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Kubota SQ-1120 Operator'S Manual Download Page 58

43

TROUBLESHOOTING

B

Generator Troubleshooting

Trouble

Possible causes

Correction

Unusual noise or vibration

Single-phase load applied beyond allowable 
level (on three phase models).

*Lower the load to acceptable level.

Bearing deteriorated.

*Replace the bearing.

Coupling damaged.

*Replace the coupling.

Frame overheated.

Cooling fan inlet or outlet blocked.

*Unblock the inlet or outlet.

Voltage too high.

*Readjust the voltage.

Overloaded.

*Reduce the load.

Voltage failure to rise.

Voltage maladjusted.

*Readjust using the voltage control.

AVR excitation output cable broken.

*Repair the cable.

AVR itself in trouble.

*Replace the AVR.

Exciter's winding short-circuited or broken.

*Replace the generator.

AVR excitation input cable broken.

*Repair the cable.

Generator's winding broken.

*Replace the generator.

AVR excitation output fuse blown out.

*Replace the fuse.

Voltage too high.

Voltage maladjusted.

*Readjust using the voltage control.

AVR voltage detection cable broken.

*Repair the cable.

AVR itself in trouble.

*Replace the AVR.

Mercury arc lamp or such conductive load 
connected.

*Disconnect such load.

Voltage hunting

Inverter or such switching load connected.

*Disconnect such load.

AVR itself in trouble.

*Replace the AVR.

Circuit breaker turned OFF.

Connected cable or load short-circuited.

*Contact a qualified electrical engineer for 
inspection.

Overloaded.

*Reduce the load.

Pilot lamp failure to light up

Lamp bulb broken.

*Replace the bulb.

Generator voltage too low.

*See "Voltage failure to rise" above.

1G296-8914.book  43 ページ  ２０１２年３月１９日　月曜日　午前１０時４０分

Summary of Contents for SQ-1120

Page 1: ...KUBOTA ...

Page 2: ... connection point for generator power and allows selection of generator or main line power to the building This will prevent the generator from charging the main power line backfeeding when the main power supply has failed or has been turned off for line repair Backfeeding can electrocute or injure line maintenance personnel Also generator and building electrical system damage can occur when norma...

Page 3: ... distributors and dealers will have the most up to date information Please do not hesitate to consult with them 3 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 instruc tions and safety regulations before y...

Page 4: ... in Cold Ambient Temperatures 15 COLD WEATHER STARTING 16 STOPPING THE ENGINE 17 EMERGENCY STOP SWITCH 18 MAINTENANCE 19 SERVICE INTERVALS 20 PERIODIC SERVICE 22 FUEL 22 Fuel Level Check and Refueling 22 Air Bleeding the Fuel System 23 Cleaning the Fuel Filter Element 23 Fuel Filter Cartridge Replacement 24 Cleaning the Water Separator Sedimenter 24 Draining Water in the Fuel Tank 25 ENGINE OIL 25...

Page 5: ...RIC WIRING 34 FAN BELT 35 Adjusting Fan Belt Tension 35 FULLY BUNDED 35 TRANSPORTING STORAGE 36 Transporting 36 Lifting Procedure 36 Storage 37 OPERATION OF THE EMERGENCY RELAY 38 TROUBLESHOOTING 40 When it is Difficult to Start the Engine 40 When Starter does not Start 40 When Output is Insufficient 41 When Engine Suddenly Stops 41 When Color of Exhaust Smoke is Black and Excessive 41 When Engine...

Page 6: ...d work safely Know your equipment and its limitations Always keep the generator in good condition A Before allowing other people to use your generator explain to them how to operate and have them read this manual before operation A DO NOT modify the engine by yourself UNAUTHORIZED MODIFICATIONS to the engine may impair the function and or safety and affect engine life WEAR SAFETY CLOTHING A DO NOT...

Page 7: ...ECTRICAL COMPONENTS Always exercise extra caution when handling electrical equipment Careless handling of electrical components can cause serious personal injury death by electrocution or property damage A DO NOT touch the electrical system during operation A Connect or disconnect the load to the AC receptacles or terminals only when the engine is stopped A Make certain that all power cables and w...

Page 8: ...EL AND LUBRICANTS A Always stop the engine before refueling and or lubricating A DO NOT smoke or allow flames or sparks in the working area Fuel is extremely flammable and explosive under certain conditions A Refuel only when the engine has cooled off Refuel in a well ventilated and open place When fuel and lubricants are spilled clean them up before starting the engine A DO NOT mix gasoline or al...

Page 9: ...aks of flammables from hoses and lines Be sure to check for leaks from hoses or pipes such as fuel and engine oil by following the maintenance check list A To avoid a fire DO NOT short across power cables and wires Check to see that all power cables and wiring are in good condition A Keep all power connections clean and tight Bare wire or frayed insulation can cause a dangerous electrical shock an...

Page 10: ...h your hand High pressure oil or fuel can cause serious personal injury A Escaping fluid under pressure has sufficient force to penetrate skin causing serious personal injury A Fluid escaping from pinholes may be invisible Use a piece of cardboard or wood to search for suspected leaks DO NOT use hands or body Use safety goggles or other eye protection when checking for leaks A If injured by escapi...

Page 11: ...arts are taken off or left loose serious personal injury can result A The battery presents an explosive hazard When the battery is being activated hydrogen and oxygen gases are extremely explosive A Keep sparks and open flames away from the battery especially when charging the battery DO NOT strike a match near the battery A DO NOT check battery charge by placing a metal object across the terminal...

Page 12: ...f you spill electrolyte on yourself flush with water and get medical attention immediately A Be sure to stop the engine and remove the key when conducting daily and periodic maintenance servicing and cleaning A Check or conduct maintenance after the engine coolant muffler or muffler cover have cooled off completely A Always use the appropriate lifting equipment and make sure safety stands are in g...

Page 13: ...o following representations for labels used on the SQ Series Generator Labels are available individually from your KUBOTA Dealer 1 Part No G3341 8851 0 5 Part No G3907 8832 0 6 Part No G3352 8836 0 2 Part No G3341 8824 0 7 Part No G3341 8830 0 3 Part No 18620 8806 0 8 Part No G3341 8831 0 4 Part No 18901 5090 0 ...

Page 14: ...9 SAFE OPERATION 9 Part No G3102 8806 0 11 Part No 6C090 5896 0 10 Part No G3341 8822 0 12 Part No G3341 8895 0 ...

Page 15: ...ger warning and caution labels with new labels from your local KUBOTA Dealer 4 If a component with danger warning and caution label s affixed is replaced with new part make sure new label s is are attached in the same location s as the replaced component 5 Mount new danger warning and caution labels by applying on a clean dry surface and pressing any bubbles to outside edge CARE OF DANGER WARNING ...

Page 16: ...major service be sure to see your KUBOTA Dealer For service contact the KUBOTA Dealership from which you purchased your generator or your local KUBOTA Dealer When in need of parts be prepared to give your dealer the generator and engine serial numbers Locate the serial numbers now and record them in the space provided below Model Serial No Generator Engine Date of Purchase Name of Dealer To be fil...

Page 17: ...tical water cooled 4 cycle diesel engine No of cylinders 3 4 3 4 4 Bore x Stroke mm 87 x 92 4 98 x 110 Displacement L 1 647 2 197 1 647 2 197 3 318 Engine Speed rpm 1500 Continuous rated output kW HP 13 6 18 2 18 4 24 7 13 6 18 2 18 4 24 7 26 8 35 9 Lubricating oil API service class CF or higher Oil capacity L 5 6 7 6 5 6 7 6 13 2 Coolant capacity L 6 6 7 4 6 6 7 4 9 3 SET Fuel Diesel fuel No 2 AS...

Page 18: ...ler 11 Fork pockets 12 Emergency stop switch 13 Fully Bunded Base bunded to 110 capacity 14 Control panel 1 Generator 2 Battery 3 Radiator 4 Recovery tank 5 Oil dipstick 6 Engine oil port 7 Oil filter cartridge 8 Fuel sedimenter cartridge water separator 9 Electric fuel feed pump 10 Fuel filter cartridge 11 Fuel tank 12 Air cleaner 13 Safety switch 14 Engine oil drain plug 15 Coolant drain plug 16...

Page 19: ...rge lamp 9 Main switch key 10 Circuit breaker 11 Voltage adjuster 12 Terminals output 13 Hour meter 14 Ground terminal 15 Door open lamp 16 Fuel gauge 1 A C Voltmeter 2 Frequency meter 3 A C Ammeter 4 Pilot lamp Green lamp 5 Glow plug lamp 6 Water temperature lamp 7 Oil pressure lamp 8 Battery charge lamp 9 Main switch key 10 Circuit breaker 11 Voltage adjuster 12 Terminals output 13 Hour meter 14...

Page 20: ... relay 5 Solenoid relay 6 Glow relay 7 Thermal relay Over current relay 8 CT Current transformer 9 Terminal Generator 10 Terminal AVR 11 Terminal Battery TB3 12 Terminal Main switch TB2 13 Terminal Auxiliary output TB1 14 Terminal Auto start unit TB4 15 Fuse 3A F1 16 Fuse 10A F2 17 Fuse 3A F3 18 Fuse 1A F4 19 Fuse 2A AVR C 3 Phase Type ...

Page 21: ...al Electrical Code NFPA National Fire Protection Association AUSTRALIAN STANDARDS and OSHA Occupational Safety and Health Administration regulations must be followed to assure compliance and safe operation Always be sure to ground earth the generator terminals to comply with the local state national or OSHA requirements One possible connection method for construction site use is as follows 1 Load ...

Page 22: ...to lights and electric heaters When connecting to lights or electric heaters the generator can be used up to the rated capacity When using a single phase it can be used up to the rated current A Power factor calculations The power factor calculation is used to determine input of the electrical devices Power factors of commonly used devices are listed in the following table A Ordinarily a motor is ...

Page 23: ...has been turned off for line repair Backfeeding can electrocute or injure line maintenance personnel Also generator and building electrical system damage can occur when normal operating power returns if unit is used without an isolation switch 1 Avoid connecting the generator to commercial power outlet 2 Avoid connecting the generator in parallel with any other generator BConnecting the Load To av...

Page 24: ... U V C 3 phase and single phase 4 terminals type A For 3 phase power source Use U V W A For single phase power source Use O U O V O W 1 Light 2 Television 3 Air conditioner 4 Electric Drill 5 Motor Pump 1 Motor 1 Electric Drill 2 Motor Pump 3 Air conditioner ...

Page 25: ... are hot Severe burns could result BHow to Open the Door Insert the door key and turn clockwise and open the machine doors The doors open together on hinges The door of the generator is equipped with a safety switch Safety switch automatically shuts off the engine when door is opened BBattery The battery is shipped in dry charged condition without electrolyte The battery must be charged properly b...

Page 26: ...ct level before attempting to start the engine 1 Place the machine on a level surface 2 Remove the oil cap 3 Add engine oil of grade CF or higher up to the upper mark on the oil level gauge A See ENGINE OIL in PERIODIC SERVICE section for engine oil capacity and checking engine oil level BCoolant To avoid personal injury A Place the machine on a level surface A DO NOT remove the radiator cap while...

Page 27: ... fuel through the fuel tank strainer 2 Make sure that dirt or water does not enter the fuel tank 3 Fill with Diesel fuel No 2 D ASTMD975 4 Below 0 C 32 F a mix of No 1 D and No 2 D is acceptable 5 Fuel level is read by fuel gauge placed on the control panel Fuel gauge is activated with the main switch key ON A If the fuel tank should empty completely causing the engine to stop then the fuel system...

Page 28: ...ve the safety devices Unauthorized modification or removal may affect the function and safety of the machine which may result in serious injury or death 1 The access door are equipped with safety devices to detect the opening and or closing condition of door 2 The door safety switch 2 is located on the access door If you turn the key switch to ON with the access door open the starter of engine wil...

Page 29: ...r circuit breaker 3 Ensure that the fuel lever is set to the OPEN Position 4 Insert the key into the main switch and turn it ON 5 Check the battery charge lamp and oil pressure lamp are ON A Do not use ether or any starting fluid for starting the engine or severe engine damage will occur A To protect the battery and the starter make sure that the starter is not continuously turned for more than 10...

Page 30: ... BWarm up in Cold Ambient Temperatures In cold weather the engine oil may be cold with increased viscosity This can delay oil circulation or abnormally low oil pressure for some time after engine start up This can result trouble in the lubrication circuit or damage to the engine moving parts To prevent the above problems perform the following instructions Warm up the engine at rated revolution wit...

Page 31: ...o not allow the starter motor to run continuously for more than 10 seconds A Be sure to warm up the engine not only in winter but also in warmer seasons An insufficiently warmed up engine can shorten its service life A When there is possibility of temperature drops below 15 C 5 F detach the battery from the machine and keep it indoor in a safe area Reinstalled the battery before the next operation...

Page 32: ...n OFF the load center circuit breaker 2 Turn OFF the circuit breakers 3 Allow the engine to run with no load for about 5 minutes before stopping the engine completely 4 Turn the main switch key to the OFF position 5 Turn the fuel lever to the CLOSE position 1 Circuit breaker A OFF 1 Main switch Key A OFF 1 Fuel lever 2 Filter bowl A CLOSE ...

Page 33: ...wer is turned off and the engine is interrupted Do not press this switch except for an emergency 1 If anything unusual occurs press the switch 1 and the engine must be stopped immediately 2 In this case be sure to turn off the main switch 3 Rotate the button to reset emergency stop 1 Emergency stop switch ...

Page 34: ...burns or fire could result Detach the battery from the engine before maintenance A DO NOT touch muffler or exhaust pipes while they are hot severe burns could result ANTI FREEZE DISPOSAL OF FLUIDS A DO NOT run the engine with installed safety guards detached A Anti freeze contains poison Wear rubber gloves to avoid personal injury In case of contact with skin wash it off immediately A DO NOT mix d...

Page 35: ...quired 35 3 Change of engine oil 5 11 4 Cleaning of air cleaner element 31 1 5 Check of battery electrolyte level 32 6 Check of fan belt tightness 35 7 Check of radiator hoses and clamp bands 30 8 Check of intake air hose 31 9 Replacement of oil filter cartridge 27 10 Replacement of fuel filter cartridge or element 23 24 11 Cleaning of sedimenter water separator 24 12 Cleaning of water jacket radi...

Page 36: ...oil 11 4 Cleaning of air cleaner element 31 1 5 Check of battery electrolyte level 32 6 Check of fan belt tightness 35 7 Check of radiator hoses and clamp bands 30 8 Check of intake air hose 31 9 Replacement of oil filter cartridge 27 10 Replacement of fuel filter cartridge or element 23 24 11 Cleaning of sedimenter water separator 24 12 Cleaning of water jacket radiator interior 30 13 Replacement...

Page 37: ...mended Fuel Cetane Rating is 45 A cetane rating greater than 50 is preferred especially for ambient temperatures below 20 C 4 F or elevations above 1500 m A Diesel Fuel Specification Type and Sulfur Content ppm used must be compliant with all applicable emission regulations for the area in which the engine is operated A Use of diesel fuel with sulfur content less than 0 10 1000 ppm is strongly rec...

Page 38: ...oses and filter A Always turn the key to OFF when air is vented and the engine is not used or it will cause the battery to discharge BCleaning the Fuel Filter Element Engine model D1703 EBG V2203 EBG Replace the fuel filter element every 500 hours of use using the following procedure 1 Close the fuel filter lever 2 Remove the top cap and rinse the inside with diesel fuel 3 Take out the element and...

Page 39: ...he Water Separator Sedimenter A Every 250 hours of operation clean the fuel filter in a clean place to prevent dust contamination A When the marker comes close to the drain out level remove the screw ring and let water flow out of the filter bowl 1 Turn the fuel lever to the CLOSE position 2 Remove the filter bowl and rinse the inside with diesel fuel 3 3 Take out the element and rinse it with die...

Page 40: ...sult Always stop the engine and allow it to cool before conducting inspections maintenance or cleaning A Contact with engine oil can damage your skin Put on gloves when handling engine oil If you come in contact with engine oil wash it off immediately A Be sure to check the engine oil on a level surface If placed on gradients oil quantity can not be measured accurately A Do not operate a diesel en...

Page 41: ...Kubota E3 specification engines A Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity according to the ambient temperatures where the engine is operated A With strict emission control regulations now in effect the CF 4 and CG 4 engine oils have been developed for use with low sulfur fuels for On Highway vehicle engines When a Non Road engine runs on high sulfu...

Page 42: ...oil drain plug and gasket 4 Add new engine oil up to the upper line of the oil level gauge BReplacing the Oil Filter Cartridge To avoid personal injury A Be sure to stop the engine before changing the oil filter cartridge A Allow engine to cool down sufficiently Oil can be hot and cause burns 1 Replace the oil filter cartridge every 500 hours of operation 2 Remove the old oil filter cartridge with...

Page 43: ...ator cap while coolant is hot When cool rotate cap slowly to the first stop to allow excess pressure to escape Then remove cap completely If overheating should occur steam gushes out from the radiator or recovery tank Allow the engine to cool before attempting to open the cap Severe burns could result BChecking Coolant Level Adding Coolant 1 Remove the radiator cap after the engine has completely ...

Page 44: ...ways remove both drain plugs and simultaneously open the radiator cap as well With the radiator cap kept closed the coolant will not drain completely Dispose of used coolant properly 2 Remove the overflow pipe of the radiator pressure cap to drain the recovery tank 3 Prescribed coolant volume L 4 An improperly tightened radiator cap or a gap between the cap and the seat increases loss of coolant 5...

Page 45: ...d then restart the engine BCleaning Radiator Core outside If dust is between the fin and tube wash it away with running water A Do not clean radiator with firm tools such as spatulas or screwdrivers They may damage the delicate fins or tubes It can cause coolant leaks or decrease cooling performance A Be careful to keep water off of electrical parts BCleaning the Radiator inside 1 Clean up the coo...

Page 46: ...e concentrated anti freeze AIR CLEANER Since the air cleaner employed on this engine is a dry type never apply oil to it 1 Open the evacuator valve once a week under ordinary conditions or daily when used in severe or dusty conditions This will get rid of large particles of dust and dirt 2 Wipe the inside air cleaner clean with cloth if it is dirty or wet 3 Avoid touching the element except when c...

Page 47: ...y A Be careful not to let the battery electrolyte contact your body or clothing A Wear eye protection and rubber gloves since the diluted sulfuric acid solution burns skin and eyes and eats holes in clothing Should this occur immediately wash it off with running water and get medical attention Mishandling of the battery shortens the service life and adds to maintenance costs Obtain the maximum per...

Page 48: ...tive then recharge in the normal manner 3 Quick recharging charges the battery at a high rate in a short time This is only for emergencies 4 Recharge the battery as early as possible or battery life will be extremely shortened 5 When exchanging an old battery for a new one use a battery of equal specifications shown in page 2 A Connect the charger positive terminal to the battery positive terminal...

Page 49: ...p the other end of the same cable to the positive red or pos terminal of the helper battery 6 Clamp the other cable to the negative black or neg terminal of the helper battery 7 Clamp the other end to the engine block or frame of the generator as far from the dead battery as possible 8 Start the disabled generator 9 disconnect the jumper cables in the exact reverse order of attachment Steps 7 6 an...

Page 50: ...st be considered Generator installation must comply with local building codes fire regulations and environmental requirements Use these instructions as a general guide only the complete installation must comply with all local state and federal building codes fire ordinances and any other applicable regulations 1 Open the access door and check for anything unusual every workday 2 Look at the point ...

Page 51: ...rk lift or etc 2 The generator is equipped with the 2 inlets in the machine bed for forklift forks Transportability is increased by 2 ways special forklift openings and 1 point lifting hook Use lifting equipment of sufficient capacity BLifting Procedure To avoid personal injury A Use hangers and wire ropes which are strong enough to withstand the weight of the machine A The apex of the wire rope d...

Page 52: ...e the battery from the generator adjust the electrolyte level and recharge it Store the battery in a dry and dark place 5 When the engine is not used for a long period of time run it for about 5 minutes under no load every 2 to 3 months to keep it free from rust If the engine is stored without any running moisture in the air may condense into dew over the sliding parts of the engine resulting in r...

Page 53: ... lamps is ON turn OFF the solenoid and electric fuel feed pump and the engine stops 2 To restart the engine turn the key switch back to OFF position then start again A When this device stops the engine it may be that a malfunction and some minor damage to the engine has occurred To limit engine damage as much as possible please do not make the assumption that shut down was a false alarm Check unit...

Page 54: ...Light up Possible Causes Countermeasures Lamp 1 Engine overheating See Precaution Overheating in PERIODIC SERVICE section See page 30 Water temperature sensor faulty Replace the water temperature sensor Water temperature sensor wiring faulty Repair the wiring Lamp 2 Insufficient engine oil Add engine oil Lubricating system in trouble Check the system Oil pressure sensor faulty Replace the sensor O...

Page 55: ... if nozzle is working properly or not If not install a new nozzle Valve clearance is wrong Engine model D1703 EBG V2203 EBG Adjust valve clearance to 0 18 to 0 22 mm when the engine is cold Engine model V3300 EBG Adjust valve clearance to 0 23 to 0 27 mm when the engine is cold Leaking valves Grind valves Fuel injection timing is wrong Adjust injection timing Engine model D1703 EBG The injection t...

Page 56: ...operation Fuel injection pressure is wrong Adjust to proper pressure 13 7 Mpa 140 kgf cm 1991 psi Injection pump wear Do not use poor quality fuel as it will cause wear of the pump Only use No 2 D diesel fuel Check the fuel injection pump element and delivery valve assembly and replace as necessary Cause Countermeasures Lack of fuel Check the fuel tank and refill the fuel if necessary Also check t...

Page 57: ...tch Check filter base gasket Cause Countermeasures Engine oil insufficient Check oil level Replenish oil as required Fan belt broken or elongated Check all moving parts carefully Coolant insufficient Replenish coolant Excessive concentration of antifreeze Add water only or change to coolant with the specified mixing ratio Radiator net or radiator fin clogged with dust Clean net or fin carefully In...

Page 58: ... short circuited or broken Replace the generator AVR excitation input cable broken Repair the cable Generator s winding broken Replace the generator AVR excitation output fuse blown out Replace the fuse Voltage too high Voltage maladjusted Readjust using the voltage control AVR voltage detection cable broken Repair the cable AVR itself in trouble Replace the AVR Mercury arc lamp or such conductive...

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Page 60: ...WIRING DIAGRAM 45 WIRING DIAGRAM ...

Page 61: ...WIRING DIAGRAM 46 ...

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