Kohler SFGLD480 Troubleshooting guide

Engine Model:
SFGLD360/480 Gas
Generator Set Models:
750/1000REZK
See Inside Front Cover for Service Assistance Information
TP-6991 8/18b
Engine Operation &
Maintenance

WARNING: This product can expose you
to chemicals, including carbon monoxide
and benzene, which are known to the State
of California to cause cancer and birth
defects or other reproductive harm.
For more information go to
www.P65warnings.ca.gov
Service Assistance
For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
DVisit the Kohler Co. website at KOHLERPower.com.
DLook at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product.
DCall toll free in the US and Canada 1-800-544-2444.
DOutside the US and Canada, call the nearest regional
office.
Headquarters Europe, Middle East,Africa
(EMEA)
Kohler EMEA Headquarters
Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: [phone]
Fax: [phone]
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: [phone]
(91) 80 3366231
Fax: [phone]
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]


5552656v1
Guascor Power, S.A.U., Sociedad Inscrita en el Registro Mercantil de Guipúzcoa, Tomo 1195, Folio 178, Sección 8, Hoja SS-3957 - C.I.F. A-48042709

DearCustomers,

PleasebeadvisedthatEPAregulation40CFRpart60subpartJJJJplacescertainrequirementson
ownersandoperatorsofnewstationarysparkignitioninternalcombustionengines.Youhave
purchasedaEPApre‐certifiedGuascorgasengineper40CFRpart60subpartJJJJand,therefore,
shouldadheretothecompliancerequirementsforpre‐certifiedenginesYourenginehasbeen
certifiedforstationaryemergencyuseonly.Assuch,thereisnotimelimitforuseofthis
emergencystationaryICEengineinemergencysituations‐asdeterminedbyanauthorizedentity.
However,theEPAdoesstrictlyregulatehowmuch,andwhenthisunitcanbeoperatedfornon‐
emergencysituations.Pleaseconsulttheregulationsforspecifics.
Thispre‐certificationdoesnotexemptyoufromStateorlocalairauthorityregulations.Infact,
manyStateandlocalairauthoritieshaveadoptedregulationsmorestringentthantheEPAandwill
requireon‐sitetestingtotheirspecifictestprotocolsregardlessofthispre‐certification.We
adviseyoutoconsultallapplicableregulationsindeterminingyourcomplianceobligationsandto
checkwithyourlocalauthoritytomakesureyourinstallationisincompliancewithlocallawsand
regulations.
GuascorengineswillsatisfytheaforementionedEPAregulationsonlyiftheengineconfigurationis
notchanged,theengineiscommissionedbyafactorytechnician,approvedDealerorService
Companytechnician,theenginemaintenancescheduleisfollowed,andthesupplygastothe
enginesmeetsthefollowingfuelspecificationIC‐G‐D‐30‐021.TheDresser‐Randbusiness,partof
SiemensPowerandGasDivision,disclaimsliabilityforalloperationalfactorsoutsideofitscontrol,
whichmayaffectyourenginesemissionsoutput.
PleasecontactDresser‐Randifyouhaveanyquestionsaboutyourengine’semissions
performance.



2.002211.810_A
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OPERATION & MAINTENANCE MANUAL SFGLD “V”
KOHLER CO – PRIME / STAND BY
1/3
CHAPTER 1 – SAFETY FEATURES AND PRECAUTIONS
IC-G-D-60-002e_B Safety precautions for KOHLER gas engines 1.1
IC-G-D-60-003e_D Review of compliance with european machinery safety regulations and "CE" mark requirements 1.9
IC-G-D-00-042e_E Sound pressure level in GAS engines 1.17
IC-G-D-00-043e_F Sound pressure level in the exhaust zone of the GAS engines 1.21
IO-C-M-00-004e_A Guide to environment-friendly waste management during product maintenance and at end of life 1.25
CHAPTER 2 – ENGINE TECHNICAL DESCRIPTION
2.1 General
IC-G-D-00-039e_F Gas engines identification plates and characteristics 2.1.1
IC-G-D-00-253e Emissions plate of Epa certified engines 2.1.9
IC-G-D-00-040e_F Gas engines general description of construction 2.1.11
IC-G-D-00-036e_G Table of technical characteristics in-line FGLD/SFGLD/SFGM/HGM engines 2.1.15
IC-G-D-00-151e Description of the components in one circuit “V” gas engines 2.1.17
IM-G-C-00-002e_F Gaps and wear limits for “V” Gas and Ethanol engines 2.1.25
IM-G-C-00-001e_F Tightening torques for Gas and Ethanol engines 2.1.33
IM-C-C-00-002e_B Tightening torques for commercial bolts & nuts 2.1.37
IC-C-D-00-025e Units conversión 2.1.41
2.2 Cooling System
IT-G-A-20-025e One circuit cooling system for gas V - engines 2.2.1
IT-G-A-20-007e_I Gas engines – pressure losses and flowrates 2.2.9
2.3 Lubrication System
IC-C-D-25-005e_C Description of lubrication system for “V” engines 2.3.1
IT-C-A-25-002e_F Automatic engine oil level controller 2.3.7
IT-C-A-25-045e_B Lube oil level indicator UL 2.3.11
IT-C-A-25-030e_G Kohler engines submerged oil preheating system 2.3.15
IC-C-D-25-006e_B Description of a crankcase Gas recirculation system 2.3.19
2.4 Fuel System
IC-G-D-50-003e EGS 02. Description 2.4.1
IT-G-E-30-001e_B Venturi type carburation - description 2.4.5
IC-G-D-30-040e_A Specification of Gas supply to tecjet 52 2.4.11
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2.5 Ignition
IC-G-D-33-002e_A Description of the GIS ignition system 2.5.1
2.6 Intake
IC-C-D-35-002e_C GAS engines intake system 2.6.1
IC-C-D-35-001e_D Air filters 2.6.5
2.7 Exhaust
IC-C-D-40-003e_A Oxidative catalytic converters 2.7.1
IC-G-D-40-002e_B Exhaust system and ventilation of the oil sump 2.7.7
2.8 Starter
IT-C-A-55-001e_J Electric starting 2.8.1
2.9 Safety and Control
IO-G-M-60-002e_K FG/FGLD/SFGLD/SFGM/SFGRD engines instrumentation 2.9.1
CHAPTER 3 – HANDLING AND STORAGE INSTRUCTIONS
IM-G-C-00-004e_A Lifting system for SFGLD/SFGM V engine 3.1.1
IO-C-M-00-001e_A Deferred start-up engine inspection and protection 3.1.7
CHAPTER 4 – OPERATING INSTRUCTIONS
IT-G-A-00-011e_C Minimum room temperature for operating Gas engines 4.1.1
IO-C-M-15-002e_A Kohler Engine barring gear operating instructions 4.1.3
IO-C-M-20-001e_D Cooling water quality and treatment 4.1.5
IC-G-D-25-003e_B motoroil 3040 plus lube oil for natural gas-fuelled and ethanol engines 4.1.11
IC-G-D-30-001e_D Fuel specifications for Gas engines. General 4.1.13
IC-G-D-30-021e_B Fuel specifications – Us natural gas 4.1.19
IO-G-M-33-010e Installation and operation manual - Gis ignition unit display 4.1.25
IO-G-T-00-003e Starting and stopping of emergency gas engines 4.1.39
IO-G-M-40-001e_D Gas engine and ethanol carburation 4.1.43
IC-C-D-40-001e_C Emission units conversion 4.1.45
IO-C-M-25-006e_G Oil level indicators 4.1.49
IO-C-M-25-005e_D Automatic oil level controller 4.1.51
IT-G-A-00-008e_A Emissions - related installation instructions 4.1.53
O&M_2.002211.810_A_10_2016
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Kohler

2.002211.810_A
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OPERATION & MAINTENANCE MANUAL SFGLD “V”
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CHAPTER 5 – MAINTENANCE INSTRUCTIONS
5.1 Maintenance Procedures
IO-G-M-00-060e_B General maintenance of gas engine 5.1.1
IO-G-M-00-061e_C Maintenance of natural gas engine SFGLD 1800 rpm prime 5.1.5
IO-G-M-00-019e_G Maintenance of natural gas engine SFGLD stand-by 5.1.13
5.2 Description of Maintenance Operations Type E
IO-G-M-25-001e_G Gas-fueled engine oil servicing instructions 5.2.1
IO-C-M-25-001e_A Oil sampling procedure 5.2.5
IO-C-M-25-004e_A engine oil change instructions 5.2.7
IO-C-M-25-003e_A 180/240/360/480/560 engines centrifugal oil filter maintenance instructions 5.2.11
IO-C-M-25-011e Maintenance of the crankcase gas recirculation system 5.2.13
IO-C-M-25-012e_A Cleaning the oil separator filter of the crankcase gas breather 5.2.17
IO-C-M-00-006e_A engine cylinder compression test 5.2.19
IO-G-M-33-001e_C Conventional spark plug changing and maintenance instructions 5.2.23
IO-G-M-33-002e_F Conventional spark plug replacement criteria in Gas engines 5.2.27
IM-G-C-33-001e_D Conventional spark plug installation instructions 5.2.31
IO-G-M-33-003e_B Check of ignition coils and spark plug wires 5.2.33
IO-G-M-33-007e_L Maintenance of spark plugs. Overview 5.2.35
IO-G-M-33-009e_A Checking the ignition timing 5.2.37
IT-G-E-10-001e_G Adjustment of Gas and Ethanol engine valves 5.2.41
IO-C-M-35-001e_E Air filters. Maintenance 5.2.45
IO-C-M-15-001e_B Damper condition monitoring 5.2.51
IO-C-M-20-002e_G Maintenance of the cooling system 5.2.55
IO-C-M-45-001e_B Maintenance of turbocharger 5.2.61
IO-G-T-35-001e_A Intake safety valve operating and maintenance procedure 5.2.65
IO-C-M-20-010e_A Maintenance of intercoolers 5.2.67
IO-C-M-60-004e Maintenance of pick-ups 5.2.71
IO-C-M-55-001e Maintenance of batteries 5.2.73
CHAPTER 6 – TROUBLESHOOTING
IO-G-T-00-001e_B Gas engines troubleshooting 6.1.1
O&M_2.002211.810_A_10_2016
Kohler
Kohler
Kohler

2.002211.810_A
10-2016 INDEX Chapter 1
SAFETY FEATURES AND PRECAUTIONS
OPERATION & MAINTENANCE MANUAL SFGLD “V”
KOHLER CO – PRIME / STAND BY
1/1
CHAPTER 1 – SAFETY FEATURES AND PRECAUTIONS
IC-G-D-60-002e_B Safety precautions for KOHLER gas engines 1.1
IC-G-D-60-003e_D Review of compliance with european machinery safety regulations and "CE" mark requirements 1.9
IC-G-D-00-042e_E Sound pressure level in GAS engines 1.17
IC-G-D-00-043e_F Sound pressure level in the exhaust zone of the GAS engines 1.21
IO-C-M-00-004e_A Guide to environment-friendly waste management during product maintenance and at end of life 1.25
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SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES
1/8
1. INTRODUCTION
All Kohler engines have been designed in accordance withEuropean Machinery Safety Regulations,
European Directive 2006/42/EC and the harmonised standards UNE-EN ISO 12100-1 and UNE-EN ISO 12100-
2. Accordingly, we supply them with the EC Declaration of Conformity and «CE» mark.
The intention has been to supply an intrinsically-safe engine, although the nature of this machine does not rule
out the possibility of potential risks, for which it is necessary to adopt certain safety precautions.
The aim of this document is to inform the users of Kohler equipment on the safety precautions which are
required for handling and operating it adequately.
Engine installations and specially fuel-powered engines must be adapted in all cases to the local regulations.
2. PRELIMINARY OBSERVATIONS
We recommend you to read these safety precaution instructions on receiving your Kohler engine. They are
part of the engine operation and maintenance manual we supply with each engine.
Therefore, we recommend that the manual be kept in perfect condition and readily available to the operator and
those responsible for engine maintenance.
Our Network of Repair Shops is at your disposal to carry out revisions and repairs under the best conditions
and in accordance with the standards established by Kohler.
The use of original spare parts ensures high performance over long periods of operation. These parts have
been manufactured with the same strict quality controls, which were used for the manufacture of the original
equipment.
3. BODILY PROTECTION
CAUTION
Wear approved bodily, sight, hearing and respiratory protection. Never wear loose clothing, jewellery or long
hair around the engine.
4. EXHAUST GASES
CAUTION
IC engine exhaust products are toxic and may cause injury or death if inhaled. All engine installations must have
an exhaust discharge pipe so that the exhaust gases are delivered into the outside air. A closed building or
shelter must be adequately vented to provide a steady supply of fresh air.
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5. ENGINE FUELS
CAUTION
If a gas engine has been cranked excessively without starting, shut off the gas fuel supply and continue
cranking the engine to purge the cylinders and exhaust system of accumulated, unburned gas. If you fail to do
this, a spark plug could ignite and cause an explosion.
Engine fuels may ignite or explode. These must be delivered to the engine with proper piping, free from leaks
and designed to resist breakage from vibration.
6. POSITIVE FUEL SHUT-OFF
CAUTION
Some means of positive fuel shut-off should be provided for emergency use.
Pressurised fuels such as natural gas, landfill or digester gas should have another positive shut off valve
(manual, automatic or valve train), other than those in the carburettor or gas pressure regulation equipment.
It is the final responsibility of the user to ensure that the installation is free from fuel or exhaust leakage and
such installation meets all applicable codes.
7. SAFETY GUARDS
CAUTION
IC engines must be provided with guards to protect persons or structures from rotating or heated parts. It is the
responsibility of the engine owner to fit such protection.
8. CRANKCASE GASES
WARNING
All the engines incorporate a crankcase gases vent to relieve pressure that builds up inside as a portion of the
combustion gases flow in through the piston rings (blow by). Make sure the vent pipe is correctly fitted, allowing
free passage of the gases.
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9. COOLING SYSTEM PRESSURE CAPS AND CONNECTIONS
CAUTION
Do not remove the pressure caps while the engine is operating or while coolant is hot. The cooling system is
under pressure and severe burns could result from the hot coolant spewing out when the cap is removed. Wait
until the engine and coolants have cooled down before removing caps from the intercooler, thermostat box,
radiator or surge tank. Always replace the weak hoses, lines and fittings.
10. IGNITION SYSTEM
CAUTION
Ignition systems can cause electric shocks. Avoid contacting ignition units and wiring.
A spark plug will fire if the storage capacitor in the electronic ignition module is connected. This may even
happen when the cable is disconnected. When this cable is connected the capacitor will discharge and fire the
spark plug which will ignite any gas which has accumulated in that cylinder. The crankshaft and driven
equipment may rotate, possibly causing personal injury or damage to equipment. Gas which has accumulated
In the exhaust system may also be ignited.
Before reconnecting the cabling of the electronic ignition module, shut off the supply of current.
Protect spark plugs, wires and coils from the rain and snow.
11. GENERATOR SETS
DANGER
The voltage produced by generator sets is dangerous for anyone who touches a part of the electrical system
while this is working. Severe, possibly fatal shock may result from contact. Make sure the generator set is
grounded before operation. Be extremely careful when the unit or surrounding area in damp or wet. When
servicing any part of the electrical system or making any connections, make sure that the main power switch is
off. Clean or service generator only when engine is shut down.
In case of an accident from electrical shock, shut down the generator set at once. If it cannot be shut down, free
the victim from the live conductor.
Avoid direct contact with the victim. Use a dry board, dry rope or any non-conducting implement to free the
victim. If the victim is unconscious, apply artificial respiration and get medical help.
Do not operate the generator set with the ammeter circuit open. Voltage, dangerous to both equipment and
personnel, can be generated in an open secondary circuit of a current transformer.
If the generator set is stopped by operation of safety devices, do not attempt or operate until the cause has
been eliminated.
When the generator set is shut down after operation, disconnect all line switches to all external power load and
parallel circuits.
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12. TIDINESS AND CLEANLINESS
WARNING
Tidiness and cleanliness are essential to endure a safe workplace. A tidy workspace with clean catwalks and
well-ordered equipment and tools, allows one to do the job better and is an important factor in accident
prevention.
13. ENGINE AND EQUIPMENT; REPAIR AND SERVICE
CAUTION
Always stop the engine before cleaning, servicing or repairing the engine or driven equipment. Place all controls
in the off position to prevent accidental restarting. If possible, lock all controls in the off position and take the
key. Put a sign on the instrument panel warning that the engine is being serviced. Before restarting, make sure
that all tools and other material are removed from the engine and equipment.
Proper service and repair is important to the safe, reliable operation of the engine and related equipment.
The procedures recommended by Kohler in this manual are effective methods for performing service and
repair operations. Some of these procedures require the use of specially-designed tools. Special tools should
be used when and as recommended. Anyone who uses a service, repair or installation procedure not
recommended by Kohler must first satisfy themselves thoroughly
that their safety will not be jeopardised by the service methods they selected.
14. ENGINE FAN BLADES
-Do not operate the engine with the fan bent, broken, modified or damaged in any way.
CAUTION
-Do not operate the engine if the fan contacts or strikes any engine accessory or the radiator shroud or core.
-Do not try to rebalance the fan. Contact the supplier if rebalancing is required.
-Ensure that all bolts attaching the fan are securely installed to a torque specified by the engine, vehicle or
boat manufacturer.
-Install the fan sothat it is directed correctly towards the radiator.
-Perform all required maintenance on the drive system, as described in this manual.
-Do not modify or substitute any partsof the engine without the approval of the Service Department of
Kohler. Take special care not to make modifications which will increase the operating speed of the fan.
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-Install the fan only if the engine has been approved for fan installation. Likewise, install a drive system
defined by Kohler.
-If the fan or drive contains any plastic or rubber component, have the fan and drive inspected by a qualified
mechanic after operation or exposure to excessively high temperatures (air temperature of over 120ºC).
-Replace the fan if indications of excessive corrosion or erosion appear in the fan.
-For reversible or adjustable pitch fans, make sure the blades are correctly locked in the proper position
prior to operation. Also, inspect the fan prior to operation to ensure that ice and dirt have not accumulated
on the fan to cause potential imbalance of the fan.
-Be sure that all fans, fan drives and belts are properly shielded.
15. TURBOCHARGERS
CAUTION
Turbochargers are designed specifically for each application. Turbochargers operate at high temperatures,
therefore all inflammable material must be kept away from them. Engines must be shut down and at room
temperature before working on turbochargers or burns will result.
16. ENGINE STORAGE CHEMICALS
DANGER
Protective oils contain a petroleum distillation, which is harmful or fatal if swallowed. Avoid contact with skin,
eyes and clothes. Vapour is harmful and causes irritation of eyes, nose, throat and skin. Use only with adequate
ventilation. Avoid breathing of vapour. Do not take internally. Keep container closed and away from heat.
Always read and observe the <<CAUTION>> labels on the containers. Do not destroy the labels on the
containers.
In general, protective compounds should not be heated over 90ºC. To heat at this temperature, the containers
must be placed in a vessel with hot water. The cover must be removed and a hole must be made in the
container to reduce the danger of explosion. Heating or direct heat is an unnecessary fire risk.
17. FIRE PROTECTION
WARNING
Locate fire extinguishers so that they are easily accessible if a fire start. Carefully maintain records of
extinguisher inspection and recharging to ensure the fire extinguishing capabilities when required. Consult your
fire extinguisher supplier or insurance engineering for recommendations required for the engine installation. It is
also recommended to have well-identified fire emergency escape routes in all engine installations, in
accordance with regulations.
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SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES
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18. CLEANING SOLVENT
CAUTION
Use approved cleaning solvents in a well ventilated area. Do not breathe fumes as some vapours can be fatal.
Keep away from open flames or sparks. Do not use gasoline or paint thinners or other highly volatile fluids for
cleaning. Always read and observe the <<CAUTION>> labels of containers. Do not destroy the labels on the
containers. Cleaning solvents can cause various kinds of skin irritations.
19. WELDING EQUIPMENT
CAUTION
Welding gas cylinders can explode if damaged. Cylinders must be stored in accordance with manufacturer’s
specifications and applicable safety requirements.
When using acetylene, check valves should be installed between the regulators and hoses to prevent flashback
into the regulators and supply tanks. Flashback could cause the regulators and supply tanks to explode.
Oily and greasy materials must be kept away from oxygen valves, hoses, etc. Oxygen, if combined with such
materials, will cause and explosive reaction.
Always wear protective eyes shields when welding, cutting or watching welding operations. Protective clothing
must be worn. Do not weld or cut near combustible materials.
20. GROUNDING PRECAUTIONS WHEN WELDING
CAUTION
When using an electrical welder on an engine, clip the ground lead as close to the welding site as possible.
Putting the ground lead too far from the welding site may result in arching across the main bearings and fusing
these to the crankshaft.
21. ELECTRICAL TOOLS
CAUTION
Make sure that electrical tools are properly grounded. Wear proper eye protection. Do not work in wet or damp
conditions. Be sure that the tool is in good condition and safety guards are in position. An electric trouble light
must also be grounded. Do not carry electric power tools by the cord. Do not yank the cord when removing from
an outlet. Instead, grasp the plug to remove it from an outlet.
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22. BATTERIES
CAUTION
Always disconnect the battery ground connection from batteries before performing any work on the engine or
equipment. This will prevent sparks or burns when accidentally shorting an electrical connection.
Never expose batteries to open flame or electric spark. The chemical action of the battery produces
hydrogenous gas which is inflammable and explosive. Do not allow the battery fluid to contact skin, eyes,
clothes or painted surfaces. The electrolyte is a sulphuric acid solution, which could cause serious burns or
damage equipment. Wear eye protection when working with batteries.
23. PRECAUTIONS WHEN USING BOOSTER BATTERIES AND CABLES
Do not attempt to jump start an engine having a frozen battery. The battery may rupture or explode. Before
starting, examine all fill vents on the battery. If ice can be seen, or if the electrolyte fluid cannot be seen, do not
attempt to start with jump cables. Batteries, charged and discharged, should be treated carefully when using
jumper cables.
The following procedures assist in reducing sparks and explosion hazards always present in both batteries
when connecting charged batteries to discharges batteries:
-Turn off all electrical loads. Remove vent caps and lay damp cloth over open vent well of each battery. The
charged booster battery or batteries must have the same voltage capacity as the discharged battery or
batteries.
-The positive post is identified by a <<+>>, pos. and red colour and is larger in diameter than the negative
post.
-The negative post is identified by a <<->> neg, and natural lead colour (grey).
24. COMPRESSED AIR
Compressed air or gases should never be used to clean clothing or your body. Compressed air can pierce the
skin and cause severe and very painful injury.
Never use your hand to check air, gas, or liquid flow rates, or check for leaks. Do not engage in <<horseplay>>
with air, gas or liquid hoses. Observe all applicable regulations as related to compressed gases.
25. INTOXICANTS AND NARCOTICS
CAUTION
Anybody under the influence of intoxicants and/or narcotics is hazard to themselves and other employees.
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26. SAFETY PRACTICES FOR HANDLING ACIDS
Cleaning with acid for certain castings and pieces of equipment is frequent. In handling them, follow these
recommendations:
-Avoid contact with skin, clothing and eyes.
-Descaling operations should be performed away from all fire, spark or other ignition sources.
-Keep acid off of concrete floors because it attacks the lime in the concrete. If solution does get on concrete
surfaces, apply an alkaline solution to neutralise.
-Acids can react with metals to form various gases. Generally, acid solutions on lime scale and rust result in
the formation of harmless carbon dioxide. However, when acids contact aluminium, zinc, cadmium, tin,
sulphur, arsenic or cyanide, poisonous and explosive gases may be generated. When descaling is done in
closed equipment, install proper ventilation to carry the gases away.
-Always store containers closed, placing these in their normal position.
-Be sure that there are no leaks in the vessel being descaled, which will permit solution to leak into opposite
side of equipment. Good practice is to fill the opposite side of the equipment being descaled with water to
level higher than the acid solution.
-Use an acid-proof pump, or an inexpensive, throw-away pump.
-Do not agitate acid solutions with compressed air.
-Applications of acid should be followed by thorough rising, then neutralising with an alkaline solution to
remove all acidic residue, to prevent further action.
-Store acid solutions in either an acid-proof wooden or synthetic rubber lined steel container.
-Check steel equipment to be treated with acid solution for copper or brass fittings or fusible metal plugs. If
possible, dissimilar metals should be removed prior to descaling to prevent electrolytic action which might
interfere with the inhibiting action of acid solution. Do not use acid to descale equipment constructed of
aluminium.
27. ENGINE LIFTING AND HANDLING
-The use of cloth slings is recommended to avoid damaging the equipment with rough movements.
-Assure that the slings do not come into contact with sensitive parts of the equipment.
-Correctly inspect all anchor points so that there is no defective welding, loose screws, etc. that might
jeopardize the lifting of the equipment.
-Verify that all pertinent structures have been inspected, are in good condition, and can support at least the
weight of the equipment plus 10%. If you are not sure, weigh the equipment prior to lifting it.
-Prior to lifting it, be sure to balance the equipment to the maximum, using slings of different lengths if
necessary.
-Keep all personnel away when the unit is in the air.
-Do not lift the equipment further than necessary.
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1. INTRODUCTION
This document describes all the design and operative features of our engines and their applications (generating
sets or others) as well as the technical solutions that we have implemented to comply with the current
machinery safety regulations. These include Royal Decree 1435/1992 and subsequent amendments, European
Directive 2006/42/CE and the harmonised standards UNE-EN ISO 12100-1 and UNE-EN ISO 12100-2.
Compliance with these is mandatory to be able to issue the Declaration of Conformity with the European
Regulations and to use the "CE" mark.
2. ENGINE DESIGN
The check for compliance with the European Regulations on Machine Safety described in this document applies
to Kohler gas and ethanol engines.
Those engines are mostly developments of their diesel counterparts whose design has passed technical audits
by renowned certification agencies - Lloyd’s Register, Bureau Veritas, Germanischer Lloyd’s, Rina, Det Norske
Veritas, Hellenic Register of Shipping, and others - for approval in marine applications and has been awarded
the ‘type approval' certificate that guarantees the suitability of the basic engineering design.
In designing and manufacturing the engines, Kohler follows risk suppression or reduction criteria,
implementing adequate solutions and adopting the necessary protective measures when it is not possible to
eliminate these risks. In this event, Kohler informs users of any residual hazards due to the incomplete
effectiveness of the protective measures, advising them that they must have specific training and use personal
protective equipment where necessary.
Similarly, in designing and manufacturing the machine as well as in writing the product information, Kohler
bears in mind not only the normal use, but also any reasonably expectable use of the machine.
3. ENGINE ROOM
The engine room or the area surrounding the engine or generating set cannot be rated as a danger zone
under current regulations since the running of the engine will under no circumstances give rise to the release of
solids, liquids or heat in it that could affect the operators' safety.
Despite this, given that the engine’s operation, service or control while running does not require anybody
very close to it, we recommend that operators should stay at a suitable safety distance to prevent the effects
of any fault or unforeseeable failure, should one occur.
Adjustment and fine-tuning operations (valve timing, oil and water level control, etc) are to be undertaken
with the engine stopped. Only qualified and trained personnel must carry out carburetion adjustments
with the engine running according to the set procedures, without putting any of the operators in danger.
4. RISK ANALYSIS
In designing the engines, we adopted technical options or solutions that avoid intrinsic and specific
engine operation hazards.
Nevertheless, due to the very concept of the machine and its operation, there still exist various
unavoidable, though limited hazards, representing a risk for the operator.
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This section reviews the design solutions implemented to overcome any machine-specific risks and the
preventive measures against unavoidable risks.
Kohler will not be liable for any injury or damage arising from any use of the engine
other than that described in the instruction manual. Operating the engine beyond its nominal conditions (e.g. in
terms of power, ignition advance, mixture strength - carburetion, etc) can have serious consequences for the
user or even put the user's life at risk and cause extensive material damage.
4.1. MATERIALS AND PRODUCTS
The materials and products used for the construction and operation of the machine do not involve any health or
safety hazard as long as operators follow the user instructions and current regulations.
4.2. EQUIPMENT DRIVES
The drive systems are safe and reliable, with clearly identified and visible controls, including adequate alarms as
well as normal and emergency stop devices.
4.3. MECHANICAL HAZARDS
The equipment supplied has been designed and built to offer sufficient stability under the planned operating
conditions. Its components are designed for appropriate resistance in operation. Product information sheets
specify the necessary inspection and maintenance programmes for safety’s sake.
We design and manufacture the moving parts of the engine to avoid any risk. Therefore they incorporate guards
or protective systems impeding physical contact that would cause injuries or accidents. Drive components
(pulleys, belts, gears, etc) have covers that can be fixed or are movable depending on the frequency of
servicing tasks. All protective devices are made solidly and resistant.
4.4. ELECTRICAL HAZARDS
The engines’ design, construction and equipment prevent or ensure possible prevention of all electrical hazards.
Refer to the “Electrical installation” section. The engines also have static elimination systems.
4.5. FIRE, EXPLOSION AND HIGH TEMPERATURE HAZARDS
We have taken precautionary measures to avoid injuries caused by hot parts or materials through physical
contact or remotely. We also addressed the risk of flying hot matters and avoided fire and overheating hazards
originating in the engine.
Various types of fluids of varying properties circulate through the engine at varying temperatures.
4.5.1. COOLING WATER
By design, all the connections in the water circuit are fitted with mechanical seals and/or bushed systems with
ethylene propylene O-rings, suitable for the high temperature of the engine coolant in the main system (120 ºC)
and in the auxiliary circuit (90 ºC). Therefore no rubber couplings are used.
4.5.2. LUBRICATING OIL
The oil circuit has been designed fully integrated into the engine so that the only outgoing pipes are those to and
from the oil cooler. Sealing of all the tubes is through mechanical seals or bushed systems with Viton O-rings,
avoiding the use of rubber couplings by all means.
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4.5.3. FORCED INDUCTION
In the supercharging circuit (downstream of the turbocharger), the components are sealed is mechanically with
Viton O-rings. Rubber sleeves and other materials have been totally discarded.
4.5.4. MANIFOLDS AND EXHAUST PIPE
To limit leak risks, the engine exhaust manifolds are mechanically sealed with special metal-reinforced joints.
For the purposes of protecting the operators from accidental contact, we have designed a cooled exhaust
manifold with the engine cooling water circulating outside and around it so that the temperature on the exhaust
manifold surface, otherwise 400 to 500 ºC, falls to the coolant temperature levels of 80 to 90 ºC.
As for the turbocharger, the turbine casing (exhaust side) is also very hot and cannot be cooled but is protected
with a heat-insulating blanket (or jacket) limiting the surface temperature to less than 90 ºC. This solution also
applies where the engine application requires the use of hot (uncooled) exhaust manifolds.
A similar type of protection covers that part of the exhaust elbow or pipe extending to the connecting flange on
the hose for connection to the external exhaust pipe. The installation project must protect this exhaust pipe.
When supplying the installation, we check for any contact with this piping and, where appropriate or for exhaust
heat recovery if desired, we protect the pipe with a stainless steel lined heat-insulating blanket.
4.6. VIBRATION
Engine vibrations do not affect operator safety, although they could be transmitted through the engine mounting
to other machines or to the building, causing a nuisance for people in the neighbourhood. Engines for
applications where structure-borne vibrations are likely to occur will be isolated from their support by elastic
vibration absorbers.
We also use flexible elements to connect all the utilities (water, fuel, oil, etc) to the outside of the engine.
4.7. NOISE
Noise generation is inherent to the engine and is generally inevitable although design approval is conditioned to
a sustainable sound level when adequate and necessary means of protection are used.
Ear protection is necessary for all the people present in the engine room when the engines are running.
Therefore, at the entrance to the engine room, there must be a clear and visible warning of the obligation for the
operators to wear ear protection.
No type of ear protection is specified, as the certified personal protective equipment usually available on the
market is considered suitable.
As regards noise outside the engine room (environmental noise pollution), it is necessary to install - and we do
install in all cases - adequate exhaust silencers to meet the local or environmental rules and regulations in force
where the engines operate.
4.8. ELECTRICAL INSTALLATION
The engine’s electrical installation consists of one terminal box for the connection of 24 V DC and 220 V, 400 V,
480 V, etc, devices, including sensors, contacts, etc. This terminal box and the wiring for these devices comply
with the low voltage wiring regulations and Directive 73/23/EEC as amended by Directive 93/68/EEC. There is a
switch on the front of this box for immediately stopping the engine in an emergency.
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