Kohler 1.4BEOR-12V Operation Manual

Operation

Heavy Duty Truck Mobile Generator Sets

Model:

1.4BEOR-12V

TP-6687 9/10a

California Proposition 65

WARNING

Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.

Product Identification Information

Product identification numbers determine service parts.
Record the product identification numbers in the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the
kits.

Generator Set Identification Numbers

Record the product identification numbers from the
generator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine Identification

Record the product identification information from the
engine nameplate.

Manufacturer

Model Designation

Serial Number

Table of Contents

Safety Precautions and Instructions 5........................................................

Introduction 9...............................................................................

Service Assistance 9........................................................................

List of Related Literature 9...................................................................

Section 1 General Information 11.............................................................

1.1 Preliminary Information 11................................................

1.2 Operating Principle 11....................................................

1.3 Directive and Standard References 11......................................

1.4 CE Identification Plate 11.................................................

1.5 Service Views 12........................................................

Section 2 General Description and Technical Data 13...........................................

2.1 Generator System 13.....................................................

2.1.1 Alternator 13....................................................

2.2 Operating Limit Conditions 13.............................................

Section 3 Operation and Use 15...............................................................

3.1 Prestart Checklist 15.....................................................

3.2 1.4BEOR Features 16....................................................

3.3 Operating Modes 16......................................................

3.4 Operating Instructions 16.................................................

3.4.1 Alarm Horn 16...................................................

3.4.2 Master On/Off Switch 17..........................................

3.4.3 Remote Control Unit 17...........................................

3.5 Scheduled Maintenance Functions 19......................................

Section 4 Troubleshooting 21.................................................................

4.1 Problems, Causes and Solutions 21........................................

4.2 Mechanical Components 21...............................................

Section 5 General Maintenance 23............................................................

5.1 International Lubricant Specifications 23....................................

5.2 ACEA Regulations, ACEA Sequences 23...................................

5.2.1 Light Duty Diesel Engines 23......................................

5.2.2 Heavy Duty Diesel Engines 24.....................................

5.3 Lubrication System 24....................................................

5.3.1 Engine Oil Selections 24..........................................

5.3.2 Oil Check 24....................................................

5.3.3 Oil Level Check 25...............................................

5.3.4 Oil and Filter Replacement 26.....................................

5.3.5 Diesel Filter Replacement 28......................................

5.4 Air Filter 28.............................................................

5.5 Control Operation Following Maintenance 29................................

Section 6 Scheduled Maintenance 31..........................................................

6.1 Service Schedule 32.....................................................

6.2 Engine Storage 33.......................................................

6.3 Restore Engine After Storage 34...........................................

Section 7 Operating Hours 35.................................................................

Appendix A Abbreviations 37..................................................................

Appendix B Operating Hour Service Log 39.....................................................

TP-6687 9/10 Table of Contents 3

Notes

TP-6687 9/104

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment,
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 accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.

This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a
hazard that will cause severe

personal injury, death,orsubstantial
property damage.

WARNING

Warning indicates the presence of a
hazard that can cause severe

personal 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.

Accidental Starting

WARNING

Accidental starting.
Can cause severe injury or death.

Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting 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
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent startingof
the generator set by an automatic
transfer switch, remote start/stop
switch, orengine startcommand from a
remote computer.

Engine Backfire/Flash
Fire

WARNING

Servicing the fuel system. A flash
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
container when 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. A fire can
cause severe injury or death.

Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.

Using engine starting fluid. A
sudden backfire can cause severe
injury or death. Do not use starting

fluid or similar agents to start an engine
equipped with air preheating (glow
plugs/starter element). The starter
element may cause an explosion in the
inlet manifold.

Exhaust System

WARNING

Safety decals affixed to the equipment
in prominent places alert 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.

TP-6687 9/10 5Safety Precautions and Instructions

Fire.
Can cause severe injury or death.

Do not smoke or permit flames or
sparks near fuels or the fuel system.

Carbon monoxide.
Can cause severe nausea,
fainting, or death.

The exhaust system must be
leakproof and routinely inspected.

Generator set operation. Carbon
monoxide cancause severenausea,
fainting, or death. Carbon monoxide

is an odorless, colorless, tasteless,
nonirritating gasthat cancause 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 accumulate andseep backinside
a potentially occupied building or
vehicle. Do not obstruct the exhaust
outlet when parking your vehicle. The
exhaust gasesmust discharge freely to
prevent carbon monoxide from
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 monoxideis an
odorless, colorless, tasteless,
nonirritating gasthat cancause death if
inhaled for even a short time. Carbon
monoxide poisoning symptoms include
but are not limited to the following:

D Light-headedness, dizziness
D Physical fatigue, weakness in

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate
or speak clearly, blurred vision

D 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 improvewithin minutesof breathing
fresh air.

Inspecting the exhaust system.
Carbon monoxide can cause severe
nausea, fainting, or death. For the

safety of thevehicle’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.

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
into the vehicle interior through
windows, 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
handling and storing fuels. Store fuels
inawell-ventilatedareaawayfrom
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot 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
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do notoperate the
generator set 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 acontainer tocatch fuel
when draining the fuel system. Wipe up
spilled fuel after draining the system.

Hazardous Noise

CAUTION

Hazardous noise.
Can cause hearing loss.

Never operate 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
105 dBA. Prolonged exposureto noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.

Hazardous Voltage/
Moving Parts

WARNING

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Servicing the generator set when it
is operating. Exposed moving parts
can cause severe injury or death.

Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replace guards, screens, and
covers before operating the generator
set.

Moving parts.

TP-6687 9/106 Safety Precautions and Instructions

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 electricalcircuits. Turnoff themain
circuit breakers of all power sources
before servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on 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.
Remove alljewelry beforeservicing the
equipment.

Hot Parts

WARNING

Hot engine and exhaust system.
Can cause severe injury or death.

Do not work on the generator set until
it cools.

Combustible materials. Fire can
cause severe injury or death. A hot

exhaust system can ignite adjacent
combustible materials. Do not locate
electrical wiring, fuel lines, or
combustible materials above the
exhaust muffler. Exercise caution
when parking your vehicle to prevent
the exhaust system and hot exhaust
gases from starting grass fires.

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.

Testing live electrical circuits.
Hazardous voltage or current can
cause severe injury or death. Have

trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probes and followthe 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, approved electrically
insulated mat. (3) Do not touch the
enclosure or components inside the
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 connections when flashing
the generator set. The alligator clips
carry line voltage when the pushbutton
is pressed to flash the generator set.

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 cap
to relieve pressure.

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 washyour hands
and nails with soap and water shortly
after handlingused engineoil. 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.

TP-6687 9/10 7Safety Precautions and Instructions

Notes

TP-6687 9/108 Safety Precautions and Instructions

Introduction

This manual provides operation instructions for

1.4BEOR model generator sets.

Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented
without notice and without any obligation or liability
whatsoever.

Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and followthe
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.

For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the heading

Generators—Electric.

D Visit the Kohler Power Systems website at

KohlerPower.com.

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents

included with the product.

D Call toll free in the US and Canada 1-800-544-2444.

The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Obtain service from an authorized Kohler distributor/
dealer to keep equipment in top condition.

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

Headquarters Europe, Middle East, Africa
(EMEA)

Kohler Power Systems
3 rue de Brennus
93200 Saint Denis
France
Phone: [phone]
Fax: [phone]

Latin America

Latin America Regional Office
Lakeland, Florida, USA
Phone: [phone]
Fax: [phone]

D Outside the US and Canada, call the nearest regional

office.

List of Related Literature

Figure 1 identifies related literature available for the
generator set covered in this manual. Only trained and
qualified personnel should install or service the
generator set.

TP-6687 9/10 Introduction 9

Literature Type Part Number

Specification Sheet (Generator) G3-54

Operation Manual (Generator) TP-6687

Installation Manual TP-6688

Service Manual (Generator) TP-6689

Parts Catalog* TP-6690

Service Manual (Engine) TP-6579

* One manual combines Generator and Engine information.

Figure 1 Generator Set Literature

Notes

TP-6687 9/1010 Introduction

Section 1 General Information

1.1 Preliminary Information

The 1.4BEOR is designed to carry out the following
function:

D Recharge the battery system on which the generator

is installed. See battery equipment manufacturer’s

instructions.

Note: The terms 1.4BEOR, power unit, and generator

set are used throughout this manual and are

used interchangeably.

1.2 Operating Principle

The 1.4BEOR is able to charge 12-volt batteries.

1.3 Directive and Standard

References

Figure 1-1 and Figure 1-2 list the legal provisions and
EU directives.

Reference Title

P.D. 459 of

24.7.96

L.D. 476 of

4.12.92

Implementation of EEC Directive 89/392
known as the Machinery Directive

Implementation of EEC Directive 89/336
regarding electromagnetic compatibility
(EMC)

1.4 CE Identification Plate

The 1.4BEOR system is manufactured in a 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 1.4BEOR, inside the
front access panel on the power unit. 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

Figure 1-1 Legal Provisions

Reference Title

98/37 Machinery directive 89/392/EEC codified

89/336 Electromagnetic compatibility (EMC)

2000/2/EC Directive regarding electromagnetic

2004/104/EC Directive regarding electromagnetic

95/54/EC Directive regarding electromagnetic

ECE R10 ECE/UN regulation regarding

98/37

compatibility (EMC) for agricultural and
forestry tractors

compatibility (EMC) for motor vehicles
and their trailers

compatibility (EMC) for motor vehicles

electromagnetic compatibility for motor
vehicles

Figure 1-2 EU Directives

TP-6687 9/10 11Section 1 General Information

1.5 Service Views

Alternator

Exhaust

Muffler

Oil Fill

Engine Rear View Alternator-End View

Air Cleaner

Fuel Inlet

Oil Filter

Fuel Return

Remote Control

Top View

Connection Harness

Battery Wire
Harness

Digital Control View

Master
On/Off
Switch

Air Inlet

Oil Drain

Plug

Figure 1-4 Service Views

Alarm
Horn

Cleaner

Fuel

Solenoid

Valve

Oil Filter

Air

Service-Side ViewEngine-Front View

Oil
Dipstick

Fuel
Pump

Fuel
Filter

TP-6687 9/1012 Section 1 General Information

Section 2 General Description and Technical Data

2.1 Generator System

Figure 2-1 and Figure 2-2 show the main components
of the generator. The function of the generator is to
supply energy using a diesel engine. Contact an
authorized distributor/dealer for service.

1

2

1. Electronic control unit (ECU) 2. Power unit

Figure 2-1 System Components

2.1.1 Alternator

The function of the alternator is to keep the vehicle
battery and the system charged. See Figure 2-2.

tp6576

2.2 Operating Limit Conditions

Alternator operating limits: The 1.4BEOR power unit
uses an alternator that is able to supply enough energy
to guarantee the function mentioned under Section 2.1.

Minimum charge level of the vehicle’s battery
required for system operation: In the event that the

vehicle remains inactive for long periods of time and if
the system’s battery charging function is deactivated or
the battery charge level falls below 10.5 volts (minimum
threshold for the system to operate), the system will not
be able to start.

1

2

1. Muffler 2. Alternator

Figure 2-2 System Components

tp6576

TP-6687 9/10 13Section 2 General Description and Technical Data

Notes

TP-6687 9/1014 Section 2 General Description and Technical Data