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- Page 1 PTRV- 17.5K PTRV- 20K PTRV-17.5KT PTRV-20KT Operator & Installation Manual Power Technology Southeast, Inc. 634 State Road #44 Leesburg, FL 34748-8103 ♦ (352) 365-2777 ♦ Fax (352) 787-5545 ♦ 3/2007 MANPTRV20...
- Page 2 Thank you for your purchase of a Power Technology Generator. The information contained in this manual applies to PTRV-17.5K & KT, PTRV-20K & KT generators. In the event you experience a problem with your generator please contact the sales dealer, one of our authorized service centers or Power Technology’s Customer Service Department directly at 1-800-760-0027 from 8:00 a.m.
- 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 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 “M”...
- Page 5 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 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 SECTION 2 “ENGINE” PRE-OPERATION CHECK Engine Break-in Period Daily Check OPERATING THE ENGINE Engine Starting Controls Check Engine After Starting Stopping the Engine ENGINE SPECIFICATIONS Kubota Model V-2203 Service Parts ENGINE MAINTENANCE SERVICE SCHEDULE ENGINE OIL MAINTENANCE Checking Engine Oil Level Lubricating Oil Specifications Engine Refill Capacities Lubricating Oil Viscosity Recommendations...
- Page 11 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 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 MODEL V-2203 V-2003-T Air Induction Naturally Aspirated Turbocharged Continuous Output 32.5 HP @ 1800 rpm 36.3 HP @ 1800 rpm Cubic Capacity 134.07 in³ (2.19L) 121.99 in³ (1.99L) Bore and Stroke 3.43 x 3.64 3.27x3.64 (87x92.4mm) (83x92.4mm) Cylinder Arrangement 4 In-Line 4 In-Line Firing Order...
- Page 14 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 CHECKING ENGINE OIL LEVEL KUBOTA V-2203 & V-2003-T ENGINE 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 16 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 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 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 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 SECTION 3 “GENERATOR END” PRINCIPLES OF OPERATION Rotating Field Assembly (Rotor) Core Assembly Field Coil Voltage Connection Electronic Voltage Regulation Exciter Field Coil Voltage Source Balance Bearing Stator Assembly “M” SERIES EXCITER TYPE GENERATOR ASEMBLY GENERATOR END TROUBLESHOOTING GUIDES Zero or Low Voltage Voltage Test 12-Volt Battery Test Overload Condition...
- Page 22 GENERATOR ASSEMBLY INFORMATION EXCITER TYPE GENERATOR The exciter pole pieces contain residual magnetism, which sets up lines of force across the air gap to the exciter armature. When the exciter begins to rotate a voltage is induced and current flow is initiated in the exciter armature AC windings.
- Page 23 ROTATING FIELD ASSEMBLY (ROTOR) The rotating field assembly consists basically of four members: 1) the shaft assembly, 2) the core assembly, 3) the field coil damper windings, and 4) balance lugs to provide a high degree of static and dynamic balance. CORE ASSEMBLY The core assembly consists of a quantity of thin steel plates compressed and fastened together to form a single laminated assembly.
- Page 24 DESCRIPTION PART NUMBER 17.5KW 20KW 1. END COVER NS-GENCAN NS-GENCAN 2. EXCITER ROTOR 02RTR1520EXC 02RTR1520EXC 3. EXCITER STATOR 02STA1520EXCG 02STA1520EXCG 4. REAR HOUSING BRACKET 02HB175 02HB15TCGE 5. ROTOR BEARING 02BRG207 02BRG207 6. MAIN STATOR ASSEMBLY** 02STMN175 02STMN20 7. MAIN ROTOR ASSEMBLY 02RTRMN175 02RTRMN20 GENERATOR ASSEMBLY...
- Page 25 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 26 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 27 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 28 RESISTANCE CHART “M” SERIES EXCITER TYPE 17.5 Marks Color Main Stator Less Than 1.0 Less Than 1.0 T1-T2 T3- Black / Black Ohm / Phase Ohm / Phase Main Rotor 2.00 2.10 Exciter Stator 23.0 – 28.0 23.0 – 28.0 F+ –...
- Page 29 RESISTANCE CHART “M” SERIES EXCITER TYPE 17.5 Marks Color Main Stator Less Than 1.0 Less Than 1.0 T1-T2 T3- Black / Black Ohm / Phase Ohm / Phase Main Rotor 2.00 2.10 Exciter Stator 23.0 – 28.0 23.0 – 28.0 F+ –...
- Page 30 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 31 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 32 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 33 3. Add oil to crankcase, to the dipstick FULL mark. 4. Connect fuel lines, remote switch, load leads and battery terminals. (Consult the Specification Charts on the Following Pages for Requirements) MODELS PTRV-17.5K PTRV-20K PTRV-17.5KT PTRV-20KT DIMENSIONS L x W x H 41”...
- Page 34 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 CHARGING AMPS. FUEL CONSUMPTION IN GALLONS PER HOUR LOAD PERCENTAGE 17.5KW 20KW...
- Page 35 GENERATOR COMPARTMENT SIZE In planning the size of the generator compartment allow for the minimum clearance of one (1) inch 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 36 AIR REQUIREMENTS CONT’D 17.5KW 20KW ENGINE SPEED IN RPM 1800 1800 OUTPUT IN HORSEPOWER 32.5 32.5 WATER FLOW – GAL. / MIN. 8.75 8.75 ENGINE INLET WATER TEMP. THERMOSTAT – RATING 180°F 180°F THERMOSTAT FULL OPEN 195°F 195°F ENGINE OUTLET WATER TEMP.MAX. 235°F 235°F HIGH TEMP.
- Page 37 GENERATOR ENCLOSURES Some installations require the Genset to be mounted inside an enclosure. Enclosures are generally constructed of heavy gauge sheet metal, and completely insulated. Enclosures are typically installed in RV’s with large unobstructed compartments. The major advantage to installing a Genset in an enclosure is to achieve a significant reduction in the unit’s sound level. In order to maintain the ambient temperature within the enclosure a forced cool air system is generally employed.
- Page 38 PTRV-17.5K / KT and PTRV-20K / KT DIMENSIONS and ENCLOSURE LAYOUT RIGHT SIDE VIEW FRONT REAR LEFT RIGHT LEFT RIGHT FRONT ENCLOSURE BASE PAN CUTOUTS...
- Page 39 INSTALLATION DIMENSIONS GENSET DIMENSIONS L x W x H 41” x 27” x 28” MINIMUM DIMENSION FOR INSIDE CLEARANCE OF AN ENCLOSURE L x W x H 43” x 29” x 29” NOTE: BESURE TO ALLOW FOR THE THICKNESS OF SOUNDMAT OR INSULATION...
- Page 40 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 41 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 42 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 44 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 45 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 46 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 47 GAC ESD2110 SERIES SPEED CONTROL UNIT The ESD2110 Speed Control Unit is part of an engine governing system designed to control engine speed and stability throughout the load range. Operating in combination with a magnetic pick-up and electric actuator the ESD2110 will maintain the proper engine speed by adjusting the fueling system according to the applied load.
- Page 48 BASLER AVC63-4 ANALOG VOLTAGE CONTROLLER The AVC63-4 voltage regulator is designed for use on 50/60 Hz brushless generators. Features include frequency compensation, over excitation shutdown, a solid-state build-up circuit and EMI filtering. The AVC63-4 attaches to the generator with spade type wire terminals for a secure connection. The AVC63-4 has three adjustable potentiometers for fine-tuning the output voltage, stability and under frequency.
- Page 49 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 50 POWER TECHNOLOGY SOUTHEAST, INC. 634 STATE ROAD 44 LEESBURG, FL 34748-8103 (352) 365-2777 FAX (352) 787-5545 12V DC ENGINE CONTROL 550 SERIES PTRV-17.5K and PTRV-20K...
- Page 51 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...
- Page 52 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 53 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 54 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 55 OVERLOAD CONDITION Check AMP Draw Check Load Engine Problem Check Stator Coil Resistance See Engine Troubleshooting Replace Stator...
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