Waukesha Gas engines Special Tools Catalog

Special Tools Catalog Waukesha * gas engines GE Power & Water Distributed Power form 398-8 8th edition *Trademark of General Electric Company

Waukesha gas engines Special Tools 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 other 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 2015, General Electric Co. All rights reserved. form 398-8 8th edition GE Power & Water Gas Engines

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. NOTICE 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. 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: NOTICE NOTICE Electrical and electronic equipment can contain harmful substances which can affect the environment and human health. 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. FORM 398-8 © Copyright 2015, General Electric Co.

SPECIAL TOOLS CATALOG TABLE OF CONTENTS 3 FORM 398-8 © Copyright 2015, General Electric Co. Table of Contents SPECIAL TOOLS APPLICATIONS.............................................................................................................. 5 GENERAL TOOLS .................................................................................................................................... 17 275GL*/ATGL* TOOLS .............................................................................................................................. 29 VHP* TOOLS............................................................................................................................................. 41 APG* 1000/16V150LTD TOOLS................................................................................................................ 53 APG 2000/3000 TOOLS ............................................................................................................................ 59 VGF* TOOLS............................................................................................................................................. 71 INTERMEDIATE SERIES TOOLS ............................................................................................................. 79 APPENDIX A – PART NUMBER INDEX.................................................................................................... 85 APPENDIX B – PART NAME INDEX ........................................................................................................ 89

4 FORM 398-8 © Copyright 2015, General Electric Co. INTRODUCTION SPECIAL TOOLS CATALOG INTRODUCTION AND USE OF THIS CATALOG Engine technology is changing at a very rapid pace driven by lean combustion and computer monitoring. The right tools are important because they allow the engine technician to perform his job in a professional and timely manner. These changes in technology and productivity requirements mandate the need for specialized tools. Recognizing these needs, Waukesha has compiled and cataloged many specialized tools. Waukesha Parts Operations markets the special purpose tools listed in this catalog. All inquiries regarding price and delivery should be directed to your authorized Waukesha Distributor or participating OEM. Tools are grouped together according to engine type. In addition, there is a General Tools section. Tools listed in this section can be applied to multiple engine model series. Special Tools Applications – The application tables list the Special Tools required for the proper service of Waukesha engines. General hand tools required for service are available in kit form and are listed at the beginning of tool section for each engine family. General Tools – This section contains special tools that apply to more than one Waukesha engine model series. Tools are represented by an illustration and description on usage. 275GL / ATGL Tools – This section contains special tools that are specific to the 275GL / ATGL engine series. Tools are represented by an illustration and description on usage. VHP Tools – This section contains special tools that are specific to the VHP engine series. Tools are represented by an illustration and description on usage. APG 1000/16V150LTD Tools – This section contains special tools that are specific to the APG 1000/16V150LTD engine series. Tools are represented by an illustration and description on usage. APG 2000/3000 Tools – This section contains special tools that are specific to the APG 2000/3000 engine series. Tools are represented by an illustration and description on usage. VGF Tools – This section contains special tools that are specific to the VGF engine series. Tools are represented by an illustration and description on usage. Intermediate Series Tools – This section contains special tools that are specific to the H2476G, F1905G, F817G, L3712G and F1197G engine models. Appendix A – This section cross-references tool part number to page number. Appendix B – This section cross-references tool description to page number. OTE: N These lists are for reference only. For the most up-to-date lists see the “Engine Support Requirements” section on the GE Distributed Power web portal.

Applications 5 FORM 398-8 © Copyright 2015, General Electric Co. VHP TOOLS SPECIAL TOOLS APPLICATIONS G/GSI/GSID GL/GLD SERIES FOUR PART NUMBER NAME X 474007 Prechamber Collet – L5108GL X 474036 Spark Plug Carrier Tool X X 494217 Compression Tester/Adapter X X X 494287 Valve Adjusting Wrench X 494290 Prechamber Removal Tool X X 474031 Valve Spring Compressor (Non CSA) X X 474033 Valve Spring Compressor (GL CSA) X 474034 Valve Spring Compressor (Series Four) X 474038 Valve Seat Extractor (Series Four) X 474040 Valve Bridge Guide Tool (Series Four) X X X 474046 Valve Guide Reamer X X X 495327 Valve Stem Seal Installer X X X 495328 Intake Valve Seat Installer (TL82981) X 495329 Exhaust Valve Seat Driver (TL82982) X 495330 Bridge Guide Pin Driver (TL84308) X X X 474044 Valve Guide Straightness Gauge X X X 474000 Camshaft Dummy Gear X X X 474005 Stop Sleeve X X X 474013 Water Pump Kit X X X 474025 Pick-up Location Guide/Cam Bearing Rollout Tool X X X 474041 9-3/8 in. Piston Ring Expander (*) X X X 474042 8-1/2 in. Piston Ring Expander (*) X X X 494085 8-1/2 in. Bore Ring Compressor (*) X X X 494206 9-3/8 in. Bore Ring Compressor (*) X X X 494284 8-1/2 in. Sleeve Plate (*) X X X 494286 9-3/8 in. Sleeve Plate (*) X X X 494364 Main Bearing Roll-Out Tool (Inline Only) (*) X X 494365 Main Bearing Roll-Out Tool (Angle Drilled) X X X 494366 Main Bearing Roll-Out Tool (T-Drilled) X X 499233 Cylinder Sleeve Removal Kit X X X 495350 Spark Plug Sleeve Seat Resurfacer X X X 474018 VHP Gas Piston Puller – 9-3/8 in. Bore (*) X X X 474019 VHP Gas Piston Puller – 8-1/2 in. Bore (*) X X X 474001 Camshaft Bearing, Roll-Out Tool X X 474003 Reducer X 474008 Spark Plug Carrier Remover Tool X 474023 CSA Spark Plug Carrier Tool X X 474012 Valve Guide Reamer T-Handle X 490049 Prechamber Removing Collet X X X 495336 Valve Guide Removal and Installation Tool – Arbor X X 495497 Valve Guide Removal and Installation Tool – Guide X 495498 Valve Guide Removal and Installation Tool – Guide

6 FORM 398-8 © Copyright 2015, General Electric Co. VHP TOOLS SPECIAL TOOLS APPLICATIONS G/GSI/GSID GL/GLD SERIES FOUR PART NUMBER NAME X X 494305 Valve Seat Grinding Stone Current Wide Bridge Heads – 30° (*) X X X 494280 Valve Seat Grinding Stone Seat Angle Stone – 30° (*) X X X 494014 Valve Seat Grinding Stone Seat Angle Stone – 20° (*) X 494331 Valve Recession Gauge X X X 476073 Cylinder Sleeve Top Puller Plate – 8-1/2 in. (*) X X 474022 Ignition Timing Disc Adjustment Tool X X X 494344 Pilot Tool X X 494267 Extension Tool X X 494268 Socket – 1-5/16 in. (*) X X X 494266 Socket – 1 in. (*) X X X 494234 Cylinder Deglazing Hone Tool (*) X X X 494236 Cylinder Deglazing Hone Tool (*) * Depending on the engine model, only one of the listed tools is required.

Applications 7 FORM 398-8 © Copyright 2015, General Electric Co. APG 1000/16V150LTD TOOLS SPECIAL TOOLS APPLICATIONS PART NUMBER NAME 472075 Piston Ring Expander 472076 Piston Ring Compressor 472077 Valve Stem Seal Installer 472080 Connecting Rod Guide Pin 472081 Connecting Rod Bearing Alignment Tool 472082 Turbocharger Water Connection Fitting Wrench 472083 Piston Extraction Tool 472086A Spark Plug Sleeve Holder 472087 Main Bearing Roll-Out Tool 472088 Hydraulic Pump 472089 Valve Seat Extractor Tool 472090 Replacement Pins for the Valve Seat Extractor (472089) 472091 Cylinder Head Lifting Tool 472092 Valve Seat Insertion Installation Tool 472093 Valve Guide Installation Tool 472094 Cylinder Sleeve Puller 472095 Connecting Rod Bushing Removal Tool 472096 Four Valve Spring Compressor Tool 472117 Spark Plug Sleeve Tool 472102 Exhaust Gas Analyzer 472108 Sensor, O 2 (for 472102) 472109 Sensor, NO, 0 – 3,000 ppm (for 472102) 472110 Sensor, NO 2 , 0 – 500 ppm (for 472102) 472103 Crankshaft Seal Driver 475075 Spark Plug Extension Puller 472101 Hand Tool Kit 475072 Digital Manometer 475073 Infrared Thermometer 494338 Timing Light 494215 Compression Tester 494217 Compression Tester Adapter 475078 Hand-Held Oscilloscope 494272 Torque Wrench 3/4 in. (*) 494273 Torque Wrench 1/2 in. (*) – Torque Wrench 3/8 in. (*) (**) 495350 Spark Plug Sleeve Seat Resurfacer 495564 Depth Gauge Kit 475076 Borescope 472118 Recess Tube Tool 472002 Crankcase Spreader 472132 Cylinder Liner Pusher/Clamp 472133 Cylinder Liner Puller Continued on next page.

8 FORM 398-8 © Copyright 2015, General Electric Co. APG 1000/16V150LTD TOOLS SPECIAL TOOLS APPLICATIONS PART NUMBER NAME 472056 Camshaft Bearing Removal and Installation Kit 472134 Valve Recession Tool 495759 Biogas Diagnostic Tool 740269 ECU Interface Cable Other items that should be on-site: 475029 O-Ring Lubricant 489341 High Temperature Fluorinated Grease * Not required if purchasing Hand Tool Kit. Included in Kit 472101. These are special small-head wrenches to ﬁt inside the inspection covers. ** Must be purchased as part of Kit 472101.

Waukesha Gas engines Special Tools Catalog

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