Kohler 1.4BEOR-12V Operation Manual

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Page 1

Operation

Heavy Duty Truck Mobile Generator Sets

Model:

1.4BEOR-12V

TP-6687 9/10a

Page 2

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

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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

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Notes

TP-6687 9/104

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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.

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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

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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

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Notes

TP-6687 9/108 Safety Precautions and Instructions

Page 9

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: (33) 1 49 178300 Fax: (33) 1 49 178301

Latin America

Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619-7568 Fax: (863) 701-7131

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

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Notes

TP-6687 9/1010 Introduction

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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.

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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

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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

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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. 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.

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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. Muffler 2. Alternator

Figure 2-2 System Components

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

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Notes

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

Page 15

Section 3 Operation and Use

3.1 Prestart Checklist

WARNING

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

The exhaust system must be leakproof and routinely 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 ifinhaled 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 and seep back inside a potentially occupied building or vehicle. Do not obstruct the exhaust outlet when parking your vehicle. The exhaust gases must discharge freely to prevent carbon monoxide from deflecting into the vehicle.

Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine.

Air Inlets. Check for clean and unobstructed air inlets.

Air Shrouding. Check for securely installed and

positioned air shrouding.

Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and maintenance.

Exhaust System. Check for exhaust leaks and blockages. Check the muffler and piping condition and check for tight exhaust system connections. Inspect the exhaust system components (exhaust manifold, exhaust outlet, exhaust line, exhaust clamps, and muffler) for cracks, leaks, and corrosion.

D Check for corroded or broken metal parts andreplace

them as needed.

D Check for loose, corroded, or missing clamps and

hangers. Tighten or replace the exhaust clamps and/or hangers as needed.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, ordeath. Carbon monoxide

is a poisonous gas present in exhaust gases. Carbon monoxide is anodorless, colorless, tasteless,nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness

D Physical fatigue, weakness in

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate or speak clearly, blurred vision

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 operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts.

D Check that the exhaust outlet is unobstructed.

D Check the exhaust gas color. If the exhaust is blue or

black, contact your authorized Kohler distributor/ dealer.

D 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.

D 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 keep the tank(s) full to ensure adequate fuel supply.

Oil Level. Check the oil level. See Figure 5-4. Maintain the oil level at or near, not over, the full mark on the dipstick.

Operating Area. Check for 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 the generator set.

TP-6687 9/10 15Section 3 Operation and Use

Page 16

3.2 1.4BEOR Features

The 1.4BEOR is equipped with the features as shown in Figure 3-1.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, ordeath. Carbon monoxide

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

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate or speak clearly, blurred vision

3.3 Operating Modes

The generator can be operated by controls located on the remote control unit, according to the settings and procedures described in the paragraphs under Section 3.4, Operating Instructions.

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1. Main electric power supply fuses (min. 200 amp for 12-volt models)

2. Diesel on/off valve

3. Fixed protection cases

Figure 3-1 Features

WARNING

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

The exhaust system must be leakproof and routinely inspected.

Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an

3.4 Operating Instructions

3.4.1 Alarm Horn

An alarm horn sounds whenever the engine starts up. The alarm horn is automatically controlled by the ECU. It is activated during the last 5 seconds of glow plug preheating and is turned off at the end of the glow plug preheating time.

1. Alarm horn

Figure 3-2 Alarm Horn Location

TP-6687 9/1016 Section 3 Operation and Use

Page 17

3.4.2 Master On/Off Switch

Always place the master switch in the ON position before starting the unit. See Figure 3-3.

12 111098765

1. Master On/Off switch

Figure 3-3 Master On/Off Switch Location

3.4.3 Remote Control Unit

Note: Specification GM66134-SA2 includes

customer-selectable controller options:

D Option GM75866-KP1: 12.0 volt autostart with

protection against continuous APU operation during weak or dead battery condition.

D Option GM75866-KP2: 12.3 volt autostart with

protection against continuous APU operation during weak or dead battery condition.

D Option GM75866-KP3: 12.0 volt unlimited autostart

without the need to reset the controller.

Note: Specification GM66134-SA1 did not include

customer-selectable controller options. Specification GM66134-SA1 includes the same controller features as those indicated for option GM75866-KP1.

General Information

D Operating voltage: 10--16 volts

D Digital control system

D Variable lighting LEDs. Bright (day)--Dimmed (night)

D Reverse polarity protection

D LED self test on activation (ON) min. 3 sec.

D Protection fuses for control signal outputs

D Waterproof connectors

The control system is provided with a signal input (pin 7C) from the alternator (D+) of the vehicle engine. After the D+ is connected to the input on the control, if the generator set is activated, it will automatically stop the engine and reset the control system on a “Battery Recharge Standby Mode—LED on”. To completely reset the system turn the Machine Status Switch to position 0.

Back View

1. Machine status switch (3 position)

2. Engine start button

3. Not used

4. Battery recharge standby mode

5. Not used

6. Operating engine status

7. Engine oil pressure sensor

8. Engine oil temperature sensor

9. Alternator (D+) operation control sensor

10. Failure to start alarm

11. Glow plug preheating sensor

12. Hourmeter LCD unit

13. Service (500 hrs)

Connector

Detail

Figure 3-4 Remote Control Unit

1. Machine Status Switch:

I Manual Mode 0 Complete Stop Position II Automatic Mode

When the Machine Status Switch is activated (position I—Manual Mode), LEDs 7, 8, 9, and 10 will be illuminated during the pre-start system checks. The pre-start system check will ensure the correct operation of the engine protection system. After the engine starts, the LEDs will no longer be illuminated, indicating that the engine is being monitored for those fault conditions. Should a fault condition occur after the engine has been successfully started, one of these LEDs will again be illuminated to indicate which fault condition was detected.

TP-6687 9/10 17Section 3 Operation and Use

Page 18

Note: To reset all the activated protection signals,

select the Manual Mode (position I) on the Machine Status Switch.

After the battery is recharged, the controller will automatically shutdown the generator and will resume monitoring of the battery voltage.

2. Engine Start Button: The generator engine is started in manual mode by pressing the Engine Start Button. Keep the button pressed until the green LED switches on indicating a successful start of the engine. The system has a safety device that prevents the starter motor from activation should the Engine Start Button be accidentally pressed while the engine is on.

The controller is preset to only crank the engine for a maximum of 5 seconds per start attempt to protect the engine starter motor. If a second attempt to start the engine is required, press the Engine Start Button again.

Note: Start the engine (press the Engine Start

Button) only after the yellow LED for the Glow Plug Preheating Sensor is switched off.

3. Not Used

4. Battery Recharge Standby Mode:

A red LED.

If the Machine Status Switch is in the Automatic Mode (position II), the LED is illuminated to indicate that the automatic battery charging system is activated in the standby mode. If the battery voltage drops below the minimum set value, the system will activate the automatic start sequence.

The integrated automatic battery charging system has been designed to operate automatically (if the Machine Status Switch is in the Automatic Mode—position II) every time the battery voltage reading (13.6 volts as standard) is lower than the minimum set value, equivalent to approx. 12.0 volts or 12.3 volts.

Controller Options GM75866-KP1 and GM75866-KP2: A maximum of 5 automatic

start attempts is set as the default.

Controller Option GM75866-KP3: The maximum number of autostarts is not limited.

The maximum starting motor cranking time is 5 seconds for each attempt.

The minimum set time for unit battery recharge is 2.5 hours of uninterrupted operation (max. 110 A/h DC).

On the basis of tests carried out, the average time set is considered to be enough to provide correct recharge for a battery in good working condition.

Note: Before starting the engine, the automatic battery

recharge start system must wait for the glow plug preheating time and for the yellow LED for the Glow Plug Preheating Sensor to be switched off.

Note: Controller Options GM75866-KP1 and

GM75866-KP2: The battery recharge system is

set to a maximum of 5 consecutive battery recharge cycles (about 12.5 hours). If a higher number of cycles is needed, there might be a problem with the battery . The system will activate the engine protection and the red LED for the Battery Recharge Standby Mode will start flashing.

Note: Controller Option GM75866-KP3: If autostarts

occur every 2.5 hours, there might be a battery/recharging problem. Contact an authorized distributor/dealer.

5. Not Used

6. Operating Engine Status:

A green LED.

The Operating Engine Status indicates the generator engine is started. After the engine stops, the LED automatically switches off.

7. Engine Oil Pressure Sensor:

A red LED protection.

The Engine Oil Pressure Sensor monitors the engine oil pressure. If the oil pressure decreases to less than the minimum set value (less than 1.4 bar (20.3 psi)), the LED is illuminated and the engine will shut down automatically after 3 seconds. In case of failure, the LED will stay on to indicate the type of failure.

8. Engine Oil Temperature Sensor:

A red LED protection.

The Engine Oil Temperature Sensor monitors the engine oil temperature. If the engine oil temperature increases over the maximum set value (greater than 130° C or 266° F), the LED is illuminated and the engine will be shutdown automatically after 3 seconds. In case of failure, the LED will stay on to indicate the type of failure.

TP-6687 9/1018 Section 3 Operation and Use

Page 19

9. Alternator (D+) Operation Control Sensor:

A red LED protection.

The Alternator Operation Control Sensor monitors the correct operation of the DC alternator (alternator regulator). If a malfunction is detected (regulator failure or driving belt breakage), the LED is illuminated and the engine will be shutdown automatically after 3 seconds. In case of failure, the LED will stay on to indicate the type of failure.

10. Failure to Start Alarm:

A red LED protection.

The LED will flash if there were 5 unsuccessful starting attempts. The Machine Status Switch must be switched to the 0 position to clear.

11. Glow Plug Preheating Sensor:

A yellow LED.

Glow plugs are used to preheat the engine as an aid to starting. The amount of preheating time will vary depending upon the external temperature. The LED will be illuminated during engine preheating.

If the preheating system detects an operation failure, the yellow LED will start flashing when the Machine Status Switch is selected.

3.5 Scheduled Maintenance Functions

The 1.4BEOR has a counter that memorizes the number of operating hours of the diesel engine. Service after 500 hours maximum. The signal reminds the user to go to an authorized Kohler distributor/dealer to service the engine.

The 1.4BEOR (while running) has a sensor system capable of detecting malfunctions in the diesel engine. In the event of malfunction, the system automatically shuts down and signals the fault on the corresponding red LED. Identify and correct the cause of the fault. See the safety precautions at the beginning of this manual. Refer to Section 4, Troubleshooting.

Test operate the generator set to verify that the cause of the shutdown has been corrected.

Note: Start the engine (press the Engine Start

Button) only after the yellow LED for the Glow Plug Preheating Sensor is switched off.

12. Hourmeter LCD Unit:

The LCD screen.

The Hourmeter LCD Unit displays the system operation hours. The recording of the hours begins after the engine is started (green LED for the Operating Engine Status is on).

13. Service:

A yellow LED.

The service light indicates that the system needs servicing.

The service interval is preset at every 500 hours.

Contact an authorized distributor/dealer for correct servicing. Reset the Service light by pressing and holding the Engine Start Button for 5 seconds after the engine has been started.

TP-6687 9/10 19Section 3 Operation and Use

Page 20

Notes

TP-6687 9/1020 Section 3 Operation and Use

Page 21

Section 4 Troubleshooting

4.1 Problems, Causes and Solutions

This section contains generator set troubleshooting, diagnostic, and repair information.

Use the following table as a quick troubleshooting

Maintain a record of repairs and adjustments performed on the equipment. If the procedures in this manual do not explain how to correct the problem, contact an authorized Kohler distributor/dealer. Use the record to help describe the problem and repairs or adjustments made to the equipment. See Appendix B, Operating Hour Service Log.

reference. The table groups generator set faults and suggests likely causes and remedies. The table also refers you to more detailed information including sections of this manual, the generator set service manual, the generator set installation manual, and the engine service manual to correct the indicated problem.

Corrective action and testing often require knowledge of electrical and electronic circuits. To avoid additional

4.2 Mechanical Components

The table below lists mechanical components of the system and describes the problems that may occur while the 1.4BEOR is running. Use this troubleshooting chart to identify possible causes and relevant solutions. Use authorized technicians when specified.

problems caused by incorrect repairs, have an authorized Kohler distributor/dealer perform service.

Problem Possible Cause Solution

Engine does not start

Starts and stops

Incorrect injection timing.

Rings worn or sticking.

Valves sticking.

Loose cylinder locknuts.

Obstructed fuel line.

Air leaks in fuel system.

Clogged tank vent hole.

Injector sticking.

Injection pump valve sticking.

Faulty fuel feeding pump.

Fuel filter clogged.

Discharged battery.

Cable connections uncertain or incorrect.

Faulty starting switch.

Faulty starting engine.

Controller options GM75866-KP1 and GM75866-KP2: Reached maximum of 5 automatic restarts.

Clogged air filter.

Governor linkage wrongly set.

Low idle speed.

Fuel filter clogged.

Air leaks in fuel system.

Clogged tank vent hole.

Faulty fuel feeding pump.

See your authorized Kohler distributor/dealer.

Replace the fuel filter.

Charge battery; see equipment manufacturer’s instructions.

See your authorized Kohler distributor/dealer.

Reset by turning the Machine Status Switch to position 0 and back to the automatic mode.

Clean or replace air filter. See Section 5.4, Air Filter.

See your authorized Kohler distributor/dealer.

Replace the fuel filter.

Bleed air lines. See TP-6689 or your authorized Kohler distributor/dealer.

See your authorized Kohler distributor/dealer.

TP-6687 9/10 21Section 4 Troubleshooting

Page 22

Problem SolutionPossible Cause

Poor acceleration

Clogged air filter.

Overloaded.

Incorrect injection timing.

Governor linkage wrongly set.

Governor spring broken.

Fuel filter clogged.

Air leaks in fuel system.

Clogged tank vent hole.

Hardened injection pump rack.

Unsteady speed

Governor linkage wrongly set.

Air leaks in fuel system.

Hardened injection pump rack.

Oil level too high.

Black smoke

Clogged air filter.

Overloaded.

Injector not adjusted.

Extra fuel control level sticking.

White smoke

Excessive idle operation.

Incomplete run-in.

Incorrect injection timing.

Rings worn or sticking.

Worn cylinder.

Fuel filter clogged.

Air leaks in fuel system.

Faulty fuel feeding pump.

Oil level too high.

Low oil pressure

Worn main connecting rod bearings.

Oil pressure sticking.

Oil pressure regulator not adjusted.

Worn oil pump.

Air into oil suction line.

Faulty pressure gauge or pressure switch.

Oil suction line clogged.

Clean or replace air filter. See Section 5.4, Air Filter.

See your authorized Kohler distributor/dealer.

Replace the fuel filter.

Bleed air lines. See TP-6689 or your authorized Kohler distributor/dealer.

See your authorized Kohler distributor/dealer.

Bleed air lines. See TP-6689 or your authorized Kohler distributor/dealer.

See your authorized Kohler distributor/dealer.

Drain oil until correct oil level is restored. Check oil level.

Clean or replace air filter. See Section 5.4, Air Filter.

See your authorized Kohler distributor/dealer.

Replace the fuel filter.

Bleed air lines. See TP-6689 or your authorized Kohler distributor/dealer.

See your authorized Kohler distributor/dealer.

Drain oil until correct oil level is restored. Check oil level.

See your authorized Kohler distributor/dealer.

TP-6687 9/1022 Section 4 Troubleshooting

Page 23

Section 5 General Maintenance

WARNING

Accidental starting. Can cause severe injury or death.

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 asfollows: (1) Move the generator set master switch tothe OFF position. (2) Disconnect the power tothe batterycharger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

WARNING

Generator Set Service. Perform generator set service at the intervals specified by the generator set operation manual.

If the generator set operates under dusty or dirty conditions, use dry compressed air to blow dust out of the alternator. With the generator set running, direct the stream of air in through the cooling slots at the alternator end.

Routine Maintenance. Refer to the following generator set service schedule, the engine service schedule, and the runtime hours shown on the 1.4BEOR Remote Control Unit to determine when to schedule routine maintenance. Service generator sets that are subject to extreme weather or dusty or dirty conditions more frequently.

Service Log. Use the Operating Hour Service Log located in Appendix B to document performed services.

Service Schedule. Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set. For example, an item requiring service every 100 hours or 1 month also requires service after 300 hours or 3 months, 500 hours or 6 months, and 1000 hours or 1 year.

Fire. Can cause severe injury or death.

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

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate thegenerator set with

the air cleaner removed.

The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the generator set. Have an authorized Kohler distributor/dealer perform generator set service.

Engine Service. Perform generator set engine service at the intervals specified by the engine operation manual.

5.1 International Lubricant Specifications

The lubricant specifications define testing performances and procedures that the lubricants need to successfully respond to in several engine testing and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind.

A.P.I. American Petroleum Institute MIL Engine oil U.S. military specifications released

for logistic reasons

ACEA European Automobile Manufacturers

Association

5.2 ACEA Regulations, ACEA Sequences

5.2.1 Light Duty Diesel Engines

B1 = Low-viscosity for frictions reduction B2 = Standard B3 = High performance (indirect injection) B4 = High quality (direct injection)

TP-6687 9/10 23Section 5 General Maintenance

Page 24

5.2.2 Heavy Duty Diesel Engines

5.3.1 Engine Oil Selections

E1 = Obsolete E2 = Standard E3 = Heavy conditions (Euro 1 -- Euro 2 engines) E4 = Heavy conditions

(Euro 1 -- Euro 2 -- Euro 3 engines)

E5 = High performance in heavy conditions

(Euro 1 -- Euro 2 -- Euro 3 engines)

5.3 Lubrication System

Use oil that displays the American Petroleum Institute (API) service doughnut symbol for diesel engines on the container. Oils that identify this information meet U.S. and international performance requirements set by the engine manufacturers and lubricant industry including the Society of Automotive Engineers (SAE). See Figure 5-1.

D The top half of the doughnut identifies the oil

performance service level or the SAE viscosity category. Use only the recommended API category C for diesel-fueled engines.

D The center of the doughnut identifies the SAE

recommended grade of oil.

D The bottom half of the doughnut identifies the SAE

energy conservation category and may result in overall fuel savings.

Figure 5-2 shows additional information on which oil to use according to air temperature when cold starting the engine.

SAE viscosity grade

SAE category API classification

10W40 or 15W40 for

-- 1 8 _C(0_F) or above

5W40 for below

-- 1 8 _C(0_F)

Figure 5-2 Engine Oil Selections

Figure 5-3 shows the recommended SAE viscosity designation for a given operating temperature.

Oil: SAE...

122

104

-- 4

-- 2 2

-- 4 0

-- 2 0

-- 3 0

15W40

10W40

10W

10W30

20W20

5W30

5W40

Note: Using unsuitable oil or neglecting an oil change

may result in engine damage that is not covered by the engine warranty.

Note: DO NOT mix different oil brands. Incompatibility

could cause a breakdown of lubricating ingredients and reduce engine protection.

1. Oil Performance Service Level or SAE Viscosity Category

2. SAE Viscosity Grade

3. Energy Conservation Category

Figure 5-3 Viscosity Designation

5.3.2 Oil Check

Check the oil level before starting and after every 8--15 hours of usage. Use only an approved engine diesel oil available at your authorized Kohler distributor/ dealer.

To avoid engine damage, it is important to follow these instructions:

D Check engine is horizontal and level.

D Check the oil level before each startup.

D Check the oil level daily after the warm (not too hot to

touch) engine is in the stopped position.

D Check that oil level does not show a reading below

the ADD mark on oil dipstick or just below reservoir FILL mark. See Figure 5-4.

Figure 5-1 API Service Symbol Doughnut

TP-6687 9/1024 Section 5 General Maintenance

Page 25

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, fuelfilter, 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.

5.3.3 Oil Level Check

The recommended oil is AGIP Sigma super TFE multigrade 10W40 specification API CH-4/CF SL, ACEA E4, E5, E7, B4. See Section 5.3.1, Engine Oil Selections. Alternatively, we recommend using Mobil Delvac 1 SHC 5W40 specification API CF ACEA E4, B4,B3. Too high an oil level causes high oil consumption and engine carbonizing.

The 1.4BEOR uses 1.2 L (1.3 qt.) of oil. Too low an oil level damages the engine. This quantity must be strictly respected.

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1. Dipstick

Figure 5-4 Dipstick Location

D Check that oil level does not show a reading above

the FULL mark on oil dipstick or to the point of overflow in reservoir above the FILL mark. See Figure 5-4.

D Check the type of oil grade usageaccording to engine

startup operating temperatures. See Section 5.3.1, Engine Oil Selections.

Note: Use of multigrade oil above 0°C(32°F) will

increase oil consumption.

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

1. Make sure the vehicle is on a level surface and the power unit is stopped.

2. Make sure the power unit has come fully to a halt.

3. Wear special protective gloves and clothing for maintenance operations.

4. Unlock with the supplied plastic key, the top and front access panels on the power unit enclosure. See Figure 5-5.

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1. Top access panel lock

2. Top access panel

3. Front access panel fastener

4. Front access panel

Figure 5-5 Power Unit Enclosure and Access Panel

Locations

WARNING

5. Turn the Master Switch (see Figure 5-6) to the OFF position.

Fire. Can cause severe injury or death.

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

TP-6687 9/10 25Section 5 General Maintenance

Page 26

Top View of U n i t

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.

4. Unlock the top access panel on the power unit enclosure with the supplied plastic key. See Figure 5-5.

5. Turn the master control switch (see Figure 5-6) to the OFF position.

1. Master On/Off switch

2. Oil fill cap

Figure 5-6 Master On/Off Switch and Oil Fill

6. Remove the dipstick and check the oil level. The right oil level is close to, but not above, the MAX mark. When the level is below or just above the MIN mark, it is time to add oil. See Figure 5-4.

7. To add oil, unscrew and remove the oil fill cap and add the amount of oil needed using a funnel. See Figure 5-6.

8. Now check the oil level again using the dipstick as indicatedinstep6.

9. After you have correctly checked the level and refilled with oil, replace the dipstick, insert and screw on the oil fill cap, and correctly replace the enclosure access panel, tightening the lock with the aid of the supplied plastic key.

5.3.4 Oil and Filter Replacement

Replace the oil and oil filter every 500 hours. Contact an authorized Kohler distributor/dealer. If the unit is used infrequently, change oil every six months.

6. Unscrew and remove the oil fill cap to make it easier to empty the oil from the engine. See Figure 5-6.

7. Unscrew the oil drain plug on the bottom of the power unit in order to drain all the oil from the engine. When it is completely drained, insert the oil drain plug and tighten it using a wrench. See Figure 5-7 and Figure 5-8.

Front View of Unit

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1. Oil drain plug

Figure 5-7 Oil Drain Plug Location

Use the following procedure to replace the lubricating oil and oil filter. Refer to Section 5.3.3 for recommended oil.

1. Make sure the vehicle is on a level surface and is at a complete rest.

2. Wear special protective gloves and clothing for maintenance operations.

3. 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

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1. Wrench

Figure 5-8 Tightening Oil Drain Plug

TP-6687 9/1026 Section 5 General Maintenance

Page 27

8. Disconnect the oil pressure switch. See Figure 5-9.

FrontViewofUnit

Note: DO NOT pollute the environment. Dispose

of used engine oil and other contaminants in a safe, approved manner.

1. Oil pressure switch

Figure 5-9 Oil Pressure Switch Location

9. Loosen and remove the two screws and remove the oil filter cover. Make sure the oil filter cover gasket is intact and replace if it is damaged. See Figure 5-10 and Figure 5-11.

Front View of Unit

10. Remove the used oil filter and replace with a new filter. See Figure 5-12.

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1. Oil filter

Figure 5-12 Removing Oil Filter

11. Replace the oil filter cover with its gasket placed correctly and tighten it using the two screws.

12. Reconnect the oil pressure switch.

13. Using a funnel, pour enough oil into the tank through the upper opening.

14. Remove the oil dipstick to check the oil level. The right oil level is close to, but not above, the MAX mark.

1. Screw 2. Oil filter cover

Figure 5-10 Oil Filter Location

1. Oil filter cover gasket

2. Oil filter 3. Oil filter cover

Figure 5-11 Removing Oil Filter Cover

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15. After filling with oil, replace the dipstick, insert and screw on the oil fill cap, and correctly replace the top and front access panels of the power unit enclosure, locking them with the supplied plastic key.

TP-6687 9/10 27Section 5 General Maintenance

Page 28

5.3.5 Fuel Filter Replacement

Use the following procedure to replace the fuel filter.

1. Unlock the front access panel of the power unit enclosure with the supplied plastic key. See Figure 5-5.

2. Turn the master switch (see Figure 5-6) to the OFF position.

3. Remove the screw and remove the fuel filter clamp. Save these parts to reuse during reassembly. Remove the fuel filter from the power unit enclosure. See Figure 5-13.

1 1

1. Hose

2. Fuel filter

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Figure 5-14 Fuel Filter

5.4 Air Filter

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate thegenerator set with

the air cleaner removed.

Use the following procedure to clean or replace the air filter.

1. Unlock the front access panel of the power unit enclosure with the supplied plastic key. See Figure 5-5.

1. Fuel hose

2. Clamp

3. Fuel filter

4. Fuel filter clamp

5. Screw

6. Power unit enclosure

7. Support pin on the engine

Figure 5-13 Fuel Filter Components

4. Remove the clamps from the fuel hoses. See Figure 5-13.

Note: DO NOT pollute the environment. Dispose

of used engine oil and other contaminants in a safe, approved manner.

5. Remove the used fuel filter and replace with a new one.

6. Replace the hoses into the fittings on the fuel filter and reattach the clamps using pliers to fasten. See Figure 5-14.

7. Replace the clamp around the fuel filter and fasten it to the support pin on the engine using the screw.

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2. Turn the master switch (see Figure 5-6) to the OFF position.

3. Remove the air filter cover by turning the knob counterclockwise. See Figure 5-15.

1. Air filter cover

2. Knob

Figure 5-15 Accessing Air Filter

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TP-6687 9/1028 Section 5 General Maintenance

Page 29

4. Loosen and remove the wing nut inorder to remove the air filter. See Figure 5-16.

5. If the air filter is dirty or clogged, replace with a new air filter.

1. Wing nut

2. Air filter

Figure 5-16 Removing Air Filter

6. Before re-installing the air filter, make sure the rubber gasket is intact or replace,if necessary. See Figure 5-17.

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1. Prefilter

2. Air filter cover

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Figure 5-18 Prefilter

8. After cleaning, replace the prefilter on the air filter cover.

9. Reassemble the air filter, making sure that the rubber gasket is in the proper position, then tighten the wingnut.

10. Make sure the air filter is mounted correctly to prevent dust orimpurities entering the intake ducts.

11. Re-attach the air filter cover again by turning the knob clockwise.

5.5 Control Operation Following Maintenance

If leaks or dripping are found, operate as follows:

1. Rubber gasket

Figure 5-17 Rubber Gasket

7. Remove four screws to disassemble the prefilter and check for clogging. If necessary, remove it from its position on the lower part of the air filter cover. Clean if clogged by blowing air through the prefilter. See Figure 5-18.

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1. If the leaks are due to incorrect assembly of components, correctly reassemble the pipes and/ or components that have been modified.

2. If the leaks are due to breakage or system irregularities, contact an authorized Kohler distributor/dealer.

After completing the maintenance operations, replace the access panels on the power unit enclosure with the supplied plastic key. See Figure 5-5.

TP-6687 9/10 29Section 5 General Maintenance

Page 30

Notes

TP-6687 9/1030 Section 5 General Maintenance

Page 31

Section 6 Scheduled Maintenance

WARNING

Accidental starting. Can cause severe injury or death.

WARNING

Fire. Can cause severe injury or death.

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

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

Operations concerning mechanical components that must be performed every 500 hours:

D Operations to adjust the rocker arm blocks. D Calibration and cleaning injector. D Replacement of the compressor drive belt. D Maintenance of the cooling fins.

TP-6687 9/10 31Section 6 Scheduled Maintenance

Page 32

6.1 Service Schedule

Every

8--15 Hr. or

Perform Service at Intervals Indicated (X)

Diesel Fuel System

Check the fuel level and fill as necessary X

Check the fuel lines and routings for leaks X

Change the diesel fuel filter * X

Lubrication System

Check the crankcase oil level when engine is warm and add oil as necessary

Change the oil in the crankcase X X

Change the oil filter X X

Intake/Exhaust System

Inspect the exhaust system components *

Check the exhaust gas condition

Inspect the air filter X

Replace the air filter X

Inspect the complete exhaust system [ X

Electrical System

Keep the truck battery charged and in good condition ] X

Check and tighten electrical connections * X X

Clean the battery cables and connections *] As required

Engine and Mounting

Adjust the rocker arm clearance X

Calibrate and clean the injector X

Replace the alternator drive belt X

Service the cooling fins on the engine X

Check for water, fuel and oil leakage * X

Retighten all nuts and bolts (DO NOT tighten cylinder head fasteners) *

Generator

Test run the generator set

Blow dust out of the generator * X

* Consult your authorized Kohler distributor/dealer for service.

[ Should be performed by your authorized Kohler distributor/dealer. ] Consult battery manufacturer’s instructions.

Before Starting

(during operation)

As required

After

First

25 Hr.

(weekly)

Every

250 Hr.

Every

500 Hr.

Every

1000 Hr.

TP-6687 9/1032 Section 6 Scheduled Maintenance

Page 33

6.2 Engine Storage

Follow the procedure below when storing your

1.4BEOR engine.

Step Description

1 Unlock and open the 1.4BEOR. See Section 5, General Maintenance.

2 Start and run the generator set at minimum idle speed until it reaches operating temperature or about 15 minutes.

See Section 3.4.

3 Stop the generator set. See Section 3.4.

4 Place the generator set master switch in the OFF position. See Section 3.4.

5 Change the oil and replace oil filter. See Section 5, General Maintenance.

Note: Using an unsuitable oil may result in engine damage that is not covered by the engine warranty.

6 Start the generator set and check for fuel and oil leaks. See Section 5.5, Control Operations Following Maintenance.

7 Bring the engine to speed for 5--10 minutes.

8 Stop the generator set. See Section 3.4.

9 Consult the battery manufacturer’s instructions regarding battery care and maintenance.

10 Disconnect and remove the battery.

a. Locate battery connection plug. b. Locate battery cable connections attached to battery connection plug. c. Disconnect the generator set engine starting battery, negative (--) lead first.

11 Recharge the battery once a month to maintain a full charge.

12 Place the battery in a warm, dry location for the storage period.

13 Empty the fuel tank completely.

14 Replace the fuel filter.

15 Spray SAE 10W oil on the exhaust and intake manifolds.

16 Close all openings to prevent debris from entering.

17 Clean the exterior of the generator set and spread a light film of oil or silicon spray over any exposed surfaces that

may be subject to rust or corrosion.

18 Seal the air inlet, exhaust pipe, and fuel tank cap with adhesive paper tape.

19 Loosen the alternator belt.

20 Ensure all sides of the 1.4BEOR are secured and closed.

21 Select a well-ventilated (not humid or dusty) location to store the generator. If necessary, cover the engine with

protective sheeting.

Note: DO NOT store the 1.4BEOR engine directly on the ground, in damp environments, in areas exposed to the elements, or near sources of danger, including less visible hazards such as high-voltage power lines, etc.

22 After one year of engine inactivity, change the coolant. See your authorized Kohler distributor/dealer for service.

23 Run the generator set once a month whenever possible.

TP-6687 9/10 33Section 6 Scheduled Maintenance

Page 34

6.3 Restore Engine After Storage

WARNING

Fire. Can cause severe injury or death.

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

Step Description

1 Remove the protective sheeting.

2 Eliminate any blockages in the exhaust and intake ducts.

3 Use a cloth soaked in a degreasing product to remove the external protective treatment.

4 Remove the intake manifold.

5 Inject lubrication oil of no more than 2 cc (0.12 cu. in.) into the valves and install the intake manifold.

6 Adjust the alternator belt tension.

7 Turn the flywheel manually to check the movement of the mechanical parts.

8 Refill the tank with fresh fuel.

9 Start the engine and run at operating speed for 5--10 minutes.

10 Switch off the engine.

11 Remove the protective oil to replace with engine oil.

12 Introduce new oil up to the correct level marked on the dipstick. See Section 5, General Maintenance.

13 Replace the filters (air, oil, fuel) with original spare parts.

14 Empty the cooling circuit completely and pour in the new coolant up to the correct level. See your authorized Kohler

distributor/dealer for service.

15 Over time, a number of engine components and lubricants lose their properties, even when the engine is not in use.

Consider whether they need replacing based not only on mileage, but also on age and wear.

16 Install the 1.4BEOR engine and make the necessary connections and unions.

17 Make sure that electrical contacts are intact and efficient.

18 Check that the engine oil is up to level.

19 Start the engine and keep at minimum speed for a few minutes.

20 Check for leaks and, if necessary, find and eliminate the cause. See Section 5.5, Control Operations Following

Maintenance.

21 Switch off the engine.

22 Double check that the engine oil is up to level.

After a period of inactivity and before installing and running the 1.4BEOR engine, it is necessary to carry out a few measures in order to ensure that it runs at maximum efficiency.

TP-6687 9/1034 Section 6 Scheduled Maintenance

Page 35

Use the log in Appendix B tokeep a cumulative record of operating hours on your generator set and the dates required services were performed. Enter hours to the nearest quarter hour.

Section 7 Operating Hours

TP-6687 9/10 35Section 7 Operating Hours

Page 36

Notes

TP-6687 9/1036 Section 7 Operating Hours

Page 37

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control;

adj. adjust, adjustment ADV advertising dimensional

Ah amp-hour AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure alt. alternator Al aluminum ANSI American National Standards

AO anticipatory only APDC Air Pollution Control District API American Petroleum Institute approx. approximate, approximately AQMD Air Quality Management District AR as required, as requested AS as supplied, as stated, as

ASE American Society of Engineers ASME American Society of

assy. assembly ASTM American Society for Testing

ATDC after top dead center ATS automatic transfer switch auto. automatic aux. auxiliary avg. average AVR automatic voltage regulator AWG American Wire Gauge AWM appliance wiring material bat. battery BBDC before bottom dead center BC battery charger, battery

BCA battery charging alternator BCI Battery Council International BDC before dead center BHP brake horsepower blk. black (paint color), block

blk. htr. block heater BMEP brake mean effective pressure bps bits per second br. brass BTDC before top dead center Btu British thermal unit Btu/min. British thermal units per minute C Celsius, centigrade cal. calorie CAN controller area network CARB California Air Resources Board CB circuit breaker cc cubic centimeter CCA cold cranking amps ccw. counterclockwise CEC Canadian Electrical Code cert. certificate, certification, certified cfh cubic feet per hour

analog to digital converter

drawing

temperature

Institute

Institute (formerly American Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

cfm cubic feet per minute CG center of gravity CID cubic inch displacement CL centerline cm centimeter CMOS complementary metal oxide

cogen. cogeneration com communications (port) coml commercial Coml/Rec Commercial/Recreational conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards

CT current transformer Cu copper cUL Canadian Underwriter’s

CUL Canadian Underwriter’s

cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dB(A) decibel (A weighted) DC direct current DCR direct current resistance deg., ° degree dept. department DFMEA Design Failure Mode and

dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung

DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator E, emer. emergency (power source) ECM electronic control module,

EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems

EIA Electronic Industries

EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection

EPS emergency power system ER emergency relay ES engineering special,

ESD electrostatic discharge

substrate (semiconductor)

Association

Laboratories

Effects Analysis

e. V. (also Deutsche Industrie Normenausschuss)

engine control module

Association

Agency

engineered special

est. estimated E-Stop emergency stop etc. et cetera (and so forth) exh. exhaust ext. external F Fahrenheit, female fglass. fiberglass FHM flat head machine (screw) fl. oz. fluid ounce flex. flexible freq. frequency FS full scale ft. foot, feet ft. lbs. foot pounds (torque) ft./min. feet per minute ftp file transfer protocol ggram ga. gauge (meters, wire size) gal. gallon gen. generator genset generator set GFI ground fault interrupter

GND, gov. governor gph gallons per hour gpm gallons per minute gr. grade, gross GRD equipment ground gr. wt. gross weight H x W x D height by width by depth HC hex cap HCHT high cylinder head temperature HD heavy duty HET high exhaust temp., high

hex hexagon Hg mercury (element) HH hex head HHC hex head cap HP horsepower hr. hour HS heat shrink hsg. housing HVAC heating, ventilation, and air

HWT high water temperature Hz hertz (cycles per second) IC integrated circuit ID inside diameter, identification IEC International Electrotechnical

IEEE Institute of Electrical and

IMS improved motor starting in. inch in. H in. Hg inches of mercury in. lb. inch pounds Inc. incorporated ind. industrial int. internal int./ext. internal/external I/O input/output IP iron pipe ISO International Organization for

J joule JIS Japanese Industry Standard

ground

engine temp.

conditioning

Commission

Electronics Engineers

O inches of water

Standardization

TP-6687 9/10 Appendix 37

Page 38

k kilo (1000) K kelvin kA kiloampere KB kilobyte (2

bytes) KBus Kohler communication protocol kg kilogram

kg/cm

kgm kilogram-meter kg/m

kilograms per square centimeter

kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb. pound, pounds

lbm/ft

pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. shd. load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side L

LWL low water level

sound power level, A weighted

LWT low water temperature m meter, milli (1/1000) M mega (10

/hr. cubic meters per hour

/min. cubic meters per minute

units), male

cubic meter

when used with SI

mA milliampere man. manual max. maximum MB megabyte (2

bytes) MCCB molded-case circuit breaker MCM one thousand circular mils meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm, mΩ milliohm MOhm, MΩmegohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard ms millisecond m/sec. meters per second MTBF mean time between failure

MTBO mean time between overhauls mtg. mounting MTU Motoren-und Turbinen-Union MW megawatt mW milliwatt μF microfarad N, norm. normal (power source) NA not available, not applicable nat. gas natural gas NBS National Bureau of Standards NC normally closed NEC National Electrical Code NEMA National Electrical

Manufacturers Association

NFPA National Fire Protection

Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe

thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment

manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health

Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph., ∅ phase PHC Phillipsr head Crimptiter

(screw) PHH Phillipsr hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only

memory psi pounds per square inch psig pounds per square inch gauge pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart, quarts qty. quantity R replacement (emergency)

power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote Res/Coml Residential/Commercial RFI radio frequency interference RH round head RHM round head machine (screw) rly. relay

rms root mean square rnd. round ROM read only memory rot. rotate, rotating rpm revolutions per minute RS right side RTU remote terminal unit RTV room temperature vulcanization RW read/write SAE Society of Automotive

Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d’unites,

International System of Units SI/EO side in/end out sil. silencer SN serial number SNMP simple network management

protocol SPDT single-pole, double-throw SPST single-pole, single-throw spec specification specs specification(s) sq. square sq. cm square centimeter sq. in. square inch SS stainless steel std. standard stl. steel tach. tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to

normal TDES time delay engine start TDNE time delay normal to

emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal THD total harmonic distortion TIF telephone influence factor TIR total indicator reading tol. tolerance turbo. turbocharger typ. typical (same in multiple

locations) UF underfrequency UHF ultrahigh frequency UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal US undersize, underspeed UV ultraviolet, undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w/ with w/o without wt. weight xfmr transformer

TP-6687 9/1038 Appendix

Page 39

Appendix B Operating Hour Service Log

Use the log below to keep a cumulative record ofoperating hours on your generator set and the dates requiredservices were performed. Enter hours to the nearest quarter hour.

Operating Hours Service Record

Date

Run

Hours

Run

Tot a l

Hours

Service

Date

Service

TP-6687 9/10 Appendix 39

Page 40

Date

Run

Operating Hours Service Record

Hours

Run

Tot a l

Hours

Service

Date

Service

TP-6687 9/1040 Appendix

Page 41

Notes

TP-6687 9/10 41

Page 42

Notes

TP-6687 9/1042

Page 43

Page 44

TP-6687 9/10a

KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455

Kohler 1.4BEOR-12V Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual