PTRV- 8 KSI PTRV-10 KSI PTRV-12 KSI Operators & Installation Manual Power Technology Southeast, Inc.
FORWARD You are now the proud owner of a Power Technology Generator powered by a Kubota engine. This engine is a product of Kubota’s quality engineering and manufacturing. The engine is made with fine materials and manufactured under the strictest quality control standards and will assure you long satisfactory service. To obtain the best use of your engine, please read this manual carefully.
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.
TABLE of CONTENTS SECTION 1: “SAFETY” 1-4 SAFE OPERATION SECTION 2: “ENGINE” PRE-OPERATION CHECK OPERATING the ENGINE with POWER CONTROL MODULE and DISPLAY ENGINE SPECIFICATIONS GENERATOR MAINTENANCE SERVICE SCHEDULE ENGINE OIL MAINTENANCE ENGINE COOLANT MAINTENANCE OPERATING HOURS AND SERVICE LOG ENGINE TROUBLESHOOTING GUIDES SECTION 3: “GENERATOR END” GENERATOR ASSEMBLY INFORMATION PTRV-8-10-12 KSI “MB” TYPE GENERATOR ASSEMBLY GENERATOR END TROUBLESHOOTING GUIDES WIRING SCHEMATICS SECTION 4: 1
SECTION 1 “SAFETY” SAFE OPERATION 1-4 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 This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels attac
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. Be sure to observe the following for safe operation.
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. SAFE HANDLING OF FUEL AND LUBRICANTS • Always stop the engine before refueling or lubricating. • DO NOT smoke or allow flames or sparks in your working area. Fuel is extremely flammable and explosive.
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. High-pressure oil or fuel can cause personal injury. • Escaping hydraulic fluid under pressure has sufficient force to penetrate skin causing serious personal injury.
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. Only use anti-freeze that is recommended and approved by Caterpillar. • Be mindful of the environment.
SECTION 2 “ENGINE” PRE-OPERATION CHECK 1 Engine Break-in Period Daily Check OPERATING THE ENGINE with POWER CONTROL MODULE and DISPLAY_____ 2-5 Feature Summary Operating Behavior Automatic Generator Start (AGS) Safety Monitoring and Shutdown LED Sequence ENGINE SPECIFICATIONS 6 Kubota Model D-1105, V-1505 Service Parts ENGINE MAINTENANCE SERVICE SCHEDULE 7 ENGINE OIL MAINTENANCE 8 Checking Engine Oil Level Lubricating Oil Specifications Engine Refill Capacities Lubricating Oil Viscosity Recomme
PRE-OPERATION CHECK ENGINE BREAK-IN PERIOD During the engine break-in period, observe the following recommendations: 1. Change the engine oil and oil filter cartridge after the first 50 hours of operation. (See “ENGINE OIL” in ENGINE MAINTENANCE SERVICE SCHEDULE). 2. In ambient temperature above 32°F (0°C) approximately 3-5 minutes without a load is sufficient for engine warm up. Allow additional warm up time when temperatures are below 32°F (0°C) before placing an operating load on the engine.
Power Controller Module (PCM) And Display (PCMD) 2
Feature Summary The PowerTech PCM controls all of the start and run processes and characteristics of any PowerTech generator. The features of the application are: Internal Ambient Temperature Sensor Provides an on-board temperature sensor. Oil Pressure Sensor / Switch Input Allows input from an external oil pressure sensor or switch. Will shut down the generator if sufficient pressure is not detected after a start-up period.
Operating Behavior Starting The generator starts in response to the “START” button being depressed for 1 second. The PCM goes into the Pre-Heat State, followed by the Cranking State, then finally, the Running State. The PCM attempts to start the generator a specific number of times (configuration parameter) before declaring a Fault. The shutdown inputs are checked before the start is attempted. If any of these inputs are active, the start process is aborted.
Automatic Generator Start (AGS) The Automatic Generator Start (AGS) allows the generator to start based upon the battery level. The trigger voltage is configurable via a configuration parameter. The entire feature can be enabled/disabled by a configuration parameter. The AGS feature is currently disabled, by default. Safety Monitoring And Shutdown The PCM monitors inputs for safety limitations which might damage the generator.
ENGINE SPECIFICATIONS MODEL Kubota D1105 Kubota V1505 Continuous Output 13.6HP @ 1800 rpm 17.9HP @ 1800 rpm Cubic Capacity 68.53 in³ (1.123.L) 91.41in³ (1.498L) Bore and Stroke 3.07” x 3.09” (78.0 x 78.4mm) 3.07” x 3.09” (78.0 x 78.4mm) 3 In-Line 4 In-Line Firing Order 1-2-3 1-3-4-2 Compression Ratio 22:1 22:1 Engine Oil Capacity 5.38qts. (5.1L) 6.34 qts. (6.0L) Coolant Capacity 3.27qts. (3.1L) 4.22qts.(4.0L) Fuel and Type Diesel No. 2-D 4 Cycle Diesel No.
GENERATOR MAINTENANCE SERVICE SCHEDULE MAINTENANCE OPERATION * SEE DAILY EVERY EVERY EVERY EVERY NOTE 150 Hrs. 250 Hrs. 500 Hrs. 1000 Hrs.
ENGINE OIL MAINTENANCE CHECKING ENGINE OIL LEVEL KUBOTA ENGINE REFILL CAPACITIES Crankcase Oil Sump and Filter D-1105 5.38Qts. (5.1L) V-1505 6.34Qts. (6.0L) LUBRICATING OIL VISCOSITY RECOMMENDATIONS ( Y ) “ADD” mark. ( X ) “FULL” mark. 1. Maintain the engine oil level between “ADD” mark and “FULL” mark on oil level gauge. Do not fill crankcase above “FULL” mark. 2. Remove the oil filler cap and add oil, if necessary. Clean the oil filler cap. Install the oil filler cap.
ENGINE COOLANT MAINTENANCE COOLANT RECOMMENDATIONS COOLANT SERVICE LIFE For optimum performance, Power Technology recommends a 1:1 mixture of water / glycol. Coolant Type NOTE: Use a mixture that will provide protection against the lowest ambient temperature. NOTE: 100 percent pure glycol will freeze at a temperature of –23°C (-9°F). Most conventional heavy-duty coolant / antifreezes use Ethylene Glycol. Propylene Glycol may also be used in a 1:1 mixture with water.
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 DATE HRs.
ENGINE TROUBLE SHOOTING ENGINE STARTS BUT WON’T RUN CODE 1 or 6 Failure To Start If “OK” Check Fuel System Check Fuel Filter/Supply Check Circuit To Actuator Bleed Air From System If “OK” Replace Actuator Check Fuel Pump / Circuit CODE 2 or 8 Engine High Water Temp.
ENGINE TROUBLE SHOOTING ENGINE STARTS BUT WON’T RUN CONTINUED CODE 3 or 8 Check Oil Level/Condition Low Oil Pressure 12 If “OK” Check Wiring From Sensor to Terminal 12 on PCM If “OK” Check Oil Pres.
ENGINE RUNS ROUGH OR SLOW No Visible Exhaust Smoke Excessive Exhaust Smoke Insufficient Fuel to Engine BLUE SMOKE BLACK SMOKE GREY/WHITE SMOKE 13 Excessive Oil Level Check Fuel Level Replace Fuel Filter Air in Fuel System Check Fuel Pump Excessive Oil Consumption Dirty Air Filter Engine Cold Engine Overheated Incomplete Combustion Engine Overloaded Clogged Muffler Over Fueling Injector High Altitude Check Safety Shutdowns And Fuel Solenoid Glow Plug Circuit Not Operating Over Fueling Inje
ENGINE WILL NOT START ENGINE CRANKS No Exhaust Smoke Check Fuel Supply 14 NO Power While Cranking Replace Solenoid Battery Dead Smoke From Exhaust Check Fuel Solenoid YES ENGINE DOES NOT CRANK Check Fuel Pump NO Air in Fuel System No Power From PCMD Check Glow Plugs Check Spark Arrestor Muffler for Clogging ENGINE CRANKS SLOW Main Switch Oil Viscosity Too Heavy Check Terminals Turn Switch On Start Switch Low Battery Voltage Starter Motor
SECTION 3 “GENERATOR END” GENERATOR ASSEMBLY INFORMATION 1 Brush Set Electronic Voltage Regulation Rotor Bearing Rotor Balance Voltage Connection 8-10-12 KW “MB” BRUSH TYPE GENERATOR ASSEMBLY 2 GENERATOR END TROUBLESHOOTING GUIDES 3-6 Zero or Low Voltage Voltage Test 12-Volt Battery Test Overload Condition WIRING SCHEMATICS AC Electrical Circuit for 8KW “MB” Generators 120 Volts Line to Neutral 240 Volts Line to Line AC Electrical Circuit for 8KW “MB” Generators 120 Volts Line to Neutral AC Electric
GENERATOR ASSEMBLY INFORMATION BRUSH SET Brush Type generators use a set of carbon or graphite brushes that are set into a spring loaded brush holder, which house and support the brushes. This brush holder is mounted in such a way as to allow the brushes to maintain a sliding electrical contact between the stationary and rotating components of the generator. This connection enables DC current to flow from the Voltage Regulator through the Brushes and into the Rotor assembly.
2 DESCRIPTION PART NUMBER 8KW 10-12KW 1. COVER SCREEN 02SCREENKUB 02SCREENKUB 2. BEARING PLATE 02BRPLKUBM 02BRPLKUBM 3. STATOR ASSEMBLY ** 02MN8KBM 02MN12KBM 4. ROTOR BEARING 02BRG6206 02BRG6206 5. BRUSH SET 02BRU7004M 02BRU7004M 6. ROTOR ASSEMBLY 02RTR8KBM 02RTR12KBM GENERATOR ASSEMBLY 02GEN8KBM 02GEN12KBM ** NOTE: Item #3 MAIN STATOR ASSEMBLY is a one-piece unit. The Stator cannot be separated from the Generator’s outer housing.
ZERO or LOW VOLTAGE Check Main Breakers are “ON” OFF ON OK 3 Wiring To Panel Main Coil Output to Breakers BAD Defective Breaker / s BAD Check Brushes if Applicable Turn “ON” Breaker / s Replace Stator Check Ohm’s On Main Stator Leads OK Check Rotor Ohm’s
VOLTAGE TEST Zero or Low Voltage 4 Check Main Breaker / s On Generator Check Gen End High Voltage Overload Check Regulator Check AMP Draw From equipment Output Voltage OK
12 VOLT BATTERY TEST One Coil Low Voltage 5 Replace Stator Both Coils Low Voltage Check Connections Check Engine RPM 1800 Replace Stator Sensing Voltage Low or None Replace Stator Replace AVR
OVERLOAD CONDITION Check AMP Draw Check Load 6 Engine Problem See Engine Troubleshooting Check Stator Coil Resistance Replace Stator
RESISTANCE CHART POWER TECHNOLOGY SOUTHEAST, INC. 634 STATE ROAD 44 LEESBURG, FL 34748-8103 (352) 365-2777 FAX (352) 787-5545 KW MAIN STATOR MAIN ROTOR AUX. WINDING BATT. CHARGE SENSING WINDING 8 0.257 83.1 2.64 0.159 0.
RESISTANCE CHART POWER TECHNOLOGY SOUTHEAST, INC. 634 STATE ROAD 44 LEESBURG, FL 34748-8103 (352) 365-2777 FAX (352) 787-5545 KW MAIN STATOR MAIN ROTOR AUX. WINDING BATT. CHARGE SENSING WINDING 8 0.257 83.1 2.64 0.159 0.
RESISTANCE CHART POWER TECHNOLOGY SOUTHEAST, INC. 634 STATE ROAD 44 LEESBURG, FL 34748-8103 (352) 365-2777 FAX (352) 787-5545 KW MAIN STATOR MAIN ROTOR AUX. WINDING BATT. CHARGE SENSING WINDING 10 0.093 72.5 0.892 0.082 0.029 12 0.093 72.5 0.892 0.082 0.
SECTION 4 “INSTALLATION” SAFETY PRECAUTIONS 1-2 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 3-8 Introduction Marine Application General Information Specification Charts Fuel Consumption in Gallons per Hour Installation Factors Generator Compar
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. Please call Power Technology Southeast, Inc. with any concerns you may have with your generator set.
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. Do not modify the fuel tank or propulsion engine fuel system. Your vehicle must be equipped with a fuel pick-up arrangement as described in the Fuel System section of this manual.
GENERATOR INSTALLATION in RECREATIONAL VEHICLES INTRODUCTION Use this section as a guide when installing a generator set in a recreational vehicle, and then refer to the appropriate operation section for specific instructions. The installation of a RV generator set shall comply with current standards of ANSI / RVIA EGS-1, NFPA 1192 / ANSI A 119.2, ANSI / NFPA 70, NFPA 551 and applicable articles of the National Electrical Code. Generator set installations must also comply with state and local requirements.
SPECIFICATION CHARTS FUEL CONNECTION FUEL RECOMMENDATION BATTERY VOLTAGE BATTERY CRANKING AMPS BATTERY COLD CRANKING AMPS BATTERY GROUND ¼” NPT DIESEL FUEL No.1-D or No.2-D ASTM / D975 12 VOLTS DC 420 590 MINIMUM NEGATIVE FUEL CONSUMPTION IN GALLONS PER HOUR LOAD PERCENTAGE 25% 50% 75% 100% 8KW .25 GPH .36 GPH .54 GPH .72 GPH 10KW .26 GPH .47 GPH .74 GPH 1.0 GPH 12KW .32 GPH .50 GPH .90 GPH 1.
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. The generator set must be securely fastened to avoid unwanted movement from vibration and road shock.
AIR REQUIREMENTS CONT’D 8KW 1800 13.6 N/A 160°F 185°F 230°F 230°F 702 42120 1700 268°F N/A ENGINE SPEED IN RPM OUTPUT IN HORSEPOWER ENGINE INLET WATER TEMP. THERMOSTAT RATING THERMOSTAT FULL OPEN ENGINE OUTLET WATER TEMP.MAX. HIGH TEMP. SHUTDOWN SWITCH HEAT REJECTION – BTU / MIN. HEAT REJECTION – BTU / HR. AIR FLOW – CU. FT. / MIN. ENGINE OIL TEMP. MAX. COMBUSTION AIR TEMP. * 10KW 1800 17.9 N/A 160°F 185°F 230°F 230°F 979 58770 1700 268°F N/A 12KW 1800 17.
PT8KSI-2 INSTALATION PREPERATION DETAIL
PT12KSI-2 INSTALATION PREPERATION DETAIL
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. In most installations both engines operate from a common fuel tank with separate pick-up tubes for each engine, not a Tee fitting arrangement.
EXHAUST SYSTEM SPARK ARRESTOR MUFFLER MAINTENANCE Gensets equipped with a spark arrestor muffler will require periodic cleaning. If the internal spark arrestor is not cleaned regularly the accumulated soot may cause excessive backpressure resulting in poor performance. To maintain optimum performance from your Power Tech Genset follow the Service Schedule in Section 2, page 4. WARNING: Exhaust system components may be hot and can cause severe burns.
EXHAUST SYSTEM Exhaust system components will vary from one installation to another; therefore a muffler and tailpipe may not always be furnished with the Genset. However, it is imperative to install a muffler and tailpipe to reduce exhaust noise and direct exhaust gases beyond the vehicles perimeter and away from the normal head-on air stream. Install a tail pipe with as few bends as possible to prevent excessive backpressure.
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.
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.
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.
BLUE to 12V GENERATOR WINDING BLUE to 12V GENERATOR WINDING RED to +12V DC YELLOW to RUN RELAY BLACK to GROUND GREEN NOT USED 06REG12DC 15 06REG12DCAT 12 VOLT DC CHARGING
16 KUBOTA 12Volt DC POWER CONTROL MODULE WIRING SCHEMATIC
