GE Power & Water

Distributed Power

Waukesha* gas engines

VHP Packaging Guide

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

form 10026-2

* Trademark of General Electric Company

Chapter 22 Maintenance Considerations
Building ventilation is required to maintain a suitable temperature inside the building and
provide enough air to the intake ¿lters if they are mounted inside. Wherever they are mount-
ed there should be easy access to the ¿lters for maintenance purposes. The engine room
temperature should not exceed 65°C and the temperature to the intake ¿lters should be be-
low 38°C or the maximum engine output will be reduced. For these situations it is usually
bene¿cial to remotely mount the ¿lters or duct air from outside the building. Precautions
must be taken so that warm air is not recirculated into the intake. Common heat sources are
from engine exhaust, radiators or coolers, building ventilation and heat from generator fans.

Exhaust silencers are often mounted on top of coolers, buildings or support structures. The
building should be designed to support any auxiliary equipment that will be mounted on it.
Exhaust systems should be con¿gured so prevailing winds do not recirculate exhaust gases
back towards the engine and so the sound level and exhaust stack emissions meet local
regulations.

TYPICAL MAINTENANCE SCHEDULE

Table 22-2: 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

Table 22-3: Typical Maintenance Schedule

Bottom End Overhaul

Daily (or as required)

Top End Overhaul

12000 Hours
1500 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
•

22 - 4 Form 10026-2
©6/2015 General Electric Company
Maintenance Considerations Chapter 22

Bottom End Overhaul

Daily (or as required)

Top End Overhaul

12000 Hours
1500 Hours

3000 Hours

4000 Hours

8000 Hours
500 Hours

720 Hours
ITEM SERVICE
Crankcase Pressure Check per crankcase breather
system maintenance
•
Engine Oil and Filter* (3,000 hours for ISO Standar
or Continuous Duty with Extender Package,
Change Oil and Filter
•
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
•
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 speci¿cation
•
Cylinder Compression (align w/ spark plug change) Check
•
Knock Sensors Inspect for dirt/grit, connector wear
and corrosion
•
Turbocharger 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 Speci¿cation
IPM-D Timing Disc/Pick-Up Clean/Inspect
•
Auxiliary Water/Coolant Hoses Inspect/Replace as necessary
•
Oil Pan Clean
•

22 - 5 Form 10026-2
© 6/2015 General Electric Company
Chapter 22 Maintenance Considerations

Bottom End Overhaul

Daily (or as required)

Top End Overhaul

12000 Hours
1500 Hours

3000 Hours

4000 Hours

8000 Hours
500 Hours

720 Hours
ITEM SERVICE
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
•
Wastegate Rebuild
•
Catalyst (emPact options), if equipped Inspect, Clean (as needed)
•
Crankcase Pressure Regulator Valve Rebuild (replace diaphragm &
o-rings)
•
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
•

22 - 6 Form 10026-2
©6/2015 General Electric Company
Maintenance Considerations Chapter 22

Bottom End Overhaul

Daily (or as required)

Top End Overhaul

12000 Hours
1500 Hours

3000 Hours

4000 Hours

8000 Hours
500 Hours

720 Hours
ITEM SERVICE
Bearing, Main Replace
•
Camshaft Bushing Replace
•
Bearing, Connecting Rod Replace
•
Auxiliary Water Thermostat Replace
•
Jacket Water Pump Rebuild
•
Push Rod Assembly Replace
•
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.

22 - 7 Form 10026-2
© 6/2015 General Electric Company