CONTENTS

How To Use This Manual Section 1.10 Rigging And Lifting

Engines
Engine Rigging And Lifting . . . . . . . . . . . . . . . . . 1.10 -- 1
CHAPTER 1 -- SAFETY AND Location Of The Lifting Eyes . . . . . . . . . . . 1.10 -- 1
Correct Method Of Rigging And
GENERAL Lifting Engine . . . . . . . . . . . . . . . . . . . . . . . . 1.10 -- 1

Section 1.00 Warning Tags And Decal Section 1.15 General Information
Locations Section Main Points . . . . . . . . . . . . . . . . . . . . . . . 1.15 -- 1
Overhaul/Repair Process . . . . . . . . . . . . . . . . . . 1.15 -- 1
Warning Tags And Decal Locations . . . . . . . . . 1.00 -- 1
Preventing Engine Damage . . . . . . . . . . . . . . . . 1.15 -- 1
12 Cylinder Engines . . . . . . . . . . . . . . . . . . . . . . 1.00 -- 2
Handling and Shipping . . . . . . . . . . . . . . . . . . . . 1.15 -- 1
Section 1.05 Safety Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 -- 2
Safety Introduction . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 1 Serial Number and Engine Nameplate . . . . . . . 1.15 -- 3
Safety Tags And Decals . . . . . . . . . . . . . . . . . . . 1.05 -- 1 Engine Identification Views . . . . . . . . . . . . . . . . 1.15 -- 4
Equipment Repair And Service . . . . . . . . . . . . . 1.05 -- 1 Right Side View . . . . . . . . . . . . . . . . . . . . . . 1.15 -- 4
Acids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 2 Left Side View . . . . . . . . . . . . . . . . . . . . . . . 1.15 -- 5
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 2 End View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 -- 6
Basic Engine Description . . . . . . . . . . . . . . . . . . 1.15 -- 7
Body Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 2
Service Tools list . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 -- 7
Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 2
Engine Standards . . . . . . . . . . . . . . . . . . . . . . . . 1.15 -- 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 2
Cleaning Solvents . . . . . . . . . . . . . . . . . . . . 1.05 -- 2 Component Weights . . . . . . . . . . . . . . . . . . 1.15 -- 9
Liquid Nitrogen/Dry Ice . . . . . . . . . . . . . . . . 1.05 -- 2 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 -- 9
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 2 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1.15 -- 10
Heated Or Frozen . . . . . . . . . . . . . . . . . . . . 1.05 -- 2 General Tightening Sequence
Interference Fit . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 -- 10
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 3 Thread Lubrication For Torque
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 -- 10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 3 Critical Engine Torque Values . . . . . . . . . 1.15 -- 11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 3 General Torque Recommendations . . . . 1.15 -- 13
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 3 Split Ring Washer Usability Criteria . . . . . . . . 1.15 -- 14
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 3 Temperature And Pressure Test Points . . . . . 1.15 -- 14
Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 3 English/Metric Conversions . . . . . . . . . . . . . . . 1.15 -- 17
Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 4 Index Of Sealants, Adhesives And
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 4 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 -- 18
Gaseous . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 4
Liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 4 Section 1.20 Specifications
Intoxicants And Narcotics . . . . . . . . . . . . . . . . . . 1.05 -- 4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 1
Pressurized Fluids/Gas/Air . . . . . . . . . . . . . . . . . 1.05 -- 4 Gear Tooth Wear - General . . . . . . . . . . . . 1.20 -- 1
Protective Guards . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 4 Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 2
Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 5 Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 2
Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 3
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 5
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 5
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 5
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 5 Crankcase Liner Bore . . . . . . . . . . . . . . . . . 1.20 -- 6
Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 5 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 7
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 5 Crankshaft Wear Limits . . . . . . . . . . . . . . . . 1.20 -- 8
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 5 Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 5 Connection Rod, Bushing And
On Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -- 5 Bearing Specifications . . . . . . . . . . . . . . . . 1.20 -- 9
Rocker Shaft Support And
Valve Bridge . . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 10
Rocker Arm Bores And Shafts . . . . . . . . . 1.20 -- 10
Intake And Exhaust Valves . . . . . . . . . . . . 1.20 -- 11
Standard Intake And Exhaust Seats . . . . 1.20 -- 12

Form 6296 First Edition iii

CONTENTS

Oversized (0.020 in.) Crankshaft Removal . . . . . . . . . . . . . . . . . . . . . 2.05 -- 18

Intake And Exhaust Seats . . . . . . . . . . . . 1.20 -- 13
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.05 -- 22
Oversized (0.030 in.)
Intake And Exhaust Seats . . . . . . . . . . . . 1.20 -- 14 Crankshaft #1 Main Bearing Removal In
Cylinder Head Valve Counterbore . . . . . . 1.20 -- 15 Field Conditions . . . . . . . . . . . . . . . . . . . . . 2.05 -- 22
Valve Clearance . . . . . . . . . . . . . . . . . . . . . 1.20 -- 16 Crankshaft #1 Main Bearing Installation In
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 16 Field Conditions . . . . . . . . . . . . . . . . . . . . . 2.05 -- 25
Valve Sequence . . . . . . . . . . . . . . . . . . . . . 1.20 -- 16 Crankshaft Main Bearings Removal In
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 17 Field Conditions . . . . . . . . . . . . . . . . . . . . . 2.05 -- 27
Crankshaft Web Deflection . . . . . . . . . . . . 1.20 -- 17 Crankshaft Main Bearings Installation In
Rear Gear Backlash Specifications . . . . 1.20 -- 18 Field Conditions . . . . . . . . . . . . . . . . . . . . . 2.05 -- 28
Accessory Gear Backlash . . . . . . . . . . . . 1.20 -- 18 Camshaft Bearing Removal In Field
Oil Pump And Oil Pump Drive Gears . . . 1.20 -- 19 Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 2.05 -- 29
Accessory Drive Ratios . . . . . . . . . . . . . . . 1.20 -- 19 Camshaft Bearing Installation In Field
Oil Pump Clearances . . . . . . . . . . . . . . . . 1.20 -- 20 Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 2.05 -- 30
Flywheel And Housing . . . . . . . . . . . . . . . 1.20 -- 21
Turbocharger Inspection . . . . . . . . . . . . . . 1.20 -- 22
Lubrication System Pressures And
Temperatures . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 22 CHAPTER 3 -- ENGINE INSPECTION
Lubrication System Engine Transient
Tilt Angles . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 22
AND OVERHAUL
Cooling System Temperatures . . . . . . . . . 1.20 -- 22
Alarm And Shutdown Setpoints . . . . . . . . 1.20 -- 23 Section 3.00 Cylinder Head
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 23 Disassembly And
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 24 Overhaul
Engine Compression Pressures . . . . . . . 1.20 -- 24 Cylinder Head Disassembly . . . . . . . . . . . . . . . . 3.00 -- 1
Break--in Schedules . . . . . . . . . . . . . . . . . 1.20 -- 25
Rocker Arms Disassembly . . . . . . . . . . . . . 3.00 -- 1
Engine Timing Data . . . . . . . . . . . . . . . . . . . . . . 1.20 -- 25
Rocker Arm Cleaning And Inspection . . . . 3.00 -- 2
Rocker Arm Assembly . . . . . . . . . . . . . . . . . 3.00 -- 3
Rocker Shaft Assembly Modifications . . . 3.00 -- 6
CHAPTER 2 -- ENGINE TEARDOWN Valve Bridge And Rocker Arm Sealing
Plug Expanders . . . . . . . . . . . . . . . . . . . . . . 3.00 -- 7
Valve Bridge Modifications . . . . . . . . . . . . . 3.00 -- 8
Section 2.00 Cylinder Head Removal Intake And Exhaust Valves . . . . . . . . . . . . . . . . 3.00 -- 9
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . 2.00 -- 1 Intake and Exhaust Valve Removal . . . . . 3.00 -- 9
Section 2.05 Crankcase Component Valve Seat Insert Removal . . . . . . . . . . . . 3.00 -- 11
Valve Guide Removal . . . . . . . . . . . . . . . . 3.00 -- 12
Removal Valve Bridge Guide Removal . . . . . . . . . . 3.00 -- 13
Piston/Connecting Rod Removal . . . . . . . . . . . 2.05 -- 1 Cylinder Head Cleaning And
Cylinder Liner Removal . . . . . . . . . . . . . . . . . . . 2.05 -- 4 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00 -- 13
Cylinder Head Casting Pressure
Vibration Damper Removal . . . . . . . . . . . . 2.05 -- 5 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00 -- 15
Front Gear Cover Removal . . . . . . . . . . . . . . . . 2.05 -- 6
Cylinder Head Casting Magnaflux . . . . . 3.00 -- 16
Magneto Drive Gear Removal . . . . . . . . . . . . . . 2.05 -- 8 Cylinder Head Lower Deck
Idler Gear Removal . . . . . . . . . . . . . . . . . . . . . . . 2.05 -- 9 Reconditioning . . . . . . . . . . . . . . . . . . . . . . 3.00 -- 17
Camshaft Gear Removal . . . . . . . . . . . . . . . . . . 2.05 -- 9 Valve Failure Analysis . . . . . . . . . . . . . . . . 3.00 -- 17
Valve Keeper Inspection . . . . . . . . . . . . . . 3.00 -- 20
Front Gear Housing Removal . . . . . . . . . . . . . 2.05 -- 10
Valve Guide Installation . . . . . . . . . . . . . . 3.00 -- 20
Rocker Arm Oil Header Removal . . . . . . . . . . 2.05 -- 11
Valve Bridge Guide Installation . . . . . . . . 3.00 -- 21
Valve Lifter Housing Removal . . . . . . . . . . . . . 2.05 -- 11 Valve Seat Installation . . . . . . . . . . . . . . . . 3.00 -- 21
Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . 2.05 -- 14 Valve Seat Grinding . . . . . . . . . . . . . . . . . . 3.00 -- 23
Barring Device Removal . . . . . . . . . . . . . . . . . . 2.05 -- 15 Valve Seat Lapping . . . . . . . . . . . . . . . . . . 3.00 -- 24
Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . 2.05 -- 15 Valve Spring Inspection . . . . . . . . . . . . . . 3.00 -- 24
Oil Pickup Screen Removal . . . . . . . . . . . . . . . 2.05 -- 16 Valve Stem Seal Installation . . . . . . . . . . . 3.00 -- 25
Intake And Exhaust Valve Installation . . 3.00 -- 26
Oil Pan Removal . . . . . . . . . . . . . . . . . . . . . . . . 2.05 -- 17

iv Form 6296 First Edition

 CONTENTS

Section 3.05 Crankcase Component Water Header Plug Installation . . . . . . . . . 4.00 -- 2

Oil Strainer Adapter Installation . . . . . . . . . 4.00 -- 4
Overhaul
Lower Valve Lifter Housing Cover
Crankcase Inspection . . . . . . . . . . . . . . . . . . . . . 3.05 -- 1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.00 -- 5
Crankcase Cleaning and Inspection . . . . . 3.05 -- 4 Valve Lifter Housing Gasket Installation . . 4.00 -- 5
Lower Liner Bore and Liner Projection Camshaft and Bearing Installation . . . . . . 4.00 -- 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 4 Gear Housing Installation . . . . . . . . . . . . . . 4.00 -- 9
Restoration Sleeve Machining . . . . . . . . . . 3.05 -- 4 Camshaft End Play Measurement . . . . . 4.00 -- 10
Lower Crankcase Bore Machining . . . . . . 3.05 -- 4 Camshaft Gear Installation . . . . . . . . . . . . 4.00 -- 11
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 8 Valve Lifter Housing Installation . . . . . . . 4.00 -- 12
Crankshaft Cleaning And Inspection . . . . 3.05 -- 8 Rocker Arm Oil Header Installation . . . . . 4.00 -- 16
Crankshaft Counterweight Retightening . 3.05 -- 9 Rear Oil Seal Retainer Installation . . . . . 4.00 -- 17
Crankshaft Journal Repair . . . . . . . . . . . . 3.05 -- 10 Main Bearing Installation . . . . . . . . . . . . . 4.00 -- 18
Crankshaft Polishing . . . . . . . . . . . . . . . . . 3.05 -- 10 Crankshaft Installation . . . . . . . . . . . . . . . 4.00 -- 20
Crankshaft Overhaul . . . . . . . . . . . . . . . . . 3.05 -- 10 Rear Oil Seal Retainer (Lower Half)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4.00 -- 22
Main Bearing Bore Inspection . . . . . . . . . 3.05 -- 11
Main Bearing Caps Installation . . . . . . . . 4.00 -- 23
Main Bearing Overhaul And Running
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 12 Crankshaft End Play Measurement . . . . 4.00 -- 25
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 14 Outside Crankshaft Thrust Ring
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4.00 -- 26
Camshaft Cleaning And Inspection . . . . . 3.05 -- 14 Crankshaft Gear Installation . . . . . . . . . . 4.00 -- 27
Camshaft Bearing Bore Inspection . . . . . 3.05 -- 16 Oil Pump Idler Gear . . . . . . . . . . . . . . . . . . 4.00 -- 29
Valve Lifters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 16 Camshaft Idler Gear Installation . . . . . . . 4.00 -- 29
Roller Type Lifters . . . . . . . . . . . . . . . . . . . 3.05 -- 16 Accessory Idler Gear Installation . . . . . . 4.00 -- 32
Hydraulic Lifters . . . . . . . . . . . . . . . . . . . . . 3.05 -- 17 Gear Backlash Measurement . . . . . . . . . 4.00 -- 32
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 18 Magneto Drive Assembly Installation . . . 4.00 -- 37
Piston Disassembly . . . . . . . . . . . . . . . . . . 3.05 -- 18 Magneto Drive Gear Installation . . . . . . . 4.00 -- 38
Piston Cleaning and Inspection . . . . . . . . . . . . 3.05 -- 19 Cylinder Liner Installation . . . . . . . . . . . . . 4.00 -- 39
Piston Ring Inspection . . . . . . . . . . . . . . . . . . . 3.05 -- 21 Piston Ring Assembly . . . . . . . . . . . . . . . . . . . . 4.00 -- 41
Piston Pin Cleaning and Inspection . . . . . . . . 3.05 -- 24 L5794GSI (P/N 205104D) And
L5774LT, L5794 (P/N 202004C)
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 24 (4 Ring Pistons) . . . . . . . . . . . . . . . . . . . . . 4.00 -- 41
Connecting Rod Disassembly . . . . . . . . . 3.05 -- 24 L5794GSI (P/N 205304V) And
Connecting Rod Cleaning And L7044GSI (P/N 205604L)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 26 (3 RIng Pistons) . . . . . . . . . . . . . . . . . . . . . 4.00 -- 44
Connecting Rod Assembly . . . . . . . . . . . . 3.05 -- 29 Piston And Connecting Rod
Connecting Rod Bearing Running Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4.00 -- 44
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 31 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.00 -- 48
Connecting Rod Bearing Running Crankcase Oil Pan Installation . . . . . . . . . . . . 4.00 -- 51
Clearance Measurement With Front Flywheel Housing Installation . . . . 4.00 -- 53
Plastigage . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 33
Ring Gear Installation . . . . . . . . . . . . . . . . 4.00 -- 54
Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 33
Timing Tape Installation . . . . . . . . . . . . . . 4.00 -- 54
Cylinder Liner Disassembly . . . . . . . . . . . 3.05 -- 33 Flywheel Installation . . . . . . . . . . . . . . . . . 4.00 -- 55
Cylinder Liner Cleaning And Rear Flywheel Housing Installation . . . . . 4.00 -- 57
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 34
Flywheel Face Runout . . . . . . . . . . . . . . . 4.00 -- 57
Cylinder Liner Deglazing . . . . . . . . . . . . . 3.05 -- 35
Barring Device Installation . . . . . . . . . . . . 4.00 -- 60
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 -- 36
Oil Filler Bracket Installation . . . . . . . . . . 4.00 -- 60
Ring Gear Removal . . . . . . . . . . . . . . . . . . 3.05 -- 36
Gear Train Lubrication . . . . . . . . . . . . . . . 4.00 -- 61
Oil Slinger/Front Oil Seal/Gear
Cover Installation . . . . . . . . . . . . . . . . . . . . 4.00 -- 61
CHAPTER 4 -- ENGINE ASSEMBLY Front Gear Cover Plates Installation . . . . 4.00 -- 65
Rear Gear Housing Cover Plate
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4.00 -- 65
Section 4.00 Crankcase Assembly Crankshaft Endplate Retightening
Crankcase Assembly . . . . . . . . . . . . . . . . . . . . . 4.00 -- 1 Procedure For Engines Built Before
November 15, 2002 . . . . . . . . . . . . . . . . . . 4.00 -- 65
Idler Gear Spindle Installation . . . . . . . . . . 4.00 -- 1
Retightening Crankshaft Endplate And
Oil Tube Installation . . . . . . . . . . . . . . . . . . . 4.00 -- 2 Front Pulley (Loose Capscrews Found)
Main Bearing Stud Installation . . . . . . . . . . 4.00 -- 2 For Engines Built Before
Dowel Installation . . . . . . . . . . . . . . . . . . . . . 4.00 -- 2 November 15, 2002 . . . . . . . . . . . . . . . . . . 4.00 -- 66

Form 6296 First Edition v

CONTENTS

Vibration Damper/Rear Crankshaft Governor Drive Gear/CEC Timing

Pulley Installation Built After Disc Removal . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 5
November 15, 2002 . . . . . . . . . . . . . . . . . . 4.00 -- 66 Governor Drive Gear/CEC Timing
Installation of Optional Front Pulley . . . . 4.00 -- 68 Disc Cleaning And Inspection . . . . . . . . . . 5.00 -- 6
Installation of Optional Stub Shaft . . . . . . 4.00 -- 68 Governor Drive Gear/CEC Timing
Lifting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 4.00 -- 70 Disc Installation . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 6
Governor Drive Shaft . . . . . . . . . . . . . . . . . . . . . 5.00 -- 8
Pressure Block . . . . . . . . . . . . . . . . . . . . . . . . . . 4.00 -- 71
Governor Drive Shaft Removal . . . . . . . . . 5.00 -- 8
Ring Gear Installation . . . . . . . . . . . . . . . . 4.00 -- 71
Governor Drive Shaft Disassembly . . . . . . 5.00 -- 8
Section 4.05 Cylinder Head Assembly Governor Drive Shaft
Cleaning And Inspection . . . . . . . . . . . . . . . 5.00 -- 8
Cylinder Head Installation . . . . . . . . . . . . . . . . . 4.05 -- 1
Governor Drive Shaft Assembly . . . . . . . 5.00 -- 10
Cylinder Head Tightening Procedure . . . . 4.05 -- 2
Governor Drive Shaft Installation . . . . . . 5.00 -- 11
Push Rod Tube Installation . . . . . . . . . . . . 4.05 -- 3
Governor Drive Housing . . . . . . . . . . . . . . . . . . 5.00 -- 11
Rocker Arm Oil header And Cylinder
Head Oil Lines Installation . . . . . . . . . . . . . 4.05 -- 3 Governor Drive Housing Removal . . . . . 5.00 -- 11
Push Rod Installation . . . . . . . . . . . . . . . . . 4.05 -- 4 Governor Drive Housing Disassembly . . 5.00 -- 12
Spark Plug Sleeve And Spark Governor Drive Housing
Plug Carrier Extension Installation . . . . . . 4.05 -- 4 Cleaning And Inspection . . . . . . . . . . . . . . 5.00 -- 12
Valve Bridge And Rocker Arm Governor Drive Housing Assembly . . . . . 5.00 -- 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.05 -- 5 Governor Drive Housing Assembly . . . . . 5.00 -- 12
Exhaust Manifolds . . . . . . . . . . . . . . . . . . . . 4.05 -- 5 Governor Drive Housing Installation . . . . 5.00 -- 13
Woodward UG-8L Governor . . . . . . . . . . . . . . 5.00 -- 14
Section 4.10 Valve Adjustment And
Woodward UG-8L Governor Linkage
Web Deflection Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 14
Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 -- 1 Woodward UG-8L Governor
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 15
Cylinder Head Series P/N 205002 . . . . . . 4.10 -- 1
Woodward UG-8L Governor
Crankshaft Web Deflection Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 15
Measurement . . . . . . . . . . . . . . . . . . . . . . . . 4.10 -- 4
Woodward UG-8L Governor
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 16
Section 4.15 Break-In Procedure After Woodward UG-8L Governor
Rebuild Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 16
Prestart Inspection . . . . . . . . . . . . . . . . . . . . . . . 4.15 -- 1 Woodward UG-8l Governor Linkage
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 17
Break-In Procedure . . . . . . . . . . . . . . . . . . . . . . . 4.15 -- 4
Woodward UG-8L Governor
Operating At Light Loads . . . . . . . . . . . . . . 4.15 -- 7 Compensation Adjustment . . . . . . . . . . . . 5.00 -- 18
Woodward UG-8l Governor High/Low
Speed Limit Adjustment . . . . . . . . . . . . . . 5.00 -- 20
Woodward UG-8L Governor Droop
CHAPTER 5 -- ENGINE SYSTEMS Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 21
Woodward UG-8 (Dial) Governor. . . . . . . . . . . 5.00 -- 21
Section 5.00 Speed Governing System Woodward UG-8 (Dial) Governor
Linkage Removal . . . . . . . . . . . . . . . . . . . . 5.00 -- 21
ESM System Speed Governing . . . . . . . . . . . . . 5.00 -- 1
Woodward UG-8 (Dial) Governor
Speed Governing Modes . . . . . . . . . . . . . . 5.00 -- 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 22
Governor Inputs And Calibrations . . . . . . . 5.00 -- 2 Woodward UG-8 (Dial) Governor
Feedforward Control (Or Load Coming Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 22
Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 2 Woodward UG-8 (Dial) Governor
Synchronizer Control (Or Alternate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 23
Dynamics) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 2 Woodward UG-8 (Dial) Governor
Woodward Speed Governing . . . . . . . . . . . . . . 5.00 -- 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 23
Woodward UG-8L Governor . . . . . . . . . . . 5.00 -- 3 Woodward UG-8 (Dial) Governor
Linkage Installation And Adjustment . . . . 5.00 -- 23
Woodward UG-8 Dial Governor . . . . . . . . 5.00 -- 3
Woodward UG-8 (Dial) Governor
Woodward EG-3P Electronic Compensation Adjustment . . . . . . . . . . . . 5.00 -- 24
Governing System . . . . . . . . . . . . . . . . . . . . 5.00 -- 3
Woodward UG-8 (Dial) Governor
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 4 High/Low Speed Adjustment . . . . . . . . . . 5.00 -- 26
Governor Linkages . . . . . . . . . . . . . . . . . . . 5.00 -- 5 Woodward UG-8 (Dial) Governor
Magnetic Pickup . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 5 Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 26
Governor Drive Gear/CEC Timing Disc Woodward EG-3P Electric Governor . . . . . . . 5.00 -- 27
Removal/Installation . . . . . . . . . . . . . . . . . . 5.00 -- 5

vi Form 6296 First Edition

 CONTENTS

Linkage Removal . . . . . . . . . . . . . . . . . . . . 5.00 -- 27 Butterfly Valve Installation . . . . . . . . . . . . 5.05 -- 13

Woodward EG-3P Governor Carburetor/Butterfly Cross Shaft
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.05 -- 14
Woodward EG-3P Governor Carburetor Cross Shaft . . . . . . . . . . . . . . . . . . . 5.05 -- 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 28 Carburetor Cross Shaft Removal . . . . . . 5.05 -- 14
Woodward EG-3P Governor Cleaning Butterfly Cross Shaft -- GSI And L5774LT . . . 5.05 -- 15
And Inspection . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 28
Woodward EG-3P Governor Butterfly Cross Shaft Removal . . . . . . . . . 5.05 -- 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 28 Fuel Gas Pressure Regulator Removal . 5.05 -- 16
Woodward EG-3P Governor Drive Right Side Installation . . . . . . . . . . . . . . . . 5.05 -- 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 28 Left Side Installation . . . . . . . . . . . . . . . . . 5.05 -- 19
Woodward EG-3P Governor Drive Fuel System Maintenance . . . . . . . . . . . . . . . . 5.05 -- 19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 29
Fisher 99 Regulator Filter Cleaning
Woodward EG-3P Governor Drive And Inspection . . . . . . . . . . . . . . . . . . . . . . 5.05 -- 19
Cleaning And Inspection . . . . . . . . . . . . . . 5.00 -- 29
Mooney Regulator . . . . . . . . . . . . . . . . . . . . . . . 5.05 -- 20
Woodward EG-3P Governor Drive
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 29 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 5.05 -- 20
Woodward EG-3P Governor Drive Regulator Adjustments . . . . . . . . . . . . . . . 5.05 -- 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 30 Disassemble Pilot . . . . . . . . . . . . . . . . . . . 5.05 -- 21
Woodward EG-3P Governor Linkage Assemble Pilot . . . . . . . . . . . . . . . . . . . . . . 5.05 -- 23
Cleaning and Inspection . . . . . . . . . . . . . . 5.00 -- 32
Filter Maintenance . . . . . . . . . . . . . . . . . . . 5.05 -- 26
Woodward EG-3P Governor Linkage
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 32 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 5.05 -- 26
Woodward EG-3P Governor Linkage Assemble Filter . . . . . . . . . . . . . . . . . . . . . 5.05 -- 27
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 33 Main Valve Maintenance . . . . . . . . . . . . . . 5.05 -- 27
Manual Shutdown Lever . . . . . . . . . . . . . . . . . . 5.00 -- 35 Disassemble Main Valve . . . . . . . . . . . . . . 5.05 -- 27
Manual Shutdown Lever Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.05 -- 28
Adjustment -- LT . . . . . . . . . . . . . . . . . . . . . 5.00 -- 35 Assemble Main Valve . . . . . . . . . . . . . . . . 5.05 -- 29
Throttle Control Disassembly . . . . . . . . . . 5.00 -- 36
Throttle Control Inspection And
Section 5.10 Ignition System
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 36 Ignition System Components . . . . . . . . . . . . . . . 5.10 -- 1
Throttle Control Assembly . . . . . . . . . . . . 5.00 -- 37 ESM Ignition System . . . . . . . . . . . . . . . . . . 5.10 -- 1
Throttle Lever Removal -- GSI . . . . . . . . . 5.00 -- 37 CEC Ignition Module . . . . . . . . . . . . . . . . . . 5.10 -- 2
Throttle Lever Installation -- GSI . . . . . . . 5.00 -- 37 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . 5.10 -- 2
Throttle Lever Adjustment -- GSI . . . . . . . 5.00 -- 37 Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 -- 2
Governor Air Actuator Adjustment Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 -- 2
(Non--ESM) . . . . . . . . . . . . . . . . . . . . . . . . . 5.00 -- 37
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 -- 2
Actuator Adjustment -- ESM . . . . . . . . . . . 5.00 -- 38
Spark Plug Removal . . . . . . . . . . . . . . . . . . 5.10 -- 2
Section 5.05 Fuel System Spark Plug Inspection . . . . . . . . . . . . . . . . . 5.10 -- 3
Fuel System Components . . . . . . . . . . . . . . . . . 5.05 -- 1 Spark Plug Installation . . . . . . . . . . . . . . . . 5.10 -- 3
Fuel Gas Pressure Regulators . . . . . . . . . 5.05 -- 1 Valve Cover Removal . . . . . . . . . . . . . . . . . 5.10 -- 5
Operation Of The Fisher 99 Fuel Gas Valve Cover Installation . . . . . . . . . . . . . . . 5.10 -- 5
Pressure Regulator . . . . . . . . . . . . . . . . . . . 5.05 -- 2 Spark Plug Sleeve And Spark Plug
Operation Of The Mooney Fuel Gas Carrier Extension Removal . . . . . . . . . . . . 5.10 -- 6
Pressure Regulator . . . . . . . . . . . . . . . . . . . 5.05 -- 3 Spark Plug Sleeve And Spark Plug
Carburetors . . . . . . . . . . . . . . . . . . . . . . . . . . 5.05 -- 4 Carrier Extension Installation . . . . . . . . . . . 5.10 -- 6
Carburetors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.05 -- 5 Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 -- 8
Carburetor Removal . . . . . . . . . . . . . . . . . . 5.05 -- 5 Ignition Coil Testing . . . . . . . . . . . . . . . . . . . 5.10 -- 8
Carburetor Disassembly . . . . . . . . . . . . . . . 5.05 -- 6 Ignition Module Installation . . . . . . . . . . . . 5.10 -- 11
Carburetor Cleaning And Inspection . . . . . 5.05 -- 7 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 -- 12
Carburetor Assembly . . . . . . . . . . . . . . . . . 5.05 -- 7 Wiring Harness Inspection . . . . . . . . . . . . 5.10 -- 12
Carburetor Installation . . . . . . . . . . . . . . . . . 5.05 -- 7 Ignition Harness Installation . . . . . . . . . . . . . . . 5.10 -- 12
Low Fuel Pressure System (LFPS) Previous Production Ignition Harness
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.05 -- 8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 -- 13
LFPS Carburetor Removal . . . . . . . . . . . . . 5.05 -- 8 Current Production Ignition Harness
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 -- 16
LFPS Carburetor Disassembly . . . . . . . . . 5.05 -- 9
Ignition Harness Installation (CSA) . . . . . . . . . 5.10 -- 20
LFPS Carburetor Assembly . . . . . . . . . . . 5.05 -- 11
CEC Ignition Module . . . . . . . . . . . . . . . . . . . . . 5.10 -- 25
Butterfly Valve Removal . . . . . . . . . . . . . . 5.05 -- 12
Butterfly Valve Disassembly -- GSI . . . . . 5.05 -- 13 CEC Ignition Module Removal . . . . . . . . . 5.10 -- 25
Butterfly Valve Assembly . . . . . . . . . . . . . 5.05 -- 13 CEC Ignition Module Installation . . . . . . . 5.10 -- 26

Form 6296 First Edition vii

CONTENTS

ESM ECU And IPM-D Installation . . . . . . . . . . 5.10 -- 26 Turbocharger Installation . . . . . . . . . . . . . . 5.20 -- 7

Governor Drive Gear/CEC Timing Disc . . . . . 5.10 -- 27 Turbocharger Oil Connections . . . . . . . . . . . . . 5.20 -- 11
Governor Drive Gear/CEC Timing Prelube Pressure Maintenance/Check
Disc Removal . . . . . . . . . . . . . . . . . . . . . . . 5.10 -- 27 Valve Inspection . . . . . . . . . . . . . . . . . . . . . 5.20 -- 14
Governor Drive Gear/CEC Timing Turbocharger Water Connections . . . . . . . . . . 5.20 -- 14
Disc Cleaning And Inspection . . . . . . . . . 5.10 -- 28
Turbocharger Heat Shields . . . . . . . . . . . . . . . 5.20 -- 17
Governor Drive Gear/CEC Timing
Disc Installation . . . . . . . . . . . . . . . . . . . . . 5.10 -- 28
Section 5.25 Cooling System
CEC Ignition Module Static Timing Set . 5.10 -- 30
Setting Hall--Effect Pickup Gap . . . . . . . . 5.10 -- 31 Cooling System Components . . . . . . . . . . . . . . 5.25 -- 1
Steps Required to Adjust CEC Ignition Jacket Water Header/Jacket Water . . . . . 5.25 -- 1
Module Timing . . . . . . . . . . . . . . . . . . . . . . 5.10 -- 32 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . 5.25 -- 1
Magneto Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 -- 33 Water Manifold . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 1
Magneto Drive Disassembly . . . . . . . . . . 5.10 -- 33 Jacket Water Pump . . . . . . . . . . . . . . . . . . . 5.25 -- 1
Magneto Drive Assembly . . . . . . . . . . . . . 5.10 -- 34 Cluster Thermostat Housing . . . . . . . . . . . 5.25 -- 3
Magneto Drive Installation . . . . . . . . . . . . 5.10 -- 35 Remote Heat Transfer Device . . . . . . . . . . 5.25 -- 4
Junction Box Installation . . . . . . . . . . . . . . . . . . 5.10 -- 35 Auxiliary Water Pump . . . . . . . . . . . . . . . . . 5.25 -- 4
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 4
Section 5.15 Air Induction System Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 4
Air Induction System . . . . . . . . . . . . . . . . . . . . . . 5.15 -- 1 Auxiliary Water Temperature Control
Air Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 -- 1 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 5
Turbochargers . . . . . . . . . . . . . . . . . . . . . . . 5.15 -- 1 Auxiliary Water Remote Heat Transfer
Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 5
Intercoolers . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 -- 1
Importance Of Cooling System Maintenance . 5.25 -- 6
Carburetor and Intake Manifold . . . . . . . . . 5.15 -- 1
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 6
Air Induction System Specifications . . . . . . . . . 5.15 -- 1
Cavitation Erosion . . . . . . . . . . . . . . . . . . . . 5.25 -- 6
Air Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 -- 2
Mineral Scale And Fouling Deposits . . . . . 5.25 -- 6
Precleaner Pad Removal . . . . . . . . . . . . . . 5.15 -- 2 Cooling System Guidelines For
Precleaner Pad Cleaning And Waukesha Engines . . . . . . . . . . . . . . . . . . . 5.25 -- 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 -- 3
Water Treatment For Engine Cooling
Precleaner Pad Installation . . . . . . . . . . . . 5.15 -- 3
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 8
Main Air Filter Element Removal . . . . . . . . 5.15 -- 3
General Comments . . . . . . . . . . . . . . . . . . . 5.25 -- 9
Main Air Filter Element Cleaning
And Inspection . . . . . . . . . . . . . . . . . . . . . . . 5.15 -- 3 I. Pretreatment . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 9
Main Air Filter Element Installation . . . . . . 5.15 -- 4 II. Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 9
Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . 5.15 -- 4 III. Mineral Scales And Fouling . . . . . . . . . 5.25 -- 9
Air Cleaner Duct Removal . . . . . . . . . . . . . 5.15 -- 5 IV. Cavitation Erosion . . . . . . . . . . . . . . . . 5.25 -- 10
Air Cleaner Duct Installation . . . . . . . . . . . 5.15 -- 7 V. Microbiological Growth . . . . . . . . . . . . . 5.25 -- 10
Air Cleaner Duct Removal -- LFPS . . . . . . . . . . 5.15 -- 8 Cooling Water Treatment
Recommendations . . . . . . . . . . . . . . . . . . . 5.25 -- 10
Air Cleaner Duct Installation -- LFPS . . . . . . . 5.15 -- 10
A. Solid Hot Water Cooling . . . . . . . . . . . . 5.25 -- 10
Air Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 -- 13
B. Ebullient Systems . . . . . . . . . . . . . . . . . 5.25 -- 11
Air Tubing Removal . . . . . . . . . . . . . . . . . . 5.15 -- 13 C. Water Quality And Testing . . . . . . . . . . 5.25 -- 12
Air Tubing Installation . . . . . . . . . . . . . . . . 5.15 -- 14 Glossary Of Terms . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 13
Intake Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 -- 14
Alkalinity . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 13
Intake Manifold Removal . . . . . . . . . . . . . 5.15 -- 14 Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 13
Intake Manifold Changes . . . . . . . . . . . . . 5.15 -- 15 Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 13
Intake Manifold Installation . . . . . . . . . . . . 5.15 -- 16 Chelates . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 13
Intake Manifold Alignment Chloride . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 13
(Manifold Completely Removed
From Engine) . . . . . . . . . . . . . . . . . . . . . . . 5.15 -- 16 Crevice Corrosion . . . . . . . . . . . . . . . . . . . 5.25 -- 13
Intake Manifold Alignment Deaeration . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 13
(Manifold In Place) . . . . . . . . . . . . . . . . . . . 5.15 -- 18 Deionization . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 13
Intake Manifold Flange Attachments . . . 5.15 -- 18 Fretting Corrosion . . . . . . . . . . . . . . . . . . . 5.25 -- 13
Intake Manifold Pressure Connections . . 5.15 -- 20 Galvanic Corrosion . . . . . . . . . . . . . . . . . . 5.25 -- 13
Hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 13
Section 5.20 Turbochargers Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 13
Turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20 -- 1 Ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 14
Turbocharger(s) Removal . . . . . . . . . . . . . . 5.20 -- 1 pH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 14
Turbocharger Cleaning And Inspection . . 5.20 -- 4

viii Form 6296 First Edition

 CONTENTS

PPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 14 Cluster Thermostat Housing And

Pretreatment . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 14 Thermostatic Valves Cleaning
And Inspection . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 34
Rainwater . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 14
Auxiliary Water Temperature Control
Selective Leaching . . . . . . . . . . . . . . . . . . 5.25 -- 14 Valve Installation . . . . . . . . . . . . . . . . . . . . 5.25 -- 36
Silica . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 14 Cluster Thermostat Housing/
Softening . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 14 Thermostatic Valves Installation . . . . . . . 5.25 -- 36
Solder Bloom . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 14 Idler Pulley Bracket Disassembly . . . . . . 5.25 -- 38
Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 14 Idler Pulley Bracket Cleaning And
Sulfate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 14 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 39
Cooling System Specifications . . . . . . . . . . . . 5.25 -- 14 Idler Pulley Bracket Assembly . . . . . . . . . 5.25 -- 39
Jacket Water Circuit -- Initial Fill . . . . . . . . . . . 5.25 -- 15 Idler Pulley Bracket Installation . . . . . . . . 5.25 -- 41
Jacket Water Pump . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 41
Auxiliary Cooling Water Circuit -- Initial Fill . . 5.25 -- 16
Jacket Water Pump Removal . . . . . . . . . . 5.25 -- 41
Cooling Water System Air Bleed . . . . . . . . . . . 5.25 -- 16
Jacket Water Pump Disassembly . . . . . . 5.25 -- 42
Jacket Water And Auxiliary Water Circuits -- Jacket Water Pump Cleaning and
Drain And Flush . . . . . . . . . . . . . . . . . . . . . 5.25 -- 17 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 43
Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 18 Jacket Water Pump Assembly . . . . . . . . . 5.25 -- 43
Idler Pulley Bearing Lubrication . . . . . . . . 5.25 -- 18 Jacket Water Pump Installation . . . . . . . . 5.25 -- 51
Auxiliary Water Pump Bearings Safety Guards . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 53
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 18 Safety Guards Removal . . . . . . . . . . . . . . 5.25 -- 53
Grease Recommendations . . . . . . . . . . . . . . . 5.25 -- 19 Safety Guards Installation . . . . . . . . . . . . 5.25 -- 54
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 19 Auxiliary Water Temperature Control Valve . . 5.25 -- 54
Jacket Water Pump Drive Belts Auxiliary Water Temperature Control
Replacement . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 19 Valve Removal . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 54
Jacket Water Pump Drive Belt Tension Auxiliary Water Temperature Control
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 20 Thermostatic Valve Inspection
Auxiliary Water Pump Drive Belt And Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 55
Replacement . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 22 Auxiliary Water Temperature Control
Auxiliary Water Pump Drive Belt Tension Valve Assembly . . . . . . . . . . . . . . . . . . . . . 5.25 -- 56
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 23 Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 56
Jacket Water Pump Seal Inspection . . . . . . . . 5.25 -- 24 Intercooler Removal . . . . . . . . . . . . . . . . . 5.25 -- 56
Crankcase Water Inlet Elbows . . . . . . . . . . . . . 5.25 -- 25 Intercooler Water Tube Modifications . . . 5.25 -- 57
Crankcase Water Inlet Elbows Removal -- Intercooler Disassembly . . . . . . . . . . . . . . 5.25 -- 62
Left Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 25 Intercooler Cleaning and Inspection . . . . 5.25 -- 64
Crankcase Water Inlet Elbows Removal -- Intercooler Assembly . . . . . . . . . . . . . . . . . 5.25 -- 64
Right Bank . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 25
Intercooler Installation . . . . . . . . . . . . . . . . 5.25 -- 67
Crankcase Water Inlet Elbows
Installation -- Left Bank . . . . . . . . . . . . . . . 5.25 -- 25 Auxiliary Water Pipe System Installation . . . . 5.25 -- 69
Crankcase Water Inlet Elbows Installation -- Auxiliary Water Pump And Bracket . . . . . . . . . 5.25 -- 72
Right Bank . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 26 Auxiliary Water Pump And Bracket
Water Pump Inlet Elbows And Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 72
Water Header . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 26 Auxiliary Water Pump And Bracket
Water Pump Inlet Elbows And Water Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 74
Header Removal . . . . . . . . . . . . . . . . . . . . 5.25 -- 26
Water Pump Inlet Elbows And Water
Section 5.30 Lubrication System
Header Installation . . . . . . . . . . . . . . . . . . . 5.25 -- 27 Lubrication System Components . . . . . . . . . . . 5.30 -- 1
Lower/Upper Bypass Tubes And Water Description . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 1
Bypass Elbows . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 28 Internal Oil Control . . . . . . . . . . . . . . . . . . . . 5.30 -- 3
Lower/Upper Bypass Tubes And Water Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 4
Bypass Elbows Removal . . . . . . . . . . . . . 5.25 -- 28
Lubricating Oil Performance . . . . . . . . . . . . 5.30 -- 4
Lower/Upper Bypass Tubes And Water
Bypass Elbows Installation . . . . . . . . . . . . 5.25 -- 28 Oil Designations . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 5
Water Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 30 Oil Additives . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 5
Oil Recommendations . . . . . . . . . . . . . . . . . 5.30 -- 5
Water Manifold Removal . . . . . . . . . . . . . 5.25 -- 30
Catalyst Contaminants . . . . . . . . . . . . . . . . 5.30 -- 5
Water Manifold Installation . . . . . . . . . . . . 5.25 -- 31
Oil Filtration Requirements . . . . . . . . . . . . . 5.30 -- 5
Cluster Thermostat Housing And
Thermostatic Valves . . . . . . . . . . . . . . . . . 5.25 -- 34 Extended Oil Drain Intervals . . . . . . . . . . . 5.30 -- 5
Waukesha Cogeneration Installations . . . 5.30 -- 6
Cluster Thermostat Housing And
Thermostatic Valves Removal . . . . . . . . . 5.25 -- 34

Form 6296 First Edition ix

CONTENTS

Sour Gas, Digester Gas, And Oil Pump Assembly . . . . . . . . . . . . . . . . . . 5.30 -- 38

Landfill Gas . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 6 Oil Pump Installation . . . . . . . . . . . . . . . . . 5.30 -- 40
Recommended Oils For Landfill Gas Prelube Y-Strainer . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 45
Applications . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 7
Recommendations For Fuel Gas Filtration Prelube Y-Strainer Removal . . . . . . . . . . . 5.30 -- 45
Of Solids And Liquids . . . . . . . . . . . . . . . . . 5.30 -- 7 Prelube Y-Strainer Cleaning And
Oil Condemning Limits . . . . . . . . . . . . . . . . 5.30 -- 8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 45
Oil Viscosity Selection . . . . . . . . . . . . . . . . . 5.30 -- 9 Prelube Y-Strainer Installation . . . . . . . . . 5.30 -- 45
Multi--Viscosity Oils . . . . . . . . . . . . . . . . . . . 5.30 -- 9 Oil Filler Pipe Removal . . . . . . . . . . . . . . . . . . . 5.30 -- 46
Synthetic Oils . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 9 Oil Filler Pipe Installation . . . . . . . . . . . . . 5.30 -- 46
Low Ambient Temperature Operation . . . 5.30 -- 10 Rocker Arm Oil Header Oil Inlet
Oil Consumption Guidelines . . . . . . . . . . . 5.30 -- 10 Tubes/Fittings . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 46
Formulas For Determining Oil Rocker Arm Oil Header Oil Inlet
Consumption Rates . . . . . . . . . . . . . . . . . . 5.30 -- 10 Tubes/Fittings installation . . . . . . . . . . . . . 5.30 -- 46
Recommended Oil Change Intervals . . . 5.30 -- 10 Oil Supply/Drain Tubes . . . . . . . . . . . . . . . . . . . 5.30 -- 48
Oil Piping Purge . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 48
Oil Cooler And Oil Filter Installation . . . . . . . . 5.30 -- 12 Oil Pilot Pressure/Governor Oil
Tube Connection . . . . . . . . . . . . . . . . . . . . 5.30 -- 49
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 12
Oil Pan Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 50
Checking Crankcase Oil Level . . . . . . . . . . . . 5.30 -- 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 50
Oil Cooler Maintenance . . . . . . . . . . . . . . . . . . 5.30 -- 12
Oil Pan Doors Installation . . . . . . . . . . . . . 5.30 -- 51
Oil System Air Bleed . . . . . . . . . . . . . . . . . . . . . 5.30 -- 13
Oil Pan Cleaning And Inspection . . . . . . . . . . 5.30 -- 51
Oil Filter Element Replacement . . . . . . . . . . . . 5.30 -- 13
Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 51
Oil Filter Relief Valve Inspection . . . . . . . . . . . 5.30 -- 15
Oil Strainer Removal . . . . . . . . . . . . . . . . . 5.30 -- 51
Magnetic Plugs . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 15 Oil Strainer Cleaning And Inspection . . . 5.30 -- 52
Turbocharger Magnetic Plug . . . . . . . . . . 5.30 -- 15 Oil Strainer Installation . . . . . . . . . . . . . . . 5.30 -- 52
Cylinder Head Magnetic Plugs . . . . . . . . 5.30 -- 16 Engine Mounted Microspin Centrifuge
Oil Temperature Control Valve . . . . . . . . . . . . . 5.30 -- 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 53
Troubleshooting Low Oil Pressure . . . . . . . . . 5.30 -- 18
Section 5.35 Exhaust System
Oil Pressure Adjustment . . . . . . . . . . . . . . . . . . 5.30 -- 19
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 1
Remote Oil Cooler Piping Removal . . . . . . . . 5.30 -- 19
Components . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 1
Remote Oil Cooler Piping Installation . . . . . . . 5.30 -- 19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 1
Remote Oil Cooler Removal . . . . . . . . . . . . . . 5.30 -- 21
Exhaust System Specifications . . . . . . . . . 5.35 -- 1
Remote Oil Cooler Cleaning And Measuring Exhaust System
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 21 Backpressure . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 2
Remote Oil Cooler Assembly . . . . . . . . . . . . . . 5.30 -- 22 Checking Exhaust Gas Temperatures . . . 5.35 -- 2
Engine Mounted Oil Cooler . . . . . . . . . . . . . . . 5.30 -- 22 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 3
Oil Cooler Piping Installation . . . . . . . . . . 5.30 -- 23 Exhaust Manifold Removal . . . . . . . . . . . . . 5.35 -- 3
Prelube System . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 30 Exhaust Manifold Disassembly . . . . . . . . . 5.35 -- 4
Prelube Pressure Maintenance . . . . . . . . . . . . 5.30 -- 30 Exhaust Manifold Assembly . . . . . . . . . . . . 5.35 -- 4
Exhaust Manifold Installation . . . . . . . . . . . 5.35 -- 5
Check Valve Inspection . . . . . . . . . . . . . . . . . . 5.30 -- 31
Turbocharger Exhaust Inlet Elbows . . . . . . . . . 5.35 -- 9
Prelube In-line Lubricator . . . . . . . . . . . . . . . . . 5.30 -- 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 9
Oil Pan Cleaning And Inspection . . . . . . . . . . 5.30 -- 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 10
Oil Pickup Screen . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 34 Turbocharger Elbow Support Brackets . . 5.35 -- 11
Oil Pickup Screen Removal . . . . . . . . . . . 5.30 -- 34 Exhaust Connections Removal . . . . . . . . 5.35 -- 11
Oil Pickup Screen Cleaning And Exhaust Connections Installation . . . . . . 5.35 -- 11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 34 Heat Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 13
Oil Pickup Screen Installation . . . . . . . . . 5.30 -- 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 13
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 -- 35
Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 14
Oil Pump Removal . . . . . . . . . . . . . . . . . . . 5.30 -- 35
Quick Disconnect Installation . . . . . . . . . . 5.35 -- 14
Oil Pump Disassembly . . . . . . . . . . . . . . . 5.30 -- 35
Exhaust Thermocouples Installation . . . . 5.35 -- 15
Oil Pump Cleaning And Inspection . . . . . 5.30 -- 37
Thermocouple Clean And Inspect . . . . . . 5.35 -- 16

x Form 6296 First Edition

 CONTENTS

Wastegates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 18 Oil Separator Installation . . . . . . . . . . . . . 5.40 -- 10

Bleeding Air . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 18 Front Oil Separator Tube Installation . . . 5.40 -- 11
Wastegates -- Late Model Water Inlet And Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 12
Outlet Tubes . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 18 Venturi Removal . . . . . . . . . . . . . . . . . . . . . 5.40 -- 12
Intercooler Water Tube Modifications . . . 5.35 -- 18 Venturi Cleaning And Inspection . . . . . . . 5.40 -- 13
Retrofit Instructions . . . . . . . . . . . . . . . . . . 5.35 -- 19 Venturi Installation . . . . . . . . . . . . . . . . . . . 5.40 -- 13
Wastegates -- P/N 295645 Series . . . . . . . . . . 5.35 -- 22 Venturi Extractor . . . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 13
Wastegate Removal -- P/N 295645 Customer Connection Venturi
Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 22 Extractor Removal . . . . . . . . . . . . . . . . . . . 5.40 -- 14
Wastegate Installation -- P/N 295645 Venturi Extractor Assembly . . . . . . . . . . . 5.40 -- 15
Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 22
Venturi Extractor Installation . . . . . . . . . . 5.40 -- 17
Wastegate Disassembly -- P/N 295645
Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 23 Exhaust Connection Venturi
Extractor Removal . . . . . . . . . . . . . . . . . . . 5.40 -- 18
Wastegate Assembly -- P/N 295645
Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 24 Venturi Extractor Assembly . . . . . . . . . . . 5.40 -- 19
LT Wastegate Backpressure Regulator . . . . . 5.35 -- 24 Venturi Extractor Installation . . . . . . . . . . 5.40 -- 20
Venturi Extractor Compressor
LT Wastegate Backpressure Regulator
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 24 Discharge Tubes . . . . . . . . . . . . . . . . . . . . 5.40 -- 21
LFPS Wastegate Vent Tubes . . . . . . . . . . . . . . 5.35 -- 27 Venturi Extractor Compressor Discharge
Tubes Removal . . . . . . . . . . . . . . . . . . . . . 5.40 -- 21
Engine Altitude Adjustments . . . . . . . . . . . . . . 5.35 -- 27
Venturi Extractor Compressor Discharge
Wastegate Adjustment . . . . . . . . . . . . . . . 5.35 -- 28 Tubes Installation . . . . . . . . . . . . . . . . . . . . 5.40 -- 22
On--Engine Adjustment -- GSI Crankcase Pressure Relief Valves . . . . . . . . . 5.40 -- 22
Engines Only . . . . . . . . . . . . . . . . . . . . . . . 5.35 -- 29
Crankcase Pressure Relief Valve
Wastegate Backpressure Adjustment On LT Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 23
Engines -- Without The ESM System . . . 5.35 -- 30
Crankcase Pressure Relief Valve
Section 5.40 Crankcase Breather Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 23
Crankcase Pressure Relief Valve
System Cleaning And Inspection . . . . . . . . . . . . . . 5.40 -- 23
Crankcase Breather System . . . . . . . . . . . . . . . 5.40 -- 1 Crankcase Pressure Relief Valve
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 24
Components . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 1 Section 5.45 Air/Gas Prelube And Start
Separator Screen . . . . . . . . . . . . . . . . . . . . . 5.40 -- 1 Systems
Oil Separator(s) . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 1
Air/Gas Prelube And Start Systems . . . . . . . . . 5.45 -- 1
Vacuum Valve/Choke Valve . . . . . . . . . . . . 5.40 -- 2
Breather Regulator . . . . . . . . . . . . . . . . . . . 5.40 -- 2 Components . . . . . . . . . . . . . . . . . . . . . . . . . 5.45 -- 1
Venturi Extractor . . . . . . . . . . . . . . . . . . . . . 5.40 -- 2 Prelube System . . . . . . . . . . . . . . . . . . . . . . 5.45 -- 1
Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 3 Start System . . . . . . . . . . . . . . . . . . . . . . . . . 5.45 -- 4
Crankcase Pressure . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 3 Prelube/Start System
Removal/Installation . . . . . . . . . . . . . . . . . . 5.45 -- 8
Crankcase Pressure Measurement . . . . . 5.40 -- 3
Crankcase Pressure Adjustment -- Bulkhead Bracket Assembly Removal . . . 5.45 -- 8
Venturi Equipped . . . . . . . . . . . . . . . . . . . . . 5.40 -- 3 Bulkhead Bracket Assembly Installation . 5.45 -- 8
Crankcase Pressure Adjustment -- Pilot Operated Prelube Valve Removal . . 5.45 -- 9
Venturi Extractor/Vacuum Valve Pilot Operated Prelube Valve
Assembly Equipped . . . . . . . . . . . . . . . . . . . 5.40 -- 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45 -- 9
Crankcase Breather Regulator . . . . . . . . . . . . . 5.40 -- 6 Prelube Pump/Motor and Connections . . . . . 5.45 -- 10
Crankcase Breather Regulator Removal . 5.40 -- 6 Prelube Pump/Motor and Connections
Crankcase Breather Regulator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45 -- 10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 6 Prelube Pump/Motor and Connections
Crankcase Breather Regulator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45 -- 11
Cleaning And Inspection . . . . . . . . . . . . . . . 5.40 -- 6 Bulkhead to Panel Bracket . . . . . . . . . . . . . . . . 5.45 -- 12
Crankcase Breather Regulator Bulkhead To Panel Bracket Removal . . . 5.45 -- 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 7
Bulkhead to Panel Bracket Installation . . 5.45 -- 13
Crankcase Separator Screen . . . . . . . . . . . . . . 5.40 -- 7
Tube Clips/Clamps Installation . . . . . . . . . . . . 5.45 -- 13
Crankcase Separator Removal . . . . . . . . . 5.40 -- 7
Air Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45 -- 16
Crankcase Separator Screen Cleaning
And Inspection . . . . . . . . . . . . . . . . . . . . . . . 5.40 -- 8 Air Starter Removal . . . . . . . . . . . . . . . . . . 5.45 -- 16
Crankcase Separator Screen Assembly . 5.40 -- 8 Air Starter Installation . . . . . . . . . . . . . . . . 5.45 -- 16
Separator Screen Maintenance . . . . . . . . . 5.40 -- 8 Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45 -- 17
Oil Separator Removal . . . . . . . . . . . . . . . . 5.40 -- 9 Electric Starter Removal/Installation . . . . 5.45 -- 17
Oil Separator Cleaning And Inspection . 5.40 -- 10

Form 6296 First Edition xi

CONTENTS

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45 -- 18 Surge Tank Assembly . . . . . . . . . . . . . . . . . 6.10 -- 5

Alternator Installation . . . . . . . . . . . . . . . . 5.45 -- 18 Surge Tank Installation . . . . . . . . . . . . . . . . 6.10 -- 5
Alternator Belt Tension . . . . . . . . . . . . . . . 5.45 -- 18 Jacket Water Heater . . . . . . . . . . . . . . . . . . . . . . 6.10 -- 6
Alternator Junction Box . . . . . . . . . . . . . . . 5.45 -- 20 Jacket Water Heater Maintenance . . . . . . . . . . 6.10 -- 6
Alternator Safety Guards . . . . . . . . . . . . . . . . . 5.45 -- 22 Jacket Water Heater Removal . . . . . . . . . . 6.10 -- 7
Jacket Water Heater Cleaning And
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10 -- 7
Jacket Water Heater Installation . . . . . . . . 6.10 -- 9
CHAPTER 6 -- ACCESSORIES
Section 6.00 Control Panel
CHAPTER 7 -- TROUBLESHOOTING
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.00 -- 1
Components . . . . . . . . . . . . . . . . . . . . . . . . . 6.00 -- 1 AND MAINTENANCE
Control Panel Removal -- Right Side . . . . 6.00 -- 1
Control Panel Installation -- Right Side . . . 6.00 -- 4 Section 7.00 Troubleshooting
Control Panel Removal -- Left Side . . . . . . 6.00 -- 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 7.00 -- 1
Control Panel Installation -- Left side . . . . 6.00 -- 5
Section 7.05 Maintenance And Storage
Section 6.05 Engine Protection Routine Maintenance . . . . . . . . . . . . . . . . . . . . . 7.05 -- 1
Systems Engine Performance Record . . . . . . . . . . . . . . . 7.05 -- 4
Engine Protection Systems . . . . . . . . . . . . . . . . 6.05 -- 1 Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 7.05 -- 5
ESM System Engine Safeties . . . . . . . . . . 6.05 -- 1 Preservation Equipment And Material . . . 7.05 -- 5
ESM Standard Components . . . . . . . . . . . 6.05 -- 2 Waukesha Engine Preservative Oil . . . . . . . . . 7.05 -- 5
Engine Protection systems --
Standard Components (Non--ESM) . . . . . 6.05 -- 4 Waukesha Engine Preservative
Oil Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.05 -- 5
“K” Type Thermocouples . . . . . . . . . . . . . . 6.05 -- 4
Use Of Other Preservative Oils And
Main Bearing Thermocouples . . . . . . . . . . . . . . 6.05 -- 6 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.05 -- 6
Main Bearing Thermocouples Removal . . 6.05 -- 6 Engine Storage -- New . . . . . . . . . . . . . . . . . . . . 7.05 -- 6
Main Bearing Thermocouples Operational Engines . . . . . . . . . . . . . . . . . . 7.05 -- 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 -- 7
Non-operational Engines . . . . . . . . . . . . . . 7.05 -- 7
Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 -- 8
Engine Storage -- Used . . . . . . . . . . . . . . . . . . . . 7.05 -- 7
Thermocouple Replacement . . . . . . . . . . . 6.05 -- 8
Operational Engines . . . . . . . . . . . . . . . . . . 7.05 -- 7
Quick Disconnect Installation . . . . . . . . . . . 6.05 -- 8
Non-operational Engines . . . . . . . . . . . . . . 7.05 -- 7
Manual Shutdown Switches . . . . . . . . . . . . . . . 6.05 -- 10
Engines -- Return To Service After Storage . . . 7.05 -- 8
Customer Supplied Control Switches . . . 6.05 -- 10
Pressure And Temperature Switches
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 -- 10
Alarm And Shutdown Setpoints . . . . . . . . 6.05 -- 10 APPENDIX A -- INDEX
Engine Gauge Panel Components
(Shipped Loose) . . . . . . . . . . . . . . . . . . . . . 6.05 -- 10 Alphabetical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . A -- 1
Remote Panel Components . . . . . . . . . . . 6.05 -- 12
CEC Detonation Sensing Module System . . . 6.05 -- 13
Knock Sensor Installation . . . . . . . . . . . . . 6.05 -- 13
DSM Installation . . . . . . . . . . . . . . . . . . . . . 6.05 -- 14
WARRANTY INFORMATION
Operation Description . . . . . . . . . . . . . . . . 6.05 -- 15 Continuous Duty Applications . . . . . . . . . . . . . . . . W -- 1
DSM System Operation . . . . . . . . . . . . . . 6.05 -- 16 Excess of Continuous Duty Applications . . . . . . . W -- 2
Default Timing Value . . . . . . . . . . . . . . . . . 6.05 -- 16 Express Limited Warranty Covering Genuine
User Interface . . . . . . . . . . . . . . . . . . . . . . . 6.05 -- 18 Waukesha Service Parts And Factory
DSM System Troubleshooting . . . . . . . . . 6.05 -- 18 Remanufactured Service Parts Used
In A Certified Overhaul . . . . . . . . . . . . . . . . . . W -- 3
Section 6.10 Miscellaneous Equipment
Express Limited Warranty For Genuine
Miscellaneous Equipment . . . . . . . . . . . . . . . . . 6.10 -- 1 Waukesha Service Parts . . . . . . . . . . . . . . . . W -- 4
Components . . . . . . . . . . . . . . . . . . . . . . . . . 6.10 -- 1 Express Limited Warranty For
Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10 -- 1 Custom Engine Control . . . . . . . . . . . . . . . . . . W -- 5
Surge Tank Removal . . . . . . . . . . . . . . . . . . 6.10 -- 1 Express Limited Warranty For The
Surge Tank Disassembly . . . . . . . . . . . . . . 6.10 -- 4 Waukesha Engenius
Surge Tank Cleaning And Inspection . . . . 6.10 -- 4 Engine System Manager (ESM) . . . . . . . . . .W - 6

xii Form 6296 First Edition