WORKSHOP MANUAL DIESEL GENERATOR J SERIES KiybotaTO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KUBOTA Generator J Series. Its divided into two parts, “Mechanism” and “Servicing”. 1 Mechanism Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing. 1 Servicing Under the heading “General” comes general precautions, check and maintenance and special tools. For each Engine and Generator section, there are troubleshooting, servicing specification lists, checking and adjusting, disassembling and assembling, and servicing which cover procedures, precautions, factory specifications and allowable limits. All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes in all information at any time without notice. Due to covering many models of this manual, illustration being used, have not been specified as one model. October 2000 © KUBOTA Corporation 2000J SERIES, WSM ‘SAFETY INSTRUCTIONS A SAFETY FIRST This symbol, the industry's “Safety Alert Symbol”, is used throughout this manual and decals on the generator itself to warn of the possibility of personal injury. Read these instructions carefully. Itis essential that you read the instructions and safety regulations before you attempt to repair or use this unit Addancer — indicates an imminently hazardous situation which, i not avoided, will result in death or serious injury. Adwannine —:indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Ar caution —:indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. IMPORTANT: Indicates that equipment or property damage could result if instructions are not OTE ives helpful BEFORE SERVICING AND REPAIRING Read all instructions and safety instructions in this manual and on your generator safety decals, Clean the work area and generator. Place 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 cable.JSERIES, WSM ‘SAFETY INSTRUCTIONS. SAFETY STARTING * Do not start the engine by shorting across starter terminals. ‘+ Unauthorized modifications to the engine may impair the function and / or safety and affect engine life. SAFETY WORKING * Do not work on the generator while under the influence of alcohol, medication, o other substances or while fatigued, ‘+ Wear close fitting clothing and safety equipment appropriate 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 more persons, take care to perform all work safely. ‘+ Do not touch the rotating or hot parts while the engine is running, + Never remove the radiator cap while the engine is running, or immediately after stopping. Otherwise, hot water will spout out from radiator. Only remove radiator cap when cool enough to touch with bare hands. Slowly loosen the cap to first stop to relieve pressure before removing completely. ‘+ Escaping fluid (fuel) under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel lines. Tighten all connections betore applying pressure. + Wear a suitable hearing protective device such as earmutts or earplugs to protect against objectionable or uncomfortable loud noises. AVOID FIRES ‘+ Fuel is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in your working area. + To avoid sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last. + Battery gas can explode. Keep sparks and open flame away from the top of battery, especially when charging the battery. ‘+ Make sure that no fuel has been spilled on the engine.J SERIES, WSM ‘SAFETY INSTRUCTIONS VENTILATE WORK AREA * If the generator 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. PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, clothing and cause blindness if splashed into eyes. Keep electrolyte away from eyes, hands and clothing. If you spill electrolyte on yourself, flush with water, and get medical attention immediately. DISPOSE OF FLUIDS PROPERLY * Do not pour fluids into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, electrolyte and other harmful waste. PREPARE FOR EMERGENCIES + Keep a first aid kit and fire extinguisher handy at all times, + Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone.JSERIES, WSM. ‘SAFETY INSTRUCTIONS. SAFETY DECALS @ The following safety decals are installed on the generator. Ha decal becomes damaged, illegible or is not on the generator, replace it. The decal part number is listed in the parts list. Part No. 18901-50902 Part No. G3907-88361 _Part No. 18620-88061 _Part No. G3907-88321 Diesel fuel 4 4 CAUTION 4 CAUTION 4 CAUTION (For Australia) ‘A DANGER Part No. 3907-88311 ‘A DANGER Part No. @3907-88301 ‘CAUTION EO1940EN24801J SERIES, Ws SM ‘SPECIFICATIONS SPECIFICATIONS [50Hz] Mode! “108 108 ane a6 “S10 “aus | sto | AUS “st | Aus | -s1D “AUS Type Revolvng-ield, brush tye ‘separate and self exciton system, AC generator insulation clase Rotor colt F Stator coi 8 Frequency 50 te ‘Standby output 5OKVA (6.0 KW) 8B KVA(e8 KW) 19.2 kVA (19.2 KW) STBKVA (17.6 KW) ima outpat SSRVA (65 KW) BOKWA(@OKN) 12 kVA (2 KW) 6RVA (16K) Vorage Bov | esov | e0v | 240v mov | eaov | 2o0v | mov Generator Rated amperage zson | 229a | asa | saa casa | soon | vara | 6o7A Number of phases Single ‘Number of poles 2 Power factor 700 Model 2a825 SEC 722-5 SEC Di005-86-SEC Vig05-86-5EC Design Number of cylinders Vertical, quid cooled, 4 cycle, diesel engine 2 a 4 Bare x Stoke 67 x68 im (252X268) 76x 73.6mm (2.99%200in) Displacement 479.0m® (29.28 cuin) [719m (49.89 cuin) 7007 en (67.08 cum) | _19950n* (81.46 oun) ‘Combustion system ‘Spherical combustion chamber ‘Compression rato 2a zen Cooling system Pressurized radiator, forced circulation with water pump Engine Lubricating system Forced tubricaton by trochola pump Lubricating of Higher than Gi D cass (APD) ‘Staring system Etectrc ype ‘Stop solenoid Energized 6 stop Energized o wun Battery ‘ae20R SSe2IR 0026R (5) Fuel tank capacity are (28 US.gals, 8.1 Imp. gals) 7oL (20.9US. gals, 17.4 Imp. gals) Cooling system capacity zat (24USqjs.2.0 Imp qis) 3.0L (22USa18.26 Imps) ga (@SUSats.2.9 impqis) 35. (87USqis.3.1 mpqis) ‘Continuous ‘Grankcase ol capacity ‘operating hours (at 3/4 lag) Bab (23U8qis.2.0 Imp.cts) aaL (86USqs.2.0 Impacts) 1904 1354 aL (46US.ts.3.8 impqis) a7L (6.0USqs.5.0 mpqis) 200K 165 Net weight 205 kg (496 bs) 255 kg (662 Ibs) 340 kg (750 65) 360 kg (698 bs) Emergency mechanism With Caster 0p ‘During engine operation, automatic shutdown wil ‘occur when either the ol pressure or the water temperature is abnormal. Option | ‘During engine operation, automatic shutdown vil ‘cur when ether the ol pressure or the water temperature is abnormal or when the fan belt breaks. None wiaa75i80JSERIES, WSM ‘SPECIFICATIONS oda a ms a =O AS 3% AS 3% ms ie even 708, sh ye, separ ard sof- xan asm, AC goto fata Folorcol:F Salo eo B equey we Sante wa @aKW resin ran) aawncirony y [remvira | vonmowm | Sim | ence [gum | aeacenn | conan 5 Voltage 380 415 240 380 V 415V 240 V seov | 415V 240 V 8 Tuber phases Three owe Powerlacer | ®0% me [we 100% wx 100% Hod TBBSES ard Vise ESSEC in ‘ia old ee, aaa borat cylinders 8 4 Borex Sika | —e7RGB aM EHRRETA) Texan (@H0x290m) Displacement 719 cm? (43.89 cu.in.) 1001 em? (61.08 eu in.) 1335 em® (81.46 cu.in.) co Sper combston camber cpr on mi wi ceaieg Presurzed dat ce rcuston wth wat panp 2 ubricating b [ere Faedhirain by rsh pare Lamreang Foran 0 dass (AP Saring ce ype Sata cree We Sion ona | Energie sop Trrgaedio an Baty es8ain 0268) Fuel ank at 73 cacy | _(98USou 81 ip. os) (2000.17 impos) ceoirg 20 ost ast ten eavsae.teineas) | @susas.29impce) j7usqe. 31 npas) rankoaso aa zat a7 sooty Gousas.r0meas) | Wousas.2ampas) (eousas.20mpas) Coninvus opera : : ‘oom hours (at 34 fad) tet Zool eet ewig ag aa) ano Ws) ig WR) Emergency op Tisha erie cpr, | aise cer aden anos wi con vu Thea resent suonatcshoornvllozur | pesare ct nator tnporeuts anemal ron ean ot aks tno omer pssure or trowat ompetie are Waser Orion Tere wi0808040J sens, Wit SPECIFICATIONS [60Hz] 31 | sa | sr | aa | 3 sa | |e we Teoh fe, sh bp: snarls and sof -oxahon yet AC Generar Iton Foto F Sorc 8 rear wore Sante riwncrmm | nowamown | ‘eanaceaum | 2oewaccosnm =| pamesupue ianm | cium | cen | Grskny 3 to Tan TaBKvA 2 (14 RW) (18.8 KW) 3 [Yotage | Wiovaeor [arreaov | iorazav [ er7ze0r | 07ae0y [ver reaav | 707az0v | tr 220” tnomese | avan_| oven | ssa | dean | “soon | cosa | ossa\ | asa Tuber of singe phases "a nber at poles e Powerlacor 0% Hod TERE TEBE eed TROSBESEC Des erica id 0, oe, dese ene borat cylinders | 2 ° 4 Borex Stake e7xeo om @axBCEH) TexTa mm @99x290H) Displacement | 479 em? (29.23 cu.in.) 719 em® (43.89 cu.in.) 1001 em? (61.08 cu.in.) 1335 om® (81.46 cu.in.) com Sper cmbuston camber Conran Cooling Pressurized radiator, forced circulation with water pump sro ‘ 2 S Lubricating ication by trochoid pum & [ee Ford Maton by ocho pum Uabteaing al Figo an GO das BP) Saring Saneg elec wpe Sin soloed Eregied woop EregzedTonn Batory aa a ‘eo0z8h (8) Foetank at 78 cromcy (080s gal 81 pal) (20.008 gun. 17.4 mp.) Cootng 2aL aoL aaL ast " eausge.20mpqs) | o2usq8.20Impqs) | @5USae.28Imeq) | (7USA8.91 megs) Crankaso 2a eat at a7 camcty | @ausae.20imede) | @eusae.20Impste) | MsuSae.a8 tmnds) | [OUSae,e6 Inpde) Gants opr we5H 08H 6.0% we0H wet ETC ass aa) KG OH 304g OH Emergency Sop ing engine pean avonaedutdom wit | Bang ange opaaon aoa Slow wil neste coururen iver ol posure or howata’" | conraan eta tel pes ore wat ‘rears conoma pate sonoma when ean bt es a casi oF noe WiGaaae40JSERIES, WSM ‘SPECIFICATIONS Woda ae we at “ST “310 “ST Tee eval ad bah ye, separate and al erataion to AS goer fata Foloreol:F Stator eo B Frequongy wore Senay trave i) 192 WAGSAKW 250A coon) 3 Prime output 125 RYE (10 KW) 17.5 KVA (14 KW) 23.5 KVA (18.8 KW) B [votage 2a 220V 220 3 Tras fae wan W504 ona Naber phases: Three Number > poss Power wx Mose Drea SEO Diaes-80-3ES Vieas 80SEC Oeson ‘rica cold ce, dese one Nunbora cylinders a a aoe Svoke | e7xGBnm 852x069) TexTaa wm 942007) Displacement 719 cm? (43.89 cu.in.) 1001 cm? (61.08 cu.in.) 1896 om? (81.46 cu.in.) Combustion comb Spec! eombuston canbe Ciel eat 221 ore Pressurized radiator, forced circulation with water pump orem & [waren Force ueaton by wctad pump Taba Tiara 6D aa (AP jean Electric ype beret Sop snd Energize 0 op Treqnedon ay Ssezah 028 (8) Fost ark oe 7 copay (0808.68 mp.) (2090.8 gale 174 inp.) cea aot oat ast ron (e2usas.20impas) (asus. 29Impq) @7usas. 84 mpas) Garkasel aa wat a7 capacity, (3.6U.S.qts., 3.0 Imp.qts.) (4.6U.S.qts., 3.8 Imp.qts.) (6.0U.S.qts., 5.0 Imp.qts.) Ganinous oping : Sentai pea vose teow aon Net weit Bog Rw) erg We) og aR) Erergony sp Ding engne opto, extort | Dung engine open, ea eldown wl ou when eter fecha thuzentecocrwnnamer” | elpressue xe wl empertre aor or wen fan al thootprecsuoartewaer”” | teas tnpete noal win Cason Opto Tee wi0aso270J SERIES, WSM DIMENSIONS DIMENSIONS 019407224601 ‘J108-STD,-AUS | J112-STD,-AUS | J116-STD, -AUS oo J106-STD,-AUS | J110-STD,-SA_— | J1148TD,-SA__| J119-STD, -SA J107-STD,-SA _| J310-STD,-AUS | J315-STO,-AUS | J320-STD, -AUS 4§313-STD 4§318-STD §824-STD Length ram (in.) 903 (86.4) 995 (39.2) 1216 (47.8) 1300 (67.1) Wieth mam (in) 599 (23.3) 593 (23.3) 611 (24.1) 611 (24.1) Height mm (in.) 860 (83.8) 860 (83.8) 922 (36.3) 922 (36.3) wro2r052er ASI) CONTENTS 1. GENERATOR (1) (2) (3) (4) (5) ‘STRUCTURE, AUTOMATIC VOLTAGE REGULATOR (A.V.R.) EMERGENCY RELAY CIRCUIT. (1) General (2) Instructions. (3) Flow Chart EARTH WIRING DIAGRAM. Mt Mat M2 Med Med MS M7 M9 M10J SERIES, WSM GENERATOR 1. GENERATOR [1] STRUCTURE EO1940EN24901 (1) Rear Cover (6) Stator Assembly (9) Fan (2482 only) (AVR. Assembly (6) Stator Housing (@) Brush Holder Assembly (7) Rotor Assembly (4) Rear Bracket (@) Fan 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 The sub coil, working as an excitation coil, supplies the field current to the rotor through A.V.R. assembly. 2, Rotor Assembly The coils are wound to magnetize the entire core. 3, Brush Holder Assembly The excitation voltage from sub coil of the stator assembly is applied to the rotor coil through the A.V.R. assembly rectifying circuit and the brush holder assembly. 4, Automatic Voltage Regulator (A.V.R.) Assembly The A.V.R. assembly maintains the AC output voltage at a constant level.JSERIES, WSM GENERATOR [2] AUTOMATIC VOLTAGE REGULATOR (A.V.R.) m NOTE + It is hazardous to proceed to any high voltage test on the alternator without having previously isconnected all connections to voltage regulator. Damages occurring to A.V.R. in such conditions will not be consid id in a warranty clai (ave, (2) Capacitor {@) Silcon Diode Stack (@) Separate Excitation Unit wrorsessJ SERIES, WSM GENERATOR The block diagram of J Series A.V.R.’s is shown below. The A.V.R. consists basically of the components detector (12) through transistor (4). To run it for practical use, the other components separate excitation unit (14) through battery (16) are combined. o & | 3) (8) “4 oJ (6) 7 i 501 (1) Exciter Cot (6) Orve Circuit (@) Ught Emiter (13) Detection Colt (2) Recitier (6) Photocoupler (10) Controller an arive (14) Separate Excitation Unit (9) Rotor Cot @) Light Recelver separately grounded (18) Key Switch (@ Transistor (@) Light Signal (11) Controter (16) Battery (12) Detector wior7260 (1) Detector The detector (12) monitors the generator’s output voltage. The generator's detection coil (13) is connected to this component. (2) Controtter The controller (11) is designed to compare the voltage picked up by the detector (12) with the preset reference voltage and to give a transistor ON and OFF signal to the drive circuit (5). When the output voltage rises too high, it is made to drop; i it drops too low, it is made to rise. (3) Photocoupler The photocoupier (6) sends a control signal to the drive circult (6). Its internally composed of light emitter (9) and light receiver (7) to send and receive light signals (8). Because of such wireless transmission, the light emitter circuit and the light receiver circuit can be electrically insulated from each other (10). On the A.V.R., the drive circuit (5) with the exciter coil (1) connected and the controller (11) with the detection coil (13) hooked up are insulated as different blocks on the circuit board. (The printed patterns of these blocks may also be arranged at a physical distance away from each other.) The photocoupler (6) itself is driven by the detection coil (13). (4) Drive circuit The drive circuit (5) is basically composed of muttiple transistors. The drive signal being picked up by the photocoupler's light receiver is weak. To intensify this signal, the final-stage transistor (4) that switches on and off the Current to the rotoris activated. For comparison, let's imagine a gearbox that gives a large torque from a small force, While the engine is stopped or in the low rpm range - that is, the generator voltage is not yet established, the drive circuit (5) behaves to keep the transistor (4) fully on. Relays behave the same way. The separate excitation unit (14) to be connected to the drive circuit (5) works to provide for the turning on condition. When the key switch (15) is turned on, the separate excitation unit (14) applies the battery voltage to the drive circuit (5), which in turn gets ready. In “Controller (11)" we discussed ‘When the output voltage rises too high, itis made to drop; fit drops too low, itis made to rise. “The higher the engine rpm becomes, the higher the generators output voltage rises. With the transistor (4) fully on, the generator’s output voltage would be too high. To cope with this problem, the controller (11) serves to limit the transistor’s (4) on-status to a lower range. In other words, the drive circuit (5) would not work if no signal would M3JSERIES, WSM GENERATOR come from the separate excitation unit (14). Let's take an example of a car engine. The separate excitation unit (14) is equivalent to a fuel cut-off solenoid valve. With this unit running, the valve stays fully open. The rpm is controlled by a governor, to which the drive circuit (5) is equivalent. Once the fuel cut-off solenoid vaive gets closed, the engine stops. Inthe same way, ifthe separate excitation unit (14) is not connected (no battery voltage applied), the generator is interrupted. (6) Transistor AAs discussed in “Drive circuit (5)" the transistor is designed to switch on and off the rotor current and to adjust the | Key switch “OFF ' +) stop solenoid is released. y Fuel is cutoff y Engine stops. E01940EN15201,J SERIES, WSM [4] EARTH EO 940ENI9101 GENERATOR electric shock, connect a grounding cable to the ground terminal and ground it as ‘shown in the figure. Use a 3 mm? or larger copper 1g cable whose grounding resistance is below 100. Ground the generator as much as possible. The end user, equipment owner or operator must ‘contact his local, state, county or municipal electric code department to determine the approved generator grounding method to be used in his application or location. 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: (1) Generator Ground Terminal (2) #6 AWG Flexible Copper Ground connection {@) Metal Ground re or Bulking Cold Water Pipe system Por NEC. Cora wroreattoGENERATOR JSERIES, WSM [5] WIRING DIAGRAM om vu = -| “| apn aes fom a M10 01940EN24001 ([yoveaN39] 4GENERATOR J SERIES, WSM | | | | | I | | u J112-STD Outside Ott trae ros ges vlae | EO1S40ENZ5001 MeatGENERATOR JSERIES, WSM J116-STD (3N19N3] Te anne a EO1940EN25101 M2GENERATOR J SERIES, WSM eo 189 oxo mymuen | wee] uw aerate arene | eal peo ba a1 ene tee ett areal ae | Lo. sis & oo0 dal T eee om wore (apa 7 oa [x08 0¥1NOo] ‘J310-STD sf=toly) Tm woRN a aE Guiana hel} (a Fb“ ' (yO. veBNGO] po LL MagGENERATOR JSERIES, WSM WS a J315-STD J320-STD | (aNI9Na) Te anne a EO1840EN25901 M14GENERATOR J SERIES, WSM co J este a ay & i aL ee ’ “ai Ooo) fo Fa 2 | i 5 or esa 7 i = i in aon ae IB | 2 sions: ae of ” io | 8 7 i (408 70¥1N001 (ou v¥3N9) MasGENERATOR JSERIES, WSM ‘J108-AUS (x09 T0¥LNoo) cue em pater mem (beth (led) Pls “id to 9010 J [E01 940EN2550%, (o1va3N30) L. M16GENERATOR J SERIES, WSM Outside Ott trea freee: st of L.. EOT@40EN25601 MazGENERATOR JSERIES, WSM ilases. a pe my woman so dwt sare B00) wee Ab ocae BE [yo.vuaN30] ee Grog Towne eee E01940EN25701 M18GENERATOR J SERIES, WSM Outside Ott trae J315-AUS 2! 8 oat Elan) ala E01940EN5801 MagGENERATOR J107-STD J110-STD JSERIES, WSMGENERATOR J SERIES, WSM J114-STD ee 0000 ar cone 2-99 MatGENERATOR JSERIES, WSM J119-STD fete 0000 fey See Te anne a =f [x08 OMINOD] se EO1S40EN26101GENERATOR J SERIES, WSM J313-STD hs 5 -eSEIEl ar wenwiae (ap es ata M23GENERATOR JSERIES, WSM ! IDK] Sad dies et A ni Te anne a J318-STD J324-STDGENERATOR J SERIES, WSM (x08 10¥1N001 * CuouveaN301 L.____ 0408 TOUNOO) EOISMOEND0) M25GENERATOR JSERIES, WSM tse tpt arena 1 game wns J114-SA (3N19N3] Te anne a EO1840EN26501GENERATOR J SERIES, WSM J119-SA Outside Ott trea na M271 SERVICING CONTENTS GENERAL (1) (2) (3) (4) 6) (6 7 (8) (9) GENERAL IDENTIFICATION PRECAUTION. LUBRICANTS, FUEL AND GOOLANT TROUBLESHOOTING (1) Generator. (2) Engine SERVICING SPECIFICATIONS (1) Generator. (2) Engine (2482, 0722] (3) Engine [D1005, v1305) TIGHTENING TORQUES (1) Tightening Torques for Special Use Screws, Bolts and Nuts (2) Tightening Torques for General Use Screws, Bolts and Nuts MAINTENANCE CHECK LIST CHECKING AND MAINTENANCE (GENERATOR) (1) Generator. (2) Engine. SPECIAL TOOLS. GENERATOR, Ol a ENGINE o ai (3) (4) 6) DISASSEMBLING AND ASSEMBLING... (1) External Component .. (2) Generator. SERVICING (1) Terminal Voltage for Each Part During Normal Periods (No-load Periods). (2) Stator Coil (3) Rotor Coil. (4) Exciter Coil (5) Control Panel (6) Emergency Relay Activates ENGINE BODY (1) Checking and Adjusting (2) Disassembling and Assembling... (3) Servicing... LUBRICATING SYSTEM... (1) Checking (2) Servicing COOLING SYSTEM (1) Checking and Adjusting (2) Disassembling and Assembling. FUEL SYSTEM (1) Checking and Adjusting (2) Disassembling and Assembling. ELECTRICAL SYSTEM.. (1) Checking (2) Disassembling and Assembling (3) Servicing 8-34 eevoovon SESS98RR woe 8ss ”J SERIES, WSM 1. GENERAL GENERAL [1] GENERAL IDENTIFICATION 1 Lo 1. Ay i @ = } ore4oencoeot [EO1940EN21101 When contacting your local KUBOTA distributor, always specify the model name and serial numbers of both engine and generator. (1) Generator Seria Number (2) Generator Modot Name (8) Engine Model Name and Serial Number wit787s80JSERIES, WSM GENERAL [2] PRECAUTION “ EO1940EN13201 01940EN20000 (e) fla fel Wi Vb, + During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws and nuts should be installed 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. + Before disassembling or servicing electrical wires, always disconnect the ground cable from the battery first ‘+ Remove oil and dirt from parts before measuring, + Use only KUBOTA genuine parts for parts replacement to maintain generator sets performance and to assure safety. + Gaskets and O-rings must be replaced during reassembly. Apply grease to new O-rings or oil seals before assembling. ‘+ When reassembling external snap rings or intemal snap rings, they must be positioned so that sharp edge faces against the direction from which a force is applied. See the figure lett. + Use only metric tools when servicing this machine, Metric sctews, bolts and nuts are not interchangeable with nonmetric fasteners, (1) Grease (A) External Snap Ring @) Force {) intemal Snap Ring wi1793520 ‘+ Before checking any generator or engine electrical component, be sure to check that all terminals and connectors are tight. ‘+ After the individual component inspection, also inspect the wire leads for continuity; that might be the cause of the problem. ‘+ The rotor and stator must be protected when disassembling and reassembling, It they are damaged, no power can be generated. + To maintain the generator’s performance and ensure safety, use only KUBOTA genuine parts for replacement. + Use extreme caution when working on electrical components. Electrical shocks cause injury or death. wi r801 160ISERIES, wSM GENERAL [3] LUBRICANTS, FUEL AND COOLANT tem Model Capacity Grade 220 ep (23USa's) Higher than CD class (API) , (2.0 Impacts.) Above 25 °C (77 °F) S108-STD, “AUS yt SAE10W-30 J110-8T0, SA gens SAE10W-30 J810-STD, -AUS fo impcts} SAE30 4313-STD me 01025 °C (82t0 77°F) Engine Oil Ji12-STD, -AUS aoe SAE10W-30 JN14-STD, -SA 1 at SAE10W-40 J318-STD, -AUS fost SAE20 318-STD a Below 0 °C (32 °F) Ji6-STD, -AUS S7L SAE1OW-30 J119-STD, -SA SAE10W-40 4J320-STD, -AUS. (6.0 US.ats,) SAE10 yorstD (6.0 Imp.cts.) J106-STD, AUS J107-STD, -SA aa J108-STD, -AUS SigeTD AGA (9.8USgals.) 4310-STD, AUS (6:1 Imp.gate.) 4313-87 Diese! fue! No.2-D oy J112-STO, -AUS [No.1-D diesel vel, it JM14-STD, -SA temperature is below J315-STD, -AUS 10°C (14 °F] 4318-STD 7OL J116-STD, -AUS (20.9 USals.) J119-STD, -SA (17.4 imp.gats.) J320-STD, -AUS. 4324.STD 23L J106-STD, -AUS pO (2.4USq's,) J107-STD, -SA oles) J708-STO, “AUS i 3.0L J110-STD, -SA 4310-STD, AUS (g2USas) ieigterD (26 imp.cts.) ean ater Sot wate lean water (Soft water Coolant aerione 3.3L Use antifreeze 50/50 J114-STD, -SA Beeee J318-STD, -AUS. g ats.) J318-STD (2.9 Imp.ats.) J116-STO, -AUS i 3.5L J119-STD, -SA 1J320-STD, -AUS. (37 US.ats,) Ja2a-sTD (3-1 Imp.ats.) wsto1087 83JSERIES, WSM [4] TROUBLESHOOTING (1) Generator m@ NOTE GENERAL ‘+ In order to replace the parts in safety, remove negative terminal of battery so as to prevent the battery and the parts from short-circuiting. + To avoid errors on delivery of spare parts, all information marked on nameplates should be supplied on parts orders, in particular model and serial number of the alternator. Also give the parts numbers from the parts list. (A) Evident Physical Defects (Overheating, Noise, Vibrations...) Fault Action Origin of fault Excessive overheating of bearing (temp. of bearing over 80°C (176 °F)) (With or without abnormal bearing noise). Replace bearing. ifthe bearing has tumed blue or ifthe grease has turned blaok,change the bearing, Bearing race badly locked (moving in its housing). Bracket misalignment. Excessive overheating of alternator frame (temperature 30 °C (8 °F) above ambient) Check + Airinlets and outlets of alternator. + Measuring equipment (Voltreter-Ammeter) + Ambient temperature. Air fiow (inlet-outlet) partially clogged or hot airis being recycled either from alternator or prime mover. ‘Alternator overloaded Fan belt slips. Excessive vibration and humming noise coming from the alternator. Alternator damaged by a significant impact which is followed by humming and vibration. Stop the gen-set and check the installation and others, Three phase alternator is single phase loaded in excess of acceptable level ‘Start up with no-load: if humming persists.. ‘Stop the gen-set immediataly. ‘Short-circuit in the alternator stator. Short-circuit in external circuit. Break or deterioration in the coupling, Break or twist in shaft extension. Shifting or short-circuit of the main field winding. Bursting or unlocking of the fan. Diode bumt, regulator, rectifier bridge damaged. ‘Smoke, sparks of flames issuing from the alternator. Stop the gen-set immediatzly. ‘Short-circuit in external circuit (including wiring between alternator and control board). Object fallen into the machine. Short-circuit or flash in stator winding wive72080J SERIES, WSM GENERAL (B) Voltage Faults (Single Phase) Measurement Trouble Checking Method Operating Possible Cause Countermeasure Condition Volimeter | Measure the vollage | Output vollage | Gircult breaker (NFB)is | Set the cioult breaker to indicates | at the output terminal | is 0 V. OFF. ON. iit goes OFF normal using a circuit tester. again, check the cause voltage but | 250 V at AC range (overload, shor circuit, no output etc.) voltage is Set the circut breaker to delivered. ON aiter removing the cause. Improper contact of NFB | Repair or replace or each terminal. Disconnected wiring Check wiring repair {inside the control box). Volimeter | Same as above. Output valage | Disconnected main coll. | Repair or replace een Beene ca eee Disconnected wiring. Repair or replace voltage and Oniy slight | Disconnected rotor coil. | Repair or replace also output output volage | Excessive wear of bush | Replace brush and lean voltage is not is delivered or improper contact of it. | the contact surface of it delivered. 2to4v Defective slip ring. (100 to 120 v) 4t08V Disconnected exciter coll_| Repair or replace (220 t0 240 V). | Defective AVA Replace Disconnected battery. | Connect battery NFB ‘Same as above. Output Abnormality of loading Locate the cause (Short- goes OFF. voltage is circuit. circuit overloaded etc.) normal 95 to and remove it. oo %otrated | improper connection of | Correct the connection vole. jumper plate. Rated ‘Check the variation | Varialion of | Detective capacitor with | Replace AVA. outputis | of engine revolution or | engine speed | AVA. not frequency when is normal i rel Fi available. ‘engine is loaded or (within 10%). | ATBroper contact of jepalr not. AMAR. connector. Defective brush and slip ring Cleaning, repair, replace Variation of | intial current is excess. | Locate the cause and engine speed remove it GereeseNs | Lowered engine output. | Repair engine Defective engine Repair engine governor. ‘Same as above. Output ‘Short-circuit of main coil Repair or replace voltage is 80% | or sub coil of rated output or less. Output ‘Short-circuit of rotor coil. Repair or replace voltageismore | Defective AVA. Replace than 130 % of rated output. wite7220J SERIES, WSM GENERAL (C) Voltage Faults (Three Phase) Measurement Trouble Checking Method Operating Possible Cause Countermeasure Condition Volimeter | Measure the vollage | Output voliage | Cireut breaker (NFB) s_| Set the ciroult breaker to indicates | at the output terminal | is Vor all | OFF. ON. WVitgoes OFF again, normal using a cicuittester. | three phases. check the cause voltage but (overload, shor circuit, nooutput | ALAC range etc) voltage is | 250 Vor 500 V Set the circuit breaker to delivered, ON aiter removing the Terminals between cause. ental Defective contact of Replace peu circuit breaker. ‘OViorone | Defective contact of Replace phase only. | circuit breaker. ‘Two other Discontinuity in one Repair or replace the phases are phase. iarae normal Voltmeter | Same as above. ‘OV output | Discontinuity n output | Repair or replace the doesnot | Set the circuit forallthree | coil stator indicate breaker to ON. phase. ‘Simultaneous shorting of | Inspect the stator or any voltage tree phases. wiring. and also no output ‘OViorone | Discontinuity in one Repair or replace the voltage is phase only. phase. stator, delivered, Discontinuity in wiring. | Repair Slight voltage | Discontinuity in rotor coil. | Repair or replace the ‘output for all rotor. ee erases. | Wear or defective Clean brush contact 10 4 (phase | contact of brush surface and sip ring voltage). surface, or replace the brush. Discontinuity in sub-coil.| Repair or replace the stator. AM.R. failure. Replace Disconnected battery. Connect battery wi98623