SECTION 4.

15
BREAK-IN PROCEDURE AFTER REBUILD

All new engines are test run at the factory before
shipment and therefore do not require break-in. Howev-
er, after an on-site overhaul, certain break-in proce-
dures must be followed to allow critical engine parts to
seat properly.
PRESTART INSPECTION
4. Verify protective guards and shields on engine and
driven equipment are secure (see Figure 4.15-1).
Remove tools, rags, fittings or any other objects that
may get caught by rotating parts.
5. Examine engine foundation for condition of grout,
tightness of hold down bolts and general alignment of
driven equipment.

Do not allow anyone under the influence of intoxi- GUARDS

cants and/or narcotics to work on or around
industrial engines. Workers under the influence of
intoxicants and/or narcotics are a hazard both to
themselves and other employees and can cause
severe personal injury or death to themselves or
others.

1. Verify cooling system valves are properly opened

and drain cocks are closed.

Always wear protective clothing when checking or Figure 4.15-1. Engine Guards
venting the cooling system on a heated engine.
Slowly loosen the air bleed petcock to relieve any 6. Check air cleaner restriction indicator. If indicator
excess pressure. Use the vent on the pressure cap shows red, clean pre-cleaner and/or air cleaner ele-
to allow pressure to escape. Escaping steam ments (see Figure 4.15-2).
and/or hot water can result in severe burns or
death.

2. Check coolant level and add coolant if necessary. If

coolant is added open cooling system air vents to allow
trapped air to escape.

3. Check for oil and/or coolant leaks.

To avoid severe personal injury or death, ensure

that all tools and other objects are removed from AIR
RESTRICTION
the unit and any driven equipment before restarting INDICATOR
the unit.
Figure 4.15-2. Air Restriction Indicator/Filter

FORM 6296 First Edition 4.15 - 1

BREAK-IN PROCEDURE AFTER REBUILD

7. With barring device turn engine over, at least two

revolutions, in a counterclockwise direction. Verify SIGHT
OIL FILLER
GLASS
nothing interferes with engine rotation (see CUP
Figure 4.15-3).

BARRING DEVICE

C
O M
M A
P
E X
N
S
A
T M
I I
O N
N

COMPENSATION
POINTER

OIL DRAIN
Figure 4.15-3. Engine Barring Device PLUG

8. Verify barring device is disengaged from flywheel.

Figure 4.15-5. Woodwardä UG-8L Governor

11. Reset and calibrate all engine protection switches

Make certain barring device is disengaged from
flywheel prior to starting engine. Remove all
wrenches from the barring device before engaging
starter. Failure to follow proper procedures could
cause severe personal injury or death.
and devices.
12. Press and hold down PRELUBE motor button for
5 minutes (see Figure 4.15-6). Check oil pressure
gauge for a minimum of 5 psi (35 kPa).

9. Check crankcase oil level daily before engine is START PRELUBE

started. Blade of dipstick is marked “low” and “full” (see
Figure 4.15-4). Always maintain oil level at “full” mark.
Both marks on dipstick are “static lines.” Dipstick
does not indicate oil level when engine is running.

LOW FULL

IGNITION

Figure 4.15-6. Control Panel

O-RING
13. Adjust valves. Refer to Section 4.10 Valve Adjust-
Figure 4.15-4. Dipstick ment in this manual.

10. Check UG-8 governor oil level in sight glass

(see Figure 4.15-5).

4.15 - 2 FORM 6296 First Edition

 BREAK-IN PROCEDURE AFTER REBUILD

Table 4.15-1. VHP Series Four Break--in Schedule

STEP SPEED ± 10 RPM BMEP PSI ± 10% TIME (MINUTES) TORQUE POWER
MINIMUM FT--LB ± 3% HP ± 3%
1 800 Minimum 10 Check for leaks, unusual noise or vibration
2 900 50 15 3113 533
3 Rated 100 30 6225 --
4 Rated ++ 130 60 8093 --
5 Rated ++ 160 60 9961 --
6 Rated ** 60 ** **
NOTE: ++If the BMEP listed exceeds the rated BMEP (as specified in the engine build package or nameplate for field break-- in), run that Step at
rated BMEP and end break-- in.
**Engine set at rated load per the appropriate “Performance Data for Production Test” S-- sheet or at rated load on the engine nameplate for field
break-- in.

Alarm and shutdown values are based on dry natural gas (900 Btu/cu. ft. SLHV).
Refer to Gaseous Fuel Specification Sheet S7884-7, Oil Recommendations Sheet
S1015-30, Service Bulletins 9-2702B and 12-1880Z or latest revisions for typical changes in operation
temperatures for jacket water and oil when running on landfill or digester gas fuels. Disregarding this
information could result in product damage.

Table 4.15-2. Alarm And Shutdown Setpoints

DESCRIPTION NORMAL ALARM SHUTDOWN
Jacket Water Outlet Temperature
180° F (82° C)
10° F (5.5° C) 20° F (11° C)
for continuous rating
Standard Cooling System above normal/design above normal/design
200° F (93° C)
temperature temperature
and intermittent rating
210 -- 235° F 5° F (3° C) 10° F (5.5° C)
Elevated Temperature Solid Water Cooling System (99 -- 113° C) above normal/design above normal/design
solid water temperature1 temperature1
210 -- 250° F
Ebullient Water Cooling System See Note 2
(100 -- 121° C)
Oil Header Temperature 180° F (82° C) 195° F (91° C) 205° F (96° C)
Oil Header Pressure 55 ±5 psi (380 ±35 kPa) 35 psi (275 kPa) 30 psi (207 kPa)
Up to 10° F (5.5° C) 15° F (8.5° C) 20° F (11° C)
Intake Manifold Temperature above design intercooler above design intercooler above design intercooler
water inlet temperature water inlet temperature water inlet temperature
Intake Manifold Pressure See SB 14-2755B (or current revision)
Main Bearing Temperature — 250 F (121° C)
10%
Overspeed — over governed speed or
driven machine limits

NOTE: 1 Waukesha Power Systems Code 1105, 1105A, or equivalent shutdown system is recommended when jacket water temperature exceeds
210° F (99° C).
2 Waukesha Power Systems Code 1106, 1106A, or equivalent shutdown system is recommended for ebulliently cooled engines.

FORM 6296 First Edition 4.15 - 3

BREAK-IN PROCEDURE AFTER REBUILD

Table 4.15-3. Lubrication System Pressures And Temperatures

MEASUREMENT U.S. METRIC
Normal stabilized oil pressure at idle speeds 15 to 40 psi 103 - 276 kPa
Normal stabilized oil pressure with engine loaded 55 ±5 psi 380 ±35 kPa
Low oil pressure (alarm) 30 psi 207 kPa
Low oil pressure (shutdown) 20 psi 138 kPa
Minimum oil pressure at the turbocharger 10 psi 68 KPa
Minimum stabilized low oil temperature 160° F 70° C
Normal stabilized oil temperature 180° F 82° C
High oil temperature (alarm) 195° F 91° C
High oil temperature (shutdown) 205° F 96° C

BREAK-IN PROCEDURE 6. Press and hold down PRELUBE button for 5 min-
utes (see Figure 4.15-7). Check oil pressure gauge for a
Proper engine break--in is required after installation of
minimum of 5 psi (35 kPa).
new piston rings. Table 4.15-4 lists the correct break--in
schedule for VHP Series Four engines. See
Table 4.15-1 additional break--in schedules. START PRELUBE

Table 4.15-4. Engine Break--In Schedule

TIME
STEP SPEED ± 10 LOAD (MINUTES)
RPM MINIMUM
1 Idle No Load Warm--Up
2 900* 25% 15
3 1200* 50% 20
4 1200* 75% 20
Run Rated Load And Speed --
5
Break--In Complete

NOTE: *Run at rated speed for electrical power generation IGNITION

application.

Figure 4.15-7. Control Panel

1. Set engine spark timing to nameplate timing or site
timing per WKIâ number.
7. Place manual speed control lever in open position
2. Be sure there is a leak free fuel gas supply to the (see Figure 4.15-8).
engine.

NOTE: Engines that are required to start at tempera-

tures below 50° F (10° C) should 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.

3. Make sure all controls are set properly for the water
and oil systems. Prelube the engine for 5 minutes prior
to starting.

4. Consideration should be given to driven equipment

speed limitations before beginning the break--in.
MANUAL SPEED
5. Reset all engine protection switches and devices. CONTROL LEVER

Figure 4.15-8. Manual Speed Control Lever

4.15 - 4 FORM 6296 First Edition

 BREAK-IN PROCEDURE AFTER REBUILD

8. Place the governor speed control lever or dial MANUAL

(SYNCHRONIZER) to 1/3 open position (if equipped) DISCONNECT (CUSTOMER
KNOB SUPPLIED)
(see Figure 4.15-9 and Figure 4.15-10).

SYNCHRONIZER

SPEED DROOP SYNCHRONIZER

LATCHING
VENT KNOB
PLUG

LOAD LIMIT SYN. INDICATOR

Figure 4.15-11. Fuel Shutoff Valve

10. Verify IGNITION (Emergency Stop) buttons are

pulled out (see Figure 4.15-7).

If oil pressure gauge

does not indicate suffi-
cient pressure within 15 seconds, shut engine
down immediately. Never operate engine without
Figure 4.15-9. Woodwardä UG--8 Dial Governor
sufficient oil pressure. Disregarding this informa-
Control
tion could result in product damage.
11. Check oil pressure as soon as the engine starts. Oil
pressure should be between 50 -- 60 psi (345 --
415 kPa) when engine is under a load. See Table 4.15-3
for complete oil pressure information.

12. Press and hold START button until engine

starts (see Figure 4.15-7).

Turbocharged engines
should not be idled for
extended periods. Accumulated carbon may dam-
age turbocharger. Shut down and restart when
needed.
GOVERNOR SPEED
CONTROL LEVER 13. Warm engine by running with little or no load until oil
pressure is normal and the coolant temperature reach-
Figure 4.15-10. Governor Speed Control Lever es 100° F(38° C). Refer to Table 4.15-2 for complete
information.
9. Open the fuel shutoff valve(s) (see Figure 4.15-11).
14. Gradually apply load to engine. Do not overload.

FORM 6296 First Edition 4.15 - 5

BREAK-IN PROCEDURE AFTER REBUILD
The fuel system requires a shutoff valve that opens
upon cranking and closes whenever engine rota-
tion ceases. Failure to provide the valve will cause
an explosive environment resulting in severe
personal injury or death.
15. Shut off fuel valves and turn off ignition.
16. Remove oil pan access covers.
17. Using an infrared pyrometer, check the connecting
rod caps and main bearing caps for “hot spots.”
Bearings of the same type should be within 10° F
(5.5° C) of each other. Rod caps should be approxi-
mately 125 -- 150° F (52 -- 66° C). Main bearing caps
(side) should be approximately 180 -- 200° F
(82 -- 93° C). Inspect bearing of any cap or bearing not
meeting specification.
18. Insert a bar between adjacent connecting rods and
check for free end play.
19. Reinstall oil pan access covers.
20. Prelube engine for 5 minutes after pressure reach-
es a minimum of 35 psi (241 kPa).
Observe all gauges
continuously for the
duration of the break-in. Shut engine down if safe
temperatures are exceeded or if pressure falls to
unsafe levels. Failure to shut down automatically
indicates a problem with the engine protection
shutdown system. Determine the cause of failure
before starting engine. Failure to comply may
result in severe equipment damage and/or
personal injury.
NOTE: Crankcase pressure could be up to 1 in. of
water maximum during break-in. Higher pressure is a
good indication of a power cylinder problem and should
be investigated. After break-in it should be 0 to --2 in. of
vacuum.
21. Start engine and run at 900 rpm (1000 or 1200 rpm
for high rpm engines) under 25% (50 BMEP) load until
oil reaches 130° F (54° C).
22. Adjust oil pressure to 50 -- 60 psi (345 -- 415 kPa).
23. Continue to run at 900 rpm (1000 or 1200 rpm for
high rpm engines), increase load to 50% (up to
100 BMEP) and run for 20 minutes.
4.15 - 6
NOTE: Refer to VHP Series Four Operation and
Maintenance Manual, Form 6287, Section 4.05 “Fuel
System Maintenance” for fuel system adjustment. This
applies to natural gas engines only. For different
fuels refer to your nameplate or call Waukesha
Engine Product Support Department.
24. Maintain speed at 900 rpm (1000 -- 1200 rpm for
high rpm engines) and increase load to 100% (138
BMEP) for 60 minutes.
25. Readjust oil pressure to 50 -- 60 psi
(345 -- 415 kPa) at 160° F (82° C).
26. Continue to run at 900 rpm (1000 -- 1200 rpm for
high rpm engines), increase load to 110% (145 BMEP)
and run for 60 minutes.
27. Check and record intake manifold pressure. If
necessary contact Waukesha Sales Engineering for
specific engine intake manifold pressure.
28. Gradually reduce engine load.
29. If applicable, place governor speed control lever or
dial in idle speed position and allow engine to idle for
5 minutes to cool down.
Always verify fuel gas valve(s) are closed after
engine shutdown. Failure to close valve(s) could
cause severe personal injury or death.
30. Close fuel valves to shut engine down.
31. Post lube engine for 5 minutes.
32. Check and adjust intake and exhaust valves for
each cylinder head. See Section 4.10 Valve Adjustment
And Web Deflection.
FORM 6296 First Edition
 BREAK-IN PROCEDURE AFTER REBUILD

OPERATING AT LIGHT LOADS Engine oil and coolant temperatures should be main-
The following information gives recommendations for tained within the standard operating ranges. Always
special operation and maintenance procedures when check thermostats for proper operation. General guide-
operating Waukesha natural gas engines at light loads lines are as follows:
or no loads for extended periods of time. · Maintain engine jacket water outlet coolant in
Light load operation is typically defined as power levels standard range of 180° F to 190° F (82° C to 89° C).
less than 50% of the maximum continuous power rating.
· Oil header temperature should be above 160° F
Gas engines usually have unstable combustion at light (71° C) to assure proper lubrication of the engine and
loads because combustion chamber pressures are minimize oil nitration rates.
lower which increases blow--by past the piston rings.
Refer to “General Data” Technical Data Book, under
This can lead to contamination of the engine oil
Control Systems see Number S8382 “Alarm And
including an increase in oil nitration rates and carboning
Shutdown Setpoints” and in the Fuels And Lubrication
of the piston ring grooves. Oil analysis is recommended
Section, Number S1015--27 “Waukesha Oil Recom-
to determine proper oil change intervals. Refer to
mendations.”
Section 5.30 Lubrication System “Oil Specifications” for
Waukesha oil recommendations. Change intervals are The crankcase breather system should be checked for
usually not affected by periodic light loading. proper operation, which will ensure that blow--by gases
are properly vented from the crankcase. The breather
If the engine is operated at less than 30% load for long
system should be adjusted to operate at a slight
periods (> 300 hours), it is recommended that the
vacuum. Refer to VHP Series Four Operation and
engine be exercised at full load for 2 hours every
Maintenance Manual, Form 6287, Section 4.40
400 hours.
“Crankcase Breather System Maintenance” for
Single electrode iridium platinum spark plugs are specifications.
recommended by Waukesha Engine and are available
from Waukesha Engine Distributors. Refer to Service
Bulletin No. 11--1895G (or latest revision) for spark plug
recommendations for all Waukesha production
engines. These spark plugs have superior corrosion
resistance and will significantly improve the engine
stability at part and full load operation compared to the
multi--electrode spark plugs.

FORM 6296 First Edition 4.15 - 7