Kubota GR1600EC2 Workshop Manual Download

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G-38

GR1600EC2, WSM

G GENERAL

8. SPECIAL TOOLS

[1] SPECIAL TOOLS FOR ENGINE

Special Use Puller Set

Code No.:

07916-09032

Application: Use exclusively for pulling out bearing, gears and other

parts with ease.

W1024050

Piston Ring Compressor

Code No.:

07909-32111

Application: Use exclusively for pushing in the piston with piston

rings into the cylinder.

W1024100

Piston Ring Tool

Code No.:

07909-32121

Application: Use exclusively for removing or installing the piston ring

with ease.

W1024150

Diesel Engine Compression Tester

Code No.:

07909-30208 (Assembly)

07909-31251 (G)

07909-30934 (A to F)

07909-31271 (I)

07909-31211 (E and F)

07909-31281 (J)

07909-31231 (H)

Application: Use to measure diesel engine compression and

diagnostics of need for major overhaul.

W1024200

(1) Gauge
(2) L Joint
(3) Adaptor A
(4) Adaptor B
(5) Adaptor C
(6) Adaptor E

(7) Adaptor F
(8) Adaptor G
(9) Adaptor H

(10) Adaptor I

(11) Adaptor J

KiSC issued 07, 2006 A

Summary of Contents for GR1600EC2

Page 1: ...GR1600EC2 WORKSHOP MANUAL KiSC issued 07 2006 A...

Page 2: ...ith troubleshooting disassembling and servicing Servicing Information on the troubleshooting servicing specification lists tightening torque checking and adjusting disassembling and assembling and ser...

Page 3: ...ual and on labels on the machine itself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the instructions and safety regulations before you...

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

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

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

Page 7: ...5 GR1600EC2 WSM SAFETY INSTRUCTIONS KiSC issued 07 2006 A...

Page 8: ...6 GR1600EC2 WSM SAFETY INSTRUCTIONS KiSC issued 07 2006 A...

Page 9: ...sel fuel No 1 D below 10 C 14 F Capacities Fuel tank 18 L 4 8 U S gals 4 0 lmp gals Engine crankcase with filter 1 2 L 1 27 U S qts 1 06 lmp qts Engine coolant with recovery tank 2 15 L 2 27 U S qts 1...

Page 10: ...mm 1 to 4 in Adjustment of cutting height Dual gauge Mounting method Quick joint Parallel linkage Weight Approx 75 kg 165 lbs Dimensions Total length 965 mm 38 0 in Total width 1110 mm 43 7 in Total...

Page 11: ...9 GR1600EC2 WSM DIMENSIONS DIMENSIONS KiSC issued 07 2006 A...

Page 12: ...G GENERAL KiSC issued 07 2006 A...

Page 13: ...THREADS G 10 4 PLUGS G 10 6 MAINTENANCE CHECK LIST G 11 7 CHECK AND MAINTENANCE G 13 1 DAILY CHECK G 13 2 CHECK POINTS OF EVERY 50 HOURS G 19 3 CHECK POINTS OF EVERY 100 HOURS G 26 4 CHECK POINT OF EV...

Page 14: ...cting your local KUBOTA distributor always specify engine serial number 2 machine serial number 1 mower serial number 3 and hour meter reading W1010594 1 Machine Serial Number 2 Engine Serial Number 3...

Page 15: ...y KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety Gaskets and O rings must be replaced during reassembly Apply grease to new O rings or oil seals before...

Page 16: ...form periodic check for a fee Do not attempt to modify or remodel any electrical parts and wiring When removing the battery cables disconnect the negative cable first When installing the battery cable...

Page 17: ...sag be required W10115870 In installing a part take care not to get wiring caught by it W10116700 After installing wiring check protection of terminals and clamped condition of wiring only connect bat...

Page 18: ...your skin and clothes If contaminated wash it off with water immediately Before recharging the battery remove it from the machine Before recharging remove cell caps Do recharging in a well ventilated...

Page 19: ...terminal Make certain there is no terminal being exposed or displaced W10123460 Make certain that there is no female connector being too open W10124300 Make certain plastic cover is large enough to co...

Page 20: ...G 7 GR1600EC2 WSM G GENERAL 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provided with tester Check for polarity and range W10126840 KiSC issued 07 2006 A...

Page 21: ...bove 25 C 77 F SAE30 10W 30 or 10W 40 4 Transmission case 2 7 L 0 71 U S gals 0 59 lmp gals KUBOTA UDT or SUPER UDT fluid 5 Mower gear box 0 33 L 0 35 U S qts 0 29 lmp qts SAE90 gear oil API service c...

Page 22: ...to 41 2 39 3 to 44 1 4 0 to 4 5 29 0 to 32 5 60 9 to 70 6 6 2 to 7 2 44 9 to 52 0 M12 12 mm 0 47 in 62 8 to 72 5 6 4 to 7 4 46 3 to 53 5 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 62 8 to 72 5 6 4 to 7 4 46...

Page 23: ...o 260 4 22 14 to 26 57 160 0 to 192 0 5 8 203 4 to 244 1 20 75 to 24 91 150 0 to 180 0 298 3 to 358 0 30 44 to 36 53 220 0 to 264 0 Shape Size Material of opponent part Ordinariness Aluminum N m kgf m...

Page 24: ...lace every 200 hr G 28 3 Transmission fluid Change every 200 hr G 29 4 Transmission oil filter Replace every 200 hr G 30 5 Transmission strainer Clean every 200 hr G 30 6 Front axle pivot Adjust every...

Page 25: ...mp Check every 200 hr G 30 Replace every 2 year G 34 18 Intake air line Check every 200 hr G 31 Replace every 2 year G 34 19 Fuel injection nozzle Injection pressure Check every 1500 hr G 32 20 Radiat...

Page 26: ...f machine body tightness of all bolts and nuts 7 Radiator screen 8 Panel screen 9 Brake play 10 Fuel level 11 Check air cleaner element Mower 1 Oil leak 2 Make sure blade cap screws are tight 3 Blades...

Page 27: ...ean reinsert it and draw it out again Check to see that the oil level is between the two notches 4 Add new oil to the prescribed level at the oil inlet 1 if necessary 5 When using a different brand or...

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

Page 29: ...and clean inside completely After cleaning reinstall the radiator screen 2 properly NOTE When assembling the panel screen 1 be sure to fit it to panel with no clearance at the bottom W1049374 Checking...

Page 30: ...he coolant level daily both the radiator and the recovery tank 4 before starting engine 1 Remove the radiator cap 1 and check to see that the coolant level is just below the fill port 2 Check to see t...

Page 31: ...2 WSM G GENERAL Greasing CAUTION Be sure to stop the engine and remove the key before greasing W1052201 1 Spindle Shaft 2 Tension Arm 3 Mower Universal Joint Apply grease on the spline shaft KiSC issu...

Page 32: ...1 1 Run the engine at half throttle 2 Engage the PTO lever 4 3 Stand up Do not get off the machine 4 Engine should shut off Seat Safety Control 2 1 Run the engine at half throttle 2 Disengage the PTO...

Page 33: ...il Level CAUTION Always stop the engine and remove the key before checking oil 1 Park the machine on a flat surface and lower the mower to the ground To check the oil level loosen filler plug 1 bolt a...

Page 34: ...he following location as shown in the figures CAUTION Be sure to stop the engine and remove the key before oiling W1053979 1 Mower Universal Joint 2 Speed Control Shaft RH 3 Speed Control Shaft LH 4 S...

Page 35: ...shown in the figures CAUTION Be sure to stop the engine and remove the key before oiling W1055120 1 Around Hole of Mower Link 2 Around Pin 3 Pivot of Mower Link 4 Pivot of Lift Arm 5 Front Link 6 Top...

Page 36: ...ling Continued 1 Apply oil to the following location as shown in the figures CAUTION Be sure to stop the engine and remove the key before oiling W1043771 1 Quick Clean Lever 2 PTO Lever Fulcrum 3 Link...

Page 37: ...at the fluid level is between the UPPER and LOWER levels CAUTION Never remove the vent plugs while the engine is running Keep electrolyte away from eyes hands and clothes If you are spattered with it...

Page 38: ...ary 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...

Page 39: ...ery three months in hot seasons and once every six months in cold seasons W1056798 3 CHECK POINTS OF EVERY 100 HOURS Changing Engine Oil CAUTION Be sure to stop the engine and remove the key before ch...

Page 40: ...he fuel line is disconnected for maintenance or repair close both ends of the fuel line with a piece of clean cloth or paper to prevent dust and dirt from entering In addition particular care must be...

Page 41: ...EVERY 200 HOURS Replacing Engine Oil Filter Cartridge CAUTION Be sure to stop the engine and remove the key before changing the oil filter cartridge Allow engine to cool down sufficiently oil can be h...

Page 42: ...ydrostatic transmission fluid or its equivalent 3 Remove the oil plug and fill with the new oil 4 After running the engine for a few minutes stop it and check the oil level again add oil to the prescr...

Page 43: ...the screw 2 by using a screwdriver 5 Apply a slight coat of oil onto the cartridge gasket 6 Tighten the filter quickly until it contacts the mounting surface Tighten filter by hand an additional 1 2...

Page 44: ...worn or damaged replace or repair them at once W1049152 6 CHECK POINT OF EVERY 400 HOURS Replacing Fuel Filter 1 Disconnect the fuel hoses and loosen the filter band to replace the fuel filter 3 NOTE...

Page 45: ...cooling system cleaner 5 Follow directions of the cleaner instruction 6 After flushing fill with clean water and anti freeze until the coolant level is just below the fill port on the radiator Instal...

Page 46: ...he relevant environmental protection regulations when disposing of anti freeze If it freezes coolant can damage the cylinders and radiator If the ambient temperature falls below 0 C or before a long t...

Page 47: ...ota s genuine long life coolant has a service life of 2 years Be sure to change the coolant every 2 years NOTE The above data represent industry standards that necessitate a minimum glycol content in...

Page 48: ...b from the socket 4 Install new bulb to the socket 5 Install the socket in housing 6 Close the hood B Replacement of the indicator light bulb 1 Open the hood 2 Turn bad bulb socket to the left And rem...

Page 49: ...loosen The blade bolt 2 has left hand threads turn clockwise to loosen NOTE Use the proper size box or socket wrench to tighten or loosen the blade mounting bolt 4 To sharpen the blades yourself clam...

Page 50: ...elt reverse the above procedure W1073387 Bleeding Fuel System Air must be removed 1 When the fuel filter or lines are removed 2 When tank is completely empty 3 After the machine has not been used for...

Page 51: ...24100 Piston Ring Tool Code No 07909 32121 Application Use exclusively for removing or installing the piston ring with ease W1024150 Diesel Engine Compression Tester Code No 07909 30208 Assembly 07909...

Page 52: ...26 in 38 0 mm 1 496 in 31 6 mm 1 244 in 41 3 mm 1 626 in 35 0 mm 1 378 in 50 8 mm 2 000 in W1024458 Radiator Tester Code No 07909 31551 Application Use to check of radiator cap pressure and leaks from...

Page 53: ...psi W1024653 Plastigage Code No 07909 30241 Application Use to check the oil clearance between crankshaft and bearing etc Measuring Green 0 025 to 0 076 mm 0 001 to 0 003 in range Red 0 051 to 0 152 m...

Page 54: ...in dia M 8 mm 0 31 in N 4 mm 0 16 in O 11 97 to 11 99 mm dia 0 4713 to 0 4721 in dia P PF1 2 Q 23 mm 0 91 in R 17 mm 0 67 in S 4 mm 0 16 in T 12 00 to 12 02 mm dia 0 4724 to 0 4732 in dia U 100 mm 3 9...

Page 55: ...5 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 Chamfer 0 3 mm 0 012 in a 6 3 m 250 in b 6 3 m 250 in A 150 mm 5 91 in B 20 mm 0 79...

Page 56: ...s 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 39 90 to 39 95 mm dia 1 5709 to 1 5728 in dia 1 Gauge 07916 50322 2 Cable 07916 50331 3 Threaded Joint...

Page 57: ...30 to 0 31 in G 2 3 mm 0 09055 in H 2 0 to 2 2 mm 0 079 to 0 087 in I 15 0 26 rad J M8 K 3 mm dia drill 0 12 in dia drill L Rc1 16 M 120 2 09 rad N 11 8 to 11 9 mm 0 465 to 0 469 in O 12 2 mm 0 480 i...

Page 58: ...to 17 8 mm dia 0 693 to 0 701 in dia L 30 0 52 rad M 9 16 18UNF N M8 O 1 5 mm 0 059 in P 10 3 to 10 5 mm 0 4055 to 0 4134 in Q 120 2 09 rad C1 Chamfer 1 mm 0 039 in C0 2 Chamfer 0 2 mm 0 008 in R0 4...

Page 59: ...l it naturally drops slowly in the course of time Thus check it everyday and inflate as necessary 2 TREAD The tread can not be adjusted IMPORTANT Do not turn discs to obtain wider tread Always attach...

Page 60: ...ications listed below or which are otherwise unfit 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 A...

Page 61: ...1 ENGINE KiSC issued 07 2006 A...

Page 62: ...CONTENTS MECHANISM 1 ENGINE BODY 1 M1 1 HALF FLOATING HEAD COVER 1 M1 2 CLOSED BREATHER 1 M1 2 LUBRICATING SYSTEM 1 M2 3 COOLING SYSTEM 1 M3 4 FUEL SYSTEM 1 M4 1 FUEL LINE 1 M4 KiSC issued 07 2006 A...

Page 63: ...W1013433 2 CLOSED BREATHER Closed breather system has been adopted to prevent the release of blowby gas into the atmosphere After its oil content is filtered by oil shield 4 the blowby gas is fed back...

Page 64: ...crankshaft 6 connecting rods 14 idle gear 5 camshaft 12 and rocker arm shaft 3 to lubricate each part Some part of oil splashed by the crankshaft or leaking and dropping from gaps of each part lubric...

Page 65: ...ing The water pump receives water from the radiator or from the cylinder head and force it into the cylinder block The thermostat opens or closes according to the water temperature When the water temp...

Page 66: ...71 MPa 140 to 150 kgf cm2 1990 to 2133 psi of the injection nozzle 1 is injected into the combustion chamber Part of the fuel fed to the injection nozzle 1 lubricates the moving parts of the needle va...

Page 67: ...2 PREPARATION 1 S18 1 Separation Engine 1 S18 3 DISASSEMBLING AND ASSEMBLING 1 S21 1 Cylinder Head and Valves 1 S21 2 Timing Gear Camshaft and Fuel Camshaft 1 S24 3 Piston and Connecting Rod 1 S28 4 C...

Page 68: ...ning nut 1 S21 Incorrect injection timing Adjust 1 S15 Fuel camshaft worn Replace Injection nozzle clogged Repair or replace 1 S34 Injection pump malfunctioning Replace 1 S24 Seizure of crankshaft cam...

Page 69: ...fuel used Use specified fuel G 8 Fuel filter clogged Replace G 31 Air cleaner clogged Clean or replace G 20 Deficient nozzle injection Repair or replace nozzle 1 S34 Deficient Output Incorrect inject...

Page 70: ...logged Clean Different type of oil Use specified type of oil G 8 Oil pump defective Repair or replace 1 S27 High Oil Pressure Different type of oil Use specified type of oil G 8 Relief valve defective...

Page 71: ...learance 0 030 to 0 057 mm 0 00118 to 0 00224 in 0 10 mm 0 0039 in Valve Stem O D 5 968 to 5 980 mm 0 23496 to 0 23543 in Valve Guide I D 6 010 to 6 025 mm 0 23661 to 0 23720 in Valve Seat Width 2 12...

Page 72: ...0161 to 0 00484 in 0 15 mm 0 0059 in Idle Gear Side Clearance 0 20 to 0 51 mm 0 0079 to 0 0201 in 0 80 mm 0 0315 in Camshaft Side Clearance 0 15 to 0 31 mm 0 0059 to 0 0122 in 0 50 mm 0 0197 in Alignm...

Page 73: ...00453 in 0 15 mm 0 0059 in Oil Ring Clearance 0 02 to 0 06 mm 0 0008 to 0 0024 in 0 15 mm 0 0059 in Connecting Rod Alignment 0 05 mm 0 0020 in Crankshaft Side Clearance 0 15 to 0 31 mm 0 0059 to 0 01...

Page 74: ...o 1 57583 in Cylinder Liner I D 67 000 to 67 019 mm 2 63779 to 2 63854 in 67 169 mm 2 6445 in Cylinder Liner Oversize I D 67 250 to 67 269 mm 2 64764 to 2 64839 in 67 419 mm 2 65429 in Engine Oil Pres...

Page 75: ...9 psi Radiator Water Leakage Test Pressure No leak at specified pressure 157 kPa 1 6 kgf cm2 23 psi Injection Pump Injection Timing 0 31 to 0 33 rad 18 to 20 before T D C Pump Element Fuel Tightness...

Page 76: ...5 7 35 4 to 41 2 Cylinder head cover screw M6 x 1 0 6 86 to 11 3 0 7 to 1 15 5 1 to 8 3 Injection pipe retaining nut M12 x 1 5 24 5 to 34 3 2 5 to 3 5 18 1 to 25 3 Overflow pipe retaining nut M12 x 1...

Page 77: ...for each cylinder 10 If the measurement is below the allowable limit apply a small amount of oil to the cylinder wall through the nozzle hole and measure the compression pressure again 11 If the comp...

Page 78: ...to the specified torque 4 Turn the flywheel until the piston exceeds its top dead center 5 Remove the cylinder head and measure the thickness of the squeezed fuses 6 If the measurement is not within t...

Page 79: ...e 1TC mark 2 on the flywheel and alignment mark 3 on the rear end plate so that the No 1 piston comes to the overlap position 6 Check the following valve clearance marked with using a thickness gauge...

Page 80: ...pressure switch to the specified torque W10349520 3 Cooling System Checking Fan Drive Belt Tension CAUTION Be sure to stop the engine and remove the key before checking belt tension 1 Measure the defl...

Page 81: ...mostat W1034560 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 Radiator Cap Air L...

Page 82: ...d with the alignment mark 2 6 If the injection timing is out of adjustment readjust the timing with shims NOTE The sealant is applied to both sides of the shims soft metal gasket shim The liquid gaske...

Page 83: ...e 6 Stop the starter when the fuel jets from the injection nozzle After that turn the flywheel by hand and raise the pressure to approx 13 73 MPa 140 kgf cm2 1991 psi 7 Now turn the flywheel back abou...

Page 84: ...ive replace the nozzle piece W10181310 Fuel Injection Pressure 1 Set the injection nozzle to a nozzle tester Code No 07909 31361 2 Slowly move the tester handle to measure the pressure at which fuel b...

Page 85: ...iator cap while operating or immediately after stopping Otherwise hot water will spout out from the radiator Wait for more than ten minutes to cool the radiator before opening the cap 1 Open the radia...

Page 86: ...disconnect the negative cable from the battery first When connecting connect the positive cable to the battery first 1 Open the bonnet 2 Disconnect the negative cable 1 from the battery 3 Disconnect t...

Page 87: ...taining snap pins 1 2 Disconnect the front coupling 2 3 Separate the engine assembly 3 with radiator from the frame 4 When reassembling W1043585 1 Air Cleaner 2 Muffler 3 Fuel Hose 4 Accelerator Wire...

Page 88: ...er 2 When reassembling Check to see if the cylinder head cover gasket is not defective W1044581 Injection Pipes 1 Loosen the screw on the pipe clamp 1 2 Detach the injection pipes 2 When reassembling...

Page 89: ...rods 3 onto the tappets 4 check to see if their ends are properly engaged with the dimples IMPORTANT After installing the rocker arm be sure to adjust the valve clearance W1045710 Tightening torque Ov...

Page 90: ...If defect is found replace tappets Before installing the tappets apply engine oil thinly around them IMPORTANT Do not change the combination of tappet and tappet guide W10209700 Valves 1 Remove the va...

Page 91: ...on the fork lever as shown in the figure NOTE The sealant is applied to both sides of the soft metal gasket shim The liquid gasket is not required for assembling Addition or reduction of shim 0 05 mm...

Page 92: ...pring 2 from the fork lever 1 3 Remove the gear case 3 When reassembling Apply a liquid gasket Three Bond 1215 or equivalent to both sides of the gear case gasket 4 Be sure to set three O rings 5 insi...

Page 93: ...o W1030437 Camshaft 1 Remove the camshaft mounting screws 1 and draw out the camshaft with gear 2 on it When reassembling When install the camshaft apply engine oil to the camshaft journals Apply engi...

Page 94: ...20 Oil Pump and Crankshaft Gear 1 Remove the oil pump gear 6 2 Remove the oil pump 5 3 Remove the collar 4 O ring 3 and crankshaft oil slinger 2 4 Remove the crankshaft gear 1 When reassembling Instal...

Page 95: ...r of the flange as well as on the inner wall of each bolt hole Cut the nozzle of the liquid gasket Three Bond 1207D or equivalent container at its second notch Apply liquid gasket about 5 mm 0 20 in t...

Page 96: ...the connecting rod to the injection pump IMPORTANT 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 i...

Page 97: ...e of the oil ring gap 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...

Page 98: ...6 When reassembling Fit the bearing 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 a on it upward Apply engi...

Page 99: ...assage of the crankshaft with compressed air Apply oil to the main bearing case screw 2 1 Install the crankshaft assembly aligning the screw hole of main bearing case with the screw hole of crankcase...

Page 100: ...the figure Match the alignment numbers a on the main bearing case assembly 1 Do the same for the main bearing case assembly 3 too When installing the main bearing case 1 face the mark FLYWHEEL to the...

Page 101: ...t to the both sides of gasket Replace the mechanical seal with new one W1058081 6 Injection Nozzle Nozzle Holder 1 Secure the nozzle retaining nut 7 with a vise 2 Remove the nozzle holder 1 and take o...

Page 102: ...r spraying 4 Wash away the read permeative liquid on the cylinder head surface with the detergent 2 5 Spray the cylinder head surface with white developer 3 6 If flawed it can be identified as red mar...

Page 103: ...lling 1 Clean a new valve guide and valve guide bore and apply engine oil to them 2 Press in a new valve guide using a valve guide replacing tool 3 Ream precisely the I D of the valve guide to the spe...

Page 104: ...alve check the contact position of the valve face and seat surface with prussian blue Visual check If the valve has been used for a long period the seat tends to come in contact with the upper side of...

Page 105: ...lve spring on a surface plate place a square on the side of the valve spring 3 Check to see if the entire side is in contact with the square Rotate the valve spring and measure the maximum tilt B If t...

Page 106: ...ith an outside micrometer 2 Measure the I D of the tappet guide bore with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged r...

Page 107: ...clearance by moving the cam gear to the font and rear 3 If the measurement exceeds the allowable limit replace the camshaft stopper W11299720 Backlash between idle gear and crank gear Factory spec 0 0...

Page 108: ...asure the camshaft journal O D with an outside micrometer 2 Measure the cylinder block bore I D for camshaft with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the al...

Page 109: ...ess in a new brushing using an idle gear bushing replacing tool until it is flush with the end of the idle gear W11373220 3 Piston and Connecting Rod Piston Pin Bore I D 1 Measure the piston pin bore...

Page 110: ...1 of bushing positions as shown in the figure until it is flush with the connecting rod 3 Drill a hole to the bushing with aligning the oil hole 2 of connecting rod Refer to the figure NOTE Be sure t...

Page 111: ...l the connecting rod on the connecting rod alignment tool Code No 07909 31661 4 Put a gauge over the piston pin and move it against the face plate 5 If the gauge does not fit squarely against the face...

Page 112: ...crankshaft alignment 4 If the measurement exceeds the allowable limit replace the crankshaft W11613530 Crankshaft side clearance Factory spec 0 15 to 0 31 mm 0 0059 to 0 0122 in Allowable limit 0 50 m...

Page 113: ...size dimensions of crankpin W11625390 Oil clearance between crankpin and crankpin bearing Factory spec 0 020 to 0 051mm 0 00079 to 0 00201 in Allowable limit 0 15 mm 0 0059 in Crankpin O D Factory spe...

Page 114: ...ing tool press in a new bearing 1 2 so that its seam 1 directs toward the exhaust manifold side See figure W10342000 Oil Clearance between crankshaft journal and crankshaft bearing 1 Factory spec 0 03...

Page 115: ...l O D Flywheel side Factory spec 43 934 to 43 950 mm 1 72968 to 1 73031 in Crankshaft bearing 2 I D Factory spec 43 984 to 44 026 mm 1 73165 to 1 73331 in Crankshaft journal O D Intermediate Factory s...

Page 116: ...he allowable limit replace the cylinder block with a new one W10367470 6 Oil Pump Rotor Lobe Clearance 1 Measure the clearance between lobes of the inner rotor and the outer rotor with a thickness gau...

Page 117: ...astigage Code No 07909 30241 onto the rotor face with grease 2 Install the cover and tighten the screws 3 Remove the cover carefully and measure the amount of the flattening with the scale and get the...

Page 118: ...2 TRANSAXLE KiSC issued 07 2006 A...

Page 119: ...TRAVELLING SYSTEM 2 M2 1 HYDRAULIC TRANSMISSION 2 M2 1 Structure 2 M2 2 Oil Flow 2 M3 3 Operation 2 M4 4 Charge Pump 2 M7 5 By pass Valve 2 M7 6 Control Linkage 2 M8 2 MOWER PTO SYSTEM 2 M9 1 Mower P...

Page 120: ...2 M1 GR1600EC2 WSM TRANSAXLE 1 STRUCTURE 1 Hydraulic Transmission Section 2 Mower PTO Section 3 Differential Gear Section 4 Rear Axle Section KiSC issued 07 2006 A...

Page 121: ...in HST via a link mechanism the speed change pedal permits simple operation of this machine starting stopping and accelerating or decelerating 1 Check Valve 2 Trunnion Arm 3 Charge Relief Valve 4 Char...

Page 122: ...en the oil passed through the filter cartridge 4 is routed to HST as charge oil by the charge pump 2 and charge relief valve 10 Overflow oil from the HST housing flows back to the transaxle 1 Pump 2 C...

Page 123: ...the pump cylinder block 1 without reciprocating motion At this time since the pump pistons do not generate pressure no pressure is transmitted to the motor pistons thus causing neither rotation of th...

Page 124: ...Pressure from the port D thrusts the motor pistons to the surface of the inclined thrust ball bearing causing them to slide on the inclined surface This causes the motor cylinder block 4 and the moto...

Page 125: ...otor pistons Port A Port C Pressure from the port C thrusts the motor pistons to the surface of the inclined thrust ball bearing causing them to slide on the inclined surface This causes the motor cyl...

Page 126: ...uman power while the engine is stopped The following paragraphs describe this mechanism Pressing the by pass valve connects the forward and reverse loops in the center section This allows oil to flow...

Page 127: ...d the swashplate rotates and forward travelling speed increases Depressing the rear end increases reverse speed The speed control arm 6 is returned to neutral position by the neutral arm 4 and the ten...

Page 128: ...ws driving power to be transmitted as follows 19T 2 Gear 7 24T Gear 6 Clutch Case 5 Spline Boss 3 PTO Shaft 1 W12345678 PTO Disengaged When the PTO lever is set at the Disengaged position the clutch l...

Page 129: ...EKING DISASSEMBLING AND SERVICING 2 S6 1 CHECKING AND ADJUSTING 2 S6 2 PREPARATION 2 S9 1 Separating Transaxle 2 S9 3 DISASSEMBLING AND ASSEMBLING 2 S16 1 Hydrostatic Transmission 2 S16 2 Transaxle Ca...

Page 130: ...alve defective Replace check valve 2 S19 By pass valve defective Replace by pass valve 2 S19 HST component parts defective Replace HST assembly 2 S17 20 Vibration and Noise Oil level is low Fill oil t...

Page 131: ...onent parts defective Replace HST assembly 2 S17 20 Oil Heat Over Oil level is low Fill oil to proper level G 8 2 S11 Excessive machine load Reduce machine load Charge pressure is too low Oil filter c...

Page 132: ...uid used Replenish or change G 8 2 S11 Noise while Turning Differential pinions or differential side gears worn or damaged Replace 2 S28 Bearing worn Replace PTO Clutch Slip Improper length of PTO rod...

Page 133: ...tion Plate 2 Thickness 0 95 to 1 05 mm 0 037 to 0 041 in 0 80 mm 0 031 in Differential Case to Differential Side Gear Clearance 0 040 to 0 082 mm 0 0016 to 0 0032 in 0 17 mm 0 0067 in Differential Cas...

Page 134: ...to 5 7 35 5 to 41 2 Hydrostatic transmission mounting screw 23 5 to 27 5 2 4 to 2 8 17 3 to 20 3 Hydrostatic transmission mounting screw 2 17 7 to 20 6 1 8 to 2 1 13 1 to 15 2 Center section mounting...

Page 135: ...nd B and tighten the holder shaft mounting screw 3 firmly This means the hydrostatic transaxle is fully in neutral Position C WARNING Use buddy system in adjusting the neutral position One of you shou...

Page 136: ...A with the adjusting screw 1 Reference Length A 10 to 12 mm 0 40 to 0 47 in Traveling speed 9 0 to 10 0 km h 5 6 to 6 2 mph Reverse 1 Loose the lock nut 3 of adjusting screw 2 Adjust the length B wit...

Page 137: ...rotating the adaptor 1 6 counterclockwise seen from underneath so that the pressure gauge adaptor can be installed on the port 11 However do not rotate the adapter 1 6 more than one rotation 5 Install...

Page 138: ...r 4 dismount the grass container 4 When remounting Open the top cover 1 Place the grass container lift lever 3 on the frame lock plate 6 While lifting the rear end of the grass container 4 hook the gr...

Page 139: ...itch 4 3 Remove the discharge duct 2 W1012965 Container Base 1 Disconnect the couplers 1 from the relays 2 2 Disconnect the connector 4 3 Remove the container base 3 W1013019 1 Filter Cover 2 Discharg...

Page 140: ...ing the transmission oil Keeping the engine at medium speed for a few minutes to prevents damage to the transmission Do not mix different bland oil together W1043955 Battery CAUTION When disconnecting...

Page 141: ...base mounting screw 1 1 2 Remove the seat base mounting screws 2 3 3 Slide the seat base 2 and remove it W1013823 Fuel Tank 1 Drain the fuel 2 Disconnect the fuel hoses 3 Remove the fuel tank 1 W10139...

Page 142: ...ver at Engaged position and then be sure to tighten two nuts 2 3 on the lower side of PTO rod 1 so that the spring length L2 reaches the specified value When reassembling IMPORTANT After completing ab...

Page 143: ...ashers 4 and brake spring 5 3 Remove the brake plate 7 4 Remove the brake rod 2 6 and brake rod 1 2 when reassembling IMPORTANT After assembling the brake rod 1 2 2 6 and brake spring 5 be sure to adj...

Page 144: ...up the frame 4 Remove the retaining ring 3 and remove the rear wheel 4 When reassembling Apply grease to the splines of the universal joint W1016017 Separating Transmission 1 Remove the transaxle moun...

Page 145: ...the breather hoses 4 5 Remove the suction pipe 1 2 5 7 and hose 6 6 Remove the suction filter case 8 W1017008 Neutral Arm Holder and Filter Bracket 1 Remove the neutral arm holder 2 with neutral arm 1...

Page 146: ...ission assembly insert the drain pipe 3 in the hole 2 surely so as not to drop out it W1017663 1 Brake Assembly 2 External Snap Ring 3 Brake Drum Tightening torque Hydrostatic transmission mounting sc...

Page 147: ...the internal snap ring 2 and the oil seal 3 NOTE When removing the oil seal 3 take care not to damage the charge pump housing 1 Take care not to damage the O ring 4 W1018141 Gerotor 1 Remove the gero...

Page 148: ...e O rings 2 7 on the plugs 1 8 W1019295 Cylinder Block Assembly and Thrust Ball Bearing 1 Remove the cylinder block assembly pump side 1 spring 2 and washer 3 2 Remove the cylinder block assembly moto...

Page 149: ...ng When reassembling Apply clean transmission oil to thrust ball bearing 1 W1019980 Cradle Bearing Slot Guide and Trunnion Arm 1 Remove the slot guide 2 and trunnion arm 3 2 Remove the cradle bearings...

Page 150: ...hoses 4 5 Remove the suction pipe 1 2 5 7 and hose 6 6 Remove the suction filter case 8 Neutral Arm Holder and Filter Bracket 1 Remove the neutral arm holder 2 with neutral arm 1 2 Remove the filter...

Page 151: ...ission assembly insert the drain pipe 3 in the hole 2 surely so as not to drop out it 1 Brake Assembly 2 External Snap Ring 3 Brake Drum Tightening torque Hydrostatic transmission mounting screw 23 5...

Page 152: ...reassembling Install the ball bearing 2 with the sealed face inside Align the tangs 4 of PTO brake friction plate with the slots 3 of transaxle case W1022814 Tightening torque PTO clutch assembly moun...

Page 153: ...utch disc and friction plate 14 from the spline boss When reassembling IMPORTANT Do not change the arrangement of brake discs 6 8 and brake friction plates 5 7 NOTE Thickness of the brake friction pla...

Page 154: ...al snap ring pliers 3 Remove the thrust collar 2 from PTO shaft 1 4 Remove the ball bearing 6 and oil seal 7 from the PTO clutch cover 5 W1023968 Beam 1 Remove the beam 1 from the transaxle case When...

Page 155: ...direction shown in figure Tighten all screws by your hand Then tighten the screws located at the circled positions first with tightening torques Next tighten the remaining screws with tightening torq...

Page 156: ...ing portion by 180 degrees W1025227 Rear Differential Gear Drive Shaft and 11T Gear Shaft RH LH 1 Remove the rear differential gear assembly 2 11T gear shafts 1 6 and drive shaft 5 2 Remove the extern...

Page 157: ...Bond 1901 or equivalent to the inner circumferential surface of differential pinion gears 5 differential side gears 3 7 and shims 4 W1025887 Rear Axle 1 Remove the rear axle 1 2 Remove the oil seal 2...

Page 158: ...found replace the hydrostatic transmission assembly W1026940 Check Valve 1 Check the ball check 5 and check valve 4 for scratches and damage 2 Check the springs 3 6 for breakage and wear 3 If anything...

Page 159: ...s between pump and motor cylinder block Pistons and cylinder blocks are matched W1028175 Thrust Ball Bearing 1 Check the thrust ball bearing 1 for scratches and excessive wear 2 If the thrust ball bea...

Page 160: ...h vernier calipers 2 If the thickness is less than the allowable limit replace it W1029467 Clutch Spring Free Length 1 Measure the free length of spring with vernier calipers 2 If the measurement is l...

Page 161: ...hickness Factory spec 3 3 to 3 5 mm 0 13 to 0 14 in Allowable limit 3 00 mm 0 118 in Thickness of brake friction plate 1 Factory spec 1 75 to 1 85 mm 0 069 to 0 073 in Allowable limit 1 60 mm 0 063 in...

Page 162: ...with an outside micrometer 6 If the backlash is not within the factory specifications adjust with shims 4 6 Reference Thickness of adjusting shims For differential pinion gear 2 3 mm 0 091 in 2 5 mm...

Page 163: ...n outside micrometer Reference Thickness of adjusting shims For 11T bevel gear shaft 4 0 2 mm 0 008 in 0 3 mm 0 012 in 0 5 mm 0 020 in For 17T 13T gear shaft LH 1 0 2 mm 0 008 in 0 3 mm 0 012 in 0 5 m...

Page 164: ...3 BRAKES KiSC issued 07 2006 A...

Page 165: ...2 SERVICING SPECIFICATIONS 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 S4 1 Pedal System Component 3 S4 2...

Page 166: ...travel excessive Adjust 3 S4 Brake shoe worn Replace 3 S8 Brake drum worn Replace 3 S8 Grease or oil on brake shoe Replace 3 S8 Brake Drags Brake pedal free travel too small Adjust 3 S4 Brake spring...

Page 167: ...3 S2 GR1600EC2 WSM BRAKES 2 SERVICING SPECIFICATIONS W1013874 Item Factory Specification Allowable Limit Brake Pedal Free Travel 15 to 25 mm 0 59 to 0 98 in KiSC issued 07 2006 A...

Page 168: ...screws bolts and nuts See page G 9 W1012736 Item N m kgf m ft lbs Steering wheel mounting nut 20 to 25 2 0 to 2 5 14 8 to 18 4 Drag link locking nut 74 8 to 81 3 7 62 to 8 29 55 2 to 60 0 Steering sup...

Page 169: ...2 DISASSEMBLING AND ASSEMBLING 1 Pedal System Component Dismounting Mower 1 See Page 7 S6 Mower Section W1011029 Dismounting Container 1 See Page 2 S9 Transaxle Section W1011095 Battery CAUTION When d...

Page 170: ...ch 4 3 Remove the discharge duct 2 W1012965 Container Base 1 Disconnect the couplers 1 from the relays 2 2 Disconnect the connector 4 3 Remove the container base 3 W1018829 1 Filter Cover 2 Discharge...

Page 171: ...connectors for hour meter 4 main switch 5 and light switch 5 Remove the indicator lamps 6 6 Remove the fuse box 7 from the steering support 7 Remove the panel 2 When reassembling W1011932 Separating E...

Page 172: ...Component 1 Remove the parking lock spring 1 2 Remove the pedal system component mounting nuts 2 3 Separate the pedal system component 3 from frame When reassembling W1015153 Tightening torque Drag li...

Page 173: ...the external snap ring 7 6 Pull out the brake drum 8 When reassembling Apply liquid gasket Three Bond 1208D or equivalent to joint face of the brake assembly NOTE After assembling the brake assembly b...

Page 174: ...4 FRONT AXLE KiSC issued 07 2006 A...

Page 175: ...NS 4 S2 3 TIGHTENING TORQUES 4 S3 4 CHECKING DISASSEMBLING AND SERVICING 4 S4 1 CHECKING AND ADJUSTING 4 S4 2 PREPARATION 4 S4 1 Separating Front Axle Assembly 4 S4 3 DISASSEMBLING AND ASSEMBLING 4 S6...

Page 176: ...toe in Replace tie rod 4 S4 6 Kingpin worn Replace front axle assembly 4 S5 Center pin collar worn Replace 4 S5 6 Center pin locking nut loosen Tighten 4 S5 Front Wheels Shimmy Improper toe in Replace...

Page 177: ...0 04 to 0 39 in Front Axle Frame to Anti vibration Bolt Clearance 0 3 to 0 5 mm 0 012 to 0 020 in Center Pin to Center Pin Collar Clearance 0 109 to 0 200 mm 0 00430 to 0 00789 in 0 210 mm 0 00828 in...

Page 178: ...and nuts on the table below are especially specified For general use screws bolts and nuts See page G 9 W1012736 Item N m kgf m ft lbs Center pin locking nut 77 4 to 90 2 7 9 to 9 2 57 2 to 66 5 Tie...

Page 179: ...g Front Axle Assembly Dismounting Mower 1 See page 7 S6 Mower Section W1011172 Battery CAUTION When disconnecting the battery cables disconnect the negative cable from the battery first When connectin...

Page 180: ...s 3 Remove the front wheels 4 Loose the anti vibration bolts 5 5 Remove the center pin locking nut 3 and draw out the center pin bolt 6 6 Separate the front axle assembly 2 When reassembling Apply gre...

Page 181: ...rance 3 If the clearance exceeds the allowable limit replace them W1012404 Tightening torque Tie rod mounting locking nut 49 9 to 54 2 N m 5 09 to 5 53 kgf m 36 8 to 40 0 ft lbs 1 Tie rod Mounting Loc...

Page 182: ...5 STEERING KiSC issued 07 2006 A...

Page 183: ...2 3 TIGHTENING TORQUES 5 S3 4 CHECKING DISASSEMNLING AND SERVICING 5 S4 1 CHECKING AND ADJUSTING 5 S4 2 PREPARATION 5 S4 1 Separating Steering Support Assembly 5 S4 3 DISASSEMBLING AND ASSEMBLING 5 S8...

Page 184: ...Cannot Steer Steering shaft and sector gear broken Replace 5 S8 Steering linkage broken Replace 5 S7 Hard Steering Tire pressure uneven Adjust Improper alignment of front wheels Replace tie rod 4 S4...

Page 185: ...5 S2 GR1600EC2 WSM STEERING 2 SERVICING SPECIFICATIONS W1013874 Item Factory Specification Allowable Limit Steering Wheel Play 30 to 70 mm 0 79 to 1 18 in KiSC issued 07 2006 A...

Page 186: ...use screws bolts and nuts See page G 9 W1012736 Item N m kgf m ft lbs Steering wheel mounting nut 20 to 25 2 0 to 2 5 14 8 to 18 4 Drag link locking nut 74 8 to 81 3 7 62 to 8 29 55 2 to 60 0 Steerin...

Page 187: ...y Dismounting Mower 1 See page 7 S6 Mower Section W1010809 Dismounting Container 1 See page 2 S9 Transaxle Section W1010875 Battery CAUTION When disconnecting the battery cables disconnect the negativ...

Page 188: ...tch 4 3 Remove the discharge duct 2 W1012965 Container Base 1 Disconnect the couplers 1 from the relays 2 2 Disconnect the connector 4 3 Remove the container base 3 W1014159 1 Filter Cover 2 Discharge...

Page 189: ...connectors for hour meter 4 main switch 5 and light switch 5 Remove the indicator lamps 6 6 Remove the fuse box 7 from the steering support 7 Remove the panel 2 When reassembling W1011711 Separating...

Page 190: ...it 3 Disconnect the accelerator wire 2 4 Separate the steering support assembly 1 When reassembling W1012258 Tightening torque Drag link locking nut 74 8 to 81 3 N m 7 62 to 8 29 kgf m 55 2 to 60 0 ft...

Page 191: ...o the sector bushes 6 7 Apply to grease to the steering bearing Adjust the clearance between the shaft retainer and the pinion gear of steering shaft Reference Length L 1 mm 0 040 in W1012713 4 SERVIC...

Page 192: ...6 ELECTRICAL SYSTEM KiSC issued 07 2006 A...

Page 193: ...CONTENTS MECHANISM 1 WIRING DIAGRAM 6 M1 2 STARTING SYSTEM 6 M3 3 CHARGING SYSTEM 6 M4 4 LIGHTING SYSTEM 6 M5 KiSC issued 07 2006 A...

Page 194: ...FF ON 12Ga BR Thermo 18Ga RW PTO Switch Open Switch Without With 18Ga Or Diode 3A 18Ga B Seat Switch Vacant Occupied 18Ga B OPC Fuse 3A 20Ga GY 18Ga W 18Ga W 18Ga RW 14Ga L 14Ga L 14Ga B 18Ga RW 18Ga...

Page 195: ...1019456 W White WR White Red BW Black White R Red WY White Yellow BR Black Red L Blue RB Red Black GW Green White P Pink RW Red White YR Yellow Red B Black RG Red Green YL Yellow Blue Br Brown RY Red...

Page 196: ...he ON position to the OFF position the engine stop solenoid moves the fuel injection pump control rack to the No Fuel Injection position and stops the engine This machine equipped the operator presenc...

Page 197: ...ic power for various electrical devices and also charges the battery while the engine runs It consists of a dynamo 4 and a regulator 6 1 Battery 2 Body Earth 3 Body Earth 4 Dynamo 5 Slow Blow Fuse 40...

Page 198: ...shifting the PTO lever And the buzzer rings 1 Battery 2 Body Earth 3 Thermo Switch 4 Oil Switch 5 Body Earth 6 Dynamo 7 Regulator 8 Slow Blow Fuse 40 A 9 Main Switch 10 Fuse 10 A 11 Fuse 3 A 12 PTO S...

Page 199: ...S10 4 Glow Plug 6 S11 5 Safety Switch 6 S12 6 Operator Presence Control OPC Switch 6 S13 7 Fuel Pump 6 S14 8 Engine Stop Solenoid 6 S14 9 Timer Relay 6 S15 10 Charging System 6 S15 11 Lighting System...

Page 200: ...Battery negative cable disconnected or improperly connected Repair or replace Slow blow fuse blown 40 A Replace G 35 Fuse Blown Frequently Short circuited Repair or replace Battery Discharges Too Quic...

Page 201: ...tainer open switch defective Replace 6 S13 Engine Does Not Stop When Main Switch is Turned OFF Fuse blown 15 A Replace G 35 Wiring harness disconnected or improperly connected between main switch ACC...

Page 202: ...l Pressure Lamp Lights Up When Engine Is Running Engine oil pressure too low Repair engine Engine oil insufficient Replenish G 26 Oil pressure switch defective Replace 6 S17 Short circuit between oil...

Page 203: ...ss than 0 1 V Glow Plug Resistance Approx 0 9 Head Light Switch Resistance OFF Infinity Resistance ON 0 Starter Commutator O D 28 0 mm 1 102 in 27 0 mm 1 063 in Commutator Difference of O D Less than...

Page 204: ...crews bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page G 9 W1012736 Item N m kgf m ft lbs Starter C terminal nut 5 9 to 11 8 0 6 to 1 2 4 3 to...

Page 205: ...ecific gravity and recharge the battery W1010650 Battery Terminal Connection 1 Turn the main switch on and turn on the head light 2 Measure the voltage with a voltmeter across the battery s positive t...

Page 206: ...he hydrometer at eye level The hydrometer reading must be taken at the highest electrolyte level Reference Specific gravity slightly varies with temperature To be exact the specific gravity decreases...

Page 207: ...m the following checks W1012030 Connector Voltage 1 Measure the voltage with a voltmeter across the connector B red terminal and chassis 2 If the voltage differs from the battery voltage 11 to 14 V th...

Page 208: ...ith 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...

Page 209: ...terminal post 7 If the motor does not run check the motor W10142670 Starter Magnet Switch Test Pull in Holding Coils NOTE Preparate a 6 V battery for the test and each test should be carried out for...

Page 210: ...fers from the battery voltage the wiring harness or main switch is faulty W10149130 Glow Plug Continuity 1 Disconnect the lead from the glow plugs 2 Measure the resistance with an ohmmeter between the...

Page 211: ...ce with an ohmmeter between the terminals 5 If the brake switch is defective replace it W10413270 Resistance between terminal a and b When plunger is pushed 0 When plunger is released Infinity Resista...

Page 212: ...tch OPC Switch Seat Switch 1 Remove the battery 2 Remove the OPC switch 1 3 Measure the resistance with an ohmmeter between the OPC switch terminals 4 If the OPC switch is defective replace it W104409...

Page 213: ...the continuity between the connector terminals with an ohmmeter 3 If it does not conduct the fuel pump is faulty W1016134 8 Engine Stop Solenoid Engine Stop Solenoid Test 1 Disconnect the 1P connector...

Page 214: ...ct jumper leads across the battery negative terminal and the timer relay terminal 2 and across the battery negative terminal and the bulb terminal 4 Connect jumper lead across the timer relay terminal...

Page 215: ...ied value measure the voltage with a volt meter 6 across the terminal red f and chassis Refer to figure B 5 If the measurement is not within specified value replace the regulator 1 W1015722 11 Lightin...

Page 216: ...aulty W1020094 Engine Oil Pressure Switch Continuity 1 Measure the resistance with an ohmmeter across the switch terminal and the chassis 2 If 0 ohm is not indicated in the normal state the switch is...

Page 217: ...tch is faulty W10599470 13 Grass Container Full Switch Grass Container Full Switch Continuity 1 Remove the battery 2 Dismount the grass container 3 Remove the filter cover 4 Disconnect the connector 1...

Page 218: ...uzzer 1 3 Connect the jumper lead between the battery positive terminal and terminal 1 of connector 4 Connect the jumper lead between the battery negative terminal and terminal 2 of connector 5 If the...

Page 219: ...th the drive lever 4 NOTE Do not damage to the brush and commutator When reassembling Apply grease to spline teeth of the armature bushing pinion gear of the overrunning clutch and armature shaft 1 Sl...

Page 220: ...58597 Rotor 1 Tap out the shaft 1 from the rotor 3 When reassembling Take care the direction of the collar 4 the flat side should face to the pulley 2 side W1064758 Tightening torque Nut 39 2 to 44 1...

Page 221: ...fference of the O D s exceeds the allowable limit correct the commutator on a lathe to the factory specification 5 Measure the mica undercut 6 If the undercut is less than the allowable limit correct...

Page 222: ...ohmmeter 2 If it conducts replace the armature 3 Check the continuity across the segments of the commutator with an ohmmeter 4 If it does not conduct replace the armature W1017767 Field Coil 1 Check...

Page 223: ...6 S24 GR1600EC2 WSM ELECTRICAL SYSTEM 2 Dynamo Bearing 1 Check the bearing for smooth rotation 2 If it does not rotate smoothly replace it W1019790 KiSC issued 07 2006 A...

Page 224: ...7 MOWER KiSC issued 07 2006 A...

Page 225: ...CONTENTS MECHANISM 1 POWER TRANSMISSION 7 M1 2 LIFTING MECHANISM 7 M2 KiSC issued 07 2006 A...

Page 226: ...t Universal Joint 8 Input Shaft 5 18T Spiral Gear 4 17T Spiral Gear 3 Output Shaft 2 Center Pulley 1 Mower Belt 7 Outer Pulley 6 Blade Shaft 9 Blade 10 1 Center Pulley 2 Output Shaft 3 17T Spiral Gear...

Page 227: ...d to raise the lift link LH 1 As a result the rear link RH 10 and LH 2 are lifted The gas spring 3 connected with lift link shaft 4 assists lifting of mower The cutting height adjusting dial 7 adjusts...

Page 228: ...EMBLING AND ASSEMBLING 7 S4 1 CHECKING AND ADJUSTING 7 S4 1 Adjusting Anti scalp Rollers 7 S4 2 Adjusting Left and Right Cutting Height 7 S5 2 PREPARATION 7 S6 1 Dismounting Mower 7 S6 3 DISASSEMBLING...

Page 229: ...ned out or worn Remove cup washer 7 S8 Engine rpm too low Mow at full throttle check and reset engine rpm Cutting Is Poor Mower blade worn or bent Sharpen or replace mower blade 7 S8 Mower blade screw...

Page 230: ...on Allowable Limit Left Tip of Blade to Right Tip of Blade Difference Less than 6 mm 0 24 in Front Tip of Blade to Rear Tip of Blade Difference Less than 5 mm 0 20 in 17T Spiral Gear to 18T Spiral Gea...

Page 231: ...ower blade screw 98 to 118 10 0 to 12 0 72 3 to 86 8 Gear box mounting screw 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 Gear box bracket mounting screw and nut 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 Pulley mo...

Page 232: ...ort position Also the top end of the lift 4 Turn the cutting height control dial to adjust height 5 Lower the mower deck Front side anti scalp roller 6 Adjust height H of the rear side anti scalp roll...

Page 233: ...deck 7 Adjust the left side equally 8 Measure the heights of blade L and R from the ground surface and calculate the difference 9 If the difference between left tip and right tip of blade is not withi...

Page 234: ...rk the machine on level ground and stop the engine 2 Set the cutting height adjusting dial 1 to 1 position 3 Set the front anti scalp rollers at the top position 4 Lower the mower lift lever 2 and loc...

Page 235: ...er and lock in the raised position When reassembling Apply grease to the spline of PTO shaft Slide the universal joint back and front to make sure the universal joint is locked securely When attach th...

Page 236: ...ar Box and Mower Belt 1 Remove the left and right belt covers from the mower deck 2 Disconnect the universal joint 4 from the gear box 1 3 Clean around the gear box 1 4 Remove the mower belt 2 from th...

Page 237: ...shaft 2 to remove the ball bearing 7 When reassembling Replace the oil seals 5 22 with new ones Apply grease to the splines of input shaft and of output shaft IMPORTANT Use the specified gear box oil...

Page 238: ...Remove the ball bearings 3 7 and collar 4 W1024413 Tightening torque Pulley mounting nut 103 to 118 N m 10 5 to 12 0 kgf m 76 0 to 87 0 ft lbs Pulley holder mounting screw 48 1 to 55 8 N m 4 9 to 5 7...

Page 239: ...7 11 6 Remove the rear link LH 4 and RH 17 7 Pull out the rue rings 7 12 and remove the clevis pins 5 13 8 Remove the lift link LH 6 and RH 14 9 Pull out the cotter pin 16 and remove the lift link 15...

Page 240: ...Backlash equal thickness of fuse 6 If the backlash exceeds the allowable limit adjust with shims 2 5 Reference Thickness of adjusting shims for 17T spiral gear 2 0 2 mm 0 0079 in 0 3 mm 0 0118 in for...

Page 241: ...n Japan 2006 07 S EI EI e Code No 9Y011 15560 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...

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Kubota GR1600EC2, Workshop Manual

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