Kubota GL6000 Workshop Manual
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Kubota GL6000 Workshop Manual

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

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  • Page 1 WORKSHOP MANUAL DIESEL GENERATOR GL6000,GL7000, GL9000,GL11000 KiSC issued 05, 2015 A...
  • Page 2 TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KUBOTA Generator GL Series. It is divided into three parts, “General”, “Mechanism” and “Servicing”.  General Information on the general precautions, check and maintenance and special tools.
  • Page 3 Record of Revisions For pdf, use search function {Search word} to find all the revised locations. Last digit Issue Reference of the Main Revised Point and Corrective Measures {Search word} month Page Code No. 2015.04 GL9000 / GL11000 Generator changed. KiSC issued 05, 2015 A...

  • Page 4: Safety First

    SAFETY INSTRUCTIONS GL6000, GL7000, GL9000, GL11000, WSM SAFETY INSTRUCTIONS 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 5 SAFETY INSTRUCTIONS GL6000, GL7000, GL9000, GL11000, WSM SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Unauthorized modifications to the engine may impair the function and / or safety and affect engine life.
  • Page 6 SAFETY INSTRUCTIONS GL6000, GL7000, GL9000, GL11000, WSM VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.
  • Page 7 SAFETY INSTRUCTIONS GL6000, GL7000, GL9000, GL11000, WSM SAFETY DECALS The following safety decals are installed on the generator. If a decal becomes damaged, illegible or is not on the generator, replace it. The decal part number is listed in the parts list.
  • Page 8 SAFETY INSTRUCTIONS GL6000, GL7000, GL9000, GL11000, WSM [Terminal Type] KiSC issued 05, 2015 A...

  • Page 9: Specifications

    SPECIFICATIONS GL6000, GL7000, GL9000, GL11000, WSM SPECIFICATIONS Model GL6000-STD GL6000-AUS Frequency 50 Hz Rated output 5.5 kW Maximum output 6.0 kW Rated voltage 220 V 240 V Generator Rated current 25 A 22.9 A Phrase and wire 1 - 2...
  • Page 10 SPECIFICATIONS GL6000, GL7000, GL9000, GL11000, WSM Model GL7000-USA GL7000-USA-TM GL7000-STD Frequency 60 Hz Rated output 6.5 kW Maximum output 7.0 kW Rated voltage 120 / 240 V 110 / 220 V Generator Rated current 54.2 / 27.1 A 59.1 / 29.5 A...
  • Page 11 SPECIFICATIONS GL6000, GL7000, GL9000, GL11000, WSM Model GL9000-STD GL9000-AUS Frequency 50 Hz Rated output 8.0 kW Maximum output 8.8 kW Rated voltage 220 V 240 V Generator Rated current 36.4 A 33.3 A Phrase and wire 1 - 2 Number of poles...
  • Page 12 SPECIFICATIONS GL6000, GL7000, GL9000, GL11000, WSM Model GL11000-USA GL11000-USA-TM GL11000-STD Frequency 60 Hz Rated output 10.0 kW Maximum output 11.0 kW Rated voltage 120 / 240 V 110 / 220 V Generator Rated current 83.3 / 41.7 A 90.9 / 45.5 A...
  • Page 13 DIMENSIONS GL6000, GL7000, GL9000, GL11000, WSM DIMENSIONS GL6000-STD, GL6000-AUS, GL9000-STD, GL9000-AUS, GL11000-STD, GL7000-STD, GL7000-USA, GL7000-USA-TM GL11000-USA, GL11000-USA-TM 1066 mm (42.0 in.) 1281 mm (50.4 in.) 618 mm (24.3 in.) 618 mm (24.3 in.) 698 mm (27.5 in.) 698 mm (27.5 in.)

  • Page 14: Table Of Contents

    GENERAL CONTENTS 1. 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 15: Identification

    GL6000, GL7000, GL9000, GL11000, WSM 1. IDENTIFICATION [1] MODEL NAME AND ENGINE SERIAL NUMBER When contacting your local KUBOTA distributor, always specify the model name and serial numbers of both engine and generator. The engine model and its serial number need to be identified before the engine can be serviced or parts replaced.

  • Page 16: 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 17: Cylinder Number

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM [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 18: Precaution

    Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.

  • Page 19: Handling Precautions For Electrical Parts And Wiring

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring. IMPORTANT  • Check...
  • Page 20 G GENERAL GL6000, GL7000, GL9000, GL11000, WSM • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp • Wind Clamp Spirally (4) Welding Dent (2) Wire Harness W10114580 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.

  • Page 21: Battery

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM [2] BATTERY • Take care not to confuse positive and negative terminal posts. • When removing battery cables, disconnect negative cable first. When installing battery cables, check for polarity and connect positive cable first.

  • Page 22: Handling Of Circuit Tester

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make certain there is no terminal being exposed or displaced. (1) Exposed Terminal (3) Sandpaper (2) Deformed Terminal (4) Rust W10123460 •...

  • Page 23: Lubricants, Fuel And Coolant

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM 4. LUBRICANTS, FUEL AND COOLANT Capacity GL6000-STD GL9000-STD GL6000-AUS GL9000-AUS Place Lubricants, fuel and coolant GL7000-STD GL11000-STD GL7000-USA GL11000-USA GL7000-USA-TM GL11000-USA-TM Higher than CF class (API) Above 25 °C (77 °F) : SAE10W-30,...
  • Page 24 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 25: Tightening Torques

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLT AND NUTS Screws, bolt and nuts whose tightening torque are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of...

  • Page 26: Maintenance Check List

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM 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 27 G GENERAL GL6000, GL7000, GL9000, GL11000, WSM Period Every Every Every Every 1 Every 2 Reference 1000 1500 year year page hours hours hours Item Check G-14 Engine oil Change G-15, 16 Check G-14 Radiator coolant (L.L.C.) Change G-24 ...

  • Page 28: Check And Maintenance

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM 7. CHECK AND MAINTENANCE [1] DAILY CHECK Checking 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 gauge (1).

  • Page 29: Check Points Of Initial 50 Hours

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM [2] CHECK POINTS OF INITIAL 50 HOURS Changing 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 30: Check Point Of Every 50 Hours

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM [3] CHECK POINT OF EVERY 50 HOURS Checking Fuel Hose and Clamp Bands CAUTION • Stop the engine when attempting the check and change prescribed below. • Remember 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.
  • Page 31 G GENERAL GL6000, GL7000, GL9000, GL11000, WSM Checking Air Cleaner Element 1. Remove the air cleaner element. 2. Use clean dry compressed air on the inside of the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm 30 psi).

  • Page 32: Check Point Of Every 200 Hours

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM Checking 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 hand. NOTE  • Check for fuel leak after checking it.

  • Page 33: Check Point Of Every 300 Hours

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM [6] CHECK POINT OF EVERY 300 HOURS Checking 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 34: Check Points Of Every 500 Hours

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM [8] CHECK POINTS OF EVERY 500 HOURS Cleaning 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 35 G GENERAL GL6000, GL7000, GL9000, GL11000, WSM Cleaning Water Jacket and Radiator Interior (Continued)  Anti-Freeze If coolant freezes, it can damage the cylinders and radiator. It is necessary, if the ambient temperature falls below 0 °C (32 °F), to remove coolant after operating or to add anti-freeze to it.

  • Page 36: Check Point Of Every 800 Hours

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM [9] CHECK POINT OF EVERY 800 HOURS 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.

  • Page 37: Check Point Of Every 1000 Hours

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM Changing Fan Belt 1. Remove the side panel. 2. Loosen the tension pulley screw (1) and the tension adjustment screw (2). 3. Remove the fan cover (4). 4. Remove the fan belt (3).

  • Page 38: Check Point Of Every 1 Year

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM [12] CHECK POINT OF EVERY 1 YEAR Changing Air Cleaner Element 1. Remove the air cleaner element. 2. Install the new air cleaner element. NOTE  • The air cleaner uses a dry element. Never apply oil to it •...
  • Page 39 G GENERAL GL6000, GL7000, GL9000, GL11000, WSM Changing Radiator Hose and Clamp Bands CAUTION • Before changing the radiator hoses and clamps, be sure to stop the engine. • Never open the pressure cap while the engine is running under heavy loads or immediately after the engine has stopped.

  • Page 40: Special Tools

    G GENERAL GL6000, GL7000, GL9000, GL11000, WSM 8. SPECIAL TOOLS Valve Seat Cutter Code No: 07909-33102 Application: Use to reseat valves. Angle: 0.785 rad. (45 °) 0.262 rad. (15 °) Diameter: 28.6 mm (1.126 in.) 38.0 mm (1.496 in.) 31.6 mm (1.244 in.) 41.3 mm (1.626 in.)
  • Page 41 G GENERAL GL6000, GL7000, GL9000, GL11000, WSM Connecting Rod Alignment Tool Code No: 07909-31661 Application: Use to check the connecting rod alignment. Applicable: Connecting rod big end I.D. range 30 to 75 mm (1.18 to 2.95 in.) dia. Connecting rod length 65 to 300 mm (2.56 to 11.81 in.)
  • Page 42 12.00 to 12.02 mm dia. (0.4724 to 0.4732 in. dia.) 100 mm (3.94 in.) M12 × P1.5 5 mm (0.20 in.) W10252400 Rotor Pulling Out Bolt (for GL6000, GL7000) Code No: G3102-10011 Application: Use to remove the rotor assembly. 18.65 to 19.0 mm (0.7343 to 0.7480 in.) 21.9 mm (0.8622 in.)
  • Page 43 G GENERAL GL6000, GL7000, GL9000, GL11000, WSM Valve Guide Replacing Tool Application: Use to press out and press fit the valve guide. 200 mm (7.87 in.) 80 mm (3.15 in.) 40 mm (1.58 in.) 20 mm dia. (0.79 in. dia.) 9.96 to 9.98 mm dia.
  • Page 44 G GENERAL GL6000, GL7000, GL9000, GL11000, WSM Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing 1. [Press Out] 135 mm (5.31 in.) 72 mm (2.83 in.) 40 mm radius (1.57 in. radius) 10 mm (0.39 in.)
  • Page 45 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 05, 2015 A...

  • Page 46: Engine Body

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM 1. ENGINE BODY [1] HALF-FLOATING HEAD COVER The rubber packing is fitting in to maintain the head cover 0.5 mm or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head.

  • Page 47: Lubricating System

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 48: Cooling System

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 49: Fuel System

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 50 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 51: Troubleshooting

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Terminal cover is open Close terminal cover – Engine Does Not Start No fuel Fill fuel – Air in the fuel system Bleed – Water in the fuel system Change fuel and –...
  • Page 52 ENGINE GL6000, GL7000, GL9000, GL11000, WSM Reference Symptom Probable Cause Solution Page Excessive engine oil Reduce to specified G-9, 14 Either White or Blue level Exhaust Gas Is Observed Piston ring and cylinder worn or stuck Repair or replace 1-S52, S57...
  • Page 53 ENGINE GL6000, GL7000, GL9000, GL11000, WSM Reference Symptom Probable Cause Solution Page Engine oil insufficient Fill oil G-9, 14 Low Oil Pressure Oil strainer clogged Clean 1-S35 Oil filter cartridge clogged Replace – Relief valve stuck with dirt Clean –...

  • Page 54: Servicing Specifications

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.05 mm 0.0020 in. Top Clearance 0.50 to 0.70 mm – 0.0197 to 0.0276 in. Compression Pressure – 2.84 to 3.24 MPa 2.26 MPa...
  • Page 55 ENGINE GL6000, GL7000, GL9000, GL11000, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Valve Spring Free Length 31.3 to 31.8 mm 28.4 mm 1.232 to 1.252 in. 1.118 in. Tilt – 1.2 mm 0.047 in. Setting Load / 64.7 N / 27.0 mm 54.9 N / 27.0 mm...
  • Page 56 ENGINE GL6000, GL7000, GL9000, GL11000, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Timing Gear Crank Gear to Idle Gear Backlash 0.043 to 0.124 mm 0.15 mm 0.00169 to 0.00488 in. 0.0059 in. Idle Gear to Cam Gear Backlash 0.047 to 0.123 mm...
  • Page 57 ENGINE GL6000, GL7000, GL9000, GL11000, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Crankshaft Alignment – 0.02 mm 0.0008 in. Crankshaft Journal to Crankshaft Bearing 1 Oil Clearance 0.034 to 0.106 mm 0.20 mm 0.00134 to 0.00417 in. 0.0079 in.
  • Page 58 ENGINE GL6000, GL7000, GL9000, GL11000, WSM LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed More than 49 kPa – 0.5 kgf/cm 7 psi At Rated Speed 196 to 441 kPa 147 kPa 2.0 to 4.5 kgf/cm 1.5 kgf/cm...
  • Page 59 ENGINE GL6000, GL7000, GL9000, GL11000, WSM FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump 0.33 to 0.37 rad – (19 to 21 °) before T.D.C. Pump Element Fuel Tightness – 13.73 MPa 140 kgf/cm 1991 psi Delivery Valve Fuel Tightness...

  • Page 60: Tightening Torques

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 61: Tightening Torques For General Use Screws, Bolts And Nuts

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM [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. Grade Standard Screw and Bolt Special Screw and Bolt...

  • Page 62: Checking, Disassembling And Servicing

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 63 ENGINE GL6000, GL7000, GL9000, GL11000, WSM Top Clearance 1. Remove the cylinder head. (Do not attempt to remove the cylinder head gasket.). 2. Move the piston up, and stick a strip of fuse [1.5 mm dia. (0.059 in. dia.), 5 to 7 mm long (0.197 to 0.276 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 64 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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.

  • Page 65: Lubricating System

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 66: Cooling System

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 specifications, adjust the tension adjustment screw.
  • Page 67 ENGINE GL6000, GL7000, GL9000, GL11000, WSM CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people. Radiator Cap Air Leakage 1. Set a radiator tester and adaptor (BANZAI Code No.: RCT-2A- 30S) on the radiator cap.

  • Page 68: Fuel System

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 69 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 70 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 71: Electrical System

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 72 ENGINE GL6000, GL7000, GL9000, GL11000, WSM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).
  • Page 73 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 74 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 75: Preparation

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM [2] PREPARATION (1) Separating Engine Draining Coolant 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 then 10 minutes to cool the radiator, before opening the cap.
  • Page 76 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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. 1. Open the generator door.
  • Page 77 ENGINE GL6000, GL7000, GL9000, GL11000, WSM Separating Engine and Generator 1. Disconnect the stator cables. 2. Remove the air cleaner, muffler and radiator hoses. 3. Remove the fan cover. 4. Remove the generator cover and disconnect the wiring harness. 5. Remove the generator mounting nuts.

  • Page 78: Disassembling And Assembling

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM [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 79 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 80 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 81 ENGINE GL6000, GL7000, GL9000, GL11000, WSM Cylinder Head and Tappet 1. Remove the cylinder head screws in the order of [10] or [14] to [1] and remove the cylinder head. 2. Remove the cylinder head gasket and O-ring (1). 3. Remove the tappets (2) from the crankcase.

  • Page 82: Timing Gears, Camshaft, Fuel Camshaft And Oil Pan

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 and separate the speed control plate (2), taking care not to damage the governor spring (4).
  • Page 83 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 84 ENGINE GL6000, GL7000, GL9000, GL11000, WSM Fuel Camshaft 1. Remove the retaining plate (1). 2. Remove the fork lever holder mounting screws (8), then draw out the injection pump gear (3) and fuel camshaft (2) with the governor fork assembly.
  • Page 85 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 86: Piston And Connecting Rod

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 87 ENGINE GL6000, GL7000, GL9000, GL11000, WSM Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) • When installing the ring, assemble the rings so that the manufacturer’s mark (12) near the gap faces the top of the piston.

  • Page 88: Crankshaft

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 89 • 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 GL6000, GL7000 and 1, 2 for GL9000, 11000) from the gear case side. (Refer to the figure.) •...

  • Page 90: Water Pump

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 91: Starter

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (7) Starter  Electromagnetic Drive Type (1) Solenoid Switch Mounting Nut (2) Starter Drive Housing (3) Drive Lever (4) Gasket (5) Solenoid Switch (6) B Terminal Nut (7) C Terminal Nut (8) Snap RIng...
  • Page 92 ENGINE GL6000, GL7000, GL9000, GL11000, WSM  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...

  • Page 93: Servicing

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM [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 94 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 95 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 96 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 97 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 98: Timing Gears, Camshaft And Fuel Camshaft

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 99 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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.
  • Page 100 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 101: Piston And Connecting Rod

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 102 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 103: Crankshaft

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 104 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 105 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 106 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 107: Cylinder

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 108: Oil Pump

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 specifications, replace the oil pump rotor assembly.

  • Page 109: Starter

    ENGINE GL6000, GL7000, GL9000, GL11000, WSM (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 110 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 111 ENGINE GL6000, GL7000, GL9000, GL11000, WSM 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 112 MECHANISM CONTENTS 1. STRUCTURE ....................2-M1 2. AUTOMATIC VOLTAGE REGULATOR (A.V.R.) ........2-M2 3. EMERGENCY RELAY CIRCUIT..............2-M5 [1] GENERAL ....................2-M5 [2] INSTRUCTIONS ..................2-M6 4. EARTH ......................2-M7 5. WIRING DIAGRAM ..................2-M8 KiSC issued 05, 2015 A...

  • Page 113: Structure

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 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 114: Automatic Voltage Regulator (A.v.r.)

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 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 115 GENERATOR GL6000, GL7000, GL9000, GL11000, WSM The block diagram of GL Series A.V.R.'s is shown below. The A.V.R. consists basically of the components detector (7) through transistor (4). (1) Exciter Coil (4) Transistor (6) Controller (8) A.V.R. (2) Rectifier (5) Drive Circuit...
  • Page 116 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 (GL6000, GL7000 : drive circuit (5), GL9000, GL11000 : photocoupler).

  • Page 117: Emergency Relay Circuit

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 3. EMERGENCY RELAY CIRCUIT [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 118: Instructions

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM [2] INSTRUCTIONS (1) Key Switch (2) Battery (12 V) (3) Oil Switch (4) Water Temperature Switch (5) Emergency Relay (6) Delay Timer Circuit (7) Sensor Input Circuit (8) Drive Timer Circuit (9) Drive Circuit...

  • Page 119: Earth

    Recommendations in the NEC, NFPA and OSHA regulations must be followed to assure compliance and safe operation. A grounding lug is provided on the KUBOTA generator frame for earth grounding depending on local, state, national or OSHA requirements. One possible connection method for construction site use is as follows.

  • Page 120: Wiring Diagram

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 5. WIRING DIAGRAM Color of Wiring B ... Black R .... Red SB ..Sky Blue Y ... Yellow W ... White LG ..Light Green L .... Blue BR ..Brown P ... Pink G ...
  • Page 121 GL6000, GL7000, GL9000, GL11000, WSM GENERATOR GL6000-STD (220V-50Hz) [CONTROL BOX] [GENERATOR] 3 mm 3 mm 3 mm 3 mm Safety Switch C.P. 15A 2 mm White Tape 2 mm Volt Pilot AC Output Terminal Meter Lamp C.P. 15A 2 mm...
  • Page 122 GL6000, GL7000, GL9000, GL11000, WSM GENERATOR GL6000-AUS (240V-50Hz) [CONTROL BOX] [GENERATOR] 3 mm 3 mm 2 mm 3 mm 250V-15A 250V-15A White Tape 2 mm 2 mm Volt Pilot AC Output Meter Lamp Receptacle C.P. 15A C.P. 15A 3 mm...
  • Page 123 GL6000, GL7000, GL9000, GL11000, WSM GENERATOR GL7000-STD (110/220V-60Hz) [GENERATOR] [CONTROL BOX] NFB (1) AC Output Terminal 5 mm 5 mm 5 mm 5 mm 2 mm 2 mm 5 mm Safety Switch 110 V 5 mm C.P. 15A 5 mm...
  • Page 124 GL6000, GL7000, GL9000, GL11000, WSM GENERATOR GL7000-USA (120/240V-60Hz) [CONTROL BOX] [GENERATOR] 5 mm 5 mm 5 mm 5 mm 3 mm L5-30R L14-30R 5 mm 5 mm C.P. 20A AC Output L6-30R Receptacle 5 mm 5 mm 5 mm 5 mm...
  • Page 125 GL6000, GL7000, GL9000, GL11000, WSM GENERATOR GL7000-USA-TM (120/240V-60Hz) [CONTROL BOX] [GENERATOR] NFB (1) AC Output Terminal 5 mm 5 mm 5 mm 5 mm 3 mm Safety Switch 3 mm 3 mm 120 V 5 mm C.P. 20A 5 mm...
  • Page 126 GL6000, GL7000, GL9000, GL11000, WSM GENERATOR GL9000-STD (220V-50Hz) [GENERATOR] [CONTROL BOX] 5 mm 5 mm 5 mm Safety Switch C.P. 15A 2 mm White Tape 2 mm Volt Pilot AC Output Terminal Meter Lamp C.P. 15A 2 mm 2 mm...
  • Page 127 GL6000, GL7000, GL9000, GL11000, WSM GENERATOR GL9000-AUS (240V-50Hz) [GENERATOR] [CONTROL BOX] 5 mm 5 mm 5 mm 2 mm 5 mm 250 V-15 A 250 V-15 A 250 V-15 A White Tape 2 mm Volt Pilot 2 mm 2 mm...
  • Page 128 GL6000, GL7000, GL9000, GL11000, WSM GENERATOR GL11000-STD (110/220V-60Hz) [GENERATOR] [CONTROL BOX] 8 mm 2 mm 8 mm 8 mm 8 mm 8 mm AC Output Terminal 2 mm C.P. 15A Safety Switch 8 mm 8 mm MW 1 110 V...
  • Page 129 GL6000, GL7000, GL9000, GL11000, WSM GENERATOR GL11000-USA (120/240V-60Hz) [GENERATOR] [CONTROL BOX] 8 mm 8 mm 8 mm L5-30R 5 mm (120 V) C.P. 30A C.P. 30A L6-30R 8 mm 8 mm (240 V) 5 mm CS6369 (50A) C.P. 20A 3 mm...
  • Page 130 GL6000, GL7000, GL9000, GL11000, WSM GENERATOR GL11000-USA-TM (120/240V-60Hz) [GENERATOR] [CONTROL BOX] 3 mm 8 mm 8 mm 8 mm 8 mm Safety Switch 8 mm 8 mm 3 mm 3 mm AC Output Terminal 120 V MW 1 C.P. 20A...
  • Page 131 SERVICING CONTENTS TROUBLESHOOTING ...................2-S1 [1] GENERATOR ...................2-S1 [2] ENGINE CIRCUIT..................2-S4 2. SERVICING SPECIFICATIONS ..............2-S6 3. TIGHTENING TORQUES ................2-S8 [1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUT ....................2-S8 [2] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUT ....................2-S9 4.

  • Page 132: Troubleshooting

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 1. TROUBLESHOOTING [1] GENERATOR Evident Physical Defect (Overheating, Noise, Vibrations, ...) Trouble Possible Cause Confirmation Countermeasure Bearing race badly locked Check the Replace Excessive condition of bearing Overheating of and grease Bearing (Temperature of...
  • Page 133 GENERATOR GL6000, GL7000, GL9000, GL11000, WSM Generator Measurement Trouble Checking Method Operating Possible Cause Countermeasure Condition Measure the Output voltage is Circuit breaker is Set the circuit Voltmeter Indicates voltage at the 0 V. breaker to ON. If Normal Voltage But...
  • Page 134 GENERATOR GL6000, GL7000, GL9000, GL11000, WSM Measurement Trouble Checking Method Operating Possible Cause Countermeasure Condition Measure the Excessive Output Improper contact of Repair or replace Output Voltage is too voltage at the Voltage the connector or High output terminal disconnected wire using a voltmeter.

  • Page 135: Engine Circuit

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM [2] ENGINE CIRCUIT Trouble Cause Confirmation Countermeasure Insufficient engine oil Check the oil level Add the engine oil Engine Stops (The Engine Stops Defective oil switch Check the oil Replace Approximately 10 switch Seconds After...
  • Page 136 GENERATOR GL6000, GL7000, GL9000, GL11000, WSM Trouble Cause Confirmation Countermeasure Burnt out 10A fuse Check the fuse Repair or replace Charge Lamp Does (10 A) and the not Light Even with wiring The Key Switch Turned "ON" When Charge lamp burned...

  • Page 137: Servicing Specifications

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 2. SERVICING SPECIFICATIONS GL6000 GL7000 Model Item -STD -AUS -USA -USA-TM -STD Frequency 50 Hz 60 Hz Voltage 220 V 240 V 120 / 240 V  110 / 220 V Current 25 A 22.9 A...
  • Page 138 GENERATOR GL6000, GL7000, GL9000, GL11000, WSM GL9000 GL11000 Model Item -STD -AUS -USA -USA-TM -STD Frequency 50 Hz 60 Hz Voltage 220 V 240 V 120 / 240 V  110 / 220 V 41.7  2 / 45.5  2 / Current 36.4 A...

  • Page 139: Tightening Torques

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 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 G-11.) [1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NOTE ...

  • Page 140: Tightening Torques For General Use Screws, Bolts And Nut

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM [2] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below. Grade Standard Screw and Bolt Special Screw and Bolt...

  • Page 141: Checking, Disassembling And Servicing

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 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 and remove the main switch (2). 3. Perform the following checks.
  • Page 142 GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 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 and the AC terminal, 30 terminal and 50 terminal, 30 terminal and 19 terminal.
  • Page 143 GENERATOR GL6000, GL7000, GL9000, GL11000, WSM Safety Switch Continuity (for Terminal Type) 1. When the safety switch (1) is turned ON and OFF, measure the resistance between the terminals of it each time. 2. (a) when the measurement are the above table value.
  • Page 144 GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 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 145 GENERATOR GL6000, GL7000, GL9000, GL11000, WSM Circuit Breaker (NFB) 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 ON. 3. If there is no continuity, it indicates that the contacts are faulty.
  • Page 146 GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 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.

  • Page 147: Emergency Relay Activates

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM (2) Emergency Relay Activates Emergency Relay Circuit 1. When the engine is running at rated rpm's connect the lead wires to the terminal of the oil switch (1) or the water temperature switch (2).

  • Page 148: Disassembling And Assembling

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM Engine Stop Solenoid Test 1. Disconnect the 1P connector from the engine stop solenoid. 2. Remove the engine stop solenoid from the engine. 3. Connect the jumper leads from the battery positive terminal to the 1P connector, and from the battery negative terminal to the engine stop solenoid body.
  • Page 149 GENERATOR GL6000, GL7000, GL9000, GL11000, WSM (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) •...
  • Page 150 GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 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 151: Servicing

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM [3] SERVICING (1) Terminal Voltage for Each Part During Normal Periods (No-load Periods) Output Terminal 1. With the NFB in the ON position, measure the voltage in each phase and each line. 2. If the factory specification is not indicated, inspect the output circuit or the wiring harness.

  • Page 152: Rotor Coil

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 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 "5. WIRING DIAGRAM” (2-M8).) Refer to "2. SERVICING Resistance Factory spec.

  • Page 153: Exciter Coil

    GENERATOR GL6000, GL7000, GL9000, GL11000, WSM 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 M at 500 V. 3. If continuous, replace the rotor assembly or contact service station.
  • Page 154 : 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 2015. 04, S, EI, EI, engusa Code No.9Y011-02693 KUBOTA Corporation 2004. 06, S, EI, EI, engusa...

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