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Summary of Contents for Power Tech Generators TPU-7000
- Page 1 TPU-7000 TPU-8000 Operators Manual Power Technology Southeast, Inc. 634 State Road 44 Leesburg, FL 34748-8103 ♦ (352) 365-2777 ♦ Fax (352) 787-5545 ♦ 4/2008...
- Page 2 Thank you for your purchase of a Power Technology Generator. The information contained in this manual applies to TPU-7000 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 BY WIRELESS REMOTE ENGINE SPECIFICATIONS ENGINE MAINTENANCE SERVICE SCHEDULE ENGINE OIL MAINTENANCE ENGINE COOLANT MAINTENANCE OPERATING HOURS AND SERVICE LOG SECTION 3: “GENERATOR END” PRINCIPLES OF OPERATION “C”...
- 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 2-2A BY WIRELESS REMOTE ENGINE SPECIFICATIONS Kubota Models D1105-B Service Parts ENGINE MAINTENANCE SERVICE SCHEDULE ENGINE OIL MAINTENANCE Checking Engine Oil Level Lubricating Oil Specifications Engine Refill Capacities Lubricating Oil Viscosity Recommendations ENGINE COOLANT MAINTENANCE Coolant 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 ENGINE SPECIFICATIONS MODEL Kubota D1105-B Continuous Output 13.6 HP @ 1800 rpm Cubic Capacity 68.5 in³ (1.12L) 3.07” x 3.09” Bore and Stroke (78.0 x 78.4mm) Cylinder Arrangement 3 In-Line Firing Order 1-2-3 Compression Ratio 22:1 Engine Oil Capacity 4.0 qts. (3.78L) Coolant Capacity 6qts.
- Page 13 Engine Maintenance Service Schedule Min. Every Maintenance *See Daily Every 100 Every 250 Every 500 Remarks Every 1000 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 14 ENGINE OIL MAINTENANCE CHECKING ENGINE OIL LEVEL KUBOTA D1105-B ENGINE REFILL CAPACITIES Crankcase Oil Sump 4.0 Qts. (3.78L) and Filter LUBRICATING OIL VISCOSITY RECOMMENDATIONS ( Y ) “ADD” mark. ( X ) “FULL” mark. The minimum ambient temperature during cold 1.
- Page 15 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 16 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 7 KW EXCITER TYPE “C” GENERATOR ASSEMBLY WIRING SCHEMATICS 120 Volt Connection “C” Series Exciter Type 120 / 240 Volt Connection “C”...
- Page 17 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 18 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 19 DESCRIPTION PART NUMBER 1. BEARING PLATE 02BR-CR 2. END BELL 02H7810 3.EXCITER STATOR 02STA7EXC 4. MAIN STATOR 02STAMNCD7 5. BELL HOUSING ** 02BHCD7 6. ROTOR BEARING 02BRG6206 7. DIODE PLATE 02PLD8CD 8. EXCITER ROTOR 02RTR7EXC 9. MAIN ROTOR 02RTRMN7EXC 10. END BELL ASSEMBLY 02EB7 11.
- Page 20 RESISTANCE CHART MARKS COLOR MAIN STATOR U1-V1 or U2-V2 POWER TECHNOLOGY SOUTHEAST, INC. MAIN ROTOR 634 STATE ROAD 44 EXCITER STATOR 83.5 F1-F2 LEESBURG, FL 34748-8103 EXCITER ROTOR 0.31 (352) 365-2777 FAX (352) 787-5545 AUX. WINDING BATT. CHARGE CH W SENSING WINDING BLUE / BROWN NOTE: THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE...
- Page 21 RESISTANCE CHART MARKS COLOR MAIN STATOR U1-V1 or U2-V2 POWER TECHNOLOGY SOUTHEAST, INC. MAIN ROTOR 634 STATE ROAD 44 EXCITER STATOR 83.5 F1-F2 LEESBURG, FL 34748-8103 EXCITER ROTOR 0.31 (352) 365-2777 FAX (352) 787-5545 AUX. WINDING BATT. CHARGE CH W SENSING WINDING BLUE / BROWN NOTE: THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE...
- Page 22 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 23 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 24 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 25 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) MODEL TPU-7000 GENERATOR DIMENSIONS L x W x H 31.375” x 24.188” x 24.625” WEIGHT 525 lbs.
- Page 26 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 .16 GPH .32 GPH .51 GPH...
- Page 27 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 28 AIR REQUIREMENTS CONT’D ENGINE SPEED IN RPM 1800 OUTPUT IN HORSEPOWER 10.5 ENGINE INLET WATER TEMP. THERMOSTAT RATING* 160°F – 180°F THERMOSTAT FULL OPEN 203°F ENGINE OUTLET WATER TEMP.MAX. 230°F HIGH TEMP. SHUTDOWN SWITCH 230°F HEAT REJECTION – BTU / MIN. HEAT REJECTION –...
- Page 29 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 30 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 32 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 33 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 34 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 35 ENGINE WILL NOT START ENGINE CRANKS ENGINE DOES NOT CRANK ENGINE CRANKS SLOW Battery Main Switch Dead No Exhaust Smoke From Exhaust Smoke Oil Viscosity Check Check Too Heavy Glow Plugs Terminals Check Fuel Check Fuel Solenoid Supply Turn Switch Check Spark NO Power Arrestor...
- Page 36 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 37 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 38 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 39 OVERLOAD CONDITION CONDITION CONDITION CONDITION Check AMP Draw Check Load Check Engine Problem Stator Coil Resistance See Engine Troubleshooting Replace Stator...
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