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Baroness GM2810, Service Manual

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Baroness GM2810 Service Manual Download Page 152

Relating to the Engine

Problem

Cause

Reference

The engine does not start (the
starter motor does not turn).

The interlock system was activated (not sitting on
the seat, parking brake not applied, rotary knife
rotation switch not set to the "OFF" position, or
traveling pedal not in neutral).

Electrical System -
Measurements - Interlock
System

Faulty interlock system component (seat switch,
neutral switch, parking brake switch, rotary knife
rotation switch (rocker switch), rotary knife
rotation relay (power relay), seat switch relay
(power relay), brake switch relay (power relay),
neutral switch relay (power relay), starter relay,
engine stop relay, rotary knife detection relay)

Electrical System -
Electrical Components
Electrical System -
Electrical Components -
Power Relays

Faulty 5A/15A fuse

Electrical System -
Electrical Components -
Fuse Box (E, H or J)

Faulty fusible link (50 A, 30 A)

Electrical System -
Electrical Components -
Fusible Link

Insufficient battery capacity or loose terminals

Electrical System -
Electrical Components -
General Inspections/
Repairs - Battery

Faulty ignition key switch

Electrical System -
Electrical Components -
Power Relays - Ignition Key
Switch

Faulty starter relay

Electrical System -
Electrical Components -
Starter Relay

Faulty starter motor

Engine Maintenance
Manual

Overheating or damage to a moving part of the
engine

Engine Maintenance
Manual

Malfunction related to electrical wire

Inspect and repair or
replace the wire-related
part.

The engine does not start (but the
starter motor turns).

No fuel

Engine Handling Manual
(Supply fuel and
automatically air bleed by
setting the ignition key
switch to the "ON"
position.)

Fuel pump does not operate.

Electrical System -
Electrical Components -
Fuel Pump

Clogged fuel filter

Engine - Inspection/Repair
of Each Part - Fuel Filter

Wrong fuel

Engine Handling Manual

GM2810

Troubleshooting

Page 8-2

Relating to the Engine

Summary of Contents for GM2810

Page 1: ...5 Unit Rotary Mower Service Manual Serial No 10001 Ver 1 0...

Page 2: ...ine Baroness parts or parts designated by Kyoeisha Note that the Baroness product warranty may not apply to defects caused by the use of parts from other companies Warning Symbols This manual uses the...

Page 3: ...ool Page 5 6 Measurement Page 5 6 Adjustment Page 5 8 Electrical components Page 5 10 General inspection and repair Page 5 27 Main body Page 6 1 Maintenance Page 6 2 Specifications Page 6 2 Operating...

Page 4: ...GM2810 Contents...

Page 5: ...Page 1 2 Training Page 1 2 Preparation Page 1 2 Operation Page 1 3 Maintenance and storage Page 1 4 Safety Signs and Instruction Signs Page 1 5 About Safety Signs and Instruction Signs Page 1 5 Safet...

Page 6: ...its task Lack of awareness of the effect of ground conditions especially slopes 1 2 3 1 2 Incorrect hitching and load distribution Never allow children or people unfamiliar with these instructions to...

Page 7: ...this purpose 5 5 6 7 8 9 1 2 3 4 1 2 3 4 5 Never drive the machine on a slope with an angle of gradient that is greater than that specified or in a place where there is a danger of the machine slippi...

Page 8: ...5 16 17 18 19 20 21 22 23 24 1 2 To reduce the fire hazard keep the engine silencer muffler battery compartment fuel storage area cutting units and drives free of grass leaves or excessive grease Clea...

Page 9: ...g condition and all hardware tightened Replace all worn or damaged decals Keep all nuts bolts and screws tight to be sure the equipment is in safe working condition Check the grass catcher frequently...

Page 10: ...GM2810 Safety Page 1 6 Safety Signs and Instruction Signs...

Page 11: ...Waste Disposal Page 2 2 About the Waste disposal Page 2 2 Disposal GM2810 Disposal Page 2 1...

Page 12: ...posal Make sure that waste generated when servicing or repairing the machine is disposed of in accordance with local regulations e g waste oil antifreeze batteries rubber products and wires etc GM2810...

Page 13: ...Page 3 4 Tightening torques Page 3 5 Standard tightening torques Page 3 5 Principal tightening torques Page 3 8 Jacking up the machine Page 3 10 About the Jacking up the machine Page 3 10 Jack up Poin...

Page 14: ...7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 84...

Page 15: ...bic Meters Cubic Centimeters m3 m3 cm3 0 7646 0 02832 16 39 Weight Tons Short Pounds Ounces Avdp sh tn lb oz Metric Tons Kilograms Grams ton kg g 0 9078 0 4536 28 3495 Pressure Pounds Sq In Pounds Sq...

Page 16: ...lever is at the 5th notch Proximity sensor Outer ends of mower units 4 5 400 mm 15 75 in from the ground Proximity sensor detection position 4 5 mower arm fulcrum cams 1 4 mm 0 04 0 16 in Distance for...

Page 17: ...efore sufficient tightening cannot be applied If screw is wet by water or oil do not tighten it with normal tightening torque If the screw is wet the torque coefficient will get smaller and it may res...

Page 18: ...75 593 02 752 34 104 134 1 060 49 1 366 40 920 50 1186 03 M14 106 134 1 080 88 1 366 40 938 21 1 186 03 140 188 1 427 58 1 917 04 1 239 14 1 663 99 M16 152 188 1 549 94 1 917 04 1 345 35 1 663 99 210...

Page 19: ...3 4 117 68 1200 1 355 78 19 3 4 117 68 1200 1 355 78 25 1 137 30 1400 1 581 74 32 1 1 4 166 72 1700 1 920 69 38 1 1 2 205 94 2100 2 372 61 50 2 245 17 2500 2 824 54 Fittings with parallel threads O r...

Page 20: ...lt heat treated M12 65P1 5 67 85 683 20 866 75 593 02 752 34 Front axle K0015200702 Bolt heat treated M20 70P1 5 370 450 3772 89 4588 65 3274 87 3982 95 Brake ass y K1720000190 Bolt heat treated M12P1...

Page 21: ...120 29 38 295 71 387 49 256 68 336 34 Diff lock valve K0024100151 Bolt w hexagon hole M10 15 29 38 295 71 387 49 256 68 336 34 Knife and knife guide K0010120302 Bolt heat treated M12 30 67 85 683 20 8...

Page 22: ...ist or jack Support the machine securely with jack stands or appropriate blocks Failure to do so may cause the machine to move or fall resulting in injury or death Use the jack up points identified in...

Page 23: ...wyt62 009 Jack up Points_003 Center of pivot rwyt62 010 Jack up Points_004 Below rear wheel motors Two locations rwyt62 032 Jack up Points_005 1 2 3 4 Maintenance standards and maintenance GM2810 Main...

Page 24: ...ule Other locations where the specified grease or lubricant is used are indicated in Greasing Points Add grease using the specified grease or lubricant Greasing Points Grease nipples are installed in...

Page 25: ...ulcrum There is one greasing point on the arm connected to each mower unit Mower units 1 4 and 5 8bq62b 025 Greasing Points_003 1 2 Mower units 2 and 3 8bq62b 026 Greasing Points_004 Lift arm fulcrum...

Page 26: ...030 Greasing Points_008 1 Grease nipple 2 locations Mower units 2 and 3 There are three greasing points on each cylinder 1 8bq62b 031 Greasing Points_009 1 Grease nipple 3 locations 4 Pivot Middle be...

Page 27: ...nts_013 Traveling pedal shaft fulcrum There are two locations 8bq62b 036 Greasing Points_014 Foot brake There are three locations 8bq62b 037 Greasing Points_015 6 7 8 Maintenance standards and mainten...

Page 28: ...GM2810 Maintenance standards and maintenance Page 3 16 Greasing...

Page 29: ...age 4 17 Raise lower circuit Page 4 19 Steering circuit Page 4 21 Rotary Knife Rotation Circuit Page 4 23 Special Tool Page 4 24 List of Special Tools Page 4 24 Measurement Page 4 30 Note Page 4 30 Tr...

Page 30: ...r s Operating Manual and Parts Catalog In order to maintain the integrity of the hydraulic device it cannot be disassembled and repaired For those parts that must be repaired by the manufacturer the d...

Page 31: ...ATON orbit motor Front wheel motor Displacement 495 0 cm3 rev 30 05 in3 rev Rear wheel motor Displacement 195 0 cm3 rev 11 90 in3 rev Rotary motor CASAPPA PLM20 20 Gear motor Displacement 21 14 cm3 re...

Page 32: ...allons Hydraulic line filter 10 m cartridge type Hydraulic oil Shell Tellus S2M46 or equivalent ISO VG46 Adjusted Value Assist valve Low pressure side 2 4 MPa 348 08 psi Under the driver s seat High p...

Page 33: ...Steering cylinder 2 Slow return valve 8 Gear pump 14 Exhaust pressure valve 3 Up down cylinder 9 Piston pump 15 Hydraulic oil filter 4 Assist valve 10 Rotary knife rotation valve 16 Suction filter 5 W...

Page 34: ...in front of the main pump 1 2 3 4 5 6 7 8 Piston pump This converts the mechanical energy of the engine to fluid energy by using the reciprocating motion of the piston This is located at the center of...

Page 35: ...tioning the oil level is regularly raised and lowered In addition due to atmospheric pressure fluctuations as well as the temperature air is flowing in and out of the hydraulic tank Therefore the vent...

Page 36: ...g Forward Traveling_001 shows flow of oil The flow of oil shows that for 4WD forward traveling shows port name 1 Oil cooler 6 Gear pump 11 Wheel motor front left 2 Wheel motor rear right 7 Oil tank 12...

Page 37: ..._001 shows the flow of oil The flow of oil shows that for raising the mower unit turning the power steering to left shows port name inside 1 Orbitrol 7 Manifold rear 13 5 cylinder 2 Control valve 8 Ma...

Page 38: ...P1 P1 a4d9ch 006 Flow of Oil during Cutting with Mower Unit_001 shows the flow of oil The flow of oil shows that for cutting with the mower unit shows port name inside 1 Oil cooler 6 2 motor 11 Gear...

Page 39: ...nch vuy27z 001 Hydraulic hose_001 Warning Be sure to depressurize the hydraulic system before maintaining or repairing it Stop the engine and lower the rake When checking for pinhole leakage of the hy...

Page 40: ...and further tightening of 3 4 to one turn will cause the sleeve to bite into the tube w7s31b 007 Bite type tube fitting_007 Fasten the nut and check that the sleeve end is a few mm apart from the tub...

Page 41: ...ck to see if the O ring is properly fitted to the groove of the main body Check to see that the thread part seat surface of O ring port and O ring are free from flaws or foreign matter Before fitting...

Page 42: ...turn from that position in the loosening direction to the setting position 2 3 After fitting the opposite screw tighten the lock nut while holding the main body with a spanner etc to ensure that the s...

Page 43: ...ntion to the following precautions when you use the sealing tape Slightly pull the sealing tape as tight as you can clearly see the thread mark on the tape while you wrap it and overlap a half of its...

Page 44: ...ng machine Then stop the engine and remove the key To depressurize the hydraulic circuit set the traveling pedal and all the drives of the operating machine to the neutral position To depressurize the...

Page 45: ...wering Assist valve B A B A B A B A SOL 1 SOL 2 A PLT B C A GA2 G1 4 GB G1 4 GA1 G1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 16UNF Manifold rising lowering rear Valve knif...

Page 46: ...st valve B A B A B A B A SOL 1 SOL 2 A PLT B C A GA2 G1 4 GB G1 4 GA1 G1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 16UNF Manifold rising lowering rear Valve knife rotation...

Page 47: ...ist valve B A B A B A B A SOL 1 SOL 2 A PLT B C A GA2 G1 4 GB G1 4 GA1 G1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 16UNF Manifold rising lowering rear Valve knife rotation...

Page 48: ...t valve B A B A B A B A SOL 1 SOL 2 A PLT B C A GA2 G1 4 GB G1 4 GA1 G1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 16UNF Manifold rising lowering rear Valve knife rotation 2...

Page 49: ...st valve B A B A B A B A SOL 1 SOL 2 A PLT B C A GA2 G1 4 GB G1 4 GA1 G1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 16UNF Manifold rising lowering rear Valve knife rotation...

Page 50: ...st valve B A B A B A B A SOL 1 SOL 2 A PLT B C A GA2 G1 4 GB G1 4 GA1 G1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 16UNF Manifold rising lowering rear Valve knife rotation...

Page 51: ...B A B A B A B A SOL 1 SOL 2 A PLT B C A GA2 G1 4 GB G1 4 GA1 G1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 16UNF Manifold rising lowering rear Valve knife rotation 2 3 4 Val...

Page 52: ...re measurements vasdfi 004 K4701000020 Pressure For the range of 0 15 MPa For the range of 0 2 175 60 psi For the range of 0 152 96 kgf cm2 Primarily used for measuring the pressure of low pressure pa...

Page 53: ...shut off the fluid to be measured during maintenance inspection or repair etc of the pressure gauge Pressure gauge joint vasdfi 006 K4701000040 Used as a joint for pressure pipes Female connector 1015...

Page 54: ...sed as an adapter for the T joint during pressure measurements Adapter 1013 12 q9c6v6 008 K3000120002 Y Used as an adapter for the T joint during pressure measurements quantity used two WP280 6 hose 1...

Page 55: ...8000542 Y Used as a plug when the hydraulic hose is removed Screw cap female PF1 2 q9c6v6 002 K3008000502 Y Used as a plug when the hydraulic hose is removed Special bushing 3 4 16UNFPT1 4 q9c6v6 003...

Page 56: ...a connector when installing the pressure gauge to the pressure measuring port O ring connector PF1 4PF1 4 q9c6v6 006 K3008000232 Y Used as a connector when installing the pressure gauge to the pressu...

Page 57: ...ushing for size alignment during pressure measurements 90 adjustable elbow 1086 6 q9c6v6 048 K3008000442 Y Used as a connector when installing the pressure gauge to the pressure measuring port Hydraul...

Page 58: ...emember that the machine must always be kept clean for pressure measurement Contamination may lead to clogging or breakage of the hydraulic circuit Review the measuring method before starting measurem...

Page 59: ...r rising lowering Assist valve B A B A B A B A SOL 1 SOL 2 A PLT B C A GA2 G1 4 GB G1 4 GA1 G1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 16UNF Manifold rising lowering rear...

Page 60: ...096 6 1 2 Attach the pressure gauge for high pressure measurements onto the O ring connector of the forward side measuring port 1 2 g5t8is 034 Forward_003 1 Forward side measuring port connector 2 Pre...

Page 61: ...erse side measurement point of the 2WD 4WD changeover valve located in the center upper area of the pivot of the main unit 1 2 7edlvx 034 Reverse_001 1 2WD 4WD changeover valve 2 Plug 6 1 Attach the O...

Page 62: ...ev it up to the maximum rpm Depress the reverse pedal It is normal if the pressure becomes 24 1 MPa 3 495 29 psi with the tires locked without slipping Items to Prepare for Measurement Prepare a press...

Page 63: ...Pa 3 0MPa SOL 1 2 4MPa 3 2 Cylinder rising lowering Assist valve B A B A B A B A SOL 1 SOL 2 A PLT B C A GA2 G1 4 GB G1 4 GA1 G1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 1...

Page 64: ...igh pressure measurements 1 2 Make sure that the parking brake is applied and then start the engine 1 z4kw7w 011 Up Down circuit_004 1 Mower unit Rev the engine up to the maximum rpm The normal pressu...

Page 65: ...Pa 3 0MPa SOL 1 2 4MPa 3 2 Cylinder rising lowering Assist valve B A B A B A B A SOL 1 SOL 2 A PLT B C A GA2 G1 4 GB G1 4 GA1 G1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 1...

Page 66: ...ow 3 Pressure gauge for low pressure measurements Make sure that the parking brake is applied and then start the engine and rev it up to the maximum rpm The normal pressure is 6 9 MPa 1 000 73 psi whe...

Page 67: ...Pa 3 0MPa SOL 1 2 4MPa 3 2 Cylinder rising lowering Assist valve B A B A B A B A SOL 1 SOL 2 A PLT B C A GA2 G1 4 GB G1 4 GA1 G1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 1...

Page 68: ...1 4 3 45 elbow 1035 6 4 Hydraulic hose 5 Pressure gauge for extremely low pressure measurements Make sure that the parking brake is applied and then start the engine and rev it up to the maximum rpm T...

Page 69: ...wering Assist valve B A B A B A B A SOL 1 SOL 2 A PLT B C A GA2 G1 4 GB G1 4 GA1 G1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 16UNF Pressure gauge Pressure gauge Manifold r...

Page 70: ...Units 1 5_002 1 Gear motor 2 Elbow 3 Hydraulic hose 1 2 Install a screw cap male onto the removed hydraulic hose and then install a screw cap female onto the elbow 1 2 4 3 gy2el3 004 Mower Units 1 5_...

Page 71: ...e 3 90 adjustable elbow Mower Units 2 3 4 1 1 2 3 4 5 syaq7s 010 Mower Units 2 3 4_001 1 Rotary Knife Rotation Valves 5 6 Caution Before starting pressure measurement make sure that there are no peopl...

Page 72: ...ary knife rotation valve for mower units 2 3 4 is being measured Make sure that the parking brake is applied and then start the engine and rev it up to the maximum rpm The normal pressure is 20 7 MPa...

Page 73: ...ure gauge Pressure gauge Pressure gauge Pressure gauge M1 1Rotary Knife Rotation Motor in side measurement M2 1Rotary Knife Rotation Motor out side measurement M2 5Rotary Knife Rotation Motor in side...

Page 74: ...ting holes at the front of 1 mower unit 1 hlnjwg 003 Rotary Knife Rotation Motor Circuit_003 1 Cutting height adjusting hole 1 2 3 Loosen the wing bolts of the knife stopper insert it onto the rotary...

Page 75: ...h pressure measurements from IN side of the gear motor of 1 mower unit and restore the original state Follow a similar procedure as IN side to install the pressure gauge for high pressure measurements...

Page 76: ...1 Traction assist switch A ON B OFF 1 1 2 3 2 Lift the seat and then remove the screw cap female of the pressure measurement port 1 2 zj5trg 001 Adjustment of Assist Valve_002 1 Seat 2 Screw cap femal...

Page 77: ...essure valve settings Make sure that the pressure gauge for low pressure measurements reads 3 0 MPa 435 10 psi Turn the adjustment knob for the low pressure valve counterclockwise to set the pressure...

Page 78: ...VE to the 2WD position and then firmly depress the brake pedal If slowly depressing the forward pedal switches the pressure at the pressure measurement port of the assist valve from a low pressure of...

Page 79: ...hen fitting hoses and hydraulic fittings follow the proper procedure for tightening After repair check to see whether the hydraulic system functions normally and whether there are any broken parts Whe...

Page 80: ...the oil becomes clean 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 If no abnormality is found operate normally and maintain according to the maintenance schedule Air bleeding Caution When you replace or rep...

Page 81: ...rse to check if the wheels rotate in correct direction When the wheels rotate in wrong direction stop the engine and then swap the lines for the motor to correct rotation direction Stop the engine whe...

Page 82: ...GM2810 Hydraulic system Page 4 54 General inspection and repair...

Page 83: ...Electrical components Page 5 10 About the Electrical components Page 5 10 Seat Switch Page 5 12 Parking Brake Switch Page 5 12 Rocker Switch Page 5 13 Rocker switch M Page 5 13 Proximity Sensors Page...

Page 84: ...pecifications Adjusted Value Parking brake switch Slight clearance Parking brake lever Clearance between the parking brake lever and the switch contact point when the brake lever at 5 notch Proximity...

Page 85: ...Fusible link 30A 25 Battery 4 Work lamp 15 Rotary knife rotation valve 26 Level switch 5 Power relay 411 16 ECU Assy 27 Seat switch 6 Power relay 602 17 Fusible link 50A 28 Diff lock valve 7 Power re...

Page 86: ...y knife rotation Power relay CA1 This power relay is linked to the rotary knife rotation switch and seat switch It controls the engine operation 1 2 3 4 5 6 7 Buzzer oil level This buzzer is linked to...

Page 87: ...witches between 2WD and 4WD It is located behind the rear wheel pivot 15 16 17 18 19 20 21 22 Potentiometer This controls the rotation of the engine It is located on the control panel which is located...

Page 88: ...1 12 100 0 Measurement of specific weight of 12V battery Check all the cells after charge Replace the battery when the specific weight is 1 225 or less or gap of that between each cell is 0 05 or mor...

Page 89: ...ng brake and leave the seat Note If you leave the seat while the engine is running apply the parking brake The engine will stop when the knife rotation switch is ON even if you apply the parking brake...

Page 90: ...tting value 40 cm 15 75 in 3 Mower unit 4 4 Mower unit 5 1 2 Caution See the list in Tightening torques Page 3 5 Note that the Baroness product warranty may not apply to defects caused by incorrect or...

Page 91: ...ee Adjusted Value of the Foot Brake Wire Page 6 3 With the parking brake at notch 5 adjust adjusting nut A and adjusting nut B of the parking brake switch to create a slight clearance at the switch co...

Page 92: ...controlled by open close of the rotary knife rotation valve by the operation switch rocker switch the rotary knife rotation relay the proximity sensor terminal relay and the solenoid valve The proximi...

Page 93: ...cker switch 2 2WD 4WD changeover switch rocker switch 3 Terminal relay 4 Solenoid 1 5 Solenoid 2 6 Power relay MR5A602A1K Diff Lock Circuit Diff lock operation is controlled by the opening closing of...

Page 94: ...t Circuit_001 1 Assist switch rocker switch 2 Terminal relay 3 Solenoid Seat Switch The seat switch is located right underneath the seat and is not usually conducted It is normal if it is conducted wh...

Page 95: ...e operation side and no conduction between sockets A and C when the rocker switch is released Proximity Sensors Proximity sensors detect through non contact methods that objects are nearby ON OFF 1 2...

Page 96: ...ed off when the object is close to the proximity sensor 1 2 Inspection of Control Output Caution Make sure not to short circuit the battery terminals Connect the battery to the connecter terminal brow...

Page 97: ...ter to the connector terminal blue 1 2 3 35efyq 001 Inspection of Output Voltage_001 1 Connector terminal brown 2 Connector terminal black output 3 Connector terminal blue It is normal if the voltage...

Page 98: ...7 and 11 Between 8 and 12 1 2 3 Caution Do not short circuit the battery terminals It is normal that there is conduction between 9 and 13 and LED1 lights up with the battery connected between COM and...

Page 99: ...urns it to its neutral position and the differential lock is disengaged 1 OFF ON ON k3y8px 001 Diff Lock Switch_001 1 Diff lock switch Inspection of Auto Return Switch Prepare a stand alone switch It...

Page 100: ...tions Voltage Resistance Holding Current DC 12 V 10 9 1 1 A 1 2 Diff lock Valve The diff lock valve is located in the upper part of the front axle Operation of the solenoid valves switches the hydraul...

Page 101: ...when the measured values are as in the table Solenoid Specifications Solenoid Number Voltage Resistance Holding Current 1 DC 12 V 10 1 2 A 2 DC 12 V 7 2 1 67 A 1 2 Assist Valve The assist valve is lo...

Page 102: ...t 75 2 1 4 3 6 5 2 5 6 1 4 3 38jyg3 004 Inspection of Power Relay_001 1 2 Normal operation is when there is continuity between relay terminals 3 and 6 and no continuity between relay terminals 4 and 5...

Page 103: ...elay The normal measured resistance between relay terminals 1 and 2 is about 75 2 1 5 3 7 6 2 7 1 6 5 3 38jyg3 007 Inspection of Power Relay_001 1 2 It is normal if there is no conduction between both...

Page 104: ...A1 DC12V N black 1 htbe2c 001 Rotary Knife Rotation Detection Relay and Engine Stop Relay_002 1 Power Relay Engine Stop Inspection of Power Relay Remove the power relay 1 2 1 The normal measured resis...

Page 105: ...e Valve Specifications Type Rating H3 12 V 35 W Fusible Link Fuse capacities of the fusible links are 30 A and 50 A 2 1 1qgabk 008 Fusible Link_001 1 Fusible link 50 A 2 Fusible link 30 A Fuse box The...

Page 106: ...s F G 5 A ECU_KeySwitch_Start H 5 A ECU_ManualRegenerationSwitch AutoRegenerationInhibitSwitch I 5 A Operating oil buzzer J 5 A Water temperature buzzer K 5 A Spare L 5 A M 15 A N 15 A O Fuse removal...

Page 107: ...temperature buzzer is normal if it emits an intermittent tone when the red wire is connected to the positive terminal and the black wire is connected to the negative terminal of a 12 V battery 1 gypy...

Page 108: ...dicates the float travel distance Normal operation is when there is continuity when the float is down and no continuity when the float is up 5 4 3 2 1 bnec97 003 Level Switch_001 1 Float travel distan...

Page 109: ...a wet cloth and flush the affected area with plenty of water The electrolyte contained in the battery is sulfuric acid Contact of the electrolyte sulfuric acid with the skin could cause blindness or b...

Page 110: ...the electrolyte overflows from the battery wipe it with a wet cloth Failure to do so could cause damage to the instruments When cleaning the battery do not use organic solvents such as benzene thinne...

Page 111: ...L E V E L L O W E R L E V E L 1 2 48yhlu 006 Inspection of the battery_001 4 5 1 Upper limit 2 Lower limit Replacement of Battery When replacing the battery note the following precautions and be sure...

Page 112: ...poor connections or electrolyte leaks from around the terminals Replace the battery with one that is the same size When replacing the battery follow these steps Removing the old battery Important Be c...

Page 113: ...tery respectively If they are connected reversely or loosely it may cause ignition explosion failure of the battery charger or damage on the vehicle or equipment due to the polarity inversion of the b...

Page 114: ...e for charging to recover the battery left for a long time A high electrolyte temperature deteriorates parts such as polar plates inside the battery and shorten its lifetime GM2810 Electrical system P...

Page 115: ...Maintenance Page 6 2 About Maintenance Page 6 2 Specifications Page 6 2 Tire Pneumatic Pressure Page 6 2 Adjusted Value Page 6 2 Main body GM2810 Main body Page 6 1...

Page 116: ...kPa kgf cm2 psi lb in Front wheel 150 1 5 21 83 Rear wheel 140 1 4 20 37 Adjusted Value mm in Rod distance between rod end centers Forward rod 923 36 34 Reverse rod 923 36 34 Neutral adjustment rod 22...

Page 117: ...4 jc5o3p 010 Adjustment of Traveling Rod_001 1 Reverse rod 2 Forward rod 3 Neutral adjustment rod 4 Pump neutral lever 5 Lever adjustment bracket Forward rod 923 mm 36 34 in jc5o3p 011 Adjustment of T...

Page 118: ...GM2810 Main body Page 6 4 Specifications...

Page 119: ...5 Removal and installation of each section Page 7 5 Mower unit Page 7 5 Rotary Knife Page 7 6 Front Roller Assy Page 7 10 Rear Roller Assy Page 7 12 Cutting Height Adjusting Plate Page 7 13 Mower Arm...

Page 120: ...GM2810 Owner s Operating Manual and Parts Catalog For information on attaching and removing optional parts and attachments refer to the handling instructions for the corresponding attachment Specifica...

Page 121: ...er 47 and inner 17 6204 Bearing driver q9c6v6 009 K4802000762 Used when installing bearings with outer 47 and inner 20 6208 Bearing driver q9c6v6 009 K4802000772 Used when installing bearings with out...

Page 122: ...l installer q9c6v6 011 K4802000782 Used when installing 35 oil seals 82 Oil seal installer q9c6v6 011 K4802000792 Used when installing 82 oil seals GM2810 Operating Machine and Mower Units Page 7 4 Sp...

Page 123: ...t to the mower arm 1 1 2 2 3 4 3 4 5 6 A A B B aqfz1n 001 Removal of Mower Unit_001 1 2 1 Nut 2 Spring washer 3 Washer 4 Shoulder bolt 5 Mower arm 6 Mower unit Pull out the mower unit to remove it Ins...

Page 124: ...roundhead pin inserted at a and then insert them at b 1 2 a b to41g1 003 Mower unit 1_002 1 Cotter pin 2 Hardened roundhead pin 1 2 3 4 Follow the steps below to remove the rotary knife Use the squar...

Page 125: ...m 2 Clip pin 3 Grip pin Pull out the mower unit 1 wsbhzf 002 Mower Units 2 3_002 1 Mower unit 1 2 Install the grip pin and clip pin in the locking hole for maintenance 2 1 wsbhzf 003 Mower Units 2 3_0...

Page 126: ...8 1 2 3 4 Mower Units 4 5 Danger Danger The rotary knife is an edged tool Handle them carefully since they could cut your hands or legs Caution When touching edged tools wear gloves since they could c...

Page 127: ...t your hands or legs Caution See the list in Tightening torques Page 3 5 Note that the Baroness product warranty may not apply to defects caused by incorrect or overtorque tightening etc Caution The r...

Page 128: ...tary knife 2 Mower unit Remove the left and right nuts and washers that are used to attach the front roller assembly to the mower frame 1 2 3 3 4 4 kaatr1 002 Removal of Front Roller Assembly_002 1 Mo...

Page 129: ...frame Note If the front roller assembly is not fully inserted tap it with a plastic hammer until it fits into the correct installation position Follow the steps below to install the disc springs and...

Page 130: ...ssembly_002 1 Mower frame 2 Rear roller assembly 3 Nut 4 Washer 1 2 3 Lift the rear roller assembly and remove it from the mower frame 1 2 ylrqcl 003 Removal of Rear Roller Assembly_003 1 Rear roller...

Page 131: ...stment Plate_001 1 Nut 2 Washer 3 Adjusting collar 1 2 Important The cutting height adjustment plate has six holes Check and mark the installation position of the bolts used to install when removing t...

Page 132: ...er Arm Removal of Mower Arm Danger Danger The rotary knife is an edged tool Handle them carefully since they could cut your hands or legs Caution When touching edged tools wear gloves since they could...

Page 133: ...See the list in Tightening torques Page 3 5 Note that the Baroness product warranty may not apply to defects caused by incorrect or overtorque tightening etc For installing it reverse the removing pr...

Page 134: ...r replace it Important Frequently inspect the rotary knife since it may become dull quickly if the machine is operated in an environment of dry soil or sand Make sure that the rotary knife is not bent...

Page 135: ...2 Rotary knife bottom side Important Before installing the rotary knife make sure that it is balanced If the edge of the rotary knife becomes chipped or thin replace it with a new one The criteria for...

Page 136: ...from the included tools to secure the rotary knife so that it does not turn Remove the two bolts spring washers and washers used to install the rotary knife Remove the knife guide 1 2 3 4 5 1 2 3 Rem...

Page 137: ...ve the key Lift the mower unit at the front 1 x9s1w3 005 Mower Units 2 3_004 1 Mower unit Remove the cotter pin and hardened roundhead pin inserted at a and then insert them at b 1 2 a b c ahk5df 002...

Page 138: ...ing washer 5 Washer 6 Knife guide Important The tightening torque for the knife mounting bolt is 67 85 N m 683 20 866 75 kgf cm Install the rotary knife For installing the rotary knife reverse the rem...

Page 139: ...ecure the rotary knife so that it does not turn Remove the two bolts spring washers and washers used to install the rotary knife Remove the knife guide 1 2 3 4 1 2 3 Remove the rotary knife 1 6 2 3 4...

Page 140: ...rpen the worn cutting edge with a grinder or sander If the edge of the rotary knife becomes chipped or thin replace it with a new one The criteria for grinding the rotary knife is described below When...

Page 141: ...nger The rotary knife is an edged tool Take extra care in handling since they could cut your hands or legs Danger Danger Using an imbalanced rotary knife may cause vibrations resulting in damage to th...

Page 142: ...arefully since it could cut your hands or legs Caution Wear gloves when touching edged tools to avoid cutting your hands Remove the mower unit See Removal of Mower Unit Page 7 5 Remove the two bolts u...

Page 143: ...ow to remove the bearing Place blocks of wood etc under the housing to create space for the bearing to be pushed out 6 7 8 1 Use an iron pipe and tap it with a plastic hammer to remove the bearing 1 2...

Page 144: ...y to defects caused by incorrect or overtorque tightening etc Place the housing upside down and then drive in the bearing and oil seal evenly Note Use a bearing driver to drive in the bearings and oil...

Page 145: ...d then install the washer and roundhead screw 1 2 3 1lbr3a 004 Inspection of Housing_015 14 15 16 1 Stop ring 2 Roundhead screw 3 Washer Insert the housing into the mower unit and then temporarily ins...

Page 146: ...e is no play in the fit of the roller and the bearing Danger Danger The rotary knife is an edged tool Handle it carefully since it could cut your hands or legs Caution When touching edged tools wear g...

Page 147: ...of Rear Roller Wear of bearings due to frequent usage and invasion of water may damage bearings to prevent smooth rotation of the roller Inspect and replace the parts such as the oil seal bearings Mak...

Page 148: ...2 Inspection of Rear Roller_002 1 Roller shaft 2 Plastic hammer 2 3 Remove collar O ring oil seal A washer bearing and oil seal B from one end of the shaft 1 1 2 2 3 3 4 4 5 5 6 6 6ehg7n 003 Inspectio...

Page 149: ...n the roller shaft is fixed and the roller is rotated Apply grease See Greasing Points Page 3 12 Install the rear roller ass y See Installation of Rear Roller Assy Page 7 12 Mower Arm Inspection of Mo...

Page 150: ...GM2810 Operating Machine and Mower Units Page 7 32 Inspection and repair of each section...

Page 151: ...Relating to the Engine Page 8 2 Relating to Traveling Page 8 5 Relating to Steering Page 8 8 Relating to Operating Machine and Mower Unit Page 8 9 Troubleshooting GM2810 Troubleshooting Page 8 1...

Page 152: ...J Faulty fusible link 50 A 30 A Electrical System Electrical Components Fusible Link Insufficient battery capacity or loose terminals Electrical System Electrical Components General Inspections Repair...

Page 153: ...seat without applying the parking brake Electrical System Measurements Interlock System Clogged air cleaner element Engine Inspection Repair of Each Part Air Cleaner Insufficient fuel Engine Handling...

Page 154: ...diator or oil cooler blocked with dirt or dust Engine Inspection Repair of Each Part Cooling System Insufficient amount of coolant This machine s Owner s Operating Manual Insufficient fan belt tension...

Page 155: ...c oil Viscosity of the hydraulic oil is wrong Hydraulic system Specifications Hydraulic system Inspection of each part repair Hydraulic oil Insufficient cooling of the hydraulic oil cooler Engine Insp...

Page 156: ...alfunction of the terminal relay Electrical system Electrical equipment Terminal relay 15A fuse blew Electrical system Electrical equipment Fuse box D Insufficient adjustment of the differential lock...

Page 157: ...rake manual Page 9 13 Insufficient adjustment of the brake adjust nut part Reference RT mechanical brake manual Page 9 13 Disk pad part has water dust oil etc Reference RT mechanical brake manual Page...

Page 158: ...contamination invasion of water air Hydraulic system Inspection of each part repair Hydraulic oil Viscosity of the hydraulic oil is wrong Hydraulic system Specifications Hydraulic system Inspection of...

Page 159: ...oil filter Malfunction of the gear pump Hydraulic system Measurement Steering circuit Hydraulic system Removal and installation of each part Gear pump Rotary knife does not rotate mower unit 2 3 4 or...

Page 160: ...n of each part Gear pump Rotary knife rotation speed is slow mower unit 2 3 4 or mower unit 1 5 Malfunction of rotary knife rotation valve Electrical system Electrical equipment Solenoid valve Rotary...

Page 161: ...e Malfunction of the gear pump Hydraulic system Measurement Steering circuit Hydraulic system Removal and installation of each part Gear pump Mower unit is not raised one mower unit Malfunction of up...

Page 162: ...lfunction of control valve Hydraulic system Removal and installation of each part Control valve Mowed face is not flat Cutting height adjustments of all the mower units are not even This machine opera...

Page 163: ...Wear of rotary knife each part repair Rotary knife Blockage inside of mower unit Removal of foreign objects and cleaning inside of mower unit Grass is wet Reduce volume of mowing Mow when grass is dry...

Page 164: ...GM2810 Troubleshooting Page 8 14 Relating to Operating Machine and Mower Unit...

Page 165: ...intenance Schedule Page 9 3 Hydraulic circuit diagram Page 9 5 Electrical Circuit Page 9 6 Electric wiring diagram Page 9 9 List of Consumables Page 9 11 RT mechanical brake manual Page 9 13 Reference...

Page 166: ...hine Mower unit Rotary knife Width 69 cm 27 in Cutting height 2 0 9 15 cm 0 79 3 60 in Cutting width 5 units 280 cm 110 in Engine Model Kubota V2403 CR TE4B Diesel Turbo Type Vertical water cooled 4 c...

Page 167: ...ng the parts Fuel Air cleaner Engine oil 8 hrs first time Engine oil filter 50 hrs first time Ignition plug Radiator Oil cooler Coolant Fan belt Battery Battery fluid Cleaning the exterior Main body T...

Page 168: ...cleaner Electromagnetic pump filter Fuel strainer Fuel pipe Cleaning the exterior By model Sedimenter Air cleaner Outer element Whichever comes first Inner element Draining and inspecting the water se...

Page 169: ...3 0MPa 2 4MPa 3 2 Cylinder rising lowering Assist valve CHG1 B A A B B A B A SOL 1 SOL 2 A B C A GA2 G1 4 GB G1 4 GA1 G 1 4 B 2WD 4WD changeover valve DR BM1 AM1 AM2 BM2 C G 1 4 3 4 16UNF 3 4 16UNF Ma...

Page 170: ...5D31R M8 M8 RW RG RB RG Differential lock SW NO Assist SW NO 4 Proximity SW 5 Proximity SW 4WD SW NO Knife rotation SW NO Relay box 1 Relay box 2 Differential lock SOL3 Differential lock SOL2 Assist S...

Page 171: ...R POWER_GND POWER_GND POWER_GND V_V_BAT3 BP V_V_BAT2 BP V_V_BAT1 BP B_D_CANH2 CAN2 H B_D_CANH1 CAN1 H B_D_CANL2 CAN2 L B_D_CANL1 CAN1 L G_R_APP1 GND 250 BrW 100 BrW 101 Br 300 BrW ECU JOINT CONN1 302...

Page 172: ...21 B 122 R 123 Y 124 R 125 G 126 W 127 R 128 B BONDER 1 BAT 103 R 102 B BONDER 3 EARTH EGR Valve RESISTOR 120ohm SENSOR COOLANT TEMP SENSOR CRANK SHAFT SENSOR CAM SHAFT SENSOR RAIL PRESSURE Oil SW SEN...

Page 173: ...RW RY RW RW W B W B B RG G B RW RW Y B G Y RY TO Connectpr Pin WIRE Size WIRE Color 031 E 032 033 E 034 035 036 E 037 038 039 E 040 041 042 E 043 044 E 045 046 E 047 048 E 049 050 E 051 052 E 053 054...

Page 174: ...nectpr Pin WIRE Size WIRE Color 200 201 202 203 204 205 208 209 210 231 232 233 234 235 250 251 252 253 254 255 256 257 ECU EDC17CV45 BONDER 4 GND5 ECU EDC17CV45 BONDER 4 GND5 ECU EDC17CV45 BONDER 4 G...

Page 175: ...1 YIS 40D SK Seal kit 1 Mower cylinders 2 3 4 5 YIS 45B SK Cylinder seal kit 4 Piston pump Y72400 908 Seal kit for piston pump 72400 1 Gear pump Y62 10313 Seal kit for gear pump PBB55RK513 1 Orbitrol...

Page 176: ...o return switch ET115G 1 Rocker switch K3661000050 Rocker switch 4 Rocker switch M K3661000100 Rocker switch M 1 Key switch PF15248 6359 0 Starter switch Assy 1 RT brake Assy Y304 2221 Repair kit for...

Page 177: ...404 1 This manual is to be used in conjunction with the Illustrated Parts List EP2318 MANUAL E404 JAPAN POWER BRAKE INCORPORATED 5dm3ww 022 RT mechanical brake manual_001 Reference GM2810 Reference Pa...

Page 178: ...2 PARTS LIST 3 3 MOUNTING PROCEDURE 4 4 ADJUSTMENT PROCEDURE 4 5 BREAK INSPECTION AND MAINTENANCE 4 6 BALL AND CAM REPLACEMENT 5 7 LINING REPLACEMENT 5 5dm3ww 023 RT mechanical brake manual_002 GM2810...

Page 179: ...secondary braking capability The brake has an open caliper design to facilitate changing linings along with a retraction spring to reduce parasitic drag It is sealed from the environment to provide a...

Page 180: ...WASHER STAINLESS 43 9060 1 18 BOLT M12 1 75 43 2126 2 19 NUT M12 1 75 63 2103 2 20 OD SEAL 77 2011 2 2 PARTS KIT ITEM NO DESCRIPTION PART NO QTY NOTE OVERHAUL KIT RT BRAKE ASSY 304 2221 1 6 LINING CAR...

Page 181: ...Nut 13 against inner Nut 12 to lock Adjustment Bolt 2 in place Torque to 45 to 55 lb ft 5 Break inspection and maintenance 5 1 Inspection of brake and surroundings Dirt or oil on the brake itself or...

Page 182: ...usting Bolt 2 taking care to orient protrusions into holes in Torque Plate 5 6 6 Install Ball Retainer Assembly 8 onto Adjusting Bolt 2 orienting balls into pockets of inner Cam 4 Install outer Cam 4...

Page 183: ...AND THE TORQUE PLATES 5 7 AFTER GREASE HAS BEEN APPLIED SLIDE TORQUE PLATES BACK AND FORTH ON SLEEVE AS FAR AS POSSIBLE TO INSURE THAT THE GREASE HAS BEEN INTRODUCED INTO THE BORES OF THE TORQUE PLATE...

Page 184: ...GM2810 Reference Page 9 20 RT mechanical brake manual...

Page 185: ...Head Office 1 26 Miyuki cho Toyokawa Aichi Pref 442 8530 Japan Tel 0533 84 1390 Fax 0533 89 3623 GM2810 SM GBZ 16C 00 S K...

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