” EA. CUSTOM ENGINE CONBAGL® IGNITION MODULE -_ INSTALLATION, — Ez OPERATION AND MAINTENANCE ea “aa Edition Ia [ Big gsten \ [Waukesha Faz) Pere ameCONTENTS SECTION 1.00 - Introduction ‘SECTION 1.05 - General Information ee eee too-1 Torque Values... 2105-1 Englist/Metric Conversions: 105-4 SECTION 1.01 - Safety SECTION 1.10 - General Engine Wiring Safetes nrodvcton yo1-1 Requirements Safety Tags And Decals to1-1 Wing. . 140-1 Equipment Repair and Service 101-1 SECTION 2.00- VHP Ignition Timing Acids WIR? VHP Ignition Timing .. 4. 2.00-1 Batenes 2101-2 ‘System Description .. = 200-1 (Body Protection 101-2 — SECTION 2.05 -VHP 6 & 12 Cylinder Ignition Chemicals 101-2 ‘Module installation General 1.01-2 CEC Ignition Module nstalation Cleaning Solvents 101-2 VHP 6 And 12 Cyinder Engines . +. 205-1 : Engine, Preparing... + 205-1 iquid Nitrogen’Dy 1 ° ea See CEC Hal Etfect Pickup, Instaling see 205-1 seinem ee CEC Timing Disc, Instaling .........essee1. 205-3 ee cred cee CEC Ignition Module, Installing + 205-3 Intererence Ft 101-2 CEC Ignition Module, Setting Cn as Production Installed Version ...........1.. 2054 Steps Required To Determine CEC Ignition Electrical 101-3 Module Switch Position 2.05-6 Genera 101-3 Dual Fuel Engines oc cesc esses 205-11 Ignition 101-3 SECTION 2.06 - VHP 16 Cylinder Ignition Exhaust 101-3 Module Installation Fire Protection 101-3 CEC Ignition Module instalation a aie ee coir Baeee tae! ngine, Preparing sosseentseseiy hs 200 Cie Soa CEC Timing Disc, Installing . 206-3 (Ceseocs) 101-3 CEC Hall Effect Pickup, Installing ss 206-4 Liguis 101-3 Engine, Assembing 208-5 intoxicants and Narcat 101-4 CEC Ignition Module, instaling.............. 208-5 ressurized Flids/Gas Ar - CEC Ignition Module Gh aaa ce ‘Setting Production Installed Version 206-6 Protective Guards Va-4 ‘Steps Required To Determine CEC Ignition Sodium Cooled Valve 101-4 Module Switch Postion - 206-7 Springs 101-4 — SECTION 3.00 — 12V-AT25GL Igntton Tools 1.01-. Timing eee jo1-4 —AT-GLIgntion Timing . - 800-1 Hysraule 101-4 — SECTION3.01-8L-AT25GL ignition Timing Pneumatic 401-4 AT-GL ignition Ting .. cen 801-1 Welsing 101-5 : SECTION 3.05 - 12V-AT25GL Ignition Genera! a Module Installation ones de CEC Ignition Module Installation Weight 101-5 T2V-ATGL Engines... ven B05=1 Fonweass WiCONTENTS Engine, Preparing 305-2 CEC Timing Disc, instaling 305-3 Hall Effect Pickup, Instaling 305-3 Engine, Assembling + 805-4 CEC Ignition Module, Installing 305-4 SECTION 3.10 - 8L-AT25GL Wiring Sche- matics And Diagram SECTION 3.11 - 8L-ATGL Ignition System Variances Ignition System Variances aat-1 SECTION 4.00 - VGF Ignition Timing Required lgntion Timings And Allowable Load Ratings For VGF Engines With Low Octane & Low Btu Fuels 400-1 SECTION 4.05 - VGF 6 & 8 Cylinder Ignition Module Installation CEC Ignition System Installation — VGF Engines 405-1 Engine, Preparing 405-2 Timing Dise, installing 405-2 Gear Housing Cover, Instaling 405-3 Hall fect Pickup, Installing 405-4 Jacket And Auxiliary Water Pump, Instaling 405-5 CEC Ignition Module, Instaling 405-5 SECTION 4.06 - VGF 12 Cylinder Ignition Module Installation ‘Component Description 406-1 Ignition Module oo 408-1 Hall Etfect Pickup < 406-1 Ignition Timing, Adjusting 408-1 Ignition System, Maintaining 406-2 Ignition Module ~ Potarty «406-2 SECTION 4.10 - VGF 12 Cylinder Ignition Wiring Diagram SECTION 4.11 - VGF 16 Cylinder Ignition Wiring Diagram SECTION 4.15 - VGF 12 & 16 Cylinder Timing Sensor Installation CEC Timing Sensor installation VGF 128 16 Cylinder 448-1 Assembly Instructions 43-1 SECTION 5.00 - Ignition Module Trouble- shooting Igntion Module Troubleshooting 500-1 CEC eniton Mo, Taxing Win nmmeter 500-4 Hal Elect Pekup, Testing 500-5 Hall tect Pickup, Testing With ‘Magnete Postion indicator 500-5 Ha est Psu, Teng OF Ege Wn Votmeter -. 600-5 Hal Elect Pickup, Testing On Engine With Votmeter 500-6 CCEC Ignition Module, Testing On Engine ...... 5.00~6 Ignton Ting, Testing 500-6 7 in And 3 Pin Connector, Testing 500-7 Crciloscope, Testing va - 5.00-8 Storage Capactor Votage Pater, Testing . 509-8 CEC Ignition Module, Testing (Bench Test)... 500-11 Perlormance, Testing (Bench Test) 500-11 Firing Patter, Testing (Bench Test) ....... 500—11 Igniion Ting, Testing (Bench Test) ...... 500—11 7 Pn And 3 Pin Connector, Testing (Gench Test) 500-12 Otciloscope Testing (Bench Tes) 500-12 Storage Capactor Votage Patter, Testng (Gench Tet 800-12 Cols, Tesing 500-12 VGF Troubleshooting Win Pigtal 500-13 SECTION 6.00 — Future Developements Waukesha's Custom Engine Control? Future .. 6.00-1 Detonation Sensing Module (DSM) = 600-1 Air/Fuel Module (AFM) = 600-1 ‘Attemator Power Option 600-1 WARRANTY Waukesha Engine Division - Dresser Industries, Inc. Express Limited Warranty For Products Used In ‘Continuous Duty Applications Express Limited Warranty For Products Used In Stand-by ‘Applications © FORM 6253SECTION 1.00 —- INTRODUCTION 3EAD THIS SECTION FIRST ONGRATULATIONS! Your purchase of a Waukesha ‘4ustom Engine Control® (CEC) Ignition Module was ‘ise investment. The Waukesha name is synonymous sith quality and durabilty for industrial engines and lated equipment. Ths ignition system was manutac- ured to provide many years of reliable service with yormal care and maintenance is manual contains important information! Be sure to Read Section 1.01, Safety, first. Be especially alert for special warnings throughout this manual. They precede nformation which is crucial to your safety and well deing, as well as anyone else working on or near the angine. The cautions and notes within this manual zontain critical information concerning the engine's >peration and maintenance procedures. This manual was preparedwith the intent that personne! working on industrial engines and electrical equipment are knowledgeable and experienced in this type of engine work. As a result, common novice language is. Used to indicate many mechanical or electrical proce- dures. This manual takes it for granted that an ‘experienced engine technician knows how to remove @ ‘common item, as well as what tool to use. Additionally, this manual takes it for granted that an experienced electrician knows how to perform any necessary wiring tasks and will conform to any applicable local codes or ordinances. Also, this manual takes it for granted that any individual performing any outlined troubleshooting procedure has been adequately trainedin all equipment necessary to perform such tasks. For procedures unique to each engine line, detailed step-by-step instructions are given. In all cases, the procedures are as complete as possible. It is the language which has been simplified. ‘The recommendations and data contained in this manual represent the latest information available at the time of printing, and is subject to change without notice. Since engine peripherals, such as customer supplied cooling systems, exhaust systems, etc., may vary with field conditions and applications, consult your local distributor for information on any subject beyond the ‘scope of this manual FORM 6is8 To0=4INTRODUCTION FORM 6253SECTION 1.01 - SAFETY SAFETIES INTRODUCTION ‘The following safety precautions are published for your information. Waukesha Engine Division, Dresserindus- tries, Inc., does not, by the publication of these precautions, imply orn any way represent that they are the sum ot all dangers present near industrial engines or fue! rating test units. If you are installing, operating or servicing a Waukesha product, itis your responsibilty to ensure full compliance with all applicable safety codes and requirements. All requirements of the Federal ‘Occupational Safety and Health Act must be met when Waukesha products are operated in areas that are under the jurisdiction of the United States of America. Waukesha products operated in other countries must be installed, operated and serviced in compliance with any and all applicable satety requirements of that ‘country. For details on safety rules and regulations in the United States, contact your local office of the Occupational Safety and Health Administration (OSHA) ‘The words “danger”, ‘warming’, “caution” and “note” are Used throughout this manual to highlight important, information. Be certain that the meanings of these alerts, ‘are known to all who Work on or near the equipment. NOTE: This symbol identities information which is NECESSARY TO THE PROPER OPERATION, MAIN- TENANCE OR REPAIR OF THE EQUIPMENT. A CAUTION | This symbol identities in- formation about hazards or unsafe practices. Disregarding this information could resultin PRODUCT DAMAGE AND/OR MINOR PERSONAL INJURY. A WARNING This symbol identifies information about hazards or unsafe practices. Disregarding this information could result in SEVERE PERSONAL INJURY OR DEATH. hazards. Disregarding this information will result in SEVERE PERSONAL INJURY OR DEATH. FORM e255 SAFETY TAGS AND DECALS A WARNING All warning tags and decals must be visible and legible to the operator while the equipment is operating. EQUIPMENT REPAIR AND SERVICE Proper maintenance, service and repair are important to the safe, reliable operation of the unit and related ‘equipment. Do not use any procedure not recom mended in the Waukesha Engine manuals for this equipment. A WARNING ‘To prevent severe injury or death, always stop the unit before cleaning, servicing or repairing the unit or any driven equipment. Place all controls in the OFF position and disconnect or lock out starters to prevent accidental restarting. It Possible, lock all controls in the OFF position and take the key. Puta sign on the control panel waming that the unit is being serviced Close all manual control valves, disconnect and lock out all energy sources tothe unit, including all fuel, electric, hydraulic, and pneumatic connections. Disconnect or lock out driven equipment to prevent the possibility of the driven equipment rotating the disabled engine. A WARNING Ensure that all tools and other objects are removed from the unit and any driven equipment before restarting the unit. A WARNING Allow the engine to cool to room temperature before cleaning, servicing or repairing the unit. Hot ‘components or fluids can cause severe personal injury or death. ‘Some engine components and fluids are extremely hot even afer the engine has been shut down. Allow sufficient time for all engine components and fiuids to cool to room temperature before attempting any service procedure. 101-4SAFETY ACIDS A WARNING Comply with the acid manufacturer's recommend: tions for proper use and handling of acids. improp- er handling or misuse could result in severe Personal injury or death. BATTERIES A WARNING Comply with the battery manufacturer's recommen- dations for procedures concerning proper battery Use and maintenance. Improper maintenance or BODY PROTECTION A WARNING Always wear OSHA approved body, sight, hearing ‘and respiratory system protection. Never wear loose clothing, jewelry or long hair around an engine. The use of improper attire or failure to use protective equipment may result in severe personal injury or death. CHEMICALS GENERAL A WARNING Always read and comply with safety labels on all containers. Do not remove or deface the container labels. Improper handling or misuse could result in ‘severe personal injury or death. CLEANING SOLVENTS. WARNING Comply with the solvent manufacturer's recom- mendations for proper use and handling of sol- vents. Improper handling or misuse could result in ‘severe personal injury or death. LIQUID NITROGENDRY ICE A WARNING ‘Comply with the liquid nitrogen/dry ice manutactur- er’s recommendations for proper use and handling of liquid nitrogen/dry ice. Improper handling or use could result in severe personal injury or death. COMPONENTS HEATED OR FROZEN A WARNING Always wear protective equipment when installing or removing heated or frozen components. Some components are heated or cooled to extreme temperatures for proper installation or removal Direct contact with these parts could cause severe personal injury or death. INTERFERENCE FIT A WARNING Always wear protective equipment when installing ‘or removing components with an interference fit Installation or removal of interference components may cause flying debris. Failure to use protective equipment may result in severe personal injury or death. COOLING SYSTEM A WARNING Always wear protective clothing when venting, flushing or blowing down the cooling system. Operational coolant temperatures can range from 180-250" F. (82-121° C.). Contact with hot coolant ‘or coolant vapor can cause severe personal injury or death. A WARNING Do not service the cooling system while the engine is operating or when the coolant is hot. Operational coolant temperatures can range from 180° ~ 250° F (82°~121°C). Contact with hot coolant or vapor can cause severe personal injury or death. Tore FORM 6255,‘SAFETY SLECTRICAL wy GENERAL | A WARNING Do not install, set up, maintain or operate any electrical components unless you are a technically qualified individual who is familiar with the electri- cal elements involved. Electrical shock can cause severe personal injury or death. A WARNING Disconnect all electrical power supplies before making any connections or servicing any partof the electrical system. Electrical shock can cause se- vere personal injury or death. IGNITION A WARNING ‘Avoid contact with ignition units and wiring. Ignition system components can store electrical energy and if contacted can cause electri shocks. Electrical shock can cause severe personal injury or death. A WARNING Properly discharge any electrical component that has the capability to store electrical energy before connecting or servicing that component. Electrical shock can cause severe personal injury or death. EXHAUST A WARNING Donot inhale engine exhaust gases. Exhaust gases are highly toxic and could cause severe personal injury or death, Ensure exhaust systems are leak free and that all exhaust gases are properly vented. A WARNING Do not touch or service any heated exhaust ‘attempting any service procedure. Contact with hot exhaust system components can cause severe Personal injury or death. FIRE PROTECTION A WARNING Refer to local and federal fire regulations for ‘guidelines for proper site fire protection. Fires can ‘cause severe personal injury or death. FUELS GENERAL A WARNING Ensure that there are no leaks in the fuel supply. Engine fuels are highly combustible and can ignite or explode causing severe personal injury or death. GASEOUS A WARNING Do not inhale gaseous fuels. Some components of fuel gas are odorless, tasteless, and highly toxic. Inhalation of gaseous fuels can cause severe Personal injury or death. A WARNING Shut off the fuel supply if a gaseous engine has been cranked excessively without starting. Crank the engine to purge the cylinders and exhaust system of accumulated unburned fuel. Failure to purge accumulated unburned fuel in the engine and exhaust system can result in an explosion resulting in severe personal injury or death. uauiD A WARNING Do not ingest liquid fuels or breathe in their vapors. Liquid fuels may be highly toxic and can result in severe personal injury or death. FORM e255 To-3SAFETY A WARNING Use protective equipment when working with liquid fuels and related components. Liquid fuel can be absorbed into the body resulting in severe personal injury or death. INTOXICANTS AND NARCOTICS WARNING Do not allow anyone under the influence of intoxi- eants and/or narcotics to work on or around industrial engines. Workers under the influence of intoxicants and/or narcotics are a hazard both to themselves and other employees and can cause severe personal injury or death to themselves or others. PRESSURIZED FLUIDS/GAS/AIR A WARNING Never use pressurized flulds/gas/air to clean cloth- ing or body parts. Never use body parts to check for leaks or flow rates. Pressurized fluids/gas/air in- jected into the body can cause severe personal injury or death. Observe all applicable local and federal regulations relating to pressurized fluid/gas/ai. PROTECTIVE GUARDS A WARNING Provide guarding to protect persons or structures. from rotating or heated parts. Contact with rotating or heated parts can result in severe personal injury or death. Itis the responsibilty of the engine owner to specify and provide guarding. SODIUM COOLED VALVE DANGER Do not cut or break open sodium cooled exhaust vaives. Contact with sodium will cause severe personal injury or death. Contact local waste management authorities to dispose of sodium cooled valves per local or federal codes. SPRINGS A WARNING Use appropriate equipment and protective gear when servicing or using products that contains springs. Springs, under tension, can eject if im- proper equipment or procedures are used. Failure to take adequate precautions can result in serious personal injury or death. TOOLS ELECTRICAL A WARNING Do not instal, set up, maintain or operate any electrical tools unless yo technically qu fied individual who is tamiliar wth them. Electrical tools use electricity and if used improperly could cause severe personal injury or death. HYDRAULIC A WARNING Do not install, set up, maintain or operate any hydraulic tools unless you are a technically quali- fied individual who is familiar with them. Hydraulic tools use extremely high hydraulic pressure and if used improperly could cause severe personal injury or death. Always follow recom: A. CAUTION | rended procedures when using hydraulietensioning devices. Improper use of hydraulic tensioning tools can cause severe engine damage. PNEUMATIC A WARNING Do not install, set up, maintain or operate any Pneumatic tools unless you are a technically qualified individual who is familiar with them. Pneumatic tools use pressurized air and if used improperly could cause severe personal injury or death. ins FORM 6253wy WELDING GENERAL A WARNING Comply with the welder manufacturer's recommen- dations for procedures concerning proper use of the welder. Improper welder use can result in severe Personal injury or death. ON ENGINE By. CAUTION ] Ensue that the welder is properly grounded be- fore attempting to weld on or near an engine. Failure to properly ground the welder could result in severe engine damage. SAFETY By. CAUTION ] Disconnect the tonition harness before welding ‘on or near an engine to eliminate charging of an ignition system capacitor. Failure to disconnect the Ignition harness could result in severe engine damage. WEIGHT A WARNING ‘Always consider the weight of the item being lifted and use only properly rated lifting equipment and approved lifting methods. Failure to take adequate precautions can result in serious personal injury or death. A WARNING Never walk or stand under an engine or component while itis suspended. Failure to adhere to this could result in severe personal injury or death. Fonm ez To-6oe ee FORM 6253SECTION 1.05 - GENERAL INFORMATION TORQUE VALUES ble 1.05-1. Metric Standard Capscrew Torque Values (Untreated Black Finish) ‘COARSE THREAD CAPSCREWS (UNTREATED BLACK FINISH) ww madten | __(e8) (a) ® oe [swe TORQUE vedtaere NOTE: The conversion factors used in these tables are as follows: One N.m equals .7375 flo and One ft-lb equals 1.355818 Nm FORW ee 05-4GENERAL INFORMATION Table 1.05-2. Metric Standard Capscrew Torque Values (Electrically Zine Plated) ‘COARSE THREAD CAPSCREWS (ELECTRICALLY ZINC PLATED) “ae © © Nm in Nm | ind | __Nm inl wae 7340 368 3050) 2249 4290 3168 5150] 3798 z © © ry Gea —————— a NOTE: The conversion factors used in these tables are as follows: One N-m equals .7375 ft-lb and One ft-lb equals aGENERAL INFORMATION ‘Table 1.05-3. U.S. Standard Capscrew Torque Values oft, © © cone Grade 1 or 2 Grade 5 Grade 8 sizer Tongue ToROUE 70) THREADS een) mene mpoen) TaneADs | pry | Oued [piaTeD | pry | oueo [piaren | pay | oweo | PLATED we-20 | em | ssw | «20 | 97 15908) 97 (19) 168,19) 42 (16) 124,14) 13305) 290 26) w-2 | me | em | 5906) 106 (12) sne-1e | 139(15) | reer) | 10812) | 203¢@9) | 17 @0) 124 (14) 2ez(9s) | 265(20) sre-2 | vs0ce) | v2 | vzeaa | eso | 2osces | 7@0 | sercn | eee | 20500 ae-16 | 222) | ve5ae | ve0c | arena) | seas | aren | sre | ree | sean ftelb (Nm) felb (Nm) felb (Nm) se-m | 20e7 | vem) | vere | a5an | ses | 2808 | oe | ae | 96) vie-v4 | 2008 | 250 | 22000 | «oe | «eo | a9 | row | cas) | sere) ve-20 | soy | evar | 2s | ss | sos | «(60 | 7:06 | 70s) | e206 ve-13_| 9%) | aser | ora | 75002 | ceca | eocen | rose | oscan | eacre) ve-20 | see | seo | sacs) | escne) | r7aon | ese | veoces) | oes) | ce co) | one-v2 | ses | eee) | «ee | voces | oncien | eacney | tesco) | waacron) | t2ecee) orev | 55075) | soe) | <0) | veocrea) | 108 cae) | oacra0) | woes) | secon | 1s8cee) se-n_| escis, | 75:02) | 6s) | rs01@00) | 19519) | ve0cves) | avorees) | vearese) | 60(aze) se-te | 051129) | e617) | 76(703) | 1701230) | 851207) | 196(184) | 200(G25) | 216(295) | 192(260) se=10 [105 (142) | 95:30) | 84114) | 270,966) | 243 (020) | ave (209) | 9751608) | 336458) | 9001407) sere | 1151056) | 102041) | 92(728) | 295 400) | 266 (381) | 2961820) | 201660) | s76(615) | 396456) 7-8 | 1601217) | 1461198) | 1261174) | 3051635) | 356,483) | 316428) | 60s(e20) | s45(730) | 404 (656) 7-14 | 175(257) | 198:2%4) | 1401790) | 4951590) | 9920691) | 9481472) | o75(015) | 061624) | 540(732) xo-e | 22scare) | 212,267) | vee 285) | 590800) | $31 720) | 472 640) | oro (1284) | e19crri0) | 728,087) so-1¢ | 20:98) [ 225,905) [ 2001271) [ e60e95) | s9¢ 805) | see 716) | 990 1942) | 91 (1208) [ 792.1074) NOTES: — Drytorque values are based on the use of clean, dry threads. — Oiled torque values have been reduced by 10% when engine oil is used as a lubricant. — Plated torque values have been reduced by 20% for new plated capscrews. — Capscrews which are threaded into aluminum may require a torque reduction of 30% or more. — The conversion factor from ft-lb to incIb is f-lb x 12 equals in-Ib FORM e255 705-3GENERAL INFORMATION ENGLISH/METRIC CONVERSIONS Table 1.05-4. Metric Bolt Diameter To Hex Head Wrench Size Conversion Table wETric Tea ott TaneaD stinoaRo ChaNeTER vino Sze wi erm we Tr = MS. 8mm 78 ‘orm 7 im we ‘erm 10 Bertram vie TB orm ve Berean vie 2m we Zen 120 20mm wae erm ee 2m wer alien %89 “en = nm 188 nm 188 conn wee een Tos-« FORM 6253‘Table 1.05-5. English to Metric Formula Conversion Table GENERAL INFORMATION ou ‘CONVERSION FORMULA EXANPLE Tare gng aa facunnoeema thes to Mites Saved mp 2Staatee [260m «2e254254~ 0868 nm ne F Cube iene to Lives Gabe ches mutes by 0.01690 waa | ape yn «0988x0010 = 15281 Orne Grae (Ounces nutpiedby 2835 eaves rame__[2i or = 21 57835= 5956 Pounds Kiograms Pounds mipiedby 04506 ews [2.550 a= 2288004596 «102289 inch Pounds Newion-metrs Te, pours uted By ©1298 eat | agp nip = 980 0.11208 «40.7 Nom Foot Pounds to Newion-meters Foot pounds mulipled by 1.3558 equals | 145 nip. 145 x 1.3558 = 197 Nm Pounas pe Sage neh Pounds pr square inhrpiadby 00708 Rioparepe Sass Conmetey [ea sihograme per sare conte» | «Si = 45x00709 = 3.2 kgm? Pounds per Square cho Pounds per sqare inch mlpldby 6.0047 Raopasea Pounos pore hed 6667 [5 sin a x6. 0047 = B1020KP a Fd Ounces Cube Centers [FIN Quoee, mutpied by 2957 aves |s os -ax2957 = 236e Gators w Unes Galion rupley 87850 equals ren | 14 gal = 8X9 7050 = 5000 Segue ravestie eves DagersFamerei inst avd) 8] oye gna: v0 100° 6 Table 1.05-6. Metric to English Formula Conversion Table CONVERSION FORMULA EXAMPLE J rrr eres Wwinaters mpeg by 0007 ea.R | mm 67x 0.0087 «268 aecnnee peerapies yer Cees cade [agsg a iesensioe=er2s6cun Grane Ones Gras pled by OUSET eal unons [605 6 = 05 xO GREET PI ce Kiegrars 1 Pou ‘ogame mpledby 2205 eave pounds | 10228 Kg = 1028842205 « 20554 be Newton-meters to Inen Pounds Newton-maters multpies by 6.85 eaU2l6 | 40.7 m= 40.7 x885=360in-b Newon-meters to Foot Pounas Newton meters muted by 0.7375 eauals | 467 nim x 167 X 0.7975 = 145 Mb arto Pounds per Savare Inch Bar mutpees by 14.5 equals pounds Per | gas ar = 85x 145 5=9.9925.5 psi BERIT SSSR Sree © [Megaman Reems [32g 3211422—485pu Raspenats Yo Pounes pet Sear tn | Mlonewcae_oalipieg by O65 ouae | roioa con vavoxaseoAe pol os} Bours per savers Inch Sua Riss cue S10 RO Cubic Centimeters to Fluid ounces | uBC centimeters muted by 29.5 equals | 96 oc = 296 x 295 = Boz eee Galore Lives munpiedby 0260 casas plone [S601 = S6OXO264 = pal Gere cergrase oops Ee ee ws Fomveass Toe=eGENERAL INFORMATION FORM 6253SECTION 1.10 - GENERAL ENGINE WIRING REQUIFEMENTS WIRING Allelectrical equipment and wiring (with the exception of the ignition system) shall comply with applicable National Electrical Codes. This Waukesha standard defines additional requirements for Waukesha engines. 1, Whenever two or more wires run together, they should be fastened together at no more than four (4) to six (6) inch intervals, closer where necessary, with “cable ties". Power wires (24 Volts or greater) should never be run together with any other instrument or control wires. Spacing or these types of wires should be four (4) to six (6) inches minimum to eliminate electrical “Noise” problems in the instrument or control wires. 2. All wires should be mounted off hot areas of the engine with insulated clips, at intervals of no more than twelve (12) inches, closer where necessary. Wires must ever be run closer than six (6) inches to exhaust ‘manifolds, turbochargers or exhaust pipes. 3. In cases where wires do not run over the engine, they should be fastened to rigid. non-moving bodies with insulated clips when possibie or "cable-ties”, Fasteners should be spaced at no more than twelve (12) inch intervals, 4, When wires run through holes, rubber grommets should be installed in holes to protect the wires. Wires should never be run over rough surfaces or sharp edges without protection (see Item 11) 5. An electrical grade RTV shouldbe applied around the wires entering all electrical devices such as Murphy Junction Boxes and gas valves, Syncro Start speed ‘Switches, microswitch boxes used in conjunction with safety equipment, solenoids, etc. An electrical grade RTV is to be applied immediately after wire installation and prior to the engine entering the test room, 6. Asmall"drip loop” should be formed.in allwires before entering the electrical devices. This will reduce the ‘amount of moisture entering electrical device via the ‘wires if an electrical grade RTV does not seal complete- ly. 7. The following procedures shouldbe followed for wires entering engine junction boxes: ‘@. Bottom entrance best and side entrance second best. 'b. Insert grommet in opening to protect wires. ‘¢. Wires to contain “drip loop” before entering box, ‘except where using bottom entrance. . When installing flexible conduit, use straight ‘connector for side entrance. If top entrance is. required, use elbow connector. 8. If wire harness has a covering, clamp hamess SO ‘openings of covering are downward. 9. The routing of wires should be determined for reliability and appearance and not by shortest distance. 10. Installation connection wire must be coiled and ‘secured to provide protection during shipment. 11. Each end of flexible metal conduit must have an insulating sleeve to protect wires trom chafing, 12. All engine mounted electrical equipment over 24 volts shall have "HIGH VOLTAGE” warning decal. Decal to be attached to all the equipment and junction boxes, on visible surface (vertical surface whenever possible). 18. Wiring that is routed in rigid or flexible conduit shall have all wire splices made only in junction boxes, outlet boxes or equipment boxes. Wire splices shall not be located in the run of any conduit. FORN es Ta0=4GENERAL ENGINE WIRING REQUIREMENTS: Tho-? FORM 6255,SECTION 2.00 - VHP IGNITION TIMING VHP IGNITION TIMING ‘SYSTEM DESCRIPTION This section lists the correct ignition timing for all VHP Products from January 1, 1980. Refer to Service Bulle- tin 11=1520A for the timing specifications for older en- gines. Table 2.00-1 lists the engines by models and uel types. The fuel types are defined in the following paragraphs. COMMERCIAL QUALITY NATURAL GAS: Anaturally occurring mixture of hydrocarbon and other gases found beneath the earth's surface, often in connection with iquid petroleum. The principle components usual- ly methane (CH.). Minor components are heavier hy- drocarbons and other gases such as nitrogen (Nz), ‘carbon dioxide (COz), helium (He), argon (Ar), oxygen (02), and hydrogen sulfide (H2S). The saturated low, heat value normally ranges from 800 - 1000 Btu? (83.54 -37.26 Jim’). Octane rating of 118 - 120. Hol- land's pipeline gas has a heat value of 820 Btu/t? (30.5, ver?) DIGESTER GAS: A fuel gas formed by the anaerobic ‘decomposition of organic matterin a digester. Itis com- posed primarily of methane (CHa) and carbon dioxide (COz). The saturated low heat value normally ranges from 500-600 Btu/t® (18.63 ~ 22.36 J/cm’), Minimum, octane rating of 120, Hydrogen sulfide (HS) is typical trace component. FIELD GAS: The saturated low heat value normally ranges from 900 ~ 1500 Btu'tt® (33.54 ~ 55.898 J/cm’). Octane rating of 115 - 118 LANDFILL GAS: A fuel gas formed by the decomposi- tion of landfill refuse. It is composed primarily of meth- ‘ane (CHs) and carbon dioxide. (CO;). The saturated Jow heat value normally ranges from 450 ~ 550 Btutt® (16.77 -20.39 J/cm’). Octane rating of118-120. Chlo- rine and fiuorine bearing compounds are typical trace components. OCTANE NUMBER: The octane number of a fuel is @ measure of i its ability to resist detonation (knock). It may be measured or calculated. For gas mixtures itis Usually calculated from a component analysis. On the motor method scale used by Waukesha, the octane ‘number ranges from 120 for methane (highest) to 0 for rormal heptane (lowes!) PROPANE, HD-S: A fuel gas found in natural gas ar petroleum, made of carbon (Cs), and hydrogen (Ha) with 97.1 octane rating. Otten used as a backup fuel. LOW BTU FUEL: Fuel having less than 700 Btuft® (26.08 J/em®), such as landfill gas, NOTE: Changing the engine timing will also change the ‘exhaust emissions and fuel economy. A. CAUTION ]2ctoration is Nor at lowed at anytime, during engine operation, regardless of the specified tim- ing. if detonation occurs at the specified timing, timing adjustment must be made to retard t ignition timing until NO audible detonation exists. Engine damage may result if detonation occurs. FoneVHP IGNITION TIMING Table 2.00-1. VHP Ignition Timing Ratio: 1 Moses | Compression F28056 225 Low Bt Fuel Type Duty Ea F26956 325 a. (Cont & it 1° [15 20956 825 Nat Gas Cont bine | 2 | 2 2 728056 70 Low Bu Cont | 20" 2 28956 10 PS Cont Bin. | 12" 1 F26956 10 Nat Gas (Cont in 207 zor | 20" F2005" 10 Nat Gas 16° 288560 10 Low Bt Cont & in 1 289561 10 Low Octane. 115mm | conan | « | | | | @ 2 zesscx_| _10 Low Octane 1i7Min__| Com ain | 6 |e |e | & | o & 289560 10 Nat Gas Cont & int Fe0sasi | 625 LPG 130° F ow" Faeescsi | 25 LPG 85° FIoW con fe fae fae fae ee |e | ae Faeesasi | 625 Nat Gas con | a | a | av | av | ae | av | ae Faeesasi | 625 Nat Gas ine, ee [ee [at [aor | aor [cet | ee F2e956s" Nat Gas a | eae |e 209563" 70 Nat Gas. (Cont = 1 la F516 6 Low Bis (Cont 20" 2 Fss216 é LPs Cont Sine | 18° 1s [1s Fa5216 é Nat Gas Cont aire | 20° [ 20° | 20° | 2a ee | 2 F36216 10 Low Bt Cont 20 | 20° | 20 | 22° eo | 2 FS5216 10 LPG cont aimee | 12° | 12 | vz | roe ° | & F36216 10 Nat Gas Cont. & int Fas216" 10 352160 105 3216 105, LowOcane 15min | comamn | - | | @ | « « 35216. 105. Low Octane i7Min. | Conainn | - | e | o | e 35216 105 PG Cont Es | | eae | ea « 35216. 105 Nat Gas, contain | — | 10° | 10° | 10° 10° Fa621681 @ Low Bt Cont. ar [ar | 2 F3521651 8 LPG 130° FCW" (Cont = ° = F3s216S) 8 LPG 85° FIGW™ Cont. we [ae [ae | 12 Fas2168) ® Nat Gas. Cont F35216S! @ Nat. Gas. tnt FasziGsr @ Nat Gas Cont Fasz1Gsr (51086, a2 Low Bu Cont ar [ar [a Ls1086. 825, Ls. Cont gine. | ve | se | tee | 15° mas ar C158 Four 200-2 FORM 6253I srocer | Compression VHP IGNITION TIMING Opera meen retype wy [oo [vee [ wo [ ooo [oon [vee 151086) 25 Nat Gas (Cont & nt rier [as aaa a [asic | — 10 me esa ieee aa =a Nat Gas, Cont. Low Octane 115 Min Low Oatane 117Min, | Cont aint. | 10° | 10° Nai Gas, Tsrees! | 02s tow Btu Contre | a ierceas: | 028 The 130" Foe con | ‘sroeesi | eas 1P6 68° FIoW™ cone |e wereessi | ez8 Nat Gas i Ls1086s! 825 Nat Gas vee [ze [ae | a2 usr08Gsi 10 Low Buu 510865! 10 Nat Gas fer 70 Nat Gas 157906. 25 Low 157906 25 Ls. ‘Cont & nt 1s 157096, 25 Nat Gas ‘Cont & int ae 157096 10 Low Btu Cont Ea 157906, 10 LPs Cont Bin | 12° | vo | az | vee | we [vet | ee 157906. 70 Nat Gas. Cont bir | 20° | 20° | 20° | 20° | 20° | 20° | 20° 790% 10 Nat Gas Cont eat eee = [ae 576060 10 Low Bt cont sir | - | ve | vor | ve | ver | ve | ve 579061 10 LowOuane 15Mn | comamr | - | ||| «| «| & 57006. 70 LowOeane 17min | comame | - | eo |e |e |e |e | & 579061 Nat Gas 1579068" Nat Gas 2 1579065) Low Bio ae og 579065 LPG 190° Few" Cont = 15790681 LPG 85 FIG Cont 5790651 Nat Gas. int 16 Ls790681 Cont, 118 ae us7906s" 170626, FoRw 6255 200-3VHP IGNITION TIMING Mocei | Compression Fuel ype 70] s60 [so | v000 | v100 | 1200 eas_| 10 Tow Su 2 78s | 10 Fs * woes | _10 Nat Gus ze [ae wows | 10 Nat Gas —[- [er 7oe2ct_| 105 Low Bt = vouzct_| 105 TowOcane 1isMin, | comainn | - | ele 70426 105) Low cane. 117 Min | Cont aint. | — | ele 704260 105) m= ‘ont SIS ele 70426 105) Nai Gee Contant | 10 | vor | so? | 10 ra Lroa26si ® Low Bu Lr0426si @ (PG 130° FIGW= = 7042681 ® LPG 85° FIGW™ cont | rr 7042681 ® Nat Gas cont] 2 2 7042681 @ Nat Gas a 1 701268" e Nat Ges ‘cont a= a 026s = Pa2906 P3806 793906 Pessos | 6 Nat Ges Cont 5 2 P3806 0 Low Bu Cont | | ze [ee 93805 10 LPs. cont bin [1 | az | a2 1 | P9800 10 Poss00 10 3906. 108 Low Bio Cont 30061 105 Lew Octane 117 Min 930061 105, Low Octane, 115 Min - |e Te [Te Te Te Te 930061 105, Ps Cont ~|-[- le [ee Te 239061 1" Nat Gas. 10 Pe300G51 Low Bt P9390651 LPG 190° F cw" 'P9390681 LPG 85° FIC ra 939068! Paa9065) Nat. Gas. int a 1 Sena tne NERO [a SG) Fa aa Nara FT NTE NET BOER eC Foo-a FORM 6253SECTION 2.05 - VHP 6 & 12 CYLINDER IGN'TION MODULE INSTALLATION (CEC IGNITION MODULE INSTALLATION — VHP 6 AND 12 CYLINDER ENGINES NOTE: Allwiring must follow accepted electrical codes and practices for the installation site. Table 2.05-1 shows the kits available to upgrade your, Waukesha VHP 6 or 12 cylinder engine with this state-of-the-art ignition system, ‘Table 2.05-1. Conversion kit, ignition timing. The electronic ignition module then directs a precisely timed votage to the appropriate col. ENGINE, PREPARING The following installation instructions are for VHP 6 or 12 cylinder engines. 1. The required power supply for the ignition module is 10-28 VDC (32 VDC Max). Ignition modules require @ ‘nominal power supply of 24 VDC for compatibility with future CEC module components. The power supply is, ‘connected to two 10 amp fuses, a switch and/or relay. Allare customer supplied. Refer to the wiring diagrams at the end of this section for the ignition module power NOTE: Grounding the “G" lead in the wiring hamess will shut off the ignition module but will draw approxi- mately 0.1 amps continuously from the power supply if 2. The ignition module must be rubber mounted (Waukesha Part No. 119058) when the mounting bracket is attached to the engine. The kit mounting brackets are for attaching the unitto the intake manifold. Astudis located on the ignition module frame to ground the ignition module tothe engine (see wiring diagram). [Za CAUTION ] Te sntion modu out ide case temperature ‘The ignition module functions by using a Hall etfect pickup to read magnetic reference marks on a disc attached to the governor drive gear hub. This method of timing determines the exact position of the crankshaft The microcircuit-based electronic ignition module interprets the sensor's impulses to set the optimum, ). 3. Remove magneto. install cover plate (Waukesha Part No. 207293) and gasket (Waukesha Part No. 199389) on magneto drive housing. Remove magneto 4, Remove the governor drive cover, lock nut from accessory drive shaft, oil slinger, and roll pin. Discard cv, | 12cve ory | KitNo. | KitNo. | Description 952-1500 | 962-1501 [sores | _es7es Tgnton Weave + | 2nsies | ansie | Moone grace supply for 6 and 12 cylinder engines. + | ansiec | ansiea | Mounting presse ‘soir a ee ee jormon Mos ‘not disconnected. 4 | zr | 21908 | ost Srcwet eo | zs | aise | tomate, i eo [wer [ce | a cet + | esse | esrae Pisvessy 1 | soseasr | sosecse | wagnete Dac 745 must not exceed 150° F ( 1 | easecaa | esecca | nal etc Pee 1 | azn | zee0r ageete Bae | core | eevee | _ Primary Hamers a wiring hamess. Discard. 1 | ores | 207222 | yagneio Sve Moveng 7 | sesaee | _s8s0ee | cance Cover Pie + ens _ense7_[ wa Trnng Dee the oi! singer, lock nut and roll pin. 1 | teste [108548 | covemor Be Housing (CEC HALL EFFECT PICKUP, INSTALLING 1. Using drill guide 475014 (Field Service Training Center Too)), drill a 9/16” hole in the governor drive housing. If drill guide is unavailable, line the dril bit up with centerline of accessory drive shaft and 4.10in. (104 mm) back from the face of the housing (see Figure 2.05-1). Tap the hole to 5/8” ~ 18 NC. Foaw e253 205-1VHP 6 & 12 CYLINDER IGNITION MODULE INSTALLATION nr DRILL sre" ae coneeiy PREVIOUS 6 CYLINDER TIMING DISC eae =n e | Brg (oe), | / aa Q recar) pave HOUSING / @ = cad pees cea te oes DATS ne NOTE: Use pertcular care to ensure the centerine of scvonsay cre 2 ss wa NOTE: Use a 4 fiuted drill bt to prevent damage to the ‘governor drive gear when drilling. 2, Remove all metal chips generated from driling and. tapping into the governor drive housing, 3. In place of the oil slinger, install magnetic disc (correct rotation) and hand tighten the timing disc nut. The current disc has four pre-drilled pin holes for production use while the previous disc has none (see Figure 2.05-2). Install pickup and set the gap between pickup and magnetic disc at 0.040” + 0.010”. NOTE: Timing disc is marked with arrow showing the correct rotation A. CAUTION | Ente Pickup to timing disc clearance is proper- ly set. Contact between pickup and disc can cause failure of these components and loss of ignition. NOTE: If the metal chips are not removed, they will accumulate on the disc's magnets, resulting in aloss of ignition. 040" 2 010") EXAMPLE: \oK-uP HOLE #1- 18" PIN HOLE #2— 8 HOLE #3 -3/16- PIN HOLE #4— V4" PIN, 205-2 FORM 6255VHP 6 & 12 CYLINDER IGNITION MODULE INSTALLATION CEC TIMING DISC, INSTALLING 1. Bar the engine over until the number 1 right bank cylinder (compression stroke) is set to 12 degrees aheadof the most advanced timing pointto set the static, engine timing. Check the engine timing tag for the specified engine timing (see Figure 2.05-3). This static timing setting for the CEC ignition module is required to ensure adjustability back to standard timing Figure 2.05-3. Current Engine Nameplate (January-1981) ‘Timing is changed with two 16 position switches located fon the ignition module (see Figure 2.05-4). Each switch can be set to separate ignition timing settings for itferent applications. Switch position 15 gives the most advanced timing on either switch “A” or “B*. The timing retards 1.0 degree for each switch position lower than, position 15 (see example in Figure 2.05-2). Grounding lead "D’ in the pickup cable (7-pin connector) activates the timing selected by switch “A”. Ungrounded lead "D" will activate the timing selected by switch “B’ CEC IGNITION MODULE ROTARY SWITCHES A AND B. NOTE: Timing selection i made by the dot on te ewe, ortne serewanver sot Figure 2.05-4. CEC Ignition Module Rotary Switches A and B FORw e253 NOTE: The use of Waukesha Engine Tool #475027 is highly recommended for accurate positioning of the timing disc. 2. Align the leading edge of the first firing magnet (marked "X" or *") with the centerline of the Hall effect pickup (see Figure 2.05-2). The last fing magnet can be identified by a second magnet trailing 15 or ® degrees, depending on the engine model. 3. Torque the timing disc nut to 180 — 160 ft-lb (203 - 217 Nm). NOTE: The ignition module requires the Waukesha Part No. 696948 or 69694 ignition coils to attain best ignition system performance. 4. Install the governor drive cover. CEC IGNITION MODULE, INSTALLING 1. Route the primary wiring hamess to Altronic ignition Coils and cut to length (refer to wiring diagrams). Proper installation requires that the four comer coils are connected to ground. instal flashover protectors and ‘new resistor spark plugs to achieve optimum ignition system performance. Connect the 7-pin wiring hamess {rom the pickup to the ignition module. NOTE: Ground the four comer coils on @ 12 cylinder and the two end coils on a 6 cylinder (see wiring diagrams) fo ensure a proper ground path. Bi CAUTION] Momentary reverse po- larity connection may permanently damage the ignition module. Check wiring connections before applying power to the Ignition module. 2. Wie the ignition module power supply to the ignition module (see Figure 2.05-11). All wting must be com- pleted BEFORE the power supply is tumed on. ° nition module rotary switches (A&B) tothe NOTE: An AC to DC power supply is not preferred unless care is taken to eliminate the possibilty of a momentary loss of AC power which will resutt in an engine shutdown. A DC voltage filter (battery) is recommended to eliminate voltage fluctuations. DO NOT turn on the fuel By. CAUTION rite ignition tining Is verified to be at an acceptable setting to prevent possible engine damage. Use a timing light to check the ignition timing while the engine is cranking ina NO-FUEL state.VHP 6 & 12 CYLINDER IGNITION MODULE INSTALLATION A CAUTION] °2,"2¢ bunste ignition wiring and pickup wiring together. Maintain a minimum separation of four to six inches. 4. Run engine. Use the ignition module's active rotary Switch, either switch “A’ ("D" lead grounded) or “B" ("D" lead ungrounded) to adjust the ignition timing to the specified setting. If proper timing CANNOT be achieved, remove the timing disc nut and adjust timing disc. Once correct timing is achieved, drill 1/8” hole through timing disc and into the gear hub. Drive the 1/8” roll pin into the disc and hub (see Figure 2.05-5). Remove the nut and coat with Loctite 242. Tighten the Nut o 150 ~ 160 f-b (203 - 217 Nm) ‘TIMING Disc. GEAR HUB Figure 2.05-5. Timing Disc Pin Location NOTE: Do not dril in existing pin holes of current production disc. Drill the pin hole between pre—driled holes. 5. Start engine. Verity shutdown switches and load carrying ability. Do not switch from po: A CAUTION | forieitoc ot i or make other large timing changes quickly while the engine is running. The large timing change may ‘cause engine damage or shutdown. A. CAUTION] 2enetwelt onoraround engine unless the igni- tion module has been unplugged. Failure to do so may damage the ignition modul A. CAUTION ] Ensines that use Two Murphy fuel shutoff valves for emergency fuel shutdowns must use an additional capacitor in parallel with the existing adapter. The additional capacitor is required to ‘supply sufficient voltage to close both Murphy fue! ‘shutdowns during emergency shutdowns. “2. CAUTION] "isthe sole responsibit- ity of the customer to that all product protection devices etfective- ly shut off both the ignition and gas simultaneously in the event of any malfunctions. CEC IGNITION MODULE, SETTING — PRODUCTION INSTALLED VERSION VHP engines have a wide range of timing settings which are dependent on the model of the engine and the type of fuel used. This variance of timing ranges from 4 degrees BTDC for GL engines on low octane fuel to 24 degrees BTDC for G and GSI engines on Natural Gas ‘and Low BTU fuel. The production version of the CEC ignition system contains a timing disc with four holes which allows for four different static timing settings (see Figure 2.05-6). These four settings allow VHP engines to reach a variety of ignition timings for various fuel applications. HOLE #1 — ye" PIN, HOLE a4 — 14" PIN Figure 2.05-6, Production Timing Dise zos-4 FORM 6255,ww ww VHP 6 & 12 CYLINDER IGNITION MODULE INSTALLATION ‘Table 2.05-2. CEC Timing Disc Pin Location FUEL WATURAL GAS AND teTu™ WATURAL GAS AND Lec NATURAL, ‘GAs. MODEL, F20056 LPG.AND 7209568) 72e05GL Fas216 Fa52168) ‘as21GL Ls1086 Lsi08Gs) ‘sr08G. 17906 Ls790Gsi ‘s790GL 70026 1704268) 708264 Table 2.05-2 lists the correct pin location in the timing disc for VHP 6 and 12 cylinder engines, Specific ignition tmmings can be achieved by changing the CEC ignition module rotary switch position. Table 2.05-3 lists the CEC rotary switch position forthe range of VHP ignition timing. FORM ezVHP 6 & 12 CYLINDER IGNITION MODULE INSTALLATION ‘Table 2.05-3. CEC Ignition Module Rotary Switch Position wou ‘DEGREES BEFORE TOP DEAD CENTER DEGREES BEFORE TOP DEAD CENTER STEPS REQUIRED TO DETERMINE CEC IGNITION MODULE SWITCH POSITION 1. Determine from the engine nameplate which hole number was used to position the CEC timing disc (see. Figure 2.05-3) 2. Determine the specified engine timing from the ‘engine nameplate. 3. Locate the proper switch setting by intersecting the ‘specified hole row (Step 1) with the specified engine timing column (Step 2) and select the switch position that is given for that timing (see Figure 2.05-4). Example: Determine the position of the CEC ignition ‘module switch on a F2895GSI that is run on natural gas at 1200 RPM, 1. From engine nameplate — Hole #2 2. From engine nameplate - 21° BTDC. 3, Proper switch position - AB NOTE: Due to manufacturing tolerances, the engine ‘may not be timed at the exact timing as shown in the Example. Adjust the engine to the timing specified on the engine nameplate by rotating the specified switch to 4 diferent position to set the correct engine timing. NOTE: Rotating either switch A or B one switch ‘position (one click) changes the engine timing 1°. For ‘example, changing the switch position from A8 to AS will advance engine timing 1°. Changing the switch position from A8 to A7 will retard engine timing 1°. ros-6 FORM 6253VHP 6 & 12 CYLINDER IGNITION MODULE INSTALLATION BLACK oe IS FUSE — 10 AMP RATING iniae LIED) RED —>— Oe ig ‘THIS LEAD GROUNDED ACTIVATES SWITCH “A” LEAD UNGROUNDED ACTIVATES SWITCH [samen eaten ‘SWITCH — 10 AMP MiN> (CUSTOMER SUPPLIED) 24VvDC NOMINAL, ak WHITE 5 switcH “a"— switc custom enaine vention MODULE Le NORMAL POWER SOURCE MIN. WIRE SIZE 14 AWG hg coset (@ustOMER SUPPLIED) gL eo ee cao sc NOTE:1. CEC FIRING ORDER ABCDEF oe 2 ENGINE FIRING ORDER 15-36-24 A CAUTION 4. All wires including “ground” wires must be connected to the specific evils as shown, 2. Ignition wires must not be bundled together with Product protection system witing jund wires should be connected between bracket mounting capscrews. 4. Momentary reverse polarity may permanently ‘damage the ignition mocule, “IF SWITCH IS LEFT CLOSED WITH THE ENGINE SHUTDOWN, THE IGNITION UNIT WILL DRAIN ABOUT 0.1 AMP FROM PoweR SOURCE, W2CYL WCYL ACYL @SCYL #BCYL aT eno 4 sw IGNITION ADAPTER, O0000000 3 1 (MURPHY GAS VALVE Figure 2.05-7. CEC Wiring Diagram (With Murphy Gas Valves) - VHP 6 Cylinder FORw 625 205-7VHP 6 & 12 CYLINDER IGNITION MODULE INSTALLATION a . base wir maSNETe PICKUP c “TMi LEAB onounDeo acrvares swiTcx "a" a THIS LEAD GnenoonDeo Activares Switch FUSE-10 AMP RATING ~ a RELAY — NORMALLY OPEN SS LSE CREE (CUSTOMER SUPPLIED) AED 9.) a 24 VDC NOMINAL ; anc WIRE SIZE 14 AWG wore , TA x : SWITCH “A” GAS SOLENOID VALVE swircn-3) ] (eitenetze To AUN A ‘CUSTOM ENGINE 7 a contnote ° Q' rontion woouLe pene myo —-9 ‘e /ERSPEED SHUTOFF en oa ESSonE ounce patina, s ane WoucrWe 3 Aue RESISTIVE 4 s ores. CEC FInNG ORDER | aecoer 2 ENGINE FIRING ORDER: > teseee oo cons A CAUTION Wey. wovl WOYL OV. WECM MOCYL = 1. Al wires including Sormecio to te epuccoa “a” Lex must nema ope Penupuasonceunetg (SOLE PROM GROUND) S'The ground wires snoutd be Sonnac between tha nopaive moma! lth col ond one othe coll bracket mounting eapeere CNomertary Taveee potrty may permanenty Gamage te tohion module, Figure 2.05: ‘CEC Wiring Diagram (Without Murphy Gas Valves) ~ VHP 6 Cylinder FORM 6255,VHP 6 & 12 CYLINDER IGNITION MODULE INSTALLATION 8 ise wre MAGNETS. Pickup © ‘its LEAD anounoeo AcrVATES BwrToH “A” suck 5 TS LEAB GRGROUNBED ACATIATES WTTCn =a FUSE ~ 10 AMP RATING ot ot Ge aE RELAY — NORMALLY CLOSED \ ane oneal eo, eee / rognouna psn wire; gt wo RE ne RIGHT BANK Asw ec pic kK s ‘CUSTOM ENGINE ‘CONTROL. 4 #TC¥L| W2CVL #BCYL HACYL ASCYL #ECYL ~ Se ws we wus se arracies Lac Reena eee, AB-CD-EPKLMNPR Por en Coe —p—dsw oe {ve Ler sac ourion wanna must mepairesancmuronmmmeuusr | dono Beare aN a Sore es BigaLes Tenn wh es A CAUTION ese Se ly aerate ieetnerny soooo000 product protection system wiring. + 2 Seneca reage! trieaa pemeen ONETION BOX Srocimecaingeacatee eich sien esonetcy stor eT. puis Scocmeny over er me pores moore eee sarswrens wert croseo wr 0:1 AMP FROM POWER SOURCE. bop RF NB, LEFT BANK Figure 2.05-8. CEC Wiring Diagram (With Murphy Gas Valves) - VHP 12 Cylinder FoAw 6253 7205-8VHP 6 & 12 CYLINDER IGNITION MODULE INSTALLATION a 8 isc wire MAGNETS a Pickup ‘THIS LEAD GROUNDED ACTIVATES SWITCH “A” BLACK 742 THIS LEAD UNGROUNDED ACTIVATES SWITCH “ 1 FUSE —10 AMP RATING ~ RELAY — NORMALLY OPEN (CUSTOMER SUPPLIED) any = Monn Om meen 24. VDC NOMINAL Power SOURCE \ Min, WIRE SIZE 14 AWG WHE Fo oJ ‘GAS SOLENOID VaLvE switcH*a" (ENERGIZED TO RUN) switcH *] Eee custom encine > Me ‘CONTROL ° oO oNFTION MODULE 5 lanown rE me TO A © a \ OVERSPEED sHUTOFF anrTion ewrrcet Paessune swircr RATING: 3 AMP INDUCTIVE 5 AMP RESISTIVE RIGHT BANK AnM np AG co NOTE:1. CEC FIFING ORDER ABCD EFKLMNPR 2. ENGINE FIRING ORDER coca 1A, 61, 5A, 21, 3R,4L, 6R, IL > 27,51, 4F, 3 W7OVL| P2CVL WSCVL ACYL SECYL EYL ™ THIS WIRE MUST BE ATTACHED BETWEEN THE NEGATIVE TERMINALS. SETHE #1 COILS ON BOTH ENGINE Gt A CAUTION 1. All wires Including “ground” wires must be connected tothe specific coils es shown. 2Igntion wires must not be Bundled together with Product protection system wiring The ground wires should be connected between ‘the negative terminal ofthe coll and one ofthe coll racket mounting eapscrews. Momentary reverse polarity may permanentiy mage the ignition module. to R FN SB LEFT BANK “G" LEAD MUST REMAIN OPEN ‘(SOLATE FROM GROUND) THE LEFT BANK IGNITION WIRING MUST BE ROUTED ‘AROUND THE FRONT OF THE ENGINE, BUT THE WIRING MUST NOT BE BUNDLED TOGETHER WITH THE GAS VALVE WIRING. Figure 2.05-10. CEC Wiring Diagram (Without Murphy Gas Valves) - VHP 12 Cylinder 205-10 FORM 6255,VHP 6 & 12 CYLINDER IGNITION MODULE INSTALLATION DC POWER SOURCES OPERATING VOLTAGE REQUIREMENTS STARTING 10VDC MINIMUM. RUNNING 1228 VDC (S2VDC CEC, 30 AMP EyaNE Daven [—— MINIMUM -10AMP NERATOR ‘SYSTEM —— saan wine S22 14 awa. BATTERY BATTERY Fei YI cnancen |_T power [——— SUPPLY S AMP @ 2evDc 10% REGULATION NOTE: An AC to DC power supply is not preferred unless care is taken o elminate the esepun/ofamamenay eso! AC power ich wlresulinan engine shutdown. Se-AC votage hier (oarery) i recommended fo elmnate vohage huctuabons, NOTE: The CEC ignition system wil uneton propery wih a power source as defined above. However, the supply Bondi amuse curanl navarcuretevelergataperpeogero shale average cuenta sre) a) tnunine het puise capably inns ase, votage hucustans onthe supply ing, inocang fe ground er Source. may cause evatc operatancvother electrical devices. For is reason, fis recommended tht be nso” Powe’ source wenng spebticaly ine grove returs. be sized for at oss! 90 ars even ough te average Curent wil be less han 6 amps. Figure 2.05-11. CEC Ignition Module Power Supply - VHP 6 And 12 DUAL FUEL ENGINES Example: Dual fue! engine — natural gas/landfil gas engine timing 1. Switches "A" and “B” must be set for both fuels Natural Gas - B8 betore engine start-up. Landfill Gas ~ A7 2. Engine must be run on both switch settings to verity correct engine timing. Engine should be run at no load ‘when verifying timing for fuels other than natural gas. The engine is run on natural gas and, due to manufac- turing tolerances, switch *B” must be changed from BE 10 B10 to obtain the correct engine timing. Since switch was adjusted 2 positions (2 clicks) higher, switch “A” ‘must also be adjusted 2 positions higher, A7 to AS. 3. Ifthe ignition module switch setting is changed to obtain the correct timing on natural gas, the other switch must also be adjusted the same number of clicks inthe NOTE: Theengine shouldbe run atnoloadto verity the same direction engine timing at switch position A9. Fonw 6255VHP 6 & 12 CYLINDER IGNITION MODULE INSTALLATION ieeca FORM 6253SECTION 5.00 — IGNITION MODULE TROUBLESHOOTING IGNITION MODULE TROUBLESHOOTING This section includes troubleshooting information for the CEC ignition module. This section will troubleshoot by two different methods. The first will include tests ‘which may be performed on the engine. The second part of this section will include troubleshooting proce- dures using a test bench. The test bench needed will be very similar to those used for testing magnetos. These bench tests should only be performed by those individu- ‘als who have the appropriate equipment (test bench) land prior knowledge required to test magnetos. The Purpose of these tests are to determine the condition of the CEC ignition module. I any of these tests determine that the CEC ignition module is defective, replace itasa unit NOTE: Individual intemal board replacement or any interna! work on the CEC ignition module is not permissible. There are no user-serviceable parts in the CEC ignition module The CEC ignition module is an electronic, digital-circuit ignition system for Waukesha spark ignited engines (See Figure 5.00-1). The system has no wearing parts, and uses the capacitor discharge principle providing high energy, precision timed sparks for maximum engine performance Crankshaft or camshatt referenced magnets with a Hall effect pickup give extremely accurate timing reference signals. The CEC ignition module's circuits provide the proper timing and distribution functions. The ignition ‘module has two 16 position timing switches which allow two timing settings to be established. These may be set, for example, for two different fuels, In operation, the CEC ignition module steps up the DC supply voltage to charge an energy storage capacitor. SCR switching devices release this stored energy in response to signals from the unit's logic circuitry which processes signals from the rotating trigger magnets, Six, eight and twelve cylinder engines employ one ‘magnet for every firing cylinder of the engine. Each firing ‘occurs at a programmed number of degrees after the magnet signal is received. Units for the 16 cylinder ‘engines use one magnet for every two firing eylinders ‘with the odd firing angle electronically synthesized by the CEC ignition module circuitry. All units use one ‘additional index magnet that trails the last fing magnet bby 9° or 15° (depending on application). This indicates that another revolution has started. Table §.00-1 lists Waukesha part numbers for various CEC ignition module components. cec MODULE, TIMING ‘SELECTOR (@ LEAD) 12-26 Vor Pickup SENSOR ‘Twi Disc aT CAMSHAFT ‘SPEED. ENGINE GROUND (TYPICAL). son Figure §.00-1. CEC Ignition System FoR eas 500-4