PTRV-3 PTRV- 3 RR Operator & 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 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 GENERATOR END TROUBLESHOOTING GUIDES WIRING SCHEMATICS and RESISTANCE CHARTS_____________________ SECTION 4: 1 2 3 4 5 6 7 8-11 1 2-4 5-6 “INSTALLATION” SAFETY
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 Check Engine After Starting Stopping the Engine ENGINE SPECIFICATIONS 3 Kubota Model E-300 Service Parts Exhaust System Requirements ENGINE MAINTENANCE SERVICE SCHEDULE Access for Routine Maintenance 4 ENGINE OIL MAINTENANCE 5 Checking Engine Oil Level Lubricating Oil Specifications Engine Refill Capacities Lubricating Oil Viscosity Recommendations ENGINE COOLANT MAINTENA
PRE-OPERATION CHECK ENGINE BREAK-IN PERIOD During the engine break-in period, observe the following recommendations: 1. Change the engine oil and clean the oil filter screen 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 time for engine warm up.
OPERATING THE ENGINE ENGINE STARTING CONTROLS 1) 2) 3) 4) 5) Generator Main / ECU Reset 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 E-300 Continuous Output Cubic Capacity 5.0 HP @ 2200 rpm 18.86 in³ (309cc) 2.95” x 2.76” Bore and Stroke (75 x 70mm) Number of Cylinders 1 Compression Ratio 23:1 Engine Oil Capacity 1.4 US Qts. (1.3L) Coolant Capacity (PTRV-3 RR) *** Coolant Capacity (PTRV-3) 4 US Qts. Diesel No. 2-D Fuel and Type 4 Cycle DC Battery Charging Not Equipped *** Coolant capacity will vary with the distance between unit and remote radiator.
ENGINE MAINTENANCE SERVICE SCHEDULE Maintenance Service Item *See Note Engine Oil Level Deterioration & Leakage Engine Oil Change Air Filter Replacement Replace Fuel Hoses Check Radiator Hoses & Clamps Abnormal Engine Noise Abnormal Generator Noise Muffler Condition Exhaust Gas Condition • • • • Every 1000 Hours Remarks X * ** Coolant Level Coolant Leakage Coolant Change Fuel Filter Fuel Leakage Min.
ENGINE OIL MAINTENANCE CHECKING ENGINE OIL LEVEL KUBOTA E-300 ENGINE REFILL CAPACITIES Crankcase Oil Sump 1.4 US Qts. (1.3L) LUBRICATING OIL VISCOSITY RECOMMENDATIONS 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 to add oil, if necessary. Clean the Oil Filler Cap and replace. 3. The Kubota E-300 is equipped with an Oil Filter Screen which is attached to the Oil Drain Plug.
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 Check Flash Code Indicator at Start / Stop Switch CODE 2 8 Check Battery Voltage Failure To Start Engine High Water Temp. Check Coolant Level/Condition If “OK” Check Fuel System Check Fuel Filter/Supply Check Coolant Temp.
ENGINE TROUBLE SHOOTING ENGINE STARTS BUT WON’T RUN CONTINUED CODE 3 Check Oil Level/Condition Low Oil Pressure 9 If “OK” Check Single Pole Oil Press.
ENGINE RUNS ROUGH OR SLOW No Visible Exhaust Smoke Excessive Exhaust Smoke Insufficient Fuel to Engine BLUE SMOKE 10 Excessive Oil Level Check Fuel Level Replace Fuel Filter Air in Fuel System Check Fuel Pump Excessive Oil Consumption BLACK SMOKE Dirty Air Filter Engine Cold Engine Overheated Incomplete Combustion Engine Overloaded Clogged Muffler Over Fueling Injector High Altitude Check Safety Shutdowns And Fuel Solenoid GREY/WHITE SMOKE Glow Plug Circuit Not Operating Over Fueling Inj
ENGINE WILL NOT START ENGINE CRANKS No Exhaust Smoke 11 Check Fuel Supply 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 ECU Check Glow Plugs Check Glow Plug Relay ENGINE CRANKS SLOW Main Switch Oil Viscosity Too Heavy Check Terminals Turn Switch On Start Switch Check Spark Arrestor Muffler for Clogging Low Battery Voltage Starter Relay Starter Motor
SECTION 3 “GENERATOR END” PRINCIPLES OF OPERATION 1 Rotating Field Assembly (Rotor) Core Assembly Field Coil Voltage Connection Exciter Field Coil Voltage Source Balance Bearing Stator Assembly GENERATOR END TROUBLESHOOTING GUIDES 2-4 Zero or Low Voltage Voltage Test Overload Condition WIRING SCHEMATICS 120 Volt Connection “S” Series Capacitor Regulated Type 220 Volt 50 Hz.
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.
ZERO or LOW VOLTAGE Check Gen Fuse BAD Check Main Breaker is “ON” OK Replace Fuse 2 OK Wiring To Panel ON Main Coil Output to Breaker OFF Turn “ON” Breaker BAD Defective Breaker BAD Replace Stator Check Ohm’s On Main Stator Leads OK Check Rotor Ohm’s
VOLTAGE TEST Zero or Low Voltage 3 Check Main Breaker On GenSet Check Gen End High Voltage Overload Replace Capacitor Check AMP Draw From equipment Output Voltage OK
OVERLOAD CONDITION Check AMP Draw Check Load 4 Check Drive Belt Tension/Condition Engine Problem See Engine Troubleshooting Check Stator Coil Resistance Replace Stator
RESISTANCE CHART KW MAIN STATOR MAIN ROTOR POWER TECHNOLOGY SOUTHEAST, INC. 634 STATE ROAD 44 LEESBURG, FL 34748-8103 (352) 365-2777 FAX (352) 787-5545 3 0.92 4.
RESISTANCE CHART KW MAIN STATOR MAIN ROTOR POWER TECHNOLOGY SOUTHEAST, INC. 634 STATE ROAD 44 LEESBURG, FL 34748-8103 (352) 365-2777 FAX (352) 787-5545 3 0.92 4.
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 3-7 Introduction Marine Application General Information Specification Charts Fuel Consumption in Gallons per Hour Engine Temperature Installation Facto
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 5/16” HOSE BARB 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% 3KW .075 GPH .150 GPH .225 GPH .300 GPH ENGINE TEMPERATURE ENGINE SPEED IN RPM OUTPUT IN HORSEPOWER ENGINE INLET WATER TEMP. ENGINE OUTLET WATER TEMP.MAX. HIGH TEMP. SHUTDOWN SWITCH COMBUSTION AIR TEMP.
GENERATOR COMPARTMENT INSTALLATION 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. The generator set must be securely fastened to avoid unwanted movement from vibration and road shock.
UNDER VEHICLE INSTALLATION PTRV-3 and PTRV-3 RR Model Generators which are designed to be installed under a vehicles floorboard require specific mounting considerations. These units are specifically engineered to be suspended from the underside of a vehicle. The antivibration mounting hardware supplied is capable of supporting the units’ suspended weight. An additional safety bolt is incorporated into each mounting bracket as a back-up safety measure.
DIMENSIONS & SYSTEM LOCATIONS 7
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.
FuelTap Schematics lf necessary the returnfuellineof your generator mustconnectviaa Y-shaped connector to the Sprinter's returnfuelline. The returnlinemustbe connected in flow withthe returning fuel! BodyBuilder fuel return ConnectauxiliaryDieselpowered generator'sfuel feed via a T| connectoror Y-connectorto the auxiliaryheater(if equipped)fuel feed line,that is connectedto the KL1 connector. Fuelreturnline fromengine O 1 0 .
EXHAUST SYSTEM Exhaust system components supplied with your unit are specifically designed for optimum performance and safety. It is imperative to install the 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 the 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.
PT-ECU-63 ENGINE CONTROL MODULE 1) 2) 3) 4) 5) ECU ON/OFF Reset 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.
POWER TECHNOLOGY SOUTHEAST, INC.
