Power Tech Generators PT-10KW Operator'S Manual Download Page 37

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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

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 Compartment Size

Compartment

Frame

Air

Requirements

SYSTEMS CONNECTION 7-12

Remote Radiator Cooling System

Remote Radiator Cooling System with AC Fan
Remote Radiator Cooling System with DC Fan

Fuel

System

Exhaust

System

Fuel

Line

Diagram

ELECTRICAL CONNECTIONS

13-15

Electrical

Wiring

AC Load Lead Connections

Motor

Loads

Kilowatt

De-Rating

Electrical

Loads

Appliance

Loads

Extension

Cords

ENGINE CONTROLS_____________________________________________________

16-19

ES52F Engine Controller

PT-ECU-63 Engine Control Module
12 Volt DC Charging

WIRING SCHEMATICS

12 Volt DC Engine Control, PT-ECU-63
12 Volt DC Engine Control, New Kubota Run Solenoid

ES52F Auto Start System with Latching Relay

ES52F Auto Start System with DC Fan

Summary of Contents for PT-10KW

Page 1: ...PT 8KW PT 10KW PT 12KW Operators Manual Power Technology Southeast Inc 634 State Road 44 Leesburg FL 34748 8103 352 365 2777 Fax 352 787 5545 4 2008 MANPT7 12...

Page 2: ...your Kubota engine or for the number of your local Kubota dealer TO OUR CUSTOMERS Thank you for your purchase of a Power Technology Generator The information contained in this manual applies to PT 8 1...

Page 3: ...Loss of revenue or the rental of equipment due to down time N Generator repairs made within the warranty period other than by an authorized Power Tech service dealer without prior written approval fro...

Page 4: ...RATION 1 2 8 10 12 KW EXCITER TYPE GENERATOR ASSEMBLY 3 GENERATOR END TROUBLESHOOTING GUIDES 4 6 WIRING SCHEMATICS 7 10 SECTION 4 INSTALLATION SAFETY PRECAUTIONS 1 2 GENERATOR INSTALLATION in RECREATI...

Page 5: ...e industry s Safety Alert Symbol is used throughout this manual and on labels attached the machine itself It warns of the potential for personal injury It is essential that you carefully read the inst...

Page 6: ...ODIFICATIONS to the engine may impair the function and or safety and affect engine life WEAR SAFETY CLOTHING DO NOT wear loose torn or bulky clothing around machinery Entanglement in rotating parts co...

Page 7: ...ine exhaust fumes can be very harmful if allowed to accumulate Be sure to run the engine in a well ventilated area where there are no people or livestock near by The exhaust gas from the muffler is ve...

Page 8: ...he radiator cap while the engine is running or immediately after stopping Wait approximately ten minutes for the radiator to cool before removing the cap Be sure the radiator drain valve petcock and h...

Page 9: ...hat is only supported by a lift jack or hoist Detach the battery from the engine before conducting service Put a DO NOT OPERATE tag in the key switch to avoid accidental starting To avoid sparks from...

Page 10: ...ULE 4 ENGINE OIL MAINTENANCE 5 Checking Engine Oil Level Lubricating Oil Specifications Engine Refill Capacities Lubricating Oil Viscosity Recommendations ENGINE COOLANT MAINTENANCE 6 Coolant Recommen...

Page 11: ...to the engine when operating To prevent a fire hazard keep foreign materials fuel and oil away from the battery wiring muffler and engine Check and clear them daily Be aware of the muffler and exhaus...

Page 12: ...or 8 seconds per attempt 9 To shut down the engine under normal operations hold the Start Stop Switch for 1 second and release 10 If a fault occurs turn Generator Main Switch OFF and then ON to reset...

Page 13: ...Output 13 6HP 1800 rpm 17 9HP 1800 rpm Cubic Capacity 68 53 in 1 123 L 91 41in 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 Cylinder Arrangement 3 In Line 4 In Line Firi...

Page 14: ...acement X Or Once a Year Damaged Worn Or Loose Belts X Or Every Two Years Replace Fuel Hoses X Or Every Two Years Check Radiator Hoses Clamps X Once a Year Abnormal Engine Noise X Abnormal Generator N...

Page 15: ...lter systems will require additional oil KUBOTA ENGINE REFILL CAPACITIES D1105 EBG1 Crankcase Oil Sump 5 38Qts 5 1L and Filter V1505 EBG1 6 34Qts 6 0L LUBRICATING OIL VISCOSITY RECOMMENDATIONS The min...

Page 16: ...Power Technology recommends a 1 1 mixture of water glycol NOTE Use a mixture that will provide protection against the lowest ambient temperature NOTE 100 percent pure glycol will freeze at a temperatu...

Page 17: ...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 SERVICE R...

Page 18: ...ssure Switch with Jumper Wire 2 pole Check Power to Hold Circuit of Run Solenoid Check Oil Pressure With Gauge Replace Oil Pressure Switch Defective Solenoid REPLACE Plug Remote Back IN Remote OK Prob...

Page 19: ...vel Replace Fuel Filter Air IN Fuel System Check Fuel PUMP Excessive Oil Level Dirty Air Filter Engine Overheated Engine Over Loaded Clogged Muffler Over Fueling Injector HIGH ALTITUDE Engine Cold Inc...

Page 20: ...wer While Cranking Defective Solenoid No Power From Starter Terminal Check Fuel Supply Check Fuel Pump Air IN Fuel System Check Glow Plugs Check Glow Plug Relay Main Switch Battery Dead Turn Switch ON...

Page 21: ...ING GUIDES 5 7 Zero or Low Voltage Voltage Test 12 Volt Battery Test Overload Condition WIRING SCHEMATICS 8 15 120 Volt Connection C Series Exciter Type 120 240 Volt Connection C Series Exciter Type 1...

Page 22: ...tage regulator An additional voltage adjustment range is provided if desired by turning the Voltage Adjust Rheostat ELECTRONIC VOLTAGE REGULATION Electronic Voltage Regulator EVR also referred to as a...

Page 23: ...ogether to form a single laminated assembly The field windings are wound around this assembly FIELD COIL Field coils of heavily insulated wire are wet wound directly onto the poles Field coil leads ar...

Page 24: ...6206 7 DIODE PLATE 02PLD8CD 02PLD8CD 02PLD8CD 8 EXCITER ROTOR 02RTR8EXC 02RTR10EXCR 02RTR12EXCR 9 MAIN ROTOR 02RTRMN8EXC 02RTR10E 02RTR12E 10 END BELL ASSEMBLY 02EB8 02EB10 02EB12 11 MAIN ROTOR ASSEMB...

Page 25: ...a one piece unit The Stator cannot be separated from the Generator s outer housing 8 10 12KW C or M BRUSH TYPE GENERATOR ASSEMBLY DESCRIPTION 1 COVER SCREEN 2 BEARING PLATE 3 STATOR ASSEMBLY 4 ROTOR B...

Page 26: ...W VOLTAGE Check Gen Fuse Check Main Breaker is ON Replace Fuse Turn ON Breaker Main Coil Output to Breaker OK BAD Check Ohm s on Exciter Leads 12 V Battery Test Replace Exciter Wiring To Panel Defecti...

Page 27: ...One Voltage Line may be Higher than the other Check AMP Draw From equipment Check Main Breaker On GenSet Check Gen End 12 VOLT BATTERY TEST One Coil Low Voltage Both Coils Low Voltage Sensing Voltage...

Page 28: ...K 7 OVERLOAD CONDITION Disconnect AVR Engine Problem Check Stator Coil Resistance See Engine Troubleshooting Replace Stator Replace AVR And Test Check AMP Draw Check Load Distribution Conduct 12 Volt...

Page 29: ...W W SENSING WINDING 0 4 0 4 0 4 BLUE BROWN NOTE THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 7...

Page 30: ...SENSING WINDING 0 4 0 4 0 4 BLUE BROWN NOTE THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 787 5...

Page 31: ...85 W NOTE THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 787 5545 AC ELECTRICAL CIRCUIT FOR MB G...

Page 32: ...NOTE THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 787 5545 AC ELECTRICAL CIRCUIT FOR MB GENER...

Page 33: ...BLUE BROWN NOTE THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 787 5545 AC ELECTRICAL CIRCUIT FO...

Page 34: ...BROWN NOTE THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 787 5545 AC ELECTRICAL CIRCUIT FOR 8K...

Page 35: ...UE BROWN NOTE THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 787 5545 AC ELECTRICAL CIRCUIT FOR...

Page 36: ...E THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 787 5545 AC ELECTRICAL CIRCUIT FOR 10 12KW C GE...

Page 37: ...ize Compartment Frame Air Requirements SYSTEMS CONNECTION 7 12 Remote Radiator Cooling System Remote Radiator Cooling System with AC Fan Remote Radiator Cooling System with DC Fan Fuel System Exhaust...

Page 38: ...d be well ventilated to prevent the accumulation of explosive gases To avoid sparks never disturb the battery charging connections while the battery is being charged Always turn off the battery charge...

Page 39: ...to avoid electrical connections by contacting the battery terminals with tools Remove wristwatch rings and all jewelry when working on the generator set 12 BACKFIRE A sudden backfire can cause seriou...

Page 40: ...s a Kubota diesel engine rotating field alternating current generator and a relay controller The generator is directly connected to the engine for permanent alignment Each controller includes a Start...

Page 41: ...here be sufficient room around the set to maintain the minimum clearance of one inch 2 AIR REQUIREMENTS Are the compartment air inlets and outlets sized to allow adequate circulation of air for coolin...

Page 42: ...mpartment Line the compartment with a good sound deadening material The material selected must be fireproof or highly fire resistant An available type of 3 layer foam material is very efficient for ab...

Page 43: ...compartments and interior spaces Plugging holes and sealing all seams will greatly reduce this hazard WARNING Drip Proofing When installing a generator the area directly beneath the generator end of t...

Page 44: ...enerally the discharge chute opening should be approximately one and one half times the size of the radiator core NOTE If the radiator is to be located in a compartment separate from the engine refer...

Page 45: ......

Page 46: ...9...

Page 47: ...s of flexible fuel line to make the connection Use proper size fuel line to accommodate the fuel flow needed Steel fuel line or high quality fuel hose is recommended either one should have a minimum o...

Page 48: ...ust system in located in an area which may become susceptible to road damage from curbs speed bumps or other road obstacles a protective device such as a skid bar or plate should be installed 7 To pre...

Page 49: ...12...

Page 50: ...te battery cables should be kept short in length thus eliminating problems with excessive voltage drop See the Table below for cable size AWG to length requirements NOTE A heavy gauge 4 ground strap m...

Page 51: ...g and running requirements of some motor loads common to mobile applications are listed in the table below Use this as a guide when selecting generator set capacity requirements involving motor loads...

Page 52: ...0 SUMP PUMP 1 3 HP 500 REFRIGERATOR 500 FURNACE FAN 1 3 HP 600 FREEZER 800 JET WATER PUMP HP 900 ELECTRIC STOVE ELEMENT 1000 SUBMERSIBLE WATER PUMP 1 HP 1000 TOASTER 1000 COFFEE MAKER 1200 DISHWASHER...

Page 53: ...ndby Current Draw 175mA Operating Current Draw Internally Protected against Reverse Polarity Speed Sensing accepts Generator AC Output Speed Sensing rated to a Maximum of 300V AC 40 C to 85 C Operatin...

Page 54: ...d relay Replace fuse relay and re test controller again Out of fuel Check fuel level add fuel if necessary Ignition control wiring not installed properly Refer to engine control wiring and check ignit...

Page 55: ...p the engine will immediately shut down and go into a fault mode Likewise for a high temperature situation 8 If engine will not start on the first attempt the PT ECU 63 will initiate the start cycle 2...

Page 56: ...12 VOLT DC CHARGING 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 06REG12DCAT 19...

Page 57: ...12V DC ENGINE CONTROL PT ECU 63 POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 787 5545...

Page 58: ...12 VOLT DC ENGINE CONTROL NEW KUBOTA RUN SOLENOID POWER TECHNOLOGY SOUTHEAST INC 634 STATE ROAD 44 LEESBURG FL 34748 8103 352 365 2777 FAX 352 787 5545...

Page 59: ...ES52F AUTO START SYSTEM with LATCHING RELAY...

Page 60: ...vent Recording Load Profiling AGS Ignition Sensing OPERATING BEHAVIOR _______________________________________________ 2 Starting Stopping Power Cycle Reset Idle State Pre Heat State Cranking State Run...

Page 61: ...Power Controller Module PCM And Display PCMD...

Page 62: ...el of the AC output This info is monitored to detect a valid start as well as limit conditions It also is reported on the PCM Over and Under Frequency conditions are reported Warm Start Adjusts the Pr...

Page 63: ...ral seconds before all the configuration information is processed and the unit is ready to accept input Idle State The Idle State is the initial state of the PCM after a Power Cycle Reset The PCM retu...

Page 64: ...utdown Reasons Fault Reason Fault Code Description Failure to Start 1 The generator was not able to start High Coolant Temperature 2 The generator coolant temperature has reached a high threshold Low...

Page 65: ...ON T RUN Check Flash Code Indicator at PCMD Engine High Water Temp Fill System With 50 50 Mix Check Coolant Level Condition Check Radiator Air Flow Belts Clean Core Tighten Replace Belts Failure To St...

Page 66: ...TARTS BUT WON T RUN CONTINUED ENGINE TROUBLE SHOOTING Check Flash Code Indicator at PCMD No AC Signal If Tripped Check Generator Check Main AC And Voltage at Breakers Low Oil Pressure Check Oil Level...

Page 67: ...uel Solenoid NO Power While Cranking Check Fuel Supply Check Fuel Pump Air in Fuel System Replace Solenoid YES NO No Power From PCMD Check Glow Plugs Check Spark Arrestor Muffler for Clogging Oil Visc...

Page 68: ...Safety Shutdowns And Fuel Solenoid Insufficient Fuel to Engine No Visible Exhaust Smoke Check Fuel Pump 7 ENGINE RUNS ROUGH OR SLOW Excessive Exhaust Smoke BLACK SMOKE Dirty Air Filter Engine Overhea...

Page 69: ...ON ON 8 Check Brushes if Applicable ZERO or LOW VOLTAGE Main Coil Output to Breakers Turn ON Breaker s OK BAD Wiring To Panel Defective Breaker s Check Ohm s On Main Stator Leads Replace Stator Check...

Page 70: ...9 VOLTAGE TEST Zero or Low Voltage High Voltage Overload Output Voltage OK Check Main Breaker s On Generator Check Regulator Check AMP Draw From equipment Check Gen End...

Page 71: ...OVERLOAD CONDITION Check AMP Draw Check Load 10 Engine Problem See Engine Troubleshooting Check Stator Coil Resistance Replace Stator...

Page 72: ...KUBOTA 12Volt DC POWER CONTROL MODULE WIRING SCHEMATIC 11...

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