Kubota G2160 Workshop Manual Download Page 356

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G2160-R48S, WSM

SPECIFICATIONS

SPECIFICATIONS

W1028929

Model

G2160-R48S

Maximum gross power

15.6 kW (21 HP)

Engine

Model

D782-E-G21

Type

Indirect injection, vertical, water cooled, 4-cycle diesel engine

Number of cylinders

Bore and stroke

67.0

73.6 mm (2.64

2.90 in.)

Total displacement

778 cm

(47.48 cu.in.)

Rated revolution

3000 rpm

Combustion chamber

Spherical type (E-TVCS)

Fuel injection pump

Bosch MD type mini pump

Governor

Centrifugal ball mechanical governor

Injection nozzle

Bosch throttle type

Injection timing

0.33 to 0.37 rad. (19

to 21

) before T.D.C.

Injection order

1-2-3

Injection pressure

13.73 MPa (140 kgf/cm

, 1990 psi)

Compression ratio

23 : 1

Lubricating system

Forced Iubrication by gear pump

Cooling system

Pressurized radiator, forced circulation with water pump

Lubricating oil

API Service classification CC or CD, Below 0

C (32

F) : SAE 10W or 10W-30, 0 to 25

(32

F to 77

F) : SAE 20 or 10W-30, Above 25

C (77

F) : SAE 30 or 10W-30

Starting system

Electric starter (12 V, 1.0 kW)

Battery

51R (12 V, 450CCA)

Fuel

No.2-D Diesel fuel (ASTM D975)

[No.1-D diesel fuel, if temperature is below

−

C (14

F)]

Capacities

Fuel tank

22 L (5.8 U.S.gals., 4.8 lmp.gals.)

Engine crankcase

2.8 L (2.95 U.S.qts., 2.4 Imp.qts.)

Engine coolant

2.1 L (2.2 U.S.qts., 1.8 Imp.qts.)

Recovery tank

0.25 L (0.26 U.S.qts., 0.22 Imp.qts.)

Transmission (Including
HST and cylinder)

4.5 L (4.75 U.S.qts., 3.86 Imp.qts.)

Mower gear case oil

0.40 L (0.42 U.S.qts., 0.35 Imp.qts.)

Tires

Front

6.50-8 (4PR) Turf

Rear

10.5-12 (4PR) Turf

Travelling
speeds

Forward

0 to 15.0 km/h (0 to 9.3 mph)

Reverse

0 to 6.0 km/h (0 to 3.8 mph)

Dimensions

Overall length
(With grass collector)

2930 mm (115.4 in.)

Overall width (With mower)

1045 mm (41.1 in.)

Overall height

1280 mm (50.4 in.)

Wheel base

1290 mm (50.8 in.)

Treads

Front

825 mm (32.5 in.)

Rear

780 mm (30.7 in.)

Weight (Without mower deck and grass
collector)

390 kg (860 lbs)

PTO

Belt drive

PTO clutch

Belt tension

Revolution (PTO speed)

2576 rpm

PTO brake

Available

KiSC issued 11, 2006 A

Summary of Contents for G2160

Page 1: ...WORKSHOP MANUAL G2160 G2160 R48S G2460G TRACTOR KiSC issued 11 2006 A...

Page 2: ...cing SERVICING The heading GENERAL includes general precautions check and maintenance and special tools Other section there are troubleshooting servicing specification lists checking and adjusting dis...

Page 3: ...al 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...

Page 4: ...Always support the machine by safety stands Do not touch the rotating or hot parts while the engine is running Never remove the radiator cap while the engine is running or immediately after stopping O...

Page 5: ...ep electrolyte away from eyes hands and clothing If you spill electrolyte on yourself flush with water and get medical attention immediately DISPOSE OF FLUIDS PROPERLY Do not pour fluids into the grou...

Page 6: ...UCTIONS The following safety decals are installed on the machine If a decal becomes damaged illegible or is not on the machine replace it The decal part number is listed in the parts list SAFETY DECAL...

Page 7: ...5 G2160 WSM SAFETY INSTRUCTIONS KiSC issued 11 2006 A...

Page 8: ...6 G2160 WSM SAFETY INSTRUCTIONS KiSC issued 11 2006 A...

Page 9: ...7 G2160 WSM SAFETY INSTRUCTIONS KiSC issued 11 2006 A...

Page 10: ...to 25 C 32 F to 77 F SAE 20 or 10W 30 Above 25 C 77 F SAE 30 or 10W 30 Starting system Electric starter 12 V 1 0 kW Battery 51R 12V 450CCA Fuel No 2 D Diesel fuel ASTM D975 No 1 D diesel fuel if temp...

Page 11: ...1 in Total width 1690 mm 66 5 in 1843 mm 72 5 in Total height 273 mm 10 7 in Mounting method Quick joint parallel linkage Adjustment of cutting height Dial gauge Cutting width 1372 mm 54 in 1524 mm 60...

Page 12: ...10 G2160 WSM DIMENSIONS DIMENSIONS KiSC issued 11 2006 A...

Page 13: ...G GENERAL KiSC issued 11 2006 A...

Page 14: ...D SCREWS BOLTS AND NUTS WITH UNC OR UNF THREADS G 10 7 MAINTENANCE CHECK LIST G 11 8 CHECK AND MAINTENANCE G 12 1 DAILY CHECK G 12 2 CHECK POINTS OF INITIAL 50 HOURS G 17 3 CHECK POINTS OF EVERY 50 HO...

Page 15: ...G2160 WSM G GENERAL 1 FEATURES 1 E TVCS engine 2 Front PTO option 3 Rugged ladder type chassis 4 Low noise high performance mower 5 Large capacity fuel tank 6 Hydraulic mower lift KiSC issued 11 2006...

Page 16: ...ing your local KUBOTA distributor always specify engine serial number 1 machine serial number 2 mower serial number 3 and hour meter reading W1010714 1 Engine Serial Number 2 Machine Serial Number 3 M...

Page 17: ...y KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety Gaskets and O rings must be replaced during reassembly Apply grease to new O rings or oil seals before...

Page 18: ...form periodic check for a fee Do not attempt to modify or remodel any electrical parts and wiring When removing the battery cables disconnect the negative cable first When installing the battery cable...

Page 19: ...ag be required W1011587 In installing a part take care not to get wiring caught by it W1011670 After installing wiring check protection of terminals and clamped condition of wiring only connect batter...

Page 20: ...r immediately Before recharging the battery remove it from the machine Before recharging remove cell caps Do recharging in a well ventilated place where there is no open flame nearby as hydrogen gas a...

Page 21: ...re is no female connector being too open W1012430 Make certain plastic cover is large enough to cover whole connector W1054624 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provid...

Page 22: ...ication CC or CD Below 0 C 32 F SAE10W or 10W 30 0 to 25 C 32 to 77 F SAE20 or 10W 30 Above 25 C 77 F SAE30 or 10W 30 4 Transmission Including HST cylinder 4 5 L 4 75 U S qts 3 86 Imp qts KUBOTA UDT o...

Page 23: ...41 2 39 3 to 44 1 4 0 to 4 5 29 0 to 32 5 60 9 to 70 6 6 2 to 7 2 44 9 to 52 0 M12 12 mm 0 47 in 62 8 to 72 5 6 4 to 7 4 46 3 to 53 5 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 62 8 to 72 5 6 4 to 7 4 46 3...

Page 24: ...32 5 to 39 3 3 31 to 4 01 24 0 to 29 0 3 8 47 5 to 57 0 4 84 to 5 82 35 0 to 42 0 61 0 to 73 2 6 22 to 7 47 45 0 to 54 0 1 2 108 5 to 130 2 11 07 to 13 29 80 0 to 96 0 149 2 to 179 0 15 22 to 18 27 11...

Page 25: ...17 4 Engine oil filter cartridge Change Every 200 Hr G 18 5 Transmission fluid Change Every 300 Hr G 26 6 Transmission oil filter cartridge Replace Every 300 Hr G 18 7 Transmission oil strainer Clean...

Page 26: ...evel in the recovery tank 4 Damage of machine body tightness of all bolts and nuts 5 Radiator screen 6 Panel screen 7 Air cleaner 8 Oiling Mower 1 Make sure blade bolts are tight 2 Check blades for we...

Page 27: ...ipstick 2 wipe it clean replace it and draw it out again Check to see that the oil level is between the two notches 4 Add new oil to the prescribed level at the oil port if necessary IMPORTANT Use the...

Page 28: ...low 10 C 14 F 3 Always use a strainer when refueling to prevent fuel injection pump contamination NOTE No 2 D is a distillate fuel of lower volatility for engines in industrial and heavy mobile servic...

Page 29: ...dle the mower blade with care 1 Dismount the mower and turn it over to expose the mower blades 2 Wedge a wooden block 1 securely between the mower blade and mower deck 3 Retighten the mower blade scre...

Page 30: ...oints before starting NOTE Oil these points on both sides of the machine 1 Apply oil to the following points W1030315 1 Link Fulcrum 2 PTO Lever Fulcrum and PTO cable 3 Front PTO Cable 4 Brake Pedal 5...

Page 31: ...4 Screw in the drain plug 1 5 Fill new oil up to upper line on the dipstick 3 IMPORTANT When using an oil of different manufacture or viscosity from the previous one remove all of the old oil Never m...

Page 32: ...ns 1 The oil filter cartridge must be changed every 300 service hours 2 Remove the oil filter cartridge with the filter wrench 3 Lightly tighten the screw 2 by using a screwdriver 4 Apply a slight coa...

Page 33: ...TION When making adjustments park the machine on a flat area block wheels stop engine and remove the key 1 If brake play is not correct loose the lock nut 2 and turn the nut 3 in the desired direction...

Page 34: ...with finger pressure of 98 N 10 kgf 22 lbs IMPORTANT When replacing fan belt be careful not to catch it on the cap under the water pump See the illustration to the left W1069477 Greasing CAUTION Be su...

Page 35: ...cleaning is required To clean the element use clean and dry compressed air on the inside of the element Air pressure should not exceed 205 kPa 2 1 kgf cm2 30 psi NOTE Operating in dusty conditions re...

Page 36: ...ngth as explained below 1 Engage the PTO lever 2 Measure tension spring length L 3 If L is shorter than 87 mm 3 43 in adjust it with the tension clutch cable adjusting nut L should be 88 to 90 mm 3 47...

Page 37: ...es or deteriorated replace them 3 Check fuel filter if it is clogged by debris and replace it IMPORTANT When the fuel line is disconnected for maintenance or repair close both ends of the fuel line wi...

Page 38: ...d When disconnecting the cables from the battery start with the negative terminal first When connecting the cables to the battery start with the positive terminal first Never check battery charge by p...

Page 39: ...se and Clamp NOTE Check to see if the radiator hoses are properly fixed every 200 hours of operation or 6 months whichever comes first 1 If clamp bands 2 are loose or water leaks tighten clamp band 2...

Page 40: ...Place the machine on level ground 2 Remove the drain plug 1 and oil inlet plug 2 and drain the used oil completely 3 After draining the oil reinstall the drain plug 1 4 Fill with new oil up to the up...

Page 41: ...transmission case to cool down sufficiently oil can be hot and may cause burns 1 Remove 2 M8 bolts 2 Remove the suction pipe 1 with O ring 2 3 Clean completely the oil strainer 3 with kerosene 4 Insta...

Page 42: ...diator cap 1 The radiator cap 1 must be removed to completely drain the coolant 3 After all coolant is drained fill with clean water and cooling system cleaner 4 Follow directions of the cleaner instr...

Page 43: ...ti freeze with water and then fill in to the rediator At 101 kPa 760 mmHg pressure atmospheric A higher boiling point is obtained by using a radiator pressure cap which permits the development of pres...

Page 44: ...lace the radiator hoses 1 and clamp bands 2 Refer to Checking Radiator Hose and Hose Clamp See page G 25 W1038187 Replacing Hydraulic Hoses 1 Replace hydraulic hoses 1 and clamp bands every 2 years or...

Page 45: ...ity IMPORTANT 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 electrical system Protected...

Page 46: ...m the socket 4 Install new bulb to the socket 5 Install the socket in housing 6 Close hood B Replacing the indicator light bulb 1 Open hood 2 Turn bad bulb socket to the left 3 Pull bulb from the sock...

Page 47: ...361 Piston Ring Tool Code No 07909 32121 Application Use exclusively for removing or installing the piston ring with ease W1048421 Diesel Engine Compression Tester Code No 07909 30208 Assembly 07909 3...

Page 48: ...ation Use to check of radiator cap pressure and leaks from cooling system Remarks Adapter 1 BANZAI Code No RCT 2A 30S W1049045 Connecting Rod Alignment Tool Code No 07909 31661 Application Use to chec...

Page 49: ...1371 Application Use to check cracks on cylinder head cylinder block etc W1050024 NOTE The following special tools are not provided so make them referring to the figure Valve Guide Replacing Tool Appl...

Page 50: ...E Injection pipe F PF1 2 G 5 mm 0 20 in H 17 mm dia 0 67 in dia I 8 mm dia 0 31 in dia J 1 0 mm 0 039 in K 17 mm dia 0 67 in dia L 6 10 to 6 20 mm dia 0 2402 to 0 2441 in dia M 8 mm 0 31 in N 4 mm 0 1...

Page 51: ...00 mm 3 94 in D 19 90 to 19 95 mm dia 0 7835 to 0 7854 in dia E 21 90 to 21 95 mm dia 0 8622 to 0 8642 in dia F 25 mm dia 0 98 in dia a 6 3 m 250 in b 6 3 m 250 in A 150 mm 5 91 in B 20 mm 0 79 in C 1...

Page 52: ...B 72 mm 2 83 in C 40 1 57 rad D 10 mm 0 39 in E 22 mm 0 87 in F 20 mm dia 0 79 in dia G 48 90 to 48 95 mm dia 1 9251 to 1 9271 in dia H 43 90 to 43 95 mm dia 1 7283 to 1 7303 in dia A 130 mm 5 12 in B...

Page 53: ...Tester Code No 07916 50045 Application This allows easy measurement of relief set pressure W1051907 Pressure Gauge 50 Code No 07916 52961 Application This pressure gauge is used to measure the low oi...

Page 54: ...to the figure Steering Wheel Puller Adaptor Application Use for removing the steering wheel with steering wheel A 22 mm 0 87 in F 116 mm 4 57 in B 64 mm 2 52 in G 5 mm 0 20 in C 11 mm 0 43 in H 9 5 m...

Page 55: ...0 71 in L 0 5 mm 0 02 in C 15 mm 0 59 in M 15 mm 0 59 in D 30 mm 1 18 in N G 3 8 E RP 1 4 O Chamfer 1 mm 0 04 in F 22 mm 0 87 in P 8 mm 0 31 in dia drill thru Chamfer 0 5 mm 0 02 in Both ends G 10 mm...

Page 56: ...0 mm 1 57 in I 4 5 mm dia 0 18 in dia B 18 mm 0 71 J 9 mm dia 0 18 in dia C 6 mm 0 24 in K RP 1 4 thread depth 15 mm 0 59 in Drill depth 20 mm 0 79 in D 3 mm 0 12 in L 0 5 mm 0 02 in E 3 mm 0 12 in M...

Page 57: ...rad 120 D 20 mm 0 79 in Q 20 mm dia 0 79 in dia E 3 4 16 UNF R 23 95 to 24 00 mm dia 0 9429 to 0 9449 in dia F Chamfer 1mm 0 04 in S 63 00 to 63 05 mm dia 2 4803 to 2 4823 in dia G 38 mm 1 50 in T 76...

Page 58: ...t recommended for use with the KUBOTA Machine may result in malfunctions or failures of the machine damage to other property and injury to the operator or others Any malfunctions or failures of the ma...

Page 59: ...1 ENGINE KiSC issued 11 2006 A...

Page 60: ...1 SEPARATING ENGINE 1 S12 1 Disassembling and Assembling 1 S12 2 ENGINE BODY 1 S17 1 Checking and Adjusting 1 S17 2 Disassembling and Assembling 1 S20 3 Servicing 1 S31 3 LUBRICATING SYSTEM 1 S46 1 C...

Page 61: ...fective Reverse switch defective Seat switch defective Wiring harness disconnected Replenish fuel Bleed fuel system Change fuel and replace fuel system Clean fuel pipe Replace fuel filter Use specifie...

Page 62: ...45 1 S51 1 S18 Either Black or Dark Gray Exhaust Gas Is Observed Overload Low grade fuel used Fuel filter clogged Air cleaner clogged Deficient nozzle injection Lessen load Use specified fuel Replace...

Page 63: ...valve stuck with dirt Relief valve spring weaken or broken Excessive oil clearance of crankshaft bearing Excessive oil clearance of crankpin bearing Excessive oil clearance of rocker arm Oil passage c...

Page 64: ...ded Radiator cap defective Overload running Head gasket defective Incorrect injection timing Unsuitable fuel used Replenish engine oil Replace fan belt or adjust fan belt tension Replenish cooling wat...

Page 65: ...Valve Clearance Cold 0 145 to 0 185 mm 0 00571 to 0 00728 in Valve Seat Width 2 12 mm 0 0835 in Valve Seat Angle 0 79 rad 45 Valve Face Angle 0 79 rad 45 Valve Recessing 0 10 to 0 10 mm 0 0039 to 0 00...

Page 66: ...0 41276 in 10 500 to 10 518 mm 0 41339 to 0 41410 in 0 15 mm 0 0059 in Push Rod Runout 0 50 mm 0 0196 in Clearance between Tappet and Guide Tappet O D Tappet Guide I D 0 016 to 0 052 mm 0 00063 to 0...

Page 67: ...in 20 000 to 20 051 mm 0 78740 to 0 78941 in 0 10 mm 0 0039 in Idle Gear Side Clearance 0 20 to 0 51 mm 0 0079 to 0 0201 in 0 60 mm 0 0236 in Piston Pin Bore I D 20 000 to 20 013 mm 0 78740 to 0 78791...

Page 68: ...4 to 44 026 mm 1 73165 to 1 73331 in 0 20 mm 0 0079 in Oil Clearance between Crankshaft Journal and Crankshaft Bearing 3 Intermediate Crankshaft Journal O D Crank bearing 3 I D 0 034 to 0 092 mm 0 001...

Page 69: ...0 0012 to 0 0055 in Clearance between Outer Rotor and Pump Body 0 07 to 0 15 mm 0 0028 to 0 0059 in End Clearance between Inner Rotor and Cover 0 075 to 0 135 mm 0 00295 to 0 00531 in Thermostat s Va...

Page 70: ...re T D C Fuel Tightness of Pump Element 14 7 MPa 150 kgf cm2 2130 psi Fuel Tightness of Delivery Valve 5 seconds 14 7 13 7 MPa 150 140 kgf cm2 2130 1990 psi Fuel Injection Pressure 13 7 to 14 7 MPa 14...

Page 71: ...ve pulley retaining screw Idle gear shaft mounting screw Connecting rod screw Flywheel bolt Main bearing case screw 2 Main bearing case screw 1 Oil pressure switch Nozzle holder M6 1 0 M6 1 0 M8 1 25...

Page 72: ...rneath the engine 4 Remove the drain plug 1 to drain oil 5 After draining screw in the drain plug 1 When refilling Fill the engine oil up to the upper line on the dipstick 3 IMPORTANT Never mix two di...

Page 73: ...ing connect the positive cable to the battery first 1 Disconnect the negative cable 1 from the battery 2 Disconnect the positive cable 2 from the battery W1019788 Bonnet and Air Cleaner 1 Disconnect t...

Page 74: ...ly 5 and tension arm 2 with tension pulley When reassembling Apply grease to the tension arm bushings and the PTO brake bushing After reassembling the PTO clutch spring be sure to adjust the front PTO...

Page 75: ...he fuel spill out of the hoses When reassembling W1021263 Universal Joint 1 Remove the universal joint mounting screws 1 2 Disconnect the universal joint 2 from the fun drive pulley When reassembling...

Page 76: ...diator When reassembling Fit the radiator to the frame adjusting the clearance between the radiator and the fan as shown in the figure Reference W1021955 Tightening torque Engine mounting nut 23 5 to...

Page 77: ...Repeat steps 9 and 10 for each cylinder 12 If the measurement is below the allowable limit apply a small amount of oil to the cylinder wall through the nozzle hole and measure the compression pressure...

Page 78: ...d gasket must be changed to new one 4 Turn the crank shaft until the piston exceeds its top dead center 5 Remove the cylinder head and measure the thickness of the squeezed fuses 6 If the measurement...

Page 79: ...C mark 1 on the flywheel and alignment mark 2 on the rear end plate so that the No 1 piston comes to the overlap position 6 Check the following valve clearance marked with using a feeler gauge When No...

Page 80: ...sion See page 1 S48 W1024919 Cylinder Head Cover 1 Remove the head cover cap nuts 2 Remove the cylinder head cover When reassembling Check to see if the cylinder head cover gasket is not defective App...

Page 81: ...cedure W10154410 Rocker Arm and Push Rod 1 Remove the rocker arm bracket nuts 2 Detach the rocker arm assembly 1 3 Remove the push rods 2 When reassembling When putting the push rods 2 onto the tappet...

Page 82: ...om the crankcase When reassembling Before installing the tappets apply engine oil thinly around them IMPORTANT Mark the cylinder number to the tappets to prevent interchanging W1027457 Valves 1 Remove...

Page 83: ...NOTE The sealant is applied to both sides of the soft metal gasket shim The liquid gasket is not required for assembling Addition or reduction of shim 0 05 mm 0 0020 in delays or advances the injecti...

Page 84: ...external snap ring 3 the collar 2 and the idle gear 1 2 Remove the idle gear shaft mounting screws 3 Remove the idle gear shaft When reassembling Install the idle gear aligning the mark on the gears...

Page 85: ...ver assembly to the crankcase W10178820 Oil Pump and Crankshaft Gear 1 Remove the oil pump gear 6 2 Remove the oil pump 5 3 Remove the collar 4 O ring 3 and oil slinger 2 4 Remove the crankshaft gear...

Page 86: ...sealant about 5 mm 0 20 in thick Within 20 minutes after the application of fluid sealant reassemble the components Wait then for about 30 minutes and pour oil in the crankcase W10265670 Connecting R...

Page 87: ...of cylinder and piston Make sure of the position of each piston by marking For example mark 1 on the No 1 piston When inserting the piston into the cylinder place the gap of the compression ring 1 on...

Page 88: ...r joint 10 on the opposite side of the oil ring gap 11 Apply engine oil to the piston pin When installing the piston pin immerse the piston in 80 C 176 F oil for 10 to 15 minutes and insert the piston...

Page 89: ...assembling Fit the bearing case gasket 3 and the bearing case cover gasket 4 with correct directions Apply liquid type gasket Three Bond 1215 or its equivalent to both sides of a new bearing case cove...

Page 90: ...stall the main bearing case assemblies in the original positions Since diameters of main bearing case vary install them in order of makings 1 2 from the gear case side Match the alignment numbers 1 or...

Page 91: ...k the valve recessing after correcting W10301620 Cylinder Head Flaw 1 Prepare an air spray red check Code No 07909 31371 2 Clean the surface of the cylinder head with detergent 2 3 Spray the cylinder...

Page 92: ...om the valve guide section 2 Measure the valve stem O D with an outside micrometer 3 Measure the valve guide I D with a small hole gauge and calculate the clearance 4 If the clearance exceeds the allo...

Page 93: ...ement W10314690 Valve Seating 1 Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact 2 If the valve does not seat all the way around the valve seat or the...

Page 94: ...he seat with a 0 79 rad 45 valve seat cutter again and visually recheck the contact between the valve and seat 5 Repeat steps 3 and 4 until the correct contact is achieved 6 Continue lapping until the...

Page 95: ...side micrometer 2 Measure the rocker arm I D with an inside micrometer and then calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the rocker arm and measure the oi...

Page 96: ...If the measurement exceeds the allowable limit replace the idle gear collar W11286770 Oil clearance between tappet and tappet guide bore Factory spec 0 016 to 0 052 mm 0 00063 to 0 00205 in Allowable...

Page 97: ...ft W11324040 Oil Clearance of Camshaft Journal 1 Measure the camshaft journal O D with an outside micrometer 2 Measure the camshaft bearing I D cylinder block bore I D for camshaft with an inside micr...

Page 98: ...in a new brushing using an idle gear bushing replacing tool until it is flush with the end of the idle gear W11373220 C Piston and Connecting Rod Piston Pin Bore I D 1 Measure the piston pin bore I D...

Page 99: ...ning the oil hole 2 of connecting rod using 4 0 mm dia 0 157 in dia drill NOTE Be sure to chamfer the oil hole circumference with an oil stone W11437590 Piston Ring Gap 1 Insert the piston ring into t...

Page 100: ...d install the connecting rod cap 2 Install the piston pin in the connecting rod 3 Install the connecting rod on the connecting rod alignment tool Code No 07909 31661 4 Put a gauge over the piston pin...

Page 101: ...e the crankshaft alignment 4 If the measurement exceeds the allowable limit replace the crankshaft W11613530 Crankshaft side clearance Factory spec 0 15 to 0 31 mm 0 0059 to 0 0122 in Allowable limit...

Page 102: ...he connecting rod screws are tightened Reference Undersize crankpin crankpin Undersize dimensions of crankpin W11625390 Oil clearance between crankpin and crankpin bearing Factory spec 0 020 to 0 051m...

Page 103: ...1 replacing tool press in a new bearing 1 2 so that its seam 1 directs toward the exhaust manifold side See figure W10342000 Oil Clearance between crankshaft journal and crankshaft bearing 1 Factory s...

Page 104: ...spec 0 028 to 0 059 mm 0 0011 to 0 0023 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Intermediate Factory spec 39 934 to 39 950 mm 1 5722 to 1 5728 in Crankshaft bearing 3 I D Factory...

Page 105: ...he specified dimension 2 Replace the piston and piston rings with oversize ones NOTE When the oversize cylinder is worn beyond the allowable limit replace the cylinder block with a new one W10367470 C...

Page 106: ...Measure the clearance between lobes of the inner rotor and the outer rotor with a feeler gauge 2 If the clearance exceeds the factory specifications replace the oil pump rotor assembly W10378950 Clea...

Page 107: ...the cover and tighten the screws 3 Remove the cover carefully and measure the amount of the flattening with the scale and get the clearance 4 If the clearance exceeds the factory specifications repla...

Page 108: ...ithin the factory specifications loosen the alternator mounting screws and relocate the alternator to adjust W10384280 Fan Belt Damage and Wear 1 Check the fan belt for damage 2 If the fan belt is dam...

Page 109: ...ll to 59 kPa 0 6 kgf cm2 9 psi 3 If the measurement is less than the factory specification replace the radiator cap W1054156 C Thermostat Thermostat Valve Opening Temperature 1 Suspend the thermostat...

Page 110: ...n belt 2 Remove the fan and fan pulley 3 Remove the water pump assembly from the gear case cover 4 Remove the water pump flange 1 5 Press out the water pump shaft 2 with the impeller 5 on it 6 Remove...

Page 111: ...is out of adjustment readjust the timing with shims 3 NOTE The sealant is applied to both sides of the shim soft metal gasket shim The liquid gasket is not required for assembling Shims are available...

Page 112: ...the bonnet and air cleaner 2 Remove the muffler 3 Remove the injection pipes and glow plugs 4 Install the injection pump pressure tester to the fuel injection pump 5 Set the throttle lever to the max...

Page 113: ...ester handle to measure the pressure at which fuel begins to jet out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer 1 in the nozzle holder t...

Page 114: ...g its direction After assembling the nozzle be sure to adjust the fuel injection pressure W10415210 Tightening torque Nozzle holder 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 ft lbs Overflow pipe...

Page 115: ...2 TRANSMISSION AND REAR AXLE KiSC issued 11 2006 A...

Page 116: ...CONTENTS MECHANISM 1 STRUCTURE 2 M1 2 HYDROSTATIC TRANSMISSION 2 M2 1 STRUCTURE 2 M2 2 OIL FLOW 2 M3 3 BY PASS VALVE 2 M4 4 CHARGE PUMP 2 M5 KiSC issued 11 2006 A...

Page 117: ...2 M1 G2160 WSM TRANSMISSION AND REAR AXLE 1 STRUCTURE W1013364 1 Hydrostatic Transmission Section 2 Gear Section 3 Rear Axle Section 4 Differential Gear Section KiSC issued 11 2006 A...

Page 118: ...ls As for operation of the hydrostatic transmission refer to Workshop Manual for G1700 G1800 G1900 G2000 Code No 9Y021 10834 W1013294 1 Charge Relief Valve 2 Charge Pump Housing 3 Charge Pump Spacer 4...

Page 119: ...valve 3 in neutral position the oil is delivered to the hydrostatic transmission through the control valve adaptor 5 and oil filter cartridge 4 5 The oil used to charge a leak of the closed circuit in...

Page 120: ...pushing is desired depress the by pass valve to connect the two sides of the loop and defeat the dynamic braking feature However this hydrostatic transmission is equipped with a means of slightly by...

Page 121: ...00 G1900 G2000 code No 9Y021 10834 Charge Relief Valve W1014384 1 Charge Relief Valve 2 Charge Pump Housing 3 O ring 4 Charge Pump Spacer 5 O ring 6 Gerotor 7 Dowel Pin 8 Center Section 9 Needle Beari...

Page 122: ...ECKING AND ADJUSTING 2 S6 2 DISASSEMBLING AND ASSEMBLING 2 S8 1 Separating Transmission 2 S8 2 Separating Hydrostatic Transmission 2 S13 3 Separating Transmission 2 S14 4 Disassembling Transmission 2...

Page 123: ...2 S1 G2160 WSM TRANSMISSION AND REAR AXLE 1 TROUBLESHOOTING 1 HYDROSTATIC TRANSMISSION KiSC issued 11 2006 A...

Page 124: ...2 S2 G2160 WSM TRANSMISSION AND REAR AXLE KiSC issued 11 2006 A...

Page 125: ...2 S3 G2160 WSM TRANSMISSION AND REAR AXLE 2 TRANSMISSION KiSC issued 11 2006 A...

Page 126: ...D 0 040 to 0 082 mm 0 00157 to 0 00323 in 26 000 to 26 021 mm 1 02362 to 1 02445 in 25 939 to 25 960 mm 1 02122 to 1 02205 in 0 17 mm 0 0067 in Differential Pinion Shaft to Differential Pinion Differe...

Page 127: ...set screw Neutral arm assembly mounting screw Drain plug Adapter bolt PS3 8 Charge pump housing mounting hex socket head screw Center section mounting hex socket head screw 39 2 to 45 1 107 8 to 130 3...

Page 128: ...en the holder shaft mounting screw 3 firmly This means the hydrostatic transaxle is fully in neutral Position C WARNING Use buddy system in adjusting the neutral position One of you should sit on the...

Page 129: ...he adaptor bolt return port from the control valve adaptor 2 Set the adaptor bolt for HST See page G 39 thread joint Code No 07916 50341 cable Code No 07916 50331 thread joint Code No 07916 50401 and...

Page 130: ...d the oil inlet plug 2 When refilling Use the specified transmission fluid Refer to LUBRICANTS FUEL AND COOLANT See Page G 8 Never work the machine immediately after changing the transmission fluid Ke...

Page 131: ...lockwise by a half turn Apply oil to the seat support Face smooth side the plane washers 6 to the seat support W1014173 Cutting Height Adjusting Dial 1 Lift the mower to the highest position 2 Remove...

Page 132: ...ut the rue ring cotters 3 and plain washers 2 Remove the upper lift links 4 3 Pull out the cotter pin 1 and plain washer 4 Remove the L H rear link assembly 2 5 Remove the R H rear link assembly retai...

Page 133: ...5 Disconnect the mower lift cylinder hose 2 from the control valve NOTE Jack up the machine by applying jacks on spots forward from the rear axle toeard the nachine center of the machine frame When re...

Page 134: ...ht contact all over the plate W1016209 Tightening torque Universal joint mounting screw 23 5 to 27 4 N m 2 4 to 2 8 kgf m 17 4 to 20 3 ft lbs Rear axle case mounting screw M12 7T Aluminum 62 7 to 72 5...

Page 135: ...e hydrostatic transmission mounting screws 2 3 3 Separate the hydrostatic transmission from the front cover When reassembling First tighten the adapter bolts into the control valve assembly Then tight...

Page 136: ...axle case 4 from the transmission 4 Take out the yoke shaft 7 and spline boss 6 When reassembling Take care not to damage the O ring Install the adjusting shims to their original position W1027308 4...

Page 137: ...n reassembling When installing the charge pump spacer place the flat portion 9 of the spacer on the opposite side of the trunnion arm 10 W1027788 Gerotor 1 Remove the gerotors 2 2 Draw out the drive p...

Page 138: ...ug W1028889 By pass Valve 1 Remove the plug 1 2 Remove the by pass valve 4 NOTE Take care not to damage the O ring on the by pass valve Take care not to damage the O ring on the plug W1029069 Oil Seal...

Page 139: ...mbly motor 3 with the motor shaft 2 4 Remove the thrust ball bearing NOTE Take care not to damage the surface of the cylinder blocks When reassembling Apply clean fluid to the surface of cylinder bloc...

Page 140: ...rom the trunnion arm 3 2 Remove the cradle bearing 1 from the housing W1031110 Pump Shaft 1 Remove the internal snap ring 1 2 Tap the pump shaft 4 with a plastic hammer slightly to side out it from th...

Page 141: ...sembly 2 with the fulcrum support assembly 1 3 Remove the external snap ring 4 4 Pull out the brake drum 5 When reassembling Apply liquid gasket Three Bond 1208D or its equivalent to face of the flang...

Page 142: ...01 5 Disassembling Rear Axle Rear Axle 1 Remove the rear axle cover 9 2 Remove the 49T gear 7 3 Remove the external snap ring 6 4 Draw out the rear axle 1 5 Remove the 12T gear shaft 11 When reassembl...

Page 143: ...ential pinions 2 differential side gears 4 and shims 1 3 NOTE Arrange the parts to know their original position When reassembling Apply molybdenum disulfide Three Bond 1901 or equivalent to the inner...

Page 144: ...r scratches and wear 2 If scratch or worm replace the cylinder block assembly 3 Check that the piston 5 spring 2 spring seat 3 and ball 4 are in each cylinder bore 4 Check the pistons for their free m...

Page 145: ...washplate 1 for scratches and excessive wear 4 If worn or scored replace the swashplate 5 Check the surface of the cradle bearings 3 for scratches and excessive wear 6 If worn or scored replace the cr...

Page 146: ...ty parts W1034423 Clearance between Differential Pinion Shaft and Differential Pinion 1 Measure the differential pinion shaft O D 2 Measure the differential pinion I D and calculate the clearance 3 If...

Page 147: ...ove the rear axle case and place fuses between 11T shaft bevel gear and 20T bevel gear Several points on the circumferential 2 Assemble the rear axle case and turn the brake shaft 3 Remove the rear ax...

Page 148: ...3 BRAKE KiSC issued 11 2006 A...

Page 149: ...RVICING SPECIFICATIONS 3 S1 3 TIGHTENING TORQUES 3 S1 4 CHECKING DISASSEMBLING AND SERVICING 3 S2 1 CHECKING AND ADJUSTING 3 S2 2 DISASSEMBLING AND ASSEMBLING 3 S2 1 Parking Brake 3 S2 2 Brake Assembl...

Page 150: ...Specification Allowable Limit Brake Spring to Plane Washer Clearance 1 0 to 0 0 mm 0 04 to 0 00 in Brake Lining Thickness 9 0 mm 0 35 in 7 5 mm 0 30 in Brake Drum I D 81 2 to 81 4 mm 3 197 to 3 205 i...

Page 151: ...ble 1 from the battery 4 Disconnect the 1P connectors 4 from the head light 3 5 Remove the wiring 5 from the bonnet 6 Remove the bonnet stay mounting screws 7 and remove the bonnet with the bonnet bra...

Page 152: ...omes into the notch 4 W1011595 Steering Wheel 1 Remove the grip of the throttle lever 1 2 Remove the steering pad and remove the steering wheel mounting nut 3 Remove the steering wheel using the steer...

Page 153: ...connect the 2P connector 3 from the seat switch 2 Remove the seat support mounting lock nuts 1 3 Remove the guide washers spring washers and screws 4 4 Remove the seat with seat support 5 5 Remove the...

Page 154: ...nder from the frame When reassembling Apply grease to the inside of rubber bushing W1013181 Brake Spring and Brake Rod 1 1 Remove the lock nut nut and plane washers 2 4 2 Remove the brake spring 3 3 P...

Page 155: ...1 Pull out the cotter pins 1 2 Remove the brake rod 3 5 3 Remove the brake assembly mounting screws 4 4 Remove the brake assembly 3 and fulcrum support assembly 2 5 Remove the external snap ring 6 6...

Page 156: ...ining is carbonized or soaked with oil replace the shoes W1014697 Brake Drum Wear 1 Measure the brake drum I D with vernier caliper 2 If the measurement exceeds the allowable limit replace it W1014861...

Page 157: ...4 FRONT AXLE KiSC issued 11 2006 A...

Page 158: ...NG TORQUES 4 S1 4 CHECKING DISASSEMBLING AND SERVICING 4 S2 1 CHECKING AND ADJUSTING 4 S2 2 DISASSEMBLING AND ASSEMBLING 4 S3 1 Separating Front Axle Assembly 4 S3 2 Disassembling Front Axle 4 S4 3 Di...

Page 159: ...to 0 4 mm 0 004 to 0 016 in 1 0 mm 0 039 in Front Axle to Front Axle Support Front Axle Front Axle Support Clearance I D O D 0 025 to 0 089 mm 0 00098 to 0 00350 in 40 000 to 40 039 mm 1 57480 to 1 57...

Page 160: ...front of frame 2 Measure the clearance between the front axle 1 and adjusting shims 2 3 If the measurement exceeds the allowable limit replace the adjusting shims 2 Reference Thickness of adjusting s...

Page 161: ...9 4 Remove the pulley 10 5 Remove the front PTO belts 8 6 Remove the cotter pin and flange bolt 3 7 Pull out the PTO brake assembly 5 and tension arm 2 with tension pulley When reassembling Apply grea...

Page 162: ...Axle Front Wheel and Tie Rod 1 Remove the front wheel cap 1 2 Remove the external snap ring and plane washer 2 3 Remove the front wheels 4 Remove the tie rod mounting lock nuts 4 5 Remove the tie rod...

Page 163: ...e the front axle I D with a cylinder gauge 2 Measure the front axle support O D with an outside micrometer and calculate the clearance 3 If the clearance exceeds the allowable limit replace them W1013...

Page 164: ...5 STEERING KiSC issued 11 2006 A...

Page 165: ...D FUNCTION OF MAIN COMPONENTS 5 M2 1 POWER STEERING ASSEMBLY 5 M2 1 Construction of Power Steering Assembly 5 M2 2 Torque Sensor 5 M3 3 Motor 5 M4 2 EPS CONTROLLER 5 M5 1 Basic Control 5 M5 2 Fool Pro...

Page 166: ...ing a hydraulic pump it is an electric power saving system in which the motor is energized only when the steering wheel is operated Therefore it causes no engine power loss enhancing fuel economy 2 Ne...

Page 167: ...fts torque sensor 3 for detecting the twisting of the torsion bar and motor 4 for generating assisting power A stopper is provided for the input shaft 1 and output shaft 5 in order to prevent twisting...

Page 168: ...tion W1013543 When a torsion torque is generated via the torsion bar between the input shaft 1 and output shaft 5 as a result of the steering wheel being turned the input shaft side slider pin moves a...

Page 169: ...d of a worm gear 1 and direct current motor 3 The worm gear 1 is engaged with the helical gear of the worm wheel 2 reducing and transmitting the motor revolution to the worm wheel W1014140 1 Worm Gear...

Page 170: ...Fool Proof When the steering wheel is kept fully turned end reaching the maximum current at the time of full assisting is applied to the motor in spite of the motor not rotating As a result all the en...

Page 171: ...the system the EPS controller stops the system and makes the warning lamp go on In this case the normal manual steering operation is applied and the abnormal condition is coded and stored in the failu...

Page 172: ...S12 12 Error code 34 5 S12 13 Error code 35 5 S13 3 SERVICING SPECIFICATIONS 5 S14 4 TIGHTENING TORQUES 5 S14 5 CHECKING DISASSEMBLING AND SERVICING 5 S15 1 CHECKING AND ADJUSTING 5 S15 1 Warning Lamp...

Page 173: ...become hard to operate the steering wheel It is not a failure it is caused because the EPS controller decreases the current applied to the motor in order to protect the EPS system To restore the norma...

Page 174: ...5 S2 G2160 WSM STEERING 2 TROUBLESHOOTING 1 TROUBLESHOOTING BASED ON EACH SYMPTOM KiSC issued 11 2006 A...

Page 175: ...5 S3 G2160 WSM STEERING KiSC issued 11 2006 A...

Page 176: ...5 S4 G2160 WSM STEERING KiSC issued 11 2006 A...

Page 177: ...5 S5 G2160 WSM STEERING KiSC issued 11 2006 A...

Page 178: ...5 S6 G2160 WSM STEERING 2 TROUBLESHOOTING BASED ON ERROR CODE 1 Error code 02 EPS System Troubleshooting Procedure KiSC issued 11 2006 A...

Page 179: ...5 S7 G2160 WSM STEERING 2 Error code 03 3 Error code 05 KiSC issued 11 2006 A...

Page 180: ...5 S8 G2160 WSM STEERING 4 Error code 06 5 Error code 11 KiSC issued 11 2006 A...

Page 181: ...5 S9 G2160 WSM STEERING 6 Error code 12 and 13 7 Error code 15 KiSC issued 11 2006 A...

Page 182: ...5 S10 G2160 WSM STEERING 8 Error code 17 9 Error code 19 and 22 KiSC issued 11 2006 A...

Page 183: ...5 S11 G2160 WSM STEERING 10 Error code 23 KiSC issued 11 2006 A...

Page 184: ...5 S12 G2160 WSM STEERING 11 Error code 32 12 Error code 34 KiSC issued 11 2006 A...

Page 185: ...5 S13 G2160 WSM STEERING 13 Error code 35 KiSC issued 11 2006 A...

Page 186: ...ped Without power assisting Less than 150 N Less than 15 kgf Less than 33 lbs Engine started With power assisting Less than 30 N Less than 3 kgf Less than 6 6 lbs Turning Torque Steering Mechanical Sy...

Page 187: ...warning lamp 2 glow for 5 seconds Check Test 1 Start the engine 2 Check that the warning lamp glows for 5 seconds and then goes off 3 If the warning lamp does not go on check if the harness is connec...

Page 188: ...problem with the EPS controller Check the power steering assembly gear case s turning torque and the hydraulic switch performance Action If the code 11 12 or 13 flashes the torque sensor harness may...

Page 189: ...of the torque sensor cable to see if the steering wheel turns unexpectedly or unstably CAUTION Be careful not to get yourself caught by the steering wheel or tire Do not pull the cable too much IMPOR...

Page 190: ...ector press the connector s lock and hold the connector itself Never pull the cable 1 Check the torque sensor 3P connector 3 and related parts for the following defects Terminal off position Terminal...

Page 191: ...g the wire harness IMPORTANT Before measuring the resistance lightly bend the root of the cable and gently pull it for easy reliable checking Be careful to keep the circuit tester probes tight at the...

Page 192: ...is too open correct as follows 3 Correction Put a precision regular screwdriver 0 9 mm 0 035 in or thinner tip in the opening Adjust the clearance to the specified value 4 If any of the above problem...

Page 193: ...factory specification recharge the battery and go to the following checking IMPORTANT After jump starting the machine s engine keep the support vehicle s engine also running for 5 minutes or longer T...

Page 194: ...he green 11 and black 12 terminals IMPORTANT While disassembling handle the power steering assembly controller and wire harness with enough care To disconnect the steering wheel be sure to use the ste...

Page 195: ...rocedures for taking measures refer to page 5 S6 W1018006 NOTE Resetting method Reset after performing checking based on the error code 1 Turn off the main switch and then turn it on 2 Perform fail sa...

Page 196: ...gear W1019944 9 Throttle Lever Operating Force Throttle Lever Operating Force 1 Set a spring balance at 20 mm 0 79 in below the tip of the throttle lever and measure the operating force 2 If the opera...

Page 197: ...0553 Parking Lock Pedal 1 Remove the parking lock pedal mounting nut 2 2 Remove the parking lock pedal 1 from the brake lock When reassembling IMPORTANT Using the oval hole make such adjustment that h...

Page 198: ...ahead position When reassembling W1020923 Separating Panel 1 Remove the speed change pedal 2 Peel the step sheet 2 halfway 3 Remove the panel mounting screws 1 4 Separate the panel When reassembling...

Page 199: ...r steering assembly mounting screws 3 5 Remove the power steering assembly with universal joint When reassembling There is a yoke at the center of the universal joint Loosen the screw to let the cente...

Page 200: ...the power steering gear case shaft IMPORTANT After assembling the power steering gear case be sure to adjust the toe in Replace the rod end mounting nut with a new one Reference Setting length L 382...

Page 201: ...switch 9 Connect the connector for servicing 1 10 Lower the front frame IMPORTANT Do not start the engine while setting Correct setting cannot be made if external force is applied to the steering whe...

Page 202: ...nnect the connector for servicing 1 8 Connect 1P connector 2 to the oil switch of the engine Check Test 1 Comply with the check test for right and left steering force setting W1024460 Measurement of S...

Page 203: ...r steering gear case 2 W1025253 Voltage Measurement of 4P Connector of EPS Controller 1 Connect the leads of circuit tester to pins No 2 Blue and No 4 Black White of EPS controller 4P connector from b...

Page 204: ...attery cable terminals are tight enough If the IG M fuse 3 blows out check the wire harness for defect Repair as required Protected circuit W1026098 FUSE NO ID LABEL CAPACITY A Protected circuit 1 EPS...

Page 205: ...6 HYDRAULIC SYSTEM KiSC issued 11 2006 A...

Page 206: ...CONTENTS MECHANISM 1 HYDRAULIC CIRCUIT LOW DUMP 6 M1 2 RELIEF VALVE 6 M2 3 CONTROL VALVE 6 M2 1 MOWER LIFTING CIRCUIT 6 M2 KiSC issued 11 2006 A...

Page 207: ...er 3 Charge Pump 4 Hydrostatic Transmission HST 5 Relief Valve 6 Valve for Mower Life Cylinder 7 Valve for Grass Collector Cylinder 8 Filter Relief Valve 9 Control Valve 10 Oil Filter Cartridge 11 Mow...

Page 208: ...VALVE In this hydraulic system the mower lifting circuit is given priority to the grass collector dumping circuit 1 MOWER LIFTING CIRCUIT Suppose that the grass collector dumping spool spool 2 9 is i...

Page 209: ...4 CHECKING DISASSEMBLING AND SERVICING 6 S3 1 CONTROL VALVE 6 S3 1 Checking and Adjusting 6 S3 2 Disassembling and Assembling 6 S5 2 CYLINDER 6 S9 1 Disassembling and Assembling 6 S9 3 MOWER LIFT LINK...

Page 210: ...f Valve Setting Pressure 2 94 to 3 43 MPa 30 0 to 35 0 kgf cm2 426 to 497 psi Filter Relief Valve Setting Pressure 1 96 to 2 45 MPa 20 0 to 25 0 kgf cm2 284 to 356 psi Transmission Fluid Including HST...

Page 211: ...m ft lbs Cam mounting nut Adaptor bolt PS 3 8 Drain pipe retaining bolt 9 16 18 UNF Adaptor on the control valve Mower lift cylinder hose Adaptor mower lift cylinder Cylinder head Cylinder piston mou...

Page 212: ...ine speed at rated speed 4 Move the mower control lever to LIFT position to operate the main relief valve 5 Read the pressure gauge 6 If the pressure is not within the factory specifications adjust wi...

Page 213: ...peed 4 Read the pressure gauge 5 If the pressure is not within the factory specifications adjust with the adjusting shims Condition Engine Speed Rated speed Oil Temperature 40 to 50 C 104 to 122 F IMP...

Page 214: ...damage to the transmission W1011896 Seat 1 Disconnect the 2P connector 3 from the seat switch 2 Remove the seat support mounting lock nuts 1 3 Remove the guide washers spring washers and screws 4 4 Re...

Page 215: ...6 5 Remove the fuel cap 4 6 Separate the fender from the frame When reassembling Apply grease to the inside of rubber bushing Clean up the step sheet and the step Apply instantaneous adhesive on the s...

Page 216: ...ly Then tighten up the control valve assembly stay mounting screw W1013013 Separating Control Valve 1 Separate the control valve 1 with the adaptors from the control valve adaptor 2 When reassembling...

Page 217: ...s 9 O ring 6 spring 8 and poppet 7 When reassembling Take care not to damage the O rings Install the relief valve noting the number of shims IMPORTANT After reassembling the relief valve be sure to ad...

Page 218: ...the frame 4 Remove the adaptor 1 When reassembling Install the adaptor as shown in the figure Keep the clearance between the mower lift cylinder hose and other parts W1017880 Tightening torque Mower...

Page 219: ...nd plane washer 4 Remove the L H rear link assembly 2 5 Remove the R H rear link assembly retaining lock nut and bolt 6 Remove the R H rear link assembly When reassembling Apply the grease to the rota...

Page 220: ...7 PTO SYSTEM KiSC issued 11 2006 A...

Page 221: ...RVICING 1 TROUBLESHOOTING 7 S1 2 SERVICING SPECIFICATIONS 7 S2 3 CHECKING DISASSEMBLING AND SERVICING 7 S3 1 CHECKING AND ADJUSTING 7 S3 2 DISASSEMBLING AND ASSEMBLING 7 S5 3 SERVICING 7 S6 KiSC issue...

Page 222: ...7 S1 G2160 WSM PTO SYSTEM 1 TROUBLESHOOTING KiSC issued 11 2006 A...

Page 223: ...0 to 2 5 mm 0 04 to 0 10 in Belt Retainer to Front PTO Belt Clearance 2 0 mm 0 08 in Tension Collar to Tension Arm Bushing Tension Collar Tension Arm Bushing Clearance O D I D 0 002 to 0 114 mm 0 0001...

Page 224: ...specifications W1010891 Adjusting Front PTO Brake 1 Place the machine on level ground and stop the engine 2 Set the PTO clutch lever to DISENGAGE position 3 Measure the clearance L between the tensio...

Page 225: ...level ground and stop the engine 2 Set the PTO clutch lever to ENGAGE position 3 Measure the clearance L between the belt retainer 2 and front PTO belt 3 4 If the measurement is not within the factory...

Page 226: ...on arm bushings and the PTO brake bushing After reassembling the PTO clutch spring be sure to adjust the front PTO belt tension See page 7 S3 After reassembling the belt stay be sure to adjust the cle...

Page 227: ...ace the PTO brake NOTE If the lining is carbonized or soaked with oil replace the PTO brake W1012662 Front PTO Pulley Wear 1 Measure the front PTO pulley O D with an outside micrometer 2 If the measur...

Page 228: ...8 ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 229: ...CONTENTS MECHANISM 1 WIRING DIAGRAM 8 M1 1 WIRING DIAGRAM with KRA system 8 M1 2 WIRING DIAGRAM without KRA system 8 M3 2 KRA Kubota Reverse Awareness SYSTEM If Equipped 8 M5 KiSC issued 11 2006 A...

Page 230: ...8 M1 G2160 WSM ELECTRICAL SYSTEM 1 WIRING DIAGRAM 1 WIRING DIAGRAM with KRA system KiSC issued 11 2006 A...

Page 231: ...8 M2 G2160 WSM ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 232: ...8 M3 G2160 WSM ELECTRICAL SYSTEM 2 WIRING DIAGRAM without KRA system KiSC issued 11 2006 A...

Page 233: ...8 M4 G2160 WSM ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 234: ...unction 2 KRA system Relay Unit KRA system relay unit consists of three parts of circuits that is inter lock circuit relay circuit reverse switch short circuit and lamp flashing circuit See page 8 M6...

Page 235: ...each time the PTO is disengaged W1012973 KRA system Electrical Circuit In KRA system engine stopping is mainly controlled by two parts that is PTO switch and reverse switch The parts shown in the fig...

Page 236: ...l pedal to NEUTRAL or REVERSE PTO switch s contact point is contacted At this moment electrical current flows as the above figure Since the electrical circuit between main switch and PTO switch is cut...

Page 237: ...rom main switch flows to engine stop timer through reverse switch and engine does not stop and runs Condition 2 On the other hand pushing KRA system switch current from main switch flows to KRA system...

Page 238: ...key stop timer is cut off Current from main switch does not flow to key stop timer On the other hand current from main switch flows to KRA system relay unit through the fuse In the KRA system relay u...

Page 239: ...ntrol pedal to FORWARD and NEUTRAL PTO lever should be disengaged Since the coil of the relay 2 is magnetized in the KRA system relay unit the contact switch is attracted to the coil side by the magne...

Page 240: ...17 3 ENGINE KEY SWITCH SHUT OFF SYSTEM 8 S19 1 CHECKING 8 S19 4 CHARGING SYSTEM 8 S20 1 CHECKING 8 S20 2 Alternator 8 S20 3 DISASSEMBLING AND ASSEMBLING 8 S21 4 Alternator 8 S21 5 SERVICING 8 S23 6 Al...

Page 241: ...8 S1 G2160 WSM ELECTRICAL SYSTEM 1 TROUBLESHOOTING KiSC issued 11 2006 A...

Page 242: ...8 S2 G2160 WSM ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 243: ...8 S3 G2160 WSM ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 244: ...8 S4 G2160 WSM ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 245: ...8 S5 G2160 WSM ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 246: ...8 S6 G2160 WSM ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 247: ...8 S7 G2160 WSM ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 248: ...8 S8 G2160 WSM ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 249: ...V Commutator O D 28 0 mm 1 102 in 27 0 mm 1 063 in Difference of O D s Less than 0 02 mm Less than 0 0008 in 0 05 mm 0 0020 in Mica Undercut 0 60 mm 0 0236 in 0 20 mm 0 0079 in Brush Length 14 0 mm 0...

Page 250: ...bolts and nuts See page G 9 W1012736 Item N m kgf m ft lbs Starter M terminal nut C terminal nut Magnetic switch mounting nut Through bolt Alternator Pulley nut 9 8 to 13 7 7 9 to 11 8 5 9 to 10 8 4...

Page 251: ...y If this advice is disregarded damage to alternator and regulator may result 1 BATTERY CHECKING Battery Voltage 1 Stop the engine and turn the main switch off 2 Connect the COM lead of the voltmeter...

Page 252: ...2 Disconnect the 4P connector from the main switch 3 Measure the voltage with a voltmeter between the connector terminal and chassis 4 If the voltage differs from battery voltage the wiring harness i...

Page 253: ...t at C position Main switch key is set at D position W1011967 Resistance 30 terminal 19 terminal Infinity 30 terminal 50 terminal Infinity 30 terminal AC terminal Infinity AC terminal 19 terminal Infi...

Page 254: ...tarter motor housing and the battery negative terminal post 7 If the motor does not run check the motor W1013277 Magnetic Switch Test 1 Disconnect the battery negative cable from the battery 2 Disconn...

Page 255: ...hassis 5 If the voltage at either position differs from the battery voltage the wiring harness or main switch is faulty W1013693 Glow Plug Continuity 1 Disconnect the lead from the glow plugs 2 Measur...

Page 256: ...rrunning clutch 6 from the housing NOTE Do not damage to the brush and commutator When reassembling Apply grease NIPPONDENSO No 50 or equivalent to the parts indicated in the figure W1015003 1 Magneti...

Page 257: ...71 Brush Wear 1 If the contact face of the brush is dirty or dusty clean it with emery paper 2 Measure the brush length A with vernier calipers 3 If the length is less than the allowable limit replace...

Page 258: ...ter 2 If it does not conduct replace the yoke assembly 3 Check the continuity across the brush 2 and yoke 3 with an ohmmeter 4 If it conducts replace the yoke assembly W1016179 Overrunning Clutch 1 In...

Page 259: ...ds across the battery negative terminal and the timer relay 2 terminal and across the battery negative terminal and the bulb terminal 4 Connect jumper lead across the timer relay 1 terminal and the bu...

Page 260: ...the negative cable from the battery 5 Measure the voltage between the B terminal 2 and the chassis 6 If the measurement is less than the factory specification disassemble the alternator and check the...

Page 261: ...he B terminal nut and remove the rear end cover W1017960 Brush Holder 1 Unscrew the two screws holding the brush holder 1 and remove the brush holder 1 W1018041 IC Regulator 1 Unscrew the three screws...

Page 262: ...etc W1018524 Retainer plate 1 Unscrew the four screws holding the retainer plate 1 and remove the retainer plate 1 W1018671 Bearing on Drive End Side 1 Press out the bearing from drive end frame 3 wi...

Page 263: ...tinuity across the slip ring and core with an ohmmeter 4 If infinity is not indicated replace it W1019305 Slip Ring 1 Check the slip ring for score 2 If scored correct with an emery paper or on a lath...

Page 264: ...ator NOTE Do not use an auto digital multimeter Because it s very hard to check the continuity of IC regulator by using it W1019909 5 ELECTRICAL EQUIPMENT CHECKING 1 Oil Pressure Switch Oil Pressure I...

Page 265: ...switch is faulty W1020510 3 Fuel Pump Connector Voltage 1 Disconnect the 2P connector from the fuel pump 2 Turn the main switch key to the ON position and measure the voltage with a voltmeter between...

Page 266: ...tery voltage the wiring harness or main switch is faulty W1028370 Head Light Switch Continuity 1 Disconnect the 1P connectors from the head light switch 1 2 Using an ohmmeter check for continuity betw...

Page 267: ...ge the wiring harness is faulty 2 Terminal Continuity 1 Measure the resistance with an ohmmeter between the terminal while pressing the brake pedal 2 Measure the resistance with an ohmmeter between th...

Page 268: ...ween the terminal when the PTO clutch lever is set at ENGAGE position 3 If the resistance values specified below are not indicated the PTO switch is faulty PTO clutch lever is set at DISENGAGE positio...

Page 269: ...1 Disconnect the 2P connector from the fuel switch 2 Using an ohmmeter check for continuity between the connector terminals There should be continuity when the fuel in the tank is empty and no contin...

Page 270: ...tch Continuity 1 Disconnect the reverse switch from the wiring harness 2 Push the switch and check the continuity between the terminals with an ohmmeter 3 If the continuity is 0 ohm the reverse switch...

Page 271: ...ed the KRA system unit is defective and replace the KRA system unit as an unit W1030717 KRA system Unit Connector Terminal Continuity 1 Measure the resistance with an ohmmeter when the main switch is...

Page 272: ...9 MOWER KiSC issued 11 2006 A...

Page 273: ...2 SERVICING SPECIFICATIONS 9 S2 3 TIGHTENING TORQUES 9 S3 4 CHECKING DISASSEMBLING AND SERVICING 9 S4 1 CHECKING AND ADJUSTING 9 S4 2 DISMOUNTING AND MOUNTING 9 S8 3 DISASSEMBLING AND ASSEMBLING 9 S1...

Page 274: ...9 S1 G2160 WSM MOWER 1 TROUBLESHOOTING KiSC issued 11 2006 A...

Page 275: ...Blade Difference Less than 4 mm 0 16 in Mower Gear Case Oil Bevel Gears Capacity Backlash 0 40 L 0 42 U S qts 0 35 lmp qts 0 13 to 0 25 mm 0 0052 to 0 0098 in Tension collar to Tension Arm Bushing Ten...

Page 276: ...lley mounting nut L H tension pulley mounting bolt and nut L H tension arm mounting bolt and nut R H tension pulley mounting bolt and nut R H tension arm mounting bolt and nut 77 4 to 90 2 98 0 to 117...

Page 277: ...blade until it balances out even W1010988 Checking Mower Belts 1 Check to see the mower belts 2 Replace the mower belt with a new one if there is found surface split at more than 3 positions When rep...

Page 278: ...dial to adjust height to the desired height 4 Lower the mower deck by pushing the hydraulic lift lever forward 5 Turn the left blade so that it is parallel to rear axle Hold drive belt and turn the r...

Page 279: ...t link 2 Reference L1 350 mm 13 8 in W1012173 Adjusting Rotation Plate 1 Park the machine on level ground and stop the engine 2 Dismount the mower 3 Turn over the mower 4 Turn the adjusting screw 3 un...

Page 280: ...ft lever backward to raise the mower deck to the top position Turn the cutting height control dial to adjust height 2 Set the anti scalp roller s height as shown to keep clearance between rollers and...

Page 281: ...Links and Universal Joint 1 Place the hydraulic lift lever 1 in the DOWN position Push down the rear links 2 to align with the mower bracket 2 Disconnect the rear links 2 from the mower deck pulling t...

Page 282: ...ing Mower 1 Turn the front wheel to the left 2 Pull out the mower deck to the right 3 Return wheels to straight ahead position 4 Reset the front anti scalp rollers to straight ahead position W1013629...

Page 283: ...rely wedge a block of wood between one blade and the mower deck in such position that it will hold the blade safely while loosing or tightening the blade screw When reassembling Be sure to assemble th...

Page 284: ...nd draw out the bevel gear shaft 21 8 Remove the bevel gear 10 ball bearing 11 shim 12 and oil seal 20 When reassembling Replace the oil seals 13 20 and gear box caps 7 8 with new Ones Check the backl...

Page 285: ...ighten the screws and nuts in the order as below to prevent the incline the gear box Tighten the reamer screws 9 to the gear box first then tighten the reamer bolt and nut 10 to the center pulley hold...

Page 286: ...2 4 to 2 8 kgf m 17 4 to 20 3 ft lbs Pulley holder mounting nut RCK54 24G RCK60B 24G 77 4 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 ft lbs 1 Grease Nipple 2 Outer Pulley Mounting Nut 3 Spring Washer 4...

Page 287: ...center pin 5 and balancer plate 1 When reassembling Apply grease to the center pin 5 Adjust the balancer spring 2 length to the factory specification with lock nut 3 W1016791 Balancer spring length L...

Page 288: ...ox cap 3 2 Place fuses the bevel gear 2 on the pinion shaft 5 3 Turn the pinion shaft 4 Take out the fuses and measure the thickness of fuses with an outside micrometer Backlash equals thickness of fu...

Page 289: ...P G2460G Supplement Printed in Japan 2001 02 S EI EI e 97897 15041 KiSC issued 11 2006 A...

Page 290: ...CONTENTS SAFETY INSTRUCTIONS P 1 SPECIFICATIONS P 6 1 GENERAL PG 1 2 ENGINE Servicing P1 S1 3 ELECTRICAL SYSTEM Mechanism P8 M1 Servicing P8 S1 KiSC issued 11 2006 A...

Page 291: ...n are mainly included for G2160 This part should be understood before proceeding with troubleshooting disassembling and servicing Servicing For G2460G s altered points there are troubleshooting servic...

Page 292: ...al 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...

Page 293: ...Always support the machine by safety stands Do not touch the rotating or hot parts while the engine is running Never remove the radiator cap while the engine is running or immediately after stopping...

Page 294: ...eep electrolyte away from eyes hands and clothing If you spill electrolyte on yourself flush with water and get medical attention immediately DISPOSE OF FLUIDS PROPERLY Do not pour fluids into the gro...

Page 295: ...TRUCTIONS The following safety decals are installed on the machine If a decal becomes damaged illegible or is not on the machine replace it The decal part number is listed in the parts list SAFETY DEC...

Page 296: ...P 5 G2460G WSM SAFETY INSTRUCTIONS KiSC issued 11 2006 A...

Page 297: ...n timing 0 30 to 0 33 rad 17 to 19 before T D C Firing order 1 2 3 Compression ratio Engine serial No below YY8644 9 0 1 Compression ratio Engine serial No above 1A0001 9 2 1 Lubricating system Forced...

Page 298: ...G2460G WSM G GENERAL 1 FEATURES 1 Gasoline engine 2 Front PTO option 3 Rugged ladder type chassis 4 Low noise high performance mower 5 Large capacity fuel tank 6 Hydraulic mower lift KiSC issued 11 20...

Page 299: ...AE10W or 10W 30 0 to 25 C 32 to 77 F SAE20 or 10W 30 Above 25 C 77 F SAE30 or 10W 30 4 Transmission Including HST and cylinder 4 5 L 4 75 U S qts 3 86 Imp qts KUBOTA UDT or SUPER UDT fluid 5 Mower gea...

Page 300: ...cartridge Change Every 200Hr PG 18 5 Transmission fluid Change Every 300Hr PG 26 6 Transmission oil filter cartridge Replace Every 300Hr PG 18 7 Transmission oil strainer Clean Every 300Hr PG 27 8 Hyd...

Page 301: ...g Amount of Fuel and Refueling CAUTION Handle fuel carefully If the engine is running do not fill the fuel tank If engine is hot let engine cool several minutes before adding fuel Do not smoke while f...

Page 302: ...ghten the mower blade screw to the specified torque 4 If the mower blade screw 2 is worn or broken replace it W1022526 Oiling CAUTION Be sure to stop the engine and remove the key before oiling Oil th...

Page 303: ...PG 2 W1030749 Replacing Engine Oil Filter Cartridge CAUTION Be sure to stop the engine before changing the oil filter cartridge Allow engine to cool down sufficiently oil can be hot and may cause burn...

Page 304: ...hever comes first 1 The fuel lines 2 is made of rubber and ages regardless of service period 2 If the fuel line 2 and clamps 1 are found damages or deteriorated replace them 3 Check fuel filter 3 if i...

Page 305: ...spark plug gap A 7 NGK BKR4E 11 spark plug is recommended W1022501 Checking Battery Condition CAUTION Never remove the vent cap while the engine is running Keep electrolyte away from eyes hands and cl...

Page 306: ...damages the machine body 3 To slow charge the battery connect the battery positive terminal to the charger positive terminal and the negative to the negative then recharge in the standard fashion 4 A...

Page 307: ...are swollen hardened or cracked NOTE Take the following actions in the event the coolant temperature be nearly or more than the boiling point what is called Overheating Park the machine in a safe plac...

Page 308: ...ained fill with clean water and cooling system cleaner 4 Follow directions of the cleaner instruction 5 After flushing fill with clean water and anti freeze until the coolant level is just below the p...

Page 309: ...IMPORTANT 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 electrical system Protected Circ...

Page 310: ...m the socket 4 Install new bulb to the socket 5 Install the socket in housing 6 Close hood B Replacing the indicator light bulb 1 Open hood 2 Turn bad bulb socket to the left 3 Pull bulb from the sock...

Page 311: ...t for Fixing Crankshaft Sleeve Code No 07916 34041 Application Use exclusively for fixing the crankshaft sleeve W1041415 Air Cooled Compression Tester Code No 07909 30251 Application Use for measuring...

Page 312: ...fter adjustment at the factory So except the authorized KUBOTA dealers you CAN NOT adjust the ignition timing The special tool is only for using in order to recover the factory original adjustment So...

Page 313: ...1A0001 WG indicates Water Cooled and Gasoline Engine 1 indicates 2001 and A indicates January So 1A indicates that the engine was manufactured on January 2001 W1010477 Alphabet or Number Year Alphabe...

Page 314: ...A CARB W1091012 Tamper Resistance KUBOTA corporation provides safeguards for the parts where never to be adjusted and is approved by EPA CARB for the purpose of this engine to be in compliance with EP...

Page 315: ...rge or replace battery Repair or replace starter Replace slow blow fuse Repair or replace main switch Replace PTO switch Replace brake switch Replace reverse switch or adjust reverse switch gap Replac...

Page 316: ...10 PG 11 1 S27 1 S28 P1 S20 PG 8 P1 S9 P1 S10 P1 S18 P8 S2 P1 S22 23 PG 8 PG 7 PG 10 PG 11 G 21 Rough Low speed Running and ldling Ignition coil defective Spark plug defective High tension cord defect...

Page 317: ...ption Oil ring worn or stuck Piston ring groove worn Valve stem and guide worn Crankshaft bearing and crank pin bearing worn Replace oil ring Replace the piston Replace valve stem and guide Replace cr...

Page 318: ...de of radiator corroded Cooling water flow route corroded Radiator cap defective Overload running Head gasket defective Incorrect ignition timing Unsuitable fuel used Replenish engine oil Replace fan...

Page 319: ...ve Clearance Cold 0 145 to 0 185 mm 0 00571 to 0 00728 in Valve Seat Width 2 12 mm 0 0835 in Valve Seat Angle 0 79 rad 45 Valve Face Angle 0 79 rad 45 Valve Recessing 0 75 to 0 95 mm 0 0295 to 0 0374...

Page 320: ...in Push Rod Alignment 0 25 mm 0 0098 in Tappet to Tappet Guide Bore Tappet Tappet Guide Bore Clearance O D I D 0 016 to 0 052 mm 0 00063 to 0 00205 in 17 966 to 17 984 mm 0 70732 to 0 70803 in 18 000...

Page 321: ...earance O D I D 0 020 to 0 084 mm 0 00079 to 0 00331 in 19 967 to 19 980 mm 0 78610 to 0 78661 in 20 000 to 20 051 mm 0 78740 to 0 78941 in 0 10 mm 0 0039 in Piston Pin Bore I D 18 000 to 18 011 mm 0...

Page 322: ...mm 0 0079 in Crankshaft Journal to Crankshaft Bearing 3 Intermediate Crankshaft Journal Crankshaft Bearing 3 Oil Clearance O D I D 0 034 to 0 092 mm 0 00134 to 0 00362 in 39 934 to 39 950 mm 1 57221...

Page 323: ...p Body Clearance 0 07 to 0 15 mm 0 0028 to 0 0059 in 0 30 mm 0 0118 in Inner Rotor to Cover End Clearance 0 075 to 0 135 mm 0 0029 to 0 0053 in 0 20 mm 0 0079 in Thermostat Valve Opening Temperature A...

Page 324: ...etaining screw Idle gear shaft mounting screw Connecting rod screw Flywheel screw Bearing case cover mounting screw Main bearing case screw 2 Main bearing case screw 1 Oil pressure switch Drain plug M...

Page 325: ...underneath the engine 4 Remove the drain plug 1 to drain oil 5 After draining screw in the drain plug 1 When refilling Fill the engine oil up to the upper line on the dipstick 3 IMPORTANT Never mix tw...

Page 326: ...cting connect the positive cable to the battery first 1 Disconnect the negative cable 1 from the battery 2 Disconnect the positive cable 2 from the battery W1019789 Bonnet and Air Cleaner 1 Disconnect...

Page 327: ...int 1 Remove the universal joint mounting screws 1 2 Disconnect the universal joint 2 from the fun drive pulley When reassembling Apply grease to the all splines on the drive shaft W1021777 Tightening...

Page 328: ...adiator When reassembling Fit the radiator to the frame adjusting the clearance between the radiator and the fan as shown in the figure Reference W1021956 Tightening torque Engine mounting nut 23 5 to...

Page 329: ...Clearance 1 Remove the cylinder head and the head gasket completely 2 Bring the piston to it TDC and fasten 1 5 mm dia 5 to 7 mm long fuse wires to 3 to 4 spots on the piston top with grease so as to...

Page 330: ...osition 7 If the clearance is not within the factory specifications adjust with the adjusting screw NOTE The sequence of cylinder numbers is given as No 1 No 2 and No 3 starting from the gear case sid...

Page 331: ...tarter 1 W1046195 Alternator and Fan Belt 1 Remove the alternator 1 2 Remove the fan 3 Remove the fan belt 2 When reassembling Check to see that there are no cracks on the belt surface See page 1 S48...

Page 332: ...ly around them Install the cylinder head Tighten the cylinder head screw gradually screw in the order of 1 to 14 after applying engine oil Retighten the cylinder head screw after running the engine fo...

Page 333: ...plastic hammer IMPORTANT Don t change the combination of valve and valve guide W1047054 C Speed Control Lever and Distributor Speed Control Plate 1 Remove the screws and copper washers 1 and separate...

Page 334: ...shops can not easily tamper with the adjustments If the ignition timing has to be adjusted remove the tamper resistance from the distributor mounting screw Reseal securely after adjusting the ignitio...

Page 335: ...loosen the distributor mounting screw 7 and turn the distributor 8 so that the ignition timing stamps on the flywheel is aligned with the mark on the rear end plate 4 Drive the plug 9 into the hexago...

Page 336: ...ear Camshaft Distributor Drive Shaft and Fork Lever 1 Remove the external snap ring 3 2 Remove the idle collar 2 2 and idle gear 1 3 Remove the camshaft stopper mounting screws 4 Remove the camshaft 4...

Page 337: ...f the flywheel screws 3 Insert two pieces of the flywheel guide screws in the holes 4 Remove all flywheel screws 5 Remove the flywheel slowly along the flywheel guide screws When reassembling Insert t...

Page 338: ...1 and the bearing case cover gasket 2 with correct directions Install the bearing case cover to position the casting mark on it upward Apply engine oil to the oil seal lip and take care that it is no...

Page 339: ...h the governor lever 1 turn the groove on the governor lever shaft 2 fully clockwise with a screwdriver to open the governor completely and then tighten the nut 3 in this position W1076333 Tightening...

Page 340: ...1100 to 1300 rpm 4 Adjust the low idling speed adjust screw 4 until the engine rpm reaches 1500 rpm 1400 to 1600 rpm with the speed control lever 3 in the minimum speed position 5 Adjust the high idl...

Page 341: ...the adjustment of governor and engine speed are executed See page P1 S27 S28 Prepare a screwdriver that fits the main jet pilot jet screws in order not to damage the main jet and pilot jet Replace th...

Page 342: ...P8 M1 G2460G WSM ELECTRICAL SYSTEM 1 WIRING DIAGRAM AND ELECTRICAL CIRCUIT 1 WIRING DIAGRAM KiSC issued 11 2006 A...

Page 343: ...P8 M2 G2460G WSM ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 344: ...P8 M3 G2460G WSM ELECTRICAL SYSTEM 2 ELECTRICAL CIRCUIT KiSC issued 11 2006 A...

Page 345: ...P8 M4 G2460G WSM ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 346: ...age Approx 12 V Air Gap 0 2 to 0 4 mm 0 008 to 0 016 in High Tension Cord 1 Resistance Engine serial No below YY8644 2 47 to 4 21 k Engine serial No above 1A0001 2 81 to 4 79 k High Tension Cord 2 Res...

Page 347: ...Inspect Primary Coil Resistance 1 Disconnect high tension cord 2 Disconnect distributor wire connector 3 Using an ohmmeter measure the resistance between the positive and negative terminals W1088375...

Page 348: ...e 2 2 If the timing is wrong loosen the distributor mounting screw 6 and turn the distributor 7 so that the ignition timing stamps on the flywheel is aligned with the mark on the rear end plate See pa...

Page 349: ...Q G2160 R48S Supplement Use this workshop manual together with Workshop Manual for G2160 issued already Printed in Japan 2001 03 S EI EI e Code No 97897 15042 KiSC issued 11 2006 A...

Page 350: ...G 3 4 MAINTENANCE CHECK LIST QG 4 5 CHECK AND MAINTENANCE QG 5 2 TRANSMISSION AND REAR AXLE Q2 M1 1 MECHANISM Q2 M1 2 SERVICING Q2 S1 6 HYDRAULIC SYSTEM Q6 M1 1 MECHANISM Q6 M1 2 SERVICING Q6 S1 7 PTO...

Page 351: ...ervicing Servicing The heading General includes general precautions check and maintenance and special tools Other section there are troubleshooting servicing specification lists checking and adjusting...

Page 352: ...STRUCTIONS The following safety decals are installed on the machine If a decal becomes damaged illegible or is not on the machine replace it The decal part number is listed in the parts list SAFETY DE...

Page 353: ...Q3 G2160 R48S WSM SAFETY INSTRUCTIONS KiSC issued 11 2006 A...

Page 354: ...Q4 G2160 R48S WSM SAFETY INSTRUCTIONS KiSC issued 11 2006 A...

Page 355: ...Q5 G2160 R48S WSM SAFETY INSTRUCTIONS KiSC issued 11 2006 A...

Page 356: ...32 F to 77 F SAE 20 or 10W 30 Above 25 C 77 F SAE 30 or 10W 30 Starting system Electric starter 12 V 1 0 kW Battery 51R 12 V 450CCA Fuel No 2 D Diesel fuel ASTM D975 No 1 D diesel fuel if temperature...

Page 357: ...5 in Total height 255 mm 10 0 in Mounting method Quick joint parallel linkage Adjustment of cutting height Dial gauge Cutting width 1219 mm 48 in Cutting height 25 to 102 mm 1 0 to 4 0 in Number of bl...

Page 358: ...Q8 G2160 R48S WSM DIMENSIONS DIMENSIONS KiSC issued 11 2006 A...

Page 359: ...1 GENERAL 1 FEATURES 1 E TVCS engine 2 Front PTO option 3 Rugged ladder type chassis 4 Low noise high performance mower 5 Large capacity fuel tank 6 Hydraulic mower lift 7 Large capacity grass collec...

Page 360: ...acting your local KUBOTA distributor always specify engine serial number 1 machine serial number 2 mower serial number 3 and hour meter reading W1010715 1 Engine Serial Number 2 Machine Serial Number...

Page 361: ...SAE10W or 10W 30 0 to 25 C 32 to 77 F SAE20 or 10W 30 Above 25 C 77 F SAE30 or 10W 30 4 Transmission Including HST cylinder 4 5 L 4 75 U S qts 3 86 Imp qts KUBOTA UDT or SUPER UDT fluid 5 Mower gear c...

Page 362: ...4 Engine oil filter cartridge Change Every 200Hr G 18 5 Transmission fluid Change Every 300Hr G 26 6 Transmission oil filter cartridge Replace Every 300Hr G 18 7 Transmission oil strainer Clean Every...

Page 363: ...1 Daily Check Oiling CAUTION Be sure to stop the engine and remove the key before oiling NOTE Oil these points on both sides of the machine 1 Oil the following points before starting W1013174 1 L Pin...

Page 364: ...50 Hours Replacing Transmission Oil Filter CAUTION Be sure to stop the engine before changing the oil filter cartridge Allow transmission case to cool down sufficiently oil can be hot and may cause b...

Page 365: ...rs Checking Hydraulic Hose CAUTION Be sure to stop the engine and remove the key before checking and replacing hydraulic hose Allow transmission case to cool down sufficiently oil can be hot and may c...

Page 366: ...l A on the oil level dipstick 3 5 After draining disassemble and clean the strainers and change the oil filter cartridge After reassembling fill with UDT or SUPER UDT hydraulic transmission fluid or i...

Page 367: ...the 4 M6 bolts and 2 bottom corner plates 5 from hopper frame 7 Remove the 2 curved bolts 7 2 hex bolts 8 4 spacers 9 4 plain washers 10 4 lock washers 11 4 hex nuts 12 bottom corner plate 14 and pipe...

Page 368: ...t recommended for use with the KUBOTA Machine may result in malfunctions or failures of the machine damage to other property and injury to the operator or others Any malfunctions or failures of the ma...

Page 369: ...trol valve adaptor 5 4 With the control valve 3 in neutral position the oil is delivered to the hydrostatic transmission through the control valve adaptor 5 and oil filter cartridge 4 5 The oil used t...

Page 370: ...le case mounting screw M12 7T Aluminum M10 7T Aluminum M12 7T M10 7T Drain pipe retaining bolt 9 16 18 UNF Speed control arm set screw Neutral arm assembly mounting screw Drain plug Adaptor bolt PS3 8...

Page 371: ...in the drain plug 1 and the oil inlet plug 2 When refilling Use the specified transmission fluid Refer to LUBRICANTS FUEL AND COOLANT See Page QG 3 Never work the machine immediately after changing th...

Page 372: ...PTO clutch return cable See page Q7 S1 Attach the center hydraulic hose of the control valve to the upper adapter of the grass collector cylinder Attach the outer hydraulic hose of the control valve t...

Page 373: ...arge Pump 4 Hydrostatic Transmission HST 5 Relief Valve 6 Valve for Mower Life Cylinder 7 Valve for Grass Collector Cylinder 8 Filter Relief Valve 9 Control Valve 10 Oil Filter Cartridge 11 Mower Lift...

Page 374: ...lector cylinder 1 is activated in the direction shown in the figure This cylinder is of double acting type The oil coming from port P flows through port B into the grass collector cylinder The oil in...

Page 375: ...l coming from port P flows through port A into the grass collector cylinder The oil in the grass collector cylinder on the other hand flows through port B into port T1 In this way the grass collector...

Page 376: ...This is single rod double acting cylinder in which the reciprocating motion of the piston is controlled by hydraulic force applied to both of its ends Cylinder Specifications W1013717 1 Nut 2 Piston 3...

Page 377: ...Q6 S2 G2160 R48S WSM HYDRAULIC SYSTEM 2 SERVICING 1 Troubleshooting KiSC issued 11 2006 A...

Page 378: ...cm2 426 to 497 psi Filter Relief valve Setting Pressure 1 96 to 2 45 MPa 20 0 to 25 0 kgf cm2 284 to 356 psi Rear link to frame stopper Clearance 1 0 to 2 0 mm 0 04 to 0 08 in Item N m kgf m ft lbs C...

Page 379: ...Remove the plug 10 4 Remove the shims 9 O ring 6 spring 8 and poppet 7 When reassembling Take care not to damage the O rings Install the relief valve noting the number of shims IMPORTANT After reassem...

Page 380: ...nder tube 3 When reassembling Visually inspect the cylinder tube for signs of scoring or damage Clean the cylinder tube 3 and piston rod assembly 2 Secure the tube end of the cylinder in a vice Insert...

Page 381: ...cking it is not twist 5 Using a tool like a screwdriver without any sharp edges install the blue external part of the piston seals 1 above the black part W1012170 Installing Cylinder Head Seal NOTE Th...

Page 382: ...ine on level ground and stop the engine 2 Set the PTO clutch lever to ENGAGE position 3 Adjust the PTO clutch return cable length so that it stretchs slightly tight IMPORTANT Check the PTO clutch leve...

Page 383: ...Q8 M1 G2160 R48S WSM ELECTRICAL SYSTEM 8 ELECTRICAL SYSTEM 1 MECHANISM 1 Wiring Diagram KiSC issued 11 2006 A...

Page 384: ...Q8 M2 G2160 R48S WSM ELECTRICAL SYSTEM KiSC issued 11 2006 A...

Page 385: ...ush the switch and check the resistance between the terminals with an ohmmeter 3 If the resistance is infinity ohms the grass collector switch 1 is faulty Replace the grass collector switch 1 W1010751...

Page 386: ...bove procedure W1010629 Item N m kgf m ft lbs Reamer bolt Mower blade screw Center pulley holder mounting screw Side blade pulley holder mounting nut and bolt Side blade pulley mounting nut LH tension...

Page 387: ...position 3 Measure the heights F R of the blade 4 If the difference between front tip of blade and rear tip of blade exceeds the factory specification adjust the length F of front links Reference L 43...

Page 388: ...nd lower lift link 2 Reference W1012174 Adjusting Rotation Plate 1 Park the machine on level ground and stop the engine 2 Dismount the mower 3 Turn over the mower 4 Turn the adjusting screw 3 until th...

Page 389: ...blade is of inverse helical type When reassembling Be sure to pay attention to how to assemble the spring plate Apply grease to the spline boss IMPORTANT Make sure the spring plate is not flattened o...

Page 390: ...rate the center pulley holder assembly from the mower deck 3 Remove the lower oil seal 7 4 Remove the internal snap ring 6 ball bearing 5 and center collar 4 5 Remove the upper oil seal 2 When reassem...

Page 391: ...grease to the bearing and oil seal lips Apply grease to the inside of center collar Replace the oil seals with new ones Be sure to pay attention to how to assemble lower oil seal Steel cover is outsi...

Page 392: ...In fitting the tension cover 2 be careful not to confuse its top and bottom as shown in the figure Apply grease to the tension arm bushing W1013954 Tightening torque Tension pulley mounting bolt and...

Page 393: ...nd bevel gear again After the backlash has been adjusted turn the pinion shaft by hand to make sure it moves smoothly Reference Thickness of adjusting shims 1 0 2 mm 0 0079 in Part No 36330 28420 0 3...

Page 394: ...e micrometer and calculate the clearance 3 If the clearance exceeds the factory specification replace them W1014933 Clearance between tension collar and tension arm bushing Factory spec 0 005 to 0 117...

Page 395: ...de No 9Y011 15044 2001 03 S EI EI e KUBOTA Corporation EDITOR KUBOTA FARM INDUSTRIAL MACHINERY SERVICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72 2...

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Kubota G2160, Workshop Manual

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