Page 1 WORKSHOP MANUAL G21LD,G21HD KiSC issued 08, 2007 A...
Page 2 All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes in all information at any time without notice. June 2005 © KUBOTA Corporation 2005 KiSC issued 08, 2007 A...
Page 3 G21LD · G21HD, WSM SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 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 safety regulations before you attempt to repair or use this unit.
Page 4 G21LD · G21HD, WSM SAFETY INSTRUCTIONS SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Do not alter or remove any part of machine safety system. • Before starting the engine, make sure that all shift levers are in neutral positions or in disengaged positions.
Page 5 G21LD · G21HD, WSM SAFETY INSTRUCTIONS VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.
Page 6 G21LD · G21HD, WSM SAFETY INSTRUCTIONS SAFETY DECALS The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list. KiSC issued 08, 2007 A...
Page 7 G21LD · G21HD, WSM SAFETY INSTRUCTIONS KiSC issued 08, 2007 A...
Page 8 G21LD · G21HD, WSM SAFETY INSTRUCTIONS KiSC issued 08, 2007 A...
Page 9 G21LD · G21HD, WSM SAFETY INSTRUCTIONS KiSC issued 08, 2007 A...
Page 10 G21LD · G21HD, WSM SPECIFICATIONS SPECIFICATIONS Model G21LD G21HD Maximum gross power 15.6 kw (21 HP) Model D782-E2-G21 Type Indirect injection, vertical, water cooled, 4-cycle diesel engine Number of cylinders 67.0 × 73.6 mm (2.64 × 2.90 in.) Bore and stroke Total displacement 778 cm (47.48 cu.in.)
Page 11 G21LD · G21HD, WSM SPECIFICATIONS Model G21LD G21HD Steering Electric power steering (EPS) Transmission Hydrostatic transmission Brake Internal expanding brake Mower Model RCK48G18-PRO Total length 900 mm (35.4 in.) Total width 1280 mm (50.4 in.) Total height 315 mm (12.4 in.) Mounting method Quick joint, parallel linkage Adjustment of cutting height...
Page 12 G21LD · G21HD, WSM DIMENSIONS DIMENSIONS KiSC issued 08, 2007 A...
Page 13 G21LD · G21HD, WSM DIMENSIONS KiSC issued 08, 2007 A...
Page 14 GENERAL KiSC issued 08, 2007 A...
Page 15: Table Of Contents
GENERAL CONTENTS 1. IDENTIFICATION..................... G-1 2. GENERAL PRECAUTIONS ................G-2 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .. G-3 [1] WIRING...................... G-3 [2] BATTERY....................G-5 [3] FUSE......................G-5 [4] CONNECTOR .................... G-5 [5] HANDLING OF CIRCUIT TESTER............G-6 4. LUBRICANTS, FUEL AND COOLANT ............G-7 5.
Page 16: Identification
G21LD · G21HD, WSM G GENERAL 1. IDENTIFICATION (1) Engine Serial Number (3) Mower Serial Number (2) Machine Serial Number (4) Hour Meter W1010714 KiSC issued 08, 2007 A...
Page 17: General Precautions
Screws, bolts and nuts should be installed in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.
Page 18: Handling Precautions For Electrical Parts And Wiring
G21LD · G21HD, WSM G GENERAL 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring. IMPORTANT • Check electrical wiring damage loosened...
Page 19 G21LD · G21HD, WSM G GENERAL • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp • Wind Clamp Spirally (4) Welding Dent (2) Wire Harness W1011458 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.
Page 20: Battery
G21LD · G21HD, WSM G GENERAL [2] BATTERY • Take care not to confuse positive and negative terminal posts. • When removing battery cables, disconnect negative cable first. When installing battery cables, check for polarity and connect positive cable first. •...
Page 21: Handling Of Circuit Tester
G21LD · G21HD, WSM G GENERAL • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make certain there is no terminal being exposed or displaced. (1) Exposed Terminal (3) Sandpaper (2) Deformed Terminal (4) Rust W1012346 • Make certain that there is no female connector being too open. (A) Correct (B) Incorrect W1012430...
Page 22: Lubricants, Fuel And Coolant
Above 25 °C (77 °F): SAE30, 10W-30 or 10W-40 4.5 L 6.0 L Transmission (Including 4.75 U.S.qts. 6.34 U.S.qts. KUBOTA UDT or SUPER UDT fluid HST & cylinder) 3.86 Imp.qts. 5.28 Imp.qts. 0.40 L Mower gear case 0.42 U.S.qts. SAE #90 gear oil 0.35 Imp.qts.
Page 23: Tightening Torques
G21LD · G21HD, WSM G GENERAL 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolts, and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of No-grade or 4T bolt SCr435,...
Page 24: American Standard Screws, Bolts And Nuts With Unc Or Unf Threads
G21LD · G21HD, WSM G GENERAL [3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS Grade SAE GR.5 SAE GR.8 Unit N·m kgf·m ft-lbs N·m kgf·m ft-lbs Nominal Diameter 5/16 23.1 to 27.8 2.35 to 2.84 17.0 to 20.5 32.5 to 39.3 3.31 to 4.01 24.0 to 29.0...
Page 25: Maintenance Check List
G21LD · G21HD, WSM G GENERAL 6. MAINTENANCE CHECK LIST Period Hour meter reading Reference Every 50 Hr page After Item Tires Check G-23 Battery condition Check Every 100 Hr G-31 Safety device Check G-27 Engine oil Change Every 100 Hr G-21 Engine oil filter cartridge Change...
Page 26 Initial elongation of the front PTO belt may occur prior to 25 hours. Adjust the tension spring length as needed to maintain belt tension. • These items should be serviced by an authorized KUBOTA Dealer, unless the owner has the proper tools and is mechanically proficient. •...
Page 27: Check And Maintenance
G21LD · G21HD, WSM G GENERAL 7. CHECK AND MAINTENANCE CAUTION • Be sure to check and service the machine on a flat place with engine shut off, the key removed, the parking brake on and chock the wheels. • Do not put yourself below the raised grass collector. •...
Page 28 G21LD · G21HD, WSM G 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 29 G21LD · G21HD, WSM G GENERAL Checking Amount of Fuel and Refueling CAUTION • Handle fuel carefully. If the engine 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.
Page 30 G21LD · G21HD, WSM G GENERAL Radiator Screen and Panel Screen Daily or after every 5 hours of operation, check to be sure the radiator screen (1) and panel screen (2) are clean. Dirt or chaff on the radiator screen (1) or radiator core decrease cooling performance.
Page 31 G21LD · G21HD, WSM G GENERAL Oiling [G21LD, G21HD] CAUTION • Be sure to stop the engine and remove the key before oiling. Oil the following points before starting. NOTE • Oil these points on both sides of the machine. 1.
Page 32 G21LD · G21HD, WSM G GENERAL Oiling [G21LD, G21HD] (Continued) CAUTION • Be sure to stop the engine and remove the key before oiling. Oil the following points before starting. NOTE • Oil these points on both sides of the machine. 1.
Page 33 G21LD · G21HD, WSM G GENERAL Oiling [G21LD] CAUTION • Be sure to stop the engine and remove the key before oiling. NOTE • Oil these points on both sides of the machine. 1. Oil the following points before starting. (1) L Pin (6) Grass Collector Linkages (2) Latch...
Page 34 G21LD · G21HD, WSM G GENERAL Oiling [G21HD] CAUTION • Be sure to stop the engine and remove the key before oiling. Oil the following points before starting. NOTE • Oil these points on both sides of the machine. 1. Apply oil to the following points. (1) Grass Catcher Cable (4) Back Cover Link (2) Pin...
Page 35 • The grass collector net material is subject to deterioration and wear. Check it frequently. Use only genuine replacement net from KUBOTA. • Make sure all shields and guards are securely in place following all service, cleaning, or repair work. [G21LD] 1.
Page 36: Check Points Of Initial 50 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 W1030949 G-21 KiSC issued 08, 2007 A...
Page 37 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 (2) Screw W1031068 Changing Mower Gear Box Oil 1.
Page 38: Check Points Of Every 50 Hours
G21LD · G21HD, WSM G GENERAL [3] CHECK POINTS OF EVERY 50 HOURS Checking Tire Pressure 1. Check the wear and damage or tires. 2. Check the tire pressure. 3. If insufficient, add air. If excessive, reduce air. 200 kPa Front 2.0 kgf/cm 28 psi...
Page 39 G21LD · G21HD, WSM G GENERAL Adjusting Fan Belt Tension CAUTION • Be sure to stop the engine and remove the key before checking belt tension. 1. If the fan drive belt becomes loose, the engine may overheat. 2. To adjust, loosen bolts and turn the alternator to tighten the belt. 3.
Page 40 G21LD · G21HD, WSM G GENERAL Greasing CAUTION • Be sure to stop the engine and remove the key before greasing. 1. Apply grease to the following points. (1) King Pin (6) Grease Nipple (Center Blade Shaft) (2) Center Pin (7) Grease Nipple (Mower Tension Arm) (3) Mower Universal Joint (8) Grass Collector Rotating Pivot...
Page 41 G21LD · G21HD, WSM G GENERAL Cleaning Air Cleaner Element 1. The air cleaner uses a dry element, never apply oil. 2. Do not touch the filter element except where cleaning is required. To clean the element, use clean and dry compressed air on the inside of the element.
Page 42 G21LD · G21HD, WSM G GENERAL Checking Safety Devices The Safety Devices in your machine help to protect you while operating. Please check this Safety Devices periodically–daily is best–to test function of the Safety Devices before operation. CAUTION To avoid personal injury : •...
Page 43 G21LD · G21HD, WSM G GENERAL Checking Safety Devices (Continued) Test 5 (PTO Safety Control 1) [G21LD] 1. Dismount the grass collector from the platform. 2. Run the engine at half throttle. 3. Engage the PTO lever (2). 4. Engine should shut off. [G21HD] 1.
Page 44: Check Points Of Every 100 Hours
G21LD · G21HD, WSM G GENERAL [4] CHECK POINTS OF EVERY 100 HOURS Changing Engine Oil 1. See page G-21. W1034674 Checking Fuel Lines And Fuel Filter CAUTION • Be sure to stop the engine and remove the key when attempting to make the following checks and changes.
Page 45 G21LD · G21HD, WSM G GENERAL Checking Battery Condition CAUTION • Never remove the vent cap while the engine is running. Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately and get medical attention.
Page 46 G21LD · G21HD, WSM G 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 47: Check Point Of Every 150 Hours
G21LD · G21HD, WSM G GENERAL [5] CHECK POINT OF EVERY 150 HOURS Changing Mower Gear Box Oil 1. See page G-22. W1036280 [6] CHECK POINTS OF EVERY 200 HOURS Changing Engine Oil Fiter Cartridge 1. See page G-21. W1036341 Checking Radiator Hose and Clamp NOTE •...
Page 48 G21LD · G21HD, WSM G GENERAL Checking Hydraulic Hose CAUTION • Be sure to stop the engine and remove the key before checking and replacing hydraulic hose. • Allow transmission case to cool down sufficiently; oil can be hot and may cause burns. •...
Page 49: Check Points Of Every 300 Hours
G21LD · G21HD, WSM G GENERAL [7] CHECK POINTS OF EVERY 300 HOURS Changing Transmission Fluid CAUTION • Be sure to stop the engine and remove the key before changing or checking the oil. • Allow transmission case to cool down sufficiently; oil can be hot and may cause burns.
Page 50: Check Point Of Every 500 Hours
G21LD · G21HD, WSM G GENERAL Cleaning Transmission Oil Strainer CAUTION • Be sure to stop the engine and remove the key before cleaning the transmission oil strainer. • Allow transmission case to cool down sufficiently; oil can be hot and may cause burns. 1.
Page 51: Check Point Of Every 1500 Hours
G21LD · G21HD, WSM G GENERAL [9] CHECK POINT OF EVERY 1500 HOURS Checking Fuel Injection Nozzle 1. See page 1-S54. W1042838 [10] CHECK POINT OF EVERY 3000 HOURS Checking Injection Pump 1. See page 1-S52. G-36 KiSC issued 08, 2007 A...
Page 52: Check Points Of Every 1 Year
G21LD · G21HD, WSM G GENERAL [11] CHECK POINTS OF EVERY 1 YEAR Replacing Air Cleaner Element 1. Remove the air cleaner element (2) once a year. IMPORTANT • The air cleaner uses a dry element, never apply oil. • Do not run the engine with filter element removed. •...
Page 53 G21LD · G21HD, WSM G GENERAL Flushing Cooling System and Changing Coolant (Continued) Anti-Freeze If cooling water freezes, the cylinders and radiator can be damaged. It is necessary, if the ambient temperature falls below 0 °C (32 °F), to remove cooling water mix it with anti-freeze and full the radiator with it.
Page 54 G21LD · G21HD, WSM G GENERAL Replacing Grass Collector Net (G21LD) 1. Remove the knob nut (1) from top of grass collector cover. 2. Remove plastic cover (2) from collector. 3. Remove the 2 clevis pins, 2 cotter-pins (3), 2 flange bolts and the height adjust stay (4) from the top of collector frame.
Page 55: Check Points Of Every 2 Years
G21LD · G21HD, WSM G GENERAL [12] CHECK POINTS OF EVERY 2 YEARS Replacing Fuel Line 1. Replace the fuel hoses (1) and hose clamps (2). Refer to “Checking Fuel Line”. (See page G-29.) (1) Fuel Hose (2) Hose Clamp Replacing Radiator Hose and Clamp Band 1.
Page 56 G21LD · G21HD, WSM G GENERAL Replacing Hydraulic Hoses CAUTION • Be sure to stop the engine and remove the key before checking and replacing hydraulic hose. • Allow transmission case to cool down sufficiently; oil can be hot and may cause burns. •...
Page 57 G21LD · G21HD, WSM G GENERAL Replacing Mower Gear Box Oil Seals 1. Replace the mower gear box oil seals (1), (2). Refer to “Disassembling Gear Box Assembly”. (See page 9-S14.) (1) Oil Seal (2) Oil Seal G-42 KiSC issued 08, 2007 A...
Page 58: Others
G21LD · G21HD, WSM G GENERAL [13] OTHERS Replacing Fuses 1. The electrical system is protected from potential damage by fuses. A blown fuse indicates that there is an overload or short somewhere in the electrical system. 2. If any of the fuses should blow, replace with a new one of the same capacity.
Page 59: Special Tools
G21LD · G21HD, WSM G GENERAL 8. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Special Use Puller Set Code No.: 07916-09032 Application: Use exclusively for pushing out bearing, gears and other parts with ease. W1048293 Piston Ring Compressor Code No.: 07909-32111 Application: Use exclusively for pushing in the piston with piston rings into the cylinder.
Page 60 G21LD · G21HD, WSM G GENERAL Oil Pressure Tester Code No.: 07916-32032 Application: Use to measure lubricating oil pressure. (1) Gauge (5) Adaptor 2 (2) Cable (6) Adaptor 3 (3) Threaded Joint (7) Adaptor 4 (4) Adaptor 1 (8) Adaptor 5 W1048722 Valve Seat Cutter Code No.:...
Page 61 G21LD · G21HD, WSM G GENERAL Nozzle Tester Code No.: 07909-31361 Application: Use to check the fuel injection pressure and spray pattern of nozzle. Measuring: 0 to 50 MPa range (0 to 500 kgf/cm , 0 to 7000 psi) W1049783 Plastigage Code No.: 07909-30241...
Page 62 G21LD · G21HD, WSM G 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 , 4267 psi) Copper gasket Flange (Material: Steel) Hex. nut 27 mm (1.06 in.) across the plat Injection pipe PF1/2 5 mm (0.20 in.)
Page 63 G21LD · G21HD, WSM G GENERAL Bushing Replacing Tool 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 64 G21LD · G21HD, WSM G GENERAL Crankshaft Bearing 1 Replacing Tool Application: Use to press out and to press fit the crankshaft bearing [Press Out] 135 mm (5.31 in.) 72 mm (2.83 in.) 40° (1.57 rad.) 10 mm (0.39 in.) 22 mm (0.87 in.) 20 mm dia.
Page 65: Special Tools For Machine
G21LD · G21HD, WSM G GENERAL [2] SPECIAL TOOLS FOR MACHINE Steering Wheel Puller Code No.: 07916-51090 Application: Use for removing the steering wheel without damaging the steering shaft. W1051779 Toe-in Gauge Code No.: 07909-31681 Application: This allows easy measurement of toe-in for all machine models.
Page 66 G21LD · G21HD, WSM G GENERAL NOTE • The following special tool is not provided, so make it referring to the figure. Steering Wheel Puller Adaptor Application: Use for removing the steering wheel with steering wheel 22 mm (0.87 in.) 116 mm (4.57 in.) 64 mm (2.52 in.) 5 mm (0.20 in.)
Page 67 G21LD · G21HD, WSM G GENERAL Adaptor Bolt for HST Application: Use for checking the charge relief valve setting pressure. 26 mm (1.02 in.) 0.4 mm (0.02 in.) 18 mm (0.71 in.) 0.5 mm (0.02 in.) 15 mm (0.59 in.) 15 mm (0.59 in.) 30 mm (1.18 in.) G 3/8...
Page 68 G21LD · G21HD, WSM G GENERAL Adaptor for Control Valve Application: Use for checking the main relief valve setting pressure. 40 mm (1.57 in.) 4.5 mm dia. (0.18 in. dia.) 18 mm (0.71.) 9 mm dia. (0.18 in. dia.) 6 mm (0.24 in.) RP 1/4 thread depth 15 mm (0.59 in.) Drill depth 20 mm (0.79 in.) 3 mm (0.12 in.)
Page 69 G21LD · G21HD, WSM G GENERAL Flange for Control Valve 1. Use for checking the relief valve setting pressure. NOTE • When using , attach with following parts. 1. O-ring: 04811-10240 2. O-ring: 04811-10600. RP 1/4 5 mm dia. (0.20 in. dia.) 14.5 mm dia.
Page 70: Implement Limitations
KUBOTA. Use of implements which exceed the maximum loading weight listed below, or which are not recommended for use with the KUBOTA Machine may result in malfunctions or failures of the machine, damage to other property and injury to the operator or others.
Page 71 ENGINE KiSC issued 08, 2007 A...
Page 72 SERVICING CONTENTS TROUBLESHOOTING ...................1-S1 2. SERVICING SPECIFICATIONS ..............1-S5 [1] ENGINE BODY ..................1-S5 [2] LUBRICATING SYSTEM .................1-S9 [3] COOLING SYSTEM.................1-S9 [4] FUEL SYSTEM ..................1-S10 3. TIGHTENING TORQUES ................1-S11 4. CHECKING, DISASSEMBLING AND SERVICING........1-S12 [1] SEPARATING ENGINE .................1-S12 (1) Disassembling and Assembling ............1-S12 [2] ENGINE BODY ..................1-S17 (1) Checking and Adjusting ..............1-S17 (2) Disassembling and Assembling ............1-S20...
Page 73: Troubleshooting
G21LD · G21HD, WSM ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel – Start Air in the fuel system Bleed fuel system – Water in the fuel system Change fuel and – replace fuel system Fuel pipe clogged Clean fuel pipe...
Page 74 G21LD · G21HD, WSM ENGINE Reference Symptom Probable Cause Solution Page Engine Does Not Battery discharged Charge battery G-31 Start Starter malfunctioning Repair or replace 8-S13 (Starter Does Not starter Run) Slow blow fuse blown Replace slow blow – fuse Main switch malfunctioning Repair or replace 8-S8...
Page 75 G21LD · G21HD, WSM ENGINE Reference Symptom Probable Cause Solution Page Deficient Output Incorrect injection timing Adjust injection 1-S52 timing Engine's moving parts seem to be seized Repair or replace – engine’s moving parts Uneven fuel injection Repair or replace 1-S52 injection pump Deficient nozzle injection...
Page 76 G21LD · G21HD, WSM ENGINE Reference Symptom Probable Cause Solution Page Low Oil Pressure Engine oil insufficient Replenish engine oil G-21 Oil strainer clogged Clean oil strainer G-35 Engine oil filter cartridge clogged Change engine oil G-21 filter cartridge Relief valve stuck with dirt Replace relief valve 1-S47 Relief valve spring weaken or broken...
Page 77: Servicing Specifications
G21LD · G21HD, WSM ENGINE 2. SERVICING SPECIFICATIONS [1] ENGINE BODY Cylinder Head Item Factory Specifications Allowable Limit Cylinder Head Surface Flatness – 0.05 mm 0.0020 in. Top Clearance 0.50 to 0.70 mm – 0.0197 to 0.0276 in. Compression Pressure 2.84 to 3.24 MPa 2.26 MPa 29.0 to 33.0 kgf/cm...
Page 78 G21LD · G21HD, WSM ENGINE Rocker Arm Item Factory Specifications Allowable Limit Clearance between Rocker Arm Shaft and Rocker Arm 0.016 to 0.045 mm 0.15 mm 0.00063 to 0.00177 in. 0.0059 in. Rocker Arm Shaft O.D. 10.473 to 10.484 mm –...
Page 79 G21LD · G21HD, WSM ENGINE Timing Gear Item Factory Specifications Allowable Limit Timing Gear Backlash Crank Gear- Idle Gear 0.043 to 0.124 mm 0.15 mm 0.00169 to 0.00488 in. 0.0059 in. Idle Gear-Cam Gear 0.047 to 0.123 mm 0.15 mm 0.00185 to 0.00484 in.
Page 80 G21LD · G21HD, WSM ENGINE Crankshaft Item Factory Specifications Allowable Limit Crankshaft Alignment – 0.02 mm 0.0008 in. Crankshaft Side Clearance 0.15 to 0.31 mm 0.50 mm 0.0059 to 0.0122 in. 0.0197 in. Oil Clearance between Crankshaft Journal and Crankshaft 0.034 to 0.106 mm 0.20 mm Bearing 1...
Page 81: Lubricating System
G21LD · G21HD, WSM ENGINE [2] LUBRICATING SYSTEM Oil Pump Item Factory Specifications Allowable Limit Engine Oil Pressure 49 kPa – At Idle Speed 0.5 kgf/cm 7 psi At Rated Speed 196 to 441 kPa 147 kPa 2.0 to 4.5 kgf/cm 1.5 kgf/cm 28 to 64 psi 21 psi...
Page 82: Fuel System
G21LD · G21HD, WSM ENGINE [4] FUEL SYSTEM Injection Pump Item Factory Specifications Allowable Limit Injection Timing 0.28 to 0.31 rad (16° to – 18°) Before T.D.C. Fuel Tightness of Pump Element – 13.73 MPa 140 kgf/cm 1991 psi Fuel Tightness of Delivery Valve 10 seconds 5 seconds 13.73 →...
Page 83: Tightening Torques
G21LD · G21HD, WSM ENGINE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-8.) Item Size x Pitch N·m kgf·m ft-lbs M6 ×...
Page 84: Checking, Disassembling And Servicing
G21LD · G21HD, WSM ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] SEPARATING ENGINE (1) Disassembling and Assembling Dismount Mower 1. See “MOWER” section. W1019171 Draining Engine Oil 1. Park the machine on level ground. 2. Start and warm up the engine for approx. 5 minutes. 3.
Page 85 G21LD · G21HD, WSM 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. 1.
Page 86 G21LD · G21HD, WSM ENGINE Wiring 1. Disconnect the tie (1) from the alternator, and remove the PTO cable (3) and wiring (2). 2. Disconnect 2P connector (5) and wiring (4) from the alternator. 3. Disconnect 1P connector (8) from the oil pressure switch. 4.
Page 87 G21LD · G21HD, WSM ENGINE Muffler, Wiring, Accelerator and Hose 1. Remove the muffler mounting screws (1), (7). 2. Remove the muffler (2). 3. Disconnect 1P connector (5) from the coolant temperature sensor. 4. Disconnect the wiring (3) from the glow plug. 5.
Page 88 G21LD · G21HD, WSM ENGINE Separating Engine 1. Pull out the hairpin cotters from the radiator. 2. Remove the engine mounting nuts, and support the engine with an engine lift hook and hoist. 3. Separate the engine with the radiator from the frame, taking care not to damage the radiator.
Page 89: Engine Body
G21LD · G21HD, WSM ENGINE [2] ENGINE BODY (1) Checking and Adjusting 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. 5.
Page 90 G21LD · G21HD, WSM ENGINE Top Clearance 1. Remove the cylinder head (Do not attempt to remove the cylinder head gasket completely). 2. Bring the piston to its top dead center fasten 1.5 mm dia. 5 to 7 mm long fuse wires to 3 to 4 spots on the piston top with grease so as to avoid the intake and exhaust valves and the combustion chamber ports.
Page 91 G21LD · G21HD, WSM ENGINE Valve Clearance IMPORTANT • The valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover and the glow plugs. 2. Align the “1TC” mark (1) on the flywheel and alignment mark (2) on the rear end plate so that the No.
Page 92: Disassembling And Assembling
G21LD · G21HD, WSM ENGINE (2) Disassembling and Assembling (A) Cylinder Head and Valves External Components 1. Remove the air cleaner stay (5). 2. Remove the water pipe 1 (2), water pipe 2 (7) and radiator (8) with the recovery tank. 3.
Page 93 G21LD · G21HD, WSM ENGINE Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe assembly (5). 2. Remove the nozzle holder assemblies (2) using a 21 mm deep socket wrench. 3. Remove the copper gasket and heat seal (3). 4.
Page 94 G21LD · G21HD, WSM ENGINE Cylinder Head 1. Loosen the pipe clamp, and remove the water return pipe. 2. Remove the cylinder head bolt in the order of (14) to (1). 3. Lift up the cylinder head to detach. 4. Remove the cylinder head gasket and O-ring. (When reassembling) •...
Page 95 G21LD · G21HD, WSM ENGINE (B) Timing Gears and Camshaft Injection Pump and Speed Control Plate 1. Remove the socket head screws and nuts, and remove the injection pump (3). 2. Remove the screws and separate the speed control plate (2), taking care not to damage the spring (4).
Page 96 G21LD · G21HD, WSM ENGINE Gear Case 1. Remove the screw (1). 2. Disconnect the start spring (2) in the speed control plate mounting hole. 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).
Page 97 G21LD · G21HD, 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) •...
Page 98 G21LD · G21HD, WSM ENGINE (C) Connecting Rod and Piston Oil Pan and Oil Strainer 1. Remove the oil pan (4). 2. Remove the oil strainer (3). (When reassembling) • Install the oil strainer, using care not to damage the O-ring (1). •...
Page 99 G21LD · G21HD, WSM ENGINE Piston 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.
Page 100 G21LD · G21HD, 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) •...
Page 101 G21LD · G21HD, WSM ENGINE (D) Crankshaft Flywheel 1. Lock the flywheel not to turn using flywheel stopper. 2. Remove the flywheel screws, except for two which must be loosened and left as they are. 3. Set a flywheel puller (Code No: 07916-32011), and remove the flywheel.
Page 102 G21LD · G21HD, WSM ENGINE Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly. (When reassembling) • Install the crankshaft sub assembly, aligning the screw hole of main bearing case 2 with the screw hole of cylinder block. •...
Page 103 G21LD · G21HD, WSM ENGINE Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (7), and remove the main bearing case assembly 1 (1), being careful with crankshaft bearing 3 (4). 2. Remove the main bearing case assembly 2 (2) and the main bearing case assembly 3 (3) as above.
Page 104: Servicing
G21LD · G21HD, WSM ENGINE (3) Servicing (A) Cylinder Head and Valve 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.
Page 105 G21LD · G21HD, WSM ENGINE Valve Recessing 1. Clean the cylinder head surface, valve face and valve seat. 2. Insert the valve into the valve guide. 3. Measure the valve recessing with a depth gauge. 4. If the measurement exceeds the allowable limit, replace the valve.
Page 106 G21LD · G21HD, WSM ENGINE Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them. 2.
Page 107 G21LD · G21HD, WSM ENGINE Correcting Valve and Valve Seat NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
Page 108 G21LD · G21HD, WSM ENGINE Free Length and Tilt of Valve Spring 1. Measure the free length (A) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring.
Page 109 G21LD · G21HD, WSM ENGINE Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. 0.25 mm Push rod runout Allowable limit 0.0098 in.
Page 110 G21LD · G21HD, WSM ENGINE Idle Gear Side Clearance 1. Set a dial indicator with its tip on the idle gear. 2. Measure the side clearance by moving the idle gear to the front and rear. 3. If the measurement exceeds the allowable limit, replace the idle gear collar.
Page 111 G21LD · G21HD, WSM ENGINE Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with a inside micrometer, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the camshaft.
Page 112 G21LD · G21HD, WSM ENGINE (C) 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.
Page 113 G21LD · G21HD, WSM ENGINE Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with a piston ring compressor and piston. 2. Measure the ring gap with a feeler gauge. 3.
Page 114 G21LD · G21HD, WSM ENGINE 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 115 G21LD · G21HD, WSM ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage (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 116 G21LD · G21HD, 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. 3.
Page 117 G21LD · G21HD, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 1. Put a strip of plastigage (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 118 G21LD · G21HD, WSM ENGINE Cylinder Wear 1. Measure the cylinder liner I.D. 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 119: Checking
G21LD · G21HD, WSM ENGINE [3] LUBRICATING SYSTEM (1) Checking Engine Oil Pressure 1. Remove the engine oil pressure switch, and set a oil pressure tester (Code No. 07916-32032). (Adapter screw size : PT 1/8) 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
Page 120 G21LD · G21HD, WSM ENGINE Clearance between Rotor and Cover 1. Put a strip of plastigage (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.
Page 121 G21LD · G21HD, WSM ENGINE [4] COOLING SYSTEM (1) Checking and Adjusting (A) Fan Belt Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and alternator pulley at specified force (98 N, 10 kgf, 22 lbs).
Page 122 G21LD · G21HD, WSM ENGINE (B) Radiator CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people. Radiator Water Leakage 1. Pour a specified amount of water into the radiator. 2.
Page 123 G21LD · G21HD, WSM ENGINE (2) Disassembling and Assembling Thermostat Assembly 1. Remove the thermostat cover mounting screws (1), and remove the thermostat cover (2). 2. Remove the thermostat assembly (4). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) to both side of the gasket (3).
Page 124 G21LD · G21HD, WSM ENGINE [5] FUEL SYSTEM (1) Checking and Adjusting (A) Injection Pump Injection Timing 1. Remove the bonnet and air cleaner. 2. Remove the muffler. 3. Remove the injection pipes and glow plugs. 4. Engage the parking brake. 5.
Page 125 G21LD · G21HD, WSM ENGINE Fuel Tightness of Pump Element 1. Remove the bonnet and air cleaner. 2. Remove the muffler. 3. Disconnect the accelerator wire. 4. Remove the air cleaner stay. 5. Remove the injection pipes and glow plugs. 6.
Page 126 G21LD · G21HD, WSM ENGINE (B) Injection Nozzle CAUTION • Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
Page 127 G21LD · G21HD, WSM ENGINE (2) Disassembling and Assembling (A) Injection Nozzle Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil. •...
Page 128 TRANSMISSION AND REAR AXLE KiSC issued 08, 2007 A...
Page 129 MECHANISM CONTENTS 1. STRUCTURE ....................2-M1 2. HYDROSTATIC TRANSMISSION ..............2-M2 [1] STRUCTURE ................... 2-M2 [2] OIL FLOW ....................2-M3 [3] BY-PASS VALVE ..................2-M4 [4] CHARGE PUMP ..................2-M5 KiSC issued 08, 2007 A...
Page 130: Structure
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE 1. STRUCTURE (1) Hydrostatic Transmission (2) Gear Section (3) Rear Axle Section (4) Differential Gear Section Section W1013364 2-M1 KiSC issued 08, 2007 A...
Page 131: Hydrostatic Transmission
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE 2. HYDROSTATIC TRANSMISSION [1] STRUCTURE (1) Charge Relief Valve (8) Cylinder Block (Pump) (15) Housing (22) Motor Shaft (2) Charge Pump Housing (9) Piston Assembly (16) Needle Bearing (23) Needle Bearing (3) Charge Pump Spacer (10) Thrust Plate (17) By-pass Valve (24) Thrust Ball Bearing...
Page 132: Oil Flow
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE [2] OIL FLOW (1) Drain Hose (4) Oil Filter Cartridge (6) Drain Hose (8) Suction Pipe (2) Rear Axle Case (5) Control Valve Adaptor (7) Rear Axle Case (9) Drain Pipe (3) Control Valve 1.
Page 133: By-Pass Valve
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE [3] BY-PASS VALVE (1) Center Section (3) Check Valve (5) By-Pass Valve (7) Orifice (2) Pump Shaft (4) Motor Shaft (6) Check Valve (8) Orifice The by-pass valve (5) is used to connect the two sides of the closed loop in the center section (1). The motor shaft (4) does not rotate when the engine is stopped or pump is not driven.
Page 134: Charge Pump
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE [4] CHARGE PUMP (1) Charge Relief Valve (5) O-ring (9) Needle Bearing (13) Dowel Pin (2) Charge Pump Housing (6) Gerotor (10) Internal Snap Ring (14) Drive Pin (3) O-ring (7) Dowel Pin (11) Oil Seal (15) Pump Shaft (4) Charge Pump Spacer...
Page 135 SERVICING CONTENTS 1. TROUBLESHOOTING ..................2-S1 2. SERVICING SPECIFICATIONS ..............2-S2 3. TIGHTENING TORQUES ................2-S3 4. CHECKING, DISASSEMBLING AND SERVICING........2-S4 [1] CHECKING AND ADJUSTING ...............2-S4 [2] DISASSEMBLING AND ASSEMBLING..........2-S6 (1) Separating Transmission ..............2-S6 (2) Separating Hydrostatic Transmission ..........2-S13 (3) Separating Transmission ..............2-S14 (4) Disassembling Transmission ............2-S15 (5) Disassembling Rear Axle ..............2-S20 (6) Disassembling Differential Gear Case ..........2-S21...
Page 136: Troubleshooting
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE 1. TROUBLESHOOTING HYDROSTATIC TRANSMISSION Reference Symptom Probable Cause Solution Page Machine Will Not Insufficient transmission fluid Fill oil to proper level G-7, G-34 Operate in Either Defective control linkage Repair or replace –...
Page 137: Servicing Specifications
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE 2. SERVICING SPECIFICATIONS Item Factory Specifications Allowable Limit Charge Relief Valve Setting pressure 0.32 to 0.41 MPa – 3.3 to 4.2 kgf/cm 47 to 60 psi Transmission Fluid Capacity 4.5 L – (Including HST and Cylinder) 4.75 U.S.qts.
Page 138: Tightening Torques
G21LD · G21HD, WSM TRANSMISSION AND REAR 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 : See page G-8.) Item N·m kgf·m ft-lbs Cam mounting nut 39.2 to 45.1 4.0 to 4.6...
Page 139: Checking, Disassembling And Servicing
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Adjusting Neutral 1. Block the front wheels with stoppers, and lift up the rear of machine with a jack. 2. Remove the left rear wheel. 3.
Page 140 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Pedal Stopper (Adjusting Maximum Forward and Reverse Traveling Speed) NOTE • This adjustment should be performed after completing the adjustment of neutral. [Forward Operation] 1. Loosen the lock nut (3) and screw back the adjusting screw (2). 2.
Page 141: Disassembling And Assembling
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE [2] DISASSEMBLING AND ASSEMBLING (1) Separating Transmission (A) Dismounting Grass Collector and Mower Dismounting Grass Collector [G21LD] 1. Pull and turn the L-pin (1) so that the spring pin can lock on the cut-out.
Page 142 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE (B) Draining Transmission Fluid Draining Transmission Fluid 1. Place an oil pan underneath the drain plug (1). 2. Remove the drain plug (1). 3. Remove the oil inlet plug (2) to completely drain the transmission fluid.
Page 143 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE (C) Separating Fender Seat 1. Disconnect the 2P connector (3) from the seat switch and fuse (4). 2. Remove the seat support mounting lock nut (1). 3. Remove the screws (5). 4. Remove the seat with seat support. 5.
Page 144 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Separating Fender 1. Remove the speed change pedal. 2. Peel the step sheet (1) halfway. 3. Remove the step support mounting screws (2). 4. Remove the step support (5) and rubber bushing (6). 5.
Page 145 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE (D) Separating Platform Connector, PTO Clutch Return Cable and Cylinder Hose 1. Disconnect the 2P connector (3) from the grass collector switch. 2. Remove the wiring (2) from the platform. 3. Disconnect the PTO clutch return cable (4). 4.
Page 146 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Brake spring, Brake Rod and Speed Change Plate 1. Remove the lock nut (5), plain washers (3), and brake spring (4). 2. Remove the brake rod (2). 3. Remove the speed change plate (1) from the speed control arm. IMPORTANT •...
Page 147 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Separating Transmission 1. Remove the universal joint mounting screws. 2. Disconnect the universal joint. 3. Remove the rear axle case mounting screws. 4. Separating the transmission from the frame. (When reassembling) • Apply grease to the splines of universal joint. •...
Page 148: Separating Hydrostatic Transmission
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Separating Hydrostatic Transmission Neutral Arm, Speed Control Arm and Hydraulic Pipes 1. Remove the neutral spring (10). 2. Remove the neutral arm assembly mounting screws (11). 3. Remove the neutral arm assembly (9). 4.
Page 149: Separating Transmission
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE (3) Separating Transmission Separating Control Valve Assembly 1. Remove the control valve assembly stay mounting screw (4). 2. Separating the control valve assembly (1) from the transmission. 3. Remove the collar (3) and O-ring (2) on the front cover. (When reassembling) •...
Page 150: Disassembling Transmission
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE (4) Disassembling Transmission (A) Hydrostatic Transmission NOTE • Work in a clean area. • Replace any damaged parts that could cause internal leakage. • Do not use grit paper, files or grinders on finished surface. •...
Page 151 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Gerotor 1. Remove the gerotors (2). 2. Draw out the drive pin (3) on the pump shaft (4). 3. Draw out the dowel pins (1). (When reassembling) • Apply clean fluid to the both sides of the gerotor. (1) Dowel Pins (3) Drive Pin (2) Gerotors...
Page 152 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Oil Seal and Needle Bearing 1. Pry the oil seal (1) off with a screwdriver. 2. Remove the needle bearings (2), (3). NOTE • Take care not to damage the center section. (When reassembling) •...
Page 153 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Swashplate 1. Remove the swashplate (1) from the housing. 2. Remove the thrust plate (4), thrust roller bearing (3) and thrust washer (2) from the Swashplate. (When reassembling) • Apply clean fluid to the thrust washer and thrust plate. •...
Page 154 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Trunnion Arm and Journal Bearing 1. Remove the trunnion arm (1). 2. Pry the oil seal (3) off with a screwdriver. 3. Press out the journal bearing (2). (When reassembling) • Apply clean field to the journal bearing. NOTE •...
Page 155: Disassembling Rear Axle
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Brake Shaft, Idle Gear Shaft and Bevel Pinion Shaft 1. Separate the front cover (1) from the transmission case (5). 2. Remove the brake shaft assembly. 3. Remove the idle gear shaft assembly. 4.
Page 156: Disassembling Differential Gear Case
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE (6) Disassembling Differential Gear Case Differential Gear 1. Remove the 20T spiral bevel gear (5) with ball bearing (6) and ball bearing (9) by puller. 2. Tap out the spring pin (10) from 20T bevel gear side. 3.
Page 157: Servicing
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE [3] SERVICING (1) Hydostatic Transmission Auxiliary Pump 1. Check the charge pump housing (2) and the gerotor assembly (1) for scratches and wear. 2. If scratch or worn, replace the charge pump complete assembly. (1) Gerotor Assembly (2) Charge Pump Housing W1047558...
Page 158 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Center Section 1. Check the surface of center section (1) for scratches and wear. 2. If scratch or wear, replace the HST assembly. 3. Check the needle bearing (2) for wear. 4. If worn, replace the needle bearing. NOTE •...
Page 159: Transmission
G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Charge Relief Valve 1. Check the charge relief cone and the seat in the auxiliary pump housing for damage. 2. Check the spring for breakage and wear. 3. If anything unusual, replace them. (1) Charge Relief Cone (3) Relief Plug (2) Spring...
Page 160 G21LD · G21HD, WSM TRANSMISSION AND REAR AXLE Backlash between Differential Pinion and Differential Side Gear 1. Set a dial gauge (lever type) on a tooth of the differential pinion. 2. Fix the differential side gear, and move the differential pinion to measure the backlash.
Page 161 BRAKES KiSC issued 08, 2007 A...
Page 162 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) Parking Brake ..................3-S4 (2) Pedal System Complete ..............3-S6 (3) Brake Assembly ..................3-S9 [3] SERVICING ....................3-S10 KiSC issued 08, 2007 A...
Page 163: Troubleshooting
G21LD · G21HD, WSM BRAKES 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Insufficient Braking Excessive brake pedal play Adjust 3-S4 Force Brake shoe worn Replace 3-S10 Brake drum worn Replace 3-S10 Grease or oil on brake shoe Replace 3-S10 Brake fulcrum shaft worn Replace 3-S9...
Page 164: Servicing Specifications
G21LD · G21HD, WSM BRAKES 2. SERVICING SPECIFICATIONS Item Factory Specifications Allowable Limit −1.0 to 0.0 mm Brake Spring to Plain Washer Clearance – −0.04 to 0.00 in. Brake Lining Thickness 9.0 mm 7.5 mm 0.35 in. 0.30 in. Brake Drum I.D.
Page 165: Tightening Torques
G21LD · G21HD, 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 : See page G-8.) Item N·m kgf·m ft-lbs Steering wheel mounting nut 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1...
Page 166: Checking, Disassembling And Servicing
G21LD · G21HD, WSM BRAKES 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Brake Pedal Play 1. Keep the brake return spring (1) off position. 2. Keep the brake pedal in return position. 3. Gently press the tip of the transaxle’s brake actuating arm (5) toward the pedal.
Page 167 G21LD · G21HD, WSM BRAKES Parking Lock Pedal 1. Remove the parking lock pedal mounting nut (2). 2. Remove the parking lock pedal (1) from the brake lock. (When reassembling) IMPORTANT • Using the oval hole, make such adjustment that the parking lock pedal be kept out of contact with the panel over the entire stroke.
Page 168: Pedal System Complete
G21LD · G21HD, WSM BRAKES Separating Panel 1. Remove the speed change pedal. 2. Peel the step sheet (2) halfway. 3. Remove the panel mounting screws (1). 4. Separate the panel (3). (When reassembling) • Clean up the step sheet and the step. Apply instantaneous adhesive on the step sheet as shown in the figure.
Page 169 G21LD · G21HD, WSM BRAKES Dismounting Grass Collector [G21HD] 1. Refer to "HIGH DUMP GRASS COLLECTOR" section. W1016642 Discharging Plate and Discharge Duct 1. Remove the discharging plate (1). 2. Remove the discharge duct (3) from the platform (5). (1) Discharging Plate (4) M8 Bolt (2) M6 Bolt (5) Platform...
Page 170 G21LD · G21HD, WSM BRAKES Separating Fender 1. Remove the speed change pedal. 2. Peel the step sheet (1) halfway. 3. Remove the step support mounting screws (2). 4. Remove the step support (5) and rubber bushing (6). 5. Remove the fuel cap (4). 6.
Page 171: Brake Assembly
G21LD · G21HD, WSM BRAKES Separating Pedal System Complete 1. Remove the return spring (3). 2. Pull out the cotter pin (7). 3. Remove the brake rod 2 (6) and plain washer. 4. Disconnect 4P connector (5) from the brake switch (4). 5.
Page 172: Servicing
G21LD · G21HD, WSM BRAKES [3] SERVICING Brake Lining Wear 1. Measure the brake lining thickness with vernier caliper. 2. If the measurement is less than the allowable limit, replace the brake shoes. 9.0 mm Factory spec. 0.35 in. Brake lining thickness 7.5 mm Allowable limit 0.30 in.
Page 173 FRONT AXLE KiSC issued 08, 2007 A...
Page 174 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] DISASSEMBLING AND ASSEMBLING..........4-S5 (1) Separating Front Axle Assembly............4-S5 (2) Disassembling Front Axle ..............4-S6 (3) Disassembling Front Axle Support Assembly ........4-S7 [3] SERVICING ....................4-S7 KiSC issued 08, 2007 A...
Page 175: Troubleshooting
G21LD · G21HD, WSM FRONT AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Front Wheels Improper toe-in adjustment Adjust 4-S4 Wander to Right or Uneven tire pressure Adjust G-23 Left Worn kingpin Replace front axle 4-S7 assembly Excessive front axle end play Adjust 4-S4 Front Wheels...
Page 176: Servicing Specifications
G21LD · G21HD, WSM FRONT AXLE 2. SERVICING SPECIFICATIONS Item Factory Specifications Allowable Limit Front Wheel Alignment Toe-in 0 to 10 mm – 0 to 0.394 in. Front Axle End Play 0.1 to 0.4 mm 1.0 mm 0.004 to 0.016 in. 0.039 in.
Page 177: Tightening Torques
G21LD · G21HD, 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 : See page G-8.) Item N·m kgf·m ft-lbs Rod end mounting nut 108.8 to 130.3 11.1 to 13.3 80.3 to 96.2...
Page 178: Checking, Disassembling And Servicing
G21LD · G21HD, WSM FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Toe-in 1. Inflate the front tires to the specified pressure. 2. Turn the front wheels straight ahead, and measure the toe-in (B- 3. If the measurement is not within the factory specifications, change the tie-rod length to adjust.
Page 179: Disassembling And Assembling
G21LD · G21HD, WSM FRONT AXLE [2] DISASSEMBLING AND ASSEMBLING (1) Separating Front Axle Assembly Dismount Mower 1. Refer to “MOWER” section. W1011444 Battery and Bonnet 1. Turn the main switch off. 2. Remove the radiator screen (2) 3. Disconnect the negative cable (1) from the battery. 4.
Page 180: Disassembling Front Axle
G21LD · G21HD, WSM FRONT AXLE Separating Front Axle Assembly 1. Remove the rod end mounting nut (1). 2. Support the frame with jacks. 3. Remove the front axle support mounting screws (3). 4. Draw out the front axle support assembly (2) forward. 5.
Page 181: Disassembling Front Axle Support Assembly
G21LD · G21HD, WSM FRONT AXLE Knuckle Arm and Kingpin 1. Remove the knuckle arm mounting bolt (3), spring washer and nut (5). 2. Remove the knuckle arm (4) and the kingpin (L.H.) (6). 3. Remove the external snap ring (1) and kingpin (R.H.) (2). (When reassembling) •...
Page 182 STEERING KiSC issued 08, 2007 A...
Page 183 MECHANISM CONTENTS 1. SYSTEM CONFIGURATION ................ 5-M1 2. CONSTRUCTION AND FUNCTION OF MAIN COMPONENTS ....5-M2 [1] POWER STEERING ASSEMBLY............5-M2 (1) Construction of Power Steering Assembly......... 5-M2 (2) Torque Sensor ................... 5-M3 (3) Motor ....................5-M4 [2] EPS CONTROLLER ................5-M5 (1) Basic Control..................
Page 184: System Configuration
G21LD · G21HD, WSM STEERING 1. SYSTEM CONFIGURATION (1) Power Steering Assembly A : Engine Revolution Signal D : Battery (2) Power Steering Gear Case (Oil Switch) E : EPS Controller B : Warning Lamp F : Steering Torque Signal C : Connector for Servicing G : Motor Driving Current The steering system employs an electric power steering (EPS).
Page 185: Construction And Function Of Main Components
G21LD · G21HD, WSM STEERING 2. CONSTRUCTION AND FUNCTION OF MAIN COMPONENTS [1] POWER STEERING ASSEMBLY (1) Construction of Power Steering Assembly The power steering assembly is mainly composed of an input shaft (1), output shaft (in the gear case side) (5), torsion bar (2) for connecting these shafts, torque sensor (3) for detecting the twisting of the torsion bar, and motor (4) for generating assisting power.
Page 186: Torque Sensor
G21LD · G21HD, WSM STEERING (2) Torque Sensor Construction The torque sensor senses the steering power and rotating direction, convert them into a voltage signal and outputs the signal to the EPS controller. The torque sensor section is composed of a slider (3), detecting ring and detecting coil (4) (slider and detecting ring are combined).
Page 187: Motor
G21LD · G21HD, WSM STEERING (3) Motor The motor is installed on the steering column (4). It is composed of a worm gear (1) and direct current motor (3). The worm gear (1) is engaged with the helical gear of the worm wheel (2), reducing and transmitting the motor revolution to the worm wheel.
Page 188: Eps Controller
G21LD · G21HD, WSM STEERING [2] EPS CONTROLLER The EPS controller detects an electric signal from the oil switch, activates the system after the engine starting and controls the motor according to an input signal from the torque sensor. The EPS controller has a self-diagnosis function. (1) Basic Control 1.
Page 189: Failure Diagnosis Function
G21LD · G21HD, WSM STEERING Failure Diagnosis Function The EPS controller monitors the input/output data and motor driving current. If an abnormal condition occurs in the system, the EPS controller stops the system and makes the warning lamp go on. In this case, the normal manual steering operation is applied and the abnormal condition is coded and stored in the failure diagnosis circuit.
Page 190 SERVICING CONTENTS 1. CAUTIONARY INSTRUCTIONS BEFORE STARTING FAILURE DIAGNOSIS ....................5-S1 2. TROUBLESHOOTING ..................5-S2 [1] TROUBLESHOOTING BASED ON EACH SYMPTOM ......5-S2 [2] TROUBLESHOOTING BASED ON ERROR CODE ......5-S3 3. SERVICING SPECIFICATIONS ..............5-S6 4. TIGHTENING TORQUES ................5-S7 5. CHECKING, DISASSEMBLING AND SERVICING.........5-S8 [1] CHECKING AND ADJUSTING ...............5-S8 (1) Warning Lamp..................5-S8 (2) Torque Sensor Cable................5-S10...
Page 191: Cautionary Instructions Before Starting Failure Diagnosis
G21LD · G21HD, WSM STEERING 1. CAUTIONARY INSTRUCTIONS BEFORE STARTING FAILURE DIAGNOSIS 1. Self-diagnosis function The EPS controller has a self-diagnosis function. If the EPS controller detects an abnormal condition in the system, it performs the following. • Making the warning lamp go on. •...
Page 192: Troubleshooting
G21LD · G21HD, WSM STEERING 2. TROUBLESHOOTING [1] TROUBLESHOOTING BASED ON EACH SYMPTOM Reference Symptom Probable Cause Solution Page Can not steer Wiring harness disconnected or immproperly Repair or replace – connected Broken power steering assembly Replace 5-S17 Broken power steering gear case Replace 5-S20 Broken power steering linkage...
Page 193: Troubleshooting Based On Error Code
G21LD · G21HD, WSM STEERING [2] TROUBLESHOOTING BASED ON ERROR CODE EPS SYSTEM TROUBLESHOOTING PROCEDURE Reference Symptom Probable Cause Solution Page Error Code 02 4P connector disconnected Connect the 5-S13 connector 30A fuse blown Replace the fuse 5-S24 Harness of 4P connector broken or Replace or repair 5-S13 disconnected...
Page 194 G21LD · G21HD, WSM STEERING Reference Symptom Probable Cause Solution Page Error Code 12 and 13 Perform fail-safe history erasing before checking the following probable causes. Torque sensor coupler water-damaged Clean and dry the 5-S13 inside of the coupler 16P coupler water-damaged Clean and dry the 5-S13 inside of the coupler...
Page 195 G21LD · G21HD, WSM STEERING Reference Symptom Probable Cause Solution Page Error Code 32 Set the right and left steering force of EPS controller, start the engine, then check and solve EPS controller is normal but error remains Repeat turning ON 5-S13 and OFF the engine and check if the error...
Page 196: Servicing Specifications
G21LD · G21HD, WSM STEERING 3. SERVICING SPECIFICATIONS Item Factory Specifications Allowable Limit Steering Wheel Play Less than 15 mm – Less than 0.59 in. Throttle Lever Operating Force 30 to 50 N – 3.1 to 5.1 kgf 66 to 110 lbs Difference in Steering Force of Steering Wheel between Right Less than 25 % –...
Page 197: Tightening Torques
G21LD · G21HD, WSM STEERING 4. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-8.) Item N·m kgf·m ft-lbs Steering wheel mounting nut 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1...
Page 198: Checking, Disassembling And Servicing
G21LD · G21HD, WSM STEERING 5. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Warning Lamp Checking of EPS System When the main switch is set to the ON position (B), the EPS controller detects the voltage signal from the oil switch (1) and makes the warning lamp (2) glow for 5 seconds.
Page 199 G21LD · G21HD, WSM STEERING Checking of Warning Lamp • The fail-safe codes recorded in the controller start flashing in the ascending order. (There may be just one code.) • After one cycle of the flashing codes, there is a longer period of no-flash time.
Page 200: Torque Sensor Cable
G21LD · G21HD, WSM STEERING (2) Torque Sensor Cable Checking Torque Sensor Cable 1. Keep the main switch at ON position (B) and disconnect the 1P connector (1) from the oil switch. Check to see if the power steering system works. (Do not start the engine.) 2.
Page 201: Torque Sensor 3P Connector
G21LD · G21HD, WSM STEERING (3) Torque Sensor 3P Connector Checking Torque Sensor 3P Connector IMPORTANT • While disassembling, handle the power steering assembly, controller and wire harness with enough care. disconnect the steering wheel, be sure to use the steering wheel puller (1) and puller adaptor (2), never any hammer.
Page 202: Torque Sensor 3P Connector Terminal
G21LD · G21HD, WSM STEERING (4) Torque sensor 3P Connector Terminal Checking the Resistance of the Torque Sensor 3 Connector Terminal 1. Using a circuit tester, measure the terminal resistance between the red and black wires, as well as that between the white and black wires of torque sensor 3P connector (1).
Page 203: Wire Harness
G21LD · G21HD, WSM STEERING Wire Harness Checking the Torque Sensor Connectors for Poor Contact 1. Check the torque sensor 3P connector (1) and related parts for the following defects. - Terminal off position - Terminal deformed or crushed - Female terminal too open: Improper connection (6) - Rubber sealing missing - Broken wire or sheath IMPORTANT...
Page 204: Checking Voltage
G21LD · G21HD, WSM STEERING (6) Checking Voltage Checking the Battery Terminal Voltage 1. Measure the voltage between the positive (+) and negative (-) battery terminals (1), (2). 2. If the voltage is out of factory specification, recharge the battery and go to the following checking.
Page 205: Error Codes And Defective Sections
G21LD · G21HD, WSM STEERING Checking Continuity between the Torque Sensor 3P Connector and EPS Controller 16P Connector 1. Using a circuit tester, check continuity between the terminals. Refer to the figure below. Resistance 0 Ω Factory spec. (between same color terminal) ∞...
Page 206: Steering Wheel Play
G21LD · G21HD, WSM STEERING (8) Steering Wheel Play 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 specification, replace the steering shaft and sector gear.
Page 207: Disassembling And Assembling
G21LD · G21HD, WSM STEERING [2] DISASSEMBLING AND ASSEMBLING (1) Separating Power Steering Assembly and EPS Controller Battery and Bonnet 1. Turn the main switch off. 2. Remove the radiator screen (1). 3. Disconnect the negative cable from the battery. 4.
Page 208 G21LD · G21HD, WSM STEERING Steering Wheel 1. Remove the grip of the throttle lever (1). 2. Remove the steering pad and remove the steering wheel mounting nut. 3. Remove the steering wheel using the steering wheel puller (Code. No. 07916-51090) and steering wheel puller adaptor. IMPORTANT •...
Page 209 G21LD · G21HD, WSM STEERING Throttle Lever Assembly and Power Steering Assembly 1. Remove the throttle lever assembly (1). 2. Remove the fuse plate (2). 3. Remove the universal joint mounting screw. 4. Remove the power steering assembly mounting screws (3). 5.
Page 210: Power Steering Gear Case
G21LD · G21HD, WSM STEERING Power Steering Gear Case Power Steering Gear Case 1. Remove the rod end mounting nut. 2. Remove the rod end (1). 3. Remove the power steering gear case mounting screws (4). 4. Remove the power steering gear case (3) with the rod end. (When reassembling) •...
Page 211: Servicing
G21LD · G21HD, WSM STEERING [3] SERVICING EPS Controller Right and Left Steering Force Setting at Neutral Position IMPORTANT • If this setting procedure is wrongly taken, the neutral position cannot be programmed in the controller. To take the procedure over again, be sure to go back to Setting Method No.
Page 212 G21LD · G21HD, WSM STEERING Erasing Fail Safe History IMPORTANT • Do not start the engine while erasing. • If the code erasing procedure is wrongly taken, the code cannot be erased. To take the procedure over again, go back to Setting Method No. 3 (with the main switch at OFF and the service connector fit in position).
Page 213 G21LD · G21HD, WSM STEERING Checking of Steering Mechanical System Checking of Power Steering Assembly 1. Remove the steering wheel. 2. Remove the power steering assembly. 3. Remove the universal joint. 4. Install the power steering assembly. 5. Attach a torque wrench to the steering shaft. 6.
Page 214 G21LD · G21HD, WSM STEERING Checking EPS Controller for Trouble 1. To see if the EPS controller is in trouble, disconnect the 4P (2) and 16P (3) connectors from the controller. Without the controller, set the main switch to “ON” position (B) and see if the IG/M fuse (10A) (c) blows out.
Page 215: Eps Check Sheet
G21LD · G21HD, WSM STEERING (1) EPS Check Sheet Check Sheet 1 : When steering wheel rotates to one direction, check and take measures in order as follows. Tire Straight 1. Park the machine on level ground. 2. Jack up or lift up the front frame. 3.
Page 216 G21LD · G21HD, WSM STEERING Checking 16P connector 1. Check 16P connector (1). 2. If the condition of steering wheel does not improve, repair the terminal. 3. If the condition of steering wheel does not improve, check torque sensor 3P connector terminal resistance. (See below.) (1) 16P Connector L : 0 to 0.1 mm (0 to 0.0039 in.) (2) Black / White Wire...
Page 217 G21LD · G21HD, WSM STEERING Check Sheet 2 : When steering turning force in heavy. Checking 16P Connector 1. Check 16P connector (1). 2. If the condition of steering wheel does not improve, repair the terminal. (1) 16P Connector L : 0 to 0.1 mm (0 to 0.0039 in.) (2) Black / White Wire (3) Red Wire (4) White Wire...
Page 218 G21LD · G21HD, WSM STEERING Resetting Neutral and Erasing Memory 1. Turn ON the main switch. 2. Disconnect the connector for servicing (1). 3. Disconnect the oil switch 1P connector (2). 4. Turn OFF the main switch. 5. Connect the connector for servicing (1). 6.
Page 219 HYDRAULIC SYSTEM KiSC issued 08, 2007 A...
Page 220 MECHANISM CONTENTS 1. HYDRAULIC CIRCUIT .................. 6-M1 [1] G21LD (LOW DUMP)................6-M1 [2] G21HD (HIGH DUMP) ................6-M2 2. RELIEF VALVE (G21LD, G21HD) ............... 6-M3 3. MOWER LIFTING CIRCUIT (G21LD, G21HD) ........... 6-M3 [1] NEUTRAL ....................6-M3 [2] UP ......................6-M4 [3] DOWN......................
Page 221: Hydraulic Circuit
G21LD · G21HD, WSM HYDRAULIC SYSTEM 1. HYDRAULIC CIRCUIT [1] G21LD (LOW DUMP) (1) Transmission Case (7) Filter Relief Valve A : Port A P1 :Pump Port (2) Oil Strainer (8) Oil Filter Cartridge B : Port B DR1 :Drain Port (3) Charge Pump (9) Control Valve C : Up...
Page 222: G21Hd (High Dump)
G21LD · G21HD, WSM HYDRAULIC SYSTEM [2] G21HD (HIGH DUMP) (1) Transmission Case (2) Oil Strainer (3) Charge Pump (4) Hydrostatic Transmission (HST) (5) Main Relief Valve (6) Valve (for Mower Lift Cylinder) (7) Filter Relief Valve (8) Oil Filter Cartridge (9) Control Valve (10) Mower Lift Cylinder (11) Valve (for High Dump Lift...
Page 223: Relief Valve (G21Ld, G21Hd)
G21LD · G21HD, WSM HYDRAULIC SYSTEM 2. RELIEF VALVE (G21LD, G21HD) This machine is equipped with two direct-acting relief valves (11), (12). The main relief valve (12) serves to control the pressures of the mower lift cylinder and grass collector cylinder and to protect the entire hydraulic system against damage.
Page 224: Down
G21LD · G21HD, WSM HYDRAULIC SYSTEM [2] UP Move the mower lifting lever to the “UP” position, and the spool 1 (for mower cylinder) (1) is activated in the direction shown in the figure. The oil coming from port P1 flows through port CL into the mower lift cylinder.
Page 225: Neutral
G21LD · G21HD, WSM HYDRAULIC SYSTEM 4. GRASS COLLECTOR LIFT CYLINDER CIRCUIT (G21LD) Suppose that the mower lifting spool 1 (1) is in the neutral position. [1] NEUTRAL The oil coming from port P1 flows to port T1. Port A and B that are connected with the grass collector lift cylinder are kept closed by the spool 2 (for grass collector lift cylinder) (2).
Page 226: Close
G21LD · G21HD, WSM HYDRAULIC SYSTEM [3] CLOSE Move the grass collector dumping lever to the “DOWN” position, and the spool 2 (for grass collector lift cylinder) (1) is activated in the direction shown in the figure. The oil coming from port P1 flows through port A into the grass collector lift cylinder.
Page 227: Neutral
G21LD · G21HD, WSM HYDRAULIC SYSTEM 5. GRASS COLLECTOR LIFT CYLINDER WITH AUXILIARY CONTROL VALVE CIRCUIT (G21HD) [1] NEUTRAL (1) Spool 1 (2) Packing (3) Plain Washer (4) Return Spring (5) O-Ring (6) Collar (7) Plain Washer (8) External Snap Ring (9) Plug (10) Spool 2 DA: Dump Port A...
Page 228: Down
G21LD · G21HD, WSM HYDRAULIC SYSTEM [3] DOWN (1) Spool 2 (for Lift Cylinder) SA : Lift Port A SB : Lift Port B PB1 : Power Beyond Port RT2 : Return Port (b) Down W1013825 Move the grass container control lever to the “DOWN” position, the spool 2 (1) is activated in the direction shown in the figure.
Page 229: Neutral
G21LD · G21HD, WSM HYDRAULIC SYSTEM 6. GRASS COLLECTOR ROTATING CYLINDER WITH AUXILIARY CONTROL VALVE CIRCUIT (G21HD) [1] NEUTRAL (1) Spool 1 (2) Packing (3) Plain Washer (4) Return Spring (5) O-Ring (6) Collar (7) Plain Washer (8) External Snap Ring (9) Plug (10) Spool 2 DA: Dump Port A...
Page 230: Rotate (Tilt Backward)
G21LD · G21HD, WSM HYDRAULIC SYSTEM [2] ROTATE (TILT BACKWARD) (1) Spool 2 (for Dump Cylinder) DA: Dump Port A DB: Dump Port B : Power Beyond Port : Return Port (a) Tilt Backward W1013999 Move the grass container control lever to the “TILT BACKWARD” position, the spool 1 (1) is activated in the direction shown in the figure.
Page 231: Return (Tilt Forward)
G21LD · G21HD, WSM HYDRAULIC SYSTEM [3] RETURN (TILT FORWARD) (1) Spool 2 (for Rotating Cylinder) DA: Dump Port A DB: Dump Port B : Power Beyond Port : Return Port (b) Tilt Forward W1014125 Move the grass container control lever to the “TILT FORWARD” position, the spool 1 (1) is activated in the direction shown in the figure.
Page 232: Grass Collector Lift Cylinder (G21Ld)
G21LD · G21HD, WSM HYDRAULIC SYSTEM 7. GRASS COLLECTOR LIFT CYLINDER (G21LD) (1) Nut (3) Cylinder Tube (5) Piston Rod B : Rod O.D. (2) Piston (4) Head A : Cylinder I.D. C : Stroke The grass collector cylinder consists of a head (4), cylinder tube (3), piston rod (5), piston (2), and other parts as shown in the above figure.
Page 233: Grass Collector Lift Cylinder And Rotating Cylinder (G21Hd)
G21LD · G21HD, WSM HYDRAULIC SYSTEM 8. GRASS COLLECTOR LIFT CYLINDER AND ROTATING CYLINDER (G21HD) (1) Piston Rod (3) Cylinder Tube (5) Nut B : Rod O.D. (2) Head (4) Piston A : Cylinder I.D. C : Stroke Both the grass collector lift cylinder and rotating cylinder consist of a head (2), cylinder tube (3), piston rod (1), piston (4) and other parts as shown in the figure above.
Page 234 SERVICING CONTENTS 1. TROUBLESHOOTING ..................6-S1 2. SERVICING SPECIFICATIONS ..............6-S3 3. TIGHTENING TORQUES ................6-S4 4. CHECKING, DISASSEMBLING AND SERVICING........6-S5 [1] CONTROL VALVE (G21LD, G21HD) ............6-S5 (1) Checking and Adjusting ..............6-S5 (2) Disassembling and Assembling ............6-S7 [2] AUXILIARY CONTROL VALVE (G21HD)..........6-S14 (1) Preparation for Disassembly.............6-S14 (2) Disassembling and Assembling ............6-S15 [3] CYLINDER ....................6-S16 (1) Mower Lift Cylinder (G21LD, G21HD) ..........6-S16...
Page 235: Troubleshooting
G21LD · G21HD, WSM HYDRAULIC SYSTEM 1. TROUBLESHOOTING G21LD Reference Symptom Probable Cause Solution Page Mower Does Not Main relief valve spring damaged Replace 6-S5 ,S12 “RISE” Main relief valve setting pressure too low Adjust 6-S5 Charge pump defective Replace 2-S15 Mower lift cylinder damaged Replace...
Page 236 G21LD · G21HD, WSM HYDRAULIC SYSTEM G21HD Reference Symptom Probable Cause Solution Page Mower Does Not Main relief valve spring damaged Replace 6-S5, S12 “RISE” Main relief valve setting pressure too low Adjust 6-S5 Charge pump defective Replace 2-S15 Mower lift cylinder damaged Replace 6-S16 Oil strainer clogged...
Page 237: Servicing Specifications
G21LD · G21HD, WSM HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specifications Allowable Limit Main Relief Valve Setting Pressure 2.94 to 3.43 MPa – 30.0 to 35.0 kgf/cm 426 to 497 psi Filter Relief Valve Setting Pressure 1.96 to 2.45 MPa –...
Page 238 G21LD · G21HD, WSM HYDRAULIC 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 : See page G-8.) G21LD Item N·m kgf·m ft-lbs Cam mounting nut 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3...
Page 239: Checking, Disassembling And Servicing
G21LD · G21HD, WSM HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CONTROL VALVE (G21LD, G21HD) (1) Checking and Adjusting Main Relief Valve Setting Pressure CAUTION • When checking, park the tractor on flat ground, apply the parking brake. 1. Disconnect the cylinder hose from the mower lift cylinder. 2.
Page 240 G21LD · G21HD, WSM HYDRAULIC SYSTEM Filter Relief Valve Setting Pressure CAUTION • When checking, park the tractor on flat ground, apply the parking brake. 1. Remove the oil filter cartridge. 2. Set the flange for control valve (see page G-54), O-rings, thread joint (Code No.: 07916-50341), cable (Code No.: 07916-50331), thread joint (Code No.: 07916-50401) and pressure gauge 50 (Code No.: 07916-52961).
Page 241: Disassembling And Assembling
G21LD · G21HD, WSM HYDRAULIC SYSTEM (2) Disassembling and Assembling Dismounting Grass Collector [G21LD] 1. Pull and turn the L-pin (1) so that the spring pin can lock on the cut-out. 2. Do the same on the opposite. 3. Remove the hopper (2). (1) L-pin (A) Lock (2) Hopper...
Page 242 G21LD · G21HD, WSM HYDRAULIC SYSTEM Draining Transmission Fluid 1. Place an oil pan underneath the drain plug (1). 2. Remove the drain plug (1). 3. Remove the oil inlet plug (2) to completely drain the transmission fluid. 4. After draining, screw in the drain plug (1) and the oil inlet plug (2). (When refilling) •...
Page 243 G21LD · G21HD, WSM HYDRAULIC SYSTEM Seat 1. Disconnect the 2P connector (3) from the seat switch and fuse (4). 2. Remove the seat support mounting lock nut (1). 3. Remove the screws (5). 4. Remove the seat with seat support. 5.
Page 244 G21LD · G21HD, WSM HYDRAULIC SYSTEM Separating Fender 1. Remove the speed change pedal. 2. Peel the step sheet (1) halfway. 3. Remove the step support mounting screws (2). 4. Remove the step support (5) and rubber bushing (6). 5. Remove the fuel cap (4). 6.
Page 245 G21LD · G21HD, WSM HYDRAULIC SYSTEM Separating Platform 1. Remove the platform mounting nuts and bolts (1). 2. Remove the platform the frame. 48.0 to 55.9 N·m Platform mounting nut and Tightening torque 4.9 to 5.7 kgf·m bolt 35.4 to 41.2 ft-lbs (1) Platform Mounting Nut and Bolt W1011920 Separating Control Valve Assembly...
Page 246 G21LD · G21HD, WSM HYDRAULIC SYSTEM Adapter, Plug and Spool 1. Remove adaptors. 2. Remove the plug. 3. Draw out the spool assembly. (When reassembling) • Take care not to damage the O-rings. • Install the adapters as shown in the figure. 35.3 N·m Tightening torque Adapter...
Page 247 G21LD · G21HD, WSM HYDRAULIC SYSTEM Relief Valve 1. Remove the bolt (1). 2. Remove the shims (3), washer with rubber (2), spring (4) and steel ball (5). 3. Remove the plug (10). 4. Remove the shims (9), O-ring (6), spring (8) and poppet (7). (When reassembling) •...
Page 248: Auxiliary Control Valve (G21Hd)
G21LD · G21HD, WSM HYDRAULIC SYSTEM [2] AUXILIARY CONTROL VALVE (G21HD) (1) Preparation for Disassembly Preparation for Disassembly 1. Remove the rear-left wheel and support the machine. 2. Lift and support the grass collector (1) as shown in figure. 3. Apply parking break and chock the front wheels. WARNING •...
Page 249: Disassembling And Assembling
G21LD · G21HD, WSM HYDRAULIC SYSTEM Auxiliary Control Valve (High Dump Control Valve) 1. Unscrew the auxiliary control valve mounting screw (2) and (3). 2. Remove the auxiliary control valve (1). 3. Remove the adaptors. (When reassembling) • Assemble the auxiliary control valve in parallel to valve stay (4). •...
Page 250: Cylinder
G21LD · G21HD, WSM HYDRAULIC SYSTEM [3] CYLINDER (1) Mower Lift Cylinder (G21LD, G21HD) Separating Mower Lift Cylinder 1. Disconnect the mower lift cylinder hose (2). 2. Pull out the cotter pins (4). 3. Separate the mower lift cylinder (3) from the frame. 4.
Page 251 G21LD · G21HD, WSM HYDRAULIC SYSTEM Piston Rod Assembly 1. Drain hydraulic oil from the cylinder, and secure the tube end of the cylinder in a vise. 2. Push the flange of the cylinder tube out of the groove of the cylinder head.
Page 252: Grass Collector Cylinder (G21Hd)
G21LD · G21HD, WSM HYDRAULIC SYSTEM Installing Cylinder Head Seal NOTE • The cylinder head seal doesn't need any particular tool to install. 1. Clean all components and check if anything is inside the groove. 2. Make sure the wiper seal (1) sliding surfaces are clean and without damage.
Page 253 G21LD · G21HD, WSM HYDRAULIC SYSTEM Rotating Cylinder Cover 1. Remove the cylinder cover (1). (1) Cylinder Cover Rotating Cylinder 1. Disconnect the hydraulic hose (4) and (5). 2. Remove the rotating cylinder mounting clevis pin (1) and (3). 3. Remove the rotating cylinder (2). 4.
Page 254 G21LD · G21HD, WSM HYDRAULIC SYSTEM Cylinder Head, Piston and Nut 1. Secure the rod end in a vise. 2. Unscrew the lock nut (4). 3. Remove the piston (3) and cylinder head (2) from the piston rod (1). (When reassembling) •...
Page 255: Arrangement Of Hydraulic Hoses (G21Hd)
G21LD · G21HD, WSM HYDRAULIC SYSTEM (4) Arrangement of Hydraulic Hoses (G21HD) Hoses 1. Connect the hoses with properly routing as shown in figures. 2. The hose PB (2) through the hole (1). 3. The hoses (6)and (5) to the LH lift cylinder are through the hole (1) and between hose SA (4), SB (3) and DA (7), DB (8) as shown in figure.
Page 256: Mower Lift Linkage (G21Ld, G21Hd)
G21LD · G21HD, WSM HYDRAULIC SYSTEM [4] MOWER LIFT LINKAGE (G21LD, G21HD) (1) Checking and Adjusting Clearance between Rear Link and Frame Stopper 1. Lift the rear link assembly (1) to the highest position. 2. Measure the clearance (L) between the rear link assembly and frame stopper (2).
Page 257 G21LD · G21HD, WSM HYDRAULIC SYSTEM (2) Disassembling and Assembling Upper Lift Link and Rear Link Assembly 1. Pull out the rue ring cotters (3) and plain washers. 2. Remove the upper lift links (4). 3. Pull out the cotter pin (1) and plain washer. 4.
Page 258 PTO SYSTEM KiSC issued 08, 2007 A...
Page 259 SERVICING CONTENTS 1. TROUBLESHOOTING ..................7-S1 2. SERVICING SPECIFICATIONS ..............7-S2 3. CHECKING, DISASSEMBLING AND SERVICING........7-S3 [1] CHECKING AND ADJUSTING ...............7-S3 [2] DISASSEMBLING AND ASSEMBLING..........7-S5 [3] SERVICING ....................7-S6 KiSC issued 08, 2007 A...
Page 260 G21LD · G21HD, WSM PTO SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Loss of Power Weakened or broken PTO clutch spring Replace 7-S5 Improper front PTO belt tension Readjust 7-S3 Improper front PTO brake setting Readjust 7-S3 Worn or damaged front PTO belt Replace 7-S5 Front PTO Noisy...
Page 261 G21LD · G21HD, WSM PTO SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specifications Allowable Limit PTO Clutch Spring Length 88.0 to 89.0 mm – 3.47 to 3.54 in. Tension Arm to Tip of Adjusting Screw Clearance 3.0 to 4.0 mm – 0.12 to 0.16 in.
Page 262: Checking And Adjusting
G21LD · G21HD, WSM PTO SYSTEM 3. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING PTO Belt Tension 1. Place the machine on level ground, and stop the engine. 2. Set the PTO clutch lever to “ENGAGE” position. 3. Measure the length (L) of PTO clutch spring (2). 4.
Page 263 G21LD · G21HD, WSM PTO SYSTEM Adjusting Belt Stay 1. Place the machine on level ground, and stop the engine. 2. Set the PTO clutch lever to “ENGAGE” position. 3. Measure the clearance (L) between the belt stay (3) and front PTO belt (1).
Page 264 G21LD · G21HD, WSM PTO SYSTEM [2] DISASSEMBLING AND ASSEMBLING Battery and Bonnet 1. Turn the main switch off. 2. Remove the radiator screen (1). 3. Disconnect the negative cable from the battery. 4. Disconnect the 1P connectors (3) from the head light (2). 5.
Page 265 G21LD · G21HD, WSM PTO SYSTEM [3] SERVICING Adjusting PTO Clutch Return Cable 1. Place the machine on level ground, and stop the engine. 2. Set the PTO clutch lever to “ENGAGE” position. 3. Adjust the PTO clutch return cable length so that it stretchs slightly tight.
Page 266 G21LD · G21HD, WSM PTO SYSTEM Front PTO Pulley Wear 1. Measure the front PTO pulley O.D. with an outside micrometer. 2. If the measurement is less than the allowable limit, replace it. 123.9 to 124.0 mm Factory spec. 4.878 to 4.882 in. Front PTO pulley O.D.
Page 267 ELECTRICAL SYSTEM KiSC issued 08, 2007 A...
Page 268 MECHANISM CONTENTS 1. WIRING DIAGRAM AND ELECTRICAL CIRCUIT........8-M1 [1] WIRING DIAGRAM (G21LD and G21HD) ..........8-M1 [2] ELECTRICAL CIRCUIT (G21LD and G21HD)........8-M2 KiSC issued 08, 2007 A...
Page 269 G21LD . G21HD, WSM SISTEMA ELÉCTRICO 1. DIAGRAMA DE CABLEADO Y CIRCUITO ELÉCTRICO [1] DIAGRAMA DE CABLEADO (G21LD y G21HD) Color de los Cables B ..Negro Br ..Marrón L ..Azul Pu ..Púrpura Y ..Amarillo BOr ..Negro / Naranja G ..
Page 270 G21LD . G21HD, WSM SISTEMA ELÉCTRICO [2] CIRCUITO ELÉCTRICO (G21LD y G21HD) Interruptor principal Color de los Cables Terminal B ..Negro Br ..Marrón L ..Azul Pu ..Púrpura Y ..Amarillo GLOW Posición de (IG / M) BOr ..Negro / Naranja G ..
Page 271 SERVICING CONTENTS 1. TROUBLESHOOTING ..................8-S1 2. SERVICING SPECIFICATIONS ..............8-S5 3. TIGHTENING TORQUES ................8-S6 4. CHECKING, DISASSEMBLING AND SERVICING.........8-S7 [1] BATTERY....................8-S7 (1) Checking .....................8-S7 [2] STARTING SYSTEM ................8-S8 (1) Checking .....................8-S8 (2) Disassembling and Assembling ............8-S12 (3) Servicing ...................8-S13 [3] ENGINE KEY SWITCH SHUT-OFF SYSTEM ........8-S15 (1) Checking ...................8-S15 [4] CHARGING SYSTEM ................8-S16 (1) Checking ...................8-S16...
Page 272 G21LD · G21HD, WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING ALL ELECTRICAL EQUIPMENT Reference Symptom Probable Cause Solution Page All Electrical Battery discharged or defective Charge or replace G-31 Equipment Does Not Operate Fuse blown Replace G-43 Battery cable disconnected or improperly Replace –...
Page 273 G21LD · G21HD, WSM ELECTRICAL SYSTEM STARTING SYSTEM Reference Symptom Probable Cause Solution Page Starter Does Not Weak battery Charge G-31 Function Faulty lead or connection (Magnet switch to Replace or repair 8-S12 motor) Starter defective Repair or replace 8-S12 Battery discharged or defective Charge or replace G-31...
Page 274 G21LD · G21HD, WSM ELECTRICAL SYSTEM CHARGING SYSTEM Reference Symptom Probable Cause Solution Page Battery Discharges Cooling fan belt slipping Adjust tension 1-S49 too Quickly Alternator defective Repair or replace 8-S17 Wiring harness disconnected or improperly Repair or replace – connected Battery discharged or defective Charge or replace...
Page 275 G21LD · G21HD, WSM ELECTRICAL SYSTEM EASY CHECKER Reference Symptom Probable Cause Solution Page Charging Indicator Fuse blown Replace G-43 Does Not Light Up Bulb blown Replace G-43 when Main Switch is Main switch defective Replace 8-S8 turned "ON" Wiring harness disconnected or improperly Repair or replace –...
Page 276: Servicing Specifications
G21LD · G21HD, WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS BATTERY Item Factory Specifications Allowable Limit Battery Voltage More than 12 V – Potential difference Less than 0.1 V – W1010878 STARTER Commutator O.D. 28.0 mm 27.0 mm 1.102 in. 1.063 in. Difference of Less than 0.02 mm 0.05 mm...
Page 277 G21LD · G21HD, 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 : See page G-8.) Item N·m kgf·m ft-lbs Starter M terminal nut 9.8 to 13.7 1.0 to 1.4 7.2 to 10.1...
Page 278: Checking, Disassembling And Servicing
G21LD · G21HD, WSM ELECTRICAL SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING CAUTION • To avoid accidental short circlet, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal. • Never remove the battery cap while the engine is running. •...
Page 279: Starting System
G21LD · G21HD, WSM ELECTRICAL SYSTEM [2] STARTING SYSTEM (1) Checking (A) Main Switch Connector Voltage 1. Open the bonnet. 2. Disconnect the 4P connector from the main switch. 3. Measure the voltage with a voltmeter between the connector terminal and chassis. 4.
Page 280 G21LD · G21HD, WSM ELECTRICAL SYSTEM Main Switch Continuity 1. Open the bonnet. 2. Disconnect the 4P connector from the main switch. 3. Remove the main switch from the panel. 4. Measure the resistance with an ohmmeter across the connector terminals when the main switch key is set at (A) position.
Page 281 G21LD · G21HD, WSM ELECTRICAL SYSTEM (B) Starter M Terminal Voltage 1. Measure the voltage with a voltmeter between the M terminal and the chassis. 2. If the voltage differs from the battery voltage, the battery’s positive cable or the battery negative cable is faulty. Voltage Factory spec.
Page 282 G21LD · G21HD, WSM ELECTRICAL SYSTEM (C) Glow Plug Lead Terminal Voltage 1. Disconnect the 1P connector (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 283: Disassembling And Assembling
G21LD · G21HD, WSM ELECTRICAL SYSTEM (2) Disassembling and Assembling (A) Starter Disassembling Starter (1) Magnetic Switch Mounting Nut (2) Housing (3) Magnetic Switch (4) C Terminal Nut (5) Shaft Assembly (6) Drive Lever (7) Overrunning Clutch (8) Armature (9) Connecting Lead (10) Yoke (11) Brush Holder (12) Mounting Screw...
Page 284: Servicing
G21LD · G21HD, WSM ELECTRICAL SYSTEM (3) Servicing (A) Starter Commutator and Mica 1. Check the contact face of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points.
Page 285 G21LD · G21HD, WSM ELECTRICAL SYSTEM Armature Coil 1. Check the continuity across the commutator and armature coil core with an ohmmeter. 2. If it conducts, replace the armature. 3. Check the continuity across the segments of the commutator with an ohmmeter.
Page 286: Engine Key Switch Shut-Off System
G21LD · G21HD, WSM ELECTRICAL SYSTEM [3] ENGINE KEY SWITCH SHUT-OFF SYSTEM (1) Checking 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 4 terminal and chassis.
Page 287: Charging System
G21LD · G21HD, WSM ELECTRICAL SYSTEM [4] CHARGING SYSTEM (1) Checking (A) Alternator Alternator 1. Disconnect the 2P connector (3) from alternator (2) after tuning the main switch OFF. 2. Perform the following checkings. (1) B Terminal (3) 2P Connector (2) Alternator W1017030 Connector Voltage...
Page 288 G21LD · G21HD, WSM ELECTRICAL SYSTEM (2) Disassembling and Assembling (A) Alternator Pulley 1. Secure the hexagonal end of the pulley shaft with a double- ended ratchet wrench as shown in the figure, loosen the pulley nut with a socket wrench and remove it. (When reassembling) 93.1 to 127.4 N·m Tightening torque...
Page 289 G21LD · G21HD, WSM ELECTRICAL SYSTEM Rear End Frame 1. Unscrew the two nuts and two screws holding the drive end frame and the rear end frame(1). 2. Remove the rear end frame (1) (1) Rear End Frame W1018366 Rotor 1.
Page 290 G21LD · G21HD, WSM ELECTRICAL SYSTEM (3) Servicing (A) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. W1018966 Stator 1. Measure the resistance across each lead of the stator coil with an ohmmeter.
Page 291 G21LD · G21HD, WSM ELECTRICAL SYSTEM Rectifier 1. Check the continuity across each diode of rectifier with an analog ohmmeter. Conduct the test in the (R × 1) setting. 2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction.
Page 292 G21LD · G21HD, WSM ELECTRICAL SYSTEM (B) Thermo Switch Connector Voltage 1. Disconnect the 1P connector from the thermo switch (1). 2. Turn the main switch key to the “ON” position, and measure the voltage with a voltmeter between the connector terminal and the chassis.
Page 293 G21LD · G21HD, WSM ELECTRICAL SYSTEM (D) Head Light Switch Connector Voltage 1. Disconnect the 1P connectors from the head light switch (1). 2. Turn the main switch key to the “ON” position, and measure the voltage with a voltmeter between the connector terminal (Red / White) and the chassis.
Page 294 G21LD · G21HD, WSM ELECTRICAL SYSTEM (E) Brake Switch Brake Switch 1) Connector Voltage 1. Turn the main switch off. 2. Disconnect the 4P connectors from the brake switch (1). 3. Set the PTO clutch lever at “DISENGAGE” position. 4. Turn the main switch to “ON” position. 5.
Page 295 G21LD · G21HD, WSM ELECTRICAL SYSTEM (F) PTO Switch PTO Switch 1) Connector Voltage 1. Turn the main switch off. 2. Disconnect the 4P connector from the PTO switch (1). 3. Turn the main switch to “ON” position. 4. Measure the voltage with a voltmeter across the connector 3 terminal and chassis.
Page 296 G21LD · G21HD, WSM ELECTRICAL SYSTEM (H) Grass Collector Switch Grass Collector Switch Continuity (G21LD) 1. Disconnect the grass collector switch (1) from the wiring harness. 2. Push the switch, and check the resistance between the terminals with an ohmmeter. 3.
Page 297 G21LD · G21HD, WSM ELECTRICAL SYSTEM (J) Relay Relay 1. Disconnect the 5P connector, and remove the relay. 2. Using an ohmmeter, check that there is continuity across the terminal 3 and 4. 3. Using an ohmmeter, check that there is no continuity across the terminals 3 and 4 when the positive terminal of a 12 V battery is connected to the terminal 2 and the negative terminal is connected to the terminal 1.
Page 298 MOWER KiSC issued 08, 2007 A...
Page 299 SERVICING CONTENTS 1. TROUBLESHOOTING ..................9-S1 2. SERVICING SPECIFICATIONS ..............9-S2 3. TIGHTENING TORQUES ................9-S3 4. CHECKING, DISASSEMBLING AND SERVICING.........9-S4 [1] CHECKING AND ADJUSTING ...............9-S4 [2] DISMOUNTING AND MOUNTING ............9-S8 [3] DISASSEMBLING AND ASSEMBLING..........9-S9 [4] SERVICING ....................9-S14 KiSC issued 08, 2007 A...
Page 300 G21LD · G21HD, WSM MOWER 1. TROUBLESHOOTING SAFETY CONTROL SYSTEM Reference Symptom Probable Cause Solution Page Blade Does Not Weaken or broken front PTO belt Replace 7-S3 to S5 Rotate Damaged mower belt Replace 9-S4, S9 Mower Belt Slipping Weaken tension spring Replace 9-S10 Damaged mower belt...
Page 301 G21LD · G21HD, WSM MOWER 2. SERVICING SPECIFICATIONS Item Factory Specifications Allowable Limit Front Tip of Blade to Rear Tip of Blade Difference Less than 5 mm – 0.20 in. Left Tip of Blade to Right Tip of Blade Difference Less than 4 mm –...
Page 302 G21LD · G21HD, 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 : See page G-8.) Item N·m kgf·m ft-lbs Reamer bolt 77.4 to 90.2 7.9 to 9.2 57.1 to 66.5 Mower blade screw...
Page 303: Checking
G21LD · G21HD, WSM MOWER 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Checking Mower Blade 1. Check the cutting edge of mower blade. 2. Sharpen the cutting edges, if the mower blades are as shown in figure (2). 3.
Page 304 G21LD · G21HD, WSM MOWER Adjusting Front and Rear Cutting Height 1. Mount the mower to the machine, and place the vehicle on a level ground. 2. Set the cutting height to “2” position. 3. Measure the heights (F), (R) of the blade. 4.
Page 305 G21LD · G21HD, WSM MOWER Adjusting Left and Right Cutting Height 1. Mount the mower to the machine, and place the machine on a level ground. 2. Set the cutting height to “2” position. 3. Measure the heights (L), (R) of the blade. 4.
Page 306 G21LD · G21HD, WSM MOWER Adjusting Cutting Height 1. To set the cutting height, pull the mower lift lever backward to raise the mower deck to the top position. Turn the cutting height control dial to adjust height. 2. Set the anti-scalp roller’s height as shown to keep clearance between rollers and ground more than 6 mm (0.24 in.).
Page 307 G21LD · G21HD, WSM MOWER [2] DISMOUNTING AND MOUNTING Anti-scalp Rollers and Cutting Height Adjusting Dial 1. Park the machine on level ground, and stop the engine. 2. Set the front anti-scalp rollers (1) sideways and at the topmost position. 3.
Page 308 G21LD · G21HD, WSM MOWER [3] DISASSEMBLING AND ASSEMBLING Universal Joint and Covers 1. Remove the universal joint. 2. Remove the left and right hand covers (1), (2). (When reassembling) • Apply grease to the splines and grease nipples of the universal joint.
Page 309 G21LD · G21HD, WSM MOWER Mower Belt, Gear Case and Center Pulley Holder 1. Turn over the mower. 2. Remove the tension springs (7), (9). 3. Remove the mower belts (1), (6). 4. Remove the RH case stay (5). 5. Remove the reamer bolts (2), (3). 6.
Page 310 G21LD · G21HD, WSM MOWER Side Blade Pulley Holder Assembly 1. Remove the side blade pulley mounting nut (2). 2. Remove the side blade pulley (3), feather key (7) (only right side blade pulley) and grease nipple (1) from the blade shaft (6). 3.
Page 311 G21LD · G21HD, WSM MOWER Disassembling LH Tension Pulley 1. Remove the tension spring from the tension arm (10). 2. Remove the tension arm mounting bolt (5) and nut (1). 3. Remove the tension arm assembly, tension collar (2) and plate (4).
Page 312 G21LD · G21HD, WSM MOWER Disassembling Mower Gear Case Assembly 1. Unscrew the drain plug (15), and drain gear case oil. 2. Remove the center pulley (22) with a puller, and remove the feather key (23) on the bevel gear shaft (20). 3.
Page 313 G21LD · G21HD, WSM MOWER [4] SERVICING Backlash between Bevel Gears 1. Remove the gear case cap (2). 2. Place fuses the 21T bevel gear (3) on the pinion shaft. 3. Turn the pinion shaft. 4. Take out the fuses, and measure the thickness of fuses with an outside micrometer.
Page 314 G21LD · G21HD, WSM MOWER Clearance between Tension Collar and Tension Arm Bushing 1. Measure the tension collar O.D. with an outside micrometer. 2. Measure the tension arm bushing I.D. with an inside micrometer, and calculate the clearance. 3. If the clearance exceeds the factory specification, replace them. Clearance between 0.005 to 0.117 mm tension collar and...
Page 315 HIGH DUMP GRASS COLLECTOR KiSC issued 08, 2007 A...
Page 316 SERVICING CONTENTS 1. TROUBLESHOOTING ..................10-S1 2. SERVICING SPECIFICATIONS ..............10-S2 3. TIGHTENING TORQUES ................10-S3 4. CHECKING, DISASSEMBLING AND SERVICING........10-S4 [1] CHECKING .....................10-S4 [2] DISASSEMBLING AND ASSEMBLING..........10-S6 (1) Dismounting Grass Collector Bag .............10-S6 (2) Platform Complete ................10-S8 (3) Lift Arm Assembly and Head Guard ..........10-S10 (4) Disassembling Grass Collector Bag ..........10-S11 KiSC issued 08, 2007 A...
Page 317 G21LD · G21HD, WSM HIGH DUMP GRASS COLLECTOR 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Grass Bag Control Is Transmission oil is low Replenish G-7, G-13 Not Smooth PTO Lever Does Not Grass collector is lifted Lower the grass –...
Page 318 G21LD · G21HD, WSM HIGH DUMP GRASS COLLECTOR 2. SERVICING SPECIFICATIONS Item Factory Specifications Allowable Limit PTO wire cable retainer length Reference 8.0 mm – 0.31 in. Rotating restriction wire cable retainer Reference 15.0 mm – length 0.59 in. Upper rear cover and top cover Clearance 3.0 to 5.0 mm –...
Page 319 G21LD · G21HD, WSM HIGH DUMP GRASS COLLECTOR 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-8.) Item N·m kgf·m ft-lbs Rear gate link flange screw 48.0 to 55.9 4.9 to 5.7...
Page 320 G21LD · G21HD, WSM HIGH DUMP GRASS COLLECTOR 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING Bag Rotating Restriction 1. Adjust the wire retainer nut (1) so that the grass collector rotates when setting the grass collector bag line (3) horizontally to the upper joint (2).
Page 321 G21LD · G21HD, WSM HIGH DUMP GRASS COLLECTOR Checking PTO Safety Control 2 CAUTION • Be sure to keep yourself out of the bag way. 1. Lift the grass collector (2) and remove the lever spring (1) then lower the grass collector (2). 2.
Page 322 G21LD · G21HD, WSM HIGH DUMP GRASS COLLECTOR [2] DISASSEMBLING AND ASSEMBLING (1) Dismounting Grass Collector Bag • Park the machine on firm level ground, shut off the engine and remove the key. • Choke the wheels when remove the wheels. Cylinder Cover, Rear Gate and Cylinder 1.
Page 323 G21LD · G21HD, WSM HIGH DUMP GRASS COLLECTOR Grass Collector Bag 1. Turn the cylinder end (1) at 1.57 rad. (90 °) as shown in figure. 2. Support the grass collector bag with block as shown in figure. 3. Remove the lift arm connector pin (3), (4) from the lift arm connector (2) as shown the figure.
Page 324 G21LD · G21HD, WSM HIGH DUMP GRASS COLLECTOR (2) Platform Complete Dismounting Grass Collector Bag 1. See page 10-S6, S7. W1016036 Front Cover, Discharge Plate and Discharge Duct 1. Remove the quick clean lever (1) and oil filler port mounting screw (2).
Page 325 G21LD · G21HD, WSM HIGH DUMP GRASS COLLECTOR Platform Complete 1. Remove the rear wheels and choke the front wheel. 2. Disconnect the PTO wire (1) from PTO lever. 3. Remove the drain hose (2) and PB2 hose (3). 4. Remove the PB1 hose (4) from the auxiliary control valve (Hi Dump Control Valve) (5).
Page 326 G21LD · G21HD, WSM HIGH DUMP GRASS COLLECTOR (3) Lift Arm Assembly and Head Guard Dismounting Grass Collector Bag 1. See pages 10-S6, S7. W1015133 Upper Lift Joint and Lower Lift Joint 1. Remove the PTO wire cable mounting pin (1) and stopper wire cable mounting pin (2).
Page 327 G21LD · G21HD, WSM HIGH DUMP GRASS COLLECTOR (4) Disassembling Grass Collector Bag Dismounting Grass Collector Bag 1. See pages 10-S6, S7. W1015248 Top Cover and Side Cover 1. Remove the bag handle (1). 2. Remove the top cover (2). 3.
Page 328 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 : ksos-pub@kubota.co.jp Printed in Japan 2007. 08, S, EI, EI, e Code No.9Y011-15091 KUBOTA Corporation 2005.

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G21ld G21hd

Kubota G21LD / G21HD Workshop Manual

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 Implement Limitations

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Tightening Torques

4 Checking, Disassembling and Servicing

Mechanism

1 Structure

2 Hydrostatic Transmission

Servicing

Servicing

Servicing

Mechanism

1 System Configuration

2 Construction and Function of Main Components

Servicing

1 Cautionary Instructions before Starting Failure Diagnosis

2 Troubleshooting

3 Servicing Specifications

4 Tightening Torques

5 Checking, Disassembling and Servicing

Mechanism

1 Hydraulic Circuit

2 Relief Valve (G21Ld, G21Hd)

3 Mower Lifting Circuit (G21Ld, G21Hd)

7 Grass Collector Lift Cylinder (G21Ld)

8 Grass Collector Lift Cylinder and Rotating Cylinder (G21Hd)

Servicing

1 Troubleshooting

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Servicing

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Quick Links

Chapters

Troubleshooting

Related Manuals for Kubota G21LD / G21HD

Summary of Contents for Kubota G21LD / G21HD