PowerTech PTRV- 8 KSI Operator And Installation Manual Download Page 35

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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

3-8

Introduction

Marine

Application

General

Information

Specification

Charts

Fuel Consumption in Gallons per Hour

Installation

Factors

Generator Compartment Size

Compartment

Frame

Air

Requirements

Air Requirements Cont’d

Dimensions and Compartment Layout

SYSTEMS CONNECTION 9-11

Fuel

System

Exhaust

System

Spark Arrestor Muffler Maintenance

ELECTRICAL CONNECTIONS

12-16

Electrical

Wiring

AC Load Lead Connections

Motor

Loads

Kilowatt

De-Rating

Electrical

Loads

Appliance

Loads

Extension

Cords

12 Volt DC Charging

12 Volt DC Power Control Module Wiring Schematic

Summary of Contents for PTRV- 8 KSI

Page 1: ...PTRV 8 KSI PTRV 10 KSI PTRV 12 KSI Operators Installation Manual Power Technology Southeast Inc 634 State Road 44 Leesburg FL 34748 8103 352 365 2777 352 787 5545 Fax 4 2007 MANKSI ...

Page 2: ...TO OUR CUSTOMERS Thank you for your purchase of a Power Technology Generator The information contained in this manual applies to PTRV 8 KSI PTRV 10 KSI and PTRV 12 KSI generators In the event you experience a problem with your generator please contact the sales dealer one of our authorized service centers or Power Technology s Customer Service Department directly at 1 800 760 0027 from 8 00 a m to...

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 from Power Tech warranty department O Damage caused by negligent maintenance such as but not limited to Failure to provide the specified type and quantity of lubricating oil cooling air flow and proper ...

Page 4: ...ANCE 8 ENGINE COOLANT MAINTENANCE 9 OPERATING HOURS AND SERVICE LOG 10 ENGINE TROUBLESHOOTING GUIDES 11 14 SECTION 3 GENERATOR END GENERATOR ASSEMBLY INFORMATION 1 PTRV 8 10 12 KSI MB TYPE GENERATOR ASSEMBLY 2 GENERATOR END TROUBLESHOOTING GUIDES 3 6 WIRING SCHEMATICS 7 9 SECTION 4 INSTALLATION SAFETY PRECAUTIONS 1 2 GENERATOR INSTALLATION in RECREATIONAL VEHICLES 3 8 SYSTEMS CONNECTION FUEL and E...

Page 5: ...he 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 instructions and safety regulations before you attempt to assemble or use this unit WARNING Indicates a potentially hazardous situation which may possibly result in serious injury or possible death CAUTI...

Page 6: ...MODIFICATIONS 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 controls or projections may cause personal injury Use additional safety items e g hardhat eye protection gloves etc as appropriate or required DO NOT operate machinery or equipment while under the infl...

Page 7: ...gine 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 very hot To prevent a fire do not expose dry grass oil or any other combustible materials to exhaust gas Keep the engine and mufflers clean all the time To avoid a fire be alert for leaks of flammables...

Page 8: ...the 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 hose clamps are tighten Check radiator pressure cap and oil fill cap before operating the engine The battery presents an explosive hazard When the battery is being activated hydrogen and oxygen gases ...

Page 9: ...that 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 an accidental short circuit always disconnect the 12V DC power at the battery Be sure to stop the engine and remove the key when conducting daily and periodic maintenance servicing and cleaning Check...

Page 10: ...AINTENANCE SERVICE SCHEDULE 7 ENGINE OIL MAINTENANCE 8 Checking Engine Oil Level Lubricating Oil Specifications Engine Refill Capacities Lubricating Oil Viscosity Recommendations ENGINE COOLANT MAINTENANCE 9 Coolant Recommendations Ethylene Glycol Propylene Glycol Checking Radiator Coolant Level Coolant Service Life Checking Reservoir Tank Coolant Level Cleaning Radiator Core OPERATING HOURS AND S...

Page 11: ...d 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 exhaust gas heat underneath the engine compartment this heat may ignite grass or other flammable materials Follow all safety precautions as outlined in the SAFE OPERATION section 1 For accurate readings th...

Page 12: ...Power Controller Module PCM And Display PCMD 2 ...

Page 13: ...vel 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 Pre Heat glow plug activation time according to the coolant temperature One Touch Remote Start Trigger In addition to control via PCM the unit will respond to an active high digital input The unit can ...

Page 14: ...al 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 returns to this state after a Stop Command The LED is not lit Pre Heat State The Pre Heat State is necessary to energize the Glow Plugs for the Cranking State The Fuel Pump is active The duration of this s...

Page 15: ...hutdown 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 Oil Pressure 3 The generator oil pressure has reached a critically low pressure High Ambient Air Temperature 4 The PCM measures an ambient air temperature above a specific threshold NOTE Temperature ...

Page 16: ...nuous 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 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 2 D 4 Cy...

Page 17: ...X Add as Needed Check for Coolant Leaks X Change Engine Coolant X Or Once a Year Check Radiator Hoses Clamps X Or Once a Year Check Fuel Level X Add as Needed Check for Fuel Leaks X Change Fuel Filter X Or Once a Year Replace Fuel Hoses X Or Every 2 Years Change Air Filter X Or Once a Year Check for Worn or Loose Belts X Replace 2 Years Check Exhaust Gas Condition X Clean Spark Arrestor Muffler X ...

Page 18: ...filter systems will require additional oil KUBOTA ENGINE REFILL CAPACITIES D 1105 Crankcase Oil Sump 5 38Qts 5 1L and Filter V 1505 6 34Qts 6 0L LUBRICATING OIL VISCOSITY RECOMMENDATIONS The minimum ambient temperature during cold engine start up and the maximum ambient temperature during engine operation determine the proper SAE viscosity grade of oil Refer to the Engine Oil Viscosity Table below...

Page 19: ... 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 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 Ethylene and Propylene Glycol provide similar protect...

Page 20: ... 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 RECORD DATE HRs RUN CUMLATIVE DATE SERVICES 10 ...

Page 21: ...WON 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 Start Check Fuel Filter Supply Check Battery Voltage Check Circuit To Actuator If OK Check Fuel System If OK Replace Actuator Bleed Air From System Check Fuel Pump Circuit ...

Page 22: ...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 Condition Check Terminal Connections at 2 3 on PCM Check Generator Wiring Replace Defective Parts as Needed If AC Signal Present Replace PCM 12 ...

Page 23: ... Safety Shutdowns And Fuel Solenoid Insufficient Fuel to Engine No Visible Exhaust Smoke Check Fuel Pump 13 ENGINE RUNS ROUGH OR SLOW Excessive Exhaust Smoke BLACK SMOKE Dirty Air Filter Engine Overheated Engine Overloaded Clogged Muffler Over Fueling Injector High Altitude GREY WHITE SMOKE Glow Plug Circuit Not Operating Excessive Oil Consumption ...

Page 24: ...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 Viscosity Too Heavy Main Switch Battery Dead Check Terminals Turn Switch On Start Switch Starter Motor Low Battery Voltage 14 ...

Page 25: ...NERATOR END TROUBLESHOOTING GUIDES 3 6 Zero or Low Voltage Voltage Test 12 Volt Battery Test Overload Condition WIRING SCHEMATICS 7 9 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 Electrical Circuit for 10 12KW MB Generators 120 Volts Line to Neutral 240 Volts Line to Line ...

Page 26: ...speeds in excess of the design frequencies the prime mover should be adequately governed to prevent excessive over speed High centrifugal forces created by excessive over speed may damage the rotor windings and field coils VOLTAGE CONNECTION The generator may be connected at the terminal board to deliver 120 240 volts to a 3 wire grounded neutral system or 120 volts only to a 2 wire distribution s...

Page 27: ...MB BRUSH TYPE GENERATOR ASSEMBLY 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 2 ...

Page 28: ...e ON ON 3 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 Rotor Ohm s OFF OK BAD ...

Page 29: ...4 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 30: ...5 One Coil Low Voltage Replace Stator Both Coils Low Voltage Replace Stator 12 VOLT BATTERY TEST Sensing Voltage Low or None Replace AVR Check Connections Check Engine RPM 1800 Replace Stator ...

Page 31: ...OVERLOAD CONDITION Check AMP Draw Check Load 6 Engine Problem See Engine Troubleshooting Check Stator Coil Resistance Replace Stator ...

Page 32: ...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 PTRV 8 KSI MB GENERATORS 120 VOLTS LINE TO NEUTRAL 240 VOLTS LINE TO LINE GENERATOR OUTPUT LEADS OPTIONAL 12V DC CHARGING RECTIFIER 2 POLE CIRCUIT BREAKER 35 AMP for 8 KW 7 ...

Page 33: ... 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 PTRV 8 KSI MB GENERATORS 120 VOLTS LINE TO NEUTRAL GENERATOR OUTPUT LEADS OPTIONAL 12V DC CHARGING RECTIFIER 2 POLE CIRCUIT BREAKER 35 AMP for 8 KW 8 12 JUMPER WIRE ...

Page 34: ...29 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 PTRV 10 12KSI MB GENERATORS 120 VOLTS LINE TO NEUTRAL 240 VOLTS LINE TO LINE GENERATOR OUTPUT LEADS OPTIONAL 12V CHARGING RECTIFIER 2 POLE CIRCUIT BREAKER 45 AMP for 10 KW 50 AMP for 12 KW 9 ...

Page 35: ... Introduction Marine Application General Information Specification Charts Fuel Consumption in Gallons per Hour Installation Factors Generator Compartment Size Compartment Frame Air Requirements Air Requirements Cont d Dimensions and Compartment Layout SYSTEMS CONNECTION 9 11 Fuel System Exhaust System Spark Arrestor Muffler Maintenance ELECTRICAL CONNECTIONS 12 16 Electrical Wiring AC Load Lead Co...

Page 36: ...ld 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 charger before disconnecting terminal clips 4 ELECTROCUTION Failure to install a generator set with an electrical system consistent with governing regulations and standards is UNLAWFUL and may cause ELECTR...

Page 37: ...ry 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 serious burns Do not operate your generator set without its air cleaner flame arrestor in place 13 FLASH FIRE A sudden flash fire can cause serious burns To avoid the possibility of a flash fire do not sm...

Page 38: ...d operation Each generator set features 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 Stop switch for test operating the set at the controller Also included is an On Off switch to reset the controller or lockout any remote switch to prevent startin...

Page 39: ...fficient room around the set to maintain the minimum clearance of one inch 3 inches at radiator 2 AIR REQUIREMENTS Are the compartment air inlets and outlets sized to allow adequate circulation of air for cooling and combustion 3 COMPARTMENT FLOOR Is the compartment floor strong enough to support the weight of the generator set 4 COOLING SYSTEM Is the cooling system large enough to adequately cool...

Page 40: ...ompartment 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 absorbing sound This type of material is easily cut to size with scissors and can be quickly installed using special fire resistant adhesive which bonds the material to almost any clean dry surface Oth...

Page 41: ... 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 the unit must incorporate a non flammable barrier This barrier needs to be made of sufficient material able to withstand and prevent molten metal burning insulation flaming or sparking particles from ...

Page 42: ...PT8KSI 2 INSTALATION PREPERATION DETAIL ...

Page 43: ...PT12KSI 2 INSTALATION PREPERATION DETAIL ...

Page 44: ...en the fuel lines with hardware that is recommended for the type of fuel line used The fuel lines should enter the generator compartment at a point nearest to the generators fuel line connection fittings Allow for a minimum of 8inches 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 e...

Page 45: ...eanout plug The spark arrestor muffler is located inside the Genset enclosure and mounted to the base pan on the non service side of the generator Easy access to the cleanout plug is obtained through an access hole in the base pan directly under the muffler TO CLEAN A SPARK ARRESTOR MUFFLER 1 Locate the access hole in the base pan 2 Insert a 9 16 8 point or 11 16 12 point socket and remove the cle...

Page 46: ...es of 117 F 65 C above ambient temperature 4 Extend the exhaust system a minimum of 1 inch 25mm beyond the vehicles perimeter Never terminate the exhaust system underneath the vehicle 5 Terminate the exhaust system in a direction which prevents the exhaust gases from being drawn back into the generator compartment and re circulated 6 If the exhaust system in located in an area which may become sus...

Page 47: ...ate 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 must be connected between the ground lug on the generator set and the frame of the vehicle All wiring connections made at the time of installation should be readily accessible for periodic inspection ...

Page 48: ...ng 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 Also note the Kilowatt De rating factor for generator set capabilities regarding air conditioners Capabilities will vary according to Kilowatt De rating BASED ON CODE G ELECTRIC MOTOR ELECTRIC MOTOR ...

Page 49: ...00 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 1200 HAIR DRYER 1200 MICROWAVE OVEN 1500 SUBMERSIBLE WATER PUMP 2 HP 1600 WATER HEATER 3000 OVEN 4500 TOTAL WATTS CHECKED EXTENSION CORDS An extension cord is normally used to provide electrical powe...

Page 50: ...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 15 ...

Page 51: ...KUBOTA 12Volt DC POWER CONTROL MODULE WIRING SCHEMATIC 16 ...

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