Kubota GL6000A-AU-B Workshop Manual
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Kubota GL6000A-AU-B Workshop Manual

Diesel generator
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WORKSHOP MANUAL
DIESEL GENERATOR
GL6000A-AU-B,
GL6000D-AU-B,
GL9000A-AU-B,
GL9000D-AU-B
KiSC issued 06, 2016 A

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Summary of Contents for Kubota 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 All illustrations, photographs and specifications contained in this manual are of the newest information available at the time of publication. KUBOTA reserves the right to change all information at any time without notice. Since this manual includes many models, information or illustrations and photographs can show more than one model.
  • Page 3 INFORMATION KiSC issued 06, 2016 A...
  • Page 4 INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 2. SAFETY DECALS .......................... I-5 3. SPECIFICATIONS........................I-13 4. DIMENSIONS ..........................I-15 KiSC issued 06, 2016 A...

  • Page 5: Safety First

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION 1. SAFETY FIRST 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.
  • Page 6 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION OPERATE SAFELY • Do not use the machine after you consume alcohol or medication or when you are tired. • Put on applicable clothing and safety equipment. • Use applicable tools only. Do not use alternative tools or parts.
  • Page 7 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION AVOID HOT EXHAUST • Servicing machine or attachments with engine operating can result in serious personal injury. Avoid exposure and skin contact with hot exhaust gases and components. • Exhaust parts and streams become very hot during operation.
  • Page 8 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION DISCARD FLUIDS CORRECTLY • Do not discard fluids on the ground, down the drain, into a stream, pond, or lake. Obey related environmental protection regulations when you discard oil, fuel, coolant, electrolyte and other dangerous waste.

  • Page 9: Safety Decals

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION 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.
  • Page 10 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION 9Y1211607INI0005US0 KiSC issued 06, 2016 A...
  • Page 11 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION 9Y1211607INI0006US0 KiSC issued 06, 2016 A...
  • Page 12 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION 9Y1211607INI0007US0 KiSC issued 06, 2016 A...
  • Page 13 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION [Analog Type] 9Y1211607INI0008US0 KiSC issued 06, 2016 A...
  • Page 14 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION 9Y1211607INI0009US0 I-10 KiSC issued 06, 2016 A...
  • Page 15 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION 9Y1211607INI0010US0 I-11 KiSC issued 06, 2016 A...
  • Page 16 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION 9Y1211607INI0011US0 CARE OF DANGER, WARNING AND CAUTION LABELS 1. Keep danger, warning and caution labels clean and free from obstructing material. 2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth.

  • Page 17: Specifications

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION 3. SPECIFICATIONS Model GL6000A-AU-B GL6000D-AU-B Design Salient-pole, revolving-field AC generator (AVR system with separate and self-excitation brush) Frequency 50 Hz 5.5 kVA Rated output (COP) 5.5 kW Rated voltage 240 V Rated amperage 22.9 A 1 - 2 ϕ...
  • Page 18 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION Model GL9000A-AU-B GL9000D-AU-B Design Salient-pole, revolving-field AC generator (AVR system with separate and self-excitation brush) Frequency 50 Hz 8.0 kVA Rated Output (COP) 8.0 kW Rated voltage 240 V Rated amperage 33.3 A 1 - 2 ϕ - W...

  • Page 19: Dimensions

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM INFORMATION 4. DIMENSIONS GL6000A-AU-B GL6000D-AU-B 1066 mm (41.97 in.) 618 mm (24.3 in.) 698 mm (27.5 in.) 9Y1211607INI0014US0 GL9000A-AU-B GL9000D-AU-B 1281 mm (50.43 in.) 618 mm (24.3 in.) 698 mm (27.5 in.) 9Y1211607INI0015US0 I-15 KiSC issued 06, 2016 A...
  • Page 20 GENERAL KiSC issued 06, 2016 A...

  • Page 21: Table Of Contents

    GENERAL CONTENTS 1. ENGINE IDENTIFICATION ......................G-1 [1] MODEL NAME AND ENGINE SERIAL NUMBER..............G-1 [2] E4B ENGINE .......................... G-2 [3] CYLINDER NUMBER ......................G-3 2. PRECAUTION ..........................G-4 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING ........G-5 [1] WIRING ..........................G-5 [2] BATTERY ..........................

  • Page 22: Engine Identification

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL 1. ENGINE IDENTIFICATION [1] MODEL NAME AND ENGINE SERIAL NUMBER You must identify the engine model name and serial number before you start a job. When you get in touch with the manufacturer, always tell your engine model name and serial number.

  • Page 23: E4B Engine

    Non-Road Emission Standards continue to change. The timing or applicable date of the specific Non-Road Emission regulations depends on the engine output classification. Over the past several years, KUBOTA has been supplying diesel engines that comply with regulations in the respective countries affected by Non-Road Emission regulations. For KUBOTA Engines, E4B will be the designation that identifies engine models affected by the next emission phase (See the table below).

  • Page 24: Cylinder Number

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL [3] CYLINDER NUMBER The cylinder numbers of KUBOTA diesel engine are designated as shown in the figure. The sequence of cylinder numbers is given as No.1, No.2 and No.3 starting from the gear case side.

  • Page 25: Precaution

    • When it is necessary to use special tools, use KUBOTA special tools. Refer to the drawings when you make special tools that you do not use frequently.

  • Page 26: Handling Precautions For Electrical Parts And Wiring

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, obey the following precautions in handling electrical parts and wiring. IMPORTANT • Check electrical wiring for damage and loosened connection every year.
  • Page 27 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL • Securely insert grommet. (1) Grommet (A) Correct (B) Incorrect WSM000001GEG0066US0 • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp (Wind Clamp Spirally) (4) Welding Dent (2) Wire Harness WSM000001GEG0067US0 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.

  • Page 28: Battery

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL [2] BATTERY • Be careful not to confuse positive and negative terminal posts. • When you remove battery cables, disconnect negative cable first. When you install battery cables, check for polarity and connect positive cable first.

  • Page 29: Handling Of Circuit Tester

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make sure that there is no terminal being exposed or displaced. (1) Sandpaper (3) Rust (2) Deformed Terminal (4) Exposed Terminal 9Y1211607GEG0016US0 • Make sure that there is no female connector being too open.

  • Page 30: Color Of Wiring

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL [6] COLOR OF WIRING • Colors of wire are specified to the color codes. • This symbol of "/" shows color with stripe (s). (An example) Red stripe on white color: W/R Color of wiring...

  • Page 31: Lubricants, Fuel And Coolant

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL 4. LUBRICANTS, FUEL AND COOLANT Capacity Place Lubricants, fuel and coolant GL6000A-AU-B GL9000A-AU-B GL6000D-AU-B GL9000D-AU-B Higher than CF class (API) • Above 25 °C (77 °F) SAE10W-30, SAE10W-30, SAE30 2.2 L 3.4 L • 0 to 25 °C (32 to 77 °F) Engine oil 0.58 U.S.gals...
  • Page 32 JUN87) • Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards, the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when operated in US EPA regulated areas.

  • Page 33: Tightening Torques

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL 5. TIGHTENING TORQUES Tighten screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual according to the table below. 9Y1211607GEG0005US0 [1] GENERAL USE SCREWS, BOLT AND NUTS Indication on top of bolt...

  • Page 34: Maintenance Check List

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL 6. MAINTENANCE CHECK LIST Observe the following for service and maintenance. The lubricating oil change intervals listed in the table below are for classes CG, CE and CD lubricating oil of API classification with a low-sulfur fuel in use. If the CF-4 of CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals than recommended in the table below depending on the operating condition.

  • Page 35: Check And Maintenance

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL 7. CHECK AND MAINTENANCE [1] DAILY CHECK Check of Engine Oil Level CAUTION • Be sure to stop the engine before checking the engine oil level. 1. Level the engine and check the oil level on the dipstick (1).
  • Page 36 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL Check of Residual Current Circuit Breaker (RCBO) WARNING • Using the generator with a non functioning RCBO can result in electrocution in the event of an electrical fault. Ensure that the RCBO is tested regularly, and that if a fault is found the unit is locked out of operation immediately.

  • Page 37: Check Points Of Initial 50 Hours

    Add engine oil to proper level. IMPORTANT • To prevent serious damage to the engine, replacement element must be highly efficient. Use only a KUBOTA genuine filter or its equivalent. (1) Engine Oil Filter Cartridge 9Y1211607GEG0013US0...

  • Page 38: Check Point Of Every 50 Hours

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL [3] CHECK POINT OF EVERY 50 HOURS Check of Fuel Hoses and Clamp Bands CAUTION • Stop the engine when attempting the check and change prescribed below. • Remember to check the fuel hose periodically. The fuel hose is subject to wear and aging, fuel may leak out onto the running engine, causing a fire.

  • Page 39: Check Points Of Every 100 Hours

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL [4] CHECK POINTS OF EVERY 100 HOURS Change of Engine Oil CAUTION • Be sure to stop engine before changing engine oil. 1. After warming up, stop the engine. 2. Place an oil pan underneath the engine.
  • Page 40 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL Check of Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and alternator pulley at specified force 98 N (10 kgf, 22 lbf). 2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust.

  • Page 41: Check Points Of Every 200 Hours

    Add engine oil to proper level. IMPORTANT • To prevent serious damage to the engine, replacement element must be highly efficient. Use only a KUBOTA genuine filter or its equivalent. (1) Engine Oil Filter Cartridge 9Y1211607GEG0013US0 Check of Radiator Hoses and Clamp Bands 1.

  • Page 42: Check Points Of Every 300 Hours

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL [6] CHECK POINTS OF EVERY 300 HOURS Check of Generator's Brush Wear 1. Check to see if the brush has worn to more than 1/2 below the standard dimensions. 2. If wear exceeds the allowable limit, replace.

  • Page 43: Check Point Of Every 500 Hours

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL [8] CHECK POINT OF EVERY 500 HOURS Cleaning of Water Jacket and Radiator Interior CAUTION • Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

  • Page 44: Check Points Of Every 800 Hours

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL (Continued)  Anti-freeze • There are 2 types of anti-freeze available: use the permanent type (PT) for this engine. • When you add anti-freeze for the first time, flush the water jacket and radiator interior with clean, soft water several times.
  • Page 45 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL Valve Clearance IMPORTANT • The valve clearance must be checked and adjusted when engine is cold. 1. Remove the head cover, the glow plugs and the timing window cover on the flywheel housing. 2. Align the 1TC mark line (2) on the flywheel and center of timing window (1) so that the No.

  • Page 46: Check Point Of Every 1000 Hours

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL [10] CHECK POINT OF EVERY 1000 HOURS Check of Generator's Ball Bearing 1. Hold the bearing (1), and push and pull the outer race in all directions to check for wear and roughness. 2. Turn the outer race to check rotation.

  • Page 47: Check Point Of Every 3000 Hours

    5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a KUBOTA-authorized pump service shop. (Fuel Tightness of Delivery Valve) 1.

  • Page 48: Check Points Of Every 1 Year

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL [13] CHECK POINTS OF EVERY 1 YEAR Replacement of Air Cleaner Primary Element 1. Remove the air cleaner primary element (2). 2. Install the new air cleaner primary element. NOTE • The air cleaner uses a dry element. Never apply oil to it.
  • Page 49 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL Replacement of Battery CAUTION • Be sure to stop the engine before disconnecting the cables. When removing the battery cables, disconnect the negative cable first. When installing the battery cables, connect the positive cable first.

  • Page 50: Special Tools

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL 8. SPECIAL TOOLS Valve Seat Cutter Code No. • 07909-33102 Application • Use to reseat valves. Angle • 0.79 rad (45°) • 0.26 rad (15°) Diameter • 28.6 mm (1.13 in.) • 31.6 mm (1.24 in.) •...
  • Page 51 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL Special Use Puller Set Code No. • 07916-09032 Application • Use exclusively to pull out bearing, gears and other parts with ease. WSM000001GEG0011US0 Connecting Rod Alignment Tool Code No. • 07909-31661 Application • Use to check the connecting rod alignment.
  • Page 52 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL 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 G-31 KiSC issued 06, 2016 A...
  • Page 53 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL NOTE • The following special tools are not provided, so make them referring to the figure. WSM000001GEG0026US0 Injection Pump Pressure Tester Application • Use to check fuel tightness of injection pumps. Pressure gauge full scale: More than 29.4 MPa (300 kgf/cm...
  • Page 54 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL Rotor Pulling Out Bolt (for GL6000A-AU-B, GL6000D-AU-B) Code No. • G3102-10011 Application • Use to remove the rotor assembly. 18.65 to 19.00 mm (0.7343 to 0.7480 in.) 21.9 mm (0.862 in.) 9.0 mm (0.35 in.) 1.2 mm (0.047 in.)
  • Page 55 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERAL Connecting Rod Small End Bushing Tool Application • Use to press out and to press fit the connecting rod small end bushing. 145 mm (5.71 in.) 25 mm (0.98 in.) 20 mm (0.79 in.) 25 mm dia. (0.98 in. dia.) 21.90 to 21.95 mm dia.
  • Page 56 ENGINE KiSC issued 06, 2016 A...
  • Page 57 MECHANISM 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 KiSC issued 06, 2016 A...

  • Page 58: Engine Body

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE 1. ENGINE BODY [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.

  • Page 59: Lubricating System

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE 2. LUBRICATING SYSTEM (1) Rocker Arm (2) Oil Pressure Switch (3) Rocker Arm Shaft (4) Valve (5) Idle Gear (6) Crankshaft (7) Oil Pump (8) Oil Strainer (9) Relief Valve (10) Push Rod (11) Tappet...

  • Page 60: Cooling System

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE 3. COOLING SYSTEM (1) Radiator (2) Water Pump (3) Cooling Fan (4) Thermostat (5) Cylinder Head (6) Cylinder Block The cooling system consists of a radiator (1), a centrifugal water pump (2), a cooling fan (3) and a thermostat (4).

  • Page 61: Fuel System

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE 4. FUEL SYSTEM (1) Injection Nozzle (2) Fuel Overflow Pipe (3) Fuel Tank (4) Fuel Filter (5) Mechanical Fuel Feed Pump (6) Injection Pump (7) Injection Pipe Fuel from the fuel tank (3) passes through the fuel filter (4), and then enters the injection pump (6) after impurities such as dirt, water, etc.
  • Page 62 SERVICING CONTENTS 1. TROUBLESHOOTING.........................1-S1 2. SERVICING SPECIFICATIONS ....................1-S4 3. TIGHTENING TORQUES......................1-S10 [1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLT AND NUTS ....1-S10 [2] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS....1-S11 4. CHECKING, DISASSEMBLING AND SERVICING ..............1-S12 [1] CHECKING AND ADJUSTING....................1-S12 (1) Engine Body ........................1-S12 (2) Lubricating System ......................1-S15 (3) Cooling System ......................1-S16...

  • Page 63: Troubleshooting

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE 1. TROUBLESHOOTING Probable Cause and Reference Symptom Solution Checking Procedure Page Engine Does Not 1. Engine room door is open Close engine room door – Start 2. No fuel Fill fuel – 3. Air in the fuel system Bleed –...
  • Page 64 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Probable Cause and Reference Symptom Solution Checking Procedure Page Engine Revolution Is 1. Fuel filter clogged or dirty Replace G-21 Not Smooth 2. Air cleaner clogged Clean or replace G-18, G-27 3. Fuel leak due to loose...
  • Page 65 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Probable Cause and Reference Symptom Solution Checking Procedure Page Low Oil Pressure 1. Engine oil insufficient Fill oil G-10, G-14 2. Oil strainer clogged Clean 1-S35 3. Oil filter cartridge clogged Replace – 4. Relief valve stuck with dirt Clean –...

  • Page 66: Servicing Specifications

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.05 mm 0.002 in. Top Clearance 0.50 to 0.70 mm – 0.020 to 0.027 in. Compression Pressure – 2.85 to 3.23 MPa 2.26 MPa...
  • Page 67 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Item Factory Specification Allowable Limit Valve Spring Free Length 31.3 to 31.8 mm 28.4 mm 1.24 to 1.25 in. 1.12 in. Tilt – 1.2 mm 0.047 in. Setting Load / 65 N / 27.0 mm 55 N / 27.0 mm...
  • Page 68 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Factory Specification Allowable Limit Item Idle Gear Side Clearance 0.20 to 0.46 mm 0.60 mm 0.0079 to 0.018 in. 0.024 in. Idle Gear Shaft to Idle Gear Bushing Oil Clearance 0.020 to 0.084 mm 0.10 mm 0.00079 to 0.0033 in.
  • Page 69 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing 3 Oil Clearance 0.028 to 0.059 mm 0.20 mm (Intermediate) 0.0011 to 0.0023 in. 0.0079 in. • Crankshaft Journal O.D. 43.934 to 43.950 mm –...
  • Page 70 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed More than – 50 kPa 0.5 kgf/cm 7 psi At Rated Speed 200 to 440 kPa 150 kPa 2.0 to 4.5 kgf/cm 1.5 kgf/cm...
  • Page 71 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE ELECTRICAL SYSTEM [STARTER] Item Factory Specification Allowable Limit Starter (Electromagnetic Drive Type) • Commutator O.D. 28.0 mm 27.0 mm 1.10 in. 1.06 in. • Difference O.D. Less than 0.4 mm 0.05 mm 0.02 in. 0.002 in.

  • Page 72: Tightening Torques

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE 3. TIGHTENING TORQUES Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque.

  • Page 73: Tightening Torques For General Use Screws, Bolts And Nuts

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE [2] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below. Indication on No-grade or 4T top of bolt...

  • Page 74: Checking, Disassembling And Servicing

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. After warming up the engine, stop it and remove the air cleaner, the muffler and all nozzle holders. 2. Install a compression tester for diesel engines to nozzle holder hole.
  • Page 75 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Top Clearance 1. Remove the cylinder head. (Do not attempt to remove the cylinder head gasket.). 2. Move the piston up, and plastigauges (1) [1.5 mm dia. (0.059 in. dia.), 5.0 to 7.0 mm long (0.20 to 0.27 in. long)] on the piston head at three positions with grease so as to avoid the intake and exhaust valves and the combustion chamber ports.
  • Page 76 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Valve Clearance IMPORTANT • The valve clearance must be checked and adjusted when engine is cold. 1. Remove the head cover, the glow plugs and the timing window cover on the flywheel housing. 2. Align the 1TC mark line (2) on the flywheel and center of timing window (1) so that the No.

  • Page 77: Lubricating System

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester. 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.

  • Page 78: Cooling System

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (3) Cooling System Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and alternator pulley at specified force 98 N (10 kgf, 22 lbf). 2. If the measurement is not within the factory specification, adjust the tension adjustment screw.
  • Page 79 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE CAUTION • When removing the radiator cap, wait at least 10 minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people. 9Y1211607ENS0015US0 Radiator Cap Air Leakage 1. Set a radiator tester and adaptor (BANZAI Code No.: RCT-2A- 30S) on the radiator cap.

  • Page 80: Fuel System

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (4) Fuel System Injection Timing 1. Remove the injection pipes. 2. Set the speed control lever to the maximum fuel discharge position. 3. Turn the flywheel counterclockwise (facing the flywheel) until fuel flows from the delivery valve holder.
  • Page 81 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. 13.7 MPa...
  • Page 82 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE CAUTION • Check the nozzle injection pressure and condition after you make sure that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.

  • Page 83: Electrical System

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (5) Electrical System CAUTION • To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal. • Never remove the battery cap while the engine is running.
  • Page 84 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Battery Specific Gravity CAUTION • If battery acid (dilute sulfuric acid) gets on you it could cause blindness or burns, or could cause corrosion of machinery and tools so please be careful when handling. • Wear safety glasses and rubber gloves when performing battery maintenance and inspection (measuring specific gravity, replenishing water, or charging).
  • Page 85 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Motor Test CAUTION • Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable from the battery.
  • Page 86 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Lead Terminal Voltage 1. Disconnect the wiring lead (1) from the glow plug (2) after turning the main switch off. 2. Turn the main switch key to the "GL" position, and measure the voltage between the lead terminal and the engine body.

  • Page 87: Preparation

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE [2] PREPARATION (1) Separating Engine Draining Engine Oil CAUTION • Be sure to stop the engine before draining the engine oil. 1. After warming up, stop the engine. 2. Place an oil pan underneath the oil drain plug (1).
  • Page 88 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Fuel Hose and Fuel Filter CAUTION • Be sure to stop the engine before removing the fuel hose. 1. Close the fuel valve (1). 2. Remove the fuel hose (2) from fuel filter (3). 3. Remove the fuel filter (3).
  • Page 89 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Separating Engine and Generator 1. Disconnect the stator cables (10). 2. Remove the air cleaner (6), muffler (4) and radiator hoses (5). 3. Loosen the fan cover (7) mounting screws. 4. Disconnect the connectors (1).

  • Page 90: Disassembling And Assembling

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE [3] DISASSEMBLING AND ASSEMBLING (1) Cylinder Head and Valves Cylinder Head Cover 1. Remove the cylinder head cover screws (1). 2. Remove the cylinder head cover (2). (When reassembling) • Check to see if the cylinder head cover gasket is not defective.
  • Page 91 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe (1). 2. Remove the nozzle holder assemblies (2). 3. Remove the copper gasket (5) and heat seal (6). 4. Remove the lead (3) from the glow plugs (4).
  • Page 92 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Rocker Arm and Push Rod 1. Remove the rocker arm bracket screws (1). 2. Remove the rocker arm assembly (2). 3. Remove the push rods (3). (When reassembling) • When putting the push rods (3) onto the tappets (4), check to see if their ends are properly engaged with the dimples.
  • Page 93 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Cylinder Head and Tappet 1. Remove the cylinder head screws in the order of (n or j) to (a) and remove the cylinder head. 2. Remove the cylinder head gasket and O-ring (1). 3. Remove the tappets (2) from the crankcase.

  • Page 94: Timing Gears, Camshaft, Fuel Camshaft And Oil Pan

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (2) Timing Gears, Camshaft, Fuel Camshaft and Oil Pan Injection Pump, Fuel Feed Pump and Speed Control Plate 1. Remove the fuel feed pump. 2. Remove the screws (1) and separate the speed control plate (2), taking care not to damage the governor spring (4) and start spring (5).
  • Page 95 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Gear Case 1. Remove the screw (1) of inside the gear case and outside screws (6). 2. Disconnect the start spring (2) in the speed control plate mounting hole. 3. Remove the gear case (3).
  • Page 96 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Fuel Camshaft 1. Remove the retaining plate (1). 2. Remove the fork lever holder mounting screws (8), then draw out the fuel camshaft (2) with the governor fork assembly. (When reassembling) • Hook the governor spring (7) to the fork lever 2 (6) before installing the fork lever assembly to the crankcase.
  • Page 97 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws (5). 2. Remove the oil pan (4) by lightly tapping the rim of the pan with a wooden hammer. 3. Remove the oil strainer (3).

  • Page 98: Piston And Connecting Rod

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (3) Piston and Connecting Rod Connecting Rod 1. Remove the connecting rod caps (1). (When reassembling) • Align the marks (a) with each other. (Face the marks toward the injection pump.) • Apply engine oil to the connecting rod screws and lightly screw it in by hand, then tighten it to the specified torque.
  • Page 99 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Piston Ring and Connecting Rod 1. Remove the piston rings (1), (2), (3) using a piston ring tool. 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) •...

  • Page 100: Crankshaft

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (4) Crankshaft Flywheel 1. Fit the stopper to the flywheel. 2. At first, remove two pieces of the flywheel screws. 3. Insert two pieces of the flywheel guide screws in the holes. 4. Remove all flywheel screws.
  • Page 101 • Install the main bearing case assemblies in original positions. Since diameters of main bearing cases vary, install them in order to marking (b) (1 for GL6000A-AU-B, GL6000D-AU-B and 1, 2 for GL9000A-AU-B, GL9000D-AU-B) from the gear case side. (Refer to the figure.) •...

  • Page 102: Water Pump

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (5) Water Pump Thermostat Assembly 1. Remove the thermostat cover mounting screws (1), and remove the thermostat cover (2). 2. Remove the thermostat assembly (4). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) to both side of the gasket (3).

  • Page 103: Starter

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (7) Starter Electromagnetic Drive Type (1) Solenoid Switch Mounting (2) Starter Drive Housing (3) Drive Lever (4) Gasket (5) Solenoid Switch (6) B Terminal Nut (7) C Terminal Nut (8) Snap RIng (9) Overrunning Clutch...
  • Page 104 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Planetary Gear Reduction Type (1) Magnetic Switch Mounting (2) Housing (3) Magnetic Switch (4) B Terminal Nut (5) C Terminal Nut (6) Drive Lever (7) Shaft Assembly (8) Overrunning Clutch (9) Connecting Lead (10) Mounting Screw...

  • Page 105: Servicing

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE [4] SERVICING (1) Cylinder Head and Valves Cylinder Head Surface Flatness 1. Clean the cylinder head surface. 2. Place a straightedge on the cylinder head's four sides and two diagonal as shown in the figure.
  • Page 106 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Valve Recessing 1. Clean the cylinder head surface, valve face and valve seat. 2. Insert the valve into the valve guide. 3. Measure the valve recessing with a depth gauge. 4. If the measurement exceeds the allowable limit, replace the valve.
  • Page 107 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (Refer to "SPECIAL TOOLS".) (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them.
  • Page 108 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Valve Lapping 1. Apply compound evenly to the valve lapping surface. 2. Insert the valve into the valve guide. Lap the valve onto its seat with a valve flapper or screwdriver. 3. After lapping the valve, wash the compound away and apply oil, then repeat valve lapping with oil.
  • Page 109 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Oil Clearance between Rocker Arm and Rocker Arm Shaft 1. Measure the rocker arm shaft O.D. with an outside micrometer. 2. Measure the rocker arm I.D. with an inside micrometer, and then calculate the oil clearance.

  • Page 110: Timing Gears, Camshaft And Fuel Camshaft

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (2) Timing Gears, Camshaft and Fuel Camshaft Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear.
  • Page 111 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Camshaft Alignment 1. Support the camshaft with V blocks on the surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Measure the camshaft alignment. 4. If the measurement exceeds the allowable limit, replace the camshaft.
  • Page 112 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Oil Clearance between Idle Gear Shaft and Idle Gear Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance.

  • Page 113: Piston And Connecting Rod

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (3) Piston and Connecting Rod Piston Pin Bore I.D. 1. Measure the piston pin bore I.D. in both the horizontal and vertical directions with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston.
  • Page 114 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with a piston ring compressor and piston. 2. Measure the ring gap with a feeler gauge.

  • Page 115: Crankshaft

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (4) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings.
  • Page 116 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigauge on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
  • Page 117 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance.
  • Page 118 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 1. Put a strip of plastigauge (Code No. 07909-30241) on the center of the journal. 2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again.

  • Page 119: Cylinder

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (5) Cylinder Cylinder Wear 1. Measure the cylinder liner I.D. at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.'s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.'s.

  • Page 120: Oil Pump

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (6) Oil Pump Rotor Lobe Clearance 1. Measure the clearance between lobes of the inner rotor and the outer rotor with a thickness gauge. 2. If the clearance exceeds the factory specification, replace the oil pump rotor assembly.

  • Page 121: Starter

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE (7) Starter Commutator and Mica 1. Check the contact face of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points.
  • Page 122 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Armature Coil 1. Check the continuity across the commutator and armature coil core with an ohmmeter. 2. If it conducts, replace the armature. 3. Check the continuity across the segments of the commutator with an ohmmeter.
  • Page 123 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM ENGINE Field Coil 1. Check 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.
  • Page 124 GENERATOR KiSC issued 06, 2016 A...
  • Page 125 MECHANISM CONTENTS 1. STRUCTURE..........................2-M1 2. AUTOMATIC VOLTAGE REGULATOR (A.V.R.) ............... 2-M2 3. EMERGENCY RELAY CIRCUIT (GL6000A-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.

  • Page 126: Structure

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR 1. STRUCTURE 1. Stator Assembly The main coil and sub coil for power generation are wound in the slots provided in the core. The main coil generates the AC output and supplies A.V.R. assembly with a sensing voltage.

  • Page 127: Automatic Voltage Regulator (A.v.r.)

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR 2. AUTOMATIC VOLTAGE REGULATOR (A.V.R.) NOTE • It is hazardous to proceed to any high voltage test on the alternator without having previously disconnected all connections to voltage regulator. Damages occurring to A.V.R. in such conditions will not be considered in a warranty claim.
  • Page 128 The controller (6) is designed to compare the voltage picked up by the detector (7) with the preset reference voltage and to give a transistor ON and OFF signal to the next circuit (GL6000A-AU-B, GL6000D-AU-B: drive circuit (5), GL9000A-AU-B, GL9000D-AU-B: photocoupler). When the output voltage rises too high, it is made to drop; if it drops too low, it is made to rise.

  • Page 129: Emergency Relay Circuit (Gl6000A-Au-B, Gl9000A-Au-B)

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR 3. EMERGENCY RELAY CIRCUIT (GL6000A-AU-B, GL9000A-AU-B) [1] GENERAL This is an automatic engine stopping device. This device senses any abnormal situation on engine and related parts, such as oil pressure, water temperature, or fan belt broken, occurring during engine operation, and activates the stop solenoid to cut off fuel to the fuel injection pump and stop the engine.This relay has two...

  • Page 130: Instructions (Gl6000A-Au-B, Gl9000A-Au-B)

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR [2] INSTRUCTIONS (GL6000A-AU-B, GL9000A-AU-B) (1) Key Switch (2) Battery (12 V) (3) Oil Pressure Switch (4) Water Temperature Sensor (5) Emergency Relay (6) Delay Timer Circuit (7) Sensor Input Circuit (8) Drive Timer Circuit (9) Drive Circuit...

  • Page 131: Generator Connection And Grounding

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR 4. GENERATOR CONNECTION AND GROUNDING WARNING • Do not operate in standing water • This generator is fitted with an neutral-earth connection at the alternator. Removal of this connection will result in non-operable RCD's and risk of electrocution.

  • Page 132: Digital Control Panel

    The GL6000D-AU-B and GL9000D-AU-B are fitted with a deep sea electronics 4520 digital control panel. 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.
  • Page 133 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Function of Control Buttons Icon Description Stop / Reset Mode This button places the controller into stop/reset mode .When an alarm is present, this button will clear any alarm conditions for which the fault has been removed. If the engine is running and the controller is put into stop mode, the controller will automatically instruct the stop solenoid to active and the engine will shut down.
  • Page 134 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Controller Display The controller's display contains the following sections. Example of the digital controller home screen with generator running. 9Y1211607GRM0011US0  Instrumentation Icons When viewing the instrumentation pages, an icon is displayed in the instrumentation icon section to indicate what section is currently being displayed.
  • Page 135 9Y1211607GRM0015US0 NOTE • In standard configuration the controller is not setup for mains fail or auto transfer switch (ATS) control. Please see your local KUBOTA dealer for configuration of these applications. 9Y1211607GRM0016US0  Alarm Icon An icon is displayed in the alarm icon section to indicate the alarm that is current active on the controller.
  • Page 136 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR  Warning Alarm Icons Warnings are non-critical alarm conditions and do not affect the operation of the generator system. They serve to draw the operator's attention to an undesirable condition. Warning alarms are self-resetting when the fault condition is removed.
  • Page 137 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR  Shutdown Alarm Icons Shutdown alarms are latching and stop the generator. The alarm must be accepted and cleared, and the fault removed to reset the module. To clear the alarm, press the stop/reset mode button on the module.
  • Page 138 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Viewing The Instrument Page  Navigation Menu To enter the navigation menu, press both the (up) and (down) buttons simultaneously. To select the required icon, press the (up) button to cycle right or the (down) button to cycle left until the desired instrumentation section is reached.
  • Page 139 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR  General Navigation It is possible to scroll through the display to view different pages of information by repeatedly operating the (up) or (down) navigation buttons. Once selected, the page will remain on the LCD display until the user selects a different page or, after an extended period of inactivity (page delay timer), the module reverts back to the home page.
  • Page 140  Digital Controller Time and Date Setting This controllers contains an onboard clock for event log and operational purposes. If the date or time displayed is incorrect, please consult your local Kubota dealer for instructions on resetting. 9Y1211607GRM0023US0 Event Log This controllers event log contains a list of the last 50 record shutdown events and the engine hours at which they occurred.

  • Page 141: Wiring Diagram

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR 6. WIRING DIAGRAM [1] GL6000A-AU-B 2-M16 KiSC issued 06, 2016 A...

  • Page 142: Gl6000D-Au-B

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR [2] GL6000D-AU-B 2-M17 KiSC issued 06, 2016 A...

  • Page 143: Gl9000A-Au-B

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR [3] GL9000A-AU-B 2-M18 KiSC issued 06, 2016 A...

  • Page 144: Gl9000D-Au-B

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR [4] GL9000D-AU-B 2-M19 KiSC issued 06, 2016 A...
  • Page 145 SERVICING CONTENTS 1. TROUBLESHOOTING.........................2-S1 [1] GENERATOR ........................2-S1 [2] ENGINE CIRCUIT .........................2-S4 2. SERVICING SPECIFICATIONS ....................2-S8 3. TIGHTENING TORQUES......................2-S10 [1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS....2-S10 [2] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS 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...

  • Page 146: Troubleshooting

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR 1. TROUBLESHOOTING [1] GENERATOR Evident Physical Defect (Overheating, Noise, Vibrations, ...) Trouble Possible Cause Confirmation Countermeasure Excessive Bearing race badly locked Check the condition of Replace Overheating of bearing and grease Bearing (Temperature Bracket misalignment...
  • Page 147 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Generator Measurement Trouble Checking Method Operating Possible Cause Countermeasure Condition Voltmeter Indicates Measure the Output voltage is Circuit breaker is Set the circuit Normal Voltage But voltage at the 0 V. breaker to ON. If it...
  • Page 148 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Measurement Trouble Checking Method Operating Possible Cause Countermeasure Condition Output Voltage Is Measure the Excessive Output Improper contact of Repair or replace too High voltage at the Voltage the connector or output terminal disconnected wire using a voltmeter.

  • Page 149: Engine Circuit

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR [2] ENGINE CIRCUIT Trouble Cause Confirmation Countermeasure Engine Stops Insufficient engine oil Check the oil level Add the engine oil (The Engine Stops Defective oil pressure switch Check the oil pressure Replace Approximately switch 10 Seconds After...
  • Page 150 • Breaker Turns Off. • Stop immediately. Engine Indicates Loaded Condition. Short circuit of generator wiring Request for repair. 9Y1211607GRS0004US0  Analog Control Panel - Easy checker (GL6000A-AU-B, GL9000A-AU-B) Trouble Cause Countermeasure When the Key Is Turned, the Lamp Bulb is defective.
  • Page 151 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR  Digital Control Panel – DSE4520 (GL6000D-AU-B, GL9000D-AU-B) Trouble Cause Countermeasure Not Starting Engine room door open. • Close engine room door. Emergency stop button • Turn button clockwise to release Engine system issue (Fail to start) •...
  • Page 152 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR NOTE • Shutdown alarms are accompanied by the sounding of a buzzer. To silence the buzzer, press the "STOP" button on the controller. • Under/over generator voltage, frequency, and battery voltage alarms are in two stages. First stage is a "warning"...

  • Page 153: Servicing Specifications

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR 2. SERVICING SPECIFICATIONS Model Item GL6000A-AU-B GL6000D-AU-B Frequency 50 Hz Voltage 240 V Current 22.9 A R - W 0.62 Ω Main coil BR - L – Sub coil G - LG/R 1.08 Ω Sub coil (DC) L/W - L/W 0.11 Ω...
  • Page 154 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Mode Item GL9000A-AU-B GL9000D-AU-B Frequency 50 Hz Voltage 240 V Current 33.3 A 1 - 3 0.34 Ω Main coil 1 - 2 – 2 - 3 – Sub coil LG - LG 1.96 Ω...

  • Page 155: Tightening Torques

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: See page "5. TIGHTENING TORQUES" on page G-12.) 9Y1211607GRS0010US0 [1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS...

  • Page 156: Tightening Torques For General Use Screws, Bolts And Nuts

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR [2] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below. Indication on No-grade or 4T top of bolt...

  • Page 157: Checking, Disassembling And Servicing

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Control Panel Main Switch 1. Open the control panel (1). 2. Disconnect the 4P connector (3) and remove the main switch (2). 3. Perform the following checks.
  • Page 158 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Main Switch Continuity 1) Main Switch Key at OFF Position 1. Set the main switch OFF position. 2. Measure the resistance with an ohmmeter across the 30 terminal (4) and the AC terminal (2). 3. Measure the resistance with an ohmmeter across the 30 terminal (4) and 50 terminal (3).
  • Page 159 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Safety Switch Continuity 1. Open the engine room door (1). 2. When the safety switch (2) is turned ON and OFF, measure the resistance between the terminals of it each time. 3. (a) when the measurement are the above table value.
  • Page 160 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Regulator 1. Start the engine. 2. Measure the output voltage of the regulator with a circuit tester. Output Voltage Terminal 6 – Terminal 2 14 V to 15 V 3. When the measurement is not the above table value, measure the input voltage of the regulator with a circuit tester.
  • Page 161 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Miniature Circuit Breaker (MCB) 1. Test for continuity between the each upper and lower breaker terminals with an ohmmeter. 2. Make sure that there is continuity when the breaker switch in 3. If there is no continuity, it indicates that the contacts are faulty.
  • Page 162 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Pilot Box 1. Continuity should exist between the terminals for each lamp. 2. If there is no continuity, change the lamp. Charge 3 terminal – 4 terminal Water temperature 2 terminal – 8 terminal Approx. 10 Ω...

  • Page 163: Emergency Relay Activation

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR (2) Emergency Relay Activation Emergency Relay Circuit 1. When the engine is running at rated rpm's connect the lead wires to the terminal of the oil pressure switch (1) or the water temperature sensor (2).
  • Page 164 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Engine Stop Solenoid Test 1. Disconnect the 3P connector (2) from the engine stop solenoid (1). 2. Remove the engine stop solenoid (1) from the engine. 3. Connect the jumper leads from the pushing coil terminal (5) to the switch (6), and from switch (6) to the battery positive terminal (9).

  • Page 165: Disassembling And Assembling

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR [2] DISASSEMBLING AND ASSEMBLING (1) External Components Panel, Cover, Control Panel 1. Close the fuel valve and remove the fuel hose. 2. Remove the hanger (2), the engine roof (3) and the generator roof (1) with fuel tank.

  • Page 166: Generator

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR (2) Generator Rear Bracket 1. Remove the rear bracket mounting nuts. 2. Disconnect the wire harness and the carbon brushes, etc. 3. Lift up the generator. 4. Remove the rear bracket (1). (When reassembling) • Clean dirt from the bearing housing.
  • Page 167 GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Rotor Assembly 1. Remove the cooling fan (2). 2. To avoid damage to the rotor assembly (1), suspend the rotor assembly (1) with a sling belt enough to keep it from lifting, and leave it suspended.

  • Page 168: Servicing

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR [3] SERVICING (1) Terminal Voltage for Each Part During Normal Periods (No-load Periods) Output Terminal 1. With the MCB (1) and RCBO (2) in the ON position, measure the voltage in each phase and each line.

  • Page 169: Rotor Coil

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR Grounding of Stator Coil 1. Measure the insulation resistance between each stator winding and lamination with a megohm meter. 2. Reading should be more than 1 MΩ at 500 V. 3. If continuous, replace the stator or contact service station.

  • Page 170: Exciter Coil

    GL6000A-AU-B, GL6000D-AU-B,GL9000A-AU-B, GL9000D-AU-B, WSM GENERATOR (4) Exciter Coil Exciter Field Winding (Sub Coil) 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 station. (Refer to 2-M16.)
  • Page 171 Editor : Farm and Industrial Machinery International Service Department Address 64, Ishizu-Kitamachi, Sakai-Ku, Sakai-City, Osaka, 590-0823, Japan Phone +81- 72-241-1129 +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 KUBOTA Corporation...

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