Kubota GL11000-CAN, Operator'S Manual

Page 1: ...UAL MANUEL DE L UTILISATEUR 1AEACAFAP0380 Code No N de code G3106 8916 8 KUBOTA Corporation 2006 PRINTED IN JAPAN IMPRIME AU JAPON READ AND SAVE THIS BOOK MANUEL A LIRE ET A CONSERVER G L 7 0 0 0 C A N G L 1 1 0 0 0 C A N ENGLISH FRANÇAIS ...

Page 2: ...GL 7000 CAN GL 11000 CAN AX L 14 20 1 AK ...

Page 3: ...OPERATOR S MANUAL ENGLISH GL7000 CAN GL11000 CAN 1AEACAFAP0380 ENGLISH READ AND SAVE THIS BOOK ...

Page 4: ...icensed electrician must install an isolation transfer switch in the building s main fuse box The switch is the connection point for generator power and allows selection of generator or main line power to the building This will prevent the generator from charging the main power line backfeeding when the main power supply has failed or has been turned off for line repair Backfeeding can electrocute...

Page 5: ...anual carefully It will help you become familiar with the operation of the generator and contains many helpful hints about generator maintenance It is KUBOTA s policy to utilize as quickly as possible every advance in our research The immediate use of new techniques in the manufacture of products may cause some small parts of this manual to be outdated KUBOTA distributors and dealers will have the...

Page 6: ...N CHECK 10 HOW TO OPEN THE DOOR 10 DAILY CHECK 10 Battery 10 Engine Oil 11 Coolant 11 Fuel 12 PRECAUTIONS ON GENERATOREQUIPPED ENGINE 12 OPERATING THE GENERATOR 13 STARTING THE ENGINE 13 Warm up in Cold Ambient Temperatures 14 COLD WEATHER STARTING 15 STOPPING THE ENGINE 15 IF THE ENGINE FAILS TO STOP IN THE USUAL PROCEDURE EMERGENCY STOP 16 MAINTENANCE 17 SERVICE INTERVALS 17 PERIODIC SERVICE 19 ...

Page 7: ...lant Loss 26 Checking Radiator Hoses and Clamps 26 Precaution at Overheating 26 Cleaning Radiator Core outside 27 Cleaning the Radiator 27 Anti Freeze 27 BATTERY 28 Battery Charging 28 Instructions for Long Term Storage 29 Battery Boost Starting 29 ELECTRIC WIRING 30 FUSE 30 FAN BELT 31 Adjusting Fan Belt Tension 31 TRANSPORTING STORAGE 32 STORAGE 32 TROUBLESHOOTING 33 GENERATOR 33 EASY CHECKER 34...

Page 8: ...e and work safely Know your equipment and its limitations Always keep the generator in good condition A Before allowing other people to use your generator explain to them how to operate and have them read this manual before operation A DO NOT modify the engine by yourself UNAUTHORIZED MODIFICATIONS to the engine may impair the function and or safety and affect engine life WEAR SAFETY CLOTHING A DO...

Page 9: ...ELECTRICAL COMPONENTS Always exercise extra caution when handling electrical equipment Careless handling of electrical components can cause serious personal injury death by electrocution or property damage A DO NOT touch the electrical system during operation A Connect or disconnect the load to the AC receptacles or terminals only when the engine is stopped A Make certain that all power cables and...

Page 10: ...e it is running since this can cause fuel spillage EXHAUST GASES FIRE PREVENTION A Engine exhaust fumes can be very harmful if allowing them to accumulate Be sure to run the engine in a well ventilated place and where there are no people or livestock near the generator A DO NOT operate the generator in a closed area such as inside houses warehouses tunnels wells ship holds tanks etc or places with...

Page 11: ...NG FLUID A Relieve all pressure in the oil and the cooling systems before any lines fittings or related items are removed or disconnected A Be alert for possible pressure when disconnecting any device from a system that utilizes pressure DO NOT check for pressure leaks with your hand High pressure oil or fuel can cause serious personal injury A Escaping fluid under pressure has sufficient force to...

Page 12: ...e a voltmeter or hydrometer A DO NOT charge battery if frozen there is a risk of explosion When battery is frozen allow the battery to warm up to 16 61 before charging A DO NOT use or charge the battery if its fluid level is below the LOWER lower limit level mark refillable type battery only Otherwise the component parts may deteriorate earlier than expected which may shorten the service life or c...

Page 13: ...ng If you spill electrolyte on yourself flush with water and get medical attention immediately A Be sure to stop the engine and remove the key when conducting daily and periodic maintenance servicing and cleaning A Check or conduct maintenance after the engine coolant muffler or muffler cover have cooled off completely A Always use the appropriate lifting equipment and make sure safety stands are ...

Page 14: ...SH Pay special attention to all labels on the generator Refer to following representations for labels used on the GL Series Generator Labels are available individually from your KUBOTA Dealer DANGER WARNING AND CAUTION LABELS ...

Page 15: ...SAFE OPERATION 8 ENGLISH ...

Page 16: ...missing warning and caution labels with new labels from your local KUBOTA dealer 4 If a component with warning and caution label s affixed is replaced with new part make sure new label s is are attached in the same location s as the replaced component 5 Mount new warning and caution labels by applying on a clean dry surface and pressing any bubbles to outside edge CARE OF WARNING AND CAUTION LABEL...

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Page 18: ...parts or major service be sure to see your KUBOTA Dealer For service contact the KUBOTA Dealership from which you purchased your generator or your local KUBOTA Dealer When in need of parts be prepared to give your dealer the generator and engine serial numbers Locate the serial numbers now and record them in the space provided below To be filled in by purchaser model Serial No Generator Engine Dat...

Page 19: ... 3 Bore x stroke mm in 67 x 68 2 6 x 2 7 Displacement L cu in 0 479 29 2 0 719 43 9 Engine speed rpm 3600 Lubricating Oil API service class CF or higher Oil capacity L U S gals 2 2 0 58 3 4 0 90 Coolant capacity L U S gals 3 7 0 98 4 1 1 1 SET Fuel Diesel fuel No 2 ASTM D975 Fuel consumption at full load L U S gals h 2 7 0 71 4 1 1 08 Fuel tank capacity L U S gals 28 7 4 Continuous Operating Hours...

Page 20: ...2 Coolant filling port 8 Engine oil drain plug 14 Oil filter cartridge 20 Battery 3 Hook 9 Door lock 15 Muffler 21 Air cleaner 4 Fuel tank cap 10 Coolant drain plug 16 Radiator 22 Door stopper 5 Fuel gauge 11 Reserve tank 17 Radiator cap 23 Fuel tank 6 Control panel 12 Fuel filter 18 Solenoid 24 Alternator 25 Safety shield ...

Page 21: ...a permanent conductor between the generator stator winding and the frame 1 A C Voltmeter 2 Glow timer lamp 3 Water temperature lamp 4 Oil pressure lamp 5 Battery charge lamp 6 Starter switch key 7 Circuit breaker 8 Hour meter 9 Ground terminal 10 Protector Receptacle 11 Full power switch A Receptacle B Receptacle C Receptacle D Receptacle ...

Page 22: ...ace of the TEST button If the RESET button is not flush with TEST button contact your KUBOTA dealer WHEN THE RESET BUTTON EXTENDS DURING OPERATION 1 Unplug all appliances from the GFCI receptacle 2 Depress the RESET button firmly into the GFCI unit until an audible click is heard If the GFCI can not be reset the GFCI is faulty Contact your KUBOTA dealer If the GFCI resets properly check such thing...

Page 23: ...ble CONTROL BOX GL7000 GL11000 1 Charge warning lamp 2 Water temperature overheat warning lamp flashes on when cooling water rises to 112 234 to 118 244 3 Engine oil pressure drop warning lamp flashes on below 68 7 to 127 5 kPa 0 7 to 1 3 kgf cm oil pressure 4 Glow timer lamp 1 Emergency unit 2 Regulator 3 Glow relay 4 Relay A 5 Relay B 6 Glow lamp timer 7 Starter relay 8 Exterior connection termi...

Page 24: ...e to extremely high levels and the AVR may get damaged A Before turning on the lamps again wait for 10 minutes or so until the lamps cool down enough A The data shown above is only a guideline to approximate load capacities and may vary from generator model to generator model with different types of loads at rated outputs These values may be different from actual applications because of the input ...

Page 25: ...onditioners and or the regulated power supply for TV sets the lights might suffer flickering This phenomenon does not indicate a fault of the generator it is caused by poor matching between the above mentioned regulated power supply and the generator s automatic voltage regulator In such a case modify the load combination to eliminate the flickering Load type Power factor Single phase induction mo...

Page 26: ...t the load to the AC receptacle only when the engine is stopped 1 Turn OFF the circuit breakers on the control panel GL7000 60Hz 120 240V GL11000 60Hz 120 240V 2 Connect the load to the A C receptacles 1 Circuit breaker A Receptacle B Receptacle C Receptacle D Receptacle 1 Circuit breaker A Receptacle B Receptacle C Receptacle D Receptacle ...

Page 27: ...et and outlet for obstructions or clogging Check radiator fins for clogging Check fan belt tension Check engine oil level Check coolant level Check generator grounding Refuel See Fuel in PERIODIC SERVICE section Care of danger warning and caution labels See DANGER WARNING AND CAUTION LABELS in SAFE OPERATION section To avoid personal injury from contact with moving parts A DO NOT open the door or ...

Page 28: ...t is necessary for the battery to be charged for a sufficient period of time Continue to charge until all cells are gassing freely and the voltage and specific gravity reading in all cells remain constant for 3 or more successive readings taken at 30 minute intervals A When the battery has been charged fully the specific gravity of electrolyte should be 1 270 to 1 290 at 20 68 BEngine Oil The gene...

Page 29: ...letely causing the engine to stop then the fuel system requires air bleeding after filling the tank and before restarting the engine See Air bleeding the fuel system in PERIODIC SERVICE section PRECAUTIONS ON GENERATOREQUIPPED ENGINE To avoid personal injury If the engine is kept running under no load or light load load factor below 30 unburnt fuel or carbon builds up in the exhaust system As a re...

Page 30: ... on the electrical devices A Check the wiring and connections of the electrical devices before starting the machine A DO NOT touch the live parts during operation STARTING THE ENGINE A Do not use ether or any starting fluid for starting the engine or severe engine damage will occur 1 Turn OFF all switches on the electrical devices 2 Turn OFF the circuit breakers on the control panel 1 Circuit brea...

Page 31: ...ult trouble in the lubrication circuit or damage to the engine moving parts To prevent the above problems perform the following instructions Warm up the engine at rated revolution with no load A When there is a severe overload or short circuit in the wiring of the generator the circuit breaker turns OFF If this happens eliminate the cause and then turn the circuit breaker ON again 6 Turn the key t...

Page 32: ... An insufficiently warmed up engine can shorten its service life A When there is possibility of temperature drops below 15 5 detach the battery from the machine and keep it indoor in a safe area Reinstalled the battery before the next operation STOPPING THE ENGINE 6 Turn the starter switch key to the PREHEAT position until the glow plug indicator goes off Ambient temperature Preheating time Above ...

Page 33: ... the door using the door knob 2 Turn the engine stop lever to STOP direction and hold it for 5 to 10 seconds to shut off the engine 3 After stopping the engine make sure that the door is closed and the main switch key is at OFF 4 The following causes are possible for such unusual engine shut off Pinpoint and correct the cause of trouble A Check for the stop solenoid A Check to see if the battery h...

Page 34: ...f fuel pipes and clamp bands 20 2 Change of engine oil 22 3 Cleaning of air cleaner element 23 1 4 Check of battery electrolyte level 28 5 Check of fan belt tension 31 6 Check of radiator hoses and clamp bands 26 7 Check of intake air hose 8 Replacement of oil filter cartridge 23 9 Replacement of fuel filter cartridge or element 10 Cleaning of fuel filter 21 11 Cleaning of water jacket radiator in...

Page 35: ...ssification and Proper SAE Engine Oil according to the ambient temperatures as shown P21 A Refer to the following table for the suitable API classification engine oil according to the fuel C Fuel A Cetane number of 45 minimum Cetane number greater than 50 is preferred especially for temperatures below 20 4 or elevations above 1500 m 5000 ft A Diesel fuels specified to EN 590 or ASTM D975 are recom...

Page 36: ...ngines in industrial and heavy mobile service SAE J313 JUN87 Grade of Diesel Fuel Oil According to ASTM D975 The cetane number is required not to be less than 45 A Be sure to use a strainer when filling the fuel tank or dirt or sand in the fuel may cause trouble in the fuel injection pump A Always use diesel fuel You are required not to use alternative fuel because its quality is unknown and affec...

Page 37: ...when bubbles do not come up any more BChecking the Fuel Pipes To avoid personal injury A Check or replace the fuel pipes after stopping the engine Broken fuel pipes can cause fires Check the fuel pipes every 50 hours of operation When if 1 If the clamp band is loose apply oil to the screw of the band and tighten the band securely 2 If the fuel pipes made of rubber became worn out replace them and ...

Page 38: ...ow it to cool before conducting inspections maintenance or cleaning A Contact with engine oil can damage your skin Put on gloves when handling engine oil If you come in contact with engine oil wash it off immediately A Be sure to check the engine oil on a level surface If placed on gradients oil quantity can not be measured accurately A Do not operate a diesel engine when engine oil is overfilled ...

Page 39: ... the previous one be sure to drain all the previous oil before adding the new engine oil BChanging Engine Oil To avoid personal injury A Be sure to stop the engine before draining engine oil A When draining engine oil place a suitable container underneath the engine and dispose of it according to local regulations A DO NOT drain oil from a hot engine Allow engine to cool down sufficiently to avoid...

Page 40: ...failure and need for engine repair BCleaning Secondary Air Filter Element Since the air cleaner employed on this engine is a dry type never apply oil to it 1 Open the evacuator valve once a week under ordinary conditions or daily when used in severe or dusty conditions This will get rid of large particles of dust and dirt 2 Wipe the inside air cleaner clean with cloth if it is dirty or wet 3 Avoid...

Page 41: ...rt A If the dust cup is mounted incorrectly dust or dirt will not collect in the cup and allow the dust to come into direct contact with the element and thus require the element be replaced prematurely BAir Cleaner with Dust Cup Remove and clean out the dust cup once a week under normal conditions or daily in extreme conditions Do not allow the dust cup to fill above half way regardless of conditi...

Page 42: ...ded with a reserve tank check the coolant level of the reserve tank When it is between the FULL and LOW marks the coolant will usually last for one day s work 3 When the coolant level drops due to evaporation add only 50 50 coolant up to the full level 4 Check to see the two drain plug one is at the crankcase side and the other is at the lower part of the radiator as shown below A If the radiator ...

Page 43: ...d or coolant leaks out overheating can occur Check to see if radiator hoses are properly fixed every 200 hours of operation or 6 months whichever comes first 1 If hose clamps are loose or water leaks tighten hose clamps securely 2 Replace hoses and hose clamps if radiator hoses are swollen hardened or cracked Replace hoses and hose clamps every 2 years or earlier as required if hoses are found to ...

Page 44: ...f antifreeze Always use a 50 50 mix of long life coolant and clean soft water in KUBOTA engines Contact KUBOTA concerning coolant for extreme conditions 1 Long life coolant hereafter LLC comes in several types Use ethylene glycol EG type for this engine 2 Before employing LLC mixed cooling water flush the radiator with fresh water Repeat this procedure 2 or 3 times to clean up the radiator and eng...

Page 45: ...plosion Immediately add distilled water until the battery s fluid level comes somewhere between the UPPER and LOWER levels A When the battery is being activated hydrogen and oxygen gases in the battery are extremely explosive Keep open sparks and flames away from the battery at all times especially when charging the battery A When charging the battery ensure the vent caps are securely in place if ...

Page 46: ...the instructions below to safely start the engine 1 Bring helper battery of the same voltage as disabled generator within easy cable reach 2 Put on safety goggles and rubber gloves 3 Ensure the vent caps are securely in place if equipped 4 Cover vent caps with damp rags Do not allow the rag to touch the battery terminals 5 Attach the red clamp to the positive red or pos terminal of the dead batter...

Page 47: ...protected from potential damage by fuses A blown fuse indicates that there is an overload or a short circuit somewhere in the electrical system If any of the fuses should blow replace with a new one of the same capacity A Before replacing a blown fuse determine why the fuse blew and make any necessary repairs Failure to follow this procedure may result in serious damage to the generator electrical...

Page 48: ...tension is not as specified loosen the lock nut and turn the adjust nut to get the belt tension within the specified range 4 Tighten up the lock nut 5 Replace fan belt if it is damaged A If belt is loosen or damaged and the fan is damaged it could result in overheating or insufficient charging Adjust correctly or replace the belt Proper fan belt tension A deflection of between 12 to 14 mm 0 47 to ...

Page 49: ... dirty engine coolant fill with new coolant and run the engine for about 5 minutes When coolant is added coolant level drops the first time the engine is started stop the engine and add more coolant 2 Remove dirty engine oil fill with new oil and run the engine for about 5 minutes to let the oil penetrate to all the parts 3 Check all the bolts and nuts and tighten if necessary 4 Remove the battery...

Page 50: ...cuit breaker is off Turn breaker ON Contact of output terminal and socket is bad Reinstall Malfunction of electrical equipment Request repair 2 Not generating Bad contact of brush Check cleaning and maintenance of contact face and contact force of brush and slipring Danger All works should be performed when stopped 3 Circuit breaker can not be operated Overload Reduce load Short circuit of load ci...

Page 51: ...Poor contact of sub winding Connect tightly Sub winding problem Check the sub winding Trouble Cause Countermeasure Not started Not turned or slow turning Battery trouble Replacement of battery Insufficient battery charge Recharge battery Slow turning at cold circumstance due to high viscosity of engine oil Fuse blown out Slow blow fuse Replace engine oil to D5W40 or D10W30 for cold Replace fuse Te...

Page 52: ...Blockage of radiator Fill cooling water Adjust belt tension Clean Terminal cover open Close terminal cover Fix terminal cover with panel lock bolts Insufficient output When loaded rotation goes slow Choke of air cleaner element Replace air cleaner element Choke of fuel system Check Choke of fuel filter Element cleaning Oil deterioration Replace engine oil Overload Refer to generator Coolant leaks ...

Page 53: ...aratus with the machine perform the following instructions 1 Remove the terminal taps cover 2 Connect the unit to the ectt with the wiring harnesses following the operator s manual of an auto stop start unit 3 To assemble the ttc set the ttc For nomenclature and connection of terminal taps are referred to the WIRING DIAGRAMS section See page37 1 Plate 2 Exterior connection terminal taps ectt 3 Ter...

Page 54: ...37 WIRING DIAGRAM ENGLISH WIRING DIAGRAM ...

Page 55: ...WIRING DIAGRAM 38 ENGLISH ...