Page 1 Engine Operation & Maintenance Engine Model: SFGLD360/480 Gas Generator Set Models: 750/1000REZK See Inside Front Cover for Service Assistance Information TP-6991 8/18b...
Page 2 Visit the Kohler Co. website at KOHLERPower.com. (86) 10 6518 7952 Fax: (86) 10 6518 7955 Look at the labels and stickers on your Kohler product East China Regional Office, Shanghai or review the appropriate literature or documents Phone: (86) 21 6288 0500 included with the product.
Page 5 Dear Customers, Please be advised that EPA regulation 40 CFR part 60 subpart JJJJ places certain requirements on owners and operators of new stationary spark ignition internal combustion engines. You have purchased a EPA pre‐certified Guascor gas engine per 40 CFR part 60 subpart JJJJ and, therefore, should adhere to the compliance requirements for pre‐certified engines Your engine has been certified for stationary emergency use only. As such, there is no time limit for use of this emergency stationary ICE engine in emergency situations ‐ as determined by an authorized entity. ...
Page 6 GENERAL INDEX 2.002211.810_A 10-2016 OPERATION & MAINTENANCE MANUAL SFGLD “V” KOHLER CO – PRIME / STAND BY O&M_2.002211.810_A_10_2016 CHAPTER 1 – SAFETY FEATURES AND PRECAUTIONS IC-G-D-60-002e_B Safety precautions for KOHLER gas engines IC-G-D-60-003e_D Review of compliance with european machinery safety regulations and "CE" mark requirements...
Page 7 GENERAL INDEX 2.002211.810_A 10-2016 OPERATION & MAINTENANCE MANUAL SFGLD “V” KOHLER CO – PRIME / STAND BY O&M_2.002211.810_A_10_2016 2.5 Ignition IC-G-D-33-002e_A Description of the GIS ignition system 2.5.1 2.6 Intake IC-C-D-35-002e_C GAS engines intake system 2.6.1 IC-C-D-35-001e_D Air filters 2.6.5 2.7 Exhaust...
Page 8 GENERAL INDEX 2.002211.810_A 10-2016 OPERATION & MAINTENANCE MANUAL SFGLD “V” KOHLER CO – PRIME / STAND BY O&M_2.002211.810_A_10_2016 CHAPTER 5 – MAINTENANCE INSTRUCTIONS 5.1 Maintenance Procedures IO-G-M-00-060e_B General maintenance of gas engine 5.1.1 IO-G-M-00-061e_C Maintenance of natural gas engine SFGLD 1800 rpm prime 5.1.5...
Page 9 2.002211.810_A 10-2016 SAFETY FEATURES AND PRECAUTIONS OPERATION & MAINTENANCE MANUAL SFGLD “V” KOHLER CO – PRIME / STAND BY O&M_2.002211.810_A_10_2016 CHAPTER 1 – SAFETY FEATURES AND PRECAUTIONS IC-G-D-60-002e_B Safety precautions for KOHLER gas engines IC-G-D-60-003e_D Review of compliance with european machinery safety regulations and "CE" mark requirements...
Page 10 The aim of this document is to inform the users of Kohler equipment on the safety precautions which are required for handling and operating it adequately.
Page 11 INDEX DATE Dep. 1 IC-G-D-60-002e July 2015 SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES O&M_2.002211.810_A_10_2016 5. ENGINE FUELS CAUTION If a gas engine has been cranked excessively without starting, shut off the gas fuel supply and continue cranking the engine to purge the cylinders and exhaust system of accumulated, unburned gas. If you fail to do this, a spark plug could ignite and cause an explosion.
Page 12: Ignition System
DATE Dep. 1 IC-G-D-60-002e July 2015 SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES O&M_2.002211.810_A_10_2016 9. COOLING SYSTEM PRESSURE CAPS AND CONNECTIONS CAUTION 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.
Page 13 Perform all required maintenance on the drive system, as described in this manual. Do not modify or substitute any parts of the engine without the approval of the Service Department of Kohler. Take special care not to make modifications which will increase the operating speed of the fan.
Page 14 DATE Dep. 1 IC-G-D-60-002e July 2015 SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES O&M_2.002211.810_A_10_2016 Install the fan only if the engine has been approved for fan installation. Likewise, install a drive system defined by Kohler. If the fan or drive contains any plastic or rubber component, have the fan and drive inspected by a qualified mechanic after operation or exposure to excessively high temperatures (air temperature of over 120ºC).
Page 15 INDEX DATE Dep. 1 IC-G-D-60-002e July 2015 SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES O&M_2.002211.810_A_10_2016 18. CLEANING SOLVENT CAUTION Use approved cleaning solvents in a well ventilated area. Do not breathe fumes as some vapours can be fatal. Keep away from open flames or sparks. Do not use gasoline or paint thinners or other highly volatile fluids for cleaning.
Page 16: Compressed Air
INDEX DATE Dep. 1 IC-G-D-60-002e July 2015 SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES O&M_2.002211.810_A_10_2016 22. BATTERIES CAUTION Always disconnect the battery ground connection from batteries before performing any work on the engine or equipment. This will prevent sparks or burns when accidentally shorting an electrical connection.
Page 17 INDEX DATE Dep. 1 IC-G-D-60-002e July 2015 SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES O&M_2.002211.810_A_10_2016 26. SAFETY PRACTICES FOR HANDLING ACIDS Cleaning with acid for certain castings and pieces of equipment is frequent. In handling them, follow these recommendations: Avoid contact with skin, clothing and eyes.
Page 18 In this event, Kohler informs users of any residual hazards due to the incomplete effectiveness of the protective measures, advising them that they must have specific training and use personal protective equipment where necessary.
Page 19 This section reviews the design solutions implemented to overcome any machine-specific risks and the preventive measures against unavoidable risks. Kohler will not be liable for any injury or damage arising from any use of the engine other than that described in the instruction manual. Operating the engine beyond its nominal conditions (e.g. in terms of power, ignition advance, mixture strength - carburetion, etc) can have serious consequences for the user or even put the user's life at risk and cause extensive material damage.
Page 20 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-60-003e May 2016 REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY SAFETY REGULATIONS AND "CE" MARK O&M_2.002211.810_A_10_2016 4.5.3. FORCED INDUCTION In the supercharging circuit (downstream of the turbocharger), the components are sealed is mechanically with Viton O-rings. Rubber sleeves and other materials have been totally discarded. 4.5.4.
Page 21 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-60-003e May 2016 REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY SAFETY REGULATIONS AND "CE" MARK O&M_2.002211.810_A_10_2016 4.9. FUEL SYSTEM  GAS The gas system design always conforms to the applicable regulations (UNE 60.620) and comprises the following elements: ERM.
Page 22 (including information about the machine’s weight), installation, assembly, disassembly, adjustment, maintenance (preventive and corrective), and counter-indications. Kohler has prepared an instruction manual in Spanish, English, French, German and Italian. This manual must be kept close to the machine, when put into service. The mechanic's handbook, intended for specialist staff who source from the manufacturer, is available in English or Spanish.
Page 23 The instruction manuals include all necessary drawings and diagrams to install, operate, maintain and inspect the machine and check it for correct operation, and make any repair, if needed, in addition to other relevant recommendations, especially in relation to safety issues. Kohler has prepared the following manuals in compliance with the Machinery Safety Directive: Installation Manual (installation and start-up).
Page 24: Safety Precautions
7. CONCLUSION The above review allows us to conclude that Kohler engines have been designed in full awareness of and in compliance with the machinery safety regulations requirements, as specified in Directive 2006/42/EC and the harmonised standards UNE-EN ISO 12100-1 and UNE-EN ISO 12100-2. Consequently, it is right to issue the relevant Declaration of Conformity and to use the "CE"...
Page 25 SOUND PRESSURE LEVEL IN GAS ENGINES O&M_2.002211.810_A_10_2016 1. INTRODUCTION The purpose of this information is to define the noise emission levels in Kohler gas engines. 2. ACOUSTIC DEFINITIONS Decibel Logarithmic unit that relates an energy magnitude with another, similar, magnitude accepted as a reference.
Page 26 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-00-042e March 2015 SOUND PRESSURE LEVEL IN GAS ENGINES O&M_2.002211.810_A_10_2016 Notes Sound power levels obtained as per the ISO 9614-2 standard. Sound pressure levels measured at 1 m from the engine, calculated as per the UNE-EN ISO-11203:1996 standard.
Page 27 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-00-042e March 2015 SOUND PRESSURE LEVEL IN GAS ENGINES O&M_2.002211.810_A_10_2016 5. NOISE EMISSION AT 1800 RPM The following table shows the sound pressure distribution in octave frequency bands and the total sound level with the engine running continuously at 1800 rpm and at 100% power. F/SFGLD/SFGM ENGINES 1000...
Page 28 IN THE GAS ENGINES EXHAUST AREA O&M_2.002211.810_A_10_2016 1. INTRODUCTION The purpose of this information is to define the noise emission levels in the Kohler gas engine exhausts. 2. ACOUSTIC DEFINITIONS Decibel Logarithmic unit that relates an energy magnitude with another, similar, magnitude accepted as a reference.
Page 29 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-00-043e July 2016 SOUND PRESSURE LEVEL IN THE GAS ENGINES EXHAUST AREA O&M_2.002211.810_A_10_2016 Notes Sound power levels obtained as per the ISO 9614-2 standard. Sound pressure levels measured at 1 m from the engine, calculated as per the UNE-EN ISO-11203:1996 standard.
Page 30 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-00-043e July 2016 SOUND PRESSURE LEVEL IN THE GAS ENGINES EXHAUST AREA O&M_2.002211.810_A_10_2016 5. NOISE EMISSION AT 1800 RPM The following table shows the sound pressure distribution in octave frequency bands and the total sound level with the engine running continuously at 1800 rpm and at 100% power.
Page 31 O&M_2.002211.810_A_10_2016 1. INTRODUCTION Waste generated during the maintenance of Kohler equipment, or at the end of their useful life, demands environmentally correct management. This guide establishes adequate environment-friendly waste management procedures that aim at keeping the environmental impact as low as possible and at boosting waste recycling and valorisation processes.
Page 32 PRODUCT INFORMATION INDEX DATE Dep.2 IO-C-M-00-004e February 2012 GUIDE TO ENVIRONMENT-FRIENDLY WASTE MANAGEMENT DURING PRODUCT MAINTENANCE AND AT END OF LIFE O&M_2.002211.810_A_10_2016 3. STAFF TRAINING Operators in charge of decontamination and disassembly shall receive adequate information and training to ensure they qualify to do the jobs involved. Besides maintenance of the equipment to prevent contamination in the event of accidental spillage or leakage, training shall cover safety procedures in relation to: (i) the storage and labelling of hazardous chemicals (pollutant, inflammable, toxic, harmful, etc.);...
Page 33 Asbestos. Asbestos is classified as a toxic and hazardous (carcinogenic) substance. Presently, there is a ban put on its marketing and use. Kohler machines are free from asbestos. Decontamination process waste and handling waste. Management of hazardous waste resulting from the decontamination process shall conform to the following.
Page 34 PRODUCT INFORMATION INDEX DATE Dep.2 IO-C-M-00-004e February 2012 GUIDE TO ENVIRONMENT-FRIENDLY WASTE MANAGEMENT DURING PRODUCT MAINTENANCE AND AT END OF LIFE O&M_2.002211.810_A_10_2016 5. WASTE MANAGEMENT Effective management of the Hazardous Waste Products deriving from machine maintenance and end of life starts with appropriate packaging, labelling and storage at the operating site.
Page 35 PRODUCT INFORMATION INDEX DATE Dep.2 IO-C-M-00-004e February 2012 GUIDE TO ENVIRONMENT-FRIENDLY WASTE MANAGEMENT DURING PRODUCT MAINTENANCE AND AT END OF LIFE O&M_2.002211.810_A_10_2016 Hazardous Waste Register. Every company that produces hazardous waste shall keep a Register in such conditions as the prevailing legislation provides. Storage of Hazardous Waste.
Page 36 INDEX Chapter 2 2.002211.810_A 10-2016 ENGINE TECHNICAL DESCRIPTION OPERATION & MAINTENANCE MANUAL SFGLD “V” KOHLER CO – PRIME / STAND BY O&M_2.002211.810_A_10_2016 CHAPTER 2 – ENGINE TECHNICAL DESCRIPTION 2.1 General IC-G-D-00-039e_F Gas engines identification plates and characteristics 2.1.1 IC-G-D-00-253e Emissions plate of Epa certified engines 2.1.9...
Page 37 INDEX Chapter 2 2.002211.810_A 10-2016 ENGINE TECHNICAL DESCRIPTION OPERATION & MAINTENANCE MANUAL SFGLD “V” KOHLER CO – PRIME / STAND BY O&M_2.002211.810_A_10_2016 2.7 Exhaust IC-C-D-40-003e_A Oxidative catalytic converters 2.7.1 IC-G-D-40-002e_B Exhaust system and ventilation of the oil sump 2.7.7 2.8 Starter...
Page 38 HGM 420/560 on the bottom right front panel of the water distribution box (See Fig. 4). NOTE When asking Kohler A Siemens Businessfor information and spare parts, please state the engine model and serial number. Fig. 1 – KOHLER Gas Engine Identification Plate...
Page 39 PRODUCT INFORMATION INDEX DATE Dep.1 IC-G-D-00-039e January 2015 GAS ENGINES IDENTIFICATION PLATES AND CHARACTERISTICS O&M_2.002211.810_A_10_2016 Fig. 2 – Identification Plate Location on 180/240 Series Engines 2.1.2...
Page 40 PRODUCT INFORMATION INDEX DATE Dep.1 IC-G-D-00-039e January 2015 GAS ENGINES IDENTIFICATION PLATES AND CHARACTERISTICS O&M_2.002211.810_A_10_2016 Fig. 3 – Identification Plate Location on 360/480/560 Series Engines 2.1.3...
Page 41 PRODUCT INFORMATION INDEX DATE Dep.1 IC-G-D-00-039e January 2015 GAS ENGINES IDENTIFICATION PLATES AND CHARACTERISTICS O&M_2.002211.810_A_10_2016 Fig. 4 – Identification Plate Location on “HGM 420/560” Engines 2.1.4...
Page 42 PRODUCT INFORMATION INDEX DATE Dep.1 IC-G-D-00-039e January 2015 GAS ENGINES IDENTIFICATION PLATES AND CHARACTERISTICS O&M_2.002211.810_A_10_2016 2. CHARACTERISTICS PLATE The characteristics plate provides engine operating data including: Firing order, ignition timing, valve adjustment, auxiliary circuit temperature, type of gas to be used, and compression ratio. Fig.
Page 43 PRODUCT INFORMATION INDEX DATE Dep.1 IC-G-D-00-039e January 2015 GAS ENGINES IDENTIFICATION PLATES AND CHARACTERISTICS O&M_2.002211.810_A_10_2016 Fig. 7 - Characteristics Plate “360/420 Series” Engines Fig. 8 - Characteristics Plate “480/560 Series” Engines 2.1.6...
Page 44 PRODUCT INFORMATION INDEX DATE Dep.1 IC-G-D-00-039e January 2015 GAS ENGINES IDENTIFICATION PLATES AND CHARACTERISTICS O&M_2.002211.810_A_10_2016 Fig. 9 – Characteristics Plate Location on “180/240 Series” Engines 2.1.7...
Page 45 PRODUCT INFORMATION INDEX DATE Dep.1 IC-G-D-00-039e January 2015 GAS ENGINES IDENTIFICATION PLATES AND CHARACTERISTICS O&M_2.002211.810_A_10_2016 Fig. 10 – Characteristics Plate Location on “360/420/480/560 Series” Engines 2.1.8...
Page 46 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-00-253e April 2016 EMISSIONS PLATE OF EPA CERTIFIED ENGINES O&M_2.002211.810_A_10_2016 1. ENGINE IDENTIFICATION PLATE The emissions plate of the engines with EPA certification under 40 CFR part 60 subpart JJJJ includes the following information: ENGINE FAMILY: EPA certification code corresponding to the engine model ENGINE DISPLACEMENT: in litres MAX.RATED KW: maximum engine power (the nominal engine power except for Prime applications...
Page 47 The next table shows the different engine codes (ENGINE FAMILY) the certified engines have been categorized xGSRB18.0180 SFGLD180 continuous xGSRB24.0240 SFGLD240 continuous, Prime xGSRB36.0360 SFGLD360 continuous, Prime xGSRB48.0480 SFGLD480 continuous, Prime xGSRB56.0560 SFGLD560 continuous xGSRB24.240E SFGLD240 Stand-by xGSRB36.360E SFGLD360 Stand-by xGSRB48.480E...
Page 48 HGM engines supercharged by high-compression ratio turbocharger and intercooler, with lean burn technology (Lambda=1.4 / 1.7) and low-pressure air/gas mixture. Kohler engines can operate on gases with different calorific capacities (LHV), see Product Information IC-G-D-30-001e. 2. GENERAL DESCRIPTION OF THE CONSTRUCTION OF THE ENGINE 2.1.
Page 49 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-00-040e May 2016 GAS ENGINES GENERAL DESCRIPTION OF CONSTRUCTION O&M_2.002211.810_A_10_2016 It is of the suspended block type for which reason it is secured with nodular cast iron caps and alloy steel studs, making the engine assembly very sturdy. The crankshaft bearings, crankpins and radii (bends) are induction-tempered to ensure surface hardness and better performance and longer life for the crankshaft.
Page 50 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-00-040e May 2016 GAS ENGINES GENERAL DESCRIPTION OF CONSTRUCTION O&M_2.002211.810_A_10_2016 2.9. CAMSHAFT The camshafts (one for in-line and two in V-engines) are made from alloy steel and induction tempered or case hardened (HGM and SFGM). The cams have been calculated to optimise the operation of all the engine distribution;...
Page 51 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-00-040e May 2016 GAS ENGINES GENERAL DESCRIPTION OF CONSTRUCTION O&M_2.002211.810_A_10_2016 2.14. INTAKE All the engines are supplied with an air filter system. Once the mixture has been made, it flows through the intake manifold immediately on a naturally aspirated engine, or after passing through the compressor and intercooler on a supercharged engine.
Page 52 Auxiliary water /55 /(131) /32 /(90) ºC / °F temperature /(176) /55 /(131) LUBRICATION SYSTEM Natural gas KOHLER MOTOROIL 3040 Plus See IC-G-D-25-003 Type of oil Biogas / Syngas MOTOROIL 2040 See IC-G-D-25-002 KOHLER MOTOROIL 99.27.046 KOHLER Propane ---------------------- See IC-G-D-25-004...
Page 53 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-00-036e March 2015 TABLE OF TECHNICAL CHARACTERISTICS FGLD/SFGLD/SFGM "V" GAS ENGINES O&M_2.002211.810_A_10_2016 Approximate oil gr/kWh / 0.35 / (0.26) 0.20 / (0.15) 0.10 / (0.07) consumption (gr/hphr) COMBUSTION SYSTEM Type of Lean burn (Lambda = 1.3 / 1.7) combustion FGLD: Fuel ratio regulation by adjusting screw (manual-mechanical carburetion) Regulation...
Page 54 PRODUCT INFORMATION INDEX DATE Dep. 8 IC-G-D-00-151e February 2015 DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS ENGINES O&M_2.002211.810_A_10_2016 Fig. 1 – Right side view 2.1.17...
Page 55 PRODUCT INFORMATION INDEX DATE Dep. 8 IC-G-D-00-151e February 2015 DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS ENGINES O&M_2.002211.810_A_10_2016 Fig. 2 – Left side view 2.1.18...
Page 56 PRODUCT INFORMATION INDEX DATE Dep. 8 IC-G-D-00-151e February 2015 DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS ENGINES O&M_2.002211.810_A_10_2016 Fig. 3 – Top view 2.1.19...
Page 57 PRODUCT INFORMATION INDEX DATE Dep. 8 IC-G-D-00-151e February 2015 DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS ENGINES O&M_2.002211.810_A_10_2016 Fig. 4 – Front view 2.1.20...
Page 58 PRODUCT INFORMATION INDEX DATE Dep. 8 IC-G-D-00-151e February 2015 DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS ENGINES O&M_2.002211.810_A_10_2016 Fig. 5 – Rear view 2.1.21...
Page 59 PRODUCT INFORMATION INDEX DATE Dep. 8 IC-G-D-00-151e February 2015 DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS ENGINES O&M_2.002211.810_A_10_2016 Crankcase Connecting rod inspection door Rocker arm inspection doors Oil pan Flywheel housing Front gear cover Cylinder head Rocker arm cover Filter Crankase gas recirculation Flywheel Vibration damper...
Page 60 PRODUCT INFORMATION INDEX DATE Dep. 8 IC-G-D-00-151e February 2015 DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS ENGINES O&M_2.002211.810_A_10_2016 Turbocharger Air cooler drain Water circuit drain Lubrication pump Wiring Box 220V Wiring Box 24V Oil filling plug Battery charge Water preheating 2.1.23...
Page 61 PRODUCT INFORMATION INDEX DATE Dep. 2 IM-G-C-00-002e January 2015 GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL ENGINES O&M_2.002211.810_A_10_2016 REFERENCE GAPS & LIMITS (mm) ITEM FGLD/SFGLD/SFGM/SFE Normal Limit DISTRIBUTION Central / Front / Rear Central / Front / Rear Camshaft bushing Ø...
Page 62 PRODUCT INFORMATION INDEX DATE Dep. 2 IM-G-C-00-002e January 2015 GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL ENGINES O&M_2.002211.810_A_10_2016 REFERENCE GAPS & LIMITS (mm.) ITEM FGLD/SFGLD/SFGM/SFE Normal Limit Clearance of ring 1 in groove 1 0.05 to 0.085 0.15 Clearance of ring 2 in groove 2 0.05 to 0.082 0.15...
Page 63 PRODUCT INFORMATION INDEX DATE Dep. 2 IM-G-C-00-002e January 2015 GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL ENGINES O&M_2.002211.810_A_10_2016 REFERENCE GAPS & LIMITS (mm) ITEM SFGLD/SFGM 560 Normal Limit DISTRIBUTION Central / Front / Rear Central / Front / Rear Camshaft bushing Ø...
Page 64 PRODUCT INFORMATION INDEX DATE Dep. 2 IM-G-C-00-002e January 2015 GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL ENGINES O&M_2.002211.810_A_10_2016 REFERENCE GAPS & LIMITS (mm.) ITEM SFGLD/SFGM 560 Normal Limit Clearance of ring 1 in groove 1 Clearance of ring 2 in groove 2 0.05 to 0.085 0.15 Clearance of ring 3 in groove 3...
Page 65 PRODUCT INFORMATION INDEX DATE Dep. 2 IM-G-C-00-002e January 2015 GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL ENGINES O&M_2.002211.810_A_10_2016 REFERENCE GAPS & LIMITS (mm) ITEM HGM 420 / 560 Normal Limit DISTRIBUTION Central / Front / Rear Central / Front / Rear Camshaft bushing Ø...
Page 66 PRODUCT INFORMATION INDEX DATE Dep. 2 IM-G-C-00-002e January 2015 GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL ENGINES O&M_2.002211.810_A_10_2016 REFERENCE GAPS & LIMITS (mm) ITEM HGM 420 / 560 Normal Limit Clearance of ring 1 in groove 1 Clearance of ring 2 in groove 2 0.060 to 0.095 0.15 Clearance of ring 3 in groove 3...
Page 67 PRODUCT INFORMATION INDEX DATE Dep. 2 IM-G-C-00-002e January 2015 GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL ENGINES O&M_2.002211.810_A_10_2016 Other considerations for taking into account with all the engines: The connecting rods and their bearing caps are marked with matching identification numbers in addition to the relevant cylinder number for assembly purposes.
Page 68 PRODUCT INFORMATION INDEX DATE Dep. 1 IM-G-C-00-001e January 2015 TIGHTENING TORQUES FOR GAS AND ETHANOL ENGINES O&M_2.002211.810_A_10_2016 In line 180/240 TIGHTENING TORQUE ITEM REFERENCE Kgm. ENGINE BLOCK Bearing capscrew (See IM-C-C-10-001e) 804* Bearing cap cross bolt (See IM-C-C-10-001e) 128* Cylinder head stud to crankcase (with Loctite 511) MOVING PARTS Counterweight to crankshaft capscrew 28.5*...
Page 69 PRODUCT INFORMATION INDEX DATE Dep. 1 IM-G-C-00-001e January 2015 TIGHTENING TORQUES FOR GAS AND ETHANOL ENGINES O&M_2.002211.810_A_10_2016 FGLD/SFGLD/SFGM 360/480/560 TIGHTENING TORQUE ITEM REFERENCE Kgm. ENGINE BLOCK Bearing cap fixing stud Bearing cap nut (See IM-C-C-10-001e) 102* 1001* Bearing cap cross bolt (See IM-C-C-10-001e) 275* Cylinder head stud to crankcase (with Loctite 511) Cyl.
Page 70 PRODUCT INFORMATION INDEX DATE Dep. 1 IM-G-C-00-001e January 2015 TIGHTENING TORQUES FOR GAS AND ETHANOL ENGINES O&M_2.002211.810_A_10_2016 HGM 420 / 560 TIGHTENING TORQUE ITEM REFERENCE Kgm. ENGINE BLOCK Bearing cap fixing stud Bearing cap nut (See IM-C-C-10-001e) 102* 1001* Bearing cap cross bolt (See IM-C-C-10-001e) 275* Cylinder head stud to crankcase (with Loctite 511) MOVING PARTS...
Page 71 PRODUCT INFORMATION INDEX DATE Dep.2 IM-C-C-00-002e February 2012 TIGHTENING TORQUES FOR COMMERCIAL BOLTS & NUTS O&M_2.002211.810_A_10_2016 1. STANDARD TIGHTENING TORQUE SPECIFICATION Tabulated below are the tightening torques for commercial bolts and nuts according to their metric threads and grades. GRADE THREAD 10.9 12.9...
Page 72 PRODUCT INFORMATION INDEX DATE Dep.2 IM-C-C-00-002e February 2012 TIGHTENING TORQUES FOR COMMERCIAL BOLTS & NUTS O&M_2.002211.810_A_10_2016 Coefficient of friction Coating Normal Lubricated Steel with cadmium 0.07 0.07 Cadmium with zinc 0.08 Cadmium with cadmium 0.07 Steel with phosphate 0.11 Phosphate with cadmium 0.11 0.08 Phosphate with zinc...
Page 73 PRODUCT INFORMATION INDEX DATE Dep.2 IM-C-C-00-002e February 2012 TIGHTENING TORQUES FOR COMMERCIAL BOLTS & NUTS O&M_2.002211.810_A_10_2016 3. AUXILIARY SCREW DRIVING PRODUCTS All screwed joints must have all their parts perfectly clean and assembled applying oil to the threads. For special applications, different products are usable for assembly.
Page 74 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-00-025e December 2013 UNITS CONVERSION O&M_2.002211.810_A_10_2016 Length 25.4 mm 0.039370 in 1 inch (in) 2.54 cm 1 mm 0.0032808 ft 0.0254 m 0.0010936 yd 304.8 mm 0.39370 in 12 in 10 mm 30.48 cm 0.032808 ft 1 foot (ft) 1 cm...
Page 75 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-00-025e December 2013 UNITS CONVERSION O&M_2.002211.810_A_10_2016 Energy 1.0551 kJ 1 kJ 1 Btu 0.94782 Btu 0.00029307 kWh (0.00027778 KWh) Temperature ºF = ºC x 1,8 + 32 K = ºC + 273,15 Presure In HG in H kg/cm 2.0360...
Page 76 2014 ONE CIRC CUIT COOL LING SYST TEM FOR GAS V-EN NGINES O&M_2.002211.810_A_10_2016 1 INTRO ODUCTION KOHLER engines req quire a cooli ing system a able to dissi pate the the ermal energy y they gener rate when in operation.
Page 77 PRODUCT INFOR RMATION INDEX DATE Dep. T-G-A-20- -025e Sept tember 2014 ONE CIRC CUIT COOL LING SYST TEM FOR GAS V-EN NGINES O&M_2.002211.810_A_10_2016 2.1 ENGINE E-MOUNTED D COOLING CIRCUIT 2.1.1 JACK KET WATER R CIRCUIT The main p ump draws c cold water fr rom the exte ernal cooling...
Page 78 PRODUCT INFOR RMATION INDEX DATE Dep. T-G-A-20- -025e Sept tember 2014 ONE CIRC CUIT COOL LING SYST TEM FOR GAS V-EN NGINES O&M_2.002211.810_A_10_2016 Figure 3– J Jacket Water r cooling syst tem. (LEFT S SIDE VIEW) 2.1.2 OILC COOLER AND D INTERCO OLER CIRC CUIT...
Page 79 PRODUCT INFOR RMATION INDEX DATE Dep. T-G-A-20- -025e Sept tember 2014 ONE CIRC CUIT COOL LING SYST TEM FOR GAS V-EN NGINES O&M_2.002211.810_A_10_2016 igure 5 Plate es Oilcooler a and intercoo Oilcooler r inlet pipe ntercooler Oilcooler ntercooler ou utlet pipe Oilcooler r outlet pipe Thermostatic...
Page 80 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-20-025e September 2014 ONE CIRCUIT COOLING SYSTEM FOR GAS V-ENGINES O&M_2.002211.810_A_10_2016 3 COOLING SYSTEM COMPONENTS 3.1 IMPELLER PUMP Responsible for passing the right amount and pressure of cooling water past all elements of the engine. This is a timing gear-driven centrifugal pump located on the front left side of the engine.
Page 81 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-20-025e September 2014 ONE CIRCUIT COOLING SYSTEM FOR GAS V-ENGINES O&M_2.002211.810_A_10_2016 3.5 WATER PREHEATING SYSTEM This is an auxiliary system that allows the engine cooling water to be at the optimum temperature when the engine starts from cold.
Page 82 PRODUCT INFOR RMATION INDEX DATE Dep. T-G-A-20- -025e Sept tember 2014 ONE CIRC CUIT COOL LING SYST TEM FOR GAS V-EN NGINES O&M_2.002211.810_A_10_2016 mostates ho ucing mostatic Val Purg 3.7 VENT An element that purges any possible e air pockets s from the cir rcuit while the e cooling circ...
Page 83 The cooling circuit should be sized taking into account these variations, as well as taking into account the fact that the cooling system may well get dirty. KOHLER recommends having a reserve capacity of 15%.
Page 84 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-20-007e May 2015 GAS ENGINES – PRESSURE LOSSES AND FLOWRATES O&M_2.002211.810_A_10_2016 1. INTRODUCTION When calculating pressure losses in the cooling circuits of gas engines. Product Information Datasheets IT-C-A-20-001e and IT-C-A-20-002e apply. The former explains how to calculate pressure losses based on the components layout.
Page 85 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-20-007e May 2015 GAS ENGINES – PRESSURE LOSSES AND FLOWRATES O&M_2.002211.810_A_10_2016 2. MINIMUM FLOWRATES FOR FGLD ENGINES 2.1 MAIN COOLING CIRCUIT Speed Minimum flowrate Delta P Engine [rpm] [bar] FGLD180 1500 0.28 4.5·10 FG180 1800 0.41 FGLD240...
Page 86 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-20-007e May 2015 GAS ENGINES – PRESSURE LOSSES AND FLOWRATES O&M_2.002211.810_A_10_2016 3. MINIMUM FLOWRATES FOR SFGLD / SFGRD / SFGM ENGINES 3.1 MAIN COOLING CIRCUIT – TWO CIRCUITS Speed Minimum flowrate Delta P Engine [rpm] [bar] 1200...
Page 87 80 (120 Main C) 0.73 1.16·10 1200 0.25 1.13·10 40 – 55 (90 Main C) 0.45 1.13·10 1500 55 (120 Main C) 0.46 1.16·10 SFGLD480 0.47 1.18·10 0.71 1.13·10 1800 0.74 1.18·10 1200 0.25 SFGLD560 1.13·10 1500 32 – 55 0.71...
Page 88 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-20-007e May 2015 GAS ENGINES – PRESSURE LOSSES AND FLOWRATES O&M_2.002211.810_A_10_2016 3.4 AUXILIARY COOLING CIRCUIT. DOUBLE-STAGE AIRCOOLER Minimum Speed Temperature Delta P Flowrate Engine [rpm] [ºC] [bar] 1200 0.47 SFGLD/SFGRD/SFGM 360 2.06·10 1500 40 – 55 1.09 1800 1.29...
Page 89 Engine Oil cooler Aircooler Thermostat Box SFGLD/SFGRD/SFGM180 YES (1 Thermostat) SFGLD/SFGRD/SFGM240 YES (1 Thermostat) SFGLD360 YES (2 Thermostats) SFGLD480 YES (2 Thermostats) SFGLD560 YES (2 Thermostats) 5.3 AUXILIARY COOLING CIRCUIT. DOUBLE-STAGE AIRCOOLER Engine Oil cooler Aircooler Thermostat Box SFGLD/SFGRD/SFGM360 YES (2 Thermostats)
Page 90 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-20-007e May 2015 GAS ENGINES – PRESSURE LOSSES AND FLOWRATES O&M_2.002211.810_A_10_2016 5.4 COOLING CIRCUIT HGM 5.4.1. Main Cooling Circuit Distribution box Motor Cyl. Block Oil cooler Thermostat Box 19.20.C60 HGM240 YES (4 Thermostats) HGM420 YES (6 Thermostats-Dist.
Page 91 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-25-005e February 2012 DESCRIPTION OF LUBRICATION SYSTEM FOR “V” ENGINES O&M_2.002211.810_A_10_2016 1. INTRODUCTION The purpose of the engine lubrication system is to: Provide pressurised oil for hydrodynamic lubrication, minimizing friction between parts moving in relation to each other (crankshaft, connecting rods, etc.).
Page 92 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-25-005e February 2012 DESCRIPTION OF LUBRICATION SYSTEM FOR “V” ENGINES O&M_2.002211.810_A_10_2016 2.3. OVERPRESSURE SAFETY VALVE The overpressure safety valve or relief valve lies at the outlet of the oil pump. Its function is to control pressure and discharge oil directly to the sump if the impulse pressure exceeds the rated pressure (8 bar / 116 psi), thus protecting engine components from failure.
Page 93 2.12. BLOW-BY GAS EXHAUST SYSTEM KOHLER engines can come with a passive or an active blow-by gas exhaust system. 2.12.1. Open or passive system (for diesel, gas and ethanol engines) The commonest standard blow-by gas exhaust system is the open system with an oil separator followed by an exhaust pipe to the outside.
Page 94 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-25-005e February 2012 DESCRIPTION OF LUBRICATION SYSTEM FOR “V” ENGINES O&M_2.002211.810_A_10_2016 Oil pump Safety valve Regulation valve Thermostat valve Oil cooler Clogged filter valve Oil filters Jet pressure valve Oil sump 3. OPERATION Oil is drawn from the sump through the grille in the suction tube by means of the oil pump. The pump supplies a specific flow of oil at a certain pressure.
Page 95 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-25-005e February 2012 DESCRIPTION OF LUBRICATION SYSTEM FOR “V” ENGINES O&M_2.002211.810_A_10_2016 through the shaft orifices to the oiling holes of the intake and exhaust valve rockers and to the valve stems. The rest of the cylinder head is spray-lubricated. Finally, on diesel engines, oil will lubricate the injection pump drive.
Page 96 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-25-005e February 2012 DESCRIPTION OF LUBRICATION SYSTEM FOR “V” ENGINES O&M_2.002211.810_A_10_2016 MAIN LUB. GALLERY COOLER SAFETY PRES. Aux. Main GEAR VALVE REG. VALVE Camshaft rocker rocker Rockers PUMP P > 8 bar P > 4,5 bar shaft shaft Injection pump drive (1)
Page 97 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-002e March 2015 AUTOMATIC ENGINE OIL LEVEL CONTROLLER O&M_2.002211.810_A_10_2016 1. INTRODUCTION If engine-driven equipment is intended for 24-hour operation or similar, it is recommended that the engine should be fitted with an oil level controller. Fig.
Page 98 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-002e March 2015 AUTOMATIC ENGINE OIL LEVEL CONTROLLER O&M_2.002211.810_A_10_2016 MT-90 Digital Tachometer °C Fig. 3 – General layout on 360/480/560 series engines/generating sets Automatic oil level controller Oil tank Filling hose Oil sump to level controller hose Venting hose Lube oil level indicator (Refer to IT-C-A-25-009e or IT-G-A-25-009e) Fig.
Page 99 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-002e March 2015 AUTOMATIC ENGINE OIL LEVEL CONTROLLER O&M_2.002211.810_A_10_2016 2. DESCRIPTION AND ASSEMBLY The oil level controller is a mechanical actuator placed on the oil sump at the bottom of the engine. It is equipped with a floater inside a small reservoir which opens or closes the oil flow into the engine crankcase.
Page 100 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-002e March 2015 AUTOMATIC ENGINE OIL LEVEL CONTROLLER O&M_2.002211.810_A_10_2016 When the engine is running, the oil level in the display must be within the normal operating range. When the engine is stopped due to oil backflow in the circuit, the oil level will exceed this range and overflow will occur, but once the engine has been started, it will return to its regular position.
Page 101 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-045e September 2015 LUBE OIL LEVEL INDICATOR UL O&M_2.002211.810_A_10_2016 1. INTRODUCTION The UL oil level indicator is a box with high and low limit adjustable switches. It provides protection against the high and low level of lubricant caused by overfilling of water inside the sump. Fig.
Page 102 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-045e September 2015 LUBE OIL LEVEL INDICATOR UL O&M_2.002211.810_A_10_2016 2. DESCRIPTION AND ASSEMBLY The function of this device is to trigger a warning alarm when the level reaches the defined low or high limit. Therefore, the high and low oil limits will vary according to the oil capacity of the sump for each model of engine, as shown hereafter.
Page 103 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-045e September 2015 LUBE OIL LEVEL INDICATOR UL O&M_2.002211.810_A_10_2016 Fig. 3 – V engines Layout The inside diameter of the outlet pipe to the sump must be at least 12 mm. The venting pipe to the sump must be 6 mm in outside diameter, connected to a point above the lubricant level and free of restriction due to bends or obstacles of any kind.
Page 104 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-045e September 2015 LUBE OIL LEVEL INDICATOR UL O&M_2.002211.810_A_10_2016 Fig. 5 – Low level sensor signal Fig. 6 – High level sensor signal 2.3.14...
Page 105 INDEX DATE Dep. 2 IT-C-A-25-030e January 2015 KOHLER POWER ENGINES SUBMERGED OIL PREHEATING SYSTEM O&M_2.002211.810_A_10_2016 1. INTRODUCTION The aim of preheating oil is to raise the oil temperature before starting the engine up to the appropriate minimum value (about 40ºC) that ensures adequate oil viscosity for loading the engine.
Page 106 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-030e January 2015 KOHLER POWER ENGINES SUBMERGED OIL PREHEATING SYSTEM O&M_2.002211.810_A_10_2016 ENGINE TYPE REFERENCE VOLTAGE POWER No. of Units 180/240 360/480 230 V/50 Hz 1500 W. SFGLD/SFGM/SFGRD 560 HGM 420/560 180/240 360/480 400 V/50Hz 1500 W.
Page 107 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-030e January 2015 KOHLER POWER ENGINES SUBMERGED OIL PREHEATING SYSTEM O&M_2.002211.810_A_10_2016 Fig. 5 - General Layout – HGM420/560 Engines 4. PERFORMANCE Warming expected from the proposed preheating system is 40ºC over 2 hours. 5. OPERATION Switching on/off of the preheating resistances is through a control integrated into the engine control panels, which assures thermal/magnetic protection of each resistance.
Page 108 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-25-006e January 2015 DESCRIPTION OF A CRANKCASE GAS RECIRCULATION SYSTEM O&M_2.002211.810_A_10_2016 1. INTRODUCTION The crankcase gas recirculation system of the engine, also called the active system, is intended to feed the flow of engine blow-by gases back into the intake air current in a clean and efficient manner and so: to eliminate one source of emissions, by burning these gases inside the engine, and thus to get one single exhaust in accordance with the prevailing legislation in different countries;...
Page 109 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-25-006e January 2015 DESCRIPTION OF A CRANKCASE GAS RECIRCULATION SYSTEM O&M_2.002211.810_A_10_2016 °C °F 12 0 °C °C ° F 1 20 B ARS ° C Fig.1: CGR on gas in-line engine FGLD/SFGLD. Fig 2: CGR on gas V-engine FGLD/SFGLD. Fig 3: CGR on HGM240 engine Fig 4: CGR on HGM 420/560 engine 2.1.
Page 110 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-25-006e January 2015 DESCRIPTION OF A CRANKCASE GAS RECIRCULATION SYSTEM O&M_2.002211.810_A_10_2016 2.2 Oil level controller. This is an oil level valve with a float that allows oil to pass into the crankcase and fill it when the level is too low, allowing the level to rise until it reaches the correct level before it cuts off the oil supply.
Page 111 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-25-006e January 2015 DESCRIPTION OF A CRANKCASE GAS RECIRCULATION SYSTEM O&M_2.002211.810_A_10_2016 2.4. Blow-by gas recirculation filter This is the real conditioner of the blow-by gases before entry into the air FILTRO RECIRCULACION GASES CARTER intake system.
Page 112 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-25-006e January 2015 DESCRIPTION OF A CRANKCASE GAS RECIRCULATION SYSTEM O&M_2.002211.810_A_10_2016 2.6. Oil feedback to crankcase Oil separated by the recirculation filter shall be fed back through a hose to the crankcase and always above the crankcase oil level.
Page 113 O&M_2.002211.810_A_10_2016 1. DESCRIPTION EGS 02 is the new control system for gas engines and it is suitable for the entire range of Kohler gas engines. These are the major features of the controller: Speed control (variable duty and island applications)
Page 114 PRODUCT INFORMATION INDEX DATE Dep.2 IC-G-D-50-003e January 2010 EGS 02. DESCRIPTION O&M_2.002211.810_A_10_2016 2. FUNCTIONALITIES 2.1 SPEED CONTROL EGS02 can ensure the engine runs at constant speed regardless of its load. Speed can be pre-programmed in the controller memory or changed externally by means of an analogue signal or through communications. 2.2 LOAD CONTROL Where EGS02 does not control speed, e.g.
Page 115 PRODUCT INFORMATION INDEX DATE Dep.2 IC-G-D-50-003e January 2010 EGS 02. DESCRIPTION O&M_2.002211.810_A_10_2016 3. EGS02 COMPLEMENTARY EQUIPMENT The EGS02 control system would keep to the following diagram: Air filter Carburetor Throttle valve 3.1 PICK-UP This sensor detects the teeth of the engine flywheel. From the teeth detection data, EGS02 can calculate the engine rotational speed.
Page 116 PRODUCT INFORMATION INDEX DATE Dep.2 IC-G-D-50-003e January 2010 EGS 02. DESCRIPTION O&M_2.002211.810_A_10_2016 3.4 THROTTLE VALVE By controlling the throttle valve, the EGS controller adjusts the amount of mixture fed into the engine. Controlling the throttle valve is the way the EGS can control the engine power or speed. 3.5 TECJET This is a valve controlling the amount of gas supplied to the engine.
Page 117 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-E-30-001e September 2015 VENTURI TYPE CARBURATION - DESCRIPTION O&M_2.002211.810_A_10_2016 1. INTRODUCTION A venturi-type carburation system comprises generically the following items: Zero Pressure Regulator (ZPR) Main Adjustment Screw (MAS) Carburettor (Mixer) CARBURATION SYSTEM Figure 1 Carburation system scheme In the case of electronic regulation, for the NOX sensor control or Lambda sensor control regulation, the main adjuxsting screw is changed by an electronic gas control valve.
Page 118 For this type of regulators (supplied by Kohler), the inlet gas pressure must not exceed 50 mbar. 3. GAS FLOW CONTROL 3.1 MAIN ADJUSTMENT SCREW (MAS) The main adjustment screw for the mixture ratio lies between regulator and carburettor.
Page 119 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-E-30-001e September 2015 VENTURI TYPE CARBURATION - DESCRIPTION O&M_2.002211.810_A_10_2016 Figure 3 Main Adjusting Screw 3.2 GAS CONTROL VALVE The gas control valve is a throttle valve, powered by an electric actuator and electronically controlled. It requires a zero pressure regulator before.
Page 120 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-E-30-001e September 2015 VENTURI TYPE CARBURATION - DESCRIPTION O&M_2.002211.810_A_10_2016 Figure 5 Gas Control Injector 4. CARBURETTOR A venturi-type carburettor consists of a barrel in a housing, which allows it to be mounted on the air intake manifold.
Page 121: Electronic Control
PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-E-30-001e September 2015 VENTURI TYPE CARBURATION - DESCRIPTION O&M_2.002211.810_A_10_2016 With a venturi type carburettor, the gas pressure need not be greater than the atmospheric pressure. Accordingly, the system includes a zero pressure regulator upstream of the carburettor. Since air and gas pressures are identical, a constant air-gas ratio is obtained throughout the operating range of the engine.
Page 122 The input pressure to Tecjet 52 must be in the range from 50 to 275 mbar (as shown on the graph-Fig. 1). For input gas pressure to Tecjet52 less than 50 mbar, consult Kohler. Accuracy may be adversely affected With the engine running, pressure drop in the Tecjet valve (delta-p) must be in the range 70-345 mbar.
Page 123 Where gas temperatures exceed the value used in the graph, the minimum pressure required for a given power will increase. Consult Kohler. Using a Tecjet 52 valve with a gas of very high volumetric Low Heat Value (LHV) may affect accuracy negatively, depending on the engine power and the gas pressure at the Tecjet.
Page 124 Tecjet52 gas temperature range: - 20 ºC to + 65 ºC Kohler recommended gas temperature in operation:+10 ºC to + 40 ºC 4. GAS FILTER To prevent damage, a 1μm or thinner mesh filter must be installed at the Tecjet gas intake.
Page 125 The ignition system manages and controls the ignition of the mixture in the combustion chamber. Firing must be accurately coordinated with the rotation of the engine and the movement of the valves of each cylinder. Two GIS ignition unit models are used by Kohler: GIS ignition unit GIS CSA ignition unit Both units have the same performance in operation.
Page 126 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-33-002e July 2013 DESCRIPTION OF THE GIS IGNITION SYSTEM O&M_2.002211.810_A_10_2016 Fig. 2 – GIS coil Fig. 3 – GIS high voltage lead Most items on the list are compatible with the CPU 95 electronic ignition system used up to now with SFGLD and HGM engines.
Page 127 The ignition system is configured at the factory. Field use of the ignition system may lead to improper engine operation and could cause serious engine damage and/or personal injury to operators and other personnel nearby. Check with Kohler Engineering Department for any queries concerning the ignition module. Do not manipulate the module without prior authorisation.
Page 128 The ignition module has an analogue input which, once configured, allows the advance ignition to be adjusted. The analogue signal can be intensity (4-20 mA) or voltage (0-10 V). With Kohler engines, this analogue input is connected to the Detcon and configured so that the ignition unit reduces the advance as the mA of the signal increase.
Page 129 It is a TTL level (5V) with a maximum intensity of +- 10 mA. With Kohler engines, this signal is used to control the Detcon, meaning that the ignition unit must be connected to the Detcon with a 2-wire screened cable.
Page 130 This means that the firmware version of the unit has to be changed to change the port used to connect to the PC. NOTE With Kohler engines, the units are pre-programmed for connecting to the PC via the USB port. The maximum USB cable length allowed is 5 metres. Potentiometers and reset button The unit has two potentiometers to adjust the advance: one for ignition schedule A and the other for ignition schedule B.
Page 131 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-33-002e July 2013 DESCRIPTION OF THE GIS IGNITION SYSTEM O&M_2.002211.810_A_10_2016 WARNING The reset button (in the GIS hardware) should not under any circumstances be pressed when the engine is in operation. Pressing the reset button cuts of ignition, which could lead to detonations in the exhaust and/or inlet manifolds.
Page 132 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-35-002e May 2016 GAS ENGINES INTAKE SYSTEM O&M_2.002211.810_A_10_2016 1. AIM The aim of this product information sheet is to describe the elements installed in series to make up the gas engine intake system. 2. INTRODUCTION The air intake system comprises the following elements mounted on the engine: Air filter.
Page 133 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-35-002e May 2016 GAS ENGINES INTAKE SYSTEM O&M_2.002211.810_A_10_2016 COVER CLAMP FILTERING ELEMENT CASING FOULING INDICATOR Fig. 2 - High-rate single-stage filter 4. TURBOCHARGER The turbocharger is installed in order to boost the air pressure fed into the intake manifold so that there is a dense air/fuel mixture in the combustion chamber.
Page 134 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-35-002e May 2016 GAS ENGINES INTAKE SYSTEM O&M_2.002211.810_A_10_2016 Air Filter Air Compressor Air Cooler Valves Piston Combustion Chamber Exhaust Turbine Non Compressed Air Hot Compressed Air 10 Intercooler Water Inlet 11 Intercooler Water Outlet 12 Cold Compressed Air Fig.
Page 135: Intake Manifold
PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-35-002e May 2016 GAS ENGINES INTAKE SYSTEM O&M_2.002211.810_A_10_2016 7. INTAKE MANIFOLD The design of the intake manifold includes special internal ribs that cause the flow to go in the right direction. In-Line Engines: The intake manifold lies on the left-hand side of the engine and distributes the mixture to the cylinders. V Engines: There are two intake manifolds: one on each side of the engine, distributing the mixture independently to the cylinders on its bank.
Page 136: Air Filters
Filter plugging occurs when pressure losses exceed 38mbar. The air filters fitted to Kohler engines can be used in dust-laden atmospheres of up to 15 mg/m . In case of greater dust concentration, it will be necessary to install mechanical air prefilters (refer to document IC-G-D-35-001e).
Page 137 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-35-001e September 2016 AIR FILTERS O&M_2.002211.810_A_10_2016 The figures below show exploded views of double-stage air filters, identifying their major components. Intake cap Fouling detector Clamp Safety cartridge S.C. washer Filter casing Main cartridge Front sealing ring Integrated axial sealing gaskets...
Page 138 PLC. The next figures show exploded views of the GHF air filter. COVER CLAMP FILTERING ELEMENT CASING FOULING INDICATOR Fig. 5 - Exploded view of Kohler High Flow two-cartridge air filters 2.6.7...
Page 139 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-35-001e September 2016 AIR FILTERS O&M_2.002211.810_A_10_2016 CASING CLAMP FILTERING ELEMENT COVER Fig. 6 - Exploded view of Kohler High Flow one-cartridge air filter 2.6.8...
Page 140 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-40-003e May 2012 OXIDATIVE CATALYTIC CONVERTERS O&M_2.002211.810_A_10_2016 1. OXIDATIVE CATALYTIC CONVERTERS Catalytic substrates consist of high-temperature resistant steel foils of alternating layers of corrugated and flat strips 100, 200, 300 or 400 cpsi (cells per square inch). The catalytic materials coated onto the surfaces of the channels consist of a refractory inorganic oxide, various substances which act as chemical promoters and stabilisers, and a combination of precious metals that can include platinum, palladium and...
Page 141 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-40-003e May 2012 OXIDATIVE CATALYTIC CONVERTERS O&M_2.002211.810_A_10_2016 The conversion efficiency of this type of oxidative catalytic converter is shown in the following table: NMHC CH2O HAPs Null 70-95% 40-90% 60-99% 60-99% 60-99% NMHC: Hydrocarbons (no methane) VOC: Volatile Organic Compounds.
Page 142 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-40-003e May 2012 OXIDATIVE CATALYTIC CONVERTERS O&M_2.002211.810_A_10_2016 The quality of the natural gas must be as specified in documents IP-GD-30 IC-001 and IC-GD-IP 30-002 on natural gas fuel. There must be no leaks from the exhaust system. There must be a minimum of 4% by volume of oxygen in the exhaust gas at the oxidative catalytic converter inlet.
Page 143 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-40-003e May 2012 OXIDATIVE CATALYTIC CONVERTERS O&M_2.002211.810_A_10_2016 The following diagram shows the overall trend as regards the degree of conversion of the catalytic converter for the different contaminants according to the exhaust gas temperature at the catalytic converter inlet. Fig.2 Reduction efficiencies according to contaminant, based on the temperature inside the catalytic converter These curves show general tendencies for oxidative catalytic converters.
Page 144 Sulphated Ash 0.6% weight Specific consumption In accordance with KOHLER specification IO-G-M-25-001 Table 3. Limit of harmful compounds entering the catalytic converter in the engine lubricating oil. 5. TECHNICAL LIMITATIONS OF COMBUSTION GAS AND EXHAUST GAS As with the lubricating oil, certain catalytic converter poisons can mix with the exhaust gas flow as a result of the combustion of the fuel used.
Page 145 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-40-003e May 2012 OXIDATIVE CATALYTIC CONVERTERS O&M_2.002211.810_A_10_2016 6. LOSS OF ACTIVITY IN THE CATALYTIC CONVERTER The activity of a catalytic converter drops progressively over time, although a series of mechanisms can cause said activity to be lost before the end of its useful life, significantly reducing exhaust pollutant reduction efficiency as shown on the following table: Mechanism Description...
Page 146: Exhaust System
PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-40-002e October 2010 EXHAUST SYSTEM AND VENTILATION OF THE OIL SUMP O&M_2.002211.810_A_10_2016 1. AIM This product information sheet describes the exhaust system and crankcase gas breather of GAS engines. 2. EXHAUST SYSTEM The exhaust system consists of the following components: Exhaust Manifold.
Page 147 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-40-002e October 2010 EXHAUST SYSTEM AND VENTILATION OF THE OIL SUMP O&M_2.002211.810_A_10_2016 Fig. 1 Example of dry exhaust manifold on a V-engine 4. TURBOCHARGER (Only in supercharged engines) A turbocharger is a centrifuge air compressor driven by a turbine that utilises the energy of the exhaust gases. It is an element of the air/fuel mixture system.
Page 148 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-40-002e October 2010 EXHAUST SYSTEM AND VENTILATION OF THE OIL SUMP O&M_2.002211.810_A_10_2016 5. EXHAUST GASES OUTLET LINE The exhaust gases produced by combustion leave the cylinders through the exhaust valves in the cylinder heads. They are expelled to the exhaust manifold during the up stroke of the pistons.
Page 149 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-40-002e October 2010 EXHAUST SYSTEM AND VENTILATION OF THE OIL SUMP O&M_2.002211.810_A_10_2016 Fig. 3 Arrangement of Crankcase Gas Breather 2.7.10...
Page 150 1. ELECTRIC STARTER 1.1. DESCRIPTION OF THE ELECTRIC STARTER SYSTEM The electric starters used to start all Kohler engines are standard commercially-available products, with a toothed pinion that moves linearly to engage with the flywheel gear. The electric starter pinion is operated with a start button. This pinion disengages as soon as the start button is released or when a tachometer relay detects a particular gear mesh frequency and disables the electric starter.
Page 151 The auxiliary start-up relay (4) should be fitted as close as possible to the engine, either in the terminal box or on the starter motor itself. The system has a series of batteries to power the electric starter. The standard batteries used by Kohler to start its engines are LEAD BATTERIES. The battery capacities are the minimum needed for the maximum current during start-up.
Page 152 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-55-001e June 2016 ELECTRIC STARTER O&M_2.002211.810_A_10_2016 Engine Voltage (V) Capacity 20 h (Ah) No of batteries in series H series E series FG/SFGLD/SFGM/SFGRD/HGM V engines, remote areas Table 2 - Battery properties for engine series The cross section of the power leads should be chosen according to the capacity of the battery chosen and the maximum length of the lead.
Page 153 PRODUCT INFORMATION INDEX DATE Dep. 3 IO-G-M-60-002e May 2016 FG/FGLD/SFGLD/SFGM/SFGRD ENGINES INSTRUMENTATION O&M_2.002211.810_A_10_2016 1. INTRODUCTION This document compiles the different variables that can be recorded on a FG/FGLD/SFGLD/SFGM/SFGRD engine with a view to setting up an operating safety chain. We classify the safety features in order of importance within two groups as follows: Minimum or obligatory safety measures Additional signals...
Page 154 PRODUCT INFORMATION INDEX DATE Dep. 3 IO-G-M-60-002e May 2016 FG/FGLD/SFGLD/SFGM/SFGRD ENGINES INSTRUMENTATION O&M_2.002211.810_A_10_2016 Table 1. Configuration of minimum engine protections. Measure Location Signal type Protection value Action Active > 105ºC (221ºF) Gradient shutdown Always Oil temperature Dual cooling circuit engines >...
Page 155 PRODUCT INFORMATION INDEX DATE Dep. 3 IO-G-M-60-002e May 2016 FG/FGLD/SFGLD/SFGM/SFGRD ENGINES INSTRUMENTATION O&M_2.002211.810_A_10_2016 Measure Location Signal type Protection value Action Active > 63ºC (145,4ºF) Alarm or warning Always Mixture Temperature Engines 90/55 and 120/55 (194/131ºF y 248/131ºF) > 65ºC (149ºF) Emergency shutdown Always >...
Page 156 PRODUCT INFORMATION INDEX DATE Dep. 3 IO-G-M-60-002e May 2016 FG/FGLD/SFGLD/SFGM/SFGRD ENGINES INSTRUMENTATION O&M_2.002211.810_A_10_2016 3. ADDITIONAL INSTRUMENTATION The following signals and/or protections can be included with the engine on express request of the client. . Table 2. Configuration of additional engine signals and/or protections Measure Location Signal type...
Page 157 PRODUCT INFORMATION INDEX DATE Dep. 3 IO-G-M-60-002e May 2016 FG/FGLD/SFGLD/SFGM/SFGRD ENGINES INSTRUMENTATION O&M_2.002211.810_A_10_2016 4. POWER REGULATION 4.1. OBLIGATORY Depending on ambient temperature, the power correction described in IC-G-B-00-001e should be made. 4.2. RECOMMENDED It is advisable to regulate the engine power according to reachable values (below the shutdown-triggering values) to avoid sudden shutdowns of the engine at facilities short of cooling.
Page 158 INDEX Chapter 3 2.002211.810_A 10-2016 HANDLING AND STORAGE INSTRUCTIONS OPERATION & MAINTENANCE MANUAL SFGLD “V” KOHLER CO – PRIME / STAND BY O&M_2.002211.810_A_10_2016 CHAPTER 3 – HANDLING AND STORAGE INSTRUCTIONS IM-G-C-00-004e_A ifting system for SFGLD/SFGM V engine 3.1.1 IO-C-M-00-001e_A Deferred start-up engine inspection and protection 3.1.7...
Page 159 PRODUCT INFORMATION INDEX DATE Dep. 8 IM-G-C-00-004e March 2016 LIFTING SYSTEM FOR SFGLD/SFGM V ENGINE O&M_2.002211.810_A_10_2016 1 GENERAL REGULATION CAUTION Always be careful when the lifting the engine or its components. Keep all the personnel away and do not walk under or around the engine when is lifted. WARNING Inspect all anchoring points to make sure that there are no faulty welds, loose bolts, etc., which could make the lifting of the engines dangerous.
Page 160 ODUCT INFORMA ATION INDEX DATE Dep. 8 -G-C-00-0 004e rch 2016 LIFTING G SYSTEM FOR SFG GLD/SFGM M V ENGIN O&M_2.002211.810_A_10_2016 2 PREPAR RATION 2.1 Use 10 to on crane and beams with 1,400 mm s separation be etween cente ers.
Page 161 ODUCT INFORMA ATION INDEX DATE Dep. 8 -G-C-00-0 004e rch 2016 LIFTING G SYSTEM FOR SFG GLD/SFGM M V ENGIN O&M_2.002211.810_A_10_2016 3.2 Do the sa ame with the other eyebo 4 REAR O OF ENGINE 4.1 Insert the e hook, (open n) in the two eyebolts...
Page 162 ODUCT INFORMA ATION INDEX DATE Dep. 8 -G-C-00-0 004e rch 2016 LIFTING G SYSTEM FOR SFG GLD/SFGM M V ENGIN O&M_2.002211.810_A_10_2016 4.3 So each s sling is direct ted toward e each side of t the engine. 4.4 Attach the e end of the sling to the p preassemble...
Page 163 ODUCT INFORMA ATION INDEX DATE Dep. 8 -G-C-00-0 004e rch 2016 LIFTING G SYSTEM FOR SFG GLD/SFGM M V ENGIN O&M_2.002211.810_A_10_2016 RESOURCES: E EQUIPMENT & PROCESSES 4.7 Operate t the crane tak king care not t to cause an ny friction or r rubbing agai nst the engin ne compone...
Page 164 2. DEFERRED START-UP STATUS APPLICATION REQUIREMENTS When planning to store a new engine for more than 6 months, the owner shall apply to Kohler for the deferred start-up status. In this event, Kohler authorised staff shall inspect and protect the engine fulfilling all the herein defined obligations.
Page 165 PRODUCT INFORMATION INDEX DATE Dep.1 IO-C-M-00-001e December 2007 DEFERRED START-UP ENGINE INSPECTION AND PROTECTION O&M_2.002211.810_A_10_2016 4. CONDITION OF ENGINES SUBJECT TO DEFERRED START-UP At the time Customer applies for the deferred start-up status, the engine can be in any of these conditions: stored in its original packaging;...
Page 166 DANGER The recommended protector contains oil distillates. Read the Material Safety Datasheet before use. Spray KOHLER MOTOROIL PROTECTOR inside all of the rocker arms covers while turning the engine  manually. Apply said protector to push rods, rocker arms, adjusting screws and valve springs.
Page 167 Dry the inside of the exhaust manifold and the camshaft housing, if found humid during inspection. Spray  KOHLER MOTOROIL PROTECTOR on the camshaft and, only in case of humidity, into the exhaust manifold. Spray a thin coat of TECTYL 506 or similar rust-preventive oil on the unpainted machined surfaces that will ...
Page 168 PRODUCT INFORMATION INDEX DATE Dep.1 IO-C-M-00-001e December 2007 DEFERRED START-UP ENGINE INSPECTION AND PROTECTION O&M_2.002211.810_A_10_2016 3.1.11...
Page 169 PRODUCT INFORMATION INDEX DATE Dep.1 IO-C-M-00-001e December 2007 DEFERRED START-UP ENGINE INSPECTION AND PROTECTION O&M_2.002211.810_A_10_2016 3.1.12...
Page 170 INDEX Chapter 4 2.002211.810_A 10-2016 OPERATING INSTRUCTIONS OPERATION & MAINTENANCE MANUAL SFGLD “V” KOHLER CO – PRIME / STAND BY O&M_2.002211.810_A_10_2016 CHAPTER 4 – OPERATING INSTRUCTIONS IT-G-A-00-011e_C Minimum room temperature for operating Gas engines 4.1.1 IO-C-M-15-002e_A Kohler Engine barring gear operating instructions 4.1.3...
Page 171 You should take into account the “Criteria for application of pre-lubrication, post-lubrication and oil and water pre-heating” described in document IC-C-D-00-008e. For lower room temperatures, check with Kohler. This limitation does not apply to the engine with single cooling circuit, like the emergency engines.
Page 172 If it is required to run the engine above of 30% of load with air inlet temperatures to the engine below 0ºC, it will be necessary to consult it with Kohler. In order to change the supply scope of these engines (out of standard).
Page 173 DATE Dep. 2 IO-C-M-15-002e March 2008 KOHLER ENGINE BARRING GEAR OPERATING INSTRUCTIONS O&M_2.002211.810_A_10_2016 1. USE OF THE BARRING GEAR The barring gear is located on the flywheel housing on the left side of the engine. It serves to turn the crankshaft during maintenance operations (valve setting, bore scoping, etc.).
Page 174: General Information
PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-20-001e February 2016 COOLING WATER QUALITY AND TREATMENT O&M_2.002211.810_A_10_2016 1. GENERAL INFORMATION When installing the engine, one point to bear in mind is the quality of the cooling water that will be used, in order to prevent heat transfer problems.
Page 175 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-20-001e February 2016 COOLING WATER QUALITY AND TREATMENT O&M_2.002211.810_A_10_2016 One of the most typical reactions is: Ca (HCO heat Ca CO Calcium bicarbonate Carbon dioxide Calcium carbonate highly soluble (760 mg/l. approx.) (hardly soluble 30 mg/l. approx.) The presence of scale has a significant impact on the performance and operation of the equipment, since some of its effects are: Reduction in heat transfer...
Page 176 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-20-001e February 2016 COOLING WATER QUALITY AND TREATMENT O&M_2.002211.810_A_10_2016 Minimum coolant requirements. PARAMETERS VALUE UNITS Transparent, neutral odour, free from Aspect and odour sediments pH value 25ºC Total hardness 35-170 / 2-9.5 ppm CO Ca / ºd Sulphates SO Max 100...
Page 177 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-20-001e February 2016 COOLING WATER QUALITY AND TREATMENT O&M_2.002211.810_A_10_2016 Natural water alkalinity generally derives from the presence of three types of ions: bicarbonates, carbonates and hydroxides. Some waters will contain other compounds (borates, silicates, phosphates, etc.) which contribute to their alkalinity;...
Page 178 The figure below can be used to check the recommended glycol ratio according to the ambient temperature. As a rule, where the objective is to increase the boiling temperature of water without it evaporating, Kohler recommends adding around 10% of glycol to the water, not only where there is risk of freezing. The antifreeze will not only prevent the possibility of the water boiling but it will also protect against possible corrosion thanks to its anticorrosive additives which antifreeze normally contains.
Page 179 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-20-001e February 2016 COOLING WATER QUALITY AND TREATMENT O&M_2.002211.810_A_10_2016 3. COOLANT TREATMENT Maintaining cooling water in good condition will avoid the aforementioned trouble with and failure of the cooling system, as well as helping us to detect possible engine malfunction. For instance, a decrease of the pH value together with an increase in the sulphate contents may be symptomatic of water pollution by exhaust gases.
Page 180 KOHLER MOTOROIL 3040 PLUS has been specially designed and is recommended for providing the highest performance in Kohler engines that operate on natural gas and ethanol. It can however be used in all kinds of naturally-aspirated or supercharged four-stroke engines, whether high or medium rated, that require a lubricant having a medium ash content.
Page 181 INDEX DATE Dep. 2 IC-G-D-25-003e October 2012 KOHLER MOTOROIL 3040 PLUS LUBE OIL FOR NATURAL GAS-FUELLED AND ETHANOL ENGINES O&M_2.002211.810_A_10_2016 4. ADVANTAGES AND BENEFITS Excellent resistance in the presence of oxidation and nitration. Very high protection of cylinder head valve seats and guides.
Page 182 The gaseous fuels used in Kohler engines may range from "dry" natural gas to different kinds of synthesis gases resulting from thermochemical processes or the anaerobic digestion of organic matters.
Page 183 Kohler can advice the customer on the availability of laboratories where to make the required gas composition analysis. In any case, Kohler reserves the right to carry out its own analysis on fuel gas fed to the engine. 4. CONTAMINANTS AND FACTORS AFFECTING THE ENGINE OPERATION The fuel gas contaminants and factors affecting the engine operation fall within these categories: Important variations in the fuel gas composition and conditions of supply.
Page 184 (See IC-G-D-30-018) 5.2. CONTAMINANTS OF FUEL GAS Listed below are the contaminants that are normally found in gases used as fuel in Kohler engines. Contaminants other than those listed are not allowed in the fuel gas. The permissible amounts of those contaminants in each type of fuel are stated in the relevant Product Information sheets.
Page 185 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-G-D-30-001e March 2014 FUEL SPECIFICATIONS FOR GAS ENGINES. GENERAL O&M_2.002211.810_A_10_2016 – 5.2.2. HALOGENATED COMPOUNDS ( F, CL, BR, I ) SUCH AS CL Halogenated compounds may be very harmful to the engine, if they are present in the form of acidic elements in the fuel gas or in the combustion products.
Page 186 Catalytic converters require the fulfillment of several special requisites in terms of fuel gas contaminants and lubricating oils used in the engine. This is why the fuel gas specifications must be checked by Kohler in accordance with the type and brand of catalytic converter whenever one is installed on the engine. (See IC-G-D-45-001) Catalytic converters may be reliably used only on natural gas-fueled engines.
Page 187 PRODUCT INFORMATION INDEX DATE Dep. 8 IC-G-D-30-021e May 2014 FUEL SPECIFICATIONS – US NATURAL GAS O&M_2.002211.810_A_10_2016 1. ANALYSIS OF FUEL GAS For the characterization of the gas to be used as a fuel, it will be necessary to carry out a chemical analysis of the same.
Page 188 Dep. 8 IC-G-D-30-021e May 2014 FUEL SPECIFICATIONS – US NATURAL GAS O&M_2.002211.810_A_10_2016 2. KOHLER SPECIFICATIONS FOR FUEL GASES 2.1. LOWER HEAT VALUE Lower heat values of natural gas may be within the following range:  37.5 / 42 MJ/m equal to 950 / 1050 Btu/SFC natural gas As for engines with a mechanical carburetion system, the maximum permissible variation in the gas LHV is ±5%...
Page 189 Listed below are the maximum permissible values of the contaminants that are normally found in natural gas used as fuel in Kohler engines. The stated limits may not be exceeded; neither are contaminants - other than those listed below - allowed in the fuel gas.
Page 190 Consult Kohler about analysis methods. 2.4.6. SOLID PARTICLES Kohler has established the following limits in connection with the presence of solid particles in fuel gas: Maximum permissible particle size: 5 microns (µm) Maximum concentration of particles 1 to 5µm in size: ...
Page 191 Oils and tar All Natural gas engines Condensable oil vapors allowed <5 m All Natural gas engines Dust Solid particles Larger size not allowed. <10 mg/m (1-5m) All Natural gas engines Summary table of natural gas fuel specifications for Kohler engines 4.1.23...
Page 192 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-010e June 2013 INSTALLATION AND OPERATION MANUAL - GIS IGNITION UNIT DISPLAY O&M_2.002211.810_A_10_2016 1. INTRODUCTION Once the display has been properly connected in accordance with the guidelines set out in IM-G-C-33-004, it is then ready for use. This document lists the steps required to configure the display and also sets out the different features provided: data visualization, parameter settings.
Page 193 2. Then, select the device you want to connect. In this case, choose the MIC4 option. 3. The node number must be entered. All KOHLER GIS units have Node ID 30 set as default. After completing these steps, press the Save button to save the settings on the display.
Page 194 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-010e June 2013 INSTALLATION AND OPERATION MANUAL - GIS IGNITION UNIT DISPLAY O&M_2.002211.810_A_10_2016 2.2. SCREEN CONFIGURATION By clicking the Display button in the Device Menu view, you access the next screen where you can configure the various display options.
Page 195 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-010e June 2013 INSTALLATION AND OPERATION MANUAL - GIS IGNITION UNIT DISPLAY O&M_2.002211.810_A_10_2016 By clicking this button, you can access the following menu: Fig. 5 - Access control In the dropdown menu at the top left, select the access level you want to configure. Once you select the access level, several options are at your disposal: Login/Logout: Login/Logout to a specific operating level with the access level selected Change Pin: Change PIN access code.
Page 196 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-010e June 2013 INSTALLATION AND OPERATION MANUAL - GIS IGNITION UNIT DISPLAY O&M_2.002211.810_A_10_2016 ACCESS PERMISSION Read only Read access to all data provided Operator Perimosos Read only Display configuration Recording of device data GIS ignition Reset errors Reset warnings Reset misfires...
Page 197 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-010e June 2013 INSTALLATION AND OPERATION MANUAL - GIS IGNITION UNIT DISPLAY O&M_2.002211.810_A_10_2016 3.1. READING PARAMETERS The following briefly explains each of the screen views where data is displayed on the ignition unit: 3.1.1. Overview This view shows global operating parameters Fig.
Page 198 Analogue Current Input Timing: Displays the correction applied by 4-20 mA signal from the Detcon. Analogue Voltage Input Timing: Displays the correction applied by an analogue voltage signal. The value for this parameter is always set to 0 in KOHLER engines as no analogue voltage signal is used to adjust the advance.
Page 199 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-010e June 2013 INSTALLATION AND OPERATION MANUAL - GIS IGNITION UNIT DISPLAY O&M_2.002211.810_A_10_2016 3.1.3. Ignition This view provides information related to the firing in each cylinder Fig. 9 – Screenshot of secondary voltage Secondary Voltage: it is an estimate value of the voltage required to generate the spark in the spark plug gap.
Page 200 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-010e June 2013 INSTALLATION AND OPERATION MANUAL - GIS IGNITION UNIT DISPLAY O&M_2.002211.810_A_10_2016 Fig. 10 – Screenshot of energy parameters 3.1.5. Firing Angle This view displays the individual timings per cylinder Fig. 11 – Screenshot of ignition timing per cylinder 3.1.6.
Page 201 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-010e June 2013 INSTALLATION AND OPERATION MANUAL - GIS IGNITION UNIT DISPLAY O&M_2.002211.810_A_10_2016 Fig. 12 – Screenshot of list of errors and warnings Clicking the button, you can access the actions menu where you can perform the following functions: Confirm Alarms Confirm Runtime Errors Activate and deactivate automatic scrolling...
Page 202 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-010e June 2013 INSTALLATION AND OPERATION MANUAL - GIS IGNITION UNIT DISPLAY O&M_2.002211.810_A_10_2016 WARNING DESCRIPTION Trigger number Number of teeth does not coincide with the set number Trigger missing Number of teeth counted is smaller than expected number Cam signal was not detected in time.
Page 203 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-010e June 2013 INSTALLATION AND OPERATION MANUAL - GIS IGNITION UNIT DISPLAY O&M_2.002211.810_A_10_2016 Fig. 13 – Screenshot of device information 3.1.8. Diagnostics This view includes further information on unit operation: board temperature, voltage. Fig. 16 – Screenshot of the unit's operating parameters 3.2.
Page 204 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-010e June 2013 INSTALLATION AND OPERATION MANUAL - GIS IGNITION UNIT DISPLAY O&M_2.002211.810_A_10_2016 3.2.1. Adjusting the ignition timing You can adjust the ignition timing on the next screen. Adjustments can be made in increments of +- 0,1 º o +- 0,5 º. Fig.
Page 205 DISPLAY O&M_2.002211.810_A_10_2016 WARNING KOHLER recommends that you do not change the energy parameters previously configured in the ignition unit Changing these can cause an engine malfunction. 3.2.3. Operational hours The spark plug burn time duration and operating hours of the unit can be adjusted on the next screen.
Page 206 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-003e September 2014 STARTING AND STOPPING OF EMERGENCY GAS ENGINES O&M_2.002211.810_A_10_2016 1 AIM The aim of this product information sheet is to define an SFGLD emergency gas engine starting and stopping procedure. 2 PREPARATIONS FOR STARTING UP FOR THE FIRST TIME Before starting up for the first time, the following operations shall be carried out: 2.1 PRE-START INSPECTION General checks:...
Page 207 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-003e September 2014 STARTING AND STOPPING OF EMERGENCY GAS ENGINES O&M_2.002211.810_A_10_2016 Fuel: Make sure that the fuel is supplied at the right pressure. If the motor is equipped with fuel cut-off valve, ensure that it is active. Air filter: Check the status of the clogged air filter indicator.
Page 208 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-003e September 2014 STARTING AND STOPPING OF EMERGENCY GAS ENGINES O&M_2.002211.810_A_10_2016 3. The generator switch can be closed once the rated speed is ready. Normally, the idle speed can be get . in 20 or 30 seconds after pressing the start button. This time depends on the batteries conditions and ambient temperature mainly.
Page 209 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-003e September 2014 STARTING AND STOPPING OF EMERGENCY GAS ENGINES O&M_2.002211.810_A_10_2016 5. Post-lubricate the engine during five minutes after shut-down (when fitted with a pre-lube/post-lubrication system), The exhaust pipe must be blocked off when the engine is shut down for long periods of time, to prevent rainwater or condensation from getting into the engine should be exposed to these elements.
Page 210: Specifications
Kohler engines include adequate tuning capabilities. 2. SPECIFICATIONS The thermal balance-sheets of Kohler for gas engines and ethanol engines (lean burn in both cases) specify the NOx emission level that can be achieved for each engine, based on the preset ignition timing and the different cooling water temperature settings.
Page 211 PRODUCT INFORMATION INDEX DATE Dep.2 IO-G-M-40-001e July 2015 GAS ENGINES AND ETHANOL ENGINES CARBURATION O&M_2.002211.810_A_10_2016 As a result, it is necessary to increase exhaust emission controls with a view to making any correction of the air/fuel ratio that may be required to prevent the engine from running at risk. 3- Unusual emission values can denote any of different problems with the engine, according to the component of the exhaust gases which is out of standard and the engine behaviour.
Page 212 PRODUCT INFORMATION INDEX DATE Dep.2 IC-C-D-40-001e November 2015 EMISSION UNITS CONVERSION O&M_2.002211.810_A_10_2016 1. EMISSION UNITS CONVERSION For further information on emission computation and units conversion, refer to ISO 8178-1 (2006). Exhaust emissions are usually stated in any of the following units: Parts per million - ppm 3 (2)
Page 213 NOx requires correction to account for the ambient humidity, defined in ISO 8178-1 (2006). For Kohler gas engines, the Qexh / Power factor normally lies between 5 - 6. To change from a dry basis concentration “Emis (ppm) “...
Page 214 PRODUCT INFORMATION INDEX DATE Dep.2 IC-C-D-40-001e November 2015 EMISSION UNITS CONVERSION O&M_2.002211.810_A_10_2016 1.3. ISO Cycles On many occasions (e.g. Marine engines), emissions are calculated by taking measurements under various operating conditions of the engine and applying weighting factors for each checkpoint. Legislations specify which cycle must be applied to calculate the emissions.
Page 215 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-25-006e March 2015 OIL LEVEL INDICATORS O&M_2.002211.810_A_10_2016 1. DESCRIPTION A level indicator is a device that combines an oil level display with high and low alarms. It provides protection against any high oil level due to possible water or fuel ingress as well as against a low level arising from high oil consumption or leakage.
Page 216 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-25-006e March 2015 OIL LEVEL INDICATORS O&M_2.002211.810_A_10_2016 High level alarm indicator Low level alarm indicator Oil controller hose to oil sump Venting hose 2-way valve Fig.2 – UL Oil level indicator With the engine at rest, the oil level in the indicator may rise up to the high limit, occasionally indicating a situation of excess oil.
Page 217 KOHLER engines do not use this latter function of the actuator, since they incorporate another system that monitors the high and low oil levels in the crankcase (Refer to IO-C-M-25-006e, IT-C-A-25-002e or...
Page 218 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-25-005e March 2015 AUTOMATIC OIL LEVEL CONTROLLER O&M_2.002211.810_A_10_2016 When the engine is running, the oil level in the display must be within the normal operating range. With the engine at rest, the oil level will go beyond this range due to oil flow back from the oil circuit, causing overfills.
Page 219 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-00-008e February 2010 EMISSIONS - RELATED INSTALLATION INSTRUCTIONS O&M_2.002211.810_A_10_2016 1. INTRODUCTION According to the United States Environmental Protection Agency (EPA) Ref. code of Federal Regulations 1048.130, these instructions are intended to give the installer of the engine all of the information that is necessary to properly install the engine.
Page 220 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-00-008e February 2010 EMISSIONS - RELATED INSTALLATION INSTRUCTIONS O&M_2.002211.810_A_10_2016 The exhaust pipeline shall be secured by means of collars through which it can slide and properly distributed fixed anchorage points. The exhaust pipeline and silencer shall be protected and heat-insulated to avoid big heat radiations into the engine room and the subsequent reduction in the engine performance.
Page 221 (Biogas) or IC-G-D-00-04e (syngas). Other gas qualities or failures in the specifications meeting can affect emissions levels, being out of the emissions levels according to the 40 CFR 60 subpart JJJJ standards. Kohler is not responsible for the emission level compliance in these situations Check leakages before engine first start.
Page 222 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-00-008e February 2010 EMISSIONS - RELATED INSTALLATION INSTRUCTIONS O&M_2.002211.810_A_10_2016 4. ENGINE-ROOM VENTILATION The correct ventilation of the engine room allows the correct engine performance; especially in the case the engine takes the air from the room. In designing a ventilation system, the same importance should be given to the necessary volume of air as to the flow direction.
Page 223 To “check / adjust fuel air ratio” the exhaust emissions and actual A/F ratios are confirmed. If adjustments are necessary, they are performed using Kohler proprietary software interface and only performed by Kohler authorized service technicians. 4.1.57...
Page 224 INDEX Chapter 5 2.002211.810_A 10-2016 MAINTENANCE INSTRUCTIONS OPERATION & MAINTENANCE MANUAL SFGLD “V” KOHLER CO – PRIME / STAND BY O&M_2.002211.810_A_10_2016 CHAPTER 5 – MAINTENANCE INSTRUCTIONS 5.1 Maintenance Procedures IO-G-M-00-060e_B General maintenance of gas engine 5.1.1 IO-G-M-00-061e_C Maintenance of natural gas engine SFGLD 1800 rpm prime 5.1.5...
Page 225 The maintenance intervals listed in this section do not in any way imply an obligation on behalf of Kohler, and are given only as a guide to users for maintenance scheduling. Users must take into account operating conditions and demands to determine the maintenance operations that should be carried out more frequently than stated on the schedule.
Page 226 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-00-060e February 2016 GENERAL MAINTENANCE OF GAS ENGINES O&M_2.002211.810_A_10_2016 DAILY MAINTENANCE 2.1. CONTROL OF COOLANT LEVEL The coolant level must be checked daily. It is necessary to ensure that there aren’t air or steam bubbles in the system.
Page 227 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-00-060e February 2016 GENERAL MAINTENANCE OF GAS ENGINES O&M_2.002211.810_A_10_2016 NEVER BRING A FLAME OR MAKE SPARKS NEAR THE BATTERIES. FLAMMABLE STEAM CAN BE PRODUCED. 2.6. LUBRICATION OIL LEAKS Inspect plant lubrication piping for oil leaks. Tighten hardware or change seals and gaskets if necessary. In addition, make sure the dipstick and filling plug on the inspection cover are tight.
Page 228 Failure to do so may not only je opardize KOHLER’s warranty, but also restrict you from obtaining the best performance for equipment.
Page 229 Jobs to be done during the initial start-up of a new engine or during the break-in phases following major overhauls (change of cylinder liners, pistons, piston rings, cylinder heads,...). They must be carried out by KOHLER authorized Repair Shop. Interval...
Page 230 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-00-061e January 2016 MAINTENANCE OF NATURAL GAS ENGINE SFGLD 1800 RPM PRIME O&M_2.002211.810_A_10_2016 ROUTINE MAINTENANCE (Type "E") Minor Jobs Interval Job Description (Operations to be performed with the engine stopped) - Vent the coolant circuit. Check automatic vent valves - Drain condensates out of the exhaust Y-pipe - Check oil pressure and temperature during the pre-lubrication phase - With the dipstick, check for a possible increase of the oil level in the oil pan due to...
Page 231 - The spark plugs change must be made attending the IO-G-M-33-007 product information*. *It’s recommend to carry out a borescope inspection and do a compression test when changing spark NOTE plugs - Ask Kohler to use another oil that it is not KOHLER MOTOROIL. 5.1.8...
Page 232 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-00-061e January 2016 MAINTENANCE OF NATURAL GAS ENGINE SFGLD 1800 RPM PRIME O&M_2.002211.810_A_10_2016 Periodic interventions (Type "R") major interventions Interval Job Description - Recondition cylinder heads. - Clean pistons, cylinder liners and cylinder head seating on block - Check valves driving system: valve lifters, rocker arms, push-rods, roller rocker arms and cams - Measure cylinder liners wear...
Page 233 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-00-061e January 2016 MAINTENANCE OF NATURAL GAS ENGINE SFGLD 1800 RPM PRIME O&M_2.002211.810_A_10_2016 Interval Job Description - Change complete pistons (Piston, piston rings, pin, circlips) - Change cylinder head springs - Change cylinder liners - Change flexible coupling condition engine-alternator - Inspection of elastic suspensions and alignments - Check axial and Radial allowance of Crankshaft...
Page 234 Power Rating of the engine for this application. If methane number is less than the specified, consult with KOHLER. For installations where the gas composition is variable, it’s recommended to reduce the periods between...
Page 235 Failure to do so may not only je opardize KOHLER’s warranty, but also restrict you from obtaining the best performance for equipment.
Page 236 Jobs to be done during the initial start-up of a new engine or during the break-in phases following major overhauls (change of cylinder liners, pistons, piston rings, cylinder heads,...). They must be carried out by KOHLER authorized Repair Shop. Interval...
Page 237 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-00-019e January 2016 MAINTENANCE OF NATURAL GAS ENGINE SFGLD STAND-BY O&M_2.002211.810_A_10_2016 1.3 Monthly maintenance Interval Job Description (Operations to be performed with the engine stopped) - Vent the coolant circuit. Check automatic vent valves. - Drain condensates out of the exhaust Y-pipe - With the dipstick, check for a possible increase of the oil level in the oil pan due to coolant leaks...
Page 238 - The spark plugs change must be made attending the IO-G-M-33-007 product information. *It is recommended cylinder endoscope revision and compression test when the spark-plug change NOTE - Ask Kohler to use another oil that it is not KOHLER MOTOROIL. 5.1.16...
Page 239 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-00-019e January 2016 MAINTENANCE OF NATURAL GAS ENGINE SFGLD STAND-BY O&M_2.002211.810_A_10_2016 Periodic interventions (Type "R") major interventions Interval Job Description - Recondition cylinder heads. - Clean pistons, cylinder liners and cylinder head seating on block - Check valves driving system: valve lifters, rocker arms, push-rods, roller rocker arms and cams - Measure cylinder liners wear...
Page 240 Power Rating of the engine for this application. If methane number is less than the specified, consult with KOHLER. For installations where the gas composition is variable, it’s recommended to reduce the periods between...
Page 241: Oil Consumption
Specific consumption (g/kWh) = [ 897 x Consumption (liters) ] / [ Power (kW) x Hours of operation ] 3. OIL ANALYSIS As a reference, Kohler recommends that oil analysis should be conducted as specified in the maintenance instructions in respect of lubricant for use in gas engines.
Page 242 PRODUCT INFORMATION INDEX DATE Dep.2 IO-G-M-25-001e January 2015 GAS-FUELED ENGINE OIL SERVICING INSTRUCTIONS O&M_2.002211.810_A_10_2016 When requesting an oil analysis, always state the type of oil used as well as the time (number of hours) the oil charge has been in service, and the engine specific oil consumption. We recommend the following properties are checked: - Viscosity - Insoluble substances...
Page 243 PRODUCT INFORMATION INDEX DATE Dep.2 IO-G-M-25-001e January 2015 GAS-FUELED ENGINE OIL SERVICING INSTRUCTIONS O&M_2.002211.810_A_10_2016 Oxidation / Nitration Oxidation is a chemical reaction of oil with oxygen. Oil oxidation can be fought by adding inhibitors, however, it will always develop when oil is mixed with air and it will accelerate under the effect of the combustion gas temperature, contaminants and oxidizing agents.
Page 244 PRODUCT INFORMATION INDEX DATE Dep.2 IO-G-M-25-001e January 2015 GAS-FUELED ENGINE OIL SERVICING INSTRUCTIONS O&M_2.002211.810_A_10_2016 An increase in the content of any metal indicates wear or damage of an engine component. The metal present in oil can identify the engine part concerned. For example: An increase in the content of lead and copper should lead to an inspection of the bearings, bushings...
Page 245 OIL SAMPLING PROCEDURE O&M_2.002211.810_A_10_2016 1. OBJECT This Product Information sheet clearly specifies a procedure for collecting oil samples from all Kohler engines, for their subsequent analyses. 2. SAMPLING ROCEDURE The oil sample for analysis must be representative of the entire operating load. Therefore, always do the sampling when oil is circulating in the engine, since this ensures product homogenization.
Page 246 DATE Dep.2 IO-C-M-25-004e May 2008 KOHLER ENGINE OIL CHANGE INSTRUCTIONS O&M_2.002211.810_A_10_2016 1. INTRODUCTION The useful life of a lube oil charge depends on many and varied factors. Determinants are the oil working time, engine oil consumption, type and grade of fuel, volume of circulating oil, lubricant quality, engine condition, oil temperature, etc.
Page 247 Dispose of waste oil in a controlled manner in compliance with the prevailing legislation on waste oil collection and management. We do not recommend adding extra additives because the oils used in Kohler engines have been formulated and produced with state-of-the-art technology so that nothing need be added to the original formulation.
Page 248 DATE Dep.2 IO-C-M-25-004e May 2008 KOHLER ENGINE OIL CHANGE INSTRUCTIONS O&M_2.002211.810_A_10_2016 3. CHANGING OF THE OIL FILTER CARTRIDGE The oil filter cartridges must be replaced each time you change oil in the engine or when the filters are clogged, a condition that generates such a low oil pressure in the gallery that the oil pressure alarm is near the setting value.
Page 249 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-25-003e June 2013 KOHLER 180/240/360/480/560 ENGINES CENTRIFUGAL OIL FILTER MAINTENANCE INSTRUCTIONS O&M_2.002211.810_A_10_2016 1. CLEANING OF FILTER After stopping the engine completely or isolating the filter from the lubrication system by means of a valve: 1.1.
Page 250 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-25-011e May 2006 MAINTENANCE OF THE CRANKCASE GAS RECIRCULATION SYSTEM O&M_2.002211.810_A_10_2016 1. MAINTENANCE OF THE RECIRCULATION SYSTEM Maintaining the crankcase gas recirculation system basically consists in changing the filtering cartridge, inspecting the installation and performing the start-up procedure after changing the cartridge. The filtering cartridges must be changed when the hours of operation specified in the maintenance guidelines have been reached or when the filter is clogged (the red indicator at the top of the filter being completely extended), whichever first occurs.
Page 251 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-25-011e May 2006 MAINTENANCE OF THE CRANKCASE GAS RECIRCULATION SYSTEM O&M_2.002211.810_A_10_2016 1.2. Inspecting the installation Detach the hose clamps and wash any oil condensate and water out of the hose. Clean the pressure control valve. 1.3.
Page 252: Troubleshooting
PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-25-011e May 2006 MAINTENANCE OF THE CRANKCASE GAS RECIRCULATION SYSTEM O&M_2.002211.810_A_10_2016 2. TROUBLESHOOTING At times, the filter clogging indicator will rise when starting the engine after a certain period shut down. This occurs because the cooling of oil in the outside of the filter leads to an increase in head losses. Once warm, oil drips and the system operates correctly again.
Page 253: Cleaning And Inspection
PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-25-012e June 2014 CLEANING THE OIL SEPARATOR FILTER OF THE CRANKCASE GAS BREATHER O&M_2.002211.810_A_10_2016 1. DISASSEMBLY Follow the instructions referring to Figure 1 that shows the different parts of the crankcase gas breather. 1. Remove the bolts and nuts nº10 & 4, taking care that the O-ring nº8 does not fall out. 2.
Page 254 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-25-012e June 2014 CLEANING THE OIL SEPARATOR FILTER OF THE CRANKCASE GAS BREATHER O&M_2.002211.810_A_10_2016 5. ALTERNATIVE FOR FV GAS ENGINES In cases where the upper body nº5 cannot be removed, due to interference with the air filter bracket (gas FV engines), remove the full gas vent and follow the instructions in point 1 to open it and then clean the metal mesh following the instructions in point 2.
Page 255 Next, do the following: Diesel and Dual Fuel Engines: Insert the tool (Kohler ref.: 19.75.065) with a copper washer in the place of the jet, to ensure adequate cylinder sealing.
Page 256 Test the remaining cylinders similarly, in correlative order. ATTENTION The table below shows compression test values for Kohler engines: These values are for guidance only, since compression checks differ if performed on a hot or cold engine; therefore what really matters is the reading variation among all the cylinders.
Page 257 INDEX DATE Dep.2 IO-C-M-00-006e February 2012 KOHLER ENGINE CYLINDER COMPRESSION TEST O&M_2.002211.810_A_10_2016 Pay special attention to the starter motor, to prevent overheating after a number of operations. Also, ensure that the rotational speed is similar, during the test. 3. CONDITIONS CAUSING LOW ENGINE COMPRESSION The following conditions principally can cause low engine compression: Scratched liner;...
Page 258: Preliminary Checks
Each plug has been visually checked and found free from imperfections and mill defects which could impair its proper operation. You can measure and adjust only some of the Kohler -referenced spark plugs. In particular, the spark gap will be measured against the values tabulated below, using thickness gauges (in the event of one-electrode spark plugs) and a special gap setting tool ref.
Page 259: Maintenance Instructions
PRODUCT INFORMATION INDEX DATE Dep.2 IO-G-M-33-001e June 2013 CONVENTIONAL SPARK PLUG CHANGING AND MAINTENANCE INSTRUCTIONS O&M_2.002211.810_A_10_2016 WARNING Under certain circumstances, the failure of a spark plug to operate properly may be due to problems with the wire: either dirt on the wire deviates the spark to earth or the wire contacts are cracked or sulphated, impeding the electric potential to reach the spark plug.
Page 260 PRODUCT INFORMATION INDEX DATE Dep.2 IO-G-M-33-001e June 2013 CONVENTIONAL SPARK PLUG CHANGING AND MAINTENANCE INSTRUCTIONS O&M_2.002211.810_A_10_2016 5. VISUAL INSPECTION OF THE SPARK PLUG CONDITION CONDITION POSSIBLE CAUSE Small deposits of white ashes on the electrodes NORMAL PREMATURE DETONATION OR IGNITION Electrodes or casing fused (Possible faulty carburetion, ignition timing or poor quality of the gas used)
Page 261 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-002e May 2016 CONVENTIONAL SPARK PLUG REPLACEMENT CRITERIA IN GAS ENGINES O&M_2.002211.810_A_10_2016 1. INTRODUCTION This document describes the various methods for detecting spark plug failure to set usable criteria for determining when the spark plugs in the engine should be replaced. 2.
Page 262 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-002e May 2016 CONVENTIONAL SPARK PLUG REPLACEMENT CRITERIA IN GAS ENGINES O&M_2.002211.810_A_10_2016 The values set in the CPU-95 unit program for the engines to which this document applies are: Energy level: E3 Minimum CAVG value: 90 Maximum CAVG value of the high voltage level in the secondary circuit: 130 (alarm on display: HI SPARK VOLT).
Page 263 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-002e May 2016 CONVENTIONAL SPARK PLUG REPLACEMENT CRITERIA IN GAS ENGINES O&M_2.002211.810_A_10_2016 5. USE OF THE GCS UNIT DIAGNOSIS CAPABILITY The GCS unit displays estimated secondary voltage values (kV) for determining if the spark plugs are reaching the end of their service life.
Page 264 Such types of grease include: Dow Corning DC-4, G.E. G-623 or GC Electronics Z5. Also apply a small amount of grease onto the wire connector and coil. 2. You can measure and adjust the spark plug gap of some of the Kohler -referenced spark plugs.
Page 265 CHECK OF IGNITION COILS AND SPARK PLUG WIRES O&M_2.002211.810_A_10_2016 1. INTRODUCTION This Product Information Sheet aims to establish a procedure for checking Kohler gas engine ignition components, namely the ignition coils and spark plug wires. The coils and spark plug wires are the following::...
Page 266 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-003e May 2016 CHECK OF IGNITION COILS AND SPARK PLUG WIRES O&M_2.002211.810_A_10_2016 Fig. 2 - Measuring the resistance of the secondary winding of an ignition coil ref. 3. SPARK PLUG WIRES The high voltage or spark plug wire conveys the high-voltage impulse produced by the coil to the spark plug. The spark plug generates the spark between its electrodes.
Page 267 Accordingly, it is hard to specify a rigorous number of hours a spark plug can be in service before needing replacement. Average intervals stated below shall by no means commit KOHLER to any liability. They are provided only as a guide to the servicing needs. According to the operating conditions, requirements, and fuel properties, user has to define whether replacing the spark plugs is necessary before or after the working times suggested in this document.
Page 268 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-007e February 2016 MAINTENANCE OF SPARK PLUGS. OVERVIEW O&M_2.002211.810_A_10_2016 3. GUIDELINES ON SPARK PLUG REPLACEMENT 1200rpm 1500rpm 1800rpm REFERENCE REFERENCE REFERENCE HOURS HOURS HOURS DOCUMENT DOCUMENT DOCUMENT 1250 1000 FG/ FGLD natural gas IO-G-M-00-073 IO-G-M-00-074 5000 4000...
Page 269 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-009e April 2013 CHECKING THE IGNITION TIMING O&M_2.002211.810_A_10_2016 1. DESCRIPTION This document describes how to check the engine ignition timing. The timing gun can be connected with the engine running or stopped. CHECKING THE IGNITION TIMING The cylinders of Line engines and those from 1 to 8 for 16V (or 1 to 6 for 12V) are on the opposite side of the engine to the timing measurement port.
Page 270 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-009e April 2013 CHECKING THE IGNITION TIMING O&M_2.002211.810_A_10_2016 3. Connect earth to the negative terminal of the battery Image 2 – Earth clamp on battery negative terminal 4. Start engine and go to the operating point chosen to measure the ignition timing. 5.
Page 271 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-33-009e April 2013 CHECKING THE IGNITION TIMING O&M_2.002211.810_A_10_2016 8. Disconnect everything when the engine has stopped. Once the engine has stopped the coils are not active. In addition, the coils discharge very quickly so there is no risk of them being live as long as they are well earthed.
Page 272: Valve Clearance
PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-E-10-001e August 2016 ADJUSTMENT OF GAS AND ETHANOL ENGINE VALVES. VALVE CLEARANCE O&M_2.002211.810_A_10_2016 1. ADJUSTING THE VALVES This operation aims to set the clearance between the valve lifter and the overhead-valve rocker. With the engine cold and the cylinder being adjusted at TDC (Top Dead Center) in the compression stroke, the clearance between the rocker arms and the valve lifters must be: 180/240/360/480 - HGM 240 ENGINE...
Page 273 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-E-10-001e August 2016 ADJUSTMENT OF GAS AND ETHANOL ENGINE VALVES. VALVE CLEARANCE O&M_2.002211.810_A_10_2016 Fig. 1 - Valve Adjustment Rocker arm Ball joint nut Rocker arm ball joint Rocker arm pushrod Valve lifter Valve lifter lock nut Adjusting screw Valves 5.2.42...
Page 274 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-E-10-001e August 2016 ADJUSTMENT OF GAS AND ETHANOL ENGINE VALVES. VALVE CLEARANCE O&M_2.002211.810_A_10_2016 FLYWHEEL ROTATION FLYWHEEL ROTATION 120° Marks on flywheel Marks on flywheel 12-13 FLYWHEEL ROTATION FLYWHEEL ROTATION 16-9 7-12 8-11 30° (PMS) (PMS) 60°...
Page 275 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-E-10-001e August 2016 ADJUSTMENT OF GAS AND ETHANOL ENGINE VALVES. VALVE CLEARANCE O&M_2.002211.810_A_10_2016 2. VALVE CLEARANCE The valve clearance control allows assessment of wear on the contact points between valve and seat. The operation is explained below. Valve clearance: use the caliper to measure the distance between the upper disk face and the mechanized upper face of the cylinder head.
Page 276 The parameter that determines the fouling level of an air filter is the airflow restriction at the air filter outlet. On Kohler engines, the maximum permissible air flow restriction or pressure loss is 38 mbar and it is measured with the engine running at rated power and load.
Page 277 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-35-001e September 2016 AIR FILTERS. MAINTENANCE O&M_2.002211.810_A_10_2016 3. Inspect the inside of the filter casing and clean it with a moistened rag. Also check the exhaust valve at the bottom of the filter and eliminate possible dirt build-ups or condensates 4.
Page 278 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-35-001e September 2016 AIR FILTERS. MAINTENANCE O&M_2.002211.810_A_10_2016 4. Verify the condition and appearance of the main filter cartridge: the filtering paper should be free from excessive dirt or breakage. Check the paper folds for homogeneous distribution and absence of deformation. Clean the filter cartridge in case of high dust concentration or if specified by the maintenance programme (see point 2.2).
Page 279 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-35-001e September 2016 AIR FILTERS. MAINTENANCE O&M_2.002211.810_A_10_2016 2.2.1. BLOW-THROUGH NEVER clean the filter cartridge mounted in the filter or on the engine or in the engine room. Moreover, it is advisable to carry out this operation at a safe distance from any object susceptible to be damaged by blown out dust.
Page 280 The parameter that determines the fouling level of an air filter is the air flow restriction at the air filter outlet. On Kohler engines, the maximum permissible airflow restriction or pressure loss is 38 mbar and it is measured with the engine running at rated power and load.
Page 281 AIR FILTERS. MAINTENANCE O&M_2.002211.810_A_10_2016 COVER CLAMP FILTERING CARTRIDGE CASING FOULING DETECTOR Fig. 3 - Exploded view of Kohler High Flow two-cartridge air filter CASING CLAMP FILTERING ELEMENT COVER Fig. 4 - Exploded view of Kohler High Flow one-cartridge air filter 5.2.50...
Page 282 PRODUCT INFORMATION INDEX DATE Dep.2 IO-C-M-15-001e September 2013 DAMPER CONDITION MONITORING O&M_2.002211.810_A_10_2016 1. INTRODUCTION It is the damper's function to minimize the impact of the torsional vibrations developing in the crankshaft. These vibrations originate in the successive explosions that take place in the combustion chambers and are transmitted to the crankshaft through the pistons and connecting rods.
Page 283 PRODUCT INFORMATION INDEX DATE Dep.2 IO-C-M-15-001e September 2013 DAMPER CONDITION MONITORING O&M_2.002211.810_A_10_2016 3. SILICONE SAMPLING METHOD An analysis of the damper silicone is essential to determine whether its properties are optimum or not. The filling plugs will be found, diametrically opposed, on the damper cover. If there is a reasonably easy access to one of those plugs, sampling can be done with the damper installed on the engine.
Page 284 PRODUCT INFORMATION INDEX DATE Dep.2 IO-C-M-15-001e September 2013 DAMPER CONDITION MONITORING O&M_2.002211.810_A_10_2016 Allow silicone fluid to reach the open end of the sample container. This may take a few seconds or hours depending on the fluid conditions and other factors: the higher the temperature, the shorter the time required.
Page 285 3.2. Silicone sample analysis performed by the manufacturer If there is any doubt about the silicone condition, it is recommended to perform a more exhaustive analysis. In this case it must send a sample to Kohler in order to perform that analysis. 5.2.54...
Page 286: Cooling System Maintenance
O&M_2.002211.810_A_10_2016 1. PROCEDURE FOR FILLING AND DRAINING THE COOLING CIRCUIT WITH ANTIFREEZE This section describes the method of filling the cooling circuits in Kohler engines, and is suitable for engines and containerized units. Prior to filling, the bleed valves on the water circuits have to be opened. On the engine side, the purge in the main circuit is located in the thermostat housing or on the inlet pipe to the latter.
Page 287 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-20-002e June 2016 COOLING SYSTEM MAINTENANCE O&M_2.002211.810_A_10_2016 The main and secondary circuits on dry-coolers, radiators or heat exchangers, are usually equipped with automatic air bleed valves. Some come with a shut-off valve for overriding, but you must ensure they are open during operation.
Page 288 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-20-002e June 2016 COOLING SYSTEM MAINTENANCE O&M_2.002211.810_A_10_2016 There are two ways to fill the circuit: 1. Fill with water previously mixed with antifreeze. This is the best system to use for filling the cooling circuits.
Page 289 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-20-002e June 2016 COOLING SYSTEM MAINTENANCE O&M_2.002211.810_A_10_2016 This is particularly true for engines that operate with water in the main circuit 120ºC when this temperature is reached, it is necessary to re-purge the circuit as the capacity to dissolve air in water decreases significantly with temperature, such that on filling the circuit with cold water, we may not have air and have significant air pockets in the entire circuit at the operating temperature.
Page 290 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-C-M-20-002e June 2016 COOLING SYSTEM MAINTENANCE O&M_2.002211.810_A_10_2016 Particular attention should be paid to the specifications of this product and the supplier's recommendations as excessive recirculation may damage some components. In addition, before refilling the circuit, it must be cleaned with water to remove all traces of hydrochloric acid in the installation.
Page 291 2. INSPECTION OF THE TURBOCHARGER The inspection and possible repair of turbochargers must be carried out by one of Kohler official or authorised Repair Shops. A turbocharger is a critical component to ensure correct operation of the engine. If the turbocharger does not work correctly, the engine will not perform as initially specified.
Page 292 If you find any fault during this inspection, you will have to check the turbocompressor completely in order to solve the problem. In this event, ask Kohler for the instruction manual specific to the turbocompressor that needs overhauling or have the turbocompressor checked by one of Kohler official or authorised Repair Shop.
Page 293 PRODUCT INFORMATION INDEX DATE Dep.2 IO-C-M-45-001e June 2008 MAINTENANCE OF TURBOCHARGER O&M_2.002211.810_A_10_2016 3. CLEANING THE TURBOCHARGER Dust particles entering the intake air pipe may cause damage to the compressor of the supercharging system. Bearing in mind that even the most efficient air filter allows a small amount of dirt to pass through, dirt will adhere to the compressor blades if there is oil or similar substances on them.
Page 294 PRODUCT INFORMATION INDEX DATE Dep.2 IO-C-M-45-001e June 2008 MAINTENANCE OF TURBOCHARGER O&M_2.002211.810_A_10_2016 Presence of foreign material in the exhaust system, resulting in breakage, deformation or knocking of the turbine impeller blades. Such material can be: loose items in the exhaust manifold, namely nuts, bolts, washers and parts that were not removed when the turbo was last overhauled, fragments of broken parts of the engine (valves, valve guides, seats, piston rings…).
Page 295: Operation And Maintenance
PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-35-001e October 2010 INTAKE SAFETY VALVE OPERATING AND MAINTENANCE PROCEDURE O&M_2.002211.810_A_10_2016 1. INTRODUCTION This Product Information document establishes the intake safety valve operating and maintenance procedure. 2. OPERATION AND MAINTENANCE 2.1. OPERATION Safety valves protect people as well as engines in case of explosions in the intake system of gas engines. They include adequately calibrated inner springs to ensure the valve opens in case of overpressure building up in the intake manifold and releases the air-fuel gas mixture until the rated pressure is restored in the intake system.
Page 296 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-35-001e October 2010 INTAKE SAFETY VALVE OPERATING AND MAINTENANCE PROCEDURE O&M_2.002211.810_A_10_2016 DAMAGED DAMAGED EDGES EDGES ABNORMAL ABNORMAL INTERSPACE INTERSPACE Fig. 1 – Pictures showing reasons for rejecting valves 2.3. MAINTENANCE INSTRUCTIONS 1. In the event the flame-killing plates are covered with dust, they must be cleaned with non-corrosive, non- flammable products.
Page 297 This document describes the correct maintenance procedure for Kohler intercoolers. 2. CLEANING THE INTERCOOLER Kohler has designed and manufactured its intercoolers with a view to minimising the necessary maintenance operations. Therefore, no special maintenance process other than cleaning is necessary for operating the intercooler.
Page 298 PRODUCT INFORMATION INDEX DATE Dep.2 IO-C-M-20-010e January 2014 MAINTENANCE OF INTERCOOLERS O&M_2.002211.810_A_10_2016 Then, dry the plates with compressed air. If any plate gets damaged during this process, you can repair it with long-nose pliers or a special-purpose tool. If the dirt is not removed by the above procedure, use a solvent, as outlined below, to get a deeper clean. ...
Page 299 PRODUCT INFORMATION INDEX DATE Dep.2 IO-C-M-20-010e January 2014 MAINTENANCE OF INTERCOOLERS O&M_2.002211.810_A_10_2016 3. REMOVING THE INTERCOOLER Here is the procedure for removing the intercooler: Stop the engine; allow water to circulate for several minutes until it cools down. Close the coolant supply (where appropriate) and remove the drain plugs and bleeders to empty the cooling circuit.
Page 300 MAINTENANCE OF PICK-UPS O&M_2.002211.810_A_10_2016 1. INTRODUCTION This document describes the procedure for correct maintenance of speed pick-ups on Kohler engines. 2. MAINTENANCE OF PICK-UPS The magnetic pick-ups serve as instant input of the engine speed or cycle (expansion or compression) to the engine control, carburetion, injection and other systems.
Page 301 O&M_2.002211.810_A_10_2016 1. INTRODUCTION This document specifies instructions and recommendations for correct inspection and maintenance of batteries in service on KOHLER machines. 2. MAINTENANCE 2.1. ROUTINE INSPECTION It is necessary to carry out the inspection and servicing tasks described below within the time intervals specified in the application-specific maintenance programme.
Page 302 Adjust and tighten the connection clips, starting with the positive one. DO NOT TIGHTEN TOO MUCH. These recommendations are of a general nature and users must follow the battery manufacturer's instructions. KOHLER shall accept no liability for troubles originating in the batteries. 5.2.74...
Page 303 INDEX Chapter 6 2.002211.810_A 10-2016 TROUBLESHOOTING OPERATION & MAINTENANCE MANUAL SFGLD “V” KOHLER CO – PRIME / STAND BY O&M_2.002211.810_A_10_2016 CHAPTER 6 – TROUBLESHOOTING IO-G-T-00-001e_B Gas engines troubleshooting 6.1.1...
Page 304: Troubleshooting Guide
GAS ENGINES TROUBLESHOOTING O&M_2.002211.810_A_10_2016 1. INTRODUCTION These instructions are intended as a guide to quick troubleshooting in Kohler gas engines. The layout SYMPTOM / PROBABLE CAUSE / REMEDY leads to the solution of many minor engine problems. At all times, an after-sales technical service is at our customers' disposal for any help to diagnose failures.
Page 305 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-001e February 2016 GAS ENGINES TROUBLESHOOTING O&M_2.002211.810_A_10_2016 SYMPTOM PROBABLE CAUSE REMEDY Ignition fails 1. Pickup broken, faulty, dirty or in wrong 1. Check, clean or change pickup as position appropriate 2. Incorrect pick-up wiring, loose or broken 2.
Page 306 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-001e February 2016 GAS ENGINES TROUBLESHOOTING O&M_2.002211.810_A_10_2016 SYMPTOM PROBABLE CAUSE REMEDY Note: Check sensors to see if problem is due to measurement failure 1. Check lubricating system and reset Engine alarm: 2. Check coolant system and reset 1.
Page 307 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-001e February 2016 GAS ENGINES TROUBLESHOOTING O&M_2.002211.810_A_10_2016 SYMPTOM PROBABLE CAUSE REMEDY Overload due to wrong reading of power Calibrate power signal signal 1. Check supply line or contact supplier Fuel system fails 2. Readjust or change spring 1.
Page 308 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-001e February 2016 GAS ENGINES TROUBLESHOOTING O&M_2.002211.810_A_10_2016 SYMPTOM PROBABLE CAUSE REMEDY Fuel system fails 1. Check supply line or contact supplier 1. Low gas pressure 2. Readjust or change spring 2. Misadjusted pressure regulator 3.
Page 309 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-001e February 2016 GAS ENGINES TROUBLESHOOTING O&M_2.002211.810_A_10_2016 SYMPTOM PROBABLE CAUSE REMEDY Readjust carburettor mixture valve.Check Too lean air-fuel mixture NOx sensor or lambda sensor signal Check, regap or change spark plus as Spark plug failure Engine shows signs of ignition appropriate failures...
Page 310 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-001e February 2016 GAS ENGINES TROUBLESHOOTING O&M_2.002211.810_A_10_2016 SYMPTOM PROBABLE CAUSE REMEDY Fill oil sump up to the specified level Low oil level Recalibrate or change, as appropriate, the Inaccurate pressure gauge pressure gauge Change filters Clogged oil filters Low oil pressure Change spring or piston, as the case may be...
Page 311 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-001e February 2016 GAS ENGINES TROUBLESHOOTING O&M_2.002211.810_A_10_2016 SYMPTOM PROBABLE CAUSE REMEDY Readjust or change regulator Broken or misadjusted regulator Contact gas supplier Insufficient gas supply pressure Inspect fuel system and repair Fuel leaks Low gas pressure Check circuit and make sure pipe diameter is Undersized pipelines adequate for the gas quality...
Page 312 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-001e February 2016 GAS ENGINES TROUBLESHOOTING O&M_2.002211.810_A_10_2016 SYMPTOM PROBABLE CAUSE REMEDY Check with a stroboscopic lamp and re-time Excessively advanced ignition as necessary Readjust carburettor mixture valve. Check MAP and MAT sensors signal Carburetion maladjustment Check NOx sensor or lambda sensor signal High exhaust gas emissions Check spark plugs, high-voltage wires and...
Page 313 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-T-00-001e February 2016 GAS ENGINES TROUBLESHOOTING O&M_2.002211.810_A_10_2016 SYMPTOM PROBABLE CAUSE REMEDY Engines with electronic carburetion and electrical throttle: 1. Adjust speed PID 1. Spees PID Misadjusted 2. Change batteries or charger 2. Low voltage in throttle actuator 3.
Page 314 KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 TP-6991 8/18b (2.002211.810) For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com E 2015, 2016, 2018 by Kohler Co. All rights reserved.

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