Waukesha F817G Series User manual

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Roghan Rd Hardfill Leachate Pump Tip Engine OM Manual
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Waukesha CORE-SSE7)
WANTED
ENGINE
POPULATION
INFORMATION
To help provide proper backup parts stock and availability at
Distributor and Factory levels, it is important that we have
information of your engine's location and application. We
would appreciate it if you would supply us with the
necessary information requested below. A complimentary
gift will be forwarded upon receipt of card.
Thank You
M-992
0OOOOOO OO OOOOO OOOOOOOOOOOOOOOOOOOOOOOOOOOO
NAME TITLE
Z COMPANY NAME
LU ADDRESS
0G ENGINE PURCHASED FROM
La
PLEASE LIST ALL WAUKESHA ENGINES YOU OWN OR SERVICE:
z0-J (G) TYPE EQUIP.
1- MODEL SERIAL NO. SPECIFICATION NO. . USED IN
n
U.!U)4L1J-JO.
.TYPE OF SERVICE ()
INTERMITTENT
CONTINUOUSSTANDBY
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BUSINESS REPLY MAIL
FIRST CLASS - PERMIT NO, 903 WAUKESHA, WI
POSTAGE WILL BE PAID BY ADDRESSEE
Waukesha Engine Division
Dresser Industries, Inc.
Dept 330
1000 W. St. Paul Avenue
Waukesha, Wisconsin 53188-4951
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Roghan Rd Hardfill Leachate Pump Tip Engine OM Manual
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OPERATION
AND
SERVICE
MANUAL
WAUKESHA
F817G SERIES
GAS AND
GASOLINE ENGINES
Waukesha (DRESSER)
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WAUKESHA F-817-G SERIES
SAFETY PRECAUTIONS
For details on safety rules and regulations in the
United States, contact your local Occupational Safety
and Health Administration (OSHA).
These safety precautions are published for your
information. The Waukesha Engine Division, Dresser
Industries, Inc., does not, by the publication of these
precautions, imply or in any way represent that these
published precautions are the sum of all dangers
present near industrial engines. If you are operating
industrial engines, it is your responsibility to ensure
that such operation is in full accordance with all
applicable safety requirements and codes. All
requirements of the United States Federal
Occupational Safety and Health Administration Act
must be met when Waukesha engines are operated
in areas that are under the jurisdiction of that United
States department. Engines operated in countries
other than the United States of America must be
installed, operated and serviced in accordance and
compliance with any and all safety requirements of
that country which may be applicable.
BODILY PROTECTION
Wear OSHA approved bodily, sight, hearing and
respiratory system protection. Never wear loose
clothing, jewelry or long hair around an engine.
EXHAUST GASES
Engine exhaust products are toxic and may cause
injury or death if inhaled. All engine installations
must have an exhaust discharge pipe so that exhaust
gases are delivered into the outside air. A closed
building or shelter must be adequately vented to
provide a steady supply of fresh air.
ENGINE FUELS
Engine fuels are highly combustible and may ignite or
explode. Fuels must be conducted to the engine with
proper piping, free from leaks, and designed to resist
breakage from vibration. When filling fuel tanks,
never smoke or use open flame in the immediate
area. Fuel tanks should be grounded to prevent
buildup of static electricity. If a gas engine has been
cranked excessively without starting, shut off the gas
fuel supply and ignition. Then crank the engine to
purge the cylinders and exhaust system of
accumulated, unburned gas. If you fail to do this, a
spark plug could ignite the gas and cause an
explosion.
POSITIVE FUEL SHUT-OFF
(natural gas, liquified petroleum gas, etc.) should
haYe another positive shut-off valve, preferably
automatic, other than those in the carburetor or gas
. pressure regulation equipment. It is the final
responsibilityof the engine ownerto ensure that the
installation is free from fuel or exhaust leakage, and
such installation meets all applicable codes.
GAS USED TO ENERGIZE STARTERS
Gas used to energize starters must be discharged
away from the engine into a harmless area. There is
also a possibility of leakage around the starter output
shaft during cranking. Ignition connections and
electrical equipment on engines exposed to a
potentially explosive atmosphere should be equipped
to eliminate spark hazard. It is the responsibility of
the engine owner to specify or provide such
connections and equipment.
SAFETY GUARDS
Engines must be provided with guards to protect
persons or structures from rotating or heated parts. It
is the responsibility of the engine owner to specify or
provide such protection.
CRANKCASE ANTI-EXPLOSION VALVES
These valves must be kept in proper working
condition to relieve crankcase pressure.
IGNITION SYSTEMS
Ignition systems can cause electrical shocks. Avoid
contacting ignition units and wiring.
COOLING SYSTEM PRESSURE CAPS AND
CONNECTIONS
Do not remove the pressure caps while the engine is
operating or while coolant is hot. The cooling system
is under pressure and severe burns could result from
the hot coolant spewing out when the cap is
removed. Wait until the engine and coolant have
cooled down before removing the radiator or surge
tank caps. Always replace weak hoses, lines, and
fittings.
FUEL INJECTORS
Never allow an injector to spray against the skin. The
fuel oil will penetrate the skin and may cause serious
infection and injury.
GENERATOR SETS
Some means of positive fuel shut-off should be
provided for emergency use. Pressurized fuels The voltage produced by generator sets is dangerous.
Roghan Rd Hardfill Leachate Pump Tip Engine OM Manual
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Active 29/01/2014
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WAUKESHA F-817-G SERIES
Severe, possibly fatal, shock may result from contact.
Make sure the generator set is grounded before
operation. Be extremely careful when the unit or
surrounding area is damp or wet.
When servicing any part of the electrical system or
making any connections, make sure main power
switch is OFF. Clean or service generator set only
when engine is shut down.
In case of an accident from electrical shock, shut
down the generator set at once. If it cannot be shut
down, free the victim from the live conductor. Avoid
direct contact with the victim. Use a dry board, dry
rope, or any nonconducting implement to free the
victim. If the victim is unconscious, apply artificial
respiration and get medical help.
Do not operate the generator set with the ammeter
circuit open. Voltage, dangerous to both equipment
and personnel, can be generated in an open
secondary circuit of a current transformer.
If the generator set is stopped by operation of safety
devices, do not attempt to operate it until the cause
has been eliminated.
Whenthe generator set is shut downafter operation,
disconnect all line switches toall external power load
and parallel circuits.
ENGINE AND EQUIPMENT, REPAIR AND SERVICE.
Always stop the engine before cleaning, servicing, or
repairing the engine or driven equipment. Place all
controls in OFF position to prevent accidental
restarting. If possible, lock all controls in the OFF
position and take the key. Put a sign on the
instrument panel warning that the engine is being
serviced. Before restarting, make sure that all tools
and other material are removed from the engine and
equipment.
Proper service and repair is important to the safe,
reliable operation of engines and related equipment.
The procedures recommended by Waukesha in this
manual are effective methods for performing service
and repair operations. Some of these procedures
require the use of specially designed tools. The
special tools should be used when and as
recommended. Anyone who uses a service, repair, or
installation procedure not recommended by
Waukesha must first satisfy themselves thoroughly
that their safety will not be jeopardized by the service
methods they select.
HOUSEKEEPING
Good housekeeping results in a clean, safe work
area. An orderly work area with clean walkways and
neatly arranged tools and equipment is a majorfactor
in accident prevention.
ENGINE FAN BLADES
1. Do not operate the engine with a fan which has
been bent, multilated, modified or in any way
damaged.
2. Do not operate the engine if the fan contacts or
strikes any engine accessory or the radiator
shroud or core.
3. Do not rebalance the fan. Contact the fan
supplier if rebalancing is required.
4. Ensure that all bolts attaching the fan are
securely installed to a torque specified by the
engine or vehicle manufacturer.
5. Install the fan so the word "front" stamped on
the fan faces the radiator.
6. Perform all required maintenance on the
subassembly to which the fan is attached
(waterpump, fan drive, etc.) (See operator/
service manual.)
7. Do not modify or substitute any parts of the
engine without the approval of the Waukesha
Engine Division Service Department. Take
special care not to make modifications which
will increase the operating speed of the fan.
8. Install the fan only if the engine has been
approved for fan installation. Likewise, install a
subassembly to which the fan is attached
(waterpump, fan drive, etc.), only if approved or
specified for use on the engine.
9. If the fan or fan drive contains any plastic or
rubber component, have the fan and drive
inspected by a qualified mechanic after
operation at or exposure to excessively high
temperatures [above 250° F. (120° C.) air
temperature].
10. Replace the fan if indications of excessive
corrosion or erosion appear in the fan.
11. For reversible or adjustable pitch fans, make
sure the blades are correctly locked in the
proper position prior to operation. Also, inspect
the fan prior to operation to ensure that ice and
dirt have not accumulated on the fan to cause
potential unbalance of the fan.
Roghan Rd Hardfill Leachate Pump Tip Engine OM Manual
Q-Pulse Id TMS652
Active 29/01/2014
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WAUKESHA F-817-G SERIES
12. Be sure all fans, fan drives and belts are
properly shielded.
TURBOCHARGERS
Turbochargers are specifically designed for each
application. Nozzle rings must not be changed
without consulting the engine manufacturer since
they limit turbocharger rpm. Excessive rpm may
result.in turbocharger failure with resultantpersonal
safety hazards. Turbochargers operate at high
temperatures. Therefore,. all flammable material
must be kept away from them. Engines must be shut
down and at room temperature before working on
turbochargers or burns will result. Keep all foreign
material away from turbocharger openings.
ENGINE STORAGE CHEMICALS
Waukesha Preservative Oil contains a petroleum
distilate which is harmful or fatal if swallowed. Avoid
contact with skin. Vapor is harmful and causes
irritation of eyes, nose, throat and skin. Use only with
adequate ventilation. Avoid prolonged or repeated
breathing of vapor. Avoid contact with skin, eyes, and
clothing. Do not take internally. Keep container.
closed and away from heat. Always read and observe
the "CAUTION- labels on the containers. Do not
destroy the labels on the containers.
Generally, heating of preservative compounds is
confined to 200° F. (93° C.) or less. These
temperatures are easily reached by placing the
preservative container in heated water. If this is
done, the container must be vented or opened to
reduce the danger of explosion. Direct heating
presents a dangerous and unnecessary fire hazard.
FIRE PROTECTION
Locate fire extinguishers so that they are easily
accessible if a fire starts. Carefully maintain records
of extinguisher inspection and recharging to ensure
the fire extinguishing capabilities when required.
Consult your fire extinguisher supplier or insurance
engineer for recommendations on the type, size, and
quantity of lire extinguishers required. Select and
post alternate routes of escape from any engine
installation. Design installation to meet all applicable
fire codes.
CLEANING SOLVENTS
Use approved cleaning solvents in a well ventilated
area. Avoid breathing fumes; some vapors can be
fatal. Keep away from Open flames or sparks. Do not
use gasoline or paint thinners or other highly volatile
fluids for cleaning. Always read and observe the.
"CAUTION" labels On containers. Do not destroy the
labels on the containers. Cleaning solvents can
cause various types of skin irritations.
WELDING EQUIPMENT
Welding gas cylinders can explode if damaged.
Cylinders must be stored in accordance with
manufacturer's specifications and applicable safety
requirements.-
When using acetylene, check valves should be
installed between the regulators and hoses to
prevent flashback into the regulators and supply
tanks. Flashback could cause the regulators and
supply tanks to explode.
Oily and greasy materials must be kept away from
oxygen valves, hoses, etc. Oxygen may combine with
such materials and an explosive reaction could
result.
Always wear protective eye shields when welding,
cutting or watching a welding operation. Protective
clothing and face shields must be worn. Do not weld
or cut near combustible materials.
GROUNDING PRECAUTIONS WHEN WELDING
When using an electric welder on an engine, clip the
ground lead as close to the welding site as possible.
Putting the ground lead too far from the welding site
may result in arcing across the main bearings, and
fusing them to the crankshaft.
ELECTRIC POWER TOOLS
Be certain the electric tool is properly grounded.
Wear proper eye protection. Do not work in wet or
damp conditions. Be sure the tool is in good condition
and safety guards are in position. An electric trouble
light must also be grounded. Do not carry electric
power tools by the cord. Do not yank the cord when
removing from an outlet; instead grasp the plug to
remove it from an outlet.
LEAD ACID BATTERIES
Always disconnect the battery ground connection
from batteries before performing any work on the
engine or equipment. This will prevent sparks or
burns when accidently shorting an electrical
connection.
Never expose batteries to .open flame or electric
spark. Battery action generates a flammable,
explosive gas. Don't allow battery fluid to contact
skin, eyes, fabrics, or painted surfaces. Battery fluid
is a sulphuric acid solution which could cause
Roghan Rd Hardfill Leachate Pump Tip Engine OM Manual
Q-Pulse Id TMS652
Active 29/01/2014
Page 8 of 140

WAUKESHA F-817-G SERIES
serious personal injury or property damage. Wear
eye protection when working with batteries.
Precautions When Using Booster
Batteries and Cables
Do not attempt to jump start an engine having a
frozen battery. The battery may rupture or explode.
Before starting, examine all fill ventson the battery. If
ice can be seen, or if the electrolyte fluid cannot be
seen, do not attempt to start with jumper cables.
Batteries should be treated carefully when using
jumper cables. The following procedures assist in
reducing sparks and explosion hazards always
present in both batteries when connecting charged
batteries to discharged batteries:
Turn off all electrical loads. Remove vent caps and lay
a damp cloth over open vent wells of each battery.
The charged booster battery or batteries must have
the same voltage capacity as the discharged battery
or batteries.
The positive post is identified by a "+", pos. and red
color and is larger in diameter than the negative post.
The negative post is identified by a "-", neg. and
gray color.
Negative Grounded Battery or Batteries
First, connect one jumper cable from the positive post
on the charged batteryor batteries to the positive post
on the discharged battery or batteries. If more than
one battery is connected in "series" or "series
parallel", connect the jumper cable to the positive
post that has the cable leading to the starting motor.
Second, connect the other jumper cable from the
negative post on the charged battery or batteries to a
good ground on the engine.
When removing jumper cables, always disconnect
the ground jumper cable from the engine before
disconnecting the other jumper cable.
Positive Grounded Battery or Batteries
This is the same procedure as for negative grounded
battery or batteries, except the negative post will
have the cable leading to the starting motor and the
positive post will be grounded.
COMPRESSED AIR
Compressed air or gases should never be used to
clean clothing or the body. Compressed air can pierce
the skin and cause severe and very painful injury.
Never use your hand to check air, gas, or liquid flow
rates. Do not engage in "horseplay- with air, gas, or
liquid hoses. Observe all applicable regulations as
related to compressed gases.
SODIUM FILLED VALVES
When handling sodium filled valves always wear
approved safety goggles, a hat or cap, long sleeves,
and gloves. If refacing of sodium filled valves is
required, do not exert undue force at the grinding
wheel as this could crack the hollow valve stem and
allow the sodium to escape.
Do not handle broken sodium filled valves with bare
hands. Sodium or sodium residue can cause severe
burns. Sodium burns are of the same nature as
caustic burns. Wash burns with large volumes of cold
water, then neutralize with vinegar. The affected
parts should then be treated as a burn and medical
attention sought.
If a broken valve should ignite, smother the flames in
dry soda ash or dry sand. Water, carbon dioxide in any
form, or carbon tetrachloride should never be used on
sodium fires since these materials react violently
with hot sodium. The smoke and fumes are irritating;
adequate ventilation should be provided and
inhalation or contact with the smoke and fumes
avoided.
Broken sodium filled valves may be stored prior to
disposal in moisture free clean oil or kerosene.
Unserviceable sodium filled valves must be disposed
of in accordance with local, state and/or federal
regulations as applicable.
INTOXICANTS AND NARCOTICS
Workers under the influence of intoxicants and/or
narcotics are unsafe workers and are a hazard to
themselves and other employees.
SAFETY PRACTICES FOR HANDLING ACIDS.
Throughout this manual, acid cleaning procedures
are recommended for certain castings or pieces of
equipment.
WARNING
Always add the acid to the water -never add water
to acid when mixing solution.
1. Avoid contact with skin, clothing, and eyes.
2. Descaling operations should be performed
away from all fire, sparks or other ignition
sources.
Roghan Rd Hardfill Leachate Pump Tip Engine OM Manual
Q-Pulse Id TMS652
Active 29/01/2014
Page 9 of 140

WAUKESHA F-817-G SERIES
3. Keep acids off of concrete floors, as it attacks
lime in the concrete. If solution does get on
concrete surfaces, apply an alkaline solution to
neutralize.
4. Acids can react with metals to form various
gases. Generally, acid solutions on lime scale
and rust. result in the formation of harmless
carbon dioxide. However, when acids contact
aluminum, zinc, cadmium, tin, sulfides, arsenic
and cyanides, poisonous and explosive gases
may be generated. When descaling is being
done in closed equipment, install proper
ventilation to carry the gases away. When an
open tank or crock is used, gases should be
diluted by adequate air flow above the open
tank.
5. Always fill closed vessels from bottom up.
6. Be sure that there are no leaks in the vessel
being descaled which will permit solution to
leak into opposite side of equipment. Good
practice is to fill the opposite side of the
equipment being descaled with water to a level
higher than the acid solution.
7. Use an acid-proof pump, or an inexpensive,
expendable one.
8. When mixing with water, pour acid into the
water, do not pour water in concentrated acid.
9. Do not agitate acid solutions with air.
10. Applications of acid should be followed by
thorough rinsing, then neutralizing with an
alkaline solution to remove all acidic residue, to
prevent further action.
11. Store acid solutions in either an acid-proof
wooden or synthetic rubber lined steel
container should be used.
12. Check steel equipment to be treated with acid
solution for copper or brass fittings or fusible*
metal plugs. If possible, dissimilar metals
should be removed prior to descaling to prevent
electrolytic action which might interfere with
the inhibiting action of acid solution. DO not use
acid to descale equipment constructed of
aluminum.
Roghan Rd Hardfill Leachate Pump Tip Engine OM Manual
Q-Pulse Id TMS652
Active 29/01/2014
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