PT-30KSI Operators Manual Power Technology Southeast
Contents
1. Power leen POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FLORIDA 34748 8102 352 365 2777 FAX 352 787 5545 TOP VIEW FOR POWER TECHNOLOGY MATERIAL NA TYPE DIMENSIONS BEND ALLOW NA 1 DATE 15JUNE10 PART 30 5 DWN BY KM SCALE NOT TO SCALE 1 SHEET2. HYHA i dHAOO XOLLdIS ALON sx did AL 531845 NOLLOA3NNOO LIOA 061 IIO ALLIKA SECTION 4 INSTALLATION SAFETY PRECAUTIONS 1 2 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 3 8 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 Enclosure View and Dimensions Base Pan Dimensions and Outlets SYSTEMS CONNECTION 9 12 Remote Radiator Cooling System Fuel System Exhaust System Fuel Line Diagram ELECTRICAL CONNECTIONS 13 16 Electrical Wiring AC Load Lead Connections Motor Loads Kilowatt De Rating Electrical Loads Appliance Loads Extension Cords BASLER AVC 63 4 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 B
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4. PT 30KSI Operators Manual Power Technology Southeast Inc 634 State Road 44 Leesburg FL 34748 8103 352 365 2777 Fax 352 787 5545 6 2010 PT30KSI FORWARD You are now the proud owner of a Power Technology Generator powered by a Kubota engine This engine 1s a product of Kubota s quality engineering and manufacturing The engine 1s 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 PT 2OKSI 2 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 EST PARTS BE OBTAINED DIRECTLY THROUGH POWER TECHNOLOGY AND SHIPPED THE SAME DAY IF ORD
5. adequate to safely maintain the amperage requirements proper size extension cord will help minimize the voltage drop between the generator set and remote location 120VOLIS 240VOLTS AWG I2 5 60 1200 500 300FT 200FT 50 600 1200 15 papass SE DOPE IST I0 EJ2U24 JI 9 ye 1224 pepeas Mod PAD Isa 212913 JI 10215 yy ZT ue a 258 2 5 rums 4299 2342 ON 213912 JE 1102 2243 520 300 1 LAH 5149715 ANIONS ONILLOOHS 1 1 Mog prous os aedy 1 1911615 mapis an q 5101880 7 dung SUP We MES 10 I0 531Ty 22 23 55 utut rede ON m yids 3402 d ON ang seq 12292 senma L sanja 091 503514 12992 12945 aou prag
6. 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 enance e Item Oil Level oration amp pe gt Oil e ter e it Level it Leakage it Change evel eakage ilter Re rent Iter Re ent sed Worn ose Belts Fuel Radiator amp Clamps mal Engine mal ator Noise Condition st Gas See Note neine Maintenance Service Schedule Remarks Or Once a Year Or Once a Year Or Once a Year As Necessary Or Once a Year Or Once a Year Or Every Two Years Or Every Two Years Once a Year 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 ser
7. drugs or while fatigued DO NOT wear radio or music headphones while operating engine CHECK BEFORE OPERATING THE ENGINE e Ifthe engine is malfunctioning DO NOT operate until repairs are made e sure all guards and shields in place before operating the engine Replace any that are damaged or missing e Check to see that the area around the engine is clear of foreigr objects before starting e Always keep the engine at least 3 feet 1 meter away from buildings or other facilities e DO NOT allow children or livestock to approach the machine while operation DO NOT start the engine by 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 E
8. side rails or coach under carriage Never run fuel lines inside of the coach Securely fasten the fuel lines with hardware that 1s 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 4 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 1s required 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 t
9. unless defective Power Tech materials 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 prod
10. ATION CHECK Engine Break in Period Daily Check OPERATING THE ENGINE Engine Starting Controls Check Engine After Starting Stopping the Engine ENGINE SPECIFICATIONS Kubota Model V 2203 MBG 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 NGINE BREAK IN PERIOD uring the engine break in period observe the following recommendations Change the engine oil and oil filter cartridge after the first 50 hours of operation See ENGINE OIL in ENGINE MAINTENANCE SERVICE SCHEDULE 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 AILY CHECK prevent future engine problems from occurring it 1s important to know and keep track of the engines yndition Below are items to be Inspected and Checked on a daily basis AUTION avoid personal injury Be sure all safety shields and guards are attached to the engine when operating e
11. DY AWAY FROM ROTATING PARTS e Keep your hands and body away from all rotating parts such as cooling fan v belts pulleys and flywheel Contact with these rotating parts can cause serious personal injury sure to stop the engine before adjusting belt tension or checking the cooling fan e 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 Glass odd pL ANTI FREEZE AND DISPOSAL OF FLUIDS e Anti freeze contains toxic chemicals Wear rubber gloves when handling anti freeze In case of contact with skin wash immediately to avoid personal injury DO NOT mix different types of Anti freeze The mixture can produce a chemical reaction resulting in the formation of harmful substances Only use anti freeze that 15 recommended and approved by Caterpillar Be mindful of the environment Before draining any fluids be prepared to dispose of them in a manner consistent with environmental protection regulations in your location When draining fluids from the engine use appropriate containers to hold the different fluids do not mix fuel oil or coolant together e 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 s
12. ERED BY 3 00 P M EST IF REQUIRED A MAJOR SERVICE MANUAL MAY BE ORDERED THROUGH POWER TECHNOLOGY S CUSTOMER SERVICE DEPARTMENT PLEASE HAVE THE GENERATOR MODEL AND SERIAL NUMBERS AVAILABLE WHEN YOU CALL THIS WILL HELP EXPEDITE SERVICE AND PARTS TO YOU 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 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 f
13. T SERVICE LIFE Coolant Type Service Life Commercial Heavy Duty Coolant Antifreeze that Meets ASTM D5345 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 1s 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 radiator 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 HRs RUN CUMLATIVE DATE SERVICES SECTION 3 GENERATOR END PRINCIPLES OF OPERATION Rotating Field Assembly Rotor Core Assembly Field Coil Voltage Connection Electronic Voltage Regulation Exciter Field Coil Voltage Source Balance B
14. To prevent a fire hazard keep foreign materials fuel and oil away from the battery wiring and engine Check and clear them daily Be aware of muffler and exhaust gas heat underneath engine compartment this heat may ignite grass or other flammable materials e Follow all safety precautions as outlined in the SAFE OPERATION section For accurate readings the engine should be on level ground when checking engine fluids Check fluids before starting the engine Cold Engine Lubrication System Check Engine oil level Check for Engine oil leaks e Cooling System Check coolant level and condition Check for coolant leaks Check for proper installation of the radiator cap Fuel System Check for sufficient quantity of fuel Check for fuel leaks Check engine after starting Warm Engine e 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 5 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 cranking the PT ECU 63 will check for an AC signal from the generator If an AC signal 15 verified the engine will sta
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16. arine use in a marine application USCG regulation 33CFR183 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 GENERATOR COMPARTMENT SIZE In planning the size of the generator compartment allow for the minimum clearance of 3 inches at the connection end and one 1 inch at all other sides 1s 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 NOTE For Gensets mounted inside an enclosure please refer to the section on Generator Enclosures for additional information and mounting requirements The generator set must be securely fastened to avoid unwanted movement from vibration and road shock If the unit 15 equipped with a mounting tray the tray 1s usually suppor
17. ccess 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 negative battery cable to the positive connection terminal of 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 COOLANT 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 15 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 1s essential that the ex
18. e 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 for specific details All wiring to the generator set shall be securely supported or harnessed to prevent abrasion Additional support 1s 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 1s equipped with a mechanism for removing the generator set from the compartment such as a mounting base or slide rack be certain all wiring 1s long enough to allow for free movement of the generator for servicing A separate 12 volt battery 15 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 c
19. e 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 All 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 lines 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 is 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 whi
20. earing Stator Assembly SERIES EXCITER TYPE GENERATOR ASEMBLY WIRING SCHEMATICS and RESISTANCE CHARTS 120 Volt Connection Series Exciter Type 120 240 Volt Connection Series Exciter Type 1 2 4 5 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 1n the exciter armature AC windings This voltage 1s 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 1s 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 15 accomplished by controlling the current fed to the exciter field coils Regulation is automatic with the static type voltage regulator An additional voltage adjustme
21. ervice be sure the engine is level and well supported Use approved stands designed for this type of service DO NOT service an engine that is only supported by a lift jack or hoist e Detach the battery from the engine before conducting service Put a NOT OPERATE tag in the key switch to avoid accidental starting e avoid sparks from an accidental short circuit always disconnect the 12V DC power at the battery Be 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 e Always use the appropriate tools and jig fixture when performing any 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 e 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 e When service is performed with two or more people present take care to perform all work safely Be aware of their location especially when starting the engine Keep a first aid kit and fire extinguisher handy at all times SECTION 2 ENGINE PRE OPER
22. esign of muffler or provided as a separate add on item 3 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 4 Extend the exhaust system a minimum of inch 25mm beyond the vehicles perimeter Never terminate the exhaust system underneath the vehicle 5 Terminate the exhaust system in a direction which prevents the exhaust gases from being drawn back into the generator compartment and re circulated 6 If exhaust system in located 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 7 To prevent excessive movement and vibration of the exhaust system install hangers and clamps designed for use exhaust systems 8 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 operati
23. haust 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 fuel 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 m
24. he USDA Forest Service Laws pertaining to application and maintenance of a Spark Arrestor may vary depending on your location and State regulations Federal laws apply on Federal lands If a generator 15 used in a forest on brush or grass covered unimproved land it must be equipped with a Spark Arrestor It 1s the responsibility of the vehicle owner or operator to install and maintain the entire exhaust system 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 15 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 15 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 The maximum allowable backpressure for the engines listed 1n this manual 1s 1 57in Hg 40mmHg 2 Muffler shall be fabricated of aluminized steel or other corrosion resistant material and be of a welded or crimp construction USDA Forest Service approved spark arrestor must be part of the integral d
25. ipment or property damage may result if instructions are not followed NOTE Indicates helpful information SAFE OPERATION Cautious operation 15 your best insurance against an accident Read and understand this section carefully before operating the engine All operators no matter how knowledgeable they may be should read this and other related manuals before operating the engine or any equipment attached to it It is the owner s responsibility to instruct all operators in safe operation Be sure to observe the following for safe operation OBSERVE SAFETY INSTRUCTIONS e Read understand and follow this OPERATORS MANUAL and LABELS ON THE ENGINE before starting and operating the engine e Learn how to operate and work safely Know your equipment and its limitations Always keep the engine in good condition e Before allowing other people to use your engine explain how to operate and have them read this manual before operation DO NOT modify the engine UNAUTHORIZED MODIFICATIONS to the engine may impair the function and or safety and affect engine life WEAR SAFETY CLOTHING DO NOT wear loose torn or bulky clothing around machinery Entanglement in rotating parts controls or projections may cause personal injury Use additional safety items e g hardhat eye protection gloves etc as appropriate or required DO NOT operate machinery or equipment while under the influence of alcohol medication or other
26. le the battery 15 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 related pulleys when unit 1s 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 1s running Have electrical service performed only by qualified electricians Be sure any unauthorized person especially children are denied a
27. llation charges of more than 1 hour labor 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
28. lts 1s 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 such 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 1s 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 15 an internal part of the static regulator The static regulator senses a change in the generator output and automatically regulates current flow 1n the exciter field coil circuit to increase or decrease the exciter field strength An adjustable rheostat sized to be compatible with the regulator 1s used to provide adjustment of the regulator sensing circuit 1 IHINASSV 3d ALL S31IH35 Hursnom JOTIE2 291 E st MOLY LS uri CNINRIGCU 20 LOCO HHCU 0 9 550 dcs TALALO 514 A UANG A 188 35 HOLVIS MYM 4 88 dOIlOS 5
29. lywheel housing intake and exhaust manifold only if flexible connection is used 3 Stand by Units are covered for a period of 1 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 sho
30. me motor loads common to mobile applications are listed 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 ELECTRIC MOTOR HORSEPOWER 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 1 for every 10 F 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 start
31. nerator 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 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 1s involved there 15 usually no starting problem provided of course the lighting and appliance load 15 not too high when unit 1s 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 1s 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 15 involved The starting and running requirements of so
32. ngine exhaust fumes can be very harmful if allowed to accumulate Be sure to run the engine in a well ventilated area where there are no people or livestock near by The exhaust gas from 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 e Relieve all pressure in the air oil and cooling systems before any lines fittings or related items are removed disconnected Be alert for possible pressure release when disconnecting any dev from a system that 1s 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 pers
33. nt range 1s provided 1f 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 very reliable device which uses solid state electronics to maintain voltage accuracy at 2 of the regulated voltage The Voltage Regulator 15 designed to automatically regulate and maintain generated AC voltage through out the load range that 1s 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 15 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 1s 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 vo
34. on an engine discharges deadly carbon monoxide with its exhaust Carbon monoxide 15 particularly dangerous since it 1s odorless tasteless and non irritating It can cause death if inhaled for even a short period of time Be especially careful 1 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 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 INVSHOVIC ANTI 1313 WOIdAL 4 ONYL OL NYNL3y ino 1903 damddns YAIWOLSND NI 137 1904 21412313 dali Tans 1428 5498 24 ZOTS Bi FE 9 5331 21915 8 9 LSWAHINOS YAMOd ANIDNA IV 531220 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 vehicl
35. onal injury e Fluid escaping from pinholes may be invisible Use piece of Hydraulic Line 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 e finjured by escaping fluid see a medical doctor immediately This fluid can produce gangrene or severe allergic reaction CAUTIONS AGAINST BURNS AND BATTERY EXPLOSION e 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 tighten Check radiator pressure cap and oil fill cap before operating the engine The battery presents an explosive hazard When the battery 15 being activated hydrogen and oxygen gases are extremely explosive e 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 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 BO
36. onnected 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 p 40 mg 2 2 po ISOM 124 6 2 AC LOAD LEAD CONNECTIONS some generator sets have four color coded leads The Black leads 11 amp L3 are hot The White or Gray lead L2 1s neutral and the Green lead 15 ground The load leads can 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 15 always the neutral lead on PTS generator sets Make sure neutral of the AC circuit in the vehicle 1s 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 1solated from the generator set when power is switched to the outside source 13 MOTOR LOADS When figuring ge
37. ou may have other rights which vary from state to state This Warranty 15 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 1s used throughout this manual and on labels attached the machine itself It warns of the potential for personal injury It 1s 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 equ
38. rt and the LED will remain ON during the normal run operation If the AC signal 1s not verified the PT ECU 63 will terminate the cranking cycle and LED will flash a fault code Starter disengages immediately after engine run 1s 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 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 SIOPPING THE ENGINE It is recommended to disconnect or reduce the power load from the generator before shutting down the engine Then follow the steps outlined above for normal shut down NOTE The PT ECU 63 is
39. s mounting area In an RV application this area 1s referred to as a compartment or enclosure 5 SYSIEMS 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 1s 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 15 generally shorter than the vehicles therefore fuel may not be available to the generator when fuel supply 15 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 15 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
40. s up this may possibly cause an overload situation 14 APPLIANCE LOADS Generator sets in recreational vehicles are often used to supply AC voltage 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 VER 20 12 y 10 _____ 112 RADO J J 1 e 1 00 1 0 12 85880 410 po _ 10 2 8 SO 122 120 2 po 1 40 1022 50 0 21122 RERIGEATOR SOD 122 FURNACEFANIGHP 6 02 12 FREEZER 1 JETWATERPUMPAHP 90 02 STOVE ELEMENT 100 SUBMERSILEWATERPUMPIHP 100 02 100 12 COFFEEMAKER 7 120 10 02 12 7120 02 211222 MICROWAVEOVEN 1500 SUBMERSIBLE WATER PUMP2HP 1002 122 WATER HEATER 3 450 22 EXTENSION CORDS An extension cord is normally used to provide electrical power from the generator set to a remote location The extension cord size and length must be
41. ss insulation with heat barrier may also be used NOTE Since a Genset 15 flexibly mounted the minimum clearance of one 1 inch will assure that the unit will not rub the sides of the compartment while the unit is in operation or while the vehicle is in transit COMPARTMENT FRAMING The generator must be bolted to a structural frame which 15 either bolted or welded to the frame of the vehicle This structural frame must be designed to withstand a minimum force of 5Gs in any direction The structural frame must support the entire outer perimeter and center section of the unit s base Additional framing may be required if excessive movement or vibration occurs AIR REQUIREMENTS Each Genset 1s equipped with a high ambient temperature shutdown switch and a high water temperature shutdown switch which will automatically shut down the Genset 1f the ambient temperature or water temperature rises 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 into the compartment is 500 sq in 3225 sq cm Remember that louvers screens and protective grills will restrict airflow A relatively open mesh screen can restrict airflow by as much as 45 The intake opening will need to be increased in size to compensate for such restrictions NOTE Ambient temperature 1s defined as the generators normal operating temperature within it
42. ted with structural framing Be sure to use all mounting holes in the tray to secure the tray to the structural framing Units not equipped with mounting tray are secured by attaching Genset mounts two front and two rear directly to the structural framing Skid mounted units can either be affixed to a tray for tray mounting or attached directly to the structural framing The generator 1s easily moved in and out of the coach by incorporating a slide rack carriage with rollers into the structural framing 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 or door must have an air intake opening equal to or greater than that 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 any hazardous fumes 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 3 layer foam sound mat is very efficient for absorbing generator noise This type of material 1s easily cut to size and can be quickly installed using the appropriate fire resistant adhesive Other materials such as fibergla
43. ucts or parts not purchased from Power 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 y
44. vice 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 33 F 106 C 223 F 60 Percent 51 C 60 F 111 C 232 F PROPYLENE GLYCOL Freeze Boil Concentration Protection Protection 50 Percent 29 C 20 F 106 C 223 F NOTE Do not use Propylene Glycol in concentrations 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 COOLAN
45. wn on the genset mounted hour meter THIS 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 A1 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 insta
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