Related Manuals for PowerTech PTRV- 8 KSI
Summary of Contents for PowerTech PTRV- 8 KSI
- Page 1 PTRV- 8 KSI PTRV-10 KSI PTRV-12 KSI Operators & Installation Manual Power Technology Southeast, Inc. 634 State Road #44 Leesburg, FL 34748-8103 ♦ (352) 365-2777 ♦ (352) 787-5545 Fax ♦ 4/2007 MANKSI...
- Page 2 3:00 p.m. EST. If required, a Major Service Manual may be ordered through Power Technology’s Customer Service Department. 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...
- Page 3 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.
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Page 4: Table Of Contents
TABLE of CONTENTS SECTION 1: “SAFETY” SAFE OPERATION SECTION 2: “ENGINE” PRE-OPERATION CHECK OPERATING the ENGINE with POWER CONTROL MODULE and DISPLAY ENGINE SPECIFICATIONS GENERATOR MAINTENANCE SERVICE SCHEDULE ENGINE OIL MAINTENANCE ENGINE COOLANT MAINTENANCE OPERATING HOURS AND SERVICE LOG ENGINE TROUBLESHOOTING GUIDES 11-14 SECTION 3: “GENERATOR END”... -
Page 5: Safety
SECTION 1 “SAFETY” SAFE OPERATION 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... -
Page 6: Safe Operation
SAFE OPERATION Cautious operation is 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. - Page 7 KEEP AREA AROUND THE ENGINE CLEAN • 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.
- Page 8 ESCAPING FLUIDS • Relieve all pressure in the air, oil and cooling systems before any lines, fittings or related items are removed or disconnected. • Be alert for possible pressure release when disconnecting any device from a system that is pressurized. DO NOT check for pressure leaks with your hands.
- Page 9 ANTI-FREEZE AND DISPOSAL OF FLUIDS • Anti-freeze contains toxic chemicals. Wear rubber gloves when handling anti-freeze. In case of contact with skin, wash immediately to avoid personal injury. • DO NOT mix different types of Anti-freeze. The mixture can produce a chemical reaction resulting in the formation of harmful substances.
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Page 10: Engine
SECTION 2 “ENGINE” PRE-OPERATION CHECK Engine Break-in Period Daily Check OPERATING THE ENGINE with POWER CONTROL MODULE and DISPLAY_____ Feature Summary Operating Behavior Automatic Generator Start (AGS) Safety Monitoring and Shutdown LED Sequence ENGINE SPECIFICATIONS Kubota Model D-1105, V-1505 Service Parts ENGINE MAINTENANCE SERVICE SCHEDULE ENGINE OIL MAINTENANCE Checking Engine Oil Level... -
Page 11: Pre-Operation Check
PRE-OPERATION CHECK ENGINE BREAK-IN PERIOD During 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. - Page 12 Power Controller Module (PCM) And Display (PCMD)
- Page 13 Feature Summary The PowerTech PCM controls all of the start and run processes and characteristics of any PowerTech generator. The features of the application are: Internal Ambient Temperature Sensor Provides an on-board temperature sensor. Oil Pressure Sensor / Switch Input Allows input from an external oil pressure sensor or switch.
- Page 14 Operating Behavior Starting The generator starts in response to the “START” button being depressed for 1 second. The PCM goes into the Pre-Heat State, followed by the Cranking State, then finally, the Running State. The PCM attempts to start the generator a specific number of times (configuration parameter) before declaring a Fault.
- Page 15 Automatic Generator Start (AGS) The Automatic Generator Start (AGS) allows the generator to start based upon the battery level. The trigger voltage is configurable via a configuration parameter. The entire feature can be enabled/disabled by a configuration parameter. The AGS feature is currently disabled, by default. Safety Monitoring And Shutdown The PCM monitors inputs for safety limitations which might damage the generator.
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Page 16: Engine Specifications
ENGINE SPECIFICATIONS MODEL Kubota D1105 Kubota V1505 Continuous Output 13.6HP @ 1800 rpm 17.9HP @ 1800 rpm Cubic Capacity 68.53 in³ (1.123.L) 91.41in³ (1.498L) 3.07” x 3.09” 3.07” x 3.09” Bore and Stroke (78.0 x 78.4mm) (78.0 x 78.4mm) Cylinder Arrangement 3 In-Line 4 In-Line Firing Order... -
Page 17: Generator Maintenance Service Schedule
GENERATOR MAINTENANCE SERVICE SCHEDULE MAINTENANCE OPERATION * SEE DAILY EVERY EVERY EVERY EVERY REMARKS NOTE 150 Hrs. 250 Hrs. 500 Hrs. 1000 Hrs. Check Engine Oil Level Add as Needed Check for Oil Deterioration & Leaks Change Engine Oil & Filter Or Once a Year Check Engine Coolant Level Add as Needed... -
Page 18: Engine Oil Maintenance
ENGINE OIL MAINTENANCE CHECKING ENGINE OIL LEVEL KUBOTA ENGINE REFILL CAPACITIES D-1105 Crankcase Oil Sump 5.38Qts. (5.1L) and Filter V-1505 6.34Qts. (6.0L) LUBRICATING OIL VISCOSITY ( Y ) “ADD” mark. ( X ) “FULL” mark. RECOMMENDATIONS 1. Maintain the engine oil level between “ADD” The minimum ambient temperature during cold mark and “FULL”... -
Page 19: Engine Coolant Maintenance
ENGINE COOLANT MAINTENANCE COOLANT RECOMMENDATIONS COOLANT SERVICE LIFE For optimum performance, Power Technology Coolant Type Service Life recommends a 1:1 mixture of water / glycol. Commercial Heavy-Duty NOTE: Use a mixture that will provide Coolant/Antifreeze that 3000 Service Hours protection against the lowest ambient Meets “ASTM D5345”... -
Page 20: Operating Hours And Service Log
OPERATING HOURS and SERVICE LOG THIS SERVICE LOG IS PROVIDED TO HELP YOU KEEP AN ACCUMULATIVE RECORD OF OPERATION HOURS ON YOUR GENERATOR SET AND THE DATES REQUIRED SERVICES WERE PERFORMED. ENTER TIME TO THE NEAREST HOUR. OPERATING HOURS SERVICE RECORD DATE HRs. - Page 21 ENGINE TROUBLE SHOOTING ENGINE STARTS BUT WON’T RUN CODE 1 or 6 Check Flash Code CODE 2 or 8 Indicator at PCMD Check Battery Failure Engine High Check Coolant Voltage To Start Water Temp. Level/Condition Check Wiring If “OK” Check Check Fuel Fill System From Sensor to...
- Page 22 ENGINE TROUBLE SHOOTING ENGINE STARTS BUT WON’T RUN CONTINUED CODE 3 or 8 Check Flash Code CODE 5 Indicator at PCMD Check Oil Low Oil Check Main AC No AC Signal And Voltage Level/Condition Pressure at Breakers Check Terminal If “Tripped” If “OK”...
- Page 23 ENGINE RUNS ROUGH OR SLOW No Visible Excessive Exhaust Smoke Exhaust Smoke Insufficient BLUE SMOKE BLACK SMOKE GREY/WHITE SMOKE Fuel to Engine Excessive Dirty Air Filter Engine Cold Oil Level Engine Overheated Incomplete Check Replace Combustion Fuel Level Fuel Filter Engine Overloaded Excessive Over Fueling...
- Page 24 ENGINE WILL NOT START ENGINE CRANKS ENGINE DOES NOT CRANK ENGINE CRANKS SLOW Battery Main Switch Dead No Exhaust Smoke From Smoke Exhaust Oil Viscosity Check Check Too Heavy Glow Plugs Terminals Check Fuel Check Fuel Solenoid Supply Turn Switch Check Spark NO Power Arrestor...
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Page 25: Generator End
SECTION 3 “GENERATOR END” GENERATOR ASSEMBLY INFORMATION Brush Set Electronic Voltage Regulation Rotor Bearing Rotor Balance Voltage Connection 8-10-12 KW “MB” BRUSH TYPE GENERATOR ASSEMBLY GENERATOR END TROUBLESHOOTING GUIDES Zero or Low Voltage Voltage Test 12-Volt Battery Test Overload Condition WIRING SCHEMATICS AC Electrical Circuit for 8KW “MB”... -
Page 26: Generator Assembly Information
GENERATOR ASSEMBLY INFORMATION BRUSH SET Brush Type generators use a set of carbon or graphite brushes that are set into a spring loaded brush holder, which house and support the brushes. This brush holder is mounted in such a way as to allow the brushes to maintain a sliding electrical contact between the stationary and rotating components of the generator. - Page 27 DESCRIPTION PART NUMBER 10-12KW 1. COVER SCREEN 02SCREENKUB 02SCREENKUB 2. BEARING PLATE 02BRPLKUBM 02BRPLKUBM 3. STATOR ASSEMBLY ** 02MN8KBM 02MN12KBM 4. ROTOR BEARING 02BRG6206 02BRG6206 5. BRUSH SET 02BRU7004M 02BRU7004M 6. ROTOR ASSEMBLY 02RTR8KBM 02RTR12KBM GENERATOR ASSEMBLY 02GEN8KBM 02GEN12KBM ** NOTE: Item #3 MAIN STATOR ASSEMBLY is a one-piece unit. The Stator cannot be separated from the Generator’s outer housing.
- Page 28 ZERO or LOW VOLTAGE Check Main Breakers are “ON” Main Coil Turn “ON” Output to Breaker / s Breakers Wiring To Defective Panel Breaker / s Check Ohm’s On Main Check Brushes Stator Leads Replace Applicable Stator Check Rotor Ohm’s...
- Page 29 VOLTAGE TEST Zero High Overload Output Voltage Voltage Low Voltage Check Check AMP Regulator Draw Check From equipment Main Breaker / s On Generator Check Gen End...
- Page 30 12 VOLT BATTERY TEST One Coil Both Coils Sensing Voltage Replace Low Voltage Low Voltage Low or None Replace Check Stator Connections Replace Stator Check Engine RPM 1800 Replace Stator...
- Page 31 OVERLOAD CONDITION Check AMP Draw Check Load Engine Problem Check Stator Coil Resistance See Engine Troubleshooting Replace Stator...
- Page 32 RESISTANCE CHART MARKS COLOR MAIN STATOR 0.257 T-1 –T-2 : T-3 – T-4 POWER TECHNOLOGY SOUTHEAST, INC. MAIN ROTOR 83.1 634 STATE ROAD 44 AUX. WINDING 2.64 Y1 – Y2 LEESBURG, FL 34748-8103 BATT. CHARGE 0.159 (352) 365-2777 FAX (352) 787-5545 SENSING WINDING 0.085 NOTE: THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE...
- Page 33 RESISTANCE CHART MARKS COLOR MAIN STATOR 0.257 T-1 – T-2 : T-3 – T-4 POWER TECHNOLOGY SOUTHEAST, INC. MAIN ROTOR 83.1 634 STATE ROAD 44 AUX. WINDING 2.64 Y1 – Y2 LEESBURG, FL 34748-8103 BATT. CHARGE 0.159 (352) 365-2777 FAX (352) 787-5545 SENSING WINDING 0.085 NOTE: THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE...
- Page 34 RESISTANCE CHART MARKS COLOR MAIN STATOR 0.093 0.093 T-1 - T-2 : T-3 – T-4 POWER TECHNOLOGY SOUTHEAST, INC. MAIN ROTOR 72.5 72.5 634 STATE ROAD 44 AUX. WINDING 0.892 0.892 Y1 –Y2 LEESBURG, FL 34748-8103 BATT. CHARGE 0.082 0.082 (352) 365-2777 FAX (352) 787-5545 SENSING WINDING 0.029...
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Page 35: Installation
SECTION 4 “INSTALLATION” SAFETY PRECAUTIONS Hot Piping Dangerous Fuels Explosive Battery Gases Electrocution Moving Parts High Voltage Explosion Hot Coolant Lethal Exhaust Gas Excessive Noise Electrical Shock Backfire Flash Fire Fire Hazard Marine Application Unit Starts Without Notice Loose Components GENERATOR INSTALLATION in RECREATIONAL VEHICLES Introduction Marine Application... - Page 36 SAFTEY PRECAUTIONS A generator set can be potentially dangerous if not properly maintained and operated. The best Safe Guard against a dangerous situation is education, good judgment and common sense. For safe trouble free operation of your generator set some general precautions are listed below. Be sure to read, understand and follow these precautions.
- Page 37 7) EXPLOSION: Never connect the negative (-) battery cable to the positive (+) connection terminal of the starter solenoid, or test the battery by shorting terminals together. This could ignite fuel vapors or cause the battery to explode. To disconnect the battery remove the negative battery cable first and reconnect it last.
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Page 38: Generator Installation In Recreational Vehicles
GENERATOR INSTALLATION in RECREATIONAL VEHICLES INTRODUCTION Use this section as a guide when installing a generator set in a recreational vehicle, and then refer to the appropriate operation section for specific instructions. The installation of a RV generator set shall comply with current standards of ANSI / RVIA EGS-1, NFPA 1192 / ANSI A 119.2, ANSI / NFPA 70, NFPA 551 and applicable articles of the National Electrical Code. - Page 39 SPECIFICATION CHARTS FUEL CONNECTION ¼” NPT FUEL RECOMMENDATION DIESEL FUEL No.1-D or No.2-D ASTM / D975 BATTERY VOLTAGE 12 VOLTS DC BATTERY CRANKING AMPS BATTERY COLD CRANKING AMPS 590 MINIMUM BATTERY GROUND NEGATIVE FUEL CONSUMPTION IN GALLONS PER HOUR LOAD PERCENTAGE 10KW 12KW .25 GPH...
- Page 40 GENERATOR COMPARTMENT SIZE In planning the size of the generator compartment or bay allow for the minimum clearance necessary to adequately cool the generator set. The thickness of insulation and sound deadening material used to line the compartment must be taken into consideration when planning this clearance. To maintain minimum clearance it may be necessary to enlarge the compartment.
- Page 41 AIR REQUIREMENTS CONT’D 10KW 12KW ENGINE SPEED IN RPM 1800 1800 1800 OUTPUT IN HORSEPOWER 13.6 17.9 17.9 ENGINE INLET WATER TEMP. THERMOSTAT RATING 160°F 160°F 160°F THERMOSTAT FULL OPEN 185°F 185°F 185°F ENGINE OUTLET WATER TEMP.MAX. 230°F 230°F 230°F HIGH TEMP.
- Page 44 SYSTEMS CONNECTION FUEL SYSTEM The diesel fuel system for the generator set must be designed to operate independently from the vehicles main engine if both engines are to be operated at the same time. The best way to do this is to have separate fuel tanks, but this is usually impractical because of space restrictions.
- Page 45 EXHAUST SYSTEM SPARK ARRESTOR MUFFLER MAINTENANCE Gensets equipped with a spark arrestor muffler will require periodic cleaning. If the internal spark arrestor is not cleaned regularly the accumulated soot may cause excessive backpressure resulting in poor performance. To maintain optimum performance from your Power Tech Genset follow the Service Schedule in Section 2, page 4.
- Page 46 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.
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Page 47: Electrical Connections
ELECTRICAL CONNECTIONS ELECTRICAL WIRING All wiring must be applicable with local electrical codes. A qualified licensed electrician must perform all electrical wiring connections. Ground Fault (GFCI) breakers must be installed to protect all vehicle branch circuits. All switches and controls must be securely mounted to prevent damage and accidental opening or closing from vibration, road shock and vehicle motion. - Page 48 MOTOR LOADS When figuring generator set capacity requirements for installation involving motor loads, do not overlook the high current demanded by the motor during start-up. The “In-Rush” of starting current may be 2 to 5 times higher than that required when the motor reaches normal operating speed. Reserve capacity must be allowed for in rush demands plus other loads, which could be on the line as the motor starts.
- Page 49 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.
- Page 50 BLUE to 12V GENERATOR WINDING BLUE to 12V GENERATOR WINDING RED to +12V DC 06REG12DC YELLOW to RUN RELAY BLACK to GROUND GREEN NOT USED 06REG12DCAT 12 VOLT DC CHARGING...
- Page 51 KUBOTA 12Volt DC POWER CONTROL MODULE WIRING SCHEMATIC...