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Waukesha VGF F18GLD Manuals
Manuals and User Guides for Waukesha VGF F18GLD. We have
1
Waukesha VGF F18GLD manual available for free PDF download: Repair Manual
Waukesha VGF F18GLD Repair Manual (429 pages)
Brand:
Waukesha
| Category:
Engine
| Size: 14.21 MB
Table of Contents
Table of Contents
2
Table 1.00-1. VGF 6 and 8 Cylinder Engine Safety Labels
22
Figure 1.00-3. Caution Label -- P/N 209107M
25
Figure 1.00-4. Danger Label -- P/N 211900
25
Figure 1.00-5. Warning Label -- P/N 211910K
25
Figure 1.00-6. Warning Label -- P/N 211910L
25
Figure 1.00-7. Warning Label -- P/N 211910N
25
Figure 1.00-8. Warning Label -- P/N 211910T
25
Figure 1.00-9. Warning Label -- P/N 211910W
26
Figure 1.00-10. Warning Label -- P/N 211911B
26
Figure 1.00-11. Warning Label -- P/N 211911J
26
Figure 1.00-12. Caution Label -- P/N 211920B
26
Figure 1.00-13. Caution Label -- P/N 211920E
27
Figure 1.00-14. Safety Label -- P/N 211930A
27
Figure 1.00-15. Caution Label -- P/N 211930C
27
Figure 1.10-1. Correct Method of Lifting
33
Table 1.10-1. Engine Dry Weights
33
Figure 1.15-1. Previous Production Model
35
Figure 1.15-2. VGF Specification Plate
36
Figure 1.15-3. Engine Nameplate
36
Figure 1.15-4. Current Nameplate
36
Figure 1.15-5. Engine Serial Number
37
Figure 1.15-9. Right Side View -- H24GLD
41
Figure 1.15-10. Right Side View -- F18GLD
42
Figure 1.15-16. Rear View -- F18G/H24G
48
Figure 1.15-17. Instrument Panel
48
Table 1.15-1. Special Tools
50
Table 1.15-2. Test Pigtail Adapters
50
Table 1.15-3. Model F18 and
51
Figure 1.15-18. Rear View F18GL/H24GL
53
Figure 1.15-19. Right and Left Side Views
54
Figure 1.15-20. Front View F18GL/H24GL
55
Table 1.15-4. F18/H24 Specific Engine
55
Figure 2.05-19. Damper Driving Flange
56
Figure 4.00-58. Front Lifting Eye
56
Figure 4.00-76. Intermediate Gear
56
Figure 5.00-22. Governor Drive
56
Figure 5.00-24. Governor Drive
56
Figure 5.25-23. Jacket Water Pump
56
Figure 5.25-30. Jacket Water Pump
56
Figure 5.25-31. Jacket Water Pump
56
Figure 3.00-1. Rocker Arm Support
57
Figure 4.00-42. Piston Cooling Jet
57
Figure 4.00-81. Oil Pump Idler Gear
57
Figure 4.00-83. Oil Pump Idler Gear
57
Figure 5.30--57. Piston Cooling Jet
57
Figure 5.35-26. Wastegate
57
Figure 5.35-50. Thermostat Housing
57
Table 1.15-5. Metric Standard Capscrew Torque Values (Untreated Black Finish)
58
Table 1.15-6. Metric Standard Capscrew Torque Values (Electrically Zinc Plated)
59
Table 1.15-7. U.S. Standard Capscrew Torque Values
60
Table 1.15-8. Metric Bolt Diameter to Hex Head Wrench Size Conversion Table
60
Table 1.15-9. English to Metric Formula Conversion Table
61
Table 1.15-10. Metric to English Formula Conversion Table
61
Figure 5.25-132. High Temperature
62
Figure 5.25-133. High Temperature
62
Table 1.15-11. Sealants, Adhesives, and Lubricants
62
Table 1.20-1. Cylinder Liner
63
Table 1.20-2. Crankcase
64
Table 1.20-3. Piston
65
Table 1.20-4. Piston Pin
65
Table 1.20-5. Piston Rings
66
Table 1.20-7. Camshaft Followers
68
Table 1.20-8. Valve Spring Clearances
69
Table 1.20-9. Flywheel and Housing
70
Table 1.20-10. Connecting Rod, Bushing and
71
Table 1.20-11. Valve Clearances
72
Table 1.20-12. Cylinder Head Clearances
73
Table 1.20-13. Rocker Arm Assemblies
74
Table 1.20-14. Camshaft
75
Table 1.20-15. Cross Bar and Guide
75
Table 1.20-17. Front Gear Train Backlash
77
Figure 3.00-19. Valve Seat
78
Figure 2.00-1. Exhaust Thermocouple
79
Figure 2.00-2. Exhaust Thermocouple Conduit
79
Figure 2.00-3. Turbocharger Discharge
79
Table 2.00-1. Special Tools for Cylinder Head
79
Figure 2.00-4. Turbocharger Discharge
80
Figure 2.00-5. Heat Shield
80
Figure 2.00-6. High Tension Coil Lead
80
Figure 2.00-7. Spark Plug Tube Tool
80
Figure 2.00-9. CSA High Tension Lead
81
Figure 2.00-10. CSA Flange Mounted Coil
81
Figure 2.00-11. Spark Plug Tube Tool
81
Figure 2.00-12. CSA Rocker Arm Cover
81
Figure 2.00-13. Rocker Arm Cover Removal Tool
81
Figure 2.00-14. Rocker Arm Support Installation
82
Figure 2.00-15. Rocker Arm Support
82
Figure 2.00-16. Rocker Arm Support Installation
82
Figure 2.00-17. Cross Bar Installation
82
Figure 2.00-18. Intake Manifold
82
Figure 2.00-19. Intake Manifold
83
Figure 2.00-20. Exhaust Manifold
83
Figure 2.00-21. CSA Conduit
83
Figure 2.00-22. Vortox Separator Bracket
83
Figure 2.00-23. Current-Water Elbow Assembly
83
Figure 2.00-24. Previous-Water Elbow Assembly
84
Figure 2.00-25. Rocker Arm Cover Studs
84
Figure 2.00-26. Cylinder Head
84
Figure 2.00-27. Lifting Eye
84
Figure 2.05-1. Connecting Rod Inspection Cover
86
Figure 2.05-2. Piston Cooling Jet
86
Table 2.05--1. Special Tools for Crankcase
86
Figure 2.05-3. Connecting Rod Access
87
Figure 2.05-4. Match Cap and Rod
87
Figure 2.05-5. Carbon Removal
87
Figure 2.05-6. Piston Removal/Installation Tool
87
Figure 2.05-7. Piston Removal
88
Figure 2.05-8. Cylinder Sleeve Removal
88
Figure 2.05-9. Sleeve Removal Tool
88
Figure 2.05-10. Parallel Pins
88
Figure 2.05-11. Upper Oil Separator Inlet Tube
89
Figure 2.05-12. Auxiliary and Jacket Water
89
Figure 2.05-13. Water Pump Idler Oil Supply
89
Figure 2.05-14. PSG Governor
89
Figure 2.05-15. Magneto
89
Figure 2.05-16. Hall--Effect Pickup Location
90
Figure 2.05-17. Vibration Damper Guard
90
Figure 2.05-18. Vibration Damper
90
Figure 2.05-20. Crankcase Seal Removal
91
Figure 2.05-21. Front Crankshaft Seal
91
Figure 2.05-22. Front Gear Cover Dowel
91
Figure 2.05-23. Lifting the Gear Housing
91
Figure 2.05-24. Camshaft and Idler Gear
92
Figure 2.05-25. Camshaft Thrust Flange
92
Figure 2.05-26. Front Gear Housing
92
Figure 2.05-27. Crankshaft Gear Removal
92
Figure 2.05-28. Oil Pump Idler Gear
92
Figure 2.05-29. Rear Engine Support
93
Figure 2.05-30. Front Engine Support
93
Figure 2.05-31. Electric Starter
93
Figure 2.05-32. Barring Device
93
Figure 2.05-33. Flywheel Removal
94
Figure 2.05-34. Flywheel Housing Removal
94
Figure 2.05-35. Rear Seal Carrier
94
Figure 2.05-36. Rear Crankshaft Seal
94
Figure 2.05-37. Rear Seal Carrier
95
Figure 2.05-38. Cam Follower Holding Tool
95
Figure 2.05-39. Camshaft Thrust Flange
95
Figure 2.05-40. Lube Oil Filters
95
Figure 2.05-41. Regulator Support Bracket
95
Figure 2.05-42. Camshaft Access Doors
96
Figure 2.05-43. Camshaft Thrust Flange
96
Figure 2.05-44. Rear Camshaft Cover
96
Figure 2.05-45. Follower Shaft Retaining
96
Figure 2.05-46. Rocker Arm Shaft
97
Figure 2.05-47. Camshaft Follower Removal
97
Figure 2.05-48. Camshaft Pilot Tool
97
Figure 2.05-49. Camshaft Removal
97
Figure 2.05-50. Lube Oil Leveler
98
Figure 2.05-51. Lube Oil Leveler
98
Figure 2.05-52. Breather System
98
Figure 2.05-53. Fuel Regulator Support
98
Figure 2.05-54. Air/Gas Starter Motor Connections
98
Figure 2.05-55. Oil Pan Removal
99
Figure 2.05-56. Oil Pump
99
Figure 2.05-57. Crankcase Spreader Tool
99
Figure 2.05-58. Main Bearing Cap Thrust Washer
99
Figure 2.05-59. Bearing Cap Crossbolt
100
Figure 2.05-60. Crankshaft Removal
100
Figure 2.05-61. Oil Gallery Plug
100
Figure 2.05-62. Oil Gallery Plug
100
Figure 2.05-63. Crankcase Rear Dowels
100
Figure 3.00-2. Rocker Arm Support Wrench
101
Figure 3.00-3. Rocker Arm Support
101
Table 3.00-1. Special Tools for Cylinder
101
Figure 3.00-4. Intake and Exhaust Rocker
102
Table 3.00-2. Rocker Arm Assemblies
102
Figure 3.00-5. Cross Bars and Seats
103
Figure 3.00-6. Cross Bar Assembly
103
Figure 3.00-7. Cross Bar Measurement
103
Figure 3.00-8. Cross Bar Guide and Seat
103
Table 3.00-3. Cross Bar ID Specifications
103
Table 3.00-4. Cross Bar Guide OD
103
Table 3.00-5. Cross Bar to Guide Clearance
104
Table 3.00-6. Cross Bar Seat Specifications
104
Figure 3.00-10. Rocker Arm Support
105
Figure 3.00-11. Spark Plug Tube
105
Figure 3.00-12. Cylinder Head Face
106
Figure 3.00-13. Measure Head for
106
Figure 3.00-14. Measure Valve Recession
106
Figure 3.00-15. Remove Water Jet
106
Figure 3.00-16. Valve Split Locks
107
Figure 3.00-17. Remove Valve Springs
107
Figure 3.00-18. Valve Removal
107
Figure 3.00-20. Valve Seat Removal Tool
107
Figure 3.00-21. Valve Guide Removal Tool
108
Figure 3.00-22. Valve Rework Dimensions
109
Table 3.00-7. Valve Clearances
110
Table 3.00-8. Valve Guide Clearances
111
Figure 3.00-23. Valve Guide Installation
112
Figure 3.00-24. Valve Seat Installation Tool
113
Figure 3.00-25. Measure Valve Recession
113
Figure 3.00-26. Valve Recession
113
Figure 3.00-27. Measure Valve Seat
114
Figure 3.00-28. Valve Seat Dimensions
114
Table 3.00-9. Valve Seat Insert Grinding
114
Table 3.00-10. Valve Seat Clearances
115
Table 3.00-11. Valve Spring Clearances
116
Figure 3.00-29. Expander Plug Location
117
Figure 3.00-30. Expander Plug Installation
117
Figure 3.00-31. Water Jet Installation
117
Figure 3.00-32. Spark Plug Holder P/N 305003J
117
Figure 3.00-33. Spark Plug Holder Seal
118
Figure 3.00-34. Spark Plug Holder Tool
118
Figure 3.00-35. P/N AE300302C Cylinder
118
Figure 3.00-36. Valve Stem Seal Installation Tool
119
Figure 3.00-37. Valve Seat
119
Figure 3.00-38. Install Valve Springs
119
Figure 3.00-39. Valve Spring Compressor
120
Figure 3.00-40. Valve Springs
120
Figure 3.00-41. Cross Bars and Seats
120
Figure 3.00-42. Rocker Cover Head Studs
120
Table 3.05-1. Crankcase Tools
121
Figure 3.05-1. Crankshaft Set Screws
122
Figure 3.05-2. 12 Cylinder Crankshaft
123
Figure 3.05-3. Crankshaft
125
Figure 3.05-4. Inspect Cam Followers
126
Table 3.05-2. Camshaft
126
Figure 3.05-5. Camshaft Follower
127
Figure 3.05-6. Camshaft Follower
127
Figure 3.05-7. Piston Pin
128
Figure 3.05-8. Piston Ring Removal
128
Table 3.05-3. Camshaft Follower Tolerances
128
Figure 3.05-9. Piston Oil Drain Holes
129
Table 3.05-4. Piston Tolerances
130
Figure 3.05-10. Check Piston Ring Groove
131
Table 3.05-5. Piston Ring Dimensions
131
Figure 3.05-11. Piston Pin
132
Figure 3.05-12. Connecting Rod
133
Figure 3.05-13. Connecting Rod, Bushing and Bearing
133
Table 3.05-7. Connecting Rod, Bushing and
133
Table 3.05-8. Connecting Rod, Bushing and
133
Figure 3.05-14. Connecting Rod Bushing Press Removal
134
Table 3.05-9. Connecting Rod, Bushing and
134
Figure 3.05-15. Connecting Rod Bushing
135
Figure 3.05-16. Connecting Rod Small End
135
Figure 3.05-17. Connecting Rod Bushing
135
Figure 3.05-18. Flexible Hone
136
Figure 3.05-19. Cylinder Sleeve Deglazing Cross Hatch Pattern
136
Table 3.05-10. Cylinder Liner Dimensions
137
Figure 3.05-20. Lower Cylinder Liner
138
Table 3.05-11. Crankcase Dimensions
138
Figure 3.05-21. Flywheel Ring Gear
139
Figure 3.05-22. Timing Tape Installation
139
Figure 3.05-23. Dual Dowel Pin Crankcase
140
Figure 3.05-24. Crankshaft Spreader Tool
141
Figure 3.05-25. Crossbolt Oil Passage
141
Figure 3.05-26. Main Bearing Cap Installation
142
Figure 3.05-27. Crossbolt Oil Passage
142
Figure 3.05-28. Measure Main Bearing
142
Figure 3.05-29. Crankshaft Main Bearing
143
Figure 3.05-30. Main Bearing Running
143
Table 3.05-12. Main Bearings
143
Figure 3.05-31. Bearing Thickness Formula
144
Table 3.05-13. Crankshaft Specifications
144
Figure 3.05-32. Measure Camshaft Bearing
145
Figure 3.05-33. Cam Thrust Bushing
145
Figure 3.05-34. Camshaft Bushing Press
145
Figure 4.00-1. Crankcase Dowel Pin
146
Figure 4.00-2. Dual Dowel Pin Crankcase
146
Table 4.00-1. Special Tools
146
Figure 4.00-3. Crankshaft Counterweights
147
Figure 4.00-4. Crankshaft Plugs
147
Figure 4.00-5. Upper Main Bearing
147
Figure 4.00-6. Crankshaft Rigging
147
Figure 4.00-7. Dual Dowel Pin Crankcase
148
Figure 4.00-8. Crankcase Spreader Tool
148
Figure 4.00-9. Main Bearing Cap Installation
148
Figure 4.00-10. Main Bearing Cap Thrust
149
Figure 4.00-11. Crossbolt Oil Passage
149
Figure 4.00-12. Crankshaft Gear Installation
149
Figure 4.00-13. Main Bearing Cap
149
Figure 4.00-14. Main Bearing Cap Thrust
150
Figure 4.00-15. Bearing Cap Crossbolt
150
Figure 4.00-16. Crossbolt Oil Passage
150
Figure 4.00-17. Crankshaft Gear Installation
150
Figure 4.00-18. Cylinder Liner Assembly
151
Figure 4.00-19. Cylinder Liner Installation Tool
151
Figure 4.00-20. Camshaft Bushing Press Installation
152
Figure 4.00-21. Cam Bearing Installation
152
Figure 4.00-22. Front Camshaft Bushing
152
Figure 4.00-23. Cylinder Head Stud
153
Figure 4.00-24. Crankcase Parallel Pin
153
Figure 4.00-25. Piston -- Connecting Rod
153
Figure 4.00-26. Connecting Rod Bushing
154
Figure 4.00-27. Middle Compression Rings
154
Figure 4.00-28. Oil Control Ring Expander
155
Figure 4.00-29. Oil Control Ring Teflon
155
Figure 4.00-30. Middle Compression Rings
155
Figure 4.00-31. Piston Ring Installation
156
Figure 4.00-32. Piston Installation Tool
156
Figure 4.00-33. Piston Ring Compressor P/N 472076
156
Figure 4.00-34. Rod End
156
Figure 4.00-35. Piston Installation
157
Figure 4.00-36. Connecting Rod Cap
157
Figure 4.00-37. Offset Adapter on Connecting Rod
157
Figure 4.00-38. Offset Adapter Dimension
158
Figure 4.00-39. Adapter Installed Inline with
158
Figure 4.00-40. Adapter Install 90_ to
158
Figure 4.00-41. Adapter Installed at Angle to Wrench
159
Figure 4.00-43. Piston Cooling Jet Clearance
159
Figure 4.00-44. Oil Galley Plug Detail
160
Figure 4.00-45. Oil Gallery Plug Installation
160
Figure 4.00-46. Oil Gallery Plug Installation
160
Figure 4.00-47. Crankcase Set Screw
160
Figure 4.00-48. Oil Gallery Plug
160
Figure 4.00-49. Pipe Adapter Installation
161
Figure 4.00-50. Stud Adapter
161
Figure 4.00-52. Prelube Connection
161
Figure 4.00-53. Rear Lifting Eye
162
Figure 4.00-54. Rear Lifting Eye Brace
162
Figure 4.00-55. Idler Gear Oil Supply
162
Figure 4.00-56. Water Pump Idler
162
Figure 4.00-57. Water Pump Idler Housing
163
Figure 4.00-59. Gear Housing Guide Pins
163
Figure 4.00-60. Gear Housing Gasket
164
Figure 4.00-61. Gear Housing Installation
164
Figure 4.00-62. Oil Supply Tube
164
Figure 4.00-63. Magneto Drive Studs
164
Figure 4.00-64. CEC Cover Studs
165
Figure 4.00-65. Remove Excess RTV in
165
Figure 4.00-66. Camshaft Installation
165
Figure 4.00-67. Camshaft Thrust Bushing
165
Table 4.05-1. Special Tools for Cylinder
166
Figure 4.05-3. Cylinder Head Installation
167
Figure 4.05-4. Cylinder Head Installation
167
Figure 4.05-5. Rear Lifting Eye Brace
167
Figure 4.05-6. Cylinder Head Bolt Tightening
167
Figure 4.05-9. Cross Bar Assembly
168
Figure 4.05-10. Cross Bar Installation
168
Figure 4.05-11. Pushrod Installation
168
Figure 4.05-12. Rocker Arm Components
169
Figure 4.05-13. Rocker Arm Support
169
Figure 4.05-14. Rocker Arm Support
169
Figure 4.05-15. Rocker Arm Support
169
Figure 4.05-16. Cylinder Head Exhaust Ports
170
Figure 4.05-17. VGF Exhaust Manifold Drain Hole
170
Figure 4.05-18. F18GL Exhaust Manifold
170
Figure 4.05-19. Water Elbow Assembly
171
Figure 4.05-20. Previous-Water Elbow Assembly
171
Figure 4.05-22. Intake Manifold Installation
171
Figure 4.05-25. Rocker Cover Installation
172
Figure 4.05-26. CSA Valve Cover
172
Figure 4.05-28. CSA Flange Mounted Coil
173
Figure 4.05-29. CSA High Tension Coil Lead
173
Figure 4.05-30. High Tension Coil Lead
173
Figure 4.10-1. High Tension Coil Lead
174
Figure 4.10-3. Rocker Cover Removal Tool P/N 472074
174
Figure 4.10-4. CSA High Tension Coil Lead
174
Figure 4.10-5. CSA Flange Mounted Coil
175
Figure 4.10-6. CSA Rocker Arm Cover
175
Figure 4.10-7. Rocker Arm Cover Removal Tool
175
Figure 4.10-8. Rocker Arm Adjusting
176
Figure 4.10-9. Rocker Arm Adjustments
176
Figure 4.10-10. CSA Valve Cover
177
Figure 4.10-11. CSA Flange Mounted Coil
177
Figure 4.10-12. CSA High Tension Coil Lead
177
Figure 4.10-13. High Tension Coil Lead
177
Section 5.00 - - Engine Speed Governing System
178
Figure 5.00-3. PSG Governor
179
Figure 5.00-5. 4024 Governor and Linkage
179
Figure 5.00-6. Governor Rod and Lever
179
Figure 5.00-7. PSG and EG3P Governor Rod
180
Figure 5.00-8. 4024 Governor and Linkage
180
Figure 5.00-9. 4024 Governor Rod Length
180
Figure 5.00-10. Governor Air Actuator
180
Figure 5.00-11. Air Actuator
181
Figure 5.00-12. PSG Governor Linkage
182
Figure 5.00-13. EG3P Governor Linkage
183
Figure 5.00-14. 4024 Governor Linkage Adjustment
184
Figure 5.00-15. Governor Speed Sensor
184
Figure 5.00-16. Alternate Speed Sensor
184
Figure 5.00-17. Ring Gear Tooth Alignment
185
Figure 5.00-18. Magnetic Pickup Sensor
185
Figure 5.00-19. Valve Adjustment (PSG)
185
Figure 5.00-20. Governor Rod
186
Figure 5.00-21. Governor Oil Drain Tube
186
Figure 5.00-23. Governor Drive Location
186
Figure 5.00-25. Governor Drive Disassembly
187
Figure 5.00-26. Governor Drive Disassembly
187
Figure 5.00-27. Governor Drive Gear, Shaft and Coupling
187
Figure 5.00-28. Governor Drive Bearings
187
Figure 5.00-29. Governor Drive Disassembly
188
Figure 5.00-30. Governor Drive
188
Figure 5.00-31. Governor Drive Assembly
188
Figure 5.00-32. Governor Drive Location
189
Figure 5.00-33. Governor Drive Installation
189
Figure 5.00-34. 4024 Actuator Mounting
189
Figure 5.00-35. 4024 Governor and
189
Figure 5.00-36. EG3P Gasket
190
Figure 5.00-38. Gasket Located on EG3P Governor Base
190
Figure 5.00-39. Magneto Drive Oil Supply
190
Figure 5.00-41. Governor Oil Drain Tube
191
Figure 5.00-43. Governor Regulator Shaft
193
Figure 5.00-44. Support Bracket
193
Figure 5.00-45. Governor Shaft Support
193
Figure 5.00-46. Universal Joints
193
Figure 5.00-47. Quick Start Oil Supply
194
Figure 5.00-48. Oil Fill Location
194
Figure 5.00-49. Governor Quick Start Oil Supply
195
Figure 5.00-50. Air Actuator Installation
196
Figure 5.00-51. Governor Throttle Control
197
Figure 5.00-52. Governor Throttle Control
197
Figure 5.05-1. Impco 200 Carburetor
198
Figure 5.05-2. H24G Impco 600 Carburetor
198
Section 5.05 - - Fuel System
198
Figure 5.05-3. F18/H24 GLD IMPCO 600D Carburetor
199
Figure 5.05-4. Impco 400 Carburetor
199
Figure 5.05-5. F18/H24 GLD Deltec Fuel System
199
Figure 5.05-6. F18/H24 GLD Deltec Fuel System
199
Figure 5.05-8. Shutoff Valve
200
Figure 5.05-9. F18G Carburetor
200
Figure 5.05-10. Impco 200 Fuel Piping
200
Figure 5.05-11. Impco 200 Balance Tube
201
Figure 5.05-12. Butterfly Valve
201
Figure 5.05-13. 4024 Actuator Linkage
201
Figure 5.05-14. Butterfly Valve
201
Figure 5.05-16. Proper Gas Valve Assembly
203
Figure 5.05-17. Balance Line
203
Figure 5.05-18. Governor Linkage
203
Figure 5.05-19. GL Impco 400 Carburetor
204
Figure 5.05-20. Intercooler to Carburetor
204
Figure 5.05-21. Butterfly Valve Housing
204
Figure 5.05-22. Impco 400 VF Carburetor
205
Figure 5.05-23. Offset Connection
205
Figure 5.05-24. Intercooler to Carburetor
205
Figure 5.05-25. Butterfly Valve Housing
205
Figure 5.05-27. 4024 Actuator Linkage
206
Figure 5.05-28. Balance Line
206
Figure 5.05-29. F18/H24G Impco Carburetor
206
Figure 5.05-30. H24G Impco
207
Figure 5.05-31. H24G Impco
207
Figure 5.05-32. H24G Impco
207
Figure 5.05-33. F18/H24G IMPCO Carburetor
207
Figure 5.05-34. Impco GLD Fuel Piping
208
Figure 5.05-35. F18/H24 GLD IMPCO 600D
208
Figure 5.05-37. Impco GLD Carburetor
208
Figure 5.05-38. Carburetor Fuel Connection
209
Figure 5.05-39. Impco GLD Fuel Piping
209
Figure 5.05-40. Impco 600D Carburetor
209
Figure 5.05-41. F18/H24GLD Impco 600D
209
Figure 5.05-42. Impco 600D Carburetor
210
Figure 5.05-43. GLD/GSID Turbo Air Inlet
210
Figure 5.05-44. Carburetor Fuel Connection
210
Figure 5.05-45. Typical Impco
211
Figure 5.05-46. Typical Impco
212
Figure 5.10-1. Ignition Module Diagnostic Leds
213
Figure 5.10-108. CEC Ignition Module
213
Figure 6.00-3. Ignition Switch
213
Figure 5.10-2. Current Ignition Module
214
Figure 5.10-3. Previous Ignition Module
214
Figure 5.10-4. CEC Timing Disc
214
Figure 5.10-5. Hall--Effect Pickup Location
214
Section 5.10 - - Ignition System - - Cec/Magneto
214
Figure 5.10-6. F18/H24 Magneto
215
Figure 5.10-7. Standard Ignition Coil
215
Figure 5.10-8. CSA Flange Mounted Ignition
216
Figure 5.10-10. Standard Ignition Coil Heat
216
Figure 5.10-11. Shielded Ignition System
216
Figure 5.10-12. CSA Stop Switch
216
Figure 5.10-13. Shielded Ignition System
217
Figure 5.10-14. #1 Cylinder Junction Box
217
Figure 5.10-15. Timing Marks
217
Figure 5.10-16. Shielded Ignition Timing Light
217
Figure 5.10-17. Shielded Ignition Switch
218
Figure 5.10-18. Rocker Arm Cover
219
Figure 5.10-20. CSA Ignition Coil
219
Figure 5.10-22. CSA Ignition Assembly
220
Figure 5.10-23. Shielded Ignition Assembly
220
Figure 5.10-24. Spark Plug Extension
221
Figure 5.10-25. Coil Installation
221
Table 5.10--1. Spark Plug Specifications
222
Table 5.10--2. Spark Plug Troubleshooting
222
Table 5.10--3. Spark Plug Recommendations
222
Figure 5.10-26. CSA Ignition Coil
223
Figure 5.10-27. Standard Ignition Coil
223
Table 5.10--4. Special Tools for Testing Ignition Coil
223
Figure 5.10-28. Ignition Module Ground Wire
224
Figure 5.10-29. Standard Ignition Coil
224
Figure 5.10-30. Standard Ignition Coil
224
Figure 5.10-31. Standard Ignition Coil
225
Figure 5.10-32. CSA Ignition Coil
225
Figure 5.10-33. CSA Ignition Coil
225
Figure 5.10-34. Standard Ignition Coil
225
Figure 5.10-35. Conduit Box
226
Figure 5.10-36. Standard Ignition Coil
226
Figure 5.10-37. CSA (Flange Mounted)
226
Figure 5.10-38. CSA Flange Mounted Coil
227
Figure 5.10-39. Spark Plug Extension
227
Figure 5.10-40. Standard Ignition Coil
227
Figure 5.10-41. Coil Ground Wire
228
Figure 5.10-42. Current Blue Coil
228
Figure 5.10-43. Coil Installation
229
Figure 5.10-44. CSA Ignition Coil
229
Figure 5.10-45. Current Ignition Module
229
Figure 5.10-47. Non CSA Ignition Harness
230
Figure 5.10-48. Current Ignition Module
230
Figure 5.10-49. Conduit Box
230
Figure 5.10-52. Current Ignition Module
231
Figure 5.10-53. Six Cylinder Ignition Module
232
Figure 5.10-54. Eight Cylinder Ignition Module
232
Figure 5.10-55. Eight Cylinder Magneto Harness
233
Figure 5.10-56. Six Cylinder Magneto Harness
233
Figure 5.10-57. Conduit Box
233
Figure 5.10-59. Wiring Harness Clip
234
Figure 5.10-60. Wiring Harness
234
Figure 5.10-61. Coil Ground Wire
234
Figure 5.10-62. Magneto Pin Connector
234
Figure 5.10-63. Previous Ignition Module Position
235
Figure 5.10-64. Current Ignition Module Position
235
Figure 5.10-65. H24 (Non--CSA) Junction
236
Figure 5.10-66. CEC Ignition Module/Junction
236
Figure 5.10-67. Junction Box and Bracket
236
Figure 5.10-68. Ignition Module Bracket
237
Figure 5.10-69. H24 KDM
237
Figure 5.10-70. F18 Bracket and Brace
237
Figure 5.10-71. H24 Bracket and Brace
238
Figure 5.10-73. CSA Ignition Harness (Right Side)
239
Figure 5.10-74. F18 Standard Ignition
239
Figure 5.10-75. H24 KDM/CSA
240
Figure 5.10-76. F18 KDM/CSA
240
Figure 5.10-77. Ignition Timing Cover
240
Figure 5.10-78. Camshaft Gear
240
Figure 5.10-79. CEC Ignition Module Timing
241
Figure 5.10-80. CEC Ignition Timing Cover
241
Figure 5.10-81. Hall--Effect Pickup
241
Figure 5.10-82. Previous Ignition Module Selector Switch
242
Figure 5.10-83. Current Ignition Module Selector Switch
242
Figure 5.10-84. CEC Ignition Module Selector Switches
242
Table 5.10--5. Ignition Module Selector Switch Settings
242
Figure 5.10-85. Ignition Module 16 Position Switches
243
Table 5.10--6. Firing Order for VGF 6 Cylinder Engines
243
Table 5.10--7. Firing Order for VGF 8 Cylinder Engines
243
Table 5.10--8. F18/H24 CEC Ignition Module Switch Positions
243
Figure 5.10-86. Conduit Box
244
Figure 5.10-87. Flywheel Timing Marks
244
Figure 5.15-1. F18 Air Cleaner
245
Figure 5.15-2. Turbocharger
245
Figure 5.15-3. Intercooler
245
Section 5.15 - - Air Induction System
245
Section 5.20 - - Turbocharger
245
Figure 5.15-4. Throttle Valve
246
Figure 5.15-5. GL Carburetor
246
Figure 5.15-6. H18G Carburetor
246
Figure 5.15-7. F18/H24GSID Carburetor
246
Figure 5.15-8. F18/H24 GLD Deltec Fuel
247
Figure 5.15-9. F18/H24 GLD IMPCO 600D Carburetor
247
Figure 5.15-10. Air Filter Restriction Indicator
247
Figure 5.15-11. GL -- Filter Restriction
247
Figure 5.15-12. Restriction Filter
248
Figure 5.15-14. F18/H24 GSID Air Cleaner with Offset Studs
250
Figure 5.15-15. F18 Air Cleaner
250
Figure 5.15-16. H24G Air Duct Brace
250
Figure 5.15-17. Dual Fuel Air Duct Support
251
Figure 5.15-19. F18/H24G IMPCO
251
Figure 5.15-20. G Air Duct Support Bracket
251
Figure 5.15-21. F18 Air Cleaner
251
Figure 5.15-22. Turbocharger Air Elbow
252
Figure 5.15-23. Closed Breather Connection
252
Figure 5.15-24. Air Duct Brace
252
Figure 5.15-25. G Air Duct Support Bracket
252
Figure 5.15-26. GLD Deltec Dual Fuel
252
Figure 5.15-27. Deltec Air Duct Mounting
253
Figure 5.15-28. Air Duct Mounting Pad
253
Figure 5.15-29. Air Duct Support Bracket
253
Figure 5.15-30. Air Duct Brace
253
Figure 5.15-31. F18/H24G IMPCO
254
Figure 5.15-32. GL Air Elbow Installation
254
Figure 5.15-33. GSID/GLD Upper Bracket
254
Figure 5.15-34. GSID/GLD Lower Bracket
254
Figure 5.15-35. GSID Carburetor
255
Figure 5.15-36. Intercooler
255
Figure 5.15-37. Deltec Air Duct
255
Figure 5.15-38. F18GLD Deltec Dual Fuel
255
Figure 5.15-39. Air Actuator
256
Figure 5.15-40. 4024 Governor
256
Figure 5.15-41. Throttle Valve
256
Figure 5.15-42. Shaft Support Bracket
256
Figure 5.15-43. Control Panel
257
Figure 5.15-44. Closed Breather System
257
Figure 5.15-45. Carburetor Air Connection
257
Figure 5.15-46. Intake Manifold Removal
257
Figure 5.15-48. Intake Manifold Installation
258
Figure 5.15-49. Carburetor Air Connection
258
Figure 5.15-50. Intake Manifold Assembly
259
Figure 5.15-51. Closed Breather System
259
Figure 5.15-53. CEC Ignition Module
260
Figure 5.15-54. 4024 Governor
260
Figure 5.15-55. Air Actuator
260
Figure 5.15-56. Butterfly Valve
260
Figure 5.15-57. Shaft Support Bracket
260
Figure 5.15-58. Shaft Support Bracket
260
Figure 5.20-1. Heat Shield
261
Figure 5.20-2. Heat Shield Attachment
261
Figure 5.20-3. Heat Shield Attachment
261
Figure 5.20-4. CSA Coil Heat Shields
262
Figure 5.20-5. Heat Shield Attachment
262
Figure 5.20-7. GLD/GSID Turbocharger Air
262
Figure 5.20-8. Turbocharger Connection
262
Figure 5.20-9. Breather Ejector
263
Figure 5.20-10. Wastegate Bypass Tube
263
Figure 5.20-11. Exhaust Outlet Elbow
263
Figure 5.20-13. Turbocharger Oil Supply Tubes
263
Figure 5.20-14. Turbocharger Oil Supply Tubes
264
Figure 5.20-15. Turbocharger Removal
264
Figure 5.20-16. Turbocharger V--Band
264
Figure 5.20-17. Turbocharger Compressor
265
Figure 5.20-18. Turbocharger Compressor
265
Table 5.20--1. Turbocharger Shaft
265
Figure 5.20-19. Turbocharger Axial (End)
266
Figure 5.20-20. Check Turbocharger Radial
267
Figure 5.20-21. Garret Turbocharger
267
Figure 5.20-22. Turbocharger Installation
268
Figure 5.20-23. Turbocharger Exhaust Inlet
268
Figure 5.20-24. Turbocharger Oil Supply
268
Figure 5.20-25. Turbocharger Oil Supply
268
Figure 5.20-28. V-Band Coupling
269
Figure 5.20-29. Wastegate Bypass Tube
269
Figure 5.20-30. Wastegate Bypass Tube
269
Figure 5.20-31. Breather Ejector
269
Figure 5.20-32. Turbocharger Air Outlet
270
Figure 5.20-33. Turbocharger Connection
270
Figure 5.20-35. GLD/GSID Turbocharger Air Inlet
270
Figure 5.20-36. Heat Shield Attachment
271
Figure 5.20-37. CSA Coil Heat Shields
271
Figure 5.20-38. Heat Shield Attachment
271
Figure 5.20-39. Heat Shield Attachment
271
Figure 5.25-1. Jacket Water Pump
272
Section 5.25 - - Cooling System
272
Figure 5.25-2. Auxiliary Water Pump
273
Figure 5.25-3. Jacket Water Thermostat Housing
273
Figure 5.25-4. Auxiliary Thermostat
273
Figure 5.25-5. Surge Tank
273
Figure 5.25-6. Thermostat Housing
273
Figure 5.25-7. Jacket Water Header Air Bleed
274
Figure 5.25-8. Intercooler Air Bleed
275
Table 5.25--4. Air Bleed Petcocks
275
Table 5.25--6. Water Drain Petcocks
276
Figure 5.25-9. Jacket Water Pump Seal
277
Figure 5.25-10. Auxiliary Water Pump Inspection
278
Figure 5.25-11. Jacket Water Pump
278
Figure 5.25-12. Jacket Water Pump Inlet
278
Figure 5.25-13. Jacket Water Pump
278
Figure 5.25-14. Water Pump Inlet Assembly
279
Figure 5.25-15. Jacket Water Pump Inlet
280
Figure 5.25-16. Jacket Water Connections
280
Figure 5.25-17. Air Bleed Tube Support
280
Figure 5.25-18. Jacket Water Pump
281
Figure 5.25-19. Jacket Water Pump
281
Figure 5.25-20. Jacket Water Pump
281
Figure 5.25-21. Auxiliary Water Pump Inspection
281
Figure 5.25-22. Auxiliary Water Pump Clamp
281
Figure 5.25-24. Jacket Water Pump Mounting
282
Figure 5.25-25. Jacket Water Pump
282
Figure 5.25-26. Jacket Water Pump
282
Figure 5.25-27. Auxiliary Water Pump Clamp
282
Figure 5.25-28. Jacket Water Pump
283
Figure 5.25-29. G Series Water Pump
283
Figure 5.25-32. Pump P/N A301060C for Naturally Aspirated Engines
284
Figure 5.25-33. Remove Impeller
284
Figure 5.25-34. Pump P/N AC301060C for Turbocharged Engines
285
Figure 5.25-35. P/N 301060A Pump Body
286
Figure 5.25-36. Press Bushing into Pump
286
Figure 5.25-37. Water Pump Oil Seal
286
Figure 5.25-38. Water Pump Bearing
287
Figure 5.25-39. Water Pump Shaft/Bearing
287
Figure 5.25-40. Water Pump Gear
287
Figure 5.25-41. Water Pump Shaft
287
Figure 5.25-42. Water Pump Seal
288
Figure 5.25-43. Water Pump Seal and
288
Figure 5.25-44. Install Inner Race on Shaft
288
Figure 5.25-45. Water Pump Gear Housing
288
Figure 5.25-46. Water Pump Gear Housing
289
Figure 5.25-47. Pump Nut
289
Figure 5.25-48. Pump P/N D301060B
289
Figure 5.25-49. Auxiliary Water Pump
289
Figure 5.25-50. Auxiliary Water Pump
290
Figure 5.25-51. Auxiliary Water Pump
290
Figure 5.25-52. Auxiliary Water Pump
290
Figure 5.25-53. Auxiliary Water Piping
290
Figure 5.25-54. Auxiliary Water Pump and
291
Figure 5.25-55. Auxiliary Water Pump
291
Figure 5.25-56. Water Pump Mounting
291
Figure 5.30--1. Oil Pump
292
Figure 5.30--2. Lube Oil Cooler Housing
292
Figure 5.30--3. Piston Cooling Control Valve
292
Section 5.30 - - Lubrication System
292
Figure 5.30--4. VGF Inline Engine Lube Oil
293
Table 5.30-1. Oil Recommendations
294
Table 5.30-2. Recommended Lube Oils for Cogeneration Applications (Using Pipeline Quality Gas)
295
Table 5.30-3. Recommended Lube Oils Landfill Gas Applications
296
Table 5.30-4. Used Oil Testing and
298
Table 5.30-5. VGF Sump and Header Temperatures and SAE Number
298
Table 5.30-6. Oil Consumption
299
Figure 5.30--5. Lube Oil Filter Canisters
300
Table 5.30-7. Recommended Oil Change Intervals for Engines Receiving Normal Maintenance
300
Table 5.30-8. Recommended Oil Change
300
Table 5.30-9. Duty Cycle Definitions
300
Figure 5.30--6. Oil Cooler
301
Figure 5.30--7. Oil Fill Location
301
Figure 5.30--8. Dipstick
301
Figure 5.30--9. Microspin Centrifuge
302
Figure 5.30--10. Microspin Cleanable Oil Filters
302
Figure 5.30--12. Oil Pressure Differential
303
Figure 5.30--13. Service and Cleaning of Microspin Centrifuge -- P/N 489300
303
Figure 5.30--14. Oil Cooler
304
Figure 5.30--15. Auxiliary Water Thermostat
305
Figure 5.30--16. Inlet Oil Cooler Water
305
Figure 5.30--17. Oil Cooler Water Tube
305
Figure 5.30--18. Oil Cooler Outlet Elbow
305
Figure 5.30--19. Oil Filter Support
305
Figure 5.30--20. Oil Filter and Cooler
306
Figure 5.30--21. Oil Filter and Cooler
306
Figure 5.30--23. Oil Cooler Cover
306
Figure 5.30--24. Oil Cooler Elements
306
Figure 5.30--26. Oil Filter to Oil Cooler
307
Figure 5.30--27. Oil Cooler Assembly
308
Figure 5.30--28. Oil Cooler Elements
308
Figure 5.30--29. Oil Cooler Cover
308
Figure 5.30--30. Oil Cooler Elements
309
Figure 5.30--31. Oil Filter and Cooler
309
Figure 5.30--32. Oil Filter and Cooler
309
Figure 5.30--33. Oil Filter and Cooler
309
Figure 5.30--34. Oil Filter Support Mounting
309
Section 5.35 - - Exhaust System
310
Figure 5.35-1. Thermocouple Conduit
311
Figure 5.35-2. Exhaust Manifold Thermocouple
311
Figure 5.35-3. Exhaust Outlet Thermocouple
311
Figure 5.35-4. Turbocharger and Heat Shield
312
Figure 5.35-5. Breather Ejector
312
Figure 5.35-6. Wastegate Actuator Vent
312
Figure 5.35-7. Exhaust Outlet Thermocouple
312
Figure 5.35-8. Wastegate Bypass Tube
312
Figure 5.35-9. Exhaust Outlet
313
Figure 5.35-10. Exhaust Outlet
313
Figure 5.35-11. Exhaust Outlet Heat Shield
313
Figure 5.35-12. Exhaust Outlet
313
Figure 5.35-13. Exhaust Outlet
314
Figure 5.35-14. Wastegate Bypass Tube
314
Figure 5.35-15. Breather Ejector
314
Figure 5.35-16. Exhaust Outlet Thermocouple
314
Figure 5.35-17. Wastegate Actuator Vent
314
Figure 5.35-18. Heat Shield
315
Figure 5.35-20. Standard Heat Shield
315
Figure 5.35-21. CSA Coil Heat Shields
315
Figure 5.35-22. Wastegate Sensing Tube
315
Figure 5.35-23. Wastegate Sensing Tube
316
Figure 5.35-24. Wastegate Actuator Vent
316
Figure 5.35-25. Wastegate Bypass Tube
316
Figure 5.35-27. Wastegate Bypass Tube
316
Figure 5.35-28. Wastegate Bypass Tube
317
Figure 5.35-29. Wastegate Sensing Tube
317
Figure 5.35-30. Heat Shield Attachment
317
Figure 5.35-31. GSID/GLD Air Cleaner
317
Figure 5.35-32. Deltec GLD Vent Tube
317
Figure 5.35-33. Wastegate Assembly
318
Figure 5.35-34. Wastegate Actuator
319
Figure 5.35-35. Actuator Adjustment
319
Table 5.35--1. Preliminary Wastegate
319
Table 5.35--2. F18GL and H24GL LCR Wastegate "A" Dimensions
319
Figure 5.35-36. Compressor Discharge and Intake Manifold
320
Figure 5.35-37. F18/H24 Turbocharger
320
Figure 5.35-38. Jacket Water Connections
321
Figure 5.35-39. Thermocouple Conduit
321
Figure 5.35-40. Cylinder Head Water
321
Figure 5.35-41. F18/H24G Auxiliary Water Pipe
321
Figure 5.35-42. Exhaust Manifold
321
Figure 5.35-43. Cylinder Head Exhaust Ports
322
Figure 5.35-44. Exhaust Manifold Drain
322
Figure 5.35-45. Exhaust Manifold
324
Figure 5.35-46. Exhaust Manifold Torque
324
Figure 5.35-47. Exhaust Manifold End
324
Figure 5.35-48. F18/H24G Manifold Heat
324
Figure 5.35-49. F18/H24G Manifold Heat
324
Figure 5.35-51. Wastegate Mounting Plate
325
Figure 5.35-52. Cylinder Head Exhaust
325
Figure 5.35-53. VGF Exhaust Manifold Drain
325
Figure 5.35-54. F18GL Bracket Location
325
Figure 5.35-55. Thermocouple Installation
326
Figure 5.35-56. Inline Engine Exhaust Thermocouple Installation
326
Figure 5.35-57. Water Elbow Assembly
326
Figure 5.35-58. Previous-Water Elbow Assembly
326
Figure 5.35-59. Jacket Water Thermostat
327
Figure 5.35-60. F18/H24G Auxiliary Water
327
Figure 5.40-1. Open Breather
328
Figure 5.40-2. Oil Separator
328
Section 5.40 - - Crankcase Breather System
328
Figure 5.40-3. Ventilation System Baffle Box
329
Figure 5.40-4. Closed Breather System
329
Figure 5.40-5. Closed Breather System
329
Figure 5.40-6. F18/H24 Deltec GLD Breather
329
Figure 5.40-7. Vacuum Regulator
329
Figure 5.40-8. GL Breather Ejector
330
Figure 5.40-9. Deltec Closed Breather
330
Figure 5.40-10. GLD Closed Breather
330
Figure 5.40-11. Previous Closed Breather
330
Figure 5.40-12. Current Closed Breather
330
Figure 5.40-13. Ventilation System Baffle
331
Figure 5.40-14. Previous Upper Oil Separator Inlet Tube
331
Figure 5.40-15. Current Upper Oil Separator Inlet Tube
331
Figure 5.40-16. GL Breather Ejector
332
Figure 5.40-17. Previous F18/H24 Breather System Adjusting Valve
332
Figure 5.40-19. Separator Body
333
Figure 5.40-20. Current Breather Regulator
333
Figure 5.40-21. Breather Regulator
334
Figure 5.40-22. Baffle Box Breather System Common Parts
335
Figure 5.40-23. Ventilation System Baffle
336
Figure 5.40-24. KDM Bracket/Baffle Box
336
Figure 5.40-25. Six Cylinder Module
336
Figure 5.40-26. Eight Cylinder Module
336
Figure 5.40-28. Oil Separator Support
337
Figure 5.40-30. Breather System Oil Drain
337
Figure 5.40-31. H24 Oil Drain Tube
337
Figure 5.40-32. GLD Closed Breather
338
Figure 5.40-33. F18/H24 Impco GLD
338
Figure 5.40-34. GLD Closed Breather System
338
Figure 5.40-35. GLD Closed Breather
339
Figure 5.40-36. G Closed Breather System
339
Figure 5.40-37. G Closed Breather System
339
Figure 5.40-38. Breather Ejector Installation
339
Figure 5.40-39. Ejector Support Bracket
339
Figure 5.40-40. Ejector Assembly
340
Figure 5.40-41. GL Breather Ejector
340
Figure 5.40-42. Breather Ejector
340
Figure 5.40-43. F18GL Ejector Breather
340
Figure 5.40-44. Vacuum Regulator
340
Figure 5.40-45. Closed Breather System
341
Figure 5.40-46. Closed Breather Ejector
342
Figure 5.40-47. Upper Oil Separator Inlet
343
Figure 5.40-48. Drain Connections
343
Figure 5.40-49. Lower Oil Separator Inlet
343
Figure 5.40-50. Oil Separator Support
343
Figure 5.40-51. Air Cleaner
343
Figure 5.40-52. Oil Separator
344
Figure 5.40-53. Oil Separator Filter Element
344
Figure 5.40-54. F18GL Bracket Location
344
Figure 5.40-55. H24GL Bracket Location
345
Figure 5.40-57. H24 GL Breather Assembly
346
Figure 5.40-59. Crankcase Oil Drains
346
Figure 5.40-60. Air Duct Assembly
347
Figure 5.40-61. Oil Separator Drain Hose
347
Figure 5.45-1. Air/Gas Starter Motor
348
Figure 5.45-2. Air/Gas Starter Motor
348
Figure 5.45-3. Air/Gas Starter Motor
348
Section 5.45 - - Starting System
348
Figure 5.45-5. Air/Gas Starter Assembly
350
Figure 5.45-6. Air/Gas Starter Motor
350
Figure 5.45-7. Air/Gas Starter Support
350
Figure 5.45-8. Air/Gas Starter Lubricator Oil
350
Figure 5.45-9. Air/Gas Starter Control
351
Figure 5.45-10. Control Valve Mounting
351
Figure 5.45-11. Start Push Button Valve
351
Figure 5.45-12. Air/Gas Starter Push Button
351
Figure 5.45-13. Air/Gas Starter Local
352
Figure 5.45-14. Air/Gas Starter Local Control
353
Figure 5.45-15. Air/Gas Starter Local Control
353
Figure 5.45-16. Air/Gas Starter Control
353
Figure 5.45-17. Remote Start Solenoid
353
Figure 5.45-18. Air/Gas Starter Remote Start
354
Figure 5.45-20. Alternator Adjustment
355
Figure 5.45-21. Alternator Belt Adjustment
356
Figure 5.45-22. Alternator Mounting Brackets
356
Figure 5.45-23. Alternator Drive Pulley
356
Figure 5.45-25. 24 Volt Alternator
357
Figure 5.45-26. Alternator Adjustment
357
Figure 6.00-1. Control Panel
358
Figure 6.00-2. Ignition Switch
358
Figure 6.00-4. Control Panel
359
Figure 6.00-5. Temperature and Oil Pressure
359
Figure 6.00-6. Manifold Pressure Gauge
359
Figure 6.00-8. Instrument Panel
359
Figure 6.00-9. Instrument Panel Installation
360
Figure 6.00-11. Auxiliary Control Panel
361
Figure 6.00-12. Oil Temperature Gauge
361
Figure 6.00-13. Oil Temperature Gauge
361
Figure 6.00-14. Oil Temperature Gauge
361
Figure 6.00-16. Jacket Water Temperature Gauge
362
Figure 6.00-18. Tachometer Magnetic Pickup
362
Figure 6.00-19. Alternative Speed Sensor
362
Figure 6.00-20. Ring Gear Tooth Alignment
363
Figure 6.00-21. Install Pickup Sensor
363
Figure 6.00-22. Manifold Pressure Gauge
363
Figure 6.00-23. Manifold Temperature Fitting
363
Figure 6.00-24. Oil Gauge Supply Tube
364
Figure 6.00-25. Oil Pressure Gauge
364
Figure 6.00-26. Manifold Pressure Gauge
364
Figure 6.00-27. Ignition Switch
364
Figure 6.00-28. Air/Gas Starter Control Valve and Vent
364
Figure 6.00-29. Instrument Panel Gauge
365
Figure 6.00-30. Control Panel Reset Switch
365
Figure 6.05-1. Manual Shutdown Lever
366
Figure 6.05-2. Ignition Switch
366
Figure 6.05-3. Optional Instrument Panel
367
Figure 6.05-4. Typical Switchgage
367
Table 6.05--1. VGF Shutdown Limits
368
Figure 6.05-5. Thermocouple Quick
369
Figure 6.05-6. Thermocouple Installation
369
Figure 6.05-7. K--Type Thermocouple
370
Figure 6.05-8. Thermocouple Installation
370
Figure 6.05-9. K--Type Thermocouple
370
Figure 6.05-10. Exhaust Thermocouple Installation
370
Figure 6.05-11. Thermocouple Installation
371
Figure 6.05-12. Thermocouple Connector
371
Figure 6.05-13. Thermocouple Conduit Mounting
371
Figure 6.05-14. Flexible Conduit Routing
371
Figure 6.05-15. Current Junction Box
371
Figure 6.05-16. Thermocouple Junction Box
372
Figure 6.05-17. Exhaust Manifold
372
Figure 6.05-18. Exhaust Outlet Thermocouple
372
Figure 6.05-19. Thermocouple Connections
372
Figure 6.05-20. Thermocouple Installation
373
Figure 6.05-21. Overspeed Shutdown
373
Figure 6.05-22. Knock Detection Module
374
Figure 6.05-23. Rear Knock Sensor
374
Figure 6.05-24. Knock Sensor Seating
375
Figure 6.10-1. Current Production Jacket Water
376
Figure 6.10-3. F18/H24 Jacket Water Heater
377
Figure 6.10-4. Water Heater Fittings
378
Figure 6.10-5. Jacket Water Heater
378
Figure 6.10-6. Heater Outlet Tube
378
Figure 6.10-7. Jacket Water Heater
378
Figure 6.10-8. Heater Inlet Tube
379
Figure 6.10-9. Temperature Controller Support
379
Figure 6.10-10. Temperature Controller
379
Figure 6.10-11. Heater Wiring Conduit
379
Figure 6.10-12. Surge Tank
380
Figure 6.10-13. Surge Tank
380
Figure 6.10-14. Surge Tank Thermostat
380
Figure 6.10-15. Surge Tank Bracket
380
Figure 6.10-16. Surge Tank
381
Figure 6.10-17. Surge Tank Installation
382
Figure 6.10-18. Oil Level Regulator Mounting
383
Figure 6.10-20. Oil Level Regulator
383
Figure 6.10-21. Oil Level Regulator Vent
383
Figure 6.10-22. Oil Level Regulator Vent
383
Figure 6.10-24. Crankshaft Pulleys
384
Figure 6.10-25. Alternator Guards
384
Figure 6.10-26. F18 Vibration Damper
384
Figure 6.10-27. F18/H24 Vibration Damper
385
Figure 6.10-28. Vibration Damper Guard
385
Figure 6.10-29. Vibration Damper Guard
385
Figure 6.10-30. Vibration Damper Guard
386
Figure 6.10-31. Vibration Damper Guard
386
Figure 6.10-32. Vibration Damper Guard
386
Figure 6.10-33. Vibration Damper Guard
386
Figure 6.10-34. Guard Cover
386
Figure 6.10-37. Alternator Guard
388
Figure 6.10-38. Alternator Adjusting Rod
388
Figure 6.10-39. Alternator Rear Guard
388
Figure 6.10-40. Flywheel Stub Shaft
389
Figure 6.10-41. Alternator Guard
389
Figure 6.10-42. Stub Shaft Assembly
389
Figure 6.10-43. Checking Stub Shaft
390
Figure 6.10-44. Indicate Flywheel Face
390
Figure 6.15-1. CEC Generator System
391
Figure 6.15-2. CEC Generator Installation
392
Figure 6.15-3. Voltage Regulator Installation
392
Figure 6.15-4. Wiring Harness Routing
392
Figure 6.15-5. CEC Type I Generator Wiring Schematic
393
Figure 6.15-6. CEC Type II Generator Wiring Schematic
394
Figure 6.15-7. CEC Type I System with
395
Figure 7.00-1. Engine Compression
405
Figure 7.00-2. Correction Factor
405
Table 7.00-1. Troubleshooting
406
Table 7.05--1. VGF F18/H24 Routine
409
Table 7.05--2. Recommended Oil Change
411
Table 7.05--3. Recommended Oil Change
411
Table 7.05--4. Duty Cycle Definitions
411
Table 7.05--5. F18 Maintenance Parts Reference
412
Table 7.05--6. H24 Maintenance Parts Reference
412
Table 7.05--7. Preservative Oils
413
Table 7.05--8. Protective Materials
413
Table 7.05--9. Preservative Oil Capacity
413
Figure 4.00-70. Camshaft Follower
423
Figure 5.45-4. Air/Gas Starter
423
Table 5.25--9. Auxiliary Cooling Water
423
Table 5.40--1. Crankcase Pressure
423
Figure 3.00-9. Rocker Arm Assembly
424
Figure 4.05-7. Spark Plug Holder
424
Figure 5.10-51. Wiring Harness
424
Figure 5.10-109. CEC Ignition Module
424
Table 1.20-6. Crankshaft
424
Figure 4.00-90. Front Gear Cover
425
Figure 4.00-111. Flywheel Housing Installation
425
Figure 5.05-7. Fuel Pressure Regulator
425
Figure 5.20-12. Exhaust Outlet
425
Figure 5.20-26. Exhaust Outlet
425
Figure 5.20-27. Exhaust Outlet
425
Figure 5.45-19. Electric Starter
425
Figure 5.00-42. Governor Linkage
426
Figure 5.05-26. Governor Linkage
426
Figure 5.05-78. Manifold Elbow
426
Figure 5.15-52. Instrument Panel
426
Figure 5.25-129. Auxiliary Water
426
Figure 5.25-131. High Temperature Water
426
Figure 6.00-7. Instrument Panel
426
Figure 6.10-2. Jacket Water Heater
426
Figure 5.10-110. Magneto Ignition System
427
Figure 5.30--48. Lube Oil Pressure Regulator
427
Figure 5.30--49. Piston Cooling Control Valve
427
Figure 5.40-18. Oil Separator
427
Figure 6.10-35. Alternator Guard
427
Figure 6.10-36. Pulley Guard
427
Table 1.20-16. Oil Pump
427
Table 3.05-6. Piston Pin
427
Figure 4.00-116. Oil Pan Gasket Installation
429
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