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Kubota CKTGL11000, Operator'S Manual, Page: 30 / 62

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Kubota CKTGL11000 Operator'S Manual Download Page 30

18

PRE-OPERATION CHECK

ENGL

ISH

C

Fuel

WARNING

To avoid personal injury:

A

DO NOT refuel when engine is
running or hot.

A

Always shut off the engine before
refueling.

A

DO NOT overfill fuel system. If any
fuel overflows, wipe it up completely
before starting operation.

A

When refueling, keep all flames,
sparks and cigarettes away from
generator.

1. Always fill the fuel through the fuel tank strainer.
2. Make sure that dirt or water does not enter the fuel

tank.

3. Fill with Diesel fuel No.2-D (ASTMD975).
4. Below 0°C (32°F) a mix of No.1-D and No.2-D is

acceptable.

5. Fuel level is read by fuel gauge.

A

If the fuel tank should empty completely causing the
engine to stop, then the fuel system requires air
bleeding after filling the tank and before restarting
the engine.
(See "Air bleeding the fuel system" in "PERIODIC
SERVICE" section.)

Summary of Contents for CKTGL11000

Page 1: ...GL6000 STD GL6000 AUS GL7000 USA GL7000 USA TM GL7000 STD GL9000 STD GL9000 AUS GL11000 USA GL11000 USA TM GL11000 STD D 2396 D 2397 G3102 8916 3 ...

Page 2: ... generator and building electrical system damage can occur when normal operating power returns if unit is used without an isolation switch 3 WARNING WARNING IMPORTANT The engine in this machine is not equipped by the manufacture with a standard spark arrester It is a violation of California Public Resource Code Section 4442 to use or operate this engine on or near any forest covered brush covered ...

Page 3: ...se some small parts of this manual to be outdated KUBOTA distributors and dealers will have the most up to date information Please do not hesitate to consult with them This symbol the industry s Safety Alert Symbol is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the inst...

Page 4: ...FAULT CIRCUIT INTERRUPTER GFCI RECEPTACLE 8 PREPARATION TO SUPPLY THE ELECTRIC POWER 10 CONNECTING THE LOAD 12 PRE OPERATION CHECK 16 OPERATING THE GENERATOR 19 SERVICE INTERVALS 23 PERIODIC SERVICE 25 TRANSPORTING STORAGE 37 TROUBLESHOOTING 38 AUTOMATIC START STOP UNIT A S S UNIT 40 WIRING DIAGRAM 41 ...

Page 5: ...only refillable battery WARNING To avoid personal injury A Exhaust gas poisoning hazard Do not use the machine in any poorly ventilated place such as indoors and tunnels A Exhaust gas poisoning and fire hazard Do not direct the exhaust to people and buildings A Electric shock hazard Do not touch the machine with wet hands A Electric shock hazard Do not touch the terminals and sockets while the mac...

Page 6: ...jury hazard Do not touch the muffler A Injury hazard Do not run the machine tilted A Injury hazard Do not move the machine while it is running A Fire hazard Stop the engine before adding fuel A Fire hazard Do not enclose the machine nor cover it with a box or the like A Fire hazard Pay attention to the type and amount of fuel A Do not get the warning label dirty or peeled off A Be sure to hand ove...

Page 7: ...eaction causing harmful substances Use approved Anti freeze A Be mindful of the environment and the ecology Before draining any fluids find out the correct way of disposing of them Observe the relevant environmental protection regulations when disposing of oil fuel coolant brake fluid filters and batteries A When draining fluids from the engine place some container underneath the engine body A DO ...

Page 8: ...ng A Check or conduct maintenance after the engine coolant muffler or muffler cover have been cooled off completely A Always use the appropriate tools and jig fixture in good condition when performing any service work Make sure you understand how to use them before service A Use ONLY correct engine barring techniques for manually rotating the engine DO NOT attempt to rotate the engine by pulling o...

Page 9: ...rator Refer to following representations for labels used on the GL Series Generator Labels are avail able individually from your KUBOTA Dealer 1 Part No G3907 8832 0 2 Part No G3907 8830 0 3 Part No G3907 8836 0 4 Part No G3907 8831 0 5 Part No G3102 5090 2 for USA 5 Part No 18901 5090 2 6 Part No G3907 8824 0 ...

Page 10: ... Part No 18620 8806 0 8 Part No G3907 8833 0 9 Part No G3102 8841 0 10 Part No G3101 8832 0 11 Part No 6C040 5559 0 12 Part No G3102 8806 0 13 Part No G3906 8831 0 14 Part No G3102 8838 0 for U S A 15 Part No G3102 8839 0 for U S A ...

Page 11: ...h a soft cloth 3 Replace damaged or missing danger warning and caution labels with new labels from your local KUBOTA Dealer 4 If a component with danger warning and caution label s affixed is replaced with new part make sure new label s is are attached in the same location s as the replaced component 5 Mount new danger warning and caution labels by applying on a clean dry surface and pressing any ...

Page 12: ......

Page 13: ...parts or major service be sure to see your KUBOTA Dealer For service contact the KUBOTA Dealership from which you purchased your generator or your local KUBOTA Dealer When in need of parts be prepared to give your dealer the generator and engine serial numbers Locate the serial numbers now and record them in the space provided below model Serial No Generator Engine Date of Purchase Name of Dealer ...

Page 14: ...ct coupled DIESEL ENGINE Model Z482 Design Vertical water cooled 4 cycle diesel engine No of cylinders 2 Bore stroke mm in ø 67 68 2 6 2 7 Displacement L cu in 0 479 29 2 Engine speed rpm 3000 3600 Lubricating Oil API service class CD or higher Oil capacity L U S gal 2 2 0 58 Coolant capacity L U S gal 3 7 0 98 SET Fuel Diesel fuel No 2 ASTM D975 Fuel consumption at full load L U S gal h 2 4 0 63 ...

Page 15: ...d DIESEL ENGINE Model D722 Design Vertical water cooled 4 cycle diesel engine No of cylinders 3 Bore stroke mm in ø 67 68 2 6 2 7 Displacement L cu in 0 719 43 9 Engine speed rpm 3000 3600 Lubricating Oil API service class CD or higher Oil capacity L U S gal 3 4 0 90 Coolant capacity L U S gal 4 1 1 1 SET Fuel Diesel fuel No 2 ASTM D975 Fuel consumption at full load L U S gal h 3 3 0 87 4 1 1 08 F...

Page 16: ...Control panel 7 Base 8 Engine oil drain plug 9 Door lock 10 Coolant drain plug 11 Reserve tank 12 Fuel filter 13 Oil dipstick 14 Oil filter cartridge 15 Muffler 16 Radiator 17 Radiator cap 18 Solenoid 19 Engine oil port 20 Battery 21 Air cleaner 22 Door stopper 23 Fuel tank 24 Alternator 25 Safety shield ...

Page 17: ...1000 USA GL7000 USA 1 A C Voltmeter 2 Glow timer lamp 3 Water temperature lamp 4 Oil pressure lamp 5 Battery charge lamp 6 Starter switch key 7 Circuit breaker 8 Hour meter 9 Ground terminal 10 Protector Receptacle 11 Pilot lamp 12 Full power switch A Receptacle B Receptacle C Receptacle D Receptacle ...

Page 18: ...10V 220V Dual voltage type GL11000 STD GL7000 STD 1 A C Voltmeter 2 Glow timer lamp 3 Water temperature lamp 4 Oil pressure lamp 5 Battery charge lamp 6 Starter switch key 7 Circuit breaker 8 Hour meter 9 Ground terminal 10 Protector Receptacle 11 Pilot lamp 12 Terminals Output 13 Full power switch A Receptacle ...

Page 19: ...ssure lamp 5 Battery charge lamp 6 Starter switch key 7 Circuit breaker 8 Hour meter 9 Ground terminal 10 Protector Receptacle 11 Pilot lamp 12 Terminals Output A Receptacle 1 A C Voltmeter 2 Glow timer lamp 3 Water temperature lamp 4 Oil pressure lamp 5 Battery charge lamp 6 Starter switch key 7 Circuit breaker 8 Hour meter 9 Ground terminal 10 Protector Receptacle 11 Pilot lamp A Receptacles ...

Page 20: ... firmly into the GFCI unit until an audible click is heard If the GFCI can not be reset the GFCI is faulty Contact your KUBOTA dealer If the GFCI resets properly check such things as fault insulation or wet wiring inside the appliance or its cord If you ve found the short it should be repaired before it is used again 1 Perform this test on a regular monthly basis to ensure proper operation of the ...

Page 21: ...CIRCUIT INTERRUPTER GFCI RECEPTACLE ENGLISH B Control Box 1 Emergency unit 2 Regulator 3 Glow relay 4 Relay A 5 Relay B 6 Glow lamp timer 7 Starter relay 8 Exterior connection terminal taps 9 Separate excitation unit ...

Page 22: ...rator capacity A Make sure that total active mercury lamp load is below 30 or so of the generator capacity Turn on the mercury lamps one by one Be careful not to turn off the lamps and on again immediately The generator voltage may rise to extremely high levels and the AVR may get damaged A Before turning on the lamps again wait for 10 minutes or so until the lamps cool down enough A The data show...

Page 23: ... Voltage V Current A Power factor Power factors of commonly used devices are listed in the following table A Ordinarily a motor is rated in kW This does not refer to motor output Motor input kVA A If a lighting system is employed together with some types of computers and inverter air conditioners and or the regulated power supply for TV sets the lights might suffer flickering This phenomenon does ...

Page 24: ...nce personnel Also generator and building electrical system damage can occur when normal operating power returns if unit is used without an isolation switch 1 Avoid connecting the generator to commercial power outlet 2 Avoid connecting the generator in parallel with any other generator B Connecting the Load Terminal output Model WARNING To avoid personal injury A Connect or disconnect the load to ...

Page 25: ... WARNING To avoid personal injury A Do not switch the voltage selector with generator on Serious damage will occur C Single phase 3 terminals type 1P3W type Dual voltage type i GL11000 STD 60Hz 110 220V 1 Light 2 Television 3 Air conditioner 4 Electric drill 5 Motor pump 1 Light 2 Television 3 Air conditioner 4 Electric drill 5 Motor pump 1 Light 2 Television 3 Air conditioner 4 Electric drill 5 M...

Page 26: ...40V WARNING To avoid personal injury A Do not switch the voltage selector with generator on Serious damage will occur C Single phase 3 terminals type 1P3W type Dual voltage type i GL11000 USA TM 60Hz 120 240V 1 Light 2 Television 3 Air conditioner 4 Electric drill 5 Motor pump 1 Light 2 Television 3 Air conditioner 4 Electric drill 5 Motor pump ...

Page 27: ... the circuit breakers on the control panel 2 Connect the load to the A C receptacles B Connecting the Load AUS Model WARNING To avoid personal injury A Connect or disconnect the load to the AC receptacle only when the engine is stopped i GL9000 AUS 50Hz 240V ii GL6000 AUS 50Hz 240V 1 Turn OFF the circuit breakers on the control panel 2 Connect the load to the A C receptacles 1 Circuit breaker A Re...

Page 28: ...evel Check coolant level Check generator grounding Refuel See Fuel in PERIODIC SERVICE section Care of danger warning and caution labels See DANGER WARNING AND CAUTION LABELS in SAFETY PRECAUTIONS section CAUTION To avoid personal injury from contact with moving parts A DO NOT open the door or generator side cover while the engine is running A Do not touch muffler or exhaust pipes while they are h...

Page 29: ...ely and the voltage and specific gravity reading in all cells remain constant for 3 or more successive readings taken at 30 minute intervals A When the battery has been charged fully the specific gravity of electrolyte should be 1 270 to 1 290 at 20 C 68 F C Engine oil The generator has been shipped without engine oil Fill with oil to the correct level before attempting to start the engine 1 Place...

Page 30: ... cigarettes away from generator 1 Always fill the fuel through the fuel tank strainer 2 Make sure that dirt or water does not enter the fuel tank 3 Fill with Diesel fuel No 2 D ASTMD975 4 Below 0 C 32 F a mix of No 1 D and No 2 D is acceptable 5 Fuel level is read by fuel gauge A If the fuel tank should empty completely causing the engine to stop then the fuel system requires air bleeding after fi...

Page 31: ... SAFETY DEVICES 1 Terminal cover is equipped with safety devices to detect the opening and or closing condition of cover 2 Safety switch 2 is located on the terminal cover If you turn the key switch to START with the terminal cover open the starter of engine will not activate 3 Turn the key switch to STOP to close the terminal cover and then restart the engine 4 If you open the terminal cover whil...

Page 32: ...en its service life 3 Ensure that the fuel lever is set to the OPEN Position 1 Fuel lever 2 Fuel filter pot A OPEN 4 Insert the key into the main switch and turn it ON 5 Check the battery charge lamp and oil pressure lamp are ON 1 Water temperature lamp 2 Oil pressure lamp 3 Battery charge lamp 4 Glow timer lamp 6 Turn the key to PREHEAT position 7 Turn the key to the START position and release wh...

Page 33: ...required when the engine is warmed up A Do not allow the starter motor to run continuously for more than 10 seconds A Be sure to warm up the engine not only in winter but also in warmer seasons An insufficiently warmed up engine can shorten its service life A When there is possibility of temperature drops below 15 C 5 F detach the battery from the machine and keep it indoor in a safe area Reinstal...

Page 34: ...ine 3 After stopping the engine make sure that the door is closed and the main switch key is at OFF 4 The following causes are possible for such unusual engine shut off Pinpoint and correct the cause of trouble A Check for the stop solenoid A Check to see if the battery has discharged too much or is in trouble A Check for disconnection of the battery terminals 1 Turn OFF all electrical device swit...

Page 35: ...tement in detail A When the battery is used for less than 100 hours in a year check its electrolyte yearly for refillable battery s only No Check point Interval Ref page First 50 hours Every 50 hours Every 100 hours Every 200 hours Every 400 hours Every 500 hours Every 800 hours Every 1500 hours Every 3000 hours Every 1 year Every 2 years 1 Check of fuel pipes and clamp bands 26 2 Change of engine...

Page 36: ... CF or better lubricating oil with a high Total Base Number TBN of 10 minimum C Fuel A Cetane number of 45 minimum Cetane number greater than 50 is preferred especially for temperatures below 20 C 4 F or elevations above 1500 m 5000 ft A If diesel fuel with sulfur content greater than 0 5 5000 ppm sulfur content is used reduce the service interval for engine oil and filter by 50 A DO NOT use diese...

Page 37: ...s a distillate fuel oil of lower volatility for engines in industrial and heavy mobile service SAE J313 JUN87 Grade of Diesel Fuel Oil According to ASTM D975 The cetane number is required not to be less than 45 A Be sure to use a strainer when filling the fuel tank or dirt or sand in the fuel may cause trouble in the fuel injection pump A Always use diesel fuel You are required not to use alternat...

Page 38: ...y more C Checking the fuel pipes CAUTION To avoid personal injury A Check or replace the fuel pipes after stopping the engine Broken fuel pipes can cause fires Check the fuel pipes every 50 hours of operation When if 1 If the clamp band is loose apply oil to the screw of the band and tighten the band securely 2 If the fuel pipes made of rubber became worn out replace them and clamp bands every two...

Page 39: ...when engine oil is overfilled This can effect the air intake system which could result in engine damage or malfunction C Checking oil level and adding engine oil 1 Check the engine oil level before starting or more than 5 minutes after stopping the engine 2 Remove the oil level gauge wipe it clean and reinstall it 3 Take the oil level gauge out again and check the oil level 4 If the oil level is t...

Page 40: ...the oil level gauge C Replacing the Oil Filter Cartridge CAUTION To avoid personal injury A Be sure to stop the engine before changing the oil filter cartridge A Allow engine to cool down sufficiently Oil can be hot and cause burns 1 Replace the oil filter cartridge every 200 hours of operation 2 Remove the old oil filter cartridge with a filter wrench Dispose of filter properly 3 Apply a film of ...

Page 41: ...ly 6 After the element is fully dried inspect the inside of the element with a light and check if it is damaged or not referring to the instructions on the label attached to the element 7 Replace the primary element every year or every 6 cleanings If the primary element is heavily stained replace it sooner At this time also replace the secondary element 8 The secondary element should be removed on...

Page 42: ...the coolant level before every op eration CAUTION To avoid personal injury A DO NOT stop the engine suddenly stop it after about 5 minutes of unloaded idling A Work only after letting the engine and radiator cool off completely more than 30 minutes after it has been stopped A DO NOT remove the radiator cap while coolant is hot When cool rotate cap slowly to the first stop to allow excess pressure ...

Page 43: ... the engine and add coolant if necessary C Changing coolant 1 To drain coolant always remove both drain plugs and simultaneously open the radiator cap as well With the radiator cap kept closed the coolant will not drain completely Dispose of used coolant properly 2 Remove the overflow pipe of the radiator pressure cap to drain the reserve tank 3 Prescribed coolant volume L U S qts include reserve ...

Page 44: ...o see if radiator water pipe is clogged C Cleaning radiator core outside If dust is between the fin and tube wash it away with running water A Do not clean radiator with firm tools such as spatulas or screwdrivers They may damage the delicate fins or tubes It can cause coolant leaks or decrease cooling performance A Be careful to keep water off of electrical parts C Cleaning the radiator Clean the...

Page 45: ...luted sulfuric acid solution burns skin and eyes and eats holes in clothing Should this occur immediately wash it off with running water and get medical attention Mishandling of the battery shortens the service life and adds to maintenance costs Obtain the maximum per formance and the longest life of the battery by handling properly and with care Engine starting will be difficult if the battery ch...

Page 46: ...le to the battery start with the positive terminal first If reversed the contact of tools on the battery may cause a shortage A DO NOT remove or disconnect the battery during operation otherwise the engine cannot be stopped with the key switch C Instructions for Long Term Storage 1 When storing the generator for long periods of time remove the battery adjust the electrolyte to the proper level and...

Page 47: ...enerators electrical system could result in severe damage to generators electrical system B Electric Wiring CAUTION To avoid personal injury Shorting of electric cable or wiring may cause a fire A Check to see if electric cables and wiring are swollen hardened or cracked A Keep dust and water away from all power connections Loose wiring and terminal parts make bad connections be sure to repair the...

Page 48: ...n the adjust nut to get the belt tension within the specified range 4 Tighten up the lock nut 5 Replace fan belt if it is damaged A If belt is loosen or damaged and the fan is damaged it could result in overheating or insufficient charging Adjust correctly or replace the belt 1 Fuse 3A External connection terminal block 2 Fuse 10A AC Accessory Line 3 Fuse 5A Glow 4 Fuse 15A Solenoid 5 Fuse 15A spa...

Page 49: ... 1 Remove dirty engine coolant fill with new coolant and run the engine for about 5 minutes When coolant is added coolant level drops the first time the engine is started stop the engine and add more coolant 2 Remove dirty engine oil fill with new oil and run the engine for about 5 minutes to let the oil penetrate to all the parts 3 Check all the bolts and nuts and tighten if necessary 4 Remove th...

Page 50: ...ircuit of load circuitry connected to output section Repair load Output cannot be obtained Rotation goes slow Voltage drops Breaker turns off Initial current is too much e g motor load Reduce load Overload Reduce load Engine indicates loaded condition Short circuit of generator wiring Stop immediately Request for repair Trouble Cause Countermeasure When the key is turned the lamp doesn t light on ...

Page 51: ...ter is dirty replace Check fuel tank Remove the settled impurities or moisture Air and water are contained in the fuel supply line Check pipe and fastening clamp If any damage exists replace it or repair Relieve air Remove water inside of fuel tank and filter Injection pipe is loosened Re tighten Engine suddenly stops Fuel shortage Refuel Insufficient engine oil Fill oil Water temperature is too h...

Page 52: ...exterior apparatus with the machine perform the following instructions 1 Remove the terminal taps cover 2 Connect the unit to the ectt with the wiring harnesses following the operator s manual of the A S S unit 3 To assemble the ttc set the ttc For nomenclature and connection of terminal taps are referred to the WIRING DIAGRAMS section See page 41 50 1 Plate 2 Exterior connection terminal taps ect...

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