Kohler 3APU-HC User manual

MODEL:
3APU-HC
Heavy Duty Truck Mobile Generator Sets
POWER SYSTEMS TP-6576 12/07b
Operation

2
THIS MANUAL IS PROPRIETY OF - ALL FORMS OF REPRODUCTION, PARTIAL OR OTHERWISE, IS STRICTLY PROHIBITED TP-657612/07b
CaliforniaProposition65
WARNING
Engineexhaustfromthisproductcontains chemicals
known to the State of California to cause cancer,
birth defects, or other reproductive harm.
Productidentificationnumbers determineservice parts.
Recordtheproductidentificationnumbersinthe spaces
belowimmediatelyafter unpackingtheproducts sothat
the numbers are readily available for future reference.
Recordfield-installed kitnumbers afterinstallingthekits.
Generator Set Identification Numbers
Record the product identification numbers from the
generatorsetnameplate(s).
ModelDesignation
Specification Number
SerialNumber
Accessory NumberAccessory Description
Engine Identification
Record the product identification information from the
enginenameplate.
Manufacturer
ModelDesignation
SerialNumber
Product Identification Information

3
THIS MANUAL IS PROPRIETY OF - ALL FORMS OF REPRODUCTION, PARTIAL OR OTHERWISE, IS STRICTLY PROHIBITED
TP-657612/07b
Safety Precautions and Instructions ................................................................................................................ 5-8
Introduction ............................................................................................................................................................ 9
ServiceAssistance ................................................................................................................................................. 9
1 General Information .................................................................................................................................... 10
1.1 Preliminary Information Regarding How the System Works .......................................................... 10
1.2 Operating Principle........................................................................................................................ 10
1.3 Identification Plate................................................................................................................... 10
1.4 Directive and Standard ReferencesApplied .................................................................................. 10
2 General Description and Technical Data ...................................................................................................11
2.1 General Description of the Heating and Cooling System.................................................................11
2.2 Heating and Cooling System......................................................................................................... 12
2.3 Characteristics of Coolant ............................................................................................................. 13
2.4 OperatingLimit Conditions............................................................................................................. 13
2.5 Fuse Section ................................................................................................................................. 13
3 Operation and Use ..................................................................................................................................... 14
3.1 Pre-Start Check List ...................................................................................................................... 14
3.2 Residual Risk of Contact With Coolant .......................................................................................... 15
3.3 3APU-HC Features ........................................................................................................................ 15
3.4 Summary Cooling System - Conventional Cooling Cycle .............................................................. 16
3.5 Summary Diagram Heating System - Heat Cycle with Overheated Heat Pump ............................. 17
3.6 Description of Operating Modes .................................................................................................... 18
3.7 OperatingInstructions ................................................................................................................... 18
3.8 Description of Keypad Functions .................................................................................................. 19
3.9 ScheduledMaintenance Function................................................................................................. 20
4 Troubleshooting ......................................................................................................................................... 21
4.1 TablesofProblems, Causesand Solutions .................................................................................... 21
4.2 TroubleshootingThermodynamic Components .............................................................................. 21
4.3 Troubleshooting MechanicalComponents...................................................................................... 22
Table of Contents

4
THIS MANUAL IS PROPRIETY OF - ALL FORMS OF REPRODUCTION, PARTIAL OR OTHERWISE, IS STRICTLY PROHIBITED TP-6576 12/07b
5 Maintenance ................................................................................................................................................ 23
5.1 GeneralMaintenance .................................................................................................................... 23
5.2 Lubricant International Specifications............................................................................................ 23
5.3 Acea Regulations -Acea Sequences ............................................................................................24
5.4 LubricationSystem ........................................................................................................................ 24
5.5 Engine Oil Selections.................................................................................................................... 24
5.6 Oil Check....................................................................................................................................... 25
5.7 Checkingthe OilLevel ................................................................................................................... 26
5.8 Oiland FilterReplacement............................................................................................................. 27
5.9 Replacingthe DieselFilter ............................................................................................................. 30
5.10 Cleaning or Replacing theAir Filter ............................................................................................... 31
5.11 Control Operations Following Maintenance ....................................................................................32
5.12 Maintenance of Thermodynamic Parts – Operating Instructions ................................................... 33
5.13 Replacing Condensation Dissipater .............................................................................................. 33
5.14 Replacing the Cab Filter ............................................................................................................... 34
6 Scheduled Preventative Maintenance....................................................................................................... 35
6.1 ScheduledPreventive Maintenance ............................................................................................... 35
6.2 SummaryTable of Scheduled Maintenance................................................................................... 35
6.3 3APU-HCStorage.......................................................................................................................... 36
6.4 Restoring the EngineAfter Storage ............................................................................................... 37
7 Operating Hours ......................................................................................................................................... 38
Table of Contents

5
THIS MANUAL IS PROPRIETY OF - ALL FORMS OF REPRODUCTION, PARTIAL OR OTHERWISE, IS STRICTLY PROHIBITED
TP-657612/07b
Safety Precautions and Instructions
IMPORTANTSAFETYINSTRUCTIONS
Electromechanicalequipment, including
generator sets, transfer switches,
switchgear, and accessories, can cause
bodily harm and pose life-threatening
danger when improperly installed,
operated, or maintained. To prevent
accidentsbeawareof potential dangers
andactsafely.Readandfollowall safety
precautions and instructions. SAVE
THESEINSTRUCTIONS.
Thismanual has several typesof safety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazardthatwillcause severe personal
injury, death, or substantial
property damage.
WARNING
Warning indicates the presence of a
hazardthatcancauseseverepersonal
injury, death, or substantial property
damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
inprominentplacesalert the operator or
service technician to potential hazards
and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
workingon the generator set.
Removethe negative (-) lead first when
disconnectingthe battery.
Reconnect the negative (-) lead last
whenreconnecting the battery.
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
generatorset master switch to the OFF
position.(2)Disconnectthepowertothe
batterycharger. (3) Removethe battery
cables, negative (-) lead first.
Reconnect the negative (-) lead last
when reconnecting the battery. Follow
theseprecautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from
a remote computer.
Engine Backfire/FlashFire
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
Servicing the fuel system.Aflash
fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the fuel injection system,
fuel line, fuel filter, fuel pump, or other
potential sources of spilled fuels or fuel
vapors. Catch fuels in an approved
containerwhen removing the fuel line
or fuel system.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
Combustible materials.Afire can
cause severe injury or death.
Generatorset engine fuels and fuel
vaporsare flammable and explosive.
Handlethese materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
witha fully charged fire extinguisher.
Select a fire extinguisher ratedABC or
BC for electrical fires or as
recommended by the local fire code or
anauthorized agency.Train all
personnelon fire extinguisher
operationandfire prevention
procedures.
Using engine starting fluid.A
sudden backfire can cause severe
injury or death. Do not use starting
fluidor similar agents to start an engine
equippedwith air preheating (glow
plugs/starter element). The starter
element may cause an explosion in the
inletmanifold.

6
THIS MANUAL IS PROPRIETY OF - ALL FORMS OF REPRODUCTION, PARTIAL OR OTHERWISE, IS STRICTLY PROHIBITED TP-6576 12/07b
Safety Precautions and Instructions
Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea, fainting,
or death.
The exhaust system must be
leakproofand routinely inspected.
Generator set operation. Carbon
monoxide can cause severe nausea,
fainting, or death. Carbonmonoxideis
an odorless, colorless, tasteless,
nonirritatinggas that can causedeath if
inhaled for even a short time. Avoid
breathingexhaust fumes when working
on or near the generator set. Never
operate the generator set inside a
buildingunlesstheexhaustgasis piped
safely outside. Never operate the
generator set where exhaust gas could
accumulate and seep back inside a
potentiallyoccupied building or vehicle.
Donotobstructthe exhaust outlet when
parkingyourvehicle.Theexhaustgases
mustdischargefreelyto prevent carbon
monoxidefromdeflectingintothevehicle.
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxideisa poisonous gas present in
exhaustgases. Carbon monoxide isan
odorless, colorless, tasteless,
nonirritatinggas that can cause deathif
inhaled for even a short time.
Carbon monoxide poisoning symptoms
includebutarenotlimitedtothefollowing:
• Light-headedness,dizziness
• Physical fatigue, weakness in
joints and muscles
• Sleepiness, mental fatigue,
inability to concentrate or speak
clearly,blurredvision
• Stomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible,seekfreshairimmediatelyand
remain active. Do not sit, lie down, or
fallasleep.Alertothersto the possibility
of carbon monoxide poisoning. Seek
medical attention if the condition of
affected persons does not improve
withinminutes of breathing fresh air.
Inspecting the exhaust system.
Carbon monoxide can cause severe
nausea, fainting, or death. For the
safety of the vehicle’s occupants, install
a carbon monoxide detector. Never
operate the generator set without a
functioningcarbon monoxide detector.
Inspect the detector before each
generator set use.
Installing the exhaust tail pipe.
Carbon monoxide can cause severe
nausea, fainting, or death. Install the
exhaust system tail pipe to prevent the
drawing of discharged exhaust gases
intothevehicleinteriorthroughwindows,
doors, air conditioners, and other
openings. Do not use flexible tail piping
because it could crack and allow lethal
exhaust fumes to enter the vehicle.
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly
explosive. Use extreme care when
handlingand storing fuels. Store fuels in
a well-ventilated area away from spark-
producing equipment and out of the
reach of children. Never add fuel to the
tankwhiletheengineisrunningbecause
spilledfuelmayigniteoncontactwithhot
parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lineswithrigidlines.Useflexible sections
to avoid fuel line breakage caused by
vibration.Donot operatethegeneratorset
in the presence of fuel leaks, fuel
accumulation, or sparks. Repair fuel
systems before resuming generator set
operation.
Draining the fuel system. Explosive
fuel vapors can cause severe injury
or death. Spilled fuel can cause an
explosion.Use a containerto catch fuel
whendraining the fuelsystem. Wipe up
spilled fuel after draining the system.
Hazardous Noise
WARNING
Hazardous noise.
Can cause hearing loss.
Neveroperate the generator set
without a muffler or with a faulty
exhaust system.
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105dBA. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protectionwhen near an operating
generator set.

7
THIS MANUAL IS PROPRIETY OF - ALL FORMS OF REPRODUCTION, PARTIAL OR OTHERWISE, IS STRICTLY PROHIBITED
TP-657612/07b
Safety Precautions and Instructions
Hazardous Voltage/
Moving Parts
WARNING
Hazardous voltage. Moving Parts.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
arein place.
Servicing the generator set when it
is operating. Exposed moving parts
can cause severe injury or death.
Keephands,feet,hair,clothing,andtest
leads away from the belts and pulleys
when the generator set is running.
Replace guards, screens, and covers
beforeoperating the generatorset.
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turn off the main
circuit breakers of all power sources
before servicing the equipment. Never
contact electrical leads or appliances
whenstandinginwateroron wet ground
because these conditions increase the
risk of electrocution.
Short circuits. Hazardous
voltage/current can cause severe
injury or death. Short circuits can
cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Removeall jewelry before servicing the
equipment.
Testing live electrical circuits.
Hazardous voltage or current can
cause severe injury or death. Have
trained and qualified personnel take
diagnosticmeasurementsof live circuits.
Useadequatelyratedtestequipmentwith
electrically insulated probes and follow
the instructions of the test equipment
manufacturer when performing voltage
tests.Observe the following precautions
when performing voltage tests: (1)
Remove all jewelry. (2) Stand on a dry,
approvedelectricallyinsulatedmat.(3)Do
not touch the enclosure or components
insidethe enclosure. (4) Be prepared for
the system to operate automatically.
(600 volts and under)
Engine block heater. Hazardous
voltage can cause severe injury or
death. The engine block heater can
cause electrical shock. Remove the
engine block heater plug from the
electrical outlet before working on the
block heater electrical connections.
Servicing the generator set.
Hazardous voltage can cause severe
injury or death. Do not touch electrical
connectionswhenflashing the generator
set. The alligator clips carry line voltage
when the pushbutton is pressed to flash
thegenerator set.
Hot Parts
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
Combustiblematerials.Firecancause
severe injury or death. A hot exhaust
system can ignite adjacent combustible
materials.Do not locateelectrical wiring,
fuellines,orcombustiblematerialsabove
the exhaust muffler. Exercise caution
whenparking your vehicle to prevent the
exhaust system and hot exhaust gases
from starting grass fires.
WARNING
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool.Then loosen the pressure capto
relievepressure.
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. For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.
Engine Fluids and
Chemical Products
Used engine oil. Contact with used
engine oil may cause severe skin
irritation. Repeated and prolonged
skin exposure may have other health
risks. Used engine oil is a suspected
carcinogen. Avoid contact with skin.
Thoroughly wash your hands and nails
with soap and water shortly after
handling used engine oil. Wash or
dispose of clothing or rags containing
usedengineoil. Dispose of used engine
oil in a responsible manner.
Contact your local recycling center for
disposalinformation and locations.
Engine Fluids and
Chemical Products
Used engine oil. Contact with used
engine oil may cause severe skin
irritation. Repeated and prolonged
skin exposure may have other
health risks. Used engine oil is a
suspected carcinogen. Avoid contact
with skin. Thoroughly wash your
hands and nails with soap and water
shortly after handling used engine oil.
Wash or dispose of clothing or rags
containing used engine oil. Dispose
of used engine oil in a responsible
manner.
Contact your local recycling center for
disposal information and locations.

8
THIS MANUAL IS PROPRIETY OF - ALL FORMS OF REPRODUCTION, PARTIAL OR OTHERWISE, IS STRICTLY PROHIBITED TP-657612/07b
Safety Precautions and Instructions
Refrigerant
WARNING
Refrigerant (R134a) in liquefied or
gas form.
Can cause severe injury or death.
Avoidinhalation or skincontact. Only
a qualified,EPA-certified technician
shouldperform service on refrigerant
systems.
WARNING
Flammable refrigerants.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near flammable refrigerants.
Useonly in well-ventilated areas.
R134a exposure symptoms.
Refrigerant (R134a) in liquefied or
gas form can cause severe injury or
death. R134arefrigerant is an odorless,
colorless, tasteless, liquefied gas that
can cause death if inhaled for even a
short time. DO NOT attempt to loosen,
tighten,orrepairanyrefrigerant lines,hoses,
connections, or fittings. Only a qualified,
EPA-certified technician should perform
serviceontheR134arefrigerantsystem.
R134a exposure symptoms include but
are not limited to the following:
• Light-headedness,dizziness
• Headache,nausea
• Physicalfatigue,weaknessinjoints
and muscles
• Frostbite burns to eyes, skin and/
or lungs
• Loss of consciousness
• Disturbed cardiac rhythm
• Asphyxiation
If experiencing any of these symptoms
and R134a exposure is possible, seek
fresh air immediately in an
uncontaminatedarea.Allexposedpersons
shouldwear a self-contained
breathing apparatus. If liquid contact
exposure has occured, flush eyes
and/or skin with warmwater for 15
minutes,then apply a sterile dressing.
Alert others of R134a refrigerant
exposure. Keep victim(s)warmand
rested.Seekmedicalattentionimmediately.
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. For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.

9
THIS MANUAL IS PROPRIETY OF - ALL FORMS OF REPRODUCTION, PARTIAL OR OTHERWISE, IS STRICTLY PROHIBITED
TP-657612/07b
Introduction
This manual provides operation instructions for 3APU-HC
model generator sets.
Informationin this publication represents dataavailable at the
time of print. Kohler Co. reserves the right to change this
publication and the products represented without notice and
withoutany obligation or liability whatsoever.
Readthismanualandcarefullyfollowallproceduresandsafety
precautionstoensureproperequipmentoperationandtoavoid
bodily injury. Read and follow the Safety Precautions and
Instructions section at the beginning of this manual. Keep this
manual with the equipment for future reference.
Theequipmentservicerequirementsareveryimportanttosafe
and efficient operation. Inspect the parts often and perform
required service at the prescribed intervals.
Obtain service from an authorized Kohler distributor/dealer to
keepequipment in topcondition.
Before installing a mobile generator set, obtain the most
current installation manual from your authorized Kohler
distributor/dealer. Only qualified persons should install
the generator set.
Service Assistance
For professional advice on generator set power requirements
and conscientious service, please contact your nearest
authorizedKohlerdistributor/dealer.
• Consult the Yellow Pages under the heading
Generators—Electric.
• Visit the Kohler Power Systems website at
KohlerPower.com.
• Lookat the labelsand stickers onyour Kohler product or
reviewthe appropriate literature or documents included
with the product.
• Call toll free in the US and Canada
1-800-544-2444.
• Outside the US and Canada, call the nearest regional
office.
Headquarters Europe, Middle East, Africa
(EMEA)
Kohler Power Systems
ZISenia122
12, rue des Hauts Flouviers
94517Thiais Cedex
France
Phone: [phone]
Fax:[phone]
LatinAmerica
LatinAmerica Regional Office
Lakeland,Florida,USA
Phone:[phone]
Fax:[phone]

10
THIS MANUAL IS PROPRIETY OF - ALL FORMS OF REPRODUCTION, PARTIAL OR OTHERWISE, IS STRICTLY PROHIBITED TP-657612/07b
Fig. 1
1.1 Preliminary Information Regarding How the System Works
The3APU- HC (AuxillaryPowerUnit-HeatingandCooling)hasbeendesignedtocarryoutthefollowingfunctions:
• 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.
• Recharging the battery of the vehicle on which the system is installed. See battery equipment manufacturer's
instructions.
1.2 Operating Principle
The 3APU- HC is able to regulate the temperature inside the vehicle cab, or in the area in which the evaporator
unitis installed.The desired temperature may be set using the controls on the keypad located on the evaporator.
See Section 3.8, Description of Keypad Functions.
1.3 Identification Plate
The3APU- HC systemis manufactured ina European Union state, and therefore complies with the safety requisites of Machinery
Directive 98/37/EC, in force since July 23, 1998.
This conformity is certified by the “CE” mark located on the body of the power unit, inside the front protective casing.
Note: Do not damage or remove the CE identification plate, even when the system is resold.
Legal provisions
Reference Title
P.D. no. 459 of 24.7.96 Implementationof EEC Directive no. 89/392 known as the Machinery Directive.
L.D. no. 476 of 4.12.92 Implementation of EEC Directive no. 89/336 regarding Electromagnetic Compatibility (EMC).
Table 1-1
EU directives
Reference Title
EU directive no. 98/37 MachineryDirective 89/392/EEC codified 98/37.
EU directive no. 89/336 ElectromagneticCompatibility (EMC).
Directive 2000/2/EC Directiveregarding electromagnetic compatibility (EMC) for agricultural and forestry tractors.
Directive 2004/104/EC Directive regarding electromagnetic compatibility (EMC) for motor vehicles and their trailers.
Directive 95/54/EC Directive regarding electromagnetic compatibility (EMC) for motor vehicles.
ECE R10 ECE/UNregulation regarding electromagnetic compatibility for motor vehicles.
Table 1-2
1.4 Directive and Standard ReferencesApplied
General Information - 1