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Power Tech Generators PTI-38 Operation Maintenance & Parts Manual

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PTI-38
OPERATION &
MAINTENANCE
MANUAL

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Summary of Contents for Power Tech Generators PTI-38

  • Page 1 PTI-38 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 ................................5 Safety ................................... 6 Safety Notes ..............................6 Operating Safety............................. 7 Accidental Start-up............................. 7 Moving Parts ............................... 8 Fire ................................8 Engine Exhaust ............................9 Voltage Hazard ............................10 Burn Hazard ..............................11 Information ...............................12 Specifications ..............................12 Component Locations ..........................13...
  • Page 4 Cooling System Maintenance ........................24 Coolant Specifications ..........................24 Checking the Coolant ..........................24 Changing the Coolant ..........................25 Cleaning the Radiator Core........................26 Fuel System Maintenance ...........................28 Fuel Pump ..............................28 Fuel Lines ..............................28 Fuel Specifications ...........................28 Bleeding the Fuel System ........................29 Draining Water from the Fuel Filters .....................30 Changing the Fuel Filters.........................31 Air Intake System Maintenance........................33 Changing the Intake Air Filter .........................33...
  • Page 5 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 6 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 7 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 8 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 9 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 10 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 11 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 12 NFORMATION PECIFICATIONS ENGINE Make Isuzu Model 4LE2X Cylinders Aspiration Turbocharged EPA Tier Tier 4 HP @ 1800rpm (Continuous Duty) Approximate Fuel Consumption 3.7 gal/hr @ Full Load Starting Voltage 12VDC Battery Cable Gauge 2 AWG Minimum Oil Capacity Approx. 8.7 Qts (8.2 L) Cooling System Capacity Approx.
  • Page 13 OMPONENT OCATIONS Page 13 of 44...
  • Page 14 Page 14 of 44...
  • Page 15 Page 15 of 44...
  • Page 16 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 17 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 18 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 19 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 20 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 21 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 22 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 23 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 24 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 25 During operation, some parts of the generator set can become extremely hot. To avoid burns, allow the engine to cool sufficiently before checking the coolant level. DO NOT remove the radiator cap while the radiator is hot. Doing so could result in extremely hot coolant spraying out.
  • Page 26 Always stop the engine before changing the coolant. DO NOT change the coolant while the engine is running. Always put the generator set in OFF mode and activate the Start Inhibit switch (if equipped) before changing the coolant. If the generator set is in AUTO mode, the generator set may start automatically, without warning.
  • Page 27 During operation, some parts of the generator set can become extremely hot. To avoid burns, allow the engine to cool sufficiently before cleaning the radiator core. Always stop the engine before cleaning the radiator core. DO NOT clean the radiator core while the engine is running.
  • Page 28 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 29 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 30 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 31 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 32 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 33 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 34 ERVICE This service log is provided to assist you in keeping track of services performed on the generator set. Date Hours Service Performed Page 34 of 44...
  • Page 35 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 36 IRING IAGRAMS 120/240V, 60H , 1Ф, A T / AS440 AVR ND W Page 36 of 44...
  • Page 37 120/240V, 60H , 1Ф, A T / SX460 AVR ND W Page 37 of 44...
  • Page 38 120/208V, 60H , 3Ф, A T / AS440 AVR ND W Page 38 of 44...
  • Page 39 120/208V, 60H , 3Ф, A T / SX460 AVR ND W Page 39 of 44...
  • Page 40 219/380V, 50H , 3Ф, A T / AS440 AVR ND W Page 40 of 44...
  • Page 41 219/380V, 50H , 3Ф, A T / SX460 AVR ND W Page 41 of 44...
  • Page 42 277/480V, 60H , 3Ф, A T / AS440 AVR ND W Page 42 of 44...
  • Page 43 277/480V, 60H , 3Ф, A T / SX460 AVR ND W Page 43 of 44...
  • Page 44 EVISIONS Revision Date Initial Release 7/22/2024 6/25/2025 Page 44 of 44...