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THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF WAUKESHA OR IT’S SUCCESSORS. WAUKESHA AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

Operator’s Manual

190-GL, 190-GLB, 190-GLC, 185-GL, 185-GM, 185GLB,

180-GL, 180-GLB, 180-GKB

WK-O-180+

BREATHE.R

Right Side - Waukesha Model 190-GL - GLB - GLC

"-MAIN JET ADJUST

Left Side - Waukesha Model 190-GL - GLB - GLC

4 WAUKESHA MODELS 190, 185, 180

CONTENTS

PAGE PAGE

DESCRIPTION__________________ 5-7 Magneto Maintenance __________ 21

General_____________________ 5 Magneto Timing _____________ 21

Crankcase ____________________ 5 Valve Clearance Adjustment ____ 22 Crankshaft __________________ 6 Resetting the Governor ________ 22 Bearings ____________________ 6 Gasoline Carburetors __________ 23 Governor ___________________ 6 Carburetor Adjustments ________ 23 Ignmon ____________________ 7 Gas-Fucl Conversion __________ 24 Carburetion __________________ 7 Gas Carburetor Adjustments ____ 25 Water Pump _________________ 7 Field Regulator Sizes __________ 25 Oil Pump ___________________ 7 Safety Fucl Valve _____________ 25

LUBRICATION _________________ 8-14 Oil Quantity ____ ____________ 8 Oil Changes _________________ 8 Selecting Oil Viscosity _________ 8 Estimated Oil Temp. __________ 9 Operating Temperatures -______ 9 Additive Type Oils ___________ 10 Special Industrial Service ______ 10 Accessory Lubrication _________ 10 Oil Filters __________________ 11 Oil Pressure Control __________ 11

REPAIR AND OVERHAUL _______ 26-33 Disassembly _________________ 26 Oil Pan Removal _____________ 26 Cylinder Sleeve Removal ______ 27 Camshaft ___________________ 27 Cam Followers ______________ 28 Valve and Mechanism-Repair __ 28 Compression Checks __________ 29 Valve Mechanism ____________ 29 Guides and Seats _____________ 29 Valve Grinding ______________ 30

Oiling System _________________ 12 Rocker Arms ________________ 14

Hand Grinding ______________ 30

Seat Insert Replacement -------31-33

REASSEMBLY ___________________ 34-40 COOLING SYSTEM _____________ 14-17

Anti-Freeze _________________ 14

Cooling System Capacities ______ 15 Thermostat Removal __________ 15

Installing Cylinder Sleeves _____ 34 Cylinder Head Gasket Crush --- 35 Piston Fitting _______________ 35 Bearing Adjustment __________ 37

Thermostat Testing ___________ 15 Side Clearances ______________ 38 Cleaning Cooling System ______ 15 Running Clearance ___________ 38 Commercial Cleaners __________ 16 Replacing Cylinder Head ------ 39 Cooling Fans ______ __________ 16 Flywheel Alignment __________ 40 Fan Bcl~ -__________________ 16 Replacing Fan Belts ___________ 17 CLEARANCES AND LlMITS ______ 41-53 Air Cleaners ----__________ ___ 17 Model 190 __________________ 41

Modcl 185 __________________ 47

SERVICE ADJUSTMENTS - _______ 18-25 Model 180 ___________________ 47

Ignition ____________________ 18 Distributor Timing ___________ 19

Maximum Safe Tilt ___________ 54 Warranty ___________________ 55

Magneto ______________ 20 Distributors and Service _______ 56

WAUKESHA MODELS 190, 185, 180 5

DESCRIPTION

GENERAL The vVaukesha 190, 185, 180 series engines are of overhead valve, wet­

sleeve construction, all incorporating the same general design features. The 190 and 185 models are six-cylinder engines; the 180 model is a four-cylinder engme.

DDIENSIONS

BORE AND STROKE CYL. DISPLACEMENT

144 Cubic inches 155 Cubic inches 216 Cubic inches 265 Cubic inches

180GL-GLB 180GKB 185GL - GLB 190GL-GLB

3.5 x 3.75 3.625 x 3.75 3.5 x 3.75 3.75 x 4

4 4 6 6

These engines are designed to give extended service life without special­ized or unusual maintenance techniques. Clean oil in the proper quantity; clean, soft, cooling water; and regular attention to such items as air cleaners, spark plugs, fuel strainers, and oil filters will insure continued reliable performance.

CRANKCASE For maximum rigidity and accurate bearing alignment, the crankcase

and cylinder block is cast as a single unit. Bearing cross walls and water baffles are generously filleted and heavy top diaphragms and bottom

left Side - Crankcase, 190-GLB

6 WAUKESHA MODELS 190, 185, 180

flanges locate and support the cylinder sleeves. The sleeves are exposed to cooling water for practically their entire length and are sealed with two rubber rings at the lower end and the cylinder head gasket at the top. No special tools are needed for installation or removal of these sleeves.

CRANKSHAFT The crankshafts used in the 190, 18j and 180 series engines are heat

treated and precision ground steel forgings. These shafts are fully balanced both statically and dynamically. The mirror finished crankpins and main bearing journals are held to extremely close tolerances to accommodate precision bearing shells without the necessity for field fitting.

It is important that the owner be acquainted with the several types of crankshafts from the standpoint of ordering service parts. All crankshafts used in recent Model 190 oil field engines are drilled for pressure lubrication to the connecting rod lower end bearings. Other 190 series engines are equipped with a metered jet lubrication system and incorporated oil transfer recesses in the main bearing journals but are not drilled. This is discussed under OILING SYSTEM.

All crankshafts used in the 185 and 180 series engines are equipped with oil transfer recesses for metered jet lubrication. Current production 185 and 180 engines employ counterbalanced shafts with 2;i" diameter crankpins. A very large number of engines have, however, been built with a conven­tional crankshaft and 2" diameter crankpins. It is possible to convert an earlier engine at time of overhaul to accommodate a counterbalanced shaft, but this change will probably require some minor reworking of the crank­case for clearance, plus replacement of the connecting rods, connecting rod bearings and pistons.

BEARINGS Precision type copper-lead bearings permit replacement without line

boring. The flanged upper and lower halves of the center main bearing absorb thrust loads on the 180 model and since it is also of the precision type, no special end-play adjust­ments are required. The same thing applies to the #3 bearings in the 185 and 190 engines. A steel-backed, babbitt-lined bush­ing supports the gear end of the camshaft. A pre-sized service bushing is available for replace­ment. Piston pins are full-floating in bored, s teel- backe d bronze bushings in the rods.

GOVERNOR

A self-contained, gear-driven governor is mounted within the 'Sear cover and a small project- Sectional View - Governor

WAUKESHA MODELS 190, 185, 180 7

ing housing. This governor is of the familiar two-weight, centrifugal type, and requires no adjustment other than establishing the desired high idle speed. _-\ screw type surge adjustment is also provided.

If it is desired to change the governor response to adapt to the engine load, repositioning of the governor spring end in the holes to"wards the end of the governor lever will provide slower governor response and less tendency to surge. Conversely, moving the spring end closer to the lever pivot will provide faster governor response but may increase the tendency to surge. After any movement of the governor spring end, it is necessary to adjust the spring tension by use of the adjusting nut to maintain the desired high idle speed.

IGNITION Ignition may be with either a fixed-timing, vertically or flange-mounted

magneto, or with a distributor and coil. With the exception of the flange­mounted magneto, used on Model 190 oil field engines and which is driven from the engine gear train, the ignition unit is driven by a spline and key on the oil pump drive shaft upper end. Adjustment and timing of these units are discussed under DISTRIBUTOR TIMING, or, MAGNETO TIMING.

CARBURETION For use with gasoline or kerosene, a standard diaphragm-type fuel

pump is used and driven from an eccentric on the camshaft. Carburetors may be for gas only, for gasoline only, or of the gas-gasoline type as specified. Carburetor adjustments are discussed under a separate heading.

WATER PUMP The water pump requires no special lubrication, packing or attention

during its service life. An internal seal is used in combination with a unit­type ball bearing and pump shaft to provide a simple, ruggedly constructed water pump.

Water Pump

OIL PUMP A high-capacity, spring-loaded vane-type pump, driven by a spiral gear

from the camshaft provides oil under pressure to the lubricating system of

12 WAUKESHA MODElS 190, 185, 180

END CLEARANCE

PROPER VAN E ASSEMBLY

Sectional View - Vane Type Oil Pump

with the vane type oil pump is not recommended and may cause low oil pressure.

o

Metered Jet Lubrication Schematic

OILING SYSTEM The oiling system employed on

the Model 190 oil field engines pro­vides full oil pressure to the crank­shaft bearings and rods, then me­ters this oil supply through small pockets in the crank journals to the accessory gears and valve mechanism.

Oil enters the vane or gear pump through the floating oil screen which picks up from the cleaner upper surface of the oil supply. Lea ving the pressure side of the pump vane, the oil passes upward through a passage in the pump sup­port and is forced into the main oil gallery extending the length of the right side of the engine.

At the front of the gallery (gear­cover end) a pressure relief valve of the non-adjustable type prevents excessive pressure build-up. Drilled passages conduct the oil from the gallery to the main bearings. The front and rear main bearing crank­shaft journals are provided with small pockets which are so aligned as to index with the incoming oil passage and bridge across the jour­nal to an outgoing oil passage. This happens for a brief portion of each revolution of the shaft. Thus, the