CD-7 CD-8 Operators 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 ENGINE SPECIFICATIONS ENGINE MAINTENANCE SERVICE SCHEDULE ENGINE OIL MAINTENANCE ENGINE COOLANT MAINTENANCE OPERATING HOURS AND SERVICE LOG ENGINE TROUBLESHOOTING GUIDES SECTION 3: “GENERATOR END” PRINCIPLES OF OPERATION “S” TYPE GENERATOR ASSEMBLY __ ___________________ GENERATOR END TROUBLESHOOTING GUIDES WIRING SCHEMATICS SECTION 4: 1-2 3 4-6 7-8 “INSTALLATION” SAFETY PRECAUTI
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 2 Engine Starting Controls Starting the Engine Check Engine After Starting Stopping the Engine ENGINE SPECIFICATIONS 3 Kubota Models D905-B and D1105-B Service Parts ENGINE MAINTENANCE SERVICE SCHEDULE 4 ENGINE OIL MAINTENANCE 5 Checking Engine Oil Level Lubricating Oil Specifications Engine Refill Capacities Lubricating Oil Viscosity Recommendations ENGINE COOLANT MAINTENANCE 6 Coolant Recommend
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.
OPERATING THE ENGINE ENGINE STARTING CONTROLS 1) 2) 3) 4) 5) Generator Main Switch must be in the ON position. Hold Start/Stop Switch for 1 second and release. Glow Plugs will preheat for 8 seconds. LED flashes slowly. Preheating will cease during engine cranking cycle. LED continues flashing. 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.
ENGINE SPECIFICATIONS MODEL Kubota D905-B Kubota D1105-B 10.5HP @ 1800 rpm 13.6 HP @ 1800 rpm Cubic Capacity 54.8 in³ (.898L) 68.5 in³ (1.12L) Bore and Stroke 2.83” x 2.90” (72 x 73.6mm) 3.07” x 3.09” (78.0 x 78.4mm) 3 In-Line 3 In-Line Firing Order 1-2-3 1-2-3 Compression Ratio 22:1 22:1 Engine Oil Capacity 4.0 qts. (3.78L) 4.0 qts. (3.78L) 5qts. (4.7L) 6qts. (5.7L) Diesel No. 2-D 4 Cycle Diesel No.
Engine Maintenance Service Schedule Maintenance Service Item *See Note Engine Oil Level Deterioration & Leakage Engine Oil Change Min.
ENGINE OIL MAINTENANCE CHECKING ENGINE OIL LEVEL KUBOTA D905-B & D1105-B ENGINE REFILL CAPACITIES Crankcase Oil Sump and Filter 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 STARTS BUT WON’T RUN Engine Runs OK Unplug Remote Start-Stop from Control Box Problem with Remote Connection.
ENGINE RUNS ROUGH or SLOW NO Visible Exhaust Smoke Excessive Exhaust Smoke BLUE Insufficient Fuel to Engine GRAY/WHITE Excessive Oil Level BLACK Check Fuel Level Replace Fuel Filter Dirty Air Filter Engine Overheated Air IN Fuel System Check Fuel PUMP Engine Over Loaded Clogged Muffler Over Fueling Injector Check Safety Shutdowns And Fuel Solenoid HIGH ALTITUDE Engine Cold Incomplete Combustion Glow Plug Not Activating Check With 12 volt DC Test Light 9 Over-fueling Injector
ENGINE WILL NOT START Engine Does NOT Crank Engine Cranks Main Switch NO Exhaust Smoke Smoke From Exhaust Check Fuel Solenoid YES Check Fuel Pump Starter Relay Check Glow Plug Relay Starter Motor NO Defective Solenoid Air IN Fuel System Battery Dead Start Switch Check Glow Plugs Check Fuel Supply NO Power While Cranking Turn Switch “ON” Check Spark Arrestor Muffler for Clogging No Power From Starter Terminal 10 Engine Cranks SLOW Oil Viscosity TOO HEAVY Check Terminal Ends LOW Batte
SECTION 3 “GENERATOR END” PRINCIPLES OF OPERATION 1-2 Rotating Field Assembly (Rotor) Core Assembly Field Coil Voltage Connection Electronic Voltage Regulation Exciter Field Coil Voltage Source Balance Bearing Stator Assembly 7-8KW EXCITER TYPE “C” GENERATOR ASSEMBLY 3 GENERATOR END TROUBLESHOOTING GUIDES 4-6 Zero or Low Voltage Voltage Test 12-Volt Battery Test Overload Condition WIRING SCHEMATICS 120 Volt Connection “C” Series Exciter Type 120 / 240 Volt Connection “C” Series Exciter Type 7-8
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. This voltage is fed to the rotating rectifier assembly, rectified and fed to the alternator field, which sets up lines of force across the air gap to the alternator stator windings and to the output circuit.
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. The field windings are wound around this assembly.
3 DESCRIPTION PART NUMBER 7KW 8KW 1. BEARING PLATE 02BR-CR 02BR-CR 2. END BELL 02H7810 02H7810 3.EXCITER STATOR 02STA7EXC 02STA8EXC 4. MAIN STATOR 02STAMNCD7 02STAMNCD8 5. BELL HOUSING ** 02BHCD7 02BHCD7 6. ROTOR BEARING 02BRG6206 02BRG6206 7. DIODE PLATE 02PLD8CD 02PLD8CD 8. EXCITER ROTOR 02RTR7EXC 02RTR8EXC 9. MAIN ROTOR 02RTRMN7EXC 02RTRMN8EXC 10. END BELL ASSEMBLY 02EB7 02EB8 11. MAIN ROTOR ASSEMBLY 02RTR7EXC-ASSY 02RTR8EXC-ASSY 12.
ZERO OR LOW VOLTAGE Check Main Breaker is “ON” Check Gen Fuse BAD OK ON OFF Main Coil Output to Breaker Replace Fuse Turn “ON” Breaker OK BAD Wiring To Panel Defective Breaker Check Ohm’s on Exciter Leads OK BAD Replace Exciter OK Replace Voltage Regulator 4 12 V Battery Test
VOLTAGE TEST Zero or Low Voltage Check Main Breaker On GenSet Overload High Voltage Output Voltage OK Check AMP Draw From equipment Replace AVR Check Load Distribution One Voltage Line may be Higher than the other Check Gen End 12 VOLT BATTERY TEST One Coil Low Voltage Replace Stator Both Coils Low Voltage Sensing Voltage Low or None Replace Stator Check Connections Check Engine RPM 1800 Replace Stator 5 Replace AVR
OVERLOAD CONDITION Check AMP Draw Check Load Distribution Disconnect AVR Conduct 12-Volt Battery Test BAD OK Engine Problem Check Stator Coil Resistance BAD See Engine Troubleshooting Replace Stator 6 OK Replace AVR And Test
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 EXCITER STATOR EXCITER ROTOR AUX. WINDING BATT. CHARGE SENSING WINDING 7 0.5 1.9 83.5 0.31 2.5 0.2 0.2 8 0.5 1.9 86.9 0.31 2.5 0.2 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 EXCITER STATOR EXCITER ROTOR AUX. WINDING BATT. CHARGE SENSING WINDING 7 0.5 1.9 83.5 0.31 2.5 0.2 0.2 8 0.5 1.9 86.9 0.31 2.5 0.2 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 3-6 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% 7KW .16 GPH .32 GPH .51 GPH .64 GPH 8KW .25 GPH .38 GPH .60 GPH .
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 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. * 7KW 1800 10.5 N/A 160°F – 180°F 203°F 230°F 230°F 673 40,397 1296 268°F N/A 8KW 1800 13.
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 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.
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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.
PT-ECU-63 ENGINE CONTROL MODULE 1) 2) 3) 4) 5) Generator Main Switch must be in the ON position. Hold Start/Stop Switch for 1 second and release. Glow Plugs will preheat for 8 seconds. LED flashes slowly. Preheating will cease during engine cranking cycle. LED continues flashing. 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.
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 14 06REG12DCAT 12 VOLT DC CHARGING
POWER TECHNOLOGY SOUTHEAST, INC.
POWER TECHNOLOGY SOUTHEAST, INC.
SECTION 5 “POWER CONTROL MODULE” FEATURE SUMMARY _________________________________________________ 1 Internal Ambient Temperature Sensor Oil Pressure Sensor / Switch Input Coolant Sensor / Switch Input Auxiliary (Generic) Shutdown Switch Input DC Power Supply Voltage Measurement AC Output Voltage Measurement AC Output Current Measurement AC Output Frequency Measurement Warm Start One-Touch Remote Start Trigger Blink Code Fault Reporting Event Recording Load Profiling AGS Ignition Sensing OPERATING BEHAVI
Power Controller Module (PCM) And Display (PCMD)
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 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 5 If “OK” Check Wiring From Sensor to Terminal 12 on PCM If “OK” Check Oil Pres.
ENGINE WILL NOT START ENGINE CRANKS No Exhaust Smoke ENGINE DOES NOT CRANK Battery Dead Smoke From Exhaust Check Fuel Solenoid Check Fuel Supply Check Glow Plugs 6 NO Power While Cranking YES Replace Solenoid Check Fuel Pump NO Air in Fuel System No Power From PCMD 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
ENGINE RUNS ROUGH OR SLOW No Visible Exhaust Smoke Excessive Exhaust Smoke Insufficient Fuel to Engine BLUE SMOKE BLACK SMOKE GREY/WHITE SMOKE 7 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 Injec
ZERO or LOW VOLTAGE Check Main Breakers are “ON” OFF ON OK 8 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 9 Check Main Breaker / s On Generator Check Gen End High Voltage Overload Check Regulator Check AMP Draw From equipment Output Voltage OK
OVERLOAD CONDITION Check AMP Draw Check Load 10 Engine Problem See Engine Troubleshooting Check Stator Coil Resistance Replace Stator
11 KUBOTA 12Volt DC POWER CONTROL MODULE WIRING SCHEMATIC
