vhp 7042gsi maintenance
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Page 1 of 4WAUKESHA ENGINEDRESSER, INC.WAUKESHA, WI 53188-4999Waukesha
TOPIC: MiscellaneousIDENT NO: 16--2523C
SUPERSEDES: 16--2523BDATE: September 15, 2003
SUBJECT: VHP Maintenance Recommendations
MODELS 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 2)and use it to record the results of regular inspections. Bymaintaining trend information on the general conditionof the engine, the necessary corrective action can betaken when a problem first becomes apparent. An earlydiagnosis will save money and reduce down time, bypreventing the development of more serious problems.
Table 1. Routine Maintenance Chart
ITEM
SERVICE
DAILYORASREQUIRED
720HRS.
2,100HRS.
4,200HRS.
8,000HRS.
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)
VHPVHP TM
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Service Bulletin No. 16--2523C
Page 2 of 4WAUKESHA ENGINEDRESSER, INC.WAUKESHA, WI 53188-4999Waukesha
ITEM
8,000HRS.
4,200HRS.
2,100HRS.
720HRS.
SERVICE
DAILYORASREQUIRED
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)
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Service Bulletin No. 16--2523C
Page 3 of 4WAUKESHA ENGINEDRESSER, INC.WAUKESHA, WI 53188-4999Waukesha
ITEM
8,000HRS.
4,200HRS.
2,100HRS.
720HRS.
SERVICE
DAILYORASREQUIRED
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-tions And Ground Wire
Custom Engine Control Detonation Sensing ModulePerform Lost SensorCheck *** (16 CylinderEngines Only)
Custom Engine Control Air/Fuel Module Inspect Harness Connec-tions And Ground Wire
Rubber Dampers In Governor Drive Gear Inspect/Replace
Engine Mounted Wire Harnesses Inspect
NOTE: * For ebullient cooled engines, hot water systems with enginewater temperature of 200F (93C) or above, engines using gaseous fuelcontaining H2S in excess of published limits; or alternate fuels such as landfill gases, refer to SB 12--1880Z or latest revision, forinformation on oil change intervals.** Indicates GL engines.*** Refer to Form 6278, Custom Engine Control) Detonation SensingModule Installation, Operation, AndMaintenanceManual, Section 4.10.
Failure to observe the abovemaintenance schedulecould result in severe personal injury or death.
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Service Bulletin No. 16--2523C
Page 4 of 4WAUKESHA ENGINEDRESSER, INC.WAUKESHA, WI 53188-4999Waukesha
ROUTINE INSPECTIONTable 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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