Kohler SFGLD360 Manuals

Manuals and User Guides for Kohler SFGLD360. We have 1 Kohler SFGLD360 manual available for free PDF download: Operation & Maintenance Manual

Kohler SFGLD360 Operation & Maintenance Manual (315 pages)

Generator Set Models 750/1000REZK

Brand: Kohler | Category: Engine | Size: 37.91 MB

General Index
6
Safety Precautions for Kohler Gas Engines
10
Introduction
10
Preliminary Observations
10
Bodily Protection
10
Engine Fuels
11
Positive Fuel Shut-Off
11
Safety Guards
11
Crankcase Gases
11
Cooling System Pressure Caps and Connections
12
Ignition System
12
Generator Sets
12
Tidiness and Cleanliness
13
Engine and Equipment; Repair and Service
13
Engine Fan Blades
13
Turbochargers
14
Engine Storage Chemicals
14
Fire Protection
14
Cleaning Solvent
15
Welding Equipment
15
Grounding Precautions When Welding
15
Electrical Tools
15
Batteries
16
Precautions When Using Booster Batteries and Cables
16
Compressed Air
16
Intoxicants and Narcotics
16
Safety Practices for Handling Acids
17
Engine Lifting and Handling
17
Engine Design
18
Engine Room
18
Risk Analysis
18
Materials and Products
19
Equipment Drives
19
Mechanical Hazards
19
Electrical Hazards
19
Forced Induction
20
Manifolds and Exhaust Pipe
20
Vibration
20
Noise
20
Fuel System
21
Gas
21
Ethanol
21
Blow-By Gases
22
Exhaust Fumes
22
Maintenance
22
Information
22
Safeguarding against Malfunction
23
Safety Precautions
24
Conclusion
24
Acoustic Definitions
25
Noise Emission at 1500 Rpm
26
Noise Emission at 1800 Rpm
27
Sound Pressure Level
28
Noise Emission at 1200 Rpm
28
Decontamination and Disassembly
31
Staff Training
32
Decontamination, Waste Processing and Management Methods
32
Hazardous Waste
32
Recommended Handling Methods
32
Non-Hazardous Waste
33
Used Oil Filter
33
Fuel Filter
33
Waste Management
34
Waste Oil
34
Engine Identification Plate
38
Basic Specifications of Gas Engines
48
General Description of the Construction of the Engine
48
Crankcase
48
Sleeves
48
Bearings
49
Cylinder Heads
49
Connecting Rods
49
Pistons
49
Camshaft
50
Distribution
50
Lubrication
50
Refrigeration
50
Intake
51
Miscellaneous
51
Tightening Torques for Commercial Bolts & Nuts
71
Standard Tightening Torque Specification
71
Coefficient of Friction for Different Coatings
72
Mechanical Properties of Screws Used
72
Auxiliary Screw Driving Products
73
Units Conversion
74
Cooling Circuit Diagram
76
Engine Mounted Cooling Circuit
77
Jack Ket Water Circuit
77
Cooling System Components
80
Impeller Pump
80
Oil Cooler
80
Engine Block
80
Water Preheating System
81
Water Temperature Regulator
81
Caja de Termostatos Circuito Principal
81
Vent
82
Expansion Tank
82
External Cooling System
82
Venting Pipes
82
Requirements of the Engine Cooling System
83
Gas Engines – Pressure Losses and Flowrates
84
Minimum Flowrates for Fgld Engines
85
Main Cooling Circuit
85
Auxiliary Cooling Circuit
85
Minimum Flowrates for Sfgld / Sfgrd / Sfgm Engines
86
Overpressure Safety Valve
92
Lubricating Oil Pressure Regulating Valve
92
Thermostatted Oil Valve
92
Centrifugal Filter
93
Blow-By Gas Exhaust System
93
Open or Passive System
93
Active O Blow-By Gas Recirculating System
93
Operation
94
Automatic Engine Oil Level Controller
97
General Layout on 180/240 Series Engines
97
General Layout on 180/240 Series Generating Sets
97
General Layout on 360/480/560 Series Engines/Generating Sets
98
Automatic Oil Level Controller
98
Lube Oil Level Indicator Ul
101
Components Specification
101
Oil Preheating System Per Type of Engine
106
General Layout - HGM 240 Engines
106
Performance
107
Configuration
108
CGR on Gas In-Line Engine FGLD/SFGLD
109
CGR on Gas V-Engine FGLD/SFGLD
109
CGR on HGM240 Engine
109
CGR on HGM 420/560 Engine
109
Oil Level Controller
110
Crankcase Gas Breather
110
Blow-By Gas Recirculation Filter
111
Crankcase Pressure Control Valve
111
Oil Feedback to Crankcase
112
Blow-By Gas Feed Pipe to the Air Intake
112
Crankcase Pressure
112
Egs 02. Description
113
Functionalities
114
Speed Control
114
Load Control
114
Control of Carburation at Different Loads
114
Egs02 Complementary Equipment
115
Pick-Up
115
Mat
115
Map
115
Throttle Valve
116
Tecjet
116
Venturi Type Carburation - Description
117
Zero Pressure Regulator
117
Carburation System Scheme
117
Gas Flow Control
118
Main Adjustment Screw (Mas)
118
Carburettor
120
Gas Control Injector
120
Carburettor and Barrel
120
Air-Gas Mixteure by Venturi Effect
121
Electronic Control
121
Specification of Gas Supply to Tecjet 52
122
Gas Pressure Range
122
Minimum Pressure at Tecjet52 Vs Maximum Power
122
Maximum Pressure at Tecjet52 Vs Maximum Power
123
Working Temperatures
124
Gas Filter
124
Description of the Gis Ignition System
126
GIS Coil
126
GIS High Voltage Lead
126
Basic Layout of the In-Line Engine Ignition System
126
Basic Layout of the V-Engine Ignition System
127
Gis Ignition Module
128
General Features
128
Functions and Operation
128
Configuration of Pickup Signals
128
Analogue/Digital Outputs
129
Visualisation Leds
129
Communications
130
PC Connection
130
Potentiometers and Reset Button
130
Technical Specifications
131
Fitting the Ignition Module
131
Overview of the Ignition System for V-Engines with 16 Cylinders
131
Gas Engines Intake System
132
Air Filter
132
Turbocharger
133
High-Rate Single-Stage Filter
133
In-Line Engines
133
Intake Manifold
135
Air Filters
136
Air Filters. Characteristics
136
General View of Double-Stage Air Filters
136
Exploded View of a Tangentially Sealed Air Filter
137
Exploded View of a Radially Sealed Air Filter
137
General Drawing of Kohler High Flow Two-Cartridge Filter
138
Exploded View of Kohler High Flow Two-Cartridge Air Filters
138
Exploded View of Kohler High Flow One-Cartridge Air Filter
139
Oxidative Catalytic Converters
140
Operating the Catalytic Converter
140
Engine Operation
141
Parts of an Oxidative Catalytic Converter
141
Optimal Working Temperatures of the Catalytic Converter
142
Technical Limitations of the Lubricating Oil
144
Technical Limitations of Combustion Gas and Exhaust Gas
144
Loss of Activity in the Catalytic Converter
145
Exhaust System and Ventilation of the Oil Sump
146
Exhaust Manifold
146
Electric Starter
150
Description of the Electric Starter System
150
Overview of Electric Start with Two Starter Motors
151
Electrical Schematic Components
151
Battery Properties for Engine Series
152
Start-Up
152
Minimum or Obligatory Safety Measures
153
Failure of the Measurement Signals
153
Table of Minimum Engine Safety Measures
153
Configuration of Minimum Engine Protections
154
Additional Instrumentation
156
Configuration of Additional Engine Signals And/Or Protections
156
Power Regulation
157
Obligatory
157
Configuration of Power Regulations
157
Lifting System for Sfgld/Sfgm V Engine
159
Front of Engine
160
Rear of Engine
161
Deferred Start-Up Status Application Requirements
164
Related Documents
164
Condition of Engines Subject to Deferred Start-Up
165
Deferred Start-Up Engine Inspection
165
Deferred Start-Up Engine Protection
166
Packing of Deferred Start-Up Engines
167
Temperature Limit in the Room or Container on Start-Up
171
Temperature Limit in the Room or Container on Operation
171
Use of the Barring Gear
173
Location on In-Line Engines
173
Location on Vee Engines
173
Corrosion
174
Cavitation
174
Scale
174
General Information
174
Microbiological Growth
175
Cooling Water Quality
175
Cooling Water Quality and Treatment
176
Minimum Coolant Requirements
176
Additives. Antifreeze
177
Coolant Treatment
179
Applications
180
Advantages and Benefits
181
Health and Safety
181
Typical Characteristics
181
Aim
182
Gases Used as Engine Fuels
182
Basic Parameters of Gaseous Fuels
182
Analysis of Fuel Gas
183
Sampling Frequency
183
Analysis Laboratories
183
Contaminants and Factors Affecting the Engine Operation
183
Kohler Specifications for Fuel Gases
184
Lower Heat Value
184
Contaminants of Fuel Gas
184
Halogenated Compounds
185
Silicon Compounds
185
Residual Oils and Tar
185
Solid Particles
185
Engines with a Catalytic Converter
186
Fuel Specifications – Us Natural Gas
187
Summary Table
191
Display Configuration
192
Device Configuration
192
Selecting a New Device
193
Screen Configuration
194
Access Control Configuration
194
Access Control
195
Use of Gis Unit Display
196
Main Menu on GIS Ignition Unit
196
Reading Parameters
197
Timing
197
Ignition Timing Display Menu
198
Ignition
199
Energy
199
Screenshot of Secondary Voltage
199
Firing Angle
200
Screenshot of Energy Parameters
200
Message Log
200
Screenshot of List of Errors and Warnings
201
Diagnostics
203
Screenshot of Device Information
203
Screenshot of the Unit's Operating Parameters
203
Adjusting the Ignition Timing
204
Adjusting Energy Parameters
204
Operational Hour
205
Preparations for Starting up for the First Time
206
Pre-Start Inspection
206
Lubrication (Oil Circuit)
206
Refrigeration (Engine Coolant Circuit)
206
Fuel
207
Before Engine Start-Up
207
Engine Start-Up
207
Operating Inspection
208
Engine Shut-Down
208
Normal Start and Stop Procedure
209
Gas Engines and Ethanol Engines Carburation
210
Specifications
210
Emission Units Conversion
212
ISO Cycles
214
C1 Cycle
214
D1 Cycle
214
D2 Cycle
214
Oil Level Indicators
215
UL Oil Level Indicator
216
Emissions - Related Installation Instructions
219
Instructions for Installation of the Exhaust Pipe
219
“V” Engine Installation of Exhaust Pipeline
220
Instructions for Installation of the Fuel Pipe
221
Axial Shift (Compression)
221
Cross Travel
221
Engine-Room Ventilation
222
Installation of Air Filters
222
Engine Instrumentation
223
In Use Testing
223
Adjust Fuel Air Ratio
223
General Maintenance of Gas Engines
225
Maintenance Intervals
225
Daily Maintenance
226
Control of Coolant Level
226
Control of Oil Level
226
Daily Recording of the Engine Data
226
Lubrication Oil Leaks
227
Coolant Leaks
227
Gas Leaks
227
Check for Sensors
227
Maintenance Program
228
Basic Maintenance Operations
229
Engine Long Term Storage
234
Monthly Maintenance
237
Oil Consumption
241
Gas-Fueled Engine Oil Servicing Instructions
241
Oil Analysis
241
Interpretation of Results
242
Viscosity
242
Tbn
242
Tan
242
Oxidation / Nitration
243
Water Content
243
Insoluble Substances
243
Content of Metallic Particles
243
Oil Sampling Procedure
245
Oil Change Procedure
246
Kohler Engine Oil Change Instructions
247
Changing of the Oil Filter Cartridge
248
To Dismount the Filter
248
Mounting the Filter
248
Cleaning of Filter
249
Maintenance of the Recirculation System
250
Changing the Filtering Cartridge
250
Inspecting the Installation
251
Performing the Start-Up Procedure
251
Troubleshooting
252
Cleaning and Inspection
253
Check for Leaks
253
Alternative for Fv Gas Engines
254
Cylinder Compression Test
256
Conditions Causing Low Engine Compression
257
Preliminary Checks
258
Changing the Spark Plugs
258
Maintenance Instructions
259
Visual Inspection of the Spark Plug Condition
260
Scope of Application
261
Use of the Cpu 95 Ignition Unit Diagnosis Capability
261
Use of the Gis Ignition Unit Diagnosis Capability
262
Secondary Voltage Values on the GIS Ignition Unit Screen
262
Use of the Gcs Unit Diagnosis Capability
263
Use of Exhaust Temperatures Per Cylinder
263
Secondary Voltage Values on the GCS Unit Screen
263
Fitting the Spark Plugs
264
Check of Ignition Coils and Spark Plug Wires
265
Coils
265
Spark Plug Wires
266
Measuring the Resistance of a Spark Plug Wire Ref
266
Maintenance of Spark Plugs. Overview
267
Operations Simultaneous with Spark Plug Replacement
267
Guidelines on Spark Plug Replacement
268
Checking the Ignition Timing
269
Engine Stopped
269
Strobe Gun Earth and Measurement Clamps
269
Earth Clamp on Battery Negative Terminal
270
Red Clamp on Positive Terminal of the Battery
270
Measuring the Timing
270
Engine Running
271
Connecting the Clamp Wearing High Voltage Gloves
271
Adjusting the Valves
272
Valve Clearance
272
Valve Adjustment
273
Pairing of Cylinders at Top Dead Center
274
Valve Clearance
275
Measurement of Valve Clearance
275
Air Filters. Maintenance
276
Maintenance of Air Filters
276
Double-Stage Air Filter Maintenance Operations
276
Inspection of the Main Filter Cartridge
276
Cleaning the Main Filter Cartridge
278
Blow-Through
279
Washing
279
Substitution of Filter Cartridges
279
Maintenance of Ghf Air Filters
280
Changing the Ghf Filtering Cartridges
280
Damper Condition Monitoring
282
Damper Temperature Control
282
Silicone Sampling Method
283
On-Site Analysis of the Silicone Sample
285
Procedure for Filling and Draining the Cooling Circuit with Antifreeze
286
Air Bleed Valve in Thermostat Housing
286
Cooling System Maintenance
286
Cooling System Maintenance
287
Automatic Air Bleed Valve
287
Cooling System Monitoring and Cleaning
289
Maintenance of Turbocharger
291
Inspection of the Turbocharger
291
Cleaning the Turbocharger
293
Turbocharger Failure Analysis
293
Intake Safety Valve
295
Operating and Maintenance Procedure
295
Inspection Guide
295
– Pictures Showing Reasons for Rejecting Valves
296
Maintenance of Intercoolers
297
Cleaning the Intercooler
297
Cleaning the Set of Plates
297
Different Intercooler Models
297
Cleaning the Water Pipes
298
Plugging the Water Pipes
298
Removing the Intercooler
299
Fitting the Intercooler
299
Maintenance of Pick-Ups
300
Maintenance of Batteries
301
Routine Inspection
301
Charging the Battery
301
Adjusting the Acid Levels
302
Changing the Battery
302
Gas Engines Troubleshooting
304
Troubleshooting Guide
304

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Kohler SFGLD360 Operation & Maintenance Manual (315 pages)

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