Page 1 of 4

WAUKESHA ENGINE
DRESSER, INC.
WAUKESHA, WI 53188-4999 Waukesha
TOPIC: Miscellaneous
IDENT NO: 16--2523C
SUPERSEDES: 16--2523B
DATE: 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 be
necessary to change some of the intervals of mainte-
nance to meet abnormal operating conditions such as
extreme cold or very dirty conditions. Pick the shortest
time 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. By
maintaining trend information on the general condition
of the engine, the necessary corrective action can be
taken when a problemfirst becomes apparent. An early
diagnosis will save money and reduce down time, by
preventing the development of more serious problems.
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
.
8
,
0
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)
VHP
VHP
TM
Service Bulletin No. 16--2523C
Page 2 of 4
WAUKESHA ENGINE
DRESSER, INC.
WAUKESHA, WI 53188-4999 Waukesha
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--2523C
Page 3 of 4
WAUKESHA ENGINE
DRESSER, INC.
WAUKESHA, WI 53188-4999 Waukesha
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
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 Module
Perform Lost Sensor
Check *** (16 Cylinder
Engines 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 engine water temperature of 200# F (93# C) or above, engines using gaseous fuel
containing H
2
S in excess of published limits; or alternate fuels such as landfill gases, refer to SB 12--1880Z or latest revision, for
information on oil change intervals.
** Indicates GL engines.
*** Refer to Form6278, CustomEngine Control) Detonation Sensing Module Installation, Operation, And Maintenance Manual, Section 4.10.
Failure to observe the above maintenance schedule
could result in severe personal injury or death.
Service Bulletin No. 16--2523C
Page 4 of 4
WAUKESHA ENGINE
DRESSER, INC.
WAUKESHA, WI 53188-4999 Waukesha
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 0
2
%
Exhaust 0
2
%
Prechamber/Intake Pressure
(Wide Open Throttle)
Over Manifold Pressure
Exhaust Back Pressure
Ignition Timing
Detonation Sensors
-