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-8 KSI, PTRV-10 KSI and PTRV-12 KSI generators. In the event you experience a
problem with your generator please contact the sales dealer, one of our authorized service centers or Power
Technology’s Customer Service Department directly at 1-800-760-0027 from 8:00 a.m. to 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 of1 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)
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
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 1-4
SECTION 2: “ENGINE”
PRE-OPERATION CHECK 1
OPERATING the ENGINE with POWER CONTROL MODULE and DISPLAY 2-5
ENGINE SPECIFICATIONS 6
GENERATOR MAINTENANCE SERVICE SCHEDULE 7
ENGINE OIL MAINTENANCE 8
ENGINE COOLANT MAINTENANCE 9
OPERATING HOURS AND SERVICE LOG 10
ENGINE TROUBLESHOOTING GUIDES 11-14
SECTION 3: “GENERATOR END”
GENERATOR ASSEMBLY INFORMATION 1
PTRV-8-10-12 KSI “MB” TYPE GENERATOR ASSEMBLY 2
GENERATOR END TROUBLESHOOTING GUIDES
3-6
WIRING SCHEMATICS
7-9
SECTION 4: “INSTALLATION”
SAFETY PRECAUTIONS 1-2
GENERATOR INSTALLATION in RECREATIONAL VEHICLES 3-8
SYSTEMS CONNECTION, FUEL and EXHAUST
9-11
ELECTRICAL CONNECTIONS 12-16
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 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 1
Engine Break-in Period
Daily Check
OPERATING THE ENGINE with POWER CONTROL MODULE and DISPLAY_____ 2-5
Feature Summary
Operating Behavior
Automatic Generator Start (AGS)
Safety Monitoring and Shutdown
LED Sequence
ENGINE SPECIFICATIONS 6
Kubota Model D-1105, V-1505
Service Parts
ENGINE MAINTENANCE SERVICE SCHEDULE 7
ENGINE OIL MAINTENANCE 8
CheckingEngine Oil Level
Lubricating Oil Specifications
Engine Refill Capacities
Lubricating Oil Viscosity Recommendations
ENGINE COOLANT MAINTENANCE 9
Coolant Recommendations
Ethylene Glycol / Propylene Glycol
Checking Radiator Coolant Level
Coolant Service Life
Checking Reservoir Tank Coolant Level
Cleaning Radiator Core
OPERATING HOURS AND SERVICE LOG 10
ENGINE TROUBLESHOOTING GUIDES 11-14
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
Power Controller Module
(PCM)
And Display
(PCMD)
2
Feature Summary
The PowerTech PCM controls all of the start and run processes and characteristics of any PowerTech
generator. The features of the application are:
Internal Ambient Temperature Sensor
Provides an on-board temperature sensor.
Oil Pressure Sensor / Switch Input
Allows input from an external oil pressure sensor or switch. Will shut down the generator if
sufficient pressure is not detected after a start-up period.
Coolant Sensor / Switch Input
Allows input from an external coolant temperature sensor or switch. Will shut down the generator if
extreme temperature is detected.
Auxiliary (Generic) Shutdown Switch Input
Allows input from any external active low (ground) switch. An active state of this switch will shut
down the generator immediately.
DC Power Supply Voltage Measurement
Measures the voltage level of the DC power supply. The DC voltage is monitored for a minimum
and will shutdown the Generator if it falls below a threshold (configuration parameter). This is also reported
on the PCM.
AC Output Voltage Measurement
Measures the voltage level of the AC output. This information is monitored to detect limit
conditions. It also is reported on the PCM. Over and Under Voltage conditions are reported.
AC Output Current Measurement
Measures the current level of the AC output. The data is reported on the PCM and is used for
current, wattage, and load measurement.
AC Output Frequency Measurement
Measures the frequency level of the AC output. This info is monitored to detect a valid start as well
as limit conditions. It also is reported on the PCM. Over and Under Frequency conditions are reported.
Warm Start
Adjusts the Pre-Heat glow plug activation time according to the coolant temperature.
One-Touch Remote Start Trigger
In addition to control via PCM, the unit will respond to an active high digital input. The unit can be
configured to either start or stop in response to activation of a momentary switch or a toggle switch.
Blink Code Fault Reporting
Simple diagnostic data is available through blink codes on a dedicated active high output. The PCM
state as well as fault codes are displayed.
Event Recording
A portion of non-volatile memory is dedicated to recording diagnostic and other events. If a clock is
available on the network, the time and date of the event is included. Events include diagnostic messages,
starts, stops, and configuration changes. Total event capacity is roughly 2,000 events.
Load Profiling
The unit records the total amount of time the generator spends in each of several load intervals.
The information is recorded each time the generator stops, showing the usage profile for that specific cycle.
AGS
Automatic Generator Starting for low battery voltage. Programmable at the factory
voltage threshold and run time. Unit can sense genset battery voltage or any other battery voltage as
required. Enabled or disabled by an external switch.
Ignition Sensing
Will shutdown genset or prevents genset from starting if DC voltage is applied from any
external source. (Example: vehicle ignition, shore power sensor, or transfer switch, etc…)
3
Operating Behavior
Starting
The generator starts in response to the “START” button being depressed for 1 second. The PCM
goes into the Pre-Heat State, followed by the Cranking State, then finally, the Running State. The
PCM attempts to start the generator a specific number of times (configuration parameter) before
declaring a Fault. The shutdown inputs are checked before the start is attempted. If any of these
inputs are active, the start process is aborted.
See the following sections for more detailed information about each state.
Stopping
The generator stops in response to the “START” button being depressed for 1 second. All relays
are returned to their reset condition (OFF). Inputs to the PCM are not actively monitored, except
the Start/Stop Button. The LED is turned off. The PCM enters the Idle State.
Power Cycle/Reset
If the power to the PCM is cycled, it will immediately shut down all relay outputs, stopping the
generator. The unit will start with all fault and status flags reset. There may be a pause of
several seconds before all the configuration information is processed and the unit is ready to
accept input.
Idle State
The Idle State is the initial state of the PCM after a Power Cycle/Reset. The PCM returns to this
state after a Stop Command. The LED is not lit.
Pre-Heat State
The Pre-Heat State is necessary to energize the Glow Plugs for the Cranking State. The Fuel
Pump is active. The duration of this state is determined by using the coolant temperature
according to the formula:
< 23 ºF cranking time = 15 seconds
23 ºF – 50 ºF cranking time = 8 seconds
> 50 ºF cranking time = 5 seconds
The LED blinks.
Cranking State
The Cranking State attempts to start the generator combustion. The starter and fuel pump are
active. Successful sustaining combustion is determined by measuring the AC Line 1 output
frequency. The LED blinks.
Running State
After an initial “ignore” time (configuration parameter), inputs are monitored for out-of-bounds
limits and, if needed, a shutdown command is issued. The LED is lit.
Fault State
The Fault State is entered if an input reaches an out-of-bounds limit. The generator is
immediately stopped. A Power Cycle/Reset is required to exit the Fault state. The LED blinks the
Fault Code(s) (see next section).
4
Automatic Generator Start (AGS)
The Automatic Generator Start (AGS) allows the generator to start based upon the battery level.
The trigger voltage is configurable via a configuration parameter. The entire feature can be
enabled/disabled by a configuration parameter. The AGS feature is currently disabled, by default.
Safety Monitoring And Shutdown
The PCM monitors inputs for safety limitations which might damage the generator. If any input is
outside of the safe operating range, the generator is immediately shutdown and the PCM enters
the FAULT state. The PCM remains in the FAULT state until a power cycle or reset occurs. The
shutdown reason is displayed by blinking the LED.
The thresholds used in determining faults are set by configuration parameters.
These inputs are only monitored when the generator is in the RUNNING state. Before starting the
generator, the following inputs are checked to see whether a start should be attempted: High
Coolant Temperature, Auxiliary switch, Ignition Sense, DC Voltage and High Ambient
Temperatures.
These inputs are averaged over 0.6 seconds to help eliminate noise and settling issues. This
averaging helps to eliminate falsely signaled shutdowns.
Shutdown Reasons
Fault Reason Fault Code Description
Failure to Start 1
The generator was not able to start.
High Coolant
Temperature
2
The generator coolant temperature has reached a
high threshold.
Low Oil Pressure 3
The generator oil pressure has reached a critically
low pressure.
High Ambient (Air)
Temperature
4
The PCM measures an ambient air temperature
above a specific threshold.
NOTE: Temperature inside the Control Box.
AC Fault 5
A Fault with the AC was detected.
DC Fault 6
A Fault with the DC (Battery) was detected.
Auxiliary Input Active 7
The Auxiliary input is active.
Sensor Malfunction 8
One of the sensors has malfunctioned..
Ignition Sense 9
Ignition Sense is active.
The fault codes are displayed on the LED by blinking a number of times equal to the fault code,
then going dark for two seconds. Multiple fault codes are displayed in the order that they have
occurred. This cycle repeats until the fault is cleared by a power cycle, reset or via RV-C.
LED Sequences
The LED on the Start Button is used to communicate the state of the generator in addition to any
fault conditions. The PCM states are different from the Fault Codes in that the states are
displayed continuously (i.e. no two second pause).
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