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SECTION 4.

50
ENGINE PROTECTION SHUTDOWN SYSTEM MAINTENANCE
ENGINE PROTECTION SHUTDOWN
SYSTEM MAINTENANCE
Maintenance of the engine protection shutdown system is generally limited to visual inspection of components.

WARNING
Switches for alarms and automatic engine shutdown must be supplied by the customer. The sensors provided are for measuring and monitoring
temperatures and WILL NOT shut the engine down
if potentially harmful temperatures are reached.
Waukesha will not be responsible for any property
damage, severe personal injury or death, due to
the failure to follow these instructions.

THERMOCOUPLE

Figure 4.50-2 Exhaust Manifold Thermocouple

K-TYPE THERMOCOUPLES INSPECTION


Thermocouples can be
extremely hot. Allow
engine to cool prior to handling thermocouple.
Failure to follow these procedures could result in
severe personal injury.

CAUTION

THERMOCOUPLE

1. Inspect thermocouples to ensure they are securely


seated (see Figure 4.50-1, Figure 4.50-2 and
Figure 4.50-3).
THERMOCOUPLE

Figure 4.50-3 F18/H24 Exhaust Outlet Thermocouple

2. Inspect connecting cables and wires for loose connections, broken wires or insulation.

QUICK
DISCONNECT

Figure 4.50-1 L36/P48 Thermocouple Connections

FORM 6284 Third Edition

4.50-1

ENGINE PROTECTION SHUTDOWN SYSTEM MAINTENANCE


MANUAL SHUTDOWN LEVER MAINTENANCE

WARNING
Always ensure that the fuel gas valve(s) are closed
after engine shutdown. Failure to close fuel gas
valve(s) could cause severe personal injury or
death.
Inspect the manual shutdown lever for proper operation (see Figure 4.50-4 and Figure 4.50-5). With the
engine running under no load, move the lever to the
CLOSED position, the engine should return to idle
speed.

PRESSURE AND TEMPERATURE SWITCH


CALIBRATION
Calibrating and testing pressure and temperature
switches should be performed by qualified service
technicians every 90 days.
OPTIONAL INSTRUMENT PANEL
Inspect the instrument panel to ensure the gauges are
operating (see Figure 4.50-6).

CONTROL PANEL

Figure 4.50-6 Control Panel

WARNING

MANUAL SHUTDOWN
LEVER

Figure 4.50-4 F18/H24 Manual Shutdown Lever

Switches operating on low oil pressure and high


jacket water temperature are required for unattended operation. Other safety switches may be
needed to suit the application. Disregarding this
information could result in severe personal injury
or death.

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.
Automatic shutdown devices consist of two main parts:
MANUAL SHUTDOWN
LEVER

Figure 4.50-5 L36/P48 Manual Shutdown Lever

4.50-2

A sending unit which is inserted into the water


jacket, lubrication system, or other system to be
monitored.
A set of contact points located in the switchgage or
related device (see Figure 4.50-7).

FORM 6284 Third Edition

ENGINE PROTECTION SHUTDOWN SYSTEM MAINTENANCE


LOCKOUT SETTING
22 PSI (151 kPA)

OIL HEADER TEMPERATURE


This switchgage is adjusted so that the contacts close
when oil temperature exceeds a specified setpoint.
176 BMEP Engines, Normal Temperature

CONTACT
ADJUSTMENT
36 38 PSI
(248 262 kPA)

Normal oil temperature reflects jacket water temperatures of 82 C (180 F) and intercooler temperatures of
29 54 C (85 130 F).
Normal: 77 91 C (170 195 F)
Alarm: 93 C (200 F)
Shutdown: 96 C (205 F)
176 BMEP Engines, Optional Temperature

MANUAL
RESET BUTTON

Figure 4.50-7 Typical Switchgage

This system is used as protection against the possibility of the engine continuing to run after the loss of oil
pressure, high intake manifold temperature, or over
heating of the cooling system. If the oil pressure drops
below a set value or the water temperature or intake
manifold above a set value, the switchgage contacts
will close and trip the gas valve to shut off the engine
fuel supply.

Optional oil temperature reflects jacket water temperatures of 129 C (265 F) and/or intercooler temperatures of 29 54 C (85 130 F).
Normal: 77 91 C (170 195 F)
Alarm: 93 C (200 F)
Shutdown: 96 C (205 F)
200 BMEP Engines, Normal Temperature
(GLD Only)
Normal oil temperature reflects jacket water temperatures of 99 C (210 F) and intercooler temperatures of
70 80 C (158 176 F).

The switchgage could also be connected to the magneto, in which case the gauge will ground out the magneto through the safety adapter as well as tripping the
fuel shutoff valve. This stops the magneto from producing ignition current and turns off the fuel supply.

Normal: 88 C (190 F)
Alarm: 93 C (200 F)
Shutdown: 96 C (205 F)

In either case, the engine is stopped before extensive


engine damage can occur.

Jacket water temperature is monitored at the water


outlet header. This switchgage is adjusted so that the
contacts close when the jacket water temperature
exceeds the specified set point.

NOTE: Switchgages are not approved for, or supplied


with, hazardous location (CSA approved) ignition
equipped engines.

RECOMMENDED SHUTDOWN
SETPOINTS
OIL HEADER PRESSURE

JACKET WATER TEMPERATURE

176 BMEP Standard Cooling System


Normal: 82 C (180 F) for continuous duty
93 C (200 F) for intermittent duty
Alarm: 5.5 C (10 F) above design temperature
Shutdown: 11 C (20 F) above design temperature

The switchgage monitors engine oil pressure at the


main oil gallery. This switchgage is adjusted so that
the contacts close when the engine oil pressure falls
below the specified point.

176 BMEP Optional Temperature Cooling System

F18/H24:

200 BMEP Cooling System (GLD Only)

Normal Pressure: 462 572 kPa (67 83 psi)


Alarm: 276 kPa (40 psi)
Shutdown: 241 kPa (35 psi)

Normal: 99 C (210 F) for continuous duty


Alarm: 5.5 C (10 F) above design temperature
Shutdown: 8.5 C (15 F) above design temperature

Normal: 99 130 C (210 265 F)


Alarm: 3 C (5 F) above design temperature
Shutdown: 5.5 C (10 F) above design temperature

L36/P48:
Normal Pressure: 324 434 kPa (47 63 psi)
Alarm: 290 kPa (40 psi)
Shutdown: 241 kPa (35 psi)
FORM 6284 Third Edition

4.50-3

ENGINE PROTECTION SHUTDOWN SYSTEM MAINTENANCE


INTAKE MANIFOLD TEMPERATURE
Monitors intake manifold charge temperature.
Depending on application, the switchgage contacts
close when the intake manifold charge temperature
exceeds the specified setpoint.
176 BMEP Normal Intercooler Temperature
With standard intercooler temperatures of 29 54 C
(85 130 F).
Normal:

Up to 5.5 C (10 F) above design I.C.


temperature
Alarm:
8.5 C (15 F) above design I.C.
temperature
Shutdown: 11 C (20 F) above design I.C.
temperature
176 BMEP Optional Intercooler Temperature
Optional intercooler temperatures of 55 80 C
(131 176 F).
Normal:

Up to 5.5 C (10 F) above design I.C.


temperature
Alarm:
5.5 C (10 F) above design I.C.
temperature
Shutdown: 8.5 C (15 F) above design I.C.
temperature

RESET
SWITCH

Figure 4.50-8 F18/H24 Overspeed Shutdown

The control box for L36 and P48 engines is mounted


on the CEC Ignition Module mounting bracket. The
reset control is on the side of the control box (see
Figure 4.50-9). The reset button must be depressed to
restart the engine.

200 BMEP Normal Intercooler Temperature


(GLD Only)
With elevated intercooler temperatures of
70 80 C (158 176 F).
Normal:

Up to 5.5 C (10 F) above design I.C.


temperature
Alarm:
5.5 C (10 F) above design I.C.
temperature
Shutdown: 8.5 C (15 F) above design I.C.
temperature
INTAKE MANIFOLD PRESSURE
Contact Waukesha Sales Engineering.

ENGINE OVERSPEED SHUTDOWN


SYSTEM OPERATION
The engine may be equipped with an optional overspeed shutdown system. This system measures
engine speed from the ignition system (CEC Ignition
Module or magneto ignition). Waukesha adjusts the
shut down speed to 15% over engine governed speed.
The control box for F18 and H24 engines is mounted
on the left rear mounting leg. The reset control is on
the side of the control box (see Figure 4.50-8). The
reset button must be depressed to restart the engine.

4.50-4

RESET
SWITCH

Figure 4.50-9 L36/P48 Overspeed Shutdown

If the overspeed shut


d o w n s y s t e m t r i ps ,
find and correct the cause before restarting the
engine. Failure to do so may damage the engine or
driven equipment.

CAUTION

NOTE: If an optional switchgage trips and shuts down


the engine, the overspeed switch will not require
resetting.

FORM 6284 Third Edition

ENGINE PROTECTION SHUTDOWN SYSTEM MAINTENANCE


KDM/DSM MAINTENANCE
KNOCK SENSOR INSTALLATION
The CEC Knock Detection Module (KDM) and Detonation System Module (DSM) systems use the same
knock sensor. The sensor installation procedure is the
same for either system.
Do not drop or mishand l e k n o c k s e n s o r.
Knock sensor damage may occur if knock sensor
is mishandled.

CAUTION

Do not over-tighten
knock sensor. Overtightening will cause damage to the knock sensor.

CAUTION

KNOCK SENSOR

Figure 4.50-10 Knock Sensor Installation

Install knock sensor into the threaded hole located in


crankcase (see Figure 4.50-10). Tighten knock sensor
to 47 54 Nm (35 40 ft-lb). Verify that the knock
sensor is seated flat against the crankcase surface.
Knock sensor MUST have full-face contact with
mounting surface. Imperfections in the surface
that the sensor mounts against can cause higher
sensor output.

ROUTINE INSPECTION
Regularly inspect the engine during operation. Duplicate the form shown in Table 4.50-1 and use it to
record the results of regular inspections. By maintaining trend information on the general condition of the
engine, the necessary corrective action can be taken
when a problem first becomes apparent. An early
diagnosis will save money and reduce down time by
preventing the development of more serious problems.
Refer to Section 4.60 Maintenance Schedule for the
recommended maintenance intervals.

Table 4.50-1 Routine Inspection Form


OPERATING INFORMATION
INSPECTION DATE
MONTH/DAY/YEAR

INSPECTION RESULTS/CORRECTIVE ACTION


INSPECTOR'S
ID/INITIALS

HOURMETER READING

Oil Header Pressure


Jacket Water Outlet Temperature
Oil Header Temperature
Tachometer (rpm)
Fuel Meter Reading
Intercooler Water Temperature
Oil Cooler Water Temperature
Gas/Air Pressure
Intake Manifold Pressure
Unusual Noises/Vibration
Oil Leaks
Coolant Leaks
Exhaust O2%
Exhaust Backpressure
Ignition Timing

FORM 6284 Third Edition

4.50-5