possible Satous Personally Figure 1.00-2, Warning Tag (P/N 2081078) - On Regulator(s), All Naturally Aspirated Gas Engines [00-1WARNING TAGS & DECAL LOCATIONS WARNING ‘This_ system Sutable For Ar Or Clean Ory Natural Gas At A Maximum Supply Pressure Of 150 PSI (CUSTOMER OF END USEA IS RESPONSIBLE TO PROVIDE OVER- PRESSURE PROTECTION TO THis SYSTEM ALL.GAS VENTED FROM THIS SYSTEM SHALL BE PIPED TOA SAFE [ARIER IN ACCORDANCE WITH APPLICABLE CODES. Cverpressuring, Imaroper_ Venting Or, Piping, And Posebie Corosion Gaosed By "usmg "Nawal Gas With “Appreciabig Amour Of Fycogen Sune "Yay "Cao “Gas Lntkage And Posttle Serate Porsona ni. Figure 1.00-3. Warning Tag (PIN 208107E) RECOMMENDED GAS SUPPLY PRESSURE 25 40 PSI MAXIM GAS SUPPLY PRESSURE 50 PS! (CUSTOMER OF END USER IS RESPONSIBLE FOR PROVISION GSE OVERPRESSURE PROTECTION FOR GAS SUPPLY TO THIS, REGULATOR AND FOR GAS SYSTEM COMPLIANCE WITH ‘APPLICABLE CODES, ALL. GAS VENTED FROM ENGINE COMPONENTS MUST BE PIPED TOA SAFE AREA N ACCORDANCE WITH APPLICABLE CODES, OVERPRESSURING. IMPROPER VENTING OF PIPING May CAUSE GAS LEAKAGE AND POSSIBLE SERIOUS PERSONAL INJURY. TURBOGHARGED ENGINES FISHER 99 REGULATOR pel Figure 1.00-4. Warning Tag (PIN 209107H) ~ On Fisher 99 Regulator(s), Turbocharged Gas Engines WARNING RECOMMENDED GAS SUPPLY PRESSURE 0.75-5 PSI MAXIMUM! GAS SUPPLY PRESSURE 8 Si (CUSTOMERLOR END USER Is RESPONSIBLE FOR PROVISION SP OvERPRESSUNE PROTECTION FOR GAS SUPPLY TO THIS REGULATOR AND FOR GAS SYSTEM COMPLIANCE WITH, [RPPLIGABLE CODES. ‘on ALL.GAS VENTED FROM ENGINE COMPONENTS MUST BE PIPED SOA SAFE AREA IN ACCORDANCE WITH APPLICABLE CODES. WA LOW BTU ENGINES, FISHER 66 REGULA OVERPRESSURING, MPROPER VENTING OR PIPING MAY CAUSE GXSTEAKAGE AND POSSIBLE SERIOUS PERSONAL INJURY. Figure 1.00-5. Warning Tag (P/N 209107L) ~ On Fisher 65 Regulator(s), Naturally Aspirated, Low Btu Engines 00-2 ORI 6248 Fist EatonWARNING TAGS & DECAL LOCATIONS A WARNING MAXIMUM GAS SUPPLY PRESSURE TO REGULATOR 50 PSI USTOMER OR END USER IS RESPONSIBLE FOR PROVISION JF OVERPAESSUNE PROTECTION FOR GAS SUPPLY TO THIS REGULATOR AND FOR GAS SrSTEM COMPLIANCE WITH. APPLICABLE CODES, ALL GAS VENTED FROM ENGINE COMPONENTS MUST BE PIPED SOX SAFE AREA IN ACCORDANCE WITH APPLICABLE CODES. OVERPRESSURING, IMPROPER VENTING OR PIPING MAY CAUSE GAS LEAKAGE AND POSSIBLE SERIOUS PERSONAL INJURY, FISHER 99 OR S2Ht REGULATOR Figure 1,00-6. Warning Tag (P/N 208107R) - On Fisher 99 And $211 Regulator(s), Turbocharged Engines [RECOMMENDED GAS SUPPLY PRESSURE 5-20" WC. | MAXIMUM GAS SUPPLY PRESSURE 22° WC, CUSTOMER OR END USERS RESPONSIBLE FOR PROVISION OF OVERPAESSURE PROTECTION FOR GAS SUPRLY TO THIS PRESSURE REDUCTION VALVE AND FOR GAS SYSTEM ‘COMPLIANCE WIT} APPLICABLE CODES. ALL GAS VENTED FROM ENGINE COMPONENTS MUST BE PIPED TOA SAFE AREA IN ACCORDANCE WITH APPLICABLE CODES. iweco, aT PRESUURE HEDUCTION VALVE OVERPRESSURING, MPROPER VENTING OR PIPING MAY CAUSE GAS LEAKAGE AND POSSIBLE SERIOUS PERSONAL INJURY, Figure 1.00-7. Warning Tag (P/N 209107U) - On IMPCO (MAXITROL) Pressure Reduction Valve, Used With 5 ~ 20° Water Column Gas Pressure WNT ‘THIS ENGINE HAS BEEN ORDERED AND BUILT WITHOUT WAUKESHA, ENGINE DIVISION DESIGNED ENGINE SAFETY SHUT-OOWN EQUIPMENT ENGINE MUST BE PROVIDED WITH FUEL SHUT-OFF TvPE SAFETY EQUIPMENT 10. PREVENT ENGINE DAMAGE AND. POSSIBLE PERSONAL INJURY OR LOSS OF Ui REFER TO WE, Sa7z%0 40 FOR RECOMMENDED SAFETY EQUIPMENT AND SETTINGS. Figure 1.00-8. Warning Tag (P/N 209107K) - On Carburetor Throttle Lever For Engines Ordered And Built Without ‘Waukesha Engine Division Designed Engine Safety Shutdown Equipment FORM 6248 Fiat Eaton 700-8WARNING TAGS & DECAL LOCATIONS 7 We NEN) | = GAS VENT CONNECTION CUSTOMER OR END USER IS RESPONSIBLE FOR VENTING OF GAS FROM THIS CONNECTION: AND PIPING TO A SAFE AREA FOMEET APPLICABLE CODES. POSSIBLE SERIOUS PERSONAL INJURY. | IMPROPER VENTING CAN CAUSE GAS LEAKAGE ANO Figure 1.00-9, Warning Tag (P/N 209107P) - For Gas Vent On Prelube Systems That Use Natural Gas For Prelube Motor A WARNING HIGH VOLTAGE Figure ¥.00-10. Warning Tag (P/N 2088408) - ‘On High Voltage Equipment 00-4 FORM 6248 Frat EatonSECTION 1.05 - SAFETY SAFETY INTRODUCTION The following safety precautions are published for your information. Waukesha Engine Division, Dresser Indus- tries, Inc., 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, operating or servicinga Waukesha product, itis your responsibilty to ‘ensure full compliance with all applicable safely 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 safely 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 “note” 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. NOTE: This symbol identities information which is NECESSARY TO THE PROPER OPERATION, MAIN- TENANCE OR REPAIR OF THE EQUIPMENT. This symbol identifies in- A CAUTION formation about hazards or unsafe practices. Disregarding this information could result in PRODUCT DAMAGE AND/OR PER- ‘SONAL INJURY. A WARNING This symbol identifies information about hazards or unsafe practices. Disregarding this information could result in SEVERE PERSONAL INJURY OR DEATH. hazards. Disregarding this information will result in ‘SEVERE PERSONAL INJURY OR DEATH. SAFETY TAGS AND DECALS A WARNING To avoid severe personal injury or death, all warning tags and decals must be visible and legible to the operator while the equipment is operating. EQUIPMENT REPAIR AND SERVICE Proper maintenance, service and repair are important to the safe, reliable operation of the unit and related equipment. Do not use any procedure not recom- mended in the Waukesha Engine manuals for this equipment, A WARNING To prevent severe personal injury or death, always stop the unit before cleaning, servicing or repairing the unit or any driven equipment. Piace 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. Puta sign on the control panel warning that the unit is being serviced. Close all manual control vaives, disconnect and lock out all energy sources to the unit, including all fuel, electric, hydraulic, and pneumatic connections. Disconnect or lock out driven equipment to prevent the possibilty of the driven equipment rotating the disabled engine. A WARNING To avoid severe personal injury or death, ensure that all tools and other objects are removed from the unit and any driven equipment before restarting the unit. A WARNING Allow the engine to cool to room temperature before cleaning, servicing or repairing the unit, Hot components or fluids can cause severe personal injury or death, ‘Some engine components and fluids are extremely hot even after the engine has been shut down. Allow sulficient time for all engine components and fluids to 00! fo room temperature before attempting any service procedure. FORM aDaS Fea EaterSAFETY ACIDS A WARNING ‘Comply with the acid manufacturer's recommenda- tions for proper use and handling of acids. Improp- er handling or misuse could result in severe personal injury or death. BATTERIES A WARNING Comply with the battery manufacturer's recommer dations for procedures concerning proper battery use and maintenance. Improper maintenance or misuse could result in severe personal injury or death. BODY PROTECTION A WARNING Always wear OSHA approved body, sight, hearing and respiratory system protection. Never wear loose clothing, jewelry or long hair around an engine. The use of improper attire or failure to use protective equipment may result in severe personal injury or death. CHEMICALS. GENERAL A WARNING Always read and comply with safety labels on all containers. Do not remove or deface the container labels. Improper handling or misuse could result in ‘severe personal injury or death. CLEANING SOLVENTS 4 WARNING Comply with the solvent manufacturer's recom- mendations for proper use and handling of sol- vents. Improper handling or misuse could result in severe personal injury or death, Do not use gaso- line, paint thinners or other highly volatile fluids for cleaning. LIQUID NITROGEN/DRY ICE A WARNING ‘Comply with the liquid nitrogen/dry ice manutactur- er's recommendations for proper use and handling of liquid nitrogen/dry ice. Improper handling or use could result in severe personal injury or death. COMPONENTS HEATED OR FROZEN A WARNING Always wear protective equipment when installing or removing heated or frozen components. Some components are heated or cooled to extreme temperatures for proper installation or removal. Direct contact with these parts could cause severe personal injury or death. INTERFERENCE FIT A WARNING ‘Always wear protective equipment when installing or removing components with an interference fit. Installation or removal of interference components may cause flying debris. Failure to use protective ipment may result in severe personal injury or th. COOLING SYSTEM A WARNING Always wear protective clothing when venting, flushing or blowing down the cooling system: Operational coolant temperatures can range from 180°~ 250° F (82°- 121°C). Contact with hot coolant or coolant vapor can cause severe personal injury or death. A WARNING Do not service the cooling system while the engine is operating or when the coolants hot. Operational coolant temperatures can range from 180° ~ 250° F (82°~ 121°C). Contact with hot coolant or vapor can cause severe personal injury or death. vez FORM Sze Frei EaionSAFETY ELECTRICAL GENERAL A WARNING Do not install, set up, maintain or operate any electrical components unless you are a technically qualified individual who is familiar with the electri- cal elements involved. Electrical shock can cause severe personal injury or death. A WARNING Disconnect all electrical power supplies before making any connections or servicing any partof the electrical system. Electrical shock can cause se- vere personal injury or death. IGNITION FIRE PROTECTION A WARNING Refer to local and federal fire regulations for guidelines for proper site fire protection. Fires can cause severe personal injury or death. FUELS GENERAL A WARNING Ensure that there are no leaks in the fuel supply. Engine fuels are highly combustible and can ignite ‘or explode causing severe personal injury or death. GASEOUS A WARNING A WARNING Avoid contact with ignition units and wiring. Igni- tion system components can store electrical ener- gy and if contacted can cause electrical shocks. Electrical shock can cause severe personal injury or death, A WARNING Properly discharge any elecrical component that has the capability to store electrical energy before connecting or servicing that component. Electrical shock can cause severe personal injury or death, EXHAUST A WARNING Donot inhale engine exhaust gases. Exhaust gases are highly toxic and could cause severe personal injury or death. Ensure exhaust systems are leak free and that all exhaust gases are properly vented, Do not inhale gaseous fuels. Some components of fuel gas are odorless, tasteless, and highly toxic. Inhalation of gaseous fuels can cause severe personal injury or death. A WARNING 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 resulting in severe personal injury or death. uiauiD A WARNING Do not ingest liquid fuels or breathe in their vapors. Liquid fuels may be highly toxic and can result in ‘severe personal injury or death. A WARNING A WARNING Do not touch or service any heated exhaust components. Allow sufficient time for exhaust components to cool to room temperature before attempting any service procedure. Contact with hot exhaust system components can cause severe personal injury or death. Use protective equipment when working with liquid fuels and related components. Liquid fuel can be absorbed into the body resulting in severe personal injury or death. FORM RDA reat Caion To5-3SAFETY INTOXICANTS AND NARCOTICS SPRINGS { A WARNING A WARNING Do not allow anyone under the influence of intoxi- cants and/or narcotics to work on or around industrial engines. Workers under the influence of intoxicants and/or narcotics are a hazard both to themselves and other employees and can cause severe personal injury or death to themselves or others. PRESSURIZED FLUIDS/GAS/AIR A WARNING Never use pressurized fluids/gas/air to clean cloth- ing or body parts. Never use body parts to check for leaks or flow rates. Pressurized fluids/gas/air in- jected into the body can cause severe personal injury or death, Observe all applicable local and federal regulations relating to pressurized fluid/gas/atr. PROTECTIVE GUARDS 4 WARNING Provide guarding to protect persons or structures ‘rom rotating or heated parts. Contact with rotating or heated parts can result in severe personal injury or death. Itisthe responsibility of the engine ownerto specify and provide guarding, ‘SODIUM COOLED VALVE 4 DANGER Do not cut or break open sodium cooled exhaust valves. Contact with sodium will cause severe personal injury or death. Contact local waste management authorities to dispose of sodium cooled valves per local or federal codes. Use appropriate equipment and protective gear when servicing or using products that contains springs. Springs, under tension, can eject if im- Proper equipment or procedures are used. Failure to take adequate precautions can result in serious personal injury or death. TOOLS ELECTRICAL A WARNING Do not install, set up, maintain or operate any electrical tools unless you are a technically quali- fied individual who is familiar with them, Electrical tools use electricity and if used improperly could ‘cause severe personal injury or death. HYDRAULIC A WARNING Do not install, set up, maintain or operate any hydraulic tools unless you are a technically quali- fied individual who is familiar with them. Hydraulic tools use extremely high hydraulic pressure and if used improperly could cause severe personal injury oF death. A CAUTION | AM2y5 follow recom. mended procedures when using hydraulic tensioning devices. Improper use of hydraulic tensioning tools can cause severe engine damage, PNEUMATIC A WARNING Do not install, set up, maintain or operate any Pheumatic tools unless you are a technically qualified individual who is familiar with them. Pneumatic tools use pressurized air and if used improperly could cause severe personal injury or death. Te-0 FORM 625 Fie EatonSAFETY WELDING GENERAL A WARNING Comply with the welder manufacturer's recommen- dations for procedures concerning proper use of the welder. Improper welder use can resultin severe personal injury or death. ON ENGINE Ba CAUTION | Ensue that tne wetder is properly grounded be- fore attempting to weld on or near an engine. Failure to properly ground the welder could resultin severe engine damage. Ba. CAUTION | connect the ignition harness before welding ‘on or near an engine to eliminate charging of an ignition system capacitor. Failure to disconnect the Ignition harness could result in severe engine damage. WEIGHT A WARNING ‘Always consider the weight of the item being lifted and use only properly rated lifting equipment and approved lifting methods. Failure to take adequate precautions can result in serious personal injury or death. A WARNING Never walk or stand under an engine or component while itis suspended. Failure to adhere to this could result in severe personal injury or death. FORM SoIE Fra Eaton i055SECTION 1.10 —- RIGGING AND LIFTING ENGINES ENGINE RIGGING AND LIFTING LOCATION OF THE LIFTING EYES A WARNING A WARNING Exercise extreme care when moving the engine or 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 prop- erly maintained lifting equipment with a lifting capacity which exceeds the known weight of the object to be lifted. Disregarding this information could result in severe personal injury or death. Table 1.10-1 shows the approximate dry weight of the VHP 12 Gylinder gas engines, ‘Table 1.10-1. Engine Dry Weights Always lift the engine using the approved lifting eyes. The VHP 12 cylinder gas engines are equipped with two pairs of lifting eyes, one pair on each cylinder bank. Lifting eyes are only meant for ing the engine. Do not use to lift driven or auxiliary equipment that may be attached to the engine. Disregarding this information could result in severe personal injury or death. The VHP 12 cylinder engine is equipped with two pairs of ling eyes, one pair on each cylinder bank. A spreader beam (P/N 4943638), is needed for the proper method of tting the engine. The lifting eyes are only meant for iting the engine. Do not use the lifting eyes to lift driven equipment that may be attached to the engine. CORRECT METHOD OF RIGGING AND LIFTING ENGINE, Lifting chains should be positioned so that they do not rub orbind against parts of the engine. A properly rigged engine will be able to be lifted in such a manner that the chains will not damage the engine. See Figure 1.10-1 and Figure 1.10-2 for examples of engine lifting A WARNING WEIGHT ENGINE 1s. kg L108 20 500 2.300 5108651 21,000 9.525 510864, 21,000 9.528 157006 20.500) 9.300 13790681 21,000 9.525 21,000) 9.505 20,500 9.300 27,000) 9.525 27,000 9525 To avoid severe personal injury or death, follow approved 1g procedures to ensure that no undue strain is placed on the lifting eyes and hoisting chainsicable sling when the engine is raised. Use the proper spreader beam to avoid ‘damage to the cylinder head studs. Figure 1.10-1, Correct Method Of Lifting Engine ~ Side Views FOR 6248 Fret Eton 70-1RIGGING AND LIFTING ENGINES Figure 1.10-2. Correct Method of Lifting Engine ~ Rear View Tio-2 FORM 6248 Fie BallonSECTION 1.15 - GENERAL INFORMATION SECTION MAIN POINTS: ‘+ Overview of the overhaul and repair process, including general considerations before starting the work such as engine handling and removal. ‘= Engine description, details and specifications. Specialized engine tool list + Conversion tables. OVERHAUL/REPAIR PROCESS Overhaul is the complete disassembly, examination, repair or replacement of components, and reassembly of the entire engine. Repair deals strictly with individual engine components. When properly planned and executed, the overhaul and repair process can be effectively completed in a safe and timely manner. PREVENTING ENGINE DAMAGE Throughout this manual CAUTIONS and NOTES ‘emphasize procedural items which need to be carefully followed to avoid serious engine damage. Other points, to remember are: + DON'T assume that procedures used for other engines also apply to the VHP engine series. 00 be certain of procedures and information for this specific engine betore starting the work. * DONT remove gears, pulleys and other related parts, by prying or pounding. DO use the correct pullers or special tools + DON'T throw nuts and bolts into a single box or container. DO identity and store nuts and bolts according to their proper assemblies. Ditterent lengths and grades of bolts are used for specific ‘purposes in certain applications. * DON'T use parts from another engine. These parts have wear-in patterns that may not match in another engine, DO use new parts, if replacement is necessary. + DON'T try to compensate for torque wrench length- ‘ening. DO use the correct tool and torque values. = DONT force parts together. DO look for burrs, foreign material or improper fits if an assembly is difficult to put together. ‘+ DONT inspect a part for precision fit if it is oil varnished, rusty or carbonized. DO clean pars first True {its cannot be calculated until true, accurate measurements are taken. Keep records of the engine history for yourself and the customer. © DONT check parts for precision fit if they are abnormally hot or cold. Temperature will greatly affect dimensions, especially large diameters. DO measure all parts at room temperature, or check composite assembly pieces at the same temperature. = DON'T jump from one subassembly to another. DO complete each subassembly from start fo finish. © DONT reassemble the engine in a contaminated parts cleaning area. DO keep the overall assembly area free from flying foreign particles which will settle on and contaminate the engine. Cover the exposed engine with a sheet of plastic at the end of each day. ‘When a component is removed, seal the engine ‘opening to prevent foreign material from entering the engine. '* DO work in a safe environment. No job should be started if it cannot be finished safely and correctly. HANDLING AND SHIPPING Whenever an overhaul of an VHP series engine is anticipated, a decision must be made to do the work on site or remove the engine to a more suitable overhaul facility. Factors which can effect your decision are: ‘© Operational requirements of the user. What is the owner's turn-around time? © Adequate lifting equipment. Is the proper lifting equipment available? Can it be safely used on site? ‘© Cleanliness of the site. A reasonably clean reas- sembly area will be required, ‘+ Proximity of an adequate overhaul facility. Realistically, most VHP series engine overhauls will be done on site. Practicality and customer requirements will be the determining factors. The VHP series engine was originally designed so that it could be easily serviced on site. Only the most unusual situations will require the removal of the engine. Ifthe engine work will be done on site, then some external engine connections may not need to be disconnected, Common sense, practicality and safety need to be your guidelines in such a situation. However, if engine removal from the site is necessary, use the steps that follow. FORM G24 Fist Cation Tae-7GENERAL INFORMATION A WARNING Use extreme care when working on or near engine installations. Make sure all fuel supply lines are CLOSED and all electrical power is OFF. Place all engine controls in the OFF position to prevent accidental restarting. If possible, lock all controls in the OFF position and take the key. Placea sign on the instrument panel advising that the engine is being serviced. Never attempt any work on an engine while it is running. Disregarding this formation could result in severe personal injury or death. ENGINE REMOVAL A WARNING 2. Disconnect driven equipment from the engine flywheel 3. Drain and property discard coolant from the engine and cooling system. 4, Disconnect coolant lines from the inlet and outlet engine connections, 5. Drain and properly discard lubricating oll rom the olt pan, filler and cooler. Disconnect the oil fter lines. 6. Disconnect or remove air intake equipment. 7. Disconnect engine exhaust connections. 8. Remove any auxiliary instrument panels and sup- Ports. Disconnect wiring cables, fuel lines, throttle linkage and any other accessory controls as required Fluids in the engine remain hot after the engine is. shutdown. These hot fluids can cause severe burns. Use care when working with engine fluid connections. Wait until the engine and its fluids cool down before proceeding with any service. Disregarding this information could result in se- vere personal injury or death, A CAUTION] 22 2112 10 follow the Ba VAL TIN | correct shutdown proce- dures before starting any work on the engine. When the engine is disconnected from its support, ‘equipment, be sure to seal all engine openings to prevent dirt and moisture from entering. Disregard- ing this information could result in product dam- age and/or personal injury. Bi CAUTION] 4%, Proved engine shipping skid, designed to remain with the engine during any handling and shipping, should be used. This ski trom Waukesha Engine. If this skid is already attached, do not remove it. f not present, arrange to get the skid to the site before engine removal is attempted. Disregarding this information could result in product damage and/or personal injury. NOTE: Tag all electrical, pneumatic, fuel, coolant and lubrication oil ines to ensure correct reassembly. 4. Check the installation for potential problems. If problems are found, ensure that corrections are made before the engine is reinstalled. Consult the Waukesha Engine Installation Manual, Form 1091-1 thru 8, and the VHP 12 cylinder gas engine Installation Drawings for installation recommendations. A WARNING ‘Never walk or stand under an engine or component while it is suspended. Always consider the weight of the engine or component and use only properly rated lifting equipment and approved lifting meth- ‘ods. Make sure the transport vehicle is adequate to handle the weights involved and can safely move the engine. Disregarding this information could result in severe personal injury or death. NOTE: See Section 1.02 of this manual for correct lifting methods and component weights. ‘B. CAUTION | Follow approved rigging procedures so that no undue strain is placed on the lifting eyes and hoisting chains/cable sling when the engine raised. Use the proper lifting device to avoid product damage and/or personal injury. 9. Using a suitable lifting device carefully ift engine as required. was-2 FORIA 6248 Fret EatonGENERAL INFORMATION SERIAL NUMBER AND ENGINE NAMEPLATE The engine model, size, specification, serial, and governing speed numbers are stamped on a nameplate (see Figure 1.15-1 and Figure 1.15-2). This nameplate is mounted on the lett side of the crankcase just below the No. 1L cylinder head. When requesting information about the engine or parts, it is important to reference both the engine model number and serial number. Ifthe nameplate is defaced ‘or detached, the serial number can be obtained directly {rom the crankcase. tis stamped on the left fring deck, just forward of the No. 1L cylinder head, Waukesha Figure 1.15-2. Nameplate - Previous Production Onna 6248 Fret Eton 75-3GENERAL INFORMATION ENGINE IDENTIFICATION VIEWS. RIGHT SIDE VIEW \ {fi} OB G® Talc oare saree oertor OA GET Ty is Toe i onaerae fa aceceer ea) oe fas ceeeee seta eee ene Raced les cee ate etree Puen Bhar eee ererrees pelea tae EC Ignition Junction Box Figure 1.15-3, Right Side View — 12 Cylinder VHP GL Ta5-4 FORM 6288 Fret EatonGENERAL INFORMATION LEFT SIDE VIEW 4, Thermostat Cluster Housing 11. Lube Oil Pan 2. Water Manifold 12, Ragulator, Gas (Left Bank) 3. Venturi Extractor 43. Lube Oil Dipstick (Left Bank) 4. Exhaust Manifold Assembiy, (Left Bank) 14. Crankease 5. Lube Oil Filler 15. Engine Leveling Bolts (Left Bank) 8. Fiywhee! and Housing 46. Prelube Pump and Motor 7. Manual Barring Device 17. Crankcase Breather (2) 8. Lube Ol Drain (Left Bank) 18. Safety Guarding 9. Lube Oil Pan Access Doors (Lett Bank) 19. Control Panel (Left Bank) 1 (0. Engine Jacket Water Drains (Left Bank) Figure 1.15-4, Left Side View ~ 12 Cylinder VHP GL. FORM 6248 First Eaton 138-5GENERAL INFORMATION REAR VIEW Flexible Exhaust Connection 8. Air Cleaners (2) ‘Wastegates (2) 7. Prechamber Manitolds (2) Turbochargers (2) 8. Intake Manifolds (2) 9. 1 1 Lifting Eyes (4) (2 each front and rear) Carburetors (2) Cylinder Head Assemblies (12) 0. Intercooler Auxiliary Pump net Figure 1.15-5. Rear View - 12 Cylinder VHP GL. Ts-6 FORM 6248 Frat EatonGENERAL INFORMATION BASIC ENGINE DESCRIPTION ‘The Waukesha VHP 12 cylinder gas engine series has the following models; LS108G/GSI, 5108GL, LS790G/GSI, 5790GL, L7042G/GSI, and 7042GL. Engines designated °G". are naturally aspirated. En- gines designated "GSI" are turbocharged and inter- cooled, Engines designated “GL” are turbocharged, intercooled and lean combustion. All engines are four cycle and rotate in the standard counter-clockwise direction, as viewed from the rear (flywheel) end. The 12 cylinders are arranged in a \V-contiguration, six on each bank. The crankcase is a single piece, rigid gray iron casing. The main bearings are teplaceable. The main bearing caps are held in place with vertical studs and lateral tie bolts, The Ccounterweighted crankshaft is made of forged steel! and has seven main bearing journals. Each engine is ‘equipped with viscous vibration dampers. There are 12 interchangeable cylinder heads, each with two Stelite” faced intake and two Stelle” faced exhaust valves. Both exhaust and intake valve seat inserts are also Stelle” faced, Roller type valve lifters and hydraulic push rods are standard. The camshaft consists of two individual segments. The connecting rods are made from drop forged steel and are rifle arilled, The cylinders have replaceable wet cylinder sleeves. The pistons are aluminum alloy with full floating piston pin. The flywheel is machined and has a ring gear attached. The exhaust driven turbocharger compresses intake air. This charged air is cooled in the intercooler then. enters the carburetor and mixes with pressurized fuel gas. The turbocharged airluel mixture enhances the engine's power and performance, The pressurized lubricating system consists of an oi! sump, gear driven pump, piping network, filters, strainers and cooler. The full flow oi! filter is externally mounted, separate from the engine. The system also consists of an externally mounted oil cooler. The cooling system has two water pumps. The main ‘water pump is belt driven and circulates the jacket water of the engine. The other belt driven pump, the auxiliary water pump, circulates water for the oil cooler and the intercooler. The engine jacket, cylinder heads, exhaust ‘manifold, turbocharger, oil and charged intake airare all water cooled, NOTE: “Stelle” is a registered trademark of Stoody Deloro Stellite, Inc: FORA 6248 Fie Eaton 75-7GENERAL INFORMATION SERVICE TOOLS LIST Table 1.15-1 lists the available tools to perform the tasks indicated on VHP 12 cylinder gas engines, In ‘some instances, substitute items may be used, but only if specifically approved by Waukesha. To order these special tools, contact your local Waukesha Engine es on eee re EE | __ Toot oesoneron 671640 ineh enontion for Shielded, CSA w FM cols) ~ cee [personae 474005 ‘Stop Sleeve aaa my fe =e 474007 Prechamber Removing Collet (5108GL only) motel Tou [once si [sus 474013 ‘Water Pump Kit a me aan 1 ra rer 474016 VHP V- Belt Tester aca neal —_— ra i eee a Tes [eth ne SS Sasso ones [eee 475006. ‘Spark Plug Gapper_ attic) Mehul) en Ane 494277, Valve Grinder ir et ea tc oom to eS Saar fessor fo Soa tara Be 475028 [AC/DC Light Source Gable 492263 ‘Magnafax® Dye Penetrant Kit ae — rons ee a See) fe Seen 475057 etter Bea (Besgnad Wit ove sand and oer Fg Guon G88) Hess a aa rasta a a soar ee ee 494152 Piston Ring Compressor 494346 Exhaust Probe | 494206 Piston Ring Compressor (9-3/8 inch bore) 494357 Oxygen Analyzer 494217 Compression Tester Adapter (18 mm) 404960, Emissions Accessory Kit FORM 6248 Frat EaibonGENERAL INFORMATION WAUKESHA aula TOOL DESCRIPTION 494366 Main Bearing intalaton Tool 498585 ‘Main Bearing instalation Tool 498385 ‘Seal Removal Toot 298300 [Oxygen Cot 94360 Span Gas Battie 9442 ‘Spark Plug Gapping Tool ry ‘Spark Pg Gapping Too! 490498 Pion Pin Retaining Pher 390259 (Gyiner Sleeve Puter 490955 Valve Guide Reamer FORM 6248 Fst Eaton 15-8GENERAL INFORMATION ee ENGINE STANDARDS COMPONENT WEIGHTS ‘Table 115-2. VHP 12 Cylinder Gas Engine Component Weights COMPONENTS wwe [ta COMPONENTS ite] 9 bot sf ae Tati witou Bucket orpap | —89 | v7 cansha re ves Tne Asse wack was | we Gansta Gear a Hage ive Ase [oa carr [on Mani Exava we foe Gov Gaur [7 anf ke [os Canecing RU OTR [= Mario Wate cs Wicd CamanonSountyGape | 4008 | zeso | janis Pechanoe wel Sn me ee) fee ae pnd Head 105 | eo = =. Cynae Ler Seo) [a ae es er vsaton Dae ita cite woof ot eet = - Pulley. Rear Crankshatt 8 w een, Testo Exheet 2 = Regulator Gas Fisher 99) 7 ES ee a : ‘hid, Sipping | 466 en eK = = Turbocharger eran | 90 Er Ll SS aan wee | Fiat w Fig ear a #—} vernal see es eS [Water Pump. Auxiliary 44 20 Tis-10 FORM 6248 Frat ationGENERAL INFORMATION CLEARANCES ‘The clearances section of the manual contains both new part tolerances as well as field condemning limits, These part tolerances are published to establish engine ratings and warranty limitation on liability of new engines and service parts. Wear limits are published as guidelines for engine ‘overtiaul and repair. These guidelines can be the basis, for the reuse of parts which, though worn, still retain service lite ata reduced performance rating. Waukesha Engine Division emphasizes that these wear limits are guidelines and, as such, must be used with discretion and with the understanding that new engine perfor- mance may not be achievable. By CAUTION | While Waukesha Engine does not recommend the reuse of pistons during engine overhauls, we recognize that this is a common field practice. Pistons experience a combination of mechanical and thermal cyclic stresses during operation. Aluminum piston life is unknown beyond recom- ‘mended overhaul. If and when end users make the decision to reuse pistons, inspection steps need to be taken to minimize failure risks. Contact your authorized Waukesha distributor for assistance. Disregarding this information could result in prod- uct damage and/or personal injury. Waukesha Engine Division's position for these wear limits is that the reuse of an engine part that does not ‘meet the new part specifications is solely the responsi bility of the person making the inspection and repair. Under no circumstances is the reuse of any part exceeding the following wear limits justified. Waukesha Engine Division assumes no liability for any damage which may occur through the reuse of engine parts which fall outside of the new part tolerances. Onna 6248 Fis Cation TaeGENERAL INFORMATION TORQUE SPECIFICATIONS GENERAL TORQUING SEQUENCE PROCEDURE ‘The sequence in which capscrews, bolts and nuts are tightened influence the distribution of fastener clamp load. Parts that use several fasteners such as cylinder heads, flywheels, oil pans, water pumps, cover plates, ‘etc. must have the fasteners tightened (or loosened) {gradually and in a specific sequence. This is necessary to avoid the excessive uneven loads that can cause ,gasket leakage, or the locking and warpage that cause damage to the parts during assembly or disassembly. la special torquing sequence diagram is not available, the following procedure should be used, First, assemble all the fasteners loosely and align and adjust the part as required to assure proper alignment with mating parts and to eliminate possibie interference with adjacent parts, then begin torquing sequence. The torquing of fasteners to their torque specifications should be done in a minimum of three steps, with no ‘more than 50 percent of the final required torque being applied in the initial step. The fasteners should be tightened in a criss-cross or diagonal pattern, as shown in Figure 1.18-6 and Figure 1.15-7, to distribute the fastener load evenly throughout the part, Use the same ‘sequence of torquing for each subsequent step until each fastener is torqued to it's torque specification. To loosen or remove the fasteners, the procedure should be done in reverse. ‘THREAD LUBRICATION FOR TORQUE FASTENERS Use only SAE 30 engine lubricating oil as a thread lubricant on those fasteners that have been assigned specific torque values. ZA. CAUTION 22.124 use Motykote- Paste G®, Bostik Never ‘Seez® or any other special thread fubricant unless specifically instructed to do so by Waukesha Engine Division. Disregarding this information could result in product damage and/or personal injury. NON-cIRCULAR MULTEBOLT cincuLaR muLTi-soLt | —squaRE FouR-BoLT igure 1.15-6. Torque Sequence For Multi-Bolt Patterns Special thread lubricants such as Molycote® Paste G or Bostik Never Seez® reduce the friction on the threads 's0 much that the actual torque on the fastener may exceed the actual torque wrench indication by as much as 41 percent. This over-torquing puts an excessive strain on the fasteners, which could be critical on such fasteners as the capscrews and studs that attach VHP- cylinder heads. ‘Also when working on a crankcase that has been hot-tank cleaned, be sure to generously apply engine oil on all studs that were hot-tanked as part of the crankcase assembly. 7 cr —fh7 Tain ea hel ce “aha dies Loy (e- J) Figure 1.15-7. Manifolds, Headers, etc. vas-12 FORM 6246 Frat EconGENERAL INFORMATION CRITICAL ENGINE TORQUE VALUES Table 1.15-3 lists critical fastener torque specifications for current VHP 12 oylinder gas engines. Fasteners not listed here should be tightened according to the general torque specitications listed in this manual. Table 1.15-3. 12 Cylinder VHP Torque Values DESCRIPTION feb Nm Cynder Heads (see Figure 11646 or special orque sequence) 1 inch capscrows 625 650) a7 BB Msn esrng Cong one Su 15-10 or spel torus Seance) come ver ove Eross-ta Capsorews 312-10 242-250, 520-339 Tain Bearing Studs (in erankcase) 50 e Genes Fat Craton 5-1 ane Fe 1.159 sper ae soaueron) a eee Gamsham Goar Nut 112-12 455-250 357610 (Carishaft Bearing Gapscrows 316-16 22-28 30-38 Telor Gear Spindle Nut, 1-1/2-12 (in erankoase, LH tvead) (use Locile™ "271 on treads) 775 — 760 7017 — 1088 ‘Oil pump hollow ior spirale capscrow and nut 3/416 300-325, 407441 [Or pump cover eapscrows, 25-30 aA "Vibration Damper Gapsorew 12-15 [voraion damper to pulley) 7-82 T8125 Crankshatt End Pate Capscrens "~ a0 6 ‘ua Sha Pate to sub ahah capscrews and nut 8-11 acd 2a 27, Plate to tywheel eapsaren, 34-10 275 285, 373 386, Flywheel to cranks capscrews 5-18 a5, 232237 (lPan Gapscrews 72-13 (Qty 6) S56 776 6-11 (02) T0812 746182 14-10 (Qty 2), 204-208 277-282 Rockar Arm Cover Capscrews 12-13 55-60 75-81 Rocker Aim Suppo Capscrews 12-13 5560 75-81 Valve Liter Serew (hed ype only) 16-18 5560 75-81 Crankshaft Counterweght Capscrews'™ 718-14 465500 es 678 (Ol Fiter Cover Bots, sw 7-50 Spark Pugs (0 = TSR 20-45 (0) 4-6 La 275 780 (wip FEL | 973 — 980 wtp FEL ‘Spark Plug Carirs ‘PROF Gs-A™. Pari | PRO® CsA Part No 1058 cn-sole | No'Srone an-sete [dk CAUTION] Staines ate! prochambor sea 12095620) must doused inne |.5106 an sare No 510 a ase [dk CAUTION) rechambercup when torquingthe sparkplugecartier to275~280 tip | “mPaUNE ape pound applied {Gro ~300 Nin (tn FEL-PHO™ C5-A* PartNo, SY005.ani-seize Compound applied to treads) or damage to equipment wil result. Gas Acrission Valve" (PIN 2116B7A used wih slainloss Sleel washer PIN 28359) 70 oe 95 Water Pump impeller 4 Holsing one nu, torque other nut to 195-200) 264-271 DESCRIPTION inib Nm ‘GEC Timing Dice nylok Gapscraws (Current Production) 45 76508 "NOTE: Ailtrques oiled unless speoiiod “Refer fo folowing diagrams and instructions for foquing procedures for connecting reds and main bearing caps. Tore the endplate capserews lo 410 fb (558 Nm). Repeal na orque sequence as necessary. Each fe the sequence is repeated he assembly's drventurheruponto he tapered puleyslaeve. The assembly sproperly ighenecioni after utorque sapplidto each botwithout {ny rolanon of tha torque wrench, Check torque annual +e" Check counterweight forqus 30 (0 80 days afer start up and then annually. -*Brevous torque values forspark plug cariors was 90-95 -b (81 ~43 Nm) (wth FELPRO® C5-A®, PartNo. 51005 an-seize compound applied to threads). A copper procnamber ses! (PIN 2095628) ws used wih Ine prechamber cup. cae argue values for previous admission valves a’e discussed in SB 9-2574A, dated February 15,1994 FOR 6248 Fist Eaton ias- 13GENERAL INFORMATION CYLINDER HEAD TORQUING PROCEDURE When being installed, cylinder heads should always be torqued in the proper sequence illustrated, using ‘new gaskets. Lubricate cap screws and washers with SAE 30 engine oil First, hand secure capscrews in positions 1 and 2 (see Figure 1.15-8), making sure that ‘the head dowels are seated. Hand start the remaining screws. The first time through the torque sequence use 25 percent of the total torque value; each succeeding time through the torque sequence increase the torque setting by 25 percent of total torque value until final torque of 625 ~ 650 ft-lb (847 - 881 N'm) is reached. In order to be sure of proper torque, the torque sequence should again be repeated with the torque wrench set to the total torque value. Do not overtorque, If any screws, are overtorqued by 20 ft-lb (27 N-m), reduce torque on all screws to 75 percent of total torque and repeat the entire torquing sequence. EXHAUST VALVE BORES WATER OUTLET ELBOW CONNECTION 7 witane Vaive Bones CYLINDER HEAD’ Figure 1.15-8, Cylinder Head Capscrew Tightening ‘And Torquing Sequence (1 — 8) Retorquing after running the engine at idle or after load testing is not required. If retorquing for any reason, use a value of 550 ~575 ft-lb (746-779 N-m) to compensate for the set which the head gasket takes (see Table 1.15-4), Table 1.15-4. Cylinder Head Capscrews INITIAL TORQUE | RETORQUING | 7/6 INCH (CAPSCREW OR | (CAPSCREWOR | STUD 1° STUD) ‘1’ STUD) 625 — 650 fb 350-5750 | 445-4508 (es7=asiNm | (74s—779Nm | (605—s10N-m Bi CAUTION ]°°,"2t intermix studs and capscrews to secure ‘cylinder head or damage to equipment will result. CONNECTING ROD CAPSCREW TORQUING PROCEDURE (PIN SERIES 205407 AND 205507) ‘A. Lubricate the the threads, and under the heads, ‘of four ferry head connecting rod capscrews with, SAE 30 engine oil B. Locate the number1” stamped in the connecting rod cap. Hand tighten a capscrew in this hole first. Hand tighten the remaining capscrews in positions 2 thru 4 (see Figure 1.16-8). ©. Following the same numerical sequence, torque the capscrews to 50% of the final torque value, D. Repeating the torque sequence, torque the capscrews to a final torque value of 180 ~ 190 ft Ibs. (244 — 257 N-m) Figure 1.15-9. Connecting Rod Cap Capscrew Tightening Sequence (Series P/N 205407 and 205507) Tas= 78 FORW 6246 Firs EaionGENERAL INFORMATION MAIN BEARING CAP TORQUING PROCEDURE This torque sequence should be used on previous ‘engines as well as current production ones. NOTE: Generously apply engine oil to main bearing cap studs, nuts and side bolts immediately before instaling them. Apply 3M Scotch Grip™ Industrial Adhesive EC 847, or equivalent, to both sides of the side bolt washers to prevent lube oil leaks. 1. Refer to Figure 1.16-10 and torque nuts 1 through 4 (in that order) to 75 fb (102 Nem}. It installing replacement caps that willbe align bored, torque to only 30 ft-lb (40 Nm). When installing more than one cap, torque nuts 1 through 4 to 75 ft-lb (102. N'm) on all caps before torquing side bolts. LEFT SIDE OF ENGINE FRONT OF ENGINE Figure 1.15-10. Main Bearing Cap Tightening/Torquing Pattern — As Viewed From Underside Of Crankcase 2. Torque all left side bolts (5) to 260 ft-lb (239 N-m), starting from the front of the engine. 3, Torque all right side bolts (6) to 250 th-b (839 Nm) starting from the front of the engine. 4. Torque nuts 1 through 4 to 275 ft-lb (373 Nem) to two steps: first 175 ft-lb (237 N-m), and then 275 ft-lb (373 Nm), FORM 6248 Frat Eaton 18-15GENERAL INFORMATION GENERAL TORQUE RECOMMENDATIONS the values specified below are to be used only in the absence of specified torquing instructions and are not to be construed as authority to change existing torque values. A tolerance of 43 percent is permissible on these values, Which are for oiled threads, ‘Table 1.18-5. U.S. Standard Capscrew Torque Valu ce O © NUMBER Grade 1 or 2 Grade 5 Grade 8 ies] 5 es seas NOTE: Dry torque values are based on tho use of clean, ory treads. lec tovaue values have been reduced by 10% wan engine oil is used asa lutvica Plated torgue values have been reduce by 20% for new plated capscrews. (Capsorens which are threaded ino aluminum may require a torque reduction of 90% or more. The conversion factor rom feb 0 seb is fb x 12 equa ns e186 FORM 6248 Fist EatonGENERAL INFORMATION ENGLISH/METRIC CONVERSIONS Table 1.15-6. English To Metric Form wwla Conversion Table CONVERSION. FORMULA EXAMPLE Inches 1 Muimeters Inches ard any hacton in decimal equivalent mulipid by 25 4 equals listers 2SIBin, = 2625.25. ‘67 mm ‘Gib Inches to Lines [ounces to Grams ‘Gubicincnes multped by 0.07698 equals ives. ‘Ounces multiplied by 28.35 equals grams, OB ooh = SOB x OOTEID = 15R9 we Di og = Bt x28.95 = 805.4 grams unas o Kilogram Pounds multiplied by 0-489 equals Klograms. 22550 bs, = 22.550 04596.» 1020877 KD Inch Pounds to Newton-meters lich pounds mulpied by 0.11298 equals Newon-metes 260 into 0 x 0.11208 = 40.7 Nm Foot Pounds to Newlon~meters Foot pours multiplied by 1.2556 equals Newonemoters, 145 fea = 145 x 1.9550 = 196.6Nm Pounds per Square inch lograms per Square Centimeter Pounds per aque inch mulipied by 0.0703 equals kilograms per square centimeter 2 kglem2 Pounds per Square inch to Kiopascals Pounds per square inch mulipled by 68947 equals kelopasca. 4568047 =210.3 KPa Fluid Ounces to Cubie Centimeters Fluid ounces multiplied by 28.57 equals Subic cantmeters. 8x2957 = 2966c0 Galens io ures Gallons mulipled by 37859 equals les 748 ga 1483 7850 = 560 2 hres Degrees Fahrenheit o Degress Centigrade, ‘Dagrees Fahrenhel minus 32 chided by 18 equals Sagreos Centigrade. 212" F -92=1.8= 100°C ‘Table 1.15-7. Metric To English Form ula Conversion Tabl CONVERSION FORMULA EXAMPLE, Milimetersto inches Milnes muliptied by 0.03007 equals nches (a7 mm = 67 «0.09907 = 26h Lives to Gable nena Lites multipied by 61.02 equals cubic inones, 1588 L= 153.8 x61 02 = 9968.9 04. In (Grams to Ounces [Grams matipied by 0.03527 equals ounces. 595 G = 595 x0008507 =21 07, Kiogeams to Pounds Kiograms malipied by 2.205 equals pounds: 10,228 xg = 10,208 x2.208 Nowon-mete inch Pounds ‘Newton-retors mulipbed by 8.85 equals Inen pours 40.7Nm=s07 x08 Newton-mtrs to Foot Pounds Newion-meters multpied by 0.7375 equals, fect pounds. 197 N= 197 x 0.7975 = 145 tela Bar io Pounds per Square Inch Bar mulled by 145 equals pounds per square neh 685 Bar = 685 x 145 = 9.902 8 ps ‘ggrams per Square Certmeter fo ans per Sure an os ‘Kiograms mulipiedby 14 22 equals pounds per ‘Sauare neh 32hg=9.2x 14.22 = 455 psi Klgpascas © Pounds per Saar ich ba Kipascals mulipied by 0.145 equals pounds per square inch ‘310 kPa = 9100.14 5 psi Cubic Centimeters to Fiid Ounces [Gubtecentmeiere maniedby 205 equals ‘uid ounces. aah 226 0 26 429.5 =8 02 Lives o Gallons Lites utipied by 0.264 equals galons 360 = 960 «0264 = 147.8 ga ‘Degrees Centigrade to Degrees Fahrer- ‘Degrees Centgrce mulipledby 9/8 pus 92 equals Degress Favenhon a s00°¢ 100x915 +92 = 212" F FORM 6248 Firat Editon Tae-7GENERAL INFORMATION INDEX OF SEALANTS, ADHESIVES AND may be used to match the general description to a LUBRICANTS specific product or is equivalent (ie. pipe sealant Parma Lok® Heavy Duty Pipe Sealant with Tetlon® orits equivalent). Waukesha does not endorse one brand ‘over another. In all cases, equivalent products may bo substituted forthe brand name listed. All pat numbers listed are the manufacturer's numbers. ‘The following is a list of sealants, adhesives and lubricants (see Table 1.15-8) required to perform the tasks in this manual. Where possible, brand names are included with the task. When they are not, this index Table 116-8, Sealants, Adhesives, And Lubricants NAME USED IN TEXT BRAND NAME/DESCRIPTION igh Temceraturs ag FEL-PRO® C5-A®, Part No, 51005 or Loctite” Anti-Seize 767/ Copper based anti-seize compound ‘ni Seire ost Never Seez” Ani Seize and Lubricating ConpoundNickle based ani-eeize compound Black Scone GE Simate™ Siicone Rubber : “Magnatx® Products Penetant(SKL-HFIS) Developer (SKD-NF-ZP-8B) Gleaner Remover Bling Agent appar Pre per Siang Paste Permatex” Non Oring Prussian Bue (rf by Loctto® Corporation) ‘eramie Bonded nigh temperature Sol fim lubreant| Clearing SoivenuMineral Spits | Amisot® SoWvert (mfg, by Standard OW Lube-Lok® 1000 or equivalent Dielectric Siicone Grease Dow Coming DC-200, GE, G-626, GC Electronics 25 Engine Of See Lubricating Ol Epoxy Sealant Seah Weds, 270 Bn Blk Erowy Potng Compounaiosive Par Nos Aandi Gasket Adveswve ‘Scotch Grip 847 Rubber and Gasket Adhesive (fg by BM), 3M ID No 62-0647-7530-9 Heavy Lube Of Vactra® 60W80 Gear OW (nig. by Mobi) Lui Soap Dove™ Dishwashing Liquid Lithia Grease ‘See Molyeote™ Paste ooquic® Primer Wem No. 74766 (mig. by Loctte® Corporation) Loctite 282, Lectie® Hem No. 2424'/a blue colored remavable ead locking compound Loctia™ a71 Loti Hem No. 27 41/a red colored thread locking compound Leste Compound #0 Lctta® nem No. 6404 Ugh Temperature Retaining Compound 40 Losite® Hycraulie Sealant Loctte® Hem No. S694 oite® RO 808 Lecto™ ern No, 60934 Locite™ 620) Lotta Nem No. 620/High Temperature Retaining Compound Lubreating OWERgine OF ‘New 0 of he ype used nthe erankease Magnatan® ‘See Bling Agent ‘Dow Coming Molycote® Paste G or CITGO Linopiex® Grease NLGI No, 2 Product Code 85-040! [amolybdenum-based grease [O-ing Lubricant Parker Super O-Lubs® dry slicone lubacant Permatex’ No. 3D Avion For AcGasket® Sealant Liquid Permatex No.2 Form-A-Gasket™ Molyeote® Paste G Lectte® item No, 3 Loctta® item No. 26 Sealant Pipe Seatant rma Lok Heavy Duly Pipe Salar wi Telon®, tem No, LHOSO Stet” Siete” ica cegistere tademark of Stoody Deloro Stelle, ne wo-40™ W040" isa registered Wademarc of the WD-40 Compa Tas FORW 6246 Frei EdionSPLIT RING WASHER USABILITY CRITERIA ‘Split ring washers are washers that, once compressed, keep an outward pressure applied on screw threads allowing friction to hold them in place. Depending on the location and application, these washers may be suitable for re-use. Do not re-use split ring washers that have flattened due to high temperatures or over-use (see Figure 1.15-11). I you are not sure if split ring washer is Suitable for re-use, replace it with a new one. DONOT RE-USE Figure 1.15-11. Split Ring Washers, During overhauls, and on all components subjected to high temperatures, Waukesha recommends replacing split ring washers. GENERAL INFORMATION FORM 6246 Fret Eion 135-10SECTION 1.20 — SPECIFICATIONS SPECIFICATIONS “The following tables cover the minimum and maximum. specifications for parts requiring inspection during routine maintenance or overhauls. The tables also ‘appear in the tasks where the inspection criteria is, required, Parts not meeting the specifications listed should be replaced. This section does not cover all components, but rather lists the most common wear parts and their allowable tolerances. All parts should be inspected for damage or wear whenever they are removed. Any questions on whether a part not covered. in this section is suitable for reuse should be referred to Waukesha Engine Division, Service Operations Waukesha provides the following wear limits to assistin deciding as to the reuse of engine parts. Many parts can bbe reused at overhaul time if wear limits do not exceed those listed in Table 1.20-1. Under no circumstances can the use of any part exceeding the established wear limits be justified. When using these wear limits, the decision to reuse engine parts must be tempered with the consideration of + Number of mating parts being reused. * Service life expected until the next overhaul + Problems that might occur in the future. + Engine application E. Horsepower requirement F. Maintenance intervals G. Type of installation Waukesha Engine Division's position for these wear limits is that the reuse of an engine part that does not ‘meet the new part specifications is solely the responsi- bility of the person making the inspection and repair Under no circumstances is the reuse of any part exceeding the following wear limits justified. ‘A CAUTION ile Waukesha Engine does not recommend the reuse of pistons during engine overhauls, we recognize that this is a common field practice. Pistons experience a combination of mechanical and thermal cyclic stresses during operation. Alu- minum piston life is unknown beyond recom- mended overhaul. If and when end users make the decision to reuse pistons, inspection steps need to, be taken to minimize failure risks. Contact your authorized Waukesha distributor for assistance. Disregarding this information could result in prod- uct damage and/or personal injury. Waukesha Engine Division assumes no liability for any damage which may occur through the reuse of engine parts which fall outside of the new part tolerances. GEAR TOOTH WEAR - GENERAL After a gear train has intially worn in, it wll have a long and trouble free lite if not overloaded and if adequately lubricated with clean oil The first sign of a gear train in trouble is unusual gear tooth noise and a sudden increase in gear backlash. Gears fail because of excess wear, plastic low of gear ‘material, surtace fatigue, or tooth failure. Mageartrain shows signs of excessive abrasive wear or scoring, it is an indication that abrasive material has passed through the gear train or there has been inadequate lubrication or both. the problems should be resolved and the affected gears replaced. The lube oil filter by-pass vaives should be inspected as wellas the oll passages and nozzles that provide lubrication to the gears. If the gears in the gear train show signs of finning, ridging, rippling, pitting, spalling or tooth breakage, there is a serious problem. These types of failures are associated, in one way or another, with tooth loads that exceed the design of the gear. the reasons for the gear tooth overload should be determined and resolved and affected gears replaced, Bearing failures, misalign- ment, torsional vibrations, or failure of the driven ‘equipment are some possible causes, TIMING GEARS The camshalt idler gear is a "hunting-tooth” design to ‘minimize tooth wear. The fractional drive ratio between the crankshaft and camshaft gears results in the idler gear timing marks realigning with the crankshaft and camshaft timing marks only once in every 184 crank- shaft revolutions. The most practical way to realign the timing marks, when timing a camshaft, is to remove the idler gear and reassemble to its timed position as previously described, FOR 6248 Fest Eaton T3077SPECIFICATIONS Table 1.20-1. Wear Limits WEAR LIMITS - GAS MEASUREMENT INCHES, METRIC (mm) Cylinder sleeve bore wear (0.00% (0.625 mn) per oh of clameter ‘Gyinder cleave bore - maximum taper (attr tdge removal ana honing) 0.0005 (0.018 mm) per inch of piston travel Cylinder sleeve out of round — maximum (0.005 (0.127 mm) Piston diameter wear 10,0005 (0.013 mer per inch of ameter measure al skit and above pin Piston pin Gameter wear 0.001 (0.025 mm) total wear Piston pn bore woar and pin bushing wear (A) in piston (0.0006 (0.01 mi) per inch of ameter ned 0.0005 (0.013 mm) per inch of ameter oumal cearance Main and connecting rods ‘10008 (0.013 mi) per inch of dlamater aver high nit Crankshatt (A) Main journal maximum outa ouna (0.0004 (0.010 me) per inch of ameter (8) Connecting rod journal out of und 0.0004 (0.010 me) per inch of ameter (© Ena pay 0.005 (0.13 mm) over high lit ‘Gamshaf - minimum oul ameter (0.0006 (0.013 mm per inch alameter under the low iit () Bushing 1D (0.0005 (0.013 mm) per inch diameter over the Pgh iit (@)Endpiay 0.010 (0.25 mun) over high nit vanes Minimum stem diameter (0.00% (0.025 mm) total wear Vane guide ~ maximum 1D 0.001 (0.088 mn) Valve seat maximum width (Original wieth 15% disturbed after 50 hours of operat n. Disregat A. CAUTION ] Piston ings must be ro- placed if they have been this information could result in product damage. T20-2 FOR 6226 Fret EaionSPECIFICATIONS Table 1.20-2. Cylinder Sleave (Used With Four Ring Pistons Only) ~ Gas — dl | 2020-030 CYLINDER SLEEVE eRaKeTUNeS oN eis SORE Pmt gos ste ano SERRE ROSIE ANE OEE | i {i 1 — MEASUREMENT TNGHES | METRIC (amp Seve yor Wot ype apa (Pet don pjecion cosine [ines (8) Farge righ euren 612A bore dove ied Won one’ dee ges) | aseosmosess | aaron Flange hh (eee ule wh finde sev geste, 9-8 neh owe ernes) Ossas=osoee | ros70-10607 (6) Shove projection above carkase er 6-12. bv eres) 0010-00068] —o0es-o.1997 Sloe poste above canicae (uth ira sove ast - 3TH bow gre) [0000-0007 | — 0000-01178 (0) Farge 00: 108 an s790 70.18 10.100 | Pan775 2508 Flange 00-7002 roan rate | 200.5120 606 {© Stove O0 (bo Tango 08 ara LHD e6 746080 Sieee OD (low lange) L702 Tove 26038 (Seve eet Tes wr3078 (6) ieee 0: 5108 an LETOO Taong8a010 | Pie be 21559 Seeve 0-702 3.3769 0.760 | 06.15 205 168 (WSteve 00 over so eee Ou ans THO o073-00r7 | ease 245708 Sieve OD owe sealaes 7042 To2i0— 102s | eat cos 200209 Seve (Doula end mas 0001 028 Sieve seal ares io caricoedewraras ova BE hbo 70005-00655] 019-0060 Sieve sala o carcass cewerce ona sid 98 wer bore 00008-00040 | —00%9-0102 "NOTE: Cylinder sieeve gasket PIN 1763750 is usod on 93/8 inch Bore PIN 208150C and 205S0H oylinderIners only. For use o standard or oversize ovinder sleeve gaskets reer fo Chapter 3 FORIA 6240 Fie Galion Ta0-3‘SPECIFICATIONS ‘Table 1.20-0. Piston (Four Ring Only) ~ Gas NOTE: Dimensions A and 6 must be measured at the locations shown FOUR RING PISTON - GAS Piston materia Tin plated aluminum aloy Piston typ: Cam ground Piatone are removed tom: Top of ranks Permissible weight vation pe st: 2 ounces (567 gram) MEASUREMENT INCHES. METRIC (mm) Piston hole center opision crown standard compression ratio 151086 (825:15 101) 5.285 6.258 758625 166.677 LS7OOGIGSI(6.25:15 101) 5.620 ~ 6.600 142.748 — 149.002 1L7042G/GSI(8.0101) 5.465 - 5.475 R81 - 190.005 10,0:1 Compression ratio s108081 6587 6.597 167.310 167.564 57006. 6.091 6.097 154757 — 154.064 30.5:4 Compression ratio 70426. -4 Ring 6092 6097 5A ToT 154.86 (A) Piston skin diameter op) inne with pinhole ‘AlLB-¥72 neh bore models (L5108 etc, L5106 te) ‘846i 8.462 21a.809 214 904 ‘AN 9-8 inch models (L7042 ele) —4 Ring 9.394 9.05 257.084 ~ 257.100 90° trom pinhole: ‘ALB? inch bore made 477.478 Bisave 216981 ‘ANG.9@ inch models —4 Ring 9350-9351 237 490 237.515 (©) Piston skirt diameter (Goto) in tne with pin Pole ‘ALB-1?2 inch bore models 766.178 BiG SAT 218387 ‘ALS.W inch models — 6 Ring 9.354 9.355 2397 592 257.817 rom pin hele ‘Al @-1/2 inch bow models 487 8.488 215.570 ~ 215595 "Al o.e inch models ~ 4 Fing 2.362 0.363 257 705 297.820, ‘(Continued i204 FORA 6248 Fret EaiionSPECIFICATIONS ee bk NOTE: Dimensions A and & must Be measured at the locations shown MEASUREMENT INCHES. METRIC (mm) (©) Paton pn bore ‘S.0004 30008 76.210 76228, (0) Piston skit to sleave clearance (rust area) ‘AIL8-12 inch and 8-3/8 inch bore models 4 RING pores 00148 3124 09682 (©) Groove wt “Top, Bn and Sra AT 8-12 inch models (5108 et, L57OO et) (0189-0190 4801 ~ 4.826 Top: Al 9-3/8 inch bore models (7042 ete) 0.1915 0.1905 8641 4 8895 2rd ard Sra Al 9-08 inch bore models (7042 ela) 4 Ring (0190-0191 48264851 “th Ong ‘Oving, AlB-12 nen bore madels osi3o3ie 71950-79756 Oil ring, AlS-18 inch bore models 4 Ring os76- 0377 9.550 9.576 FORM 6248 Firs Eaton 120-5SPECIFICATIONS Table 1.20-4. Piston Rings (Four Ring Piston Only) - Gas 4} — arene cusamance warns roan el Ce LOAD AT DIA. (LO) A Jae= LOAD AT DIA. (LO) (GAUGE O1AMETER) E (SIDECLEARANCE) \— K (RADIAL WALL 9 "THICKNESS) toe P50 PISTON RINGS (FOUR RING PISTON ONLY) GAS Top fag, (LS108G/GSUGL, LS7OOG/GSIGL, L7042GIGSVGL) Crowned plasma coated compression (op marked wih notch) ‘Second rng Thi ng: (LST08GIGSVGI, L5790G/GSIGL, L7042G/GS), tapered face compression (top marked op” and marked with notch) 7O42GL, ‘Scraper laced compression ting (top marked wth indentation) pered face compression (lop marked "op" and marked with noth) Fourth ing: (ll VHP Gas Engines), conformable grooved ol ing with expander Gop marked wih notch) Winans san Tones WISSSG [Taso —[—aaon eon [same ao sence Te EA ee Sees Oey | RRR | BESSY os cee (Sagas smeeet no fee Cea oases a ae ee rea CaReaeey | Pee Oy | fae AaNR By Bagman T2068 FOR 6240 Frei EatonSPECIFICATIONS a G |AUGE DIAMETER) E (SIDE CLEARANCE) a = ere cteannen TANGENTIAL LOAD (LT whe K (RADIAL WALL THICKNESS) (wots) LOAD AT DIA. (LO) |e LOAD Ar DIA. (LO) ‘Measurement Top ‘2nd and ard ath (O) Ring wai 7oK2e. 0.1850 0.1865 mn (6899-4797 mm) ‘91850 -0.1865 (4699-4707 mm) 0.3720 ~ 037361 (tag 9.487 mm (€) Ring, piston groove, side dlearanc LstoseiGsvat, L57e0G/6SGL ‘.0025 - 00050 im, {0.064 0.427 mm) 9.0040 0.0065 (6.102 0165 rn) ‘9.0090 - 0.0085 m (076 —0.1407mm) Lror2ciesi ‘0.0050 -0 00751. (270805 mm) 0.0035 - 0.0060 (02080901524) ‘0.0026 0.0080 n (01036 “0127 mm) os2et (0.0050 0.0075 in (oer 0.191 mm) 0.0035 - 0.0060 (i089 “0.452 mm) ‘0.0026 - 0.0060 (060127 mm) (UD) Loadin bs, at gauge diameter LSI0SG/GSIGL, (57600GSV6L 30s (FSR) (mIMUM 15-2215. 68-9940) 17042 GIGS! 22ibs. (19.6) (rina) 135-205 ibs (61-9349) 7042 GL 22 bs (18.8kg) (inimum) 195 -205hbs (6.1-93k (ET Tangential oad, nibs, al end clearance {5108 /GSVGI, LS7e0G.GSVGL 285 98.5 bs. (129-175 4a) 17042 G/GSi 240-980 ibs. (109-172 Kg) Tose GL 240 98.0ibs. (109-17 24g) FORM 6248 Fit Eaton‘SPECIFICATIONS ‘Table 1.20-5. PIN 2051301 Cylinder Sleeve (Sleeve Used On GL. 9-9/8 Inch Bore* Only) - Gas I A CAUTION be used with this cylinder sleeve. Cylinder sleeve gasket should NOT -——# 1 MEASUREMENT INCHES: METRIC (mm) ‘Sloeve iype: Wel ype, replaceable (A) Heat dam projection 0.045 — 0.088 1S 1265 (@) Flange eign (0.5695 ~ 0.5655 1491314388 (€) Sleeve projection above crankcase ‘0.0010 0.0060. ‘10254 0.1528 (©) Flange OD: 70426 10.611 10.616 2695519 - 269.646 (€) Sleeve OD (beiow flange) 70426. 10.300 - 10.805, 261,620 261.747 iF) Sleeve longth 18.625, 473078 (6) Sieeve 1 70826 9.5759 9.9768 238.193 - 238188 (H) Sleeve OD lower seal area: OH2GL 10.200 — 10245 260.096 - 280.223 ‘Sleeve 1D out of round ents (installed in crankcase) one 0.0508 ‘Sloove seal area to crankcase clearance 1010005 ~ 0.0040 00527 - 0.1018 ‘NOTE: Preferred application, used wit three rng pistons. Acceptable appeaton, used with four rng piston 120-8 FORM 6248 Firat EatonSPECIFICATIONS e ‘Table 1.20-6, Three Ring Piston (PIN 205504D) (Piston Used On GL 9-9/8 Bore With P/N 20510L Liner Only) ~ Gas e ee = a NOTE: Dimensions A and 6 must be measured at ‘he locations shown THREE RING PISTON - GAS Piston materia Tin plated aluminum alloy Piston ype: Cam ground Pietons are removed from: Top of crankcase e Parisi weight variation per set. 2 ounces (667 gama) MEASUREMENT INCHES. (METRIC (mm) Piston hole center to platon crown 6.094 154.787, (A) Paton skit lamer (tp) in tne wah pin oe 9596-9397 237194 = 257.159 90° tom pinhole 9.359.355 257-541 = 237.820 (©) Pston skit chametor baton) inne wih pn le 2.354 9.365) 237 592 297.617 90 rom pinhole 362 8.068 237,705 237 820 (©) Piston pin bore ‘3.0004 - 3.0009) 762100767228) (0) Piston skirt sbeve clearance (vast area) 0125-00143 0.3124 00969 (©) Groove wiath Top (01920 -0.1980 area 49022 ‘nd 0.189 ~0.180 1.8008 — 4.6260 od (0.251 - 0.252 5.375 6.401 FORM 6248 Fist Eaton 120-9SPECIFICATIONS Table 1.20-7. Piston Rings (Used On GL 9-9/8 inch Bore With Three Ring Piston And P/N 205130L Cylinder Sleeve Only) - Gas | esa 1B (END CLEARANCE) ‘TANGENTIAL LOAD (LT) wis ———} 4} 4 Loan ar ova. 00) 2 ngs?) (GAUGE DIAMETER) E (SIDE CLEARANCE) = K (RADIAL WALL "THICKNESS) 5 nl = eo “Top ings Plasma coated (op marked with notch) ‘Second rng: Soraper groove compression (op marked wih indentation mar) Third ving: Conformable grooved olsing wih expander Measurement Top 2nd 3rd (A) Rng gauge dameter 375m (26.125mom)_| 97S 58 Sm) | _TSm (208 Emm) 0035-0047 0.965 - 0.080, 0015-0035 n, (6) Ang end clearance at gauge diameter (1308 8508 (Post 202 (8 “08 ry 0317 o.902in 9202-0917 in 0210-0227 in {C) Ring racial wall thickness (8.052 - 7,761 mm) (7.671 -8.052 mm) (5.410 ~ 5.7658 mm) argwon 0.1850 = 0.1665 n 07880-01885. ‘2478-02490. « ng wie (4.6990 - 4.7371 mm) (4.6990 - 4.7371 mm) (6.2865 - 6.3246 mm) 00055-00080 00025 - 0.905010 ‘9002-0 0065in CED Fing, patan groove, aide clearance {0.1143 - 0.2032 mm) (0.0635 - 0.127 mm) (0.0508 ~ 0.1143 mm) (0) Loa ins, at gauge ameter zo. (2240) 35, 5 : (LT) Tangentaload, ns at end Searance : E 54, 8188, Ta0-70 FORM 6246 Fist EatonTable 1.20-8. Crankcase - Gas SPECIFICATIONS CYLINDER’ BLOCK. MEASUREMENT INCHES: METRIC (mm) (A) Sleave counterbore diameter 15108 and LS7G0 10.199 - 10208. 2590055 — 259,190, ‘Sleeve counterbore clameter 7042 0625 — 10.608 269.875 — 260.951 (6) Sleave counter bore depth 6-172 ch Dore 015600 05625 14.224 14.288 Sleave counter bore deoth 8.3/8 nch bore (0.5595 05625 142114288) (©) Crankcase upper Bore: 5108 and (5700 9750-9 760 247 650 247.904 Crankease upper bore: L7082 oat? 10% 262.051 — 262.178, (0) Crankcase lower bore: 15108 and US700 9678 9.680 245.621 — 245,072 Crankease lower bore: L7042 70.246 10.288 260 248 - 260.299) ‘rankoase main bearing joumal bore 66630-66015, 169.240 — 169.202 (Crankease camshall bearing bore 3762 a.759 95.301 95.926 FORA 6248 Fret ion 730-71‘SPECIFICATIONS ‘Table 1.20-9, Crankshaft Wear Limits MEASUREMENT INCHES: METRIC (mm) ‘Grankshatt ‘Grankshatt end play (end play adustmart 0.005 in. (6.076 mm) shims), (0.005 0.016 0.127 0406 “Thrust ring thickness (standard) 0215-0217 3.463 5512 “Connecting rod bearing runing clearance (Gametal clearance") ‘0.0042 0.0081 10-1059 02087 (A) Connecting rod bearing journal ameter (6.2485 ~6.2500 758712 = 168.750 (8) Main bearing journal darter 6.2885 6250, 58,712 198.750 Main bearing running clearance (Gametal clearance” ‘0.0048 ~ 0.0080 0.1149 0.2260 (©) Connecting rod end play (0.029 - 0.081 (0.7366 — 1.047 "NOTE: "Main and connecting rod bearing running clearance” (dame clearance") = calculated bearing D. minus journal. Table 1.20-10, Piston Pin - Gas MEASUREMENT INCHES METRIC (mm) (A) Piston pin diameter 72 nh bore 29967 29902 76.1670 ~ 76.1797 Piston pin aiarmote 9-78 inch bore 2.9969 20008 76.1720 76.1847 Piston pin length 51086 157906 7-582 185, 70826, e192 22 Piston in 12 nch bore ‘o.0012 00022 (0.0305 0.0550 Piston pin 9-38 nen Boe (0.001 — 0.002 0.0254 0.0508 Tao FORM 6248 Frat EatonSPECIFICATIONS EASUREMENT GRES [WERE @ crrecrs oii cass meee [sao (Seg ans re ae onat seois-s0m0 | r6aie—rem 0b wares cuae_aome [aoe (orci bog tessa | “enor ee Garon br supe aarasGacuaesoarrgveaauneeraine | —yooaaomr | over war ceca ocean otee~oet [aye FORM 6248 Fist Eaton 120-18SPECIFICATIONS Table 1.20-12. Valve Train Clearances - Gas INTAKE INTAKE AND EXHAUST MEASUREMENT INCHES. METRIC (mm) (A) Valve overall ena on (OO geeTeenes (ke and exnaus) 10.889 6.428 Gt engines 10383 270.428 iste) 10837 218.280 )Vaive stem dameter GIGS! engines (esse) 0557-0588 14.140 14.173 {Sxrausy top) 08831 -0 5596 saan 142489 {Genaust (bcm) taper 63573-08560 1a 350 ~ 147752 GL ongines (take and exhaus (0857-0558) 34148 14173 {©} valve read ameter (intake and 2825 - 2.895 71755 72.008 (0) Valve face angle ay ; (ONES asin take and exaust goats aor sss ‘ok enaines ‘ntake) 20045 (erate Bo D) vane sest wiih S88 engnes 20° 026s 6701 {ako and exhaust (Gontnvea) Ya0-4 FORM 6248 Frat EaitonSPECIFICATIONS ee dol TARE AND AUST TEASURENENT ORES ETS TaD ea geet a ite pn gh alone si Tae (PEs grip ce Sere oh) a7 sean AES crawratoueeninanaiatony | 2588-05615 vane (gat ve ncn es gases goze gonna (el oy 3358-38 3s (Shah 82 8382888 2a 8a eR See onan ae wee ors‘SPECIFICATIONS TE AAT ERENT EE a = a x3 =, BBs B3 PR SEF Scone pyro zo70-ai8 x. 21388 8248 1 i na be ay ‘ia Ene ieee Sono zona Re igesume [wots (hinscatn sa SE aan 120-16 FORW bo48 Fret EaionTable 1.20-13, Valve Clearance SPECIFICATIONS MEASUREMENT INCHES METRIC (mm) Valve clearance (hydraulic Wers) ‘am it (609 camshaft) Ietake valve iter vavel at piston TOG (0.098 (60018-0078) 0.9806 (70.4572 0.5586) Intake titer wavet at 17° BTOC (0.229 (Pston travel rm TOO) (0405 Nominal 15.8166 (Piston vavel rom TOG) (6.2867 Nominal) Exhaust iter ave! at 20" ATDG (0315 (Piston wavol rom TOO) {o.02t0 Nema) 1007 (Piston ave om TOO) (0.3534 Nominal VALVE LIFTERS MEASUREMENT INCHES: METRIC (mmm) Valve ter body OD 14065 — 1.4975) ‘aa ort - 38 0968 valve titer guide 1D 74905 — 1.5008, 38,0875 98.1127 Vane ier body to valve ier guide learance 1.902 — 0.004 051 = 0.101 Table 1.20-14. Camshatt (Hea pee sonpaigion be Diba eae bs a MEASUREMENT INCHES: METRIC (mm) (A) Camshaft journal diameter 3498 - 9.400) 138 849 65.075 Camshaft journal running Gearance (heoretical) 10.003 - 0.0056 0.076 —0.142 Camshaft end play 0,005 0.008 (0127-0208 End Play Adusiment 1002 shims “Tasting thickness (standard) ‘a 3.982 ‘Gam take) 16.345 ‘Cam it exhaust) 17107 ok arm ratio 70926104 "NOTE: Camshat couping must never be loose, FORM 6246 Fist Canon 730-17SPECIFICATIONS Table 1.20-15, Valve Springs. MEASUREMENT INCHES. METRIC (mm) TA take and exhaust valve spring ree length ‘204035 and 204005A [innr) Sasn6x18 6mm 71.8 mm 204135 (outer) sane 2081354 (outer) #592 3176 Intake valve closed spring length 2040354 (nner 30 @ 664 be lb, 762 mm @ 3012 KG TEKS 208135A (outer) 327/64 6 120108. 5S {26.91 mmm @ SHAD Kg 22.27 Kg Exhaust valve closed spring length 204035 (nner) 30 567 iba 225ibs 762mm @ 2572k9 4 96K 200135 (outer), 3.27164 @ 111 bs 5 bs (86.9 mm @ 50.95hg +227 Kg intake valve open spring ength 2080358 (anes) 2.10164 @ 1262 6s +518. 3.94 mm @ 6724491227 IG 2041358 (outer) 2.23/32 © 235 bs. 110 bs 68,06 mm @ 105.609 14.54 4g Exhaust valve open spring length 204035 (nner) 2i7i64 @ Hibs 15 bs, 7mm @ 498KG 2227 ky 204195 (outer) 2-1WI6 @ 205 bs 210 bs, 68.5 mm @ 92.99 hg 44 5449 oat, oauce ‘VIEW FROM FLYWHEEL END DIAL GAUGE POSITION FOR MEASUREMENT 3 ‘Table 1.20-16. Crankshatt Web Deflection Measurement with Connecting Rods Installed ‘CRANKSHAFT WEB DEFLECTION SPECIFICATIONS Total of 0 007" (010258 mm) deflection tom postive to negalve. Except rear Total of 0 0015" (0.0881 mn) rom postive to negative T2018 FOR 6248 Fst GattonSPECIFICATIONS INTAKE Toc exnausT ‘OPENS, ‘CLOSES. wl, ae ‘SEQUENCE OF EVENTS: exnaust 103° INTAKE ‘OPEN OPENS 2a 248° euuust rae orn OPEN nTaKe’” EXHAUST] ee ‘OPENS. Figure 1.20-1. Valve Sequence ~ Crankshatt Degrees ‘Shown Table 1.20-17. Rocker Arm Bores And Shafts r 8 4 MEASUREMENT INCHES: METRIC (mm) (A) Rocker arm bushing bore LD. (machined in absorb) 1375-1576 34.925 ~ 34,950 (8) Rocker arm shart, 13735-15745 348869949125 unring dlearance, rocker arm bushing wo shalt ‘0.0005 0.0005 (0.0127 0.0635 FORM 6248 Fret Eaton 120-19SPECIFICATIONS ‘Tablo 1.20-18, Rear Gear Backlash Specifications 1-CAM GEAR 2—CAMIOLER GEAR, 3 CRANK GEAR. 4 OW PUMP IDLER GEAR 5— ACCESSORY IDLER GEAR 8 — ACCESSORY (MAGNETO) DRIVE GEAR MEASUREMENT INCHES METRIC (mm) (A) Tiring gears (helical gears), ‘Normal to tooth ‘008 0012 70.208 0.306 Tn plane of tation ‘.9082 — 0.0122 (0.2083 0.5098 Governor dive gears ‘Magneto shalt o intermediate shal (spur gears) 60 and 72 oath gears (0.005 — 0.007 ier 0.78 “42 and 90 tooth gears 0.003 - 0.005 (0.076 0.727 Trlermedioie shaft governor [epial gears), ‘Normal tooth (0.008 - 0.006 aoa 0.82 Tn plane of tation (governor gear) (0.0057 ~ 00085 orate 02159) "NOTE: The engine carishat idler gear a “Hunting-Tooth design, to minimize oth wear. The factonal dive rato between the crankshatt {and camshaft gears resus inthe ler gear timing marks re-abgrang wi the crankshat and carmehaf liming marks only ance in every 154 ‘rankshaftrevoutons. The most practical way orealgn ihe timing marks, when amiga camshaft sto remove the der gear and re-assemie {ois tmed postion as previously described Ta0-20 FORM 6248 Frat EatonTable 1.20-19. Oi Pump And Oil Pump Drive Gears SPECIFICATIONS 1-CaM GeaR 2—CAMIDLER GEAR SI CRANK GEAR. OIL PUMP IDLER GEAR 5" ACCESSORY IDLER GEAR 8" ACCESSORY (MAGNETO) DRIVE GEAR 7 Olt PUMP DRIVE GEAR OIL PUMP DRIVE GEAR MEASUREMENT INCHES, METRIC (mm) Idler gear between crankshalt gear and ol pump ave gear (8) Backiash wit crankshatt gear Normalto tooth Bons-o01 | 0203-0305 In plane of rotation ‘o.0082 0.0122 | 02083 0.3009 (B) Backlash with oll pump dive gear ‘Nomatio tooth 001s -o.020 | 0301-0508 Tn plane of rotation (0.0155 00204 | 0.886 -o5182 (©) End play (nclucng clamp load compression o spindle) 008-0025 | 0209-0695 (0) Bushing inside diameter (machined in assert) 15005-15015 _| 98.1127 08.1969 (E) ier spincle(rotow) outside diameter (ree state)” 14988 —1.8970_| 380171 ~ 98,0208 (F) Funning clearance between spindle ee sate) and busting” 0.0035-0.005" | 00889-0127" (Ol pump dive gears (G) Backlash between external ol pump ove gears Backlash, normal to tooth 0080010 | 0205-0254 Backlash in plane of rotation ‘000820010 | 02083-0254 (Continued) FORM 6248 Frat Eaton 120-84SPECIFICATIONS acy 223 MEASUREMENT INCHES, METRIC (mm) DiPump Clearances (H) Hub clearance with of pump body ce —o040 | 0859-1016 Drive shat bushing insige ameter (intody Tavis 19765] 949125 94.9077 (in cover 11250512515 | 91.7627 ~31.7881 Drive shat ameter (©) Beay section 19720 19725 | sa.5e88 348516 (W) Cover section 1240012485 | 31.6902 ~31 7119 ‘Running clearance between shat and bushing (in cover ‘002 0.0085 [00508 - 0.0889 (Ky inbody (02-0000 | 0.051 - 0.0869 Oilpump pumping gears (0 Backlash between pumping pears Backlash normal fo tooth Dor5-0020 | 0381-0508 (0.076 0.02 0.408 ~ 0.539 Backlash in plane of tation (End play (0.005 (minimum) (0.127 (rinimum (N) Pumping gear ier Bushing inside dameter 710005 ~ 1.0015 25.4127 — 25.4981 (0) Pumping ear (len shat dametor (0.9900 0.9905 | 253402 25.3619 {(P) Pumping gear fer) ranning learanoe 0.002 —0.0085 | 0.051 - 0.0889 002-0008 | 0.051020 (@) Racial clearance between outside dameler of pumping gears ang oll puma body bores ~Gutside diameter wil be slightly larger and running Geaence wil be sight smaller because of aler spindle capscrew Camp load 520-28 FORM 6248 Frat EatonSPECIFICATIONS ‘Table 1.20-20. VHP Accessory Gear Backlash rs cr fered ee ae Gcttalonesiooets Gocicad ate oecaa Seen aro cing esc Saas see eae "NOTE: These backlash its are based on gear tooth fhickness and oe ‘Table 1.20-21. Accessory Drive Ratios ‘because of nberen! secondary folerances, Du must not Be less than 75% of Pe munitram backlash valve iste ater distance design tolerances. Actual backlash may vary shghiy MEASUREMENT DRIVE RATIO DIRECTION OF ROTATION Consen 38 Cw oonng at ont of nae viion panera magnet ave 05 Gi fookng ater of ene on gear cover) a7 cow Governor ve rates 078, 0978 135 19, cow Ovorpeed severe 0 caw Tacrorwe 5 ow Roomate rm cow Speed och 72 cow Oipune (nan Ge sar iz Gir oki tron omar Ring gertaring ior ‘Cran fino 1857 [ Ew tooing at ve ender eto anata” 1s ow ‘Allowable Speed Range For Various Woodward Governors vee 1300 1550 APH G82 "2000 4000 RPM GB 10 900 1100 RPM PG-PL™ 2501200 RPM NOTE: * Cranking rato = Ring Gear Teeth Staring Motor Pinion Toeth “Thamagnata rection ofrolation designated is determined by looking at he deve endot the magneto. Therefore he magneto rotation esignanion s oppeste fo the rofaion ofthe engine snve. ACW enkine dive requires a magneto designated as CCW and vce versa. en norma on inl maintain allowable governor speed, PG-PL PQvPL Speed sotings Should nol be attmpied wieut hovough ne operating speed fs changed k may Do nectesary fo charge the govemor ave gears obtain a dive relic tat smo are set at Woodman oral pressure verses ongie speed. He ajusing nowtedge of te proeaure FORM 6248 First Eaton 720-28‘SPECIFICATIONS ‘Table 1.20-22. Flywheel And Housing OT F | fe MED | {fe MEASUREMENT (TI) INCHES METRIC (mm) (A) Flywheel pt bearing bore run-out 0.008 0.190 (8) Fiywhesi face runout on whee 0.016 0.406 (©) Fiywhee! nousing bore run-out 0012 (0.905 (0) Fiywheet housing rear face run-out oor 0.305 (€) Fywes| clutch or coupling mounting face run-out 0.016 0.406 (F) Fywhee clutch or coupling lot diameter run-out 0.005 0.130 (G) Flywee! housing rear face to crankshaft ange 3219-5281 722560 194.197 Flywheel housing ‘SAE Siz: #00 Staring motor fange size: #3 ‘Starting motor pinion data: 68 poh 120-28 FORM 6288 Frat Eaton‘Table 1.20-23. Turbo inspection SPECIFICATIONS TuRusT BEARING TURBINE WHEEL / MAGNETIC ‘BASE. DIAL, INDICATOR, ‘ADAPTER oFFser tel EXTENSION ROD, COMPRESSOR WHEEL - G t t omg unas | 7 wolttion | vata ass TURBO NSPESTION tose! Fil Measurement Tada easuret SENT Sa 0060202 ay [006-000 (076 ONE Table 1.2024 ubrleatonSytom Pressures MEASUREMENT us, HETAIS Tomaleabizedol peau wih ore wa 88 sate Law oipess om ies 27a Taw pss nase) ET wea Moma of sseoa Pe URN woos ai Table 1.20-25. Lubrication System Temperatures MEASUREMENT 3 wen eo ov of nome wot ma Hora eabtad wow HOF we iho pre re 2 oe Twble 12026, Lubeation Sytem Engine Hansient Th Angles ATITUDE DEGREE few 2 Figen 7 "NOTE: Permissible continuous duly engine ti angies af iow oll mark, based on keeping suction soreen submerged FORM 6248 Fit Eaton 720-25SPECIFICATIONS Table 1.20-27. Cooling System Temperatures Normal: JACKET WATER OUTLET TEMPERATURE!: Normal: ‘Standard Cooling System: 40°F (82° C) foe continuous rating 200" F {83° G) foe interment ating Elevated Temperature Solid Water Cooling System: 210° 295" F (82° ~ 119°C) soll water Ebullient Cooling System 212" ~250° F (100° 121°C) NOTE: | See Table 120-28 or alarm and shutdown lomperatres. By CAUTION ] Aermens shutsown val ues aro based on dry natural gas (900 BTU/cu. tt. SLHV). Refer to Gas- e0us Fuel Specification Sheet S7884C and Lube Oil Recommendations Sheet S1015Y or latest revi- sions for typical changes in operation temperatures for jacket water and lube oil when running on landfill or digester gas fuels. Disregarding this information could result in product damage. ‘Table 1.20-28. Alarm And Shutdown Setpoints Alarm: Shutdown: JACKET WATER OUTLET TEMPERATURE Normal: Alarm: ‘Shutdown: ‘Standard Gooling System: Elevated Temperature Solid Water Cooling System: Ebullient Cooting System 180° F (82° 0) for continous rating 200" F (83° Ch for intermiont rating 10° F (55°C) above normalidesign temperature 20° F (11° ©) above normaliesign temperature 210° ~ 255° F (82! 119°C) solid water 5° F (3° C) above normalidesign temperature’ 10° F (55°C) above normaliesign operating temperature Normal: 212° 250° (100°- 121°) Alarm: ‘Soe Note ? below Shutdown: _ See Note? beiow Normal: 180° F (620) LUBE OIL HEADER TEMPERATURE Alarm: 195°F (@1"0) Shutdown: _ 205°F (96°) Normal: 40-55 pl (275 ~380 KPa} LUBE OIL. HEADER PRESSURE ‘Alarm: 30 psi (207 kPa) 20 psi (138 KPa) INTAKE MANIFOLD TEMPERATURE (GSI AND GL ENGINES) Up 6 10°F (55°C) abave design intercooler water ile temperature 15" F (8°) above design intercooler water int temperature 20" F (11°C) above design intercooler wate in temperature INTAKE MANIFOLD PRESSURE Contact Waukesha Engine Application Engineering Deparment MAIN BEARING TEMPERATURE ‘Shutdown: 250F (121° 0) OVERSPEED ‘Shutdown: 10% over governed speed NOTE: Washes Pores Stems Code 1105, 1058, or equvalen hutown system i recorended when cle wae tonperatie grecods 210° F (09 Waukesha Power Systems Code 1106, 11064, or equivalent shutdown system is recommended for ebulienty cooled engines. Ta0-26 FORM 6248 Fit EatonSPECIFICATIONS Tablo 1.20-29, Capacities MEASUREMENT us, METRIC Lubrication System Capacities Sian figvet mary Etsy We3tie Lube i iter BB gal 136 3tiNe Oi caver 8 n=") 62 ca 26.1 Live Si conte Oinchy 0 gal Salve ibe ol saner O75 ca 28.uke math Flcord total amount fr future reference. “otal capacity of lube ol system, Fol pan, iter, cooler, 61, rn ‘engine, then add ol as required te bring a level nal pan back 1 righ Governor — Air Starter Capacities [UGS governor 08 reservow Tat Tate [EGBIOP governor oll reservoir 15.at Taine, PG-PL governor al reservoir 1Bat vate Air stair oil reserva for ane shot ibicator 20 Pat oauive Air motonzed pre-lube motor in-line hibiaton 05 Pat O2tive ‘Jacket Water Capacities B12 inch bore 107 gar 405 Live 48 inch bo 100 ga ‘37 Live Surge tank cr 123 Lite (il cooler water (5 nen ameter) 34 gal WLive Giller wate (8 nen lametes, 5 aa 20Lite Gicoler water (10 nch ameter) 54 9a) Sete intercooler water capaci ‘550 oat zoe damage to equipment. A CAUTION] 12 inet reach spark plugs must be used with 1/2 inch reach spark plug carriers. Mixing spark plug carrier and spark plug components will cause Table 1.20-20. 1/2 Inch Reach Spark Plugs (Used With 1/2 Inch Reach Spark Plug Cartiers Only) Spank [rune | wex | reach | car | casker ‘APPLICATION Pricooser | remm | oars | vein [202% 1 ves | Standard tor G51 model wed wih CEC. A, M0000 paveaaaea | 18mm | 1000 | sein | 22220, ves | cies: Proven or soak py mound et, FOOD CA prveooeon | 1amm | 027s | vain [292] Yeo GiGSi- Shielded CEC - CSA prvcosvm | 8mm | 0675 | zn [QI] ves Standard or GL CEC igion prconeon | sam | 1000 | sein [22205] ves | ac Provision or park pug mounted col FMGOD0 —CEA Pmecoaon | tam | os7s | zim | 210] ves GL Provision for sparkplug mounted co, At Il -CSA Soarkpia azo 7mm with V2 ne each (NOTE: "Torque 104045 fb ary (58 - 61 Nim) Use steel gasket PIN 400868. Tag ay " r ena shielded inion system used, dghton a Gonnecior nuts and spark plug extensions tnger tight plus 1/80 1/4 tun. Do not {ouch terminal connectors vith bare hers and make sure all parts are ean before assembing ne’ Al ured conecions on ‘Shelate/ magnates std cor should be Pagar tgntoned any mn FORM 6248 Fret Editon 720-27SPECIFICATIONS A. CAUTION | YH? St 1318 inch reach spark plugs must be used with 1/16 inch reach spark plug carriers. Mixing spark plug carrier and spark plug compo- nents will cause damage to equipment. Table 1.20-31. VHP GL 13/6 Inch Reach Spark Plugs (Used With 13/16 Inch Reach Spark Plug Carriers Only) SPARK «| Tore | Hex | ReacH | GaP | GASKET APPLICATION me | oma Ton-fited GL (Used wih Ph 63654" Boe CoP) Pmsooees | semm | oer | rae Jooisimm| Ye ‘dorsi (nctoh we | 80101 | vey] Wanstead GL (Used wth Pn 65665 Bw Cay Pmisossow | ramm | ors | 26 |ecteamm| ¥ pe etna 010% Tor aiaiod GL (Used win Pa ea8o4 Bue Com Pmeosoet | 1mm | 0875 | 136 | gabimm | Yes CF bah ecaneptsean) : prsoeoeu | temm | oars | rane [000m | vee Shalded GL (Used wih Pn 696940 col) Pil APPLICATION 419/16 INCH SPARK PLUG CARRIERS aosserit Teed on 510861 or 208507 eed on S790GL and 7O4RGL (NOTE: Torque to 40 15 fb dy (54 67 Nr). Usa stool gaskot PN 499865, ten a shielded gniion system's usod,tghien all connector nuts and sparkplug extensions finger ight pls 18 te 1 tum. Do not touch terminal connectors with bare fingers and make sure al pats are clean belore assembing them. All iuried connections on shee magneos ar ol shouldbe Anger fered ony Seer to Se 11-3696 fr adaitonal GL spark plug information GAS ENGINE COMPRESSION PRESSURE ‘COMPRESSION PRESSURE - PSI AT NORMAL CRANKING SPEED ‘COMPRESSION RATIO. NOTE: Use these compression values during troubleshooting to assis in determining engine conden. Figure 1.20-2. Engine Compression Pressures Ta0-28 FORM 6246 Fst EaiionSPECIFICATIONS ENGINE TIMING DATA B CAUTION | Ths intormation doos NOT supercede Special Application Approval data found on the engine nameplate. Disregarding this information could result in product damage. NOTE: Changing the engine timing wilalso change the exhaust emissions and fue! economy. ‘Table 1.20-32 and Table 1.20-33 list the correct ignition timing for VHP 12 Cylinder engines from January 1, 1980. Refer to Service Bulletin 11-1820A for the timing specifications for older engines. Both Table 1.20-32 and Table 1.20-33 list the engines by models and fuel types. Table 1.20-32 provides data for engines that are not DSM equipped and Table 1,20-33 provides data for engines that are DSM ‘equipped. The fuel types are defined in the following paragraphs. COMMERCIAL QUALITY NATURAL GAS: A natu- rally occurring mixture of hydrocarbon and other gases found beneath the earth’s surface, often in connection with liquid petroleum. The principle com ponent is usually methane (CH,). Minor components are heavier hydrocarbons and other gases such as nitrogen (Nz), carbon dioxide (COz), helium (He), argon (Ar), oxygen (Oz), and hydrogen sulfide (HS). The heat value normally ranges from 900 - 1000 Biurit? SLHV (33.54 ~ 37.26 J/cm). Octane rating of 118 - 120. Holland's pipeline gas has a heat value of 820 Btu SLHV (30.5 Jom?) DIGESTER GAS: A fuel gas formed by the anaerobic decomposition of organic matter in a digester. It is, composed primarily of methane (CH) and carbon dioxide (CO2). The heat value normally ranges from '500 — 600 Blut? SLHV (18.63 ~ 22.36 Wem). Octane raling of 120. Hydrogen sulfide (H2S) is a typical trace component. FIELD GAS: The heat value normally ranges from 900 - 1500 Blu/ftS SLHV (33.54 - 55.898 J/cm?), Octane rating of 115 ~ 118, LANDFILL GAS: A fue! gas formed by the decomposi- tion of landfill refuse. It is composed primarily of methane (CHg) and carbon dioxide. (CO2). The heat value normally ranges from 450 - 550 Btu/ft® SLHV (16.77 ~ 20.39 Jicm’). Octane rating of 118 - 120, Chlorine and fluorine bearing compounds are typical ‘race components. OCTANE NUMBER: The octane number of a fuel is a measure of If its ability to resist detonation (knock). It may be measured or calculated. For gas mixtures itis. usually calculated from a component analysis. On the motor method scale used by Waukesha, the octane ‘umber ranges from 120 for methane (best) to 0 for normal heptane (worst), PROPANE, HD-5: A fuel gas made of carbon (C3), and hydrogen (Hg) with 97.1 octane rating, Often used as a backup fuel LOW BTU FUEL: Fuel having less than 700 Btu/t® (26.08 J/cm), such as landfill gas. Di CAUTION] etenstion is wor at lowed at any time during jine operation, regardless of the specified tim- ing. If detonation occurs at the specified timing, a timing adjustment must be made to retard the ignition timing until NO audible detonation exists. Engine damage may result if detonation occurs. FORM 6246 Fest Faion 120-39SPECIFICATIONS _— Table 1.20-92. Ignition Timing Data (Non-DSM) OPERATING RPM 600 | 700 | 800 | 900 | 1000 [ 1100 | 1200 COMPRESSION MopEL_| “RATIO: Duty FUEL TYPE IGNITION TIMING (° BTDC) 151086, 8254 Cont Low Btu ar [ar [er [ew [26 | ae [ow 51086, 3254 A HO-S LPG. we le fe fie | |e | ie 151086, 8251 Ai Nat, Gas av [ar [ar [ee | ae | oe | ew e108" 8251 o Nat Gas =a el em |oalaer 51086) 10:1 Cont Low Btu 20 [ao [oe [oe [ae [ae | a Ls1086 08 Al HD-5 LPG. we fe pe fie |e |e | ie 51086) 708 Ar Nat Gas Ee ee 151086" 10:4 Cont ‘Nat Gas sae |e ||| ear) [5108651 258 Cont Tow eu we le le le we Le 1510805" 8258 Cont HO-SLPG e[elele oe tstesasi [e251 Cont HO-SLPG we fie foe fe foe [oe [ae Lst08sst 825% ont Nal, Gas ze [em [2 [ee | ce | ae | om L5108Gst 8254 tat Nat Gas we [ae [ie [ie [ie | ie |e Lsi08esr 825: Cont Nat Gas ~[-T-[- J - TI - Te 510668" 82511 tat Nat. Gas ~t- {= T-T- Te Ls1066S1 103) ont Low Btu we [ae [ie fie |e [ie |e 15108681 10:1 Cont Nat Gas we Le pie |e | we ie | is L5108GSt 101 tne Nat. Gas =a ~[-T- Te Ls10865r 101 al Nat. Gas = ~T-T- Te si0eG 1058 a Low Bu 20 [20 [20° [ao | oo | oo | oo 51066, 10s a LowOcare tsmn [oe [oe |e |e] «| » | 6 51006, 1054 al Low Octane 117mm [10° [1 | xo | | 1 | 10 | 10 5106Gt_ 10.5 al Nat. Gas ve fie fie fie De foe [ow [57906 e254 (Cont Low Bus we lee le [ee |e | oe | oe (57906 82541 al HD-5 LPG, ve |e [ie fe |e [as | is 157906 225 A Nat Gas ze [ee [ae [ow | ae | aw | oe 157806 108 Cont Low Btu 20° | 20° | 20° | 20" | 20" | 20 | 20 157006 10 A HD-5LPG, we [ae fae fie fe [ve | (57906 10 A Nat Gas 20 | 207 | 20" | 20" | 20° | a0 | 20° s700g" 101 Al Nat, 625 -~[-T-T-T- TI - fe TS79085I 3254 Cone Low Btu a [ee fer fer fee |e ae ta7e0asr= 32541 ont HD-5 LPG, *lelelele le |e 179068 3.2551 ont HD-5 LPG. we fe fe fe foe fe |e 15790851 2257 (Gone Nat. Oss ee [ar fer fer | er | er | or (S7906S1 8254 Inte Nat. Gas 2 [2 | 2 | 20 | ao | ie | oe ‘s7e0asr 0254 ont Nat. Gas [ee eee eee |e a Ls7906sr 3.25 Inte Nat. Gas ~ TTT ee T0-30 FORM 6248 Fist Eaton‘SPECIFICATIONS e ‘OPERATING RPM ‘600 [700 [ 800 [800 [1000 | 1100 | 1200 ‘COMPRESSION MoDEL_| RATIO buy, FUEL TYPE IGNITION TIMING (° BDC) S70GL, 108 o Low Btu 6 pe le [w]e | | S706, 708 a Tow Octane smin Le tele fle |e |e | « 37006. 1051 a Tow Octane. 117M, [10 | 10> | 10" | > | v0" | 10" | 10) 37006 10:1 ‘a Nat Gas wo fo lopmlol«i|n [rose a Cont tou eo [2 [oo [2 [ee | oe | ow (70426 mn ‘al HD-5LPG. we [ve [ie |e |e | ie | is 70826 om a Nat Gas eer [20> [20 [ew | ee | ae | on 70826 708 Cont iow ew 20 | 20° | 20" | em | ae | ee | oe L706 08 ‘Al HD-S LPG wm Le fe | fo | | & L70826 0 al Nat Gas aor | 20° [207 [22 [22° [26 | 2 Lower 08 ‘al Nal Gas ~{-T-T-T[- T- Te 70268) a Cont Low Bia ar [er [ar [ee [ee [ae [oe 17022081 at Cont HO-S LPG. efelelel[eleles LroseGSI a Cont HO-SLPG. we ae fe fe |e |e |e L7os26s a Cont Nat Gas ar [er [ar [ee [ee [ee [ex Lrose681 a Tat Nat Gas ee fe fis [as pis | e@ L70eeasir et Cont Nat Gas -~[-[-[-[-[- [Te 708265" oH ine Nat as =e esos |e 1 Tool Tost Cont ow Bia — pe pe pele lie [ie 7oH2GL, 1051 o Low Octane, 115 Min ~[efelele le ]e 7oHeGL, 1051 ‘i Low Octane, 17 Min 1 [ae [10 | 10 | 10 | 107 7oa2Gt 1054 al Nat Gas w fo fo fw] io | | 10 ToHRSL 1051 Cont HO-5LPG. «l[*|l*]# NOTE:* These engines run with an etevaied jacks! wale lomperature Between 210: and 250° F (00: ~ 121° Oils necessary to aust he ignton timing lo 'low fora greater margn of protection from detonaton. Changing tne engine timing wil aso change the exhaust ‘missions and fue! economy SL W. Temperature 130° F (54°) 1 W. Temperature 85° F (29° C) FORM 6246 Fist Eation 720-31SPECIFICATIONS Table 1.20.83. DSM Timing Data (DSM Equipped) OPERATING APM 600 [ 700 | 800 | 900 | 1000 | 1100 | 1200 COMPRESSION Mopet_| "RATIO Duty _| FUEL TYPE DSM TIMING (° BTOC) 51086 2259 Cont | towew [15-20 [15 —e0" | 5- a0 [10-24 [1-28 [e-20 [tee 151086, 2254 ‘Al | HO-5UPG [12— 16 [12-10 [12-18] 9-18 | ove" [0-1 | 9-15" Ls1086, 225: ‘ar Nat.Gas [1-20 [15—er |is—21 fre—en [re—ae [10-20 [ya —2m 151086" 8258 A [_Nat. Gas = = : E ~ ser ed 108 Cont| towBs [14 —20° [1420 [16am [16-25 | 2a [18am [1828 Ls1086, 1081 ai] Wo-5uPG [oni [oi |o-1 [on fon [e- | on1z Ts1086, 10 ‘AL | Nat Gas_[14~20 [14—o0° [16-22 [16-2 [ra-20 [1a -o6 [10-28 51080" 10 ‘Cont | Nat Gas = 2 e E ~ [ser 1510805 Cont, | towsw [16-22 [16-22 [16-22 [16-20 [16-225 [16-22 | 16-20) 15109650" Cont | HO-SLPG | 3-9 | oe ae |a-e [oe [oe Ls108Gse= Cont. | HO-SLPG | 6-12 | 6-12 Bn [one [on [one 15106651 ‘Cont | _Nat.Gas [16-22 [16-22 [16-22 [16-22 | 620" [162 [16-22 15108681 Toke | Nat Gas [12-16 [12-16 [ave [v2 ve [1216 | re 18" [12-18 510865 Cont | Nat Gas: Ei i = E = [renee Ls1086si toe [Nat Gas, E = = : = fenie {510868 Cont | Lowen |2—1e [eww [12-10 [12-18 | 2—1e | eas | oie 15108681 ‘Cont. | Nat.Gas [2-16 [12-10 [12-16 | 2-16 | 12-18" | os | ow {510865 Inte | Nat. Gas) E ois 5108680" 101 ‘al__|_ Nat. Gas E e e = = [ons 1086. 10531 a Towa [14-20 [14-20 [420° [14 20° | 14-20" [1420 [aoe 1086 1051 ai 0-6 | 0-6 | 0-6 | 0-6 | 0-6 | o-e | 0-6 1086. tos au ator | 4etor | aat0r | 410° | 410° | a—t0® | 4-20" ‘ro8a, Tos a -4 o-ie [o-i [oie [e-vw few foi (57800, 3254 Cont | towee [16-22 [16-22 [1622 [eon [ve 26 [18-26 [1628 157806, 8251 AL [ wo-5uPG |r2-16 [2-1 [rv | 15 | ots [ome [ois 157006, 8254 A [ Nat Gas [16-22 [16-22 [16-o2: [teow [te -2e [r8—ae [18-28 (57006, 108 Gort [| towana | 14—20" | 14-20" | 1420" [14 20" | 4-20" | 14-20" | 1420" 157006, 108 mi__| mostra |e-1 [e-1e [e-ie [enw | 6-12 | 6-1 | oi L706, 108 ‘Al | Nat Gas [14-20 [14-20 [14-20" [1a 00" [ 14-20" [14-20 [14 20" 1s7906" 708 At__| Nat. Gas = = = E = lone 120-32 FORK 6248 Fret EatonSPECIFICATIONS ‘OPERATING RPM 00 | 700 | 800 | 900 | 1000 | 1100 | 1200 COMPRESSION MODEL DUTY | FUEL TYPE DSM TIMING (° BTOC) 157606851 3251 Gon. | tows [15-21 [15-20 [iso [ve 20 [15-21 [tsar [seh 1579065" 3254 Gon. | nostro | a-e | a-@ | o-9 | 3-9 | a-@ | ano isrooasr= | __82511 Gon, | HO-sLPG 6-12 | 6-1 | oie [enw [oi | o- | om 5790651 8254 Gon [Nat Gas_ [15-21 [15—er [as—an [as—an |ts—2n [a5—an [i520 15780881 8251 trie | Nat.Gas_ [16-22 [16-22 [16-22 [18 ~20> [14 —20- [121 [1218 1570065" 82541 Gon | Nat Gas | — = = = = 7 [ise 1579068" e254 To | Nat Gas | = = = = ~_ pene 7006. 10:1 al Low Buu [10-16 | 10-16 | 1016 | 10~ 16 [10-6 | 10-16 | 0-168 Tow Octane, : . ; 7 57006L 101 al ow Ociane. | gg | 0-6 | o-e | o-e | o-e | 0-6 | 0-6 3 Low Ociane : ‘i 5 ; 7906. 104 a oan 10° | ato" | 4-t0" | a1" | 4-0 57908 308 al__[ Nat Gas [4-10 [4-10 [4-10 [4-10 | aio [6-1 00s a Gon [tows [14-20 [ra a0" [oa ao- [ve 28 J o-2e eae [18 —o8 170426, a4 AL HO-SUPG [12-16 [12-1 [12 10" 9-15 [ois | o-15 170826 ea ‘Al__|Nat.Gas_[14~20° [420° [razor 1-26 [re -2e | 18-28 170426, 10:1 Cont | Lowa | 14~20" | 14-20" [14-201 16-20 | 18-24 [1928 (0426 10 al | HO-StPG | 6-12 [6-12 | 6-12 10 | ae [ae 170026 105) ‘Al__| Nat. Gas [14-20% [14 -20° 14-20 16-22 [28 [aoe 70026" 10:1 an | NatGas_| = = = 5 = [is-28 (702268) on Gon [ towsu [15-21 [15-26 [sor [ton [re_ae [ean [eo Lroaeasr= a con | HostPs | 3-9" a= | oe 3-9 [3-8 7042651 en Cont | Ho-5iPG | 6-12 | oie | o- ee [ee 17022651 ea Gon. [Nat Gas [15-217 [15-20 | 15—an [1-26 | 8-26 | eee [aon reac a Te | Nat Ges | 9-15" | o-is [onas | 9-1 | a-1s | o-as | 9-15) 7082050" ea on | NatGas | = = = S 15-25 Laas a1 In| Nat. Gas = S — [eas 7oe2GL 1051 Gon. | towsu | - [10-16 [10-16 [10-16 10-16 [10-16 | 10-10 7oa2G. 105 al - | 0-8 | 0-6 | 0-6 | o-6 | 0-8 | o-e roszeL 1054 al = | 4-to | ato" | ato | 4-10» | a-t0° | 4-10 ToaeGt 105 al] natcas [aie [4-10 [4-10 [aw |s-1 [a1 [s-10" NOTE: These engines 1un with an elevated jackal water lemperature beween 210- and 250: F (99 ~ 121°C). ie necessary fo adjust he ignition tng foafow fora greater margin of protection from detonation, Changing the engine timing wil alse change the exhaust ‘Srissions and fue LW. Temperatu ay 30°F (64°) 1 W. Temperatura 85° F (28° C) FOR 6248 Frat Eaton 120-33CHAPTER 2 - ENGINE TEARDOWN CONTENTS SECTION 2.00 - CYLINDER HEAD REMOVAL SECTION 2.05 - CRANKCASE REMOVAL Oma 6248 Frei EatonSECTION 2.00 - CYLINDER HEAD REMOVAL CYLINDER HEAD REMOVAL NOTE: Be sure that you have read and understood the safely and warning information in Section 1.01, Safety, land Section 1.02 Rigging and Lifting Engines, before proceeding. A WARNING Failure to take adequate precautions when ser ing this product can result in severe personal injury ‘or death, 4 WARNING Never walk or stand under an engine or component while it is suspended. Always consider the weight of the item being lifted. Use properly rated lifting equipment and approved lifting methods. If not ‘supported by a properly rated lifting device, some heavy parts may fall when loosened. Failure to take ult in severe personal NOTE: As part of the overhaul process, the exhaust manifold, intake manifold and water manifold should already be removed. If not, refer to Chapter § of this manual, for removal procedures for those particular items. Chapter 5 covers the removal of all the external components of the engine. Procedures have been included in this section to allow cylinder heads to be removed.in field conditions, when the manifolds may not normally be removed. NOTE: Service Bulletin 15-2007B, Exhaust Manifold ‘Support Bracket, describes how to fabricate and use ‘exhaust manifold support brackets, when itis desired to remove cylinder heads without removing the exhaust ‘manifolds. If support brackets are not available, an alternative method is to remove six cylinder heads (three from each cylinder bank) in a pattern that allows for full support of the exhaust manifolds as outlined in the following. B. CAUTION]! repatr work requires removal of the cylinder heads from one or both banks while the exhaust ‘manifold stays in place, care must be taken so that proper support is maintained for the exhaust manifold. To provide this support, only a limited number of cylinder heads can be removed at any fone time. This specific technique provides the proper supportto the exhaust manifold. f sufficient ‘support is not provided to the exhaust manifold and associated components, severe damage can occur to these parts. Leave the exhaust manifold secured to cylinder heads 1L, 1, 3L, 3R, SL and SR on Lett and Right cylinder banks whilo cylinder heads 2L, 2R, 4L, 4R, 6L and 6R are removed. When the removed cylinder heads are replaced and secured to the exhaust manifold, then cylinder heads 1L, 1R, 3L, 3A, SL and 5A on Left and Right cylinder banks can be removed. A CAUTION | 222%, sisassembiy, drain all coolant com- pletely from the engine. Prevent dirt or water from entering the oil sump when removing the cylinder heads and liners. A WARNING This procedure is atwo person operation. To do this procedure alone is dangerous and can result in severe personal injury or death. 1. Refer to Chapter and remove spark plug assembly. A WARNING Ensure that the fuel source is completely shut off prior to working on fuel system components Clear the engine supply lines and piping of accumulated {gas before performing any maintenance work on the fuel system or severe personal injury or death could result. 2. Refer to Chapter 5 and disconnect the fuel supply tube from the admission valve body (GL). 3, Refer to Chapter 5 and remove the admission valve assembly from the cylinder head (GL). 4, Remove the rocker arm covers and gaskets from the cylinder heads. FORM 6248 Firs Eavon 200-7CYLINDER HEAD REMOVAL NOTE: Do not mix parts between rocker arm assem- blies, lift both sides of the rocker arm assemblies off together. 5. Remove the rocker arm support capscrews and washers (8 capscrews per head, 1/2 x 4-3/4 inches). ‘Move the rocker arm assemblies to a suitable work- bench (See Figure 2.00-1). Figure 2.00-1. Rocker Arms 6. Remove the rocker arm oil supply tubes from the cylinder heads (see Figure 2.00-2). Remove the male Connector tube fittings from the cylinder head castings. ROCKER ARM o1L ‘SUPPLY TUBE FERRULE NUT, ~ Fennue & Figure 2.00-2. Install Rocker Arm Oil Supply Tubes: MALE CONNECTOR ‘TUBE FITTING. A CAUTION] "¥er2utic push rods must be stored in the vertical position to prevent the oil from leaking out of the hydraulic valve lifters. Disregarding this information could result in product damage. 7. Pull out the hydraulic push rods (2 rods per cylinder head) (see Figure 2.00-3). Tag the push rods as they are removed, so that they can be installed in their original locations. Place the pushrods in clean plastic bags to keep dirt and debris out of the hydraulic ifters. HYDRAULIC PUSH RODS Figure 2.00-3. Push Rods And Water Outlet Elbows 8. Remove the wator outlet elbows (2 ferry head, 2 hex head capscrews per elbow, 1/2 x 1-3/4 inches, with lock washers) (see Figure 2.00-3). Remove and discard the rectangular rubber seals from the ends of each elbow (see Figure 2.00-4) GASKETS Figure 2.00-4. Water Outlet Elbow Gaskets 200-2 FORM 6240 Fret EatonCYLINDER HEAD REMOVAL 9. Remove two capscrows (2 hex head 1/2 x §-1/2 inches, with washers and 2 hex head 1/2 x 8-1/2", with washers) from the exhaust manifold ‘(see Figure 2,00-5). i EXHAUST | MANIFOLD Figure 2.00-5. Exhaust Manifold ~ Rear View 40. Loosen the gasket seal where the exhaust manifold joins the cylinder head, 11. Remove four capscrews (GL models, hex head, 1/2 x 1-3/8" with washers and lockwashers) (G/GSI models, hex head, 1/2 x 1-1/4" with washers and lockwashers) from the intake manifold (see Figure 2.00-6), NOTE: Loosen the intake manifold capscrews on all cylinder heads 10 to allow the intake manifold to be moved back, am CAPSCREWS. INTAKE MANIFOLD Figure 2.00-6, Intake Manifold 12. Loosen the gasket seal where the intake manifold joins the oylinder head. A WARNING Each cylinder head weighs approximately 195 Ibs. (89 Kg). Use a suitable lifting device and exercise caution to avoid severe personal injury or death. 18. Thread an eye bolt (1/2"~13) into the rocker arm cover capscrew bore closest to the water outlet elbow connection. Install a suitable fing chain, (see Figure 2.00-7), INSTALL EVE BOLT, Figure 2.00-7. Eye Bolt Location — 12 Cylinder Engines 14. Remove the capscrews and washers securing the neads to the engine block (8 capsorews per head; 2 short, 6 long) (see Figure 2,00-8). Seen ae 3 Cramer exo Ceabenci oy ma Figure 2.00-8. Cylinder Heads FORM 6248 Fie Eaton 200-3CYLINDER HEAD REMOVAL - CRANKCASE, CYLINDER HEAD weight UNBALANCED ‘A. CAUTION | 72 2°24 damage to the deck surface or the dowel locating pins, raise the cylinder head at an angle that closely approximates the angle of the crankcase. 15. Liftthe head off the engine using an overhead lifting deviee (see Figure 2.00-9). NOTE: A pry bar may be needed to free the cylinder head from the head gasket. NOTE: The push rod cover assemblies may lit of with the cylinder head or remain attached to the valve lifter housing. In any case, remove the push rod cover assemblies from either the cylinder head or vaive lifter housing, B CAUTION | Pesition the cylinder heads on a wooden board or pallet. Place each head on its side to avoid damage to the nozzle of the prechamber cup on GL models. Figure 2.00-9. Lifting The Cylinder Head 16. Remove the head gaskets from the engine biock. Scrape any gasket material from the cylinder head and ‘engine block. 200-4 FOR 6248 First EatonSECTION 2.05 - CRANKCASE REMOVAL PISTON/CONNECTING ROD REMOVAL A WARNING This procedure is a two person operation. To do this procedure alone is dangerous and can result in severe personal injury or death. Remove only one piston B. CAUTION rr connocting rod ae. sembly at one time. Removing more than one cylinder may cause damage to equipment. NOTE: Drain all engine oil before proceeding. Engine coolant should already be drained. 1. Remove the connecting rod cap (4 ferry head capscrews) (see Figure 2.05-1) ‘CONNECTING ROD CAPS. Figure 2.051. Capecrows Connecting Rod Cape To-ensure removal ofthe Ay CAUTION | erie caroon rage and to avoid nicking or scratching the piston with the carbon scraper, bar the engine over to move each piston to its lowest point of travel. Do not cut down into the A CAUTION] Fino trevet zone when removing the carbon ridge from the cylinder sleeve bore. Disregarding this information could result in product damage. 2. Usea suitable carbon scraper to remove the caroon, ridge from the cylinder sleeve bore (see Figure 2.05-2) The ridge is confined to the area above the upper range of top piston ring travel. Figure 2.05-2. Carbon Ridge 3, Install a piston puller (P/N 474018, for 8-1/2 in. bore, P/N474019, for 9-38 in, bore) into the two threaded holes in the piston crown (see Figure 2.05-3). Use a suitable refacing tool to unplug the holes and clean hardened carbon from the threads without causing damage to the bore. Install aliting chain to the piston puller. Figure 2.05-3. Install Piston Puller A WARNING Each piston and connecting rod assembly weighs approximately 90 Ibs. (41 Kg). Use a suitable lifting device and exercise caution during removal or installation to avoid severe personal injury or death. NOTE: The piston and connecting rod assembly con- sists of the piston, piston rings, piston pin and two retaining rings, piston pin bushings, connecting rod and connecting rod bearing. FORM e240 Fra Eaion 205-7CRANKCASE REMOVAL Do not allow the coi necting rod to contact the crankshaft after the bearing halves have been removed. Insure that plastic is wrapped around the end of the connecting rodto preventthe connecting rod end end from damaging the cylinder sleeve bore. A CAUTION NOTE: The piston slides out of the cylinder block with relative ease until the lower part ofthe skirt reaches the ‘upper portion of the sleeve. At this point, the piston may ‘become cocked, causing it to bind in the sleeve. To prevent this from happening, lightly jiggle the piston back and forth as it is raised. 4, Pull the piston and connecting rod assembly out of the cylinder block at an angle that closely approximates the angle of the crankcase (see Figure 2.05-4) INCORRECT connect Figure 2.05-4. Remove Piston/Connecting Rod Assembly CAUTION |S2n7e

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