Waukesha VR Series, Service Manual

Page 1: ......

Page 2: ...ERIES GAS AND DIESEL ENGINES I Waukesha I I VRD155 VRG155 VRD232 VRG232 VRG265 VRD283 VRG283 VRD310 VRD310S VRG310 Copyright 1974 Waukesha Engine Division Dresser Industries Inc Waukesha Wisconsin 531...

Page 3: ...een crankedexcessivelywithout starting shut off the gas fuel supply and ignition Then crank the engine to purge the cylinders and exhaust system of accumulated unburned gas If you fail to do this a sp...

Page 4: ...gine is shut down In case of an accident from electrical shock shut down the generator set at once If it cannot be shut down free the victim from the live conductor Avoid direct contact with the victi...

Page 5: ...thout consulting the engine manufacturer since they limit turbocharger rpm Excessive rpm may result in turbochargerfailure with resultantpersonal safety hazards Turbochargers operate at high temperatu...

Page 6: ...generates a flammable explosive gas Don t allow battery fluid to contact skin eyes fabrics or paintedsurfaces Batteryfluid is a sulphuric acid solution which could cause serious personal injury or pr...

Page 7: ...aning procedures are recommendedfor certain castings or pieces of equipment I WARNING Always add the acid to the water never add water to acid when mixing solution 2 Descaling operations should be per...

Page 8: ...R REPARACIONES A L ATTENTION DE L OPERATEUR POUR VOTRE PROPRE SECURITE POSEZ CETTE PANCARTE SUR LES ORGANES DE DEMARRAGE DU MOTEUR AVANT DE COMMENCER LES OPERATIONS D ENTRETIEN MASCHINIST 1M INTERESSE...

Page 9: ...NCION ESTA UNlOAD ESTA EN REPARACIONES NO ARRANQUE NO INTENTE PONER EN MARCHA CON MANIJA NI CON MANUBRIO ATTENTION MOTEUR EN COURS D ENTRETIEN NE PAS DEMARRER LANCER NI AMORCER WARNUNG VORSICHT EINHEI...

Page 10: ...767 Gulf Coast Regional Office 14505 Torrey ChaseBlvd Suite 106 Houston Texas77014 Phone 713 893 4170 Telex 775753 Western Canada Regional Office Suite 418 LancasterBldg 304 8th Avenue S W Calgary Alb...

Page 11: ...cidentor improper installation or storage B Upon Buyer s submissionof a claim asprovided aboveand its substantiationSellershall at its option either i repair or replaceits product part or work at the...

Page 12: ...ing System Capacity 5 4 Cooling System Description 3 4 Cooling System Design 1 4 Cooling System Installation Recommendations 5 5 Cooling System Maintenance 2 10 Crankcase Design 4 3 Crankshaft Design...

Page 13: ...orrespondence 4 Terms on repair to avoid delay all re pairs will be C O D unless prior arrange ments are made with the distributor In situations which may fall within the parame ter of the Waukeshasta...

Page 14: ...ject Page Safety Precautions 2 Selecting Oil Viscosity 2 4 Service Limits Tahle 4 13 Service Schedule and Procedures 2 6 Space Requirements 5 3 Spark Plug Adjustments 2 14 Special Application Cranksha...

Page 15: ...e to fuel use or construction wiIIbe pointed out as needed Overhaul instructions are not included except where certain special procedures are required SPECIFICATIONS information located in the REPAIR...

Page 16: ...m 92 0 inches 3 3 4 Stroke mm 95 0 Speed Range rpm 1200 2200 Gasoline Maximum Continuous Horsepower 37 HP 2000 rpm I Nat Gas 29 HP 2000 rpm Normal Oil Pressure psi 25 35 avg 1500 rpm 12 mi 800 rnm OF...

Page 17: ...liters 2 54 inches 3 5 8 Bore mm 92 0 inches 33 4 Stroke mm 95 0 Speed Range rpm 1200 2200 MaximumContinuous Horsepower 36 2000rpm Normal OilPressure psi 25 351avg 1500 rpm 12 min 800 rpm of 200 220 O...

Page 18: ...e mm 92 0 inches 3 3 4 Stroke mm 95 0 Speed Range rpm 1200 2200 MaximumContinuous Horsepower Gasoline 53 2000 rpm Nat Gas 46 2000rpm Normal OilPressure psi 25 35 avg 1500 rpm 12 min 800 rom OF 200 220...

Page 19: ...32 liters 3 8 inches 3 5 8 Bore mm 92 0 inches 33 4 Stroke mm 95 0 Speed Range rpm 1200 2200 MaximumContinuous Horsepower 55 2000 rpm Normal OilPressure psi 25 35 avg 1500 rpm 12 min 800 rom of 200 22...

Page 20: ...re mm 95 0 inches 4 Stroke rum 102 0 Speed Range rpm 1200 2200 MaximumContinuous Horsepower Gasoline 72 QQQ rpm Nat Gas 58 20oorpm Normal OilPressure psi 25 50 avg 1500 rpm 12 min 800 rpm OF 200 220 O...

Page 21: ...d Range rpm 1200 2400 1200 2400 MaximumContinuous Horsepower Gasoline 83 QQQ rpm 2 1 QOO rpm Nat Gas 66 2000rpm 73 2000rpm Normal OilPressure psi 25 50 avg 1500 rpm 25 50 avg 1500 rpm 12 min 800 rpm 1...

Page 22: ...102 0 111 0 111 0 Speed Range rpm 1500 2200 1500 2400 1200 2200 Max Cont Horsepower 61 2000 rpm 79 2000rpm 122 2400 rpm Normal Oil Pressure psi 25 50 avg 1500 rpm 25 50 avg 1500 rpm 25 50 avg 1500 rpm...

Page 23: ...ENGINE REFERENCE POINTS FRONT CRANKSHAFT PULLEY END REAR FLYWHEEL END t1H OOI 174 FIRING ORDER Six Cylinders 1 5 3 6 2 4 Four Cylinders 1 2 4 3 CRANKSHAFT PULLEY FRONT FLYWHEEL REAR RIGHT SIDE LEFT SI...

Page 24: ...MH OOl l72 STAMPED SERIAL NUMBER LOCATION MH 16 10 MH 16 11 NAME PLATE LOCATION ML 16 9 UNDERSTANDING WAUKESHA MODEL DESIGNATIONS ENGINE SERIES l TYPE OF FUEL G GAS D DIESEL DISPLACEMENTIN CUBIC INCH...

Page 25: ...OPERATING 1 7 STOPPING 1 8 QUICK TROUBLE CHECK CHART FOR OPERATORS 1 9 COLD WEATHER STARTING 1 10 BREAK IN PROCEDURE 1 10 EXERCISE OF STANDBY UNITS 1 10 LIGHT LOAD OPERATION 1 10 ENGINE PERFORMANCE RE...

Page 26: ...I llt GENUINE WAUKESHA PARTS ARE AVAILABLE WORLDWIDE AND MUST BE ORDERED THROUGH YOUR LOCAL WAUKESHA DISTRIBUTOR FOR THE DISTRIBUTOR CLOSEST TO YOU REFER TO THE DISTRIBUTOR LISTING IN THIS MANUAL Wau...

Page 27: ...ater equipment Examine for tension pump alternator and other good condition and correct MH 201 2 ML SOO 49 MH 20S 10 Trace through the external cooling system to make sure all control valves are prope...

Page 28: ...level as indicated on the dipstick prior to starting engine Stop engine and recheck oil level after 5 to 10 minutes operation at low idle Add oil as required to bring level to full mark MH II 6B Fill...

Page 29: ...efore re starting after an overspeed shutdown Some Synchro Start overspeed switches incorporate an automatic re set and do not in clude a re set button MH 202 10 MH 92 16 Position the choke control of...

Page 30: ...afety control is effective If adequate oil pressure is not indicated within 25 to 30 seconds shut the engine down at once and correct the cause Never operate without an adequate oil pressure indicatio...

Page 31: ...ngines run at 25 50 psi These are high idle readings 1500 rpm All operating temperatures range from 180 1950F 182 2 90 6 C Changes from normal may be signsof developing trouble MH 208 32 Check general...

Page 32: ...or snow from getting into the engine A pail or bucket inverted over the exhaust pipe will be sufficient Test the coolant solution for adequate anti freeze to pro tect the engine from freezingduring sh...

Page 33: ...trash shutter open and fan operating raw water valvesopen to heat exchanger CHECK AIR INTAKE AND EXHAUST SYSTEMS FOR BLOCKS air filter dirty check air restriction indicator air intake or exhaust outle...

Page 34: ...ate under no load conditions for other than very brief periods Loads of at least one third up to the normal rated capacity are recommended Ordinarily an exercise run of one to one and one half hours w...

Page 35: ...e coolant shows need for cooling system servicing Air cleaners and breathers should be checked daily for cleanliness and tightness Examine engine foundation for condition of grout tight ness of hold d...

Page 36: ...STRIBUTOR ADJUSTMENTS 2 12 SPARK PLUG ADJUSTMENTS 2 14 MAGNETO SERVICING 2 15 TIMING THE MAGNETO 2 15 ALTERNATOR SERVICING 2 15 ALTERNATOR PULLEY REMOVAL AND INSTALLATION TOOL 2 17 INJECTION PUMP MAIN...

Page 37: ...ANTICIPATE YOUR PARTS REQUIREMENTS a ORDER PARTS EARLY IN THE DAY b KEEP A SUPPLY OF NORMAL MAINTENANCE PARTS IN STOCK e OBTAIN A PARTS STOCKING RECOMMENDATION FROM YOUR DISTRIBUTOR 2 2 IIAI I S ttl l...

Page 38: ...tandpoint of cetane rating and operation al satisfaction with the followingexceptions 1 There may be Jet A from some refinerieswhich does not meet our minimum cetane value of 40 In casesof doubt a cet...

Page 39: ...as MIL L 45199B or MIL L 2104C and by the manufacturer as S 3 For Class A engines operating on gasoline or gas Waukesha Engine Division recommends lubricating oil designated by the API as CC SD or SE...

Page 40: ...saturation is reached these oils tend to dump out all of the suspended con taminants in a relatively short period of time Laboratory analysis will not predict the dump out point precisely consequentl...

Page 41: ...200 S4 2 6 MH 03 4 MH 200 S3 FUEL FILTER Diesel Only Check sediment bowl daily for accumulation and drain if necessary Replace fuel filter element when lube oil and filter are changed MH 208 32 FAN B...

Page 42: ...be prelubricated Lubricate shaft every 1000 hours IGNITION POINTS Adjust point clearance every 500 hours Replace points and condensor if necessary After adjusting points be sure to check and adjust en...

Page 43: ...lter element clogging is now by passing the filter and going through the engine itself This dirty oil may reduce engine life materially All VR Series engines except VRG and VRD 155 and 232 engines are...

Page 44: ...ows and connections to 150 50 inch lbs At this force one extra turn is perinissible to position fitting Use non hardening gasket adhesive on threads for sealing AIR CLEANERS Follow the directions atta...

Page 45: ...elements proceed as follows I I Do not rap beat or drop element 1 Compressed air cleaning Direct clean dry air max 100 psi inside element moving nozzle up and down while rotating element 2 Water wash...

Page 46: ...over the thermostats and fitted with a REMOVINGTHERMOSTAT MH 21 21 good quality thermometer suspended in the water so that the sensitive bulb portion does not rest directly on the bucket bottom or sid...

Page 47: ...ith a fine hone Neveruse abra sive cloth or paper regardless of what the abrasivematerial is A file is equally unsatisfactory with regard to continued point life although improved performance may be o...

Page 48: ...e lead to the ungrounded side of the starting battery and attach the other lead to the primary wire connection at the side of the distributor Final timing should be done with the engine running using...

Page 49: ...he settings per meter instructions 3 Start the engine and read directly from the meter 4 If the specified dwell angle is incorrect stop the engine and adjust the point gap repeat as required Increasin...

Page 50: ...rotated until the proper timing mark aligns with the timing hole pointer in the flywheel housing and number one piston is coming up on compression stroke This is the point at which firing occurs when...

Page 51: ...l be open and the test light will not glow Then test the switch with the engine running The oil pressure will close the switch and the test light should glow If the test results are unsatisfactory ins...

Page 52: ...emoved first This is done by removing lines from inject ors and pump and removing bracket bolt from engine block I I Clean all fittings before disconnecting them and plug or cap all openings after fit...

Page 53: ...tor is skilled in its use there is little actual repair work that can be accomplishedon injectors If a nozzle is suspected of improper operation it may be given a general test by allowing it to spray...

Page 54: ...f the main spray in the chamber Energy cells should be removed for cleaning or replace ment when fuel injectors are found to be faulty or when poor fuel combustion is evident Excessive exhaust smoke m...

Page 55: ...IES MH 09 39 FULL LOAD SPRAY PATTERN PINTLE INJECTOR MH 09 40 SPRAY RAGGED UNSATISFACTORY PINTLE INJECTOR 2 20 MH 09 39 IDLE SPRAY PATTERN PINTLE INJECTOR MH 09 40 LEAKING NOZZEL VALVE UNSATISFACTORY...

Page 56: ...ean away carbon from surface around orifice do not scrape surface as seriousdamagemay result Use a brass wire brush to clean pintle end of valve Use a wooden or brass strip to dislodge hard carbon par...

Page 57: ...Replace carbon stop seal before reinstalling Injector in engine Remove old seal by breaking with needle nose pliers Use Roosa master tool part No 16477 to install new seal Check upper seal for possibl...

Page 58: ...as power mixture ad POWER FUEL MIXTURE ADJUSTMENT VALVE EFfKTlVE ONlY AT FULL LOAD IDLE FUEL MIXTURE ADJUSTMENT SCREW EFFKlIV ONLY T IOLESPUD IDLE SPEED ADJUSTING MH 214 6 NATURAL GAS CARBURETOR just...

Page 59: ...et only when the cam follower is on the base circle of the camshaft that is to say the cam follower must not be on any part of the camshaft lobe Referring to the illustration of cam lobe relationship...

Page 60: ...compression or pressures lower than normal call for further checking Valve regrinding piston ring replacement or other overhaul procedures may be required to correct the problem MANIFOLD VACUUM TEST...

Page 61: ...ssivedeterioration 4 Protection of cooling system intercoolers and LPG vaporizers against freezing rusting or seizure or water pump seals 5 Protection of a general nature against the elements rain sno...

Page 62: ...ful or fatal if swallowed Avoid contact with skin Vapor is harmful Causesirritation of eyes nose throat and skin Use only with adequate ventilation Avoid prolonged or repeated breath ing of vapor Avoi...

Page 63: ...rk plugs and squirt or spray several teaspoons of pre 2 28 servative oil into each combustion chamber Coat injectors or spark plugs and reinstall E Remove distributor cap or magneto cover and apply sm...

Page 64: ...reair from this source Heating of Preservative Compounds Many preservative compounds are most effective when heated before application If possible engine should be warmed prior to applying preservativ...

Page 65: ...s of a week up to several months depending on climatic and storage conditions Whenever dampness or long term storage up to a year seem likely carry out the following operations after the above steps a...

Page 66: ...arger is considerably lower than is normally encountered at equivalent loads in gasoline engines The turbine or driving member of the unit is made of a special heat resisting alloy and is surrounded b...

Page 67: ...ERAL All air duct and gasket connections should be routinely checked for tightness and leaks Repair any loose or leaking connection immediately Ingestion of dirt into the compres sor can cause severe...

Page 68: ...EXELBOW _ CENTERBOLT FILTER SHELL OIL COOLER BASE should be removed from the water passage area of the cooler at this time The sludge deposits within the cooler core may be cleaned out by several solv...

Page 69: ...ROUBLESHOOTING 3J OPERATING CONTROLS 3 3 ELECTRICAL SYSTEM 3 3 COOLING SYSTEM 3 4 AIR INTAKE SYSTEM 3 4 EXHAUST SYSTEM 3 5 FUEL SYSTEMS 3 5 IGNITION SYSTEMS 3 8 LUBRICATION SYSTEM 3 9 GOVERNING SYSTEM...

Page 70: ...WAUKESHA VR SERIES I AI rs ttl lt I llt ALWAYS SPECIFY THE ENGINE MODEL DESIGNATION SPECIFICATION NUMBER AND SERIAL NUMBER AS FOUND ON THE ENGINE NAMEPLATE ML IOOO 29 3 2...

Page 71: ...good trouble shooting OPERATING CONTROLS Most VR Series engines are equipped with the following operating controls See illustrations a Ammeter b Watertemperature gauge c Oil pressuregauge d Throttle...

Page 72: ...the engine cylinder jacket The water enters the engine in the area of the cylinder sleeve lower ends From here the water flow is directed about the cylinder sleevesin an even manner until it passes u...

Page 73: ...power 2 Poor fuel economy 3 Excessivevalvetemperatures and premature wear 4 Jacket water overheating The exhaust system of an engine particularly long exhaust pipes can accumulate quite a bit of cond...

Page 74: ...ows through the angled passageto the pumping cylinder At this point charging of the cycle the rollers are in the valley or relieved part of the cam between lobes The fuel is trapped in the cylinder fo...

Page 75: ...rough the inlet fitting of the injector around the injector valve At the instant the pressure of the fuel against the valve exceeds the predetermined spring force the valveis lifted off its seat allow...

Page 76: ...pressure of valve may be varied by changing compres sion of spring with adjusting screw Excess fuel which is not forced into combustion chamber returns to fuel tank through leakoff connection and drip...

Page 77: ...essun relief valve in the oil pump To adjust pressurt the oil pan must be removed to get at the pump Turn the relief valve adjusting screw in to increase oil pressure back it out to decrease pressure...

Page 78: ...crankcaseand cylinder head to a tube fitting on the head From this fitting oil passes to the hollow rocker arm shaft and then to each valve in turn to provide controlled oiling of the valves and guide...

Page 79: ...ich is manually controlled by the throttle shaft linkage in regulating engine speed A light idle spring is provided for more sensitive regulation at the low speed range The limits of throttle travel a...

Page 80: ...ward due to the reduced centrifugal force Through the linkage system this weight movement causes the throttle valve to open and admit more fuel and air to the engine thus restoring normal loaded speed...

Page 81: ...e CAUTION DO NOT ATTEMPT TO ROTATE CRANKSHAFT WITH STARTER Replacepiston assemblyand possibly sleeve Determine cause of seizure insufficient ring gap insufficient lubri cation inadequate cooling overl...

Page 82: ...stem malfunction b Lube oil viscosity too high Mistimed or faulty ignition system gasoline engines Poor compression a Worn rings b Leaking valves c Leaking head gasket Fuel shut off control in off pos...

Page 83: ...ater at strainers ftlters and fuel tank Replace ftlter elements b Air in fuel diesels b Operate hand primer until air is expelled Repair source of air entering into system c Insufficient fuel supply c...

Page 84: ...ty air cleaner element i Restriction in intake and or exhaust system j Turbocharger malfunction VRD 310S only k Insufficient warm up period I a Replace scored piston sleeveand rings Adjust ring gap b...

Page 85: ...as fuel system f Clogged or improperly adjusted f Clean or adjust main carburetor jet gasoline engines Injectors malfunction diesels a Clogged spray tip a Overhaul injector clean tip or replace b Dirt...

Page 86: ...Adjust gasoline engines Governor linkage sticky or sloppy Remove all dirt and burrs from link age Realign and re set Turbocharger malfunction Repair or replace VRD 3IOS only Low or fluctuating CAUTION...

Page 87: ...cosity oil as recommended in PREVENTNE MAINTENANCE Lubricating oil foaming Use oil grade recommended in PREVENTNE MAINTENANCE Check for water leaks into oil Clogged oil inlet screen Remove and clean s...

Page 88: ...uge inaccurate Compare to master gauge temperature replace gauge Inoperative thermostat Replace thermostat High cooling water NOTE COOL ENGINE temperature SLOWLY Gauge inaccurate Compare to master gau...

Page 89: ...rbocharger seal damaged Repair or replace VRD31OS only Stuck worn piston rings Renew rings Turbocharger drain restricted Repair or replace VRD31OS only One or more pistons with rings Remove piston cor...

Page 90: ...ore injectors a Replace all defective injectors inoperative diesels b Misfiring ignition system b Repair or replace components as gasoline engines required Crankshaft a Cracked a Conduct a complete in...

Page 91: ...seal leakage Repair or replace VRD310S only Dirt buildup in turbo compressor Repair or replace housing VRD310S only Carbon buildup behind turbine Repair or replace wheel VRD310S only High lubricating...

Page 92: ...veclearance Readjust valveclearance Stickingvalvesor rocker arms Free up or replace Misfitted or excessivelyworn Replace timing gears Excessivefuel Carburetors adjusted over Readjust consumption rich...

Page 93: ...just gas engines Insufficient line pressure Increase line pressure Incorrect orifice and or spring Replace orifice and or spring in gas regulator Undersize gas regulator Replace with gas regulator of...

Page 94: ...ION GASOLINE ENGINES 4 7 WATER PUMP SEAL INSTALLATION 4 7 WATER PUMP PULLEY INSTALLATION 4 8 OIL PAN REMOVAL AND REPLACEMENT 4 8 RUBBER VIBRATION DAMPER REPLACEMENT 4 8 VISCOUS VIBRATION DAMPER REPLAC...

Page 95: ...rS ttl ltl ltllt ALWAYS INCLUDE THE PART NUMBER WHEN KNOWN ALONG WITH THE DESCRIPTION OF THE PART STATE THE QUANTITY OF THE PART YOU WISH TO ORDER IF A SPECIAL PART IS NEEDED THE ENGINE APPLICATION S...

Page 96: ...LVES The cast iron cylinder head is designed and fabricated especially for the temperatures and pressures of industrial use The cylinder head of VRG 283 and VRG 310 engines is of two piece constructio...

Page 97: ...ings The top groove contains a black seal ring and the bottom groove a red seal ring 4 4 The following procedure should be used to measure cyl inder sleeve projection 1 After removal of head clean car...

Page 98: ...ed require particular care to prevent bending denting or breakage All parts should be covered to protect them from dirt This will also speed reassemblyby reducing clean up time at assembly When parts...

Page 99: ...aterial and heat treatment Do not mix attaching parts Lock washers cotter pins or other locks should be used to lock each nut and cap screw when specified Gears Always use tools recommended or equival...

Page 100: ...Seriesdieselengines except VRD 155 and 232 Models must be installed with the springtowards the top of the piston as illustrated Do not expand rings more than is necessary to slip over the piston Over...

Page 101: ...re in this area and at the same time avoid placing the oil pan bolts in an inaccessible position These long cap screws must be reo moved before removingthe oil pan On reinstalling these cap screws it...

Page 102: ...vibration damper is on inches T I R By keeping runout within limits considerable engine vibration can be eliminated thus limiting the possibility of serious vibration damage to the engine Vibration d...

Page 103: ...h or scribe prior to disassembly to assure reassembly in the same relative position 3 Remove compressor housing by bending down lock tabs then removing lock tabs clamps and cap screws Exercise care in...

Page 104: ...ING 1 6 BOLT 5 16 18 6 7 LOCKPLATE 3 8 CLAMP 3 9 LOCKNUT 1 10 COMPRESSOR WHEEL 1 11 TURBINE WHEEL ASSEMBLY 1 12 PISTON RING 1 13 BOLT I 4 20 4 14 LOCKPLATE 2 15 BACKPLATE 1 16 THRUST SPRING 1 17 SEAL...

Page 105: ...nter housing and backplate and install over shaft and thrust collar Use care not to break the piston ring when engaging into seal bore Backplate is easily installed if open end position of piston ring...

Page 106: ...om internal sur faces if present 3994 681 Journal surfaces must not be scored Polish surfaces with crocus cloth Thrust surface must be clean and smooth 5010 1752 066 Ring groove shoulders must be free...

Page 107: ...9 153 8 Liters Ounces to Grams 28 35 x Ounces Example 21 Ounces 21 x 28 35 595 35 grams Pounds to Kilograms 4536 x Lbs Example 22 550 Lbs 22 550 x 4536 10 228 Kg Inch Pounds to Newton meters Inch Lb x...

Page 108: ...8 9 1 2 1 4 28 7 0 9 11 1 5 5 16 18 13 1 8 18 2 5 5 16 24 15 2 1 21 2 9 3 8 16 24 3 3 34 4 7 3 8 24 27 3 7 38 5 3 7 16 14 38 5 3 54 7 5 7 16 20 42 5 8 60 8 7 1 2 13 58 7 9 82 11 3 1 2 20 65 8 9 90 12...

Page 109: ...n with engine warm ML 02 185 VR GAS AND GASOLINE TORQUE VALUES FOOT POUNDS Kgm VRG 155 VRG 232 VRG 265 VRG 283 AND 310 Cylinder HeadCap 112 117 112 117 112 117 129 133 Screw Solid 15 5 16 2 15 5 16 2...

Page 110: ...l 67 69 67 69 67 69 67 69 9 2 9 5 9 2 9 5 9 2 9 5 9 2 9 5 Crank Bolt 75 85 75 85 75 85 229 238 10 4 11 8 10 4 11 8 10 4 11 8 31 7 32 9 Fuel Injector 12 17 12 17 10 11 10 11 1 7 2 4 1 7 2 4 1 4 1 5 1 4...

Page 111: ...023 026 Hclly exeept 0 53 0 58 mm 0 58 0 66 mm 0 58 0 66 mm 0 58 0 66 mm 0 58 0 66 mm VRGI55 Delco Hemy Mallory N A Approx 022 Approx 022 Approx 022 Approx 022 0 56mm 0 56 mm O 56mm 0 56mm Distributor...

Page 112: ...109 474 109 423 115 824 115 773 115 824 115 773 E SleeveDiameter 4 3 32 4 3 32 4 11 32 4 11 32 BelowFlange 104mm l04mm 110mm 110mm F SleeveLength Less 7 1 16 7 1 16 7 5 16 7 7 16 Heat Dam 179mm 179mm...

Page 113: ...050 0 038 SleeveBore Maximum 002 002 002 002 Taper 0 050 0 050 0 050 0 050 SleeveSealArea to 0045 002 0035 001 0035 001 0005 0045 CrankcaseClearance 0 114 0 050 0 088 0 025 0 088 0 025 0 013 0 114 VRG...

Page 114: ...D CrankcaseLower Bore 4 031 4 032 4 281 4 282 4 281 4 282 4 281 4 283 102 387 102 412 108 737 108 762 108 737 108 762 108 737 108 788 CrankcaseMainBearing 2 4210 2 4215 2 8175 2 8165 2 8175 2 8165 2...

Page 115: ...015 0 005 0 017 0 005 0 017 0 005 0 017 WeightVariation 737_ 3 grams 1185_ 5 grams 1073_ 5 grams 1130_ 4 grams per piston per piston per piston per piston A Piston Pin Hole 1 2497 1 2500 1 2499 1 250...

Page 116: ...WeightVariation 737 3 grams 737 3 grams 828 4 grams 1113 _ 4 grams per piston per piston per piston per piston A Piston Pin Hole 1 2497 1 2500 1 2497 1 2500 1 2497 1 2500 1 2499 1 2502 Bore 31 742 31...

Page 117: ...3rd 010 020 010 020 015 055 015 055 0 254 0 508 0 254 0 508 0 381 1 397 0 381 1 397 4th 015 055 015 055 0 381 1 397 0 381 1 397 B Ring Gauge Top 3 625 7 8 3 625 7 8 3 750 9 0 3 875 9 8 Diameter 92 07...

Page 118: ...0930 0935 0930 0935 0930 0935 0930 2 374 2 362 2 374 2 362 2 374 2 362 2 374 2 362 2nd 0935 0925 0935 0925 0935 0930 0935 0925 2 374 2 349 2 374 2 349 2 374 2 362 2 374 2 349 3rd 0935 0925 0935 0925...

Page 119: ...92 075 C Ring Wall Top 170 160 194 184 194 184 158 168 4 318 4 064 4 927 4 673 4 927 4 673 4 013 4 267 2nd 170 160 194 184 171 181 158 168 4 318 4 064 4 927 4 673 4 343 4 597 4 013 4 267 3rd 170 160 1...

Page 120: ...7 15 57 124 61 912 61 887 Diameter C Main BearingJournal 040 040 040 040 MaximumUndersize 1 016 1 016 1 016 1 016 D MainBearingRun 0002 0027 0002 0027 0005 0035 0015 0045 ning Clearance 0 005 0 068 0...

Page 121: ...1 899 61 874 Diameter C MainBearingJournal 040 040 040 040 MaximumUndersize 1 016 1 016 1 016 1 016 D MainBearingRunning 0002 0027 0015 0045 0015 0045 001 004 Clearance 0 005 0 068 0 038 0 114 0 038 0...

Page 122: ...503 Diameter 31 752 31 757 31 752 31 757 31 752 31 757 31 752 31 757 D BushingPressIn 0045 0070 0045 0070 0045 0070 0045 0070 Rod 0 114 0 177 0 114 0 177 0 114 0 177 0 114 0 177 E LargeEnd Finish 2 42...

Page 123: ...57 31 752 31 757 31 752 31 757 31 752 31 757 D BushingPressIn 0045 0070 0045 0070 0045 0070 0045 0070 Rod 0 114 0 177 0 114 0 177 0 114 0 177 0 114 0 177 E LargeEnd Finish 2 4205 2 4200 2 4205 2 4200...

Page 124: ...448 ValveStem Diameter 372 371 372 371 372 371 372 371 Exhaust 9 448 9 423 9 448 9 423 9 448 9 423 9 448 9 423 ValveLip Thickness 063 063 063 063 Intake 1 600 1 600 1 600 1 600 ValveLip Thickness 063...

Page 125: ...ust Seat Angle Intake 450 450 450 450 L Guide Extends Above 843 833 843 833 781 771 843 833 Head Intake 21 412 21 158 21 412 21 158 19 837 19 583 21 412 21 158 Guide Extends Above 937 927 937 927 937...

Page 126: ...p Thickness 052 062 052 062 055 055 Intake 1 321 1 574 1 321 1 574 1 397 1 397 ValveLip Thickness 052 062 052 062 067 067 Exhaust 1 321 1 574 1 321 1 574 1 702 1 702 ValveFace Seat 002 002 002 002 Run...

Page 127: ...896 23 799 23 545 22 225 21 971 22 225 21 971 M Guide Bore In Head 624 625 624 625 6245 625 6245 625 15 849 15 875 15 849 15 875 15 862 15 875 15 862 15 875 N Intake Insert 314 318 314 318 Counterbore...

Page 128: ...11 12 585 12 611 12 585 DriveShaft Bushing 1 0005 1 0015 1 0005 1 0015 6265 6270 6265 6270 LD Bottom 25 413 25 438 25 413 25 438 15 913 15 926 15 913 15 926 DriveShaft Running 495 4945 495 4945 4945 4...

Page 129: ...11 12 585 DriveShaft Bushing 1 0005 1 0015 1 0005 1 0015 6265 6270 6265 6270 I D Bottom 25 413 25 438 25 413 25 438 15 913 15 926 15 913 15 926 DriveShaft Running 495 4945 495 4945 4945 494 4945 494 S...

Page 130: ...RPM 12 1500 RPM 240 BTDC 240 BTDC 340 BTDC 360 BTDC 16 1800 RPM 16 1800 RPM 16 1800 RPM 16 2200 RPM 26 BTDC 260 BTDC 360 BTDC 380 BTDC 19 2200 RPM 19 2200 RPM 19 2200 RPM 22 2400 RPM Timing Gear Backl...

Page 131: ...UIREMENTS 5 3 STATIONARY INSTALLATIONS 5 3 PREPARING UNIT FOR SERVICE 5 3 COOLING SYSTEM 5 4 AIR INTAKE SYSTEM 5 5 EXHAUST SYSTEM 5 5 LUBRICATION OIL SYSTEM 5 6 ANGULAR OPERATING LIMITS 5 6 FUEL SYSTE...

Page 132: ...UANTITY OF THE PART YOU WISH TO ORDER IF A SPECIAL PART IS NEEDED THE ENGINE APPLICATION SHOULD ALSO BE STATED GENUINE WAUKESHA PARTS ARE AVAILABLE WORLDWIDE AND MUST BE ORDERED THROUGH YOUR LOCAL WAU...

Page 133: ...some shimsunder both engine and driven equipment so future alignment problems at time of rebuilding or replacement will not present a pro blem The nature of any shimming procedure is essentially cut...

Page 134: ...ing a Radiator or Other Cooler Design for Continuous Duty Operation 1 Use l800F 195 F for VR155 engine water outlet temperature On compressor applications use l800F engine water outlet temperature to...

Page 135: ...ate clean supply of combustion air for internal combustion en gines These are as follows 1 Combustion air required for engines installed in heated air conditioned buildings may upset heating and venti...

Page 136: ...odified for jobs different from their original purpose without proper consideration to the type of oil pan or oil pump used In other cases the ramps or stockpiles on which the machine is working are t...

Page 137: ...iness of fuel before and during handling Admission of minute foreign particles even in small quantities will seriously wear the close clearances necesfWlI yto seal the engine against internal hydrauli...

Page 138: ...ing bore con centricity 1 Support a dial indicator in the same general manner as shown and check the runout of the housing bore all the way around MH 13 4 CHECKINGHOUSINGBORE RUN OUT 2 If the flywheel...

Page 139: ...icator with the tolerance given in the Fits and Clearances section MH 13 2 CHECKING FLYWHEEL FACE RUN OUT MH 13 1 CHECKING PILOT BEARING BORE RUN OUT I I The importance of correct crankshaft endplay c...

Page 140: ...SSUE 1 LUBE OIL ANALYSIS AND FILTRATION Vol 6 ISSUE 2 ENGINE CONTROL Vol 6 ISSUE 3 TURBOCHARGING COOLING SYSTEM Vol 7 ISSUE 1 PISTONS RINGS AND SLEEVES Vol 7 ISSUE 2 PREVENTIVE MAINTENANCE Vol 7 ISSUE...

Page 141: ...S SCHEDULING PREVENTIVE MAINTENANCE TORQUE POSTER FOR PREVIOUS ENGINE MODELS TORQUE POSTER FOR CURRENT ENGINE MODELS This information is available to assist in your maintenance needs through your loca...

Page 142: ...ur engine s Operation and Service Manual and the 7th Edition of the Parts and Service Digest Waukesha Engine Preservative Oil is available in one gallon containers Order Part Number 166709A ENGINE PAI...