Kubota GL6000A-AU-B Workshop Manual

WORKSHOP MANUAL

DIESEL GENERATOR

GL6000A-AU-B,

GL6000D-AU-B,

GL9000A-AU-B,

GL9000D-AU-B

KiSC issued 06, 2016 A

TO THE READER

This Workshop Manual tells the servicing personnel about the mechanism, servicing and

maintenance of the GL Series. It contains 4 parts: "Information", "General", "Mechanism" and

"Servicing".

 Information

This section primarily contains information below.

• Safety First

• Safety Decals

• Specifications

• Dimensions

 General

This section primarily contains information below.

• Engine Identification

• General Precautions

• Maintenance Check List

• Check and Maintenance

• Special Tools

 Mechanism

This section contains information on the structure and the function of the unit. Before you continue

with the subsequent sections, make sure that you read this section.

Refer to the latest version of Workshop Manual for diesel engine mechanism that this manual does

not include.

• Booklet: Code No. 9Y021-01870

• PDF file in Kubota Web Site: Code No. 9Y011-01870

 Servicing

This section primarily contains information below.

• Troubleshooting

• Servicing Specifications

• Tightening Torques

• Checking, Disassembling and Servicing

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.

June, 2016

KiSC issued 06, 2016 A

I INFORMATION

KiSC issued 06, 2016 A

CONTENTS

1. SAFETY FIRST .............................................................................................................................. I-1

2. SAFETY DECALS .......................................................................................................................... I-5

3. SPECIFICATIONS........................................................................................................................ I-13

4. DIMENSIONS ............................................................................................................................... I-15

INFORMATION

KiSC issued 06, 2016 A

INFORMATION

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

I-1

1. SAFETY FIRST

WSM000001INI0001US1

BEFORE YOU START SERVICE

• Read all instructions and safety instructions in this

manual and on your engine safety decals.

• Clean the work area and engine.

• Park the machine on a stable and level ground.

• Let the temperature of the engine decrease before

you start a job.

• Stop the engine, then remove the key.

• Disconnect the battery negative cable.

• Hang a "DO NOT OPERATE" tag in the operator

station.

WSM000001INI0002US0

START SAFELY

• Do not do the procedures below when you start the

engine.

– short across starter terminals

– bypass the safety start switch

• Do not make unauthorized modifications to the

engine. This can cause damage and decrease the

engine life.

WSM000001INI0003US0

SAFETY FIRST

• This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the

machine itself to warn of the possibility of personal injury. Read these instructions carefully.

• It is essential that you read the instructions and safety regulations before you try to repair or use this

unit.

DANGER

• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

• Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate

injury.

IMPORTANT

• Indicates that equipment or property damage could result if instructions are not followed.

NOTE

• Gives helpful information.

KiSC issued 06, 2016 A

INFORMATION

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

I-2

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.

• When 2 or more persons do servicing, make sure

that you do it safely.

• Do not touch the hot parts or parts that turn when the

engine operates.

• Do not remove the radiator cap when the engine

operates, or immediately after it stops. If not, hot

water can spout out from the radiator. Only remove

the radiator cap when it is at a sufficiently low

temperature to touch with bare hands. Slowly loosen

the cap to release the pressure before you remove it

fully.

• Released fluid (fuel or hydraulic oil) under pressure

can cause damage to the skin and cause serious

injury. Release the pressure before you disconnect

hydraulic or fuel lines. Tighten all connections before

you apply the pressure.

• Do not open a fuel system under high pressure.

The fluid under high pressure that stays in fuel lines

can cause serious injury. Do not disconnect or repair

the fuel lines, sensors, or any other components

between the fuel pump and injectors on engines with

a common rail fuel system under high pressure.

• Put on an applicable ear protective device (earmuffs

or earplugs) to prevent injury against loud noises.

• Be careful about electric shock. The engine

generates a high voltage of more than DC100 V in

the ECU and is applied to the injector.

WSM000001INI0004US0

PROTECT AGAINST HIGH PRESSURE SPRAY

• Spray from high pressure nozzles can penetrate the

skin and cause serious injury. Keep spray from

contacting hands or body.

• If an accident occurs, see a doctor immediately. Any

high pressure spray injected into the skin must be

surgically removed within a few hours or gangrene

may result.

Doctors unfamiliar with this type of injury should

reference a knowledgeable medical source.

9Y1211607INI0001US0

KiSC issued 06, 2016 A

INFORMATION

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

I-3

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. Exhaust gases and components reach

temperatures hot enough to burn people, ignite, or

melt common materials.

9Y1211607INI0002US0

EXHAUST FILTER CLEANING

• Servicing machine or attachments during exhaust

filter cleaning can result in serious personal injury.

Avoid exposure and skin contact with hot exhaust

gases and components.

• During auto or manual/stationary exhaust filter

cleaning operations, the engine will operate at

elevated idle and hot temperatures for an extended

period of time. Exhaust gases and exhaust filter

components reach temperatures hot enough to burn

people, or ignite, or melt common materials.

9Y1211607INI0003US0

PREVENT A FIRE

• Fuel is very flammable and explosive under some

conditions. Do not smoke or let flames or sparks in

your work area.

• To prevent sparks from an accidental short circuit,

always disconnect the battery negative cable first

and connect it last.

• The battery gas can cause an explosion. Keep the

sparks and open flame away from the top of battery,

especially when you charge the battery.

• Make sure that you do not spill fuel on the engine.

WSM000001INI0005US0

KEEP A GOOD AIRFLOW IN THE WORK AREA

• If the engine is in operation, make sure that the area

has good airflow. Do not operate the engine in a

closed area. The exhaust gas contains poisonous

carbon monoxide.

WSM000001INI0006US0

KiSC issued 06, 2016 A

INFORMATION

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

I-4

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.

WSM000001INI0007US0

PREVENT ACID BURNS

• Keep electrolyte away from your eyes, hands and

clothing. Sulfuric acid in battery electrolyte is

poisonous and it can burn your skin and clothing and

cause blindness. If you spill electrolyte on yourself,

clean yourself with water, and get medical aid

immediately.

WSM000001INI0008US0

PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher ready at all

times.

• Keep the emergency contact telephone numbers

near your telephone at all times.

WSM000001INI0009US0

KiSC issued 06, 2016 A

INFORMATION

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

I-5

2. SAFETY DECALS

The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not

on the machine, replace it. The decal part number is listed in the parts list.

WSM000001INI0013US0

[Digital Type]

9Y1211607INI0004US0

KiSC issued 06, 2016 A

INFORMATION

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

I-6

9Y1211607INI0005US0

KiSC issued 06, 2016 A

INFORMATION

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

I-7

9Y1211607INI0006US0

KiSC issued 06, 2016 A

INFORMATION

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

I-8

9Y1211607INI0007US0

KiSC issued 06, 2016 A

INFORMATION

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

I-9

[Analog Type]

9Y1211607INI0008US0

KiSC issued 06, 2016 A

INFORMATION

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

I-10

9Y1211607INI0009US0

KiSC issued 06, 2016 A

INFORMATION

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

I-11

9Y1211607INI0010US0

KiSC issued 06, 2016 A

INFORMATION

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

I-12

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.

3. Replace damaged or missing danger, warning and caution labels with new labels.

4. If a component with danger, warning and caution label(s) affixed is replaced with new part, make sure new label(s)

is (are) attached in the same location(s) as the replace component.

5. Mount new danger, warning and caution labels by applying on a clean dry surface and pressing any bubbles to

outside edge.

9Y1211607INI0012US0

KiSC issued 06, 2016 A

INFORMATION

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

I-13

3. SPECIFICATIONS

*Conversion Formula: HP = 0.746 kW, PS = 0.7355 kW

Model GL6000A-AU-B GL6000D-AU-B

Generator

Design Salient-pole, revolving-field AC generator (AVR system with separate and self-excitation brush)

Frequency 50 Hz

Rated output (COP)

5.5 kVA

5.5 kW

Rated voltage 240 V

Rated amperage 22.9 A

Phase and wire 1 - 2 ϕ - W

Power factor 100 %

Number of poles 2

Insulation Rotor coil: Class F, Stator coil: Class B

Voltage regulation 5 % (No load to full load)

Total harmonic distortion 8 % (No load), 22 % (Full load)

Type of coupling Direct coupled

Engine

Model Z482

Design Vertical, water-cooled, 4-cycle diesel engine

Number of cylinders 2

Bore × stroke ϕ 67 × 68 mm (2.6 × 2.7 in.)

Displacement 0.479 L (29.2 cu.in.)

Engine speed 3000 min

-1

(rpm)

Lubricating oil API service class CF or higher

Oil capacity 2.2 L (0.58 U.S.gals)

Coolant capacity 3.7 L (0.98 U.S.gals)

Set

Fuel Diesel fuel No. 2 (ASTM D975)

Fuel consumption (at full load) 2.4 L/h (0.63 U.S.gals/h)

Fuel tank capacity 28 L (7.4 U.S.gals)

Continuous operating hours 12 hrs

Battery (V × Ah/5Hr) 44B19R (12 V × 27 Ah/5Hr)

Starting system Electric

Dimension (L × W × H) 1066 mm × 618 mm × 698 mm (41.97 in. × 24.3 in. × 27.5 in.)

Approx net weight 235 kg (518 lbs.)

Controller Analog Digital - DSE4520

Receptacles 2 × 15A (IP56 rated, auto switched)

Electrical protection 25A MCB (2 Pole), 16A RCBO 30mA (2 Pole) × 2, MEN link at alternator.

Shutdown system

In case of abnormal: Oil pressure, water temperature

Emergency stop button, engine room door opened

– Under/Over voltage and frequency

KiSC issued 06, 2016 A

INFORMATION

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

I-14

*Conversion Formula: HP = 0.746 kW, PS = 0.7355 kW

9Y1211607INI0013US0

Model GL9000A-AU-B GL9000D-AU-B

Generator

Design Salient-pole, revolving-field AC generator (AVR system with separate and self-excitation brush)

Frequency 50 Hz

Rated Output (COP)

8.0 kVA

8.0 kW

Rated voltage 240 V

Rated amperage 33.3 A

Phase and wire 1 - 2 ϕ - W

Power factor 100 %

Number of poles 2

Insulation Rotor coil: Class F, Stator coil: Class B

Voltage regulation 5 % (No load to full load)

Total harmonic distortion 4 % (No load), 6 % (Full load)

Type of coupling Direct coupled

Engine

Model D722

Design Vertical, water-cooled, 4-cycle diesel engine

Number of cylinders 3

Bore × stroke ϕ 67 × 68 mm (2.6 × 2.7 in.)

Displacement 0.719 L (43.9 cu.in.)

Engine speed 3000 min

-1

(rpm)

Lubricating oil API service class CF or higher

Oil capacity 3.4 L (0.90 U.S.gals)

Coolant capacity 4.1 L (1.1 U.S.gals)

Set

Fuel Diesel fuel No. 2 (ASTM D975)

Fuel consumption (at full load) 3.3 L/h (0.87 U.S.gals/h)

Fuel tank capacity 28 L (7.4 U.S.gals)

Continuous operating hours 8.5 hrs

Battery (V × Ah/5Hr) 55B24R (12 V × 36 Ah/5Hr)

Starting system Electric

Dimension (L × W × H) 1281 mm × 618 mm × 698 mm (50.43 in. × 24.3 in. × 27.5 in.)

Approx net weight 280 kg (617 lbs.)

Controller Analog Digital - DSE4520

Receptacles 3 × 15A (IP56 rated, auto switched)

Electrical protection 40A MCB (2 Pole), 16A RCBO 30mA (2 Pole) × 3, MEN link at alternator.

Shutdown system

In case of abnormal: Oil pressure, water temperature

Emergency stop button, engine room door opened

– Under/Over voltage and frequency

KiSC issued 06, 2016 A

INFORMATION

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

I-15

4. DIMENSIONS

9Y1211607INI0014US0

9Y1211607INI0015US0

GL6000A-AU-B

GL6000D-AU-B

L 1066 mm (41.97 in.)

W 618 mm (24.3 in.)

H 698 mm (27.5 in.)

GL9000A-AU-B

GL9000D-AU-B

L 1281 mm (50.43 in.)

W 618 mm (24.3 in.)

H 698 mm (27.5 in.)

KiSC issued 06, 2016 A

G GENERAL

KiSC issued 06, 2016 A

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