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6277-5 Web
6277-5 Web
6277-5 Web
DISCLAIMERS:
All information, illustrations and specifications in this manual are based on the latest information available at the time
of publishing. The illustrations used in this manual are intended as representative reference views only. Products are
under a continuous improvement policy. Thus, information, illustrations and/or specifications to explain and/or
exemplify a product, service or maintenance improvement may be changed at any time without notice.
NOTICE
Review all applicable Service Bulletins and other documentation, and check with your Authorized Distributor for
updates that may supersede the contents of this manual.
DISPOSAL STATEMENT:
Disposal requirements for waste electrical and electronic equipment:
NOTICE
Electrical and electronic equipment can contain harmful substances which can affect the environment and human
health.
WEEE symbol (Waste of Electrical and Electronic Equipment): The symbol for the separated disposal of electrical
and electronic equipment is a crossed-out waste bin on wheels (Directive 2012/19/EU Waste Electrical and Electronic
Equipment).
You must not dispose any electrical and electronic equipment marked with this symbol (battery-operated electrical
appliances, measurement equipment, light-bulbs, etc.) in the domestic waste but dispose of these separately. Always
use the waste return and collection systems locally available and contribute to the reuse, recycling and all other forms
of use for waste electrical and electronic equipment.
Form 6277-5
© Copyright 2023, INNIO's Waukesha Engine
Contents
Form 6277-5
i © Copyright 2023, INNIO's Waukesha Engine
Contents
Form 6277-5
ii © Copyright 2023, INNIO's Waukesha Engine
Contents
Form 6277-5
iii © Copyright 2023, INNIO's Waukesha Engine
Contents
GOVERNOR OIL CHANGE AND FILL (UG-8L MOONEY GAS REGULATOR TYPICAL
GOVERNOR) ........................................ 4.00-1 ADJUSTMENT AND HOOKUP
GOVERNOR ROD........................................ 4.00-2 LOCATIONS ........................................4.05-17
GOVERNOR ROD INSPECTION AND FISHER GAS REGULATOR TYPICAL
LUBRICATION ...................................... 4.00-2 ADJUSTMENT AND HOOKUP
LOCATIONS ........................................4.05-18
Section 4.05 – FUEL SYSTEM
RICH BURN APPLICATIONS.........................4.05-19
MAINTENANCE
NATURALLY ASPIRATED ENGINES WITH IMPCO
FISHER GAS REGULATORS ......................... 4.05-1
MODEL 600 AND 600D
FILTER MAINTENANCE (FISHER
CARBURETORS...................................4.05-19
REGULATOR) ............................................. 4.05-1
TURBOCHARGED ENGINES WITH IMPCO
FILTER ELEMENT REMOVAL .................. 4.05-1
MODEL 600 AND 600D
CLEANING / INSPECTION /
CARBURETORS...................................4.05-21
REPLACEMENT .................................... 4.05-2
NATURALLY ASPIRATED ENGINES OPERATING
FILTER ELEMENT INSTALLATION............ 4.05-2
ON LOW BTU GAS WITH (SINGLE FUEL) IMPCO
MOONEY GAS REGULATORS ....................... 4.05-3
MODEL 600 SERIES CARBURETORS ......4.05-22
REGULATOR FILTER CLEANING AND
TURBOCHARGED ENGINES OPERATING ON
INSPECTION ........................................ 4.05-3
LOW BTU GAS (SINGLE FUEL) WITH IMPCO
MOONEY GAS REGULATOR
MODEL 600 CARBURETORS..................4.05-25
ADJUSTMENTS .................................... 4.05-4
NATURALLY ASPIRATED ENGINES OPERATING
MOONEY GAS REGULATOR MAINTENANCE
ON LOW BTU GAS AND NATURAL GAS (DUAL
SCHEDULE .......................................... 4.05-5
FUEL) CARBURETION...........................4.05-27
MOONEY GAS REGULATOR REPLACEMENT
TURBOCHARGED ENGINES OPERATING ON
SERVICE PARTS AND KITS..................... 4.05-6
LOW BTU GAS AND NATURAL GAS (DUAL FUEL)
MOONEY GAS REGULATOR CARTRIDGE
WITH IMPCO MODEL 600
REMOVAL ............................................ 4.05-7
CARBURETOR.....................................4.05-30
CARTRIDGE INSTALLATION ................... 4.05-7
NATURALLY ASPIRATED ENGINES WITH
EXHAUST GAS ANALYSIS FOR WAUKESHA
PARALLEL CARBURETION ....................4.05-33
ENGINES ................................................... 4.05-8
6- AND 12-CYLINDER GSI ENGINES OPERATING
ADMISSION VALVE MAINTENANCE – GL
ON NATURAL GAS FUEL (850 – 900 BTU) WITH
ENGINE ..................................................... 4.05-9
LOW FUEL PRESSURE SYSTEM ............4.05-35
ADMISSION VALVE REMOVAL – GL
LEAN BURN APPLICATIONS ........................4.05-37
ENGINE ............................................... 4.05-9
ENGINES WITH IMPCO 600D CARBURETORS
ADMISSION VALVE DISASSEMBLY – GL
AND ENGINE-MOUNTED FISHER 99
ENGINE ............................................... 4.05-9
REGULATORS (FUEL ONLY PRECHAMBER
ADMISSION VALVE CLEAN AND INSPECT – GL
SYSTEM) ............................................4.05-37
ENGINE ............................................... 4.05-9
ENGINES WITH IMPCO 600D CARBURETORS
LOCKNUT REPLACEMENT (P/N 211587 AND P/N
NATURAL GAS FUEL AIR / FUEL
211587A ADMISSION VALVES)...............4.05-10
PRECHAMBER ....................................4.05-39
ADMISSION VALVE SERVICE KIT
ENGINES OPERATING ON LOW BTU FUEL WITH
INSTALLATION ....................................4.05-11
IMPCO 600D CARBURETORS ................4.05-40
FUEL SYSTEM ADJUSTMENT GENERAL
6- AND 12-CYLINDER ENGINES OPERATING ON
INFORMATION...........................................4.05-14
NATURAL GAS FUEL (850 – 900 BTU) WITH LOW
EXHAUST GAS ANALYSIS FOR WAUKESHA
FUEL PRESSURE SYSTEM ....................4.05-42
ENGINES ............................................4.05-14
ENGINES OPERATING ON DUAL FUEL WITH
OXYGEN ANALYZER ............................4.05-15
IMPCO 600D CARBURETORS ................4.05-44
RICH BURN (GSI) .................................4.05-16
ENGINES OPERATING ON NATURAL GAS
(PRIMARY FUEL) AND HD-5 PROPANE VAPOR
Form 6277-5
iv © Copyright 2023, INNIO's Waukesha Engine
Contents
Form 6277-5
v © Copyright 2023, INNIO's Waukesha Engine
Contents
Auxiliary Water Temperature Control Thermostatic Cleanable Filter Elements........................4.30-17
Valve Inspection and Testing ...................4.25-19 Disassembly of Microspin P/N 489189
Auxiliary Water Temperature Control Valve Centrifuge............................................4.30-17
Assembly.............................................4.25-20 Microspin Centrifuge Cleaning – P/N
Auxiliary Water Temperature Control Valve 489189 ...............................................4.30-18
Installation ...........................................4.25-21 Microspin Centrifuge Assembly – P/N
JACKET / AUXILIARY WATER PUMP .............4.25-21 489189 ...............................................4.30-18
Jacket Water Pump Inspection .................4.25-21
Section 4.35 – EXHAUST SYSTEM
AUXILIARY WATER PUMP
MAINTENANCE
INSPECTION .......................................4.25-22
EXHAUST SYSTEM BACKPRESSURE
Section 4.30 – LUBRICATION SYSTEM MEASUREMENT ......................................... 4.35-1
MAINTENANCE EXHAUST SYSTEM TEMPERATURE
OIL FILL – INITIAL PROCEDURE .................... 4.30-1 MONITORING ............................................. 4.35-1
OIL COOLER AND LUBE OIL FILTER INSTALLATION EXHAUST SYSTEM INSPECTION................... 4.35-2
REQUIREMENTS......................................... 4.30-2
Section 4.40 – CRANKCASE BREATHER
CRANKCASE OIL LEVEL CHECKING .............. 4.30-2
SYSTEM MAINTENANCE
OIL CHANGE .............................................. 4.30-3
SEPARATOR SCREEN ................................. 4.40-1
OIL PAN ..................................................... 4.30-3
CRANKCASE SEPARATOR SCREEN
OIL PICKUP SCREEN ................................... 4.30-4
REMOVAL ............................................ 4.40-1
Oil Pickup Screen Removal – 6-Cylinder ...... 4.30-4
CRANKCASE SEPARATOR SCREEN CLEANING
OIL PICKUP SCREEN CLEANING AND
AND INSPECTION ................................. 4.40-2
INSPECTION – 6-CYLINDER.................... 4.30-4
CRANKCASE SEPARATOR SCREEN
OIL PICKUP SCREEN INSTALLATION – 6-
ASSEMBLY .......................................... 4.40-2
CYLINDER............................................ 4.30-5
OIL SEPARATOR(S)..................................... 4.40-3
OIL PICKUP SCREEN REMOVAL – 12-
Oil Separator Cleaning and Inspection – 6- and 12-
CYLINDER............................................ 4.30-5
Cylinder Engines .................................... 4.40-4
OIL PICKUP SCREEN CLEANING AND
OIL SEPARATOR CLEANING AND INSPECTION –
INSPECTION – 12-CYLINDER .................. 4.30-6
16-CYLINDER ENGINE ........................... 4.40-5
OIL PICKUP SCREEN INSTALLATION – 12-
CURRENT PRODUCTION 12-CYLINDER FILTER
CYLINDER............................................ 4.30-6
ELEMENT REPLACEMENT ..................... 4.40-6
OIL PICKUP SCREEN REMOVAL – 16-
OIL SEPARATOR DIAPHRAGM KITS........4.40-10
CYLINDER............................................ 4.30-7
CRANKCASE PRESSURE CHECK.................4.40-10
OIL PICKUP SCREEN CLEANING AND
CRANKCASE PRESSURE ADJUSTMENT
INSPECTION – 16-CYLINDER .................. 4.30-7
CONTROLS ...............................................4.40-11
OIL PICKUP SCREEN INSTALLATION – 16-
6-CYLINDER ENGINE CRANKCASE PRESSURE
CYLINDER............................................ 4.30-8
ADJUSTMENT CONTROLS ....................4.40-11
OIL COOLER .............................................. 4.30-8
12-CYLINDER ENGINE CRANKCASE PRESSURE
LUBE OIL SYSTEM AIR BLEED ...................... 4.30-9
ADJUSTMENT CONTROLS ....................4.40-12
LUBE OIL FILTER ........................................ 4.30-9
16-CYLINDER ENGINE CRANKCASE PRESSURE
LUBE OIL FILTER ELEMENT
ADJUSTMENT CONTROLS ....................4.40-12
REPLACEMENT .................................... 4.30-9
CRANKCASE PRESSURE ADJUSTMENT .......4.40-12
LUBE OIL FILTER RELIEF VALVE ..................4.30-12
CRANKCASE BREATHER REGULATOR.........4.40-13
LUBE OIL STRAINER ..................................4.30-13
CLEANING AND INSPECTION ................4.40-13
MAGNETIC PLUG .......................................4.30-14
CRANKCASE PRESSURE RELIEF VALVE.......4.40-14
LUBE OIL PRESSURE ADJUSTMENT ............4.30-15
PRELUBE Y-STRAINER ...............................4.30-15 Section 4.45 – PRELUBE AND STARTING
MICROSPIN...............................................4.30-16 SYSTEM MAINTENANCE
Centrifuge............................................4.30-16 ELECTRIC STARTER ................................... 4.45-1
Form 6277-5
vi © Copyright 2023, INNIO's Waukesha Engine
Contents
APPENDIX A – WARRANTY
Form 6277-5
vii © Copyright 2023, INNIO's Waukesha Engine
Contents
Form 6277-5
viii © Copyright 2023, INNIO's Waukesha Engine
HOW TO USE THIS MANUAL
Your purchase of a Waukesha VHP engine was a wise There are five chapters within the manual and each
investment. Thank you for your order. In the industrial chapter contains one or more sections. The title of each
engine field, the name Waukesha stands for quality and chapter or section appears at the top of each page. To
durability. With proper care and maintenance, this locate information on a specific topic, see the Table of
engine will provide many years of reliable service. Contents at the front of the manual.
BEFORE PLACING THE ENGINE IN SERVICE, READ ALWAYS BE ALERT FOR THE SPECIAL WARNINGS
AND UNDERSTAND CHAPTER 1, CHAPTER 2 AND WITHIN THE MANUAL TEXT. THESE WARNINGS
CHAPTER 3 VERY CAREFULLY. THESE CHAPTERS PRECEDE INFORMATION THAT IS CRUCIAL TO
COVER SAFETY, GENERAL INFORMATION AND YOUR SAFETY AS WELL AS OTHER PERSONNEL
ENGINE OPERATION. WORKING ON OR NEAR THE ENGINE. CAUTIONS,
NOTICES OR NOTES IN THE MANUAL CONTAIN
Always be alert for the special warnings within the
INFORMATION THAT RELATES TO POSSIBLE
manual text. These warnings precede information that is
DAMAGE TO THE ENGINE OR ITS COMPONENTS
crucial to your safety as well as other personnel working
DURING ENGINE OPERATION OR MAINTENANCE
on or near the engine.
PROCEDURES.
Section 1.00 – Safety Labels and Locations – Provides
Recommendations and data contained in the manual
the location of all warning tags and labels and a duplicate
are the latest information available at the time of this
of each tag is illustrated in case the labels or tags
printing and are subject to change without notice.
become lost or damaged.
Consult your local distributor or Waukesha Service
Section 1.05 – Safety – Provides a list of warnings, Operations Department for updated information as well
cautions and notices to make you aware of the dangers as information on subjects beyond the scope of this
present during operation and maintenance of the manual.
engine. READ THEM CAREFULLY AND FOLLOW
THEM COMPLETELY.
Section 1.10 – Rigging and Lifting Engines – Provides
information on engine weights and proper lifting
procedures.
Section 1.15 – General Information – Provides basic
engine data such as nameplate data, component
weights, torque specifications and clearances. This
section also supplies torque values of metric and
standard capscrews as well as conversion data.
Chapter 2 – Engine Systems – Provides basic
information on each engine system.
Chapter 3 – Engine Start-up and Shutdown – Provides
prestart inspection and routine start-up and shutdown
procedures, and describes operation of the engine.
Chapter 4 – Maintenance – Provides information for
operators’ care of Waukesha engines.
Chapter 5 – Troubleshooting and Storage – Provides
basic engine troubleshooting, and storage procedures.
Form 6277-5
ix © Copyright 2023, INNIO's Waukesha Engine
This Page Intentionally Left Blank
Form 6277-5
x © Copyright 2023, INNIO's Waukesha Engine
SAFETY AND GENERAL
SECTION 1.00
SAFETY LABELS AND LOCATIONS
SAFETY LABEL LOCATIONS NOTE: Not all labels are installed on all engines.
Application will depend on model of engine and optional
Warning tags and decals are placed so that they are equipment ordered. Example: air/gas starter instead of
visible and readable by the operator when the engine is an electrical starter.
running. This section provides detailed diagrams and
location of the safety labels on VHP engines. Pages Clean surfaces of engine of all dirt, oil, etc. before
1.00-10 through 1.00-13 show examples of the applying labels.
safety labels.
SAFETY LABELS
! WARNING
The safety labels have specific placement and must be
replaced if they are defaced or removed for any reason.
All safety labels must be legible
to alert personnel of safety
Form 6277-5
1.00-1 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
Form 6277-5
1.00-2 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
211920F
211920D 211911B
211930A
211930A
211920E 211910A
211910K
211910K
211911E
211910S
211910W
211930A
211910J
211920D
211910K
211910K
211911C
211910E
Figure 1.00-1: 6-Cylinder Safety Label Locations – Right and Left Side
NOTE: Labels shown apply to standard engine. Labels can be affected by optional equipment specified.
Form 6277-5
1.00-3 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
Form 6277-5
1.00-4 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
211930A
211930A
211910A 211910J
211920D 211920D
211930A 211930A
211910K
211910K
211911
Form 6277-5
1.00-5 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
211920D 211920D
211910N
211910W
211920E
211910K
211910J
211920F 211920N 211911C
211920F
211920D
211920D
211910N 211911B
211920E
211910K
211910S
211911E
B
y
211911C
211910A
211910N 211920H
Figure 1.00-3: 12-Cylinder Safety Label Locations – Left and Right Side
NOTE: Labels shown apply to standard engine. Labels can be affected by optional equipment specified.
Form 6277-5
1.00-6 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
Form 6277-5
1.00-7 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
211920E 211920E
211911C
211920F 211911B 211910N*
211920H
* Both sides.
NOTE: Labels shown apply to standard engine. Labels can be affected by optional equipment specified.
Form 6277-5
1.00-8 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
211930A
211930A
211911M
211911M
211930A
211930A
211910J
211910J
Form 6277-5
1.00-9 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
211910A
211910A
211910E
211910E
211910K
211910J
Form 6277-5
1.00-10 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
211910M 211910S
211910N 211910W
150
211911
Form 6277-5
1.00-11 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
211911B
211911C
Form 6277-5
1.00-12 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
211920E
211911E
211920F
211920D 211920H
Form 6277-5
1.00-13 © Copyright 2023, INNIO's Waukesha Engine
SAFETY LABELS AND LOCATIONS
211930A
Form 6277-5
1.00-14 © Copyright 2023, INNIO's Waukesha Engine
SECTION 1.05
SAFETY
!
The following safety precautions are published for your
information. INNIO Waukesha does not, by the attention, become alert, your safety is
involved! Please read and abide by
publication of these precautions, imply or in any way
the message that follows the safety
represent that they are the sum of all dangers present
alert symbol.
near industrial engines.
If you are installing, operating, or servicing a INNIO ! DANGER
Waukesha product, it is your responsibility to ensure full
compliance with all applicable safety codes and Indicates a hazardous situation that, if not
requirements. All requirements of the Federal avoided, will result in death or serious injury.
Occupational Safety and Health Act must be met when
INNIO Waukesha products are operated in areas that
are under the jurisdiction of the United States of ! WARNING
America. INNIO Waukesha products operated in other
countries must be installed, operated and serviced in Indicates a hazardous situation that, if not
compliance with any and all applicable safety avoided, could result in death or serious injury.
requirements of that country. Site Lockout/Tagout
requirements must be followed when servicing the
equipment.
! CAUTION
For details on safety rules and regulations in the United
States, contact your local office of the Occupational Indicates a hazardous situation that, if not
Safety and Health Administration (OSHA). avoided, could result in minor or moderate injury.
The words DANGER, WARNING, CAUTION and
NOTICE are used throughout this manual to highlight
important information. Be certain that the meanings of NOTICE
these alerts are known to all who work on or near the
equipment. Indicates a situation which can cause damage to the
engine, personal property and/or the environment, or
Follow the safety information throughout this manual in cause the equipment to operate improperly.
addition to the safety policies and procedures of your
employer.
NOTE: Indicates a procedure, practice or condition that
should be followed in order for the engine or component
to function in the manner intended.
Form 6277-5
1.05-1 © Copyright 2023, INNIO's Waukesha Engine
SAFETY
Table 1.05-1: Safety Symbol Definitions
Symbol Description
Symbol Description
Warnings
Crush Hazard (Side Pinned)
Asphyxiation Hazard
Burn Hazard
Entanglement Hazard
Explosion Hazard
Fire Hazard
Form 6277-5
1.05-2 © Copyright 2023, INNIO's Waukesha Engine
SAFETY
Prohibitions
Hazardous Chemicals
Do not operate with guards removed
High-Pressure Hazard
Do not leave tools in the area
Impact Hazard
Drugs and Alcohol Prohibited
Pinch-Point Hazard
Lifting/Transporting only by qualified
personnel
Pressure Hazard
Welding only by qualified personnel
Mandatory Actions
Puncture Hazard
Sever Hazard
Form 6277-5
1.05-3 © Copyright 2023, INNIO's Waukesha Engine
SAFETY
Symbol Description
Miscellaneous
ERGENC
M
E
Emergency Stop
STOP
Grounding Point
PE Physical Earth
Form 6277-5
1.05-4 © Copyright 2023, INNIO's Waukesha Engine
SAFETY
SAFETY LABELS
ACIDS
All safety labels must be legible to alert
personnel of safety hazards. Replace any Always read and comply with the acid
BATTERIES
EQUIPMENT REPAIR AND SERVICE
Always read and comply with the battery
Always stop the engine before cleaning, manufacturer’s recommendations for
servicing or repairing the engine or any procedures concerning proper battery
driven equipment. Be sure to follow the use and maintenance.
procedures listed below and apply site
Lockout/Tagout requirements.
• Place all controls in the OFF position Batteries contain sulfuric acid and
and disconnect or lock out starters to generate explosive mixtures of hydrogen
prevent accidental restarting. and oxygen gases. Keep any device that
• If possible, lock all controls in the OFF may cause sparks or flames away from
position and remove the key. the battery to prevent explosion.
• Put a sign on the control panel warning
that the engine is being serviced. Always wear protective glasses or
• Close all manual control valves. goggles and protective clothing when
• Disconnect and lock out all energy working with batteries. You must follow
sources to the engine, including all fuel, the battery manufacturer’s instructions on
electric, hydraulic and pneumatic safety, maintenance and installation
connections. procedures.
• Disconnect or lock out driven
equipment to prevent the possibility of
the driven equipment rotating the
BODY PROTECTION
disabled engine.
Always wear OSHA-approved body,
Allow the engine to cool to room sight, hearing and respiratory system
temperature before cleaning, servicing or protection. Never wear loose clothing,
repairing the engine. Some engine jewelry or long hair around an engine.
components and fluids are extremely hot
even after the engine has been shut
down. Allow sufficient time for all engine
components and fluids to cool to room CHEMICALS
temperature before attempting any
service procedure. GENERAL
Exercise extreme care when moving the
engine or its components. Never walk or Always read and comply with the safety
stand directly under an engine or labels on all containers. Do not remove or
component while it is suspended. Always deface the container labels.
consider the weight of the engine or the
components involved when selecting
hoisting chains and lifting equipment. Be
positive about the rated capacity of lifting
equipment. Use only properly maintained
lifting equipment with a lifting capacity that
exceeds the known weight of the object to
be lifted.
Form 6277-5
1.05-5 © Copyright 2023, INNIO's Waukesha Engine
SAFETY
CLEANING SOLVENTS ELECTRICAL
Always read and comply with the solvent GENERAL
manufacturer’s recommendations for
proper use and handling of solvents. Do Equipment must be grounded by qualified
not use gasoline, paint thinners or other personnel in accordance with IEC
highly volatile fluids for cleaning. (International Electric Code) and local
electrical codes.
LIQUID NITROGEN
Do not install, set up, maintain or operate
Always read and comply with the liquid
any electrical components unless you are
nitrogen manufacturer’s
a technically qualified individual who is
recommendations for proper use and
familiar with the electrical elements
handling of liquid nitrogen.
involved.
HEATED OR FROZEN
Always wear protective equipment when Always label “high voltage” on engine-
installing or removing heated or frozen mounted equipment over 24 volts
components. Some components are nominal.
heated or cooled to extreme
temperatures for proper installation or
removal.
Always wear protective equipment when Avoid contact with ignition units and
installing or removing components with wiring. Ignition system components can
an interference fit. Installation or removal store electrical energy, and if contacted,
of interference components may cause can cause electrical shock.
flying debris.
Do not service the cooling system while An Emergency Shutdown must never be
the engine is operating or when the used for a normal engine shutdown.
coolant or vapor is hot. Operational Doing so may result in unburned fuel in
coolant temperatures can range from the exhaust manifold. Failure to comply
180° – 250°F (82° – 121°C). increases the risk of an exhaust
explosion.
Form 6277-5
1.05-6 © Copyright 2023, INNIO's Waukesha Engine
SAFETY
EXHAUST LIQUIDS
PROTECTIVE GUARDS
FUELS Provide guarding to protect persons or
structures from rotating or heated parts. It
GENERAL is the responsibility of the engine owner to
specify and provide guarding. See OSHA
Ensure that there are no leaks in the fuel standards on “machine guarding” for
supply. Engine fuels are highly details on safety rules and regulations
combustible and can ignite or explode. concerning guarding techniques.
SPRINGS
TOOLS
Shut off the fuel supply if a gaseous
engine has been cranked excessively
ELECTRICAL
without starting. Crank the engine to
purge the cylinders and exhaust system
Do not install, set up, maintain or operate
of accumulated unburned fuel. Failure to
any electrical tools unless you are a
purge accumulated unburned fuel in the
technically qualified individual who is
engine and exhaust system can result in
familiar with them.
an explosion.
Form 6277-5
1.05-7 © Copyright 2023, INNIO's Waukesha Engine
SAFETY
HYDRAULIC
! CAUTION
Do not install, set up, maintain or operate
any hydraulic tools unless you are a The safety message that follows has a CAUTION
technically qualified individual who is level hazard.
familiar with them. Hydraulic tools use
extremely high hydraulic pressure.
Ensure that all tools and other objects are
Always follow recommended procedures removed from the unit and any driven
when using hydraulic tensioning devices. equipment before restarting the unit.
PNEUMATIC
WEIGHT
Always consider the weight of the item
being lifted and use only properly rated
lifting equipment and approved lifting
methods.
WELDING
Comply with the welder manufacturer’s
recommendations for procedures
concerning proper use of the welder.
Form 6277-5
1.05-8 © Copyright 2023, INNIO's Waukesha Engine
SAFETY
NOTICE
The safety messages that follow have NOTICE level
hazards.
Form 6277-5
1.05-9 © Copyright 2023, INNIO's Waukesha Engine
SAFETY
Form 6277-5
1.05-10 © Copyright 2023, INNIO's Waukesha Engine
SECTION 1.10
RIGGING AND LIFTING ENGINES
WEIGHT
! WARNING ENGINE
lb kg
Form 6277-5
1.10-1 © Copyright 2023, INNIO's Waukesha Engine
RIGGING AND LIFTING ENGINES
! WARNING
WARNING
WARNING
Form 6277-5
1.10-2 © Copyright 2023, INNIO's Waukesha Engine
RIGGING AND LIFTING ENGINES
Figure 1.10-5: 12- and 16-Cylinder Correct Method of Lifting Engines – 12-Cylinder Side Views Shown
Form 6277-5
1.10-3 © Copyright 2023, INNIO's Waukesha Engine
RIGGING AND LIFTING ENGINES
Form 6277-5
1.10-4 © Copyright 2023, INNIO's Waukesha Engine
SECTION 1.15
GENERAL INFORMATION
GENERAL INFORMATION See Figure 1.15-2 through Figure 1.15-12 for engine
identification views.
VHP G, GSI and GL engines (see Table 1.15-1) are
4-cycle. Six-cylinder engines are inline configuration, FEATURES AND BENEFITS
while 12- and 16-cylinder engines are V-configuration.
All engines rotate in the standard counterclockwise The design features of the VHP engine family include:
direction, as viewed from the rear (flywheel) end. • High horsepower
Table 1.15-1: Engine Models • Sturdy construction, rugged and compact
• Low exhaust emissions
F3521G
6-Cylinder Engines • Easy access and serviceability to all major
F3521GL
components
L5790G
12-Cylinder Engines
L7042G • Fuel-efficient and minimal fuel system complexity
P9390GSI
16-Cylinder Engines
P9390GL
Form 6277-5
1.15-1 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
MODEL
DRESSER WAUKESHA
SERIAL DRESSER INC.
NUMBER WAUKESHA, WISCONSIN U.S.A. DATE
COMP.
RATIO
IGN.TIMING
BTDC GOVERNED SPEED RPM
CARB ADJ.
211853M
HP/kW INTAKE EXHAUST
OVERLOAD
HP/kW
FIRING ORDER
Form 6277-5
1.15-2 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
The crankcase is a rigid gray iron casting (16-cylinder The crankcase is a gray iron casting (16-cylinder
engines are two-piece). The main bearings are engines are two-piece). For assembled rigidity, the main
replaceable. The counterweighted crankshaft is made bearing caps are attached to the crankcase with both
of forged steel and has seven main bearing journals. vertical studs and lateral tie bolts. This feature makes the
Each engine is equipped with a viscous vibration crankcase assembly more rigid and lengthens the life of
damper. the main bearings.
Form 6277-5
1.15-3 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
PISTONS Once the WKI value is known, it can be entered into the
ECU using the ESP software. This is important, since
The pistons are machined from one-piece castings. The
spark timing and engine derate curves are adjusted
dimension of the piston skirt at room temperature is
based on the value of the WKI stored in the ECU.
slightly larger at a point 90° to the piston pin bore. This
feature allows the piston to expand from a shape that is For applications with changing fuel conditions, such as
somewhat oval to one that is almost perfectly round a wastewater treatment plant with natural gas backup,
when operating at stabilized engine temperatures. the ESM can be signaled about the fuel’s changing WKI
value in real time using the two WKI analog input wires
CYLINDER SLEEVES in the Customer Interface Harness. The calibration of the
customer interface wires, WKI+ and WKI-, is shown in
Each wet-type cylinder sleeve has a flange at its upper
Table 1.15-2. An input less than 2 mA or greater than 22
end to locate it in the crankcase upper deck. The sleeves
mA indicates a wiring fault, and the default WKI value is
have three external ring grooves to hold the lower
used instead.
crankcase bore seals.
Table 1.15-2: Calibration of Remote WKI Input
CAMSHAFTS
ANALOG USER INPUT 4 mA 20 mA
The design of the camshaft lobe and camshaft
minimizes valve overlap and reduces the flow of gases WKI Fuel Quality Signal 20 WKI 135 WKI
between the intake and exhaust ports. This improves * Trademark of INNIO Waukesha Gas Engines, Inc.
fuel efficiency and lowers exhaust emissions.
WKI
The WKI* is an analytical tool developed by INNIO
Waukesha Gas Engines as a method for calculating the
knock resistance of gaseous fuels. It is a calculated
numeric value used to determine optimum engine
settings based on a specific site’s fuel gas composition.
The WKI value can be determined using the WKI
computer program for Microsoft Windows operating
system that is distributed to INNIO Waukesha Gas
Engines Technical Data Book holders, and which is also
available by contacting a Distributor or INNIO Waukesha
Gas Engines Sales Engineering Department, or by
downloading it from the customer portal
(www.innio.com).
The WKI program is also built into EngCalc3.3, which is
a Microsoft Excel-based computer program that allows
users to obtain site-specific engine data based on their
input site conditions and fuel analysis. The WKI program
will calculate the WKI value from a customer’s fuel
analysis breakdown. EngCalc3.3 expands the WKI
program to allow the input of fuel contaminants, such as
H2S and siloxanes, to determine if they are within the fuel
contaminant limits.
Form 6277-5
1.15-4 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
NOTE: Changing the engine timing will also change the Deutsch
exhaust emissions and fuel economy. Lookout
Magnaflux Products: Penetrant (SKL-HF/S) Developer
CUSTOM ENGINE CONTROL IGNITION MODULE
(SKD-NF-ZP-9B) Cleaner/Remover (SKC-NF/ZC-7B) (USA
Waukesha’s Custom Engine Control (CEC) Ignition 847-657-5300) (UK +44 0 1793 524566)
Module (IM) is standard equipment. The CEC ignition Microsoft Windows
system uses a Hall-effect pickup and a special timing
MODBUS
disc to determine the exact position of the crankshaft.
The CEC IM interprets the sensor’s impulses to set the National Instruments
optimum ignition timing. The CEC IM then directs a Permatex Non Drying Prussian Blue (Bluing Agent) (mfg. by
precisely timed voltage to the appropriate ignition coil. Loctite Corporation) (877-376-2839)
Plastigage – used for measuring small clearances
CUSTOM ENGINE CONTROL DETONATION
(248-354-7700)
SENSING MODULE
Stellite is a registered trademark of Stoody Deloro Stellite,
Waukesa’s CEC Detonation Sensing Module (DSM), Inc.
which functions with the CEC IM, is standard equipment.
INNIO Waukesha Knock Index / WKI
The DSM protects the engines from damage due to
detonation on an individual cylinder basis. Engine Woodward
mounted detonation sensors monitor engine output from
each cylinder. When the signal exceeds a
predetermined limit, the DSM retards the ignition timing
for the cylinder associated with that sensor. As soon as
conditions permit, the DSM will advance spark timing to
the original timing set point.
Form 6277-5
1.15-5 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
!
lubricants that may be required to perform the tasks in
this manual. Where possible, brand names are listed in the container when using
the procedure. When brand names are not used, general sealants, adhesives, lubricants
names are used. This index may be used to match the and other shop aids.
general description to a specific product or its equivalent
(i.e., pipe sealant = Perma Lok Heavy Duty Pipe Sealant
with Teflon or its equivalent). INNIO Waukesha does not
endorse one brand over another. In all cases, equivalent
products may be substituted for the brand name listed.
All part numbers listed are the manufacturer’s numbers.
Dielectric Silicone Grease Dow Corning DC-200, G.E. G-624, GC Electronics 25 (989-496-4400)
Form 6277-5
1.15-6 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
Permatex High Tack Spray-A-Gasket Sealant Loctite Item No. 99MA (877-376-2839)
Perma Lok Heavy Duty Pipe Sealant with Teflon, Item No. LH050 (USA
Pipe Sealant
800-714-0170) (UK +44 0 1962 711661)
Plastigage Plastigage /used for measuring small clearances (248-354-7700)
RTV Dow Corning RTV #734 or GE Red RTV 106 (989-496-4400)
Form 6277-5
1.15-7 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
Form 6277-5
1.15-8 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
1 2 3 4 5 6 7 1
10
24 11
12
13
14
16 17 23 22 21 20 19 18 17 16 15
Form 6277-5
1.15-9 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
1 2 3 4 5 6 7
20
19
18 17 10 16 15 14 13 12 11 10 9
Form 6277-5
1.15-10 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
1 2
9
3
6 5
Form 6277-5
1.15-11 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
12-CYLINDER GSI VIEWS
1 2 3
22
21 12 8 20 19 18 17 16 15 14 13 12 11 10 9
Form 6277-5
1.15-12 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
1 2 3 4
21
20
19
18 17 11 9 16 15 14 13 12 11 10 9 8 7
Form 6277-5
1.15-13 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
12-CYLINDER GL VIEWS
1 2 3
5
25
6
24
23
7
22 21 10 20 19 18 17 16 15 14 13 12 11 10 9 8
Form 6277-5
1.15-14 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
1 2 3 4 5
23
22
21
20
19
18 17 12 10 16 15 14 13 12 11 10 9
Form 6277-5
1.15-15 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
20 21 1 2 3 4
19
18 5
17
6
16
7
15
14
10
13
11
12
Form 6277-5
1.15-16 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
16-CYLINDER GL VIEWS
19 20 21 1 22 2 3
18
17
16
14
4
15
13
11
12 10 9 8 7 6
Form 6277-5
1.15-17 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
1 2 1
16
3
15
4
13 6
5
12
14 11 10 9 8
Form 6277-5
1.15-18 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
1 2
8
4
5
5
Form 6277-5
1.15-19 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
! WARNING
MODEL dB(A)
6-Cylinder 103 dB(A)
12-Cylinder 107 dB(A)
16-Cylinder 105 dB(A)
ENGINE SPECIFICATIONS
NOTICE
Alarm and shutdown values are based on dry natural
gas (900 BTU/cu. ft. SLHV). See latest editions of
Gaseous Fuel Specification Sheet S7884-6 and Lube
Oil Recommendations Service Bulletin 12-1880 for
typical changes in operation temperatures for jacket
water and lube oil when running on landfill or digester
gas fuels.
GENERAL SPECIFICATIONS
Engine Model 6-Cylinder 12-Cylinder 16-Cylinder
Type 4-cycle 4-cycle 4-cycle
Aspiration, G Naturally aspirated Naturally aspirated N/A
Aspiration, GSI N/A N/A Turbocharged, intercooled
Turbocharged, intercooled Turbocharged, intercooled
Aspiration, GL N/A
and lean burn and lean burn
Number of cylinders Inline-6, 4-valves per cylinder V-12, 4-valves per cylinder V-16, 4-valves per cylinder
F2895: 8.50 x 8.50 in. L5790: 8.50 x 8.50 in.
(216 x 216 mm) (216 x 216 mm) P9390: 9.375 x 8.50 in.
Bore x stroke
F3521: 9.375 x 8.50 in. L7042: 9.375 x 8.50 in. (238 x 216 mm)
(238 x 216 mm) (238 x 216 mm)
Form 6277-5
1.15-20 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
GENERAL SPECIFICATIONS
Engine Model 6-Cylinder 12-Cylinder 16-Cylinder
F2895: 2,894 cu. in. (47 L) L5790: 5,790 cu. in. (95 L) P9390G, GSI, GL:
Displacement
F3521: 3,520 cu. in. (58 L) L7042: 7,040 cu. in. (115 L) 9,388 cu. in. (154 L)
Compression ratio G, GSI 8.25:1 8:1 (G Only Option: 10:1) 8:1 (G Only Option: 10:1)
Compression ratio GL 10:1 10:1 10.5:1
Speed range 700 – 1,200 rpm (see engine nameplate)
Low idle 450 rpm 450 rpm 450 rpm
Lubrication System
Oil sump capacity, including
66 gal (250 L) 90 gal (340 L) 165 gal (625 L)
filter and cooler*
Oil pan (Low level mark) 35 gal (132.5 L) 35 gal (132.5 L) 80 gal (303 L)
Oil pan (High level mark) 45 gal (170.3 L) 45 gal (170.3 L) 110 gal (416 L)
Lube oil filter capacity 20 gal (75.7 L) 36 gal (136.3 L) 45 gal (170 L)
(8 in.) 6.9 gal (26.1 L) (8 in.) 6.9 gal (26.1 L)
Oil cooler capacity 10 gal (38 L)
(10 in.) 10 gal (37.8 L) (10 in.) 10 gal (37.8 L)
Main filter 15 micron at @ 90% efficiency 15 micron at @ 90% efficiency 15 micron at @ 90% efficiency
Micro-fiberglass filter 15 micron at @ 90% efficiency 15 micron at @ 90% efficiency 15 micron at @ 90% efficiency
Strainer screen 74 micron 74 micron 74 micron
Micro-fiberglass filter 15 micron @ 90% efficiency 15 micron @ 90% efficiency 15 micron @ 90% efficiency
Normal lube oil pressure 55 ± 5 psi (380 ± 5 kPa) 55 ± 5 psi (380 ± 5 kPa) 55 ± 5 psi (380 ± 5 kPa)
Low oil pressure alarm setpoint 35 psi (207 kPa) 35 psi (207 kPa) 30 psi (173 kPa)
Low oil pressure shutdown
30 psi (138 kPa) 30 psi (138 kPa) 25 psi (103 kPa)
setpoint
Minimum oil pressure at turbo 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa)
Prelube duration 5 minutes
Postlube duration 5 minutes after operation
Normal oil header temperature 180°F (82°C) 180°F (82°C) 180°F (82°C)
Oil header temperature alarm
195°F (91°C) 195°F (91°C) 195°F (91°C)
setpoint
Oil header temperature
205°F (96°C) 205°F (96°C) 205°F (96°C)
shutdown setpoint
Governor and Air Starter Capacities
UG8 governor oil reservoir 1.5 quart (1.1 L) 1.5 quart (1.1 L) 1.5 quart (1.1 L)
Air starter oil reservoir for one
2.0 pint (0.9 L) 2.0 pint (0.9 L) 2.0 pint (0.9 L)
shot lubricator
Air motorized pre-lube motor,
0.5 pint (0.2 L) 0.5 pint (0.2 L) 0.5 pint (0.2 L)
inline lubricator
Cooling System (Jacket Water and Auxiliary Circuit)
Normal charge air cooler inlet temperature 130°F (54°C)
8.5 in. bore:
Jacket water capacity, engine 52.5 gal (199 L)
107 gal (405 L) 148 gal (560 L)
only 9.375 in. bore:
48.5 gal (184 L)
Surge tank capacity (optional) 23 gal (87 L) 45.5 gal (183 L) 45.5 gal (183 L)
Form 6277-5
1.15-21 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
GENERAL SPECIFICATIONS
Engine Model 6-Cylinder 12-Cylinder 16-Cylinder
Intercooler water capacity 2.75 gal (10.4 L) 5.50 gal (20 L) 11 gal (42 L)
Oil cooler water capacity 5 gal (19 L) 6.5 gal (24.6 L) 9.4 gal (35.6 L)
Total system capacity Add appropriate options to obtain total capacity
Exhaust System
Maximum permissible
See Table 1.15-10 Maximum Allowable Exhaust Backpressure and Reductions for Speed and
backpressure @ rated load
Load on page 1.15-24
and speed
Crankcase Breather System
Crankcase vacuum 0 to -1 (negative) inch-H2O (0 to -25.4 mm-H2O [negative])
Jacket Water Outlet Temperature
180°F (82°C) for continuous rating
Normal:
200°F (93°C) for intermittent rating
Standard cooling system
Alarm: 10°F (5.5°C) above normal/design temperature
Shutdown: 20°F (11°C) above normal/design temperature
Normal: 210 – 235°F (99 – 113°C) solid water
Elevated temperature solid Alarm: 5°F (3°C) above normal/design temperature**
water cooling system
Shutdown: 10°F (5.5°C) above normal/design operating temperature**
Intake Manifold Temperature
Up to 10°F (5.5°C) above design intercooler water inlet
GSI & GL engines Normal:
temperature
Alarm: 15°F (8.5°C) above design intercooler water inlet temperature
Shutdown: 20°F (11°C) above design intercooler water inlet temperature
Intake Manifold Pressure
Contact Waukesha Sales Engineering Department
Fuel System
Natural gas pressure at regulator G engines 5 – 10 psi (34.5 – 69 kPa)
Natural gas pressure at regulator GSI engines 24 – 50 psi (165 – 345 kPa)
Natural gas pressure at regulator GL engines 30 – 50 psi (207 – 345 kPa)
GSI – 6 in. (152 mm) of water column
Natural gas pressure at regulator Low Fuel Pressure System
GL – 6 in. (152 mm) of water column at regulator and 30 psig
engines
(206.8 kPa) prechamber fuel supply
Air Induction System
Maximum permissible restriction @ rated load and speed 15 inch-H2O (381 mm-H2O)
Required filtering efficiency (coarse dust test per SAE726C) 99.7%
Starting System
Electric starting 24 volts DC
Air pressure starting 150 psi (1,043 kPa) (maximum) Pressure is based on 50°F (10°C) lube oil temperature
Miscellaneous
See Table 1.15-18 1/2 in. Reach Spark Plugs (Used on G and GSI, and 1/2 in. Reach Spark
Spark plug gap Plug Carriers on GL Only) on page 1.15-29 and Table 1.15-19 VHP GL 13/16 in. Reach Spark
Plugs (Used With 13/16 in. Reach Spark Plug Carriers Only) on page 1.15-30
Form 6277-5
1.15-22 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
GENERAL SPECIFICATIONS
Engine Model 6-Cylinder 12-Cylinder 16-Cylinder
Engine timing See Engine Nameplate
Main bearing temp shutdown 250°F (121°C)
Overspeed shutdown 10% over governed speed
Valve Train
Valve Clearance – Hydraulic
Not applicable – 0.000
valve lifters
* Total capacity of lube oil system. Fill oil pan, filter, cooler, etc., run engine, then add oil as required to bring oil level in oil pan
back to high mark. Record total amount for future reference.
** Waukesha Power Systems Code 1105, 1105A, or equivalent shutdown system recommended when jacket water temperature
exceeds 210°F (99°C).
NOMINAL
STD./OPT. QTY. START TO OPEN FULL OPEN P/N
TEMPERATURE
Std. 1 120°F (49°C) 111°F (44°C) 130°F (54°C) 496873
Opt. 1 75°F (24) 70°F (21°C) 85°F (29°C) 496867
Opt. 1 190°F (105°C) 185°F (85°C) 200°F (93°C) 496868
Form 6277-5
1.15-23 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
Table 1.15-10: Maximum Allowable Exhaust Backpressure and Reductions for Speed and Load
The maximum allowable exhaust backpressure for a VHP GSI* engine is 21 in. (533 mm) of water column
pressure (4.5 kPa) at 180 BMEP at 1,200 rpm. This pressure must be reduced by 1.5 in. (38 mm) of water column
(0.37 kPa) for every 100 rpm that the maximum rated speed is below 1,200 rpm and reduced by 1.5 in. (38 mm)
of water column (0.37 kPa) for every 10 BMEP that the maximum rated load is below 180 BMEP. Allowable
backpressure is not reduced below 4.0 in. (101.6 mm) of water column pressure (1 kPa). At reduced load and/
or speed, the backpressure on the engine will decrease by the operating characteristic of the exhaust system.
Max Exhaust Backpressure = 21 – 1.5 x ([1,200 – rpm]/100) – 1.5 x ([180 – BMEP]/10) inch-H2O
LEAN BURN, TURBOCHARGED AND INTERCOOLED, VHP GL MODELS
The maximum allowable exhaust backpressure for a VHP GL engine is 13.5 in. (343 mm) of water column
pressure (3.4 kPa) at 160 BMEP at 1,200 rpm. This pressure must be reduced by 1.0 in. (25.4 mm) of water
column (0.25 kPa) for every 100 rpm that the maximum rated speed is below 1,200 rpm and reduced by 1.0 in.
(25.4 mm) of water column (0.25 kPa) for every 10 BMEP that the maximum rated load is below 160 BMEP.
Allowable backpressure is not reduced below 4.0 in. (101.6 mm) of water column pressure (1 kPa). At reduced
load and/or speed the backpressure on the engine will decrease by the operating characteristic of the exhaust
system.
Max Exhaust Backpressure = 13.5 – ([1,200 – rpm]/100) – ([160 – BMEP]/10) inch-H2O
* This applies only to VHP GSI engines with the ejector-style breather system. For other engines, contact the Waukesha Sales
Engineering Department.
Table 1.15-11: P/N 208569D Air Valves Inlet Pressures and Pilot Pressures to Shift
Form 6277-5
1.15-24 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
475357 O2 Analyzer
Form 6277-5
1.15-25 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
Form 6277-5
1.15-26 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
Table 1.15-15: Metric to English Formula Conversion Table
CONVERSION FORMULA
Brake Horse Power (BHP) to Brake Mean Effective
BMEP (psi) = [BHP x 792,000] divided by [Displacement (in.3) x rpm]
Power (BMEP) in Pounds Per Square inch (psi)
Kilowatts (kWb) to Brake Mean Effective Power
BMEP (bar) = [kWb x 1,200] divided by [Displacement (L) x rpm]
(BMEP) in Bar
Form 6277-5
1.15-27 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
TORQUE VALUES
CRITICAL ENGINE TORQUE VALUES
Table 1.15-17 lists the torque values needed for the
basic maintenance of VHP engines.
NOTICE
32 – 38 (dry) 43 – 52 (dry)
13/16 in. reach spark plugs must be used with 13/16 in. reach carriers and 1/2 in.
reach spark plugs must be used with 1/2 in. reach carriers.
Lubrication System
Filter Cover Capscrews 35 – 37 47 – 50
Oil Pan Access Covers (Current P/N E200224 with two capscrews) 6–8 8.10 – 10.8
Oil Pan Door Clamp Capscrews 18 – 20 24 – 27
Pressure Relief Valve Equipped Oil Pan Access Covers 100 – 105 in.-lb 11.2 – 11.7
NOTE: All torques oiled unless specified.
Form 6277-5
1.15-28 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
NOTICE
1/2 in. reach spark plugs must be used with 1/2 in.
reach spark plug carriers.
Table 1.15-18: 1/2 in. Reach Spark Plugs (Used on G and GSI, and 1/2 in. Reach Spark Plug Carriers on GL Only)
Form 6277-5
1.15-29 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
NOTICE
VHP GL 13/16 in. reach spark plugs must be used with
13/16 in. reach spark plug carriers.
Table 1.15-19: VHP GL 13/16 in. Reach Spark Plugs (Used With 13/16 in. Reach Spark Plug Carriers Only)
Form 6277-5
1.15-30 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
GENERAL TORQUE RECOMMENDATIONS
The values specified in the following tables are to be
used only in the absence of specified torquing
instructions and are not to be construed as authority to
change existing torque values. A tolerance of ±3 percent
is permissible on these values, which are for oiled
threads.
Table 1.15-20: Metric Standard Capscrew Torque Values (Untreated Black Finish)
ISO
PROPERTY 5.6 8.8 10.9 12.9
CLASS
Form 6277-5
1.15-31 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
ISO PROPERTY
8.8 10.9 12.9
CLASS
Form 6277-5
1.15-32 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
Table 1.15-21: Metric Standard Capscrew Torque Values (Electrically Zinc Plated)
ISO
PROPERTY 5.6 8.8 10.9 12.9
CLASS
Form 6277-5
1.15-33 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
ISO PROPERTY
8.8 10.9 12.9
CLASS
Form 6277-5
1.15-34 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
Table 1.15-22: U.S. Standard Capscrew Torque Values
SAE
GRADE
NUMBER
GRADE 1 OR 2 GRADE 5 GRADE 8
SIZE/
THREADS TORQUE in.-lb (N·m) TORQUE in.-lb (N·m) TORQUE in.-lb (N·m)
PER INCH
THREADS DRY OILED PLATED DRY OILED PLATED DRY OILED PLATED
1/4 – 20 62 (7) 53 (6) 44 (5) 97 (11) 80 (9) 73 (8) 142 (16) 133 (15) 124 (14)
1/4 – 28 71 (8) 62 (7) 53 (6) 124 (14) 106 (12) 97 (11) 168 (19) 159 (18) 133 (15)
5/16 – 18 133 (15) 124 (14) 106 (12) 203 (23) 177 (20) 168 (19) 292 (33) 265 (30) 230 (26)
5/16 – 24 159 (18) 142 (16) 124 (14) 230 (26) 203 (23) 177 (20) 327 (37) 292 (33) 265 (30)
3/8 – 16 212 (24) 195 (22) 168 (19) 372 (42) 336 (38) 301 (34) 531 (60) 478 (54) 416 (47)
ft-lb (N·m) ft-lb (N·m) ft-lb (N·m)
3/8 – 24 20 (27) 18 (24) 16 (22) 35 (47) 32 (43) 28 (38) 49 (66) 44 (60) 39 (53)
7/16 – 14 28 (38) 25 (34) 22 (30) 49 (56) 44 (60) 39 (53) 70 (95) 63 (85) 56 (76)
7/16 – 20 30 (41) 27 (37) 24 (33) 55 (75) 50 (68) 44 (60) 78 (106) 70 (95) 62 (84)
1/2 – 13 39 (53) 35 (47) 31 (42) 75 (102) 68 (92) 60 (81) 105 (142) 95 (129) 84 (114)
1/2 – 20 41 (56) 37 (50) 33 (45) 85 (115) 77 (104) 68 (92) 120 (163) 108 (146) 96 (130)
9/16 – 12 51 (69) 46 (62) 41 (56) 110 (149) 99 (134) 88 (119) 155 (210) 140 (190) 124 (168)
9/16 – 18 55 (75) 50 (68) 44 (60) 120 (163) 108 (146) 96 (130) 170 (230) 153 (207) 136 (184)
5/8 – 11 83 (113) 75 (102) 66 (89) 150 (203) 135 (183) 120 (163) 210 (285) 189 (256) 168 (228)
5/8 – 18 95 (129) 86 (117) 76 (103) 170 (230) 153 (207) 136 (184) 240 (325) 216 (293) 192 (260)
3/4 – 10 105 (142) 95 (130) 84 (114) 270 (366) 243 (329) 216 (293) 375 (508) 338 (458) 300 (407)
3/4 – 16 115 (156) 104 (141) 92 (125) 295 (400) 266 (361) 236 (320) 420 (569) 378 (513) 336 (456)
7/8 – 9 160 (217) 144 (195) 128 (174) 429 (582) 386 (523) 343 (465) 605 (820) 545 (739) 484 (656)
7/8 – 14 175 (237) 158 (214) 140 (190) 473 (461) 426 (578) 379 (514) 675 (915) 608 (824) 540 (732)
910 819
1.0 – 8 235 (319) 212 (287) 188 (255) 644 (873) 580 (786) 516 (700) 728 (987)
(1,234) (1,110)
990 891 792
1.0 – 14 250 (339) 225 (305) 200 (271) 721 (978) 649 (880) 577 (782)
(1,342) (1,208) (1,074)
NOTE:
• Dry torque values are based on the use of clean, dry threads.
• Oiled torque values have been reduced by 10% when engine oil is used as a lubricant.
• Plated torque values have been reduced by 20% for new plated capscrews.
• Oiled torque values should be reduced by 10% from dry when nickel-based antiseize compound is used as a lubricant.
• Capscrews which are threaded into aluminum may require a torque reduction of 30% or more.
• The conversion factor from ft-lb to in.-lb is ft-lb x 12 equals in.-lb.
Form 6277-5
1.15-35 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
DECLARATION OF CONFORMITY
Form 6277-5
1.15-36 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
DECLARATION OF INCORPORATION
Form 6277-5
1.15-37 © Copyright 2023, INNIO's Waukesha Engine
GENERAL INFORMATION
Form 6277-5
1.15-38 © Copyright 2023, INNIO's Waukesha Engine
ENGINE SYSTEMS
SECTION 2.00
SPEED GOVERNING SYSTEM DESCRIPTION
Form 6277-5
2.00-1 © Copyright 2023, INNIO's Waukesha Engine
SPEED GOVERNING SYSTEM DESCRIPTION
Alternating current-generating units tied in with other
2 units should have droop set sufficiently high (30 to 50 on
1 the dial) to prevent interchange of load between the
units. If one unit in the plant, or system has enough
capacity, its governor may be set on zero droop and it
will regulate the frequency of the entire system. This unit
will take all the load changes within the limits of its
capacity and will control frequency if its capacity is not
exceeded.
The system frequency is adjusted by operating the
synchronizer of the governor having zero droop. the
SPEED DROOP SYNCHRONIZER distribution of load between units is accomplished by
operating the synchronizers of the governors having
speed droop.
LOAD LIMIT SYN. INDICATOR
NOTICE
3
Do not manually force the engine linkage to increase
fuel without first turning load limit knob to 10.
The load limit control hydraulically limits the load that can
be put on the engine by restricting the terminal output
shaft rotation of the governor, and consequently, the
4 quantity of fuel supplied to the engine. The control may
also be used for shutting down the engine by turning it
to zero.
An optional synchronizing motor may be mounted on a
special cover for the governor to provide remote speed
5
control. Its use enables the operator to match the output
of an engine driven machine with that of other units. The
motor is that of the split field, series wound, reversible
Figure 2.00-1: Woodward UG-8 Dial Governor type. It can be used on either direct current or alternating
current at its specified voltage. A slip coupling is
1 - Sight Glass 4 - Oil Drain Plug provided between the motor shaft and the synchronizer
2 - Oil Filler Cup 5 - Compensation control knob on the governor. This coupling is a friction
3 - Compensation Needle Valve type.
Adjustment (Behind Plug)
Droop is incorporated in the governor through a linkage WOODWARD UG-ACTUATOR GOVERNOR
which varies the compression of the speeder (speed The Woodward UG-Actuator Governor is a proportional
adjusting spring) as the output shaft rotates. Increased electric/hydraulic actuator. The UG-Actuator converts
fuel reduces spring compression, reduces the governor an electrical input signal to a proportional hydraulic
setting accordingly, and the unit will gradually reduce its output-shaft position to control engine fuel flow. The
speed as load is applied. This relationship between load UG-Actuator provides the advantages of electronic
and speed acts as a resistance to load changes when control while using the same linkages as the UG-8
the unit is interconnected with other units either governors. The UG-Actuator is outwardly similar to the
mechanically or electrically. UG-8L governor.
As droop is reduced toward zero, the unit becomes able
to change load without changing speed. As a general
rule, units running alone should be set on zero droop,
interconnected units should be run at the lowest droop
setting that will give satisfactory load division.
Form 6277-5
2.00-2 © Copyright 2023, INNIO's Waukesha Engine
SPEED GOVERNING SYSTEM DESCRIPTION
1
1
2
WOODWARD
C
O M
2
M
A
P
E X
N
3
S
A
T M
I I
O
N
N
5
Figure 2.00-3: 6-Cylinder EG-3P Actuator
7
GOVERNOR LINKAGE
The governor linkage (see Figure 2.00-3) connects the
Figure 2.00-2: Woodward UG-8L Governor governor output shaft with the carburetor butterfly shaft.
UG-8L governors (see Figure 2.00-4) have a hand lever
1 - Sight Glass 5 - Oil Drain Plug on the side of the governor to manually set the engine to
2 - Oil Filler Cup 6 - Drive Shaft the desired speed. UG-8 dial governors (see Figure
3 - Terminal Shaft 7 - Compensation 2.00-1) manually control engine speed with a dial
4 - Compensation Needle Valve
control. All engines have a manual shutdown lever (see
Pointer (behind plug)
Figure 2.00-5) added to the linkage on the carburetor
side, that enables the operator to manually close the fuel
WOODWARD EG-3P ELECTRONIC GOVERNING valves in the event of an emergency.
SYSTEM
The Woodward EG-3P electronic governing system
(see Figure 2.00-3) consists of three components: the
magnetic pickup, the control unit and the actuator. The
system is capable of isochronous operation (will
maintain the same engine speed regardless of engine
load). The control unit is off-engine mounted and is
usually in the control room. It is the device that interrupts
the signal that is sent from the magnetic pickup. The
control unit then compares the magnetic signal through
circuitry and makes the proper adjustments through the
actuator. The governor actuator is engine-mounted, and
is the mechanical device that physically moves the
carburetor butterflies. Located on the mounting pad of
the governor drive housing on the front right side of the
engine, the governor actuator is driven from the
accessory drive gear.
Form 6277-5
2.00-3 © Copyright 2023, INNIO's Waukesha Engine
SPEED GOVERNING SYSTEM DESCRIPTION
Figure 2.00-4
Form 6277-5
2.00-4 © Copyright 2023, INNIO's Waukesha Engine
SPEED GOVERNING SYSTEM DESCRIPTION
0 10 0 10 0 10 0 10 0 10 0 10 0 10
0 10 0 10
RAMP TIME RESET
2301A LOAD SHARING & SPEED CONTROL OPEN
FOR CLOSE
MIN FOR
CB FUEL RATED
AUX
CLOSE TO
LOAD 20--46VOC OVERRIDE SPEED SPM
SHARING LOAD SUPPLY FAILED TRIM SYNC SPEED
LINES SIGNAL _ SPEED ACTUATOR OR INPUT SIGNAL
+ SIGNAL JUMPER INPUT
+ _ + + _ + _
PT CT CT CT
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
START ACTUATOR
FUEL LIMT COMPENSATION RESET GAIN
0 10 0 10 0 10 0 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Form 6277-5
2.00-5 © Copyright 2023, INNIO's Waukesha Engine
SPEED GOVERNING SYSTEM DESCRIPTION
A signal from a pneumatic supply pressurizes the
2 governor speed setting mechanism. The speed is
determined by the amount of air pressure that is supplied
1 to the actuator. Typical pneumatic pressure range is 3 –
15 psi (20.7 – 103.4 kPa). Governors operating at these
3
pressures will control the engine speed between 800
and 1,200 rpm.
Figure 2.00-9
Form 6277-5
2.00-6 © Copyright 2023, INNIO's Waukesha Engine
SECTION 2.05
FUEL SYSTEM DESCRIPTION
Form 6277-5
2.05-1 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM DESCRIPTION
1 1
3
3
6
6
2
2
5 5
7
4
Form 6277-5
2.05-2 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM DESCRIPTION
1
1
3
4 4
2 2
6
7 6
5
Form 6277-5
2.05-3 © Copyright 2023, INNIO's Waukesha Engine
NOTES:
ENGINE LUBE
FURNISHED BY CUSTOMER OIL HEADER
1 CUSTOMER OR END USER IS RESPONSIBLE
FOR VENTING GAS FROM THIS SYSTE M AIR
AND PIPING TO A SAFE AREA TO MEET IN
APPICABLE CODES. AIR/FUEL
VENT
FUEL
2. THIS SHEET DEPICTS ENGINE CONTROL POSITIONS
WHEN OPERATING IN THE FOLLOWING MODE. BALANCE OR CONTROL LINE
FUEL: STANDARD NATURAL GAS VOLUME
ENGINE: RUNNING JUNCTION FOR STARTING OPTIONS CHAMBER
(SEE INSERT FOR START CYCLE)
EXHAUST MANIFOLD
LEFT BANK “F” CARBURETOR INLET
GAS PRESSURE SAMPLE POINT
“A” MIX ADJUST
SCREW CARBURETOR
GOVERNOR CONTROLLED
CYLINDER
HEAD LEFT BANK
2.05-4
PRECHAMBER MANIFOLD 3--WAY N. C. ELECTRIC
SOLENOID VALVE FOR AIR
GAS PRESSURE START WITHOUT PNEUMATIC
REGULATOR ENGINE LUBE CONTROL PANEL
PRECHAMBER OIL HEADER
“B”
PIOLT OPERATED AIR
VALVE SUPPLY STANDARD NATURAL GAS
PRECHAMBER PRESSURE TAP 35--50 PSI
POINT “C”
PRECHAMBER MANIFOLD
AIR/GAS
VOLUME SUPPLY
“E”
CHAMBER
EXHAUST MANIFOLD
RIGHT BANK “F” CARBURETOR INLET
GAS PRESSURE SAMPLE POINT PRECHAMBER GAS START UP
RESTRICTOR PLATE GAS PRESSURE SOLENOID VALVE
“A” MIX ADJUST (DE--ENERGIZED, ELECTRIC START ONLY)
REGULATOR
SCREW
Form 6277-5
2.05-5 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM DESCRIPTION
2 4
18
3
17 5
9
16 8 6
13 10
12 7
15
14
11
Form 6277-5
2.05-6 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM DESCRIPTION
CARBURETOR(S) PILOT-OPERATED PRECHAMBER GAS VALVE – GL
ENGINE
6- , 12- and 16-cylinder engines have a carburetor
mounted just below the center of each intake manifold The prechamber gas valve (see Figure 2.05-8) is located
(see Figure 2.05-7). on a line off the main fuel gas pressure regulator gas inlet
pipe tee. This valve admits high-pressure gas to the
prechamber fuel regulator.
The air/gas supply from the bulkhead is connected to the
Prelube and Start pushbutton valves. The normally open
2 port of each valve vents the downstream side when the
1 pushbutton valve is not depressed. The vented air/gas
supply is directed back to the bulkhead where it is piped
to a safe location.
Depressing the Start pushbutton causes the pilot air
pressure to be directed to the pilot operated starter pre-
engage valve. Enroute to the starter pre-engage valve,
a portion is diverted to the pilot operated prechamber
gas valve. Before reaching the gas valve, the pilot
pressure passes through an orifice check valve, air/gas
3 plenum (volume tank) and shuttle valve. When the pilot
pressure opens the prechamber gas valve, a line off the
Figure 2.05-7: Carburetor – Right-Side View Fisher 99 main fuel gas pressure regulator gas inlet
admits high pressure gas to the prechamber fuel
1 - Prechamber 3 - Manual Speed regulator. The orifice check valve and air/gas plenum act
Manifold Control
as a pneumatic timer to retard the blow down of pilot
2 - Carburetor
pressure when the Start pushbutton is released.
The carburetor produces a combustible mixture by
automatically mixing air and fuel in the proper
proportions. It consists of an air inlet housing, a gas inlet,
two air flow measuring valves, two diaphragm-operated
gas metering valves and a butterfly valve.
The amount of air going to the engine is sensed by the
air flow measuring valves, which rise in direct proportion
to the volume of air passing through them. Each gas
metering valve is mechanically fixed to an air flow
measuring valve, so the gas passages are opened by an
amount that is proportional to the amount of air entering
the engine. The tapered gas metering valve is shaped to
admit the correct amount of gas at any height to which
the air flow measuring valve rises. This operation allows
the engine to maintain a specific air/fuel ratio throughout
its operating range.
The amount of air/fuel mixture flowing out of the
carburetor is controlled by the position of the butterfly
valve in the carburetor throat.
The air/fuel mixture passes from the carburetor to the
intake manifold.
Figure 2.05-8: 6-Cylinder GL Prechamber Gas Valve
Form 6277-5
2.05-7 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM DESCRIPTION
PRECHAMBER GAS SAFETY SHUTDOWN VALVE – The prechamber regulator (see Figure 2.05-10) controls
GL ENGINE the amount of fuel available to the prechamber
manifolds. The flow to the prechamber manifolds is fuel
The prechamber gas safety shutdown valve (see Figure
only. All of the air needed for combustion is pushed into
2.05-9) admits downstream gas pressure to the opposite
the prechamber by the piston on its compression stroke.
side of the shuttle valve once engine lube oil pressure
reaches or exceeds 20 psi (137 kPa). When the pressure
in the air/gas plenum bleeds down, the shuttle valve
shifts position and the downstream gas pressure
assumes the task of holding the pilot gas valve open.
The time delay provided by the check valve and air/gas
plenum keeps pilot pressure on the gas valve long
enough for lube oil pressure to rise and shift the shuttle
valve. Lube oil pressure continues to admit gas to the
prechamber regulator as long as the engine is running.
If the engine stops, loss of engine lube oil pressure
automatically causes the prechamber gas safety Figure 2.05-10
shutdown valve to stop the flow of downstream gas to
Fed by high pressure fuel from the Fisher 99 main fuel
the prechamber gas valve, which effectively shuts off the
gas pressure regulator supply line, the prechamber
supply of high pressure gas to the prechamber regulator.
regulator is set to maintain a specific prechamber
If the engine fails to start, insufficient lube oil pressure
manifold over intake manifold pressure differential
prevents the downstream gas from passing to the
(measured in inches of mercury).
prechamber gas valve, so the gas supply shuts off as
soon as the pilot pressure in the air/gas plenum is If the force of the pilot spring exceeds the force of the
exhausted. In both cases, any gas in the downstream outlet pressure (as exerted against the bottom of the
line passes to the vent tube and is exhausted at the diaphragm), the guide stem is held down (see Figure
customer’s bulkhead connection. 2.05-11). Pilot spring pressure, as plus compression of
the valve spring holds the valve plug away from the gas
inlet orifice allowing flow to the outlet system (via the
1 prechamber gas valve).
Form 6277-5
2.05-8 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM DESCRIPTION
CYLINDER HEAD ADMISSION VALVE ASSEMBLIES
– GL ENGINE
10 5
6
9 1
7
8
Form 6277-5
2.05-9 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM DESCRIPTION
The top half of the prechamber is located in the bottom CUSTOM ENGINE CONTROL AIR/FUEL MODULE
of the spark plug carrier. The lower portion of the SYSTEM (OPTIONAL)
prechamber is a separate piece with a three-hole nozzle
The Custom Engine Control (CEC) Air/Fuel Module
(see Figure 2.05-13). The prechamber is filled with the
(AFM) system is designed to control the air/fuel ratio of
rich air/fuel mixture through the admission valve. The
Waukesha’s gaseous fueled, industrial engines (see
prechamber fuel charge is leaned out by air flow into the
Figure 2.05-14). An engine’s air/fuel ratio defines the
prechamber during the compression stroke. This
amount of air in either weight or mass in relation to a
process is designed to be highly turbulent, ensuring
single amount of fuel supplied to an engine for
good mixing of each prechamber charge. The spark plug
combustion. Air/fuel ratio influences engine power,
then ignites the prechamber mixture, which directs a
emissions and fuel economy. By controlling an engine’s
flame torch through the nozzle holes into the lean
air/fuel ratio with the AFM system, you will benefit in fuel
mixture in the main combustion chamber. The main
savings, emissions control and/or peak engine
chamber fuel charge then ignites.
performance. The AFM system regulates and maintains
the engine’s air/fuel ratio even with changes in engine
load, speed, fuel pressure and fuel quality.
3
2
2
1
4
1
Figure 2.05-14
Form 6277-5
2.05-10 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM DESCRIPTION
The basic AFM system consists of an oxygen sensing
system, intake manifold pressure transducer (catalyst
and lean burn only), electronic control module (AFM
module), stepper (see Figure 2.05-15) and exhaust
thermocouple. The oxygen sensor continually reports
the concentration of oxygen in the exhaust to the AFM
module. Based on this signal, the AFM module then
determines if a correction to the air/fuel ratio is required.
If a change is needed, a command is sent to a stepper
motor (installed on the fuel regulator) which influences 1
the fuel flow to the engine. The exhaust thermocouple
ensures exhaust temperatures are high enough to
permit correct system operation.
The AFM module is equipped with several features to
inform site personnel of system status. These features
include:
• “Power” and “Alarm” lights (LED display) on the front
panel of the AFM module (see Figure 2.05-14)
– The green “Power” LED is lit anytime power is 2
applied to the AFM module.
– The yellow “Alarm” LED is lit any time the AFM
system’s diagnostic functions are activated or when
AFM execution has been stopped by the operator
(such as during the saving of a data-set).
• An alpha-numeric liquid crystal display (LCD display)
visible from the front of the AFM module allows the
operator to monitor important system parameters. Figure 2.05-15: 6-Cylinder AFM Stepper
• A sealed membrane keypad located on the front of the
1 - Main Fuel Gas 2 - AFM Stepper
AFM module
Regulator
Form 6277-5
2.05-11 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM DESCRIPTION
1 - Special Piping 2 - Carburetor Figure 2.05-19: 12-Cylinder Low Fuel Pressure System
Piping
Form 6277-5
2.05-12 © Copyright 2023, INNIO's Waukesha Engine
SECTION 2.10
IGNITION SYSTEM DESCRIPTION
Form 6277-5
2.10-1 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM DESCRIPTION
3 2
Figure 2.10-2: CEC Ignition Module Figure 2.10-3: CEC Timing Disc
Form 6277-5
2.10-2 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM DESCRIPTION
2
3
1
Form 6277-5
2.10-3 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM DESCRIPTION
IGNITION COILS
NOTICE
Run the AutoCal program after doing any repair or
replacement of cylinder heads, gaskets, liners,
pistons or knock sensors. The DSM AutoCal program
automatically establishes detonation levels so that the
DSM system can operate properly. Failure to run the
AutoCal program could result in poor engine
performance and engine damage.
1
Form 6277-5
2.10-4 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM DESCRIPTION
GL engines may be equipped with either 1/2 in. or 13/16 NOTE: An unmarked Waukesha spark plug carrier
in. reach spark plugs. On GL engines, each spark plug indicates 1/2 in. reach.
is housed within a spark plug carrier and fires the rich
See latest edition of Service Bulletin 11-2750 for
fuel mixture in the respective prechamber. The flame
information on longer reach spark plugs (13/16 in.) and
torch ignites the lean mixture in the main combustion
longer reach spark plug carriers (13/16 in.) as a service
chamber. Spark plug life will depend on the site
option on GL engines. Carriers are marked with the
experience. The spark plug carriers (see Figure
spark plug reach (thread length). Carrier and spark plug
2.10-9) are stamped to identify the spark plug reach. If a
size must be verified prior to installation. An unmarked
Waukesha spark plug carrier is not marked, it is 1/2 in.
Waukesha spark plug carrier indicates 1/2 in. reach.
reach. The spark plug carriers are threaded directly into
the cylinder head and the spark plug is threaded into the
spark plug carrier. The GL engines use spark plug
carriers because of the special combustion
characteristics of these engines (see Figure 2.10-10).
Form 6277-5
2.10-5 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM DESCRIPTION
1 1
3 3
1
7 4
6
5
Form 6277-5
2.10-6 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM DESCRIPTION
Form 6277-5
2.10-7 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM DESCRIPTION
Form 6277-5
2.10-8 © Copyright 2023, INNIO's Waukesha Engine
SECTION 2.15
AIR INDUCTION SYSTEM DESCRIPTION
AIR INDUCTION SYSTEM COMPONENTS The turbocharger(s) for 6- and 12-cylinder engines are
side-mounted at the rear of the engine.
The air intake system consists of the following
components: The turbochargers for 16-cylinder engines are centered
to the left and right of the exhaust stack on top of the
• Air Cleaner(s)
engine.
• Turbocharger(s) (GSI, GL)
The turbine side of each turbocharger is part of the
• Intercooler(s) (GSI, GL) exhaust system, the compressor side is part of the air
• Carburetor(s) (G, GSI, GL) induction system. A shaft connects the two. When the
• Intake Manifold(s) (G, GSI, GL) turbine spins through the expansion of exhaust gases
exiting the engine, the movement of the compressor
AIR CLEANER(S) wheel causes the air passing through the air cleaner,
enroute to the carburetor, to be compressed.
The air cleaner removes dirt and dust from the air
admitted to the engine.
Six-cylinder engines have one air cleaner (see Figure 1
2.15-1), while 12- and 16-cylinder engines have two air
cleaners (see Figure 2.15-2 and Figure 2.15-3). Each air
cleaner consists of the air filter frame, main air filter
element, prefilter pad, air intake restriction indicator and
rain shield.
The air cleaner(s) for 6- and 12-cylinder engines are
side-mounted at the rear of the engine. 3
The air cleaners for 16-cylinder engines are mounted
beneath the intake manifolds on G engines and the top 4
front of the engine on GSI and GL engines. 2
The air restriction indicator on 6- and 12-cylinder
Figure 2.15-1: 6-Cylinder GSI – Rear View
engines will show “red” if the air intake restriction is 15
in. (381 mm) of water. This indicates a clogged or dirty 1 - Turbocharger 3 - Air Restriction
main air filter element and/or clogged or dirty precleaner 2 - Intercooler Indicator
element. On 16-cylinder engines, gauges mounted on 4 - Air Cleaner
each air cleaner register the condition of the air filters.
The air restriction gauge must show in the green, for both INTERCOOLER(S)
the prefilter and final filter. A toggle switch allows the
operator to select the filter reading desired. Intercooler(s) (GSI and GL engines) are mounted on the
rear of the engine on 6- and 12-cylinder engines (see
TURBOCHARGER(S) Figure 2.15-1 and Figure 2.15-2). 16-cylinder engines
have the intercooler mounted to the front and rear of the
Six-cylinder GSI and GL engines have one turbocharger
exhaust stack (see Figure 2.15-3).
(see Figure 2.15-1); all other VHP GSI and GL engines
have two turbochargers, one for each bank (see Figure
2.15-2 and Figure 2.15-3).
Form 6277-5
2.15-1 © Copyright 2023, INNIO's Waukesha Engine
AIR INDUCTION SYSTEM DESCRIPTION
Each intercooler is a box-type tube and fin assembly. On 6-cylinder engines, the carburetor is mounted on the
Heated compressed air from the turbocharger(s) enters underside of the intake manifold on the outside of the
the intercooler(s) and flows over a series of tubes cylinder bank (see Figure 2.15-4). 12- and 16-cylinder
through which the auxiliary water system coolant is engines have a carburetor on both the right and left side,
circulated. The temperature of the compressed air is one for each cylinder bank, as well as two intake
reduced, which makes it denser. manifolds, one for each bank, mounted on opposite
sides of the crankcase vee (Figure 2.15-5 and Figure
2.15-6).
2
1 3 The intake manifold(s) connect the carburetor(s) to the
intake ports of the cylinders and equally distribute the air/
fuel mixture to each.
1
4
2
1 - Intercooler 3 - Intercooler
2 - Turbocharger 4 - Air Cleaner
Form 6277-5
2.15-2 © Copyright 2023, INNIO's Waukesha Engine
AIR INDUCTION SYSTEM DESCRIPTION
Form 6277-5
2.15-3 © Copyright 2023, INNIO's Waukesha Engine
AIR INDUCTION SYSTEM DESCRIPTION
Form 6277-5
2.15-4 © Copyright 2023, INNIO's Waukesha Engine
SECTION 2.20
TURBOCHARGER SYSTEM DESCRIPTION
TURBOCHARGER SYSTEM
COMPONENTS
GSI and GL engines are turbocharged. The
turbocharger system consists of the following
components:
• Turbochargers
• Connecting Hose(s)
• Connecting Piping
TURBOCHARGER(S)
6-cylinder GSI and GL engines have one turbocharger
(see Figure 2.20-1); all other VHP GSI and GL engines
have two turbochargers, one for each bank (see Figure Figure 2.20-2: 12-Cylinder GL Turbochargers – Rear View
2.20-2 and Figure 2.20-3).
Form 6277-5
2.20-1 © Copyright 2023, INNIO's Waukesha Engine
TURBOCHARGER SYSTEM DESCRIPTION
Form 6277-5
2.20-2 © Copyright 2023, INNIO's Waukesha Engine
SECTION 2.25
COOLING SYSTEM DESCRIPTION
Form 6277-5
2.25-1 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
10
3
2
1
5 4
Figure 2.25-1: G Engine Cooling System Schematic – Standard Jacket Water Temperature
Form 6277-5
2.25-2 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
12
3 4
2
1
12
6 5
9
8
10
11
Figure 2.25-2: G Engine Cooling System Schematic – Elevated Jacket Water Temperature
Form 6277-5
2.25-3 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
12
3 4
13
2
1
14
6 5 12
8
9
10
11
Figure 2.25-3: GSI Engine Cooling System Schematic – Standard and Elevated Jacket Water Temperatures
Form 6277-5
2.25-4 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
13
3 4
14
2
15 41
6 5 13
7
8
10
9
11
12
Figure 2.25-4: GL Engine Cooling System Schematic – Standard and Elevated Jacket Water Temperatures
Form 6277-5
2.25-5 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
EXHAUST MANIFOLD
From each cylinder head, water passes up through the 1
water outlet elbow connection (see Figure 2.25-5) to one
segment of the water-jacketed exhaust manifold(s). A
portion of the cooling water also exits the head through
a hole centered below the exhaust port (see Figure
2.25-6). Each exhaust manifold assembly is comprised
of six individual water-cooled segments.
3
2
1
Figure 2.25-6
Figure 2.25-5
1 - Water Outlet Elbow 3 - Water Hole to
1 - Water Outlet Elbow 2 - Exhaust Manifold Connection Exhaust Manifold
Segment 2 - Cylinder Head 4 - Exhaust Port
Form 6277-5
2.25-6 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
JACKET WATER HEADER / JACKET WATER
The coolant passageways in both the crankcase and
cylinder heads comprise the jacket water system. The
jacket water header is integrally cast within the 2
crankcase. Coolant water circulates around the cylinder
sleeves inside the cylinder block. Water flows up through 1
the water passage openings in the deck of each cylinder
head, flows around the valve seats and exhaust guides, 3
and up to the water-cooled exhaust manifold(s).
WATER MANIFOLD
5
The water manifold (see Figure 2.25-7, Figure 2.25-8
and Figure 2.25-9) receives the cooling water flowing out
of each segment of the exhaust manifold and routes it to 6
the cluster thermostat housing on 6- and 12-cylinder
engines. On 16-cylinder engines, the thermostats are
located in the connector elbows between the exhaust
manifold segments and the water manifold.
Form 6277-5
2.25-7 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
THERMOSTAT HOUSINGS
1 By regulating the circulation of coolant, multiple
thermostatic valves control the jacket water temperature
normally at 180°F (83°C). A variety of other control
temperatures are available.
2
3 4
Figure 2.25-8: 12-Cylinder Cooling Components 1
1 - Cluster Thermostat 3 - Auxiliary Water
Housing Pump
2 - Water Manifold 4 - Jacket Water Pump
6
1
2
5
Figure 2.25-10
1 - Water Manifold 3 - Auxiliary Water NOTE: Landfill gas and high-temperature application
2 - Jacket Water Pump Pump engines use a weir notched seal thermostat design for a
gradual transition of coolant flow. This thermostat series,
does not require a “lead thermostat” because of the weir
notch seal design.
Form 6277-5
2.25-8 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
The thermostats start to open as the engine warms up JACKET WATER REMOTE HEAT TRANSFER
to its normal operating temperature. A portion of the DEVICE
coolant is diverted to the remote heat transfer device,
The jacket water remote heat transfer device may be a
which absorbs the heat and directs the coolant back to
radiator, cooling fan, cooling tower, heat exchanger or
the jacket water pump. The coolant supply from the heat
other devices.
transfer device mixes with that portion of the coolant that
continues to flow down the bypass tube(s) to provide a AUXILIARY WATER PUMP
blend that is within the normal range.
The auxiliary water pump, driven by two belts from the
When the cooling water temperature rises 5°F (2.8°C) crankshaft pulley, is mounted at the front of the oil pan.
above the Start to Open rating of the lead thermostat, the The suction side of the auxiliary water pump is
remaining thermostatic valves begin to open. Opening connected to the outlet port of the auxiliary water
of the secondary thermostats allows an even greater temperature control valve (see Figure 2.25-12). The
portion of the cooling water to be directed to the heat discharge of the pump is directed to the intercooler inlet
transfer device. This operation results in rapid warm up through external piping.
when the thermostatic valves are fully closed and
efficient cooling once the valves open.
SURGE TANK
The optional surge tank provides a coolant reservoir for
the engine. A sight gauge on the side of the surge tank
allows the operator to easily view the coolant level (see
Figure 2.25-11).
Figure 2.25-11
Form 6277-5
2.25-9 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
7 3
B
C
4
6
5
Form 6277-5
2.25-10 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
INTERCOOLER(S)
On GSI and GL engines, the intercooler(s) cool the inlet
air to the turbochargers to provide denser air to the
turbochargers. The intercooler(s) are located at the rear
of the engine on 6- and 12- cylinder engines (see Figure
2.25-13) and on top of the engine on 16-cylinder engines
(see Figure 2.25-14).
Form 6277-5
2.25-11 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
OIL COOLER AUXILIARY WATER TEMPERATURE CONTROL
VALVE
Exiting the outlet port of the intercooler, the coolant flows
to the remote or off engine-mounted oil cooler. One thermostatic valve controls the temperature of the
auxiliary coolant. To maintain the correct temperature,
The oil cooler is a tube and baffle type assembly (see
the valve controls the flow of cooling water from the heat
Figure 2.25-16 and Figure 2.25-17). While the coolant
transfer device.
flows through a bundle of tubes in the oil cooler, the lube
oil circulates around them. Heat from the oil passes The thermostatic valve is enclosed in a housing on the
through the tubes to the coolant which carries it to a heat suction side of the auxiliary water pump.
transfer device for dissipation. From the heat transfer
The thermostat housing has one outlet port stamped A
device, the coolant passes back to the auxiliary water
and two inlet ports stamped B (oil cooler) and C (heat
pump to repeat the circuit.
transfer device) (see Figure 2.25-18). The casting of the
thermostat housing prevents the flow of cooling water
through inlet port C when the thermostat is fully closed.
1 The flow from the oil cooler enters bypass port B and
exits outlet port A enroute to the auxiliary water pump.
The thermostatic valve begins to open as the engine
warms up to its normal operating temperature. The
casting of the thermostat housing is such that inlet port
B becomes restricted as outlet port C starts to open.
Therefore, a smaller portion of the coolant is received
from the oil cooler, while a greater portion of the cooling
water comes from the heat transfer device (see Figure
2.25-18). Cool water passing out the heat transfer device
enters port C of the thermostat housing and combines
2 with hot water passing through bypass port B. The
cooling water exiting outlet port A is a blend that falls
Figure 2.25-16: 6-Cylinder Oil Cooler within the normal range.
Form 6277-5
2.25-12 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
Form 6277-5
2.25-13 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM DESCRIPTION
Form 6277-5
2.25-14 © Copyright 2023, INNIO's Waukesha Engine
SECTION 2.30
LUBRICATION SYSTEM DESCRIPTION
The lubrication system consists of the following The bottom of the crankcase is enclosed by an oil pan.
components: The lube oil pump, gear-driven off the crankshaft, is
externally mounted at the front. The pump draws oil from
• Oil Pan and Pickup Screen
the lowest point in the oil pan and delivers it to the oil
• Oil Pump cooler. The lube oil pump has an pressure relief valve
• Oil Cooler preset at the factory (see Table 1.15-9 Lubrication
System Pressures on page 1.15-23 for specifications).
• Temperature Control Valve
This relief valve protects the oil pump from high initial oil
• Pressure Regulating Valve pressures at start up prior to the engine oil reaching
• Full-Flow Lube Oil Filter normal operating temperatures. A box-shaped pickup
screen prevents foreign material in the oil pan from
• Filter Relief Valve(s)
entering the lube oil circuit.
• Oil Strainer
NOTE: The oil cooler assembly was shipped loose. The
• External Piping (customer-supplied) oil cooler must be either skid or remote mounted by the
customer. The assembly consists of the oil cooler,
PRELUBE SYSTEM COMPONENTS temperature control valve and pressure regulating valve.
• Prelube Pump and Prelube Motor
Coolant is pumped through the cooler by the auxiliary
• Prelube Pushbutton Valve water pump. While the coolant flows through a bundle of
• Pilot-Operated Prelube Valve tubes in the oil cooler, the lube oil circulates around
them. Heat from the oil passes through the tubes to the
• Inline Lubricator
coolant which carries it to a heat transfer device for
• Oil Pressure Gauge dissipation.
The lube oil temperature control is maintained by the
thermostat housing which contains two thermostatic
valves (see Figure 2.30-1).
Form 6277-5
2.30-1 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
2
1 3 1
2
8 4
7 5
6
1
3
6 5
Figure 2.30-2: P/N 208428 Series – Oil Temperature
Figure 2.30-1: Lube Oil Temperature Control Valve Control Valve
1 - Cover Plate 5 - Bypass Inlet Port 1 - Thermostatic 5 - Oil Cooler Port (C)
Element 6 - Identification Plate
2 - Oil Outlet Port 6 - Oil Cooler Inlet Port
2 - Outlet Port (A) 7 - Thermostat
3 - Spring 7 - Lead Thermostat
3 - O-Ring Seal Housing
4 - Secondary
Thermostat 4 - Lip Seal 8 - Bypass Port (B)
The thermostat (single thermostat) housing used in G/ The casting of the thermostat housing prevents the flow
GSI engine applications has one outlet port stamped “A” of oil through inlet port “C” when the thermostat is fully
and two inlet ports stamped “B” (bypass) and “C' (cooler) closed. The flow from the oil pump enters bypass port
(see Figure 2.30-2 and Figure 2.30-3). “B” and exits outlet port “A” enroute to the full-flow lube
oil filter. In this position, oil bypasses the cooler for faster
warm up.
The thermostatic valve begins to open as the engine
warms up to its normal operating temperature. The
casting of the thermostat housing is such that inlet port
“B”becomes restricted as outlet port “C” starts to open.
The gradual opening of the thermostatic valve allows a
portion of the oil flow from the pump to be shunted to the
oil cooler. Cool oil passing out of the oil cooler enters port
“C” of the thermostat housing and combines with hot oil
passing through bypass port “B”. The oil exiting outlet
port is a combination of hot bypass oil and cool oil
passing out of the oil cooler making the mixture a
“blended” temperature. The thermostat senses the
blended temperature and adjusts to maintain it at a
constant level.
Form 6277-5
2.30-2 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
1 2 3
3
2
1 4
6 5 4
Form 6277-5
2.30-3 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
The oil filter housing also contains one or two bypass
relief valves. A pressure differential (see Table
2 1.15-9 Lubrication System Pressures on page 1.15-23
1 for specifications) opens the relief valves and allows the
flow of oil to bypass the filter elements enroute to the lube
oil strainer. If the filter elements get clogged, the bypass
relief valves act as a safety device to ensure that the
engine receives a supply of lubrication oil, although
unfiltered.
3 NOTE: The lube oil filter assembly is shipped loose and
must be either skid or remote-mounted by the customer.
A lube oil strainer is mounted to the main oil header on
the left side of the engine. The strainer is downstream
from the full-flow lube oil filter and represents the last
attempt at catching dirt and foreign material before it
enters the engine. The strainer contains a cleanable,
stainless-steel mesh element with a nominal filter rating
of 74 microns. Two magnet rods are externally mounted
on the element to catch any ferrous metal debris
suspended in the lube oil.
The lube oil strainer contains one bypass pressure relief
valve. A pressure differential (see Table
1.15-9 Lubrication System Pressures on page 1.15-23
for specifications) opens the valve and allows the oil flow
to bypass the strainer element enroute to the main oil
header (see Figure 2.30-6).
Form 6277-5
2.30-4 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
INTERNAL OIL CONTROL Oil supply tubes tapped off the internal oil passage
leading to the front main bearing supplies a continuous
The main oil header is an integral part of the crankcase
spray of oil to the gear train. The lube oil hole in the lower
casting Figure 2.30-7. Internal passages in the
front main bearing allows pressurized oil to flow down a
crankcase direct the flow of pressurized oil to the main
drilled passageway in the main bearing cap to lubricate
bearings via drillings in the main bearing saddles.
the oil pump idler gear spindle.
Internal passages in the crankcase casting also direct
1 2 the flow of pressurized oil to the camshaft bearing
saddles to provide lubrication of the main camshaft
bearings (bushings). Oil flows through holes in the
camshaft bearing caps and down passageways in the
cam follower housing. This lubricates the roller cam
followers and camshaft lobes, after which it drops back
11 3 to the oil pan.
An external oil supply line off the main oil header carries
4 oil to a separate external rocker arm oil header. Supply
tubes from the rocker arm oil header direct the flow of oil
to the rocker arm assemblies and valves.
10 5 Excess oil drains down a cored passage in the cylinder
head and runs down the outside of the push rod tubes
6 to a drainage passage in the cam follower guides. The
passage directs the flow of oil to a drainage hole in the
9 cam follower housing where it flows back to the oil pan
via the camshaft recess.
7 The flow of pressurized oil through the fixed cam follower
8 capscrews of the rocker arm assemblies also supplies
oil to the cam followers, where the excess oil joins the
flow from the cored passage in the cylinder head.
Figure 2.30-6 The flow of pressurized oil through the external system
is depicted in Figure 2.30-8.
1 - Strainer Head 7 - Stainless Steel
2 - Pressure Relief Element The turbochargers receive oil from the main oil header
Valve 8 - Drain Plug via an externally mounted oil supply line. A drain line
3 - Lube Oil Outlet 9 - Element Housing connected to the cam follower housing returns the oil to
4 - O-Ring 10 - Rubber Seal the pan after lubrication of the turbocharger bearings.
5 - Band Retainer 11 - Lube Oil Inlet
To ensure quick lubrication of the rocker arm assemblies
6 - Magnet Rod
and turbochargers at start-up, each external supply line
The flow of oil passes from the main bearing journals into is provided with a check valve to keep the oil from
the T-drilled crankshaft and then up through drilled draining back into the oil pan when the engine is shut
passages in the connecting rods. After lubricating the down. The check valves also prevent excessive
connecting rod bearing, piston pin bushing and piston lubrication of the rocker arm assemblies, valves and
pin, the pressurized oil passes through an opening in the turbochargers during continuous or intermittent prelube.
top of the rod. The oil spray exiting the rod cools the
underside of the piston crown and drains back to the oil
pan.
Form 6277-5
2.30-5 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
1
5
8
2
7
20 3
19
18 10
11
12
13
17
16
15 14
Form 6277-5
2.30-6 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
= 3
1
4
2
5
12 8
7
A
C B
11
10
Form 6277-5
2.30-7 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
OIL PAN AND PICKUP SCREEN NOTE: Guards removed for clarity.
The bottom of the crankcase is enclosed by the oil pan.
The oil pump draws oil from the lowest point in the oil pan
and delivers it to the oil cooler. The oil pickup screen
(see Figure 2.30-9) prevents foreign material in the oil
pan from entering the lube oil circuit.
OIL PUMP
The lube oil pump, gear-driven by the gear train, is
externally mounted. On 6- and 12-cylinder engines, the
oil pump is located on the front of the engine, below the
crankshaft (see Figure 2.30-10). On 16-cylinder
engines, the oil pump is located on the right rear of the Figure 2.30-11: 16-Cylinder Engine Oil Pump
engine, mounted on the flywheel housing (see Figure
2.30-11).
Form 6277-5
2.30-8 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
OIL COOLER OIL STRAINER
NOTE: The oil cooler assembly is engine-mounted on The lube oil strainer contains one bypass pressure relief
6-cylinder engines, optionally mounted on 12-cylinder valve. A pressure differential of 15 psi (103 kPa) opens
engines and shipped loose on 16-cylinder engines. the valve and allows the oil flow to bypass the strainer
Shipped loose oil cooler must be either skid- or remote- element enroute to the main oil header (see Figure
mounted by the customer. The assembly consists of the 2.30-14).
oil cooler, temperature control valve and pressure
regulating valve.
The oil cooler (see Figure 2.30-12 and Figure 2.30-13)
is a tube and baffle type assembly. Coolant is pumped
through the cooler by the auxiliary water pump. While the
coolant flows through a bundle of tubes in the oil cooler,
the lube oil circulates around them. Heat from the oil
passes through the tubes to the coolant which carries it
to a heat transfer device for dissipation.
Thermostatic valve(s) are enclosed in a housing
mounted at the oil cooler outlet (see Figure 2.30-12).
Form 6277-5
2.30-9 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
1
2
4
6
Form 6277-5
2.30-10 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
1 - Bell Knob 8 - Rotor Can
1 2 - Bell Housing 9 - Paper Insert
3 - Rotor Assembly 10 - Baffle Screen
(see item 14) Assembly
2 4 - Bell Clamp 11 - O-Ring
5 - O-Ring 12 - Rotor Turbine
6 - Base Shaft/Body 13 - Assembly Diagram
3 7 - Can Nut (top 14 - Sub-Assembly
marked “TOP” or Diagram
“UP”)
4
13
22
6
Form 6277-5
2.30-11 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
3
2
1 2
1 4
3
5
7
6
Figure 2.30-18
1 - Start 3 - E-Stop
Figure 2.30-19: Prelube Motor/Pump Assembly – Similar
2 - Prelube
All Engines
Form 6277-5
2.30-12 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
PRELUBE VALVE INLINE LUBRICATOR
The prelube valve opens to admit air from a branch of ! WARNING
the main air/gas supply line, which turns the prelube
pump air motor to activate the prelube pump (see Figure
2.30-20). If high-pressure gas is used to
drive the air/gas prelube pump
motor, vent the motor exhaust to
a safe area in conformance with
all applicable codes.
Figure 2.30-21
Form 6277-5
2.30-13 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM DESCRIPTION
LUBE OIL LEVEL REGULATOR – (OPTIONAL) NOTE: The regulator should be adjusted so that when
the engine lube oil is at the proper level, the regulator
The regulator, if equipped, is mounted on the left lower
sight glass is full to the midpoint.
side of the engine (see Figure 2.30-22 and Figure
2.30-23). The regulator will maintain the engine
NOTICE
crankcase lube oil to the correct level. Make-up oil at
atmospheric pressure from a raised tank is supplied to To prevent the regulator from malfunctioning, the inlet
the regulator inlet. screen to the regulator should be cleaned regularly.
Figure 2.30-22
Figure 2.30-23
Form 6277-5
2.30-14 © Copyright 2023, INNIO's Waukesha Engine
SECTION 2.35
EXHAUST SYSTEM DESCRIPTION
3
! CAUTION 2
4
1
Paint on high-temperature
exhaust components will
thermally decompose as the
exhaust system comes up to
operating temperature.
Decomposition products may
include the following
substances.
• Carbon dioxide
• Carbon monoxide
Figure 2.35-1
• Nitrogen oxides
• Sulfur oxides 1 - Wastegate 3 - Exhaust Piping
• Halogenated compounds 2 - Turbocharger 4 - Exhaust Manifold
• Metal oxide(s)
Avoid exposure to paint
decomposition products and
provide sufficient ventilation
until the state of the paint on the
exhaust system has stabilized.
Form 6277-5
2.35-1 © Copyright 2023, INNIO's Waukesha Engine
EXHAUST SYSTEM DESCRIPTION
EXHAUST MANIFOLD(S) NOTE: Valve cover and rocker arms shown removed.
The exhaust port of each cylinder is connected to one Thermocouples are used to monitor engine exhaust
water-jacketed segment of the exhaust manifold. Each temperatures. High exhaust temperatures greatly
water-cooled exhaust manifold assembly is comprised increase the potential for detonation and have a direct
of six individual segments (see Figure 2.35-2). One impact on the life of many engine components.
exhaust manifold segment is joined to the next by a
One thermocouple is mounted in the exhaust port of
manifold pilot. The exhaust port of each cylinder head is
each exhaust manifold segment to measure the
connected to one water-jacketed segment of the
temperature of the exhaust exiting the respective
exhaust manifold. Water outlet elbows (see Figure
cylinder head (see Figure 2.35-3). One thermocouple is
2.35-2) connect the water outlet hole in each cylinder
also mounted before each exhaust elbow (G engine) or
head with the exhaust manifold segments.
turbocharger (GSI/GL engines) and reflects the exhaust
temperature of the cylinder bank (an average of the
exhaust temperatures of each individual cylinder).
Figure 2.35-2
Form 6277-5
2.35-2 © Copyright 2023, INNIO's Waukesha Engine
EXHAUST SYSTEM DESCRIPTION
2
3
1
13 4
12 9 7 5 3 1
10 5
14
11 10 8 6 4 2
6
8
14 13 12 11 10 98 7 6 54 3 2 1
Form 6277-5
2.35-3 © Copyright 2023, INNIO's Waukesha Engine
EXHAUST SYSTEM DESCRIPTION
TURBOCHARGER(S) WASTEGATE(S)
A wastegate-controlled turbocharger (see Figure A water-cooled exhaust wastegate (see Figure 2.35-4)
2.35-4) is provided for each cylinder bank. The is mounted at the outlet of each exhaust manifold. The
compressor side of the turbocharger is part of the air wastegate is a load limiting device. At a predetermined
induction system; the turbine side is part of the exhaust point, intake manifold pressure counteracts the tension
system. When the turbine spins through the expansion of a spring, and a valve opens to bypass a portion of the
of exhaust gases exiting the engine, the movement of engine exhaust around the turbocharger turbine. In this
the compressor wheel causes the air passing through way, the air intake boost pressure is held within an
the air cleaner enroute to the carburetor to be acceptable range.
compressed.
Exhaust gases driving (or bypassing) the turbocharger
turbine exit the engine through the exhaust stack.
Exhaust gases passing through the flexible exhaust
connection are directed into the atmosphere through
customer-supplied exhaust piping.
1
EXHAUST SYSTEM SPECIFICATIONS
See Table 1.15-10 Maximum Allowable Exhaust
Backpressure and Reductions for Speed and Load on
page 1.15-24 for specifications.
The maximum exhaust system backpressure for all
2 engine models is 12 in. (305 mm) of water column at
1200 rpm, 145 Brake Mean Effective Pressure (BMEP)
(full load). Subtract 1 in. (25 mm) of water column for
each 100 rpm reduction. Subtract 1 in. (25 mm) of water
column for each 10 BMEP reduction. Do not apply these
reductions beyond a minimum exhaust system
backpressure of 4 in. (102 mm) of water column.
Based upon production test data in general, the
maximum exhaust temperature variation (on an engine
running at 1000 and 1200 rpm @138 BMEP on natural
gas fuel) between cylinders on the same bank is
approximately 100°F (38°C). The maximum exhaust
temperature variation between respective cylinders on
different banks (1R versus 1L, 2R versus 2L, etc.) is
approximately 50°F (23.5°C).
NOTE: Since air/fuel ratio, ambient air temperature and
Figure 2.35-4: 6-Cylinder Turbocharger and Wastegate many other factors may affect exhaust gas
temperatures, call the Waukesha Field Service
1 - Wastegate 2 - Turbocharger Department if additional information is required.
Form 6277-5
2.35-4 © Copyright 2023, INNIO's Waukesha Engine
SECTION 2.40
CRANKCASE BREATHER SYSTEM DESCRIPTION
SEPARATOR SCREEN
6- and 12-cylinder engines have one crankcase Figure 2.40-2: 12-Cylinder Crankcase Separator Screen
separator scree. On 6-cylinder engines, the separator
1 - Separator Screen 2 - Cylinder Head
screen is located on top of the cylinder block on the rear
left side (see Figure 2.40-1). On 12-cylinder engines, the The crankcase separator screen allows vapors to be
separator screen is located on top of the cylinder block vented from the crankcase. It also serves to stop a
on the rear right side (see Figure 2.40-2). 16-cylinder portion of the oil carried by these vapors from reaching
engines do not have separator screens. the oil separator. As the oil mist and vapors pass out of
the crankcase, the expanded metal elements in the
separator screen restrict the flow of much of the oil,
dropping the surplus back into the oil pan.
Form 6277-5
2.40-1 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM DESCRIPTION
OIL SEPARATOR(S) As the crankcase vapors and oil mist pass through the
oil separator, much of the oil adheres to the steel mesh
Six-cylinder and 12-cylinder G engines have one oil
element contained in the inlet side of the separator
separator located at the rear of the engine (see Figure
housing. This surplus oil condenses, drops into the base
2.40-3).
of the separator and returns to the oil pan through a drain
tube in the base of the separator housing (see Figure
2.40-5). The crankcase vapors pass into the venturi
extractor, where they are drawn into the exhaust stack
and discharged into the atmosphere.
1
2 4
1 6
9
8
2
7
Form 6277-5
2.40-2 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM DESCRIPTION
As the crankcase vapors and oil mist pass through the The new system is designed to replace the previous
oil separator, much of the oil adheres to the steel mesh breather system and is beneficial in engine applications
element contained in the inlet side of the separator that utilize an exhaust catalyst or have crankcase
housing. This surplus oil condenses, drops into the base breather emission concerns.
of the separator and returns to the oil pan (see Figure
With the new closed breather system, the contaminated
2.40-5).
crankcase gases enter the oil separator (inlet) and flow
The crankcase vapors are drawn through the cellular through the valve diaphragm into the filter element. The
foam contained in the outlet side of the separator and valve maintains a slight negative crankcase pressure to
pass through breather tubes to the venturi extractor, reduce engine weeping and prevent damage to the
where they are discharged into the atmosphere through engine seals. Soot and other contaminants are trapped
the exhaust stack. by the filter element media, and then the oil is separated
from the air. The oil collects at the bottom of the filter
As the crankcase vapors pass into the oil separator, the
housing and is returned to the crankcase through a drain
flow of oil is restricted by a removable corrugated steel
hose. A check valve is incorporated into the drain hose
mesh element. The condensed oil returns to the oil pan
to prevent reverse oil flow from the crankcase. The
through a drain tube in the base of the separator housing.
filtered gases then flows through the oil separator outlet
The crankcase vapors pass into the venturi extractor,
and into the air box inlet.
where they are drawn into the exhaust stack and
discharged into the atmosphere. The oil separator uses a replaceable filter element that
is composed of microfiberglass. When the filter
OIL SEPARATOR(S) – CURRENT PRODUCTION 12- becomes restricted (through normal use), the crankcase
CYLINDER pressure will change from slightly negative to slightly
positive. When this occurs, a new filter element should
Closed Breather System Kit (Updated – 12-Cylinder be installed. Typical replacement is at 3-month intervals.
(Blow-Thru Engines (Kit N/A to Draw-Thru See CURRENT PRODUCTION 12-CYLINDER FILTER
Engines))) ELEMENT REPLACEMENT on page 4.40-6.
A new closed breather system kit for 12-cylinder engines
has been released: part number G-962-503.
See S-07232-342, Retrofit Assembly Instructions, and
600764, Standard Case Breather Drawing, for details on
the installation of the closed breather system kit. Figure
2.40-6 is shown for reference only.
Form 6277-5
2.40-3 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM DESCRIPTION
Form 6277-5
2.40-4 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM DESCRIPTION
CHOKE VALVE / VACUUM VALVE On 12-cylinder engines that are not equipped with a
venturi extractor, the crankcase pressure is adjusted
The choke valve/vacuum valve allows the crankcase
with a vacuum valve assembly, of which there are
pressure to be adjusted externally. On G engines, the
different configurations (see Figure 2.40-9 and Figure
vacuum valve is located on top of the oil separator. On
2.40-10). On 12-cylinder engines equipped with a
GSI engines the vacuum valve is located on the breather
venturi extractor, the choke valve is located on the end
tube leading to the venturi. On GL engines and some GSI
of the venturi extractor (see Figure 2.40-11).
engines (if venturi extractor-equipped), the choke valve
is located at the front of the venturi extractor. See
CRANKCASE BREATHER SYSTEM MAINTENANCE
on page 4.40-1 for procedures to adjust the
crankcase pressure.
On 6-cylinder engines, crankcase pressure is adjusted
with either a venturi/adjusting capscrew assembly (see
Figure 2.40-7), an ejector breather/adjusting valve
assembly (see Figure 2.40-8) or a vacuum valve (see
Figure 2.40-9).
Form 6277-5
2.40-5 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM DESCRIPTION
BREATHER REGULATOR
1
2 The crankcase breather regulator assembly (see Figure
2.40-12) automatically performs fine adjustments to
maintain a negative crankcase pressure as the engine
changes speed and load. Maintaining a negative
crankcase pressure is important to prevent oil leaks and
3 vacate harmful vapors, but too much pressure pulls in
environmental dust and dirt. With less load, less vacuum
4 is required to vacate crankcase vapors.
Figure 2.40-9
1
2
3
4
Figure 2.40-12
Figure 2.40-10 The crankcase breather regulator assembly is
connected to the ejector breather or venturi extractor
1 - Butterfly Valve 3 - Adjusting
Capscrew through a tee and pipe nipple arrangement.
2 - Hex Nut
4 - Breather Tube The breather regulator is above the water manifold in the
center of the crankcase vee.
While the manual crankcase pressure adjustment
procedures represent coarse adjustments to the
breather system, the crankcase vacuum regulator
automatically performs the fine adjustments that are
necessary to compensate for variations in speed and
load. Maintaining a negative crankcase pressure is
important to prevent oil leaks and vacate harmful vapors,
but too much pressure pulls in environmental dust and
dirt.
1 2
With less load, less vacuum is required to vacate
crankcase vapors. When the turbocharger compressor
discharge air is reduced, a floating disc or plate within
the crankcase breather regulator assembly drops down
Figure 2.40-11: 12-Cylinder GL Venturi Extractor / Choke
to restrict the amount of outside air pulled in (see Figure
Valve Assembly 2.40-13).
Form 6277-5
2.40-6 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM DESCRIPTION
8 2
1
7
2
Figure 2.40-14: Venturi Assembly – GSI Engines
6
1 - Vacuum Valve 2 - Venturi
3
1 2
5
4
Form 6277-5
2.40-7 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM DESCRIPTION
CRANKCASE PRESSURE RELIEF VALVES
(OPTION)
! WARNING
Form 6277-5
2.40-8 © Copyright 2023, INNIO's Waukesha Engine
SECTION 2.45
PRELUBE AND STARTING SYSTEM DESCRIPTION
START SYSTEM
• Start Pushbutton Valve
• Pilot-Operated Starter Pre-engage Valve/Starter
Motor (Customer-Supplied)
• Pilot-Operated Prechamber Gas Valve (GL Engine)
• Prechamber Gas Safety Shutdown Valve (GL Engine)
NOTE: The main air/gas supply has branch lines
(customer supplied) leading to the pilot operated
prelube valve, the pilot operated starter pre-engage
valve(s) and the pilot operated starter valve(s).
PRELUBE SYSTEM
PRELUBE PUSHBUTTON VALVE
The PRELUBE pushbutton valve activates the prelube
system (see Figure 2.45-1). The prelube system
circulates oil through the engine and turbocharger(s) to
provide the engine adequate lubrication during start-up.
Form 6277-5
2.45-1 © Copyright 2023, INNIO's Waukesha Engine
PRELUBE AND STARTING SYSTEM DESCRIPTION
1 2
Figure 2.45-1
1 - START 2 - PRELUBE
2
1
DEL
SUP
EXH
Form 6277-5
2.45-2 © Copyright 2023, INNIO's Waukesha Engine
PRELUBE AND STARTING SYSTEM DESCRIPTION
Depressing the prelube pushbutton causes the
! WARNING
“EXH(AUST)” port to close as the “DEL(IVERY)” port is
opened. The pilot air pressure is directed back to the
From the bulkhead, all gas bulkhead (via the prelube tube) where it passes to the
vented from the system must be pilot operated prelube valve.
piped to a safe area in
conformance with all applicable
codes.
2
1
3
13
12 4
14 7
15 11
10
9 8
Form 6277-5
2.45-3 © Copyright 2023, INNIO's Waukesha Engine
PRELUBE AND STARTING SYSTEM DESCRIPTION
INLINE LUBRICATOR
2
! WARNING
1
If high-pressure gas is used to
drive the air/gas prelube pump
motor, be sure to vent the motor
exhaust to a safe area in 3
conformance with all applicable
codes.
4
7
6
Figure 2.45-4
Form 6277-5
2.45-4 © Copyright 2023, INNIO's Waukesha Engine
PRELUBE AND STARTING SYSTEM DESCRIPTION
The ports of the three-way start pushbutton valve (see
NOTICE Figure 2.45-2) are stamped “SUP(PLY),” “EXH(AUST)”
Oil drains back into the oil sump after engine and “DEL(IVERY).” The air/gas supply from the
shutdown, leaving a minimal amount of oil at key wear bulkhead (see Figure 2.45-10 and Figure 2.45-11) is
points. Since the crankshaft starts to turn before the connected to the normally closed “SUP(PLY)” port of the
oil pump begins to circulate oil, “dry” starts result in pushbutton valve. The normally open port of the valve,
bearing damage and an accelerated wear rate. stamped “EXH(AUST),” vents the downstream side
when the pushbutton valve is not depressed. The vented
air/gas supply is directed back to the bulkhead via the
The prelube pump and motor (see Figure 2.45-7) vent tube.
circulate the oil through the engine when the PRELUBE
pushbutton is pressed. ! WARNING
Figure 2.45-7
PILOT-OPERATED STARTER PRE-ENGAGE
VALVE / STARTER MOTOR – CUSTOMER-
1 - Prelube Pump 3 - Prelube Motor SUPPLIED
2 - Inline Lubricator
The pilot-operated starter pre-engage valve opens to
admit air from a branch of the main air/gas supply line.
OIL PRESSURE GAUGE The air/gas pressure causes the starter pinion to shift
When the lubrication system is properly primed, into engagement with the flywheel ring gear. Movement
pressure begins to register on the lube oil pressure of the pinion to the engage position opens a passageway
gauge. Generally, about 30 seconds prelube is for air pressure to pass through to the pilot operated
recommended before the engine is cranked. More time starter valve(s). The pilot-operated starter valve(s) open
may be required after the oil filter is serviced or if the oil to admit air from another branch of the main air/gas
cooler has been drained. supply line, which activates the starter motor to crank the
engine. See Table 1.15-11 P/N 208569D Air Valves Inlet
NOTE: For more information on the prelube system, Pressures and Pilot Pressures to Shift on page 1.15-24
see LUBRICATION SYSTEM DESCRIPTION on page for specifications.
2.30-1.
On dual starter arrangements, the pre-engage
connections are in series, so that the pinions of both
START SYSTEM starters are engaged with the ring gear before the pilot
operated valves admit air to the starter motors.
START PUSHBUTTON VALVE
NOTE: Pilot pressure must be sufficient in order for the
The START pushbutton valve activates the starter motor
valve to function pilot operated prelube valve and pilot
system (see Figure 2.45-1). On air/gas starter systems,
operated prechamber gas valve.
the START pushbutton valve activates a series of valves
that allow air/gas pressure to activate the air/gas starter
motor. On electric start systems, an additional solenoid
is added to the system to replace the signal normally
provided by air/gas pressure.
Form 6277-5
2.45-5 © Copyright 2023, INNIO's Waukesha Engine
PRELUBE AND STARTING SYSTEM DESCRIPTION
PILOT-OPERATED PRECHAMBER GAS VALVE – GL
ENGINE 1 2 3 4
Enroute to the starter pre-engage valve, the air/gas
supply passes through a tee fitting (just in front of the
lube oil strainer) where a portion is diverted to the pilot-
operated prechamber gas valve. Before reaching the
gas valve, the pilot pressure passes through an orifice
check valve, air/gas plenum (volume tank) and shuttle
valve. When the pilot pressure opens the prechamber
gas valve, a line off the 99 regulator gas inlet pipe tee
admits high-pressure gas to the prechamber fuel
regulator. The orifice check valve and air/gas plenum act
as a pneumatic timer to retard the blow down of pilot
pressure when the start pushbutton is released.
5
PRECHAMBER GAS SAFETY SHUTDOWN VALVE –
GL ENGINE
Figure 2.45-8
The prechamber gas safety shutdown valve admits
downstream gas pressure to the opposite side of the 1 - Pilot Inlet Port 4 - Pilot Inlet Port (pilot
(downstream gas supply from air/gas
shuttle valve once engine lube oil pressure reaches or
from prechamber plenum)
exceeds 20 psi (139 kPa). When the pressure in the air/ gas safety 5 - Pilot Outlet Port (to
gas plenum bleeds down, the shuttle valve shifts shutdown valve) pilot-operated
position and the downstream gas pressure holds the 2 - Viton Seal prechamber GA
pilot gas valve open (see Figure 2.45-8). The time delay 3 - Stainless-Steel Ball valve)
provided by the check valve and air/gas plenum keeps
pilot pressure on the gas valve long enough for lube oil If the engine stops, loss of engine lube oil pressure
pressure to rise and shift the shuttle valve. Lube oil automatically causes the prechamber gas safety
pressure continues to admit gas to the prechamber shutdown valve to stop the flow of downstream gas to
regulator as long as the engine is running. the prechamber gas valve, which effectively shuts off the
supply of high-pressure gas to the prechamber
regulator. If the engine fails to start, insufficient lube oil
pressure prevents the downstream gas from passing to
the prechamber gas valve, so the gas supply shuts off
as soon as the pilot pressure in the air/gas plenum is
exhausted. In both cases, any gas in the downstream
line passes to the vent tube (from the exhaust port of the
prechamber gas safety shutdown valve) and is
exhausted at the customer’s bulkhead connection.
Form 6277-5
2.45-6 © Copyright 2023, INNIO's Waukesha Engine
CONTROLS LUBRICATION
SYSTEM
PRE--LUBE PUMP
SOLENOID VALVES AIR LINE LUBRICATOR
FOR AUTOMATIC OR REMOTE ELECTRIC CONTROLS
(WITHOUT PNEUMATIC CONTROL PANEL)
PRE--LUBE START
(ALLENAIR) (MAC) CHECK
VALVE
NOTES:
1. SYMBOLS CONFORM TO ANSI Y32--10 B A 2 1
STANDARD.
START
SUPPLY
A PILOT OPERATED PRELUBE
VALVE (SHRADER)
PRE--LUBE
*E P 0.375--18 NPT AIR SUPPLY WHEN
2.45-7
AIR STARTER IS NOT SUPPLIED
BY W.E.D.
RESERVOIR RESERVOIR
OUT
*
IN IN OUT
ONE SHOT
“Y” STRAINER “Y” STRAINER LUBRICATOR
PRE--ENGAGED PRE--ENGAGED
AIR STARTER AIR STARTER
ONE SHOT AIR SUPPLY 1.500--11 NPT
LUBRICATOR 60 TO 150 PSI STD. AIR EXHAUST
Figure 2.45-9: Schematic – Pneumatic Control System for Air Only Start and Prelube – G/GSI Engines
AIR EXHAUST 2.50--8 NPT
2.50--8 NPT
PNEUMATIC
START
PRELUBE AND STARTING SYSTEM DESCRIPTION
PRE--LUBE PUMP
“Y” STRAINER
ENGINE
* .375 -- 18 NPSF
2.45-8
PRELUBE AND STARTING SYSTEM DESCRIPTION
OUT
*
IN IN OUT HEAVY PHANTOM LINES INDICATE
4
PILOT LINES FOR DUAL START.
ONE SHOT
“Y” STRAINER “Y” STRAINER LUBRICATOR
5. ALL SYMBOLS ARE SHOWN IN A
DE--ENERGIZED STATE.
PRE--ENGAGED PRE--ENGAGED
AIR/GAS STARTER AIR/GAS STARTER 2.50--8 NPT SEE SD 6143 -- 49 FOR CUSTOMER
6
ONE SHOT CONNECTIONS LOCATION
CUSTOMERS SUPPLY
LUBRICATOR 2.50--8 NPT 1.500 -- 11 NRT. CONNECTIONS 6
Figure 2.45-10: Schematic – Pneumatic Control System for Air / Gas Start and Prelube – G/GSI Engines
60 TO 150 PSI AIR/GAS STD.
6 PNEUMATIC
6 START
2.45-9
AIR STARTER IS NOT SUPPLIED
9 2 9 BY W.E.D.
ORIFICE
CHECK VALVE PRECHAMBER
PILOT OPERATED
ONE SHOT VALVE
LUBRICATOR
“Y” STRAINER “Y” STRAINER VOLUME CHAMBER
Figure 2.45-11: Schematic – Pneumatic Control System for Air / Gas Start and Prelube – GL Engine
SHUT--OFF VALVE CUSTOMERS SUPPLY 1.500--11 NPT CONNECTIONS 8
(CUSTOMER SUPPLIED) 60 TO 150 PSI STD. AIR/GAS
Figure 2.45-12
Figure 2.45-13
Form 6277-5
2.45-10 © Copyright 2023, INNIO's Waukesha Engine
SECTION 2.50
ENGINE PROTECTION SHUTDOWN SYSTEM DESCRIPTION
!
automatic engine shutdown
must be supplied by the
customer. The sensors
provided are for measuring and
Figure 2.50-1: 12-Cylinder Lube Oil Inlet Temperature
monitoring temperatures and
Sensor
WILL NOT shut the engine down
if potentially harmful 1 - Sensor Cable 3 - Lube Oil Strainer
temperatures are reached. 2 - Strainer Adapter 4 - Temperature
Sensor
K-TYPE THERMOCOUPLES
Thermocouples are used to measure lube oil (see
Figure 2.50-1), jacket water (see Figure 2.50-2) and
intake manifold (left and right bank on Vee engines) air
temperature (see Figure 2.50-4). These thermocouples
are wired through the thermocouple junction box to a
remote-mounted instrument panel (customer-supplied
or as a Waukesha option). Additional thermocouples Figure 2.50-2: 12-Cylinder Jacket Water Temperature
(see Figure 2.50-3 and Figure 2.50-5) are used to Sensor
measure exhaust temperature and turbine inlet
temperature.
Form 6277-5
2.50-1 © Copyright 2023, INNIO's Waukesha Engine
ENGINE PROTECTION SHUTDOWN SYSTEM DESCRIPTION
2 3
1
13 4
12 9 7 5 3 1
10 5
14
11 10 8 6 4 2
6
8 14 13 12 11 10 98 7 6 54 32 1
7
1 2
Form 6277-5
2.50-2 © Copyright 2023, INNIO's Waukesha Engine
ENGINE PROTECTION SHUTDOWN SYSTEM DESCRIPTION
Additional K-Type thermocouples that may be found on THERMOCOUPLE JUNCTION BOX
the engine are:
The function of the thermocouple junction box (see
• Thermocouples used to monitor the main bearing Figure 2.50-7) is to serve as the main junction point for
temperatures (see Figure 2.50-6). All thermocouples the wiring of engine protection shutdowns.
end at the thermocouple junction box when shipped.
It is the customer’s responsibility to connect the wiring
to the remote-mounted instrument panel. Main 2
bearing sensor logic must be supplied by the
customer.
Figure 2.50-7
Form 6277-5
2.50-3 © Copyright 2023, INNIO's Waukesha Engine
ENGINE PROTECTION SHUTDOWN SYSTEM DESCRIPTION
E-Stop button(s) are located on the left and right sides
of the 12-cylinder engines (see Figure 2.50-9 and Figure
2.50-10).
!
least 10 minutes after the engine
is stopped. Do not restart an
overheated engine or an engine
that has been shutdown by the
engine protection system until
the reason for the shutdown has
been determined and corrected.
Always ensure that the fuel gas
valve(s) are closed after engine
shutdown.
!
lock-out/tag-out procedure to
prevent accidental starting of NOTE: The emergency shutdown button should be
the engine once the engine is pulled out (OFF position) at all times, unless an
shutdown. The only exception is emergency situation occurs that requires the immediate
if the engine is in a “Stand-by” shutdown of the engine.
mode.
When an E-stop button is pressed, the engine performs
an emergency stop see EMERGENCY SHUTDOWN on
page 3.00-8.).
Form 6277-5
2.50-4 © Copyright 2023, INNIO's Waukesha Engine
ENGINE PROTECTION SHUTDOWN SYSTEM DESCRIPTION
IGNITION SWITCH DETONATION SENSING MODULE AND SENSORS
On 16-cylinder engines, the engine may be shut down ! WARNING
by turning the ignition switch, located on the control
panel, to the OFF position (see Figure 2.50-12). Always
shut down the fuel gas supply after engine shutdown. For maximum engine
!
protection, the DSM system
must be connected to a safety
shutdown. The DSM system is
considered a safety system and,
as such, must be connected to
shutdown the engine if the
engine cannot be brought out of
detonation.
Figure 2.50-13
Form 6277-5
2.50-5 © Copyright 2023, INNIO's Waukesha Engine
ENGINE PROTECTION SHUTDOWN SYSTEM DESCRIPTION
One detonation sensor per cylinder is installed just
below the intake manifold (see Figure 2.50-16). These
2 sensors send their signals back to the DSM module.
1 3
See latest edition of Form 6278, Custom Engine Control
Detonation Sensing Module Installation Operation &
Maintenance Manual.
Figure 2.50-14
1 - “Power” 3 - “Shutdown”
Figure 2.50-16
2 - “Alarm”
P1B P1A
91
ALARM +24V
SHUTDOWN +24V
GND
SENSOR 01
GND
SENSOR 02
SENSOR 03
SENSOR 04 PWR LVL
SELECTOR
SENSOR 05
CLOCK
SENSOR 06
RESET
SENSOR 07
.5 DEG
SENSOR 08
ELEC EN
SENSOR 09 DATA 5
SENSOR 10 DATA 4
SENSOR 11 DATA 3
SENSOR 12 DATA 2
SENSOR 13 DATA 1
SENSOR 14 DATA 0
SENSOR 15 VSS
SENSOR 16 MANUAL
Form 6277-5
2.50-6 © Copyright 2023, INNIO's Waukesha Engine
ENGINE START-UP AND SHUTDOWN
SECTION 3.00
ENGINE START-UP AND SHUTDOWN
PRESTART INSPECTION
! WARNING
! WARNING
Figure 3.00-1: 12-Cylinder Engine Guards
5. On 6- and 12-cylinder engines, check air cleaner
Slowly loosen the air bleed
restriction indicator. If indicator shows red, clean
petcock to relieve any excess
pre-cleaner and/or air cleaner elements (see Figure
pressure.
3.00-2). Sixteen-cylinder engines have indicator
gauges that are checked while the engine is running.
Form 6277-5
3.00-1 © Copyright 2023, INNIO's Waukesha Engine
ENGINE START-UP AND SHUTDOWN
7. Check the crankcase oil level daily before the engine
is started. The blade of the dipstick is marked “LOW”
and “FULL” (see Figure 3.00-4). Always maintain the
oil level at the “FULL” mark. Both marks on the
dipstick are “static lines.” The dipstick does not
indicate where the level of the oil should be when the
engine is running.
2 LOW FULL
! WARNING 2
3.00-3).
E
N
S
A
T M
I I
O
N
N
Form 6277-5
3.00-2 © Copyright 2023, INNIO's Waukesha Engine
ENGINE START-UP AND SHUTDOWN
8. Check UG-8 governor oil level in sight glass (see
Figure 3.00-5).
1 2
9. Examine the engine foundation for condition of
grout, tightness of hold-down capscrews and
general alignment of driven equipment.
Paint on high-temperature 3
exhaust components will
thermally decompose as the
exhaust system comes up to Figure 3.00-6: 12-Cylinder Control Panel
operating temperature.
Decomposition products may 1 - START 3 - E-Stop
include the following 2 - PRELUBE
substances.
• Carbon dioxide
• Carbon monoxide 1
• Nitrogen oxides 2
• Sulfur oxides
• Halogenated compounds
• Metal oxide(s)
Avoid exposure to paint
decomposition products and
provide sufficient ventilation 3
until the state of the paint on the
exhaust system has stabilized. Figure 3.00-7: 16-Cylinder Control Panel
1 - PRELUBE 3 - START
1. Reset all engine protection switches and devices. 2 - IGNITION
2. Press and hold down the PRELUBE button for 5 3. Place the manual speed control lever in the OPEN
minutes to operate the prelube motor (see Figure position (see Figure 3.00-8, Figure 3.00-9 and
3.00-6 and Figure 3.00-7). Check the lube oil Figure 3.00-10).
pressure gauge for a minimum of 5 psi (35 kPa).
Form 6277-5
3.00-3 © Copyright 2023, INNIO's Waukesha Engine
ENGINE START-UP AND SHUTDOWN
Form 6277-5
3.00-4 © Copyright 2023, INNIO's Waukesha Engine
ENGINE START-UP AND SHUTDOWN
9. Warm the engine by running with little or no load until
the oil pressure is normal and the coolant
1
temperature reaches 100°F (38°C). See Table
1.15-6 VHP Series Two Engine Specifications on
page 1.15-20 for operating pressures and
temperatures.
10. Gradually apply load to avoid overloading the
engine.
NOTE: Engines that are required to start at
temperatures below 50°F (10°C) should be equipped
with both an oil and coolant heater. These devices allow
the engine to be started with the proper oil flow. If the
heaters are manually controlled, allow the engine to
2 become warm enough for normal starting.
3
ENGINE DURING OPERATION CHECKS
NOTICE
Figure 3.00-13: Customer-Supplied Fuel Shutoff Valve
Stop the engine immediately if the oil pressure is low
1 - Manual Disconnect 3 - Vent Plug
or fluctuating.
Knob
2 - Latching Knob
6. On 6- and 12-cylinder engines, make sure that the 1. Observe and record the normal operating readings
E-Stop buttons are pulled out (see Figure 3.00-6). for oil pressure, oil temperature and coolant
On 16-cylinder engines turn the ignition switch to the temperature on the engine instrument panel (see
ON position (see Figure 3.00-7). Figure 3.00-14) or optional remote instrument panel
(see Figure 3.00-15). See Table 1.15-6 VHP Series
7. Press the START button until engine starts (see
Two Engine Specifications on page 1.15-20 for
Figure 3.00-6 and Figure 3.00-7).
operating pressures and temperatures.
8. Check for oil pressure as soon as the engine starts.
See Table 1.15-6 VHP Series Two Engine
Specifications on page 1.15-20 for operating
pressures.
NOTICE
If the lube oil pressure gauge does not indicate
sufficient oil pressure within 15 seconds, shut the
engine down immediately. Never operate the engine
without the proper oil pressure indication.
Form 6277-5
3.00-5 © Copyright 2023, INNIO's Waukesha Engine
ENGINE START-UP AND SHUTDOWN
Figure 3.00-15: Optional Remote Instrument Panel 3. Listen to the engine. Certain problems, such as
occasional misfiring, turbocharger bearing failure or
2. Check the air restriction indicator on the air cleaner water pump problems, may first be noticeable in the
while the engine is running. See AIR INTAKE engine sound.
SYSTEM MAINTENANCE on page 4.15-1 and
clean/replace precleaner and/or air cleaner 4. Visually examine fuel, coolant and lubrication lines
elements if indicator shows red on 6- and 12-cylinder for signs of leaks, damage or corrosion.
engines (see Figure 3.00-16). On 16-cylinder 5. Observe the governor control rod. Engine misfire
engines, check that the air restriction gauge is can be seen as an occasional “twitch” of the control
showing in the green for both the prefilter and final rod.
filter (see Figure 3.00-17). A toggle switch allows the 6. Monitor the DSM module (see Figure 3.00-18) for
operator to select the filter reading desired. The system status. The DSM is equipped with several
toggle switch should be left in the FINAL FILTER features to inform site personnel of system status.
position during engine operation. These features include:
• “Power,” “Alarm” and “Shutdown” lights (LED
display) on the front panel of the DSM module
• A liquid crystal display (LCD) located inside the
DSM module which continually shows the current
1 status of the system through diagnostic codes
• The capability to drive remote alarms or lights
Form 6277-5
3.00-6 © Copyright 2023, INNIO's Waukesha Engine
ENGINE START-UP AND SHUTDOWN
1 2 3
1 - “Power” 3 - “Shutdown” • The red “Pickup” LED is lit when there is no Hall-
effect pickup signal being detected by the IM due
2 - “Alarm”
to a failed pickup, an incorrect air gap setting
7. If red “Shutdown” light is illuminated, shut down the and/or incorrect (bad) wiring. The pickup LED will
engine if automatic devices have not already done also be lit when the engine is at rest.
so. Call a Waukesha certified technician for
• The red “Application” LED is lit whenever the IM
assistance.
detects a magnet pattern that does not match the
8. The yellow “Alarm” light illuminates to indicate that application for which the IM Selector Switch is set
sensor output has been lost or disconnected. Call a (6- versus 8-cylinder) or when the incorrect IM
Waukesha certified technician for assistance. model is installed (inline IM model versus vee
NOTE: See latest edition of Form 6268 or Form 6278, engine IM model). Additionally, this LED will light
Custom Engine Control Detonation Sensing Module when the Hall-effect pickup is lost (disconnected
Installation Operation & Maintenance Manual, for or failed), or if a magnet is lost or is very weak. The
information concerning the DSM. application LED will also light when the Selector
Switch is in the “B” position (no application).
NOTE: See latest edition of Form 6253 (previous
production) or Form 6272, (current production) Custom
Engine Control Ignition Module Installation, Operation &
Maintenance Manual, for further information concerning
the IM.
9. Monitor the three diagnostic LEDs on front of the IM
housing: “Power,” “Pickup” and “Application” (see
Figure 3.00-19). These LEDs give operators visual
confirmation on (1) incoming power, (2) Hall-effect
pickup signal and (3) proper application settings
(see Figure 3.00-19).
Form 6277-5
3.00-7 © Copyright 2023, INNIO's Waukesha Engine
ENGINE START-UP AND SHUTDOWN
!
least 10 minutes after the engine
Allow the engine to cool for at is stopped. Do not restart an
overheated engine or an engine
!
least 10 minutes after the engine
is stopped. Do not restart an that has been shutdown by the
overheated engine or an engine engine protection system until
that has been shutdown by the the reason for the shutdown has
engine protection system until been determined and corrected.
the reason for the shutdown has Always ensure that the fuel gas
been determined and corrected. valve(s) are closed after engine
Always ensure that the fuel gas shutdown.
valve(s) are closed after engine
shutdown.
!
lock-out/tag-out procedure to
Always apply your company’s prevent accidental starting of
the engine once the engine is
!
lock-out/tag-out procedure to
prevent accidental starting of shutdown. The only exception is
the engine once the engine is if the engine is in a “Stand-by”
shutdown. The only exception is mode.
if the engine is in a “Stand-by”
mode.
In the event of an emergency, the engine may be shut
down by using the E-Stop button(s) (6- and 12-cylinder)
NOTE: Routine gas engine shutdown is performed or ignition switch (16-cylinder). The manual shutdown
through the engine control panel (control panel is either lever or governor speed lever/dial may be used to return
Waukesha, packager or customer supplied). the engine to idle speed. In all cases after engine
shutdown, the fuel shutdown valve(s) must be closed.
1. Gradually reduce engine load.
2. Place the governor speed control lever or dial in idle NOTE: Some governors may not have a speed control
speed position, and allow the engine to idle for 5 lever. The UG-8 dial governor is equipped with a dial
minutes to cool down engine temperatures. speed control.
3. Under normal operation, close the fuel valves to shut
the engine down.
4. Press and hold the PRELUBE button for 5 minutes
to post-lube the engine.
NOTICE
If the engine is being shut down for an extended period
of time, cap the exhaust pipe to prevent moisture or
contaminants from entering the engine.
Form 6277-5
3.00-8 © Copyright 2023, INNIO's Waukesha Engine
ENGINE START-UP AND SHUTDOWN
Emergency Shutdown Procedure – 6- and
12-Cylinder Engines
! WARNING
!
stop the engine to avoid
imminent personal injury or
property damage. Never use an
emergency shutdown to stop
the engine under normal
circumstances, as this may
result in unburned fuel in the
exhaust system which could
ignite. Figure 3.00-20: 6-Cylinder GSI Manual Speed Control
Lever
Form 6277-5
3.00-9 © Copyright 2023, INNIO's Waukesha Engine
ENGINE START-UP AND SHUTDOWN
! WARNING
Form 6277-5
3.00-10 © Copyright 2023, INNIO's Waukesha Engine
MAINTENANCE
SECTION 4.00
SPEED GOVERNING SYSTEM MAINTENANCE
Before performing any service, maintenance or repair GOVERNOR OIL CHANGE AND FILL (UG-8L
procedures, review SAFETY on page 1.05-1 and GOVERNOR)
RIGGING AND LIFTING ENGINES on page 1.10-1. 1. Place a small oil pan beneath the governor.
2. Remove oil drain plug from governor and allow oil to
GOVERNOR MAINTENANCE drain (see Figure 4.00-2).
Check oil level in sight glass daily (see Figure 4.00-1). 3. Replace oil drain plug.
4. Lift up oil filler cap and slowly add oil until the oil
appears at the line marked on the sight glass.
NOTE: Use the same oil as used in the engine
crankcase.
Figure 4.00-1
Change oil every 8,000 hours. Use the same lubricating
oil used in the engine crankcase.
Form 6277-5
4.00-1 © Copyright 2023, INNIO's Waukesha Engine
SPEED GOVERNING SYSTEM MAINTENANCE
2 3
2 4
1
WOODWARD
7 6 5
Nut 7 - Right-Hand
3 - Rod End Bearing Threads
Jam Nut
4 - Rod End Bearing
GOVERNOR ROD
GOVERNOR ROD INSPECTION AND LUBRICATION
1. Inspect that the jam nuts on both ends of the
governor rod are secure (see Figure 4.00-3).
2. Inspect the governor rod for straightness and
damage.
3. Lubricate the grease fittings on both ends of the
governor rod at each oil change. Clean off any
excess grease.
Form 6277-5
4.00-2 © Copyright 2023, INNIO's Waukesha Engine
SECTION 4.05
FUEL SYSTEM MAINTENANCE
Figure 4.05-1
Form 6277-5
4.05-1 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
FILTER ELEMENT INSTALLATION
1 2
2
3
3
Form 6277-5
4.05-2 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
d. Slide machine screw through center of filter
element. Thread screw into filter head.
e. Thread filter head hex nut onto filter body.
2. Thread other end of filter head hex nut onto pilot
chamber orifice pipe nipple.
3. Apply Perma-Lok Heavy Duty Pipe Sealant with
Teflon to threads of fittings and connect pilot
chamber supply tube (see Figure 4.05-2) to body of
filter assembly.
Filter Maintenance
Figure 4.05-4: Filter Housing
The filter element is subject to plugging and must be
inspected and replaced as necessary. The frequency of 2. Inspect filter element and replace if necessary (see
inspection and replacement of the filter element Figure 4.05-5).
depends on severity of service conditions and the length
of time in service.
! WARNING
Form 6277-5
4.05-3 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
MOONEY GAS REGULATOR ADJUSTMENTS
The Mooney regulators were designed to track similarly
to the previous Fisher regulator. The gas/air setting and
carburetor adjustments will remain the same as those
used with the Fisher regulator. Mooney regulators
require specific supply pressures depending on engine
model (see Table 4.05-1).
Table 4.05-1: Mooney Regulator Fuel Pressures
Form 6277-5
4.05-4 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
MOONEY GAS REGULATOR MAINTENANCE SCHEDULE
1 2 3
6
12
7
11
10
9
8
Form 6277-5
4.05-5 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
3. Inspect all other components (replace as needed). MOONEY GAS REGULATOR REPLACEMENT
SERVICE PARTS AND KITS
NOTE: A spare cartridge may be installed and the
regulator returned to service if time is a factor. Make sure
1
the stem O-ring is still in place in the pilot body before
2 installing the new cartridge. If the O-ring was removed,
install a new O-ring over the stem of the cartridge
assembly prior to installing it in the pilot body (see Figure
4.05-10 and Figure 4.05-11).
P/N DESCRIPTION
Figure 4.05-10: Cartridge Assembly
214172 Pilot
489668 Cartridge
214174 Filter 1 2
214171 Main Valve (RB)
214171A Main Valve (LB)
214175 Fixed Restrictor Orifice
P/N DESCRIPTION
Pilot Maintenance Kit (Pivot Assembly O-
489669 Ring, Diaphragm, Closing Cap O-Ring,
Adjusting Assembly O-Ring)
4 3
Cartridge Assembly Maintenance Kit
(Bottom Cap O-Ring, Plug and Stem
489667 Assembly, Orifice O-Ring, Lower Body
Insert O-Ring, Upper Body Insert O-Ring, Figure 4.05-11: Stem O-Ring
Stem O-Ring)
1 - Loading 3 - Stem O-Ring
1.5 in. Main Valve Maintenance Kit
489670 2 - Inlet 4 - Outlet
(Diaphragm and Body Seal)
1.5 in. Main Valve Overhaul Kit (Low
489671 Differential Main Spring, Diaphragm,
Throttle Plate, Body Seal)
Type 30A Filter Maintenance Kit (Element
489666
and O-Ring)
Form 6277-5
4.05-6 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
MOONEY GAS REGULATOR CARTRIDGE
REMOVAL
1. Depressurize pilot and main valve. Unscrew and 1
remove cartridge (see Figure 4.05-10). 2
2. Remove stem O-ring from pilot body using suitable
tool (a paper clip works well). Do not scratch O-ring
groove (see Figure 4.05-11).
NOTE: The loading and inlet ports are interchangeable
with one another.
3. Remove bottom cap from cartridge body and
remove internal parts. Use a heavy paper clip or
0.045 in. (1.14 mm) diameter wire to push out orifice 3
assembly (pilot valve). Do not damage O-ring
sealing surface of body cartridge (see Figure
4.05-12).
Figure 4.05-13
2 1
3 A
Figure 4.05-12
CARTRIDGE INSTALLATION
1. Assemble cartridge by placing O-ring on bottom cap;
then install return spring, orifice spring, stem guide,
plug and stem, orifice and O-ring, and backup Figure 4.05-14
washer (see Figure 4.05-15).
1 - Stem 2 - Body Insert
2. Install bottom cap assembly into body insert. Return
spring will force orifice into position as cap assembly A = 0.32 in. (8.1 mm)
is screwed into body insert (see Figure 4.05-13).
Tighten to specifications. See Fuel System in Table
1.15-17 Critical Engine Torque Values on page 1.15-
28 for specific torque values.
Form 6277-5
4.05-7 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
1 - Stem O-Ring 7 - Plug and Stem
1 2 - O-Rings Assembly
3 - Body Insert 8 - Stem Guide
4 - Backup Washer 9 - Return Spring
5 - Orifice O-Ring 10 - Orifice Spring
2 6 - Orifice 11 - O-Ring
12 - Bottom Cap
4. Apply Parker Super O-Lube and slide O-ring onto
stem.
3 5. Verify O-ring is lubricated and in position on stem.
Install cartridge into pilot body and tighten to
specifications. See Fuel System in Table
1.15-17 Critical Engine Torque Values on page 1.15-
28 for specific torque values. Do not overtighten
(see Figure 4.05-11 and Figure 4.05-16).
Form 6277-5
4.05-8 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
! WARNING
Form 6277-5
4.05-9 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
5. Inspect the threads inside the admission valve body, THREAD LOCATION SIZE
where the locknut threads in, and the threads on the
Inside the admission valve body where
outside of the admission valve body where the valve 9/16-18 NF
the locknut threads in.
will be threaded into the cylinder head. If the threads
are damaged, they may be repaired using the
appropriate tap and die sizes listed in Table 4.05-4.
Table 4.05-4: Thread Sizes
1 2 3 4 5 6 7 8 9
10
Figure 4.05-20
Form 6277-5
4.05-10 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
ADMISSION VALVE SERVICE KIT INSTALLATION g. With smaller circumference positioned towards
the cold tube, position seat on top of cold tube.
NOTICE
NOTE: If parts are assembled properly, label on cold
Intermixing components with those of other valves is tube will be inserted into the admission valve body first.
not permitted. Admission valves (and rebuild kits) are h. Holding thumb and forefinger over ends of
inspected as assemblies during manufacture. assembled parts, insert them into admission
valve body from bottom.
NOTE: The parts in the service kit are assembled in the NOTICE
proper order for installation in the valve body (see Figure
4.05-19). The service kit parts may separate after the Do not overtorque the locknut or the tube may be
packaging is removed. If the parts become separated, permanently damaged.
an easy way to identify the hot and cold poppets is to
visually inspect the inside of the poppets (see Figure 2. Use an inch-pound torque wrench and hex socket to
4.05-21). Another way to identify the poppets is to install tighten the locknut to specifications. See Fuel
the spring. The spring will extend farther out of the cold System in Table 1.15-17 Critical Engine Torque
poppet (see Figure 4.05-21). The protrusion on the Values on page 1.15-28 for specific torque values.
spring seat must face the cold tube. The end of the cold
3. Install a new O-ring (P/N 209992) on the admission
tube that is marked with the label is inserted into the
valve body. To prevent tears when the assembly is
admission valve body first. Proper assembly is required.
inserted into the cylinder head admission valve bore,
lubricate the O-ring with Parker Super O-Lube (P/N
475029).
1 2 3
ADMISSION VALVE ASSEMBLY – GL ENGINE
NOTICE
The service kit parts may separate after the packaging
is removed. There are internal differences between
the hot and cold poppets, as well as the hot (flame trap)
Figure 4.05-21: Spring Depth in Cold Poppet
and cold (check valve) sides of the tube. The valve will
1 - Hot Poppet 3 - Cold Poppet not function properly if incorrectly assembled.
2 - Spring Do not mix parts from various admission valves;
1. Hold the valve body upright, with the hex head up, components are in matched sets.
and install the kit parts from below in the following
steps:
NOTE: Before assembling, all parts must be dry and oil-
a. Position hot poppet on level surface with pointed free.
end facing up.
1. Look into both poppets. Note that the bore of the hot
b. Slide black hot tube down over hot poppet. poppet is approximately 1/8 in. deeper than the cold
c. With small round protrusion facing up, slide poppet.
spring seat down into hot tube until raised flange
NOTE: The parts in the service kit are assembled in the
on spring seat contacts upper circumference of
proper order for installation in the valve body (see Figure
hot poppet. Protrusion must face cold tube.
4.05-22). The service kit parts may separate after the
d. Install spring on the small round protrusion on packaging is removed. If the parts become separated,
end of spring seat. an easy way to identify the hot and cold poppets is to
e. Position cold poppet over spring with pointed visually inspect the inside of the poppets (see Figure
end up. 4.05-22). Another way to identify the poppets is to install
the spring. The spring will extend farther out of the cold
f. With label end of cold tube at the top, slide cold
poppet (see Figure 4.05-22). The cold poppet and spring
tube down over cold poppet, spring and spring
are installed in the end of the tube that is marked with the
seat until it contacts raised flange on spring seat.
label. Proper assembly is required.
Form 6277-5
4.05-11 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
11. Install a new O-ring on the admission valve body. To
1 2 3 prevent tears when the assembly is inserted into the
cylinder head admission valve bore, lubricate the
O-ring with Parker Super O-Lube.
Figure 4.05-22: Spring Seats in Cold Poppets NOTE: Previous production admission valves use a
copper washer.
1 - Hot Poppet 3 - Cold Poppet
2. Install a new stainless-steel washer at the bottom of
2 - Spring the cylinder head admission valve bore (see Figure
2. Install the spring in the open end of the cold poppet 4.05-23).
(see Figure 4.05-22).
NOTICE
3. Look into each end of the tube. Note that one end
has a larger diameter counterbore (to fit the tip of the During installation of a P/N 211587C, P/N 211587B,
hot poppet), while the other end of the tube has a P/N 211587A or an upgraded P/N 211587 valve, make
small opening encircled with a lip (spring seat). sure only a stainless-steel washer is used and is
4. Insert the cold poppet (spring end first) into the tube seated flat against the seating surface in the cylinder
until the end of the spring contacts the spring seat. head. If the stainless-steel washer is damaged, fuel
Verify that the tip of the poppet sticks out slightly. leaks will occur.
NOTE: If the entire poppet fits within the tube, then the
wrong (hot) end of the tube has been selected. Fit the
cold poppet into the other end of the tube. 1
5. Install the hot poppet into the opposite end of the
tube. The flat side of the poppet must face toward
the open end of the tube, so that the tip of the poppet
seats inside the counterbore.
6. Hold the tube assembly upright in one hand with the
tip of the cold poppet pointing upward. Use a finger
to keep the hot poppet in the other end of the tube.
7. Place the tube seat over the tip of the cold poppet, 2
so that the lip on the seat fits within the tube ID.
8. With the long hex on top, slide the admission valve
body over the cold poppet end of the tube until the
entire assembly fits easily within the valve body. Figure 4.05-23
9. Finger-tighten the locknut into the end of the 1 - Admission Valve 2 - Stainless-Steel
admission valve body. Washer
NOTICE NOTICE
Do not overtorque the locknut or the tube may be Do not use copper washer P/N 16409 with P/N
permanently damaged. 211587A admission valve or with a P/N 211587 valve
that has been upgraded by machining the locknut. If
10. Use an inch-pound torque wrench and Allen socket the copper washer is used, the new assembly torque
to tighten the locknut to specifications. See Fuel will drive the admission valve through the washer,
System in Table 1.15-17 Critical Engine Torque causing damage.
Values on page 1.15-28 for specific torque values.
3. Install the admission valve in the cylinder head bore.
Form 6277-5
4.05-12 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
5. Reattach both ends of the prechamber fuel inlet tube
NOTICE on the prechamber manifold and the admission
Do not overtighten the admission valve or the valve valve assembly. Finger-tighten the ferrule nuts. Use
may become damaged. a wrench to tighten the ferrule nuts. Inspect for fuel
leaks.
4. Tighten the valve to specifications. See Fuel
System in Table 1.15-17 Critical Engine Torque
Values on page 1.15-28 for specific torque values.
Form 6277-5
4.05-13 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
1
3
4
2
8
6
7
10
1 - Probe 6 - CO Meter
2 - Exhaust Elbow 7 - Flowmeter
3 - Probe 8 - Oxygen Analyzer
4 - Exhaust Elbow 9 - Water Trap
5 - Optional Temperature Controller and Heated 10 - Flowmeter
Sample Line for Ambient Temperatures Below 32°F
(0°C)
NOTE: Temperature controller and exhaust analyzer available in 110- or 120-volt.
NOTICE
All tubing connections must be leak-free.
Form 6277-5
4.05-14 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
A carbon monoxide (CO) analyzer is required when High sample temperatures can also be very detrimental
setting a GSI (rich burn) engine and when used with an to good analyzer performance. Common causes of high
oxygen (O2) analyzer, provides an even more accurate temperature are very short sample lines and excessively
method of setting a GSI (rich burn) engine. high sample flow rates. Maintaining 2 SCFH flow makes
it easy to maintain an acceptable temperature.
An oxygen (O2) analyzer is a mandatory piece of
equipment to ensure correct air/fuel ratio settings on GL The following summarizes the requirements of an
(lean burn) engines. acceptable emissions sampling system:
• A filter to separate water (compatible with corrosive
The oxygen analyzer should be capable of measuring
exhaust gases)
oxygen in 0.1% increments up to 25%.
• A flowmeter and/or regulator to control sample
The uses of an exhaust gas analyzer are numerous: pressure and flow to 2 inch-H2O (51 mm-H2O) at 2
• Proper adjustment of GL series engines SCFH
• Troubleshooting engine problems • Sample lines properly designed to prevent
Waukesha has assembled all of the components you excessively hot or cold samples. The sample
need to properly test emissions. They are listed in latest temperature entering the analyzer must be more than
edition of Waukesha Special Tool Catalog Form No. 36°F, but less than 100°F (2°C, but less than 38°C).
393. Contact your Distributor for pricing information. • An analyzer capable of producing reliable and
Figure 4.05-24 shows an emissions sampling system. accurate test results
Form 6277-5
4.05-15 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
RICH BURN (GSI) NOTE: The Best Economy level of 17:1 air/fuel ratio
may not be obtainable depending upon engine
When setting a VHP GSI Waukesha engine, reference
condition, ignition system capability, load and fuel
is made to finding the lowest intake manifold pressure
quality (detonation resistance).
and turning the carburetor mixture adjustment capscrew
in to increase the pressure or lower the vacuum by 1.5 The Waukesha preferred and most accurate method of
inch-Hg (38 mm-Hg). These two settings are Best Power setting an engine is by the use of exhaust gas analysis.
(BP) and Best Economy (BE) settings. See Figure For example, if an engine is to be set to the Best
4.05-25. Economy setting, the carburetor capscrew is simply
adjusted to obtain the observed oxygen (O2) and carbon
monoxide (CO) readings for the engine model being
used. Figure 4.05-26 shows the relationship between
PRESSURE
GAUGE
0.5, Hg
1.5 inch-Hg percent of oxygen (O2) and carbon monoxide (CO) in the
exhaust and their associated air/fuel ratio.
ATMOSPHERIC (30, HgA) TURBO
Table 4.05-5 indicates typical levels of emissions which
RICH 15. 5:1
B.P.
STOICH.
16.09
17. 0:1
B.E.
LEAN
are attainable by an engine in good operating condition
running on commercial quality natural gas of 90 WKI
AIR/FUEL RATIO value.
% OBSERVED
CARBURETOR GRAMS/HP-HR MASS VOLUME EXCESS
MODEL DRY
SETTING AFR AFR AIR RATIO
NOx CO NMHC THC CO O2
Lowest Manifold
8.5 32.0 0.35 2.3 1.15 0.30 15.5:1 9.3:1 0.97
(Best Power)
Equal NOx & CO 12.0 12.0 0.35 2.3 0.45 0.30 15.9:1 9.6:1 0.99
G, GSI Catalytic Conv.
13.0 9.0 0.30 0.20 0.38 0.30 15.95:1 9.6:1 0.99
Input (3-way)
Standard (Best
22.0 1.5 0.25 1.5 0.02 1.35 17.0:1 10.2:1 1.06
Economy)
GL Standard 1.5 2.65 1.0 5.5 0.06 9.8 28.0:1 16.8:1 1.74
NOTE: The table above indicates emission levels that are valid for new engines for the duration of the standard
warranty period and are attainable by an engine in good operating condition running on commercial quality natural
gas of 900 BTU/ft3 (35.38 MJ/m3 [25, V (0; 101.325)]) SLHV, WKI value of 91 or higher, 93% methane content by
volume, and at ISO standard conditions. Emissions are based on standard engine timing at WKI value of 91 with an
absolute humidity of 42 grains/lb. See engine-specific WKI Power and Timing curves for standard timing. Unless
otherwise noted, these emission levels can be achieved across the continuous duty speed range and from 75% to
110% of the ISO Standard Power (continuous duty) rating. Contact your local Waukesha representative or
Waukesha’s Sales Engineering Department for emission values which can be obtained on a case-by-case basis for
specific ratings, fuels and site conditions.
Form 6277-5
4.05-16 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
MOONEY GAS REGULATOR TYPICAL
ADJUSTMENT AND HOOKUP LOCATIONS
The carburetor adjusting screw is located on the
carburetor body and is used during fuel system
CARBON MONOXIDE OXYGEN
adjustment procedure (see Figure 4.05-27).
3
CATALYST SETPOINT A/F = 15.95
DRY VOLUME PERCENT
.38
Figure 4.05-27
STOICHIOMETRIC A/F = 16.09
The main fuel gas regulator external adjustment
0 changes the spring tension in the lower housing.
14 15 16 17 18 19 20 21
The gas-over-air (gas/air) adjustment is controlled by
RICH SPINDT A/F LEAN
adjusting the stem screw and locknut located at the
bottom of the pilot assembly (see Figure 4.05-28).
Figure 4.05-26: Standard Natural Gas Oxygen and Turning the stem screw clockwise will increase spring
Carbon Monoxide tension, increasing the gas/air. Turning the screw
NOTE: This curve plotted for laboratory fuel. Actual air/ counterclockwise will reduce spring tension and reduce
fuel ratio values will depend upon fuel composition, but the gas/air setting.
relationships for CO and O2 will remain constant.
NOTE: Emission levels are given for pre-catalyst
measurements.
These emission levels can be achieved using
commercial quality natural gas fuel across the
continuous duty speed range and from 75% to 110% of
the continuous duty horsepower (ISO Standard Power).
It should be noted that these values are based on
laboratory data. Limited tradeoffs can be made to
change emission levels or fuel economy. Emission
levels for constant speed applications, certified
performance and emission values can be obtained on a
case-by-case basis for specific ratings, fuels and site
conditions. Contact Waukesha’s Sales Engineering
Department or your local Waukesha Distributor.
Form 6277-5
4.05-17 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
FISHER GAS REGULATOR TYPICAL ADJUSTMENT
AND HOOKUP LOCATIONS
The main fuel gas regulator external adjustment
changes the spring tension in the lower housing (see
Figure 4.05-30).
2
1
6
2
Figure 4.05-28
5
1 - Locknut 2 - Adjusting Screw
3
4
Initial setting is a stem length of approximately 2.75 in.
(6.98 cm) measured from adjuster housing fitting (see
Figure 4.05-7). Figure 4.05-30: Main Fuel Gas Pressure Regulators,
External Adjustment
Water manometer connections on the fuel regulator(s)
are shown in Figure 4.05-29. 1 - Spring Seat 4 - Adjusting
2 - Rubber Seal Capscrew
3 - Closing Cap 5 - Locknut
6 - Dynaseal Washer
Water manometer connections on the fuel regulator(s)
are shown in Figure 4.05-31 and Figure 4.05-32.
Figure 4.05-29
Form 6277-5
4.05-18 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
! WARNING
Regulator Setting
1. Set the primary, or “line” regulator to provide 5 – 10
Figure 4.05-33: Turbocharger Exhaust Inlet Elbow – Right psi (34.5 – 69 kPa) at the inlet to the engine-mounted
Bank
regulator(s).
Form 6277-5
4.05-19 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
2. Adjust the engine-mounted regulator(s) so that the NOTE: Leaning the mixture in accordance with Step 4
gas pressure at the carburetor inlet is 4-1/2 ± 1/2 may reduce the ability of the engine to respond to load
inch-H2O (114.3 ± 12.7 mm-H2O) above carburetor changes. Response may be improved by readjusting the
air horn pressure at no load. On Vee engines, banks mixture toward rich (counterclockwise) to approach the
to be within 1/2 inch-H2O (12.7 mm-H2O). Normally, intake manifold vacuum noted in Step 3 in Carburetor
the spring adjustment should be screwed down only Adjustment (6-Cylinder Engines) on page 4.05-25,
far enough to clear the cap. and Step 3 in Carburetor Adjustment (Each Bank for 12-
or 16-Cylinder Engine) on page 4.05-20. Increased
Carburetor Adjustment (6-Cylinder Engine) fuel consumption will result; therefore, a compromised
1. Turn the carburetor mixture adjustment capscrew six setting toward the leaner mixture is recommended.
full turns counterclockwise from the full clockwise Carburetor Adjustment (Each Bank for 12- or
position. 16-Cylinder Engine)
2. Apply rated load at rated speed, or maximum 1. Turn both banks’ carburetor mixture adjustment
available load if less than rated. A load that produces capscrew six full turns counterclockwise from the full
3 – 6 inch-Hg (76.2 – 152.4 mm-Hg) intake manifold clockwise position.
vacuum is preferred for response to mixture
adjustment(s). 2. Apply rated load at rated speed, or maximum
available load if less than rated. A load that produces
NOTICE 3 – 6 inch-Hg (76.2 – 152.4 mm-Hg) intake manifold
vacuum is preferred for response to mixture
Always verify that all cylinders are firing before adjustment.
adjusting the carburetor. Individual exhaust
thermocouples have been provided for this purpose. NOTICE
Failure to do so may cause serious engine damage.
Always verify that all cylinders are firing before
adjusting the carburetor. Individual exhaust
For Best Power: λ 0.97, 15.5:1 Air/Fuel Ratio (AFR) thermocouples have been provided for this purpose.
Failure to do so may cause serious engine damage.
3. Turn the mixture adjustment capscrew clockwise
(toward lean) until the intake manifold vacuum just
begins to decrease. Note the highest vacuum For Best Power: λ 0.97, 15.5:1 AFR
reading.
3. On either bank, turn the carburetor load adjustment
For Stoichiometric and Best Economy (Intermittent
capscrew clockwise (toward lean) until the intake
Duty Rating): λ 1.0, 16.09:1 AFR manifold vacuum begins to decrease, then slightly
4. Complete Step 3 (Best Power Adjustment). counterclockwise to return to maximum vacuum.
Continue to turn the mixture adjustment capscrew Note the highest vacuum reading. Do the same on
clockwise far enough to decrease the intake the other bank.
manifold vacuum by 1/2 inch-Hg (12.7 mm-Hg). For Stoichiometric and Best Economy (Intermittent
For Best Economy (Continuous Duty Rating): λ Duty Rating Best): λ 1.0, 16.09:1 AFR
1.06, 17.0:1 AFR 4. Complete Step 3 (Best Power Adjustment). On one
5. Complete Step 3 (Best Power Adjustment). bank at a time, continue to turn the mixture
Continue to turn the load adjustment capscrew adjustment capscrew clockwise until the intake
clockwise far enough to decrease the intake manifold vacuum decreases 1/4 inch-Hg (6.35
manifold vacuum by 1-1/2 inch-Hg (38.1 mm-Hg). mm-Hg).
NOTE: The carburetor load adjustment capscrew For Best Economy (Continuous Duty Rating): λ
setting called for in Step 1 is intended to be over rich. As 1.06, 17.0:1 AFR
it is adjusted toward lean, there will be a distinct loss of 5. Complete Step 3 (Best Power Adjustment). On one
power when leaned beyond the Best Power air/fuel ratio. bank at a time, turn the mixture adjustment capscrew
If the engine is operating under governor control with clockwise until the intake manifold vacuum
less than wide open butterfly plates, the power loss can decreases 3/4 inch-Hg (19.05 mm-Hg).
be recognized by a decrease of intake manifold vacuum
with a naturally aspirated engine.
Form 6277-5
4.05-20 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
NOTE: The carburetor load adjustment capscrew Physical Requirements
setting called for in Step 1 is intended to be over rich. As • A 2 in. pipe size Fisher 99 regulator. Two regulators
it is adjusted toward lean, there will be a distinct loss of on the 12- and 16-cylinder engines.
power when leaned beyond the Best Power air/fuel ratio.
If the engine is operating under governor control with • The regulator must have a 1-1/8 in. orifice.
less than wide open butterfly plates, the power loss can • The regulator has a cadmium spring, 3 – 12 in. (76.2 –
be recognized by a decrease of intake manifold vacuum 304.8 mm) of water column (H2O).
with a naturally aspirated engine.
• The regulator is to be mounted as close to the
Vee Engine Intake Manifold Vacuum Balance carburetor as possible.
Form 6277-5
4.05-21 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
For Stoichiometric and Best Economy (Intermittent For Best Power: λ 0.97, 15.5:1 AFR
Duty Rating): λ 1.0, 16.09:1 AFR 3. On either bank, turn the carburetor mixture
4. Complete Step 3 (Best Power Adjustment). adjustment capscrew clockwise (toward lean) until
Continue to turn the mixture adjustment capscrew the intake manifold pressure begins to increase,
clockwise far enough to increase the intake manifold then slightly counterclockwise to return to minimum
pressure by 1/2 inch-Hg (12.7 mm-Hg). pressure. Note lowest pressure reading. Do the
For Best Economy (Continuous Duty Rating): same on the other bank.
λ1.06, 17.0:1 AFR For Stoichiometric and Best Economy (Intermittent
5. Complete Step 3 (Best Power Adjustment). Duty Rating): λ 1.0, 16.09:1 AFR
Continue to turn the mixture adjustment capscrew 4. Complete Step 3 (Best Power Adjustment). On one
clockwise far enough to increase the intake manifold bank at a time, continue to turn the mixture
pressure by 1-1/2 inch-Hg (38.1 mm-Hg). adjustment capscrew clockwise until the intake
manifold pressure increases 1/4 inch-Hg (6.35
NOTE: The carburetor mixture adjustment capscrew
mm-Hg).
setting called for in Step 1 is intended to be over rich. As
it is adjusted toward lean, there will be a distinct loss of For Best Economy (Continuous Duty Rating): λ
power when leaned beyond the Best Power air/fuel ratio. 1.06, 17.0:1 AFR
If the engine is operating under governor control with 5. Complete Step 3 (Best Power Adjustment). On one
less than wide open butterfly plates, the power loss can bank at a time, turn the mixture adjustment capscrew
be recognized by an increase of intake manifold farther clockwise until the intake manifold pressure
pressure with a turbocharged engine. increases 3/4 inch-Hg (19.05 mm-Hg).
NOTE: Leaning the mixture in accordance with Step 4
Vee Engine Intake Manifold Vacuum Balance
may reduce the ability of the engine to respond to load
changes. Response may be improved by readjusting the Check the intake manifold pressure on both banks at
mixture toward rich (counterclockwise) to approach the rated load and speed. If the difference is greater than 1/2
intake manifold pressure noted in Step 3 in Carburetor inch-Hg (12.7 mm-Hg), check/adjust the fuel settings.
Adjustment (6-Cylinder Engine) on page 4.05-21 and
Step 3 in Carburetor Adjustment (Each Bank for 12- or NATURALLY ASPIRATED ENGINES OPERATING
16-Cylinder Engine) on page 4.05-22. Increased fuel ON LOW BTU GAS WITH (SINGLE FUEL) IMPCO
consumption will result; therefore, a compromised MODEL 600 SERIES CARBURETORS
setting toward the leaner mixture is recommended. The following adjustment procedures apply to engines
Carburetor Adjustment (Each Bank for 12- or using 400 – 800 BTU/ft3 (15.7 – 31.5 MJ/m3) SLHV gas.
16-Cylinder Engine) NOTE: Before making any fuel mixture or regulator
1. Turn the carburetors’ mixture adjustment capscrew adjustments on a Vee block engine, both governor-
six full turns counterclockwise from the full clockwise controlled throttle plates and the hand throttle located in
position. the carburetors must be balanced. Each pair of butterfly
plates must fully close or open in unison. If adjustments
2. Apply rated load at rated speed, or maximum
are required, loosen the capscrews holding the universal
available load if less than rated. A load that produces
joint discs in the cross-shaft assembly, reposition the
a positive intake manifold pressure is preferred for
discs and tighten the capscrews. When checking the
response to mixture adjustment.
carburetor butterfly in the CLOSED position, back off the
idle adjusting capscrew to allow the butterfly plate to fully
NOTICE
close. When the governor goes to full stroke, the
Always verify that all cylinders are firing before carburetor butterfly plate must not overtravel the wide-
adjusting the carburetor. Individual exhaust open, straight-up-and-down position. Up to 5° lean
thermocouples have been provided for this purpose. toward closing is acceptable. The results of the above
Failure to do so may cause serious engine damage. static adjustments can be observed when the engine is
running by comparing the manifold vacuum between
banks. Readjust the idle adjusting capscrew.
Form 6277-5
4.05-22 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
Physical Requirements
• Based on the fuel’s Saturated Low Heating Value
(SLHV), Table 4.05-6 states the required regulator
and gas pressure.
• Two regulators are installed on the 12- and 16-cylinder
engines.
• The regulator(s) is to be mounted as close to the
carburetor as possible.
FUEL SLHV BTU/FT3 REQUIRED PRESSURE AVAILABLE SUPPLY REGULATOR MAKE &
(MJ/m3) @ CARB. PRESSURE @ REGULATOR MODEL
1 – 5 psi (6.9 – 34.5 kPa) Fisher 66
25 – 26 inch-H2O
400 – 450 (15.7 – 17.7) Fisher S-201 Dark Green
(635 – 660 mm-H2O) 5 – 10 psi (34.5 – 68.9 kPa)
Spring
20 in. H2O – 5 psi
15 – 16 inch-H2O Fisher 66
451 – 500 (17.8 – 19.7) (508 mm-H2O – 34.5 kPa)
(381 – 406 mm-H2O)
5 – 10 psi (34.5 – 68.9 kPa) Fisher S-201 Gray Spring
8 – 20 inch-H2O
IMPCO 91
(203 – 508 mm-H2O)
5 – 6 inch-H2O
501 – 800 (19.8 – 31.4) 20 inch-H2O – 5 psi
(127 – 152 mm-H2O) Fisher 66
(508 mm-H2O – 34.5 kPa)
5 – 10 psi (34.5 – 68.9 kPa) Fisher S-201 Red Spring
Form 6277-5
4.05-23 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
For Stoichiometric and Best Economy (Intermittent For Best Power: λ 0.97, 15.5:1 AFR
Duty Rating): λ 1.0, 16.09:1 AFR 3. On either bank, turn the carburetor load adjustment
4. Complete Step 3 (Best Power Adjustment). capscrew clockwise (toward lean) until the intake
Continue to turn the mixture adjustment capscrews manifold vacuum begins to decrease, then slightly
clockwise far enough to decrease the intake counterclockwise to return to maximum vacuum.
manifold vacuum by 1/2 inch-Hg (12.7 mm-Hg). Note the highest vacuum reading. Do the same on
For Best Economy (Continuous Duty Rating): λ the other bank.
1.06, 17.0:1 AFR For Stoichiometric and Best Economy (Intermittent
5. Complete Step 3 (Best Power Adjustment). Duty Rating): λ 1.0, 16.09:1 AFR
Continue to turn the load adjustment capscrews 4. Complete Step 3 (Best Power Adjustment). On one
clockwise far enough to decrease the intake bank at a time, continue to turn the mixture
manifold vacuum by 1-1/2 inch-Hg (38.1 mm-Hg). adjustment capscrew clockwise until the intake
manifold vacuum decreases 1/4 inch-Hg (6.35
NOTE: The carburetor mixture adjustment capscrew
mm-Hg).
setting called for in Step 1 is intended to be overrich. As
it is adjusted toward lean, there will be a distinct loss of For Best Economy (Continuous Duty Rating): λ
power when leaned beyond the Best Power air/fuel ratio. 1.06, 17.0:1 AFR
If the engine is operating under governor control with 5. Complete Step 3 (Best Power Adjustment). On one
less than wide open butterfly plates, the power loss can bank at a time, turn the mixture adjustment capscrew
be recognized by a decrease of intake manifold vacuum farther clockwise until the intake manifold vacuum
with a naturally aspirated engine. decreases 3/4 inch-Hg (19.05 mm-Hg).
NOTE: Leaning mixture in accordance with Step 4 may NOTE: The carburetor mixture adjustment capscrew
reduce the ability to respond to load changes. Response setting called for in Step 1 is intended to be overrich. As
may be improved by readjusting the mixture toward rich it is adjusted toward lean, there will be a distinct loss of
(counterclockwise) to approach the intake manifold power when leaned beyond the Best Power air/fuel ratio.
pressure noted in Step 3 in Carburetor Adjustment (6- If the engine is operating under governor control with
Cylinder Engines) on page 4.05-23 and Step 3 in less than wide open butterfly plates, the power loss can
Carburetor Adjustment (Each Bank for 12- or be recognized by a decrease of intake manifold vacuum
16-Cylinder Engine) on page 4.05-24. Increased fuel with a naturally aspirated engine.
consumption will result; therefore, a compromised
setting toward the leaner mixture is recommended. Vee Engine Intake Manifold Vacuum Balance
Carburetor Adjustment (Each Bank for 12- or Check the intake manifold vacuum on both banks at
16-Cylinder Engine) rated load and speed. If the difference is greater than 1/2
inch-Hg (12.7 mm-Hg), recheck/adjust the fuel settings.
1. Turn both banks’ carburetor mixture adjustment
capscrew five full turns counterclockwise from the NOTICE
full clockwise position.
2. Apply rated load at rated speed, or maximum load if Never attempt to equalize bank-to-bank intake
less than rated. A load that produces 3 – 6 inch-Hg manifold vacuum readings by adjusting the governor
(76.2 – 152.4 mm-Hg) intake manifold vacuum is butterfly plates out of mechanical synchronism.
preferred for response to mixture adjustment.
Form 6277-5
4.05-24 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
TURBOCHARGED ENGINES OPERATING ON LOW
! WARNING
BTU GAS (SINGLE FUEL) WITH IMPCO MODEL 600
CARBURETORS
Do not inhale gaseous fuels.
The following adjustment procedures apply to engines Some components of fuel gas
using 400 – 800 BTU/ft3 (15.7 – 31.5 MJ/m3) SLHV gas. are odorless, tasteless and
NOTE: Before making any fuel mixture or regulator highly toxic.
adjustments on a Vee block engine, both governor-
controlled throttle plates and the hand throttle located in
the carburetors must be balanced. Each pair of butterfly Regulator Setting (6-Cylinder Engine and / or Each
plates must fully close or open in unison. If adjustments Bank of 12- or 16-Cylinder Engine)
are required, loosen the capscrews holding the universal
joint discs in the cross-shaft assembly, reposition the 1. Verify that the available supply pressure to the
discs and tighten the capscrews. When checking the regulator(s) is 25 – 50 psi (172 – 345 kPa).
carburetor butterfly in the CLOSED position, back off the 2. Adjust the engine-mounted Fisher regulator(s) with
idle adjusting capscrew to allow the butterfly plate to fully the engine at no load to obtain the required gas over
close. When the governor goes to full stroke, the air (gas/air) pressure based on the fuel’s SLHV listed
carburetor butterfly plate must not overtravel the wide- in Table 4.05-7.
open, straight-up-and-down position. Up to 5° lean
NOTE: Gas/air is only measured at the first carburetor
toward closing is acceptable. The results of the above
(closest to the air cleaner). On Vee engines, banks to be
static adjustments can be observed when the engine is
within 1/2 in. (12.7 mm) of water column (H2O).
running by comparing the manifold vacuum between
banks. Readjust the idle adjusting capscrew.
Carburetor Adjustment (6-Cylinder Engines)
Physical Requirements 1. Turn the carburetor mixture adjustment capscrew
• 25 – 50 psi (172 – 345 kPa) line pressure to Fisher 99 five full turns counterclockwise from the full
regulator(s) clockwise position on both carburetors. If engine is
difficult to start at this setting, turn both adjusting
• A 2 in. (5.1 cm) pipe size regulator. Two regulators on capscrews clockwise in equal increments until the
the 12- and 16-cylinder engines engine starts.
• The regulator must have a 1.125 in. (28.5 cm) orifice 2. Apply rated load at rated speed, or maximum
• The regulator spring is determined by fuel’s lower available load if less than rated load. A load that
heating value (SLHV)see Table 4.05-7 produces a positive intake manifold pressure is
preferred for response to mixture adjustment.
Table 4.05-7: Regulator Spring and Gas/Air
Requirements
NOTICE
FUEL SLHV BTU/FT3 REGULATOR
GAS/AIR*
(MJ/m3) SPRING Always verify that all cylinders are firing before
adjusting the carburetor. Individual exhaust
400 – 450 (15.7 – 17.7) 25 – 26 Red
thermocouples have been provided for this purpose.
451 – 500 (17.8 – 19.7) 15 – 16 Red Failure to do so may cause serious engine damage.
Cadmium (Pink
501 – 800 (19.8 – 31.4) 5–6
on P9390GSI)
For Best Power: λ 0.97, 15.5:1 AFR
* Gas over air pressure differential – inches water column.
3. Turn the mixture adjustment capscrew clockwise in
• 0.38 in. (9.7 mm) lD minimum balance line to equal increments on both carburetors (toward lean)
carburetor air horn on first carburetor (carburetor until the intake manifold pressure just begins to
closest to intercooler) increase. Note the lowest pressure reading.
• Regulators are to be mounted as close to carburetors
as possible
Form 6277-5
4.05-25 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
For Stoichiometric and Best Economy (Intermittent For Best Power: λ 0.97, 15.5:1 AFR
Duty Rating): λ 1.0, 16.09:1 AFR 3. On either bank, turn the mixture adjustment
4. Complete Step 3 (Best Power Adjustment). capscrew clockwise in equal increments on both
Continue to turn the mixture adjustment capscrews carburetors (toward lean) until the intake manifold
in equal increments clockwise to increase the intake pressure just begins to increase, then back off
manifold pressure by 1/2 inch-Hg (12.7 mm-Hg). slightly to return to minimum pressure. Note the
For Best Economy (Continuous Duty Rating): λ lowest pressure reading. Do the same on the other
1.06, 17.0:1 AFR bank.
For Stoichiometric and Best Economy (Intermittent
5. Complete Step 3 (Best Power Adjustment).
Continue to turn the mixture adjustment capscrews Duty Rating): λ 1.0, 16.09:1 AFR
in equal increments clockwise to increase the intake 4. Complete Step 3 (Best Power Adjustment).
manifold pressure by 1-1/2 inch-Hg (38.1 mm-Hg). Continue to turn the mixture adjustment capscrews
in equal increments clockwise to increase the intake
NOTE: The carburetor mixture adjustment capscrew
manifold pressure by 1/4 inch-Hg (6.35 mm-Hg).
setting called for in Step 1 is intended to be overrich. As
it is adjusted toward lean, there will be a distinct loss of For Best Economy (Continuous Duty Rating): λ
power when leaned beyond the Best Power air/fuel ratio. 1.06, 17.0:1 AFR
If the engine is operating under governor control with 5. Complete Step 3 (Best Power Adjustment).
less than wide open butterfly plates, the power loss can Continue to turn the mixture adjustment capscrews
be recognized by an increase of intake manifold in equal increments clockwise to increase the intake
pressure on a turbocharged engine. manifold pressure by 3/4 inch-Hg (19.05 mm-Hg).
NOTE: Leaning the mixture in accordance with Step 4 NOTE: The carburetor mixture adjustment capscrew
may reduce the ability of the engine to respond to load setting called for in Step 1 is intended to be overrich. As
changes. Response may be improved by readjusting the it is adjusted toward lean, there will be a distinct loss of
mixture toward rich (counterclockwise) to approach the power when leaned beyond the Best Power air/fuel ratio.
intake manifold pressure noted in Step 3 in Carburetor If the engine is operating under governor control with
Adjustment (6-Cylinder Engines) on page 4.05-25 and less than wide open butterfly plates, the power loss can
Step 3 in Carburetor Adjustment (Each Bank for 12- be recognized by an increase of intake manifold
Cylinder Engine) on page 4.05-26. Increased fuel pressure on a turbocharged engine.
consumption will result; therefore, a compromised
setting toward the leaner mixture is recommended. NOTE: Leaning the mixture in accordance with Step 4
may reduce the ability of the engine to respond to load
Carburetor Adjustment (Each Bank for 12-Cylinder changes. Response may be improved by readjusting the
Engine) mixture toward rich (counterclockwise) to approach the
intake manifold pressure noted in Step 3 in Carburetor
NOTICE Adjustment (6-Cylinder Engines) on page 4.05-25 and
Step 3 in Carburetor Adjustment (Each Bank for 12-
Always verify that all cylinders are firing before Cylinder Engine) on page 4.05-26. Increased fuel
adjusting the carburetor. Individual exhaust consumption will result; therefore, a compromised
thermocouples have been provided for this purpose. setting toward the leaner mixture is recommended.
Failure to do so may cause serious engine damage.
Vee Engine Intake Manifold Pressure Balance
1. Turn the carburetor mixture adjustment capscrew Check the intake manifold pressure on both banks at
five full turns counterclockwise from the full rated load and speed. If the difference is greater than 1/2
clockwise position on all four carburetors. If engine inch-Hg (12.7 mm-Hg), check/adjust the fuel settings.
is difficult to start at this setting, turn all adjusting
capscrews clockwise in equal increments until the
NOTICE
engine starts.
Never attempt to equalize bank-to-bank intake
2. Apply rated load at rated speed, or maximum manifold vacuum readings by adjusting the governor
available load if less than rated load. A load that butterfly plates out of mechanical synchronism.
produces a positive intake manifold pressure is
preferred for response to mixture adjustment.
Form 6277-5
4.05-26 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
NOTE: Gas pressure to the carburetor(s) may be Physical Requirements
somewhat less at full load than the initial no load setting. • Natural Gas Regulator Requirements
If the drop is more than 3 inch-H2O (76.2 mm-H2O), an
– 5 – 10 psi (34.5 – 69.0 kPa) line pressure to Fisher
insufficient supply pressure to the regulator, undersize
S-201 regulator
piping, incorrect regulator orifice size, or inadequate
regulator capacity could be the cause. – 2 in. (5.1 cm) pipe size regulator. Two regulators on
the 12- and 16-cylinder engines.
NATURALLY ASPIRATED ENGINES OPERATING – 1 in. (2.54 cm) orifice for regulator
ON LOW BTU GAS AND NATURAL GAS (DUAL
FUEL) CARBURETION – Red spring (3-1/2 – 6-1/2 in. [88.9 – 165.1 mm] of
water column [H2O])
The following adjustment procedures are for dual fuel
• Low BTU gas regulator selection is based on the fuel’s
engines with the gas BTU/ft3 value of 400 – 800 (15.7 –
Lower Heat Value (SLHV). See Table 4.05-8.
31.5 MJ/m3) and 875 – 950 (34.4 – 37.4 MJ/m3) SLHV.
• Regulator(s) are to be mounted as close to carburetors
NOTE: Before making any fuel mixture or regulator as possible.
adjustments on a Vee block engine, both governor-
controlled throttle plates and the hand throttle located in
the carburetors must be balanced. Each pair of butterfly
plates must fully close or open in unison. If adjustments
are required, loosen the capscrews holding the universal
joint discs in the cross-shaft assembly, reposition the
discs and tighten the capscrews. When checking the
carburetor butterfly in the CLOSED position, back off the
idle adjusting capscrew to allow the butterfly plate to fully
close. When the governor goes to full stroke, the
carburetor butterfly plate must not overtravel the wide-
open, straight-up-and-down position. Up to 5° lean
toward closing is acceptable. The results of the above
static adjustments can be observed when the engine is
running by comparing the manifold vacuum between
banks. Readjust the idle adjusting capscrew.
Form 6277-5
4.05-27 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
2. Apply rated load at rated speed, or maximum
! WARNING
available load if less than rated. A load that produces
3 – 6 inch-Hg (76.2 – 152.4 mm-Hg) intake manifold
Do not inhale gaseous fuels. vacuum is preferred for response to mixture
Some components of fuel gas adjustment.
are odorless, tasteless and
For Best Power: λ 0.97, 15.5:1 AFR
highly toxic.
3. Turn the mixture adjustment capscrew clockwise
(toward lean) until the intake manifold vacuum just
begins to decrease. Note the highest vacuum
Regulator Setting for Natural Gas Operation reading.
(6-Cylinder and / or Each Bank for 12- or
For Stoichiometric and Best Economy (Intermittent
16-Cylinder Engine)
Duty Rating): λ 1.0, 16.09:1 AFR
1. Set the primary, or “line” regulator to provide
5 – 10 psi (34.5 – 69.0 kPa) at the inlet to the engine- 4. Complete Step 3 (Best Power Adjustment).
mounted regulator(s). Continue to turn the mixture adjustment capscrew
clockwise far enough to decrease the intake
2. Adjust the engine-mounted regulator(s) with the manifold vacuum by 1/2 inch-Hg (12.7 mm-Hg).
engine at no load so that the gas pressure at the
second carburetor inlet (carburetor closest to the For Best Economy (Continuous Duty Rating): λ
intake manifold) is 4-1/2 ± 1/2 inch-H2O (114.3 ± 12.7 1.06, 17.0:1 AFR
mm-H2O) . 5. Complete Step 3 (Best Power Adjustment).
Continue to turn the mixture adjustment capscrew
Regulator Setting for Low BTU Gas Operation clockwise far enough to decrease the intake
(6-Cylinder and / or Each Bank for 12- or manifold vacuum by 1-1/2 inch-Hg (38.1 mm-Hg).
16-Cylinder Engine)
Carburetor Adjustment for Natural Gas Operation
1. Verify that supply pressure to regulator(s) meets the (Each Bank for 12- or 16-Cylinder Engine)
requirements of Table 4.05-8 for the fuel used.
NOTE: All adjustments in this section refer to the natural
2. Adjust the regulator(s) with the engine at no load to
gas carburetor only (second carburetor – closest to
obtain the required gas pressure at the carburetor
intake manifold).
inlet based on the requirements of Table 4.05-8 for
the fuel used.
NOTICE
Carburetor Adjustment for Natural Gas Operation
(6-Cylinder Engine) Always verify that all cylinders are firing before
adjusting the carburetor. Individual exhaust
NOTE: All adjustments in this section refer to the natural thermocouples have been provided for this purpose.
gas carburetor only (second carburetor – closest to Failure to do so may cause serious engine damage.
intake manifold).
Form 6277-5
4.05-28 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
For Best Power: λ 0.97, 15.5:1 AFR 2. Apply rated load at rated speed, or maximum
3. On either bank, turn the carburetor mixture available load if less than rated load. A load that
adjustment capscrew clockwise (toward lean) until produces 3 – 6 inch-Hg (76.2 – 152.4 mm-Hg) intake
the intake manifold vacuum begins to decrease, manifold vacuum is preferred for response to mixture
then slightly counterclockwise to return to maximum adjustments.
vacuum. Note the highest vacuum reading. Do the For Best Power: λ 0.97, 15.5:1 AFR
same on the other bank. 3. Turn the mixture adjustment capscrew clockwise
For Stoichiometric and Best Economy (Intermittent (toward lean) until the intake manifold vacuum just
Duty Rating): λ 1.0, 16.09:1 AFR begins to decrease. Note the highest vacuum
4. Complete Step 3 (Best Power Adjustment). On one reading.
bank at a time, continue to turn the mixture For Stoichiometric and Best Economy (Intermittent
adjustment capscrew clockwise until the intake Duty Rating): λ 1.0, 16.09:1 AFR
manifold vacuum decreases 1/4 inch-Hg (6.35 mm- 4. Complete Step 3 (Best Power Adjustment).
Hg). Continue to turn the mixture adjustment capscrew
For Best Economy (Continuous Duty Rating): λ clockwise far enough to decrease the intake
1.06, 17.0:1 AFR manifold vacuum by 1/2 inch-Hg (12.7 mm-Hg).
5. Complete Step 3 (Best Power Adjustment). On one For Best Economy (Continuous Duty Rating): λ
bank at a time, turn the mixture adjustment capscrew 1.06, 17.0:1 AFR
farther clockwise until the intake manifold vacuum 5. Complete Step 3 (Best Power Adjustment).
decreases 3/4 inch-Hg (19.05 mm-Hg). Continue to turn the mixture adjustment capscrew
6. The intake manifold vacuum on each bank should clockwise far enough to decrease the intake
now be 1-1/2 inch-Hg (38.1 mm-Hg) less than the manifold vacuum by 1-1/2 inch-Hg (38.1 mm-Hg).
readings noted for Step 3. If not, adjust each bank
by half the difference until the values are correct. Carburetor Adjustment for Low BTU Gas Operation
(Each Bank for 12- or 16-Cylinder Engine)
Carburetor Adjustment for Low BTU Gas Operation
NOTE: All adjustments in this section refer to the first
(6-Cylinder Engine)
carburetor only (carburetor closest to the air cleaner). Do
NOTE: All adjustments in this section refer to the first not readjust the second carburetor from settings
carburetor only (carburetor closest to the air cleaner). Do determined in Carburetor Adjustment for Natural Gas
not readjust the second carburetor from settings Operation (Each Bank for 12- or 16-Cylinder Engine) on
determined in Carburetor Adjustment for Natural Gas page 4.05-28.
Operation (6-Cylinder Engine) on page 4.05-28.
NOTE: Carburetor Adjustment for Natural Gas
NOTE: Steps in Carburetor Adjustment for Natural Gas Operation (Each Bank for 12- or 16-Cylinder Engine) on
Operation (6-Cylinder Engine) on page 4.05-28 must be page 4.05-28 must be completed before performing the
completed before performing the low BTU gas low BTU gas carburetor adjustment.
carburetor adjustment.
NOTICE
NOTICE
Always verify that all cylinders are firing before
Always verify that all cylinders are firing before adjusting the carburetor. Individual exhaust
adjusting the carburetor. Individual exhaust thermocouples have been provided for this purpose.
thermocouples have been provided for this purpose. Failure to do so may cause serious engine damage.
Failure to do so may cause serious engine damage.
Form 6277-5
4.05-29 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
2. Apply rated load at rated speed, or maximum load if NOTE: The carburetor mixture adjustment capscrew
less than rated. A load that produces 3 – 6 inch-Hg settings are intended to be overrich. As it is adjusted
(76.2 – 152.4 mm-Hg) intake manifold vacuum is toward lean, there will be a distinct loss of power when
preferred for response to mixture adjustment. leaned beyond the Best Power air/fuel ratio. If the engine
For Best Power: λ 0.97, 15.5:1 AFR is operating under governor control with less than wide
open butterfly plates, the power loss can be recognized
3. On either bank, turn the carburetor mixture by a decrease of intake manifold vacuum with a naturally
adjustment capscrew clockwise (toward lean) until aspirated engine.
the intake manifold vacuum begins to decrease,
then slightly counterclockwise to return to maximum NOTE: Leaning the mixture may reduce the ability of
vacuum. Note highest vacuum reading. Do the same the engine to respond to load changes. Response may
on the other bank. be improved by readjusting the mixture toward rich
(counterclockwise). Increased fuel consumption will
For Stoichiometric and Best Economy (Intermittent
result; therefore, a compromise setting toward the leaner
Duty Rating): λ 1.0, 16.09:1 AFR
mixture is recommended.
4. Complete Step 3 (Best Power Adjustment). On one
bank at a time, continue to turn the mixture TURBOCHARGED ENGINES OPERATING ON LOW
adjustment capscrew clockwise until the intake BTU GAS AND NATURAL GAS (DUAL FUEL) WITH
manifold vacuum decreases 1/4 inch-Hg (6.35 mm- IMPCO MODEL 600 CARBURETOR
Hg).
The following adjustment procedures apply to engines
For Best Economy (Continuous Duty Rating): λ utilizing dual fuel with a BTU/ft3 value of 400 – 800 (15.7
1.06, 17.0:1 AFR – 31.5 MJ/m3) and 875 – 950 (34.4 – 37.4 MJ/m3) SLHV.
5. Complete Step 3 (Best Power Adjustment). On one NOTE: Before making any fuel mixture or regulator
bank at a time, turn the mixture adjustment capscrew adjustments on a Vee block engine, both governor-
farther clockwise until the intake manifold vacuum controlled throttle plates and the hand throttle located in
decreases 3/4 inch-Hg (19.05 mm-Hg). the carburetors must be balanced. Each pair of butterfly
6. Intake manifold vacuum on each bank should now plates must fully close or open in unison. If adjustments
be 1-1/2 inch-Hg (38.1 mm-Hg) less than the are required, loosen the capscrews holding the universal
readings noted for Step 3. If not, adjust each bank joint discs in the cross-shaft assembly, reposition the
by half the difference until the values are correct. discs and tighten the capscrews. When checking the
carburetor butterfly in the CLOSED position, back off the
Vee Engine Intake Manifold Vacuum Balance idle adjusting capscrew to allow the butterfly plate to fully
Check the intake manifold vacuum on both banks at close. When the governor goes to full stroke, the
rated load and speed. If the difference is greater than carburetor butterfly plate must not overtravel the wide-
1/2 inch-Hg (12.7 mm-Hg), check/adjust the fuel open, straight-up-and-down position. Up to 5° lean
settings. toward closing is acceptable. The results of the above
static adjustments can be observed when the engine is
NOTICE running by comparing the manifold vacuum between
banks. Readjust the idle adjusting capscrew.
Never attempt to equalize bank-to-bank intake
manifold vacuum readings by adjusting the governor Physical Requirements
butterfly plates out of mechanical synchronism. • 25 – 50 psi (172 – 345 kPa) line pressure to both natural
gas and low BTU gas regulators
• 2 in. pipe size Fisher 99 regulator. Two regulators on
NOTE: Gas pressure to the carburetor(s) may be
the 12- and 16-cylinder engines.
somewhat less at full load than the initial no load setting.
If the pressure drop is more than 3 inch-H2O (76.2 – 1-1/8 in. orifice in each regulator
mm-H2O), an insufficient gas supply pressure to the – Cadmium springs in natural gas regulators
regulator, undersize piping, incorrect regulator orifice – Low BTU gas regulator springs are determined by
size or inadequate regulator capacity could be the the fuel’s Lower Heat Value (SLHV). See Table
cause. 4.05-9.
• Regulators are to be mounted as close to carburetors
as possible.
Form 6277-5
4.05-30 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
Table 4.05-9: Low BTU Regulator Spring and Gas Over
Air Requirements NOTICE
FUEL SLHV REGULATOR Always verify that all cylinders are firing before
GAS/AIR*
BTU/FT3 (MJ/M3) SPRING adjusting the carburetor. Individual exhaust
400 – 450 thermocouples have been provided for this purpose.
25 – 26 Red
(15.7 – 17.7) Failure to do so may cause serious engine damage.
451 – 500
15 – 16 Red
(17.8 – 19.7)
1. Turn the carburetor mixture adjustment capscrew six
501 – 800 Cadmium full turns counterclockwise from the full clockwise
5–6
(19.8 – 31.5) (Pink on P9390GSI) position.
* Gas over air pressure differential – inches water column. 2. Apply rated load at rated speed, or maximum
available load if less than rated. A load that produces
! WARNING a positive intake manifold pressure is preferred for
response to mixture adjustments.
Do not inhale gaseous fuels. For Best Power: λ 0.97, 15.5:1 AFR
Some components of fuel gas
are odorless, tasteless and 3. Turn the mixture adjustment capscrew clockwise
highly toxic. (toward lean) until the intake manifold pressure just
begins to increase. Note the lowest pressure
reading.
For Stoichiometric and Best Economy (Intermittent
Regulator Setting for Natural Gas Operation Duty Rating): λ 1.0, 16.09:1 AFR
(6-Cylinder Engines and / or Each Bank for 12- or
16-Cylinder Engine) 4. Complete Step 3 (Best Power Adjustment).
Continue to turn the mixture adjustment capscrew
1. Set the primary, or “line” regulator to provide 25 – 50 clockwise far enough to increase the intake manifold
psi (172 – 345 kPa) at the inlet to the engine-mounted pressure by 1/2 inch-Hg (12.7 mm-Hg).
regulator.
For Best Economy (Continuous Duty Rating): λ
2. Adjust the engine-mounted regulator(s) with the 1.06, 17.0:1 AFR
engine at no load so that the gas/air pressure at the
second carburetor inlet (carburetor closest to the 5. Complete Step 3 (Best Power Adjustment).
intake manifold) is 4-1/2 ± 1/2 in. (114.3 ± 12.7 mm) Continue to turn the mixture adjustment capscrew
of water column (H2O). clockwise far enough to increase the intake manifold
pressure by 1-1/2 inch-Hg (38.1 mm-Hg).
Regulator Setting for Low BTU Gas Operation
(6-Cylinder Engines and / or Each Bank of Carburetor Adjustment for Natural Gas Operation
12-Cylinder Engine) (Each Bank for 12- or 16-Cylinder Engine)
1. Verify that available supply pressure to regulators is NOTE: All adjustments in this section refer to the natural
25 – 50 psi (172 – 345 kPa). gas carburetor only (second carburetor closest to intake
manifold).
2. Adjust the low BTU gas regulator(s) so that the gas
over air (gas/air) pressure at the first carburetor inlet NOTICE
(carburetor closest to intercooler) is equal to the
values in Table 4.05-9 for the fuel’s SLHV. Always verify that all cylinders are firing before
adjusting the carburetor. Individual exhaust
Carburetor Adjustment for Natural Gas Operation
thermocouples have been provided for this purpose.
(6-Cylinder Engine)
Failure to do so may cause serious engine damage.
NOTE: All adjustments in this section refer to the
second carburetor only (carburetor closest to intake
manifold). 1. Turn both carburetor mixture adjustment capscrews
six full turns counterclockwise from the full clockwise
position. Do this on both banks.
Form 6277-5
4.05-31 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
2. Apply rated load at rated speed, or maximum 2. Apply rated load at rated speed, or maximum
available load if less than rated. A load that produces available load if less than rated load. A load that
a positive intake manifold pressure is preferred for produces a positive intake manifold pressure is
response to mixture adjustment. preferred for response to mixture adjustment.
For Best Power: λ 0.97, 15.5:1 AFR For Best Power: λ 0.97, 15.5:1 AFR
3. On either bank, turn the carburetor mixture 3. Turn the mixture adjustment capscrew clockwise
adjustment capscrew clockwise (toward lean) until (toward lean) until the intake manifold pressure just
the intake manifold pressure begins to increase, begins to increase, then back off slightly to return to
then slightly counterclockwise to return to minimum minimum pressure. Note the lowest pressure
pressure. Note lowest pressure reading. Do the reading.
same on the other bank. For Stoichiometric and Best Economy (Intermittent
For Stoichiometric and Best Economy (Intermittent Duty Rating): λ 1.0, 16.09:1 AFR
Duty Rating): λ 1.0, 16.09:1 AFR 4. Complete Step 3 (Best Power Adjustment).
4. Complete Step 3 (Best Power Adjustment). On one Continue to turn the mixture adjustment capscrews
bank at a time, continue to turn the load adjustment in equal increments clockwise to increase the intake
capscrew clockwise until the intake manifold manifold pressure by 1/2 inch-Hg (12.7 mm-Hg) for
pressure increases 1/4 inch-Hg (6.35 mm-Hg). intermittent rating.
For Best Economy (Continuous Duty Rating): λ For Best Economy (Continuous Duty Rating): λ
1.06, 17.0:1 AFR 1.06, 17.0:1 AFR
5. Complete Step 3 (Best Power Adjustment). On one 5. Complete Step 3 (Best Power Adjustment).
bank at a time, turn the mixture adjustment capscrew Continue to turn the mixture adjustment capscrews
farther clockwise until the intake manifold pressure in equal increments clockwise to increase the intake
increases 3/4 inch-Hg (19.05 mm-Hg). manifold pressure by 1-1/2 inch-Hg (38.1 mm-Hg).
6. Intake manifold pressure on each bank should now Carburetor Adjustment for Low BTU Gas Operation
be 1-1/2 inch-Hg (38.1 mm-Hg) higher than the (Each Bank for 12- or 16-Cylinder Engine)
readings noted in Step 3. If not, adjust each bank half
the difference until the values are correct. NOTE: All adjustments in this section refer to the first
carburetor only (carburetor closest to the intercooler).
Carburetor Adjustment for Low BTU Gas Operation Do not readjust the second carburetor from the settings
(6-Cylinder Engine) determined in Carburetor Adjustment for Natural Gas
NOTE: All adjustments in this section refer to the first Operation (Each Bank for 12- or 16-Cylinder Engine) on
carburetor only (carburetor closest to the intercooler). page 4.05-28.
Do not readjust the second carburetor from the settings
determined in Carburetor Adjustment for Natural Gas NOTICE
Operation (6-Cylinder Engine) on page 4.05-28.
Always verify that all cylinders are firing before
adjusting the carburetor. Individual exhaust
NOTICE
thermocouples have been provided for this purpose.
Always verify that all cylinders are firing before Failure to do so may cause serious engine damage.
adjusting the carburetor. Individual exhaust
thermocouples have been provided for this purpose.
1. Turn both carburetor mixture adjustment capscrews
Failure to do so may cause serious engine damage.
five full turns counterclockwise from the full
clockwise. If engine is difficult to start at this setting,
1. Turn the carburetor mixture adjustment capscrew turn both adjusting capscrews clockwise in equal
five full turns counterclockwise from the full increments until the engine starts.
clockwise position. If engine is difficult to start at this 2. Apply rated load at rated speed, or maximum
setting, turn adjusting capscrew clockwise until the available load if less than rated load. A load that
engine starts. produces a positive intake manifold pressure is
preferred for response to mixture adjustment.
Form 6277-5
4.05-32 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
For Best Power: λ 0.97, 15.5:1 AFR NOTE: The carburetor mixture adjustment capscrew
3. On either bank, turn the mixture adjustment settings are intended to be overrich. As it is adjusted
capscrew clockwise (toward lean) until the intake toward lean, there will be a distinct loss of power when
manifold pressure just begins to increase, then back leaned beyond the Best Power air/fuel ratio. If the engine
off slightly to return to minimum pressure. Note the is operating under governor control with less than wide
lowest pressure reading. Do the same on the other open butterfly plates, the power loss can be recognized
bank. by an increase of intake manifold pressure with a
turbocharged engine.
For Stoichiometric and Best Economy (Intermittent
Duty Rating): λ 1.0, 16.09:1 AFR NOTE: Leaning the mixture may reduce the ability of
the engine to respond to load changes. Response may
4. Complete Step 3 (Best Power Adjustment). On one be improved by readjusting the mixture toward rich
bank at a time, continue to turn the mixture (counterclockwise). Increased fuel consumption will
adjustment capscrews in equal increments result; therefore, a compromise setting toward the leaner
clockwise to increase the intake manifold pressure mixture is recommended.
by 1/4 inch-Hg (6.35 mm-Hg).
For Best Economy (Continuous Duty Rating): λ NATURALLY ASPIRATED ENGINES WITH
1.06, 17.0:1 AFR PARALLEL CARBURETION
5. Complete Step 3 (Best Power Adjustment). On one Physical Requirements
bank at a time, continue to turn the mixture
adjustment capscrews in equal increments • Carburetors
clockwise to increase the intake manifold pressure – IMPCO DG200T, two in parallel on each bank
by 3/4 inch-Hg (19.05 mm-Hg). • Regulators
6. Intake manifold pressure on each bank should now – IMPCO 91, 2 in. Two on each bank, one for each
be 1-1/2 inch-Hg (38.1 mm-Hg) higher than the fuel. Natural gas regulators have the spring removed
readings noted in Step 3. If not, adjust each bank half and are mounted in the inverted position. Digester
the difference until the values are correct. gas regulators have the spring in place and are
Vee Engine Intake Manifold Pressure Balance mounted upright.
• Gas Supply Pressure to Regulators
Check the intake manifold pressure on both banks at
rated load and speed. If the difference is greater than 1/2 – 8 – 20 in. (203 – 508 mm) of water column (H2O) is
inch-Hg (12.7 mm-Hg), check/adjust the fuel settings. recommended for both fuels. Excessive supply
pressure will cause the regulator to shut off.
NOTICE Insufficient supply pressure may result in too low
regulator outlet pressure to the carburetors.
Never attempt to equalize bank-to-bank intake
• Regulator Outlet Pressures:
manifold vacuum readings by adjusting the governor
butterfly plates out of mechanical synchronism. – Natural Gas: approximately 1 inch-H2O (25.4
mm-H2O) negative. Not adjustable.
NOTE: Gas pressure to the carburetor(s) may be – Digester gas: 3 – 6 inch-H2O (76.2 – 152.4 mm-H2O)
somewhat less at full load than the initial no load setting. adjustable. Set at 4 – 5 inch-H2O (101.6 – 127
If the drop is more than 3 in. (76.2 mm) of water column, mm-H2O) initially.
an insufficient supply pressure to the regulator,
NOTE: Accurate regulator outlet pressure
undersize piping, incorrect regulator orifice size or
measurement cannot be made unless gas is flowing
inadequate regulator capacity could be the root cause.
through the regulator.1 If the top or spring side of the
regulator diaphragm case is vented to the carburetor air
horn with a balance line, then the water manometer used
for measuring outlet gas pressure must be the vent side
connected to the balance line instead of open to
atmosphere. Disconnect the balance line while checking
pressure if using an ounces per square inch gauge.
Form 6277-5
4.05-33 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
6. On one bank at a time, turn the adjustment toward
! WARNING
closed until intake manifold vacuum decreases
approximately 1/2 inch-Hg (12.7 mm-Hg).
Do not inhale gaseous fuels.
7. Vacuum should now be approximately 1 inch-Hg
Some components of fuel gas
(25.4 mm-Hg) less than the maximum noted in Step
are odorless, tasteless and
5 and the butterfly valve position should be similar.
highly toxic.
If not, repeat the adjustments to assure compliance
with procedure.
NOTE: Because the left bank and right bank governor
Natural Gas Operation butterfly valves are connected together, any adjustment
1. To operate on natural gas, the normally open on one bank that causes governor response will produce
solenoid valve in the line to the upright regulator on the same vacuum change on both banks.
each bank must be energized to shut off the gas
NOTE: Left bank and right bank intake manifold
supply to those regulators.
vacuum readings should be nearly equal. If more than
2. The mixture adjustment on each carburetor should 1/2 inch-Hg (12.7 mm-Hg) difference, check if the
be set at 2/3 – 3/4 rich unless they have already been governor butterfly valves are mechanically
set for digester gas operation. synchronized. Correct if necessary.
3. The butterfly valve mixture adjustment just
downstream of the inverted regulator is for natural NOTICE
gas. Set them approximately half open prior to initial
start-up. After start-up, adjust as required for best Never attempt to equalize bank-to-bank intake
idle operation. manifold vacuum readings by adjusting the governor
butterfly plates out of mechanical synchronism.
NOTICE
Digester Gas Operation
Adjust the butterfly mixture adjustment valve in small
increments. Small changes to the valve position result 1. For digester gas operation, the solenoid valve
in large changes to the air/fuel ratio. Allow the engine upstream from the upright digester gas regulator on
to stabilize between adjustments. each bank must be de-energized so that it is open.
2. With the engine running no load, check digester gas
4. Apply rated load at rated speed. A load that pressure between the regulator outlet and the
produces 3 – 6 inch-Hg (76.2 – 152.4 mm-Hg) intake carburetor inlet. Set at 4 – 5 inch-H2O (101.6 – 127
manifold vacuum is preferred for response to mixture mm-H2O), both banks equal to within 1/2 in. (12.7
adjustment. Carburetor throttles must be wide open. mm).
5. On one bank at a time, while observing intake 3. Apply rated load at rated speed. A load that
manifold vacuum, move the mixture adjustment produces 3 – 6 inch-Hg (76.2 – 152.4 mm-Hg) intake
butterfly valve toward full open. If intake manifold manifold vacuum is preferred for response to mixture
vacuum increases as the valve is opened, leave it at adjustment. Carburetor throttles must be wide open.
the maximum vacuum position. If vacuum remains
constant or decreases, move the valve toward the 4. On one bank at a time, while watching intake
closed position to lean the mixture. Note the point at manifold vacuum, turn the mixture adjustment
which vacuum just begins to decrease and back off capscrew on both carburetors from full rich toward
slightly to return to maximum vacuum. Note that lean until vacuum begins to decrease, then back off
reading. Do the same on the other bank. slightly to return to maximum vacuum. Turn the
adjustment the same amount on both carburetors,
If equipped with exhaust temperature indication, keeping them even. Do the same on the other bank.
adjust for maximum temperature. Exhaust
temperature is highest at the mixture ratio that If equipped with Air/Fuel Ratio Control, omit Step 5
produces maximum vacuum. and adjust in accordance with latest edition of
SA-7546.
If equipped with Air/Fuel Ratio Control, omit Steps
6 and 7. Adjust in accordance with latest edition of
SA-7546.
Form 6277-5
4.05-34 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
NOTE: Exhaust temperature may be observed instead 6- AND 12-CYLINDER GSI ENGINES OPERATING
of intake manifold vacuum. Adjust for maximum ON NATURAL GAS FUEL (850 – 900 BTU) WITH
temperature. LOW FUEL PRESSURE SYSTEM
RATED OR
Always verify that all cylinders are firing before NORMAL
adjusting the carburetor. Individual exhaust IDLE (INITIAL
MODEL OPERATING
thermocouples have been provided for this purpose. SETTING)
LOAD (FINAL
Failure to do so may cause serious engine damage. SETTING)
F3521GSI 5.5 5 ± 0.5
5. On one bank at a time, turn the mixture adjustment
capscrew on both carburetors toward lean until Physical Requirements
intake manifold vacuum decreases slightly,
• Main Fuel Supply
approximately 1/2 inch-Hg (12.7 mm-Hg). After
making this adjustment on both banks, vacuum – The gas supply pressure and regulation system
should be approximately 1 inch-Hg (25.4 mm-Hg) must be capable of supplying 6 in. (152 mm) of water
less than the maximum that was observed. This is a column (H2O) gas pressure to the carburetor(s).
compromise setting between maximum available – Fuel supply to comply with latest edition of
horse power and improved fuel economy. Further Waukesha’s S7884-6, Gaseous Fuel Specification.
economy improvement can be made by adjusting
each carburetor a little more toward lean. – Gas regulator sizing information:
6. If vacuum begins to decrease as soon as the • Use the Waukesha Technical Data to obtain the
carburetor mixture adjustment is moved away from engine fuel flow requirement (Heat Balance
full rich, or if the carbon monoxide (CO) level is below Section).
1% at full rich, increase the digester gas regulator • Select a regulator control spring capable of
outlet pressure 1/2 – 1 inch-H2O (12.7 – 25.4 mm- providing the gas over air (gas/air) pressure. See
H2O) of on both banks and recheck. Increase the Table 4.05-10 for the appropriate engine model.
regulator outlet pressure as much as required to An adjustment range of approximately ± 3 inch-
enable turning the carburetor mixture adjustment H2O (76.2 mm-H2O) of from nominal is desirable.
away from full rich without immediate vacuum • The regulator drop should be less than 1 inch-H2O
decrease or dropping below 0.38% CO. (25.4 mm-H2O) for the required flow range (see
NOTE: If the carburetor mixture adjustment capscrew Table 4.05-10).
can be turned 1/3 or more away from full rich before – Customer-furnished regulator(s) and gas shutoff
vacuum begins to decrease, reduce the digest gas valve(s) to be mounted as close to carburetor(s) as
regulator outlet pressure 1/2 – 1 inch-H2O (12.7 – 25.4 possible
mm-H2O) on each bank and recheck.
– Customer to supply 0.40 in. (10 mm) ID minimum
NOTE: For best fuel economy over a broad operating regulator balance line(s) to carburetor(s)
load range, the preferred compromise is reduced – Customer to supply gas pressure top location(s) for
regulator outlet pressure and maximum vacuum at instrumenting gas/air pressure differential
nearly full rich setting of the carburetor mixture
• Governor Linkage Adjustment
adjustment. If that adjustment combination causes
difficult starting, increase the regulator outlet pressure – Check/adjust governor to throttle control linkage to
as required. assure that throttle plate(s) is closed when the
governor is in the minimum stroke position. When
the governor goes to full stroke, the throttle plate(s)
must not overtravel the wide open, straight up and
down position. Up to 5° toward closing is preferred.
Form 6277-5
4.05-35 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
Carburetor Adjustment (Each Bank of 12-Cylinder
! WARNING
Engine)
Form 6277-5
4.05-36 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
5. Check the intake manifold pressures on both banks. Physical Requirements
If the difference is greater than 1/2 inch-Hg (12.7 • 35 – 50 psi (241 – 345 kPa) input line pressure to the
mm-Hg) recheck fuel settings. Fisher regulator(s)
NOTICE • 2 in. (5 cm) pipe size Fisher 99 regulator(s) (two on
Vee engines)
Do not attempt to equalize bank-to-bank pressures by – 1.125 in. (28.6 mm) orifice
adjusting throttle plates out of synchronization.
– Cadmium spring (3 – 12 in. [76 – 309 mm] of water
column [H2O])
6. Tighten locking nuts on carburetor metering valves.
– 0.38 in. (9.7 mm) ID minimum balance line to
NOTE: These instructions apply to sales and/or field carburetor air horn(s)
gas with a Low Heat Value (SLHV) of 850 – 900
BTU/ft3 (33 – 35 MJ/m3). • Regulator(s) are to be mounted as close to carburetor
as possible (normally furnished with engine).
NOTE: Gas/air pressure at the carburetor(s) may be
less at full load than at the initial idle setting. This drop Fuel System Adjustment Prior to Engine Start-Up
should not be more than 1-1/2 inch-H2O (38.1
mm-H2O). Any more pressure drop would indicate ! WARNING
insufficient supply pressure to the regulator, under size
piping, incorrect regulator orifice size, inadequate Do not inhale gaseous fuels.
regulator capacity or a malfunctioning regulator. Some components of fuel gas
are odorless, tasteless and
NOTICE highly toxic.
Form 6277-5
4.05-37 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
7. From the fitting in the connection between the
exhaust manifold and the turbocharger, install a
NOTICE
sample line with an ON/OFF valve to measure Always verify that all cylinders are firing before
exhaust manifold oxygen (O2) concentration (both adjusting the carburetor. Individual exhaust
banks on Vee engines). thermocouples have been provided for this purpose.
8. Install water manometer to measure gas over air Failure to do so may cause serious engine damage.
(gas/air) pressure differential between carburetor
gas inlet(s) and carburetor air horn(s) (both banks on 4. Follow break-in procedure up to nameplate rated
Vee engines). speed and load.
Fuel System Adjustment Settings After Engine 5. With engine at rated speed and load, verify that gas/
Start-Up air is within tolerance specified in Table 4.05-11. If
gas/air is not within specified limits at rated speed
1. At idle speed and no load, adjust the engine- and load, it will be necessary to bring the engine back
mounted Fisher 99 regulator(s) to the gas/air to idle conditions and readjust the regulator. When
pressure listed in Table 4.05-11. The banks are to the gas/air is within tolerance at rated speed and
be within 1/2 in. (12.7 mm) of water column on Vee load, adjust carburetor mixture capscrew(s) if
engines. required to obtain O2 level of 9.8 ± 0.1% measured
2. At idle speed and no load, adjust prechamber fuel before the turbocharger.
regulator to 6 ± 1 inch-Hg (152.4 ± 25.4 mm-Hg)
differential pressure (prechamber manifold over NOTICE
intake manifold pressure). Tighten locking nuts on
regulator. Do not attempt to equalize bank-to-bank pressures by
3. Follow break-in procedure up to rated speed and adjusting throttle plates out of synchronization.
100 BMEP, or approximately 10 in. (25.4 cm) of Hg
gauge intake manifold pressure (or 40 in. [101.6 cm] 6. On Vee engines, check intake manifold pressure on
of HgA. HgA = barometer plus intake manifold both banks. If this difference is greater than 1
pressure in inches of Hg). If unable to attain 100 inch-Hg (25.4 mm-Hg), recheck throttle plate
BMEP, adjust carburetor mixture capscrew(s) to synchronization.
obtain O2 level of 9.8 ± 0.5% measured before the 7. Special fuel system settings must be approved by
turbocharger (both banks on Vee engines). Turn the Waukesha Sales Engineering department.
capscrew in (clockwise) to increase oxygen level or
out (counterclockwise) to decrease O2 level. Set
engine at rated speed and add load to produce 100
BMEP.
Form 6277-5
4.05-38 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
ENGINES WITH IMPCO 600D CARBURETORS 6. Turn carburetor mixture capscrew(s) one turn
NATURAL GAS FUEL AIR / FUEL PRECHAMBER counterclockwise from the full clockwise position
(both banks on a Vee engine).
NOTE: Before making any fuel mixture or regulator
adjustments on a Vee block engine, both governor- 7. Make sure that the prechamber gas controls are
controlled throttle plates and the hand throttle located in properly vented to a safe location.
the carburetors must be balanced. Each pair of butterfly 8. Install a digital manometer, capable of measuring in
plates must fully close or open in unison. If adjustments Inches of Mercury (Hg), to measure the differential
are required, loosen the capscrews holding the universal pressure between the prechamber manifold and the
joint discs in the cross-shaft assembly, reposition the intake manifold (right bank only on Vee engines).
discs and tighten the capscrews. When checking the
9. From the same fitting in the prechamber manifold,
carburetor butterfly in the CLOSED position, back off the
install a sample line with an ON/OFF valve to
idle adjusting capscrew to allow the butterfly plate to fully
measure exhaust manifold oxygen (O2)
close. When the governor goes to full stroke, the
carburetor butterfly plate must not overtravel the wide- concentration (right bank only on Vee engines).
open, straight-up-and-down position. Up to 5° lean 10. From the fitting in the connection between the
toward closing is acceptable. The results of the above exhaust manifold and the turbocharger, install a
static adjustments can be observed when the engine is sample line with an ON/OFF valve to measure
running by comparing the manifold vacuum between exhaust manifold O2 concentration (both banks on a
banks. Readjust the idle adjusting capscrew. Vee engine).
Physical Requirements 11. Install a water manometer to measure the gas over
air pressure (Gas/Air) differential between the
• 35 – 50 psi (241 – 345 kPa) input line pressure to the carburetor gas inlet(s) and the carburetor air horn(s)
Fisher regulator(s) (both banks on a Vee engine).
• 2 in. (5 cm) pipe size Fisher 99 regulator(s) (2 on Vee
engines) Preliminary Settings After Engine Start-Up
– 1.125 in. (28.6 mm) orifice 1. At idle speed and no load, adjust the engine-
mounted Fisher 99 regulator(s) to the gas/air
– Cadmium spring (3 – 12 in. [7.62 – 30.48 cm] of water
pressure listed in Table 4.05-12. On a Vee engine,
column [H2O]).
the banks are to be within 1/2 inch-H2O (12.7 mm-
– 0.38 in. (9.7 mm) ID minimum balance line to H2O).
carburetor air horn(s)
2. Adjust the prechamber fuel only regulator to 6 ± 1/2
• Regulator(s) are to be mounted as close to carburetor inch-Hg (152.4 ± 12.7 mm-Hg) differential pressure
as possible (normally furnished with engine). (prechamber manifold over intake manifold
pressure).
Fuel System Adjustment Prior to Engine Start-Up
1. Set the primary or line regulator to provide Table 4.05-12: Gas Over Air Settings
35 – 50 psi (241 – 345 kPa) at the inlet to the engine-
ONLY FOR NATURAL GAS
mounted Fisher 99 regulator(s).
MODEL IDLE FULL LOAD
2. Open the prechamber fuel control valve by turning it
fully counterclockwise. F2895GL 7 ± 1/2 6 ± 1/2
3. Close the prechamber air control valve by turning it F3521GL 5 ± 1/2 4 ± 1/2
fully clockwise. L5790GL 7 ± 1/2 6 ± 1/2
4. Turn the prechamber fuel/air regulator 16 turns P9390GL 7 ± 1/2 6 ± 1/2
counterclockwise from the full clockwise position.
(The locking nut should be positioned against the NOTE: Gas over air pressure differential – inches water
square.) column.
5. Turn the prechamber fuel only regulator nine turns
counterclockwise from the full clockwise position.
(The locking nut should be positioned against the
square.)
Form 6277-5
4.05-39 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
NOTICE NOTICE
Always verify that all cylinders are firing before Do not attempt to equalize bank-to-bank pressures by
adjusting the carburetor. Individual exhaust adjusting throttle plates out of synchronization.
thermocouples have been provided for this purpose.
Failure to do so may cause serious engine damage. 2. On Vee engines, check the intake manifold pressure
on both banks. If the difference is greater than 1
3. Follow break-in procedure up to 100 BMEP. If unable inch-Hg (25 mm-Hg), recheck the throttle plate
to attain 100 BMEP, adjust carburetor(s) according synchronization (see Physical Requirements on
to Step 5 first, then return to Step 4. page 4.05-39).
4. Set engine at rated speed and add load to produce 3. (As applicable) check O2 level in prechamber
100 BMEP, or approximately 10 in. (25.4 cm) of Hg manifold. If it exceeds 6%, repeat Steps 4 – 10 in
gauge intake manifold pressure (or 40 in. [101.6 cm] Preliminary Settings After Engine Start-Up on page
of HgA. HgA = barometer plus intake manifold 4.05-39 and Steps 1 – 2 in Final Fuel System
pressure in inches of Hg). Adjustments on page 4.05-40.
5. Adjust the carburetor mixture capscrew(s) to obtain 4. Tighten locking nuts on regulators and control
an O2 level of 9.8 ± 0.3% measured before the valves.
turbocharger (both banks on Vee engines). Turn the
NOTE: These instructions apply to natural gas with a
carburetor mixture capscrew clockwise to increase
saturated low heat value (SLHV) of 850 – 900 BTU/ft3
O2 level or counterclockwise to decrease O2 level.
(33 – 35 MJ/m3)
6. Turn the fuel/air regulator clockwise to obtain
9 ± 1 inch-Hg (228.6 ± 25.4 mm-Hg) differential NOTE: Gas/Air pressure at the carburetor(s) may be
(prechamber manifold over intake manifold less at full load than at the initial idle setting. This drop
pressure). Measure right bank only on Vee engines. should not be more than 2 inch-H2O (50.8 mm-H2O). Any
greater pressure drop would indicate insufficient supply
7. Open prechamber air valve by turning it fully pressure to the regulator capacity or a malfunctioning
counterclockwise. regulator.
8. (As applicable) Adjust prechamber fuel control valve
and prechamber air control valve to obtain 3 ± 1% ENGINES OPERATING ON LOW BTU FUEL WITH
O2 level in the prechamber manifold (right bank only IMPCO 600D CARBURETORS
on Vee engines). If O2 is above 3% with both valves NOTE: Before making any fuel mixture or regulator
wide open, turn air valve toward CLOSED position adjustments on a Vee block engine, both governor-
(CW) until correct O2 level is attained. If O2 is below controlled throttle plates and the hand throttle located in
3% with both valves wide open, turn gas valve the carburetors must be balanced. Each pair of butterfly
toward closed position (CW) until correct O2 level is plates must fully close or open in unison. If adjustments
attained. are required, loosen the capscrews holding the universal
joint discs in the cross-shaft assembly, reposition the
9. Check exhaust O2 levels and reset to 9.8 ± 0.3% if
discs and tighten the capscrews. When checking the
required (see Step 5).
carburetor butterfly in the CLOSED position, back off the
10. Follow break-in procedure up to Rated Load. idle adjusting capscrew to allow the butterfly plate to fully
close. When the governor goes to full stroke, the
Final Fuel System Adjustments carburetor butterfly plate must not overtravel the wide-
1. Set engine at rated load and speed (in the field, open, straight-up-and-down position. Up to 5° lean
maximum load available if less than rated load). toward closing is acceptable. The results of the above
Check carburetor gas/air pressure(s) and reset if static adjustments can be observed when the engine is
required (see Table 4.05-12). Adjust carburetor running by comparing the manifold vacuum between
mixture capscrew(s) to obtain an O2 level of 9.8% ± banks. Readjust the idle adjusting capscrew.
0.1% measured before the turbocharger.
Form 6277-5
4.05-40 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
Physical Requirements Preliminary Settings After Engine Start-Up
• 35 – 50 psi (241 – 345 kPa) input line pressure to the 1. At idle speed and no load adjust the engine-mounted
Fisher regulator(s) Fisher 99 regulator(s) to the Gas/Air pressure listed
• 2 in. (5 cm) pipe size Fisher 99 regulator(s) (two on below. On a Vee engine, the banks are to be within
Vee engines) 1/2 in. (12.7 mm) of water column (H2O).
– 1.125 in. (28.6 mm) orifice Gas/Air pressure differential – inches of water
column:
– Red spring (0.25 – 2 psig [1.7 – 13.8 kPa])
– 0.38 in. (9.7 mm) ID minimum balance line to 400 BTU/Ft3 = 30 in. (762 mm)
carburetor air horn(s) 500 BTU/Ft3 = 12 in. (305 mm)
• Regulator(s) are to be mounted as close to carburetor 600 BTU/Ft3 = 0.5 in. (13 mm)
as possible (normally furnished with engine).
2. Adjust prechamber fuel only regulator to 13 ± 1/2
Fuel System Adjustment Prior to Engine Start-Up inch-Hg (33.02 ± 1.27 cm-Hg) differential pressure
1. Set the primary or line regulator to provide (prechamber manifold over intake manifold
35 – 50 psi (241 – 345 kPa) at the inlet to the engine- pressure).
mounted Fisher 99 regulator(s). 3. Follow break-in procedure and set engine at rated
2. Turn the prechamber fuel only regulator fully speed and add load to produce 50 BMEP, or
clockwise (locking nut positioned against the approximately 0 in. (0 mm) of Hg gauge intake
square), and then five turns counterclockwise. manifold pressure (or 30 in. [76.2 mm] of HgA. HgA
= barometer plus intake manifold pressure in inches
3. Turn carburetor mixture capscrew(s) full open
of Hg).
(counterclockwise) (both banks on Vee engines).
4. Adjust the Fisher 99 regulator(s) to obtain the
! WARNING percent O2 level (± 0.3%) shown in Figure 4.05-34
for the specific fuel being run (both banks on Vee
Do not inhale gaseous fuels. engines). To increase the exhaust O2 level, lower the
Some components of fuel gas gas/air pressure. To decrease the exhaust O2 level,
are odorless, tasteless and raise the gas/air pressure.
highly toxic.
Form 6277-5
4.05-41 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
2. On Vee engines, check the intake manifold pressure
on both banks. If the difference is greater than 1 inch-
9.4 Hg (25 mm-Hg), recheck the throttle plate
synchronization (see Physical Requirements on
9.2 page 4.05-41). Do not attempt to equalize bank-to-
bank pressures by adjusting throttle plates out of
EXHAUST OXYGEN (%)
synchronization.
9.0
3. If improved carburetor tracking is required, the
carburetor mixture capscrews may be used.
8.8
4. Tighten locking nuts on regulators.
NOTE: These instructions apply to sales and/or field
8.6 = 1.68
(LOW BTU FUEL)
gas with a low heat value (lhv) of 400 – 600 BTU/ft3.
8.4
NOTE: Gas/air pressure at the carburetor(s) may be
less at full load than at the initial idle setting. This drop
8.2 should not be greater than 2 inch-H2O (50.8 mm-H2O).
350 450 550 650 Any more pressure drop would indicate insufficient
FUEL SATURATED LOW HEAT VALVE supply pressure to the regulator capacity or a
(SLHV) (BTU/FT3) malfunctioning regulator.
AIR/ FUEL ACTUAL
= AIR/ FUEL STOICHIOMETRIC
6- AND 12-CYLINDER ENGINES OPERATING ON
NATURAL GAS FUEL (850 – 900 BTU) WITH LOW
Figure 4.05-34: Exhaust Oxygen vs. Fuel Saturated Low FUEL PRESSURE SYSTEM
Heat Value
NOTE: Before making any fuel mixture or regulator
NOTICE adjustments on a Vee block engine, both governor-
controlled throttle plates and the hand throttle located in
Always verify that all cylinders are firing before the carburetors must be balanced. Each pair of butterfly
adjusting the carburetor. Individual exhaust plates must fully close or open in unison. If adjustments
thermocouples have been provided for this purpose. are required, loosen the capscrews holding the universal
Failure to do so may cause serious engine damage. joint discs in the cross-shaft assembly, reposition the
discs and tighten the capscrews. When checking the
5. At rated speed and 100 BMEP, or approximately carburetor butterfly in the CLOSED position, back off the
40 inch-Hg (101.6 cm-Hg) absolute intake manifold idle adjusting capscrew to allow the butterfly plate to fully
pressure, adjust Fisher 99 regulator(s) to obtain the close. When the governor goes to full stroke, the
percent exhaust O2 level (± 0.3%) shown in Figure carburetor butterfly plate must not overtravel the wide-
open, straight-up-and-down position. Up to 5° lean
4.05-34 for the specific fuel being run (both banks on
toward closing is acceptable. The results of the above
Vee engines).
static adjustments can be observed when the engine is
6. Follow break-in procedure up to rated load. running by comparing the manifold vacuum between
banks. Readjust the idle adjusting capscrew.
Final Fuel System Adjustments
1. Set engine at rated load and speed (in the field, Physical Requirements
maximum load available if less than rated load). • Main Fuel Supply
Adjust Fisher 99 regulator(s) to obtain the percent
– Gas supply pressure and regulation system must be
exhaust O2 level (± 0.1%) shown in Figure 4.05-34
capable of supplying 6 in. (152.4 mm) water column
for the specific fuel being run. Adjust both banks on
(H2O) gas pressure to the carburetor(s).
Vee engines.
– Fuel supply to comply with latest edition of
NOTICE Waukesha’s Gaseous Fuel Specification S-7884-6.
Form 6277-5
4.05-42 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
– Main Gas Regulator Sizing Information:
NOTICE
• Use the Waukesha Technical Data to obtain the
engine fuel flow requirement (heat balance If gas compressor is used to develop prechamber fuel
section). pressure, compressor oil carryover should be
• Select a regulator control spring capable of controlled to meet this fuel specification.
providing the gas over air (gas/air) pressure listed
in Table 4.05-13 for the appropriate engine model. – Customer-furnished gas shutoff valve to be
An adjustment range of approximately 3 inch-H2O mounted as close to engine as possible.
(76 mm-H2O) of from nominal is desirable. – Check/adjust governor to throttle control linkage to
assure that throttle plate(s) is closed when the
• The regulator droop should be less than 1 inch-
governor is in the minimum stroke position. When
H2O (25.4 mm-H2O) for the required flow range.
the governor goes to full stroke, the throttle plate(s)
Table 4.05-13: Gas Over Air Settings must not over travel the wide open, straight up and
down position. Up to 5° toward closing is preferred.
RATED OR
NORMAL Fuel System Adjustment Prior to Engine Start-Up
IDLE (INITIAL
MODEL OPERATING 1. Turn prechamber fuel regulator fully in (clockwise)
SETTING)
LOAD (FINAL (locking nut positioned against the square) and then
SETTING) nine turns out (counterclockwise).
F2895GL 2. Turn carburetor metering valve(s) to 15°.
6.5 6 ± 0.5
L5790GL
F3521GL 5.5 5 ± 0.5
! WARNING
NOTE: Gas over air pressure differential – inches water Do not inhale gaseous fuels.
column. Some components of fuel gas
– Customer-furnished regulator(s) and gas shutoff are odorless, tasteless and
valve(s) to be mounted as close to carburetor(s) as highly toxic.
possible.
– Customer to supply 0.40 in. (10.2 mm) ID minimum
regulator balance line(s) to carburetor(s). 3. Make sure that the prechamber gas controls are
– Customer to supply gas pressure top location(s) for properly vented to a safe location.
instrumenting gas/air pressure differential. 4. Install a digital manometer, capable of measuring
• Prechamber Fuel Supply inches of mercury (Hg), to measure the differential
– 30 – 50 psig (206 – 345 kPa) gas supply pressure to pressure between the prechamber manifold and the
prechamber system. This pressure must be intake manifold (right bank only on a Vee engine).
available for engine start-up. 5. Install an exhaust emission sample probe in the
– Maximum prechamber fuel temperature not to connection between the exhaust manifold and the
exceed 225°F (107°C). turbocharger. connect a sample line with an ON/OFF
valve to the sample probe for measuring exhaust
– Prechamber gas flow requirement for natural gas is manifold oxygen (O2) concentration (both banks on
4.5 SCFM for a VHP 6-cylinder engine and
Vee engine).
9.0 SCFM for a VHP 12-cylinder engine.
6. Install a water manometer to measure the gas/air
– Prechamber fuel supply to comply with latest edition
pressure differential between the carburetor gas
of Waukesha’s Gaseous Fuel Specification
inlet and the carburetor air inlet (both banks on Vee
S-7884-6.
engines).
Form 6277-5
4.05-43 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
Preliminary Settings After Engine Start-Up Final Fuel System Adjustments
1. At idle speed and no load adjust the main 1. Set engine at rated load and speed (in the field,
regulator(s) to the gas/air pressure listed in Table maximum load available if less than rated load).
4.05-13. The banks are to be within 1/2 inch-H2O Check carburetor gas/air pressure(s) and reset if
(12.7 mm-H2O) on Vee engines. required (see Table 4.05-13). Adjust carburetor
metering valve(s) to obtain O2 level of 9.8 ± 0.1%
2. Adjust prechamber fuel regulator to 5 ± 1 inch-Hg
measured before the turbocharger.
(127 ± 25.4 mm-Hg) differential pressure
(prechamber manifold over intake manifold
NOTICE
pressure).
Do not attempt to equalize bank-to-bank pressures by
NOTICE adjusting throttle plates out of synchronization.
Always verify that all cylinders are firing before
adjusting the carburetor. Individual exhaust 2. On Vee engine, check the intake manifold pressures
thermocouples have been provided for this purpose. on both banks. If the difference is greater than 1 inch-
Failure to do so may cause serious engine damage. Hg (25.4 mm-Hg); recheck the Physical
Requirements on page 4.05-42 for throttle plate
synchronization.
3. Follow break-in procedure up to 100 BMEP. If unable
to attain 100 BMEP, adjust carburetor according to 3. Tighten locking nuts on prechamber regulator and
Step 5 first, then return to Step 4. carburetor metering valve(s).
4. Set engine at rated speed and add load to produce NOTE: These instructions apply to sales and/or field
100 BMEP, or approximately 10 in. (25.4 cm) of Hg gas with a low heat value (SLHV) of 850 – 900 BTU/ft3
gauge intake manifold pressure (or 40 in. [101.6 cm] (33 – 35 MJ/m3).
of HgA, HgA = barometer plus intake manifold
pressure in inches of Hg). NOTE: Gas/air pressure of the carburetor(s) may be
less at full load than at the initial idle setting. This drop
5. Adjust carburetor metering valve(s) to obtain an O2 should not be more than 1-1/2 inch-H2O (38 mm-H2O).
level of 9.8 ± 0.5% measured before the Any more pressure drop would indicate insufficient
turbocharger. Turn the metering valve(s) toward supply pressure to the regulator, undersize piping,
“lean” (clockwise) to increase O2 level or towards incorrect regulator orifice size, inadequate regulator
“rich” (counterclockwise) to decrease O2 level. capacity or a malfunctioning regulator.
Form 6277-5
4.05-44 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
NOTE: Before making any fuel mixture or regulator
! WARNING
adjustments on a Vee block engine, both governor-
controlled throttle plates and the hand throttle located in
the carburetors must be balanced. Each pair of butterfly Do not inhale gaseous fuels.
plates must fully close or open in unison. If adjustments Some components of fuel gas
are required, loosen the capscrews holding the universal are odorless, tasteless and
joint discs in the cross-shaft assembly, reposition the highly toxic.
discs and tighten the capscrews. When checking the
carburetor butterfly in the CLOSED position, back off the
idle adjusting capscrew to allow the butterfly plate to fully
close. When the governor goes to full stroke, the 4. Make sure that the prechamber gas controls are
carburetor butterfly plate must not overtravel the wide- properly vented to a safe location.
open, straight-up-and-down position. Up to 5° lean 5. Install a digital manometer, capable of measuring
toward closing is acceptable. The results of the above inches of mercury (Hg), to measure the differential
static adjustments can be observed when the engine is pressure between the prechamber manifold and the
running by comparing the manifold vacuum between intake manifold (right bank only on a Vee engine).
banks. Readjust the idle adjusting capscrew. 6. From the fitting in the connection between the
Physical Requirements exhaust manifold and the turbocharger, install a
sample line with an ON/OFF valve to measure
• 35 – 50 psi (241 – 345 kPa) input line pressure to the exhaust manifold oxygen (O2) concentration (both
Fisher regulator(s)
banks on a Vee engine).
• 2 in. (5.08 cm) pipe size Fisher 99 regulator(s) (two on
7. Install a water manometer to measure the gas over
Vee engines)
air (gas/air) pressure differential between the gas
– 1.125 (28.6 mm) in. orifice pressure regulator outlets and the carburetor air horn
– Low heat value above 600 BTU/ft3 (23.6 MJ/m3). (both banks on a Vee engine).
Use red spring.
Preliminary Settings After Engine Start-Up
– Low heat value below 600 BTU/ft3 (23.6 MJ/m3).
Use yellow spring. NOTE: Fuel adjustments can be performed
independently on low or high BTU fuel, in any order.
– 0.38 in. (9.7 mm) ID minimum balance line to
carburetor air horn(s) Landfill or Digester Gas (Low BTU Fuel)
• Regulator(s) are to mounted as close to carburetor as 1. Switch fuel solenoids to low BTU fuel.
possible (normally furnished with engine). 2. At idle speed and no load, adjust the low BTU fuel
Fisher 99 regulator(s) to the gas/over air pressure
Fuel System Adjustment Prior to Engine Start-Up shown in Figure 4.05-35 for the specific fuel being
1. Set the primary or line regulator to provide run (± 2 in. [50.8 mm] of water column [H2O]). On a
35 – 50 psi (241 – 345 kPa) at the inlet to the engine- Vee engine the banks are to be within 1/2 inch-H2O
mounted Fisher 99 regulator(s). (12.7 mm-H2O).
2. Turn the prechamber fuel only regulator fully
clockwise (locking nut positioned against the
square), and then five turns counterclockwise.
3. (Butterfly valves method) Turn mixture adjustment
butterfly valve(s) full open and turn carburetor
mixture capscrew(s) fully counterclockwise (both
banks on Vee engines).
Or
(Carburetor and butterfly method) Turn the
carburetor mixture capscrew(s) to full clockwise
position, then back out two turns. Turn mixture
adjusting butterfly valve(s) full open (both banks on
a Vee engine).
Form 6277-5
4.05-45 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
8.8
(Carburetor and butterfly method) At rated
AIR/FUEL ACTUAL
= AIR/FUEL STOICHIOMETRIC speed and load, or approximately 58 in. (147.32
8.6 cm) of HgA intake manifold pressure (in the
500 600 700 800 900 field, maximum load available if less than rated
FUEL SATURATED LOW HEAT VALUE load) adjust the carburetor mixture capscrew(s)
(SLHV) (BTU/ft3) to obtain the percent O2 (± 0.1%) shown in
Figure 4.05-36 for the specific fuel being run.
Figure 4.05-36: Exhaust Oxygen vs. Fuel Saturated Low
Heat Value
Form 6277-5
4.05-46 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
6. Final high BTU fuel system adjustment.
NOTICE
a. At rated speed and load, or approximately 58 in.
Do not attempt to equalize bank-to-bank pressures by (147.32 cm) of HgA intake manifold pressure (in
adjusting throttle plates out of synchronization. the field, maximum load available if less than
rated load) adjust the mixture adjustment
b. On a Vee engine, adjust both banks and check butterfly valve(s) to obtain the percent O2 (±
the intake manifold pressure on both banks. If the 0.1%) shown in Figure 4.05-36 for the specific
difference is greater than 1 inch-Hg (25.4 fuel being run.
mm-Hg), recheck Physical Requirements on
page 4.05-45 for throttle plate synchronization. NOTICE
c. Tighten locking nuts on low BTU regulators and
Do not attempt to equalize bank-to-bank pressures by
locking capscrews on the butterfly mixture
adjusting throttle plates out of synchronization.
adjusting valves.
Natural Gas (High BTU Fuel) b. On a Vee engine, adjust both banks and check
1. Switch fuel solenoids to high BTU fuel. the intake manifold pressure on both banks. If the
difference is greater than 1 inch-Hg (25.4 mm-
2. At idle speed and no load, adjust the high BTU fuel Hg), recheck Physical Requirements on page
Fisher 99 regulator(s) to the gas/air pressure shown 4.05-45 for throttle plate synchronization.
in Figure 4.05-36 for the specific fuel being run (± 2
inch-H2O [± 51 mm-H2O]). On a Vee engine, the c. Tighten locking nuts on high BTU regulators and
lock capscrews on butterfly mixture adjusting
banks are to be within 1/2 inch-H2O (12.7 mm-H2O).
valves.
3. Adjust or recheck prechamber fuel regulator
adjustment at 10 ± 1 inch-Hg (25.4 ± 2.54 cm-Hg) NOTE: These instructions apply to sales and/or field
differential pressure between the prechamber gas with a low heat value (lhv) of 450 – 900 BTU/ft3
manifold and the intake manifold pressure. (17.7 – 35.4 MJ/m3) used in dual fuel applications.
4. At rated speed and 50 BMEP, or approximately NOTE: Gas/air pressure to the carburetor may be less
28 in. (71.12 cm) of HgA intake manifold pressure, at full load than initial idle setting.
adjust the high BTU fuel Fisher 99 regulator(s) (both
banks on a Vee) to obtain the percent O2 (± 0.3%) ENGINES OPERATING ON NATURAL GAS
shown in Figure 4.05-36 for the specific fuel being (PRIMARY FUEL) AND HD-5 PROPANE VAPOR
run. (SECONDARY FUEL FOR EMERGENCY BACKUP)
NOTE: Before making any fuel mixture or regulator
NOTICE adjustments on a Vee block engine, both governor-
controlled throttle plates and the hand throttle located in
Always verify that all cylinders are firing before the carburetors must be balanced. Each pair of butterfly
adjusting the carburetor. Individual exhaust plates must fully close or open in unison. If adjustments
thermocouples have been provided for this purpose. are required, loosen the capscrews holding the universal
Failure to do so may cause serious engine damage. joint discs in the cross-shaft assembly, reposition the
discs and tighten the capscrews. When checking the
5. At rated speed and 100 BMEP, or approximately carburetor butterfly in the CLOSED position, back off the
40 in. (101.6 cm) of HgA intake manifold pressure, idle adjusting capscrew to allow the butterfly plate to fully
turn the mixture adjustment butterfly valve(s) (both close. When the governor goes to full stroke, the
banks on a Vee) to obtain the percent O2 (0.3%) carburetor butterfly plate must not overtravel the wide-
shown in Figure 4.05-36 for the specific fuel being open, straight-up-and-down position. Up to 5° lean
run. Turn the mixture adjustment butterfly valve(s) toward closing is acceptable. The results of the above
toward the closed position to increase O2 level or static adjustments can be observed when the engine is
toward the open position to decrease the O2 level. running by comparing the manifold vacuum between
Do not readjust the Fisher 99 regulator (high BTU banks. Readjust the idle adjusting capscrew.
fuel) gas/air pressure.
Form 6277-5
4.05-47 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
Physical Requirements 8. Install a water manometer to measure the gas over
• 30 – 50 psi (206 – 345 kPa) line pressure to Fisher 99 air (gas/air) pressure differential between the gas
(natural gas) regulator(s) pressure regulator outlets and the carburetor air horn
(both banks on Vee engines).
• 2 in. pipe size Fisher regulator(s)
9. Install a digital manometer, capable of measuring
– 1.125 in. (28.6 mm) orifice inches of Hg, to measure carburetor air inlet
– Saturated Low Heat Value 850 BTU/ft3 pressure (both banks on Vee engines).
(33.4 MJ/m3) and above. Cadmium spring. 10. Turn turbo air bypass valves to half open (both banks
– 0.38 in. (9.7 mm) ID minimum balance line to on Vee engines).
carburetor air horn
NOTE: Air bypass valves are preset at the factory.
• 30 – 35 psi (206 – 345 kPa) line pressure to Waukesha
11. Preset the engine-mounted propane regulators, by
Modified Fisher S-211 (propane) regulator(s)
removing the closing cap and adjusting the upper
• 2 in. Pipe Size Fisher – Propane Regulator control spring seat 1 in. (25.4 mm) below the top
– 0.75 (19.1 mm) in. orifice edge of the regulator case (both banks on Vee
engines).
– Saturated Low Heat Value 2250 BTU/ft3
88.46 MJ/m3 (nominal). Gray spring. Fuel System Adjustment After Engine Start-Up
– 0.38 in. (9.7 mm) ID minimum balance line to NOTE: Fuel adjustments to be performed
carburetor air horn independently on natural gas first and HD-5 propane
• Regulators described above are furnished with second.
engine.
Natural Gas (Low BTU)
Fuel System Adjustments Prior to Engine Start-Up 1. Switch solenoids for natural gas operation (both
1. Set the natural gas primary or line regulators to banks on Vee engines).
provide 30 – 50 psi (206 – 345 kPa) at the inlet to the 2. Switch ignition timing to natural gas fuel operation.
engine-mounted Fisher 99 regulators. See specified ignition system wiring and instruction
2. Set the propane line regulators to provide 30 – 35 psi for proper timing control.
(206 – 241 kPa) at the inlet to the engine-mounted 3. At idle speed and no load, adjust the natural gas fuel
propane regulators. Fisher 99 regulator(s) to a gas over air (gas/air)
3. Turn the prechamber fuel regulator adjusting differential pressure of 7 ± 1/2 in. (177 ± 12.7 mm) of
capscrews fully clockwise (locking nut positioned water column (H2O). On Vee engines, banks to be
against the square). Then turn the natural gas within 1/2 inch-H2O (12.7 mm-H2O).
regulator adjustment nine turns counterclockwise 4. Adjust prechamber fuel regulator adjustment to
and the propane regulator adjustment twelve turns 6 ± 1 inch-Hg (152.4 ± 25.4 mm-Hg) differential
counterclockwise. pressure between the prechamber manifold and
4. Turn mixture adjusting butterfly valves half open. intake manifold pressure.
Turn the carburetor mixture capscrew(s) to the full 5. At rated speed and 50 BMEP, or approximately
counterclockwise position (both banks on Vee 28 in. (71.12 mm) of HgA intake manifold pressure,
engines). adjust the natural gas Fisher 99 regulator(s) (both
5. Make sure that the prechamber gas controls are banks on Vee engines) to obtain an exhaust O2 level
properly vented to a safe location. of 9.8 ± 0.3%.
6. Install a digital manometer, capable of measuring
inches of mercury (Hg), to measure the differential NOTICE
pressure between the prechamber manifold and the
intake manifold (right bank only on a Vee engine). Always verify that all cylinders are firing before
adjusting the carburetor. Individual exhaust
7. From the fitting in the exhaust manifold before the thermocouples have been provided for this purpose.
turbocharger, install a sample line with an ON/OFF Failure to do so may cause serious engine damage.
valve to measure exhaust manifold oxygen (O2)
concentration (both banks on Vee engines).
Form 6277-5
4.05-48 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
6. At rated speed and 100 BMEP, or approximately 5. At rated speed and no load, turn the mixture
40 in. (101.6 cm) of HgA intake manifold pressure, adjusting butterfly valves (both banks on Vee
turn the mixture adjusting butterfly valves (both engines) to obtain an exhaust O2 level of
banks on Vee engines) to obtain an exhaust O2 level 10.0 ± 1.0%. Turn the mixture adjusting valves
of 9.8 ± 0.3%. Turn the mixture adjusting butterfly toward the closed position to increase O2 level, or
valves, toward the CLOSED position to increase O2 toward the open position to decrease O2 level.
level, or toward the OPEN position to decrease O2
6. At rated speed and 60 BMEP, or approximately
level. Do not readjust Fisher 99 regulators (natural 28 in. (71.12 mm) of HgA intake manifold pressure,
gas fuel) gas/air pressure. turn the air bypass valves (both banks on Vee
7. Final natural gas fuel system adjustments engines) to obtain carburetor air inlet pressure of 42
a. At rated speed and load, or approximately 58 in. ± 1 in. (106.68 ± 2.54 cm) of HgA. On Vee engines,
(147.32 cm) of HgA intake manifold pressure (in banks to be within 1 inch-Hg (25.4 mm-Hg). Turn the
the field, use maximum load available if less than mixture adjusting butterfly valves (both banks on
rated load), turn the mixture adjusting butterfly Vee engines) to obtain an exhaust O2 level of 9.6 ±
valves (both banks on Vee engines) to obtain an 0.5%.
exhaust O2 level of 9.8 ± 0.1% for natural gas.
NOTICE
b. On Vee engines, check the intake manifold
pressure on both banks. If the difference is Always verify that all cylinders are firing before
greater than 1 inch-Hg (25.4 mm-Hg), recheck adjusting the carburetor. Individual exhaust
Physical Requirements on page 4.05-48 for thermocouples have been provided for this purpose.
throttle plates synchronization. Failure to do so may cause serious engine damage.
Form 6277-5
4.05-49 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
NOTE: These instructions apply to sales and/or field – Customer-furnished regulator(s) and gas shutoff
gas with a saturated low heat value (SLHV) of valve(s) to be mounted as close to carburetor(s) as
850 – 900 BTU/ft3 (33 – 35 MJ/m3) for natural gas and possible.
2,250 BTU/ ft3 (88 MJ/m3) (nominal) for HD-5 propane – Customer to supply 0.40 in. (10.2 mm) ID minimum
fuel used in dual fuel applications. regulator balance line(s) to carburetor(s).
NOTE: Gas/air pressure to the carburetor may be less – Customer to supply gas pressure top location(s) for
at full load than the initial idle setting. instrumenting gas/air pressure differential.
• Prechamber Fuel Supply
6- AND 12-CYLINDER ENGINES OPERATING ON
LANDFILL GAS FUEL (400 – 500 BTU) DIGESTER – 30 – 50 psig (206 – 345 kPa) gas supply pressure to
GAS FUEL (500 – 650 BTU) WITH LOW FUEL prechamber system. This pressure must be
PRESSURE SYSTEM available for engine start-up.
– Maximum prechamber fuel temperature not to
Physical Requirements
exceed 225°F (107°C).
• Main Fuel Supply
– Prechamber gas flow requirement for natural gas is
– Gas supply pressure and regulation system must be 6.5 SCFM for a VHP 6-cylinder engine and
capable of supplying 6 in. (152.4 mm) of water 13.0 SCFM for a VHP 12-cylinder engine.
column (H2O) gas pressure to the carburetor(s).
– Prechamber fuel supply to comply with latest edition
– Fuel supply to comply with latest edition of of Waukesha’s Gaseous Fuel Specification
Waukesha’s Gaseous Fuel Specification S-7884-6. S-7884-6.
– Main gas regulator sizing information:
NOTICE
• Use the Waukesha Technical Data to obtain the
engine fuel flow requirement (heat balance If gas compressor is used to develop prechamber fuel
section). pressure, compressor oil carryover should be
• Select a regulator control spring capable of controlled to meet this fuel specification.
providing the gas over air (gas/air) pressure listed
in Table 4.05-14 for the appropriate engine model. – Customer-furnished gas shutoff valve to be
an adjustment range of approximately ± 3 inch- mounted as close to engine as possible.
H2O (76.2 mm-H2O) of from nominal is desirable. • Check/Adjust governor to throttle control linkage to
• The regulator droop should be less than 1 inch- assure that throttle plate(s) is closed when the
H2O (25.4 mm-H2O) for the required flow range. governor is in the minimum stroke position. When the
governor goes to full stroke, the throttle plate(s) must
Table 4.05-14: Gas Over Air Settings not overdrive the wide open, straight up and down
position. Up to 5° toward closing is preferred.
GAS OVER AIR PRESSURE DIFFERENTIAL – IN.
WATER COLUMN Fuel System Adjustment Prior to Engine Start-Up
RATED OR 1. Turn prechamber fuel regulator fully clockwise
NORMAL (locking nut positioned against the square) and then
IDLE (INITIAL
MODEL OPERATING five turns counterclockwise.
SETTING)
LOAD (FINAL 2. Turn carburetor metering valve(s) to 20°.
SETTING)
F2895GL, ! WARNING
6.5 6 ± 0.5
L5790GL
Do not inhale gaseous fuels.
F3521GL 5.5 5 ± 0.5
Some components of fuel gas
NOTE: Gas over air pressure differential – inches water are odorless, tasteless and
column. highly toxic.
Form 6277-5
4.05-50 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
3. Make sure that the prechamber gas controls are
properly vented to a safe location.
NOTICE
4. Install a digital manometer, capable of measuring Since the Vee engines are “cross blown” on LFPS
inches of mercury (Hg), to measure the differential (draw-thru) engines, carburetor adjustment on one
pressure between the prechamber manifold and the bank affects performance of the opposite bank
intake manifold (right bank only on a Vee engine). cylinders. In other words, adjustment of the left bank
5. Install an exhaust emission sample probe in the carburetor will change the oxygen level and
connection between the exhaust manifold and the temperature of the exhaust in the right bank (and vice
turbocharger. Connect a sample line with an ON/ versa).
OFF valve to the sample probe for measuring
exhaust manifold oxygen (O2) concentration (both
NOTE: For example: an O2 level of 11% is measured in
banks on Vee engines).
the right bank exhaust. To lower this O2 level back to the
6. Install a water manometer to measure the gas/air specified 9.8%, the left bank carburetor metering valve
pressure differential between the carburetor gas will have to be adjusted.
inlet and the carburetor air inlet (both banks on Vee
engines). 6. Follow break-in procedure up to rated load.
NOTICE
9.4
Always verify that all cylinders are firing before
adjusting the carburetor. Individual exhaust 9.2
EXHAUST OXYGEN (%)
Form 6277-5
4.05-51 © Copyright 2023, INNIO's Waukesha Engine
FUEL SYSTEM MAINTENANCE
2. On Vee engines, check the intake manifold
pressures on both banks. If the difference is greater
than 1 in. (25.4 mm) of Hg, recheck Physical
Requirements on page 4.05-50 for throttle plate
synchronization.
NOTICE
Do not attempt to equalize bank-to-bank pressures by
adjusting throttle plates out of synchronization.
Form 6277-5
4.05-52 © Copyright 2023, INNIO's Waukesha Engine
SECTION 4.10
IGNITION SYSTEM MAINTENANCE
Form 6277-5
4.10-1 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM MAINTENANCE
3. Install the terminal nut.
1 4. See Table 1.15-18 1/2 in. Reach Spark Plugs (Used
2 on G and GSI, and 1/2 in. Reach Spark Plug Carriers
on GL Only) on page 1.15-29 and Table
1.15-19 VHP GL 13/16 in. Reach Spark Plugs (Used
With 13/16 in. Reach Spark Plug Carriers Only) on
3 page 1.15-30 and set the spark plug gap.
NOTICE
The presence of oil or grease on the ceramic insulator
of the spark plug can cause flashover. Flashover, a
condition where the spark fails to jump the gap
4 because of an easier path to ground, results in misfire.
When using Actrel 3338L for cleaning, always wear
10 rubber gloves to prevent the cleaner from touching the
hands, as burning may occur.
! WARNING
Form 6277-5
4.10-2 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM MAINTENANCE
1 1
3 3
NOTICE
Do not use oil or anti-seize compound on the spark
plug threads. The spark plug may be overtorqued if
oiled. Overtorquing distorts the spark plug and may
crack the ceramic construction. Anti-seize compound
may foul the firing tip, resulting in a plug shorted to
ground.
By missing the threaded hole in the spark plug carrier
bore, the spark plug gap may be inadvertently closed
or altered. Exercise caution to avoid bumping the
electrodes into the spark plug carrier counterbore. Figure 4.10-4
8. The rubber vent cap is pre-cut at the factory, but
7. Torque the spark plug to specifications. See Ignition needs to be pulled back initially to ensure proper
System in Table 1.15-17 Critical Engine Torque operation. About half of the rubber vent cap
Values on page 1.15-28 for specific torque values. circumference is cut; the remaining half acts as a
NOTE: The rubber recess cover keeps dirt and debris rubber hinge.
out of the spark plug well and functions as a rain shield 9. Using your thumb, gently pull the rubber vent cap
for those engines that are outside. Any accumulation of toward the center hole of the spark plug recess cover
rain water in the spark plug well can short out the spark until the vent hole is exposed (see Figure 4.10-5).
plug, resulting in a misfire or a stalled engine. Before Release the vent cap. The cap should close.
installing VHP spark plug recess covers (see Figure
4.10-4), check to be sure that the rubber vent caps are
opened. If the rubber vent caps are not opened, the
spark plug recess covers and spark plug extensions may
pop off the spark plugs due to pressure buildup.
Form 6277-5
4.10-3 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM MAINTENANCE
4 2
Figure 4.10-5
10. During normal operation, pressures generated in the
spark plug recess will vent through the vent hole in
3
the spark plug recess cover. During venting of
pressure, the upper half of the rubber vent cap will
pop up and then return to the CLOSED position.
NOTE: If the rubber vent cap is torn off, the spark plug
Figure 4.10-6: G, GSI Engines CSA Spark Adapter and
recess cover should be replaced when it is to be used in Coil
outdoor environments.
11. Install the spark plug recess cover on the spark plug 1 - Connector Cable 3 - Rubber Recess
extension assembly. 2 - Spark Plug Adapter Cover
4 - Coil
NOTE: The rubber spark plug boots must be installed
on the P/N 211357H spark plug extensions. These boots 2. Remove the rubber recess cover from the bottom of
prevent flashover from the spark plug insulators. the spark plug recess. The recess cover is cut on one
side to allow the recess cover to be removed from
NOTE: Krytox GPL-206 (P/N 489341) is a higher- the spark plug adapter.
temperature fluorinated grease.
3. Remove the coil, spark plug adapter and spark plug
12. On P/N 211357H extension assemblies, lightly coat from the cylinder head (see Figure 4.10-7).
the inside surface of the spark plug boot on the
extension with a high-performance fluorinated
grease such as Krytox GPL-206 (P/N 489341) or 1
equivalent. Install the spark plug extension
assembly to spark plug (see Figure 4.10-1).
13. Attach the spark plug cable to the ignition coil. Make
sure that the cable terminal connection bottoms out
in the coil contact well. Fit the rubber boot over the
coil terminal connection. On P/N 211357H
extensions, ensure the rubber boot is fitted over the
upper end of the spark plug extension. Secure the
cable by snapping it into the cable clip mounted on 3
the rocker arm cover.
2
Form 6277-5
4.10-4 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM MAINTENANCE
SPARK PLUG INSTALLATION – CSA (G, GSI
! CAUTION
ENGINES)
1. Install the steel gasket on the spark plug (see Figure 3. Verify that the spark plug is clean. If necessary, use
4.10-8). Use only new steel gaskets. Verify that the a dielectric solvent to remove any grease or oily
gasket is flat against the gasket seat (see Figure fingerprints. Waukesha Service Operations
4.10-8). recommends the use of Actrel 3338L dielectric
solvent to clean the extensions.
NOTICE
Do not use oil or anti-seize compound on the spark
plug threads. The spark plug may be overtorqued if
oiled. Overtorquing distorts the spark plug and may
crack the ceramic construction. Anti-seize compound
may foul the firing tip, resulting in a plug shorted to
ground.
Form 6277-5
4.10-5 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM MAINTENANCE
SPARK PLUG REMOVAL – CSA (GL ENGINE) (13/16
IN. CURRENT PRODUCTION)
NOTICE
NOTE: Previous production CSA GL engines used a Do not pull on the spark plug cables to remove the
“long” coil (P/N 69694D), mounted directly to a shielded spark plug extensions. Pulling on the cable may
1/2 in. spark plug. This configuration is used with the loosen or detach the terminal connection within the
previous 1/2 in. shorter spark plug carriers. See Table Teflon tube.
1.15-18 1/2 in. Reach Spark Plugs (Used on G and GSI,
and 1/2 in. Reach Spark Plug Carriers on GL Only) on
page 1.15-29 for previous components. See SPARK 1. Disconnect the spark plug extension from the coil.
PLUG REMOVAL – CSA (G, GSI ENGINES) on page 2. Remove three capscrews, lock washers and coil
4.10-4 for similar procedures. Conversion Kits are from the coil adapter.
available to update to the new configuration shown in 3. Remove four capscrews, washers and coil adapter
Figure 4.10-9. from the spark plug carrier.
4. Remove spark plug extension and the spark plug
from the spark plug carrier (see Figure 4.10-9).
1
SPARK PLUG INSTALLATION – CSA (GL ENGINE)
(13/16 IN. CURRENT PRODUCTION)
2
NOTICE
13/16 in. reach spark plugs must be used with 13/16
in. reach carriers, and 1/2 in. reach spark plugs must
3 4 be used with 1/2 in. reach carriers.
NOTICE
7 The spark plug gasket must be properly seated to seal
the combustion chamber and transfer heat from the
plug.
Form 6277-5
4.10-6 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM MAINTENANCE
7. Install spark plug in the spark plug carrier with spark
! WARNING
plug tool (P/N 475037).
Figure 4.10-10
1 2 3
Figure 4.10-11
1 - Boot 3 - O-Ring
2 - Spark Plug Extension
Form 6277-5
4.10-7 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM MAINTENANCE
#1 RB
TDC
#1 RB #1 RB
TDC TDC TDC
1
ROTATION
5
4
3 2
Form 6277-5
4.10-8 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM MAINTENANCE
A
ACTIVE W/
B
ACTIVE W/
2
D”GROUNDED
“ “D”OPEN
WAUKESHA P/N
3
Figure 4.10-13: Timing Switches “A” and “B”
Each timing adjust switch has 16 switch positions (0 – Figure 4.10-14: Flywheel Timing Opening
15) with a 1° timing variation per position. Switch position
1 - Timing Opening 3 - Flywheel Housing
15 gives the most advanced timing, while switch position
0 is full retard. 2 - Timing Tape
4. Adjust the “A” switch as required to achieve correct
timing. Single-fuel ignition adjustments are now
complete.
Form 6277-5
4.10-9 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM MAINTENANCE
NOTE: Increasing the timing switch position by one will
! WARNING
advance the timing 1°. Decreasing the timing switch
position by one will retard the timing 1°.
As a safety measure, ground all
5. Run the engine on secondary fuel with the “D” lead
the pins. Some breakerless
(found in the 7-pin connector from box) open and
the CEC DSM deactivated.
NOTE: VHP gas engines are to be run with no load on
! ignition systems have more
than one storage capacitor.
fuels other than natural gas fuel. With natural gas fuel,
the engines may be run at any load.
NOTE: If the ignition switch is in the OFF position, the
6. Check engine timing at the flywheel using a timing
capacitor is immediately grounded when the ignition
light (see Figure 4.10-14).
harness is reconnected to the CEC ignition module.
7. Adjust the “B” switch as required to achieve correct
timing. Dual-fuel ignition adjustments are now NOTE: VHP gas engines are to be run with no load on
complete. fuels other than natural gas fuel. With natural gas fuel,
the engines may be run at any load.
NOTE: Increasing the timing switch position by one will
advance the timing 1°. Decreasing the timing switch
SHIELDED IGNITION HARNESS – G, GSI
position by one will retard the timing 1°.
ENGINES
NOTICE The braided plastic CEC shielded ignition harness for 6-
and 12-cylinder G and GSI engines has a split in the
To prevent the timing from being altered, always harness to the ignition coil to install an inductive timing
replace the white caps over the timing switches once light (see Figure 4.10-15). Install the timing light pickup
the desired setting has been selected. around either wire.
! WARNING
Form 6277-5
4.10-10 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM MAINTENANCE
Figure 4.10-16
Form 6277-5
4.10-11 © Copyright 2023, INNIO's Waukesha Engine
IGNITION SYSTEM MAINTENANCE
Form 6277-5
4.10-12 © Copyright 2023, INNIO's Waukesha Engine
SECTION 4.15
AIR INTAKE SYSTEM MAINTENANCE
1
AIR FILTER
On 6- and 12-cylinder engines, the air restriction
indicator (see Figure 4.15-2) will show “red” if the air
intake restriction is 15 inch-H2O (381 mm-H2O). This
indicates a clogged or dirty main air filter element and/or
clogged or dirty precleaner element.
On 16-cylinder engines, a gauge for each air filter
indicates the condition of the precleaner filter and main
air filter. Each gauge should register in the “green range.”
10
A switch allows the operator to monitor the pressure of 7
the precleaner and main filter pressure independently.
Form 6277-5
4.15-1 © Copyright 2023, INNIO's Waukesha Engine
AIR INTAKE SYSTEM MAINTENANCE
4
1
Form 6277-5
4.15-2 © Copyright 2023, INNIO's Waukesha Engine
AIR INTAKE SYSTEM MAINTENANCE
MAIN AIR FILTER ELEMENT – 6- AND 12- 2. Raise up and remove the rain shield.
CYLINDER 3. Peel the precleaner pad off the main air filter
element.
MAIN AIR FILTER ELEMENT REMOVAL – 6- AND 12- 4. Loosen the rear locknut (5/16 in.) on each mounting
CYLINDER stud until the flat washer behind it can be brought
Inspect and clean the main air filter element daily or as forward far enough to clear the step in the welded
required. Replace main air filter element if the air bracket of the main air filter frame (see Figure
restriction indicator “indicates red” after the air cleaner 4.15-1).
is cleaned and the precleaner pad has been replaced or 5. Swing the four mounting studs to the outside in a
cleaned. horizontal motion. Remove the main air filter frame
1. Locate the four threaded mounting studs on the air and element.
cleaner assembly and loosen the front locknut (5/16
in.) on each (see Figure 4.15-1 and Figure 4.15-3). MAIN AIR FILTER ELEMENT CLEANING AND
INSPECTION – 6- AND 12-CYLINDER
1. Clean the main air filter element using the following
method.
1 a. Gently tap the element on a flat surface with the
dirty side of the element down.
! WARNING
2
Never use your hand to check
for leaks or determine airflow
rates when using compressed
3 air. Compressed air can pierce
the skin.
Wear protective equipment to
protect your skin. Wear safety
glasses to shield your eyes from
flying dirt and debris.
4
b. Using an OSHA-approved safety nozzle, direct
compressed air through the element opposite
the direction of the air flow, as indicated by the
orange arrow on the instruction label. The air
pressure should be a maximum of 30 psi (207
kPa).
5 NOTICE
Form 6277-5
4.15-3 © Copyright 2023, INNIO's Waukesha Engine
AIR INTAKE SYSTEM MAINTENANCE
3. Do not clean and reuse the main air filter element
! WARNING
more than three times. Replace with a new element.
4. Inspect the air duct for cracks. All of the combustion
The location of the air restriction
air must pass through the main air filter element, not
indicator relative to the intake
through cracks or defects in the air cleaner
manifold causes it to be
assembly. If inspection of the duct work and intake
subjected to high pressure if the
manifold yields an accumulation of dust and grit, it is
engine backfires. A restriction
an indication that the main air filter element is not
filter must be installed in the
properly maintained or that air is getting into the
indicator air passage to dampen
system around or behind the element.
high pressure surges which
5. Inspect all air duct hoses. Replace any hose that is would otherwise damage the
cracked or aged. indicator. Through the
projection of broken material,
MAIN AIR FILTER ELEMENT INSTALLATION – 6- damage to the indicator might
AND 12-CYLINDER pose a potential danger to
NOTE: The orange flow arrow on the instruction label persons standing nearby. The
points toward the air outlet side. Always store the restriction filter also protects
elements with the air outlet side down. Dirt and dust on against the entrance of dust and
the outlet side will pass into the engine when the element dirt in the event that the
is installed. restriction indicator is broken
off or removed.
1. Install the main air filter element with the instruction
label facing up. Fit the deflection brace on the outlet
side of the filter element over the horizontal bar 9. Verify that the restriction filter is in place between the
running across the front of the air duct chamber. clean air tap and indicator.
2. Place the frame over the main air filter element.
3. Swing the four threaded mounting studs to the inside
! CAUTION
in a horizontal motion so that they fit within the
welded brackets on the air filter frame. Move the flat Do not grasp the indicator
!
washer behind the rear locknut back into the step in housing; the plastic may crack
the welded bracket. or break resulting in a hand
injury.
4. Install the precleaner pad between the rain shield
and the main air filter element. If necessary, use a
drop of adhesive on the corners to keep it from
falling.
5. Lower the rain shield on the four mounting studs. PREFILTER PAD – 16-CYLINDER
6. Alternately tighten the rear locknuts (5/16 in.).
PREFILTER PAD REMOVAL – 16-CYLINDER
7. Alternately tighten the front locknuts (5/16 in.) on the
four mounting studs. The prefilter is a filament pad that increases the life of
the main air filter element (see Figure 4.15-4 and Figure
8. Check the frame of the main air filter element to verify 4.15-6). Inspect and clean the prefilter pad daily or as
that its perimeter is sealed tightly. Damage to the required. This can be done while the engine is running.
frame may result in improper element sealing. Replace the prefilter pad every 4,000 running hours, or
NOTE: After the restriction problem is corrected, reset more often if necessary.
the indicator by depressing the black button on the
plastic housing.
Form 6277-5
4.15-4 © Copyright 2023, INNIO's Waukesha Engine
AIR INTAKE SYSTEM MAINTENANCE
PREFILTER PAD INSTALLATION – 16-CYLINDER
NOTICE
The dark blue sides of the prefilter pads must face the
main air cleaner elements or damage to equipment
could result.
3. Discard the prefilter pads. 4. Pull out the main air filter elements.
Form 6277-5
4.15-5 © Copyright 2023, INNIO's Waukesha Engine
AIR INTAKE SYSTEM MAINTENANCE
5
6
Form 6277-5
4.15-6 © Copyright 2023, INNIO's Waukesha Engine
AIR INTAKE SYSTEM MAINTENANCE
MAIN AIR FILTER ELEMENT CLEANING AND MAIN AIR FILTER ELEMENT INSTALLATION –
INSPECTION – 16-CYLINDER 16-CYLINDER
1. Clean the main air filter element using the following
method. NOTICE
a. Gently tap the element on a flat surface with the On new engines, remove the cardboard insert
dirty side of the element down. between the rain shield and prefilter pad before
starting the engine.
! WARNING
The pleats of the main air filter must be positioned
vertically in the air filter housing or damage to
Never use your hand to check equipment could result.
for leaks or determine airflow
rates when using compressed
air. Compressed air can pierce NOTE: The hand on the side of the filter element points
the skin. toward the air outlet side of the air filter housing. Also, a
Wear protective equipment to label with a pair of eyes printed on it is positioned on the
protect your skin. Wear safety air inlet side of the filter element. These eyes should be
glasses to shield your eyes from visible from the air filter housing inlet opening and at the
flying dirt and debris. top of the air cleaner, if the filter is properly installed. If
both labels are missing, one side of the air filter element
has a metal brace horizontally across the back. This side
should be positioned toward the air outlet side. Always
b. Using an OSHA-approved safety nozzle, direct store the elements with the air outlet side down. Dirt and
compressed air through the element opposite dust on the outlet side will pass into the engine when the
the direction of the air flow, as indicated by the element is installed.
hand on the side of the filter element. The air 1. Install the main air filter elements with the hand on
pressure should be a maximum of 30 psi (207 the side of the filter elements pointing toward the air
kPa). outlet side of the filter housings. Ensure that the
pleats of the elements are positioned vertically.
NOTICE
NOTICE
Do not use compressed air when cleaning the air filter
element. Compressed air can easily damage the Make sure the dark blue sides of the prefilter pads face
pleated paper of the main air filter element. the main air cleaner elements or damage to equipment
could result.
c. Air-dry the element. Do not use compressed air.
2. Carefully examine the element after cleaning. If 2. Install the new prefilter pads in the grates so that the
damaged, replace. dark blue sides of the prefilter pads will face toward
the main air filter elements when the prefilter pads
NOTE: Use only Waukesha-supplied air filter elements.
are installed.
3. Do not clean and reuse the main air filter element
3. Position the front grate and prefilter pad assemblies
more than three times. Replace with a new element.
on the air filter housings and secure using the four
4. Inspect the air duct for cracks. All of the combustion clamps (see Figure 4.15-5).
air must pass through the main air filter element, not
4. Install the rain shields.
through cracks or defects in the air cleaner
assembly. If inspection of the duct work and intake
manifold yields an accumulation of dust and grit, it is
an indication that the main air filter element is not
properly maintained or that air is getting into the
system around or behind the element.
5. Inspect all air duct hoses. Replace any hose that is
cracked or aged.
Form 6277-5
4.15-7 © Copyright 2023, INNIO's Waukesha Engine
AIR INTAKE SYSTEM MAINTENANCE
Form 6277-5
4.15-8 © Copyright 2023, INNIO's Waukesha Engine
SECTION 4.20
TURBOCHARGER SYSTEM MAINTENANCE
TURBOCHARGER INSPECTION
! WARNING
NOTICE
Do not run the engine if the air cleaner is not operating
efficiently or if leaks exist in the ducting.
3. With the engine shut down, inspect all air ducting for
loose clamps or connections. Check the manifold
connections to the turbine inlet and at the engine
exhaust manifold gaskets.
Form 6277-5
4.20-1 © Copyright 2023, INNIO's Waukesha Engine
TURBOCHARGER SYSTEM MAINTENANCE
4. Visually repeat the inspection while the engine is 5. Run the engine at rated output and listen for unusual
running. sounds at the turbocharger, especially those of
5. Monitor the turbochargers for unusual vibrations or metal contacting metal. If any noise of this type is
noise. If excessive vibration is evident, shut down the apparent, contact your Waukesha authorized
engine and call your Waukesha authorized service service agent.
agent.
6. Establish a schedule with your Waukesha WASTEGATE ADJUSTMENT FOR
authorized service agent to inspect the interior of the ALTITUDE
compressor for accumulations of dirt. Dirt can cause The engine must be in good operating condition and
the compressor wheel to become unbalanced, ignition system properly timed with the fuel system
which reduces efficiency and causes bearing failure. adjusted according to Waukesha’s recommendations
before adjusting the wastegate(s).
TURBOCHARGER LUBRICATION CHECK
NOTICE
NOTICE
Do not attempt to adjust the wastegate(s) to
Before operating a new or rebuilt turbocharger (or compensate for engine wear and misadjustment.
starting a new engine for the first time), check to
Always verify that all cylinders are firing before
ensure that the turbocharger is receiving proper
adjusting the wastegate. Individual exhaust
lubrication.
thermocouples have been provided for this purpose.
Since the Vee engines are “cross blown,” wastegate
1. Remove the oil drain tube (see Figure 4.20-3) from adjustment on one bank affects performance of the
the turbocharger(s). opposite bank cylinders. In other words, adjustment of
the left bank wastegate will change the intake pressure
of the right bank (and vice versa).
1
Do not attempt to equalize bank-to-bank pressures by
adjusting throttle plates out of synchronization.
Form 6277-5
4.20-2 © Copyright 2023, INNIO's Waukesha Engine
TURBOCHARGER SYSTEM MAINTENANCE
Form 6277-5
4.20-3 © Copyright 2023, INNIO's Waukesha Engine
TURBOCHARGER SYSTEM MAINTENANCE
Form 6277-5
4.20-4 © Copyright 2023, INNIO's Waukesha Engine
SECTION 4.25
COOLING SYSTEM MAINTENANCE
Before performing any service, maintenance or repair A minimum of 30% ethylene glycol is generally
procedures, review SAFETY on page 1.05-1 and recommended for adequate antifreeze and corrosion
RIGGING AND LIFTING ENGINES on page 1.10-1. protection. The amount should not exceed 67% to avoid
impairing the heat transfer processes. A concentration
COOLING SYSTEM MAINTENANCE beyond this percentage does not tend to lower the
freezing point any further and may result in engine
NOTE: See latest edition of Service Bulletin 4-2429 for damage.
detailed information on cooling system guidelines and
water treatment recommendations. Since it effectively raises the boiling point of the water,
the use of ethylene glycol is also beneficial in hot
COOLING SYSTEM ADDITIVES temperatures. Therefore, ethylene glycol treated water
is still recommended in those climates where antifreeze
Standard closed heat exchanger or radiator-cooled is not normally required (see Table 4.25-1).
cooling systems operating up to 250°F (121°C) must be
treated with industrial-grade inhibited antifreeze or with Table 4.25-1: Water Versus Glycol Concentration
some other effective commercial coolant treatment
PERCENT WATER / COMMENTS
product. These products usually provide corrosion
GLYCOL
protection by forming a film on the surfaces of the cooling
system and also act as a scale suppressant by modifying Minimum Glycol for Adequate
70/30
or conditioning the dissolved scale-forming minerals. To Antifreeze/Corrosion Protection
work effectively, all antifreeze and water treatment Best for Corrosion, Freezing and
50/50
products require a clean system, free of dirt, oil, scale Boiling Protection
and rust.
With heat exchanger cooling systems, it should be
Ethylene Glycol remembered that the circulation of ethylene glycol
solution only protects the closed system coolant.
The most common coolant additive is ethylene glycol. Therefore, the heat exchanger coolant supply, as well
The required proportion normally depends on the lowest as the auxiliary coolant circuit, must also be protected.
ambient temperature levels from which the system must
be protected. A mix of 50% water and 50% ethylene Propylene Glycol
glycol will produce the best results for freezing and
Propylene glycol has similar cooling properties when
boiling protection, but coolant efficiency is reduced by
compared to ethylene glycol. Ethylene glycol has the
as much as 15%. Since the radiator cooling system
advantage of lower viscosity than propylene glycol at
effectiveness drops by approximately 2 – 3% for each
temperatures less than 0°F (-17°C). Propylene glycol
10% of glycol concentration, the radiator sizing for the
has a low toxicity, and it may be less stringently regulated
specified heat rejection value must be taken into account
than ethylene glycol. Propylene glycol also has been
to accommodate this relationship.
proven to alleviate cavitation erosion that may be
experienced when using ethylene glycol solutions.
Other treatments the engine operator should consider
are (see Table 4.25-2):
Form 6277-5
4.25-1 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
Table 4.25-2: Other Cooling System Treatments • Overloaded engine
TREATMENT COMMENTS • Airbound system
Although a maximum hardness of • Insufficient air circulation
200 ppm is acceptable for initial fill • Exhaust recirculation
Deionized, Distilled or
and make-up, use only softened
Softened Water
water, where the insolubles may be Cooling System Recommendations
as low as 0.5 ppm.
1. Ensure the rise in coolant temperature does not
Sodium Nitrate Iron and steel corrosion inhibitor. exceed 10°F (5.6°C).
Molybdate Slows the growth of bacteria. 2. Maintain drop in system pressure at 8 – 15 psi (55 –
Tolyltriazole Copper corrosion inhibitor. 103 kPa). Low pressure promotes cavitation
erosion, and high pressure causes water pump seals
Synthetic Polymer Prevents hard scale buildup.
to leak.
Borax Buffer Corrects the water pH to 8.5.
3. Analyze raw water chemistry to verify water does not
General corrosion inhibitor; over contain contaminants and is not too hard. Use only
0.1% concentration is not soft water where insolubles are as low as 0.5 ppm.
recommended for industrial Hard water accelerates the formation of scale
engines. A concentration that is too
deposits.
Silicates high can cause the coolant in the
radiator to gel, resulting in solid 4. Analyze coolant chemistry every month to verify it
deposits. High silicate inhibitor contains proper inhibitor and additive
concentration is used primarily for concentrations.
high-speed aluminum engines.
5. Measure antifreeze content according to lowest
COOLING SYSTEM SPECIFICATIONS AND anticipated temperature; refill as needed with same
RECOMMENDATIONS brand.
6. Maintain coolant pH between 8.5 and 10.5; an acidic
Cooling System Specifications coolant with a pH of less than 7 will speed corrosion
Ensure that the temperature of the coolant leaving the of cast iron, aluminum and steel, and a pH of 11 or
engine (as indicated by the temperature gauge) does not higher will accelerate corrosion of aluminum and
exceed 220°F (104°C). solder.
7. Check cooling system level each day or consider
See Table 1.15-6 VHP Series Two Engine
installation of a coolant low-level shutdown switch.
Specifications on page 1.15-20 for the jacket water
Even if a high coolant temperature switch is
outlet temperature alarm and safety shutdown setpoints.
provided, it will not shut engine down if system runs
low on coolant.
NOTICE
8. Check cooling system for rust, sludge or other
Customer-supplied fuel shutoff type safety equipment foreign matter. Clean and flush entire cooling system
must be provided. once each year, unless evidence of corrosion or
sediment buildup demonstrates need for more
frequent changes. Use only clean, soft water.
Engine overheating, as evidenced by high jacket coolant
9. To eliminate recirculation of particles and
temperatures, may be caused by one or more of the
contaminants in cooling system, install a cleanable
following conditions:
filter (sized at approximately 10 microns) in coolant
• Restricted airflow through the radiator flow. Inspect and clean filter on a regular basis.
• Defective thermostats 10. Frequently inspect hoses and all cooling system
• Worn jacket water pump connections for cracks and leaks. Do this when
engine is operating at normal pressure.
• Excessive jacket water pump suction
11. On a radiator, check for damaged fan blades, a
• Blown head gasket
poorly fitting shroud, sticking shutters or dirt in
• Faulty temperature gauge radiator core. Repair or clean as needed.
• Low coolant level 12. Check radiator cap gasket for proper seal.
Form 6277-5
4.25-2 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
13. If a heat exchanger is used, inspect it for scale or NOTE: 12-cylinder shown; all engines are similar.
corrosion and, when necessary, clean inside of
NOTE: To facilitate draining and flushing of the engine
tubes with a round, soft-wire brush. Flush with
jacket water, replace one of the 3/4 in. NPT countersunk
cleaning solvent.
headless pipe plugs with a customer-supplied ball valve
14. Periodically remove intercooler and clean tubes with (see Figure 4.25-1). The ball valve must be threaded to
a soft-wire brush or circulate a suitable cleaning accept both a hose connection and pipe plug.
solution.
2. Open the air bleed petcock(s) on top of the cluster
15. Consider the installation of the following cooling thermostat housing on 6- and 12-cylinder engines
system safety accessories: and on top of the water manifold on 16-cylinder
• A high coolant temperature shutdown device engines.
• A low coolant level shutdown device 3. Attach the supply line to the ball valve and add
treated cooling water to the crankcase.
• A coolant level sight glass
NOTE: Always fill the engine from the bottom up to
To avoid scored pistons and other serious problems, a
minimize the formation of damaging air pockets. As the
high coolant temperature shutdown device will stop the
engine fills, air is pushed up and out.
engine if the coolant gets too hot. A low coolant level
device will shut down the engine if the coolant level drops ! WARNING
excessively, preventing cracked or warped cylinder
heads, exhaust manifolds and water manifolds. A sight
glass is a quick and easy method of visually checking Antifreeze solution is toxic and
the coolant level. poisonous. Always wear
protective clothing when
working with antifreeze
JACKET WATER COOLING CIRCUIT – solution. Follow the safety
INITIAL FILL instructions provided on the
NOTE: The following description is not applicable to container provided by the
permanent vent systems. manufacturer.
1. Remove the 3/4 in. NPT countersunk headless pipe
plugs from the drain hole just below the level of the 4. Add coolant to the engine until the level causes it to
jacket water header (see Figure 4.25-1). escape from the petcock(s) on top of the cluster
thermostat housing on 6- and 12-cylinder engines.
On 16-cylinder engines, petcock(s) are located on
top of the water manifold. See Table 1.15-6 VHP
Series Two Engine Specifications on page 1.15-20
for jacket water capacities.
1 5. Close the cluster thermostat housing petcock(s) and
continue filling the system until the level of the
coolant reaches the top of the surge tank or radiator.
6. Close the ball valve and unthread the hose
connection.
Form 6277-5
4.25-3 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
!
permanent vent systems.
connection is removed. If the 1. Open the air bleed petcocks in the intercooler
lever of the ball valve is coolant inlet/outlet bonnets.
inadvertently bumped open, the
absence of a plug will cause the 2. Open the air bleed petcocks on the intercooler
coolant to drain. During coolant inlet and outlet tubes located behind the
operation, loss of any coolant venturi extractor.
may result in catastrophic 3. Open the air bleed petcocks in the inlet side of the
engine damage. Escaping wastegate water return tubes.
steam and/or hot water can 4. From the top of the surge tank or radiator, add
cause severe burns. treated cooling water to the auxiliary cooling circuit.
5. Continue filling the circuit until the level causes it to
7. Apply Perma-Lok Heavy Duty Pipe Sealant with escape from the air bleed petcock(s) in the
Teflon to the threads of the pipe plug. Install the plug intercooler coolant inlet/outlet bonnet(s). Close the
in the ball valve. petcock(s) when water begins to flow out in a solid
steady stream.
NOTICE 6. Continue filling the auxiliary cooling circuit until the
level causes it to escape from the petcocks in the
Air in the cooling system speeds up the formation of intercooler coolant supply and the inlet side of the
rust, increases corrosion and produces hot spots wastegate water return tubes. Close the petcocks
within the engine. when coolant begins to flow out in a solid steady
stream. See Table 1.15-6 VHP Series Two Engine
8. Bleed trapped air (see COOLING CIRCUITS – AIR Specifications on page 1.15-20 for the capacities of
BLEED on page 4.25-5). the various auxiliary cooling circuit components.
9. Top off the surge tank or radiator. NOTE: Customer-supplied items and connections not
included. Items supplied by Waukesha include the
auxiliary water pump, intercooler, oil cooler and the
engine-mounted intercooler water supply and return
piping.
7. Continue filling the auxiliary cooling circuit until the
level of the coolant reaches the top of the surge tank
or radiator.
NOTICE
Air in the cooling system speeds up the formation of
rust, increases corrosion and produces hot spots
within the engine.
Form 6277-5
4.25-4 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
3. Final Bleed: Once the temperature of the jacket Jacket 1 Top of jacket water pump
water circuit has stabilized (as indicated by the Water 1 Top of water manifold
panel-mounted temperature gauge), reopen each
Intercooler cross pipes (2 per
petcock. Close the petcock when the water begins 4
intercooler)
to flow out in a solid steady stream. Auxiliary
Intercooler top center (2 per
4
NOTICE intercooler)
Form 6277-5
4.25-5 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
COOLING CIRCUITS – DRAIN AND FLUSH Table 4.25-4: Water Drain Petcocks
3. Verify that the customer-supplied ball valve is in the Jacket 2 Water manifold (front and rear)
Water
CLOSED position. Remove the pipe plug and attach Jacket water pump housing (see
the drainage line. 1 exit hole in side panel of safety
guard assembly)
4. Drain the coolant from the jacket water and auxiliary
cooling circuits. Avoid delay so that the coolant is 2 Intercooler (4 each intercooler)
drained before the rust and sediment has a chance Auxiliary 1 Auxiliary water pump (bottom)
to settle.
1 Wastegate (1 per wastegate)
5. Open all air bleed petcocks.
7. Close all water drain petcocks. Apply Perma-Lok
6. Open all water drain petcocks (see Table 4.25-4).
Heavy Duty Pipe Sealant with Teflon to the threads,
Remove all drain plugs. Place a small catch pan
and install all drain plugs.
beneath each petcock before opening.
8. Select and inspect an internal surface that is suitable
for gauging the effectiveness of the cleaning and
descaling solution. If necessary, insert a piece of drill
welding rod into the water passage opening to feel
for an accumulation of lime and mineral scale
deposits.
Form 6277-5
4.25-6 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
9. Attach the supply line to the ball valve and add clean, 21. Let the engine run about 10 minutes to stir up any
soft water to the crankcase. Always fill the engine rust or sediment in the cooling water system.
from the bottom up to minimize the formation of air
NOTE: Contaminants left in the cooling circuits will
pockets. As the engine fills, air is pushed up and out.
reduce or deplete the effectiveness of the cleaning
10. Successively close each air bleed petcock when solution.
water begins to flow out in a solid steady stream.
Begin at the lowest petcock and finish at the highest. ! WARNING
11. Close the cluster thermostat housing petcock(s) and
continue filling the jacket water system until the level Slowly loosen the drain
reaches the top of the surge tank or radiator. petcocks to relieve any excess
12. Bleed trapped air. Begin at the lowest petcock and pressure.
finish at the highest. Bleed one petcock at a time.
Close the petcock when the hissing stops and water
begins to flow out in a solid steady stream. Always wear protective clothing
13. Attach the supply line and add clean, soft water to when draining the cooling
the surge tank or radiator of the auxiliary cooling systems on a heated engine.
circuit.
14. Top off the surge tank or radiator of the jacket water
circuit.
15. Successively close each air bleed petcock when
water begins to flow out in a solid steady stream. 22. Stop the engine. Drain the crankcase and all cooling
16. Continue filling the auxiliary cooling circuit until the system accessories. Drain the auxiliary cooling
level reaches the top of the surge tank or radiator. circuit. Avoid delay so that the water is completely
drained while the rust and sediment are still in
17. Bleed trapped air. Begin at the lowest petcock and suspension.
finish at the highest. Bleed one petcock at a time.
Close the petcock when the hissing stops and water 23. Attach the supply line and fill the jacket water and
begins to flow out in a solid steady stream. auxiliary cooling circuits with a suitable cleaning
solution. Use a non-acidic, non-corrosive,
18. Top off the surge tank or radiator of the auxiliary biodegradable compound that prevents the loss of
cooling circuit. metal in the engine and avoids damage to internal
gaskets and seals.
! WARNING
NOTE: Follow the manufacturer’s recommendations
for the proper concentration of cleaning solution and
Slowly loosen the air bleed
length of cleaning time.
petcock to relieve any excess
pressure. 24. Bleed trapped air.
25. Top off the surge tank or radiator of the jacket water
and auxiliary cooling circuits.
Always wear protective clothing 26. Start the engine. Let it run for at least 10 minutes or
when bleeding the cooling until the cleaning solution is depleted.
system on a heated engine.
27. To ensure that the contaminants remain in
suspension, drain the cooling circuits as quickly as
possible.
28. Inspect internal surfaces. If the results are not
19. Start the engine and slowly reopen each air bleed satisfactory, refill the engine with cleaning solution.
petcock. Close the petcock when the hissing stops Repeat Steps 23 – 27 as necessary.
and water begins to flow out in a solid steady stream. 29. To flush the systems of cleaning solution and any
20. Slowly reopen each air bleed petcock when the residual contaminants, fill the jacket water and
engine jacket water temperature has stabilized (as auxiliary cooling circuits with clean, soft water. Drain
indicated by the panel-mounted temperature immediately.
gauge). Close the petcock when the water begins to
flow out in a solid steady stream.
Form 6277-5
4.25-7 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
NOTICE
Air can be drawn into the system through small leaks
in the cooling circuit. The problem is compounded
when the void created by any loss of coolant is filled
by more air. Air in the cooling system speeds up the Figure 4.25-2: 12-Cylinder Idler Pulley Bearing Lube
formation of rust, increases corrosion and produces
1 - Water Drain Cock 2 - Safety Panel
hot spots within the engine. If aeration causes the
coolant to foam, the probability of engine damage due NOTE: 6- and 12-cylinder engines are similar.
to overheating is greatly increased.
! WARNING
1
Always install a pipe plug in the
ball valve when the hose
Form 6277-5
4.25-8 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
2. Using a hand-held grease gun, apply one stroke of
Lithoplex Grease No. 2 (Multipurpose Lithium
Complex Formula Containing Molybdenum
Disulfide) to the grease fitting.
GREASE RECOMMENDATIONS
A Lithium complex-type grease is now recommended
over the Lithium soap-based grease because of its
ability to resist water. Lithium complex-type grease also
Figure 4.25-4: 6-Cylinder Auxiliary Water Pump Lube provides superior rust protection qualities (especially
steel surfaces), as well as its thermal and mechanical
NOTE: One or two grease fittings, depending on pump stability at high operating temperatures. The Lithium
model. complex grease has a continuous operating
temperature of approximately 350°F (177°C), whereas
the Lithium soap-based grease has an upper operating
temperature limit of approximately 225°F (107°C).
Form 6277-5
4.25-9 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
! WARNING
Form 6277-5
4.25-10 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
7. Place a new drive belt in the rear groove of the rear
crankshaft pulley. The rear groove is the one closest
to the gear cover. Slip the belt into the rear groove of
the jacket water pump pulley.
8. Place a new drive belt into the second last groove of
the rear crankshaft and jacket water pump pulleys.
9. Rotate the idler pulley bracket clockwise to seat the
jacket water pump drive belts in the two pulley
grooves.
10. See JACKET WATER PUMP DRIVE BELT
TENSION ADJUSTMENT on page 4.25-11 to
adjust the belts.
! WARNING
Figure 4.25-8: 6-Cylinder Adjusting / Idler Lever
Assembly
Always install the safety guards
NOTE: 12- and 16-cylinder engines are similar. after completing any service
5. Loosen the pivot capscrew on which the idler pulley operation. Never operate the
bracket turns (see Figure 4.25-9). Loosen the slotted engine with the safety guards
lock capscrew to unlock the position of the bracket. removed.
The belt tension is released as the idler pulley
bracket rotates.
11. Install the safety guards.
1
JACKET WATER PUMP DRIVE BELT
TENSION ADJUSTMENT
Check the tension and condition of the two jacket water
2 pump drive belts weekly. Replace the drive belts every
8,000 running hours or as necessary.
! WARNING
Figure 4.25-9: Tighten Idler Pulley Bracket Capscrews – 1. Remove the safety guard.
12-Cylinder Shown
Form 6277-5
4.25-11 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
1
2
3 4
5
6
Form 6277-5
4.25-12 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
NOTE: If the tension tester is not available, moderate
NOTICE hand pressure should deflect the long part of the belt
Belts that are too tight result in excessive stretching approximately 0.25 – 0.50 in. (6 – 13 mm) or as a general
and overheating. Too much tension may also damage rule, 0.01562 in. (0.4 mm) per 1 in. (25.4 mm) of belt span
drive components, such as sheaves and shafts, and measured from pulley center to pulley center.
lead to premature failure of the idler pulley and/or 7. Tighten the slotted lock capscrew on the idler pulley
water pump bearings. bracket when the proper belt tension is obtained
(see Figure 4.25-11). Tighten the pivot capscrew.
Belts that are too loose result in belt slippage. Slippage
causes burn spots, overheating, rapid wear and 8. Inspect the belts for proper seating. V-belts should
breakage. The vibration created by loose belts may ride on the sides of the pulley sheaves, not on the
also be sufficient to cause unnecessary wear of the bottom of the groove.
pulley grooves. 9. Verify that the tension of the front drive belt is
between 11.9 and 17.5 lbf (53 and 77 N). Verify the
4. To reset the belt tension, insert a pry bar between tension of the rear drive belt.
the upper edge of the idler pulley bracket and the 10. See AUXILIARY WATER PUMP DRIVE BELT
untapped boss on the left bank side of the water TENSION ADJUSTMENT on page 4.25-16.
pump housing (see Figure 4.25-12). To tighten the
drive belts, use the pad above the untapped boss for ! WARNING
leverage and push up on the pry bar to move the idler
pulley bracket downward (CW).
Always install the safety guards
5. Holding the pry bar in position, use the tension tester after completing any service
to apply inward pressure to the center of the longest operation. Never operate the
unsupported span on the front drive belt (between engine with the safety guards
the jacket water pump pulley and the crankshaft removed.
pulley).
Form 6277-5
4.25-13 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
3. Inspect the drive belts for fraying, cracks or wear.
Belts must not be glazed, split, peeled or greasy. 5
Replace as necessary. 4
7
14
13
12
11
Form 6277-5
4.25-14 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
Form 6277-5
4.25-15 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
1
2
3 4
5
6
Form 6277-5
4.25-16 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
NOTE: Since the circumference of new belts is
! WARNING
somewhat smaller, reuse of the setting established for
the discarded drive belts will result in belts that are too
tight. Always install the safety guards
after completing any service
3. To loosen the drive belts, back the upper thin hex
operation. Never operate the
locknut on the threaded rod away from the adjusting
engine with the safety guards
lever. The pivot point of the idler lever follows the
removed.
adjusting lever in a counter clockwise direction. The
downward movement of the idler pulley releases the
drive belt tension.
4. When the correct tension is obtained, thread the 3/8 10. Install the safety guards.
in. elastic stop lock on the upper end of the threaded
rod toward the adjusting lever. Be sure that the AUXILIARY WATER TEMPERATURE
locknuts (thin hex and elastic stop) on each side of CONTROL VALVE – GL ENGINES
the adjusting lever are properly tightened.
Remove and test the thermostat in the auxiliary cooling
5. Inspect the belts for proper seating. V-belts should circuit annually. Inspect the thermostat sooner if an
ride on the sides of the pulley sheaves, not on the increase or decrease in coolant temperature cannot be
bottom of the groove. traced to a malfunctioning water pump, loose belts,
6. Because of initial stretching, recheck the belt tension excessive engine load or other cooling system-related
after 10 minutes run time. Check the belt tension problems. The coolant temperature at the intercooler
again after the first 30 minutes run time and then coolant inlet is either 85°F or 130°F (29°C or 54°C),
every 250 hours thereafter. depending upon application.
Form 6277-5
4.25-17 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
2 2
1 1
4
5
4
6
7
6 5
Figure 4.25-18: 6-Cylinder Auxiliary Water Temperature
Control Valve
Figure 4.25-20: 16-Cylinder Auxiliary Water Temperature
1 - Support Bracket 5 - Thermostat
Control Valve
2 - To Bypass Inlet Port Housing
B (from oil cooler) 6 - U-Bolt 1 - Outlet Port A 5 - To Inlet Port C (from
3 - Auxiliary Water 7 - To Inlet Port C (from 2 - Auxiliary Water heat transfer
Pump heat transfer Pump device)
4 - Outlet Port A device) 3 - To Bypass Inlet Port 6 - Support Bracket
B (from oil cooler) 7 - Thermostat
4 - U-Bolt Housing
1 2 3
3. Remove the flange connection from bypass inlet port
B (from the oil cooler).
4. Remove the coolant outlet port flange (stamped A)
from the thermostat housing (four capscrews, with
flat washers).
! WARNING
Form 6277-5
4.25-18 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
6. Remove the U-bolt securing the coolant inlet pipe
nipple to the oil pan support bracket (5/16 in. flat
NOTICE
washers, lock washers and hex nuts). Do not boil the thermostatic valve. Excessive
7. Move the thermostat housing assembly to a suitable temperatures will force the valve to exceed its normal
workbench. operating travel and may result in permanent damage.
AUXILIARY WATER TEMPERATURE CONTROL b. Gradually heat the water while stirring with a
THERMOSTATIC VALVE INSPECTION AND quality glass laboratory thermometer (see
TESTING Figure 4.25-21). Observe the action of the valve.
c. The valve should begin to open at the Start to
Open temperature rating listed in Table
1.15-8 Auxiliary Cooling Water Thermostat on
page 1.15-23, and be completely open at the Full
Open temperature, plus or minus 5°F (2.8°C).
d. Remove the valve and observe its closing action.
The valve should seal evenly and tightly (see
Figure 4.25-22).
2 1
Figure 4.25-22
Form 6277-5
4.25-19 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
AUXILIARY WATER TEMPERATURE CONTROL 5. Take note of the temperature rating and part number
VALVE ASSEMBLY stamped on the old thermostatic valve. The part
1. Pull the lip seal out of the thermostat housing. Use a number and nominal temperature rating are
rolling-head pry bar for best results. stamped on the metal spring frame (see Figure
4.25-24). If the old valve is not available, check the
! WARNING engine specification pack to be sure that the new
valve is correct.
Do not allow a caustic solution 6. Install the new thermostatic valve with the expansion
to contact your skin, clothing or element facing outward.
eyes. Always use approved 7. Place a new O-ring in the thermostat housing outlet
caustic solutions in a well- port flange. Lubricate the O-ring with clean glycol.
ventilated area.
Always wear protective
1
equipment when using caustic
solutions.
! WARNING
3
Never use your hand to check
for leaks or determine airflow
rates when using compressed
air. Compressed air can pierce 4
the skin.
Wear protective equipment to
protect your skin. Wear safety
glasses to shield your eyes from
flying dirt and debris.
Form 6277-5
4.25-20 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
! WARNING
! WARNING
Form 6277-5
4.25-21 © Copyright 2023, INNIO's Waukesha Engine
COOLING SYSTEM MAINTENANCE
NOTICE
The presence of coolant at the “weep hole” indicates
that the jacket water pump must be rebuilt. A defective
water pump seal results in coolant loss and
contamination of the inner ball bearing grease.
! WARNING
NOTICE
The presence of coolant at the shaft seals indicates
that the jacket water pump must be rebuilt. A defective
water pump seal results in coolant loss and
contamination of the inner ball bearing grease.
Form 6277-5
4.25-22 © Copyright 2023, INNIO's Waukesha Engine
SECTION 4.30
LUBRICATION SYSTEM MAINTENANCE
1. Remove the cap from the oil filler pipe on the lower
rear left side of the engine (see Figure 4.30-1).
2. See LUBE OIL FILTER on page 4.30-9 and fill the
oil filter with the proper grade oil.
Figure 4.30-2
3. Insert the make-up line and add lube oil to the oil pan.
Periodically remove the dipstick and take note of the 1 - O-Ring
reading.
5. Stop adding oil and start the prelube pump. The
4. Continue to add oil to the oil pan until the level prelube pump must be run to fill the oil lines, oil
reaches the “FULL” mark on the dipstick (see Figure cooler, the full-flow lube oil filter and oil strainer. It
4.30-2). also ensures that the bearings, turbochargers and
other moving parts of the engine are properly
lubricated.
NOTICE
Filter must be filled with lubricating oil before first start
and after each element change.
Form 6277-5
4.30-1 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
6. Depress the bypass valve plunger inside filter to CRANKCASE OIL LEVEL CHECKING
allow air to escape. Before first start-up, vent air
through the cover vent while the prelube pump is still Check the crankcase oil level daily while the engine is
running. A continuous flow of oil from the vent line is running. For convenience, a dipstick is located on both
required and indicates that all air has been removed the right and left side of the oil pan (see Figure 4.30-2).
from the lube oil system. The blade of the dipstick is marked “LOW” and “FULL.”
Always maintain the oil level at the “FULL” mark. Both
7. Run the prelube pump until pressure is indicated on marks on the dipstick are “static lines.” The dipstick does
the oil pressure gauge. Stop the prelube pump, wait not indicate where the level of the oil should be when the
a few minutes for the oil to drain back into the engine is running.
crankcase, check the dipstick and add oil to the oil
pan until the level returns to the “FULL” mark. When checking the oil level, carefully examine the
condition of the oil on the dipstick. Replace the oil any
8. Install the oil filler cap, start the engine and wait until
time it appears diluted, thickened by sludge or otherwise
the lube oil has warmed up to its normal operating
deteriorated. The useful life of the oil depends on a
temperature. Shut the engine down, wait for the oil
number of factors, which include the engine load,
to drain back into the pan and then check the level
temperature, fuel quality, atmospheric dirt, moisture and
one more time. Add oil if the level is below the “FULL”
the level of maintenance. If oil performance problems
mark.
arise, consult your oil supplier.
9. Check the crankcase oil level daily before the engine
is started. The blade of the dipstick is marked “LOW” Always pay close attention to engine operating
and “FULL.” Always maintain the oil level at the temperatures. If engine jacket water and oil
“FULL” mark. Both marks on the dipstick are “static temperatures are maintained according to engine
lines.” The dipstick does not indicate where the level specifications, particularly during periods of light load
of the oil should be when the engine is running. operation, the problems resulting from condensation of
corrosive vapors in the crankcase can be minimized.
OIL COOLER AND LUBE OIL FILTER When using an engine oil for which there is no previous
INSTALLATION REQUIREMENTS operating experience, a detailed oil analysis by qualified
professionals is strongly recommended. A well-
1. All piping connections to and from the engine and monitored maintenance program also should be
between lubrication system accessories are to be established for the first year of usage and the
supplied by the customer. Place the optional ship performance of the engine should be carefully observed
loose lube oil cooler and lube oil filter assemblies as against all external operating conditions. This procedure
close to the engine as possible. All customer will help to determine if the selected oil is really suitable
connections to the engine must be flexible. for your particular operation.
2. Verify that all lines between the engine and the lube
NOTE: If any questions arise with regard to the
oil filter and lube oil cooler assemblies are clean and
foregoing information call the Waukesha Product
free from scale.
Support or Sales Engineering Departments. See the
3. Filter must be filled with lubricating oil before first latest edition of Service Bulletin 12-1880 for more
start and after element change. Depress bypass information on lubricating oils.
valve plunger inside filter to allow air to escape.
Before first start-up, vent air through the cover vent
while prelube pump is running. A continuous flow of
oil from the vent line is required, and indicates that
all air has been removed from the system.
4. See LUBE OIL PRESSURE ADJUSTMENT on
page 4.30-15 and adjust the lube oil pressure.
Form 6277-5
4.30-2 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
OIL PAN
To change the oil, drain the oil pan and all lube oil system
! WARNING
accessories: oil cooler, full-flow oil filter and lube oil
strainer. Proceed as follows: Allow oil to cool prior to working
on lube oil system components.
NOTE: Drain oil when warm for best results. Hot oil can cause severe burns.
1. Oil pan: Remove the 2 in. square-head drain plug.
For convenience, four drain plugs are provided, one
at each corner of the oil pan. Retain an oil sample for
Wear protective equipment and
oil analysis. Install the drain plugs when the oil has
use caution while working on
drained.
lube oil system components.
NOTE: Installation of a customer-supplied ball valve
and pump facilitates draining of the oil pan.
2. Oil Cooler: Remove the drain plug at the bottom of
the oil cooler shell midway between the inlet and rear
bonnets. Install the drain plug when the oil has NOTE: Since it is necessary to drain the oil pan and lube
drained. oil system accessories, schedule the cleaning during a
3. Full-Flow Lube Oil Filter: Remove the upper drain regular oil change interval.
plug from the oil filter housing to drain sludge and NOTE: Drain oil when warm.
dirty oil from the filter element chamber. Remove the
1. Drain the oil pan, oil cooler, full-flow oil filter and lube
lower plug to drain oil from the clean oil chamber
oil strainer.
(see Figure 4.30-8). Install the drain plugs when the
oil has drained. 2. Loosen the oil pan door clamp capscrews (see
Figure 4.30-3). Rotate the assembly about 45° to
4. Lube Oil Strainer: Remove the drain plug (3/8 in.) at
remove the door from the access hole.
the bottom of the strainer element housing (see
Figure 4.30-14). Install the drain plug when the oil 3. A small pool of oil about 3/4 in. deep will normally
has drained. accumulate on each end of the oil pan where the
casting is recessed. Only a thin film will cover the
5. When the oil has drained, ensure all the drain plugs
other internal surfaces. Using absorbent cloths, wipe
are reinstalled.
the oil pan clean. Thoroughly clean the channel that
6. See OIL PAN on page 4.30-3 and clean the oil connects the two recessed areas.
pan.
4. Clean the oil pickup screen (see OIL PICKUP
NOTICE SCREEN on page 4.30-4).
Form 6277-5
4.30-3 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
1 - O-Ring 3 - Washer
2 - O-Ring
5. Install the oil pan doors. Hold each door so that the 2. Remove the pickup screen assembly from the oil
rear clamp is 45° from the vertical position. Insert the pan.
clamp into the oil pan access hole. Holding the door 3. Remove the baffle and oil tubes from the pickup
against the face of the access hole, rotate the door screen.
until the clamp is in the horizontal position. Tighten
the door clamp capscrew to specifications. See 4. Scrape the old gasket material from the oil tube
Lubrication System in Table 1.15-17 Critical Engine flanges and baffle box. Old gasket material left on
Torque Values on page 1.15-28 for specific torque the mating surfaces may cause air or unfiltered oil to
values. leak into the oil tubes.
6. See OIL CHANGE on page 4.30-3 and refill the 5. Remove two capscrews, lock washers, gasket and
engine with the proper quantity and grade of oil elbow from the crankcase.
lubrication oil (see Lubrication System in Table 6. Remove two capscrews, lock washers and cover
1.15-6 VHP Series Two Engine Specifications on bracket from the crankcase.
page 1.15-20).
OIL PICKUP SCREEN CLEANING AND INSPECTION
OIL PICKUP SCREEN – 6-CYLINDER
1. Clean all parts of the assembly in a non-volatile
OIL PICKUP SCREEN REMOVAL – 6-CYLINDER cleaning solution or solvent. Flush the screen from
the inside out for best results.
! WARNING
! WARNING
Allow oil to cool prior to working
on lube oil system components. Never use your hand to check
Hot oil can cause severe burns. for leaks or determine airflow
rates when using compressed
air. Compressed air can pierce
Wear protective equipment and the skin.
use caution while working on Wear protective equipment to
lube oil system components. protect your skin. Wear safety
glasses to shield your eyes from
flying dirt and debris.
Form 6277-5
4.30-4 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
3. Inspect the pickup screen for tears or holes. Replace 2. Loosely install the oil elbow in the crankcase with a
the screen if damaged. gasket, two capscrews and lock washers.
4. Inspect the baffle box for broken welds, split seams 3. Apply a fast-setting gasket adhesive, such as 3M
or cracks around the oil tube holes. Replace the Scotch-Grip Rubber And Gasket Adhesive, on the
baffle if damaged. oil tube flanges. Position new gaskets on the flanges.
4. Install the oil tubes in the screening element. Place
the baffle over the screen, aligning the holes with
those in the flange gaskets.
5. Obtain a new gasket for the elbow and apply gasket
adhesive to one side. Press the sticky side of the
3 gasket onto the baffle, aligning the holes with those
in the box.
6. To ensure proper alignment, install the four
2 capscrews and lock washers to hold the pickup
4
screen assembly together. After the unit is
positioned in the oil pan, remove one capscrew.
1 Slide the capscrew through the elbow or cover
bracket and thread it back into the pickup screen
assembly. Follow this procedure with the remaining
three capscrews. Wrench-tighten only after all
capscrews are in place.
7. Tighten the four capscrews to secure the oil elbow
and cover bracket to the crankcase.
2
2 OIL PICKUP SCREEN REMOVAL – 12-CYLINDER
7
! WARNING
5
Form 6277-5
4.30-5 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
OIL PICKUP SCREEN CLEANING AND INSPECTION
– 12-CYLINDER
1. Clean all parts of the assembly in a non-volatile
cleaning solution or solvent. Flush the screen from
3 the inside out for best results.
! WARNING
2
Never use your hand to check
for leaks or determine airflow
1 rates when using compressed
air. Compressed air can pierce
the skin.
Wear protective equipment to
protect your skin. Wear safety
glasses to shield your eyes from
flying dirt and debris.
2
Form 6277-5
4.30-6 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
OIL PICKUP SCREEN REMOVAL – 16-CYLINDER OIL PICKUP SCREEN CLEANING AND INSPECTION
– 16-CYLINDER
! WARNING 1. Clean all parts of the assembly in a non-volatile
cleaning solution or solvent. Flush the screen from
Allow oil to cool prior to working the inside out for best results.
on lube oil system components.
Hot oil can cause severe burns. ! WARNING
Form 6277-5
4.30-7 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
2
3
1
9 7
8
2 6
1 - Gasket 6 - Screen
2 - Ferry-Head Capscrew 7 - Oil Tube
3 - Gasket 8 - Lockwire
4 - Baffle 9 - Oil Elbow
5 - Capscrew
OIL PICKUP SCREEN INSTALLATION – 16- OIL COOLER
CYLINDER
Drain the oil from the oil cooler at each oil change.
1. Install a new gasket on the inlet side of the oil tube
flange. Position the baffle over the screen and insert Clean and inspect the oil cooler annually. Inspect the oil
the tube. cooler sooner if an increase in oil temperature cannot be
traced to a malfunctioning auxiliary water pump, loose
2. Position a new gasket on the elbow inlet flange.
belts, a faulty thermostat or excessive engine load.
Install the two ferry-head capscrews and washers to
hold all parts of the assembly together. Use the two Plugged tubes or scale deposits inhibit the flow of
capscrews with the head holes (see Figure 4.30-7) coolant which reduces oil cooling effectiveness.
and finger-tighten only.
NOTE: Schedule the oil cooler cleaning during a
3. Position the assembly in the oil pan. Position a new regular oil change interval, since it is necessary to drain
gasket on the elbow outlet flange and install the oil the oil pan and lube oil system accessories.
outlet flange on the side of the oil pan with two ferry-
head capscrews and lock washers.
4. Install the pickup screen to the oil pan floor with two
capscrews and lock washers.
5. Tighten the elbow inlet flange capscrews. Slide a
new lockwire through the hole in the heads of the
capscrews (see Figure 4.30-6). Twist the ends of the
wire together until taut.
Form 6277-5
4.30-8 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
LUBE OIL SYSTEM AIR BLEED NOTE: If oil filter inlet and outlet pressure gauges are
not provided, they may be ordered from Waukesha.
Air-bleed the lube oil system at least once each day.
Proceed as follows: 1. Drain both chambers of the full-flow oil filter. Two
drain plugs are provided in the oil filter housing (see
NOTE: The petcock on the full-flow oil filter cover is the Figure 4.30-8). Remove the upper plug to drain
only air bleed through which the lube oil system may be sludge and dirty oil from the filter element chamber.
purged of air pockets. Remove the lower plug to drain oil from the clean oil
1. Initial Bleed: Start the prelube pump and open the chamber.
filter cover petcock. NOTE: Based on environmental and engine operating
2. Close the petcock when oil begins to flow out in a conditions, the lubrication oil may require changes that
steady stream. are much more frequent than those recommended by
3. Check Bleed: Start the engine and reopen the filter Waukesha. Many variables are involved in determining
cover petcock. the proper time between oil changes, some of which may
not even be known until after a problem develops. The
4. Close the petcock when oil begins to flow out in a oil type, the severity of the environment and the internal
steady stream. condition of the engine are only a few of many variables
5. Final Bleed: Once the engine is running at normal that have a direct effect on the frequency at which the oil
operating temperature, reopen the filter cover must be changed.
petcock.
6. Close the petcock when oil begins to flow out in a
! WARNING
steady stream.
The cover compresses powerful
LUBE OIL FILTER springs on the filter element
posts. Use special care to
! WARNING remove the oil filter cover.
Oil
Distance
Filter Number Number
Engine Between
Shell of Short of Long
Long
ID
LUBE OIL FILTER ELEMENT REPLACEMENT
6-Cylinder 12 in. 6 2 180°
Full-flow lube oil filter elements should be replaced
12-Cylinder 16 in.
whenever the lube oil is changed and may often require 9 3 120°
more frequent replacement. 16-Cylinder 18 in.
When the filter is new, the drop in oil pressure through 3. Leaving the longest capscrews in place, remove the
the filter is around 2 – 3 psi (14 – 21 kPa) under normal short capscrews working in a clockwise direction.
operating temperatures. To determine the pressure
differential, subtract the reading of the oil filter outlet
pressure gauge from the reading of the inlet pressure
gauge. When the pressure differential rises to 12 – 15
psi (83 – 103 kPa), the filter elements are clogged and
must be replaced.
Form 6277-5
4.30-9 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
! WARNING 2 3
7
4. Loosen the long capscrews, giving each an equal
amount of turn. Alternately loosen each of the long
capscrews to slowly ease the filter cover up (see
Figure 4.30-8).
5
6
1
2
Figure 4.30-9: Full-Flow Lube Oil Filter
Form 6277-5
4.30-10 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
NOTICE
Those filter elements that are stamped with an arrow
must be installed with the arrow pointing down.
Elements that have a band around the center may be
installed with either end pointing down.
= 1 = 2
Form 6277-5
4.30-11 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
Form 6277-5
4.30-12 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
LUBE OIL STRAINER 2. Remove the four capscrews and washers from the
strainer head to detach the element housing.
! WARNING 3. Remove the rubber seal from the inside groove at
the top of the element housing.
Allow oil to cool prior to working 4. Pull down on the stainless-steel wire mesh element
on lube oil system components. to detach it from the head.
Hot oil can cause severe burns.
5. Remove the two band retainers and the two
magnetic rods externally mounted on the element.
6. Clean the element in solvent. Flushing the element
Wear protective equipment and
from the inside out produces the best results.
use caution while working on
lube oil system components. ! WARNING
Form 6277-5
4.30-13 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
MAGNETIC PLUG
! WARNING
Form 6277-5
4.30-14 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
1 7
6
3
5
Form 6277-5
4.30-15 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
! WARNING
1
2 Never use your hand to check
for leaks or determine air flow
rates when using compressed
5
air. Compressed air can pierce
4 the skin.
MICROSPIN
Initial centrifuge servicing should be about 4 weeks after
start-up, sooner if the oil is heavily contaminated. A
5 maximum buildup of 0.75 in. (19.05 mm) is allowed on
4 3 the centrifuge paper insert. Noting the buildup will help
in establishing a cleaning interval.
Figure 4.30-21
CENTRIFUGE
1 - Plug 4 - Strainer Body
2 - To Prelube Pump 5 - Screen ! WARNING
3 - From Oil Pan
Always read and comply with
4. Pull out the cylindrical steel mesh screen.
the manufacturer’s instructions
5. Flush the screening element in a non-volatile and warnings on the container
cleaning solution or solvent. when using cleaning solvent.
Cleaning solvents may be toxic
NOTICE or flammable. Keep away from
heat or flame. Always use
High-pressure compressed air may damage the approved cleaning solvents in a
screening element. well-ventilated area. Do not use
gasoline, paint thinners or other
highly volatile fluids for
cleaning.
Form 6277-5
4.30-16 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
Under normal operating conditions, the centrifuge 1. Shut off the oil supply valve and wait 2 minutes for
should be cleaned and its paper insert removed at every the oil pressure to drop to zero and the rotor to stop
scheduled oil change, or as experience dictates. The spinning.
centrifuge can be cleaned while the engine remains
running provided the oil supply valve is shut off (see ! WARNING
Disassembly of Microspin P/N 489189 Centrifuge on
page 4.30-17 for proper procedures). Allow oil to cool prior to working
on lube oil system components.
CLEANABLE FILTER ELEMENTS Hot oil can cause severe burns.
The cleanable oil elements (see Figure 4.30-22) should
be removed from the oil filtration canister and cleaned in
a solvent tank at every other regularly scheduled oil Wear protective equipment and
change, or when the oil pressure differential between the use caution while working on
canister inlet and outlet exceeds 15 psi (103 kPa). If an lube oil system components.
oil pressure differential of 2 – 15 psi (14 – 103 kPa)
cannot be obtained after normal cleaning, the cleanable
filter elements may be ultrasonically cleaned. It is
recommended that an oil pressure gauge be installed to
monitor the oil “ΔP” pressure. The engine must be shut
down to service the cleanable oil filters. 2. Loosen and remove the side bell clamp (see Figure
4.30-23).
3. Turn the bell knob counterclockwise until it is free.
4. Grasp the top bell knob and remove the bell housing
from the base (this will expose the rotor assembly).
5. Insert a screwdriver under the rotor assembly and
raise the rotor assembly up 1 – 2 in. (25.4 – 50.8 mm)
to allow oil to drain from the rotor into the body base.
When the oil is drained from the rotor assembly, lift
it straight up until it clears the base shaft.
6. Position the unit on a clean work table and remove
the knurled can nut from the rotor assembly.
NOTICE
Use caution during disassembly to avoid damage to
the brass bushings.
Form 6277-5
4.30-17 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
MICROSPIN CENTRIFUGE CLEANING – P/N 489189
1
1. Remove the paper insert from the rotor can by
inserting a narrow flat tool between the paper insert
2 and the rotor can. Run the tool around the inside of
the can and remove the paper insert. Clean the
contaminant build up in the rotor can, and insert a
new paper insert.
3
NOTICE
Remove rubber O-rings prior to placing parts in the
4
13 solvent tank to prevent damage to equipment.
5 ! WARNING
9
2. Clean the baffle screen assembly, rotor turbine, rotor
14 can, covers and jets in a suitable solvent tank.
10
MICROSPIN CENTRIFUGE ASSEMBLY – P/N
489189
1. Install the baffle screen and new O-ring on the
11 turbine rotor.
NOTICE
12 The knurled can nut must be tightened hand-tight only,
or damage to equipment could result.
Form 6277-5
4.30-18 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
1 2
Form 6277-5
4.30-19 © Copyright 2023, INNIO's Waukesha Engine
LUBRICATION SYSTEM MAINTENANCE
Form 6277-5
4.30-20 © Copyright 2023, INNIO's Waukesha Engine
SECTION 4.35
EXHAUST SYSTEM MAINTENANCE
Before performing any service, maintenance or repair 5. Excessive exhaust backpressure may be due to one
procedures, review SAFETY on page 1.05-1 and or more of the following conditions:
RIGGING AND LIFTING ENGINES on page 1.10-1. • Undersized piping
• Elbows, bends or sudden enlargements in the
EXHAUST SYSTEM BACKPRESSURE piping
MEASUREMENT
• Plugged catalytic converter
Monitor the exhaust system backpressure regularly. The • Pipe obstructions
maximum backpressure must not exceed specification.
• Exit losses
1. Drill and tap a hole (1/4 in. NPT) in the customer-
supplied exhaust piping. Place the hole 12 in. (305
mm) downstream from the mating flange of the EXHAUST SYSTEM TEMPERATURE
Waukesha-supplied flexible exhaust connection. MONITORING
The measurement must be taken before the silencer Exhaust temperatures can be an important diagnostic
or catalytic converter, if provided, and should be tool but there are differences found between rich and
away from any bend or elbow in the exhaust piping. lean burn engines:
2. Install a tubing connector in the hole. Use only non- • Rich Burn – Very rich mixture will lower exhaust
corroding stainless-steel fittings. temperature and a very lean mixture will also lower
Normal exhaust temperatures are model- exhaust temperature.
dependent; that is, air/fuel ratio and load- • Lean Burn – Very rich mixture will raise exhaust
dependent, naturally aspirated, turbocharged, temperature.
lightly loaded, heavily loaded and ignition timing all
affect the exhaust temperature. See the Waukesha • Both Systems – Very low temperatures are an
Gas Engine Technical Data manual for specific indication of misfiring.
details. NOTE: Verification of proper thermocouple readings is
3. Connect one end of a water manometer to the essential.
connector and vent the free end to the atmosphere. The maximum exhaust temperature variation across the
The manometer line fitting must not protrude beyond entire engine should be within 100°F (47°C) for all
the inner surface of the exhaust pipe or an inaccurate models.
reading may result.
NOTE: Since air/fuel ratio, ambient air temperature and
4. Measure the exhaust backpressure at rated speed
many other factors may affect exhaust gas
and load. Corrective action must be taken if the
temperatures, call the Waukesha Field Service
backpressure exceeds the specified limit.
Department if additional information is required.
Check engine exhaust temperatures for each cylinder
daily. Monitor the exhaust temperatures when the
engine is running at rated speed and load.
One exhaust thermocouple is mounted in each exhaust
manifold segment. A thermocouple is also mounted
before each turbocharger.
Form 6277-5
4.35-1 © Copyright 2023, INNIO's Waukesha Engine
EXHAUST SYSTEM MAINTENANCE
Be on the alert for wide differences between cylinders or EXHAUST SYSTEM INSPECTION
between cylinder banks. The actual exhaust
1. Inspect the exhaust manifolds and exhaust piping for
temperature readings are not as important as the
leaks.
variations that may occur.
2. Record the exhaust manifold temperatures for
1. Rotate the pyrometer selector switch to select the
reference.
cylinder to be monitored.
NOTE: Right bank and left bank are determined by
standing at the flywheel end of the engine facing the
flywheel. The cylinders farthest from the flywheel on the
left and right side are the No. 1L and No. 1R cylinders,
respectively.
2. Record the temperature value for each cylinder.
Form 6277-5
4.35-2 © Copyright 2023, INNIO's Waukesha Engine
SECTION 4.40
CRANKCASE BREATHER SYSTEM MAINTENANCE
Before performing any service, maintenance or repair 2. Remove the capscrews, lock washers, gaskets and
procedures, review SAFETY on page 1.05-1 and the separator screen assembly from the top of the
RIGGING AND LIFTING ENGINES on page 1.10-1. cylinder block.
NOTE: After cleaning, servicing or replacing any
component of the crankcase breather system, recheck 1
the crankcase pressure to verify that it is within
specification and that all system components are 2
functioning properly. 3
4
SEPARATOR SCREEN 9
On 6-cylinder engines, the separator screen is located 5
in the firing deck of the crankcase at the rear of the
engine (see Figure 4.40-1). On 12-cylinder engines, the
separator screen is located in the rear right side of the
engine on the cylinder firing deck. Sixteen-cylinder
engines do not have separator screens. 8
1 - Elbow 6 - Gaskets
2 - Hose Clamp 7 - Separator Screen
3 - Breather Tube 8 - Flange
4 - Hose Clamp 9 - Hose
5 - Hose Clamps
Form 6277-5
4.40-1 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
CRANKCASE SEPARATOR SCREEN CLEANING CRANKCASE SEPARATOR SCREEN ASSEMBLY
AND INSPECTION 1. Position a new gasket over the rectangular hole on
the top of the cylinder block (rear right corner) (see
! WARNING Figure 4.40-1, Figure 4.40-2, Figure 4.40-3 and
Figure 4.40-4). Verify that the gasket surfaces are
Always read and comply with clean and completely free of grease and oil.
the manufacturer’s instructions
2. Install the separator screen in the cylinder block.
and warnings on the container
when using cleaning solvent. 3. Install a new gasket on top of the separator screen.
Cleaning solvents may be toxic 4. Fasten the separator screen and breather transition
or flammable. Keep away from assembly to the top of the cylinder block lock
heat or flame. Always use washers and capscrews.
approved cleaning solvents in a
5. Install the oil separator tubing.
well-ventilated area. Do not use
gasoline, paint thinners or other
highly volatile fluids for
cleaning.
1
1. Wash the screen in a non-volatile cleaning solution
or solvent, if necessary.
2
2. Remove the separator screen and breather tube
assembly.
! WARNING
Form 6277-5
4.40-2 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
OIL SEPARATOR(S)
Six-cylinder and 12-cylinder G engines have one oil
separator located at the rear of the engine (see Figure
4.40-5).
1
1
2 4
2
5
4
6
9
8
Figure 4.40-4: 12-Cylinder Crankcase Separator Screen
Assembly
Figure 4.40-5
Form 6277-5
4.40-3 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
OIL SEPARATOR CLEANING AND INSPECTION –
6- AND 12-CYLINDER ENGINES
Clean the oil separator at each oil change.
NOTE: Current production separators have elongated
indentations along the circumference of the cover. This
indicates that the upper foam filter is removable.
1. Disconnect the breather plumbing from the
separator as required and remove the oil separator
from the engine. Release the two latches on the
separator and remove the cover (see Figure
4.40-5).
2. Remove the O-ring from the cover.
3. Pry the screen out of the cover and remove the foam
(see Figure 4.40-6). Remove the upper screen from
the inside of the cover.
Figure 4.40-7
5. Wipe the inside of the cover clean.
6. Install the upper screen to the inside of the cover.
7. Place the foam into place in the retaining screen
(see Figure 4.40-8).
Figure 4.40-6
4. Wash the foam in a detergent solution and wring dry
by hand (see Figure 4.40-7). Do not use a mineral-
based solvent.
Figure 4.40-8
8. Press the retaining screen and foam into the cover
(see Figure 4.40-9).
Form 6277-5
4.40-4 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
2. Loosen the retaining clamp and remove the lid from
the body of the oil separator (see Figure 4.40-11 and
Figure 4.40-12).
2 3
6
4
Figure 4.40-9
9. Install the O-ring on the cover. Figure 4.40-11: 16-Cylinder Oil Separator
10. Clean the lower separator body in a solvent tank. 1 - Lid 4 - Separator Body
Allow the separator to dry (see Figure 4.40-10). 2 - O-Ring 5 - Wing Nut
3 - Filter 6 - Nut
Figure 4.40-10
11. Install the separator on the engine. Connect the drain
tube to the separator (if equipped).
12. Install the cover on the separator. Install the breather
plumbing as required.
Form 6277-5
4.40-5 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
7. Install the filter element in the separator body with
1 the handle on the filter facing up, and hand-tighten
the wing nut.
8. Place the rubber O-ring seal on the inside rim of the
lid.
9. Position the lid and clamp on the separator body and
secure by tightening the nut on the clamp.
Form 6277-5
4.40-6 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
4. Install bottom half of oil separator onto top half.
Form 6277-5
4.40-7 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
Table 4.40-1: G-962-503 VHP-12 GSI Retrofit Kit Parts List
Form 6277-5
4.40-8 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
Form 6277-5
4.40-9 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
OIL SEPARATOR DIAPHRAGM KITS
New oil separator diaphragm kits have been released. 1
3
9
Form 6277-5
4.40-10 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
6-CYLINDER ENGINE CRANKCASE PRESSURE
ADJUSTMENT CONTROLS
1 On 6-cylinder engines, crankcase pressure is adjusted
with either a venturi/adjusting capscrew assembly (see
Figure 4.40-19), an ejector breather/adjusting valve
assembly (see Figure 4.40-20) or vacuum valve (see
Figure 4.40-21).
Figure 4.40-17
1
1
2
4
Figure 4.40-18 2
1 - Vent 3 - Manometer
2 - Shutoff Valves 4 - To Crankcase
3. Measure the crankcase pressure and perform all
pressure adjustments while the engine is operating Figure 4.40-20: 6-Cylinder Ejector Breather / Adjusting
at rated speed and load (see CRANKCASE Valve Assembly
PRESSURE ADJUSTMENT on page 4.40-12).
1 - Adjusting Valve 2 - Ejector Breather
4. Remove the manometer line and tube connector.
Install the pipe plug.
Form 6277-5
4.40-11 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
12-CYLINDER ENGINE CRANKCASE PRESSURE
ADJUSTMENT CONTROLS
On 12-cylinder engines that are not equipped with
venturi extractor, the crankcase pressure is adjusted
with a vacuum valve assembly, of which there are
different configurations (see Figure 4.40-21 and Figure
4.40-22). On 12-cylinder engines equipped with a
venturi extractor, a choke valve is located on the end of
the venturi extractor (see Figure 4.40-23).
2
1
1
2
Figure 4.40-23
Form 6277-5
4.40-12 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
d. Clean and inspect the crankcase breather CLEANING AND INSPECTION
regulator assembly.
e. Clean and inspect the venturi extractor
! WARNING
assembly.
Never use your hand to check
f. Inspect the air cleaner prefilter pads and main
for leaks or determine airflow
filter elements. Clean or replace as necessary.
rates when using compressed
g. Measure the exhaust backpressure. Excessive air. Compressed air can pierce
backpressure reduces breather system the skin.
effectiveness.
Wear protective equipment to
NOTE: After cleaning, servicing or replacing any protect your skin. Wear safety
component of the crankcase breather system, recheck glasses to shield your eyes from
the crankcase pressure to verify that it is within flying dirt and debris.
specification and that all system components are
functioning properly.
Figure 4.40-24
NOTE: Location varies with engine model.
While there is no manual adjustment of the crankcase
breather regulator, it should be inspected annually for an
accumulation of dirt or grit. Harsh environments may
dictate more frequent attention.
Form 6277-5
4.40-13 © Copyright 2023, INNIO's Waukesha Engine
CRANKCASE BREATHER SYSTEM MAINTENANCE
NOTICE
If replacement of the breather regulator housing or
valve assembly is necessary, be sure to order the
1 correct part numbers. Since air flow requirements vary
between engine models and applications, the
housings and valves are sized or weighted differently
and are not interchangeable.
5
6
Figure 4.40-25
Figure 4.40-26
1 - Housing 5 - Valve Hub 1. Shut down the engine and allow it to cool.
2 - Rod 6 - O-Ring
2. Lift the valve off its seat to verify that the plate is free
3 - E-Clip 7 - Screen
to move.
4 - Valve Plate 8 - Locknut
2. Inspect the regulator housing for cracks. ! WARNING
3. Inspect the regulator rod for scratches or burrs.
The number of pressure relief
4. Inspect the O-ring for cuts, tears or loss of elasticity.
valves used on the engine
5. Inspect the valve plate for nicks, cracks or damage.
! depends on the volume of the
crankcase. When using this
option, never operate the engine
without proper number of valves
on the engine. The ability of the
system to function is dependent
upon the proper number of relief
valves.
Form 6277-5
4.40-14 © Copyright 2023, INNIO's Waukesha Engine
SECTION 4.45
PRELUBE AND STARTING SYSTEM MAINTENANCE
! WARNING
Figure 4.45-1
ELECTRIC STARTER
AIR / GAS STARTER LUBRICATION
! WARNING RESERVOIR
1. Prior to each start, check the air/gas starter reservoir
Always disconnect electrical for lubricant (see Figure 4.45-2 and Figure 4.45-3).
power during inspection of
electrical components.
Figure 4.45-2
Form 6277-5
4.45-1 © Copyright 2023, INNIO's Waukesha Engine
PRELUBE AND STARTING SYSTEM MAINTENANCE
3. Replace the plug.
1 2
1
3
5 4
2
Figure 4.45-4
NOTICE
The lubricator is intended for systems using dry, clean
natural gas. Any appreciable amount of hydrogen
sulfide (H2S), particularly when combined with
moisture, will cause corrosion and adversely effect the
lubricator and its operation.
Figure 4.45-3 From the point of use, some oil mist may escape into
the surrounding atmosphere. Users are referred to
1 - Reservoir 2 - Plug OSHA safety and health standards for limiting oil mist
contamination and use of protecting equipment.
INLINE LUBRICATOR The maximum operating temperature of the lubricator
is 175°F (79°C).
! WARNING
Form 6277-5
4.45-2 © Copyright 2023, INNIO's Waukesha Engine
PRELUBE AND STARTING SYSTEM MAINTENANCE
ADJUSTMENTS
1
Periodically check the lubricator drip rate. If the prelube
pump motor exhaust is oil-free or contains an excessive
amount of oil, manual adjustment is necessary.
2 1. Locate the oiler adjusting capscrew at the top of the
8 3 sight feed dome on the lubricator housing cover.
4 2. Pull the lock ring on the adjusting capscrew upward
to release the drip rate setting.
3. Adjust the drip rate only when there is a constant rate
of air/gas flow through the lubricator. Oil drops are
atomized by the air/gas flowing through the
lubricator throat. Monitor the drip rate through the
sight feed dome. All of the drops visible in the dome
7 are delivered to the prelube pump motor.
5
4. Adjust the lubricator to provide a light oil vapor at the
prelube motor exhaust (about 4 – 5 drops per
minute). Turn the adjusting capscrew clockwise to
decrease the drip rate, turn the capscrew
6 counterclockwise to increase it.
5. Push the lock ring on the adjusting capscrew
downward to lock the drip rate setting.
Figure 4.45-5: Inline Lubricator 6. Monitor the prelube pump motor for a few days
following the adjustment. Readjust the drip rate if
1 - Oiler Adjusting 5 - Reservoir Level
necessary.
Screw Sight Glass
2 - Sight Feed Dome 6 - Drain Plug
CLEANING
3 - Vent Plug 7 - 8 oz (0.2 L)
4 - Air/Gas Outlet Reservoir Clean the inline lubricator monthly.
8 - Air/Gas Inlet 1. With the inlet pressure shut off, slowly loosen the oil
fill plug in the lubricator housing cover. Loosening
NOTICE the plug exposes a bleed orifice that reduces
pressure in the oil reservoir. Remove the oil fill plug.
Ensure that oil level of the inline lubricator is always
2. Remove the drain plug at the bottom of the reservoir.
visible in the sight glass. DO NOT OVERFILL the
Drain the oil.
reservoir.
3. Unthread the reservoir from the lubricator housing
2. Remove the plug and fill the reservoir to the proper cover.
level. DO NOT OVERFILL. The oil level must always 4. Inspect the O-ring on the upper lip of the reservoir for
be visible in the sight glass. Use the proper grade of tears, cuts or general deterioration. Replace as
oil. Add SAE 10W oil at 32°F (0°C) and above. Use necessary.
No. 2 Diesel Oil when ambient temperatures fall
below 32°F (0°C).
3. Inspect the O-ring on the neck of the oil fill plug for
tears, cuts or general deterioration. Replace as
necessary.
4. Install the plug in the lubricator housing cover.
Form 6277-5
4.45-3 © Copyright 2023, INNIO's Waukesha Engine
PRELUBE AND STARTING SYSTEM MAINTENANCE
! WARNING ALTERNATOR
VHP engines have an optional 24-volt alternator. This
Never use your hand to check alternator can be used to run accessories or recharge
for leaks or determine airflow starting system batteries. Two styles of alternators are
rates when using compressed available. One alternator is driven from a jackshaft out of
air. Compressed air can pierce the front gear housing (see Figure 4.45-6). The other
the skin. alternator option is driven from a pulley installed on the
crankshaft (see Figure 4.45-7).
Wear protective equipment to
protect your skin. Wear safety The alternator uses two drive belts to increase belt life
glasses to shield your eyes from and ensure reliability.
flying dirt and debris.
NOTE: These belts are a matched set and must be
replaced as a pair to ensure proper operation.
Form 6277-5
4.45-4 © Copyright 2023, INNIO's Waukesha Engine
PRELUBE AND STARTING SYSTEM MAINTENANCE
BATTERY CONNECTION JACKSHAFT ALTERNATOR V-BELT
1. When connecting a battery and alternator, make TENSION
certain the ground polarity of the battery and the
ground polarity of the alternator are the same. ! WARNING
2. When connecting a booster battery, always connect
the negative battery terminals together and the Always stop the unit before
positive battery terminals together. cleaning, servicing or repairing
3. When connecting a charger to the battery, connect the unit or any driven
the charger positive lead to the battery positive equipment.
terminal first. The charger negative lead to the
battery negative terminal is connected last.
4. Never operate the alternator on open circuit. Make
certain all connections in the circuit are secure. 1. Loosen the upper pivot capscrew on the upper end
of the alternator (see Figure 4.45-8).
5. Do not short across or ground any of the terminals
on the alternator.
6. Do not attempt to polarize the alternator.
ALTERNATOR SERVICING
The frequency of inspection is determined largely by the
type of operating conditions. High-speed operation, high
temperatures and dust and dirt all increase the wear of
brushes, slip rings and bearings.
At regular intervals, inspect the terminals for corrosion
and loose connections. Inspect the wiring for frayed
insulation. Inspect the mounting capscrews for
tightness, and the belt for alignment, proper tension and
wear. Belt tension should be adjusted on a routine basis.
When adjusting belt tension, apply pressure against the
stator laminations and between the end frames and not
against either end frame. Figure 4.45-8: Alternator Belt Adjustment Pivot
2. Loosen the adjusting capscrew on the alternator
ALTERNATOR NOISE (see Figure 4.45-9).
Noise from an alternator may be caused by worn or dirty
bearings, loose mounting capscrews, a loose drive
pulley, a defective diode or a defective stator. Inspect for
any of these causes and repair or replace as necessary.
Form 6277-5
4.45-5 © Copyright 2023, INNIO's Waukesha Engine
PRELUBE AND STARTING SYSTEM MAINTENANCE
3. When the desired belt tension is reached, tighten the ALTERNATOR V-BELT MAINTENANCE
adjusting capscrew and pivot capscrew.
1. Always use new, matching belt sets.
NOTE: A new belt is adjusted to a greater tension due 2. When replacing belts, always replace the entire set
to tension loss which occurs during break-in. of belts, not just the ones that look worn. This will
ensure proper belt operation.
CRANKSHAFT ALTERNATOR V-BELT 3. To check belt tension, depress the belt with your
TENSION fingers. A tensioned belt will feel alive and springy.
Belts that are too tight will not deflect and loose belts
! WARNING will feel dead.
4. Keep belts at the proper tension. New belts will
Always stop the unit before stretch shortly after installation. Loose belts will slip,
cleaning, servicing or repairing causing power loss and heat buildup. Belts that are
the unit or any driven too tight will deteriorate rapidly and wear out engine
equipment. shaft bearings.
5. To avoid belt damage, always loosen the pulley
adjustment when installing belts. Never pry a belt
over a pulley.
1. Remove the guarding from the alternator.
2. Loosen the lower pivot capscrew on the end of the
alternator (see Figure 4.45-10).
Form 6277-5
4.45-6 © Copyright 2023, INNIO's Waukesha Engine
SECTION 4.50
ENGINE PROTECTION SYSTEM MAINTENANCE
Before performing any service, maintenance or repair 1. Inspect the thermocouples (see Figure 4.50-1,
procedures, review SAFETY on page 1.05-1 and Figure 4.50-2, Figure 4.50-3 and Figure 4.50-4) to
RIGGING AND LIFTING ENGINES on page 1.10-1. ensure they are securely seated.
Maintenance of the engine protection system is 2. Inspect connecting cables and wires for loose
generally limited to visual inspection of components. connections, broken wires or insulation.
! WARNING
!
automatic engine shutdown
must be supplied by the
customer. The sensors
provided are for measuring and
monitoring temperatures and
WILL NOT shut the engine down
if potentially harmful
temperatures are reached.
It is the customer’s Figure 4.50-1: Jacket Water Temperature Sensor
(Inspect Thermocouple and Connecting Harness)
!
responsibility to provide engine
protection switches and fuel
shutoff valves wired to
simultaneously shut off the
ignition and the fuel for the
following conditions: normal
shutdown, overspeed, low lube
oil pressure, high jacket water
temperature and high intake
manifold pressures.
Thermocouples can be
extremely hot. Allow engine to
cool prior to handling
thermocouple.
Form 6277-5
4.50-1 © Copyright 2023, INNIO's Waukesha Engine
ENGINE PROTECTION SYSTEM MAINTENANCE
OPTIONAL SENSORS
2
The optional CEC Air/Fuel Module (AFM) uses sensors
in the exhaust outlet that require periodic inspection.
Figure 4.50-3: Exhaust Thermocouples
1. Inspect the sensors (see Figure 4.50-5 and Figure
1 - Inspect 2 - Exhaust Manifold 4.50-6) to ensure they are securely seated.
Thermocouple End Section
Temperature 2. Inspect connecting cables and wires for loose
Sensor and connections, broken wires or insulation.
Connecting
Harness
Form 6277-5
4.50-2 © Copyright 2023, INNIO's Waukesha Engine
ENGINE PROTECTION SYSTEM MAINTENANCE
5
Figure 4.50-7: 12-Cylinder GL Manual Shutdown Lever
Figure 4.50-6: Lean Burn Oxygen Sensing Assembly
DETONATION SENSING MODULE AND
1 - Lean Burn Oxygen 4 - Sensor Block
Sensor 5 - Heater
SENSORS
2 - Gasket 6 - Thermocouple
! WARNING
3 - Special Pipe Nipple
Figure 4.50-8
Form 6277-5
4.50-3 © Copyright 2023, INNIO's Waukesha Engine
ENGINE PROTECTION SYSTEM MAINTENANCE
Form 6277-5
4.50-4 © Copyright 2023, INNIO's Waukesha Engine
SECTION 4.55
VALVE ADJUSTMENT
Before performing any service, maintenance or repair 2. Remove the rocker arm cover capscrews, washers
procedures, review SAFETY on page 1.05-1, RIGGING and spark plug cable clips (two capscrews per
AND LIFTING ENGINES on page 1.10-1 and the cover).
following safety message.
NOTE: A special tool (P/N 494287) may be used for
removing the rocker arm cover capscrews. The same
VALVE ADJUSTMENT tool can also be used for loosening the cam follower
capscrews and rocker arm adjusting capscrews,
NOTICE enabling the operator to perform multiple operations
without switching tools.
In any procedure where the rocker arms may have
been removed or disturbed, the cylinder head 3. Remove the rocker arm covers. Use a rubber mallet
replaced or if it is suspected that the valves may have to loosen the covers, if necessary.
been adjusted incorrectly, do not rotate the crankshaft NOTE: Set the valves in the order that the engine fires
until all rocker arm adjusting capscrews have been (see Table 4.55-1). The cylinder firing order appears on
completely backed off. the engine nameplate. Each piston must be brought into
top dead center position, compression stroke.
NOTE: All VHP gas engines use hydraulic valve lifters. 4. Using the engine barring device (see Figure
4.55-1), turn the engine over in a counterclockwise
To compensate for slight differences in wear between direction (facing the flywheel) until the piston of the
the valves and valve seats, adjust the valve clearance first cylinder in the firing order is at top dead center
every 3 months (2,160 hours). Install new rocker arm (compression stroke) (see Table 4.55-1).
cover gaskets when the valve adjustments are
performed.
NOTICE
Shut the engine down and allow it to cool for at least 1
hour before adjusting the valves.
Form 6277-5
4.55-1 © Copyright 2023, INNIO's Waukesha Engine
VALVE ADJUSTMENT
Table 4.55-1: Valve Settings
Form 6277-5
4.55-2 © Copyright 2023, INNIO's Waukesha Engine
VALVE ADJUSTMENT
NOTE: To obtain the proper end clearance between the
intake and exhaust rocker arms and the support, place 1 3
a feeler gauge 0.015 – 0.020 in. (0.381 – 0.508 mm) for
the exhaust rocker arm, and 0.010 – 0.015 in. (0.254 – 2
0.381 mm) for the intake rocker arm, between one end
of the rocker arm and the support. The adjusting
capscrew cam followers should be centered on the valve
stem tips. If the cam followers are not properly centered,
loosen the two capscrews and slightly shift the rocker
arm support. After the best position is obtained, torque
the rocker arm support capscrews to specifications. See
Crankcase Components in Table 1.15-17 Critical
Engine Torque Values on page 1.15-28 for specific
torque values. 4
5. Loosen the locknuts and adjusting capscrews at all
four valve stem tips (see Figure 4.55-2).
Figure 4.55-3: Previous Production Rocker Arm
Adjusting Capscrews
1 3
2
Figure 4.55-2
6. Look for cracks or breakage around the ball and cam
follower insert of the rocker arm adjusting capscrews
(see Figure 4.55-3 and Figure 4.55-4). Verify that the
ball rotates freely in all directions without binding. 4
Replace the adjusting capscrew, if necessary.
Form 6277-5
4.55-3 © Copyright 2023, INNIO's Waukesha Engine
VALVE ADJUSTMENT
7. Mark the two fixed cam follower capscrews (see
Figure 4.55-6). Back out the fixed capscrews 1/2 turn
to remove the preload from the hydraulic valve lifters. 1
Verify that the hydraulic valve lifter plunger is fully
extended up against the C-clip (see Figure 4.55-5).
2
1
3 2
3
Figure 4.55-6
Form 6277-5
4.55-4 © Copyright 2023, INNIO's Waukesha Engine
VALVE ADJUSTMENT
19. Rotate the cam followers of the two exhaust rocker
arm adjusting capscrews to feel for equal contact
with the valve stem tips. Readjust, if necessary.
20. Turn the two fixed cam follower capscrews
clockwise 1/2 turn to their original setting. Preloading
the hydraulic valve lifter backs the plunger off the C-
clip and moves it into the upper range of lifter travel.
Torque each cam follower capscrew to
specifications. See Crankcase Components in
Table 1.15-17 Critical Engine Torque Values on
page 1.15-28 for specific torque values.
21. Rotate the cam followers of the two intake and two
exhaust rocker arm adjusting capscrews to feel for
equal contact with the valve stem tips.
22. Rotate the engine counterclockwise to the next
cylinder in the firing order, top dead center
(compression stroke). Repeat the above procedures
for each cylinder in the firing order (see Table
4.55-1). Watch each mating cylinder for valve
overlap.
23. After all valves are adjusted and before starting the
engine, use the engine barring device to manually
rotate the engine in a counterclockwise direction to
be certain that no oversights have occurred which
might cause valve and piston interference.
24. Scrape the old gasket material from the valve covers
and cylinder heads.
25. Verify that the rocker arm cover and cylinder head
gasket surfaces are clean and completely free of
grease and oil.
26. Place new gaskets on the rocker arm covers.
NOTICE
Carefully check the cylinder head for any old gasket
debris before installing the rocker arm covers.
Form 6277-5
4.55-5 © Copyright 2023, INNIO's Waukesha Engine
VALVE ADJUSTMENT
Form 6277-5
4.55-6 © Copyright 2023, INNIO's Waukesha Engine
SECTION 4.60
MAINTENANCE SCHEDULE
!
such as extreme cold or very dirty conditions. Pick the
shortest time listed when given a choice.
Regularly inspect the engine in operation (see Table
4.60-1). Duplicate the ENGINE PERFORMANCE
RECORD on page 4.60-5 and use it to record the
results of regular inspections. By maintaining trend
information on the general condition of the engine, the
necessary corrective action can be taken when a
problem first becomes apparent. An early diagnosis will
save money and reduce down time by preventing the
development of more serious problems.
Table 4.60-1: Routine Maintenance Chart
DAILY OR AS REQUIRED
1,500 HRS.
2,500 HRS.
4,000 HRS.
8,000 HRS.
250 HRS.
500 HRS.
720 HRS.
ITEM SERVICE
Check/Clean or
Air Cleaner Filter Element •
Replace
Air Starter Lubricator Check/Fill •
Control Rod Ends and Linkage Clean/Lubricate •
Cooling Systems Fluid Level (Jacket and
Check/Fill •
Auxiliary)
Crankcase Oil Level Check/Fill •
Governor Oil Level Check/Fill •
Governor Synchronizer or Speed Control Adjust •
Oil Filter Release Trapped Air •
Check/Clean or
Pre-Cleaner Element •
Replace
Prelube Motor Reservoir Check/Fill •
Power Take-off Lubricate •
Form 6277-5
4.60-1 © Copyright 2023, INNIO's Waukesha Engine
MAINTENANCE SCHEDULE
DAILY OR AS REQUIRED
1,500 HRS.
2,500 HRS.
4,000 HRS.
8,000 HRS.
250 HRS.
500 HRS.
720 HRS.
ITEM SERVICE
Engine Oil & Filter* (ISO Standard or Change Oil and Filter •
Continuous Duty with Microspin)
Engine Oil & Filter* (Excess of ISO Standard Change Oil and Filter •
or Continuous Duty)
Engine Oil & Filter* (Light Load Operation) Change Oil and Filter •
Engine Oil & Filter* (Standby Duty) (Annually Change Oil and Filter • •
or 250 hours, whichever is reached first)
Form 6277-5
4.60-2 © Copyright 2023, INNIO's Waukesha Engine
MAINTENANCE SCHEDULE
DAILY OR AS REQUIRED
1,500 HRS.
2,500 HRS.
4,000 HRS.
8,000 HRS.
250 HRS.
500 HRS.
720 HRS.
ITEM SERVICE
99 Regulator(s) Adjust •
Form 6277-5
4.60-3 © Copyright 2023, INNIO's Waukesha Engine
MAINTENANCE SCHEDULE
DAILY OR AS REQUIRED
1,500 HRS.
2,500 HRS.
4,000 HRS.
8,000 HRS.
250 HRS.
500 HRS.
720 HRS.
ITEM SERVICE
Form 6277-5
4.60-4 © Copyright 2023, INNIO's Waukesha Engine
MAINTENANCE SCHEDULE
Date Time
Serial No. Spec. No. Model
Hour Meter Reading rpm Ambient Temperature
Ignition Timing Load Hours on Spark Plugs
Oil Temperature Oil Pressure
Jacket Water Temperature Outlet Inlet
Auxiliary Water Temperature In Out
Gas/Air Pressure Supply Pressure
Intake Manifold Pressure Intake Manifold Temperature
Exhaust Manifold Oxygen %
Exhaust Backpressure Crankcase Pressure (Positive/Negative)
Detonation Module Status
Unusual Noise(s) Vibration
Oil Leaks (Location)
Coolant Leaks (Location)
EXHAUST MANIFOLD
EXHAUST MANIFOLD TEMPERATURES: TEMPERATURE
(PRE-TURBINE)
1. 1. LB
2. 2. RB
3. 3.
4. 4.
5. 5.
6. 6.
7. 7.
8. 8.
Form 6277-5
4.60-5 © Copyright 2023, INNIO's Waukesha Engine
MAINTENANCE SCHEDULE
Form 6277-5
4.60-6 © Copyright 2023, INNIO's Waukesha Engine
TROUBLESHOOTING AND STORAGE
SECTION 5.00
TROUBLESHOOTING
Form 6277-5
5.00-1 © Copyright 2023, INNIO's Waukesha Engine
TROUBLESHOOTING
NOTICE
Insufficient or no air intake: Bar the engine over by hand to verify that cylinders
are clear. Inspect the intake manifold for
accumulations of lube oil.
Form 6277-5
5.00-2 © Copyright 2023, INNIO's Waukesha Engine
TROUBLESHOOTING
Form 6277-5
5.00-3 © Copyright 2023, INNIO's Waukesha Engine
TROUBLESHOOTING
Form 6277-5
5.00-4 © Copyright 2023, INNIO's Waukesha Engine
TROUBLESHOOTING
! WARNING
Shut off the gas Overheated combustion chamber
supply for positive deposits cause the engine to run on Allow engine to cool down before attempting to stop.
shutdown of gas auto ignition.
engines. Inspect
the intake manifold
for accumulations
of oil.
Form 6277-5
5.00-5 © Copyright 2023, INNIO's Waukesha Engine
TROUBLESHOOTING
Shut down the engine Change oil and filter elements. Determine and correct
Lube oil dilution.
source of dilution.
immediately; investigate cause.
Lube oil of low viscosity. Change to higher viscosity oil as recommended.
Use oil grade recommended. Check for coolant leaks
Lube oil foaming.
into oil.
Clogged oil inlet screen(s). Remove and clean screen(s).
Engine is operated at angles that
Operate within maximum safe tilt angles (see
exceed the maximum safe tilt
Specifications).
specification.
Dirty oil cooler. Clean.
Low gas/air pressure. Insufficient line pressure. Increase line pressure.
Form 6277-5
5.00-6 © Copyright 2023, INNIO's Waukesha Engine
TROUBLESHOOTING
! WARNING
Allow the engine to cool.
Gauge inaccurate.
High jacket water temperature. Gauge line clogged or valve shut. Replace line, open valve.
Low coolant level. Fill cooling system.
Broken or loose water pump belts. Replace or adjust belts.
Air bound cooling system. Purge air from cooling system.
Engine overloaded. Determine and correct cause.
Leaking pump seals. Repair pump.
Completely thaw cooling system before restarting
Frozen coolant.
engine.
Incorrect ignition timing. Reset ignition timing.
Compare to master gauge; replace gauge if
Gauge inaccurate.
necessary.
Clogged gauge line or the gauge line
Replace line or open valve.
valve is shut.
High auxiliary water temperature.
Broken or loose auxiliary water
Replace or adjust belts.
pump belts.
Clogged heat exchanger or
Clean heat exchanger/intercooler.
intercooler.
Form 6277-5
5.00-7 © Copyright 2023, INNIO's Waukesha Engine
TROUBLESHOOTING
Form 6277-5
5.00-8 © Copyright 2023, INNIO's Waukesha Engine
TROUBLESHOOTING
Form 6277-5
5.00-9 © Copyright 2023, INNIO's Waukesha Engine
TROUBLESHOOTING
Form 6277-5
5.00-10 © Copyright 2023, INNIO's Waukesha Engine
TROUBLESHOOTING
Table 5.00-2: Spark Plug Troubleshooting
NOTE: If any of the above conditions exist, be sure to correct the cause before installing new spark plugs.
Form 6277-5
5.00-11 © Copyright 2023, INNIO's Waukesha Engine
TROUBLESHOOTING
Form 6277-5
5.00-12 © Copyright 2023, INNIO's Waukesha Engine
SECTION 5.05
STORAGE
Form 6277-5
5.05-1 © Copyright 2023, INNIO's Waukesha Engine
STORAGE
INNIO Waukesha Preservative Oil will not protect engine
surfaces in close contact with used engine oil. INNIO
NOTICE
Waukesha Preservative Oil will only do an effective job Engines stored outdoors or in humid environments
if added to clean engine oil. If high sulfur (gas or diesel) may require more frequent preservations and
or dirty oil has left highly corrosive oil in the bearings and inspections.
close-contact surfaces, the INNIO Waukesha
Preservative Oil vapors will not be able to form a
protective layer on these surfaces. Water-contaminated
engine oil will also prevent the preservative oil vapor
from forming a protective layer. Engines with dirty oil
should receive an oil change and be run long enough to
circulate the clean oil before adding the INNIO
Waukesha Preservative Oil.
INNIO Waukesha Preservative Oil is not intended as a
protective coating for external surfaces of the engine.
Other excellent products are available for protecting
polished or machined surfaces and should be used
when needed.
1. Begin with a cold engine (below 38°C [100°F])
containing clean engine oil and filter elements.
2. Add the required amounts of INNIO Waukesha
Preservative Oil to the oil pan, oil bath air filters, fuel
tanks and multi-plunger injection pumps.
3. Crank engine for approximately 20 seconds, if
possible, to help disperse INNIO Waukesha
Preservative Oil through fuel lines, injectors and
injection pumps.
4. Remove rocker arm covers, spark plugs or injectors.
Add the required amounts of INNIO Waukesha
Preservative Oil to each cylinder through the injector
or spark plug openings and replace the plugs or
injectors. Apply INNIO Waukesha Preservative Oil
to the rocker area with a brush, by pouring.
NOTE: On GL engines, allow ample time (1 minute
minimum) before installing spark plugs to allow INNIO
Waukesha Preservative Oil to flow through the spark
plug sleeve prechamber.
NOTE: Wipe engine clean and dry. Apply wax-type
masking tape or similar material to all openings in air
cleaners, exhaust outlets, breathers, magneto vents and
open line fittings. Use cardboard, plywood or metal
covers where practical to facilitate closing off openings
in the engine.
5. Engines may be stored up to 1 year after being
treated with INNIO Waukesha Preservative Oil. If
storage is to exceed this period, inspect engine
annually and repeat preservation routine. If deferred
start-up will be requested, Form 866 (deferred start-
up Engine Inspection form) will also need to be filled
out and submitted to the Warranty Administrative
Department.
Form 6277-5
5.05-2 © Copyright 2023, INNIO's Waukesha Engine
STORAGE
! WARNING
Form 6277-5
5.05-3 © Copyright 2023, INNIO's Waukesha Engine
STORAGE
Table 5.05-1: Engine Preservation Requirements
NOTICE
INNIO Waukesha Preservative Oil is not formulated as
a protective coating for external surfaces.
Form 6277-5
5.05-4 © Copyright 2023, INNIO's Waukesha Engine
STORAGE
Excellent products for polished and machined surfaces
are available on the market and should be used when
needed (see Table 5.05-3).
! WARNING
Form 6277-5
5.05-5 © Copyright 2023, INNIO's Waukesha Engine
STORAGE
Form 6277-5
5.05-6 © Copyright 2023, INNIO's Waukesha Engine
APPENDIX A – WARRANTY
Form 6277-5
© Copyright 2023, INNIO's Waukesha Engine
Form 6277-5
© Copyright 2023, INNIO's Waukesha Engine
INNIO's Waukesha Engine
1101 WEST ST. PAUL AVENUE,
WAUKESHA, WI 53188
www.innio.com