SECTION 3.

00
ENGINE STARTUP AND SHUTDOWN
PRESTART INSPECTION

WARNING
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.

WARNING
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.

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.

FORM 6284 Third Edition

BARRING
DEVICE

Figure 3.00-1 Barring Device Location

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).

3.00-1

ENGINE STARTUP AND SHUTDOWN

FUEL SHUTOFF
VALVE

STARTUP PROCEDURES

WARNING
Failure to follow the startup procedure in the operators manual may cause engine damage and could
result in severe personal injury or death.

MANUAL
DISCONNECT KNOB

VENT PLUG

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
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.

CAUTION

WARNING
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.
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.

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.

WARNING
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.
DELTEC CARBURETOR

Figure 3.00-3 Deltec Carburetor

3.00-2

3. Reset switches on either oil pressure gauge or

water temperature gauge.
4. Reset magnetic switch on gas control valve (if
equipped).
FORM 6284 Third Edition

ENGINE STARTUP AND SHUTDOWN

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.

WARNING
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.

WARNING
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.

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
CARBURETION
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
CARBURETION
1. Shut the engine down by disengaging the external
load (if possible), closing the main fuel valve and turning off the ignition.

If the engine is being

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.

2. Simultaneously stop the breather motor and the

fuel gas compressors (if so equipped).

STARTUP PROCEDURE DELTEC

CARBURETION

NOTE: Be sure there is gas supply to the engine.

CAUTION

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.

STARTUP PROCEDURE GENERATOR

APPLICATIONS
1. Place governor throttle control lever 1/3 open. Verify main ignition switch is in ON position.

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

ENGINE STARTUP AND SHUTDOWN

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
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.

CAUTION

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

SYMPTOM
Doesn't start

Slow start and/or

Low power

Runs hot

PROBABLE CAUSE

REMEDY

Check controls

Follow the startup for resetting the engine controls.

Remote or automatic operation engines have special
procedures.

Check the fuel system

Verify that fuel is available to the engine. Check that

the gas valves are in the OPEN position.

Check air intake and exhaust systems

Check air filter is clean. Verify air intake or exhaust

outlet is not capped.

Check connections and auxiliary

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 the ignition system

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.

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

ENGINE STARTUP AND SHUTDOWN

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
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.

CAUTION

FORM 6284 Third Edition

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.

3.00-5