PTSY-20-B20 20% Bio-Diesel Compliant Genset Operator
Contents
1. ELECTRIC MOTOR BASED ON CODE G ELECTRIC MOTOR HORSEPOWER STARTING WATTS RUNNING WATTS V 2000 1100 1 3800 1800 2 6000 2800 3 8000 4000 4 11000 5500 5 13000 6500 KILOWATT DE RATING units are rated at 1 0 power factor The Kilowatts of the generator set will decrease 3 5 per 1 000 feet 305m above 500 feet 152m above sea level De rate 196 for every 10 5 5 C above 68 F ELECTRICAL LOADS While the electrical load of the vehicle should have been calculated prior to purchase of the generator set you may want to recheck the load before installing the set to make sure the capacity is ample to meet the demands without possible overloading The lighting load is usually easiest to calculate in most cases simply add the wattage of each lamp to be operated off the generator set Note that in many applications not all of the lights or lamps are in the generator sets AC circuit Some are DC powered by the 12 volt battery in the vehicle Make sure the total includes only lights actually on the generator sets AC circuit The lighting load is usually not to heavy in mobile installations however it must be accurately calculated to prevent overloading For example if all lights are on at the same time and the air conditioner or other motor equipment starts up this may possibly cause an overload situation 14 APPLIANCE LOADS Generator sets in recreational vehicles are often used to supply AC voltag2. 21 188 SYSTEMS CONNECTION FUEL SYSTEM The diesel fuel system for the generator set must be designed to operate independently from the vehicles main engine if both engines are to be operated at the same time The best way to do this is to have separate fuel tanks but this is usually impractical because of space restrictions In most installations both engines operate from a common fuel tank with separate pick up tubes for each engine not a Tee fitting arrangement This prevents either or both engines from being starved for fuel The generator set fuel pick up tube is generally shorter than the vehicles therefore fuel may not be available to the generator when fuel supply is low This will prevent the generator from depleting the fuel supply needed by the main engine NOTE Using a simple Tee fitting to supply both engines from a common fuel line is not recommended This practice may possible cause a fuel starvation situation to either or both engines Also if excessive pressure were to build up in the main supply line it could possible cause a failure of the generators fuel lines or connectors and a hazardous fuel leak may occur Care must be taken when routing the fuel line from the main tank to the generator set Keep the fuel line as short as possible while maintaining adequate clearance from the exhaust system Fuel lines must be run along the frame side rails or coach under carriage Never run fuel lines inside of
3. 018 8 96 TA DUNASAAT XLOBDIN tv AVON ALVLS 69 LSVAH LNOS 4 TYNOLLdO S3DICNAS 351v 5 3OVIITIOA e prouspog RALA CENS ON ON SHA 1901 lt 91846 ond 99 OA MOT 80188019 YOPIMS 341836 10 md PI MJM 10 WI d ON qms UML Ajddng 05 Png 29 pny MOTD 001 29 2 79940 JISO2SIA jsneuxq IOUS ON Kao g MO TS SMNV31O ANIONA LON SAOd ANTIONGA SMNV3O ANIONA 15 LON THM SunpeJod JON WNO MOTD 19AO 10339 uopduinsuo 5 19AQ 559 uonsnquio 9jo duroou 8 IO 9 15890 A MONS MOV I3 MONS AAA IOUS ISNEYXH 59 A onq y prous og ong puy suMopjnus Ayayeg yoy 4 ur PNA RALA CENS I on 35 9 dISTA ON AAO
4. INIT 312 V IH INIT 312 V IH u TALMAN HIVTA 0I MIVTA 0 5 HO IVIS Veda 5 WNIT IVT VIOL HHAOLVISdIAGL LNSISINV NO AUVA TIM ONIGVAY ASTHL ALON ANIT VT V5 0I Un VD 91 VIN ozo DNIANIM DONISNAS PA PLA AV soduing 020 1 455 FLV Td SR Y N reel OVI IM POY YOLVLS evec LaL te xv 1117 96 VIN VIN re NIVIA 018 8 1 DUNASATT LIT VD 01 oco oco YOLV LS PT vr AVOA ALVIS 759 ONI LSVAHLNOS ADOTONHOAL 4 0100 SXAYN 12 9I LHVHO GWONVLSISHY 12 ANTTI OL ANTI SI IOA 07 TV LLOYIN OL ANTI SLTOA 021 5 5 5 WOH IVORILOTHI OV AMIT SIV TA ANIT 312 V IH u TALAAN NTA HIVTA OL V5 0I 5 NIV 5 13 5 TALIA s SINIL 3OWV IH 0 ANIT 2 1 90 TN 1 NO AAVA TIIM 4 HSHHL ALON WA PLA VO 91 oco 020 DNIGNIA DNISNAS rid Ve MV rodum 0 0 DNIGNI
5. VOLTAGE TEST Output Voltage OK Zero High Or Voltage Low Voltage Check AMP Check Replace Draw Main Breaker AVR From equipment On GenSet Check Load Distribution One Voltage Line Check may be Gen End Higher than the other 12 VOLT BATTERY TEST One Coil Both Coils Sensing Voltage Replace Low Voltage Low Voltage Low or None AVR Replace Stator Replace Check Stator Connections Check Engine RPM 1800 Replace Stator See Engine Troubleshooting Engine Problem OVERLOAD CONDITION Check AMP Draw Check Load Distribution Disconnect AVR Conduct 12 Volt Battery Test Check Stator Coil Resistance BAD Replace Stator OK Replace AVR And Test RESISTANCE CHART PTSMH MODELS SERIES EXCITER TYPE KW 15 17 5 20 Marks Color Main Stator Less Than 1 0 Less Than 1 0 Less Than 1 0 1 2 Black Black Ohm Phase Ohm Phase Ohm Phase T3 T4 Main Rotor 1 84 2 00 2 10 N A N A Exciter Stator 23 0 28 0 23 0 28 0 23 0 28 0 F C Black Black Exciter Rotor 0 655 0 720 0 655 0 720 0 655 0 720 N A N A Aux Winding 1 0 1 4 1 0 1 4 1 0 1 4 EI E4 Black Black SERIES EXCITER TYPE KW 16 21 Marks Color 020 020 2 10Ga Black Black Main Rotor 3 1 3 3 N A N A Exciter Stator 145 145 Fl F2 Red White Exciter Rotor Diode Plate Assembly
6. KSeries Exciter Type GENERATOR ASSEMBLY INFORMATION EXCITER TYPE GENERATOR The exciter pole pieces contain residual magnetism which sets up lines of force across the air gap to the exciter armature When the exciter begins to rotate a voltage is induced and current flow is initiated in the exciter armature AC windings This voltage is fed to the rotating rectifier assembly rectified and fed to the alternator field which sets up lines of force across the air gap to the alternator stator windings and to the output circuit A static voltage regulator is connected to the generator output The regulator will rectify part of the output voltage to provide a DC voltage to the exciter field coils This will increase the density of the lines of force in the exciter increasing the voltage induced into the exciter armature windings and therefore to the rotating rectifiers The rotating rectifier output will be increased which will increase the alternator field strength and generator output will build up its rated voltage Adjustment of the generator output to the rated voltage level is accomplished by controlling the current fed to the exciter field coils Regulation is automatic with the static type voltage regulator An additional voltage adjustment range is provided if desired by turning the Voltage Adjust Rheostat ELECTRONIC VOLTAGE REGULATION Electronic Voltage Regulator EVR also referred to as an Automatic Voltage Regulator AVR is a ve
7. PTSY 20 B20 20 Bio Diesel Compliant Genset Operator amp Installation Manual Power Technology Southeast Inc 634 State Road 44 Leesburg FL 34748 8103 352 365 2777 Fax 352 787 5545 e 4 2009 FORWARD You are now the proud owner of a Power Technology Generator powered by a Kubota engine This engine is a product of Kubota s quality engineering and manufacturing The engine is made with fine materials and manufactured under the strictest quality control standards and will assure you long satisfactory service To obtain the best use of your engine please read this manual carefully It will help you become familiar with the operation of the engine and contains many helpful hints regarding engine maintenance Continuing improvements and advancements in product design may have caused changes to your engine which are not included in this manual Please contact Power Technology s Customer Service Department for latest information on your Kubota engine or for the number of your local Kubota dealer TO OUR CUSTOMERS Thank you for your purchase of a Power Technology Generator The information contained in this manual applies to 15 PTSMH 17 5 and PTSMH 20 generators In the event you experience a problem with your generator please contact the sales dealer one of our authorized service centers or Power Technology s Customer Service Department directly at 1 800 760 0027 from 8 00 a m to 5 00 p m EST Please have the
8. only if flexible connection is used 3 Stand by Units are covered for a period of year from date of installation or 1000 hours or 24 months from the date of manufacture whichever comes first 4 Replacement Parts are warranted 30 days Excluding the following voltage regulators fuses controllers capacitors brushes and switches WHAT POWER TECHNOLOGY WILL DO Power Tech will at our option repair or replace any part covered by this warranty which becomes defective malfunctions or otherwise fails to conform to this warranty under normal use and service during the term of this warranty WHAT YOU MUST DO TO OBTAIN WARRANTY SERVICE In order to obtain warranty repairs you must deliver the product together with proof of purchase to an authorized Power Tech service facility In the case of repairs pertaining to the engine only you must use an authorized dealer or distributor of that make of engine to be covered under their warranty Engines used in the manufacture of Power Tech products are warranted solely by the engine manufacturer PRIOR APPROVAL IS REQUIRED FOR ANY WARRANTY SERVICE Failure to obtain authorization prior to the repair being performed will result in the claim being denied claims must be submitted within 30 days of the repair Along with the following a copy of the original repair order Power Tech authorization number Power Tech serial number and operation hours shown on the genset mounted hour meter TH
9. Hoses amp Clamps s Once a Near Abnormal Engine X Noise Abnormal X Generator Noise Muffler Condition X Exhaust Gas X Condition Engine oil and filter must be changed after the first 50 hours of operation Then every 100 hours or once a year whichever comes first Air filter replacement interval will vary depending on operating conditions Adverse conditions may require frequent service NOTE Under normal operation items such as Belts Hoses and Filters are not covered by Power Technology Southeast Inc Limited Warranty 4 ENGINE COOLANT MAINTENANCE COOLANT RECOMMENDATIONS For optimum performance Power Technology recommends a 1 1 mixture of water glycol NOTE Use a mixture that will provide protection against the lowest ambient temperature NOTE 100 percent pure glycol will freeze at a temperature of 23 C 9 F Most conventional heavy duty coolant antifreezes use Ethylene Glycol Propylene Glycol may also be used in a 1 1 mixture with water Ethylene and Propylene Glycol provide similar protection against freezing and boiling See the tables below ETHYLENE GLYCOL Freeze Boil Concentration Protection Protection 50 Percent 36 C 33 F 106 C 223 F 60 Percent 519 60 F 111 C 232 F PROPYLENE GLYCOL Freeze Boil Concentration Protection Protection 50 Percent 299 20 F 106 C 223 F NOTE Do not use Propylene Glycol in concentratio
10. 0 8M 8 8 8 AC LOAD LEAD CONNECTIONS Some generator sets have four color coded leads The Black leads L1 amp L3 are hot The White or Gray lead L2 is neutral and the Green lead is ground The load leads be routed directly from the junction box to the vehicle AC circuit or transfer switch connection installations require that the load leads be routed through flexible conduit from the generator end bracket to the junction box location The load lead junction box must be accessible for servicing and inspection AC load lead L2 White or Gray is always the neutral lead on PTS generator sets Make sure the neutral of the AC circuit in the vehicle is connected to the L2 White or Gray lead If equipment ground type plugs and receptacles 3 prong are used in the vehicle the green wire must be connected to the chassis ground On vehicles which also have provisions for using an outside AC power source the neutral lead as well as the Black L1 amp L3 hot leads must be completely isolated from the generator set when power is switched to the outside source 13 MOTOR LOADS When figuring generator set capacity requirements for installation involving motor loads do not overlook the high current demanded by the motor during start up The In Rush of starting current may be 2 to 5 times higher than that required when the motor reaches normal operating speed Reserve capacity must be allowed for in rush demands plus
11. 1 462 1 334 N A N A Aux Phase 0 20 Jumper N A Black Black Sensing Winding 0 20 0 20 N A 16Ga Black Black Hd ALL SIHLLIXH SHAS N NOLLOHNNOO LIOA OTI SO LV INIA S TIIOO Md AL SHINS NOLLOANNOO LIOA Orc OcI ATALVAVddS CXLV IOSI HV LLON 10 S OL ANII SLTOA 0 1 SARIS WON TVOM DATA OV wd NIT 312 V TH ANIT 312 V IH TALMAN LLAMA HIVTA V2 01 HIVTA V5 0I SHO LV IS HO IVIS SINIT 2 1 YOO ANIT HVT VIOL 1 NO DNIGNS48G AAVA TIM SONIGVAA HSHHL ALON Wel VD 91 VIN oco 020 DNIGNIA DNISNAS rid Ve MV idum 0 0 DNIGNIA ATENASSV ALV Td V N V N peel cov T HGOIG VOLO WALIOXA Spsce LSL TSE LLLC S9e TSE YM Gri Srl Stl HOLVIS WALIOXA 018 8vLVC Td OUNASATT VIN VIN SOIO vr AVON ALVIS vt9 weld 3 g VO 01 IA amp I 020 000 YOLVLS LSVAHLNOS ADO IONHOGLL YAMOd 30100 SXHIVIN Iz 91 LHVHO 40NVLISISWI 11 IVOILLOHIN OL ANTI 61 10 001 SATS AOA IVORILOTTH OV
12. IS HONON SNAN PAT PNA b GENI O s uno DOM 1033 o v dog a qeordd J 1033 1 P s wyo 7999 5 JOVI 9An 9joq SUNM 8 5 Un L jndjno NO SIIYVIAT 5 291 3D V L IOA 10 0447 pu u5 y9 UC juouidimbo S MBIG 8 y9 dlAV 1999 gt i REL O MO MOT A ISUIOA 10 1541 10335 o ve dos 93utjsisoy 100 103835 x29 IUISUY 99S ouidu q seq MBIA 1994 NOILIGNOS GVO THHAO 10
13. a radiator not supplied by Power Technology consult your radiator manufacturer to ensure that heat rejection values are met GENERATOR COMPARTMENT SIZE In planning the size of the generator compartment or bay allow for the minimum clearance necessary to adequately cool the generator set The thickness of insulation and sound deadening material used to line the compartment must be taken into consideration when planning this clearance To maintain minimum clearance it may be necessary to enlarge the compartment The generator set must be securely fastened to avoid unwanted movement from vibration and road shock If the unit is equipped with a mounting tray the tray is usually supported on the ends by angle iron and has a full door for service access Be sure to use all mounting holes in the tray to secure the tray to the vehicle support structure Units not equipped with mounting tray are secured by attaching Genset mounts two in front two in rear directly to the vehicle frame Skid mounted units can either be affixed to a tray for tray mounting or attached directly to the vehicle frame The generator is easily removed from the coach if a carriage with rollers is incorporated into the support structure When designing the compartment allow sufficient access for routine maintenance and for removal when major service is required Also keep in mind that the compartment door must have air intake opening having a free area equal to or greater than that
14. aware of others in your vicinity Make sure that your exhaust discharges away from other vehicles and buildings CAUTION Make sure the exhaust system components are positioned well away from drain openings beneath the generator set Also be sure not to block access to the oil drain plug 11 ANTI 1303 IVOIdAL OINVL OL and MO aariddns YIWOLSNID 1 NI 1309 13903 2T412313 earn 1305 55 8 25 XVI 59 25 bb 31V 1S 569 uel 26 02 DNI LSv3H 1n0S A90 10NH231 YIMOd 2 A SYSQNTIAD 3NISN3 LY S3TZZON 1 12 ELECTRICAL CONNECTIONS ELECTRICAL WIRING wiring must be applicable with local electrical codes A qualified licensed electrician must perform all electrical wiring connections Ground Fault GFCT breakers must be installed to protect all vehicle branch circuits All switches and controls must be securely mounted to prevent damage and accidental opening or closing from vibration road shock and vehicle motion Battery load leads and the remote switch panel connections are necessary for completing the installation Make final connections to the battery only after all other connections have been made as this will prevent unintentional starting Some specific details on each connection are stated in the following paragraphs Refer to the wiring diagram fo
15. generator model and serial numbers available when you call This will help expedite service and parts to you Parts may be obtained directly through Power Technology and shipped the same day if ordered by 3 00 p m EST Generator Model Number Generator Serial Number POWER TECHNOLOGY SOUTHEAST INC 634 STATE RD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 787 5545 www PowerTech Gen com Limited Warranty on Power Tech Generators Power Technology Southeast Inc warrants to you the original purchaser that each product of our manufacture is free from defects in materials and workmanship That each generator will deliver its rated output as indicated on The Power Technology Nameplate if properly installed serviced and operated under normal conditions in accordance with Power Technology s instructions THE WARRANTY COVERAGE TERMS 2 years from date of purchase or 3000 hours whichever comes first or 36 months from the date of manufacture Parts and labor including diagnostic labor removal and reinstallation are covered for the first 12 months from date in service or 1000 hours whichever comes first Parts and labor are covered only on the following generator and engine parts for 2 years or 3000 hours whichever comes first Generator Parts Main Rotor and Main Stator Engine Parts Cylinder Block cylinder head crankshaft camshaft cylinder head gears connecting rods flywheel and flywheel housing intake and exhaust manifold
16. if instructions are not followed NOTE Indicates helpful information OPERATON Cautious operation is your bst insurance against an accident Read and understand this section carefully bfore operating the engine All operators no matter hoWnoledgeale they may b should read this and other related manuals bfore operating the engine any eyipment attached to 1 415 the omer s responsillity to instruct all operators in safe operation Be sure to oberve the follomg for safe operation SFETWSRUTONS Read understand and follow this xOPERATORSMANHKL LABELSON TH E ENGNE bfore starting and operating the engine Learn howo operate and wrk safely Knowour egipment its limitations Alsv ys keep the engine in good condition Before allomg other people to use your engine explain how to operate and have them read this manual bfore operation DO NOT modify the engine KAUBREED MODFCATONSo the engine y impair the function andor safety and affect engine life WEAR SFETYLOTNG DO NOT war loose torn or blky clothing around machinery Entanglement in rotating parts controls or progctions may cause personal k additional safety ite ms eg hardhat eye protection gloves etc as appropriate or regired DO NOT operate machinery or hile under the influence of alcohol me dication or other drugs or hile fatigued DO NOT war radio or music headphone
17. of service DO NOT service an engine that is only supported by a lift jack or hoist Detach the battery from the engine before conducting service Put a DO NOT OPERATE tag in the key switch to avoid accidental starting To avoid sparks from an accidental short circuit always disconnect the 12V DC power at the battery sure to stop the engine and remove the key when conducting daily and periodic maintenance servicing and cleaning Check or conduct maintenance after the engine radiator muffler or muffler cover has cooled off completely Always use the appropriate tools and jig fixture when performing service work Be sure to understand and follow the instructions included with these tools e Use ONLY correct engine barring techniques for manually rotating the engine DO NOT attempt to rotate the engine by pulling or prying on the cooling fan and V belt Serious personal injury or damage to the cooling fan may occur Replace fuel hoses and hose clamps every 2 years or earlier whether they are damaged or not They are made of rubber and are aged gradually When service is performed with two or more people present take to perform all work safely Be aware of their location especially when starting the engine Keep first aid kit and fire extinguisher handy at all times SECTION 2 ENGINE PRE OPERATION CHECK Engine Break in Period Daily Check OPERATING THE ENGINE Engine St
18. other loads which could be on the line as the motor starts Air conditioning units are the most common type of motor loads for a generator set in a recreational vehicle The starting characteristics of the different makes of air conditioners vary greatly For example a particular 12 000 BTU unit may have lower starting requirements than a 10 000 BTU unit of another make When only one unit is involved there is usually no starting problem provided of course the lighting and appliance load is not too high when unit is started The trend seems to be toward larger capacity air conditioners and the use of more than one unit in larger vehicles Simultaneously starting two large units can present a problem if the capacity is marginal Because of the variation in starting characteristics of the different makes of air conditioners no definite statement can be made in this publication regarding multiple motor starting capabilities Delayed starting or use of easy starting devices on air conditioner units should be considered whenever simultaneous starting of more than one motor is involved The starting and running requirements of some motor loads common to mobile applications are listed in the table below Use this as a guide when selecting generator set capacity requirements involving motor loads Also note the Kilowatt De rating factor for generator set capabilities regarding air conditioners Capabilities will vary according to Kilowatt De rating
19. run the engine in a well ventilated area where there are no people or livestock near by The exhaust gas from the muffler is very hot To prevent a fire do not expose dry grass oil or any other combustible materials to exhaust gas Keep the engine and mufflers clean all the time To avoid a fire be alert for leaks of flammables from hoses and lines Be sure to check for leaks from hoses and pipes such as fuel and hydraulic by following the maintenance check list To avoid a fire do not short across power cables and wires Check to see that all power cables and wires are in good condition Keep all power connections clean Bare wire or frayed insulation can cause a dangerous electrical shock and personal injury CALIFORNIA Proposition 65 Warning Diesel Engine Exhaust and some of it s constituents are known by the State of California to cause Cancer Birth Defects and Other Reproductive harm ESCAPING FLUIDS Relieve all pressure in the air oil and cooling systems before any lines fittings or related items are removed or disconnected Be alert for possible pressure release when disconnecting any dev from a system that is pressurized DO NOT check for pressure leaks with your hands High pressure oil or fuel can cause personal injury Escaping hydraulic fluid under pressure has sufficient force to penetrate skin causing serious personal injury 28 Hydraulic Line Fluid escaping from pinholes may be invisible Use
20. starts but shuts down after Oil Bypass period due to low oil high temp extra Oil temp extra input wiring improperly connected Check wiring for proper connections Engine starts but running LED does not illuminate Fault short or overload on one of the annunciated outputs Check for fault once fault is corrected then operation resumes Annunciation output not working Fault short or overload on one of the annunciated outputs Check for fault once fault is corrected then operation resumes Preheat LED works OK but timer output does not activate Fault short or overload on timer output Check for fault once fault is corrected then operation resumes 17 PT ECU 63 ENGINE CONTROL MODULE 1 Generator Main Switch must be in the ON position 2 Hold Start Stop Switch for 1 second and release 3 Glow Plugs will preheat for 8 seconds LED flashes slowly 4 Preheating will cease during engine cranking cycle LED continues flashing 5 Engine begins an 8 seconds crank cycle After 4 seconds of cranking the PT ECU 63 will check for an AC signal from the generator If an AC signal is verified the engine will start and the LED will remain ON during the normal run operation If the AC signal is not verified the PT ECU 63 will terminate the cranking cycle and LED will flash a fault code 6 Starter disengages immediately after engine run is verified 7 PT ECU 63 deactivat
21. A ATENASSV ALV Td V N V N peel cov T HGOIG NOLO WH IIOXH lt lt 8 TSE LLLC S9e TSE YM Gri Srl Srl HOLVIS WALIOXA 018 8vLVC Td OUNASATT VIN VIN SOIO vr ALVIS 769 weld 01 IA amp I 000 020 YOLVLS LSVAHLNOS ADO IONHOGLL YAMOd 30100 SXHIVIN Iz 91 LHVHO 40NVLISISWI SECTION 4 INSTALLATION SAFETY PRECAUTIONS Hot Piping Dangerous Fuels Explosive Battery Gases Electrocution Moving Parts High Voltage Explosion Hot Coolant Lethal Exhaust Gas Excessive Noise Electrical Shock Backfire Flash Fire Fire Hazard Marine Application Unit Starts Without Notice Loose Components GENERATOR INSTALLATION in RECREATIONAL VEHICLES Introduction Marine Application General Information Specification Charts Fuel Consumption in Gallons per Hour Installation Factors Generator Compartment Size Compartment Frame Air Requirements Air Requirements Cont d SYSTEMS CONNECTION Remote Radiator Cooling System Remote Radiator Cooling System with AC Fan Remote Radiator Cooling System with DC Fan Fuel System Exhaust System Fuel Line Diagram ELECTRICAL CONNECTIONS Electrical Wiring AC Load Lead Connections Motor Loads Kilowatt De Rating Electrical Loads Appliance Loads Extension Cords ENGINE CONTROLS 552 Engine controller GAC ESD2110 Series Speed Control Unit PT ECU 63 Engine Control Module WIRING S
22. AD IN WATTS CORD LENGTH 120 VOLTS 240 VOLTS AWG 10 AWG 12 AWG 14 5 600 1200 500 FT 300 FT 200 FT 10 1200 2400 250 FT 150 FT 100 FT 20 2400 4800 125 FT 75 FT 50 FT 30 3600 7200 60 FT 35 FT 25 FT 40 4800 9600 30 FT 15 FT 10 FT 50 6000 12000 15 TROUBLESHOOTING Trouble Possible Cause Suggested Action Unit does not operate when powered to test mode Power leads to unit are reversed Confirm correct wiring for ground And bat and re attempt testing Bad ground connection from engine to controller unit Run wire directly from battery to the ground terminal 6 on controller unit Engine doe not crank Battery 15 low or terminals are dirty Clean terminals and re charge battery Replace battery 1f necessary Crank circuitry wiring improperly connected Refer to engine control wiring and check crank connections Bad ground connection from engine to controller Run wire directly from battery to the ground terminal 6 on controller unit Crank relay damaged Or on board fuse is blown Check wiring on board 10A fuse and relay Replace fuse relay and re test controller again Engine cranks but doesn t start Out of fuel Check fuel level add fuel 1f necessary Ignition control wiring not Refer to engine control wiring and check installed properly ignition connections Fuel relay damaged Check fuel relay and replace 1f damaged Engine
23. CHEMATICS 12 Volt DC Engine Control PT ECU 63 12 Volt DC Engine Control New Kubota Run Solenoid 12 Volt DC Engine Control for 200 300 400 Series 12 Volt DC Engine Control for 200 300 400 Series with Electronic Governor 12 Volt DC Engine Control for 500 Series 552 Auto Start System with Latching Relay 1 2 3 6 7 12 13 15 16 19 SAFTEY PRECAUTIONS A generator set can be potentially dangerous if not properly maintained and operated The best Safe Guard against a dangerous situation is education good judgment and common sense For safe trouble free operation of your generator set some general precautions are listed below Be sure to read understand and follow these precautions Please call Power Technology Southeast Inc with any concerns you may have with your generator set 1 HOT PIPING An engine and exhaust system may get extremely hot while running Do not work on a generator set until it has sufficiently cooled 2 DANGEROUS FUELS Use extreme caution when handling storing and using fuels fuels are highly explosive in a vaporous state Store fuel in a well ventilated area away from spark producing equipment Keep fuels and all chemicals out of the reach of children Never add fuel to the tank while the engine is running Spilled fuel may ignite on contact with hot parts or from ignition spark Always keep fuel lines and connections tight and in good condition Don t replace flexible fuel lines with rigid line
24. IS WARRANTY DOES NOT COVER THE FOLLOWING A Normal wear items including but not limited to turbo chargers fuel injector s starter alternator and electronic components as well as normal engine and or generator wear Travel time and fuel charges to and from the repair facility or travel time and fuel charges for mobile service Except stationary units with a maximum of 2 hours travel time B Defects malfunctions or failure resulting from accidents abuse misuse improper servicing improper installation improper storage and lack of performance of required maintenance service C Products which have been subjected to alteration modification neglect or unauthorized repairs D Troubleshooting routine service tune ups replacement of filters belts coolant lubricants hoses clamps exhaust system components fuel system components gaskets and or seals E Electrical items damaged by welding or jump starting F Damage caused by water ingestion or electrolysis G Damage caused by ingestion of substances other than clean filtered air fuel or intake water H Damage caused by faulty repairs performed by a repair facility not authorized in writing by Power Tech I Damage caused by operation with improper fuel or at speeds loads conditions modifications or installation contrary to published specifications or recommendations J Original installation charges and startup costs K Removal and re installation charges of more than 1 hour lab
25. OMBUSTION AIR TEMP N A N A N A Combustion Air Temperature The output of the engine will decrease about 1 for every 10 F of air temperature above 77 F or 25 C IMPORTANT Insulation and Sound Absorbing Material used inside of the generator compartment Must Not reduce the specified airspace clearances or restrict the airflow around the generator Such reduction in airspace may lead to an overheating situation and reduced generator performance Also be sure the air inlet and outlet openings meet the specified requirements Allow clearance inside the generator compartment for easy access when routine maintenance is required WARNING The generator compartment Must Be sealed to prevent hazardous fumes and vapors from entering the vehicles other compartments and interior spaces Plugging holes and sealing all seams will greatly reduce this hazard WARNING Drip Proofing When installing a generator the area directly beneath the generator end of the unit must incorporate a non flammable barrier This barrier needs to be made of sufficient material able to withstand and prevent molten metal burning insulation flaming or sparking particles from contacting any flammable materials at the bottom of the compartment SYSTEMS CONNECTION REMOTE RADIATOR COOLING SYSTEM Use the following data in designing and installing the generator set cooling system To insure a safe effective installation be sure the cooling system selected follows th
26. T Allow engine to cool and release pressure from the cooling system before opening the radiator pressure cap To release the pressure cover the radiator cap with a thick cloth then turn it slowly counterclockwise to the first stop After the pressure is released and the engine has cooled remove the cap 9 LETHAL EXHAUST GAS When installing an exhaust system position the tail pipe end so that the discharged gases may not be drawn into the vehicle interior through windows doors air conditioners etc The engine powering your generator set discharges deadly carbon monoxide as part of the exhaust gas when running It is essential that the exhaust system be leak proof and routinely inspected 10 EXCESSIVE NOISE Never operate the generator set without an adequate muffler or with a faulty exhaust system Exposure to excessive noise can lead to a hearing impairment 11 ELECTRICAL SHOCK A battery can cause electrical burns and shocks Use reasonable care when working near the battery to avoid electrical connections by contacting the battery terminals with tools Remove wristwatch rings and all jewelry when working on the generator set 12 BACKFIRE A sudden backfire can cause serious burns Do not operate your generator set without its air cleaner flame arrestor in place 13 FLASH FIRE A sudden flash fire can cause serious burns To avoid the possibility of a flash fire do not smoke or permit a flame or spark to occur near the carburetor fu
27. TERY VOLTAGE 12 VOLTS DC BATTERY CRANKING AMPS 420 BATTERY COLD CRANKING AMPS 590 MINIMUM BATTERY GROUND NEGATIVE FUEL CONSUMPTION IN GALLONS PER HOUR LOAD PERCENTAGE 15KW 17 5KW 20KW 25 33 39 GPH 45 GPH 5096 67 GPH 79 90 75 1 01 1 18 GPH 1 35 GPH 100 1 35 1 57 1 80 INSTALLATION FACTORS Each generator set 1s received as a unit which are shipped loose for assembly after the except for the optional exhaust system components set is installed in the vehicle When preplanning the installation the following factors must be considered 1 COMPARTMENT SIZE 2 AIR REQUIREMENTS 3 COMPARTMENT FLOOR 4 COOLING SYSTEM 5 FUEL SYSTEM 6 EXHAUST SYSTEM 7 ELECTRICAL CONNECTIONS Will there be sufficient room around the set to maintain the minimum clearance of one inch Are the compartment air inlets and outlets sized to allow adequate circulation of air for cooling and combustion Is the compartment floor strong enough to support the weight of the generator set Is the cooling system large enough to adequately cool the generator set Is the fuel system properly designed to prevent fuel starvation of either the main engine or generator engine Will the exhaust system meet all safety requirements after installation Will all systems battery load and remote switch be compatible with the vehicles system NOTE When using
28. Technology Power Technology reserves the right to make design improvements and model changes without any obligation to change units or parts previously manufactured Warranty registration card must be completed and mailed to Power Tech at the above address to validate the Warranty This is the only express warranty on Power Tech products No person agent or dealer is authorized to give any Warranties on behalf of Power Technology Southeast Inc and not to assume for Power Technology Southeast Inc any other liability in connection with any of its products unless made in writing and signed by an officer of Power Technology Southeast Inc LIMITATIONS ON OUR RESPONSIBILITY WITH RESPECT TO PRODUCTS PURCHASED AND USED FOR PERSONAL FAMILY OR HOUSEHOLD USE Our responsibility is to repair or replace defective parts as stated above We will not be responsible for any other expenses losses or inconvenience which you may Sustain as a result of the purchase use malfunction or defective condition of our products ANY IMPLIED WARRANTIES INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED IN DURATION TO THE PERIOD SET FORTH ABOVE Some states do not allow limitations on how long an implied Warranty lasts or the exclusion or limitation of incidental or consequential damages so the above Limitations or exclusions may not apply to you This Warranty gives you specific legal rights and you may have other rights which vary fro
29. XOCSTULUG NVONHSN NVONHSN NVONHSN HHAOO MAMOT MMSLI ASI HHSINN Luvd NOLdUS3d HALON x mj A IHIANRV 19290 6998 45 pepnjour 1o dnoo pue uez 2291 douo S amp THINRV 8 19M0 1 pojeedos 9 1ouueo 191 ou oooidouo e SATHIARV WA xx VNMICNHDOO I NADO A IHINSV NOSIULYG ATAUNSV NVB UNATTULYG UNGI ALAJ 140 ALV Id FUGTIOUAG SUGcsOUdG S NOM ONYO NOM ONYO ONC ICNN SO 9INIAV 0 A IHINRSV CV 0 SINAI CV 0 196 S VONOST Id HO ALV Id I AAMIC AAMOTI LYVd NGLdYSAG 8 L 9 cr m 4 4 E 199 Qu H TEHE LI ZERO oR LOW VOLTAGE Check Main Breaker is Check Gen Fuse Main Coil Replace pes i to Turn ON Fuse Breaker Panel Break ias danni Check Ohm s on Exciter Leads BAD 12 V Battery Test Replace Exciter OK Replace Voltage Regulator
30. a piece of cardboard or wood to search for suspected leaks do not use hands and body Use safety goggles or other eye protection when checking for leaks If injured by escaping fluid see a medical doctor immediately This fluid can produce gangrene or severe allergic reaction CAUTIONS AGAINST BURNS AND BATTERY EXPLOSION To avoid burns be alert for hot components during operation and just after the engine has been shut off Such as the muffler muffler cover radiator piping engine body coolants engine oil etc DO NOT remove the radiator cap while the engine is running or immediately after stopping Wait approximately ten minutes for the radiator to cool before removing the cap Be sure the radiator drain valve petcock and hose clamps are tighten Check radiator pressure cap and oil fill cap before operating the engine The battery presents an explosive hazard When the battery is being activated hydrogen and oxygen gases are extremely explosive Keep sparks and open flames away from the battery especially during charging DO NOT strike a match near the battery DO NOT check a batteries charge by placing a metal object across the terminals Use a voltmeter or hydrometer DO NOT charge a battery if frozen it may possibly explode Frozen batteries must be warm up to at least 61 F 16 C before charging KEEP HANDS AND BODY AWAY FROM ROTATING PARTS Keep your hands and body away from all rotating parts such as cooling
31. arting Controls Starting the Engine Check Engine After Starting Stopping the Engine ENGINE SPECIFICATIONS Kubota Model s V 1903 BG V 2003 T and V 2203 BG Service Parts ENGINE MAINTENANCE SERVICE SCHEDULE ENGINE OIL MAINTENANCE Checking Engine Oil Level Lubricating Oil Specifications Engine Refill Capacities Lubricating Oil Viscosity Recommendations ENGINE COOLANT MAINTENANCE Coolant Recommendations Ethylene Glycol Propylene Glycol Checking Radiator Coolant Level Coolant Service Life Checking Reservoir Tank Coolant Level Cleaning Radiator Core OPERATING HOURS AND SERVICE LOG ENGINE TROUBLESHOOTING GUIDES Engine Starts but Won t Run Engine Runs Rough or Slow Engine Will Not Start 8 10 PRE OPERATION CHECK ENGINE BREAK IN PERIOD During the engine break in period observe the following recommendations 1 Change the engine oil and oil filter cartridge after the first 50 hours of operation See ENGINE OIL in ENGINE MAINTENANCE SERVICE SCHEDULE 2 In ambient temperature above 32 F 0 C approximately 3 5 minutes without a load is sufficient for engine warm up Allow additional warm up time when temperatures are below 32 F 0 C before placing an operating load on the engine DAILY CHECK To prevent future engine problems from occurring it is important to know and keep track of the engines condition Below are items to be Inspected and Checked on a daily basis CAUTION To avoid personal
32. cranking the PT ECU 63 will check for an AC signal from the generator If an AC signal is verified the engine will start and the LED will remain ON during the normal run operation If the AC signal is not verified the PT ECU 63 will terminate the cranking cycle and LED will flash a fault code Starter disengages immediately after engine run is verified PT ECU 63 deactivates the Low Oil Pressure and High Water Temperature Switches for 6 seconds this will assure oil pressure build up time If oil pressure does not build up the engine will immediately shut down and go into a fault mode Likewise for a high temperature situation If engine will not start on the first attempt the PT ECU 63 will initiate the start cycle 2 more times before going into a fault mode Glow Plugs will preheat for 8 seconds per attempt Engine will crank for 8 seconds per attempt To shut down the engine under normal operations hold the Start Stop Switch for 1 second and release 10 If a fault occurs turn Generator Main Switch OFF and then ON to reset PT ECU 63 CHECKING ENGINE AFTER STARTING 1 2 3 4 Allow the engine to warm up 3 to 5 minutes before applying a load In colder climates allow few extra minutes longer Perform a visual inspection of all areas of the engine and generator Listen for any abnormal noises Check for any abnormal exhaust gases STOPPING THE ENGINE It is recommended to disconnect or reduce the power load from the gene
33. ction requirements of the generator and engine block when designing the cooling system A supplemental cooling fan capable of 500cfm 28 m min should be installed to supply air to the generator compartment for these requirements Connect the radiator fan motor to the generator output leads L1 and L2 Be sure the radiator fan motor rotates in the correct direction and is of the proper voltage To protect against overload and short circuits it is recommended that the motor be adequately fused Install fuses between the motor and L1 L2 connection A close relationship exists between the cooling system design and the generator compartment size Availability of space is often the determining factor in the cooling system design See the Compartment Size section of this manual prior to designing and installing the generator cooling system CAUTION The fill inlet and reservoir tank must be located at the highest point in the cooling system If the fill inlet is not located as directed coolant will not completely fill the engine The cooling system must be purged of all air pockets for the system to function properly If air pockets remain in the engine the high water temperature shutdown switch will malfunction and cause the engine to over heat Also if the cooling system 15 not completely full the low water level shutdown switch will prevent normal engine operations 20 438 REMOTE RADIATOR ASSEMBLY pre _ 27
34. e for appliances With the exception of a resistance type load such as a water heater requirements for appliances are usually low However such loads must not be overlooked when calculating the total wattage requirements To avoid an overload situation reserve capacity should also be calculated for unanticipated appliance loads The average power requirements for some common electrical appliances are listed below as a guide DETERMINING ALTERNATOR LOAD REQUIREMENTS CHECK Y APPLIANCE WATTS REQUIRED VCR 70 LIGHT BULB 100 RADIO 100 TELEVISION 100 STEREO 100 FRY PAN 150 HOME COMPUTER 150 VACUUM CLEANER 250 ATTIC FAN 1 4 HP 400 SUMP PUMP 1 3 HP 500 REFRIGERATOR 500 FURNACE FAN 1 3 HP 600 FREEZER 800 JET WATER PUMP 74 HP 900 ELECTRIC STOVE ELEMENT 1000 SUBMERSIBLE WATER PUMP 1 HP 1000 TOASTER 1000 COFFEE MAKER 1200 DISHWASHER 1200 HAIR DRYER 1200 MICROWAVE OVEN 1500 SUBMERSIBLE WATER PUMP 2 HP 1600 WATER HEATER 3000 OVEN 4500 TOTAL WATTS CHECKED EXTENSION CORDS An extension cord is normally used to provide electrical power from the generator set to a remote location The extension cord size AWG and length must be adequate to safely maintain the amperage requirements A proper size extension cord will help minimize the voltage drop between the generator set and remote location AMPS LO
35. e of static and dynamic blance Although the blance remain dynamically stale at speeds in excess of the design fregencies the prime mover should b adegately governed to prev ent excessive over speed fh centrifugal forces created b excessive over speed may dama ge the rotor mdings and field coils BEARNG The generator rotor assemby is suspended on a sh ielded factory luhicated baring A visual inspection of the baring is recommended at typical service intervals F signs of abormal var or leakage are oberved the baring should bre use ligids of any kind to clean the generator end and baring ABMBLY The stator assemby consists of laminations steel mounted in a rolled steel frame Random ound stator coils are fitted into the insulated slots A IHINRV N SuIsnouy 191 0 5 sy 1 Jo 18 ou j1un e SK TH ARV YOLVS NVN WA OAWDH OW ADOOZNADG ADOLEINADG ADO LSINA 70 ATSIASV OCNIAGLL3O INIA3LL3O SINN ALAO A TANSY NVIA OCNIAS 0 SINS ATANSV NVN 0 HO LO 5 HOOLS IHG 0 21 lt 1 ONG AVAF DNUCSTVSO DALS 0 HOLVS NUCST2LI O WATSTULUG
36. el lines fuel filter fuel pump or other potential source of spilled fuel or vapors 14 FIRE HAZARD Be careful when parking your vehicle to prevent grass fires from being started by hot exhaust gases or exhaust system Keep away from hot engine and generator parts to avoid burning yourself Keep the generator set and compartment clean and free of debris especially combustible materials Never store fuel oil or rags in the generator compartment 15 MARINE APPLICATION RV generator sets do not comply with United States Coast Guard USCG requirements They must not be used for marine applications Use only generator sets specified for marine use in a marine application USCG regulation 183 requires a generator set to be ignition protected for use in a gasoline fueled environment 16 UNIT STARTS WITHOUT NOTICE To prevent accidental starting on the units with remote start stop switch always disconnect the battery by removing the negative terminal first and then the positive Always disconnect the unit in this manner before working on the generator or any equipment connected to it 17 LOOSE COMPONENTS Periodically check for and tighten any fasteners that may have become loose from vibration or road shock Serious damage may possibly occur if components become dislodged or misaligned 2 SPECIFICATION CHARTS FUEL CONNECTION Ya NPT FUEL RECOMMENDATION DIESEL FUEL No 1 D or No 2 D ASTM D975 BAT
37. es the Low Oil Pressure and High Water Temperature Switches for 6 seconds this will assure oil pressure build up time If oil pressure does not build up the engine will immediately shut down and go into a fault mode Likewise for a high temperature situation 8 Ifengine will not start on the first attempt the PT ECU 63 will initiate the start cycle 2 more times before going into a fault mode Glow Plugs will preheat for 8 seconds per attempt Engine will crank for 8 seconds per attempt 9 release To shut down the engine under normal operations hold the Start Stop Switch for 1 second and 10 If a fault occurs turn Generator Main Switch OFF and then ON to reset PT ECU 63 Fault Codes Failure to start Engine High Water Temperature Low Oil Pressure No AC Signal Low Coolant Level Option 12VDC NOTE The PT ECU 63 is designed to operate on 12V DC power In a low battery situation the PT ECU 63 may not initiate the normal cranking cycle To start the generator you can press and hold the Start Stop Switch for approximately 10 seconds or until the engine starts Once the engine starts the PT ECU 63 will resume normal operations If this situation reoccurs charge or replace the battery 19 LED Flashes gt LI START STOP MASTER O4 SWITCH SWITCH LOW OIL 8 63 120 VAC 9 TOULNOD ANIONY AcI Srcc L8L 25690 LLLC s9 TSE
38. ese parameters Power Technology offers radiator assemblies which meet these requirements and will adequately cool the generator Select the radiator assembly best suited for the generator installation Due to the multitude of coach manufacturers and the variety of generator installations only general guidelines are provided Adapt these recommendations to the installation In a typical installation the radiator assembly 15 installed in the same compartment as the generator If a blower fan radiator assembly is used cooling air is drawn across the generator and engine and then through the radiator If a suction fan radiator assembly is used the suction fan pulls cooling air through the radiator and then past the generator set If the radiator assembly alone is used the installer must supply an electric blower or suction fan to circulate the cooling air See the specification table for total air requirements Depending on space limitations the radiator can be located in front of adjacent to or in a ventilated remote location from the engine compartment no more than 10 feet from the generator To prevent re circulation of heated air be sure to maintain a tight seal between the radiator and the discharge chute Generally the discharge chute opening should be approximately one and one half times the size of the radiator core NOTE If the radiator is to be located in a compartment separate from the engine refer to the engine combustion air and heat reje
39. fan v belts pulleys and flywheel Contact with these rotating parts can cause serious personal injury Be sure to stop the engine before adjusting belt tension or checking the cooling fan DO NOT run the engine without safety guards installed Be sure the safety guards are properly aligned and securely fastened before operating the engine 3 2222 Glass M Abit Fy ANTI FREEZE AND DISPOSAL OF FLUIDS Anti freeze contains toxic chemicals Wear rubber gloves when handling anti freeze In case of contact with skin wash immediately to avoid personal injury e DO NOT mix different types of Anti freeze The mixture can iia produce a chemical reaction resulting in the formation of harmful substances Only use anti freeze that is recommended and approved by Caterpillar Bemindful ofthe environment Before draining any fluids be prepared to dispose of them in a manner consistent with environmental protection regulations in your location e When draining fluids from the engine use appropriate containers to hold the different fluids do not mix fuel oil or coolant together Dispose of spent filter cartridges and batteries properly DO NOT pollute the soil or any water source Never pour fluids down a drain CONDUCTING SAFETY CHECKS AND MAINTENANCE When performing safety checks or engine service be sure the engine is level and well supported Use approved stands designed for this type
40. h a low voltage that air conditioning will have more difficulty in starting and long starting lines may overload generator and trip circuit breakers EXCITER FIELD COIL VOLTAGE SOURCE Field coil DC voltage is obtained by rectifying the voltage from the phase to neutral line of the generator output or either appropriate terminal to provide the needed voltage reference The rectifier bridge is an internal part of the static regulator The static regulator senses a change in the generator output and automatically regulates current flow in the exciter field coil circuit to increase or decrease the exciter field strength An adjustable rheostat sized to be compatible with the regulator is used to provide adjustment of the regulator sensing circuit 1 ROTATNG FELD The rotating field assemby consists bsically of four membrs 1 the shaft assemby 2 the core field coil damp mdings and Jblance lugs to provide a high degree of static and dynamic blance CORE ABMBLY The core assemby consists of a qantity of thin steel plates compressed and fastened together to form a single laminated assemby The fiel d imdings are wund around this assemby FELD COL Field coils of heavily insulated we are et vund directly onto the poles Field coil leads are bought out to the rectifier assemby for conn ection to the source of DC excitation voltage BALANCE The rotor assemby is precision blanced toahi gh degre
41. inch 25mm beyond the vehicles perimeter Never terminate the exhaust system underneath the vehicle 4 Terminate the exhaust system in a direction which prevents the exhaust gases from being drawn back into the generator compartment and re circulated 5 If the exhaust system in located in an area which may become susceptible to road damage from curbs speed bumps or other road obstacles a protective device such as a skid bar or plate should be installed 6 To prevent excessive movement and vibration of the exhaust system install hangers and clamps designed for use in exhaust systems 7 Never join or tee the generator exhaust system and the vehicle exhaust system together Doing so may cause excessive back pressure on the generator engine also condensation from one engine can damage the other engine WARNING LETHAL EXHAUST GAS When installing the exhaust system position the tail pipe end so that discharged exhaust gases are not drawn into the vehicle interior through windows doors air conditioners etc During operation an engine discharges deadly carbon monoxide with its exhaust Carbon monoxide is particularly dangerous since it is odorless tasteless and non irritating It can cause death if inhaled for even a short period of time Be especially careful if operating the generator set when parked under calm windless conditions Gases may accumulate in these conditions Park your vehicle so that the exhaust discharges downwind Always be
42. injury sure all safety shields and guards are attached to the engine when operating To prevent a fire hazard keep foreign materials fuel and oil away from the battery wiring muffler and engine Check and clear them daily Be aware of the muffler and exhaust gas heat underneath the engine compartment this heat may ignite grass or other flammable materials e Follow all safety precautions as outlined in the SAFE OPERATION section 1 For accurate readings the engine should be on level ground when checking engine fluids 2 Check fluids before starting the engine Cold Engine Lubrication System Check Engine oil level Check for Engine oil leaks Cooling System Check coolant level and condition Check for coolant leaks Check for proper installation of the radiator cap e Fuel System Check for sufficient quantity of fuel Check for fuel leaks 3 Check engine after starting Warm Engine Proper Operation Check for easy engine start Check for fluid leaks Check for abnormal engine noises Check for abnormal exhaust gas 1 OPERATING THE ENGINE ENGINE STARTING CONTROLS 1 2 3 4 3 6 7 8 9 Generator Main Switch must be in the ON position Hold Start Stop Switch for 1 second and release Glow Plugs will preheat for 8 seconds LED flashes slowly Preheating will cease during engine cranking cycle LED continues flashing Engine begins an 8 seconds crank cycle After 4 seconds of
43. l Filter Dirty Air Filter Engine Overheated Engine Over Loaded Clogged Muffler Over Fueling Injector Check Safety Shutdowns HIGH ALTITUDE And Fuel Solenoid Engine Cold Incomplete Combustion Over fueling Injector Glow Plug Not Activating Check With 12 volt DC Test Light ENGINE WILL NOT START Engine Does NOT Engine Crank Cranks SLOW Engine Cranks NO Smoke Exhaust From Smoke Exhaust Start Switch Starter Relay Oil Viscosity TOO HEAVY Check LOW Terminal Battery Ends Voltage Check Fuel Solenoid NO Check Power While Glow Plug Start ped Check Spark Arrestor Muffler for Clogging Defective Solenoid No Power From Starter Terminal 10 SECTION 3 GENERATOR END PRINCIPLES OF OPERATION 12 Rotating Field Assemby Rotor Core Assemby Field Coil Voltage Connection Electronic Voltage Regulation Exciter Field Coil Voltage Source Balance Bearing Stator Assemby SERIES EXITER TYPE GENERATOR ASEMBLY 3 KSERIES TYPE GENERATOR ASSEMBLY 4 GENERATOR END TROBLESHOOTING GIDES 3 Zro or Low Voltage Voltage Test 1 olt Battery Test Overload Condition RESISTANCE CHART _ 8 WIRING SCHEMATICS 93 10 Volt Connection Series Exciter Type 10 Volt Connection Series Exciter Type 10 Volt Connection KSeries Exciter Type VR 4 10 Volt Connection KSeries Exciter Type VR 3A 10 Volt Connection
44. m state to state This Warranty is in lieu of all other Warranties expressed or implied and of any other obligations or liability on our part Our responsibility for any and all losses and IN NO EVENT WILL WE BE LIABLE FOR LOSS OF USE LOSS OF PROFITS INCONVIENCE COMMERCIAL LOSS OR OTHER INCIDENTIAL OR CONSEQUENTIAL DAMAGES WHATSOEVER Power Technology S E Inc P O Box 490133 Leesburg FL 34749 USA Z code 04 20 2010 SECTION 1 SAFETY SAFE OPERATION 1 4 Observe Safety Instructions Wear Safety Clothing Check Before Operating the Engine Keep Area Around the Engine Clean Safe Handling of Fuel and Lubricants Exhaust Gases and Fire Prevention Escaping Fluids Cautions Against Burns and Battery Explosion Keep Hands and Body Away From Rotating Parts Anti Freeze and Disposal of Fluids Conducting Safety Checks and Maintenance SAFETY FIRST This symbol the industry s Safety Alert Symbol is used throughout this manual and on labels attached the machine itself It warns of the potential for personal injury It is essential that you carefully read the instructions and safety regulations before you attempt to assemble or use this unit WARNING Indicates a potentially hazardous situation which may possibly result in serious injury or possible death CAUTION Indicates a potentially hazardous situation which may possibly result in minor injury IMPORTANT Indicates that equipment or property damage may result
45. ns that exceed 50 percent glycol because of Propylene Glycol s reduced heat transfer capability Use Ethylene Glycol in conditions that require additional protection against boiling or freezing CHECKING RADIATOR COOLANT LEVEL Remove the radiator cap after the engine has completely cooled and check to see that coolant reaches the supply port 1 Fill to the bottom of the fill neck and check after every 25 hours of operation COOLANT SERVICE LIFE Coolant Type Service Life Commercial Heavy Duty Coolant Antifreeze that Meets ASTM 05345 3000 Service Hours or Two Years Commercial Heavy Duty Coolant Antifreeze that Meets ASTM D4985 3000 Service Hours or One Year NOTE Do not use a commercial coolant antifreeze that only meets the ASTM D3306 or D4656 specification This type of coolant antifreeze is made for light duty automotive applications CHECKING RESERVOIR TANK COOLANT LEVEL At a Minimum of 25 Hours of Operation Ensure that the coolant level of the radiator reservoir tank is between the upper limit FULL and the lower limit LOW on the side of the reservoir tank CLEANING RADIATOR CORE Visually inspect the core for any obstructions such as dirt or debris Use running water to clean particles from between fins IMPORTANT Never use hard objects to clean radiat
46. on and maintenance of a Spark Arrestor may vary depending on your location and State regulations Federal laws apply on Federal lands If a generator is used in a forest on brush or grass covered unimproved land it must be equipped with a Spark Arrestor It is the responsibility of the vehicle owner or operator to install and maintain the entire exhaust system in good working condition CAUTION Any person s who installs an unapproved Muffler Spark Arrestor or other exhaust system component and or modifies an exhaust system or component that may result in a hazardous condition is liable for damages injuries or warranty expense caused by such unapproved installation and or modification 10 EXHAUST SYSTEM IMPORTANT SAFETY TIPS When exhaust system components are not furnished by Power Technology as part of the Genset the installer is responsible for meeting the following requirements 1 Only use exhaust system components which do not restrict exhaust flow A restricted exhaust system will create excessive backpressure and may cause poor engine performance and possible engine damage 2 Maintain a minimum of 3 inches 76mm between the exhaust system components and any surrounding combustible materials If the minimum clearance cannot be maintained an insulating shield must be installed to prevent the combustible material from exceeding temperatures of 117 F 65 C above ambient temperature 3 Extend the exhaust system a minimum of 1
47. or core damage to core could result OPERATING HOURS and SERVICE LOG THIS SERVICE LOG IS PROVIDED TO HELP YOU KEEP AN ACCUMULATIVE RECORD OF OPERATION HOURS ON YOUR GENERATOR SET AND THE DATES REQUIRED SERVICES WERE PERFORMED ENTER TIME TO THE NEAREST HOUR OPERATING HOURS SERVICE RECORD DATE HRs RUN CUMLATIVE DATE SERVICES ENGINE STARTS BUT WON T RUN Unplug Remote Engine Runs Start Stop from Control Box Problem with Remote Connection Contact Jump across Equipment Manufacturer Oil Pressure Switch with Jumper Wire 2 pole Oil Pressure Switch Check Power Single Pole to Hold Circuit of Run Solenoid Disconnect Wire to Test Check Oil Pressure With Gauge If OK Has Power NO Power Replace Defective Solenoid Check Oil Pressure Switch REPLACE Safety Shutdown System Plug Remote Back IN Remove Wire From Water Temperature Switch Replace Switch Has Power NO Power Engine runs OK NO Power Remote OK Problem with Remote Replace Water Temperature Switch Check Wiring Check Shutdown Relay ENGINE RUNS ROUGH or SLOW NO Visible Exhaust Smoke Insufficient Fuel to Engine Excessive Exhaust Smoke BLUE Excessive Oil Level GRAY WHITE Check Replace Fuel Level Fue
48. or for outside units 2 hours for compartment mounted units and 3 hours for below deck marine units Customer is responsible for additional labor charges due to difficult access removal or installation L Starting batteries and labor or charges related to battery service M Loss of revenue or the rental of equipment due to down time N Generator repairs made within the warranty period other than by an authorized Power Tech service dealer without prior written approval from Power Tech warranty department O Damage caused by negligent maintenance such as but not limited to Failure to provide the specified type and quantity of lubricating oil cooling air flow and proper coolant mixture and level Failure to provide adequate air intake or maintenance of the air intake system Failure to provide scheduled maintenance as prescribed in supplied manuals P Engine fluids such as fuel oil or coolant antifreeze Q Shop supplies such as adhesives cleaning agents rags paint or other miscellaneous supplies R Use of other than factory supplied or approved repair parts or procedures Replacement of a failed Power Tech component with a non Power Tech component voids the Power Tech warranty on that component and any and all failures related to that component S Fuel injection pumps repaired by anyone other than the factory authorized dealer or distributor of that engine T Expenses incurred investigating performance complaints unless defective Power Tech materials
49. or workmanship are discovered U Generator sets used in rental applications V Cleaning service or repair of generator sets the have not been kept free of dirt debris or other items that prevent the unit from being able to operate properly W Any generator set not application approved X Loss of excitation due to prolonged storage Y Any damage attributed to low battery monitoring or automatic generator starting systems Z Optional accessories are warranted solely by the manufacturer of that item including but not limited to the following item Block heaters oil pan heaters electric cooling fans air bag isolators compartment heaters fuel tanks trailers battery chargers battery monitors To obtain warranty service For your nearest Power Tech authorized service center on the World Wide Web at http www powertech gen com parts_service php Call 1 352 365 2777 or write to Power Tech Warranty Department P O Box 490133 Leesburg FL 34749 USA Power Tech must be notified in writing within five 5 business days of any product failure General Conditions This Warranty is the sole property of the original owner user A transfer of ownership shall terminate this Warranty This Warranty is only valid within the contiguous United States and Canada Warranty coverage is available outside the U S and Canada please speak to a factory representative for those details This Warranty does not cover any products or parts not purchased from Power
50. r specific details All wiring to the generator set shall be securely supported or harnessed to prevent abrasion Additional support is required to prevent exposure to the exhaust system and any possible leakage of fuel oil or grease At least 2 inches of clearance must be maintained between electrical wiring and hot exhaust parts Wiring must not be located directly below or close to the fuel system oil fill and drain locations If the coach is equipped with a mechanism for removing the generator set from the compartment such as a mounting base or slide rack be certain all wiring is long enough to allow for free movement of the generator for servicing A separate 12 volt battery is recommended for the generator set With a separate battery cables should be kept short in length thus eliminating problems with excessive voltage drop See the Table below for cable size to length requirements NOTE A heavy gauge 4 ground strap must be connected between the ground lug on the generator set and the frame of the vehicle All wiring connections made at the time of installation should be readily accessible for periodic inspection and servicing DISTANCE BETWEEN CABLE SIZE AWG REQUIREMENTS GENERATOR SET AND AT VARIOUS TEMPERATURES BATTERY 0 18 C 32 F 0 C 75 F 24 C 40 12 2M 00 0 1 30 9 2M 0 1 2 25 7 6M 1 2 4 20 6 1M 2 2 6 15 4 6M 2 4 6 107 3 0 4 6 8 5 1 5M 6 6 8 2 57
51. rator before shutting down the engine Then follow the steps outlined above for normal shut down NOTE The PT ECU 63 is designed to operate on 12V DC power In a low battery situation the PT ECU 63 may not initiate the normal cranking cycle To start the generator you can press and hold the Start Stop Switch for approximately 10 seconds or until the engine starts Once the engine starts the PT ECU 63 will resume normal operations If this situation re occurs charge or replace the battery IMPORTANT Damage to the Starter Motor Starter Solenoid Run Solenoid or any generator component due to excessive or prolonged starting attempts attributed to an external Low Battery Control Monitoring or Auto Start System will not be covered by the Power Technology Southeast Inc Limited Warranty Engine Maintenance Service Schedule Maintenance Sun Service See Daily Every 100 250 Every 5001 1000 Remarks Note 25 Hours Hours Hours Hours Hours Engine Oil Level Deterioration amp X Leakage Engine Oil X Or Once Change a Year Oil Filter X Or Once Change a Year Coolant Level X Coolant Leakage X Coolant Change X Or Once a Year Fuel Level As Necessary Fuel Leakage X X Or Once a Year placement X Or Once a Year placement Damaged Worn X Or Every Two Or Loose Belts Years Replace Fuel Or Every Two X Hoses Years Check Radiator
52. related pulleys when unit is running Replace guards covers and screens before operating the generator set Serious personal injury may occur from contact with moving parts 6 HIGH VOLTAGE Remember the function of a generator set is to produce electricity Wherever electricity is present there is a potential danger of electrocution Apply the same precautions to the vehicles electrical appliances as you would for any home appliance Keep away from electrical circuits and wiring while the generator set is running Have electrical service performed only by qualified electricians Be sure any unauthorized person especially children are denied access to the generator set Keep the compartment door securely latched or locked at all times Be sure the generator is properly grounded Never touch electrical leads or appliances with wet hands or when standing on wet ground 1 7 EXPLOSION Never connect the negative battery cable to the positive connection terminal of the starter solenoid or test the battery by shorting terminals together This could ignite fuel vapors or cause the battery to explode To disconnect the battery remove the negative battery cable first and reconnect it last Do not modify the fuel tank or propulsion engine fuel system Your vehicle must be equipped with a fuel pick up arrangement as described in the Fuel System section of this manual Fuel tank and installation must conform to applicable regulations 8 HOT COOLAN
53. required if excessive vibration occurs AIR REQUIREMENTS Each engine is equipped with a high water temperature shutdown switch which will automatically shut down the set if the operating temperature climbs too high To prevent the generator set from shutting down make sure the compartment openings are large enough to allow adequate circulation of cooling air The minimum free air opening in the compartment door is 400 sq in or 2580 sq cm Remember that louvers screens and protective grills will restrict airflow A relatively open mesh screen will restrict airflow as much as 45 The intake opening must be increased to compensate for such restrictions NOTE Ambient temperature is defined as the generators normal operating temperature within its mounting area In an RV application this area is referred to as a compartment or bay 5 AIR REQUIREMENTS CONT D 15KW 17 5 20KW ENGINE SPEED IN RPM 1800 1800 1800 OUTPUT IN HORSEPOWER 26 36 6 325 WATER FLOW GAL MIN 7 93 8 75 8 75 ENGINE INLET WATER TEMP N A N A N A THERMOSTAT RATING 180 F 180 F 180 F THERMOSTAT FULL OPEN 1959 1959 1959 ENGINE OUTLET WATER 230 F 235 235 HIGH TEMP SHUTDOWN SITCH 230 F 230 F 230 F HEAT REJECTION BTU MIN 1295 1650 1650 HEAT REJECTION BTU HR 77 700 99 000 99 000 AIR FLOW CU MIN 2120 2120 2120 ENGINE OIL TEMP MAX 268 F 268 F 268 F C
54. ry reliable device which uses solid state electronics to maintain voltage accuracy at 2 of the regulated voltage The Voltage Regulator is designed to automatically regulate and maintain the generated AC voltage through out the load range that is from no load to full load VOLTAGE CONNECTION The generator may be connected at the terminal board to deliver 120 240 volts to a 3 wire grounded neutral system or 120 volts only to a 2 wire distribution system If any equipment requires 240 volts then the 120 240 volt connection must be used If all equipment requires 120 volts then the 120 volt connection is preferred even if two lines leave the same switch box The two lines at the inputs to the switch box are both connected to the un grounded 120 volt lines from the generator The 120 volt connection enables the Electronic Voltage Regulator EVR to hold the voltage very close to the 115 or 120 volts as initially adjusted regardless of the power distribution amount the different distribution lines The 120 volt connection is recommended if the entire electrical load requires only 115 or 120 volts Although the 120 240 volt connection may also be used when all loads requires only 110 volts it should be pointed out that this connection the 240 volts is regulated and the lightly loaded phase or line will deliver a high line to neutral voltage and the heavily loaded phase will deliver a low line to neutral voltage The heavily loaded line may have suc
55. s If you notice any fuel leakage fuel accumulation or electrical sparks DO NOT OPERATE THE GENERATOR SET 3 EXPLOSIVE BATTERY GASES The gases generated by a battery being charged are highly explosive Do not smoke or permit any flames or sparks to occur near a battery at any time especially when it 15 being charged Avoid contact between terminals with tools to prevent sparks and possible burns Always remove wristwatch rings or other jewelry before handling a battery Any compartment containing batteries should be well ventilated to prevent the accumulation of explosive gases To avoid sparks never disturb the battery charging connections while the battery is being charged Always turn off the battery charger before disconnecting terminal clips 4 ELECTROCUTION Failure to install a generator set with an electrical system consistent with governing regulations and standards is UNLAWFUL and may cause ELECTROCUTION of vehicle occupants Your generator set must not be used to Back Feed by connecting it to a building or outdoor electrical circuit Back feeding can cause serious injury or death to utility personnel working to repair a power outage and may also seriously injure persons in your vehicle Unauthorized connections are unlawful in some states and or localities A transfer switch must be installed to prevent interconnection of the generator set power and outside power 5 MOVING PARTS Keep hands feet and clothing away from belts and
56. s hile operating engine CHCK BEFORE OPERATNG TH ENGNE e fthe engine is malfunc tioning DO NOT operate until repairs are made sure all guards and shields in place bfore operating the engine Replace a ny that are damaged or missing Check to see that the area around the engine is clear of foreigr 5 bfore starting Alays keep the engine at least Feet from bildings or other facilities DO NOT allowhildren or livestock to approach the machine hile in operation DO NOT start the engine p shorting across starter terminals 1 KEEP AREA AROUND THE ENGINE CLEAN SAFE HANDLING OF FUEL AND LUBRICANTS EXHAUST GASES AND FIRE PREVENTION Be sure to stop the engine before cleaning Keep the engine clean and free of accumulated dirt grease and trash DO NOT stop the engine without idling Temperatures around the engine rises suddenly Keep the engine idling for about 5 minutes before stopping Always stop the engine before refueling or lubricating DO NOT smoke or allow flames or sparks in your working area Fuel is extremely flammable and explosive Never store flammable liquids in the engine compartment Refuel at a well ventilated and open place If fuel or lubricants spill clean up immediately and properly dispose of DO NOT mix gasoline or alcohol with diesel fuel The mixture can cause a fire Engine exhaust fumes can be very harmful if allowed to accumulate Be sure to
57. specified under the Air Requirements section of this manual Make sure that the compartment is vapor tight and completely sealed off from the inside of the vehicle to prevent exhaust or other items from entering the vehicle Avoid road splash and the possibility of igniting combustible materials beneath the coach by enclosing all unnecessary free space beneath the generator compartment Line the compartment with a good sound deadening material The material selected must be fireproof or highly fire resistant An available type of 3 layer foam material is very efficient for absorbing sound This type of material is easily cut to size with scissors and can be quickly installed using special fire resistant adhesive which bonds the material to almost any clean dry surface Other materials such as fiberglass insulation with heat barrier have also been used successfully in mobile installations NOTE Since a Genset is flexibly mounted the minimum clearance of one inch 2 inches at the radiator end will assure that the sides of the compartment and the set will not rub while the set is in operation or while the vehicle is in transit COMPARTMENT FRAMING The generator must be bolted to a metal frame which is either bolted or welded to the frame of the vehicle This frame must be designed to withstand a minimum force of 5Gs in any direction The frame must support the entire base plate around the outer perimeter and center section Additional framing may be
58. the coach Securely fasten the fuel lines with hardware that is recommended for the type of fuel line used The fuel lines should enter the generator compartment at a point nearest to the generators fuel line connection fittings Allow for a minimum of 8inches of flexible fuel line to make the connection Use proper size fuel line to accommodate the fuel flow needed Steel fuel line or high quality fuel hose is recommended either one should have a minimum of 14 ID and strong enough to withstand road and climatic conditions EXHAUST SYSTEM Exhaust system components will vary from one installation to another therefore a muffler and tailpipe may not always be furnished with the Genset However it is imperative to install a muffler and tailpipe to reduce exhaust noise and direct exhaust gases beyond the vehicles perimeter and away from the normal head on air stream Install a tail pipe with as few bends as possible to prevent excessive backpressure A properly installed exhaust system must be vapor tight quiet and completely safe for the vehicle its occupants and surroundings Installation of an approved Spark Arrestor is highly recommended The exhaust system components must be approved and properly installed to meet the codes and regulations required by Federal and State agencies Exhaust Mufflers and Spark Arrestors supplied by Power Technology meet code and standard requirements set forth by the USDA Forest Service Laws pertaining to applicati
Download Pdf Manuals
Related Search