SECTION 4.

15
AIR INTAKE SYSTEM MAINTENANCE

AIR INTAKE SYSTEM MAINTENANCE Precleaner Pad Removal -- 6 And 12 Cylinder

AIR FILTER MAINTENANCE
On 6 and 12 cylinder engines, the air restriction indicator
(see Figure 4.15-1) will show “red” if the air intake
restriction is 15 in. (381 mm) of water. This indicates a
clogged or dirty main air filter element and/or clogged or
dirty precleaner element.
On 16 cylinder engines a gauge for each air filter
indicates the condition of the precleaner filter and main
air filter. Each gauge should register in the “green
range.” A switch allows the operator to monitor the
pressure of the precleaner and main filter pressure
independently.
The precleaner is a foam rubber pad that increases the
life of the main air filter element. Inspect and clean the
precleaner pad daily or as required. This can be done
while the engine is running. Replace the precleaner pad
every 4000 running hours, or more often if necessary.
1. Locate the four threaded mounting studs on the air
cleaner assembly and loosen the front lock nut
(5/16 inch) on each (see Figure 4.15-2). (The rear
locknut is loosened only for removal of the main air filter
frame and element.)
2. Raise up and remove the rain shield.
3. Peel the precleaner pad off the main air filter
element.

AIR DUCT

MAIN AIR FILTER

ELEMENT

AIR RESTRICTION
INDICATOR

PRECLEANER
PAD

FILTER ELEMENT
FRAME

RAIN SHIELD

Figure 4.15-1. Air Cleaner Assembly -- 6 And 12 Cylinder Engines

FORM 6277 Second Edition 4.15 -- 1

AIR INTAKE SYSTEM MAINTENANCE

AIR FILTER ELEMENT

Precleaner Pad Installation -- 6 And 12 Cylinder
AIR
DUCT
AIR FILTER
FRAME On new engines remove
RAIN the cardboard insert be-
SHIELD tween the rainshield and precleaner pad must be
removed before the engine is started. Disregarding
this information could result in product damage.

1. Reinstall the precleaner pad between the rain shield

and the main air filter element. If necessary, use a drop
of adhesive on the corners to keep it from falling.

2. Do not clean and reuse the precleaner pad more than

FRONT
three times. Replace with a new precleaner pad.
LOCK BRACKET
NUT STEP NOTE: Use only Waukesha supplied precleaner pads.

3. Lower the rain shield on the four mounting studs of

the air cleaner assembly. Alternately re-tighten the front
lock nuts (5/16 inch).

4. Clean or replace the main air filter element if the air

FLAT intake restriction indicator shows “red” after installation
WASHER
of a new or cleaned precleaner pad.
REAR FLAT MOUNTING
LOCK NUT WASHER STUD
Main Air Filter Element Removal -
6 And 12 Cylinder
Figure 4.15-2. Air Cleaner Assembly --
Inspect and clean the main air filter element daily or as
6 And 12 Cylinder Engines
required. Replace main air filter element if the air
restriction indicator “indicates red” after the air cleaner is
Precleaner Pad -- Cleaning And Inspection -- cleaned and the precleaner pad has been replaced or
6 And 12 Cylinder cleaned.
1. Wash the precleaner pad with soap and water. 1. Locate the four threaded mounting studs on the air
cleaner assembly and loosen the front lock nut
Do not use compressed (5/16 inch) on each (see Figure 4.15-2 and
air when cleaning the Figure 4.15-3).
precleaner pad. Compressed air can easily damage
the foam rubber pad. 2. Raise up and remove the rain shield.

3. Peel the precleaner pad off the main air filter

2. Air dry the pad. Do not use compressed air.
element.

4. Loosen the rear lock nut (5/16 inch) on each

mounting stud until the flat washer behind it can be
brought forward far enough to clear the step in the
welded bracket of the main air filter frame (see
Figure 4.15-2).

5. Swing the four mounting studs to the outside in a

horizontal motion. Remove the main air filter frame and
element.

4.15 -- 2 FORM 6277 Second Edition

 AIR INTAKE SYSTEM MAINTENANCE

Do not use compressed

AIR CLEANER air when cleaning the air
ASSEMBLY filter element. Compressed air can easily damage
the pleated paper of the main air filter element.

C. Air dry the element. Do not use compressed air.

AIR 2. Carefully examine the element after cleaning. If
RESTRICTION
INDICATOR damaged, replace.

NOTE: Use only Waukesha supplied air filter elements.

MOUNTING STUD
(4 TOTAL) 3. Do not clean and reuse the main air filter element
more than three times. Replace with a new element.

4. Inspect the air duct for cracks. All of the combustion

AIR FILTER FRAME
air must pass through the main air filter element, not
through cracks or defects in the air cleaner assembly. If
inspection of the duct work and intake manifold yields an
accumulation of dust and grit, it is an indication that the
main air filter element is not properly maintained or that
air is getting into the system around or behind the
element.

5. Inspect all air duct hoses. Replace any hose that is

cracked or aged.

Main Air Filter Element Installation --

RAIN SHIELD
Figure 4.15-3. Air Cleaner Assembly -- 6 Cylinder
Main Air Filter Element -- Cleaning And Inspection
-- 6 And 12 Cylinder
1. Clean the main air filter element using the following
method.
A. Gently tap the element on a flat surface with the
dirty side of the element down.
6 And 12 Cylinder
NOTE: The orange flow arrow on the instruction label
points toward the air outlet side. Always store the
elements with the air outlet side down. Dirt and dust on
the outlet side will pass into the engine when the
element is installed.
1. Install the main air filter element with the instruction
label facing up. Fit the deflection brace on the outlet side
of the filter element over the horizontal bar running
across the front of the air duct chamber.
2. Place the frame over the main air filter element.

3. Swing the four threaded mounting studs to the inside

Compressed air can pierce the skin and cause
severe injury or death. Never use your hand to check
for leaks or to determine air flow rates. Wear safety
glasses to shield your eyes from flying dirt and
debris.
B. Using an OSHA approved safety nozzle, direct
compressed air through the element opposite the
direction of the air flow, as indicated by the
orange arrow on the instruction label. The air
pressure should be a maximum of 30 psi
(207 kPa).
in a horizontal motion so that they fit within the welded
brackets on the air filter frame. Move the flat washer
behind the rear lock nut back into the step in the welded
bracket.
4. Install the precleaner pad between the rain shield
and the main air filter element. If necessary, use a drop
of adhesive on the corners to keep it from falling.
5. Lower the rain shield on the four mounting studs.
6. Alternately tighten the rear lock nuts (5/16 inch).
7. Alternately tighten the front lock nuts (5/16 inch) on
the four mounting studs.

FORM 6277 Second Edition 4.15 -- 3

AIR INTAKE SYSTEM MAINTENANCE

8. Check the frame of the main air filter element to verify 1. Raise up and remove the rain shields.
that its perimeter is sealed tightly. Damage to the frame
may result in improper element sealing. 2. Open the front grate to remove the prefilter pads from
the prefilter frame (see Figure 4.15-5).
NOTE: After the restriction problem is corrected, reset
the indicator by depressing the black button on the
plastic housing.

The location of the air restriction indicator relative

to the intake manifold causes it to be subjected to
high pressure if the engine backfires. A restriction
filter must be installed in the indicator air passage to
dampen high pressure surges which would other-
wise damage the indicator. Through the projection
of broken material, damage to the indicator might
pose a potential danger to persons standing nearby.
The restriction filter also protects against the
entrance of dust and dirt in the event that the
Figure 4.15-5. Prefilter Pad -- 16 Cylinder
restriction indicator is broken off or removed.
Disregarding this information could result in severe
personal injury or death. 3. Discard the prefilter pads.

9. Verify that the restriction filter is in place between the
clean air tap and indicator.
Do not grasp the indicator housing; the plastic may
crack or break resulting in a hand injury.
Prefilter Pad Removal -- 16 Cylinder
The prefilter is a filament pad that increases the life of
the main air filter element (see Figure 4.15-4 and
Figure 4.15-6). Inspect and clean the prefilter pad daily
or as required. This can be done while the engine is
running. Replace the prefilter pad every 4000 running
hours, or more often if necessary.
Prefilter Pad Installation -- 16 Cylinder
The dark blue sides of the
prefilter pads must face
the main air cleaner elements or damage to equip-
ment could result.
1. Install the new prefilter pads in the grates so that the
dark blue sides of the prefilter pads will face towards the
main air filter elements when the prefilter pads are
installed.
2. Close the front grate door and secure by inserting the
ends of the grate in the slots in the prefilter frame (see
Figure 4.15-5).
3. Install the rain shields.

Main Air Filter Element Removal -- 16 Cylinder

Inspect and clean the main air filter element daily or as
required. Replace main air filter element if the air
restriction indicator “indicates red” after the air cleaner is
cleaned and the prefilter pad has been replaced.
1. Raise up and remove the rain shield.

2. Locate the four mounting clamps on the front of the

air cleaner assemblies and loosen the clamps to remove
the prefilter frame and prefilter pads (see
Figure 4.15-5).

3. Discard the prefilter pads.

Figure 4.15-4. Air Cleaner Assembly -- 16 Cylinder 4. Pull out the main air filter elements.

4.15 -- 4 FORM 6277 Second Edition

 AIR INTAKE SYSTEM MAINTENANCE

AIR CLEANER
HOUSING

PREFILTER CLAMPS

DECAL

MAIN AIR FILTER

ELEMENT

PREFILTER FRAME
WITH HINGED GRID

PREFILTER ELEMENT
(COLORED SIDE IN)

Figure 4.15-6. Air Cleaner Assembly -- 16 Cylinder Engines

Main Air Filter Element -- Cleaning And Inspection
-- 16 Cylinder
1. Clean the main air filter element using the following
method.
Do not use compressed
air when cleaning the air
filter element. Compressed air can easily damage
the pleated paper of the main air filter element.

A. Gently tap the element on a flat surface with the C. Air dry the element. Do not use compressed air.
dirty side of the element down. 2. Carefully examine the element after cleaning. If
damaged, replace.

NOTE: Use only Waukesha supplied air filter elements.

Compressed air can pierce the skin and cause
severe injury or death. Never use your hand to check 3. Do not clean and reuse the main air filter element
for leaks or to determine air flow rates. Wear safety more than three times. Replace with a new element.
glasses to shield your eyes from flying dirt and
4. Inspect the air duct for cracks. All of the combustion
debris.
air must pass through the main air filter element, not
through cracks or defects in the air cleaner assembly. If
B. Using an OSHA approved safety nozzle, direct
inspection of the duct work and intake manifold yields an
compressed air through the element opposite the
accumulation of dust and grit, it is an indication that the
direction of the air flow, as indicated by the hand
main air filter element is not properly maintained or that
on the side of the filter element. The air pressure
air is getting into the system around or behind the
should be a maximum of 30 psi (207 kPa).
element.

5. Inspect all air duct hoses. Replace any hose that is

cracked or aged.

FORM 6277 Second Edition 4.15 -- 5

AIR INTAKE SYSTEM MAINTENANCE
Main Air Filter Element Installation -- 16 Cylinder
On new engines remove
the cardboard insert be-
tween the rainshield and prefilter pad before start-
ing the engine. Disregarding this information could
result in product damage.
The pleats of the main air
filter must be positioned
vertically in the air filter housing or damage to
equipment could result.
NOTE: The hand on the side of the filter element points
toward the air outlet side of the air filter housing. Also a
label with a pair of eyes printed on it is positioned on the
air inlet side of the filter element. These eyes should be
visible from the air filter housing inlet opening and at the
top of the air cleaner, if the filter is properly installed. If
both labels are missing, one side of the air filter element
has a metal brace horizontally across the back. This side
should be positioned, towards the air outlet side. Always
store the elements with the air outlet side down. Dirt and
dust on the outlet side will pass into the engine when the
element is installed.
4.15 -- 6
1. Install the main air filter elements with the hand on
the side of the filter elements pointing toward the air
outlet side of the filter housings. Ensure that the pleats of
the elements are positioned vertically.
Make sure he dark blue
sides of the prefilter pads
face the main air cleaner elements or damage to
equipment could result.
2. Install the new prefilter pads in the grates so that the
dark blue sides of the prefilter pads will face towards the
main air filter elements when the prefilter pads are
installed.
3. Position the front grate and prefilter pad assemblies
on the air filter housings and secure using the four
clamps (see Figure 4.15-5).
4. Install the rain shields.
FORM 6277 Second Edition