SECTION 1.15 GENERAL INFORMATION INTRODUCTION TO THE VGF MODELS GENERAL INFORMATION

Transcription

1 SECTION 1.15 GENERAL INFORMATION INTRODUCTION TO THE VGF MODELS Waukesha Engine, Dresser, Inc. manufactures both inline and vee block VGF engines. Inline engines are designated the F1 (6 cylinder) and H24 ( cylinder). Vee block engines are designated the L36 ( cylinder) and P4 (16 cylinder). The VGF F1 engine is a 6 cylinder, 4-cycle engine, and has a total cylinder displacement of 1 litres (6 cubic in.). The F1 bore and stroke is 152 x 165 mm (5. x 6.5 in.), and piston speed is. meters per second (150 feet per minute) at 0 rpm. The VGF H24 engine is an cylinder, 4-cycle engine, and has a total cylinder displacement of 24 litres (62 cu. in.). The H24 bore and stroke is 152 x 165 mm (5. x 6.5 in.), and piston speed is. meters per second (150 feet per minute) at 0 rpm. The VGF L36 model is a cylinder, 4-cycle engine, and has a total cylinder displacement of 2,13 cubic in. (35. litres). The L36 bore and stroke is 5. x 6.5 in. (152 x 165 mm) and piston speed is 150 feet per minute (. metres per second) at 0 rpm. The engine rotates in a counterclockwise direction (facing the flywheel). The VGF P4 model is a 16 cylinder, 4-cycle engine, and has a total cylinder displacement of 2,24 cubic in. (4. litres). The P4 bore and stroke is 5. x 6.5 in. (152 x 165 mm) and piston speed is 150 feet per minute (. metres per second) at 0 rpm (same as L36). The engine rotates in a counterclockwise direction (facing the flywheel). Both inline and vee block VGF engines are available in GL, GLD or GSID configurations. The F1/H24 engine also comes in a G configuration. The GL and GLD models have a compression ratio of :1. The GL LCR model (F1/H24 engines only) has a compression ratio of.:1. The G/GSID model has a compression ratio of.6:1. The F1/H24 G engine is a non-turbocharged rich combustion (stoichiometric) engine that operates on natural gas for reduced emissions. The GL engine operates on natural gas and is designed to burn a lean air/fuel mixture for low fuel consumption and reduced emissions. GL engines are equipped with a turbocharger that forces high velocity ambient air through the intercooler, carburetor and intake manifold, before entering the combustion chamber. The GLD engine is also a lean burn combustion engine, except this engine uses a draw-thru fuel system. The turbocharger draws the air/fuel mixture from the carburetors to the turbocharger, then forces the mixture into the intercooler, intake manifold and finally into the combustion chamber. This system allows operation with a much lower fuel pressure than the GL series. The GSID engine is a rich combustion (stoichiometric) engine that uses a draw-thru fuel system. The turbocharger draws the air/fuel mixture from the carburetors to the turbocharger, then forces the mixture into the intercooler, intake manifold and finally into the combustion chamber. The GSID is typically operated at a setting just rich of stoichiometric (usually when operating with a three way catalyst to produce very low NOx emissions). GENERAL INFORMATION SERIAL NUMBERS AND ENGINE NAMEPLATE The VGF engine nameplate provides the following information: model number, serial number, date inspected, special application approval number (power approval), valve clearance, compression ratio, firing order, governed speed, altitude limit at which an engine derate takes place, primary and secondary fuel ratings which show the fuel, minimum Waukesha Knock Index (WKI ), ignition timing, rated output in horsepower and kilowatts, and overload rating in horsepower and kilowatts (see Figure and Figure ). This nameplate is located on the forward end of the intake manifold (F1/H24) or the left bank intake manifold (L36/P4) (see Figure and Figure ). FORM 624 Third Edition

2 DRESSER Figure Current F1/H24 Nameplate DRESSER When requesting information, you will need to reference both the engine model and serial numbers. If the nameplate is defaced or detached, the serial number may be obtained directly off the crankcase. To locate it, look directly above the nameplate location, on the cylinder head deck of the crankcase. Figure Current L36/P4 Nameplate FORM 624 Third Edition

3 Figure VGF F1/H24 Nameplate Location Intake Manifold Vacuum/Pressure Gauge: displays the approximate intake manifold pressure or intake manifold vacuum downstream of the throttle plate (see Figure ). Oil Temperature Switchgage: monitors engine oil temperature at the oil filter housing (see Figure ). This switchgage should be adjusted so that the switchgage contacts close when the engine oil temperature exceeds a setpoint as specified in Section 4.50 Engine Protection Shutdown System Maintenance on page NOTE: Switchgages are not approved for, or supplied with, hazardous location (CSA approved) ignition equipped engines. Ammeter: monitors current output of the belt driven alternator option. Magneto On/Off Switch: is to be used as a normal or emergency shutdown switch. This switch will open the magneto ignition circuit (to ground) in the OFF position which blocks the current flow path and closes the magneto ignition circuit to allow current flow from the magneto to the transformer coils in the ON position (see Figure ). Pushbutton Start Switch: is used to complete the cranking circuit to the starter solenoid (electric starters) or to engage the starter valve (air/gas starters) (see Figure ). Figure VGF L36/P4 Nameplate Location INSTRUMENT PANEL GAUGES Oil Pressure Switchgage: monitors engine oil pressure at the main oil gallery (see Figure ). This switchgage should be adjusted so that the switchgage contacts close when the engine oil pressure falls below a setpoint as specified in Section 4.50 Engine Protection Shutdown System Maintenance on page Jacket Water Temperature Switchgage: monitors engine jacket water temperature at the water outlet header (see Figure ). This switchgage should be adjusted so that the switchgage contacts close when the engine jacket water temperature exceeds a setpoint as specified in Section 4.50 Engine Protection Shutdown System Maintenance on page Intake Manifold Temperature Gauge: monitors intake manifold charge temperature downstream of the intercooler (see Figure ). Setpoint depends on application. Electronic Tachometer: displays engine crankshaft revolutions per minute (rpm) with a digital readout (see Figure ). FORM 624 Third Edition

4 INTAKE MANIFOLD VACUUM/PRESSURE GAUGE OIL TEMPERATURE SWITCHGAGE OIL PRESSURE SWITCHGAGE JACKET WATER TEMPERATURE SWITCHGAGE INTAKE MANIFOLD TEMPERATURE SWITCHGAGE SHUTDOWN RESET ELECTRONIC TACHOMETER/HOURMETER MAGNETO ON/OFF SWITCH PUSHBUTTON START SWITCH Figure Instrument Panel ENGINE COMPONENT DESCRIPTION CRANKCASE The crankcase is made of a cast iron alloy with nodular iron main bearing caps. Main bearing caps are secured in place with two main bearing capscrews and two crossbolts per bearing. Upper and lower crankcase doors are provided to allow access to the camshaft, the crankshaft and connecting rods. The lubrication system is a full pressure system with a gear type pump and three external full flow filter cannisters. An engine mounted cooler reduces the oil temperature. CRANKSHAFT Waukesha VGF engines rotate in the standard counterclockwise direction when facing the flywheel. The forged steel crankshaft is dynamically balanced and fully counterweighted and supported by seven main bearings in the F1 and L36. The H24 and P4 use nine main bearings. A viscous vibration damper mounted on the front of the crankshaft reduces torsional stress. CONNECTING RODS The connecting rods are a drop forged alloy steel with a split serrated mating surface. PISTONS The pistons are made of an aluminum alloy, with a cast-in resist alloy top ring insert and a full floating piston pin. The pistons have a patented combustion bowl that allows the use of a lean air/fuel ratio mixture for fuel economy and reduced emissions. The piston and the crown are oil jet cooled and use three rings. CYLINDER SLEEVES The cylinder sleeves are replaceable, wet style and sealed with O-rings FORM 624 Third Edition

5 CAMSHAFT Pivoted roller cam followers are used to transmit camshaft motion to the valves. CYLINDER HEAD AND VALVES This engine uses individual valve-in-head cylinder heads. Two Stellite faced intake and two Stellite faced exhaust valves, with replaceable valve seats and guides are used in interchangeable cylinder heads. NOTE: Stellite is a registered trademark of Stoody Deloro Stellite Inc. TURBOCHARGER High efficiency, radial flow turbocharger(s) is mounted on top of the exhaust manifold on the engine. The turbocharger uses expanding exhaust gases to drive the compressor turbine and generate the required boost levels for the engine. INTERCOOLER A single box type intercooler is mounted on the engine. The intercooler on GL engines receives air from the turbocharger, cools the charge air and delivers the air to the carburetor. On GLD and GSID engines, the intercooler receives the air/fuel mixture from the carburetor, draws it through the turbocharger, then cools the air/fuel charge for delivery to the intake manifold. CARBURETOR The naturally aspirated G model is equipped with a side draft carburetor. The GL model has push-thru carburetion. The GLD and GSID models have draw-thru carburetion. Gas regulators are different depending on application and are generally engine mounted. The standard equipment air cleaner is an engine mounted, two stage, dry element air cleaner with a rain shield and service indicator. INTAKE MANIFOLD The air/fuel mixture passes through the intake manifold located on the left side of the engine. The individual ignition coils for each cylinder are mounted on the intake manifold(s). EXHAUST MANIFOLD The exhaust manifold is located on the right side of the engine and supplies the exhaust gases to drive the turbochargers. The manifold is jacket water cooled and sound damped with coolant that is supplied by water elbows from each cylinder head. FORM 624 Third Edition

6 ENGINE IDENTIFICATION VIEWS F1/H24 LEFT SIDE VIEW Exhaust Outlet 15. Engine Support 2. Turbocharger 16. Jack Screw 3. Instrument Panel 1. Oil Drain 4. Intake Manifold 1. Oil Filters 5. Lifting Eye 1. Oil Cooler 6. Intercooler 20. Auxiliary Water Thermostat. Hand Throttle 21. Magneto. Butterfly Valve 22. Vibration Damper. Carburetor 23. Jacket Water Inlet. Flywheel And Housing 24. Oil Fill. Engine Timing Window 25. Jacket Water Outlet. Auxiliary Water Piping 26. Jacket Thermostat Housing. Fuel Inlet 2. Governor. Engine Barring Device 2. Ignition Coils Figure Left Side View F1GL FORM 624 Third Edition

7 CEC Ignition Module 16. Oil Drain 2. Breather Baffle Box 1. Fuel Pressure Regulator 3. Exhaust Outlet 1. Auxiliary Water Piping 4. Instrument Panel 1. Oil Cooler 5. Lifting Eye 20. Oil Filters 6. Carburetor 21. Vibration Damper. Air Cleaner 22. Jacket Water Inlet. Air Filter Restriction Indicator 23. Hall-effect Pickup (CEC Ignition). Hand Throttle 24. Volt DC Generator (CEC Ignition). Butterfly Valve 25. Oil Fill. Flywheel And Housing 26. Jacket Water Outlet. Engine Timing Window 2. Thermostat Housing. Fuel Shutoff Valve 2. Ignition Coils. Engine Support 2. Breather Oil Separator 15. Jack Screw 30. CEC Junction Box Figure Left Side View H24G FORM 624 Third Edition 1.15-

8 RIGHT SIDE VIEW Heat Shield. Auxiliary Water Piping 2. Exhaust Outlet 15. Jack Screw 3. Wastegate 16. Engine Support 4. Ignition Coils 1. Auxiliary Water Pump 5. Exhaust Manifold 1. Auxiliary Water Inlet 6. Jacket Water Thermostat Housing 1. Oil Dipstick. Jacket Water Outlet 20. Starter Motor Location. Jacket Water Header 21. Oil Drain. Gear Housing 22. Flywheel And Housing. Jacket Water Inlet 23. Breather Oil Separator. Jacket Water Pump 24. Intercooler. Vibration Damper 25. Air Cleaner. Breather Piping Figure Right Side View H24GL FORM 624 Third Edition

9 Exhaust Outlet. Engine Support 2. Heat Shield 15. Jack Screw 3. Wastegate 16. Auxiliary Water Inlet 4. Exhaust Manifold 1. Auxiliary Water Piping 5. Ignition Coils 1. Water Header 6. Spark Plug Location 1. Fuel Inlet. Jacket Water Thermostat Housing 20. Oil Dipstick. Jacket Water Outlet 21. Starter Motor Location. Jacket Water Bypass Outlet 22. Oil Drain. Jacket Water Inlet 23. Air Cleaner. Vibration Damper 24. Flywheel And Housing. Gear Housing 25. Intercooler. Auxiliary Water Pump 26. Carburetor Adjust Figure Right Side View H24GLD, Impco Carburetor FORM 624 Third Edition 1.15-

10 Exhaust Outlet. Jacket Water Header 2. Heat Shield. Starter Motor Location 3. Wastegate 15. Oil Drain 4. Exhaust Manifold 16. Flywheel and Housing 5. Jacket Water Outlet 1. Breather Oil Separator 6. Lifting Eye 1. Intercooler. Jacket Water Header Inlet 1. Auxiliary Water Inlet. Vibration Damper 20. Air Duct. Gear Housing 21. Carburetor. Jack Screw 22. Main Adjusting Screw. Engine Support 23. Fuel Inlet. Dip Stick 24. Ignition Coils Figure Right Side View F1GLD, Deltec Carburetor And High Temperature Application FORM 624 Third Edition

11 Exhaust Outlet 15. Auxiliary Water Pump 2. Heat Shield 16. Auxiliary Water Inlet 3. Wastegate 1. Auxiliary Water Piping 4. Exhaust Manifold 1. Water Header 5. Jacket Water Thermostat Housing 1. Dip Stick 6. Jacket Water Outlet 20. Breather Oil Separator. Thermostat Housing Air Bleed 21. Oil Drain. Breather Piping 22. Starter Location. Jacket Water Pump 23. Flywheel And Housing. Jacket Water Inlet 24. Air Duct. Vibration Damper 25. Fuel Inlet. Gear Housing 26. Intercooler. Engine Support 2. Carburetor. Jack Screw 2. Ignition Coils Figure Right Side View F1GSID FORM 624 Third Edition 1.15-

12 FRONT VIEW Exhaust Outlet. Oil Cooler 2. Jacket Water Outlet. Fuel Shutoff Valve 3. Spark Plug Location. Barring Device 4. Lifting Eye 15. Jack Screw 5. Ignition Coils 16. Engine Support 6. Breather Oil Separator 1. Vibration Damper. Intake Manifold 1. Jacket Water Inlet. Oil Fill 1. Jacket Water Pump. Gear Housing 20. Water Header. Auxiliary Water Piping 21. Jacket Water Thermostat Housing. Fuel Pressure Regulator 22. Air Cleaner Figure Front View F1G/H24G FORM 624 Third Edition

13 Exhaust Outlet 15. Barring Device 2. Turbocharger 16. Engine Support 3. Jacket Water Outlet 1. Jack Screw 4. Turbocharger To Intercooler Air Connection 1. Oil Pan 5. Spark Plug Location 1. Vibration Damper 6. Lifting Eye 20. Jacket Water Inlet. Ignition Coils 21. Jacket Water Pump. Breather Oil Separator 22. Gear Housing. Intake Manifold 23. Water Header. Oil Fill 24. Air Cleaner. Fuel Inlet 25. Jacket Water Thermostat Housing. Auxiliary Water Thermostat 26. Wastegate. Auxiliary Water Piping 2. Heat Shield. Oil Cooler Figure Front View F1GL/H24GL FORM 624 Third Edition 1.15-

14 REAR VIEW Exhaust Outlet. Auxiliary Water Piping 2. Turbocharger. Auxiliary Water Thermostat 3. Heat Shield. Timing Window 4. Air Cleaner. Fuel Inlet 5. Intercooler 15. Carburetor 6. Starter Motor Location 16. Instrument Panel. Engine Support 1. Breather Oil Separator. Jack Screw 1. Ignition Coils. Oil Drain 1. Intercooler Air Inlet. Flywheel And Housing 20. Lifting Eye Figure Rear View F1GL/H24GL FORM 624 Third Edition

15 Exhaust Outlet. Fuel Pressure Regulator 2. Air Cleaner. Timing Window 3. Air Filter Restriction Indicator. Carburetor 4. Auxiliary Water Piping. Butterfly Valve 5. Starter Motor Location 15. Intake Manifold 6. Engine Support 16. Instrument Panel. Jack Screw 1. Breather Oil Separator. Oil Drain 1. Ignition Coils. Flywheel And Housing 1. Lifting Eye. Fuel Shutoff Valve Figure Rear View F1G FORM 624 Third Edition

16 Exhaust Outlet. Fuel Shutoff Valve 2. Air Cleaner Assembly. Fuel Pressure Regulator 3. Air Filter Restriction Indicator. Timing Window 4. Carburetor. Butterfly Valve 5. Fuel Piping 15. Instrument Panel 6. Starter Motor Location 16. Intake Manifold. Engine Support 1. Breather Oil Separator. Jack Screw 1. Ignition Coils. Oil Drain 1. Auxiliary Water Piping. Flywheel And Housing 20. Lifting Eye Figure Rear View F1G/H24G, Dual Fuel FORM 624 Third Edition

17 ENGINE IDENTIFICATION VIEWS L36/P4 LEFT SIDE VIEW Hand Throttle. Oil Filter Housing 2. Engine Speed Governor. DSM Control Module 3. Intake Manifold (Left Bank). DSM Filter 4. Magnetic Timing Pickup Location. Jacket Water Inlet 5. Engine Timing Window 15. Jacket Water Outlet 6. Lifting Eye 16. Exhaust Outlet. Flywheel Housing 1. Wastegate. Engine Barring Device 1. Intercooler. Ignition Module 1. Air Cleaner Assembly (2). Oil Fill 20. Carburetor (GL) Figure Left Side View L36GL FORM 624 Third Edition

18 RIGHT SIDE VIEW Exhaust Manifold Assembly (Right Bank). Lifting Eye (4) 2. Engine Breather System. Magnetic Timing Pickup Location 3. Intake Manifold Assembly (Right Bank). Air Cleaner Assembly (2) 4. Auxiliary Water Thermostat. Fuel Inlet 5. Oil Cooler 15. Main Adjustment Screw 6. Oil Cooler Drain Plug 16. Carburetor. Auxiliary Water Pump 1. Closed Breather Butterfly Valve. Explosion Relief Valve 1. Intercooler. Starter Location 1. Turbocharger. Flywheel Housing 20. Exhaust Outlet Figure Right Side View P4GLD Or GSID FORM 624 Third Edition

19 FRONT VIEW Exhaust Outlet. Oil Filter Housing 2. Jacket Water Outlet. Oil Drain 3. Ignition Coil (). Oil Cooler 4. Lifting Eye (4). Cylinder Head 5. Intake Manifold Assembly. Rocker Cover 6. Exhaust Manifold Assembly. Engine Breather. Vibration Damper. Jacket Water Inlet Figure Front View L36/P4GL FORM 624 Third Edition

20 REAR VIEW Carburetors (GL). Oil Cooler 2. Intercooler. Flywheel 3. Air Cleaner Assembly (2). Oil Filter Housing 4. Fuel Inlet (GL). Rear Gear Train Housing 5. Intake Manifold Assembly. Lifting Eye (4) 6. Flywheel Housing. Hand Throttle. Starter Location. Governor Figure Rear View L36/P4GL FORM 624 Third Edition

21 Fuel Inlet (GLD). Flywheel 2. Air Cleaner Assembly (2). Oil Drain 3. Intake Manifold Assembly (2). Oil Filter Housing 4. Flywheel Housing. Rear Gear Train Housing 5. Lifting Eye (4). Hand Throttle 6. Starter Location. Governor. Oil Cooler Figure Rear View L36/P4GLD or GSID FORM 624 Third Edition

22 GENERAL SPECIFICATIONS Table Model VGF F1/H24/L36/P4 General Specifications (Part 1 of 3) ENGINE MODEL F1 H24 L36 P4 Type 4-cycle overhead valve 4-cycle overhead valve 4-cycle overhead valve 4-cycle overhead valve Aspiration, G Naturally aspirated Naturally aspirated Aspiration, GL, GLD, GSID Number of cylinders Bore x stroke Turbocharged, intercooled Inline-6, 4-valves per cylinder 152 x 165 mm (5. x 6.5 in.) Turbocharged, intercooled Inline-, 4-valves per cylinder 152 x 165 mm (5. x 6.5 in.) Turbocharged, Intercooled 60 V, 4-valves per cylinder 152 x 165 mm (5. x 6.5 in.) Turbocharged, Intercooled 60 V16, 4-valves per cylinder 152 x 165 mm (5. x 6.5 in.) Displacement 1 litres (6 cu. in.) 24 litres (62 cu. in.) 35. litres (213 cu. in.) 4. litres (224 cu. in.) G/GL/GLD Compression ratio :1 :1 :1 :1 GL Low Compression ratio.:1.:1 GSID Compression ratio.6:1.6:1.6:1.6:1 Speed range - G, GSID, GL, GLD 00 0 rpm 00 0 rpm rpm Low Speed 00 0 rpm High Speed rpm Low Speed 00 0 rpm High Speed Speed range - GLD/ rpm 1500 rpm 1500 rpm 1500 rpm Piston speed - G, GSID, GL, GLD Piston speed - GLD/2.25 m/sec (150 0 rpm.1 m/sec ( rpm.25 m/sec (150 0 rpm.1 m/sec ( rpm.25 m/sec. (150 0 rpm.1 m/sec. ( rpm.25 m/sec. (150 0 rpm.1 m/sec. ( rpm Low idle rpm rpm rpm rpm BEARINGS MAIN Number Diameter x width Total projected area/ bearing Diameter x width Total projected area/ bearing Sump capacity, including filter and cooler Main filter Normal oil pressure Normal oil pressure: F1/H24GSID/GL/GLD at 5 C (15 F) Oil Temp 5 x 46 mm (5.32 x 1.1 in.) 434. sq. cm (6.4 sq. in.) 5 x 46.0 mm (4.53 x 1.1 in.) 31.4 sq. cm (4.2 sq. in.) 5 x 46 mm (5.32 x 1.1 in.) 55.1 sq. cm (6. sq. in.) BEARINGS CRANKPIN 5 x 46.0 mm (4.53 x 1.1 in.) sq. cm (65.6 sq. in.) LUBRICATION SYSTEM 160 x 52 mm (6.30 x 2.05 in.) 52.4 sq. cm (0.4 sq. in.) 5 x 46.0 mm (4.53 x 1.1 in.) 634. sq. cm (.4 sq. in.) 160 x 52 mm (6.30 x 2.05 in.) 4. sq. cm (6.2 sq. in.) 5 x 46.0 mm (4.53 x 1.1 in.) 46.4 sq. cm (1.2 sq. in.) 3.3 litres (22 gallons) 6 litres (2 gallons) 163 litres (43 gallons) 216 litres (5 gallons) 15 micron 0% efficiency kpa (6 3 psi) 51 ±41 kpa (5 ±6 psi) 15 micron 0% efficiency kpa (6 3 psi) 51 ±41 kpa (5 ±6 psi) 15 micron 0% efficiency kpa (4 63 psi) 51 ±41 kpa (55 ± psi) 15 micron 0% efficiency kpa (4 63 psi) Low oil pressure alarm 26 kpa (40 psi) 26 kpa (40 psi) 26 kpa (40 psi) 26 kpa (40 psi) Low oil pressure shutdown setpoint 241 kpa (35 psi) 241 kpa (35 psi) 241 kpa (35 psi) 241 kpa (35 psi) Prelube duration Prelube pressure at 24 C (5 F) Oil Temp Prelube flow Postlube (after hot shutdown) 30 seconds every 30 minutes 30 seconds every 30 minutes 5 minutes before each engine start or 5 minutes each hour when not running 5 minutes before each engine start or 5 minutes each hour when not running kpa (25 psi) kpa (25 psi) kpa (25 psi) kpa (25 psi) 3..2 l/minute ( gpm) 3..2 l/minute ( gpm) 3..2 l/minute ( gpm) 3..2 l/minute ( gpm) 5 minutes 5 minutes 5 minutes 5 minutes FORM 624 Third Edition

23 Table Model VGF F1/H24/L36/P4 General Specifications (Continued), (Part 2 of 3) ENGINE MODEL F1 H24 L36 P4 Normal oil header temperature Crankcase pressure, open system Crankcase pressure, closed system Jacket water capacity, engine only Auxiliary water capacity, engine only Maximum inlet head, water pump Minimum inlet head, water pump Normal temperature range at psi High jacket water temperature setpoint Jacket water inlet flange, ANSI 5 lb. Jacket water outlet flange, ANSI 5 lb. (size 0 per DIN 256 mm) G - Natural gas pressure at regulator GSID - Natural gas pressure at regulator GL - Natural gas pressure at regulator GLD - Natural gas pressure at regulator G - Natural gas inlet pipe size GSID - Natural gas inlet pipe size GL - Natural gas inlet pipe size Maximum permissible back pressure Exhaust outlet, pipe flange, ANSI 5 lb. G Exhaust outlet, pipe flange, ANSI 5 lb. GSID, GL, GLD Maximum permissible restriction High intake manifold air temp. shutdown setpoint (0 F intercooler H 2 O) High intake manifold air temp. protection setpoint (5 F intercooler H 2 O) LUBRICATION SYSTEM (CONTINUED) 5 C (15 F) 5 C (15 F) 5 C (15 F) 5 C (15 F) CRANKCASE BREATHER SYSTEM zero to +6 mm (+3.0 in.) H 2 O 6 mm ( 3.0 in.) to zero H 2 O COOLING SYSTEM 60 litres (16 gallons) 5 litres (20 gallons) 166 litres (44 gallons) 21 litres (5 gallons) 23 litres (6 gallons) 23 litres (6 gallons) 5 litres (15 gallons) 5 litres (15 gallons).5 m (2 ft.).5 m (2 ft.) 15 m (50 ft.) 15 m (50 ft.) See Engineering Standard Sheet S424-1 C ( 15 F) 1 C ( 15 F) 1 C ( 15 F) 1 C ( 15 F) 3 C (200 F) 3 C (200 F) 6.2 mm (3 in.) 6.2 mm (3 in.) 2 mm (4 in.) 2 mm (4 in.) 6.2 mm (3 in.) 6.2 mm (3 in.) 6.2 mm (3 in.) 6.2 mm (3 in.) FUEL SYSTEM 34-6 kpa (5 - psig) 34-6 kpa (5 - psig) 203 mm ( in.) H 2 O minimum 26 kpa (25 40 psig) 50 mm (20 in.) H 2 O minimum 203 mm ( in.) H 2 O minimum 26 kpa (25 40 psig) 50 mm (20 in.) H 2 O minimum 203 mm ( in.) H 2 O minimum 345 kpa (25 50 psig) 203 mm (.0 in.) H 2 O minimum 203 mm ( in.) H 2 O minimum 345 kpa (25 50 psig) 203 mm (.0 in.) H 2 O minimum 3.1 mm (1.5 in.) NPT 3.1 mm (1.5 in.) NPT 50. mm (2.0 in.) NPT 50. mm (2.0 in.) NPT 50. mm (2.0 in.) NPT 50. mm (2.0 in.) NPT 31. mm (1.25 in.) NPT 31. mm (1.25 in.) NPT 50. mm (2.0 in.) NPT 50. mm (2.0 in.) NPT EXHAUST SYSTEM 31 mm (15 in.) H 2 O 31 mm (15 in.) H 2 O 31 mm (15 in.) H 2 O 31 mm (15 in.) H 2 O mm (6 in.) mm (6 in.) 203 mm ( in.) 203 mm ( in.) 254 mm ( in.) 254 mm ( in.) AIR INDUCTION SYSTEM 31 mm (15 in.) H 2 O 31 mm (15 in.) H 2 O 31 mm (15 in.) H 2 O 31 mm (15 in.) H 2 O 1 C (160 F) 1 C (160 F) 46 C (5 F) 46 C (5 F) FORM 624 Third Edition

24 Table Model VGF F1/H24/L36/P4 General Specifications (Continued), (Part 3 of 3) ENGINE MODEL F1 H24 L36 P4 STARTING SYSTEM Electric starting 24 volts DC 24 volts DC 24 volts DC 24 volts DC Air pressure starting.3 bar (150 psi).3 bar (150 psi).3 bar (150 psi).3 bar (150 psi) MISCELLANEOUS Heaviest engine part - cylinder block assembly 522 kg (50 lb.) 64 kg (1530 lb.) 0 kg (200 lb.) 160 kg (300 lb.) Heaviest engine part - top overhaul, cylinder head 36 kg (0 lb.) 36 kg (0 lb.) 36 kg (0 lb.) 36 kg (0 lb.) assembly Recommended minimum spacing between engines mm (36 in.) mm (36 in.) 1524 mm (60 in.) 1534 mm (60 in.) Recommended minimum overhead clearance 2 m (6 ft.) 2 m (6 ft.) 2 m (6 ft.) 2 m (6 ft.) Weight - approximate dry 2500 kg (5500 lb.) 320 kg (200 lb.) 500 kg (,200 lb.) 660 kg (,00 lb.) Flywheel housing Number of teeth on ring gear SAE No. 0 (Same as SAE No. 0 except metric taps) SAE No. 0 (Same as SAE No. 0 except metric taps) Firing order 1, 5, 3, 6, 2, 4 1, 4, 2, 6,, 5,, 3 SAE No. 00 (Same as SAE No. 0 except metric taps) SAE No. 00 (Same as SAE No. 0 except metric taps) R 6L 5R 2L 3R 4L 6R 1L 2R 5L 4R 3L 1R 1L 4R 4L 2R 2L 6R 6L R L 5R 5L R L 3R 3L FORM 624 Third Edition

25 SPECIFIC FASTENER TORQUE VALUES GENERAL INFORMATION Table lists critical fastener torque specifications for the F1/H24 engine. Fasteners not listed here should be tightened according to the general torque specifications listed in Table Table Table F1/H24 Specific Engine Torques NOTE: *= Oil Lubricated ITEM NEWTON- METERS (N m) FOOT-LBS (ft-lb) FASTENER SPECIFICATIONS Cam gear 1 60 P/N 206, M x 45 mm Connecting rod capscrews * * P/N A/B Crankshaft counterweight bolts P/N Exhaust manifold to cylinder head screws 2 53 P/N 30525, M x 150 Grade. P/N 30524, M x 50 Grade. Anti-Seize Flywheel capscrews P/N B, M16 x 1.5 x 0 mm, Grade. Front crankshaft hub capscrews 1 P/N 25402, M x 0, Grade. Head stud to crankcase 2 P/N C Head stud nut *40 *354 P/N Idler gear 2 20 P/N 202, M x 20 mm Intake manifold to cylinder head screws M, Loctite 242 M, Loctite 242 Jacket water pump front impeller nut P/N B, Apply Loctite 242 Jacket water pump center nut 16 4 P/N Jacket water pump rear nut 2 P/N 30443, Apply Loctite 242 Knock sensor Magneto drive nut 0 5 P/N 23315, M20, Grade, Apply Loctite 242 Magneto drive nut 0 5 P/N WS05066, M16, thin nut, Apply Loctite 242 Oil pump cover P/N 2033, M x 25 mm Oil pump to crankcase 65 P/N 2024, M x 45 mm Oil pan 51 3 P/N 206, M x 30 mm Apply Loctite 242 Oil pump idler gear 6 0 P/N 35046, M x 0, Grade. Apply Loctite 242 Piston cooling jets M Hollow Screw Rocker arm adjustment nuts 4 55 P/N Rocker arm support capscrews 3 2 P/N 2032, M, Grade Rocker cover nuts 3 2 P/N 2003, M Spark plugs Spark plug tube to cylinder head * * FORM 624 Third Edition

26 Table lists critical fastener torque specifications for the L36/P4 engine. Fasteners not listed here should be tightened according to the general torque specifications listed in Table Table Table L36/P4 Specific Engine Torques ITEM NEWTON- METERS (N m) FOOT-LBS (ft-lb) FASTENER SPECIFICATIONS Auxiliary water pump front nut 20. P/N , M Flange Nut Loctite 21 Auxiliary water pump rear gear nut P/N , M Flange Nut Loctite 21 Connecting rod capscrews * * P/N A/B Crankshaft counterweight capscrews P/N Camshaft driven gear capscrews 5 2 P/N WS15 M x 30 mm, Grade. Crankshaft damper adapter to front of crankshaft P/N SHCS M16 x 1.5, Grade. Exhaust manifold to cylinder head capscrews 2 53 P/N 30525, M x 150 mm Grade. P/N 30524, M x 50 mm Grade. Anti-Seize Flywheel spacer to rear of crankshaft P/N SHCS M1, Grade. Flywheel capscrews to adapter P/N WS2053, M16 x 0 mm, Grade. Head stud to crankcase 2 P/N E Head stud nut Intake manifold to cylinder head capscrews *15 N m 3 N m 40 N m 51 *6 ft-lb 231 ft-lb 34 ft-lb 3 65 P/N M, Loctite 242 M, Loctite 242 Jacket water pump front impeller nut 2 5 P/N A Loctite 242 Jacket water pump rear gear nut *16 *0 P/N 305, M1 x 1.5 Knock sensor Magneto drive nut , M20, Grade Main bearing stud to crankcase 2 P/N Oil pan 5 2 P/N 25632, M 30 mm Grade. Oil pan door 26 1 P/N Oil pump drive gear nut P/N , M34 x 1.5 mm Oil pump cover P/N 2033, M x 25 mm Oil pump to crankcase 1 60 P/N 2031, M16 x 5 mm, Loctite 242 Oil pump relief valve to oil pump 50 3 P/N WS1, M x 5 mm Oil pump relief valve cover 50 3 P/N WS1, M x 5 mm Piston cooling jets M Hollow Screw Pressure relief valve equipped oil pan doors in-lb P/N 103F Rocker arm adjustment nuts 4 55 P/N Rocker arm support capscrews 3 2 P/N 2032, M, Grade Rocker cover nuts 3 2 P/N 2003, M Spark plugs Spark plug tube * * Turbocharger to inlet adapter 3 50 NOTE: *= Oil Lubricated P/N 25520, M x 30 mm P/N 206, M x 45 mm FORM 624 Third Edition

27 GENERAL TORQUE VALUES Table Metric Standard Capscrew Torque Values (Untreated Black Finish) COARSE THREAD CAPSCREWS (UNTREATED BLACK FINISH) ISO PROPERTY CLASS SIZE TORQUE TORQUE TORQUE TORQUE N m in-lb N m in-lb N m in-lb N m in-lb M M M M M M M N m ft-lb N m ft-lb N m ft-lb N m ft-lb M M M M M M M M M M M M FINE THREAD CAPSCREWS (UNTREATED BLACK FINISH) ISO PROPERTY CLASS... SIZE N m TORQUE TORQUE TORQUE ft-lb N m ft-lb N m ft-lb M x M x M x M x M16 x M1 x M20 x M22 x M24 x NOTE: The conversion factors used in these tables are as follows: One N m equals 0.35 ft-lb and one ft-lb equals N m. FORM 624 Third Edition

28 Table Metric Standard Capscrew Torque Values (Electrically Zinc Plated) COARSE THREAD CAPSCREWS (ELECTRICALLY ZINC PLATED) ISO PROPERTY CLASS SIZE TORQUE TORQUE TORQUE TORQUE N m in-lb N m in-lb N m in-lb N m in-lb M M M M M M M N m ft-lb N m ft-lb N m ft-lb N m ft-lb M M M M M M M M M M M M FINE THREAD CAPSCREWS (ELECTRICALLY ZINC PLATED) ISO PROPERTY CLASS... SIZE N m TORQUE TORQUE TORQUE ft-lb N m ft-lb N m ft-lb M x M x M x M x M16 x M1 x M20 x M22 x M24 x NOTE: The conversion factors used in these tables are as follows: One N m equals 0.35 ft-lb and one ft-lb equals N m FORM 624 Third Edition

29 Table U.S. Standard Capscrew Torque Values SAE GRADE NUMBER GRADE 1 OR 2 GRADE 5 GRADE THREADS DRY OILED PLATED DRY OILED PLATED DRY OILED PLATED SIZE/ TORQUE TORQUE TORQUE THREADS PER INCH N m (in-lb) N m (in-lb) N m (in-lb) 1/4 20 (62) 6 (53) 5 (44) () (0) 1 (15) 16 (2) 15 (3) (4) 1/4 2 (1) (62) 6 (53) (4) (6) () 1 (16) 1 (15) 15 (3) 5/ (3) (4) (6) 23 (203) 20 (1) 1 (16) 33 (22) 30 (265) 26 (230) 5/ (15) 16 (2) (4) 26 (230) 23 (203) 20 (1) 3 (32) 33 (22) 30 (265) 3/ (2) 22 (15) 1 (16) 42 (32) 3 (336) 34 (301) 60 (531) 54 (4) 4 (416) N m (ft-lb) N m (ft-lb) N m (ft-lb) 3/ 24 2 (20) 24 (1) 22 (16) 4 (35) 43 (32) 3 (2) 66 (4) 60 (44) 53 (3) /16 3 (2) 34 (25) 30 (22) 56 (4) 60 (44) 53 (3) 5 (0) 5 (63) 6 (56) / (30) 3 (2) 33 (24) 5 (55) 6 (50) 60 (44) 6 () 5 (0) 4 (62) 1/2 53 (3) 4 (35) 42 (31) 2 (5) 2 (6) 1 (60) 2 (5) (5) 1 (4) 1/ (41) 50 (3) 45 (33) 5 (5) 4 () 2 (6) 163 (0) 6 () 0 (6) /16 6 (51) 62 (46) 56 (41) (0) 4 () () 2 (155) 10 (0) 16 (4) / (55) 6 (50) 60 (44) 163 (0) 6 () 0 (6) 230 () 20 (153) 14 (6) 5/ 3 (3) 2 (5) (66) 203 (150) (5) 163 (0) 25 (2) 256 (1) 22 (16) 5/ 1 (5) (6) 3 (6) 230 () 20 (153) 14 (6) 325 (240) 23 (216) 260 (12) 3/4 2 (5) 0 (5) 1 (4) 366 (20) 32 (243) 23 (216) 50 (35) 45 (33) 40 (300) 3/ (5) 1 (4) 5 (2) 400 (25) 361 (266) 320 (236) 56 (420) 5 (3) 456 (336) / 21 (160) 15 (4) () 52 (42) 523 (36) 465 (343) 20 (605) 3 (545) 656 (44) / 23 (15) 2 (15) 10 (0) 461 (43) 5 (426) 5 (3) 15 (65) 24 (60) 32 (540) (235) 2 (2) 255 (1) 3 (644) 6 (50) 00 (516) 34 () (1) (2) (250) 305 (225) 21 (200) (21) 0 (64) 2 (5) 42 (0) 0 (1) 4 (2) NOTE: Dry torque values are based on the use of clean, dry threads. Oiled torque values have been reduced by % 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 equals in-lb. ENGLISH/METRIC CONVERSIONS Table Metric Bolt Diameter To Hex Head Wrench Size Conversion METRIC BOLT DIAMETER METRIC STANDARD WRENCH SIZE METRIC BOLT DIAMETER METRIC STANDARD WRENCH SIZE M3 6 mm M1 2 mm M4 mm M20 30 mm M5 mm M22 32 mm M6 mm M24 36 mm M mm M2 41 mm M mm M30 46 mm M 16 or 1 mm M33 50 mm M 1 or 1 mm M36 55 mm M 21 or 22 mm M3 60 mm M16 24 mm M42 65 mm FORM 624 Third Edition

30 Table English To Metric Formula Conversion Inches to Millimeters CONVERSION FORMULA EXAMPLE Inches and any fraction in decimal equivalent multiplied by 25.4 equals millimeters. 2-5/ in. = x 25.4 = 66. mm Cubic Inches to Litres Cubic inches multiplied by equals litres. 3 cu. in. = 3 x = 153. L Ounces to Grams Ounces multiplied by 2.35 equals grams. 21 oz. = 21 x 2.35 = 55 g Pounds to Kilograms Inch Pounds to Newton-meters Foot Pounds to Newton-meters Pounds per Square Inch to Kilograms per Square Centimeter Pounds per Square Inch to Kilopascals Pounds multiplied by equals kilograms. Inch pounds multiplied by 0.3 equals Newton-meters. Foot pounds multiplied by equals Newton-meters. Pounds per square inch multiplied by equals kilograms per square centimeter. Pounds per square inch multiplied by 6.4 equals kilopascals. 22,550 lbs. = 22,550 x =,22 kg 360 in-lb = 360 x 0.3 = 40. N m 5 ft-lb = 5 x = 1 N m 45 psi = 45 x = 3.2 kg/cm 2 45 psi = 45 x 6.4 = 3 kpa Fluid Ounces to Cubic Centimeters Fluid ounces multiplied by 2.5 equals cubic centimeters. oz. = x 2.5 = 23 cc Gallons to Litres Gallons multiplied by 3.53 equals litres. gal. = x 3.53 = 560 L Degrees Fahrenheit to Degrees Centigrade Degrees Fahrenheit minus 32 divided by 1. equals degrees Centigrade. 2 F = 0 C Table Metric To English Formula Conversion CONVERSION FORMULA EXAMPLE Millimeters to Inches Millimeters multiplied by equals inches. 6 mm = 6 x = 2.6 in. Litres to Cubic Inches Litres multiplied by equals cubic inches L = 153. x = 35 cu. in. Grams to Ounces Grams multiplied by equals ounces. 55 g = 55 x = 21.0 oz. Kilograms to Pounds Kilograms multiplied by equals pounds.,22 kg =,22 x = 22,553 lbs. Newton-meters to Inch Pounds Newton-meters to Foot Pounds Bar to Pounds per Square Inch Kilograms per Square Centimeter to Pounds per Square Inch (psi) Kilopascals to Pounds per Square Inch (psi) Newton-meters multiplied by.5 equals inch pounds. Newton-meters multiplied by 0.35 equals foot pounds. Bar multiplied by.5 equals pounds per square inch. Kilograms per square centimeter multiplied by.22 equals pounds per square inch. Kilopascals multiplied by 0.5 equals pounds per square inch. 40. N m = 40. x.5 = 360 in-lb 1 N m = 1 x 0.35 = 5 ft-lb 65 Bar = 65 x.5 = 33 psi 3.2 kg/cm 2 = 3.2 x.22 = 46 psi 3 kpa = 3 x 0.5 = 45.0 psi Cubic Centimeters to Fluid Ounces Cubic centimeters multiplied by equals fluid ounces. 236 cc = 236 x =. oz. Litres to Gallons Litres multiplied by equals gallons. 560 L = 560 x = gal. Degrees Centigrade to Degrees Fahrenheit Btu per cubic feet to Mega Joules per cubic meter Degrees Centigrade multiplied by 1. plus 32 equals Degrees Fahrenheit. Btu per cubic feet multiplied by equals mega joules per cubic meter [25, V(0;1.325kPa)] 0 C = 0 x = 2 F 00 Btu/ft 3 x = 35.3 MJ/m [25, V(0;1.325kPa)] FORM 624 Third Edition

31 INDEX OF SEALANTS, ADHESIVES, AND LUBRICANTS The following is a list of sealants, adhesives and lubricants (see Table 1.15-) required to perform the tasks in this manual. Where possible, brand names are included with the task. When they are not, this index may be used to match the general description to a specific product or its equivalent (i.e. pipe sealant = Perma Lok Heavy Duty Pipe Sealant with Teflon or its equivalent). Waukesha does not endorse one brand over another. In all cases, equivalent products may be substituted for the brand name listed. All part numbers listed are the manufacturer's numbers. Table Sealants, Adhesives, And Lubricants NAME USED IN TEXT BRAND NAME/DESCRIPTION High Temperature Anti-Seize compound FEL-PRO C5-A, P/N 505 or Loctite Anti-Seize 6/Copper based anti-seize compound Anti-Seize Bostik Never Seez Anti-Seize and Lubricating Compound/Nickle based anti-seize compound Black Silicone G.E. Silmate Silicone Rubber Bluing Agent Magnaflux Products: Penetrant (SKL-HF/S) Developer (SKD-NF-ZP-B) Cleaner/Remover (SKC-NF/ZC-B) Bluing Paste Permatex Non Drying Prussian Blue (mfg. by Loctite Corporation) Ceramic bonded high temperature solid film lubricant Lube-Lok 00 or equivalent Cleaning Solvent/Mineral Spirits Amisol Solvent (mfg. by Standard Oil) Dielectric Silicone Grease Dow Corning DC-200, G.E. G-624, GC Electronics 25 Engine Oil See Lubricating Oil Epoxy Sealant Scotch Weld No. 20 B/A Black Epoxy Potting Compound/Adhesive, P/N's. A and B (3M ID No (PA) Gasket Adhesive Scotch Grip 4 Rubber and Gasket Adhesive (mfg. by 3M), 3M ID No Heavy Oil Vactra 0W0 Gear Oil (mfg. by Mobil) Liquid Soap Dove Dishwashing Liquid Lithium Grease See Molycote Paste G Locquic Primer T Item No. 456 (mfg. by Loctite Corporation) Loctite 242 Loctite Item No /a blue colored removable thread locking compound Loctite 21 Loctite Item No. 21/a red colored thread locking compound Loctite Compound 40 Loctite Item No /High Temperature Retaining Compound 40 Loctite Hydraulic Sealant Loctite Item No Loctite RC /60 Loctite Item No Loctite 620 Loctite Item No /High Temperature Retaining Compound Lubricating Oil/Engine Oil New oil of the type used in the crankcase Magnaflux See Bluing Agent Metal Assembly Spray Dow Corning Lubricant G-n Molycote Paste G O-ring Lubricant Permatex No. 3D Aviation Form-A-Gasket Sealant Liquid Permatex No. 2 Form-A-Gasket Sealant Permatex High Tack Spray-A-Gasket ) Pipe Sealant Stellite WD-40 Dow Corning Molycote Paste G or CITGO Lithoplex Grease NLGI No. 2 Product Code /a molybdenum-based grease Parker Super O-Lube /dry silicone lubricant Loctite Item No. 3D Loctite Item No. 2C Loctite Item No. MA Perma Lok Heavy Duty Pipe Sealant with Teflon, Item No. LH050 Stellite is a registered trademark of Stoody Deloro Stellite, Inc. WD-40 is a registered trademark of the WD-40 Company FORM 624 Third Edition