PTS-30 PTS-35 PTS-40 PTS-50 Operators Manual & Supplemental Manual For Stand-By Generators 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.
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.
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.
OPERATING THE ENGINE NON-ECU CONTROLLED ENGINE STARTING CONTROLS 3. Press the Start / Stop switch to the “Start” position. This will engage the starter motor and start the engine. 4. Release the Start / Stop switch when the engine starts. 1. Main Switch: Turns power On or Off to the engine start circuit. 2. ON Position: Must be in this position for the engine to start and run. 3. OFF Position: Used to cut the power to the start circuit of the engine.
MODELS V3600-E3 · V3600-T-E3 · V3800-DI-T-E3 · V3300-E3BG · V3600-T-E3BG · V3800-DI-T-E3BG 1J411-8911-4
ENGLISH CONTENTS SAFE OPERATION .............................................................................................. 1 SERVICING OF THE ENGINE .................................................................................. 1 NAMES OF PARTS ................................................................................................... 2 PRE-OPERATION CHECK........................................................................................ 3 BREAK-IN .....................................
AIR CLEANER ..................................................................................................... 21 Cleaning Primary Air Filter Element.................................................................................. 21 Evacuator valve ................................................................................................................. 21 For the air cleaner with a dust cup (optional).....................................................................
ENGLISH FOREWORD You are now the proud owner of a KUBOTA Engine. This engine is a product of KUBOTA quality engineering and manufacturing. It is made of fine materials and under a rigid quality control system. It will give 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 about engine maintenance.
1 SAFE OPERATION Careful operation is your best assurance against an accident. Read and understand this section carefully before operating the engine. All operators, no matter how much experience they may have, should read this and other related manuals before operating the engine or any equipment attached to it. It is the owner's obligation to provide all operators with this information and instruct them on safe operation. Be sure to observe the following for safe operation. 1.
ENGLISH 2 SAFE OPERATION 3. CHECK BEFORE STARTING & OPERATING THE ENGINE A Be sure to inspect the engine before operation. Do not operate the engine if there is something wrong with it. Repair it immediately. A Ensure all guards and shields are in place before operating the engine. Replace any that are damaged or missing. A Check to see that you and others are a safe distance from the engine before starting. A Always keep the engine at least 3 feet (1 meter) away from buildings and other facilities.
6. EXHAUST GASES & FIRE PREVENTION A Engine exhaust fumes can be very harmful if allowed to accumulate. Be sure to run the engine in a well ventilated location and where there are no people or livestock near the engine. A The exhaust gas from the muffler is very hot. To prevent a fire, do not expose dry grass, mowed grass, oil or any other combustible materials to exhaust gas. Keep the engine and muffler clean at all times. A To avoid a fire, be alert for leaks of flammable substances from hoses and lines.
ENGLISH 4 SAFE OPERATION 8. CAUTIONS AGAINST BURNS & BATTERY EXPLOSION A To avoid burns, be cautious of hot components, e.g. muffler, muffler cover, radiator, hoses, engine body, coolants, engine oil, etc. during operation and after the engine has been shut off. A DO NOT remove the radiator cap while the engine is running or immediately after stopping. Otherwise hot water will spout out from the radiator. Wait until the radiator is completely cool to the touch before removing the cap.
10. ANTI-FREEZE & DISPOSAL OF FLUIDS A Anti-freeze contains poison. Wear rubber gloves to avoid personal injury. In case of contact with skin, wash it off immediately. A DO NOT mix different types of Anti-freeze. The mixture can produce a chemical reaction causing harmful substances. Use approved or genuine KUBOTA Antifreeze. A Be mindful of the environment and the ecology. Before draining any fluids, determine the correct way to dispose of them.
ENGLISH 6 SAFE OPERATION A Replace fuel pipes and lubricant pipes with their hose clamps every 2 years or earlier whether they are damaged or not. They are made of rubber and age gradually. A When servicing is performed together by two or more persons, take care to perform all work safely. A Keep a first aid kit and fire extinguisher handy at all times. 12. WARNING AND CAUTION LABELS Part No.19077-8724-1 or 16667-8724-1 (55mm in diameter) (37mm in diameter) Part No.
SERVICING OF THE ENGINE Your dealer is interested in your new engine and has the desire to help you get the most value from it. After reading this manual thoroughly, you will find that you can do some of the regular maintenance yourself. However, when in need of parts or major service, be sure to see your KUBOTA dealer. For service, contact the KUBOTA Dealership from which you purchased your engine or your local KUBOTA dealer. When in need of parts, be prepared to give your dealer the engine serial number.
ENGLISH 2 NAMES OF PARTS NAMES OF PARTS (1) Intake manifold (2) Speed control lever (3) Engine stop lever (4) Shut off solenoid (5) Fuel feed pump (6) Cooling fan (7) Engine hook (8) Oil filter cartridge (9) Fuel filter (10) Oil filler plug (11) Exhaust manifold (12) Alternator (13) Starter (14) Fan belt (15) Oil pressure switch (16) Flywheel (17) Oil drain plug (18) Oil pan
3 PRE-OPERATION CHECK BREAK-IN During the engine break-in period, observe the following by all means: 1. Change engine oil and oil filter cartridge after the first 50 hours of operation. (See "ENGINE OIL" in "PERIODIC SERVICE" section.) 2. When ambient temperature is low, operate the machine after the engine has been completely warmed up. DAILY CHECK To prevent trouble from occurring, it is important to know the conditions of the engine well. Check it before starting.
ENGLISH 4 OPERATING THE ENGINE OPERATING THE ENGINE STARTING THE ENGINE(NORMAL) 1. Set the fuel lever to the "ON" position. CAUTION To avoid personal injury: A Do not allow children to approach the machine while the engine is running. A Be sure to install the machine on which the engine is installed, on a flat place. A Do not run the engine on gradients. A Do not run the engine in an enclosed area. Exhaust gas can cause air pollution and exhaust gas poisoning.
4. Insert the key into the key switch and turn it "ON". 5 8. Warm up the engine at medium speed without load. A If the glow lamp should redden too quickly or too slowly, immediately ask your KUBOTA dealer to check and repair it. A If the engine does not catch or start at 10 seconds after the starter switch is set at "STARTING" position, wait for another 30 seconds and then begin the engine starting sequence again. Do not allow the starter motor to run continuously for more than 20 seconds.
ENGLISH 6 OPERATING THE ENGINE STOPPING THE ENGINE 1. Return the speed control lever to low idle, and run the engine under idling conditions. A If equipped with a turbo-charger, allow the engine to idle for 5 minutes before shutting it off after a full load operation. Failure to do so may lead to turbo-charger trouble. 2. The engine should stop with the starter switch placed at the OFF position. (In case of non-stopping, set the engine stop lever to the "STOP" position manually.) 3.
BFuel CAUTION To avoid personal injury: A Fluid escaping from pinholes may be invisible. Do not use hands to search for suspected leaks; Use a piece of cardboard or wood, instead. If injured by escaping fluid, see a medical doctor at once. This fluid can produce gangrene or a severe allergic reaction. A Check any leaks from fuel pipes or fuel injection pipes. Use eye protection when checking for leaks. Be careful not to empty the fuel tank.
ENGLISH 8 MAINTENANCE MAINTENANCE CAUTION To avoid personal injury: A Be sure to conduct daily checks, periodic maintenance, refueling or cleaning on a level surface with the engine shut off and remove the key. A Before allowing other people to use your engine, explain how to operate, and have them read this manual before operation. A When cleaning any parts, do not use gasoline but use regular cleanser. A Always use proper tools, that are in good condition.
MAINTENANCE 9 ENGLISH SERVICE INTERVALS Observe the following for service and maintenance.
ENGLISH 10 MAINTENANCE A The jobs indicated by must be done after the first 50 hours of operation. *1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions. *2 After 6 times of cleaning. *3 Consult your local KUBOTA Dealer for this service. *4 Replace only if necessary. A When the battery is used for less than 100 hours in a year, check its electrolyte yearly.
11 A CJ-4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and is Not Recommended for use in Kubota E3 specification engines.
ENGLISH 12 PERIODIC SERVICE PERIODIC SERVICE FUEL Fuel is flammable and can be dangerous. You should handle fuel with care. CAUTION To avoid personal injury: A Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion. A Be careful not to spill fuel during refueling. If fuel should spill, wipe it off at once, or it may cause a fire. A Do not fail to stop the engine before refueling. Keep the engine away from the fire.
13 [GRAVITY FEED SYSTEM] A Be sure to use a strainer when filling the fuel tank, or dirt or sand in the fuel may cause trouble in the fuel injection pump. A For fuel, always use diesel fuel. You are required not to use alternative fuel, because its quality is unknown or it may be inferior in quality. Kerosene, which is very low in cetane rating, adversely affects the engine. Diesel fuel differs in grades depending on the temperature.
ENGLISH 14 PERIODIC SERVICE BChecking the fuel pipes BCleaning the fuel filter pot CAUTION To avoid personal injury; A Check or replace the fuel pipes after stopping the engine. Broken fuel pipes can cause fires. Every 100 hours of operation, clean the fuel filter in a clean place to prevent dust intrusion. 1. Close the fuel filter lever. Check the fuel pipes every 50 hours of operation. When if; 1. If the clamp band is loose, apply oil to the screw of the band, and tighten the band securely. 2.
15 BFuel filter cartridge replacement 1. Replace the fuel filter cartridge with a new one every 500 operating hours. 2. Apply fuel oil thinly over the gasket and tighten the cartridge into position by hand-tightening only. 3. Finally, vent the air. A Do not operate a diesel engine when engine oil is overfilled. This oil can drain through the air intake system, which cause engine disacceleration and oil leaks from breather pipings.
ENGLISH 16 PERIODIC SERVICE 4. If the oil level is too low, remove the oil filler plug, and add new oil to the prescribed level. 5. After adding oil, wait more than 5 minutes and check the oil level again. It takes some time for the oil to drain down to the oil pan. Models V3600-E3, V3600-T-E3, V3800-DI-T-E3, V3300-E3BG, V3600-T-E3BG, V3800-DI-T-E3BG Engine oil quantity 13.2 L (3.49 U.S. gal.
BReplacing the oil filter cartridge CAUTION To avoid personal injury: A Be sure to stop the engine before changing the oil filter cartridge. A Allow engine to cool down sufficiently, oil can be hot and cause burns. 1. Replace the oil filter cartridge. Oil filter cartridge should be replaced after the initial 50 hours of operation and every 500 hours thereafter. 2. Remove the old oil filter cartridge with a filter wrench. 3. Apply a film of oil to the gasket for the new cartridge. 4.
ENGLISH 18 PERIODIC SERVICE BChecking coolant level, adding coolant 1. Remove the radiator cap, after the engine has completely cooled, and check to see that coolant reaches the supply port. 3. When the coolant level drops due to evaporation, add water only up to the full level. 4. Check to see that two drain cocks; one is at the crankcase side and the other is at the lower part of the radiator as figures below. (1) Radiator pressure cap 2.
BChanging coolant BChecking radiator hoses and clamp 1. To drain coolant, always open both drain cocks and simultaneously open the radiator cap as well. With the radiator cap kept closed, a complete drain of water is impossible. 2. Remove the overflow pipe of the radiator pressure cap to drain the recovery tank. 3. Prescribed coolant volume (U.S.gallons) Models V3600-E3, V3600-T-E3, V3800-DI-T-E3, V3300-E3BG, V3600-T-E3BG, V3800-DI-T-E3BG 19 Quantity 9.0 L (2.38 U.S. gal.
ENGLISH 20 PERIODIC SERVICE BAnti-freeze CAUTION To avoid personal injury: A When using anti-freeze, put on some protection such as rubber gloves (Antifreeze contains poison.). A If should drink anti-freeze, throw up at once and take medical attention. A When anti-freeze comes in contact with the skin or clothing, wash it off immediately. A Do not mix different types of antifreeze. The mixture can produce chemical reaction causing harmful substances.
AIR CLEANER Since the air cleaner employed on this engine is a dry type, never apply oil to it. 1. Open the evacuator valve once a week under ordinary conditions - or daily when used in a dusty place. This will get rid of large particles of dust and dirt. 2. Wipe the inside air cleaner clean with cloth if it is dirty or wet. 3. Avoid touching the primary element except when cleaning. 4. When dry dust adheres to the element, blow compressed air from the inside turning the element.
ENGLISH 22 PERIODIC SERVICE BDust indicator (optional) If the red signal on the dust indicator attached to the air cleaner is visible, the air cleaner has reached the service level. Clean the element immediately, and reset the signal with the "RESET" button. FAN BELT BAdjusting Fan Belt Tension CAUTION To avoid personal injury: ABe sure to stop the engine and remove the key before checking the belt tension. ABe sure to reinstall the detached safety shield after maintenance or checking.
23 CARRIAGE AND STORAGE CARRIAGE CAUTION To avoid personal injury: A Fix the engine securely not to fall during operation. A Do not stand near or under the engine while carrying it. A The engine is heavy. In handling it, be very alert not to get your hands and body caught in. 1. Use carrier such as crane when carrying the engine, or hurt your waist and yourself. Support the engine securely with rope not to fall while carrying it. 2.
ENGLISH 24 TROUBLESHOOTING TROUBLESHOOTING If the engine does not function properly, use the following chart to identify and correct the cause. BWhen it is difficult to start the engine Cause Fuel is thick and doesn't flow. Air or water mixed in fuel system Countermeasures * Check the fuel tank and fuel filter. * Remove water, dirt and other impurities. * As all fuel will be filtered by the filter, if there should be water or other foreign matters on the filter, clean the filter with kerosene.
BWhen engine overheats Cause Countermeasures Engine oil insufficient * Check oil level. Replenish oil as required. Fan belt broken or elongated * Change belt or adjust belt tension. Coolant insufficient * Replenish coolant. Excessive concentration of antifreeze * Add water only or change to coolant with the specified mixing ratio. Radiator net or radiator fin clogged with dust * Clean net or fin carefully. Inside of radiator or coolant flow route corroded * Clean or replace radiator and parts.
ENGLISH 26 SPECIFICATIONS SPECIFICATIONS Model Type Number of cylinders Bore and stroke V3600-E3 V3600-T-E3 Vertical, water-cooled, 4-cycle diesel 4 98 × 120 (3.86 × 4.72) mm (in.) Total displacement L(cu.in.) Combustion type SAE NET Intermittent kW / min-1(rpm) H.P. (SAEJ1349) (HP / min-1 (rpm)) SAE NET Continuous kW / min-1(rpm) H.P. (SAEJ1349) (HP / min-1 (rpm)) SAE Standby kW / min-1(rpm) H.P.
Model Type Number of cylinders Bore and stroke V3800-DI-T-E3 Vertical, water-cooled, 4-cycle diesel 4 100 × 120 (3.94 × 4.72) mm (in.) Total displacement L(cu.in.) Combustion type SAE NET Intermittent kW / min-1(rpm) H.P. (SAEJ1349) (HP / min-1 (rpm)) SAE NET Continuous kW / min-1(rpm) H.P. (SAEJ1349) (HP / min-1 (rpm)) SAE Standby kW / min-1(rpm) H.P. (SAEJ1349) (HP / min-1 (rpm)) Maximum bare speed min-1(rpm) Maximum bare idling speed min-1(rpm) Order of firing 3.
ENGLISH 28 SPECIFICATIONS Model V3300-E3BG Vertical, water-cooled, 4-cycle diesel Type Number of cylinders Bore and stroke Total displacement Combustion type 4 98 × 110 (3.86 × 4.33) 3.318 (202.49) Spherical type (E-TVCS) 30.6 / 1800 (41.0 / 1800) 25.0 / 1500 (33.5 / 1500) mm (in.) L(cu.in.) SAE NET Continuous kW / min-1(rpm) H.P. (SAEJ1349) (HP / min-1 (rpm)) SAE Standby H.P.
Model V3600-T-E3BG Vertical, water-cooled, 4-cycle diesel Type Number of cylinders Bore and stroke Total displacement Combustion type 4 98 × 120 (3.86 × 4.72) 3.620 (220.9) Spherical type (E-TVCS) 39.2/1800 (52.5/1800) 32.1/1500 (43.0/1500) mm (in.) L(cu.in.) SAE NET Continuous kW / min-1(rpm) H.P. (SAEJ1349) (HP / min-1 (rpm)) SAE Standby H.P. (SAEJ1349) kW / min-1(rpm) (HP / min-1 (rpm)) Maximum bare speed Order of firing Direction of rotation Injection pump 29 min-1(rpm) 43.1/1800 (57.
ENGLISH 30 SPECIFICATIONS Model Type Number of cylinders Bore and stroke V3800-DI-T-E3BG Vertical, water-cooled, 4-cycle diesel 4 100 × 120 (3.94 × 4.72) mm (in.) Total displacement L(cu.in.) Combustion type SAE NET Intermittent kW / min-1(rpm) H.P. (SAEJ1349) (HP / min-1 (rpm)) SAE NET Continuous kW / min-1(rpm) H.P. (SAEJ1349) (HP / min-1 (rpm)) SAE Standby kW / min-1(rpm) H.P. (SAEJ1349) (HP / min-1 (rpm)) Maximum bare speed min-1(rpm) Maximum bare idling speed min-1(rpm) Order of firing 3.
WIRING DIAGRAMS BV3600-E3, V3600-T-E3, V3300-E3BG, V3600-T-E3BG 31 ENGLISH WIRING DIAGRAMS
ENGLISH 32 WIRING DIAGRAMS BV3800-DI-T-E3
BV3800-DI-T-E3BG 33 ENGLISH WIRING DIAGRAMS
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-3300 & V-3300-T 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 12 volt DC Test Light 14 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 15 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 ENGINE and GENERATOR DIAGRAM_____________________________________ 6 SECTION A: GENERATOR MARATHON MAGNAPLUS GENERATOR MANUAL __________________________ 1-19 Installation Operation Maintenance SECTION B: VOLTAGE REGULATORS and ENGINE CONTROLLERS MARATHON SE350 VOLT
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.
6 KUBOTA V-3300 & V-3300T ENGINE with MARATHON GENERATOR END
SECTION A: GENERATOR
SECTION B: VOLTAGE REGULATORS and ENGINE CONTROLLERS
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.
GAC ESD2100 SERIES SPEED CONTROL UNIT The ESD2100 Speed Control Unit is part of an engine governing system designed to control engine speed and stability throughout the load range. Operating in combination with a magnetic pick-up and electric actuator the ESD2100 will maintain the proper engine speed by adjusting the fueling system according to the applied load. By maintaining a set engine speed the generator voltage output and frequency will remain constant and stable.
SECTION C: WIRING SCHEMATICS
POWER TECHNOLOGY SOUTHEAST, INC.
POWER TECHNOLOGY SOUTHEAST, INC.
POWER TECHNOLOGY SOUTHEAST, INC.
120 VOLT, SINGLE PHASE, 4 WIRE CONNECTION “M” SERIES EXCITER TYPE
120 / 240 VOLT, SINGLE PHASE, 4 WIRE CONNECTION “M” SERIES EXCITER TYPE
220 VOLT, SINGLE PHASE, 4 WIRE EUROPEAN CONNECTION “M” SERIES EXCITER TYPE
RESISTANCE CHART “M” SERIES EXCITER TYPE KW 30 35 40 Less Than 1.0 Ohm / Phase Less Than 1.0 Ohm / Phase Less Than 1.0 Ohm / Phase 0.75 0.875 0.75 Exciter Stator 23.0 – 28.0 23.0 – 28.0 23.0 – 28.0 Exciter Rotor 0.12 0.12 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 12 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 12 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 12-Volt Battery Test BAD OK Engine Problem Check Stator Coil Resistance BAD See Engine Troubleshooting Replace Stator 3 OK Replace AVR And Test
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6$)(7< 35(&$87,216 Safety precautions are absolutely necessary during installation and maintenance of your Athlon ™ generator. Warning messages are contained throughout this document, often marked with a cautionary . These messages are for your protection. symbol, such as Before any work is done: x Be sure installation conforms to all applicable safety and local electrical codes. Licensed electricians should perform all installations.
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35,1&,3/( 2) 23(5$7,21 AthlonTM generators are brushless, self excited or permanent magnet generator (PMG) excited, synchronous AC generators. All units utilize sophisticated Automatic Voltage Regulators (AVR) to control the output voltages and frequencies. The self excited generator is made up of six major components: main stator (armature), main rotor (field), exciter stator (field), exciter rotor (armature), rectifier assembly, and voltage regulator (AVR).
supplies this in-rush of starting current, the generator voltage dips temporarily. If the motor is too large for the generator, the generator’s voltage dips greater than 30 percent. This may result in the motor starter de-energizing or the motor stalling. 6SHFLDO &RQGLWLRQV Outdoor Operations – Generators subjected to outside operation must be protected from the environments by fiberglass or metal housings with the proper forced air (fan) ventilation.
,167$//$7,21 Different generating set configurations will require different levels of site installation. For example, most enclosed sets that include switchboards and circuit breakers will require little or no connectors, passthroughs or wiring for grounding whereas open configurations will likely require both. Please read and follow each section as it applies to the specific generating set being installed. /,)7,1* The Lifting Lugs on the generator are meant to support the generator only.
components. Be sure to follow approved working practices, particularly when reaching inside the assembly to install and fastened coupling hardware. 7:2 %($5,1* *(1(5$7256 Following the coupling manufacturer’s guidelines for proper fit and alignment, a flexible coupling should be used to join the engine to the generator. For belt-driven generators, avoid axial load on the bearings by verifying the alignment of the pulleys and belts.
92/7$*( $1' )5(48(1&< Verify that the voltage and frequency outputs listed on the generator nameplate match those required for the generatRU set application. $95 6(77,1*6 The automatic voltage regulator (AVR) settings are pre-adjusted by the factory to give acceptable performance for initial testing. However, if adjustments need to be made, the AVR can be accessed by removing the saddle box cover.
2.4.4.
2.4.4.
2.4.4.
2.4.4.
23(5$7,21 7(67,1* 2) *(1(5$725 6(7 While testing, covers may need to be removed to make adjustments, which will expose live circuits and components. Only qualified personnel should SHUIRUP Westing and adjustments. 7(67 (48,30(17 Use a voltmeter, frequency meter and a current and/or power meter to perform basic checkout of the generating set. Measurements should be made either line-to-line or line-to-neutral. Using a power factor meter is recommended if applying a reactive load, i.e.
/2$' 7(67,1* $95 $'-8670(176 After adjusting the voltage and stability, the AVR will not typically require further adjustment. However, if voltage collapse or poor voltage regulation result when a load is applied, additional adjustments may need to be made. Please see the subsections below on the other possible adjustments to determine if one or more of these will fix the problem being experienced.
voltage across terminals X and XX should be within 5% of 70 volts. This is the correct setting of the excitation trip. Stop the generator to reset. 6HH ZLULQJ GLDJUDPV $SSHQGL[ ( 29(5 92/7$*( 29(5 9 Only for the AGR321 AVR The over voltage function removes generator excitation (AVR output) if the AVR sensing input is lost. In addition, this AVR includes an output to trip an optional external circuit breaker.
wire to connect the neutral terminal to the earth terminal, both located inside the saddle box. If unsure, check the continuity between the neutral terminal inside the saddle box and any inner, unpainted panel in the saddle box. The gen-set builder is responsible for verifying the generator frame generating set bedplate and the main ground output terminal are electrically bonded.
4. SERVICE Performing routine service will help keep your generator running smoothly. The condition of the winding and bearings should be examined periodically, especially if the generator has been idle for a long time. Also, regular inspection and maintenance is required for generators fitted with air filters. 4.1 AIR FILTERS Removal of filters exposes live parts. Unit must be OFF. Air filters for the removal of airborne particulate matter (dust) are offered as an additional option.
4.2.1 WINDING CONDITION ASSESSMENT Be sure to disconnect the AVR and ground the leads of the Resistance Temperature Detector (RTD) before conducting this test. To determine the condition of the windings, the insulation resistance is measured from each phase-to-phase and from each phase to neutral. This measurement should be conducted as part of regular maintenance after extended shutdown periods, or if the insulation resistance value is suspected to be low, e.g., wet or dirty windings.
Short Circuit Method The short circuit method is a process that should only be performed by a technician qualified in the safe operating practices required around generator sets. Contact the factory for detailed instructions, should this method be chosen. 4.3 BEARINGS All bearings are supplied from the factory pre-packed with Athlon Generator grease, conforming to the specifications of Kluber Asonic GHY 72 grease. Do not mix with any grease of different specifications.
7528%/( 6+227,1* *8,'( Athlon generators are provided with excitation control systems. Four automatic voltage regulator (AVR) systems are available across the range of generator models and sizes. The following will assist the user in determining any faults. Follow the guide for the proper AVR in question.
$*5 $95 SYMPTOMS SOLUTIONS Generator produces no voltage x x Generator produces unstable voltage Generator produces high voltage Generator produces low voltage at no load Generator produces low voltage with load applied Check speed with tachometer Check residual voltage and flash the field as necessary VHH 6HFWLRQ Verify generator connections Check diodes Test and adjust or replace AVR x x x x x x x x x x Check speed with tachometer.
5(6,'8$/ 92/7$*( &+(&. This procedure is appropriate for use to with either AGR460 or AGR440 regulators.) With the generator set stationary, remove the regulator access cover and leads X and XX from the AVR. Start the unit and measure voltage across the regulator terminals 7-8 on AGR460 AVR or P2-P3 on AGR440 AVR. Stop the set, and replace leads X and XX on the AVR terminals. If the measured voltage was above 5 volts, the generator should operate normally.
$*5 $95 SYMPTOMS SOLUTIONS Generator produces no voltage x Check link K1-K2 on auxiliary terminals of AVR Verify generator connections Check diodes Test and adjust or replace AVR x x x Generator produces low voltage with load applied Generator produces high voltage Generator produces unstable voltage x x x x x x Check speed with tachometer Check diodes Test and adjust or replace AVR Check speed with tachometer Verify generator connections Check load PF.
$*5 $95 SYMPTOMS SOLUTIONS Generator produces no voltage x Check link K1-K2 on auxiliary terminals of AVR Verify generator connections Check diodes Test and adjust or replace AVR x x x Generator produces low voltage with load applied Generator produces high voltage Generator produces unstable voltage x x x x x x Check speed with tachometer Check diodes Test and adjust or replace AVR Check speed with tachometer Verify generator connections Check load PF.
(;&,7$7,21 7(676 &+(&.,1* 30* RQ XQLWV ILWWHG Z 30* With the unit operating, measure voltages at the regulator terminals P2, P3 and P4. These should be balanced and within the following ranges: 50 Hz generators - 170-180 volts 60 Hz generators - 200-216 volts Should the voltages be unbalanced, stop the set, remove the PMG sheet metal cover from the non-drive end bracket and disconnect the multi-pin plug in the PMG output leads. Check leads P2, P3, and P4 for continuity.
plate carrying positive-biased diodes. Insure that correct polarity diodes are fitted to each respective plate. The recommended torque for tightening diodes is 4.06 - 4.74 Nm (36-42 in lb). 6XUJH 6XSSUHVVRU The surge suppressor is a metal-oxide varistor (“variable resistor” used to protect circuits against excessive voltage by acting as a spark gap) connected across the two rectifier plates to prevent transient reverse voltages in the field winding from damaging the diodes.
:LQGLQJ 5HVLVWDQFHV Frame Size AG164A AG164B AG164C AG164D AG184E AG184F AG184G AG184H AG184J AG224C AG224D AG224E AG224F AG224G AG274C AG274D AG274E AG274F AG274G AG274H AG274J AG274K AG4C AG4D AG4E AG4F AG5C AG5D AG5E AG5F AG6G AG6H AG6J AG6K Main Rotor 0.44 0.48 0.52 0.56 0.64 0.74 0.83 0.89 0.96 0.59 0.64 0.69 0.83 0.94 1.12 1.26 1.34 1.52 0.69 0.82 2.08 2.08 0.91 1.04 1.17 1.35 1.55 1.77 1.96 2.16 1.75 1.88 2.09 2.
81%$/$1&(' 0$,1 7(50,1$/ 92/7$*(6 Unbalanced voltages indicate a fault on the main stator winding or main cables to the circuit breaker. These faults may also cause noticeable load increase on the engine. Disconnect the main cables and separate the winding leads U1-U2, (U5-U6), V1-V2, (V5-V6), W1-W2, (W5-W6) to isolate each winding section. $95 3(5)250$1&( 7(67,1* AVR CONTROLLED GENERATORS Frame Size Section Frame Size Section Resistance Resistance AG164A 0.81 AG4C 0.0083 AG164B 0.
$33(1',; $ $7+/21 *(1(5$725 :$55$17< NOTE: This warranty is extended only to Athlon industrial or commercial clients. It does not extend to customers of Athlon clients. :$55$17< 3(5,2' Athlon warrants Standby Duty Generators to be free from defects in materials and workmanship for a period of 24 months from date of commissioning, 30 months from date of shipment, or 1200 hours of run time, whichever occurs first.
$33(1',; % *(1(5$725 '$7$ 02'(/ 180%(5 Athlon Generators use a model number system conforming to that used by many manufacturers of similar types and models of generators. For example, Athlon Generator Model AG224D can be interpreted as shown below: $* ' Manufacturer Frame Number Number of Poles Core Designation )UDPH 1XPEHU – refers to the frame size of the generator and follows industry standard. AthlonTM offers frame sizes of 16, 18, 22, 27, 4, 5, and 6.
CONNECTION DIAGRAMS Terminal Ends IEC NEMA U1 U2 U5 U6 T1 T4 T7 T10 V1 V2 V5 V6 T2 T5 T8 T11 W1 W2 W5 W6 T3 T6 T9 T12 Double Delta 1PH 3W T3 T5 T9 T11 DOUBLE DELTA 1 PH 3 W T6 L2 T2 T1 L0 T4 60 T7 L – L0 HZ T8 T12 L1 T10 50 L – L0 L–L 28 L-L 200 220 240 220 L-L0 100 110 120 110
Parallel Low Zig Zag 1PH 3W T6 T2 T12 T8 T3 T5 T9 T11 T4 L0 T1 L1 L2 T10 L – L0 T7 L – L0 L– L PARALLEL LOW ZIG ZAG 1 PH 3 W HZ L-L 200 220 240 220 60 50 L-L0 100 110 120 110 Series High Delta 3PH 4W L1 T12 T1 SERIES HIGH DELTA 3 PH 4 W L – L0 T9 HZ T4 T6 L0 T7 L3 T10 T11 T8 T5 T2 60 50 L – L0 T3 L– L L2 29 L-L 240 277 200 220 240 L-L0 120 139 100 110 120
Parallel Low Wye (Star) 3PH 4W L1 T1 PARALLEL LOW WYE (STAR) T7 3 PH 4 W HZ T10 T4 T12 T5 T6 T9 L3 L–L T11 T3 60 T2 L – L0 T8 L-L 208 220 230 240 190 400 415 50 L2 L-L0 120 127 133 139 110 115 127 Series High Wye (Star) 3PH 4W T1 L1 SERIES HIGH WYE (STAR) 3 PH 4 W T4 HZ T7 L– L 60 T12 T10 T6 T9 T11 T8 T5 T3 50 T2 L3 L2 L – L0 30 L-L 416 440 460 480 380 400 415 L-L0 240 254 266 277 219 231 240
$33(1',; & 3$5$//(/ 23(5$7,21 3DUDOOHOLQJ %DVLFV The following points are basic criteria, which must be met before two units can be paralleled. Additional paralleling circuitry x Voltage regulator-paralleling provisions (Note: AVR Model AG460 is not suitable for parallel operation).
'URRS AWKORQ Generators use the droop method. The method of kVAr sharing is to create a generator voltage characteristic, which falls with decreasing power factor (increasing kVAr). This is achieved with a current transformer (C.T.), which provides a signal dependent on current phase angle (i.e. power factor) to the AVR. If parallel operation is envisioned for your generator, please contact the factory at time of ordering, so that the proper accessories can be provided.
APPENDIX D SAE DATA SAE ADAPTOR / COUPLING COMBINATIONS Adaptor 6 5 4 3 2 1 1/2 0 0 Coupling 6.5 7.5 6.5 7.5 ALPHA 6.5 7.5 8 10 11.5 8 10 11.5 10 11.5 11.5 14 17.75D 14 18 17.75D 14 18 17.
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SAE PLATE BOLT TORQUE VALUES Model Number Bolt Size Torque (Nm) Torque (Ft-lb) AG16 M10 X 30 mm 75 55 AG18 M10 X 50 mm 75 55 AG22 M16 X 35 mm 320 236 AG27 M16 X 55 mm 320 236 AG4 M20 X 55 mm 625 461 AG5 M16 X 65 mm 625 461 AG6 M 24 X 65 mm 1072 791 36
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$33(1',; ) $7+/21 *(1(5$725 &(57,),&$7,216 Athlon™ Generators are designed and manufactured for safe and reliable operation, in factories certified to ISO 9001:2000. Athlon™ Generators are rated for standby or continuous duty. Athlon™ AC synchronous generators are brushless 4 pole, self-ventilated alternators, which create 60 Hz power at 1800 RPM or 50 Hz power at 1500 RPM. The generators can be provided in one or two bearing configurations.
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TM TM ATHLON GENERATOR LLC Montross, Virginia
