Maintenance Intervals (16-2523C)

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Page 1 WAUKESHA ENGINEDRESSER, INC.WAUKESHA, WI 53188-4999Waukesha

TOPIC: Miscellaneous

IDENT NO: 16--2523C

SUPERSEDES: 16--2523B

DATE: September 15, 2003

SUBJECT: VHP Maintenance RecommendationsMODELS AFFECTED: Standard VHP Engines (Excluding Series Four!)

The following maintenance schedule has been deter-

mined for normal operating conditions. It may benecessary to change some of the intervals of mainte-nance to meet abnormal operating conditions such asextreme cold or very dirty conditions. Pick the shortesttime listed when given a choice.

Regularly inspect the engine in operation (see Table 1).

Duplicate the Routine Inspection Form (see Table

and use it to record the results of regular inspectionsmaintaining trend information on the general conditof the engine, the necessary corrective action cantaken when a problem first becomes apparent. An ediagnosis will save money and reduce down time,preventing the development of more serious proble

Table 1. Routine Maintenance Chart

ITEM

SERVICE

D A I L Y O R A S R E Q U I R E D

7 2 0 H R S .

2 , 1

0 0 H R S .

4 , 2

0 0 H R S .

Air Cleaner Filter Element Check/Clean or Replace "

Air Starter Lubricator Check/Fill "

Control Rod Ends and Linkage Clean/Lubricate "

Cooling Systems Fluid Level (Jacket and Auxiliary) Check/Fill "Crankcase Oil Level Check/Fill "

Governor Oil Level Check/Fill "

Oil Filter Release Trapped Air "

Pre--Cleaner Element Check/Clean or Replace "

Prelube Motor Reservoir Check/Fill "

Power Take--off Lubricate "

Cooling Water Analysis (Ebullient) Check "

Battery Electrolyte Check/Fill "

Belt Tension Check "

Air Actuator Lubricate "

Auxiliary Water Pump Inspect/Lubricate "

Fan Hub and Idler Pulley Bearings Lubricate "

Generator Bearings Lubricate "

Engine Oil * (Analysis) Analysis "

Engine Oil & Filter * (ISO Standard or Continuous Duty) (Refer to S.B. 12--1880Z) Change Oil and Filter 1500 Hours

Engine Oil And Filter * (ISO Standard or Continuous Duty With Microspin!) --(Refer to S.B. 12--1880Z) Change Oil and Filter "

Oil Cooler (Oil Side) (Maintain with appropriate oil drainage Interval) Drain

(Continued)

VHPVHPTM



Service Bulletin No. 16--2523C

Page 2 of 4 WAUKESHA ENGINEDRESSER, INC.WAUKESHA, WI 53188-4999Waukesha

ITEM 8

, 0 0 0 H R S .

4 , 2

0 0 H R S .

2 , 1

0 0 H R S .

7 2 0 H R S .

SERVICE

D A I L

Y O R A S R E Q U I R E D

Microspin (Maintain with appropriate oil drainage Interval) Clean

Water Pump Idler Puller Bearings Lubricate "

Crankcase Breather Clean "

Governor Rod Ends & Control Linkage Lubricate "

Ignition Cables: Primary and Secondary Connection Inspect "

Crankcase Pressure Check "

Fuel System Adjustment Adjust "

Safety Controls/Engine Protection Devices Test/Calibrate "

Valve Clearance Adjust "

Valve Cover Gasket Replace "

Ignition Timing Check "

Magnetic Plugs Clean "

Prechamber Regulator** Adjust "

Oil Filter Seal Replace "

Wastegate Vent Plug Inspect/Clean "

Spark Plugs (2,500 -- 4,000 hours or as necessary) Replace "

Lube Oil Strainer Element Clean "

Admission Valve Assembly** Clean or Replace "

Admission Valve Washer** Replace "

Admission Valve O --ring** Replace "

Cylinder Compression Check "

Electric Starter Bearings Lubricate "

Governor--Synchronizer Motor Bearings Lubricate "

Fuel Regulator Filter Clean/Replace "

Carburetor Air/Gas Valves Clean/Inspect "

Carburetor Diaphragm Inspect "

Magneto Drive Disc Replace "

Cooling Water Analysis Check "

Water Pump Inspect "Turbocharger Clean/Inspect "

Main and Rod Bearings Inspect "

Cooling System (Jacket and Auxiliary) Clean and Flush "

Cooling System Thermostats Remove and Test "

Crankcase Oil Pickup Screen Clean "

Engine Mounting and Alignment Check "

Exhaust Back Pressure Check "

(Continued)



Service Bulletin No. 16--252

Page 3 WAUKESHA ENGINEDRESSER, INC.WAUKESHA, WI 53188-4999Waukesha

ITEM 4

, 2 0 0 H R S .

2 , 1

0 0 H R S .

7 2 0 H R S .

SERVICE

D A I L

Y O R A S R E Q U I R E D

Oil Filter Relief Valve Inspect

High Tension Wires Replace

Ignition Primary Terminals, Harness Plug Inspect

CEC Ignition Module Timing Disc Magnets Clean/Inspect

Lube Oil and Jacket Water Hoses Replace

Oil Pan Clean

Vibration Damper Capscrews Retorque

Hydraulic Governor Oil (or as necessary) Change

Intercooler Clean/Inspect

Carburetor Gasket Replace

Carburetor Air/Gas Valve Replace

Belts (Engine) Replace

Carburetor Diaphragm Replace

Crankcase Pressure Relief Valves Inspect

Ignition Coils Inspect

Spark Plug Extensions Replace

Ignition Magneto Rebuild

Ignition Primary Terminals, Connections, Harness Plug, and Wires Inspect

Wastegate Rebuild

Custom Engine Control! Ignition Module Inspect Harness Connec-

tions And Ground Wire

Custom Engine Control! Detonation Sensing Module Inspect Harness Connec-


Custom Engine Control! Detonation Sensing ModulePerform Lost SensorCheck *** (16 CylinderEngines Only)

Custom Engine Control! Air/Fuel Module Inspect Harness Connec-


Rubber Dampers In Governor Drive Gear Inspect/Replace

Engine Mounted Wire Harnesses Inspect

NOTE: * Forebullientcooled engines, hotwatersystems with enginewatertemperatureof 200# F(93# C) or above,engines using gaseous f

containing H 2 S in excess of published limits; or alternate fuels such as landfill gases, refer to SB 12 --1880Z or latest revision, information on oil change intervals. ** Indicates GL engines. *** Refer to Form 6278, Custom Engine Control) Detonation Sensing Module Installation, Operation, And Maintenance Manual, Section 4.

Failure to observe the above maintenance schedulecould result in severe personal injury or death.



Service Bulletin No. 16--2523C

Page 4 of 4 WAUKESHA ENGINEDRESSER, INC.WAUKESHA, WI 53188-4999Waukesha

ROUTINE INSPECTION

Table 2. Routine Inspection Form

DATE ENGINE PERFORMANCE RECORD

ITEM READING REMARKS

Hourmeter Reading

Tachometer (RPM)

Fuel Meter Reading

Engine Temperature

Oil Temperature

Coolant Temperature

Intercooler Water Temp.

Oil Cooler Water Temp.

Gas/Air Pressure

Manifold Pressure Pos/Neg

Crankcase Pressure Pos/Neg

Unusual Noise(s) Vibration

Oil Leaks

Coolant leaks

Prechamber 02%

Exhaust 02%

Prechamber/Intake Pressure(Wide Open Throttle)Over Manifold Pressure

Exhaust Back Pressure

Ignition Timing

Detonation Sensors

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Maintenance Intervals (16-2523C)