Waukesha VHP Series Four L5774 / L5794 / L7044 12-Cylinder With ESM Parts Catalog

This document contains proprietary and trade secret information. The receiver of this document accepts it in confidence and agrees that, without the prior expressed written permission of GE’s Waukesha gas engines, it will (1) not use the document, its content or any copy thereof for any purpose that may harm GE in any way; (2) not copy or reproduce the document in whole, or in part; and (3) not disclose to others either the document or the confidential or trade secret information contained therein. All sales and information herein supplied is subject to the current version of the Standard Terms of Sale, including limitation of liability. All non-GE trademarks, service marks, logos, slogans, and trade names (collectively “marks”) are the properties of their respective owners. Original Instructions (English) The English version of this manual controls over any error in or conflicting interpretation of any translation. Waukesha gas engines Waukesha, Wisconsin 53188 Printed in U.S.A. © Copyright 12/2011 All rights reserved. GE Energy Gas Engines Waukesha gas engines VHP Series Four 12 cylinder with ESM parts catalog form 6302-2 2nd edition

FORM 6302-2 © 12/2011 DISCLAIMERS: All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Products are under a continuous improvement policy. Thus, information, illustrations and/or specifications to explain and/or exemplify a product, service or maintenance improvement may be changed at any time without notice. ALL RIGHTS RESERVED: No part of this publication may be reproduced or used in any form by any means – graphic, electronic or mechanical, including photocopying, recording, taping or information storage and retrieval systems – without the written permission of General Electric. DIVERSION CONTROL STATEMENT: Any technology, including technical data, or software contained herein were originally exported from the United States, or the originating country of this transmission, in accordance with the U.S. Export Administration Regulations and/or originating jurisdiction Export Regulations. Diversion (export, re-export, transfer, sale, review, use, disclosure, or distribution) contrary to such law(s) is prohibited. This prohibition includes no diversion to Cuba, Iran, Myanmar, North Korea, Sudan and Syria; plus any additional sanctioned country of the originating country of this transmission if not originating from the United States. DISPOSAL STATEMENT: Disposal requirements for waste electrical and electronic equipment: WEEE symbol (Waste of Electrical and Electronic Equipment): The symbol for the separated disposal of electrical and electronic equipment is a crossed-out waste bin on wheels (Directive 2002/96/EC Waste Electrical and Electronic Equipment). You must not dispose any electrical and electronic equipment marked with this symbol (battery-operated electrical appliances, measurement equipment, light-bulbs, etc.) in the domestic waste but dispose of these separately. Always use the waste return and collection systems locally available and contribute to the reuse, recycling and all other forms of use for waste electrical and electronic equipment. California Proposition 65 Warning Certain components in this product and its related accessories contain chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. Wash hands after handling. California Proposition 65 Warning The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. NOTICE Review all applicable Service Bulletins and other documentation, and check with your Authorized Distributor for updates that may supersede the contents of this manual. NOTICE Electrical and electronic equipment can contain harmful substances which can affect the environment and human health.

1 FORM 6302-2 © 12/2011 TABLE OF CONTENTS Alphabetical Index of Parts ......................................... 1 Customer Ordering Procedure ................................... 5 Parts Catalog Information ........................................... 6 Parts Illustrations and Parts Lists ..................... 8 – 169 Part Number Index – Appendix A ........................... A-1 Engine Preservation Products – Appendix B.......... B-1 Warranty ................................................................ W-1 ALPHABETICAL INDEX OF PARTS A Actuator, Gas Regulator ......................................... 165 Air Cleaner................................................... 145 – 147 Air Start/Prelube Control ......................................... 155 Air Start/Prelube Control Wiring ............................. 157 Air/Fuel Module Harnesses .................................... 131 Air/Gas Motorized Prelube Pump.................................. 109 Prelube Pump Motor ........................................ 111 Arms, Rocker ............................................................ 17 Auxiliary Water Pump .................................. 101 – 103 High Capacity ........................................ 105 – 107 B Barring Device .......................................................... 95 Breather ....................................................... 113 – 115 Extractor, L5794LT........................................... 119 L5794LT ........................................................... 117 Rear of Gear Housing ...................................... 121 Bridges, Valve .......................................................... 15 C Camshaft, Valve Lifter, Idler Gear ............................ 51 Carburetor .............................................................. 149 Centrifuge, Microspin, Engine Mounted ................... 93 Connecting Rod ........................................................ 23 Connections, Water .................................................. 19 Control Air Start/Prelube ............................................... 155 Control Unit Wiring, Engine .................................... 169 Control Unit, Engine ............................................... 167 Cooler, Oil ........................................................ 31 – 35 Crankcase ....................................................... 37 – 39 Crankshaft, Pulley, Flywheel, Vibration Damper ...... 25 Cylinder Head ........................................................... 13 Cylinder Head, Rocker Arms .................................... 17 Cylinder Head, Valve Bridges, Spark Plug Sleeve ...15 Cylinder Liner ........................................................... 23 E ECU ........................................................................ 167 Engine Control Unit ................................................ 167 Engine Control Unit Wiring ..................................... 169 Engine Mounted Oil Cooler ............................. 31 – 35 Exhaust Manifold.............................................................. 87 Outlet......................................................... 53 – 55 Extractor Breather, L5794LT .................................. 119 F Filler Oil ..................................................................... 123 Filter Oil ....................................................................... 91 Flywheel ................................................................... 25 Housing .............................................................. 95 G Gas Regulator ............................................. 159 – 163 Gas Regulator Actuator .......................................... 165 Gear Cover ............................................................... 89 Governor Heinzmann 2080 ................................................ 63 Linkage - GSI and L5774LT ............................... 67 Linkage - L5794LT ............................................. 65 H Harnesses Air/Fuel Module ................................................ 131 ESM, Stepper Motors ....................................... 131 Head, Cylinder ................................................... 15, 17 Header, Oil ............................................................... 21 Housing Jacket Water Thermostat ................................. 127 Housing, Valve Lifter ................................................ 43 I Idler Gear................................................... 37 – 39, 51 Ignition ...................................................................... 45 Coil ..................................................................... 47 Control Panel ..................................................... 49 Harness .............................................................. 47 Module Mounting................................................ 45 Intake Manifold Butterfly Housing ....................................... 81 – 83 L5794LT ............................................................. 85 Intercooler........................................................ 69 – 75 Draw Thru – L5794LT ............................... 77 – 79

2 FORM 6302-2 © 12/2011 J Jacket Water Pump ......................................... 97 – 99 Jacket Water Thermostat Housing ......................... 127 Junction Box ........................................................... 153 L L5774 LT Wastegate And Connections .................. 137 L5774 LT Wastegate Backpressure Regulator....... 141 Lifter Housing ........................................................... 43 Lifting Eye ........................................................ 37 – 39 M Magnetic Pickup ....................................................... 95 Manifold Exhaust .............................................................. 87 Intake ........................................................ 81 – 83 Intake, L5794LT ................................................. 85 Water ............................................................... 125 Microspin Centrifuge Engine Mounted ................................................. 93 Motor Prelube Air/Gas Pump ..................................... 111 O Oil Cooler, Engine Mounted ........................... 31 – 35 Filler ................................................................. 123 Filter ................................................................... 91 Header ............................................................... 21 Pan..................................................................... 27 Pickup Screen .................................................... 29 Pump................................................................ 129 Strainer .............................................................. 41 P Pan, Oil ..................................................................... 27 Piston........................................................................ 23 Prelube Pump Motor, Air/Gas................................. 111 Prelube Pump, Air/Gas Motorized .......................... 109 Pump Oil ..................................................................... 129 Prelube, Air/Gas Motorized .............................. 109 Water ........................................................ 97 – 99 Water, Auxiliary ..................................... 101 – 103 Water, Auxiliary High Capacity ............. 105 – 107 Push Rods ................................................................ 19 R Regulator Backpressure L5774 LT ..................................................... 141 Wastegate Backpressure L5794 LT ..................................................... 143 Regulator, Gas ............................................ 159 – 163 Rocker Arms ............................................................. 17 Rods, Push ............................................................... 19 S Safety Guards......................................................... 151 Screen, Oil Pickup .................................................... 29 Sleeve, Spark Plug ................................................... 15 Spark Plug ................................................................ 47 Spark Plug Sleeve .................................................... 15 Strainer, Oil............................................................... 41 T Thermostat Housing, Jacket Water ........................ 127 Turbocharger Air Connections.................................................. 57 Heat Shields....................................................... 61 Oil Connections.................................................. 59 Water Connections ............................................ 61 Turbochargers And Exhaust Outlet ................. 53 – 55 V Valve Bridges ........................................................... 15 Valve Lifter................................................................ 51 Valve Lifter Housing ................................................. 43 Valves ....................................................................... 13 Vibration Damper...................................................... 25 W Warnings And Cautions ..................................... 9 – 11 Wastegate Backpressure Regulator L5774 LT ..................................................... 141 L5794 LT ..................................................... 143 Connections L5774 LT ..................................................... 137 L5794 LT ..................................................... 139 L5794GSI .................................................... 133 L7044 GSI ................................................... 135 Water Connections ................................................... 19 Turbocharger ..................................................... 61 Water Manifold ....................................................... 125

3 FORM 6302-2 © 12/2011 Water Pump..................................................... 97 – 99 Auxiliary................................................. 101 – 103 High Capacity ................................... 105 – 107 Wiring Air Start/Prelube Control .................................. 157 Engine Control Unit .......................................... 169

4 FORM 6302-2 © 12/2011 NOTES

5 FORM 6302-2 © 12/2011 PART NUMBERS ARE FOR REFERENCE ONLY. REFER TO ENGINE SPECIFICATION. CUSTOMER ORDERING PROCEDURE 1. Waukesha genuine parts are available worldwide and must be ordered through your local Waukesha Distributor. NOTE: Part numbers in this catalog are for reference only and should not be used for ordering parts. Your Waukesha Distributor will refer to your engine specification to make certain you receive the correct parts for your engine. 2. Top level assembly numbers may not all be available as service parts. 3. Always specify to your Waukesha Distributor the engine model designation, specification number, and serial number as found stamped on the engine nameplate (see Figure 1). 4. Always include the part number, when known, along with the description of the part. State the quantity of the part you wish to order. Do not use the word “complete” or designate the quantity by sets. EXAMPLE: 168660–filter element–(1) Ordered. NOTE: Quantities listed in this catalog are quantity per engine. 5. If a special part is needed, the engine application should also be stated. 6. Anticipate your parts requirements: • Order parts early in the day. • Keep a supply of normal maintenance parts in stock. • Obtain a parts stocking recommendation from your local Waukesha Distributor. Figure 1. Nameplate – Current Production

6 FORM 6302-2 © 12/2011 ALWAYS GIVE YOUR MODEL AND SERIAL NUMBER WHEN ORDERING PARTS PARTS CATALOG INFORMATION PARTS CATALOG FORMAT Illustration Number A) Group Number. B) For each different illustration in the same group this number advances by 1. C) For each repeated illustration this number advances by 1. Item No. The first column lists the item numbers which correspond to the item numbers in the illustration. Part Number And Description The second column lists the part numbers. The last column lists the description of the part. Parts included in assemblies are preceded by one dot and parts included in subassemblies are preceded by two or three dots. Engine Model Quantity The columns headed by engine model numbers list the quantity of the part per engine except when parts are listed more than once in the catalog. The quantity per engine is the total of the quantities listed individually on separate pages. Extent Of Parts Catalog Coverage This catalog contains only standard or selected option parts. Variations of these parts as well as other parts are not included. Contact your local Waukesha Distributor for assistance in identifying parts not included in this catalog. EXAMPLE: 0 0 2 . 0 0 A BC ITEM NO. PART NUMBER L5774 L5794 L7044 DESCRIPTION LT GSI LT GSI GROUP 2 CA204066K 12 12 12 12 SHAFT, Exhaust Rocker Arm-Assembly 1 • A204066K 12 12 12 12 • ARM, Rocker, Exhaust 2 •• 167480G 24 24 24 24 •• BUSHING, Rocker Arm 3 •• 28462 12 12 12 12 •• RIVET, Steel, 3/16" 4 • 153886K 12 12 12 12 • SUPPORT, Rocker Arm, Oil 5 • A153889K 24 24 24 24 • SCREW, Rocker Arm Adjusting 6 • 21227 24 24 24 24 • NUT, Thin Hex, 5/8"-18 7 • A204069G 12 12 12 12 • SHAFT, Rocker Arm-Assembly 8 •• Y18802 24 24 24 24 •• COVER, Pushrod, Lower

7 FORM 6302-2 © 12/2011 PART NUMBERS ARE FOR REFERENCE ONLY. REFER TO ENGINE SPECIFICATION. NOTES

8 FORM 6302-2 © 12/2011 ALWAYS GIVE YOUR MODEL AND SERIAL NUMBER WHEN ORDERING PARTS W A U K E S H A NOTE: Labels shown apply to standard engine. Labels can be affected by optional equipment specified. 1 REAR VIEW 1