Kubota GL6000A-AU-B Workshop Manual Download

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ENGINE

GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM

1-S5

Valve Spring

Free Length

Tilt

Setting Load /
Setting Length

31.3 to 31.8 mm

1.24 to 1.25 in.

–

65 N / 27.0 mm

6.6 kgf / 27.0 mm

15 lbf / 1.06 in.

28.4 mm

1.12 in.

1.2 mm

0.047 in.

55 N / 27.0 mm

5.6 kgf / 27.0 mm

12 lbf / 1.06 in.

Rocker Arm Shaft to Rocker Arm

• Rocker Arm Shaft

• Rocker Arm

Oil Clearance

O.D.

I.D.

0.016 to 0.045 mm

0.00063 to 0.0017 in.

10.473 to 10.484 mm

0.41233 to 0.41275 in.

10.500 to 10.518 mm

0.41339 to 0.41409 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 0.0020 in.

17.966 to 17.984 mm

0.70733 to 0.70803 in.

18.000 to 18.018 mm

0.70867 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 0.012 in.

–

26.88 mm

1.058 in.

0.50 mm

0.020 in.

0.01 mm

0.0004 in.

26.83 mm

1.056 in.

Camshaft Journal to Cylinder Block Bore

• Camshaft Journal

• Cylinder Block Bore

Oil Clearance

O.D.

I.D.

0.050 to 0.091 mm

0.0020 to 0.0035 in.

32.934 to 32.950 mm

1.2967 to 1.2972 in.

33.000 to 33.025 mm

1.2993 to 1.3001 in.

0.15 mm

0.0059 in.

–

Timing Gear

• Crank Gear to Idle Gear

• Idle Gear to Cam Gear

• Idle Gear to Injection Pump Gear

• Crank Gear to Oil Pump Drive Gear

Backlash

0.0430 to 0.124 mm

0.00170 to 0.00488 in.

0.0470 to 0.123 mm

0.00185 to 0.00484 in.

0.0460 to 0.124 mm

0.00182 to 0.00488 in.

0.0410 to 0.123 mm

0.00162 to 0.00484 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

Item

Factory Specification

Allowable Limit

KiSC issued 06, 2016 A

Summary of Contents for GL6000A-AU-B

Page 1: ...WORKSHOP MANUAL DIESEL GENERATOR GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B KiSC issued 06 2016 A ...

Page 2: ...subsequent sections make sure that you read this section Refer to the latest version of Workshop Manual for diesel engine mechanism that this manual does not include Booklet Code No 9Y021 01870 PDF file in Kubota Web Site Code No 9Y011 01870 Servicing This section primarily contains information below Troubleshooting Servicing Specifications Tightening Torques Checking Disassembling and Servicing A...

Page 3: ...I INFORMATION KiSC issued 06 2016 A ...

Page 4: ...CONTENTS 1 SAFETY FIRST I 1 2 SAFETY DECALS I 5 3 SPECIFICATIONS I 13 4 DIMENSIONS I 15 INFORMATION KiSC issued 06 2016 A ...

Page 5: ...he engine This can cause damage and decrease the engine life WSM000001INI0003US0 SAFETY FIRST 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 instructions and safety regulations before you try to repair or use this unit ...

Page 6: ...draulic or fuel lines Tighten all connections before you apply the pressure Do not open a fuel system under high pressure The fluid under high pressure that stays in fuel lines can cause serious injury Do not disconnect or repair the fuel lines sensors or any other components between the fuel pump and injectors on engines with a common rail fuel system under high pressure Put on an applicable ear ...

Page 7: ...erate at elevated idle and hot temperatures for an extended period of time Exhaust gases and exhaust filter components reach temperatures hot enough to burn people or ignite or melt common materials 9Y1211607INI0003US0 PREVENT A FIRE Fuel is very flammable and explosive under some conditions Do not smoke or let flames or sparks in your work area To prevent sparks from an accidental short circuit a...

Page 8: ...007US0 PREVENT ACID BURNS Keep electrolyte away from your eyes hands and clothing Sulfuric acid in battery electrolyte is poisonous and it can burn your skin and clothing and cause blindness If you spill electrolyte on yourself clean yourself with water and get medical aid immediately WSM000001INI0008US0 PREPARE FOR EMERGENCIES Keep a first aid kit and fire extinguisher ready at all times Keep the...

Page 9: ...5 2 SAFETY DECALS The following safety decals are installed on the machine If a decal becomes damaged illegible or is not on the machine replace it The decal part number is listed in the parts list WSM000001INI0013US0 Digital Type 9Y1211607INI0004US0 KiSC issued 06 2016 A ...

Page 10: ...INFORMATION GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B WSM I 6 9Y1211607INI0005US0 KiSC issued 06 2016 A ...

Page 11: ...INFORMATION GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B WSM I 7 9Y1211607INI0006US0 KiSC issued 06 2016 A ...

Page 12: ...INFORMATION GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B WSM I 8 9Y1211607INI0007US0 KiSC issued 06 2016 A ...

Page 13: ...INFORMATION GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B WSM I 9 Analog Type 9Y1211607INI0008US0 KiSC issued 06 2016 A ...

Page 14: ...INFORMATION GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B WSM I 10 9Y1211607INI0009US0 KiSC issued 06 2016 A ...

Page 15: ...INFORMATION GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B WSM I 11 9Y1211607INI0010US0 KiSC issued 06 2016 A ...

Page 16: ...with soap and water dry with a soft cloth 3 Replace damaged or missing danger warning and caution labels with new labels 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 replace component 5 Mount new danger warning and caution labels by applying on a clean dry surface and pressing any bubb...

Page 17: ...of cylinders 2 Bore stroke ϕ 67 68 mm 2 6 2 7 in Displacement 0 479 L 29 2 cu in Engine speed 3000 min 1 rpm Lubricating oil API service class CF or higher Oil capacity 2 2 L 0 58 U S gals Coolant capacity 3 7 L 0 98 U S gals Set Fuel Diesel fuel No 2 ASTM D975 Fuel consumption at full load 2 4 L h 0 63 U S gals h Fuel tank capacity 28 L 7 4 U S gals Continuous operating hours 12 hrs Battery V Ah ...

Page 18: ... of cylinders 3 Bore stroke ϕ 67 68 mm 2 6 2 7 in Displacement 0 719 L 43 9 cu in Engine speed 3000 min 1 rpm Lubricating oil API service class CF or higher Oil capacity 3 4 L 0 90 U S gals Coolant capacity 4 1 L 1 1 U S gals Set Fuel Diesel fuel No 2 ASTM D975 Fuel consumption at full load 3 3 L h 0 87 U S gals h Fuel tank capacity 28 L 7 4 U S gals Continuous operating hours 8 5 hrs Battery V Ah...

Page 19: ...L9000D AU B WSM I 15 4 DIMENSIONS 9Y1211607INI0014US0 9Y1211607INI0015US0 GL6000A AU B GL6000D AU B L 1066 mm 41 97 in W 618 mm 24 3 in H 698 mm 27 5 in GL9000A AU B GL9000D AU B L 1281 mm 50 43 in W 618 mm 24 3 in H 698 mm 27 5 in KiSC issued 06 2016 A ...

Page 20: ...G GENERAL KiSC issued 06 2016 A ...

Page 21: ...NTENANCE CHECK LIST G 13 7 CHECK AND MAINTENANCE G 14 1 DAILY CHECK G 14 2 CHECK POINTS OF INITIAL 50 HOURS G 16 3 CHECK POINT OF EVERY 50 HOURS G 17 4 CHECK POINTS OF EVERY 100 HOURS G 18 5 CHECK POINTS OF EVERY 200 HOURS G 20 6 CHECK POINTS OF EVERY 300 HOURS G 21 7 CHECK POINT OF EVERY 400 HOURS G 21 8 CHECK POINT OF EVERY 500 HOURS G 22 9 CHECK POINTS OF EVERY 800 HOURS G 23 10 CHECK POINT OF ...

Page 22: ...re as below Engine Series Production Year To be continued Number or Alphabet Series Number or Alphabet Series 1 05 include WG 7 03 2 V3 8 07 3 08 A EA RK 4 SM include WG B 03 KET Production 5 Air Cooled Gasoline C V3 07 KEW Production 6 GZ OC AC EA E Alphabet or Number Year Alphabet or Number Year 1 2001 F 2015 2 2002 G 2016 3 2003 H 2017 4 2004 J 2018 5 2005 K 2019 6 2006 L 2020 7 2007 M 2021 8 2...

Page 23: ...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 cover to identify Output classification and Emission Control Inf...

Page 24: ...D AU B WSM G 3 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 9Y1211607GEG0003US0 KiSC issued 06 2016 A ...

Page 25: ...emble When you assemble the external or internal snap rings make sure that the sharp edge 3 faces against the direction from which force 2 is applied Make sure that you try to operate the engine after you repair or assemble it Do not try to give a heavy load immediately if not you can cause serious damage to the engine 9Y1211607GEG0004US0 Before checking any generator or engine electrical componen...

Page 26: ... for a fee Do not try 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 WSM000001GEG0062US0 1 WIRING Securely tighten wiring terminals WSM000001GEG0063US0 Do not let wiring contact dangerous part WSM000001GEG0064US0 Repair or change torn or aged wiring immedia...

Page 27: ...or movable part where sag be required WSM000001GEG0068US0 In installing a part be careful not to get wiring caught by it 9Y1211607GEG0014US0 After installing wiring check protection of terminals and clamped condition of wiring WSM000001GEG0070US0 1 Grommet A Correct B Incorrect 1 Clamp Wind Clamp Spirally 2 Wire Harness 3 Clamp 4 Welding Dent 1 Wiring 2 Clamp A Correct B Incorrect 1 Wiring A Corre...

Page 28: ...ff with water immediately Before you recharge the battery remove it from the machine Before you recharge remove cell caps Recharge in a well ventilated place where there is no open flame nearby as hydrogen gas and oxygen are formed WSM000001GEG0071US0 3 FUSE Use fuses with specified capacity Neither too large nor small capacity fuse is acceptable Never use steel nor copper wire in place of fuse Do...

Page 29: ...e that there is no female connector being too open WSM000001GEG0076US0 Make sure that plastic cover is large enough to cover whole connector WSM000001GEG0077US0 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provided with tester Check for polarity and range WSM000001GEG0078US0 1 Sandpaper 2 Deformed Terminal 3 Rust 4 Exposed Terminal A Correct B Incorrect 1 Cover A Correct B In...

Page 30: ...o the color codes This symbol of shows color with stripe s An example Red stripe on white color W R WSM000001GEG0079US0 Color of wiring Color code Black B Brown Br Green G Gray Gy or Gr Blue L Light Green Lg Orange Or Pink P Purple Pu or V Red R Sky Blue Sb White W Yellow Y 1 Wire Color 2 Stripe KiSC issued 06 2016 A ...

Page 31: ...ne oil 2 2 L 0 58 U S gals 0 48 Imp gals 3 4 L 0 90 U S gals 0 75 Imp gals 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 0 98 U S gals 0 81 Imp gals 4 1 L 1 1 U S gals 0 90 Imp gals Clean water Soft water Use antifreeze 50 ...

Page 32: ...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 33: ...o 0 95 5 8 to 6 8 7 9 to 8 8 0 80 to 0 90 5 8 to 6 5 9 81 to 11 2 1 00 to 1 15 7 24 to 8 31 7 9 to 8 8 0 80 to 0 90 5 8 to 6 5 M8 8 0 mm 0 31 in 18 to 20 1 8 to 2 1 13 to 15 17 to 19 1 7 to 2 0 13 to 14 24 to 27 2 4 to 2 8 18 to 20 18 to 20 1 8 to 2 1 13 to 15 M10 10 mm 0 39 in 40 to 45 4 0 to 4 6 29 to 33 32 to 34 3 2 to 3 5 24 to 25 48 to 55 4 9 to 5 7 36 to 41 40 to 44 4 0 to 4 5 29 to 32 M12 1...

Page 34: ... 6 Replacement of oil filter cartridge G 16 G 20 7 Check of fuel hoses and clamp bands G 17 8 Cleaning of air cleaner primary element G 18 9 Check of fan belt tension G 19 10 Cleaning of fuel filter element G 19 11 Check of radiator hoses and clamp bands G 20 12 Check of intake air hose G 20 13 Check of generator s brush ware G 21 14 Check of generator s slip ring G 21 15 Replacement of fuel filte...

Page 35: ...ngine oil according to ambient temperatures Refer to 4 LUBRICANTS FUEL AND COOLANT on page G 10 9Y1211607GEG0023US0 Check of 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 ...

Page 36: ...ow the standard starting procedure for the generator 2 Remove any items that may be plugged into the receptacles 3 Turn the MCB 1 and all RCBO s 2 to the ON position switch up 4 Press the T test button 3 at the base of the RCBO 2 5 Make sure that the RCBO 2 trip to the OFF position when the test button is depressed 6 If this does not occur Stop the generator immediately remove the keys and lock ou...

Page 37: ...e level is below than lower level line 2 add the distilled water to pour level of each cell 3 If the battery can not be charged even though the electrolyte level is correct replace the battery 9Y1211607GEG0012US0 Replacement of 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 wr...

Page 38: ... or repair them at once 3 The fuel hose 2 is made of rubber and ages regardless of period of service Replace the fuel hose 2 together with the hose clamp 1 every two years and securely tighten 4 However if the fuel hoses 2 and hose clamps 1 are found damaged or deteriorated earlier than two years then change or remedy IMPORTANT When the fuel hose is disconnected for change close both ends of the f...

Page 39: ...2 add the distilled water to pour level of each cell 3 If the battery can not be charged even though the electrolyte level is correct replace the battery 9Y1211607GEG0012US0 Cleaning of Air Cleaner Primary Element 1 Remove the air cleaner primary element 2 2 Use clean dry compressed air on the inside of the primary element 2 Pressure of compressed air must be under 205 kPa 2 1 kgf cm2 30 psi Maint...

Page 40: ...nd Wear 1 Check the fan belt for damage 2 If the fan belt 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 9Y1211607GEG0029US0 Cleaning of Fuel Filter Element 1 Close the fuel valve 1 2 Remove the fuel filter element 2 3 After cleaning the fuel filter element 2 screwing it in by ...

Page 41: ...he radiator hoses 2 are properly fixed every 200 hours of operation or every six months whichever comes first 2 If clamp bands 1 are loose or water leaks tighten bands securely Replace hoses and tighten clamp bands securely if radiator hoses are swollen hardened or cracked 3 Replace hoses and clamp bands every 2 years or earlier if checked and found that hoses are swollen hardened or cracked 9Y121...

Page 42: ...F EVERY 400 HOURS Replacement of 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 9Y1211607GEG0034US0 Brush length Stretch out of the Holder Standard length All model 15 0 mm 0 591 in Allowable limit GL6000A AU B GL6000D AU B 4 5 mm 0 18 in GL9000A AU B GL9000D AU ...

Page 43: ...uction 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 engine with...

Page 44: ...ds that shows the minimum glycol content necessary in the concentrated anti freeze When the coolant level decreases because of evaporation add clean soft water only to keep the anti freeze mixing ratio less than 50 If there is a leakage add anti freeze and clean soft water in the specified mixing ratio The anti freeze absorbs moisture Keep new anti freeze in a tightly sealed container Do not use t...

Page 45: ...p 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 After turning the flywheel co...

Page 46: ...he factory specifications replace the adjusting washer in the nozzle holder to adjust it 9Y1211607GEG0038US0 Check of 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 9Y1211607GEG0039US0 Check of Nozzle Valve Seat Tightness 1 Set the injection nozzle to a nozzle tester 2...

Page 47: ...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 73 MPa 140 0 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 0 to 130 0 kgf cm2 from 1991 to 1849 p...

Page 48: ... connect it firmly 9Y1211607GEG0042US0 14 CHECK POINTS OF EVERY 2 YEARS Replacement of Fuel Hoses and Clamp Bands CAUTION Stop the engine when attempting to 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 t...

Page 49: ...ug 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 port Install the radiator cap securely 5 Fill with coolant up to FULL mark on the recovery tank 6 Start and operate the engine for few minutes 7 Stop the engine r...

Page 50: ...sel engine compression and diagnostics of need for major overhaul WSM000001GEG0014US0 Oil Pressure Tester Code No 07916 32032 Application Use to measure lubricating oil pressure WSM000001GEG0015US0 Plastigauge Code No 07909 30241 Application Use to check the oil clearance between crankshaft and bearing etc Measuring range Green 0 025 to 0 076 mm 0 00099 to 0 0029 in Red 0 0510 to 0 152 mm 0 00201 ...

Page 51: ...onnecting rod big end I D 30 to 75 mm dia 1 2 to 2 9 in dia Connecting rod length 65 0 to 300 mm 2 56 to 11 8 in WSM000001GEG0020US0 Red Check Code No 07909 31371 Application Use to check cracks on cylinder head cylinder block etc WSM000001GEG0023US0 Flywheel Puller Code No 07916 32011 Application Use exclusively to remove the flywheel with ease WSM000001GEG0018US0 Auxiliary Socket for Fixing Cran...

Page 52: ...AU B GL9000A AU B GL9000D AU B WSM G 31 Radiator Tester Code No 07909 31551 Application Use to check of radiator cap pressure and leaks from cooling system Remarks BANZAI Code No RCT 2A 30S 9Y1211607GEG0048US0 KiSC issued 06 2016 A ...

Page 53: ...PF 1 2 C Copper gasket D Flange Material Steel E Hex nut 27 mm 1 1 in across the plat F Adhesive application G Fillet welding on the enter circumference H Retaining nut I 17 mm dia 0 67 in dia J 8 0 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 0 241 to 0 244 in dia N 8 0 mm 0 31 in O 4 0 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 ...

Page 54: ...0 mm dia 0 39 in dia I 305 mm 12 0 in J 55 to 65 mm 2 2 to 2 5 in K 2 09 rad 120 L 37 mm 1 5 in M 7 70 to 8 00 mm dia 0 304 to 0 314 in dia C0 5 Chamfer 0 5 mm 0 02 in A 200 mm 7 87 in B 80 mm 3 1 in C 40 mm 1 6 in D 20 mm dia 0 79 in dia E 9 960 to 9 980 mm dia 0 3922 to 0 3929 in dia F 5 50 to 5 70 mm dia 0 217 to 0 224 in dia G 25 mm 0 98 in H 6 00 to 6 10 mm dia 0 237 to 0 240 in dia I 5 0 mm ...

Page 55: ...n B 25 mm 0 98 in C 20 mm 0 79 in D 25 mm dia 0 98 in dia E 21 90 to 21 95 mm dia 0 8622 to 0 8641 in dia F 19 90 to 19 95 mm dia 0 7835 to 0 7854 in dia A 135 mm 5 31 in B 72 mm 2 8 in C 40 mm radius 1 6 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 1 886 to 1 887 in dia H 43 90 to 43 95 mm dia 1 729 to 1 730 in dia A 130 mm 5 12 in B 72 mm 2 8 in C 40 ...

Page 56: ...1 ENGINE KiSC issued 06 2016 A ...

Page 57: ...CONTENTS 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 MECHANISM KiSC issued 06 2016 A ...

Page 58: ...ODY 1 HALF FLOATING HEAD COVER The rubber packing is fitting in to maintain the head cover 0 5 mm 0 02 in or so off the cylinder head This arrangement helps reduce noise coming from the cylinder head 9Y1211607ENM0001US0 1 Cylinder Head Cover 2 Rubber Packing KiSC issued 06 2016 A ...

Page 59: ...rced 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 9Y1211607ENM0002US0 1 Rocker Arm 2 Oil Pressure Switch 3 R...

Page 60: ...eceives 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 9Y1211607ENM0003US0 1...

Page 61: ...3 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 9Y1211607ENM0004US0 1 Injection Nozzle 2 Fuel Overflow Pipe 3 Fuel...

Page 62: ...6 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 Timing Gears C...

Page 63: ...ection pipe retaining nut Tighten retaining nut 1 S28 10 Incorrect injection timing Adjust 1 S18 11 Fuel camshaft worn Replace 1 S34 12 Injection nozzle clogged Clean or replace 1 S20 13 Injection pump malfunctioning Replace 1 S19 1 S32 14 Seizure of crankshaft camshaft piston cylinder or bearing Repair or replace 1 S36 to 1 S39 1 S52 to 1 S57 15 Compression leak from cylinder Replace head gasket ...

Page 64: ...or replace G 18 G 27 5 Deficient nozzle injection Repair or replace nozzle G 25 Deficient Output 1 Incorrect injection timing Adjust 1 S18 2 Engine s moving parts seem to be seizing Repair or replace 3 Uneven fuel injection Replace injection pump 1 S19 4 Deficient nozzle injection Repair or replace nozzle 1 S20 5 Compression leak Replace head gasket tighten cylinder head screw glow plug and nozzle...

Page 65: ...ective Repair or replace 1 S34 1 S58 High Oil Pressure 1 Different type of oil Use specified type of oil G 10 2 Relief valve defective Replace Engine Overheated 1 Engine oil insufficient Fill oil G 10 G 14 2 Fan belt broken or tensioned improperly Replace or adjust G 19 3 Coolant insufficient Fill coolant G 14 G 22 4 Radiator net and radiator fin clogged with dust Clean 5 Inside of radiator corrod...

Page 66: ...1 to 0 00728 in Valve Seat Angle 0 79 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 0012 to 0 0022 in 5 968 to 5 980 mm 0 2350 to 0 2354 in 6 010 to 6 025 mm 0 2367 to 0 2372 in 0 10 mm 0 0039 in Valve Seat Angle Width 0 79 rad 45 2 12 mm 0 0835 in Valve Face Angle 0 79 rad 45 Valve Recessing Intake and Exhaust 0 10 to 0 10 mm...

Page 67: ... mm 0 70867 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 0 012 in 26 88 mm 1 058 in 0 50 mm 0 020 in 0 01 mm 0 0004 in 26 83 mm 1 056 in Camshaft Journal to Cylinder Block Bore Camshaft Journal Cylinder Block Bore Oil Clearance O D I D 0 050 to 0 091 mm 0 0020 to 0 0035 in 32 934 to 32 950 mm 1 2967 to 1 2972 in 33 000 to...

Page 68: ...to 0 017 in 0 15 to 0 30 mm 0 0059 to 0 011 in 1 20 mm 0 0472 in 1 20 mm 0 0472 in 1 20 mm 0 0472 in Connecting Rod Alignment 0 05 mm 0 002 in Piston Pin to Small End Bushing Piston Pin Small End Bushing Oil Clearance O D I D 0 014 to 0 038 mm 0 00056 to 0 0014 in 20 002 to 20 011 mm 0 78748 to 0 78783 in 20 025 to 20 040 mm 0 78839 to 0 78897 in 0 10 mm 0 0039 in Crankshaft Alignment 0 02 mm 0 00...

Page 69: ...rankpin Bearing Crankpin Crankpin Bearing Oil Clearance O D I D 0 020 to 0 051 mm 0 00079 to 0 0020 in 33 959 to 33 975 mm 1 3370 to 1 3375 in 33 995 to 34 010 mm 1 3384 to 1 3389 in 0 15 mm 0 0059 in Crankshaft Side Clearance 0 15 to 0 31 mm 0 0059 to 0 012 in 0 50 mm 0 020 in Cylinder Liner Standard I D 67 000 to 67 019 mm 2 6378 to 2 6385 in 67 169 mm 2 6444 in Cylinder Liner Oversize 0 25 mm 0...

Page 70: ... 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 seconds or more 90 60 kPa 0 9 0 6 kgf cm2 10 9 psi Radiator Water Leakage Test Pressure No leak at specified pressure 160 kPa 1 6 kgf cm2 23 psi Item Factory Specification Allowable...

Page 71: ... Length 28 0 mm 1 10 in Less than 0 05 mm 0 002 in 0 50 to 0 80 mm 0 020 to 0 031 in 16 0 mm 0 630 in 27 0 mm 1 06 in 0 4 mm 0 02 in 0 20 mm 0 0079 in 10 5 mm 0 413 in Starter Planetary Gear Reduction Type Commutator Difference Mica Brush O D O D Undercut Length 30 0 mm 1 18 in Less than 0 02 mm 0 0008 in 0 50 to 0 80 mm 0 020 to 0 031 in 14 0 mm 0 551 in 29 0 mm 1 14 in 0 5 mm 0 02 in 0 20 mm 0 0...

Page 72: ... 34 2 5 to 3 5 18 to 25 Overflow pipe retaining nut M12 1 5 20 to 24 2 0 to 2 5 15 to 18 Nozzle holder assembly M20 1 5 49 to 68 5 0 to 7 0 37 to 50 Glow plug M8 1 7 9 to 14 0 80 to 1 5 5 8 to 10 Rocker arm bracket screw M6 1 9 81 to 11 2 1 00 to 1 15 7 24 to 8 31 Cylinder head screw M8 1 25 38 to 42 3 8 to 4 3 28 to 31 Fan drive pulley screw M12 1 5 98 1 to 107 10 0 to 11 0 72 4 to 79 5 Idle gear...

Page 73: ...rs as shown below 9Y1211607ENS0007US0 Indication on top of bolt No grade or 4T 7T Indication on top of nut No grade or 4T Unit 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 8 9 81 to 11 2 1 00 to 1 15 7 24 to 8 31 M8 18 to 20 1 8 to 2 1 13 to 15 24 to 27 2 4 to 2 8 18 to 20 M10 40 to 45 4 0 to 4 6 29 to 33 48 to 55 4 9 to 5 7 36 to 41 M12 63 to 72 6 4 to 7 4 47 to 53 78 to ...

Page 74: ...er 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 applying...

Page 75: ...ed torque 4 Turn the flywheel until the piston exceeds its top dead center 5 Remove the cylinder head and measure the width of the crushed plastigauges 2 with the scale 3 6 If the measurement is not within the factory specification 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 asse...

Page 76: ...he 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 After turning the fl...

Page 77: ...Oil 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 9Y1211607ENS0011US0 Engine oil pressure At idle speed Factory specifica tion More than 50 kPa 0 5 kgf cm2 7 psi At rated speed Factory specifica tion 2...

Page 78: ... out and deeply sunk in the pulley groove replace it 9Y1211607ENS0013US0 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 3 in 4 If the meas...

Page 79: ...the measurement is less than the factory specification replace the radiator cap 9Y1211607ENS0016US0 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 W...

Page 80: ...hickness of 0 20 mm 0 0079 in 0 25 mm 0 0098 in 0 30 mm 0 012 in 0 35 mm 0 014 in and 0 175 mm 0 00689 in Combine these shims for adjustments Addition or reduction of shim 0 05 mm 0 002 in delays or advances the injection timing by approx 0 009 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 below to chec...

Page 81: ...to increase 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 1990 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 7 to 12 7 MPa from 140 to 130 kgf cm2 fro...

Page 82: ...tester handle to measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specification replace the adjusting washer 1 in the nozzle holder to adjust it Reference Pressure variation with 0 025 mm 0 00098 in difference of adjusting washer thickness Approx 240 kPa 2 4 kgf cm2 34 psi 9Y1211607ENS0023US0 Nozzle Valve Seat Tightness 1 Set the ...

Page 83: ...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 9Y1211607ENS0025US0 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 spec...

Page 84: ...y line is not on the gradation baseline 0 position turn the adjustment screw until it matches 5 When zero adjustment is complete wipe the prism and cover surface with a soft cloth or tissue paper Measurement of test fluid 1 Open the cover and drip test fluid on the prism surface using the included rod 2 Close the cover 3 Aim in a direction that is bright look into the lens and read the gradation o...

Page 85: ... magnet switch 9Y1211607ENS0027US0 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 start...

Page 86: ...from the battery voltage the wiring harness or main switch is faulty 9Y1211607ENS0029US0 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 ...

Page 87: ...the radiator before opening the cap 1 Place a vessel underneath the water drain plug 1 2 Open the water drain plug 1 and remove the radiator cap to completely drain the coolant 3 After all coolant is drained close the water drain plug 1 Refer to 4 LUBRICANTS FUEL AND COOLANT on page G 10 9Y1211607ENS0032US0 Battery CAUTION Be sure to stop the engine before disconnecting the cables When removing th...

Page 88: ...l tank 2 Remove the front frame 6 and rear cover 4 and side cover 5 3 Remove the cleaner cover 8 4 Disconnect the connector between the generator 10 and control panel 12 5 Disconnect the ground cables 7 6 Remove the control panel 12 with battery isolator switch 11 7 Remove the cooling air port cover 9 9Y1211607ENS0035US0 1 Fuel Valve 2 Fuel Hose 3 Fuel Filter 1 Generator Roof 2 Hanger 3 Engine Roo...

Page 89: ...to 27 N m 2 0 to 2 8 kgf m 15 to 20 lbf ft Stator mounting screw 6 to 8 N m 0 6 to 0 9 kgf m 5 to 6 lbf ft Rotor assembly mounting screw 35 to 44 N m 3 5 to 4 5 kgf m 26 to 32 lbf ft PTO shaft 48 to 55 N m 4 9 to 5 7 kgf m 36 to 41 lbf ft Tightening torque Generator mounting nut 54 to 68 N m 5 5 to 7 0 kgf m 40 to 50 lbf ft Stator mounting screw 19 to 21 N m 1 9 to 2 2 kgf m 14 to 15 lbf ft Rotor ...

Page 90: ... the 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 9Y1211607ENS0039US0 Tightening torque Cylinder head cover screw 6 87 to 11 2 N m 0 700 to 1 15 kgf m 5 07 to 8 31 lbf ft 1 Cylinder Head Cover Screw 2 Cylinder Head Cover A GL6000A AU B GL6000D AU B B GL9000A AU B GL9000...

Page 91: ... seal hole 2 Turn screw 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 9Y1211607ENS0041US0 Tightening torque ...

Page 92: ...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 9Y1211607ENS0042US0 Tightening torque Rocker arm bracket screw 9 81 to 11 2 N m 1 00 to 1 15 kgf m 7 24 to 8 31 lbf ft 1 Rocker Arm Bracket Screw 2 Rocker Arm Assembly 3 Push Rod 4 Tappet A GL6000A AU B GL6000D AU B B GL9000A AU ...

Page 93: ... 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 9Y1211607ENS0043US0 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 7...

Page 94: ...ever 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 00098 in delays or advances the injection timing by approx 0 009 rad 0 5 In disassembling and replacing be sure to use the same number of new gasket shims with the same thickness 9Y1211607ENS0045US0 Fan Drive Pulley 1 Set the stopper...

Page 95: ...ear 1 When reassembling Install the idle gear aligning the alignment mark 4 on the gears referring to the figure 9Y1211607ENS0048US0 Camshaft 1 Remove the camshaft mounting screws 1 and draw out the camshaft 2 with gear 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 9Y1211607ENS0049US0 1 ...

Page 96: ...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 9Y1211607ENS0051US0 1 Retaining Plate 2 Fuel Camshaft 3 Injection Pump Gear 4 Governor Sleeve 5 Fork Lever 1 6 F...

Page 97: ... AU B GL9000D AU B 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 0 to 5 0 mm 0 12 to 0 19 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 ...

Page 98: ... with the grip of 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 markin...

Page 99: ...site side 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 s...

Page 100: ... directions Install 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 9Y1211607ENS0057US0 Crankshaft Assembly 1 Remove the main bearing case screw 2 1 2 Pull out the crankshaft assembly When reassembling Clean...

Page 101: ... B GL6000D AU B and 1 2 for GL9000A AU B GL9000D AU B 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 outw...

Page 102: ... 9Y1211607ENS0061US0 6 Injection 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 9Y1211607ENS0062US0 1 Thermostat Cover Mounting Screw 2 Thermostat Co...

Page 103: ...aw 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 9Y1211607ENS0063US0 1 Solenoid Switch Mounting Nut 2 Starter Drive Housing 3 Drive Lever 4 Gasket 5 Soleno...

Page 104: ...holding 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 9Y1211607ENS0064US0 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 ...

Page 105: ...dge on the combustion chamber 9Y1211607ENS0065US0 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 5 to 10 minutes after spraying 4 Wash away the read permeative liquid on the cylinder head surface with the detergent 2 5 Spray the cylinder hea...

Page 106: ... 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 9Y1211607ENS0068US0 Valve recessing Intake and exhaust Factory specification 0 10 protrusion to 0 10 recessing mm 0 0039 protrusion to 0 0039 recessing in Allowable limit 0 30 recessing mm 0 012 re...

Page 107: ...2 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 26 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 ...

Page 108: ... spring 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 9Y1211607ENS0072US0 Valve Spring Setting Load 1 Place ...

Page 109: ...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 9Y1211607ENS0076US0 Oil clearance between rocker arm and rocker arm shaft Factory specification 0 016 to 0 045 mm 0 00063 to 0 0017 in Allowable limit 0 15 mm 0 0059 in Rocker arm s...

Page 110: ...e clearance by moving the cam gear to the font and rear 3 If the measurement exceeds the allowable limit replace the camshaft stopper 9Y1211607ENS0079US0 Backlash between idle gear and crank gear Factory specification 0 0430 to 0 124 mm 0 00170 to 0 00488 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and cam gear Factory specification 0 0470 to 0 123 mm 0 00185 to 0 00484 in Allo...

Page 111: ...ournal 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 9Y1211607ENS0082US0 Camshaft alignment Allowable limit 0 01 mm 0 0004 in Cam height of intake and exhaust Factory specification 26 88 mm 1 058 in Allow...

Page 112: ...e 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 9Y1211607ENS0084US0 Oil clearance between idle gear shaft and idle gear bushing Factory specificat...

Page 113: ...all 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 9Y1211607ENS0087US0 Piston pin bore I D Factory specification 20 000 to 20 013 mm 0 78741 to 0 78791 in Allowable limit 20 05 mm 0 7894 i...

Page 114: ...ing 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 9Y1211607ENS0090US0 Piston ring gap...

Page 115: ...l 3 Measure the crankshaft alignment 4 If the measurement exceeds the allowable limit replace the crankshaft 9Y1211607ENS0092US0 Crankshaft side clearance Factory specification 0 15 to 0 31 mm 0 0059 to 0 012 in Allowable limit 0 50 mm 0 020 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 02 in Thrust be...

Page 116: ...rsize dimensions of crankpin 9Y1211607ENS0093US0 Oil clearance between crankpin and crankpin bearing Factory specification 0 020 to 0 051 mm 0 00079 to 0 0020 in Allowable limit 0 15 mm 0 0059 in Crankpin O D Factory specification 33 959 to 33 975 mm 1 3370 to 1 3375 in Crankpin bearing I D Factory specification 33 995 to 34 010 mm 1 3384 to 1 3389 in Undersize Bearing Code Number Marking 0 2 mm 0...

Page 117: ...rects toward the exhaust manifold side See figure 9Y1211607ENS0095US0 Oil Clearance between crankshaft journal and crankshaft bearing 1 Factory specification 0 0340 to 0 106 mm 0 00134 to 0 00417 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory specification 39 934 to 39 950 mm 1 5722 to 1 5728 in Crankshaft bearing 1 I D Factory specification 39 984 to 40 040 mm 1 5742 to 1 576...

Page 118: ...in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Flywheel side Factory specification 43 934 to 43 950 mm 1 7297 to 1 7303 in Crankshaft bearing 2 I D Factory specification 43 978 to 43 993 mm 1 7315 to 1 7320 in Crankshaft journal O D Intermediate Factory specification 39 934 to 39 950 mm 1 5722 to 1 5728 in Crankshaft bearing 3 I D Factory specification 39 978 to 39 993 mm 1 5740 to 1 ...

Page 119: ...linder 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 9Y1211607ENS0098US0 Cylinder I D Factory specification 67 000 to 67 019 mm 2 6378 to 2 6385 in Allowable limit 67 169 mm 2 6444 in A Top B Middle C ...

Page 120: ... pump rotor assembly 9Y1211607ENS0100US0 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 specification replace oil pump rotor assembly 9Y1211607...

Page 121: ... 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 9Y1211607ENS0103US0 Commutator O D Factory specifica tion Electromag netic drive type 28 0 mm 1 10 in Planetary gear reduction type 30 0 mm 1 18 in Allowable limit Electromag netic drive type 27 0 mm 1 06 in Planetary gear reduction type 29 0 mm 1 14 in Di...

Page 122: ...damage 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 9Y1211607ENS0105US0 Brush Holder 1 Check the continuity acr...

Page 123: ...the continuity 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 9Y1211607ENS0107US0 1 Lead 2 Brush 3 Yoke KiSC issued 06 2016 A ...

Page 124: ...2 GENERATOR KiSC issued 06 2016 A ...

Page 125: ...000A AU B GL9000A AU B 2 M4 1 GENERAL 2 M4 2 INSTRUCTIONS GL6000A AU B GL9000A AU B 2 M5 4 GENERATOR CONNECTION AND GROUNDING 2 M6 5 DIGITAL CONTROL PANEL 2 M7 6 WIRING DIAGRAM 2 M16 1 GL6000A AU B 2 M16 2 GL6000D AU B 2 M17 3 GL9000A AU B 2 M18 4 GL9000D AU B 2 M19 MECHANISM KiSC issued 06 2016 A ...

Page 126: ... 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 9Y1211607GRM0001US0 1 Rear Cover 2 A V R Assembly 3 Bru...

Page 127: ...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 9Y1211607GRM0002US0 1 A V R 2 Capacitor A GL6000A AU B GL6000D AU B B GL9000A AU B GL9000D AU B KiSC issued 06 2016 A ...

Page 128: ...The drive signal from the previous 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 beh...

Page 129: ...tes the stop solenoid to cut off fuel 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 much...

Page 130: ...he 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 en...

Page 131: ...rounding and connection method to be used in their application or location The generator has been designed and manufactured in accordance with AS NZS3000 and its reference standards as relevant Testing has been conducted in accordance with AS NZS3017 A neutral earth connection has been installed at the alternator and RCD s are fitted for each receptacle socket outlet In accordance with AS NZS3012 ...

Page 132: ...anel The following information pertains to the controller in its standard GL series configuration For custom configurations please see your local KUBOTA dealer 9Y1211607GRM0008US0 Description of Controls Control of the panel is via push buttons mounted on its face The main buttons are stop reset mode auto mode and manual start mode For normal operation these are the only controls on the panel that...

Page 133: ... into auto mode This mode allows the controller to command starting of the generator automatically The controller will monitor the remote start input and once a start request is made the generator will be automatically started Upon removal of the starting signal the controller will instruct the stop solenoid to active and the engine will shut down The controller will then await the next start even...

Page 134: ...t section is currently being displayed 9Y1211607GRM0012US0 Auto Run Icon When running in auto mode and on the home page an icon is displayed in the auto run section to indicate the source of the auto start signal 9Y1211607GRM0013US0 Icon Description Generator voltage and frequency instrumentation screen Engine speed instrumentation screen Hours run instrumentation screen Battery voltage instrument...

Page 135: ...zer To reset the alarm icon and buzzer rectify the fault cause then press the stop reset button If multiple alarms are active at the same time the alarm icon automatically cycles through all the appropriate icons to indicate each alarm which is active 9Y1211607GRM0017US0 Icon Description Appears when the engine is at rest and the unit is in stop mode Appears when the engine is at rest and the unit...

Page 136: ...is running when it has been instructed to stop Battery Under Voltage The DC supply has fallen below the low volts pre set pre alarm setting Battery Over Voltage The DC supply has risen above the high volts pre set pre alarm setting Generator Under Voltage The generator output voltage has fallen below the pre set pre alarm setting Generator Over Voltage The generator output voltage has risen above ...

Page 137: ...ated indicating insufficient oil pressure High Coolant Temperature The controller detects that the engine coolant sender has been activated indicating high coolant temperature Fail To Start The engine has failed to start after three start attempts Generator Under Voltage The generator output voltage has fallen below the pre set alarm setting Generator Over Voltage The generator output voltage has ...

Page 138: ...t the top press the auto mode button to enter that instrumentation section If the auto mode button is not pressed the display automatically returns to the home page after the configured setting of the LCD scroll timer Navigation Menu Icon 9Y1211607GRM0021US0 Icon Description Generator voltage instrumentation Generator instrumentation Mains instrumentation Disabled in standard configuration Current...

Page 139: ... has been selected and is automatically displayed after a period of inactivity page delay timer of the module facia buttons It also contains the voltage reading of the generator that is measured from the controller s voltage inputs Frequency Displays the frequency of the generators AC output Alternator Charge Votlage Shows the charge voltage as measured at the alternator Battery Voltage Shows volt...

Page 140: ...both up and down buttons simultaneously the navigation menu is then displayed Once entered cycle to the event log section and enter To view the individual events in the event log scroll through by pressing the up or down buttons until the LCD screen displays the desired event Continuing to press down the up or down buttons will cycle through the past alarms after which the display shows the most r...

Page 141: ...GENERATOR GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B WSM 2 M16 6 WIRING DIAGRAM 1 GL6000A AU B KiSC issued 06 2016 A ...

Page 142: ...GENERATOR GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B WSM 2 M17 2 GL6000D AU B KiSC issued 06 2016 A ...

Page 143: ...GENERATOR GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B WSM 2 M18 3 GL9000A AU B KiSC issued 06 2016 A ...

Page 144: ...GENERATOR GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B WSM 2 M19 4 GL9000D AU B KiSC issued 06 2016 A ...

Page 145: ...OLTS AND NUTS 2 S11 4 CHECKING DISASSEMBLING AND SERVICING 2 S12 1 CHECKING AND ADJUSTING 2 S12 1 Control Panel 2 S12 2 Emergency Relay Activation 2 S18 2 DISASSEMBLING AND ASSEMBLING 2 S20 1 External Components 2 S20 2 Generator 2 S21 3 SERVICING 2 S23 1 Terminal Voltage for Each Part During Normal Periods No load Periods 2 S23 2 Stator Coil 2 S23 3 Rotor Coil 2 S24 4 Exciter Coil 2 S25 5 Sub Coi...

Page 146: ...Fan belt 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 im...

Page 147: ...nside the control 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 250 V 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 i...

Page 148: ...th A V R Replace A V R Improper contact of brushes Inspect and clean the brush contact surface or repair 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 250 V at AC range Output voltage is low Lowered engine rotation Adjustment of rotational sp...

Page 149: ...level Replace Over heat Check the monitor and the radiator clog Repair or replace Engine breakdown Check the engine exterior and oil level Repair 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 The Charge Lamp Lights Alternator Charge Fail Illuminates After the Engine Starts Disconnected wiring harness or shor...

Page 150: ...t Breaker Can Not Be Operated Overload Reduce load Short circuit 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 Counte...

Page 151: ...nsult KUBOTA dealer Engine under speed Generator under frequency Check electrical load ensure it is not over limitation Consult KUBOTA dealer Check for fuel shortage Engine over speed Generator over frequency Check electrical load ensure it is not over limitation Consult KUBOTA dealer Alternator charge fail Check fan belt and replace if required Check alternator and replace if required Water tempe...

Page 152: ...e alarms are in two stages First stage is a warning where the alarm symbol will appear on the controller screen This occurs at a predetermined setting if this setting is then exceeded the shutdown alarm will occur The generator will automatically shut down and a buzzer will be activated Once shutdown has occurred the warning symbol will remain on the control panel screen until it is cleared with t...

Page 153: ...Ω BR L Sub coil G LG R 1 08 Ω Sub coil DC L W L W 0 11 Ω Detecting coil LG L 0 05 Ω Rotor coil 59 5 Ω Air gap 0 5 mm 0 02 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 0 004 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 Circuit breaker capacity 23 A K...

Page 154: ...coil LG LG 1 96 Ω Sub coil DC L W L W 0 08 Ω Detecting coil R R 0 04 Ω Rotor coil 55 5 Ω Air gap 0 7 mm 0 03 in Slip ring Outside diameter 64 mm 2 5 in Correction limit 62 5 mm 2 46 in Standard run out 0 1 mm 0 004 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 breaker capacity 33 5 A KiSC issued 06 ...

Page 155: ...d nuts on the table apply engine oil to their threads and seats before tightening GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B 9Y1211607GRS0011US0 Item N m kgf m lbf ft Stator mounting screw 6 to 8 0 6 to 0 9 5 to 6 Rotor assembly mounting screw 35 to 44 3 5 to 4 5 26 to 32 PTO shaft mounting screw 48 to 55 4 9 to 5 7 36 to 41 Engine mounting nut 20 to 27 2 0 to 2 8 15 to 20 Generator mount...

Page 156: ... Indication on top of bolt No grade or 4T 7T Indication on top of nut No grade or 4T Unit N m kgf m lbf ft N m kgf m lbf ft M4 0 98 to 2 9 0 10 to 0 30 0 73 to 2 1 M5 2 0 to 3 9 0 20 to 0 40 1 5 to 2 8 M6 7 9 to 9 3 0 80 to 0 95 5 8 to 6 8 9 81 to 11 2 1 00 to 1 15 7 24 to 8 31 M8 18 to 20 1 8 to 2 1 13 to 15 24 to 27 2 4 to 2 8 18 to 20 M10 40 to 45 4 0 to 4 6 29 to 33 48 to 55 4 9 to 5 7 36 to 4...

Page 157: ...ector 3 and remove the main switch 2 3 Perform the following checks 9Y1211607GRS0013US0 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 9Y1211607GRS0014US0 1 Control Panel 2 Main Switch 3 4P Connector Voltage Connector 30 terminal chassis Approx battery voltage KiSC...

Page 158: ...ce with an ohmmeter across the 30 terminal 4 and the 19 terminal 1 3 Measure the resistance with an ohmmeter across the 30 terminal 4 and the AC terminal 2 4 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 4 and the 19 ...

Page 159: ...able value The safety switch 2 is failure then please exchange it 9Y1211607GRS0016US0 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 9Y1211...

Page 160: ...put voltage 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 9Y1211607GRS0018US0 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 ...

Page 161: ...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 9Y1211607GRS0019US0 1 Miniature Circuit Breaker MCB A GL6000A AU B GL6000D AU B B GL9000A...

Page 162: ...he terminals for each lamp 2 If there is no continuity change the lamp 9Y1211607GRS0020US0 Charge 3 terminal 4 terminal Approx 10 Ω 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 Pressure 5 Glow KiSC issued 06 2016 A ...

Page 163: ...e switch 1 if it is defective 9Y1211607GRS0022US0 Water Temperature Sensor 1 Insert the water temperature sensor 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 sensor is defective IMPORTANT Be careful when handling the water temperature sensor so that you do not drop it When ass...

Page 164: ...s from the ground terminal 3 to the battery negative terminal 8 6 The plunger push out from the solenoid body when the switch 6 is turn on 7 The plunger pull into the solenoid body when the switch 6 is turn off 8 Turn on the switch 7 then turn on the switch 6 the plunger push out from the solenoid body and it keeps in holding position after turn off the switch 6 9 If the solenoid plunger is not bo...

Page 165: ...6 and rear cover 4 and side cover 5 4 Remove the cleaner cover 8 5 Disconnect the connector between the generator 10 and control panel 12 6 Disconnect the ground cables 7 7 Remove the control panel 12 with battery isolator switch 11 8 Remove the cooling air port cover 9 9Y1211607GRS0025US0 1 Generator Roof 2 Hanger 3 Engine Roof 4 Rear Frame 5 Side Cover 6 Front Frame 7 Ground Cables 8 Cleaner Cov...

Page 166: ...to position the bearing correctly Misalignment may make it difficult to install the bearing or what s worse damage it NOTE Be careful not to confuse the direction of the snap ring of the bearing GL6000A AU B GL6000D AU B GL9000A AU B GL9000D AU B 9Y1211607GRS0026US0 Stator Assembly and Stator Housing 1 Hoist up the stator assembly 1 2 Remove the stator assembly 1 take care not to damage the windin...

Page 167: ...caused by loose fittings Handle carefully to avoid damaging the winding 9Y1211607GRS0028US0 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 9Y1211607GRS00...

Page 168: ...on the voltage variation 2 If the resistance is not as specified replace the stator or contact service station Refer to 2 M16 Measurement is not possible with a regular tester 9Y1211607GRS0031US0 Detecting Coil 1 Measure the coil resistance between each auxiliary winding 2 If the factory specification is not indicated replace the stator or contact service station Refer to 2 M16 9Y1211607GRS0032US0...

Page 169: ... assembly or contact service station Refer to 2 M16 9Y1211607GRS0034US0 Grounding of Rotor Coil 1 Connect leads of a megohm meter between each lead and exciter rotor laminations 2 Reading should be more than 1 MΩ at 500 V 3 If continuous replace the rotor assembly or contact service station 9Y1211607GRS0035US0 Checking Generator s Ball Bearing 1 Hold the bearing 1 and push and pull the outer race ...

Page 170: ... the insulation resistance between each lead and the laminations with a megohm meter 2 A reading should be more than 1 MΩ at 500 V 3 If continuous replace the exciter coil assembly or contact service station 9Y1211607GRS0038US0 5 Sub Coil DC Sub Coil DC 1 Measure the coil resistance between each lead with a miliohm meter 2 If the resistance is not as specified replace the stator or contact service...

Page 171: ...l Machinery International Service Department 64 Ishizu Kitamachi Sakai Ku Sakai City Osaka 590 0823 Japan Phone Address 72 241 1129 Fax 81 81 72 245 2484 E mail ks_g ksos pub kubota com Printed in Japan 2016 06 S EI EI engusa Code No 9Y111 16070 ...

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Kubota GL6000A-AU-B, Workshop Manual

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