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PowerTech PT-10-3 Manual

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PT-10-3
Operators
Manual
Power Technology Southeast, Inc.
634 State Road #44 Leesburg, FL 34748-8103
♦ (352) 365-2777 ♦ Fax (352) 787-5545 ♦
8/2010
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 PTS-10T-3 generators. Your generator was custom built to your specific requirements and
may or may not be equipped with each of these options listed. Installation requirements will vary depending
on your application; therefore Power Technology can only suggest general installation requirements. (See
Installation Requirements in Section 3) Follow all Safety Instructions as outlined in Sections 1 and 3 of this
manual. Other important Safety Precautions are posted through out the manual as well.
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.
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
POWER TECHNOLOGY SOUTHEAST, INC.
Export Warranty on All Power Technology Products
The Power Technology standard commercial warranty shall be modified as follows
for all sales and delivery of products outside of the United States and Canada.
The terms of the warranty shall be for a period of 12 months from the delivery to the
first retail user.
Dealer shelf life shall be 6 months from date of shipment. In no case shall the warranty
period exceed 18 months from date of shipment.
Warranty shall cover defected materials and workmanship for the above time period.
Power Technology shall supply replacement parts at no charge. The customer shall be
responsible for all transportation costs, import duties, legal documents including but not
limited to import licenses, customs declaration or inspection services.
In all cases if local warranty services are available through manufacturers representation,
manufacturers’ standard warranty shall supersede Power Technology’s warranty and any
warranty or parts and labor shall be that of the manufacturer. The terms and conditions of
the manufacturer warranty shall be those offered by the manufacturer for the country or
region covered by the manufacturers’ representative.
TABLE of CONTENTS
SECTION 1: “SAFETY”
SAFE OPERATION 1-4
SECTION 2: “ENGINE”
PRE-OPERATION CHECK 1
OPERATING INSTRUCTIONS for SUB-ZERO CONDITIONS _____________ 2-3
OPERATING THE ENGINE ES-52 CONTROLLED_______________________ 4
ENGINE SPECIFICATIONS 5
ENGINE POWER FACTORS _________________________________________ 6-7
ENGINE MAINTENANCE SERVICE SCHEDULE 8
ENGINE OIL MAINTENANCE 9
ENGINE COOLANT MAINTENANCE 10
OPERATING HOURS AND SERVICE LOG 11
ENGINE TROUBLESHOOTING GUIDES 12-14
SECTION 3: “GENERATOR END”
SAFETY PRECAUTIONS 1-2
INSTALLATION REQUIREMENTS & RECOMMENDATIONS____________ 3
GENERATOR ASSEMBLY INFORMATION____________________________ 4-5
ENGINE and GENERATOR DIAGRAM________________________________ 6
SECTION A: GENERATOR__________________________________________ 1-19
SECTION B: VOLTAGE REGULATORS and ENGINE CONTROLLER______ 1-9
SECTION C: WIRING SCHEMATIC___________________________________ 1-19
SECTION D: GENERATOR END TROUBLESHOOTING__________________ 1-3
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 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.
2
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.
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 24 V 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 1
Engine Break-in Period
Daily Check
OPERATING INSTRUCTIONS for SUB-ZERO CONDITIONS ____________________ 2-3
Coolant System
Lubricating System
Fuel System
Electrical System
OPERATING THE ENGINE
ES-52 CONTROLLED 4
Engine Starting Controls
Check Engine After Starting
Stopping the Engine
ENGINE SPECIFICATIONS 5
Kubota Model’s D-1105-T-E3B2
Service Parts
ENGINE POWER FACTORS _______________________________________________ 6-7
Power De-rating with Reduced Fuel for High Altitudes
Atmospheric Pressure vs. Altitude
Atmospheric Temperature & Humidity Power Lose
Atmospheric Factors Chart
Accessory Power Requirements
ENGINE MAINTENANCE SERVICE SCHEDULE 8
ENGINE OIL MAINTENANCE 9
Checking Engine Oil Level
Lubricating Oil Specifications
Engine Refill Capacities
Lubricating Oil Viscosity Recommendations
ENGINE COOLANT MAINTENANCE 10
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 11
ENGINE TROUBLESHOOTING GUIDES
12-14
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 INSTRUCTIONS
for
SUB-ZERO CONDITIONS
To operate a Power Technology Stand-By Generator System in sub-zero climates, advanced
preparations to the Coolant System, Lubricating System, and Fuel System are essential. Start-up and
Operating Procedures also require special consideration. The following is a list of procedures which
Power Technology highly recommends before operating a Stand-By Generator System under extreme
cold conditions.
COOLANT SYSTEM
Perform a visual inspection of the coolant system components and connections for signs of
leakage, repair or replace as needed. Completely drain coolant from the system into a container for
proper disposal. Flush system with clean water or use a commercially available radiator flush if
necessary to remove deposits. Excessive build-up may require professional cleaning by a radiator shop.
Also remember to clean away dirt and debris from the outside of the radiator. Use running water to clean
dirt particles from between the fins. Never use a hard object to clean the radiator core.
Extreme cold will cause rubber products to become hard and brittle. Inspect hoses and belts for
signs of cracking and wear, replace as needed.
To refill the coolant system, premix a 50/50 solution of Ethylene Glycol and distilled water.
Following the Engine Manufacturers Manual fill the system to the recommended level and test run the
engine to purge any trapped air. Recheck the coolant level and top off as needed.
NOTE: Use a Spectrometer to test and confirm the proper protection level of the coolant solution.
A Hydrometer tester may be unreliable and should not be used.
Optional Coolant System Heater
: Installing a coolant heater in a Stand-By Generator System will
facilitate cold climate starting. These heaters are available in several configurations, including size,
supply voltage and output wattage. Operating on the Thermosyphoning principle the coolant heater
draws cold coolant from the lower engine block, heats the coolant, which rises and returns to the top of
the engine thus circulating heated coolant throughout the engine. Coolant heaters are available in several
thermostatically regulated ranges, also the heating element is protected by an overheat thermostat.
To turn the coolant heater ON or OFF it may be wired into an oil pressure switch, which will turn OFF
the heater when the engine starts and maintains oil pressure and back ON when the engine stops and oil
pressure drops.
LUBRICATING SYSTEM
When operating a Stand-By Generator System in a sub-zero environment adhering to the Engine
Oil Maintenance Schedule is crucial. Using the proper Viscosity and Grade of motor oil is extremely
important as is installing an oil filter approved by the Engine Manufacturer. Incorrect oil viscosity and
inferior grade filters may restrict oil flow through the engine during extreme cold conditions causing
harmful wear to internal engine components.
Use high quality Multi-Viscosity oil, which meets or exceeds API specifications CD/CE or CF4.
For temperatures (–20°C) 4°F and above use 5W-30 viscosity.
For temperatures (–20°C) 4°F and below use 5W-20 viscosity.
2
FUEL SYSTEM
In temperate climatic conditions Diesel engines perform well using ASTM-2-D (No.2 Diesel
Fuel). However, when temperatures drop below (0°C) 32°F it will be necessary to use ASTM-1-D
(No.1 Diesel Fuel). Either type should exceed a minimum Cetane number of 45.
In extreme cold conditions with temperatures in the (–30°C) –22°F range it may be necessary to
use Jet Fuel or No.1 Kerosene to start the engine.
ELECTRICAL SYSTEM
The electrical components must be able to endure the extra demand of sub-zero conditions and
be capable of delivering the necessary power to start the engine. A well maintained and fully charged
battery is essential. At temperatures above (0°C) 32°F the Battery must be capable of delivering a
minimum of 675 CCA (Cold Cranking Amps). At temperatures below (0°C) 32°F the Battery must be
capable of delivering a minimum of 1450 CCA.
Optional Air Intake Heater: Installing an air intake heater in a Stand-By Generator System will facilitate
cold climate starting. The air intake heater consists of 3 glow plugs mounted just ahead of the air intake
manifold. When activated during the starting cycle the air entering the engine is preheated, which helps
the engine to start easier. Once started allow addition warm-up time for the engine to reach normal
operating temperature before placing the generator into operation.
IMPORTANT: Never use Ether or other starting fluids to start a Diesel engine. Severe damage to the
engine may occur.
3
OPERATING THE ENGINE
ES-52 CONTROLLED
ENGINE STARTING CONTROLS
1) Generator Main Switch must be in the ON position.
2) Toggle the Start/Stop Switch to the Start position.
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 ES-52 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 ES-52 will
terminate the cranking cycle and LED will flash a fault code.
6) Starter disengages immediately after engine run is verified.
7) ES-52 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 ES-52 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, toggle the Start/Stop Switch to the Stop
position.
10) If a fault occurs turn Generator Main Switch OFF and then ON to reset ES-52.
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.
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.
4
ENGINE POWER FACTORS
ALTITUDE POWER LOSS FACTORS
High altitudes can cause sizeable losses or reductions in available power. The exact amount of
loss can be difficult to estimate, because these losses vary with the type of engine. Generally, two stroke
engines lose more power than four stroke engines, and turbocharged or supercharged engines lose less
power than naturally aspirated engines.
Naturally aspirated 4-cycle engines will lose roughly 3% power per 1000 feet in altitude rise.
Therefore, an engine producing 100 HP at sea level will produce approximately 91 HP at 3000 feet
elevation.
POWER DE-RATING WITH REDUCED FUEL FOR HIGH ALTITUDES
ATMOSPHERIC PRESSURE vs ALTITUDE
6
ALTITUDE - FT
ALTITUDE DE-RATING FACTOR
ALTITUDE POWER CORRECTION
TURBOCHARGED ENGINE
NATURALLY ASPIRATED
ENGINES
75% FUEL SETTING
80% FUEL SETTING
85% FUEL SETTING
90% FUEL SETTING
95% FUEL SETTING
100% FUEL SETTING
0 3280 6500 9840 13120
0 1000 2000 3000 4000
ALTITUDE - FT
ALTITUDE - M
750
700
650
600
550
500
450
29.6
27.6
25.6
23.7
21.7
19.7
17.8
ATMOSPHERIC PRESSURE
(MM Hg)
ATMOSPHERIC PRESSURE
(IN Hg)
ATMOSPHERIC TEMPERATURE & HUMIDITY POWER LOSSES
These losses are generally considered to be nominal with values seldom exceeding 5%. Natural
atmospheric variations, however, can combine causing nearly 20% de-rating. For example, air of 120°F
(50°C) at 100% humidity. Even 100°F (40°C) temperature at 90% to 100% humidity will cause a 10%
de-rating. The local and/or field operating conditions must be evaluated and the power de-rated from
SAE J-1349 per these factors.
ACCESSORY POWER REQUIREMENTS
Additional power deductions should be made for any accessories that are installed. These deductions are
necessary to accurately identify the expected net power available for the prime power requirement. The
accessory items are variable for each installation / application, and can’t be determined or deducted by
the engine manufacturer. The following accessories are typical in a Stand-By Generator application.
Auxiliary Alternator / Generator End
Engine Alternator
Drive Belts and Pulleys
Cooling Fan
7
TEMPERATURE RELATIVE HUMIDITY
°C °F 30% 40% 50% 60% 70% 80% 90% 100%
25 77 1.000 .997 .992 .990 .984 .980 .977 .973
30 86 .985 .980 .973 .969 .964 .957 .954 .949
35 95 .966 .960 .953 .947 .940 .934 .928 .920
40 104 .948 .940 .931 .924 .915 .907 .899 .892
45 113 .928 .919 .907 .897 .886 .878 .867 .855
50 122 .910 .895 .882 .869 .854 .841 .830 .815
ATMOSPHERIC FACTORS CHART
POWER AVAILABLE DUE TO TEMPERATURE AND HUMIDITY VARIATIONS
ENGINE SPECIFICATIONS
SERVICE PARTS
Power Technology Part #
Filters:
Oil ----------------------------------------------------------------------------------- 01FO05S
Fuel ---------------------------------------------------------------------------------- 08FF081
Air ----------------------------------------------------------------------------------- 04FA221
Belts:
With Alternator or Idler Pulley--------------------------------------------------03BF1305
Without Alternator or Idler Pulley----------------------------------------------03BF7305
Thermostat-------------------------------------------------------------------------03THM0305NEW
3
MODEL Kubota D1105-EBG1 Kubota V1505-EBG1
Continuous Output 13.6HP @ 1800 rpm 17.9HP @ 1800 rpm
Cubic Capacity 68.53 in³ (1.123.L) 91.41in³ (1.498L)
Bore and Stroke
3.07” x 3.09”
(78.0 x 78.4mm)
3.07” x 3.09”
(78.0 x 78.4mm)
Cylinder Arrangement 3 In-Line 4 In-Line
Firing Order 1-2-3 1-3-4-2
Compression Ratio 22:1 22:1
Engine Oil Capacity 5.38qts. (5.1L) 6.34 qts. (6.0L)
Coolant Capacity 3.27qts. (3.1L) 4.22qts. (4.0L)
Fuel and Type
Diesel No. 2-D
4 Cycle
Diesel No. 2-D
4 Cycle
Minimum Fuel Consumption See Specification Chart See Specification Chart
ENGINE OIL MAINTENANCE
Ambient Temperature Oil Viscosity
Above 25°C (77°F)
SAE 10W-30
SAE 30 or
SAE 10W-40
0 to 25°C (32° to 77°F)
SAE 10W-30
SAE 20 or
SAE10W-40
Below 0°C (32°F)
SAE 10W-30
SAE 10W or
SAE 10W-40
5
CHECKING ENGINE OIL LEVEL
( 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 ENGINE
REFILL CAPACITIES
D1105-EBG1
Crankcase Oil Sump 5.38Qts. (5.1L)
and Filter
V1505-EBG1
6.34Qts. (6.0L)
LUBRICATING OIL VISCOSITY
RECOMMENDATIONS
The 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
the following Specification
API Class
CF
Engine Oil
Engine Maintenance Service Schedule
Maintenance
Service Item
*See
Note
Daily
Min.
Every
25 Hours
Every 100
Hours
Every 250
Hours
Every 500
Hours
Every
1000
Hours
Remarks
Engine Oil Level
Deterioration &
Leakage
X
Engine Oil
Change
*
X
Or Once
a Year
Oil Filter
Change
X
Or Once
a Year
Coolant Level
X
Coolant Leakage
X
Coolant Change
X Or Once a Year
Fuel Level
X
As Necessary
Fuel Leakage
X
Fuel Filter Re-
placement
X Or Once a Year
Air Filter Re-
placement
**
X Or Once a Year
Damaged Worn
Or Loose Belts
X
Or Every Two
Years
Replace Fuel
Hoses
X
Or Every Two
Years
Check Radiator
Hoses & Clamps
X
Once a Year
Abnormal Engine
Noise
X
Abnormal
Generator Noise
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.
8
ENGINE COOLANT MAINTENANCE
10
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.
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)
NOTE: Do not use Propylene Glycol. 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.
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
DATE HRs. RUN CUMLATIVE DATE SERVICES
11
Engine Runs OK
Has Power NO Power
Has Power NO Power
Engine runs OK NO Power
12
ENGINE STARTS
BUT WON’T RUN
Unplug Remote
Start-Stop from
Control Box
Problem with
Remote Connection.
Contact
Equipment Manufacture
r
Jump across
Oil Pressure Switch
with Jumper Wire
(2 pole)
Check Power
to Hold Circuit
of Run Solenoi
d
Check
Oil Pressure
With Gauge
Replace
Oil Pressure Switch
Defective Solenoid
REPLACE
Plug Remote
Back IN
Remote OK
Problem with Remote
Check
Safety Shutdown
System
Remove Wire From
Water Temperature Switch
Replace Water
Temperature
Switch
Check Shutdown
Relay
Check Wirin
g
Oil Pressure Switch
Single Pole
Disconnect Wire to Test
If “OK”
Replace
Switch
BLUE
GRAY/WHITE
BLACK
13
ENGINE RUNS
ROUGH or SLOW
NO Visible Exhaust Smoke Excessive Exhaust Smoke
Insufficient
Fuel to Engine
Check
Fuel Level
Replace
Fuel Filter
Air IN
Fuel
System
Check
Fuel
PUMP
Excessive Oil Level
Dirty Air Filter
Engine Overheated
Engine Over Loaded
Clogged Muffler
Over Fueling Injector
HIGH ALTITUDE
Engine Cold
Incomplete
Combustion
Over-fueling
Injector
Glow Plug
Not Activating
Check
With DC
Test Light
Check
Safety Shutdowns
And
Fuel Solenoid
YES NO
14
ENGINE WILL NOT
START
Engine Cranks
Engine Does NOT
Crank
Engine
Cranks SLOW
NO
Exhaust
Smoke
Smoke
From
Exhaust
Check Fuel
Solenoid
NO
Power While
Cranking
Defective
Solenoid
No Power
From
Starter Terminal
Check
Fuel
Supply
Check
Fuel
Pump
Air IN
Fuel
System
Check
Glow
Plugs
Check
Glow Plug
Relay
Main Switch Battery
Dead
Turn
Switch
“ON”
Start
Switch
Starter
Relay
Starter
Motor
Oil Viscosity
TOO HEAVY
LOW
Battery
Voltage
Check
Terminal
Ends
Check Spark
Arrestor
Muffler for
Clogging
SECTION 3
“GENERATOR END”
SAFETY PRECAUTIONS _________________________________________________ 1-2
INSTALLATION REQUIREMENTS_________________________________________ 3
GENERATOR ASSEMBLY INFORMATION__________________________________ 4-5
SECTION A: GENERATOR
MARATHON MAGNAPLUS GENERATOR MANUAL __________________________ 1-19
Installation
Operation
Maintenance
SECTION B: VOLTAGE REGULATORS and ENGINE CONTROLLERS
MARATHON SE350 VOLTAGE REGULATOR INSTRUCTION MANUAL _______________ 1-3
BASLER AVC64-4 ANALOG VOLTAGE CONTROLLER ______________________________ 4-6
ES-52 ENGINE CONTROL MODULE ______________________________________________ 7-8
APEC 3100 ELECTRONIC ENGINE SPEED GOVERNING SYSTEM _____________________ 9
SECTION C: WIRING SCHEMATICS
REDCO PANEL ASSEMBLY _____________________________________________________ 1
120 VOLT, SINGLE PHASE, 4 WIRE CONNECTION “M” SERIES EXCITER TYPE________ 1
120/240 VOLT, SINGLE PHASE, 4 WIRE CONNECTION “M” SERIES EXCITER TYPE_____ 2
220 VOLT, SINGLE PHASE, 4 WIRE EUROPEAN CONNECTION “M” SERIES EXCITER TYPE 3
RESISTANCE CHART 10KW “M” SERIES EXCITER TYPE____________________________ 4
SECTION D: GENERATOR END TROUBLESHOOTING GUIDES
ZERO OR LOW VOLTAGE _______________________________________________________ 1
VOLTAGE TEST / 24 VOLT BATTERY TEST _______________________________________ 2
OVERLOAD CONDITION ________________________________________________________ 3
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 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
INSTALLATION
REQUIREMENTS & RECCOMENDATIONS
Installation requirements may vary with each application depending on generator
specification and optional equipment. Listed below are general recommendations for installing a
Power Technology Stand-By Generator. Only qualified and licensed personnel should be
employed to perform the installation. Follow all Safety Procedures outlined in this manual as
well as those in the optional equipment manuals.
Depending on location, Local and or State Building Codes may apply to
the installation. Be sure to check with the appropriate authorities prior to installation and obtain
the required permits which apply.
NOTE: Damage to the generator and optional equipment due to improper installation may not be
covered by Power Technology Southeast, Inc. Limited Warranty.
LOCATING THE GENERATOR:
A permanent location for the generator is a major factor to consider when planning an
installation. These units are large and extremely heavy and will require a substantial foundation
like a concrete slab to support its weight. Placing the generator directly on the earth is not
recommended, dirt and debris can be drawn into the generator causing untimely component
failure. Another consideration is water drainage, low lying areas prone to flooding should be
avoided. Therefore planning for a permanent location is an important first step in the installation.
Local and or State Building Codes may mandate dimensions and materials used in a foundation
or slab.
SERVICABILITY:
As with any machine the generator will require periodic maintenance. Be sure the
generator is accessible on all sides. Recommended clearance between the generator and other
objects is at least 2 feet. This clearance is also required for proper ventilation and cooling. Avoid
locating the generator next to an object which may cause an air flow restriction.
EXHAUST ROUTING:
The exhaust from the generator must be safely routed away from all building openings.
Avoid exhausting near windows, doors, air handlers, roof eves and vents. Avoid exhausting into
confined areas with little or no air circulation. Avoid exhausting near neighboring structures as
well. The exhaust system should be routinely inspected and maintained. Local and or State
Building Codes may mandate exhaust routing.
ELECTRICAL CONNECTION:
In most installations the generator is connected to a buildings existing electrical system as
a back-up electrical supply. This means the generator will be wired into the buildings electrical
panel typically through an automatic transfer switch. Wiring and connections must be made by a
licensed electrician in accordance with Local and or State Building Codes.
FUEL STORAGE:
Depending upon the specific application, the type of fuel storage tank and capacity must
be considered. Typically a fuel storage tank which meets UL 142 Specifications is required.
Location and connections may be mandated by Local and or State Building Codes. Consult your
fuel supplier as to fuel maintenance and extended storage requirements. Adding a fuel stabilizer
may be necessary to extend the usable fuel life.
3
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.
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.
4
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.
5
SECTION A:
GENERATOR
SECTION C:
WIRING SCHEMATICS
SECTION D:
GENERATOR END
TROUBLESHOOTING GUIDE
BAD OK ON OFF
OK
BAD
OK
1
ZERO OR LOW
VOLTAGE
Check Gen Fuse
Check Main
Breaker is “ON”
Replace
Fuse
Turn “ON”
Breaker
Main Coil
Output to
Breaker
OK
BAD
Check Ohm’s on
Exciter Leads
24 V Battery Test
Replace Exciter
Wiring To
Panel
Defective
Breaker
Replace
Voltage Regulator
2
VOLTAGE TEST
Zero
or
Low Voltage
High
Voltage
Overload
Output
Voltage OK
Replace
AVR
Check Load Distribution
One Voltage Line
may be
Higher than the other
Check AMP
Draw
From equipment
Check
Main Breaker
On GenSet
Check
Gen End
24 VOLT
BATTERY TEST
One Coil
Low Voltage
Both Coils
Low Voltage
Sensing Voltage
Low or None
Replace
AVR
Check
Connections
Check Engine
RPM 1800
Replace Stator
Replace
Stator
Replace
Stator
BAD OK
BAD OK
3
OVERLOAD
CONDITION
Disconnect
AVR
Engine Problem
Check
Stator Coil
Resistance
See Engine
Troubleshooting
Replace Stator
Replace AVR
And Test
Check AMP Draw
Check Load Distribution
Conduct
24-Volt Battery Test
… 58


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