Kubota G23 Workshop Manual Download Page 1

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G23,G26

WORKSHOP MANUAL

KiSC issued 08, 2009 A

Summary of Contents for G23

Page 1: ...G23 G26 WORKSHOP MANUAL KiSC issued 08 2009 A ...

Page 2: ...Before you continue with the subsequent sections make sure that you read this section Refer to the latest version of Workshop Manual Code No 9Y021 01870 for the diesel engine mechanism that this workshop manual does not include Q Servicing This section contains information below Troubleshooting Servicing Specifications Tightening Torques Checking Disassembling and Servicing All illustrations photo...

Page 3: ...I INFORMATION KiSC issued 08 2009 A ...

Page 4: ...CONTENTS 1 SAFETY FIRST I 1 2 SAFETY DECALS I 4 3 SPECIFICATIONS I 9 4 DIMENSIONS I 11 INFORMATION KiSC issued 08 2009 A ...

Page 5: ... disengaged positions Do not start the engine when you stay on the ground Start the engine only from operator s seat WSM000001INI0015US0 SAFETY FIRST This symbol the industry s Safety Alert Symbol is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the instructions and safet...

Page 6: ...you disconnect hydraulic or fuel lines Tighten all connections before you apply the pressure Do not open a fuel system under high pressure The fluid under high pressure that stays in fuel lines can cause serious injury Do not disconnect or repair the fuel lines sensors or any other components between the fuel pump and injectors on engines with a common rail fuel system under high pressure Put on a...

Page 7: ...tions when you discard oil fuel coolant electrolyte and other dangerous waste WSM000001INI0007US1 PREVENT ACID BURNS Keep electrolyte away from your eyes hands and clothing Sulfuric acid in battery electrolyte is poisonous and it can burn your skin and clothing and cause blindness If you spill electrolyte on yourself clean yourself with water and get medical aid immediately WSM000001INI0008US1 PRE...

Page 8: ...owing safety decals pictorial safety labels 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 WSM000001INI0014US0 9Y1210294INI0002US0 KiSC issued 08 2009 A ...

Page 9: ...INFORMATION G23 G26 WSM I 5 EU 9Y1210294INI0003US0 KiSC issued 08 2009 A ...

Page 10: ...INFORMATION G23 G26 WSM I 6 EU 9Y1210294INI0004US0 KiSC issued 08 2009 A ...

Page 11: ...INFORMATION G23 G26 WSM I 7 EU 9Y1210294INI0005US0 KiSC issued 08 2009 A ...

Page 12: ...ry with a soft cloth 3 Replace damaged or missing pictorial safety labels with new labels 4 If a component with pictorial safety label s affixed is replace with new part make sure new label s is are attached in the same locations s as the replace component 5 Mount new pictorial safety labels by applying on a clean dry surface and pressure any bubbles to outside edge 9Y1210294INI0009US0 KiSC issued...

Page 13: ...esel fuel ASTM D975 No 1 D diesel fuel if temperature is below 10 C 14 F Capacities Fuel tank 20 5 L 5 4 U S gals 4 5 Imp gals Engine crankcase 3 1 L 3 3 U S qts 2 7 Imp qts 3 5 L 3 7 U S qts 3 1 Imp qts Engine coolant with recovery tank 3 1 L 3 3 U S qts 2 7 Imp qts 3 3 L 3 5 U S qts 2 9 Imp qts Transmission case 11 0 L 11 6 U S qts 9 7 Imp qts Mower gear case oil 1 9 L 2 0 U S qts 1 7 Imp qts 2 ...

Page 14: ...ick joint parallel linkage Adjustment of cutting height Dial gauge Cutting width 1219 mm 48 0 in 1372 mm 54 0 in Cutting height 25 to 102 mm 1 0 to 4 0 in Number of blades 2 Weight Approx 120 kg 265 lbs 135 kg 298 lbs Discharge direction Rear side Grass collector Model GCK G23LD GCK G26HD Container capacity 560 L 148 U S gals 110 Imp gals 640 L 169 U S gals 141 Imp gals Weight Approx 35 kg 77 lbs ...

Page 15: ...INFORMATION G23 G26 WSM I 11 EU 4 DIMENSIONS LD 9Y1210294INI0007US0 KiSC issued 08 2009 A ...

Page 16: ...INFORMATION G23 G26 WSM I 12 EU HD 9Y1210294INI0008US0 KiSC issued 08 2009 A ...

Page 17: ...G GENERAL KiSC issued 08 2009 A ...

Page 18: ... Around the Machine G 16 2 Mower G 19 3 While Sitting on the Operator s Seat G 19 4 Turning the Key Switch ON G 19 5 Starting the Engine G 19 6 Others G 20 2 CHECK POINTS OF INITIAL 50 HOURS G 20 3 CHECK POINTS OF EVERY 50 HOURS G 22 4 CHECK POINTS OF EVERY 100 HOURS G 37 5 CHECK POINT OF EVERY 150 HOURS G 38 6 CHECK POINTS OF EVERY 200 HOURS G 39 7 CHECK POINTS OF EVERY 400 HOURS G 44 8 CHECK POI...

Page 19: ...N 1 SERIAL NUMBER When contacting your local KUBOTA distributor always specify engine serial number tractor serial number and hour meter reading To be continued 1 Machine Serial Number 2 Engine Serial Number 3 Mower Serial Number KiSC issued 08 2009 A ...

Page 20: ...ee the cylinder numbers of KUBOTA diesel engine in the figure The sequence of cylinder numbers is No 1 No 2 and No 3 and it starts from the gear case side WSM000001GEG0056US0 4 Grass Catcher Serial Number LD 5 Grass Catcher Serial Number HD 6 Hour Meter Tachometer KiSC issued 08 2009 A ...

Page 21: ... before you measure Use only KUBOTA genuine parts for replacement to keep the machine performance and to make sure of safety You must replace the gaskets and O rings when you assemble again Apply grease 1 to new O rings or oil seals before you assemble When you assemble the external or internal snap rings make sure that the sharp edge 3 faces against the direction from which force 2 is applied Whe...

Page 22: ... 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 cables connect the positive cable first WSM000001GEG0062US1 1 WIRING Securely tighten wiring terminals WSM000001GEG0063US1 Do not let wiring contact dangerous part WSM000001GEG0064US1 Securely insert grommet WSM000001GEG0066US1 1 ...

Page 23: ...quired WSM000001GEG0068US1 In installing a part take care not to get wiring caught by it WSM000001GEG0069US1 After installing wiring check protection of terminals and clamped condition of wiring only connect battery WSM000001GEG0070US1 1 Clamp Wind Clamp Spirally 2 Wire Harness 3 Clamp 4 Welding Dent 1 Wiring 2 Clamp A Correct B Incorrect 1 Wiring A Incorrect 1 Cover Securely Install Cover KiSC is...

Page 24: ...ging 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 and oxygen are formed WSM000001GEG0071US1 3 FUSE Use fuses with specified capacity Neither too large or small capacity fuse is acceptable Never use steel or copper wire in place of fuse Do not install working light radio set etc...

Page 25: ...female connector being too open WSM000001GEG0076US1 Make certain plastic cover is large enough to cover whole connector WSM000001GEG0077US1 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provided with tester Check for polarity and range WSM000001GEG0078US1 1 Exposed Terminal 2 Deformed Terminal 3 Sandpaper 4 Rust A Correct B Incorrect 1 Cover A Correct B Incorrect KiSC issued 0...

Page 26: ...s symbol of shows color with stripe s An example Red stripe on white color W R WSM000001GEG0079US0 Color of wiring Color code Black B Brown Br Green G Gray Gy or Gr Blue L Light Green Lg Orange Or Pink P Purple Pu or V Red R Sky Blue Sb White W Yellow Y 1 Wire Color 2 Stripe KiSC issued 08 2009 A ...

Page 27: ...s Fresh clean water with anti freeze 3 Engine crankcase 3 1 L 3 3 U S qts 2 7 Imp qts 3 5 L 3 7 U S qts 3 1 Imp qts Engine oil API Service Classification CD CE or CF Above 25 C 77 F SAE30W SAE10W 30 or 15W 40 0 to 25 C 32 to 77 F SAE20 SAE10W 30 or 15W 40 Below 0 C 32 F SAE10W SAE10W 30 or 15W 40 4 Transmission case 11 0 L 11 6 U S qts 9 7 Imp qts KUBOTA UDT or SUPER UDT fluid 5 Mower gear box 1 9...

Page 28: ...re pin 1 Brake pedal 7 HST speed change pedal 2 HST pedal boss 1 Tension PTO arm 1 PTO 1 Parking lock pedal 2 Cruise control 2 Differential lock pedal 4 Cutting height cam 3 Under duct 5 Sensor rod 2 Duct cleanup system 3 Seat adjuster 4 Throttle cable 1 Moderate amount Oil Mower universal joint 5 Until grease overflows Multipurpose EP2 grease NLGI Grade No 2 Mower lift cylinder 5 Front RH link 1 ...

Page 29: ...ubricating oil at shorter intervals Lubricating oil recommended when a low sulfur or high sulfur fuel is employed P Recommendable X Not Recommendable Transmission oil KUBOTA SUPER UDT 1 KUBOTA Original Transmission hydraulic fluid The oil used to lubricate the transmission is also used as hydraulic fluid To insure proper operation of the hydraulic system and complete lubrication of the transmissio...

Page 30: ...to 4 6 29 to 33 32 to 34 3 2 to 3 5 24 to 25 48 to 55 4 9 to 5 7 36 to 41 40 to 44 4 0 to 4 5 29 to 32 61 to 70 6 2 to 7 2 45 to 52 M12 63 to 72 6 4 to 7 4 47 to 53 78 to 90 7 9 to 9 2 58 to 66 63 to 72 6 4 to 7 4 47 to 53 103 to 117 10 5 to 12 0 76 0 to 86 7 M14 108 to 125 11 0 to 12 8 79 6 to 92 5 124 to 147 12 6 to 15 0 91 2 to 108 167 to 196 17 0 to 20 0 123 to 144 M16 167 to 191 17 0 to 19 5 ...

Page 31: ...3 to 18 1 111 to 131 9 16 150 to 178 15 3 to 18 1 111 to 131 217 to 260 22 2 to 26 5 160 to 191 5 8 204 to 244 20 8 to 24 8 151 to 179 299 to 357 30 5 to 36 4 221 to 263 Shape Size Material of opponent part Ordinariness Aluminum N m kgf m lbf ft N m kgf m lbf ft Tapered screw R1 8 13 to 21 1 3 to 2 2 9 4 to 15 13 to 19 1 3 to 2 0 9 4 to 14 R1 4 25 to 44 2 5 to 4 5 18 to 32 25 to 34 2 5 to 3 5 18 t...

Page 32: ...leaner element Clean 3 3 3 3 3 3 3 3 3 3 3 3 every 50 Hr G 32 1 Replace every 1 year G 45 12 Battery condition Check 3 3 3 3 3 3 3 3 3 3 3 3 every 50 Hr G 33 13 Battery charging Check 3 3 3 3 3 3 3 3 3 3 3 3 every 50 Hr G 34 14 Front PTO belt tension Adjust 3 3 3 3 3 3 3 3 3 3 3 3 every 50 Hr G 36 3 15 Brake Adjust 3 3 3 3 3 3 every 100 Hr G 37 16 Fan drive belt Check 3 3 3 3 3 3 every 100 Hr G 37...

Page 33: ...in the U S EPA nonroad emission regulation As the engine owner you are responsible for the performance of the required maintenance on the engine according to the above instruction Please see the Warranty Statement in detail 9Y1210294GEG0004US0 24 Injection pump Check every 3000 Hr G 45 25 Radiator Clean every 2 years G 47 26 Coolant Change every 2 years G 47 27 Anti Freeze every 2 years G 47 28 Mo...

Page 34: ... nuts 7 Radiator screen 8 Panel screen 9 Brake free travel 10 Fuel level 11 Check air cleaner 9Y1210294GEG0007US0 Checking Engine Oil Level CAUTION To avoid personal injury Be sure to stop the engine before checking the oil level 1 Park the machine on a flat surface 2 Check engine oil before starting the engine or 5 minutes or more after the engine has stopped 3 To check the oil level draw out the...

Page 35: ... trash to get into the fuel system Be careful not to let the fuel tank become empty otherwise air will enter the fuel system necessitating bleeding before next engine start Be careful not to spill during refueling If should spill wipe it off at once or it may cause a fire To prevent condensation water accumulation in the fuel tank fill the tank before parking overnight NOTE No2 D is a distillate f...

Page 36: ... Pressure WARNING To avoid personal injury Do not attempt to mount a tyre on a rim This should be done by a qualified person with the proper equipment Always maintain the correct tyre pressure Do not inflate tyres above the recommended pressure shown in the Operator s Manual Inflation pressure in front tyres rises quickly when using compressed air CAUTION Never operate machine with a loose rim whe...

Page 37: ... level and Lowest level marks of recovery tank 1 2 When the coolant level drops due to evaporation add water only In case of leakage add anti freeze and water in the specified mixing ratio up to the Highest level See page G 47 IMPORTANT If the radiator cap has to be removed follow the caution above and securely retighten the cap Use clean distilled water and anti freeze to fill the radiator 9Y1210...

Page 38: ...rsonal injury Be sure to stop the engine and remove the key before changing the oil and the oil filter Allow engine to cool down sufficiently oil can be hot and may cause burns 1 Remove the oil filter 2 Put a film of clean engine oil on the rubber seal of the new filter 3 Tighten the filter quickly until contacts the mounting surface Tighten filter by hand an additional 1 2 turn only 4 After new f...

Page 39: ... off if necessary 5 Properly dispose of used oil IMPORTANT To prevent serious damage to the hydraulic system use only a KUBOTA genuine filter 9Y1210294GEG0075US0 Checking Gear Box Oil CAUTION To avoid personal injury Be sure to stop the engine and remove the key before changing the oil Remove the right and left hand shields from the mower deck 1 To drain the used oil remove the oil level dipstick ...

Page 40: ...the brake pedal fully 2 Engage the PTO lever 3 Turn the key switch to the START position 4 The engine should not crank Q Safety Start Control 2 1 Disengage the PTO lever 2 Release the brake pedal 3 Turn the key to the START position 4 The engine should not crank Q Seat Safety Control 1 1 Run the engine at half throttle 2 Engage the PTO lever 3 Stand up DO NOT GET OFF THE MACHINE 4 Engine should sh...

Page 41: ...ng CAUTION To avoid personal injury Be sure to stop the engine and remove the key before greasing 1 Oil the location shown in the figures 9Y1210294GEG0024US0 1 Throttle Cable G23 2 Throttle Cable G26 A G23 B G26 KiSC issued 08 2009 A ...

Page 42: ...personal injury Be sure to stop the engine and remove the key before greasing 1 Apply a grease to the following positions as figures 9Y1210294GEG0025US0 1 Front Axle 2 Front Axle 3 Brake Pedal Link 4 Brake Pedal Link 5 Brake Pedal Link KiSC issued 08 2009 A ...

Page 43: ... to stop the engine and remove the key before greasing 1 Apply a grease to the following positions as figures 9Y1210294GEG0026US0 1 Brake Pedal Link 2 HST Speed Change Pedal Dumper 3 HST Speed Change Pedal Dumper 4 HST Pedal Boss 5 PTO Tension Arm 6 PTO Shaft KiSC issued 08 2009 A ...

Page 44: ...ury Be sure to stop the engine and remove the key before greasing 1 Apply a grease to the following positions as figures 9Y1210294GEG0027US0 1 Parking Lock Pedal Link 2 Cruise Control Link 3 Def Lock Pedal Link 4 Def Lock Pedal Link 5 Rear Tyre LH KiSC issued 08 2009 A ...

Page 45: ...ine and remove the key before greasing 1 Apply a grease to the following positions as figures 9Y1210294GEG0028US0 1 Mower Lift Arm Rear RH 2 Duct Cleanup System Link 3 Sensor System Pivot 4 Duct Cleanup System Link 5 Duct Cleanup System Link 6 Universal Joint 7 Grease Nipple KiSC issued 08 2009 A ...

Page 46: ...ry Be sure to stop the engine and remove the key before greasing 1 Apply a grease to the following positions as figures 9Y1210294GEG0029US0 1 Mower Lift Cylinder 2 Mower Lift Link 3 Mower Lift Arm Front LH 4 Mower Lift Link 5 Mower Lift Arm Rear LH KiSC issued 08 2009 A ...

Page 47: ...e to stop the engine and remove the key before greasing 1 Apply a grease to the following positions as figures 9Y1210294GEG0030US0 1 Mower Lift Arm Front RH 2 Mower Lift Link Rear RH 3 Dump Cylinder LD 4 Dumper Cylinder LD 5 Grass Container Rotation Pivot LD KiSC issued 08 2009 A ...

Page 48: ... avoid personal injury Be sure to stop the engine and remove the key before greasing 1 Apply a grease to the following positions as figures 9Y1210294GEG0031US0 1 Lock Lever LD 2 Grass Catcher HD 3 Grass Container Lift Cylinder HD KiSC issued 08 2009 A ...

Page 49: ...e mower to the ground To check the oil level draw out the dipstick wipe it clean replace it and draw it out again Check to see that the oil level lies between the two notches If the level is too low add new oil to the prescribed level at the oil inlet Refer to LUBRICANTS FUEL AND COOLANT in this section NOTE Check the oil level of the transmission case with the mower lifted up IMPORTANT If oil lev...

Page 50: ... the inside of the element with a light and check if it is damaged or not Referring to the instructions on the label attached to the case 3 Replace the air cleaner element if Once yearly or after every sixth cleaning whichever comes first NOTE Check to see if the evacuator valve is blocked with dust IMPORTANT The air cleaner uses a dry element never apply oil Do not run the engine with the filter ...

Page 51: ...luid level is between the UPPER and LOWER levels CAUTION To avoid personal injury Never remove the vent caps while the engine is running Keep electrolyte away from eyes hands and clothes If you are spattered with it wash it away completely with water immediately and get medical attention Wear eye protection and rubber gloves when working around battery Mishandling the battery 1 shortens the servic...

Page 52: ...s at the bottom of vent wells if necessary add distilled water in a well ventilated area 2 The water in the electrolyte 3 evaporates during recharging Liquid shortage damages the battery Excessive liquid spills over and 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 s...

Page 53: ...he state of charge See reference chart below to determine if charging is necessary Q Direction for storage 1 When storing the machine for a long period remove the battery from the machine adjust the electrolyte to the proper level and store in a dry place out of direct sunlight 2 The battery self discharges while it is stored Recharge it once every three months in hot seasons and once every six mo...

Page 54: ...sion arm 8 If not make the stay contact with the tension arm 8 by loosening the bolt Then tighten the bolt again 8 Attach the covers and engine cover 1 9 Disengage the PTO lever Reference Spring Length L 88 to 91 mm 3 46 to 3 58 in G26 1 Remove the cover 2 Measure tension spring 12 length L 3 If L is shorter than 113 mm 4 45 in adjust it with the tension clutch cable adjusting nut L should be 113 ...

Page 55: ...e to belt between pulleys 3 If tension is incorrect loosen the alternator mounting bolts 1 and using a lever placed between the alternator 2 and the engine block pull the alternator 2 out until the deflection of the belt falls within the acceptable limits 4 Replace fan belt if it is damaged 9Y1210294GEG0039US0 Adjusting HST Neutral Spring WARNING To avoid personal injury Do not operate if the mach...

Page 56: ...ntenance or repair close both ends of the fuel line 2 with clean plug of suitable size to prevent dust and dirt from entering Particular care must be taken not to admit dust and dirt into the fuel system Entrance of dust and dirt cause malfunction of the fuel pump 9Y1210294GEG0041US0 5 CHECK POINT OF EVERY 150 HOURS Checking Gear Box Oil CAUTION To avoid personal injury Be sure to stop the engine ...

Page 57: ...ciently oil can be hot and may cause burns 1 Remove the filter cover if model with engine filter cover 2 Remove the oil filter 3 Put a film of clean engine oil on the rubber seal of the new filter 4 Tighten the filter quickly until it contacts the mounting surface Tighten filter by hand an additional 1 2 turn only 5 After new filter has been replaced the engine oil normally decreases a little Make...

Page 58: ...Make sure that the transmission fluid does not leak through the seal and check the fluid level Top off if necessary 5 Properly dispose of used oil 9Y1210294GEG0021US0 Adjusting Front Axle Pivot If the front axle pivot pin adjustment is not correct front wheel vibration can occur causing vibration in the steering wheel 1 Remove the split pin 2 tighten the adjusting nut 1 tightening torque 20 N m 2 ...

Page 59: ... checking power steeling line 1 Check to see that all lines are tight and not damaged 2 If hoses are found worn or damaged replace or repair them at once To be continued 1 Power Steering Pressure Hose 2 Power Steering Pressure Hose 3 Mower Lift Cylinder Hose 4 Front PTO Clutch Pressure Hose 5 Front PTO Delivery Hose KiSC issued 08 2009 A ...

Page 60: ...5US0 6 Front PTO Return Hose 7 Grass Container Dump Cylinder Hose LD 8 Grass Container Dump Cylinder Hose HD 9 Grass Container Lift Cylinder Hose HD 10 Grass Container Lift Cylinder Hose LH HD 11 Grass Container Dump Cylinder Hose HD KiSC issued 08 2009 A ...

Page 61: ...rheating Take the following actions in the event the coolant temperature be nearly or more than the boiling point what is called Overheating 1 Stop the machine operation in a safe place and keep the engine unloaded idling 2 Do not stop the engine suddenly but stop it after about 5 minutes of unloaded idling 3 Keep yourself well away from the machine for further 10 minutes or while the steam is blo...

Page 62: ...ed oil NOTE If oil level is low do not run the engine IMPORTANT Do not operate the machine immediately after changing the transmission fluid Run the engine at medium speed for a few minutes to prevent damage to the transmission 9Y1210294GEG0048US0 Cleaning Transmission Strainer When changing the transmission fluid disassemble and rinse the strainer with nonflammable solvent to completely clean off...

Page 63: ...POINT OF EVERY 1 YEAR Replacing Air Cleaner Element See page G 32 9Y1210294GEG0053US0 11 CHECK POINTS OF EVERY 2 YEARS Replacing Fuel Lines 1 Replace the hose and the clamps Refer to Checking Fuel Line and Fuel Filter See page G 38 9Y1210294GEG0054US0 Replacing Hydraulic Hose 1 Replace hoses and hose clamps every 2 years or earlier if checked and found that hoses are swollen hardened or cracked Se...

Page 64: ...eplacing Mower Gear Box Seal 1 Replace the mower gear box oil seals 1 2 3 Refer to Mower section 9Y1210294GEG0058US0 Replacing Intake Air Line See page G 43 9Y1210294GEG0059US0 1 Oil Seal 2 Oil Seal 3 Oil Seal KiSC issued 08 2009 A ...

Page 65: ...aner instruction 6 After flushing fill with clean water and anti freeze until the coolant level is just below the port 7 Fill with clean water and anti freeze up to the upper line of recovery tank 8 Install the radiator cap securely 9 Start and operate the engine for a few minutes 10 Stop the engine Check coolant level and add coolant if necessary IMPORTANT Do not start engine without coolant Use ...

Page 66: ... term storage let out cooling water completely or mix fresh water with long life coolant and fill the radiator and reserve tank with the mixture 1 Long life coolant hereafter LLC comes in several types Use ethylene glycol EG type for this engine 2 Before employing LLC mixed cooling water fill the radiator with fresh water and empty it again repeat this procedure 2 or 3 times to clean up the inside...

Page 67: ... 2 years Be sure to change the coolant every 2 years NOTE The above date represent industry standards that necessitate a minimum glycol content in the concentrated anti freeze When the coolant level drops due to evaporation add water only to keep the anti freeze mixing ratio less than 50 In case of leakage add anti freeze and water in the specified mixing ratio before filling in to the radiator 9Y...

Page 68: ...n fuse determine why the fuse blew and make any necessary repairs Failure to follow this procedure may result in serious damage to the machine electrical system If any of the fuses should blow replace with a new one of the same capacity Q Protected Circuit 9Y1210294GEG0062US0 Fuse NO Capacity A Protected circuit 1 10 Parking 2 15 Solenoid 3 15 Hazard Light 4 10 ACC 5 15 Horn 6 15 Beacon 7 15 Head ...

Page 69: ... the machine 2 Remove the two snap pins and the shaft and then remove the mower duct with sliding it NOTE When reinstalling the mower duct make sure that the both stays of the mower cover are set between the two washers 3 Turn the mower deck over to expose the blades 4 Wedge a block of wood between the blade and mower housing as illustrated 5 The blade bolts 5 have right hand threads turn counterc...

Page 70: ... and bolt head NOTE Make sure that the cup washer is not flattened out or worn Replace the cup washer if either is damaged 9 Before checking or replacing the blade wipe grass and mud off the top and inside of the mower NOTE Make sure that the direction of the pin holder and the cup washer is same as shown in the figure IMPORTANT Tighten the 2 blade bolts to 98 to 117 6 N m 10 to 12 kgf m 72 to 87 ...

Page 71: ... Indicator Light Bulb Socket Bulb 1 Remove the meter panel 1 from the machine 2 Remove the indicator light bulbs 2 9Y1210294GEG0078US0 Indicator light bulb Socket bulb Capacity 2 W 1 Meter Panel 2 Indicator Light Bulb KiSC issued 08 2009 A ...

Page 72: ...12US0 Piston Ring Tool Code No 07909 32121 Application Use exclusively for removing or installing the piston ring with ease WSM000001GEG0013US0 Diesel Engine Compression Tester Code No 07909 30208 Assembly 07909 30934 A to F 07909 31211 E and F 07909 31231 H 07909 31251 G 07909 31271 I 07909 31281 J Application Use to measure diesel engine compression and diagnostics of need for major overhaul WSM...

Page 73: ...tter Code No 07909 33102 Application Use to reseat valves Angle 0 79 rad 45 0 26 rad 15 Diameter 28 6 mm 1 13 in 31 6 mm 1 24 in 35 0 mm 1 38 in 38 0 mm 1 50 in 41 3 mm 1 62 in 50 8 mm 2 00 in WSM000001GEG0016US0 Radiator Tester Code No 07909 31551 Application Use to check of radiator cap pressure and leaks from cooling system Remarks Adaptor 1 BANZAI Code No RCT 2A 30S WSM000001GEG0017US0 1 Gauge...

Page 74: ... the fuel injection pressure and spray pattern of nozzle Measuring range 0 to 50 MPa 0 to 500 kgf cm2 0 to 7000 psi WSM000001GEG0021US0 Plastigage Code No 07909 30241 Application Use to check the oil clearance between crankshaft and bearing etc Measuring range Green 0 025 to 0 076 mm 0 001 to 0 003 in Red 0 051 to 0 152 mm 0 002 to 0 006 in Blue 0 102 to 0 229 mm 0 004 to 0 009 in WSM000001GEG0022...

Page 75: ...5 to 12 8 mm dia 0 492 to 0 504 in dia L 8 9 to 9 1 mm 0 350 to 0 358 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 012 in A 20 mm dia 0 79 in dia B 9 96 to 9 98 mm dia 0 3921 to 0 3929 in dia C 5 5 to 5 7 mm dia 0 2165 to 0 2244 in dia D 220 mm 8 66 in E 80 mm 3 15 in F 40 mm 1 58 in G 25 mm 0 98 in H 5 mm 0 197 in I 6 0 to 6 1 mm dia 0 236 to 0 240 in dia J 18 mm...

Page 76: ... dia 0 8622 to 0 8642 in dia F 25 mm dia 0 98 in dia C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 012 in a 6 3 µm 250 µin b 6 3 µm 250 µin A 150 mm 5 91 in B 23 mm 0 91 in C 100 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 C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 C...

Page 77: ...51 80 to 51 90 mm dia 2 0393 to 2 0433 in dia C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 012 in A 130 mm 5 12 in B 72 mm 2 83 in C 40 mm radius 1 57 in radius D 9 mm 0 35 in E 24 mm 0 95 in F 20 mm dia 0 79 in dia G 68 mm dia 2 68 in dia H 47 38 to 47 48 mm dia 1 865 to 1 869 in dia C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 012 in ...

Page 78: ...r 07916 52040 2 Gasket 04714 00200 3 Connector 3 07916 51331 4 Vacuum Gauge 07916 51331 5 Pressure Gauge Low Pressure 07916 51301 6 Pressure Gauge High Pressure in Relief Valve Set Pressure Tester 07916 50321 7 HN Tube in Relief Valve Set Pressure tester 07916 50331 8 Valve Seat Driver 07916 60841 9 Connector 1 07916 60811 10 Connector 2 07916 60821 11 Long Connector 07916 60831 12 Adaptor 1 07916...

Page 79: ...ntly and keep them tightened Q Inflation Pressure Though the inflation pressure is factory set to the prescribed level it naturally drops slowly in the course of time Thus check it everyday and inflate as necessary 9Y1210294GEG0011US0 2 WHEEL IMPORTANT When re fitting or adjusting a wheel tighten the bolts to the following to torques then recheck after driving the machine 200 m 182 yard after one ...

Page 80: ... 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 machine resulting from use with improper implements are not covered by the warranty 9Y1210294GEG0077US0 9Y1210294GEG0073US0 Maximum axle loading weight MODEL Front axle Wf Rear axle Wr Total gross weight G23 400 kg ...

Page 81: ...1 ENGINE KiSC issued 08 2009 A ...

Page 82: ...20 2 DISASSEMBLING AND ASSEMBLING 1 S23 1 Separating Engine 1 S23 2 Removing Engine Outer Parts 1 S30 3 Cylinder Head and Valves 1 S30 4 Gear Case and Timing Gears 1 S34 5 Piston and Connecting Rod 1 S38 6 Flywheel and Crankshaft 1 S40 3 SERVICING 1 S42 1 Cylinder Head and Valves 1 S42 2 Timing Gears Camshaft and Governor Gear 1 S50 3 Piston and Connecting Rod 1 S53 4 Crankshaft 1 S57 5 Cylinder 1...

Page 83: ...zzle holder 1 S32 Improper valve timing Correct or replace timing gear 1 S37 Piston ring and cylinder worn Replace 1 S39 Excessive valve clearance Adjust 1 S16 Starter Does Not Run Battery discharged Charge G 34 Starter malfunctioning Repair or replace 6 S25 Main switch malfunctioning Repair or replace 6 S8 6 S9 Safety switches improperly adjusted or defective Adjust or replace 6 S11 Wiring discon...

Page 84: ...lve guide worn Replace 1 S44 Oil leaking due to defective seals or packing Replace Fuel Mixed into Lubricant Oil Injection pump s plunger worn Repair or replace 1 S36 Deficient nozzle injection Repair or replace nozzle 1 S31 Injection pump broken Replace 1 S36 Water Mixed into Lubricant Oil Head gasket defective Replace 1 S32 Cylinder block or cylinder head flawed Replace 1 S32 Low Oil Pressure En...

Page 85: ...lean or replace Radiator cap defective Replace 1 S18 Overload running Reduce the load Head gasket defective Replace 1 S32 Incorrect injection timing Adjust 1 S20 Unsuitable fuel used Use specified fuel G 9 Battery Quickly Discharged Battery electrolyte insufficient Replenish distilled water and charge G 34 Fan belt slips Adjust belt tension or replace 1 S18 Wiring disconnected Connect Alternator d...

Page 86: ...Clearance O D I D 0 030 to 0 057 mm 0 0012 to 0 0022 in 5 968 to 5 980 mm 0 2350 to 0 2354 in 6 010 to 6 025 mm 0 2367 to 0 2372 in 0 10 mm 0 0039 in Valve Face Angle Intake 0 79 rad 45 Angle Exhaust 0 79 rad 45 Valve Seat Angle Intake and exhaust 0 79 rad 45 Width 2 12 mm 0 0835 in Valve Spring Free Length 31 3 to 31 8 mm 1 24 to 1 25 in 28 4 mm 1 12 in Tilt 1 2 mm 0 047 in Setting Load 65 N 27 0...

Page 87: ...ar 1 Idle Gear Bushing Idle Gear Shaft 1 Clearance I D O D 0 020 to 0 084 mm 0 00079 to 0 0033 in 20 000 to 20 051 mm 0 78741 to 0 78940 in 19 967 to 19 980 mm 0 78611 to 0 78661 in 0 10 mm 0 0039 in Idle Gear Idle Gear 1 Side Clearance 0 20 to 0 51 mm 0 0079 to 0 020 in 0 80 mm 0 031 in Camshaft Side Clearance Alignment 0 15 to 0 31 mm 0 0059 to 0 012 in 0 50 mm 0 020 in 0 01 mm 0 0004 in Cam Hei...

Page 88: ... mm 0 0059 in Connecting Rod Alignment 0 05 mm 0 002 in Crankshaft Alignment 0 02 mm 0 0008 in Crankshaft to Crankshaft Bearing 1 Crankshaft Journal Crankshaft Bearing 1 Oil Clearance O D I D 0 0340 to 0 106 mm 0 00134 to 0 00417 in 43 934 to 43 950 mm 1 7297 to 1 7303 in 43 984 to 44 040 mm 1 7315 to 1 7320 in 0 20 mm 0 0079 in Crankshaft to Crankshaft Bearing 2 Crankshaft Journal Crankshaft Bear...

Page 89: ...n 72 150 mm 2 8406 in Cylinder Oversized 72 250 to 72 269 mm 2 8445 to 2 8452 in 72 400 mm 2 8504 in Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed More than 49 kPa 0 50 kgf cm2 7 1 psi At Rated Speed 197 to 441 kPa 2 00 to 4 50 kgf cm2 28 6 to 63 9 psi 147 kPa 1 50 kgf cm2 21 3 psi Inner Rotor to Outer Rotor Clearance 0 030 to 0 14 mm 0 0012 to 0 0055 in Outer Rotor ...

Page 90: ...Pressure No leak at specified pressure Item Factory Specification Allowable Limit Injection Pump Injection Timing 3200 min 1 rpm 0 3360 to 0 3622 rad 19 25 to 20 75 before T D C Pump Element Fuel Tightness 13 73 MPa 140 0 kgf cm2 1991 psi Delivery Valve Fuel Tightness 10 seconds 13 73 12 75 MPa 140 0 130 0 kgf cm2 1991 1849 psi 5 seconds 13 73 12 75 MPa 140 0 130 0 kgf cm2 1991 1849 psi Injection ...

Page 91: ...0 065 mm 0 0014 to 0 0025 in 6 960 to 6 975 mm 0 2741 to 0 2746 in 7 010 to 7 025 mm 0 2760 to 0 2765 in 0 10 mm 0 0039 in Valve Face Angle Intake 1 0 rad 60 Angle Exhaust 0 79 rad 45 Valve Seat Angle Intake 1 0 rad 60 Angle Exhaust 0 79 rad 45 Width 2 12 mm 0 0835 in Valve Spring Free Length 37 0 to 37 5 mm 1 46 to 1 47 in 36 5 mm 1 44 in Tilt 1 0 mm 0 039 in Setting Load 117 4 N 31 0 mm 11 97 kg...

Page 92: ...r Bushing Idle Gear 1 Idle Gear Bushing Idle Gear Shaft 1 Clearance I D O D 0 020 to 0 054 mm 0 00079 to 0 0021 in 26 000 to 26 021 mm 1 0237 to 1 0244 in 25 967 to 25 980 mm 1 0224 to 1 0228 in 0 10 mm 0 0039 in Idle Gear Idle Gear 1 Side Clearance 0 20 to 0 51 mm 0 0079 to 0 020 in 0 80 mm 0 031 in Camshaft Side Clearance Alignment 0 070 to 0 22 mm 0 0028 to 0 0086 in 0 30 mm 0 012 in 0 01 mm 0 ...

Page 93: ...008 in 0 15 mm 0 0059 in Connecting Rod Alignment 0 05 mm 0 002 in Crankshaft Alignment 0 02 mm 0 0008 in Crankshaft to Crankshaft Bearing 1 Crankshaft Crankshaft Bearing 1 Oil Clearance O D I D 0 0340 to 0 114 mm 0 00134 to 0 00448 in 47 934 to 47 950 mm 1 8872 to 1 8877 in 47 984 to 48 048 mm 1 8892 to 1 8916 in 0 20 mm 0 0079 in Crankshaft to Crankshaft Bearing 2 Crankshaft Crankshaft Bearing 2...

Page 94: ... in 76 15 mm 2 998 in Cylinder Oversized 76 500 to 76 519 mm 3 0119 to 3 0125 in 76 65 mm 3 018 in Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed More than 49 kPa 0 50 kgf cm2 7 1 psi At Rated Speed 197 to 441 kPa 2 00 to 4 50 kgf cm2 28 6 to 63 9 psi 147 kPa 1 50 kgf cm2 21 3 psi Inner Rotor to Outer Rotor Clearance 0 060 to 0 18 mm 0 0024 to 0 0071 in Outer Rotor to...

Page 95: ...Pressure No leak at specified pressure Item Factory Specification Allowable Limit Injection Pump Injection Timing 3200 min 1 rpm 0 3360 to 0 3622 rad 19 25 to 20 75 before T D C Pump Element Fuel Tightness 13 73 MPa 140 0 kgf cm2 1991 psi Delivery Valve Fuel Tightness 10 seconds 13 73 12 75 MPa 140 0 130 0 kgf cm2 1991 1849 psi 5 seconds 13 73 12 75 MPa 140 0 130 0 kgf cm2 1991 1849 psi Injection ...

Page 96: ...9 to 41 2 Item Dimension Pitch N m kgf m lbf ft Cylinder head cover screw M7 1 0 7 to 8 0 7 to 0 9 5 to 6 Cylinder head screw M10 1 25 64 to 68 6 5 to 7 0 47 to 50 Main bearing case screw 1 M8 1 25 30 to 34 3 0 to 3 5 22 to 25 Main bearing case screw 2 M9 1 25 49 to 53 5 0 to 5 5 37 to 39 Flywheel screw M10 1 25 54 to 58 5 5 to 6 0 40 to 43 Connecting rod screw M8 1 0 42 to 46 4 2 to 4 7 31 to 33 ...

Page 97: ...small amount of oil to the cylinder wall through the glow plug hole or nozzle hole and measure the compression pressure again 8 If the compression pressure is still less than the allowable limit check the top clearance valve clearance and cylinder head 9 If the compression pressure increases after applying oil check the cylinder wall and piston rings NOTE Check the compression pressure with the sp...

Page 98: ...lignment mark 2 on the rear end plate so that the No 1 piston comes to the overlap position 6 Check the following valve clearance using a feeler gauge 7 if the clearance is not with in the factory specifications adjust with the adjusting screw Valve clearance marked with can be adjusted NOTE The sequence of cylinder numbers is given as No 1 No 2 and No 3 starting from the gear case side After adju...

Page 99: ...e specified torque 9Y1210294ENS0007US0 Relief Valve 1 Remove the oil filter base 2 Check the relief valve for dirt and the seat and ball for damage 3 If damaged replace 4 Check the free length of spring 5 If less than the allowable limit replace 9Y1210294ENS0008US0 Engine oil pressure Factory specifica tion At idle speed More than 49 kPa 0 50 kgf cm2 7 1 psi At rated speed 197 to 441 kPa 2 00 to 4...

Page 100: ...lace it 9Y1210272ENS0018US0 CAUTION When removing the radiator cap wait at least ten minutes after the engine has stopped and cooled down Otherwise hot water may gush out scalding nearby people 9Y1210294ENS0011US0 Radiator Cap Air Leakage 1 Set a radiator tester 1 and adaptor 2 on the radiator cap 2 Apply the specified pressure 88 kPa 0 90 kgf cm2 13 psi and measure the time for the pressure to fa...

Page 101: ...S0 Thermostat Valve Opening Temperature 1 Suspend the thermostat in the water by a string with its end inserted between the valve and seat 2 Heating the water gradually read the temperature when the valve opens and leaves the string 3 Continue heating and read the temperature when the valve opens approx 8 mm 0 3 in 4 If the measurement is not within the factory specifications replace the thermosta...

Page 102: ...ng with shims NOTE The liquid gasket is not required for assembling Shims are available in thickness of 0 20 mm 0 0079 in 0 25 mm 0 0098 in 0 30 mm 0 012 in and 0 175 mm 0 00689 in Combine these shims for adjustments Addition or reduction of shim 0 05 mm 0 002 in delays or advances the injection timing by approx 0 009 rad 0 5 In disassembling and replacing the injection pump be sure to use the sam...

Page 103: ...tarter when the fuel jets from the injection nozzle After that turn the flywheel by the hand and raise the pressure to approx 13 73 MPa 140 0 kgf cm2 1991 psi 7 Now turn the flywheel back about half a turn to keep the plunger free Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13 73 to 12 75 MPa from 140 0 to 130 0 kgf cm2 from 1991 to 1849 psi 8 Meas...

Page 104: ...the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer 1 in the nozzle holder to adjust it Reference Pressure variation with 0 01 mm 0 0004 in difference of adjusting washer thickness Approx 235 kPa 2 4 kgf cm2 34 1 psi 9Y1210294ENS0017US0 Valve Seat Tightness 1 Set the injection nozzle to a nozzle te...

Page 105: ...refilling Fill with the new oil up to the upper line on the dipstick 4 IMPORTANT Never mix two different types of oil Use the proper SAE Engine Oil according to ambient temperatures Refer to LUBRICANTS FUEL AND COOLANT See page G 9 9Y1210294ENS0018US0 Tightening torque Nozzle holder 35 to 39 N m 3 5 to 4 0 kgf m 26 to 28 lbf ft Overflow pipe nut 20 to 24 N m 2 0 to 2 50 kgf m 15 to 18 lbf ft Nozzl...

Page 106: ...ving Front Weight 1 Loosen the front weight mounting bolts 2 2 Remove the front weight 3 3 Remove the front weight bracket 1 4 Remove the hydraulic hose cover 4 9Y1210294ENS0020US0 Bonnet and Under Cover 1 Open the bonnet 3 and then loosen the knob bolts and pull forward to remove the under cover 4 2 Disconnect the connectors 1 for head light and remove the bonnet bracket 2 with bonnet 9Y1210294EN...

Page 107: ... fan shroud mounting bolts 2 3 When reassembling Return the accelerator wire and the wiring harness to the original position as shown in the picture 9Y1210294ENS0022US0 1 Accelerator Wire 2 Bolt 3 Fan Shroud 4 Bolt 5 Wiring Harness KiSC issued 08 2009 A ...

Page 108: ...iring connector 8 from the coolant temperature sensor 5 Remove the bonnet support 6 When reassembling Connect the fuel hoses securely Return the fuel hoses and the wiring harness to the original position as shown in the pictures 9Y1210294ENS0023US0 1 Overflow Fuel Hose 2 Accelerator Wire 3 Fuel Hose 4 Pin 5 Fuel Filter 6 Bonnet Support 7 Coolant Temperature Sensor 8 Wiring Connector 9 Band KiSC is...

Page 109: ...5 Remove the PTO clutch assembly mounting bolts 4 6 Remove the PTO clutch assembly 5 When reassembling Adjust the PTO clutch spring tension Refer to page G 36 9Y1210294ENS0024US0 1 PTO Clutch Drive Belt 2 Belt Cover 3 Belt Tension Pulley 4 PTO Clutch Assembling Mounting Bolt 5 PTO Clutch Assembly 6 Belt Tension Pulley Stay 7 Tension Pulley Spring Nut 8 Tension Pulley Spring KiSC issued 08 2009 A ...

Page 110: ...inal 7 Disconnect the connector 10 from the engine stop solenoid wiring harness When reassembling Connect the ground cables to the engine rear end plate and the engine mount frame securely Return the wiring harness to the original position as shown in the pictures 9Y1210294ENS0025US0 1 Wiring Connector for Engine Oil Pressure Sensor 2 Wiring Connector for Starter ST Terminal 3 Wiring Harness for S...

Page 111: ...e 2 Separate the engine from the front axle 3 Remove the engine support 1 When reassembling 9Y1210294ENS0027US0 Tightening torque Engine mounting nut 25 9 to 27 4 N m 2 6 to 2 8 kgf m 19 1 to 20 3 lbf ft 1 Ground Cable 2 Engine Mounting Nut 3 Engine Mounting Frame RH 4 Fan Belt 5 Engine Mounting Nut 6 Engine Mounting Frame LH 7 Coupling 8 Coupling Mounting Bolt 9 Fan Belt Drive Pulley Tightening t...

Page 112: ...3 and the fan belt 6 Remove the heat proof cover 9 the muffler 7 and the exhaust manifold 7 Remove the drive pulley from the flywheel 9Y1210294ENS0028US0 3 Cylinder Head and Valves Cylinder Head Cover 1 Disconnect the breather hose 2 Remove the cylinder head cover nuts 3 Remove the cylinder head cover 1 When reassembling Check to see if the cylinder head cover gasket is not defective 9Y1210294ENS0...

Page 113: ...e screw driver 1 lightly into the heat seal hole 2 Turn screw driver three or four times each way 3 While turning the screw driver slowly pull the heat seal 4 out together with the injection nozzle gasket 3 4 If the heat seal drops repeat the above procedure When reassembling Heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleaning or for service 9Y12...

Page 114: ...e cylinder head gasket with a new one When mounting the gasket set it to the pin pipe holes Take care not to mount it reversely The cylinder head should be free of scratches and dust Install the cylinder head using care not to damage the gasket After applying engine oil to the thread of screws tighten them in several steps and specified sequence a to n NOTE Do not use O ring on the pin pipe It is ...

Page 115: ...g Wash the valve stem and valve guide hole and apply engine oil sufficiently After installing the valve spring collets lightly tap the stem to assure proper fit with a plastic hammer IMPORTANT Do not change the combination of valve and valve guide 9Y1210294ENS0037US0 Thermostat Assembly 1 Remove the thermostat cover mounting screws 1 and remove the thermostat cover 2 2 Remove the thermostat assemb...

Page 116: ...urface Apply the adhesive also on the center of the flange as well as on the inner wall of each screw hole Cut the nozzle of the liquid gasket container at its second notch Apply liquid gasket about 5 0 mm 0 19 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 9Y1210294ENS0038US0 Fan Drive Pulley...

Page 117: ...e 1 When reassembling Apply a liquid gasket Three Bond 1215 or equivalent to both sides of the solenoid cover gasket and control plate gasket Be careful not to drop the governor spring 2 into the crankcase 9Y1210294ENS0041US0 1 Gear Case a Bolt Length 45 mm 1 8 in b Bolt Length 50 mm 2 0 in c Bolt Length 55 mm 2 2 in d Bolt Length 65 mm 2 6 in e Bolt Length 68 mm 2 7 in f Bolt Length 70 mm 2 8 in ...

Page 118: ...eassembling When installing the injection pump insert the control rack pin 2 firmly into the groove 7 of the thrust lever of fork lever NOTE Addition or reduction od shim 0 05 mm 0 002 in delays or advances the injection timing by approx 0 0087 rad 0 50 In disassembling and replacing be sure to use the same number or new gasket shims with the same thickness 9Y1210294ENS0042US0 1 Notch 2 Control Ra...

Page 119: ...il thinly to the fuel camshaft before installation Make sure to assemble the external snap ring of the governor shaft Check the governor shaft for smooth rotation IMPORTANT When replacing the ball bearing of governor shaft securely fit the ball bearing 9 to the crankcase apply an adhesive Three Bond 1324B or equivalent to the set screw 12 and fasten the screw until its tapered part contracts the c...

Page 120: ... method as above When reassembling Before inserting the piston into the cylinder apply enough engine oil to the piston When inserting the piston into the cylinder face the mark on the connecting rod to the injection pump NOTE Do not change the combination of cylinder and piston Make sure of the position of each piston by marking For example mark 1 on the No 1 piston When installing the piston into...

Page 121: ...11 Apply engine oil to the piston pin When installing the connecting rod to the piston immerse the piston in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin to the piston When installing the connecting rod to the piston align the mark 8 on the connecting rod to the fan shaped concave 9 NOTE Mark the same number on the connecting rod and the piston so as not to change the combination ...

Page 122: ...earing case gasket 3 and the bearing case cover gasket 4 with correct directions Install the bearing case cover 6 to position the casting mark UP on it upward Apply engine oil to the oil seal 5 lip and take care that it is not rolled when installing Tighten the bearing case cover mounting screws with even force on the diagonal line 9Y1210294ENS0048US0 Tightening torque Flywheel screw 54 to 58 N m ...

Page 123: ...g cases Apply clean engine oil to the bearings Install the main bearing case assemblies in original positions Since diameters of main bearing cases vary install them in order of markings b A B C from the gear case side Match the alignment numbers a on the main bearing case assembly 1 When installing the main bearing case 1 and 2 face the mark FLYWHEEL to the flywheel Install the thrust bearing 3 w...

Page 124: ... bearing and between the piston pin and small end bushing NOTE After checking the top clearance be sure to assemble the cylinder head with a new cylinder head gasket G23 G26 9Y1210294ENS0051US0 Cylinder Head Surface Flatness 1 Clean the cylinder head surface 2 Put a straightedge on the cylinder head s four sides and two diagonal as shown in the figure 3 Measure the clearance with a thickness gauge...

Page 125: ...t 2 Insert the valve into the valve guide 3 Measure the valve recessing with a depth gauge 4 If the measurement exceeds the allowable limit replace the valve 5 If it exceeds the allowable limit after replacing the valve replace the cylinder head G23 G26 9Y1210294ENS0053US0 1 Red Permeative Liquid 2 Detergent 3 White Developer Valve recessing Factory specification 0 10 protrusion to 0 10 recessing ...

Page 126: ...he specified dimension G23 G26 IMPORTANT Do not hit the valve guide with a hammer during replacement 9Y1210294ENS0055US0 Clearance between valve stem and valve guide Factory specification 0 030 to 0 057 mm 0 0012 to 0 0022 in Allowable limit 0 10 mm 0 0039 in Valve stem O D Factory specification 5 968 to 5 980 mm 0 2350 to 0 2354 in Valve guide I D Factory specification 6 010 to 6 025 mm 0 2367 to...

Page 127: ... around the seat or the contact is less than 70 of the factory specification correct the valve seat See the next section 3 If the valve contact width cannot get the factory specification replace the valve or correct the contact of the valve seat M00000003ENS0111US1 Valve contact width Factory specification 2 12 mm 0 0835 in 1 Correct 2 Incorrect 3 Incorrect KiSC issued 08 2009 A ...

Page 128: ...n blue The valve seating surface must show good contact all the way around G23 G26 9Y1210294ENS0056US0 Valve Lapping 1 Apply the compound evenly to the valve lapping surface 2 Insert the valve into the valve guide Lap the valve onto its seat with a valve flapper or screwdriver 3 After lapping the valve wash the compound away and apply oil then repeat valve lapping with oil 4 Apply prussian blue to...

Page 129: ... compress it to the same length it is actually compressed in the engine 2 Read the compression load on the gauge 3 If the measurement is less than the allowable limit replace it G23 G26 9Y1210294ENS0059US0 Tilt A Allowable limit 1 2 mm 0 047 in Free length B Factory specification 31 3 to 31 8 mm 1 24 to 1 25 in Allowable limit 28 4 mm 1 12 in Tilt A Allowable limit 1 0 mm 0 039 in Free length B Fa...

Page 130: ... the allowable limit replace the push rod 9Y1210272ENS0068US0 Oil clearance between rocker arm and rocker arm shaft Factory specification 0 016 to 0 045 mm 0 00063 to 0 0017 in Allowable limit 0 15 mm 0 0059 in Rocker arm shaft O D Factory specification 10 473 to 10 484 mm 0 41233 to 0 41275 in Rocker arm I D Factory specification 10 500 to 10 518 mm 0 41339 to 0 41409 in Oil clearance between roc...

Page 131: ...uide bore Factory specification 0 016 to 0 052 mm 0 00063 to 0 0020 in Allowable limit 0 10 mm 0 0039 in Tappet O D Factory specification 17 966 to 17 984 mm 0 70733 to 0 70803 in Tappet guide bore I D Factory specification 18 000 to 18 018 mm 0 70867 to 0 70937 in Oil Clearance between tappet and tappet guide bore Factory specification 0 020 to 0 062 mm 0 00079 to 0 0024 in Allowable limit 0 07 m...

Page 132: ...70 to 0 123 mm 0 00185 to 0 00484 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and injection pump gear Factory specification 0 0460 to 0 124 mm 0 00182 to 0 00488 in Allowable limit 0 15 mm 0 0059 in Backlash between oil pump drive gear and crank gear Factory specification 0 0410 to 0 123 mm 0 00162 to 0 00484 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear 1 and...

Page 133: ...Measure the height of the cam at its highest point with an outside micrometer 2 If the measurement is less than the allowable limit replace the camshaft G23 G26 9Y1210294ENS0067US0 Camshaft side clearance Factory specification 0 15 to 0 31 mm 0 0059 to 0 012 in Allowable limit 0 50 mm 0 020 in Camshaft side clearance Factory specification 0 070 to 0 22 mm 0 0028 to 0 0086 in Allowable limit 0 30 m...

Page 134: ... 1 2972 in Camshaft bearing I D Cylinder block bore I D Factory specification 33 000 to 33 025 mm 1 2993 to 1 3001 in Oil clearance of camshaft journal Factory specification 0 050 to 0 091 mm 0 0020 to 0 0035 in Allowable limit 0 15 mm 0 0059 in Camshaft journal O D Factory specification 35 934 to 35 950 mm 1 4147 to 1 4153 in Camshaft bearing I D Cylinder block bore I D Factory specification 36 0...

Page 135: ...e gear M00000003ENS0126US1 3 Piston and Connecting Rod Piston Pin Bore i D 1 Measure the piston pin bore I D in both the horizontal and vertical directions with a cylinder gauge 2 If the measurement exceeds the allowable limit replace the piston G23 G26 9Y1210294ENS0070US0 A When Removing B When Installing Piston pin bore I D Factory specification 20 000 to 20 013 mm 0 78741 to 0 78791 in Allowabl...

Page 136: ... to 0 0029 in Allowable limit 0 15 mm 0 0059 in Piston pin O D Factory specification 20 002 to 20 011 mm 0 78748 to 0 78783 in Small end bushing I D Factory specification 20 025 to 20 040 mm 0 78839 to 0 78897 in Oil clearance between piston pin and small end bushing Factory specification 0 014 to 0 038 mm 0 00056 to 0 0014 in Allowable limit 0 15 mm 0 0059 in Piston pin O D Factory specification ...

Page 137: ...with a piston 2 Measure the ring gap with a thickness gauge 3 If the measurement exceeds the allowable limit replace the piston ring G23 G26 9Y1210294ENS0073US0 Connecting rod alignment Allowable limit 0 05 mm 0 002 in Piston ring gap Top ring Factory specifica tion 0 20 to 0 35 mm 0 0079 to 0 013 in Allowable limit 1 25 mm 0 0492 in Second ring Factory specifica tion 0 35 to 0 50 mm 0 014 to 0 01...

Page 138: ... between piston ring and piston ring groove Second ring Factory specifica tion 0 0900 to 0 120 mm 0 00355 to 0 00472 in Allowable limit 0 15 mm 0 0059 in Oil ring Factory specifica tion 0 040 to 0 080 mm 0 0016 to 0 0031 in Allowable limit 0 15 mm 0 0059 in Clearance between piston ring and piston ring groove Second ring Factory specifica tion 0 0850 to 0 112 mm 0 00335 to 0 00440 in Allowable lim...

Page 139: ...llowable limit 0 50 mm 0 020 in Oversize Bearing Code Number Marking 0 20 mm 0 0079 in Thrust bearing 1 02 15261 23950 020 OS Thrust bearing 2 02 15261 23970 020 OS 0 40 mm 0 016 in Thrust bearing 1 04 15261 23960 040 OS Thrust bearing 2 04 15261 23980 040 OS Oversize 0 20 mm 0 0079 in 0 40 mm 0 016 in Dimension A 46 10 to 46 30 mm 1 815 to 1 822 in 46 30 to 46 50 mm 1 823 to 1 830 in Dimension B ...

Page 140: ... 9Y1210294ENS0077US0 Oil clearance between crankpin and crankpin bearing Factory specification 0 020 to 0 051 mm 0 00079 to 0 0020 in Allowable limit 0 15 mm 0 0059 in Crankpin O D Factory specification 33 959 to 33 975 mm 1 3370 to 1 3375 in Crankpin bearing I D Factory specification 33 995 to 34 010 mm 1 3384 to 1 3389 in Undersize Bearing Code Number Marking 0 20 mm 0 0079 in Crankpin bearing 0...

Page 141: ... screws are tightened Reference Undersize dimensions of crankpin 9Y1210294ENS0078US0 Oil clearance between crankpin and crankpin bearing Factory specification 0 029 to 0 091 mm 0 0011 to 0 0036 in Allowable limit 0 20 mm 0 0079 in Crankpin O D Factory specification 39 959 to 39 975 mm 1 5732 to 1 5738 in Crankpin bearing I D Factory specification 40 040 to 40 050 mm 1 5764 to 1 5767 in Undersize 0...

Page 142: ...0417 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory specification 43 934 to 43 950 mm 1 7297 to 1 7303 in Crankshaft bearing 1 I D Factory specification 43 984 to 44 040 mm 1 7317 to 1 7338 in Undersize Bearing Code Number Marking 0 20 mm 0 0079 in Crankshaft bearing 1 02 1G460 23910 020 US 0 40 mm 0 016 in Crankshaft bearing 1 04 1G460 23920 040 US Undersize Models 0 20 mm 0 ...

Page 143: ... a new bearing 1 2 so that its seam 1 directs toward the exhaust manifold side See figure 9Y1210294ENS0081US0 Oil Clearance between crankshaft journal and crankshaft bearing 1 Factory specification 0 0340 to 0 114 mm 0 00134 to 0 00448 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory specification 47 934 to 47 950 mm 1 8872 to 1 8877 in Crankshaft bearing 1 I D Factory specifica...

Page 144: ...e limit 0 20 mm 0 0079 in Crankshaft journal O D Flywheel side Factory specification 43 934 to 43 950 mm 1 7297 to 1 7303 in Crankshaft bearing 2 I D Factory specification 43 978 to 43 993 mm 1 7315 to 1 7320 in Crankshaft journal O D Intermediate Factory specification 43 934 to 43 950 mm 1 7297 to 1 7303 in Crankshaft bearing 3 I D Factory specification 43 978 to 43 993 mm 1 7315 to 1 7320 in Bea...

Page 145: ...journal O D Intermediate Factory specification 47 934 to 47 950 mm 1 8872 to 1 8877 in Crankshaft bearing 2 I D Factory specification 47 984 to 48 029 mm 1 8892 to 1 8909 in Oil clearance between crankshaft journal and crankshaft bearing 3 Factory specification 0 034 to 0 098 mm 0 0014 to 0 0038 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Flywheel side Factory specification 51 921 ...

Page 146: ...9Y1210294ENS0085US0 Correct Cylinder Oversize G26 1 When the cylinder is worn beyond the allowable limit bore and hone it to the specified dimension 2 Replace the piston and piston rings with oversize ones Oversize 0 5 mm 0 02 in NOTE When the oversize cylinder is worn beyond the allowable limit replace the cylinder block with a new one 9Y1210294ENS0086US0 Cylinder liner I D Factory specifica tion...

Page 147: ...ace oil pump rotor assembly 9Y1210272ENS0095US0 7 Oil Pump G26 Rotor Lobe Clearance 1 Measure the clearance between lobes of the inner rotor and the outer rotor with a thickness gauge 2 If the clearance exceeds the factory specifications replace the oil pump rotor assembly 9Y1210294ENS0087US0 Clearance between Outer Rotor and Pump Body 1 Measure the clearance between the outer rotor and the pump b...

Page 148: ...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 replace oil pump rotor assembly 9Y1210294ENS0089US0 Clearance between rotor and cover Factory specification 0 025 to 0 075 mm 0 00099 to 0 0029 in KiSC issued 08 2009 A ...

Page 149: ...2 TRANSAXLE KiSC issued 08 2009 A ...

Page 150: ...4 BRAKE 2 M4 5 PTO CLUTCH 2 M5 1 MECHANICAL PTO CLUTCH 2 M5 1 Structure 2 M5 2 PTO Clutch Engaged 2 M6 3 PTO Clutch Disengaged 2 M7 2 HYDRAULIC PTO CLUTCH 2 M8 1 Structure 2 M8 2 PTO Clutch Engaged 2 M9 3 PTO Clutch Disengaged 2 M10 MECHANISM KiSC issued 08 2009 A ...

Page 151: ...tial gear section 7 etc as shown in the above figure 9Y1210294TXM0001US0 1 HST Section 2 Brake Section 3 Pinion Shaft 4 Hydraulic Pump Section 5 Differential Lock Section 6 Rear Axle LH Section 7 Differential Gear Section A From Engine B To Differential Gear and Rear Axle R Right Side L Left Side C Transaxle Case Front Section D Transaxle Case Rear Section KiSC issued 08 2009 A ...

Page 152: ...everse 2 Oil Passage 3 Centre Case 4 Relief Valve Forward 5 Check Port Forward 6 By pass Valve 7 Check Port Reverse 8 Brake Lever 9 Brake Disk 10 Steel Ball 11 HST Pump Shaft 12 Poppet L 13 Spring 14 Spring 15 Thrust Ball Bearing 16 Cir clip 17 Swash plate and Cradle Bearing 18 HST Motor Shaft 19 Cir clip 20 Piston 21 Cylinder Block A Front Side B Rear Side R Right Side L Left Side KiSC issued 08 ...

Page 153: ...al Outer Cover 5 Ball Bearing 6 Cir clip 7 Steel Chain 8 Splocket 9 Ball Bearing 10 Final Inner Cover 11 Machine Frame 12 Oil Seal 13 Oil Seal 14 Differential Lock Clutch 15 Differential Gear Shaft LH 16 Side Gear 17 Differential Pinion Bevel Gear 18 Collar 19 Spiral Bevel Gear 20 Ball Bearing 21 Shim 22 Cir clip 23 Differential Gear Shaft RH 24 Differential Case 25 Differential Pinion Shaft 26 Sh...

Page 154: ...11 and friction plate 5 and etc as shown in the figure The brake disk is mounted on the HST motor shaft 9 9Y1210294TXM0004US0 1 Cam Lever 2 O ring 3 Brake Cover 4 Actuator 5 Friction Plate 6 Cir clip 7 Oil Seal 8 Needle Bearing 9 HST Motor Shaft 10 Cir clip 11 Brake Disk 12 Steel Ball KiSC issued 08 2009 A ...

Page 155: ... the belt tension pulley is FREE the brake spring pulls the PTO brake shoe and this brake shoe locks the belt driven pulley 9Y1210294TXM0005US0 1 Pulley 2 Ball Bearing 3 Brake Spring 4 Ball Bearing 5 Cir clip 6 Front PTO Shaft 7 Front PTO Bracket 8 Engine Mounting Bracket LH 9 Brake Shoe 10 Pulley 11 Tension PTO Arm 12 Stay 13 Spring 14 PTO Wire Bracket 15 Clutch Wire 16 Spring 17 V Belt 18 PTO Br...

Page 156: ...nsion PTO pulley 14 mounted on the tension PTO arm 3 is pushed to the V belt 11 When the V belt tension becomes tight the rotation of the pulley 1 is transmitted through the V belt 11 to the pulley 9 9Y1210294TXM0009US0 1 Pulley Engine Flywheel Side 2 Spring 3 Tension PTO Arm 4 Stay 5 Spring 6 PTO Wire Bracket 7 Clutch Wire 8 Spring 9 Pulley PTO Clutch Side 10 Brake Shoe 11 V Belt 12 PTO Brake Ass...

Page 157: ...and rotation of the pulley 1 is not transmitted to the pulley 9 Since the spring 8 pulls the PTO brake assy 12 the brake shoe 10 mounted on the PTO brake assy 12 brakes the rotation of the pulley 9 9Y1210294TXM0010US0 1 Pulley Engine Flywheel Side 2 Spring 3 Tension PTO Arm 4 Stay 5 Spring 6 PTO Wire Bracket 7 Clutch Wire 8 Spring 9 Pulley PTO Clutch Side 10 Brake Shoe 11 V Belt 12 PTO Brake Assy ...

Page 158: ...ley 5 Ball Bearing 6 Ball Bearing 7 Cir clip 8 Plate Back 9 Plate Disk 10 Plate Separate 11 PTO Front Case 12 O ring 13 PTO Rear Case 14 Ring Seal 15 Plug 16 Ball Bearing 17 Cir clip 18 Oil Seal 19 Cir clip 20 Front PTO Shaft 21 PTO Clutch Case 22 Brake Spring 23 Clutch Piston 24 Ring Seal 25 Brake Plate 26 Brake Disk 27 Ball Bearing 28 Oil Seal 29 Cir clip 30 PTO Spline Boss KiSC issued 08 2009 A...

Page 159: ...ing 7 the disk plates 4 and the separate plates 5 And the engine power is transmitted from the pulley 1 through the spline boss 3 the disk plates 4 the separate plates 5 and the PTO clutch case 11 to the front PTO shaft 8 9Y1210294TXM0007US0 1 Belt Driven Pulley 2 Front Case 3 Spline Boss 4 Disk Plate 5 Separate Plate 6 Clutch Piston 7 Brake Spring 8 Front PTO Shaft 9 Brake Plate 10 Brake Disk 11 ...

Page 160: ...side The brake disks 10 and the brake plates 9 mounting on the PTO clutch case 8 are braked by its friction And the disk plates 4 and the separate plates 5 mounting on the spline boss 3 and the PTO clutch case 8 are separated 9Y1210294TXM0008US0 1 Pulley 2 Case 3 Spline Boss 4 Disk Plate 5 Separate Plate 6 Clutch Piston 7 Brake Spring 8 PTO Clutch Case 9 Brake Plate 10 Brake Disc A PTO Clutch Dise...

Page 161: ...G 2 S7 1 CHECKING AND ADJUSTING 2 S7 2 PREPARATION 2 S14 1 Separating Transaxle 2 S14 3 DISASSEMBLING 2 S24 1 Transaxle 2 S24 2 PTO Clutch 2 S34 4 SERVICING 2 S37 1 Hydrostatic Transmission 2 S37 2 Transaxle Case 2 S39 3 Brake Case 2 S40 4 Mechanical PTO Clutch 2 S41 5 Hydraulic PTO Clutch 2 S42 SERVICING KiSC issued 08 2009 A ...

Page 162: ...es not move smoothly Inspect or replace check and high pressure relief valve 2 S38 Component parts is defective Replace hydrostatic transmission assembly 2 S23 Vibration and Noise Oil level is too low Check oil level or fill oil to proper level G 19 Speed control pedal linkage defective Repair linkage 2 S8 2 S17 Charge pressure is too low Solution order 1 Replace oil filter cartridge G 21 2 Check ...

Page 163: ...on oil level up to proper level G 19 Radiator net clogged Clean radiator net Excessive machine load Reduce machine load Improper charge pressure 1 Check high relief pressure 2 S9 2 S10 2 Replace transmission oil filter cartridge G 21 3 Replace check and high pressure relief valve 2 S9 2 S10 4 Inspect and replace charge relief valve 2 S38 Machine Will Not Stop in Neutral Position Speed control link...

Page 164: ... Turning Differential pinions or differential side gears worn or damaged Replace 2 S33 Differential lock binding does not disengaged Replace 2 S31 Bearings worn Replace 2 S33 Differential Lock Can Not be Set Deferential lock shift fork damaged Replace 2 S31 Deferential lock shifter mounting pin damaged Replace 2 S31 Differential lock pin damaged Replace 2 S31 Differential Lock Pedal Does Not Retur...

Page 165: ...PTO clutch spring broken Replace 2 S34 1 S27 PTO clutch spring tension adjustment improper Adjust G 36 PTO Shaft Does Not Rotate PTO clutch malfunctioning Repair or replace 2 S34 2 S35 PTO Clutch Operating Pressure is Low Transmission oil improper or insufficient Replenish or change G 19 Relief valve malfunctioning Check or replace 2 S13 PTO Clutch Drags Brake plate excessive worn Replace 2 S37 Cl...

Page 166: ... 70 mm 0 140 to 0 15 in 3 40 mm 0 13 in Friction Plate Thickness 2 95 to 3 05 mm 0 116 to 0 120 in 2 55 mm 0 100 in Mechanical PTO Clutch Brake Lining Thickness 5 7 to 6 3 mm 0 224 to 0 248 in 4 0 mm 0 157 in Mechanical PTO Clutch Front PTO Pulley O D 123 9 to 124 0 mm 4 878 to 4 882 in 123 0 mm 4 843 in Hydraulic PTO Clutch PTO Clutch Disk Thickness 1 50 to 1 70 mm 0 0591 to 0 669 in 1 35 mm 0 05...

Page 167: ...agon socket head plug Forward and Reverse 30 to 44 3 0 to 4 5 22 to 32 Hexagon socket head screw 2 5 to 3 0 0 26 to 0 31 1 8 to 2 2 Rear tyre mounting bolt 108 5 to 130 2 11 1 to 13 3 80 0 to 96 0 Transmission assembly mounting bolt M14 124 to 147 12 6 to 15 0 91 2 to 108 Transmission assembly mounting bolt M14 135 9 to 147 13 9 to 15 0 100 2 to 108 4 Rear axle case mounting bolt M10 39 to 44 4 0 ...

Page 168: ... front and the rear side of the wheels not to move the tractor Remove the cover from the fender 2 Lift up the rear wheels safely by the rigid jacks 3 Remove the rear right wheel from the tractor 9Y1210294TXS0005US0 Stopper bolt length Reference Forward 20 mm 0 79 in Reverse 18 mm 0 71 in Maximum speed at engine max rpm Reference Forward 14 0 to 15 5 km h 8 70 to 9 63 mph Reverse 8 5 to 10 0 km h 5...

Page 169: ...g 6 After adjusting the neutral position tighten the lock screw 2 securely 9Y1210294TXS0006US0 Charge Relief Pressure CAUTION When checking park the machine on flat ground 1 Lift up the rear wheels by supporting the machine frame 2 Remove the plug G 1 4 2 or 4 from the HST centre section then install the adaptor G 1 4 and pressure gauge 3 Start the engine and run it at the maximum speed 4 Read the...

Page 170: ... is not same as factory specification check the high pressure relief valve and related hydraulic components IMPORTANT Measure quickly the high relief pressure within about 10 seconds NOTE When reinstalling the hexagon socket head plug apply liquid lock Three Bond 1324 or its equivalent to the plug 9Y1210294TXS0008US0 High relief pressure Forward Factory specification Oil temperature at 50 C 122 F ...

Page 171: ... is not same as factory specifications check the high pressure relief valve and related hydraulic components IMPORTANT Measure quickly the high relief pressure within about 10 seconds NOTE When reinstalling the hexagon socket head plug apply liquid lock Three Bond 1324 or its equivalent to the plug 9Y1210294TXS0010US0 High relief pressure Reverse Factory specification Oil temperature at 50 C 122 F...

Page 172: ...sing point and the machine stopping point If the distance is more than approximately 3 to 5 m 10 to 16 feet strengthen the HST neutral spring tension so that the machine will stop in approximately 3 to 5 m 10 to 16 feet after releasing the foot from the speed control pedal Reference 2 Remove the step from the machine Loosen the lock nut 1 Turn the adjusting nut 2 half turn to pull the HST neutral ...

Page 173: ...uire at the first time 5 After finding the distance A hold the setscrew 6 to a vice and fasten the hexagon socket head screw 2 with specified torque On this occasion use a copper plate etc for the vice jaws not to damage the setscrew 6 6 Install the relief valve in the HST 7 Check the relief pressure as indicated in page 2 S9 and 2 S10 The distance A is for refresh only Make sure to check the reli...

Page 174: ...O clutch delivery hose to the PTO clutch assembly securely Condition Engine speed Maximum Oil temperature 45 to 55 C 113 to 131 F 9Y1210294TXS0012US0 Adjusting Clearance between Tension PTO Arm and Release Arm 1 Set the PTO lever 1 to DISENGAGED position B to make the clutch wire 7 to be free 2 Push the release arm 6 toward the tension PTO arm 2 to contact Tighten the bolt 5 3 Check clearance betw...

Page 175: ...nsmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 9 Never work the tractor immediately after changing the transmission oil Keeping the engine at medium speed for a few minutes to prevents damage to the transmission Do not mix different brands oil together 9Y1210294TXS0013US0 Battery CAUTION When disconnecting the battery cables disconnect the negative cable from the bat...

Page 176: ...e the grass collector pins 5 easily 3 Remove the grass collector pins 5 4 Disconnect the wiring harness coupler 6 5 Disconnect the hydraulic hoses 7 6 Remove the grass collector by hooking it 9Y1210294TXS0015US0 1 Grass Collector 2 Frame 3 Nylon Sling 4 Hydraulic Hose 5 Grass Collector Pin 6 Wiring Harness Coupler 7 Hydraulic Hose KiSC issued 08 2009 A ...

Page 177: ...RANSAXLE G23 G26 WSM 2 S16 EU Seat 1 Disconnect the seat switch connector 3 2 Remove the snap pin 2 3 Remove the seat 1 9Y1210294TXS0016US0 1 Seat 2 Snap Pin 3 Seat Switch Connector KiSC issued 08 2009 A ...

Page 178: ...the parking brake lever 7 3 Remove the handrails 4 6 and the lever grips 5 4 Disconnect the wiring harness the fuel hoses and the fuel feed pump under the fender 9Y1210294TXS0017US0 1 Fender 2 Speed Control Pedal 3 Bolt M8 4 Handrail RH 5 Lever Grip 6 Handrail LH 7 Parking Brake Lever KiSC issued 08 2009 A ...

Page 179: ...et mounting bolts 5 Remove the hydraulic control valve assembly 1 with the fender bracket 2 When reassembling Reassemble the parts to the original positions referring to pictures 9Y1210294TXS0018US0 1 Hydraulic Control Valve Assembly 2 Fender Bracket 3 Hydraulic Filter Cartridge 4 Spring 5 Hydraulic Pipe 6 Hydraulic Pipe 7 Hydraulic Pipe 8 Wiring Harness 9 Wiring Harness 10 Safety Switch 11 Safety...

Page 180: ... fuel tank bottom side not to leak fuel from the fuel tank 4 Remove the fender mounting bolts 5 Disconnect the duct lever linkage 6 Remove the fuel tank 1 from the machine body When reassembling Reassemble the parts to the original positions 9Y1210294TXS0019US0 1 Fuel Tank 2 Fuel Tank Stay 3 Tank Cushion 4 Tank Bracket 5 Duct Lever KiSC issued 08 2009 A ...

Page 181: ...collector support assembly 1 with a nylon sling 5 Remove the grass collector support mounting bolts 7 6 Separate the grass collector support assembly 1 from the machine body When reassembling 9Y1210294TXS0020US0 Tightening torque Rear tyre mounting bolt 108 5 to 130 2 N m 11 1 to 13 3 kgf m 80 0 to 96 0 lbf ft 1 Grass Collector Support Assembly 2 Duct 3 Tie Rod 4 Wiring Harness 5 Rear Tyre 6 Disas...

Page 182: ...ct Plate 2 1 Reassemble the parts to the original position referring to the pictures 9Y1210294TXS0022US0 Tightening torque Transmission assembly mounting bolt M14 124 to 147 N m 12 6 to 15 0 kgf m 91 2 to 108 lbf ft 1 Bolt 2 Plate RH 3 Bolt 4 Duct Plate RH 5 Plate LH 6 Flange Nut 7 Duct Plate 1 Bolt 2 Plate LH 3 Collar 4 Lower Duct 5 Tie Rod 6 Duct Flat Rod 7 Plain Washer 8 Rue Ring Cotter 9 Plate...

Page 183: ... the parts to the original position referring to the pictures 9Y1210294TXS0023US0 1 Frame 2 Lower Duct 3 Duct Plate LH 4 Duct Flat Rod 5 Disassembling Stand 6 Duct Plate RH 7 Duct 8 Rue Ring Cotter 9 Duct Lock Plate 10 Duct Spring 11 Plain Washer KiSC issued 08 2009 A ...

Page 184: ...assembly with nylon slings Loose the parking lock over the rear coupling 5 G26 only Remove the PTO return pipe from the transmission case assembly 8 6 Remove the transmission case assembly 8 from the machine frames When reassembling 9Y1210294TXS0025US0 Tightening torque Transmission assembly mounting bolt M14 135 9 to 147 N m 13 9 to 15 0 kgf m 100 2 to 108 4 lbf ft 1 Wiring Harness 2 Hydraulic Pi...

Page 185: ...ar axle case mounting bolts 4 3 Remove the rear axle cases 3 5 When reassembling Do not damage the O ring 9Y1210294TXS0024US0 Tightening torque Rear axle case mounting bolt M10 39 to 44 N m 4 0 to 4 5 kgf m 28 8 to 32 5 lbf ft 1 Hydraulic Pipe 2 Hydraulic Pipe 3 Rear Axle Case RH 4 Bolt 5 Rear Axle Case LH 6 O ring KiSC issued 08 2009 A ...

Page 186: ...nt to the joint surface of the final outside cover and the final inner cover Do not forget O ring 13 9Y1210294TXS0026US0 Tightening torque Rear axle case docking bolt M10 39 to 44 N m 4 0 to 4 5 kgf m 28 8 to 32 5 lbf ft 1 Bolt 2 Final Outside Cover 3 Final Inside Cover 4 Final Sprocket 5 Ball Bearing 6 Drive Chain 7 Chain Tensioner 8 Gear Shaft Drive 9 Ball Bearing 10 Ball Bearing 11 Plain Washer...

Page 187: ... cir clip 2 with a long nose snap ring plier 5 3 Remove the cir clip 7 from the rear axle 4 4 Tap out the rear axle 4 from the final out side cover 6 9Y1210294TXS0027US0 1 Ball Bearing 2 Cir clip 3 Oil Seal 4 Rear Axle 5 Long Nose Snap Ring Plier 6 Final Outside Cover 7 Cir clip 8 Cir clip KiSC issued 08 2009 A ...

Page 188: ... Remove the oil filter 3 4 Remove the flow priority valve 4 When reassembling Check the O ring before reassembling Clean the oil filter and line filter before reassembling 9Y1210294TXS0028US0 1 Relief Valve 2 Hydraulic Pump 3 Oil Filter 4 Flow Priority Valve 5 Line Filter 6 Double Ring KiSC issued 08 2009 A ...

Page 189: ...ver mounting bolts 3 3 Remove the spring plate 2 and the brake case assembly When reassembling Replace the front gasket with a new one 9Y1210294TXS0029US0 1 Spring 2 Spring Plate 3 Bolt M8 4 Brake Cover 5 Brake Cam Lever 6 Hydraulic Transmission HST 7 Front Gasket KiSC issued 08 2009 A ...

Page 190: ...ator 3 3 Remove cir clip 7 from the brake cam lever 8 4 Remove the brake cam lever 8 from the brake cover 2 When reassembling If the O rings 9 are damaged replace them Apply grease to the ball and install the ball to the brake cover 9Y1210294TXS0030US0 1 Cir clip 2 Brake Cover 3 Actuator 4 Brake Disk 5 Friction Plate 6 Ball 7 Cir clip 8 Brake Cam Lever 9 O ring KiSC issued 08 2009 A ...

Page 191: ...nd Pinion Shaft 1 Remove the HST pump shaft 6 and the HST motor shaft 1 from the transmission case 4 2 Remove the gear pump idle gear 5 from the transmission case 4 When reassembling Put the shims on the pinion shaft and install the front cover HST on the transmission case 9Y1210294TXS0032US0 1 Bolt M8 2 O ring 3 Bearing 4 Pump Shaft 5 Front Gasket 6 Centre Section Port Block Cover 7 Motor Shaft 8...

Page 192: ... bolts 1 2 Remove the fork rod 2 with the differential lock cover 3 3 Remove the shift fork 5 and the spring 6 When reassembling If the O ring 7 is damaged replace it 9Y1210294TXS0033US0 1 Bolt M10 2 Fork Rod 3 Differential Lock Cover 4 Transmission Case 5 Shift Fork 6 Spring 7 O ring KiSC issued 08 2009 A ...

Page 193: ...m 1 Remove the cir clips 1 5 2 Remove the shims 3 7 When reassembling Install the same shim to the same position 9Y1210294TXS0034US0 1 Cir clip LH 2 Transmission Case 3 Shim LH 4 Ball Bearing LH 5 Cir clip RH 6 Ball Bearing RH 7 Shim RH KiSC issued 08 2009 A ...

Page 194: ...nstall the same shim 10 to the same position After installing the shim check and adjust the differential gear backlash 9Y1210294TXS0035US0 1 Pinion Shaft 2 Transmission 3 Differential Gear 4 Differential Rear Case 5 Differential Side Gear 6 Rear Pinion Shaft 7 Differential Pinion Gear 8 Ball Bearing 9 Spring Pin 10 Shim 11 Differential Pinion Collar KiSC issued 08 2009 A ...

Page 195: ...he mechanical PTO clutch assembly 1 When reassembling Adjust clearance between the tension PTO arm and the release arm Refer to page 2 S13 9Y1210294TXS0051US0 1 Mechanical PTO Clutch Assembly 2 Clutch Wire 3 Bolt 4 Pulley 5 Front PTO Shaft 6 Split Pin 7 Plain Washer 8 Spring 9 Belt Stay 10 Ball Bearing 11 Bolt 12 PTO Bracket 13 Ball Bearing 14 Cir clip KiSC issued 08 2009 A ...

Page 196: ...ulic PTO Clutch 2 1 Remove the case mounting bolts 2 Separate the front case 4 and the rear case 5 3 Remove the cir clip 2 4 Remove the spline boss 1 from the front case 4 When reassembling Do not damage the O ring and the oil seal 9Y1210294TXS0053US0 1 Cir clip 2 Cir clip 3 Pulley 4 Front Case 5 Bearing 1 Spline Boss 2 Cir clip 3 Oil Seal 4 Front Case 5 Rear Case 6 O ring 7 Ball Bearing 8 Ball Be...

Page 197: ...nd the front PTO shaft 2 from the rear case 4 5 Remove the cir clip 11 and the ball bearing 12 from the front PTO shaft 2 When reassembling Do not damage the oil seal Install the disk plates and the separate plates to the original positions 9Y1210294TXS0054US0 1 Cir clip 2 Front PTO Shaft 3 Clutch Case 4 Rear Case 5 Backing Plate 6 Disk Plate 7 Separate Plate 8 Oil Seal 9 Cir clip 10 Cir clip 11 C...

Page 198: ... 9Y1210294TXS0055US0 4 SERVICING 1 Hydrostatic Transmission Centre Section 1 Check the centre section surface 1 for scratches or wear 2 If deep scratch or excessive wear is found replace the hydrostatic transmission assembly 9Y1210294TXS0036US0 1 Cir clip 2 PTO Clutch Spring Compression Tool 3 Clutch Case 4 Nut 5 Washer 6 Brake Spring 7 Clutch Piston 8 Ring Seal 9 Brake Plate 10 Brake Disk 11 Ring...

Page 199: ...1 and the pistons 2 for scratches and wear 2 If there are scratch or worn replace the cylinder block assembly 3 Check the pistons for their free movement in the cylinder block bores 4 If the piston or the cylinder block is scored replace the cylinder block assembly 5 Check the polished face 4 of the cylinder block for scoring If it is scored replace the cylinder block assembly NOTE Do not intercha...

Page 200: ... is worn replace it 9Y1210294TXS0041US0 Needle Bearing 1 Check the needle bearing 1 for wear 2 If the needle bearing 1 is worn replace it 9Y1210294TXS0042US0 2 Transaxle Case Bearing 1 Hold the inner race and push and pull the outer race in all directions to check wear and roughness 2 Apply the transmission oil to the bearing and hold the inner race And turn the outer race to check rotation 3 If t...

Page 201: ...adjust the shims 4 9Y1210294TXS0044US0 3 Brake Case Flatness of Actuator and Bearing Holder 1 Place a straightedge of 150 mm 5 91 in or more in length on the contacting surface of the actuator and the bearing holder 2 Inspect the friction surface of the actuator and the bearing holder with the straightedge and determine if a 0 30 mm 0 0118 in feeler gauge will fit on the part of wear 3 If it will ...

Page 202: ...he measurement is less than the allowable limit replace the PTO brake 9Y1210294TXS0049US0 Front PTO Pulley Wear 1 Measure the front PTO pulley O D with an outside micrometer 2 If the measurement is less than the allowable limit replace it 9Y1210294TXS0050US0 Height of cam plate and ball Factory specification 17 96 to 18 96 mm 0 71 to 0 75 in Allowable limit 17 47 mm 0 69 in Brake dick thickness Fa...

Page 203: ...Place the part on a surface plate 2 Check the flatness by inserting a feeler gauge allowable limit size underneath it at least four points 3 If the gauge can be inserted replace it 9Y1210294TXS0059US0 Brake Spring Free Length 1 Measure the free length of brake spring with venire calipers 2 If the measurement is less than the allowable limit replace it 9Y1210294TXS0060US0 Thickness of PTO clutch di...

Page 204: ...ake Plate 1 Measure the PTO brake plate thickness with a vernier caliper 2 If the thickness is less than allowable limit replace it 9Y1210294TXS0062US0 PTO brake disk thickness Factory specification 2 90 to 3 10 mm 0 115 to 0 122 in Allowable limit 2 70 mm 0 11 in PTO brake plate thickness Factory specification 1 9 to 2 1 mm 0 075 to 0 082 in Allowable limit 1 82 mm 0 0728 in KiSC issued 08 2009 A...

Page 205: ...3 FRONT AXLE KiSC issued 08 2009 A ...

Page 206: ... 3 S2 3 TIGHTENING TORQUES 3 S3 4 CHECKING DISASSEMBLING AND SERVICING 3 S4 1 CHECKING AND ADJUSTING 3 S4 2 DISASSEMBLING AND ASSEMBLING 3 S5 1 Separating Front Axle Assembly 3 S5 2 Disassembling Front Axle 3 S8 3 SERVICING 3 S9 SERVICING KiSC issued 08 2009 A ...

Page 207: ... Right or Left Improper toe in adjustment Adjust 3 S4 Uneven tyre pressure Adjust G 61 Worn kingpin Replace front axle assembly 3 S7 Front Wheels Shimmy Improper toe in adjustment Adjust 3 S4 Worn kingpin Replace front axle assembly 3 S7 Excessive clearance between front axle centre bush and centre shaft Replace 3 S9 KiSC issued 08 2009 A ...

Page 208: ...l Alignment Toe in 0 to 5 mm 0 to 0 2 in Front Axle Rocking force 20 to 300 N 2 0 to 30 0 kgf 4 4 to 67 5 lbf Center Pin to Pin Support Bushing Center Pin Bushing Clearance O D I D 0 to 231 mm 0 to 0 00909 in 19 850 to 20 000 mm 0 781510 to 0 78740 in 20 000 to 20 081 mm 0 78741 to 0 79059 in 0 70 mm 0 028 in KiSC issued 08 2009 A ...

Page 209: ...ightening torques of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page G 12 9Y1210294FAS0003US0 Item N m kgf m lbf ft Tie rod end nut 17 7 to 34 3 1 8 to 3 5 13 1 to 25 3 KiSC issued 08 2009 A ...

Page 210: ...s adjust as following Q Adjusting procedure 1 Remove the split pin 2 Push and pull the kingpin 3 with a push pull gauge 2 Tighten or loosen the adjusting nut 1 so that the measurement of rocking force comes to factory specifications 3 If the slot and pin hole do not meet align the nut until they do meet within factory specifications 4 Install the new cotter pin When reassembling Be sure to split t...

Page 211: ...llers Front as shown the figure below RCK48 RCK54 Two places 2 Set the cutting height less than 88 9 mm 3 5 in For installation and uninstallation set the anti scalp rollers Rear as shown in the figure RCK48 RCK54 Two places 3 Place the mower lift lever in the DOWN position When mounting Reverse the dismounting procedures 9Y1210294FAS0006US0 1 Anti scalp Roller Front 2 Anti scalp Roller Rear 3 Cle...

Page 212: ...et 7 and disconnect the connectors 5 from the head lights 4 Remove the bonnet 7 and the under cover 6 5 Remove the front weight bracket from the front axle frame 8 6 Remove the cover stay 3 the PTO cover 4 and cover plate 9 9Y1210294FAS0007US0 1 Front Weight 2 Front Weight Bracket 3 Cover Stay 4 PTO Cover 5 Connector 6 Under Cover 7 Bonnet 8 Front Axle Frame 9 Cover Plate 10 PTO Clutch Assembly Ki...

Page 213: ...move the nut 4 and the centre shaft 7 9 Separate the front axle assembly 3 from the machine When reassembling Adjust the front axle rocking force 9Y1210294FAS0008US0 Front axle rocking force Factory specification 20 to 300 N 2 0 to 30 6 kgf 4 4 to 67 5 lbf Tightening torque Tie rod end nut 17 7 to 34 3 N m 1 8 to 3 5 kgf m 13 1 to 25 3 lbf ft 1 Hydraulic Hose 2 Power Steering Cylinder 3 Front Axle...

Page 214: ...e the cir clips 1 and the kingpins 5 9 from the front case assembly 8 5 Remove the bushes 6 7 10 from the front case assembly 8 When reassembling Apply grease to the grease fittings and the bushes 9Y1210294FAS0009US0 Tightening torque Tie rod end nut 17 7 to 34 3 N m 1 8 to 3 5 kgf m 13 1 to 25 3 lbf ft 1 Cir clip 2 Nut 3 Split Pin 4 Power Steering Cylinder Assembly 5 Kingpin RH 6 Bush 7 Bush 8 Fr...

Page 215: ...imit replace it 9Y1210294FAS0010US0 Clearance between centre pin and pin support bushing Factory specification 0 to 0 231 mm 0 to 0 00909 in Allowable limit 0 70 mm 0 0276 in Centre pin O D Factory specification 19 850 to 20 000 mm 0 78149 to 0 78740 in bushing I D Factory specification 20 000 to 20 081 mm 0 78740 to 0 79059 in 1 Front Axle 2 Bushing 3 Centre Pin L Front Axle Centre Bush I D M Pla...

Page 216: ...4 STEERING KiSC issued 08 2009 A ...

Page 217: ...CONTENTS 1 HYDRAULIC CIRCUIT 4 M1 1 G23 MECHANICAL PTO CLUTCH MODEL 4 M1 2 G26 HYDRAULIC PTO CLUTCH MODEL 4 M2 2 STEERING CONTROLLER 4 M3 3 STEERING CYLINDER 4 M4 MECHANISM KiSC issued 08 2009 A ...

Page 218: ... steering cylinder 12 etc The flow priority valve 7 located in the hydraulic control valve assembly 6 divides the oil into two directions One is the control flow to power steering constantly 9 5 L min 2 5 U S gals min 2 1 Imp gals min and the other is excessive flow to control valve of implement lift control By operating the power steering body the required amount of oil is fed to the steering cyl...

Page 219: ... The flow priority valve 7 located in the hydraulic control valve assembly 6 divides the oil into two directions One is the control flow to power steering constantly 9 5 L min 2 5 U S gals min 2 1 Imp gals min and the other is excessive flow to control valve of implement lift control By operating the power steering body the required amount of oil is fed to the steering cylinder 12 9Y1210294STM0002...

Page 220: ...tor 13 while oil is discharged from other two chambers On the other hand rotation of the steering wheel is directly transmitted to the rotor through the spool 7 drive shaft 10 etc Accordingly the metering device serves to supply the steering cylinder with oil amount of which corresponds to the rotation of the steering wheel The wheels are thus turned by the angle corresponding to the rotation of t...

Page 221: ...ering movement to both front wheels The steering cylinder provide force in both directions Depending upon direction the steering wheel is turned pressure oil enters at one end of the cylinder to extend or the other end to retract it thereby turning front wheel of the tractor 9Y1210294STM0004US0 1 Rod 2 Wiper Seal 3 Internal Snap Ring 4 Guide 5 O ring 6 Seal Ring 7 Center Piston 8 Piston O ring 9 E...

Page 222: ... 4 S2 3 TIGHTNING TORQUES 4 S3 4 CHECKING DISASSEMBLING AND SERVICING 4 S4 1 CHECKING 4 S4 1 Power Steering Relief Valve 4 S4 2 DISASSEMBLING 4 S5 1 Power Steering Cylinder 4 S5 2 Power Steering Controller 4 S7 3 SERVICING 4 S8 SERVICING KiSC issued 08 2009 A ...

Page 223: ...sed Steering controller malfunctioning Replace 4 S7 Front Wheels Wander to Right and Left Steering controller malfunctioning Replace 4 S7 Air sucked in pump due to lack of oil Replenish G 19 Air sucked in pump from suction circuit Repair Insufficient bleeding Bleed 4 S5 Cylinder malfunctioning Repair or replace 4 S5 Improper toe in adjustment Adjust 3 S4 Tyre pressure uneven Inflate G 61 Wheels Ar...

Page 224: ...n Allowable Limit Relief Valve Operating Pressure 8 34 to 8 82 MPa 85 0 to 90 0 kgf cm2 1210 to 1270 psi Item Factory Specification Allowable Limit Steering Cylinder I D 40 000 to 40 062 mm 1 5748 to 1 5772 in 40 100 mm 1 5787 in Piston Rod to Guide Clearance 0 020 to 0 070 mm 0 00079 to 0 0027 in 0 200 mm 0 00787 in KiSC issued 08 2009 A ...

Page 225: ... See page G 12 9Y1210294STS0003US0 9Y1210294STS0004US0 Item N m kgf m lbf ft Steering wheel mounting nut 20 to 25 2 0 to 2 6 15 to 18 Power steering hose 24 to 27 2 4 to 2 8 18 to 20 Power steering cylinder mounting screw 48 to 55 4 9 to 5 7 36 to 41 Tie rod end slotted nut 18 to 34 1 8 to 3 5 13 to 25 Axial ball joint 74 to 84 7 5 to 8 6 54 6 to 62 0 KiSC issued 08 2009 A ...

Page 226: ...the above mentioned lock position by operation force at approximately 9 8 N 1 0 kgf 2 2 lbf of outer NOTE After set a pressure gauge be sure to bleed air Note that the pressure valve changes by the pump action of the power steering controller when the steering operation is continued after the steering wheel is lightly locked and accurate relief valve pressure cannot be measured After checking reli...

Page 227: ...ing NOTE Tighten the slotted nut to 18 N m 1 8 kgf m 13 lbf ft If the slot and pin hole do not meet tighten the nut until they do meet and install the cotter pin Be sure to split the cotter pin like an anchor After connecting the power steering hoses starting the engine steer the steering wheel to left or right turning end and bleed the air in the power steering hydraulic circuit 9Y1210294STS0006U...

Page 228: ...from its groove Simultaneously support this action by pushing from the outside of the cylinder tube with another little screwdriver or another tool 5 Push out the piston rod assembly 9 and take off the guide assembly 3 When reassembling NOTE Seals must be exchanged after disassembling Apply transmission fluid to the exchanged seals Enter the piston rod and block the guide assemblies with the snap ...

Page 229: ...connect the power steering hoses to their original position and tighten them to the specified torque After connecting the hoses to the power steering controller start the engine and steer the steering wheel to left or right turning end and bleed the air in the power steering hydraulic circuit 9Y1210294STS0010US0 Tightening torque Steering wheel mounting nut 20 to 25 N m 2 0 to 2 6 kgf m 15 to 18 l...

Page 230: ...od guide I D with a cylinder gauge 2 Measure the rod O D with an outside micrometer and calculate the clearance 3 If the clearance exceeds the allowable limit replace as a unit 9Y1210294STS0012US0 Steering cylinder I D Factory specification 40 000 to 40 062 mm 1 5787 to 1 5772 in Allowable limit 40 100 mm 1 5787 in Clearance between rod and guide Factory specification 0 020 to 0 070 mm 0 00079 to ...

Page 231: ...5 HYDRAULIC SYSTEM KiSC issued 08 2009 A ...

Page 232: ...LIC PTO LD MODEL 5 M3 4 G26 HYDRAULIC PTO HD MODEL 5 M4 2 HYDRAULIC PUMP 5 M5 3 RELIEF VALVE 5 M6 4 FLOW PRIORITY VALVE 5 M7 5 CONTROL VALVE 5 M8 6 LIFT CYLINDER 5 M12 1 MOWER LIFT CYLINDER 5 M12 2 DUMP CYLINDER LD 5 M12 3 DUMP CYLINDER HD 5 M12 4 GRASS COLLECTOR LIFT CYLINDER HD 5 M13 MECHANISM KiSC issued 08 2009 A ...

Page 233: ...ntrol valve for the mower the grass collector and other hydraulic component parts as shown in the hydraulic circuit above after dividing the hydraulic oil by the flow priority valve 9Y1210294HYM0001US0 1 Power Steering Cylinder 2 Power Steering Controller 3 Relief Valve Power Steering 4 Oil Filter 5 Relief Valve Oil Filter 6 HST Hydrostatic Transmission 7 HST Motor 8 By pass Valve 9 Orifice 10 Che...

Page 234: ... the grass collector and other hydraulic component parts as shown in the hydraulic circuit above after dividing the hydraulic oil by the flow priority valve 9Y1210294HYM0002US0 1 Power Steering Cylinder 2 Power Steering Controller 3 Relief Valve Power Steering 4 Oil Filter 5 Relief Valve Oil Filter 6 HST Hydrostatic Transmission 7 HST Motor 8 By pass Valve 9 Orifice 10 Check and High Pressure Reli...

Page 235: ...ass collector and other hydraulic component parts as shown in the hydraulic circuit above after dividing the hydraulic oil by the flow priority valve 9Y1210294HYM0003US0 1 Power Steering Cylinder 2 Power Steering Controller 3 Relief Valve Power Steering 4 Oil Filter 5 Relief Valve Oil Filter 6 HST Hydrostatic Transmission 7 HST Motor 8 By pass Valve 9 Orifice 10 Check and High Pressure Relief Valv...

Page 236: ...d other hydraulic component parts as shown in the hydraulic circuit above after dividing the hydraulic oil by the flow priority valve 9Y1210294HYM0004US0 1 Power Steering Cylinder 2 Power Steering Controller 3 Relief Valve Power Steering 4 Oil Filter 5 Relief Valve Oil Filter 6 HST Hydrostatic Transmission 7 HST Motor 8 By pass Valve 9 Orifice 10 Check and High Pressure Relief Valve Forward 11 Che...

Page 237: ...driven by the HST pump shaft and the idle gear 12 in the transmission case Maximum displacement is as follows 9Y1210294HYM0005US0 Displacement Engine speed Condition 27 5 L min 7 3 U S gals min 6 1 Imp gals min At 3200 min 1 rpm At no load 1 Pump Cover 2 Driven Gear 3 Bush 4 Drive Gear 5 Bush 6 Double Ring 7 Straight Pin 8 Side Plate 9 Transmission Front Cover 10 Oil Seal 11 Cir clip 12 Idle Gear ...

Page 238: ...draulic pump flows into the hydraulic control valve When the pressure rises above the valve setting pressure and overcomes the spring force the relief poppet opens Oil then flows out to the transmission case through T port preventing any further rise in pressure The relief poppet closes again when enough oil is released to drop pressure below the valve setting pressure Reference Relief valve setti...

Page 239: ... U S gals min 2 1 Imp gals min to the PF port with priority and excessive flow to the EF port 9Y1210294HYM0008US0 1 Front Case 2 Relief Valve Seat 3 Relief Poppet 4 Relief Spring 5 Relief Valve 6 Shim and Plain Washer 7 Flow Priority Valve 8 Line Filter EF EF Port To Hydraulic Control Valve and Mower Grass Collector Cylinders P Pump Port Suction T Tank Port PF PF Port To Power Steering Hydraulic P...

Page 240: ... Mower Lift Cylinder 6 Mower Lift Cylinder 7 Dump Cylinder 8 O ring 9 Return Spring 10 Bolt 11 Plain Washer 12 Stop Collar 13 Spring Cap 14 Orifice 15 Orifice 16 Orifice A Oil from hydraulic pump B Oil to transmission case P Pump Port T Tank Port A1 Control Valve Oil Port A2 Control Valve Oil Port A3 Control Valve Oil Port B2 Control Valve Oil Port B3 Control Valve Oil Port C E G Spool is pushed i...

Page 241: ...urns through A1 port to T port and the mower lowers 9Y1210294HYM0014US0 1 Valve Body 2 Grass Collector Lift Cylinder 3 Spool Grass Collector Lift Cylinder 4 Spool Dump Cylinder 5 Spool Mower Lift Cylinder 6 Mower Lift Cylinder 7 Dump Cylinder 8 O ring 9 Return Spring 10 Hexagon Bolt 11 Plain Washer 12 Stop Collar 13 Spring Cap 16 Orifice A Oil from hydraulic pump B Oil to transmission case P Pump ...

Page 242: ...gh B2 port to the grass collector dump cylinder 7 The hydraulic oil in the dump cylinder returns A2 port to T port Grass collector is closed 9Y1210294HYM0015US0 1 Valve Body 2 Grass Collector Lift Cylinder 3 Spool Grass Collector Lift Cylinder 4 Spool Dump Cylinder 5 Spool Mower Lift Cylinder 6 Mower Lift Cylinder 7 Dump Cylinder 8 O ring 9 Return Spring 10 Hexagon Bolt 11 Plain Washer 12 Stop Col...

Page 243: ...ass collector lift cylinders 2 is flowed through B3 port to the transmission case The grass collector is lowered down 9Y1210294HYM0016US0 1 Valve Body 2 Grass Collector Lift Cylinder 3 Spool Grass Collector Lift Cylinder 4 Spool Dump Cylinder 5 Spool Mower Lift Cylinder 6 Mower Lift Cylinder 7 Dump Cylinder 8 O ring 9 Return Spring 10 Hexagon Bolt 11 Plain Washer 12 Stop Collar 13 Spring Cap 14 Or...

Page 244: ...9Y1210294HYM0010US0 3 DUMP CYLINDER HD This dump cylinder consists of the cylinder sub assy 1 the piston 3 the rod sub assy 2 and other parts as shown in the figure This dump cylinder is a single rod double acting cylinder in which the reciprocating motion of the piston 3 is controlled by the hydraulic force applied to the both ends 9Y1210294HYM0011US0 1 Cylinder 2 Cir clip 3 Rod 4 Paking 5 Seal A...

Page 245: ...re above 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 9Y1210294HYM0012US0 1 Piston Rod 2 Head 3 Cylinder Tube 4 Piston 5 Nut A Cylinder I D B Rod O D C Stroke Item Grass Collector Lift Cylinder Cylinder tube I D A 40 mm 1 57 in Rod O D B 25 mm 0 98 in Stroke C 483 5 to 485 5 mm 19 0 to 19 1 in...

Page 246: ...TIGHTENING TORQUES 5 S4 4 CHECKING DISASSEMBLING AND SERVICING 5 S5 1 CHECKING AND ADJUSTING 5 S5 2 DISASSEMBLING 5 S8 1 Removing Hydraulic Parts 5 S8 2 Disassembling 5 S15 3 SERVICING 5 S18 1 Hydraulic Pump 5 S18 2 Lift Cylinder 5 S19 SERVICING KiSC issued 08 2009 A ...

Page 247: ...ic pump defective Replace 5 S9 Oil strainer clogged Clean or replace G 44 Insufficient transmission fluid Refill G 19 Loosen or worn hydraulic hoses and adaptors Tighten or replace Grass Collector Does Not Lower Control valve malfunctioning Replace 5 S10 Hydraulic pump defective Replace 5 S9 Oil strainer clogged Clean or replace G 44 Insufficient transmission fluid Refill G 19 Loosen or worn hydra...

Page 248: ...f valve setting pressure too low Adjust 5 S5 Hydraulic pump defective Replace 5 S9 Lift cylinder damaged Replace 5 S14 Oil strainer clogged Clean or replace G 44 Insufficient transmission fluid Refill G 19 Loosen or worn hydraulic hoses and adaptors Tighten or replace Grass Collector Does Not Lower Control valve malfunctioning Replace 5 S10 Grass Collector Drops By Its Weight Control valve malfunc...

Page 249: ...rol Valve Oil Flow Above 18 0 L min 4 8 U S gals min 4 0 Imp gals min Gear Tooth to Case Clearance 0 15 mm 0 0059 in Pump Gear O D 33 520 to 33 530 mm 1 3197 to 1 3200 in Pump Case I D 33 570 to 33 577 mm 1 3217 to 1 3219 in Bushing to Pump Gear Shaft Clearance 0 020 to 0 091 mm 0 00079 to 0 0035 in 0 12 mm 0 0047 in Pump Gear Shaft O D 14 970 to 14 980 mm 0 58937 to 0 58976 in Bushing I D 15 000 ...

Page 250: ... 7 1 5 10 8 Adaptor Mower lift cylinder 35 3 3 6 26 0 Adaptor Grass collector cylinder 35 3 3 6 26 0 Cylinder head 250 to 300 25 5 to 30 6 184 to 221 Cylinder piston mounting lock nut 300 to 350 30 6 to 35 7 221 to 258 Item N m kgf m lbf ft Cylinder hose 22 0 to 25 0 2 2 to 2 5 16 2 to 18 4 Cylinder adaptor 1 4 NPTF 24 5 2 5 18 1 Cylinder head 98 07 to 117 68 10 0 to 12 0 72 33 to 86 8 Cylinder pi...

Page 251: ...e setting pressure 8 If the pressure is not within the factory specifications adjust the pressure with the adjusting shims 6 Condition Engine speed 1495 to 1505 min 1 rpm Oil temperature 45 to 55 C 113 to 131 F IMPORTANT Measure quickly so that the main relief valve may not be in operation more than 10 seconds Reference Thickness of adjusting shims 0 2 mm 0 008 in Part No 31351 37960 0 1 mm 0 004 ...

Page 252: ...ling plug and fix the flowmeter hose and the flowmeter 4 Check that a flow volume meets the specifications when the engine revolution is at about 3200 min 1 rpm 5 If the volume varies from the specification replace the priority valve then take measurement again Condition Engine speed 3200 min 1 rpm Oil temperature 50 C 122 F 9Y1210294HYS0005US0 Power steering oil flow Factory specification Above 9...

Page 253: ...from the transmission case 9 4 Fix the flowmeter hose OUT to the transmission case 9 5 Check that a flow volume meets the specifications when the engine revolution is set at 3200 min 1 rpm 6 If the oil flow volume varies from the specification replace the flow priority valve then take measurement again Condition Engine speed 3200 min 1 rpm Oil temperature 50 C 122 F 9Y1210294HYS0006US0 Hydraulic p...

Page 254: ...lugs at the bottom of the transmission case and both sides on the rear axle case 2 After draining reinstall the plugs 3 Remove the oil strainer 4 Clean the oil strainer When reassembling Do not damage the O ring 9Y1210294HYS0007US0 Transmission oil capacity 11 0 L 11 6 U S qts 9 7 Imp qts 1 Drain Plug 2 Rear Tyre LH 3 Oil Strainer 4 O ring KiSC issued 08 2009 A ...

Page 255: ...emove the operator s seat 2 Remove the mower control cam dial 3 Remove the HST fan cover 4 Remove the HST return pipe 1 5 Remove the relief valve 2 from the front case 4 6 Remove the flow priority valve 3 from the front case 4 When reassembling Clean the relief valve and the flow priority valve 9Y1210294HYS0009US0 1 Hydraulic Pump 2 Front Case 1 HST Return Pipe 2 Relief Valve Main 3 Flow Priority ...

Page 256: ...move the hydraulic control valve 1 with the fender support 2 and hydraulic oil filter as shown in the pictures 3 Remove the hydraulic control valve 1 When reassembling Connect the hydraulic hoses and pipes to the original position 9Y1210294HYS0010US0 1 Hydraulic Control Valve 2 Fender Bracket KiSC issued 08 2009 A ...

Page 257: ... adaptor of the mower lift cylinder 2 4 Remove the joint pins 5 9 5 Remove the mower lift cylinder 2 When reassembling Connect the mower hose to the adaptor of the mower lift cylinder securely 9Y1210294HYS0011US0 1 Cylinder Cover 2 Mower Lift Cylinder 3 Snap Pin 4 Plain Washer 5 Joint Pin 6 Mower Hose 7 Cotter Rue Ring 8 Plain Washer 9 Joint Pin KiSC issued 08 2009 A ...

Page 258: ...r cover 2 4 Disconnect the cylinder hoses 9 10 5 Remove the clevispin 8 and the cylinder shaft 13 6 Remove the grass collector dump cylinder 5 When reassembling Connect the cylinder hose to the original position 9Y1210294HYS0012US0 1 Grass Collector Control Lever 2 Cylinder Cover 3 Split Pin 4 Plain Washer 5 Grass Collector Dump Cylinder 6 Split Pin 7 Plain Washer 8 Clevispin 9 Cylinder Hose 10 Cy...

Page 259: ...tion hoses 7 8 5 Remove the cylinder shaft 12 and the joint pin 14 6 Remove the grass collector dump cylinder 6 When reassembling Connect the rotation hose to the original position 9Y1210294HYS0013US0 1 Bag Frame RH 2 Rear Frame 3 Front Bag Frame 4 Bag Frame LH 5 Bottom Plate 6 Dump Cylinder 7 Upper Rotation Hose 8 Lower Rotation Hose 9 Cylinder Collar 10 Split Pin 11 Plain Washer 12 Cylinder Shaf...

Page 260: ... 1 2 4 Remove the cylinder rod 7 and the joint pin 5 Remove the lift cylinder 3 6 Remove the lift cylinder 5 referring to the lift cylinder 3 When reassembling Connect the lift lower hoses securely 9Y1210294HYS0014US0 1 Lift Lower Hose LH 2 Lift Lower Hose LH 3 Lift Cylinder LH 4 Lift Lower Hose RH 5 Lift Cylinder RH 6 Lift Lower Hose RH 7 Cylinder Rod 8 Rue Ring Cotter 9 Hydraulic Lock Pipe RH 10...

Page 261: ...1 Disassemble the relief valve 2 Remove the flow priority valve 8 When reassembling Check the O rings Clean the line filter 9Y1210294HYS0016US0 1 Pump Cover Casing 2 Bush 3 Driven Gear 4 Side Plate 5 Bush 6 Double Ring 7 Front Case 8 Oil Seal 9 Cir clip 10 Drive Gear 11 Straight Pin Tightening torque Relief valve 29 4 to 34 3 N m 3 0 to 3 5 kgf m 21 7 to 25 3 lbf ft Flow priority valve 49 0 to 53 ...

Page 262: ...the plug and the outer components to the original position as shown in the figures 9Y1210294HYS0017US0 Mower Lift Cylinder NOTE Mower lift cylinder component parts are not adopted 1 If the mower lift cylinder 1 is defective replace it 1 with a new one 2 If oil leaks from the mower lift cylinder 1 replace it 1 with a new one 9Y1210294HYS0018US0 1 Hydraulic Control Valve A G23 LD B G23 HD C G26 LD D...

Page 263: ...reassembling Visually inspect the cylinder tube for signs of scoring or damage Clean the cylinder tube and piston rod assembly Secure the tube end of cylinder in a vice Insert the piston rod assembly to the cylinder tube after covering the seal with new hydraulic oil and using care not to damage the piston seal on the piston Screw the cylinder head When reassembling Visually inspect the cylinder t...

Page 264: ...e thickness is less than the allowable limit replace it 9Y1210294HYS0023US0 Clearance between tip of gear tooth and cashing Allowable limit 0 15 mm 0 0059 in Gear O D Factory specification 33 520 to 33 530 mm 1 3197 to 1 3200 in Case I D Factory specification 33 570 to 33 577 mm 1 3217 to 1 3219 in 1 Case Pump Front Cover 2 Drive Gear 3 Driven Gear A Case I D B Gear O D Clearance between bushing a...

Page 265: ...ace piston rod on V blocks 2 Set a dial indicator on the center of the rod 3 Turn the piston rod and read the dial indicator 4 If the measurement exceeds the allowable limit replace it 9Y1210294HYS0024US0 Piston rod bend Allowable limit 0 25 mm 0 0098 in KiSC issued 08 2009 A ...

Page 266: ...6 ELECTRICAL SYSTEM KiSC issued 08 2009 A ...

Page 267: ...6 M5 1 ELECTRICAL CIRCUIT 6 M5 2 IC REGULATOR 3P CONNCTOR TYPE 6 M6 4 LIGHTING SYSTEM 6 M7 1 ELECTRICAL CIRCUIT 6 M7 5 GAUGES 6 M8 1 ELECTRICAL CIRCUIT 6 M8 2 HOUR AND TACHOMETER 6 M8 3 FUEL LEVEL GAUGE 6 M9 4 WATER TEMPERATURE GAUGE 6 M9 6 BUZZER SYSTEM 6 M10 1 ELECTRICAL CIRCUIT 6 M10 2 BUZZER 6 M10 3 GRASS COLLECTOR DUCT SWITCH 6 M10 MECHANISM KiSC issued 08 2009 A ...

Page 268: ...ELECTRICAL SYSTEM G23 G26 WSM 6 M1 EU 1 WIRING DIAGRAM 1 G23 KiSC issued 08 2009 A ...

Page 269: ...ELECTRICAL SYSTEM G23 G26 WSM 6 M2 EU 2 G26 KiSC issued 08 2009 A ...

Page 270: ...The main switch automatically returns to the ON position the terminal BAT is connected only to the terminal GLOW thereby causing the starting circuit to be opened stopping the starter motor When the main switch turned from the ON position to the OFF position the fuel cut off solenoid 15 moves the fuel injection pump control rack to the No Fuel Injection position and stops the engine 9Y1210294ELM00...

Page 271: ... Normal close PTO Shift Lever Switch 1 1 2 1 Connector 2 Plunger A 2 Connector Type B 4 Connector Type Brake Pedal Switch PTO Lever Switch 2 Seat Switch Grass Collector L Lowest position U Up position Safety Engine Start OPC Safety Depress Disengaged On seat L position Start Running U position Start Running Off seat L position Start Running U position Start Running Engaged On seat L position Not S...

Page 272: ...pplies electric power for various electrical devices and also charges the battery while the engine runs 9Y1210294ELM0003US0 1 Hour and TachoMeter 2 Battery Charge Lamp 3 Frame Earth 4 Alternator 5 Fuse 6 Electrical Device 7 Slow Blow Fuse 8 Main Switch 9 Starter Motor 10 Battery KiSC issued 08 2009 A ...

Page 273: ...meter When turning on the main switch to ON position the hour meter indicates operated hours While the engine runs the tachometer indicates the present engine revolutions RY Red Yellow lead 2 is a lead to the main switch WR White Red lead 3 is a lead to the charge lamp 9Y1210294ELM0004US0 1 Sb Sky Blue Lead 2 RY Red Yellow Lead 3 WR White Red Lead 4 Alternator Assembly 5 IC Regulator 6 Load 7 Load...

Page 274: ...Lamp 9 Water Temperature Gauge 10 Fuel Gauge 11 Combination Lamp Rear L 12 Combination Lamp Rear R 13 Combination Lamp Front L 14 Combination Lamp Front R 15 Thermo Unit 16 Fuel Sensor 17 Licence Plate Lamp 18 Oil Pressure Switch 19 Frame Earth 20 Trailer Socket 21 Brake Lamp Switch Optional 22 Head Light 40 45W 23 Alternator 24 Fuse 25 Slow Blow Fuse 50A 26 Fuse 27 Flasher Unit 28 Horn 29 Combina...

Page 275: ... starting the engine this meter indicates the present engine revolution The meter picks up the voltage from the IC regulator located in the alternator The IC regulator sends a signal of the engine revolution to the meter The meter calculates the signal It changes and indicates the signal to the engine revolution in cooperation with the voltage 9Y1210294ELM0007US0 1 Hour and Tachometer 2 Water Temp...

Page 276: ... the thermo unit are connected by the wiring The water temperature gauge detects the resistance from the thermo unit The water temperature gauge indicates the coolant temperature in the engine cylinder head The relationship between the resistance of thermo unit and reading on the water temperature gauge is as follows 9Y1210294ELM0009US0 Resistance of Fuel Level Sensor Reading on Fuel Level Gauge A...

Page 277: ... 3 GRASS COLLECTOR DUCT SWITCH Grass collector duct switch is located at the grass collector duct The grass collector duct switch detects the grass quantity in the grass collector bag When the grass bag is full of grass the switch lever 3 is set to ON At this moment the battery current from the buzzer flows through the grass collector duct switch to the machine frame earth When the grass bag is no...

Page 278: ...y Switch 6 S11 6 Operator Presence Control OPC Switch 6 S13 7 Grass Collector Duct Switch 6 S14 8 Grass Collector Buzzer 6 S14 9 Fuel Pump 6 S14 10 Engine Stop Solenoid 6 S15 11 Timer Relay 6 S15 12 Charging System 6 S16 13 Alternator 6 S16 14 Combination Switch 6 S18 15 Gauge 6 S24 2 DISASSEMBLING AND ASSEMBLING 6 S25 1 Starter 6 S25 2 Alternator 6 S26 3 SERVICING 6 S26 1 Starter 6 S26 2 Alternat...

Page 279: ... replace Cooling fan belt slipping Adjust tension G 37 Symptom Probable Cause Solution Reference Page Starter Motor Does Not Operate Battery discharged or defective Recharge or replace G 34 Slow blow fuse blown Replace G 50 Safety switch improperly adjusted or defective Repair or replace 6 S11 Wiring harness disconnected or improperly connected between main switch 50 terminal and safety switches b...

Page 280: ...al Repair or replace Engine Stops When Brake Pedal Is Engaged Wrong wiring of seat switch and grass collector switch Proper Wiring 6 S13 Engine Suddenly Stops Seat switch not operated Adjust the switch position 6 S13 Symptom Probable Cause Solution Reference Page Charging Lamp Does Not Light When Main Switch Is Turned ON Fuse blown 15 A Replace G 50 Wiring harness disconnected or improperly connec...

Page 281: ...b blown Replace G 50 Wiring harness disconnected or improperly connected Repair or replace Hazard Light Does Not Flicker Flasher unit defective Replace 6 S22 Turn Signal Light Does Not Light Fuse blown 15 A Replace G 50 Bulb blown Replace Wiring harness disconnected or improperly connected Repair or replace Flasher unit defective Replace 6 S22 Blinker switch defective Replace Turn Signal Light Ind...

Page 282: ... improperly connected between panel board and oil pressure switch Repair or replace Symptom Probable Cause Solution Reference Page Fuel Gauge Does Not Function Fuel gauge defective Replace 4 S7 Fuel level sensor defective Replace 6 S24 Wiring harness disconnected or improperly connected between fuel gauge and fuel level sensor Repair or replace Coolant Temperature Gauge Does Not Function Coolant t...

Page 283: ...ead Light Switch Switch OFF ON Infinity 0 Ω Blinker Switch Switch OFF R L Infinity 0 Ω 0 Ω Hazard Light Switch Switch OFF ON Infinity 0 Ω Starter Commutator Mica Brush O D Difference of O D s Under cut Length 30 0 mm 1 181 in Less than 0 02 mm 0 0008 in 0 50 to 0 80 mm 0 0197 to 0 0315 in 14 0 mm 0 551 in 29 0 mm 1 142 in 0 05 mm 0 0020 in 0 20 mm 0 0079 in 9 0 mm 0 354 in Alternator Stator Rotor ...

Page 284: ...Tightening torques of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page G 12 9Y1210294ELS0003US0 Item N m kgf m lbf ft Starter B terminal nut 5 9 to 11 8 0 6 to 1 2 4 3 to 8 7 KiSC issued 08 2009 A ...

Page 285: ...ed damage to alternator and regulator may result 9Y1210278ELS0004US0 1 Battery Battery Voltage 1 Stop the engine and turn the main switch OFF 2 Connect the COM lead of the voltmeter to the battery s negative terminal post and the lead to the positive terminal post and measure the battery voltage 3 If the battery voltage is less than the factory specification check the battery specific gravity and ...

Page 286: ...ase of 1 C 0 0004 with an increase of 1 F in temperature and increases by 0 0007 with a decreases of 1 C 0 0004 with a decrease of 1 F Therefore using 20 C 68 F as a reference the specific gravity reading must be corrected by the following formula Specific gravity at 20 C Measured value 0 0007 electrolyte temperature 20 C Specific gravity at 68 F Measured value 0 0004 electrolyte temperature 68 F ...

Page 287: ...an ohmmeter across the B terminal and the G terminal and measure the resistance across the B terminal and the ACC terminal 3 If 0 ohm is not indicated these contacts of the main switch are faulty 4 Main Switch Key at START Position 1 Set and hold the main switch key at the START position 2 Measure the resistance with an ohmmeter across the B terminal and the G terminal across the B terminal and th...

Page 288: ...e pinion gear should pop out when a jumper lead is connected from the battery positive terminal to the S terminal It s a correct 5 Disconnect the jumper lead to the starter C terminal Then the pinion gear should remain popped out It s a correct IMPORTANT Testing time must be 3 to 5 seconds 9Y1210294ELS0008US0 4 Glow Plug Lead Terminal Voltage 1 Disconnect the wiring lead 2 from the glow plug 1 aft...

Page 289: ...the resistance with an ohmmeter across the switch terminals 4 If the resistance values specified below are not indicated the safety switch is faulty Q Plunger is pushed into the switch body Q Plunger is released 9Y1210294ELS0010US0 Glow plug resistance Factory specification Approx 0 9 Ω Resistance 1 terminal 5 2 terminal 6 Factory specification 0 Ω Resistance 3 terminal 7 4 terminal 8 Factory spec...

Page 290: ...nger is pushed into the switch body Q Plunger is released 9Y1210294ELS0011US0 Resistance 1 terminal 5 2 terminal 6 Factory specification 0 Ω Resistance 3 terminal 7 4 terminal 8 Factory specification 0 Ω Resistance 1 terminal 5 2 terminal 6 Factory specification Infinity Resistance 3 terminal 7 4 terminal 8 Factory specification Infinity 1 Brake Pedal Switch 2 2P Connector LH 3 2P Connector RH 4 P...

Page 291: ...erator leave the seat 1 Measure the resistance between terminals 3 2 If continuity is not infinity the switch is faulty Replace it When switch is pushed When operator sits on the seat 1 Measure the resistance between terminals 3 2 If continuity is not 0 Ω the switch is faulty Replace it 9Y1210294ELS0012US0 Resistance When switch is not pushed When operator leave the seat Infinity When switch is pu...

Page 292: ...e terminal and the terminal 1 1 4 Check the buzzer function 5 If the buzzer noise level is low change the buzzer with a new one Reference 9Y1210294ELS0014US0 9 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 the connector terminals 3 If the voltage differs from the battery vo...

Page 293: ...terminal 4 and chassis 3 Turn the main switch on and measure the voltage across the connector terminal 3 and chassis 4 If these voltages differ from the battery voltage the wiring harness or main switch is faulty 9Y1210294ELS0018US0 Test of Timer Relay 1 Remove the timer relay from the tractor 2 Connect jumper leads across the battery positive terminal and the timer relay terminal 3 and across the...

Page 294: ...ore with an ohmmeter 4 If infinity is not indicated replace it WSM000001ELS0040US0 Rotor 1 Measure the resistance across the slip rings with an ohmmeter 2 If the resistance is not the factory specification replace it 3 Check the continuity across the slip ring and core with an ohmmeter 4 If infinity is not indicated replace it WSM000001ELS0041US0 Slip Ring 1 Check the slip ring for score 2 If scor...

Page 295: ...he brush is defective replace it WSM000001ELS0043US0 Rectifier 1 Check the continuity across each diode of rectifier with resistance range of circuit tester 2 The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction 9Y1210294ELS0021US0 Brush length Factory specification 10 5 mm 0 413 in Allowable limit 8 4 mm 0 331 in KiSC issued...

Page 296: ...ch Continuity When Setting Switch at OFF Position 1 Set the light switch to the OFF position 2 Measure the resistance with an ohmmeter across the red yellow lead 1 to the orange lead 4 the red yellow lead 1 to the yellow lead 3 3 If infinity is not indicated the head light switch is faulty 1 Combination Switch 2 Red Yellow Lead 3 Green Lead 4 Black Blue Lead 5 Blue White Lead 6 Yellow Lead 7 Orang...

Page 297: ...h knob to the OFF position 2 Measure the resistance with an ohmmeter across the green lead 1 and red white lead 2 and across to the green lead 1 and green white lead 3 3 If infinity is indicated the combination switch is faulty Resistance Switch at ON position Red Yellow lead 1 Orange lead 4 0 Ω Red Yellow lead 1 Yellow lead 3 1 Red Yellow Lead 2 Blue White Lead 3 Yellow Lead 4 Orange Lead 5 Red W...

Page 298: ...nal switch knob to the LEFT position 2 Measure the resistance with an ohmmeter across the green lead 1 and red white lead 2 and across to the green lead 1 and green white lead 3 3 If 0 Ω is not indicated the combination switch is faulty Resistance Switch knob at RIGHT position Green lead 1 Red White lead 4 0 Ω Green lead 1 Green White lead 3 Infinity 1 Green Lead 2 Red White Lead 3 Green White Lea...

Page 299: ...sition 1 Set the hazard switch knob to the ON position 2 Measure the resistance with an ohmmeter across the black blue lead 1 and the blue white lead 2 3 If 0 Ω is not indicated the combination switch is faulty 9Y1210294ELS0022US0 Resistance Hazard switch at OFF position Black Blue lead 1 Blue White lead 2 Infinity 1 Black Blue Lead 2 Blue White Lead A Hazard Switch OFF Position Resistance Hazard ...

Page 300: ...nal light switch to the left Make sure that the right hand light stays on and the left hand light gives flashes earlier by about 20 flashes than when the hazard lamp is activated Then move the turn signal light switch to the right and make sure the corresponding actions take place 3 Now set the main switch to the ACC position and move the blinker switch alone Make sure the same actions as above re...

Page 301: ...e charge lamp does not light the wiring harness or fuse is faulty 9Y1210294ELS0025US0 Engine Oil Pressure Lamp 1 Disconnect the lead 2 from the engine oil pressure switch 1 after turning the main switch OFF 2 Turn the main switch ON and connect a jumper lead from the lead to the chassis 3 If the engine oil pressure indicator lamp does not light the wiring harness is faulty 9Y1210294ELS0026US0 1 Al...

Page 302: ...in switch OFF 2 Turn the main switch ON and measure the voltage with a voltmeter across the lead terminal and the chassis If the voltage differs from the battery voltage the wiring harness fuse or coolant temperature gauge is faulty 2 Sensor Continuity 1 Measure the resistances with an ohmmeter across the sensor terminal and the chassis 2 If the reference value is not indicated the sensor is fault...

Page 303: ...then separate the end frame 4 yoke 2 and armature 1 3 Remove the two screws 5 and then take out the brush holder 3 from the end frame 4 When reassembling Apply grease to the spline teeth A of the armature 1 9Y1210294ELS0031US0 Voltage while engine runs at idling speeds Hour meter terminal Alternator body Approx battery voltage 1 Sb Sky Blue Lead 2 RY Red Yellow Lead 3 WR White Red Lead 4 3P Connec...

Page 304: ... increasing the engine revolution 3 If the battery charging voltage does not increase the alternator is faulty 4 Replace the alternator as an assembly 9Y1210294ELS0033US0 3 SERVICING 1 Starter Overrunning Clutch 1 Inspect the pinion for wear or damage 2 If there is any defect replace the overrunning clutch assembly 3 Check that the pinion turns freely and smoothly in the overrunning direction and ...

Page 305: ...ace 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 the yoke assembly and brush holder 9Y1210294ELS0034US0 Brush Holder 1 Check the continuity across the brush holder and the holder support with an ohmmeter 2 If it conducts replace the brush holder 9Y1210294ELS0035US0 Commutator O D...

Page 306: ...ct replace the armature WSM000001ELS0037US0 Field Coil 1 Check the continuity across the lead 1 and brush 2 with an ohmmeter 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 WSM000001ELS0038US0 2 Alternator Bearing 1 Check the bearing for smooth rotation 2 If it does not rotate smooth...

Page 307: ...RICAL SYSTEM G23 G26 WSM 6 S29 EU Alternator Components 1 When the alternator does not generate or does not charge the battery replace the alternator as an assembly 9Y1210294ELS0036US0 KiSC issued 08 2009 A ...

Page 308: ...7 MOWER KiSC issued 08 2009 A ...

Page 309: ...CONTENTS 1 POWER TRANSMISSION 7 M1 2 MOWER GEAR CASE POWER TRAIN 7 M2 3 LIFTING MECHANISM 7 M3 MECHANISM KiSC issued 08 2009 A ...

Page 310: ...lades Q Power Transmission Engine flywheel PTO clutch belts PTO clutch Universal joint 1 Input shaft Bevel gear case 2 Mower centre case Idle gears Blade spindle case LH 3 RH Blade LH 4 Blade RH 9Y1210294MOM0001US0 1 Universal Joint 2 Bevel Gear Case 3 Blade Spindle Case LH 4 Blade LH KiSC issued 08 2009 A ...

Page 311: ...Shaft RH Input shaft 19 Spiral gear 18 Spiral gear 21 Output shaft 7 Gear RH 6 Gear 8 Gear 10 Gear 12 Blade shaft RH 13 9Y1210294MOM0002US0 1 Blade Spindle Case LH 2 Gear 3 Blade Shaft LH 4 Gear 5 Bearing Shaft 6 Gear RH 7 Output Shaft 8 Gear 9 Bearing Shaft 10 Gear 11 Bearing Shaft 12 Gear 13 Blade Shaft RH 14 Blade Spindle Case RH 15 Straight Pin 16 Oil Seal 17 Centre Case 18 Spiral Gear 19 Inpu...

Page 312: ...is extended by the oil pressure of the hydraulic system And the lift link 2 and the front arm LH 4 rotates counterclockwise The height link 5 and the connect link 6 are pulled The rear arm LH 7 rotates counterclockwise The lift lower link LH 8 is lifted up and the mower deck is lifted up 9Y1210294MOM0003US0 1 Mower Lift Cylinder 2 Lift Link 3 Front Arm 4 Front Arm LH 5 Height Link 6 Connect Link 7...

Page 313: ...NG 7 S1 2 SERVICING SPECIFICATIONS 7 S2 3 TIGHTENING TORQUES 7 S3 4 CHECKING DISASSEMBLING AND SERVICING 7 S4 1 CHECKING AND ADJUSTING 7 S4 2 DISASSEMBLING AND ASSEMBLING 7 S5 3 SERVICING 7 S15 SERVICING KiSC issued 08 2009 A ...

Page 314: ...up washer flattened out or worn Replace cup washer 7 S8 Engine rpm too low Mow at full throttle check and reset engine rpm Cutting Is Poor Mower blade worn or broken Sharpen or replace mower blade 7 S4 Mower blade screw loosen Retighten mower blade screw 7 S6 Cutting height improper Adjust cutting height 7 S4 Ground speed too fast Slow down Low tyre inflation Add air to correct G 18 Anti scalp rol...

Page 315: ...Factory Specification Allowable Limit Input Shaft without Mower Belt Turning Force Less than 118 N 12 0 kgf 26 5 lbf Turning Torque Less than 1 5 N m 0 15 kgf m 1 1 lbf ft Bevel Gears in Gear Box Backlash 0 10 to 0 30 mm 0 0039 to 0 0118 in 0 40 mm 0 0157 in KiSC issued 08 2009 A ...

Page 316: ...and nuts See page G 12 9Y1210294MOS0003US0 Item N m kgf m lbf ft Mower blade screw 98 to 117 6 10 0 to 12 0 72 3 to 86 7 Blade spindle case mounting bolt to mower deck 48 to 56 4 9 to 5 7 35 4 to 41 3 Blade spindle case mounting bolt to centre case 48 to 56 4 9 to 5 7 35 4 to 41 3 Bevel gear case mounting bolt 48 to 56 4 9 to 5 7 35 4 to 41 3 KiSC issued 08 2009 A ...

Page 317: ...stments Wear heavy gloves or wrap end of the blade with a rag when you handle blades Blades may be sharp 1 Park the machine on a level surface 2 Tyre inflation pressure must be correct 3 Raise the mower lift lever to the top position Turn the cutting height control dial to adjust height to the desired height 4 Lower the mower deck by pushing the mower lift lever forward 5 Turn the left blade so th...

Page 318: ... outside blade tip L to the level surface Then turn the right blade so that it is parallel to rear axle Measure from outside blade tip R to the level surface 7 Adjust the bolts with the lock nut on mower stay so that the difference between measurements L and R is less than 3 mm 0 12 in 9Y1210294MOS0006US0 2 DISASSEMBLING AND ASSEMBLING Drain Gear Box Oil 1 Tilt the mower deck 2 Remove the drain pl...

Page 319: ...the proper size box or socket wrench to loosen or tighten the blade mounting bolt When reassembling Wedge a wooden block 3 between the blade 1 and the mower housing Tighten the blade bolt clockwise as shown in the picture C 9Y1210294MOS0008US0 Mower blade mounting bolt Tightening torque 98 to 117 6 N m 10 to 12 kgf m 72 3 to 86 7 lbf ft 1 Blade LH 2 Blade Bolt 3 Wooden Block A Loosen B Tighten C I...

Page 320: ...er size box or socket wrench to loosen or tighten the blade mounting bolt When reassembling Wedge a wooden block 3 between the blade 1 and the mower housing Tighten the blade bolt counterclockwise as shown in the picture C 9Y1210294MOS0015US0 Mower blade mounting bolt Tightening torque 98 to 117 6 N m 10 to 12 kgf m 72 3 to 86 7 lbf ft 1 Blade RH 2 Blade Bolt 3 Wooden Block A Loosen B Tighten C In...

Page 321: ...he share pins 4 2 Remove the pin holder 2 3 Remove the spindle guard 7 When reassembling Install the KUBOTA genuine parts for the share pins 4 9Y1210294MOS0009US0 1 Spindle Holder 2 Pin Holder 3 Blade 4 2 Share Pins 5 Cup Washer 6 Bolt 7 Spindle Guard 8 Straight Pin KiSC issued 08 2009 A ...

Page 322: ...se mounting bolts 6 4 Remove the mower gear case assembly 5 from the mower deck When reassembling 9Y1210294MOS0010US0 Blade spindle case mounting bolt to mower deck Tightening torque 48 to 56 N m 4 9 to 5 7 kgf m 35 4 to 41 3 lbf ft 1 Duct Front Cover 2 Blade Spindle Case RH 3 Universal Joint 4 Blade Spindle Case LH 5 Mower Gear case Assembly 6 Bolt KiSC issued 08 2009 A ...

Page 323: ...liquid gasket Three Bond 1208 D or its equivalent to the joint surface between the centre case and the blade spindle cases 9Y1210294MOS0011US0 Blade spindle case mounting bolt to centre case Tightening torque 48 to 56 N m 4 9 to 5 7 kgf m 35 4 to 41 3 lbf ft 1 Blade Spindle Case RH 2 Centre Case 3 Bevel gear Case 4 Blade Spindle Case LH 5 Bolt KiSC issued 08 2009 A ...

Page 324: ...pindle case When reassembling Install the gear LH to the blade shaft LH Install the gear RH to the blade shaft RH 9Y1210294MOS0012US0 1 Cir clip 2 O ring 3 Ball Bearing 4 Ball Bearing 5 Collar 6 Ball Bearing 7 Oil Seal 8 Bearing Holder 9 Cir clip 10 Stopper Collar 11 Stop Collar 12 Gear LH 13 Blade Shaft LH 14 Blade Spindle Case 15 Gear RH 16 Blade Shaft RH LH Left Blade Spindle Case RH Right Blad...

Page 325: ...e out the shims 4 from the centre case 1 When reassembling Install the shims to the centre case securely Do not damage the O ring of the bevel gear case 9Y1210294MOS0013US0 Bevel gear case mounting bolt M10 Tightening torque 48 to 56 N m 4 9 to 5 7 kgf m 35 4 to 41 3 lbf ft 1 Centre Case 2 Bevel Gear Case 3 Bolt 4 Shim KiSC issued 08 2009 A ...

Page 326: ...r component parts from the bevel gear case 8 When reassembling Do not damage the O ring Install the component parts to the original position 9Y1210294MOS0016US0 1 Oil Seal 2 Cir clip 3 Shim 4 Input Shaft 5 Ball Bearing 6 Spiral Gear 7 Ball Bearing 8 Bevel Gear Case 9 Output Shaft 10 Spiral Gear 11 Ball Bearing 12 Shim 13 Shim 14 Cir clip 15 Cap 16 Cir clip 17 Ball Bearing 18 Gear RH KiSC issued 08...

Page 327: ...ion mark with the paint as shown in the picture 5 Remove the other component parts from the centre case 6 When reassembling Do not lose the locating balls Install the locating balls to the original position securely 9Y1210294MOS0014US0 1 Ball Bearing 2 Bearing LH Gear 3 Ball Bearing 4 Bearing Shaft 5 Cir clip 6 Centre Case 7 Bearing 8 Cir clip 9 Bearing RH Gear 10 Locating Ball A Paint Mark B RCK5...

Page 328: ...ting the backlash between the spiral gear on the input shaft 3 and the spiral gear 5 on the output shaft 4 install the shims 8 9 Reference RCK45 G23 RCK54 G26 Thickness of shim 1 0 2 mm 0 0079 in 0 3 mm 0 0118 in 0 5 mm 0 0197 in Thickness of shim 6 0 2 mm 0 0079 in 0 3 mm 0 0118 in 0 5 mm 0 0197 in 9Y1210294MOS0017US0 Backlash between spiral gears Factory specification 0 10 to 0 30 mm 0 0039 to 0...

Page 329: ...8 GRASS COLLECTOR KiSC issued 08 2009 A ...

Page 330: ...IFICATIONS 8 S2 3 TIGHTENING TORQUES 8 S3 4 CHECKING DISASSEMBLING AND SERVICING 8 S4 1 CHECKING 8 S4 2 DISASSEMBLING GRASS COLLECTOR 8 S5 1 Disassembling Grass Collector LD 8 S5 2 Disassembling Grass Collector HD 8 S8 SERVICING KiSC issued 08 2009 A ...

Page 331: ...e Cause Solution Reference Page Grass Bag Control Is Not Smooth Transmission oil is low Replenish G 19 Engine Shuts Off When Engage the PTO Lever Grass collector switch defective Replace 6 S13 Fuse blown Replace G 50 Grass collector is lifted Lower the grass collector KiSC issued 08 2009 A ...

Page 332: ...3 G26 WSM 8 S2 EU 2 SERVICING SPECIFICATIONS 9Y1210294GCS0003US0 Item Factory Specification Allowable Limit Grass collector link plate Grass collector bag rear frame opens smoothly and closes tight KiSC issued 08 2009 A ...

Page 333: ... specified For general use screws bolts and nuts See page G 12 LD HD 9Y1210294GCS0004US0 Item N m kgf m lbf ft Bag frame mounting bolt and nut 4 0 to 5 0 0 4 to 0 5 3 0 to 3 7 Item N m kgf m lbf ft Hydraulic lift cylinder line 24 to 28 2 4 to 2 9 17 7 to 20 7 Dump cylinder adaptor 47 to 57 4 8 to 5 8 34 7 to 42 0 KiSC issued 08 2009 A ...

Page 334: ...collector control lever to TILT BACKWARD position 3 Check if the grass collector rear cover 7 opens smoothly 4 Set the grass collector control lever to TILT FORWARD position 5 Check if the grass collector rear cover 7 closes securely and no clearance between the grass collector rear cover 7 and the grass collector bag connector comp 6 Tighten the bolt 1 securely 9Y1210294GCS0001US0 Grass collector...

Page 335: ... Turn the lock lever 2 to outside of the machine 3 Slide the bag pins 4 into the hook 3 4 Pull and turn the both L pins 1 5 Tilt the grass collector forward and them lock the both L pins 1 When mounting Shut off the engine Move the grass collector control lever several times Reverse the above dismounting procedure 9Y1210294GCS0005US0 1 L Pin 2 Lock Lever 3 Hook 4 Bag Pin A PULL B TURN KiSC issued ...

Page 336: ...ve the rear plate 10 and the front plate 11 6 Remove the bag net 8 not to damage When reassembling Hook the bag net to the bag frame referring the picture 9Y1210294GCS0006US0 1 Front Cover LH 2 Rear Cover RH 3 Rear Centre Cover 4 Rear Cover LH 5 Rear Handle 6 Front Cover RH 7 Rear Centre Cover 8 Bag Net 9 Hinge Lever Pin 10 Rear Plate 11 Front Plate 12 Bag Frame A Bag hook point KiSC issued 08 200...

Page 337: ...the nut 2 and the lock collars 4 5 When reassembling Install the parts to the original position 9Y1210294GCS0007US0 Tightening torque Bag frame mounting bolt and nut 4 0 to 5 0 N m 0 4 to 0 5 kgf m 3 0 to 3 7 lbf ft 1 Bag Frame 2 Nut 3 Plain Washer 4 Lock Collar 5 Lock Collar 6 Bolt KiSC issued 08 2009 A ...

Page 338: ... Grass Collector HD Grass Collector Covers 1 Remove the rear covers 1 3 2 Remove the front covers 3 Remove the rear cover 2 4 Remove the cover 4 9Y1210294GCS0008US0 1 Rear Cover LH 2 Rear Cover 3 Rear Cover RH 4 Cover 5 Front Cover KiSC issued 08 2009 A ...

Page 339: ...nylon sling 2 4 Disconnect the lift arm joint 6 5 Remove the lift upper arms 4 the lift lower arm 5 and the upper base LH 3 When reassembling 9Y1210294GCS0009US0 Tightening torque Hydraulic lift cylinder line 24 to 28 N m 2 4 to 2 9 kgf m 17 7 to 20 7 lbf ft 1 Lift Cylinder 2 Nylon Sling 3 Upper Base LH 4 Lift Upper Arm LH 5 Lift Lower Arm LH 6 Lift Arm Joint 7 Wooden Block KiSC issued 08 2009 A ...

Page 340: ...remove the rear arm 5 and the link plate 4 When reassembling Grass collector bag rear frame opening check is needed Tighten the link upper plate mounting bolts in proper position 9Y1210294GCS0010US0 1 Lift Upper Arm LH 2 Lift Lower Arm LH 3 Upper Base LH 4 Link Plate 5 Rear Arm 6 Link Upper Plate 7 Bolt KiSC issued 08 2009 A ...

Page 341: ...te 8 5 Remove the frame 10 6 Remove the rear arm 11 and the link plate 12 When reassembling Grass collector bag rear frame opening check is needed Tighten the link upper plate mounting bolts in the proper position 9Y1210294GCS0011US0 1 Lift Upper Arm RH 2 Lift Lower Arm RH 3 Lift Arm Joint 4 Lift Arm Joint 5 Lift Cylinder 6 Upper Base RH 7 Nylon Sling 8 Sensor Plate 9 Spring Plate 10 Frame 11 Rear...

Page 342: ...Remove the dump cylinder 5 from the bottom plate 6 When reassembling Connect the hydraulic hoses to the dump cylinder 9Y1210294GCS0012US0 Tightening torque Dump cylinder adaptor 47 to 57 N m 4 8 to 5 8 kgf m 34 7 to 42 0 lbf ft 1 Bag RH Frame 2 Rear Frame 3 Bag Front Frame 4 Bag LH Frame 5 Dump Cylinder 6 Bottom Plate KiSC issued 08 2009 A ...

Page 343: ...ode No 9Y111 02940 2009 05 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 72 245 2484 E mail ksos pub kubota co jp ...

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