1. Manuals
  2. Brands
  3. Kohler Manuals
  4. Portable Generator
  5. 7APU
  6. Installation manual

Kohler 7APU Installation Manual

Heavy duty truck mobile generator sets
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Installation
Heavy Duty Truck Mobile Generator Sets
Model:
7APU
TP-6583 3/08

Advertisement

Table of Contents
loading

Related Manuals for Kohler 7APU

Summary of Contents for Kohler 7APU

  • Page 1 Installation Heavy Duty Truck Mobile Generator Sets Model: 7APU TP-6583 3/08...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Section 1 Introduction .
  • Page 4 Section 6 Installation Drawings ............Appendix A Generator Selection and Wattage Requirements .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting Engine Backfire/Flash Electromechanical equipment, Fire including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose WARNING life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely.
  • Page 6 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 Hazardous Voltage/ Testing live electrical circuits. WARNING Hazardous voltage or current can Moving Parts cause severe injury or death. Have trained and qualified personnel take diagnostic measurements live WARNING circuits. Use adequately rated test equipment with electrically insulated Hot coolant and steam. probes and follow the instructions of the Can cause severe injury or death.
  • Page 8 Notice NOTICE This generator set does not comply with United States Coast Guard (USCG) requirements and must not be used for marine applications. For marine installations use only generator sets specified for marine use. USCG Regulation 33CFR183 requires that a generator must ignition...

  • Page 9: Section 1 Introduction

    Section 1 Introduction Information in this publication represents data available 1.2 Generator Set Specifications at the time of print. Kohler Co. reserves the right to change this publication and the products represented Refer to the model’s specification sheet G3-48 for details.
  • Page 10 Notes Section 1 Introduction TP-6583 3/08...

  • Page 11: Section 2 Location And Mounting

    Section 2 Location and Mounting 2.1 General Considerations Dimensions are in mm (in.) and This section deals with the factors to consider in an not to scale. installation. Before making final plans for locating an APU generator set, consider the following items for the proposed location: 1.

  • Page 12: Mounting

    In addition, ensure the mounting location of the APU: can support the generator set weight. provides ample room for routine service of generator set’s engine, controller, and fuel system components. provides enough air flow to allow required cooling combustion. Figure 2-3. Specification sheet G3-48.

  • Page 13: Attach Apu To Truck Frame Rail

    2.4 Attach APU to Truck Frame 2.4.1 Mounting Option A Rail 1. Align the mounting plates to indicated mounting hole(s) and slot location(s) scribed on the truck’s 1. Determine if mounting option A, B, or C, will work frame rail. best for your truck’s frame rail application.

  • Page 14: Mounting Option B

    2.4.2 Mounting Option B 10. Place the remaining mounting plate flush to the front side of the truck’s frame rail. 1. Use a 16 mm (5/8 in.) size drill bit and drill the four 17.5 mm (11/16 in.) mounting holes. Remove any 11.

  • Page 15: Section 3 Fuel System

    Section 3 Fuel System 3.2 Fuel System WARNING Fuel system design. The 7APU generator set operates off a shared fuel tank with a separate dip-tube arrangement as shown in Figure 3-1. The dip-tube arrangement has a bulkhead seal that contains a fuel supply line and a fuel return line that is secured by a Explosive fuel vapors.

  • Page 16: Fuel Lines And Hoses

    Obtain a from mm (in.) and not complete list of maintenance and service parts from to scale. bottom of your authorized Kohler distributor/dealer. fuel tank. Part Description Part Number Fuel Tank Connection Kit GM52273 Figure 3-2 Maintenance and Service Parts 3.4.1...

  • Page 17: Installing The Fuel Hoses

    10. Subtract 25-50 mm (1-2 in.) from the bottom depth 14. Secure both fuel lines with one hand. Use the other mark and scribe another mark on the fuel supply hand to tighten the 1/4-20 mounting bolt securely. line to indicate the new depth requirement. Note: Ensure both fuel lines do not rotate around the 11.
  • Page 18 5. Place a hose clamp over the 6.4 mm (1/4 in.) dia. 10. Place a hose clamp over the 8 mm (5/16 in.) dia. fuel return hose. fuel supply hose. 6. Slide the 6.4 mm (1/4 in.) dia. fuel return hose over 11.

  • Page 19: Section 4 Exhaust System

    Do not obstruct the The exhaust system is not pre-installed on the 7APU exhaust outlet when parking your vehicle. The exhaust gases generator set and must be fitted at the installation site.

  • Page 20: Exhaust Piping

    Check that the exhaust outlet is unobstructed. See Figure 4-1. 4.1.4 Completing Exhaust Inspection After the 7APU generator set installation is completed, it is important to test operate the exhaust system. Note: For 7APU operation information, see publication TP-6582. Note: Allow a minimum of 30 seconds of generator set...

  • Page 21: Section 5 Electrical System

    Section 5 Electrical System 5.1.1 APU Power Connections WARNING Figure 5-1 demonstrates the APU generator set that contains the following plug connections: Communication connection plug Load connection (power) plug Moving parts. Hazardous voltage. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place.

  • Page 22: Power Distribution Box

    5.2 Power Distribution Box Note: Dimensions are mm [in.] and are not to scale. 5.2.1 Location Considerations Mounting location considerations. Figure 5-2 shows 3.8 cm [1-1/2 in.] R min. an ideal location for the power distribution box on the floor, under the sleeper bunk. Figure 5-3 Harness Bending Radius Allow at least 25 mm (1.0 in.) of clearance between the power distribution box and the nearest...

  • Page 23: Power Distribution Box Connections

    4. Align mounting slots on the power distribution box with the drilled mounting holes. 5. Place fasteners through slots and drilled mounting holes. Tighten securely. 6. Measure and scribe a mark where the 41 mm (1 5/8 in.) dia. hole will be drilled. See Figure 5-6. 4 mm Front view 36.5 mm...

  • Page 24: Connect The Block Heater Harness

    5.2.5 Connect the Block Heater 8. Connect the wires going to the vehicle’s engine block heater to the corresponding hot, neutral, and Harness ground connectors of the block heater wire harness. See Figure 5-10. Note: If the vehicle that the APU is installed on does not come equipped with a block heater for the vehicle’s engine, proceed to Section 5.6.2, Connect the Battery Charger Harness.

  • Page 25: Remote Apu Controller

    Customer-interface connectors allow sleeper cab location as shown in Figure 5-12. connections from the keypad to the HVAC system, the power distribution box, and the 7APU generator set. See Figure 5-2. TP-6583 3/08 Section 5 Electrical System...

  • Page 26: Route The Wiring

    5.4.1 Route the Wiring 4. Route the P6 or 9-pin connector end of the load connection harness through the cutout opening. Note: DO NOT bend wire at a 90° angle when routing See Figure 5-14. through materials. A minimum 1.9 cm (3/4 in.) bending radius recommended.

  • Page 27: Hvac Connections

    (--) See the Operation Manual TP-6582 for the APU lead last. See Section 5.7, Battery and Controller operation and troubleshooting information. Connections. If you need further assistance, contact your authorized Kohler distributor/dealer. TP-6583 3/08 Section 5 Electrical System...

  • Page 28: Hvac Keypad/Display

    5.6 HVAC Keypad/Display 4. HVAC OFF Key. Turns system off. Note that the data display remains on. You can continue to The HVAC keypad/display is arranged for logical adjust setpoint, display temperature readings, and operation. See Figure 5-20 for HVAC keypad/display activate the manual fan to circulate air while the features.

  • Page 29: Connect The Apu Wiring Harness

    5.6.1 Connect the APU Wiring Harness 2. Measure and scribe a mark where each of the four mounting holes will be drilled. See Figure 5-23. 1. Connect the P3A or 16-pin connector on the APU wiring harness to the P3B or 16-pin connector mounted to the truck’s floor.

  • Page 30: Connect The Battery Charger

    3. Test the operation of the APU, the remote in-cab computer. keypad/display, and the HVAC Keypad/display system. 1. Consult the battery manufacturer’s instructions Note: For 7APU operation information, see regarding battery care and maintenance. publication TP-6582. 2. Locate the load connection plug (power harness). See Figure 5-1.
  • Page 31 Section 6 Installation Drawings Figure 6-1 Power Distribution Box Assembly, GM60447 TP-6583 3/08 Section 6 Installation Drawings...
  • Page 32 Figure 6-2 Wiring Diagram, GM60094A-A, Sheet 1 of 2 Section 6 Installation Drawings TP-6583 3/08...
  • Page 33 Figure 6-3 Wiring Diagram, GM60094B-A, Sheet 2 of 2 TP-6583 3/08 Section 6 Installation Drawings...
  • Page 34 Figure 6-4 Dimension Print, ADV-7409A-A Section 6 Installation Drawings TP-6583 3/08...
  • Page 35 GM62181/GM60791 Figure 6-5 Dimension Print, Battery Charger GM62181 TP-6583 3/08 Section 6 Installation Drawings...
  • Page 36 Notes Section 6 Installation Drawings TP-6583 3/08...
  • Page 37 Appendix A Generator Selection and Wattage Requirements Consider total wattage requirements (lights, motors, are DC powered by a 12-volt battery. Make sure the appliances) when selecting a generator set or when calculated total wattage includes only lights actually on sizing wattage usage in which available space and the generator set AC circuit.
  • Page 38 Appendix B Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute est. estimated ABDC after bottom dead center center of gravity E-Stop emergency stop alternating current cubic inch displacement etc. et cetera (and so forth) analog to digital centerline...
  • Page 39 Motoren-und Turbinen-Union read only memory kilobyte (2 bytes) megawatt rot. rotate, rotating KBus Kohler communication protocol milliwatt revolutions per minute μF kilogram microfarad right side kg/cm kilograms per square N, norm. normal (power source) remote terminal unit...
  • Page 40 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters TP-6583 3/08 7 Jurong Pier Road Singapore 619159 E 2008 by Kohler Co. All rights reserved. Phone (65)6264-6422, Fax (65)6264-6455...

Table of Contents