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PowerTech PTRV-3 Manual

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PTRV-3
PTRV- 3 RR
Operator
&
Installation
Manual
Power Technology Southeast, Inc.
634 State Road #44 Leesburg, FL 34748-8103
♦ (352) 365-2777 ♦ Fax (352) 787-5545 ♦
10/2005
MANPTRV3
FORWARD
You are now the proud owner of a Power Technology Generator powered by a Kubota engine.
This engine is a product of Kubota’s quality engineering and manufacturing. The engine is made
with fine materials and manufactured under the strictest quality control standards and will assure you long
satisfactory service. To obtain the best use of your engine, please read this manual carefully. It will help you
become familiar with the operation of the engine and contains many helpful hints regarding engine
maintenance. Continuing improvements and advancements in product design may have caused changes to
your engine, which are not included in this manual.
Please contact Power Technology’s Customer Service Department for latest information on your Kubota
engine or for the number of your local Kubota dealer.
TO OUR CUSTOMERS
Thank you for your purchase of a Power Technology Generator. The information contained in this
manual applies to PTRV-3 and PTRV-3 RR 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
TABLE of CONTENTS
SECTION 1: “SAFETY”
SAFE OPERATION 1-4
SECTION 2: “ENGINE”
PRE-OPERATION CHECK 1
OPERATING THE ENGINE 2
ENGINE SPECIFICATIONS 3
ENGINE MAINTENANCE SERVICE SCHEDULE 4
ENGINE OIL MAINTENANCE 5
ENGINE COOLANT MAINTENANCE 6
OPERATING HOURS AND SERVICE LOG 7
ENGINE TROUBLESHOOTING GUIDES 8-11
SECTION 3: “GENERATOR END”
PRINCIPLES OF OPERATION 1
GENERATOR END TROUBLESHOOTING GUIDES 2-4
WIRING SCHEMATICS and RESISTANCE CHARTS_____________________ 5-6
SECTION 4: “INSTALLATION”
SAFETY PRECAUTIONS 1-2
GENERATOR INSTALLATION in RECREATIONAL VEHICLES
3-7
SYSTEMS CONNECTION 8-9
ELECTRICAL CONNECTIONS 10-12
ENGINE CONTROLS_______________________________________________ 13
12V DC ENGINE CONTROL WIRING SCHEMATIC
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 2
Engine Starting Controls
Check Engine After Starting
Stopping the Engine
ENGINE SPECIFICATIONS 3
Kubota Model E-300
Service Parts
Exhaust System Requirements
ENGINE MAINTENANCE SERVICE SCHEDULE 4
Access for Routine Maintenance
ENGINE OIL MAINTENANCE 5
Checking Engine Oil Level
Lubricating Oil Specifications
Engine Refill Capacities
Lubricating Oil Viscosity Recommendations
ENGINE COOLANT MAINTENANCE 6
Coolant Recommendations
Ethylene Glycol / Propylene Glycol
Coolant Service Life
Checking Reservoir Tank Coolant Level
Cleaning Radiator Core
OPERATING HOURS AND SERVICE LOG 7
ENGINE TROUBLESHOOTING GUIDES
8-11
Engine Starts but Won’t Run – Codes 1 and 2
Engine Starts but Won’t Run – Codes 3 and 4
Engine Runs Rough or Slow
Engine Will Not Start
EXHAUST SYSTEM
Exhaust system components supplied with your unit are specifically designed for optimum performance
and safety. It is imperative to install the muffler and tailpipe to reduce exhaust noise and direct exhaust gases
beyond the vehicles perimeter and away from the normal head-on air stream. Install the tail pipe with as few
bends as possible to prevent excessive backpressure. A properly installed exhaust system must be vapor tight,
quiet and completely safe for the vehicle, its occupants and surroundings.
IMPORTANT SAFETY TIPS:
Replacement Exhaust System components which are not furnished by Power Technology SE, Inc., must
meet the following requirements. It is the responsibility of the installer and owner to use the proper
materials and installation techniques to assure a safe and trouble free Exhaust System.
1) Only use exhaust system components, which do not restrict exhaust flow. A restricted exhaust
system will create excessive backpressure and may cause poor engine performance and possible
engine damage.
2) Muffler shall be fabricated of aluminized steel or other corrosion resistant material and be of a
welded or crimp construction. A USDA Forest Service approved spark arrestor must be part of the
integral design of the muffler or provided as a separate add-on item.
3) Maintain a minimum of 3 inches (76mm) between the exhaust system components and any
surrounding combustible materials. If the minimum clearance cannot be maintained, an insulating
shield must be installed to prevent the combustible material from exceeding temperatures of 117°F
(65°C) above ambient temperature.
4) Extend the exhaust system a minimum of 1 inch (25mm) beyond the vehicles perimeter. Never
terminate the exhaust system underneath the vehicle.
5) Terminate the exhaust system in a direction, which prevents the exhaust gases from being drawn
back into the generator compartment and re-circulated.
6) If the exhaust system in located in an area which may become susceptible to road damage from
curbs, speed bumps, or other road obstacles a protective device such as a skid bar or plate should be
installed.
7) To prevent excessive movement and vibration of the exhaust system, install hangers and clamps
designed for use in exhaust systems.
8) Never join or tee the generator exhaust system and the vehicle exhaust system together. Doing so
may cause excessive back pressure on the generator engine, also condensation from one engine can
damage the other engine.
WARNING: LETHAL EXHAUST GAS!
When installing the exhaust system position the tail pipe end so that
discharged exhaust gases are not drawn into the vehicle interior through windows, doors, air conditioners, etc.
During operation an engine discharges deadly carbon monoxide with its exhaust. Carbon monoxide is
particularly dangerous since it is odorless, tasteless, and non-irritating. It can cause death if inhaled for even a
short period of time. Be especially careful if operating the generator set when parked under calm, windless
conditions. Gases may accumulate in these conditions. Park your vehicle so that the exhaust discharges
downwind. Always be aware of others in your vicinity. Make sure that your exhaust discharges away from other
vehicles and buildings.
CAUTION: Make sure the exhaust system components are positioned well away from drain openings beneath
the generator set. Also, be sure not to block access to the oil drain plug.
9
… 39 …


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