Serial No. Specification No.

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Waukesha

YHp12 Cylinder G/GSI/GL Repair & Overhaul ManualFirst Edition

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This document contains proprietary and trade secret information and is given to the receiver in confidence. The receiver by reception and retention of the document accepts the document In confidence and agrees that, except as with the prior expressed written permission of Waukesha Engine, Dresser, Inc., itwill; (1) notusethedocumentorany copy thereof or the confidential or trade secret information therein; (2) not copy or reproduce the document in whole, or in part without the prior written approval of Waukesha Engine, Dresser, Inc.; and (3) not disclose to others either the document orthe confidential or trade secret information contained therein. All sales and information herein supplied subject to Standard Terms of Sale, including limitation of liability. WAUKESHA, DRESSER, and WKI are registered trademarks of Dresser, Inc. VHPT" and DRESSER logo are trademarks of Dresser, Inc. All other trademarks, service marks, logos, slogans, and trade names (collectively "marks~) are the properties of their respective owners. Dresser, Inc. disclaims any proprietary interest in these marks owned by others.

Waukesha)

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

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CONTENTSWarranty List Of Illustrations List Of Tables How To Use This ManualWelding ................................... 1.05 - 5 General ............................. 1.05 - 5 On Engine ........................... 1.05 - 5 Weight .................................... 1.05 - 5

Section 1.10 - Rigging And Lifting EnginesEngine Rigging And Lifting . . . . . . . . . . . . . . . . . . 1.10 - 1 Location Of The Lifting Eyes ................ 1.1 0 - 1

CHAPTER 1 - SAFETY AND GENERALSection 1.00 - Warning Tags & Decal LocationsWarning Tags And Decal Locations .......... t .00-1

Correct Method Of Rigging And Lifting Engine ........................ 1.1 0 - 1

Section 1.15 - General InformationSection Main Points: ....................... 1 .15 - 1 Overhaul/Repair Process ................... 1 .15 - 1 Preventing Engine Damage ................. 1 .15 - 1 Handling And Shipping ..................... 1 .15 - 1 Engine Removal ........................... 1 .15 - 2 Serial Number And Engine Nameplate ........ 1.15 - 3 Engine Identification Views .................. 1 .15 - 4 Right Side View ........................... 1.15 - 4 Left Side View ............................. 1.15-5 RearView ................................ 1.15-6 Basic Engine Description ................... 1 .15 - 7 Service Tools List .......................... 1.15 - 8 Engine Standards ......................... 1 .15 - 10 Component Weights ...................... 1.15 - 10 Clearances .............................. 1.15 - 11 Torque Specifications ..................... 1.15 - 12 General Torquing Sequence Procedure ...... 1.15 - 12 Thread Lubrication For Torque Fasteners .......................... 1.15 - 12 Critical Engine Torque Values .............. 1.15 - 13 Cylinder Head Torquing Procedure .......... 1.15 - 14 Connecting Rod Capscrew Torquing Procedure (P/N Series 205407 And 205507) ............................ 1.15 - 14 Main Bearing Cap Torquing Procedure ....... 1.15 - 15 General Torque Recommendations .......... 1.15 - 16 English/Metric Conversions ................ 1 .15 - 17 Index Of Sealants. Adhesives And Lubricants 1.15 - 18 Split Ring Washer Usability Criteria .......... 1 .15 - 19

Section 1.05 - SafetySafety Introduction ......................... 1.05 - 1 Safety Tags And Decals ..................... 1.05 - 1 Equipment Repair And Service ............... 1.05 - 1 Acids ..................................... 1.05 - 2 Batteries .................................. 1 .05 - 2 Body Protection ............................ 1.05 - 2 Chemicals ................................. 1.05 - 2 General ............................. Cleaning Solvents .................... Liquid Nitrogen/Dry Ice ................ Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.05 1.05 1.05 1.05 2 2 2 2

Heated Or Frozen .................... 1.05 - 2 Interference Fit ....................... 1.05 - 2 Cooling System ............................ 1.05 - 2 Electrical ............ . . . . . . . . . . . . . . . . . . . . .. 1.05 - 3 General ....... . . . . . . . . . . . . . .. . . . . . .. 1.05 - 3 Ignition .............................. 1.05 - 3 Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.05 - 3 Fire Protection ............................. 1.05 - 3 Fuels ..................................... 1.05 - 3 General ............................. Gaseous ............................ Liquid ............................... Intoxicants And Narcotics .................... 1.05 1.05 1.05 1.05 3 3 3 4

Pressurized Fluids/Gas/Air ................... 1.05 - 4 Protective Guards .......................... 1.05 - 4 Sodium Cooled Valve ....................... 1.05 - 4 Springs ................................... 1.05 - 4 Tools ..................................... 1.05 - 4 Electrical ............................ 1 .05 - 4 Hydraulic ............................ 1.05 - 4 Pneumatic ........................... 1.05 - 4

Form 6248 First Edition

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CONTENTS

Section 1.20 - SpecificationsSpecHications ............................. 1.20 - 1 Gear Tooth Wear - General ................. 1.20 - 1 Timing Gears .............................. 1.20 - 1 Engine Timing Data ....................... 1.20 - 29

CHAPTER 3 - ENGINE INSPECTION AND OVERHAULSection 3.00 - Cylinder Head DisassemblyCylinder Head Disassembly ................. 3.00 - 1 Rocker Arms .............................. 3.00 - 1

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CHAPTER 2 - ENGINE TEAR DOWNSection 2.00 - Cylinder Head RemovalCylinder Head Removal .................... 2.00 - 1

Intake And Exhaust Valves .................. 3.00 - 8 Valve Seat Insert And Valve Guide Removal ............................ 3.00 - 9 Cylinder Head Cleaning And Inspection ...... 3.00 - 10 Cylinder Head Casting Pressure Testing ..... 3.00 - 12 Cylinder Head Casting Magnaflux@ .......... 3.00 - 13 Cylinder Head Lower Deck Recondition ...... 3.00 - 14 Valve Failure Analysis .................... 3.00 - 14 Cylinder Head Assembly .................. 3.00 - 19 Valve Guide Installation .................... 3.00 - 19 Cylinder Head Casting Plug Installation ...... 3.00 - 20 Valve Seat Insert Installation ............... 3.00 - 20 Valve Seat Grinding ....................... 3.00 - 21 Valve Seat Lapping ....................... 3.00 - 22 Intake And Exhaust Valve Installation ........ 3.00 - 23

Section 2.05 - Crankcase RemovalPiston/Connecting Rod Removal ............. 2.05 - 1 Cylinder Sleeve Removal ................... 2.05 - 4 Vibration Damper Removal .................. 2.05 - 5 Front Gear Cover Removal .................. 2.05 - 7 Magneto Drive Gear Removal ............... 2.05 - 9 Idler Gear Removal ....................... 2.05 - 10 Gamshaft Gear Removal ................... 2.05 - 10 Front Gear Housing Removal ............... 2.05 - 11 Rocker Arm Oil Header Removal ............ 2.05 - 12 Valve LHter Housing Removal .............. 2.05 - 13 Camshaft Removal ........................ 2.05 - 15 Barring Device Removal ................... 2.05 - 16 Flywheel Removal ........................ 2.05 - 16 Oil Pickup Screen Removal ................ 2.05 - 18 Oil Pan Removal .......................... 2.05 - 19 Crankshaft Removal ...................... 2.05 - 20 Crankcase ............................... 2.05 - 24 Crankshaft No.1 Main Bearing Removal In Field Conditions ........................ 2.05 - 24 Crankshaft No. 1 Main Bearing Installation In Field Conditions ........................ 2.05 - 27 Crankshaft Main Bearings Removal In Field Cond~ions ............................ 2.05 - 29 Crankshaft Main Bearings Installation In Field Cond~ions ............................ 2.05 - 30 Camshaft Bearing Removal In Field Conditions ............................ 2.05 - 31 Camshaft Bearing Installation In Field Conditions ............................ 2.05 - 32

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Section 3.05 - Crankcase DisassemblyCrankcase ................................ 3.05 - 1 Crankcase Cleaning And Inspection .......... 3.05 - 1 Lower Sleeve Bore And Sleeve Projection Inspection . . . . . . . . . . . . . . . . . . 3.05 - 3 Crankcase Lower Bore Restoration .......... 3.05 - 3 Main Bearing Bore Cleaning And Inspection ........................... 3.05 - 5 Main Bearing Running Clearance ............ 3.05 - 6 Camshaft Bearing Bore Inspection ........... 3.05 - 9 Crankshaft ................................ 3.05 - 9 Crankshaft Cleaning And Inspection .......... 3.05 - 9 Crankshaft Journal Repair ................ 3.05 - 11 Crankshaft Polishing ..................... 3.05 - 11 Crankshaft Repair ........................ 3.05 - 11 Crankshaft Counterweight Retorque ......... 3.05 - 12 Camshaft ................................ 3.05 - 14 Camshaft Cleaning And Inspection .......... 3.05 - 14

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Form 6248 First Ednion

CONTENTS

Valve Lifters .............................. 3.05 - 15 Roller Type Lifters ........................ 3.05 - 15 Hydraulic Lifters .......................... 3.05 - 16 Piston ................................... 3.05 - 17 Piston Disassembly ....................... 3.05 - 17 Piston Cleaning And Inspection ............. 3.05 - 18 Piston Ring Inspection ..................... 3.05 - 23 Piston Ring Assembly ..................... 3.05 - 27 8-1/2 Inch Bore G/GSI/GL (4 Ring Piston) .... 3.05 - 27 9-3/8 Inch Bore G/GSI (4 Ring Piston) ....... 3.05 - 29 Previous Production 9-3/8 Inch Bore GL (4 Ring Piston) ...................... 3.05 - 30 Current Production 9-3/8 Inch Bore GL (3 Ring Piston) ...................... 3.05 - 31 Piston Pin Cleaning And Inspection ......... 3.05 - 32 Connecting Rod .......................... 3.05 - 33 Connecting Rod Disassembly .............. 3.05 - 33 Connecting Rod Cleaning And Inspection .... 3.05 - 35 Connecting Rod Assembly ................. 3.05 - 38 Connecting Rod Bearing Running Clearance .......................... 3.05 - 40 Connecting Rod Bearing Running Clearance Measurement With Plastigage .................... 3.05 - 42 Cylinder Sleeve .......................... 3.05 - 42 Cylinder Sleeve Disassembly ............... 3.05 - 42 Cylinder Sleeve Cleaning And Inspection .... 3.05 - 43 Cylinder Sleeve Deglazing ................. 3.05 - 47 Flywheel ................................. 3.05 - 48 Ring Gear Removal ....................... 3.05 - 48 Ring Gear Installation ..................... 3.05 - 48

Lower Valve Lifter Housing Cover Installation ........................... 4.00 - 5 Valve Lifter Housing Gasket Installation ........................... 4.00 - 6 Camshaft And Bearing Installation ........... 4.00 - 6 Gear Housing Installation .................. 4.00 - 10 Camshaft End Play Measurement ........... 4.00 - 11 Cam Gear Installation ..................... 4.00 - 12 Valve Lifter Housing Installation ............. 4.00 - 13 Rocker Arm Oil Header Installation .......... 4.00 - 18 Rear Oil Seal Retainer Installation .......... 4.00 - 18 Main Bearing Installation ................... 4.00 - 20 Crankshaft Installation ..................... 4.00 - 22 Rear Oil Seal Retainer (Lower Half) Installation .............. 4.00 - 25 Main Bearing Caps Installation ............. 4.00 - 26 Crankshaft End Play Measurement .......... 4.00 - 26 Outside Crankshaft Thrust Ring Installation .......................... 4.00 - 28 Crankshaft Gear Installation ............... 4.00 - 30 Oil Pump Idler Gear ....................... 4.00 - 31 Camshaft Idler Gear Installation ............ 4.00 - 32 Accessory Idler Gear Installation ............ 4.00 - 35 Gear Backlash Measurement ............... 4.00 - 36 Magneto Drive Assembly Installation ........ 4.00 - 37 Magneto Drive Gear Installation ............ 4.00 - 39 Cylinder Sleeve Installation ................ 4.00 - 41 Piston And Connecting Rod Installation ...... 4.00 - 42 Oil Pan .................................. 4.00 - 46 Crankcase Installation ..................... 4.00 - 49 Front Flywheel Housing Installation ......... 4.00 - 50 Timing Tape Installation .................... 4.00 - 51

CHAPTER 4 - ENGINE ASSEMBLYSection 4.00 - Crankcase AssemblyCrankcase Assembly ....................... 4.00 - 1 Idler Gear Spindle Installation ............... 4.00 - 1 Oil Tube Installation ........................ 4.00 - 1 Main Bearing Stud Installation ............... 4.00 - 2 Dowel Installation .......................... 4.00 - 3 Water Header Plug Installation ............... 4.00 - 3 Lube Oil Strainer Adapter Installation ......... 4.00 - 5

Flywheel Installation ...................... 4.00 - 52 Magnetic Pickup Sensor Installation ......... 4.00 - 53 Rear Flywheel Housing Installation .......... 4.00 - 54 Flywheel/Flywheel Housing Bore And Face Runout Measure ................ 4.00 - 55 Barring Device Installation ................. 4.00 - 58 Oil Filler Bracket Installation ................ 4.00 - 58 Gear Train Lubrication ..................... 4.00 - 59 Oil Slinger/Front Oil Seal/Gear Cover Installation .......................... 4.00 - 60 Front Gear Cover Plates Installation ......... 4.00 - 64

Form 6248 First Ed~ion

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CONTENTS

Rear Gear Housing Cover Plate Installation .......................... 4.00 - 64 Vibration Damper/Crankshaft Pulley Installation .......................... 4.00 - 65

Governor Drive Gear/CEC Disc (Previous Production) Installation ....... 5.00 - 8 Governor Drive Shaft ...................... 5.00 - 10 Governor Drive Shaft Removal ............. 5.00 - 10 Governor Drive Shaft Disassembly .......... 5.00 - 10 Governor Drive Shaft Cleaning And Inspection .............. 5.00 - 11 Governor Drive Shaft Assembly ............. 5.00 - 11 Governor Drive Shaft Installation ............ 5.00 - 12

Section 4.05 - Cylinder Head AssemblyCylinder Head Installation ................... 4.05 - 1 Cylinder Head Torquing Procedure ........... 4.05 - 3 Exhaust Manifolds ......................... 4.05 - 5

Section 4.10 - Valve Adjustment And Web DeflectionValve Adjustment Procedure ................ 4.10 - 1 Crankshaft Web Deflection Measurement ........................... 4.10 - 4

Governor Drive Housing ................... 5.00 - 13 Governor Drive Housing Removal ......... , . 5.00 - 13 Governor Drive Housing Disassembly ....... 5.00 - 13 Governor Drive Housing Cleaning And Inspection .............. 5.00 - 13 Governor Drive Housing Assembly .......... 5.00 - 14

CHAPTER 5 - ENGINE SYSTEMSSection 5.00 - Speed Governing SystemSpeed Governing System Components ....... 5.00 - 1 Speed Governing System Description ........ 5.00 - 1 Woodward UG-8L Governor ................ 5.00 - 1 Woodward UG-8 Dial Governor ............. 5.00 - 1 Woodward EG-3P Electronic Governing System .............................. 5.00 - 1 Governor Linkages ......................... 5.00 - 2 Magnetic Pickup ........................... 5.00 - 2 Control Panel ............................. 5.00 - 2 Overspeed Governor ....................... 5.00 - 2 Governor Drive Gear/CEC Timing Disc ....... 5.00 - 3 Governor Drive Gear/CEC Timing Disc (Current Production) Removal .......... 5.00 - 3 Governor Drive Gear/CEC Timing Disc (Current Production) Cleaning And Inspection ........................... 5.00 - 4 Governor Drive Gear/CEC Timing Disc (Current Production) Installation ........ 5.00 - 4 Governor Drive Gear/CEC Disc (Previous Production) Removal ......... 5.00 - 6 Governor Drive Gear/CEC Disc (Previous Production) Disassembly ..... 5.00 - 7 Governor Drive Gear/CEC Disc (Previous Production) Cleaning And Inspection ........................... 5.00 - 7 Governor Drive Gear/CEC Disc (Previous Production) Assembly ........ 5.00 - 7

Governor Drive Housing Installation ....... , . 5.00 - 14 Governors ............................... 5.00 - 16 Woodward UG-8L Governor Linkage Removal ........................... 5.00 - 16 Woodward UG-8L Governor Removal ....... 5.00 - 17 Woodward UG-8L Governor Disassembly .,. 5.00 - 17 Woodward UG-8L Governor Assembly ...... 5.00 - 17 Woodward UG-8L Governor Installation ..... 5.00 - 18 UG-8L Governor Linkage Installation And Adjustment ......................... 5.00 - 19 Woodward UG-8L Governor Compensation Adjustment ............ 5.00 - 22 Woodward UG-8L Governor High/Low Speed Limn Adjustment .............. 5.00 - 24 Woodward UG-8L Governor Droop Adjustment ......................... 5.00 - 24 Woodward UG-8 (Dial) Governor Linkage Removal ........................... 5.00 - 25 Woodward UG-8 (Dial) Governor Removal ... 5.00 - 26 Woodward UG-8 (Dial) Governor Disassembly ........................ 5.00 - 27 Woodward UG-8 (Dial) Governor Assembly ........................... 5.00 - 27 Woodward UG-8 (Dial) Governor Installation .......................... 5.00 - 27 Woodward UG-8 (Dial) Governor Linkage Installation And Adjustment ........... 5.00 - 27 Woodward UG-8 Dial Governor Compensation Adjustment ............ 5.00 - 29 Woodward UG-8 Dial Governor High/Low Speed Adjustment ................... 5.00 - 30

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vi

Form 6248 First Edition

CONTENTS

Woodward UG-8 (Dial) Governor Droop Adjustment ......................... 5.00 - 31 Woodward EG-3P Electric Governor Linkage Removal .................... 5.00 - 31 Woodward EG-3P Governor Removal ....... 5.00 - 32 Woodward EG-3P Governor Disassembly ... 5.00 - 32 Woodward EG-3P Governor Cleaning And Inspection .......................... 5.00 - 33 Woodward EG-3P Governor Assembly ...... 5.00 - 33 EG-3P Governor Drive Removal ............ 5.00 - 33 EG-3P Governor Drive Disassembly ........ 5.00 - 34 EG-3P Governor Drive Cleaning And Inspection .......................... 5.00 - 35 EG-3P Governor Drive Assembly ........... 5.00 - 35 EG-3P Governor Drive Installation .......... 5.00 - 35 Woodward EG-3P Governor Installation ..... 5.00 - 36 EG-3P Governor Linkage Cleaning And Inspection .......................... 5.00 - 37 EG-3P Governor Linkage Installation And Adjustment ......................... 5.00 - 38 Manual Shutdown Lever - GL .............. 5.00 - 40 Manual Shutdown Lever Adjustment - GL .... 5.00 - 40 Manual Shutdown Lever Removal - GIGSI ... 5.00 - 42 Manual Shutdown Lever Installation GIGSI .............................. 5.00 - 42 Manual Shutdown Lever Adjustment GlGSI .............................. 5.00 - 42 Overspeed Governor ...................... 5.00 - 42 Overspeed Governor Removal ............. 5.00 - 42 Overspeed Governor Adjustment ........... 5.00 - 43 Overspeed Governor Installation ............ 5.00 - 43 Hour Meter .............................. 5.00 - 44 Hour Meter Removal ...................... 5.00 - 44 Hour Meter Installation .................... 5.00 - 44 Tachometer Drive ......................... 5.00 - 45 Tachometer Drive Removal ................ 5.00 - 45 Tachometer Drive Installation ............... 5.00 - 45

Prechamber Gas Safety Shutdown Valve GL .................................. 5.05 - 5 Prechamber Regulator - GL ................. 5.05 - 5 Prechamber Manffolds - GL ................. 5.05 - 6 Butterfly Cross Shaft - GlGSI ............... 5.05 - 6 Butterfly Cross Shaft Removal - GIGSI ....... 5.05 - 6 Butterfly Cross Shaft Installation - GIGSI ............................. 5.05 - 7 Carburetor Cross Shaft - GL ................ 5.05 - 8 Carburetor Cross Shaft Removal - GL ........ 5.05 - 8 Carburetor Cross Shaft Installation - GL ...... 5.05 - 8 Prechamber Manffold Cross Pipe - GL ....... 5.05 - 9 Prechamber Manffold Cross Pipe Removal - GL ....................... 5.05 - 9 Prechamber Manffold Cross Pipe Installation - GL ..................... 5.05 - 10 Carburetors .............................. 5.05 - 11 Carburetor Removal - GIGS I ............... 5.05 - 11 Carburetor Disassembly - G/GSI ............ 5.05 - 12 Carburetor Cleaning And Inspection GIGSI .............................. 5.05 - 12 Carburetor Assembly - GIGS I .; ............ 5.05 - 13 Carburetor Installation - GIGSI ............. 5.05 - 13 Carburetor Removal - GL ..... :: ........... 5.05 - 15 Carburetor Disassembly - GL .............. 5.05 - 15 Carburetor Cleaning And Inspection - GL .... 5.05 - 16 Carburetor Assembly - GL ................. 5.05 - 17 Carburetor Installation - GL ................ 5.05 - 17 Butterfly Valve(s) ......................... 5.05 - 18 Butterfly Valve Removal - GIGSI ............ 5.05 - 18 Butterfly Valve Disassembly - GlGSI ........ 5.05 - 18 Butterfly Valve Assembly - GIGSI ........... 5.05 - 19 Butterfly Valve Installation - GIGSI .......... 5.05 - 19 Admission Valve - GL ..................... 5.05 - 19 Admission Valve Removal - GL ............. 5.05 - 19 Admission Valve Disassembly - GL ......... 5.05 - 19 Admission Valve Cleaning And Inspection - GL ..................... 5.05 - 19 Admission Valve Assembly ................. 5.05 - 20 Admission Valve Installation - GL ........... 5.05 - 20 Prechamber Cup - GL ..................... 5.05 - 21 Prechamber Cup Removal - GL ............ 5.05 - 21

Section 5.05 - Fuel SystemFuel System Components ................... 5.05 - 1 Main Fuel Gas Pressure Regulators .......... 5.05 - 1 Operation Of The Fisher 99 Main Fuel Gas Pressure Regulator .. .. .. .. .. .. .. . 5.05 - 4 Carburetors .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.05 - 5 Pilot Operated Prechamber Gas Valve - GL . . . 5.05 - 5Form 6248 First Ed~ion

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CONTENTS

Prechamber Cup Cleaning And Inspection - GL ..................... 5.05 - 22 Prechamber Cup Installation - GL .......... 5.05 - 22 Prechamber Manifold - GL ................. 5.05 - 23 Prechamber Manifold Removal - GL ........ 5.05 - 23 Prechamber Manifold Installation - GL ....... 5.05 - 24 Main Fuel Gas Pressure Regulator (Fisher 99) ............................ 5.05 - 25 Main Fuel Gas Pressure Regulator (Fisher 99) Removal ................. 5.05 - 25 Right Bank Installation ..................... 5.05 - 25 Left Bank Installation ...................... 5.05 - 28 Prechamber Regulator (Fisher 95L) - GL ...................... 5.05 - 29 Prechamber Regulator (Fisher 95L) Removal - GL ...................... 5.05 - 29 Prechamber Regulator (Fisher 95L) Installation - GL ..................... 5.05 - 30 Fuel System Maintenance ................. 5.05 - 33 Fisher 99 Regulator Filter Cleaning And Inspection .......................... 5.05 - 33

CEC Ignition Module Removal .............. 5.10 - 19 CEC Ignition Module Installation ............ 5.10 - 19 Governor Drive Gear/CEC Timing Disc (Current Production) ......... 5.10 - 20 Governor Drive Gear/CEC TIming Disc Removal (Current Production) ......... 5.10 - 20 Governor Drive Gear/CEC TIming Disc Cleaning And Inspection (Current Production) ................. 5.10 - 20 Governor Drive Gear/CEC TIming Disc Installation (Current Production) ....... 5.10 - 21 CEC Ignition Module Static TIming SET (Current Production) ................. 5.10 - 22 Selling The Air Gap Specification (Current And Previous Production) ..... 5.10 - 24 CEC Ignition Module TIming Set (Current Production) ................. 5.10 - 24 Steps Required To Adjust CEC Ignition Module Timing (Current Production) .... 5.10 - 25 Governor Drive Gear/CEC Timing Disc (Previous Production) ........ 5.10 - 26 Governor Drive Gear/CEC TIming Disc (Previous Production) Removal ... 5.10 - 26 Governor Drive Gear/CEC TIming Disc (Previous Production) Cleaning And Inspection .............. 5.10 - 26 Governor Drive gear/CEC Timing Disc (Previous Production) Installation ...... 5.10 - 27 CEC Ignition Module Ignition TIming (Previous Production) Set ............. 5.10 - 28 Steps Required To Adjust CEC Ignition Module TIming (Previous Production) ... 5.10 - 30 Magneto ................................. 5.10 - 30 Drive Disc Coupling Replacement ........... 5.10 - 30 Magneto - Static Timing Set ................ 5.10 - 32 Magneto - Ignition Timing Set .............. 5.10 - 37 Magneto Adapter ......................... 5.10 - 39 Magneto Adapter Disassembly ............. 5.10 - 39 Magneto Adapter Cleaning And Inspection ... 5.10 - 40 Magneto Adapter Assembly ................ 5.10 - 40 Magneto Drive ........................... 5.10 - 42 Magneto Drive Disassembly ................ 5.10 - 42 Magneto Drive Assembly .................. 5.10 - 43

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Section 5.10 - Ignition SystemIgnition System Components ................ 5.10 - 1 CEC Ignition Module ....................... 5.10 - 1 Magneto .................................. 5.10 - 1 Wiring Harness ............................ 5.10 - 1 Ignition Coils .............................. 5.10-1 Spall< Plugs ............................... 5.10 - 1 Spark Plugs ............................... 5.10- 1 Spark Plug Carrier Removal - GL . . . . . . . . . . .. 5.10 - 1 Spark Plug Carrier Installation - GL .......... 5.10 - 3 Spark Plug Carrier Removal - CSA .......... 5.10 - 3 Spark Plug Carrier Installation - CSA ......... 5.10 - 4 Spark Plug Removal ....................... 5.10 - 5 Spark Plug Inspection ...................... 5.10 - 7 Spark Plug Installation . . . . . . .. . . . . . . . . . . . . .. 5.10 - 8 Spark Plug Extension Repair ............... 5.1 0 - 10 Ignition Coils ............................. 5.10 - 11 Wiring Harness ........................... 5.10 - 13 Wiring Harness Removal .................. 5.10 - 13 Wiring Harness Inspection ................. 5.10 - 14 Wiring Harness Installation ................. 5.10 - 15 CEC Ignition Module ...................... 5.10 - 19

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Form 6248 First Edition

CONTENTS

Section 5.15 - Air Induction SystemAir Induction System ....................... 5.15 - 1 Air Cleaners .............................. 5.15 - 1 Turbochargers ............................. 5.15 - 1 Intercoolers ............................... 5.15 - 1 Carburetor And Intake Manifold .............. 5.15 - 1 Air Induction System Specifications .......... 5.15 - 1 Air Cleaners .............................. 5.15 - 2 Precleaner Pad Removal ................... 5.15 - 2 Precleaner Pad Cleaning And Inspection ...... 5.15 - 3 Precleaner Pad Installation .................. 5.15 - 3 Main Air fiRer Element Removal ............. 5.15 - 3 Main Air Filter Element Cleaning And Inspection ........................... 5.15 - 3 Main Air FiRer Element Installation ........... 5.15 - 4 Air Restriction Indicator ..................... 5.15 - 4 Air Cleaner Ducts .......................... 5.15 - 5 Air Cleaner Duct Removal - G ............... 5.15 - 5 Air Cleaner Duct Installation - G ............. 5.15 - 7 Air Cleaner Duct Removal - GSI/GL .......... 5.15 - 8 Air Cleaner Duct Installation - GSI/GL ....... 5.15 - 10 Air Tubing ............................... 5.15 -10 Air Tubing Removal - G ................... 5.15 - 10 Air Tubing Installation - G .................. 5.15 - 11 Air Tubing Removal - GSI ................. 5.15 - 11 Air Tubing Installation - GSI ................ 5.15 - 12 Air Tubing Removal - GL .................. 5.15 - 12 Air Tubing Installation - GL ................ 5.15 - 14 Intake ManHolds .......................... 5.15 - 14 Intake Manifold Removal - G/GSI ........... 5.15 - 14 Intake Manifold Installation - GlGSI ......... 5.15 - 15 Intake Manifold Flange Attachments ......... 5.15 - 16 Intake ManHold Flange Attachments GlGSI .............................. 5.15-16 Left Bank ................................ 5.15-16 Right Bank ............................... 5.15-17 Intake Manifold Removal - GL .............. 5.15 - 18 Intake ManHold Installation - GL ............ 5.15 - 19 Intake ManHold Flange Attachments - GL .... 5.15 - 20 Left Bank ................................ 5.15-20 Right Bank ............................... 5.15 - 20

Section 5.20 - TurbochargersTurbochargers ............................. 5.20 - 1 Turbocharger(s) Removal ................... 5.20 - 1 Turbocharger Cleaning And Inspection ....... 5.20 - 3 Turbocharger Installation ................... 5.20 - 8 Prelube Pressure Maintenance/Check Valve Inspection ............................. 5.20 - 12

Section 5.25 - Cooling SystemCooling System Components ................ 5.25 - 1 Jacket Water Header/Jacket Water . . . . . . . . . . . 5.25 - 1 Exhaust Manifold .......................... 5.25 - 1 Water Manifold ............................ 5.25 - 1 Jacket Water Pump ........................ 5.25 - 2 Cluster Thermostat Housing . . . . . . . . . . . . . . . . . 5.25 - 7 Remote Heat Transfer Device ............... 5.25 - 7 Auxiliary Water Pump ...................... 5.25 - 7 Intercooler ................................ 5.25 - 8 Oil Cooler ................................. 5.25 - 8 Auxiliary Water Temperature Control Valve .... 5.25 - 8 Auxiliary Water Remote Heat Transfer Device .............................. 5.25 - 9 Cooling System Problems ................... 5.25 - 9 Scale Build-up, Cavitation Erosion And Corrosion ............................ 5.25 - 9 Scale Build-up ............................ 5.25 - 9 CavHation Erosion ......................... 5.25 - 9 Corrosion ................................ 5.25 - 10 Water Treatment .......................... 5.25 - 10 Ethylene Glycol ........................... 5.25 - 10 Cooling System Specifications And Recommendations ..................... 5.25 - 11 Cooling System Specifications . . . . . . . . . . . . .. 5.25 - 11 Cooling System Recommendations ......... 5.25 - 11 Jacket Water CircuH - InHial Fill ............. 5.25 - 12 Auxiliary Cooling Water Circuit - Initial Fill .... 5.25 - 13 Cooling Water System Air Bleed ............ 5.25 - 14 Jacket Water And Auxiliary Cooling Water Circuits - Drain And Flush ............... 5.25 - 14 Grease Fittings ........................... 5.25 - 17 Idler Pulley Bearing Lubrication ............. 5.25 - 17 Auxiliary Water Pump Bearings Lubrication ... 5.25 - 17 Grease Recommendations ................. 5.25 - 17

Form 6248 First EdHion

Ix

CONTENTS

Belts .................................... 5.25 - 18 Jacket Water Pump Drive Belts Replacement ....................... 5.25 - 18 Jacket Water Pump Drive Belt Tension Adjustment ......................... 5.25 - 19 Auxiliary Water Pump Drive Belt Replacement ....................... 5.25 - 21 Auxiliary Water Pump Drive Bett Tension Adjustment ......................... 5.25 - 22 Jacket Water Pump Seal Inspection ......... 5.25 - 23 Crankcase Water Inlet Elbows .............. 5.25 - 24 Crankcase Water Inlet Elbows Removal Left Bank ........................... 5.25 - 24 Crankcase Water Inlet Elbows Removal Right Bank ......................... 5.25 - 25 Crankcase Water Inlet Elbows Installation - Left Bank ............... 5.25 - 25 Crankcase Water Inlet Elbows Installation Right Bank ......................... 5.25 - 25 Water Pump Inlet Elbows And Water Header . 5.25 - 26 Water Pump Inlet Elbows And Water Header Removal .................... 5.25 - 26 Water Pump Inlet Elbows And Water Header Installation ................... 5.25 - 27 Lower/Upper Bypass Tubes And Water Bypass Elbows ........................ 5.25 - 28 Lower/Upper Bypass Tubes And Water Bypass Elbows Removal ............. 5.25 - 28 Lower/Upper Bypass Tubes And Water Bypass Elbows Installation ............ 5.25 - 29 Water Manifold ........................... 5.25 - 31 Water Manifold Removal ........ , .......... 5.25 - 31 Water Manifold Installation ................. 5.25 - 32 Cluster Thermostat Housing And Thermostatic Valves .................... 5.25 - 34 Cluster Thermostat Housing And Thermostatic Valves Removal ......... 5.25 - 34 Cluster Thermostat Housing And Thermostatic Valves Cleaning And Inspection .......................... 5.25 - 35 Cluster Thermostat Housing/Thermostatic Valves Installation .......................... 5.25 - 37 Idler Pulley Bracket ....................... 5.25 - 39 Idler Pulley Bracket Removal ............... 5.25 - 39 Idler Pulley Bracket Disassembly ........... 5.25 - 39

Idler Pulley Bracket Cleaning And Inspection .......................... 5.25 - 41 Idler Pulley Bracket Assembly .............. 5.25 - 41 Idler Pulley Bracket Installation ............. 5.25 - 43 Jacket Water Pump ....................... 5.25 - 44 Jacket Water Pump Removal ............... 5.25 - 44 Jacket Water Pump Disassembly ........... 5.25 - 45 Jacket Water Pump Cleaning And Inspection .......................... 5.25 - 46 Jacket Water Pump Assembly .............. 5.25 - 47 Jacket Water Pump Installation ............. 5.25 - 54 Safety Guards ............................ 5.25 - 56 Safety Guards Removal ................... 5.25 - 56 Safety Guards Installation .................. 5.25 - 57 Auxiliary Water Temperature Control Valve ... 5.25 - 58 Auxiliary Water Temperature Control Valve Removal .......................... 5.25 - 58 Auxiliary Water Temperature Control Thermostatic Valve Inspection And Test ............................... 5.25 - 58 Auxiliary Water Temperature Control Valve Assembly ........................... 5.25 - 59 Auxiliary Water Temperature Control Valve Installation .......................... 5.25 - 60 Intercooler ............................... 5.25 - 60 Intercooler Removal ...................... 5.25 - 60 Intercooler Disassembly ................... 5.25 - 66 Intercooler Cleaning And Inspection ......... 5.25 - 67 Intercooler Assembly ...................... 5.25 - 68 Intercooler Installation ..................... 5.25 - 71 Crankcase Vee Pipe Connection Installation ............................ 5.25 - 73 Auxiliary Water Pump And Bracket .......... 5.25 - 77 Auxiliary Water Pump And Bracket Removal ........................... 5.25 - 77 Auxiliary Water Pump And Bracket Installation .......................... 5.25 - 79

)

Section 5.30 - Lubrication SystemLubrication System Components ............. 5.30 - 1 Description ............................... 5.30 - 1 Internal Oil Control ......................... 5.30 - 3 Lube Oil Specifications ..................... 5.30 - 4 Oil Designations ........................... 5.30 - 4 Oil Recommendations ...................... 5.30 - 4

x

Form 6248 First

Ed~ion

CONTENTS

Waukesha Cogeneration Installations ......... 5.30 - 5 Sour Gas & Alternate Fuel Gas Recommendations ...................... 5.30 - 5 Recommended Lube Oils For Sour Gas And Alternate Fuel (Landfill) Gas Applications 5.30 - 5 Fuel Coalescer Specification For A~ernative Fuel Application ............ 5.30 - 6 Lube Oil Condemning Limits ................ 5.30 - 6 Lube Oil Analysis .......................... 5.30 - 8 Oil Viscosity Selection ...................... 5.30 - 9 Multi-viscosity Oils. . . . . . . . . . . . . . . . . . . . . . . . . 5.30 - 9 Synthetic Oils ............................. 5.30 - 9 Low Ambient Temperature Operation ......... 5.30 - 9 Lube Oil Consumption Rates ................ 5.30 - 9 Formulas ................................. 5.30 - 9 Recommended Oil Change Intervals ........ 5.30 - 10 Lube Oil Piping Purge ..................... 5.30 - 11 Oil Cooler And Lube Oil Filter Installation ............................ 5.30 - 12 Lube Oil Change ......................... 5.30 - 12 Checking Crankcase Oil Level .............. 5.30 - 13 Oil Cooler Maintenance .................... 5.30 - 13 Lube Oil System Air Bleed ................. 5.30 - 13 Lube Oil Lube OilFi~er Fi~er

Oil Pickup Screen Installation ............... 5.30 - 29 Lube Oil Pump ........................... 5.30 - 29 Lube Oil Pump Removal ................... 5.30 - 29 Lube Oil Pump Disassembly ............... 5.30 - 29 Lube Oil Pump Cleaning And Inspection ..... 5.30 - 31 Lube Oil Pump Assembly .................. 5.30 - 32 Lube Oil Pump Installation ................. 5.30 - 37 Prelube Y -strainer ........................ 5.30 - 40 Prelube Y -strainer Removal ................ 5.30 - 40 Prelube Y-strainer Cleaning And Inspection .......................... 5.30 - 40 Prelube Y -strainer Installation .............. 5.30 - 40 Oil Filler Pipe Removal .................... 5.30 - 41 Oil Filler Pipe Removal .................... 5.30 - 41 Oil Filler Pipe Installation .................. 5.30 - 41 Rocker Arm Oil Header Oil Inlet Tubes/Fittings ......................... 5.30 - 42 Rocker Arm Oil Header Oil Inlet Tubes/Fittings Installation ............. 5.30 - 42 Turbo Oil Supply!Drain Tubes .............. 5.30 - 43 Turbo Oil Supply!Drain Tubes Installation .......................... 5.30 - 43 Lube Oil Pilot Pressure/Governor. Oil Tube Connection ............................ 5.30 - 44 Oil Pan Doors ............................ 5.30 - 45 Oil Pan Doors Removal .................... 5.30 - 45 Oil Pan Doors Installation .................. 5.30 - 46 Lube Oil Strainer ......................... 5.30 - 46 Lube Oil Strainer Removal ................. 5.30 - 46 Lube Oil Strainer Cleaning And Inspection .......................... 5.30 - 47 Lube Oil Strainer Installation ............... 5.30 - 47

Element Replacement ........ 5.30 - 13 Relief Valve Inspection ....... 5.30 - 15

Magnetic Plugs ........................... 5.30 - 16 Oil Cooler Piping Removal ................. 5.30 - 16 Oil Cooler Piping Installation ............... 5.30 - 18 Oil Cooler Removal ....................... 5.30 - 18 Oil Cooler Cleaning And Inspection ......... 5.30 - 19 Oil Cooler Installation ..................... 5.30 - 19 Lube Oil Temperature Control Valve ......... 5.30 - 21 Troubleshooting Low Lube Oil Pressure ...... 5.30 - 24 Lube Oil Pressure Adjustment .............. 5.30 - 24 Prelube System .......................... 5.30 - 24 Prelube Pressure Maintenance ............. 5.30 - 25 Check Valve Inspection .................... 5.30 - 26 In-line Lubricator ......................... 5.30 - 26 Oil Pan Clean And Inspect ................. 5.30 - 28 Oil Pickup Screen ......................... 5.30 - 28 Oil Pickup Screen Removal ................ 5.30 - 28 Oil Pickup Screen Cleaning And Inspection .......................... 5.30 - 29Form 6248 First Edition

Section 5.35 - Exhaust SystemExhaust System ........................... 5.35 - 1 Components .............................. 5.35 - 1 Description ............................... 5.35 - 1 Exhaust System Specifications .............. 5.35 - 2 Measuring Exhaust System Backpressure .. . . . . . . . . . . . . . . . . . . . . .. 5.35 - 2 Checking Exhaust Gas Temperatures ........ 5.35 - 2 Exhaust Manifold .......................... 5.35 - 3 Exhaust Manifold Removal .................. 5.35 - 3 Exhaust Manifold Disassembly .............. 5.35 - 5

xl

CONTENTS

Exhaust Manifold Assembly ................. 5.35 - 5 Exhaust Manifold Installation ................ 5.35 - 6 Turbo Exhaust Inlet Elbows ................ 5.35 - 10 Turbo Exhaust Inlet Elbows Removal ........ 5.35 - 10 Turbo Exhaust Inlet Elbows Installation ...... 5.35 - 11 Exhaust Connections - G .................. 5.35 - 13 Exhaust Connections Removal - G ......... 5.35 - 13 Exhaust Connections Installation - G ........ 5.35 - 14 Exhaust Connections Removal - GSI/GL .... 5.35 - 14 Exhaust Connections Installation - GSI/GL ... 5.35 - 15 Thermocouples ........................... 5.35 - 16 Thermocouple Replacement ............... 5.35 - 16 Exhaust Thermocouples Installation ......... 5.35 - 18 Thermocouple Clean And Inspect ........... 5.35 - 19 Wastegates .............................. 5.35 - 20 Wastegates - Bleeding Air ................. 5.35 - 20 PIN Series 208372 Wastegate Removal ..... 5.35 - 20 PIN Series 208372 Wastegate Disassembly .. 5.35 - 21 PIN Series 208372 Wastegate Cleaning And Inspection .............. 5.35 - 23 PIN Series 208372 Wastegate Assembly ..... 5.35 - 24 PIN Series 208372 Wastegate Calibration .... 5.35 - 25 PIN Series 295645 Wastegate Removal Draw Thnu Only ..................... 5.35 - 28 PIN Series 295645 Wastegate Disassembly - Draw Thru Only ........ 5.35 - 29 PIN Series 295645 Wastegate Calibration Setup - Draw Thru Only .............. 5.35 - 29 PIN Series 295645 Calibration Procedure Test - Draw Thru Only ............... 5.35 - 30 PIN Series 295645 Wastegate Installation - Draw Thru Only ......... 5.35 - 31 Engine AHttude Adjustments ................ 5.35 - 32

Venturi - GSI .............................. 5.40 - 2 Crankcase Pressure Measurement ........... 5.40 - 3 Crankcase Pressure Measurement G/GSI/GL ........................... 5.40 - 3 Crankcase Pressure Adjustment G/GSI Venturi Equipped ............... 5.40 - 3 Crankcase Pressure Adjustment (Venturi ExtractorNacuum Valve Assembly Equipped) - GSI/GL ......... 5.40 - 4 Crankcase Separator Screen ................ 5.40 - 6 Crankcase Separator Screen Removal ....... 5.40 - 6 Crankcase Separator Screen Cleaning And Inspection .......................... 5.40 - 6 Crankcase Separator Screen Assembly ....... 5.40 - 6 Oil Separators ............................. 5.40 - 7 Oil Separator Removal - G .................. 5.40 - 7 Oil Separator Installation - G ................ 5.40 - 8 Oil Separator Removal - GSI/GL ............. 5.40 - 8 Oil Separator Cleaning And Inspection GSI/GL .............................. 5.40 - 9 Oil Separator Installation - GSI/GL ........... 5.40 - 9 Crankcase Breather Regulator - GSI/GL ..... 5.40 - 10 Crankcase Breather Regulator Removal GSI/GL ............................. 5.40 - 10 Crankcase Breather Regulator Disassembly - GSI/GL ............... 5.40 - 10 Crankcase Breather Regulator Cleaning And Inspection - GSI/GL . . . .. 5.40 - 11 Crankcase Breather Regulator Installation - GSI/GL ................. 5.40 - 11 Venturi .................................. 5.40 - 12 Venturi Removal - GSI .................... 5.40 - 12 Venturi Cleaning And Inspection - GSI ...... 5.40 - 12 Venturi Installation - GSI ................... 5.40 - 12 Venturi Extractor - GSI/GL ................ 5.40 - 12

)

Section 5.40 - Crankcase Breather SystemCrankcase Breather System ................. 5.40 - 1 Components .............................. 5.40 - 1 Description ............................... 5.40 - 1 Separator Screen .......................... 5.40 - 1 Oil Separator(s) ........................... 5.40 - 1 Vacuum Valve/Choke Valve ................. 5.40 - 1 Breather Regulator ......................... 5.40 - 2 Venturi Extractor - GSI/GL .................. 5.40 - 2

Venturi Extractor Removal - GSI/GL ......... 5.40 - 12 Venturi Extractor Cleaning And Inspection - GSI/GL ................. 5.40 - 14 Venturi Extractor Assembly - GSI/GL ........ 5.40 - 15 Crankcase Pressure Relief Valves .......... 5.40 - 16 Crankcase Pressure Relief Valve Exercise ... 5.40 - 16 Crankcase Pressure Relief Valve Removal ... 5.40 - 16 Crankcase Pressure Relief Valve Cleaning And Inspection ...................... 5.40 - 17

)

xii

Form 6248 First Edition

CONTENTS

Crankcase Pressure Relief Valve Assembly ........................... 5.40 - 17 Breather Tubes ........................... 5.40 - 18 Breather Tube Removal - GSI .............. 5.40 - 18 Breather Tube Installation - GSI ............ 5.40 - 19 Breather Tube Removal - GL ............... 5.40 - 20 Breather Tube Installation - GL ............. 5.40 - 21 Venturi Extractor Compressor Discharge Tubes ................................ 5.40 - 22 Venturi Extractor Compressor Discharge Tubes Removal ..................... 5.40 - 22 Venturi Extractor Compressor Discharge Tubes Installation .................... 5.40 - 23

Air Starter ............................... 5.45 - 24 Air Starter Removal ....................... 5.45 - 24 Air Starter Installation ..................... 5.45 - 25 Electric Starter ........................... 5.45 - 26 Electric Starter Removal ................... 5.45 - 26 Electric Starter Installation ................. 5.45 - 26

CHAPTER 6 - ACCESSORIESSection 6.00 - Control PanelControl Panel ............................. 6.00 - 1 Components .............................. 6.00 - 1

Section 5.45 - Air/Gas Prelube And Start SystemsAir/Gas Prelube And Start Systems .......... 5.45 - 1 Components .............................. 5.45 - 1 Prelube System ........................... 5.45 - 1 Start System .............................. 5.45 - 4 Prelube/Start System Removal/Installation ..................... 5.45 - 9 Bulkhead Bracket Assembly Removal ........ 5.45 - 9 Bulkhead Bracket Assembly Installation ........................... 5.45 - 9 Pilot Operated Prelube Valve Removal ....... 5.45 - 10 Pilot Operated Prelube Valve Installation .......................... 5.45 - 11 Prelube Pump/Motor And Connections ....... 5.45 - 12 Prelube Pump/Motor And Connections Removal ........................... 5.45 - 12 Prelube Pump/Motor And Connections Installation .......................... 5.45 - 13 Lube Oil Pressure Gauge Tubes And Fitting (Former Engine Mounted Panel) ......... 5.45 - 14 Lube Oil Pressure Gauge Tubes And Fitting Removal ..................... 5.45 - 14 Lube Oil Pressure Gauge Tube Fitting Installation .......................... 5.45 - 14 Bulkhead To Panel Bracket ................. 5.45 - 14 Bulkhead To Panel Bracket Removal ........ 5.45 - 14 Bulkhead To Panel Bracket Installation ...... 5.45 - 15 Tube Clips/Clamps Installation .............. 5.45 - 17 Prechamber Gas Valves - GL .............. 5.45 - 19 Prechamber Gas Valves Removal (GL) ...... 5.45 - 19 Prechamber Gas Valves Installation (GL) .... 5.45 - 22Form 6248 First Ednion

Control Panel Removal - Right Side .......... 6.00 - 1 Control Panel Installation - Right Side ........ 6.00 - 3 Control Panel Removal - Left Side .... . . . . . . . 6.00 - 4 Control Panel Installation - Left Side ......... 6.00 - 5

Section 6.05 - Engine Protection SystemsEngine Protection Systems .................. 6.05 - 1 Components .............................. 6.05 - 1

"K" Type Thermocouples ................... 6.05 - 1Thermocouple Junction Box .... " ............ 6.05 - 6 Manual Shutdown Switches ................. 6.05 - 6 Customer Supplied Control Switches ......... 6.05 - 6 Pressure And Temperature Switches Calibration ........................... 6.05 - 6 Alarm And Shutdown Setpoints .............. 6.05 - 7 Engine Gauge Panel Components (Shipped Loose) ...................... 6.05 - 8 Remote Panel Components ................. 6.05 - 9 Custom Engine Control Detonation Sensing Module System ................ 6.05 - 10 DSM System Operation . . . . . . . . . . . . . . . . . . . . 6.05 - 11 Defautt Timing Value ...................... 6.05 - 11 User Interface ............................ 6.05 - 13 DSM System Troubleshooting .............. 6.05 - 14

Section 6.10 - Miscellaneous EquipmentMiscellaneous Equipment ................... 6.1 0 - 1 Components .............................. 6.10 - 1 Surge Tank ............................... 6.10 - 2 Surge Tank Removal ....................... 6.10 - 2

xIII

CONTENTS

Surge Tank Disassembly .................... 6.10 - 3 Surge Tank Cleaning And Inspection ......... 6.10 - 4 Surge Tank Assembly ...................... 6.10 - 4 Surge Tank Installation ..................... 6.10 - 4 Jacket Water Heater ....................... 6.10 - 5 Jacket Water Heater Removal ............... 6.10 - 5 Jacket Water Heater Cleaning And Inspection ........................... 6.10 - 6 Jacket Water Heater Installation ............. 6.10 - 6

)

CHAPTER 7 - TROUBLESHOOTING AND MAINTENANCESection 7.00 - TroubleshootingTroubleshooting ........................... 7.00 - 1

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

)

Alphabetical Index . ......................

A- 1

xlv

Form 6248 First EdHion

ILLUSTRATIONS LIST OF ILLUSTRATIONSSection 1.00 - Warning Tags & Decal LocationsFigure 1.00-1. Sample Of Warning Tag Placement . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.00 - 1 Figure 1.00-2. Warning Tag (PIN 209107B) On Regulator(s), All Naturally Aspirated Gas Engines ......................... 1.00 - 1 Figure 1.00-3. Warning Tag (PIN 209107E) .. 1.00 - 2 Figure 1.00-4. Warning Tag (P/N 209107H) On Fisher 99 Regulator(s), Turbocharged Gas Engines . . . . . . . . . . . . . . . . . . . . . . . .. 1.00 - 2 Figure 1.00-5. Warning Tag (PIN 209107L) On Fisher 66 Regulator(s), Naturally Aspirated, Low Btu Engines ............ 1.00 - 2 Figure 1.00-6. Warning Tag (P/N 209107R) On Fisher 99 And S211 Regulator(s), Turbocharged Engines ................ 1.00 - 3 Figure 1.00-7. Warning Tag (P/N 209107U) On IMPCO (MAXITROL) Pressure Reduction Valve, Used With 5 - 20, Water Column Gas Pressure . . . . . . . . . .. 1.00 - 3 Figure 1.00-8. Warning Tag (PIN 209107K) On Carburetor Throttle Lever For Engines Ordered And Built Without Waukesha Engine Division Designed Engine Safety Shutdown Equipment ................. 1.00 - 3 Figure 1.00-9. Warning Tag (PIN 209107P) For Gas Vent On Prelube Systems That Use Natural Gas For Prelube Motor ..... 1.00 - 4 Figure 1.00-10. Warning Tag (P/N 208840A) On High Voltage Equipment. . . . . . . . . . .. 1.00 - 4 Figure 1.15-7. Manifolds, Headers, etc...... 1.15 -12 Figure 1.15-8. Cylinder Head Capscrew TIghtening And Torquing Sequence (1 - 8) .................... 1.15 -14 Figure 1.15-9. Connecting Rod Cap Capscrew TIghtening Sequence (Series PIN 205407 and 205507) ........................ 1.15 -14 Figure 1 .15-10. Main Bearing Cap TIghtening{Torquing Pallern - As Viewed From Underside Of Crankcase ........ 1.15 - 15Figurel.15-11.Spl~RingWashers

........ 1.15-19

Section 1.20 - SpecificationsFigure 1.20-1. Valve Sequence Crankshaft Degrees Shown . . . . . . . . . . . 1.20 - 19 Figure 1.20-2. Engine Compression Pressures .......................... 1.20 - 28

Section 2.00 - Cylinder Head RemovalFigure 2.00-1. Rocker Arms ................ 2.00 - 2 Figure 2.00-2. Install Rocker Arm Oil Supply Tubes ........................ 2.00 - 2 Figure 2.00-3. Push Rods And Water Outlet Elbows ........................ 2.00 - 2 Figure 2.00-4. Water Outlet Elbow Gaskets .. 2.00 - 2 Figure 2.00-5. Exhaust Manifold~

Rear View. 2.00 - 3

Figure 2.00-6. Intake Manifold ': , ............ 2.00 - 3 Figure 2.00-7. Eye Bolt Location 12 Cylinder Engines .................. 2.00 - 3 Figure 2.00-8. Cylinder Heads .............. 2.00 - 3 Figure 2.00-9. Lilting The Cylinder Head ..... 2.00 - 4

Section 1.10 - Rigging And Lifting EnginesFigure 1.10-1. Correct Method Of Lifting Engine - Side Views ...... . . . . . . . . . . .. 1.10 - 1 Figure 1.10-2. Correct Method of Lifting Engine - Rear View ................... 1.10 - 2

Section 2.05 - Crankcase RemovalFigure 2.05-1. Capscrews Connecting Rod Caps ................. 2.05 - 1 Figure 2.05-2. Carbon Ridge ............... 2.05 - 1 Figure 2.05-3. Install Piston Puller .......... 2.05 - 1 Figure 2.05-4. Remove Piston/Connecting Rod Assembly ....................... 2.05 - 2 Figure 2.05-5. Connecting Rod ............. 2.05 - 2 Figure 2.05-6. Bearing Cap ................ 2.05 - 2 Figure 2.05-7. Keep Connecting Rod Caps And Blades Properly Mated ............ 2.05 - 3 Figure 2.05-8. Cylinder Sleeve Puller ........ 2.05 - 4 Figure 2.05-9. Cylinder Sleeve ............. 2.05 - 4 Figure 2.05-10. Vibration Dampers/Crankshaft Pulleys .............................. 2.05 - 5 Figure 2.05-11 . Crankshaft Pulley Stop Sleeve .............................. 2.05 - 6 Figure 2.05-12. Rear Vibration Damper/Rear Crankshaft Pulley ..................... 2.05 - 6

Section 1.15 - General InformationFigure 1.15-1. Nameplate Current Production ................... 1.15 - 3 Figure 1.15-2. Nameplate Previous Production .................. 1.15 - 3 Figure 1.15-3. Right Side View 12CylinderVHPGL .................. 1.15-4 Figure 1.15-4. Left Side View 12CylinderVHPGL .................. 1.15-5

)

Figure 1.15-5. RearView12CylinderVHPGL .................. 1.15-6 Figure 1.15-6. Torque Sequence For MuHi-Bolt Pallerns .................. 1.15 - 12 Form 6248 First Edition

xv

ILLUSTRATIONS

Figure 2.05-13. Gear Cover Plates Front Left ............................ 2.05 - 7 Figure 2.05-14. Rear Gear Housing Front Left ............................ 2.05 - 7 Figure 2.05-15. Ball Bearing ............... 2.05 - 7 Figure 2.05-16. Gear Cover ................ 2.05 - 8 Figure 2.05-17. Front Oil Seal .............. 2.05 - 8 Figure 2.05-18. Oil Slinger And O-Ring ...... 2.05 - 9 Figure 2.05-19. Magneto Drive Gear ........ 2.05 - 9 Figure 2.05-20. Drive Shaft ................ 2.05 - 9 Figure 2.05-21. Magneto Drive ............. 2.05 - 9 Figure 2.05-22. Lock Idler Gear Capscrews . 2.05 - 10 Figure 2.05-23. Gamshaft Idler Gear Upper .............................. 2.05 - 10 Figure 2.05-24. Gamshaft Cover Plate ...... 2.05 - 10 Figure 2.05-25. Unlocking The Camshaft Gear Nut ........................... 2.05 - 10 Figure 2.05-26. Oil Pan Gapscrew Front Left ........................... 2.05 - 11 Figure 2.05-27. Valve Lifter Housing Front .............................. 2.05 - 11 Figure 2.05-28. Front Gear Housing ........ 2.05 - 11 Figure 2.05-29. Rocker Arm Oil Header ..... 2.05 - 12 Figure 2.05-30. Longer Capscrew Locations For Mounting The Rocker Arm Oil Header .......................... 2.05 - 12 Figure 2.05-31. Valve Lifter Guides ........ 2.05 - 13 Figure 2.05-32. Valve Lifter Housing Cover .. 2.05 - 13 Figure 2.05-33. Raising The Valve Lifter Housing ............................ 2.05 - 13 Figure 2.05-34. Valve Lifter Housing Assembly ........................... 2.05 - 14 Figure 2.05-35. Gamshaft Set Screw On Valve Lifter Housing Cover ........ 2.05 - 14 Figure 2.05-36. Valve Lifter Housing Rear ............................... 2.05 - 14 Figure 2.05-37. Lower Valve Lifter Housing Cover .............................. 2.05 - 14 Figure 2.05-38. Thrust Washer ............ 2.05 - 15 Figure 2.05-39. Shim Pack ................ 2.05 - 15 Figure 2.05-40. Cam Bearing Cap ......... 2.05 - 15 Figure 2.05-41. Valve Lifter Housing Gasket - Front ...................... 2.05 - 16 Figure 2.05-42. Front Flywheel Housing Rear Left ........................... 2.05 - 16 Figure 2.05-43. Flywheel Lifting Bracket .... 2.05 - 16 Figure 2.05-44. Rear Flywheel Housing ..... 2.05 - 16 Figure 2.05-45. Remove Flywheel ......... 2.05 - 17 Figure 2.05-46. Front Flywheel Section ..... 2.05 - 17 Figure 2.05-47. Oil Pickup Screen Assembly12 Cylinder ......................... 2.05 - 18

Figure 2.05-48. Bolt Holes In Engine Block .. 2.05 - 19 Figure 2.05-49. Oil Pan Cross Cuts Rear Right .......................... 2.05 - 19 Figure 2.05-50. Oil Pump Gear ............ 2.05 - 20 Figure 2.05-51. Oil Pump Gear Assembly ... 2.05 - 20 Figure 2.05-52. Crankshaft Gear Mount .... 2.05 - 21 Figure 2.05-53. Lower Oil Retainer Plate .... 2.05 - 21 Figure 2.05-54. Wick Seal ................ 2.05 - 22 Figure 2.05-55. Cross-Tie Bolts ........... 2.05 - 22 Figure 2.05-56. Main Bearing Cap ......... 2.05 - 22 Figure 2.05-57. No.1 Main Bearing Cap .... 2.05 - 22 Figure 2.05-58. Thrust Bearing ............ 2.05 - 23 Figure 2.05-59. Crankshaft ............... 2.05 - 23 Figure 2.05-60. Bearings ................. 2.05 - 23 Figure 2.05-61. Oil Tubes ................. 2.05 - 24 Figure 2.05-62. Crankcase - Inside Front ... 2.05 - 24 Figure 2.05-63. Upper Retainer Plate ....... 2.05 - 24 Figure 2.05-64. Cross Tie Bolts ............ 2.05 - 25 Figure 2.05-65. No.1 Main Bearing ........ 2.05 - 25 Figure 2.05-66. Bearing Rollout ........... 2.05 - 26 Figure 2.05-67. Roll Pin Installation ........ 2.05 - 26 Figure 2.05-68. No.1 Main Bearing Cap .... 2.05 - 27 Figure 2.05-69. Main Bearing Cap Stamped Identification Numbers ............... 2.05 - 27 Figure 2.05-70. Oil Pump Gear Assembly ... 2.05 - 28 Figure 2.05-71. Main Bearing Cap Tightening(Torquing Pattern - As Viewed From Underside Of Crankcase ........ 2.05 - 28 Figure 2.05-72. Main Bearing ............. 2.05 - 29 Figure 2.05-73. Bearing Rollout ........... 2.05 - 30 Figure 2.05-74. Main Bearing Cap Stamped Identification Numbers ....... 2.05 - 30 Figure 2.05-75. Cross Tie Bolts ............ 2.05 - 31 Figure 2.05-76. Main Bearing Gap Tightening{Torquing Pattern - As Viewed From Underside Of Crankcase ........ 2.05 - 31 Figure 2.05-n. Cam Bearing Cap ......... 2.05 - 31

)

)

Section 3.00 - Cylinder Head DisassemblyFigure 3.00-1. Rocker Arm Assembly ........ 3.00 - 1 Figure 3.00-2. Fixed Valve Lifter Screw ...... 3.00 - 2 Figure 3.00-3. Rocker Arm Adjusting Screws . 3.00 - 2 Figure 3.00-4. Rocker Arm Shaft ............ 3.00 - 2 Figure 3.00-5. Exhaust Rocker Arm Bushings 3.00 - 4 Figure 3.00-6. Rocker Arm Bushings ........ 3.00 - 4 Figure 3.00-7. Intake Rocker Arm Bushings .. 3.00 - 5 Figure 3.00-8. Intake Actuator Rocker Arm Bushings ............................ 3.00 - 5 Figure 3.00-9. Rocker Arm Assembly ........ 3.00 - 6 Figure 3.00-10. Intake Actuator Assembly .... 3.00 - 7Form 6248 First Edition

xvi

ILLUSTRATIONS

Figure 3.00-11. Cylinder Head Assembly Exploded View ....................... 3.00 - 8 Figure 3.00-12. Install Valve Stem Seal ...... 3.00 - 8 Figure 3.00-13. Tack Weld Valve To Valve Seat ........................... 3.00 - 9 Figure 3.00-14. Valve Seat Insert Removal ... 3.00 - 9 Figure 3.00-15. Valve Seat Insert Removal ... 3.00 - 9 Figure 3.00-16. Core Plug Locations - Top .. 3.00 - 10 Figure 3.00-17. Core Plug Locations - Front 3.00 - 10 Figure 3.00-18. Core Plug Locations - Right 3.00 - 10 Figure 3.00-19. Core Plug Locations - Left .. 3.00 - 11 Figure 3.00-20. Core Plug Locations Boltom ............................. 3.00 - 11 Figure 3.00-21 . Check Cylinder Head Deck For Warpage ........................ 3.00 - 12 Figure 3.00-22. Cylinder Head Pressure Test Plates ......................... 3.00 - 12 Figure 3.00-23. Water Outlet Hole ......... 3.00 - 13 Figure 3.00-24. Cylinder Head Intake Port Side ..................... 3.00 - 14 Figure 3.00-25. Checking Valve Stems For Straightness ..................... 3.00 - 15 Figure 3.00-26. Checking Head Perpendicularity ..................... 3.00 - 16 Figure 3.00-27. Cylinder Head Valve ....... 3.00 - 16 Figure 3.00-28. Margin Wear .............. 3.00 - 16 Figure 3.00-29. Installing Valve Guides ..... 3.00 - 19 Figure 3.00-30. Valve Seat Insert .......... 3.00 - 20 Figure 3.00-31. Measure Valve Seat Concentricity ........................ 3.00 - 21 Figure 3.00-32. Valve Lapping ............. 3.00 - 22 Figure 3.00-33. Good Valve And Seat Contact ........................ 3.00 - 23 Figure 3.00-34. Checking Valve Spring Height ............................. 3.00 - 24 Figure 3.00-35. Install Valve Stem Seal ..... 3.00 - 24 Figure 3.00-36. Cylinder Head Assembly Exploded View ...................... 3.00 - 25 Figure 3.00-37. Valve Spring Compressor ... 3.00 - 25 Figure 3.00-38. Valve Compressor Special BoH Installation Locations ............. 3.00 - 25 Figure 3.00-39. Assembled Cylinder Head Cross Sectional View ................ 3.00 - 26

Figure 3.05-5. Determine Bearing Thickness . 3.05 - 8 Figure 3.05-6. Select Main Bearing Shells For Proper Running Clearance ......... 3.05 - 8 Figure 3.05-7. Camshaft Bearing Bore ....... 3.05 - 9 Figure 3.05-8. Crankshaft Set Screws ...... 3.05 - 10 Figure 3.05-9.12 Cylinder Crankshaft ...... 3.05 - 11 Figure 3.05-10.12 Cylinder Crankshaft ..... 3.05 - 13 Figure 3.05-11. Camshaft Valve Lifter Body Bottom View ........................ 3.05 - 15 Figure 3.05-12. Camshaft Valve Lifters And Guides ............................. 3.05 - 15 Figure 3.05-13. Lubricate Valve Lifter Rollers ............................. 3.05 - 16 Figure 3.05-14. Hydraulic Lifter ............ 3.05 - 16 Figure 3.05-15. Push Rod ................ 3.05 - 16 Figure 3.05-16. Hydraulic Lifter Internal View ........................ 3.05 - 17 Figure 3.05-17. Hydraulic Lifter - Installation 3.05 - 17 Figure 3.05-18. Piston Assembly .......... 3.05 - 17 Figure 3.05-19. Piston And Rings .......... 3.05 - 18 Figure 3.05-20. Piston Oil Drain Holes ...... 3.05 - 18 Figure 3.05-21. Check Piston Ring Groove Clearance .............. " ........... 3.05 - 23 Figure 3.05-22. Install Piston Rings ........ 3.05 - 27 Figure 3.05-23. Oil Control Ring Detail 8-1/2 Inch Bore ...................... 3.05 - 27 Figure 3.05-24. Compression Ring Detail ... 3.05 - 28 Figure 3.05-25. Barrel-faced C9IlIpression Ring Detail ............ ,~ ........... 3.05 - 28 Figure 3.05-26. 9-3/8, Bore G,GSI Piston Ring Configuration ................... 3.05 - 29 Figure 3.05-27. Previous Production 9-3/8, Bore GL Piston Ring Configuration PIN 205404Z ....................... 3.05 - 30 Figure 3.05-28. Current Production Piston Ring Detail 9-3/8 Inch Bore GL (3-Ring Piston) ..................... 3.05 - 31 Figure 3.05-29. Current Production 9-3/8 Inch Bore GL (3-Ring Piston) .............. 3.05 Figure 3.05-30. Connecting Rod ........... 3.05 Figure 3.05-31. Bearing Cap .............. 3.05 Figure 3.05-32. Align Rod Pin Bushing Split Line ........................... 3.05 Figure 3.05-33. Clean Connecting Rod Lube Oil Passageways ............... 3.05 Figure 3.05-34. Connecting Rod Twist Gap . 3.05 Figure 3.05-35. Rod Cap Roll Pin .......... 3.05 Figure 3.05-36. Connecting Rod Cap Capscrew Tightening Sequence ROil Pin Equipped ................... 3.05 Figure 3.05-37. Check Rod Bearing Bore For Out-Of-Round And Taper ......... 3.05 Figure 3.05-38. Weight Classification Stamp Location ............................ 3.05 - 31 - 33 - 33 - 33 - 33 - 36 - 36

Section 3.05 - Crankcase DisassemblyFigure 3.05-1. Lower Sleeve Bore .......... 3.05 - 3 Figure 3.05-2. Lower Bore And Restoration Sleeve Dimensions ................... 3.05 - 4

- 37 - 37 - 38

)

Figure 3.05-3. Main Bearing Bores .......... 3.05 - 5 Figure 3.05-4. Main Bearing Cap TIghtening{Torquing Pattern - As Viewed From Underside Of Crankcase ......... 3.05 - 6Form 6248 First Edition

xvII

ILLUSTRATIONS

Figure 3.05-39. Rod Pin Bushing .......... 3.05 - 38 Figure 3.05-40. Verify Orientation Of Rod Pin Bushings Oil Groove ................. 3.05 - 39 Figure 3.05-41. Connecting Rod Bearings .. 3.05 - 40 Figure 3.05-42. Position Bearing Shell Above Bearing Seat ........................ 3.05 - 40 Figure 3.05-43. Installing Bearing Shell ..... 3.05 - 40 Figure 3.05-44. Keep Connecting Rod Caps And Blades Properly Mated ........... 3.05 - 41 Figure 3.05-45. Connecting Rod Cap Capscrew Tightening Sequence - Roll Pin Equipped ........................... 3.05 - 41 Figure 3.05-46. Cylinder Sleeve ........... 3.05 - 42 Figure 3.05-47. Flexible Hone ............. 3.05 - 47 Figure 3.05-48. Cylinder Sleeve Deglazing Cross Hatch Pattern ................. 3.05 - 47 Figure 3.05-49. Flywheel Ring Gear ........ 3.05 - 48

Figure 4.00-22. Outside Camshaft Thrust Ring .......................... 4.00 - 9 Figure 4.00-23. Shim Pack ................ 4.00 - 10 Figure 4.00-24. Thrust Washer ............ 4.00 - 10 Figure 4.00-25. Gear Housing Flange ...... 4.00 - 10 Figure 4.00-26. Rear Gear Housing Flange . 4.00 - 10 Figure 4.00-27. Verify That Bottoms Are Flush .............................. 4.00 - 11 Figure 4.00-28. Measuring Camshaft End Play ............................... 4.00 -11 Figure 4.00-29. Prevent Lateral Movement Of Camshaft ........................ 4.00 - 12 Figure 4.00-30. Prevent Camshaft Rotation . 4.00 - 12 Figure 4.00-31. Cam Gear Key ............ 4.00 - 12 Figure 4.00-32. Locking The Camshaft Gear Nut ........................... 4.00 - 13 Figure 4.00-33. Valve Lifter Housing Assembly ........................... 4.00 - 13 Figure 4.00-34. Lowering The Valve Lifter Housing ............. _.............. 4.00 - 14 Figure 4.00-35. Rear Gear Housing Gasket . 4.00 - 14 Figure 4.00-36. Valve Lifter Housing - Front. 4.00 - 15 Figure 4.00-37. Fasten Valve Lifter Housing To Rear Gear Housing ............... 4.00 - 15 Figure 4.00-38. Camshaft Cover Plate ...... 4.00 - 15 Figure 4.00-39. Camshaft Set Screw On Valve Lifter Housing Cover ............ 4.00 - 15 Figure 4.00-40. Valve Lifter Housing - Rear . 4.00 - 16 Figure 4.00-41. Lubricate Valve Lifter Rollers ......... _.............. 4.00 - 16 Figure 4.00-42. Install Valve Lifter Guides ... 4.00 - 16 Figure 4.00-43. Longer Capscrew Locations For Mounting The Rocker Amn Oil Header .......................... 4.00 - 17 Figure 4.00-44. Pipe Tee Magnet Plug ...... 4.00 - 18 Figure 4.00-45. Rocker Arm Oil Header Rear ............................... 4.00 - 18 Figure 4.00-46. Rocker Arm Oil Header ..... 4.00 - 18 Figure 4.00-47. Rear Oil Seal RetainerUpper Half .......................... 4.00 - 19 Figure 4.00-48. Cut Rope Type Seal ....... 4.00 - 19 Figure 4.00-49. Rear Oil Seal Retainer Upper Ha~ .......................... 4.00 - 19 Figure 4.00-50. Rear Oil Seal Retainer Upper Half ........... _.............. 4.00 - 20 Figure 4.00-51. Front Main Bearing Cap .... 4.00 - 20 Figure 4.00-52. Install Roll Pins In Front Main Bearing Cap ................... 4.00 - 21 Figure 4.00-53. Upper Fully Grooved Main Bearing Shells - Bearing Saddles . 4.00 - 21 Figure 4.00-54. Lower Ungrooved Main Bearing Shells - Bearing Caps ...... , . 4.00 - 22Form 6248 First Edition

)

Section 4.00 - Crankcase AssemblyFigure 4.00-1. Crankcase - Inside Front ..... 4.00 - 1 Figure 4.00-2. Gear Train Oil Spray Tube .... 4.00 - 1 Figure 4.00-3. Oil Tubes ................... 4.00 - 2 Figure 4.00-4. Main Bearing Cap Studs Old And New Styles .................. 4.00 - 2 Figure 4.00-5. Main Bearing Cap Studs ...... 4.00 - 2 Figure 4.00-6. Water Header/Oil Outlet Plugs Rear Left ............................ 4.00 - 3 Figure 4.00-7. Oil Outlet Plugs Rear Right View ...................... 4.00 - 3 Figure 4.00-8. 3/4, NPT Oil Header Pipe Plugs ........................... 4.00 - 4 Figure 4.00-9. Crankcase - Main Oil Header Rear Right ........................... 4.00 - 5 Figure 4.00-10. Lube Oil Strainer Adapter .... 4.00 - 5 Figure 4.00-11. Lower Valve Lifter Housing Cover ............................... 4.00 - 5 Figure 4.00-12. Crankcase - Top Rear ...... 4.00 - 6 Figure 4.00-13. Valve Lifter Housing GasketFront ............................... 4.00 - 6 Figure 4.00-14. Valve Lifter Housing GasketRear ................................ 4.00 - 6 Figure 4.00-15. Camshaft Bearing Saddles .. 4.00 - 7 Figure 4.00-16. Install Roll Pins In Front Cam Bearing Cap .................... 4.00 - 7 Figure 4.00-17. Cam Bearings ............. 4.00 - 7 Figure 4.00-1 8. Inside Camshaft Thrust Ring . 4.00 - 8 Figure 4.00-19. Front Cam Bearing Cap ..... 4.00 - 9 Figure 4.00-20. Cam Bearing Cap .......... 4.00 - 9 Figure 4.00-21. Camshaft Thrust Ring ....... 4.00 - 9 xviii

)

ILLUSTRATIONS

Figure 4.00-55. Crankshaft Set Screws ..... 4.00 - 22 Figure 4.00-56. Crankshaft Set Screw Locations (6) ........................ 4.00 - 23 Figure 4.00-57. Crankshaft Guiding ........ 4.00 - 23 Figure 4.00-58. Crankshaft Oil Grooves .... 4.00 - 24 Figure 4.00-59. Crankshaft Placement ...... 4.00 - 24 Figure 4.00-60. Install Inside Thrust Ring ... 4.00 - 24 Figure 4.00-61. Rear Oil Seal Retainer Assembly ........................... 4.00 - 25 Figure 4.00-62. Trim Rear Oil Seal Retainer Gasket ............................. 4.00 - 25 Figure 4.00-63. Main Bearing Gap TIghtening[Torquing Pattern - As Viewed From Underside Of Crankcase ........ 4.00 - 26 Figure 4.00-64. Torque Front Main Bearing Cap ............................... 4.00 - 26 Figure 4.00-65. Measure Crankshaft End Play ........................... 4.00 - 27 Figure 4.00-66. Bump Crankshaft Towards Rear ............................... 4.00 - 27 Figure 4.00-67. Crankshaft End Play ....... 4.00 - 27 Figure 4.00-68. Roll Pins ................. 4.00 - 28 Figure 4.00-69. Install Roll Pins In Crankshaft .......................... 4.00 - 28 Figure 4.00-70. Crankshaft Thrust Ring (Half) Up ........................... 4.00 - 29 Figure 4.00-71. Outside Thrust Ring Cap Side ........................... 4.00 - 29 Figure 4.00-72. Outside Thrust Ring Saddle Side ........................ 4.00 - 29 Figure 4.00-73. Crankshaft Thrust Washer .. 4.00 - 29 Figure 4.00-74. Thrust Washer ............ 4.00 - 30 Figure 4.00-75. Crankshaft Gear .......... 4.00 - 30 Figure 4.00-76. Crankshaft Gear Mount .... 4.00 - 30 Figure 4.00-77. Oil Pump Gear Assembly ... 4.00 - 31 Figure 4.00-78. Secure Spindle Screw Head 4.00 - 31 Figure 4.00-79. Torque Spindle Screw Hex Nut ............................ 4.00 - 31 Figure 4.00-80. Idler Gear ................ 4.00 - 32 Figure 4.00-81. Idler Gear ................ 4.00 - 32 Figure 4.00-82. Camshaft Idler Gear ....... 4.00 - 32 Figure 4.00-83. Camshaft Idler Gear Upper .............................. 4.00 - 33 Figure 4.00-84. Camshaft Idler Gear TIming Marks ....................... 4.00 - 33 Figure 4.00-85. Gam Gear/Camshaft Idler Gear TIming ........................ 4.00 - 33 Figure 4.00-86. Lock Idler Gear Capscrews . 4.00 - 35 Figure 4.00-87. Accessory Idler Gear TIming Marks ....................... 4.00 - 35 Figure 4.00-88. Accessory Idler Gear Lower .............................. 4.00 - 35Form 6248 First Ednion

Figure 4.00-89. Gear Backlash ............ 4.00 - 36 Figure 4.00-90. Magneto Drive Assembly ... 4.00 - 37 Figure 4.00-91 . Remove Adapter Cover Side Bons .......................... 4.00 - 38 Figure 4.00-92. Mount Magneto Drive Assembly ........................... 4.00 - 38 Figure 4.00-93. Accessory Idler Gear TIming Marks ....................... 4.00 - 39 Figure 4.00-94. Drive Shaft ............... 4.00 - 39 Figure 4.00-95. Mount Magneto Drive Gear . 4.00 - 39 Figure 4.00-96. Magneto Drive Gear TIghtening And Torquing Pattern ....... 4.00 - 40 Figure 4.00-97. PIN 205130L Cylinder Sleeve Caution Tape ................. 4.00 - 41 Figure 4.00-98. Cylinder Sleeve ........... 4.00 - 41 Figure 4.00-99. Spiraling O-rings .......... 4.00 - 42 Figure 4.00-100. Sleeve Projection ........ 4.00 - 42 Figure 4.00-101. Piston And Connecting Rod ............................... 4.00 - 42 Figure 4.00-102. Connecting Rod Bearings . 4.00 - 43 Figure 4.00-103. Connecting Rod Bore And Bearing Shell ....................... 4.00 - 43 Figure 4.00-104. Installing Bearing Shell .... 4.00 - 44 Figure 4.00-105. Connecting Rod Position .. 4.00 - 44 Figure 4.00-106. Connecting Rod Position .. 4.00 - 45 Figure 4.00-107. Connecting Rod Cap Gaps crew Tightening Sequence Roll Pin Equipped ................... 4.00 - 45 Figure 4.00-108. Oil Pickup Screen Assembly 12 Cylinder ......................... 4.00 - 46 Figure 4.00-109. Oil Pan Seal ............. 4.00 - 47 Figure 4.00-110. Oil Pan Seal - Front Right . 4.00 - 47 Figure 4.00-111. Dipstick ................. 4.00 - 48 Figure 4.00-112. Expansion Plug Location .. 4.00 - 48 Figure 4.00-113. Oil Pan Cross Cuts Rear Right .......................... 4.00 - 49 Figure 4.00-114. Oil Pan GapscrewFront Right ......................... 4.00 - 49 Figure 4.00-115. Oil Pan GapscrewFront Left ........................... 4.00 - 50 Figure 4.00-116. Crankcase - Rear ........ 4.00 - 50 Figure 4.00-117. Front Flywheel Section .... 4.00 - 50 Figure 4.00-118. Front Flywheel Housing Capscrew TIghtening Pattern .......... 4.00 - 50 Figure 4.00-119. Flywheel TIming Tape Locations ........................... 4.00 - 51 Figure 4.00-120. TIming Tape ............. 4.00 - 51 Figure 4.00-121. Orient Crank Gear ........ 4.00 - 52 Figure 4.00-122. Ufting The Flywheel ...... 4.00 - 52 Figure 4.00-123. Flywheel Mounting ....... 4.00 - 52 Figure 4.00-124. Mount Flywheel .......... 4.00 - 53 Figure 4.00-125. Remove Ufting Bracket ... 4.00 - 53

xix

ILLUSTRATIONS

Figure 4.00-126. Ring Gear Tooth Alignment 4.00 - 53 Figure 4.00-127. Install Magnetic Pickup Sensor ............................. 4.00 - 53 Figure 4.00-128. Rear Flywheel Housing Capscrew TIghtening Pattern .......... 4.00 - 54 Figure 4.00-129. Flywheel, Flywheel Housing Bore And Face Runout ............... 4.00 - 55 Figure 4.00-130. Flywheel Housing Rear Face Runout ........................ 4.00 - 55 Figure 4.00-131. Total Indicator Reading (TIR) In Inches ...................... 4.00 - 56 Figure 4.00-132. Flywheel Face Runout On Wheel .......................... 4.00 - 56 Figure 4.00-133. Flywheel Housing Bore Runout ............................. 4.00 - 56 Figure 4.00-134. Horizontal Support Bar .... 4.00 - 57 Figure 4.00-135. Flywheel Pilot Bearing Bore Runout ........................ 4.00 - 57 Figure 4.00-136. Front Flywheel Housing Rear Left ........................... 4.00 - 58 Figure 4.00-137. Mount Oil Filler BracketRear Left ........................... 4.00 - 58 Figure 4.00-138. Oil Filler Pipe/BracketRear Left ........................... 4.00 - 58 Figure 4.00-139. Grease Gear Train ....... 4.00 - 59 Figure 4.00-140. Lube Gear Train .......... 4.00 - 59 Figure 4.00-141. Oil Slinger/O-Ring ........ 4.00 - 60 Figure 4.00-142. Gear Cover .............. 4.00 - 60 Figure 4.00-143. Front Oil Seal ............ 4.00 - 60 Figure 4.00-144. Install Front Oil Seal ...... 4.00 - 61 Figure 4.00-145. Oil Pan Cross Cuts Front Left ........................... 4.00 - 61 Figure 4.00-146. Gear Cover TIghtening Pattern (A - F) ...................... 4.00 - 62 Figure 4.00-147. Installing The Gear Cover. 4.00 - 63 Figure 4.00-148. Gear Cover PlatesFront Left ........................... 4.00 - 64 Figure 4.00-149. Rear Gear Housing Front Left ........................... 4.00 - 64 Figure 4.00-150. Vibration Damper/Crankshaft Pulleys ............................. 4.00 - 65 Figure 4.00-151. Side Section View "5V" And "C" Section Groove Pulleys ........... 4.00 - 67 Figure 4.00-152. Torquing End Plate capscrews ......................... 4.00 - 68

Figure 4.05-4. Push Rod Cover ............. 4.05 - 3 Figure 4.05-5. Push Rods ................. 4.05 - 4 Figure 4.05-6. Rocker Arm Oil Supply Tube Rear Left ............................ 4.05 - 4 Figure 4.05-7. Exhaust Manifold Gasket ..... Figure 4.05-8. Prelube Motor Air/Gas Supply Tube ......... . . . . . . . . . . . . . . . . Figure 4.05-9. Exhaust Manifold - Left Bank . Figure 4.05-10. Exhaust Manifold End Sections - Left Bank .................. Figure 4.05-11. Water Outlet Elbow Gaskets . 4.05 - 5 4.05 - 5 4.05 - 5 4.05 - 6 4.05 - 6

Figure 4.05-12. Exhaust ManHold Right Bank .......................... 4.05 - 6 Figure 4.05-13. Water Outlet Elbows Rear Right ........................... 4.05 - 7 Figure 4.05-14. Exhaust Manifold - Front .... 4.05 - 7 Figure 4.05-15. Exhaust Manifold - Left Bank 4.05 - 7 Figure 4.05-16. Thermocouple ConnectorRear Right .......................... 4.05 - 7

Section 4.10 - Valve Adjustment And Web DeflectionFigure 4.10-1. Engine Firing Order 12 Cylinder .......................... Figure 4.10-2. Rocker Arms ................ Figure 4.10-3. Rocker Arm Adjusting Screws . Figure 4.10-4. Hydraulic Lifter ............ ,. Figure 4.10-5. Engine Shimming Procedure .. 4.10 4.10 4.10 4.10 4.10 1 2 2 2 5

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Section 5.00 - Speed Governing SystemFigure 5.00-1. 2301 A Load Sharing And Speed Control ....................... Figure 5.00-2. 2301A Speed Control ........ Figure 5.00-3. Governor Drive Housing ...... Figure 5.00-4. Hall-Effect Pickup ........... Figure 5.00-5. Current Production CEC TIming Disc .......................... Figure 5.00-6. Current Production Governor Drive Gear.. . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5.00-7. Current Production Governor Drive Gear ........... , ............... Figure 5.00-8. Flywheel TIming Opening ..... Figure 5.00-9. Current Production CEC TIming Disc .......................... Figure 5.00-10. Current Production CEC TIming Disc .......................... Figure 5.00-11. Governor Drive Housing ..... Figure 5.00-12. Hall- Effect Pickup ......... Figure 5.00-13. Previous Production CEC Disc ............................ Figure 5.00-14. Previous Production Governor Drive Gear .................. Figure 5.00-15. Previous Production Governor Drive Gear .................. 5.00 5.00 5.00 5.00 2 3 3 3

5.00 - 4 5.00 - 4 5.00 - 4 5.00 - 5 5.00 - 5 5.00 - 5 5.00 - 6 5.00 - 6 5.00 - 6 5.00 - 6 5.00 - 7

Section 4.05 - Cylinder Head AssemblyFigure 4.05-1. Cylinder Head Gasket ........ 4.05 - 1 Figure 4.05-2. Lifting The Cylinder Head 12 Cylinder Engines .................. 4.05 - 2 Figure 4.05-3. Cylinder Head Capscrew TIghtening And Torquing Sequence (1 - 8) .............................. 4.05 - 3

xx

Form 6248 First Edition

ILLUSTRATIONS

Figure 5.00-16. Previous Production Governor Drive Gear Vibration Damper Installation. 5.00 - 7 Figure 5.00-17. Previous Production Governor Drive Gear ........................... 5.00 - 8 Figure 5.oo-t 8. Previous Production Governor Drive Gear ........................... 5.00 - 8 Figure 5.00-19. Previous Production Timing Disc .......................... 5.00 - 9 Figure 5.00-20. Previous Production CEC Disc ............................ 5.00 - 9 Figure 5.00-21. Governor Drive Housing ..... 5.00 - 9 Figure 5.00-22. Governor Drive Shaft Assembly ........................... 5.00 - 10 Figure 5.00-23. Governor Drive Shaft ...... 5.00 - 10 Figure 5.00-24. Governor Drive Shaft Assembly ........................... 5.00 - 11 Figure 5.00-25. Governor Drive Gear ....... 5.00 - 12 Figure 5.00-26. Oil Line And Hall-Effect Pickup ............................. 5.00 - 13 Figure 5.00-27. Governor Drive Housing .... 5.00 - 13 Figure 5.00-28. Governor Drive Assembly Front Right ......................... 5.00 - 13 Figure 5.00-29. Governor Drive Housing Rear ............................... 5.00 - 14 Figure 5.00-30. Governor Drive Housing Rear ............................... 5.00 - 14 Figure 5.00-31. Governor Drive Assembly Front Right ......................... 5.00 - 14 Figure 5.00-32. Govemor Drive Housing .... 5.00 - 15 Figure 5.00-33. Oil Line And Hall-Effect Pickup ............................. 5.00 - 15 Figure 5.00-34. Govemor Rod ............. 5.00 - 16 Figure 5.00-35. Govemor Rod G, GSI Engines ..................... 5.00 - 16 Figure 5.00-36. Governor Rod GL Engines (Throttle Control Shown Installed) ...... 5.00 - 16 Figure 5.00-37. Governor Rod - GL Engines (Throttle Control Shown Installed) ...... 5.00 - 17 Figure 5.00-38. UG-8L Governor Assembly. 5.00 - 17 Figure 5.00-39. Governor Assembly ........ 5.00 - 17 Figure 5.00-40. UG-SL Governor Linkage .. 5.00 - 18 Figure 5.00-41. UG-S Govemor Linkage Adjustment Information For 51 OSGL, 5790GL And 7042GL ................ 5.00 - 19 Figure 5.00-42. UG-S Linkage Adjustment Information For 51 OSGL, 5790GL And 7042GL - Low Pressure Fuel, Draw Thru Carburetion .................... 5.00 - 19 Figure 5.00-43. Angle Finder In "No Fuel" Pos~ion ............................ 5.00 - 20

Figure 5.00-44. Governor Rod G, GSI Engines ..................... 5.00 - 20 Figure 5.00-45. Governor Rod - GL Engines (Throttle Control Shown Installed) ...... 5.00 - 20 Figure 5.00-46. Governor Rod - GL Engines (Throttle Control Shown Installed) ...... 5.00 - 21 Figure 5.00-47. Governor Rod ............. 5.00 - 21 Figure 5.00-48. Woodward UG-8L Governor 5.00 - 22 Figure 5.00-49. Woodward UG-8L Governor - Top View ......................... 5.00 - 24 Figure 5.00-50. Governor Rod ............. 5.00 - 25 Figure 5.00-51. Governor Rod G, GSI Engines ..................... 5.00 - 25 Figure 5.00-52. Governor Rod - GL Engines (Throttle Control Shown Installed) ...... 5.00 - 25 Figure 5.00-53. Governor Rod - GL Engines (Throttle Control Shown Installed) ...... 5.00 - 26 Figure 5.00-54. Governor ................. 5.00 - 26 Figure 5.00-55. Governor Assembly ........ 5.00 - 27 Figure 5.00-56. Governor Rod ............. 5.00 - 27 Figure 5.00-57. Governor Rod G, GSI Engines ..................... 5.00 - 28 Figure 5.00-58. Governor Rod - GL Engines (Throttle Control Shown Installed) ...... 5.00 - 28 Figure 5.00-59. Governor Rod - GL Engines (Throttle Control Shown Installed) ...... 5.00 - 28 Figure 5.00-SO. Governor Rod Assembly ... 5.00 - 28 Figure 5.00-61. Woodward UG-S Dial Governor ....................... 5.00 - 29 Figure 5.00-62. EG-3P Governor Rod ...... 5.00 - 31 Figure 5.00-63. Governor Rod G, GSI Engines ..................... 5.00 - 31 Figure 5.00-64. Governor Rod - GL Engines (Throttle Control Shown Installed) ...... 5.00 - 32 Figure 5.00-65. Governor Rod - GL Engines (Throttle Control Shown Installed) ...... 5.00 - 32 Figure 5.00-66. Splined Connector ......... 5.00 - 32 Figure 5.00-67. Governor Drive ............ 5.00 - 33 Figure 5.00-6S. Governor Drive Internal View ........................ 5.00 - 34 Figure 5.00-69. Governor Drive ............ 5.00 - 35 Figure 5.00-70. Splined Connector ......... 5.00 - 36 Figure 5.00-71. Gasket ................... 5.00 - 36 Figure 5.00-72. EG-3P GovernorBottom View ........................ 5.00 - 36 Figure 5.00-73. Ring Gear Tooth Alignment . 5.00 - 36 Figure 5.00-74. Install Magnetic Pickup Sensor ............................. 5.00 - 37 Figure 5.00-75. Governor Rod Assembly ... 5.00 - 37 Figure 5.00-76. EG-3P Governor Linkage Adjustment Information For 51 08GL, 5790GL And 7042GL ................ 5.00 - 38

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I

Form 6248 Rrst Edition

xxi

ILLUSTRATIONS

Figure 5.00-77. EG-3P linkage Adjustment Information For 51 08GL, 5790GL And 7042GL - Low Pressure Fuel, Draw Thru Carburetion .................... 5.00 - 38 Figure 5.00-78. Governor Rod ............. 5.00 - 39 Figure 5.00-79. Governor Rod G, GSI Engines ..................... 5.00 - 39 Figure 5.00-80. Governor Rod - GL Engines (Throttle Control Shown Installed) ...... 5.00 - 40 Figure 5.00-81. Governor Rod - GL Engines (Throttle Control Shown Installed) ...... 5.00 - 40 Figure 5.00-82. Orientate Manual Shutdown Lever .............................. 5.00 - 41 Figure 5.00-83. Lock Manual Shutdown Lever .............................. 5.00 - 41 FIgure 5.00-84. Governor Rod - GL Engines (Throttle Control Shown Installed) ...... 5.00 - 41 Figure 5.00-85. Butterfly Valve linkage Adjustment - L5108G, L5790G, L7042G Engines .................... 5.00 - 42 Figure 5.00-86. Overspeed Pressure Swttch 5,00 - 42 Figure 5.00-87. Overspeed Governor ....... 5.00 - 43 Figure 5.00-88. Overspeed Governor ....... 5.00 - 43 Figure 5.00-89. Overspeed Pressure Switch 5.00 - 44 Figure 5.00-90. Tachometer/Hour Meter .... 5.00 - 44 Figure 5.00-91. Hour Meter ............... 5.00 - 44 Figure 5.00-92. Nylok Plugs ............... 5.00 - 45 Figure 5.00-93. Tachometer Drive Assembly 5.00 - 45 Figure 5.00-94. Tachometer/Hour Meter .... 5.00 - 46 Figure 5.00-95. Magneto Drive AssemblyFront Right ......................... 5.00 - 46 Figure 5.00-96. Nylok Plugs ............... 5.00 - 46

Figure 5.05-12. Prechamber Cross PipeRight Bank .......................... 5.05 - 9 Figure 5.05-13. Prechamber Cross PipeLeft Bank ............................ 5.05 - 9 Figure 5.05-14. Prechamber Cross Pipe Retainer ............................ 5.05 - 10 Figure 5.05-15. Cross Pipe Tee ............ 5.05 - 10 Figure 5.05-16. Prechamber Cross Pipe Left Bank ............ _.............. 5.05 - 10 Figure 5.05-17. Carburetor Assembly G/GSI .............................. Figure 5.05-18. Air/Gas Valve Assembly .... Figure 5.05-19. Air/Gas Valve ............. Figure 5.05-20. Carburetor Cross Shaft Assembly ........................... Figure 5.05-21. Carburetor Assembly - GL .. Figure 5.05-22. Air/Gas Valve Assembly .... 5.05 - 11 5.05 - 12 5.05 - 12 5.05 - 13 5.05 - 15 5.05 - 16

Figure 5.05-23. Air/Gas Valve ............. 5.05 - 16 Figure 5.05-24. Carburetor Bonnet Baffle Welds ............... _.............. 5.05 - 16 Figure 5.05-25. Carburetor - Left Bank ..... Figure 5.05-26. Carburetor Cross Shaft Assembly ........................... Figure 5.05-27. Butterfly Valve GlGSI ...... Figure 5.05-28. Admission Valve Assembly . Figure 5.05-29. Spring Seats In Cold Poppets ............................ 5.05 - 17 5.05 - 18 5.05 - 18 5.05 - 19 5.05 - 20 - 20 - 21 - 21 - 22 - 22 - 23 - 23 - 24 - 25 - 25 - 25 - 26 - 26 - 26 - 27

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Section 5.05 - Fuel SystemFigure 5.05-1. Fuel System Diagram - G .... 5.05 - 1 Figure 5.05-2. Fuel System Diagram - GSI .. 5.05 - 2 Figure 5.05-3. Fuel System Schematic - GL . 5.05 - 3 Figure 5.05-4. Fisher 99 Main Fuel Gas Pressure Regulator Cross Sectional View ................. 5.05 - 4 Figure 5.05-5. 95L Prechamber Regulator Cross Sectional View ................. 5.05 - 6 Figure 5.05-6. Butterfly Cross Shaft Assembly ............................ 5.05 - 6 Figure 5.05-7. Crankcase Center Bores G/GSI - Right Bank ................... 5.05 - 7 Figure 5.05-8. Universal Joint Disc Spider ... 5.05 - 7 Figure 5.05-9. Carburetor Cross Shaft Assembly ............................ 5.05 - 8 Figure 5.05-10. Crankcase Center Bores GL - Right Bank ...................... 5.05 - 8 Figure 5.05-11. Universal Joint Disc Spider .. 5.05 - 8

Figure 5.05-30. Install Stainless Steel Washer In Cylinder Head ..... _.............. 5.05 Figure 5.05-31. Prechamber Puller Assembly ............ _.............. 5.05 Figure 5.05-32. Prechamber Puller Assembly ........................... 5.05 Figure 5.05-33. Prechamber Puller Assembly ........................... 5.05 Figure 5.05-34. Install Prechamber Cup .... 5.05 Figure 5.05-35. Prechamber Gas Supply Left Bank ............ _.............. 5.05 Figure 5.05-36. Prechamber Manifold ...... 5.05 Figure 5.05-37. Prechamber Manifold ...... 5.05 Figure 5.05-38. Fisher 99 Regulator Tube Connections - GSI .................. 5.05 Figure 5.05-39. Fisher 99 Regulator Tube Connections - GL ................... 5.05 Figure 5.05-40. BoR Holes In Engine Block .. 5.05 Figure 5.05-41. Fisher 99 Regulator Bracket - Right Bank ................ 5.05 Figure 5.05-42. Fisher 99 Regulator Mounting Orientation - Right Bank - Top View ... 5.05 Figure 5.05-43. Main Fuel Gas Regulator Right Bank ......................... 5.05 Figure 5.05-44. Carburetor Gas Inlet Right Bank ......................... 5.05

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xxii

Form 6248 First Ednion

ILLUSTRATIONS

Figure 5.05-45. Dresser Elbow Coupling .... 5.05 - 27 Figure 5.05-46. Dresser Elbow Coupling .... 5.05 - 27 Figure 5.05-47. Fisher 99 Regulator Tube Connections - GSI .................. 5.05 - 28 Figure 5.05-48. Fisher 99 Regulator Tube Connections - GL ................... 5.05 - 28 Figure 5.05-49. Fisher 99 Regulator Bracket Left Bank ........................... 5.05 - 28 Figure 5.05-50. Fisher 99 Regulator Mounting Orientation - Left Bank - Top View ..... 5.05 - 28 Figure 5.05-51. Prechamber Regulator Front Right ......................... 5.05 - 29 Figure 5.05-52. Prechamber Regulator - GL 5.05 - 29 Figure 5.05-53. Prechamber Regulator ..... 5.05 - 30 Figure 5.05-54. Prechamber Regulator Mounting Bracket .................... 5.05 - 30 Figure 5.05-55. Intake Manifold Flange Aftachments - Right Bank ............ 5.05 - 31 Figure 5.05-56. Prechamber Regulator Front Right ......................... 5.05 - 31 Figure 5.05-57. Prechamber Regulator/ManHold Tube Connections - GL .............. 5.05 - 32 Figure 5.05-58. Prechamber Gas Supply Left Bank ........................... 5.05 - 33 Figure 5.05-59. Fisher 99 Regulator Fuel Gas Fitter ........................... 5.05 - 33 Figure 5.05-60. Fisher 99 Regulator Filter ... 5.05 - 34

Figure 5.10-17. Triangular Ignition Coil Bracket ............................ 5.10-13 Figure 5.10-18. Wire Harness Assembly .... 5.10 - 14 Figure 5.10-19. Harness Cable Clip Front Right ......................... 5.10 - 14 Figure 5.10-20. Electronic Ignttion System Diagram ............................ 5.10-16 Figure 5.10-21. Wire Harness - Right Bank Carburetor And Intake Manifold Removed For Clarity .......................... 5.10-17 Figure 5.10-22. Wire Harness - Front Right . 5.10 - 17 Figure 5.10-23. Wire Harness Cable Clip Locations ........................... 5.10 - 17 Figure 5.10-24. Retaining Clip ............. 5.10 - 18 Figure 5.10-25. Attaching Cable Clip Support Braces ..................... 5.10 - 18 Figure 5.10-26. Triangular Ignition Coil Bracket ............................ 5.10-18 Figure 5.10-27. Magneto Pin Connector Cable .............................. 5.10-18 Figure 5.10-28. Ignition Module ............ 5.10 - 19 Figure 5.10-29. Mounting Brackets ......... 5.10 - 19 Figure 5.1 0-30. Ignition Module' ............ 5.10 - 19 Figure 5.1 0-31. Governor Drive Housing .... 5.10 - 20 Figure 5.10-32. Hall-effect Pickup ......... 5.10 - 20 Figure 5.10-33. Current Production CEC Timing Disc ......................... 5.10 - 20 Figure 5.10-34. Current Produetjon Govemor Drive Gear. .......................... 5.10 - 20 Figure 5.10-35. Current Production Timing Tool ............................... 5.10 - 21 Figure 5.10-36. Flywheel Timing Opening ... 5.10 - 21 Figure 5.10-37. Current Production CEC Timing Disc ......................... 5.10 - 22 Figur