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Summary of Contents for Power Technologies POWERPAC-APU
- Page 1 POWERPAC -APU OWNER’S MANUAL AND SERVICE GUIDE Generator Model _____________________ Generator Serial #___________________ POWER TECHNOLOGY S.E., INC. 634 State Road 44 Leesburg, Florida 34748-8102 Phone (352) 365-2777 Fax (352) 787-5545 www.PowerPacAPU.com...
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Page 2: Table Of Contents
CONTENTS INTRODUCTION Overview Requirements for installation Parts list Tools required SAFETY ALERTS AND CONSIDERATIONS Alerts Considerations INSTALLING THE POWERPAC APU Preparation of the PowerPac Locating the PowerPac on the frame rail Assemble the mounting clips, bolts, and spacers Mounting the PowerPac to the frame Exhaust pipe INSTALLING FUEL TUBES AND LINES General considerations... -
Page 3: Wiring Diagrams
CONTENTS CONTINUED OPERATION OF POWERPAC APU Daily checks and maintenance schedule Starting and stopping the PowerPac APU Powering appliance and auxiliary systems ENGINE SPECIFICATIONS Model Service parts list POWERPAC APU MAINTENANCE Engine maintenance service schedule Engine oil maintenance and specifications Checking engine oil Lubricating oil specifications Lubricating oil capacities... -
Page 4: Introduction
INTRODUCTION You are now the proud owner of a Power Technology SE. Inc. PowerPac APU Idle Reduction System. The PowerPac is an auxiliary power unit designed to run completely separate from Your main truck engine. It provides 120 volts AC power to the cab of your truck to Run the air-conditioning and heating unit supplied with the unit. -
Page 5: To Our Customer
TO OUR CUSTOMER Thank you for your purchase of a Power Technology Generator. The information contained in this manual applies only to PowerPac APU Idle Reduction Systems. In the event you should experience a problem with your system please contact the sales dealer, or Power Technology’s Customer Service Department directly at 1-800-760-0027 from 8:00 a.m. -
Page 6: Requirements For Installation
REQUIREMENTS FOR INSTALLATION PARTS LIST 1- PowerPac APU Unit 1- Loose Parts Bag 1- Driver control box 1- Terminal block 1- Terminal block cover 4- ¾ x 7” mounting bolts 8- ¾ SAE flat washers 4- ¾ Ny-lok nuts 4- Aluminum frame clips 1- Fuel pickup tube 1- Remote panel 1- 1 ¼... -
Page 7: Tools Required
TOOLS REQUIRED Typical mechanics tools Drill 1 ¼ Hole saw Tape measure Utility knife Tubing cutter ½” NPT Tap (for fuel pickup tube) ¾” Drill bit or tapered drill bit (for ½” NPT tap) Heavy grease (to keep metal shavings out of fuel tank) Liquid thread sealant Transmission jack, forklift or engine hoist SAFETY ALERTS AND PRECAUTIONS... - Page 8 5) MOVING PARTS- Keep hands, feet, and clothing away from belts, fan and related pulleys when unit is running. Replace guards, covers and screens before operating the generator set. Serious personal injury may occur from contact with moving parts. 6) HIGH VOLTAGE-Remember the function of a generator set is to produce electricity. Wherever electricity is present there is a potential danger of electrocution.
- Page 9 13) 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.
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Page 10: Installing The Powerpac Apu
LOCATE THE POWERPAC-APU ON THE FRAME RAIL When choosing a location for the PowerPac-APU, several things need to be considered. Vehicles with longer wheel bases should have the PowerPac mounted closer to the sleeper to avoid obstructions in the road such as railroad tracks, speed bumps, curbs or anything else that may come in contact with the PowerPac. -
Page 11: Assemble The Mounting Clips, Bolts, And Spacers
Make certain the Fresh Air Inlet is NOT Obstructed ASSEMBLE THE MOUNTING CLIPS, BOLTS, SPACERS The Powerpac APU comes with all the hardware required for the complete installation of the unit. The loose parts bag contains all the necessary bolts, washers, nuts, and frame rail clips. Separate all parts to insure that you have the following: 4- Frame rail clips, 4- ¾”... - Page 12 Frame Clamp Place the 2 - ¾” x 7” bolts through the holes on the underside of the frame rail. Making sure both bottom and top bolts are level, snug up the bottom nuts. Securely mounted bottom clamp.
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Page 13: Exhaust Gases And Fire Prevention
Once all 4 nuts are snug, recheck alignment of the bolts. If all 4 bolts are straight, torque nuts to 100 foot lbs. ONLY after all nuts are torqued should you remove the lifting device. Note: Truck frames may have varying thickness. If the clamp will not fit easily onto the frame, mount direct to the frame or use a weight/load rated mounting bracket system. -
Page 14: Installing Fuel Tubes And Lines
INSTALLING THE FUEL TUBES AND LINES The diesel fuel system for the PowerPac APU must be designed to operate independently from the vehicles main engine if both engines are to be operated at the same time. In most installations both engines operate from a common fuel tank with separate pick-up tubes for each engine, not a Tee fitting arrangement. -
Page 16: General Considerations
GENERAL CONSIDERATIONS Tools Required for Fuel Pick-Up Installation Tape Measure Tubing Cutter Drill Heavy Grease ¼” Drill Bit Thread sealant Step Reamer Bit or ¾” Drill Bit Diesel fuel vapors can be very explosive. Use caution when working in or around the area of the fuel tank. - Page 17 After checking for baffles and fuel gauge linkage, pick a spot on fuel tank for the fuel pick-up tubes (usually top center of tank on end closest to the APU). Apply heavy grease to spot where hole is to be drilled. The grease will help keep metal shavings out of fuel tank.
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Page 18: Installing The Battery Cables
INSTALLING THE BATTERY CABLES IMPORTANT! DO NOT CONNECT BATTERY POSITIVE CABLE UNTIL THE POWERPAC UNIT IS READY TO BE TEST RUN. Turn the main power switch on the PowerPac APU to the OFF position to ensure the unit will not start prematurely. -
Page 19: Motor Loads
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 20: Electrical Loads
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. -
Page 21: Installing The Driver Control Panel
EXTENSION CORDS An extension cord is normally used to provide electrical power from the generator set to a remote location. The extension cord size (AWG#) and length must be adequate to safely maintain the amperage requirements. A proper size extension cord will help minimize the voltage drop between the generator set and remote location. - Page 22 DRIVER CONTROL PANEL DIAGRAM White/Red Wire – sends start/stop signal to the APU Red Wire- 12v DC constant Orange Wire- LED signal wire Gray Wire- 12v Power to hour meter while unit is running Green Wire- Ground...
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Page 23: Mounting The Control Box
MOUNTING THE CONTROL BOX Once all connections are made to the start/stop switch and the hour meter, fasten the control box to the desired location with the screws provided. INSTALLING THE POWER OUTLET BOX SELECT LOCATION Determine where you want to mount the AC power outlet box. This should be mounted where the driver has easy access to the outlets. - Page 24 AC POWER TERMINAL BLOCK DIAGRAM Red Wire- 30 Amp circuit for Heating / Air conditioner unit. Black Wire- 20 Amp circuit for Driver’s comfort appliances. White Wire- AC Neutral Green Wire- Ground MOUNTING THE POWER OUTLET BOX After all connections are made, fasten the power outlet box to desired location with the screws that are provided.
- Page 25 INSTALLING THE AIR CONDITIONING AND HEATING SYSTEM The PowerPac APU system uses a heating and air conditioning unit supplied by Dometic called “ TUNDRA”. A complete installation manual is included with the Tundra unit. Use this manual to successfully install the heating and air conditioner unit. When making electrical connections for the heating and air conditioning system, be sure to use the RED wire on the terminal block to power the system.
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Page 26: Finishing The Powerpac Installation
FINISHING THE POWERPAC INSTALLATION CHECK LIST Unit is securely mounted to vehicle All fasteners are torqued to specification Fuel lines are properly secured Battery cables are properly secured Power cable is properly secured Cables and fuel lines are away from moving components Cables and fuel lines are away from exhaust Fuel lines are double clamped and all clamps are tight All AC power connections are complete and tight... - Page 27 Once engine is running smooth, check the PowerPac for coolant, fuel, oil and exhaust leaks. Place the PowerPac cover on the unit. IMPORTANT!! Do NOT run the unit without the front cover for longer than 5 minutes. The front cover is necessary for the cooling system of the PowerPac. Damage may occur if the unit is allowed to run longer than 5 minutes.
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Page 28: Daily Checks And Maintenance Schedule
OPERATION OF THE POWERPAC UNIT 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 29: Starting And Stopping The Powerpac Apu
Starting and Stopping the PowerPac APU CHECK BEFORE OPERATING THE ENGINE • If the engine is malfunctioning DO NOT operate until repairs are made. • Be sure all guards and shields are in place before operating the engine. Replace any that are damaged or missing. •... -
Page 30: Powering Appliance And Auxiliary Systems
Stopping the Engine It is recommended to disconnect or reduce the power load by turning off appliances before shutting down the engine. Then follow the steps outlined above for normal shutdown. Powering Appliances and Auxiliary Systems Once the PowerPac APU is running, you will have AC power through the power outlet box. Plug devices such as television, DVD player, cell phone charger etc. -
Page 31: Engine Specifications
ENGINE SPECIFICATIONS MODEL KUBOTA Z482 CATERPILLAR CO.5 Continuous Output 8.5 HP @ 2800 rpm 8.5 HP @ 2800 rpm Fuel and type Diesel, 4 cycle Diesel, 4 cycle Cylinder Arrangement 2 In-line 2 In-line Bore and Stroke 2.64 x 2.69 (67 x 68mm) Cubic Capacity 29.23in (.479L) - Page 32 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 34 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 Capacitor Refer to Power Tech Service Center Replace Capacitor...
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Page 35: Engine Will Not Start
ENGINE WILL NOT START Engine Cranks Engine Does NOT Engine 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 36: High Altitude
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 37: Checking Engine Oil
ENGINE OIL MAINTENANCE V-1903-BG, V-2003-T, V-2203-BG ENGINE CHECKING ENGINE OIL LEVEL REFILL CAPACITIES Crankcase Oil Sump 8.5 Qts. (8.04L) and Filter LUBRICATING OIL VISCOSITY RECOMMENDATIONS ( Y ) “ADD” mark. ( X ) “FULL” mark. The minimum ambient temperature during cold 1. -
Page 38: Engine Coolant Maintenance
ENGINE COOLANT MAINTENANCE COOLANT SERVICE LIFE Coolant Type Service Life COOLANT RECOMMENDATIONS Commercial Heavy-Duty Coolant/Antifreeze that 3000 Service Hours For optimum performance, Power Technology Meets “ASTM D5345” or Two Years recommends a 1:1 mixture of water / glycol. Commercial Heavy-Duty NOTE: Use a mixture that will provide Coolant/Antifreeze that 3000 Service Hours... - Page 39 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 40 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.
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