AIE G Series User manual
G-SERIES INSTALL &
MAINTENANCE MANUAL
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TABLE OF CONTENTS
MODEL IDENTIFICATION 6
LOCATION OF IMPORTANT COMPONENTS AND CONNECTIONS 9
FUEL RECOMMENDATIONS 16
ENGINE OIL RECOMMENDATIONS 16
OPERATOR INTERFACE 18
SHELTER CONSTRUCTION 22
MOUNTING / FLOOR LOADING 23
VIBRATION 24
VENTILATION 24
AIR INLET 25
AIR OUTLET 26
EXHAUST PIPING 27
FUEL SYSTEM 29
DIESEL AND GASOLINE FUEL 30
GASEOUS FUELS 31
ELECTRICAL CONNECTIONS / EMERGENCY STOP WIRING / BATTERY 31
TESTING 32
PRE-START CHECKS 32
BEFORE STARTING THE GENSET 33
OPERATING AT HIGH ALTITUDES 34
OPERATING IN HOT AMBIENT TEMPERATURES 34
OPERATION 32
INSTALLATION 21
SAFETY
INTRODUCTION
3
6
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OPERATING IN COLD AMBIENT TEMPERATURES 34
BREAKING IN A NEW ENGINE 34
EXERCISING THE GENSET 35
TRANSPORTATION, STORAGE, AND RETURNING TO SERVICE 35
MAINTENANCE
TROUBLESHOOTING/ FAULT ICONS
SUPPORTING DOCUMENTS
APPENDIX B: AC WIRING SCHEMATIC
AIE EMISSIONS HOLD HARMLESS STATEMENT
36
37
41
42
44
SAFETY
Thoroughly read this manual before operating the genset. The following symbols are used throughout this manual and on the
genset to warn of the potential hazards to the operator, service personnel, or equipment.
When using the AUTO starting feature, electric shock and moving parts hazards are possible due to unexpected starting. Make sure
that the genset is NOT in AUTO mode whenever performing maintenance or service or when the genset is stored.
***All operators, no matter how knowledgeable, should read this and related manuals before operating the engine or any
attached equipment. It is the owner’s responsibility to instruct all operators in safe operation. Be sure to observe the following
warnings for safe operation.***
Alerts you to an immediate hazard that will result in severe personal injury or death.
Alerts you to a hazard or unsafe practice that can result in severe personal injury or death.
Alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage.
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• Diesel, Gasoline and Vapor type fuels are combustible. Do not smoke or make/break electrical connections when
these fumes are present.
• Keep ames, sparks, pilot lights, and arc-producing equipment and all other sources of ignition well away from fuel
sources.
• Fuel lines must be secured, free of leaks and separated or shielded from electrical wiring.
• Disable any automatic starting systems before performing inspections or service on the genset to avoid electric shock
from unexpected start.
• Generator electrical output connections must be made by a trained and experienced electrician in accordance with
applicable codes.
• The genset must not be connected to the public power utility or any other source of electrical power. Back-feed could
lead to electrocution of utility personnel and/or damage equipment. An approved switching device must be used to
prevent interconnections.
• Use caution when working with live electrical equipment. Remove jewelry, wear tight tting clothing, and only use
insulated tools.
• Electric shock can be deadly. Always insulate yourself from ground and never operate the genset when wet.
EXHAUST GAS IS DEADLY
GENERATOR VOLTAGE IS DEADLY
SAFETY
• Engine exhaust fumes can be very harmful if allowed to accumulate. Only operate the engine in a well-ventilated
area.
• Inspect for exhaust leaks at every startup and aer every eight hours of operation.
• Exposure to exhaust gases can cause carbon monoxide poisoning.
• Engine cooling air must not be used for heating working or living spaces or compartments.
• Disable any automatic starting systems before storing the genset in a conned area.
EXHAUST GAS IS DEADLY
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• Wear safety glasses.
• Do not smoke near battery.
• To reduce arcing when disconnecting or reconnecting battery cables, always disconnect the negative (-) battery cable
rst and reconnect it last.
• Flammable vapor can cause an engine to over speed and become diicult to stop, resulting in possible re,
explosion, severe personal injury and death.
• Do not operate gensets where a ammable vapor environment can be created by fuel spill or leak.
BATTERY GAS IS EXPLOSIVE
FLAMMABLE VAPOR CAN CAUSE AN ENGINE TO OVERSPEED
SAFETY
• Exhaust gas can be extremely hot. Do not point toward people. Keep machine more than 1 meter (3 feet) from
ammable materials.
• Check for fuel leaks before each operation.
• Stop the engine before adding fuel to tank (where applicable)
• Anti-freeze coolant contains ethylene glycol, which is toxic to humans and animals. Clean up spills and dispose of
used engine coolant in accordance with local regulations.
GENERAL CAUTIONS
• Disable any automatic starting systems before performing inspections or service on the genset to avoid unexpected
start.
• Do not wear loose clothing or jewelry near moving parts such as fans, belts and pulleys.
• Keep hands away from moving parts.
MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH
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INTRODUCTION
This manual covers the installation, operation, and maintenance of the G-Series family of gensets. Be sure to read the entire
manual thoroughly before rst use and obey all safety warning information contained within. Proper installation and use
as described in this manual will ensure your genset operates at peak performance. The owner is responsible for proper
installation observing all local electrical and building codes. The owner is also responsible for performing regular maintenance
as described in the supplied engine Operator’s Manual.
The engine model and serial number can be found on the engine valve cover toward the front of the engine (Kubota) or on the side
of the engine block (JCB). The alternator model and serial number are located on the side of the barrel of the alternator (shown
above)
You should record the model and serial numbers below for quick reference in the future.
MODEL IDENTIFICATION
MODEL # SERIAL #
ENGINE:
GENERATOR:
Kubota Engine Model and Serial Number location on top of valve cover.
MODEL AND SERIAL NUMBER LOCATION (KUBOTA):
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INTRODUCTION
JCB Engine Model and Serial Number location on side of block under exhaust and on back engine above the ywheel
housing.
MODEL AND SERIAL NUMBER LOCATION (JCB):
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INTRODUCTION
The location of major components needed for operation and maintenance are shown below. For more details see the
MAINTENANCE section in the manufacture’s engine manual provided with the genset.
G-9 TO G-13 MECHANICAL DIESEL OPEN UNIT
LOCATION OF IMPORTANT COMPONENTS
AND CONNECTIONS
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G-20 TO G-30 COMMON RAIL DIESEL OPEN UNIT
INTRODUCTION
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G-20 TO G-50 SPARK IGNITED OPEN UNIT (KUBOTA ENGINE)
INTRODUCTION
G-20
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G-9 TO G-50 OPEN AND ENCLOSED UNIT DETAIL
INTRODUCTION
3, 4, 9
3, 4, 9
2
7
8
12
6
5
5
1
11
NUMBER ITEM / FUNCTION
1EMERGENCY STOP
2EXHAUST OUTLET
3GENERATOR
CONTROLLER
4MAIN CIRCUIT
BREAKER
5RADIATOR FILL
6FUEL FILTER
7AIR FILTER
8OIL DRAIN
9FUSE/RELAY PANEL
11 OIL FILL
12 GENERATOR AVR
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FUEL RECOMMENDATIONS
ENGINE OIL RECOMMENDATIONS
***Fuel is combustible and can cause severe personal injury or death. Do not smoke near fuel tanks or equipment.
Keep all ames, sparks, or all other sources of ignition well away.***
For diesel engines, the use of ultra-low sulfur fuel (15ppm or 0.0015 wt.%) is mandatory when operated in US EPA
regulated areas. The use of Kerosene, whether blended with diesel or otherwise is prohibited within US EPA regulated
areas. Please use No. 2-D S15 diesel fuel as an alternative to No. 2-D and use No. 1-D S15 for ambient temperatures below
-10°C (14°F).
The minimum recommended Cetane rating is 45. A Cetane rating of greater than 50 is preferred, especially for ambient
temperatures below -20°C (-4°F) for elevations above 1500m (5000 .). Kerosene, which has a very low in Cetane rating,
adversely aects the engine and is prohibited within US EPA regulated areas and should be avoided in areas outside of US
EPA regulated areas.
Biodiesel blends of up to 5% (B5) may be used in the genset. Blends of biodiesel above 5% may void the engine warranty.
Biodiesel fuels must be blended according to EN 590 or ASTM D975. Raw processed vegetable oils are not acceptable for
use in any concentration.
• For LP engines, use Commercial LPG only and ensure the fuel supply is a liquid withdrawal type.
• For Natural Gas engines, use Commercial Natural Gas (including CNG). For wellhead gas usage, please refer to the
Kubota Application Manual.
• For Gasoline engines, use unleaded gasoline and E10 only. Do not use gasoline blended with methyl alcohol.
Use engine oil that is recommended by model below (on the following page). Change the viscosity of engine oil according
to the ambient temperature (Figure 4). Synthetic oil may be used aer the initial break-in period. Maintain proper engine
oil change intervals when using full synthetic engine oil, do not extend the oil change interval.
INTRODUCTION
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INTRODUCTION
FIGURE 4: OIL VISCOSITY VS. AMBIENT TEMPERATURE
KUBOTA SPARK IGNITED ENGINES
Engine oil should have properties of API classification SL or higher
Change the type of oil according to the ambient temperature
Above 25 degrees C (77 degrees F) SAE 30 or SAE 10W-30 /
SAE 15W-40
0 degrees C to 25 degrees C (32 to 77 degrees F) SAE 20 or SAE10W-30
0 degrees C to -20 degrees C (32 to -4 degrees F) SAE 20 or SAE10W-30
Below -20 degrees C (-4 degrees F) SAE 5W-30
KUBOTA DIESEL ENGINES
Engine oil should be API classification CJ-4 or CK-4
Change the type of oil according to the ambient temperature
Above 25 degrees C (77 degrees F) 10W-30 or 10W-40 or
15W-40
-10 degrees C to 25 degrees C (14 to 77 degrees F) 10W-30 or 10W-40 or
15W-40
Below -10 degrees C (14 degrees F) 10W-30 or 10W-40
JCB DIESEL ENGINES
Engine oil should be API classification of CH-4 or better
Change the type of oil according to the ambient temperature
MIN TEMP MAX TEMP
SAE 0W30 -40 C (-40 F) 30 C (86 F)
SAE 0W20 -40 C (-40 F) 10 C (50 F)
SAE 5W20 -30 C (-22 F) 10 C (50 F)
SAE 5W40 -30 C (-22 F) 40 C (104 F)
SAE 10W30 -20 C (-4 F) 40 C (104 F)
SAE 15W40 -15 C (-5 F) 50 C (122 F)
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OPERATOR INTERFACE
INTRODUCTION
The main operator interface is installed in the control box on the outside of the genset enclosure or mounted in the same
control box on an open unit. The control box contains a Deep Sea control panel (see below various Deep Sea control
panels), main generator breaker, voltage sensing fuses and current transformers. The Deep Sea panel is responsible for all
genset starting, stopping, and safety monitoring. For more information on using the Deep Sea panel, refer to the Deep Sea
Controller Operator Manual supplied with the genset.
Examples of Deep Sea Controllers oered on the G-Series are as follows:
DEEP SEA 4510
STARTING THE GENSET
NOTE: For further details, see Section 5 in the Deep Sea Operators Manual entitled Operation
STOPPING THE GENSET
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INTRODUCTION
DEEP SEA 6110 MKIII
STARTING THE GENSET
NOTE: For further details, see Section 5 in the Deep Sea Operators Manual entitled Operation
STOPPING THE GENSET
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DEEP SEA 7310
STARTING THE GENSET
NOTE: For further details, see Section 5 in the Deep Sea Operators Manual entitled Operation
STOPPING THE GENSET
INTRODUCTION
Table of contents
