PT-20KSI-2 Operator Installation Manual
Contents
1. NOM LNOM 128 SIMVIS INIONT ONILOOHS INIONA 23 15 LON TIM dung ve 10 9 1 1 MOTS ANIONA a 42242 1 ave or Seen 10 yusurdguba2. 1531 103835 SupooysaqqnorL 225 PAD NOW 1 SIMVIS INIONT SNILOOHS ANIONA
3. _ 91895 LIOA 01 SECTION 4 INSTALLATION SAFETY PRECAUTIONS ot Ping Dang Fp a Nigh tase tot GENERATOR INSTALLATION in RECREATIONAL VEHICLES Seance SYSTEMS CONNECTION ELECTRICAL CONNECTIONS PRECAUTIONS generator canbe potentially dangerous i at maintained and operated The best Sate Guard against a dangerous situation seduction good judgment and common sense For safe wouble fee operation of your generator st some general rections listed belo sure to ead understand abd Follow these precautions Peas call Power Technology Southeast Ine with any cancers you may have with your genera 1 HOT PIPING An engine and exhaust system may ho while running Do not work on 8 set un it as cooled 2 DANGEROUS FUELS Use exteme caution when storing and using fuels fuels are highly explosive vapors tat Store well ventilated area away fom spark producing equipment Keep fuels chemicals of the reach of eld Never ad fel o
4. or Auto Start System will not be covered by the Power Technology Southeast Ine Limited Warranty ENGINE SPECIFICATIONS MODEL 2203 MBG SERVICE PARTS Power Technology Air ith Plas Canister Alternator osBF0203 Engine Maintenane Schedule names every 100fevery 25 1000 Remarks Note Hours Hours Hours Level ration amp x row OF Once 5 is Or Once aver Leakage x Or Oneea Year AsNecesary Or Once wer Re Ve x Or Once a Year 5 Oe Belts Years Or Every Two Years Radiator Year nal Engine Mor Noise Condition x Fagin and Wer must be changed ae the SU Rows Then every Air ter replacement interval wl depending on operating conditions Adverse conditions may require service NOTE Under normal operation ims such Hoses and not co Technology Southeast In Limited Warranty ENGINE OIL MAINTENANCE CHECKING ENGINE LEVEL ADD mak 8 FULL mark 1 Maina the engine ol evel between snark and FULL o aleve gauge Do ot above FULL mat 2 Remove the
5. with as bends as possible to prevent excosive backpressure A exhaust system mist be vapor tight quiet and completely for the vehicle ts occupants and stutoundings Instalation ofan approved Spark Amestor The exhaust components must be approved and propery installed meet the codes and regulations Federal and State agencies Exhaust Murs and Spark supplied by Power Technology meet code and standard requirements st the USDA Forest Service Laws petaining aplication and maintenance Spark may vary on your locaton and State regulations Federal laws apply on Fedral lands generator used ina forest oa brush sass covered unimproved land he equipped witha Spark tis the responsibility ofthe vehicle owner or operator natal and maintain the ene exhaust system in good working condition CAUTION Any person 6 who installs an unapproved Mu Spark other exhaust system component andor modifies an exhaust sytem or component tht may in a hazardous condition fs ible or damages injuries or warranty expense caused by such unapproved installation andr modification IMPORTANT SAFETY TIPS exhaust system components by Power Technology as part ofthe Gens the for meeting the following Yequirements 1 Only use exhaus
6. transfer Sitch must be installed to prevent inftconnection ofthe geeratar st power and ouside power 5 MOVING PARTS Keep hands fet and clothing away belts and relate pulleys when uit Replace guards covers and sccons before operating the generator set Serious Injury may from with moving 6 HIGH VOLTAGE Remember the funtion ofa generator set 6 produce Wherever electricity present ther isa potential danger of electrocution Apply the same precautions the electrical appliances as you would far any hme appliance Keep circuits and wiring while the generator set is running Have electrical sevice performed only by quid electricians sure any unauthorized person especially are denied acess othe gencrator se Keep the comparunent door securely latched or locked tl times sure the generator properly grounded Never touch electrical or appliances with wet hands of when standing on Wet ground 1 connc the battery cable positive connection terminal ofthe solenoid ots the by shorting terminals together Tas could ante fel vapors or the Battery explode disconnect the remove the negative cable fist and reconnect Do modify the ful tank or propulsion engine ul sistem Your vehicle must be e
7. tthe rotating eters The rotating rectifier ouput wil be increased which the Alternator field strength and generator wll build up erated voltage Adhstnent ofthe generator utp to tered is accomplished by controlling the current fd othe excite coils Regulation is automatic with the type regulator An addtional voltage adjustment range is provided if desired by tuming the Voltage Adjust ELECTRONIC VOLTAGE REGULATION leconic Voltage Regulator EVR refered Automatic Voltage Regulator AVR savory oiable device which uses solid state elctoacs to maintain accuaey at 52 of the voltage The Voltage Regulator is designed to automatically epuate and maintain the AC volage through out he load range that f fom no lod ofl oad VOLTAGE CONNECTION The generator may be connected atthe terminal board deliver 120240 volts to wire grounded neural system only to a2 wite distribution sytem Ifany equipment requires then the 20 240 ol must be wed equipment requires 120 vlls then 8120501 connection is preferred even lines lave the same switch box The lines at he inputs tothe switch box are the ungrounded 120 olt lines fom generator The 20 valt connection enables Eleevonic Voltage Regulator EVR to hold the volage very close to the 11
8. 20 51 2 Operator Installation Manual FORWARD You ae now the proud of a Power Technology Generator powered by Kubota This engine sa product of Kubota s quality engineering manufacturing The engine made with fine materials and manufactured under the quality contol standards and will asure you Tong satisfactory service To obtain the best use of your engine please read this manual carefully wil you become familiar with he opeation ofthe engine and contains many help hints regarding engine mainfenance Continuing improvements and advancements in design may have caused changes your engine which ae ot included this manual Please contact Power Technology s Customer Service Department fr latest infomation on your Kubota engine or forthe numberof your Kubota dealer TO OUR CUSTOMERS THANK YOU FOR YOUR PURCHASE OF A POWER TECHNOLOGY GENERATOR THE INFORMATION CONTAINED IN THIS MANUAL APPLIES PT 2OKSI2 GENERATORS IN THE EVENT YOU EXPERIENCE A PROBLEM WITH YOUR GENERATOR PLEASE CONTACT THE SALES DEALER ONE OF OUR AUTHORED SERVICE CENTERS OR POWER TECHNOLOGY S CUSTOMER SERVICE DEPARTMENT DIRECTLY 1 800 760 0027 FROM 8 00 5 00 P M EST PARTS OBTAINED DIRECTLY THROUGH POWER TECHNOLOGY AND SHIPPED THE GAME DAY IF ORDERED 3 00 EST IF REQUIRED A MAJOR SERVICE MANUAL MAY BE ORDERED TH
9. holes and scaling cams Wi really this hazard WARNING Drip Proofing When installing generator the beneath the generator end of he unit mst incorporate a non flammable This brit be made of sufficient material able to withstand and prevent metal During insulation Naming sparking particles fom Petting te compartment oor or dipping beneth the lofi ee mats it SYSTEMS CONNECTION FUEL SYSTEM The diese ue system forthe generator st mst be designed to operate independently fom the vehicles main engine i both engines are to be operated atthe same time best way todo this isto ave separate ful tanks this is usually impractical because of space most installations oth engines operate Som a common fuel tank with separate pick up tes for each engine nota Tee iting arrangement This rents citer or bath engines being staved for ful The generator se us pickup ube i generally Shorter than the vehicles therefore may not be available tothe generator whet fel supply i This will event the generator from depleting te supply needed by the main engine NOTE
10. 8 Never jin or tee the generator exaust system and te vehicle exhaust system together Doing so excessive back pressure on the generator engine also condensation fom one engine an damage the otber engine 8 6 WARNING LETHAL EXHAUST GAS When installing sytem postion the pipe end so that discharged exhaust gases are not drawn int the vehicle through windows doors ait conditioner During operation an engine discharges deadly carbon monoxide with is exhaust Carbon monoxide is pariclaly dangerous since it odorless and ean death inhaled for even shot of time Be especially if operating the generator set whon parked under calm Conditions Gases may accumulate in these conditions your Vehicle thatthe exhaust discharges downwind Always be aware of others in your vicinity Make sure your exaust discharges away from thr vehicles and buildings CAUTION Make the exhaust system components are positioned well dain openings beneath he generator Also be to Block accesso the il dain plug 1905 WOIdAL 4 ELECTRICAL CONNECTIONS ELECTRICAL All wiring mst be applicable with cas qualified licensed electrician must perform all wiring connec
11. filer cap an il if necessary Clean the filer he il filler esp The capacities for the engine crankcase the approximate capacity of the sump plus a sander ier iter Systems will oqure addtional it KUBOTA REFILL CAPACTIIES 0 Sump nd Fier LUBRICATING OIL RECOMMENDATIONS The minimum ambient temperature daring cold agin start up and the maximum ambient temperature daring engine operation determine the proper SAE viscosity grade of ol Refer tothe Engine Viscosity Table Below Minimum Temperate ode determine the required oi viscosity fr starting an engine in cold Refer tothe Engine Viscosity Table below Maximum Temperature in onde to the Viscosity for engine operation a the highest temperate that is LUBRICATING OIL Temperature Visesiy SPECIFICAT SAE TOW Above2 C SAE 30 or Use only good quality which meets the following Specification SAE 20 oF SAEIOW 40 SAE 32 F SAE 1OW or Engine Oi 10 40 ENGINE COOLANT MAINTENANCE COOLANT RECOMMENDATIONS COOLANT SERVICE LIFE For optimum perfomance Power Technoloxy ecommends 1 1 mixture of wate glyco NOTE Use a mixture ha
12. Ambien temperature define asthe generators normal operating within mounting asa nan RV application this is referred to compartment or enclosure REQUIREMENTS CONT RW ENGINESFEEDIN 1800 OUTPUT IN HORSEPOWER 325 WATER FLOW GAL 375 ENGINE INLET WATER THERMOSTAT RATING THERMOSTAT FULL DSF ENGINE OUTLET WATER TEMP 256 HIGH TEMP SHUTDOWN SWITCH THEAT BTU 1650 HEAT REIECTION BTU 35 000 REMOTE RADIATOR 192 AIR FLOW FT MIN TENGINE COMBUSTION AIR TEMP Combustion Air Temperature The engine wll derease about 1 for very 10 F of ar temperature above 77 25 C IMPORTANT Insulation and Sound Absoybing Material used inside ofthe generator compartment Must Not reduce the specified airspace clearance of oe 1 restrict the alow around the Such reduction in aispace may ead overeating situation and reduced generator petfommance Also be the ai and outlet openings meet the specified requirements Allow inside the generator compartment for easy access when routine maintenance is quite WARNING The generator compartment Must prevent hazardous fumes and tering the vehicles other compartnents and
13. Using simple Te iting supply bath engines from a common ful in isnot recommended This practice may posible cause starvation situation citer ath engines Als if excessive presse Were buildup inthe main supply line posible caus ofthe generator fuel lines or connectors ad hazardous fel leak may occu Care must be taken wen touting the line from the main tank to te generator set the fe as shor as possible while mustang adequate clearance fom th exhaust system Fuel lines must be run along the frame side also coach unde carriage Never fun lines inside ofthe coach Securely ston the ful nes with hardware tats recommended forthe type of fuel line used The felines should enter the generator compartment point nearest the generators ft ine connection fitings Allow fora of Sinches of leible line make the conection Use proper siz lie to accommodate the fis Now needed Sel fel high quality ful hoses recommended ether one should have minimum of ID and strong enough to withstand oad and climatic conditions EXHAUST SYSTEM Exhaust system components wll vary from one instalation another therefore muffler and tailpipe not always furnished with the Gensel However itis imperative to installa muffler and to reduce exhaust ois and diet gases beyond the perimeter and away fom the normal head on air scam
14. is essential that you carefully read the instructions and safety regulations before you attempt to assemble use this unit sation which result in nites sation whieh IMPORTANT Indicates that equipment property damage may ifinsructions are nt followed NOTE ti SAFE OPERATION Cautious operation i your insurance an Read and understand this section before operating the engine operators mer how knowledgeable they be should read his ain tic elated manuals before operating te engine any equipment attached Teste owner s esponsibility all peratosin safe Be sure observe the following for safe operation OBSERVE SAFETY INSTRUCTION understand and this OPERATORS MANUAL and LABELS ON THE ENGINE before string and operating the engine Lear how to operte and work safely Know your equipment and imitations Always engine in good Before allowing other people use your enue expaia how to operate and fave them read this manual before operation DONOT modify the engine UNAUTHORIZED MODIFICATIONS tothe engine may impair the function andor safety and affect engine WEAR SAFETY CLOTH
15. 5 120 volts adjusted regardless ofthe power disuibution amount th ferent distribution lines The 120 voltconneetion srconmended if the electrical load only 115 120 volts Although the 120 240 volt connection may aso be whe requires only 110 vols shouldbe pointed out that this connection the 240 vols i regulated and thelial loaded phase Tin wil dtivera high line voltage andthe heal Toaded phase will deliver alow linet neutral voltage The heavily loaded line may have such alow voltage that ir conditioning wll have ore dificult in starting and long stating lines may overload generator and trip breakers EXCITER FIELD COIL VOLTAGE SOURCE Feld coll DC voltage is obtained by the voltage from the phase to line ofthe generator ouput or ets appropriate provide the needed voltage reference The rectifier bridge trad ofthe regulator The regulator senses change Jn the ouput and automatically regulates inthe excite Increase decrease th excite suength An adjustable rheostat sized be compatible with he egulatoris sed to provide adjustment ofthe regulator sensing WOLVWINGS SIAL WELDON ESE 501715
16. ADS When figuring generator set requirements for installation involving motor loads do nat overtook the high demanded bythe during start up The of starting may times higher that equted when the motor reaches normal operating speed Reserve capacity must be allowed fr in ash demands plus eer loads which could be on the line as the motor Airconditioning units are the most common ype of mots loads fora generator set ina recreational vehicle The starting characteristics ofthe diferent makes of air conditioners vary geal For example paticulr 12 000 BTU unt may have lower tring requirements hana 10 000 BTU mike When onl one unt involved thre i usually no starting problem provided course lighting and appliance lod isnot high when wit is stated The tad seems be toward laser capacity conditioners and the use of more than one lager ehicles Simullancously starting two lage units can present problem ithe s mara Because ofthe variation in stating characteristics ofthe diferent makes of ait condones no definite statement canbe made inthis publication regarding starting capabilites Delayed starting or use of easy starting devices on condone uns should he considered whenever simultaneous stating of more than one moter The and requirements of some motor loads common to mobile appliati
17. ENGINE ENGINE SPECIFICATIONS ENGINE MAINTENANCE SERVICE SCHEDULE 4 ENGINE MAINTENANCE ENGINE COOLANT MAINTENANCE OPERATING HOURS AND SERVICE LOG 1 CHECK BREAK IN PERIOD Ming the engine breakin observe the fllowing ecommendtions Change the engine and iter care after the fest 50 hours of operation ENGINE in ENGINE MAINTENANCE SERVICE SCHEDULE ambient temperature above 32 F C approximately 3 5 minutes without lod for engine warm up Allow ational warm uptime whea temperatures are below 32 F 0 C before placing an operating load on the engine AILY CHECK prevent engine problems fom occurring itis important to know and keep tack ofthe engines Below ate itm tobe Inspected and Checked basis AUTION avoid personal injury safety and guards are atachod to the engine when operating 5 To preventa fie hazard foreign materials ful and away fom the wing and engine Check and clear them daily Be aware ofthe muller and exhaust gas heat underneath engine compartment this heat may ignite gras other mater Follow all safety precautions as outlined inthe SAFE OPERATION scion For accurate readings the engine should be on level ground when checking engine us Check Hid before staring the engine Col
18. ING NOT wear loose om or bulky clothing around machinery Entanglement in pats or projections may eats personal injury Use suditional eye loves et appropriate o required operate machinery or equipment while ude the inMuence of leah mediation other dng ot while DONOT wear radio or music headphones while operating CHECK BEFORE OPERATING THE ENGINE engine malfunctioning DO NOT ae made Best all guards and rein place before operating the engine Replace ay hat are damaged or Check to soe that he asa around the engine is ler of starting Always keep the at eat aay fom other Tails 5 NOT allow ivestck approach the machine while in operation 5 sur the engin by shorting across starter 1 KEEP AREA AROUND THE ENGINE CLEAN Be sure to stop the engine before cleaning clean fie of accumulated di grease stop the engine witout dling Temperatures around the engine ses suey Keep the engine fr about 5 minutes before sopping SAFE HANDLING OF FUEL AND LUBRICANTS Always stop the engine before or lubricating stoke or allow sparks in your working flammable and ex
19. N In RECREATIONAL VEHICLES INTRODUCTION Use thissetin guide when installing a generator in a recreational vehicle and then refer tothe appropiate operation section fr specific instructions When installing a RV generator set the must comply withthe Safety Sundards of ANSI RVIA EGS 1 2003 ANSI 192 NFPA SOIC and applicable articles of ANSI NFPA 70 ofthe National Code Generator set insulation must also comply with state and local requirements MARINE APPLICATION RY generator ses not comply with United States Coast Guard USCG requirements and must not be used for marine applications Use only generator sets fr marine sein marine Insalations USCG regulation 153 requires a generator be ignition protected when used Jina gasoline envionment INFORMATION This information section covers the RV generator set models listed below detemnine which model involved check the mode number found onthe Power Technology nameplate attached the frame ofthe being installed Fllo all ensure proper installation and operation ach genoatr set Kubota diese engine rotating eld alternating generator and a contol box The generator is dicey connceted engin for permanent alignment Each contol box includes Sop switch and a On reset contol module or lockout emote sich to preve
20. ROUGH POWER TECHNOLOGY S CUSTOMER SERVICE DEPARTMENT PLEASE HAVE THE GENERATOR MODEL AND SERIAL NUMBERS AVAILABLE WHEN YOU CALL THis Generator Model Number Generator Serial Numbe POWER TECHNOLOGY SOUTHEAST INC 634 STATE RD 44 LEESBURG FL 34748 8108 352 368 2777 FAX 352 797 5545 www PowerTect Gen om Limited Warranty an Power Tech Generators 4 einen ese canna sts a tate in nt eo ee ee TABLE of CONTENTS SECTION SAFETY SAFE OPERATION SECTION 2 PRE OPERATION CHECK OPERATING THE ENGINE ENGINE SPECIFICATIONS ENGINE MAINTENANCE SERVICE SCHEDULE ENGINE OIL MAINTENANCE ENGINE COOLANT MAINTENANCE OPERATING HOURS AND SERVICE COG SECTION 3 GENERATOR END PRINCIPLES OF OPERATION SERIES EXCITER TYPE GENERATOR ASSEMBLY WIRING SCHEMATICS and RESISTANCE CHARTS SECTION 4 INSTALLATION SAFETY PRECAUTIONS GENERATOR INSTALLATION RECREATIONAL VERICIES SYSTEMS CONNECTION ELECTRICAL CONNECTION SECTION 1 SAFETY SAFE OPERATION 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 personal injury I
21. and heck flr every 25 houts of operation Ata Minimum of 25 Houts of Operation Ensure that the coolant level of the ator reserve tank is between the upper limit FULL and the lower LOW on the side ofthe reserve CLEANING RADIATOR CORE Visually inspect the for any obstruction such stor debris Use runing water clean cles fom between fins IMPORTANT Never use hand object ocean radiator core damage to core could sult OPERATING HOURS and SERVICE LOC SECTION 3 GENERATOR END PRINCIPLES OF OPERATION SERIES EXCITER TYPE GENERATOR ASEMBLY WIRING SCHEMATICS and RESISTANCE CHARTS 45 GENERATOR ASSEMBLY INFORMATION EXCITER TYPE GENERATOR The excite pole poses contain residual magnetism which set ines offre the at the exter amature When the begins orotate a voltage is induced and current nated inthe amature AC windings This voltage 5 fed othe rotating wet assembly and fed othe which ets up lines of fore the alt gap the Stator windings and the ouput stati voltage regulator i othe gencrator ouput_ The regulator will of he ouput vllage provide a DC tothe exter coils Tis the density ofthe lines of foes inthe te voltage induced into the armature windings and
22. ator set must be securely fastened avoid unwanted movement rom vibration and oad shock Ifthe equipped witha mounting tay the way supported with structural Be sure to use all mounting hoes inthe tay the tay Unis not equipped with mounting way are secured by attaching Genet mounts and re othe structural framing Skid mounted unis can ether be affixed for ay mounting attached tothe framing The generate is easily moved in a out of the by Incorporating lide rack wit oles int the structural framing When designing the compartment allow acess for routine maintenance and fr removal when major sevice is Also keepin mind that the compartment or door must have an intake eal or rater than that specified under the Air Requirements section ofthis manual Make that the compartment i vapor tight and completly sale of fom the ofthe vehicle to prevent any Fzardous fumes from entering the vehicle Avoid road splash and the possiblity of combustible materials bencth she coach hy enclosing all uanccesay ce space Beneath the generator compartment Line the compartment good sound deadening material material selected must be fireproof or highly resistant foam sound mati er efficient fr absobing generator oie This typeof materials
23. cut size and be quickly installed using the appropriate ie resistant Other material uch fiberglass insulation with heat basier may be used NOTE Since a Genst is mounted minimum clearance of one 1 inch wil assur thatthe unit will nt ub the sides ofthe compartment while the isi operation or while the vehicle isin COMPARTMENT FRAMING The generator must be bolted structural fame whieh bolted or welded to the frame ofthe vehicle This frame must be designed withstand a minimum force of ia any The fame must suppor the emit outer perimeter and ofthe unit base Adina flaming may be equited iFexcessive movement or vibration occurs AIR REQUIREMENTS Each Genset is equipped with high ambient temperature shutdown switch anda high water temperature shutdown swith which wll automaticaly shut down the Genset if the ambient temperature or water temperature high prevent the generator St fom sting down make sue the compartment openings large enough to allow adequate etculation of cooling it The minimum fee opening into the compartment 00 4 in or 3228 sq cm Remember that louvers and leet wil restrict airflow relatively open mesh seen can esti flow by as much 459 The intake opening will be increased in siz to compensate for Such restrictions NOTE
24. d Engine System Chock Engine oil evel Check for Engine ol leaks Cooling System Chock coolant vel and condition Check for coolant leaks Cheek for proper insta tion of the radiator cap Fuel System Check or sufficient quantity of fuel Check for fel leaks Check engine afer stating Warm Engine Proper Operation Check for easy engine start Chock for id leaks Check for abnormal engine noses Chock for abnormal exhaust gs OPERATING THE ENGINE ENGINE STARTING CONTROLS 1 Generator Main Switch must be inthe ON position 2 Hold Switch for 1 second and 3 Glow Plugs wil preheat for seconds LED slowly 3 reheating wll cease during engine cranking cycle LED continues Mashing 3 Engine begins an seconds crank 4 seconds of eranking PT ECU 3 will hock AC signal fom the generator AC signal the engine will stat and the LED ill emaia ON during the normal run operation Ith AC signal the will the cranking and LED wil fash fault code 6 dsengages immediately after engine uni verified 7 PT ECU 63 deactivates the Low Oil Pressure and High Water Temperature Switches for 6 scconds this wil assure pressure build up ime Ii pressure doesnot build up the engin wil immediately shut down and go into faut mode Likewise high temperature situation Tenge w
25. den flash fre cause serious bums To avoid the possibility flash donot Smoke permit aflame spark to occu near the earburetr line fel ier ue pump or other potential of pled flor vapors 14 FIRE HAZARD Be earful when parking you vehicle to prevent grass fom being stated by hot exhaust gases or exhaust system Keep avay fom hot engine and generator pats avoid ourslt Keep the generator set and compartment clean and fice of debris specially combustible materials Never stor fuel ol rags inthe generator compartment 15 MARINE APPLICATION RV generator ets no comply with United States Cost Gua USCG equrements They must not be used for marine applications Use only generator sets Specified for marine use ina marine application USCG regulation SSCFRIS reqs a eto be ignition protected use gasoline fueled envionment 16 UNIT STARTS WITHOUT NOTICE To prevent accidental starting on the units with emote Sop switch always disconnect the battery by removing the negative terminal ist and hen the positive 7 Always disconnect the unit inthis manner before working on the or equipment connected 17 LOOSE COMPONENTS Periodically check fr and tighten any that may have lose fiom vibration oF road shock Serious damage may possibly occur components become Aislodgod or misaligned 2 GENERATOR INSTALLATIO
26. e requirements 2 REQUIREMENTS the compartment ines and outs sized tallow cooling nd combustion 3 COMPARTMENT FLOOR Ts the compartment tong enough support the ef the generate set 4 COOLING SYSTEM Ts the cooing system large enough adequately cool the 5 FUEL SYSTEM Is the fel system propery designed prevent Fl strvation of ether the man engine or generator engine 6 EXHAUST SYSTEM safety 7 ELECTRICAL CONNECTIONS Will the exhaust system meet al Loca State and Federal requirements Willall systems battery load and ste compatible withthe vehicles system NOTE When wing a radiator not supplied by Power Technology consult you adit manufacturer ensure ha heat ejection ales met 4 GENERATOR COMPARTMENT SIZE In planning the sizeof the generator compartment fr the minimum clearance of 3 inches tthe connection end and one 1 ach all ober sides is nevessty to adequately cool the generator ss The thicknes of insulation and sound deadening material ued the compartment must be taken consideration when planing this clearance To maintain minimum clearance it may be necessity to enlarge the compartment For Geass mounted inside an enclosure please refer tothe on Generator Enclosures information and mounting The gener
27. he terminals Use volmeter or DONOT charge a battery if frozen it may possibly explode Frozen must be warm upto atleast 61 F 16 C before charging KEEP HANDS AND BODY AWAY FROM ROTATING PARIS a Bed fo all ting pack in elt pls and thee Cote i se she ig engine betes tension the cooling 2 DO NOT nn he engine sr thy ae propery igo and fastened ef operating fe engine ANTLFREEZE AND DISPOSAL OF FLUIDS contains toxic chemicals Wear ruber gloves when handling anti freeze In case of contact with skin wash immediately to soi personal injury DONOT mis diferent Ami feeze The mixture ean a chemical reaction resulting inthe formation of haf Substances Only use at feze that recommended and approved by Caterpillar Be mind ofthe enviroument Before any Buds be dispose of them consistent with vironmental protection regulation in your location When draining Mids rom the engine se appropiate containers to old the diferent Mud donot mix fc ol coolant Dispose of spent iter eansidges and batteries prop polite the or any water Never pour Buds downa drain NDUCTING SAFETY CHECKS AND MAINTENANCE 2 Whe
28. il not start onthe 65 will the 2 mote times efor going into fault mode Glow Plugs wil fr 8 seconds po attempt Engine will tank fr seconds ate 9 To shut dow the engine under nomal operation hold the Switch for second and release 10 1F fault occurs tum Generator Main Switch OFF and then ON to reset CHECKING ENGINE AFTER STARTING 1 Allow the engine to warm up 3 to 5 minutes before applying load In coder climates allow a few extra minutes longer 2 Perform a visual inspection of al ofthe engin and generator 3 Listen fr any abnormal noises 4 Check for any bara exhaust gases STOPPING THE ENGINE ecommended to disconnect or reduce the power lead fom the generator before shutting down the engine Then follow the outlined above far shutdown NOTE The PT ECU 63 is designed operate on 12 DC power Ina low battery situation the PT ECU 3 may at itt the cranking stat genefator you can press and hold the Switch fr approximately 10 seconds he engine stats Once the engine starts the PT ECU 63 wil sume normal operations I this ition replace he hater IMPORTANT Damage tothe Starter Motor Starter Solenoid Run Solenoid or any generator component due to excessive prolonged starting exeral Low
29. ized DO NOT check for Pressure wit your hands Hih peessure or fuclean pany dev ase persona 5 Escaping hydraulic unde penetrate serious personal Fluid escaping fom pinholes may be invisible Use picce of cardboard or wood fr suspected leaks do not we tans body Use safety or eye when checking fr leaks injure by escaping Mid sce a medial doctor immediatly This ud can produce gangrene severe allergic reaction CAUTIONS AGAINST BURNS AND BATTERY EXPLOSION Toavoul bums be for hot components operation and just ae the engine has been shut of Such the mule enue over radiator piping engine body coolants engine 5 remove the radiata while the eagine i running stopping Wat approximately ten minutes forthe lator to before removing the cap the radiator dai ptcook hose clamps tighten Chek radiator pressure cap andl fil before operating the engine preseas an explosive hazard Whon the baer is ing hydrogen and oxygen gases ae extremely explosive Keep sparks and open flames away fom the battery especially during charging NOT match near the chock charge by placing a objet across t
30. loading For sample ial lights ae atthe same and the conltioner ther motor equipment starts up this may possibly eaus an overload situation APPLIANCE LOADS in recreational vices are often used to supply AC voltage for appliances With the exception af a resistance type load sich asa water heater equrement for appliances are usualy low However lads thst not be overlooked when calculating the total wattage requirements Ta avoid an overoad situation reserve capacity should als for unanticipated appliance lads The average power requirements for sine common electrical appliances ae listed below asa guide DETERMINING ALTERNATOR LOAD REQUIREMENTS EXTENSION cops A extension is normally used to provide electrical power frm generator set remote location The extension cord size and length must be adequate safely the ape requirements prope ize extension cord wil help minimize the voltage drop the generator set and emote orton CORDTENGTT 1200 SOFT 200 FT 16 T2007 290 OFT 13 20 2406 9007 TSF 30 3606 72007 OFT FT 290 0007 30FT TFT TFT 30 sea
31. n safety checks or engine service be the engine level and well supported Use approved sands designed for his type of sevice DO NOT service an engine thats only supported jack or hos Detich the battery from the engine before conducting sevice Put a DO NOT OPERATE tag the key site avoid accidental starting To voidspars fom an accidental short always disconnect she De power ate Bente ony cars timer the ey when contig daily and servicing Chookorcondut maintenance afr the engine radiator ue or 7 muffler cover has cooled Always use the appropriate tots when performing fervice work sure t understand and flow theists with these tol ONLY correct engine barring techniques foe manually ating he engine DO NOT to the engine pulling prying fn the cooling fan and personal injury or damage tothe may Replace fuel hoses and hose clamps every eater whether they are damaged or not They are made of ruber and are aged gradually When sevice is performed with more peopl presen take care to perform all work safely Be aware of ter especially when starting the engine fis a kit and extinguisher handy a al mes SECTION 2 PRE OPERATION CHECK OPERATING THE
32. nt starting while service being performed contol box may be quipped with switch operate the mechani used to move the generator of he coach Servicing Supplied by the coach manufacture After the sets atlached the fame ofthe vehicle all thats usually to make operational are the following 1 Attaching the exhaust system 2 Add proper amount of radiator coo Add oi to crankease tothe dipstick FULL mark 4 fue line mote switch oad leads and battery terminals Consul the Charts on the Following Pages for Requirements FREE AIR OPENING Squat nes FUEL CONNECTION FUEL RECOMMENDATION DIESEL FUEL DOS BATTERY VOLTAGE TIVOLTS OC THATTERY CRANKING ANTS 327 BATTERY COLD CRANKING AMPS BATTERY GROUND NEGATIVE CHARGING AMPS CONSUMPTION IN GALLONS PER TOAD PERCENTAGE 25 35 INSTALLATION FACTORS Each generator set recived unit except or the optional exhaust system component hich are shipped lose assembly after the Sts installed in the vehicle When peeplanning the instalation the following factors must be considered 1 COMPARTMENT SIZE Will there be sufcient om around the set to maintain the minimum leaanc
33. ons listed inthe able below Use this guide when selecting generator set requirements involving motor lads Also note the Kilowatt factor for generator st capabilites regarding ir scconing to Kilowatt Devating TLECTRICMOTOR TASED ON ELECTRIC MOTOR HORSEPOWER STARTING WATTS RUNNING WATTS 20007 1100 TR 000 2509 30007 5 3590 590 All units rated at 1 0 power factor ofthe generator set wll decrease 3 5 per 1 000 feet 305m above 500 fet 152m above Sa evel 19 for every 10 F 38 C above oer ELECTRICAL LOADS While the electrical load of the vehicle should have been calculated prior to purchase ofthe generator set you may want to recheck the Toad before isang the sue the capacity is ample meet the demands without possible overloading he lighting load is easiest calculate most cases simply ad the watage of each lamp to be operated of the generator st Noe tht in many applications nt all ofthe lights axe inthe generator sets Some are DC powered by the 12 oltbatery in the vehicle Make Sure the wal includes only onthe ses lighting load is usually oto heavy mobile installation however it mst be accurately calculated prevent over
34. plosive Never te guide nthe engine ata well venuated and plac I fuel ubicans spill yp immediately and propery of DONOT mix gasoline or alcool with diesel fuel The mixture GASES AND FIRE PREVENTION Engine exhaust fumes canbe very accumulate Be sue run the engine in area where thee are no people nearby 2 Theexhaust rom the mur every bot To prevent fie expose dy rss ll or anyother combusable materials to exaust gas Keep the eae and mules clean ll he 2 Toavoid fire alert for leaks of fom hoses std Ties sure to check for leaks from hoses an pies such as fuel and hydraulic by following the maintenance chee list To avoid fie donot sort across power and wires Chock tose hat all power cables and wires aren good onion Keep all power connections clean Bue wie ot Fayed insulation ean ease dangerous clerical shock and personal injury CALIFORNIA Propastion 65 Warning Diesel Engine Exhaust and some of es know by the Sate of California Defects and Other Reproductive ham ESCAPING FLUIDS 2 all pressure in the oll and colin systems before any ies items removed or Bealer fo possible pressure when disconacet fiom hat is pressur
35. quipped with fel pick up arangemeat as described inthe Fuel System section of this anual Ful tank and installation must sonform to applicable egulations 5 HOT COOLANT Allow engine 1 cool and telease pressure fom cooling system before opening the pressure ep To the pressure cover the radiator cap witha thik lah then urn it slowly counterelockwise tothe fst sop After he pressures eleased and the engine has cooled remove the 9 LETHAL EXHAUST GAS When installing an exhaust position the pipe end so thatthe discharged gases may not be drawn ito the vehicle inferior trough windows doors conditioners et The engine powering your generator st discharges carbon monoxide as ofthe exhadse gas when sunning I exhaust be leakproof and inspected 10 EXCESSIVE NOISE Never operate the generator without an adequate mae o witha exhaust system Exposure excesive nose os bearing 11 ELECTRICAL SHOCK cause electrical urns and shocks Use reasonable cae when working near the bar to avoid electra connections by contacting the ery terminals with tools Remove wristwatch rings and al jewelry when working onthe generator 12 BACKFIRE A sudden backfire can cause serious bums Do not operate your generator st without air leaner ame arestor in place 13 FLASH FIRE A sud
36. st be connected between the ground lig on the generator et the lame ofthe vehicle All wing connections made at the ime stallation should be readily accessible for periodic inspection and servicing DISTANCE HETWEEN CABLE SIZE WO REQUIREMENTS TCE 50 AC LOAD LEAD CONNECTIONS Some generator sets have four color coded lads The Black leads LI amp 13 are hot The White of Gay lead L2 and the Green lad is ground lad Teas ean routed fiom the junction box tothe vehicle transfer switch connection installations regi thatthe loud Teads be outed though conduit fom the generator end bracket othe junction box location The load ea junction box must be accessible for servicing and inspection AC load lead 12 White or Gray the lead on PTS generator sets Make sue the ofthe AC vehicle i connected tthe 12 Whit or Gy lead equpmeat ground type plugs and receptacles 3 prong are used inthe vehicle the wise must be the chassis round On vehicles which also have provisions fr using ouside power source ead as Wells the Black Li amp hot leads must be completly isolated fom the generator se when powers itched othe outside MOTOR LO
37. t system components which dono exhaust restricted exhaust system will reate excessive backpressure and poor engine performance and possible gine damage The maximum allowable backpressure forthe engines listed inthis manual is Omni 2 shall be fabricated of aluminized material be welded o crimp constuction A USDA Forest Service approved spk arrestor must be part of the integral ofthe mule o povided as separate add on tem Maintain a minimum of 3 inches between the exhaust system components any surrounding combustible materials Ifthe minimum clearance be maintained insulting shield must be isle prevent the combustible material fom exceeding temperatures of 65 C above ambient temperate 4 Extend the exhaust ystom a minimum of neh 2Smm beyond the vehicles perimeter Never terminate the exhaust system underneath the vehicle Terminate the exhaust system ina which prevents the exhaust gases fom being dawn nck into the generator compartment and the exhaust system in located in an area which may Become susceptible road damage rom urs speed bumps or other oud obstacles a protective device such skid plate should be ital To prevent excessive movement and vibration ofthe exhaust system install hangers and clamps designed for use in exhaust ystems
38. t will provide agains the lowest ambient NOTE 100 percent glycol eeze at temperature of 23 C 37 Most conventional heavy duty anticezes use Ethylene Glycol Propylene may bo used ina 11 mixture with water and Propslene Glycol provide Similar protection against and boing See the tables below Coolant Type Service Life Commercial Heavy Duty Coolant Antifeeze that 3000 Service Hours Meets ASTM DS345 oc Two Years Commercial Heavy Duty that 3000 Service Hours Meets ASTM Year NOTE Do not use commercial oolatantifeeze that nly mets the ASTM 05506 oF D46S6 specification This ype of made light duty applications ETHYLENE Freeze Boil CHECKING RESERVOIR Concentration Protection Protection COOLANT LEVEL hearer near PROPYLENE GLYCOL Freeze oil Concentration Protection Protection NOTE Do not we Propslene ian that exceed 50 percent glycol because of Propylene reduced eat capability Use Ethylene in conditions that require additional protection oiling CHECKING RADIATOR COOLANT LEVEL Remove cap aller th engine has completely cooled and check to see ool reaches the supply por 1 bottom ofthe ill eck
39. the ak while the engin s runing Spilled may ignite on contact with hot pat frm nition spark Always keep lines nd connections tight and in good Don t replace exible fuel lines wih gi I ou notice any eakage fel accumulation sparks DO NOT OPERATE THE GENERATOR SET EXPLOSIVE BATTERY GASES The gases generat by a battery boing charged are highly explosive smoke permit any lames o spark occur especially when itis being charged Avoid contact between with fools prevent sparks and possible burs remove rags or other jewely before handing Any compartment containing batteries shouldbe wel ventilated prevent the ccurulation of explosive gies To avoid sparks never disturb the battery charging connections while the toy is being charge Always off charge before daconnesting ternal clips 4 ELECTROCUTION Failure to installa generator set with system consistent with governing regulations and standard ig UNLAWFUL and may cause ELECTROCUTION of vehicle Your generator st must not be used Back Feed by comectng it a building letra iui Back Feeding can injury death to uty working a power outage and may also seriously injure persons in your hile Unauthorized connections ae some states andr
40. tions Ground Fault breakers must be installed protect ll brinch and contol must be securely mounted to prevent damage and opening o closing fom vibation road shock and vehicle motion Barter load lads andthe remote switch panel connections necessary for completing ination Make final connections othe battery only al other connections have been made will preven unintentional starting Some specific details on each connection ar sted in the fllawing Paragraphs Refer to the wiring diagram specific details wiring to the generator set shal sccuely Supported or harnessed to prevent Additional support is ruled to prevent exposure tothe exaust system and any possible of us or grease 2 inches of clearance must be electrical wiring and hot exhaust Wiring mus not be loated below or close the fel system fill and rai locations the couch i equipped witha mechanism for removing the set fom the compartment such mounting basso slide tak be certain ll wing slong ough tallow for movement ofthe generator for servicing A separate 12 olt battery is recommended for et Wih separate bate cables shouldbe kept shor in length thus eliminating problems with excessive voltage See the Table Below for cable size AWG to length requirements A heavy gauge 8 ground strap mu
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