Power Tech Generators PT-8000 Operator's Manual
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Power Tech Generators PT-8000 Operator's Manual

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3.2013
MANPT8-12
SINGLE OR THREE PHASE
PT-8000
PT-10000
PT-12000
Operators
Manual
Power Technology Southeast, Inc.
634 State Road #44
♦ (352) 365-2777 ♦ Fax (352) 787-5545 ♦
Leesburg, FL 34748-8103

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  • Page 1 PT-8000 PT-10000 PT-12000 Operators Manual Power Technology Southeast, Inc. 634 State Road #44 Leesburg, FL 34748-8103 ♦ (352) 365-2777 ♦ Fax (352) 787-5545 ♦ 3.2013 MANPT8-12 SINGLE OR THREE PHASE...
  • Page 2 FORWARD You are now the proud owner of a Power Technology Generator powered by a Kubota engine. This engine is a product of Kubota’s quality engineering and manufacturing. The engine is made with fine materials and manufactured under the strictest quality control standards and will assure you long satisfactory service.
  • Page 3 Limited Warranty on Power Tech Generators Power Technology Southeast, Inc. warrants to you, the original purchaser, that each product of our manufacture is free from defects in materials, and workmanship. That each generator will deliver its rated output as indicated on The Power Technology Nameplate, if properly installed, serviced, and operated under normal conditions in accordance with Power Technology’s instructions.

  • Page 4: Table Of Contents

    TABLE of CONTENTS SECTION 1: “SAFETY” SAFE OPERATION SECTION 2: “ENGINE” PRE-OPERATION CHECK OPERATING THE ENGINE ENGINE SPECIFICATIONS ENGINE MAINTENANCE SERVICE SCHEDULE ENGINE OIL MAINTENANCE ENGINE COOLANT MAINTENANCE OPERATING HOURS AND SERVICE LOG ENGINE TROUBLESHOOTING GUIDES 8-10 SECTION 3: “GENERATOR END” PRINCIPLES OF OPERATION 8-10-12 KW EXCITER TYPE GENERATOR ASSEMBLY GENERATOR END TROUBLESHOOTING GUIDES...

  • 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.

  • Page 10: Engine

    SECTION 2 “ENGINE” PRE-OPERATION CHECK Engine Break-in Period Daily Check OPERATING THE ENGINE Engine Starting Controls Starting the Engine Check Engine After Starting Stopping the Engine ENGINE SPECIFICATIONS Kubota Models D1105-EBG1 and V1505-EBG1 Service Parts ENGINE MAINTENANCE SERVICE SCHEDULE ENGINE OIL MAINTENANCE Checking Engine Oil Level Lubricating Oil Specifications Engine Refill Capacities...

  • 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: Operating The Engine

    OPERATING THE ENGINE ENGINE STARTING CONTROLS 1) Generator Main Switch must be in the ON position. 2) Hold Start/Stop Switch for 1 second and release. 3) Glow Plugs will preheat for 8 seconds. LED flashes slowly. 4) Preheating will cease during engine cranking cycle. LED continues flashing. 5) Engine begins an 8 seconds crank cycle, After 4 seconds of cranking the PT-ECU-63 will check for an AC signal from the generator.

  • Page 13: Engine Specifications

    ENGINE SPECIFICATIONS MODEL Kubota D1105-EBG1 Kubota V1505-EBG1 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 14: Engine Maintenance Service Schedule

    Engine Maintenance Service Schedule Min. Every Maintenance *See Daily Every Every 100 Every 250 Every 500 1000 Remarks Service Item Note 25 Hours Hours Hours Hours Hours Engine Oil Level Deterioration & Leakage Engine Oil Or Once Change a Year Oil Filter Or Once Change...

  • Page 15: Engine Oil Maintenance

    ENGINE OIL MAINTENANCE CHECKING ENGINE OIL LEVEL KUBOTA ENGINE REFILL CAPACITIES D1105-EBG1 Crankcase Oil Sump 5.38Qts. (5.1L) and Filter V1505-EBG1 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 16: 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 17: 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 18: Engine Starts But Won't Run

    ENGINE STARTS BUT WON’T RUN Engine Runs OK Unplug Remote Start-Stop from Control Box Problem with Remote Connection. Contact Jump across Equipment Manufacturer Oil Pressure Switch with Jumper Wire (2 pole) Oil Pressure Switch Check Power Single Pole to Hold Circuit Check of Run Solenoid Disconnect Wire to Test...

  • Page 19: Engine Runs Rough Or Slow

    ENGINE RUNS ROUGH or SLOW NO Visible Exhaust Smoke Excessive Exhaust Smoke BLUE Insufficient Fuel to Engine GRAY/WHITE Excessive Oil Level BLACK Check Replace Fuel Level Fuel Filter Dirty Air Filter Engine Overheated Air IN Check Engine Over Loaded Fuel Fuel System PUMP...
  • Page 20 ENGINE WILL NOT START Engine Does NOT Engine Engine Cranks Crank Cranks SLOW Main Switch Battery Dead Smoke Turn Exhaust From Oil Viscosity Switch Smoke Exhaust Start TOO HEAVY “ON” Switch Check Check Glow Terminal Battery Check Plugs Ends Voltage Starter Fuel Check Fuel...

  • Page 21: Generator End

    SECTION 3 “GENERATOR END” GENERATOR ASSEMBLY INFORMATION Brush Type Exciter Type Electronic Voltage Regulation Voltage Connection Field Coil Voltage Source (Exciter Type Only) Rotating Field Assembly (Rotor) Core Assembly Field Coil Balance Bearing Stator Assembly EXCITER TYPE “C” GENERATOR ASSEMBLY BRUSH TYPE “C”...
  • Page 22 GENERATOR ASSEMBLY INFORMATION BRUSH and EXCITER TYPE GENERATOR BRUSH TYPE 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 23 FIELD COIL VOLTAGE SOURCE (EXCITER TYPE ONLY) Field coil DC voltage is obtained by rectifying the voltage from the phase to neutral line of the generator output, or either appropriate terminal to provide the needed voltage reference. The rectifier bridge is an internal part of the static regulator. The static regulator senses a change in the generator output and automatically regulates current flow in the exciter field coil circuit to increase or decrease the exciter field strength.
  • Page 24 DESCRIPTION PART NUMBER 10KW 12KW 1. BEARING PLATE 02BR-CR 02BR-CR 02BR-CR 2. END BELL 02H7810 02H10KW-CR 02H10KW-CR 3.EXCITER STATOR 02STA8EXC 02STA10EXCR 02STA12EXCR 4. MAIN STATOR 02STAMNCD8 02STACI7210 02STAMN12 5. BELL HOUSING ** 02BHTPU7 02BHTPU7 02BHTPU7 6. ROTOR BEARING 02BRG6206 02BRG6206 02BRG6206 7.
  • Page 25 DESCRIPTION 1. COVER SCREEN 2. BEARING PLATE 3. STATOR ASSEMBLY ** 4. ROTOR BEARING 5. BRUSH SET 6. ROTOR ASSEMBLY ** NOTE: Item #3 MAIN STATOR ASSEMBLY is a one-piece unit. The Stator cannot be separated from the Generator’s outer housing. 8 –...
  • Page 26 12-Lead Generators 4-Lead Generators High (Series) Wye, 3P4W High (Series) Delta, 3P3W Approx. 380V to 480V L-L, Approx. 200V to 277V L-L 219V to 277V L-N Single Phase, Dual Voltage Approx. 240V L-L, 8 - AVR 120V L-N 6 - AVR 7 - AVR 7 - AVR 7 - AVR...
  • Page 27 ZERO VOLTAGE Check Main Check Gen Fuse Breaker is “ON” Main Coil Output to Replace Turn “ON” Breaker Fuse Breaker Wiring To Defective Panel Breaker Check Ohm’s on Exciter Leads 12 V Battery Test Replace Exciter Replace Voltage Regulator...
  • Page 28 VOLTAGE TEST Output Overload Zero High Voltage OK Voltage Low Voltage Check AMP Check Draw Replace Main Breaker From equipment On GenSet Check Load Distribution One Voltage Line Check may be Gen End Higher than the other 12 VOLT BATTERY TEST One Coil Both Coils Sensing Voltage...
  • Page 29 OVERLOAD CONDITION Check AMP Draw Check Load Distribution Disconnect Conduct 12-Volt Battery Test Engine Problem Check Stator Coil Resistance See Engine Troubleshooting Replace Stator Replace AVR And Test...
  • Page 30 MARKS COLOR MAIN STATOR U1-V1 or U2-V2 MAIN ROTOR POWER TECHNOLOGY SOUTHEAST, INC. EXCITER STATOR 86.9 87.4 89.0 F1-F2 634 STATE ROAD 44 EXCITER ROTOR 33.8 33.8 34.0 LEESBURG, FL 34748-8103 AUX. WINDING (352) 365-2777 FAX (352) 787-5545 BATT. CHARGE CH W SENSING WINDING BLUE / BROWN...
  • Page 31 MARKS COLOR MAIN STATOR U1-V1 or U2-V2 MAIN ROTOR POWER TECHNOLOGY SOUTHEAST, INC. EXCITER STATOR 86.9 87.4 89.0 F1-F2 634 STATE ROAD 44 EXCITER ROTOR 33.8 33.8 34.0 LEESBURG, FL 34748-8103 AUX. WINDING (352) 365-2777 FAX (352) 787-5545 BATT. CHARGE CH W SENSING WINDING BLUE / BROWN...
  • 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 0.257 U1-V1 or U2-V2 POWER TECHNOLOGY SOUTHEAST, INC. MAIN ROTOR 83.1 634 STATE ROAD 44 AUX. WINDING 2.64 LEESBURG, FL 34748-8103 BATT. CHARGE 0.159 CH W (352) 365-2777 FAX (352) 787-5545 SENSING WINDING 0.085 BLUE / BROWN NOTE: THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE JUMPER...
  • Page 35 RESISTANCE CHART MARKS COLOR MAIN STATOR 0.257 U1-V1 or U2-V2 POWER TECHNOLOGY SOUTHEAST, INC. MAIN ROTOR 83.1 634 STATE ROAD 44 AUX. WINDING 2.64 LEESBURG, FL 34748-8103 BATT. CHARGE 0.159 CH W (352) 365-2777 FAX (352) 787-5545 SENSING WINDING 0.085 BLUE / BROWN NOTE: THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE 2 POLE CIRCUIT BREAKER...
  • Page 36 RESISTANCE CHART MARKS COLOR MAIN STATOR 0.093 0.093 U1-V1 or U2-V2 POWER TECHNOLOGY SOUTHEAST, INC. MAIN ROTOR 72.5 72.5 634 STATE ROAD 44 AUX. WINDING 0.892 0.892 LEESBURG, FL 34748-8103 BATT. CHARGE 0.082 0.082 CH W (352) 365-2777 FAX (352) 787-5545 SENSING WINDING 0.029 0.029...
  • Page 37 RESISTANCE CHART MARKS COLOR MAIN STATOR 0.093 0.093 U1-V1 or U2-V2 POWER TECHNOLOGY SOUTHEAST, INC. MAIN ROTOR 72.5 72.5 634 STATE ROAD 44 AUX. WINDING 0.892 0.892 LEESBURG, FL 34748-8103 BATT. CHARGE 0.082 0.082 CH W (352) 365-2777 FAX (352) 787-5545 SENSING WINDING 0.029 0.029...

  • Page 38: 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 39 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 40 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.
  • Page 41 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 42 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 .21 GPH...
  • Page 43 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 44 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 45 SYSTEMS CONNECTION REMOTE RADIATOR COOLING SYSTEM Use the following data in designing and installing the generator set cooling system. To insure a safe effective installation, be sure the cooling system selected follows these parameters. Power Technology offers radiator assemblies, which meet these requirements and will adequately cool the generator.
  • Page 46 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 47 EXHAUST SYSTEM IMPORTANT SAFETY TIPS: When exhaust system components are not furnished by Power Technology as part of the Genset, the installer is responsible for meeting the following requirements. 1) Only use exhaust system components, which do not restrict exhaust flow. A restricted exhaust system will create excessive backpressure and may cause poor engine performance and possible engine damage.
  • Page 49 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 50 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 51 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 52 ES52F ENGINE CONTROLLER The ES52F Engine Controller is designed to enable automatic Start/Stop capability as well as providing fault protection for the generator. The ES52F will automatically Start the generator upon command and will monitor vital engine and generator functions. In the event a failure was to occur, the ES52F will automatically Stop the engine thus preventing further problems.
  • Page 53 TROUBLESHOOTING Trouble Possible Cause Suggested Action Unit does not operate when powered to test Power leads to unit are Confirm correct wiring for ground mode reversed. And bat, and re-attempt testing. Bad ground connection from Run wire directly from battery – to the engine to controller unit.
  • Page 54 PT-ECU-63 ENGINE CONTROL MODULE 1) Generator Main Switch must be in the ON position. 2) Hold Start/Stop Switch for 1 second and release. 3) Glow Plugs will preheat for 8 seconds. LED flashes slowly. 4) Preheating will cease during engine cranking cycle. LED continues flashing. 5) Engine begins an 8 seconds crank cycle, After 4 seconds of cranking the PT-ECU-63 will check for an AC signal from the generator.
  • Page 55 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 56 POWER TECHNOLOGY SOUTHEAST, INC. 634 STATE ROAD 44 LEESBURG, FL 34748-8103 (352) 365-2777 FAX (352) 787-5545 12V DC ENGINE CONTROL PT-ECU-63...
  • Page 57 OVERLOAD CONDITION Check AMP Draw Check Load Engine Problem Check Stator Coil Resistance See Engine Troubleshooting Replace Stator...

This manual is also suitable for:

Pt-10000Pt-12000

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