Kohler 3APU-HC User manual

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

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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

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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

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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

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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.

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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.

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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.

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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.

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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]

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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

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TP-657612/07b
2 - General Description and Technical Data
WARNING
Refrigerant (R134a) in liquefied or
gas form.
Can cause severe injury or death.
Avoid inhalation or skin contact. Only
a qualified,EPA-certified technician
should perform 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, or repair any refrigerant lines, hoses, connections, or fittings. Only a qualified,EPA-certified technician should perform service
on the R134a refrigerant system. R134a exposure symptoms include but are not limited to the following:
• Light-headedness,dizziness
• Headache,nausea
• Physical fatigue, weakness in joints 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 uncontaminated area.All
exposed persons should wear a self-contained breathing apparatus. If liquid contact exposure has occured, flush eyes and/or skin with
warm water for 15 minutes, then apply a sterile dressing. Alert others of R134a refrigerant exposure. Keep victim(s) warm and rested.
Seek medical attention immediately.
2.1 General Description of the Heating and Cooling System
The3APU- HC consists of the following main units/elements:
• Power unit
• Condenser
•Evaporator
• Cooling circuit pipes and electrical cables
• Accessories

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9
10
7
Fig. 2 Fig. 3
Fig. 4 Fig. 5
13
2
6
5
4
8
General Description and Technical Data - 2
2.2 Heatingand Cooling System
Description of the main functional components
Figures 2, 3, 4 and 5 show the main components of the heating and cooling system:
1Support structure of the power unit.
2Power unit: it's function is to supply energy at the right power to the entire system, by the action of a diesel engine.
3Electrical and control box: this box, which is to be only serviced by an authorizedkohler technician.
4Compressor: the function of the compressor is to increase the pressure of the coolant by compressing it and sending it to the
condenser by transforming it from gas to liquid form.
5Alternator: the function of the alternator is to keep the vehicle battery and the system charged.
6Exhaust gas muffler.
7Condenser: the function of the condenser is to transform the coolant from gas to liquid form.
8Evaporator: it's function is to cool/heat or regulate ambient temperature inside the area in which it is
installed.
9Control panel: allows manual access to all the system functions.
10 Adjustablenozzlesfor the distribution/direction of the airflow.
Power Unit
Power Unit
Condenser
Evaporator

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TP-657612/07b
2 - General Description and Technical Data
Fig. 6
F 3
F 4
F 5
F 6
F 2
F 1
Fig. 7
2.5 Fuse Section
12 Volt
F1 20 A – Condenser electric fan
F2 30A– Starter motor terminal
F3 30A – Evaporator general supply
F4 10A – Fuel electric fan
F5 10A– AC compressor
F6 60A – Glow plug general supply
2.3 Characteristics of Coolant
Recommended products: Fluorocarboncoolant: R-134a - ( TETRAFLUORETHANE ).
Compressor oil: PAG 46 or alternatively SP 10 or SP 20
Note: Avoid contact with fluorocarbon coolants. DO NOT service coolant system. ContactanAuthorizedKohlerDistributor/
Dealer for coolant service.
2.4 Operating Limit Conditions
The 3APU- HC system uses an alternator that is able to supply enough energy to guarantee
the functions mentioned under Section 2.2 Heating and Cooling System.
In the event that the vehicle remains inactive for long periods of time, and furthermore, if the
system’s battery charging function is deactivated, if the battery charge level falls below 10.5
Volts (minimum threshold for the 3APU- HC system to operate), the system will not be able to
start.
Minimum charge
level of the vehicle’s
battery required for
the3APU-HCsystem
operation
Alternator operating
limits
WARNING
Refrigerant (R134a) in liquefied or
gas form. Can cause severe injury
or death.
Avoidinhalation or skin contact. Only a
qualified,EPA-certified technician should
performserviceon refrigerant systems.

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Operation and Use - 3
3.1 Pre-Start Check List
WARNING
Carbon monoxide.
Can cause severe nausea, fainting,
or death.
Theexhaustsystem must be leakproof
androutinely 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. Avoid
breathingexhaustfumeswhenworking
on or near the generator set. Never
operate the generator set inside a
buildingunlesstheexhaustgas is piped
safely outside. Never operate the
generatorsetwhereexhaust gas could
accumulate and seep back inside a
potentiallyoccupiedbuildingorvehicle.
Donotobstructtheexhaustoutlet when
parking your vehicle. The exhaust
gasesmustdischarge freely to prevent
carbon monoxide from deflecting into
thevehicle.
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present
inexhaust gases. Carbon monoxide is
an odorless, colorless, tasteless,
nonirritating gas that can cause death
if inhaled for even a short time.
Carbonmonoxidepoisoningsymptoms
include but are not limited to the
following:
•Light-headedness, dizziness
•Physicalfatigue,weaknessin joints
and muscles
•Sleepiness,mentalfatigue,inability
to concentrate or speak clearly,
blurredvision
•Stomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible,seek fresh air immediately and
remain active. Do not sit, lie down, or fall
asleep. Alert others to 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
functioning carbon monoxide detector.
Inspect the detector before each
generator set use.
To ensure continued satisfactory
operationperformthefollowingchecksor
inspections before or at each startup, as
designated,andatthe intervals specified
intheserviceschedule.Inaddition,some
checks require verification after the unit
starts.
Air Cleaner. Check for a clean and
installed air cleaner element to prevent
unfilteredair from entering the engine.
Air Inlets. Check for clean and
unobstructed air inlets.
Air Shrouding. Check for securely
installedand positioned airshrouding.
Battery. Check for tight battery
connections. Consult the battery
manufacturer’s instructions regarding
batterycare and maintenance.
Exhaust System. Check for exhaust
leaks and blockages. Check the muffler
and piping condition and check for tight
exhaustsystemconnections.Inspect the
exhaust system components (exhaust
manifold, exhaust outlet, exhaust line,
exhaust clamps, and muffler) for cracks,
leaks,and corrosion.
•Checkfor corroded or broken metal
parts and replace them as needed.
•Check for loose, corroded, or
missing clamps and hangers.
Tighten or replace the exhaust
clamps and/or hangers as needed.
•Check that the exhaust outlet is
unobstructed.
•Check the exhaust gas color. If the
exhaustisblue orblack,contactyour
authorizedKohlerdistributor/dealer.
•Visually inspect for exhaust leaks
(blowby). Check for carbon or soot
residue on exhaust components.
Carbon and soot residue indicates
an exhaust leak. Seal leaks as
needed.
•Ensure that the carbon monoxide
detector is (1) in the vehicle, (2)
functional, and (3) energized
whenever the generator set
operates.
Note: Never operate the generator
set without a functioning
carbon monoxide detector.
Fuel Level. Check the fuel level and
keepthe tank(s) full to ensure adequate
fuelsupply.
OilLevel.Checktheoil level. SeeFigure
20. Maintain the oil level at or near, not
over, the full mark on the dipstick.
OperatingArea. Checkfor obstructions
that could block the flow of cooling air.
Keep the air intake area clean. Do not
leave rags, tools, or debris on or near
thegenerator set.

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Fig. 8 Fig. 9
Fig.10 Fig. 11
IE
RCR
FS
min 200 A - 12 V
3.2 Residual Risk of Contact With Coolant
3 - Operation and Use
3.3 3APU- HC Features
The 3APU- HC heating and cooling system is equipped with the following features:
••
••
•Main electric power supply fuse FS (Fig. 8).
•Split stop button for IE (Fig. 9).
•Fixed protection cases (CR) (Fig. 11).
•Engine status switch (Fig. 9).
•Heat status switch sensor (Fig. 9).
•Cooling status switch (Fig. 9).
•Diesel on/off valve (R) (Fig. 10).
Introduction
First aid treatment in the event of
contact with the coolant.
WARNING
Refrigerant (R134a) in liquefied or
gas form. Can cause severe injury
or death.
Avoid inhalation or skin contact. Only
a qualified, EPA-certified technician
should perform service on refrigerant
systems.
This risk exists in the event of accidental contact with the coolant. The characteristics and the safety
warnings of the coolant are described in Section 2.3 Characteristics of Coolant.
Origin of the
residual risk
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, or repair any refrigerant lines, hoses, connections, or fittings. Only a qualified,
EPA-certified technicianshould perform service on the R134arefrigerant system. R134a
exposure symptoms include but are not limited to the following:
• Light-headedness,dizziness
• Headache,nausea
• Physical fatigue, weakness in joints 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
immediatelyinanuncontaminated area.Allexposedpersonsshouldweara self-contained
breathingapparatus. If liquid contact exposure has occured, flush eyes and/or skin with
warmwaterfor15minutes,thenapply a sterile dressing.AlertothersofR134a refrigerant
exposure. Keep victim(s) warm and rested. Seek medical attention immediately.

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Operation and Use - 3
Fig. 12
3.4 Summary Diagram Cooling System
Legend:
1 AC Compressor
2 Cycle Inversion Valve
3 Engine Muffler
4 Gas as Exchanger (+Others)
5 Non-Return Valve
6 Throttle Valve
7 Non-Return Valve
8 Dewatering Filter
9 AC Gas Condenser
10 Non-Return Valve
11 Throttle Valve
12 Non-Return Valve
13 AC Gas Evaporator
14 Liquid Container
R134a Low Pressure Gas (BP)
R134a High Pressure Gas (AP)
Conventional Cooling Cycle

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TP-657612/07b
Fig. 12Fig. 13
3.5 Summary Diagram Heating System
Heat Cycle with Overheated Heat Pump
3 - Operation and Use
11 Throttle Valve
12 Non-Return Valve
13 AC Gas Evaporator
14 Liquid Container
R134a Low Pressure Gas (BP)
R134a High Pressure Gas (AP)
Overheated R134a Gas (BP)
Legend:
1 AC Compressor
2 Cycle Inversion Valve
3 Engine Muffler
4 Gas as Exchanger (+Others)
5 Non-Return Valve
6 Throttle Valve
7 Non-Return Valve
8 Dewatering Filter
9 AC Gas Condenser
10 Non-Return Valve

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Operation and Use - 3
WARNING
Carbon monoxide.
Can cause severe nausea, fainting,
or death.
Theexhaustsystemmustbeleakproof
androutinely 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.Avoid breathing exhaust fumes when
working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely
outside.Never operate the generator set where exhaust gas could accumulateand seep backinside a potentially occupied building
orvehicle.Do not obstruct theexhaust outlet when parking yourvehicle. The exhaust gasesmustdischarge freely to preventcarbon
monoxidefrom deflecting into the vehicle.
Carbon monoxide symptoms.
Carbon monoxide can 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 deathif inhaled for even a short time.
Carbon monoxide poisoning symptoms include but are not limited to the following:
• Light-headedness,dizziness
• Physical fatigue, weakness in joints and muscles
• Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
• Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active.
Donotsit, lie down, or fallasleep.Alertothersto the possibility ofcarbonmonoxide poisoning. Seek medicalattentionif the condition
of affected persons does not improve within minutes of breathing fresh air.
3.6 Description of Operating Modes
Operating mode types for the user
The3APU- HC heating and cooling system can be operated by meansof the controls locatedon the evaporator unit, according to
the settings and procedures described in the paragraphs under Section 3.7 Operating Instructions.
3.7 Operating Instructions
Control equipment and commands
The control panel on the 3APU- HC system has been designed to handle the heating and cooling of
special vehicleswherethepoweris suppliedbythedieselengine. Inadditiontoit'snormalheating and cooling
functions it also supervises and controls correct function of the diesel engine. It can also monitor
battery voltage,and, ifnecessary,rechargesthebatteryautomaticallyafteramanualresetwiththe
POWER/REC.BATT Main Switch. See Section 3.8 .Description of Keypad Functions.
Switching ON and OFF: Activates and deactivates the 3APU- HC.
Operating Mode: Enablesyou to choose between cooling, fan only,and heating modes.
Fan Power Control: Allows you to direct and open + - the fins located on the evaporator.
Ventilation Control: Allows controllingthe speed of theair emitted in the environment by turningthe three speed selectorswitch.
General
description of
control device

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TP-657612/07b
1
2
3
4
10 9
8
67
5
3.8 Description of Evaporator Functions
This keypad located on the evaporator allows the user to program all the system functions.
1 POWER/REC.BATT – Main switch
–Voltage position on panel (primary switch, enabling all system functions to be activated Fig. 7 p. 13)
OOFF position, totally DEACTIVATED (acts also as safety switch)
=Automatic battery charge position (see 1).
If the battery voltage drops below 12.5 Volts, the Power Unit will set in to recharge the battery for about 6 hours (minimum
battery recharge). Once the battery is recharged, the system automatically switches off.
2 AIR Switch (Fan speed switch)
Allows the user to regulate the flow of air desired inside the cab.
3 TEMP Switch
Allows the user to set the desired temperature inside the cab.
4 Yellow LED - Glow plug status
Displays to the user, if the glow plug is preheating.
Before activating the engine starting button, wait until the yellow LED 4 of the “glow plug status” turns off (about 5
seconds).
5 Two-Colored LED (Red/Green) – Engine status
Shows whether or not the engine is running.
Red —> engine off Green —> engine on
6 Orange LED – Heating status
Displays when the heat pump is working. LED lights up when system is in the heat mode.
7 Blue LED – Cooling status
Displays when the air conditioner’s compressor is working. LED lights up when system is in the cooling mode.
Fig. 12Fig. 14
3 - Operation and Use

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Operation and Use - 3
8 LCD Counter Unit (hour meter)
Displays the number of hours that the engine has been run.
Keepstrack ofthe number of hours on the unit to service the engine (500 hours MAX).
9 AC Switch/HEAT Switch
–Airconditioner ON
OOnlyfunction fan
=Heating on (heat pump)
Note: When the system is set in heating mode, there is an automatic reduction of 50% in the evaporator's air
flow for all stages of ventilation. This is necessary to increase heating power.
10 START – Engine Start
When the position is pressed, the Power Unit engine is started (release when the engine status LED changes from red to
green).
Note:
The starting control unit is set for 6 sequential attempts at switching on the engine with a stand-by time of about 30 seconds. If the
system does not start after all the attempts at switching on, the 3APU-HCwill maintain the OFF status and visualize the RED LED
5(engine off status) on the counter/hour meter module 8.
If the above occurs, please seek assistance from an authorized Kohler Distributor/Dealer.
3.9 Scheduled Maintenance Functions
The 3APU-HC has a counter that memorizes the number of operating hours of the diesel engine.
Servicing should be carried out 500 hours MAXIMUM.
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.
If the above occurs, see your authorized Kohler Distributor/Dealer.