SECTION 3.00 ENGINE STARTUP AND SHUTDOWN PRESTART INSPECTION Be sure that the clutch, circuit breaker, or other main power transmission device is disconnected. Generators develop voltage as soon as the engine starts turning. Starting the engine with equipment engaged can cause machine damage or severe personal injury or death. 1. Inspect drive belts (alternator or other driven equipment). Examine condition of belt and verify correct belt tension. If a cooling fan is used, be sure it is free to turn, properly lubricated and the belt tension is correct. 2. Trace entire cooling system to verify all control valves are properly opened and all drain cocks are closed. 3. Check coolant level. If a large quantity of coolant is added, be sure to open the cooling system air vents to allow any air trapped in the system to escape. 4. Check for evidence of oil, fuel and coolant leaks along all gasket surfaces. 5. Make certain all guards and shields are secure on engine and equipment. 6. Remove all loose tools, rags, fittings, or other equipment that may be picked up by rotating parts. 7. Air storage reservoirs for air starting systems should be purged at least once a day to eliminate water buildup in the tanks. This will reduce rust and scale contamination to the air starting system. Every air starting system should include one or more drain cocks in the air lines. Before starting the engine, bleed off some of the compressed air. This will aid in keeping moisture from condensing inside the air starting system. Make certain that the barring device is disengaged from flywheel. Remove all wrenches before engaging the starter. Starting the engine with the barring device engaged can cause machine damage or severe personal injury or death from tools thrown by the barring device. 8. Using barring device turn engine over several revolutions to verify nothing will interfere with operation (see Figure 3.00-1). The barring device is located on the front left rear gear housing. Figure 3.00-1 Barring Device Location BARRING DEVICE 9. Check oil level daily. Add oil as necessary to maintain level above low mark. 10. Operate automatic prelube system (if equipped) until a positive indication is seen on oil pressure gauge. 11. Rotate fuel shutoff valve to start position (see Figure 3.00-2). FORM 6284 Third Edition 3.00-1
MANUAL DISCONNECT KNOB Figure 3.00-2 Fuel Shutoff Valve NOTE: Magneto equipped engines are shipped with the ignition system grounded to prevent accidental starting. This ground wire must be removed to operate the engine. All VGF engines CAUTION include hand throttle controls for emergency shutdown procedures. Make sure that the hand throttle is maintained in the open position during startup and normal running conditions. Disregarding this information could result in product damage and/or personal injury. The Deltec carburetor (see Figure 3.00-3) does not stop the flow of fuel gasses. A positive gas shutoff valve that opens upon cranking and closes whenever engine rotation stops must be installed before the carburetor. Figure 3.00-3 Deltec Carburetor FUEL SHUTOFF VALVE VENT PLUG The Deltec carburetion system must have a positive gas shutoff valve that opens upon cranking and closes whenever engine rotation stops. Failure to provide the valve will cause an explosive environment resulting in severe personal injury or death. DELTEC CARBURETOR STARTUP PROCEDURES Failure to follow the startup procedure in the operators manual may cause engine damage and could result in severe personal injury or death. Always read and follow the model specific information in the Waukesha Operation and Maintenance Manual. Contact Waukesha's Sales Engineering Department for additional information or with questions regarding a specific engine or installation. Engines equipped with Deltec carburetors use specific startup and shutdown procedures. Deltec carburetors operate on a fixed venturi system and do not have a positive fuel shut-off. This lack of fuel shut-off within the fuel mixer means that fuel gas will flow into the engine whenever the main gas control valve is open. During a start and stop sequence the engine and exhaust system may be flooded with gas. This could cause an exhaust system explosion. To prevent this situation, Deltec carburetion systems must have a positive gas shutoff valve that opens upon cranking and closes whenever engine rotation stops. The Deltec carburetion system must have a positive gas shutoff valve that opens upon cranking and closes whenever engine rotation stops. Failure to provide the valve will cause an explosive environment resulting in severe personal injury or death. COLD WEATHER STARTING PRESSURIZING ENGINES WITHOUT PREHEATER Pressurizing the lubrication system is especially important in cold weather. If there is no prelube pump, crank the engine over several times, without fuel or ignition, until oil pressure is indicated on the oil pressure gauge. The engine should not be started if there is no pressure indication on the oil pressure gauge. RESTART PROCEDURE 1. Reset tripped control before attempting to start the engine after an emergency shutdown. 2. If an emergency shutdown or an alarm has sounded, always find and correct the problem before trying to start the engine. 3. Reset switches on either oil pressure gauge or water temperature gauge. 4. Reset magnetic switch on gas control valve (if equipped). 3.00-2 FORM 6284 Third Edition
SHUTDOWN PROCEDURE 1. Reduce engine load gradually. 2. Remove load by disengaging main clutch or other power transmission device (generator circuit breaker, etc.). 3. Place throttle control lever in medium idle speed position and allow engine to idle for a few minutes to equalize engine temperatures. After the engine is stopped, allow it to cool for at least 10 minutes before repairing engine. Do not restart an overheated engine or an engine that has been shut down by the engine protection system until the reason for the shutdown has been determined and corrected. Disregarding this information could result in severe personal injury or death. 4. Gas engines are normally stopped by shutting off fuel supply. Gas engines that are equipped with an ignition switch can be stopped by placing ignition switch in the OFF position. Gas supply to the engine must be shut off when ignition power is interrupted or when any safety switch is activated. Disregarding this information could result in severe personal injury or death. 5. If engine is equipped with a prelube system, postlube engine for 5 minutes after every shutdown. If the engine is being CAUTION shut down for an extended period of time, cap the exhaust pipe to prevent moisture or other contaminants from entering the engine. Disregarding this information could result in product damage. STARTUP PROCEDURE DELTEC NOTE: If engine fuel supply compressors are used on your engine, the compressors should be started prior to crank initiation. 1. Initiate cranking with the ignition system ON and the fuel system gas valve closed. Allow 3 to 5 seconds before opening the gas valve to allow for a purge cycle in the engine. This purge cycle helps to reduce the probability of an exhaust explosion. 2. If the engine fails to start after 15 or 20 seconds of cranking, simultaneously discontinue cranking, close the fuel system gas valve and turn off the ignition. 3. Upon next start attempt, follow procedure in Step 1. Waukesha recommends a maximum of three unsuccessful start attempts. If the engine does not start after three attempts begin troubleshooting. NOTE: Step 3 allows the exhaust system to purge on the next start cycle and reduce the probability of an exhaust explosion. NOTE: Be aware that engines equipped with Deltec fuel systems may be factory supplied with a speed switch that activates the main fuel valve. It is the customer's responsibility to provide logic to open the main valve on increasing speed (during start) and close the main fuel valve on decreasing speed (during stop). PLANNED SHUTDOWN DELTEC 1. Shut the engine down by simultaneously closing the main fuel valve, deactivating the shutdown devices, stopping the breather motor (if so equipped), and stopping the fuel gas compressors (if so equipped). 2. Leave the ignition on for 3 to 5 seconds after the fuel valve is closed to burn any unburned air/fuel mixture in the intake manifold and engine. EMERGENCY SHUTDOWN DELTEC 1. Shut the engine down by disengaging the external load (if possible), closing the main fuel valve and turning off the ignition. 2. Simultaneously stop the breather motor and the fuel gas compressors (if so equipped). STARTUP PROCEDURE GENERATOR APPLICATIONS 1. Place governor throttle control lever 1/3 open. Verify main ignition switch is in ON position. NOTE: Be sure there is gas supply to the engine. 2. To start engines with prelube/start control panels, depress and hold down the START button until the engine starts. If prelube system includes interlock, depress and hold down START button (actuates prelube prior to cranking). If the prelube interlock is bypassed, then both START and BYPASS buttons must be depressed and held down. 3. Check for oil pressure indication when engine starts. FORM 6284 Third Edition 3.00-3
CAUTION If oil pressure is not indicated within 10 seconds, shut down the engine. Never operate the engine without adequate oil pressure indication. Disregarding this information could result in product damage. Do not assume that a faulty gauge or cold oil is responsible for a no oil pressure indication. Check that the shutdown control oil pressure reset has released (when applicable). The engine can continue to operate with low or no oil pressure since the reset must be released by oil pressure before the low oil pressure shutdown control becomes effective. The oil pressure reset release is effected when the control knob rotates to the RUN position, the shutdown control reset latch knob or rod projects slightly from the body and the switchgage lockout is released. 4. Warm engine by running with little or no load until oil pressure reaches normal range and coolant temperature reaches 38 C (100 F). NOTE: Oil pressure can reach 690 kpa (100 psi) with cold oil at startup. 5. Move carburetor hand throttle to wide open position. NOTE: Turbocharged engines are somewhat more sensitive to the rate at which a load is applied. Apply the load at a rate which allows the turbocharger time to respond to the increasing exhaust as energy. 6. If possible, apply load to engine gradually to prevent overloading engine. Engines that are required to start at temperatures below 10 C (50 F) must be equipped with both an oil and coolant heater. These devices allow the engine to be started with the proper oil flow. If the heaters are manually controlled, allow the engine to become warm enough for normal starting. 7. Open governor throttle to desired engine speed. Do not operate a turbocharged engine for CAUTION long periods at light loads or idle. Normal duty cycles and occasional idle of a few minutes are acceptable. Stop the engine if idling without load for periods of 10 minutes or more. Disregarding this information could result in product damage. NOTE: When engines idle for extended periods or come up to temperature with no load, the turbocharger may be damaged with accumulated carbon. This carbon buildup does not occur when a turbocharged engine is operating at normal and heavy loads. NOTE: Run a turbocharged engine to idle for three to five minutes before shutting down. This allows the temperature of the lubricating oil and turbochargers to stabilize at moderate levels. NOTE: If the engine is difficult to start, or will not run properly, see Table 3.00-1 to troubleshoot the causes. Table 3.00-1 Startup Troubleshooting Doesn't start Slow start and/or Low power SYMPTOM PROBABLE CAUSE REMEDY Check controls Check the fuel system Check air intake and exhaust systems Check connections and auxiliary Check the ignition system Follow the startup for resetting the engine controls. Remote or automatic operation engines have special procedures. Verify that fuel is available to the engine. Check that the gas valves are in the OPEN position. Check air filter is clean. Verify air intake or exhaust outlet is not capped. Check throttle and governor control linkage for equipment freedom from sticking and interference. If cranking speed is low, check the air supply (air starter). Check for water on ignition parts and wires, signs or corrosion at wire terminals or broken wires. Look for spark plugs that are worn out or poorly gapped. Runs hot Check the cooling system Verify the following: The coolant level is correct, the system is not air locked, the radiator is not blocked, the shutter is open and the fan is operating. Also verify that the raw water valves are open to the heat exchanger and that the air circulation is not poor as a result of wind conditions or faulty installation. NOTE: If these checks do not solve the problem, refer to the Troubleshooting Table in Chapter 5. 3.00-4 FORM 6284 Third Edition
STARTUP PROCEDURE COMPRESSOR APPLICATIONS 1. Set governor throttle control to 1/3 open position. 2. Pull out both manual shutdown switches. NOTE: Be sure there is gas supply to the engine. 3. Press START button. If the oil pressure CAUTION gauge does not indicate sufficient oil pressure within 10 seconds, shut the engine down immediately. Never operate the engine without the proper oil pressure indication. Failure to follow these instructions could cause severe engine damage and/or severe personal injury. 4. Check for oil pressure as soon as engine starts. 5. Warm engine by running with little or no load until oil pressure is normal and coolant temperature reaches 38 C (100 F). 6. Maintain oil level at FULL mark on dipstick. Check oil level daily. Always check oil when engine is running and at normal operating temperature. 7. Gradually apply a load to engine to avoid overload. FORM 6284 Third Edition 3.00-5