GE Power

Waukesha* gas engines

VHP Packaging Guide

*
with ESM1 and AFR2
General packaging guidelines to help meet the best recommended practices for the application and
use of Waukesha VHP L5794GSI, L7042GSI S4, L7044GSI, and P9394GSI engines with ESM1 and AFR2.

form 10026-4

* Indicates a trademark of the General Electric Company

Chapter 23 Maintenance Considerations
TYPICAL MAINTENANCE SCHEDULE
Table 23-2: Typical Service Schedule

Engine Model Top End Overhaul Hours Bottom End Overhaul Hours
L5794GSI 25,000 50,000
L7042GSI S4 32,000 64,000
L7044GSI 22,000 44,000
P9394GSI 24,000 48,000

Table 23-3: Typical Maintenance Schedule

Bottom End Overhaul

Daily (or as required)

Top End Overhaul

12000 Hours
2000 Hours

3000 Hours

4000 Hours

8000 Hours
500 Hours

720 Hours
ITEM SERVICE
Air Cleaner Filter Element Check/Clean or Replace •
Pre-Lube Motor Lubricator (if equipped) Check/Fill •
Cooling Systems Fluid Level (Jacket and Auxiliary) Check/Fill •
Crankcase Oil Level Check/Fill •
ESP Fault History (If active alarms) Review (Monthly)
•
Engine Oil Analysis
•
ESP Total Fault History Review (Monthly) •
Auxiliary Water Pump Lubricate •
Idler Pulley Bearings (both Jacket & Auxiliary
Pumps)
Lubricate
•
Spark Plugs Replace •
Ignition Coils Inspect, replace o-ring as needed •
Spark Plug Extensions Inspect, replace rubber boot and
o-ring as needed
•
Belts - JW & AW pumps, and alternator (if
equipped)
Check/adjust
•
Crankcase Pressure Check per crankcase breather
system maintenance
•
Engine Oil and Filter* (3,000 hours or annually,
whichever comes first) for ISO Standard or
Change Oil and Filter
•
Continuous Duty with Extender Package,
Microspin, High Capacity Oil Pan w/o analysis)
Oil Cooler* (Oil Side) (Maintain with appropriate oil
change interval)
Drain
•
Oil Separator* (Microspin) (Maintain with
appropriate oil change interval)
Clean per lubrication system
maintenance
•
Magnetic Plugs (turbo & rocker arm) Clean per lubrication system
maintenance
•

23 - 4 Form 10026-4
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Maintenance Considerations Chapter 23

Bottom End Overhaul

Daily (or as required)

Top End Overhaul

12000 Hours
2000 Hours

3000 Hours

4000 Hours

8000 Hours
500 Hours

720 Hours
ITEM SERVICE
Oxygen Sensors (with AFR2 or emPact options
only)
Replace**
•
Gas Regulator Filter Clean/Replace per fuel system
maintenance
•
Cooling Water Analysis Check
•
Engine Protection Devices Test and Calibrate**
•
Valve Clearance Adjust per valve adjustment
procedure and specification
•
Cylinder Compression (align w/ spark plug change) Check
•
Knock Sensors Inspect for dirt/grit, connector wear
and corrosion
•
Turbocharger (12-cylinder) Clean/Inspect per turbocharger
maintenance
•
Cooling System (Jacket and Auxiliary), if no
analysis program
Clean and Flush
•
Crankcase Oil Pickup Screen (low capacity oil pan
only)
Clean
•
Engine Mounting and Alignment Check
•
Exhaust Backpressure Check
•
Throttle Actuator Linkage Inspect, Lubricate, Test (as needed)
•
ESM (& emPact, if equipped) System Wiring Visually Inspect Wire Harnesses,
Secure Connections, Check Ground
•
Connections, Verify Incoming Power
is Within Specification
IPM-D Timing Disc/Pick-Up Clean/Inspect
•
Auxiliary Water/Coolant Hoses Inspect/Replace as necessary
•
Oil Pan Clean
•
Intercooler (Air-Side) Clean/Inspect
•
Carburetor Air/Gas Valve Inspect/Replace as necessary
•
Carburetor Diaphragm Replace
•
Carburetor Gasket Replace
•
All belts (Engine) Inspect/Replace
•
Crankcase Pressure Relief Valves, if equipped Inspect
•
Crankcase Breather Element Replace
•
Breather Check Valve Clean/Inspect
•

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Chapter 23 Maintenance Considerations

Bottom End Overhaul

Daily (or as required)

Top End Overhaul

12000 Hours
2000 Hours

3000 Hours

4000 Hours

8000 Hours
500 Hours

720 Hours
ITEM SERVICE
Wastegate Rebuild
•
Catalyst (emPact options), if equipped Inspect, Clean (as needed)
•
Crankcase Pressure Regulator Valve Rebuild (replace diaphragm &
o-rings)
•
Turbocharger (16-cylinder) Clean/Inspect per turbocharger
maintenance
•
Cylinder Heads Rebuild
•
Crankshaft Inspect
•
Conn Rod Inspect/Replace
•
Bearing, Idler Pulley Replace
•
Plunger, Relief Valve Replace
•
Bushing, Oil Pump Gear Replace
•
Spring, Relief Valve Replace
•
Jacket Water Thermostat Replace
•
Rod Bearing Asm. Replace
•
Bearing, Gov. Rod End Replace
•
Spindle, Idler Gear Replace
•
Bearing, Idler Gear - Front Replace
•
Spindle, Oil Pump Gear Replace
•
Cylinder Liner Replace
•
Oil Pump Rebuild
•
Bushing, Piston Pin Replace
•
Auxiliary Water Pump Rebuild
•
Bearing, Main Replace
•
Camshaft Bushing Replace
•
Bearing, Connecting Rod Replace
•
Auxiliary Water Thermostat Replace
•
Jacket Water Pump Rebuild
•
Push Rod Assembly Replace
•

23 - 6 Form 10026-4
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Maintenance Considerations Chapter 23

Bottom End Overhaul

Daily (or as required)

Top End Overhaul

12000 Hours
2000 Hours

3000 Hours

4000 Hours

8000 Hours
500 Hours

720 Hours
ITEM SERVICE
Lube Oil Thermostat Replace
•
Tappet Asm, Valve Replace
•
Damper, Vibration Replace
•
Camshaft Inspect
•
Bearing, Idler Gear - Rear Replace
•
* Because of ongoing evaluation and continual updates to Waukesha’s oil recommendations, see the latest edition of Waukesha
Lube Oil Recommendations S1015-30 in Technical Data

** Local regulations may require more frequent maintenance

EMERGENCY SPARES
An emergency spares list is available upon request. Please contact application engineering
or local sales representative.

SPECIAL TOOLS
Waukesha has developed various special tools which have been designed to simplify per-
forming maintenance on a VHP engine.

Table 23-4: Special Tools for VHP

L7042GSI S4

P9394GSI
L5794GSI

L7044GSI

PART NUMBER DESCRIPTION

X X X X 494217 COMPRESSION TESTER/ADAPTER
X X X X 494287 VALVE ADJUSTING WRENCH
X X X X 494385 SEAL REMOVER TOOL
X X X X 474034 VALVE SPRING COMPRESSOR
X X X X 474038 VALVE SEAT EXTRACTOR
X X X X 474040 VALVE BRIDGE GUIDE TOOL
X X X X 474046 VALVE GUIDE REAMER
X X X X 495327 VALVE STEM SEAL INSTALLER
X X X X 495328 INTAKE VALVE SEAT INSTALLER
X X X X 495329 EXHAUST VALVE SEAT DRIVER
X X X X 495330 BRIDGE GUIDE PIN DRIVER
X X X X 474044 VALVE GUIDE STRAIGHTNESS GAUGE
X X X X 474000 CAMSHAFT DUMMY GEAR
X X X X 474005 STOP SLEEVE
X X X X 474013 WATER PUMP KIT

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Chapter 23 Maintenance Considerations

L7042GSI S4

P9394GSI
L5794GSI

L7044GSI
PART NUMBER DESCRIPTION
X X X X 474025 CAM BEARING ROLLOUT TOOL
X X X 474041 9-3/8 IN. PISTON RING EXPANDER
X 474042 8-1/2 IN. PISTON RING EXPANDER
X 494085 8-1/2 IN. BORE RING COMPRESSOR
X X X 494206 9-3/8 IN. BORE RING COMPRESSOR
X 494284 8-1/2 IN. SLEEVE PLATE
X X X 494286 9-3/8 IN. SLEEVE PLATE
X X X X 494366 MAIN BEARING ROLL-OUT TOOL (T-DRILLED)
X X X X 499233 CYLINDER SLEEVE REMOVAL KIT
X X X X 495350 SPARK PLUG SLEEVE SEAT RESURFACER
X X X 474018 VHP GAS PISTON PULLER – 9-3/8 IN. BORE
X 474019 VHP GAS PISTON PULLER – 8-1/2 IN. BORE

NOTE: Hand Tool Kit 494261 is recommended as the best method to obtain the needed hand
tools and torque wrenches.

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©2017 General Electric Company