Table Of Contents - Kohler SFGLD480 Operation & Maintenance Manual

Table of Contents

General Index6
Safety Precautions For Kohler Gas Engines10
Introduction10
Preliminary Observations10
Bodily Protection10
Engine Fuels11
Positive Fuel Shut-Off11
Safety Guards11
Crankcase Gases11
Cooling System Pressure Caps And Connections12
Ignition System12
Generator Sets12
Tidiness And Cleanliness13
Engine And Equipment; Repair And Service13
Engine Fan Blades13
Turbochargers14
Engine Storage Chemicals14
Fire Protection14
Cleaning Solvent15
Welding Equipment15
Grounding Precautions When Welding15
Electrical Tools15
Batteries16
Precautions When Using Booster Batteries And Cables16
Compressed Air16
Intoxicants And Narcotics16
Safety Practices For Handling Acids17
Engine Lifting And Handling17
Engine Design18
Engine Room18
Risk Analysis18
Materials And Products19
Equipment Drives19
Mechanical Hazards19
Electrical Hazards19
Forced Induction20
Manifolds And Exhaust Pipe20
Vibration20
Noise20
Fuel System21
Gas21
Ethanol21
Blow-By Gases22
Exhaust Fumes22
Maintenance22
Information22
Safeguarding Against Malfunction23
Safety Precautions24
Conclusion24
Acoustic Definitions25
Noise Emission At 1500 Rpm26
Noise Emission At 1800 Rpm27
Sound Pressure Level28
Noise Emission At 1200 Rpm28
Decontamination And Disassembly31
Staff Training32
Decontamination, Waste Processing And Management Methods32
Hazardous Waste32
Recommended Handling Methods32
Non-Hazardous Waste33
Used Oil Filter33
Fuel Filter33
Waste Management34
Waste Oil34
Engine Identification Plate38
Basic Specifications Of Gas Engines48
General Description Of The Construction Of The Engine48
Crankcase48
Sleeves48
Bearings49
Cylinder Heads49
Connecting Rods49
Pistons49
Camshaft50
Distribution50
Lubrication50
Refrigeration50
Intake51
Miscellaneous51
Tightening Torques For Commercial Bolts & Nuts71
Standard Tightening Torque Specification71
Coefficient Of Friction For Different Coatings72
Mechanical Properties Of Screws Used72
Auxiliary Screw Driving Products73
Units Conversion74
Cooling Circuit Diagram76
Engine Mounted Cooling Circuit77
Jack Ket Water Circuit77
Cooling System Components80
Impeller Pump80
Oil Cooler80
Engine Block80
Water Preheating System81
Water Temperature Regulator81
Caja De Termostatos Circuito Principal81
Vent82
Expansion Tank82
External Cooling System82
Venting Pipes82
Requirements Of The Engine Cooling System83
Gas Engines – Pressure Losses And Flowrates84
Minimum Flowrates For Fgld Engines85
Main Cooling Circuit85
Auxiliary Cooling Circuit85
Minimum Flowrates For Sfgld / Sfgrd / Sfgm Engines86
Overpressure Safety Valve92
Lubricating Oil Pressure Regulating Valve92
Thermostatted Oil Valve92
Centrifugal Filter93
Blow-By Gas Exhaust System93
Open Or Passive System93
Active O Blow-By Gas Recirculating System93
Operation94
Automatic Engine Oil Level Controller97
General Layout On 180/240 Series Engines97
General Layout On 180/240 Series Generating Sets97
General Layout On 360/480/560 Series Engines/Generating Sets98
Automatic Oil Level Controller98
Lube Oil Level Indicator Ul101
Components Specification101
Oil Preheating System Per Type Of Engine106
General Layout - Hgm 240 Engines106
Performance107
Configuration108
Cgr On Gas In-Line Engine Fgld/Sfgld109
Cgr On Gas V-Engine Fgld/Sfgld109
Cgr On Hgm240 Engine109
Cgr On Hgm 420/560 Engine109
Oil Level Controller110
Crankcase Gas Breather110
Blow-By Gas Recirculation Filter111
Crankcase Pressure Control Valve111
Oil Feedback To Crankcase112
Blow-By Gas Feed Pipe To The Air Intake112
Crankcase Pressure112
Egs 02. Description113
Functionalities114
Speed Control114
Load Control114
Control Of Carburation At Different Loads114
Egs02 Complementary Equipment115
Pick-Up115
Mat115
Map115
Throttle Valve116
Tecjet116
Venturi Type Carburation - Description117
Zero Pressure Regulator117
Carburation System Scheme117
Gas Flow Control118
Main Adjustment Screw (Mas)118
Carburettor120
Gas Control Injector120
Carburettor And Barrel120
Air-Gas Mixteure By Venturi Effect121
Electronic Control121
Specification Of Gas Supply To Tecjet 52122
Gas Pressure Range122
Minimum Pressure At Tecjet52 Vs Maximum Power122
Maximum Pressure At Tecjet52 Vs Maximum Power123
Working Temperatures124
Gas Filter124
Description Of The Gis Ignition System126
Gis Coil126
Gis High Voltage Lead126
Basic Layout Of The In-Line Engine Ignition System126
Basic Layout Of The V-Engine Ignition System127
Gis Ignition Module128
General Features128
Functions And Operation128
Configuration Of Pickup Signals128
Analogue/Digital Outputs129
Visualisation Leds129
Communications130
Pc Connection130
Potentiometers And Reset Button130
Technical Specifications131
Fitting The Ignition Module131
Overview Of The Ignition System For V-Engines With 16 Cylinders131
Gas Engines Intake System132
Air Filter132
Turbocharger133
High-Rate Single-Stage Filter133
In-Line Engines133
Intake Manifold135
Air Filters136
Air Filters. Characteristics136
General View Of Double-Stage Air Filters136
Exploded View Of A Tangentially Sealed Air Filter137
Exploded View Of A Radially Sealed Air Filter137
General Drawing Of Kohler High Flow Two-Cartridge Filter138
Exploded View Of Kohler High Flow Two-Cartridge Air Filters138
Exploded View Of Kohler High Flow One-Cartridge Air Filter139
Oxidative Catalytic Converters140
Operating The Catalytic Converter140
Engine Operation141
Parts Of An Oxidative Catalytic Converter141
Optimal Working Temperatures Of The Catalytic Converter142
Technical Limitations Of The Lubricating Oil144
Technical Limitations Of Combustion Gas And Exhaust Gas144
Loss Of Activity In The Catalytic Converter145
Exhaust System And Ventilation Of The Oil Sump146
Exhaust Manifold146
Electric Starter150
Description Of The Electric Starter System150
Overview Of Electric Start With Two Starter Motors151
Electrical Schematic Components151
Battery Properties For Engine Series152
Start-Up152
Minimum Or Obligatory Safety Measures153
Failure Of The Measurement Signals153
Table Of Minimum Engine Safety Measures153
Configuration Of Minimum Engine Protections154
Additional Instrumentation156
Configuration Of Additional Engine Signals And/Or Protections156
Power Regulation157
Obligatory157
Configuration Of Power Regulations157
Lifting System For Sfgld/Sfgm V Engine159
Front Of Engine160
Rear Of Engine161
Deferred Start-Up Status Application Requirements164
Related Documents164
Condition Of Engines Subject To Deferred Start-Up165
Deferred Start-Up Engine Inspection165
Deferred Start-Up Engine Protection166
Packing Of Deferred Start-Up Engines167
Temperature Limit In The Room Or Container On Start-Up171
Temperature Limit In The Room Or Container On Operation171
Use Of The Barring Gear173
Location On In-Line Engines173
Location On Vee Engines173
Corrosion174
Cavitation174
Scale174
General Information174
Microbiological Growth175
Cooling Water Quality175
Cooling Water Quality And Treatment176
Minimum Coolant Requirements176
Additives. Antifreeze177
Coolant Treatment179
Applications180
Advantages And Benefits181
Health And Safety181
Typical Characteristics181
Aim182
Gases Used As Engine Fuels182
Basic Parameters Of Gaseous Fuels182
Analysis Of Fuel Gas183
Sampling Frequency183
Analysis Laboratories183
Contaminants And Factors Affecting The Engine Operation183
Kohler Specifications For Fuel Gases184
Lower Heat Value184
Contaminants Of Fuel Gas184
Halogenated Compounds185
Silicon Compounds185
Residual Oils And Tar185
Solid Particles185
Engines With A Catalytic Converter186
Fuel Specifications – Us Natural Gas187
Summary Table191
Display Configuration192
Device Configuration192
Selecting A New Device193
Screen Configuration194
Access Control Configuration194
Access Control195
Use Of Gis Unit Display196
Main Menu On Gis Ignition Unit196
Reading Parameters197
Timing197
Ignition Timing Display Menu198
Ignition199
Energy199
Screenshot Of Secondary Voltage199
Firing Angle200
Screenshot Of Energy Parameters200
Message Log200
Screenshot Of List Of Errors And Warnings201
Diagnostics203
Screenshot Of Device Information203
Screenshot Of The Unit's Operating Parameters203
Adjusting The Ignition Timing204
Adjusting Energy Parameters204
Operational Hour205
Preparations For Starting Up For The First Time206
Pre-Start Inspection206
Lubrication (Oil Circuit)206
Refrigeration (Engine Coolant Circuit)206
Fuel207
Before Engine Start-Up207
Engine Start-Up207
Operating Inspection208
Engine Shut-Down208
Normal Start And Stop Procedure209
Gas Engines And Ethanol Engines Carburation210
Specifications210
Emission Units Conversion212
Iso Cycles214
C1 Cycle214
D1 Cycle214
D2 Cycle214
Oil Level Indicators215
Ul Oil Level Indicator216
Emissions - Related Installation Instructions219
Instructions For Installation Of The Exhaust Pipe219
"V" Engine Installation of Exhaust Pipeline220
Instructions For Installation Of The Fuel Pipe221
Axial Shift (Compression)221
Cross Travel221
Engine-Room Ventilation222
Installation Of Air Filters222
Engine Instrumentation223
In Use Testing223
Adjust Fuel Air Ratio223
General Maintenance Of Gas Engines225
Maintenance Intervals225
Daily Maintenance226
Control Of Coolant Level226
Control Of Oil Level226
Daily Recording Of The Engine Data226
Lubrication Oil Leaks227
Coolant Leaks227
Gas Leaks227
Check For Sensors227
Maintenance Program228
Basic Maintenance Operations229
Engine Long Term Storage234
Monthly Maintenance237
Oil Consumption241
Gas-Fueled Engine Oil Servicing Instructions241
Oil Analysis241
Interpretation Of Results242
Viscosity242
Tbn242
Tan242
Oxidation / Nitration243
Water Content243
Insoluble Substances243
Content Of Metallic Particles243
Oil Sampling Procedure245
Oil Change Procedure246
Kohler Engine Oil Change Instructions247
Changing Of The Oil Filter Cartridge248
To Dismount The Filter248
Mounting The Filter248
Cleaning Of Filter249
Maintenance Of The Recirculation System250
Changing The Filtering Cartridge250
Inspecting The Installation251
Performing The Start-Up Procedure251
Troubleshooting252
Cleaning And Inspection253
Check For Leaks253
Alternative For Fv Gas Engines254
Cylinder Compression Test256
Conditions Causing Low Engine Compression257
Preliminary Checks258
Changing The Spark Plugs258
Maintenance Instructions259
Visual Inspection Of The Spark Plug Condition260
Scope Of Application261
Use Of The Cpu 95 Ignition Unit Diagnosis Capability261
Use Of The Gis Ignition Unit Diagnosis Capability262
Secondary Voltage Values On The Gis Ignition Unit Screen262
Use Of The Gcs Unit Diagnosis Capability263
Use Of Exhaust Temperatures Per Cylinder263
Secondary Voltage Values On The Gcs Unit Screen263
Fitting The Spark Plugs264
Check Of Ignition Coils And Spark Plug Wires265
Coils265
Spark Plug Wires266
Measuring The Resistance Of A Spark Plug Wire Ref266
Maintenance Of Spark Plugs. Overview267
Operations Simultaneous With Spark Plug Replacement267
Guidelines On Spark Plug Replacement268
Checking The Ignition Timing269
Engine Stopped269
Strobe Gun Earth And Measurement Clamps269
Earth Clamp On Battery Negative Terminal270
Red Clamp On Positive Terminal Of The Battery270
Measuring The Timing270
Engine Running271
Connecting The Clamp Wearing High Voltage Gloves271
Adjusting The Valves272
Valve Clearance272
Valve Adjustment273
Pairing Of Cylinders At Top Dead Center274
Measurement Of Valve Clearance275
Air Filters. Maintenance276
Maintenance Of Air Filters276
Double-Stage Air Filter Maintenance Operations276
Inspection Of The Main Filter Cartridge276
Cleaning The Main Filter Cartridge278
Blow-Through279
Washing279
Substitution Of Filter Cartridges279
Maintenance Of Ghf Air Filters280
Changing The Ghf Filtering Cartridges280
Damper Condition Monitoring282
Damper Temperature Control282
Silicone Sampling Method283
On-Site Analysis Of The Silicone Sample285
Procedure For Filling And Draining The Cooling Circuit With Antifreeze286
Air Bleed Valve In Thermostat Housing286
Cooling System Maintenance286
Automatic Air Bleed Valve287
Cooling System Monitoring And Cleaning289
Maintenance Of Turbocharger291
Inspection Of The Turbocharger291
Cleaning The Turbocharger293
Turbocharger Failure Analysis293
Intake Safety Valve295
Operating And Maintenance Procedure295
Inspection Guide295
– Pictures Showing Reasons For Rejecting Valves296
Maintenance Of Intercoolers297
Cleaning The Intercooler297
Cleaning The Set Of Plates297
Different Intercooler Models297
Cleaning The Water Pipes298
Plugging The Water Pipes298
Removing The Intercooler299
Fitting The Intercooler299
Maintenance Of Pick-Ups300
Maintenance Of Batteries301
Routine Inspection301
Charging The Battery301
Adjusting The Acid Levels302
Changing The Battery302
Gas Engines Troubleshooting304
Troubleshooting Guide304