Kubota WSM GR2100EC Workshop Manual Download Page 78

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GR2100EC, WSM

ENGINE

1-S7

Crankshaft Journal to Crankshaft Bearing 3
(Intermediate)

Oil Clearance

0.028 to 0.059 mm

0.00110 to 0.00232 in.

0.20 mm

0.0079 in.

Crankshaft Journal
(O.D.)

39.934 to 39.950 mm

1.57221 to 1.57284 in.

Crankshaft Bearing
3
(I.D.)

39.978 to 39.993 mm

1.57394 to 1.57453 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.

0000010075E

Item

Factory Specification

Allowable Limit

LUBRICATING SYSTEM

Item

Factory Specification

Allowable Limit

Engine Oil Pressure

At Idle Speed

More than 49 MPa

0.5

7 psi

At Rated Speed

196 to 441 MPa

2.0 to 4.5

28 to 64 psi

147 MPa

1.5

21 psi

Oil Pump

Inter Rotor to Outer
Rotor
(Clearance)

0.03 to 0.14 mm

0.0012 to 0.0055 in.

Outer Rotor to
Pump Body
(O.D.)

0.07 to 0.15 mm

0.0028 to 0.0059 in.

Inter Rotor to Cover
(I.D.)

0.075 to 0.135 mm

0.00295 to 0.00531 in.

0000004340E

KiSC issued 04, 2006 A

Summary of Contents for WSM GR2100EC

Page 1: ...GR2100EC WORKSHOP MANUAL KiSC issued 04 2006 A ...

Page 2: ...mbling and servicing Information on the troubleshooting servicing specification lists tightening torque checking and adjusting disassembling and assembling and servicing which cover procedures precautions factory specifications and allowable limits All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publicat...

Page 3: ...positions A Never start the engine while standing on ground Start the engine only from operator s seat This symbol the industry s Safety Alert Symbol is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the instructions and safety regulations before you attempt to repair or u...

Page 4: ...ping Otherwise hot water will spout out from radiator Only remove radiator cap when cool enough to touch with bare hands Slowly loosen the cap to first stop to relieve pressure before removing completely A Escaping fluid fuel or hydraulic oil under pressure can penetrate the skin causing serious injury Relieve pressure before disconnecting hydraulic or fuel lines Tighten all connections before app...

Page 5: ...m eyes hands and clothing If you spill electrolyte on yourself flush with water and get medical attention immediately DISPOSE OF FLUIDS PROPERLY A Do not pour fluids into the ground down a drain or into a stream pond or lake Observe relevant environmental protection regulations when disposing of oil fuel coolant electrolyte and other harmful waste PREPARE FOR EMERGENCIES A Keep a first aid kit and...

Page 6: ...NS 4 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 DECALS 0000009636E KiSC issued 04 2006 A ...

Page 7: ...GR2100EC WSM SAFETY INSTRUCTIONS 5 0000009633E KiSC issued 04 2006 A ...

Page 8: ...GR2100EC WSM SAFETY INSTRUCTIONS 6 0000009634E KiSC issued 04 2006 A ...

Page 9: ...ngine coolant with recovery tank 2 35 L 2 48 U S qts 2 07 lmp qts Transmission case 3 3 L 0 87 U S gals 0 73 lmp gals Front axle case 1 9 L 0 50 U S gals 0 42 lmp gals Dimensions Overall length with grass catcher 2540 mm 100 0 in Overall width 1280 mm 50 4 in Overall height 1230 mm 48 4 in Wheel base 1280 mm 50 4 in Tread Front 825 mm 32 5 in Rear 800 mm 31 5 in Weight without mower and grass catc...

Page 10: ...g 176 lbs Dimensions Total length 871 mm 34 3 in Total width 1270 mm 50 0 in Total height 305 mm 12 0 in Discharge direction Rear Gear box oil 0 40 L 0 42 U S qts 0 35 Imp qts Model GCK450GR Grass catcher Container capacity 450 L 118 9 U S gals 99 0 Imp gals Weight Approx 50 kg 110 lbs NOTE Manufacture s estimate The company reserves the right to change the specifications without notice 0000010041...

Page 11: ...GR2100EC WSM DIMENSIONS 9 DIMENSIONS 0000009634E KiSC issued 04 2006 A ...

Page 12: ...G GENERAL KiSC issued 04 2006 A ...

Page 13: ...H UNC OR UNF 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 POINTS OF EVERY 150 HOURS G 28 5 CHECK POINTS OF EVERY 200 HOURS G 29 6 CHECK POINT OF EVERY 400 HOURS G 34 7 CHECK POINTS OF EVERY 1 YEAR G 35 8 CHECK POINTS OF EVERY 2 YEARS G 38 9 OTHERS G 38 8 S...

Page 14: ...ing your local KUBOTA distributor always specify engine serial number 2 machine serial number 1 mower serial number 3 and hour meter reading 1 Machine Serial Number 3 Mower Serial Number 2 Engine Serial Number 4 Hour Meter 0000010047E KiSC issued 04 2006 A ...

Page 15: ...ly KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety A Gaskets and O rings must be replaced during reassembly Apply grease to new O rings or oil seals before assembling See the figure left side A When reassembling external snap rings or internal snap rings they must be positioned so that sharp edge faces against the direction from which a force is appl...

Page 16: ...check for a fee A Do not attempt to modify or remodel any electrical parts and wiring A When removing the battery cables disconnect the negative cable first When installing the battery cables connect the positive cable first 1 WIRING A Securely tighten wiring terminals A Do not let wiring contact dangerous part A Securely insert grommet 1 Negative Terminal 2 Positive Terminal 0000000613E 1 Correct...

Page 17: ...d A In installing a part take care not to get wiring caught by it A After installing wiring check protection of terminals and clamped condition of wiring only connect battery 1 Clamp 3 Clamp Wind Clamp Spirally 4 Welding Dent 2 Wire Harness 0000000617E 1 Wiring A Correct 2 Clamp B Incorrect 0000000618E 1 Wiring A Incorrect 0000000619E 1 Cover Securely Install Cover 0000000620E KiSC issued 04 2006 ...

Page 18: ...n and clothes If contaminated wash it off with water immediately A Before recharging the battery remove it from the machine A Before recharging remove cell caps A Do recharging in a well ventilated place where there is no open flame nearby as hydrogen gas and oxygen are formed 3 FUSE A Use fuses with specified capacity Neither too large or small capacity fuse is acceptable A Never use steel or cop...

Page 19: ...e certain there is no terminal being exposed or displaced A Make certain that there is no female connector being too open A Make certain plastic cover is large enough to cover whole connector A Correct B Incorrect 0000000624E 1 Exposed Terminal 3 Sandpaper 2 Deformed Terminal 4 Rust 0000000625E A Correct B Incorrect 0000000626E 1 Cover A Correct B Incorrect 0000000627E KiSC issued 04 2006 A ...

Page 20: ...GR2100EC WSM GENERAL G 7 5 HANDLING OF CIRCUIT TESTER A Use tester correctly following manual provided with tester A Check for polarity and range 0000000628E KiSC issued 04 2006 A ...

Page 21: ...87 U S gals 0 73 lmp gals KUBOTA UDT or SUPER UDT fluid 5 Front axle case 1 9 L 0 50 U S gals 0 42 lmp gals 6 Mower gear box 0 40 L 0 42 U S qts 0 35 lmp qts SAE90 gear oil API service classification more than GL 3 Greasing No Place No of greasing points Capacity Type of grease 7 Engine transmission universal joint 1 Until grease overflows SAE multi purpose type grease 8 King pin 2 9 Center pin 2 ...

Page 22: ... to 32 5 60 9 to 70 6 6 2 to 7 2 44 9 to 52 0 M12 12 mm 0 47 in 62 8 to 72 5 6 4 to 7 4 46 3 to 53 5 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 62 8 to 72 5 6 4 to 7 4 46 3 to 53 5 103 to 117 10 5 to 12 0 76 0 to 86 7 M14 14 mm 0 55 in 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 16 mm 0 63 in 167 to 191 17 0 to 19 5 123 to 141 197 to 22...

Page 23: ... 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 0000001414E Shape Size Material of opponent part Ordinariness Aluminum ft lbs ft lbs Tapered screw R1 8 12 7 to 21 6 1 3 to 2 2 9 4 to 15 9 12 7 to 19 6 1 3 to 2 0 9 4 to 15 4 R1 4 24 5 to 44 1 2 5 to 4 5 18 1 to 32 5 24 5 to 34 3 2 5 to 3 5 18 1 to 25 4 R3 8 49 0 to 88 3 5 0 to 9 0 36 2 t...

Page 24: ...29 3 Transmission and Front axle cases fluid Change every 200 hr G 30 G 32 4 Transmission oil filter Replace every 200 hr G 31 5 Transmission strainer Clean every 200 hr G 31 6 Front axle pivot Adjust every 200 hr G 34 7 Safety device Check every 50 hr G 19 8 Oiling every 50 hr G 22 9 Greasing every 50 hr G 21 10 Mower gear box oil Check every 50 hr G 20 Change every 150 hr G 28 11 Air cleaner ele...

Page 25: ...ck every 200 hr G 33 Replace every 2 years G 33 18 Radiator hose and clamp Check every 200 hr G 31 Replace every 2 years G 38 19 Radiator core Check every 200 hr G 35 20 Radiator Clean every 1 year G 35 21 Coolant Change every 1 year G 35 22 Mower gear box oil seal Replace every 2 years G 38 23 Fuel system Bleed Ser vice as re quired G 41 24 Fuse Replace G 38 25 Blade Replace G 40 26 Mower belt Re...

Page 26: ...ery tank 6 Damage of 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 A Mower 1 Oil leak 2 Make sure blade cap screws are tight 3 Blades for wear or damage 4 Check all hardware 5 Make sure all pins are in place 6 Mower deck cleaning 7 Greasing A While sitting in the operator s seat 1 Speed control pedal and brake ...

Page 27: ...einsert 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 viscosity oil from the previous one remove all of the old oil and oil filter Never mix two different types of oil 6 Use the proper Engine Oil SAE according to the ambient temperatures See page G 8 1 Engin...

Page 28: ... 10 14 3 Always use a strainer when refueling to prevent fuel injection pump contamination A No 2 D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service SAE J313 JUN87 Grade of Diesel Fuel Oil according to ASTM D975 Fuel tank capacity 18 L 4 8 U S gals 4 0 Imp gals Flash point Water and Sediment volume Carbon Residue on 10 percent Residuum Ash weight Min Max ...

Page 29: ...be 3 Tighten the fan drive belt as necessary For this refer to CHECK POINT EVERY 100 HOURS 4 If scale forms in the tube clean with the scale inhibitor or its equivalent 5 Each time the panel screen 1 is covered with grass during operation rub it off the screen with hand Check the radiator screen 2 from time to time if grass accumulates 6 If the dust or chaff has accumulated inside of the panel rem...

Page 30: ...ly in the course of time Thus check it every day and inflate as necessary Checking Transmission Fluid Level 1 Park the machine on a flat surface lower the implement to the ground and shut off engine and remove the key 2 Raise the operator s seat 3 To check the oil level draw out the dipstick 1 wipe it clean reinsert it and draw it out again Check to see that the oil level lies between the two notc...

Page 31: ...level drops due to evaporation add water only up to just below the fill port of the radiator and the full level of the recovery tank 4 In case of leakage add coolant and water in the specified mixing ratio up to the full level See page G 35 A If the radiator cap has to be removed follow the caution above and securely retighten the cap A Use clean distilled coolant and water to fill the radiator an...

Page 32: ... the brake pedal 3 Turn the key to the START position 4 The engine should not crank B 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 shut off B Seat Safety Control 2 1 Run the engine at half throttle 2 Disengage the PTO lever 3 Release the brake pedal 4 Stand up Do not get off the machine 5 Engine should shut off...

Page 33: ... A Align the arrow marks when reinstalling the air cleaner cover Checking Mower Gear Box Oil Level A 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 check plug 1 bolt and check to see that the oil level is just below the oil check plug 1 port If the level is too low add new oil to the...

Page 34: ...pply a grease to the following locations as figures A Be sure to stop the engine and remove the key before greasing 1 Engine Transmission 3 King Pin Support Universal Joint 4 Glide Steer Bolt 2 Center Pin 5 Glide Steer Rear Arm 0000010055E KiSC issued 04 2006 A ...

Page 35: ...oil to the following location as figures A Be sure to stop the engine and remove the key before oiling 1 Mower Universal Joint 4 Seat Adjuster 2 Speed Control Shaft RH 5 Throttle Cable 3 Speed Control Shaft LH 0000009558E KiSC issued 04 2006 A ...

Page 36: ...on as figures A Be sure to stop the engine and remove the key before oiling 1 Around Hole of Mower Link 6 Hinge 2 Around Pin 7 PTO Lever Fulcrum 3 Pivot of Mower Link 8 Hydraulic Lift Lever Fulcrum 4 Pivot of Lift Arm 9 Link Fulcrum 5 Front Link 0000010056E KiSC issued 04 2006 A ...

Page 37: ...l regularly and add distilled water as required so that the fluid level is between the UPPER and LOWER levels A Never remove the vent plugs while the engine is running A 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 A Wear eye protection and rubber gloves when working around battery 1 Mishandl...

Page 38: ...essary 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 3 To slow charge the battery connect the battery positive terminal to the charger positive terminal and the negative to the negative then recharge in the standard fashion 4 A boost charge is only ...

Page 39: ...ery three months in hot seasons and once every six months in cold seasons 3 CHECK POINTS OF EVERY 100 HOURS Changing Engine Oil A Be sure to stop the engine and remove the key before changing the oil A Allow engine to cool down sufficiently oil can be hot and may cause burns 1 To change the used oil remove the drain plug 1 at the bottom of the engine and drain the oil completely The used oil can b...

Page 40: ... 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 take not to admit dust and dirt into the fuel pump Entrance of even a small amount of dust or dirt cause premature wear and malfunction of the fuel pump and injector components Checking Brake A When making a...

Page 41: ...mo to adjust 4 CHECK POINTS OF EVERY 150 HOURS Changing Mower Gear Box Oil A Be sure to stop the engine and remove the key before changing the oil 1 To drain the used oil remove the oil filler plug 1 at the mower gear box tilt the mower deck and drain the oil completely into the oil pan 2 Fill with the new oil See page G 8 3 After filling reinstall the oil filler plug 1 Deflection A Factory spec 7...

Page 42: ...ly a slight coat of oil onto the rubber gasket of new cartridge 3 Tighten the filter quickly until it contacts the mounting surface Tighten filter by hand an additional 1 2 turn only 4 After the cartridge has been replaced the engine oil level normally lowers a little Add engine oil to proper level Check for oil leaks around filter gasket A To prevent serious damage to the engine element of recomm...

Page 43: ...e 6 After reassembling fill with UDT or SUPER UDT hydrostatic 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 prescribed level A Operate only at low rpm immediately after changing the transmission fluid and filter cartridge Keep the engine at medium speed for a few...

Page 44: ...w 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 turn only 7 Assemble the cover and mount the grass container 8 After the new cartridge has been replaced the transmission fluid level normally lowers a little Add fluid to proper level Check for oil leaks arou...

Page 45: ... reinstall the drain plugs 3 4 Remove the right or left breather plugs 1 5 Fill with the new oil up to the upper notch on the dipstick 2 A After ten minutes check the oil level again add oil to prescribed level 6 After filling reinstall the filling plug 2 and breather plugs 1 Front axle case fluid capacity 1 9 L 0 50 U S gals 0 42 Imp gals 1 Breather Plug A Oil level is acceptable within 2 Filling...

Page 46: ...ficiently oil can be hot and may cause burns Check to see if hydraulic hoses are properly fixed every 200 hours of operation 1 Check to see that all lines and hose clamps are tight and not damaged 2 If hoses and clamps are found worn or damaged replace or repair them at once 1 Power Steering Hose RH 3 Mower Lift Cylinder Hose 2 Power Steering Hose LH 0000010063E KiSC issued 04 2006 A ...

Page 47: ...with a specified torque 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 A If the fuel line is removed be sure to properly bleed the fuel system See page G 41 Clearance between front axle bracket and frame A Factory spec 81 to 83 mm 3 19 to 3 26 in Tightening torque Front axle bracket mounting screw and nut 4...

Page 48: ... clean water and anti freeze until the coolant level is just below the fill port on the radiator Install the radiator cap securely 7 Fill with coolant up to FULL mark on the recovery tank 8 Start and operate the engine for a few minutes 9 Stop the engine and let cool Check coolant level of recovery tank 2 and add coolant if necessary A Do not start engine without coolant A Use clean fresh water an...

Page 49: ...ve the 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 or before a long term storage let out coolant 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 ...

Page 50: ...t additive components and the engine may fail to perform as specified 2 When the LLC is mixed do not employ any radiator cleaning agent The LLC contains anti corrosive agent If mixed with the cleaning agent sludge may build up adversely affecting the engine parts 3 Kubota s genuine long life coolant has a service life of 2 years Be sure to change the coolant every 2 years A The above data represen...

Page 51: ...o Disassembling Gear Box See page 8 S10 9 OTHERS Replacing Fuses 1 Open the hood 2 Remove the blown fuse 3 Place a new 3 A or 10 A or 15 A or 30 A or 40 A fuse in position A Never jump the fuse with wire or foil or install a larger capacity fuse than is recommended B Protected circuit 0000010067E 0000009581E 0000010068E Fuse No ID Label Capacity A Protected circuit 1 E G STOP a 15 Engine stop time...

Page 52: ...rom 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 remove it 3 Pull bulb from the socket 4 Push new bulb into the socket 5 Install the socket 6 Close the hood Head light bulb 12V 24 W Indicator light bulb 14 0 rated voltage 0 27 AMP 2 MSCP 0000009584E KiSC ...

Page 53: ... counterclockwise to loosen The blade bolt 2 has left hand threads turn clockwise to loosen A Use the proper size box or socket wrench to tighten or loosen the blade mounting bolt 4 To sharpen the blades yourself clamp the blade securely in a vise Use a large mill file and file along the original bevel until sharp 5 To check the blade for balance place a small rod though the centre hole If the bla...

Page 54: ...ime Bleeding procedure is as follows 1 Fill the fuel tank with fuel 2 Start the engine and run for about 30 seconds and then stop the engine Tightening torque Gear box mounting screw LH Reamer 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 ft lbs Gear box mounting screw RH 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 ft lbs Gear box stay mounting screw LH Reamer 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 ft lbs Gear box ...

Page 55: ...de No 07909 32121 Application Use exclusively for removing or installing the piston ring with ease 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 0000000677E 0000000678E 0000000679E 1 Gauge 7 Ad...

Page 56: ...909 33102 Application Use to reseat valves Angle 0 785 rad 45 0 262 rad 15 Diameter 28 6 mm 1 126 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 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 1 Gauge 4 Adaptor L 2 L Joint 5 Adaptor M 3 Adaptor K ...

Page 57: ...e fuel injection pressure and spray pattern of nozzle Measuring 0 to 50 MPa range 0 to 500 0 to 7000 psi 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 mm 0 002 to 0 006 in Blue 0 102 to 0 229 mm 0 004 to 0 009 in Red Check Code No 07909 31371 Application Use t...

Page 58: ...t F PF 1 2 G 5 mm 0 20 in H 17 mm dia 0 67 in dia I 8 mm dia 0 31 in dia J 1 0 mm 0 039 in K 17 mm dia 0 67 in dia L 6 10 to 6 20 mm dia 0 2402 to 0 2441 in dia M 8 mm 0 31 in N 4 mm 0 16 in O 11 97 to11 99 mm dia 0 4713 to 0 4721 in dia P PF 1 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 94 in V M12 x P1 5 a Adhesive application b Fil...

Page 59: ...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 dia 0 98 in dia H 5 mm 0 197 in I 6 0 to 6 1 mm dia 0 236 to 0 240 in dia J 18 mm dia 0 71 in dia K 10 6 to 10 7 mm dia 0 417 to 0 421 in dia L 6 9 to 7 1 mm dia 0 272 to 0 280 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 0000000816E KiSC issued 04 2006 A ...

Page 60: ... 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 Chamfer 0 3 mm 0 012 in a 6 3 248 b 6 3 248 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 Chamfer 0...

Page 61: ...mm dia 0 39 in dia 0000000818E Press Out A 135 mm 5 31 in B 72 mm 2 83 in C 40 mm radius 1 57 in radius D 10 mm 0 39 in E 22 mm 0 87 in F 20 mm dia 0 79 in dia G 47 90 to 47 95 mm dia 1 8858 to 1 8878 in dia H 43 90 to 43 95 mm dia 1 7283 to 1 7303 in dia Press Fit 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...

Page 62: ...Adaptor E PS3 8 07916 50341 07916 50392 5 Adaptor B M18 x P1 5 9 Adaptor F PF1 2 07916 50361 07916 62601 10 Adaptor 58 PT1 4 07916 52391 0000000705E 1 Hydrostatic Transmission 8 Valve Seat Driver Tester 07916 52040 07916 60841 2 Gasket 04714 00200 9 Connector 1 07916 60811 3 Connector 3 07916 51331 10 Connector 2 07916 60821 4 Vacuum Gauge 11 Long Connector 07916 51331 07916 60831 5 Pressure Gauge...

Page 63: ...rect tire pressure Do not inflate tires above the recommended pressure as shown below A Do not use tires larger than specified Tire sizes Inflation pressure Front 16 x 7 50 8 4PR 200 kPa 2 0 29 psi Rear 23 x 10 50 12 4PR 140 kPa 1 4 20 psi 0000010071E A Do not turn discs to obtain wider tread A Always attach tires as shown in the drawing A If not attached as illustrated transmission parts may be d...

Page 64: ...s 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 Any malfunctions or failures of the machine resulting from use with improper implements are not covered by the warranty Maximum axle loading weight Front axle Wf Rear axle Wr Total gross weight 300 kg 661 lbs...

Page 65: ...1 ENGINE KiSC issued 04 2006 A ...

Page 66: ...CONTENTS 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 04 2006 A ...

Page 67: ... 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 to the intake manifold through breather valve 3 to be used for re combustion 1 Cylinder Head Cover 2 Rubber Packing 0000004839E 1 Breather Hose 4 Oil Shield 2 Cylinder Head Cover 5 Rubber Packing 3 Breather Va...

Page 68: ...t 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 lubricates these parts piston 13 cylinders small ends or connecting rods tappets 11 push rods 10 inlet and exhaust valves 4 and timing gears 1 Rocker Arm 2 Oil Pressure Switch 3 Rocker Arm Shaft 4 Valve 5 Idle Gear 6...

Page 69: ...he 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 temperature is high the thermostat opens to allow the water to flow from the cylinder head to the radiator When the water temperature is low the thermostat close to flow the water only to the water pump 1 Radi...

Page 70: ...1 MPa 140 to 150 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 valve inside the nozzle then returns to the fuel tank through the fuel overflow pipe 2 from the upper part of the nozzle holder 1 Injection Nozzle 2 Fuel Overflow Pipe 3 Fuel Tank 4 Fuel Filter 5 Fuel Feed Pump ...

Page 71: ...TION 1 S20 1 Separating Engine 1 S20 3 DISASSEMBLING AND ASSEMBLING 1 S24 1 Cylinder Head and Valves 1 S24 2 Oil Pan Timing Gears Camshaft and Fuel Camshaft 1 S27 3 Pistons and Connecting Rods 1 S32 4 Crankshaft 1 S34 5 Waterpump 1 S37 6 Injection Nozzle 1 S38 4 SERVICING 1 S38 1 Cylinder Head and Valve 1 S38 2 Timing Gear Camshaft and Fuel Camshaft 1 S45 3 Piston and Connecting Rod 1 S47 4 Cranks...

Page 72: ...uel camshaft worn Replace A Injection nozzle clogged Repair or replace 1 S38 A Injection pump malfunctioning Replace 1 S28 A Seizure of crankshaft camshaft piston cylinder or bearing Repair or replace A Compression leak from cylinder Replace head gasket tighten cylinder head screw glow plug and nozzle holder 1 S10 A Improper valve timing Correct or replace timing gear 1 S30 A Piston ring and cylin...

Page 73: ...logged Replace G 38 A Air cleaner clogged Clean or replace G 20 35 A Deficient nozzle injection Repair or replace nozzle 1 S38 Deficient Output A Incorrect injection timing Adjust 1 S16 A Engine s moving parts seem to be seizing Repair or replace A Uneven fuel injection Replace injection pump 1 S28 A Deficient nozzle injection Repair or replace nozzle 1 S38 A Compression leak Replace head gasket t...

Page 74: ...f oil G 8 A Oil pump defective Repair or replace 1 S31 High Oil Pressure A Different type of oil Use specified type of oil G 8 A Relief valve defective Replace Engine Overheated A Engine oil insufficient Replenish G 8 A Fan belt broken or tensioned improperly Replace or adjust G 28 1 S13 A Coolant insufficient Replenish G 8 A Radiator net and radiator fin clogged with dust Clean A Inside of radiat...

Page 75: ...0 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 mm 0 0835 in Angle 0 785 rad 45 Valve Face Angle 0 785 rad 45 Valve Spring Free Length 31 3 to 31 8 mm 1 232 to 1 252 in 28 4 mm 1 118 in Tilt 1 2 mm 0 047 in Setting Load 64 7 N 6 6 kgf 14 6 lbs 54 9 N 5 6 kgf 12...

Page 76: ...e 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 Alignment 0 01 mm 0 0004 in Cam Height Intake and Exhaust 26 88 mm 1 0583 in 26 83 mm 1 0563 in Camshaft Journal to Cylinder Block Bore Oil Clearance 0 050 to 0 091 mm 0 00197 to 0 00358 in 0 15 mm 0 0059 in Camshaft Journal O D 32 934 to 32 950 mm 1 29661 to 1 2972...

Page 77: ... mm 0 0016 to 0 0031 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 0122 in 0 50 mm 0 0197 in Alignment 0 02 mm 0 0008 in Crankpin to Crankpin Bearing Oil Clearance 0 020 to 0 051 mm 0 00079 to 0 00201 in 0 15 mm 0 0059 in Crankpin O D 33 959 to 33 975 mm 1 33697 to 1 33760 in Crankpin Bearing I D 33 995 to 34 010 mm 1 33893 to...

Page 78: ...iner Oversize I D 67 250 to 67 269 mm 2 64764 to 2 64839 in 67 419 mm 2 65429 in 0000010075E Item Factory Specification Allowable Limit LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed More than 49 MPa 0 5 7 psi At Rated Speed 196 to 441 MPa 2 0 to 4 5 28 to 64 psi 147 MPa 1 5 21 psi Oil Pump Inter Rotor to Outer Rotor Clearance 0 03 to 0 14 mm 0 0012...

Page 79: ...sure No leak at specified pressure 157 kPa 1 6 23 psi 0000010076E FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump Injection Timing 0 28 to 0 31 rad 16 to 18 before T D C Pump Element Fuel Tightness 13 7 MPa 140 1991 psi Delivery Valve Fuel Tightness 10 seconds 13 73 12 75 MPa 140 130 1991 1849 psi 5 seconds 13 73 12 75 MPa 140 130 1991 1849 psi Fuel Injection Nozzle Injection...

Page 80: ... 31 1 Fan drive pulley screw M12 x 1 5 98 0 to 107 8 10 0 to 11 0 72 3 to 79 5 Idle gear shaft mounting screw M6 x 1 0 9 8 to 11 3 1 00 to 1 15 7 2 to 8 3 Connecting rod screw M7 x 0 75 26 5 to 30 4 2 7 to 3 1 19 5 to 22 4 Flywheel screw M10 x 1 25 53 9 to 58 8 5 5 to 6 0 39 8 to 43 4 Bearing case cover mounting screw M6 x 1 0 9 8 to 11 3 1 00 to 1 15 7 2 to 8 3 Main bearing case screw 2 M7 x 1 0 ...

Page 81: ...7 and 8 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 compression pressure is still less than the allowable limit check the top clearance valve clearance and cylinder head 12 If the compression pressure increases after applying oil check the cylinder ...

Page 82: ...rews 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 the factory specifications check the oil clearance between the crankpin and crankpin bearing and between the piston pin and small end bushing A After checking the top clearance be sure to assemble...

Page 83: ...ark 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 When No 1 piston is at the compression top dead center position When No 1 piston is at the overlap position 7 If the clearance is not within the factory specifications adjust with the adjusting screw A The sequence of cylinder numbers is given ...

Page 84: ... tighten the engine oil pressure switch to the specified torque 3 Cooling System Checking Fan Drive Belt Tension A Be sure to stop the engine and remove the key before checking belt tension 1 Measure the deflection A depressing the belt halfway between the fan drive pulley 1 and dynamo pulley 2 at specified force 98 N 10 kgf 22 lbs 2 If the measurement is not within the factory specifications loos...

Page 85: ... 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 6 mm 0 236 in 4 If the measurement is not within the factory specifications replace the thermostat A Good B Bad 0000000920E Thermostat s valve opening temperature Fac...

Page 86: ...No RCT 2A 30S and raise the water pressure to the specified pressure 3 Check the radiator for water leaks 4 For water leak from the pinhole repair with the radiator cement When water leak is excessive replace the radiator A 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 0000000922E Pressu...

Page 87: ...es of the shim soft metal gasket shim The liquid gasket is not required for assembling A Shims are available in thickness of 0 20 mm 0 0079 in 0 25 mm 0 0098 in and 0 30 mm 0 0118 in Combine these shims for adjustments A Addition or reduction of shim 0 05 mm 0 0020 in delays or advances the injection timing by approx 0 0087 rad 0 5 A In disassembling and replacing the injection pump be sure to use...

Page 88: ...control lever to the maximum speed position 6 Run the starter to increase the pressure 7 If the pressure can not reach the allowable limit replace the pump with new one or repair with a Kubota authorized pump service shop A Never try to disassemble the injection pump assembly For repairs you are strongly requested to contact a Kubota authorized pump service shop Fuel tightness of pump element Allo...

Page 89: ...el at this position and clock the time taken for the pressure to drop from 13 73 to 12 75 MPa from 140 to 130 from 1991 to 1849 psi 8 Measure the time needed to decrease the pressure from 13 73 to 12 75 MPa from 140 to 130 from 1991 to 1849 psi 9 If the measurement is less than allowable limit replace the pump with new one or repair with a Kubota authorized pump service shop A Never try to disasse...

Page 90: ...s not within the factory specifications replace the adjusting washer 1 in the nozzle holder to adjust it Reference A Pressure variation with 0 01 mm 0 0004 in difference of adjusting washer thickness Approx 235 kPa 2 3 34 psi A Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes A If the fume from the nozzle directly contacts the...

Page 91: ... 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 radiator drain plug 2 and remove radiator cap 1 to completely drain the coolant 2 After all coolant is drained close the drain plug 2 Valve seat tightness Factory spec No fuel leak at 12 75 MPa 130 1849 psi 0000000935E C...

Page 92: ...ture Refer to LUBRICANTS FUEL AND COOLANT See page G 8 Battery A When disconnecting the battery cables disconnect the negative cable from the battery first When connecting connect the positive cable to the battery first 1 Open the bonnet 2 Remove the radiator net 3 Disconnect the negative cable 1 from the battery 4 Disconnect the positive cable 2 from the battery and remove the battery 3 Engine Oi...

Page 93: ...emove the side bonnet 3 Air Cleaner Muffler Fuel Hose and Wire Harness 1 Remove the air cleaner 1 and muffler 2 2 Disconnect the fuel hoses 3 3 Disconnect the accelerator wire 4 4 Disconnect the wire harness 5 1 Bonnet 4 Wire Harness 2 Bonnet Bracket 5 Connector 3 Side Bonnet 0000009461E 1 Air Cleaner 4 Accelerator Wire 2 Muffler 5 Wire Harness 3 Fuel Hose 0000009513E KiSC issued 04 2006 A ...

Page 94: ...engine assembly 6 with radiator from the frame 3 When reassembling Tightening torque Front coupling mounting screw 23 5 to 27 4 2 4 to 2 8 17 4 to 20 3 ft lbs Engine mounting nut 23 5 2 4 17 4 ft lbs 1 Radiator Stopper 4 Joint Pin 2 Radiator Stopper Snap Pin 5 Front Coupling 3 Frame 6 Engine Assembly 0000010085E KiSC issued 04 2006 A ...

Page 95: ...er 2 When reassembling A Check to see if the cylinder head cover gasket is not defective Injection Pipes 1 Loosen the screw on the pipe clamp 1 2 Detach the injection pipes 2 When reassembling A Sent compressed air into the pipes to blow out dust Then reassemble the pipes in the reverse order Tightening torque Air cleaner stay screw 23 5 to 27 4 2 4 to 2 8 17 4 to 20 3 ft lbs Engine support screw ...

Page 96: ...ing A When putting the push rods 2 onto the tappets 3 check to see if their ends are properly engaged with the dimples A After installing the rocker arm be sure to adjust the valve clearance Tightening torque Overflow pipe retaining nut 19 6 to 24 5 2 0 to 2 5 14 5 to 18 1 ft lbs Nozzle holder assembly 49 0 to 68 6 5 0 to 7 0 36 2 to 50 6 ft lbs Glow plug 7 85 to 14 7 0 8 to 1 5 5 8 to 10 8 ft lbs...

Page 97: ... sequence starting from the centre A Tighten them uniformly or the head may deform in the long run A Retighten the cylinder head screws after running the engine for 30 minutes Tappets 1 Remove the tappets 1 from the crankcase When reassembling A Visually check the contact between tappets and cams for proper rotation If defect is found replace tappets A Before installing the tappets apply engine oi...

Page 98: ...ually check the O ring 1 apply engine oil and install it A Securely fit the O ring to the oil strainer A To avoid uneven tightening tighten oil pan mounting screws in diagonal order from the center A Using the hole 6 numbered 3 install the oil strainer by mounting screw A Scrape off the old adhesive completely Wipe the sealing surface clean Now apply new adhesive 3 to 5 mm 0 12 to 0 20 in thick al...

Page 99: ...as shown in the figure A The sealant is applied to both sides of the soft metal gasket shim The liquid gasket is not required for assembling A Addition or reduction of shim 0 05 mm 0 0020 in delays or advances the injection timing by approx 0 0087 rad 0 5 A In disassembling and replacing be sure to use the same number of new gasket shims with the same thickness Fan Drive Pulley 1 Secure the flywhe...

Page 100: ...ng 2 from the fork lever 1 3 Remove the gear case 3 When reassembling A Apply a liquid gasket Three Bond 1215 or equivalent to both sides of the gear case gasket 4 A Be sure to set three O rings 5 inside the gear case 1 Screw Inside 4 Gear Case Gasket 2 Start Spring 5 O rings 3 Gear Case 6 Screw 0000004067E KiSC issued 04 2006 A ...

Page 101: ...oto Camshaft 1 Remove the camshaft mounting screws 1 and draw out the camshaft with gear 2 on it When reassembling A When install the camshaft apply engine oil to the camshaft journals A Apply engine oil to the camshaft mounting screws And tighten them Tightening torque Idle gear shaft mounting screw 9 8 to 11 3 1 00 to 1 15 7 2 to 8 3 ft lbs 1 Idle Gear 4 Idle Gear Shaft Mounting 2 Idle Gear Coll...

Page 102: ...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 crankhshaft gear 1 When reassembling A Install the collar 4 after aligning the marks on the gears See the figure at Idle Gear 1 Retaining Plate 5 Fork Lever 1 2 Fuel Camshaft 6 Fork Lever 2 3 Injection Pump Gear 7 Governor Spring 4 Governor Sleeve 8 Fork...

Page 103: ...reassembling A Before inserting the piston into the cylinder apply enough engine oil to the piston A When inserting the piston into the cylinder face the mark on the connecting rod to the injection pump A 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 A When installing the piston into the cylinder place...

Page 104: ...ide of the oil ring gap 11 A Apply engine oil to the piston pin A When installing the connecting rod to the piston immerse the piston in 80 176 oil for 10 to 15 minutes and insert the piston pin to the piston A When installing the connecting rod to the piston align the mark 8 on the connecting rod to the fan shaped concave 9 A Mark the same number on the connecting rod and the piston so as not to ...

Page 105: ...cover 6 When reassembling A Fit the bearing case gasket 3 and the bearing case cover gasket 4 with correct directions A Install the bearing case cover 6 to position the casting mark UP a on it upward A Apply engine oil to the oil seal 5 lip and take care that it is not rolled when installing A Tighten the bearing case cover mounting screws with even force on the diagonal line Tightening torque Fly...

Page 106: ...er comes to the center of the third cylinder 4 Repeat the above steps to draw out all the crankshaft When reassembling A Clean the oil passage of the crankshaft with compressed air A Install the crankshaft assembly aligning the screw hole of main bearing case screw 2 with the screw hole of crankcase A When tightening the main bearing case screw 2 1 apply oil to it and screw by hand before tighteni...

Page 107: ...g 3 4 5 Install the bearing with the oil groove c up A Match the alignment numbers a on the main bearing case assembly 1 A Do the same for the main bearing case assembly 2 2 and the main bearing case assembly 3 too A When installing the main bearing case 1 and 2 face the mark FLYWHEEL to the flywheel A Install the thrust bearing 8 with its oil groove facing outward A Confirm that the main bearing ...

Page 108: ...an and fan pulley 3 Remove the water pump assembly from the gear case cover 4 Remove the water pump flange 1 5 Press out the water pump shaft 2 with the impeller 5 on it 6 Remove the impeller from the water pump shaft 7 Remove the mechanical seal 4 When reassembling A Apply a liquid gasket Three Bond 1215 or equivalent to the both sides of gasket A Replace the mechanical seal with new one 1 Thermo...

Page 109: ...al lines as shown in the figure 3 Measure the clearance with a thickness gauge 4 If the measurement exceeds the allowable limit correct it with a surface grinder A Do not place the straightedge on the combustion chamber A Be sure to check the valve recessing after correcting Tightening torque Nozzle holder 34 3 to 39 2 3 5 to 4 0 25 3 to 28 9 ft lbs Overflow pipe retaining nut 19 6 to 24 5 2 0 to ...

Page 110: ... marks Valve Recessing 1 Clean the cylinder head surface valve face and valve seat 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 still exceeds the allowable limit after replacing the valve replace the cylinder head 1 Red Permetive Liquid 3 White Developer 2 Detergent 0000000875E Va...

Page 111: ...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 specified dimension A Do not hit the valve guide with a hammer during replacement Clearance between valve stem and valve guide Factory spec 0 030 to 0 057 mm 0 00118 to 0 00224 in Allowable limit 0 10 mm 0 0039 ...

Page 112: ...oes not seat all the way around the valve seat or the valve contact is less than 70 correct the valve seating as follows 3 If the valve contact does not comply with the reference value replace the valve or correct the contact of valve seating Valve seat width Factory spec 2 12 mm 0 0835 in 1 Correct 3 Incorrect 2 Incorrect 0000000879E KiSC issued 04 2006 A ...

Page 113: ...a 0 785 rad 45 valve seat cutter again and visually recheck the contact between the valve and seat 5 Repeat steps 3 and 4 until the correct contact is achieved 6 Continue lapping until the seated rate becomes more than 70 of the total contact area Valve Lapping 1 Apply compound evenly to the valve lapping surface 2 Insert the valve into the valve guide Lap the valve onto its seat with a valve flap...

Page 114: ...ocker Arm and Rocker Arm Shaft 1 Measure the rocker arm shaft O D with an outside micrometer 2 Measure the rocker arm I D with an inside micrometer and then calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the rocker arm and measure the oil clearance again If it still exceeds the allowable limit replace also the rocker arm shaft Free length A Factory spec 31 3...

Page 115: ...with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the tappet Push rod alignment Allowable limit 0 25 mm 0 0098 in 0000000885E Oil clearance between tappet and tappet guide bore Factory spec 0 016 to 0 052 mm 0 00063 to 0 00205 in Allowable limit 0 10 mm 0 0039 in Tappet O D Factory spec 17 966 to 17 984 mm 0 70...

Page 116: ...he cam gear to the front and rear 3 If the measurement exceeds the allowable limit replace the camshaft stopper Backlash between idle gear and crank gear Factory spec 0 043 to 0 124 mm 0 00169 to 0 00488 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and cam gear Factory spec 0 047 to 0 123 mm 0 00185 to 0 00484 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and i...

Page 117: ...nal 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 allowable limit replace the camshaft Camshaft alignment Allowable limit 0 01 mm 0 0004 in 0000000891E Cam height of intake and exhaust Factory spec 26 88 mm 1 0583 in Allowable limit 26 83 mm 1 0563 in 0000000892E Oil clearan...

Page 118: ... bushing using an idle gear bushing replacing tool until it is flush with the end of the idle gear 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 Oil clearance between idle gear shaft and idle gear bushing Factory spec 0 020 to ...

Page 119: ...hing 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 A Be sure to chamfer the oil hole circumference with an oil stone Oil clearance between piston pin and small end bushing Factory spec 0 014 to 0 038 mm 0 00055 to 0 00150 in Allowable limit 0 10 mm 0 0039 in Piston pin O D ...

Page 120: ...ble limit replace the piston ring 4 If the clearance still exceeds the allowable limit with new ring replace the piston Piston ring gap Top ring Factory spec 0 15 to 0 30 mm 0 0059 to 0 0118 in Allowable limit 1 20 mm 0 0472 in Second ring Factory spec 0 30 to 0 45 mm 0 0118 to 0 0177 in Allowable limit 1 20 mm 0 0472 in Oil ring Factory spec 0 15 to 0 30 mm 0 0059 to 0 0118 in Allowable limit 1 2...

Page 121: ...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 plate measure the space between the pin of the gauge and the face plate 6 If the measurement exceeds the allowable limit replace the connecting rod Space between gauge pin face plate Allowable limit 0 05 mm 0 0020 in 0000000902E KiSC issu...

Page 122: ...t alignment 4 If the measurement exceeds the allowable limit replace the crankshaft Crankshaft side clearance Factory spec 0 15 to 0 31 mm 0 0059 to 0 0122 in Allowable limit 0 50 mm 0 0197 in Oversize Bearing Code Number Marking 0 2 mm 0 008 in Thrust bearing 1 02 15261 23950 020 OS Thrust bearing 2 02 15261 23970 020 OS 0 4 mm 0 016 in Thrust bearing 1 04 15261 23960 040 OS Thrust bearing 2 04 1...

Page 123: ...od screws are tightened Reference A Undersize crankpin bearing A Undersize dimensions of crankpin Oil clearance between crankpin and crankpin bearing Factory spec 0 020 to 0 051 mm 0 00079 to 0 00201 in Allowable limit 0 15 mm 0 0059 in Crankpin O D Factory spec 33 959 to 33 975 mm 1 33697 to 1 33760 in Crankpin bearing I D Factory spec 33 995 to 34 010 mm 1 33893 to 1 33898 in Undersize Bearing C...

Page 124: ...l and crankshaft bearing 1 Factory spec 0 034 to 0 106 mm 0 00134 to 0 00417 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory spec 39 934 to 39 950 mm 1 57221 to 1 57284 in Crankshaft bearing 1 I D Factory spec 39 984 to 40 040 mm 1 57417 to 1 57638 in Undersize Bearing Code Number Marking 0 2 mm 0 008 in Crankshaft bearing 1 02 15861 23910 020 US 0 4 mm 0 016 in Crankshaft bear...

Page 125: ...f the oil clearance exceeds the allowable limit replace the crankshaft bearing 2 crankshaft bearing 3 5 If the same size bearing is useless because of the crankshaft journal wear replace it with an undersize one referring to the table and figure A Be sure not to move the crankshaft while the bearing case screws are tightened Dimension A Factory spec 0 0 to 0 3 mm 0 0 to 0 0118 in 1 Seam A Dimensio...

Page 126: ...Marking 0 2 mm 0 008 in Crankshaft bearing 2 02 15694 23930 020 US Crankshaft bearing 3 02 15861 23860 020 US 0 4 mm 0 016 in Crankshaft bearing 2 04 15694 23940 040 US Crankshaft bearing 3 04 15861 23871 040 US Undersize 0 2 mm 0 008 in 0 4 mm 0 016 in Dimension A 1 8 to 2 2 mm radius 0 071 to 0 087 in radius 1 8 to 2 2 mm radius 0 071 to 0 087 in radius Dimension B 3 mm dia 0 12 in dia 3 mm dia ...

Page 127: ...d Pump Body 1 Measure the clearance between the outer rotor and the pump body with a thickness gauge 2 If the clearance exceeds the factory specifications replace the oil pump rotor assembly Cylinder I D Oversize Factory spec 67 250 to 67 269 mm 2 64764 to 2 64839 in Allowable limit 67 419 mm 2 65429 in Finishing Horn to 1 2 to 2 0 m Rmax 0 000047 to 0 000079 in Rmax Oversize Part Name Code Number...

Page 128: ... the cover and tighten the screws 3 Remove the cover carefully and measure the amount of the flattening with the scale and get the clearance 4 If the clearance exceeds the factory specifications replace the oil pump rotor assembly Clearance between rotor and cover Factory spec 0 075 to 0 135 mm 0 00295 to 0 00531 in 0000000918E KiSC issued 04 2006 A ...

Page 129: ...2 TRANSAXLE KiSC issued 04 2006 A ...

Page 130: ...e 2 M2 2 Oil Flow 2 M3 3 Operation 2 M4 4 By pass Valve 2 M7 5 Control Linkage 2 M8 2 GLIDE STEER SECTION 2 M9 1 General 2 M9 2 Operation 2 M11 3 FRONT WHEEL DRIVE SECTION 2 M12 3 MOWER PTO SYSTEM 2 M13 1 MOWER PTO CLUTCH 2 M13 4 OTHERS 2 M15 1 HYDRAULIC PUMP SECTION 2 M15 KiSC issued 04 2006 A ...

Page 131: ...shown above This machine is equipped with left and right clutches in transaxle 1 Hydraulic Pump Section 3 Front Wheel Drive Section 5 Glide Steer Section 7 Rear Axle Section 2 Input Shaft 4 Bevel Gear Section 6 Hydrostatic Transmission 8 Mower PTO Section 0000010096E KiSC issued 04 2006 A ...

Page 132: ...nnion arm 2 in HST via a link mechanism the speed change pedal permits simple operation of the machine starting stopping and increasing or decreasing speed 1 Check and High Pressure 7 Spring Cylinder Block 14 Pump Shaft 21 By pass Spool Relief Valve 8 Washer 15 Ball Bearing 22 By pass Spring 2 Trunnion Arm 9 Thrust Ball Bearing 16 Oil Seal 23 Journal Bearing 3 Center Section 10 Swashplate 17 Motor...

Page 133: ... provides the functionality of a charge relief valve Therefore the oil passed through the filter cartridge is routed to HST as charge oil Overflow oil from the HST housing flows back to the transaxle 1 Pump 5 Hydraulic Control Valve 9 By pass Valve A From Power Steering 2 Check and High Pressure Assembly 10 Check and High Pressure Controller Relief Valve Forward 6 Hydraulic Pump Relief Valve Rever...

Page 134: ...rate pressure no pressure is transmitted to the motor pistons thus causing neither rotation of the motor cylinder block 15 nor that of the motor shaft engaged with it Thus the machine is stationary B Neutral 1 Filter Cartridge 7 Hydraulic Control Valve 11 Lubricating Orifice 14 Piston 2 HST Relief Valve Assembly 12 Check and High Pressure 15 Cylinder Block Mower 3 Power Steering Controller 8 Hydra...

Page 135: ...causing them to slide on the inclined surface This causes the motor cylinder block 15 and the motor shaft engaged with it to rotate This causes the machine to move forward The inclination of the pump swashplate 9 determines the motor shaft speed B Forward 1 Filter Cartridge 7 Hydraulic Control Valve 11 Lubricating Orifice 14 Piston 2 HST Relief Valve Assembly 12 Check and High Pressure 15 Cylinder...

Page 136: ...lined thrust ball bearing causing them to slide on the inclined surface This causes the motor cylinder block 15 and the motor shaft engaged with it to rotate This causes the machine to move reverse The inclination of the pump swashplate 9 determines the motor shaft speed B Reverse 1 Filter Cartridge 7 Hydraulic Control Valve 11 Lubricating Orifice 14 Piston 2 HST Relief Valve Assembly 12 Check and...

Page 137: ...owing paragraphs describe this mechanism Pressing the by pass valve connects the forward and reverse loops in the center section This allows oil to flow between the forward and reverse loops through the by pass valve to rotate only the motor cylinder block This means that pressing the by pass valve while the engine is stopped that is while the pump shaft is not rotating permits rotating the motor ...

Page 138: ... 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 tension of neutral spring 5 At the same time the swashplate is returned to neutral when the pedal is released 1 Speed Change Pedal 3 Speed Change Plate 5 Neutral Spring 6 Speed Control Arm 2 Speed Change Rod ...

Page 139: ...n the rear transaxle The clutch lever 2 is connected to the king pin support on the front axle with the wire 3 When turning left or right the wire connecting to the king pin support on the front axle disengages only the steering clutch of the turn side This shuts off driving power to the rear wheel on the inside of the turn On the other hand the rear wheel on the outside of the turn has driving po...

Page 140: ...he rear axle Therefore on a minimum turn the right and left rear wheels will have more free spins causing greater damage to turf B For Glide Steer System In the Glide Steer system driving power is transmitted only to the right and left front wheels and the rear wheel on the outside of the turn The rear wheel on the inside of the turn does not receive driving power Assuming that the speeds of the d...

Page 141: ...ft 5 Right drive shaft Spline boss Clutch case 11T gear shaft 65T gear shaft Rear wheel RH B On Turning Right or Left On turning right or left the steering clutch on the inner side of the turn is disengaged No driving power is transmitted to the rear wheels on the inside of the turn At this time right and left front wheels and the rear wheel on the outside of the turn drive the machine When the fr...

Page 142: ...his machine always has the front axle driven Driving power is transmitted to the front axle as follows Motor shaft 3 15T gear 4 29T gear 2 Front wheel drive shaft 1 1 Front Wheel Drive Shaft 3 Motor Shaft 2 29T Gear 4 15T Gear 0000010109E KiSC issued 04 2006 A ...

Page 143: ...tion the clutch lever 2 connected to the PTO lever via a link mechanism rotates to the rear side of the machine The clutch lever pushes the spline boss 3 toward the rear side of the machine via the thrust collar 10 which eliminates the clearance between the clutch disc and friction plate 4 causing friction necessary to transmit driving power This allows driving power to be transmitted as follows 1...

Page 144: ...ch creates clearance between the clutch disc and friction plate 4 causing no friction This eliminates the clearance between brake discs and friction plate 9 causing friction Driving power to the PTO shaft 1 is thus shut off and brake engages to prevent the PTO shaft 1 from free spinning 1 PTO Shaft 6 24T Gear 2 Clutch Lever 7 19T 2 Gear 3 Spline Boss 8 Spring 4 Clutch Disc and Friction 9 Brake Dis...

Page 145: ... pump 1 is mounted on the transaxle case The power to drive the hydraulic pump 1 is transmitted as follows Input shaft 4 25T gear 3 on input shaft Hydraulic pump gear shaft 2 1 Hydraulic Pump 3 25T Gear 2 Hydraulic Pump Gear 4 Input Shaft Shaft 0000010110E KiSC issued 04 2006 A ...

Page 146: ...RVICING 2 S6 1 CHECKING AND ADJUSTING 2 S6 2 PREPARATION 2 S9 1 Separating Transaxle 2 S9 2 Separating Hydrostatic Transmission 2 S17 3 DISASSEMBLING AND ASSEMBLING 2 S19 1 Hydrostatic Transmission 2 S19 2 Transaxle Case 2 S21 4 SERVICING 2 S27 1 Hydrostatic Transmission 2 S27 2 Transaxle Case 2 S29 KiSC issued 04 2006 A ...

Page 147: ...nd high pressure relief valve 2 S20 A By pass valve defective Replace by pass valve 2 S20 A HST component parts defective Replace HST assembly 2 S18 Vibration and Noise A Oil level is low Fill oil to proper level G 8 2 S11 A Control linkage defective Speed change pedal to speed control arm Repair control linkage 2 S7 15 A Charge pressure is too low A Oil filter cartridge clogged Replace oil filter...

Page 148: ...embly 2 S18 Oil Heat Over A Oil level is low Fill oil to proper level G 8 2 S11 A Excessive machine load Reduce machine load A Charge pressure is too low A Oil filter cartridge clogged Replace oil filter cartridge G 31 A HST relief valve defective Replace HST relief valve 6 S11 A Hydraulic pump defective Replace hydraulic pump 6 S8 Machine Will Not Stop in Neutral Position A Control linkage defect...

Page 149: ...ce 2 S27 A Improper adjustment of wire Adjust 2 S16 4 S5 The Driving Power to Rear Wheel on inside of Turn is not Shut Off at the Time of Turning A Steering clutch disc and friction plate are agglutinated Replace 2 S27 A Improper adjustment of wire Adjust 2 S16 4 S5 A Wire broken Replace 2 S16 4 S7 0000010117E MOWER PTO SECTION Symptom Probable Cause Solution Reference Page PTO Clutch Slip A Impro...

Page 150: ...tch Spring Free Length 45 mm 1 77 in 42 mm 1 65 in PTO brake disc 1 Thickness 2 85 to 3 05 mm 0 11 to 0 12 in 2 75 mm 0 108 in PTO Brake Disc Thickness 3 3 to 3 5 mm 0 13 to 0 14 in 3 0 mm 0 118 in Brake Friction Plate 1 Thickness 1 75 to 1 85 mm 0 069 to 0 073 in 1 60 mm 0 063 in Brake Friction Plate 2 Thickness 0 95 to 1 05 mm 0 037 to 0 041 in 0 80 mm 0 031 in Clutch spline plate Thickness 0 75...

Page 151: ...7 5 to 90 2 7 91 to 9 19 57 2 to 66 5 Transaxle mounting screw 48 1 to 55 8 4 9 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 hex socket head screw 17 7 to 20 6 1 8 to 2 1 13 1 to 15 2 By pass valve plug 15 0 1 53 11 1 Check valve plug 30 0 3 06 ...

Page 152: ... arm 1 Position B 8 Rotate the holder shaft 2 clockwise so that the rear wheels turn in reverse 9 Then rotate it counterclockwise until the rear wheels stop completely 10 Put a mark on the neutral arm 1 Position A 11 Set the holder shaft 2 where it is right in the center between position A and B and tighten the holder shaft mounting screw 3 firmly This means the hydrostatic transaxle is fully in n...

Page 153: ...7 to 0 91 in Adjusting Maximum Speed A This adjustment should be performed after completing the adjustment of neutral Forward 1 Loose the lock nut 2 of adjusting screw 2 Adjust the length A with the adjusting screw 1 Reference A Length A 10 to 12 mm 0 40 to 0 47 in A 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 with the adj...

Page 154: ...nd apply the parking brake 1 Remove the hexagon socket head plug 9 16 18 UNF from P1 1 or P2 2 then install the adaptor cable and pressure gauge 2 Start the engine and run it at maximum speed 3 Depress the speed change pedal to forward or reverse and read the pressure gauge to measure the high relief pressure 4 If the measurement is not same as factory specification check the high pressure relief ...

Page 155: ...nt the grass container 1 When reassembling A Pull the grass container lock rod 4 and hold it to hook the stopper A Put the container pipe frame 6 on the stay 5 A Release the grass container lock rod 4 so that the lock arm 7 holds the container pipe frame 6 A Grip the grass container lock handle 2 with the handle 3 And turn the container 1 around the container pipe frame 6 that held by the lock arm...

Page 156: ...ectors 2 3 Open the switch cover 6 And disconnect the connector 4 from the grass container full switch 5 4 Remove the discharge duct 3 5 Remove the container base 7 1 Coupler 5 Grass Container Full Switch 2 Connector 6 Switch Cover 3 Discharge Duct 7 Container Base 4 Connector 0000009314E KiSC issued 04 2006 A ...

Page 157: ...smission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 8 A Never work the machine immediately after changing the transmission oil Keeping the engine at medium speed for a few minutes to prevents damage to the transmission A Do not mix different blands oil together Battery A When disconnecting the battery cables disconnect the negative cable from the battery first When connect...

Page 158: ... mounting screws 1 1 2 Remove the seat base mounting screws 2 3 3 Slide the seat base 2 and remove it Fuel Tank 1 Drain the fuel 2 Disconnect the fuel hoses 3 Remove the fuel tank 1 1 Seat 2 Snap Pin 0000010128E 1 Fuel Cap 4 Step Sheet 2 Fender 5 Speed Change Pedal 3 Fender Mounting Screw 0000009320E 1 Seat Base Mounting Screw 1 3 Seat Base Mounting Screw 2 2 Seat Base 0000009321E 1 Fuel Tank 0000...

Page 159: ...ever 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 A After completing above assembling adjustment repeat the motion several times to set the PTO lever at Disengaged and Engaged position Then finally set the PTO lever at Engaged position Be sure to check that the upper side of PT...

Page 160: ...pring 3 3 Remove the brake plate 5 4 Remove the brake rod 2 4 and brake rod 1 6 When reassembling A After assembling the brake rod 1 2 4 6 and brake spring 3 be sure to adjust the brake pedal free travel see page 3 S4 1 PTO Switch 4 Filling Pipe 2 Spring 5 Beam 3 PTO Lever 0000009324E Tightening torque Brake plate mounting screw 35 to 40 3 47 to 4 07 25 1 to 29 5 ft lbs 1 Lock Nut 4 Brake Rod 2 2 ...

Page 161: ...reassembling A Apply grease to the splines of the universal joint Front Wheel Drive Shaft 1 Remove the bearing holder 1 2 Disconnect the front wheel drive shaft 2 and spline boss 3 from transaxle When reassembling A Install the spline boss 3 a shown in figure 1 Speed Change Plate 4 Speed Change Rod 2 Rue Ring Pin 5 Lock Nut 3 Speed Control Arm 0000010131E Tightening torque Universal joint mounting...

Page 162: ...smission 1 Remove the transaxle mounting screws 2 2 Separate the transaxle 1 from the frame When reassembling 1 Rue Ring Pin 3 Adjusting Nut 2 Wire Stay 4 Glide Steer Wire 0000010136E Tightening torque Power steering pipe 20 0 to 25 0 2 04 to 2 54 14 76 to 18 43 ft lbs Rear wheel mounting nut 77 5 to 90 2 7 91 to 9 19 57 2 to 66 5 ft lbs 1 Power Steering Pipe 3 Rear Wheel To Power Steering Control...

Page 163: ...eer levers 10 13 8 Remove the spring stays 15 16 Neutral Arm Holder and Filter Bracket 1 Remove the neutral arm holder 2 with neutral arm 1 2 Remove the hydraulic control valve assembly 3 with filter cartridge 1 Speed Control Arm 9 Return Spring 2 Neutral Spring 10 Glide Steer Lever 3 Breather Hose 11 Wire Stay 4 Cooling Fan 12 Wire Stay 5 Control Valve Pipe 13 Glide Steer Lever 6 Suction Pipe 1 1...

Page 164: ...ion assembly insert the drain pipe 3 in the hole 2 surely so as not to drop out it 1 Brake Assembly 3 Brake Drum 2 External Snap Ring 0000009335E Tightening torque Hydrostatic transmission mounting screw 23 5 to 27 5 2 4 to 2 8 17 3 to 20 3 ft lbs Hydrostatic transmission mounting screw 2 17 7 to 20 6 1 8 to 2 1 13 1 to 15 2 ft lbs 1 Hydrostatic Transmission 3 Drain Pipe Assembly 4 Hydrostatic Tra...

Page 165: ...soft hammer and separate the center section 1 from the HST housing 2 When reassembling A Cover the splines of each shaft with thin tape to protect the sealing lip of the oil seals A Place a new gasket on the HST housing A Take care not to damage the surface of cylinder blocks pistons and center section 1 Front Drive Shaft 4 Bevel Gear Shaft 2 15T Gear 5 External Snap Ring 3 34T Gear 6 Shim 0000010...

Page 166: ...e cylinder block assembly motor side 5 3 Remove the thrust ball bearing 4 When reassembling A Apply clean transmission oil to thrust ball bearing cylinder block and piston A Take care not to damage the surface of cylinder blocks and pistons Tightening torque By pass valve plug 15 0 1 53 11 1 ft lbs 1 Spring 3 O ring 2 By pass Spool 4 Plug 0000009343E Tightening torque Check and high pressure relie...

Page 167: ...nd trunnion arm 3 2 Remove the cradle bearings 1 from the HST housing When reassembling A Apply clean transmission oil to the cradle bearings 1 and trunnion arm A Fasten down the cradle bearing to the HST housing 2 Transaxle Case Hydraulic Pump 1 Unscrew the hydraulic pump mounting screws 2 2 Remove the hydraulic pump 1 When reassembling 1 Thrust Ball Bearing 6 Internal Snap Ring 2 Swashplate 7 Oi...

Page 168: ...n reassembling A Install the ball bearing 2 with the sealed face inside A Align the tangs 4 of PTO brake friction plate with the slots 3 of transaxle case Tightening torque PTO clutch assembly mounting screw 17 7 to 20 6 1 8 to 2 1 13 1 to 15 2 ft lbs 1 PTO Clutch Assembly 3 Slot 2 Ball Bearing 4 Tang 0000009348E KiSC issued 04 2006 A ...

Page 169: ...5 and the spline boss 9 with clutch disc and friction plate 10 3 Then remove the thrust needle bearing 6 collar 7 and spring 8 4 Remove the external snap ring 11 clutch disc and friction plate 10 from the spline boss 1 24T Gear 7 Collar 2 Clutch 8 Spring 3 Brake Disc and Friction Plate 9 Spline Boss 4 PTO Shaft 10 Clutch Disc and Friction Plate 5 Clutch Case 11 External Snap Ring 6 Thrust Needle B...

Page 170: ...nap ring 3 with external 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 Beam and Wire Lever 1 Remove the wire levers 1 3 and beam 2 from the transaxle case 1 PTO Shaft 5 PTO Clutch Cover 2 Thrust Collar 6 Ball Bearing 3 External Snap Ring 7 Oil Seal 4 Clutch Lever 0000010145E 1 Wire Lever 3 Wire Lever 2 Beam 000...

Page 171: ...he direction shown in figure A 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 torque Tightening torque Transaxle case screw 7 8 to 8 8 0 8 to 0 9 5 8 to 6 5 ft lbs 1 Transaxle Case Rear Side F Front Side 2 Transaxle Case Screw R Rear Side 3 Transaxle Case Front Side A Screws Wh...

Page 172: ...ng Clutch Clutch Lever 11T Gear Shaft 42T Gear Shaft and Drive Shaft 1 Remove the steering clutches 2 8 clutch levers 3 5 11T gear shafts 1 9 42T gear shaft 4 and drive shaft 10 from transaxle case 1 Pump Drive Gear 5 17T 13T Gear Shaft 2 Input Shaft 6 External Snap Ring 3 Intermediate Shaft 7 Collar 4 19T 2 Gear 8 Needle Bearing 0000010147E 1 11T Gear Shaft LH 7 Spacer 2 Steering Clutch LH 8 Stee...

Page 173: ...2 and remove the rear wheel hub 3 4 Remove the oil seal 4 bush 5 collar 6 and external snap ring 7 from 67T gear shaft 8 4 SERVICING 1 Hydrostatic Transmission Center Section 1 Check the surfaces 1 of center section for scratches or wear 2 If deep scratch or excessive wear is found replace the hydrostatic transmission assembly 1 Internal Snap Ring 6 External Snap Ring 2 Clutch Plate 7 Spacer 3 Clu...

Page 174: ...r free movement in the cylinder block bores 5 If the piston or the cylinder block is scored replace the cylinder block assembly 6 Check the polished face 1 of cylinder block for scoring 7 If scored replace the cylinder block assembly A Do not interchange pistons between pump and motor cylinder block Pistons and cylinder blocks are matched Thrust Ball Bearing 1 Check the thrust ball bearing 1 for s...

Page 175: ...r wear 3 If the oil seals and bushings are worn or damaged replace them 2 Transaxle Case Checking Bearing 1 Hold the inner race and push and pull the outer race in all directions to check for wear and roughness 2 Apply transmission fluid to the bearing and hold the inner race Then turn the outer race to check rotation 3 If there is any defect replace it 1 Seal Surface 3 Ball Bearing 2 Bearing Surf...

Page 176: ...lipers 2 If the measurement is less than the allowable limit replace it Thickness of PTO clutch disc Factory spec 1 3 to 1 5 mm 0 051 to 0 059 in Allowable limit 1 2 mm 0 047 in 0000009359E Thickness of pressure plate Factory spec 1 55 to 1 65 mm 0 061 to 0 065 in Allowable limit 1 50 mm 0 059 in Thickness of friction plate 1 Factory spec 1 55 to 1 65 mm 0 061 to 0 065 in Allowable limit 1 50 mm 0...

Page 177: ...f the thickness is less than the allowable limit replace it PTO brake disc 1 thickness Factory spec 2 85 to 3 05 mm 0 11 to 0 12 in Allowable limit 2 75 mm 0 108 in PTO brake disc thickness Factory spec 3 3 to 3 5 mm 0 13 to 0 14 in Allowable limit 3 00 mm 0 118 in 0000010153E 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 Thickn...

Page 178: ...A 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 mm 0 020 in For 17T 13T gear shaft RH 5 0 2 mm 0 008 in 0 3 mm 0 012 in 0 5 mm 0 020 in A Tooth contact More than 35 Thickness of friction plate Factory spec 0 75 to 0 85 mm 0 030 to 0 033 in Allowable limit 0 70 mm 0 028 in Thick...

Page 179: ...3 BRAKES KiSC issued 04 2006 A ...

Page 180: ...RVICING 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 Brake Assembly 3 S8 KiSC issued 04 2006 A ...

Page 181: ...e Adjust 3 S4 A Brake shoe worn Replace 3 S8 A Brake drum worn Replace 3 S8 A Grease or oil on brake shoe Replace 3 S8 Brake Drags A Brake pedal free travel too small Adjust 3 S4 A Brake spring weaken or broken Replace 3 S8 Heavy Brakes A Brake pedal rusted Repair or replace 3 S8 A Brake cam lever rusted Replace 3 S8 0000010174E KiSC issued 04 2006 A ...

Page 182: ...GR2100EC WSM BRAKES 3 S2 2 SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Brake Pedal Free Travel 15 to 25 mm 0 59 to 0 98 in 0000009613E KiSC issued 04 2006 A ...

Page 183: ...ews bolts and nuts See page G 9 Item ft lbs Steering wheel mounting nut 20 to 25 2 0 to 2 5 14 8 to 18 4 Power steering hose mounting nut 24 0 to 28 0 2 45 to 2 85 17 71 to 20 65 Steering support mounting screw 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 Pedal system component mounting nut 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 0000010175E KiSC issued 04 2006 A ...

Page 184: ...ING 1 Pedal System Component Dismounting Mower 1 See page 8 S6 Mower Section Dismounting Container 1 See page 2 S9 Transaxle Section Battery A When disconnecting the battery cables disconnect the negative cable from the battery first When connecting connect the positive cable to the battery first 1 Open the bonnet 2 Remove the radiator net 3 Disconnect the negative cable 1 from the battery 4 Disco...

Page 185: ...e container base 7 Seat 1 Remove the snap pin 2 2 Remove the seat 1 Fender 1 Remove the speed change pedal 5 2 Peel the step sheet 4 halfway 3 Remove the fuel cap 1 4 Remove the fender 2 1 Coupler 5 Grass Container Full Switch 2 Connector 6 Switch Cover 3 Discharge Duct 7 Container Base 4 Connector 0000009314E 1 Seat 2 Snap Pin 0000010128E 1 Fuel Cap 4 Step Sheet 2 Fender 5 Speed Change Pedal 3 Fe...

Page 186: ...itch 4 and light switch 5 Remove the indicator lamps 5 6 Remove the fuse box 6 from the steering support 7 Remove the panel 2 When reassembling Separating Engine 1 See page 1 S20 Engine Section Tightening torque Steering wheel mounting nut 20 to 25 2 0 to 2 5 14 8 to 18 4 ft lbs 1 Steering Wheel 4 Main Switch 2 Panel 5 Indicator Lamp 3 Side Bonnet 6 Fuse Box 0000010178E 0000010179E KiSC issued 04 ...

Page 187: ...om the pedal system component 2 Disconnect the speed change rod 2 from the pedal system component Tightening torque Power steering hose mounting nut 24 0 to 28 0 2 45 to 2 85 17 71 to 20 65 ft lbs Steering support mounting screw 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 ft lbs 1 Cylinder Hose LH A Bottom View 2 Cylinder Hose RH P Pump Port 3 Return Hose Connected to Delivery Hose 4 Delivery Hose T Tank...

Page 188: ...rnal snap ring 7 6 Pull out the brake drum 8 When reassembling A Apply liquid gasket Three Bond 1208D or equivalent to joint face of the brake assembly A After assembling the brake assembly be sure to adjust the brake pedal free travel see page 3 S4 Tightening torque Pedal system component mounting nut 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 ft lbs 1 Parking Lock Spring 3 Pedal System Component 2 Ped...

Page 189: ...4 FRONT AXLE KiSC issued 04 2006 A ...

Page 190: ...CONTENTS 1 STRUCTURE 4 M1 KiSC issued 04 2006 A ...

Page 191: ...reduced by the bevel gear shaft 17 and 35T bevel gear 14 then the power is transmitted to the front axle shaft 16 The differential system allows each wheel to rotate at a different speed to make turning easier 1 King Pin Support 2 Front Axle Case Front Side 3 Differential Gear Assembly 4 Differential Pinion Shaft 5 Differential Pinion Gear 6 Differential Yoke Shaft RH 7 Differential Side Gear 8 Be...

Page 192: ...S2 3 TIGHTENING TORQUES 4 S3 4 CHECKING DISASSEMBLING AND SERVICING 4 S4 1 CHECKING AND ADJUSTING 4 S4 2 PREPARATION 4 S6 1 Separating Front Axle Assembly 4 S6 3 DISASSEMBLING AND ASSEMBLING 4 S9 1 Front Axle Assembly 4 S9 4 SERVICING 4 S12 KiSC issued 04 2006 A ...

Page 193: ...r steering circuit Bleed Front Wheels Can Not Be Driven A Front wheel driving gears in front axle gear case broken Replace 4 S9 A Universal joint broken Replace 4 S7 A Front wheel drive gears in transmission broken Replace 2 S26 A Front differential gear broken Replace 4 S11 12 Noised A Gear backlash excessive Adjust or replace 4 S13 to 15 A Oil insufficient Replenish 4 S6 A Bearings damaged or br...

Page 194: ...19 439 to 19 460 mm 0 76532 to 0 76614 in Differential Pinion Shaft to Differential Pinion Clearance 0 025 to 0 055 mm 0 00098 to 0 00217 in 0 25 mm 0 0096 in Differential Pinion Shaft O D 9 960 to 9 975 mm 0 39212 to 0 39272 in Differential Pinion I D 10 000 to 10 015 mm 0 39370 to 0 39429 in Differential Pinion Gear to Differential Side Gear Backlash 0 1 to 0 3 mm 0 004 to 0 012 in Bevel Pinion ...

Page 195: ...o 2 85 17 71 to 20 65 Front wheel mounting screw 108 5 to 130 2 11 07 to 13 29 80 to 96 Front axle bracket mounting screw 48 1 to 55 9 4 9 to 5 7 35 5 to 41 2 Tie rod slotted nut 17 7 to 34 3 1 8 to 3 5 13 0 to 25 3 King pin support mounting nut 19 6 to 25 5 2 0 to 2 6 14 4 to 18 8 Front gear case cover mounting screw 17 7 to 20 6 1 8 to 2 1 13 0 to 15 1 Front axle case screw 9 8 to 11 3 1 00 to 1...

Page 196: ...B A 4 If the measurement is not within the factory specifications adjust the tie rod length Toe in Adjusting 1 Loosen the lock nuts 1 2 Turn the tie rod 2 until to be factory specification 3 Tighten the lock nuts 1 Toe in B A Factory spec 0 to 5 mm 0 00 to 0 20 in A Wheel to Wheel Distance B Wheel to Wheel Distance at Front at Rear C Front 0000010186E 1 Lock Nut 2 Tie rod 0000004097E KiSC issued 0...

Page 197: ...ition 4 Confirm that the left and right rear wheels do not rotate manually 5 Turn the steering wheel to left or right 6 When the rear wheel on the side to which the steering wheel is turned is rotated manually measure the length L1 of the steering cylinder tube 7 If the measurement is not within the factory specifications adjust the length L2 of Glide Steer wire boot A Do not turn the steering whe...

Page 198: ...e oil level again add oil to prescribed level A Use KUBOTA UDT or SUPER UDT fluid Refer to LUBRICANTS FUEL AND COOLANT See page G 8 Battery A When disconnecting the battery cables disconnect the negative cable from the battery first When connecting connect the positive cable to the battery first 1 Open the bonnet 2 Remove the radiator net 3 Disconnect the negative cable 1 from the battery 4 Discon...

Page 199: ...der 1 When reassembling A Adjust the Glide Steer See page 4 S5 Front Wheel and Joint Cover 1 Lift up the front side of machine and place the disassembling stand under the front axle frame 2 Remove the front wheels 3 Remove the joint cover mounting screws and slide the joint cover 1 When reassembling 1 Bonnet 4 Wire Harness 2 Bonnet Bracket 5 Connector 3 Side Bonnet 0000009461E Tightening torque Po...

Page 200: ...y 1 from the frame When reassembling A Apply the grease to center pin of front axle assembly A Reinstall the shims 4 6 and collar 5 on the front axle bracket retaining screw 3 as shown in the figure 1 Power Steering Cylinder Holder 3 Glider Steer Wire 2 Power Steering Cylinder Holder 4 Front Axle Assembly Mounting Screw 5 Power Steering Cylinder 0000010192E Tightening torque Front axle bracket Mou...

Page 201: ...ar case assembly 2 When reassembling A Do not interchange left and right front gear case assembles Front Gear Case Cover 1 Remove the front gear case cover 1 with bevel gear 3 When reassembling A Take care not to damage the O ring 4 A Install the front gear case cover 1 to position the square mark 2 on it upward Tightening torque Tie rod slotted nut 17 7 to 34 3 1 8 to 3 5 13 0 to 25 3 ft lbs 1 Ti...

Page 202: ... the front axle case A Install the front axle case screw 3 noting its direction as shown in the figure A Tentatively tighten the front axle case screws 3 at intervals of every other one to join the front side and rear side front axle cases 1 2 Then tighten all front axle case screws 3 with a specified tightening torque 1 35T Bevel Gear 3 Front Axle Shaft 2 Collar 0000010196E 1 Oil Seal 4 Ball Bear...

Page 203: ... Gear Assembly 1 Remove the 10T bevel gears 1 8 with bearing 2 Remove the differential yoke shafts 3 6 3 Remove the differential gear assembly 4 1 Oil Seal 3 Shim 2 Front Axle Case Real Side 4 Bevel Pinion Shaft 0000010199E 1 Pipe 3 Ball Bearing 2 Shim 4 15T Bevel Gear 0000010200E 1 10T Bevel Gear LH 5 Shim 2 Shim 6 Differential Yoke Shaft RH 3 Differential Yoke Shaft LH 7 Shim 4 Differential Gear...

Page 204: ...gure 4 SERVICING Clearance between Differential Gear Case and Differential Side Gear 1 Measure the differential side gear boss O D 2 Measure the differential case bore I D and calculate the clearance 3 If the clearance exceeds the allowable limit replace faulty parts 1 Steel Ball 6 Differential Gear Case 2 Shim 7 Differential Pinion Shaft 3 Differential Pinion Gear 8 External Snap Ring 4 Different...

Page 205: ...cklash 3 If the measurement exceeds the factory specifications adjust with the differential pinion gears shims Reference A Thickness of adjusting shims For pinion gear 2 3 mm 0 091 in 2 5 mm 0 098 in 2 7 mm 0 106 in 2 9 mm 0 114 in Clearance between differential pinion shaft and differential pinion gear Factory spec 0 025 to 0 055 mm 0 00098 to 0 00217 in Allowable limit 0 25 mm 0 0096 in Differen...

Page 206: ...ess of the fuses with an outside micrometer 6 If the backlash is not within the factory specifications adjust with shims 1 4 Reference A Thickness of adjusting shims For Bevel pinion shaft 1 0 5 mm 0 020 in 0 8 mm 0 031 in 1 0 mm 0 039 in 1 2 mm 0 047 in 1 4 mm 0 055 in For Bevel gear 4 0 6 mm 0 024 in 0 8 mm 0 031 in 1 2 mm 0 039 in 1 2 mm 0 047 in 1 4 mm 0 055 in Backlash between bevel pinion sh...

Page 207: ...T bevel gear 2 and measure the thickness of the fuses with an outside micrometer 7 If the backlash is not within the factory specifications adjust with shims 1 4 Reference A Thickness of adjusting shims For 15T Bevel gear 1 0 6 mm 0 024 in 0 8 mm 0 031 in 1 0 mm 0 039 in 1 2 mm 0 047 in 1 4 mm 0 055 in For 10T Bevel gear 4 0 6 mm 0 024 in 0 8 mm 0 031 in 1 0 mm 0 039 in 1 2 mm 0 047 in 1 4 mm 0 05...

Page 208: ...5 STEERING KiSC issued 04 2006 A ...

Page 209: ...CONTENTS 1 HYDRAULIC CIRCUIT 5 M1 2 STEERING CONTROLLER 5 M2 3 STEERING CYLINDER 5 M4 KiSC issued 04 2006 A ...

Page 210: ...l valve assembly 1 steering controller 4 steering cylinder 5 etc The oil is supplied to the steering controller 4 through the hydraulic control valve assembly 1 by the hydraulic pump 2 With the steering wheel at neutral the oil returns through the steering controller 4 to the hydraulic control valve assembly 1 Turn the steering wheel and just a required amount of oil is sent to the steering cylind...

Page 211: ...e metering device 2 Namely when the rotor is driven two chambers suck in oil due to volumetric change in the pup chambers formed between the rotor 11 and the stator 12 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 6 drive shaft 9 etc Accordingly the metering device serves to supply the steerin...

Page 212: ...ntroller It controls the maximum pressure of the power steering system Its setting pressure is as follows 8 3 to 8 8 MPa 84 6 to 89 7 1204 to 1276 psi 1 Relief Valve P P Port From Hydraulic Control Valve Assembly T T Port To Hydraulic Control Valve Assembly 0000010213E KiSC issued 04 2006 A ...

Page 213: ...steering 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 1 Rod 4 Guide 7 Center Piston 10 Cylinder Tube 2 Wiper Ring 5 O ring 8 Piston O ring 11 Rod O ring 3 Internal Snap Ring 6...

Page 214: ...RQUES 5 S3 4 CHECKING DISASSEMBLING AND SERVICING 5 S4 1 CHECKING AND ADJUSTING 5 S4 2 PREPARATION 5 S5 1 Separating Power Steering Controller 5 S5 2 Separating Power Steering Cylinder 5 S8 3 DISASSEMBLING AND ASSEMBLING 5 S11 1 Power Steering Cylinder 5 S11 KiSC issued 04 2006 A ...

Page 215: ...5 S8 Front Wheels Wander to Right and Left A Steering controller malfunctioning Replace 5 S8 A Air sucked in pump due to lack of oil Replenish G 8 17 A Air sucked in pump from suction circuit Repair 6 S6 8 A Insufficient bleeding Bleed A Cylinder malfunctioning Replace 5 S11 A Improper toe in adjustment Adjust 4 S4 A Tire pressure uneven Inflate G 49 Wheels Are Turned to a Direction Opposite to St...

Page 216: ...ry Specification Allowable Limit Steering Wheel Play 30 to 70 mm 0 79 to 1 18 in 0000009619E POWER STEERING BODY Item Factory Specification Allowable Limit Relief Valve Operating Pressure 8 3 to 8 8 MPa 84 6 to 89 7 1204 to 1276 psi 0000010215E KiSC issued 04 2006 A ...

Page 217: ...to 2 5 14 8 to 18 4 Power steering hose mounting nut 24 0 to 28 0 2 45 to 2 85 17 71 to 20 65 Power steering cylinder hose nut 24 0 to 28 0 2 45 to 2 85 17 71 to 20 65 Front wheel mounting screw 108 5 to 130 2 11 07 to 13 29 80 to 96 Front axle bracket mounting screw 48 1 to 55 9 4 9 to 5 7 35 5 to 41 2 Tie rod slotted nut 17 7 to 34 3 1 8 to 3 5 13 0 to 25 3 Tie rod screw 74 to 84 7 5 to 8 6 54 6...

Page 218: ... 3 Fully turn the steering wheel to the left or right to check the feeling which the steering wheel lightly locks Read the relief valve operating pressure when the steering wheel to the above mentioned lock position A After set a pressure gauge be sure to bleed air A Note that the pressure value changes by the pump action of the power steering controller when the steering operation is continued af...

Page 219: ...ng the battery cables disconnect the negative cable from the battery first When connecting connect the positive cable to the battery first 1 Open the bonnet 2 Remove the radiator net 3 Disconnect the negative cable 1 from the battery 4 Disconnect the positive cable 2 from the battery and remove the battery 3 0000010126E 0000010177E 1 Negative Cable 3 Battery 2 Positive Cable 0000010084E KiSC issue...

Page 220: ...he container base 7 Seat 1 Remove the snap pin 2 2 Remove the seat 1 Fender 1 Remove the speed change pedal 5 2 Peel the step sheet 4 halfway 3 Remove the fuel cap 1 4 Remove the fender 2 1 Coupler 5 Grass Container Full Switch 2 Connector 6 Switch Cover 3 Discharge Duct 7 Container Base 4 Connector 0000009314E 1 Seat 2 Snap Pin 0000010128E 1 Fuel Cap 4 Step Sheet 2 Fender 5 Speed Change Pedal 3 F...

Page 221: ...onnectors for hour meter main switch 4 and light switch 5 Remove the indicator lamps 5 6 Remove the fuse box 6 from the steering support 7 Remove the panel 2 When reassembling Tightening torque Steering wheel mounting nut 20 to 25 2 0 to 2 5 14 8 to 18 4 ft lbs 1 Steering Wheel 4 Main Switch 2 Panel 5 Indicator Lamp 3 Side Bonnet 6 Fuse Box 0000010178E KiSC issued 04 2006 A ...

Page 222: ...n connecting connect the positive cable to the battery first 1 Open the bonnet 2 Remove the radiator net 3 Disconnect the negative cable 1 from the battery 4 Disconnect the positive cable 2 from the battery and remove the battery 3 Tightening torque Power steering hose mounting nut 24 0 to 28 0 2 45 to 2 85 17 71 to 20 65 ft lbs 1 Cylinder Hose LH A Bottom View 2 Cylinder Hose RH P Pump Port 3 Ret...

Page 223: ...er 1 When reassembling A Adjust the Glide Steer See page 4 S5 Front Wheel and Joint Cover 1 Lift up the front side of machine and place the disassembling stand under the front axle frame 2 Remove the front wheels 3 Remove the joint cover mounting screws and slide the joint cover 1 When reassembling 1 Bonnet 4 Wire Harness 2 Bonnet Bracket 5 Connector 3 Side Bonnet 0000009461E Tightening torque Pow...

Page 224: ... 1 from the frame When reassembling A Apply the grease to center pin of front axle assembly A Reinstall the shims 4 6 and collar 5 on the front axle bracket retaining screw 3 as shown in the figure 1 Power Steering Cylinder Holder 3 Glider Steer Wire 2 Power Steering Cylinder Holder 4 Front Axle Assembly Mounting Screw 5 Power Steering Cylinder 0000010192E Tightening torque Front axle bracket Moun...

Page 225: ...eering Cylinder and Tie rod 1 Remove the cylinder hose adaptors 2 3 2 Remove the tie rods 1 4 from piston rod 6 3 Remove the external snap rings 5 When reassembling A Be sure to install the hose adaptors 2 3 as shown figure left A After reassembling the tie rod be sure to adjust the toe in Refer to 4 S4 A Apply liquid lock to the thread of piston rod 6 Tightening torque Tie rod slotted nut 17 7 to...

Page 226: ...6 HYDRAULIC SYSTEM KiSC issued 04 2006 A ...

Page 227: ...TENTS 1 HYDRAULIC CIRCUIT 6 M1 2 HYDRAULIC PUMP 6 M2 3 HYDRAULIC CONTROL VALVE 6 M3 1 MOWER LIFT CIRCUIT 6 M4 2 HST RELIEF VALVE 6 M8 4 MOWER LIFT CYLINDER 6 M9 5 MOWER LINKAGE 6 M10 KiSC issued 04 2006 A ...

Page 228: ...Assembly 8 Control Valve 11 Main Relief Valve 3 HST Relief Valve 5 Steering Controller 9 Hydraulic Pump 6 Mower Lift Cylinder 1 The oil is supplied by the hydraulic pump 9 which is driven by pump drive shaft in the transaxle case As the pump drive shaft is engaged with the input shaft which connected to the propeller shaft the hydraulic pump 9 starts running when engine is started 2 The hydraulic ...

Page 229: ...ear 8 Hydraulic pump is driven by the pump drive shaft in the transaxle case Maximum displacement is as follows Displacement Engine speed Condition 10 4 L min 2 75 U S gal min 2 29 Imp gal min At 3000 rpm at no load 1 Casing 5 Cover 2 Drive Gear 6 Oil Seal 3 Side Plate 7 Internal Snap Ring 4 O ring 8 Driven Gear 0000010228E KiSC issued 04 2006 A ...

Page 230: ...r via a link mechanism and oil from hydraulic pump is changed flow direction by the spool 4 1 Check Valve P Pump Port PS1 Power Steering Port F1 Filter Port 2 HST Relief Valve T Tank Port To Power Steering To Filter Cartridge 3 Main Relief Valve To Transaxle Case Controller F2 Filter Port 4 Spool for Control Valve T1 Tank Port To T Port PS2 Power Steering Port From Filter Cartridge C Cylinder Port...

Page 231: ...rt then flows to power steering controller Since the oil does not flow through passage 4 in spool to check valve 1 C port is closed by check valve 1 Therefore the oil in mower lift cylinder does not flow out through C port and the mower maintains its position B Neutral 1 Check Valve P Pump Port T1 Tank Port To T Port PS1 Power Steering Port 2 Main Relief Valve T Tank Port C Cylinder Port To Power ...

Page 232: ... check valve 1 The oil flows through C port to mower lift cylinder Therefore the mower is lifted While the hydraulic lift lever is set to the LIFT position the oil does not flow through passage 4 in spool to PS1 port B Lift 1 Check Valve P Pump Port T1 Tank Port To T Port PS1 Power Steering Port 2 Main Relief Valve T Tank Port C Cylinder Port To Power Steering 3 Spool To Transaxle Case Controller ...

Page 233: ...ver is set to LIFT position the main relief valve 2 opens Then the oil flows out through the main relief valve 2 to PS1 port preventing any further rise in pressure B Overload 1 Check Valve P Pump Port T1 Tank Port To T Port PS1 Power Steering Port 2 Main Relief Valve T Tank Port C Cylinder Port To Power Steering 3 Spool To Transaxle Case Controller 4 Passage 0000010239E KiSC issued 04 2006 A ...

Page 234: ...s pushed by flat face 2 of spool and opened The oil in mower lift cylinder is forced out through C port to T port by the weight of the mower causing the mower to lower The oil forced out returns the transaxle case B Down 1 Check Valve P Pump Port T1 Tank Port To T Port PS1 Power Steering Port 2 Flat Face T Tank Port C Cylinder Port To Power Steering 3 Main Relief Valve To Transaxle Case Controller...

Page 235: ...hrough the filter cartridge and is supplied through H port as the charge oil to HST Therefore the HST relief valve 1 provides the functionality of a charge relief valve The oil that is relieved by HST relief valve 1 passes in the valve poppet and flows through T port to the transaxle case 1 HST Relief Valve P Pump Port PS1 Power Steering Port F1 Filter Port T Tank Port To Power Steering To Filter ...

Page 236: ...LINDER The mower lift cylinder consists of cylinder tube 1 cylinder rod 3 and other parts as shown in the figure above This cylinder is single acting type 1 Cylinder Tube 2 Snap Ring 3 Cylinder Rod 4 Packing 5 Scraper 0000010245E KiSC issued 04 2006 A ...

Page 237: ... is rotated to pull the lift link 7 As a result mower is lifted The cutting height adjusting dial 4 adjusts the cutting height of mower by rotating the adjusting cam 3 The level of mower deck is adjusted by adjusting the cutting height fine tuning bolt length 5 1 Rear Link 2 Mower Lift Cylinder 3 Adjusting Cam 4 Cutting Height Adjusting Dial 5 Cutting Height Fine Turning Bolt 6 Lift Link Shaft 7 L...

Page 238: ...NG DISASSEMBLING AND SERVICING 6 S4 1 CHECKING AND ADJUSTING 6 S4 2 PREPARATION 6 S5 1 Separating Hydraulic Control Valve and Hydraulic Pump 6 S5 2 Mower Lift Cylinder 6 S9 3 DISASSEMBLING AND ASSEMBLING 6 S11 1 Hydraulic Control Valve Assembly 6 S11 2 Mower Lift Linkage 6 S12 KiSC issued 04 2006 A ...

Page 239: ...ng damaged Replace 6 S11 A Main Relief valve setting pressure too low Adjust 6 S4 A Hydraulic pump defective Replace 6 S8 A Oil strainer clogged Clean or replace G 31 A Insufficient transmission oil Refill G 8 17 Mower Does Not Lower A Control valve malfunctioning Repair or replace 6 S11 Mower Drops by Its Weight A Lift cylinder worn or damaged Replace 6 S10 A Control valve malfunctioning Replace ...

Page 240: ...C WSM HYDRAULIC SYSTEM 6 S2 2 SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Main Relief Valve Setting Pressure 9 5 to 11 0 MPa 97 to 112 1378 to 1595 psi 0000010248E KiSC issued 04 2006 A ...

Page 241: ...e screws bolts and nuts See page G 9 Item ft lbs Bolt joint 24 5 to 34 3 2 50 to 3 49 18 1 to 25 2 Hydraulic pump mounting screw 17 7 to 20 6 1 8 to 2 1 13 1 to 15 2 Adaptor 20 0 to 25 0 2 04 to 2 54 14 8 to 18 4 Drain pipe mounting screw 5 0 to 7 0 0 51 to 0 71 3 69 to 5 16 Joint pipe 20 0 to 25 0 2 04 to 2 54 14 8 to 18 4 0000010249E KiSC issued 04 2006 A ...

Page 242: ... lever to the LIFT position to operate the main relief valve and read the gauge 5 If the pressure is not within the factory specifications adjust with the adjusting shims 3 Condition A Engine speed Maximum A Oil temperature 45 to 55 113 to 131 Reference A Thickness of shim 0 1 mm 0 004 in 0 2 mm 0 008 in 0 4 mm 0 016 in Main relief valve setting pressure Factory spec 9 5 to 11 0 MPa 97 to 112 1378...

Page 243: ...connect the couplers 1 from the relays 2 Disconnect the connectors 2 3 Open the switch cover 6 And disconnect the connector 4 from the grass container full switch 5 4 Remove the discharge duct 3 5 Remove the container base 7 0000010177E 1 Coupler 5 Grass Container Full Switch 2 Connector 6 Switch Cover 3 Discharge Duct 7 Container Base 4 Connector 0000009314E KiSC issued 04 2006 A ...

Page 244: ...r SUPER UDT fluid Use of other oils may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 8 A Never work the machine immediately after changing the transmission oil Keeping the engine at medium speed for a few minutes to prevents damage to the transmission A Do not mix different blands oil together Seat 1 Remove the snap pin 2 2 Remove the seat 1 Fender 1 ...

Page 245: ...ect the fuel hoses 3 Remove the fuel tank 1 Beam 1 Disconnect the connector from the PTO switch 1 2 Remove the spring 2 from the PTO lever 3 3 Remove the PTO rod 4 Remove the filling pipe 4 5 Remove the beam 5 1 Seat Base Mounting Screw 1 3 Seat Base Mounting Screw 2 2 Seat Base 0000009321E 1 Fuel Tank 0000009323E 1 PTO Switch 4 Filling Pipe 2 Spring 5 Beam 3 PTO Lever 0000009324E KiSC issued 04 2...

Page 246: ... joint 1 2 Remove the hydraulic pump 2 with the suction pipe 2 3 Remove the suction pipe 2 from the hydraulic pump 1 Brake Rod 1 8 Power Steering Pipe 2 Brake Plate From Power Steering Unit 3 Filter cartridge Controller 4 Neutral Arm Holder 9 Cylinder Hose 5 Breather Hose 10 Drain Hose 6 Control Valve Pipe 11 Hydraulic Control Valve 7 Power Steering Pipe Assembly To Power Steering Unit Controller ...

Page 247: ...rs 2 3 Open the switch cover 6 And disconnect the connector 4 from the grass container full switch 5 4 Remove the discharge duct 3 5 Remove the container base 7 Seat 1 Remove the snap pin 2 2 Remove the seat 1 0000010177E 1 Coupler 5 Grass Container Full Switch 2 Connector 6 Switch Cover 3 Discharge Duct 7 Container Base 4 Connector 0000009314E 1 Seat 2 Snap Pin 0000010128E KiSC issued 04 2006 A ...

Page 248: ...he mower lift cylinder 1 2 Remove the both side of lift link 4 from the lift shaft 3 3 Remove the clevis pins 6 8 and remove the mower lift cylinder 1 1 Fuel Cap 4 Step Sheet 2 Fender 5 Speed Change Pedal 3 Fender Mounting Screw 0000009320E 1 Mower Lift Cylinder 6 Clevis Pin 2 Cylinder Hose 7 Rue Ring 3 Lift Shaft 8 Clevis Pin 4 Lift Link 9 Adaptor 5 Rue Ring Pin 10 Plain Washer 0000010256E KiSC i...

Page 249: ... After reassembling the main relief valve be sure to adjust the main relief valve setting pressure see page 6 S4 HST Relief Valve 1 Remove the plug 4 2 Draw out the spring 2 and poppet 1 When reassembling A Take care not to damage the O ring 3 Tightening torque Adaptor 20 0 to 25 0 2 04 to 2 54 14 8 to 18 4 ft lbs Drain pipe mounting screw 5 0 to 7 0 0 51 to 0 71 3 69 to 5 16 ft lbs Joint pipe 20 ...

Page 250: ...emove the clevis pins 4 16 6 Remove the lift link LH 5 and RH 14 7 Remove the cutting height adjusting dial knob 12 8 Remove the plate spring 9 9 Unscrew the lock nut 8 and remove the cutting height adjusting rod 11 and adjusting cam 10 1 Cylinder Hose Adaptor 3 Spring 2 O ring 4 Poppet 0000010260E 1 Screw 2 Lock Nut 3 Rear Link LH 4 Clevis Pin 5 Lift Link LH 6 Rue Ring 7 Rue Ring 8 Lock Nut 9 Pla...

Page 251: ...7 ELECTRICAL SYSTEM KiSC issued 04 2006 A ...

Page 252: ...CONTENTS 1 WIRING DIAGRAM 7 M1 2 STARTING SYSTEM 7 M3 3 CHARGING SYSTEM 7 M4 4 LIGHTING SYSTEM 7 M5 KiSC issued 04 2006 A ...

Page 253: ...GR2100EC WSM ELECTRICAL SYSTEM 7 M1 1 WIRING DIAGRAM 0000009632E KiSC issued 04 2006 A ...

Page 254: ...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 Yellow LW Blue White Sb Sky Blue 0000004213E KiSC issued 04 2006 A ...

Page 255: ...rter motor When the main switch turned from the ON position to the OFF position the engine stop solenoid moves the fuel injection pump control rack to the No Fuel Injection position and stop the engine This machine equipped the operator presence control OPC system which automatically stops the engine when operator stands from the seat while shifting the PTO lever The engine of this machine also st...

Page 256: ...wer 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 4 Dynamo 7 Main Switch 9 Charge Lamp 2 Body Earth 5 Slow Blow Fuse 40 A 8 Fuse 10 A 10 Hour Meter 3 Body Earth 6 Regulator 0000009629E KiSC issued 04 2006 A ...

Page 257: ...ting the PTO lever And the buzzer rings 1 Battery 7 Regulator 13 Grass Container Full 18 Oil Pressure Lamp 2 Body Earth 8 Slow Blow Fuse 40 A Switch 19 Charge Lamp 3 Thermo Switch 9 Main Switch 14 Buzzer Relay 20 Easy Checker 4 Oil Switch 10 Fuse 10 A 15 Buzzer 21 Head Light Switch 5 Body Earth 11 Fuse 3 A 16 Thermo Lamp 22 Head Light 6 Dynamo 12 PTO Switch 17 Grass Container Full Lamp 23 Hour Met...

Page 258: ...8 4 Glow Plug 7 S9 5 Safety Switch 7 S10 6 Operator Presence Control OPC Switch 7 S11 7 Fuel Pump 7 S12 8 Engine Stop Solenoid 7 S12 9 Time Relay 7 S13 10 Charging System 7 S14 11 Lighting System 7 S14 12 Coolant Temperature Sensor 7 S16 13 Grass Container Full Switch 7 S16 2 DISASSEMBLING AND ASSEMBLING 7 S18 1 Starter 7 S18 2 Dynamo 7 S19 3 SERVICING 7 S20 1 Starter 7 S20 2 Dynamo 7 S22 KiSC iss...

Page 259: ...nnected or improperly connected Repair or replace A Slow blow fuse blown 40 A Replace G 38 Fuse Blown Frequently A Short circuited Repair or replace 0000010265E BATTERY Battery Discharges Too Quickly A Battery defective Replace 1 S21 A Dynamo defective Repair or replace 7 S19 A Regulator defective Replace A Wiring harness disconnected or improperly connected between battery positive terminal and r...

Page 260: ...s Turned OFF A Fuse blown 15 A Replace G 38 A Wiring harness disconnected or improperly connected between main switch ACC terminal and engine stop solenoid Repair or replace A Engine stop solenoid defective Replace 7 S12 A Timer relay defective Replace 7 S13 Engine Does Not Start A Engine stop solenoid defective Replace 7 S12 A Timer relay defective Replace 7 S13 0000010267E CHARGING SYSTEM Sympto...

Page 261: ...hts Up When Engine Is Running A Engine oil pressure too low Repair engine A Engine oil insufficient Replenish G 8 14 A Oil pressure switch defective Replace 7 S15 A Short circuit between oil pressure switch lead and chassis Repair Oil Pressure Lamp Does Not Light When Main Switch Is Turned ON and Engine Is Not Running A Fuse blown 10 A Replace G 38 A Bulb blown Replace G 39 A Oil pressure switch d...

Page 262: ...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 0 05 mm 0 002 in 0 4 mm 0 016 in Mica Undercut 0 50 to 0 80 mm 0 0197 to 0 0315 in 0 20 mm 0 0079 in Brush Length 16 0 mm 0 630 in 10 5 mm 0 413 in 0000009626E KiSC issued 04 2006 A ...

Page 263: ...of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page G 9 Item ft lbs Starter C terminal nut 5 9 to 11 8 0 6 to 1 2 4 3 to 8 7 Dynamo stator nut 39 2 to 44 1 4 0 to 4 5 28 9 to 32 5 0000010270E KiSC issued 04 2006 A ...

Page 264: ...nal and the voltage across the battery s negative terminal post and the chassis 3 If the measurement exceeds the factory specification clean the battery terminal posts and cable clamps and tighten them firmly 2 Main Switch Main Switch 1 Open the bonnet 2 Disconnect the 4P connector and remove the main switch 1 3 Perform the following checks Connector Voltage 1 Measure the voltage with a voltmeter ...

Page 265: ...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 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 an...

Page 266: ...minal post 7 If the motor does not run check the motor Starter Magnet Switch Test Pull in Holding Coils A Preparate a 6 V battery for the test and each test should be carried out for 3 to 5 seconds 1 Checking Pull in Coil 1 Connect jumper lead from the battery s negative terminal post to the C terminal 2 The plunger should be attracted strongly when a jumper lead is connected from the battery posi...

Page 267: ...rs from the battery voltage the wiring harness or main switch is faulty Glow Plug Continuity 1 Disconnect the lead from the glow plugs 2 Measure the resistance with an ohmmeter between the glow plug terminal and the chassis 3 If 0 ohm is indicated the screw at the tip of the glow plug and the housing are short circuited 4 If the factory specification is not indicated the glow plug is faulty Voltag...

Page 268: ...an ohmmeter between the terminals 5 If the brake switch 1 is defective replace it Resistance between terminal a and b When plunger is pushed 0 When plunger is released Infinity Resistance between terminal c and d When plunger is pushed 0 When plunger is released Infinity 1 PTO Switch a to d Switch Terminal 2 PTO Lever 0000010271E Resistance between terminal a and b When plunger is pushed 0 When pl...

Page 269: ...ntrol OPC Switch 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 Resistance between switch terminals When plunger is pushed 0 When plunger is released Infinity 1 Safety Switch for Grass Container 0000009476E Resistance between switch terminals When plunger is...

Page 270: ...y between the connector terminals with an ohmmeter 3 If it does not conduct the fuel pump is faulty 8 Engine Stop Solenoid Engine Stop Solenoid Test 1 Disconnect the 1P connector from the engine stop solenoid 2 Remove the engine stop solenoid from the engine 3 Connect the jumper leads from the battery positive terminal to the 1P connector and from the battery negative terminal to the engine stop s...

Page 271: ...s across the battery positive terminal and the timer relay terminal 3 and across the battery positive terminal and the timer relay terminal 4 3 Connect 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 1 and the bulb terminal 5 The bulb lights up when ...

Page 272: ...easure the battery voltage with a volt meter 3 If the measurement is not within the specified values replace the regulator 11 Lighting System Head Light Switch Continuity 1 Disconnect the wiring leads from head light switch and remove it 2 Measure the resistance with an ohmmeter across the head light switch terminals in each position 3 If the resistance differs from the factory specifications the ...

Page 273: ...faulty 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 faulty 3 If infinity is not indicated at pressure over 4 9 kPa 0 5 7 psi the switch is faulty 1 Engine Oil Pressure Switch a From Oil Pressure Lamp 0000001185E Resistance Switch terminal Chassis In normal sta...

Page 274: ... specifications the switch is faulty 13 Grass Container Full Switch Grass Container Full Switch Continuity 1 Remove the battery 2 Dismount the grass container 3 Open the switch cover 1 4 Disconnect the grass container full switch 2 lead 5 measure the resistance with an ohmmeter between the grass container full switch terminals 6 If the grass container full switch is defective replace it Voltage Co...

Page 275: ...ng to the grass condition 1 Dismount the grass container see page 2 S9 2 Open the switch cover 1 3 Loose the wing nut 3 and align the position indicator 2 with switch position A 4 Set the position change lever 4 up 5 Close the switch cover and remount the grass container and start mowing 6 If the discharge duct is plugged align the position indicator 2 with switch position B 7 If the grass contain...

Page 276: ... connecting lead 7 2 Remove the magnetic switch 5 3 Remove the rear end frame 9 4 Remove the brush 11 from brush holder 12 5 Remove the brush holder 12 6 Draw out the yoke 6 from the starter drive housing 3 7 Draw out the armature 16 with the drive lever 4 A Do not damage to the brush and commutator When reassembling A Apply grease to spline teeth of the armature bushing pinion gear of the overrun...

Page 277: ...embling Rotor 1 Tap out the shaft 1 from the rotor 3 When reassembling A Take care the direction of the collar 4 the flat side should face to the pulley 2 side Tightening torque Nut 39 2 to 44 1 4 0 to 4 5 28 9 to 32 5 ft lbs 1 Screw 3 Nut 2 Stator 4 Stator Comp 0000001176E 1 Shaft 4 Collar 2 Pulley 5 Bearings 3 Rotor 6 Collar 0000001177E KiSC issued 04 2006 A ...

Page 278: ...e commutator O D with an outside micrometer at several points 3 If the minimum O D is less than the allowable limit replace the armature 4 If the difference 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 it with a saw blade and chamfer the segment edges 00...

Page 279: ...ty across the brush holder and the holder support with an ohmmeter 2 If it conducts replace the brush holder Armature Coil 1 Check the continuity across the commutator and armature coil core with an 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 Brush length A Factory spec 16...

Page 280: ...t 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 2 Dynamo Bearing 1 Check the bearing for smooth rotation 2 If it does not rotate smoothly replace it 1 Lead 3 Yoke 2 Brush 0000001173E 0000001178E KiSC issued 04 2006 A ...

Page 281: ...8 MOWER KiSC issued 04 2006 A ...

Page 282: ...CONTENTS 1 POWER TRANSMISSION 8 M1 2 LIFTING MECHANISM 8 M2 KiSC issued 04 2006 A ...

Page 283: ...ws B Center Blade PTO Shaft Universal Joint 6 Input Shaft 10 21T Spiral Gear 9 16T Spiral Gear 11 Bevel Gear Shaft 13 Center Blade 14 B Left Side Blade PTO Shaft Universal Joint 6 Input Shaft 10 21T Spiral Gear 9 16T Spiral Gear 11 Bevel Gear Shaft 13 Center Blade Pulley 12 Mower Belt Left Side 2 Left Side Blade Pulley 1 Blade Shaft Left Side 7 Left Side Blade 8 B Right Side Blade PTO Shaft Univer...

Page 284: ...aulic system on the machine For avoiding danger the mower should be kept lifting when traveling When the hydraulic lift lever 3 is moved to LIFT position the lift links 4 are risen with lift link shaft 2 by the oil pressure of hydraulic system Therefore rear links 5 are lifted at the same time A Never operate mower in transport position 0000010223E KiSC issued 04 2006 A ...

Page 285: ...NG DISASSEMBLING AND ASSEMBLING 8 S4 1 CHECKING AND ADJUSTING 8 S4 1 Adjusting Anti Scalp Rollers 8 S4 2 Adjusting Left and Right Cutting Height 8 S5 2 PREPARATION 8 S6 1 Dismounting Mower 8 S6 3 DISASSEMBLING AND ASSEMBLING 8 S8 1 Mower 8 S8 4 SERVICING 8 S14 1 Gear Box 8 S14 KiSC issued 04 2006 A ...

Page 286: ... Engine rpm too low Mow at full throttle check and reset engine rpm Cutting is Poor A Mower blade worn or bent Sharpen or replace mower blade G 40 8 S8 A Mower blade screw loosen Retighten mower blade screw 8 S8 A Cutting height improper Adjust cutting height 8 S5 A Ground speed too fast Slow down A Tire pressure uneven Adjust G 49 A Anti scalp rollers not adjusted correctly Adjust anti scalp roll...

Page 287: ...e Limit Left Tip of Blade to Right Tip of Blade Difference Less than 3 mm 0 1181 in Front Tip of Blade to Rear Tip of Blade Difference Less than 5 mm 0 20 in 21T Spiral Gear to 16T Spiral Gear Backlash 0 13 to 0 25 mm 0 0051 to 0 0098 in 0 40 mm 0 157 in 0000010226E KiSC issued 04 2006 A ...

Page 288: ... to 66 5 Gear box stay mounting screw RH 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 Center Blade pulley holder mounting screw 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 Pulley mounting nut Right side 88 0 to 117 6 8 98 to 11 99 65 0 to 86 7 Pulley mounting nut Left side 103 to 118 10 5 to 12 0 76 0 to 87 0 Pulley holder mounting screw 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 Tension pulley mounting screw and nut ...

Page 289: ...port position Also the top end of the lift 4 Turn the cutting height control dial to adjust height 5 Lower the mower deck B Front side anti scalp roller 6 Adjust height H of the rear side anti scalp roller to one of four positions to approximately 19 mm 0 75 in between rollers and ground Adjust both side rollers to the same height 7 Install the roller with attaching hardware B Rear side anti scalp...

Page 290: ... 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 within the factory specification adjust the length of cutting height fine tuning bolt 2 Reference A Length of cutting height fine tuning bolt H 46 to 54 mm 1 812 to 2 125 in Difference L R between left tip and...

Page 291: ... 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 deck on level ground by hydraulic lift lever 2 Front Link 1 Pull the lever fulcrum fixing pin 2 and turn it counterclockwise to lock 2 Push down the link fixing lever 1 3 Remove the front link 3 from the mower deck When reassembling A Wh...

Page 292: ...d lock in the raised position When reassembling A Apply grease to the spline of PTO shaft A Slide the universal joint back and front to make sure the universal joint is locked securely A When attach the rear links make sure the length of the rear links Dismounting Mower 1 Turn the front wheel to the right 2 Pull out the mower deck to the left 1 Rotate Plate Rod 3 L pin 2 Rear Link 4 Universal Join...

Page 293: ... it will hold the blade safely while loosing or tightening the blade screw When reassembling A Be sure to assemble the plate spring 2 between the mower blade 3 and the mower blade screw 1 A Make sure the cup washer is not flattened out or worn causing blade to slip easily Replace two cup washers if either is damaged Tightening torque Mower blade screw 88 0 to 117 6 8 98 to 11 99 65 0 to 86 7 ft lb...

Page 294: ...ng screw LH reamer 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 ft lbs Gear box mounting screw RH 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 ft lbs Gear box stay mounting screw LH reamer 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 ft lbs Gear box stay mounting screw RH 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 ft lbs 1 Mower Belt LH 7 Gear Box Stay LH 2 Gear Box 8 Gear Box Stay RH 3 Mower Belt RH 9 Gear Box Stay Mounting S...

Page 295: ...il seal 2 When reassembling A Replace the oil seals 2 5 and gear case caps 13 22 with new ones A Apply grease to the spline of input shaft and of bevel gear shaft A Use the specified gear box oil A Refer to LUBRICANTS FUEL AND COOLANT See page G 8 A While tapping out the input shaft 9 from the gear case 23 set the mating portion of external snap ring 12 on input shaft upward Mower gear case oil Ca...

Page 296: ...e bearing and oil seal lips A Apply grease to the inside of center collar A Replace the oil seals with new ones A Be sure to pay attention to how to assemble lower oil seal A Apply liquid gasket Three Bond 1208D or its equivalent to the face of center pulley holder Tightening torque Center blade pulley holder mounting screw 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 ft lbs 1 Center Blade Holder Mounting...

Page 297: ...emove the grease nipple 1 2 Unscrew the pulley mounting nut 2 and remove the pulley 3 and feather key 13 only right side 3 Tap out the blade shaft 12 4 Remove the pulley holder 7 from the mower deck 5 Remove the oil seal 4 11 6 Remove the ball bearings 5 10 and collar 9 Tightening torque Pulley mounting nut Rright side 88 0 to 117 6 8 98 to 11 99 65 0 to 86 7 ft lbs Pulley mounting nut Left side 1...

Page 298: ...n collar 3 Tightening torque Tension pulley mounting screw and nut Right side 108 5 ti 130 2 11 07 to 13 29 80 0 to 96 0 ft lbs Tension pulley mounting screw and nut Left side 47 5 to 57 0 4 84 to 5 82 35 0 to 42 0 ft lbs Tension arm mounting screw Only left side and nut 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 ft lbs 1 Grease Nipple 9 Tension Arm 2 Shim 10 Mower Deck 3 Tension Collar 11 Plate 4 Tensi...

Page 299: ...2006 03 S EI EI e Code No 9Y011 15412 2005 04 S EI EI e 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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