SECTION 1.

15
GENERAL INFORMATION

GENERAL INFORMATION
VHPä Series Fourâ engines (see Figure 1.15-1 and
Table 1.15-1) are 4--cycle; 6 cylinder engines are in--line
configuration, while 12 cylinder engines are V--configu-
ration. All engines rotate in the standard counterclock-
wise direction, as viewed from the rear (flywheel) end.
Table 1.15-1. Engine Models
6 Cylinder Engines F3524GSI
L5774LT
L5794GSI
12 Cylinder Engines L5794LT
L7044GSI

“GSI” engines are rich combustion (stoichiometric) with

turbocharging and intercooling.
Figure 1.15-1. VHP L7044GSI Engine
“LT” engines are designed to burn a lean air/fuel mixture
for low fuel consumption and reduced emissions with a
turbulent, open chamber design.
BASIC ENGINE DESCRIPTION
Refer to Figure 1.15-4 through Figure 1.15-9 for engine The crankcase is a rigid gray iron casting. The main
identification views. bearings are replaceable. The counterweighted crank-
shaft is made of forged steel and has seven main
FEATURES AND BENEFITS bearing journals. Each engine is equipped with a
This publication provides procedures to maintain the viscous vibration damper.
unique aspects of Series Four engines. Series Four There are interchangeable cylinder heads, each with
engines offer increased power while using components two intake and two exhaust valves. Both exhaust and
that have proven reliability. Some of the unique aspects intake valve seat inserts are replaceable. Roller type
of Series Four engines are: valve lifters and hydraulic push rods are standard. The
camshaft is heavy duty for long life. The connecting rods
· Completely new robust cylinder head assembly are made from drop forged steel and are rifle drilled. The
offering improved reliability and durability cylinders have replaceable wet cylinder liners. The
· Ignition coils mounted directly on the valve rocker pistons use a full floating piston pin. The flywheel is
covers, improving ignition characteristics machined and has a ring gear attached.
The exhaust driven turbocharger compresses intake air.
· Standard or shielded ignition wiring This charged air is cooled in the intercooler and then
enters the carburetor and mixes with pressurized fuel
· Water piping routed above the engine for easier
gas. The turbocharged air/fuel mixture enhances the
maintenance
engine’s power and performance.
· Water--cooled turbocharger center sections and
additional heat shielding

· High performance pistons

· Robust crankshaft material

FORM 6287 First Edition 1.15 -- 1

GENERAL INFORMATION

The pressurized lubricating system consists of an oil CRANKSHAFT

sump, pump, piping network, full flow centrifical bypass The underslung crankshaft is made of a low alloy, high
filters, strainers and cooler. The full flow oil filter is tensile strength forged steel. The crankshaft is counter-
externally mounted, separate from the engine. weighted to achieve a near perfect balance of rotating
The cooling system has two water pumps. The main forces.
water pump circulates the jacket water of the engine. A viscous vibration damper is installed on the forward
The auxiliary water pump circulates water for the oil end of the crankshaft along with a gear that drives the
cooler and the intercooler. The engine jacket, cylinder front end gear train and accessories. The flywheel, with
heads, exhaust manifold, oil and charged intake air are ring gear, is installed on the rear end of the crankshaft
all water cooled. and is machined to accept several options.
COMPONENT DESCRIPTIONS INTAKE MANIFOLD(S)
CYLINDER HEAD AND VALVES The air/fuel mixture passes through the intake man-
The P/N 205002 series cylinder heads are standard on ifold(s) where it is distributed to the individual cylinders.
Series Four engines. Each cylinder head has four valves, EXHAUST MANIFOLD(S)
two intake and two exhaust (see Figure 1.15-2). The new
The exhaust port of each cylinder head is connected to
cylinder heads offer the following features:
one water--cooled segment of the exhaust manifold.
· Improved cooling The water--cooled exhaust manifold(s) assembly is
comprised of individual segments (one for each cylinder
· Superior valve life head). Each exhaust manifold segment is joined to the
next by a manifold pilot.
· Increased overhaul interval
CONNECTING RODS
· Rigid valve bridge assembly
The connecting rods are machined to ensure maximum
strength, precise balance and consistent weight be-
tween cylinders. They are made of a low alloy, high
tensile strength forged steel, and are rifle--drilled to
supply pressurized lube oil from the crankshaft to the
piston pin bushings. The split line of the rod and cap
allows for removal of the connecting rod assembly up
through the cylinder liner bore.
The serrated split line ensures precise alignment and
transfer of loads. The caps and rods are match
numbered to ensure that each cap is mated with the
correct blade during re--assembly.
The connecting rod cap fasteners, like all critical
fasteners used on the engine, are torqued to specific
values.
TURBOCHARGER(S)
High efficiency, water cooled center housing, radial flow
turbocharger(s) are mounted on the rear of the engine
and generate the required boost levels for the engine.
PISTONS
Figure 1.15-2. P/N 205002 Series Cylinder Head The pistons are machined from one--piece castings.
Cutaway View Each piston is cam--ground. This means the dimension
of the piston skirt at room temperature is slightly larger at
CRANKCASE a point 90 degrees to the piston pin bore. This feature
allows the piston to expand from a shape that is
The crankcase is a gray iron casting. For assembled
somewhat oval to one that is almost perfectly round
rigidity, the main bearing caps are attached to the
when operating at stabilized engine temperatures.
crankcase with both vertical studs and lateral tie bolts.
This feature makes the crankcase assembly more rigid
and lengthens the life of the main bearings.

1.15 -- 2 FORM 6287 First Edition

 GENERAL INFORMATION

CYLINDER LINERS CARBURETOR(S)

Each wet type cylinder liner has a flange at its upper end The carburetor(s) consists of a main body, with a
to locate it in the crankcase upper deck. The liners have conventional throttle valve and diaphragm operated gas
three external ring grooves to hold the lower crankcase metering valves. The flow of air through the carbure-
bore seals. tor(s) is controlled by the throttle valve in the carburetor
throat, as in any other carburetor. The amount of air
CAMSHAFTS going to the engine is measured by air--flow measuring
The design of the camshaft lobe and cam minimizes valves, which rise in direct proportion to the air volume
valve overlap and reduces the flow of gases between passing through. The gas metering valves are mechani-
the intake and exhaust ports. This improves fuel cally fixed to the air measuring valves, and rise with
efficiency and lowers exhaust emissions. them, thus opening the gas passages an amount
proportionate to the air entering the engine. This
CUSTOM ENGINE CONTROL IGNITION MODULE
establishes and holds a definite air/fuel ratio throughout
Waukesha Engine’s Custom Engine Control (CEC) the operating range. The actual movement of the parts
Ignition Module (IM), is standard equipment. The CEC results from the negative air pressure at the air
ignition system uses a Hall--effect pickup and a special measuring valves, which is communicated to the back
timing disc to determine the exact position of the side of each diaphragm through two small holes.
crankshaft. The CEC IM interprets the sensor’s im-
pulses to set the optimum ignition timing. The CEC IM ENGINE SAFETY SHUTDOWNS
then directs a precisely timed voltage to the appropriate
ignition coil.
CUSTOM ENGINE CONTROL DETONATION Switches for alarms and automatic engine shut-
SENSING MODULE down must be supplied by the customer. The
Waukesha Engine’s CEC Detonation Sensing Module sensors provided are for measuring and monitoring
(DSM), which functions with the CEC IM, is standard temperatures and WILL NOT shut the engine down if
equipment. The DSM protects the engines from dam- potentially harmful temperatures are reached. Dis-
age due to detonation on an individual cylinder basis. regarding this information could result in severe
Engine mounted detonation sensors monitor engine personal injury or death.
output from each cylinder. When the signal exceeds a
Engine instrument and safety shutdowns are not
predetermined limit, the DSM retards the ignition timing
supplied as standard equipment, due to the wide variety
for the cylinder associated with that sensor. As soon as
of customer needs. Instruments and safety shutdowns
conditions permit, the DSM will advance spark timing to
are the customer’s responsibility. Oil pressure, intake
the original timing set point.
manifold pressure, water temperature, exhaust temper-
INTERCOOLER(S) ature, main bearing, overspeed and oil temperature are
the minimum required for engine protection. Switches
The intercooler(s) (the box--type tube and fin assem-
should be wired to an alarm to warn of high tempera-
blies mounted at the rear of the engine) are standard.
tures and low pressure as well as provide for automatic
The configuration of the upper and lower bonnets create
engine shutdown if potentially harmful temperatures,
a U--shaped path that enables the cooling water to pass
pressure or overspeed conditions exist.
through the core assembly four times before exiting the
unit at the top. Header plates separate the air passing
through the casing from the cooling water in the upper
and lower bonnets.
A supply tube connected to the intercooler cooling water
inlet, provides a continuous supply of cooling water to
the wastegate(s)(one per turbocharger). The cooling
water enters the lower housing of the wastegate(s) and
passes through a cavity that encircles the valve guide.
Exiting the outlet port on the opposite side of the lower
housing, the water passes to the intercooler cooling
water outlet through a water return tube.

FORM 6287 First Edition 1.15 -- 3

GENERAL INFORMATION

SERIAL NUMBERS AND ENGINE NAMEPLATE rated output in horsepower and kilowatts, and overload
For ease in identification, the engine model, serial and rating in horsepower and kilowatts. This nameplate is
specification numbers are stamped on a nameplate located on the lower left side of the crankcase, adjacent
(see Figure 1.15-3). to the front of the engine.

The engine nameplate provides the following informa- When requesting information, you will need to reference
tion: model number, serial number, date inspected, both the engine model and serial numbers. If the
special application approval number (power approval), nameplate is defaced or detached, the serial number
valve clearance, compression ratio, firing order, gov- may be obtained directly off the crankcase. To locate it,
erned speed, altitude limit at which an engine derate look directly above the nameplate location, on the
takes place, primary and secondary fuel ratings which cylinder head deck of the crankcase.
show the fuel, minimum WKIâ value, ignition timing,

SAA # SERVICE TYPE

MODEL
WAUKESHA ENGINE
SERIAL DRESSER INC.
NUMBER WAUKESHA, WISCONSIN U.S.A. DATE
COMP.
RATIO

THIS ENGINE IS FACTORY EQUIPPED AS LISTED. HP(kW) ARE PER

ISO 3046/1. CONSULT A W.E.D. AUTHORIZED DISTRIBUTOR OR W.E.D.
APPLICATION ENGINEERING FOR ADDITIONAL INFORMATION.
ALTITUDE LIMIT
PRIMARY SECONDARY FT/M
FUEL
TM AIR INLET TEMP
MIN. WKI LIMT O
F/ C
O

IGN.TIMING
BTDC GOVERNED SPEED RPM

CARB ADJ.

SERVICE VALVE CLEARANCE IN. /mm

211853M
HP/kW INTAKE EXHAUST
OVERLOAD
HP/kW

FIRING ORDER

Figure 1.15-3. P/N 211853M

1.15 -- 4 FORM 6287 First Edition

 GENERAL INFORMATION

ENGINE IDENTIFICATION VIEWS

SIX CYLINDER VIEWS

25 1 2 3 4 5 6 1

24 7

23
9

22
10

11

12

13

21 20 19 18 17 16 15 14

1. Lifting Eyes 14. Lube Oil Drain (Right Side)

2. Cylinder Head Assemblies (6) 15. Engine Leveling Bolts (Right Side)
3. Intake Manifold 16. Junction Box
4. Control Panel 17. Lube Oil Dipstick
5. Detonation Sensing Module Filter 18. Regulator, Gas
6. CEC Ignition Module 19. Carburetor
7. Detonation Sensing Module 20. Lube Oil Pan Access Doors
8. Governor 21. Manual Shutdown Lever
9. Governor Speed Control Hand Lever 22. Water Drains (Right Side)
10. Magneto Drive (Behind Detonation Sensing Module) 23. Breather Regulator
11. Vibration Damper (Inside Guard) 24. Oil Separator
12. Lube Oil Pump 25. Exhaust Outlet
13. Auxiliary Water Pump

Figure 1.15-4. Right Side View -- 6 Cylinder

FORM 6287 First Edition 1.15 -- 5

GENERAL INFORMATION

1 2 3 4 5
13

21

6
20

7
19

18

17 16 15 14 13 12 11 10 9 8

1. Oil Pressure Regulating Valve 12. Lube Oil Pan

2. Thermostat Cluster Housing 13. Crankcase
3. Exhaust Manifold Assembly 14. Lube Oil Strainer
4. Water Manifold 15. Oil Temperature/Pressure Control Valves
5. Oil Header 16. Lubricator
6. Flywheel and Housing 17. “Y” Strainer
7. Manual Barring Device 18. Prelube Pump and Motor
8. Lube Oil Drain (Left Side) 19. Oil Cooler
9. Engine Leveling Bolts (Left Side) 20. Safety Guarding
10. Lube Oil Pan Access Doors (Left Side) 21. Pressure Block
11. Engine Temp. Connections/Controls Junction Box

Figure 1.15-5. Left Side View -- 6 Cylinder

1.15 -- 6 FORM 6287 First Edition

 GENERAL INFORMATION

8
4

6 5

1. Turbocharger 6. Lube Oil Drain

2. Intercooler 7. Oil Filler
3. Flywheel Housing 8. Air Cleaner
4. Timing Cover 9. Wastegate
5. Flywheel

Figure 1.15-6. Rear View -- 6 Cylinder

FORM 6287 First Edition 1.15 -- 7

GENERAL INFORMATION

TWELVE CYLINDER VIEWS

1 2 3 4

24 8
9

10

23
11

22 13 21 20 19 18 17 16 15 14 13 12

1. Exhaust Manifold Assembly (Right Bank) 13. Engine Leveling Bolts (Right Bank)
2. Control Panel (Right Bank) 14. Magneto Adapter
3. Water Piping 15. CEC Ignition Module
4. Detonation Sensing Module Filter 16. Junction Box
5 Oil Cooler 17. Lube Oil Dipstick (Right Bank)
6. Jacket Water Pump 18. Regulator, Gas (Right Bank)
7. Governor 19. Carburetor (Right Bank)
8. Magneto Drive 20. Manual Speed Control
9. Governor Speed Control Hand Lever 21. Lube Oil Strainer
10. Detonation Sensing Module 22. Lube Oil Drain (Right Bank)
11. Vibration Damper 23. Flexible Lube Oil Connection
12. Lube Oil Pump 24 Water Drains (Right Bank)

Figure 1.15-7. Right Side View -- 12 Cylinder GSI

1.15 -- 8 FORM 6287 First Edition

 GENERAL INFORMATION

1 2 3 4 5

23

22

21

20
6

19 7

18 17 16 15 14 13 12 11 10

1. Thermostat Cluster Housing 13. Lube Oil Pan

2. Control Panel (Left Bank) 14. Regulator, Gas (Left Bank)
3. Water Manifold 15. Lube Oil Dipstick (Left Bank)
4. Exhaust Manifold Assembly (Left Bank) 16. Crankcase
5. Cylinder Head Assemblies (Left Bank) 17 Engine Jacket Water Drains (Left Bank)
6 Wastegate Backpressure Regulator 18. Prelube Pump and Motor
7. Flywheel and Housing 19. Safety Guarding
8. Manual Barring Device 20. Lubricator
9. Lube Oil Filler 21. Microspin Oil Filter Housing
10. Lube Oil Drain (Left Bank) 22 Crankcase Breather (2)
11. Engine Leveling Bolts (Left Bank) 23. Oil Cooler
12 Lube Oil Pan Access Doors (Left Bank)

Figure 1.15-8. Left Side View -- 12 Cylinder LT

FORM 6287 First Edition 1.15 -- 9

GENERAL INFORMATION

3 2 2 3

4
5

5
6
6
7

8
8

10

1. Flexible Exhaust Connection 6. Lifting Eyes (4) (2 each front and rear)
2. Wastegates (2) 7. Intake Manifolds (2)
3. Turbochargers (2) 8. Carburetors (2)
4. Cylinder Head Assemblies (12) 9. Oil Outlet Flexible Connection to Filter
5. Air Cleaners (2) 10. Intercooler

Figure 1.15-9. Rear View -- 12 Cylinder

1.15 -- 10 FORM 6287 First Edition

 GENERAL INFORMATION

SERIES FOURt
t ENGINE SPECIFICATIONS

Alarm and shutdown values are based on dry natural gas (900 Btu/cu. ft. SLHV).
Refer to Gaseous Fuel Specification Sheet S7884--6 and Lube Oil Recommenda-
tions Service Bulletin 12--1880Y or latest revisions for typical changes in operation temperatures for jacket
water and lube oil when running on landfill or digester gas fuels. Disregarding this information could result in
product damage.

Table 1.15-2. Series Four Specifications

GENERAL SPECIFICATIONS -- SERIES FOUR
Engine Model F3524GSI L5774LT L5794GSI/LT L7044GSI
Type 4--cycle 4--cycle 4--cycle 4--cycle
Turbocharged and Turbocharged and Turbocharged and
Aspiration, GSI intercooled -- intercooled intercooled
Turbocharged inter- Turbocharged inter-
Aspiration, LT -- cooled and lean burn cooled and lean burn --

Inline--6, V--12, V--12, V--12,

Number of cylinders 4--valves per cylinder 4--valves per cylinder 4--valves per cylinder 4--valves per cylinder
9.375 x 8.50 in. 8.50 x 8.50 in. 8.50 x 8.50 in. 9.375 x 8.50 in.
Bore x stroke (238 x 216 mm) (216 x 216 mm) (216 x 216 mm) (238 x 216 mm)
Displacement 3520 cu. in. (58 litres) 5788 cu. in. (115 litres) 5788 cu. in. (115 litres) 7040 cu. in. (115 litres)
L5794GSI -- 8.25:1
Compression ratio 8:1 10.2:1 L5794LT -- 10.2:1 8:1

Speed range 700 -- 1200 rpm (see engine nameplate)

Low idle 700 rpm
Lubrication System
Sump capacity, including filter
and cooler 66 gallons (250 litres) 90 gallons (340 litres) 90 gallons (340 litres) 90 gallons (340 litres)

Oil pan (Low level mark) 35 gallons (132.5 litres) 35 gallons (132.5 liters) 35 gallons (132.5 liters) 35 gallons (132.5 litres)
Oil pan (High level mark) 45 gallons (170.3 litres) 45 gallons (170.3 liters)) 45 gallons (170.3 liters)) 45 gallons (170.3 litres)
Lube oil filter capacity 20 gallons (75.7 litres) 36 gallons (136.3 litres) 36 gallons (136.3 litres) 36 gallons (136.3 litres)
(7.25 in. x 38 in.) (7.25 in. x 52 in.) (7.25 in. x 52 in.) (7.25 in. x 52 in.)
Oil cooler capacity 4 gallons (15 litres) 5 gallons (19 litres) 5 gallons (19 litres) 5 gallons (19 litres)
15 micron at @ 15 micron at @ 15 micron at @ 15 micron at @
Main filter 90% efficiency 90% efficiency 90% efficiency 90% efficiency
15 micron at @ 15 micron at @ 15 micron at @ 15 micron at @
Micro-fiberglass filter 90% efficiency 90% efficiency 90% efficiency 90% efficiency
Strainer screen 74 micron 74 micron 74 micron 74 micron
55 ± 5 psi 55 ± 5 psi 55 ± 5 psi 55 ± 5 psi
Normal lube oil pressure (380 ±35 kPa) (380 ±35 kPa) (380 ±35 kPa) (380 ±35 kPa)
Low oil pressure alarm setpoint 35 psi (203 kPa) 35 psi (310 kPa) 35 psi (310 kPa) 35 psi (310 kPa)
Low oil pressure shutdown
setpoint 30 psi (138 kPa) 30 psi (275 kPa) 30 psi (275 kPa) 30 psi (275 kPa)

Prelube duration 5 minutes

Normal oil header temperature 165° F (74° C) 165° F (74° C) 165° F (74° C) 165° F (74° C)
Oil header temperature alarm
setpoint 195° F (91° C) 195° F (91° C) 195° F (91° C) 195° F (91° C)

Oil header temperature shut-

down setpoint 205° F (96° C) 205° F (96° C) 205° F (96° C) 205° F (96° C)

Air/Gas Starter
Air starter oil reservoir one shot
lubricator 2.0 pint (0.9 litre) 2.0 pint (0.9 litre) 2.0 pint (0.9 litre) 2.0 pint (0.9 litre)

Air motorized pre--lube motor,

in--line lubricator 0.5 pint (0.2 litre) 0.5 pint (0.2 litre)) 0.5 pint (0.2 litre)) 0.5 pint (0.2 litre)

FORM 6287 First Edition 1.15 -- 11

GENERAL INFORMATION

Governor
UG8 governor oil reservoir 1.5 quart (1.1 litre) 1.5 quart (1.1 litre) 1.5 quart (1.1 litre) 1.5 quart (1.1 litre)
Cooling System (Jacket Water And Auxiliary System)
Normal charge air cooler inlet
temperature 130° F (54° C)

Jacket water capacity, engine

only 48.5 gallons (183.6 liters) 107 gallons (405 liters) 107 gallons (405 liters) 107 gallons (405 liters)

Surge tank capacity (optional) 23 gallons (87 litres) 45.5 gallons (183 litres) 45.5 gallons (183 litres) 45.5 gallons (183 litres)
Intercooler water capacity 2.75 gallons (10.4 litres) 5.50 gallons (20 litres) 5.50 gallons (20 litres) 5.50 gallons (20 litres)
Oil cooler water capacity 5 gallons (19 litres) 6.5 gallons (24.6 litres) 6.5 gallons (24.6 litres) 6.5 gallons (24.6 litres)
Exhaust System
Maximum permissible backpressure @ rated load and speed See Table 4.35-1 Maximum Allowable Exhaust Backpressure
Crankcase Breather System
Crankcase vacuum 0 to --1 in. (negative) (0 to --25.4 mm (negative)) H2O
Jacket Water Outlet Temperature
Normal: 180° F (82° C) for continuous and intermittent rating
Standard Cooling
g System
y Alarm: 10° F (5.5° C) above normal/design temperature
Shutdown: 20° F (11° C) above normal/design temperature
Intake Manifold Temperature
Normal: Up to 10° F (5.5° C) above design intercooler water inlet temperature
GSI & LT Engines
g Alarm: 15° F (8.5° C) above design intercooler water inlet temperature
Shutdown: 20° F (11° C) above design intercooler water inlet temperature
Intake Manifold Pressure
Contact Waukesha Engine Sales Engineering Department (Also see Section 4.05 Fuel System Maintenance “Fuel System Adjustments GSI
Engines” and “Fuel System Adjustments LT Engines”)
Fuel System
Natural gas pressure at regulator “GSI” models 24 -- 50 psi (165 -- 345 kPa)
Natural gas pressure at regulator “LT” models 35 -- 50 psi (241 -- 345 kPa)
Natural gas pressure at regulator “Low Fuel Pressure” models 6 in. (152mm)
Air Induction System
Maximum permissible restriction @ rated load and speed 15 in. (381 mm) of H2O
Required filtering efficiency (coarse dust test per SAE726C) 99.7%
Starting System
Electric starting 24 volts DC
Air starting pressure 150 psi (1043 kPa)(MAX) Pressure is based on 50° F (10° C) lube oil temperature
Air/gas starter reservoir SAE 10W oil at 32° F (0° C) and above.
lubricant Use No. 2 Diesel Oil when ambient temperatures fall below 32° F (0° C)
SAE 10W oil at 32° F (0° C) and above.
In--line lubricator lubricant Use No. 2 Diesel Oil when ambient temperatures fall below 32° F (0° C)
Miscellaneous
Spark plug gap See Table 1.15-3 13/16 Inch Reach Spark Plugs For P/N 205002 Series Cylinder Heads
Engine timing Refer To Engine Nameplate
Main bearing temperature shut-
down 250° F (121° C)

Overspeed shutdown 10% over governed speed

Valve Train
Valve Clearance -- Hydraulic
lifters See Section 4.55 Valve Adjustment (P/N 205002 Series Cylinder Head)

NOTE: *Total capacity of lube oil system. Fill oil pan, filter, cooler, etc., run engine, then add oil as required to bring oil level in oil pan back to high mark.
Record total amount for future reference.

1.15 -- 12 FORM 6287 First Edition

 GENERAL INFORMATION

13/16 inch reach spark SERVICE TOOLS LIST

plugs must be used with
You will need the following special tools to perform the
P/N 205002 series cylinder heads. Failure to use the
operator tasks on Series Four engines (see Table 1.15-4).
proper reach spark plugs will cause damage to
See Form M--398B Waukesha Special Tools Catalog for
equipment.
a complete listing of tools available for your engine. To
order these special tools, contact your local Waukesha
Table 1.15-3. 13/16 Inch Reach Spark Plugs For Engine Distributor. In some instances, substitute items
P/N 205002 Series Cylinder Heads may be used but only if specifically approved by
ENGINE P/N GAP Waukesha.
GSI 60999Z 0.015 in (0.381 mm) Table 1.15-4. Service Tools
LT 69919 0.011 in (0.28 mm)
WAUKESHA TOOL DESCRIPTION
TOOL P/N
ENGINE TIMING DATA 474016 VHP V-- Belt Tester
474022 Timing Tool
Detonation is NOT al- 475006 Spark Plug Spreading Tool
lowed at any time during Spark Plug Socket (NEW) (7/8 inch Socket
engine operation, regardless of the specified tim- 475037 15-1/2--inch long w/rubber O--ring insert)
ing. If detonation occurs at the specified timing, a 475072 Digital Manometer/Calibrator Kit
timing adjustment must be made to retard the
475029 O--Ring Lube
ignition timing until NO audible detonation exists.
Spark Plug Thread and Seat Cleaner (18 mm)
Engine damage may result if detonation occurs. 475065 for 13/16 inch reach spark plug bores

Refer to the engine nameplate for the proper engine 494258 Slack Tube Manometer
timing value. 494287 Valve Adjusting Wrench
494338 Induction Timing Light
NOTE: Changing the engine timing will also change the
exhaust emissions and fuel economy. KRYTOXâ GPL--206 grease -- for spark plug
489341 boot and extension

WAUKESHA KNOCK INDEXâ (WKIâ) 494215 Compression Tester

494217 Compression Tester Adapter
The WKIâ software developed by Waukesha Engine,
475007 02 Analyzer
represents a major leap forward in field gas analysis.
This new method replaces the Octane Method analysis 475357 02 Analyzer
method previously used. 475068 02 Analyzer
475039 02 Sensor Socket
The WKI software greatly improves the accuracy of
475067 CO/HC Analyzer
calculating fuel knock resistance of field gas, natural
494360 Exhaust Analyzer Accessory Kit
gas, and low Btu gases. In addition, the WKI software is
able to account for the “knock improver” characteristics
of inert gases which are often found in gaseous fuels.
When used in conjunction with the Waukesha Custom
Engine Control Detonation Sensing Module, Waukesha
is often able to maximize power ratings and optimize
performance on poor quality fuels while maintaining an
adequate knock safety margin.

FORM 6287 First Edition 1.15 -- 13

GENERAL INFORMATION

TORQUE VALUES
Table 1.15-5 lists the torque values needed for the basic maintenance of Series Four engines.
Table 1.15-5. Torque Values Series Four Engine Basic Maintenance*
DESCRIPTION ft-lb N×m
Spark Plugs
13/16 inch reach spark plugs must be used with P/N 205002 cylinder
heads. Failure to use proper reach spark plugs will cause damage to 32 -- 38 ft-lb (dry) 43 -- 52 N×m (dry)
equipment.

Rocker Arm Support Capscrews, (4 Per Cylinder Head) 1/2--13 x 5-1/2 in. (See “Rocker Arm
Assembly Torque Sequence” Below For Torque Value Of Center Capscrew) 66 -- 70 ft-lb 89.5 -- 95 N×m

Oil Pan Access Covers 18 -- 20 ft-lb 24 -- 27 N×m

Pressure Relief Valve Equipped Oil Pan Access Covers 18 -- 20 ft-lb 24 -- 27 N×m
DESCRIPTION in-lb N×m
Spark Plug Carrier Extension Nuts 200 in-lb 22.59 N×m
Spark Plug Sleeve Nuts 200 in-lb 22.59 N×m
Early production models only -- Small diamond shaped cover on side of cylinder heads (2 capscrews) 40 -- 50 in-lb 4.5 -- 5.6 N×m
Rocker Arm Support Capscrew (1 Per Cylinder Head) 3/8--16 x 6-3/4 (See “Rocker Arm Assembly
Torque Sequence” Below) 200 in-lb 22.59 N×m

Rocker Arm Cover Capscrews 200 in-lb 22.59 N×m

Ignition Coil Nuts 132 -- 156 in-lb 15 -- 17.6 N×m
NOTE: * All torques oiled unless specified.

ROCKER ARM ASSEMBLY TORQUE SEQUENCE TEMPERATURE AND PRESSURE TEST

POINTS
5 1 2 Refer to Figure 1.15-11 through Figure 1.15-14 for
location of temperature and pressure test points on all
VHP Series Four engines.
3
4 Pressures
P2 Exhaust Manifold
P3 Exhaust Back Pressure
Temperatures
TORQUE THIS CAPSCREW T2 Exhaust Manifold P3, T3
LAST DURING INSTALLATION.
REMOVE THIS CAPSCREW T3 Exhaust Stack
FIRST DURING REMOVAL.

Figure 1.15-10. Rocker Arm Assembly Installation

(Sequence Reversed For Removal)

Torque the center caps-

crew of the rocker arm P2, T2
assemblies last during installation of the rocker arm
assemblies, to prevent damage to equipment.

1. Tighten four end capscrews and lock washers on

rocker arm assembly to 66 -- 70 ft-lb (89 -- 95 N×m).

2. Tighten remaining center capscrew and washer to

200 in-lbs (23 N×m).

Figure 1.15-11. Rear View -- 6 Cylinder

1.15 -- 14 FORM 6287 First Edition

 GENERAL INFORMATION

EP

P4 T4
LEFT SIDE

P1, T1 T5

P6 P5 P8 T6
RIGHT SIDE

Pressures Temperatures
P1 Intake Manifold T1 Intake Manifold
P2 Exhaust Manifold T2 Exhaust Manifold
P3 Exhaust Back Pressure T3 Exhaust Stack
P4 Oil T4 Oil
P5 Carburetor Air -- At Tee On Balance Tube T5 Jacket Water Outlet
P6 Carburetor Fuel T6 Auxiliary Water Inlet
P8 Crankcase Vacuum Other
EP Exhaust Probe

Figure 1.15-12. Right And Left Side Views -- 6 Cylinder

FORM 6287 First Edition 1.15 -- 15

GENERAL INFORMATION

P2, T2

T6 P8 P1, T1

LEFT SIDE
T5

P2, T2

T4 P4 P6 P5
RIGHT SIDE
Pressures Temperatures
P1 Intake Manifold T1 Intake Manifold
P2 Exhaust Manifold T2 Exhaust Manifold
P3 Exhaust Back Pressure T3 Exhaust Stack
P4 Oil T4 Oil
P5 Carburetor Air -- At Tee On Balance Tube T5 Jacket Water Outlet
P6 Carburetor Fuel T6 Auxiliary Water Inlet
P8 Crankcase Vacuum Other
EP Exhaust Probe
Figure 1.15-13. Right And Left Side Views -- 12 Cylinder GSI, LT

1.15 -- 16 FORM 6287 First Edition

 GENERAL INFORMATION

P3, T3

EP

P2, T2
P2, T2

Pressures Temperatures
P1 Intake Manifold T1 Intake Manifold
P2 Exhaust Manifold T2 Exhaust Manifold
P3 Exhaust Back Pressure T3 Exhaust Stack
P4 Oil T4 Oil
P5 Carburetor Air -- At Tee On Balance Tube T5 Jacket Water Outlet
P6 Carburetor Fuel T6 Auxiliary Water Inlet
P8 Crankcase Vacuum Other
EP Exhaust Probe

Figure 1.15-14. Rear View -- 12 Cylinder

FORM 6287 First Edition 1.15 -- 17

GENERAL INFORMATION

GENERAL TORQUE VALUES

Table 1.15-6. Metric Standard Capscrew Torque Values (Untreated Black Finish)
COARSE THREAD CAPSCREWS (UNTREATED BLACK FINISH)
ISO
PROPERTY 5.6 8.8 10.9 12.9
CLASS
TORQUE TORQUE TORQUE TORQUE
SIZE
N×m in-lb N×m in-lb N×m in-lb N×m in-lb
M3 0.6 5 1.37 12 1.92 17 2.3 20
M4 1.37 12 3.1 27 4.4 39 10.4 92
M5 2.7 24 10.5 93 15 133 18 159
M6 4.6 41 10.5 93 15 133 10.4 92
M7 7.6 67 17.5 155 25 221 29 257
M8 11 97 26 230 36 319 43 380
M10 22 195 51 451 72 637 87 770
N×m ft-lb N×m ft-lb N×m ft-lb N×m ft-lb
M12 39 28 89 65 125 92 150 110
M14 62 45 141 103 198 146 240 177
M16 95 70 215 158 305 224 365 269
M18 130 95 295 217 420 309 500 368
M20 184 135 420 309 590 435 710 523
M22 250 184 570 420 800 590 960 708
M24 315 232 725 534 1020 752 1220 899
M27 470 346 1070 789 1519 1113 1810 1334
M30 635 468 1450 1069 2050 1511 2450 1806
M33 865 637 1970 1452 2770 2042 3330 2455
M36 1111 819 2530 1865 3560 2625 4280 3156
M39 1440 1062 3290 2426 4620 3407 5550 4093
FINE THREAD CAPSCREWS (UNTREATED BLACK FINISH)
ISO
PROPERTY 8.8 10.9 12.9
CLASS
TORQUE TORQUE TORQUE
SIZE
N×m ft-lb N×m ft-lb N×m ft-lb
M8 x 1 27 19 38 28 45 33
M10 x 1.25 52 38 73 53 88 64
M12 x 1.25 95 70 135 99 160 118
M14 x 1.5 150 110 210 154 250 184
M16 x 1.5 225 165 315 232 380 280
M18 x 1.5 325 239 460 339 550 405
M20 x 1.5 460 339 640 472 770 567
M22 x 1.5 610 449 860 634 1050 774
M24 x 2 780 575 1100 811 1300 958
NOTE: The conversion factors used in these tables are as follows: One N∙m equals 0.7375 ft-lb and one ft-lb equals 1.355818 N∙m.

1.15 -- 18 FORM 6287 First Edition

 GENERAL INFORMATION

Table 1.15-7. Metric Standard Capscrew Torque Values (Electrically Zinc Plated)
COARSE THREAD CAPSCREWS (ELECTRICALLY ZINC PLATED)
ISO
PROPERTY 5.6 8.8 10.9 12.9
CLASS
TORQUE TORQUE TORQUE TORQUE
SIZE
N×m in-lb N×m in-lb N×m in-lb N×m in-lb
M3 0.56 5 1.28 11 1.8 16 2.15 19
M4 1.28 11 2.9 26 4.1 36 4.95 44
M5 2.5 22 5.75 51 8.1 72 9.7 86
M6 4.3 38 9.9 88 14 124 16.5 146
M7 7.1 63 16.5 146 23 203 27 239
M8 10.5 93 24 212 34 301 40 354
M10 21 186 48 425 67 593 81 717
N×m in-lb N×m in-lb N×m in-lb N×m in-lb
M12 36 26 83 61 117 86 140 103
M14 58 42 132 97 185 136 220 162
M16 88 64 200 147 285 210 340 250
M18 121 89 275 202 390 287 470 346
M20 171 126 390 287 550 405 660 486
M22 230 169 530 390 745 549 890 656
M24 295 217 675 497 960 708 1140 840
M27 435 320 995 733 1400 1032 1680 1239
M30 590 435 1350 995 1900 1401 2280 1681
M33 800 590 1830 1349 2580 1902 3090 2278
M36 1030 759 2360 1740 3310 2441 3980 2935
M39 1340 988 3050 2249 4290 3163 5150 3798
FINE THREAD CAPSCREWS (ELECTRICALLY ZINC PLATED)
ISO
PROPERTY 8.8 10.9 12.9
CLASS
TORQUE TORQUE TORQUE
SIZE
N×m ft-lb N×m ft-lb N×m ft-lb
M8 x 1 25 18 35 25 42 30
M10 x 1.25 49 36 68 50 82 60
M12 x 1.25 88 64 125 92 150 110
M14 x 1.5 140 103 195 143 235 173
M16 x 1.5 210 154 295 217 350 258
M18 x 1.5 305 224 425 313 510 376
M20 x 1.5 425 313 600 442 720 531
M22 x 1.5 570 420 800 590 960 708
M24 x 2 720 531 1000 737 1200 885
NOTE: The conversion factors used in these tables are as follows: One N∙m equals 0.7375 ft-lb and one ft-lb equals 1.355818 N∙m.

FORM 6287 First Edition 1.15 -- 19

GENERAL INFORMATION

Table 1.15-8. U.S. Standard Capscrew Torque Values

SAE
GRADE
NUMBER
Grade 1 or 2 Grade 5 Grade 8
SIZE/
THREADS TORQUE TORQUE TORQUE
PER INCH in-lb (N×m) in-lb (N×m) in-lb (N×m)

THREADS DRY OILED PLATED DRY OILED PLATED DRY OILED PLATED
1/4 -- 20 62 (7) 53 (6) 44 (5) 97 (11) 80 (9) 159 (18) 142 (16) 133 (15) 124 (14)
1/4 -- 28 71 (8) 62 (7) 53 (6) 124 (14) 106 (12) 97 (11) 168 (19) 159 (18) 133 (15)
5/16 -- 18 133 (15) 124 (14) 106 (12) 203 (23) 177 (20) 168 (19) 292 (33) 265 (30) 230 (26)
5/16 -- 24 159 (18) 142 (16) 124 (14) 230 (26) 203 (23) 177 (20) 327 (37) 292 (33) 265 (30)
3/8 -- 16 212 (24) 195 (22) 168 (19) 372 (42) 336 (38) 301 (34) 531 (60) 478 (54) 416 (47)
ft-lb (N×m) ft-lb (N×m) ft-lb (N×m)
3/8 -- 24 20 (27) 18 (24) 16 (22) 35 (47) 32 (43) 28 (38) 49 (66) 44 (60) 39 (53)
7/16 -- 14 28 (38) 25 (34) 22 (30) 49 (56) 44 (60) 39 (53) 70 (95) 63 (85) 56 (76)
7/16 -- 20 30 (41) 27 (37) 24 (33) 55 (75) 50 (68) 44 (60) 78 (106) 70 (95) 62 (84)
1/2 -- 13 39 (53) 35 (47) 31 (42) 75 (102) 68 (92) 60 (81) 105 (142) 95 (129) 84 (114)
1/2 -- 20 41 (56) 37 (50) 33 (45) 85 (115) 77 (104) 68 (92) 120 (163) 108 (146) 96 (130)
9/16 -- 12 51 (69) 46 (62) 41 (56) 110 (149) 99 (134) 88 (119) 155 (210) 140 (190) 124 (168)
9/16 -- 18 55 (75) 50 (68) 44 (60) 120 (163) 108 (146) 96 (130) 170 (230) 153 (207) 136 (184)
5/8 -- 11 83 (113) 75 (102) 66 (89) 150 (203) 135 (183) 120 (163) 210 (285) 189 (256) 168 (228)
5/8 -- 18 95 (129) 86 (117) 76 (103) 170 (230) 153 (207) 136 (184) 240 (325) 216 (293) 192 (260)
3/4 -- 10 105 (142) 95 (130) 84 (114) 270 (366) 243 (329) 216 (293) 375 (508) 338 (458) 300 (407)
3/4 -- 16 115 (156) 104 (141) 92 (125) 295 (400) 266 (361) 236 (320) 420 (569) 378 (513) 336 (456)
7/8 -- 9 160 (217) 144 (195) 128 (174) 429 (582) 386 (523) 343 465() 605 (820) 545 (739) 484 (656)
7/8 -- 14 175 (237) 158 (214) 140 (190) 473 (461) 426 (578) 379 (514) 675 (915) 608 (824) 540 (732)
1.0 -- 8 235 (319) 212 (287) 188 (255) 644 (873) 580 (786) 516 (700) 910 (1234) 819 (1110) 728 (987)
1.0 -- 14 250 (339) 225 (305) 200 (271) 721 (978) 649 (880) 577 (782) 990 (1342) 891 (1208) 792 (1074)
NOTE: Dry torque values are based on the use of clean, dry threads.
Oiled torque values have been reduced by 10% when engine oil is used as a lubricant.
Plated torque values have been reduced by 20% for new plated capscrews.
Capscrews which are threaded into aluminum may require a torque reduction of 30% or more.
The conversion factor from ft-lb to in-lb is ft-lb x 12 equals in-lb.

ENGLISH/METRIC CONVERSIONS
Table 1.15-9. Metric Bolt Diameter To Hex Head Wrench Size Conversion Table

METRIC BOLT DIAMETER METRIC STANDARD METRIC BOLT DIAMETER METRIC STANDARD
WRENCH SIZE WRENCH SIZE
M3 6 mm M18 27 mm
M4 7 mm M20 30 mm
M5 8 mm M22 32 mm
M6 10 mm M24 36 mm
M7 11mm M27 41 mm
M8 13 mm M30 46 mm
M10 16 or 17 mm M33 50 mm
M12 18 or 19 mm M36 55 mm
M14 21 or 22 mm M39 60 mm
M16 24 mm M42 65 mm

1.15 -- 20 FORM 6287 First Edition

 GENERAL INFORMATION

Table 1.15-10. English To Metric Formula Conversion Table

CONVERSION FORMULA EXAMPLE
Inches and any fraction in decimal equivalent
Inches to Millimeters multiplied by 25.4 equals millimeters. 2-5/8 in. = 2.625 x 25.4 = 66.7 mm

Cubic Inches to Litres Cubic inches multiplied by 0.01639 equals litres. 9388 cu. in. = 9388 x 0.01639 = 153.9 L
Ounces to Grams Ounces multiplied by 28.35 equals grams. 21 oz. = 21 x 28.35 = 595 g
Pounds to Kilograms Pounds multiplied by 0.4536 equals kilograms. 22,550 lb. = 22,550 x 0.4536 = 10,229 kg
Inch pounds multiplied by 0.113 equals
Inch Pounds to Newton--meters Newton--meters. 360 in-lb = 360 x 0.113 = 40.7 N×m

Foot pounds multiplied by 1.3558 equals

Foot Pounds to Newton--meters Newton--meters. 145 ft-lb = 145 x 1.3558 = 197 N×m

Pounds per square inch multiplied by 0.0690

Pounds per Square Inch to Bars equals bars. 9933 psi = 9933 x 0.0690 = 685 Bar

Pounds per Square Inch to Pounds per square inch multiplied by 0.0703
Kilograms per Square Centimeter equals kilograms per square centimeter. 45 psi = 45 x 0.0703 = 3.2 kg/cm2

Pounds per Square Inch to Pounds per square inch multiplied by 6.8947
Kilopascals equals kilopascals. 45 psi = 45 x 6.8947 = 310 kPa

Fluid ounces multiplied by 29.57 equals

Fluid Ounces to Cubic Centimeters cubic centimeters. 8 oz. = 8 x 29.57 = 237 cc

Gallons to Litres Gallons multiplied by 3.7853 equals litres. 148 gal. = 148 x 3.7853 = 560 L
Degrees Fahrenheit to Degrees Degrees Fahrenheit minus 32 divided by 1.8
Centigrade equals degrees Centigrade. 212° F -- 32 ¸ 1.8 = 100° C

Table 1.15-11. Metric To English Formula Conversion Table

CONVERSION FORMULA EXAMPLE
Millimeters to Inches Millimeters multiplied by 0.03937 equals inches. 67 mm = 67 x 0.03937 = 2.6 in.
Litres to Cubic Inches Litres multiplied by 61.02 equals cubic inches. 153.8 L = 153.8 x 61.02 = 9385 cu. in.
Grams to Ounces Grams multiplied by 0.03527 equals ounces. 595 g = 595 x 0.03527 = 21.0 oz.
Kilograms to Pounds Kilograms multiplied by 2.205 equals pounds. 10,228 kg = 10,228 x 2.205 = 22,553 lb.
Newton--meters multiplied by 8.85 equals
Newton--meters to Inch Pounds inch pounds. 40.7 N×m = 40.7 x 8.85 = 360 in-lb

Newton--meters multiplied by 0.7375 equals

Newton--meters to Foot Pounds foot pounds. 197 N×m = 197 x 0.7375 = 145 ft-lb

Bars multiplied by 14.5 equals pounds per

Bars to Pounds per Square Inch square inch. 685 Bar = 685 x 14.5 = 9933 psi

Kilograms per Square Centimeter Kilograms per square centimeter multiplied by

to Pounds per Square Inch (psi) 14.22 equals pounds per square inch. 3.2 kg/cm2 = 3.2 x 14.22 = 46 psi

Kilopascals to Pounds per Square Inch Kilopascals multiplied by 0.145 equals pounds
(psi) per square inch. 310 kPa = 310 x 0.145 = 45.0 psi

Cubic centimeters multiplied by 0.0338 equals

Cubic Centimeters to Fluid Ounces fluid ounces. 236 cc = 236 x 0.0338 = 7.98 oz.

Litres to Gallons Litres multiplied by 0.264 equals gallons. 560 L = 560 x 0.264 = 148 gal.
Degrees Centigrade to Degrees Degrees Centigrade multiplied by 1.8 plus 32
Fahrenheit equals degrees Fahrenheit. 100° C = 100 x 1.8 + 32 = 212° F

FORM 6287 First Edition 1.15 -- 21

GENERAL INFORMATION

INDEX OF SEALANTS, ADHESIVES AND be used to match the general description to a specific
LUBRICANTS product or its equivalent (ie. pipe sealant = Perma Lokâ
Heavy Duty Pipe Sealant with Teflon or its equivalent).
The following is a list of sealants, adhesives and Waukesha does not endorse one brand over another. In
lubricants (see Table 1.15-12) required to perform the all cases, equivalent products may be substituted for the
tasks in this manual. Where possible, brand names are brand name listed. All part numbers listed are the
included with the task. When they are not, this index may manufacturer’s numbers.

Table 1.15-12. Sealants, Adhesives, And Lubricants

NAME USED IN TEXT BRAND NAME/DESCRIPTION
High Temperature
Anti--seize compound FEL--PROâ C5--Aâ, P/N 51005 or Loctiteâ Anti--Seize 767/ Copper based anti--seize compound

Anti--Seize Bostik Never Seezâ Anti--Seize and Lubricating Compound/Nickle based anti--seize compound
Black Silicone G.E. Silmateâ Silicone Rubber
MAGNAFLUXâ Products: Penetrant (SKL--HF/S) Developer (SKD--NF--ZP--9B) Cleaner/Remover
Bluing Agent (SKC--NF/ZC--7B)
Bluing Paste Permatexâ Non Drying Prussian Blue (mfg. by Loctite Corporation)
Ceramic bonded high temperature
solid film lubricant Lube--Lokâ 1000 or equivalent

Cleaning Solvent/Mineral Spirits Amisolä Solvent (mfg. by Standard Oil)

Dielectric Silicone Grease Dow Corning DC--200, G.E. G--624, GC Electronics 25
Engine Oil See Lubricating Oil
Scotch Weldâ No. 270 B/A Black Epoxy Potting Compound/Adhesive, P/N’s. A and B
Epoxy Sealant (3M ID No. 62--3266--7430--6 (PA)
Gasket Adhesive Scotch Gripâ 847 Rubber and Gasket Adhesive (mfg. by 3M), 3M ID No. 62--0847--7530--3
Heavy Lube Oil Vactraâ 80W90 Gear Oil (mfg. by Mobil)
High Temperature Fluorinated
Grease Krytoxâ GPL--206 (P/N 489341)

Liquid Soap Doveâ Dishwashing Liquid

Lithium Grease See Molycoteä Paste G
Locquicâ Primer “T” Item No. 74756 (mfg. by Loctite Corporation)
Loctiteâ 242 Loctiteâ Item No. 24241/a blue colored removable thread locking compound
Loctiteâ 271 Loctiteâ Item No. 27141/a red colored thread locking compound
Loctiteâ Compound 40 Loctiteâ Item No. 64041/High Temperature Retaining Compound 40
Loctiteâ Hydraulic Sealant Loctiteâ Item No. 56941
Loctiteâ RCt/609 Loctiteâ Item No. 60931
Loctiteâ 620 Loctiteâ Item No. 620--40/High Temperature Retaining Compound
Lubricating Oil/Engine Oil New oil of the type used in the crankcase
Magnafluxä See Bluing Agent
Metal Assembly Spray Dow Corning Lubricant G--n
Dow Corning Molycoteä Paste G or CITGO Lithoplexâ Grease NLGI No. 2 Product Code 55--340/
Molycoteä Paste G a molybdenum--based grease
O--ring Lubricant Parker Super O--Lubeä/dry silicone lubricant
Permatexâ Aviation
Form--A--Gasketâ Sealant Liquid Loctiteâ Item No. 3D

Permatexâ Form--A--Gasketâ
No. 2 Sealant Loctiteâ Item No. 2C

Permatexâ High Tack

Spray--A--Gasketâ Sealant Loctiteâ Item No. 99MA

Pipe Sealant Perma Lokâ Heavy Duty Pipe Sealant with Teflon, Item No. LH050
Stelliteâ Stelliteâ is a registered trademark of Stoody Deloro Stellite, Inc.
WD--40â WD--40â is a registered trademark of the WD--40 Company.

1.15 -- 22 FORM 6287 First Edition