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Kubota D902-E4B, Service Manual, Page: 3 / 32

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Table of Contents 

 

 

1. Attention Statements

 ··············································································· 

1 

 

2. General Safety Instructions

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2 

 

3. Specifications

 ···························································································· 

4 

 

4. General

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5 

4.1 Dimension ························································································ 5 

 

5. General Par ts Description

 ······························································ 7 

5.1 Serial Number ···················································································· 7 
5.2 Main Components ··············································································· 8 

 

6. Ser vice Data

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11 

6.1 Technical Specification ········································································ 11 
6.2 Generator ························································································ 12 

(1) Exciting Amperage ············································································ 13 
(2) Resistance Value ············································································ 13 
(3) Armature (Main Stator) #1 ································································· 14 
(4) Exciter Winding (Main Stator) ····························································· 15 
(5) Exciter Stator J (Brown) – K (Red) ······················································· 16 
(6) Rotor ··························································································· 17 
(7) Inspect Diode ················································································· 18 
(8) Inspect the Transformer ···································································· 19 
(9) Inspect the Volt meter ······································································ 19 

(10) Inspect the Breaker ········································································· 20 
(11) Inspect the Voltage regulator  ····························································· 20 

 

7. Tightening Torque

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22 

7.1 Specific Torque

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22 

7.2 General Torque

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23 

 

8. Periodical Check for Engine

 ·································································· 

24 

 

9. Trouble Shooting

 ····················································································· 

25 

 

10. Wiring Diagram

 ························································································ 

27 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Summary of Contents for D902-E4B

Page 1: ...File DGO 442_GL14000 USA SERVICE MANUAL GL14000 USA ...

Page 2: ...ng of diesel engine generators designated as GL14000 USA Shindaiwa products require necessary maintenance and adjustment to ensure product longevity safety and desired performance Fully understand this service manual before operating or performing service The information contained in this service manual describes equipment available at the time of publication While every attempt has been made to p...

Page 3: ...2 Generator 12 1 Exciting Amperage 13 2 Resistance Value 13 3 Armature Main Stator 1 14 4 Exciter Winding Main Stator 15 5 Exciter Stator J Brown K Red 16 6 Rotor 17 7 Inspect Diode 18 8 Inspect the Transformer 19 9 Inspect the Volt meter 19 10 Inspect the Breaker 20 11 Inspect the Voltage regulator 20 7 Tightening Torque 22 7 1 Specific Torque 22 7 2 General Torque 23 8 Periodical Check for Engin...

Page 4: ... service and maintenance of the equipment Completely understand the equipment safety and caution notifications Throughout this manual are special attention statements A statement preceded by the triangular attention symbol and the word WARNING contains information that should be acted upon to prevent serious bodily injury A statement preceded by the triangular attention symbol and the word CAUTION...

Page 5: ...y ventilated area such as inside of the building Entangled Injuries under By Moving Component NEVER reach or touch moving components during operation ALWAYS stop the engine during inspection to prevent serious bodily injury by entangled accident under moving component Electric shock Injuries Burns Never inspect equipment during use Never service or inspect when equipment while it is being operated...

Page 6: ...g the label s make sure to place the new label s in the same position STOP the equipment immediately when abnormal circumstances are noticed STOP the equipment immediately whenever abnormal circumstances are noticed such as unusual noise smell vibration and etc It may lead to a serious accident or fatal damage of the equipment or properties Inflammables Keep the equipment far away from fire such a...

Page 7: ...ated Output hp 20 7 Rated Speed rpm 3 600 Displacement cu in liters 55 0 898 Combustion System Indirect Injection Cooling Method Water cooled Starting Method Electric Fuel No 2 D S15 EPA regulation Lubricating Oil API service type CD class or better Fuel Tank Capacity gal liters 9 6 36 4 Lubricant Volume gal liters 0 95 3 6 Coolant Volume gal liters 1 1 4 1 including sub tank 0 16 0 6 Starting Mot...

Page 8: ...5 4 General 4 1 Dimension Unit below is shown by mm ...

Page 9: ...6 ...

Page 10: ...7 5 General Parts Description 5 1 Serial Number Unit Serial Number Engine Serial Number ...

Page 11: ...8 5 2 Main Components ...

Page 12: ...d speed adjusting rod To Check 1 Remove the coupler and rod 2 Supply a DC 12V 220mA from the battery to the coupler and the motor would rotate one direction 3 Switch the positive and negative wires from the battery and connect the wires to the coupler in reverse again The motor shall rotate other direction Engine Stop Solenoid Feature supply or stop fuel Diode Feature Convert to AC to DC Refer to ...

Page 13: ...ring the engine operation for safety reasons Ground Fault Circuit Interrupter GFCI 1 Phase Receptacle 20A Feature 1 Supply AC output 2 Detect the electric leakage and shut off the output 1 Phase Receptacle 30A 120 240V Feature Supply AC output Level Switch spill containment Feature detects the liquid volume accumulated in the spill containment Oil Pan Feature accumulate oil used to lubricate the e...

Page 14: ... coolant temp read 20 Glow lamp ON for 10 sec Automatic Preheat System Max rpm at no load 3600 min 1 Lubricant oil pressure 0 1 0 49MPa 1 5kgf cm Coolant temperature 70 100 Frame temperature limit within 80 Sealed bearing temperature limit within 60 Speed regulation Momentary within 10 Steady state deviation within 5 Voltage regulation Momentary within 20 Steady state deviation within 1 0 Frequenc...

Page 15: ...12 6 2 Generator Stator Rotor Main Stator Exciter Stator Front Bracket Rear Bracket Main Rotor Cooling Fan Ball bearing ...

Page 16: ...nal resistance of the winding is tolerated within 10 at 20 of the ambient temperature The resistance must be measured by low resistance tester It cannot be measured by multi purpose tester due to index error Measurement value Ω Main Stator Exciter Stator Rotor 1 2 3 4 5 Armature Exciter Winding J K Exciter Field Armature Between U W A B B C C D 0 14Ω 0 29Ω 5 8Ω 8 60Ω 0 83Ω B W R G Y Br L Or Gr Vi ...

Page 17: ...14 3 Armature Main Stator 1 Measure the resistance among the U W by the low resistance tester Each shall be 0 14Ω U W U W ...

Page 18: ...15 4 Exciter Winding Main Stator The resistance among A B B C and C D by the low resistance tester Each shall be 0 29Ω C B A D C B A D ...

Page 19: ...16 5 Exciter Stator J Brown K Red Measure resistance among the J K by the resistance ohm tester It shall be 5 8Ω K R J Br K R J Br ...

Page 20: ...ish with sand paper and measure Exciter Winding the resistance among the two points as shown in the photo above by the low resistance tester It shall be 8 6Ω Field Winding the resistance among the two points as shown in the photo above by the low resistance tester It shall be 0 83Ω 1 3 4 2 Rotor Rectifier ...

Page 21: ...e rectifier as per the procedures described above 1 Insert the red probe positive to the Anode and the black prove negative to the Cathode Display shall show 0 6V 2 Insert the black probe negative to the Anode and the red prove positive to the Cathode Display shall show 2 6V 1 2 Anode Cathode Cathode The cutout corner is positive as it is indicated in the side and angled corners are negative Anode...

Page 22: ...t meter ELECTRIC SHOCK WARNING Never touch the terminals during operation 1 Start engine 2 Connect the probe of the tester to the terminals in the back of the volt meter and measure the voltage among the terminals 3 The volt meter is a malfunctioning if the needle of the meter does not deflect Measure the voltage of the volt meter Red Orange Yellow Brown Orange ...

Page 23: ...nob turns 1 Shut off engine Turn the main circuit breaker OFF 2 Check the resistance with a ohmmeter between upper terminal and lower terminal of Upper Terminal Lower Terminal U U W W The ohmmeter should display the symbol of infinity or similar per the ohmmeter that you may use 1 Shut off engine Turn the main circuit breaker ON 2 Check the resistance with a ohmmeter between upper terminal and low...

Page 24: ... Hz at no load 2 Turn the voltage selector located in the front panel to MAX position 3 Dial the VR4 that locates in the printed circuit to the middle Criterion U W 1 phase 255 2V Otherwise adjust the VR1 volume until it shows 255 2V Position of the VR1 VR4 volume ...

Page 25: ...AD ENGINE BOLT 10 M10x1 25x20 2 28 5 34 3 291 349 9 PLUG DRAIN SOCKET PLUG DRAIN M12x1 25x13 3 39 3 49 0 401 499 10 PIPE EXHAUST ENGINE PIPE EXHAUST NUT 8 M8 6 17 7 21 5 181 219 11 LEAD SWITCH MAGNETIC NUT M8 1 9 9 11 7 101 119 12 TERMINAL BATTERY BATTERY NUT M6 2 5 0 6 0 51 61 13 LEAD TERMINAL BATTERY BOLT M8 2 6 9 8 8 71 89 14 HARNESS WIRE PLUG GLOW NUT M4 1 1 0 1 7 11 17 15 HARNESS WIRE OIL PRE...

Page 26: ...6149 627 23 239 20 30 204 306 11712 1194 Ｍ10 1 5 24 248 21 31 214 316 9744 994 46 473 40 60 408 612 18560 1893 Ｍ12 1 75 42 433 37 54 377 551 14162 1444 81 825 70 100 714 1020 26976 2751 Ｍ14 2 0 68 690 60 85 612 867 19320 1970 129 1313 110 160 1122 1632 36800 3753 Ｍ16 2 0 106 1076 90 130 918 1326 26376 2690 201 2049 170 250 1734 2549 50240 5123 Ｍ18 2 5 145 1480 125 180 1275 1835 32256 3289 276 2819...

Page 27: ...ck Add Coolant 6 Coolant Change or 2 years 7 Clean Fuel Filter 1 st 2 nd 8 Change Fuel Filter 9 Drain Water Clean Fuel Tank 10 Check Leakage Fuel Oil Water 11 Check Add Battery Liquid 12 Clean Air Element 1 st 2 nd 13 Change Air Element 14 Adjust tension V belt 1 st 2 nd 15 Change V belt or 2 years 16 Clean Radiator Fin 17 Clean Radiator inside 18 Change Fuel Hose Oil Hose Vibration absorbing Rubb...

Page 28: ...lace exciter stator Check exciter winding Refer to page 15 Replace main stator rectifier 1 and rectifier 2 Check main stator Refer to page 14 Replace main controller AVR Replace main stator Check transformer Check if wire is damaged or disconnected Refer to page 19 Replace transformer Replace lead wire Replace voltage regulator Replace lead wire Check Voltage regulator Check if wire is damaged or ...

Page 29: ...nsformer Check if wire is damaged or disconnected Refer to page 19 NO NO Replace transformer Replace lead wire OK Check speed control motor Refer to page 9 NO Replace speed control motor Replace main controller OK Check items NO AC OUTPUT Refer to page 25 OK ...

Page 30: ...10 Wiring Diagram 27 ...

Page 31: ...28 ...

Page 32: ...KUBOTA ENGINE AMERICA CORPORATION 505 Schelter Road Lincolnshire IL 60069 Telephone 847 955 2500 www kubotaengine com ...

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