CONTENTS. List of Illustrations List of Tables How To Use This Manual CHAPTER 1 SAFETY AND GENERAL Section 1.00 Warning Tags And Decal Locations

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1 List of Illustrations List of Tables How To Use This Manual CHAPTER 1 SAFETY AND GENERAL Section 1.00 Warning Tags And Decal Locations Warning Tags And Decal Locations Section 1.05 Safety Safety Introduction Safety Tags And Decals Equipment Repair And Service Acids Batteries Body Protection Chemicals General Cleaning Solvents Liquid Nitrogen/Dry Ice Components Heated Or Frozen Interference Fit Cooling System Electrical General Ignition Exhaust Fire Protection Fuels General Gaseous Liquid Intoxicants And Narcotics Pressurized Fluids/Gas/Air Protective Guards Springs Tools Electrical Hydraulic Pneumatic Weight Welding General On Engine Section 1.10 Rigging And Lifting Engines Rigging And Lifting Engine Section 1.15 General Information Introduction To The VGF Models General Information Serial Numbers And Engine Nameplate Instrument Panel Gauges Engine Component Crankcase Crankshaft Connecting Rods Pistons Cylinder Sleeves Camshaft Cylinder Head And Valves Turbocharger Intercooler Carburetor Intake Manifold Exhaust Manifold Engine Identification Views F18/H Left Side View Right Side View Front View Rear View Engine Identification Views L36/P Left Side View Right Side View Front View Rear View General Specifications Specific Fastener Torque Values General Torque Values English/metric Conversions Index Of Sealants, Adhesives, And Lubricants CHAPTER 2 ENGINE SYSTEMS Section 2.00 Speed Governing System Speed Governing System F18/H24 Governor Governing Linkage Quick Start Oil Supply Governor Throttle Control L36/P48 Governor Governor Drive (If Equipped) Governor Linkage Air Actuator For PSG Governors Control Panel Section 2.05 Fuel System Fuel System Components Carburetor Carburetor GL Fuel Pressure Regulator GL Balance Line Carburetor GLD/GSID Fuel Pressure Regulator zero pressure (If Equipped) Throttle Valves Manual Fuel Shutoff Valve (If Equipped) Operation Custom Engine Control Air/Fuel Module System System Operator Interface Theory Of Operation iii

2 Section 2.10 Ignition System CEC Ignition Module System Magneto Ignition System Ignition System Component CEC Ignition Module CEC Hall-effect Pickup CEC Timing Magnets High Tension Leads Wiring Harness Ignition Coils Spark Plugs Hazardous Location Ignition System (CSA Approved) Component (Optional) Ignition Switch Shielded Ignition Coil Shielded Spark Plug Primary Wiring Secondary Wiring Ignition Module Polarity CEC Generator System CEC Knock Detection Module System F18/H24 Only System Operator Interface Components Ignition Systems Served CEC Detonation Sensing Module L36/P Section 2.15 Air Intake System Air Intake System Intercooler Carburetors And Intake Manifolds Intake Manifold Air Cleaners Section 2.20 Turbocharger System Turbocharger System Turbochargers Turbocharger Wastegate (If Equipped) Turbocharger Operation Turbocharger Lubrication Turbocharger Inspection Operation And Tips Section 2.25 Cooling System Cooling System F18/H Jacket Water Pump (If Equipped) Auxiliary Water Pump (If Equipped) Thermostat Housing Auxiliary Cooling Thermostatic Valve Surge Tank (If Equipped) Cooling System L36/P Jacket Water Pump (If Equipped) Auxiliary Water Pump (If Equipped) Jacket Water Heater (If Equipped) Thermostat Housing (If Equipped) Auxiliary Water Thermostatic Valve Section 2.30 Lubrication System Lubrication System Oil Flow F18/H L36/P Oil Pump And Suction Line Oil Pump Oil Filters And Housing Oil Cooler Pressure Regulating Valve And Oil Thermostat Piston Cooling Control Valve Magnetic Plug Oil Level Regulator Optional Oil Pressure Section 2.35 Exhaust System Exhaust System Exhaust Manifold Exhaust Thermocouples (If Equipped) Exhaust System (Customer Supplied) Turbocharger Operation Section 2.40 Crankcase Breather System Crankcase Breather System F18/H24 Breather Systems L36/P48 Breather Systems Connecting Tube Oil Separator Assembly Adjusting Valve GL Adjusting Valve L36/P48 GLD/GSID Only Oil Separator Drain Breather System Specifications Catalytic Converter Or Heat Recovery Silencer Arrangement GL Only Crankcase Pressure Relief Valve L36/P48 Only Section 2.45 Starting System Air/Gas Starter Operation Electric Starter Operation Section 2.50 Engine Protection Shutdown System Engine Protection Shutdown System Operation K-Type Thermocouples Thermocouple Junction Box Manual Shutdown Lever iv

3 Ignition Switch Customer Supplied Safety Shutdown Switches Optional Instrument Panel Pressure And Temperature Switch Calibration CHAPTER 3 ENGINE STARTUP AND SHUTDOWN Section 3.00 Engine Startup And Shutdown Prestart Inspection Startup Procedures Cold Weather Starting Pressurizing Engines Without Preheater Restart Procedure Shutdown Procedure StartUp Procedure Deltec Carburetion Planned ShutDown Deltec Carburetion Emergency ShutDown Deltec Carburetion StartUp Procedure Generator Applications StartUp Procedure Compressor Applications CHAPTER 4 MAINTENANCE AND STORAGE Section 4.00 Speed Governing System Governor System Quick Start Governor Oil Supply F18/H24 Only Magnetic Speed Sensor Gap Adjustment PSG, 4024 And EG3P Governor Only Section 4.05 Fuel System F18/H24 And L36/P48 Engines Physical Requirements F18G And H24G With Impco 200 D, 400 VF3 Or 600 VFI Carburetors Startup Preliminary Settings After Engine Startup Final Fuel System Adjustments F18GL/H24GL And L36GL/P48GL With Impco 200 D Or 600 VFI Carburetors Natural Gas (Blow-thru Carburetion) Startup Preliminary Settings After Engine Startup Final Fuel System Adjustments F18GL/H24GL With Impco 400 VF3 Carburetors Natural Gas Or Low Compression Ratio (Natural Gas Or Propane) (Blow-thru Carburetion) Startup Preliminary Settings After Engine Startup Final Fuel System Adjustments F18GLD/H24GLD And L36GLD/P48GLD With Impco 600 VFI Carburetors (Draw-thru Carburetion) Startup Preliminary Settings After Engine Startup Final Fuel System Adjustments F18GLD/H24GLD And L36GLD/P48GLD With Deltec Carburetors (Draw-thru Carburetion) Physical Requirements Startup Preliminary Settings After Engine Startup Final Fuel System Adjustments L36GSID/P48GSID With Deltec Carburetors Natural Gas Or Propane (Draw-thru Carburetion) Physical Requirements Startup Final Fuel System Adjustments F18/H24GSID With Impco 600 VFI Carburetor Natural Gas (Draw-thru Carburetion) Startup Preliminary Settings After Engine Startup Final Fuel System Adjustments F18G/H24G Dual Fuel Natural Gas Or Propane Startup Preliminary Settings After Engine Startup F18G/H24g Dual Fuel Natural Gas Or Digester Gas Fuel System Adjustment Prior To Engine Startup Preliminary Settings After Engine Startup F18/H24GLD And L36/P48GLD/GSID With Deltec Carburetors Dual Fuel Physical Requirements Fuel System Adjustment Procedure High Rating (HR) 12.1/13.7 Bar (176/200 BMEP) GLD/2 with Deltec Carburetors and Dungs Regulator Physical Requirements Fuel System Adjustment Procedure Section 4.10 Ignition System Ignition System Hall-effect Pickup CEC Ignition Module CEC Timing Magnet Cleaning And Inspection Magnetic Timing Disc Timing Magnets Hall-effect Pickup Installation Ignition Module Switch Settings Spark Plug Removal Standard Ignition v

4 vi Spark Plug Removal CSA Shielded Ignition Spark Plug Installation CSA Shielded Ignition CSA Shielded Ignition System Ignition Coils Shielded Ignition Timing Spark Plug Specifications Ignition Module Power supply Ignition Module Leds CEC Ignition Module Timing Adjustment Dynamic Basic Timing Specification CEC Magneto Installation Setting Ignition Timing Static Timing Adjustment Dynamic Basic Timing Specification CEC Generator Servicing Section 4.15 Air Intake System Air Intake System Air Filter Filter Replacement F18/H24G/GL Filter Replacement F18/H24GSID/GLD Filter Replacement L36/P48GL Filter Replacement L36/P48GSID/GLD Wastegate Vent Tube Section 4.20 Turbocharger System Turbocharger System Turbocharger Inspection Turbocharger Lubrication Turbocharger Operation Magnetic Plug Section 4.25 Cooling System Cooling System Standard Hot Water Cooling System Pretreatment Corrosion Mineral Scales And Fouling Water Treatment Jacket Water Circuit Initial Fill, F18/H Auxiliary Cooling Water Circuit Initial Fill, F18/H Cooling Water System Air Bleed, F18/H Jacket Water And Auxiliary Cooling Water Circuits Drain And Flush, F18/H Jacket Water Circuit Initial Fill, L36/P Auxiliary Water Circuit Initial Fill, L36/P Cooling water System Air Bleed L36/P Initial Air Bleed (Engine Not Running) Jacket Water System Auxiliary Water System Check Air Bleed (Engine Not Running) Jacket Water System Auxiliary Water System Final Air Bleed (Engine Not Running) Jacket Water System Auxiliary Water System Jacket Water And Auxiliary Water Circuits Drain And Flush, L36/P Jacket Water Heater F18/H Jacket Water Heater L36/P Section 4.30 Lubrication System Oil Preheat/Prelube Operation Prelube (For Automatic Start Units) Oil Pressure Gauge Oil Specifications Oil Designations Oil Additives Oil Recommendations Catalyst Contaminants Oil Filtration Requirements Extended Oil Drain Intervals Waukesha Cogeneration Installations Oil Recommendations Sour Gas, Digester Gas, And Landfill Gas Oil Recommendations Recommended Oil For Landfill Gas Applications Recommendations For Fuel Gas Filtration Of Solids And Liquids Solid Particulate Removal: Liquid And Aerosol Removal From Fuel Gas: Design Criteria: Recommended Coalescing Filter: Oil Condemning Limits Oil Viscosity Selection Multi-viscosity Oils Synthetic Oils Low Ambient Temperature Operation Oil Consumption Rates Formulas For Determining Oil Consumption Rates Oil Change Intervals Oil Change Procedure F18/H Oil Change Procedure L36/P Microspin Cleanable Oil Filtering System Initial Microspin Centrifuge Inspection Starting Microspin Centrifuge Servicing Microspin Centrifuge Centrifuge Cleanable Filter Elements Disassembly Of Microspin P/N Centrifuge Cleaning Of Microspin Centrifuge (P/N ) Assembly Of Microspin Centrifuge (P/N ) Disassembly Of Microspin Centrifuge (P/N )

5 Cleaning Microspin Centrifuge (P/N ) Assembly Of Microspin Centrifuge Shell And Tube Oil Cooler Prelube/Postlube System Prelube/Postlube Specifications Electric Prelube Motor Section 4.35 Exhaust System Exhaust System Backpressure Measurement Section 4.40 Crankcase Breather System Crankcase Breather System Oil Separator Filter Element Replacement F18 GL and H24 GL closed Breather system Crankcase Pressure Crankcase Pressure Check Breather ejector adjustment Crankcase Pressure Adjustment: Closed Breather Butterfly Valve Adjustment Crankcase Breather Regulator Cleaning And Inspection Regulator Foam Cleaning And Inspection Crankcase Pressure Relief Valve L36/P Section 4.45 Starting System Electric Starter Air/Gas Starter Air Starter Lubricator Alternator Battery Connection Alternator Servicing Alternator Noise Alternator V-belt Tension V-Belt Section 4.50 Engine Protection Shutdown System Engine Protection Shutdown System K-Type Thermocouples Inspection Manual Shutdown Lever Pressure And Temperature Switch Calibration Optional Instrument Panel Recommended Shutdown Setpoints Oil Header Pressure Oil Header Temperature BMEP Engines, Normal Temperature BMEP Engines, Optional Temperature BMEP Engines, Normal Temperature (GLD Only) Jacket Water Temperature BMEP Standard Cooling System BMEP Optional Temperature Cooling System BMEP Cooling System (GLD Only) Intake Manifold Temperature BMEP Normal Intercooler Temperature BMEP Optional Intercooler Temperature BMEP Normal Intercooler Temperature (GLD Only) Intake Manifold Pressure Engine Overspeed Shutdown System Operation KDM/DSM Knock Sensor Installation Routine Inspection Section 4.55 Valve Adjustment Rocker arm Cover Removal Standard Coil Flange Mounted Coil (CSA) Valve Adjustment Rocker arm Cover Installation Section 4.60 Schedule Chart Recommended Oil Change Intervals Engine Performance Record Section 4.65 Engine Storage Engine Storage Preservation Equipment And Material Sprays And Atomizers Waukesha Engine Preservative Oil Preservative Oil Usage Other Preservative Oils And Materials Engine Storage New Operational Internal Component Protection External Component Protection Non-Operational Engine Storage Used Operational Non-Operational Engines Returned To Service After Storage CHAPTER 5 TROUBLESHOOTING Section 5.00 Troubleshooting Troubleshooting Chart APPENDIX A INDEX Alphabetical Index... A-1 vii

6 WARRANTY INFORMATION Continuous Duty Applications...W-1 Excess of Continuous Duty Applications...W-2 Express Limited Warranty For Genuine Waukesha Service Parts...W-3 Express Limited Warranty For Custom Engine Control...W-4 viii

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