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Power Tech Generators PTGK-20 Operation & Maintenance Manual

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PTGK-20
OPERATION &
MAINTENANCE
MANUAL

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Summary of Contents for Power Tech Generators PTGK-20

  • Page 1 PTGK-20 OPERATION & MAINTENANCE MANUAL...
  • Page 2 WARNING: Engine exhaust, some of its constituents, certain vehicle components and fluids, contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WARNING: This product can expose you to chemicals including carbon monoxide, toluene, and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 3 ABLE OF ONTENTS Table of Contents ............................... 3 Foreword ................................7 Safety ................................... 8 Safety Notes ..............................8 Operating Safety............................. 9 Accidental Start-up............................. 9 Moving Parts .............................10 Fire ................................10 Engine Exhaust ............................11 Voltage Hazard ............................12 Burn Hazard ..............................13 Information ...............................14 Specifications ..............................14 Component Locations ..........................15 The Generator Controller ..........................18...
  • Page 4 Coolant Specifications ..........................26 Checking the Coolant ..........................26 Changing the Coolant ..........................27 Cleaning the Radiator Core........................28 Fuel System Maintenance ...........................29 Fuel Pump ..............................29 Fuel Lines ..............................29 Fuel Specifications ...........................29 Bleeding the Fuel System ........................30 Changing the Fuel Filters.........................31 Air Intake System Maintenance........................32 Changing the Intake Air Filter .........................32 Service Log ................................33 Basic Troubleshooting .............................34...
  • Page 5 219/380V, 50Hz, 3Ф, A-Type Gen End w/ AS440 AVR ......................40 219/380V, 50Hz, 3Ф, A-Type Gen End w/ SX460 AVR ................42 Page 5 of 45...
  • Page 6 277/480V, 60Hz, 3Ф, A-Type Gen End w/ AS440 AVR ................43 277/480V, 60Hz, 3Ф, A-Type Gen End w/ SX460 AVR ................44 Revisions ................................45 Page 6 of 45...
  • Page 7 OREWORD Thank you for your purchase of a Power Tech 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 Power Tech generator, please fully read and understand this manual.
  • Page 8 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 9 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 10 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 11 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 12 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 13 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 14 NFORMATION PECIFICATIONS ENGINE Make Kubota Model WG2503 Cylinders Aspiration Natural Aspiration EPA Tier / CARB Tier Tier 2 / Tier 3 HP @ 1800rpm (Continuous Duty) 1.3 gal/hr @ ½ Load Approximate Fuel Consumption 2.6 gal/hr @ Full Load Starting Voltage 12VDC Battery Cable Gauge 2 AWG Minimum...
  • Page 15 OMPONENT OCATIONS Page 15 of 45...
  • Page 16 Page 16 of 45...
  • Page 17 Page 17 of 45...
  • Page 18 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 19 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 20 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 21 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 22 AINTENANCE CHEDULE 1000 2000 Maintenance Service Item Daily Remarks notes Hours Hours Hours Hours      Check Engine Oil Level      Check Coolant Level  Check for Oil, Fuel, and    ...
  • Page 23 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 gasoline engines. Engine oil should meet API classification of SL or higher.
  • Page 24 Always put the generator set in OFF mode 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 25 5. Drain the oil using one of the following methods: 6. If not already fitted, install the supplied nipple on to the oil drain valve. 7. Install a 5/8” hose over the nipple on the end of the drain valve and route hose out the bottom of the enclosure into an appropriate container.
  • Page 26 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 27 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 28 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. Close radiator drain and refill radiator with appropriate coolant. 10.
  • Page 29 YSTEM AINTENANCE The fuel system pulls fuel from the fuel tank, filters out dirt and impurities, 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 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 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 33 ERVICE This service log is provided to assist you in keeping track of services performed on the generator set. Date Hours Service Performed Page 33 of 45...
  • Page 34 ASIC ROUBLESHOOTING TROUBLE POSSIBLE CAUSE SUGGESTED ACTION Put controller in AUTO mode by Controller is not in AUTO pressing the AUTO (A) button on mode the local controller Generator will not start from Remote connection plug is Check remote control plug is remote panel or other not connected plugged in...
  • Page 35 IRING IAGRAMS 120/240V, 60H , 1Ф, A-T / AS440 AVR ND W Page 35 of 45...
  • Page 36 120/240V, 60H , 1Ф, A-T / SX460 AVR ND W Page 36 of 45...
  • Page 37 220V S , 50H , 1Ф, A-T / AS440 AVR INGLE ND W Page 37 of 45...
  • Page 38 220V S , 50H , 1Ф, A-T / SX460 AVR INGLE ND W Page 38 of 45...
  • Page 39 120/208V, 60H , 3Ф, A-T / AS440 AVR ND W Page 39 of 45...
  • Page 40 120/208V, 60H , 3Ф, A-T / SX460 AVR ND W Page 40 of 45...
  • Page 41 219/380V, 50H , 3Ф, A-T / AS440 AVR ND W Page 41 of 45...
  • Page 42 219/380V, 50H , 3Ф, A-T / SX460 AVR ND W Page 42 of 45...
  • Page 43 277/480V, 60H , 3Ф, A-T / AS440 AVR ND W Page 43 of 45...
  • Page 44 277/480V, 60H , 3Ф, A-T / SX460 AVR ND W Page 44 of 45...
  • Page 45 EVISIONS Revision Date Initial Release 6/5/2024 Page 45 of 45...