PG 1 OPERATORS MANUAL Cover Sheet CD7 8000 CD7000 CD 7 8

User Manual: CD7000

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CD-7

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Operators

Manual

Power Technology Southeast, Inc.

634 State Road 44 Leesburg, FL 34748-8103

♦ (352) 365-2777 ♦ Fax (352) 787-5545 ♦

3/2007

MANCD7

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 CD-7 and CD-8 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.

Generator Model Number____________________________________________

Generator Serial Number_____________________________________________

POWER TECHNOLOGY SOUTHEAST, INC.

634 STATE RD. 44

LEESBURG, FL. 34748-8103

(352) 365-2777

FAX (352) 787-5545

www.PowerTech-Gen.com

Limited Warranty on Power Tech Generators

Power Technology Southeast, Inc. warrants to you, the original purchaser, that each product of our manufacture is free from defects in materials, and workmanship. That

each generator will deliver its rated output as indicated on The Power Technology Nameplate, if properly installed, serviced, and operated under normal conditions in

accordance with Power Technology’s instructions.

THE WARRANTY COVERAGE TERMS:

2 years from date of purchase, or 3000 hours whichever comes first, or 36 months from the date of manufacture. Parts, and labor, including diagnostic labor, removal, and

reinstallation are covered for the first 12 months from date in service or 1000 hours whichever comes first.

Parts and labor are covered only on the following generator and engine parts for 2 years or 3000 hours whichever comes first. Generator Parts: Main Rotor and Main

Stator. Engine Parts: Cylinder Block, cylinder head, crankshaft, camshaft, cylinder head gears, connecting rods, flywheel and flywheel housing, intake and exhaust manifold

(only if flexible connection is used).

3) Stand-by Units are covered for a period of 1 year from date of installation, or 1000 hours, or 24 months from the date of manufacture whichever comes first.

4) Replacement Parts are warranted: 30 days. (Excluding the following: voltage regulators, fuses, controllers, capacitors, brushes, and switches)

________________________________________________________________________________________________________________________________

WHAT POWER TECHNOLOGY WILL DO:

Power Tech will at our option, repair or replace any part covered by this warranty which becomes defective, malfunctions or otherwise fails to conform to this warranty

under normal use and service during the term of this warranty.

WHAT YOU MUST DO TO OBTAIN WARRANTY SERVICE:

In order to obtain warranty repairs you must deliver the product, together with proof of purchase to an authorized Power Tech service facility. In the case of repairs

pertaining to the engine only, you must use an authorized dealer or distributor of that make of engine, to be covered under their warranty. Engines used in the manufacture

of Power Tech products are warranted solely by the engine manufacturer.

PRIOR APPROVAL IS REQUIRED FOR ANY WARRANTY SERVICE

Failure to obtain authorization prior to the repair being performed will result in the claim being denied.

All claims must be submitted within 30 days of the repair. Along with the following: a copy of the original repair order, Power Tech authorization number, Power Tech

serial number, and operation hours shown on the genset mounted hour meter.

THIS WARRANTY DOES NOT COVER THE FOLLOWING:

A. Normal wear items, including but not limited to: turbo-chargers, fuel injector (s), starter, alternator, and electronic components, as well as normal engine and/or generator

wear. A1. Travel time and fuel charges to and from the repair facility or travel time and fuel charges for mobile service. (Except stationary units with a maximum of 2-hours

travel time.) B. Defects, malfunctions or failure resulting from accidents, abuse, misuse, improper servicing, improper installation, improper storage, and lack of

performance of required maintenance service. C. Products which have been subjected to alteration, modification, neglect or unauthorized repairs. D. Troubleshooting,

routine service, tune-ups, replacement of filters, belts, coolant, lubricants, hoses, clamps, exhaust system components, fuel system components, gaskets and/or seals. E.

Electrical items damaged by welding or jump-starting. F. Damage caused by water ingestion or electrolysis. G. Damage caused by ingestion of substances other than clean

filtered air, fuel, or intake water. H. Damage caused by faulty repairs performed by a repair facility not authorized in writing by Power Tech. I. Damage caused by operation

with improper fuel or at speeds, loads, conditions, modifications, or installation contrary to published specifications or recommendations. J. Original installation charges and

startup costs. K. Removal and re-installation charges of more than 1-hour labor for outside units, 2-hours for compartment mounted units, and 3-hours for below deck

marine units. Customer is responsible for additional labor/charges due to difficult access, removal or installation. L. Starting batteries and labor or charges related to battery

service. M. Loss of revenue or the rental of equipment due to down time. N. Generator repairs made within the warranty period other than by an authorized Power Tech

service dealer without prior written approval from Power Tech warranty department. O. Damage caused by negligent maintenance such as but not limited to: Failure to

provide the specified type and quantity of lubricating oil, cooling air flow, and proper coolant mixture and level. Failure to provide adequate air intake/or maintenance of the

air intake system. Failure to provide scheduled maintenance as prescribed in supplied manuals. P. Engine fluids such as fuel, oil or coolant/antifreeze. Q. Shop supplies such

as adhesives, cleaning agents, rags, paint, or other miscellaneous supplies. R. Use of other than factory supplied or approved repair parts or procedures. Replacement of a

failed Power Tech component with a non-Power Tech component voids the Power Tech warranty on that component and any and all failures related to that component. S.

Fuel injection pumps repaired by anyone other than the factory authorized dealer or distributor of that engine. T. Expenses incurred investigating performance complaints

unless defective Power Tech materials or workmanship are discovered. U. Generator sets used in rental applications. V. Cleaning, service, or repair of generator sets the

have not been kept free of dirt, debris, or other items that prevent the unit from being able to operate properly. W. Any generator set not application approved. X. Loss of

excitation due to prolonged storage. Y. Any damage attributed to low battery monitoring or automatic generator starting systems. Z. Optional accessories are warranted

solely by the manufacturer of that item including but not limited to the following item: Block heaters, oil pan heaters, electric cooling fans, air-bag isolators, compartment

heaters, fuel tanks, trailers, battery chargers, battery monitors.

To obtain warranty service: For your nearest Power Tech authorized service center, on the World Wide Web at: http://www.powertech-gen.com/parts_service.php

Call 1-352-365-2777 or write to Power Tech Warranty Department, P.O. Box 490133 Leesburg, FL 34749 USA.

Power Tech must be notified in writing within five (5) business days of any product failure.

General Conditions:

This Warranty is the sole property of the original owner /user.

A transfer of ownership shall terminate this Warranty.

This Warranty is only valid within the contiguous United States and Canada.

Warranty coverage is available outside the U.S. and Canada; please speak to a factory representative for those details.

This Warranty does not cover any products or parts not purchased from Power Technology.

Power Technology reserves the right to make design improvements and model changes without any obligation to change units or parts previously manufactured.

Warranty registration card must be completed and mailed to Power Tech at the above address to validate the Warranty.

This is the only express warranty on Power Tech products

No person, agent, or dealer is authorized to give any Warranties on behalf of Power Technology Southeast, Inc., and not to assume for Power Technology Southeast,

Inc. any other liability in connection with any of its products unless made in writing and signed by an officer of Power Technology Southeast, Inc.

LIMITATIONS ON OUR RESPONSIBILITY WITH RESPECT TO PRODUCTS PURCHASED AND USED FOR PERSONAL, FAMILY OR HOUSEHOLD USE:

Our responsibility is to repair or replace defective parts as stated above. We will not be responsible for any other expenses, losses or inconvenience which you may

Sustain as a result of the purchase, use, malfunction or defective condition of our products. ANY IMPLIED WARRANTIES, INCLUDING WARRANTIES OF

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED IN DURATION TO THE PERIOD SET FORTH ABOVE.

Some states do not allow limitations on how long an implied Warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above

Limitations or exclusions may not apply to you. This Warranty gives you specific legal rights and you may have other rights which vary from state to state.

This Warranty is in lieu of all other Warranties, expressed or implied and of any other obligations or liability on our part.

Our responsibility for any and all losses and IN NO EVENT WILL WE BE LIABLE FOR LOSS OF USE, LOSS OF PROFITS, INCONVIENCE, COMMERCIAL LOSS

OR OTHER INCIDENTIAL OR CONSEQUENTIAL DAMAGES WHATSOEVER.

Power Technology S.E., Inc.

P.O. Box 490133 Leesburg, FL 34749 USA.

Z code 04/20/2010

TABLE of CONTENTS

SECTION 1: “SAFETY”

SAFE OPERATION 1-4

SECTION 2: “ENGINE”

PRE-OPERATION CHECK 1

OPERATING THE ENGINE 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 8-10

SECTION 3: “GENERATOR END”

PRINCIPLES OF OPERATION 1-2

“S” TYPE GENERATOR ASSEMBLY __ ___________________ 3

GENERATOR END TROUBLESHOOTING GUIDES 4-6

WIRING SCHEMATICS 7-8

SECTION 4: “INSTALLATION”

SAFETY PRECAUTIONS 1-2

GENERATOR INSTALLATION ______________________________ 3-6

SYSTEMS CONNECTION 7-9

ELECTRICAL CONNECTIONS 10-12

ENGINE CONTROLS_______________________________________________ 13-14

WIRING SCHEMATICS

SECTION 5: “POWER CONTROL MODULE”

POWER CONTROL MODULE (PCM) and DISPLAY (PCMD) _____________ 1-3

TROUBLESHOOTING GUIDES ______________________________________ 4-10

12 VOLT DC POWER CONTROL MODULE WIRING SCHEMATIC _______ 11

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.

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.

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.

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.

SECTION 2

“ENGINE”

PRE-OPERATION CHECK 1

Engine Break-in Period

Daily Check

OPERATING THE ENGINE 2

Engine Starting Controls

Starting the Engine

Check Engine After Starting

Stopping the Engine

ENGINE SPECIFICATIONS 3

Kubota Models D905-B and D1105-B

Service Parts

ENGINE MAINTENANCE SERVICE SCHEDULE 4

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

Checking Radiator Coolant Level

Coolant Service Life

Checking Reservoir Tank Coolant Level

Cleaning Radiator Core

OPERATING HOURS AND SERVICE LOG 7

ENGINE TROUBLESHOOTING GUIDES 8-10

Engine Starts but Won’t Run

Engine Runs Rough or Slow

Engine Will Not Start

PRE-OPERATION CHECK

ENGINE BREAK-IN PERIOD

During the engine break-in period, observe the following recommendations:

1. Change the engine oil and oil filter cartridge after the first 50 hours of operation.

(See “ENGINE OIL” in ENGINE MAINTENANCE SERVICE SCHEDULE).

2. In ambient temperature above 32°F (0°C) approximately 3-5 minutes without a load is sufficient

for engine warm up. Allow additional warm up time when temperatures are below 32°F (0°C)

before placing an operating load on the engine.

DAILY CHECK

To prevent future engine problems from occurring, it is important to know and keep track of the engines

condition. Below are items to be Inspected and Checked on a daily basis.

CAUTION:

To avoid personal injury:

• Be sure all safety shields and guards are attached to the engine when operating.

• To prevent a fire hazard, keep foreign materials, fuel and oil away from the battery, wiring, muffler

and engine. Check and clear them daily. Be aware of the muffler and exhaust gas heat underneath the

engine compartment, this heat may ignite grass or other flammable materials.

• Follow all safety precautions as outlined in the “SAFE OPERATION” section.

1. For accurate readings the engine should be on level ground when checking engine fluids.

2. Check fluids before starting the engine. (Cold Engine)

• Lubrication System: Check Engine oil level

Check for Engine oil leaks

• Cooling System: Check coolant level and condition

Check for coolant leaks

Check for proper installation of the radiator cap

• Fuel System: Check for sufficient quantity of fuel

Check for fuel leaks

3. Check engine after starting. (Warm Engine)

• Proper Operation: Check for easy engine start

Check for fluid leaks

Check for abnormal engine noises

Check for abnormal exhaust gas

OPERATING THE ENGINE

ENGINE STARTING CONTROLS

1) Generator Main Switch must be in the ON position.

2) Hold Start/Stop Switch for 1 second and release.

3) Glow Plugs will preheat for 8 seconds. LED flashes slowly.

4) Preheating will cease during engine cranking cycle. LED continues flashing.

5) Engine begins an 8 seconds crank cycle, After 4 seconds of cranking the PT-ECU-63 will check

for an AC signal from the generator. If an AC signal is verified the engine will start and the LED

will remain ON during the normal run operation. If the AC signal is not verified the PT-ECU-63

will terminate the cranking cycle and LED will flash a fault code.

6) Starter disengages immediately after engine run is verified.

7) PT-ECU-63 deactivates the Low Oil Pressure and High Water Temperature Switches for 6

seconds, this will assure oil pressure build-up time. If oil pressure does not build-up the engine will

immediately shut down and go into a fault mode. Likewise for a high temperature situation.

8) If engine will not start on the first attempt the PT-ECU-63 will initiate the start cycle 2 more times

before going into a fault mode. Glow Plugs will preheat for 8 seconds per attempt. Engine will

crank for 8 seconds per attempt.

9) To shut down the engine under normal operations, hold the Start/Stop Switch for 1 second and

release.

10) If a fault occurs turn Generator Main Switch OFF and then ON to reset PT-ECU-63.

CHECKING ENGINE AFTER STARTING

1) Allow the engine to warm up 3 to 5 minutes before applying a load. In colder climates allow a few

extra minutes longer.

2) Perform a visual inspection of all areas of the engine and generator.

3) Listen for any abnormal noises.

4) Check for any abnormal exhaust gases.

STOPPING THE ENGINE

It is recommended to disconnect or reduce the power load from the generator before shutting down the

engine. Then follow the steps outlined above for normal shut down.

NOTE: The PT-ECU-63 is designed to operate on 12V DC power. In a low battery situation the

PT-ECU-63 may not initiate the normal cranking cycle. To start the generator you can press and

hold the Start/Stop Switch for approximately 10 seconds or until the engine starts. Once the

engine starts the PT-ECU-63 will resume normal operations. If this situation re-occurs, charge or

replace the battery.

IMPORTANT: Damage to the Starter Motor, Starter Solenoid, Run Solenoid or any generator component

due to excessive or prolonged starting attempts attributed to an external Low Battery Control Monitoring

or Auto-Start System will not be covered by the Power Technology Southeast, Inc. Limited Warranty.

ENGINE SPECIFICATIONS

SERVICE PARTS

Power Technology Part #

Filters:

Oil ----------------------------------------------------------------------------------- 01FO05S

Fuel ---------------------------------------------------------------------------------- 08FF081

Air with Metal Canister----------------------------------------------------------- 04FA080

Air with Plastic Canister---------------------------------------------------------- 04FA2E1

Belt: ------------------------------------------------------------------------------------------ 03BF7305

Radiator Hoses:

Upper ------------------------------------------------------------------------------- 03HS7CDU

Lower ------------------------------------------------------------------------------- 03HSCDL

MODEL Kubota D905-B Kubota D1105-B

Continuous Output 10.5HP @ 1800 rpm 13.6 HP @ 1800 rpm

Cubic Capacity 54.8 in³ (.898L) 68.5 in³ (1.12L)

Bore and Stroke 2.83” x 2.90”

(72 x 73.6mm)

3.07” x 3.09”

(78.0 x 78.4mm)

Cylinder Arrangement 3 In-Line 3 In-Line

Firing Order 1-2-3 1-2-3

Compression Ratio 22:1 22:1

Engine Oil Capacity 4.0 qts. (3.78L) 4.0 qts. (3.78L)

Coolant Capacity 5qts. (4.7L) 6qts. (5.7L)

Fuel and Type Diesel No. 2-D

4 Cycle

Diesel No. 2-D

4 Cycle

Minimum Fuel Consumption See Specification Chart See Specification Chart

Engine Maintenance Service Schedule

Maintenance

Service Item *See

Note

Daily

Min.

Every

25 Hours

Every 100

Hours

Every 250

Hours

Every 500

Hours

Every

1000

Hours

Remarks

Engine Oil Level

Deterioration &

Leakage

Engine Oil

Change * X

Or Once

a Year

Oil Filter

Change X

Or Once

a Year

Coolant Level X

Coolant Leakage X

Coolant Change X Or Once a Year

Fuel Level X As Necessary

Fuel Leakage X

Fuel Filter Re-

placement X Or Once a Year

Air Filter Re-

placement ** X Or Once a Year

Damaged Worn

Or Loose Belts X

Or Every Two

Years

Replace Fuel

Hoses X Or Every Two

Years

Check Radiator

Hoses & Clamps

Once a Year

Abnormal Engine

Noise X

Abnormal

Generator Noise X

Muffler Condition

Exhaust Gas

Condition X

* Engine oil and filter must be changed after the first 50 hours of operation. Then every 100

hours or once a year whichever comes first.

** Air filter replacement interval will vary depending on operating conditions. Adverse conditions may

require frequent service.

NOTE: Under normal operation items such as Belts, Hoses and Filters are not covered by Power

Technology Southeast, Inc. Limited Warranty.

ENGINE OIL MAINTENANCE

Ambient Temperature Oil Viscosity

Above 25°C (77°F)

SAE 10W-30

SAE 30 or

SAE 10W-40

0 to 25°C (32° to 77°F)

SAE 10W-30

SAE 20 or

SAE10W-40

Below 0°C (32°F)

SAE 10W-30

SAE 10W or

SAE 10W-40

CHECKING ENGINE OIL LEVEL

( 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.

The refill capacities for the engine crankcase

Reflect the approximate capacity of the

crankcase or sump plus a standard oil filter.

Auxiliary oil filter systems will require

additional oil.

KUBOTA D905-B & D1105-B ENGINE

REFILL CAPACITIES

Crankcase Oil Sump 4.0 Qts. (3.78L)

and Filter

LUBRICATING OIL VISCOSITY

RECOMMENDATIONS

The minimum ambient temperature during cold

engine start-up and the maximum ambient

temperature during engine operation determine the

proper SAE viscosity grade of oil.

Refer to the Engine Oil Viscosity Table below

(Minimum Temperature) in order to determine the

required oil viscosity for starting an engine in cold

conditions.

Refer to the Engine Oil Viscosity Table below

(Maximum Temperature) in order to select the oil

viscosity for engine operation at the highest ambient

temperature that is anticipated.

LUBRICATING OIL

SPECIFICATION

Use only good quality

lubricating oil, which meets

or exceeds of the following

Specification

API-CD

Higher

ENGINE COOLANT MAINTENANCE

COOLANT SERVICE LIFE

Coolant Type Service Life

Commercial Heavy-Duty

Coolant/Antifreeze that 3000 Service Hours

Meets “ASTM D5345” or Two Years

Commercial Heavy-Duty

Coolant/Antifreeze that 3000 Service Hours

Meets “ASTM D4985” or One Year

NOTE: Do not use a commercial

coolant/antifreeze that only meets the ASTM

D3306 or D4656 specification. This type of

coolant/antifreeze is made for light duty

automotive applications.

CHECKING RESERVOIR TANK

COOLANT LEVEL

(At a Minimum of 25 Hours of Operation)

Ensure that the coolant level of the radiator

reservoir tank is between the upper limit (FULL)

and the lower limit (LOW) on the side of the

reservoir tank.

CLEANING RADIATOR CORE

Visually inspect the core for any obstructions such

as dirt or debris. Use running water to clean

particles from between fins.

IMPORTANT: Never use hard objects to clean

radiator core, damage to core could result.

COOLANT RECOMMENDATIONS

For optimum performance, Power Technology

recommends a 1:1 mixture of water / glycol.

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. Ethylene and Propylene Glycol provide

similar protection against freezing and boiling.

See the tables below.

ETHYLENE GLYCOL

Freeze Boil

Concentration Protection Protection

50 Percent -36°C (-33°F) 106°C (223°F)

60 Percent -51°C (-60°F) 111°C (232°F)

PROPYLENE GLYCOL

Freeze Boil

Concentration Protection Protection

50 Percent -29°C (-20°F) 106°C (223°F)

NOTE: Do not use Propylene Glycol in

concentrations that exceed 50 percent glycol

because of Propylene Glycol’s reduced heat

transfer capability. Use Ethylene Glycol in

conditions that require additional protection

against boiling or freezing.

CHECKING RADIATOR COOLANT LEVEL

Remove the radiator cap after the engine has

completely cooled and check to see that

coolant reaches the supply port.

1. Fill to the bottom of the fill neck and

check after every 25 hours of operation.

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 SERVICE RECORD

DATE HRs. RUN CUMLATIVE DATE SERVICES

Engine Runs OK

Has Power NO Power

Engine runs OK NO Power

ENGINE STARTS

BUT WON’T RUN

Unplug Remote

Start-Stop from

Control Box

Problem with

Remote Connection.

Contact

Equipment Manufacture

Jump across

Oil Pressure Switch

with Jumper Wire

(2 pole)

Check Power

to Hold Circuit

of Run Solenoi

Check

Oil Pressure

With Gauge

Replace

Oil Pressure Switch

Defective Solenoid

REPLACE

Plug Remote

Back IN

Remote OK Problem with Remote

Check

Safety Shutdown

System

Remove Wire From

Water Temperature Switch

Replace Water

Temperature

Switch

Check Shutdown

Relay

Check Wirin

Oil Pressure Switch

Single Pole

Disconnect Wire to Test

If “OK”

Replace

Switch

BLUE

GRAY/WHITE

BLACK

ENGINE RUNS

ROUGH or SLOW

NO Visible Exhaust Smoke Excessive Exhaust Smoke

Insufficient

Fuel to Engine

Check

Fuel Level

Replace

Fuel Filter

Air IN

Fuel

System

Check

Fuel

PUMP

Excessive Oil Level

Dirty Air Filter

Engine Overheated

Engine Over Loaded

Clogged Muffler

Over Fueling Injector

HIGH ALTITUDE

Engine Cold

Incomplete

Combustion

Over-fueling

Injector

Glow Plug

Not Activating

Check

With 12 volt DC

Test Light

Check

Safety Shutdowns

And

Fuel Solenoid

YES NO

ENGINE WILL NOT

START

Engine Cranks Engine Does NOT

Crank

Engine

Cranks SLOW

Exhaust

Smoke

From

Exhaust

Check Fuel

Solenoid

Power While

Cranking

Defective

Solenoid

No Power

From

Starter Terminal

Check

Fuel

Supply

Check

Fuel

Pump

Air IN

Fuel

System

Check

Glow

Plugs

Check

Glow Plug

Relay

Main Switch Battery

Dead

Turn

Switch

“ON” Start

Switch

Starter

Relay

Starter

Motor

Oil Viscosity

TOO HEAVY

LOW

Battery

Voltage

Check

Terminal

Ends

Check Spark

Arrestor

Muffler for

Clogging

SECTION 3

“GENERATOR END”

PRINCIPLES OF OPERATION 1-2

Rotating Field Assembly (Rotor)

Core Assembly

Field Coil

Voltage Connection

Electronic Voltage Regulation

Exciter Field Coil Voltage Source

Balance

Bearing

Stator Assembly

7-8KW EXCITER TYPE “C” GENERATOR ASSEMBLY 3

GENERATOR END TROUBLESHOOTING GUIDES 4-6

Zero or Low Voltage

Voltage Test

12-Volt Battery Test

Overload Condition

WIRING SCHEMATICS 7-8

120 Volt Connection “C” Series Exciter Type

120 / 240 Volt Connection “C” Series Exciter Type

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.

A static voltage regulator is connected to the generator output. The regulator will rectify part of

the output voltage to provide a DC voltage to the exciter field coils. This will increase the density of the

lines of force in the exciter, increasing the voltage induced into the exciter armature windings, and

therefore, to the rotating rectifiers. The rotating rectifier output will be increased which will increase the

alternator field strength and generator output will build up its rated voltage. Adjustment of the generator

output to the rated voltage level is accomplished by controlling the current fed to the exciter field coils.

Regulation is automatic with the static type voltage regulator. An additional voltage adjustment range is

provided if desired by turning the Voltage Adjust Rheostat.

ELECTRONIC VOLTAGE REGULATION

Electronic Voltage Regulator (EVR) also referred to, as an Automatic Voltage Regulator (AVR)

is a very reliable device, which uses solid-state electronics to maintain voltage accuracy at ±2% of the

regulated voltage. The Voltage Regulator is designed to automatically regulate and maintain the

generated AC voltage through out the load range that is from no load to full load.

VOLTAGE CONNECTION

The generator may be connected at the terminal board to deliver 120/240 volts to a 3 wire

grounded neutral system, or 120-volts only to a 2 wire distribution system. If any equipment requires

240-volts, then the 120/240-volt connection must be used. If all equipment requires 120-volts then

the 120-volt connection is preferred, even if two lines leave the same switch box. The two lines at

the inputs to the switch box are both connected to the un-grounded 120-volt lines from the generator.

The 120-volt connection enables the Electronic Voltage Regulator (EVR) to hold the voltage very

close to the 115 or 120 volts, as initially adjusted, regardless of the power distribution amount the

different distribution lines. The 120-volt connection is recommended if the entire electrical load

requires only 115 or 120 volts.

Although the 120/240-volt connection may also be used when all loads requires only 110 volts, it

should be pointed out that this connection, the 240-volts, is regulated and the lightly loaded phase, or

line, will deliver a high line to neutral voltage and the heavily loaded phase will deliver a low line to

neutral voltage. The heavily loaded line may have such a low voltage that air conditioning will have

more difficulty in starting, and long starting lines may overload generator and trip circuit breakers

EXCITER FIELD COIL VOLTAGE SOURCE

Field coil DC voltage is obtained by rectifying the voltage from the phase to neutral line of the

generator output, or either appropriate terminal to provide the needed voltage reference.

The rectifier bridge is an internal part of the static regulator. The static regulator senses a change

in the generator output and automatically regulates current flow in the exciter field coil circuit to

increase or decrease the exciter field strength. An adjustable rheostat sized to be compatible with

the regulator is used to provide adjustment of the regulator sensing 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.

FIELD COIL

Field coils of heavily insulated wire are “wet” wound directly onto the poles. Field coil leads are

brought out to the rectifier assembly for connection to the source of DC excitation voltage.

BALANCE

The rotor assembly is precision balanced to a high degree of static and dynamic balance.

Although the balance will remain dynamically stable at speeds in excess of the design frequencies, the

prime mover should be adequately governed to prevent excessive over speed. High centrifugal forces

created by excessive over speed may damage the rotor windings and field coils.

BEARING

The generator rotor assembly is suspended on a shielded factory lubricated ball bearing. A visual

inspection of the bearing is recommended at typical service intervals. If signs of abnormal wear

or leakage are observed, the bearing should be replaced. Never use liquids of any kind to clean the

generator end and bearing.

STATOR ASSEMBLY

The stator assembly consists of laminations of steel mounted in a rolled steel frame. Random

wound stator coils are fitted into the insulated slots.

DESCRIPTION PART NUMBER

7KW 8KW

1. BEARING PLATE 02BR-CR 02BR-CR

2. END BELL 02H7810 02H7810

3.EXCITER STATOR 02STA7EXC 02STA8EXC

4. MAIN STATOR 02STAMNCD7 02STAMNCD8

5. BELL HOUSING ** 02BHCD7 02BHCD7

6. ROTOR BEARING 02BRG6206 02BRG6206

7. DIODE PLATE 02PLD8CD 02PLD8CD

8. EXCITER ROTOR 02RTR7EXC 02RTR8EXC

9. MAIN ROTOR 02RTRMN7EXC 02RTRMN8EXC

10. END BELL ASSEMBLY 02EB7 02EB8

11. MAIN ROTOR ASSEMBLY 02RTR7EXC-ASSY 02RTR8EXC-ASSY

12. END PLATE ASSEMBLY 02EP7 02EP8

GENERATOR ASSEMBLY 02GEN7EXCCD 02GENCD8E

VOLTAGE REGULATOR 06REG24 06REG24

** NOTE: Item #5 BELL HOUSING is not part of the Generator End assembly.

ITER TYPE “

”

ERAT

R A

EMBLY

BAD OK ON OFF

BAD

ZERO OR LOW

VOLTAGE

Check Gen Fuse Check Main

Breaker is “ON”

Replace

Fuse Turn “ON”

Breaker

Main Coil

Output to

Breaker

BAD

Check Ohm’s on

Exciter Leads

12 V Battery Test

Replace Exciter

Wiring To

Panel

Defective

Breaker

Replace

Voltage Regulator

VOLTAGE TEST

Zero

Low Voltage

High

Voltage

Overload Output

Voltage OK

Replace

AVR

Check Load Distribution

One Voltage Line

may be

Higher than the other

Check AMP

Draw

From equipment

Check

Main Breaker

On GenSet

Check

Gen End

12 VOLT

BATTERY TEST

One Coil

Low Voltage

Both Coils

Low Voltage

Sensing Voltage

Low or None

Replace

AVR

Check

Connections

Check Engine

RPM 1800

Replace Stator

Replace

Stator

Replace

Stator

BAD OK

OVERLOAD

CONDITION

Disconnect

AVR

Engine Problem Check

Stator Coil

Resistance

See Engine

Troubleshooting

Replace Stator Replace AVR

And Test

Check AMP Draw

Check Load Distribution

Conduct

12-Volt Battery Test

RESISTANCE CHART

KW 7 8 MARKS COLOR

MAIN STATOR 0.5 0.5 U1-V1 or U2-V2 B-B

MAIN ROTOR 1.9 1.9 *** ---

EXCITER STATOR 83.5 86.9 F1-F2 R-W

EXCITER ROTOR 0.31 0.31 *** ---

AUX. WINDING 2.5 2.5 AW Y-Y

BATT. CHARGE 0.2 0.2 CH W W-W

SENSING WINDING 0.2 0.2 *** BLUE / BROWN

NOTE: THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE

POWER TECHNOLOGY SOUTHEAST, INC.

634 STATE ROAD 44

LEESBURG, FL 34748-8103

(352) 365-2777 FAX (352) 787-5545

AC ELECTRICAL CIRCUIT FOR 7 –8 KW “C” GENERATORS 120 VOLTS LINE TO NEUTRAL

GENERATOR OUTPUT LEADS

OPTIONAL 12V CHARGING

TO 12V REGULATOR

2 POLE CIRCUIT BREAKER

30 AMP for 7 KW

35 AMP for 8 KW

#12

JUMPER

WIRE

RESISTANCE CHART

KW 7 8 MARKS COLOR

MAIN STATOR 0.5 0.5 U1-V1 or U2-V2 B-B

MAIN ROTOR 1.9 1.9 *** ---

EXCITER STATOR 83.5 86.9 F1-F2 R-W

EXCITER ROTOR 0.31 0.31 *** ---

AUX. WINDING 2.5 2.5 AW Y-Y

BATT. CHARGE 0.2 0.2 CH W W-W

SENSING WINDING 0.2 0.2 *** BLUE / BROWN

NOTE: THESE READINGS WILL VARY DEPENDING ON AMBIENT TEMPERATURE

POWER TECHNOLOGY SOUTHEAST, INC.

634 STATE ROAD 44

LEESBURG, FL 34748-8103

(352) 365-2777 FAX (352) 787-5545

AC ELECTRICAL CIRCUIT FOR 7 –8 KW “C” GENERATORS 120 VOLTS LINE TO NEUTRAL 240 VOLTS LINE TO LINE

GENERATOR OUTPUT LEADS

OPTIONAL 12V CHARGING

TO 12V REGULATOR

2 POLE CIRCUIT BREAKER

30 AMP for 7 KW

35 AMP for 8 KW

SECTION 4

“INSTALLATION”

SAFETY PRECAUTIONS 1-2

Hot Piping

Dangerous Fuels

Explosive Battery Gases

Electrocution

Moving Parts

High Voltage

Explosion

Hot Coolant

Lethal Exhaust Gas

Excessive Noise

Electrical Shock

Backfire

Flash Fire

Fire Hazard

Marine Application

Unit Starts Without Notice

Loose Components

GENERATOR INSTALLATION in RECREATIONAL VEHICLES 3-6

Introduction

Marine Application

General Information

Specification Charts

Fuel Consumption in Gallons per Hour

Installation Factors

Generator Compartment Size

Compartment Frame

Air Requirements

Air Requirements Cont’d

SYSTEMS CONNECTION 7-9

Fuel System

Exhaust System

Fuel Line Diagram

ELECTRICAL CONNECTIONS 10-12

Electrical Wiring

AC Load Lead Connections

Motor Loads

Kilowatt De-Rating

Electrical Loads

Appliance Loads

Extension Cords

ENGINE CONTROLS______________________________________________________ 13-14

PT-ECU-63 Engine Control Module

12 Volt DC Charging

WIRING SCHEMATICS

12 Volt DC Engine Control, PT-ECU-63

12 Volt DC Engine Control for CD-7 and CD-8 Models

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.

1) HOT PIPING: An engine and exhaust system may get extremely hot while running. Do not work on a

generator set until it has sufficiently cooled.

2) DANGEROUS FUELS: Use extreme caution when handling, storing and using fuels. All fuels are highly

explosive in a vaporous state. Store fuel in a well ventilated area away from spark producing

equipment. Keep fuels and all chemicals out of the reach of children. Never add fuel to the

tank while the engine is running. Spilled fuel may ignite on contact with hot parts or from

ignition spark. Always keep fuel lines and connections tight and in good condition. Don’t

replace flexible fuel lines with rigid lines. If you notice any fuel leakage, fuel accumulation

or electrical sparks, DO NOT OPERATE THE GENERATOR SET.

3) EXPLOSIVE BATTERY GASES: The gases generated by a battery being charged are highly explosive.

Do not smoke or permit any flames or sparks to occur near a battery at any time, especially

when it is being charged. Avoid contact between terminals with tools to prevent sparks and

possible burns. Always remove wristwatch, rings, or other jewelry before handling a battery.

Any compartment containing batteries should be well ventilated to prevent the accumulation

of explosive gases. To avoid sparks never disturb the battery charging connections while the

battery is being charged. Always turn off the battery charger before disconnecting terminal

clips.

4) ELECTROCUTION: Failure to install a generator set with an electrical system consistent with governing

regulations and standards is UNLAWFUL and may cause ELECTROCUTION of vehicle

occupants. Your generator set must not be used to “Back Feed” by connecting it to a building

or outdoor electrical circuit. Back feeding can cause serious injury or death to utility

personnel working to repair a power outage and may also seriously injure persons in your

vehicle. Unauthorized connections are unlawful in some states and/or localities. A transfer

switch must be installed to prevent interconnection of the generator set power and outside

power.

5) MOVING PARTS: Keep hands, feet, and clothing away from belts and related pulleys when unit is running.

Replace guards, covers, and screens before operating the generator set. Serious personal

injury may occur from contact with moving parts.

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. Keep the compartment door securely latched

or locked at all times. Be sure the generator is properly grounded. Never touch electrical

leads or appliances with wet hands, or when standing on wet ground.

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. Fuel tank and installation must conform to applicable

regulations.

8) HOT COOLANT: Allow engine to cool and release pressure from the cooling system before opening the

radiator pressure cap. To release the pressure, cover the radiator cap with a thick cloth then

turn it slowly counterclockwise to the first stop. After the pressure is released and the engine

has cooled, remove the cap.

9) LETHAL EXHAUST GAS: When installing an exhaust system position the tail pipe end so that the

discharged gases may not be drawn into the vehicle interior through windows, doors, air

conditioners, etc. The engine powering your generator set discharges deadly carbon

monoxide as part of the exhaust gas when running. It is essential that the exhaust system be

leak proof and routinely inspected.

10) EXCESSIVE NOISE: Never operate the generator set without an adequate muffler or with a faulty exhaust

system. Exposure to excessive noise can lead to a hearing impairment.

11) ELECTRICAL SHOCK: A battery can cause electrical burns and shocks. Use reasonable care when

working near the battery to avoid electrical connections by contacting the battery terminals

with tools. Remove wristwatch, rings and all jewelry when working on the generator set.

12) BACKFIRE: A sudden backfire can cause serious burns. Do not operate your generator set without its air

cleaner / flame arrestor in place.

13) FLASH FIRE: A sudden flash fire can cause serious burns. To avoid the possibility of a flash fire do not

smoke or permit a flame or spark to occur near the carburetor, fuel lines, fuel filter, fuel

pump or other potential source of spilled fuel or vapors.

14) FIRE HAZARD: Be careful when parking your vehicle to prevent grass fires from being started by hot

exhaust gases or exhaust system. Keep away from hot engine and generator parts to avoid

burning yourself. Keep the generator set and compartment clean and free of debris, especially

combustible materials. Never store fuel, oil or rags in the generator compartment.

15) MARINE APPLICATION: RV generator sets do not comply with United States Coast Guard (USCG)

requirements. They must not be used for marine applications. Use only generator sets

specified for marine use in a marine application. USCG regulation 33CFR183 requires a

generator set to be ignition protected for use in a gasoline-fueled environment.

16) UNIT STARTS WITHOUT NOTICE: To prevent accidental starting on the units with remote start / stop

switch, always disconnect the battery by removing the negative (-) terminal first and then the

positive (+). Always disconnect the unit this manner before working on the generator or any

equipment connected to it.

17) LOOSE COMPONENTS: Periodically check for and tighten any fasteners that may have become loose

from vibration or road shock. Serious damage may possibly occur if components become

dislodged or misaligned.

GENERATOR INSTALLATION

in RECREATIONAL VEHICLES

INTRODUCTION

Use this section as a guide when installing a generator set in a recreational vehicle, and then refer

to the appropriate operation section for specific instructions. The installation of a RV generator set shall

comply with current standards of ANSI / RVIA EGS-1, NFPA 1192 / ANSI A 119.2, ANSI / NFPA 70,

NFPA 551 and applicable articles of the National Electrical Code. Generator set installations must also

comply with state and local requirements.

MARINE APPLICATION

RV generator sets do not comply with United States Coast Guard (USCG) requirements and

must not be used for marine applications. Use only generator sets specified for marine use in marine

installations. USCG regulation 33CFR183 requires a generator set to be “ignition protected” when used

in a gasoline fueled environment.

GENERAL INFORMATION

This information section covers the RV generator set models listed below. To determine which

model is involved, check the model number found on the Power Technology nameplate attached to the

frame of the generator being installed. Follow all instructions to ensure proper installation and operation.

Each generator set features a Kubota diesel engine, rotating-field alternating current generator,

and a relay controller. The generator is directly connected to the engine for permanent alignment. Each

controller includes a Start / Stop switch for test operating the set at the controller. Also included is an On

/Off switch to reset the controller or lockout any remote switch to prevent starting while service is being

performed. The controller may be equipped with a switch to operate the mechanism used to move the

generator out of the coach for servicing. (Supplied by the coach manufacture). After the set is attached

to the frame of the vehicle, all that is usually required to make it operational is the following.

1. Attaching the exhaust system.

2. Add proper amount of radiator coolant.

3. Add oil to crankcase, to the dipstick FULL mark.

4. Connect fuel lines, remote switch, load leads and battery terminals.

(Consult the Specification Charts on the Following Pages for Requirements)

MODEL CD-7 CD-8

GENERATOR DIMENSIONS L x W x H 33.5” x 24.5” x 18.3” 35.5” x 24.5” x 19”

WEIGHT 390 lbs. 420 lbs.

ENGINE Kubota D905-B or D1105-B Kubota D1105-B

RPMs 1800 1800

KW RATING 7 8

AC VOLTAGE 120 or 120 / 240 120 or 120 / 240

AMPERAGE 58 / 29 66 / 33

Hz 60 60

PHASE 1 1

GENERATOR COMPARTMENT

FREE AIR OPENING

277

Square Inches

277

Square Inches

SPECIFICATION CHARTS

FUEL CONNECTION ¼” NPT

FUEL RECOMMENDATION DIESEL FUEL No.1-D or No.2-D ASTM / D975

BATTERY VOLTAGE 12 VOLTS DC

BATTERY CRANKING AMPS 420

BATTERY COLD CRANKING AMPS 590 MINIMUM

BATTERY GROUND NEGATIVE

FUEL CONSUMPTION IN GALLONS PER HOUR

LOAD PERCENTAGE 7KW 8KW

25% .16 GPH .25 GPH

50% .32 GPH .38 GPH

75% .51 GPH .60 GPH

100% .64 GPH .72 GPH

INSTALLATION FACTORS

Each generator set is received as a unit except for the optional exhaust system components,

which are shipped loose for assembly after the set is installed in the vehicle. When preplanning the

installation, the following factors must be considered.

1. COMPARTMENT SIZE: Will there be sufficient room around the set to maintain

the minimum clearance of one inch?

2. AIR REQUIREMENTS: Are the compartment air inlets and outlets sized to allow

adequate circulation of air for cooling and combustion?

3. COMPARTMENT FLOOR: Is the compartment floor strong enough to support the

weight of the generator set?

4. COOLING SYSTEM: Is the cooling system large enough to adequately cool the

generator set? **

5. FUEL SYSTEM: Is the fuel system properly designed to prevent fuel

starvation of either the main engine or generator engine?

6. EXHAUST SYSTEM: Will the exhaust system meet all safety requirements

after installation?

7. ELECTRICAL CONNECTIONS: Will all systems, (battery, load and remote switch)

be compatible with the vehicles system?

** NOTE: When using a radiator not supplied by Power Technology consult your radiator

manufacturer to ensure that heat rejection values are met.

GENERATOR COMPARTMENT SIZE

In planning the size of the generator compartment or bay allow for the minimum clearance

necessary to adequately cool the generator set. The thickness of insulation and sound deadening material

used to line the compartment must be taken into consideration when planning this clearance. To

maintain minimum clearance it may be necessary to enlarge the compartment. The generator set must be

securely fastened to avoid unwanted movement from vibration and road shock. If the unit is equipped

with a mounting tray the tray is usually supported on the ends by angle iron and has a full door for

service access. Be sure to use all mounting holes in the tray to secure the tray to the vehicle support

structure. Units not equipped with mounting tray are secured by attaching Genset mounts (two in front,

two in rear) directly to the vehicle frame. Skid mounted units can either be affixed to a tray for tray

mounting or attached directly to the vehicle frame. The generator is easily removed from the coach if a

carriage with rollers is incorporated into the support structure. When designing the compartment allow

sufficient access for routine maintenance and for removal when major service is required. Also keep in

mind that the compartment door must have air intake opening having a free area equal to or greater than

that specified under the “Air Requirements” section of this manual. Make sure that the compartment is

vapor tight and completely sealed off from the inside of the vehicle to prevent exhaust or other items

from entering the vehicle. Avoid road splash and the possibility of igniting combustible materials

beneath the coach by enclosing all unnecessary free space beneath the generator compartment.

Line the compartment with a good sound deadening material. The material selected must be

fireproof or highly fire resistant. An available type of 3-layer foam material is very efficient for

absorbing sound. This type of material is easily cut to size with scissors and can be quickly installed

using special fire resistant adhesive which bonds the material to almost any clean dry surface. Other

materials such as fiberglass insulation with heat barrier have also been used successfully in mobile

installations.

NOTE: Since a Genset is flexibly mounted the minimum clearance of one inch (2 inches at the radiator

end) will assure that the sides of the compartment and the set will not rub while the set is in operation or

while the vehicle is in transit.

COMPARTMENT FRAMING

The generator must be bolted to a metal frame, which is either bolted or welded to the frame of

the vehicle. This frame must be designed to withstand a minimum force of 5Gs in any direction. The

frame must support the entire base plate around the outer perimeter and center section. Additional

framing may be required if excessive vibration occurs.

AIR REQUIREMENTS

Each engine is equipped with a high water temperature shutdown switch, which will

automatically shut down the set if the operating temperature climbs too high. To prevent the generator

set from shutting down make sure the compartment openings are large enough to allow adequate

circulation of cooling air. The minimum free air opening in the compartment door is 400 sq. in. or 2580

sq. cm. Remember that louvers, screens and protective grills will restrict airflow. A relatively open mesh

screen will restrict airflow as much as 45%. The intake opening must be increased to compensate for

such restrictions.

NOTE: Ambient temperature is defined as the generators normal operating temperature within its

mounting area. In an RV application this area is referred to as a compartment or bay.

AIR REQUIREMENTS CONT’D

* Thermostat Rating: Lower Temperature – Old Style

Higher Temperature – New Style

* Combustion Air Temperature: The output of the engine will decrease about 1% for

every 10°F of air temperature above 77°F or 25°C.

IMPORTANT: Insulation and Sound Absorbing Material used inside of the generator compartment

Must Not reduce the specified airspace clearances or restrict the airflow around the generator. Such

reduction in airspace may lead to an overheating situation and reduced generator performance. Also be

sure the air inlet and outlet openings meet the specified requirements. Allow clearance inside the

generator compartment for easy access when routine maintenance is required.

WARNING: The generator compartment Must Be sealed to prevent hazardous fumes and vapors from

entering the vehicles other compartments and interior spaces. Plugging holes and sealing all seams will

greatly reduce this hazard.

WARNING: Drip Proofing! When installing a generator, the area directly beneath the generator end of

the unit must incorporate a non-flammable barrier. This barrier needs to be made of sufficient material

able to withstand and prevent molten metal, burning insulation, flaming or sparking particles from

contacting any flammable materials at the bottom of the compartment.

7KW 8KW

ENGINE SPEED IN RPM 1800 1800

OUTPUT IN HORSEPOWER 10.5 13.6

ENGINE INLET WATER TEMP. N/A N/A

THERMOSTAT RATING* 160°F – 180°F 160°F - 180°F

THERMOSTAT FULL OPEN 203°F 203°F

ENGINE OUTLET WATER TEMP.MAX. 230°F 230°F

HIGH TEMP. SHUTDOWN SWITCH 230°F 230°F

HEAT REJECTION – BTU / MIN. 673 885

HEAT REJECTION – BTU / HR. 40,397 53,135

AIR FLOW – CU. FT. / MIN. 1296 1471

ENGINE OIL TEMP. MAX. 268°F 268°F

COMBUSTION AIR TEMP. * N/A N/A

SYSTEMS CONNECTION

FUEL SYSTEM

The diesel fuel system for the generator set must be designed to operate independently from the vehicles

main engine if both engines are to be operated at the same time. The best way to do this is to have separate fuel

tanks, but this is usually impractical because of space restrictions. 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 generator set fuel pick-up tube is generally

shorter than the vehicles; therefore fuel may not be available to the generator when fuel supply is low. This will

prevent the generator from depleting the fuel supply needed by the main engine.

NOTE: Using a simple Tee fitting to supply both engines from a common fuel line is not recommended. This

practice may possible cause a fuel starvation situation to either or both engines. Also, if excessive pressure were

to build up in the main supply line it could possible cause a failure of the generators fuel lines or connectors and

a hazardous fuel leak may occur.

Care must be taken when routing the fuel line from the main tank to the generator set. Keep the fuel line

as short as possible while maintaining adequate clearance from the exhaust system. Fuel lines must be run along

the frame side rails or coach under carriage. Never run fuel lines inside of the coach. Securely fasten the fuel

lines with hardware that is recommended for the type of fuel line used. The fuel lines should enter the generator

compartment at a point nearest to the generators fuel line connection fittings. Allow for a minimum of 8inches

of flexible fuel line to make the connection. Use proper size fuel line to accommodate the fuel flow needed.

Steel fuel line or high quality fuel hose is recommended, either one should have a minimum of ¼” ID and

strong enough to withstand road and climatic conditions.

EXHAUST SYSTEM

Exhaust system components will vary from one installation to another; therefore a muffler and tailpipe

may not always be furnished with the Genset. However, it is imperative to install a 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 a 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. Installation of an approved Spark Arrestor is required.

The exhaust system components must be approved and properly installed to meet the codes and

regulations required by Federal and State agencies. Exhaust Mufflers and Spark Arrestors supplied by Power

Technology meet code and standard requirements set forth by the USDA Forest Service.

Laws pertaining to application and maintenance of a Spark Arrestor may vary depending on your

location and State regulations. Federal laws apply on Federal lands. If a generator is used in a forest, on brush or

grass covered unimproved land it must be equipped with a Spark Arrestor. It is the responsibility of the vehicle

owner or operator to install and maintain the entire exhaust system in good working condition.

CAUTION: Any person (s) who installs an unapproved Muffler, Spark Arrestor or other exhaust system

component, and/or modifies an exhaust system or component that may result in a hazardous condition is liable

for damages, injuries or warranty expense caused by such unapproved installation and/or modification.

EXHAUST SYSTEM

IMPORTANT SAFETY TIPS:

When exhaust system components are not furnished by Power Technology as part of the Genset, the

installer is responsible for meeting the following requirements.

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.

ELECTRICAL CONNECTIONS

ELECTRICAL WIRING

All wiring must be applicable with local electrical codes. A qualified licensed electrician must

perform all electrical wiring connections. Ground Fault (GFCI) breakers must be installed to protect all

vehicle branch circuits. All switches and controls must be securely mounted to prevent damage and

accidental opening or closing from vibration, road shock and vehicle motion.

Battery, load leads and the remote switch panel connections are necessary for completing the

installation. Make final connections to the battery only after all other connections have been made, as this

will prevent unintentional starting. Some specific details on each connection are stated in the following

paragraphs. Refer to the wiring diagram for specific details. All wiring to the generator set shall be securely

supported or harnessed to prevent abrasion. Additional support is required to prevent exposure to the exhaust

system and any possible leakage of fuel, oil, or grease. At least 2 inches of clearance must be maintained

between electrical wiring and hot exhaust parts. Wiring must not be located directly below or close to the

fuel system, oil fill and drain locations. If the coach is equipped with a mechanism for removing the

generator set from the compartment such as a mounting base or slide rack, be certain all wiring is long

enough to allow for free movement of the generator for servicing.

A separate 12-volt battery is recommended for the generator set. With a separate battery, cables

should be kept short in length thus eliminating problems with excessive voltage drop. See the Table below

for cable size (AWG) to length requirements.

NOTE: A heavy gauge #4 ground strap must be connected between the ground lug on the generator set and

the frame of the vehicle. All wiring connections made at the time of installation should be readily accessible

for periodic inspection and servicing.

DISTANCE BETWEEN

GENERATOR SET AND

BATTERY

CABLE SIZE (AWG) REQUIREMENTS

AT VARIOUS TEMPERATURES

0°F (-18°C) 32°F (0°C) 75°F (24°C)

40’ (12.2M) 00 0 1

30’ (9.2M) 0 1 2

25’ (7.6M) 1 2 4

20’ (6.1M) 2 2 6

15’ (4.6M) 2 4 6

10’ (3.0M) 4 6 8

5’ (1.5M) 6 6 8

2.5’ (0.8M) 8 8 8

AC LOAD LEAD CONNECTIONS

Some generator sets have four color-coded leads. The Black leads (L1 & L3) are hot. The White or

Gray lead (L2) is neutral and the Green lead is ground. The load leads can be routed directly from the

junction box to the vehicle AC circuit or transfer switch connection. All installations require that the load

leads be routed through flexible conduit from the generator end bracket to the junction box location. The

load lead junction box must be accessible for servicing and inspection.

AC load lead (L2) White or Gray is always the neutral lead on PTS generator sets. Make sure the

neutral of the AC circuit in the vehicle is connected to the (L2) White or Gray lead. If equipment ground type

plugs and receptacles (3 prong) are used in the vehicle, the green wire must be connected to the chassis

ground. On vehicles, which also have provisions for using an outside AC, power source, the neutral lead as

well as the Black (L1 & L3) hot leads must be completely isolated from the generator set when power is

switched to the outside source.

MOTOR LOADS

When figuring generator set capacity requirements for installation involving motor loads, do not

overlook the high current demanded by the motor during start-up. The “In-Rush” of starting current may

be 2 to 5 times higher than that required when the motor reaches normal operating speed. Reserve

capacity must be allowed for in rush demands plus other loads, which could be on the line as the motor

starts.

Air conditioning units are the most common type of motor loads for a generator set in a

recreational vehicle. The starting characteristics of the different makes of air conditioners vary greatly.

For example, a particular 12,000 BTU unit may have lower starting requirements than a 10,000 BTU

unit of another make. When only one unit is involved there is usually no starting problem provided of

course the lighting and appliance load is not too high when unit is started.

The trend seems to be toward larger capacity air conditioners and the use of more than one unit in larger

vehicles. Simultaneously starting two large units can present a problem if the capacity is marginal.

Because of the variation in starting characteristics of the different makes of air conditioners, no definite

statement can be made in this publication regarding multiple-motor starting capabilities.

Delayed starting or use of “easy starting” devices on air conditioner units should be considered

whenever simultaneous starting of more than one motor is involved. The starting and running

requirements of some motor loads common to mobile applications are listed in the table below. Use this

as a guide when selecting generator set capacity requirements involving motor loads. Also note the

Kilowatt De-rating factor for generator set capabilities regarding air conditioners. Capabilities will vary

according to “Kilowatt De-rating”.

BASED ON CODE “G” ELECTRIC MOTOR ELECTRIC MOTOR

HORSEPOWER STARTING WATTS RUNNING WATTS

½ 2000 1100

1 3800 1800

2 6000 2800

3 8000 4000

4 11000 5500

5 13000 6500

KILOWATT DE-RATING

All units are rated at 1.0 power factor. The Kilowatts of the generator set will decrease 3.5% per

1,000 feet (305m) above 500 feet (152m) above sea level. De-rate 1% for every 10 °F (5.5°C) above

68°F.

ELECTRICAL LOADS

While the electrical load of the vehicle should have been calculated prior to purchase of the generator

set, you may want to recheck the load before installing the set to make sure the capacity is ample to meet

the demands without possible overloading.

The lighting load is usually easiest to calculate in most cases, simply add the wattage of each

lamp to be operated off the generator set. Note that in many applications, not all of the lights or lamps

are in the generator sets AC circuit. Some are DC powered by the 12-volt battery in the vehicle. Make

sure the total includes only lights actually on the generator sets AC circuit. The lighting load is usually

not to heavy in mobile installations however it must be accurately calculated to prevent overloading. For

example, if all lights are on at the same time and the air conditioner or other motor equipment starts up,

this may possibly cause an overload situation.

APPLIANCE LOADS

Generator sets in recreational vehicles are often used to supply AC voltage for appliances. With

the exception of a resistance-type load such as a water heater, 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.

DETERMINING ALTERNATOR LOAD REQUIREMENTS

CHECK √ APPLIANCE WATTS REQUIRED

VCR 70

LIGHT BULB 100

RADIO 100

TELEVISION 100

STEREO 100

FRY PAN 150

HOME COMPUTER 150

VACUUM CLEANER 250

ATTIC FAN 1/4 HP 400

SUMP PUMP 1/3 HP 500

REFRIGERATOR 500

FURNACE FAN 1/3 HP 600

FREEZER 800

JET WATER PUMP ¾ HP 900

ELECTRIC STOVE ELEMENT 1000

SUBMERSIBLE WATER PUMP 1 HP 1000

TOASTER 1000

COFFEE MAKER 1200

DISHWASHER 1200

HAIR DRYER 1200

MICROWAVE OVEN 1500

SUBMERSIBLE WATER PUMP 2 HP 1600

WATER HEATER 3000

OVEN 4500

TOTAL WATTS CHECKED

EXTENSION CORDS

An extension cord is normally used to provide electrical power from the generator set to a remote

location. The extension cord size (AWG#) and length must be adequate to safely maintain the amperage

requirements. A proper size extension cord will help minimize the voltage drop between the generator

set and remote location.

AMPS LOAD IN WATTS CORD LENGTH

120 VOLTS 240 VOLTS AWG#10 AWG#12 AWG#14

5 600 1200 500 FT 300 FT 200 FT

10 1200 2400 250 FT 150 FT 100 FT

20 2400 4800 125 FT 75 FT 50 FT

30 3600 7200 60 FT 35 FT 25 FT

40 4800 9600 30 FT 15 FT 10 FT

50 6000 12000 15 FT ----- -----

PT-ECU-63 ENGINE CONTROL MODULE

1) Generator Main Switch must be in the ON position.

2) Hold Start/Stop Switch for 1 second and release.

3) Glow Plugs will preheat for 8 seconds. LED flashes slowly.

4) Preheating will cease during engine cranking cycle. LED continues flashing.

5) Engine begins an 8 seconds crank cycle, After 4 seconds of cranking the PT-ECU-63 will check

for an AC signal from the generator. If AC signal is verified the engine will start and the LED

will remain ON during the normal run operation. If the AC signal is not verified the PT-ECU-63

will terminate the cranking cycle and LED will flash a fault code.

6) Starter disengages immediately after engine run is verified.

7) PT-ECU-63 deactivates the Low Oil Pressure and High Water Temperature Switches for 6

seconds, this will assure oil pressure build-up time. If oil pressure does not build-up the engine

will immediately shut down and go into a fault mode. Likewise for a high temperature situation.

8) If engine will not start on the first attempt the PT-ECU-63 will initiate the start cycle 2 more

times before going into a fault mode. Glow Plugs will preheat for 8 seconds per attempt. Engine

will crank for 8 seconds per attempt.

9) To shut down the engine under normal operations, hold the Start/Stop Switch for 1 second and

release.

10) If a fault occurs turn Generator Main Switch OFF and then ON to reset PT-ECU-63.

Fault Codes: LED Flashes

Failure to start 1

Engine High Water Temperature 2

Low Oil Pressure 3

No AC Signal 4

Low Coolant Level (Option) 5

NOTE: The PT-ECU-63 is designed

to operate on 12V DC power. In a low

battery situation the PT-ECU-63 may

not initiate the normal cranking cycle.

To start the generator you can press

and hold the Start/Stop Switch for

approximately 10 seconds or until the

engine starts. Once the engine starts

the PT-ECU-63 will resume normal

operations. If this situation reoccurs,

charge or replace the battery.

12 VOLT DC CHARGING

BLUE to 12V GENERATOR WINDING

RED to +12V DC

YELLOW to RUN RELAY

BLACK to GROUND

GREEN NOT USED

06REG12DC

06REG12DCAT

12V DC ENGINE CONTROL

PT-ECU-63

POWER TECHNOLOGY SOUTHEAST, INC.

634 STATE ROAD 44

LEESBURG, FL 34748-8103

(352) 365-2777 FAX (352) 787-5545

12 VOLT DC ENGINE CONTROL for CD-7 & CD-8

POWER TECHNOLOGY SOUTHEAST, INC.

634 STATE ROAD 44

LEESBURG, FL 34748-8103

(352) 365-2777 FAX (352) 787-5545

SECTION 5

“POWER CONTROL MODULE”

FEATURE SUMMARY _________________________________________________ 1

Internal Ambient Temperature Sensor

Oil Pressure Sensor / Switch Input

Coolant Sensor / Switch Input

Auxiliary (Generic) Shutdown Switch Input

DC Power Supply Voltage Measurement

AC Output Voltage Measurement

AC Output Current Measurement

AC Output Frequency Measurement

Warm Start

One-Touch Remote Start Trigger

Blink Code Fault Reporting

Event Recording

Load Profiling

AGS

Ignition Sensing

OPERATING BEHAVIOR _______________________________________________ 2

Starting

Stopping

Power Cycle/Reset

Idle State

Pre-Heat State

Cranking State

Running State

Fault State

AUTOMATIC GENERATOR START (AGS) ________________________________ 3

SAFETY MONITORING and SHUTDOWN

LED SEQUENCES

TROUBLESHOOTING GUIDES __________________________________________ 4-10

Engine Starts but Won’t Run

Engine Starts but Won’t Run (Continued)

Engine Will Not Start

Engine Runs Rough or Slow

Zero or Low Voltage

Voltage Test

Overload Condition

12 VOLT DC POWER CONTROL MODULE WIRING SCHEMATIC ___________ 11

Power Controller Module

(PCM)

And Display

(PCMD)

Feature Summary

The PowerTech PCM controls all of the start and run processes and characteristics of any PowerTech

generator. The features of the application are:

Internal Ambient Temperature Sensor

Provides an on-board temperature sensor.

Oil Pressure Sensor / Switch Input

Allows input from an external oil pressure sensor or switch. Will shut down the generator if

sufficient pressure is not detected after a start-up period.

Coolant Sensor / Switch Input

Allows input from an external coolant temperature sensor or switch. Will shut down the generator if

extreme temperature is detected.

Auxiliary (Generic) Shutdown Switch Input

Allows input from any external active low (ground) switch. An active state of this switch will shut

down the generator immediately.

DC Power Supply Voltage Measurement

Measures the voltage level of the DC power supply. The DC voltage is monitored for a minimum

and will shutdown the Generator if it falls below a threshold (configuration parameter). This is also reported

on the PCM.

AC Output Voltage Measurement

Measures the voltage level of the AC output. This information is monitored to detect limit

conditions. It also is reported on the PCM. Over and Under Voltage conditions are reported.

AC Output Current Measurement

Measures the current level of the AC output. The data is reported on the PCM and is used for

current, wattage, and load measurement.

AC Output Frequency Measurement

Measures the frequency level of the AC output. This info is monitored to detect a valid start as well

as limit conditions. It also is reported on the PCM. Over and Under Frequency conditions are reported.

Warm Start

Adjusts the Pre-Heat glow plug activation time according to the coolant temperature.

One-Touch Remote Start Trigger

In addition to control via PCM, the unit will respond to an active high digital input. The unit can be

configured to either start or stop in response to activation of a momentary switch or a toggle switch.

Blink Code Fault Reporting

Simple diagnostic data is available through blink codes on a dedicated active high output. The PCM

state as well as fault codes are displayed.

Event Recording

A portion of non-volatile memory is dedicated to recording diagnostic and other events. If a clock is

available on the network, the time and date of the event is included. Events include diagnostic messages,

starts, stops, and configuration changes. Total event capacity is roughly 2,000 events.

Load Profiling

The unit records the total amount of time the generator spends in each of several load intervals.

The information is recorded each time the generator stops, showing the usage profile for that specific cycle.

AGS

Automatic Generator Starting for low battery voltage. Programmable at the factory

voltage threshold and run time. Unit can sense genset battery voltage or any other battery voltage as

required. Enabled or disabled by an external switch.

Ignition Sensing

Will shutdown genset or prevents genset from starting if DC voltage is applied from any

external source. (Example: vehicle ignition, shore power sensor, or transfer switch, etc…)

Operating Behavior

Starting

The generator starts in response to the “START” button being depressed for 1 second. The PCM

goes into the Pre-Heat State, followed by the Cranking State, then finally, the Running State. The

PCM attempts to start the generator a specific number of times (configuration parameter) before

declaring a Fault. The shutdown inputs are checked before the start is attempted. If any of these

inputs are active, the start process is aborted.

See the following sections for more detailed information about each state.

Stopping

The generator stops in response to the “START” button being depressed for 1 second. All relays

are returned to their reset condition (OFF). Inputs to the PCM are not actively monitored, except

the Start/Stop Button. The LED is turned off. The PCM enters the Idle State.

Power Cycle/Reset

If the power to the PCM is cycled, it will immediately shut down all relay outputs, stopping the

generator. The unit will start with all fault and status flags reset. There may be a pause of

several seconds before all the configuration information is processed and the unit is ready to

accept input.

Idle State

The Idle State is the initial state of the PCM after a Power Cycle/Reset. The PCM returns to this

state after a Stop Command. The LED is not lit.

Pre-Heat State

The Pre-Heat State is necessary to energize the Glow Plugs for the Cranking State. The Fuel

Pump is active. The duration of this state is determined by using the coolant temperature

according to the formula:

< 23 ºF cranking time = 15 seconds

23 ºF – 50 ºF cranking time = 8 seconds

> 50 ºF cranking time = 5 seconds

The LED blinks.

Cranking State

The Cranking State attempts to start the generator combustion. The starter and fuel pump are

active. Successful sustaining combustion is determined by measuring the AC Line 1 output

frequency. The LED blinks.

Running State

After an initial “ignore” time (configuration parameter), inputs are monitored for out-of-bounds

limits and, if needed, a shutdown command is issued. The LED is lit.

Fault State

The Fault State is entered if an input reaches an out-of-bounds limit. The generator is

immediately stopped. A Power Cycle/Reset is required to exit the Fault state. The LED blinks the

Fault Code(s) (see next section).

Automatic Generator Start (AGS)

The Automatic Generator Start (AGS) allows the generator to start based upon the battery level.

The trigger voltage is configurable via a configuration parameter. The entire feature can be

enabled/disabled by a configuration parameter. The AGS feature is currently disabled, by default.

Safety Monitoring And Shutdown

The PCM monitors inputs for safety limitations which might damage the generator. If any input is

outside of the safe operating range, the generator is immediately shutdown and the PCM enters

the FAULT state. The PCM remains in the FAULT state until a power cycle or reset occurs. The

shutdown reason is displayed by blinking the LED.

The thresholds used in determining faults are set by configuration parameters.

These inputs are only monitored when the generator is in the RUNNING state. Before starting the

generator, the following inputs are checked to see whether a start should be attempted: High

Coolant Temperature, Auxiliary switch, Ignition Sense, DC Voltage and High Ambient

Temperatures.

These inputs are averaged over 0.6 seconds to help eliminate noise and settling issues. This

averaging helps to eliminate falsely signaled shutdowns.

Shutdown Reasons

Fault Reason Fault Code Description

Failure to Start 1 The generator was not able to start.

High Coolant

Temperature

2 The generator coolant temperature has reached a

high threshold.

Low Oil Pressure 3 The generator oil pressure has reached a critically

low pressure.

High Ambient (Air)

Temperature

4 The PCM measures an ambient air temperature

above a specific threshold.

NOTE: Temperature inside the Control Box.

AC Fault 5 A Fault with the AC was detected.

DC Fault 6 A Fault with the DC (Battery) was detected.

Auxiliary Input Active 7 The Auxiliary input is active.

Sensor Malfunction 8 One of the sensors has malfunctioned..

Ignition Sense 9 Ignition Sense is active.

The fault codes are displayed on the LED by blinking a number of times equal to the fault code,

then going dark for two seconds. Multiple fault codes are displayed in the order that they have

occurred. This cycle repeats until the fault is cleared by a power cycle, reset or via RV-C.

LED Sequences

The LED on the Start Button is used to communicate the state of the generator in addition to any

fault conditions. The PCM states are different from the Fault Codes in that the states are

displayed continuously (i.e. no two second pause).

PCM State

PCM State LED Notes

Idle State off

Pre-Heat Blink (25% duty cycle)

Cranking State Blink (50% duty cycle)

Running State on

Fault State <various> See “Shutdown Reasons”

Section

CODE 2 or 8

Replace Defective

Parts as Needed

Check Wiring

From Sensor to

Terminal 13 on PCM

If “OK”

Check Sensor

CODE 1 or 6

ENGINE TROUBLE SHOOTING

ENGINE STARTS BUT WON’T RUN

Check Flash Code

Indicator at

PCMD

Engine High

Water Temp.

Fill System

With 50/50 Mix

Check Coolant

Level/Condition

Check Radiator

Air Flow / Belts

Clean Core

Tighten / Replace

Belts

Failure

To Start

Check Fuel

Filter/Supply

Check Battery

Voltage

Check Circuit

To Actuator

If “OK” Check

Fuel System

If “OK” Replace

Actuator

Bleed Air

From System

Check Fuel

Pump / Circuit

If “OK”

Check Wiring

From Sensor to

Terminal 12 on PCM

If “OK” Check

Oil Pres. Sensor

Replace Defective

Parts as Needed

CODE 5 CODE 3 or 8

ENGINE STARTS BUT WON’T RUN

CONTINUED

ENGINE TROUBLE SHOOTING

Check Flash Code

Indicator at

PCMD

No AC Signal

If “Tripped”

Check Generator

Check Main AC

And Voltage

at Breakers

Low Oil

Pressure

Check Oil

Level/Condition

Check Terminal

Connections at

2&3 on PCM

Check Generator

Wiring

Replace Defective

Parts as Needed

If AC Signal

Present Replace

PCM

ENGINE WILL NOT START

ENGINE DOES NOT CRANK ENGINE CRANKS ENGINE CRANKS

SLOW

No Exhaust

Smoke

Smoke From

Exhaust

Check Fuel

Solenoid

NO Power

While

Cranking

Check Fuel

Supply

Check Fuel

Pump

Air in

Fuel System

Replace

Solenoid

YES NO

No Power

From

PCMD

Check

Glow Plugs

Check Spark

Arrestor

Muffler for

Clogging

Oil Viscosity

Too Heavy

Main Switch Battery

Dead

Check

Terminals

Turn Switch

Start Switch

Starter Motor

Low Battery

Voltage

Engine Cold

Incomplete

Combustion

Over Fueling

Injector

Excessive

Oil Level

BLUE SMOKE

Replace

Fuel Filter

Check

Fuel Level

Air in

Fuel System

Check Safety

Shutdowns

And Fuel Solenoid

Insufficient

Fuel to Engine

No Visible

Exhaust Smoke

Check

Fuel Pump

ENGINE RUNS ROUGH OR SLOW

Excessive Exhaust Smoke

BLACK SMOKE

Dirty Air Filter

Engine Overheated

Engine Overloaded

Clogged Muffler

Over Fueling Injector

High Altitude

GREY/WHITE SMOKE

Glow Plug Circuit

Not Operating

Excessive

Oil Consumption

Check Main

Breakers are

“

”

Check Brushes

Applicable

ZERO or LOW

VOLTAGE

Main Coil

Output to

Breakers

Turn “ON”

Breaker / s

BAD

Wiring To

Panel

Defective

Breaker / s

Check Ohm’s

On Main

Stator Leads

Replace

Stator Check Rotor

Ohm’s

OFF

OKBAD

VOLTAGE TEST

Zero

Low Volta

High

Voltage

Overload Output

Voltage

Check

Main Breaker / s

On Generator

Check

Regulator

Check AMP

Draw

From equipment

Check

Gen End

OVERLOAD CONDITION

Check AMP Draw

heck Load

Engine Problem

See Engine

Troubleshooting

Check

Stator Coil

Resistance

lace Stator

KUBOTA

12Volt DC POWER CONTROL MODULE

WIRING SCHEMATIC

PG 1 OPERATORS MANUAL Cover Sheet CD7 8000 CD7000 CD 7 8

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