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Power Tech Generators PTI-25 Operation & Maintenance Manual

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PTI-25
PTI-30
OPERATION &
MAINTENANCE
MANUAL

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Summary of Contents for Power Tech Generators PTI-25

  • Page 1 PTI-25 PTI-30 OPERATION & MAINTENANCE MANUAL...
  • Page 2 WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well-ventilated area.  If in an enclosed area, vent the exhaust to the outside. ...
  • Page 3 ABLE OF ONTENTS Table of Contents ............................... 3 Foreword ................................6 Safety ................................... 7 Safety Notes ..............................7 Operating Safety............................. 8 Accidental Start-up............................. 8 Moving Parts ............................... 9 Fire ................................9 Engine Exhaust ............................10 Voltage Hazard ............................11 Burn Hazard ..............................12 Information ...............................13 Specifications ..............................13 Component Locations ..........................14...
  • Page 4 Cooling System Maintenance ........................25 Coolant Specifications ..........................25 Checking the Coolant ..........................25 Changing the Coolant ..........................26 Cleaning the Radiator Core........................27 Fuel System Maintenance ...........................29 Fuel Pump ..............................29 Fuel Lines ..............................29 Fuel Specifications ...........................29 Bleeding the Fuel System ........................30 Draining Water from the Fuel Filters .....................31 Changing the Fuel Filters.........................32 Air Intake System Maintenance........................34 Changing the Intake Air Filter .........................34...
  • Page 5 219/380V, 50Hz, 3Ф, A & C-Type Gen End w/ AS440 AVR ...............52 219/380V, 50Hz, 3Ф, C-Type Gen End w/ 63-4 AVR ..................53 277/480V, 60Hz, 3Ф, A & C-Type Gen End w/ AS440 AVR ...............54 277/480V, 60Hz, 3Ф, C-Type Gen End w/ 63-4 AVR ..................55 Revisions ................................56 Page 5 of 56...
  • Page 6 OREWORD Thank you for your purchase of a PowerTech generator set. It is engineered to the utmost quality standards, manufactured in a strict quality control environment, and will assure you a long, satisfactory service. To have the best performance from your PowerTech generator, please fully read and understand this manual.
  • Page 7 AFETY AFETY OTES This symbol indicates a safety alert. It is used to indicate potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury and death. This manual has several types of safety precautions and instructions: DANGER, WARNING, CAUTION, NOTICE, and Note.
  • Page 8 PERATING AFETY Before operating this generator, be sure to read and understand all instructions. This generator set has been designed for safe operation in a specific application. DO NOT modify or use this generator set for any application other than that it has been designed for.
  • Page 9 Moving Parts DANGER Moving Parts. Will cause severe injury or death. While in operation, there may be exposed moving parts. DO NOT wear loose, torn, or bulky clothing around the generator set.  Be sure all guards and shields are in place before operating the generator set. ...
  • Page 10 DO NOT attempt to use ether or other starting aids. Doing so may cause a flash fire and/or  damage the engine. Inspect and replace any damaged wiring if necessary.  Engine Exhaust WARNING Carbon Monoxide Can cause severe nausea, fainting, or death.
  • Page 11 Voltage Hazard DANGER Hazardous Voltage Will cause severe injury or death. Whenever electricity is present, there is an electrocution risk. Following proper safety procedures can reduce the risk of electrocution. When connecting the generator set, be sure to follow any local, state, and National Electric ...
  • Page 12 Burn Hazard WARNING WARNING Hot Engine and Exhaust System Hot Coolant and Steam Can cause severe injury or death. Can cause severe injury or death. During operation, some components of the generator set can become extremely hot. These parts include, but are not limited to, the engine, exhaust manifold and piping, muffler, generator end, and voltage regulator.
  • Page 13 Approx. 8.7 Qts (8.2 L) Cooling System Capacity Approx. 12 Qts (11.4 L) GENERATOR Brushless with Automatic Voltage Generator Type Regulator 25,000W @ 60Hz PTI-25 20,800W @ 50Hz (Optional) Generator Output (Continuous Prime) 30,000W @ 60Hz PTI-30 25,000W @ 50Hz (Optional) MAINTENANCE PARTS...
  • Page 14 OMPONENT OCATIONS Page 14 of 56...
  • Page 15 Page 15 of 56...
  • Page 16 Page 16 of 56...
  • Page 17 ENERATOR ONTROLLER NTRODUCTION This generator set is equipped with one of PowerTech’s advanced PTG series electronic generator controllers. The PTG series controllers provide manual and remote starting capability, as well as other options such as auto start on low battery and generator exercising. In addition to starting and shutting down the generator set, the PTG controllers monitor and display engine and generator parameters, such as, operating hours, engine speed, engine temperature, oil pressure, battery voltage, generator voltage, frequency, and more.
  • Page 18 PERATING THE ENERATOR TART To ensure proper and reliable operation, always inspect the generator set daily and prior to each startup. Verify that the engine oil level is at the correct level. Add if necessary.  Verify that the coolant is at the correct level. Add if necessary. ...
  • Page 19 EMOTE AND TARTING THE ENERATOR If desired, the generator set is capable of being started either manually from a remote panel or automatically via an external signal from a transfer switch or other device. The following steps are used to set up the controller to accept an external start signal. Ensure the Pre-Start checks above have been completed before putting the generator set into AUTO mode.
  • Page 20 AINTENANCE For the longest life and reliable operation, it is important that the generator set is maintained periodically according to the factory’s specifications. Maintenance should be performed in a safe and environmentally friendly manner. Before servicing this generator, be sure to read and understand all instructions. This generator set has been designed for safe operation in a specific application.
  • Page 21 AINTENANCE CHEDULE 1000 Maintenance Service Item Daily Remarks notes Hours Hours Hours      Check Engine Oil Level      Check Coolant Level  Check for Oil, Fuel, and      ...
  • Page 22 NGINE AINTENANCE High quality engine oil is crucial to reliable operation and increased life expectancy of the generator set. Engine oil provides lubrication and cooling to the internal components of the engine. Lubricating Oil Specifications It is important to use a high quality, multi-grade engine oil designed for diesel engines. Engine oil should meet API classification of CJ-4 or higher.
  • Page 23 Always put the generator set in OFF mode and activate the Start Inhibit switch (if equipped) before checking the oil. If the generator set is in AUTO mode, the generator set may start automatically, without warning. 1. Shut down the generator set and put it in OFF mode. 2.
  • Page 24 4. Allow the generator set to sit for at least 5 minutes to allow the generator set to cool and allow oil to flow back to the oil pan. 5. If not already fitted, install the supplied nipple on to the oil drain valve. 6.
  • Page 25 OOLING YSTEM AINTENANCE The cooling system circulates coolant through the engine where it absorbs excess heat from the engine. The coolant then flows through the radiator where this waste heat is exhausted to the atmosphere. Proper maintenance will help prolong the life of your generator set. Coolant Specifications It is important to use a high-quality engine coolant.
  • Page 26 1. Shut down the generator set and put it in OFF mode. 2. If equipped, activate the Start Inhibit switch. 3. Ensure the generator set is on a level surface and properly supported. 4. Allow the generator set to cool fully. 5.
  • Page 27 5. Carefully open the radiator cap, allowing any pressure to vent before removing. 6. Open the radiator drain on the bottom of the radiator and drain old coolant into an appropriate container. 7. Drain the overflow bottle and refill. 8. Check all hoses and hose clamps. Replace if necessary. 9.
  • Page 28 of the radiator and may cause the generator set to run hotter or overheat. Periodic cleaning of the radiator core is recommended to ensure proper air flow. Visually inspect the core for any obstructions, such as dirt or other foreign objects. Use running water to flush debris from between the fins.
  • Page 29 YSTEM AINTENANCE The fuel system pulls diesel fuel from the fuel tank, filters out water and other contaminants, then conveys it to the engine for combustion. Unused fuel is returned to the fuel tank through a return line. To prevent engine damage and excess wear, the use of proper fuels and proper fuel system maintenance is required.
  • Page 30 Bleeding the Fuel System DANGER WARNING WARNING Moving Parts. Hot Engine and Exhaust Risk of Fire Will cause severe injury or System Can cause severe injury or death. Can cause severe injury or death. death. During operation, some parts of the generator set can become extremely hot. To avoid burns, allow the engine to cool sufficiently before bleeding the fuel system.
  • Page 31 Draining Water from the Fuel Filters DANGER WARNING WARNING Moving Parts. Hot Engine and Exhaust Risk of Fire Will cause severe injury or System Can cause severe injury or death. Can cause severe injury or death. death. During operation, some parts of the generator set can become extremely hot. To avoid burns, allow the engine to cool sufficiently before draining the fuel filters.
  • Page 32 Changing the Fuel Filters DANGER WARNING WARNING Moving Parts. Hot Engine and Exhaust Risk of Fire Will cause severe injury or System Can cause severe injury or death. Can cause severe injury or death. death. During operation, some parts of the generator set can become extremely hot. To avoid burns, allow the engine to cool sufficiently before changing the fuel filters.
  • Page 33 12. Dispose of the old filter according to local regulations. Fuel Pump Filter Replacement 1. Shut down the generator set and put it in OFF mode. 2. If equipped, activate the Start Inhibit switch. 3. Ensure the generator set is on a level surface and properly supported. 4.
  • Page 34 NTAKE YSTEM AINTENANCE The air intake system pulls in outside air, filters out contaminants, and supplies it to the engine for combustion. Changing of the intake air filter is required to prevent engine damage and excess wear. Changing the Intake Air Filter DANGER WARNING Moving Parts.
  • Page 35 ERVICE This service log is provided to assist you in keeping track of services performed on the generator set. Date Hours Service Performed Page 35 of 56...
  • Page 36 ASIC ROUBLESHOOTING TROUBLE POSSIBLE CAUSE SUGGESTED ACTION Put controller in AUTO mode by Controller is not in AUTO mode pressing the AUTO (A) button on the local controller Remote connection plug is not Check remote control plug is Generator will not start from connected plugged in remote panel or other...
  • Page 37 IRING IAGRAMS 120V O , 60H , 1Ф, AE-T / AS440 AVR ND W Page 37 of 56...
  • Page 38 120V O , 60H , 1Ф, C-T / AS440 AVR ND W Page 38 of 56...
  • Page 39 120V O , 60H , 1 P , C-T / 63-4 AVR HASE ND W Page 39 of 56...
  • Page 40 120/240V, 60H , 1Ф, AE-T / AS440 AVR ND W Page 40 of 56...
  • Page 41 120/240V, 60H , 1Ф, C-T / AS440 AVR ND W Page 41 of 56...
  • Page 42 120/240V, 60H , 1Ф, C-T / 63-4 AVR ND W Page 42 of 56...
  • Page 43 220V S , 50H , 1Ф, AE-T / AS440 AVR INGLE ND W Page 43 of 56...
  • Page 44 220V S , 50H , 1Ф, C-T / AS440 AVR INGLE ND W Page 44 of 56...
  • Page 45 220V S , 50H , 1Ф, C-T / 63-4 AVR INGLE ND W Page 45 of 56...
  • Page 46 120/240V, 60H , 3Ф, A & C-T / AS440 AVR ND W Page 46 of 56...
  • Page 47 120/240V, 60H , 3Ф, A-T / SX460 AVR ND W Page 47 of 56...
  • Page 48 120/240V, 60H , 3Ф, C-T / 63-4 AVR ND W Page 48 of 56...
  • Page 49 120/208V, 60H , 3Ф, A & C-T / AS440 AVR ND W Page 49 of 56...
  • Page 50 120/208V, 60H , 3Ф, A-T / SX460 AVR ND W Page 50 of 56...
  • Page 51 120/208V, 60H , 3Ф, C-T / 63-4 AVR ND W Page 51 of 56...
  • Page 52 219/380V, 50H , 3Ф, A & C-T / AS440 AVR ND W Page 52 of 56...
  • Page 53 219/380V, 50H , 3Ф, C-T / 63-4 AVR ND W Page 53 of 56...
  • Page 54 277/480V, 60H , 3Ф, A & C-T / AS440 AVR ND W Page 54 of 56...
  • Page 55 277/480V, 60H , 3Ф, C-T / 63-4 AVR ND W Page 55 of 56...
  • Page 56 EVISIONS Revision Date Initial Release 7/20/2022 2/27/2023 Page 56 of 56...

This manual is also suitable for:

Pti-30