Kohler SDMO PERFORM 3000 XL TB UK C5 Instructions for use

33522201001_1_1
11/2019
Manuel d'utilisation et d’entretien
(Notice originale)
Instruction and maintenance manual
(Translation of the original note)
PERFORM
3000 XL TB UK C5
3000 XL TB UK C5

A
16
11
17
9
4
3
2
12
1
6
4
6
8
14
8
5
10
5
7
14
15
11
13
18

B
C
3
2
1
5
5
4
8
7
6
3
3
5
5
5
4
4
6
6
7
8
1
2

D
E
F
FRANCE:
0.806.800.107 (Prix appel)
1
2
3
6
4
5
1
3
2
1
1
2

CONTENTS
1..Preface
2..Instructions and safety regulations (personal protection)
3..Getting started with the generating set
4..Using the generator set
5..Generating set maintenance
6..Transporting and storing the generating set
7..Repairing minor faults
8..Technical specifications
9..Conditions of warranty
1 Preface
IMPORTANT
Material damage
Before use, read this manual and the safety instructions provided alongside it thoroughly.
Keep these safe throughout the unit's service life and always adhere to the safety advice and
the usage and maintenance instructions contained therein.
The information contained in this manual is taken from technical data available at the time of print (the photos shown in this manual
are not legally binding). In line with our policy of continually improving the quality of our products, this information may be amended
without warning. On request, we can supply our original manuals in French via our website.
In this manual, dangers are represented by the following two symbols:
DANGER
[Appropriate pictogram(s)]
RISK TO THE HEALTH OF THOSE CONCERNED
DANGER OF DEATH (if appropriate)
Indicates an imminent danger which may result in death or serious injury. Failure to follow the
instruction shown may pose serious risks to the health and life of those concerned.
IMPORTANT
Material damage
[At-risk equipment]
Indicates an at-risk situation. Failure to follow the instructions provided may result in minor
injuries to those concerned or material damage.
2 Instructions and safety regulations (personal protection)
The instructions and safety regulations must be read carefully and followed to avoid endangering personal health and safety. If
there is any doubt over the meaning of the instructions, please contact your nearest agent.
2.1 Meaning of the pictograms on the generating set
DANGER
DANGER: risk of electric shock
GROUND
DANGER:risk of burns
Before starting, check the oil level.
1
2
3
DANGER:
1 - Refer to the documentation supplied with the unit.
2 - Emission of toxic exhaust gases. Do not use in a confined or poorly
ventilated area.
3 - Stop the unit before filling with fuel.
2.2 General guidelines
Never let other people use the unit without ensuring they have all of the necessary instructions beforehand. Never allow a child to
touch the unit, even when switched off, and do not operate the unit when animals are in the vicinity (fear, disturbance, etc.).
In all cases, respect the local regulations currently in place concerning the use of the units. Exhaust gases, fuel and oil are toxic
products; take all necessary protective measures.
2.3 Guidelines for protecting the environment
Drain the engine oil into a designated container: never drain or discard engine oil onto the ground.
As far as possible, avoid sound reverberating through walls or buildings (the noise will be amplified).
If the unit is used in wooded, bushy or uncultivated areas and if the exhaust silencer is not fitted with a spark arrester, clear any
vegetation away from the area and take care that the sparks do not cause a fire. Once the unit is no longer being used (end of
product life), take it to a waste collection point.
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2.4 Risks relating to exhaust gases
DANGER
RISK OF POISONING
DANGER OF DEATH (if appropriate)
The carbon monoxide present in the exhaust gas may lead to death by inhalation if the
concentration levels in the atmosphere are too high.
Always use the unit in a well ventilated area where the gases cannot accumulate.
For safety reasons and for correct operation of the unit, correct ventilation is essential (risk of poisoning, engine overheating and
accidents involving, or damage to, the surrounding equipment and property). If it is necessary to operate it inside a building, the
exhaust gases must be evacuated outside and adequate ventilation must be provided so that any people or animals present are not
affected.
2.5 Risk of fire
DANGER
RISK OF FIRE
DANGER OF DEATH
Never operate the unit in areas containing flammable products (risk of sparks). Keep all
flammable or explosive materials (e.g. petrol, oil, cloth, etc.) out of the way when unit is
running. Never cover the unit with any type of material while it is in operation or just after it has
been turned off: always wait until the engine cools down (at least 30 minutes).
2.6 Risk of burns
IMPORTANT
Before any intervention, wait for the unit to cool down (at least 30 minutes).
When running and just after stopping, the oil, engine and the exhaust silencer are hot and may cause burns if contact is made.
2.7 Risk of electrocution
DANGER
RISK OF ELECTROCUTION
DANGER OF DEATH
Units supply electrical current while operating; comply with the applicable legislation as well as
the installation and usage recommendations given in this manual. If you are in any doubt
regarding installation, please contact your nearest agent.
Do not connect the unit directly to other power sources (such as the mains for example); fit a
source changeover panel.
Never touch stripped cables or disconnected connectors. Never handle a unit with wet hands
or feet. Never expose the equipment to liquid splashes or rainfall, and do not place it on wet
ground.
2.7.1 Temporary or semi-temporary installation (work site, show, fairground, etc.)
A - If the unit is not equipped with an integrated differential protection device at delivery (standard version with insulated neutral on
the unit's earth terminal):
- Use a differential device calibrated to 30mA at the output of each of the unit's sockets (place each device at least 1 metre from
the unit, protecting it from weather conditions).
- If one or more mobile or portable devices are used occasionally, the unit does not need to be earthed.
B - If the unit is equipped with an integrated differential protection device at delivery (standard version with alternating neutral
connected to the unit's earth terminal - for use with TT or TN systems):
- Connect the unit to the earth: attach a 10 mm2 copper wire to the unit's earth terminal (A1) and to a galvanised steel earthing
rod set 1 metre into the ground.
2.7.2 Fixed installation or mains failure
When supplying a fixed installation (e.g. as backup for mains outages), the unit must be connected by a qualified electrician in
accordance with the regulations applicable at the installation site. The units are not designed to be connected directly to an
installation (risk of electrocution or damage to equipment).
A - If the unit is not equipped with an integrated differential protection device at delivery (standard version with insulated neutral on
the unit's earth terminal):
- Use a source inverter.
- The unit does not need to be earthed.
B - If the unit is equipped with an integrated differential protection device at delivery (standard version with alternating neutral
connected to the unit's earth terminal - for use with TT or TN systems):
- Use a source inverter.
- Connect the unit to the earth: attach a 10 mm2 copper wire to the unit's earth terminal (A1) and to a galvanised steel
earthing rod set 1 metre into the ground.
2.7.3 Mobile application
The units are intended to operate while stationary. They may not be installed on a vehicle or other mobile equipment unless a study
has been carried out analysing the unit's various installation and usage specifications. It is prohibited to use the unit whilst it is in
motion. If earthing is not possible, connect the unit's earth terminal (A1) to the vehicle earth.
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2.7.4 Connection and choice of cables
For all connections, use flexible, strong rubber-sheathed cables which comply with standard IEC 60245-4 or equivalent cables, and
ensure that these are kept in perfect condition. Only use one item of class I electrical equipment per socket and connect up
equipment using a cable equipped with a PE protective conductor (green/yellow); this protective conductor is not required for
class II equipment. Adhere to the cross sections and lengths recommended in this table during installation or when using electrical
extensions.
Equipment type:
Single-phase
Three-phase
Type of unit connector:
10 A
16 A
32 A
10 A
16 A
Recommended cable cross section:
mm²
AWG
mm²
AWG
mm²
AWG
mm²
AWG
mm²
AWG
0 to 50 m
4
10
6
9
10
7
1.5
14
2.5
12
51 to 100 m
10
7
10
7
25
3
2.5
12
4
10
Length of
cable used
101 to 150 m*
10
7
16
5
35
2
4
10
6
9
*This cable length is the maximum permitted length, and must not be exceeded.
Installation method = cables on raceway or non-drilled tablet/Permitted drop in voltage = 5%/Multi-core conductors/Cable type PVC 70°C (e.g.
H07RNF)/Ambient temperature =30°C.
2.8 Risk of hearing loss
DANGER
RISK OF HEARING LOSS
Suitable hearing protection must be worn at all times when the unit is running.
2.9 Risks during handling operations, use and maintenance
For safety reasons, all operations must be carried out by staff with the necessary skills and using suitable
equipment. Maintenance must be carried out on a regular and conscientious basis, using only original parts. Gloves
must be worn.
Safety guidelines for handling petroleum products:
DANGER
RISK OF POISONING OR EXPLOSION
Respect the local regulations in force concerning the handling of petroleum products. Fill up
when the unit is switched off and the engine cold. Smoking, using a naked flame, producing
sparks and making telephone calls are forbidden when filling the tank. After filling, always
check that the tank's filler cap is properly tightened. Clean any traces of fuel with a clean cloth
and wait until the vapors have dispersed before starting the unit. If the fuel is exposed to high
temperatures for a period of several hours (containers or generating set stored in a vehicle
parked in the sun, for example), harmful vapors could be released causing a risk of poisoning
or of feeling unwell.
The fluids used by the units, such as oils and fuels, are dangerous products. Never inhale or
ingest; avoid prolonged or repeated contact with the skin.
Safety guidelines for handling batteries:
DANGER
RISK OF POISONING OR EXPLOSION
Follow the battery manufacturer's recommendations. Only use insulated tools. Keep away
from fire or naked flames. Always ensure adequate ventilation during charging.
3 Getting started with the generating set
3.1 Key to illustrations
The cover illustrations can be used to identify the various components of the generating set. The procedures in the manual refer to
these illustrations using letters and numbers as identifiers: "A1" refers to the number 1 on figure A.
Earth terminal
A1
Starter-recoil reel handle
A9
Air filter cover attachment
D3
Oil dipstick/filler plug
A2-B1
Electrical sockets
A11
Foam element
D5
Filler neck
B2
Voltage selector
A10
Paper element
D6
Dipstick upper limit
B3
Oil drain screw
A12-B5
Exhaust silencer
A15
Dipstick lower limit
B4
Fuel filter
A13-C1
Spark arrester
E1
Fuel level indicator
A3
Fuel filter retaining clips
C2
Spark arrester mounting bolt
E2
Fuel tank cap
A4
Sediment bowl
A14-C8
Exhaust silencer protection
E3
Fuel taps
A5
Cover mounting bolt
C4
Spark plug
A16-F2
Air filter
A6
Cover mounting nut
C5
Spark plug cap
F1
"Normal" position
D1
Cover
C3
Circuit breakers
A17
"Low temperatures" position
D2
Sediment bowl cover
C6
GSC101-Generator Smart Care
A18
Switch
A7
Sediment bowl seal
C7
Choke
A8
Air filter cover
D4
The unit may be equipped with the "GS101-Generator Smart Care" option (A18): the Bluetooth GSC101 box
transmits all the information needed to monitor the unit to an application to be installed on your mobile phone; this
includes maintenance dates, a maintenance aid, and the map of approved resellers for any spare parts required.
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3.2 Initial commissioning
On taking delivery and commissioning the unit:
1. Check that it is complete and not damaged in any way.
2. If the unit is fitted with a transport bracket, remove it.
The transport bracket is a metal plate located underneath the engine, close to the
earth terminal. Although useful for transportation, it will prevent optimum operation
of the unit (noise, vibration).
To remove it: lift the unit slightly and place it on a block then remove the nut (1) and
the clamp (2).
3. Check the oil and fuel levels and top them up if necessary.
4. If necessary, connect the battery, starting with the positive terminal.
Observe the polarity of the battery terminals when connecting it: as this could cause serious damage to the electrical equipment.
Some units require a running-in period. Contact your nearest agent for more information.
3.3 Installing Generator Smart Care (Option)
The unit may be equipped with the "GS101-Generator Smart Care" option (A18):
1. Secure the Bluetooth GSC101 box to the unit,
2. Download and install the free Generator Smart Care* application onto a mobile phone or tablet,
3. Create an account,
4. Activate Bluetooth on the phone or tablet,
5. Follow the instructions on the application to pair the phone or the tablet with the Bluetooth GSC101 box.
Generator Smart Care displays all the information needed to monitor the unit in the application; this includes maintenance date
alerts and reminders, a maintenance aid, and the map of approved resellers for any spare parts required.
*Available free from the App Store and Google Play (excluding any connection fees charged by the phone system operator).
4 Using the generator set
Before using the unit, always:
1. Check that the unit is correctly installed and that it is ready to start.
2. Make sure you have understood all of the operating procedures.
To stop the unit in an emergency: turn the key to the "OFF" position and close the fuel tap(s), if fitted.
4.1 Positioning the generating set for operation
DANGER
RISK OF POISONING - CARBON MONOXIDE
DANGER OF DEATH (if appropriate)
Carbon monoxide is invisible, odorless and non-irritating and can cause death in less than an
hour. Always use the unit in a well ventilated area where the gases cannot accumulate.
In the event of headache, nausea or vomiting: stop the unit immediately, ventilate and
evacuate the area and call for help.
1. Choose a site that is clean, well ventilated and sheltered from bad weather.
2. Position the unit on a flat horizontal surface that has sufficient load-bearing capacity to prevent it from sinking.
The units are designed for stationary operation: they must not be installed on a vehicle or other mobile equipment unless a study taking
into account the different specific requirements for use of the unit has been carried out.
3. Check that the angle of the unit, in all directions, does not exceed 10°.
4.2 Check the generating set is in a good general condition (bolts, hoses)
Inspect the entire unit before start-up and after each use to prevent any faults or damage.
1. Check that the unit is clean, in particular the air intake zones (engine air intake, air vents, air filter, etc.).
2. Check all of the unit's pipes and hoses to ensure they are in good condition and that there are no leaks.
Pipes or hoses must be replaced by a specialist technician. Please contact your nearest agent.
3. Tighten any loose bolts.
The cylinder head bolts must be retightened by a specialist technician. Please contact your nearest agent.
4.3 Checking the engine oil level and topping up
1. If the unit has been used, leave to cool for at least 30 minutes
2. Remove the oil dipstick/filler plug (A2-B1) by unscrewing it, and wipe the dipstick.
3. Insert the oil dipstick/filler plug in the filler neck (B2) without tightening it, then take it out again.
4. Visually check the level: it must be between the upper limit (B3) and lower limit (B4) on the dipstick.
If the oil level is too low: open the oil filler cap, use a funnel to top up the tank (using oil that complies with the specifications in the
manual), then screw the oil filler plug back in.
If the oil level is too high: drain some of the oil into a suitable container.
5. Check the level again before screwing the oil dipstick/filler plug back in fully.
6. Check that there are no oil leaks, and wipe away any traces of oil with a clean cloth.
4.4 Checking the fuel level and topping up
With the unit on a flat, level surface, visually inspect the fuel level on the indicator (A3): the red marker on the indicator should be
between the maximum level (F = full) and the minimum level (E = empty). If necessary, fill with fuel:
1. Unscrew the fuel tank cap (A4).
2. Fill the fuel tank using a funnel, taking care not to spill any fuel and checking the level at regular intervals: the fuel level
indicator must be at position "F".
Do not overfill the tank; there should not be any fuel in the filler neck.
3. Carefully tighten the fuel tank cap.
4. All traces of fuel should be wiped off with a clean cloth.
1
2
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4.5 Starting the generating set
Once the daily checks have been performed, and having read the instructions and safety regulations carefully:
If the outdoor temperature is above 0°C:
If the outdoor temperature is below 0°C:
1.
Open the fuel tap (A5).
1.
Open the fuel tap (A5)
2.
Check that the air filter is in the normal position for use
(D1).
2.
Place the air filter in the "low temperature" position (D2).
3.
If the generating set is cold, move the choke control
(A8) to position "I".
3.
Move the choke control (A8) to position "I".
4.
Move the switch (A7) to "ON ON" " or "I I". ".
4.
Move the switch (A7) to "ON ON" " or "I I". ".
5.
Slowly pull the starter-recoil reel handle (A9) until there
is some resistance, then let it return gently.
5.
Slowly pull the starter-recoil reel handle (A9) until there is some
resistance, then let it return gently.
6.
Then pull the starter-recoil reel handle quickly and
sharply until the unit starts.
6.
Then pull the starter-recoil reel handle quickly and sharply until the
unit starts.
If the unit does not start, wait one minute before repeating the
process no more than three times.
If the unit does not start, wait one minute before repeating the process no
more than three times.
4.6 Using the electricity supplied
1. Allow the unit speed to stabilise and the temperature to rise (approx. 3 to 5 min.).
2. If the choke (A8) was used, return it gradually to its original position.
3. Connect the equipment to be used to the electrical sockets (A11) on the unit.
4. Place the voltage selector (A10) in the position corresponding to the voltage you need to use (115V or 230V).
4.7 Switching the generating set off
1. Disconnect the equipment used, taking care to close the cover for the unit's electrical sockets (A11) .
2. Allow the unit to run idle for 1 or 2 minutes.
3. Set the switch (A7) to "OFF" or "O ": the unit will shut down.
4. Close the fuel taps (A5).
5. Ensure the unit is properly ventilated and to avoid any risk of fire, wait for it to be fully cool (at least 30 minutes) before
covering it and storing it.
Even when the unit is turned off, the engine continues to give off heat.
5 Generating set maintenance
As a safety measure, maintenance should be performed on the generating set regularly and carefully by people who have the
necessary experience and are equipped with suitable tools, in respect of current regulations. The maintenance operations to be
carried out are detailed in the maintenance table. The interval for this is supplied as a guide and for generating sets operating with
fuel and oil which conform to the specifications given in this manual. The maintenance intervals can be shortened depending on the
generating set's operating conditions and requirements. It is important to note that the warranty shall not be valid if generating set
maintenance has not be performed correctly.
5.1 Reminder of use
Ensuring maintenance is performed regularly and correctly will guarantee safety and performance. The oil, filter elements and,
where present, the spark plug, are consumables which must be in good condition for the unit to operate correctly.
Replace them regularly as often as is needed (the reference for ready-to-use maintenance kits is given in the table of
technical specifications where applicable). The warranty becomes void in the event of failure to respect the maintenance
recommendations. For any questions about a special operation, please contact your nearest agent who will advise and help you.
5.2 Maintenance intervals table
The maintenance frequency is given as an indication only and is for devices using fuel and oil complying with the specifications
given in this manual. The maintenance intervals can be shortened depending on the unit's operating conditions and requirements.
Perform the maintenance operations at the indicated due dates even if the number of hours' operation has not been reached. The
warranty will be invalidated if maintenance of the unit has not been performed correctly.
After
In hours, months or years, whichever comes first
Operation to be carried out:
5 hours
3 months/
50 hours
Every
3 months/
50 hours
Every
6 months/
100 hours
Every
1 year/
200 hours
Every
2 years/
500 hours
Clean the unit
X
X
Clean the spark arrester
X
Unit
Replace the spark plug
X
Oil
Change
X
X
X
Replace the fuel filter
X
Fuel
Clean the sediment bowl
X
Clean
X
X
X
X
Air filter
Replace
X
Part numbers of parts to be used during maintenance:
RKS1
Major service
to be carried
out by one of
our agents.
France:
0.806.800.107
(call charge)
Major service
to be carried
out by one of
our agents.
France:
0.806.800.107
(call charge)
5.3 Performing the maintenance operations
1. Shut down the unit and wait at least 30 minutes for it to cool.
2. Disconnect the cap(s) of the spark plug(s) and disconnect the "-" terminal on the battery (if fitted).
3. Carry out maintenance in accordance with the information given in this manual and, to avoid the risk of damage to the unit,
only use original parts or their equivalent.
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5.3.1 Drain the engine oil
To ensure that the oil service is performed quickly and correctly, the oil must be changed when the engine is warm (start the unit
and allow it to run for a few minutes if necessary).
1. Place a suitable container under the oil drain screw (A12-B5), then remove the oil dipstick/filler plug (A2-B1) and the oil
drain screw.
2. After draining completely, carefully refit the oil drain screw.
3. Use a funnel to top up with oil (using oil which complies with the specifications given in this manual), and regularly check
the level.
The oil level must be between the minimum and maximum marks on the dipstick. If the oil level is too low, keep topping it up. If the oil
level is too high, drain some off.
4. Refit and tighten the oil dipstick/filler plug.
5. Wipe away any traces of oil with a clean cloth and check that there are no leaks.
5.3.2 Clean the sediment bowl.
1. Close the fuel tap (A5).
2. Unscrew the cover retaining screws (C4) and nuts (C5).
3. Remove the cover (C3).
4. Unscrew the sediment bowl (A14-C8).
5. Use clean fuel to clean the sediment bowl, then dry it completely.
6. Check that the cover (C6) and seal (C7) for the sediment bowl are in good condition: replace them if they are damaged.
7. Screw the sediment bowl back on.
8. Refit the cover and carefully tighten its mounting screws and nuts.
9. Open the fuel tap and check that there are no leaks.
10. All traces of fuel should be wiped off with a clean cloth and the fuel tap closed again.
5.3.3 Replace the fuel filter
1. Close the fuel taps (A5).
2. Note the direction of assembly for the fuel filter (A13-C1).
3. Place a suitable container underneath the fuel filter and undo the two clips (C2).
The fuel filter is removed.
4. Observing the direction of fitting, fit a new fuel filter and secure it using the two clips.
5. All traces of fuel should be wiped off with a clean cloth and the fuel taps opened.
6. Check that there are no leaks then close the fuel taps again.
5.3.4 Clean or replace the air filter
IMPORTANT
Risk of fire or explosion: for a foam element, only use soapy water and clean engine oil during
this operation.
If the filter elements are excessively dirty or damaged (torn, pierced), it is essential to replace them with new elements and at least
every 3 cleaning procedures.
1. Unlock the air filter cover (D4 & D3) and remove it.
2. Remove the filter elements (D5 & D6) for cleaning.
3. Clean the foam element: wash it in soapy water, carefully rinse it and leave it to dry completely.
4. Soak the foam element in a little clean engine oil and squeeze it to remove any excess oil (do not wring it out).
If there is too much oil remaining in the foam, the unit will emit smoke when it is first started.
5. Replace the paper element.
6. Refit the filter elements, then refit the air filter cover and lock it.
5.3.5 Replace the spark plug.
1. Disconnect the spark plug cap (F1).
2. Use a dry air spray to clean the spark plug wells.
3. Use a spark plug spanner to unscrew the spark plug (A16-F2) and discard it.
4. Fit a new spark plug in position and tighten it by hand to avoid damaging the threads.
5. Use a spark plug spanner to tighten the spark plug by 1/2 turn after it is seated to compress the washer.
5.3.6 Cleaning the spark arrester
1. On the exhaust silencer, unscrew the spark arrester mounting bolt (E2).
2. Remove the spark arrester (E1).
3. Using a wire brush, remove the carbon deposits from the spark arrester screen.
4. Check that the spark arrester is in good condition (no holes or cracks), and replace it if necessary.
5. Refit the spark arrester on the exhaust silencer protection (E3) and retighten the spark arrester mounting bolt.
5.3.7 Cleaning the generating set
To ensure it continues to run correctly, the unit must be cleaned regularly. If the unit is installed inside, always check that the
installation is clean and in good condition. If the unit is being used outside (building sites, dusty, muddy or densely wooded areas,
corrosive environment, etc.), it must be cleaned more frequently.
Use of water sprays or high pressure cleaning equipment is prohibited as this may seriously damage the unit.
1. Use a brush to gently clean the engine air intakes and outlets and, if present, the spark arrester.
2. Clean the unit with a sponge and water mixed with a mild detergent (car shampoo, for example), then rinse with fresh
water to remove all traces of the cleaning product.
A cleaning foam may be used and wiped off using a soft, absorbent cloth. Stubborn stains may be removed using a suitable solvent (white
spirit or equivalent) and wiped off using a soft, absorbent cloth.
3. Check the general condition of the unit (no leakage, tightness of nuts and bolts, connections and hoses, etc.)
4. Apply an anti-rust product to damaged areas, change defective parts and damaged labels if necessary.
Only use original parts and consult an agent if necessary.
18/22