TOPIC: Fuel System
IDENT NO: 9-4075
275GL*
SUBJECT: Rod End Maintenance Manual Correction
MODELS AFFECTED: 275GL
The purpose of this bulletin is to inform the field
about a correction to Form 6354-2, 275GL+ with
ESM Operation & Maintenance Manual.
Tape or staple the pages attached to the end of
this bulletin into Form 6354-2 as replacement
pages.
The manual states that the control rod ends and
linkage should be cleaned and lubricated every
1,000 hours. However, the control rod ends and
linkage actually should not be lubricated at all
and should instead be inspected and cleaned
every 4,000 hours.
The complete corrected information follows.
* Trademark of INNIO Waukesha Gas Engines, Inc.
All other trademarks are the property of their respective owners.
08/01/2016
Copyright © 2016, INNIO Waukesha Gas Engines, Inc.
DATE: August 2016
SUPERSEDES: NEW
The actuator linkage must be inspected and
cleaned every 4,000 hours.
1. Shut down the engine.
2. Verify jam nuts on both ends of actuator
rods are secure.
3. Verify the rod ends are centered on their
pivots and are free throughout the travel.
Adjust as required.
4. Inspect rod ends. Replace if worn.
5. Inspect actuator rods for straightness and
damage. Repair or replace as necessary.
6. Verify proper operation of actuators by
performing a manual calibration of
actuators using ESP.
7. Inspect wastegate and bypass valve shafts
for binding or excessive looseness. Repair or
replace as required.
NOTICE
The rod ends for throttle, wastegate and bypass
must be clean and dry. Application of grease, oil or
dry film lubricant can cause sticking or binding of the
linkage and result in erratic performance.
Remove the preservative grease applied to the
joints for shipping before running the engine.
Use an appropriate solvent, brush and rags to
make sure all grease and paint is removed. Any
remaining grease may carburize and cause the
linkage to bind.
Page 1 of 1
MAINTENANCE SCHEDULE

ROUTINE MAINTENANCE
Table 4.50-2: 12V/16V 275GL + Routine Maintenance Chart

8,760 HRS. OR ANNUALLY

4,000 HRS. OR 6 MONTHS
AS REQUIRED

1,000 HRS.
ITEM SERVICE

Air Cleaner Filter Element Check/Clean or Replace •

Air Starter Lubricator Check/Fill •
Cooling Systems Fluid Level (Jacket and Auxiliary) Check/Fill •
Crankcase Oil Level Check/Fill •
Spark Plugs Replace •
Prechamber Regulator Adjust •
Control Rod Ends and Linkage Inspect/Clean •
Engine Oil (Continuous Duty) Analyze •
NOx Sensor Check/Replace •
Spark Plugs Replace •
Valve Clearance Adjust •
Crankcase Pressure Check/Adjust •
Oil Cooler Drain •
Oil Filter Elements Replace •
Admission Valve Assembly Clean or Replace •
Cooling Water Analysis Check •
Crankcase Breather Clean •
Engine Oil (Continuous Duty) Change •
Cylinder Compression/Borescope Check •
Engine Mounting and Alignment Check •
Main and Rod Bearings Inspect •
Intercooler Clean and Inspect •
Cooling System (Jacket and Auxiliary) Clean and Flush •
Cooling System Thermostats Remove and Test •
Exhaust Backpressure Test •
Crankcase Pressure Relief Valves Inspect •
Turbocharger Clean/Inspect •
Wastegate Vent Line Inspect/Clean •
Main Chamber Regulator Filter Replace •

FORM 6354-2
4.50-2 © 8/2012
 AIR INTAKE AND TURBOCHARGER SYSTEM MAINTENANCE
TURBOCHARGER MAINTENANCE
This section includes information on turbocharger
system inspection, lubrication, maintenance and
operation.
TURBOCHARGER INSPECTION
NOTICE
Inspection and repair of turbochargers must be
performed by a factory-qualified service agent.
1. Inspect engine air cleaner. Service if required.
2. Inspect turbocharger mounting and connections for
oil and air leaks. Repair or replace as necessary.
NOTICE
Do not run the engine if the air cleaner is not operating
efficiently or if leaks exist in the ducting. Dust leaking
into the air ducting can damage the engine and the
turbochargers.
3. With engine shut down, inspect all air ducting for
loose clamps or connections. Check manifold
connections to turbine inlet and at engine exhaust
manifold gaskets. Repair or replace as necessary.
TURBOCHARGER WASTEGATE AND AIR BYPASS
The actuator linkage must be cleaned and inspected
every 4,000 hours.
To perform maintenance to the actuator linkage,
complete the following:
1. Shut down engine.
2. Verify jam nuts on both ends of actuator rods are
secure.
3. Verify the rod ends are centered on their pivots
and are free throughout the travel. Adjust as required.
4. Inspect rod ends. Replace if worn.
5. Inspect actuator rods for straightness and damage.
Repair or replace as necessary.
6. Verify proper operation of actuators by performing a
manual calibration using ESP.
7. Inspect wastegate and bypass valve shafts for
binding and excessive looseness. Repair or
replace if required.
NOTICE
The rod ends for throttle, wastegate and bypass
must be clean and dry. Application of grease, oil or
dry film lubricant can cause sticking or binding of the
linkage and result in erratic performance.
4.15-3
Remove the preservative grease applied to the joints for
shipping before running the engine. Use an appropriate
solvent, brush and rags to make sure all grease and
paint is removed. Any remaining grease may carburize
and cause the linkage to bind.
TURBOCHARGER LUBRICATION
NOTICE
Before operating a new or rebuilt turbocharger (or
starting a new engine for the first time), check to
ensure that the turbocharger is receiving proper
lubrication.
1. Remove oil drain tube from turbocharger.
2. Activate automatic prelube system and visually
check for oil flow at turbocharger oil drain area.
3. Reconnect oil drain tube only after oil is observed at
oil drain area.
4. Start engine and run at reduced speeds until coolant
temperature gauge indicates a jacket water
temperature of 38°C (100°F).
5. Run engine at rated output and listen for unusual
sounds in turbocharger, especially those of metal
contacting metal. If any noise of this type is apparent,
immediately shut down engine and contact your
Waukesha authorized service agent.
TURBOCHARGER OPERATION
NOTICE
Do not operate the turbocharger without the air inlet
and exhaust outlet connections installed. The
turbocharger can generate enough force to draw
objects into it.
NOTICE
Do not operate the engine under load until the jacket
water temperature is 38°C (100°F).
1. Run prelube system for a full 90 seconds before
each engine start to ensure all moving parts,
especially the turbocharger, are properly lubricated
(special attention must be given to a new
turbocharger or one that has been stored;
see TURBOCHARGER LUBRICATION on page
4.15-3).
2. Idle engine for 3 – 4 minutes before shutdown.
FORM 6354-2
© 8/2012
 MAINTENANCE
SECTION 4.00
ESM CONTROL SYSTEM MAINTENANCE
Before performing any service, maintenance or repair
procedures, review SAFETY on page 1.05-1.
THROTTLE, WASTEGATE AND BYPASS
ACTUATOR INSPECTION AND
MAINTENANCE
! WARNING
Always read and comply with
safety labels. Do not remove or
deface the container labels.
Every 4,000 hours, all actuator linkages must be
inspected and cleaned (see Figure 4.00-1) .
Figure 4.00-1: Throttle Actuator Shown
4.00-1
To perform maintenance to the actuator linkages,
complete the following:
1. Shut down engine.
2. Verify jam nuts on both ends of actuator rods are
secure (see Figure 4.00-2).
3. Verify the rod ends are centered on their pivots
and are free throughout the travel. Adjust as required.
4. Inspect rod ends. Replace if worn.
5. Inspect actuator rods for straightness and damage.
Repair or replace as necessary.
6. Verify proper operation of actuators by performing a
manual calibration using ESP.
7. Inspect wastegate and bypass valve shafts for
binding and excessive looseness. Repair or
replace if required.
NOTICE
The rod ends for throttle, wastegate and bypass
must be clean and dry. Application of grease, oil or
dry film lubricant can cause sticking or binding of the
linkage and result in erratic performance.
Remove the preservative grease applied to the joints for
shipping before running the engine. Use an appropriate
solvent, brush and rags to make sure all grease and
paint is removed. Any remaining grease may carburize
and cause the linkage to bind.
FORM 6354-2
© 8/2012