SECTION 4.

60
MAINTENANCE SCHEDULE
MAINTENANCE CHART

WARNING
Failure to observe the maintenance schedule
listed below could result in severe personal injury
or death.

Air Cleaner Filter Element

Clean or Replace

Air Cleaner Precleaner Element

Clean

Air Starter Lubricator

Fill

Control Rod Ends and Linkage

Lubricate

Cooling Systems Level

Check

Crankcase Oil Level

Check

Governor Oil Level

Check/Fill

Governor Rod Ends

Lubricate

Ignition Cables - Primary and Secondary

Connections

Inspect

Cooling Water Analysis

Check

Crankcase Pressure

Check

Oil Pressure Safety

Calibrate/Test

Regulator

Adjust

Shutdown Controls

Calibrate/Test

Water Temperature Shutdown

Calibrate/Test

Quick Start Governor Oil Filter

Change

Cooling System - Jacket Water and

Auxiliary Water

Clean and Flush

Cooling System Thermostats

Remove and Test

Cooling System Tube Bundle

Clean

Crankcase Oil Pickup Screens

Clean

Crankcase Pressure Relief Valves

Exercise and Inspect

FORM 6284 Third Edition

8000 HOURS

4000 HOURS

2500 HOURS

1440 HOURS

1000 HOURS

720 HOURS

500 HOURS

ANNUALLY

EVERY 6 MONTHS

EVERY 3 MONTHS

SERVICE

WEEKLY

ITEM

DAILY OR AS REQUIRED

Table 4.60-1 VGF Routine Maintenance Chart (Part 1 of 2)

4.60-1

MAINTENANCE SCHEDULE

8000 HOURS

4000 HOURS

2500 HOURS

1440 HOURS

1000 HOURS

720 HOURS

500 HOURS

ANNUALLY

EVERY 6 MONTHS

EVERY 3 MONTHS

SERVICE

WEEKLY

ITEM

DAILY OR AS REQUIRED

Table 4.60-1 VGF Routine Maintenance Chart (Continued), (Part 2 of 2)

Exhaust Backpressure

Check

Full-Flow Filter Relief Valve

Inspect

Governor - Synchronizer or Speed Control

Adjust

High Tension Wires

Replace

Ignition Primary Terminals - Harness Plug

Inspect

Intercooler

Clean

Main and Rod Bearings

Inspect

Oil Pan

Clean

Turbochargers

Clean and Inspect

Rocker Arm Cover Gasket

Replace

CEC Ignition Timing Magnets

Check

Engine Oil (Continuous Duty)

Analyze

Ignition Timing - Magneto

Check

Engine Oil* (Continuous Duty) GSID

Change

Engine Oil* (Continuous Duty) GL, GLD

Change

Magnetic Plug - Turbo Supply

Clean

Oil Cooler (Oil Side)

Drain

At Oil Change

Oil Filter Elements and Seals

Change

At Oil Change

Spark Plugs

Replace

Valve Clearance

Adjust

Ignition Timing - CEC Ignition Module

Check

Crankcase Breather

Clean

Engine Mounting and Alignment

Check

Governor Compensating Needle Valve

Adjust

Ignition Magneto Drive Coupling

Replace

Carburetor - Air/Gas Valve

Clean and Inspect

Carburetor - Diaphragm

Replace

Carburetor Gasket

Replace

Ignition Magneto/Harness Plug

Test and Inspect

Ignition Transformer Coils

Test and Inspect

* For ebullient cooled engines, hot water systems with engine water temperature of 93 C (200 F) or above, engines using gaseous fuel
containing H2S in excess of published limits, or alternate fuels such as landfill gases, refer to Recommended Oil Change Intervals this
section (contains SB 12-1880Y information) or the latest SB 12-1880Y revision.

4.60-2

FORM 6284 Third Edition

MAINTENANCE SCHEDULE
RECOMMENDED OIL CHANGE INTERVALS
The use of some types of oil, as well as dusty environment, marginal installation, internal engine condition and/or operating the engine with malfunctioning
carburetion equipment may require more frequent oil changes. Waukesha Engine recommends that the
lubricating oil be monitored with a professional oil analysis program. Extended oil change intervals may
cause varnish deposits, oil oxidation, or sludge conditions to appear in the engine, which an oil analysis
cannot detect. Disregarding this information could result in engine damage. Contact your local Waukesha
Distributor for periodic engine maintenance.

CAUTION

NOTE: Always change the oil filters when changing the engine oil.
Table 4.60-1 Recommended Oil Change Intervals For Engines Receiving Normal Maintenance
ENGINES
ISO STANDARD OR
OPERATED IN
ENGINE MODEL CONTINUOUS POWER
EXCESS OF ISO
RATING
STD POWER

LIGHT LOAD
OPERATION

EBULLIENT COOLED OR
HOT WATER SYSTEM
WITH ENGINE WATER
TEMPERATURE 200 F
(93 C) OR ABOVE

STANDBY
DUTY

FOR ENGINES OPERATING WITH OIL HEADER TEMPERATURES 195F (91C) OR BELOW
VGF, G, GL, GLD
Natural Gas, HD-5
Propane

Normal 1000 hours

(extended 1250 hours*)

500 hours

1000 hours

720 hours

500 hours or
annually

VGF GSID
Natural Gas, HD-5
Propane

Normal 720 hours

(extended 900 hours*)

500 hours

720 hours

500 hours

500 hours or
annually

* Extended oil drain intervals listed are acceptable if a Microspin centrifuge in conjunction with a Waukesha supplied oil filtration system is
used and an oil analysis program is followed.

Table 4.60-2 Recommended Oil Change Intervals For Engines Receiving Normal Maintenance And Using Gaseous
Fuel Containing H2S
ENGINES
ISO STANDARD OR
OPERATED IN
ENGINE MODEL CONTINUOUS POWER
EXCESS OF ISO
RATING
STD POWER

LIGHT LOAD
OPERATION

EBULLIENT COOLED OR
HOT WATER SYSTEM
WITH ENGINE WATER
TEMPERATURE 200 F
(93 C) OR ABOVE

STANDBY
DUTY

FOR ENGINES OPERATING WITH ELEVATED OIL SUMP TEMPERATURE

VGF Series

360 hours

250 hours

360 hours

360 hours

250 hours

Table 4.60-3 Duty Cycle Definitions

The highest load and speed which can be applied 24 hours a day, 7 days a week, 365 days per

ISO STANDARD OR CONTINUOUS year, except for normal maintenance. It is permissible to operate the engine at up to 10% overload
or maximum load indicated by the intermittent rating, whichever is lower, for two hours in each
POWER RATING
24 hour period.

GENERATOR STANDBY POWER

RATING

In a system used as a backup or secondary source of electrical power, this rating is the output the
engine will produce continuously (no overload), 24 hours per day, for the duration of the prime
power source outage.

INTERMITTENT POWER RATING

This rating is the highest load and speed that can be applied in variable speed mechanical system
application only. Operation at this rating is limited to a maximum of 3500 hours per year.

GENERATOR PEAK SHAVING

Peak shaving is operation of an engine for a limited time to meet short term peak power
requirements. Speed, loading, and hours per year of operation will affect the recommended oil
change interval.

LIGHT LOAD OPERATION

Power levels less than 50% of the maximum continuous power rating.

FORM 6284 Third Edition

4.60-3

MAINTENANCE SCHEDULE
ENGINE PERFORMANCE RECORD
Engine operating information, recorded during regular inspections, is necessary to apply proper Routine Maintenance schedules. Accurate records will help to control costs by avoiding unnecessary servicing, ensuring needed
servicing, and providing trend information on the general engine condition. It is recommended that a record of the
following information be kept.
Table 4.60-4 Engine Performance Form

Date

Time

Serial No.

Spec. No.

Model

Hourmeter Reading

rpm

Ambient Temperature

Ignition Timing

Load

Hours On Spark Plugs

Oil Temperature

Oil Pressure

Jacket Water Temperature

Outlet

Gas/Air Pressure

Supply Pressure

Int. Manifold Pressure

Int. Manifold Temperature

Inlet

Exh. Manifold Oxygen %

Exh. Backpressure

Crankcase Pressure (Positive/Negative)

Auxiliary Water Temperature

In

Out

Unusual Noise(s) Vibration

Oil Leaks (Location)
Coolant Leaks (Location)
EXHAUST MANIFOLD TEMPERATURES:

EXHAUST MANIFOLD TEMPERATURE

(PRE-TURBINE)

1.

1.

LB

2.

2.

RB

3.

3.

4.

4.

5.

5.

6.

6.

7.

7.

8.

8.

4.60-4

FORM 6284 Third Edition