Power Tech Generators PT-10KSIC Manual

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WARNING:
Breathing diesel engine exhaust exposes you to chemicals known to the
State of California to cause cancer and birth defects or other
reproductive harm.
Always start and operate the engine in a well-ventilated area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel
WARNING:
This product can expose you to chemicals including carbon monoxide
and benzene, which are known to the State of California to cause cancer
and birth defects or other reproductive harm.
For more information go to www.P65Warnings.ca.gov.

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Table of Contents .......................................................................................................................................... 3
Foreword ....................................................................................................................................................... 5
Safety ............................................................................................................................................................ 6
Safety Notes .............................................................................................................................................. 6
Operating Safety ....................................................................................................................................... 7
Accidental Start-up ................................................................................................................................ 7
Moving Parts ......................................................................................................................................... 8
Fire ........................................................................................................................................................ 8
Engine Exhaust ..................................................................................................................................... 9
Voltage Hazard.................................................................................................................................... 10
Burn Hazard ........................................................................................................................................ 11
Information .................................................................................................................................................. 12
Specifications .......................................................................................................................................... 12
Component Locations ............................................................................................................................. 13
The PTG Series Controller .......................................................................................................................... 16
Introduction.............................................................................................................................................. 16
Interface .................................................................................................................................................. 16
LCD Display ........................................................................................................................................ 16
LED Status Light ................................................................................................................................. 17
Buttons ................................................................................................................................................ 17
Modes .................................................................................................................................................. 18
Controller Operation ................................................................................................................................ 18
Viewing Parameters ............................................................................................................................ 18
Event History ....................................................................................................................................... 19
Operating the Generator Set ....................................................................................................................... 20
Pre-Start .................................................................................................................................................. 20
Manually Starting the Generator Set ....................................................................................................... 20
Remote and Auto Starting the Generator Set ......................................................................................... 21
Manually Shutting Down the Generator Set ............................................................................................ 21
Maintenance ................................................................................................................................................ 22
Maintenance Schedule ............................................................................................................................ 23
Engine Oil Maintenance .......................................................................................................................... 24
Lubricating Oil Specifications .............................................................................................................. 24

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Checking the Engine Oil Level ............................................................................................................ 24
Changing the Engine Oil and Filter ..................................................................................................... 25
Cooling System Maintenance ................................................................................................................. 26
Coolant Specifications ......................................................................................................................... 26
Checking the Coolant .......................................................................................................................... 27
Changing the Coolant ......................................................................................................................... 28
Cleaning the Radiator Core ................................................................................................................. 29
Fuel System Maintenance ....................................................................................................................... 30
Fuel Pump ........................................................................................................................................... 30
Fuel Lines ............................................................................................................................................ 30
Fuel Specifications .............................................................................................................................. 30
Bleeding the Fuel System ................................................................................................................... 31
Changing the Fuel Filters .................................................................................................................... 32
Air Intake System Maintenance .............................................................................................................. 34
Changing the Intake Air Filter .............................................................................................................. 34
Service Log ................................................................................................................................................. 35
Basic Troubleshooting ................................................................................................................................. 36
Wiring Diagrams .......................................................................................................................................... 37
120/240 VAC – A Type Generator End with AS440 AVR ....................................................................... 37
120VAC Only– CE Type Generator End with VR3.1B AVR ................................................................... 38
120/240VAC – CE Type Generator End with VR3.1B AVR .................................................................... 39
Control Wiring with PTG350 Controller ................................................................................................... 40
Revisions ..................................................................................................................................................... 41

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Thank you for your purchase of a Power Tech generator set. It is engineered to the utmost quality
standards, manufactured in a strict quality control environment, and will assure you a long, satisfactory
service. To have the best performance from your Power Tech generator, please fully read and
understand this manual.
This manual is written to provide you with the information you need to safely operate and maintain your
generator. This manual was up to date at time of printing/downloading, due to our continuous
improvement of our products, we reserve the right to change the information contained in this manual
without notice.
Power Tech recommends the use of only genuine Power Tech parts. Other parts may not perform as
well, may damage the generator set, and may result in injury. In addition, the use of other parts may void
your warranty.
For technical questions on your generator please contact your sales dealer, one of our authorized service
centers or Power Tech’s Customer Service Department at 1-800-760-0027. To expedite your call, please
have the generator model and serial numbers available.
For service parts, please contact Power Tech’s Parts Department at 1-800-760-0027 or order directly
from our website at www.powertechgenerators.com.
634 SR 44 W.
Leesburg, FL 34748
Toll Free: 800-760-0027
Fax: [phone]
www.powertechgenerators.com

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SAFETY NOTES
This symbol indicates a safety alert. It is used to indicate potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury and death.
This manual has several types of safety precautions and instructions: DANGER, WARNING, CAUTION,
NOTICE, and Note.
DANGER
Danger indicates the presence of a hazard that will cause severe personal injury, death, or
substantial property damage.
WARNING
Warning indicates the presence of a hazard that can cause severe personal injury, death, or
substantial property damage.
CAUTION
Caution indicates the presence of a hazard that will or can cause minor personal injury or property
damage.
NOTICE
Notice communicates installation, operation, or maintenance information that is safety related but not
hazard related.
Note
Note indicates additional important or helpful information.

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OPERATING SAFETY
Before operating this generator, be sure to read and understand all instructions. This
generator set has been designed for safe operation in a specific application. DO NOT
modify or use this generator set for any application other than that it has been designed for.
Improper usage can cause damage, injury, or death. All installation and service work must
be performed by properly trained and qualified personnel. Electrical installation,
troubleshooting, and repair should only be performed by a qualified electrician.
The following guidelines should always be obeyed.
 Read, understand and follow all safety precautions and warnings before operating the generator
set.
 Be sure to read and follow all safety decals affixed to the generator set.
 DO NOT modify the generator set. Unauthorized modifications may affect the life of the generator
set; as well as, result in injury or death.
 The area around the generator set should be clean and free of debris.
 DO NOT operate machinery or equipment while under the influence of alcohol, medication, other
drugs, or while fatigued.
 When connecting the generator set, be sure to follow any local, state, and National Electric Code
(NEC) guidelines.
Accidental Start-up
This generator set may start without warning. While in operation, there may be exposed moving parts.
 Before working on the generator set or connected equipment, ensure the generator set is
disabled. The genset may be disabled by first properly shutting down the generators set. Next,
disconnect the battery cables, negative (-) lead first, and/or turn the battery disconnect switch (if
equipped) to the OFF position.
WARNING
Accidental start-up.
Can cause severe injury or death.
DANGER
Moving Parts.
Will cause severe injury or death.

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Moving Parts
While in operation, there may be exposed moving parts.
 DO NOT wear loose, torn, or bulky clothing around the generator set.
 Be sure all guards and shields are in place before operating the generator set.
 Keep your hands and body away from all rotating parts, such as cooling fan, belts, pulleys, etc.
 Stop and disable the generator set before servicing.
Fire
A fire can cause severe injury or death. To reduce the risk of fire:
 DO NOT smoke near the fuel system or fuel tank.
 DO NOT operate the generator set in the vicinity of spilled fuels or flammable vapors.
 DO NOT operate the generator set in the presence of fuel leaks, fuel accumulation, or other
flammable materials.
 Keep the engine and engine bay clean and free of accumulated dirt, grease, and trash.
 Keep the genset idling for 5-6 minutes before stopping. Temperatures around the genset may
increase suddenly.
 DO NOT fill the fuel tank near open flames or while smoking.
 Shut down the generator set and allow it to cool before fueling.
 DO NOT run the generator set with a damaged, loose, or missing fuel cap.
 If fuel or lubricants spill, clean up immediately and properly dispose of.
 DO NOT attempt to use ether or other starting aids. Doing so may cause a flash fire and/or
damage the engine.
 Inspect and replace any damaged wiring if necessary.
DANGER
Moving Parts.
Will cause severe injury or death.
WARNING
Risk of Fire
Can cause severe injury or death.

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Engine Exhaust
During operation, the generator set will release engine exhaust into the surrounding atmosphere. This
exhaust contains carbon monoxide, an odorless, colorless, tasteless, nonirritating gas. The inhalation of
carbon monoxide, even for a short period, can result in death. To reduce the risk of carbon monoxide
poisoning:
 Avoid breathing engine exhaust while working on or around the generator set.
 DO NOT run the generator indoors unless the exhaust is routed outside properly.
 Routinely inspect the exhaust system for leaks and repair if necessary.
 DO NOT operate the generator set where exhaust fumes can accumulate and/or leak into an
occupied space.
 DO NOT operate the generator set without a properly functioning exhaust system.
Carbon monoxide poisoning symptoms include the following:
 Dizziness, Light Headedness
 Physical Fatigue
 Weakness in muscles and joints
 Sleepiness
 Inability to Concentrate
 Mental Fatigue
 Blurred Vision
 Inability to Speak Clearly
 Stomachache, Nausea, and/or Vomiting
If you experience any of these symptoms, immediately seek fresh air. Remain active and do not sit, lie
down, or fall asleep. Seek immediate medical attention if the symptoms do not improve when breathing
fresh air.
WARNING
Carbon Monoxide
Can cause severe nausea,
fainting, or death.

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Voltage Hazard
Whenever electricity is present, there is an electrocution risk. Following proper safety procedures can
reduce the risk of electrocution.
 When connecting the generator set, be sure to follow any local, state, and National Electric Code
(NEC) guidelines.
 Shut down the generator set and turn off all breakers before servicing the unit.
 Never make electrical connections while standing in water or on wet ground.
 Use extreme caution when testing voltage. It is advisable to have a trained and qualified person
take the measurements.
 Inspect and replace any damaged wiring if necessary.
 Make sure all electrical covers are in place before operating the genset.
WARNING
Hazardous Voltage
Backfeed to the utility system can
cause property damage, severe
injury, or death.
Whenever the generator set is connected as standby power, a transfer switch is required to prevent
electrical backfeed into the utility electrical grid. Electrical backfeed is illegal and can result in the severe
injury or death of utility company personnel working on power lines. The generator set must be installed
following local, state, and National Electric Code (NEC) guidelines.
DANGER
Hazardous Voltage
Will cause severe injury or death.

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Burn Hazard
WARNING
Hot Coolant and Steam
Can cause severe injury or death.
During operation, some components of the generator set can become extremely hot. These parts
include, but are not limited to, the engine, exhaust manifold and piping, muffler, generator end, and
voltage regulator. In addition, the engine coolant can become extremely hot and cause pressure to build
up in the cooling system. Removing the pressure cap, before allowing the generator set to cool down,
could cause hot coolant and/or steam to be released, resulting in severe injury or death.
 DO NOT touch or lean against hot exhaust or engine components.
 Allow the generator set to cool down completely before servicing.
 Never make electrical connections while standing in water or on wet ground.
WARNING
Hot Engine and Exhaust System
Can cause severe injury or death.

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SPECIFICATIONS
ENGINE
Make Kubota
Model V1505
Cylinders 4
Aspiration Natural Aspiration
EPA Tier Tier 4
HP @ 1800rpm (Continuous Duty) 18.0
Approximate Fuel Consumption 0.47 gal/hr @ ½ Load
1.1 gal/hr @ Full Load
Starting Voltage 12VDC
Battery Cable Gauge 2 AWG Minimum
Oil Capacity Approx. 4.5 Qts (4.3 L)
Cooling System Capacity Approx. 6.5 Qts (6.1 L)
GENERATOR
Generator Type Brushless with Automatic Voltage
Regulator
Generator Output
(Continuous Prime)
PT-10KSIC 10000W @ 60Hz
8300W @ 50Hz (Optional)
PT-12KSIC 12000W @ 60Hz
10000W @ 50Hz (Optional)
MAINTENANCE PARTS
Replacement Air Filter Element 04FA221
Replacement Primary Fuel Filter 08FF17
Replacement Inline Fuel Filter 08FFG17B
Replacement Oil Filter 01FO05S
These and other additional parts available at powertechgenerators.com.

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COMPONENT LOCATIONS

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INTRODUCTION
This generator set is equipped with Power Tech’s advanced PTG series electronic generator controller.
The PTG series controller provides manual and remote starting capability, as well as, other options such
as auto start on low battery and generator exercising. In addition to starting and shutting down the
generator set, the PTG controller monitors and displays engine and generator parameters, such as,
operating hours, engine speed, engine temperature, oil pressure, battery voltage, generator voltage and
frequency. The PTG series controller is also capable of displaying and storing Diagnostic Trouble Codes
(DTC) and faults.
INTERFACE
LCD Display
The LCD display is the primary source of information on the controller. The LCD display allows you to
view and change settings, monitor engine sensors, and monitor generator output.

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LED Status Light
In addition to the LCD Display, the PTG series controller also has a Status LED on the front face. The
Status LED color changes to show the status of the generator set.
 Green = Engine running with no issues
 Amber = Engine running with one or more warnings
 Red = Engine shut down for a failure
Buttons
The PTG series controller is controlled by the 6 buttons on the front face. The function of each buttons is
described in the following chart.
Item Name Description
OFF Button Used for turning off the generator set or exiting out of
AUTO mode.
NOTE: The OFF button is not intended to function as
an Emergency Stop. There are conditions in which it
will not shutdown the generator set.
AUTO Button Used for placing the controller into AUTO mode. Once
in AUTO mode the controller waits for a start
command to be received.
RUN Button Used to start the engine manually. The OFF button
must be used to shut down the engine if manually
started from front panel.
UP Button Used for moving around in the menu, changing a
settings value, or changing the currently displayed
parameter page.
ENTER Button Used for entering the menu system, accepting
settings, or locking the LCD screen when viewing
parameters.
DOWN Button Used for moving around in the menu, changing a
settings value, or changing the currently displayed
parameter page.

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Modes
The following table describes the different operating modes of the controller:
Mode / State Description
OFF When in the OFF mode, the generator set is shutdown and cannot be
remotely started. The generator set can be started manually from the
local controller.
AUTO When in the AUTO mode, the controller waits to receive an external
start signal from a remote panel, transfer switch or other device.
RUNNING When the generator set is running, the controller monitors engine &
generator parameters and waits to receive a stop command.
FAILURE When a failure occurs, the controller shuts down the generator set and
displays the reason for failure. The controller must be reset using the
OFF button on the local controller. The controller cannot be reset or
started from a remote source.
CONTROLLER OPERATION
Viewing Parameters
Various engine and generator parameters can be viewed on the LCD Display. The parameters will
automatically scroll, but by pressing the UP or DOWN buttons you can scroll through to the information
you want to see. Once on the information desired, press the ENTER button to lock the screen and
prevent it from automatically scrolling. A lock icon will appear to signify that the display is locked. Press
the ENTER button again to unlock it. What parameters are displayed depends on what mode the
controller is in. If a parameter is highlighted, that indicates the parameter is outside the acceptable range
and either a warning or fault will be displayed as well.
In OFF mode, no parameters are available.
In AUTO mode, the following parameters are available:
 Battery Voltage
 Engine Temperature
 Oil Pressure
 Engine Hours
While running, the following parameters are available:
 Battery Voltage
 Engine Temperature

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 Oil Pressure
 Engine Hours (Total running time)
 Running Time (Current running time)
 Engine Speed
 AC Frequency
 Genset Voltage
Event History
The PTG series controller is capable of storing up to 150 events in the Event History. Events range from
starting and stopping to warnings and failures. Information stored in the Events History may be useful in
determining when the generator set was last run, why the generator set shut down, and other
troubleshooting.
To access the Event History:
 Press the OFF button to put the controller in OFF mode. The controller must be in the OFF mode
in order to access the Event History.
 Press the ENTER button to bring up the menu.
 Use the UP or DOWN buttons to scroll until Events History is highlighted.
 Press the ENTER button to access the Event History.
 Once in the Event History, use the UP or DOWN buttons to scroll through all the stored events.
 Press the ENTER button to exit the Event History.
Each event in the Event History entry will have the following information:
 What event number it is out of the total number of events stored. The most recent events are
displayed first and with the lowest number.
 The type of event
o EVENT = Informational items
o WARNING = A fault that needs to be corrected but did not result in a shutdown of the
generator set.
o FAILURE = A severe fault that resulted in the shutdown of the generator set. This needs
to be corrected before attempting to restart the generator set.
 A description of the event.
 The time and date the event occurred.

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PRE-START
To ensure proper and reliable operation, always inspect the generator set daily and prior to each startup.
 Verify that the engine oil level is at the correct level. Add if necessary.
 Verify that the coolant is at the correct level. Add if necessary.
 Check for leaks and/or fluids in the compartment. Clean and/or repair as necessary.
 Check fuel level in tank.
 Check battery cables and terminals are secure.
 Check battery terminals for corrosion.
 Check for water in fuel and drain if necessary.
 Check the controller for DTC codes or failures.
 Verify drive belt tension is correct.
 Inspect all hoses and belts for damage or wear. Replace if necessary.
 Inspect wiring for damage, fraying, bare spots, and proper connection. Replace if necessary.
 Ensure the area around the generator set is free of loose objects and debris.
 Verify all guards and covers are in place and securely fastened.
 Ensure the Main Set AC Circuit Breaker is in the OFF position.
 Ensure the Master Power Switch is in the OFF position.
MANUALLY STARTING THE GENERATOR SET
The generator set is capable of being started automatically, remotely and from the local controller on the
genset. The following steps are used to start the generator set manually from the local controller. Ensure
the Pre-Start checks above have been completed before attempting to start the generator set.
1. Set the Master Power Switch to the ON position. The controller will power on and boot-up to the
last start mode used.
2. Press the OFF (O) button to put the controller in MANUAL mode. The screen will display NOT
IN AUTO START ENABLED.
3. Press the RUN (I) button to start the generator set. The screen will display a PREHEATING
count down, a CRANKING countdown, and then display MANUAL RUN..
4. Allow the engine to warm up for 1-2 minutes.
5. Verify that all engine and generator output parameters are nominal.
6. Turn the Main Set AC Circuit Breaker to the ON position to start supplying power.
7. Continue to monitor the generator set during operation to ensure it is operating correctly.