Related Manuals for Kohler 3APU-HC
Summary of Contents for Kohler 3APU-HC
- Page 1 Operation Heavy Duty Truck Mobile Generator Sets MODEL: 3APU-HC POWER SYSTEMS TP-6576 12/07b...
- Page 2 California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Engine Identification Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that Record the product identification information from the the numbers are readily available for future reference.
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Page 3: Table Of Contents
Operation and Use ............................. 14 Pre-Start Check List ........................14 Residual Risk of Contact With Coolant ..................15 3APU-HC Features ........................15 Summary Cooling System - Conventional Cooling Cycle .............. 16 Summary Diagram Heating System - Heat Cycle with Overheated Heat Pump ......17 Description of Operating Modes .................... - Page 4 Replacing the Cab Filter ....................... 34 Scheduled Preventative Maintenance ....................... 35 Scheduled Preventive Maintenance ....................35 Summary Table of Scheduled Maintenance ................... 35 3APU-HC Storage .......................... 36 Restoring the Engine After Storage ....................37 Operating Hours ............................38 TP-6576 12/07b...
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Page 5: Safety Precautions And Instructions
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Accidental Starting Servicing the fuel system. A flash Electromechanical equipment, including fire can cause severe injury or death. generator sets, transfer switches, Do not smoke or permit flames or WARNING switchgear, and accessories, can cause sparks near the fuel injection system, bodily harm and pose life-threatening fuel line, fuel filter, fuel pump, or other... - Page 6 Safety Precautions and Instructions Exhaust System Inspecting the exhaust system. Draining the fuel system. Explosive Carbon monoxide can cause severe fuel vapors can cause severe injury nausea, fainting, or death. For the or death. Spilled fuel can cause an WARNING safety of the vehicle’s occupants, install explosion.
- Page 7 Safety Precautions and Instructions Testing live electrical circuits. Hazardous Voltage/ WARNING Hazardous voltage or current can Moving Parts cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits. WARNING Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment Hot coolant and steam.
- Page 8 Safety Precautions and Instructions Refrigerant R134a exposure symptoms. Notice Refrigerant (R134a) in liquefied or gas form can cause severe injury or NOTICE WARNING death. R134a refrigerant is an odorless, colorless, tasteless, liquefied gas that Saltwater damage. Saltwater quickly can cause death if inhaled for even a deteriorates metals.
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Page 9: Introduction
Information in this publication represents data available at the Obtain service from an authorized Kohler distributor/dealer to time of print. Kohler Co. reserves the right to change this keep equipment in top condition. publication and the products represented without notice and without any obligation or liability whatsoever. -
Page 10: General Information
General Information - 1 Preliminary Information Regarding How the System Works 3APU- HC (Auxillary Power Unit-Heating and Cooling) has been designed to carry out the following functions: • Heating and cooling of the area in which it is installed (vehicle cabs or other areas to be air-conditioned), according to the specifications shown inside this documentation. -
Page 11: General Description And Technical Data
2 - General Description and Technical Data WARNING WARNING Flammable refrigerants. Refrigerant (R134a) in liquefied or Can cause severe injury or death. gas form. Can cause severe injury or death. Do not smoke or permit flames or sparks near flammable refrigerants. Avoid inhalation or skin contact. -
Page 12: Heating And Cooling System
Power unit: it's function is to supply energy at the right power to the entire system, by the action of a diesel engine. Electrical and control box: this box, which is to be only serviced by an authorized kohler technician. -
Page 13: Characteristics Of Coolant
Avoid inhalation or skin contact. Only a qualified, EPA -certified technician should perform service on refrigerant systems. Note: Avoid contact with fluorocarbon coolants. DO NOT service coolant system. Contact an Authorized Kohler Distributor/ Dealer for coolant service. Operating Limit Conditions... -
Page 14: Operation And Use
Inspecting the exhaust system. exhaust is blue or black, contact your and routinely inspected. Carbon monoxide can cause severe authorized Kohler distributor/ dealer. nausea, fainting, or death. For the • Visually inspect for exhaust leaks safety of the vehicle’s occupants, install Generator set operation. -
Page 15: Residual Risk Of Contact With Coolant
3 - Operation and Use Residual Risk of Contact With Coolant First aid treatment in the event of R134a exposure symptoms. Refrigerant (R134a) in liquefied or gas form can cause contact with the coolant. severe injury or death. R134a refrigerant is an odorless, colorless, tasteless, liquefied gas that can cause death if inhaled for even a short time. -
Page 16: Summary Cooling System - Conventional Cooling Cycle
Operation and Use - 3 Summary Diagram Cooling System Conventional Cooling Cycle Fig. 12 Legend: AC Compressor 11 Throttle Valve Cycle Inversion Valve 12 Non-Return Valve Engine Muffler 13 AC Gas Evaporator Gas as Exchanger (+Others) 14 Liquid Container Non-Return Valve R134a Low Pressure Gas (BP) Throttle Valve Non-Return Valve... -
Page 17: Summary Diagram Heating System - Heat Cycle With Overheated Heat Pump
3 - Operation and Use Summary Diagram Heating System Heat Cycle with Overheated Heat Pump Fig. 12 Fig. 13 Legend: AC Compressor 11 Throttle Valve Cycle Inversion Valve 12 Non-Return Valve Engine Muffler 13 AC Gas Evaporator Gas as Exchanger (+Others) 14 Liquid Container Non-Return Valve R134a Low Pressure Gas (BP) -
Page 18: Description Of Operating Modes
Operation and Use - 3 WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. -
Page 19: Description Of Keypad Functions
3 - Operation and Use Description of Evaporator Functions This keypad located on the evaporator allows the user to program all the system functions. Fig. 12 Fig. 14 POWER/REC.BATT – Main switch Voltage position on panel (primary switch, enabling all system functions to be activated Fig. 7 p. 13) –... -
Page 20: Scheduled Maintenance Function
The signal reminds the user to go to an authorized Kohler Distributor/Dealer to service the engine. Note: 3APU-HC (while running) has a sensor system capable of detecting malfunctions in the diesel engine as well as in the heating and cooling system. In the event of malfunctions the system automatically switches off, and signals the fault on the RED LED 5 (engine off status) located on the counter/hour meter module 8. -
Page 21: Troubleshooting
Maintain a record of repairs and adjustments performed on the equipment. If the procedures in this manual do not explain how to correct the problem, contact an authorized Kohler distributor/dealer. Use the record to help describe the problem and repairs or adjustments made to the equipment. -
Page 22: Troubleshooting Mechanical Components
Low idle speed. See your authorized Kohler Distributor/Dealer. Fuel filter clogged. See your authorized Kohler Distributor/Dealer. Bleed air lines. See TP-6577 or your authorized Kohler Distributor/Dealer. Air leaks in fuel system. Clogged tank vent hole. See your authorized Kohler Distributor/Dealer. -
Page 23: Maintenance
See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the Accidental starting. generator set. Have an authorized Kohler distributor/dealer Can cause severe injury or death. perform generator set service. Disconnect the battery cables before working on the generator set. -
Page 24: Acea Regulations - Acea Sequences
Engine Oil Selections Model SAE Viscosity Grade API Category -18° C (0° F) below -18° C or above (0° F) CF-2 3APU-HC CF-4 CG-4 10W-40 5W-40 CH-4 Fig. 16 Fig. 17 TP-6576 12/07b THIS MANUAL IS PROPRIETY OF... -
Page 25: Oil Check
Check Oil Level. Check the oil level before starting and after every 8—15 hours of usage. Use only an approved engine diesel oil available at your authorized Kohler distributor/dealer. To avoid engine damage it is important to follow these instructions: •... -
Page 26: Checking The Oil Level
Note: Too high an oil level causes high oil consumption and engine carbonizing. Too low an oil level damages the engine. See Fig. 18. Model L (qt.) 3APU-HC 1.2 (1.13) This quantity has to be strictly respected. Fig. 18 Step Description Make sure the vehicle is on a level surface and the generator set is stopped. -
Page 27: Oil And Filter Replacement
5 - Maintenance Oil and Filter Replacement Frequency Every 500 hours See your authorized Kohler Distributor/Dealer. Replacing the lubricating oil and oil filter. Recommended oil AGIP SIGMA SUPER TFE MULTIGRADE 10W40 specification API CH-4/CF SL, ACEA E4,E5,E7,B4. Replacement - If used infrequently: every 6 months. - Page 28 Maintenance - 5 Fig. 22 Fig. 23 Fig. 24 Fig. 25 Fig. 26 Fig. 27 Fig.28 TP-6576 12/07b THIS MANUAL IS PROPRIETY OF - ALL FORMS OF REPRODUCTION, PARTIAL OR OTHERWISE, IS STRICTLY PROHIBITED...
- Page 29 5 - Maintenance Step Description Using a funnel, pour enough oil into the tank through the upper opening (Fig. 29). Remove the dipstick to check the oil level. The right oil level is close to, but not above, the “MAX” mark (Fig. 29). Once you have correctly carried out the fill up, replace the dipstick (C), insert and screw on the plug (F) and correctly replace the protection case (D) tightening it with the screw (E) by means of the supplied spanner (Fig.
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Page 30: Replacing The Diesel Filter
Maintenance - 5 Replacing the Diesel Filter Step Description Loosen the screw (Q) in order to remove the clamp (R). Preserve these parts for following assembly. Remove the diesel filter (S) from the case in order to facilitate the following operations (Fig. 31). Flatten the clamps (T) using pliers to remove them from the coupling points (U). -
Page 31: Cleaning Or Replacing The Air Filter
5 - Maintenance 5.10 Cleaning or Replacing the Air Filter Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed. Remove the air filter cover (V), by turning the knob counterclockwise (Z)(Fig. 33). Loosen and remove the wing nut (X) in order to remove the filter element (J) (Fig. -
Page 32: Control Operations Following Maintenance
If the leaks are due to incorrect assembly of components, correctly reassemble the pipes and/or components that have been modified; b) If the leaks are due to breakage or system irregularities, contact the authorized Kohler Distributor/Dealer. After completing the maintenance operations, replace the protection case (B) and fasten it with the screw (A) by means of the supplied spanner (Fig. -
Page 33: Maintenance Of Thermodynamic Parts - Operating Instructions
It is extremely important to observe the quantities recommended. Contact an authorized Kohler Distributor/Dealer to carry out the system refill. If water is seen outside and underneath the vehicle cab (while the system is running) this is not to be considered Effects of a sign of fault. -
Page 34: Replacing The Cab Filter
Evaporator Filter Every 500 hours To ensure that the system works correctly and to remain within the conditions of the warranty, use the original spare parts recommended by an Authorized Kohler Distributor/Dealer. Step Description Make sure the heating an cooling system has come fully to a hault. Also make sure the vehicle is on a level surface and is at a complete rest. -
Page 35: Scheduled Preventative Maintenance
Replacing the diesel fuel filter. See Section 5, Maintenance. Replacing the air filter. See Section 5, Maintenance. Adjusting rocker arm clearance. See your authorized Kohler/Distributor/Dealer. Calibration and cleaning injector. See your authorized Kohler/Distributor/Dealer. Servicing of the engine cooling fins. See your authorized Kohler/Distributor/Dealer. -
Page 36: 3Apu-Hc Storage
Select a well-ventilated (not humid or dusty) location to store the generator. If necessary, cover the engine with protective sheeting. Note: After one year of engine inactivity, the coolant must be changed. See your authorized Kohler Distributor/ Dealer for Service. -
Page 37: Restoring The Engine After Storage
Introduce new oil (see “Lubricants”) up to the correct level marked on the dipstick. Replace the filters (air, oil, fuel) with original spare parts. Empty the cooling circuit completely and pour in the new coolant up to the correct level. See your authorized Kohler Distributor/Dealer for service. -
Page 38: Operating Hours
Operating Hours - 7 Use the log below to keep a cumulative record of operating hours on your generator set and the dates required services were performed. Enter hours to the nearest quarter hour. Operating Hours Service Record Date Hours Total Service Service... - Page 39 7 - Operating Hours Use the log below to keep a cumulative record of operating hours on your generator set and the dates required services were performed. Enter hours to the nearest quarter hour. Operating Hours Service Record Date Hours Total Service Service...
- Page 40 POWER SYSTEMS KOHLER CO., Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the U.S. and Canada, phone 1-800-544-2444 TP-6576 12/07b KohlerPower.com 2007 by Kohler Co. All rights reserved...