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Kubota GL11000 Workshop Manual Download Page 136

2-S5

GL6000, GL7000, GL9000, GL11000, WSM

GENERATOR

W1088099

Charge Lamp Does 
not Light Even with 
The Key Switch 
Turned "ON" When 
The Engine is 
Stopped

Burnt out 10A fuse

Check the fuse 

(10 A) and the 

wiring

Repair or replace

Charge lamp burned

Check the charge 

lamp and the wiring

Trouble

Cause

Confirmation

Countermeasure

KiSC issued 05, 2015 A

Summary of Contents for GL11000

Page 1: ...WORKSHOP MANUAL DIESEL GENERATOR GL6000 GL7000 GL9000 GL11000 KiSC issued 05 2015 A ...

Page 2: ...art should be understood before proceeding with troubleshooting disassembling and servicing Servicing There are troubleshooting servicing specification lists checking and adjusting disassembling and assembling and servicing which cover procedures precautions factory specifications and allowable limits All information illustrations and specifications contained in this manual are based on the latest...

Page 3: ...search function Search word to find all the revised locations Lastdigit of the Code No Issue month Main Revised Point and Corrective Measures Search word Reference Page 3 2015 04 GL9000 GL11000 Generator changed KiSC issued 05 2015 A ...

Page 4: ...on the machine itself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoide...

Page 5: ...ter stopping Otherwise hot water will spout out from radiator Only remove radiator cap when cool enough to touch with bare hands Slowly loosen the cap to first stop to relieve pressure before removing completely Escaping fluid fuel or hydraulic oil under pressure can penetrate the skin causing serious injury Relieve pressure before disconnecting hydraulic or fuel lines Tighten all connections befo...

Page 6: ...ion regulations when disposing of oil fuel coolant electrolyte and other harmful waste PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin clothing and cause blindness if splashed into eyes Keep electrolyte away from eyes hands and clothing If you spill electrolyte on yourself flush with water and get medical attention immediately PREPARE FOR EMERG...

Page 7: ...STRUCTIONS The following safety decals are installed on the generator If a decal becomes damaged illegible or is not on the generator replace it The decal part number is listed in the parts list Receptacle Type SAFETY DECALS KiSC issued 05 2015 A ...

Page 8: ...5 GL6000 GL7000 GL9000 GL11000 WSM SAFETY INSTRUCTIONS Terminal Type KiSC issued 05 2015 A ...

Page 9: ... coil B Rotor coil F Engine Design Vertical liquid cooled 4 cycle diesel Model name Z482 E2B SEC 2 Rated output 6 9 kW Speed 3000 min 1 rpm Number of cylinder Bore x Stroke 2 67 x 68 mm 2 2 52 x 2 68 in Displacement 0 479 L 29 23 cu in Fuel tank capacity 28 L 7 4 U S gals Crankcase oil capacity 2 2 L 0 58 U S gals Starting system Electric type 12 V 0 8 kW Battery 38B20R 12 V x 28 Ah 5 Hr Continuou...

Page 10: ...or coil F Engine Design Vertical liquid cooled 4 cycle diesel Model name Z482 E2B SEC 3 Rated output 8 1 kW Speed 3600 min 1 rpm Number of cylinder Bore x Stroke 2 67 x 68 mm 2 2 52 x 2 68 in Displacement 0 479 L 29 23 cu in Fuel tank capacity 28 L 7 4 U S gals Crankcase oil capacity 2 2 L 0 58 U S gals Starting system Electric type 12 V 0 8 kW Battery 38B20R 12 V x 28 Ah 5 Hr Continuous operating...

Page 11: ... Rotor coil F Engine Design Vertical liquid cooled 4 cycle diesel Model name D722 E2B SEC 2 Rated output 10 3 kW Speed 3000 min 1 rpm Number of cylinder Bore x Stroke 3 67 x 68 mm 3 2 52 x 2 68 in Displacement 0 719 L 48 89 cu in Fuel tank capacity 28 L 7 4 U S gals Crankcase oil capacity 3 4 L 0 90 U S gals Starting system Electric type 12 V 1 0 kW Battery 55B24R 12 V x 36 Ah 5 Hr Continuous oper...

Page 12: ...l B Rotor coil F Engine Design Vertical liquid cooled 4 cycle diesel Model name D722 E2B SEC 2 Rated output 12 2 kW Speed 3600 min 1 rpm Number of cylinder Bore x Stroke 3 67 x 68 mm 3 2 52 x 2 68 in Displacement 0 719 L 48 89 cu in Fuel tank capacity 28 L 7 4 U S gals Crankcase oil capacity 3 4 L 0 90 U S gals Starting system Electric type 12 V 1 0 kW Battery 55B24R 12 V x 36 Ah 5 Hr Continuous o...

Page 13: ...SIONS W1038971 GL6000 STD GL6000 AUS GL7000 STD GL7000 USA GL7000 USA TM GL9000 STD GL9000 AUS GL11000 STD GL11000 USA GL11000 USA TM L 1066 mm 42 0 in 1281 mm 50 4 in W 618 mm 24 3 in 618 mm 24 3 in H 698 mm 27 5 in 698 mm 27 5 in KiSC issued 05 2015 A ...

Page 14: ...BOLTS G 11 6 MAINTENANCE CHECK LIST G 12 7 CHECK AND MAINTENANCE G 14 1 DAILY CHECK G 14 2 CHECK POINTS OF INITIAL 50 HOURS G 15 3 CHECK POINT OF EVERY 50 HOURS G 16 4 CHECK POINT OF EVERY 100 HOURS G 16 5 CHECK POINT OF EVERY 200 HOURS G 18 6 CHECK POINT OF EVERY 300 HOURS G 19 7 CHECK POINT OF EVERY 400 HOURS G 19 8 CHECK POINTS OF EVERY 500 HOURS G 20 9 CHECK POINT OF EVERY 800 HOURS G 22 10 CH...

Page 15: ... engine serial number is an identified number for the engine It is marked after the engine model number It indicates month and year of manufacture as follows Year of manufacture W1035676 Alphabet or Number Year Alphabet or Number Year 4 2004 G 2016 5 2005 H 2017 6 2006 J 2018 7 2007 K 2019 8 2008 L 2020 9 2009 M 2021 A 2010 N 2022 B 2011 P 2023 C 2012 R 2024 D 2013 S 2025 E 2014 T 2026 F 2015 V 20...

Page 16: ...vices listed in the appropriate KUBOTA Operator s Manual or in the appropriate E4B KUBOTA Workshop Manual Use of incorrect replacement parts or replacement parts from other emission level engines for example E2B engines may result in emission levels out of compliance with the original E4B design and EPA or other applicable regulations Please refer to the emission label located on the engine head c...

Page 17: ...G GENERAL 3 CYLINDER NUMBER The cylinder numbers of KUBOTA diesel engine are designated as shown in the figure The sequence of cylinder numbers is given as No 1 No 2 and No 3 starting from the gear case side W1011077 KiSC issued 05 2015 A ...

Page 18: ...ssembling external or internal snap rings position them so that the sharp edge faces against the direction from which force is applied Be sure to perform run in the serviced or reassembled engine Do not attempt to give heavy load at once or serious damage may result to the engine W10109040 Before checking any generator or engine electrical component be sure to check that all terminals and connecto...

Page 19: ...ler to perform periodic check for a fee Do not attempt to modify or remodel any electrical parts and wiring When removing the battery cables disconnect the negative cable first When installing the battery cables connect the positive cable first W10111140 1 WIRING Securely tighten wiring terminals W10112160 Do not let wiring contact dangerous part W10113130 Securely insert grommet W10113880 1 Negat...

Page 20: ...part where sag be required W10115870 In installing a part take care not to get wiring caught by it W10116700 After installing wiring check protection of terminals and clamped condition of wiring only connect battery W10117350 1 Clamp Wind Clamp Spirally 2 Wire Harness 3 Clamp 4 Welding Dent 1 Wiring 2 Clamp A Correct B Incorrect 1 Wiring A Incorrect 1 Cover Securely Install Cover KiSC issued 05 20...

Page 21: ...f with water immediately Before recharging the battery remove it from the machine Before recharging remove cell caps Do recharging in a well ventilated place where there is no open flame nearby as hydrogen gas and oxygen are formed W10118160 3 FUSE Use fuses with specified capacity Neither too large or small capacity fuse is acceptable Never use steel or copper wire in place of fuse Do not install...

Page 22: ...in that there is no female connector being too open W10124300 Make certain plastic cover is large enough to cover whole connector W10125190 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provided with tester Check for polarity and range W10126840 1 Exposed Terminal 2 Deformed Terminal 3 Sandpaper 4 Rust A Correct B Incorrect 1 Cover A Correct B Incorrect KiSC issued 05 2015 A ...

Page 23: ...L11000 USA TM 1 Engine oil 2 2 L 2 3 U S qts 1 9 Imp qts 3 4 L 3 6 U S qts 3 0 Imp qts Higher than CF class API Above 25 C 77 F SAE10W 30 SAE10W 30 SAE30 0 to 25 C 32 to 77 F SAE10W 30 SAE10W 40 SAE20 Below 0 C 32 F SAE10W 30 SAE10W 40 SAE10 2 Fuel 28 L 7 4 U S gals 6 2 Imp gals Refer to NOTE 3 Coolant 3 7 L 3 9 U S qts 3 3 Imp qts 4 1 L 4 3 U S qts 3 6 Imp qts Clean water Soft water Use antifreez...

Page 24: ...fur fuel sulfur content 0 50 5000 ppm to 1 0 10000 ppm is used as a diesel fuel change the engine oil and oil filter at shorter intervals approximately half DO NOT USE Fuels that have sulfur content greater than 1 0 10000 ppm Diesel fuels specified to EN 590 or ASTM D975 are recommended No 2 D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service SAE J313 JUN8...

Page 25: ...1 2 1 00 to 1 15 7 24 to 8 31 7 85 to 8 82 0 80 to 0 90 5 79 to 6 50 M8 8 mm 0 31 in 17 7 to 20 5 1 8 to 2 1 13 1 to 15 1 16 7 to 19 6 1 7 to 2 0 12 3 to 14 4 23 6 to 27 4 2 4 to 2 8 17 4 to 20 2 17 7 to 20 5 1 8 to 2 1 13 1 to 15 1 M10 10 mm 0 39 in 39 3 to 45 1 4 0 to 4 6 29 0 to 33 2 31 4 to 34 3 3 2 to 3 5 23 2 to 25 3 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 39 3 to 44 1 4 0 to 4 5 29 0 to 32 5 M...

Page 26: ...y 300 hours Every 400 hours Every 500 hours Reference page 1 Engine oil Check G 14 Change G 15 16 2 Radiator coolant L L C Check G 14 Change G 24 3 Air cleaner element Clean G 17 Change G 24 4 Fan belt Check G 17 Change G 23 5 Fuel line Fuel hose and clamp bands Check G 16 Change G 25 6 Battery Check G 15 17 Change G 25 7 Radiator hose and clamp bands Check G 18 Change G 25 8 Oil filter cartridge ...

Page 27: ...6 Change G 25 6 Battery Check G 15 17 Change G 25 7 Radiator hose and clamps Check G 18 Change G 25 8 Oil filter cartridge Change G 15 18 9 Fuel filter element Clean G 18 Change G 19 10 Valve clearance Check G 22 11 Water jacket Radiator interior Clean G 20 12 Generator s brush ware Check G 19 13 Generator s slip ring Check G 19 14 Generator s ball bearing Check G 23 15 Damage in electric wiring a...

Page 28: ... the proper SAE Engine oil according to ambient temperatures Refer to 4 LUBRICANTS FUEL AND COOLANT G 9 W1021730 Checking Coolant Level CAUTION Do not remove the radiator cap while operating or immediately after stopping Otherwise hot water will spout out from the radiator Wait for more than ten minutes to cool the radiator before opening the cap 1 Remove the radiator cap and check to see that the...

Page 29: ...e changing the engine oil filter cartridge 1 Remove the engine oil filter cartridge 1 with the filter wrench 2 Apply engine oil slightly to the rubber gasket of new cartridge 3 Install the new cartridge screwing it in by hand Over tightening may cause deformation of the rubber gasket 4 After the cartridge has been changed the engine oil level normally lowers a little Add engine oil to proper level...

Page 30: ...sconnected for change close both ends of the fuel line with a piece of clean cloth or paper to prevent dust and dirt from entering Entrance of dust and dirt causes malfunction of the fuel injection pump In addition particular care must be taken not to admit dust and dirt into the fuel pump W1035921 4 CHECK POINT OF EVERY 100 HOURS Changing Engine Oil CAUTION Be sure to stop engine before changing ...

Page 31: ...t is damaged replace it 3 Check if the fan belt is worn and sunk in the pulley groove 4 If the fan belt is nearly worn out and deeply sunk in the pulley groove replace it W1209480 Fan Belt Tension 1 Measure the deflection A depressing the belt halfway between the fan drive pulley and alternator pulley at specified force 98 N 10 kgf 22 lbf 2 If the measurement is not within the factory specificatio...

Page 32: ...years or earlier if checked and found that hoses are swollen hardened or cracked W1014590 Changing Engine Oil Filter Cartridge CAUTION Be sure to stop the engine before changing the engine oil filter cartridge 1 Remove the engine oil filter cartridge 1 with the filter wrench 2 Apply engine oil slightly to the rubber gasket of new cartridge 3 Install the new cartridge screwing it in by hand Over ti...

Page 33: ...ERY 400 HOURS Changing Fuel Filter Element 1 Close the fuel valve 1 2 Remove the fuel filter element 2 3 Install the new fuel filter element screwing it in by hand NOTE Check for fuel leak after replaced it W1052658 Brush length Stretch out of the Holder Standard length All model 15 0 mm 0 59 in Allowable limit GL6000 GL7000 4 5 mm 0 18 in GL9000 GL11000 7 5 mm 0 30 in H Brush Length Slip ring O D...

Page 34: ... instruction 6 After flushing fill with clean water and anti freeze until the coolant level is just below the port Install the radiator cap securely 7 Fill with coolant up to FULL mark on the recovery tank 3 8 Start and operate the engine for few minutes 9 Stop the engine remove the key and let cool 10 Check coolant level of recovery tank 3 and add coolant if necessary IMPORTANT Do not start engin...

Page 35: ...the anti freeze with water and then fill in to the radiator At 1 013 x 100000 Pa 1 033 kgf cm2 pressure atmospheric A higher boiling points is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system NOTE The above data represents industry standards that necessitate a minimum glycol content in the concentrated anti freeze When the coolant level ...

Page 36: ...at the compression top dead center or the overlap position Now referring to the table below readjust the valve clearance The piston is at the compression top dead center when both the IN and EX valves do not move it is at the overlap position when both the valves move Finally turn the flywheel 6 28 rad 360 and align the TC marking line and the center of timing window Adjust all the other valve cle...

Page 37: ...el begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer in the nozzle holder to adjust it W10182100 Nozzle Spraying Condition 1 Set the injection nozzle to a nozzle tester and check the nozzle spraying condition 2 If the spraying condition is defective replace the nozzle piece W10182120 Nozzle Valve Seat Tightness 1 Set the i...

Page 38: ...ly to the stop to relieve any excess pressure before removing cap completely 1 Stop the engine and let cool down 2 To drain the coolant open the water drain plug 2 and remove radiator cap 1 The radiator cap must be removed to completely drain the coolant 3 After all coolant is drained close the water drain plug 2 4 Fill with clean water and anti freeze until the coolant level is just below the por...

Page 39: ...check the fuel line Never fail to check the fuel line periodically The fuel line is subject to wear and aging fuel may leak out onto the running engine causing a fire 1 Change the fuel hoses 2 together with clamps 1 every 2 years or whenever they are found to be damaged W1053457 Changing Battery CAUTION Be sure to stop the engine before disconnecting the cables When removing the battery cables dis...

Page 40: ...024200 Oil Pressure Tester Code No 07916 32032 Application Use to measure lubricating oil pressure W1024318 Plastigauge Code No 07909 30241 Application Use to check the oil clearance between crankshaft and bearing etc Measuring Green 0 025 to 0 076 mm 0 001 to 0 003 in range Red 0 051 to 0 152 mm 0 002 to 0 006 in Blue 0 102 to 0 229 mm 0 004 to 0 009 in W1024719 Special Use Puller Set Code No 079...

Page 41: ...09 31371 Application Use to check cracks on cylinder head cylinder block etc W1024909 Flywheel Puller Code No 07916 32011 Application Use exclusively for removing the flywheel with ease W1059257 Auxiliary Socket for Fixing Crankshaft Sleeve Code No 07916 34041 Application Use exclusively for fixing the crankshaft sleeve W1024532 Radiator Tester Code No 07909 31551 Application Use to check of radia...

Page 42: ...he enter circumference H Retaining nut I 17 mm dia 0 67 in dia J 8 mm dia 0 31 in dia K 1 0 mm 0 039 in L 17 mm dia 0 67 in dia M 6 10 to 6 20 mm dia 0 2402 to 0 2441 in dia N 8 mm 0 31 in O 4 mm 0 16 in P 11 97 to 11 99 mm dia 0 4713 to 0 4720 in dia Q PF 1 2 R 23 mm 0 91 in S 17 mm 0 67 in T 4 mm 0 16 in U 12 00 to 12 02 mm dia 0 4724 to 0 4732 in dia V 100 mm 3 94 in W M12 P1 5 X 5 mm 0 20 in A...

Page 43: ...921 to 0 3929 in dia F 5 5 to 5 7 mm dia 0 2165 to 0 2244 in dia G 25 mm 0 98 in H 6 0 to 6 1 mm dia 0 236 to 0 240 in dia I 5 mm 0 197 in J 20 mm dia 0 787 in dia K 12 5 to 12 8 mm dia 0 492 to 0 504 in dia L 8 9 to 9 1 mm 0 350 to 358 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 012 in A 150 mm 5 91 in B 30 mm 1 18 in C 20 mm 0 79 in D 25 mm dia 0 98 in dia E 21...

Page 44: ...mm 2 83 in C 40 mm radius 1 57 in radius D 10 mm 0 39 in E 22 mm 0 87 in F 20 mm dia 0 79 in dia G 47 90 to 47 95 mm dia 1 8858 to 1 8878 in dia H 43 90 to 43 95 mm dia 1 7283 to 1 7303 in dia A 130 mm 5 12 in B 72 mm 2 83 in C 40 mm radius 1 57 in radius D 9 mm 0 35 in E 24 mm 0 95 in F 20 mm dia 0 79 in dia G 68 mm dia 2 68 in dia H 43 90 to 43 95 mm dia 1 7283 to 1 7303 in dia KiSC issued 05 20...

Page 45: ...CONTENTS MECHANISM 1 ENGINE BODY 1 M1 1 HALF FLOATING HEAD COVER 1 M1 2 LUBRICATING SYSTEM 1 M2 3 COOLING SYSTEM 1 M3 4 FUEL SYSTEM 1 M4 KiSC issued 05 2015 A ...

Page 46: ...Y 1 HALF FLOATING HEAD COVER The rubber packing is fitting in to maintain the head cover 0 5 mm or so off the cylinder head This arrangement helps reduce noise coming from the cylinder head W1013396 1 Cylinder Head Cover 2 Rubber Packing KiSC issued 05 2015 A ...

Page 47: ... forced to crankshaft 6 connecting rods 14 idle gear 5 camshaft 12 and rocker arm shaft 3 to lubricate each part Some part of oil splashed by the crankshaft or leaking and dropping from gaps of each part lubricates these parts piston 13 cylinders small ends or connecting rods tappets 11 push rods 10 inlet and exhaust valves 4 and timing gears 1 Rocker Arm 2 Oil Pressure Switch 3 Rocker Arm Shaft 4...

Page 48: ...ceives water from the radiator or from the cylinder head and force it into the cylinder block The thermostat opens or closes according to the water temperature When the water temperature is high the thermostat opens to allow the water to flow from the cylinder head to the radiator When the water temperature is low the thermostat close to flow the water only to the water pump 1 Radiator 2 Water Pum...

Page 49: ...to 14 71 MPa 140 to 150 kgf cm2 1990 to 2133 psi of the injection nozzle 1 is injected into the combustion chamber Part of the fuel fed to the injection nozzle 1 lubricates the moving parts of the needle valve inside the nozzle then returns to the fuel tank through the fuel overflow pipe 2 from the upper part of the nozzle holder 1 Injection Nozzle 2 Fuel Overflow Pipe 3 Fuel Tank 4 Fuel Filter 5 ...

Page 50: ...ystem 1 S16 4 Fuel System 1 S18 5 Electrical System 1 S21 2 PREPARATION 1 S25 1 Separating Engine 1 S25 3 DISASSEMBLING AND ASSEMBLING 1 S28 1 Cylinder Head and Valves 1 S28 2 Timing Gears Camshaft Fuel Camshaft and Oil Pan 1 S32 3 Piston and Connecting Rod 1 S36 4 Crankshaft 1 S38 5 Water Pump 1 S40 6 Injection Nozzle 1 S40 7 Starter 1 S41 4 SERVICING 1 S43 1 Cylinder Head and Valves 1 S43 2 Timi...

Page 51: ...tioning Replace 1 S19 S32 Seizure of crankshaft camshaft piston cylinder or bearing Repair or replace 1 S36 to S39 1 S52 to S57 Compression leak from cylinder Replace head gasket tighten cylinder head screw glow plug and nozzle holder 1 S12 31 Improper valve timing Correct or replace timing gear G 22 Piston ring and cylinder worn Replace 1 S52 S57 Excessive valve clearance Adjust G 22 Starter Does...

Page 52: ... moving parts seem to be seizing Repair or replace Uneven fuel injection Replace injection pump 1 S20 Deficient nozzle injection Repair or replace nozzle 1 S20 Compression leak Replace head gasket tighten cylinder head screw glow plug and nozzle holder 1 S12 Excessive Lubricant Oil Consumption Piston ring s gap facing the same direction Shift ring gap direction 1 S36 Oil ring worn or stuck Replace...

Page 53: ... oil Use specified type of oil G 9 Oil pump defective Repair or replace 1 S34 S58 High Oil Pressure Different type of oil Use specified type of oil G 9 Relief valve defective Replace Engine Overheated Engine oil insufficient Fill oil G 9 14 Fan belt broken or tensioned improperly Replace or adjust G 17 Coolant insufficient Fill coolant G 14 20 Radiator net and radiator fin clogged with dust Clean ...

Page 54: ... Valve Seat Angle 0 785 rad 45 Width 2 12 mm 0 0835 in Valve Stem to Valve Guide Valve Stem Valve Guide Clearance O D I D 0 030 to 0 057 mm 0 00118 to 0 00224 in 5 968 to 5 980 mm 0 23496 to 0 23543 in 6 010 to 6 025 mm 0 23661 to 0 23720 in 0 10 mm 0 0039 in Valve Seat Angle Width 0 785 rad 45 2 12 mm 0 0835 in Valve Face Angle 0 785 rad 45 Valve Recessing Intake and Exhaust 0 10 to 0 10 mm 0 003...

Page 55: ...9 to 0 41410 in 0 15 mm 0 0059 in Push Rod Alignment 0 25 mm 0 0098 in Tappet to Tappet Guide Bore Tappet Tappet Guide Bore Oil Clearance O D I D 0 016 to 0 052 mm 0 00063 to 0 00205 in 17 966 to 17 984 mm 0 70732 to 0 70803 in 18 000 to 18 018 mm 0 70866 to 0 70937 in 0 10 mm 0 0039 in Camshaft Cam Height Side Clearance Alignment Intake and Exhaust 0 15 to 0 31 mm 0 0059 to 0 0122 in 26 88 mm 1 0...

Page 56: ...9 to 0 00331 in 19 967 to 19 980 mm 0 78610 to 0 78661 in 20 000 to 20 051 mm 0 78740 to 0 78941 in 0 10 mm 0 0039 in Piston Pin Bore I D 20 000 to 20 013 mm 0 78740 to 0 78791 in 20 05 mm 0 7894 in Piston Ring Clearance Second Ring Oil Ring Clearance Clearance 0 90 to 0 120 mm 0 00354 to 0 00472 in 0 04 to 0 08 mm 0 0016 to 0 0031 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in Piston Ring Gap Top Ring Se...

Page 57: ...3 mm 1 73142 to 1 73201 in 0 20 mm 0 0079 in Crankshaft Journal to Crankshaft Bearing 3 Intermediate Crankshaft Journal Crankshaft Bearing 3 Oil Clearance O D I D 0 028 to 0 059 mm 0 00110 to 0 00232 in 43 934 to 43 950 mm 1 72968 to 173031 in 43 978 to 43 993 mm 1 73142 to 1 73201 in 0 20 mm 0 0079 in Crankpin to Crankpin Bearing Crankpin Crankpin Bearing Oil Clearance O D I D 0 020 to 0 051 mm 0...

Page 58: ...0 0055 in Outer Rotor to Pump Body Clearance 0 07 to 0 15 mm 0 0028 to 0 0059 in Inner Rotor to Cover Clearance 0 075 to 0 135 mm 0 00295 to 0 00531 in Fan Belt Tension 7 0 to 9 0 mm 98 N 0 28 to 0 35 in 98 N 10 kgf 22 lbf Thermostat Valve Opening Temperature At Beginning Valve Opening Temperature Opened Completely 69 5 to 72 5 C 157 1 to 162 5 F 85 C 185 F Radiator Cap Pressure Falling Time 10 se...

Page 59: ...sure When the pressure is 12 75 kPa 130 kgf cm2 1849 psi the valve seat must be fuel tightness Starter Electromagnetic Drive Type Commutator Difference Mica Brush O D O D Undercut Length 28 0 mm 1 102 in Less than 0 05 mm 0 0002 in 0 50 to 0 80 mm 0 0197 to 0 0315 in 16 0 mm 0 630 in 27 0 mm 1 063 in 0 4 mm 0 016 in 0 20 mm 0 0079 in 10 5 mm 0 413 in Starter Planetary Gear Reduction Type Commutato...

Page 60: ...0 to 2 5 14 5 to 18 1 Nozzle holder assembly M20 x 1 5 49 0 to 68 6 5 0 to 7 0 36 2 to 50 6 Glow plug M8 x 1 7 85 to 14 7 0 8 to 1 5 5 8 to 10 8 Rocker arm bracket screw M6 x 1 9 8 to 11 3 1 00 to 1 15 7 2 to 8 3 Cylinder head screw M8 x 1 25 37 3 to 42 2 3 8 to 4 3 27 5 to 31 1 Fan drive pulley screw M12 x 1 5 98 1 to 107 9 10 0 to 11 0 72 3 to 79 6 Idle gear shaft mounting screw M6 x 1 9 8 to 11...

Page 61: ... W1012705 Grade Nominal Unit Diameter Standard Screw and Bolt Special Screw and Bolt N m kgf m lbf ft N m kgf m lbf ft M6 7 9 to 9 3 0 80 to 0 95 5 8 to 6 9 9 8 to 11 3 1 00 to 1 15 7 23 to 8 32 M8 17 7 to 20 6 1 8 to 2 1 13 0 to 15 2 23 5 to 27 5 2 4 to 2 8 17 4 to 20 3 M10 39 2 to 45 1 4 0 to 4 6 28 9 to 33 3 48 1 to 55 9 4 9 to 5 7 35 4 to 41 2 M12 62 8 to 72 6 6 4 to 7 4 46 3 to 53 5 77 5 to 9...

Page 62: ...nder piston ring top clearance valve and cylinder head 6 If the measurement is below the allowable limit apply a small amount of oil to the cylinder wall through the nozzle hole and measure the compression pressure again 7 If the compression pressure is still less than the allowable limit check the top clearance valve clearance and cylinder head 8 If the compression pressure increases after applyi...

Page 63: ...ad screws to the specified torque 4 Turn the flywheel until the piston exceeds its top dead center 5 Remove the cylinder head and measure the thickness of the squeezed fuses 6 If the measurement is not within the factory specifications check the oil clearance between the crankpin and crankpin bearing and between the piston pin and small end bushing NOTE After checking the top clearance be sure to ...

Page 64: ... top dead center or the overlap position Now referring to the table below readjust the valve clearance The piston is at the compression top dead center when both the IN and EX valves do not move it is at the overlap position when both the valves move Finally turn the flywheel 6 28 rad 360 and align the TC marking line and the center of timing window Adjust all the other valve clearance as required...

Page 65: ...il strainer clogged Oil filter cartridge clogged Oil gallery clogged Excessive oil clearance Foreign matter in the relief valve When reassembling After checking the engine oil pressure tighten the engine oil pressure switch to the specified torque W10349520 Engine oil pressure At idle speed Factory spec More than 49 kPa 0 5 kgf cm2 7 psi At rated speed Factory spec 196 to 441 kPa 2 0 to 4 5 kgf cm...

Page 66: ... and deeply sunk in the pulley groove replace it W1016443 Thermostat Valve Opening Temperature 1 Suspend the thermostat in the water by a string with its end inserted between the valve and seat 2 Heating the water gradually read the temperature when the valve opens and leaves the string 3 Continue heating and read the temperature when the valve opens approx 8 mm 0 315 in 4 If the measurement is no...

Page 67: ...he measurement is less than the factory specification replace the radiator cap W1054156 Radiator Water Leakage 1 Pour a specified amount of water into the radiator 2 Set a radiator tester and an adaptor BANZAI Code No RCT 2A 30S and raise the water pressure to the specified pressure 3 Check the radiator for water leaks 4 For water leak from the pinhole repair with the radiator cement When water le...

Page 68: ...quired for assembling Shims are available in thickness of 0 20 mm 0 0079 in 0 25 mm 0 0098 in and 0 30 mm 0 0118 in Combine these shims for adjustments Addition or reduction of shim 0 05 mm 0 0020 in delays or advances the injection timing by approx 0 0087 rad 0 5 In disassembling and replacing the injection pump be sure to use the same number of new shims with the same thickness Refer to figure b...

Page 69: ... the pressure 6 Stop the starter when the fuel jets from the injection nozzle After that turn the flywheel by hands and raise the pressure to approx 13 7 MPa 140 kgf cm2 1991 psi 7 Now turn the flywheel back about half a turn to keep the plunger free Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13 73 to 12 75 MPa from 140 to 130 kgf cm2 from 1991 to...

Page 70: ...ndle to measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer 1 in the nozzle holder to adjust it Reference Pressure variation with 0 025 mm 0 0010 in difference of adjusting washer thickness Approx 235 kPa 2 4 kgf cm2 34 psi W10182100 Nozzle Valve Seat Tightness 1 Set the injection nozzle to...

Page 71: ... If you are spattered with it wash it away completely with water immediately Keep open sparks and flames away from the battery at all times Hydrogen gas mixed with oxygen becomes very explosive Battery Voltage 1 Stop the engine 2 Measure the voltage with a circuit tester between the battery terminals 3 If the battery voltage is less than the factory specification check the battery specific gravity...

Page 72: ... hydrometer at eye level The hydrometer reading must be taken at the highest electrolyte level Reference Specific gravity slightly varies with temperature To be exact the specific gravity decreases by 0 0007 with an increase of 1 C 0 0004 with an increase of 1 F in temperature and increases by 0 0007 with a decreases of 1 C 0 0004 with a decrease of 1 F Therefore using 20 C 68 F as a reference the...

Page 73: ... magnet switch W1019297 Magnetic Switch Test 1 Disconnect the battery negative cable from the battery 2 Disconnect the battery positive cable from the battery 3 Disconnect the leads from the starter B terminal 4 Remove the starter from the engine 5 Connect a jumper lead from the starter S terminal 1 to the battery positive terminal 2 6 Connect a jumper lead momentarily between the starter s body a...

Page 74: ...fers from the battery voltage the wiring harness or main switch is faulty W1019299 Glow Plug Continuity 1 Disconnect the lead from the glow plugs 2 Measure the resistance with an ohmmeter between the glow plug terminal and the engine body 3 If 0 ohm is indicated the screw at the tip of the glow plug and the housing are short circuited 4 If the factory specification is not indicated the glow plug i...

Page 75: ... drain the coolant 3 After all coolant is drained close the water drain plug 1 Refer to 4 LUBRICANTS FUEL AND COOLANT G 9 W1023465 Draining Engine Oil CAUTION Be sure to stop the engine before draining the engine oil 1 After warming up stop the engine 2 Place an oil pan underneath the oil drain plug 1 3 Open the oil drain plug 1 and remove the oil filler cap to completely drain the engine oil 4 Af...

Page 76: ...se 1 Close the fuel valve 1 2 Remove the fuel hose 2 W1045893 Panel Cover Control Panel 1 Close the fuel valve and remove the fuel hose 2 Remove the hanger 2 the engine roof 3 and the generator roof 1 with fuel tank 3 Remove the front frame 6 and rear cover 4 and side cover 5 4 Disconnect the connector between the generator 9 and control panel 10 5 Disconnect the ground cables 7 6 Remove the contr...

Page 77: ...2 0 to 2 8 kgf m 14 5 to 20 2 lbf ft Stator mounting screw 5 9 to 8 8 N m 0 6 to 0 9 kgf m 4 4 to 6 5 lbf ft Rotor assembly mounting screw 34 3 to 44 1 N m 3 5 to 4 5 kgf m 25 3 to 32 5 lbf ft PTO shaft 48 1 to 55 9 N m 4 9 to 5 7 kgf m 35 5 to 41 2 lbf ft Tightening torque Generator mounting nut 53 9 to 68 6 N m 5 5 to 7 0 kgf m 39 8 to 50 6 lbf ft Stator mounting screw 18 to 22 N m 1 9 to 2 2 kg...

Page 78: ...he screws to the pipe clamp 1 2 Remove the injection pipes 2 When reassembling Sent compressed air into the pipes to blow out dust Then reassemble the pipes in the reverse order W1028640 Tightening torque Cylinder head cover screw 6 86 to 11 3 N m 0 7 to 1 15 kgf m 5 1 to 8 3 lbf ft 1 Cylinder Head Cover Screws 2 Cylinder Head Cover a GL6000 GL7000 b GL9000 GL11000 Tightening torque Injection pipe...

Page 79: ...ew driver three or four times each way 3 While turning the screw driver slowly pull the heat seal 4 out together with the injection nozzle gasket 3 4 If the heat seal drops repeat the above procedure When reassembling Heat seal 4 and injection nozzle gasket 3 must be changed when the injection nozzle is removed for cleaning or for service W1021255 Tightening torque Overflow pipe retaining nut 19 6...

Page 80: ... push rods 3 onto the tappets 4 check to see if their ends are properly engaged with the dimples IMPORTANT After installing the rocker arm be sure to adjust the valve clearance W1021437 Tightening torque Rocker arm bracket screw 9 8 to 11 3 N m 1 00 to 1 15 kgf m 7 2 to 8 3 lbf ft 1 Rocker Arm Bracket Screws 2 Rocker Arm Assembly 3 Push Rod 4 Tappet a GL6000 GL7000 b GL9000 GL11000 KiSC issued 05 ...

Page 81: ...ng engine oil to it and seat surface before fitting it After installing the engine let it run for 30 minutes and retighten the head bolt Before retightening it loosen it by 0 52 to 0 79 rad 30 to 90 W1025645 Valves 1 Remove the valve caps 2 2 Remove the valve spring collet 3 pushing the valve spring retainer 4 by valve spring replacer 1 3 Remove the valve spring retainer 4 valve spring 5 and valve...

Page 82: ... the rod engages with the slot 10 on the fork lever NOTE The sealant is applied to both sides of the soft metal gasket shim The liquid gasket is not required for assembling Addition or reduction of shim 0 025 mm 0 0010 in delays or advances the injection timing by approx 0 0087 rad 0 5 In disassembling and replacing be sure to use the same number of new gasket shims with the same thickness W114860...

Page 83: ...hen reassembling Install the idle gear aligning the alignment mark 4 on the gears referring to the figure W1030437 Camshaft 1 Remove the camshaft mounting screws 1 and draw out the camshaft with gear 2 on it When reassembling When install the camshaft apply engine oil to the camshaft journals Apply engine oil to the camshaft mounting screws And tighten them W1030808 1 Screw Inside 2 Start Spring 3...

Page 84: ...p and Crankshaft Gear 1 Remove the oil pump gear 5 2 Remove the oil pump 6 3 Remove the collar 4 O ring 3 and crankshaft oil slinger 2 4 Remove the crankshaft gear 1 with a puller When reassembling Install the collar 4 after aligning the marks on the gears See page the figure at Idle Gear W10180290 1 Retaining Plate 2 Fuel Camshaft 3 Injection Pump Gear 4 Governor Sleeve 5 Fork Lever 1 6 Fork Leve...

Page 85: ... GL9000 GL11000 Using the hole 6 numbered 3 install the oil strainer by mounting screw IMPORTANT Scrape off the old adhesive completely Wipe the sealing surface clean using waste cloth soaked with gasoline Now apply new adhesive 3 to 5 mm 0 12 to 0 20 in thick all over the contact surface Apply the adhesive also on the center of the flange as well as on the inner wall of each bolt hole Cut the noz...

Page 86: ...f a hammer 3 Draw out the other piston in the same method as above When reassembling Before inserting the piston into the cylinder apply enough engine oil to the piston When inserting the piston into the cylinder face the mark on the connecting rod to the injection pump IMPORTANT Do not change the combination of cylinder and piston Make sure of the position of each piston by marking For example ma...

Page 87: ...of the oil ring gap 11 Apply engine oil to the piston pin When installing the connecting rod to the piston immerse the piston in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin to the piston When installing the connecting rod to the piston align the mark 8 on the connecting rod to the fan shaped concave 9 IMPORTANT Mark the same number on the connecting rod and the piston so as not t...

Page 88: ...all the bearing case cover to position the casting mark UP on it upward Apply engine oil to the oil seal lip and take care that it is not rolled when installing Tighten the bearing case cover mounting screws with even force on the diagonal line W1031168 Crankshaft Assembly 1 Remove the main bearing case screw 2 1 2 Pull out the crankshaft assembly When reassembling Clean the oil passage of the cra...

Page 89: ...GL7000 and 1 2 for GL9000 11000 from the gear case side Refer to the figure Match the alignment number a on all main bearing case assembly 1 Do the same for the main bearing case assembly 2 2 and the main bearing case assembly 3 too When installing the main bearing case 1 and 2 face the mark FLYWHEEL to the flywheel Install the thrust bearing 7 with its oil groove facing outward Make sure that the...

Page 90: ...tion Nozzle Nozzle Holder 1 Secure the nozzle retaining nut 7 with a vise 2 Remove the nozzle holder 1 and take out parts inside When reassembling Assemble the nozzle in clean fuel oil Install the push rod 4 noting its direction After assembling the nozzle be sure to adjust the fuel injection pressure W1062045 1 Thermostat Cover Mounting Screw 2 Thermostat Cover 3 Thermostat Cover Gasket 4 Thermos...

Page 91: ...w out the armature 10 with the drive lever 3 NOTE Do not damage to the brush and commutator When reassembling Apply grease DENSO CO LTD No 50 or equivalent to the parts indicated in the figure Joint of solenoid switch a Bushing b Drive lever c Collar d Teeth of pinion gear e Armature shaft f W1012736 1 Solenoid Switch Mounting Nut 2 Starter Drive Housing 3 Drive Lever 4 Gasket 5 Solenoid Switch 6 ...

Page 92: ...lding the spring up 5 Remove the brush holder 13 6 Draw out the armature 11 and yoke 12 from the housing 7 Draw out the shaft assembly 7 with the drive lever 6 and overrunning clutch 8 from the housing When reassembling W1012736 1 Magnetic Switch Mounting Nut 2 Housing 3 Magnetic Switch 4 B Terminal Nut 5 C Terminal Nut 6 Drive Lever 7 Shaft Assembly 8 Overrunning Clutch 9 Connecting Lead 10 Mount...

Page 93: ... on the combustion chamber W1027737 Cylinder Head Flaw 1 Prepare an air spray red check Code No 07909 31371 2 Clean the surface of the cylinder head with detergent 2 3 Spray the cylinder head surface with the red permeative liquid 1 Leave it five to ten minutes after spraying 4 Wash away the read permeative liquid on the cylinder head surface with the detergent 2 5 Spray the cylinder head surface ...

Page 94: ...sure the valve guide I D with a small hole gauge and calculate the clearance 4 If the clearance exceeds the allowable limit replace the valves If it still exceeds the allowable limit replace the valve guide W1031174 Valve recessing Intake and exhaust Factory spec 0 10 protrusion to 0 10 recessing mm 0 0039 protrusion to 0 0039 recessing in Allowable limit 0 30 recessing mm 0 0118 recessing in 1 Cy...

Page 95: ...2 Fitting the valve check the contact position of the valve face and seat surface with prussian blue Visual check If the valve has been used for a long period the seat tends to come in contact with the upper side of the valve face 3 Grind the upper surface of the seat with a 0 262 rad 15 valve seat cutter until the valve seat touches to the center of the valve face so that a equals b as shown in t...

Page 96: ...ing on a surface plate place a square on the side of the valve spring 3 Check to see if the entire side is in contact with the square Rotate the valve spring and measure the maximum tilt A If the measurement exceeds the allowable limit replace it 4 Check the entire surface of the valve spring for scratches If there is any defect replace it W11157830 Valve Spring Setting Load 1 Place the valve spri...

Page 97: ...appet O D with an outside micrometer 2 Measure the I D of the tappet guide bore with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the tappet W11231410 Oil clearance between rocker arm and rocker arm shaft Factory spec 0 016 to 0 045 mm 0 00063 to 0 00177 in Allowable limit 0 15 mm 0 0059 in Rocker arm shaft O D...

Page 98: ...re the side clearance by moving the cam gear to the font and rear 3 If the measurement exceeds the allowable limit replace the camshaft stopper W11299720 Backlash between idle gear and crank gear Factory spec 0 043 to 0 124 mm 0 00169 to 0 00488 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and cam gear Factory spec 0 047 to 0 123 mm 0 00185 to 0 00484 in Allowable limit 0 15 mm ...

Page 99: ...rnal 1 Measure the camshaft journal O D with an outside micrometer 2 Measure the cylinder block bore I D for camshaft with a inside micrometer and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the camshaft W11335580 Camshaft alignment Allowable limit 0 01 mm 0 0004 in Cam height of intake and exhaust Factory spec 26 88 mm 1 0583 in Allowable limit 26 83 mm ...

Page 100: ...the used idle gear bushing using an idle gear bushing replacing tool Refer to SPECIAL TOOLS When installing 1 Clean a new idle gear bushing and idle gear bore and apply engine oil to them 2 Press in a new brushing using an idle gear bushing replacing tool until it is flush with the end of the idle gear W11373220 Oil clearance between idle gear shaft and idle gear bushing Factory spec 0 020 to 0 08...

Page 101: ... a new small end bushing and small end hole and apply engine oil to them 2 Using a small end bushing replacing tool press in a new bushing service parts taking care to see that the position of the connecting rod oil hole matches the bushing hole Servicing parts dimension W11437590 Piston pin bore I D Factory spec 20 000 to 20 013 mm 0 78740 to 0 78791 in Allowable limit 20 05 mm 0 7894 in Oil clea...

Page 102: ...onnecting rod 3 Install the connecting rod on the connecting rod alignment tool Code No 07909 31661 4 Put a gauge over the piston pin and move it against the face plate 5 If the gauge does not fit squarely against the face plate measure the space between the pin of the gauge and the face plate 6 If the measurement exceeds the allowable limit replace the connecting rod W10314620 Piston ring gap Top...

Page 103: ...easure the crankshaft alignment 4 If the measurement exceeds the allowable limit replace the crankshaft W11613530 Crankshaft side clearance Factory spec 0 15 to 0 31 mm 0 0059 to 0 0122 in Allowable limit 0 50 mm 0 0197 in Oversize Bearing Code Number Marking 0 2 mm 0 008 in Thrust bearing 1 02 15261 23950 020 OS Thrust bearing 2 02 15261 23970 020 OS 0 4 mm 0 016 in Thrust bearing 1 04 15261 2396...

Page 104: ...rsize dimensions of crankpin W11625390 Oil clearance between crankpin and crankpin bearing Factory spec 0 020 to 0 051mm 0 00079 to 0 00201 in Allowable limit 0 15 mm 0 0059 in Crankpin O D Factory spec 33 959 to 33 975 mm 1 33697 to 1 33760 in Crankpin bearing I D Factory spec 33 995 to 34 010 mm 1 33839 to 1 33898 in Undersize Bearing Code Number Marking 0 2 mm 0 008 in Crankpin bearing 02 15861...

Page 105: ... 1 directs toward the exhaust manifold side See figure W10342000 Oil Clearance between crankshaft journal and crankshaft bearing 1 Factory spec 0 034 to 0 106 mm 0 00134 to 0 00417 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory spec 39 934 to 39 950 mm 1 57221 to 1 57284 in Crankshaft bearing 1 I D 39 984 to 40 040 mm 1 57417 to 1 57638 in Undersize Bearing Code Number Marking...

Page 106: ...e limit 0 20 mm 0 0079 in Crankshaft journal O D Flywheel side Factory spec 43 934 to 43 950 mm 1 72968 to 1 73031 in Crankshaft bearing 2 I D Factory spec 43 978 to 43 993 mm 1 73142 to 1 73201 in Crankshaft journal O D Intermediate Factory spec 39 934 to 39 950 mm 1 57221 to 1 57284 in Crankshaft bearing 3 I D Factory spec 39 978 to 39 993 mm 1 57394 to 1 57453 in Oversize Part Name Marking 0 2 ...

Page 107: ...r is worn beyond the allowable limit bore and hone it to the specified dimension 2 Replace the piston and piston rings with oversize ones NOTE When the oversize cylinder is worn beyond the allowable limit replace the cylinder block with a new one W10367470 Cylinder I D Factory spec 67 000 to 67 019 mm 2 63780 to 2 63854 in Allowable limit 67 169 mm 2 64445 in A Top B Middle C Bottom Skirt a Right ...

Page 108: ...e the oil pump rotor assembly W10381420 Clearance between Rotor and Cover 1 Put a strip of plastigauge Code No 07909 30241 onto the rotor face with grease 2 Install the cover and tighten the screws 3 Remove the cover carefully and measure the amount of the flattening with the scale and get the clearance 4 If the clearance exceeds the factory specifications replace oil pump rotor assembly W10382660...

Page 109: ... paper 2 Measure the brush length A with vernier calipers 3 If the length is less than the allowable limit replace the yoke assembly and brush holder W1075476 Commutator O D Factory spec Electromagnetic drive type 28 0 mm 1 102 in Planetary gear reduction type 30 0 mm 1 181 in Allowable limit Electromagnetic drive type 27 0 mm 1 063 in Planetary gear reduction type 29 0 mm 1 142 in Difference of O...

Page 110: ... replace the clutch assembly 2 Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction 3 If the pinion slips or does not turn in both directions replace the overrunning clutch assembly NOTE Do not wash off the grease in the overrunning clutch with the chemicals or oils W1075769 Brush Holder 1 Check the continuity across the brush hol...

Page 111: ...ntinuity across the lead 1 and brush 2 with an ohmmeter 2 If it does not conduct replace the yoke assembly 3 Check the continuity across the brush 2 and yoke 3 with an ohmmeter 4 If it conducts replace the yoke assembly W1076156 1 Lead 2 Brush 3 Yoke KiSC issued 05 2015 A ...

Page 112: ...CONTENTS MECHANISM 1 STRUCTURE 2 M1 2 AUTOMATIC VOLTAGE REGULATOR A V R 2 M2 3 EMERGENCY RELAY CIRCUIT 2 M5 1 GENERAL 2 M5 2 INSTRUCTIONS 2 M6 4 EARTH 2 M7 5 WIRING DIAGRAM 2 M8 KiSC issued 05 2015 A ...

Page 113: ... coils are wound to magnetize the entire core 3 Brush Holder Assembly The excitation voltage from sub coil of the stator assembly is applied to the rotor coil through the A V R assembly rectifying circuit and the brush holder assembly 4 Automatic Voltage Regulator A V R Assembly The A V R assembly maintains the AC output voltage at a constant level W1015204 1 Rear Cover 2 A V R Assembly 3 Brush Ho...

Page 114: ...s to proceed to any high voltage test on the alternator without having previously disconnected all connections to voltage regulator Damages occurring to A V R in such conditions will not be considered in a warranty claim W1016141 1 A V R 2 Capacitor A GL6000 GL7000 B GL9000 GL11000 KiSC issued 05 2015 A ...

Page 115: ...iagram of GL Series A V R s is shown below The A V R consists basically of the components detector 7 through transistor 4 1 Exciter Coil 2 Rectifier 3 Rotor Coil 4 Transistor 5 Drive Circuit 6 Controller 7 Detector 8 A V R 9 Detection Coil KiSC issued 05 2015 A ...

Page 116: ...ous circuit controller 6 is weak To intensify this signal the final stage transistor 4 that switches on and off the current to the rotor coil 3 is activated For comparison let s imagine a gearbox that gives a large torque from a small force While the engine is stopped or in the low rpm range that is the generator voltage is not yet established the drive circuit 5 behaves to keep the transistor 4 f...

Page 117: ...el to the fuel injection pump and stop the engine This relay has two independent timer functions a start relay and a stop relay The start relay does not activate this relay for a specified time period after the engine has started IMPORTANT When this device stops the engine it may be that some minor damages to the engine has occurred To limit engine damage as mush as possible please do not make the...

Page 118: ... stop solenoid 11 Upon receipt of an output from the sensor input circuit 7 the timer will start to operate Drive circuit 9 Drives the external relay 10 for a given delay time upon receipt of an output from the drive timer circuit 8 Consists of a power transistor and a diode to remove surge volts from the relay 3 Operating principle EG 1 controls so that While an attempt was made to start the engi...

Page 119: ...c code department to determine the approved generator grounding method to be used in his application or location Recommendations in the NEC NFPA and OSHA regulations must be followed to assure compliance and safe operation A grounding lug is provided on the KUBOTA generator frame for earth grounding depending on local state national or OSHA requirements One possible connection method for construct...

Page 120: ...000 GL7000 GL9000 GL11000 WSM GENERATOR 5 WIRING DIAGRAM Color of Wiring W1019456 B Black R Red SB Sky Blue Y Yellow W White LG Light Green L Blue BR Brown P Pink G Green O Orange GR Gray KiSC issued 05 2015 A ...

Page 121: ...mm 2 2 mm 2 2 mm 2 2 mm 2 LG LG R R R B R B Y W Y W R R Y Y BR O L L B R BR BR O L L B R 2 mm 2 2 mm 2 2 mm 2 2 mm 2 5 mm 2 5 mm 2 2 mm 2 2 mm 2 2 mm 2 2 mm 2 L W L L L W 1 2 3 4 BR G Y Y O P P O GR G W LG 1 2 3 4 5 mm 2 2 mm 2 2 mm 2 LG LG R BR R GR 2 mm 2 3 mm 2 2 mm 2 5 mm 2 2 mm2 3 mm 2 LB WS OS RS 1 RS 2 L 2 L 1 30 AC 19 50 Earth 30 AC 19 50 1 2 3 4 1 2 3 4 5 Y W Y L G L O O G L L Y NO NC COM...

Page 122: ...50V 15A R 2 mm 2 R 2 mm 2 AC Output Receptacle 3 mm 2 G Earth Terminal NFB White Tape R 3 mm2 Volt Meter V PL Pilot Lamp R W R W R L 3 mm2 3 mm 2 R W G 3 mm 2 3 mm 2 5 mm 2 G GR R 5 mm 2 3 mm 2 M Battery Starter W W BR 3 mm 2 Glow Plug Oil Switch Engine Stop Solenoid Water Temperature Switch B Y B W 2 mm 2 5 mm 2 LG 2 mm 2 2 mm 2 2 mm 2 LG R 2 mm2 5 mm2 BR 3 mm 2 R GR 2 mm 2 3 mm 2 3 mm 2 3 mm 2 B...

Page 123: ...use Box 3A 5A 10A 15A LG LG R R R B R B Y W Y W 2 mm 2 2 mm 2 2 mm 2 2 mm 2 Regulator Slow Blow Fuse 40A BR O L L B R BR BR O L L B R 2 mm 2 2 mm 2 2 mm 2 2 mm 2 R R Y Y 5 mm 2 5 mm 2 NO NC COM Safety Switch L Y Y W Y L G L 1 2 3 4 5 Relay 1 2 3 4 O O G L Relay Combination Lamp Y B B Y Y R B W R B W B Y B B Y Y G B W R B W B R W R W 1A Y G R R B Y O 2 mm2 30 AC 19 50 Y W B W W R B Y Y R L W R W R ...

Page 124: ...mm 2 Combination Lamp Y B B Y Y R B W R B W B Y B B Y Y G B W R B W B R W R W 1A Y G Hour Meter R R B Y O 2 mm2 30 AC 19 50 Starter Switch Y W B W W R B Y Y R L W R W R 2 mm 2 Y R B O G 2 mm2 L K J I H G F C B A LB WS OS RS 1 RS 2 L 2 L 1 30 AC 19 50 Earth Outside Output Terminal G O W B R B 1 2 3 4 5 6 Glow Lamp Timer Starter Relay 3 mm 2 O P GR GR 1 2 3 5 Glow Relay 3 mm 2 3 mm 2 BR BR R B G 3 5...

Page 125: ...witch L Y Y W Y L G L 1 2 3 4 5 Relay 1 2 3 4 O O G L Relay Y G Hour Meter R R B Y O 2 mm 2 30 AC 19 50 Starter Switch Y W B W W R B Y Y R L W R W R 2 mm 2 Y R B O G 2 mm2 L K J I H G F C B A LB WS OS RS 1 RS 2 L 2 L 1 30 AC 19 50 Earth Outside Output Terminal R W R W 1A Glow Relay Starter Relay Glow Lamp Timer G O W B R B 1 2 3 4 5 6 3 mm 2 O P GR GR 1 2 3 5 3 mm 2 3 mm 2 BR BR R B G 3 5 1 2 Oil ...

Page 126: ...3 5 G O W B R B 1 2 3 4 5 6 5 mm 2 L W R W 1 2 3 4 5 6 7 LG GR G O Y W Y R W R O O G Y Y W O O G Y Y W Y B B Y Y R B W R B W B Y B B Y Y G B W R B W B L Y NO NC COM 1 2 3 4 5 Y W Y L G L 1 2 3 4 O O G L Y G R R B Y O 2 mm 2 30 AC 19 50 Y W B W W R B Y Y R L W R W R 2 mm2 Y R B O G 2 mm 2 L K J I H G F C B A LB WS OS RS 1 RS 2 L 2 L 1 30 AC 19 50 Earth R W R W 1A 9Y0210269GRT001US GL9000 STD 220V 5...

Page 127: ...tion Lamp Y G Hour Meter Starter Switch R R B Y O 2 mm2 30 AC 19 50 Y W B W W R B Y Y R L W R W R 2 mm2 Y R B O G 2 mm 2 L K J I H G F C B A LB WS OS RS 1 RS 2 L 2 L 1 30 AC 19 50 Earth Outside Output Terminal Glow Relay Starter Relay Glow Lamp Timer 3 mm 2 3 mm 2 BR BR R B G 3 5 1 2 3 mm 2 3 mm 2 O P GR GR 1 2 3 5 G O W B R B 1 2 3 4 5 6 2 mm 2 2 mm 2 LG 2 mm 2 LG R 2 mm 2 5 mm 2 BR 3 mm 2 R GR 2...

Page 128: ... mm 2 Glow Plug Oil Switch Water Temperature Switch Engine Stop Solenoid W W B Y BR 3 mm 2 B W Fuse Box 3A 5A 10A 15A LG LG R R R B R B Y W Y W 2 mm 2 2 mm 2 2 mm 2 2 mm 2 Regulator Slow Blow Fuse 50A R R Y Y 5 mm 2 5 mm 2 BR O L L B R BR BR O L L B R 2 mm 2 2 mm 2 2 mm 2 2 mm 2 5 mm 2 G 3 mm 2 GR R 5 mm 2 Battery Starter M L Y NO NC COM Y W Y L G L 1 2 3 4 5 Relay Relay 1 2 3 4 O O G L Y G Hour M...

Page 129: ... mm 2 2 mm 2 2 mm 2 2 mm 2 R R Y Y 5 mm 2 5 mm 2 BR O L L B R BR BR O L L B R 2 mm 2 2 mm 2 2 mm 2 2 mm 2 2 mm 2 2 mm 2 L L W 2 mm 2 2 mm 2 L L W 2 mm 2 2 mm 2 LG 2 mm 2 LG R 2 mm2 5 mm 2 BR 3 mm 2 R GR 2 mm2 3 mm 2 2 mm 2 5 mm2 Glow Plug Oil Switch Water Temperature Switch Engine Stop Solenoid W W B Y BR 3 mm 2 B W 5 mm 2 G 3 mm2 GR R 5 mm 2 Battery Starter M Glow Relay Starter Relay Glow Lamp Ti...

Page 130: ...3 mm 2 2 mm 2 5 mm2 W W B Y BR 3 mm2 B W 5 mm 2 G 3 mm 2 GR R 5 mm 2 M BR BR R B G O P GR GR G O W B R B 3 mm 2 3 mm 2 3 mm 2 3 mm 2 3 5 1 2 1 2 3 5 1 2 3 4 5 6 L Y NO NC COM Y W Y L G L 1 2 3 4 5 1 2 3 4 O O G L Y B B Y Y R B W R B W B Y B B Y Y G B W R B W B Y G R R B Y O 2 mm2 30 AC 19 50 R W R W 1A Y W B W W R B Y Y R L W R W R 2 mm 2 Y R B O G 2 mm 2 LB WS OS RS 1 RS 2 L 2 L 1 30 AC 19 50 L K...

Page 131: ...QUES FOR GENERAL USE SCREWS BOLTS AND NUT 2 S9 4 CHECKING DISASSEMBLING AND SERVICING 2 S10 1 CHECKING AND ADJUSTING 2 S10 1 Control Panel 2 S10 2 Emergency Relay Activates 2 S16 2 DISASSEMBLING AND ASSEMBLING 2 S17 1 External Components 2 S17 3 SERVICING 2 S20 1 Terminal Voltage for Each Part During Normal Periods No load Periods 2 S20 2 Stator Coil 2 S20 3 Rotor Coil 2 S21 4 Exciter Coil 2 S22 K...

Page 132: ...t slips Fan belt tension Adjust Excessive Vibration and Humming Noise Coming from The Generator Short circuit in the generator stator Stop the gen set and check the short circuit installation and others Repair or replace Loosen bolt of generator mounting Generator Damaged by a Significant Impact Which is Followed by Humming and Vibration Short circuit in external circuit Stop the gen set immediate...

Page 133: ...ontrol box Check wiring and repair Voltmeter Does not Indicate Any Voltage and Also Output Voltage is not Delivered Measure the voltage at the output terminal using a voltmeter 250V at AC range Output voltage is 0 V Disconnected stator coil Repair or replace Lack of residual magnetism Replace rotor Only slight output voltage is delivered Excessive wear of brush or improper contact of it Replace br...

Page 134: ...r or replace the brushes Variation of engine speed is excessive Insufficient engine output Repair engine Defective engine governor Repair engine Measure the voltage at the output terminal using a voltmeter 250V at AC range Output voltage is low Lowered engine rotation Adjustment of rotational speed Short circuit of stator coil or sub coil Repair or replace Short circuit of rotor coil Repair or rep...

Page 135: ...epair or add the engine oil Insufficient engine oil Check the oil level Add the engine oil Insufficient fuel Check the fuel level Add the fuel Engine Does not Stop When Key Switch is OFF Position Battery is disconnected Check the battery Replace Burnt out 15 A fuse Check the fuse 15 A Replace Broken or disconnected wiring harness Check the wiring harness and fuse 15 A Repair or replace Defective k...

Page 136: ... Does not Light Even with The Key Switch Turned ON When The Engine is Stopped Burnt out 10A fuse Check the fuse 10 A and the wiring Repair or replace Charge lamp burned Check the charge lamp and the wiring Trouble Cause Confirmation Countermeasure KiSC issued 05 2015 A ...

Page 137: ... 28 0 25 BR L 0 28 0 25 Sub coil G LG R 1 08 0 93 Sub coil DC L W L W 0 11 0 09 Detecting coil LG L 0 05 0 07 Rotor coil 59 5 Air gap 0 5 mm 0 020 in Slip ring Outside diameter 49 7 mm 1 96 in Correction limit 47 5 mm 1 87 in Standard run out 0 1 mm 0 003 in Limit run out 0 15 mm 0 0059 in Brush length Standard 15 mm 0 59 in Limit 4 5 mm 0 18 in Bearing 6205 DDUNCX Regulated voltage value 5 Circui...

Page 138: ... 0 10 2 3 0 12 0 10 Sub coil LG LG 1 96 1 68 1 73 Sub coil DC L W L W 0 08 0 07 Detecting coil R R 0 04 0 03 Rotor coil 55 5 Air gap 0 7 mm 0 03 in Slip ring Outside diameter 64 mm 2 51 in Correction limit 62 5 mm 2 46 in Standard run out 0 1 mm 0 003 in Limit run out 0 15 mm 0 0059 in Brush length Standard 15 mm 0 59 in Limit 7 5 mm 0 30 in Bearing 6306 DDUNCX Regulated voltage value 5 Circuit br...

Page 139: ... seats before tightening GL6000 GL7000 GL9000 GL11000 W1046366 Item N m kgf m lbf ft Stator mounting screw 5 9 to 8 8 0 6 to 0 9 4 4 to 6 5 Rotor assembly mounting screw 34 3 to 44 1 3 5 to 4 5 25 3 to 32 5 PTO shaft mounting screw 48 1 to 55 9 4 9 to 5 7 35 5 to 41 2 Engine mounting nut 19 6 to 27 4 2 0 to 2 8 14 5 to 20 2 Generator mounting nut 19 6 to 27 4 2 0 to 2 8 14 5 to 20 2 Item N m kgf m...

Page 140: ...r Standard Screw and Bolt Special Screw and Bolt N m kgf m lbf ft N m kgf m lbf ft M4 1 0 to 2 9 0 1 to 0 3 0 7 to 2 1 M5 1 9 to 3 6 0 2 to 0 4 1 4 to 2 7 M6 7 9 to 9 3 0 80 to 0 95 5 8 to 6 9 9 8 to 11 3 1 00 to 1 15 7 23 to 8 32 M8 17 7 to 20 6 1 8 to 2 1 13 0 to 15 2 23 5 to 27 5 2 4 to 2 8 17 4 to 20 3 M10 39 2 to 45 1 4 0 to 4 6 28 9 to 33 3 48 1 to 55 9 4 9 to 5 7 35 4 to 41 2 M12 62 8 to 72...

Page 141: ... remove the main switch 2 3 Perform the following checks W1021025 Connector Voltage 1 Measure the voltage with a voltmeter between the connector 30 terminal and chassis 2 If the voltage differs from the battery voltage the wiring harness is faulty W1014533 1 Control Panel 2 Main Switch A Terminal Type B Receptacle Type Voltage Connector 30 terminal chassis Approx battery voltage KiSC issued 05 201...

Page 142: ...nce across the 30 terminal and the AC terminal 3 If 0 ohm is not indicated these contacts of the main switch are faulty 4 Main Switch Key at START Position 1 Set and hold the main switch key at the START position 2 Measure the resistance with an ohmmeter across the 30 terminal and the 19 terminal across the 30 terminal and the 50 terminal and across the 30 terminal and the AC terminal 3 If 0 ohm i...

Page 143: ...table value THe safety switch 1 is failure then please exchange it W10210220 Lamp Timer for Glow Plug 1 Remove the lamp timer from inside of the panel 2 Connect the battery 4 lamp timer 1 and bulb 2 as shown in the figure 3 The bulb 2 light up when contacting the lead wire 1 3 with positive terminal of the battery 4 and goes off approximately 6 seconds late the lamp relay is proper W1022263 Resist...

Page 144: ...ltage of the regulator with a circuit tester 4 When the measurement is the above table value the regulator is failure Replace it NOTE When the input voltage of the regulator is out of specification check a dynamo W1042693 Output Voltage Terminal 6 Terminal 2 14 V to 15 V Input Voltage Terminal 1 Terminal 3 Approx 14 V 1 Terminal 1 2 Terminal 2 3 Terminal 3 4 Terminal 4 5 Terminal 5 6 Terminal 6 Ki...

Page 145: ...en the breaker switch in ON 3 If there is no continuity it indicates that the contacts are faulty Replace the breaker NOTE When there is a short circuit in the wiring the circuit breaker trips off If this happens eliminate the cause then reset the circuit breaker If the circuit breaker holds test the load for faults W1022525 1 Circuit Breaker A GL6000 GL7000 B GL9000 GL11000 KiSC issued 05 2015 A ...

Page 146: ...minals for each lamp 2 If there is no continuity change the lamp W1022841 Charge 3 terminal 4 terminal Approx 10 Water temperature 2 terminal 8 terminal Oil pressure 7 terminal 8 terminal Glow 1 terminal 5 terminal 1 Pilot Box 2 Charge 3 Water Temperature 4 Oil Temperature 5 Glow KiSC issued 05 2015 A ...

Page 147: ...it is defective W1020329 Water Temperature Switch 1 Insert the water temperature switch 1 in the engine oil and continue the circuit when the oil temperature rises to 112 to 118 C 234 to 244 F 2 Check that the resistance is 0 ohm in case water temperature switch is defective IMPORTANT Be careful when handling the water temperature switch so that you do not drop it When assembling the switch apply ...

Page 148: ...2 DISASSEMBLING AND ASSEMBLING 1 External Components Panel Cover Control Panel 1 Close the fuel valve and remove the fuel hose 2 Remove the hanger 2 the engine roof 3 and the generator roof 1 with fuel tank 3 Remove the front frame 6 and rear cover 4 and side cover 5 4 Disconnect the connector between the generator 9 and control panel 10 5 Disconnect the ground cables 7 6 Remove the control panel ...

Page 149: ...ful to position the bearing correctly Misalignment may make it difficult to install the bearing or what s worse damage it IMPORTANT Be careful not to confuse the direction of the snap ring of the bearing GL6000 GL7000 GL9000 GL11000 W1030949 Stator Assembly and Stator Housing 1 Hoist up the stator assembly 1 2 Remove the stator assembly 1 take care not to damage the winding and the rotor 3 Remove ...

Page 150: ...aused by loose fittings Handle carefully to avoid damaging the winding W1066726 Replacing Ball Bearing 1 Hook the puller until it clicks onto the outer bearing ring and then pull off the bearing When reassembling Keep new bearing sealed until use Clean dirt from the bearing housing When tapping in the bearing press it by tapping on the inner race gently with special tool W1067349 Tightening torque...

Page 151: ...8933 2 Stator Coil Main Coil Winding 1 Test for continuity between coil leads with a milliohm meter Many kind of wiring have been arranged in the stator depending on the voltage variation 2 If the resistance is not as specified replace the stator or contact service station Refer to 5 WIRING DIAGRAM 2 M8 Measurement is not possible with a regular tester W1026118 Output voltage Factory spec Rated vo...

Page 152: ...ohm meter 2 Reading should be more than 1 M at 500 V 3 If continuous replace the stator or contact service station W1069388 3 Rotor Coil Main Field Winding Rotor Coil 1 Measure the coil resistance between each end of field coil 2 If the resistance is not as specified replace the rotor assembly or contact service station Refer to 5 WIRING DIAGRAM 2 M8 W1026895 Resistance Factory spec Refer to 2 SER...

Page 153: ...ith a miliohm meter 2 If the resistance is not as specified replace the stator or contact service station Refer to 5 WIRING DIAGRAM 2 M8 W1027306 Grounding of Exciter Field Coil Sub Coil 1 Measure the insulation resistance between each lead and the laminations with a megohm meter 2 A reading should be more than 1 M at 500 V 3 If continuous replace the exciter coil assembly or contact service stati...

Page 154: ...ice Department Address 64 Ishizu Kitamachi Sakai Ku Sakai City Osaka 590 0823 Japan Phone 81 72 241 1129 Fax 81 72 245 2484 E mail ks_g ksos pub kubota com KUBOTA Corporation Printed in Japan 2015 04 S EI EI engusa 2004 06 S EI EI engusa Code No 9Y011 02693 ...

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