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

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)

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.

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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