MAINTENANCE SCHEDULE & CHECKLISTS
4012/16 Diesel, February 1997 6
0
EVERY 2500 HOURS OR 12 MONTHS IF
NECESSARY
VALVE SEAT INSERTS
Examine the valve seats for pitting and wear.
If necessary reface them using a planetary
grinder and then hand lap the valves into
their seats using grinding paste. In cases of
extreme wear or burning, fit new inserts,
(see
Section R4 in the Workshop Manual).
V
ALVE SPRINGS
Measure the free length. Compare with a
new spring (See page 41 in Workshop
Manual Schedule of Wear and Renewal
Limits). Reject any spring which may have
a
permanent set.
Check the ends of the springs for
squareness.
ROCKERS AND ROCKER BRIDGES
Inspect the bridge pieces and their guide
also each rocker on its shaft for wear and
replace where necessary.
INJECTOR TUBES
These do not require replacing unless they
are leaking.
PISTONS AND LINERS
Using a blunt scraper, remove excessive
carbon from the piston crown and the liner
flange face. Do not use emery cloth. Do not
allow any carbon to find its way down
between the piston and liner. Rotate the
engine as required. Wipe the bores clean and
lubricate before refitting the cylinder heads.
EVERY 2500 HOURS OR 12 MONTHS
COOLING SYSTEM
Drain off the coolant in the fresh water
system using the drain plug fitted in the oil
cooler end covers. Refill the system as
described on
page 27.
G
ENERAL ATTENTION
Also carry out all checks and fit replacement
parts as listed for each service period in the
Maintenance Schedule.
EVERY 12 MONTHS CHANGE THE
WOODWARD GOVERNOR OIL
Remove the drain plug from the front of the
governor whilst the engine is still warm and
collect the 1/2 gallon / 2 litres of oil in a
suitable container. Refit the plug and refill
with a similar quantity of diesel fuel.
Reconnect the batteries, start the engine
and run it at a low speed. Cycle the governor
by opening the needle valve by two or three
turns. Let the governor hunt for a minute or
two, then stop the engine and drain the
governor. Repeat this flushing operation
and then replace the diesel fuel with new
SAE30 or SAE15W/40 engine oil.
Restart the engine and reset the
compensation adjustment and needle valve
setting. (See Sections AA54-AA75 in the
W
orkshop Manual
for UG10 and 3161
governors).
FIRST MAJOR OVERHAUL
If service schedules are adhered to major
overhauls may not be required until 20,000
hours of operation have been completed.
The charge air cooler and heat exchanger
will also need to be inspected at 10,000
hours for internal cleaning of the inside and
outside of the tubes, and the maintenance
period determined for future overhauls.
The FIRST assessment of engine condition
will enable maintenance engineers to plan
the time of major overhauls i.e. 10,000 and
20,000 hours to be carried out at convenient
times e.g. to coincide with annual refits or
factory shut-downs.
The oil change intervals may be altered
according to operating experience over 1000
hours by agreement with Perkins Engines
(Stafford) Limited and subject to oil analyses
being carried out on a regular basis, see
pages 1
9 & 2 0 .
WARNING
DISCONNECT
BATTERIES AND ALL
OTHER MEANS OF STARTING.
ALWAYS WEAR PROTECTIVE GLOVES
AND GOGGLES.
