PTS-15T-3 Operators Manual Power Technology Southeast, Inc.
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.
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.
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.
TABLE of CONTENTS SECTION 1: “SAFETY” 1-4 SAFE OPERATION SECTION 2: “ENGINE” PRE-OPERATION CHECK OPERATING INSTRUCTIONS for SUB-ZERO CONDITIONS _____________ OPERATING THE ENGINE PT-ECU-64 CONTROLLED__________________ ENGINE SPECIFICATIONS ENGINE POWER FACTORS _________________________________________ ENGINE MAINTENANCE SERVICE SCHEDULE ENGINE OIL MAINTENANCE ENGINE COOLANT MAINTENANCE OPERATING HOURS AND SERVICE LOG ENGINE TROUBLESHOOTING GUIDES SECTION 3: 1 2-3 4 5 6-7 8 9 10 11 12-14 “GENERATOR
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 attac
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.
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.
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.
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.
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 PT-ECU-64 CONTROLLED 4 Engine Starting Controls Check Engine After Starting Stopping the Engine ENGINE SPECIFICATIONS 5 Kubota Model’s V-1505T Service Parts ENGINE POWER FACTORS _______________________________________________ 6-7 Power De-rating with Reduced Fuel f
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.
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.
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.
OPERATING THE ENGINE PT-ECU-64 CONTROLLED ENGINE STARTING CONTROLS 1) 2) 3) 4) 5) Generator Main Switch must be in the ON position. Toggle the Start/Stop Switch to the Start position. Glow Plugs will preheat for 8 seconds. LED flashes slowly. Preheating will cease during engine cranking cycle. LED continues flashing. Engine begins an 8 seconds crank cycle, After 4 seconds of cranking the PT-ECU-64 will check for an AC signal from the generator.
ENGINE SPECIFICATIONS MODEL V-1505-T Air Induction Turbo-Charged Continuous Output 22 HP @ 1800 rpm Cubic Capacity 91.41 in³ (1.498L) Bore and Stroke 3.076x3.09 (78.0x78.4mm) Cylinder Arrangement 4 In-Line Compression Ratio 22.1 Engine Oil Capacity 4.5 qts. (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.
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.
Engine Maintenance Service Schedule Maintenance Service Item *See Note Engine Oil Level Deterioration & Leakage Engine Oil Change Min.
ENGINE OIL MAINTENANCE CHECKING ENGINE OIL LEVEL V-1505T ENGINE REFILL CAPACITIES Crankcase Oil Sump and Filter LUBRICATING OIL VISCOSITY RECOMMENDATIONS ( 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.
ENGINE COOLANT MAINTENANCE COOLANT RECOMMENDATIONS COOLANT SERVICE LIFE For optimum performance, Power Technology recommends a 1:1 mixture of water / glycol. Coolant Type 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.
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 DATE HRs.
ENGINE STARTS BUT WON’T RUN Engine Runs OK Unplug Remote Start-Stop from Control Box Problem with Remote Connection.
ENGINE RUNS ROUGH or SLOW NO Visible Exhaust Smoke Excessive Exhaust Smoke BLUE Insufficient Fuel to Engine GRAY/WHITE Excessive Oil Level BLACK Check Fuel Level Replace Fuel Filter Dirty Air Filter Engine Overheated Air IN Fuel System Check Fuel PUMP Engine Over Loaded Clogged Muffler Over Fueling Injector Check Safety Shutdowns And Fuel Solenoid HIGH ALTITUDE Engine Cold Incomplete Combustion Glow Plug Not Activating Check With DC Test Light 13 Over-fueling Injector
ENGINE WILL NOT START Engine Does NOT Crank Engine Cranks Main Switch NO Exhaust Smoke Smoke From Exhaust Check Fuel Solenoid YES Check Fuel Pump Starter Relay Check Glow Plug Relay Starter Motor NO Defective Solenoid Air IN Fuel System Battery Dead Start Switch Check Glow Plugs Check Fuel Supply NO Power While Cranking Turn Switch “ON” Check Spark Arrestor Muffler for Clogging No Power From Starter Terminal 14 Engine Cranks SLOW Oil Viscosity TOO HEAVY Check Terminal Ends LOW Batte
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 _______________ BASLER AVC64-4 ANALOG
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.
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.
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.
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.
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.
SECTION A: GENERATOR
SECTION B: VOLTAGE REGULATORS and ENGINE CONTROLLERS
MARATHON SE350 VOLTAGE REGULATOR The SE350 electronic voltage regulator is designed to control the output of a brush less AC generator by regulating the current into the exciter field. Features include frequency compensation, automatic voltage build-up and EMI suppression. The SE350 attaches to the generator with spade type wire terminals for a secure connection. The SE350 has three adjustable potentiometers for fine-tuning the output voltage, stability and under frequency.
MARATHON SE350 VOLTAGE REGULATOR EXCITER POWER CIRCUIT: Connect the regulator wire F+ to the generator F+ or F1 field terminal. Connect the regulator wire F- to the generator F- or F2 field terminal SENSING / POWER INPUT CIRCUIT: Input power and sensing is achieved through terminals 3 and 4. The voltage input requirement of the SE350 is 190 to 240V AC. A 4 Amp 250V – 5x20 mm fuse is supplied with the regulator.
MARATHON SE350 VOLTAGE REGULATOR START-UP PROCEDURE: Ensure the voltage regulator is correctly connected to the generator. Refer to the specific connection diagram supplied with the generator. Set the regulator voltage adjust to full counter-clockwise (minimum voltage level). Set the stability control full clockwise (maximum stability level). Connect the positive lead of a 100V DC voltmeter to F1 and the negative lead of the voltmeter to F2 or use an appropriate AC voltmeter on the generator output leads.
BASLER AVC63-4 ANALOG VOLTAGE CONTROLLER The AVC63-4 voltage regulator is designed for use on 50/60 Hz brushless generators. Features include frequency compensation, over excitation shutdown, a solid-state build-up circuit and EMI filtering. The AVC63-4 attaches to the generator with spade type wire terminals for a secure connection. The AVC63-4 has three adjustable potentiometers for fine-tuning the output voltage, stability and under frequency.
BASLER MODEL AVC63-4 VOLTAGE REGULATOR Control is different on previous versions of the AVC63-4. When adjusting the Underfrequency Control on previous versions, clockwise rotation decreased the corner frequency while counterclockwise increased the corner frequency. NOTE: Further reference to corner frequency adjustments of the AVC63-4 are for the Current Version and should be reversed for the Previous Version.
BASLER MODEL AVC63-4 VOLTAGE REGULATOR IMPORTANT: The exciter field DC resistance must be 15 Ohms or higher and less than 100 Ohms. If the exciter field DC resistance is less than 15 Ohms and the full load field current does not exceed the maximum continuous current rating of the controller, a resistor of ample wattage must be added in series with the field to increase the total resistance to 15 Ohms.
PT-ECU-64 ENGINE CONTROL MODULE 1) 2) 3) 4) 5) Generator Main Switch must be in the ON position. Toggle the Start/Stop Switch to the Start position. Glow Plugs will preheat for 8 seconds. LED flashes slowly. Preheating will cease during engine cranking cycle. LED continues flashing. Engine begins an 8 seconds crank cycle, After 4 seconds of cranking the PT-ECU-64 will check for an AC signal from the generator.
APECS 3100 ELECTRONIC ENGINE SPEED GOVERNING SYSTEM APECS Advanced Proportional Engine Control System is an engine speed governing system that maintains the engine speed / RPMs by adjusting the Fuel Control Actuator controlling the fuel injection unit. The APECS microprocessor-based Controller processes the signal received from a speed sensor, in this application a Magnetic Pick-up and compares it to the programmed settings. These setting are maintained regardless of the load applied to the engine.
SECTION C: WIRING SCHEMATICS
POWER TECHNOLOGY SOUTHEAST, INC.
1 120 VOLT, SINGLE PHASE, 4 WIRE CONNECTION “M” SERIES EXCITER TYPE
2 120 / 240 VOLT, SINGLE PHASE, 4 WIRE CONNECTION “M” SERIES EXCITER TYPE
3 220 VOLT, SINGLE PHASE, 4 WIRE EUROPEAN CONNECTION “M” SERIES EXCITER TYPE
RESISTANCE CHART “M” SERIES EXCITER TYPE KW Main Stator 15 Less Than 1.0 Ohm / Phase Main Rotor 0.75 Exciter Stator 23.0 – 28.0 Exciter Rotor 0.
SECTION D: GENERATOR END TROUBLESHOOTING GUIDE
ZERO OR LOW VOLTAGE Check Main Breaker is “ON” Check Gen Fuse BAD OK ON OFF Main Coil Output to Breaker Replace Fuse Turn “ON” Breaker OK BAD Wiring To Panel Defective Breaker Check Ohm’s on Exciter Leads OK BAD Replace Exciter OK Replace Voltage Regulator 1 24 V Battery Test
VOLTAGE TEST Zero or Low Voltage Check Main Breaker On GenSet Overload High Voltage Output Voltage OK Check AMP Draw From equipment Replace AVR Check Load Distribution One Voltage Line may be Higher than the other Check Gen End 24 VOLT BATTERY TEST One Coil Low Voltage Replace Stator Both Coils Low Voltage Sensing Voltage Low or None Replace Stator Check Connections Check Engine RPM 1800 Replace Stator 2 Replace AVR
OVERLOAD CONDITION Check AMP Draw Check Load Distribution Disconnect AVR Conduct 24-Volt Battery Test BAD OK Engine Problem Check Stator Coil Resistance BAD See Engine Troubleshooting Replace Stator 3 OK Replace AVR And Test
