Kubota GL6000 - User Manual

WORKSHOP MANUAL
DIESEL GENERATOR
GL6000,GL7000,
GL9000,GL11000
KiSC issued 05, 2015 A

Summary

To the Reader

General

Information on general precautions, check and maintenance, and special tools.

Mechanism

Information on construction and function of the generator.

Servicing

Troubleshooting, servicing specifications, checking, adjusting, and assembly.

Record of Revisions

Safety Instructions

Safety First

Warning symbol explanation and essential safety reading instructions.

Before Servicing and Repairing

Pre-service checks including reading instructions, cleaning, and cooling.

Safety Starting

Precautions for starting the engine safely, avoiding modifications.

Safety Working

Guidelines for safe operation while working on the generator.

Avoid Fires

Precautions to prevent fires, related to fuel and battery.

Ventilate Work Area

Importance of ventilation to avoid carbon monoxide poisoning.

Dispose of Fluids Properly

Guidelines for environmentally safe disposal of fluids.

Prevent Acid Burns

Precautions against battery acid burns and immediate actions.

Prepare for Emergencies

Recommendations for having emergency equipment and numbers ready.

Safety Decals

Specifications

Generator Specifications

Specifications for the generator component.

Engine Specifications

Specifications for the engine component.

Dimensions

General Section Contents

General Information

Table of contents for the General section.

General Information

1. Identification

Information for identifying the generator and engine models and serial numbers.

Model Name and Engine Serial Number

Details on finding model and serial numbers for identification.

2. E4 B Engine

Information about E4B engines and emission control standards.

3. Cylinder Number

Designation of cylinder numbers for KUBOTA diesel engines.

2. Precaution

General precautions for disassembly, servicing, and reassembly.

3. Handling Precautions for Electrical Parts and Wiring

Precautions for handling electrical components and wiring safely.

1. Wiring

Guidelines for secure wiring and preventing contact with dangerous parts.

2. Battery

Precautions for handling battery cables, capacity, and cleaning.

3. Fuse

Guidelines for using fuses with specified capacity and avoiding improper use.

4. Connector

Procedures for separating and handling electrical connectors.

5. Handling of Circuit Tester

Instructions for correct usage and checks when using a circuit tester.

4. Lubricants, Fuel and Coolant

Table detailing recommended lubricants, fuel, and coolant capacities.

Engine Oil Notes

Table for suitable API classification of engine oil based on fuel type.

Fuel Notes

Recommendations for fuel cetane rating and sulfur content compliance.

5. Tightening Torques

Table for tightening torques of general use screws, bolts, and nuts.

1. General Use Screws, Bolt and Nuts

Specification table for tightening general screws, bolts, and nuts.

2. Stud Bolts

Torque specifications for stud bolts based on material and size.

6. Maintenance Check List

Comprehensive checklist of maintenance items and their required intervals.

7. Check and Maintenance

Procedures for checking and maintaining the generator.

1. Daily Check

Daily checks for engine oil and coolant levels.

2. Check Points of Initial 50 Hours

Checks and replacements required at the initial 50 hours of operation.

3. Check Point of Every 50 Hours

Checks for fuel hose and clamp bands every 50 hours.

4. Check Point of Every 100 Hours

Engine oil change procedure required every 100 hours.

5. Check Point of Every 200 Hours

Checks for radiator hose and clamp bands, and engine oil filter cartridge.

6. Check Point of Every 300 Hours

Checks for generator brush wear and slip-ring condition.

7. Check Point of Every 400 Hours

Fuel filter element replacement procedure.

8. Check Points of Every 500 Hours

Procedure for cleaning the water jacket and radiator interior.

9. Check Point of Every 800 Hours

Procedure for checking and adjusting valve clearance.

10. Check Point of Every 1000 Hours

Procedure for checking generator ball bearings.

11. Check Point of Every 1500 Hours

Procedures for checking fuel injection pressure and nozzle spray.

12. Check Point of Every 1 Year

Air cleaner element replacement and wiring checks.

13. Check Point of Every 2 Years

Coolant replacement procedure.

8. Special Tools

List of special tools required for maintenance and their applications.

Mechanism Section Contents

1. Engine Body

Description of the engine body, focusing on the head cover.

Half-Floating Head Cover

Explanation of the half-floating head cover and its function.

2. Lubricating System

Explanation of the engine's lubricating system and its components.

3. Cooling System

Explanation of the engine's cooling system and its components.

4. Fuel System

Explanation of the engine's fuel system and its operation.

Servicing Section Contents

1. Troubleshooting

Common engine troubleshooting guide for starting and running issues.

2. Servicing Specifications

Servicing specifications for engine body components like cylinder head and valve timing.

3. Tightening Torques

Tightening torques for special use screws, bolts, and nuts.

1. General Use Screws, Bolt and Nuts

Tightening torques for general use screws, bolts, and nuts.

2. Tightening Torques for General Use Screws, Bolts and Nut

Tightening torques for general use screws, bolts, and nuts.

4. Checking, Disassembling and Servicing

Checking engine body, starting with compression pressure measurement.

1. Checking and Adjusting

Checking engine body, starting with compression pressure measurement.

1. Daily Check

Daily checks for engine oil and coolant levels.

2. Check Points of Initial 50 Hours

Checks and replacements required at the initial 50 hours of operation.

3. Check Point of Every 50 Hours

Checks for fuel hose and clamp bands every 50 hours.

4. Check Point of Every 100 Hours

Engine oil change procedure required every 100 hours.

5. Check Point of Every 200 Hours

Checks for radiator hose and clamp bands, and engine oil filter cartridge.

6. Check Point of Every 300 Hours

Checks for generator brush wear and slip-ring condition.

7. Check Point of Every 400 Hours

Fuel filter element replacement procedure.

8. Check Points of Every 500 Hours

Procedure for cleaning the water jacket and radiator interior.

9. Check Point of Every 800 Hours

Procedure for checking and adjusting valve clearance.

10. Check Point of Every 1000 Hours

Procedure for checking generator ball bearings.

11. Check Point of Every 1500 Hours

Procedures for checking fuel injection pressure and nozzle spray.

12. Check Point of Every 1 Year

Air cleaner element replacement and wiring checks.

13. Check Point of Every 2 Years

Coolant replacement procedure.

2. Disassembling and Assembling

Procedures for draining coolant and engine oil.

1. Separating Engine

Procedures for draining coolant and engine oil before separation.

3. Disassembling and Assembling

Procedures for removing the cylinder head cover and injection pipes.

1. Cylinder Head and Valves

Procedures for removing the cylinder head cover and injection pipes.

2. Timing Gears, Camshaft, Fuel Camshaft and Oil Pan

Procedures for removing the injection pump and fan drive pulley.

3. Piston and Connecting Rod

Procedures for removing connecting rod caps and pistons.

4. Crankshaft

Procedures for removing the flywheel and bearing case cover.

5. Water Pump

Procedures for removing the thermostat and water pump assemblies.

6. Injection Nozzle

Procedures for removing and adjusting the nozzle holder.

7. Starter

Procedures for disassembling the starter (Electromagnetic Drive Type).

4. Servicing

Checking cylinder head surface flatness and detecting cylinder head flaws.

1. Cylinder Head and Valves

Checking cylinder head surface flatness and detecting cylinder head flaws.

2. Timing Gears, Camshaft and Fuel Camshaft

Procedures for checking timing gear backlash and idle gear side clearance.

3. Piston and Connecting Rod

Procedures for measuring piston pin bore ID and checking oil clearance.

4. Crankshaft

Procedures for checking crankshaft side clearance and alignment.

5. Cylinder

Procedures for checking cylinder wear and correcting cylinders.

6. Oil Pump

Procedures for checking oil pump rotor lobe and rotor/cover clearance.

7. Starter

Procedures for checking commutator, mica, and brush wear.

4. Servicing (Generator)

Table of contents for the Servicing section (Generator related).

1. Troubleshooting (Generator)

Troubleshooting guide for generator physical defects like overheating and vibration.

2. Servicing Specifications (Generator)

Servicing specifications for generator components like coils and air gap.

3. Tightening Torques (Generator)

Tightening torques for special generator use screws, bolts, and nuts.

2. Tightening Torques for General Use Screws, Bolts and Nut

Tightening torques for general generator use screws, bolts, and nuts.

4. Checking, Disassembling and Servicing (Generator)

Checking control panel components, including the main switch.

1. Checking and Adjusting (Generator)

Checking control panel components, including the main switch.

2. Emergency Relay Activates

Checking the emergency relay circuit and the function of oil/water switches.

2. Disassembling and Assembling (Generator)

Procedures for removing the generator's external components like panels and covers.

2. Generator

Procedures for removing the rear bracket and stator assembly.

3. Servicing (Generator)

Checking terminal voltage and stator coil resistance.

2. Stator Coil

Checking detecting coil resistance and stator coil grounding.

3. Rotor Coil

Checking rotor coil resistance and grounding.

4. Exciter Coil

Checking exciter coil resistance and grounding.

5. Sub Coil (DC)

Checking DC sub coil resistance.

Generator Section Contents

1. Structure

Explains the structure of the generator's stator, rotor, and AVR assembly.

2. Automatic Voltage Regulator (A.V.R.)

Information and notes regarding the Automatic Voltage Regulator (AVR).

3. Emergency Relay Circuit

General explanation of the automatic engine stopping device and its functions.

1. General (Emergency Relay Circuit)

Detailed instructions on the circuit configuration and operating principles of the emergency relay.

4. Earth

Instructions for proper generator grounding to prevent electric shock.

5. Wiring Diagram

Color code legend for wiring diagrams.

Kubota GL6000 Specifications