Kubota J112-STD, J108-STD, J110-STD, J114-STD, J107-STD Operator's Manual

...

G3907-8911-5

ENGLISH

To prevent electrical shock the following instruction must be followed.

Before the generator can be connected to a building’s electrical system, a licensed 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 or injure line maintenance personnel. Also, generator and building electrical system damage can occur when normal operating power returns if unit is used without an isolation switch.

WARNING

FOREWORD

You are now the proud owner of a KUBOTA Diesel Engine Generator. This generator is a product of KUBOTA quality engineering and manufacturing. It is made of fine materials and under a rigid quality control system with correct maintenance. It will give you long, satisfactory service. To obtain the best use of your generator, please read this manual 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 The immediate use of new techniques in the manufacture of products may cause some small parts of this manual to be outdated.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 most up-to-date information. Please do not hesitate to consult with them.

ENGLISH

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 attempt to assemble or use this unit.

3 3 3

IMPORTANT : Indicates that equipment or property damage could result

NOTE : Gives helpful information.

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, may result in minor or moderate injury.

if instructions are not followed.

SAFETY FIRST

CONTENTS

SAFE OPERATION .................................................................................................. 1

SERVICING OF GENERATOR....................................................................................1

SPECIFICATIONS .......................................................................................................2

1 Phase Type ................................................................................................................... 2

3 Phase Type ................................................................................................................... 5

NOMENCLATURE ....................................................................................................... 8

Control Panel.................................................................................................................. 10

Easy Checker ................................................................................................................. 13

Control Box.....................................................................................................................13

PREPARATION TO SUPPLY THE ELECTRIC POWER...........................................14

CONNECTING THE LOAD ........................................................................................16

Connection Notes........................................................................................................... 16

Connecting the Load (Standard Model) ......................................................................... 16

Connecting the Load (AUS Model)................................................................................. 18

HANDLING THE CIRCUIT BREAKER.......................................................................19

Handling the Circuit Breaker (Protector) (Australian model) .......................................... 19

PRE-OPERATION CHECK ........................................................................................20

DAILY CHECK........................................................................................................20

Battery ............................................................................................................................ 20

Engine Oil....................................................................................................................... 21

Coolant ........................................................................................................................... 21

Fuel ................................................................................................................................ 21

ENGLISH

OPERATING THE GENERATOR .............................................................................. 22

Starting the Engine......................................................................................................... 22

Cold Weather Starting .................................................................................................... 24

Stopping the Engine ....................................................................................................... 25

If the Engine Fails to Stop in the Usual Procedure (EMERGENCY STOP) ................... 25

MAINTENANCE ......................................................................................................... 27

SERVICE INTERVALS ...........................................................................................27

PERIODIC SERVICE .................................................................................................29

FUEL ...................................................................................................................... 29

Fuel Level Check and Refueling .................................................................................... 29

Air Bleeding the Fuel System ......................................................................................... 30

Checking the Fuel Pipes ................................................................................................ 31

Cleaning the Fuel Filter Pot ............................................................................................ 31

ENGINE OIL ........................................................................................................... 32

Checking Oil Level and Adding Engine Oil..................................................................... 32

Changing Engine Oil ...................................................................................................... 33

Replacing the Oil Filter Cartridge ................................................................................... 34

AIR CLEANER........................................................................................................34

Cleaning Secondary Air Filter Element .......................................................................... 34

Cleaning Primary Air Filter Element ............................................................................... 35

Evacuator Valve ............................................................................................................. 35

For the Air Cleaner with a Dust Cup............................................................................... 35

RADIATOR ............................................................................................................. 36

Checking Coolant Level, Adding Coolant....................................................................... 36

ENGLISH

CONTENTS

Changing Coolant........................................................................................................... 37

Remedies for quick decrease of coolant ........................................................................ 37

Checking Radiator Hoses and Clamps .......................................................................... 38

Precaution Overheating.................................................................................................. 38

Cleaning Radiator Core (outside) ................................................................................... 38

Cleaning the Radiator..................................................................................................... 38

Anti-freeze ...................................................................................................................... 38

BATTERY ............................................................................................................... 39

Battery Charging ............................................................................................................ 39

Instructions for Long Term Storage ................................................................................ 41

Battery Boost Starting .................................................................................................... 41

ELECTRIC WIRING ............................................................................................... 41

PERIODIC SERVICING AND CLEANING OF THE GENERATOR........................42

FUSE ...................................................................................................................... 44

FAN BELT ..............................................................................................................45

Adjusting Fan Belt Tension ............................................................................................ 45

TRANSPORTING / STORAGE ..................................................................................46

Transporting ................................................................................................................... 46

Storage........................................................................................................................... 46

TROUBLESHOOTING ...............................................................................................47

Generator .......................................................................................................................47

Easy Checker ................................................................................................................. 48

Engine ............................................................................................................................ 48

AUTOMATIC START/STOP UNIT (A S/S UNIT) ....................................................... 50

WIRING DIAGRAM .................................................................................................... 51

SAFE OPERATION

Careful operation is your best insurance against an accident. Read and understand this operator’s manual carefully before operating the generator. All operators, no matter how much experience they may have had, should read this manual and all labels on the generator before operating the generator. It is the owner's responsibility to instruct all operators in safe operation.

Be sure to observe the following for safe operation.

OBSERVE SAFETY INSTRUCTIONS

A Read and understand carefully this OPERATOR'S

MANUAL and LABELS ON THE GENERATOR before attempting to start and operate the generator.

A Learn how to operate 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.

1SAFE OPERATION

ENGLISH

WEAR SAFETY CLOTHING

A DO NOT wear loose, torn or bulky clothing around the

generator that may catch on working controls and projections causing personal injury.

A Use additional safety items, e.g. hard hat, safety

protections, gloves, etc., as appropriate or required.

A DO NOT operate generator or any equipment attached to

it while under the influence of alcohol, medication, or other substances, or while fatigued.

A DO NOT wear radio or music headphones while

operating the generator.

SAFE OPERATION2

CHECK BEFORE OPERATION & STARTING THE ENGINE

ENGLISH

A Always turn off the circuit breaker and all switches for the

electrical devices before starting the generator.

A Check the wiring and connections of the electrical

devices before starting the generator.

A Be sure to check the engine before operation. If

something is wrong with the engine, repair it immediately and before operation.

A Keep all guards and shields in place before operating the

generator. Replace any that are damaged or missing.

A Check to see that bystanders are in a safe distance from

the generator before starting.

A Always keep the generator at least 1 m away from

buildings and other facilities.

A DO NOT allow children or livestock to approach the

generator while the engine is running.

A DO NOT start the engine by shorting across starter

terminals or bypassing normal starting circuit. The generator may start unexpectedly causing electric shock to others.

HANDLING 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 wiring are in good

condition. Bare wire or frayed insulation can cause dangerous electrical shock, burns or death.

A DO NOT use the generator in damp or wet conditions.

Handling terminals and cables with wet hands can result in personal injury or death.

A Always shut the engine off and allow to cool before

cleaning. Use water sparingly when cleaning the outside of the generator. Make sure that water does not splash onto the electrical system or into the generator.

A DO NOT touch the generator with wet hands. You may

get an electric shock that can cause burns or death.

A DO NOT connect this generator to any building's

electrical system unless an isolation switch has been installed by a licensed electrician.

A DO NOT run other generators in parallel.

KEEP THE AREA AROUND THE ENGINE CLEAN

A Be sure to stop the engine before cleaning. A Keep the engine clean and free of accumulated dirt,

grease and trash to avoid a fire. Store flammable fluids away from sparks and fire.

A DO NOT stop the engine without idling. Sudden stops

can cause temperatures around the engine to rise suddenly. Keep the engine idling for about 5 minutes before stopping.

SAFE HANDLING OF FUEL AND LUBRICANTS

A Always stop the engine before refueling and/or

lubricating.

A DO NOT smoke or allow flames or sparks in the working

area. Fuel is extremely flammable and explosive under certain conditions.

A Refuel only when the engine has cooled off. Refuel in a

well ventilated and open place. When fuel and lubricants are spilled, clean them up before starting the engine.

A DO NOT mix gasoline or alcohol with diesel fuel. The

mixture can cause a fire and damage engine components.

A Operate the generator on a firm and level surface only.

DO NOT tilt or move the generator while it is running since this can cause fuel spillage.

3SAFE OPERATION

ENGLISH

SAFE OPERATION4

EXHAUST GASES & FIRE PREVENTION

ENGLISH

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 without proper ventilation.

A DO NOT operate the generator where the building or

other obstructions block off air circulation or where exhaust gas can accumulate.

A The exhaust gas from the muffler is very hot. To prevent

a fire, DO NOT expose to dry grass, papers, oil and any other combustible materials to exhaust gas. Also, keep the engine and muffler clean at all times.

A To avoid fire, be alert for leaks of flammables from hoses

and lines. Be sure to check for leaks from hoses or pipes, such as fuel and engine oil by following the maintenance check list.

A To avoid a fire, DO NOT short across power cables and

wires. Check to see that all power cables and wiring are in good condition.

A Keep all power connections clean and tight. Bare wire or

frayed insulation can cause a dangerous electrical shock and personal injury.

HANDS AND BODY AWAY FROM THE ROTATING PARTS

A DO NOT operate the generator with the side covers

removed or open. Serious personal injury may result if fingers or clothing are caught in the rotating parts.

A Be sure to stop the engine before checking or adjusting

belt tension and cooling fan.

A To avoid personal injury, keep your hands and body

away from the rotating parts, such as cooling fan, V-belt, fan drive V-belt, pulleys or flywheel.

A DO NOT run the engine with installed safety guards

detached. Install safety guards securely before operation.

ESCAPING 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

penetrate skin causing serious personal injury.

A Fluid escaping from pinholes may be invisible.

Use a piece of cardboard or wood to search for suspected leaks: DO NOT use hands or body. Use safety goggles or other eye protection when checking for leaks.

A If injured by escaping fluid, see a medical doctor at once.

This fluid can produce gangrene or severe allergic reaction.

5SAFE OPERATION

ENGLISH

SAFE OPERATION6

CAUTIONS AGAINST BURNS & BATTERY EXPLOSION

ENGLISH

A To avoid burns, be alert for hot components, e.g. muffler,

muffler cover, radiator, pipes, hoses, engine body, coolant, engine oil, etc. during operation and just after the engine has been shut off.

A DO NOT remove the radiator cap while the engine is

running or immediately after stopping. Otherwise hot water from the radiator will escape under pressure causing injury by scalding. Wait for more than 10 minutes to allow the coolant to cool down, before removing the cap.

A Make sure to close the drain valve of coolant and engine

oil, close radiator pressure cap and tighten hose clamps before operating. If any of these parts are taken off, or left loose, serious personal injury can result.

A The battery presents an explosive hazard. When the

battery is being activated, hydrogen and oxygen gases are extremely explosive.

A Keep sparks and open flames away from the battery,

especially when charging the battery. DO NOT strike a match near the battery.

A DO NOT check battery charge by placing a metal object

across the terminals. Use 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 C (61 F) 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 cause an explosion. Add distilled water until the fluid level

CONDUCTING SAFETY CHECKS & MAINTENANCE

A Know how to stop the generator quickly, and understand

operation of all the controls. DO NOT permit anyone to operate the generator without proper instruction.

A When checking engine or servicing, place the generator

in an open area and level ground. DO NOT work on anything that is supported ONLY by lift jacks or a hoist. Always use blocks or safety stands to support the generator before servicing.

A Detach the battery from the generator before conducting

service. Put a “DO NOT OPERATE!” tag on the key switch and remove the key to avoid accidental starting.

A To avoid sparks from an accidental short circuit, always

disconnect the battery’s ground cable (-) first and connect it last.

A Sulfuric acid in battery electrolyte is poisonous. It is

strong enough to burn skins and 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.

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 in good condition when performing any service work. Make sure that you understand how to use the equipment before servicing.

A Use ONLY the correct engine flywheel rotating

techniques for manually rotating the engine. DO NOT attempt to rotate the engine by pulling or prying on the cooling fan or V-belt. This practice can cause serious personal injury or premature machine damage to the cooling fan.

A Replace fuel, lubricant and coolant hoses with their hose

clamps every 2 years or earlier if required. They are made of rubber and deteriorate over time whether used or not.

A When servicing is performed together by two or more

persons, take care to perform all work safely.

A Keep first aid kit and fire extinguisher handy at all times.

7SAFE OPERATION

ENGLISH

SAFE OPERATION8

DANGER, WARNING AND CAUTION LABELS

ENGLISH

Pay special attention to all labels on the generator. Refer to following representations for labels used on the J-Series Generator. Labels are available individually from your KUBOTA Dealer.

(1) Part No. G3907-8832-0 (2) Part No. G3907-8830-0

(3) Part No. G3907-8836-0 (4) Part No. G3907-8831-0

(5) Part No. 18901-5090-2

(6) Part No. G3907-8824-0

(7) Part No. 18620-8806-0 (8) Part No. G3907-8833-0

9SAFE OPERATION

ENGLISH

For the Z482 or D722-mounted machines only.

SAFE OPERATION10

CARE OF DANGER, WARNING AND CAUTION LABELS

ENGLISH

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 from your local KUBOTA Dealer.

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 replaced component.

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

SERVICING OF GENERATOR

Your dealer is interested in your new generator and has the desire to help you get the most value from it. After reading this manual thoroughly, you will find that you can do some of the regular maintenance yourself. However, when in need of 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.

1SERVICING OF GENERATOR

ENGLISH

Model Serial No.

Generator

Engine

Date of Purchase

Name of Dealer

(To be filled in by purchaser)

[Engine model : D1005, V1305]

[Engine model : Z482, D722]

(1) Generator serial number (2) Generator model (3) Engine serial number

2 SPECIFICATIONS

SPECIFICATIONS

ENGLISH

MOKUJIYOU

B1 Phase Type

GENERATOR

Model Unit

Design

Frequency Hz 50 60 50

Rated Output (COP)

Rated Voltage V 220 240 110/220 127/220 220 240 Phase & Wire φ-w 1-2 1-3 1-2 Power Factor % 100 No. of Poles - 2 Insulation - Rotary coil: Class F, Stator coil: Class B Voltage Regulation % 7 (No load to full load) Type of Coupling Direct coupled

DIESEL ENGINE

Model Z482-B-SEC D722-B-SEC Design Vertical, water-cooled, 4-cycle diesel engine No. of cylinders 2 3 Bore x stroke mm φ67 x 68 φ67 x 68 Displacement L 0.479 0.719 Engine speed rpm 3000 3600 3000 Lubricating Oil API service class CD or higher Oil capacity L 2.2 3.4 Coolant capacity L 2.3 3.0

SET

kVA 5.5 6.5 8

kW 5.5 6.5 8

J106 J107 J108

-STD -AUS -STD -SA -STD -AUS Salient-pole, revolving-field AC generator

(AVR system with separate and self-excitation brush)

Fuel Diesel fuel No. 2 (ASTM D975) Fuel consumption (at full load) L 2.3 2.8 3.2 Fuel tank capacity L 37 37 Continuous Operating Hours hrs 16.0 13.2 11.5

Battery (V x Ah/5Hr)

Starting System Electric

L x W x H (with wheel) mm

Approx Net Wt. kg 225 255

Output

Option Caster Sound Level (full load at 7m) dB(A) 74.0 76.0 75.0 Emergency Stop System - In case of abnormal: Oil pressure, water temperature

AMPS

AMPS A 25.0 22.9

Terminal - - Receptacle - - - - -

38B20R

(12V x 28Ah)

923 x 593 x 860

(1037)

59.1/

29.5

51.2/

29.5

55B24R

(12V x 36Ah)

995 x 593 x 860

(1037)

36.4 33.3

GENERATOR

3SPECIFICATIONS

Model Unit

Design

Frequency Hz 60 50 60

kVA 10 12 14

Rated Output (COP)

kW 10 12 14

Rated Voltage V 110/220 127/220 220 240 110/220 127/220 Phase & Wire φ-w 1-3 1-2 1-3 Power Factor % 100 No. of Poles - 2 Insulation - Rotary coil: Class F, Stator coil: Class B

Voltage Regulation %

Type of Coupling Direct coupled

DIESEL ENGINE

Model D722-B-SEC D1005-BG-SEC Design Vertical, water-cooled, 4-cycle diesel engine No. of cylinders 3 Bore x stroke mm φ67 x 68 φ76 x 73.6 Displacement L 0.719 1.001 Engine speed rpm 3600 3000 3600 Lubricating Oil API service class CD or higher Oil capacity L 3.4 4.3 Coolant capacity L 3.0 3.3

SET

J110 J112 J114

-STD -SA -STD -AUS -STD -SA Salient-pole, revolving-field AC generator

(AVR system with separate and self-excitation brush)

11.5/

14.0

11.5/

14.0

7 (No load to full

load)

8 (No load to full load)

ENGLISH

Fuel Diesel fuel No. 2 (ASTM D975) Fuel consumption (at full load) L 4.2 4.5 5.8 Fuel tank capacity L 37 79 Continuous Operating Hours hrs 8.5 17.0 13.5

Battery (V x Ah/5Hr)

Starting System Electric

L x W x H (with wheel) mm

Approx Net Wt. kg 255 340

Output

Option Caster - Sound Level (full load at 7m) dB(A) 76.5 76.5 81.0

Emergency Stop System -

AMPS

AMPS A

Terminal - Receptacle---- --

55B24R

(12V x 36Ah)

995 x 593 x 860

(1037)

In case of

abnormal: Oil

pressure, water

temperature

90.9/

45.5

78.7/

45.5

In case of abnormal: Oil pressure, water

temperature, fan belt broken

54.5 50.0

80D26R(S)

(12V x 55Ah)

1215 x 611 x 922

63.6 x 2 /63.6

90.6/

63.6

4 SPECIFICATIONS

GENERATOR

Model Unit

ENGLISH

Design

Frequency Hz 50 60

kVA 16 18.8 11.5/18.8

Rated Output (COP)

kW 16 18.8 11.5/18.8

Rated Voltage V 220 240 110/220 127/220 Phase & Wire φ-w 1-2 1-3 Power Factor % 100 No. of Poles - 2 Insulation - Rotary coil: Class F, Stator coil: Class B Voltage Regulation % 8 (No load to full load) Type of Coupling Direct coupled

DIESEL ENGINE

Model V1305-BG-SEC Design Vertical, water-cooled, 4-cycle diesel engine No. of cylinders 4 Bore x stroke mm φ76 x 73.6 Displacement L 1.335 Engine speed rpm 3000 3600 Lubricating Oil API service class CD or higher Oil capacity L 5.7 Coolant capacity L 3.5

SET

-STD -AUS -STD -SA

(AVR system with separate and self-excitation brush)

J116 J119

Salient-pole, revolving-field AC generator

Fuel Diesel fuel No. 2 (ASTM D975) Fuel consumption (at full load) L 6.0 7.5 Fuel tank capacity L 79 Continuous Operating Hours hrs 13.0 10.5 Battery (V x Ah/5Hr) 80D26R(S) (12V x 55Ah) Starting System Electric L x W x H (with wheel) mm 1300 x 611 x 922

Approx Net Wt. kg 380

Output

Option Caster - Sound Level (full load at 7m) dB(A) 77.5 82.0

Emergency Stop System -

AMPS

AMPS A 72.7 66.7

Terminal - Receptacle - - - -

In case of abnormal:

Oil pressure, water temperature, fan belt broken

85.5 x 2 /85.5

90.6/85.5

B3 Phase Type

5SPECIFICATIONS

GENERATOR

Model Unit

Design

Frequency Hz 50 60

Rated Output (COP)

Rated Voltage V 380 415 240 220 Phase & Wire φ-w 3-4 Power Factor % 80 80 100 80 No. of Poles - 2 Insulation - Rotary coil: Class F, Stator coil: Class B Voltage Regulation % 8 (No load to full load) Type of Coupling Direct coupled

DIESEL ENGINE

Model D722-B-SEC Design Vertical, water-cooled, 4-cycle diesel engine No. of cylinders 3 Bore x stroke mm φ67 x 68 Displacement L 0.719 Engine speed rpm 3000 3600 Lubricating Oil API service class CD or higher Oil capacity L 3.4 Coolant capacity L 3.0

SET

kVA 10 10 6 12.5

kW 8 8 6 10

-STD -AUS -STD Salient-pole, revolving-field AC generator

(AVR system with separate and self-excitation brush)

J310 J313

ENGLISH

Fuel Diesel fuel No. 2 (ASTM D975) Fuel consumption (at full load) L 3.2 4.2 Fuel tank capacity L 37 Continuous Operating Hours hrs 11.5 8.5 Battery (V x Ah/5Hr) 55B24R (12V x 36Ah) Starting System Electric L x W x H (with wheel) mm 995 x 593 x 860 (1037) Approx Net Wt. kg 255

Output

Option Caster Sound Level (full load at 7m) dB(A) 75.0 76.5 Emergency Stop System - In case of abnormal: Oil pressure, water temperature

AMPS

AMPS A 15.2 13.9 8.3 x 3 32.8

Terminal - Receptacle - - -

6 SPECIFICATIONS

GENERATOR

Model Unit

ENGLISH

Design

Frequency Hz 50 60

Rated Output (COP)

DIESEL ENGINE

Model D1005-BG-SEC Design Vertical, water-cooled, 4-cycle diesel engine No. of cylinders 3 Bore x stroke mm φ76 x73.6 Displacement L 1.001 Engine speed rpm 3000 3600 Lubricating Oil API service class CD or higher Oil capacity L 4.3 Coolant capacity L 3.3

SET

kVA 15 15 9 17.5

kW 12 12 9 14

-STD -AUS -STD Salient-pole, revolving-field AC generator

(AVR system with separate and self-excitation brush)

J315 J318

Fuel Diesel fuel No. 2 (ASTM D975) Fuel consumption (at full load) L 4.5 5.8 Fuel tank capacity L 79 Continuous Operating Hours hrs 17.0 13.5 Battery (V x Ah/5Hr) 80D26R(S) (12V x 55Ah) Starting System Electric L x W x H (with wheel) mm 1215 x 611 x 922 Approx Net Wt. kg 340

Output

Option Caster - Sound Level (full load at 7m) dB(A) 76.5 81.0

Emergency Stop System -

AMPS

AMPS A 22.8 20.9 12.5 x 3 45.9

Terminal - Receptacle - - -

In case of abnormal:

Oil pressure, water temperature, fan belt broken

GENERATOR

7SPECIFICATIONS

Model Unit

Design

Frequency Hz 50 60

Rated Output (COP)

DIESEL ENGINE

Model V1305-BG-SEC Design Vertical, water-cooled, 4-cycle diesel engine No. of cylinders 4 Bore x stroke mm φ76 x73.6 Displacement L 1.335 Engine speed rpm 3000 3600 Lubricating Oil API service class CD or higher Oil capacity L 5.7 Coolant capacity L 3.5

SET

kVA 20 20 10.8 23.5

kW 16 16 10.8 18.8

-STD -AUS -STD Salient-pole, revolving-field AC generator

(AVR system with separate and self-excitation brush)

J320 J324

ENGLISH

Output

Option Caster - Sound Level (full load at 7m) dB(A) 77.5 82.0

Emergency Stop System -

AMPS

AMPS A 30.4 27.8 15 x 3 61.7

Terminal - Receptacle - - -

In case of abnormal:

Oil pressure, water temperature, fan belt broken

8 NOMENCLATURE

NOMENCLATURE

ENGLISH

MOKUJIYOU

(1) Control panel (2) Hook (3) Coolant filling port (4) Fuel tank cap (5) Door (6) Engine oil drain plug (7) Air cleaner (8) Battery (9) Reserve tank (10) Fuel cock (11) Engine oil port (12) Oil dipstick (13) Oil filter cartridge (14) Radiator (15) Coolant drain plug (radiator) (16) Coolant drain plug (engine) (17) Fuel tank (18) Generator (19) Muffler (20) Base (21) Fork pockets (22) Fuel gauge (23) Terminal cover

9NOMENCLATURE

ENGLISH

NOMENCLATURE10

BControl Panel

ENGLISH

Standard Model

C 1 Phase Type (220V Type)

[J106-STD, J108-STD]

[J112-STD, J116-STD]

C 1 Phase Type (110V/220V Dual voltage type)

[J107-STD, J110-STD]

[J114-STD, J119-STD]

(1) A.C. Voltmeter (2) Glow plug lamp (3) Water temperature lamp (4) Oil pressure lamp (5) Battery charge lamp (6) Main switch (key)

(7) Circuit breaker (8) Hour meter (9) Ground terminal (10) Terminal (Autostart unit) (11) Terminals (output)

(1) A.C. Voltmeter (2) Glow plug lamp (3) Water temperature lamp (4) Oil pressure lamp (5) Battery charge lamp (6) Main switch (key)

(7) Circuit breaker (8) Hour meter (9) Ground terminal (10) Terminal (Autostart unit) (11) Terminals (output)

11NOMENCLATURE

C 1 Phase Type (127V/220V Dual voltage type)

[J107-SA, J110-SA]

[J114-SA, J119-SA]

C 3 Phase Type

[J310-STD, J313-STD]

ENGLISH

[J315-STD, J318-STD, J320-STD, J324-STD]

(1) A.C. Voltmeter (2) Glow plug lamp (3) Water temperature lamp (4) Oil pressure lamp (5) Battery charge lamp (6) Main switch (key)

(7) Circuit breaker (8) Hour meter (9) Ground terminal (10) Terminal (Autostart unit) (11) Terminals (output)

(1) A.C. Voltmeter (2) Glow plug lamp (3) Water temperature lamp (4) Oil pressure lamp (5) Battery charge lamp (6) Main switch (key)

(7) Circuit breaker (8) Hour meter (9) Ground terminal (10) Terminal (Autostart unit) (11) Terminals (output)

NOMENCLATURE12

AUS Model

C 1 Phase Type

ENGLISH

[J106-AUS, J108-AUS]

[J112-AUS, J116-AUS]

C 3 Phase Type

[J310-AUS]

[J315-AUS, J320-AUS]

The J106-AUS is equipped with 2 receptacles.

(1) A.C. Voltmeter (2) Glow plug lamp (3) Water temperature lamp (4) Oil pressure lamp (5) Battery charge lamp (6) Main switch (key)

(7) Circuit breaker (8) Hour meter (9) Ground terminal (10) Terminal (Autostart unit) (11) Receptacles (12) Circuit protector (Receptacle)

(1) A.C. Voltmeter (2) Glow plug lamp (3) Water temperature lamp (4) Oil pressure lamp (5) Battery charge lamp (6) Main switch (key)

(7) Circuit breaker (8) Hour meter (9) Ground terminal (10) Terminal (Autostart unit) (11) Receptacles (12) Circuit protector (Receptacle)

13NOMENCLATURE

BEasy Checker

When an abnormal condition occurs with a part monitored by the easy checker while the engine is running, a lamp flashes to warn the operator of the impending trouble.

(1) Charge warning lamp (2) Water temperature-overheat warning lamp, flashes on when cooling water rises to 112 to 118 C. (3) Engine oil pressure drop warning lamp, flashes on below 39 to 59 kPa (0.4 to 0.6 kgf/cm ) oil pressure. (4) Glow plug lamp

BControl Box

ENGLISH

(1) Excitation unit (2) Emergency relay (3) Starter relay (4) Glow relay (5) Glow lamp timer (6) Relay (7) Relay (Solenoid)

14 PREPARATION TO SUPPLY THE ELECTRIC POWER

PREPARATION TO SUPPLY THE ELECTRIC POWER

ENGLISH

1. Generator grounding

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 (National Electrical Code), NFPA (National Fire Protection Association), AUSTRALIAN STANDARDS and OSHA (Occupational Safety and Health Administration) regulations must be followed to assure compliance and safe operation. Always be sure to ground (earth) the generator terminals to comply with the local, state, national or OSHA requirements.

One possible connection method for construction site use is as follows:

(1) Generator ground terminal (A) #6AWG

Flexible copper ground connection (B) Metal ground rod or building cold water pipe system per N.E.C. code

15PREPARATION TO SUPPLY THE ELECTRIC POWER

Typical

Apparatus

Light and

heaters

Commutator

motor

Induction

motor

J106 5.5 kW 2.8 kW 0.8 kW

3.3 kW

4.0 kW

5.0 kW

6.0 kW

7.0 kW

8.0 kW

9.4 kW

5.0 kW

6.3 kW

7.5 kW

8.8 kW

10.0 kW

11.8 kW

0.8 kW

1.2 kW

1.6 kW

2 kW

2.4 kW

3.7 kW

4.4 kW

5.5 kW

5.9 kW

7.4 kW

6.5 kW

8 kW

10 kW

12 kW

14 kW

16 kW

18.8 kW

8 kW

10 kW

12 kW

14 kW

16 kW

18.8 kW

J107

J108

J110

J112

J114

J116

J119

J310

J313

J315

J318

J320

J324

AC devices Electric power (W) = Voltage (V) Current (A) Power factor

Load type Power factor

Single-phase induction motors 0.4 to 0.75

3-phase induction motors 0.65 to 0.85 Electric heaters, incandescent

lamps

1.0

AC arc welder 0.4 to 0.6

Commutator motor 0.8 to 0.95 Fluorescent lamps, mercury

lamps

0.4 to 0.9

Motor input (kVA)

Motor output (kW)

Motor efficiency power factor

2. Recommended capacity of electrical devices

APPLICATION RANGE

You can operate the J-series generator in the following range.

A Connecting a motor.

When connecting to a line starting motor, these generators may be used to start a submerged pump of

3.7kW, 5.5kW, 7.5kW (three phase). When starting the motor, the voltage drops immediately. The circuit may be opened if an electromagnetic switch is connected to the same circuit. When connecting two motors or more, make sure the total current capacity of the motors does not exceed the total rated current.

A Connecting to lights and electric heaters.

When connecting to lights or electric heaters, the generator can be used up to the rated capacity. When using a single phase, it can be used up to the rated current.

A Power factor calculations.

The power factor calculation is used to determine input of the electrical devices.

Power factors of commonly used devices are listed in the following table.

ENGLISH

A Keep an inverter load below 50% of the generator

capacity.

A Make sure that total active mercury lamp load is below

30% or so of the generator capacity. Turn on the mercury lamps one by one. Be careful not to turn off the lamps and on again immediately. The generator voltage may rise 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 characteristics peculiar to each load.

A Ordinarily, a motor is rated in kW. This does not refer

to motor output.

A If a lighting system is employed together with some

types of computers and inverter air-conditioners 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.

16 CONNECTING THE LOAD

CONNECTING THE LOAD

ENGLISH

MOKUJIYOU

BConnection Notes

To avoid personal injury: A Before the generator can be

connected to a building’s electrical system, a licensed 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 or injure line maintenance personnel. Also, generator and building electrical system damage can occur when normal operating power returns if unit is used without an isolation switch.

(1) Circuit breaker (2) Terminals (output) (3) Cover lock bolt

C Single phase 2 terminals type

i ) J106-STD, J108-STD, J112-STD, J116-STD 50Hz 220V

[Single phase]

1. Avoid connecting the generator to commercial power

outlet.

2. Avoid connecting the generator in parallel with any

other generator.

BConnecting the Load (Standard Model)

To avoid personal injury: A Connect or disconnect the load to

the AC receptacles or terminals only when the engine is stopped.

A For your safety, close the terminal

cover after connecting the load.

A For your safety, secure the cover

with the lock bolts.

1. Turn OFF the circuit breaker on the control panel.

2. Connect the load to the A.C. output terminals.

3. Be sure to close the terminal cover after connecting

the load.

(1) Light (2) Television (3) Air conditioner (4) Electric drill (5) Motor pump

17CONNECTING THE LOAD

C Single phase 3 terminals type (1P3W type)

(Dual voltage type)

i ) J107-STD, J110-STD 60Hz 110/220V ii) J107-SA, J110-SA, J114-SA, J119-SA 60Hz 127/220V

[Single phase]

(1) Light (2) Television (3) Air conditioner (4) Electric drill (5) Motor pump

C Single phase 4 terminals type (1P4W type)

(Dual voltage type)

i ) J114-STD, J119-STD 60Hz 110/220V

[Single phase]

C 3 phase and single phase 4 terminals type

A For 3 phase power source

i ) J310-STD, J315-STD, J320-STD 50Hz 380V Use (W)-(V)-(U) ii) J313-STD, J318-STD, J324-STD 60Hz 220V Use (W)-(V)-(U)

[Three phase]

(1) Motor

A For single phase power source

i ) J310-STD, J315-STD, J320-STD 50Hz 2 20V Use (O)- (U), (O)-( V), ( O)-( W ) ii) J313-STD, J318-STD, J324-STD 60Hz 1 27V Use (O)- (U), (O)-( V), ( O)-( W )

[Single phase]

ENGLISH

(1) Light (2) Television (3) Air conditioner (4) Electric drill (5) Motor pump

(1) Light (2) Television (3) Air conditioner

CONNECTING THE LOAD18

[ A list of receptacles ]

Single Phase 3 Phase

Model 56S0315 56S0310 56S0520 56S0532

J106-

AUS

2000

J108-

AUS

3000

J112-

J116-

AUS

4000

J310-

AUS

0310

J315-

J320-

AUS

3001

A For single phase power source

i ) J310-STD, J315-STD, J320-STD 50Hz 380V single phase Use (U)-(V), (V)-(W), (W)-(U)

ENGLISH

ii) J313-STD, J318-STD, J324-STD 60Hz 220V single phase Use (U)-(V), (V)-(W), (W)-(U)

[Single phase]

(1) Electric drill (2) Motor pump (3) Air conditioner

BConnecting the Load (AUS Model)

2. Connect the load to the A.C. receptacles.

[Receptacles use]

To avoid personal injury: A Connect or disconnect the load to

the AC receptacle only when the engine is stopped.

1. Turn OFF the circuit breakers on the control panel.

(1) Circuit breaker

(1) Single phase (2) 3 phase

19HANDLING THE CIRCUIT BREAKER

HANDLING THE CIRCUIT BREAKER

MOKUJIYOU

C Single phase (3 terminals - Dual voltage type)

Panel control is designed to have the two A.C. circuit breaker. Turn ON the same voltage number circuit breaker as using the A.C. voltage.

[3 terminals type]

(1) Circuit breaker

A Do not add the A.C. load directly, using the circuit

breaker.

A The simultaneous generation of 220V power source

and 110V (or 127V) power source is possible but the total load should not exceed the following rated output.

ENGLISH

BHandling the Circuit Breaker (Protector)

(Australian model)

Each of the receptacles is provided with an over-current circuit protector. If any of the circuit protectors is activated and the current flow is interrupted, stop the engine and check the load.

(1) Circuit breaker (Main) (2) Circuit protector (Receptacle) (3) Receptacles

C Resetting the Circuit Protector

1. If an over-current occurs, the center knob of the circuit protector pops up.

2. Press down the knob to reset the circuit protector.

To avoid personal injury: A Before resetting the circuit protector,

be sure to stop the engine. An attempt to reset it with the engine running is very dangerous.

20 PRE-OPERATION CHECK

PRE-OPERATION CHECK

ENGLISH

DAILY CHECK

To prevent problems from occurring, it is important to know the condition of the generator. Always perform the following check items before starting the generator.

To avoid personal injury: A Before checking or servicing the

generator, make sure it is on a level surface with the engine shut off.

C Check items

-Check for oil and coolant leakage

-Check cooling air inlet 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 the possibility of battery explosion:

The battery comes in two types: refillable and non-refillable. For using the refillable type battery, follow the instructions below. A DO NOT use or charge the battery if

the fluid level is below the LOWER (lower limit level) mark. Otherwise, the battery component parts may deteriorate prematurely, shorten the battery's service life; which may cause an explosion. Immediately, add distilled water until the battery's fluid level comes somewhere between the UPPER and LOWER levels.

A Keep all sparks and flames away

from the battery and fuel tank. A battery, especially when charging, will give off hydrogen and oxygen gases which can explode and cause serious personal injury.

To avoid personal injury from contact with moving parts;

A DO NOT open the door or generator

side cover while the engine is running.

A Do not touch muffler or exhaust

pipes while they are hot; Severe burns could result.

BBattery

The battery is shipped in dry, charged condition without electrolyte. The battery must be charged properly before using for the first time.

1. Remove the vent plugs.

2. Fill cells up to the upper level with electrolyte. [Specific gravity of sulfuric acid 1.270 to 1.290 (at 20 C=68 F)]

3. Allow the battery to sit for about one hour after filling.

4. If the electrolyte level is dropped, refill with electrolyte up to the upper level.

5. Replace the vent plugs.

6. Charge the battery at the normal charging rate of 6.0 amperes.

7. Wash off any electrolyte which may have spilled.

(1) Vent plug opening (2) Electrolyte level indication tube (3) Indicated level

(A) Upper level (B) Lower level

21PRE-OPERATION CHECK

A The duration of dry charged efficiency, will decrease in

proportion to the period of time elapsed after shipment and during storage. To obtain the longest service life of the battery, it 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 C =68 F).

BEngine Oil

The generator has been shipped without engine oil. Fill with oil to the correct level before attempting to start the engine.

1. Place the machine on a level surface.

2. Remove the oil cap.

3. Add engine oil of grade CD or higher, up to the upper mark on the oil level gauge.

A See "ENGINE OIL" in "PERIODIC SERVICE" section

for engine oil capacity and checking engine oil level.

BFuel

ENGLISH

To avoid personal injury: A DO NOT refuel when engine is

running or hot.

A Always shut off the engine before

refueling.

A DO NOT overfill fuel system. If any

fuel overflows, wipe it up completely before starting operation.

A When refueling, keep all flames,

sparks and cigarettes away from generator.

1. Always fill the fuel through the fuel tank strainer.

2. Make sure that dirt or water does not enter the fuel tank.

3. Fill with Diesel fuel No.2-D (ASTMD975).

4. Below 0 C (32 F) a mix of No.1-D and No.2-D is acceptable.

5. Fuel level is read by fuel gauge.

BCoolant

To avoid personal injury:

A Place the machine on a level surface. A DO NOT remove the radiator cap

while coolant is hot. When cool, rotate the radiator cap slowly to the first stop to allow excess pressure to escape. Then remove cap completely.

1. Remove the radiator cap and fill with specified coolant until the coolant level is just below the port.

2. Fill with coolant to the “FULL” mark on the reserve tank.

3. Securely tighten radiator cap and reserve tank cap.

A See "RADIATOR" in "PERIODIC SERVICE" section

for changing coolant.

A If the fuel tank should empty completely 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.)

22 OPERATING THE GENERATOR

OPERATING THE GENERATOR

ENGLISH

MOKUJIYOU

To avoid personal injury: A Read " SAFE OPERATION" in the

front of this manual.

A Read the danger, warning and

caution labels located on the generator.

A To avoid the danger of exhaust fume

poisoning, do not operate the engine in a closed building without proper ventilation.

A Always turn OFF the circuit breaker

before starting the generator.

A Turn OFF all switches 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.

BStarting the Engine

1. Turn off all switches on the electrical devices.

2. Turn off the circuit breakers on the control panel.

[Dual voltage type]

[ 3 Phase type etc.]

(1) Circuit breaker (2) "OFF"

23OPERATING THE GENERATOR

3. Ensure that the fuel lever is set to the "OPEN" Position.

(1) Fuel lever (2) Water separator

(A) "OPEN"

4. Insert the key into the main switch and turn it "ON".

5. Check the battery charge lamp and oil pressure lamp are "ON".

6. Turn the key to "GLOW" position.

A See "Cold Weather Starting" section as to the

preheating times.

7. Turn the key to the "START" position and release when the engine starts.

(1) Main switch (Key) (A) "OFF"

(B) "ON" (C) "GLOW" (D) "START"

ENGLISH

(1) Water temperature lamp (2) Oil pressure lamp (3) Battery charge lamp (4) Glow timer lamp

A Do not use ether or any starting fluid for starting the

engine, or severe engine damage will occur.

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.

A Do not run the starter motor continuously for more

than 10 seconds at a time, or it may damage the starter. If the engine fails to start, wait for about 30 seconds and try again.

8. Check to see that the battery charge lamp, oil pressure lamp and water temperature lamp are "OFF".

9. Check the warning lamps.

Whenever the engine stops automatically during operation, correct the problem before restarting the engine.

10.For 5 minutes after engine start-up, allow engine to warm up without applying any load.

A If load should be applied to the engine without this

warm-up period, trouble such as seizure, breakage or premature wear may develop.

OPERATING THE GENERATOR24

Ambient temperature Warm-up time requirement

Above 0

(32 F) At least 10 minutes

0 C(32 F) to -10 C(14 F)

10 to 20 minutes

Below -10

(14 F)

More than 20 minutes

Ambient temperature Preheating time

Above 10 C (50 F) NO NEED 10 C (50 F) to

-5 C (23 F)

Until glow lamp goes off

*Below -5 C (23 F)

Approx. 5 seconds after

the glow lamp goes off

Limit of continuous use 20 seconds

C Warm-up in cold ambient temperatures

In cold weather, the engine oil may be cold with increased viscosity. This can delay oil circulation or abnormally low

ENGLISH

oil pressure for some time after engine start-up. This can result 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.

BCold Weather Starting

If the ambient temperature is below * -5 C (23 F) and the engine is very cold, start it in the following manner: Take steps (1) through (5) in "Starting the Engine" section.

6. Turn the main switch (key) to the "GLOW" position until the glow plug indicator goes off.

A If the ambient temperature is low, the preheating time

will take longer.

11.Turn ON the circuit breaker on the control panel.

[Dual voltage type]

[3 Phase type etc.]

A Shown below are the standard preheating times for

various temperatures. This operation, however, is not required, when the engine is warmed up.

7. Turn the key to "ST" ("START") position and the engine should start.

(If the engine fails to start after 10 seconds, turn off the key for 30 seconds. Then repeat steps (6) and (7) above.)

A Do not allow the starter motor to run continuously for

more than 10 seconds.

A Be sure to warm up the engine, not only in winter, but

also in warmer seasons. An insufficiently warmed-up engine can shorten its service life.

A When there is possibility of temperature drops below

-15 C (5 F) detach the battery from the machine, and keep it indoor in a safe area. Reinstalled the battery before the next operation.

(1) Circuit breaker (2) "ON"

12.Turn ON the electrical device switches for the connections.

25OPERATING THE GENERATOR

BStopping the Engine

1. Turn OFF all electrical device switches for connected loads.

2. Turn OFF the circuit breakers.

3. Allow the engine to run with no load for about 5 minutes before stopping the engine completely.

4. Turn the main switch (key) to the "OFF" position.

BIf the Engine Fails to Stop in the Usual

Procedure (EMERGENCY STOP)

If the engine does not stop after turning the key switch to "OFF" position, take the following (emergency stop) procedure.

To avoid personal injury: A Keep your hands away from the

rotating parts, such as cooling fan and V-belt. Otherwise personal injury may be caused when manipulating the engine stop lever.

1. Open 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.

[Engine model : Z482, D722]

ENGLISH

(1) Main switch (Key) (A) "OFF"

5. Turn the fuel lever to the "CLOSE" position.

(1) Fuel lever (2) Filter bowl

(A) "CLOSE"

[Engine model : D1005, V1305]

(1) Engine stop lever (A) "START"

(B) "STOP"

OPERATING THE GENERATOR26

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

ENGLISH

engine shut-off. Pinpoint and correct the cause of trouble.

A Check for the stop solenoid. A Check to see if the battery has discharged too

much or is in trouble.

A Check for disconnection of the battery terminals.

MAINTENANCE

SERVICE INTERVALS

Observe the following for service and maintenance.

Interval

400

Every

500

hours

No.

Check point

First

hours

Every

hours

Every

100

hours

Every

hours

Every

200

hours

1 Check of fuel pipes and clamp bands 31

2 Change of engine oil 33

27MAINTENANCE

ENGLISH

Ref.

page

3 Cleaning of air cleaner element

34,

4 Check of battery electrolyte level 39

5 Check of fan belt tightness 45

Check of radiator hoses and clamp

bands

7 Replacement of oil filter cartridge 34

Replacement of fuel filter cartridge or

element

Cleaning of water jacket (radiator

interior)

10 Replacement of fan belt 45

11 Check of valve clearance -

Check of generator carbon brush

Replace if necessary.

13 Replacement of air cleaner element

Check of damage in electric wiring and

loose connections

42 *2

34,

Replacement of fuel pipes and clamp

bands

Replacement of radiator hoses and

clamp bands

17 Replacement of battery 39

18 Change of radiator coolant (L.L.C.) 37

A The jobs indicated by must be done after the first 50 hours of operation. *1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions. *2 Generator carbon brush should be checked more often in dusty conditions than in normal conditions. *3 After 6 times of cleaning. *4 Consult your local KUBOTA Dealer for this service. A When the battery is used for less than 100 hours in a year, check its electrolyte yearly. (for refillable battery’s only)

31 *4

28 MAINTENANCE

Interval

No.

ENGLISH

Check point

Every

800

hours

Every

hours

1000

Every

year

1 Check of fuel pipes and clamp bands 31

2 Change of engine oil 33

Every

year

Ref.

page

3 Cleaning of air cleaner element

34,

4 Check of battery electrolyte level 39

5 Check of fan belt tightness 45

Check of radiator hoses and clamp

bands

7 Replacement of oil filter cartridge 34

Replacement of fuel filter cartridge or

element

Cleaning of water jacket (radiator

interior)

10 Replacement of fan belt 45

11 Check of valve clearance -

Check of generator carbon brush

Replace if necessary.

13 Replacement of air cleaner element

Check of damage in electric wiring and

loose connections

42 *2

34,

Replacement of fuel pipes and clamp

bands

Replacement of radiator hoses and

clamp bands

31 *4

17 Replacement of battery 39

18 Change of radiator coolant (L.L.C.) 37

PERIODIC SERVICE

29PERIODIC SERVICE

ENGLISH

FUEL

Fuel is flammable and can be dangerous. You should handle fuel with care.

To avoid personal injury: A DO NOT mix gasoline or alcohol with

diesel fuel. This mixture can cause an explosion.

A Be careful not to spill fuel during

refueling. If fuel should spill, wipe it off at once, or it may cause a fire.

A Stop the engine before refueling.

Keep the machine away from the fire.

A Be sure to stop the engine while

refueling or bleeding and when cleaning or changing fuel filter or fuel pipes. DO NOT smoke when working around the machine or when refueling.

A Check the above fuel systems in a

well ventilated and open place.

A When fuel and lubricant are spilled,

refuel after the machine cooled down.

BFuel Level Check and Refueling

1. Check to see that the fuel level is above the lower limit of the fuel level gauge.

2. If the fuel is too low, add fuel to the upper limit. Do not overfill.

[Engine model : Z482, D722]

[Engine model : D1005, V1305]

(1) Fuel level gauge

PERIODIC SERVICE30

Model Capacity

J106, J107

[Engine model : Z482-B]

37 (9.8)

J108, J110, J310, J313

[Engine model : D722-B]

J112, J114, J315, J318

[Engine model : D1005-BG]

J116, J119, J320, J324

[Engine model : V1305-BG]

79 (20.9)

L (U.S.gal.)Fuel tank capacity

No.2-D is a distillate fuel oil of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN87)

ENGLISH

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 affect the generator performance. Kerosene, which is very low in cetane rating, adversely affects the engine. Diesel fuel differs in grades depending on the temperature.

A Be careful not to let the fuel tank become empty, or air

can enter the fuel system, necessitating bleeding before next engine start.

BAir Bleeding the Fuel System

To avoid personal injury; A Do not bleed a hot engine as this

could cause fuel to spill onto a hot exhaust manifold creating a danger of fire.

Air bleeding of the fuel system is required if; A after the fuel filter and pipes have been detached and

refitted;

A after the fuel tank has become empty; or A before the engine is to be used after long storage.

[PROCEDURE]

1. Fill the fuel tank to the fullest extent. Open the fuel filter cock.

2. Loosen air vent plug of the fuel filter a few turns.

3. Screw back the plug when bubbles do not come up any more.

4. Open the air vent plug on top of the fuel injection pump.

5. Retighten the plug when bubbles do not come up any more.

(1) Fuel filter cock (2) Air vent plug (3) Fuel filter pot

(A) "OPEN" (B) "CLOSE"

31PERIODIC SERVICE

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 clamp bands every two years.

3. If the fuel pipes and clamp bands are found worn or damaged before two years' pass, replace or repair them at once.

4. After replacement of the pipes and bands, air-bleed the fuel system.

A When the fuel pipes are not installed, plug them at

both ends with clean cloth or paper to prevent dirt from entering. Dirt in the pipes can cause fuel injection pump malfunction.

BCleaning the Fuel Filter Pot

Every 100 hours of operation, clean the fuel filter in a clean place to prevent dust intrusion.

1. Close the fuel filter lever.

(1) Fuel filter lever (2) Fuel filter pot

2. Remove the top cap, and rinse the inside with diesel fuel.

3. Take out the element, and rinse it with diesel fuel.

4. After cleaning, reinstall the fuel filter, keeping out of dust and dirt.

5. Air-bleed the injection pump.

(A) "CLOSE" (B) "OPEN"

ENGLISH

(1) Clamp band (2) Fuel pipe

A Entrance of dust and dirt can cause a malfunction of

the fuel injection pump and the injection nozzle. Wash the fuel filter cup periodically.

(1) O ring (2) Filter element (3) Spring (4) Filter bowl (5) Screw ring

PERIODIC SERVICE32

ENGINE OIL

ENGLISH

To avoid personal injury: A Be sure to stop the engine before

checking and changing the engine oil and the oil filter cartridge.

A DO NOT touch muffler or exhaust

pipes while they are hot; severe burns could result. Always stop the engine and allow 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.

BChecking Oil Level and Adding Engine Oil

1. Check the engine oil level before starting or more than 5 minutes after stopping the engine.

2. Remove the oil level gauge, wipe it clean and reinstall it.

3. Take the oil level gauge out again, and check the oil level.

[Engine model : Z482, D722]

[Engine model : D1005, V1305]

A Do not operate a diesel engine when engine oil is

overfilled. This can effect the air intake system which could result in engine damage or malfunction.

(1) Oil port (2) Oil level gauge

[Lower end of oil level gauge] (A) Engine oil level within this range is proper.

4. If the oil level is too low, remove the oil port, and add

Model Capacity

J106, J107 [Engine model : Z482-B]

2.2 (2.3)

J108, J110, J310, J313 [Engine model : D722-B]

3.4 (3.6)

J112, J114, J315, J318 [Engine model : D1005-BG]

4.3 (4.5)

J116, J119, J320, J324 [Engine model : V1305-BG]

5.7 (6.0)

new oil to the prescribed level.

5. After adding oil, wait more than 5 minutes and check the oil level again. It takes some time for the oil to drain down to the oil pan.

6. If the engine is operated with the oil level nearing the lower limit, the oil may deteriorate more quickly than normal, therefore, keeping the oil level near the upper limit is recommended.

Engine oil capacity L (U.S.qts.)

A Engine oil should be MIL-L-2104C or have properties

of API classification CF grades or higher. Change the type of engine oil according to the ambient temperature.

33PERIODIC SERVICE

BChanging Engine Oil

ENGLISH

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 being burned.

1. Change oil after the initial 50 hours of operation and every 100 hours thereafter.

2. Remove the drain plug to drain the engine oil. Drain all the old oil, drains easier and completely when the engine is warm. Inspect drain plug gasket. Replace if damaged.

[Engine model : Z482, D722]

A When using oil of different brands from the previous

one, be sure to drain all the previous oil before adding the new engine oil.

[Engine model : D1005, V1305]

(1) Engine oil drain plug

3. Install the oil drain plug and gasket.

4. Add new engine oil up to the upper line of the oil level gauge.

PERIODIC SERVICE34

BReplacing the Oil Filter Cartridge

ENGLISH

To avoid personal injury: A Be sure to stop the engine before

changing the oil filter cartridge.

A Allow engine to cool down

sufficiently. Oil can be hot and cause burns.

5. After the new cartridge has been replaced, the engine oil level normally decreases a little. Therefore run the engine for a while and check for oil leaks through the seal before checking the engine oil level. Add oil if necessary.

A Completely wipe off any oil sticking to the machine in

the filter area.

AIR CLEANER

1. Replace the oil filter cartridge every 200 hours of operation.

2. Remove the old oil filter cartridge with a filter wrench. Dispose of filter properly.

3. Apply a film of oil to the gasket of the new cartridge.

4. Screw in the cartridge by hand. When the gasket contacts the seal surface, tighten the cartridge firmly only by hand. If you tighten the cartridge with a wrench, it will be tightened too much.

[Engine model : Z482, D722]

[Engine model : D1005, V1305]

(1) Oil filter cartridge (2) Remove with a filter wrench (Tighten with your hand)

To avoid personal injury: A Be sure to stop the engine before

cleaning air filter element.

A Make sure hooking clip is tight enough. If it is loose,

dust and dirt may be sucked into the engine, causing excessive wear or premature engine 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 touching the element except when cleaning.

4. When dry dust adheres to the element, blow compressed air from the inside turning the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm , 30 psi).

5. When carbon or oil adheres to the element, soak the element in detergent for 15 minutes, then wash it several times in water, rinse with clean water and dry it naturally.

6. After the element is fully dried, inspect the inside of the element with a light, and check if it is damaged or not. (referring to the instructions on the label attached to the element.)

7. Replace the primary element every year or every 6 cleanings. If the primary element is heavily stained, replace it sooner. At this time, also replace the secondary element.

8. The secondary element should be removed only if it is to be replaced.

9. To protect the engine, do not remove the secondary element in normal servicing of the primary element.

[Engine model : Z482, D722]

35PERIODIC SERVICE

BCleaning Primary Air Filter Element

1. To clean the element, use clean dry compressed air on the inside of the element. Air pressure at the nozzle must not exceed 205 kPa (2.1 kgf/cm , 30 psi). Maintain reasonable distance between the nozzle and filter.

2. To wash the elements, use Donaldson ND-1500 Filter Cleaner, or its equivalent, which is especially effective on oily and soot-laden filters. Follow instructions that are supplied with the filter cleaner.

BEvacuator Valve

Open the evacuator valve once a week under ordinary conditions - or daily when used in dusty condition - to get rid of large particles of dust and dirt.

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.

ENGLISH

[Engine model : D1005, V1305]

(1) Air cleaner body (2) Cover (3) Secondary element (4) Primary element (5) Evacuator valve (6) Hooking clip (7) Air cleaner

(1) Air cleaner body (2) Secondary element (3) Primary element (4) Dust cup (5) "TOP" mark (6) Evacuator valve

BFor the Air Cleaner with a 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 conditions. Install the air cleaner dust cup with "TOP" indicated on the rear of the cup in the upward position with horizontally mounted air cleaner bodies or vertically mounted air cleaner bodies, the cup may be mounted in any direction.

PERIODIC SERVICE36

RADIATOR

Make it a rule to check the coolant level before every operation.

ENGLISH

To avoid personal injury: A DO NOT stop the engine suddenly,

stop it after about 5 minutes of unloaded idling.

A Work only after letting the engine and

radiator cool off completely (more than 30 minutes after it has been stopped).

A DO NOT remove the radiator cap

while coolant is hot. When cool, rotate cap slowly to the first stop to allow excess pressure to escape. Then remove cap completely. If overheating should occur, steam gushes out from the radiator or reserve tank; Allow the engine to cool before attempting to open the cap. Severe burns could result.

2. If the radiator is provided 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.

(1) Reserve tank (2) Cap

3. When the coolant level drops due to evaporation, add only coolant up to the full level.

4. Check to see the two drain cocks; one is at the crankcase side and the other is at the lower part of the radiator as shown below.

(A) "FULL" Upper line 0.6 L (0.63 U.s.qts.) (B) "LOW"

BChecking Coolant Level, Adding Coolant

1. Remove the radiator cap after the engine has completely cooled, and check to see that coolant reaches the supply port.

(1) Radiator cap (2) Coolant filling port

[Engine model : Z482, D722]

[Engine model : D1005, V1305]

Engine model Coolant capacity

Z482-B-SEC 2.3 (2.43)

D722-B-SEC 3.0 (3.17)

D1005-BG-SEC 3.3 (3.49)

V1305-BG-SEC 3.5 (3.70)

Season

Summer

Winter (When temperature drops below 0 C (32 F)) or all season

Coolant

Pure water and radiator cleaner

Pure water and anti-freeze (See "Anti-freeze" in "RADIATOR" section.)

37PERIODIC SERVICE

BChanging Coolant

1. To drain coolant, always open both drain cocks and simultaneously open the radiator cap as well. With the radiator cap kept closed, the coolant will not drain completely. Dispose of used coolant properly.

2. Remove the overflow pipe of the radiator pressure cap to drain the reserve tank.

3. Prescribed coolant volume

L (U.S.qt s.)

4. An improperly tightened radiator cap or a gap between the cap and the seat increases loss of coolant.

5. Coolant (Radiator cleaner and anti-freeze)

ENGLISH

(1) Coolant drain cock (Radiator) (2) Radiator (3) Coolant drain cock (Engine)

A If the radiator cap has to be removed, proceed with

caution and securely retighten the cap.

A If coolant is leaking, consult your local KUBOTA

Dealer.

A Make sure that muddy or sea water is not used in the

radiator.

A Use clean, fresh water and 50% anti-freeze to fill the

recovery tank.

A Do not refill reserve tank with coolant over the "FULL"

level mark.

A Be sure to close the radiator cap securely. If the cap is

loose or improperly closed, coolant may leak out and decrease the level quickly.

A When coolant is added, coolant level may drop the

first time the engine is started. Stop the engine, and add coolant if necessary.

BRemedies for quick decrease of coolant

1. Check for dust and dirt between the radiator fins and cooling tube. Clean the fins and the tubes as if necessary.

2. Check the tension of the fan belt. If loose, tighten it securely.

3. Check the internal blockage in the radiator cooling tubes. If scale forms in the tubes, clean with the scale inhibitor or its equivalent.

PERIODIC SERVICE38

BChecking Radiator Hoses and Clamps

ENGLISH

To avoid personal injury: A Be sure to check radiator hoses and

hose clamps periodically. If radiator hoses are damaged 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 be swollen, hardened or cracked.

(1) Radiator hose (2) Hose clamp

BPrecaution Overheating

Take the following actions in the event the coolant temperature is nearly or more than the boiling point, which is called "Precaution overheating". Take these actions if the engine’s the alarm lamp lights up.

1. Turn off all output circuit breakers and keep the engine running without load.

2. Do not stop the engine suddenly. Stop it after about 5 minutes of unloaded idling.

3. If the engine stops within about 5 minutes of running under no load, immediately leave and keep yourself away from the machine. Do not open the hood and any other part.

4. Keep yourself and others well away from the engine for an additional 10 minutes or while the steam continues to blow out.

5. Checking that there is no danger of being burned eliminate the causes of overheating according to the manual, see "TROUBLESHOOTING" section. And then restart the engine.

BCleaning Radiator Core (outside)

If dust is between the fin and tube, wash it away with running water.

A Do not clean radiator with firm tools such as spatulas

or screwdrivers. They may damage the delicate fins or tubes. It can cause coolant leaks or decrease cooling performance.

A Be careful to keep water off of electrical parts.

BCleaning the Radiator

Clean the cooling system of the engine every 500 hours. In addition, clean it before adding anti-freeze and before stopping use of anti-freeze.

BAnti-freeze

To avoid personal injury: A When using anti-freeze, put on some

protection such as rubber gloves (Anti-freeze contains poison.).

A If should drink anti-freeze, throw up

at once and take medical attention.

A When anti-freeze comes in contact

with the skin or clothing, wash it off immediately.

A Do not mix different types of anti-

freeze. The mixture can produce chemical reaction causing harmful substances.

A Anti-freeze is extremely flammable

and explosive under certain conditions. Keep fire and children away from anti-freeze.

A When draining fluids from the

engine, place some container underneath the engine body.

A Do not pour waste onto the grounds,

down a drain, or into any water source.

A Also, observe the relevant

environmental protection regulations when disposing of 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.

39PERIODIC SERVICE

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 engine block from inside.

3. Mixing the LLC Premix 50% LLC with 50% clean soft water. When mixing, stir it up well, and then fill into the radiator.

4. The procedure for the mixing of water and anti-freeze differs according to the make of the anti-freeze. Refer to SAE J1034 standard, more specifically also to SAE J814c.

Vol %

Anti-freeze

50 -37 -34 108 226

At 1.013 x 10 Pa (760 mmHg) pressure (atmospheric) A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.

5. Adding the LLC (1) Add only water if the coolant level reduces in the

cooling system by evaporation.

(2) If there is a coolant leak, add the LLC of the same

manufacturer and type in the same coolant percentage.

*Never add any long-life coolant of different

manufacturer. (Different brands may have different additive components, and the engine may fail to perform as specified.)

6. When the LLC is mixed, do not employ any radiator cleaning agent. The LLC contains anticorrosive agent. If mixed with the cleaning agent, sludge may build up, adversely affecting the engine parts.

7. Kubota's genuine long-life coolant has a service life of 2 years. Be sure to change the coolant every 2 years.

A The above data represent industry standards that

necessitate minimum glycol content in the concentrated anti-freeze.

Freezing Point Boiling Point*

CFCF

BATTERY

To avoid personal injury: A Be careful not to let the battery

electrolyte contact your body or clothing.

A Wear eye protection and rubber

gloves, since the diluted sulfuric acid solution burns skin and eyes, and eats holes in clothing. Should this occur, immediately wash it off with running water and get medical attention.

Mishandling of the battery shortens the service life and adds to maintenance costs. Obtain the maximum performance and the longest life of the battery by handling properly and with care. Engine starting will be difficult, if the battery charge is low. Be sure to keep the battery in a fully charged state for best performance and battery life.

BBattery Charging

To avoid the possibility of battery explosion: The batteries come in two types:

refillable and non-refillable. For using the refillable type battery, follow the instructions below. A DO NOT use or charge the battery if

the fluid level is below the LOWER (lower limit level) mark. Otherwise, the battery component parts may deteriorate prematurely, which will shorten the battery’s service life or may cause an explosion. 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 equipped).

A When disconnecting the cable from

the battery, start with the negative terminal, and when connecting them, start with the positive terminal first.

A DO NOT check the battery charge by

placing a metal object across the terminals. Use a voltmeter or hydrometer.

ENGLISH

PERIODIC SERVICE40

1. Make sure that each electrolyte level is to the bottom of vent wells, if necessary, add only distilled water in a well-ventilated place.

ENGLISH

(1) Battery electrolyte level (A) "TOO LOW"

(B) "PROPER" (C) "TOO HIGH"

2. To slow charge the battery, connect the charger positive terminal to the battery positive terminal, and the negative to the negative, then recharge in the normal manner.

3. Quick recharging charges the battery at a high rate in a short time. This is only for emergencies.

4. Recharge the battery as early as possible, or battery life will be extremely shortened.

5. When exchanging an old battery for a new one, use a battery of equal specifications shown in page 2 to 7.

(1) Thick cable red (+) (2) Battery case (3) Negative / ground cable black (-) (4) Plug

(A) "HIGHEST LEVEL" (B) "LOWEST LEVEL"

A Connect the charger positive terminal to the battery

positive terminal, and negative to the negative.

A When disconnecting the cable from the battery, start

with the negative terminal first. When connecting the cable to the battery, start with the positive terminal first. If reversed, the contact of tools on the battery may cause a shortage.

A DO NOT remove or disconnect the battery during

operation, otherwise the engine cannot be stopped with the key switch.

BInstructions for Long Term Storage

1. When storing the generator for long periods of time, remove the battery, adjust the electrolyte to the proper level, and store in a dry and dark place.

2. The battery naturally discharges while it is stored. Recharge it once a month in summer, and every 2 months in winter.

41PERIODIC SERVICE

6. Clamp the other cable to the negative (black, (-) or neg.) terminal of the helper battery.

7. Clamp the other end to the engine block or frame of the generator as far from the dead battery as possible.

8. Start the disabled generator.

9. disconnect the jumper cables in the exact reverse order of attachment. (Steps 7, 6 and 5).

10. Remove and discard the damp rags.

ENGLISH

BBattery Boost Starting

To avoid serious personal injury. A Battery gases can explode. Keep

cigarettes, sparks, and flames away from battery.

A If generator battery is frozen, do not

battery boost start engine.

A Do not connect other end of negative

(-) jumper cable to negative (-) terminal of generator battery.

When battery boost starting engine, follow 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 battery and clamp the other end of the same cable to the positive (red, (+) or pos.) terminal of the helper battery.

A This machine has a 12 volt negative 1 ground starting

system.

A Use only same voltage for jump starting. A Use of a higher voltage source on generators

electrical system could result in severe damage to generators electrical system.

ELECTRIC WIRING

To avoid personal injury: Shorting of electric cable or wiring may cause a fire.

A Check to see if electric cables and

wiring are swollen, hardened or cracked.

A Keep dust and water away from all

power connections. Loose wiring and terminal parts make bad connections, be sure to repair them before starting the engine.

Damaged wiring reduces the capacity of electrical parts. Change or repair damaged wiring immediately.

(1) Dead battery (2) Lay a damp rag over vent caps. (3) Jumper cables (4) Engine block or frame (5) Helper battery (A) Connect cables in numerical order. Disconnect in reverse order after use.

PERIODIC SERVICE42

PERIODIC SERVICING AND CLEANING OF THE GENERATOR

ENGLISH

To avoid personal injury: A Only a qualified electrical engineer

must be allowed to do the servicing and cleaning.

A Before starting a periodic service,

disconnect the negative cable from the battery’s negative terminal to keep off the automatic start/stop device. Otherwise the device may get activated during the servicing job, possibly starting the engine unexpectedly and getting you injured. Also draw out the starter key beforehand.

A Before starting a periodic service,

stop the engine and wait until the engine cools down enough. Otherwise you may get scalded yourself.

1. Loosen the three M6 x 12 mm lock screws of the cleaner cover, and take out the cleaner cover.

(1) Cleaner cover (2) Lock screw (M6 x 12 mm)

2. Checkpoints and clean-up zones (1) Carbon brush holder assembly (2) Coupler (3) Coupler (4) Coupler (5) Diode stack terminal

Also remove dust and other foreign substances off the housing and cords.

A Check on the generator periodically to keep it at full

capacity for a long time.

A It is prohibited to run the generator in a poorly-

ventilated, dusty or humid place. If the generator is operated under a very dusty condition, dust and other foreign substances may get sucked in through its air intake. Such foreign substances may build up on conductive parts like the couplers and carbon brush. The deposits may cause poor contact, short-circuit or earlier worn-out carbon brush.

A To avoid the above trouble, remove the cleaner cover,

and check the carbon brush holder, terminals, couplers, and housing at regular intervals. If any foreign substance is found accumulated on these parts, clean them up.

A If any part is found discolored or deformed, replace

the part in question with new one.

A In practice, take the following procedure for the

periodic servicing and cleaning.

C Inspection procedure A Check the carbon brush every 1000 hours of

operation.

A As the generator becomes dirty, remove the cleaner

cover and check all the parts inside.

A To clean up the parts, use a soft brush and take care

not to damage the cords and other parts. Wipe off water and oil, if any, with waste cloth.

(1) Carbon brush holder assembly (2) Coupler (3) Coupler (4) Coupler (5) Diode stack terminal

3. Checking and cleaning the carbon brush holder assembly

A Be careful not to remove the two M4 x 8 mm machine

screws of the two cords (3 and 4) during this job.

(1) Loosen the two M6 x 15 mm bolts (2) and take out

the carbon brush holder (1).

(2) Remove dust and other foreign substances off

the terminals and body of the carbon brush holder assembly.

(3) Check the stretch allowance of the carbon brush

every 1000 hours of operation.

43PERIODIC SERVICE

(4) If the above allowance is shorter than 7 mm,

replace the carbon brush holder assembly with new one. In replacing, be careful not to confuse the colors of cords (3 and 4). M4 x 8 mm machine screw tightening torque:

1.0 to 1.4 N-m (0.1 to 0.14 kgf-m)

(5) Reassemble the above parts.

M6 x 15 mm bolt tightening torque:

7.84 to 11.8 N-m (0.8 to 1.2 kgf-m)

(1) Carbon brush holder assembly (2) Bolt (3) Black/White (4) Red/White

4. Checking and cleaning the couplers (1) There are three sets of couplers in total. (2) Disconnect all the couplers, and clean up the wire

slots and coupling zones.

(3) Finally, reassemble these parts.

(1) Coupler (A) "CLEAN UP"

5. Checking and cleaning the diode stack terminals (1) Remove foreign substances off the body and

cords.

(2) Disconnect the cords from the four flat terminals

and clean up the joints.

(3) Finally, reconnect the cords with care not to

confuse the cord colors. The cords have their respective polarities.

ENGLISH

(1) Carbon brush holder assembly (2) Brush

(A) More than 7 mm

(1) Red/White (2) Light green (3) Light green (4) Blue

PERIODIC SERVICE44

6. Double-checking (1) Double-check to see if the couplers are reinserted

deep enough.

ENGLISH

(2) Using the clamps, secure the cables and cords to

keep them out of contact with the bearing and rotor.

(3) Retighten the cleaner cover lock screws.

M6 x 12 mm lock screw tightening torque:

7.84 to 11.8 N-m (0.8 to 1.2 kgf-m)

(4) Trial-run the generator under no load to make

sure there is nothing unusual. If anything is unusual, remove its cause.

(1) Clamp

FUSE

The electrical system is 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.

(1) Fuse box

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 system. Refer to “TROUBLESHOOTING“ section of this manual or your local KUBOTA Dealer for specific information.

[J106, J107, J108, J110, J310, J313] [Engine model : Z482, D722]

(1) Fuse 3A (2) Fuse 10A (3) Fuse 5A (4) Fuse 15A (5) Fuse 15A (6) Fuse 10A

: External connection terminal block : AC (Accessory Line) : Glow : Solenoid : (spare) : (spare)

45PERIODIC SERVICE

Proper fan belt tension

A deflection of between 7 to 9 mm (0.28 to 0.35 in.) when the belt is pressed in the middle of the span.

[J112, J114, J116, J119, J315, J318, J320, J324] [Engine model : D1005, V1305]

(1) Fuse 3A (2) Fuse 10A (3) Fuse 5A (4) Fuse 5A (5) Fuse 10A

: External connection terminal block : AC (Accessory Line) : Glow : (spare) : (spare)

FAN BELT

BAdjusting Fan Belt Tension

[Engine model : Z482, D722]

ENGLISH

[Engine model : D1005, V1305]

To avoid personal injury: A Be sure to stop the engine and

remove the key before checking the belt tension.

A Be sure to reinstall the detached

safety shield after maintenance or checking.

1. Stop the engine and remove the key.

2. Apply moderate thumb pressure to belt between pulleys.

3. If tension is incorrect, loosen the alternator mounting bolts and, using a lever placed between the alternator and the engine block, pull the alternator out until the deflection of the belt falls within acceptable limits.

4. 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.

(1) Fan belt (2) Bolt and nut

(A) 7 to 9 mm (0.28 to 0.35 in.) (under load of 98 N (22.1 lbs.))

46 TRANSPORTING / STORAGE

Model Approx. gross wt. kg (lbs.)

J106, J107

[Engine model: Z482-B]

260 (573)

J108, J110, J310, J313

[Engine model: D722-B]

J112, J114, J315, J318

[Engine model: D1005-BG]

J116, J119, J320, J324

[Engine model: V1305-BG]

290 (639)

410 (904)

455 (1003)

TRANSPORTING / STORAGE

ENGLISH

MOKUJIYOU

BTransporting

BStorage

To avoid personal injury: A Secure the generator to prevent

movement during operation.

A DO NOT stand near or under the

generator while it is suspended.

A The generator is heavy. Utilize

suitable equipment to lift and transport. Keep hands and feet away from under the suspended generator.

A When transporting the generator,

remove the (-) battery cable, close the fuel cock lever, and keep the generator level to prevent fuel spillage.

A Use hangers and wire ropes which

are strong enough to withstand the weight of the machine.

1. When transporting the generator, use only suitable transporting equipment, such as crane, fork lift or etc.

2. The generator is equipped with the 2 inlets in the machine bed for forklift forks. Transportability is increased by 2 ways; special forklift openings and 1point lifting hook. Use lifting equipment of sufficient capacity.

To avoid personal injury: A DO NOT clean the machine with

engine running.

A To avoid the danger of exhaust fume

poisoning, do not operate the engine in a closed building without proper ventilation.

A When storing the generator just after

running, let the engine cool off.

Before storing the generator for more than a few months, remove any dirt on the machine, and:

1. Remove 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 from the generator, adjust the electrolyte level, and recharge it. Store the battery in a dry and dark place.

5. When the engine is not used for a long period of time, run it for about 5 minutes under no load every 2 to 3 months to keep it free from rust. If the engine is stored without any running, moisture in the air may condense into dew over the sliding parts of the engine, resulting in rust.

6. If you forget to run the engine for longer than 5 to 6 months, apply enough engine oil to the valve guide and valve stem seal and make sure the valves work smoothly before starting the engine.

7. Store the generator in a flat place and remove the key.

8. Do not store the generator in a place where flammable materials such as dry grass or straw are present.

9. When covering the generator for storage, let engine and muffler cool off completely.

10. Operate the engine after checking and repairing damaged wiring or pipes, and clearing flammable materials carried by rodents, insects or birds.

TROUBLESHOOTING

47TROUBLESHOOTING

MOKUJIYOU

To avoid personal injury: A Always perform any check at ”STOP” condition except for special check in which

operation is required.

A Do not touch the charging section during operation. A Keep your hands and body away from the rotating parts during operation.

If the machine does not function properly, use the following chart to identify and correct the cause.

BGenerator

Trouble Cause Countermeasure

After electrical equipment connected, generator does not operate.

Not generated Bad contact of brush Check, cleaning and maintenance of

Circuit breaker can not be operated.

Output cannot be obtained.

Rotation goes slow. Voltage drops. Breaker turns off.

Engine indicates loaded condition.

Circuit breaker is off. Turn breaker “ON“

Contact of output terminal and socket is bad.

Malfunction of electrical equipment Request repair.

Overload Reduce load.

Short circuit of load circuitry connected to output section

Initial current is too much. (e.g. motor load)

Overload Reduce load.

Short circuit of generator wiring Stop immediately.

Reinstall.

contact face and contact force of brush and slip ring. ( Danger: All works should be performed when stopped)

Repair load.

Reduce load.

Request for repair.

ENGLISH

48 TROUBLESHOOTING

BEasy Checker

Trouble Cause Countermeasure

ENGLISH

When the key is turned, the lamp doesn’t light on.

The water temperature lamp lights on when operating.

The oil pressure lamp lights on when operating.

The battery charge lamp lights on when operating.

Bulb is below or defective. Replace

Component or wiring defect of charging circuit

Engine overheating. See “Precaution Overheating“ in

Water temperature sensor faulty. Replace the water temperature sensor.

Water temperature sensor wiring faulty. Repair the wiring.

Insufficient engine oil. Add engine oil.

Lubricating system in trouble. Check the system.

Oil pressure sensor faulty. Replace the sensor.

Oil pressure sensor wiring faulty. Repair the wiring.

Fan belt loose or damaged. Readjust belt tension or replace the belt.

Alternator terminal in poor contact. Connect tightly.

Alternator problem. Check the alternator.

Check, repair

“RADIATOR“ section. (See page 38.)

The engine is not interrupted on the Z482, D722 models.

BEngine

Trouble Cause Countermeasure

Not started. Not turned or

slow turning.

Normal turning, but not started.

Engine starts but stops immediately.

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)

Fuel shortage. Refuel.

Fuel does not flow. Check fuel filter. If filter is dirty, replace.

Air and water are contained in fuel supply line.

Injection pipe is loosened. Re-tighten.

Fuse between solenoid input code

and grounding is blown.

Engine oil shortage. Add engine oil to upper limit of gauge.

Replace engine oil to D5W40 or D10W30

for cold.

Replace fuse.

Check fuel tank. Remove the settled

impurities or moisture.

Check pipe and fastening clamp. If any

damage exists, replace or repair.

Relieve air. Remove water inside of fuel tank and

filter.

Replace fuse after checking that no trouble exists on moving section of solenoid. (10A)

Trouble Cause Countermeasure

Rotation is irregular. Fuel shortage. Refuel.

Fuel does not flow. Check fuel filter. If filter is dirty, replace.

Check fuel tank. Remove the settled impurities or moisture.

Air and water are contained in the fuel supply line.

Injection pipe is loosened. Re-tighten.

Engine suddenly stops. Fuel shortage. Refuel.

Insufficient engine oil. Full oil.

Water temperature is too high.

Insufficient cooling water. Loosened water pump belt. Blockage of radiator.

Belt broken Replace.

Alternator defective Replace.

Insufficient output. When loaded, rotation goes slow.

Coolant leaks out. Insufficient cooling water. Fill cooling water.

Exhaust gas is bad. Choke of air cleaner element. Clean air cleaner element.

Abnormal sound Large vibration.

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.

Loosened fan belt. Adjust belt tension.

Blockage of radiator. Clean.

Engine oil is over filled. Remove oil to upper limit of gauge.

Fuel quality is bad. Replace fuel with good quality fuel.

Crack of vibration-proof rubber. Replace.

Others. Check, repair.

Check pipe and fastening clamp. If any damage exists, replace it, or repair.

Relieve air.

Remove water inside of fuel tank and filter.

Fill cooling water.

Adjust belt tension.

Clean.

49TROUBLESHOOTING

ENGLISH

If you ha ve an y ques tion s, co ntact your KUBOT A dea ler. D1005, V1305 engine only

50 AUTOMATIC START/STOP UNIT (A S/S UNIT)

AUTOMATIC START/STOP UNIT (A S/S UNIT)

ENGLISH

To connect the machine to the A S/S UNIT the generator is equipped with the ECTT on the left side panel of the control panel. To connect the exterior apparatus 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 the A S/S unit.

3. To assemble the TTC, set the TTC, reversing the up/ down sides of the cover.

For nomenclature and connection of terminal taps are referred to the “WIRING DIAGRAM” section . (See page

51.)

(1) Control panel (2) Exterior connection terminal taps (ECTT) (3) Terminal taps cover (TTC)

A For D1005, V1305 engine type the exterior connection

terminal taps are placed on the right side of control panel.