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PT-3000
Operator & Installation Manual
Generator Serial #_______________
POWER TECHNOLOGY SOUTHEAST, INC.
634 STATE ROAD. 44
LEESBURG, FL. 34748-8102
PHONE (352) 365-2777 FAX (352) 787-5545
www.PowerPacAPU.com
E-Mail PowerPac@Atlantic.net
4/2008
MANPT3
CONTENTS
INTRODUCTION 1-3
Forward
Requirements for Installation
Parts List
Tools Required
SAFETY ALERTS AND PRECAUTIONS 4-6
Alerts
Precautions
INSTALLING THE PT-3000 7-8
Preparation for Installation
Locating on the Frame Rail
Assemble the Mounting Clips, Bolts, and Spacers
Mounting to the Frame Rail
Exhaust Pipe
INSTALLING FUEL PICK-UP TUBE AND LINES 9-11
General Considerations
Install Tank Pick-up Tube
Routing and Connecting Fuel Lines
INSTALLING THE BATTERY CABLES 12
Cable Routing
Connecting to Batteries
INSTALLING THE AC POWER OUTPUT LEADS 12-13
Routing
Terminal Block
Connections
INSTALLING THE DRIVER CONTROL PANEL 14-15
Wiring Schematic
Selecting Location
Mounting
INSTALLING THE POWER OUTLET BOX 15
Selecting Location
Routing Wires
Connections
Mounting
INSTALLING THE OPTIONAL AIRCONDITIONING
AND HEATING SYSTEMS 16-18
FINISHING THE POWERPAC INSTALLATION
Installing Battery Charger
Check List
First Time Start Up
Purging Air from Fuel System
CONTENTS
OPERATION OF POWERPAC APU 19-22
Daily Checks and Maintenance Schedule
Starting and Stopping the PowerPac APU
Powering Appliance and Auxiliary Systems
ENGINE SPECIFICATIONS 23
Model
Service Parts List
POWERPAC APU MAINTENANCE 24-28
Engine Maintenance Service Schedule
Checking Engine Oil
Lubricating Oil Specifications
Lubricating Oil Capacities
Lubricating Oil and Filter Change
Coolant Recommendations
Checking Coolant Level
Checking Recovery Tank Coolant Level
Cleaning Radiator Core
Fuel Filter Change
Air Filter Change
Fan Belt Check
Generator Drive Belt
WIRING DIAGRAMS 29-31
PT-3000 – PT-ECU-64 Wiring Schematics
AC Electrical Circuit
PT-ECU-64 Control Module
TROUBLESHOOTING GUIDES 32-38
Engine Troubleshooting
Generator Troubleshooting
WARRANTY INFORMATION 39
Power Technology Southeast, Inc. Limited Warranty
INTRODUCTION
You are now the proud owner of a PT-3000 Idle Reduction System.
The PT-3000 is an auxiliary power unit designed to operate completely separate
from your main truck systems. It provides 120 volts AC to power an electric air-
conditioning and heating unit. The PT-3000 also provides AC power for use with
other devices such as, television, microwave, engine block heater and other appliances.
FORWARD
This PT-3000 System is a product of Power Technology Southeast. Inc. PT-3000
systems are made with the finest materials and manufactured under the strictest quality
control standards to assure you long satisfactory service.
To obtain the best results from your PT-3000 system, please read and follow this
manual carefully. It will help you become familiar with the operation of the system and
contains many helpful hints regarding use and maintenance.
This manual was written to assist with the installation of the PT-3000. Although
the manual is not specific to any particular vehicle, the information in this manual will
provide the installer with the necessary information to correctly and safely install the unit.
The PT-3000 can be easily installed by a qualified mechanic. The installer must also have
a basic understanding of electricity and electrical wiring.
Use this manual as a guide when installing the PT-3000 system, and then refer to
the appropriate operation section for specific instructions. The installation of a PT-3000
system shall comply with current standards of NFPA 70, NFPA 551, and applicable
articles of the National Electric Code. Generator set installations must also comply with
state and local requirements.
Follow all instructions in this manual to ensure proper installation and operation.
Each generator set features a dependable Kubota diesel engine, rotating-field alternating
current generator, and an ECU engine controller. Located on the unit mounted Control
Panel is an on/off switch to reset the controller or lockout the remote switch to prevent
accidental starting while servicing the unit.
1
After the unit is attached to the frame of the vehicle, all that is usually required to
make it operational are the following.
Install the fuel pick-up tube assembly
Route and install fuel lines
Install and connect remote panel
Attach Load Leads to vehicle’s AC electrical circuit
Install and connect Battery Charger
Check radiator coolant level
Check crankcase lubricating oil level
Connect DC battery cables.
Continuing improvements and advancements in product design may cause
changes not included in this manual. Please contact Power Technology’s Customer
Service Department for the latest information regarding your PT-3000 system.
TO OUR CUSTOMER
Thank you for your purchase of a PT-3000System. The information contained in
this manual applies only to PT-3000 Idle Reduction Systems.
In the event you should experience a problem with your system please contact the sales
dealer, authorized PT-3000 Service Center or Power Technology’s Customer Service
Department directly at (352) 365-2777 from 8:00 a.m. to 5:00 p.m. EST Monday through
Friday. Please have the system model and serial numbers available when you call, this
will help expedite service and parts to you.
POWER TECHNOLOGY SOUTHEAST, INC.
634 STATE ROAD. 44
LEESBURG, FL. 34748-8102
(352) 365-2777 FAX (352) 787-5545
www.PowerPacAPU.com
E-Mail Power Pac@Atlantic.net
2
REQUIREMENTS FOR INSTALLATION
PARTS LIST
1 - PT-3000 Unit
1 - Battery Charger
1 - Terminal block
1 - Terminal block cover
2 - Frame Mounting Angle Brackets (L&R)
8 - ½” x 2 Mounting Bolts, Nuts and Washers
6 - 5/8” x 2 ½” Mounting Bolts, Nuts and Washers
1 - Fuel pickup tube
1 - Cab mounted Start/Stop panel
1 - 1 ¼ rubber grommet
4 - #4 hose clamps
2 - Battery cable ends
2 - Heat shrinks (for battery cable ends)
10 - Sheet metal screws
20 - Wire ties
TOOLS REQUIRED
Typical mechanics tools
Drill
1 ¼” Hole saw
Tape measure
Utility knife
Tubing cutter
½” NPT Tap (for fuel pickup tube)
3/4” Drill bit or tapered drill bit (for ½” NPT tap)
Heavy grease (to keep metal shavings out of fuel tank)
Liquid thread sealant
Transmission jack, forklift or overhead hoist
3
SAFETY ALERTS AND PRECAUTIONS
A generator set can be potentially dangerous if not properly
maintained and operated. The Best safeguard 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.
SAFETY PRECAUTIONS
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 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 the 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.
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, fan 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.
4
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 closed or secured at all times. Be sure the generator set is properly
grounded to chassis. Never touch generator electrical leads or appliances with wet hands,
or when standing on wet ground.
7) EXPLOSION - Never connect the negative (-) battery cable to the positive (+)
connection terminal of the starter solenoid, or test the battery by shorting the 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
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 tailpipe
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 should 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 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) 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 fuel lines, fuel
filter, fuel pump or other potential source of spilled fuel or vapors.
13) 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.
5
14) UNIT STARTS WIITHOUT NOTICE - To prevent accidental starting of the unit
with remote start/stop switch, always turn the ON/OFF switch located on the set mounted
Control Panel to the OFF position, then 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.
15) 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.
16) DIESEL ENGINE DAMAGE - To prevent engine damage from occurring, do not
operate the unit before completing the installation which includes, checking engine oil
level, connecting fuel lines, checking coolant level, and making sure all electrical
connections are made.
6
CALIFORNIA
Proposition 65
Warning
Diesel Engine Exhaust and some
of its constituents are known by the
State of California to cause
Cancer, Birth Defects and Other
Reproductive harm.
INSTALLING THE PT-3000
PREPERATION OF PT-3000
Select the location for the PT-3000. Determine if you will need spacers to clear
any bolts or anything that may interfere with installing the unit to the frame rail. If
spacers are required, longer mounting bolts may be required for the install.
LOCATE THE PT-3000 ON THE FRAME RAIL
When choosing a location for the PT-3000, several things need to be considered.
Vehicles with a longer wheel base should have the PT-3000 mounted to avoid
obstructions in the road such as railroad tracks, speed bumps, curbs, etc. Each truck is
different and may require a different installation process. Before beginning the
installation, lay out the placement of all the components that will be installed.
The PT-3000 is designed to be mounted on the existing frame rails of the truck.
Mounting the unit on the frame rail with supplied frame angle brackets and hardware is
the only acceptable installation. Fabrication of another mounting rail may be unsafe with
the given weight and balance of the unit.
Standard PT-3000 Location: Vehicle passenger side.
This is the standard installation choice. Replaces steps into vehicle cab or further
back by the cat walk. Some trucks have steps to the catwalk on the drivers’ side frame
rail, however the passenger side will usually have fewer obstructions.
Alternate PT-3000 Location: Vehicle Driver Side.
This is a secondary installation location. It may be necessary to remove existing
steps to the catwalk.
Radiator must have free air flow with no obstructions
Radiator must be protected from grease sling
Cooling air for the PT-3000 engine and generator is drawn into the enclosure
through an air duct and discharges through the rear panel. These areas must remain free
of any obstructions that would restrict normal air flow.
ASSEMBLE THE MOUNTING BRACKETS
The PT-3000 comes with all the hardware required for the complete installation of
the unit. The loose parts contain all the necessary bolts, nuts and washers for assembling
the frame rail mounting angle brackets.
7
MOUNTING THE PT-3000 TO THE FRAME
Be sure to use a forklift, transmission jack, overhead lift or other device to lift the
PT-3000. Make sure the unit is stable before trying to place it on the frame rail. Determine
the height the unit needs to be installed and secure the mounting brackets to the enclosure.
Place the unit in the desired location and mark the mounting holes on the frame side rail.
Drill the frame rail to accept the 5/8” bolts and securely fasten.
EXHAUST PIPE
Maintain a minimum 3” clearance between any exhaust components and any
surrounding combustible materials. If the minimum clearance cannot be met an insulating
shield designed for exhaust components must be used. Extend the exhaust outlet a
minimum of 1” past the perimeter of the vehicle. The exhaust system CANNOT be
terminated under the vehicle chassis. Exhaust outlet must be in a position, which prevents
exhaust gases from entering the living quarters. The exhaust system should be routed in a
manner, which eliminates the possibility of re-circulation into the PT-3000 enclosure.
A skid plate may be installed to protect the PT-3000 and exhaust system from road hazards.
Joining the PT-3000 exhaust together with the trucks main exhaust may cause irreparable
harm pleases consult with Power Tech prior to making any such connections.
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,
to 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.
8
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