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
10-2016 GENERAL INDEX
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
O&M_2.002211.810_A_10_2016
Kohler

2.002211.810_A
10-2016 GENERAL INDEX
OPERATION & MAINTENANCE MANUAL SFGLD “V”
KOHLER CO – PRIME / STAND BY
2/3
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
Kohler
Kohler

2.002211.810_A
10-2016 GENERAL INDEX
OPERATION & MAINTENANCE MANUAL SFGLD “V”
KOHLER CO – PRIME / STAND BY
3/3
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
O&M_2.002211.810_A_10_2016

PRODUCT INFORMATION INDEX DATE
Dep. 1
IC-G-D-60-002e B July 2015
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.
1.1
O&M_2.002211.810_A_10_2016