Ample Power Genie, Manual

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be a separate battery, or the prime battery that the Genie charges.
The starting wire should be a #8 gauge. The starter and throttle
solenoid requires 12-Volt power. The main alternator can be 12,
24, or 48 Volts.
The positive output of the alternator must be connected to the bat-
tery that is being charged.
The negative output of the alternator must be connected to the neg-
ative distribution point for both the Genie starter battery and the
battery being charged by the alternator (12/24/48-Volt).
Operating the Genie
The Genie is typically shipped without engine coolant or oil. Be
sure to check for coolant and oil before operating the engine.
Before operating the Genie, be sure that no obstructions are
present that can interfere with belts and pulleys. Check the
level of crankcase oil, and engine coolant. Open the sea water
petcock for the Genie.
Before each use of the Genie, it is good practice to observe that
there is coolant in the heat exchanger, and oil in the crankcase.
For oil recommendations, refer to the Kubota manual. (For our
own diesel engines we use Delo 400 15-40W from Chevron,
which meets or exceeds warranty requirements of many U.S. made
diesels.)
Note: The Regulator should be turned off until the engine has
started and has a chance to warm.
Before cranking the engine, it is a good idea to preheat the cyclin-
der with the glow plugs. Preheat is not always necessary, but it
does reduce cranking time. As mentioned, the water in the exhaust
is pumped out using pressure from the engine. Prolonged cranking
will flood the engine in the marine model.
After 10-15 seconds of preheat, the control switch can be rotated to
crank the engine. Once the engine fires, release the control switch
and allow it to return to the ‘ON’ position. It is a good idea at this
point to verify that water is exiting the exhaust.
Allow the engine to warm for a few minutes before activating the
Regulator. If the alternator is connected to a battery selector switch,
be sure that the switch is on before activating the regulator.
Normally, the engine is run until the batteries are charged, and then
shut off. With manual start/stop units, separate instrumentation is
required to determine full charge on the batteries.
Diesel Fuel
In many parts of the world, diesel fuel has a lower cetane rating
than U.S. fuels. Even in the U.S. for our own diesels we use an ad-
ditive regularly, and suggest that fuel be treated for the Genie with
a diesel additive. These additives are extra refined oils that enable
complete combustion and help to keep the engine injector clean.
Some users report using a high grade two-cycle oil as an additive
for low sulphur fuels typical in South America. Excessive smoking
is often due to poor fuels, an overload on the engine, or insufficient
fuel reaching the injectors.
Adjusting Engine RPM with Throttle Solenoids
The RPM that the Genie operates at can be adjusted with the throt-
tle linkage rod.
Alternator Current/Power Limit
If engine RPM is adjusted less than that of the factory setting, it
will be necessary to adjust maximum alternator output to less than
rated Amps. Current limit adjustment is described in the Regulator
manual.
Current and Power settings are programmed with the EnerMatic
Controller.
The engine produces black smoke when it is overloaded. The en-
gine works hardest when current is high, and voltage is at the ab-
sorption point . . . about 14.4/28.8/57.6 Volts. To place the engine
under load, deeply discharge the battery and then begin charging.
Adjust the current limit, to less than rated Amps. As the voltage
rises, and before current through the battery declines, adjust the
limit so that the engine is not producing black smoke. Final current
adjustment should be 15-25% below the black smoke amperage.
Engine Troubleshooting
The most common cause of failure to start is lack of fuel, which
can be caused by air in the lines, an empty tank, a fuel cock that is
not on, or a clogged fuel line or filter.
A blocked vent line may also cause fuel starvation.
To bleed the engine, loosen the bleed nut above the fuel intake and
allow all the air to escape. This nut takes a 12 mm wrench. After
bleeding all the air from the system, the engine will usually start
readily.
Check the air cleaner to verify that sufficient air flow is possible.
Make sure that the engine is not flooded with sea water. Is the
exhaust sea cock open?
NOTE: Never spray any chemical into the intake of the engine.
This can permanently damage internal parts.
Alternator and Regulator Troubleshooting
Refer to the Regulator or EnerMatic manual for more troubleshoot-
ing suggestions.
Support
Support for the Smart Alternator Regulator and EnerMatic Con-
troller is available at: http://www.amplepower.com/phpBB3.
Maintenance
Follow the instructions in the Kubota Manual for engine main-
tenance. Note that the EnerMatic Controller has a stop feature
that can be programmed to stop the engine at a specific hour and
minute.
When doing a scheduled maintenance procedure on the engine, al-
ways remove all power to the engine starter and EnerMatic Con-
troller.
At this time, make sure all nuts and bolts are tight. It is critical that
the alternator bolts do not work loose. When that happens the flat
plate may crack from the repetitive torque pulses from the alterna-
tor.
The EnerMatic Controller has a check out menu which enables
setting and resetting engine controls. If there is any doubt about
proper operations, use the check out menu to evaluate the system.
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