ESI KPG Series Manual

OPERATIONS & MAINTENANCE
MANUAL
www.ESIalaska.com
ESI Designed and built
Kubota 03 Series Diesel Engine
Mecc Alte ECP or ECO Gen End
APplicable models
KPG-14-D15-MR2S
KPG-15-D17-MR2S
KPG-18-V20-MR2S
KPG-20-V22-MR2S
KPG-23-V20T-MR2S
KPG-24-V24-MR2S

ESIalaska.com
Anchorage:
Fairbanks:
Seattle:
Williston:
7780 Old Seward Hwy
1919 Van Horn Road
17660 W. Valley Hwy
5064 Bennett Loop
Anchorage, AK 99518
Fairbanks, AK 99701
Tukwilla, WA 98188
Williston, ND 58801
[phone] | [phone]
[phone] | [phone]
[phone]
[phone]
Equipment Source, Inc.
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ESIalaska.com
Anchorage:
Fairbanks:
Seattle:
Williston:
7780 Old Seward Hwy
1919 Van Horn Road
17660 W. Valley Hwy
5064 Bennett Loop
Anchorage, AK 99518
Fairbanks, AK 99701
Tukwilla, WA 98188
Williston, ND 58801
[phone] | [phone]
[phone] | [phone]
[phone]
[phone]
Equipment Source, Inc.
General Information
&
Warranty

ESIalaska.com
Equipment Source, Inc.
THIS PAGE INTENTIONALLY LEFT BLANK

Anchorage:
Fairbanks:
Seattle:
Williston:
7780 Old Seward Hwy
1919 Van Horn Road
17660 W. Valley Hwy
5064 Bennett Loop
Anchorage, AK 99518
Fairbanks, AK 99701
Tukwilla, WA 98188
Williston, ND 58801
[phone] | [phone]
[phone] | [phone]
[phone]
[phone]
Equipment Source, Inc.
OPERATORS
MANUAL
KPG Generator
Kubota Powered Generators by ESI
SPECIFICATIONS
See product specification sheet for product
specifications
www.ESIalaska.com
For Parts & Service:
Fairbanks, Alaska
907.458.9049
FAI-[email protected]
Anchorage, Alaska
907.341.2250
ANC-[email protected]
Seattle, Washington
425.251.6119
FAI-[email protected]
Williston, North Dakota
701.774.5312
Williston-[email protected]

KPG GENERATOR INTRODUCTION
Rev August 2019 | Copyright © 2019 Equipment Source, Inc. 1
1 Introduction
1.1 General Description
ESI built KPG generators come in a variety of configurations and sizes. Refer to unit specifications and
manual components for specific details. General operation and maintenance remains the same for all of
these units.
1.2 Manual Applicability
This manual is applicable to the following Equipment Source Incorporated (ESI) machine models:
Model
Description
KPG Series
Skid mounted ESI Generators
KPG Enclosure Series
ESI Generators with Enclosures
This manual should be kept with the machine at all times. Immediately contact Equipment Source
Incorporated (manufacturer) or an authorized dealer to obtain a copy of this manual if missing or
damaged. Refer to www.equipmentsourceinc.com for current contact information.
1.3 Manual Scope
This manual contains basic operating and maintenance instructions for the above listed product. For
detailed service instructions concerning specific electrical or mechanical components, refer to the
operation and maintenance manual provided by the manufacture of the specific component or contact
an authorized service provider. Operation and Maintenance instructions for the generator controller can
be found in the separate controller manual included with the generator.
1.4 Warranty
Review the warranty before operating or working on the unit. The warranty contains important safety
and operational requirements. Contact ESI for the latest warranty information.
1.5 Installation
Review the installation requirements before installing, operating or working on the unit. The installation
requirements contain important information and must be adhered to in order to maintain warranty.
Contact ESI for the latest installation requirements.
WARNING
Read and understand this manual before operating the machine to avoid serious
injury or death.
!

KPG GENERATOR IMPORTANT SAFETY INSTRUCTIONS
Rev August 2019 | Copyright © 2019 Equipment Source, Inc. 2
2 IMPORTANT SAFETY INSTRUCTIONS
2.1 Training
Never allow untrained personnel to operate or service the machine. Take time to read the
manual and discuss safe practices with jobsite personnel.
Read and understand the operating section of this manual.
Take time to familiarize yourself with the controls and instructional placards before operating or
servicing.
Contact your dealer or service provider if additional training is necessary.
2.2 Operating
Some components are hot while in operation. Keep clothing and combustibles away.
Wear protective clothing, such as gloves, appropriate to the jobsite.
Observe changes in the operating environment and respond accordingly.
Generators vibrate in normal use. During and after the use of the generator, inspect the
generator as well as extension cords and power supply cords connected to it for damage
resulting from vibration. Have damaged items repaired or replaced as necessary. Do not use
plugs or cords that show signs of damage such as broken or cracked insulation or damaged
blades.
2.3 Service
Only trained service technicians should attempt to service the machine.
Properly shutdown the machine and let cool completely before attempting to service any
component.
Never defeat the safety devices
Never modify the machine
WARNING

SAVE THESE INSTRUCTIONS. This manual contains important instructions that
should be followed during the operation and maintenance of the generator,
battery and heater.
!

KPG GENERATOR Operation
Rev August 2019 | Copyright © 2019 Equipment Source, Inc. 3
3 Transporting
3.1 Lifting
3.2 Transporting
1. Lift the machine following the guidelines presented below.
2. If applicable: ensure all doors are closed and latched.
3. Remove any hoods in the way before lifting.
4. Lift the unit using ONLY designated lifting points or fork pockets.
3.3 Storage
Units placed in storage must be stored out of the elements and protected from rain, snow and
sunlight. The warranty will be voided for units left exposed to the elements during storage. ESI built
unit enclosures provide sufficient protection when properly closed.
3.3.1 Short-Term Storage (less than 90 days)
1. Shutdown the machine
2. Close all doors (if applicable)
3.3.2 Long-Term Storage (greater than 90 days)
1. Shutdown the machine
2. Verify that the main breaker and control switches are in the off position
3. Disconnect the battery
4. Drain water from fuel filters.
5. Secure/Close vents and openings (if applicable).
CAUTION

Ensure that any equipment used to lift the unit is rated for the weight of the
unit.
!

KPG GENERATOR Operation
Rev August 2019 | Copyright © 2019 Equipment Source, Inc. 4
4 Operation
4.1 System Operation
Refer to individual component manuals for operation of those components. This unit should only be
operated by trained personnel familiar with the operation of the entire system. Refer to the PRE-
OPERATION CHECK portion of the Engine Manual
4.2 Recommended Fuels and Fueling Instructions
Use ULSD No.1 or ULSD No.2. For continuous duty operation, a refilling schedule should be established.
4.3 Engine Heat - 120V Power Input
If a cold start is required, use the 120V engine pre-heat circuit to warm the engine block and engine oil
prior to starting. The engine should be pre-heated for approximately 4-hours if the ambient
temperature is below -7°C (20°F). Longer preheat cycles may become necessary in extremely cold
conditions.
Use a grounded flexible extension cord rated at 15A minimum to connect the machine to a 120V power
supply. There is an orange, three-prong “Y” located on each of the generators.
4.4 Monitoring and Operation
4.4.1 Minimum Loading of Diesel Engines
Diesel generator engines require that a minimum average load be maintained. An average load
of 75% of the rated output of the generator must be maintained to avoid damaging the unit
(often referred to as “Wet-Stacking”). Prolonged use of the generator at loads less than 75% of
rated output will void the warranty, reduce the life span of the engine and cause damage to the
unit. Refer to the ESI Warranty Summary for further details. Consider using a load bank to
maintain minimum loading on the engine.
4.4.2 Daily Inspection & Startup Inspection (required)
Conduct general inspection of the unit
Listen for abnormal sounds
Check fluid levels
Check all hoses for damage (including but not limited to fuel lines and coolant lines)
Check engine temperature
Check containment for accumulation of liquids.
Check vents for icing or other obstructions (if applicable)
Observe recommended maintenance schedule
Check for error codes on control units for KPG and any other equipment associated with the
unit.
CAUTION
Do not overfill tank. Tank should be filled to only 90% of the full volume to allow
thermal expansion.
!

KPG GENERATOR Operation
Rev August 2019 | Copyright © 2019 Equipment Source, Inc. 5
4.5 Long Run Oil Tank (LRT)
A LRT equipped ESI generator has increased service intervals up to 3000 hours
oOil change intervals should be determined using an oil sample analysis at regular
intervals to determine maximum service interval.
oOperating conditions may affect the service interval of the LRT.
The service interval of the LRT may change if operating conditions change
Prefill oil filters with oil when completing an oil change on a LRT equipped unit. This reduces the
likelihood of damaging air bubbles in the oil system.
Users can expect some oil seeping between engine base and long run oil pan on LRT
installations. This is a normal condition for operating the LRT and is not warrantable.
Great care should be taken to limit vibration of the generator. Excessive vibration will cause
premature failure of LRT seals and is not warrantable. See warranty and installation instructions
for further details.

KPG GENERATOR Maintenance Records
Rev August 2019 | Copyright © 2019 Equipment Source, Inc. 6
5 Maintenance
5.1 Maintenance Schedule
Table 1. Maintenance Schedule
Interval
Maintenance Instruction
Notes
Daily
See section 4.4.2 of this manual for additional
requirements
Complete at every
inspection
Every 50 hours
Check of fuel pipes and clamp bands
Check radiator hoses and clamp bands

Drain water separator
Varies by model
Engine Oil Change and Oil Replacement Intervals
Standard Oil Pan (Kubota Recommendation)
oInitial Oil Change: 50 hours
oInterval:
KPG-06 to KPG-24: 200 hours
KPG-28 & KPG-36: 250 hours
KPG-45: 500 hours
Long Run Oil Pan (LRT) Option
oInterval: 3,000 hours
Engine oil must
meet API Spec: CF,
CF-4, CG-4, CH-4 or
CI-4
See section 4.5 for
additional notes on
LRT oil changes.
Every 200 hours
(KPG-06 to KPG-24)
OR
Every 250 hours
(KPG-28 & KPG-45)
Clean air cleaner element
Change Engine Oil and Oil Filter (KPG-06 to KPG-
36)
Check and clean fuel filter
Check battery electrolyte level
Check fan belt tightness
Check intake air line
Inspect generator (see generator section of this
manual)
Every 500 hours

Change Engine Oil and Oil Filter Cartridge (KPG-
45, standard oil pan)
Replace fuel filter cartridge
Remove sediment in fuel tank
Clean water jacket (radiator interior)
Replace fan belt
Clean water separator
Every one or two
months
Charge battery as needed
CAUTION
Some of the following maintenance operations should only be completed by a trained
technician. Do not attempt to open electrical panels unless you are a trained
technician. Maintenance schedule must be adhered to and documented in order to
maintain warranty. Maintenance programs should be tailored to the specific
generator, environment and operating conditions.
!

KPG GENERATOR Maintenance Records
Rev August 2019 | Copyright © 2019 Equipment Source, Inc. 7
Every Year
Replace air cleaner element
Clean Generator (blow out with air) and inspect
Change Engine Oil and Oil Filter
Air filter element
may need cleaning
more frequently
depending on
environmental
conditions
Every 800 hours

Check valve clearance
Every 1500 hours

Check fuel injectors
Every 3000 hours
Change Engine Oil and Oil Filter Cartridge (units
equipped with LRT)
Check turbo charge (if unit is equipped with a
turbo)

Check supply pump
Every Two Years
Change radiator coolant
Replace battery
Replace radiator hoses and clamp bands
Replace fuel pipes and clamp bands
Replace intake air line
Replace fan belt (or every 500 hours, whichever
occurs first)
Every 10,000 hours
/ 2 years

Inspect Generator sealed bearings
At 30,000 hours

Replace Generator sealed bearings
5.2 Engine Service
Use engine operator’s or service manual provided for further instruction on how to complete routine
service or trouble shooting.
5.3 Battery Service
The engine starting circuit is supplied by a single 12V battery. No maintenance is required other than
normal charging and occasional replacement.
To replace the battery, sequentially remove the negative ground lead, positive power lead and the
bracket holding the battery in the tray. Replace the battery by securing in the tray, connecting the
positive lead and then connecting the ground lead.

KPG GENERATOR Maintenance Records
Rev August 2019 | Copyright © 2019 Equipment Source, Inc. 8
6 Maintenance Records
Table 2. Machine Data
Machine Serial Number
Engine Serial Number
Generator Serial Number
Table 3. Maintenance Records
Date
Engine Hours
Service
Personnel
Service
Location
Description of work completed

KPG GENERATOR Maintenance Records
Rev August 2019 | Copyright © 2019 Equipment Source, Inc. 9

KPG GENERATOR Maintenance Records
Rev August 2019 | Copyright © 2019 Equipment Source, Inc. 10

KPG GENERATOR Maintenance Records
Rev August 2019 | Copyright © 2019 Equipment Source, Inc. 11

ESIalaska.com
Anchorage:
Fairbanks:
Seattle:
Williston:
7780 Old Seward Hwy
1919 Van Horn Road
17660 W. Valley Hwy
5064 Bennett Loop
Anchorage, AK 99518
Fairbanks, AK 99701
Tukwilla, WA 98188
Williston, ND 58801
[phone] | [phone]
[phone] | [phone]
[phone]
[phone]
Equipment Source, Inc.
Commonly Replaced KPG Parts
See next page for LRT options and remote fuel filters when applicable
Engine Series
Model
Kubota
Engine
Oil Filter Air Filter Fuel Filter Oil Capacity
KPG-05
Z482
15426-32430
P822686
12581-43012
2.6 Liters / 0.69 Gal
KPG-06-NG
DG972
HH150-32430 1G659-11222 N/A
3.4 Liters / 0.90 Gal
KPG-06-LP
WG972
3.4 Liters / 0.90 Gal
05 Series
KPG-06-MQ
D1005
HH160-32093 15741-11083 15221-43170
5.1 Liter / 1.35 Gal
KPG-06
D1005
5.1 Liter / 1.35 Gal
KPG-08
D1105
5.1 Liters / 1.35 Gal
KPG-10
D1305
5.7 Liters / 1.50 Gal
KPG-12
V1505
5.7 Liters / 1.50 Gal
03 Series
KPG-14
D1503
HH164-32430 70000-11081 HH166-43560
7.0 Liters / 1.85 Gal
KPG-15
D1703
7.0 Liters / 1.85 Gal
KPG-18
V2003
9.5 Liters / 2.50 Gal
KPG-20
V2203
9.5 Liters / 2.50 Gal
KPG-24
V2403
9.5 Liters / 2.50 Gal
V3 Series
KPG-28 V3300
HH1C0-32430
3A111-19130 (inner)
59800-26110 (outer)
HH166-43560
& R60S
13.2 Liters / 3.50 Gal
KPG-36
V3600
R2401-42280 (inner)
59700-26112 (outer)
13.2 Liters / 3.50 Gal
KPG-45
V3800
13.2 Liters / 3.50 Gal
Long Run Oil Option (LRT)
Replaces standard oil filter and oil capacity from chart above for units with LRT installed
Model
LRT Model
LRT Size
Oil Filter (2ea.)
Oil Capacity
KPG-06 to KPG-12
05SMLRT
9 Gallon
16121-32430
32 Quarts / 8 Gal
KPG-06 to KPG-12
05LRT
19 Gallon
48 Quarts / 12 Gal
KPG-15 to KPG-24
03LRT
19 Gallon
48 Quarts / 12 Gal
KPG-28 to KPG-45
V3LRT
26 Gallon
64 Quarts 16 Gal
Remote Racor Fuel Filter
In addition to fuel filters from above chart for units with auxiliary Racor Fuel filter installed.
Model
Filter Part Number
120AS Racor Fuel Filter
R12S
660R2 Racor Fuel Filter
R60S
Part numbers may vary for non-standard products. Always have unit Stock # available when calling for parts.

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Equipment Source, Inc.
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KPG Model Breakdown
----
KPG = Kubota Power Generator ME1 = Modular Enclosure Size 1
FPG = Fiat Powered Generator 6kw to 12kw
CPG = Cat Powered Generator ME2 = Modular Enclosure Size 2
JPG = John Deere Powered Gen. 14kw to 24kw
IPG = Isuzu Powered Generator AR2 = Arctic Re-Air Size 2
14kw to 24kw
Nominal Output (KW) AR3 = Arctic Re-Air Size 3
28kw to 45kw
Z48 = Kubota Z482 ENC = Misc. Enclosure
DG97N = Kubota DG972 NG BR = Bull Rail Trailer
WG97P = Kubota WG972 LP F120 = Skid Mounted Fuel Tank
WG97G = Kubota WG972 Gas Size in Gallons
WG16P = Kubota WG1605 LP LRT = Long Run Oil Tank
WG16G = Kubota WG1605 Gas
WG25G = Kubota WG2503 Gas
D10 = Kubota D1005
D11 = Kubota D1105
D13 = Kubota D1305 MeccAlte
V15 = Kubota V1505 MR8S = ECP28-S or ECO28-S
D15 = Kubota D1503 6KW to 12KW
4V18 = Kubota D1803 T4F MR2S = ECP32-S or ECO32-S
4V24 = Kubota V2403 T4F 14KW to 24KW
4V38 = Kubota V3800 T4F MR2L = ECP32-L or ECO32-L
28KW to 45KW
MREC = NPE32-C/4 (Pancake)
D17 = Kubota D1703 6KW
V20 = Kubota V2003 MREF = NPE32-F (Pancake)
V20T = Kubota V2003T 26.5kw
V22 = Kubota V2203 M16F = S16F-150 (3600 RPM)
V24 = Kubota V2403 4KW to 6KW & APU
V33 = Kubota V3300 Marathon
V36 = Kubota V3600 AS36 = 361PSL1652
V38 = Kubota V3800 50KW 3P Dual Voltage
N45 = Fiat N45SM2X.A008 Stamford
N6 = Fiat N67TM1X.A008 S11L BCI164A1L
6kw
ATT = Misc AT&T Spec Generators
TERRA= GCI Terra Project
GCI = Misc GCI Spec Generators
TCC = TCC Clinic Back Up
R = Reconectable 12-Lead
1 = Dedicated Single Phase
M = Mecc Alte 4-Lead
S = Stamford 3 = Dedicated Three Phase
A = Marathon S = Dedicated Three Phase
Switchable: 208/240 to 240/480
Phase Configuration
Spec Built Generators (Examples)
Generator End
AR2
Generator End Model
Output
Engine
ESI Generators
KPG
18
V20
Type
Enclosures & Accessories
M
R
8S
Gen End Make
MR8S
T3 & Flex
K:\00_Literature\32_Price Book\00_Working Files\ESI Product Pricing and Inventory

ESIalaska.com
Anchorage:
Fairbanks:
Seattle:
Williston:
7780 Old Seward Hwy
1919 Van Horn Road
17660 W. Valley Hwy
5064 Bennett Loop
Anchorage, AK 99518
Fairbanks, AK 99701
Tukwilla, WA 98188
Williston, ND 58801
[phone] | [phone]
[phone] | [phone]
[phone]
[phone]
Equipment Source, Inc.
THIS PAGE INTENTIONALLY LEFT BLANK