Page 1 WORKSHOP MANUAL GR1600EU KiSC issued 11, 2013 A...
Page 2 TO THE READER This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of the GR1600EU, GR1600F and GR1600ID. It contains 4 parts: "Information", "General", "Mechanism" and "Servicing".  Information This section primarily contains information below. • Safety First •...
Page 3 Record of Revisions For pdf, use search function {Search word} to find the all revised locations. Last digit Issue Reference of the Main Revised Point and Corrective Measures {Search word} month Page Code No. 2013.03 GR1600ID and RCK42-GR16 models are added. I-9, {GR1600ID}, {RCK42-GR16} G-1,...
Page 4 INFORMATION KiSC issued 11, 2013 A...
Page 5: Table Of Contents
INFORMATION 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 KiSC issued 11, 2013 A...
Page 6: Safety First
GR1600EU, WSM INFORMATION 1. SAFETY FIRST 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.
Page 7 GR1600EU, WSM INFORMATION OPERATE SAFELY • Do not use the machine after you consume alcohol or medication or when you are tired. • Put on applicable clothing and safety equipment. • Use applicable tools only. Do not use alternative tools or parts.
Page 8 GR1600EU, WSM INFORMATION KEEP A GOOD AIRFLOW IN THE WORK AREA • If the engine is in operation, make sure that the area has good airflow. Do not operate the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.
Page 9: Safety Decals
GR1600EU, WSM INFORMATION 2. SAFETY DECALS The following 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.
Page 10 GR1600EU, WSM INFORMATION 9Y1210595INI0002US0 KiSC issued 11, 2013 A...
Page 11 GR1600EU, WSM INFORMATION 9Y1210595INI0003US0 KiSC issued 11, 2013 A...
Page 12 GR1600EU, WSM INFORMATION 9Y1210595INI0007US0 KiSC issued 11, 2013 A...
Page 13 2. Clean pictorial safety labels with soap and water, dry with a soft cloth. 3. Replace 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.
Page 14: Specifications
GR1600EU, WSM INFORMATION 3. SPECIFICATIONS Model GR1600EU GR1600F GR1600ID Model Z482-E3-GX Type Liquid-cooled diesel Total displacement 479 cm (29.2 cu.in.) Engine gross power (DIN) 10.0 kW (13.6 HP) *1 No. of cylinders Engine Starter Electric starter with battery Battery 51R (12 V, 475CCA) Diesel fuel No.1 [below −10 °C (14 °F)]...
Page 15: Dimensions
GR1600EU, WSM INFORMATION 4. DIMENSIONS [1] GR1600EU, GR1600F 9Y1210595INI0005US0 I-10 KiSC issued 11, 2013 A...
Page 16: Gr1600Id
GR1600EU, WSM INFORMATION [2] GR1600ID 9Y1210595INI0009US0 I-11 KiSC issued 11, 2013 A...
Page 17 GENERAL KiSC issued 11, 2013 A...
Page 18 GENERAL CONTENTS 1. IDENTIFICATION ......................... G-1 [1] MODEL NAME AND SERIAL NUMBERS ................G-1 [2] CYLINDER NUMBER ......................G-2 2. GENERAL PRECAUTIONS......................G-3 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING ........G-4 [1] WIRING ..........................G-4 [2] BATTERY ..........................G-6 [3] FUSE ............................
Page 19: Identification
GR1600EU, WSM GENERAL 1. IDENTIFICATION [1] MODEL NAME AND SERIAL NUMBERS When contacting your local KUBOTA distributor, always specify engine serial number (2), machine serial number (1), mower serial number (3) and hour meter reading. (1) Machine Serial Number [A] RCK42GR...
Page 20: Cylinder Number
GR1600EU, WSM GENERAL [2] CYLINDER 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.
Page 21: General Precautions
• When it is necessary to use special tools, use KUBOTA special tools. Refer to the drawings when you make special tools that you do not use frequently.
Page 22: Handling Precautions For Electrical Parts And Wiring
GR1600EU, WSM GENERAL 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, obey the following precautions in handling electrical parts and wiring. IMPORTANT • Check electrical wiring for damage and loosened connection every year.
Page 23 GR1600EU, WSM GENERAL • Securely insert grommet. (1) Grommet (A) Correct (B) Incorrect WSM000001GEG0066US0 • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp (Wind Clamp Spirally) (4) Welding Dent (2) Wire Harness WSM000001GEG0067US0 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.
Page 24: Battery
GR1600EU, WSM GENERAL [2] BATTERY • Be careful not to confuse positive and negative terminal posts. • When you remove battery cables, disconnect negative cable first. When you install battery cables, check for polarity and connect positive cable first. • Do not install any battery with capacity other than is specified (Ah).
Page 25: Handling Of Circuit Tester
GR1600EU, WSM GENERAL • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make sure that there is no terminal being exposed or displaced. (1) Exposed Terminal (3) Sandpaper (2) Deformed Terminal (4) Rust WSM000001GEG0075US0 • Make sure that there is no female connector being too open.
Page 26: Color Of Wiring
GR1600EU, WSM GENERAL [6] COLOR OF WIRING • Colors of wire are specified to the color codes. • This symbol of "/" shows color with stripe(s). (An example) Red stripe on white color: W/R Color of wiring Color code Black...
Page 27: Lubricants, Fuel And Coolant
• 0 to 25 °C (32 to 77 °F): SAE20, 10W-30 or 15W-40 • Below 0 °C (32 °F): SAE10W, SAE10W-30 or 15W-40 2.8 L Transmission KUBOTA UDT or SUPER UDT 0.74 U.S.gals case fluid* 0.62 lmp.gals 0.33 L 0.35 L...
Page 28 • Oil amount when the oil level is at the upper level of the oil level gauge. • KUBOTA original transmission hydraulic fluid. IMPORTANT • To prevent serious damage to hydraulic systems, use only KUBOTA genuine fluid or its equivalent. 9Y1210595GEG0054US0 G-10...
Page 29 • 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 ownership experience, we highly recommend Super UDT-2 to be used instead of standard hydraulic/transmission fluid.
Page 30: Tightening Torques
GR1600EU, WSM GENERAL 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLTS AND NUTS Tighten screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual according to the table below. Indication on top of bolt No-grade or 4T...
Page 31: Hydraulic Fittings
GR1600EU, WSM GENERAL [3] HYDRAULIC FITTINGS (1) Hydraulic Hose Fittings Tightening torque Hose size Thread side N·m kgf·m lbf·ft 13.8 to 15.6 1.40 to 1.60 10.2 to 11.5 22.6 to 27.4 2.30 to 2.80 16.7 to 20.2 45.2 to 52.9 4.60 to 5.40...
Page 32: Metric Screws, Bolts And Nuts
GR1600EU, WSM GENERAL [4] METRIC SCREWS, BOLTS AND NUTS Grade Property class 8.8 Property class 10.9 Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft 24 to 27 2.4 to 2.8 18 to 20 30 to 34 3.0 to 3.5 22 to 25 48 to 55 4.9 to 5.7...
Page 33: Maintenance Check List
GR1600EU, WSM GENERAL 6. MAINTENANCE CHECK LIST The following servicing tasks should be carried out on the machine at the stated running-time intervals. Indication on hour meter Refer- After Item ence since 100 150 200 250 300 350 400 450 500 550 600...
Page 34 • *1: This maintenance should be done daily more often in dusty conditions than in normal conditions. Suggested cleaning interval is every 100 hours in normal conditions. *2: These items should be serviced by an authorized KUBOTA Dealer, unless the owner has the proper tools and is mechanically proficient.
Page 35: Check And Maintenance
GR1600EU, WSM GENERAL 7. CHECK AND MAINTENANCE CAUTION • Be sure to check and service the machine on a flat place with engine shut off, the parking brake on and chock the wheels. 9Y1210595GEG0004US0 [1] DAILY CHECK To prevent trouble from occurring, it is important to know the condition of the machine. Check the following items before starting.
Page 36 GR1600EU, WSM GENERAL Checking Engine Oil Level CAUTION To avoid personal injury: • Always stop the engine and remove the key before checking oil. 1. Check engine oil before starting and 5 minutes or more after the engine has stopped.
Page 37 GR1600EU, WSM GENERAL Checking Cleaning Radiator to Prevent Overheating WARNING To avoid serious injury or death: • Engine components can get extremely hot from operation. To prevent severe burns, do not touch these areas while the engine is running, or immediately after it is turned off.
Page 38 GR1600EU, WSM GENERAL Checking Tire Pressure WARNING To avoid serious injury or death: • Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment. • Always maintain the correct tire pressure.
Page 39 GR1600EU, WSM GENERAL Checking Coolant Level CAUTION To avoid personal injury: • Be sure to stop the engine and remove the key before checking coolant level. • Do not remove the radiator cap when the engine is hot. Loosen cap slightly, to the stop, to relieve any excess pressure before removing cap completely.
Page 40 GR1600EU, WSM GENERAL Greasing CAUTION To avoid personal injury: • Be sure to stop the engine and remove the key before greasing. (1) Spindle Shaft [A] RCK42GR (2) Tension Arm [B] RCK42-GR16 (3) Belt Tension Pivot (4) Mower Universal Joint...
Page 41: Check Points Of Every 50 Hours
GR1600EU, WSM GENERAL [2] CHECK POINTS OF EVERY 50 HOURS Checking Safety Device [GR1600EU, GR1600F] The safety Devices in your machine are designs to protect you while operating. Please check these Safety Devices periodically - daily is best - to do test function of the Safety Devices before operation.
Page 42 • Do not allow anyone near machine while testing. • If the machine does not pass one of the following tests, do not operate the machine. See your local KUBOTA Dealer. • Sit on operator's for all tests. IMPORTANT • Check the following tests before operating the machine.
Page 43 GR1600EU, WSM GENERAL Cleaning Air Cleaner Element CAUTION To avoid personal injury: • Be sure to stop engine and remove the key before cleaning air cleaner element. 1. Remove the air cleaner cover and element. a) Undo the hook. b) Turn the cover clockwise and detach it.
Page 44 GR1600EU, WSM GENERAL Checking Mower Gear Box Oil Level CAUTION To avoid personal injury: • Always stop the engine and remove the key before checking oil. 1. Park the machine on a flat surface and lower the mower to the ground.
Page 45 GR1600EU, WSM GENERAL Oiling CAUTION To avoid personal injury: • Be sure to stop the engine and remove the key before oiling. 1. Apply oil to the following location as shown in the figures. (1) Mower Universal Joint (4) Seat Adjuster...
Page 46 (16) PTO Lever (Fulcrum) (9) Pivot of Lift Arm (17) Link Fulcrum (10) Front Link (18) Mower Lift Lever (Fulcrum) (11) Top Cover Lock Lever (12) Frame Shaft [A] GR1600EU, GR1600F (13) Top Cover Hinge 9Y1210595GEG0017US0 G-28 KiSC issued 11, 2013 A...
Page 47 GR1600EU, WSM GENERAL Checking Battery Condition DANGER To avoid the possibility of battery explosion: For the refillable type battery, follow the instructions below. • Do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark.
Page 48 GR1600EU, WSM GENERAL (Continued) (For non-accessible maintenance-free type batteries.) Maintenance-free, non-accessible batteries are designed to eliminate the need to add water. Yet the volume of electrolyte above plates may eventually become depleted due to abnormal conditions such as high heat or improper regulator setting. Use voltmeter to check the state of charge.
Page 49 GR1600EU, WSM GENERAL Battery Charging DANGER To avoid serious injury or death: • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.
Page 50: Check Points Of Every 100 Hours
GR1600EU, WSM GENERAL [3] CHECK POINTS OF EVERY 100 HOURS Checking Fuel Line and Fuel Filter CAUTION To avoid personal injury: • Be sure to stop the engine and remove the key when attempting to make the following checks and changes.
Page 51 After adjustment, retighten lock nut securely. 15 to 25 mm Play "A" Factory specification 0.59 to 0.98 in. (1) Brake Pedal [A] GR1600EU, GR1600F (2) Lock Nut [B] GR1600ID (3) Nut (4) Spring 9Y1210595GEG0062US0 G-33...
Page 52 GR1600EU, WSM GENERAL Checking Fan Drive Belt Tension CAUTION To avoid personal injury: • Be sure to stop the engine and remove the key before checking belt tension. If the fan drive belt becomes loose, the engine may overheat. 1. To adjust, remove the right cover (1).
Page 53: Check Point Of Every 150 Hours
IMPORTANT • To prevent serious damage to the engine, element of recommended type must be used. Use only a genuine KUBOTA filter or its equivalent. (1) Engine Oil Filter Cartridge 9Y1210595GEG0025US0 G-35 KiSC issued 11, 2013 A...
Page 54 GR1600EU, WSM GENERAL Changing Engine Oil CAUTION To avoid personal injury: • Be sure to stop the engine and remove the key before changing the oil. • Allow engine to cool down sufficiently; oil can be hot and may cause burns.
Page 55 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. (1) Transmission Oil Filter Cartridge [A] GR1600EU, GR1600F (2) Screw...
Page 56 GR1600EU, WSM GENERAL Adjusting Front Axle Pivot 1. Jack up the front of machine. 2. Tighten the center pin locking nut (1) with specified torque. 3. Measure the clearance between the front axle frame (2) and anti-vibration bolt (3). 4. If the measurement exceeds the factory specification, adjust the anti-vibration bolt.
Page 57: Check Points Of Every 400 Hours
0.74 U.S.gals 0.62 Imp.gals (1) Suction Pipe Oil level is acceptable within this (2) Drain Plug range. (3) O-ring (Small) [A] GR1600EU, GR1600F (4) O-ring (Large) [B] GR1600ID (5) Strainer (6) Boss (7) Transmission Oil Filter Cartridge (8) Dipstick 9Y1210595GEG0026US0...
Page 58: Check Point Of Every 1500 Hours
GR1600EU, WSM GENERAL Cleaning Transmission Strainer When changing the transmission fluid, disassemble and rinse the strainer with nonflammable solvent to completely clean off filings. Check O-rings (2), (3), replace if damaged, cracked or hardened.When reassembling be careful not to damage the parts.
Page 59: Check Points Of Every 1 Year
GR1600EU, WSM GENERAL [9] CHECK POINTS OF EVERY 1 YEAR Replacing Air Cleaner Element 1. Change the element once a year. 9Y1210595GEG0035US0 Flushing Cooling System and Changing Coolant CAUTION To avoid personal injury: • Do not remove the radiator cap when the engine is hot.
Page 60 GR1600EU, WSM GENERAL (Continued)  Anti-freeze CAUTION To avoid personal injury: • When using anti-freeze, put on some protection such as rubber gloves (Anti-freeze contains poison.). • If should drink anti-freeze, throw up at once and take medical attention. • When anti-freeze comes in contact with the skin or clothing, wash it off immediately.
Page 61 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 •...
Page 62: Check Points Of Every 2 Years
GR1600EU, WSM GENERAL [10] CHECK POINTS OF EVERY 2 YEARS Replacing Fuel Lines 1. Replace the fuel line. Refer to G-32. 9Y1210595GEG0038US0 Replacing Engine Breather Hose 1. Replace the engine breather hose. Refer to 1-M1. 9Y1210595GEG0039US0 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.
Page 63: Service As Required
GR1600EU, WSM GENERAL [11] SERVICE AS REQUIRED Replacing Fuses 1. Open the hood. 2. Remove the blown fuse. 3. Place a new 3 A, 10 A, 15 A fuse or 40 A slow blow fuse in position. NOTE • Never "jump" the fuse with wire or foil, or install a larger capacity fuse than is recommended.
Page 64: Mower
GR1600EU, WSM GENERAL [12] MOWER (1) RCK42GREU, RCK42GRF Checking and Replacing Mower Blade WARNING To avoid serious injury: • Be sure to stop the engine and remove the key. • Blades may be sharp. When you handle blades, wear heavy gloves or wrap end of blade with a rag.
Page 65 GR1600EU, WSM GENERAL Replacing Mower Belt 1. Remove the mower deck from the machine. 2. Remove the left and right hand shield (4), (5) from the mower deck. [RCK42GRF only] 3. Clean around the pulleys to remove the belt (3) from the pulleys.
Page 66: Rck42-Gr16
GR1600EU, WSM GENERAL (2) RCK42-GR16 Checking and Replacing Blade WARNING To avoid serious injury: • Be sure to step the engine and remove the key. • Blades may be sharp. When you handle blades, wear heavy gloves or wrap and of blade with a Before checking or replacing the blade, wipe grass and mud off the top and inside of the mower.
Page 67 GR1600EU, WSM GENERAL Mower Belt Replacement 1. Remove the mower deck from the machine according to the procedure "DISMOUNTING THE MOWER DECK". 2. Remove the all shields from the mower deck. 3. Clean around the pulleys to remove the belt (1) from the pulleys.
Page 68: Special Tools
GR1600EU, WSM GENERAL 8. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Special Use Puller Set Code No. • 07916-09032 Application • Use exclusively to pull out bearing, gears and other parts with ease. WSM000001GEG0011US0 Piston Ring Compressor Code No. • 07909-32111 Application •...
Page 69 GR1600EU, WSM GENERAL Diesel Engine Compression Tester (for Injection Nozzle) Code No. • 07909-30208 (Assembly) • 07909-30934 (A to F) • 07909-31211 (E and F) • 07909-31231 (H) • 07909-31251 (G) • 07909-31271 (I) • 07909-31281 (J) Application • Use to measure diesel engine compression and diagnostics of need for major overhaul.
Page 70 GR1600EU, WSM GENERAL Connecting Rod Alignment Tool Code No. • 07909-31661 Application • Use to check the connecting rod alignment. Applicable range • Connecting rod big end I.D. 30 to 75 mm dia. (1.2 to 2.9 in. dia.) • Connecting rod length 65.0 to 300 mm (2.56 to 11.8 in.)
Page 71 GR1600EU, WSM GENERAL Injection Pump Pressure Tester Application • Use to check fuel tightness of injection pumps. Pressure gauge full scale: More than 29.4 MPa (300 kgf/cm , 4270 psi) PF 1/2 Copper gasket Flange (Material Steel) Hex. nut 27 mm (1.1 in.) across the plat...
Page 72 GR1600EU, WSM GENERAL Bushing Replacing Tools Application • Use to press out and to press fit the bushing. 1. For small end bushing 145 mm (5.71 in.) 20 mm (0.79 in.) 100 mm (3.94 in.) 19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.) 21.90 to 21.95 mm dia.
Page 73 GR1600EU, WSM GENERAL Crankshaft Bearing 1 Replacing Tool Application • Use to press out and press fit the crankshaft bearing 1. [Press Out] 135 mm (5.31 in.) 72 mm (2.8 in.) 40 mm radius (1.6 in. radius) 10 mm (0.39 in.) 22 mm (0.87 in.)
Page 74: Special Tools For Machine
GR1600EU, WSM GENERAL [2] SPECIAL TOOLS FOR MACHINE Relief Valve Pressure Tester Code No. • 07916-50045 Application • This allows easy measurement of relief valve setting pressure. (1) Gauge (07916-50322) (6) Adaptor C (PS3/8) (07916-50371) (2) Cable (07916-50331) (7) Adaptor D (PT1/8) (07916-50381)
Page 75 GR1600EU, WSM GENERAL HST Relief Pressure Gauge Adaptors (Adaptor 1) Application • This allows easy measurement of hydrostatic transmission hydraulic pressure. 5.94 to 6.00 mm dia. (0.234 to 0.236 in. dia.) 8.165 to 8.187 mm dia. (0.3215 to 0.3223 in. dia.) 8.4 mm dia.
Page 76 GR1600EU, WSM GENERAL HST Relief Pressure Gauge Adaptors (Adaptor 2) 10 mm (0.394 in.) 3 mm (0.1181 in.) 2.0 to 2.4 mm (0.079 to 0.094 in.) 3 mm (0.12 in.) 5.8 mm (0.23 in.) 1.5 mm (0.06 in.) 9 mm dia. (0.35 in. dia.) 8.200 to 8.215 mm dia.
Page 77 GR1600EU, WSM GENERAL Short Neck Wrench Application • This allows easy removal and installation of the hexagon socket head plug from the HST center section. 90 mm (3.543 in.) 7 to 8 mm (0.28 to 0.31 in.) 11 mm (0.433 in.) 6.35 mm (0.25 in.)
Page 78: Tires
GR1600EU, WSM GENERAL 9. TIRES [1] TIRE PRESSURE CAUTION To avoid personal injury: • Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment. • Always maintain the correct tire pressure.
Page 79: Implement Limitations
KUBOTA. Use with implements which are not sold or approved by KUBOTA and which exceed the maximum specifications listed below, or which are otherwise unfit for use with the KUBOTA Tractor may result in malfunctions 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.]...
Page 80 ENGINE KiSC issued 11, 2013 A...
Page 81 MECHANISM CONTENTS 1. ENGINE BODY........................... 1-M1 [1] HALF-FLOATING HEAD COVER ..................1-M1 [2] CLOSED BREATHER ......................1-M1 2. LUBRICATING SYSTEM......................1-M2 3. COOLING SYSTEM ........................1-M3 4. FUEL SYSTEM........................... 1-M4 [1] FUEL LINE ........................... 1-M4 KiSC issued 11, 2013 A...
Page 82: Engine Body
GR1600EU, WSM ENGINE 1. ENGINE BODY [1] HALF-FLOATING HEAD COVER The rubber packing is fitting in to keep the head cover 0.5 mm (0.02 in.) or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head.
Page 83: Lubricating System
GR1600EU, WSM ENGINE 2. LUBRICATING SYSTEM (1) Rocker Arm (2) Oil Pressure Switch (3) Rocker Arm Shaft (4) Valve (5) Idle Gear (6) Crankshaft (7) Oil Pump (8) Oil Strainer (9) Relief Valve (10) Push Rod (11) Tappet (12) Camshaft...
Page 84: Cooling System
GR1600EU, WSM ENGINE 3. COOLING SYSTEM (1) Radiator (2) Water Pump (3) Cooling Fan (4) Thermostat (5) Cylinder Head (6) Cylinder Block The cooling system consists of a radiator (1), a centrifugal water pump (2), a cooling fan (3) and a thermostat (4).
Page 85: Fuel System
GR1600EU, WSM ENGINE 4. FUEL SYSTEM [1] FUEL LINE (1) Injection Nozzle (2) Fuel Overflow Pipe (3) Fuel Tank (4) Fuel Filter (5) Fuel Feed Pump (6) Fuel Filter (7) Injection Pump (8) Injection Pipe Fuel from the fuel tank (3) passes through the fuel filter (4), and then enters the injection pump (7) after impurities such as dirt, water, etc.
Page 86 SERVICING CONTENTS 1. TROUBLESHOOTING.........................1-S1 2. SERVICING SPECIFICATIONS ....................1-S4 3. TIGHTENING TORQUES......................1-S9 4. CHECKING, DISASSEMBLING AND SERVICING ..............1-S10 [1] CHECKING AND ADJUSTING....................1-S10 (1) Engine Body ........................1-S10 (2) Lubricating System ......................1-S13 (3) Cooling System ......................1-S14 (4) Fuel System........................1-S16 [2] PREPARATION ........................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...
Page 87: Troubleshooting
GR1600EU, WSM ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Fill fuel Start Air in the fuel system Bleed G-45 Water in the fuel system Change fuel and G-32 repair or replace fuel system...
Page 88 GR1600EU, WSM ENGINE Reference Symptom Probable Cause Solution Page Either White or Blue Excessive engine oil Reduce to specified G-9, Exhaust Gas Is level G-18 Observed Piston ring and cylinder worn or stuck Repair or replace 1-S45, 1-S50 Incorrect injection timing...
Page 89 GR1600EU, WSM ENGINE Reference Symptom Probable Cause Solution Page Low Oil Pressure Engine oil insufficient Fill G-9, G-18 Oil strainer clogged Clean – Oil filter clogged Replace G-35 Relief valve stuck with dirt Clean – Relief valve spring weaken or broken Replace –...
Page 90: Servicing Specifications
GR1600EU, WSM ENGINE 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Compression Pressure 2.85 to 3.23 MPa 2.26 MPa 29.0 to 33.0 kgf/cm 23.0 kgf/cm 413 to 469 psi 327 psi • Variance Among Cylinder – 10 % or less Top Clearance 0.50 to 0.70 mm...
Page 91 GR1600EU, WSM ENGINE Item Factory Specification Allowable Limit Tappet to Tappet Guide Oil Clearance 0.016 to 0.052 mm 0.10 mm 0.00063 to 0.0020 in. 0.0039 in. • Tappet O.D. 17.966 to 17.984 mm – 0.70733 to 0.70803 in. • Tappet Guide Bore I.D.
Page 92 GR1600EU, WSM ENGINE Item Factory Specification Allowable Limit Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.038 mm 0.10 mm 0.00056 to 0.0014 in. 0.0039 in. • Piston Pin O.D. 20.002 to 20.011 mm – 0.78748 to 0.78783 in.
Page 93 GR1600EU, WSM ENGINE Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing 2 Oil Clearance 0.028 to 0.051 mm 0.20 mm (Flywheel Side) 0.0011 to 0.0020 in. 0.0079 in. • Crankshaft Journal O.D. 43.934 to 43.950 mm – 1.7297 to 1.7303 in.
Page 94 GR1600EU, WSM ENGINE COOLING SYSTEM Item Factory Specification Allowable Limit Fan Belt Tension 7.0 to 9.0 mm / 98 N – 0.28 to 0.35 in. / 98 N (10 kgf, 22 lbs) Thermostat Valve Opening 80.5 to 83.5 °C –...
Page 95: Tightening Torques
GR1600EU, WSM ENGINE 3. TIGHTENING TORQUES Tightening torques of screws and nuts on the table below are especially specified. (For general use screws and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Dimension × Item N·m kgf·m lbf·ft Pitch Front coupling mounting screw M8 ×...
Page 96: Checking, Disassembling And Servicing
GR1600EU, WSM ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Disconnect the 2P connector from the fuel pump. 4. Remove the air cleaner, the muffler and all injection nozzles.
Page 97 GR1600EU, WSM ENGINE Top Clearance 1. Remove the cylinder head. (Do not try to remove the cylinder head gasket.) 2. Move the piston up, and stick a strip of plastigauge (1) [5.0 to 7.0 mm long (0.20 to 0.27 in. long)] on the piston head at three positions with grease so as to avoid the intake and exhaust valves and the combustion chamber ports.
Page 98 GR1600EU, WSM ENGINE Valve Clearance IMPORTANT • The valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover (1) and the glow plugs. Remove the flywheel cover (4). [GR1600F, GR1600ID only] 2. Align the "1TC" mark (2) on the flywheel and alignment mark (3) on the rear end plate so that the No.
Page 99: Lubricating System
GR1600EU, WSM ENGINE (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester (Code No.: 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
Page 100: Cooling System
GR1600EU, WSM ENGINE (3) Cooling System Checking Fan Drive Belt Tension CAUTION To avoid personal injury: • Be sure to stop the engine and remove the key before checking belt tension. IMPORTANT • When replacing the fan drive belt, be careful not to catch it on the cap under the water pump.
Page 101 GR1600EU, WSM ENGINE Thermostat Valve Opening Temperature 1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat. 2. Heating the water gradually, read the temperature when the valve opens and leaves the string.
Page 102: Fuel System
5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a KUBOTA-authorized pump service shop. 13.7 MPa...
Page 103 12.8 MPa (from 140 to 130 kgf/cm , 1990 to 1850 psi). 9. If the measurement is less than allowable limit, replace the pump with new one or repair with a KUBOTA-authorized pump service shop. 10 seconds 13.7 → 12.8 MPa Factory specification 140 →...
Page 104 GR1600EU, WSM ENGINE Fuel Injection Pressure 1. Set injection nozzle nozzle tester (Code No. 07909-31361). 2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle. 3. If the measurement is not within the factory specifications, replace the adjusting washer (1) in the nozzle holder to adjust it.
Page 105: Preparation
GR1600EU, WSM ENGINE [2] PREPARATION (1) Separation of the Engine Draining Coolant CAUTION • Never open the radiator cap while operating or immediately after stopping. Otherwise, hot water will spout out from the radiator. Wait for more than ten minutes to cool the radiator, before opening the cap.
Page 106 GR1600EU, WSM ENGINE 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.
Page 107 GR1600EU, WSM ENGINE Air Cleaner, Muffler, Fuel Hose and Wire Harness 1. Remove the air cleaner (1) and muffler (2). 2. Disconnect the fuel hoses (3). 3. Disconnect the accelerator wire (4). 4. Disconnect the wire harness (5). 5. Remove the flywheel cover (6). [GR1600F, GR1600ID only]...
Page 108: Disassembling And Assembling
GR1600EU, WSM ENGINE Engine Assembly 1. Remove the radiator retaining snap pins (1). 2. Disconnect the front coupling (2). 3. Separate the engine assembly (3) with radiator from the frame (4). (When reassembling) 24 to 27 N·m Front coupling mounting 2.4 to 2.8 kgf·m...
Page 109 GR1600EU, WSM ENGINE Cylinder Head Cover 1. Remove the head cover screws (1). 2. Remove the cylinder head cover (2). (When reassembling) • Check to see if the cylinder head cover gasket is not damaged. 6.87 to 11.2 N·m Tightening torque Cylinder head cover screw 0.78 to 1.15 kgf·m...
Page 110 GR1600EU, WSM ENGINE Rocker Arm and Push Rod 1. Remove the rocker arm bracket screws (1). 2. Remove the rocker arm assembly (2). 3. Remove the push rods (3). (When reassembling) • When putting the push rods (3) onto the tappets (4), check to see if their ends are properly engaged with the dimples.
Page 111: Timing Gear, Camshaft And Fuel Camshaft
GR1600EU, WSM ENGINE Valves 1. Remove the valve caps (2). 2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1). 3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6).
Page 112 GR1600EU, WSM ENGINE Fan Drive Pulley 1. Secure the flywheel to keep it from turning. 2. Remove the fan drive pulley screw. 3. Draw out the fan drive pulley with a puller. (When reassembling) • Install the pulley to crankshaft, aligning the mark (1) on them.
Page 113 GR1600EU, WSM ENGINE Idle Gear 1. Remove the external snap ring (3), the collar (2) and the idle gear (1). 2. Remove the idle gear shaft mounting screws (4). 3. Remove the idle gear shaft (5). (When reassembling) • Apply engine oil to the idle gear shaft mounting screw (4). And tighten them.
Page 114 GR1600EU, WSM ENGINE Fuel Camshaft 1. Remove the retaining plate (1). 2. Remove the fork lever holder mounting screws (8), then draw out the injection pump gear (3) and fuel camshaft (2) with the governor fork assembly. (When reassembling) • Hook the governor spring (7) to the fork lever 2 (6) as shown in the figure before installing the fork lever assembly to the crankcase.
Page 115: Piston And Connecting Rod
GR1600EU, WSM ENGINE Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws (5). 2. Remove the oil pan (4) by lightly tapping the rim of the pan with a wooden hammer. 3. Remove the oil strainer (3).
Page 116 GR1600EU, WSM ENGINE Pistons 1. Turn the flywheel and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer. 3. Draw out the other piston in the same method as above.
Page 117 GR1600EU, WSM ENGINE Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool (Code No. 07909-32121). 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) • When installing the ring, assemble the rings so that the manufacturer's mark (12) near the gap faces the top of the piston.
Page 118: Crankshaft
GR1600EU, WSM ENGINE (4) Crankshaft Flywheel 1. Secure the flywheel to keep it from turning using a flywheel stopper. (Refer to G-54.) 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) • Align the "1TC" mark (a) on the outer surface of the flywheel horizontally with the alignment mark (b) on the rear end plate.
Page 119 GR1600EU, WSM ENGINE Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly. (When reassembling) • Clean the oil passage of the crankshaft with compressed air. • Apply oil to the main bearing case screw 2 (1).
Page 120 GR1600EU, WSM ENGINE Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (1), and remove the main bearing case assembly 1 (2), being careful with crankshaft bearing 3 (4), (5). 2. Remove the main bearing case assembly (3) as above. Keep in mind, however, that the thrust bearing (8) is installed in the main bearing case assembly (3).
Page 121: Water Pump
GR1600EU, WSM ENGINE (5) Water Pump Thermostat Assembly 1. Remove the thermostat cover mounting screws, and remove the thermostat cover (1). 2. Remove the thermostat assembly (3). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (2).
Page 122: Servicing
GR1600EU, WSM ENGINE [4] SERVICING (1) Cylinder Head and Valves Cylinder Head Surface Flatness 1. Clean the cylinder head surface. 2. Place a straightedge on the cylinder head's four sides and two diagonal as shown in the figure. 3. Measure the clearance with a thickness gauge.
Page 123 GR1600EU, WSM ENGINE Clearance between Valve Stem and Valve Guide 1. Remove carbon from the valve guide section. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. with a small hole gauge, and calculate the clearance.
Page 124 GR1600EU, WSM ENGINE Valve Seating 1. Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact. 2. If the valve does not seat all the way around the valve seat or the valve contact is less than 70 %, correct the valve seating as follows.
Page 125 GR1600EU, WSM ENGINE Valve Lapping 1. Apply compound evenly to the valve lapping surface. 2. Insert the valve into the valve guide. Lap the valve onto its seat with a valve flapper or screwdriver. 3. After lapping the valve, wash the compound away and apply oil, then repeat valve lapping with oil.
Page 126 GR1600EU, WSM ENGINE Oil Clearance between Rocker Arm and Rocker Arm Shaft 1. Measure the rocker arm shaft O.D. with an outside micrometer. 2. Measure the rocker arm I.D. with an inside micrometer, and then calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the rocker arm and measure the oil clearance again.
Page 127: Timing Gear, Camshaft And Fuel Camshaft
GR1600EU, WSM ENGINE (2) Timing Gear, Camshaft and Fuel Camshaft Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear.
Page 128 GR1600EU, WSM ENGINE Camshaft Alignment 1. Support the camshaft with V blocks on the surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Measure the camshaft alignment. 4. If the measurement exceeds the allowable limit, replace the camshaft.
Page 129: Piston And Connecting Rod
GR1600EU, WSM ENGINE Oil Clearance between Idle Gear Shaft and Idle Gear Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance.
Page 130 GR1600EU, WSM ENGINE Oil Clearance between Piton Pin and Small End Bushing 1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer. 2. Measure the small end bushing I.D. with an inside micrometer, and calculate the oil clearance.
Page 131 GR1600EU, WSM ENGINE Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with piston. 2. Measure the ring gap with a thickness gauge. 3. If the measurement exceeds the allowable limit, replace the piston ring.
Page 132: Crankshaft
GR1600EU, WSM ENGINE (4) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings.
Page 133 GR1600EU, WSM ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigauge (Code No.: 07909-30241) on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
Page 134 GR1600EU, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance.
Page 135 GR1600EU, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) 1. Put a strip of plastigauge (Code No. 07909-30241) on the center of the journal. 2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again.
Page 136: Cylinder
GR1600EU, WSM ENGINE (5) Cylinder Cylinder Wear 1. Measure the I.D. of the cylinder at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.'s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.'s.
Page 137 GR1600EU, WSM ENGINE Clearance between Outer Rotor and Pump Body 1. Measure the clearance between the outer rotor and the pump body with a thickness gauge. 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.
Page 138 TRANSAXLE KiSC issued 11, 2013 A...
Page 139 MECHANISM CONTENTS 1. STRUCTURE..........................2-M1 2. TRAVELLING 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 ......................
Page 140: Structure
GR1600EU, WSM TRANSAXLE 1. STRUCTURE (1) Hydraulic Transmission (2) Mower PTO Section (4) Rear Axle Section (6) Bearing which Supports the Section (3) Differential Gear Section (5) Bearing which Supports the Drive Shaft Rear Axle The transaxle of this machine is constructed as shown above.
Page 141: Travelling System
GR1600EU, WSM TRANSAXLE 2. TRAVELLING SYSTEM [1] HYDROSTATIC TRANSMISSION (1) Structure (1) Check Valve (8) Piston (15) Oil Seal (22) By-pass Plug (2) Trunnion Arm (9) Spring (Cylinder Block) (16) Pump Shaft (23) By-pass Spool (3) Charge Relief Valve (10) Washer...
Page 142: Oil Flow
GR1600EU, WSM TRANSAXLE (2) Oil Flow (1) Pump (4) Filter Cartridge (7) Lubricating Orifice (9) Neutral Orifice (2) Charge Pump (5) Motor (8) Check Valve (Reverse) (10) Charge Relief Valve (3) Check Valve (Forward) (6) By-pass Valve The closed oil-hydraulic loop connects between the pump (1) and the motor (5) in HST.
Page 143: Operation
GR1600EU, WSM TRANSAXLE (3) Operation Neutral (1) Cylinder Block (Pump) (5) Lubricating Orifice (8) Transaxle Case (11) Charge Relief Valve (2) Swashplate (6) Check Valve (Forward) (9) Oil Strainer (12) Filter Cartridge (3) Piston (7) By-pass Valve (10) Check Valve (Reverse)
Page 144 GR1600EU, WSM TRANSAXLE Forward (1) Cylinder Block (Pump) (5) Lubricating Orifice (8) Transaxle Case (11) Charge Relief Valve (2) Swashplate (6) Check Valve (Forward) (9) Oil Strainer (12) Filter Cartridge (3) Piston (7) By-pass Valve (10) Check Valve (Reverse) (13) Charge Pump...
Page 145 GR1600EU, WSM TRANSAXLE Reverse (1) Cylinder Block (Pump) (5) Lubricating Orifice (8) Transaxle Case (11) Charge Relief Valve (2) Swashplate (6) Check Valve (Forward) (9) Oil Strainer (12) Filter Cartridge (3) Piston (7) By-pass Valve (10) Check Valve (Reverse) (13) Charge Pump...
Page 146: Charge Pump
GR1600EU, WSM TRANSAXLE (4) Charge Pump The charge pump revolves in combination with pump shaft to draw oil from the transaxle case, and feed oil to the charge circuit. The charge pump is necessary to make up for leakage from the pump and motor, preventing system.
Page 147: Control Linkage
GR1600EU, WSM TRANSAXLE (6) Control Linkage (1) Speed Change Pedal (3) Speed Change Plate (5) Neutral Spring (6) Speed Control Arm (2) Speed Change Rod (4) Neutral Arm The speed change pedal (1) and the trunnion arm of variable swashplate are linked with the speed change rod (2), speed change plate (3) and the speed control arm (6).
Page 148: Mower Pto System
GR1600EU, WSM TRANSAXLE [2] MOWER PTO SYSTEM (1) Mower PTO Clutch The mower PTO clutch is equipped with mechanical independent clutches of wet multi-plates type. The PTO shaft (1) is engaged with the spline boss (3). The clutch case (5) is engaged with the 24T gear (6).
Page 149 GR1600EU, WSM TRANSAXLE PTO "Disengaged" When the PTO lever is set at the "Disengaged" position, the clutch lever (2) connected to the PTO lever via a link mechanism rotates to the front side of the machine. Spring (8) tension pushes the spline boss (3) toward...
Page 150 SERVICING CONTENTS 1. TROUBLESHOOTING.........................2-S1 2. SERVICING SPECIFICATIONS ....................2-S3 3. TIGHTENING TORQUES......................2-S5 4. CHEKING, DISASSEMBLING AND SERVICING................2-S6 [1] CHECKING AND ADJUSTING....................2-S6 (1) 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...
Page 151: Troubleshooting
GR1600EU, WSM TRANSAXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page System Will Not Oil level is low Fill oil to proper level G-9, Operate in Either 2-S12 Direction Control linkage damaged Repair control linkage 2-S6, (Speed change pedal to speed control arm)
Page 152 GR1600EU, WSM TRANSAXLE Reference Symptom Probable Cause Solution Page Oil Over Heat Oil level is low Fill oil to proper level G-9, 2-S12 Excessive machine load Reduce machine load 2-S6, 2-S16 Charge pressure is too Oil filter cartridge Replace oil filter...
Page 153: Servicing Specifications
GR1600EU, WSM TRANSAXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit HST Charge Pressure Setting Pressure 0.900 to 1.10 MPa – (Oil temperature at 50 °C (122 °F)) 9.18 to 11.2 kgf/cm 131 to 159 psi PTO CLUTCH Item Factory Specification...
Page 154 GR1600EU, WSM TRANSAXLE DIFFERENTIAL Item Factory Specification Allowable Limit Differential Case to Differential Side Gear Clearance 0.040 to 0.082 mm 0.17 mm 0.0016 to 0.0032 in. 0.0067 in. • Differential Case Bore I.D. 22.500 to 22.521 mm – 0.88583 to 0.88665 in.
Page 155: Tightening Torques
GR1600EU, WSM TRANSAXLE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m lbf·ft Brake plate mounting screw 34 to 40 3.5 to 4.0...
Page 156: Cheking, Disassembling And Servicing
GR1600EU, WSM TRANSAXLE 4. CHEKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) HST Speed Change System Adjustment of HST Neutral Position 1. Block the front wheels with stoppers, and lift up the rear of machine with a jack. 2. Remove the left rear wheel.
Page 157: Hst Charge Pressure
(2) Lock Nut (4) Adjusting Screw 9Y1210595TXS0016US0 (2) HST Charge Pressure [A] GR1600EU, GR1600F Removing Container 1. 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.
Page 158 GR1600EU, WSM TRANSAXLE Discharge Duct 1. Remove the filter cover (1). 2. Remove the screws (3) for the discharge duct (2). 3. Disconnect the spring (4) and the coupler (5). 4. Remove the discharge duct (2). (1) Filter Cover (4) Spring...
Page 159: Specifications
GR1600EU, WSM TRANSAXLE [C] checking Checking HST Charge Pressure CAUTION • Park the machine on level ground, and apply the parking brake. • Adjust HST neutral first. 1. Remove the plug (1) from the hydraulic control valve assembly. 2. Install the gauge hose adaptor, gauge hose and pressure gauge.
Page 160: Preparation
1. Refer to "[2] PREPARATION (DISMOUNTING MOWER)" on page 7-S10. 9Y1210595TXS0017US0 [A] GR1600EU, GR1600F Removing Container 1. 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.
Page 161 GR1600EU, WSM TRANSAXLE Discharge Duct 1. Remove the filter cover (1). 2. Remove the screws (3) for the discharge duct (2). 3. Disconnect the spring (4) and the coupler (5). 4. Remove the discharge duct (2). (1) Filter Cover (4) Spring...
Page 162 IMPORTANT • Park the machine on lever ground. • Use the KUBOTA UDT or SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system. Refer to "4. LUBRICANTS, FUEL AND COOLANT" on page G-9.
Page 163 GR1600EU, WSM TRANSAXLE 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.
Page 164 GR1600EU, WSM TRANSAXLE PTO Rod Spring 1. Remove the two nuts (2) (3) and spring (4). (When reassembling) 1. Assemble a fuel tank, a seat base and a fender. 2. Setting the PTO lever at "Disengaged" position and lifting the...
Page 165 GR1600EU, WSM TRANSAXLE Beam 1. Disconnect the connector from the PTO switch (1). 2. Remove the spring (2) from the PTO lever (3). 3. Remove the PTO rod. 4. Remove the filling pipe (4). 5. Remove the hose clamp (7) of breather hose (6).
Page 166 GR1600EU, WSM TRANSAXLE Speed Control Plate 1. Remove the split pin (2), and disconnect the speed change plate (1) and speed control arm (3). 2. Separate the speed change plate (1) and speed change rod (4). IMPORTANT • After assembling the speed change plate (1) and speed change rod (4), be sure to adjust the speed change pedal restriction.
Page 167: Separating Hydrostatic Transmission
GR1600EU, WSM TRANSAXLE (2) Separating Hydrostatic Transmission Speed Control Arm, Neutral Spring, Cooling Fan and Others 1. Remove the neutral spring (2). 2. Remove the speed control arm (1). 3. Remove the cooling fan (3). 4. Remove the breather hoses (4).
Page 168 GR1600EU, WSM TRANSAXLE Suction Filter Case 1. Remove the hose (3). 2. Remove the suction filter case (1) with the suction pipe 2 (2). 3. Remove the suction pipe 2 (2) from the suction filter case (1). 4. Remove the boss (7) and strainer (6) from the suction filter case (1).
Page 169 GR1600EU, WSM TRANSAXLE Neutral Arm Holder and Filter Bracket 1. Remove the neutral arm holder mounting screws (M8) (4). 2. Remove the filter bracket (2) with the neutral arm holder (3). 3. Remove the charge pipe (6). (When reassembling) NOTE •...
Page 170 GR1600EU, WSM TRANSAXLE Brake Assembly 1. Remove the brake assembly (1). 2. Remove the external snap ring (2). And pull out the brake drum (3). (When reassembling) • Apply liquid gasket (Three Bond 1206D or equivalent) to joint face of brake assembly and hydrostatic transmission thinly.
Page 171: Disassembling And Assembling
GR1600EU, WSM TRANSAXLE [3] DISASSEMBLING AND ASSEMBLING (1) Hydrostatic Transmission 15T Gear, 34T Gear and Bevel Gear Shaft 1. Remove the external snap ring (4). And pull out the 15T gear (1) and 34T gear (2). 2. Remove the bevel gear shaft (3).
Page 172 GR1600EU, WSM TRANSAXLE Center Section 1. Remove the center section mounting hex. socket head screws. 2. Tap the center section (1) with soft hammer and separate the center section (1) from the HST housing (2). (When reassembling) • Cover the splines of each shaft with thin tape to protect the sealing lip of the oil seals.
Page 173 GR1600EU, WSM TRANSAXLE Cylinder Block Assembly and Thrust Ball Bearing 1. Remove the cylinder block assembly (pump side) (1), spring (2) and washer (3). 2. Remove the cylinder block assembly (motor side) (5). 3. Remove the thrust ball bearing (4).
Page 174: Transaxle Case
GR1600EU, WSM TRANSAXLE (2) Transaxle Case Disassembling PTO Clutch Assembly 1. Remove the PTO cover assembly (1) with the brake disc and friction plate, PTO clutch assembly (3) and 24T gear (2) from the transaxle case. 2. Remove the ball bearing (4) from the transaxle case.
Page 175 GR1600EU, WSM TRANSAXLE Disassembling PTO Cover Assembly 1. Pull out the PTO shaft (1) from PTO clutch cover (5) until external snap ring (3) touches clutch lever (4). 2. Tap out the PTO shaft (1) while opening the external snap ring (3) with external snap ring pliers.
Page 176 GR1600EU, WSM TRANSAXLE Assembling PTO Clutch Assembly NOTE • When assembling the PTO clutch assembly to the transaxle assembly installed in the machine, refer to "(3) PTO Clutch" on page 2-S33. 1. Place the transaxle case so that the front side faces upward.
Page 177 GR1600EU, WSM TRANSAXLE (Continued) 1. Remove the PTO shaft from the spline boss carefully. 2. Install the PTO clutch assembly (18) which assembles the 24T gear, spline boss, brake disc and friction plate in the transaxle case. NOTE • Align the tongues (16) of the brake friction plate with the grooves (17) of transaxle case.
Page 178 GR1600EU, WSM TRANSAXLE Transaxle Case 1. Remove the transaxle case screws (2). 2. Separate the front side of transaxle case (1). (When reassembling) • Apply the liquid gasket (Three Bond 1206D or its equivalent) without any break along the sealing groove on the front side of transaxle case: the coating width and height should be 2 mm (0.078 in.) and 1.5 mm (0.059 in.), respectively.
Page 179 GR1600EU, WSM TRANSAXLE (Continued) NOTE • Do not apply the liquid gasket on the oil passage "A" shown in the figure. • Install the transaxle case screws (2) in the direction shown in figure. • Tighten all screws by the hand. Then, tighten the screws located at the circled positions "B"...
Page 180 GR1600EU, WSM TRANSAXLE Input Shaft, 19T-2 Gear and 17T-13T Gear Shaft 1. Remove the input shaft (1). 2. Remove the intermediate shaft (2) and 19T-2 gear (3) with collars (6) and needle bearing (7). 3. Remove the 17T-13T gear shaft (4).
Page 181 GR1600EU, WSM TRANSAXLE Rear Differential Gear, Drive Shaft and 11T Gear Shaft (RH, LH) 1. Remove the rear differential gear assembly (3), 11T gear shafts (1), (7) and drive shaft (5). 2. Remove the external snap ring (8) and bearing (4) from drive shaft (5).
Page 182 GR1600EU, WSM TRANSAXLE Rear Axle 1. Remove the rear axle (1). 2. Remove the oil seal (2) from the rear axle (1) (1) Rear Axle (2) Oil Seal 9Y1210595TXS0051US0 2-S32 KiSC issued 11, 2013 A...
Page 183: Pto Clutch
GR1600EU, WSM TRANSAXLE (3) PTO Clutch Dismounting Mower 1. Refer to "[2] PREPARATION (DISMOUNTING MOWER)" on page 7-S10. 9Y1210595TXS0017US0 Draining Transmission Fluid 1. Refer to G-39. 9Y1210595TXS0053US0 Separating PTO Cover Assembly with PTO Clutch Assembly 1. Remove the two nuts (4), (5) and spring (6).
Page 184 GR1600EU, WSM TRANSAXLE  Reinstalling PTO Cover Assembly with PTO Clutch to the Transaxle Assembly installed in the machine. 9Y1210595TXS0055US0 Pre-Assembly PTO Cover Assembly 1. Separate the PTO cover assembly (1) and PTO clutch assembly (3) with brake disc and friction plate (2).
Page 185 GR1600EU, WSM TRANSAXLE Installation of PTO Cover Assembly with PTO Clutch Assembly 1. Clean the mating surface of the transaxle case (3) and PTO cover assembly. 2. Tighten the stud bolts (1) at three locations shown in figure by hand.
Page 186 GR1600EU, WSM TRANSAXLE (Continued) 1. Align the bolt holes of PTO cover assembly (13) with the stud bolts (1). Then slide the PTO cover assembly (13) slowly in direction of arrow in figure. 2. When the distance "A" is 15 to 16 mm (0.59 to 0.62 in.), the PTO cover assembly (13) would be blocked from sliding.
Page 187 IMPORTANT • Park the machine on level ground. • Use the KUBOTA UDT or SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system. Refer to "4. LUBRICANTS, FUEL AND COOLANT" on page G-9.
Page 188: Servicing
GR1600EU, WSM TRANSAXLE [4] SERVICING (1) Hydrostatic Transmission Charge Pump 1. Check the charge pump housing (1) and gerotor assembly (2) for scratches and wear. 2. If scratch or worn, replace the charge pump assembly. (1) Charge Pump Housing (2) Gerotor Assembly...
Page 189 GR1600EU, WSM TRANSAXLE Cylinder Block Assembly 1. Check the cylinder blocks (4) and pistons (3) for scratches and wear. 2. If you find, replace the cylinder block assembly. 3. Check that the piston (3) and spring (2) are in each cylinder bore.
Page 190: Transaxle Case
GR1600EU, WSM TRANSAXLE (2) Transaxle Case Checking Bearing 1. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness. 2. Apply transmission fluid to the bearing, and hold the inner race.
Page 191 GR1600EU, WSM TRANSAXLE PTO Brake Disc Wear 1. Measure the thickness of PTO brake disc with a vernier caliper. 2. If the thickness is less than the allowable limit, replace it. 3.30 to 3.50 mm Factory specification 0.130 to 0.137 in.
Page 192 GR1600EU, WSM TRANSAXLE Clearance between Differential Pinion Gear and Differential Pinion Shaft 1. Measure the differential pinion gear (1) I.D.. 2. Measure the differential pinion shaft (2) O.D., and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace faulty parts.
Page 193 GR1600EU, WSM TRANSAXLE Backlash between 11T Bevel Gear Shaft and 17T-13T Gear Shaft 1. Stick a strip of plastigauge the three spots on the 11T bevel gear shaft (3) with grease. 2. Reassemble the hydrostatic transmission and transaxle case. 3. Fix the transaxle case, and push the by-pass valve.
Page 194 BRAKES KiSC issued 11, 2013 A...
Page 195 MECHANISM CONTENTS 1. BRAKE MECHANISM......................... 3-M1 KiSC issued 11, 2013 A...
Page 196 GR1600EU, WSM BRAKES 1. BRAKE MECHANISM Internal expanding brake drum is used in braking system for GR series. Brake drum (1) is connected to idle gear shaft. Idle gear shaft is located between drive gear and final gear. Brake shoes (4) will be expanded via brake cam lever (2) when you press the brake pedal.
Page 197 SERVICING CONTENTS 1. TROUBLESHOOTING.........................3-S1 2. SERVICING SPECIFICATIONS ....................3-S2 3. TIGHTENING TORQUES......................3-S3 4. CHECKING, DISASSEMBLING AND SERVICING ..............3-S4 [1] CHECKING AND ADJUSTING....................3-S4 [2] DISASSEMBLING AND ASSEMBLING ................3-S4 (1) Pedal System Component....................3-S4 (2) Brake Assembly.......................3-S7 KiSC issued 11, 2013 A...
Page 198: Troubleshooting
GR1600EU, WSM BRAKES 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Insufficient Braking Brake pedal free travel excessive Adjust 3-S4 Force Brake shoe worn Replace 3-S7 Brake drum worn Replace 3-S7 Grease or oil on brake shoe Replace 3-S7 Brake Drags...
Page 199: Servicing Specifications
GR1600EU, WSM BRAKES 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Brake Pedal Free Travel 15 to 25 mm – 0.59 to 0.98 in. 9Y1210595BRS0002US0 3-S2 KiSC issued 11, 2013 A...
Page 200: Tightening Torques
GR1600EU, WSM BRAKES 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m lbf·ft Steering wheel mounting nut 20 to 24 2.0 to 2.5...
Page 201: Checking, Disassembling And Servicing
GR1600EU, WSM BRAKES 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Brake Pedal Free Travel CAUTION • Stop the engine, remove the key, and chock the wheels before checking brake pedal. 1. Release the parking brake. 2. Loosen the lock nut (1) and adjusting nut (2).
Page 202 GR1600EU, WSM BRAKES Fender 1. Remove the speed change pedal (5). 2. Peel the step sheet (4) halfway. 3. Remove the fuel cap (1). 4. Remove the fender (2). (1) Fuel Cap (4) Step Sheet (2) Fender (5) Speed Change Pedal...
Page 203 GR1600EU, WSM BRAKES Steering Support Assembly 1. Disconnect 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).
Page 204: Brake Assembly
GR1600EU, WSM BRAKES (2) Brake Assembly Brake Assembly 1. Remove the lock nut (1), plain washers (2) and brake spring (3). 2. Remove the brake plate (5). 3. Remove the brake rod (4). 4. Remove the brake assembly (6). 5. Remove the external snap ring (8).
Page 205 FRONT AXLE KiSC issued 11, 2013 A...
Page 206 SERVICING CONTENTS 1. TROUBLESHOOTING.........................4-S1 2. SERVICING SPECIFICATIONS ....................4-S2 3. TIGHTENING TORQUES......................4-S3 4. CHECKING, DISASSEMBLING AND SERVICING ..............4-S4 [1] CHECKING AND ADJUSTING....................4-S4 [2] PREPARATION ........................4-S4 (1) Separating Front Axle Assembly ..................4-S4 [3] DISASSEMBLING AND ASSEMBLING ................4-S6 (1) Front Axle Assembly......................4-S6 [4] SERVICING ...........................4-S6 KiSC issued 11, 2013 A...
Page 207: Troubleshooting
GR1600EU, WSM FRONT AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Front Wheels Wander Tire pressure uneven Adjust G-60 to Right or Left Improper toe-in Replace tie-rod 4-S4, 4-S6 Kingpin worn Replace front axle 4-S5 assembly Center pin collar worn...
Page 208: Servicing Specifications
GR1600EU, WSM FRONT AXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Front Wheel Alignment Toe-in 1.0 to 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.
Page 209: Tightening Torques
GR1600EU, WSM FRONT AXLE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m lbf·ft...
Page 210: Checking, Disassembling And Servicing
GR1600EU, WSM FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Toe-in 1. Inflate the tires to the specified pressure. 2. Turn the front wheels straight ahead. 3. Measure the toe-in (B-A). 4. If the measurement is not within the factory specifications, replace the tie-rod.
Page 211 GR1600EU, WSM FRONT AXLE 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).
Page 212: Disassembling And Assembling
GR1600EU, WSM FRONT AXLE [3] DISASSEMBLING AND ASSEMBLING (1) Front Axle Assembly Tie-rod 1. Remove the tie-rod mounting locking nut (1). 2. Remove the tie-rod (2). 48 to 55 N·m Tie-rod mounting locking Tightening torque 4.9 to 5.7 kgf·m 36 to 41 lbf·ft...
Page 213 STEERING KiSC issued 11, 2013 A...
Page 214 SERVICING CONTENTS 1. TROUBLESHOOTING.........................5-S1 2. SERVICING SPECIFICATIONS ....................5-S2 3. TIGHTENING TORQUES......................5-S3 4. CHECKING, DISASSEMNLING AND SERVICING..............5-S4 [1] CHECKING AND ADJUSTING....................5-S4 [2] PREPARATION ........................5-S4 (1) Separating Steering Support Assembly................5-S4 [3] DISASSEMBLING AND ASSEMBLING ................5-S6 (1) Steering Support Assembly .....................5-S6 [4] SERVICING ...........................5-S6 KiSC issued 11, 2013 A...
Page 215: Troubleshooting
GR1600EU, WSM STEERING 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page 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...
Page 216: Servicing Specifications
GR1600EU, WSM STEERING 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Steering Wheel Play 30 to 70 mm – 1.2 to 2.7 in. 9Y1210595STS0002US0 5-S2 KiSC issued 11, 2013 A...
Page 217: Tightening Torques
GR1600EU, WSM STEERING 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m lbf·ft Steering wheel mounting nut 20 to 24 2.0 to 2.5...
Page 218: Checking, Disassemnling And Servicing
GR1600EU, WSM STEERING 4. CHECKING, DISASSEMNLING AND SERVICING [1] CHECKING AND ADJUSTING Steering Wheel Play 1. Turn the front wheels straight ahead. 2. Rotate the steering wheel lightly by hand, and measure the play. 3. If the measurement exceeds the factory specifications, replace the steering shaft and sector gear.
Page 219 GR1600EU, WSM STEERING Steering Wheel, Side Bonnet and Panel 1. Remove the steering wheel (1). 2. Remove the side bonnet (3). 3. Remove the accelerator lever grip. 4. Disconnect the connectors for hour meter (4), main switch (5) and light switch.
Page 220: Disassembling And Assembling
GR1600EU, WSM STEERING [3] DISASSEMBLING AND ASSEMBLING (1) Steering Support Assembly Steering Shaft and Sector Gear 1. Remove the shaft retainer (4). 2. Remove the sector gear mounting screw (5), and remove the sector gear (8). 3. Remove the steering bearing (1) and ball bearing (3).
Page 221: Electrical System
ELECTRICAL SYSTEM KiSC issued 11, 2013 A...
Page 222 MECHANISM CONTENTS 1. WIRING DIAGRAM........................6-M1 [1] 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..........................
Page 223: Wiring Diagram
GR1600EU, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM [1] GR1600EU, GR1600F 6-M1 KiSC issued 11, 2013 A...
Page 224 GR1600EU, WSM ELECTRICAL SYSTEM [2] GR1600ID 6-M2 KiSC issued 11, 2013 A...
Page 225: Gr1600Eu, Gr1600F
GR1600EU, WSM ELECTRICAL SYSTEM 2. STARTING SYSTEM [1] GR1600EU, GR1600F (1) Battery (7) Slow Blow Fuse (40 A) (13) Grass Container Open Switch (18) Fuse (IG/M) (10 A) (2) GND (8) Fuel Feed Pump (14) Grass Container Open Relay (19) Main Switch...
Page 226: Gr1600Id
GR1600EU, WSM ELECTRICAL SYSTEM [2] GR1600ID (1) Battery (6) GND (11) Engine Stop Timer Relay (16) Main Switch (2) GND (7) Slow Blow Fuse (40 A) (12) Seat Switch (17) Brake Switch (3) Starter Motor (8) Fuel Feed Pump (13) Diode (3A)
Page 227: Charging System
GR1600EU, WSM ELECTRICAL SYSTEM 3. CHARGING SYSTEM (1) Battery (4) Dynamo (6) Regulator (8) Main Switch (2) GND (5) Slow Blow Fuse (40 A) (7) Fuse (10 A) (9) Charge Lamp (3) GND The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs.
Page 228: Lighting System And Meter Panel
GR1600EU, WSM ELECTRICAL SYSTEM 4. LIGHTING SYSTEM AND METER PANEL [1] GR1600EU, GR1600F (1) Battery (9) Regulator (16) Grass Container Full Switch (22) Oil Pressure Lamp (2) GND (10) Fuse (10 A) Relay (23) Charge Lamp (3) Glow Plug (11) Main Switch...
Page 229: Gr1600Id
GR1600EU, WSM ELECTRICAL SYSTEM [2] GR1600ID (1) Battery (7) Dynamo (12) Engine Overheat Horn Relay (17) Charge Lamp (2) GND (8) Slow Blow Fuse (40 A) (13) Engine Overheat Horn (18) Easy Checker™ (3) Glow Plug (9) Regulator (14) Glow Plug Lamp...
Page 230 (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 ................6-S22 (1) Starter..........................6-S22...
Page 231: Troubleshooting
GR1600EU, WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page All Electrical Battery discharged or damaged Recharge or replace G-29, Equipments Do Not 1-S20 Operate Battery positive cable disconnected or improperly Repair or replace 1-S20 connected Battery negative cable disconnected or...
Page 232 GR1600EU, WSM ELECTRICAL SYSTEM STARTING SYSTEM Reference Symptom Probable Cause Solution Page Starter Motor Does Battery discharged or damaged Recharge or replace G-29, Not Operate 1-S20 Slow blow fuse blown (40 A) Replace G-45 Wiring harness disconnected or improperly Repair or replace –...
Page 233 GR1600EU, WSM ELECTRICAL SYSTEM LIGHTING SYSTEM Reference Symptom Probable Cause Solution Page Head Light Does Not Fuse blown (10 A) Replace G-45 Light Bulb blown Replace G-45 Wiring harness disconnected or improperly Repair or replace – connected (between main switch ACC terminal...
Page 234: Servicing Specifications
GR1600EU, WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Battery Voltage More than – 12 V Potential Less than – Difference 0.1 V Glow Plug Resistance Approx. 0.9 Ω – Head Light Switch Resistance OFF Infinity –...
Page 235: Tightening Torques
GR1600EU, WSM ELECTRICAL SYSTEM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m lbf·ft Starter (C terminal nut) 5.9 to 11...
Page 236: Cheking, Disassembling And Servicing
GR1600EU, WSM ELECTRICAL SYSTEM 4. CHEKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Battery Battery Voltage 1. Stop the engine and turn the main switch off. 2. Connect the COM (-) lead of the voltmeter to the battery's negative cable (1) and the (+) lead to the positive cable (2), and measure the battery voltage.
Page 237 GR1600EU, WSM ELECTRICAL SYSTEM Battery Charging DANGER To avoid serious injury or death: • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.
Page 238: Main Switch
GR1600EU, WSM ELECTRICAL SYSTEM (Continued) (For non-accessible maintenance-free type batteries.) Maintenance-free, non-accessible batteries are designed to eliminate the need to add water. Yet the volume of electrolyte above plates may eventually become depleted due to abnormal conditions such as high heat or improper regulator setting. Use voltmeter to check the state of charge.
Page 239 GR1600EU, WSM ELECTRICAL SYSTEM 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 B terminal and the ACC terminal, B terminal and ST terminal, B terminal and G terminal.
Page 240: Starter
GR1600EU, WSM ELECTRICAL SYSTEM (3) Starter Motor Test CAUTION • Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable and the leads from the starter.
Page 241: Safety Switch
GR1600EU, WSM ELECTRICAL SYSTEM (4) Safety Switch PTO Switch 1. Remove the battery. 2. Remove the fender. 3. Disconnect the connector from the PTO switch (1). 4. Measure the resistance with an ohmmeter between the terminals. 5. If the PTO switch is damaged, replace it.
Page 242: Operator Presence Control (Opc) Switch
GR1600EU, WSM ELECTRICAL SYSTEM Top Cover and Grass Container Open Switch [GR1600EU, GR1600F] 1. Remove the battery. 2. Remove the open switches (1) (2). 3. Measure the resistance with an ohmmeter between the switch terminals. 4. If the switches are damaged, replace them.
Page 243: Glow Plug
GR1600EU, WSM ELECTRICAL SYSTEM (6) Glow Plug Lead Terminal Voltage 1. Disconnect the wiring lead (1) from the glow plug (2) after turning the main switch off. 2. Turn the main switch key to the "PREHEAT" position, and measure the voltage between the lead terminal and the chassis.
Page 244: Fuel Pump
GR1600EU, WSM ELECTRICAL SYSTEM (7) Fuel Pump Connector Voltage 1. Disconnect the 2P connector from the fuel pump. 2. Turn the main switch key to the "ON" position, and measure the voltage with a voltmeter between the connector terminals. 3. If the voltage differs from the battery voltage, the wiring harness or main switch is faulty.
Page 245: Engine Stop Timer Relay
GR1600EU, WSM ELECTRICAL SYSTEM (9) Engine Stop Timer Relay Timer Relay Connector Voltage 1. Disconnect the connector from the timer relay after turning the main switch off. 2. Measure the voltage with a voltmeter across the connector terminal 4 and chassis.
Page 246: Charging System
GR1600EU, WSM ELECTRICAL SYSTEM (10) Charging System No-load Dynamo Output 1. Disconnect the lead wires from the dynamo. 2. Start the engine and operate the dynamo at the rated speed. 3. Measure the output voltage with a volt meter. 4. If the measurement is not within the specified values, replace the dynamo.
Page 247: Lighting System
GR1600EU, WSM ELECTRICAL SYSTEM (11) Lighting System Head Light Switch 1. Disconnect the wiring leads from head light switch and remove 2. Measure the resistance with an ohmmeter across the head light switch terminals in each position. 3. If the resistance differs from the factory specifications, the head light switch is faulty.
Page 248: Coolant Temperature Switch
GR1600EU, WSM ELECTRICAL SYSTEM Engine Oil Pressure Switch 1. Measure the resistance with an ohmmeter across the switch terminal and the chassis. 2. If 0 ohm is not indicated in the normal state, the switch is faulty. 3. If infinity is not indicated at pressure over 50 kPa (0.5 kgf/cm 7 psi), the switch is faulty.
Page 249: Grass Container Full Switch [Gr1600Eu, Gr1600F]
GR1600EU, WSM ELECTRICAL SYSTEM (13) Grass Container Full Switch [GR1600EU, GR1600F] Grass Container Full Switch Continuity 1. Remove the battery. 2. Dismount the grass container. 3. Remove the filter cover. 4. Disconnect the connector (1) from the grass container full switch (2).
Page 250: Grass Container Full Switch Timer Relay [Gr1600Eu, Gr1600F]
GR1600EU, WSM ELECTRICAL SYSTEM (14) Grass Container Full Switch Timer Relay [GR1600EU, GR1600F] Removing Relay 1. Remove the grass container. 2. Remove the discharge duct. 3. Remove the screws (1). 4. Push the relay stay (2). 5. Remove the timer relay (3).
Page 251: Relays (Starter, Engine Overheat Horn, Grass Container Open, Grass Container Full Switch, Buzzer)
(1) Stater Relay (2) Engine Overheat Horn Relay 9Y1210595ELS0001US0 Removing Grass Container Open Relay, Grass Container Full Switch Relay, Buzzer Relay [GR1600EU, GR1600F] 1. Remove the grass container. 2. Remove the discharge duct. 3. Remove the screws (1). 4. Push the relay stay (2).
Page 252: Disassembling And Assembling
GR1600EU, WSM ELECTRICAL SYSTEM [2] DISASSEMBLING AND ASSEMBLING (1) Starter (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...
Page 253: Dynamo
GR1600EU, WSM ELECTRICAL SYSTEM (2) Dynamo Stator 1. Remove the nut (3) and separate the stator comp. (4). 2. Remove the screws (1) and remove the stator (2). 40 to 44 N·m Tightening torque 4.0 to 4.5 kgf·m 29 to 32 lbf·ft...
Page 254: Servicing
GR1600EU, WSM ELECTRICAL SYSTEM [3] SERVICING (1) Starter Overrunning Clutch 1. Inspect the pinion for wear or damage. 2. If there is any problem, replace the overrunning clutch assembly. 3. Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction.
Page 255 GR1600EU, WSM ELECTRICAL SYSTEM Brush Holder 1. Check the continuity across the brush holder and the holder support with an ohmmeter. 2. If it conducts, replace the brush holder. 9Y1210595ELS0043US0 Armature Coil 1. Check the continuity across the commutator and armature coil core with an ohmmeter.
Page 256: Dynamo
GR1600EU, WSM ELECTRICAL SYSTEM (2) Dynamo Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. 9Y1210595ELS0046US0 6-S26 KiSC issued 11, 2013 A...
Page 257 MOWER KiSC issued 11, 2013 A...
Page 258 MECHANISM CONTENTS 1. POWER TRANSMISSION......................7-M1 [1] RCK42GREU, RCK42GRF ....................7-M1 [2] RCK42-GR16 ........................7-M3 2. LIFTING MECHANISM ....................... 7-M4 KiSC issued 11, 2013 A...
Page 259: Power Transmission
GR1600EU, WSM MOWER 1. POWER TRANSMISSION [1] RCK42GREU, RCK42GRF (1) Center Pulley (4) 18T Spiral Gear (7) Mower Belt (9) Blade Shaft (2) Output Shaft (5) Input Shaft (8) Universal Joint (10) Blade (3) 17T Spiral Gear (6) Outer Pulley The power is transmitted from transmission case to blades as follows.
Page 260 GR1600EU, WSM MOWER The mower belt moves in the arrow direction. 9Y1210595MOM0003US0 7-M2 KiSC issued 11, 2013 A...
Page 261: Rck42-Gr16
GR1600EU, WSM MOWER [2] RCK42-GR16 (1) Input Shaft (3) Output Shaft (5) Center Pulley (6) Gear Box Assembly (2) 17T Spiral Gear (4) 18T Spiral Gear The power is transmitted from transmission case to blades as follows. PTO Shaft → Universal Joint → Input Shaft (1) → 17T Spiral Gear (2) → 18T Spiral Gear (4) → Output Shaft (3) →...
Page 262: Lifting Mechanism
GR1600EU, WSM MOWER 2. LIFTING MECHANISM (1) Lift Link LH (4) Lift Link Shaft (7) Cutting Height Adjusting Dial (9) Lift Link RH (2) Rear Link LH (5) Mower Lift Lever (8) Adjusting Cam (10) Rear Link RH (3) Gas Spring (6) Lift Link The rear link RH (10) and mower lift lever (5) are linked with lift link RH (9) and lift link (6).
Page 263 SERVICING CONTENTS 1. TROUBLESHOOTING.........................7-S1 2. SERVICING SPECIFICATIONS ....................7-S3 3. TIGHTENING TORQUES......................7-S4 4. CHECKING, DISASSEMBLING AND SERVICING ..............7-S5 [1] CHECKING AND ADJUSTING....................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...
Page 264 GR1600EU, WSM MOWER 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Blade Does Not Turn PTO system malfunctioning Check transmission – Mower belt broken Replace mower belt 7-S14 Blade Speed Is Slow Mower belt loosen Replace mower belt 7-S14 or tension spring...
Page 265 GR1600EU, WSM MOWER Reference Symptom Probable Cause Solution Page Blades Scalping Cutting height too low Increase the height – Grass Blades speed too fast Decrease the speed – Ridges in terrain – – Rough or uneven terrain – – Bent blade(s)
Page 266 GR1600EU, WSM MOWER 2. SERVICING SPECIFICATIONS RCK42GREU, RCK42GRF Item Factory Specification Allowable Limit Left Tip of Blade to Right Tip of Blade Difference Less than – 6.0 mm 0.24 in. Front Tip of Blade to Rear Tip of Blade Difference Less than –...
Page 267 GR1600EU, WSM MOWER 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) RCK42GREU, RCK42GRF Item N·m kgf·m lbf·ft...
Page 268 GR1600EU, WSM MOWER 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) RCK42GREU, RCK42GRF Adjusting Anti-scalp Rollers IMPORTANT • The flattest cut can be achieved by having the anti-scalp rollers adjusted off the ground. Check anti-scalp roller adjustments each time the mower deck cutting height is changed.
Page 269 GR1600EU, WSM MOWER Adjusting Left and Right Cutting Height 1. Park the machine on level surface. 2. Wheel pressure must be correct. 3. Raise up the mower deck to the transport position. (Also the top end.) 4. Turn the cutting height control dial (1) to the "3" position.
Page 270 GR1600EU, WSM MOWER Adjusting Parallel Linkage 1. Park the machine on a level surface. 2. Wheel pressure must be correct. 3. Adjust the cutting height so that blade is level. 4. Position mower blade in the Front-to-Rear position. 5. Measure the height of blade "X" and "Y" from the ground surface and calculate the difference.
Page 271 GR1600EU, WSM MOWER Adjusting the Mower Deck (Side to Side) CAUTION 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 and of blade with a rag.
Page 272 GR1600EU, WSM MOWER (Continued) 11. Measure from the level surface to the bottom of the discharge cover at point "D" as shown in the figure below. This will be measurement (Y). 12. The difference between measurement (Y) and (X) should be 88 mm (3.5 in.)
Page 273 GR1600EU, WSM MOWER [2] PREPARATION (DISMOUNTING MOWER) (1) RCK42GREU, RCK42GRF CAUTION • To avoid personal injury: Shut off the engine and remove the key before dismounting the mower. 9Y1210595MOS0028US0 Cutting Height Adjusting Dial 1. Park the machine on level ground, and stop the engine.
Page 274 GR1600EU, WSM MOWER Dismounting Mower 1. Turn the front wheel to the right. 2. Pull out the mower deck to the left. 9Y1210595MOS0010US0 (2) RCK42-GR16 Cutting Height Adjusting Dial 1. Park the machine on level ground, and stop the engine.
Page 275 GR1600EU, WSM MOWER Disconnecting the Rear Link 1. Release the L-pins (1). 2. Disconnecting the rear link (2) from the mower bracket (3). (1) L-pin "UNLOCK" (2) Rear link "RELEASE" (3) Mower bracket 9Y1210595MOS0023US0 7-S12 KiSC issued 11, 2013 A...
Page 276 GR1600EU, WSM MOWER Removing the Universal Joint 1. Remove the bolt (1) and stay (3) from the frame. 2. Shorten the universal joint cover (2) from the coupler of the universal joint. 3. Pull back the coupler (5) of the universal joint.
Page 277 GR1600EU, WSM MOWER [3] DISASSEMBLING AND ASSEMBLING (1) RCK42GREU, RCK42GRF Mower Blades (Left Blade and Right Blades) 1. Turn over the mower. 2. Remove the mower blade screw (1), and remove the shim (2), two cup washers (3), mower blade (4) and dust cover (6).
Page 278 GR1600EU, WSM MOWER Disassembling Gear Box 1. Remove the drain plug (10), and drain the gear box oil. 2. Remove the pulley mounting screw (1), and remove the pulley (3). 3. Remove the case cover (15). 4. Remove the shim (14) and 18T spiral gear (12) with ball bearing (13).
Page 279 GR1600EU, WSM MOWER Disassembling Pulley Holder 1. Remove the grease fitting (12). 2. Remove the pulley mounting nut (11), and remove the pulley (10). 3. Tap out the blade shaft (1). 4. Remove the pulley holder (6) from the mower deck.
Page 280 GR1600EU, WSM MOWER (2) RCK42-GR16 Removing Mower Blades Before you remove the blade, wipe grass and mud off the top and inside of the mower. Especially clean up the inside of the belt cover, because otherwise the belt life will decrease.
Page 281 GR1600EU, WSM MOWER Disassembling Gear Box (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) Gear Case...
Page 282 GR1600EU, WSM MOWER Disassembling Pulley Holder (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 1.
Page 283 GR1600EU, WSM MOWER (3) Mower Lift Linkage (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 (10) Gas Spring...
Page 284 GR1600EU, WSM MOWER [4] SERVICING (1) Gear Box [RCK42GREU, RCK42GRF] Backlash between 17T Spiral Gear and 18 Spiral Gear 1. Remove the 18T spiral gear (6) from gear box. 2. Stick the strip of plastigauge the 18T spiral gear (6) with grease.
Page 285 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ks_g.ksos-pub@kubota.com Printed in Japan 2013. 11, S, EI, EI, engusa Code No.9Y111-05953 2011.

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Gr1600f Gr1600id

Kubota GR1600EU Workshop Manual

Information

General

1 Identification

2 General Precautions

3 Handling Precautions for Electrical Parts and Wiring

4 Lubricants, Fuel and Coolant

5 Tightening Torques

6 Maintenance Check List

7 Check and Maintenance

8 Special Tools

9 Tires

10 Implement Limitations

Mechanism

1 Engine Body

2 Lubricating System

3 Cooling System

4 Fuel System

Servicing

Mechanism

1 Structure

2 Travelling System

Servicing

Servicing

Servicing

Servicing

Mechanism

1 Wiring Diagram

3 Charging System

4 Lighting System and Meter Panel

Servicing

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Kubota GR1600EU