POWERPAC APU

INSTALLATION MANUAL

AND

OWNERS GUIDE

Generator Model_________________________

Generator Serial #________________________

POWER TECHNOLOGY SOUTHEAST, INC.

634 STATE ROAD. 44

LEESBURG, FL. 34748-8102

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

www.PowerPacAPU.com

E-Mail PowerPac@Atlantic.net

5/2007 MANAPUCB

CONTENTS

INTRODUCTION 1-3

Forward

Requirements for Installation

Parts List

Tools Required

SAFETY ALERTS AND PRECAUTIONS 4-6

Alerts

Precautions

INSTALLING THE POWERPAC APU 7-10

Preparation of the PowerPac

Locate the PowerPac on the Frame Rail

Assemble the Mounting Clips, Bolts, and Spacers

Mounting the PowerPac to the Frame Rail

Exhaust Pipe

INSTALLING FUEL PICK-UP TUBE AND LINES 11-13

General Considerations

Install Tank Pick-up Tube

Routing and Connecting Fuel Lines

INSTALLING THE BATTERY CABLES 14

Cable Routing

Connecting to Batteries

INSTALLING THE AC POWER OUTPUT LEADS 14

Routing

Terminal Block

Connections

INSTALLING THE DRIVER CONTROL PANEL 15-16

Selecting Location

Mounting

Wiring Schematic

INSTALLING THE POWER OUTLET BOX 17

Selecting Location

Routing Wires

Connections

Mounting

INSTALLING AIRCONDITIONING AND HEATING SYSTEMS 18-20

FINISHING THE POWERPAC INSTALLATION

Check List

First Time Start Up

Purging Air from Fuel System

CONTENTS

OPERATION OF POWERPAC APU 21-24

Starting and Stopping the PowerPac APU

Daily Checks and Maintenance Schedule

Powering Appliance and Auxiliary Systems

ENGINE SPECIFICATIONS 25

Model

Service Parts List

POWERPAC APU MAINTENANCE 26-29

Engine Maintenance Service Schedule

Engine Specifications and Service Parts

Checking Engine Oil

Lubricating Oil Specifications

Lubricating Oil Capacities

Lubricating Oil and Filter Change

Coolant Recommendations

Checking Coolant Level

Checking Recovery Tank Coolant Level

Cleaning Radiator Core

Fuel Filter Change

Air Filter Change

Fan Belt Check

Generator Drive Belt

INSTALLING THE SHORE POWER 30-33

TRANFER SWITCH (OPTIONAL)

Transfer Switch Operation

Location and Wiring Transfer Switch

Wiring Schematic

INSTALLING THE KEY-LESS REMOTE 34-35

START SYSTEM (OPTIONAL)

System Components

Programming a New Remote Control Transmitter

Programming an Extra Remote Transmitter

WIRING DIAGRAMS 36-38

PowerPac APU – PCM Wiring Schematics

AC Electrical Circuit

Circuit Breaker Location

POWER CONTROL MODULE PCM and DISPLAY PCMD 39-42

TROUBLESHOOTING GUIDES 43-49

Engine Troubleshooting

Generator Troubleshooting

WARRANTY INFORMATION 50

Power Technology Southeast, Inc. Limited Warranty

INTRODUCTION

You are now the proud owner of a PowerPac APU Idle Reduction System.

The PowerPac is an auxiliary power unit designed to operate completely separate

from your main truck systems. It provides 120 volts AC to power an electric air-

conditioning and heating unit. The PowerPac also provides AC power for use with

other devices such as, television, coffee makers

VCRs, engine block heater and other appliances that add comfort to every day life.

FORWARD

This PowerPac APU System is a product of Power Technology Southeast. Inc.

PowerPac APU systems are made with the finest materials and manufactured under the

strictest quality control standards to assure you long satisfactory service.

To obtain the best results from your PowerPac APU system, please read and

follow this manual carefully. It will help you become familiar with the operation of the

system and contains many helpful hints regarding use and maintenance.

This manual was written to assist with the installation of the PowerPac APU.

Although the manual is not specific to any particular vehicle, the information in this

manual will provide the installer with the necessary information to correctly and safely

install the unit. The PowerPac APU can be easily installed by a qualified mechanic. The

installer must also have a basic understanding of electricity and electrical wiring.

Use this manual as a guide when installing the PowerPac APU system, and then

refer to the appropriate operation section for specific instructions. The installation of a

PowerPac APU system shall comply with current standards of NFPA 70, NFPA 551, and

applicable articles of the National Electric Code. Generator set installations must also

comply with state and local requirements.

Follow all instructions in this manual to ensure proper installation and operation.

Each generator set features a dependable Kubota or Caterpillar diesel engine, rotating-

field alternating current generator, and an ECU engine controller. Located on the unit

mounted Control Box is an on/off switch to reset the controller or lockout the remote

switch to prevent accidental starting while servicing the unit.

1

After the set is attached to the frame of the vehicle, all that is usually required to

make it operational are the following.

Install the fuel pick-up tube assembly

Route and install fuel lines

Install and connect remote panel

Attach Load Leads to vehicle’s AC electrical circuit

Fill radiator with coolant

Fill crankcase with lubricating oil

Connect DC battery cables.

Continuing improvements and advancements in product design may cause

changes not included in this manual. Please contact Power Technology’s Customer

Service Department for the latest information regarding your PowerPac APU system.

TO OUR CUSTOMER

Thank you for your purchase of a PowerPac APU System. The information

contained in this manual applies only to PowerPac APU Idle Reduction Systems.

In the event you should experience a problem with your system please contact the sales

dealer, authorized PowerPac APU Service Center or Power Technology’s Customer

Service Department directly at 352-365-2777 from 8:00 a.m. to 5:00 p.m. EST Monday

through Friday. Please have the system model and serial numbers available when you

call, this will help expedite service and parts to you.

POWER TECHNOLOGY SOUTHEAST, INC.

634 STATE ROAD. 44

LEESBURG, FL. 34748-8102

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

www.PowerPacAPU.com

E-Mail Power Pac@Atlantic.net

2

REQUIREMENTS FOR INSTALLATION

PARTS LIST

1 - PowerPac APU Unit

1 - Terminal block

1 - Loose Parts Bag Containing

1 - Terminal block cover

4 - ¾ x 7” mounting bolts

8 - ¾ SAE flat washers

4 - ¾ Ny-lok nuts

2 - Lower bolt slot reinforcement plates

4 - Aluminum frame clips

4 - Frame to Unit spacers

1 - Fuel pickup tube

1 - Cab mounted Start/Stop panel

1 - 1 ¼ rubber grommet

4 - #4 hose clamps

2 - Battery cable ends

2 - Heat shrink ( for battery cable ends )

8 - Sheet metal screws

20 - Wire ties

TOOLS REQUIRED

Typical mechanics tools

Drill

1 ¼” Hole saw

Tape measure

Utility knife

Tubing cutter

½” NPT Tap (for fuel pickup tube)

3/4” Drill bit or tapered drill bit (for ½” NPT tap)

Heavy grease (to keep metal shavings out of fuel tank)

Liquid thread sealant

Transmission jack, forklift or overhead hoist

3

SAFETY ALERTS AND PRECAUTIONS

A generator set can be potentially dangerous if not properly

maintained and operated. The Best safeguard against a

dangerous situation is education, good judgment and common

sense. For safe trouble free operation of your generator set

some general precautions are listed below. Be sure to read,

understand and follow these precautions.

SAFETY PRECAUTIONS

1) HOT PIPING - An engine and exhaust system may get extremely hot while

running. 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 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 the 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.

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, fan 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.

4

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 closed or secured at all times. Be sure the generator set is properly

grounded to chassis. Never touch generator 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 the 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

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 tailpipe

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 should 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 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) 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 fuel lines, fuel

filter, fuel pump or other potential source of spilled fuel or vapors.

13) 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.

5

14) UNIT STARTS WIITHOUT NOTICE - To prevent accidental starting of the unit

with remote start/stop switch, always turn the ON/OFF switch located on the set mounted

Control Box to the OFF position, then disconnect the battery by removing the negative (-)

terminal first and then the positive (+). Always disconnect the unit in this manner before

working on the generator or any equipment connected to it.

15) 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.

16) DIESEL ENGINE DAMAGE - To prevent engine damage from occurring, do not

operate the PowerPac APU before completing the installation which includes, checking

engine oil level, connecting fuel lines, checking coolant level, and making sure all

electrical connections are made.

6

CALIFORNIA

Proposition 65

Warning

Diesel Engine Exhaust and some

of its constituents are known by the

State of California to cause

Cancer, Birth Defects and Other

Reproductive harm.

INSTALLING THE POWERPAC APU

PREPERATION OF POWERPAC APU

Select the location for the Powerpac APU. Determine if you will need spacers to

clear any bolts or anything that may interfere with installing the Powerpac to the frame rail.

If spacers thicker than ½” are required, longer mounting bolts may be required for the

install. Offset mounting spacers are available to allow units to be mounted near a cross-

member, etc.

LOCATE THE POWERPAC ON THE FRAME RAIL

When choosing a location for the PowerPac APU, several things need to be

considered. Vehicles with longer wheel bases should have the PowerPac mounted closer to

the sleeper to avoid obstructions in the road such as railroad tracks, speed bumps, curbs or

anything else that may come in contact with the PowerPac. Each truck is different and may

require a different installation process. Before beginning the installation, lay out the

placement of ALL the components that will be installed. Below are some suggestions on

locations to install each component.

The Powerpac APU is designed to be mounted on the existing frame rails of the

truck. Mounting the unit on the frame rail with supplied frame clamps is the only

acceptable installation. Fabrication of another mounting rail may be unsafe with the given

weight and balance of the PowerPac APU.

DO NOT DRILL HOLES, CUT OR WELD ON THE TRACTORS FRAME RAILS!!

These procedures will VOID the tractors OEM Warranty.

Standard PowerPac APU Location: Vehicle passenger side.

This is the standard installation choice. Most drivers sleep with their head on the

drivers’ side. This application is the quietest and will less likely interfere with the drivers

sleep. Some trucks have steps to the catwalk on the drivers’ side frame rail. The passenger

side will usually have fewer obstructions.

Alternate PowerPac APU Location: Vehicle Driver Side.

This is a secondary installation location. It may be necessary to remove steps to

catwalk. Not as quiet while the driver is sleeping.

7

Air Inlet

Radiator must have free air flow with no obstructions

Radiator must be protected from grease sling

Cooling air for the APU engine and generator is drawn into the enclosure through

an air duct on right side of the unit and discharges through the lower rear panel. These

areas must remain free of any obstructions that would restrict normal air flow.

ASSEMBLE THE MOUNTING CLIPS, BOLTS, SPACERS

The Powerpac APU comes with all the hardware required for the complete

installation of the unit. The loose parts bag contains all the necessary bolts, washers, nuts,

and frame rail clips. Separate all parts to insure that you have the following: 4- Frame rail

clips, 4- ¾” x 7” bolts, 8- ¾” flat washers, 4- ¾” lock nuts, 4- ¼” thick spacers and 2-

lower bolt reinforcement plates.

Once all parts are located, put ¾” washers on all 4 bolts. Set the 4 frame rail clips

on the frame roughly where the unit will be installed. Make sure all clips slide easily onto

frame rail. If forced damage may occur to the clips.

MOUNTING THE POWERPAC TO THE FRAME

Be sure to use a forklift, transmission jack, overhead lift or other device to lift the

PowerPac. Make sure the unit is stable before trying to place it on the frame rail. Remove

the front cover. Place the PowerPac on desired location on frame rail. Start with the top and

insert the 2 - ¾” x 7” bolts through the holes on the panel closest to the frame rail. Slide the

frame clip onto bolt all the way to the frame. Place washer and nut on the bolt and run the

nut down until its snug. Place one washer and one slot reinforcement plate on each lower

bolt. Place the 2 - ¾” x 7” bolts through the holes on the underside of the frame rail.

Making sure both bottom and top bolts are level, snug up the bottom nuts. Once all 4 nuts

are snug, recheck alignment of the bolts. If all 4 bolts are straight, torque nuts to 100 foot

lbs. ONLY after all nuts are torqued should you remove the lifting device.

Note: Truck frames may vary in thickness. If the frame clamp will not fit easily onto the

truck frame rail, DO NOT use the frame clamps for mounting. Damage to the frame clamp

will occur if forced or hammered onto the truck frame rail. An alternate method of

mounting the APU to the truck frame rail is to use a pair of heavy steel bars 3/8” thick x

2”wide minimum. The length of the steel bars will depend on the height of the truck frame

rail. Drill holes for the upper and lower mounting bolts to match the height of the truck

frame rail.

8

Air Outlet

Make sure the bolt length is

sufficient to allow for at least

1 full thread to protrude through

the Ny-Lok nut. Bolts may be installed

in either direction to avoid obstructions.

NOTE:

Installing the lower left bolt with the

head of the bolt inside the enclosure

will avoid interference with the exhaust

flex pipe.

Aluminum Frame Clamp

Place the 2 – ¾” x 7” bolts through the holes on the underside of the frame rail. Making sure

both bottom and top bolts are level, then snug up the bottom nuts.

Securely mounted bottom Frame Clamp

9

EXHAUST PIPE

Maintain a minimum 3” clearance between any exhaust components and any

surrounding combustible materials. If the minimum clearance cannot be met an insulating

shield designed for exhaust components must be used. Extend the exhaust outlet a

minimum of 1” past the perimeter of the vehicle. The exhaust system CANNOT be

terminated under the vehicle chassis. Exhaust outlet must be in a position, which prevents

exhaust gases from entering the living quarters. The exhaust system should be routed in a

manner, which eliminates the possibility of re-circulation into the APU enclosure.

A skid plate may be installed to protect the APU and exhaust system from road hazards.

Joining the APU exhaust together with the trucks main exhaust may cause irreparable harm

pleases consult with Power Tech prior to making any such connections.

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,

to 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.

10

INSTALLING THE FUEL TUBES AND LINES

The diesel fuel system for the PowerPac APU must be designed to operate

independently from the vehicles main engine. In most installations both engines operate

from a common fuel tank with separate pick-up tubes for each engine, not a Tee fitting

arrangement. This prevents either or both engines from being starved for fuel. The APU

fuel pick-up tube should be shorter than the vehicles; therefore fuel may not be available

to the APU when fuel supply is low. This will prevent the APU from depleting the fuel

supply needed by the main drive engine.

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

recommended. This practice may possibly 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

possibly cause a failure of the APU’s fuel lines or connectors and a hazardous fuel leak

may occur.

Care must be taken when routing the fuel lines from the main tank to the APU. Keep

the fuel line as short as possible while maintaining adequate clearance from the exhaust

system and moving components. Fuel lines must be run along the frame side rails or

under carriage. Never run fuel lines inside the cab. Securely fasten the fuel lines with the

hardware that is recommended for the type of fuel line that is used. Allow a minimum of

8 inches of flexible fuel line to make the connection.

Fuel Pick-up Tube Assembly

Fuel Pick-up should be at least 3” shorter

than the depth of the fuel tank. Measure

the fuel tank and cut pick-up tubes to

desired length. Carefully bend the 3/16”

return tube 3” to 4” away from the supply

tube. Pull both tubes together and insert

into tank. Return tube will spring back to

the bent position. Tighten fitting and attach

fuel hoses.

11

GENERAL CONSIDERATIONS

Diesel fuel vapors can be very explosive. Use caution when

working in or around the area of the fuel tank.

Before drilling into a fuel tank it is recommended to drain all fuel

from the tank.

Be very careful when drilling into a fuel tank. Sparks can be

caused by an electric drill or a drill bit that may cause an explosion. (SUGGESTION)

Apply heavy grease around the holes when drilling and tapping into fuel tank to keep

metal shavings from falling into fuel tank.

DO NOT SMOKE WHILE WORKING NEAR FUEL TANK.

VERY IMPORTANT!! Check fuel tank for baffles and gauge arms before drilling into

fuel tank. A fuel pick-up could interfere with the floats and render your fuel gauge

inoperable.

12

Tools Required for Fuel Pick-Up Installation

Tape Measure Tubing Cutter

Drill Heavy Grease

¼” Drill Bit Thread sealant

Step Reamer Bit or ¾” Drill Bit ½” NPT Tap

INSTALL TANK PICK-UP

After checking for baffles and fuel gauge linkage, pick a spot on fuel tank for the fuel

pick-up tubes (usually top center of tank on end closest to the APU). Apply heavy grease

to spot where hole is to be drilled. The grease will help keep metal shavings out of fuel

tank. Drill a ¼” pilot hole. You may want to use several different drill bit sizes to get up

to the ¾” bit required for the fuel pick-up tube. Once you have a ¾” hole, clean all metal

shavings from the hole. Reapply heavy grease and using the ½” NPT tap the threads for

the fuel pick-up tube. Clean area very thoroughly. Determine the length needed for the

pick-up tube. The recommended length for the pick-up tube is 3” shorter than the depth

of the fuel tank. Cut pick-up tube to length needed. Carefully bend the 3/16” return tube

3” to 4” away from the supply tube. Pull both tubes together and insert into tank. Return

tube will spring back to the bent position. Apply thread sealant to the threads of the pick-

up tube and screw into fuel tank. Be sure that pick-up tube connections are suitably

positioned to allow connecting the fuel hoses and clamps.

ROUTING AND CONNECTING THE FUEL LINES

Care must be taken when routing the fuel lines. You must route lines so they can

be strapped securely and in a way that they will not come into contact with anything hot,

or any moving components. Suggested routing of fuel lines is as follows: Lines coming

out of the PowerPac, Run up into the inside of frame rails. Strap lines either to the

backside of the unit, or at first bend in the frame rail. Run along the inside of the frame

rail until you reach the fuel tank and the fuel pick-up tubes. Be sure that you have no

kinks in the line and that the line is run away from anything abrasive. Strap fuel lines

securely with tie straps or clamps.

Once fuel line is secure, cut the fuel lines to desired length with a hose cutter or

utility knife. Trim the hose loom back approximately 1 ½”. There are 2 different size

hoses. The 5/16 hose is for fuel supply and the 3/16 hose is for fuel return. Place 2 - #4

hose clamps (provided) on the end of the 5/16-fuel line and slip onto the larger of the two

tubes on the fuel pick-up tube. Tighten both clamps on the 5/16-fuel line. Once the

supply line is secure, do the same with the 3/16 return line. Make sure all 4 clamps are

secure.

13

INSTALLING THE BATTERY CABLES

IMPORTANT! DO NOT CONNECT BATTERY POSITIVE CABLE UNTIL

THE POWERPAC UNIT IS READY TO BE TEST RUN.

Turn the main power switch on the PowerPac APU to the OFF position to ensure

the unit will not start prematurely.

Route the positive and negative battery cables from the PowerPac APU to the

batteries. Cut battery cables to desired length. Strip the insulation on both cables back

about ½”. Slide heat shrink over the end of the cables. Place copper connector

onto the end of the positive cable and crimp with a crimping tool. Slide heat shrink

up over the crimped spot on the connector and apply heat to heat shrink. Use the same

procedure on the negative battery cable.

Be sure the areas where the battery cables are to be connected are clean and free

of debris that may cause a bad connection. DO NOT connect the positive battery cable

until the installation is complete.

ROUTING AC POWER WIRES AND REMOTE CONTROL WIRES

The remote start wires should be routed with the AC output wires. Make sure the

remote wires are secured inside the frame rail. Run the remote start wires through the

same grommet used for the AC power cable. Secure harness using wire ties. Route the

harness to the location where the control panel will be mounted.

INSTALLING THE AC POWER OUTPUT WIRES

The AC power output wires (SO cord / cable) should be routed in a way that they

will not come into contact with anything abrasive. Suggested routing of the power cable

is, run the loose end of the cable up to the frame rail. Clamp or tie the cable. Run the

cable inside the frame rail making sure they are secured. Once under the cab, route cable

to the underside of the bunk area.

Inside the sleeper, lift bunk, determine where the heating and air conditioner unit

will be installed (see section on installing heating and air conditioner) locate an area to

mount the terminal block. The terminal block will be the central power connection from

the APU. Once desired location is determined, use a 1 ¼” hole saw to make a hole for the

AC output leads to come into the sleeper area. After hole is drilled, place 1 ¼” grommet

in the hole to assure that chaffing doesn’t occur. Run AC output leads through this

grommet. Secure the terminal block to the floor using the screws provided.

NOTE: To prevent cracking the terminal block, mount to a hard flat surface.

14

INSTALLING THE DRIVER CONTROL PANEL

SELECTING LOCATION

The Driver control panel incorporates the PCMD which can be outfitted with an

optional Thermostat and or Timer. The PCMD controls and monitors the PowerPac

APU’s functions. The control panel should be conveniently mounted in the sleeper for

easy access to the occupant. Once the location is determined, plug the keyed Molex

connector from the wiring harness into the back of the PCMD, then fasten the control

panel with the screws provided. (See wiring schematic for connecting optional

Thermostat and Timer)

Standard PCMD

PCMD With Optional Thermostat and Timer

PCMD With Optional Timer

15

PCMD With Optional Thermostat

IMPORTANT:

The thermostat set point of the Air Conditioning / Heating system must be set

LOWER then the set point of the APU’s thermostat, located on the Driver

Control Panel. This applies when using either the A/C or Heating.

16

PCMD WIRING SCHEMATIC

with

OPTIONAL THERMOSTAT and TIMER

INSTALLING THE POWER OUTLET BOX

SELECT LOCATION

Determine the location for the AC power outlet box. It should be mounted where the

driver has easy access to the outlets. Consideration should be taken as to the devices the

driver will need AC power for such as, Television, microwave, refrigerator etc.

Suggestion, mount the outlet box where most of the appliances a driver may use will be

within reach of the outlets without the use of extension chords.

ROUTING WIRES

Once location has been chosen for the power outlet box, route the wires back to the

terminal block making sure the wires are secured with wire ties or clamps. These wires

should be run in a way that they will not interfere with anything under the bunk and clear

of anything abrasive.

CONNECTIONS

Once wires are secured connections for the AC power can be made. Cut the outlet box

cord to the desired length. Carefully remove approximately 2” to 2 ½” of the outer jacket

from the cord. Separate the 3 wires and crimp the appropriate terminal connector to each

wire. Connect the black positive (+) wire to the black wire on the terminal block. Connect

the white wire to the white wire on the terminal block and the green wire to the ground

(green) wire on the terminal block.

MOUNTING THE POWER OUTLET BOX

Secure the power outlet box to desired location with the screws provided.

Red Wire- 30 Amp circuit for Heating / Air Conditioner unit.

Black Wire- 20 Amp circuit for Driver’s comfort appliances, and

Engine Block heater if equipped.

White Wire- AC Neutral

Green Wire- Ground 17

INSTALLING THE AIR CONDITIONING AND HEATING SYSTEM

The PowerPac APU system uses a heating and air conditioning unit manufactured

by the Dometic corporation. A complete installation manual is with the heating and air

conditioning system. Use this manual to successfully install the heating and air

conditioner unit.

When making electrical connections for the heating and air conditioning system,

be sure to use the RED wire on the terminal block to power the system. The white and

green wires will be connected to the terminals along with the power outlet box white and

green wires. It is VERY IMPORTANT these connections be made this way to prevent

overload to a single circuit. Make certain all connections are tight and secure.

Once all connections are made, install the terminal block cover using the screws

provided.

FINISHING THE POWERPAC INSTALLATION

CHECK LIST

Unit is securely mounted to vehicle

All fasteners are torque to specification

Fuel lines are properly secured

Battery cables are properly secured

Power cable is properly secured

Cables and fuel lines are away from moving components

Cables and fuel lines are away from exhaust

Fuel lines are double clamped and all clamps are tight

All AC power connections are complete and tight

Driver control panel installation is complete

Power outlet box installation is complete

Heating and Air conditioner installation is complete

18

FIRST TIME START UP

Before starting the PowerPac APU:

Check oil level in the PowerPac

Check coolant level

Make sure all electrical connections are complete

Make sure fuel lines are connected and contain no kinks

Make sure driver control panel Start/Stop switch is in OFF position

Make sure the main power switch in the control box on the APU is in OFF position

Connect the positive cable from the PowerPac to the truck battery

Purge all air from fuel system (See Below)

Check that Air Conditioner / Heater and all AC loads are Turned OFF.

IMPORTANT: Purging Air from Fuel System

Before starting the PowerPac APU for the first time it is important to purge the

fuel system of all air trapped in the fuel lines. To do this disconnect the Positive +

terminal of the electric fuel pump from the wiring harness and jumper it to a +12V DC

source (Positive + Battery post or the “B” terminal of the Alternator). The pump will

begin pumping fuel and force any trapped air out through the return line. Continue

pumping fuel through the system for 1 minute. Disconnect the jumper wire and reconnect

the Positive + terminal of the fuel pump to the wiring harness. The PowerPac APU is

now ready to start.

Turn the main power switch located on the control box inside the APU to the ON

position. Inside the truck, turn the driver’s control switch to the ON position. The APU

will begin the pre-heat and engine cranking cycle.

WARNING: Be careful of moving parts!!!

Once the engine has started, check the PowerPac for coolant, fuel, oil and exhaust

leaks. Place the PowerPac cover on the unit.

IMPORTANT!! DO NOT run the unit without the front cover for longer than 5

minutes. The front cover is necessary for efficient cooling system performance. Damage

may occur from over heating if the unit is allowed to run with the cover removed.

With a multi-meter, check the voltage at the AC power outlet box in the sleeper of

the truck. Voltage should read between 120 to 125 volts AC. Check the DC voltage at the

batteries to ensure the PowerPac is recharging the truck batteries.

Allow PowerPac to run for approximately 10 minutes and check again for

coolant, oil, fuel and exhaust leaks. After checking the PowerPac over thoroughly, test

the heating and air conditioning unit for proper operation. Allow the PowerPac to run for

30 minutes with the heating and air conditioning unit in operation. This will put a load on

the PowerPac and allow the unit to build up more heat. At the end of the 30-minute time

period, turn the heating and air conditioning unit off and push the driver control panel

switch for the PowerPac to the OFF Position. Remove the front cover and check for

coolant leaks. If no leaks are visible, replace front cover.

19

Congratulations, The installation is complete.

20

Starting and Stopping the PowerPac APU

CHECK BEFORE OPERATING THE ENGINE If the engine is malfunctioning DO NOT operate until repairs

are made.

Be sure cover, guards and shields are in place before operating

the engine. Replace any that are damaged or missing.

Check to see that the area around the engine is clear of foreign

objects before starting.

DO NOT allow children or animals to approach the APU

while in operation.

DO NOT start the engine by shorting across starter terminals.

Engine Starting Controls

PowerPac Main switch (located on the internal control box on the APU) must

be in ON position.

NOTE: This switch should be in the ON position except when performing

maintenance or to prevent starting for any reason.

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.

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.

21

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).

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 ECU 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.

Stopping the Engine

NOTE: It is recommended to disconnect or reduce the power load by turning off

appliances before shutting down the engine.

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.

Powering Appliances and Auxiliary Systems

Once the PowerPac APU is running, you will have AC power through the power

outlet box. Plug devices such as television, DVD player, cell phone charger etc. directly

into outlet.

For the heating and air conditioning system please refer to the user’s guide

supplied with the heating and air conditioning system.

IMPORTANT: Damage to starter motor, starter solenoid, run solenoid or any generator

component due to excessive or prolonged starting attempts, or attributed to an external

low battery control monitoring or auto start system not approved by Power Technology

SE Inc. will not be covered by the Power Technology SE inc. limited warranty.

22

OPERATION OF THE POWERPAC UNIT

Engine Break-in Period

During the engine break-in period, first 50 hours of operation observe the following

recommendations:

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

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

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 Checks and Maintenance Schedule

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 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 gases/smoke

23

APPLIANCE LOADS

APU’s maybe used to supply AC voltage for appliances. With the exception of a

resistance-type load such as a heating element, requirements for appliances are usually

low. However, such loads must not be overlooked when calculating the total wattage

requirements. To avoid an overload situation, reserve capacity should also be calculated

for unanticipated appliance loads. The average power requirements for some common

electrical appliances are listed below as a guide. PowerPac APU’s have 2400 watts

available to power appliance loads.

DETERMINING ALTERNATOR LOAD REQUIREMENTS

CHECK

APPLIANCE WATTS REQUIRED

VCR / DVD 70

LIGHT BULB 100

RADIO 100

TELEVISION 100

STEREO 100

FRY PAN 150

HOME COMPUTER 150

REFRIGERATOR 500

TOASTER 1000

COFFEE MAKER 1200

HAIR DRYER 1200

MICROWAVE OVEN 1500

10,000 BTU A/C UNIT – COOLING 1500

10,000 BTU A/C UNIT – HEATING 2300

14,000 BTU A/C UNIT – COOLING 1900

14,000 BTU A/C UNIT - HEATING 2900

TOTAL

WATTS CHECKED

NOTE: 120 Volts x Amps = Watts

EXTENSION CORDS

An extension cord is normally used to provide electrical power from the APU 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 APU and remote location.

AMPSLOAD IN WATTS CORD LENGTH

120 VOLTS AWG#10 AWG#12 AWG#14

5 600 500 FT 300 FT 200 FT

10 1200 250 FT 150 FT 100 FT

20 2400 125 FT 75 FT 50 FT

30 3600 60 FT 35 FT 25 FT

24

ENGINE SPECIFICATIONS

ENGINE MODEL KUBOTA Z - 482 CATERPILLAR CO.5

Continuous Output 8.5 HP @ 2800 rpm 8.5 HP @ 2800 rpm

*Fuel and type Diesel, 4 cycle Diesel, 4 cycle

Cylinder Arrangement 2 In-line 2 In-line

Bore and Stroke 2.64 x 2.69 (67 x 68mm) 2.64 x 2.83 (67 x 72mm)

Cubic Capacity 29.23in3

(.479L) 31 in³ (.507L)

Compression Ratio 21:1 23:1

Engine oil Capacity 3.7 quarts (3.5L) 3.7 quarts (3.5L)

Coolant System Capacity 5 quarts (4.7L) 5 quarts (4.7L)

*15% Bio Diesel is an approved fuel for these engines.

SERVICE PARTS

Oil Filters: Power Pac 01F0091 PowerPac 01FOC

Kubota 70000-32091

Fuel Filters: PowerPac 08FFER12T PowerPac 08FFER12T

Racor R12T Racor R12T

Air Filters: PowerPac 04FA221 PowerPac 04FA2SE1

Engine Air 2SE1

Belts:

Generator Drive Belt PowerPac 03BELT5KW PowerPac 03BELT5KW

Fan Belt PowerPac 03BF5K PowerPac 03BF5C

Kubota 17594-9701 Caterpillar 183-3942

The APU Serial# Plate provides information on Engine Model, Service Parts, etc.

NOTE: If the Generator Drive Belt fails after the Initial Warranty Period, it will be replaced free

of charge (Belt Only). Return the defective belt, shipping prepaid to Power Technology to receive

a free replacement belt.

A spare generator drive belt maybe purchased from Power Technology if desired.

25

APU Maintenance Service Schedule

NOTE:

* Engine oil and filter must be changed after the first 50 hours of operation. Then every 500

hours or once a year whichever comes first.

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

may require frequent service.

*** Poor fuel quality may require frequent filter replacements.

NOTE: Under normal operation items such as Fan Belt, Hoses and Filters (Except for Generator

Drive Belt) are not covered by Power Technology Southeast, Inc. Limited Warranty.

26

Maintenance

Service Item

See

Note

Check

Daily

Every 500

Hours

Every 1000

Hours

Every 2000

Hours

Check Engine Oil Level

Deterioration &Leakage X

Abnormal Engine Noise X

Change Oil and Filter * X

Check Coolant Level and

Leakage X

Change Coolant X

Check Radiator Hoses and

Clamps X

Replace Radiator Hoses

and Clamps Or Every Two Years

Replace Thermostat Or Every Two Years

Clean Radiator Fins Or Once a Year

Check for Fuel Leakage X

Change Fuel Filter *** X

Replace Fuel Hoses Or Every Two Years

Change Air Filter ** X

Check Fan Belt Tension X

Replace Fan Belt X

Adjust Valve Lash X

Check Generator

Line Voltage Once a Year

Check for Abnormal

Generator Noise X

Muffler Condition X

Exhaust Gas Condition X

Check Frame Clamps and

All Fasteners X

Check Wiring Connectors X

Clean Inside Enclosure Or Once a Year

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

27

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.

Kubota Z – 482 and CAT CO.5 ENGINE

REFILL CAPACITIES

Crankcase Oil Sump Z - 482 3.7 Qts. (3.5L)

and Filter CO.5 3.7 Qts. (3.5L)

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

temperatures.

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 or Higher

After initial break-in

period synthetic oils are

approved for use. Use of

synthetic oils will not

extend required service

and change intervals.

CHANGING LUBRICATING

OIL and FILTER

Check APU Maintenance Service Schedule for required service intervals.

1. Turn OFF Main Switch located on the Control Box.

2. Open oil pan drain valve and drain oil into a suitable container for disposal.

3. Spin OFF oil filter and discard used filter.

4. Lubricate O-Ring on new oil filter and spin ON, tighten firmly by hand.

5. Close oil pan drain valve and fill engine with recommended oil to FULL mark on the dip stick.

6. Turn ON Main Switch located on the Control Box and press the Start Button located on the

driver’s Control Panel.

7. With engine running visually check for oil leaks.

8. Stop engine and check oil level and add to FULL mark on the dip stick.

ENGINE COOLANT MAINTENANCE

28

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 in the coolant

recovery tank is between the upper limit (FULL)

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

recovery 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.

SERVICE PROCEDURES

FUEL FILTER / WATER SEPARATOR

The following procedure outlines the steps required for servicing the Racor Fuel Filter / Water

Separator installed on all PowerPac APU’s. Suggested fuel filter element change at 500 hour intervals

is standard for Racor filters. Operating in adverse conditions or poor quality fuel may require frequent

filter replacements. Follow all safety guidelines when handling fuel and properly discard

contaminated fuel and used element. Avoid injury, shutdown APU and turn OFF Main Switch located

on the Control Box. Allow hot surfaces sufficient time to cool before handling.

1. Open drain valve at the bottom of the See-thru Bowl and drain fuel into a suitable container for

disposal. Open vent plug on filter head to facilitate draining if necessary.

2. Spin off filter element from filter mounting head, separate See-thru Bowl from element and

discard used element.

3. Clean out See-thru Bowl and close drain valve. Lubricate O-Ring and spin onto new filter

element, tighten firmly by hand.

4. Fill filter element and bowl with clean fuel. Lubricate element seal and spin onto filter

mounting head, tighten firmly by hand. Check vent plug and tighten.

5. Turn ON Main Switch located on the Control Box and press the Start Button located on the

drivers Control Panel.

6. With engine running visually check for fuel leaks. Correct if necessary with engine shutdown

and Main Switch in the OFF position.

AIR FILTER ELEMENT

Suggested air filter element change at 500 hours is standard, however operating in adverse

conditions may require frequent filter replacements.

1. Un-clip or un-screw end cap of air filter housing.

2. Remove used air filter element and discard.

3. Wipe clean the inside of the housing and cap.

4. Install new filter element and replace housing cap.

FAN BELT

Fan Belt tension should be checked daily to ensure proper air flow, coolant circulation and

alternator charging. Adjust fan belt tension as necessary. Replace fan belt if damaged or at 2000 hours

of operation.

1. Loosen bolt on alternator adjustment bracket.

2. Adjust fan belt tension or remove old belt.

3. Install new fan belt, adjust tension and tighten bolt on alternator adjustment bracket.

GENERATOR DRIVE BELT

INFORMATION

Power Pac APU’s utilize an exclusively engineered drive system between the engine and the

generator end. A combination of custom designed components produces a smooth and reliable drive

connection. The Poly V-Belt is specifically manufactured to Power Technology’s engineering

standards and is backed up with a Life Time Warranty. (See Warranty Page for Details)

Should the Drive Belt ever require service or replacement contact your nearest Dealer or Power

Technology’s Service Dept. at 800-760-2777.

29

INSTALLING AND WIRING THE OPTIONAL

SHORE POWER AUTO TRANSFER SWITCH

The automatic shore power transfer switch will allow the Air / Heat

and accessories to be powered from an outside 120 volt power source. Two

power cords are provided. One cord powers the Air Conditioning / Heat

circuit and one cord powers the accessories circuit.

When plugged into an external 120 volt outlet the contactors in the

switch box switch the loads from generator power to shore power.

When only one cord is plugged into 120 volt power, only that circuit

will receive power from the external power source.

See the chart below for switch operation

AC/Heat Accessories

Powered Powered

Generator Operating Yes Yes

(no shore power)

Air Conditioner cord powered Yes No

with shore power

Accessories cord powered No Yes

with shore power

Air Conditioner and Accessories Yes Yes

powered with shore power

Generator operating and Yes Yes

Air Conditioner shore cord

powered from shore From Shore From Generator

Generator operating and Yes Yes

Accessory shore cord From Generator From Shore

powered from shore

30

Select a location to install the shore power transfer switch. It must be

installed in one of the interior compartments of the truck to insure that

moisture and dirt do not get into the box and its components. Keep in mind

that the cords will need to be stored and accessible for use.

Once a location is selected secure the box to the compartment with

four screws.

Route the generator power cable from the APU to the box. Route the

cable through the entrance connector and connect the four wires to the

contactors and ground as shown.

Red to Term 8 on A/C contactor

Black to Term 8 on Acc. Contactor

White to Term 7 on A/C contactor

(with jumper to 7 on Acc. contactor)

Green to ground stud in box.

Route the Cab power OUT cable to a suitable location

For connection to the Air Conditioner and Cab Power Plugs as instructed on

page 18.

Install the box cover and secure.

31

SHORE POWER AUTO TRANSFER SWITCH

32

SHORE POWER AUTO TRANSFER SWITCH

33

INSTALLING THE KEY-LESS REMOTE START SYSTEM

The Key-less Remote System is composed of two units, a transmitter (fob) and a

receiver. Each remote system is unique and will not work with other systems. In the event

of a lost transmitter (fob), the replacement fob can be programmed to work with the

installed receiver.

The receiver is mounted inside the PowerPac APU Control Box; the fob is carried

with the operator. The receiver operates on the 12 volt DC system. The receiver is

capable of switching 10 amps. and has a standard automotive 10-amp fuse for protection.

The receiver can be used with up to 4 transmitters.

The transmitter has two buttons, which control two different functions. The

smaller button is the ON/OFF button, and is marked with the universal ON/OFF symbol.

Pressing this button will Start or Stop the APU. The larger button is marked with the

universal symbol for a timer. This is a two minute timer and is not adjustable.

In the event the fob is lost or misplaced, additional fobs are available and can be

programmed by the consumer to work with the existing receiver. Please follow the

instruction to program a new transmitter/ transmitters.

34

PROGRAMMING A NEW REMOTE CONTROL TRANSMITTER

1. With the power turned on, unplug the jumper from the receiver. The jumper is

located on the printed circuit board and can be accessed through the open area on

the side of the receiver. To unplug the jumper, pull it straight out. It may be

necessary to use a long nose plier to grasp and remove it.

2. Turn the receiver power off for a minimum of 5 seconds and then turn the power

back on. At this time the light/lights connected to the receiver will only be on for

5 to 6 seconds before they go off. The remote control must start to be

programmed while the light/lights are on.

3. Press one of the buttons on the remote control once;

It can be either the timer button or the on/off button. The light/lights will flash

twice.

4. Press one of the buttons on the remote control for the second time. It can be

either the timer button or the on/off button. The light/lights will flash three times.

5. Press one of the buttons on the remote control for the third time. It can be either

the timer button or the on/off button. The light/lights will flash four times.

6. Press one of the buttons on the remote control for the fourth time. It can be either

the timer button or the on/off button. The light/lights will go off.

7. The new remote unit is now programmed to work with the receiver.

8. Replace the jumper that you removed in step one.

9. The unit is now ready for operation.

PROGRAMING AN EXTRA REMOTE TRANSMITTER

This instruction is if you wish to use two remotes to control the same receiver. To do

this, you must RE-PROGRAM the original remote along with the extra unit.

1. With power turned on, unplug the jumper from the receiver. The jumper is located on the

printed circuit board and can be accessed through the open area on the side of the receiver.

To unplug the jumper, pull it straight out. It may be necessary to use a long nose plier to grasp

and remove it.

2. Turn the receiver power off for a minimum of 5 seconds and then turn the power

back on. At this time the light/lights connected to the receiver will only be on for

5 to 6 seconds before they go off. The remote controls must start to be

programmed while the light/lights are on. Please note that it does not matter

which remote is programmed first.

3. Press the big button on either the original or the extra remote control once. The

light/lights will flash twice.

4. Press the big button on either the original or the extra remote control for the

second time. The light/lights will flash three times.

5. Press the big button on either the original or the extra remote control for the third

time. The light/lights will flash four times.

6. Press the big button on either the original or the extra remote control for the

fourth time. The light/lights will go off.

Please note that you will have to press one of the buttons on both the original and the new

remote at least once to make both of them functional for the same receiver while

programming from

step 3 to step 5.

7. The new and the original remote unit are now programmed to work with the

receiver.

8. Replace the jumper that you removed in step one.

9. The unit is now ready for operation.

35

36

KUBOTA Z-482

POWERPAC APU

POWER CONTROL MODULE

WIRING SCHEMATIC

120 VOLTS

37

CATERPILLAR CO.5

POWERPAC APU

POWER CONTROL MODULE

WIRING SCHEMATIC

120 VOLTS

RESISTANCE CHART

20 Amp.

Circuit Breaker

Accessories

30 Amp

Circuit Breaker

A/C and Heat

Circuit Breakers are located in the end of the generator on the lower right hand side of the APU.

Access through the front hatch door in the lower compartment. Press the button to re-set the circuit

breaker.

CAUTION: DO NOT re-set circuit breakers with APU running. Be aware of hot surfaces when

accessing circuit breakers.

38

KW 5 COLOR

MAIN STATOR .343 Blue/Brown – Black/White

MAIN ROTOR 2.482 N/A

POWER TECHNOLOGY SOUTHEAST, INC. 634 STATE ROAD 44

LEESBURG, FL 34748-8103

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

AC ELECTRICAL CIRCUIT FOR 5 KW “S”

GENERATOR

GENERATOR

OUTPUT LEADS

CIRCUIT BREAKERS

20 AMP

30 AMP

NOTE: THESE READINGS WILL VARY

DEPENDING ON AMBIENT TEMPERATURE

Power Controller Module (PCM)

And Display (PCMD)

39

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…)

40

Operating Behavior

StartingThe 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.

StoppingThe 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).

41

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

42

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POWER TECHNOLOGY SOUTHEAST, INC.

Limited Warranty on Power Pack APU Generators

Power Technology Southeast, Inc. warrants to you, the original owner, that each

product of our manufacture is free from defects in materials, and workmanship. If

properly installed, serviced, and operated under normal conditions in accordance

with power Technology’s instructions.

THE WARRANTY WILL BE IN EFFECT FOR THE FOLLOWING PERIOD

1) 3 years from in service date or 42 months from date of

manufacture or 3000 hours whichever comes first. Parts, and labor,

including diagnostic labor, removal and reinstallation are covered for

the first 24 months from date in service or 2000 hours which ever

comes first. Parts are covered on the following generator and engine

parts for 3 years or 3000 hours whichever comes first. Generator

Parts: Cylinder Block, cylinder head, crankshaft, pistons, rings,

valves, valve lifters, manifolds and other major castings. See Engine

Manufacturers Warranty guide.

2) The Poly- V Generator Drive Belt is warranted to the original owner

for the operating life of the APU unit. It will be replaced free of

charge to the original owner. Labor charges for Belt Replacement are

NOT covered under this warranty after the 2 year or 2000 hour

period.

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 Technology Service facility or in the case

of Engine Repairs you may use any Authorized dealer or distributor, or any

generator service facility considered competent by Power Technology.

PRIOR APPROVAL is REQUIRED for ANY WARRANTY SERVICE

THIS WARRANTY DOES NOT COVER

1) Defects, malfunctions or failure resulting from accidents, abuse, or

misuse, improper servicing, lack of performance or required

maintenance service or normal wear.

2) Products which have been subjected to alteration, modification,

neglect, or unauthorized repairs.

3) Replacement of filters, belts, antifreeze or lubricants.

4) Electrical items damaged by welding or jump-starting.

5) Damaged caused by contaminated oil, bad fuel, use of ether or any

starting fluid, rust contaminates in the fuel system or improper

mixture of antifreeze and water.

6) The replacement of complete assembly (unless prior approval has

been granted by Power Technology). Components must be

disassembled and repaired as necessary.

7) Overtime labor requested by the customer.

8) Starting Batteries.

9) Damage caused by water entering the engine by any means.

10) Failure of fuel system components due to impurities in the fuel,

routine fuel system maintenance and fuel filter replacement.

11) Any damage caused by overheating that is not a direct result of a

defect in material or workmanship.

12) Any damage caused by failure to immediately correct a known or

suspected engine, generator or accessory problem.

13) Travel time, mileage or labor for repair or removal of a Power

Technology Product from its application and reinstallation excepts as

indicated below.

a) Removal and Reinstallation: Power Technology will pay the

following stated labor at straight time only for Warranty work

requiring removal and reinstallation of Power Technology

products in the following applications. Provided such work is

performed by a Power Technology authorized service center or

designated service representative.

b) On highway commercial vehicles applications, up to a

maximum of 2 hours.

14) Loss of generator excitation due to prolonged storage.

15) Any damage attributed to a non PowerPac or POWER

TECHNOLOGY SE, INC. external Lower Battery Control

Monitoring or Auto-Generator Start system.

8/2006

50

General Conditions

1) This Warranty is the sole property of the

original owner. A transfer of ownership shall

terminate this Warranty.

2) This Warranty is only valid within the United

States and Canada.

3) This Warranty does not cover any products or

parts not purchased from Power Technology.

4) Problems arising from improper installation are

the responsibility of the installer and are not

covered by the Power Technology Warranty.

5) Power Technology reserves the right to make

design improvements and model changes

without any obligation to change units or parts

previously manufactured.

6) Warranty registration card must be completed

and mailed to Power Technology to validate

the Warranty.

7) Electric cab air conditioning and heating systems

8) sold by Power Technology SE are warranted by the

manufacturer of the particular system and not by Power

Technology SE. See warranty information provided

with HVAC unit.

THIS IS THE ONLY EXPRESS WARRANTY ON

POWER TECHNOLOGY 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.

This Warranty is in lieu of all other Warranties, expressed

or implied and of any other obligations or liability on our

part. WARRANTIES OF MERCHANT-ABILITY OR

FITNESS FOR A PARTICULAR PURPOSE ARE

EXCLUDED. Our responsibility for any and all losses and

damages resulting from any cause whatsoever, including

our negligence, alleged damaged or defective goods,

whether such defects are discoverable or latent, shall be

limited to the repair or replacement of defective parts as

stated above.

IN NO EVENT WILL WE LIABLE FOR LOSS OF USE,

LOSS OF PROFITS, INCONVIENCE, COMMERCIAL

LOSS OR OTHER INCIDENTIAL OR

CONSQUENTIAL DAMAGES WHATSOEVER.