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.
CONTENTS INTRODUCTION Forward Requirements for Installation Parts List Tools Required 1-3 SAFETY ALERTS AND PRECAUTIONS Alerts Precautions 4-6 INSTALLING THE PT-3000 Preparation for Installation Locating on the Frame Rail Assemble the Mounting Clips, Bolts, and Spacers Mounting to the Frame Rail Exhaust Pipe 7-8 INSTALLING FUEL PICK-UP TUBE AND LINES General Considerations Install Tank Pick-up Tube Routing and Connecting Fuel Lines 9-11 INSTALLING THE BATTERY CABLES Cable Routing Connectin
CONTENTS OPERATION OF POWERPAC APU Daily Checks and Maintenance Schedule Starting and Stopping the PowerPac APU Powering Appliance and Auxiliary Systems 19-22 ENGINE SPECIFICATIONS Model Service Parts List 23 POWERPAC APU MAINTENANCE 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 C
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 airconditioning 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.
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.
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 s
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.
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.
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.
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.
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.
GENERAL CONSIDERATIONS Tools Required for Fuel Pick-Up Installation Tape Measure Tubing Cutter Drill Heavy Grease ¼” Drill Bit Thread sealant Step Reamer Bit or ¾” Drill Bit Diesel fuel vapors can be very explosive. Use caution when working in or around the area of the fuel tank. Before drilling into a fuel tank it is recommended to drain all fuel from the tank. Be very careful when drilling into a fuel tank. Sparks can be caused by an electric drill or a drill bit that may cause an explosion.
INSTALLING THE FUEL TUBES AND LINES The diesel fuel system for the PT-3000 must be designed to operate independently from the vehicles main engine. In most installations both engines operate from a common fuel tank with separate pick-up tubes for each engine, not a Tee fitting arrangement. This prevents either or both engines from being starved for fuel. The APU’s fuel pick-up tube should be shorter than the vehicles; therefore fuel may not be available to the APU when fuel supply is low.
INSTALL TANK PICK-UP After checking for baffles and fuel gauge linkage, pick a spot on fuel tank for the fuel pick-up tubes (usually top center of tank on end closest to the APU). Apply heavy grease to spot where hole is to be drilled. The grease will help keep metal shavings out of fuel tank. Drill a ¼” pilot hole. You may want to use several different drill bit sizes to get up to the ¾” bit required for the fuel pick-up tube. Once you have a ¾” hole, clean all metal shavings from the hole.
INSTALLING THE BATTERY CABLES IMPORTANT! DO NOT CONNECT BATTERY POSITIVE CABLE UNTIL THE PT-3000 UNIT IS READY TO BE TEST RUN. Turn the main power switch on the PT-3000 to the OFF position to ensure the unit will not start prematurely. Route the positive and negative battery cables from the PT-3000 to the batteries. Cut battery cables to desired length. Strip the insulation on both cables back about ½”. Slide heat shrink over the end of the cables.
AC POWER TERMINAL BLOCK DIAGRAM Black Wire- 25 Amp AC Circuit White Wire- AC Neutral Green Wire- Ground 13
DIRVER CONTROL PANEL DIAGRAM Viewed from Rear of Panel Connect Wires to Switch as Shown White/Red Wire – sends start/stop signal to the APU Red Wire- 12v DC constant Orange Wire- LED Indicator Gray Wire- 12v DC Power to hour meter, operating time.
MOUNTING THE CONTROL BOX Once all connections are made to the start/stop switch and the hour meter, fasten the control box to the desired location with the screws provided. INSTALLING THE POWER OUTLET BOX SELECT LOCATION Determine the location for the AC power outlet box. It should be mounted where the driver has easy access to the outlets. Consideration should be taken as to the devices the driver will need AC power for such as, Television, microwave, refrigerator etc.
INSTALLING THE AIR CONDITIONING AND HEATING SYSTEM (Optional) The PT-3000 system uses a heating and air conditioning unit manufactured by the Dometic Corporation. A complete installation manual is with the heating and air conditioning system. Use this manual to successfully install the heating and air conditioner unit. When making electrical connections for the heating and air conditioning system, be sure to use the RED wire on the terminal block to power the system.
FINISHING THE INSTALLATION CHECK LIST Unit is securely mounted to vehicle All fasteners are torque to specification Fuel lines are properly secured Battery cables are properly secured Power cable is properly secured Cables and fuel lines are away from moving components Cables and fuel lines are away from exhaust Fuel lines are double clamped and all clamps are tight All AC power connections are complete and tight Driver control panel installation is complete Power outlet box insta
Once the engine has started, check the APU for coolant, fuel, oil and exhaust leaks. Place the APU cover on the unit. With a multi-meter, check the voltage at the AC power outlet box in the sleeper of the truck. Voltage should read between 120 to 125 volts AC. Allow APU to run for approximately 10 minutes and check again for coolant, oil, fuel and exhaust leaks. After checking the APU over thoroughly, test the heating and air conditioning unit for proper operation.
OPERATION OF THE PT-3000 Engine Break-in Period During the engine break-in period, first 50 hours of operation 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) In ambient temperature above 32°F (0°C) approximately 3-5 minutes without a Load is sufficient for engine warm up.
Starting and Stopping the PT-3000 CHECK BEFORE OPERATING THE ENGINE • • • • • If the engine is malfunctioning DO NOT operate until repairs are made. Be sure cover, 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. DO NOT allow children or animals to approach the APU while in operation. DO NOT start the engine by shorting across starter terminals.
3) If a fault occurs during the operation of the PT-3000, correct the problem and then reset the PT ECU-64. To do this the main power switch for the APU (located on the internal control panel on the APU) must be turned OFF then back ON. This will clear the fault code. IMPORTANT: Make sure driver control panel switch is in the OFF position before attempting to clear fault codes. If driver control panel switch is in ON position when resetting the ECU, the unit will start and possibly cause injury.
APPLIANCE LOADS PT-3000 maybe used to supply AC voltage for appliances. With the exception of a resistance-type load such as a heating element, requirements for appliances are usually low. However, such loads must not be overlooked when calculating the total wattage requirements. To avoid an overload situation, reserve capacity should also be calculated for unanticipated appliance loads. The average power requirements for some common electrical appliances are listed below as a guide.
ENGINE SPECIFICATIONS MODEL Kubota E-300 Continuous Output Cubic Capacity 5.0 HP @ 2200 rpm 18.86 in³ (309cc) 2.95” x 2.76” (75 x 70mm) 1 23:1 1.4 US Qts. (1.3L) 4 US Qts. Diesel No.
ENGINE MAINTENANCE SERVICE SCHEDULE Maintenance Service Item *See Note Engine Oil Level Deterioration & Leakage Engine Oil Change Air Filter Replacement Replace Fuel Hoses Check Radiator Hoses & Clamps Abnormal Engine Noise Abnormal Generator Noise Muffler Condition Exhaust Gas Condition • • • • Every 1000 Hours Remarks X * ** Coolant Level Coolant Leakage Coolant Change Fuel Filter Fuel Leakage Min.
ENGINE OIL MAINTENANCE CHECKING ENGINE OIL LEVEL KUBOTA E-300 ENGINE REFILL CAPACITIES Crankcase Oil Sump 1.4 US Qts. (1.3L) LUBRICATING OIL VISCOSITY RECOMMENDATIONS 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 to add oil, if necessary. Clean the Oil Filler Cap and replace. 3. The Kubota E-300 is equipped with an Oil Filter Screen which is attached to the Oil Drain Plug.
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.
SERVICE PROCEDURES FUEL FILTER / WATER SEPARATOR The following procedure outlines the steps required for servicing the Racor Fuel Filter / Water Separator installed on PT-3000 generators. Suggested fuel filter element change at 500 hour intervals is standard for Racor filters. Operating in adverse conditions or poor quality fuel may require frequent filter replacements. Follow all safety guidelines when handling fuel and properly discard contaminated fuel and used element.
POWER TECHNOLOGY SOUTHEAST, INC.
RESISTANCE CHART KW MAIN STATOR MAIN ROTOR POWER TECHNOLOGY SOUTHEAST, INC. 634 STATE ROAD 44 LEESBURG, FL 34748-8103 (352) 365-2777 FAX (352) 787-5545 3 0.92 4.
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.
ENGINE WILL NOT START ENGINE CRANKS No Exhaust Smoke 32 Check Fuel Supply NO Power While Cranking Replace Solenoid Battery Dead Smoke From Exhaust Check Fuel Solenoid YES ENGINE DOES NOT CRANK Check Fuel Pump NO Air in Fuel System No Power From ECU Check Glow Plugs Check Glow Plug Relay ENGINE CRANKS SLOW Main Switch Oil Viscosity Too Heavy Check Terminals Turn Switch On Start Switch Check Spark Arrestor Muffler for Clogging Low Battery Voltage Starter Relay Starter Motor
ENGINE RUNS ROUGH OR SLOW No Visible Exhaust Smoke Excessive Exhaust Smoke Insufficient Fuel to Engine BLUE SMOKE 33 Excessive Oil Level Check Fuel Level Replace Fuel Filter Air in Fuel System Check Fuel Pump Excessive Oil Consumption BLACK SMOKE Dirty Air Filter Engine Cold Engine Overheated Incomplete Combustion Engine Overloaded Clogged Muffler Over Fueling Injector High Altitude Check Safety Shutdowns And Fuel Solenoid GREY/WHITE SMOKE Glow Plug Circuit Not Operating Over Fueling Inj
ENGINE TROUBLE SHOOTING ENGINE STARTS BUT WON’T RUN CODE 1 Check Flash Code Indicator at Start / Stop Switch CODE 2 34 Check Battery Voltage Failure To Start Engine High Water Temp. Check Coolant Level/Condition If “OK” Check Fuel System Check Fuel Filter/Supply Check Coolant Temp.
ENGINE TROUBLE SHOOTING ENGINE STARTS BUT WON’T RUN CONTINUED CODE 3 Check Oil Level/Condition Low Oil Pressure 35 If “OK” Check Single Pole Oil Pres.
ZERO or LOW VOLTAGE Check Gen Capacitor BAD OK Replace Capacitor 36 OK Wiring To Panel Check Main Breakers are “ON” ON OFF Main Coil Output to Breakers Turn “ON” Breaker / s BAD Defective Breaker / s BAD Replace Stator Check Ohm’s On Main Stator Leads OK Check Rotor Ohm’s
VOLTAGE TEST Zero or Low Voltage 37 Check Main Breaker / s On Generator Check Gen End High Voltage Overload Replace Capacitor Check AMP Draw From equipment Output Voltage OK
OVERLOAD CONDITION Check AMP Draw Check Load 38 Check Drive Belt Tension/Condition Engine Problem See Engine Troubleshooting Check Stator Coil Resistance Replace Stator
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.
