Kohler 3APU-HC-12V Installation Manual
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Kohler 3APU-HC-12V Installation Manual

Kohler 3APU-HC-12V Installation Manual

Heavy duty truck mobile generator sets
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Installation
Heavy Duty Truck Mobile Generator Sets
Model:
3APU-HC-12V
3APU-HC-24V
TP-6577 7/08a

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Summary of Contents for Kohler 3APU-HC-12V

  • Page 1 Installation Heavy Duty Truck Mobile Generator Sets Model: 3APU-HC-12V 3APU-HC-24V TP-6577 7/08a...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Section 1 General Information .
  • Page 4 Section 9 Pipe and Cable Connections ........... . . Fastening Pipes and Cables, Fixed Cab Version .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting Servicing the fuel system. A flash Electromechanical equipment, fire can cause severe injury or death. including generator sets, transfer Do not smoke or permit flames or WARNING switches, switchgear, and accessories, sparks near the fuel injection system, can cause bodily harm and pose fuel line, fuel filter, fuel pump, or other...
  • Page 6 Generator set operation. Carbon Installing the exhaust tail pipe. Hazardous Noise monoxide can cause severe nausea, Carbon monoxide can cause severe fainting, or death. Carbon monoxide nausea, fainting, or death. Install the exhaust system tail pipe to prevent the CAUTION is an odorless, colorless, tasteless, nonirritating gas that can cause death if drawing of discharged exhaust gases...
  • Page 7 Grounding electrical equipment. Hot Parts Refrigerant Hazardous voltage cause severe injury or death. Electrocution WARNING WARNING is possible whenever electricity is present. Ensure you comply with all applicable codes standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits.
  • Page 8 Notice NOTICE Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces. NOTICE Canadian installations only. standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1.

  • Page 9: Section 1 General Information

    Information in this publication represents data available Check that the exhaust outlet is directed out and at the time of print. Kohler Co. reserves the right to away from truck fairings and chassis, including the change this publication and the products represented sleeper cab.

  • Page 10: Ce Identification Plate

    1.5 CE Identification Plate This conformity is certified by the CE mark located on the body of the power unit, inside the front protective casing. See Figure 1-3. Note: Do not damage or remove the CE identification plate, even when the system is resold. tp6576 Figure 1-3 Identification Plate Location Section 1 General Information...

  • Page 11: Section 2 Power Unit Location And Mounting

    Section 2 Power Unit Location and Mounting This section deals with the factors to consider in an Screws and nuts are available in different hardness installation. Before making final plans for locating an ratings. To indicate hardness, American Standard APU generator set, consider the following items for the hardware uses a series of markings and metric proposed location: hardware uses a numeric system.

  • Page 12: Mounting

    If the APU is mounted below the truck’s cab, allow at The mounting brackets can be configured for crosswise least 13 mm (0.5 in.) of clearance between the cab and or lengthwise mounting to avoid obstructions in the the APU. The vehicle cabin air bag system should be frame rail.

  • Page 13: Frame Assembly Hardware

    If the assembly solution of the lengthwise power unit 2.2.2 Frame Clamp Assembly Hardware frame is chosen, use two M14 flat head screws. See See Figure 2-7 for the frame clamp assembly hardware. Figure 2-5. Open the bag of assembly parts and ensure that no Note: The head of the screws must be inside the parts are missing.

  • Page 14: Tie Rod Assembly

    2.2.4 Tie Rod Assembly Note: In the crosswise assembly, use M14 x 40 hex head screws instead of the M14 x 40 flat Assemble the tie rod assembly for the power unit frame hex head screws. on a workbench using the following procedure: 1.

  • Page 15: Clamp Mounting To Frame Rail

    6. Mount the tie rods using M14 x 40 hex head screws, M14 washers, and M14 nuts supplied. Tighten the nuts at a torque of 135 Nm (97.65 ft. lb). Figure 2-6 Figure 2-9 through Figure 2-12. 2.2.5 Clamp Mounting to Frame Rail Use the following procedure to clamp the mounting to the frame rail: tp6577...
  • Page 16 4. Insert the supplied mounting bolt into the power 6. Attach clamp onto the frame rail. unit frame. See Figure 2-17 and Figure 2-18. 7. Attach the supplied self-locking M14 nut and tighten by hand. Repeat steps 4 thru 7 for the next three clamps.

  • Page 17: Power Unit Frame

    2.2.6 Power Unit Frame 3. After identifying a suitable location on the vehicle frame, position the frame of the power unit near the Use the following procedure to mount the power unit vehicle frame rail. See Figure 2-15. frame: 4. Rest the back of the power unit frame against the 1.
  • Page 18 Notes Section 2 Power Unit Location and Mounting TP-6577 7/08...

  • Page 19: Section 3 Power Unit Installation

    Section 3 Power Unit Installation Authorized Kohler distributor/dealer technicians must observe the following regulations: DO NOT stand or walk under the units during lifting or transport. DO NOT move or rotate lifted units by their cables or pipes. Use appropriate and safe equipment when working above the vehicle.
  • Page 20 5. Unscrew and discard the four M8 self-locking nuts from the M8 threaded bolts, located under the power unit. See Figure 3-6. tp6577 tp6577 1. Vehicle side frame 2. Power unit 1. Nuts, self-locking, M8, qty. 4 3. Secured power unit frame 2.

  • Page 21: Section 4 Evaporator Installation

    Section 4 Evaporator Installation The position of the evaporator inside the cab must be 4.2 Use Counter Frame as agreed between the installer and the final customer Template (vehicle owner) before installation. Use the counter frame as a template to indicate the hole locations as shown in Figure 4-3.

  • Page 22: Mount Counter Frame

    4.3 Mount Counter Frame 4. Place the counter frame against a flat surface on the wall. Be sure to keep it horizontal. Mount the evaporator at medium height inside the cab to enable air to mix in heating mode. 4.4 Drill and Bore Holes 1.

  • Page 23: Mount Evaporator

    6. Insert the four supplied rubber cable guides into the Note: If the wall inside the cab is tilted on the front, bored holes from the exterior side of the cab. See use two spacers with a min. of 6.5 mm (0.26 Figure 4-7.

  • Page 24: Attach Antipollution Filter

    4. Ensure the condensation drainage hose is 2. Attach the antipollution filter to the evaporator as fastened securely to evaporator base coupling. shown in Figure 4-13. Tighten securely. See Figure 4-11. tp6577 tp6577 1. Coupling at evaporator base 1. Antipollution filter 2.

  • Page 25: Section 5 Condenser Installation

    Section 5 Condenser Installation condenser application. Before making final plans for WARNING locating the condensing unit, consider the following items for the proposed location: Wear protective goggles and clothing when using power tools, hand tools, or compressed air. Refrigerant (R134a) in liquefied or The engine and generator set may use both gas form.
  • Page 26 1. Loosen side screws located on the side of the condenser unit. See Figure 5-2. tp6577 1. Screwdriver 2. Screw, socket hex head, M8 x 16, qty. 2 3. Nut, M8 4. Wrench, M8 5. Container support Figure 5-4 Secure Container Support 5.
  • Page 27 7. Use a pair of rivet pliers (not supplied) to secure the 10. Lubricate the threaded conical surface with container support. See Figure 5-7. compressor oil supplied (can substitute Suniso SP10/SP20 or an equivalent lubricant) and insert the copper conical gasket. See Figure 5-10. tp6577 1.
  • Page 28 13. Position liquid container onto container support. See Figure 5-13. 14. Ensure the O-ring is properly lubricated. Figure 5-13. tp6577 1. G6 pipe 2. G6 pipe upper conical ring nut 3. G6 pipe lower O-ring nut Figure 5-15 Secure Lower O-Ring Nut tp6577 19.

  • Page 29: Install Condenser On Cab

    21. Join and tighten the G6 union fitting to the upper 5.2 Install Condenser on Cab coupling of container. See Figure 5-18. 1. See Section 5.1, Install Liquid Container on Note: The G6 union is supplied with an O-ring that Condenser.
  • Page 30 4. Measure and scribe two boring points at 310 mm (12.2 in.) as shown in Figure 5-22. Note: The four boring points in the structure are also needed to insert the supplied M6 nutsert fasteners. 5. Use a 9 mm (0.35 in.) diameter drill bit to drill the four bore holes.

  • Page 31: Section 6 Refrigerant Hoses And Power Unit Connections

    Section 6 Refrigerant Hoses and Power Unit Connections The engine and generator set may use both American WARNING Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts. Screws and nuts are available in different hardness ratings.

  • Page 32: Assemble Refrigerant Hoses, Clamps, And Fittings

    G8 hoses with adhesive tape to prevent delivery and return hoses. Contact your entry of impurities until system attachment is authorized Kohler distributor/dealer to order this complete. tool. Failure to do so may void your warranty. See Figure 6-2. tp6577 1.

  • Page 33: Connect Refrigerant Hoses

    7. Use the CLIC 205 tool to tighten the hose clamps 2. Connect the G10 refrigerant gas return hose to the securely. See Figure 6-7. power unit using the 90° union fitting with access points. See Figure 6-8. Note: Cover the unconnected ends of the G10 and G8 hoses with adhesive tape to prevent 3.
  • Page 34 Notes Section 6 Refrigerant Hoses and Power Unit Connections TP-6577 7/08...

  • Page 35: Section 7 Fuel System And Power Unit Connections

    Section 7 Fuel System and Power Unit Connections 7.1 Fuel System WARNING Fuel system design. The 3APU-HC generator set operates off a shared fuel tank with a separate diptube arrangement as shown in Figure 7-1. The diptube arrangement has a suction pipe and gasket(s) that contains a fuel supply line with a fuel return line that is Explosive fuel vapors.

  • Page 36: Fuel Lines And Hoses

    Fuel supply line 5 mm (0.2 in.) internal diameter Use only the fuel tank connection kit included with the APU. Obtain a complete list of maintenance and service parts from your authorized Kohler distributor/dealer. tp6577 1. Gasket mounting holes, qty. 5 7.4 Measure Depth and Drill Fuel...

  • Page 37: Install Fuel Lines

    8. Deburr the edges of all drilled holes. 16. Use the supplied self-tapping screws to attach the suction pipe to the fuel tank. Tighten securely. See 9. Place the preassembled bulkhead seal near the Figure 7-7. top on the end the fuel tank. Position the fuel supply line so that it is flush with the end of the fuel tank.
  • Page 38 Note: The diesel on/off valve is a fuel system 8. Open the 9--11mm (0.35--0.43 in.) diameter hose shutoff device that must be connected to the clamp and slide it near the end on the hose; release fuel supply hose. DO NOT attach the fuel the clamp to close.

  • Page 39: Section 8 Lubrication

    See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the generator set. Have an authorized Kohler distributor/dealer perform generator set service. 8.1 Lubricant International Specifications Lubricant specifications define testing performances and procedures that the lubricants need to successfully 1.

  • Page 40: Engine Oil Selections

    Use only the recommended API category C 8--15 hours of usage. Use only an approved engine for diesel-fueled engines. diesel oil available at your authorized Kohler distributor/ The center of the doughnut identifies the SAE dealer. recommended grade of oil.

  • Page 41: Oil Level Check

    Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first.

  • Page 42: Air Filter

    2. If the leaks are due to breakage or system necessary, remove it from its position on the lower irregularities, contact authorized Kohler part of the air filter cover. Clean if clogged. See distributor/dealer. Figure 8-10. After completing the maintenance operations, replace 5.

  • Page 43: Section 9 Pipe And Cable Connections

    Section 9 Pipe and Cable Connections Read this entire section of this manual including safety WARNING information before proceeding any further and determine which mounting location is best for your condenser application. Wear protective goggles and clothing when using power tools, hand tools, or compressed air.

  • Page 44: Power Unit Pipe And Cable Connections, Fixed Cab Version

    9.2 Power Unit Pipe and Cable Note: Check that the curvature of the pipes during passage from the vehicle frame to the back Connections, Fixed Cab of the cab is adequate. See Figure 9-4 and Version Figure 9-5. Nonobservance of this point could lead to pipes being crushed, thereby The condenser mounting operation below is only compromising the performance of the...

  • Page 45: Fastening Pipes And Cables, Tipping Cab Version

    9.3 Fastening Pipes and Cables, Tipping Cab Version The condenser mounting operation below is only indicated for vehicles with a tipping cab. 1. Install the power unit. See Section 3, Power Unit Installation. 2. Install the evaporator counter frame. Section 4.3, Mount Counter Frame. 3.

  • Page 46: Mount Gas Recharge Access Points

    4. When the cab rotation fulcrum point has been 8. Find a suitable mounting location for the rubber reached, fix the tube bundle to the sheet flooring hose clamp and use a 3.5 mm (9/64 in.) drill bit to beneath the cab, boring 3.5 mm (9/64 in.) diameter drill a hole into the cab exterior.

  • Page 47: Condenser Pipe And Cable Connections

    9.6 Condenser Pipe and Cable Note: The special G6 fitting has a conical seat; therefore, we recommend using Loctite 554 Connections refrigerant sealant (to be applied only on the threading) and an extremely tight torque to WARNING prevent the coolant gas leaking and to stop air conditioning system from emptying.

  • Page 48: Evaporator Pipe And Cable Connections

    7. Place condenser shroud over condenser unit. See 1. Make sure the condenser is mounted on the back Figure 9-16. of the cab before assembling the evaporator pipes and cables. See Section 5, Condenser Installation, and Section 9.6, Condenser Pipe and Cable Connections.
  • Page 49 4. Ensure the condensation drainage pipe is fastened 9. Mark the correct length for the G6 pipe with respect securely to evaporator’s base coupling. See to the G6 union fitting. See Figure 9-23. Figure 9-20. tp6577 1. Fitting, G6 union 2.
  • Page 50 14. Insert the three clic clamps onto pipe G10, then 19. Insert the supplied O-ring on the G6 union. insert the flanged union G10 into pipe G10 and 20. Attach pipe G6 to nipple G6 on the bypass valve on tighten the clamps.

  • Page 51: Condensation Dissipater Assembly

    9.8 Condensation Dissipater Assembly 1. Ensure that the evaporator unit and all relative pipes are mounted correctly. See Section 4, Evaporator Installation, Section 9.7, Evaporator Pipe and Cable Connections. 2. Insert the dissipater into the condensation dissipation terminal coupling, if not already tp6577 inserted.

  • Page 52: Filling Gas Circuit With R134A

    9.9 Filling Gas Circuit with R134A 1. See Section 9.5, Mount Gas Recharge Access Points. WARNING 2. Connect the taps of the gas charger station, not supplied, to the relevant access points. Figure 9-36. Note: Before refilling the gas circuit, keep the system in vacuum for at least 30 minutes.

  • Page 53: Section 10 Electrical Connections

    Section 10 Electrical Connections 2. Locate the supplied super seal electrical harness. WARNING See Figure 10--2. Harness is connected to power distribution box. Hazardous voltage. Moving parts. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place.
  • Page 54 Notes Section 10 Electrical Connections TP-6577 7/08...

  • Page 55: Section 11 Battery And Connections

    Section 11 Battery and Connections 11.1 Connect Battery Power Wiring WARNING Harness 1. Consult the battery manufacturer’s instructions regarding battery care and maintenance. 2. Locate the battery power harness attached to the Accidental starting. power unit. See Figure 11-1. Can cause severe injury or death. Disconnect the battery cables before working on the...

  • Page 56: Battery Power Supply Connections

    4. After attaching the connectors, insert the two plastic clamps supplied and fasten the battery connectors. See Figure 11-3. tp6577 1. Positive battery cable connection 2. Negative battery cable connection Figure 11-4 Battery Power Cable Connections, Typical tp6577 3. Connect the red or positive (+) cable connection to the positive pole of vehicle’s original battery.

  • Page 57: Section 12 Installation Completion

    Section 12 Installation Completion Carbon monoxide symptoms. Carbon monoxide can WARNING cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following: D Light-headedness, dizziness...

  • Page 58: Exhaust System Inspection/Operation

    The exhaust system is already installed on the 1. Check the exhaust gas color. If the exhaust is blue 3APU-HC generator set. See Figure 12-1. or black, contact your authorized Kohler distributor/ dealer. Note: For more information on locating and mounting the generator set, see Section 2, Power Unit 2.

  • Page 59: Section 13 Technical Data

    Section 13 Technical Data R134a exposure symptoms. Refrigerant (R134a) in WARNING liquefied or gas form can cause severe injury or death. R134a refrigerant is an odorless, colorless, tasteless, liquefied gas that can cause death if inhaled for even a short time. DO NOT attempt to loosen, tighten, or repair any refrigerant lines, hoses, connections, or fittings.

  • Page 60: Specifications

    13.2 Specifications 12-Volt Model 24-Volt Model Length, mm (in.) Power unit 710 (27.95) Condenser 675 (26.56) 570 (22.43) Evaporator Height, mm (in.) 600 (23.56) Power unit 385 (15.15) Condenser 370 (14.50) Evaporator Depth, mm (in.) 288 (11.34) Power unit Condenser 140 (5.50) 160 (6.25) Evaporator...

  • Page 61: Cooling System

    13.4 Cooling System 13.5 Heating System The conventional cooling cycle diagram is shown in The heat cycle summary diagram is shown in Figure 13-1. Figure 13-2. tp6576 tp6576 R134a Low Pressure Gas (LP) R134a Low Pressure Gas (LP) R134a High Pressure Gas (HP) R134a High Pressure Gas (HP) Overheated R134a Gas (LP) 1.
  • Page 62 Notes Section 13 Technical Data TP-6577 7/08...

  • Page 63: Section 14 Wiring Diagrams

    Section 14 Wiring Diagrams 12V — Code 00.2193.257.0 24V — Code 00.2193.260.0 Note: Legend on next page Figure 14-1 Power Unit Cable Harness TP-6577 7/08 Section 14 Wiring Diagrams...
  • Page 64 Legend for Figure 14-1: T1: Heat timing relay 4 Condenser E/fan Ø 305 D1:Diode 5 Fuel supply E/valve R1:Condenser E/fan relay 6 AC gas compressor R2:Starting motor relay 7 Main earth cable harness R3:Protection/engine safety relay 8 Gas safety pressure switch ON 2/Off 27 (bar) R4:Diesel fuel E/valve relay 9 Engine oil temperature sensor NO <130°C R5:AC compressor relay...
  • Page 65 Length 5 m (16.45 ft.) Code 00.2186.223.0 Length 10 m (32.80 ft.) Code 00.2186.219.0 Legend: 1 Packard 2-way connector M 2 Super Seal 3-way connector M 3 Super Seal 4-way connector M 4 Super Seal 5-way connector M 5 Packard 2-way connector F 6 Super Seal 2-way connector F 7 Mate-N-Lok 1-way connector F 8 Mate-N-Lok 9-way connector F...
  • Page 66 BROWN/WHITE 12V — Code 00.2186.215.0 24V — Code 00.2186.226.0 Note: Legend on next page Figure 14-4 Evaporator Cable Harness Section 14 Wiring Diagrams TP-6577 7/08...
  • Page 67 Legend for Figure 14-4: Note: The bridge connector is between the cable harness and the battery charger module M1 T21: Resistance (for heat pump): (inside the evaporator compartment). This 3.3 ohms (12-volt model) should be used only as a one-time emergency 5 ohms (24-volt model) procedure if module M1 is not functioning 22: Resistance (second suction fan):...
  • Page 68 12V — Code 00.2186.215.0 24V — Code 00.2186.226.0 Note: Legend on next page Figure 14-6 Keypad Function Guide Cable Harness Section 14 Wiring Diagrams TP-6577 7/08...
  • Page 69 Legend for Figure 14-6: Mode activation selector switch (AC/fan/heat) The automatic battery charger system may be Adjustable room thermostat configured with the Immediate Auto Switchoff function. Mate-N-Lok 15-way connector (split interf.) This function allows the power unit diesel engine Main panel/battery charger switch (running in the normal battery recharge process) to Motor APU starting button immediately stop the engine when the vehicle primary...
  • Page 70 tp6577 tp6577 Figure 14-9 Molex (Battery Charge Management) Figure 14-8 Molex (Check Setup Management) Position 25 Section 14 Wiring Diagrams TP-6577 7/08...

  • Page 71: Appendix A Abbreviations

    Appendix A 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 72 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 73 Notes TP-6577 7/08...
  • Page 74 Notes TP-6577 7/08...
  • Page 76 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-6577 7/08a 7 Jurong Pier Road Singapore 619159 E 2007, 2008 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

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3apu-hc-24v

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