3/2007

MANPTRV20

PTRV- 17.5K

PTRV- 20K

PTRV-17.5KT

PTRV-20KT

Operator

&

Installation

Manual

Power Technology Southeast, Inc.

634 State Road #44 Leesburg, FL 34748-8103

♦ (352) 365-2777 ♦ Fax (352) 787-5545 ♦

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. It will help you become familiar with the operation of the engine and contains many helpful hints regarding engine maintenance. Continuing improvements and advancements in product design may have caused changes to your engine, which are not included in this manual.

Please contact Power Technology’s Customer Service Department for latest information on 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 PTRV-17.5K & KT, PTRV-20K & KT 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 5:00 p.m. EST.

Please have the generator model and serial numbers available when you call. This will help expedite service and parts to you. Parts may be obtained directly through Power Technology and shipped the same day if ordered by 3:00 p.m. EST. If required, a Major Service Manual may be ordered through Power

Technology’s Customer Service Department.

Generator Model Number____________________________________________

Generator Serial Number_____________________________________________

POWER TECHNOLOGY SOUTHEAST, INC.

634 STATE RD. 44

LEESBURG, FL. 34748-8103

(352) 365-2777

FAX (352) 787-5545 www.PowerTech-Gen.com

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.

THE WARRANTY COVERAGE TERMS:

2 years from date of purchase, or 3000 hours whichever comes first, or 36 months from the date of manufacture. Parts, and labor, including diagnostic labor, removal, and reinstallation are covered for the first 12 months from date in service or 1000 hours whichever comes first.

Parts and labor are covered only on the following generator and engine parts for 2 years or 3000 hours whichever comes first. Generator Parts: Main Rotor and Main

Stator. Engine Parts: Cylinder Block, cylinder head, crankshaft, camshaft, cylinder head gears, connecting rods, flywheel and flywheel housing, intake and exhaust manifold

(only if flexible connection is used).

3) Stand-by Units are covered for a period of 1 year from date of installation, or 1000 hours, or 24 months from the date of manufacture whichever comes first.

4) Replacement Parts are warranted: 30 days. (Excluding the following: voltage regulators, fuses, controllers, capacitors, brushes, and switches)

________________________________________________________________________________________________________________________________

WHAT POWER TECHNOLOGY WILL DO:

Power Tech will at our option, repair or replace any part covered by this warranty which becomes defective, malfunctions or otherwise fails to conform to this warranty under normal use and service during the term of this warranty.

WHAT YOU MUST DO TO OBTAIN WARRANTY SERVICE:

In order to obtain warranty repairs you must deliver the product, together with proof of purchase to an authorized Power Tech service facility. In the case of repairs pertaining to the engine only, you must use an authorized dealer or distributor of that make of engine, to be covered under their warranty. Engines used in the manufacture of Power Tech products are warranted solely by the engine manufacturer.

PRIOR APPROVAL IS REQUIRED FOR ANY WARRANTY SERVICE

Failure to obtain authorization prior to the repair being performed will result in the claim being denied.

All claims must be submitted within 30 days of the repair. Along with the following: a copy of the original repair order, Power Tech authorization number, Power Tech serial number, and operation hours shown on the genset mounted hour meter.

THIS WARRANTY DOES NOT COVER THE FOLLOWING:

A. Normal wear items, including but not limited to: turbo-chargers, fuel injector (s), starter, alternator, and electronic components, as well as normal engine and/or generator wear. A1. Travel time and fuel charges to and from the repair facility or travel time and fuel charges for mobile service. (Except stationary units with a maximum of 2-hours travel time.) B. Defects, malfunctions or failure resulting from accidents, abuse, misuse, improper servicing, improper installation, improper storage, and lack of performance of required maintenance service. C. Products which have been subjected to alteration, modification, neglect or unauthorized repairs. D. Troubleshooting, routine service, tune-ups, replacement of filters, belts, coolant, lubricants, hoses, clamps, exhaust system components, fuel system components, gaskets and/or seals. E.

Electrical items damaged by welding or jump-starting. F. Damage caused by water ingestion or electrolysis. G. Damage caused by ingestion of substances other than clean filtered air, fuel, or intake water. H. Damage caused by faulty repairs performed by a repair facility not authorized in writing by Power Tech. I. Damage caused by operation with improper fuel or at speeds, loads, conditions, modifications, or installation contrary to published specifications or recommendations. J. Original installation charges and startup costs. K. Removal and re-installation charges of more than 1-hour labor for outside units, 2-hours for compartment mounted units, and 3-hours for below deck marine units. Customer is responsible for additional labor/charges due to difficult access, removal or installation. L. Starting batteries and labor or charges related to battery service. M. 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 coolant mixture and level. Failure to provide adequate air intake/or maintenance of the air intake system. Failure to provide scheduled maintenance as prescribed in supplied manuals. P. Engine fluids such as fuel, oil or coolant/antifreeze. Q. Shop supplies such as adhesives, cleaning agents, rags, paint, or other miscellaneous supplies. R. Use of other than factory supplied or approved repair parts or procedures. Replacement of a failed Power Tech component with a non-Power Tech component voids the Power Tech warranty on that component and any and all failures related to that component. S.

Fuel injection pumps repaired by anyone other than the factory authorized dealer or distributor of that engine. T. Expenses incurred investigating performance complaints unless defective Power Tech materials or workmanship are discovered. U. Generator sets used in rental applications. V. Cleaning, service, or repair of generator sets the have not been kept free of dirt, debris, or other items that prevent the unit from being able to operate properly. W. Any generator set not application approved. X. Loss of excitation due to prolonged storage. Y. Any damage attributed to low battery monitoring or automatic generator starting systems. Z. Optional accessories are warranted solely by the manufacturer of that item including but not limited to the following item: Block heaters, oil pan heaters, electric cooling fans, air-bag isolators, compartment heaters, fuel tanks, trailers, battery chargers, battery monitors.

To obtain warranty service: For your nearest Power Tech authorized service center, on the World Wide Web at: http://www.powertech-gen.com/parts_service.php

Call 1-352-365-2777 or write to Power Tech Warranty Department, P.O. Box 490133 Leesburg, FL 34749 USA.

Power Tech must be notified in writing within five (5) business days of any product failure.

General Conditions:

This Warranty is the sole property of the original owner /user.

A transfer of ownership shall terminate this Warranty.

This Warranty is only valid within the contiguous United States and Canada.

Warranty coverage is available outside the U.S. and Canada; please speak to a factory representative for those details.

This Warranty does not cover any products or parts not purchased from Power Technology.

Power Technology reserves the right to make design improvements and model changes without any obligation to change units or parts previously manufactured.

Warranty registration card must be completed and mailed to Power Tech at the above address to validate the Warranty.

This is the only express warranty on Power Tech products

No person, agent, or dealer is authorized to give any Warranties on behalf of Power Technology Southeast, Inc., and not to assume for Power Technology Southeast,

Inc. any other liability in connection with any of its products unless made in writing and signed by an officer of Power Technology Southeast, Inc.

LIMITATIONS ON OUR RESPONSIBILITY WITH RESPECT TO PRODUCTS PURCHASED AND USED FOR PERSONAL, FAMILY OR HOUSEHOLD USE:

Our responsibility is to repair or replace defective parts as stated above. We will not be responsible for any other expenses, losses or inconvenience which you may

Sustain as a result of the purchase, use, malfunction or defective condition of our products. ANY IMPLIED WARRANTIES, INCLUDING WARRANTIES OF

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED IN DURATION TO THE PERIOD SET FORTH ABOVE.

Some states do not allow limitations on how long an implied Warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above

Limitations or exclusions may not apply to you. This Warranty gives you specific legal rights and you may have other rights which vary from state to state.

This Warranty is in lieu of all other Warranties, expressed or implied and of any other obligations or liability on our part.

Our responsibility for any and all losses and IN NO EVENT WILL WE BE LIABLE FOR LOSS OF USE, LOSS OF PROFITS, INCONVIENCE, COMMERCIAL LOSS

OR OTHER INCIDENTIAL OR CONSEQUENTIAL DAMAGES WHATSOEVER.

Power Technology S.E., Inc.

P.O. Box 490133 Leesburg, FL 34749 USA.

Z code 04/20/2010

TABLE of CONTENTS

SECTION 1: “SAFETY”

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

PRINCIPLES OF OPERATION

“M” SERIES EXCITER TYPE GENERATOR ASSEMBLY __

GENERATOR END TROUBLESHOOTING GUIDES

WIRING SCHEMATICS and RESISTANCE CHARTS_____________________

SECTION 4: “INSTALLATION”

SAFETY PRECAUTIONS

GENERATOR INSTALLATION in RECREATIONAL VEHICLES

SYSTEMS CONNECTION

ELECTRICAL CONNECTIONS

12V DC ENGINE CONTROL WIRING SCHEMATIC

POWER CONTROL MODULE (PCM) and DISPLAY (PCMD) _____________

TROUBLESHOOTING GUIDES ______________________________________

12 VOLT DC POWER CONTROL MODULE WIRING SCHEMATIC _______

1-4

1

2

3

4

5

6

7

8-10

1-2

3

4-6

7-8

1-2

3-9

10-13

14-19

1-3

4-10

11

SECTION 1

“SAFETY”

SAFE OPERATION

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

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

1-4

This symbol, the 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.

CAUTION:

Indicates a potentially hazardous situation, which

may possibly result in minor injury.

IMPORTANT: Indicates that equipment or property damage may result

if instructions are not followed.

NOTE: Indicates helpful information.

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.

OBSERVE SAFETY INSTRUCTIONS

• Read, understand and follow this “OPERATORS MANUAL”

and “LABELS ON THE ENGINE” before starting and operating

the engine.

• Learn how to operate and work safely. Know your equipment

and its limitations. Always keep the engine in good condition.

• Before allowing other people to use your engine, explain how

to operate and have them read this manual before operation.

• DO NOT modify the engine. UNAUTHORIZED

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

influence of alcohol, medication, or other drugs, or

while fatigued.

• DO NOT wear radio or music headphones while operating engine.

CHECK BEFORE OPERATING THE ENGINE

• If the engine is malfunctioning DO NOT operate until repairs

are made.

• Be sure all guards and shields are in place before operating

the engine. Replace any that are damaged or missing.

• Check to see that the area around the engine is clear of foreign

objects before starting.

• Always keep the engine at least 3 feet (1 meter) away from

buildings or other facilities.

• DO NOT allow children or livestock to approach the machine

while in operation.

• DO NOT start the engine by shorting across starter terminals.

1

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. Never store

flammable liquids in the engine compartment.

• Refuel at a well-ventilated and open place. If fuel or lubricants

spill, clean up immediately and properly dispose of.

• DO NOT mix gasoline or alcohol with diesel fuel. The mixture

can cause a fire.

EXHAUST GASES AND FIRE PREVENTION

• Engine 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 from hoses and

lines. Be sure to check for leaks from hoses and pipes, such as

fuel and hydraulic by following the maintenance check list.

• To avoid a fire, do not short across power cables and wires.

Check to see that all power cables and wires are in good

condition. Keep all power connections clean. Bare wire or

frayed insulation can cause a dangerous electrical shock and

personal injury.

CALIFORNIA

Proposition 65 Warning

Diesel Engine Exhaust and some

of it’s constituents are known by the

State of California to cause

Cancer, Birth Defects and Other

Reproductive harm.

2

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.

• Fluid escaping from pinholes may be invisible. Use a piece of

cardboard or wood to search for suspected leaks: do not use

hands and body. Use safety goggles or other eye protection

when checking for leaks.

• If injured by escaping fluid, see a medical doctor immediately.

This fluid can produce gangrene or severe allergic reaction.

CAUTIONS AGAINST BURNS AND BATTERY EXPLOSION

•

To avoid burns, be alert for hot components during operation and

just after the engine has been shut off. Such as the muffler, muffler

cover, radiator, piping, engine body, coolants, engine oil, etc.

• DO NOT remove 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 are extremely explosive.

• Keep sparks and open flames away from the battery, especially

during charging. DO NOT strike a match near the battery.

• DO NOT check a batteries charge by placing a metal object across

the terminals. Use a voltmeter or hydrometer.

• DO NOT charge a battery if frozen, it may possibly explode. Frozen

batteries must be warm up to at least 61°F (16°C) before charging.

KEEP HANDS AND BODY AWAY FROM ROTATING PARTS

• Keep your hands and body away from all rotating parts, such

as cooling fan, v-belts, pulleys and flywheel. Contact with these

rotating parts can cause serious personal injury.

• Be sure to stop the engine before adjusting belt tension or checking

the cooling fan.

• DO NOT run the engine without safety guards installed. Be sure the

safety guards are properly aligned and securely fastened before operating

the engine.

3

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. Before draining any fluids, be

prepared to dispose of them in a manner consistent with

environmental protection regulations in your location.

• When draining fluids from the engine, use appropriate containers to

hold the different fluids, do not mix fuel, oil or coolant together.

• Dispose of spent filter cartridges and batteries properly.

• DO NOT pollute the soil, or any water source. Never pour fluids

down a drain.

CONDUCTING SAFETY CHECKS AND MAINTENANCE

• When performing safety checks or engine service, be sure the engine is level

and well supported. Use approved stands designed for this type of service.

DO NOT service an engine 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 or conduct maintenance after the engine, radiator, muffler, or muffler cover has cooled off completely.

• Always use the appropriate tools and jig-fixture when performing any

service work. Be sure to understand and follow the instructions included

with these tools.

• Use ONLY correct engine barring techniques for manually rotating the engine. DO NOT attempt to rotate the engine by pulling or prying on the cooling fan and V-belt. Serious personal injury or damage to the cooling fan may occur.

• Replace fuel hoses and hose clamps every 2 years or earlier whether they

are damaged or not. They are made of rubber and are aged gradually.

• When service is performed with two or more people present, take care

to perform all work safely. Be aware of their location especially when

starting the engine.

• Keep a first aid kit and fire extinguisher handy at all times.

4

SECTION 2

“ENGINE”

PRE-OPERATION CHECK

Engine Break-in Period

Check

OPERATING THE ENGINE

Engine Starting Controls

Check Engine After Starting

Stopping the Engine

1

2

ENGINE SPECIFICATIONS

Kubota Model V-2203

Parts

ENGINE MAINTENANCE SERVICE SCHEDULE

3

4

ENGINE OIL MAINTENANCE 5

Checking Engine Oil Level

Lubricating

Engine Refill Capacities

Lubricating Oil Viscosity Recommendations

6 ENGINE COOLANT MAINTENANCE

Coolant Recommendations

Ethylene Glycol / Propylene Glycol

Checking Radiator Coolant Level

Coolant Service Life

Checking Reservoir Tank Coolant Level

Cleaning Radiator Core

OPERATING HOURS AND SERVICE LOG 7

ENGINE TROUBLESHOOTING GUIDES 8-10

Engine Starts but Won’t Run

Engine Runs Rough or Slow

Engine Will Not Start

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.

DAILY CHECK

To prevent future engine problems from occurring, it is important to know and keep track of the engines condition. Below are items to be Inspected and Checked on a daily basis.

CAUTION:

To avoid personal injury:

• Be sure all safety shields and guards are attached 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 the engine should be on level ground when checking engine fluids.

2. Check fluids before starting the engine. (Cold Engine)

• Lubrication System: Check Engine oil level

Check for Engine oil leaks

• Cooling System:

Check coolant level and condition

Check for coolant leaks

Check for proper installation of the radiator cap

• Fuel System: Check for sufficient quantity of fuel

Check for fuel leaks

3. Check engine after starting. (Warm Engine)

• Proper Operation: Check for easy engine start

Check for fluid leaks

Check for abnormal engine noises

Check for abnormal exhaust gas

1

OPERATING THE ENGINE

ENGINE STARTING CONTROLS

1) Generator Main Switch must be in the ON position.

2) Hold Start/Stop Switch for 1 second and release.

3) Glow Plugs will preheat for 8 seconds. LED flashes slowly.

4) Preheating will cease during engine cranking cycle. LED continues flashing.

5) 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. If an AC signal is verified the engine will start and the LED will remain ON during the normal run operation. If the AC signal is not verified the PT-ECU-63 will terminate the cranking cycle and LED will flash a fault code.

6) Starter disengages immediately after engine run is verified.

7) PT-ECU-63 deactivates the Low Oil Pressure and High Water Temperature Switches for 6 seconds, this will assure oil pressure build-up time. If oil pressure does not build-up 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 more times before going into a fault mode. Glow Plugs will preheat for 8 seconds per attempt. Engine will crank for 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 PT-ECU-63.

CHECKING ENGINE AFTER STARTING

1) Allow the engine to warm up 3 to 5 minutes before applying a load. In colder climates allow a few

extra minutes longer.

2) Perform a visual inspection of all areas of the engine and generator.

3) Listen for any abnormal noises.

4) Check for any abnormal exhaust gases.

STOPPING THE ENGINE

It is recommended to disconnect or reduce the power load from the generator before shutting down the engine. Then follow the steps outlined above for normal shut down.

NOTE: The PT-ECU-63 is designed to operate on 12V DC power. In a low battery situation the

PT-ECU-63 may not initiate the normal cranking cycle. To start the generator you can press and hold the Start/Stop Switch for approximately 10 seconds or until the engine starts. Once the engine starts the PT-ECU-63 will resume normal operations. If this situation re-occurs, charge or replace the battery.

IMPORTANT: Damage to the Starter Motor, Starter Solenoid, Run Solenoid or any generator component due to excessive or prolonged starting attempts attributed to an external Low Battery Control Monitoring or Auto-Start System will not be covered by the Power Technology Southeast, Inc. Limited Warranty.

2

ENGINE SPECIFICATIONS

MODEL V-2203 V-2003-T

Air Induction Naturally Aspirated Turbocharged

Continuous Output 32.5 HP @ 1800 rpm 36.3 HP @ 1800 rpm

Cubic Capacity 134.07 in³ (2.19L) 121.99 in³ (1.99L)

Bore and Stroke 3.43 x 3.64 3.27x3.64

(87x92.4mm) (83x92.4mm)

Cylinder Arrangement 4 In-Line 4 In-Line

Firing Order 1-3-4-2 1-3-4-2

Compression Ratio 23:1 22:1

Engine Oil Capacity 8.5 qts. (8.04L) 8.5 qts. (8.04L)

Fuel and Type Diesel 4 Cycle Diesel 4 Cycle

Minimum Fuel Consumption See Specification Chart See Specification Chart

SERVICE PARTS

Power Technology Part #

Filters:

Air with Metal Canister----------------------------------------------------------- 04FA080

Air with Plastic Canister---------------------------------------------------------- 04FA2E1

Belts:

With

3

Maintenance

Service Item

Engine Oil Level

Deterioration &

Leakage

Engine Oil

Change

Oil Filter

Change

Coolant Level

Coolant Leakage

Coolant Change

Fuel Level

Engine Maintenance Service Schedule

*See

Note

Daily

Min.

Every

25 Hours

Every 100

Hours

Every 250

Hours

Every 500

Hours

*

X

X

X

X

X

X

Every

1000

Hours

X

Fuel Leakage X

Fuel Filter Re- placement

Air Filter Re- placement

Damaged Worn

Or Loose Belts

**

X

Replace Fuel

Hoses

X

X

X

Remarks

Or Once a Year

Or Once a Year

Or Once a Year

As Necessary

Or Once a Year

Or Once a Year

Or Every Two

Years

Or Every Two

Years

Check Radiator

Hoses & Clamps

Abnormal Engine

Noise

Abnormal

Generator Noise

X

X Once a Year

X

Muffler Condition

X

Exhaust Gas

Condition

X

* Engine oil and filter must be changed after the first 50 hours of operation. Then every 100

hours or once a year whichever comes first.

** Air filter replacement interval will vary depending on operating conditions. Adverse conditions may

require frequent service.

NOTE: Under normal operation items such as Belts, Hoses and Filters are not covered by Power

Technology Southeast, Inc. Limited Warranty.

4

CHECKING ENGINE OIL LEVEL

ENGINE OIL MAINTENANCE

( 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.

The refill capacities for the engine crankcase

Reflect the approximate capacity of the crankcase or sump plus a standard oil filter.

Auxiliary oil filter systems will require additional oil.

KUBOTA V-2203 & V-2003-T ENGINE

REFILL CAPACITIES

Crankcase Oil Sump 8.5 Qts. (8.04L)

and Filter

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

(Minimum Temperature) in order to determine the required oil viscosity for starting an engine in cold conditions.

Refer to the Engine Oil Viscosity Table below

(Maximum Temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.

LUBRICATING OIL

SPECIFICATION

Use only good quality lubricating oil, which meets or exceeds of the following

Specification

API-CD or

Higher

Ambient Temperature Oil Viscosity

SAE 10W-30

Above 25°C (77°F) SAE 30 or

SAE 10W-40

0 to 25°C (32° to 77°F)

Below 0°C (32°F)

SAE 20 or

SAE 10W-30

SAE10W-40

SAE 10W-30

SAE 10W or

SAE 10W-40

5

ENGINE COOLANT MAINTENANCE

COOLANT RECOMMENDATIONS

For optimum performance, 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 protection against freezing and boiling.

See the tables below.

ETHYLENE GLYCOL

Freeze Boil

Concentration Protection Protection

50 Percent -36°C (-33°F) 106°C (223°F)

60 Percent -51°C (-60°F) 111°C (232°F)

PROPYLENE GLYCOL

Freeze Boil

Concentration Protection Protection

50 Percent -29°C (-20°F) 106°C (223°F)

NOTE: Do not use Propylene Glycol in concentrations that exceed 50 percent glycol because of Propylene Glycol’s reduced heat transfer capability. Use Ethylene Glycol in conditions that require additional protection against boiling or freezing.

CHECKING RADIATOR COOLANT LEVEL

Remove the radiator cap after the engine has completely cooled and check to see that coolant reaches the supply port.

1. Fill to the bottom of the fill neck and check after every 25 hours of operation.

COOLANT SERVICE LIFE

Coolant Type Service Life

Commercial Heavy-Duty

Coolant/Antifreeze that 3000 Service Hours

Meets “ASTM D5345” or Two Years

Commercial Heavy-Duty

Coolant/Antifreeze that 3000 Service Hours

Meets “ASTM D4985” or One Year

NOTE: Do not use a commercial coolant/antifreeze that only meets the ASTM

D3306 or D4656 specification. This type of coolant/antifreeze is made for light duty automotive applications.

CHECKING RESERVOIR TANK

COOLANT LEVEL

(At a Minimum of 25 Hours of Operation)

Ensure that the coolant level of the radiator reservoir tank is between the upper limit (FULL) and the lower limit (LOW) on the side of the reservoir tank.

CLEANING RADIATOR CORE

Visually inspect the core for any obstructions such as dirt or debris. Use running water to clean particles from between fins.

IMPORTANT: Never use hard objects to clean radiator core, damage to core could result.

6

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 SERVICE RECORD

SERVICES

7

ENGINE STARTS

BUT WON’T RUN

Unplug Remote

Start-Stop from

Engine Runs OK

Control Box

Problem with

Remote Connection.

Jump across

Contact

Equipment Manufacturer

Oil Pressure Switch with Jumper Wire

(2 pole)

Check Power to Hold Circuit of Run Solenoid

Oil Pressure Switch

Single Pole

Disconnect Wire to Test

Check

Oil Pressure

With Gauge

If “OK”

Replace

Switch

Replace

Oil Pressure Switch

Defective Solenoid

REPLACE

Check

Safety Shutdown

System

Plug Remote

Back IN

Remove Wire From

Water Temperature Switch

Has Power

Remote OK

NO Power

Engine runs OK NO Power

Problem with Remote

Replace Water

Temperature

Switch

Check Shutdown

Relay

Check Wiring

8

Check

Fuel Level

NO Visible Exhaust Smoke

Insufficient

Fuel to Engine

Air IN

Fuel

System

Check

Safety Shutdowns

And

Fuel Solenoid

Replace

Fuel Filter

ENGINE RUNS

ROUGH or SLOW

Check

Fuel

PUMP

9

Excessive Exhaust Smoke

BLUE

Excessive Oil Level

GRAY/WHITE

BLACK

Dirty Air Filter

Engine Overheated

Engine Over Loaded

Clogged Muffler

Over Fueling Injector

HIGH ALTITUDE

Glow Plug

Not Activating

Check

With 12 volt DC

Test Light

Engine Cold

Incomplete

Combustion

Over-fueling

Injector

Engine Cranks

NO

Exhaust

Smoke

Smoke

From

Exhaust

Turn

Switch

“ON”

ENGINE WILL NOT

START

Engine Does NOT

Crank

Main Switch

Check Fuel

Solenoid

NO

Power While

Cranking

Check

Fuel

Supply

YES NO

Defective

Solenoid

No Power

From

Starter Terminal

Check

Fuel

Pump

Air IN

Fuel

System

Check

Glow

Plugs

Check

Glow Plug

Relay

Check Spark

Arrestor

Muffler for

Clogging

Start

Switch

Starter

Relay

Starter

Motor

Battery

Dead

Check

Terminal

Ends

Engine

Cranks SLOW

Oil Viscosity

TOO HEAVY

LOW

Battery

Voltage

10

SECTION 3

“GENERATOR END”

PRINCIPLES OF OPERATION

Rotating Field Assembly (Rotor)

Core

Coil

Voltage

Electronic Voltage Regulation

Exciter Field Coil Voltage Source

Balance

Bearing

Stator

“M” SERIES EXCITER TYPE GENERATOR ASEMBLY

GENERATOR END TROUBLESHOOTING GUIDES

Zero or Low Voltage

Voltage

12-Volt Battery Test

Condition

WIRING SCHEMATICS and RESISTANCE CHARTS___________________________

120 Volt Connection “M” Series Exciter Type

120 / 240 Volt Connection “M” Series Exciter Type

1-2

3

4-6

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.

A static voltage regulator is connected to the generator output. The regulator will rectify part of the output voltage to provide a DC voltage to the exciter field coils. This will increase the density of the lines of force in the exciter, increasing the voltage induced into the exciter armature windings, and therefore, to the rotating rectifiers. The rotating rectifier output will be increased which will increase the alternator field strength and generator output will build up its rated voltage. Adjustment of the generator output to the rated voltage level is accomplished by controlling the current fed to the exciter field coils.

Regulation is automatic with the static type voltage 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 an Automatic Voltage Regulator (AVR) is a very reliable device, which uses solid-state electronics to maintain voltage accuracy at ±2% of the regulated voltage. The Voltage Regulator is designed to automatically regulate and maintain the generated AC voltage through out the load range, that is from no load to full load.

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 system. If any equipment requires

240-volts, then the 120/240-volt connection must be used. If all equipment requires 120-volts then the 120-volt connection is preferred, even if two lines leave the same switch box. The two lines at the inputs to the switch box are both connected to the un-grounded 120-volt lines from the generator.

The 120-volt connection enables the Electronic Voltage Regulator (EVR) to hold the voltage very close to the 115 or 120 volts, as initially adjusted, regardless of the power distribution amount the different distribution lines. The 120-volt connection is recommended if the entire electrical load requires only 115 or 120 volts.

Although the 120/240-volt connection may also be used when all loads requires only 110 volts, it should be pointed out that this connection, the 240-volts, is regulated and the lightly loaded phase, or line, will deliver a high line to neutral voltage and the heavily loaded phase will deliver a low line to neutral voltage. The heavily loaded line may have such a low voltage that air conditioning will have more difficulty in starting, and long starting lines may overload generator and trip circuit breakers

EXCITER FIELD COIL VOLTAGE SOURCE

Field coil DC voltage is obtained by rectifying the voltage from the phase to neutral line of the generator output, or either appropriate terminal to provide the needed voltage reference.

The rectifier bridge is an internal part of the static regulator. The static regulator senses a change in the generator output and automatically regulates current flow in the exciter field coil circuit to increase or decrease the exciter field strength. An adjustable rheostat sized to be compatible with the regulator is used to provide adjustment of the regulator sensing circuit.

1

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.

FIELD COIL

Field coils of heavily insulated wire are “wet” wound directly onto the poles. Field coil leads are brought out to the rectifier assembly for connection to the source of DC excitation voltage.

BALANCE

The rotor assembly is precision balanced to a high degree of static and dynamic balance.

Although the balance will remain dynamically stable at 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.

BEARING

The generator rotor assembly is suspended on a shielded factory lubricated ball bearing. A visual inspection of the bearing is recommended at typical service intervals. If signs of abnormal wear or leakage are observed, the bearing should be replaced. Never use liquids of any kind to clean the generator end and bearing.

STATOR ASSEMBLY

The stator assembly consists of laminations of steel mounted in a rolled steel frame. Random wound stator coils are fitted into the insulated slots.

2

DESCRIPTION

1. END COVER

PART NUMBER

17.5KW 20KW

NS-GENCAN NS-GENCAN

2. EXCITER ROTOR

3. EXCITER STATOR

4. REAR HOUSING BRACKET

5. ROTOR BEARING

02RTR1520EXC

02STA1520EXCG 02STA1520EXCG

02HB175

02BRG207

02RTR1520EXC

02HB15TCGE

02BRG207

6. MAIN STATOR ASSEMBLY** 02STMN175 02STMN20

7. MAIN ROTOR ASSEMBLY 02RTRMN175 02RTRMN20

GENERATOR ASSEMBLY 02GEN175TCGE 02GEN20TCGE

VOLTAGE REGULATOR 06REG634AVC 06REG634AVC

**NOTE:

Item #6 MAIN STATOR ASSEMBLY is a one-piece unit. The Stator cannot be separated from the Generator’s outer housing.

“M” SERIES EXCITER TYPE GENERATOR ASSEMBLY

ZERO

OR

LOW

VOLTAGE

Check Gen Fuse

BAD OK

Replace

Fuse

OK

Wiring To

Panel

Defective

Breaker

Main Coil

Output to

Breaker

Check Main

Breaker is “ON”

BAD

ON

Check Ohm’s on

Exciter Leads

BAD

OFF

Turn “ON”

Breaker

OK

12 V Battery Test

Replace Exciter

OK

Replace

Voltage Regulator

4

One Coil

Low Voltage

Replace

Stator

Zero or

Low Voltage

Check

Main Breaker

On GenSet

Check

Gen End

High

Voltage

Replace

AVR

Check AMP

Draw

From equipment

Check Load Distribution

One Voltage Line

may be

Higher than the other

12 VOLT

BATTERY TEST

Both Coils

Low Voltage

Check

Connections

RPM 1800

VOLTAGE TEST

Check Engine

Replace Stator

5

Overload

Sensing Voltage

Low or None

Replace

Stator

Output

Voltage OK

Replace

AVR

OVERLOAD

CONDITION

Check AMP Draw

BAD

Engine Problem

See Engine

Troubleshooting

Check Load Distribution

Disconnect

AVR

Conduct

12-Volt Battery Test

OK

Replace Stator

Check

Stator Coil

Resistance

Replace AVR

And Test

6

Main Stator

Main Rotor

Exciter Stator

Exciter Rotor

Aux. Winding

RESISTANCE CHART “M” SERIES EXCITER TYPE

Less Than 1.0

Ohm / Phase

2.00

23.0 – 28.0

0.655 – 0.720

1.0 – 1.4

Less Than 1.0

Ohm / Phase

2.10

23.0 – 28.0

0.655 – 0.720

1.0 – 1.4

T1-T2 T3-

T4

N/A

F+ – C

N/A

E1 – E4

Black / Black

N/A

Black / Black

N/A

Black / Black

120 VOLT CONNECTION “M” SERIES EXCITER TYPE

Main Stator

Main Rotor

Exciter Stator

Exciter Rotor

Aux. Winding

RESISTANCE CHART “M” SERIES EXCITER TYPE

Less Than 1.0

Ohm / Phase

2.00

23.0 – 28.0

0.655 – 0.720

1.0 – 1.4

Less Than 1.0

Ohm / Phase

2.10

23.0 – 28.0

0.655 – 0.720

1.0 – 1.4

T1-T2 T3-

T4

N/A

F+ – C

N/A

E1 – E4

Black / Black

N/A

Black / Black

N/A

Black / Black

120 / 240 VOLT CONNECTION “M” SERIES EXCITER TYPE

SECTION 4

“INSTALLATION”

SAFETY PRECAUTIONS

Hot Piping

Dangerous

Explosive Battery Gases

Electrocution

Parts

High

Explosion

1-2

Lethal Exhaust Gas

Excessive

Shock

Backfire

Fire

Fire

Application

Unit Starts Without Notice

Loose

GENERATOR INSTALLATION in RECREATIONAL VEHICLES

Introduction

Application

General

3-9

Specification

Fuel Consumption in Gallons per Hour

Factors

Generator Compartment Size

Frame

Air

Air Requirements Cont’d

Enclosures

Dimensions and Enclosure Layout

Installation Dimensions

SYSTEMS CONNECTION 10-13

Remote Radiator Cooling System

System

Exhaust

Fuel

ELECTRICAL CONNECTIONS 14-19

Electrical

AC Load Lead Connections

Motor

De-Rating

Electrical

Loads

Extension

GAC Engine Governing System

BASLER

ECU-63 Engine Control Module

WIRING SCHEMATIC

12V DC Engine Control 550 Series

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.

1) HOT PIPING: An engine and exhaust system may get extremely hot while running. Do not work on a generator set until it has sufficiently cooled.

2) DANGEROUS FUELS: Use extreme caution when handling, storing and using fuels. All fuels are highly explosive in a vaporous state. Store fuel in a well ventilated area away from spark producing equipment. Keep fuels and all chemicals out of the reach of children. Never add fuel to the tank while the engine is running. Spilled fuel may ignite on contact with hot parts or from ignition spark. Always keep fuel lines and connections tight and in good condition. Don’t replace flexible fuel lines with rigid lines. If you notice any fuel leakage, fuel accumulation or electrical sparks, DO NOT OPERATE THE GENERATOR SET.

3) EXPLOSIVE BATTERY GASES: The gases generated by a battery being charged are highly explosive.

Do not smoke or permit any flames or sparks to occur near a battery at any time, especially when it is being charged. Avoid contact between terminals with tools to prevent sparks and possible burns. Always remove wristwatch, rings, or other jewelry before handling a battery.

Any compartment containing batteries should 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 ELECTROCUTION of vehicle occupants. Your generator set must not be used to “Back Feed” by connecting it to a building or outdoor electrical circuit. Back feeding can cause serious injury or death to utility personnel working to repair a power outage and may also seriously injure persons in your vehicle. Unauthorized connections are unlawful in some states and/or localities. A transfer switch must be installed to prevent interconnection of the generator set power and outside power.

5) MOVING PARTS: Keep hands, feet, and clothing away from belts and related pulleys when unit is running.

Replace guards, covers, and screens before operating the generator set. Serious personal injury may occur from contact with moving parts.

6) HIGH VOLTAGE: Remember the function of a generator set is to produce electricity. Wherever electricity is present there is a potential danger of electrocution. Apply the same precautions to the vehicles electrical appliances as you would for any home appliance. Keep away from electrical circuits and wiring while the generator set is running. Have electrical service performed only by qualified electricians. Be sure any unauthorized person; especially children are denied access to the generator set. Keep the compartment door securely latched or locked at all times. Be sure the generator is properly grounded. Never touch electrical leads or appliances with wet hands, or when standing on wet ground.

1

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. Fuel tank and installation must conform to applicable regulations.

8) HOT COOLANT: Allow engine to cool and release pressure from the cooling system before opening the radiator pressure cap. To release the pressure, cover the radiator cap with a thick cloth then turn it slowly counterclockwise to the first stop. After the pressure is released and the engine has cooled, remove the cap.

9) LETHAL EXHAUST GAS: When installing an exhaust system position the tail pipe end so that the discharged gases may not be drawn into the vehicle interior through windows, doors, air conditioners, etc. The engine powering your generator set discharges deadly carbon monoxide as part of the exhaust gas when running. It is essential that the exhaust system be leak proof and routinely inspected.

10) EXCESSIVE NOISE: Never operate the generator set without an adequate muffler or with a faulty exhaust system. Exposure to excessive noise can lead to a hearing impairment.

11) ELECTRICAL SHOCK: A battery can cause electrical burns and shocks. Use reasonable care when working near the battery 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 smoke or permit a flame or spark to occur near the carburetor, fuel lines, fuel filter, fuel pump or other potential source of spilled fuel or vapors.

14) FIRE HAZARD: Be careful when parking your vehicle to prevent grass fires from being started by hot exhaust gases or exhaust system. Keep away from hot engine and generator parts to avoid burning yourself. Keep the generator set and compartment clean and free of debris, especially combustible materials. Never store fuel, oil or rags in the generator compartment.

15) MARINE APPLICATION: RV generator sets do not comply with United States Coast Guard (USCG) requirements. They must not be used for marine applications. Use only generator sets specified for marine use in a marine application. USCG regulation 33CFR183 requires a generator set to be ignition protected for use in a gasoline-fueled environment.

16) UNIT STARTS WITHOUT NOTICE: To prevent accidental starting on the units with remote start / stop switch, always disconnect the battery by removing the negative (-) terminal first and then the positive (+). Always disconnect the unit in this manner before working on the generator or any equipment connected to it.

17) LOOSE COMPONENTS: Periodically check for and tighten any fasteners that may have become loose from vibration or road shock. Serious damage may possibly occur if components become dislodged or misaligned.

2

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. When installing a RV generator set the installation must comply with the current Safety Standards of ANSI / RVIA EGS-1-2003, ANSI A 119.2

/ NFPA 501C and applicable articles of ANSI / NFPA 70 of the National Electrical Code. Generator set installations must also comply with state and local requirements.

MARINE APPLICATION

RV generator sets do not comply with United States Coast Guard (USCG) requirements and must not be used for marine applications. Use only generator sets specified for marine use in marine installations. USCG regulation 33CFR183 requires a generator set to be “ignition protected” when used in a gasoline fueled environment.

GENERAL INFORMATION

This information section covers the RV generator set models listed below. To determine which model is involved, check the model number found on the Power Technology nameplate attached to the frame of the generator being installed. Follow all instructions to ensure proper installation and operation.

Each generator set features a Kubota diesel engine, rotating-field alternating current generator, and a control box. The generator is directly connected to the engine for permanent alignment. Each control box includes a Start / Stop switch, and a On /Off switch to reset the control module or lockout any remote switch to prevent starting while service is being performed. The control box may also be equipped with a switch to operate the mechanism used to move the generator in/out of the coach for servicing. (Supplied by the coach manufacture). After the set is attached to the frame of the vehicle, all that is usually required to make it operational is the following.

1. Attaching the exhaust system.

2. Add proper amount of radiator coolant.

3. Add oil to crankcase, to the dipstick FULL mark.

4. Connect fuel lines, remote switch, load leads and battery terminals.

(Consult the Specification Charts on the Following Pages for Requirements)

MODELS

DIMENSIONS L x W x H

WEIGHT

ENGINE

RPMs

AC VOLTAGE

AMPERAGE

Hz

PHASE

GENERATOR COMPARTMENT

FREE AIR OPENING

RADIATOR AIR REQUIREMENTS

PTRV-17.5K PTRV-20K PTRV-17.5KT PTRV-20KT

41” x 27” x 28” 42” x 27” x 28” 41” x 27” x 28” 42” x 27” x 28”

840 lbs. 850 lbs. 840 lbs. 850lbs.

Kubota V-2203 Kubota V-2003-T Kubota V-2203 Kubota V-2003-T

1800 1800 1800 1800

17.5 20 17.5 20

120 / 240 120 / 240 120/240 120/240

146/73 166/83 146/73 166/83

60 60 60 60

1 1 1 1

400

Square Inches

2120 CFM

400

Square Inches

2120 CFM

400

Square Inches

2120 CFM

400

Square Inches

2120 CFM

3

SPECIFICATION CHARTS

FUEL CONNECTION

FUEL RECOMMENDATION

BATTERY VOLTAGE

BATTERY CRANKING AMPS

BATTERY COLD CRANKING AMPS

BATTERY GROUND

CHARGING AMPS.

¼” NPT

DIESEL FUEL No.1-D or No.2-D ASTM / D975

12 VOLTS DC

420

590 MINIMUM

NEGATIVE

40

75%

100%

FUEL CONSUMPTION IN GALLONS PER HOUR

LOAD PERCENTAGE

25%

50%

17.5KW

.39 GPH

.79 GPH

1.18 GPH

1.57 GPH

20KW

.45 GPH

.90 GPH

1.35 GPH

1.80 GPH

INSTALLATION FACTORS

Each generator set is received as a unit except for the optional exhaust system components, which are shipped loose for assembly after the set is installed in the vehicle. When preplanning the installation, the following factors must be considered.

1. COMPARTMENT SIZE: Will there be sufficient room around the set to maintain

the minimum clearance of one (1) inch?

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 the

generator set? **

5. FUEL SYSTEM: Is the fuel system properly designed to prevent fuel

6. EXHAUST SYSTEM:

starvation of either the main engine or generator engine?

Will the exhaust system meet all Local, State and Federal safety requirements?

7. ELECTRICAL CONNECTIONS: Will all systems, (battery, load and remote switch)

be compatible with the vehicles system?

** NOTE:

When using a radiator not supplied by Power Technology consult your radiator manufacturer to ensure that heat rejection values are met.

4

GENERATOR COMPARTMENT SIZE

In planning the size of the generator compartment allow for the minimum clearance of one (1) inch 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.

NOTE: For Gensets mounted inside an enclosure please refer to the section on “Generator Enclosures” for additional information and mounting requirements.

The generator set must be securely fastened to avoid unwanted movement from vibration and road shock. If the unit is equipped with a mounting tray the tray is usually supported with structural framing. Be sure to use all mounting holes in the tray to secure the tray to the structural framing. Units not equipped with mounting tray are secured by attaching Genset mounts (two front and two rear) directly to the structural framing. Skid mounted units can either be affixed to a tray for tray mounting or attached directly to the structural framing. The generator is easily moved in and out of the coach by incorporating a slide rack carriage with rollers into the structural framing. When designing the compartment allow sufficient access for routine maintenance and for removal when major service is required. Also keep in mind that the compartment or door must have an air intake opening equal to or greater than that specified under the “Air Requirements” section of this manual. Make sure that the compartment is vapor tight and completely sealed off from the inside of the vehicle to prevent any hazardous fumes from entering the vehicle. Avoid road splash and the possibility of igniting combustible materials beneath the coach by enclosing all unnecessary free space beneath the generator compartment.

Line the compartment with a good sound deadening material. The material selected must be fireproof or highly fire resistant. 3-layer foam sound mat is very efficient for absorbing generator noise.

This type of material is easily cut to size and can be quickly installed using the appropriate fire resistant adhesive. Other materials such as fiberglass insulation with heat barrier may also be used.

NOTE: Since a Genset is flexibly mounted the minimum clearance of one (1) inch will assure that the unit will not rub the sides of the compartment while the unit is in operation or while the vehicle is in transit.

COMPARTMENT FRAMING

The generator must be bolted to a structural frame, which is either bolted or welded to the frame of the vehicle. This structural frame must be designed to withstand a minimum force of 5Gs in any direction. The structural frame must support the entire outer perimeter and center section of the unit’s base. Additional framing may be required if excessive movement or vibration occurs.

AIR REQUIREMENTS

Each Genset is equipped with a high ambient temperature shutdown switch and a high water temperature shutdown switch, which will automatically shut down the Genset if the ambient temperature or water temperature rises too high. To prevent the generator set from shutting down make sure the compartment openings are large enough to allow adequate circulation of cooling air. The minimum free air opening into the compartment is 400 sq. in. or 2580 sq. cm. Remember that louvers, screens and protective grills will restrict airflow. A relatively open mesh screen can restrict airflow by as much as

45%. The intake opening will need to be increased in size to compensate for such restrictions.

NOTE: Ambient temperature is defined as the generators normal operating temperature within its mounting area. In an RV application this area is referred to as a compartment or enclosure.

5

AIR REQUIREMENTS CONT’D

ENGINE SPEED IN RPM

OUTPUT IN HORSEPOWER

WATER FLOW – GAL. / MIN.

ENGINE INLET WATER TEMP.

THERMOSTAT – RATING

17.5KW 20KW

1800

32.5

8.75

N/A

180°F

1800

32.5

8.75

N/A

180°F

THERMOSTAT FULL OPEN

ENGINE OUTLET WATER TEMP.MAX.

HIGH TEMP. SHUTDOWN SWITCH

195°F

235°F

230°F

195°F

235°F

230°F

HEAT REJECTION – BTU / MIN.

HEAT REJECTION – BTU / HR.

1650

99,000

1650

99,000

REMOTE RADIATOR

AIR FLOW – CU. FT. / MIN.

1920 1920

ENGINE OIL TEMP. MAX.

COMBUSTION AIR TEMP. *

268°F

N/A

268°F

N/A

*Combustion Air Temperature: The output of the engine will decrease about 1% for

every 10°F of air temperature above 77°F or 25°C.

IMPORTANT: Insulation and Sound Absorbing Material used inside of the generator compartment

Must Not reduce the specified airspace clearance of one (1) inch or restrict the airflow around the generator. Such reduction in airspace may lead to an overheating situation and reduced generator performance. Also be sure the air inlet and outlet openings meet the specified requirements. Allow clearance inside the generator compartment for easy access when routine maintenance is required.

WARNING: The generator compartment Must Be sealed to prevent hazardous fumes and vapors from entering the vehicles other 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 penetrating the compartment floor or dripping beneath the compartment.

6

GENERATOR ENCLOSURES

Some installations require the Genset to be mounted inside an enclosure. Enclosures are generally constructed of heavy gauge sheet metal, and completely insulated. Enclosures are typically installed in RV’s with large unobstructed compartments. The major advantage to installing a Genset in an enclosure is to achieve a significant reduction in the unit’s sound level.

In order to maintain the ambient temperature within the enclosure a forced cool air system is generally employed. Two blower fans capable of producing a minimum of 465 CFM each should be mounted at the generator end of the enclosure. Cooling air circulates around the generator end and engine, forcing excess heat to exit through an air duct outlet to the outside air.

Since hot air will rise the air duct outlet opening should be located near the inside top surface of the enclosure, the opening should be approximately 25 square inches.

Openings in the base of the enclosure and compartment floor are required for the engine exhaust pipe, oil drain hose and engine breather hose. Other holes for fuel lines, electrical leads, remote radiator hoses, etc. are usually located in the rear wall of the enclosure. Be sure to seal around these items to prevent fumes or vapors from entering the vehicles compartment. Two hinged doors at the front of the enclosure enable unobstructed access to the engine and control box for routine maintenance. A removable service panel in the rear wall of the enclosure facilitates servicing the back side of the Genset.

The clearance between the enclosure and the vehicles compartment walls is another consideration. Except for the rear wall of the enclosure the clearances at the top, sides and front can be minimal. A ½” gap per side is enough clearance for easy installation or removal. At the rear of the enclosure the compartment depth must be large enough to accommodate the two blower fans and system connections. A minimum of 10” between the enclosure and rear compartment wall is required for this area. Also, remember a 400 sq. inch free air opening is required to supply the forced air cooling system. See section on “Air Requirements” for details.

Dimensions and layouts are provided for your planned installation, be sure to follow all requirements. Power Technology’s Customer Service Department is available to answer any questions you may have concerning your Genset and installation.

IMPORTANT: When installing a RV generator set the installation must comply with the current Safety Standards of ANSI / RVIA EGS-1-2003, ANSI A 119.2 / NFPA 501C and applicable articles of ANSI / NFPA 70 of the National Electrical Code. Generator set installations must also comply with state and local requirements.

IMPORTANT: An enclosure manufactured by any person (s) other then Power Technology must follow the requirements set forth in this manual. All specifications must be adhered to; failure to do so may affect your Power Technology Southeast, Inc. Limited Warranty.

7

PTRV-17.5K / KT and PTRV-20K / KT

DIMENSIONS and ENCLOSURE LAYOUT

RIGHT SIDE VIEW

FRONT REAR

LEFT

RIGHT

LEFT

FRONT

ENCLOSURE BASE PAN CUTOUTS

8

RIGHT

INSTALLATION DIMENSIONS

9

GENSET

DIMENSIONS

L x W x H

41” x 27” x 28”

MINIMUM

DIMENSION FOR

INSIDE CLEARANCE

OF AN ENCLOSURE

L x W x H

43” x 29” x 29”

NOTE: BESURE TO

ALLOW FOR THE

THICKNESS OF

SOUNDMAT OR

INSULATION

SYSTEMS CONNECTION

REMOTE RADIATOR COOLING SYSTEM

Use the following data in designing and installing the generator set cooling system. To insure a safe effective installation, be sure the cooling system selected follows these parameters. Power

Technology offers radiator assemblies, which meet these requirements and will adequately cool the generator. Select the radiator assembly best suited for the generator installation.

Due to the multitude of coach manufacturers and the variety of generator installations, only general guidelines are provided. Adapt these recommendations to the installation. In a typical installation the radiator assembly is installed in the same compartment as the generator. If a blower fan radiator assembly is used, cooling air is drawn across the generator and engine and then through the radiator. If a suction fan radiator assembly is used the suction fan pulls cooling air through the radiator and then past the generator set. If the radiator assembly alone is used the installer must supply an electric blower or suction fan to circulate the cooling air. See the specification table for total air requirements.

Depending on space limitations the radiator can be located in front of, adjacent to, or in a ventilated remote location from the engine compartment, no more than 10 feet from the generator. To prevent recirculation of heated air be sure to maintain a tight seal between the radiator and the discharge chute.

Generally 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 to the engine combustion air and heat rejection requirements of the generator and engine block when designing the cooling system. A supplemental cooling fan capable of 500cfm (28.m³/min) should be installed to supply air to the generator compartment for these requirements.

Connect the radiator fan motor to the generator output leads L1 and L2. Be sure the radiator fan motor rotates in the correct direction and is of the proper voltage. To protect against overload and short circuits it is recommended that the motor be adequately fused. Install fuses between the motor and

L1 / L2 connection. A close relationship exists between the cooling system design and the generator compartment size. Availability of space is often the determining factor in the cooling system design. See the “Compartment Size” section of this manual prior to designing and installing the generator cooling system.

CAUTION: The fill inlet and reservoir tank must be located at the highest point in the cooling system.

If the fill inlet is not located as directed, coolant will not completely fill the engine. The cooling system must be purged of all air pockets for the system to function properly. If air pockets remain in the engine the high water temperature shutdown switch will malfunction and cause the engine to over heat. Also if the cooling system is not completely full, the low water level shutdown switch will prevent normal engine operations.

REMOTE RADIATOR ASSEMBLY

10

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. This prevents either or both engines from being starved for fuel. The generator set fuel pick-up tube is generally shorter than the vehicles; therefore fuel may not be available to the generator when fuel supply is low. This will prevent the generator from depleting the fuel supply needed by the main engine.

NOTE: Using a simple Tee fitting to supply both engines from a common fuel line is not recommended. This practice may possible cause a fuel starvation situation to either or both engines. Also, if excessive pressure were to build up in the main supply line it could possible cause a failure of the generators fuel lines or connectors and a hazardous fuel leak may occur.

Care must be taken when routing the fuel line from the main tank to the generator set. Keep the fuel line as short as possible while maintaining adequate clearance from the exhaust system. Fuel lines must be run along the frame side rails or coach under carriage. Never run fuel lines inside of the coach. Securely fasten 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, either one should have a minimum of ¼” ID and strong enough to withstand road and climatic conditions.

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. A properly installed exhaust system must be vapor tight, quiet and completely safe for the vehicle, its occupants and surroundings. Installation of an approved Spark Arrestor is required.

The exhaust system components must be approved and properly installed to meet the codes and regulations required by Federal and State agencies. Exhaust Mufflers and Spark Arrestors supplied by Power

Technology meet code and standard requirements set forth by the USDA Forest Service.

Laws pertaining to application and maintenance of a Spark Arrestor may vary depending on your location and State regulations. Federal laws apply on Federal lands. If a generator is used in a forest, on brush or grass covered unimproved land it must be equipped with a Spark Arrestor. It is the responsibility of the vehicle owner or operator to install and maintain the entire exhaust system in good working condition.

CAUTION: Any person (s) who installs an unapproved Muffler, Spark Arrestor or other exhaust system component, and/or modifies an exhaust system or component that may result in a hazardous condition is liable for damages, injuries or warranty expense caused by such unapproved installation and/or modification.

11

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. The maximum allowable backpressure for the engines listed in this manual is

1.57in Hg, (40mmHg).

2) Muffler shall be fabricated of aluminized steel or other corrosion resistant material and be of a welded or crimp construction. A USDA Forest Service approved spark arrestor must be part of the integral design of the muffler or provided as a separate add-on item.

3) Maintain a minimum of 3 inches (76mm) between the exhaust system components and any

surrounding combustible materials. If the minimum clearance cannot be maintained, an insulating shield must be installed to prevent the combustible material from exceeding temperatures 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 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 prevent excessive movement and vibration of the exhaust system, install hangers and clamps

designed for use in exhaust systems.

8) Never join or tee the generator exhaust system and the vehicle exhaust system together. Doing so may cause excessive back pressure on the generator engine, also condensation from one engine can damage the other engine.

WARNING: LETHAL EXHAUST GAS! When installing the exhaust system position the tail pipe end so that discharged exhaust gases are not drawn into the vehicle interior through windows, doors, air conditioners, etc. During operation an engine discharges deadly carbon monoxide with its exhaust. Carbon monoxide is particularly dangerous since it is odorless, tasteless, and non-irritating. It can cause death if inhaled for even a short period of time. Be especially careful if operating the generator set when parked under calm, windless conditions. Gases may accumulate in these conditions. Park your vehicle so that the exhaust discharges downwind. Always be aware of others in your vicinity. Make sure that your exhaust discharges away from other vehicles and buildings.

CAUTION: Make sure the exhaust system components are positioned well away from drain openings beneath the generator set. Also, be sure not to block access to the oil drain plug.

12

13

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.

Battery, load leads and the remote switch panel connections are necessary for completing the installation. Make final connections to the battery only after all other connections have been made, as this will prevent unintentional starting. Some specific details on each connection are stated in the following paragraphs. Refer to the wiring diagram for specific details. All wiring to the generator set shall be securely supported or harnessed to prevent abrasion. Additional support is required to prevent exposure to the exhaust system and any possible leakage of fuel, oil, or grease. At least 2 inches of clearance must be maintained between electrical wiring and hot exhaust parts. Wiring must not be located directly below or close to the fuel system, oil fill and drain locations. If the coach is equipped with a mechanism for removing the generator set from the compartment such as a mounting base or slide rack, be certain all wiring is long enough to allow for free movement of the generator for servicing.

A separate 12-volt battery is recommended for the generator set. With a separate 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 and servicing.

DISTANCE BETWEEN

GENERATOR SET AND

BATTERY

40’ (12.2M)

30’ (9.2M)

25’ (7.6M)

20’ (6.1M)

15’ (4.6M)

10’ (3.0M)

5’ (1.5M)

2.5’ (0.8M)

CABLE SIZE (AWG) REQUIREMENTS

AT VARIOUS TEMPERATURES

0°F (-18°C)

00

0

1

2

2

4

6

8

32°F (0°C)

0

1

2

2

4

6

6

8

75°F (24°C)

1

2

4

6

6

8

8

8

AC LOAD LEAD CONNECTIONS

Some generator sets have four color-coded leads. The Black leads (L1 & L3) are hot. The White or

Gray lead (L2) is neutral and the Green lead is ground. The load leads can be routed directly from the junction box to the vehicle AC circuit or transfer switch connection. All installations require that the load leads be routed through flexible conduit from the generator end bracket to the junction box location. The load lead junction box must be accessible for servicing and inspection.

AC load lead (L2) White or Gray is always the neutral lead on PTS generator sets. Make sure the neutral of the AC circuit in the vehicle is connected to the (L2) White or Gray lead. If equipment ground type plugs and receptacles (3 prong) are used in the vehicle, the green wire must be connected to the chassis ground. On vehicles, which also have provisions for using an outside AC, power source, the neutral lead as well as the Black (L1 & L3) hot leads must be completely isolated from the generator set when power is switched to the outside source.

14

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.

Air conditioning units are the most common type of motor loads for a generator set in a recreational vehicle. The starting characteristics of the different makes of air conditioners vary greatly.

For example, a particular 12,000 BTU unit may have lower starting requirements than a 10,000 BTU unit of another make. When only one unit is involved there is usually no starting problem provided of course the lighting and appliance load is not too high when unit is started.

The trend seems to be toward larger capacity air conditioners and the use of more than one unit in larger vehicles. Simultaneously starting two large units can present a problem if the capacity is marginal.

Because of the variation in starting characteristics of the different makes of air conditioners, no definite statement can be made in this publication regarding multiple-motor starting capabilities.

Delayed starting or use of “easy starting” devices on air conditioner units should be considered whenever simultaneous starting of more than one motor is involved. The starting 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”.

ELECTRIC MOTOR

HORSEPOWER

BASED ON CODE “G” ELECTRIC MOTOR

STARTING WATTS RUNNING WATTS

½ 2000 1100

1 3800

2 6000

1800

2800

3 8000

4 11000

5 13000

4000

5500

6500

KILOWATT DE-RATING

All units are rated at 1.0 power factor. The Kilowatts of the generator set will decrease 3.5% per

1,000 feet (305m) above 500 feet (152m) above sea level. De-rate 1% for every 10 °F (5.5°C) above

68°F.

ELECTRICAL LOADS

While the electrical load of the vehicle should have been calculated prior to purchase of the generator set, you may want to recheck the load before installing the set to make sure the capacity is ample to meet the demands without possible overloading.

The lighting load is usually easiest to calculate in most cases, simply add the wattage of each lamp to be operated off the generator set. Note that in many applications, not all of the lights or lamps are in the generator sets AC circuit. Some are DC powered by the 12-volt battery in the vehicle. Make sure the total includes only lights actually on the generator sets AC circuit. The lighting load is usually not to heavy in mobile installations however it must be accurately calculated to prevent overloading. For example, if all lights are on at the same time and the air conditioner or other motor equipment starts up, this may possibly cause an overload situation.

15

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.

The average power requirements for some common electrical appliances are listed below as a guide.

DETERMINING ALTERNATOR LOAD REQUIREMENTS

CHECK √ APPLIANCE WATTS

VCR 70

100

RADIO

TELEVISION

STEREO

100

100

100

150

ATTIC FAN 1/4 HP

SUMP PUMP 1/3 HP

REFRIGERATOR

FURNACE FAN 1/3 HP

FREEZER

JET WATER PUMP ¾ HP

ELECTRIC STOVE ELEMENT

SUBMERSIBLE WATER PUMP 1 HP

TOASTER

DISHWASHER

SUBMERSIBLE WATER PUMP 2 HP

150

250

400

500

500

600

800

900

1000

1000

1000

1200

1200

1200

1500

1600

OVEN

TOTAL WATTS CHECKED

3000

4500

EXTENSION CORDS

An extension cord is normally used to provide electrical power from the generator set to a remote location. The extension cord size (AWG#) and length must be adequate to safely maintain the amperage requirements. A proper size extension cord will help minimize the voltage drop between the generator set and remote location.

AMPS LOAD IN WATTS

120 VOLTS 240 VOLTS

CORD LENGTH

AWG#10 AWG#12 AWG#14

5

10

20

30

600

1200

2400

3600

1200

2400

4800

7200

500 FT

250 FT

125 FT

60 FT

300 FT

150 FT

75 FT

35 FT

200 FT

100 FT

50 FT

25 FT

40 4800 9600 30 FT 15 FT 10 FT

50 6000 12000 -----

16

GAC ESD2110 SERIES SPEED CONTROL UNIT

The ESD2110 Speed Control Unit is part of an engine governing system designed to control engine speed and stability throughout the load range. Operating in combination with a magnetic pick-up and electric actuator the ESD2110 will maintain the proper engine speed by adjusting the fueling system according to the applied load. By maintaining a set engine speed the generator voltage output and frequency will remain constant and stable.

17

BASLER AVC63-4 ANALOG VOLTAGE CONTROLLER

The AVC63-4 voltage regulator is designed for use on 50/60 Hz brushless generators. Features include frequency compensation, over excitation shutdown, a solid-state build-up circuit and EMI filtering. The AVC63-4 attaches to the generator with spade type wire terminals for a secure connection.

The AVC63-4 has three adjustable potentiometers for fine-tuning the output voltage, stability and under frequency. The regulator is encapsulated in a protective plastic shell and back filled with an electronic compound, which provides protection from environmental hazards.

AVC63-4 Specifications:

DC Output Power 4 Amps at 63V DC

7 at DC

9 at

Exciter Field DC resistance

AC Power Input

Sensing Input

15 Ohms Min. – 100 Ohms Max.

190 – 240V AC, Single Phase, 50/60 Hz ±10%, Burden: 500VA

190 – 240V AC, Single Phase, 50/60 Hz ±10%, Common with AC

Voltage Adjust Range

Regulation

171 – 264V AC than ±1.0% No Load to Full Load

Response Time

Suppression

Over Excitation Shutdown

Less Than ±1.5% Change in Sensing Voltage

Field Voltage shuts down after time delay if exciter field voltage exceeds 100V DC, ±5%

Voltage Build-Up

Power Dissipation

Operating Temperature

Internal provisions for automatic voltage build-up from generator residual voltage as low as 6V AC

8-Watts Max.

-40°F (-40°C) to 140°F (60°C)

1) Voltage Control

2) Stability Control

3) Underfrequency Control

18

PT-ECU-63 ENGINE CONTROL MODULE

1) Generator Main Switch must be in the ON position.

2) Hold Start/Stop Switch for 1 second and release.

3) Glow Plugs will preheat for 8 seconds. LED flashes slowly.

4) Preheating will cease during engine cranking cycle. LED continues flashing.

5) 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. If an AC signal is verified the engine will start and the LED will remain ON during the normal run operation. If the AC signal is not verified the PT-ECU-63 will terminate the cranking cycle and LED will flash a fault code.

6) Starter disengages immediately after engine run is verified.

7) PT-ECU-63 deactivates the Low Oil Pressure and High Water Temperature Switches for 6 seconds, this will assure oil pressure build-up time. If oil pressure does not build-up 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 more times before going into a fault mode. Glow Plugs will preheat for 8 seconds per attempt. Engine will crank for 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 PT-ECU-63.

Failure to start

Engine Temperature

1

2

Low Oil Pressure

No AC Signal

3

4

Coolant 5

NOTE: The PT-ECU-63 is designed to operate on 12V DC power. In a low battery situation the PT-ECU-63 may not initiate the normal cranking cycle.

To start the generator you can press and hold the Start/Stop Switch for approximately 10 seconds or until the engine starts. Once the engine starts the PT-ECU-63 will resume normal operations. If this situation reoccurs, charge or replace the battery.

19

634 STATE ROAD 44

FL 34748-8103

(352) 365-2777 FAX (352) 787-5545

POWER TECHNOLOGY SOUTHEAST, INC.

12V DC ENGINE CONTROL 550 SERIES

PTRV-17.5K and PTRV-20K

ENGINE WILL NOT START

ENGINE CRANKS ENGINE DOES NOT CRANK ENGINE CRANKS

SLOW

No Exhaust

Smoke

Check Fuel

Solenoid

NO Power

While

Cranking

Smoke From

Exhaust

Battery

Dead

Main Switch

Check Fuel

Supply

Check Fuel

Pump

Check

Glow Plugs

Check Spark

Arrestor

Muffler for

Clogging

Check

Terminals

Turn Switch

On

Start Switch

Air in

YES NO

Fuel System

Starter Motor

Oil Viscosity

Too Heavy

Low Battery

Voltage

Replace

Solenoid

No Power

From

PCMD

ENGINE RUNS ROUGH OR SLOW

No Visible

Exhaust Smoke

Insufficient

Fuel to Engine

Check

Fuel Level

Air in

Fuel System

Replace

Fuel Filter

Check

Fuel Pump

Check Safety

Shutdowns

And Fuel Solenoid

Excessive Exhaust Smoke

BLUE SMOKE

BLACK SMOKE GREY/WHITE SMOKE

Excessive

Oil Level

Excessive

Oil Consumption

Dirty Air Filter

Engine Overheated

Engine Overloaded

Clogged Muffler

Over Fueling Injector

High Altitude

Engine Cold

Incomplete

Combustion

Over Fueling

Injector

Glow Plug Circuit

Not Operating

ZERO or LOW

VOLTAGE

Wiring To

Panel

Check Brushes if

Applicable

OK

Defective

Breaker / s

Check Main

Breakers are

“ON”

ON

Main Coil

Output to

Breakers

BAD

OFF

Turn “ON”

Breaker / s

Replace

Stator

BAD

Check Ohm’s

On Main

Stator Leads

OK

Check Rotor

Ohm’s

VOLTAGE TEST

Zero or

Low Voltage

Check

Main Breaker / s

On Generator

Check

Gen End

High

Voltage

Check

Regulator

Overload

Check AMP

Draw

From equipment

Output

Voltage

OK

Engine Problem

See Engine

Troubleshooting

OVERLOAD CONDITION

Check AMP Draw

Check Load

Check

Stator Coil

Resistance

Replace Stator