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Contents Safety ............................................................................................................................................................ 3

General information ..................................................................................................................................... 3

Safety regulations for startup and operation, special Instructions for applications with gaseous fuel ....... 3

Gas System ................................................................................................................................................ 3

General Repair Instructions ...................................................................................................................... 4

Gas Engine generator .................................................................................................................................... 5

Working Principle .......................................................................................................................................... 5

There are two main engines: ......................................................................................................................... 5

QSK45G ENGINE ............................................................................................................................................ 6

Front View of Engine ................................................................................................................................. 6

Right Side View of Engine ......................................................................................................................... 6

Left Side View of Engine ............................................................................................................................ 6

Top View of Engine ................................................................................................................................... 7

Back View of Engine .................................................................................................................................. 7

Caution .......................................................................................................................................................... 8

Winter fronts and Shutters ........................................................................................................................... 8

Engine Shutdown .......................................................................................................................................... 8

Electronic Components ................................................................................................................................. 9

Operating Instructions .................................................................................................................................. 9

QSK60G ENGINE ............................................................................................................................................ 9

Lubricating Parts ....................................................................................................................................... 9

Piston Cooling ......................................................................................................................................... 10

Front Side View ....................................................................................................................................... 10

Full-Flow Oil Filter Head .......................................................................................................................... 10

Cooling System ........................................................................................................................................ 11

Thermostat Housing Flow- LTA (Two Pump-Two Loop) ......................................................................... 11

Air Fuel Mix ............................................................................................................................................. 11

Exhaust System ....................................................................................................................................... 12

3

Safety

General information This product may pose a risk of injury or damage in the following cases:

• Incorrect use

• Operation, maintenance and repair by unqualified personnel

• Modifications or conversions

• Noncompliance with the safety instructions and warning notices Safety.

Safety regulations for startup and operation, special Instructions for

applications with gaseous fuel

Gas System Gas supply shut-off: The incomplete machine does not have its own gas supply shutoff

device. This must be designed by the plant designer according to site conditions.

The connection to the gas supply network is made by the plant designer in accordance

with regulations

The plant designer must use certified gas trains for the fuel supply to the product and

connection to the gas supply network. The connection conditions and dimensions must be

coordinated with the manufacturer.

In flow direction, gas trains have:

• A manual shutoff fitting

• A gas filter

• Two gas shutoff valves

• A pressure regulating device

The gas train must be fitted with an automatic leak check.

The gas shutoff valves are activated via two different paths from the control system,

whereby one gas shutoff valve respectively is activated via one of the paths.

Gas trains must be monitored to detect minimum pressure.

The plant designer must ensure that the gas train is positioned directly in front of the

engine, however a maximum of three meters before the interface of the engine. The

interface is the flange in front of the gas volume regulator of the product.

In the case of network supply pressures higher than 120 mbar, additional equipment is

required on the gas train.

The gas pressure regulator must be equipped with an approved safety shut-off valve and a

safety discharge valve to ensure safety in case of excessive outlet pressure at the pressure

regulator. Gas discharge must be routed to a safe area (to atmosphere).

If the gas supply is connected to a vessel or if gases containing oxygen are used, the gas

train must be equipped with a temperature-monitored flame arrester.

4

General Repair Instructions Have maintenance or repair work carried out by qualified and authorized personnel only.

Allow the product to cool down to less than 50°C before starting maintenance work (risk

of explosion of oil vapors, fluids and lubricants, risk of burning).

Before starting work, relieve pressure in systems and compressed-air lines which are to

be opened. Use suitable containers of adequate capacity to catch fluids and lubricants.

When changing the oil or working on the fuel system, ensure that the service room is

adequately ventilated.

Never carry out maintenance and repair work with the product in operation, unless:

• Expressly permitted to do so following a written procedure.

• The product is running in the low load range and only for as long as absolutely

necessary.

Secure the product against unintentional starting, e.g. with start interlock.

Attach “Do not operate” sign in the operating area or to control equipment.

Disconnect the battery. Lock contactors.

Close the main valve on the compressed-air system and vent the compressed-air line

when pneumatic

Starters are fitted.

Disconnect the control equipment from the product.

The following applies to starters with copper-beryllium alloy pinions:

• Wear breathing protection of filter class P3 during maintenance work. Do not

blow out the interior of the flywheel housing or the starter with compressed air.

Clean the flywheel housing inside with a class dust extraction device.

• Observe the safety data sheet

Below is a partial listing of engine is classified as safety-related:

Air Compressor

Flywheel Mounting Cap Screws

Air Controls

Fuel Shutoff Assemblies

Air Shutoff Assemblies

Fuel Supply Tubes

Balance Weights

Lifting Brackets

Cooling Fan

Throttles Controls

Fan Hub Assembly

Turbocharger Compressor

Fan Mounting Bracket(s)

Turbocharger Oil Drain Line(s)

5

Fan Mounting Cap Screws

Turbocharger Oil Supply Line(s)

Fan Hub Spindle

Turbocharger Turbine Casing

Flywheel

Flywheel Crankshaft Adapter

Gas Engine generator An engine-generator is the combination of an electrical generator and an engine (prime mover)

mounted together to form a single piece of equipment. This combination is also called an engine-

generator set or a gen-set. In many contexts, the engine is taken for granted and the combined

unit is simply called a generator.

Working Principle An electricity generation, a generator is a device that converts mechanical energy to electrical

energy for use in an external circuit. The source of mechanical energy may vary widely from a

hand crank to an internal combustion engine. Generators provide nearly all of the power for

electric power grids.

There are two main engines:

QSK45G ENGINE

QSK60GENGINE

6

QSK45G ENGINE

Front View of Engine

There are following parts of gas engine in front view:

After cooler

Air filter

Thermostat housing

Water filter

Intake manifold

Ignition control module

Crankcase breather

Vibration damper

LTA coolant pump

Front gear housing

Throttle actuator

Right Side View of Engine There are following parts of gas engine in right side view:

Alternator

CENSE module

Coil on plug

Exhaust outlets

Turbocharger

Fuel inlet

Gas mass flow sensor

Fuel control valve

Air filter

After cooler

Thermostat housing

Hot side (thermostat)

Ignition control module

Low temperature coolant circuit pipe

Water pump (engine)

Oil filters

Oil pans

Left Side View of Engine There are following parts of gas engine in left side view:

Air filter

7

Turbocharger coolant return hose

Crossover air pipes

Turbocharger

Exhaust outlets

AVR/control box

Emergency stop

DC terminal box

Air outlet(alternator fan)

Flywheel housing

Oil pan

Crankcase breather

Crankcase breather drain

Crankcase breather oil drain

Left bank CM558(ECM)

LTA coolant pump

Ignition control module

Coil on plug

Water transfer pipes

After cooler

Top View of Engine There are following parts of gas engine in top view:

DC terminal box

Alternator

Exhaust outlets

Coil on plug

Wiring harness

Air filters

After cooler

Frame rail

Low temperature water pipe

High temperature water pipe

Rocker cover

Crossover air pipes

Back View of Engine There are following parts of gas engine in back views:

Air box

8

Fuel control valve

Gas mass flow sensor

Fuel inlet

Coil on plug

AC terminal box

Frame rail

Oil pan

DC terminal box

Emergency stop

Caution Do not idle for extended periods of time. Excessive idle time can cause poor engine

performance.

Cold weather

Ambient temperature

0 to -32 OC [32 to-25 OF]

Use 50-percent ethylene glycol antifreeze and 50-percent water foe the engine

coolant mixture. Refer to maintenance specifications (section V) lubricating oil

recommendations for the correct.

-32 to 54 OC [-25 to -65 OF]

Use 60-percent ethylene glycol antifreeze and 40-percent water foe the engine

coolant mixture. Refer to maintenance specifications (section V) lubricating oil

recommendations for the correct.

The following cold weather operating aids are required for cold weather operations.

Winter fronts and Shutters It can be used on a vehicle or equipment to reduce air flow through the radiator core into the

engine compartment. This can reduce the time required to warm the engine and help maintain the

engine coolant temperature. The engine coolant temperature specifications are in the

maintenance specification (section V).

Engine Shutdown Allow the engine to idle 3 to 5 minutes before shutting it off after a full load operation. This

allows adequate cool down of piston, cylinders, bearings and turbocharger components.

Turn the ignition switch to the OFF position. If the engine does not shut down, refer to

troubleshooting symptom (section TS).

9

Electronic Components There are two CM558 modules.

The CM558 sub system modules:

Solid state fully encapsulated and can connect with nine cylinders.

Non –serviceable

Module has two 50 pin Deutsch connection.

The CM558 sub system modules monitor for:

Engine speed/position

Throttle position sensor

Knock sensor

Intake manifold pressure sensor

Operating Instructions The gas mass flow sensor mounted on the outside of the fuel control valve measures the amount

of fuel being fixed with the intake air. The sensor is a hot wire thermometer that measures the

amount of power required to keep an electrically heated wire at a constant temperature. The wire

requires more power to maintain a constant temperature as more fuel flows by the wire. The

sensor has a built in circuit board that controls the sensor.

The CM558 supplies the sensor with 14 VDC and a return. The sensor provides a signal between

0 and 5 VDC that proportional to the gas mass flow. It uses this input for fuel control.

The fuel inlet pressure sensor

The fuel outlet pressure sensor

The intake manifold temperature sensor

The compressor outlet pressure sensor

The heated oxygen sensor

The exhaust back pressure sensor

QSK60G ENGINE

Lubricating Parts

Oil suction tube

Oil pump discharge

High pressure relief valve

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Oil pump transfer tube

Block connection

Oil flow to filter head

Oil filters

Oil flow from filter head

Oil filters

Oil supply to oil coolers

Oil cooler

Cooled oil to flywheel housing

Main oil riffle

Oil supply to main bearings

Sensing riffle to pressure regulator

Pressure regulator valve

Piston Cooling Oil flow from oil cooler

Oil supply to main oil riffle

Oil supply to left bank overhead

Oil supply to right bank overhead

Oil supply to rocker levers

Left bank piston cooling nozzle regulator

Piston cooling nozzle

Right bank piston cooling nozzle regulator

Oil supply to Right bank piston cooling nozzle

Oil supply to turbochargers

Turbocharger oil drain to sump

Front Side View

Main oil supply

Oil supply to idler gear

Oil supply to accessory drive

Oil supply to gear cover

Oil supply to Rockford fan clutch

Oil supply to water pumps drive.

Full-Flow Oil Filter Head Oil supply from lubricating oil pump

Oil supply through filter head to oil filters

Lubricating oil filters

Bypass valve – open position

Oil supply from oil filter

11

Oil supply oil coolers

Bypass valve – closed position

Cooling System LTA coolant flow from LTA radiator

LTA water pump

LTA coolant flow to after cooler

After cooler

LTA return to thermostat housing

Thermostat housing

LTA coolant return to LTA lamp

LTA coolant return to LTA radiator

Coolant inlet to water pump

Coolant return from after cooler

Coolant return from turbocharger

Turbocharger coolant supply

Water pump to after cooler

Coolant bypass return to water pump

Coolant return to radiator

Thermostat Housing Flow- LTA (Two Pump-Two Loop) Right bank coolant to thermostat housing

Left bank coolant to thermostat housing

Coolant bypass to water pump

Coolant filters

Coolant return to engine radiators

LTA coolant from after cooler

LTA thermostat open

LTA coolant return to low temperature after cooler radiator

LTA thermostat closed

LTA coolant to low temperature after cooler coolant pump.

Air Fuel Mix Intake air

Fuel supply

Fuel/air mixer

Turbocharger compressor

Air/fuel mixture flow to after cooler

Throttle actuator

Thermostat housing

Cylinder head intake port

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Intake manifold

Exhaust System Exhaust port

Exhaust manifold

Turbocharger exhaust outlet