Kubota GR1600EU Workshop Manual Download

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ELECTRICAL SYSTEM

GR1600EU, WSM

6-S9

Main Switch Continuity
1) Main Switch Key at OFF Position

1. Set the main switch

OFF

position.

2. Measure the resistance with an ohmmeter across the

terminal

and the

ACC

terminal,

terminal and

terminal,

terminal

and

terminal.

3. If infinity is not indicated, the contacts of the main switch are

faulty.

2) Main Switch Key at ON Position

1. Set the main switch

position.

2. Measure the resistance with an ohmmeter across the

terminal

and the

ACC

terminal.

3. If 0 ohm is not indicated, the

–

ACC

contact of the main switch

are faulty.

3) Main Switch Key at PREHEAT Position

1. Set and hold the main switch key at the

PREHEAT

position.

2. Measure the resistance with an ohmmeter across the

terminal

and the

terminal, and measure the resistance across the

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

terminal

and the

terminal, across the

terminal and the

terminal,

and across the

terminal and the

ACC

terminal.

3. If 0 ohm is not indicated, these contacts of the main switch are

faulty.

9Y1210595ELS0013US0

Resistance

terminal –

ACC

terminal

Infinity

terminal –

terminal

terminal –

terminal

Resistance

terminal –

ACC

terminal

Ω

Resistance

terminal –

terminal

Ω

terminal –

ACC

terminal

Resistance

terminal –

terminal

Ω

terminal –

terminal

terminal –

ACC

terminal

(1)

Terminal

(2)

ACC

Terminal

(3)

Terminal

(4)

Terminal

KiSC issued 11, 2013 A

Summary of Contents for GR1600EU

Page 1: ...GR1600EU WORKSHOP MANUAL KiSC issued 11 2013 A ...

Page 2: ...m This section contains information on the structure and the function of the unit Before you continue with the subsequent sections make sure that you read this section Servicing This section primarily contains information below Troubleshooting Servicing Specifications Tightening Torques Checking Disassembling and Servicing All illustrations photographs and specifications contained in this manual a...

Page 3: ...it of the Code No Issue month Main Revised Point and Corrective Measures Search word Reference Page 2 2013 03 GR1600ID and RCK42 GR16 models are added GR1600ID RCK42 GR16 I 9 G 1 G 9 and others 3 2013 11 Error characters of recommended inflation max tire pressure are corrected G 20 KiSC issued 11 2013 A ...

Page 4: ...I INFORMATION KiSC issued 11 2013 A ...

Page 5: ...CONTENTS 1 SAFETY FIRST I 1 2 SAFETY DECALS I 4 3 SPECIFICATIONS I 9 4 DIMENSIONS I 10 1 GR1600EU GR1600F I 10 2 GR1600ID I 11 INFORMATION KiSC issued 11 2013 A ...

Page 6: ...n disengaged positions Do not start the engine when you stay on the ground Start the engine only from operator s seat WSM000001INI0015US0 SAFETY FIRST This symbol the industry s Safety Alert Symbol is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the instructions and safe...

Page 7: ...ou disconnect hydraulic or fuel lines Tighten all connections before you apply the pressure Do not open a fuel system under high pressure The fluid under high pressure that stays in fuel lines can cause serious injury Do not disconnect or repair the fuel lines sensors or any other components between the fuel pump and injectors on engines with a common rail fuel system under high pressure Put on an...

Page 8: ...ions when you discard oil fuel coolant electrolyte and other dangerous waste WSM000001INI0007US0 PREVENT ACID BURNS Keep electrolyte away from your eyes hands and clothing Sulfuric acid in battery electrolyte is poisonous and it can burn your skin and clothing and cause blindness If you spill electrolyte on yourself clean yourself with water and get medical aid immediately WSM000001INI0008US0 PREP...

Page 9: ...wing safety decals pictorial safety labels are installed on the machine If a decal becomes damaged illegible or is not on the machine replace it The decal part number is listed in the parts list WSM000001INI0014US0 9Y1210595INI0001US0 KiSC issued 11 2013 A ...

Page 10: ...INFORMATION GR1600EU WSM I 5 9Y1210595INI0002US0 KiSC issued 11 2013 A ...

Page 11: ...INFORMATION GR1600EU WSM I 6 9Y1210595INI0003US0 KiSC issued 11 2013 A ...

Page 12: ...INFORMATION GR1600EU WSM I 7 9Y1210595INI0007US0 KiSC issued 11 2013 A ...

Page 13: ...lace damaged or missing pictorial safety labels with new labels from your local KUBOTA Dealer 4 If a component with pictorial safety label s affixed is replaced with new part make sure new label s is are attached in the same location s as the replaced component 5 Put new pictorial safety labels by applying on a clean dry surface and pressing any bubbles to outside edge 9Y1210595INI0006US0 KiSC iss...

Page 14: ...1280 mm 50 39 in Tread Front 750 mm 29 5 in Rear 820 mm 32 3 in 825 mm 32 4 in Weight 420 kg 683 lbs 370 kg 815 lbs Traveling system Tires Front 15 6 00 6 PR Rear 20 10 00 8 PR Steering Manual Sector gear type Transmission Hydrostatic transmission Brake Internal expanding brake Speed control Foot pedal Differential Bevel gear Traveling speed Forward 0 to 10 0 km h 0 to 6 2 mph Reverse 0 to 5 0 km ...

Page 15: ...INFORMATION GR1600EU WSM I 10 4 DIMENSIONS 1 GR1600EU GR1600F 9Y1210595INI0005US0 KiSC issued 11 2013 A ...

Page 16: ...INFORMATION GR1600EU WSM I 11 2 GR1600ID 9Y1210595INI0009US0 KiSC issued 11 2013 A ...

Page 17: ...G GENERAL KiSC issued 11 2013 A ...

Page 18: ...TANDARD SCREWS BOLTS AND NUTS WITH UNC OR UNF THREADS G 14 6 PLUGS G 14 6 MAINTENANCE CHECK LIST G 15 7 CHECK AND MAINTENANCE G 17 1 DAILY CHECK G 17 2 CHECK POINTS OF EVERY 50 HOURS G 23 3 CHECK POINTS OF EVERY 100 HOURS G 32 4 CHECK POINT OF EVERY 150 HOURS G 35 5 CHECK POINTS OF EVERY 200 HOURS G 35 6 CHECK POINTS OF EVERY 400 HOURS G 39 7 CHECK POINT OF EVERY 1500 HOURS G 40 8 CHECK POINT OF E...

Page 19: ...ing your local KUBOTA distributor always specify engine serial number 2 machine serial number 1 mower serial number 3 and hour meter reading 9Y1210595GEG0002US0 1 Machine Serial Number 2 Engine Serial Number 3 Mower Serial Number 4 Hour Meter A RCK42GR B RCK42 GR16 KiSC issued 11 2013 A ...

Page 20: ...DER NUMBER The cylinder numbers of KUBOTA diesel engine are designated as shown in the figure The sequence of cylinder number is given as No 1 No 2 and No 3 starting from the front cover side 9Y1210595GEG0052US0 KiSC issued 11 2013 A ...

Page 21: ...ng pins their splits must face the direction from which a force is applied See the figure left side To prevent damage to the hydraulic system use only specified fluid or equivalent Clean the parts before you measure them Tighten the fittings to the specified torque Too much torque can cause damage to the hydraulic units or the fittings Not sufficient torque can cause oil leakage When you use a new...

Page 22: ... to modify or remodel any electrical parts and wiring When removing the battery cables disconnect the negative cable first When installing the battery cables connect the positive cable first WSM000001GEG0062US0 1 WIRING Securely tighten wiring terminals WSM000001GEG0063US0 Do not let wiring contact dangerous part WSM000001GEG0064US0 Repair or change torn or aged wiring immediately WSM000001GEG0065...

Page 23: ...where sag be required WSM000001GEG0068US0 In installing a part be careful not to get wiring caught by it WSM000001GEG0069US0 After installing wiring check protection of terminals and clamped condition of wiring WSM000001GEG0070US0 1 Grommet A Correct B Incorrect 1 Clamp Wind Clamp Spirally 2 Wire Harness 3 Clamp 4 Welding Dent 1 Wiring 2 Clamp A Correct B Incorrect 1 Wiring A Incorrect 1 Cover Sec...

Page 24: ...recharge the battery remove it from the machine Before you recharge remove cell caps Recharge in a well ventilated place where there is no open flame nearby as hydrogen gas and oxygen are formed WSM000001GEG0071US0 3 FUSE Use fuses with specified capacity Neither too large nor small capacity fuse is acceptable Never use steel nor copper wire in place of fuse Do not install working light radio set ...

Page 25: ...male connector being too open WSM000001GEG0076US0 Make sure that plastic cover is large enough to cover whole connector WSM000001GEG0077US0 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provided with tester Check for polarity and range WSM000001GEG0078US0 1 Exposed Terminal 2 Deformed Terminal 3 Sandpaper 4 Rust A Correct B Incorrect 1 Cover A Correct B Incorrect KiSC issued 1...

Page 26: ... symbol of shows color with stripe s An example Red stripe on white color W R WSM000001GEG0079US0 Color of wiring Color code Black B Brown Br Green G Gray Gy or Gr Blue L Light Green Lg Orange Or Pink P Purple Pu or V Red R Sky Blue Sb White W Yellow Y 1 Wire Color 2 Stripe KiSC issued 11 2013 A ...

Page 27: ...10W 30 or 15W 40 4 Transmission case 2 8 L 0 74 U S gals 0 62 lmp gals KUBOTA UDT or SUPER UDT fluid 5 Mower gear box 0 33 L 0 35 U S qts 0 29 lmp qts 0 35 L 0 37 U S qts 0 31 lmp qts SAE90 gear oil API service classification more than GL 3 Greasing No Place No of greasing point Capacity Type of grease GR1600EU GR1600F GR1600ID 6 Engine transmission universal joint 1 Until grease overflows Multi p...

Page 28: ...id or its equivalent 9Y1210595GEG0054US0 Greasing No Place No of greasing point Capacity Type of grease GR1600EU GR1600F GR1600ID Grass catcher 19 Top cover look lever 2 Moderate amount Engine oil 20 Frame shaft 2 21 Top cover 2 22 Arm bracket 1 23 Rear quick clean lever 4 Mower 24 Mower universal joint 1 Until grease overflows Multi purpose EP2 grease NLGL Grade No 2 25 Spindle shafts 2 26 Belt t...

Page 29: ...EVER use diesel fuel with sulfur content greater than 0 05 500 ppm for EXTERNAL EGR type engine DO NOT use diesel fuel with sulfur content greater than 1 0 10000 ppm Diesel fuels specified to EN 590 or ASTM D975 are recommended No 2 D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service SAE J313 JUN87 Transmission Oil KUBOTA Super UDT 2 For an enhanced owners...

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

Page 31: ...0 21 7 to 28 9 ϕ10 t1 0 39 3 to 49 0 4 00 to 5 00 29 0 to 36 1 ϕ12 t1 5 49 1 to 68 6 5 00 to 7 00 36 2 to 50 6 ϕ15 t1 6 108 to 117 11 0 to 12 0 79 6 to 86 7 ϕ18 t1 6 108 to 117 11 0 to 12 0 79 6 to 86 7 Item Thread side Tightening torque N m kgf m lbf ft Fitting with O ring G 1 8 45 to 53 4 5 to 5 5 33 to 39 G 1 4 74 to 83 7 5 to 8 5 55 to 61 G 3 8 93 2 to 102 9 50 to 10 5 68 8 to 75 9 G 1 2 113 t...

Page 32: ... to 11 5 16 3 to 19 7 1 67 to 2 00 12 0 to 14 6 5 16 23 1 to 27 7 2 36 to 2 82 17 0 to 20 5 33 to 39 3 4 to 3 9 25 to 28 3 8 48 to 56 4 9 to 5 7 36 to 41 61 to 73 6 3 to 7 4 45 to 53 1 2 110 to 130 11 3 to 13 2 81 2 to 95 8 150 to 178 15 3 to 18 1 111 to 131 9 16 150 to 178 15 3 to 18 1 111 to 131 217 to 260 22 2 to 26 5 160 to 191 5 8 204 to 244 20 8 to 24 8 151 to 179 299 to 357 30 5 to 36 4 221...

Page 33: ... G 24 9 Oiling every 50 Hr G 27 10 Greasing every 50 Hr G 26 11 Mower gear box oil Check every 50 Hr G 26 Change every 150 Hr G 35 12 Air cleaner element Clean every 50 Hr G 25 Replace every 1 year G 41 13 Battery condition Check every 50 Hr G 29 14 Brake Adjust every 100 Hr G 33 15 Fan drive belt Check every 100 Hr G 34 16 Fuel filter element Check every 100 Hr G 32 Replace every 400 Hr G 40 17 F...

Page 34: ... the owner has the proper tools and is mechanically proficient 3 Consult your local KUBOTA Dealer for this service 4 Replace only if necessary 9Y1210595GEG0056US0 24 Mower gear box oil seal Replace every 2 years G 44 25 Engine breather hose Replace every 2 years G 44 26 Fuel system Bleed Service as required G 45 27 Fuse Replace G 45 28 Blade Replace G 46 G 48 29 Mower belt Replace G 47 No Item Ind...

Page 35: ...body tightness of all bolts and nuts 7 Radiator screen 8 Panel screen 9 Brake play 10 Air cleaner primary element 11 Fuel level 12 Oiling 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 While sitting in the operator s seat 1 Speed control pedal and brake pedal 2 Parking brake...

Page 36: ... is running do not fill the fuel tank If engine is hot let engine cool several minutes before adding fuel Do not smoke while filling the fuel tank or servicing the fuel system Fill fuel tank only to bottom of filler neck Check the fuel level Take care that the fuel tank does not become empty IMPORTANT Use Diesel fuel only 1 Use No 2 D diesel fuel 2 Use No 1 D diesel fuel if the temperature is belo...

Page 37: ...sure the radiator screen 2 and radiator core are clean Dirt or chaff on the radiator screen 2 or radiator core decrease cooling performance 1 Remove the radiator screen 2 and panel screen 1 and remove all foreign material 2 Remove the dust from between the fins and the tube 3 Tighten the fan drive belt as necessary For this refer to 3 CHECK POINTS OF EVERY 100 HOURS on page G 32 4 If scale forms i...

Page 38: ...course of time Thus check it every day and inflate as necessary 9Y1210595GEG0009US0 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 th...

Page 39: ...st below the fill port 2 Check to see that the coolant level is between the FULL and LOW marks of recovery tank 4 3 When the coolant 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 Refer to G 41 IMPORTANT If the radiator ...

Page 40: ...d personal injury Be sure to stop the engine and remove the key before greasing 9Y1210595GEG0012US0 1 Spindle Shaft 2 Tension Arm 3 Belt Tension Pivot 4 Mower Universal Joint Apply grease on the spline shaft A RCK42GR B RCK42 GR16 KiSC issued 11 2013 A ...

Page 41: ... Release the brake pedal 3 3 Turn the key to the START position 4 The engine should not crank Seat Safety Control 1 1 Run the engine at half throttle 2 Engage the PTO lever 4 3 Stand up Do not get off the machine 4 Engine should shut off Seat Start Control 2 1 Run the engine at half throttle 2 Disengage the PTO lever 4 3 Release the brake pedal 3 4 Stand up Do not get off the machine 5 Engine shou...

Page 42: ... position 4 The engine should not crank 9Y1210595GEG0058US0 Checking OPC System GR1600ID The OPC Operator Presence Control system in your machine are designed to protect you whole operating Please check these OPC system periodically daily is best to test function of the OPC system before operation CAUTION To avoid personal injury Do not allow anyone near the machine while testing If the machine do...

Page 43: ...the element with a light and check if it is damaged or not Referring to the instructions on the label attached to the case 3 Replace the air cleaner element if Once yearly or after every sixth cleaning whichever comes first NOTE Check to see if the evacuator valve is blocked with dust Operating in dusty conditions requires more frequent maintenance IMPORTANT The air cleaner uses a dry element neve...

Page 44: ... oil filler plug 1 port 3 If the level is too low add new oil to the prescribed level at the oil inlet Refer to 4 LUBRICANTS FUEL AND COOLANT on page G 9 9Y1210595GEG0015US0 Lubricating All Grease Fitting CAUTION To avoid personal injury Be sure to stop the engine and remove the key before greasing 1 Apply grease to the following locations as shown in the figures 9Y1210595GEG0016US0 1 Oil Filler P...

Page 45: ...re to stop the engine and remove the key before oiling 1 Apply oil to the following location as shown in the figures To be continued 1 Mower Universal Joint 2 Speed Control Pedal Shaft RH 3 Speed Control Pedal Shaft LH 4 Seat Adjuster 5 Throttle Cable KiSC issued 11 2013 A ...

Page 46: ...wer Link 7 Around Pin 8 Pivot of Mower Link 9 Pivot of Lift Arm 10 Front Link 11 Top Cover Lock Lever 12 Frame Shaft 13 Top Cover Hinge 14 Arm Bracket 15 Quick Clean Lever 16 PTO Lever Fulcrum 17 Link Fulcrum 18 Mower Lift Lever Fulcrum A GR1600EU GR1600F KiSC issued 11 2013 A ...

Page 47: ...ttery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WASH HANDS AFTER HANDLING Never remove the vent plugs while the engine is running Keep electrolyte away from eyes hands and clothes If you are spattered with it wash it away completely with water immediately ...

Page 48: ...eted due to abnormal conditions such as high heat or improper regulator setting Use voltmeter to check the state of charge See reference chart below to determine if charging is necessary The factory installed battery is of non refillable type If the battery is work charge the battery or replace it with new one 9Y1210595GEG0060US0 Battery voltage Reference state of charge 12 6 100 Full charge 12 4 ...

Page 49: ...attery 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 for emergencies It will partially charges the battery at a high rate and in a short time When using a boost charged battery it is necessary to r...

Page 50: ...s made of rubber and ages regardless of service period 2 If the fuel line 2 and clamps 1 are found to be damaged or deteriorated replace them 3 Check fuel filter 3 if it is clogged by debris or contaminated with water replace it IMPORTANT When the fuel line is disconnected for maintenance or repair close both ends of the fuel line with a piece of clean cloth or paper to prevent dust and dirt from ...

Page 51: ... free travel ranges from 15 to 25 mm 0 59 to 0 98 in 2 If it is not correct loosen the lock nut 2 and turn the nut 3 in the desired direction until the proper play is achieved After adjustment retighten lock nut securely 9Y1210595GEG0062US0 Play A Factory specification 15 to 25 mm 0 59 to 0 98 in 1 Brake Pedal 2 Lock Nut 3 Nut 4 Spring A GR1600EU GR1600F B GR1600ID KiSC issued 11 2013 A ...

Page 52: ... dynamo 2 outward to tighten the belt 3 After adjustment securely tighten the bolts Moderate belt tension The belt should deflect approx 10 mm 0 39 in when the center of the belt is depressed with finger pressure of 98 N 10 kgf IMPORTANT When replacing the fan drive belt be careful not to catch it on the cap under the water pump 9Y1210595GEG0063US0 Deflection A Factory specification 10 mm 0 39 in ...

Page 53: ...remove the key before changing the oil filter cartridge Allow engine to cool down sufficiently oil can be hot and may cause burns 1 The oil filter cartridge 1 must be changed every 200 service hours 2 Apply 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 c...

Page 54: ...5 Fill the crankcase with new oil of the proper type to the F mark on the dipstick See 4 LUBRICANTS FUEL AND COOLANT on page G 9 Always check the level with the dipstick before adding more oil 6 To check the oil level Remove the dipstick wipe it clean insert it and draw it out again Check to see that the oil level is between the two marks 7 Reinstall the oil fill cap and tighten it securely Reinst...

Page 55: ...nly 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 around filter gasket IMPORTANT To prevent serious damage to hydraulic system the replacement filter must be a highly efficient 10 µm filter Use only a genuine KUBOTA filter or its equivalent 9Y1210595G...

Page 56: ...31US0 Checking Intake Air Line 1 Check to see that hose 1 and clamps 2 are tight and not damaged 2 If hose 1 and clamps 2 are found worn or damaged replace or repair them at once 9Y1210595GEG0032US0 Tightening torque Center pin locking nut 77 4 to 90 2 N m 7 90 to 9 19 kgf m 57 1 to 66 5 lbf ft Clearance between front axle frame and anti vibration bolt A Factory specification 0 30 to 0 50 mm 0 012...

Page 57: ...PER 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 IMPORTANT Operate only at low rpm immediately after changing the transmission fluid and filter cartridge Keep the engine at medium speed for a few minutes to insure proper lubricat...

Page 58: ...EG0027US0 Replacing Fuel Filter 1 Disconnect the fuel hoses and loosen the filter band to replace the fuel filter 3 NOTE If the fuel line is removed be sure to properly bleed the fuel system Refer to G 32 9Y1210595GEG0033US0 7 CHECK POINT OF EVERY 1500 HOURS Checking Fuel Injection Nozzle Injection Pressure 1 Check the fuel injection nozzle Refer to 1 CHECKING AND ADJUSTING on page 1 S10 9Y1210595...

Page 59: ...ner instruction 6 After flushing fill with 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 3 and add coolant if necessary IMPORTANT Do not start...

Page 60: ...erm storage let out coolant completely or mix fresh water with long life coolant hereafter LLC and fill the radiator and reserve tank with the mixture 1 Long life coolant comes in several types Use ethylene glycol EG type for this engine 2 Before employing LLC mixed coolant fill the radiator with fresh water and empty it again Repeat this procedure 2 or 3 times to clean up the inside 3 Mixing the ...

Page 61: ...aning agent The LLC contains anti corrosive agent If mixed with the cleaning agent sludge may build up adversely affecting the engine parts 7 KUBOTA s genuine long life coolant has a service life of 2 years Be sure to change the coolant every 2 years NOTE The above data represent industry standards that necessitate a minimum glycol content in the concentrated anti freeze When the coolant level dro...

Page 62: ...0039US0 Replacing Radiator Hose 1 Replace hoses and clap bands every 2 years or earlier if checked and found that hoses are swollen hardened or cracked 9Y1210595GEG0040US0 Replacing Intake Air Line 1 Replace the intake air line Refer to G 38 9Y1210595GEG0041US0 Replacing Mower Gear Box Oil Seals 1 Replace the mower gear box oil seals Refer to 3 DISASSEMBLING AND ASSEMBLING on page 7 S14 9Y1210595G...

Page 63: ...lb from the socket 4 Push new bulb into the socket 5 Install the socket 6 Close the hood 9Y1210595GEG0044US0 Bleeding Fuel System Air must be removed 1 When the fuel filter or lines are removed 2 When tank is completely empty 3 After the machine has not been used for a long period of time Bleeding procedure is as follows 1 Fill the fuel tank with fuel 2 Turn the key switch to the ON position and h...

Page 64: ...ht hand threads turn counterclockwise to loosen The blade bolt 2 has left hand threads turn clockwise to loosen 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 blade is not balanced file the heavy side of the blade until balance is...

Page 65: ...Slip the belt 3 over the top of the left side pulley 4 Remove the both brackets which mounts the gear box 6 to the mower deck 5 To install a new belt reverse the above procedure 9Y1210595GEG0046US0 Tightening torque Bolt 1 79 to 90 N m 8 0 to 9 2 kgf m 58 to 66 lbf ft Bolt and Nut 2 48 to 55 N m 4 9 to 5 7 kgf m 36 to 41 lbf ft 1 Bolt 2 Bolt Nut 3 Belt 4 Left Hand Shield 5 Right Hand Shield 6 Mowe...

Page 66: ...the proper size box or socket wrench to tighten or loosen the blade mounting bolt Black blade 2 to be assembled at discharge deflector Black color side Red blade 3 to be assembled at mower deck wall Red color side 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...

Page 67: ...eys Slip the belt over the top of the pulley 4 Remove the right bracket 3 which mounts the gear box 2 to the mower deck NOTE Tighten each bolt and nut with following torque Bolt M12 77 6 to 90 2 N m 8 0 to 9 2 kgf m 58 to 66 lbf ft Bolt M10 and Nut M10 48 1 to 55 9 N m 4 9 to 5 7 kgf m 36 to 41 lbf ft 5 To install a new belt reverse the above procedure 9Y1210595GEG0068US0 1 Belt 2 Gear Box 3 Right...

Page 68: ...ing gears and other parts with ease WSM000001GEG0011US0 Piston Ring Compressor Code No 07909 32111 Application Use exclusively to push in the piston with piston rings into the cylinder WSM000001GEG0012US0 Piston Ring Tool Code No 07909 32121 Application Use exclusively to remove or install the piston ring with ease WSM000001GEG0013US0 KiSC issued 11 2013 A ...

Page 69: ...utter Code No 07909 33102 Application Use to reseat valves Angle 0 79 rad 45 0 26 rad 15 Diameter 28 6 mm 1 13 in 31 6 mm 1 24 in 35 0 mm 1 38 in 38 0 mm 1 50 in 41 3 mm 1 63 in 50 8 mm 2 00 in WSM000001GEG0016US0 Radiator Tester Code No 07909 31551 Application Use to check of radiator cap pressure and leaks from cooling system Remarks Adaptor 1 BANZAI Code No RCT 2A 30S WSM000001GEG0017US0 1 Gaug...

Page 70: ...ozzle Measuring range 0 to 50 MPa 0 to 500 kgf cm2 0 to 7200 psi WSM000001GEG0021US0 Plastigauge Code No 07909 30241 Application Use to check the oil clearance between crankshaft and bearing etc Measuring range Green 0 03 to 0 07 mm 0 001 to 0 003 in Red 0 05 to 0 1 mm 0 002 to 0 006 in Blue 0 1 to 0 2 mm 0 004 to 0 009 in WSM000001GEG0022US0 Red Check Code No 07909 31371 Application Use to check ...

Page 71: ...7 mm dia 0 67 in dia M 6 10 to 6 20 mm dia 0 241 to 0 244 in dia N 8 0 mm 0 31 in O 4 0 mm 0 16 in P 11 97 to 11 99 mm dia 0 4713 to 0 4720 in dia Q PF 1 2 R 23 mm 0 91 in S 17 mm 0 67 in T 4 0 mm 0 16 in U 12 00 to 12 02 mm dia 0 4725 to 0 4732 in dia V 100 mm 3 94 in W M12 P1 5 X 5 0 mm 0 20 in A 220 mm 8 66 in B 80 mm 3 1 in C 40 mm 1 6 in D 20 mm dia 0 79 in dia E 9 960 to 9 980 mm dia 0 3922 ...

Page 72: ... mm dia 0 8622 to 0 8641 in dia F 25 mm dia 0 98 in dia C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 012 in a 6 3 µm 250 µin b 6 3 µm 250 µin A 150 mm 5 91 in B 23 mm 0 91 in C 100 mm 3 94 in D 19 90 to 19 95 mm dia 0 7835 to 0 7854 in dia E 21 90 to 21 95 mm dia 0 8622 to 0 8641 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 ...

Page 73: ...0 79 in dia G 47 90 to 47 95 mm dia 1 886 to 1 887 in dia H 43 90 to 43 95 mm dia 1 729 to 1 730 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 01 in A 130 mm 5 12 in B 72 mm 2 8 in C 40 mm radius 1 6 in radius D 9 0 mm 0 35 in E 24 mm 0 94 in F 20 mm dia 0 79 in dia G 68 mm dia 2 7 in dia H 39 90 to 39 95 mm dia 1 571 to 1 572 in dia C1 Chamfer 1 0 mm 0 039 in ...

Page 74: ...or B M18 P1 5 07916 50361 6 Adaptor C PS3 8 07916 50371 7 Adaptor D PT1 8 07916 50381 8 Adaptor E PS3 8 07916 50392 9 Adaptor F PF1 2 07916 62601 10 Adaptor 58 PT1 4 07916 52391 1 Hydrostatic Transmission Tester 07916 52040 2 Gasket 04714 00200 3 Connector 3 07916 51331 4 Vacuum Gauge 07916 51331 5 Pressure Gauge Low Pressure 07916 51301 6 Pressure Gauge High Pressure in Relief Valve Set Pressure ...

Page 75: ...mm 0 32 in E 14 2 mm 0 55905 in F 7 6 to 8 0 mm 0 30 to 0 31 in G 2 3 mm 0 09055 in H 2 0 to 2 2 mm 0 079 to 0 087 in I 0 26 rad 15 J M8 K 3 mm dia drill 0 12 in dia drill L Rc1 8 M 2 09 rad 120 N 11 8 to 11 9 mm 0 465 to 0 469 in O 12 2 mm 0 480 in P 2 mm 0 079 in Q 3 mm 0 118 in R 8 mm 0 31496 in S 2 mm 0 079 in T 2 mm 0 079 in U 17 4625 mm dia 0 6875 in dia V 7 7 mm 0 303 in W 10 7 mm 0 421 in ...

Page 76: ... dia H 8 200 to 8 215 mm dia 0 3228 to 0 3234 in dia I 9 2 mm dia 0 16 in dia J 12 16 to 12 29 mm dia 0 4787 to 0 4839 in dia K 17 6 to 17 8 mm dia 0 693 to 0 701 in dia L 0 52 rad 30 M 9 16 18UNF N M8 O 1 5 mm 0 059 in P 10 3 to 10 5 mm 0 4055 to 0 4134 in Q 2 09 rad 120 C1 Chamfer 1 mm 0 039 in C0 2 Chamfer 0 2 mm 0 008 in R0 4 Radius 0 4 mm 0 016 in R0 2 Radius 0 2 mm 0 008 in A 9 7 to 10 3 mm ...

Page 77: ...6 mm 1 00 to 1 01 in E 57 4 to 57 6 mm 2 26 to 2 27 in F 21 4 to 21 6 mm 0 843 to 0 850 in G 15 mm 0 59 in H 115 mm 4 53 in I 103 4 to 103 6 mm 4 071 to 4 078 in J 47 4 to 47 6 mm 1 866 to 1 874 in K 44 9 to 45 1 mm 1 77 to 1 78 in L 15 4 to 15 6 mm 0 607 to 0 614 in M 83 6 to 84 1 mm dia 3 30 to 3 31 in dia N 72 15 to 72 45 mm dia 2 841 to 2 852 in dia O 4 9 mm 0 19 in P 33 9 to 34 1 mm 1 33 to 1...

Page 78: ...to the prescribed level it naturally drops slowly in the course of time Thus check it everyday and inflate as necessary 9Y1210595GEG0069US0 2 TREAD The tread can not be adjusted IMPORTANT Do not turn discs to obtain wider tread Always attach tires as shown in the drawing If not attached as illustrated transmission parts may be damaged NOTE Use the tapered bolts for wheels with beveled or tapered h...

Page 79: ...alfunctions or failures of the tractor damage to other property and injury to the operator or others Any malfunctions or failures of the tractor resulting from use with improper implements are not covered by the warranty WSM000001GEG0083US0 9Y1210595GEG0070US0 MODEL Maximum axle loading weight GR1600EU GR1600F Front axle Wf Rear axle Wr Total gross weight 250 kg 551 lbs 450 kg 992 lbs 600 kg 1323 ...

Page 80: ...1 ENGINE KiSC issued 11 2013 A ...

Page 81: ...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 MECHANISM KiSC issued 11 2013 A ...

Page 82: ...06US0 2 CLOSED BREATHER Closed breather system has been adopted to prevent the release of blow by gas into the atmosphere After its oil content is filtered by oil shield 4 the blow by gas is fed back to the intake manifold through breather valve 3 to be used for re combustion 9Y1210595ENM0002US0 1 Cylinder Head Cover 2 Rubber Packing 1 Breather Tube 2 Cylinder Head Cover 3 Breather Valve PCV 4 Oil...

Page 83: ...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 9Y1210595ENM0003US0 1 Rocker Arm 2 Oil Pressure Switch 3 Rocker Arm Shaft 4 Val...

Page 84: ...ater 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 9Y1210595E...

Page 85: ... to 150 kgf cm2 2000 to 2130 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 9Y1210595ENM0005US0 1 Injection Nozzle 2 Fuel Overflow Pipe 3 Fuel Tank 4 Fuel Filte...

Page 86: ... 1 S19 1 Separation of the Engine 1 S19 3 DISASSEMBLING AND ASSEMBLING 1 S22 1 Cylinder Head and Valves 1 S22 2 Timing Gear Camshaft and Fuel Camshaft 1 S25 3 Piston and Connecting Rod 1 S29 4 Crankshaft 1 S32 5 Water Pump 1 S35 6 Injection Nozzle 1 S35 4 SERVICING 1 S36 1 Cylinder Head and Valves 1 S36 2 Timing Gear Camshaft and Fuel Camshaft 1 S41 3 Piston and Connecting Rod 1 S43 4 Crankshaft 1...

Page 87: ...ton cylinder or bearing Repair or replace Compression leak from cylinder Replace head gasket tighten cylinder head screw glow plug and nozzle holder 1 S23 1 S24 1 S25 Improper valve timing Correct or replace timing gear 1 S27 Piston ring and cylinder worn Replace 1 S45 1 S50 Excessive valve clearance Adjust 1 S12 Starter Does Not Run Battery discharged Charge G 29 Starter malfunctioning Repair or ...

Page 88: ...tion Replace injection pump 1 S25 Deficient nozzle injection Repair or replace nozzle 1 S35 Compression leak Replace head gasket tighten cylinder head screw glow plug and nozzle holder 1 S23 1 S24 Excessive Lubricant Oil Consumption Piston ring s gap facing the same direction Shift ring gap direction 1 S30 Oil ring worn or stuck Replace 1 S31 1 S45 Piston ring groove worn Replace piston 1 S31 1 S4...

Page 89: ... Repair or replace 1 S28 High Oil Pressure Different type of oil Use specified type of oil G 9 Relief valve damaged Replace Engine Overheated Engine oil insufficient Fill G 9 Fan belt broken or tensioned improperly Replace or adjust G 34 Coolant insufficient Fill G 9 Radiator net and radiator fin clogged with dust Clean Inside of radiator corroded Clean or replace G 41 Coolant flow route corroded ...

Page 90: ...de Valve Stem Valve Guide Clearance O D I D 0 030 to 0 057 mm 0 0012 to 0 0022 in 5 968 to 5 980 mm 0 2350 to 0 2354 in 6 010 to 6 025 mm 0 2367 to 0 2372 in 0 10 mm 0 0039 in Valve Seat Width Angle 2 12 mm 0 0835 in 0 79 rad 45 Valve Face Angle 0 79 rad 45 Valve Spring Free Length Tilt Setting Load Setting Length 31 3 to 31 8 mm 1 24 to 1 25 in 65 N 6 6 kgf 15 lbs 27 0 mm 1 06 in 28 4 mm 1 12 in ...

Page 91: ...e Clearance 0 20 to 0 51 mm 0 0079 to 0 020 in 0 80 mm 0 031 in Camshaft Side Clearance Alignment Cam Height Intake and Exhaust 0 15 to 0 31 mm 0 0059 to 0 012 in 26 88 mm 1 058 in 0 50 mm 0 020 in 0 01 mm 0 0004 in 26 83 mm 1 056 in Camshaft Journal to Cylinder Block Bore Camshaft Journal Cylinder Block Bore Oil Clearance O D I D 0 050 to 0 091 mm 0 0020 to 0 0035 in 32 934 to 32 950 mm 1 2967 to...

Page 92: ...o Piston Ring Groove Second Ring Oil Ring Clearance Clearance 0 0850 to 0 115 mm 0 00335 to 0 00452 in 0 02 to 0 06 mm 0 0008 to 0 002 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in Connecting Rod Alignment 0 05 mm 0 0020 in Crankshaft Side Clearance Alignment 0 15 to 0 30 mm 0 0059 to 0 011 in 0 50 mm 0 0197 in 0 02 mm 0 0008 in Crankpin to Crankpin Bearing Crankpin Crankpin Bearing Oil Clearance O D I D...

Page 93: ...84 to 40 026 mm 1 5742 to 1 5758 in 0 20 mm 0 0079 in Cylinder Liner I D 67 000 to 67 019 mm 2 6378 to 2 6385 in 67 169 mm 2 6444 in Cylinder Liner Oversize I D 67 250 to 67 269 mm 2 6477 to 2 6483 in 67 419 mm 2 6543 in Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed At Rated Speed More than 50 kPa 0 5 kgf cm2 7 psi 200 to 440 kPa 2 0 to 4 5 kgf cm2 29 to 64 psi 150 k...

Page 94: ... Water Leakage Test Pressure No leak at specified pressure 160 kPa 1 6 kgf cm2 23 psi Item Factory Specification Allowable Limit Injection Pump Injection Timing 0 32 to 0 34 rad 18 to 20 before T D C Pump Element Fuel Tightness 13 7 MPa 140 kgf cm2 1990 psi Delivery Valve Fuel Tightness 10 seconds 13 7 12 8 MPa 140 130 kgf cm2 1990 1850 psi 5 seconds 13 7 12 8 MPa 140 130 kgf cm2 1990 1850 psi Fue...

Page 95: ... 2 8 18 to 20 Engine support screw M10 1 25 48 to 55 4 9 to 5 7 36 to 41 Cylinder head cover screw M6 1 0 6 87 to 11 2 0 700 to 1 15 5 07 to 8 31 Injection pipe retaining nut M12 1 5 25 to 34 2 5 to 3 5 18 to 25 Overflow pipe retaining nut M12 1 5 20 to 24 2 0 to 2 5 15 to 18 Nozzle holder assembly M20 1 5 49 to 68 5 0 to 7 0 37 to 50 Glow plug M8 1 0 7 9 to 14 0 80 to 1 5 5 8 to 10 Rocker arm bra...

Page 96: ...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 wall and piston r...

Page 97: ...rn the flywheel until the piston exceeds its top dead center 5 Remove the cylinder head and measure the squeezed plastigauges 2 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 NOTE After checking the top clearance be sure to assemble the cylinder head with a new cylinder...

Page 98: ...lign the 1TC mark 2 on the flywheel and alignment mark 3 on the rear end plate so that the No 1 piston comes to the overlap position 6 Check the following valve clearance marked with using a thickness gauge When No 1 piston is at the overlap position 7 If the clearance is not within the factory specifications adjust with the adjusting screw NOTE The sequence of cylinder numbers is given as No 1 an...

Page 99: ...nsufficient Oil pump damaged Oil strainer clogged Oil filter cartridge clogged Oil gallery clogged Excessive oil clearance Foreign matter in the relief valve When reassembling After checking the engine oil pressure tighten the engine oil pressure switch to the specified torque 9Y1210595ENS0007US0 Engine oil pressure At idle speed Factory specifica tion More than 50 kPa 0 5 kgf cm2 7 psi At rated s...

Page 100: ...kgf 22 lbs 2 If the measurement is not within the factory specifications loosen the dynamo mounting screws 3 and relocate the dynamo to adjust 9Y1210595GEG0023US0 Fan Belt Damage and Wear 1 Check the fan belt for damage 2 If the fan belt is damaged replace it 3 Check if the fan belt is worn and sunk in the pulley groove 4 If the fan belt is nearly worn out and deeply sunk in the pulley groove repl...

Page 101: ... the pressure to fall to 60 kPa 0 6 kgf cm2 9 psi 3 If the measurement is less than the factory specification replace the radiator cap 9Y1210595ENS0012US0 Radiator Water Leakage 1 Pour a specified amount of water into the radiator 2 Set a radiator tester 1 Code No 07909 31551 and an adapter 2 BANZAI Code No RCT 2A 30S and raise the water pressure to the specified pressure 3 Check the radiator for ...

Page 102: ...ss Refer to figure below to check the thickness of the shims 9Y1210595ENS0014US0 Fuel Tightness of Pump Element 1 Remove the engine stop solenoid 2 Remove the injection pipes and glow plugs 3 Install the injection pump pressure tester to the injection pump 4 Install the injection nozzle 1 jetted with the proper injection pressure to the injection pump pressure tester 2 Refer to the figure 5 Set th...

Page 103: ...nt is less than allowable limit replace the pump with new one or repair with a KUBOTA authorized pump service shop NOTE Never try to disassemble the injection pump assembly For repairs you are strongly requested to contact a KUBOTA authorized pump service shop 9Y1210595ENS0093US0 CAUTION Check the injection pressure and condition after you make sure that there is nobody standing in the direction t...

Page 104: ...0 01 mm 0 0004 in difference of adjusting washer thickness Approx 240 kPa 2 4 kgf cm2 34 psi 9Y1210595ENS0019US0 Valve Seat Tightness 1 Set the injection nozzle to a nozzle tester Code No 07909 31361 2 Raise the fuel pressure and keep at 12 8 MPa 130 kgf cm2 1850 psi for 10 seconds 3 If any fuel leak is found replace the nozzle piece 9Y1210595ENS0020US0 Fuel injection pressure Factory specificatio...

Page 105: ...ngine Oil 1 Start and warm up the engine for approx 5 minutes 2 Place an oil pan underneath the engine 3 Remove the drain plug 1 to drain oil 4 After draining screw in the drain plug 1 When refilling Fill the engine oil up to the upper line on the dipstick 3 IMPORTANT Never mix two different type of oil Use the proper SAE Engine Oil according to ambient temperature Refer to 4 LUBRICANTS FUEL AND C...

Page 106: ...rom the battery 3 Disconnect the positive cable 2 from the battery and remove the battery 3 9Y1210595ENS0023US0 Bonnet and Side Bonnet 1 Disconnect the connectors 5 from the head light 2 Remove the wire harness 4 from the bonnet 3 Remove the bonnet 1 with bonnet bracket 2 4 Remove the side bonnet 3 9Y1210595ENS0024US0 1 Negative Cable 2 Positive Cable 3 Battery 1 Bonnet 2 Bonnet Bracket 3 Side Bon...

Page 107: ...er 1 and muffler 2 2 Disconnect the fuel hoses 3 3 Disconnect the accelerator wire 4 4 Disconnect the wire harness 5 5 Remove the flywheel cover 6 GR1600F GR1600ID only 9Y1210595ENS0025US0 1 Air Cleaner 2 Muffler 3 Fuel Hose 4 Accelerator Wire 5 Wire Harness 6 Flywheel Cover KiSC issued 11 2013 A ...

Page 108: ...enoid 6 Remove the wire bracket 7 Remove the engine support LH 7 and RH 5 When reassembling Check to see that there are no cracks on the belt surface IMPORTANT After reassembling the fan belt be sure to adjust the fan belt tension 9Y1210595ENS0027US0 Tightening torque Front coupling mounting screw 24 to 27 N m 2 4 to 2 8 kgf m 18 to 20 lbf ft Engine mounting nut 24 N m 2 4 kgf m 18 lbf ft 1 Radiat...

Page 109: ...nd the heat seal 6 4 Remove the lead 3 from the glow plugs 4 5 Remove the glow plugs 4 When reassembling Replace the copper gasket and heat seal with new one 9Y1210595ENS0030US0 Tightening torque Cylinder head cover screw 6 87 to 11 2 N m 0 78 to 1 15 kgf m 5 07 to 8 31 lbf ft 1 Head Cover Screws 2 Cylinder Head Cover Tightening torque Injection pipe retaining nut 25 to 34 N m 2 5 to 3 5 kgf m 18 ...

Page 110: ...d screws after applying sufficient oil Tighten the cylinder head screws diagonal sequence starting from the centre Tighten them uniformly or the head may deform in the long run Retighten the cylinder head screws after running the engine for 30 minutes 9Y1210595ENS0096US0 Tappets 1 Remove the tappets 1 from the crankcase When reassembling Visually check the contact between tappets and cams for prop...

Page 111: ...5 first and install the speed control plate 2 Be sure to place the copper washers underneath two screws 1 Two screws 1 in the upper of the speed control plate 2 Position the slot 9 on the fork lever just under the slot 8 on the crankcase Insert the injection pump 3 so that the control rod 7 should be pushed by the idling adjusting spring 6 at its end and the pin 10 on the rod engages with the slot...

Page 112: ...ar Case 1 Remove the screw 1 of inside the gear case and outside screws 6 2 Disconnect the start spring 2 from the fork lever 1 3 Remove the gear case 3 When reassembling Apply a liquid gasket Three Bond 1215 or equivalent to both sides of the gear case gasket 4 Be sure to set three O rings 5 inside the gear case 9Y1210595ENS0037US0 Tightening torque Fan drive pulley screw 98 1 to 107 N m 10 0 to ...

Page 113: ...0595ENS0038US0 Camshaft 1 Remove the camshaft mounting screws 1 and draw out the camshaft with gear 2 on it When reassembling When install the camshaft apply engine oil to the camshaft journals Apply engine oil to the camshaft mounting screws And tighten them 9Y1210595ENS0039US0 Tightening torque Idle gear shaft mounting screw 9 81 to 11 2 N m 1 00 to 1 15 kgf m 7 24 to 8 31 lbf ft 1 Idle Gear 2 I...

Page 114: ...US0 Oil Pump and Crankshaft Gear 1 Remove the oil pump gear 6 2 Remove the oil pump 5 3 Remove the collar 4 O ring 3 and crankshaft oil slinger 2 4 Remove the crankshaft gear 1 When reassembling Install the collar 4 after aligning the marks on the gears See the figure at Idle Gear 9Y1210595ENS0041US0 1 Retaining Plate 2 Fuel Camshaft 3 Injection Pump Gear 4 Governor Sleeve 5 Fork Lever 1 6 Fork Le...

Page 115: ...e flange as well as on the inner wall of each bolt hole Cut the nozzle of the liquid gasket Three Bond 1207D or equivalent container at its second notch Apply liquid gasket about 5 0 mm 0 19 in thick Within 20 minutes after the application of fluid sealant reassemble the components Wait then for about 30 minutes and pour oil in the crankcase 9Y1210595ENS0042US0 3 Piston and Connecting Rod Connecti...

Page 116: ... connecting rod to the injection pump IMPORTANT Do not change the combination of cylinder and piston Make sure of the position of each piston by marking For example mark 1 on the No 1 piston When installing the piston into the cylinder place the gaps of all of the piston rings as shown in the figure Carefully insert the pistons using a piston ring compressor 1 Otherwise their chrome plated section...

Page 117: ... the oil ring gap 11 Apply engine oil to the piston pin When installing the connecting rod to the piston immerse the piston in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin to the piston When installing the connecting rod to the piston align the mark 8 on the connecting rod to the fan shaped concave 9 NOTE Mark the same number on the connecting rod and the piston so as not to chang...

Page 118: ...When reassembling Fit the bearing case gasket 3 and the bearing case cover gasket 4 with correct directions Install the bearing case cover 6 to position the casting mark UP a on it upward Apply engine oil to the oil seal 5 lip and be careful that it is not rolled when installing Tighten the bearing case cover mounting screws with even force on the diagonal line 9Y1210595ENS0099US0 Tightening torqu...

Page 119: ...ssage of the crankshaft with compressed air Apply oil to the main bearing case screw 2 1 Install the crankshaft assembly aligning the screw hole of main bearing case with the screw hole of crankcase 9Y1210595ENS0048US0 Tightening torque Main bearing case screw 2 27 to 30 N m 2 7 to 3 1 kgf m 20 to 22 lbf ft 1 Main Bearing Case Screw 2 KiSC issued 11 2013 A ...

Page 120: ... figure Match the alignment numbers a on the main bearing case assembly 1 Do the same for the main bearing case assembly 3 too When installing the main bearing case 1 face the mark FLYWHEEL to the flywheel Install the thrust bearing 8 with its oil groove facing outward Make sure that the main bearing case moves smoothly after tightening the main bearing case screw 1 to the specified torque 9Y12105...

Page 121: ...lent to the both sides of gasket Replace the mechanical seal with new one 9Y1210595ENS0051US0 6 Injection Nozzle Nozzle Holder 1 Secure the nozzle retaining nut 7 with a vise 2 Remove the nozzle holder 1 and remove parts inside When reassembling Assemble the nozzle in clean fuel oil Install the push rod 4 noting its direction After assembling the nozzle be sure to adjust the fuel injection pressur...

Page 122: ...ng 4 Wash away the read permeative liquid on the cylinder head surface with the detergent 2 5 Spray the cylinder head surface with white developer 3 6 If flawed it can be identified as red marks 9Y1210595ENS0054US0 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...

Page 123: ... 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 IMPORTANT Do not hit the valve guide with a hammer during replacement 9Y1210595ENS0057US0 Clearance between valve stem and valve guide Factory specification 0 030 to 0 057 mm 0 0012 to 0 0022 in A...

Page 124: ... the contact position of the valve face and seat surface with prussian blue Visual check If the valve has been used for a long period the seat tends to come in contact with the upper side of the valve face 3 Grind the upper surface of the seat with a 0 26 rad 15 valve seat cutter until the valve seat touches to the center of the valve face so that a equals b as shown in the figure 4 Grind the seat...

Page 125: ...ng on a surface plate place a square on the side of the valve spring 3 Check to see if the entire side is in contact with the square Rotate the valve spring and measure the maximum tilt B If the measurement exceeds the allowable limit replace it 4 Check the entire surface of the valve spring for scratches If there is any problem replace it 9Y1210595ENS0102US0 Valve Spring Setting Load 1 Place the ...

Page 126: ...meter 2 Measure the I D of the tappet guide bore with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the tappet 9Y1210595ENS0065US0 Oil clearance between rocker arm and rocker arm shaft Factory specification 0 016 to 0 045 mm 0 00063 to 0 0017 in Allowable limit 0 15 mm 0 0059 in Rocker arm shaft O D Factory spec...

Page 127: ...e cam gear to the font and rear 3 If the measurement exceeds the allowable limit replace the camshaft stopper 9Y1210595ENS0068US0 Backlash between idle gear and crank gear Factory specification 0 0430 to 0 124 mm 0 00170 to 0 00488 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and cam gear Factory specification 0 0470 to 0 123 mm 0 00185 to 0 00484 in Allowable limit 0 15 mm 0 00...

Page 128: ... camshaft journal O D with an outside micrometer 2 Measure the cylinder block bore I D for camshaft with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the camshaft 9Y1210595ENS0071US0 Camshaft alignment Allowable limit 0 01 mm 0 0039 in Cam height of intake and exhaust Factory specification 26 88 mm 1 058 in Allowable limit 26 83 mm 1 0...

Page 129: ...ng using an idle gear bushing replacing tool until it is flush with the end of the idle gear 9Y1210595ENS0073US0 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 9Y1210595ENS0074US0 Oil clearance between idle gear shaft and idle g...

Page 130: ...ons as shown in the figure until it is flush with the connecting rod 3 Drill a hole to the bushing with aligning the oil hole 2 of connecting rod Refer to the figure NOTE Be sure to chamfer the oil hole circumference with an oil stone 9Y1210595ENS0076US0 Oil clearance between piston pin and small end bushing Factory specification 0 014 to 0 038 mm 0 00056 to 0 0014 in Allowable limit 0 10 mm 0 003...

Page 131: ...od on the connecting rod alignment tool Code No 07909 31661 4 Put a gauge over the piston pin and move it against the face plate 5 If the gauge does not fit squarely against the face 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 9Y1210595ENS0079US0 Piston ring gap Top ring Factory specifica tion 0...

Page 132: ...t alignment 4 If the measurement exceeds the allowable limit replace the crankshaft 9Y1210595ENS0081US0 Crankshaft side clearance Factory specification 0 15 to 0 30 mm 0 0059 to 0 011 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 ...

Page 133: ...s of crankpin 9Y1210595ENS0082US0 Oil clearance between crankpin and crankpin bearing Factory specification 0 020 to 0 051 mm 0 00079 to 0 0020 in Allowable limit 0 15 mm 0 0059 in Crankpin O D Factory specification 33 959 to 33 975 mm 1 3370 to 1 3375 in Crankpin bearing I D Allowable limit 33 995 to 34 010 mm 1 3384 to 1 3389 in Undersize Bearing Code Number Marking 0 20 mm 0 0079 in Crankpin be...

Page 134: ...tool press in a new bearing 1 2 so that its seam 1 directs toward the exhaust manifold side See figure 9Y1210595ENS0084US0 Oil Clearance between crankshaft journal and crankshaft bearing 1 Factory specification 0 0340 to 0 106 mm 0 00134 to 0 00417 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory specification 39 934 to 39 950 mm 1 5722 to 1 5728 in Crankshaft bearing 1 I D Fact...

Page 135: ... D Flywheel side Factory specification 43 934 to 43 950 mm 1 7297 to 1 7303 in Crankshaft bearing 2 I D Factory specification 43 984 to 44 026 mm 1 7317 to 1 7333 in Crankshaft journal O D Intermediate Factory specification 39 934 to 39 950 mm 1 5722 to 1 5728 in Crankshaft bearing 3 I D Factory specification 39 984 to 40 026 mm 1 5742 to 1 5758 in Undersize Bearing Code Number Marking 0 20 mm 0 0...

Page 136: ...it replace the cylinder block with a new one 9Y1210595ENS0087US0 6 Oil Pump Rotor Lobe Clearance 1 Measure the clearance between lobes of the inner rotor and the outer rotor with a thickness gauge 2 If the clearance exceeds the factory specifications replace the oil pump rotor assembly 9Y1210595ENS0088US0 Cylinder I D Factory specification 67 000 to 67 019 mm 2 6378 to 2 6385 in Allowable limit 67...

Page 137: ... Code No 07909 30241 onto the rotor face with grease 2 Install the cover and tighten the screws 3 Remove the cover carefully and measure the amount of the flattening with the scale and get the clearance 4 If the clearance exceeds the factory specifications replace the oil pump rotor assembly 9Y1210595ENS0090US0 Clearance between outer rotor and pump body Factory specification 0 070 to 0 15 mm 0 00...

Page 138: ...2 TRANSAXLE KiSC issued 11 2013 A ...

Page 139: ...G SYSTEM 2 M2 1 HYDROSTATIC TRANSMISSION 2 M2 1 Structure 2 M2 2 Oil Flow 2 M3 3 Operation 2 M4 4 Charge Pump 2 M7 5 By pass Valve 2 M7 6 Control Linkage 2 M8 2 MOWER PTO SYSTEM 2 M9 1 Mower PTO Clutch 2 M9 MECHANISM KiSC issued 11 2013 A ...

Page 140: ...s machine is constructed as shown above 9Y1210595TXM0002US0 1 Hydraulic Transmission Section 2 Mower PTO Section 3 Differential Gear Section 4 Rear Axle Section 5 Bearing which Supports the Rear Axle 6 Bearing which Supports the Drive Shaft KiSC issued 11 2013 A ...

Page 141: ...hange pedal permits simple operation of this machine starting stopping and accelerating or decelerating This HST has check valves 1 and does not have relief valves 9Y1210595TXM0003US0 1 Check Valve 2 Trunnion Arm 3 Charge Relief Valve 4 Charge Pump 5 Center Section 6 Cylinder Block Pump 7 Piston Spring 8 Piston 9 Spring Cylinder Block 10 Washer 11 Thrust Ball Bearing 12 Swashplate 13 Cradle Bearin...

Page 142: ...l passed through the filter cartridge 4 is routed to HST as charge oil by the charge pump 2 and charge relief valve 10 Overflow oil from the HST housing flows back to the transaxle 9Y1210595TXM0004US0 1 Pump 2 Charge Pump 3 Check Valve Forward 4 Filter Cartridge 5 Motor 6 By pass Valve 7 Lubricating Orifice 8 Check Valve Reverse 9 Neutral Orifice 10 Charge Relief Valve KiSC issued 11 2013 A ...

Page 143: ...cylinder block 1 without reciprocating motion At this time since the pump pistons do not generate pressure no pressure is transmitted to the motor pistons thus causing neither rotation of the motor cylinder block 4 nor that of the motor shaft engaged with it Thus the machine is stationary 9Y1210595TXM0005US0 1 Cylinder Block Pump 2 Swashplate 3 Piston 4 Cylinder Block Motor 5 Lubricating Orifice 6...

Page 144: ... from the port D thrusts the motor pistons to the surface of the inclined thrust ball bearing causing them to slide on the inclined surface This causes the motor cylinder block 4 and the motor shaft engaged with it to rotate This causes the machine to move forward The inclination of the pump swashplate 2 determines the motor shaft speed 9Y1210595TXM0006US0 1 Cylinder Block Pump 2 Swashplate 3 Pist...

Page 145: ...ons Port A Port C Pressure from the port C thrusts the motor pistons to the surface of the inclined thrust ball bearing causing them to slide on the inclined surface This causes the motor cylinder block 4 and the motor shaft engaged with it to rotate This causes the machine to move reverse The inclination of the pump swashplate 2 determines the motor shaft speed 9Y1210595TXM0007US0 1 Cylinder Bloc...

Page 146: ...n power while the engine is stopped The following paragraphs describe this mechanism Pressing the by pass valve connects the forward and reverse loops in the center section This allows oil to flow 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...

Page 147: ...shplate 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 9Y1210595TXM0010US0 1 Speed Change Pedal 2 Speed Change Rod 3 Speed Change Plate 4 Neutral Arm 5 Neutr...

Page 148: ...ngaged position 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 a...

Page 149: ...eates 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 9Y1210595TXM0013US0 1 PTO Shaft 2 Clutch Lever 3 Spline Boss 4 Clutch Disc and Friction Plate 5 Clutch Case 6 24T Gea...

Page 150: ...HST Speed Change System 2 S6 2 HST Charge Pressure 2 S7 2 PREPARATION 2 S10 1 Separating Transaxle 2 S10 2 Separating Hydrostatic Transmission 2 S17 3 DISASSEMBLING AND ASSEMBLING 2 S21 1 Hydrostatic Transmission 2 S21 2 Transaxle Case 2 S24 3 PTO Clutch 2 S33 4 SERVICING 2 S38 1 Hydrostatic Transmission 2 S38 2 Transaxle Case 2 S40 SERVICING KiSC issued 11 2013 A ...

Page 151: ...l to speed control arm Repair control linkage 2 S6 2 S16 Charge pressure is too low Oil filter cartridge clogged Replace oil filter cartridge G 37 Charge pump damaged Replace charge pump 2 S21 Charge relief valve damaged Repair or replace charge relief valve 2 S21 Check valve damaged Replace check valve 2 S22 By pass valve damaged Replace by pass valve 2 S22 HST component parts damaged Replace HST...

Page 152: ...obable Cause Solution Reference Page Excessive or Unusual Noise at All Time Improper backlash between 11T bevel gear and 17T 13T gear shaft Adjust 2 S43 Improper backlash between differential pinion and differential side gear Adjust 2 S42 Bearing worn Replace Insufficient or improper type of transmission fluid used Fill or change G 9 2 S12 Noise while Turning Differential pinions or differential s...

Page 153: ...sure Plate Thickness 1 55 to 1 65 mm 0 0611 to 0 0649 in 1 50 mm 0 0591 in Friction Plate 1 Thickness 1 55 to 1 65 mm 0 0611 to 0 0649 in 1 50 mm 0 0591 in Friction Plate 2 Thickness 0 75 to 0 85 mm 0 030 to 0 033 in 0 70 mm 0 028 in Clutch Spring Free Length 45 mm 1 8 in 42 mm 1 7 in PTO Brake Disc Thickness 3 30 to 3 50 mm 0 130 to 0 137 in 3 00 mm 0 118 in Brake Friction Plate 1 Thickness 1 75 ...

Page 154: ...r 42T Gear Boss Clearance I D 0 040 to 0 082 mm 0 0016 to 0 0032 in 22 500 to 22 521 mm 0 88583 to 0 88665 in 0 17 mm 0 0067 in Differential Pinion Gear to Differential Pinion Shaft Differential Case Bore Differential Side Gear Boss Clearance I D O D 0 025 to 0 055 mm 0 00099 to 0 0021 in 10 000 to 10 015 mm 0 39370 to 0 39429 in 9 960 to 9 975 mm 0 3922 to 0 3927 in 0 25 mm 0 0098 in Differential...

Page 155: ...8 31 Transaxle mounting screw 48 to 55 4 9 to 5 7 36 to 41 Hydrostatic transmission mounting screw 24 to 27 2 4 to 2 8 18 to 20 Hydrostatic transmission mounting screw 2 18 to 20 1 8 to 2 1 13 to 15 Center section mounting hex socket head screw 18 to 20 1 8 to 2 1 13 to 15 By pass valve plug 15 1 5 11 Check valve plug 30 3 1 22 PTO clutch assembly mounting screw 18 to 20 1 8 to 2 1 13 to 15 Beam m...

Page 156: ...center between position A and B and tighten the holder shaft mounting screw 3 firmly This means the hydrostatic transaxle is fully in neutral Position C WARNING Use buddy system in adjusting the neutral position One of you should sit on the operator s seat adjust the engine rpm and step on the speed change pedal The other should adjust the neutral position 9Y1210595TXS0014US0 Speed Change Pedal Re...

Page 157: ... Pull the top cover lock lever 2 to open the top cover 1 2 Set the grass container lift lever 4 in LEVER LOCK position 3 Lift up the rear of the grass container 3 4 Lift up the whole grass container and remove When attaching Open the top cover 1 Set the grass container lift lever 4 in LEVER LOCK position Lift the rear end of the grass container 3 set the grass container 3 onto the frame shaft so t...

Page 158: ... for the discharge duct 2 3 Disconnect the spring 4 and the coupler 5 4 Remove the discharge duct 2 9Y1210595TXS0002US0 B GR1600ID Removing the Rear Cover 1 Remove the rear cover 1 9Y1210595TXS0077US0 1 Filter Cover 2 Discharge Duct 3 Screw 4 Spring 5 Coupler 1 Rear Cover KiSC issued 11 2013 A ...

Page 159: ... FOR MACHINE on page G 56 3 Start the engine and run engine speed at maximum speed 4 Read the pressure gauge to measure the HST charge pressure 5 If the measurement is not within the factory specification check the hydraulic control valve and the related hydraulic components Condition Engine speed Maximum Oil temperature 50 C 122 F 9Y1210595TXS0006US0 HST charge pressure Factory specification 0 90...

Page 160: ...Lift up the whole grass container and remove When attaching Open the top cover 1 Set the grass container lift lever 4 in LEVER LOCK position Lift the rear end of the grass container 3 set the grass container 3 onto the frame shaft so that a clearance L is about 0 to 50 mm 0 to 1 9 in Lock the grass container 3 with the grass container lift lever 4 in CONTAINER LOCK position Close the top cover 1 R...

Page 161: ...oupler 5 4 Remove the discharge duct 2 9Y1210595TXS0002US0 Container Base 1 Disconnect the connector 2 2 Remove the container base 1 9Y1210595TXS0005US0 B GR1600ID Removing the Rear Cover 1 Remove the rear cover 1 9Y1210595TXS0077US0 1 Filter Cover 2 Discharge Duct 3 Screw 4 Spring 5 Coupler 1 Container Base 2 Connector 1 Rear Cover KiSC issued 11 2013 A ...

Page 162: ...embly and each hydraulic pipe is found At least 5 minutes after stopping the engine check the oil level again using the dipstick If the oil level is lower than the H level indicated on the dipstick fill the oil tank with transmission fluid additionally up to the H level Perform the above mentioned operation again And make sure that the oil level is not low level Disconnect the universal joint of m...

Page 163: ...d cutting height control dial 6 2 Remove the speed change pedal 7 3 Remove the seat base 2 4 Peel the step sheet 8 halfway 5 Remove the fuel cap 4 6 Remove the relay stay 9 7 Disconnect the connectors for the timer relay grass container full switch relay grass container relay and buzzer relay 8 Remove the fender 5 9Y1210595TXS0020US0 Fuel Tank 1 Drain the fuel 2 Disconnect the fuel hoses 3 Remove ...

Page 164: ...ged 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 IMPORTANT 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 PTO arm 5 and the lower ...

Page 165: ...e rod 1 6 2 Remove the lock nut 1 plain washers 2 and brake spring 3 3 Remove the brake plate 5 4 Remove the brake rod 2 4 and brake rod 1 6 When reassembling After assembling the brake rod 1 2 4 6 and brake spring 3 be sure to adjust the brake pedal free travel Refer to 4 CHECKING DISASSEMBLING AND SERVICING on page 3 S4 9Y1210595TXS0024US0 1 PTO Switch 2 Spring 3 PTO Lever 4 Filling Pipe 5 Beam ...

Page 166: ...pper and lift up the frame 4 Remove the retaining ring 3 and remove the rear wheel 4 When reassembling Apply grease to the splines of the universal joint 9Y1210595TXS0026US0 Separating Transmission 1 Remove the transaxle mounting screws 2 2 Separate the transaxle 1 from the frame When reassembling 9Y1210595TXS0027US0 1 Speed Change Plate 2 Split Pin 3 Speed Control Arm 4 Speed Change Rod 5 Lock Nu...

Page 167: ... breather ports set the hose clamp at 1 to 2 mm 0 04 to 0 07 in from the hose end Fix the breather hose 4 with a cord clamp 9 so that the breather hose 4 does not contact with the cooling fan shaft 8 In this case wind the cord clamp 9 around the breather hose 4 in the direction indicated by the arrow mark shown in the figure Fix the breather hose 4 on the suction pipe 6 with the clamp as shown in ...

Page 168: ...the suction filter case 1 After setting the O ring 4 in the suction pipe 2 2 install the suction pipe 2 2 in the suction filter case 1 After setting the O ring 9 in the transaxle case 8 install the suction filter case 1 in the transaxle case 8 9Y1210595TXS0029US0 Tightening torque Suction pipe 2 mounting screw 7 9 to 8 8 N m 0 80 to 0 90 kgf m 5 8 to 6 5 lbf ft Suction filter case mounting screw 7...

Page 169: ... 6 When reassembling NOTE Apply the oil to two O rings 5 on the charge pipe 6 Insert the charge pipe 6 straight into the charge port 7 Be careful not to damage the O ring Next insert the filter bracket 2 straight into the charge pipe 6 9Y1210595TXS0081US0 1 Neutral Arm 2 Filter Bracket 3 Neutral Arm Holder 4 Neutral Arm Holder Mounting Screw M8 5 O ring 6 Charge Pipe 7 Charge Port KiSC issued 11 2...

Page 170: ...transmission assembly 1 Cover the splines of front drive shaft with thin tape to protect the sealing lip of the oil seal NOTE When reassembling the hydrostatic transmission assembly insert the drain pipe 3 in the hole 2 surely so as not to drop out it 9Y1210595TXS0032US0 Tightening torque Brake Assembly Mounting Screw 7 9 to 8 8 N m 0 80 to 0 90 kgf m 5 8 to 6 5 lbf ft 1 Brake Assembly 2 External ...

Page 171: ...pump housing 1 4 Remove the internal snap ring 2 and the oil seal 3 NOTE When removing the oil seal 3 be careful not to damage the charge pump housing 1 Be careful not to damage the O ring 4 9Y1210595TXS0082US0 Gerotor 1 Remove the gerotor 1 2 Draw out the drive pin 2 on the pump shaft 3 When reassembling Apply clean transmission oil to the both side of gerotors 9Y1210595TXS0035US0 1 15T Gear 2 34...

Page 172: ...spool 2 and spring 1 When reassembling Be careful not to damage the O ring 3 on the plug 4 9Y1210595TXS0084US0 Check Valve 1 Remove the plugs 1 8 2 Draw out the springs 3 6 3 Draw out the check valve 4 and ball check 5 When reassembling Be careful not to damage the O rings 2 7 on the plugs 1 8 9Y1210595TXS0085US0 Tightening torque Center section mounting hex socket head screw 18 to 20 N m 1 8 to 2...

Page 173: ...e the internal snap ring 8 and tap out the motor shaft 10 NOTE When removing the oil seal 7 be careful not to damage the HST housing When reassembling Apply clean transmission oil to thrust ball bearing 1 9Y1210595TXS0087US0 Cradle Bearing Slot Guide and Trunnion Arm 1 Remove the slot guide 2 and trunnion arm 3 2 Remove the cradle bearings 1 from the HST housing When reassembling Apply clean trans...

Page 174: ...utch case 7 and the spline boss 12 with clutch disc and friction plate 13 5 Remove the thrust needle bearing 8 thrust collar 9 collar 10 and spring 11 6 Remove the external snap ring 14 clutch disc and friction plate 13 from the spline boss 12 When reassembling 9Y1210595TXS0042US0 Tightening torque PTO cover assembly mounting screw 18 to 20 N m 1 8 to 2 1 kgf m 13 to 15 lbf ft 1 PTO Cover Assembly...

Page 175: ... 2 Tap out the PTO shaft 1 while opening the external snap 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 9Y1210595TXS0043US0 1 PTO Shaft 2 Thrust Collar 3 External Snap Ring 4 Clutch Lever 5 PTO Clutch Cover 6 Ball Bearing 7 Oil Seal KiSC issued 11 2013 A ...

Page 176: ... in the PTO shaft 2 Install the spline boss 10 which assembles the clutch disc and friction plate in PTO shaft 2 7 Turn the clutch case 7 clockwise while pushing spline boss 10 and lock the spline boss 10 which assembles clutch disc and friction plate to the clutch case 7 8 Install the brake discs 13 15 and friction plate 12 14 in the spline boss 10 IMPORTANT Do not change the arrangement of the b...

Page 177: ...ll the PTO cover assembly 19 while you make sure that tongues 16 of brake friction plate do not come off from the grooves 17 of transaxle case See A in the figure Tighten the PTO cover assembly mounting screws evenly 4 After installing the PTO cover assembly 19 in the transaxle case push up the PTO lever and ensure that the PTO shaft rotates smoothly 9Y1210595TXS0078US0 Beam 1 Remove the beam 1 fr...

Page 178: ...should be 2 mm 0 078 in and 1 5 mm 0 059 in respectively Also apply the liquid gasket on the grooves around holes A shown in the figure NOTE Apply the liquid gasket thinly to both front and rear sides only in the oil seal receiving part B of rear axle Be sure to remove extra liquid gasket therefrom if present To be continued 1 Transaxle Case Front Side 2 Transaxle Case Screw 3 Transaxle Case Rear ...

Page 179: ...crews located at the circled positions B first with tightening torques Next tighten the remaining screws with tightening torque 9Y1210595TXS0046US0 Tightening torque Transaxle case screw 9 81 to 11 2 N m 1 00 to 1 15 kgf m 7 24 to 8 31 lbf ft 1 Transaxle Case Front Side 2 Transaxle Case Screw 3 Transaxle Case Rear Side F Front Side R Rear Side A Oil Passage B Screws Which Tightened First with Tigh...

Page 180: ...n by 180 degrees 9Y1210595TXS0047US0 Rear Differential Gear Drive Shaft and 11T Gear Shaft RH LH 1 Remove the rear differential gear assembly 2 11T gear shafts 1 6 and drive shaft 5 2 Remove the external snap ring 3 and washer 4 from drive shaft 5 9Y1210595TXS0048US0 1 Input Shaft 2 Intermediate Shaft 3 19T 2 Gear 4 17T 13T Gear Shaft 5 External Snap Ring 6 Collar 7 Needle Bearing 1 11TGear Shaft ...

Page 181: ... 6 4 Remove the differential pinion gears 5 differential side gear 7 and shims 4 NOTE Arrange the parts to know their original position When reassembling Apply molybdenum disulfide Three Bond 1901 or equivalent to the inner circumferential surface of differential pinion gears 5 differential side gears 3 7 and shims 4 9Y1210595TXS0050US0 1 11TGear Shaft LH 2 Bush 3 Rear Differential Gear Assembly 4...

Page 182: ...TRANSAXLE GR1600EU WSM 2 S32 Rear Axle 1 Remove the rear axle 1 2 Remove the oil seal 2 from the rear axle 1 9Y1210595TXS0051US0 1 Rear Axle 2 Oil Seal KiSC issued 11 2013 A ...

Page 183: ... and spring 6 2 Pull out the PTO cover assembly 1 with PTO clutch 10 slowly NOTE If PTO cover assembly 1 sticks to the transaxle case 7 move the PTO arm 2 up and down IMPORTANT When pulling out the PTO cover assembly 1 with PTO clutch check if any parts remain inside the transaxle case 7 9Y1210595TXS0054US0 1 PTO Cover Assembly 2 PTO Arm 3 PTO Rod 4 Nut 5 Nut 6 Spring 7 Transaxle Case 8 Ball Beari...

Page 184: ... 1 4 NOTE Thickness of the brake friction plate 1 4 is greater than that of the brake friction plate 2 5 4 Then attach the brake friction plate 1 to the PTO cover assembly 1 installed in the template 7 5 After you make sure that the brake friction plate 1 4 is fixed to the PTO cover assembly 1 remove the template 7 from the PTO cover assembly 1 IMPORTANT After attaching the brake friction plate 1 ...

Page 185: ...ver assembly 4 5 Install the brake discs brake friction plate 2 6 PTO clutch assembly 7 and 24T gear 8 to the PTO cover assembly 4 6 Align the tongues of brake friction plate 1 and 2 See A in figure NOTE After aligning the tongues of brake friction plate 1 and 2 do not try to rotate the PTO shaft 7 Insert the PTO rod 10 to the hole 11 or PTO arm 9 Then install the PTO cover assembly 4 with PTO clu...

Page 186: ...es 16 of brake friction plate 2 align with the grooves of transaxle case further push the PTO cover assembly 13 If the PTO cover assembly 13 is installed correctly the distance A should become 5 0 mm 0 20 in or less 5 Install the PTO cover mounting bolts in three remained bolt holes And tighten them slowly and evenly until the PTO cover assembly 13 contacts to the transaxle case 6 Remove the stud ...

Page 187: ...ck the oil level again using the dipstick 5 If the oil level is lower than the H level indicated on the dipstick fill the oil tank with transmission fluid additionally up to the H level 6 Perform the above mentioned operation again And make sure that the oil level is not low level 7 Disconnect the universal joint of mower deck form the PTO shaft Shaft the PTO lever to Engage position and check to ...

Page 188: ...ce the hydrostatic transmission assembly 9Y1210595TXS0059US0 Check Valve 1 Check the ball check 5 and check valve 4 for scratches and damage 2 Check the springs 3 6 for breakage and wear 3 If anything unusual replace the check valve assembly 9Y1210595TXS0060US0 By pass Valve 1 Check the by pass spool 3 and spring 4 2 If problems are found replace them 9Y1210595TXS0091US0 1 Charge Pump Housing 2 Ge...

Page 189: ...cylinder block Pistons and cylinder blocks are matched 9Y1210595TXS0062US0 Thrust Ball Bearing 1 Check the thrust ball bearing 1 for scratches and excessive wear 2 If the thrust ball bearing 1 is worn replace it 9Y1210595TXS0063US0 Pump Shaft 1 Check the seal surface 1 the bearing surface 2 and the ball bearing 3 2 If the shaft is rough or grooved replace it 3 If the ball bearing is worn replace i...

Page 190: ... the thickness is less than the allowable limit replace it 9Y1210595TXS0068US0 Clutch Spring Free Length 1 Measure the free length of spring with vernier calipers 2 If the measurement is less than the allowable limit replace it 9Y1210595TXS0069US0 Thickness of PTO clutch disc Factory specification 1 3 to 1 5 mm 0 052 to 0 059 in Allowable limit 1 2 mm 0 047 in Thickness of pressure plate Factory s...

Page 191: ...ion 3 30 to 3 50 mm 0 130 to 0 137 in Allowable limit 3 00 mm 0 118 in Thickness of brake friction plate 1 Factory specification 1 75 to 1 85 mm 0 0689 to 0 0728 in Allowable limit 1 60 mm 0 0630 in Thickness of brake friction plate 2 Factory specification 0 950 to 1 05 mm 0 0374 to 0 0413 in Allowable limit 0 80 mm 0 031 in Clearance between differential case and differential side gear Factory sp...

Page 192: ...outside micrometer 6 If the backlash is not within the factory specifications adjust with shims 4 6 Reference Thickness of adjusting shims For differential pinion gear 2 3 mm 0 091 in 2 5 mm 0 098 in 2 7 mm 0 11 in 2 9 mm 0 11 in Tooth contact More than 35 9Y1210595TXS0074US0 Clearance between differential pinion gear and differential pinion shaft Factory specification 0 025 to 0 055 mm 0 00099 to...

Page 193: ...outside micrometer Reference Thickness of adjusting shims For 11T bevel gear shaft 3 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 Tooth contact More than 35 9Y1210595TXS0075US0 Backlash between 11T bevel gear shaft and 17T 13T gear shaft Factory...

Page 194: ...3 BRAKES KiSC issued 11 2013 A ...

Page 195: ...CONTENTS 1 BRAKE MECHANISM 3 M1 MECHANISM KiSC issued 11 2013 A ...

Page 196: ...ive gear and final gear Brake shoes 4 will be expanded via brake cam lever 2 when you press the brake pedal Brake shoes 4 expand outward and it is touched inside of brake drum 1 Friction between brake shoes 4 and drum generates braking power 9Y1210595BRM0001US0 1 Brake Drum 2 Brake Cam Lever 3 Brake Assy 4 Brake Shoe 5 Cam Pin 6 Brake Fulcrum 7 Spring A Disengage B Engage KiSC issued 11 2013 A ...

Page 197: ...NG 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 S7 SERVICING KiSC issued 11 2013 A ...

Page 198: ...l free travel excessive Adjust 3 S4 Brake shoe worn Replace 3 S7 Brake drum worn Replace 3 S7 Grease or oil on brake shoe Replace 3 S7 Brake Drags Brake pedal free travel too small Adjust 3 S4 Brake spring weaken or broken Replace 3 S7 Heavy Brakes Brake pedal rusted Repair or replace 3 S6 Brake cam lever rusted Replace 3 S7 KiSC issued 11 2013 A ...

Page 199: ...BRAKES GR1600EU WSM 3 S2 2 SERVICING SPECIFICATIONS 9Y1210595BRS0002US0 Item Factory Specification Allowable Limit Brake Pedal Free Travel 15 to 25 mm 0 59 to 0 98 in KiSC issued 11 2013 A ...

Page 200: ...s bolts and nuts Refer to 5 TIGHTENING TORQUES on page G 12 9Y1210595BRS0003US0 Item N m kgf m lbf ft Steering wheel mounting nut 20 to 24 2 0 to 2 5 15 to 18 Drag link locking nut 76 to 80 7 7 to 8 2 56 to 59 Steering support mounting screw 48 to 55 4 9 to 5 7 36 to 41 Pedal system component mounting nut 48 to 55 4 9 to 5 7 36 to 41 KiSC issued 11 2013 A ...

Page 201: ...ass valve of HST and ensure that the rear wheel rotates Reference Brake spring length A 73 0 to 74 0 mm 2 88 to 2 91 in 9Y1210595BRS0016US0 2 DISASSEMBLING AND ASSEMBLING 1 Pedal System Component Dismounting Mower 1 Refer to 2 PREPARATION DISMOUNTING MOWER on page 7 S10 9Y1210595TXS0017US0 Removing Container 1 Refer to 2 PREPARATION on page 2 S10 9Y1210595BRS0005US0 Battery 1 Refer to 2 S13 9Y1210...

Page 202: ...r 4 main switch 5 and light switch 5 Remove the indicator lamps 6 6 Remove the fuse box 7 from the steering support 7 Remove the panel 2 When reassembling 9Y1210595BRS0010US0 Separating Engine 1 Refer to 2 PREPARATION on page 1 S19 9Y1210595BRS0011US0 1 Fuel Cap 2 Fender 3 Fender Mounting Screw 4 Step Sheet 5 Speed Change Pedal Tightening torque Steering Wheel mounting nut 20 to 24 N m 2 0 to 2 5 ...

Page 203: ...95BRS0013US0 Pedal System Component 1 Remove the parking lock spring 1 2 Remove the pedal system component mounting nuts 2 3 Separate the pedal system component 3 from frame When reassembling 9Y1210595BRS0014US0 Tightening torque Drag link locking nut 76 to 80 N m 7 7 to 8 2 kgf m 56 to 59 lbf ft Steering support mounting screw 48 to 55 N m 4 9 to 5 7 kgf m 36 to 41 lbf ft 1 Steering Support 2 Acc...

Page 204: ...ake assembly Tighten the brake assembly mounting screws 7 while pushing up the brake arm lever 10 by the hand NOTE After assembling the brake assembly be sure to adjust the brake pedal free travel Refer to 1 CHECKING AND ADJUSTING on page 3 S4 9Y1210595BRS0015US0 Tightening torque Brake Assembly Mounting Screw 7 9 to 8 8 N m 0 80 to 0 80 kgf m 5 8 to 6 5 lbf ft 1 Lock Nut 2 Plain Washer 3 Brake Sp...

Page 205: ...4 FRONT AXLE KiSC issued 11 2013 A ...

Page 206: ... TIGHTENING TORQUES 4 S3 4 CHECKING DISASSEMBLING AND SERVICING 4 S4 1 CHECKING AND ADJUSTING 4 S4 2 PREPARATION 4 S4 1 Separating Front Axle Assembly 4 S4 3 DISASSEMBLING AND ASSEMBLING 4 S6 1 Front Axle Assembly 4 S6 4 SERVICING 4 S6 SERVICING KiSC issued 11 2013 A ...

Page 207: ...er toe in Replace tie rod 4 S4 4 S6 Kingpin worn Replace front axle assembly 4 S5 Center pin collar worn Replace 4 S5 4 S6 Center pin locking nut loosen Tighten 4 S5 Front Wheels Shimmy Improper toe in Replace tie rod 4 S4 4 S6 Kingpin worn Replace front axle assembly 4 S5 Center pin collar worn Replace 4 S5 4 S6 Steering linkage loosen or worn Tighten or replace 4 S5 KiSC issued 11 2013 A ...

Page 208: ... 10 mm 0 040 to 0 39 in Front Axle Frame to Anti vibration Bolt Clearance 0 30 to 0 50 mm 0 012 to 0 019 in Center Pin to Center Pin Collar Clearance Center Pin Boss I D Center Pin Collar O D 0 109 to 0 200 mm 0 00430 to 0 00787 in 25 400 to 25 430 mm 1 0000 to 1 0011 in 25 230 to 25 291 mm 0 99331 to 0 99570 in 0 210 mm 0 00827 in KiSC issued 11 2013 A ...

Page 209: ...n the table below are especially specified For general use screws bolts and nuts Refer to 5 TIGHTENING TORQUES on page G 12 9Y1210595FBS0003US0 Item N m kgf m lbf ft Center pin locking nut 78 to 90 7 9 to 9 2 58 to 66 Tie rod mounting locking nut 48 to 55 4 9 to 5 7 36 to 41 KiSC issued 11 2013 A ...

Page 210: ...mounting Mower 1 Refer to 2 PREPARATION DISMOUNTING MOWER on page 7 S10 9Y1210595TXS0017US0 Battery CAUTION 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 Disconnect the negative cable 1 from the battery 3 Disconnect the positive cable 2 from the battery and remove the ba...

Page 211: ...jacks 3 Remove the front wheels 4 Loose the anti vibration bolts 5 5 Remove the center pin locking nut 3 and draw out the center pin bolt 6 6 Separate the front axle assembly 2 When reassembling Apply grease to the outer side of center pin collar 4 9Y1210595FBS0006US0 1 Bonnet 2 Bonnet Bracket 3 Side Bonnet 4 Wire Harness 5 Connector Tightening torque Center pin locking nut 78 to 90 N m 7 9 to 9 2...

Page 212: ...e clearance exceeds the allowable limit replace them 9Y1210595FBS0008US0 Tightening torque Tie rod mounting locking nut 48 to 55 N m 4 9 to 5 7 kgf m 36 to 41 lbf ft 1 Tie rod Mounting Locking Nut 2 Tie rod Clearance between center pin boss and center pin collar Factory specification 0 109 to 0 200 mm 0 00430 to 0 00787 in Allowable limit 0 210 mm 0 0827 in Center pin boss I D A Factory specificat...

Page 213: ...5 STEERING KiSC issued 11 2013 A ...

Page 214: ...ENING TORQUES 5 S3 4 CHECKING DISASSEMNLING AND SERVICING 5 S4 1 CHECKING AND ADJUSTING 5 S4 2 PREPARATION 5 S4 1 Separating Steering Support Assembly 5 S4 3 DISASSEMBLING AND ASSEMBLING 5 S6 1 Steering Support Assembly 5 S6 4 SERVICING 5 S6 SERVICING KiSC issued 11 2013 A ...

Page 215: ...Inoperable Steering Steering shaft and sector gear broken Replace 5 S6 Steering linkage broken Replace 5 S5 Hard Steering Tire pressure uneven Adjust G 60 Improper alignment of front wheels Replace tie rod 4 S4 4 S6 Bearing stuck Replace 5 S6 Steering shaft and sector gear stuck Replace 5 S6 KiSC issued 11 2013 A ...

Page 216: ...STEERING GR1600EU WSM 5 S2 2 SERVICING SPECIFICATIONS 9Y1210595STS0002US0 Item Factory Specification Allowable Limit Steering Wheel Play 30 to 70 mm 1 2 to 2 7 in KiSC issued 11 2013 A ...

Page 217: ...screws bolts and nuts Refer to 5 TIGHTENING TORQUES on page G 12 9Y1210595STS0003US0 Item N m kgf m lbf ft Steering wheel mounting nut 20 to 24 2 0 to 2 5 15 to 18 Drag link locking nut 75 to 81 7 6 to 8 3 55 to 60 Steering support mounting screw 48 to 55 4 9 to 5 7 36 to 41 Sector gear mounting screw 48 to 55 4 9 to 5 7 36 to 41 KiSC issued 11 2013 A ...

Page 218: ...XS0017US0 Removing Container 1 Refer to 2 PREPARATION on page 2 S10 9Y1210595BRS0005US0 Battery 1 Refer to 2 S13 9Y1210595BRS0006US0 Discharge Duct 1 Refer to 2 S11 9Y1210595BRS0007US0 Container Base 1 Refer to 2 S11 9Y1210595BRS0008US0 Seat 1 Remove two snap pins 2 4 2 Remove the seat 1 and snap plate 3 9Y1210595TXS0019US0 Fender 1 Remove the speed change pedal 5 2 Peel the step sheet 4 halfway 3...

Page 219: ...nnect the drag link 4 from the sector gear 3 2 Disconnect the connectors for the starter relay timer relay regulator and buzzer unit 3 Disconnect the accelerator wire 2 4 Separate the steering support assembly 1 When reassembling 9Y1210595BRS0012US0 Tightening torque Steering Wheel mounting nut 20 to 24 N m 2 0 to 2 5 kgf m 15 to 18 lbf ft 1 Steering Wheel 2 Panel 3 Side Bonnet 4 Hour Meter 5 Main...

Page 220: ...ector bushes 6 7 Apply to grease to the steering bearing Adjust the clearance between the shaft retainer and the pinion gear of steering shaft Reference Length L 1 mm 0 04 in 9Y1210595STS0005US0 4 SERVICING Steering Support Bushing Wear 1 Visually inspect the sector bushes 1 for signs of wear or damage 2 If problem are found replace the sector bush 1 9Y1210595STS0007US0 Tightening torque Steering ...

Page 221: ...6 ELECTRICAL SYSTEM KiSC issued 11 2013 A ...

Page 222: ...GR1600EU GR1600F 6 M1 2 GR1600ID 6 M2 2 STARTING SYSTEM 6 M3 1 GR1600EU GR1600F 6 M3 2 GR1600ID 6 M4 3 CHARGING SYSTEM 6 M5 4 LIGHTING SYSTEM AND METER PANEL 6 M6 1 GR1600EU GR1600F 6 M6 2 GR1600ID 6 M7 MECHANISM KiSC issued 11 2013 A ...

Page 223: ...ELECTRICAL SYSTEM GR1600EU WSM 6 M1 1 WIRING DIAGRAM 1 GR1600EU GR1600F KiSC issued 11 2013 A ...

Page 224: ...ELECTRICAL SYSTEM GR1600EU WSM 6 M2 2 GR1600ID KiSC issued 11 2013 A ...

Page 225: ...itch 19 turned from the ON position to the OFF position the engine stop solenoid 5 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 With the PTO lever shifted to the ENGAGE position the en...

Page 226: ...ly to the terminal ON thereby causing the starting circuit to be opened stopping the starter motor 3 When the main switch 16 turned from the ON position to the OFF position the engine stop solenoid 5 moves the fuel injection pump control rack to the No Fuel Injection position and stop the engine This machine is equipped with the operator presence control OPC system which automatically stops the en...

Page 227: ...lectric power for various electrical devices and also charges the battery while the engine runs It consists of a dynamo 4 and a regulator 6 9Y1210595ELM0002US0 1 Battery 2 GND 3 GND 4 Dynamo 5 Slow Blow Fuse 40 A 6 Regulator 7 Fuse 10 A 8 Main Switch 9 Charge Lamp KiSC issued 11 2013 A ...

Page 228: ...210595ELM0003US0 1 Battery 2 GND 3 Glow Plug 4 Coolant Temperature Switch 5 Oil Pressure Switch 6 GND 7 Dynamo 8 Slow Blow Fuse 40 A 9 Regulator 10 Fuse 10 A 11 Main Switch 12 Engine Overheat Horn Relay 13 Engine Overheat Horn 14 Grass Container Full Switch 15 Delay Timer 16 Grass Container Full Switch Relay 17 Buzzer Relay 18 Buzzer 19 Glow Plug Lamp 20 Coolant Temperature Lamp 21 Grass Container...

Page 229: ...witch 4 The oil pressure lamp 16 lights when the engine oil pressure drops below the prescribed level The charge lamp 17 lights when the dynamo 7 is not charging the battery 1 while the engine runs 9Y1210595ELM0007US0 1 Battery 2 GND 3 Glow Plug 4 Coolant Temperature Switch 5 Oil Pressure Switch 6 GND 7 Dynamo 8 Slow Blow Fuse 40 A 9 Regulator 10 Fuse 10 A 11 Main Switch 12 Engine Overheat Horn Re...

Page 230: ... 8 Engine Stop Solenoid 6 S14 9 Engine Stop Timer Relay 6 S15 10 Charging System 6 S16 11 Lighting System 6 S17 12 Coolant Temperature Switch 6 S18 13 Grass Container Full Switch GR1600EU GR1600F 6 S19 14 Grass Container Full Switch Timer Relay GR1600EU GR1600F 6 S20 15 Relays Starter Engine Overheat Horn Grass Container Open Grass Container Full Switch Buzzer 6 S21 2 DISASSEMBLING AND ASSEMBLING ...

Page 231: ...cted or improperly connected Repair or replace 1 S20 Slow blow fuse blown 40 A Replace G 45 Fuse Blown Frequently Short circuited Repair or replace G 45 Symptom Probable Cause Solution Reference Page Battery Discharges Too Quickly Battery damaged Replace 1 S20 Dynamo damaged Repair or replace 6 S23 Regulator damaged Replace 6 S16 Wiring harness disconnected or improperly connected between battery ...

Page 232: ...lace 6 S12 Engine Does Not Stop When Main Switch is Turned OFF Fuse blown 15 A Replace G 45 Wiring harness disconnected or improperly connected between main switch ACC terminal and engine stop solenoid Repair or replace Engine stop solenoid damaged Replace 6 S14 Timer relay damaged Replace 6 S15 Engine Does Not Start Engine stop solenoid damaged Replace 6 S14 Timer relay damaged Replace 6 S15 Symp...

Page 233: ... 45 Oil Pressure Lamp Lights Up When Engine Is Running Engine oil pressure too low Repair engine Engine oil insufficient Fill G 36 Oil pressure switch damaged Replace 6 S18 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 Fuse blown 10 A Replace G 45 Bulb blown Replace G 45 Oil pressure switch...

Page 234: ...2 V Less than 0 1 V Glow Plug Resistance Approx 0 9 Ω Head Light Switch Resistance OFF Resistance ON Infinity 0 Ω Starter Commutator Commutator Mica Brush O D Difference of O D Undercut Length 28 0 mm 1 10 in Less than 0 05 mm 0 002 in 0 50 to 0 80 mm 0 020 to 0 031 in 16 0 mm 0 630 in 27 0 mm 1 06 in 0 40 mm 0 016 in 0 20 mm 0 0079 in 10 5 mm 0 413 in KiSC issued 11 2013 A ...

Page 235: ... nuts on the table below are especially specified For general use screws bolts and nuts Refer to 5 TIGHTENING TORQUES on page G 12 9Y1210595ELS0008US0 Item N m kgf m lbf ft Starter C terminal nut 5 9 to 11 0 60 to 1 2 4 4 to 8 6 Dynamo stater nut 40 to 44 4 0 to 4 5 29 to 32 KiSC issued 11 2013 A ...

Page 236: ...rge the battery 9Y1210595ELS0009US0 Battery Terminal Connection 1 Turn the main switch on and turn on the head light 2 Measure the voltage with a voltmeter across the battery s positive terminal post and the cable terminal 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 cla...

Page 237: ... the bottom of vent wells 4 if necessary add distilled water in a well ventilated area 2 The water in the electrolyte 3 evaporates during recharging Liquid shortage damages the battery Excessive liquid spills over and damages the machine 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...

Page 238: ...of direct sunlight 2 The battery self discharges while it is stored Recharge it once every three months in hot seasons and once every six months in cold seasons 9Y1210595GEG0019US0 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 9Y1210595ELS0011US0 Connector Voltage 1 Measure the voltage with a voltmeter across t...

Page 239: ...ohmmeter across the B terminal and the G terminal and measure the resistance across the B terminal and the ACC terminal 3 If 0 ohm is not indicated these contacts of the main switch are faulty 4 Main Switch Key at START Position 1 Set and hold the main switch key at the START position 2 Measure the resistance with an ohmmeter across the B terminal and the G terminal across the B terminal and the S...

Page 240: ...minal post 7 If the motor does not run check the motor 9Y1210595ELS0014US0 Starter Magnet Switch Test Pull in Holding Coils NOTE Prepare a 6 V battery for the test and you must do each test 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 b...

Page 241: ...stance with an ohmmeter between the terminals 5 If the brake switch is damaged replace it 9Y1210595ELS0017US0 Resistance between terminal a and b When plunger is pushed 0 Ω When plunger is released Infinity Resistance between terminal c and d When plunger is pushed 0 Ω When plunger is released Infinity 1 PTO Switch 2 PTO Lever a to d Switch Terminal Resistance between terminal a and b When plunger...

Page 242: ...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 damaged replace it 9Y1210595ELS0019US0 Resistance between switch terminals When plunger is pushed 0 Ω When plunger is released Infinity 1 Top cover Open Switch 2 Grass Container Open Switch Resistance between switch termi...

Page 243: ...attery voltage the wiring harness or main switch is faulty 9Y1210595ELS0020US0 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...

Page 244: ...ity between the connector terminals with an ohmmeter 3 If it does not conduct the fuel pump is faulty 9Y1210595ELS0023US0 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 termina...

Page 245: ...onnect jumper leads 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 bu...

Page 246: ...oupler 2 of regulator being connected measure the voltage with a volt meter 5 across the terminal blue a and terminal blue c Refer to figure A 3 If the measurement is not within the specified value replace the wire harness between the dynamo 4 and regulator 1 4 If the measurement is within the specified value measure the voltage with a volt meter 6 across the terminal red f and chassis Refer to fi...

Page 247: ... faulty 9Y1210595ELS0031US0 Engine Oil Pressure Lamp Harness 1 Disconnect the wiring harness from the engine oil pressure switch 1 with the main switch OFF 2 Turn the main switch ON and connect a jumper lead 2 from the the chassis to the wiring harness 3 If the engine oil pressure indicator lamp does not light the wiring harness is faulty 9Y1210595ELS0032US0 Resistance Factory specifica tion OFF I...

Page 248: ... If a certain voltage is not indicated the wiring harness is faulty 2 Coolant Temperature Switch Continuity 1 Disconnect the 1P connector and remove the thermo switch 2 Using an ohmmeter check for continuity between the switch terminal and the chassis The figure shows the operation hysteresis 3 If infinity is indicated at temperature over factory specifications the switch is faulty 9Y1210595ELS003...

Page 249: ...ed replace it 9Y1210595ELS0035US0 Buzzer 1 Remove the air intake net under the meter panel 2 Disconnect the lead from buzzer 1 3 Connect the jumper lead between the battery positive terminal and terminal 1 of connector 4 Connect the jumper lead between the battery negative terminal and terminal 2 of connector 5 If the buzzer does not whistle replace it 9Y1210595ELS0036US0 Resistance between switch...

Page 250: ...ery positive terminal and the Yellow terminal 2 3 Connect the jumper lead across the battery negative terminal and the Black terminal 4 and across the battery negative terminal and the Blue terminal 4 Connect the jumper lead across the Red terminal 3 and the bulb terminal 5 The bulb lights up when disconnecting the jumper lead from the Red White terminal 1 0 7 to 1 3 seconds the timer relay is pro...

Page 251: ... relay stay 2 5 Remove the relays 3 4 5 9Y1210595ELS0004US0 Relay 1 Connect jumper leads across the battery positive terminal and 85 terminal 2 and across the battery negative terminal and 86 terminal 6 2 Connect leads of an ohmmeter to 87a terminal 3 and 30 terminal 5 3 Check continuity between 87a terminal 3 and 30 terminal 5 4 If continuity is 0 ohms the relay is proper 9Y1210595ELS0005US0 1 St...

Page 252: ...r 4 NOTE Do not cause damage to the brush and commutator When reassembling Apply grease to spline teeth of the armature bushing pinion gear of the overrunning clutch and armature shaft 9Y1210595ELS0037US0 1 Sleeve Bearing 2 Bushing 3 Starter Drive Housing 4 Drive Lever 5 Magnet Switch 6 Yoke 7 Connecting Lead 8 Through Bolt 9 Rear End Frame 10 Bushing 11 Brush 12 Brush Holder 13 Brush Spring 14 Br...

Page 253: ...LS0048US0 Rotor 1 Tap out the shaft 1 from the rotor 3 When reassembling Be careful the direction of the collar 4 the flat side should face to the pulley 2 side 9Y1210595ELS0049US0 Tightening torque Nut 40 to 44 N m 4 0 to 4 5 kgf m 29 to 32 lbf ft 1 Screw 2 Stator 3 Nut 4 Stator Comp 1 Shaft 2 Pulley 3 Rotor 4 Collar 5 Bearings 6 Collar KiSC issued 11 2013 A ...

Page 254: ...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 9Y1210595ELS0041US0 Brush Wear 1 If the contact face of the brush is dirty or dusty clean it with emery paper 2 Measure the brush length A with vernier calipers 3 If the ...

Page 255: ...eter 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 9Y1210595ELS0044US0 Field Coil 1 Check the continuity across the lead 1 and brush 2 with an ohmmeter 2 If it does not conduct replace the yoke assembly 3 Check the continuity across the brush 2 and yoke 3 with an ohmmeter 4 If it con...

Page 256: ...ELECTRICAL SYSTEM GR1600EU WSM 6 S26 2 Dynamo Bearing 1 Check the bearing for smooth rotation 2 If it does not rotate smoothly replace it 9Y1210595ELS0046US0 KiSC issued 11 2013 A ...

Page 257: ...7 MOWER KiSC issued 11 2013 A ...

Page 258: ...CONTENTS 1 POWER TRANSMISSION 7 M1 1 RCK42GREU RCK42GRF 7 M1 2 RCK42 GR16 7 M3 2 LIFTING MECHANISM 7 M4 MECHANISM KiSC issued 11 2013 A ...

Page 259: ...ft Universal Joint 8 Input Shaft 5 18T Spiral Gear 4 17T Spiral Gear 3 Output Shaft 2 Center Pulley 1 Mower Belt 7 Outer Pulley 6 Blade Shaft 9 Blade 10 9Y1210595MOM0001US0 1 Center Pulley 2 Output Shaft 3 17T Spiral Gear 4 18T Spiral Gear 5 Input Shaft 6 Outer Pulley 7 Mower Belt 8 Universal Joint 9 Blade Shaft 10 Blade KiSC issued 11 2013 A ...

Page 260: ...MOWER GR1600EU WSM 7 M2 The mower belt moves in the arrow direction 9Y1210595MOM0003US0 KiSC issued 11 2013 A ...

Page 261: ...t Input Shaft 1 17T Spiral Gear 2 18T Spiral Gear 4 Output Shaft 3 Center Pulley 5 Mower Belt Outer Pulley Blade Shaft Blade 9Y1210595MOM0005US0 The mower belt moves in the arrow direction 9Y1210595MOM0004US0 1 Input Shaft 2 17T Spiral Gear 3 Output Shaft 4 18T Spiral Gear 5 Center Pulley 6 Gear Box Assembly KiSC issued 11 2013 A ...

Page 262: ...e the lift link LH 1 As a result the rear link RH 10 and LH 2 are lifted The gas spring 3 connected with lift link shaft 4 assists lifting of mower The cutting height adjusting dial 7 adjusts cutting height of mower by rotating the adjusting cam The position of rear link RH 10 and LH 2 are adjusted by cutting height fine turning bolt on lift link 6 and lift link LH 1 9Y1210595MOM0002US0 1 Lift Lin...

Page 263: ...G 7 S5 1 RCK42GREU RCK42GRF 7 S5 2 RCK42 GR16 7 S7 2 PREPARATION DISMOUNTING MOWER 7 S10 1 RCK42GREU RCK42GRF 7 S10 2 RCK42 GR16 7 S11 3 DISASSEMBLING AND ASSEMBLING 7 S14 1 RCK42GREU RCK42GRF 7 S14 2 RCK42 GR16 7 S17 3 Mower Lift Linkage 7 S20 4 SERVICING 7 S21 1 Gear Box RCK42GREU RCK42GRF 7 S21 2 Gear Box RCK42 GR16 7 S21 SERVICING KiSC issued 11 2013 A ...

Page 264: ...nti scalp rollers not adjusted correctly Adjust anti scalp rollers 7 S5 Mower Is Not Lifted Linkage system broken Replace linkage system 7 S20 Discharge Chute Plugged Grass too wet Wait grass dry Grass too long Adjust cutting height Cutting too low Adjust cutting height Engine rpm too low Increase engine rpm Ground speed too fast Slow down Restricted airflow Streaking of Uncut Grass Ground speed t...

Page 265: ...ce the belt 7 S14 7 S17 Excessive Vibration Debris on mower deck or in pulleys Clean the debris Damaged mower belt Replace the mower belt 7 S14 7 S17 Damaged pulleys Replace the pulleys 7 S14 7 S17 Pulleys out of alignment Replace the pulleys 7 S14 7 S17 Blades out of balance Balance the blades G 46 G 48 Mower Loads Down Machine Engine rpm too low Increase engine rpm Ground speed too fast Slow dow...

Page 266: ...piral Gear to 18T Spiral Gear Backlash 0 13 to 0 25 mm 0 052 to 0 0098 in 0 40 mm 0 016 in Item Factory Specification Allowable Limit Left Tip of Blade to Right Tip of Blade Difference Less than 3 0 mm 0 12 in Front Tip of Blade to Rear Tip of Blade Difference Less than 5 0 mm 0 20 in Y Discharge Cover Height D Point to X Right Blade Tip Height Difference Not more than 88 mm 3 5 in 17T Spiral Gear...

Page 267: ...ng screw and nut 48 to 55 4 9 to 5 7 36 to 41 Pulley mounting screw gear box 78 to 90 7 9 to 9 2 58 to 66 Pulley mounting nut pulley holder 103 to 117 10 5 to 12 0 76 0 to 86 7 Pulley holder mounting screw 48 to 55 4 9 to 5 7 36 to 41 Item N m kgf m lbf ft Mower blade screw 98 1 to 117 10 0 to 12 0 72 4 to 86 7 Bolt M12 77 6 to 90 2 8 0 to 9 2 58 to 66 Bolt M10 and Nut M10 48 1 to 55 9 4 9 to 5 7 ...

Page 268: ...ting height control dial to adjust height 5 Lower the mower deck Front side anti scalp roller 6 Adjust height H of the front side anti scalp roller to one of holes to approximately 6 0 to 13 mm 0 24 to 0 51 in between rollers and ground Adjust both side rollers to the same height 7 Install the roller with attaching hardware Rear side anti scalp roller 8 Adjust height H of the rear side anti scalp ...

Page 269: ...lly 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 Length of cutting height fine tuning bolt H 16 to 20 mm 0 63 to 0 79 in 9Y1210595MOS0005US0 Difference L R between left tip and right tip o...

Page 270: ...TION To avoid personal injury Shut off the engine and remove the key Set parking brake Allow the blades to stop before making adjustments Blades may be sharp when you handle blades wear heavy gloves or wrap end of blade with a rag 1 Park the machine on level surface 2 Make sure the mower blades are level Then tighten the lock nuts securely Adjust L of front links with lock nut so that B A is 0 to ...

Page 271: ...rear axle Hold drive belt and turn the right blade so that it is parallel to axle 7 Measure from each outside blade tip L and R to the level surface The difference between measurements should be less than 3 mm 0 12 in 8 Loosen the locknut at both sides of the machine Adjust the cutting height fine tuning bolts so that the difference between measurements L and R is less than 3 mm 0 12 in 9 Lock the...

Page 272: ...Stopper The mower lift stoppers are designed to keep the balance of the mower deck when lifting the mower to the highest position Make sure that the stopper is in contact with the underside of the frame To adjust 1 Lift the mower to the highest position 2 Loosen the lock nut and adjust the stopper on left side so that the bolt head is in contact with the underside of the frame 3 Lower the mower de...

Page 273: ...ont link 3 from the mower deck When reassembling When you attach the front link make sure the length of the front link 9Y1210595MOS0008US0 Rear Link and Universal Joint 1 Disconnect the rotate plate rod 1 2 Disconnect the rear link 2 from the mower deck pulling the L pins 3 3 Disconnect the universal joint 4 from the PTO shaft 4 Raise the mower lift lever and lock in the raised position When reass...

Page 274: ... rollers at the top position 4 Lower the mower lift lever 2 and lock in the lower position 9Y1210595MOS0007US0 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 When you attach the front link make sure the length of the front link 9Y1210595MOS0008US0 1 Cutting Hei...

Page 275: ... WSM 7 S12 Disconnecting the Rear Link 1 Release the L pins 1 2 Disconnecting the rear link 2 from the mower bracket 3 9Y1210595MOS0023US0 1 L pin 2 Rear link 3 Mower bracket A UNLOCK B RELEASE KiSC issued 11 2013 A ...

Page 276: ...rten the universal joint cover 2 from the coupler of the universal joint 3 Pull back the coupler 5 of the universal joint 4 Disconnect the universal joint 4 into the PTO shaft until the coupler locks 9Y1210595MOS0024US0 1 Bolt 2 Universal Joint Cover 3 Stay 4 Universal Joint 5 Coupler KiSC issued 11 2013 A ...

Page 277: ...5MOS0031US0 Gear Box and Mower Belt 1 Remove the left and right belt covers from the mower deck 2 Disconnect the universal joint 4 from the gear box 1 3 Clean around the gear box 1 4 Remove the mower belt 2 from the tension pulley 3 5 Remove the gear box mounting screws 5 and gear box bracket mounting screws and nuts 6 6 Remove the gear box 1 and mower belt 2 9Y1210595MOS0012US0 Tightening torque ...

Page 278: ...haft 2 to remove the ball bearing 7 When reassembling Replace the oil seals 5 22 with new ones Apply grease to the splines of input shaft and of output shaft IMPORTANT Use the specified gear box oil Refer to 4 LUBRICANTS FUEL AND COOLANT on page G 9 9Y1210595MOS0032US0 Gear box oil capacity 0 33 L 0 35 U S qts 0 29 Imp qts Tightening torque Pulley mounting screw 78 to 90 N m 7 9 to 9 2 kgf m 58 to...

Page 279: ...Remove the ball bearings 3 7 and collar 4 9Y1210595MOS0033US0 Tightening torque Pulley mounting nut 103 to 117 N m 10 5 to 12 0 kgf m 76 0 to 86 7 lbf ft Pulley holder mounting screw 48 to 55 N m 4 9 to 5 7 kgf m 36 to 41 lbf ft 1 Blade Shaft 2 Oil Seal 3 Ball Bearing 4 Collar 5 Pulley Holder Mounting Screw 6 Pulley Holder 7 Ball Bearing 8 Pulley Holder Mounting Nut 9 Oil Seal 10 Pulley 11 Pulley ...

Page 280: ... two plain washers between the blade and bolt head Make sure that the cup washer is not flattened out or worn this may cause blade to slip excessively Replace the two cup washers if either is damaged IMPORTANT Tighten the 2 blade bolts 5 6 to 98 to 117 6 N m 10 to 12 kgf m 73 to 86 lbf ft of torque 9Y1210595MOS0025US0 Mower Belt Replacement 1 Remove the all shields from the mower deck 2 Clean arou...

Page 281: ...ear 13 When reassembling Replace the oil seals 5 24 with new ones Apply grease to the splines of input shaft and of output shaft IMPORTANT Use the specified gear box oil Refer to 4 LUBRICANTS FUEL AND COOLANT on page G 9 9Y1210595MOS0029US0 1 Pulley Mounting Screw 2 Washer 3 Pulley 4 Output Shaft 5 Oil Seal 6 Internal Snap Ring 7 Shim 8 Ball Bearing 9 Shim 10 Internal Snap Ring 11 Drain Plug 12 Ge...

Page 282: ...arings 3 7 and collar 4 9Y1210595MOS0030US0 1 Blade Shaft 2 Oil Seal 3 Ball Bearing 4 Collar 5 Pulley Holder Mounting Screw 6 Pulley Holder 7 Ball Bearing 8 Oil Seal 9 Pulley Plate 10 Pulley Holder Mounting Nut 11 Pulley 12 Pulley Mounting Nut Tightening torque Pulley holder mounting nut 103 to 117 N m 10 5 to 12 0 kgf m 76 0 to 87 0 lbf ft Pulley holder mounting screw 48 to 55 N m 4 9 to 5 7 kgf ...

Page 283: ...out the rue rings 7 11 6 Remove the rear link LH 4 and RH 17 7 Pull out the rue rings 7 12 and remove the clevis pins 5 13 8 Remove the lift link LH 6 and RH 14 9 Pull out the cotter pin 16 and remove the lift link 15 from the mower lift lever 9Y1210595MOS0034US0 1 Screw 2 Gas Spring Mounting Nut 3 Lock Nut 4 Rear Link LH 5 Clevis Pin 6 Lift Link LH 7 Rue Ring 8 Rue Ring 9 Gas Spring Mounting Nut ...

Page 284: ... gear case cover 5 2 Put a strip of plastigauge on the 18T spiral gear 6 with grease 3 Attach the bevel gear case cover 5 4 Turn the input shaft 1 5 Remove the plastigauge and measure the plastigauge The backlash is equal to the thickness of plastigauge 6 If the backlash exceeds the allowable limit adjust with shims 2 7 Reference Thickness of adjusting shims for 17T spiral gear 2 0 20 mm 0 0079 in...

Page 285: ...STRIAL 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 ks_g ksos pub kubota com 2011 06 S EI EI engusa Printed in Japan 2013 11 S EI EI engusa Code No 9Y111 05953 ...

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Kubota GR1600EU, Workshop Manual

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