Page 1 WORKSHOP MANUAL GR2100EC KiSC issued 04, 2006 A...
Page 2 TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KUBOTA GR2100EC. It is divided into three parts, "General", "Mechanism" and "Servicing". B General Information on the product identification, the general precautions, maintenance check list, check and maintenance and special tools are described.
Page 3 GR2100EC, WSM SAFETY INSTRUCTIONS 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 GR2100EC, WSM SAFETY INSTRUCTIONS SAFETY WORKING A Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued. A Wear close fitting clothing and safety equipment appropriate to the job. A Use tools appropriate to the work. Makeshift tools, parts, and procedures are not recommended.
Page 5 GR2100EC, WSM SAFETY INSTRUCTIONS VENTILATE WORK AREA A 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. 0000000757E PREVENT ACID BURNS A Sulfuric acid in battery electrolyte is poisonous.
Page 6: Safety Decals
GR2100EC, 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. 0000009636E KiSC issued 04, 2006 A...
Page 7 GR2100EC, WSM SAFETY INSTRUCTIONS 0000009633E KiSC issued 04, 2006 A...
Page 8 GR2100EC, WSM SAFETY INSTRUCTIONS 0000009634E KiSC issued 04, 2006 A...
Page 9: Specifications
GR2100EC, WSM SPECIFICATIONS SPECIFICATIONS Model GR2100EC Maker KUBOTA Model D782-E2-GX Type Indirect injection. Vertical, water-cooled, 4-cycle diesel Number of cylinders Bore and stroke 67 x 73.6 mm (2.64 x 2.90 in.) Total displacement (47.46 cu.in.) Engine gross power (DIN) 15.6 kW (20.9 HP)
Page 10 GR2100EC, WSM SPECIFICATIONS Model RCK48GR Cutting width 1219 mm (48.0 in.) Cutting height 25 to 102 mm (1 to 4 in.) Adjustment of cutting height Dial gauge Mounting method Quick joint, Parallel linkage Weight (Approx.) 80 kg (176 lbs) Mower Total length 871 mm (34.3 in.) Dimensions...
Page 11 GR2100EC, WSM DIMENSIONS DIMENSIONS 0000009634E KiSC issued 04, 2006 A...
Page 12 GENERAL KiSC issued 04, 2006 A...
Page 13: Table Of Contents
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-7 4. LUBRICANTS, FUEL AND COOLANT ................G-8 5. TIGHTENING TORQUES ....................G-9 [1] GENERAL USE SCREWS, BOLT AND NUTS .............G-9 [2] METRIC SCREWS, BOLTS AND NUTS ...............G-9 [3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF...
Page 14: Identification
GR2100EC, WSM GENERAL 1. IDENTIFICATION When contacting your local KUBOTA distributor, always specify engine serial number (2), machine serial number (1), mower serial number (3) and hour meter reading. (1) Machine Serial Number (3) Mower Serial Number (2) Engine Serial Number...
Page 15: General Precautions
A Remove oil and dirt from parts before measuring. A Use only KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety. A Gaskets and O-rings must be replaced during reassembly.
Page 16: Handling Precautions For Electrical Parts And Wiring
GR2100EC, WSM 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. A Check electrical wiring for damage and loosened connection every year.
Page 17 GR2100EC, WSM GENERAL A Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp *Wind Clamp Spirally (4) Welding Dent (2) Wire Harness 0000000617E A Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.
Page 18: Battery
GR2100EC, WSM GENERAL [2] BATTERY A Take care not to confuse positive and negative terminal posts. A When removing battery cables, disconnect negative cable first. When installing battery cables, check for polarity and connect positive cable first. A Do not install any battery with capacity other than is specified (Ah).
Page 19 GR2100EC, WSM GENERAL A In separating connectors, do not pull wire harnesses. A Hold connector bodies to separate. (A) Correct (B) Incorrect 0000000624E A Use sandpaper to remove rust from terminals. A Repair deformed terminal. Make certain there is no terminal being exposed or displaced.
Page 20: Handling Of Circuit Tester
GR2100EC, WSM GENERAL [5] HANDLING OF CIRCUIT TESTER A Use tester correctly following manual provided with tester. A Check for polarity and range. 0000000628E KiSC issued 04, 2006 A...
Page 21: Lubricants, Fuel And Coolant
2.46 lmp.qts. Above 25 ) : SAE30, 10W-30 or 10W-40 3.3 L Transmission case 0.87 U.S.gals. 0.73 lmp.gals. KUBOTA UDT or SUPER UDT fluid* 1.9 L Front axle case 0.50 U.S.gals. 0.42 lmp.gals. 0.40 L SAE90 gear oil Mower gear box 0.42 U.S.qts.
Page 22: Tightening Torques
GR2100EC, WSM GENERAL 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLT AND NUTS Screws, bolt and nuts whose tightening torque are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of No-grade or 4T bolt Material of bolt SS400, S20C...
Page 23: American Standard Screws, Bolts And Nuts With Unc Or Unf Threads
GR2100EC, WSM GENERAL [3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS SAE GR.5 SAE GR.8 Grade Unit Norminal ft-lbs ft-lbs 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 47.5 to 57.0 4.84 to 5.82...
Page 24: Maintenance Check List
GR2100EC, WSM GENERAL 6. MAINTENANCE CHECK LIST A The jobs indicated by must be done initially. A *1 : This maintenance should be done daily more often in dusty conditions than in normal conditions. Suggested cleaning interval is every 100 hours in normal conditions. Indication on hour meter (Hr) Ref- Period...
Page 25 GR2100EC, WSM GENERAL Indication on hour meter (Hr) Ref- Period After por- since ence Item tant page every Check G-27 100 hr Fuel line every Replace G-38 2 years every Check G-33 200 hr Hydraulic hose every Replace G-33 2 years every Check G-31...
Page 26: Check And Maintenance
GR2100EC, WSM GENERAL 7. CHECK AND MAINTENANCE A Be sure to check and service the machine on a flat place with engine shut off, the parking brake on and chock the wheels. 0000001417E [1] DAILY CHECK To prevent trouble from occurring, it is important to know the condition of the machine. Check the following items before starting.
Page 27 GR2100EC, WSM GENERAL Checking Engine Oil Level A 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. 2. Wipe dipstick (2) area clean. 3.
Page 28 GR2100EC, WSM GENERAL Checking Amount of Fuel and Refueling A 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 29 GR2100EC, WSM GENERAL Checking and Cleaning Radiator to Prevent Overheating A Be sure to stop the engine and remove the key before cleaning. Daily or after every 5 hours of operation, check to be sure the radiator screen (2) and radiator core are clean. Dirt or chaff on the radiator screen radiator...
Page 30 GR2100EC, WSM GENERAL Checking Tire Pressure A Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment. A Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure. A Inflation pressure in front tires rises quickly when using compressed air.
Page 31 GR2100EC, WSM GENERAL Checking Coolant Level A Do not remove the radiator cap when the engine is hot. Loosen cap slightly, to the stop, to relieve any excess pressure before removing cap completely. Check the coolant level daily both the radiator and the recovery tank (4) before starting engine.
Page 32: Check Points Of Every 50 Hours
GR2100EC, WSM GENERAL [2] CHECK POINTS OF EVERY 50 HOURS Checking Safety Device A Do not allow anyone near the machine while testing. A If the machine does not pass one of the following tests, do not operate the machine. 1.
Page 33 GR2100EC, WSM 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. Air pressure should not exceed 205 kPa (2.1 , 30 psi).
Page 34 GR2100EC, WSM GENERAL Lubricating All Grease Nipple 1. Apply a grease to the following locations as figures. A Be sure to stop the engine and remove the key before greasing. (1) Engine Transmission (3) King Pin Support Universal Joint (4) Glide Steer Bolt (2) Center Pin (5) Glide Steer Rear Arm 0000010055E...
Page 35 GR2100EC, WSM GENERAL Oiling 1. Apply oil to the following location as figures. A Be sure to stop the engine and remove the key before oiling. (1) Mower Universal Joint (4) Seat Adjuster (2) Speed Control Shaft (RH) (5) Throttle Cable (3) Speed Control Shaft (LH) 0000009558E KiSC issued 04, 2006 A...
Page 36 GR2100EC, WSM GENERAL Oiling (Continued) 1. Apply oil to the following location as figures. A Be sure to stop the engine and remove the key before oiling. (1) Around Hole of Mower Link (6) Hinge (2) Around Pin (7) PTO Lever (Fulcrum) (3) Pivot of Mower Link (8) Hydraulic Lift Lever (Fulcrum) (4) Pivot of Lift Arm...
Page 37 GR2100EC, WSM GENERAL Oiling (Continued) 1. Apply oil to the following location as figures. A Be sure to stop the engine and remove the key before oiling. (1) Glide Steer Wire 0000010057E Checking Battery Condition A To avoid the possibility of battery explosion: For the refillable type battery, follow the instructions below.
Page 38 GR2100EC, WSM GENERAL B Battery Charging A 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. A When charging the battery, ensure the vent caps are securely in place (if equipped).
Page 39: Check Points Of Every 100 Hours
GR2100EC, WSM GENERAL B Battery Charging (Continued) (For non-accessible maintenance-free type batteries.) Maintenance-free, non-accessible batteries are designed to eliminate the need to add water. Yet the volume of electrolyte (3) above plates may eventually become depleted due to abnormal conditions such as high heat or improper regulator setting. Use a voltmeter to check the state of charge.
Page 40 GR2100EC, WSM GENERAL Checking Fuel Line and Fuel Filter A Be sure to stop the engine and remove the key when attempting to make the following checks and changes. A Never fail to check the fuel lines periodically. The fuel lines are subject to wear and aging.
Page 41: Check Points Of Every 150 Hours
GR2100EC, WSM GENERAL Checking Fan Drive Belt Tension A Be sure to stop the engine and remove the key before checking belt tension. 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley (1) and dynamo pulley (2) at specified force (98 N, 10 kgf, 22 lbs).
Page 42: Check Points Of Every 200 Hours
A 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 0000009569E KiSC issued 04, 2006 A...
Page 43 GR2100EC, WSM GENERAL Changing Transmission Fluid A Be sure to stop the engine and remove the key before changing or checking the oil. A Allow transmission case to cool down sufficiently; oil can be hot and may cause burns. The fluid in the transmission case is also used for the hydrostatic drive system.
Page 44 Check for oil leaks around filter gasket. A To prevent serious damage to hydraulic system, the replacement filter must be a highly efficient, 10 filter. Use only a genuine KUBOTA filter or its equivalent. (1) Transmission Oil Filter (2) Screw Cartridge...
Page 45 GR2100EC, WSM GENERAL Changing Front Axle Case Oil 1. Park the machine on a firm, flat and level surface. 2. To drain the used oil, remove the right and left drain plugs (3) and filling plug (2) at the front axle case and drain the oil completely into the oil pan.
Page 46 GR2100EC, WSM GENERAL Checking Hydraulic Hose A Be sure to stop the engine and remove the key before checking and replacing hydraulic case. A Allow transmission case to cool down sufficiently; oil can be hot and may cause burns. Check to see if hydraulic hoses are properly fixed every 200 hours of operation.
Page 47: Check Point Of Every 400 Hours
GR2100EC, WSM GENERAL Adjusting Front Axle Pivot 1. Jack up the front of machine. 2. Measurement the clearance between the front axle bracket (1) and frame (5). 3. If the measurement exceeds the factory specification, adjust the front axle bracket mounting screw and nut (4). 4.
Page 48: Check Points Of Every 1 Year
GR2100EC, WSM GENERAL [7] CHECK POINTS OF EVERY 1 YEAR Replacing Air Cleaner Element 1. Change the element once a year. 0000009576E Flushing Cooling System and Changing Coolant A Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.
Page 49 GR2100EC, WSM GENERAL Flushing Cooling System and Changing Coolant (Continued) B Anti-Freeze A When using anti-freeze, put on some protection such as rubber gloves (Anti-freeze contains poison.). A If should drink anti-freeze, throw up at once and take medical attention. A When anti-freeze comes in contact with the skin or clothing, wash it off immediately.
Page 50 3. Kubota's genuine long-life coolant has a service life of 2 years. Be sure to change the coolant every 2 years. A The above data represent industry standards that necessitate a minimum glycol content in the concentrated anti-freeze.
Page 51: Check Points Of Every 2 Years
GR2100EC, WSM GENERAL [8] CHECK POINTS OF EVERY 2 YEARS Replacing Fuel Lines 1. Replace the fuel line. Refer to "Checking Fuel Lines and Fuel Filter". (See page G- 27.) 0000010067E Replacing Radiator Hose 1. Replace hoses and clap bands every 2 years or earlier if checked and found that hoses are swollen, hardened or cracked.
Page 52 GR2100EC, WSM GENERAL Replacing Bulbs (A) Replacement of the head light bulb 1. Open the hood. 2. Turn bulb socket to remove socket from head light housing. 3. Push bulb down and turn one quarter turn to remove bulb from the socket.
Page 53 GR2100EC, WSM GENERAL Checking and Replacing Mower Blade A Be sure to stop the engine and remove the key. A Blades may be sharp. When you handle blades, wear heavy gloves or wrap end of blade with a rag. B Checking Blade 1.
Page 54 GR2100EC, WSM GENERAL Replacing Mower Belt 1. Remove the left and right belt covers from the mower deck. 2. Disconnect the universal joint from the gear box (2). 3. Clean around the gear box (2). 4. Remove the mower belt RH (3) from the tension pulley (4). 5.
Page 55: Special Tools
GR2100EC, WSM GENERAL 8. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Special Use Puller Set Code No : 07916-09032 Application : Use exclusively for pulling out bearing, gears and other parts with ease. 0000000677E Piston Ring Compressor Code No : 07909-32111 Application : Use exclusively for pushing in the piston with piston rings into the cylinder.
Page 56 GR2100EC, WSM GENERAL Diesel Engine Compression Tester (for Glow Plug) Code No : 07909-39081 (Assembly) 07909-31301 (L) 07909-31291 (K) 07909-31311 (M) Application : Use to measure diesel engine compression and diagnostics of need for major overhaul. (1) Gauge (4) Adaptor L (2) L Joint (5) Adaptor M (3) Adaptor K...
Page 57 GR2100EC, WSM GENERAL Connecting Rod Alignment Tool Code No : 07909-31661 Application : Use to check the connecting rod alignment. Applicable : Connecting rod big end I.D. range 30 to 75 mm (1.18 to 2.95 in.) dia. Connecting rod length 65 to 300 mm (2.56 to 11.81 in.) 0000000684E Nozzle Tester...
Page 58 GR2100EC, WSM GENERAL Injection Pump Pressure Tester Application : Use to check fuel tightness of injection pumps. Pressure gauge full scale : More than 29.4 MPa (300 , 4267 psi) Copper gasket Flange (Material : Steel) Hex. nut 27 mm (1.06 in.) across the plat Retaining nut PF 1/2 5 mm (0.20 in.)
Page 59 GR2100EC, WSM GENERAL Valve Guide Replacing Tool Application : Use to press out and press fit the valve guide. 20 mm dia. (0.79 in. dia.) 9.96 to 9.98 mm dia. (0.3921 to 0.3929 in. dia.) 5.5 to 5.7 mm dia. (0.2165 to 0.2244 in. dia.) 220 mm (8.66 in.) 80 mm (3.15 in.) 40 mm (1.58 in.)
Page 60 GR2100EC, WSM GENERAL Bushing Replacing Tools Application : Use to press out and to press fit the bushing. 1. For small end bushing 145 mm (5.71 in.) 20 mm (0.79 in.) 100 mm (3.94 in.) 19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.) 21.90 to 21.95 mm dia.
Page 61 GR2100EC, WSM GENERAL Flywheel Stopper Application : Use to loosen and tighten the flywheel screw. 200 mm (7.87 in.) 30 mm (1.18 in.) 20 mm (0.79 in.) 15 mm (0.59 in.) 8 mm (0.31 in.) 10 mm dia. (0.39 in. dia.) 0000000818E Crankshaft Bearing 1 Replacing Tool Application : Use to press out and press fit the crankshaft...
Page 62: Special Tools For Tractor
GR2100EC, WSM GENERAL [2] SPECIAL TOOLS FOR TRACTOR Relief Valve Pressure Tester Code No : 07916-50045 Application : This allows easy measurement of relief set pressure. (1) Gauge (07916-50322) (6) Adaptor C (PS3/8) (2) Cable (07916-50331) (07916-50371) (3) Threaded Joint (7) Adaptor D (PT1/8) (07916-50401) (07916-50381)
Page 63: Tires
GR2100EC, WSM GENERAL 9. TIRES [1] TIRE PRESSURE A Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment. A Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure as shown below. A Do not use tires larger than specified.
Page 64: Implement Limitations
KUBOTA. Use of implements which are not sold or approved by KUBOTA and which exceed the maximum specifications listed below, or which are otherwise unfit for use with the KUBOTA Machine may result in malfunctions or failures of the machine, damage to other property and injury to the operator or others. [Any malfunctions or failures of the machine resulting from use with improper implements are not covered by the warranty.]...
Page 65 ENGINE KiSC issued 04, 2006 A...
Page 66 CONTENTS 1. ENGINE BODY .........................1-M1 [1] HALF-FLOATING HEAD COVER ..................1-M1 [2] CLOSED BREATHER.....................1-M1 2. LUBRICATING SYSTEM ....................1-M2 3. COOLING SYSTEM ......................1-M3 4. FUEL SYSTEM.........................1-M4 [1] FUEL LINE ........................1-M4 KiSC issued 04, 2006 A...
Page 67: Engine Body
GR2100EC, WSM ENGINE 1. ENGINE BODY [1] HALF-FLOATING HEAD COVER The rubber packing is fitting in to maintain the head cover 0.5 mm (0.02 in.) or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head. (1) Cylinder Head Cover (2) Rubber Packing 0000004839E...
Page 68: Lubricating System
GR2100EC, WSM ENGINE 2. LUBRICATING SYSTEM (1) Rocker Arm (2) Oil Pressure Switch (3) Rocker Arm Shaft (4) Valve (5) Idle Gear (6) Crankshaft (7) Oil Pump (8) Oil Strainer (9) Relief Valve (10) Push Rod (11) Tappet (12) Camshaft (13) Piston (14) Connecting Rod (15) Oil Filter Cartridge...
Page 69: Cooling System
GR2100EC, WSM ENGINE 3. COOLING SYSTEM (1) Radiator (2) Water Pump (3) Cooling Fan (4) Thermostat (5) Cylinder Head (6) Cylinder Block The cooling system consists of a radiator (1), a centrifugal water pump (2), a cooling fan (3) and a thermostat (4). The coolant is cooled through the radiator core, and the cooling fan (3) set behind the radiator (1) pushes cooling air through the radiator core to improve cooling.
Page 70: Fuel System
GR2100EC, WSM ENGINE 4. FUEL SYSTEM [1] FUEL LINE (1) Injection Nozzle (2) Fuel Overflow Pipe (3) Fuel Tank (4) Fuel Filter (5) Fuel Feed Pump (6) Fuel Filter (7) Injection Pump (8) Injection Pipe Fuel from the fuel tank (3) passes through the fuel filter (4), and then enters the injection pump (7) after impurities such as dirt, water, etc.
Page 71 CONTENTS 1. TROUBLESHOOTING....................... 1-S1 2. SERVICING SPECIFICATIONS ..................1-S4 3. TIGHTENING TORQUES ....................1-S9 4. CHECKING, DISASSEMBLING AND SERVICING ............1-S10 [1] CHECKING AND ADJUSTING ..................1-S10 (1) Engine Body ......................1-S10 (2) Lubricating System ....................1-S13 (3) Cooling System ..................... 1-S13 (4) Fuel System......................
Page 72: Troubleshooting
GR2100EC, WSM ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not Start A No fuel Replenish fuel A Air in the fuel system Bleed G-41 A Water in the fuel system Change fuel and G-27, 38 repair or replace fuel system A Fuel pipe clogged Clean...
Page 73 GR2100EC, WSM ENGINE Reference Symptom Probable Cause Solution Page A Fuel filter clogged or dirty Engine Revolution Is Replace G-27, 34 Not Smooth A Air cleaner clogged Clean or replace G-20, 35 A Fuel leak due to loose injection pipe retaining Tighten retaining nut 1-S24 A Injection pump malfunctioning...
Page 74 GR2100EC, WSM ENGINE Reference Symptom Probable Cause Solution Page A Head gasket defective Water Mixed into Replace 1-S26 Lubricant Oil A Cylinder block or cylinder head flawed Replace A Engine oil insufficient Low Oil Pressure Replenish G-8, 14 A Oil strainer clogged Clean A Oil filter clogged Replace...
Page 75: Servicing Specifications
GR2100EC, WSM ENGINE 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Compression Pressure 2.84 to 3.24 MPa 2.26 MPa 29.0 to 33.0 23.0 412 to 469 psi 327 psi Variance Among 10 % or less Cylinder Top Clearance 0.50 to 0.70 mm 0.0197 to 0.0276 in.
Page 76 GR2100EC, WSM ENGINE Item Factory Specification Allowable Limit Tappet to Tappet Guide Clearance 0.016 to 0.052 mm 0.10 mm 0.00063 to 0.00205 in. 0.0039 in. Tappet 17.966 to 17.984 mm (O.D.) 0.70732 to 0.70803 in. Tappet Guide Bore 18.000 to 18.018 mm (I.D.) 0.70866 to 0.70937 in.
Page 77 GR2100EC, WSM ENGINE Item Factory Specification Allowable Limit Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.038 mm 0.10 mm 0.00055 to 0.00150 in. 0.0039 in. Piston Pin 20.002 to 20.011 mm (O.D.) 0.78748 to 0.078783 in. Small End Bushing 20.025 to 20.040 mm (I.D.) 0.78839 to 0.78897 in.
Page 78 GR2100EC, WSM ENGINE Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing 3 Oil Clearance 0.028 to 0.059 mm 0.20 mm (Intermediate) 0.00110 to 0.00232 in. 0.0079 in. Crankshaft Journal 39.934 to 39.950 mm (O.D.) 1.57221 to 1.57284 in. Crankshaft Bearing 39.978 to 39.993 mm 1.57394 to 1.57453 in.
Page 79 GR2100EC, WSM ENGINE COOLING SYSTEM Item Factory Specification Allowable Limit Fan Belt Tension 7 to 9 mm / 98 N 0.28 to 0.35 in. / 98N (10 kgf, 22 lbs) Thermostat Valve Opening 69.5 to 72.5 Temperature 157.1 to 162.5 (At Beginning) Valve Opening Temperature...
Page 80 GR2100EC, WSM ENGINE 3. TIGHTENING TORQUES Tightening torques of screws and nuts on the table below are especially specified. (For general use screws and nuts : See page G-9.) Item Size x Pitch ft-lbs Front coupling mounting screw M8 x 1.25 23.5 to 27.4 2.4 to 2.8 17.4 to 20.3...
Page 81: Checking, Disassembling And Servicing
GR2100EC, WSM ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Disconnect the 2P connector from the fuel pump. 4. Remove the air cleaner, the muffler and all injection nozzles. 5.
Page 82 GR2100EC, WSM ENGINE Top Clearance 1. Remove the cylinder head. (Do not attempt to remove the cylinder head gasket.). 2. Move the piston up, and stick a strip of fuse [1.5 mm dia. (0.059 in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the piston head at three positions with grease so as to avoid the intake and exhaust valves and the combustion chamber ports.
Page 83 GR2100EC, WSM ENGINE Checking Valve Clearance A The valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover (1) and the glow plugs. 2. Align the "1TC" mark (2) on the flywheel and alignment mark (3) on the rear end plate so that the No.
Page 84: Lubricating System
GR2100EC, WSM ENGINE (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester (Code No.: 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds. 3.
Page 85 GR2100EC, WSM ENGINE Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.
Page 86 GR2100EC, WSM ENGINE A When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people. 0000000922E Radiator Cap Air Leakage 1. Set a radiator tester (1) and adaptor (2) (BANZAI Code No.: RCT-2A-30S) on the radiator cap.
Page 87: Fuel System
GR2100EC, WSM ENGINE (4) Fuel System Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid. 3. Turn the flywheel counterclockwise (facing the flywheel) until fuel flows from the delivery valve holder. 4. Continue to turn the flywheel slowly, and stop it as soon as the fuel level at the tip of the delivery valve holder begins to increase.
Page 88 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. 13.7 MPa...
Page 89 12.75 MPa (from 140 to 130 , from 1991 to 1849 psi). 9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. 10 seconds 13.73 12.75 MPa Factory spec.
Page 90 GR2100EC, WSM ENGINE A Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. A If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
Page 91: Preparation
GR2100EC, WSM ENGINE Valve Seat Tightness 1. Set the injection nozzle to a nozzle tester (Code No. 07909- 31361). 2. Raise the fuel pressure, and keep at 12.75 MPa (130 1849 psi) for 10 seconds. 3. If any fuel leak is found, replace the nozzle piece. No fuel leak at 12.75 MPa Valve seat tightness...
Page 92 GR2100EC, WSM ENGINE Draining Engine Oil 1. Start and warm up the engine for approx. 5 minutes 2. Place an oil pan underneath the engine. 3. Remove the drain plug (1) to drain oil. 4. After draining, screw in the drain plug (1). (When refilling) A Fill the engine oil up to the upper line on the dipstick (3).
Page 93 GR2100EC, WSM ENGINE Bonnet and Side Bonnet 1. Disconnect the connectors (5) from the head light. 2. Remove the wire harness (4) from the bonnet. 3. Remove the bonnet (1) with bonnet bracket (2). 4. Remove the side bonnet (3). (1) Bonnet (4) Wire Harness (2) Bonnet Bracket...
Page 94 GR2100EC, WSM ENGINE Engine Assembly 1. Remove the radiator stopper snap pins (2). 2. Disconnect the front coupling (5). 3. Separate the engine assembly (6) with radiator from the frame (3). (When reassembling) 23.5 to 27.4 Front coupling mounting 2.4 to 2.8 screw 17.4 to 20.3 ft-lbs Tightening torque...
Page 95: Disassembling And Assembling
GR2100EC, WSM ENGINE [3] DISASSEMBLING AND ASSEMBLING (1) Cylinder Head and Valves Dynamo, Fan Belt and Radiator 1. Disconnect the radiator hoses and separate the radiator (1) with recovery tank (2) from engine assembly. 2. Remove the cooling fan (9) and fan pulley. 3.
Page 96 GR2100EC, WSM ENGINE Nozzle Holder Assembly and Glow Plugs 1. Remove the overflow pipe (1). 2. Remove the nozzle holder assemblies (2). 3. Remove the copper gasket (5) and the heat seal (6). 4. Remove the lead (3) from the glow plugs (4). 5.
Page 97 GR2100EC, WSM ENGINE Cylinder Head 1. Loosen the pipe clamp, and remove the water return pipe. 2. Remove the cylinder head screw in the order of (n) to (a). 3. Lift up the cylinder head to detach. 4. Remove the cylinder head gasket and O-ring (1). (When reassembling) A Replace the cylinder head gasket with a new one.
Page 98: Oil Pan, Timing Gears, Camshaft And Fuel Camshaft
GR2100EC, WSM ENGINE Valves 1. Remove the valve caps (2). 2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1). 3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6). 4.
Page 99 GR2100EC, WSM ENGINE 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 governor spring (4). 3.
Page 100 GR2100EC, WSM ENGINE Gear Case 1. Remove the screw (1) of inside the gear case and outside screws (6). 2. Disconnect the start spring (2) from the fork lever 1. 3. Remove the gear case (3). (When reassembling) A Apply a liquid gasket (Three Bond 1215 or equivalent) to both sides of the gear case gasket (4).
Page 101 GR2100EC, WSM ENGINE Idle Gear 1. Remove the external snap ring (3), the collar (2) and the idle gear (1). 2. Remove the idle gear shaft mounting screws (4). 3. Remove the idle gear shaft (5). (When reassembling) A Apply engine oil to the idle gear shaft mounting screw (4). And tighten them.
Page 102 GR2100EC, 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) A Hook the governor spring (7) to the fork lever 2 (6) as shown in the figure before installing the fork lever assembly to the crankcase.
Page 103: Pistons And Connecting Rods
GR2100EC, WSM ENGINE (3) Pistons and Connecting Rods Connecting Rods 1. Remove the connecting rod caps (1). (When reassembling) A Align the marks (a) with each other. (Face the marks toward the injection pump.). A Apply engine oil to the connecting rod screws and lightly screw it in by hand, then tighten it to the specified torque.
Page 104 GR2100EC, 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) A When installing the ring, assemble the rings so that the manufacturer's mark (12) near the gap faces the top of the piston.
Page 105: Crankshaft
GR2100EC, WSM ENGINE (4) Crankshaft Flywheel 1. Secure the flywheel to keep it from turning using a flywheel stopper. (Refer to "SPECIAL TOOLS".) 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) A Set the No. 1 crankpin at the top dead center (T.D.C.). A Align the "1TC"...
Page 106 GR2100EC, WSM ENGINE Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Turn the crankshaft to set the crankpin of the third cylinder to the bottom dead center. Then draw out the crankshaft until the crankpin of the second cylinder comes to the center of the third cylinder.
Page 107 GR2100EC, WSM ENGINE Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (9), and remove the main bearing case assembly 1 (1), being careful with crankshaft bearing 3 (4) (5). 2. Remove the main bearing case assembly 2 (2) and the main bearing case assembly (3) as above.
Page 108: Waterpump
GR2100EC, WSM ENGINE (5) Waterpump Thermostat Assembly 1. Remove the thermostat cover mounting screws, and remove the thermostat cover (1). 2. Remove the thermostat assembly (3). (When reassembling) A Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (2).
Page 109: Injection Nozzle
GR2100EC, WSM ENGINE (6) 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) A Assemble the nozzle in clean fuel oil. A Install the push rod (4), noting its direction. A After assembling the nozzle, be sure to adjust the fuel injection pressure.
Page 110 GR2100EC, WSM ENGINE Cylinder Head Flaw 1. Prepare an air spray red check (Code No. 07909-31371). 2. Clean the surface of the cylinder head with the detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying. 4.
Page 111 GR2100EC, WSM ENGINE Clearance between Valve Stem and Valve Guide 1. Remove carbon from the valve guide section. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. with a small hole gauge, and calculate the clearance.
Page 112 GR2100EC, WSM ENGINE Valve Seating 1. Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact. 2. If the valve does not seat all the way around the valve seat or the valve contact is less than 70 %, correct the valve seating as follows.
Page 113 GR2100EC, WSM ENGINE Correcting Valve and Valve Seat A Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. A After correcting the valve seat, be sure to check the valve recessing.
Page 114 GR2100EC, 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 115 GR2100EC, 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 alignment Allowable limit 0.0098 in. 0000000885E Oil Clearance between Tappet and Tappet Guide Bore 1.
Page 116: Timing Gear, Camshaft And Fuel Camshaft
GR2100EC, WSM ENGINE (2) Timing Gear, Camshaft and Fuel Camshaft Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear.
Page 117 GR2100EC, WSM ENGINE Camshaft Alignment 1. Support the camshaft with V blocks on the surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Measure the camshaft alignment. 4. If the measurement exceeds the allowable limit, replace the camshaft.
Page 118: Piston And Connecting Rod
GR2100EC, WSM ENGINE Oil Clearance between Idle Gear Shaft and Idle Gear Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance. 3.
Page 119 GR2100EC, WSM ENGINE Oil Clearance between Piston Pin and Small End Bushing 1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer. 2. Measure the small end bushing I.D. with an inside micrometer, and calculate the oil clearance. 3.
Page 120 GR2100EC, WSM ENGINE Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with piston. 2. Measure the ring gap with a thickness gauge. 3. If the measurement exceeds the allowable limit, replace the piston ring.
Page 121 GR2100EC, WSM ENGINE Connecting Rod Alignment 1. Remove the crankpin bearing, and install the connecting rod cap. 2. Install the piston pin in the connecting rod. 3. Install the connecting rod on the connecting rod alignment tool (Code No. 07909-31661). 4.
Page 122: Crankshaft
GR2100EC, WSM ENGINE (4) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings.
Page 123 GR2100EC, 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 centre 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 124 GR2100EC, 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 125 GR2100EC, WSM ENGINE Replacing Crankshaft Bearing 1 (When removing) 1. Press out the used crankshaft bearing 1 using a crankshaft bearing 1 replacing tool. (Refer to "SPECIAL TOOLS".) (When installing) 1. Clean a new crankshaft bearing 1 and crankshaft journal bore, and apply engine oil to them.
Page 126: Cylinder
GR2100EC, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) (Continued) (Reference) A Undersize crankshaft bearing 2 and 3 Undersize Bearing Code Number Marking Crankshaft bearing 2 02 15694-23930 020 US 0.2 mm 0.008 in. Crankshaft bearing 3 02 15861-23860 020 US...
Page 127: Oil Pump
GR2100EC, WSM ENGINE Correcting Cylinder 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. 67.250 to 67.269 mm Factory spec. 2.64764 to 2.64839 in. Cylinder I.D. [Oversize] 67.419 mm Allowable limit 2.65429 in.
Page 128 GR2100EC, 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 129 TRANSAXLE KiSC issued 04, 2006 A...
Page 130 CONTENTS 1. STRUCTURE........................2-M1 2. TRAVELLING SYSTEM....................2-M2 [1] HYDROSTATIC TRANSMISSION ..................2-M2 (1) Structure ........................2-M2 (2) Oil Flow........................2-M3 (3) Operation.........................2-M4 (4) By-pass Valve......................2-M7 (5) Control Linkage .......................2-M8 [2] GLIDE STEER SECTION ....................2-M9 (1) General........................2-M9 (2) Operation.......................2-M11 [3] FRONT WHEEL DRIVE SECTION ................2-M12 3.
Page 131: Structure
GR2100EC, WSM TRANSAXLE 1. STRUCTURE (1) Hydraulic Pump Section (3) Front Wheel Drive Section (5) Glide Steer Section (7) Rear Axle Section (2) Input Shaft (4) Bevel Gear Section (6) Hydrostatic Transmission (8) Mower PTO Section The transaxle of this machine is constructed as shown above. This machine is equipped with left and right clutches in transaxle.
Page 132: Travelling System
GR2100EC, WSM TRANSAXLE 2. TRAVELLING SYSTEM [1] HYDROSTATIC TRANSMISSION (1) Structure (1) Check and High Pressure (7) Spring (Cylinder Block) (14) Pump Shaft (21) By-pass Spool Relief Valve (8) Washer (15) Ball Bearing (22) By-pass Spring (2) Trunnion Arm (9) Thrust Ball Bearing (16) Oil Seal (23) Journal Bearing (3) Center Section...
Page 133: Oil Flow
GR2100EC, WSM TRANSAXLE (2) Oil Flow (1) Pump (5) Hydraulic Control Valve (9) By-pass Valve A : From Power Steering (2) Check and High Pressure Assembly (10) Check and High Pressure Controller Relief Valve (Forward) (6) Hydraulic Pump Relief Valve (Reverse) B : To Power Steering (3) Filter Cartridge (7) Main Relief Valve...
Page 134: Operation
GR2100EC, WSM TRANSAXLE (3) Operation B Neutral (1) Filter Cartridge (7) Hydraulic Control Valve (11) Lubricating Orifice (14) Piston (2) HST Relief Valve Assembly (12) Check and High Pressure (15) Cylinder Block (Mower) (3) Power Steering Controller (8) Hydraulic Pump Relief Valve (Reverse) (16) By-pass Valve (4) Control Valve...
Page 135 GR2100EC, WSM TRANSAXLE B Forward (1) Filter Cartridge (7) Hydraulic Control Valve (11) Lubricating Orifice (14) Piston (2) HST Relief Valve Assembly (12) Check and High Pressure (15) Cylinder Block (Mower) (3) Power Steering Controller (8) Hydraulic Pump Relief Valve (Reverse) (16) By-pass Valve (4) Control Valve (9) Swashplate...
Page 136 GR2100EC, WSM TRANSAXLE B Reverse (1) Filter Cartridge (7) Hydraulic Control Valve (11) Lubricating Orifice (14) Piston (2) HST Relief Valve Assembly (12) Check and High Pressure (15) Cylinder Block (Mower) (3) Power Steering Controller (8) Hydraulic Pump Relief Valve (Reverse) (16) By-pass Valve (4) Control Valve (9) Swashplate...
Page 137: By-Pass Valve
GR2100EC, WSM TRANSAXLE (4) By-pass Valve Normally, when the engine is stopped, the pump shaft and pump cylinder block engaged with it do not rotate. Thus, the motor shaft does not rotate. However, pressing the by-pass valve in the center section permits moving the machine with human power while the engine is stopped.
Page 138: Control Linkage
GR2100EC, WSM TRANSAXLE (5) Control Linkage (1) Speed Change Pedal (3) Speed Change Plate (5) Neutral Spring (6) Speed Control Arm (2) Speed Change Rod (4) Neutral Arm The speed change pedal (1) and the trunnion arm of variable swashplate are linked with the speed change rod (2), speed change plate (3) and the speed control arm (6).
Page 139: Glide Steer Section
GR2100EC, WSM TRANSAXLE [2] GLIDE STEER SECTION (1) General This machine is equipped with the Glide Steer system. On turning, the Glide Steer system provides a mechanism that allows a turf-friendly minimum turn by driving the front wheels and the rear wheel on the outside of the turn at the same time.
Page 140 GR2100EC, WSM TRANSAXLE The following paragraphs describe how the machines equipped with normal 4WD and the Glide Steer turn. 0000010104E B For Normal 4WD The machine with four wheels has a wheel base. Because of this, turning the machine creates a difference in the length of tracks made by the differential gears in the front axle and in the rear axle.
Page 141: Operation
GR2100EC, WSM TRANSAXLE (2) Operation B On Going Straight On going straight, the right and left steering clutches in transaxle are engaged to transmit driving power to the right and left rear wheels. At this time, all four wheels drive the machine. Spring tension pushes the spline boss (4) in the steering clutch toward the inside of the machine, which eliminates the clearance between clutch disc and...
Page 142: Front Wheel Drive Section
GR2100EC, WSM TRANSAXLE [3] FRONT WHEEL DRIVE SECTION This machine always has the front axle driven. Driving power is transmitted to the front axle as follows : Motor shaft (3) 15T gear (4) 29T gear (2) Front wheel drive shaft (1) (1) Front Wheel Drive Shaft (3) Motor Shaft (2) 29T Gear...
Page 143: Mower Pto System
GR2100EC, WSM TRANSAXLE 3. MOWER PTO SYSTEM [1] MOWER PTO CLUTCH The mower PTO clutch is equipped with mechanical independent clutches of wet multi-plates type. The PTO shaft (1) is engaged with the spline boss (3). The clutch case (5) is engaged with the 24T gear (6). Normally, spring (8) tension pushes the spline boss (3) in the PTO clutch toward the front side of the machine, which creates clearance between clutch disc...
Page 144 GR2100EC, WSM TRANSAXLE B PTO "Disengaged" When the PTO lever is set at the "Disengaged" position, the clutch lever (2) connected to the PTO lever via a link mechanism rotates to the front side of the machine. Spring (8) tension pushes the spline boss (3) toward the front side of the machine, which creates clearance between the clutch disc and friction plate (4), causing no friction.
Page 145: Others
GR2100EC, WSM TRANSAXLE 4. OTHERS [1] HYDRAULIC PUMP SECTION The hydraulic pump (1) is mounted on the transaxle case. The power to drive the hydraulic pump (1) is transmitted as follows : Input shaft (4) 25T gear (3) on input shaft Hydraulic pump gear shaft (2) (1) Hydraulic Pump (3) 25T Gear...
Page 146 CONTENTS 1. TROUBLESHOOTING....................... 2-S1 2. SERVIVING SPECIFICATIONS ..................2-S4 3. TIGHTENING TORQUES ....................2-S5 4. CHECKING, DISASSEMBLING AND SERVICING ............2-S6 [1] CHECKING AND ADJUSTING ..................2-S6 [2] PREPARATION ....................... 2-S9 (1) Separating Transaxle ....................2-S9 (2) Separating Hydrostatic Transmission..............2-S17 [3] DISASSEMBLING AND ASSEMBLING...............
Page 147: Troubleshooting
GR2100EC, WSM TRANSAXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Oil level is low System Will Not Fill oil to proper level G-8, 2-S11 Operate in Either A Control linkage defective (Speed change pedal Repair control linkage 2-S7, 15 Direction to speed control arm) A Charge pressure is...
Page 148 GR2100EC, WSM TRANSAXLE A Oil level is low Less of Power Fill oil to proper level G-8, 2-S11 A Control linkage defective (Speed change pedal Repair control linkage 2-S7, 15 to speed control arm) A Charge pressure is A Oil filter cartridge Replace oil filter G-31 cartridge...
Page 149 GR2100EC, WSM TRANSAXLE BEVEL GEAR SECTION Reference Symptom Probable Cause Solution Page A Improper backlash between 11T bevel gear Excessive or Unusual Adjust 2-S32 Noise at All Time and 17T-13T gear shaft A Bearing worn Replace A Insufficient or improper type of transmission Replenish or change G-8, 2-S11 fluid used...
Page 150: Serviving Specifications
GR2100EC, WSM TRANSAXLE 2. SERVIVING SPECIFICATIONS Item Factory Specification Allowable Limit HST Relief Valve Setting Pressure 0.9 to 1.1 MPa (Oil temperature at 50 , 122 9.2 to 11.2 130.6 to 159.5 psi High relief pressure Setting Pressure 18.5 to 22.2 MPa 189 to 226 2684 to 3263 psi PTO Clutch Disc...
Page 151 GR2100EC, WSM TRANSAXLE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9) Item ft-lbs Brake plate mounting screw 35 to 40 3.47 to 4.07 25.1 to 29.5 Universal joint mounting screw...
Page 152: Checking, Disassembling And Servicing
GR2100EC, WSM TRANSAXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Adjustment of HST Neutral Position 1. Lift up the front and rear of the machine, and support it with disassembling jacks. 2. Remove the left rear wheel. 3. Start the engine, and set at approx. 1500 to 3000 (rpm).
Page 153 GR2100EC, WSM TRANSAXLE Speed Change Pedal Restriction A This adjustment should be performed after completing the adjustment of neutral. 1. Set the speed change pedal (1) to "NEUTRAL" position, and apply the parking brake. 2. Check that the pin (3) of speed change pedal lock with the brake pedal arm (2).
Page 154 GR2100EC, WSM TRANSAXLE HST Relief Pressure A When checking, park the machine on level ground, apply the parking brake. A This checking should be performed after completing the adjustment of neutral. 1. Remove the plug (Rc 1/8) (1) from the hydraulic control valve assembly.
Page 155: Preparation
GR2100EC, WSM TRANSAXLE [2] PREPARATION (1) Separating Transaxle Dismounting Mower 1. See page 8-S6. ("Mower" Section) 0000010126E Dismounting the Container A Park the machine on a firm and level ground. A Stop the engine, and remove the key. 1. Grip the grass container lock handle (2) with the handle (3). Ground the grass container (1) as shown in the figure.
Page 156 GR2100EC, WSM TRANSAXLE Container Base 1. Disconnect the couplers (1) from the relays. 2. Disconnect the connectors (2). 3. Open the switch cover (6). And disconnect the connector (4) from the grass container full switch (5). 4. Remove the discharge duct (3). 5.
Page 157 A After running the engine for few minutes, stop the engine and check the oil level again, if low, add oil to prescribed level. A Use only the KUBOTA UDT or SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system.
Page 158 GR2100EC, WSM TRANSAXLE Seat 1. Remove the snap pin (2). 2. Remove the seat (1) . (1) Seat (2) Snap Pin 0000010128E Fender 1. Remove the speed change pedal (5). 2. Peel the step sheet (4) halfway. 3. Remove the fuel cap (1). 4.
Page 159 GR2100EC, WSM TRANSAXLE PTO Rod Spring 1. Remove the two nuts (2) (3) and spring (4). (When reassembling) 1. Assemble a fuel tank, a seat base and a fender. 2. Setting the PTO lever at "Disengaged" position and lifting the PTO arm (5) slightly by hands directly, the upper side of PTO arm (5) and lower nut (6) on the upper side of PTO rod (1) make contact, and there is no play between them.
Page 160 GR2100EC, WSM TRANSAXLE Beam 1. Disconnect the connector from the PTO switch (1). 2. Remove the spring (2) from the PTO lever (3). 3. Remove the PTO rod 4. Remove the filling pipe (4). 5. Remove the beam (5). (1) PTO Switch (4) Filling Pipe (2) Spring (5) Beam...
Page 161 GR2100EC, WSM TRANSAXLE Speed Control Plate 1. Remove the rue ring pin (2), and disconnect the speed change plate (1) and speed control arm (3). 2. Separate the speed change plate (1) and speed change rod (4). A After assembling the speed change plate (1) and speed change rod (4), be sure to adjust the speed change pedal restriction (see page 2-S7).
Page 162 GR2100EC, WSM TRANSAXLE Glide Steer Wire 1. Remove the rue ring pin (1). 2. Loose the adjusting nut (3). 3. Disconnect the Glide Steer wire (4) and wire stay (2). (When reassembling) A Adjust the length "A" with adjusting nut (3) on the Glide Steer wire (4).
Page 163: Separating Hydrostatic Transmission
GR2100EC, WSM TRANSAXLE (2) Separating Hydrostatic Transmission Speed Control Arm, Neutral Spring, Cooling Fan and Others 1. Remove the neutral spring (2). 2. Remove the speed control arm (1). 3. Remove the cooling fan (4). 4. Remove the breather hoses (3). 5.
Page 164 GR2100EC, WSM TRANSAXLE Brake Assembly 1. Remove the brake assembly (1). 2. Remove the external snap ring (2). And pull out the brake drum (3). (1) Brake Assembly (3) Brake Drum (2) External Snap Ring 0000009335E Hydrostatic Transmission Assembly 1. Remove the hydrostatic transmission assembly (1). A When reassembling hydrostatic...
Page 165: Disassembling And Assembling
GR2100EC, WSM TRANSAXLE [3] DISASSEMBLING AND ASSEMBLING (1) Hydrostatic Transmission 15T Gear, 34T Gear and Bevel Gear Shaft 1. Remove the front drive shaft (1) 2. Remove the external snap ring (5). And pull out the 15T gear (2) and 34T gear (3). 3.
Page 166 GR2100EC, WSM TRANSAXLE By-pass Valve 1. Remove the plug (4) and draw out the the by-pass spool (2) and spring (1). (When reassembling) A Take care not to damage the O-ring (3) on the plug (4). 15.0 Tightening torque By-pass valve plug 1.53 11.1 ft-lbs (1) Spring...
Page 167: Transaxle Case
GR2100EC, WSM TRANSAXLE Swashplate, Pump Shaft and Motor Shaft 1. Remove the swashplate (2) and thrust ball bearing (1) from the HST housing. 2. Remove the internal snap ring (5), and tap out the pump shaft (3) and oil seal (4). 3.
Page 168 GR2100EC, WSM TRANSAXLE PTO Clutch Assembly 1. Remove the PTO clutch assembly (1) and the ball bearing (2) from the transaxle case. (When reassembling) A Install the ball bearing (2) with the sealed face inside. A Align the tangs (4) of PTO brake friction plate with the slots (3) of transaxle case.
Page 169 GR2100EC, WSM TRANSAXLE Disassembling PTO Clutch Assembly 1. Remove the 24T gear (1), clutch (2), brake disc and friction plate (3) from PTO shaft (4). 2. While pressing the clutch (2), turn the clutch case (5) clockwise. Then, separate the clutch case (5) and the spline boss (9) with clutch disc and friction plate (10).
Page 170 GR2100EC, WSM TRANSAXLE Disassembling PTO Clutch Assembly (Continued) 1. Pull out the PTO shaft (1) from PTO clutch cover (5) until external snap ring (3) touches clutch lever (4). 2. Tap out the PTO shaft (1) while opening the external snap ring (3) with external snap ring pliers.
Page 171 GR2100EC, WSM TRANSAXLE Transaxle Case 1. Remove the transaxle case screws (2). 2. Separate the rear side of transaxle case (1). (When reassembling) A Apply liquid gasket (Three Bond 1208D or equivalent) to joint face of the transaxle case. A Install the transaxle case screws (2) in the direction shown in figure.
Page 172 GR2100EC, WSM TRANSAXLE Pump Drive Gear, Input Shaft, 19T-2 Gear and 17T-13T Gear Shaft 1. Remove the pump drive gear (1) and input shaft (2). 2. Remove the intermediate shaft (3) and 19T-2 gear (4) with collars (7) and needle bearing (8). 3.
Page 173: Servicing
GR2100EC, WSM TRANSAXLE Disassembling Steering Clutch 1. Remove the internal snap ring (1). 2. Remove the clutch plate (2) and spline boss (5) with clutch disc and friction plate (3) from the steering clutch case (10). 3. Remove the spacer (7), spring (8) and clutch collar (9). 4.
Page 174 GR2100EC, WSM TRANSAXLE Check and High Pressure Relief Valve 1. Check the check and high pressure relief valves (4) (5) for scratches and damage. 2. Check the springs (3) (6) for breakage and wear. 3. If anything unusual, replace the check and high pressure relief valve assembly.
Page 175: Transaxle Case
GR2100EC, WSM TRANSAXLE Pump Shaft 1. Check the seal surface (1), the bearing surface (2) and the ball bearing (3). 2. If the shaft is rough or grooved, replace it. 3. If the ball bearing is worn, replace it. (1) Seal Surface (3) Ball Bearing (2) Bearing Surface 0000004178E...
Page 176 GR2100EC, WSM TRANSAXLE PTO Clutch Disc Wear 1. Measure the thickness of PTO clutch disc with vernier calipers. 2. If the thickness is less than the allowable limit, replace it. 1.3 to 1.5 mm Factory spec. 0.051 to 0.059 in. Thickness of PTO clutch disc 1.2 mm...
Page 177 GR2100EC, WSM TRANSAXLE PTO Brake Disc Wear 1. Measure the thickness of PTO brake disc with a vernier caliper. 2. If the thickness is less than the allowable limit, replace it. 2.85 to 3.05 mm Factory spec. 0.11 to 0.12 in. PTO brake disc 1 thickness 2.75 mm...
Page 178 GR2100EC, WSM TRANSAXLE Friction Plate and Clutch Plate 1. Measure the thickness of friction plate and clutch plate with vernier calipers. 2. If the thickness is less than the allowable limit, replace it. 0.75 to 0.85 mm Factory spec. 0.030 to 0.033 in. Thickness of friction plate 0.70 mm...
Page 179 BRAKES KiSC issued 04, 2006 A...
Page 180 CONTENTS 1. TROUBLESHOOTING....................... 3-S1 2. SERVICING SPECIFICATIONS ..................3-S2 3. TIGHTENING TORQUES ....................3-S3 4. CHECKING, DISASSEMBLING AND SERVICING ............3-S4 [1] CHECKING AND ADJUSTING ..................3-S4 [2] DISASSEMBLING AND ASSEMBLING................. 3-S4 (1) Pedal System Component..................3-S4 (2) Brake Assembly....................... 3-S8 KiSC issued 04, 2006 A...
Page 181: Troubleshooting
GR2100EC, WSM BRAKES 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Brake pedal free travel excessive Insufficient Braking Adjust 3-S4 Force A Brake shoe worn Replace 3-S8 A Brake drum worn Replace 3-S8 A Grease or oil on brake shoe Replace 3-S8 A Brake pedal free travel too small...
Page 182: Servicing Specifications
GR2100EC, WSM BRAKES 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Brake Pedal Free Travel 15 to 25 mm 0.59 to 0.98 in. 0000009613E KiSC issued 04, 2006 A 3-S2...
Page 183 GR2100EC, 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-9) Item ft-lbs Steering wheel mounting nut 20 to 25 2.0 to 2.5 14.8 to 18.4 Power steering hose mounting nut...
Page 184: Checking, Disassembling And Servicing
GR2100EC, WSM BRAKES 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Brake Pedal Free Travel A Stop the engine, remove the key, and chock the wheels before checking brake pedal. 1. Release the parking brake. 2. Loosen the lock nut (1). 3.
Page 185 GR2100EC, WSM BRAKES Container Base 1. Disconnect the couplers (1) from the relays. 2. Disconnect the connectors (2). 3. Open the switch cover (6). And disconnect the connector (4) from the grass container full switch (5). 4. Remove the discharge duct (3). 5.
Page 186 GR2100EC, WSM BRAKES Steering Wheel, Side Bonnet and Panel 1. Remove the steering wheel (1). 2. Remove the side bonnet (3). 3. Remove the accelerator lever grip. 4. Disconnect the connectors for hour meter, main switch (4) and light switch. 5.
Page 187 GR2100EC, WSM BRAKES Steering Support Assembly 1. Disconnect the power steering hose (1) (2) (3) (4). 2. Disconnect the connectors for the timer relay, regulator and buzzer unit. 3. Disconnect the accelerator wire (6). 4. Separate the steering support assembly (5). (When reassembling) A Be sure to connect the power steering hose to their original position, and tighten them to the specified torque.
Page 188: Brake Assembly
GR2100EC, WSM BRAKES Pedal System Component 1. Remove the parking lock spring (1). 2. Remove the pedal system component mounting nuts (2). 3. Separate the pedal system component (3) from frame. (When reassembling) Pedal system 48.1 to 55.8 Tightening torque component mounting 4.9 to 5.7 35.5 to 41.2 ft-lbs...
Page 189: Front Axle
FRONT AXLE KiSC issued 04, 2006 A...
Page 190 CONTENTS 1. STRUCTURE........................4-M1 KiSC issued 04, 2006 A...
Page 191 GR2100EC, WSM FRONT AXLE 1. STRUCTURE (1) King Pin Support (2) Front Axle Case (Front Side) (3) Differential Gear Assembly (4) Differential Pinion Shaft (5) Differential Pinion Gear (6) Differential Yoke Shaft, (7) Differential Side Gear (8) Bevel Gear (9) Bevel Pinion Shaft (10) Differential Yoke Shaft, (11) Front Axle Case (Rear Side)
Page 192 CONTENTS 1. TROUBLESHOOTING....................... 4-S1 2. SERVICING SPECIFICATIONS ..................4-S2 3. TIGHTENING TORQUES ....................4-S3 4. CHECKING, DISASSEMBLING AND SERVICING ............4-S4 [1] CHECKING AND ADJUSTING ..................4-S4 [2] PREPARATION ....................... 4-S6 (1) Separating Front Axle Assembly ................4-S6 [3] DISASSEMBLING AND ASSEMBLING................. 4-S9 (1) Front Axle Assembly....................
Page 193: Troubleshooting
GR2100EC, WSM FRONT AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Tire pressure uneven Front Wheels Wander Adjust G-49 to Right or Left A Improper toe-in adjustment (improper Adjust 4-S4 alignment) A Tie-rod end loose Tighten 4-S9 A Air sucked in power steering circuit Bleed A Front wheel driving gears in front axle gear Front Wheels Can Not...
Page 194: Servicing Specifications
GR2100EC, WSM FRONT AXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Front Wheel Alignment Toe-in 0 to 5 mm 0.00 to 0.20 in. Differential Gear Case to Differential Side Clearance 0.040 to 0.082 mm 0.17 mm Gear 0.00157 to 0.00323 in. 0.0067 in.
Page 195 GR2100EC, 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-9.) Item ft-lbs Power steering cylinder hose 24.0 to 28.0 2.45 to 2.85 17.71 to 20.65 Front wheel mounting screw...
Page 196: Checking, Disassembling And Servicing
GR2100EC, WSM FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Toe-in 1. Inflate the tires to the specified pressure. 2. Turn the front wheels straight ahead. 3. Measure the toe-in (B-A). 4. If the measurement is not within the factory specifications, adjust the tie-rod length.
Page 197 GR2100EC, WSM FRONT AXLE Adjusting Glide Steer A Park the machine on level ground, apply the parking brake. A Stop the engine and remove the key. A This adjustment should be performed after completing the adjustment of toe-in. 1. Lift up the machine while kept parallel, and support it with disassembling jacks.
Page 198: Preparation
A Fill the oil up to the upper line on the filling plug with dipstick (2). A After ten minutes, check the oil level again, add oil to prescribed level. A Use KUBOTA UDT or SUPER UDT fluid. Refer to "LUBRICANTS, FUEL AND COOLANT"...
Page 199 GR2100EC, WSM FRONT AXLE Bonnet and Side Bonnet 1. Disconnect the connectors (5) from the head light. 2. Remove the wire harness (4) from the bonnet. 3. Remove the bonnet (1) with bonnet bracket (2). 4. Remove the side bonnet (3). (1) Bonnet (4) Wire Harness (2) Bonnet Bracket...
Page 200 GR2100EC, WSM FRONT AXLE Power Steering Cylinder Holder 1. Unscrew the power steering cylinder holder mounting screws (2). 2. Remove the power steering cylinder holder (1). (When reassembling) A Reinstall the Glide Steer wire (3) as shown in the figure. (1) Power Steering Cylinder Holder (3) Glider Steer Wire (2) Power Steering Cylinder Holder...
Page 201: Disassembling And Assembling
GR2100EC, WSM FRONT AXLE [3] DISASSEMBLING AND ASSEMBLING (1) Front Axle Assembly Power Steering Cylinder 1. Remove the cotter pin and remove the slotted nut for tie-rod (1). 2. Remove the power steering cylinder mounting screws and remove the power steering cylinder (2) with tie-rod. (When reassembling) A Tighten the slotted nut to 17.7 (1.8...
Page 202 GR2100EC, WSM FRONT AXLE 35T Bevel Gear and Front Axle 1. Remove the 35T bevel gear (1). 2. Remove the collar (2). 3. Tap out the front axle shaft (3). (1) 35T Bevel Gear (3) Front Axle Shaft (2) Collar 0000010196E Front Gear Case 1.
Page 203 GR2100EC, WSM FRONT AXLE Bevel Pinion Shaft 1. Remove the bevel pinion shaft (4) from the rear side of front axle case (2). 2. Remove the oil seal (1). (1) Oil Seal (3) Shim (2) Front Axle Case (Real Side) (4) Bevel Pinion Shaft 0000010199E 15T Bevel Gear...
Page 204: Servicing
GR2100EC, WSM FRONT AXLE Differential Gear Assembly 1. Remove the bevel gear (10). 2. Remove the bearings (5), (9) with the puller. 3. Remove the external snap ring (8). 4. Remove the differential pinion shaft (7). 5. Remove the differential pinion gears (3), differential side gears (4) and shims (2).
Page 205 GR2100EC, WSM FRONT AXLE Clearance between Differential Pinion Shaft and Differential Pinion Gear 1. Measure the differential pinion shaft O.D.. 2. Measure the differential pinion gear I.D., and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace faulty parts.
Page 206 GR2100EC, WSM FRONT AXLE Backlash between Bevel Pinion Shaft and Bevel Gear 1. Stick a strip of fuse to three spots on the bevel gear (3) with grease. 2. Fix the front side and rear side of front axle case. 3.
Page 207 GR2100EC, WSM FRONT AXLE Backlash between 10T Bevel Gear and 15T Bevel Gear 1. Stick a strip of fuse to three spots on the 15T bevel gear (2) with grease. 2. Fix the front side and rear side of front axle case. 3.
Page 208 STEERING KiSC issued 04, 2006 A...
Page 209 CONTENTS 1. HYDRAULIC CIRCUIT .....................5-M1 2. STEERING CONTROLLER ....................5-M2 3. STEERING CYLINDER ....................5-M4 KiSC issued 04, 2006 A...
Page 210 GR2100EC, WSM STEERING 1. HYDRAULIC CIRCUIT (1) Hydraulic Control Valve (3) Oil Strainer (5) Steering Cylinder A : To HST Assembly (4) Steering Controller B : To Mower Lift Cylinder (2) Hydraulic Pump This machine is provided with a full hydrostatic power steering. In the full hydrostatic power steering, the steering controller (4) is connected to the steering cylinder (5) with only the hydraulic piping.
Page 211 GR2100EC, WSM STEERING 2. STEERING CONTROLLER The steering controller consists of a control valve (3) and a metering device (2). B Control Valve The control valve is a rotating spool type. When the steering wheel is not turned, the position of the spool (6) and sleeve (8) is kept neutral by the centering spring (7).
Page 212 GR2100EC, WSM STEERING B Relief Valve The relief valve (1) is located in the steering controller. It controls the maximum pressure of the power steering system. Its setting pressure is as follows. 8.3 to 8.8 MPa 84.6 to 89.7 1204 to 1276 psi (1) Relief Valve P : P Port (From Hydraulic Control...
Page 213: Steering Cylinder
GR2100EC, WSM STEERING 3. STEERING CYLINDER (1) Rod (4) Guide (7) Center Piston (10) Cylinder Tube (2) Wiper Ring (5) O-ring (8) Piston O-ring (11) Rod O-ring (3) Internal Snap Ring (6) Seal Ring (9) External Snap Ring The steering cylinder is single piston both rod double-acting type. This steering cylinder is installed parallel to the front axle and connected to tie-rods.
Page 214 CONTENTS 1. TROUBLESHOOTING....................... 5-S1 2. SERVICING SPECIFICATIONS ..................5-S2 3. TIGHTENING TORQUES ....................5-S3 4. CHECKING, DISASSEMBLING AND SERVICING ............5-S4 [1] CHECKING AND ADJUSTING ..................5-S4 [2] PREPARATION ....................... 5-S5 (1) Separating Power Steering Controller ..............5-S5 (2) Separating Power Steering Cylinder ............... 5-S8 [3] DISASSEMBLING AND ASSEMBLING...............
Page 215: Troubleshooting
GR2100EC, WSM STEERING 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Steering controller malfunctioning Cannot Be Steered Replace 5-S8 A Hose broken Replace 5-S8 A Power steering oil improper Hard Steering Change with specified G-8, 30 A Hydraulic pump malfunctioning Replace 6-S8 A Steering controller malfunctioning...
Page 216: Servicing Specifications
GR2100EC, WSM STEERING 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Steering Wheel Play 30 to 70 mm 0.79 to 1.18 in. 0000009619E POWER STEERING BODY Item Factory Specification Allowable Limit Relief Valve Operating Pressure 8.3 to 8.8 MPa 84.6 to 89.7 1204 to 1276 psi 0000010215E KiSC issued 04, 2006 A...
Page 217 GR2100EC, WSM STEERING 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9) Item ft-lbs Steering wheel mounting nut 20 to 25 2.0 to 2.5 14.8 to 18.4 Power steering hose mounting nut...
Page 218: Checking, Disassembling And Servicing
GR2100EC, WSM STEERING 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Steering Wheel Play 1. Turn the front wheels straight ahead. 2. Rotate the steering wheel lightly by hand, and measure the play. 3. If the measurement exceeds the factory specifications, replace the steering shaft and sector gear.
Page 219: Preparation
GR2100EC, WSM STEERING [2] PREPARATION (1) Separating Power Steering Controller Dismounting Mower 1. See page 8-S6. ("Mower" Section) 0000010126E Dismounting Container 1. See page 2-S9. ("Transaxle" Section) 0000010177E Battery A When disconnecting the battery cables, disconnect the negative cable from the battery first. When connecting, connect the positive cable to the battery first.
Page 220 GR2100EC, WSM STEERING Container Base 1. Disconnect the couplers (1) from the relays. 2. Disconnect the connectors (2). 3. Open the switch cover (6). And disconnect the connector (4) from the grass container full switch (5). 4. Remove the discharge duct (3). 5.
Page 221 GR2100EC, WSM STEERING Steering Wheel, Side Bonnet and Panel 1. Remove the steering wheel (1). 2. Remove the side bonnet (3). 3. Remove the accelerator lever grip. 4. Disconnect the connectors for hour meter, main switch (4) and light switch. 5.
Page 222: Separating Power Steering Cylinder
GR2100EC, WSM STEERING Steering Controller 1. Disconnect the power steering hoses (1), (2), (3), (4). 2. Remove the steering controller mounting screws and remove the steering controller (5). (When reassembling) A Be sure to connect the power steering hoses to their original position, and tighten them to the specified torque.
Page 223 GR2100EC, WSM STEERING Bonnet and Side Bonnet 1. Disconnect the connectors (5) from the head light. 2. Remove the wire harness (4) from the bonnet. 3. Remove the bonnet (1) with bonnet bracket (2). 4. Remove the side bonnet (3). (1) Bonnet (4) Wire Harness (2) Bonnet Bracket...
Page 224 GR2100EC, WSM STEERING Power Steering Cylinder Holder 1. Unscrew the power steering cylinder holder mounting screws (2). 2. Remove the power steering cylinder holder (1). (When reassembling) A Reinstall the Glide Steer wire (3) as shown in the figure. (1) Power Steering Cylinder Holder (3) Glider Steer Wire (2) Power Steering Cylinder Holder (4) Front Axle Assembly...
Page 225: Disassembling And Assembling
GR2100EC, WSM STEERING Power Steering Cylinder 1. Remove the cotter pin and remove the slotted nut for tie-rod (1). 2. Remove the power steering cylinder mounting screws and remove the power steering cylinder (2) with tie-rod. (When reassembling) A Tighten the slotted nut to 17.7 (1.8 , 13 ft-lbs).
Page 226: Hydraulic System
HYDRAULIC SYSTEM KiSC issued 04, 2006 A...
Page 227 CONTENTS 1. HYDRAULIC CIRCUIT .....................6-M1 2. HYDRAULIC PUMP......................6-M2 3. HYDRAULIC CONTROL VALVE ..................6-M3 [1] MOWER LIFT CIRCUIT....................6-M4 [2] HST RELIEF VALVE......................6-M8 4. MOWER LIFT CYLINDER ....................6-M9 5. MOWER LINKAGE ......................6-M10 KiSC issued 04, 2006 A...
Page 228: Hydraulic Circuit
GR2100EC, WSM HYDRAULIC SYSTEM 1. HYDRAULIC CIRCUIT (1) Hydrostatic Transmission (4) Hydraulic Control Valve (7) Check Valve (10) Oil Strainer (2) Oil Filter Cartridge Assembly (8) Control Valve (11) Main Relief Valve (3) HST Relief Valve (5) Steering Controller (9) Hydraulic Pump (6) Mower Lift Cylinder The hydraulic system of this machine is composed of a hydraulic pump (9), hydraulic control valve assembly (4), mower lift cylinder (6) and other components.
Page 229: Hydraulic Pump
GR2100EC, WSM HYDRAULIC SYSTEM 2. HYDRAULIC PUMP The hydraulic pump is composed of the casing (1), cover (5), side plate (3), drive gear (2) and driven gear (8). Hydraulic pump is driven by the pump drive shaft in the transaxle case. Maximum displacement is as follows.
Page 230: Hydraulic Control Valve
GR2100EC, WSM HYDRAULIC SYSTEM 3. HYDRAULIC CONTROL VALVE (1) Check Valve P : Pump Port PS1: Power Steering Port F1 : Filter Port (2) HST Relief Valve T : Tank Port (To Power Steering (To Filter Cartridge) (3) Main Relief Valve (To Transaxle Case) Controller) F2 : Filter Port...
Page 231: Mower Lift Circuit
GR2100EC, WSM HYDRAULIC SYSTEM [1] MOWER LIFT CIRCUIT B Neutral (1) Check Valve P : Pump Port T1 : Tank Port (To T Port) PS1: Power Steering Port (2) Main Relief Valve T : Tank Port C : Cylinder Port (To Power Steering (3) Spool (To Transaxle Case)
Page 232 GR2100EC, WSM HYDRAULIC SYSTEM B Lift (1) Check Valve P : Pump Port T1 : Tank Port (To T Port) PS1: Power Steering Port (2) Main Relief Valve T : Tank Port C : Cylinder Port (To Power Steering (3) Spool (To Transaxle Case) Controller) (4) Passage...
Page 233 GR2100EC, WSM HYDRAULIC SYSTEM B Overload (1) Check Valve P : Pump Port T1 : Tank Port (To T Port) PS1: Power Steering Port (2) Main Relief Valve T : Tank Port C : Cylinder Port (To Power Steering (3) Spool (To Transaxle Case) Controller) (4) Passage...
Page 234 GR2100EC, WSM HYDRAULIC SYSTEM B Down (1) Check Valve P : Pump Port T1 : Tank Port (To T Port) PS1: Power Steering Port (2) Flat Face T : Tank Port C : Cylinder Port (To Power Steering (3) Main Relief Valve (To Transaxle Case) Controller) (4) Spool...
Page 235: Hst Relief Valve
GR2100EC, WSM HYDRAULIC SYSTEM [2] HST RELIEF VALVE (1) HST Relief Valve P : Pump Port PS1: Power Steering Port F1 : Filter Port T : Tank Port (To Power Steering (To Filter Cartridge) (To Transaxle Case) Controller) F2 : Filter Port PS2: Power Steering Port (From Filter Cartridge) (From Power Steering...
Page 236: Mower Lift Cylinder
GR2100EC, WSM HYDRAULIC SYSTEM 4. MOWER LIFT CYLINDER (1) Cylinder Tube (2) Snap Ring (3) Cylinder Rod (4) Packing (5) Scraper The mower lift cylinder consists of cylinder tube (1), cylinder rod (3) and other parts as shown in the figure above. This cylinder is single acting type.
Page 237: Mower Linkage
GR2100EC, WSM HYDRAULIC SYSTEM 5. MOWER LINKAGE (1) Rear Link (2) Mower Lift Cylinder (3) Adjusting Cam (4) Cutting Height Adjusting Dial (5) Cutting Height Fine Turning Bolt (6) Lift Link Shaft (7) Lift Link The rear link (1) and lift link shaft (6) are linked with the lift link (7). As the hydraulic lift lever is set to the "LIFT"...
Page 238 CONTENTS 1. TROUBLESHOOTING....................... 6-S1 2. SERVICING SPECIFICATIONS ..................6-S2 3. TIGHTENING TORQUES ....................6-S3 4. CHECKING, DISASSEMBLING AND SERVICING ............6-S4 [1] CHECKING AND ADJUSTING ..................6-S4 [2] PREPARATION ....................... 6-S5 (1) Separating Hydraulic Control Valve and Hydraulic Pump ........6-S5 (2) Mower Lift Cylinder....................
Page 239 GR2100EC, WSM HYDRAULIC SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Control valve malfunctioning Mower Does Not Rise Repair or replace 6-S11 A Lift cylinder damaged Replace 6-S10 A Main Relief valve spring damaged Replace 6-S11 A Main Relief valve setting pressure too low Adjust 6-S4 A Hydraulic pump defective...
Page 240: Servicing Specifications
GR2100EC, WSM HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Main Relief Valve Setting Pressure 9.5 to 11.0 MPa 97 to 112 1378 to 1595 psi 0000010248E KiSC issued 04, 2006 A 6-S2...
Page 241 GR2100EC, 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-9) Item ft-lbs Bolt joint 24.5 to 34.3 2.50 to 3.49 18.1 to 25.2 Hydraulic pump mounting screw 17.7 to 20.6...
Page 242: Checking, Disassembling And Servicing
GR2100EC, WSM HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Main Relief Valve Setting Pressure 1. Remove the cylinder hose (1) form the mower lift cylinder. 2. Install the adaptor and pressure gauge. 3. Start the engine and set at maximum speed. 4.
Page 243: Preparation
GR2100EC, WSM HYDRAULIC SYSTEM [2] PREPARATION (1) Separating Hydraulic Control Valve and Hydraulic Pump Dismounting Container 1. See page 2-S9. ("Transaxle" Section) 0000010177E Container Base 1. Disconnect the couplers (1) from the relays. 2. Disconnect the connectors (2). 3. Open the switch cover (6). And disconnect the connector (4) from the grass container full switch (5).
Page 244 A After running the engine for few minutes, stop the engine and check the oil level again, if low, add oil to prescribed level. A Use only the KUBOTA UDT or SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system.
Page 245 GR2100EC, WSM HYDRAULIC SYSTEM Seat Base 1. Loose the seat base mounting screws 1 (1). 2. Remove the seat base mounting screws 2 (3). 3. Slide the seat base (2) and remove it. (1) Seat Base Mounting Screw 1 (3) Seat Base Mounting Screw 2 (2) Seat Base 0000009321E Fuel Tank...
Page 246 GR2100EC, WSM HYDRAULIC SYSTEM Hydraulic Control Valve Assembly 1. Disconnect the brake rod 1 (1) and brake plate (2). 2. Remove the brake plate (2) from neutral arm holder. 3. Remove the filter cartridge (3), breather hose (5) and neutral arm holder (4).
Page 247: Mower Lift Cylinder
GR2100EC, WSM HYDRAULIC SYSTEM (2) Mower Lift Cylinder Dismounting Container 1. See page 2-S9. ("Transaxle" Section) 0000010177E Container Base 1. Disconnect the couplers (1) from the relays. 2. Disconnect the connectors (2). 3. Open the switch cover (6). And disconnect the connector (4) from the grass container full switch (5).
Page 248 GR2100EC, WSM HYDRAULIC SYSTEM Fender 1. Remove the speed change pedal (5). 2. Peel the step sheet (4) halfway. 3. Remove the fuel cap (1). 4. Remove the fender (2). (1) Fuel Cap (4) Step Sheet (2) Fender (5) Speed Change Pedal (3) Fender Mounting Screw 0000009320E Mower Lift Cylinder...
Page 249: Disassembling And Assembling
GR2100EC, WSM HYDRAULIC SYSTEM [3] DISASSEMBLING AND ASSEMBLING (1) Hydraulic Control Valve Assembly Adaptor and Filter Joint 1. Remove the adaptors (2) (3). 2. Unscrew the drain pipe mounting screw, and remove the drain pipe (4). 3. Remove the joint pipe (1). 4.
Page 250: Mower Lift Linkage
GR2100EC, WSM HYDRAULIC SYSTEM Check Valve 1. Remove the cylinder hose adaptor (1). 2. Draw out the spring (3) and poppet (4). (When reassembling) A Take care not to damage the O-ring (2). (1) Cylinder Hose Adaptor (3) Spring (2) O-ring (4) Poppet 0000010260E (2) Mower Lift Linkage...
Page 251: Electrical System
ELECTRICAL SYSTEM KiSC issued 04, 2006 A...
Page 252 CONTENTS 1. WIRING DIAGRAM......................7-M1 2. STARTING SYSTEM ......................7-M3 3. CHARGING SYSTEM.......................7-M4 4. LIGHTING SYSTEM ......................7-M5 KiSC issued 04, 2006 A...
Page 253: Wiring Diagram
GR2100EC, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM 0000009632E KiSC issued 04, 2006 A 7-M1...
Page 254 GR2100EC, WSM ELECTRICAL SYSTEM Color of Wiring W..White WR..White / Red BW..Black / White R..Red WY..White / Yellow BR..Black / Red L..Blue RB..Red / Black GW..Green / White P..Pink RW..Red / White YR..Yellow / Red B..Black RG..Red / Green YL..Yellow / Blue Br..Brown RY..Red / Yellow LW..Blue / White...
Page 255: Starting System
GR2100EC, WSM ELECTRICAL SYSTEM 2. STARTING SYSTEM (1) Battery (7) Engine Stop Time Relay (12) Grass Container Open (16) Fuse (3 A) (2) Body Earth (8) Fuel Feed Pump Switch (17) Fuse (10 A) (3) Starter Motor (9) Slow Blow Fuse (40 A) (13) Grass Container Open (18) Main Switch (4) Glow Plug...
Page 256: Charging System
GR2100EC, WSM ELECTRICAL SYSTEM 3. CHARGING SYSTEM (1) Battery (4) Dynamo (7) Main Switch (9) Charge Lamp (2) Body Earth (5) Slow Blow Fuse (40 A) (8) Fuse (10 A) (10) Hour Meter (3) Body Earth (6) Regulator The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs.
Page 257: Lighting System
GR2100EC, WSM ELECTRICAL SYSTEM 4. LIGHTING SYSTEM (1) Battery (7) Regulator (13) Grass Container Full (18) Oil Pressure Lamp (2) Body Earth (8) Slow Blow Fuse (40 A) Switch (19) Charge Lamp (3) Thermo Switch (9) Main Switch (14) Buzzer Relay (20) Easy Checker (4) Oil Switch (10) Fuse (10 A)
Page 258 CONTENTS 1. TROUBLESHOOTING....................... 7-S1 2. SERVICING SPECIFICATIONS ..................7-S4 3. TIGHTENING TORQUES ....................7-S5 4. CHECKING, DISASSEMBLING AND SERVICING ............7-S6 [1] CHECKING AND ADJUSTING ..................7-S6 (1) Battery ........................7-S6 (2) Main Switch ......................7-S6 (3) Starter........................7-S8 (4) Glow Plug ........................ 7-S9 (5) Safety Switch......................
Page 259: Troubleshooting
GR2100EC, WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Battery discharged or defective All Electrical Recharge or replace G-25, 1-S21 Equipments Do Not A Battery positive cable disconnected Repair or replace Operate improperly connected A Battery negative cable disconnected...
Page 260 GR2100EC, WSM ELECTRICAL SYSTEM STARTING SYSTEM Reference Symptom Probable Cause Solution Page A Battery discharged or defective Starter Motor Does Recharge or replace G-25, 1-S21 Not Operate A Slow blow fuse blown (40 A) Replace G-38 A Wiring harness disconnected or improperly Repair or replace connected (between main switch ST terminal and safety switches, between safety switches...
Page 261 GR2100EC, WSM ELECTRICAL SYSTEM LIGHTING SYSTEM Reference Symptom Probable Cause Solution Page A Fuse blown (10 A) Head Light Does Not Replace G-38 Light A Bulb blown Replace G-39 A Wiring harness disconnected or improperly Repair or replace connected (between main switch terminal and head light switch, between head...
Page 262: Servicing Specifications
GR2100EC, WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Battery Voltage More than 12 V Potential Difference Less than 0.1 V Glow Plug Resistance Approx. 0.9 Head Light Switch Resistance OFF Infinity Resistance ON Starter Commutator 28.0 mm 27.0 mm (O.D.) 1.102 in.
Page 263 GR2100EC, 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-9) Item ft-lbs Starter (C terminal nut) 5.9 to 11.8 0.6 to 1.2 4.3 to 8.7 Dynamo (stator nut)
Page 264: Checking, Disassembling And Servicing
GR2100EC, WSM ELECTRICAL SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Battery Battery Voltage 1. Stop the engine and turn the main switch off. 2. Connect the COM (-) lead of the voltmeter to the battery's negative terminal post (2) and the (+) lead to the positive terminal post (1), and measure the battery voltage.
Page 265 GR2100EC, WSM ELECTRICAL SYSTEM Main Switch Continuity 1) Main Switch Key at OFF Position 1. Set the main switch OFF position. 2. Measure the resistance with an ohmmeter across the B terminal and the ACC terminal, B terminal and ST terminal, B terminal and G terminal.
Page 266: Starter
GR2100EC, WSM ELECTRICAL SYSTEM (3) Starter Motor Test A Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable and the leads from the starter.
Page 267: Glow Plug
GR2100EC, WSM ELECTRICAL SYSTEM (4) Glow Plug Lead Terminal Voltage 1. Disconnect the wiring lead (1) from the glow plug (2) after turning the main switch off. 2. Turn the main switch key to the "PREHEAT" position, and measure the voltage between the lead terminal and the chassis.
Page 268: Safety Switch
GR2100EC, WSM ELECTRICAL SYSTEM (5) Safety Switch PTO Switch 1. Remove the battery. 2. Remove the fender. 3. Disconnect the connector from PTO switch (1). 4. Measure the resistance with an ohmmeter between the terminals. 5. If the PTO switch (1) is defective, replace it. When plunger is pushed Resistance (between...
Page 269: Operator Presence Control (Opc) Switch
GR2100EC, WSM ELECTRICAL SYSTEM Grass Container Open Switch 1. Remove the battery. 2. Dismount the grass container. 3. Disconnect the safety switch (1) lead. 4. Measure the resistance with an ohmmeter between the saety switch terminals. 5. If the safety switch is defective, replace it. When plunger is pushed Resistance (between...
Page 270: Fuel Pump
GR2100EC, WSM ELECTRICAL SYSTEM (7) Fuel Pump Connector Voltage 1. Disconnect the 2P connector from the fuel pump. 2. Turn the main switch key to the "ON" position, and measure the voltage with a voltmeter between the connector terminals. 3. If the voltage differs from the battery voltage, the wiring harness or main switch is faulty.
Page 271: Time Relay
GR2100EC, WSM ELECTRICAL SYSTEM (9) Time Relay Timer Relay Connector Voltage 1. Disconnect the connector from the timer relay after turning the main switch off. 2. Measure the voltage with a voltmeter across the connector terminal 4 and chassis. 3. Turn the main switch on, and measure the voltage across the connector terminal 3 and chassis.
Page 272: Charging System
GR2100EC, WSM ELECTRICAL SYSTEM (10)Charging System No-load Dynamo Output 1. Disconnect the lead wires from the dynamo. 2. Start the engine and operate the dynamo at the rated speed. 3. Measure the output voltage with a volt meter. 4. If the measurement is not within the specified values, replace the dynamo.
Page 273 GR2100EC, WSM ELECTRICAL SYSTEM Engine Oil Pressure Lamp 1. Disconnect the lead from the engine oil pressure switch after turning the main switch OFF. 2. Turn the main switch ON and connect a jumper lead from the lead to the chassis. 3.
Page 274: Coolant Temperature Sensor
GR2100EC, WSM ELECTRICAL SYSTEM (12)Coolant Temperature Sensor Coolant Temperature Sensor 1) 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 275 GR2100EC, WSM ELECTRICAL SYSTEM Buzzer 1. Remove the air intake net. 2. Disconnect the lead from buzzer (1). 3. Connect the jumper lead between the battery positive terminal and terminal 1 of connector. 4. Connect the jumper lead between the battery negative terminal and terminal 2 of connector.
Page 276: Disassembling And Assembling
GR2100EC, WSM ELECTRICAL SYSTEM [2] DISASSEMBLING AND ASSEMBLING (1) Starter (1) Sleeve Bearing (2) Bushing (3) Starter Drive Housing (4) Drive Lever (5) Magnet Switch (6) Yoke (7) Connecting Lead (8) Through Bolt (9) Rear End Frame (10) Bushing (11) Brush (12) Brush Holder (13) Brush Spring (14) Brush...
Page 277: Dynamo
GR2100EC, WSM ELECTRICAL SYSTEM (2) Dynamo Stator 1. Remove the nut (3) and separate the stator comp. (4). 2. Unscrew the screws (1) and remove the stator (2). (When reassembling) 39.2 to 44.1 Tightening torque 4.0 to 4.5 28.9 to 32.5 ft-lbs (1) Screw (3) Nut (2) Stator...
Page 278: Servicing
GR2100EC, WSM ELECTRICAL SYSTEM [3] SERVICING (1) Starter Overrunning Clutch 1. Inspect the pinion for wear or damage. 2. If there is any defect, replace the overrunning clutch assembly. 3. Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction.
Page 279 GR2100EC, WSM ELECTRICAL SYSTEM Brush Wear 1. If the contact face of the brush is dirty or dusty, clean it with emery paper. 2. Measure the brush length (A) with vernier calipers. 3. If the length is less than the allowable limit, replace the yoke assembly and brush holder.
Page 280: Dynamo
GR2100EC, WSM ELECTRICAL SYSTEM Field Coil 1. Check the continuity across the lead (1) and brush (2) with an ohmmeter. 2. If it does not conduct, replace the yoke assembly. 3. Check the continuity across the brush (2) and yoke (3) with an ohmmeter.
Page 281 MOWER KiSC issued 04, 2006 A...
Page 282 CONTENTS 1. POWER TRANSMISSION....................8-M1 2. LIFTING MECHANISM .....................8-M2 KiSC issued 04, 2006 A...
Page 283 GR2100EC, WSM MOWER 1. POWER TRANSMISSION (1) Left Side Blade Pulley (5) Right Side Blade Pulley (9) 21T Spiral Gear (13) Bevel Gear Shaft (2) Mower Belt (Left Side) (6) Universal Joint (10) Input Shaft (14) Center Blade (3) Gear Box (7) Blade Shaft (Left Side) (11) 16T Spiral Gear (15) Right Side Blade...
Page 284: Lifting Mechanism
GR2100EC, WSM MOWER 2. LIFTING MECHANISM (1) Lift Cylinder (3) Hydraulic Lift Lever (4) Lift Link (5) Rear Link (2) Lift Link Shaft The lifting of mower is performed by the hydraulic system on the machine. For avoiding danger, the mower should be kept lifting when traveling. When the hydraulic lift lever (3) is moved to "LIFT"...
Page 285 CONTENTS 1. TROUBLESHOOTING....................... 8-S1 2. SERVICING SPECIFICATIONS ..................8-S2 3. TIGHTENING TORQUES ....................8-S3 4. CHECKING, DISASSEMBLING AND ASSEMBLING ............ 8-S4 [1] CHECKING AND ADJUSTING ..................8-S4 (1) Adjusting Anti-Scalp Rollers ..................8-S4 (2) Adjusting Left and Right Cutting Height..............8-S5 [2] PREPARATION .......................
Page 286 GR2100EC, WSM MOWER 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A PTO system malfuntioning Blade Does Not Turn Check transmission A Mower belt broken Replace mower belt 8-S9 A Mower belt loosen Blade Speed is Slow Replace mower belt 8-S9 of tension spring A Grass clogged...
Page 287: Servicing Specifications
GR2100EC, WSM MOWER 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Left Tip of Blade to Right Tip of Blade Difference Less than 3 mm 0.1181 in. Front Tip of Blade to Rear Tip of Blade Difference Less than 5 mm 0.20 in.
Page 288 GR2100EC, 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-9) Item ft-lbs Mower blade screw 88.0 to 117.6 8.98 to 11.99 65.0 to 86.7 Gear box mounting screw LH (Reamer) 77.5 to 90.2...
Page 289: Checking, Disassembling And Assembling
GR2100EC, WSM MOWER 4. CHECKING, DISASSEMBLING AND ASSEMBLING [1] CHECKING AND ADJUSTING (1) Adjusting Anti-Scalp Rollers Adjusting Anti-scalp Rollers A The flattest cut can be achieved by having the anti-scalp rollers adjusted off the ground. Check anti-scalp roller adjustments each time the mower deck cutting height is changed.
Page 290: Adjusting Left And Right Cutting Height
GR2100EC, WSM MOWER (2) Adjusting Left and Right Cutting Height Adjusting Left and Right Cutting Height 1. Park the machine on level surface. 2. Wheel pressure must be correct. 3. Raise up the mower deck to the transport position. (Also the top end.) 4.
Page 291: Preparation
GR2100EC, WSM MOWER Adjusting Parallel Linkage 1. Park the machine on a level surface. 2. Wheel pressure must be correct. 3. Adjust the cutting height so that blade is level. 4. Position mower blade in the Front-to-Rear position. 5. Measure the height of blade X and Y from the ground surface and calculate the difference.
Page 292 GR2100EC, WSM MOWER Rear Link and Universal Joint 1. Disconnect the rotate plate rod (1). 2. Disconnect the rear link (2) from the mower deck, pulling the L-pins (3). 3. Disconnect the universal joint (4) from the PTO shaft. 4. Raise the mower lift lever and lock in the raised position. (When reassembling) A Apply grease to the spline of PTO shaft.
Page 293: Disassembling And Assembling
GR2100EC, WSM MOWER [3] DISASSEMBLING AND ASSEMBLING (1) Mower Mower Blades 1. Turn over the mower. 2. Unscrew the mower blade screw (1), and remove the plate spring (2), mower blade (3) and dust cover (4). A To remove the blade securely, wedge a block of wood between one blade and the mower deck in such position that it will hold the blade safely while loosing or tightening the blade screw.
Page 294: Gear Box
GR2100EC, WSM MOWER Mower Belt 1. Remove the left and right belt covers from the mower deck. 2. Disconnect the universal joint from the gear box (2). 3. Clean around the gear box (2). 4. Remove the mower belt RH (3) from the tension pulley (4). 5.
Page 295 GR2100EC, WSM MOWER Disassembling Mower Gear Box Assembly 1. Unscrew the drain plug (17), and drain gear case oil. 2. Remove the center blade pulley (1) with a puller, and remove the feather key (3) on the bevel gear shaft (4). 3.
Page 296 GR2100EC, WSM MOWER Disassembling Center Blade Pulley Holder 1. Remove the center blade pulley holder mounting screws (1). 2. Separate the center blade puller holder from the mower deck. 3. Remove the lower oil seal (7). 4. Remove the internal snap ring (6), ball bearing (5) and center collar (4).
Page 297 GR2100EC, WSM MOWER Disassembling Side Blade Pulley Holder (1) Grease Nipple (2) Pulley Mounting Nut (3) Pulley (4) Oil Seal (5) Ball Bearing (6) Pulley Holder Mounting (7) Pulley Holder (8) Pulley Holder Mounting Screw (9) Collar (10) Ball Bearing (11) Oil Seal (12) Blade Shaft (13) Feather Key...
Page 298 GR2100EC, WSM MOWER Disassembling Tension Pulley 1. Remove the spring from the tension arm (9). 2. Remove the tension arm mounting nut (4) and screw (12) (only left side). 3. Remove the tension arm assembly, tension collar (3) and plate (11) (only right side).
Page 299 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 2006. 03, S, EI, EI, e Code No.9Y011-15412 KUBOTA Corporation 2005.

Kubota WSM GR2100EC 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 Tires

10 Implement Limitations

1 Engine

1 Engine Body

2 Lubricating System

3 Cooling System

4 Fuel System

Table of Contents

1 Troubleshooting

2 Servicing Specifications

4 Checking, Disassembling and Servicing

2 Transaxle

1 Structure

2 Travelling System

3 Mower Pto System

4 Others

Table of Contents

1 Troubleshooting

2 Serviving Specifications

4 Checking, Disassembling and Servicing

3 Brakes

1 Troubleshooting

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Table of Contents

1 Troubleshooting

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Table of Contents

1 Troubleshooting

2 Servicing Specifications

4 Checking, Disassembling and Servicing

6 Hydraulic System

Table of Contents

2 Servicing Specifications

4 Checking, Disassembling and Servicing

7 Electrical System

Table of Contents

1 Troubleshooting

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Kubota WSM GR2100EC