SERVICE BULLETIN TOPIC: Satety Controls IDENT NO: 1—2197A SUPERSEDES: 1—2197 DATE: March 19, 1982 REVISED SUBJECT: TEMPERATURE SENSORS FOR MAIN BEARINGS. MODELS AFFECTED: VHP-Series-Engines: Waukesha Engine Division has a system available for monitoring the temperature of each main bearing. The system uses thermocouples as sensing devices. Leads from the thermocouples are run to a junction box, mounted on or near the engine; monitors or scanners are connected at the box. Monitors and scanners can be set to detect a maximum temperature limit, and to activate an audio or visual alarm if the bearing temperature exceeds that limit. The monitoring system may be ordered on new engines, or may be added to an engine during a major overhaul. Due to the complexity of the project, we do not recommend field installation at any time other than overhaul (On engines equipped with this system, the thermocouples are mounted in the main bearing caps. Current production engines have bearing caps that are predrilled for thermocouples. Previous engines had undrilled caps; you must drill and tap a hole for a thermocouple in each cap before installing the system. The thermocouple leads pass through packing gland fittings mounted in the oil pan and are channeled to a junction box, where the customer-supplied measuring equipment is connected. The oil pan can be modified by drilling and tapping holes for the necessary fittings. MODIFYING UNDRILLED MAIN BEARING CAPS To install the system in an engine with undrilled main bearing caps, you must drill and tap a hole in each cap as follows: You must determine whether the engine has fully grooved or partially grooved lower main bearings before drilling and tapping holes. Previous engines had fully grooved lower main bearings. The hole must be drilled 3/4” trom the front face of intermediate caps, or 1-5/16" from the front face of all other caps. Current production engines have partially grooved lower main bearings. The holes must be drilled on center of the bearing caps. 1. Remove the bearing caps and identify the location of each cap. 2. With the front of the cap toward you, spotface it according to the dimensions given in the illustration. It is important to maintain the 7-1/64” + 1/16” dimension. The surface must be cleaned up through a minimum arc of 240° at a minimum radius of 1/4” (250 rms). This ensures a proper seating surface for the valve lock nut.Page 2 of Service Bulletin no. 1—2197A dated March 19, 1982. DRILL THRU 272 CrORILL) Dau /3e, 18 DEER 7837 BRYSEAL NSF, 578° DEEP, SURFACE CLEAN UP 2aoewin, anc. fine nagus OF V4 BsoRws ML-20-94 3. Engines with fully grooved lower main bearings: Find the center of the main bearing cap (6-1/8" from the side face). Mark off a 15° angle from the center of the cap to the spotfaced area. On all but intermediate caps, measure 1-5/16” from the front of the cap. On intermediate caps, measure 3/4” from the front face. Punch a mark at the intersection of the 15° angle and the 1-8/16” or 3/4” measurement from the front face of the cap. Engines with partially grooved lower main bearings: Punch a mark on the centerline of the cap. (See illustration.) ML-20-98 4. Remove the bearing shells, if not already removed. At the punch mark, drill a 272" ("I" drill size) diameter hole through the cap at @ 15° angle (as illustrated). Redrill the hole 11/32, 7/8” deep. Tap the hole 1/8"-27 NPSF, 5/8” deep. All holes should be free of burrs. Remove all drilling chips from the bearing caps and oil pan. 5. Replace the caps and the bearings. Torque to specifications and in sequence as instructed in Service Bulletin no. 6-1793C. Bearing caps must be reinstalled in their original locations. 6. Install the thermocouples in the drilled and tapped holes. The thermocouples are spring-loaded; they will seat themselves as you screw the threaded portion into the holes. a | ———— THeRMocourLe “71S?Page 3 of Service Bulletin no. 1-2197A dated March 19, 1982. MODIFYING STANDARD OIL PANS 6 AND 12 CYLINDER ENGINES On 6 and 12 cylinder engines, drill and tap seven holes on the left side of the engine oil pan. Before ¢rilling, spotface an area around holes 1 and 7 (see illustration) 3/4” in diameter, to a maximum depth of 1/16”. NOTE If the oll pan casting does not have door pads cast solid between door openings, you must spotface an area for each drilled and tapped hole. Drill all seven holes 1-3/4” from the top of the pan and 5-7/8" to the right of the center lines of the oil pan doors. Holes 1, 3, and 5 are drilled 11/32" diameter through the pan to a depth of 1-3/8”; this is to break any sharp edges. Tapthe holes 1/8”-27 dryseal NPSF to a depth of 5/16". Holes 2, 4, 6 and 7 are drilled 11/32” diameter through the pan, and tapped 1/8”-27 dryseal NPSF to a depth of 5/16”. ML213-65 CLIPS AND DRILLING LOCATIONS: 6 AND 12 CYLINDER ENGINES Install a packing gland fitting in each hole and torque the back portion of the fitting to 20-25 ft Ibs. Before tightening the front portion of @ fitting, pull the corresponding lead through it The leads cannot be taut; there must be a small amount of slack, Take up the excess slack between the thermocouple and the fitting by gently pulling on the wire. After adjusting for the proper amount of slack, secure the wire in position by tightening the front portion of the fitting. BACK (TORQUE To Tousprt Les) i | — 1 it Wi Qn iL — Sa ML-213:63 PACKING GLAND FITTING Outside the oil pan, theleads are carried upward above the ail pan doors, and are then gathered and run collectively to the junction box. MOUNTING THE CLIPS AND JUNCTION BOX - 6 CYLINDER ENGINES On 6 cylinder engines, the leads are held by four clips. Clip supports are needed to mountthe first two clips, due to their low mounting holes. (See illustration.) The first clip (part _no. 169013) needs @ support {part no. 168847C), which is mounted in the uppermost of the two holes between the first and second oil pan doors. Use a 3/8"-16 x 3/4” screw and a lock washer to fasten the support (part nos. 21343 and 21052). Mount the clip to the support with the same hardware and a nut (part no. 21189). fa \ ae retioe ML21361 CLIPS AND SUPPORTS: 6 CYLINDER ENGINESPage 4 of Service Bulletin no. 1—2197A dated March 19, 1982, The second clip (part no. 169013G) must also be mounted on a support (part no. 168847F), Mount the clip under the top bolt of the cil dipstick flange. Mount the remaining two clips in existing holes on the engine crankcase, with 3/8"-16 x 3/4” cap screws and 3/8” lock washers (part nos. 21343 and 21052} You may mount the junction box in any convenient place, either on or off the engine; see illustration for the suggested on-engine mounting location. Keep in mind, however, that all thermocouple leads must reach it. Leads are 15 feet long. Attach the box to the mounting bracket, using 1/4"-20 x 5/8” cap screws, 1/4” lock washers and 1/4” nuts (part nos. 21273, 21050 and (21173). Use 1/2”-13 x 3-1/2” cap screws and 1/2" lock washers to mount the bracket (part nos. 21444 and 21084). If you are mounting iton the engine, remove four of the bolts that support the oil header assembly above the second oil pan door. Mount the bracket in these holes. Since this location is over the oil header assembly, use spacers (part no. 120132D) on the mounting screws between the bracket and the header. Mount the terminal block track in the box, using no. 10-32 x 1/2” phillips head screws, no. 10- 32 nuts and no. 10 lock washers (part nos. 21128, 21263 and 21049). The leads pass through heat-shrink tubing and into a connector mounted in the bottom of the box. One end of the tubing should be flush with the end of the connector, inside the box. If the bracket is mounted in the suggested on- engine location, it will interfere with the oil line connection for the accessory drive. Use a pipe nipple and a coupling (part nos. 65110X and 78209W) at the oil line connection to extend it out of the way. MOUNTING THE CLIPS AND JUNCTION BOX - 12 CYLINDER ENGINES On 12 cylinder engines, the leads are supported by three clips. Use 1/2"-13 x 3/4” cap screws and 1/2” lock washers to mount the clips in existing holes on the crankcase (part nos. 21422 and 21839). A clip is also included to be mounted on the crankcase under an existing bolt. You may mount the junction box in any convenient place, either on or off the engine; see illustration for the suggested on-engine mounting location. Keep in mind, however, that all thermocouple leads must reach it. Leads are 15 feet long. JUNCTION BOX 12 CYLINDER ENGINES Attach the box to its mounting bracket, using 1/4"-20 x 5/8" cap screws, 1/4" lock washers and 1/4"-20 nuts (part nos. 21273, 21050 and 21173). Use 3/8"-16 x 3/4” cap screws and 3/8” lock washers to mount the bracket (part nos. 21343 and 21052). if you are mounting iton the engine, attach the bracket in existing holes between the third and fourth oil pan doors. Use no. 10-32 x 1/2” screws, no. 10 lock washers and no. 10-32 nuts to mount the terminal block track in the box (part nos. 21128, 21049 and 21263). The leads pass through a Bakelite bushing mounted in the top of the box. MODIFYING STANDARD OIL PANS - 16 CYLINDER ENGINES On 16 cylinder engines, drill and tap 10 holes on the left side of the engine oil pan. Drill the holes 1-1/2" from the top of the pan and 5-9/16" to the right of the center lines of the oil pan doors.Page 5 of Service Bulletin no. 1—2197A dated March 19, 1982. (See illustration.) Drill the holes 11/32” diameter, through the pan. Tap the holes 1/8""- 27 dryseal NPSF through the pan. ML.213-66 CLIPS AND DRILLING LOCATIONS. 16 CYLINDER ENGINES Install a packing gland fitting in each hole and torque the back portion of the fitting to 20-25 ft Ibs. Before tightening the front portion of a fitting, pull the corresponding lead through it. The leads cannot be taut; there must be a small amount of slack. Take up the excess slack between the thermcouple and the fitting by gently pulling on the wire. After adjusting for the proper amount of slack, secure the wire in position by tightening the front portion of the fitting. MOUNTING THE CLIPS AND JUNCTION BOX - 16 CYLINDER ENGINES Outside the oil pan, the leads are carried upward above the oil pan doors, and are gathered and run collectively to a junction box. The leads are supported by five clips. Mount the clips on the crankcase, in existing holes, with 1/2"-13 x 3/4” cap screws and 1/2” lock washers (part nos. 21422 and 21054). You may mount the junction box in any convenient place, either on or off the engine; see illustration for the suggested on-engine ‘mounting location. Keep in mind, however, that all thermocouples leads must reach it. Leads are 15 feet long. Use 3/8”-16 x 7/8” cap screws, 3/8” lock JG/ih washers and 3/8”-16 nuts to attach the box to the bracket (part nos. 21346, 21189 and 21052). Mount the bracket, using 1/2"-13 x 1” cap screws and 1/2” lock washers (part nos. 21425 and 21084). If you are mounting it on the engine, attach the bracket in existing holes above and to the left of the first oil pan door. Use no. 10-32 x 1/2" screws, no. 10 lock washers and no. 10-32 nuts to mount the terminal block track in the box (part nos. 21128, 21049 and 21263). The leads pass through a Bakelite bushing that is mounted in the top of the box. WIRING THE JUNCTION BOX See illustration for details of a sample junction box for a 6 cylinder VHP series engine. Electrical connections in the junction box are made at terminal blocks. There are four wiring terminals in each terminal block, and one block for each thermocouple. Two of the wiring terminals are for thermocouple leads, and the other two are for the monitoring equipment hookup leads. MBER FER MARIN STRP AS SHOWN arofoiarra Teetses @ T anaes t ML213-66 6 CYLINDER ENGINE JUNCTION BOX WIRING The terminal blocks slide into a tray, in a single row. Attach this tray to the junction box, using ‘the appropriate hardware - see MOUNTING THE CLIPS AND JUNCTION BOX. Numbered tags are included for labeling the thermocouple terminals. For quick identification of the monitoring equipment terminals, you should hand-number the fiber marking strip that is in front of them. TECHNICAL PUBLICATIONS DEPARTMENTPagé 6 of Service Bulletin no. 12197 dated March 19, 1982 TEMPERATURE SENSOR INSTALLATION VHP SERIES 16 CYLINDER ENGINES PART NO. QUANTITY DESCRIPTION 208426 10 Thermocouple 208416 10 Fitting, Packing Gland 208420 1 Track, Terminal 208419 10 Block, Terminal 21128 2 Screw, Machine, Fillister Head, No. 10:32 x 1/2” 21263 2 Nut, Hex, No. 10:32 21049 2 Washer, Lock, No. 10 169013R 5 clip 21422 5 Screw, Cap, Hex Head, 1/213 x 3/4”” 21054 9 Washer, Lock, 1/2" 208009 1 Bracket, Junction Box 21425 4 Screw, Cap, Hex Head, 1/2"-13 x 1” | 2084134 1 Box, Junction 21346 4 Screw, Cap, Hex Head, 3/8”-16 x 7/8” 21082 4 Washer, Lock, 3/8” 21189 4 Nut, Hex, 3/8”-16 9513136 1 Bushing, Bakelite 8899 1 Tag #1 88994 1 Tag #2 88098 1 Tag #3 Ba99c 1 Tag 4 8899D 1 Tag #5 BEO9E 1 Tag *6 953058F 1 Tag #7 9530586 1 Tag #8 953058H 1 Tag #9 953058) 1 Tag #10Page 7 of Service Bulletin no. 1—2197A dated March 19, 1982 TEMPERATURE SENSOR INSTALLATION VHP SERIES 12 CYLINDER ENGINES PART NO. QUANTITY DESCRIPTION 208412 1 Bracket, Junction Box 208413 i Box, Junction 21343 4 Screw, Cap, Hex Head, 3/8"-16 x 3/4" } 21052 4 Washer, Lock, 3/8” 21273 4 Screw, Cap, Hex Head, 1/4”-20 x 5/8” 21050 4 Washer, Lock, 1/4” 21173 4 Nut, Hex, 1/420 21128 2 Screw, Machine, Fillister Head, No. 10-32 x 1/2” 208419 7 Block, Terminal 208420 1 Track, Terminal 208426 7 Thermocouple 208416 7 Fitting, Packing Gland 951313H 1 Bushing, Bakelite 1690136 3 Clip 169013 1 Clip 21422 3 Screw, Cap, Hex Head, 1/2”-13 x 3/4” 21539 3 Washer, Lock, 1/2 3899 1 Tag *1 BB99A vr Tag #2 88998 1 Tag #3 Be99C 1 Tag #4 B899D 1 Tag #5 B899E 1 Tag *6 953058 1 Tag *7 21263 2 Nut, Hex, No, 10:32 21049 2 Washer, Lock. No. 10Page 8 of Service Bulletin no. 121974 dated March 19, 1982. TEMPERATURE SENSOR INSTALLATION VHP SERIES 6 CYLINDER ENGINES PART NO. ‘QUANTITY DESCRIPTION 2084128 1 Bracket, Junction Box 208413 1 Box, Junction 21444 4 Screw, Cap, Hex Head, 1/2”-13 x 3-1/2" 1201320 4 Spacer 21273 4 Screw, Cap, Hex Head, 1/4”-20 x 5/8" 21050 4 Washer, Lock, 1/4”” 21173 4 Nut, Hex, 1/4"-20 21128 2 Screw, Machine, Fillister Head, No. 10-32 x 1/2” | 21263 2 Nut, Hex, No, 10-32 | 21049 2 Washer, Lock, No. 10 | 208420 1 Track, Terminal 208419 7 Block, Terminal 208426 7 Thermocouple 208416 7 Fitting, Packing Gland 106031 1 Connector, 90° 168847E 1 Support Clip 1690136 1 clip 169013 3 Clip | 168847¢ 1 Support Clip 21343 3 Screw, Cap, Hex Head, 3/8”-16 x 3/4” 21052 3 Washer, Lock, 3/8” 21189 2 Nut, Hex, 3/8”-16 2078568 1 Tube, Heat Shrink 65110X 1 Nipple, Pipe, 1/8” x 3/4” 78209W 1 Coupling, Pipe, 1/8” B899 1 Tag *1 BB99A 1 Tag #2 38998 1 Tag #3 g899c 1 Tag #4 88990 1 Tag #5 B899E 1 Tag *6 953058F 1 Tag *7srerpouoruy voy, sro ue 121089 ue word ue 10099 ‘o9po1sz - ae11002, sozouszao] | vororsz | ~ - 8 veitooe | eozocsevo 19 ‘e06e64 ‘ayaeneny op100%, ‘asri00e seui00%, wonon eg! 4 | agriooz| z| verioe |» vertooz | 000020 tse-020007 ‘eeny aoro0e, ow on 1 | aero} 2} o6vo0e |v actos | wozeooev | 1s0-s0-a0c907 aortooz, ‘asrio0e set1o0z ozzoozn| 1] sgvtcoz| z | vertooz | vertooz | Nozzooes 7 ~ sas aoriooz | asri00z aL 11002 wozesozo] 1 | soviooz} z} weno |» veriooe | Hozesozw “aseees aopiooz ‘o6y1002 act1002 oocesozo| 1 | aoniooe] z | vero |» vettooz | sozesozv | ts ‘oueses Isa'so-a96824 areca sa-aseac4 aorio0e ‘aspiooe actt002 wononvea] 1 | aariooz| z | vero |» vettooz | »ozesoew isp-0968z4 v9 ontuvas | avo ontuvan avo | savanosowuana| avo], ese ‘avo | _ Avawassy NINE Nivwinous | “niviwuvan | owavaa wiv wonv| 4 | omuvaa| * | omavaa | + onuvaa | 3gvoxNveD aarivoaus | anvuainas | 3iviqgMuaint vuumassn| 5 nivw| | wvauany | > Nivw | “auvanvis oaiuasua | ~asrmsaaua Sianassy snows ‘u31N39 |aaviaawe3int BSVONNVED lauvanws auvanvis ‘auvanvis Page 9 of Service Bulletin no. 1—2197A dated March 19, 1982.