Waukesha VR Series User manual

OPERATION
AND'
SERVICE
MANUAL
WAUKESHA VR SERIES
GAS AND DIESEL ENGINES
I Waukesha I~ I
VRD155
VRG155
VRD232
VRG232
VRG265
VRD283
VRG283
VRD310
VRD310S
VRG310 '
Copyright 1974
Waukesha Engine Division
Dresser Industries, Inc.
Waukesha, Wisconsin 53187 Revised by A W.
Printed in U.S.A. 7/84 5C

WAUKESHA VR SERIES
SAFETY PRECAUTIONS
For details on safety rules and regulations in the
Un'itedStates,contactyourlocalOccupationalSafety
and HealthAdministration (OSHA).
These safety precautions are published for your
information.TheWaukeshaEngineDivision,Dresser
Industries,Inc.,doesnot, bythe publicationofthese
precautions,implyor in anywayrepresentthatthese
published precautions are the sum of all dangers
presentnearindustrial engines.If youareoperating
industrial engines,it isyour responsibilityto ensure
that such operation is in full accordancewith all
applicable safety requirements and codes. All
requirements of the United States Federal
OccupationalSafety and HealthAdministration Act
must be met when Waukeshaenginesare operated
in areasthat areunderthejurisdiction ofthat United
States department. Engines operated in countries
other than the United States of America must be
installed, operatedand servicedin accordanceand
compliancewith any and all safety requirementsof
that country which maybe applicable.
BODILYPROTECTION
Wear OSHA approved bodily, sight, hearing and
respiratory system protection. Never wear loose
clothing, jewelry or long hair around an engine.
EXHAUSTGASES
Engine exhaust products are toxic and may cause
injury or death if inhaled. All engine installations
musthaveanexhaustdischargepipesothatexhaust
gases are delivered into the outside air. A closed
building or shelter must be adequately vented to
providea steadysupplyof fresh air.
ENGINEFUELS
Enginefuelsarehighlycombustibleandmayigniteor
explode.Fuelsmustbeconductedtothe enginewith
properpiping,free from leaks,anddesignedto resist
breakagefrom vibration. When filling fuel tanks,
never smoke or use open flame in the immediate
area. Fuel tanks should be grounded to prevent
buildup of static electricity. If a gasengine hasbeen
crankedexcessivelywithout starting,shutoffthegas
fuel supply and ignition. Then crank the engine to
purge the cylinders and exhaust system of
accumulated,unburned gas. If you fail to do this, a
spark plug could ignite the gas and cause an
explosion.
POSITIVEFUELSHUT-OFF
Some means of positive fuel shut-off should be
provided for emergency use. Pressurized fuels
(natural gas, liquified petroleum gas, etc.) should
have another positive shut-off valve, preferably
automatic,other than those in the carburetoror gas
pressure regulation equipment. It is the final
responsibilityof the engineownerto ensurethat the
installation isfree from fuel or exhaustleakage,and
such installation meetsall applicablecodes.
GAS USEDTO ENERGIZESTARTERS
Gas used to energize starters must be discharged
away from the engine into a harmlessarea.Ignition
connections and electrical equipment on engines
exposedto apotentiallyexplosiveatmosphereshould
be equipped to eliminate spark hazard. It is the
responsibility of the engine owner to specify or
providesuch connectionsand equipment.
SAFETYGUARDS
Engines must be provided with guards to protect
personsor structuresfrom rotatingorheatedparts.It
isthe responsibilityofthe engineownerto specifyor
providesuch protection.
CRANKCASEANTI-EXPLOSIONVALVES
These valves must be kept in proper working
condition to relievecrankcasepressure.
IGNITIONSYSTEMS
Ignition systemscan causeelectrical shocks.Avoid
contacting ignition units and wiring.
A spark plug will fire if the storage capacitor in a
breakerless magneto has been charged by hand-
turning the magneto.Thishappenseventhough the
ignition system harness is disconnected at the
magneto.When the harnessisreconnected,andthe
ignition switch is in the "on" position,the capacitor
will discharge and fire a spark plug. The plug will
ignite anygasthat hasaccumulatedinthat cylinder.
The crankshaft and driven equipment may rotate,
possibly causing personal injury or damage to
equipment.Gasthat hasaccumulatedintheexhaust
systemmayalsobe ignited.
2

WAUKESHA VR SERIES
Before reconnecting the ignition harness to a
breakerless magneto, discharge the storage
capacitorto ground. Dothis byclippingoneendof a
wire leadto the magnetohousing. Then touch the
other end to the harness connector pins on the
magneto.You will hear a snap when a capacitor
discharges.
If the ignition switch is in the "off" position, the
capacitoris immediatelydischargedtogroundwhen
the ignition harness is reconnectedto the magneto.
As a safety measure, ground all the pins. Some
breakerlessignition systems have more than one
storagecapacitor.
WARNING I
If agasenginehasbeencrankedexcessivelywithout
starting, shut off the gas fuel supply and ignition.
Thencrank the engine to purge the cylinders and
exhaustsystemofaccumulated,unburnedgas.If you
fail to do this, a sparkplug could ignite the gasand
causean explosion.
COOLINGSYSTEMPRESSURECAPS
ANDCONNECTIONS
Donot removethe pressurecapswhile the engineis
operatingor while coolantishot.Thecoolingsystem
isunderpressureandsevereburnscouldresultfrom
the hot coolant spewing out when the cap is
removed.Wait until the engine and coolant have
cooleddown before removingthe radiator or surge
tank caps. Always replace weak hoses, lines, and
fittings.
FUELINJECTORS
Neverallowan injectorto sprayagainstthe skin.The
fuel oil will penetratethe skinand maycauseserious
infection and injury.
GENERATORSETS
Thevoltageproducedbygeneratorsetsisdangerous.
Severe,possiblyfatal, shockmayresultfromcontact.
Make sure the generator set is grounded before
operation. Be extremely careful when the unit or
surrounding area is dampor wet.
When servicing any part of the electrical systemor
making any connections, make sure main power
switch is OFF.Clean or servicegenerator set only
when engine is shut down.
In case of an accident from electrical shock, shut
down the generator set at once.If it cannotbeshut
down, free the victim from the liveconductor'.Avoid
direct contact with the victim. Usea dry board,dry
rope, or any.nonconducting implement to free the
victim. If the victim is unconscious,apply artificial
respiration and get medical help.
Donot operatethe generator set with the ammeter
circuit open.Voltage,Clangerousto both equipment
and personnel, can be generated in an open
secondarycircuit of a current transformer.
If the generatorset is stoppedbyoperationof safety
devices,do not attempt to operateit until the cause
has beeneliminated.
Whenthegeneratorsetisshutdownafteroperation,
disconnectall line switchestoallexternalpowerload
and parallel circuits.
ENGINEAND EQUIPMENT,REPAIRAND SERVICE
Alwaysstoptheenginebeforecleaning,servicing,or
repairing the engine or driven equipment.Placeall
controls in OFF position to prevent accidental
restarting. If possible,lock all controls in the OFF
position and take the key. Put a sign on the
instrument panel warning that the engine is being
serviced.Beforerestarting, makesure that all tools
andother material areremovedfrom the engineand
equipment.
Properservice and repair is important to the safe,
reliableoperationof enginesandrelatedequipment.
TheproceduresrecommendedbyWaukeshain this
manualareeffectivemethodsfor performingservice
and repair operations. Some of these procedures
require the use of specially designed tools. The
special tools should be used when and as
recommended.Anyonewho usesaservice,repair,or
installation procedure not recommended by
Waukesha must first satisfy themselvesthoroughly
that their safetywill notbejeopardizedbytheservice
methodsthey select.
HOUSEKEEPING
Good housekeepingresults in a clean, safe work
area.An orderlywork areawith cleanwalkwaysand
neatlyarrangedtoolsandequipmentisamajorfactor
in accidentprevention.
' ..
3

WAUKESHA VR SERIES
ENGINEFANBLADES TURBOCHARGERS
1. Donotoperatethe enginewith afan which has
been bent. multilated. modifiedor in any way
damaged.
2. Donotoperatethe engineif thefancontactsor
strikes any engine accessoryor the radiator
shroudor core.
3. Do not rebalance the fan. Contact the fan
supplier if rebalancingis required.
4. Ensure that all bolts attaching the fan are
securelyinstalled to a torque specifiedbythe
engineor vehicle manufacturer.
5. Install the fan so the word "front" stampedon
the fan facesthe radiator.
6. Perform all required maintenance on the
subassemblytowhichthefanisattached(water
pump. fan drive. etc.) (See operator/ service
manual.)
7. Do not modify or substitute any parts of the
engine without the approvalof the Waukesha
Engine Division Service Department. Take
special care not to make modificationswhich
will increasethe operatingspeedof the fan.
8. Install the fan only if the engine has been
approvedfor fan installation.Likewise.installa
subassemblytowhichthefan isattached(water
pump. fan drive. etc.), only if approved or
specifiedfor useon the engine.
9. If the fan or fan drive contains any plastic or
rubber component. have the fan and drive
inspected by a qualified mechanic after
operation at or exposureto excessivelyhigh
temperatures [above 250 0 F. (120 0 C.) air
temperature].
10. Replace the fan if indications of excessive
corrosionor erosionappearin the fan.
11. For reversible or adjustable pitch fans. make
sure the blades are correctly locked in the
properpositionprior to operation.Also.inspect
the fan prior tooperationto ensurethat iceand
dirt havenot accumulatedon the fan to cause
potential unbalanceof the fan.
12. Be sure all fans. fan drives and belts are
properlyshielded.
Turbochargers are specifically designed for each
application. Nozzle rings must not be changed
without consulting the engine manufacturer since
they limit turbocharger rpm. Excessiverpm may
resultinturbochargerfailure with resultantpersonal
safety hazards. Turbochargers operate at high
temperatures. Therefore. all flammable material
must bekeptawayfrom them.Enginesmustbeshut
down and at room temperature beforeworking on
turbochargersor burns will result. Keepall foreign
materialawayfrom turbocharqeropenings.
ENGINESTORAGECHEMICALS
Waukesha PreservativeOil contains a petroleum
distilatewhich is harmful orfatal ifswallowed.Avoid
contact with skin. Vapor is harmful and causes
irritation ofeyes.nose.throatandskin.Useonlywith
adequateventilation. Avoid prolongedor repeated
breathingofvapor.Avoidcontactwith skin.eyes.and
clothing. Do not take internally. Keep container
closedandawayfrom heat.Alwaysreadandobserve
the "CAUTION" labels on the containers. Do not
destroythe labelson the containers.
Generally. heating of preservative compounds is
confined to 200 0 F. (93 0 C.) or less. These
temperatures are easily reached by placing the
preservative container in heated water. If this is
done. the container must be vented or openedto
reduce the danger of explosion. Direct heating
presentsa dangerousand unnecessaryfire hazard.
FIREPROTECTION
Locate fire extinguishers so that they are easily
accessibleif afire starts.Carefullymaintain records
of extinguisher inspectionandrechargingto ensure
the fire extinguishing capabilities when required.
Consultyourfire extinguishersupplieror insurance
engineerfor recommendationsonthetype.size.and
quantity of fire extinguishers required. Select and
post alternate routes of escapefrom any engine
installation.Designinstallationto meetallapplicable
fire codes.
CLEANINGSOLVENTS
Useapprovedcleaning solventsin a well ventilated
area. Avoid breathing fumes; some vaporscan be
fatal. Keepawayfrom openflamesor sparks.Donot
usegasolineorpaintthinners orotherhighlyvolatile
fluids for cleaning. Always read and observethe
"CAUTION"labelson containers.Donotdestroythe
4

WAUKESHA VR SERIES
labels on the containers. Cleaning solvents can
causevarioustypesof skin irritations.
WELDINGEQUIPMENT
Welding gas cylinders can explode if damaged.
Cylinders must be stored in accordance with
manufacturer'sspecificationsandapplicablesafety'
requirements.
When using acetylene, check valves should be
installed between the regulators and hoses to
prevent flashback into the regulators and supply
tanks. Flashbackcould cause the regulators and
supplytanksto explode.
Oily and greasymaterials must be kept away from
oxygenvalves,hoses,etc.Oxygenmaycombinewith
such materials and an explosive reaction could
result.
Always wear protectiveeye shields when welding,
cutting or watching a welding operation.Protective
clothingandfaceshieldsmustbeworn. Donotweld
or cut nearcombustiblematerials.
GROUNDINGPRECAUTIONSWHENWELDING
When usinganelectricwelderonanengine,clipthe
groundleadascloseto the welding site aspossible.
Puttingthe groundleadtoofarfromtheweldingsite
may result in arcingacrossthe main bearings,and
fusing them to the crankshaft.
ELECTRICPOWERTOOLS
Be certain the electric tool is properly grounded.
Wear proper eye protection. Do not work in wet or
dampconditions.Besurethetoolisingoodcondition
andsafetyguardsare in position.An electrictrouble
light must also be grounded.Do not carry electric
powertools bythe cord.Donotyankthe cordwhen
removingfrom an outlet; instead graspthe plug to
removeit from an outlet.
LEADACIDBATTERIES
Always disconnect the battery ground connection
from batteries before performing any work on the
engine or equipment. This will prevent sparks or
burns when accidently shorting an electrical
connection.
Never exposebatteries to open flame or electric
spark. Battery action generates a flammable,
explosivegas. Don't allow battery fluid to contact
skin, eyes,fabrics,or paintedsurfaces.Batteryfluid
is a sulphuric acid solution which could cause
serious personal injury or property damage.Wear
eyeprotectionwhen working with batteries.
PrecautionsWhen UsingBooster
Batteriesand Cables
Do not attempt to jump start an engine having a
frozen battery.The battery mayrupture or explode.
Beforestarting,examineallfill ventsonthebattery.If
icecan be seen,or if the electrolytefluid cannotbe
seen,do not attempt to start with jumper cables.
Batteries should be treated carefully when using
jumper cables.The following proceduresassist in
reducing sparks and explosion hazards always
present in both batterieswhen connectingcharged
batteriesto dischargedbatteries:
Turnoff allelectricalloads.Removeventcapsandlay
a damp cloth over open vent wells of each battery.
The chargedboosterbattery or batteries must have
the samevoltagecapacityasthe dischargedbattery
or batteries.
The positivepost is identified by a "r". pos.and red
colorandislargerindiameterthanthe negativepost.
The negativepost is identified by a "r-", neg. and
graycolor.
NegativeGroundedBatteryor Batteries
First,connectonejumpercablefromthepositivepost
onthechargedbatteryorbatteriestothepositivepost
on the dischargedbatteryor batteries.If morethan
one battery is connected in "series" or "series
parallel", connect the jumper cableto the positive
postthat hasthe cableleadingto the startingmotor.
Second,connect the other jumper cable from the
negativepostonthe chargedbatteryor batteriestoa
goodground onthe engine.
When removing jumper cables, always disconnect
the ground jumper cable from the engine before
disconnectingthe otherjumper cable.
PositiveGroundedBatteryor Batteries
Thisis the sameprocedureasfor negativegrounded
battery or batteries, exceptthe negative post will
havethe cableleadingto the starting motorandthe
positivepostwill begrounded.
5

WAUKESHA VR SERIES
COMPRESSEDAIR 1. Avoid contact with skin, clothing, and eyes.
Compressedair or gases should never be used to
cleanclothing orthe body.Compressedaircanpierce
the"skin and cause severeand very painful injury.
Neveruseyour handto checkair, gas,or liquid flow
rates.Do not engagein "horseplay" with air, gas,or
liquid hoses. Observeall applicableregulations as
relatedto compressedgases.
SODIUMFILLEDVALVES
When handling sodium filled valves always wear
approvedsafetygoggles,a hat or cap,longsleeves,
and gloves. If refacing of sodium filled valves is
required, do not exert undue force at the grinding
wheel asthis couldcrackthe hollow valvestemand
allow the sodium to escape.
Donot handlebrokensodiumfilled valveswith bare
hands.Sodiumor sodium residuecan causesevere
burns. Sodium burns are of the same nature as
causticburns.Washburnswith largevolumesofcold
water, then neutralize with vinegar. The affected
parts should then be treated as a burn and medical
attention sought.
Ifabrokenvalveshouldignite,smotherthe flamesin
drysodaashordrysand.Water,carbondioxideinany
form,orcarbontetrachlorideshouldneverbeusedon
sodium fires since these materials react violently
with hotsodium.Thesmokeandfumesareirritating;
adequate ventilation should be provided and
inhalation or contact with the smoke and fumes
avoided.
Brokensodium filled valvesmay be stored prior to
disposal in moisture free clean oil or kerosene.
Unserviceablesodiumfilled valvesmustbedisposed
of in accordance with local, state and/or federal
regulationsas applicable.
INTOXICANTSAND NARCOTICS
Workers under the influence of intoxicants and/or
narcotics are unsafe workers and are a hazardto
themselvesand other employees.
SAFETYPRACTICESFORHANDLINGACIDS.
Throughout this manual, acid cleaning procedures
are recommendedfor certain castings or piecesof
equipment.
I WARNING'
Always add the acid to the water - never add water
to acid when mixing solution.
2. Descaling operations should be performed
away from all fire, sparks or other ignition
sources.
3. Keepacids off of concrete floors, as it attacks
lime in the concrete. If solution does get on
concretesurfaces,applyan alkaline solutionto
neutralize.
4. Acids can react with metals to form various
gases.Generally,acid solutions on lime scale
and rust result in the formation of harmless
carbon dioxide. However,when acids contact
aluminum, zinc,cadmium,tin, sulfides,arsenic
and cyanides,poisonousand explosivegases
may be generated. When descaling is being
done in closed equipment. install proper
ventilation to carry the gasesaway. When an
open tank or crock is used, gases should be
diluted by adequate air flow above the open
tank.
5. Always fill closedvesselsfrom bottom up.
6. Be sure that there are no leaks in the vessel
being descaledwhich will permit solution to
leak into opposite side of equipment. Good
practice is to fill the opposite side of the
equipmentbeingdescaledwith water toa level
higher than the acid solution.
7. Use an acid-proof pump, or an inexpensive,
expendableone.
8. When mixing with water, pour acid into the
water, do not pour water in concentratedacid.
9. Do not agitate acid solutions with air.
10. Applications of acid should be followed by
thorough rinsing, then neutralizing with an
alkalinesolutionto removeall acidicresidue,to
preventfurther action.
11. Store acid solutions in either an acid-proof
wooden or synthetic rubber lined steel
container should be used.
12. Checksteel equipmentto be treated with acid
solution for copperor brassfittings or fusible
metal plugs. If possible, dissimilar metals
shouldberemovedpriortodescalingto prevent
electrolytic action which might interfere with
the inhibiting actionofacidsolution.Donotuse
acid to descale equipment constructed of
aluminum.
6

ENGINE OPERATOR
FOR YOUR SAFETY, ATTACH THIS SIGN TO THE
ENGINE STARTING CONTROLS BEFORE
SERVICING.
OPERADOR DE MAQUINA:
PARA SU SEGURIDAD, FIJE ESTE LETRERO A LOS
CONTROLES DE ARRANQUE ANTES DE
COMENZAR REPARACIONES.
A L'ATTENTION DE L'OPERATEUR:
POUR VOTRE PROPRE SECURITE, POSEZ CETTE
PANCARTE SUR LES ORGANES DE DEMARRAGE
DU MOTEUR AVANT DE COMMENCER LES
OPERATIONS D'ENTRETIEN.
MASCHINIST
1M INTERESSE IHRER SICHERHEIT: BRINGEN SIE
DIESE ANWEISUNG AM ANLASSER DER
MASCHINE AN, BEVOR SIE DIE EINHEIT
OBERHOLEN.
I
WAUKESHA ENGINE DIVISION
DRESSER INDUSTRIES, INC.
1000 W. ST. PAUL AVE.
WAUKESHA, WI U.S.A. 53187

WARNING! THIS UNIT IS BEING SERV'ICED. DO NOT
START, CRANK OR BAR THIS ENGINE OVER!
ATENCION! ESTA UNlOAD ESTA EN REPARACIONES.
NO ARRANQUE. NO INTENTE PONER EN MARCHA
CON MANIJA NI CON MANUBRIO.
ATTENTION! MOTEUR EN COURS D'ENTRETIEN
NE PAS DEMARRER, LANCER, NI AMORCER.
WARNUNG! VORSICHT! EINHEIT WIRD UBERHOL T.
MASCHINE NICHT ANLASSEN, NICHT
ANKURBELN, KEINE UMDREHUNG MIT HEBEL.

WAUKESHA VR SERIES
HOME AND REGIONAL OFFICE DIRECTORY
Forthe location of your nearest Distributor contact the RegionalOffice closestto you.
HOME OFFICE
Waukesha Engine Division
1000 W. St. PaulAvenue
Waukesha,Wisconsin 53186
- Mailing Address-
P.O. Box379
Waukesha,Wisconsin 53187
Phone:[phone]
Telex:26769
Cable:ENGINEWAUKESHAWIS
U. S. REGIONAL OFFICES
Central Regional Office
999 PlazaDrive
Suite 458
Schaumburg, IL 60195
Phone:[phone]
TWX:910-651-1910 CHIOFFSCHBU
Rocky Mountain Regional Office
5680 S.SyracuseCircle
Suite 300
Englewood,Colorado80111
Phone:[phone]
TWX:910-935-0713
Eastern Regional Office
7310 Ritchie Highway,Suite 316
Glen Burnie, MD 21061
Phone:[phone]
Telex:87673
Western Regional Office
901 Moraga Road,Suite C
Lafayette,California 94549
Phone:[phone]
RCA:289767
Gulf Coast Regional Office
14505 TorreyChaseBlvd.
Suite 106
Houston,Texas77014
Phone:[phone]
Telex:775753
Western Canada Regional Office
Suite 418, LancasterBldg.
304-8th Avenue S.W.
Calgary,Alberta T2PIC2
Phone:[phone]
Telex:03824780
INTERNATIONAL REGIONAL OFFICES
Waukesha Engine Division
Dresser Europe, S.A.
Europe & Africa Regional Office
Blvddu Souverain 191-197 - (B.3)
B-1160 Brussels,Belgium
Phone:[phone]
Telex23184
Cable:WAUKESHA
Waukesha Engine Division
Dresser Europe, S.A.
Middle East Regional Office
Blvddu Souverain 191-197 - (B.3)
B-1160 Brussels,Belgium
Phone:[phone]
Telex:23184
Cable:WAUKESHA
Waukesha Engine Division - DISA
Dresser Industries, Inc.
Far East Regional Office
1 Scotts Road,#24-09
Shaw Centre,Singapore0922
Republicof Singapore
Phone:[phone]
Telex:RS26139WKENGD
Cable:WAUKASIA
Waukesha Engine Division
Dresser de Venezuela C. A.
South America/Caribbean Regional Office
Apartado80700
Caracas1080-A, Venezuela
Phone:[phone]
Telex:24842 WAUKEVC
.. '

WAUKESHA VR SERIES
Waukesha Engine Division
Dresser Industries, Inc.
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY
Effective September 1, 1976
A. Sellerwarrantsonly that its products and parts,when shipped,and its work (includingstart-up),when
performed, will meet all applicablespecificationsand other specific product and work requirements,in.
cluding thoseof performance,if any, of this agreement,and will be freefrom defectsin materialandwork.
rnanship,With respectto products,partsandwork not manufacturedor performedby Seller,Seiler'sonly
obligation shall be to assignto Buyer, to the extent possible,whateverwarranty Sellerreceivesfrom the
Manufacturer. All claims for defective products or parts under this warranty must be madein writing im-
mediatelyupon discoveryand, in any event,within eighteen(18) monthsafter shipment, but not to exceed
twelve (12) months of serviceor 4000 operating hoursafter initial startup, whicheverOccursfirst, and all
claimsfor defectivework must be madein writing immediatelyupondiscoveryand in any eventwithin one
(1) year of conpletion thereof by Seller,Defectiveitemsmustbeheldfor Seiler'sinspectionandif requested
by Sellerreturnedto the originalf.o.b. point, transportationprepaid.THE FOREGOINGISEXPRESSLYIN
LIEU OF ALL OTHER WARRANTIES WHATSOEVER, EXPRESS,IMPLIED AND STATUTORY IN.
CLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES TO MERCHANTABILITY AND
FITNESS. It is understood that Seiler'swarranty shall not apply to products or parts, which in Seiler's
opinion, havebeendamagedasa result of overloading,overspeeding,overheating,inadequatemaintenance,
accidentor improperinstallationor storage.
B. Upon Buyer's submissionof a claim asprovidedaboveand its substantiationSellershallat its option
either (i) repair or replaceits product, part or work at the businessestablishmentof a WaukeshaDistributor
or other locationauthorizedby Waukesha,duringsaidDistributor normalbusinesshours.ThisWarrantydoes
not include reimbursementof any costsfor transportingthe product or part to suchestablishment,or for
removalor reinstallation of a product when necessaryin connectionwith aWarrantyrepair,or (ii) refundan
equitableportion of the purchaseprice. In no eventshallSellerbe liablefor the costof laborin connection
with replacementor repairof defectivepartswhen the engineor power unit hasbeenin the possessionot
the usingowneror rentaloperatorfor a periodof six (6) monthsor longer.
C. THE FOREGOING IS SELLER'S ONLY OBLIGATION AND BUYER'S EXCLUSIVEREMEDY FOR
BREACH OF WARRANTY AND, EXCEPTFOR GROSSNEGLIGENCEWILLFUL MISCONDUCTAND
REMEDIES PERMITTED UNDER THE PERFORMANCE,INSPECTIONAND ACCEPTANCEAND THE
PATENTS CLAUSES HEREOF, THE FOREGOING IS BUYER'S EXCLUSIVE REMEDY AGAINST
SELLER FOR A.LL CLAIMS ARISING HEREUNDER OR RELATING HERETO WHETHER SUCH
CLAIMS ARE BASEDON BREACHOF CONTRACT,TORT (INCLUDING NEGLIGENCEAND STRICT
LIABILITY) OROTHERTHEORIES;BUYER'SFAILURE TO SUBMITA CLAIM AS PROVIDEDABOVE
SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR DAMAGES OR OTHER RELIEF, INCLUDING BUT
NOT LIMITED TO CLAIMS BASED ON LATENT DEFECTS.IN NO EVENT SHALL BUYER BE EN-
TITLED TO INCIDENTAL OR CONSEQUENTIAL DAMAGES. ANY ACTION ARISING HEREUNDER
OR RELATING HERETOWHETHER BASEDON BREACHOF CONTRACT,TORT (INCLUDING NEG-
LIGENCEAND STRICT LIABILITY) OF OTHERTHEORIES,MUSTBECOMMENCEDWITHIN ONE(1)
YEAR AFTER THE CAUSEOFACTION ACCRUESOR IT SHALL BE BARRED.
7

WAUKESHA VR SERIES
TABLE
OF
Subject Page
SAFETY PRECAUTIONS
DISTRIBUTOR DIRECTORY .
TABLE OF CONTENTS/INDEX
DISTRIBUTORS AND SERVICE
12
14
INTRODUCTION .
15
ENGINE ILLUSTRATIONS
16
WARRANTY .
CONTENTS
Subject Page
2
OPERATION
1-1
8
PREVENTIVE MAINTENANCE
2-1
TROUBLE SHOOTING
3-1
Systems Description
Trouble Shooting Chart
REPAIR AND REPLACEMENT
Engine Construction
Repair Procedures
Fits and Clearances
4-1
7
INSTALLATION ...
5-1
INDEX
Subject Page
Air Cleaners 2-9
Air Intake System Description 3-4
Air Intake System Installation
Recommendations 5-5
Alignment 5-3
Alternator Servicing 2-15
Alternator Pulley Removal and
Installation Tool 2-17
Angular Operating Limits. . . . . . 5-6
Automatic Starting . 5-3
Basic Engine Data .
Before Starting Engine.
Break-in Procedure ...
.... 4-18
.. 1-3
............ 1-10
Camshaft Design .... . .. 4-5
Checking Flywheel and Housing Runout and
Crankshaft End Play . . 5-8
Cleaning The Cooling System. . . . . . . . . . . . .2-11
Cleaning And Inspection of Engine Parts .... . . 4-5
Cold Weather Starting. . . . . . . . . .... 1-10
Compression Testing. . . . .2-25
Connecting Rod Design . .. 4-4
Cooling System Capacity. . . . . . . . . . . . . . . . . . 5-4
Cooling System Description . . . 3-4
Cooling System Design. . . . . . . . . . . . . . . '1-4
Cooling System Installation Recommendations 5-5
Cooling System Maintenance. . .. 2-10
Crankcase Design. . . . .. . . .. . . . . 4-:3
Crankshaft Design. . . . 4-4
Cylinder Head And Valve Design... . .. 4-:3
Cylinder Sleeve Design. .4-4
Distributor Adjustment .
Dwell Angle, Adjustment of . . .2-12
.. ... 2-14
Subject Page
Electrical System Description 3-3
Energy Cell and Pintle Nozzle Service 2-19
Engine Foundations 5-3
Engine Performance Record 1-11
Engine Warm-Up. . . 1-11
Exercise of Standby Units 1-10
Exhaust System Description 3-5
Exhaust System Installation Recommendations 5-5
Firing Order 23
Fits and Clearances 4-19
Fuel Filter 2-9
Fuels 2-3
Fuel Systems Description . . .. . . .. . . . . . . 3-5
Fuel System Installation Recommendations 5-6
Gas Carburetor Adjustments 2-23
Gas Carburetion Description .. . 3-6
Gasoline Carburetor Adjustments 2-22
Gasoline Carburetion Description 3-5
Governor Adjustments. . 2-23
Governoring Systems Description 3·11
Ignition Systems Description. . . . . . :3-8
Injector (Poncil) Description, Fuel :3-7
Injector (Pintle) Description, Fuel. 3-8
Injection Pump Description .. . 3-6
Injection Pump Maintenance 2-17
Injection Pump Operation a-6
Injector. Reinstalling Pencil Type .2-22
Injector Test, Fuel. . .2-18
12

WAUKESHA VR SERIES
DISTRIBUTORS AND SERVICE
The WaukeshaEngine Division, Dresser Industries, InC.,has established a system of reputable dis-
tributors with trained mechanics and full facilities for maintenance and rebuilding, and to carry
an adequate parts stock in all areas of major enginepopulationall over the world. Their sales
engineers are available for installation consultation. If youcannot locate a Waukeshadistributor in
your area, contact the Waukesha Service Department, 1000West St. Paul Avenue,Waukesha,Wis-
consin 53186,or call [phone].
Authorized distributors Can respond to your
service needs more quickly if the following
procedures are observed:
1. Giveengine model, serial number andspeci-
fication number which are stamped on the
nameplate attached to the crankcase. The
serial number is also stamped on the crank-
case at either the gear cover or flywheel
housingend.
2. When ordering parts, always furnish the
complete description andpart number,where
known, of the parts wanted. Do not use the
words "complete" or "sets" - state thequan-
tity of each item required.
3. Tell the distributor how and where to ship
parts--state whether to ship by freight, ex-
press or parcel post--furnish shippingpoint
and post office address. Without specific
shippinginstructions the distributor will use
his owndiscretion and willnotberesponsible
for any charges by doingso. Be sure to mark
your name, address, and where you can be
reached on any order for parts as well as on
any correspondence.
4. Terms on repair--to avoid delay, all re-
pairs will be C.O.D. unless prior arrange-
ments are made with the distributor.
In situations whichmay fall within the parame-
ter of the Waukeshastandard warranty obliga-
tions, proceed as follows:
1. Whenplacing a request for service, speci-
fically state that the repair is believed to be
within the terms of warranty (this may be
indicated on the purchase order if desired).
Produce documentation showingthe date of
start up or installation of the engine andthe
engine model, serial number and specifica-
tion number.
2. Oncethe service or repair is completed,pay
for the service and/or parts in accordance
with whatever terms were previously ar-
ranged, but indicate with the payment that a
claim is pending under the provisions of
warranty.
3. Confirmationof the submission ofawarranty
claim can be requested from the Waukesha
distributor handlingtherepair. This is usual-
ly done by a notation on the distributor's in-
voice to the enduser.
4. The WaukeshaDistributor will notify youvia
letter or credit on an invoice of the decision
of Waukesha as to the request for warranty
on a particular repair.
5. Any parts replaced in the repair whichmay
be subject to warranty shouldbe left withthe
distributor for proper handling.
6. Any part replaced under warranty assumes
the identity of the part whichit replaces in
regard to warranty. That is to say, if the en-
gine is six months old the new part placed
in that engine for a failed part is six months
old in regard to any future warranty deter-
mination.
Remember - you own the best. If repairs are neededuse only GenuineWaukeshaParts purchased
from AuthorizedWaukeshaDistributors.
14

WAUKESHA VR SERIES
INDEX
Subject
Page
Light Load Operation. . . . . ... . . 1-10
Lubrication Guide 2-4
Lubricating Oils 2-4
Lubrication System Description . 3-9
Lubricating Oil System Installation
Recommendations. . . . . . . . . .. . 5-6
Magneto Servicing 2-15
Manifold Vacuum Test 2-25
Metric Conversion Formulas...................... .4-14
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . .. . . . .. . . ... 5-:~
Oil Changes 2-5
Oil Change Procedure 2-;;
Oil Consumption. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . 2-5
Oil Cooler. . . . . . .. . .. . . . . . .. . . . . .. . . .. . . . . . . 2-:13
Oil Filters. . . . . . . . . . . . . . . . . . . . .. . 2-8
Oil Pan Removal and Replacement 4-8
Oil Pressures.................................. . 3-10
Oil Pump Inlet Screen 2-9
Oil Pump Installation 4-7
Operating Controls. . 3-3
Operating Engine 1-7
Operational Inspection 1-11
Pencil Injector Adjustment 2-21
Pintle Injector Spray Patterns. . . . . .. . 2-20
Pintle Nozzle Service 2-19
Piston Design 4-4
Pistons and Rings, Installation of 4-7
Preparing Engine For Operation After
Storage 2-29
Preparing Unit For Service ;'-:1
Preservation Equipment and Materials 2-29
Preservative Oil. . . . . . . . . . . . . . . . . . . . . . . . . .. . 2-30
Protection of Engine and Parts. . . . . . . . . . .. 4-5
Removal of Rust or Corrosion 4-7
Repair of Damaged Machined and Polished
Surfaces . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Repairing Damaged Threads 4-7
(Cont.)
Subject
Page
Safety Precautions 2
Selecting Oil Viscosity 2-4
Service Limits Tahle 4-13
Service Schedule and Procedures 2-6
Space Requirements 5-3
Spark Plug Adjustments 2-14
Special Application Crankshafts 4-12
Starting Engine 1-6
Stationary Installations 5-3
Stopping Engine 1-8
Storage, Basic Requirements 2-26
Storage, Conventional 2-2R
Storing Engines That Have Been In Service 2-29
Storing New Engines 2-2R
Storage, Nucle-Oil 2-27
Storage of Fuel Injectors 2-30
Test Procedures For Engine Protection Devices 2-26
Thermostat Removal & Testing 2-11
Timing Data, Gas and Gasoline Engines 4-37
Timing Data, Injection Pump 4-1R
Timing Gear Backlash 4-37
Timing Gear Bushing Clearances 4-37
Timing Light, Use of 2-14
Timing the Magneto 2-15
Torq ue Recommendations 4-16
Torque Recommendations, General 4-15
Torque Values, VR Diesel Engines 4-17
Torque Values, VR Gas and Gasoline Engines 4-16
Trouble Check Chart for Operators 1-9
Trouble Shooting 3-3
Trouble Shooting Chart 3-13
Turbocharged Engines (VRD31OS) 2-31
Turbocharger Overhaul 4-10
Turbocharger Preventive Maintenance 2-32
Valve Clearances , 2-24
Valve Timing 4-37
Vibration Damper Replacement 4-R
Water Pump Pulley Installation 4-7
Water Pump Seal Installation 4-7
13

WAUKESHA VR SERIES
INTRODUCTION
Waukesha VR engines are intended for portable and stationary
applications such as material handling, portable water pumps,
road construction and generator sets. They are four stroke, high
speed, over-head valve engines, available in four and sixcylinder
in-line versions. These engines are capable of running on
gasoline, natural gas, and diesel fuel.
The information in this manual has been written in an easy to
read style and arranged in a time saving manner to provide
technical information for Waukesha VR engines. The common
construction features of these engines make it convenient to
operate and service any engine in the series through the use of
this manual. Differences in procedures due to fuel use or
construction wiIIbe pointed out as needed. Overhaul instructions
are not included, except where certain special procedures are
required. SPECIFICATIONS information, located in the
REPAIR AND REPLACEMENT UNIT, will allow a competent
mechanic to determine when parts are no longer usable.
All tabular data and recommendations contained in this manila I
represent the latest information available at the time of printing,
and are of course subject to change.
Throughout this manual we have used symbols to stress impor-
tant information. These symbols and their meanings are as
follows:
WARNING II.... This symbol precedes information which,
.' if disregarded, may result in injury or
death of the user of the engine or to others.
I~· !hi.s symbol precedes inf~rmation which,
If disregarded, may result In damage to the
engine.
NOTE· This symbol precedes information which is
I .
vital to the operation or maintenance of
the engine.
15

WAUKESHA VR SERIES
MH-001-174
VRG 155 GASOLINE ENGINE - RIGHT FRONT VIEW
ENGINE MODEL VRG 155
Displacement cu in. 155
liters 2,54
inches 3 5/8"
Bore mm 92,0
inches 3 3/4"
Stroke mm 95,0
Speed Range rpm 1200 - 2200
Gasoline
- - -
Maximum Continuous Horsepower 37 HP
@ 2000 rpm I
Nat. Gas. 29 HP
@ 2000 rpm
Normal Oil Pressure psi 25-35 (avg.)
@ 1500 rpm
12 (mi~) @800 rnm
OF 200 - 220
Oil Temperature
or
93,3 - 104,4
OF 180 - 200
Normal Coolant Temperature
or
82,2 - 93,3
.025 in. .636 mm
Spark Plug Gap
Weight (Dry) Ibs. 520
kg. 236
16

WAUKESHA VR SERIES
MH-001-171
VRD 155 DIESELENGINE- LEFT SIDEVIEW
ENGINEMODEL VRD 155
cu. in. 155
Displacement liters 2,54
inches 3 5/8"
Bore mm 92,0
inches 33/4"
Stroke mm 95,0
Speed Range rpm 1200-2200
MaximumContinuous Horsepower 36@2000rpm
Normal OilPressure psi 25-351avg~-~ 1500 rpm
12 min @800 rpm
of 200 -220
Oil Temperature
OC
93,3 -104,4
of 180 - 200
Normal Coolant Temperature
OC
82,2 -93,3
Weight(Dry) lbs. 565
kg. 257
17

WAUKESHA VR SERIES
MH-00I-3
VRG 232 GASOLINEENGINE- RIGHT FRONT VIEW
ENGINEMODEL VRG 232
Displacement cu in. 232
liters 3,8
inches 3 5/8"
Bore mm 92,0
inches 3 3/4"
Stroke mm 95,0
Speed Range rpm 1200 -2200
MaximumContinuous Horsepower Gasoline 53 ~ 2000 rpm
Nat. Gas 46@2000rpm
Normal OilPressure psi 25 - 35 (avg.)
@ 1500 rpm
12 (min) @ 800 rom
OF 200 -220
Oil Temperature oC 93,3 - 104,4
OF 180 -200
Normal Coolant Temperature oC 82,2 -93,3
.025 in. .636mm
Spark PlugGap
Weight(Dry) lbs. 607
kg. 305
18

WAUKESHA VR SERIES
MH-001-173
VRD 232 DIESELENGINE- LEFT FRONT VIEW
ENGINEMODEL VRD 232
Displacement cu in. 232
liters 3,8
inches 3 5/8"
Bore mm 92,0
inches 33/4"
Stroke mm 95,0
Speed Range rpm 1200-2200
MaximumContinuous Horsepower 55@ 2000 rpm
Normal OilPressure psi 25 - 35 (avg.)@ 1500 rpm
12{min)@800 rom
of 200 -220
OilTemperature oC 93,3 - 104,4
of 180 -200
Normal Coolant Temperature oC 82,2 -93,3
Weight lbs. 870
kg. 395
19

WAUKESHA VR SERIES
MH-001-7
VRG 265 GASOLINEENGINE- RIGHT FRONTVIEW
ENGINEMODEL VRG265
Displacement cu. in. 265
liters 4,3
inches 33/4"
Bore mm 95,0
inches 4"
Stroke
rum
102,0
Speed Range rpm 1200 - 2200
MaximumContinuous Horsepower Gasoline 72~~QQQ rpm
Nat. Gas 58@20oorpm
Normal OilPressure psi 25-50 ~avg.~
® 1500 rpm
12 min @ 800 rpm
OF 200 -220
OilTemperature oC 93,3 -104,4
OF 170-190
Normal Coolant Temperature oC 76,6 -87,7
.025 in. .636mm
Spark PlugGap
Weight(Dry) lbs. 745
kg. 339
20