WARRANTY ‘The Seller warrants to the Buyer that the equipment to be delivered hereunder will be free fron defacts in matertal, worknanship and.titie and will be of the. kind” described in the contract. THE FOREGOING WARRANTY TS EXCLUSIVE “AND. TN™ LIEU. OF” ALL OTHER WARRANTIES WHETHER WRITTEN, ORAL OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS’ FOR PURPOSE). If 1t appears within one year from the date the equipnent. is placed "in. service but no later than eighteen (18) months from the date of delivery to the Buyer, whichever first occurs, that the equipment does not meet the warranty specified above and the’ Buyer notifies the Seller” promptly, the Seller shall correct any defect, at the Seller's option, efther by repairing any defective part or parts or by naking available, at the Seller's factory, a repaired or replacenent parts The liability of the Seller” to. the. Buyer (oxcept as to title) [rising out of the supplying of the equipment, or its use, whether on warranty, contract or negligence, shall notin any case exceed the cost OF corracting defects “in the equipment or part thereof and upon expiration of the warranty period all such liability shall terminate. he foregoing shall constitute the sole ramody of the Guyer and the sole Tabitity of the Seller. ‘The preceding paragraph shall not apply and the SeTler assures no Tyability whatsoever for breach of warranty when there is evidence that the defect arose as the result of "(a) abuse or negligence in the ‘operation of the equipment, (b) failure to maintain the equipnent properly, (e) overloading or overspeeding, or (d) use of repair parts not approved by the Seller. The warranty given to the Seller by its supplier of special equipment, Jneluding but not Tinfted £0 generators, switchgear and control, reduc” ton gears and. centrifugal compressors, is hereby assigned ‘without Fecourse by the Seller to the Buyer.” AS TO THIS. SPECIAL EQUIPMENT, WHICH GENERALLY BEARS. THE NAMEPLATE OF THE SELLERS SUPPLIER, THE SELLER ASSUMES NO. LIABILITY WHATSOEVER. FOR BREACH OF WARRANTY. WHETHER WRITTEN, “ORAL OR INPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS’ FOR PURPOSE)WARNINGS, CAUTIONS, AND NOTE: WARNINGS, CAUTIONS, AND NOTES Improper or careless operaton of maintsnance ofthis equpment may ‘Tens serbushazars er beh equa’ an perenne To mize [tnt damage fo property andthe cangr to personnel working on ot ‘Sound the oqupmert, WAANINGS, CALTIONs, and NOTES are posed ‘oughou to manu to alet te uset to the possbaty of acecetal ‘equipment camage, personal uy, or deat. Since we eannot foresee Stat posuble danger useyoursommen sons and be alt for dangerous Suatens, . ANOTEindeatas.nessentlopraingprocedur or condtion which must betughignted. A NOTE appears as ols: ore ‘Whar changing the engin ubrcaing ol als change the ol ters [ACAUTIONindcatestnatifnespactfodprecautonisnotheeded, damans, rar bt "ACAUTIONappears slows CAUTION ‘FOINGURe AGANST ANY HAZARDOUS MALFUNCTION OF THIS EQUIPMENT, ALWAYS USE THE ESeSEIED Pans WHEN MAKING REPAIRS, [AWARNING incates thatthe specied precauton'snotheeded, heres as wellas damage to property. A (WARNING appears as flows: ZAWARNING ‘THE IGNITION sySTEM PRODUCES EXTREMELY HIGH VOLTAGE. DO NOT TOUCH HIGH ‘TENSION TERMINALS WHEN THE ENGIE IS OPERATING, ‘Some general precautions hat shed aways be practiced when operating or maitaring he equpment are fstdin te folowing pagos, Make sure ‘hata personne read tego procaine and achere to hor CAUTION SANYEAEANING SOLVENTS GAN IPRITATE THE S12 EVES. ANDLUNGS. FOLLOW MANUraGrUHER S PRECAUTIONS WHEN USING SOLVENTS -~ PROTECT YOURSELF FROM BeNeincunes cauTION RANAYS SE HaNo PROTECTION WHEN HANDLING EXTREMELY COLD TEMS. ‘CAUTION. Son SURE THE ROCKER ARM ASSENOLIES OLER IS NSTALLED PROPERLY TO HELP BEScNT NASEGUATE LUBRICATION AND ENGINE DAMAGE. s COOPER ‘iax-Superior larued 6Gas ENGINE INSTRUCTION MANUAL ZA WARNING $e mmorecr AGANST THe DANGER OF EXPLOSION, ALWAYS USE A GROUNDED, SeALao LNT NTE GRaoASE. ZXWARNING Many oF THE PARTS HANDLED DURING MAINTENANCE ARE HEAVY. EXTREME ‘GAUTION MUsr 86 UsED To CURE THAT PERSONNEL ARE NOT MJURED BY FALLING PARTS OR NADEGUATELY RESTRANED PARTS ZXAWARNING. Ser one staRTING THe ENGINE, ALWAYS PURGE THE EXIAUST SYSTEM OF GReURNED FUEL: CRanie THe ENGINE FOR AT LEAST 10 SECONDS WITH THE fenimion ano FUELOFE ZAWARNING ‘MAKE SURE NO ONE IS AROUND THE ENGINE WHEN ITS BEING STARTED. ZAWARNING ‘{faen PERFORMING MAINTENANCE, MAKE SURE THE FLYWHEEL IS LOCKED FROM ‘TUnwinG 30 THAT THE ENGINE WILL NOT ROTATE UNEXPECTEDLY AND INJURE PERSONNEL. ZXWARNING ‘fren REMOVING PARTS THAT ARE SPRING LOADED, ALWAYS USE THE PROPER TOSLSIN THE CORREST MANNER TO AVOID INJURY. ZAWARNING ‘SNOT ATTEMPT TO RESTART AN ENGINE AFTER A SAFETY SHUT DOWN HAS ‘OCCURRED; DETERMINE THE PROBLEM THAT CAUSED THE SHUT DOWN AND GonRecr it Finst. ZN WARNING So NOT REMOVE THE CRANKCASE DOORS OR COVERS WHICH MIGHT LET FRESH AIR INTOTHE CRANKGASE UNTIL 16 MINUTES (MIUBIUM) AFTER THE ENGINE IS STOPPED. ZXWARNING ‘ALWAYS PERFORM THE ROUTING SERVICE INSPECTIONS AT THE PRESCRIBED TIME INTERVALS. Ca cooPER, ‘jax-Superior lesves 383WARNINGS, CAUTIONS, AND NOTES WARNING [NEVER ATTEMPT TO PERFORM ANY SERVICE WHILE THE ENGINE 1S RUNNING. THE ENGINE CONTROL LEVER OR SWITCH MUST BEN THE “STOP” POSITION. DO NOT ‘TOUGH ANY MOVING PARTS OR A RUNNING ENGINE. ZAWARNING DURING AND AFTER OPERATION, THE TURBOCHARGERS AND EXHAUST PIPES ARE Ror. DONOT TOUCH THEM. SERVICE THE TURBOCHARGERS ONLY WHEN THE Engines coat. : WARNING ‘BO NOT OPEN THE COOLING SYSTEM WHILE THE ENGINE IS HOT (DURING. ‘GPERATION Of AFTER), OPENING A COOLANT SYSTEM WHEN I'S STILL HOT CAN RELEASE STEAM AND HoT LIQUIED, REGULTING IN SEVERE BURNS. MONITOR. ENGINE COOLANT TENPERATURE AND WAIT UNTIL IS COOL, (ZSAWARNING {When LIFTING THE ENGINE, MAKE SURE THE HOIST WAS ENOUGH CAPACITY. MAKE ‘SUne THar THE SLING, HOOK. ANO CRANE AREIN GOOD WORKING ORDER. USETHE Tinting eRACKETS PROVIDED ON THE ENGINE. ZXWARNING NEVER SHUT DOWN AN OVERHEATED ENGINE WITH THE LOAD STILL APPLIED. (ZAWARNING. ‘ALWAvs WEAR SAFETY GLASSES AND SAFETY SHOES. WEAR HEAVY GLOVES, EAR PROTECTION, RESPIRATORS, ANO OTHER SAFETY EQUIPMENT AS NEEDED. ZAWARNING Loose rirtina CLOTHING, NECKTIES, SCARVES, ETC., SHOULD NOT BE WORN NEAR ‘OPERATING MACHINERY AS THE CLOTHING CAN BE PULLED INTO MOVING PARTS. KEEP LONG HAIR TIED BACK. ZAWARNING ‘Tig ONLY PERSON WHO MAY REMOVE A “DO NOT OPERATE” TAG FROM THE ENGINE ‘Tug PERSON WHO PLACED IT THERE. DO NOT OPERATE THE ENGINE IF THIS TAG {8 PRESENT. ZXAWARNING ‘ALWAYS USE THE CORRECT HAND TOOLS IN THE PROPER MANNER. s cooPER ‘jax Superior leswesensGAS ENGINE INSTAUSTION WANUAL, ZAWARNING Use CAUTION WHEN DRAINING COOLANT. DO NOT LET FLUID CONTAGT THE SKN OR EVES. CAPTURE ALL OF THE FLUNG To PREVENT ENVIRONMENTAL CONTAMINATION. WARNING NEVER OPERATE THE MACHINERY WITHOUT ALL SAFETY GUARDS AND SHIELDS PROPERLY INSTALLED. ZAWARNING REGULARLY CHECK FOR FUEL LEAKS AND EXHAUST LEAKS THAT COULD RESULT IN DIRE OM DEPLOSION. REPAIR LEAKS MIVEDIATELY. ZXWARNING Soe ONLY NoN- FLAMMABLE CLEANING SOLVENTS. NEVER USE GASOLINE OR OTHER FLAMMABLE PRODUCTS FOR GLEANING PURPOSES, ZXWARNING Fa PART Is HEAVY, GET ANOTHER PERSON TO HELP YOU. IF NECESSARY, USE A SACK OR CHAIN BLOCK. coofen ‘jax-Suporior ened nsTABLE OF CONTENTS The material in this instruction manual has been arranged in sections, each dealing with a specific subject or subdivision of the engine. The sections are arranged alphabetically and the tities and main contents are listed below. ‘SUBJECT SECTION GENERAL ENGINE DATA. eee eee a Foreword Standard Engine Data Operating Pressures and Temperatures Set-up Torques for Studs and Bolts Ignition and Valve Tining Valve Clearances Suggested Alarm and Shutdown Settings Standard Sizes, Clearances, and Near Limits Torsional Data UERECATING OIL Pee eee eee Cee General Lubrication of SUPERIOR Engines (ES 1001) INSTRUCTIONS FOR INSTALLATION... . eee c General. Installation Preparing Foundation Block Installing the Complete Unit Cheeking Crankshaft Al igament Installing’ and Aligning’ the Driven fquipment Grouting the Engine and Orivan Equipment Fastening and Final Al sgnment Cooling Water Treatment Service Piping Addendus Floxible Coupling Addendum Protection of Engines and Compressors for Storage (ES § and ES 7) STARTING SYSTEM AND ELECTRONIC AIR-FUEL RATIO CONTROLS... . Intraduct ion Installation Starting System Electronic Air-Fuel Ratio Control System Supplementary InstructionsTABLE OF CONTENTS SUBJECT BEDPLATE, CRANKSHAFT, AND MAIN BEARINGS Bedplate Crankshaft Main Bearings Crankshaft Alignment Main Bearing Tenperature Shutdown System CYLINDER BLOCK, CYLINDER LINERS, AKO CYLINDER HEADS ytinger Black Cylinder Liners. Cylinder Heads Inlet. and Exhaust Valves Gas. Admission Valves. oo) ing Water Treatment PISTONS AND CONNECTING RODS . . Pistons Piston Pins Connecting Rods Piston and Connecting Rod CCRUSHAET AND VALVE OPERATING GEAR General Canshatt Timing Ginenaft Idlers Adjusting Chain Tension Removing the chain Canshart Bearings Renoval of canshaft Canshart. Inspection Can Followers Valve Push Rods and Rocker Arms IGNITION SYSTEM... = General Checking Ignition Timing Ignition Systen Stopping the Engine Spark Plug Maintenance Trouble Shocting cT10NTABLE_OF CONTENTS sue cro CCOVERNOR AND CONTROLS... Seer oo General Governor Hount ing and Drive ‘Overspeed Governor LUBRICATING OIL SYSTEM... ee ee : Eee 1 General Lubricating 011 system COOLING WATER SYSTER 2... ee pooudG W General ool ing Water Pumps ool ing Water Punp Orive Heat. Exchangers ool ing Water Treatment Engine Storage During Freezing Weather NAINTENANCE_AND INSPECTION ce eC eee General Rules Inspection and Maintenance Routine Overhaul Trouble shoot ing Reconnended Engine Maintenance Schedule PARTS CATALOG [RUKILIARY EQUIPHENTSECTION A GENERAL ENGINE DATA oewoan The Superior Gas Engine is of the heavy duty, vee, multi-cylinder, spark ignited gas type; designed espectally for reliability, and Tong life of trouble free operation. Compact, rugged construction allows a wide range of applications. Ready accessibility of all wearing parts ineans Simplified naintenance and dependable service. Lubricating oil 1s, pressure foread to” all” working parts of the engine. All working parts Bre totally enclosed to minimize. wear and other troubles which might occur 1f dust or other foreign matter were allowed to reach then. ‘The engine described in this manual is of the four-stroke cycle type, in hich 2 power stroke” occurs once in every two revolutions of "the Crankshaft, The “foursstroke cycle operates as follows: | (1) suction Stroke, (2) compression stroke, (3) power stroke, and (4) exhaust stroke During the suction stroke the exhaust valve {s closed and inlet and gas gas admission valves are. open. The descending piston draws 2 fresh ixture of air and gas into the cylinder. Near bottom dead center both inlet and gas aduission valves close and on tthe succeeding upward. stroke, the piston compresses the mixture. At a point somewhat before top dead'center, ignition (from the spark plus) Securs. The spark, igniting the air-gas mixture, results in combustion Of the ‘compressed gis. The rapid rise in tonperature and prassure of the burning gases forces the piston downward for the power stroke. Near the end of the power stroke the exhaust valve opens. On the next Upward stroke the burned gases are expelled from the cylinder, thus completing the four-stroke cycle The exhaust gases are conducted by a manifold to an exhaust turbine. This turbine “turns on a comon shaft (but in a Separate conpartnent) with a conteifugal blower. The blower draws ia atnospheric. air and Forces it under pressure through intercoolers and into the engine intake manifolds. The afr at this stage is more dense than atnospheric air and therefore each cylinder recoives a greater weight of air than it would if. the alr were taken into the cylinder at atmospheric pressure. ‘This allove a corresponding. increase in” the amount of gas which can be burned efficiently and gives 4 propartionally greater output for a given Cylinder size and engine speed. Cooling of the intake air also reduces tthe possibility of detonation. The valve timing 13 s0 arranged that the intake valve opens before, and the exhaust valve closes after, top. dead center. During the period of Valve overlap” sone of the supercharging air. is blown through the cylinder, resulting ia amore complete scavenging of the burned gases. fn order’ that fuel gas will not be" lost into. the exhaust during this Scavenging period the “gat “adaission valve is closed, and opens at approximately the sane tine as the exhaust valve closes. anSECTION A ‘The purpose of this manual is to familiarize operating and maintenance personnel with the design and construction of the engine. Thus, they can Understand the functions of the various parts and know how to care for ‘them in order to obtain the most satisfactory engine perforaance. Engine rated speod and horsepower are stanped on the nameplate and these Figures’ should never de exceeded. Engine model designations and serial hnunbers are also. stanped on tho naneplate; and these figures, particularly the serial minber, should always be stated when ordering parts or in any correspondence with the factory or sales agencies. Other {tons stamped’ on the engine nanaplate include bore and stroke, ignition fining, and firing order.SECTION A STANDARD ENGINE DATA Hode) Brake Horsepower (BHP) at 900 RW. 126TL 12sGT 16GTL_ 16s6T 1650 2000 2200 2650 mum Tdle Speed ~ RPM 650 Operating Speed - RPM RENNES 660-900 Bore x Stroke REIT doi x o-ay2 EIRING ORDER - Counter-Clockwise Rotation AZ Cylinder - TReTL = AR-4L ~ QRZ, - SR-GL - 3R-3L ~ SR-SL 1S Cylinder - TR-IL = SR-3L ~ 2R-2L - SR-BL - GR-BL ~ GR-6L - TRATL - ARAL NOTE: Right and Left Cylinder Banks and Direction of Rotation are determined by viewing the engine from the Flywheel End. CAPACITIES GALLONS cy 16 cyl. Lubricating oi! Sump - (Including Cooter) « 165“... 220 Water in Engine 140 180 OPERATING PRESSURES AND TEMPERATURES Lube O11 Pressure ~ Normal 34045 PSI Lube 011 Temperature ~ Normal it 149-150" F Lube O11 Tenperature - Normal OUT 155-175¢ F Water Temperature from Engine ~ Normal 170-180 ° F ‘SET-UP TORQUES FoR STUDS AND BOLTS NOTE: Torque figures are for threads lubricated with engine of! or siailar petroleua base lubricants ~ D0 NOT USE ANY COMPOUNDS CCONTATNING MOLYBDENUM DISULFIDE AS A THREAD LUBRICANT. FOOT POUNDS Nain Bearing Cap Bolts Block to Ded Stud Nuts 22) Camshaft Sprocket Clasp Ring tapscrens Connect ing Rod Bolt Nuts Cylinder Head stud tuts Rocker Arm Bracket Capscréws Camshaft Bearing Cap Capscrews Flywheel Capscrews a Cam Follower Bracket Capscrews Crankshaft Sprocket Assenbly Bolt Nuts Vibration Damper Capscrews .... : End Cover Capscrews. Spark Plug ~ 161m (w/o Torque Wrench 1/4 Turn} -aeSECTION A 5. IGNITION AND VALVE TIMING 1M CRAMKSHAET DEGREES Inlet Opens so.sseese++ Exhaust Closed” wor Before ToC 1 age “After TDC + Check above angles, for camshaft timing purposes only, with .125" valve Tash. Check valve events at point Nhere'Tash 1s Just taken up (pushrod will not’ turn). Ignition Timing. ..-...+++ See Air/Fuel ratio Data sheet Spark Plug Gap... 023" ~ .028" NOTE: +/- 2 Degree Tolerance atTowed on inlet and exhaust, valve timing. Spark Timing must be accurate. 6. VALVE CLEARANCES was Inlet Valve seeeesseees O18 Exhaust Valve "1 ‘a3or Gas Admission Valve ‘oust 7. SUGGESTED ALARM AND SHUTDOWN SETTINES, low Jacket Water Pressure - Alarm w.eesseesee = 19 PSIG * Low Jackst ater Pressure = Shitdow 2.1 CNEIN 7 psig + High Jacket Water Temperature (from Engine) = Alarm’ ..c.c..2 185 of High Jacket Water Temperature (Fron Engine) ~ Shutdown’ ...... 195 oF ow Intercooler Water Pressure - shutdown 5 sic + High Intereaoler Vater Tenperature (Into’Inercaoier) 10 *F low Lube O11 Pressure ~ Al 1 2 este Low Lube O11 Pressure - Shutdown is 516 High Lube Of1 Temperature ~ Alarm“. 21s High Lube O11 Temperature - Shutdown 208 Low Turbocharger Lube O11 Pressure ~ Shutdown 18 PSIG Engine Overspeed - Shutdown Compressor Orive = $00 RPM Engine Speed 990 APH 750 ROM Engine Speed 20.002000000.2 825 RPM Generator Drive ~ 900 RPM Engine Speed | 1035 APH 730 RM Engine Speea 2000000000001 "aes what + Add 5 PSI for Pressurized Systems ‘++ For Conventionally Cooled EnginesSection & Addons STANDARD SIZES AND CLEARANCES AND WEAR LIMITS MODEL v_GAS Item Cylinder Liner Bore ‘Top Ring Travel Area (any Point) ~ Bottom of Liner Piston Skirt Diameter (Bottom) Piston Clearance (Skirt Bottom) Piston Compression Ring Gap (#) = Piston Compression Ring Gap (92 = 3-8) neneren saton Compression Ring Wieth (#1) ~ Piston Compression Ring Groove Wideh (#1) ~ Ring Side Clearance (#1) =~ Piston Compression Ring wiaeh (22-3 = 4) = Piston Compression Ring Groove Width (#2 ~ 3 ‘Ring Side Clearance (#2 - 3-4) Piston OF Ring Gap (75 - 6) Piston Pin Diameter =~ Piston Bore for Pin — ‘Piston Pin Clearance i Piston Connecting Rod Bushing Bore ----: 603-83 (ots 19-172) Standard Dimension 19,000" = 10,002" e.g" = 9,990" 003" = .012" +080" = 060" 040" = .060" 1865" = 2198 -198" loose" 0075) 21863"~ 1880" stg = 12" “ooso" = Leos J03s T3100" = er 3.4988" = 3. soi" Toots = 3.5020" = To030" = Max. (or Min.) allowaal e worn 10, 029: 10. 007" oes” s1s0" 190" 195" toseSTANDARD SIZES AND CLEARANCES AND WEAR LIMITS (cont’d) MODEL V GAS (10" X 105") TEM STANDARD DIMENSION section A Aadendum MAX. (or MIN.) ALLOWABLE WORK Lubricating of1 Pump internal Gear Backlash —- Labricating Oil Pump Gear End Play (003-914) —--—- (033-633) kubricating oi1 Pump Radial Clearance Between Gear Testh « Housing Bore Lubricating oi2 Pump Shaft Diameter ———~ Lubricating oi] Pup Bushing sore ~ Clearance ==-—=--— .ou" sors" Toa" -oa2" +7500" e753" T0030 ‘SEGE/CLEARANCE sos" <020" 022" +026" to5am 057" -o13" sos" 2.7495" a.7see tooase 008"Section B LUBRICATING OL We recommend that a good grade of compounded mineral oil of a deter~ font type be ured in these engines, The ofl should be stable under the ESmpcrature conditions encountered ia the engine and should be resistant fo omidation, foaming and sludgiag. The best assurance of obtaining 2 ‘Sultuble oil is to use only products of well-known merit, produced by Jetponuible concerns, and used in accordance with their recommendation Sce'CES Superior Engineering Standard ES 1001, immediately following this section. ‘Both new and used off can have corrosive elements and the supplier should bo caren #9 furnish oils which are compatible with tin or lead base bab- Bits und it is also highly desirable that it be non-corrosive to copper-lead alloys. ‘The use of an SAE 40 grade oll is recommended. If the ambient temper: [ures are below freezing, an off of lighter grade may be used for intermittent Sperating conditions and SAE 40 for continuous service. For low temperature operation, the pour point of the oil, at the minimum Eurting fermperature to be expected, should be carefully considered. It is Heit egscntial that the ei be suiliciently Quld so that it will fow to the pamp under all conditions. “The oil sump holds the proper amount of lubricating oil, and the running Jeual shoula be maintained close to the mark on the sight glass. In regard {Snainace periods, we suggest that the first batch of oil be drained and Miter alegente renewed after about 400. hours of service. There~ cites the iter cartridges should be changed and the drainage period can be increased to 1000 hrs. or more, providing the filter cartridges are Kept ph good cuape and the off remaina reasonably clean. Experience will deter- io Bi then to change filter elements and oil, and in this connection it Joule be pointed out that it is more economical to maintain food shape, However, if the oll is badly discolored and loaded with in~ ESlubles, it should be drained off when new filter elements are installed. [ieCraesey checks of the ol co determine the quantity of solids and Dung ap of any corrosive elements should be a regular part of the maintes fance procedure. These teat rerults can serve as a guide to oil drain period. NOTE: When new elements are installed in the filters, a suffictent noun of lubricating oil rmust be added into the aystem to compensate foe that which has been drained from the filters. 1 B20 - Ed. Se](COOPER INDUSTRIES ‘AJAX-SUPERIOR ENGINEERING STANDARD, LUBRICATION OF CES SUPERIOR ENGINES Lo GENERAL 1.1 ‘This specification is aplieable to all Superior engines except forthe 1700 and 2400 Series. See ES 1005 for lubreation specifications for these models. 1.2. The lubrication of Superior engines requtes the ust of premium quality, SAE 40 brictng ois designed for heavy duty engine serve. 1.3 Customers planing 1 operate engines with exhaust caaist systems, high sulfur fuels, heavy ‘ae! lls landil gas and fels other Un standard commercial grades should contact the Superior Engineering Department for bricant and maimenance recommendations, 2.0 QUALITY AND PERFORMANCE: 2.1 Cooper Eneray Services does not guaranee the quality or performance of lubricating ols ‘Sasfacory oll ality is the responsibly of the refiner, blender or rebrander. Only repuable Companies with proper service organizations should be used 2s supplies. 2.2 Cooper Bneray Services doesnot endorse particular brands of oll, For customers convenience, ile ofthe preferred ubriewing ol by brand name is maintained by Cooper Energy Services. ‘Customers ae invited to advte the Superoe Engineering Department or service representatives ‘shat brands of ols are preferred. Cooper Energy Services can then advise which product have tiven satisfactory sevice in similar applications. 3.0. GENERAL SPECIFICATION: 3.1. The general specification for hbricting ll for use in Superior engines i a follows: Specification Range Tes Procedure Viscosity St @ 100°C 12.5 0 163, ASTM D 235 SO °C, 204 Maximum ASTM D 445 Viscosity index: 70 Minium ast D270 Fash Point 400°F @04°C) Minimum ASTM D 92 Pour Poi: IF (°C) Maximum ASTM D 97‘COOPER INDUSTRIES AJAX.SUPERIOR ENGINEERING STANDARD 40 3.2. The Gllowing vscosiy information is presented in obsolete units. This information is équvalet othe ranges above and is provided for informational use only. Specification Range “Tes Procedure Viscosity: ‘SUS @ 210°F mw ss ASTM D 88 SUS @ 100°F 1100 Maximum ASTM D 88 RECOMMENDATIONS BY ENGINE TYPE: 4.1, Recommentaton for Superioc dual ful and diesel (comomession inte) engines: Heavy duty train ols meeting or exceeding the performance requirement of MIL-L-2104E and AP (CDIVSE wih sulted ash (ASTM D 874) levels ess tan 1.0%. 4.2 Recommendation for Suoecior natal as (park anid) ¢ cycle engines: Heavy duty gas ‘ogi ol formulated specifically for rasa gas engine sevice. Sulfated ash (ASTM D 874) levels of betwee 0.5 and 1.0% are equied. Engines fueled witn narra gas conaining sulfur should se ols with total base mumber(TBN) of greater than 6 by ASTM D 2856. 4.3. aging bring Se contne in iguid iit ovee 1 = Engines using Nigh sulfur fuels should receive special Consideration and ean equie the use of highly alkaline lbricaing oils, Customers considering ‘he use of high sulfur fuels should eanact Superior Enginering (or asiance. f 44 Oils Ta enerally Recommer 4.4.1 AshlessorJow ash ea8 engine cil: Ales o low ash gas engine ols sulfated ash of es than 0.59 by ASTM D 874) are not generally recommended. These bls may perform sasfaconily in maul aspired engines burning low sulfur fuels however, tener engine protzion and longer dean intervals can be eve using the cls deseribed above. 442 Bah ash oli: Oils ha have sulfted ash (ASTM D 874) levels shove 14% are oc recoramended for general service Although higher ash lls may be necessary for some speific fuels and service conditions, excessive ash may eause spark pig fouling, or form combustion chamber deposit that induce detonation, pre= Ignkion, vavesieking, and impaired cing performance xs 1001 |COOPER INDUSTRIES AJAXSUPERIOR 50 60 ENGINEERING STANDARD LUBRICATING OIL. MAINTENANCE: “The engine ol and fers shouldbe changed afer the fet 400 hours ona new or overhauled engine. ‘Afcs be fist oil change the oll and filers should be changed every 1000 hours. Cooper Energy Services strongly recommends thar customers use a borstory analysis program to ensure proper lubricane performance. An experienced, repuable lab shouldbe wed and results shouldbe earefily tnalyzed and wonded. Regular monitoring ofthe crankcate oll conion car help establish ol change fut pevods for a specific uni Ol condion and ace meal element tends can be effective Giagnosie ard preventive maintenance tools. ‘COMPRESSOR LUBRICANT: Lbreans rable for Superior engine service generally can be used inthe compressor fame, Refer io Superior Engineering Standard ES 1002 for spcitic recommendations. = | simSection © (GENERAL INSTALLATION ‘The success of en engine instllation depends greatly upon the construction fof the foundation end upon the care exercised in lining up the engine to the comected generator. Poor installation will reult In excessive. vibro- tion and continual change In aligrment. The result is poor performance end failure of vital pors. For this reaion, The C.E.S. Superior cannot Guarentee on engine unless the instructions in regard to alignment given In the following have been followed, Engines ond generator are frequently mounted on cant or structural steel sub-frones, ot the menufecturers plant, to provide @ complete generating Unit, Similar units are also made up with pumps or gears of other equip~ iment driven by the engine. In such corer, the instellation method is the some os described in’ the following text for engine and generator instlla Fions; end the term "generator" may be construed to mean any one of these tens, ot the cate may be wherever it appears in the text. Even though the engine and generator might be mounted ono gui sub-feme, ond corefully lined up ot the monufoeturer's plant during senblyz the possibility of sub-frane deflection, by rough hendling during shipment, or by improper bolting to the foundation, still exists, The clign- iment of engine end generator should therefore be rechecked during instalio- Hon; end any handling or bolting deflections of the sub-frame, thot may have affected this alignment, should be corrected before the unit iz ploced in operation, The following instructions will cover the method for elignment checking, ond will elso cover the steps to be tcken in meking the necessary comectiont if misclignment is feund. rigid ‘When preporing the foundation on which the generator unit is to be mounted clways abtein certified outline print. Do not ina Figures or cuts in builetine for soles litercture, ‘The foundation block dimensions, nomally shown on outline prints, are minimum Figures besad on firm ground, hand clay, or gravel under the installation. For tend, mud or ather soft subsoil, the size of the foundation block must besuf- ficiently inerecaed and it design must be properly revised to compensate for the poorer quality of the footing material. 50 - fa, 15 Mwction C PREPARING THE FOUNDATION SLOCK [A rigid template, of the same length ond width at the top edges of the foundation, thould be made up to propery lozate all engine and other foundation bolts. This femplete should be securely supported in a level postion chove the foundation block form. lis height should be such that it will support all foundation bats at thefr proper height In accordance withthe fourdation plan furnished by the mono fecturer. The foundation belts, with shield tubes around each bot, should be suspended from properly located holes in the template. The nurs, which hold the Kolty inthe tem= plete, should be adjusted fo provide bolt extensions cove the foundation block in Eecordance with the foundation plon furnished by the manufacturer. The shield tubes should be 0 supported that thelr upper ends will be flush with the top of the Finished foundotion block; and their lower ends should be plugged, or otherwise closed in ageinet the feundation bolts, t0 prevent concrete from entering at thot point. Reinforcement should be placed in the form, and the conerete should be poured in cone continuous operation. During pouring, the concrete should be tamped or otherwise worked fo remove all cir pocket and fe Insure compeciness. Porticulor tention should be given to working the concrete ot the sides of the fom or ot any ‘ther surfaces which may be left exposed in the final installation. After pouting is Completed, the concrete should be allowed to thoraughly set nd then the forms Should be removed. Any surface patching fourd necessary should be done immed tly ofter the removal of the for while the concrete is sil relatively "green". The foundation block should be sprinkled frequently to keep its surface moist for {everel days after pouring in onde: that the curing may be regulated fr best develop- iment of sirength ond hardness, It should clo be protected against freezing during this timer in fact its temperature should be kept above SOF, for best curing, Sut ficient Hie mutt be allowed for thorough curing of the foundation bleck before ony equipment is placed upon it. ISTALLING THE COMPLETE UNIT = (Engine on Sub-Size) Foundation Plan and Outli (Close reference should be made to # this He). ‘When the foundotion block her become fully cured, preparations should be mode for placing the engine ox follows: (e) Remove the unit from its shipping medium, and move it over the foundation block es near cx posible In alignment with Its foundation bolts. Keep the sub-baxe some dite chove the foundation, however, in erder to allow working room for subsequent operations. 2 C50 Ed, 1-54 5 Section ¢ (©) Make certain thet the sub-base support flanges are thoroughly cleaned ‘of al ut and dirt or other foreign matter. The above clecning epera- Fions should alee include the removal ofall greae or ol, which might impair adhesion, from any surfaces which will come into’ contact with grouting. (©) Consider jackscrew plate thickness and foundation plate thickries ‘where these plates are vied, and serew the fackscrews down through the Ib-bore wwpport flanges by an amount sufficient to provide space for T= 1/4" grout thickness, Place one ofthe stel plates, supplied with the engine, under each jackscrew; end carefully lower the unit down aver the foundation bolts until the jackscrews are resting on the plates, Ad- just the [ockserews until they all bear equelly on thelr respective plater, ‘ond further until the unit is setting level in both longitudinal ond frans~ verse directions, CHECKING ENGINE CRANKSHAFT ALIGNMENT ‘The proper procedure for checking erenkshaft alignment i os follows (2) Remove lower bare caver adfacent fo Flywheel end of engine, (6) Observe the inside face of the webs ofthe lest crankshaft throw. If there cre no center punch marks in evidence, place one center punch indent in the canter of each web opproximately ane inch up from the bse of the shortert web (directly opposite ecch ether). (©) Insert a dicl indicator type of strain gauge so thet it will be held by the center punch mark. (@) Toke svccestive indiector readings in the following positions: at neor bottom center as the connecting rod will permit; 90° from top center; top center; 90° from top center (opposite side); end near bottom canter (eppanite side). (6) Total variation in reodings may not exceed .008". INSTALLING AND ALIGNING THE DRIVEN EQUIPMENT After the engine har been placed on the foundation and its erankshoft alignment fhos been checked, but before grouting, the driven equipment should also be placed in its proper position over the foundation in opproximate alignment with the engine. If the engine ‘wheel was removed during the previous operation, i must be remounted before the driven equipment can be cligned, 50 - &4. 165Section ¢ {A flexible coupling must be vied between the engine ond the driven equipment in Seder to protect the respective shaft: egeinst misalignment strains under all operat ing ond temperature conditions. See subsequent °C" sections for alignment of the flex ‘only when such equipment is furnished.) le coupling. (This epplies Shift the deven eqiipment er engine of both sideways ond alto reise or lower it os fequited to obtein the best posible aligement. Proper lining up mey take a little tine, but si ebsolutely exential, Flexible couplings should not be required to Compensate for any misclignment that con be eliminated. Every base plate is flightly elastic; therefore, every unit must be aligned in place. NOTE: Thin metol shims, totaling 1/16" to 1/8", may be placed under the driven eclpment to permit later readjustment of height If such is ever found necessary. ‘Ritention should alto be given to the longitedinal position of the driven equipment bearings end t0 any fleeting and flexible members of the couplings. All longitu Site tks eae uses set or RV sem” Use a eu 30 ES secu coven. Bfoe sping RIV teat, cotng of Teng 505 SSould be apn toe al sre ini problems of eve Fema 12 Te sree tl we wed FED VO po lad hn wy E> 7" Sekai pane. "Ute Spano 40 when ing sree 4129 Wrap the magneto in PCTSD VCI paper and securely cover with plastic wrap. For CCES sock uns, the magneto shall be removed from the engine wrapped in PC7SD CI paper and placed in a waterproof box. 32.10 Brush Teetyl $02-C or equal on all external movements suchas springs or linkages Bo) 220 See hee a et pn se pas a “Tosament of Turbochargers 2. Esha ute fang aston piece mest be covered wit 1" mate piywood, > on Wick fa nepone pss set or REV saat end inal wih ast Sos tling. Defrespifing RTV salam a cong of Tony 52-¢ sh top oh mel see mize pol fever eave b, Flanged air inlet for engines without engine mounted ar cleaners willbe covered similar toute flange, ©, Engine air inlet connections without Mange wil be covered with 6 mil plastic and sealed with 2° wide waterproof tape oF uve heat shrunk plastic NOTE: Turbochargers do not require Tectyl or like coatings sprayed on the rotor assembly. 4. Engines with engine mounted air cleaners or silencer should have the sir cleaner Inlet sealed with 6 mil plastic either using 2° wide waterproof tape or hea shuns plastic. 2.313, Carbureted naually aspirated engines without mounted air cleaners shall have Intake and exhaust anges covered witha" marine plywood, 2" hick lt neoprene gasket ‘sheet or RTV sealant and insalled with atleast SO% bolting. Before applying RTV Sealant, a coating of Teety! S06 should be applied to the metal surface to minimize problems of cover removal (engines without ar cleaners, see 33.114. Flere = Tentiet | wmesecrom| (ermine | “Sater [Steet 5007COOPER INDUSTRIES AJAX SUPERIOR, ENGINEERING STANDARD E> 2 B® 3.3.4 Outdoor storage of engines prior to packaging isnot recommended. Therefore, cover / ‘mits wid a heavy waterproof tarp during transportation or any short term outdoor fxposure. Engines must not lave the manufacruring plant without being tarps. AJAX-SUPERIOR WILL NOT BE RESPONSIBLE FOR ACCELERATED BREAKDOWN OF RUST PROTECTION ON ENGINES THAT ARE STORED OUTSIDE LONG TERM. 2.218 Caution tags should be atached to the unit to indicate the treatment performed (ee below for example. 33,8 Any component engine pars or aftermarkeervice pars shipped loose that have unpainted metal surfaces, shall be sprayed or brushed with Tecty! $02-C or equal, ‘wrapped in plastic or protective paper, and packed in wooden boxes. NOTE: Teciyl 502-C or equal must never be uted where oll ow is not present to Aisolve it or where cleaning of pars prior startup isnot practical. NOTE: PCTSD CI paper may be purchased from Daubert Chemieal Company or one oftheir distributors. 3.4 Engines - Ajax 241 Unit shall be drained of oll and water, 2:42 Water piping shall be sealed with 4" plywood cover with four (4) bolts minimum, 343 Cover exhaust pon(s) with %" plywood cover stached with four (4) bolts (inimam), 5.44 Guide openings at cylinder end 1 be covered with 2" plywood cover held in plae by four (4 bois (minima. 5.43 All sip loose or aftermarkeuservie parts with unpainted metal surface shall be coated ‘with Teer! $O2-C or equal and wrapped with protective paper or sealed in pas, 5.44 Ends of crankshaft tobe wrapped with protective wax paper and sealed wit tape 5.47 Gas inet piping shall be sealed with a pipe plug. 2.48 Outdoor storage prior to packaging is nt recommended. Therefore, cover the unit with heavy waerproof tarp during transport or any shorter outdoor exposure, The ‘nit must not leave the manufacturing plane withou boing tarped. AJAX-SUPERIOR WILL NOT BE RESPONSIBLE FOR ACCELERATED BREAKDOWN OF RUST PROTECTION ON ENGINES THAT ARE STORED OUTSIDE LONG TERM. ESS a TL mie] oe. | Sr i Ge] ee Pee en‘COOPER INDUSTRIES AJAX-SUPERIOR, ENGINEERING STANDARD 4.0 REQUIRED PROTECTION TAGS AND PROTECTION REMOVAL PROCEDURES, 46.1 The following tg will be stached tothe treated Superor engine and all compressor frames Front of Tag Back of Tag Feutlerucone pomcirein. When toot recy Soil db pr ekcocte at a oh Freee ore pac ean set he ek [venice ei a compa sh Saas ceeeie nes fe tnt terete afar recapgs Wes Sats be ogg. ep hows septate ‘econ ESS‘COOPER INDUSTRIES. AJAXSUPERIOR, ENGINEERING STANDARD PROTECTION OF ENGINES AND COMPRESSORS FOR EXPORT SHIPMENT OR HAZARDOUS STORAGE 1.0 SCOPE, ‘This procedure explains the necessary tes required to protect engines and compressors from rust and oxidation during export shipment or hazardous storage. Export shipment applies to transport in 2 sal- laden amosphere or anywhere outside North America. Hazardous storage applies toa highly damaging sumosphere (suchas saltladen, sand-laden, or high huis). 2.0 PROTECTION LIFE 2.1. Minimum protection afforded by this procedure Is approximately one year. Maximum protection is dependent on the environment 2.2. Ics the responsbiliy ofthe customer, packager, or warehouse at which the nits are being stored to periodically monitor the conditions ofthe units for protection breakdowns ‘The frequency oF inspection depends on the conditions ofthe environment, but should be at leas every three (3) months. When a breakdown is observed, ze old coatings should be removed andthe unit protected per this sandard. Ifa protection breakdown is found during the inal one year period, Ajax-Superior Technical Field Service should be oti 2.3 Units in storage should be flushed out and recoated at least every eighteen months assure adequate protection. 2.4 Any addtional protection beyond this standard, required by the customer, should be segodted with Ajax-Superior Marketing Deparment, Marketing should contact Ajax- ‘Soperor Quality Control Deparment to determine If customer request is reasonable and ‘whether we can meet these standards, 25 Icis the responsiblity of Ajax-Superor’s Marketing Department to Geslgnate onthe sales release whea special protection and packaging i necestary 3.0 REQUIREMENTS, 3.1 Compressor Cylinders Sit Standard Lube and Mini-Lube Cylinders Alleylinders are to be shipped ina waterproof box aftr coating a well as al related parts which are shipped loose 142 NonsLube Cutinder Prepare per Engineering Standard ES2, [Ee Conroe Fane Box the entire unit in a waterproof box whea specified on sles cles,‘COOPER INDUSTRIES AIAXSUPERIOR ENGINEERING STANDARD 3.3 Engines - Superior Follow te sora eqicemens of Engineering Standard ESS with fotowing adcons: 221 Protetve comings mist be removed pir wo st except lem 3 below. 532 Pump. mixture of 30/50 Teryl$02-C and diesel feline the fel lines for deel and dal fuel engines 333 Spray avery light fllm of Tecryl 502-C inside the power cylinders and reinstall the spark plugs/injector nozales(elean burn nozzles. NOTE: Normally, Texyl $02-C will not have to be removed from the power cylinders prior to wart as it is a combustible and will bum cleanly inside the combustion chamber. BEFORE STARTING THE UNIT, however, the power «ylinders shoul be visually inspected using a borescope to assure tht there is no water collection, rust damage o 3 lage aecumuluion of Teal. Fush large accumulations of Tey! wih a stoddard solvent prior to star. Remove any accumulations of soddard solvent before sarng engin, 354 After removing side covers, spray all exposed machined surfaces inside the crankcase ‘with Tey! 502-C or equal, incuding eankshaf, connecting rods, liners piston skirts, Camshafts, chain drives and gear dives 5.28 Engines wit mounted air cleaner + Remove the fter assembly and spray inside all piping with Tecyl $02-C, ( + Do not spray dretly onto the rurbocharger rotor or into the carburetor. Seal inlet Piping as described in BSS. + Oil bath and oi weted screen Mer assemblies must be coated with Teel $02-C on all unpaired surfaces, + Dey type filter assemblies must have the fer elements removed from the housing and sealed in plastic. The frame must be coated with Tee! 506 on all unpainted faces, Ship the fer assembly in a seperate waterproof box. Magneto: ‘Remove from engine, wrap in PCTSD VCI paper or wax paper and Selina water. root wooden box. 57 Box the engine in a waterproof box whenever specified on sale release. 41348 The engine should not be barred over after the rust proofing hes been accomplished, as tls removes the protective film. NOTE: PCISD VCI paper may be purchased from Daubert Chemical Company ot tne oftheir distributors ES7 ~ stnCOOPER INDUSTRIES Engines - Ajax Follow the storage requirements for Engineering Standard ESS with the following addins: S41 Spray all intermalsurfaes with Testy $02-C or equivalent 142 Cost exhaust port flange and cylinder mounting flange at gulde(s) with Tear $06 prior 1m covering with wooden cove. 4.0 REQUIRED PRC AL ON REMOVAL PROCEDURE lingers shouldbe tagged as specified in Enginsering Standard ESS, AJAX-SUPERIOR ENGINEERING STANDARD idl LE oN cM | fel | mm | oITarim s¥sTeM 90 ELECTRONIC ATR-FUEL RATIO CONTROLS PANEL ASSEMBLY P/N 033-846-¢01 ‘402 CONTENTS, PAGE 4. nerpooucrrow 2 A. INSTALLATION Mountings swe ee errr ee Contral conrections 211112 err res Connection Descriptions eer eee oa C. STARTING SYSTEM Starting Sequence of Eveyts Boece ee OT Soerat ion Pair eee Dns Control Comeueat sdeutitication 2222222 i0% 14a Stoogeng Sequence of Ewen’s STL LLL aac! Adjustments eee ee leases 16 tnedaned DTD LIT IIILIIiit 16-17 oneengine LLL L Le 1, ELECTRONIC AIR-FNEL RATIO CONTROL SYSTEH P/M n3s=725 (THH/DYNALCO KOO 2500) Air-Fuel Ratio fata Sheet) 22D t iene er eee eee er eee eT Preliminary Set-Up - ao Verification ss 222d Pret a Troubleshootiag Fells FE, SUPPLENENTARY THSTRUCTTONS. Pre-Turbine Temperature Seneral Combustion Character sctics fshaust Temperature ee tee Starting the Engine the First Tine Bas Metering Valve Set-Up Procedure’ v2... : ag Rovernor Travels : I pee sEcrrow 9tt x at a ca on 3 ca LIST oF teLusteations esearerr0n Controt Pane! Component Layout. Controt Pane? Schenatic Controt Pane? Mount ing Controt Pane! Connections Sequence of Starting Event Fuel Valves Start Systen Components Fuel Valves Control Circuftry Start Fuel Valve Adjustment. Operational Schematic of Air-Fue! Contro} ‘in-Fuel Ratio Data Sheet Shipping and Restriction Screws Controtier Electrical Connections Controtter le] Gas Metering Valve (8ST, Vee) Fuel Gas Metering Valve (Taine) Ate Butterfly Linkage Gas Contro} Linkage (?6-PL Governor) Cae Contvot Linkage (UEP Governor) Whay Shaft Gas Contral Linkage (EGR-INC, 10° & 25° Governor) as Contro? Linkage (PHA Governor) fas Control Linkage (1l6- Governor) WO/Lay Shaft Gas Control Linkage (3199 Actutor} pace 0 2 6 18 0 a 2 2 30 n Fry au % a 2 Fy PROE 1A. WTRoDUCTION This guide describes correct operating procedures for the Starting System and AirsFuel Ratio (AFR) controls of SUPERIOR's 12 & 16 cylinder reget VEE engines. SyrboTs have been used throughaut this guide to indicate important infor= ination or criticaT instructions. These symbols and their meanings are 38 foTlows: MOTE eee eee An operating procedure which is essential to highTight, for. proper maintenance and operation of the engine. 7 CAUTION Soe ee Operating procedures practices which Afrnot serictly observed, aay result {in danage to or destruction of the engine. WARNING... . ss 5 Operating procedires/pract ices, which $f not correctly followed, nay result {n personal injury or Toss of Tife. The 12 and 16 cylinder model YEE Engines are equipped with SUPERIOR's Electronic Analog Air-Fue! Ratio (AF2) Controls and Preunatic Starting Logie. "the pane! is det‘gned to perform two basic functions: 1) To maintain the proper AFR for successful operation of the Engine at a given spesd and Toad range. This function is automatically control ied. 2) To start and stop the engine by controtting the fue? valves and'an fgnition ground switch. This function is manually controlled. SECTTON 0 PAGE 2 (CONTROL PANEL COMPONENTS FIGURE AL PAGE 3 SECTION 08. INSTALLATION For reliable performance, the AFR Control & Starting Panel requires the Felloving mounting and interconnect ans: i 1) wouNrIN = The pane] should be installed inside a suitable enclosure to protect it from dirt and excessive moisture. Tt 1s usually sounted within the engine's alarm end. safety shutdown pane? (see Figure A1). This provides. the required protection and easy access to intercon nections. = The panel mst be mounted in an upright vertical position, Tt should not exceed 10° fron the versieat position (see Figure Bl). gum 8-1 IMpaopE® MOUNT PROPER MOUNT = The pane) must pe property Interfaceu with other engine controts and Safety shutdown systems 95 described ie this guide. 2) connections = The Following list (dentifies the input and output comect tons. Sone of these connactions are on both the control panel and the engine bulkhead (CP & £6), sone only on the contro! panel (CP only), fnd some only on the engine Suikhead (EB only). See sK-7029 for SECTION 9 PAGE 4@ 8 48 Olle Sere oay Bp Co tt Alt toes oa de ge ot Bo lite Bee eB eB event | |e Grae ER See i re SECTION 0 CONTROL PANEL CONNECTIONS FLguRe. Panel Connect ion (See Figure 8-2) ® Perntsstve Signa? ¢ supply Pressure ° 9 Fuel Manifold Pressure 8 M812 Ate Manttord Pressure 68 Mefe # right manifolds) ” Fuel contrat Yalve ° (valve from SUPER mounted ‘in customer contro} panel) te 1 Panel vent Atmosphere (Sate location) 6 Fuel Valves Signa? 8 7 Ignition Ground ee 0 Air Butterfly Stanat 8 6 Fuel Control valve ° (valve. fren SUPERTOR mounted a customer's Control pane!) pases3) DESCRIPTEON OF THE COMNECTYONS Connection 8 - Permissive Signal (Input, P only) ‘A 30-160 PSI contro! pressure supplied from the custoner's safety shutdove circuit. This signal turns on the supply pressure (CONNECTION c) to the panel, and must be vented to shutdown the engine. Connection ¢ = Supply Pressure (Input, CP only) ‘A 60-100 PSI contro! pressure supplied by the custoner. This pressure is used to supply the AFR fand starting sections oF the panel. CAUTION | | Supply pressure must be clean and dry for relfable | operation, Synthetic cororessur lubricants in the | Sir or gas straam may cause component fatlure. | iRef: Tsies7-3, located at end of Mis Section) | Connection 9 - Fuel Manifold Pressure (Input CP & £8) A pressure from the fuel gas manifold that is sent to the APR section of the control pane! via this connection. this pressure 1s used to ingicate the ‘oad and’ speed of the engine. ove | This pressure 1s not adjusted by the AFR panel. The engine governor will adjust the fuel manifole pressure to maintain load snd speed. Connection 11 £ 12 = Air Manifold Pressure (Input, CP & E8) A pressure fron the left bank and right bank intake pressure is used by the control to calculate the air- fuel mixture, Pressure witl vary with load, speed and changes in panel constants. SECTION © Pace onaSECTION 9 Connection 16 817 ‘uel Control Valve (Input & Output, CP onty) ‘A 30-50 PST signal that is sent from the start sec- ‘fon of the panel (CDANECTION 16) to a S-nay pull valve (fuel control valve). khen the fuel control Walve ts activated (by puling the knob), the signal From CONNECTION 16 returns to CONNECTION’ 17 r 1 WARNING It i If natural gas is used as the supply pressure, the fue? Leontral valve vent must be connected to a safe location. I Connection 1 - Panel Vent (Output, CP only) AN] of the panel's components vent through this loca~ fon. The pipe size shoud be based on 1 SCPI flow rate at 2 in, water colum maximum a1 Towable back= pressure. WARNING If natural gas 4s used as the supply pressure, the panel vent mist be connected separately to a safe i i i 1 i | Vocatton. 1 NOTE: D0 NOT connect to engine dutkhead connection 3. Connection 6 = Fuel Valves" Signal (Output, CP F EB) This connection sends 2 35-50 PSI ramping signal to the engine-nounted fuel valves. This signal pressure must be 35-50 PSI for the engine to #2in~ tain speed and Toad, Loss of signal pressure wil Stop the engine by closing the fuel valves. The ramp tine agiustment 1s on the AFR panel. Connection 7 = tgnition Ground Output, cP # £3) This connection sends 2 25-80 PST signal. to the engine-nounted ignition ground switcr. When the Signal 1s. 35°50 PSI, the switch Ts opan and the ignition 1s ungroundes (engine wit! operate). Loss of signal pressure will ground the ignition systen,| wut ( | . ‘The ignition ground switch is used to purge the engine | during start ing, and should fot. be used to shutdown the | engine. Connection 10 = Air dutterfly Signal (Output, CP & E28) ‘This connection sends a 0-45 PSI signa) to the engine-nounted air butterfly valves. The signal pressure powers an air bina cylinder that opens ‘ng closes the air buttertly valves. The valves are used to maintain AFR by regulating the intake ‘afr mnifold pressure. When the signal is 45 PST, ‘ir butterfTy’ valves are fully open, thus. maximum ‘Bir monifold pressure wit] occur. Lots of air Signal will close the vaTves, and result in mint imum air manifold pressure. STARTING SYSTEM (Loca? & Manuel) The starting system section of the pane? controls the starting events once the engine ts cranking and’ the operator hes activated the fuel control waive (Connection 16-4 17). This system controls. the signals to the gnition ground switch end’ to the fuel valves during the starting cycle, rin eyele’and stopping eyele- ( t 1} SEQUENCE OF STARTING EVENTS: The starting sequence consists of two steps: 1, The Purge tyete 2. The Starting & Running Cyctes See Figure C-1 for reference) | SECTION 9 paces |CONTROL PRESSURE TO FUEL VALVES - (PSIG) SEQUENCE OF STARTING EVENTS 30 RUN VALVE FULLYOPEN 20 RUN VALVE BEGINS TO OPEN ‘START VALVE FULLY OPEN 18 (GOVERNOR TAKES CONTROL, OF GAS METERING VALVE, 10 ‘START FUEL VALVE BEGINS TO OPEN, RUN FUEL VALVE CLOSES, AND IGNITION ‘CGE | SYSTEMUNGROLADS. ° 10 See. RANKING STARTS TIME - (SEC) 80-120 SEC. TOUR secTION 9 PAGE 93 The Purge Cycle The prpre of the purge cjcle 1 to exe! fue tron the Se meet sara Eston ator tne inition systn ¢ Beene Pent oe. k sepia toe of 10 seroe During the purge cycle, the engine ts to crank 10+ seconds under the fotloring conditions: a) Fuel control valve deactivated. b) Ignition system grounded. €) Start fuel valve closed. 4G) Run fuel valve closed and vent open. | | WaRHINE | to purge the engine properly my result in an | explosion tn the exhaust system. I Step 2: The Starting & Running cycle The purpose of this step fs to control the amount of supply fuel to the engine upon starting. If alvoxe. a gradual increase in’ the amount of fuel pressure intil it ultimately reaches the full anount necessary for cperation. ( cuck mr Se Soa START FL Fu VALVE VALVE uring the Sterting Cycle, the following conditions must exist: a) Fuel Control Valve activated by the operator. b) Ignition turned on (ungrounded). ©) Vent closes on the Run Fuel Valve. 4) Start Fuel Valve opens ata controlled rate, ‘gradually increasing the fuel manifold pressure, (See Figure C-2.) SECTION 0 PAGE 10= hen there is sufficient fuel in the combustion chamber, the - tngine will start and begin to accelerate to idle speed. The governor witl contro! engine speed by throttling fuel manifold pressure. Nove | If ene engine Monts, close the Fuer control velve. | Kruse enough eine’ to'parge the engin, aed forte” | | Raunt Phy cetayed igeeion swier'ee grog the | ee | 1ahe = The Running cycte starts as the Run Fuel Valve begins to open and is conpTete then the valve 1s fully open. = The Run Fuel Valve is opened at a controled rate. 2) STARTING SYST OpERATION Operationally, this section of the pane? has three segments: 1)" inputs, 2} Adjustments and 3) Outputs. The Inputs are: ( Permissive Signal - a 30-180 PSIG pressure fron the Unit's contro} shutdown circuttry St Comnecrton 8. Fuel Control Valve - a pressure from the two-position, Gyreccway, self-latening pull vaive (conection 17). Adjustments to the panel components are sin‘nal. They are thi Tonition OFF Delay, the ramp tine, and a bias pressure, Details are in the subsequent section covering adjustaents. The Outputs are: Ignition Ground = signal pressure ungrounds the ign‘ ysteny loss of pressure grounds the Syston: (CHMNECTION 7) SECTION 9 PASE 11