WORKSHOP MANUAL DIESEL GENERATOR

1 WORKSHOP MANUALDIESEL GENERATORGL6000,GL7000,GL9000,GL11000 KiSC issued 05, 2015 ATO THE READERThis WORKSHOP MANUAL has been prepared to provide servicing personnel withinformation on the mechanism, service and maintenance of KUBOTA GENERATOR GLSeries. It is divided into three parts, General , Mechanism and Servicing . GeneralInformation on the general precautions, check and maintenance and special tools. MechanismInformation on the construction and function are included. This part should beunderstood before proceeding with troubleshooting, disassembling and servicing. ServicingThere are troubleshooting, servicing specification lists, checking and adjusting,disassembling and assembling, and servicing which cover procedures, precautions,factory specifications and allowable information illustrations and specifications contained in this MANUAL are based onthe latest product information available at the time of right is reserved to make changes in all information at any time without 2004 KUBOTA Corporation 2004 KiSC issued 05, 2015 ARecord of RevisionsFor pdf, use search function {Search word} to find all the revised digit of the Code monthMain Revised Point and Corrective Measures {Search word}Reference / GL11000 GENERATOR issued 05, 2015 A1GL6000, GL7000, GL9000, GL11000, WSMSAFETY INSTRUCTIONSSAFETY INSTRUCTIONSBEFORE SERVICING AND REPAIRING Read all instructions and safety instructions in thismanual and on your GENERATOR safety decals.

2 Clean the work area and GENERATOR . Park the GENERATOR on a firm and level ground. Allow the engine to cool before proceeding. Stop the engine, and remove the key. Disconnect the battery negative FIRSTThis symbol, the industry s Safety Alert Symbol , is used throughout this MANUAL and on labels onthe machine itself to warn of the possibility of personal injury. Read these instructions is essential that you read the instructions and safety regulations before you attempt to repair or usethis unit. DANGER: Indicates an imminently hazardous situation which, if not avoided, will result indeath or serious injury. WARNING: Indicates a potentially hazardous situation which, if not avoided, could result indeath or serious injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result inminor or moderate injury. IMPORTANT: Indicates that equipment or property damage could result if instructions are notfollowed.

3 NOTE: Gives helpful issued 05, 2015 A2GL6000, GL7000, GL9000, GL11000, WSMSAFETY INSTRUCTIONSSAFETY STARTING Do not start the engine by shorting across starterterminals or bypassing the safety start switch. Unauthorized modifications to the engine may impairthe function and / or safety and affect engine WORKING Do not work on the GENERATOR while under theinfluence of alcohol, medication, or other substancesor while fatigued. Wear close fitting clothing and safety equipmentappropriate to the job. Use tools appropriate to the work. Makeshift tools,parts, and procedures are not recommended. When servicing is performed together by two or morepersons, take care to perform all work safely. Do not touch the rotating or hot parts while the engineis running. Never remove the radiator cap while the engine isrunning, or immediately after stopping. Otherwise, hotwater will spout out from radiator. Only removeradiator cap when cool enough to touch with barehands.

4 Slowly loosen the cap to first stop to relievepressure before removing completely. Escaping fluid (fuel or hydraulic oil) under pressurecan penetrate the skin causing serious injury. Relievepressure before disconnecting hydraulic or fuel all connections before applying pressure. Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionableor uncomfortable loud FIRES Fuel is extremely flammable and explosive undercertain conditions. Do not smoke or allow flames orsparks in your working area. To avoid sparks from an accidental short circuit,always disconnect the battery negative cable first andconnect it last. Battery gas can explode. Keep sparks and openflame away from the top of battery, especially whencharging the battery. Make sure that no fuel has been spilled on the issued 05, 2015 A3GL6000, GL7000, GL9000, GL11000, WSMSAFETY INSTRUCTIONSVENTILATE WORK AREA If the engine must be running to do some work, makesure the area is well ventilated.

5 Never run the enginein a closed area. The exhaust gas contains poisonouscarbon OF FLUIDS PROPERLY Do not pour fluids into the ground, down a drain, orinto a stream, pond, or lake. Observe relevantenvironmental protection regulations when disposingof oil, fuel, coolant, electrolyte and other ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It isstrong enough to burn skin, clothing and causeblindness if splashed into eyes. Keep electrolyteaway from eyes, hands and clothing. If you spillelectrolyte on yourself, flush with water, and getmedical attention FOR EMERGENCIES Keep a first aid kit and fire extinguisher handy at alltimes. Keep emergency numbers for doctors, ambulanceservice, hospital and fire department near issued 05, 2015 A4GL6000, GL7000, GL9000, GL11000, WSMSAFETY INSTRUCTIONSThe following safety decals are installed on the a decal becomes damaged, illegible or is not on the GENERATOR , replace it.

6 The decal part number is listedin the parts list.[Receptacle Type]SAFETY DECALSKiSC issued 05, 2015 A5GL6000, GL7000, GL9000, GL11000, WSMSAFETY INSTRUCTIONS[Terminal Type]KiSC issued 05, 2015 A6GL6000, GL7000, GL9000, GL11000, WSMSPECIFICATIONSSPECIFICATIONS* Conversion Formula : HP = kW, PS = kWW1028103 ModelGL6000-STDGL6000-AUSG eneratorFrequency50 HzRated kWMaximum kWRated voltage220 V240 VRated current 25 APhrase and wire1 - 2 Number of poles2 Power Factor1 InsulationStator coil: B Rotor coil: FEngineDesignVertical, liquid cooled, 4 cycle, dieselModel nameZ482-E2B-SEC-2 Rated kWSpeed3000 min-1 (rpm)Number of cylinder - Bore x Stroke2 - 67 x 68 mm (2 - x in.) L ( )Fuel tank capacity28 L ( )Crankcase oil L ( )Starting systemElectric type 12 V / kWBattery38B20R 12 V x 28 Ah / 5 HrContinuous operating hours (at rated load)12 hrsNet weight kg (lbs)235 kg (518 lbs)OutputReceptacle6-15R 215A 2 Terminal2P KiSC issued 05, 2015 A7GL6000, GL7000, GL9000, GL11000, WSMSPECIFICATIONS* Conversion Formula : HP = kW, PS = kWW1030469 ModelGL7000-USAGL7000-USA-TMGL7000-STDG eneratorFrequency60 HzRated kWMaximum kWRated voltage120 / 240 V110 / 220 VRated current / / APhrase and wire1 - 4 Number of poles2 Power Factor1 InsulationStator coil: B Rotor coil: FEngineDesignVertical, liquid cooled, 4 cycle, dieselModel nameZ482-E2B-SEC-3 Rated kWSpeed3600 min-1 (rpm)Number of cylinder - Bore x Stroke2 - 67 x 68 mm (2 - x in.)

7 L ( )Fuel tank capacity28 L ( )Crankcase oil L ( )Starting systemElectric type 12 V / kWBattery38B20R 12 V x 28 Ah / 5 HrContinuous operating hours (at rated load)10 hrsNet weight kg (lbs)235 kg (518 lbs)OutputReceptacleL14-30RL6-30RL5-30R5 -20RA (GFCI)5-20RA (GFCI)5-15R x 2 Terminal 3 PKiSC issued 05, 2015 A8GL6000, GL7000, GL9000, GL11000, WSMSPECIFICATIONS* Conversion Formula : HP = kW, PS = kWW1030823 ModelGL9000-STDGL9000-AUSG eneratorFrequency50 HzRated kWMaximum kWRated voltage220 V240 VRated current APhrase and wire1 - 2 Number of poles2 Power Factor1 InsulationStator coil: B Rotor coil: FEngineDesignVertical, liquid cooled, 4 cycle, dieselModel nameD722-E2B-SEC-2 Rated kWSpeed3000 min-1 (rpm)Number of cylinder - Bore x Stroke3 - 67 x 68 mm (3 - x in.) L ( )Fuel tank capacity28 L ( )Crankcase oil L ( )Starting systemElectric type 12 V / kWBattery55B24R 12 V x 36 Ah / 5 HrContinuous operating hours (at rated load) hrsNet weight kg (lbs)280 kg (617 lbs)OutputReceptacle6-15R 215A 3 Terminal2P KiSC issued 05, 2015 A9GL6000, GL7000, GL9000, GL11000, WSMSPECIFICATIONS* Conversion Formula : HP = kW, PS = kWW1031698 ModelGL11000-USAGL11000-USA-TMGL11000-ST DG eneratorFrequency60 HzRated kWMaximum kWRated voltage120 / 240 V110 / 220 VRated current / / APhrase and wire1 - 3 Number of poles2 Power Factor1 InsulationStator coil: B Rotor coil: FEngineDesignVertical, liquid cooled, 4 cycle, dieselModel nameD722-E2B-SEC-2 Rated kWSpeed3600 min-1 (rpm)Number of cylinder - Bore x Stroke3 - 67 x 68 mm (3 - x in.)

8 L ( )Fuel tank capacity28 L ( )Crankcase oil L ( )Starting systemElectric type 12 V / kWBattery55B24R 12 V x 36 Ah / 5 HrContinuous operating hours (at rated load)7 hrsNet weight kg (lbs)280 kg (617 lbs)OutputReceptacleCS6369 (50 A)L6-30RL5-30R5-20R (GFCI) 25-20R (GFCI)5-15R 2 KiSC issued 05, 2015 A10GL6000, GL7000, GL9000, GL11000, WSMDIMENSIONSDIMENSIONSW1038971GL6000-ST D, GL6000-AUS,GL7000-STD, GL7000-USA, GL7000-USA-TMGL9000-STD, GL9000-AUS, GL11000-STD,GL11000-USA, GL11000-USA-TML1066 mm ( in.)1281 mm ( in.)W618 mm ( in.)618 mm ( in.)H698 mm ( in.)698 mm ( in.)KiSC issued 05, 2015 ACONTENTSGENERAL1. G-1[1] MODEL NAME AND ENGINE SERIAL NUMBER .. G-1[2] E4B G-2[3] CYLINDER NUMBER .. G-32. G-43. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND G-5[1] WIRING .. G-5[2] G-7[3] G-7[4] G-7[5] HANDLING OF CIRCUIT G-84. LUBRICANTS, FUEL AND COOLANT .. G-95. TIGHTENING TORQUES .. G-11[1] GENERAL USE SCREWS, BOLT AND G-11[2] STUD G-116.

9 MAINTENANCE CHECK G-127. CHECK AND G-14[1] DAILY CHECK .. G-14[2] CHECK POINTS OF INITIAL 50 G-15[3] CHECK POINT OF EVERY 50 HOURS .. G-16[4] CHECK POINT OF EVERY 100 HOURS .. G-16[5] CHECK POINT OF EVERY 200 HOURS .. G-18[6] CHECK POINT OF EVERY 300 HOURS .. G-19[7] CHECK POINT OF EVERY 400 HOURS .. G-19[8] CHECK POINTS OF EVERY 500 G-20[9] CHECK POINT OF EVERY 800 HOURS .. G-22[10]CHECK POINT OF EVERY 1000 HOURS .. G-23[11]CHECK POINT OF EVERY 1500 HOURS .. G-23[12]CHECK POINT OF EVERY 1 G-24[13]CHECK POINT OF EVERY 2 YEARS .. G-248. SPECIAL G-26 KiSC issued 05, 2015 AG-1GL6000, GL7000, GL9000, GL11000, WSMG GENERAL1. IDENTIFICATION[1] MODEL NAME AND ENGINE SERIAL NUMBERWhen contacting your local KUBOTA distributor, always specifythe model name and serial numbers of both engine and engine model and its serial number need to be identifiedbefore the engine can be serviced or parts replaced.

10 Engine Serial NumberThe engine serial number is an identified number for the is marked after the engine model indicates month and year of manufacture as follows. Year of manufactureW1035676 Alphabet or NumberYearAlphabet or NumberYear42004G201652005H201762006J2018 72007K201982008L202092009M2021A2010N2022 B2011P2023C2012R2024D2013S2025E2014T2026 F2015V2027(1) Model Name(2) Serial Number(3) Engine Model Name and Serial Number(4) GENERATOR Model Name and Serial Number [A] GL6000, GL7000[B] GL9000, GL11000 KiSC issued 05, 2015 AG-2GL6000, GL7000, GL9000, GL11000, WSMG GENERAL Month of D722-5A0001"5" indicates 2005 and "A" indicates , 5A indicates that the engine was manufactured in January, [2] E4B ENGINE[Example : Engine Model Name D902-E4B-XXXX]The emission controls previously implemented in various countries to prevent air pollution will be stepped up asNon-Road Emission Standards continue to change. The timing or applicable date of the specific Non-Road Emissionregulations depends on the engine output the past several years, KUBOTA has been supplying DIESEL engines that comply with regulations in therespective countries affected by Non-Road Emission regulations.