Kubota GR1600EC2 Workshop Manual
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Kubota GR1600EC2 Workshop Manual

Kubota GR1600EC2 Workshop Manual

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WORKSHOP MANUAL
GR1600EC2
KiSC issued 07, 2006 A

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Summary of Contents for Kubota GR1600EC2

  • Page 1 WORKSHOP MANUAL GR1600EC2 KiSC issued 07, 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 GR1600EC2. It is divided into three parts, “General”, “Mechanism” and “Servicing”. General Information on the tractor identification, the general precautions, maintenance check list, check and maintenance and special tools are described.
  • Page 3 GR1600EC2, WSM SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit.
  • Page 4 GR1600EC2, WSM SAFETY INSTRUCTIONS SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Do not alter or remove any part of machine safety system. • Before starting the engine, make sure that all shift levers are in neutral positions or in disengaged positions.
  • Page 5 GR1600EC2, WSM SAFETY INSTRUCTIONS VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.

  • Page 6: Safety Decals

    GR1600EC2, WSM SAFETY INSTRUCTIONS SAFETY DECALS The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list. KiSC issued 07, 2006 A...
  • Page 7 GR1600EC2, WSM SAFETY INSTRUCTIONS KiSC issued 07, 2006 A...
  • Page 8 GR1600EC2, WSM SAFETY INSTRUCTIONS KiSC issued 07, 2006 A...

  • Page 9: Specifications

    GR1600EC2, WSM SPECIFICATIONS SPECIFICATIONS Model GR1600EC2 Maker KUBOTA Model Z482-E2-GX Type Indirect injection. Vertical, water-cooled, 4-cycle diesel Number of cylinders Bore and stroke 67 x 68 mm (2.64 x 2.68 in.) Total displacement 479 cm (29.9 cu.in.) Engine gross power (DIN) 10.0 kW (13.4 HP)
  • Page 10 GR1600EC2, WSM SPECIFICATIONS Model RCK42GREC2 Cutting width 1067 mm (42.0 in.) Cutting height 25 to 102 mm (1 to 4 in.) Adjustment of cutting height Dual gauge Mounting method Quick joint, Parallel linkage Weight (Approx.) 75 kg (165 lbs) Mower...
  • Page 11 GR1600EC2, WSM DIMENSIONS DIMENSIONS KiSC issued 07, 2006 A...
  • Page 12 GENERAL KiSC issued 07, 2006 A...

  • Page 13: Table Of Contents

    GENERAL CONTENTS 1. IDENTIFICATION..................... G-1 2. GENERAL PRECAUTIONS ................G-2 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .. G-3 [1] WIRING...................... G-3 [2] BATTERY....................G-5 [3] FUSE......................G-5 [4] CONNECTOR .................... G-5 [5] HANDLING OF CIRCUIT TESTER............G-7 4. LUBRICANTS, FUEL AND COOLANT ............G-8 5.

  • Page 14: Identification

    GR1600EC2, WSM G 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

    Screws, bolts and nuts should be installed in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.

  • Page 16: Handling Precautions For Electrical Parts And Wiring

    GR1600EC2, WSM G GENERAL 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring. IMPORTANT • Check electrical wiring damage loosened connection every year.
  • Page 17 GR1600EC2, WSM G GENERAL • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp • Wind Clamp Spirally (4) Welding Dent (2) Wire Harness W10114580 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.

  • Page 18: Battery

    GR1600EC2, WSM G GENERAL [2] BATTERY • Take care not to confuse positive and negative terminal posts. • When removing battery cables, disconnect negative cable first. When installing battery cables, check for polarity and connect positive cable first. • Do not install any battery with capacity other than is specified (Ah).
  • Page 19 GR1600EC2, WSM G GENERAL • In separating connectors, do not pull wire harnesses. • Hold connector bodies to separate. (A) Correct (B) Incorrect W10122720 • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make certain there is no terminal being exposed or displaced.

  • Page 20: Handling Of Circuit Tester

    GR1600EC2, WSM G GENERAL [5] HANDLING OF CIRCUIT TESTER • Use tester correctly following manual provided with tester. • Check for polarity and range. W10126840 KiSC issued 07, 2006 A...

  • Page 21: Lubricants, Fuel And Coolant

    0 to 25 °C (32 to 77 °F) : SAE20, 10W-30 or 10W- 1.06 lmp.qts. Above 25 °C (77 °F) : SAE30, 10W-30 or 10W-40 2.7 L Transmission case 0.71 U.S.gals. KUBOTA UDT or SUPER UDT fluid* 0.59 lmp.gals. 0.33 L SAE90 gear oil Mower gear box 0.35 U.S.qts.

  • Page 22: Tightening Torques

    GR1600EC2, WSM G GENERAL 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of...

  • Page 23: American Standard Screws, Bolts And Nuts With Unc Or Unf Threads

    GR1600EC2, WSM G GENERAL [3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS SAE GR.5 SAE GR.8 Grade Unit Nominal N·m kgf·m ft-lbs N·m kgf·m 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...

  • Page 24: Maintenance Check List

    GR1600EC2, WSM G GENERAL 6. MAINTENANCE CHECK LIST IMPORTANT • The jobs indicated by must be done initially. • *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.
  • Page 25 GR1600EC2, WSM G GENERAL Period Indication on hour meter (Hr) Refer- After Impor- ence since tant page Item every Check G-27 100 hr Fuel line every Replace G-34 2 year every Check G-30 200 hr Radiator hose and clamp every...

  • Page 26: Check And Maintenance

    GR1600EC2, WSM G GENERAL 7. CHECK AND MAINTENANCE CAUTION • Be sure to check and service the machine on a flat place with engine shut off, the parking brake on and chock the wheels. [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 GR1600EC2, WSM G GENERAL Checking Engine Oil Level CAUTION • 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.
  • Page 28 GR1600EC2, WSM G GENERAL Checking Amount of Fuel and Refueling CAUTION • Handle fuel carefully. If the engine is running, do not fill the fuel tank. If engine is hot, let engine cool several minutes before adding fuel. Do not smoke while filling the fuel tank or servicing the fuel system.
  • Page 29 GR1600EC2, WSM G GENERAL Checking Cleaning Radiator to Prevent Overheating CAUTION • 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 (2) or radiator core decrease cooling performance.
  • Page 30 GR1600EC2, WSM G GENERAL Checking Transmission Fluid Level 1. Park the machine on a flat surface, lower the implement to the ground and shut off engine and remove the key. 2. Raise the operator's seat. 3. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again.
  • Page 31 GR1600EC2, WSM G GENERAL Greasing CAUTION • Be sure to stop the engine and remove the key before greasing. (1) Spindle Shaft (3) Mower Universal Joint (Apply grease (2) Tension Arm on the spline shaft) W1052201 KiSC issued 07, 2006 A...

  • Page 32: Check Points Of Every 50 Hours

    GR1600EC2, WSM G GENERAL [2] CHECK POINTS OF EVERY 50 HOURS Checking Safety Device CAUTION • Do not allow anyone near the machine while testing. • If the machine does not pass one of the following tests, do not operate the machine.
  • Page 33 GR1600EC2, WSM G GENERAL Cleaning Air Cleaner Element 1. The air cleaner uses a dry element, never apply oil. 2. Do not touch the filter element except where cleaning is required. To clean the element, use clean and dry compressed air on the inside of the element.
  • Page 34 GR1600EC2, WSM G GENERAL Oiling 1. Apply oil to the following location as shown in the figures. CAUTION • Be sure to stop the engine and remove the key before oiling. (1) Mower Universal Joint (4) Seat Adjuster (2) Speed Control Shaft (RH)
  • Page 35 GR1600EC2, WSM G GENERAL Oiling (Continued) 1. Apply oil to the following location as shown in the figures. CAUTION • Be sure to stop the engine and remove the key before oiling. (1) Around Hole of Mower Link (6) Top Cover Lock Lever...
  • Page 36 GR1600EC2, WSM G GENERAL Oiling (Continued) 1. Apply oil to the following location as shown in the figures. CAUTION • Be sure to stop the engine and remove the key before oiling. (1) Quick Clean Lever (3) Link Fulcrum (2) PTO Lever (Fulcrum)
  • Page 37 GR1600EC2, WSM G GENERAL Checking Battery Condition DANGER • To avoid the possibility of battery explosion: For the refillable type battery, follow the instructions below. • Do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark. Otherwise,...
  • Page 38 GR1600EC2, WSM G GENERAL Battery Charging DANGER • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.

  • Page 39: Check Points Of Every 100 Hours

    GR1600EC2, WSM G GENERAL 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 GR1600EC2, WSM G GENERAL Checking Fuel Line and Fuel Filter CAUTION • Be sure to stop the engine and remove the key when attempting to make the following checks and changes. • Never fail to check the fuel lines periodically. The fuel lines are subject to wear and aging.

  • Page 41: Check Point Of Every 150 Hours

    IMPORTANT • To prevent serious damage to the engine, element of recommended type must be used. Use only a genuine KUBOTA filter or its equivalent (1) Engine Oil Filter Cartridge W1019390 KiSC issued 07, 2006 A G-28...
  • Page 42 GR1600EC2, WSM G GENERAL Changing Transmission Fluid CAUTION • Be sure to stop the engine and remove the key before changing or checking the oil. • Allow transmission case to cool down sufficiently; oil can be hot and may cause burns.
  • Page 43 IMPORTANT • To prevent serious damage to hydraulic system, the replacement filter must be a highly efficient, 10 μm filter. Use only a genuine KUBOTA filter or its equivalent. (1) Transmission Oil Filter Cartridge (2) Screw W1063614...

  • Page 44: Check Point Of Every 400 Hours

    GR1600EC2, WSM G GENERAL Adjusting Front Axle Pivot 1. Jack up the front of machine. 2. Tighten the center pin locking nut (1) with specified torque. 3. Measure the clearance between the front axle frame (2) and anti- vibration bolt (3).

  • Page 45: Check Point Of 1500 Hours

    GR1600EC2, WSM G GENERAL [7] CHECK POINT OF 1500 HOURS Checking Fuel Injection Nozzle (Injection Pressure) 1. Check the fuel injection nozzle. Refer to “Fuel Injection Pressure”. (See page 1-S17.) [8] CHECK POINTS OF EVERY 1 YEAR Replacing Air Cleaner Element 1.
  • Page 46 GR1600EC2, WSM G GENERAL Flushing Cooling System and Changing Coolant (Continued) Anti-Freeze CAUTION • When using anti-freeze, put on some protection such as rubber gloves (Anti-freeze contains poison.). • If should drink anti-freeze, throw up at once and take medical attention.

  • Page 47: Check Points Of Every 2 Years

    The LLC contains anti-corrosive agent. If mixed with the cleaning agent, sludge may build up, adversely affecting the engine parts. 3. Kubota's genuine long-life coolant has a service life of 2 years. Be sure to change the coolant every 2 years. NOTE •...

  • Page 48: Others

    GR1600EC2, WSM G GENERAL [10] OTHERS Replacing Fuses 1. Open the hood. 2. Remove the blown fuse. 3. Place a new 3 A or 10 A or 15 A or 30 A or 40 A fuse in position. IMPORTANT • Never "jump" the fuse with wire or foil, or install a larger capacity fuse than is recommended.
  • Page 49 GR1600EC2, WSM G GENERAL Checking and Replacing Mower Blade CAUTION • Be sure to stop the engine and remove the key. • Blades may be sharp. When you handle blades, wear heavy gloves or wrap end of blade with a rag.
  • Page 50 GR1600EC2, WSM G GENERAL Replacing Mower Belt 1. Remove the mower deck from the machine. 2. Remove the left and right hand shield (4), (6) from the mower deck. 3. Clean around the pulleys to remove the belt (3) from the pulleys.

  • Page 51: Special Tools

    GR1600EC2, WSM G 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. W1024050 Piston Ring Compressor Code No.: 07909-32111 Application: Use exclusively for pushing in the piston with piston rings into the cylinder.
  • Page 52 GR1600EC2, WSM G 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...
  • Page 53 GR1600EC2, WSM G GENERAL Nozzle Tester Code No.: 07909-31361 Application: Use to check the fuel injection pressure and spray pattern of nozzle. Measuring: 0 to 50 MPa range (0 to 500 kgf/cm , 0 to 7000 psi) W1024653 Plastigage Code No.:...
  • Page 54 GR1600EC2, WSM G GENERAL Injection Pump Pressure Tester Application: Use to check fuel tightness of injection pumps. Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm , 4267 psi) Copper gasket Flange (Material : Steel) Hex. nut 27 mm (1.06 in.) across the plat...
  • Page 55 GR1600EC2, WSM G GENERAL Bushing Replacing Tool Application: Use to press out and 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 56: Special Tools For Machine

    GR1600EC2, WSM G GENERAL Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing 1. [Press Out] 135 mm (5.31 in.) 72 mm (2.83 in.) 40 mm radius (1.57 in. radius) 10 mm (0.39 in.) 22 mm (0.87 in.)
  • Page 57 GR1600EC2, WSM G GENERAL HST Relief Pressure Gauge Adaptors 1. Adaptor 1 5.94 to 6.00 mm dia. (0.234 to 0.236 in. dia.) 8.165 to 8.187 mm dia. (0.3215 to 0.3223 in. dia.) 8.4 mm dia. (0.3307 in. dia.) 8.2 mm (0.32 in.) 14.2 mm (0.55905 in.)
  • Page 58 GR1600EC2, WSM G GENERAL 2. Adaptor 2 10 mm (0.394 in.) 3 mm (0.1181 in.) 2.0 to 2.4 mm (0.079 to 0.094 in.) 3 mm (0.12 in.) 5.8 mm (0.23 in.) 1.5 mm (0.06 in.) 9 mm dia. (0.35 in. dia.) 8.200 to 8.215 mm dia.

  • Page 59: Tires

    GR1600EC2, WSM G GENERAL 9. TIRES [1] TIRE PRESSURE CAUTION • Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment. • Always maintain the correct tire pressure.

  • Page 60: 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 61 ENGINE KiSC issued 07, 2006 A...
  • Page 62 MECHANISM CONTENTS 1. ENGINE BODY ..................... 1-M1 [1] HALF-FLOATING HEAD COVER ............1-M1 [2] CLOSED BREATHER................1-M1 2. LUBRICATING SYSTEM ................1-M2 3. COOLING SYSTEM ..................1-M3 4. FUEL SYSTEM ..................... 1-M4 [1] FUEL LINE ....................1-M4 KiSC issued 07, 2006 A...

  • Page 63: Engine Body

    GR1600EC2, 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.

  • Page 64: Lubricating System

    GR1600EC2, WSM ENGINE 2. LUBRICATING SYSTEM (1) Rocker Arm (2) Oil Pressure Switch (3) Rocker Arm Shaft (4) Valve (5) Idle Gear (6) Crankshaft (7) Oil Pump (8) Oil Strainer (9) Relief Valve (10) Push Rod (11) Tappet (12) Camshaft...

  • Page 65: Cooling System

    GR1600EC2, WSM ENGINE 3. COOLING SYSTEM (1) Radiator (2) Water Pump (3) Cooling Fan (4) Thermostat (5) Cylinder Head (6) Cylinder Block The cooling system consists of a radiator (1), a centrifugal water pump (2), a cooling fan (3) and a thermostat (4).

  • Page 66: Fuel System

    GR1600EC2, 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 67 SERVICING CONTENTS 1. TROUBLESHOOTING ..................1-S1 2. SERVICING SPECIFICATIONS ..............1-S4 3. TIGHTENING TORQUES ................1-S9 4. CHECKING, DISASSEMBLING AND SERVICING........1-S10 [1] CHECKING AND ADJUSTING .............1-S10 (1) Engine Body..................1-S10 (2) Lubricating System ................1-S13 (3) Cooling System.................1-S13 (4) Fuel System ..................1-S15 [2] PREPARATION ..................1-S18 (1) Separation Engine ................1-S18 [3] DISASSEMBLING AND ASSEMBLING..........1-S21 (1) Cylinder Head and Valves ..............1-S21...

  • Page 68: Troubleshooting

    GR1600EC2, WSM ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel Start Air in the fuel system Bleed G-37 Water in the fuel system Change fuel and G-27, 34 repair or replace fuel...
  • Page 69 GR1600EC2, WSM ENGINE Reference Symptom Probable Cause Solution Page Engine Revolution Is Fuel filter clogged or dirty Replace G-27, 31 Not Smooth Air cleaner clogged Clean or replace G-20 Fuel leak due to loose injection pipe retaining nut Tighten retaining nut...
  • Page 70 GR1600EC2, WSM ENGINE Reference Symptom Probable Cause Solution Page Water Mixed into Head gasket defective Replace 1-S23 Lubricant Oil Cylinder block or cylinder head flawed Replace – Low Oil Pressure Engine oil insufficient Replenish G-8, 14 Oil strainer clogged Clean –...

  • Page 71: Servicing Specifications

    GR1600EC2, 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 kgf/cm 23.0 kgf/cm 412 to 469 psi 327 psi Variance Among – 10 % or less...
  • Page 72 GR1600EC2, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Tappet to Tappet Guide Oil 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.
  • Page 73 GR1600EC2, WSM ENGINE ENGINE BODY (Continued) 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 0.78783 in.
  • Page 74 GR1600EC2, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing Oil Clearance 0.028 to 0.051 mm 0.20 mm 3 (Intermediate) 0.00110 to 0.00201 in. 0.0079 in. Crankshaft Journal 39.934 to 39.950 mm – (O.D.) 1.57221 to 1.57284 in.
  • Page 75 GR1600EC2, WSM ENGINE COOLING SYSTEM Item Factory Specification Allowable Limit Fan Belt Tension 7 to 9 mm / 98 N – 0.28 to 0.35 in. / 98 N (10 kgf, 22 lbs) Thermostat Valve Opening 80.5 to 83.5 °C –...

  • Page 76: Tightening Torques

    GR1600EC2, 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 N·m kgf·m ft-lbs Front coupling mounting screw M8 x 1.25...

  • Page 77: Checking, Disassembling And Servicing

    GR1600EC2, WSM ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Disconnect the 2P connector from the fuel pump. 4. Remove the air cleaner, the muffler and all injection nozzles.
  • Page 78 GR1600EC2, 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 79 GR1600EC2, WSM ENGINE Valve Clearance IMPORTANT • The valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover (1) and the glow plugs. 2. Align the “1TC” mark (2) on the flywheel and alignment mark (3) on the rear end plate so that the No.

  • Page 80: Lubricating System

    GR1600EC2, WSM ENGINE (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester (Code No.: 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
  • Page 81 GR1600EC2, 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 82: Fuel System

    GR1600EC2, WSM ENGINE Radiator Water Leakage 1. Pour a specified amount of water into the radiator. 2. Set a radiator tester (1) (Code No. 07909-31551) and an adapter (2) (BANZAI Code No.:RCT-2A-30S) and raise the water pressure to the specified pressure.
  • Page 83 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 84 GR1600EC2, WSM ENGINE CAUTION • Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.

  • Page 85: Preparation

    GR1600EC2, 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 kgf/cm 1849 psi) for 10 seconds. 3. If any fuel leak is found, replace the nozzle piece.
  • Page 86 GR1600EC2, 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).
  • Page 87 GR1600EC2, WSM ENGINE Air Cleaner, Muffler, Fuel Hose and Wire Harness 1. Remove the air cleaner (1) and muffler (2). 2. Disconnect the fuel hoses (3). 3. Disconnect the accelerator wire (4). 4. Disconnect the wire harness (5). (1) Air Cleaner...

  • Page 88: Disassembling And Assembling

    GR1600EC2, 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 can pulley.
  • Page 89 GR1600EC2, WSM ENGINE Nozzle Holder Assembly and Glow Plug 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).
  • Page 90 GR1600EC2, 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 (j) to (a). 3. Lift up the cylinder head to detach. 4. Remove the cylinder head gasket and O-ring (1).

  • Page 91: Timing Gear, Camshaft And Fuel Camshaft

    GR1600EC2, WSM ENGINE (2) Timing Gear, Camshaft and Fuel Camshaft Injection Pump and Speed Control Plate 1. Remove the socket head screws and nuts, and remove the injection pump (3). 2. Remove the screws and separate the speed control plate (2), taking care not to damage the governor spring (4).
  • Page 92 GR1600EC2, 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) • Apply a liquid gasket (Three Bond 1215 or equivalent) to both sides of the gear case gasket (4).
  • Page 93 GR1600EC2, WSM ENGINE Idle Gear 1. Remove the external snap ring (3), the collar (2) and the idle gear (1). 2. Remove the idle gear shaft mounting screws (4). 3. Remove the idle gear shaft (5). (When reassembling) • Apply engine oil to the idle gear shaft mounting screw (4). And tighten them.
  • Page 94 GR1600EC2, WSM ENGINE Fuel Camshaft 1. Remove the retaining plate (1). 2. Remove the fork lever holder mounting screws (8), then draw out the injection pump gear (3) and fuel camshaft (2) with the governor fork assembly. (When reassembling) • Hook the governor spring (7) to the fork lever 2 (6) as shown in the figure before installing the fork lever assembly to the crankcase.

  • Page 95: Piston And Connecting Rod

    GR1600EC2, WSM ENGINE Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws (5). 2. Remove the oil pan (4) by lightly tapping the rim of the pan with a wooden hammer. 3. Remove the oil strainer (3).
  • Page 96 GR1600EC2, WSM ENGINE Pistons 1. Turn the flywheel and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer. 3. Draw out the other piston in the same method as above.
  • Page 97 GR1600EC2, WSM ENGINE Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool (Code No. 07909-32121). 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) • When installing the ring, assemble the rings so that the manufacturer’s mark (12) near the gap faces the top of the piston.

  • Page 98: Crankshaft

    GR1600EC2, 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) • Align the “1TC” mark (a) on the outer surface of the flywheel horizontally with the alignment mark (b) on the rear end plate.
  • Page 99 GR1600EC2, WSM ENGINE Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly. (When reassembling) • Clean the oil passage of the crankshaft with compressed air. • Apply oil to the main bearing case screw 2 (1).
  • Page 100 GR1600EC2, WSM ENGINE Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (1), and remove the main bearing case assembly 1 (2), being careful with crankshaft bearing 3 (4), (5). 2. Remove the main bearing case assembly (3) as above. Keep in mind, however, that the thrust bearing (8) is installed in the main bearing case assembly (3).

  • Page 101: Water Pump

    GR1600EC2, WSM ENGINE (5) Water Pump Thermostat Assembly 1. Remove the thermostat cover mounting screws, and remove the thermostat cover (1). 2. Remove the thermostat assembly (3). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (2).

  • Page 102: Servicing

    GR1600EC2, WSM ENGINE [4] SERVICING (1) Cylinder Head and Valves Cylinder Head Surface Flatness 1. Clean the cylinder head surface. 2. Place a straightedge on the cylinder head’s four sides and two diagonal as shown in the figure. 3. Measure the clearance with a thickness gauge.
  • Page 103 GR1600EC2, 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 104 GR1600EC2, 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 105 GR1600EC2, WSM ENGINE Valve Lapping 1. Apply compound evenly to the valve lapping surface. 2. Insert the valve into the valve guide. Lap the valve onto its seat with a valve flapper or screwdriver. 3. After lapping the valve, wash the compound away and apply oil, then repeat valve lapping with oil.
  • Page 106 GR1600EC2, WSM ENGINE Oil Clearance between Rocker Arm and Rocker Arm Shaft 1. Measure the rocker arm shaft O.D. with an outside micrometer. 2. Measure the rocker arm I.D. with an inside micrometer, and then calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the rocker arm and measure the oil clearance again.

  • Page 107: Timing Gear, Camshaft And Fuel Camshaft

    GR1600EC2, 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 108 GR1600EC2, 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 109: Piston And Connecting Rod

    GR1600EC2, WSM ENGINE Oil Clearance between Idle Gear Shaft and Idle Gear Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance.
  • Page 110 GR1600EC2, WSM ENGINE Oil Clearance between Piton Pin and Small End Bushing 1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer. 2. Measure the small end bushing I.D. with an inside micrometer, and calculate the oil clearance.
  • Page 111 GR1600EC2, 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 112: Crankshaft

    GR1600EC2, 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 113 GR1600EC2, WSM ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage (Code No.: 07909-30241) on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
  • Page 114 GR1600EC2, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance.
  • Page 115 GR1600EC2, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) 1. Put a strip of plastigage (Code No. 07909-30241) on the center of the journal. 2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again.

  • Page 116: Cylinder

    GR1600EC2, WSM ENGINE (5) Cylinder Cylinder Wear 1. Measure the I.D. of the cylinder at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.’s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.’s.
  • Page 117 GR1600EC2, WSM ENGINE Clearance between Outer Rotor and Pump Body 1. Measure the clearance between the outer rotor and the pump body with a thickness gauge. 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.
  • Page 118 TRANSAXLE KiSC issued 07, 2006 A...
  • Page 119 MECHANISM CONTENTS 1. STRUCTURE ....................2-M1 2. TRAVELLING SYSTEM ................2-M2 [1] HYDRAULIC TRANSMISSION ............... 2-M2 (1) Structure .................... 2-M2 (2) Oil Flow ....................2-M3 (3) Operation ................... 2-M4 (4) Charge Pump..................2-M7 (5) By-pass Valve ..................2-M7 (6) Control Linkage.................. 2-M8 [2] MOWER PTO SYSTEM.................

  • Page 120: Structure

    GR1600EC2, WSM TRANSAXLE 1. STRUCTURE (1) Hydraulic Transmission (2) Mower PTO Section (3) Differential Gear Section (4) Rear Axle Section Section KiSC issued 07, 2006 A 2-M1...

  • Page 121: Travelling System

    GR1600EC2, WSM TRANSAXLE 2. TRAVELLING SYSTEM [1] HYDRAULIC TRANSMISSION (1) Structure (1) Check Valve (8) Piston (15) Oil Seal (22) By-pass Plug (2) Trunnion Arm (9) Spring (Cylinder Block) (16) Pump Shaft (23) By-pass Spool (3) Charge Relief Valve (10) Washer...

  • Page 122: Oil Flow

    GR1600EC2, WSM TRANSAXLE (2) Oil Flow (1) Pump (4) Filter Cartridge (7) Lubricating Orifice (9) Neutral Orifice (2) Charge Pump (5) Motor (8) Check Valve (Reverse) (10) Charge Relief Valve (3) Check Valve (Forward) (6) By-pass Valve The closed oil-hydraulic loop connects between the pump (1) and the motor (5) in HST.

  • Page 123: Operation

    GR1600EC2, WSM TRANSAXLE (3) Operation Neutral (1) Cylinder Block (Pump) (5) Lubricating Orifice (8) Transaxle Case (11) Charge Relief Valve (2) Swashplate (6) Check Valve (Forward) (9) Oil Strainer (12) Filter Cartridge (3) Piston (7) By-pass Valve (10) Check Valve (Reverse)
  • Page 124 GR1600EC2, WSM TRANSAXLE Forward (1) Cylinder Block (Pump) (5) Lubricating Orifice (8) Transaxle Case (11) Charge Relief Valve (2) Swashplate (6) Check Valve (Forward) (9) Oil Strainer (12) Filter Cartridge (3) Piston (7) By-pass Valve (10) Check Valve (Reverse) (13) Charge Pump...
  • Page 125 GR1600EC2, WSM TRANSAXLE Reverse (1) Cylinder Block (Pump) (5) Lubricating Orifice (8) Transaxle Case (11) Charge Relief Valve (2) Swashplate (6) Check Valve (Forward) (9) Oil Strainer (12) Filter Cartridge (3) Piston (7) By-pass Valve (10) Check Valve (Reverse) (13) Charge Pump...

  • Page 126: Charge Pump

    GR1600EC2, WSM TRANSAXLE (4) Charge Pump The charge pump revolves in combination with pump shaft to draw oil from the transaxle case, and feed oil to the charge circuit. The charge pump is necessary to make up for leakage from the pump and motor, preventing system.

  • Page 127: Control Linkage

    GR1600EC2, WSM TRANSAXLE (6) Control Linkage (1) Speed Change Pedal (3) Speed Change Plate (5) Neutral Spring (6) Speed Control Arm (2) Speed Change Rod (4) Neutral Arm The speed change pedal (1) and the trunnion arm of variable swashplate are linked with the speed change rod (2), speed change plate (3) and the speed control arm (6).

  • Page 128: Mower Pto System

    GR1600EC2, WSM TRANSAXLE [2] MOWER PTO SYSTEM (1) Mower PTO Clutch The mower PTO clutch is equipped with mechanical independent clutches of wet multi-plates type. The PTO shaft (1) is engaged with the spline boss (3). The clutch case (5) is engaged with the 24T gear (6).
  • Page 129 SERVICING CONTENTS 1. TROUBLESHOOTING ..................2-S1 2. SERVICING SPECIFICATIONS ..............2-S4 3. TIGHTENING TORQUES ................2-S5 4. CHEKING, DISASSEMBLING AND SERVICING ........2-S6 [1] CHECKING AND ADJUSTING ...............2-S6 [2] PREPARATION ..................2-S9 (1) Separating Transaxle................2-S9 [3] DISASSEMBLING AND ASSEMBLING..........2-S16 (1) Hydrostatic Transmission..............2-S16 (2) Transaxle Case.................2-S21 [4] SERVICING ....................2-S29 (1) Hydrostatic Transmission..............2-S29 (2) Transaxle Case.................2-S31...

  • Page 130: Troubleshooting

    GR1600EC2, WSM TRANSAXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page System Will Not Oil level is low Fill oil to proper level G-8, 2-S11 Operate in Either Control linkage defective (Speed change pedal Repair control 2-S6, 15 Direction to speed control arm)
  • Page 131 GR1600EC2, WSM TRANSAXLE (Continued) Reference Symptom Probable Cause Solution Page Loss of Power Oil level is low Fill oil to proper level G-8, 2-S11 Control linkage defective (Speed change pedal Repair control 2-S6, S15 to speed control arm) linkage Charge pressure is too...
  • Page 132 GR1600EC2, WSM TRANSAXLE DIFFERENTIAL GEAR SECTION Reference Symptom Probable Cause Solution Page Excessive or Improper backlash between 11T bevel gear and Adjust 2-S34 Unusual Noise at All 17T-13T gear shaft Time Improper backlash between differential pinion Adjust 2-S33 and differential side gear...

  • Page 133: Servicing Specifications

    GR1600EC2, WSM TRANSAXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Charge Relief Valve Setting Pressure 0.3 to 0.5 MPa – (Oil temperature at 50 °C, 122 °F) 3.1 to 5.1 kgf/cm 43.5 to 72.5 psi PTO Clutch Disc Thickness 1.3 to 1.5 mm...

  • Page 134: Tightening Torques

    GR1600EC2, 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 N·m kgf·m ft-lbs Brake plate mounting screw 34 to 40 3.47 to 4.07...

  • Page 135: Cheking, Disassembling And Servicing

    GR1600EC2, WSM TRANSAXLE 4. CHEKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Adjustment of HST Neutral Position 1. Block the front wheels with stoppers, and lift up the rear of machine with a jack. 2. Remove the left rear wheel.
  • Page 136 GR1600EC2, WSM TRANSAXLE Adjusting Maximum Speed NOTE • This adjustment should be performed after completing the adjustment of neutral. [Forward] 1. Loose the lock nut (2) of adjusting screw. 2. Adjust the length (A) with the adjusting screw (1). (Reference) •...
  • Page 137 GR1600EC2, WSM TRANSAXLE Charge Relief Pressure CAUTION • When checking, park the machine on level ground, apply the parking brake. 1. Remove the hexagon socket head plug from P1 (1) or P2 (2), using the short neck hexagon wrench (see page G-45).

  • Page 138: Preparation

    GR1600EC2, WSM TRANSAXLE [2] PREPARATION (1) Separating Transaxle Dismounting Mower 1. See Page 7-S6. (“Mower” Section) W1012761 Dismounting the Container CAUTION • Park the machine on a firm and level ground. • Stop the engine, and remove the key. 1. Open the top cover (1) with the top cover lock lever (2).
  • Page 139 GR1600EC2, WSM TRANSAXLE Discharge Duct 1. Remove the filter cover (1) and the duct plate (3). 2. Disconnect the connector (5) from the grass container full switch (4). 3. Remove the discharge duct (2). (1) Filter Cover (4) Grass Container Full Switch...
  • Page 140 IMPORTANT • Use the KUBOTA UDT or SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system. Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page G-8.)
  • Page 141 GR1600EC2, WSM TRANSAXLE Fender 1. Remove the speed change pedal (5). 2. Peel the step sheet (4) halfway. 3. Remove the fuel cap (1). 4. Remove the fender (2). (1) Fuel Cap (4) Step Sheet (2) Fender (5) Speed Change Pedal...
  • Page 142 GR1600EC2, WSM TRANSAXLE PTO Rod Spring 1. Remove the two nuts (2) (3) and spring (4). (When reassembling) 1. Assemble a fuel tank, a seat base and a fender. 2. Setting the PTO lever at “Disengaged” position and lifting the...
  • Page 143 GR1600EC2, 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...
  • Page 144 GR1600EC2, 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). IMPORTANT • After assembling the speed change plate (1) and speed change rod (4), be sure to adjust the speed change pedal restriction.

  • Page 145: Disassembling And Assembling

    GR1600EC2, WSM TRANSAXLE [3] DISASSEMBLING AND ASSEMBLING (1) Hydrostatic Transmission Speed Control Arm, Neutral Spring, Cooling Fan and Others 1. Remove the neutral spring (2). 2. Remove the speed control arm (1). 3. Remove the cooling fan (3). 4. Remove the breather hoses (4).
  • Page 146 GR1600EC2, 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 W1017501 Hydrostatic Transmission Assembly 1. Remove the hydrostatic transmission assembly (1).
  • Page 147 GR1600EC2, WSM TRANSAXLE 15T Gear, 34T Gear and Bevel Gear Shaft 1. Remove the external snap ring (4). And pull out the 15T gear (1) and 34T gear (2). 2. Remove the bevel gear shaft (3). (1) 15T Gear (4) External Snap Ring...
  • Page 148 GR1600EC2, WSM TRANSAXLE Center Section 1. Remove the center section mounting hex. socket head screws. 2. Tap the center section (1) with soft hammer and separate the center section (1) from the HST housing (2). (When reassembling) • Cover the splines of each shaft with thin tape to protect the sealing lip of the oil seals.
  • Page 149 GR1600EC2, 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).

  • Page 150: Transaxle Case

    GR1600EC2, WSM TRANSAXLE (2) Transaxle Case Speed Control Arm, Neutral Spring, Cooling Fan and Others 1. Remove the neutral spring (2). 2. Remove the speed control arm (1). 3. Remove the cooling fan (3). 4. Remove the breather hoses (4).
  • Page 151 GR1600EC2, 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 Hydrostatic Transmission Assembly 1. Remove the hydrostatic transmission assembly (1).
  • Page 152 GR1600EC2, WSM TRANSAXLE PTO Clutch Assembly 1. Remove the PTO clutch assembly (1) and the ball bearing (2) from the transaxle case. (When reassembling) • Install the ball bearing (2) with the sealed face inside. • Align the tangs (4) of PTO brake friction plate with the slots (3) of transaxle case.
  • Page 153 GR1600EC2, 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 (9) clockwise. Then, separate the clutch case (9) and the spline boss (13) with clutch disc and friction plate (14).
  • Page 154 GR1600EC2, 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 155 GR1600EC2, WSM TRANSAXLE Transaxle Case 1. Remove the transaxle case screws (2). 2. Separate the rear side of transaxle case (1). (When reassembling) • Apply liquid gasket (Three Bond 1208D or equivalent) to joint face of the transaxle case. NOTE •...
  • Page 156 GR1600EC2, WSM TRANSAXLE Input Shaft, 19T-2 Gear and 17T-13T Gear Shaft 1. Remove the input shaft (1). 2. Remove the intermediate shaft (2) and 19T-2 gear (3) with collars (6) and needle bearing (7). 3. Remove the 17T-13T gear shaft (4).
  • Page 157 GR1600EC2, WSM TRANSAXLE Rear Differential Gear Assembly 1. Remove the 42T gear mounting screws (1). 2. Remove the 42T gear (2) and differential side gear (3). 3. Remove the differential pinion shaft (6). 4. Remove the differential pinion gears (5), differential side gear (7) and shims (4).

  • Page 158: Servicing

    GR1600EC2, WSM TRANSAXLE [4] SERVICING (1) Hydrostatic Transmission Charge Pump 1. Check the charge pump housing (1) and gerotor assembly (2) for scratches and wear. 2. If scratch or worn, replace the charge pump assembly. (1) Charge Pump Housing (2) Gerotor Assembly...
  • Page 159 GR1600EC2, WSM TRANSAXLE Cylinder Block Assembly 1. Check the cylinder blocks (4) and pistons (3) for scratches and wear. 2. If scratch or warn, replace the cylinder block assembly. 3. Check that the piston (3) and spring (2) are in each cylinder bore.

  • Page 160: Transaxle Case

    GR1600EC2, WSM TRANSAXLE (2) Transaxle Case Checking Bearing 1. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness. 2. Apply transmission fluid to the bearing, and hold the inner race.
  • Page 161 GR1600EC2, WSM TRANSAXLE PTO Brake Disc Wear 1. Measure the thickness of PTO brake disc with a vernier caliper. 2. If the thickness is less than the allowable limit, replace it. 3.3 to 3.5 mm Factory spec. 0.13 to 0.14 in.
  • Page 162 GR1600EC2, WSM TRANSAXLE Clearance between Differential Pinion Gear and Differential Pinion Shaft 1. Measure the differential pinion gear (1) I.D.. 2. Measure the differential pinion shaft (2) O.D., and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace faulty parts.
  • Page 163 GR1600EC2, WSM TRANSAXLE Backlash between 11T Bevel Gear Shaft and 17T-13T Gear Shaft 1. Stick a strip of fuse the three spots on the 11T bevel gear shaft (3) with grease. 2. Reassemble the hydrostatic transmission and transaxle case. 3. Fix the transaxle case, and push the by-pass valve.
  • Page 164 BRAKES KiSC issued 07, 2006 A...
  • Page 165 SERVICING CONTENTS 1. TROUBLESHOOTING ..................3-S1 2. SERVICING SPECIFICATIONS ..............3-S2 3. TIGHTENING TORQUES ................3-S3 4. CHECKING, DISASSEMBLING AND SERVICING........3-S4 [1] CHECKING AND ADJUSTING ...............3-S4 [2] DISASSEMBLING AND ASSEMBLING..........3-S4 (1) Pedal System Component ..............3-S4 (2) Brake Assembly ..................3-S8 KiSC issued 07, 2006 A...

  • Page 166: Troubleshooting

    GR1600EC2, WSM BRAKES 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Insufficient Braking Brake pedal free travel excessive Adjust 3-S4 Force Brake shoe worn Replace 3-S8 Brake drum worn Replace 3-S8 Grease or oil on brake shoe Replace 3-S8 Brake Drags...

  • Page 167: Servicing Specifications

    GR1600EC2, WSM BRAKES 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Brake Pedal Free Travel 15 to 25 mm – 0.59 to 0.98 in. W1013874 KiSC issued 07, 2006 A 3-S2...

  • Page 168: Tightening Torques

    GR1600EC2, 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 N·m kgf·m ft-lbs Steering wheel mounting nut 20 to 25 2.0 to 2.5...

  • Page 169: Checking, Disassembling And Servicing

    GR1600EC2, WSM BRAKES 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Brake Pedal Free Travel CAUTION • Stop the engine, remove the key, and chock the wheels before checking brake pedal. 1. Release the parking brake. 2. Loosen the lock nut (1) 3.
  • Page 170 GR1600EC2, WSM BRAKES Discharge Duct 1. Remove the filter cover (1) and the duct plate (3). 2. Disconnect the connector (5) from the grass container full switch (4). 3. Remove the discharge duct (2). (1) Filter Cover (4) Grass Container Full Switch...
  • Page 171 GR1600EC2, WSM BRAKES Seat 1. Remove two snap pins (2), (4). 2. Remove the seat (1) and seat plate (3). (1) Seat (3) Seat Plate (2) Snap pin (4) Snap Pin W1011458 Fender 1. Remove the speed change pedal (5).
  • Page 172 GR1600EC2, WSM BRAKES Steering Support Assembly 1. Disconnect the drag ling (4) from the sector gear (3). 2. Disconnect the connectors for the timer relay, regulator and buzzer unit. 3. Disconnect the accelerator wire (2). 4. Separate the steering support assembly (1).

  • Page 173: Brake Assembly

    GR1600EC2, WSM BRAKES (2) Brake Assembly Brake Assembly 1. Remove the lock nut (1), plain washers (2) and brake spring (3). 2. Remove the brake plate (5). 3. Remove the brake rod 2 (4). 4. Remove the brake assembly (6).

  • Page 174: Front Axle

    FRONT AXLE KiSC issued 07, 2006 A...
  • Page 175 SERVICING CONTENTS 1. TROUBLESHOOTING ..................4-S4 2. SERVICING SPECIFICATIONS ..............4-S2 3. TIGHTENING TORQUES ................4-S3 4. CHECKING, DISASSEMBLING AND SERVICING........4-S4 [1] CHECKING AND ADJUSTING ...............4-S4 [2] PREPARATION ..................4-S4 (1) Separating Front Axle Assembly............4-S4 [3] DISASSEMBLING AND ASSEMBLING..........4-S6 (1) Front Axle Assembly ................4-S6 [4] SERVICING ....................4-S6 KiSC issued 07, 2006 A...

  • Page 176: Troubleshooting

    GR1600EC2, WSM FRONT AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Front Wheels Tire pressure uneven Adjust – Wander to Right or Improper toe-in Replace tie-rod 4-S4, 6 Left Kingpin worn Replace front axle 4-S5 assembly Center pin collar worn...

  • Page 177: Servicing Specifications

    GR1600EC2, WSM FRONT AXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Front Wheel Alignment Toe-in 1 to 10 mm – 0.04 to 0.39 in. Front Axle Frame to Anti-vibration Bolt Clearance 0.3 to 0.5 mm – 0.012 to 0.020 in.

  • Page 178: Tightening Torques

    GR1600EC2, 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 N·m kgf·m ft-lbs Center pin locking nut 77.4 to 90.2...

  • Page 179: Checking, Disassembling And Servicing

    GR1600EC2, WSM FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Toe-in 1. Inflate the tires to the specified pressure. 2. Turn the front wheels straight ahead. 3. Measure the toe-in (B-A). 4. If the measurement is not within the factory specifications, replace the tie-rod.
  • Page 180 GR1600EC2, WSM FRONT AXLE Bonnet and Side Bonnet 1. Disconnect the connectors (5) from the head light. 2. Remove the wire harness (4) from the bonnet. 3. Remove the bonnet (1) with bonnet bracket (2). 4. Remove the side bonnet (3).

  • Page 181: Disassembling And Assembling

    GR1600EC2, WSM FRONT AXLE [3] DISASSEMBLING AND ASSEMBLING (1) Front Axle Assembly Tie-rod 1. Remove the tie-rod mounting locking nut (1). 2. Remove the tie-rod (2). (When reassembling) 49.9 to 54.2 N·m Tie-rod mounting locking Tightening torque 5.09 to 5.53 kgf·m 36.8 to 40.0 ft-lbs...
  • Page 182 STEERING KiSC issued 07, 2006 A...
  • Page 183 SERVICING CONTENTS 1. TROUBLESHOOTING ..................5-S4 2. SERVICING SPECIFICATIONS ..............5-S2 3. TIGHTENING TORQUES ................5-S3 4. CHECKING, DISASSEMNLING AND SERVICING ........5-S4 [1] CHECKING AND ADJUSTING ...............5-S4 [2] PREPARATION ..................5-S4 (1) Separating Steering Support Assembly ..........5-S4 [3] DISASSEMBLING AND ASSEMBLING..........5-S8 (1) Steering Support Assembly ..............5-S8 [4] SERVICING ....................5-S8 KiSC issued 07, 2006 A...

  • Page 184: Troubleshooting

    GR1600EC2, WSM STEERING 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Cannot Steer Steering shaft and sector gear broken Replace 5-S8 Steering linkage broken Replace 5-S7 Hard Steering Tire pressure uneven Adjust – Improper alignment of front wheels Replace tie-rod...

  • Page 185: Servicing Specifications

    GR1600EC2, WSM STEERING 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Steering Wheel Play 30 to 70 mm – 0.79 to 1.18 in. W1013874 KiSC issued 07, 2006 A 5-S2...

  • Page 186: Tightening Torques

    GR1600EC2, 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 N·m kgf·m ft-lbs Steering wheel mounting nut 20 to 25 2.0 to 2.5...

  • Page 187: Checking, Disassemnling And Servicing

    GR1600EC2, WSM STEERING 4. CHECKING, DISASSEMNLING AND SERVICING [1] CHECKING AND ADJUSTING Steering Wheel Play 1. Turn the front wheels straight ahead. 2. Rotate the steering wheel lightly by hand, and measure the play. 3. If the measurement exceeds the factory specifications, replace the steering shaft and sector gear.
  • Page 188 GR1600EC2, WSM STEERING Discharge Duct 1. Remove the filter cover (1) and the duct plate (3). 2. Disconnect the connector (5) from the grass container full switch (4). 3. Remove the discharge duct (2). (1) Filter Cover (4) Grass Container Full Switch...
  • Page 189 GR1600EC2, WSM STEERING Seat 1. Remove two snap pins (2), (4). 2. Remove the seat (1) and seat plate (3). (1) Seat (3) Seat Plate (2) Snap Pin (4) Snap Pin W1011217 Fender 1. Remove the speed change pedal (5).
  • Page 190 GR1600EC2, WSM STEERING Steering Support Assembly 1. Disconnect the drag link (4) from the sector gear (3). 2. Disconnect the connectors for the timer relay, regulator and buzzer unit. 3. Disconnect the accelerator wire (2). 4. Separate the steering support assembly (1).

  • Page 191: Disassembling And Assembling

    GR1600EC2, WSM STEERING [3] DISASSEMBLING AND ASSEMBLING (1) Steering Support Assembly Steering Shaft and Sector Gear 1. Remove the shaft retainer (4). 2. Remove the sector gear mounting screw (5), and remove the sector gear (8). 3. Remove the steering bearing (1) and ball bearing (3).

  • Page 192: Electrical System

    ELECTRICAL SYSTEM KiSC issued 07, 2006 A...
  • Page 193 MECHANISM CONTENTS 1. WIRING DIAGRAM ..................6-M1 2. STARTING SYSTEM ..................6-M3 3. CHARGING SYSTEM ................... 6-M4 4. LIGHTING SYSTEM ..................6-M5 KiSC issued 07, 2006 A...

  • Page 194: Wiring Diagram

    GR1600EC2, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM Out Let 14Ga.R Grass Container Grass Container Top Cover Seat Switch Open Switch Open Switch (Vacant) (Without) (Open) (Occupied) (With) (Close) Fuse (Engine Stop)(15A) 14Ga.R 14Ga.Gy 18Ga.Y 18Ga.YW 18Ga.GY Brake Switch PTO Switch 18Ga.B...
  • Page 195 GR1600EC2, 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 ..

  • Page 196: Starting System

    GR1600EC2, WSM ELECTRICAL SYSTEM 2. STARTING SYSTEM (1) Battery (7) Engine Stop Time Relay (13) Grass Container Open Relay (18) Fuse (10 A) (2) Body Earth (8) Fuel Feed Pump (14) Diode (3 A) (19) Main Switch (3) Starter Motor...

  • Page 197: Charging System

    GR1600EC2, 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 198: Lighting System

    GR1600EC2, WSM ELECTRICAL SYSTEM 4. LIGHTING SYSTEM (1) Battery (7) Regulator (13) Grass Container Full Switch (19) Charge Lamp (2) Body Earth (8) Slow Blow Fuse (40 A) (14) Buzzer Relay (20) Easy Checker (3) Thermo Switch (9) Main Switch...
  • Page 199 SERVICING CONTENTS 1. TROUBLESHOOTING ..................6-S1 2. SERVICING SPECIFICATIONS ..............6-S4 3. TIGHTENING TORQUES ................6-S5 4. CHEKING, DISASSEMBLING AND SERVICING ........6-S6 [1] CHECKING AND ADJUSTING ...............6-S6 (1) Battery....................6-S6 (2) Main Switch..................6-S8 (3) Starter ....................6-S10 (4) Glow Plug..................6-S11 (5) Safety Switch ..................6-S12 (6) Operator Presence Control (OPC) Switch ........6-S13 (7) Fuel Pump..................6-S14 (8) Engine Stop Solenoid ...............6-S14 (9) Timer Relay..................6-S15...

  • Page 200: Troubleshooting

    GR1600EC2, WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page All Electrical Battery discharged or defective Recharge or replace G-24, Equipments Do Not 1-S19 Operate Battery positive cable disconnected or Repair or replace – improperly connected Battery negative cable disconnected or Repair or replace –...
  • Page 201 GR1600EC2, WSM ELECTRICAL SYSTEM STARTING SYSTEM Reference Symptom Probable Cause Solution Page Starter Motor Does Battery discharged or defective Recharge or replace G-24, Not Operate 1-S19 Slow blow fuse blown (40 A) Replace G-35 Wiring harness disconnected or improperly Repair or replace –...
  • Page 202 GR1600EC2, WSM ELECTRICAL SYSTEM LIGHTING SYSTEM Reference Symptom Probable Cause Solution Page Head Light Does Not Fuse blown (10 A) Replace G-35 Light Bulb blown Replace G-35 Wiring harness disconnected or improperly Repair or replace – connected (between main switch ACC terminal...

  • Page 203: Servicing Specifications

    GR1600EC2, WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Battery Voltage More than 12 V – Potential Less than 0.1 V – Difference Approx. 0.9 Ω Glow Plug Resistance – Head Light Switch Resistance OFF Infinity –...

  • Page 204: Tightening Torques

    GR1600EC2, 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 N·m kgf·m ft-lbs Starter (C terminal nut) 5.9 to 11.8...

  • Page 205: Cheking, Disassembling And Servicing

    GR1600EC2, WSM ELECTRICAL SYSTEM 4. CHEKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Battery Battery Voltage 1. Stop the engine and turn the main switch off. 2. Connect the COM (-) lead of the voltmeter to the battery’s negative terminal post (2) and the (+) lead to the positive terminal post (1), and measure the battery voltage.
  • Page 206 GR1600EC2, WSM ELECTRICAL SYSTEM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).

  • Page 207: Main Switch

    GR1600EC2, WSM ELECTRICAL SYSTEM (2) Main Switch Main Switch 1. Open the bonnet. 2. Disconnect the 4P connector and remove the main switch (1). 3. Perform the following checks. (1) Main Switch W1012030 Connector Voltage 1. Measure the voltage with a voltmeter across the connector B (red) terminal and chassis.
  • Page 208 GR1600EC2, 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 209: Starter

    GR1600EC2, WSM ELECTRICAL SYSTEM (3) Starter Motor Test CAUTION • Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable and the leads from the starter.

  • Page 210: Glow Plug

    GR1600EC2, 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 211: Safety Switch

    GR1600EC2, WSM ELECTRICAL SYSTEM (5) Safety Switch PTO Switch 1. Remove the battery. 2. Remove the fender. 3. Disconnect the connector from the PTO switch (1). 4. Measure the resistance with an ohmmeter between the terminals. 5. If the PTO switch is defective, replace it.

  • Page 212: Operator Presence Control (Opc) Switch

    GR1600EC2, WSM ELECTRICAL SYSTEM Top Cover and Grass Container Open Switch 1. Remove the battery. 2. Remove the open switches (1) (2). 3. Measure the resistance with an ohmmeter between the switch terminals. 4. If the switches are defective, replace them.

  • Page 213: Fuel Pump

    GR1600EC2, 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 214: Timer Relay

    GR1600EC2, WSM ELECTRICAL SYSTEM (9) Timer Relay Timer Relay Connector Voltage 1. Disconnect the connector from the timer relay after turning the main switch off. 2. Measure the voltage with a voltmeter across the connector terminal 4 and chassis. 3. Turn the main switch on, and measure the voltage across the connector terminal 3 and chassis.

  • Page 215: Lighting System

    GR1600EC2, WSM ELECTRICAL SYSTEM Regulation Voltage CAUTION • To avoid personal injury, do not touch the rotating or hot parts while the engine is running. NOTE • Before performing this checking, make sure that the no-load dynamo output is proper.
  • Page 216 GR1600EC2, 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.

  • Page 217: Coolant Temperature Sensor

    GR1600EC2, 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 218 GR1600EC2, 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 219: Disassembling And Assembling

    GR1600EC2, WSM ELECTRICAL SYSTEM [2] DISASSEMBLING AND ASSEMBLING (1) Starter (1) Sleeve Bearing (2) Bushing (3) Starter Drive Housing (4) Drive Lever (5) Magnet Switch (6) Yoke (7) Connecting Lead (8) Through Bolt (9) Rear End Frame (10) Bushing (11) Brush...

  • Page 220: Dynamo

    GR1600EC2, 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). 39.2 to 44.1 N·m Tightening torque 4.0 to 4.5 kgf·m 28.9 to 32.5 ft-lbs...

  • Page 221: Servicing

    GR1600EC2, 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 222 GR1600EC2, WSM ELECTRICAL SYSTEM Brush Holder 1. Check the continuity across the brush holder and the holder support with an ohmmeter. 2. If it conducts, replace the brush holder. W1017672 Armature Coil 1. Check the continuity across the commutator and armature coil core with an ohmmeter.

  • Page 223: Dynamo

    GR1600EC2, WSM ELECTRICAL SYSTEM (2) Dynamo Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. W1019790 KiSC issued 07, 2006 A 6-S24...
  • Page 224 MOWER KiSC issued 07, 2006 A...
  • Page 225 MECHANISM CONTENTS 1. POWER TRANSMISSION ................7-M1 2. LIFTING MECHANISM ................. 7-M2 KiSC issued 07, 2006 A...

  • Page 226: Power Transmission

    GR1600EC2, WSM MOWER 1. POWER TRANSMISSION (1) Center Pulley (4) 18T Spiral Gear (7) Mower Belt (9) Blade Shaft (2) Output Shaft (5) Input Shaft (8) Universal Joint (10) Blade (3) 17T Spiral Gear (6) Outer Pulley The power is transmitted from transmission case to blades as follows.
  • Page 227 GR1600EC2, WSM MOWER 2. LIFTING MECHANISM (1) Lift Link LH (4) Lift Link Shaft (7) Cutting Height Adjusting Dial (9) Lift Link RH (2) Rear Link LH (5) Mower Lift Lever (8) Adjusting Cam (10) Rear Link RH (3) Gas Spring (6) Lift Link The rear link RH (10) and mower lift lever (5) are linked with lift link RH (9) and lift link (6).
  • Page 228 SERVICING CONTENTS 1. TROUBLESHOOTING ..................7-S1 2. SERVICING SPECIFICATIONS ..............7-S1 3. TIGHTENING TORQUES ................7-S1 4. CHECKING, DISASSEMBLING AND ASSEMBLING ........7-S4 [1] CHECKING AND ADJUSTING ...............7-S4 (1) Adjusting Anti-scalp Rollers ..............7-S4 (2) Adjusting Left and Right Cutting Height ..........7-S5 [2] PREPARATION ..................7-S6 (1) Dismounting Mower ................7-S6 [3] DISASSEMBLING AND ASSEMBLING..........7-S8 (1) Mower ....................7-S8...
  • Page 229 GR1600EC2, WSM MOWER 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Blade Does Not Turn PTO system malfunctioning Check transmission – Mower belt broken Replace mower belt 7-S8 Blade Speed Is Slow Mower belt loosen Replace mower belt 7-S8 or tension spring...

  • Page 230: Servicing Specifications

    GR1600EC2, WSM MOWER 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Left Tip of Blade to Right Tip of Blade Difference Less than 6 mm – 0.24 in. Front Tip of Blade to Rear Tip of Blade Difference Less than 5 mm –...
  • Page 231 GR1600EC2, 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 N·m kgf·m ft-lbs Mower blade screw 98 to 118 10.0 to 12.0...

  • Page 232: Checking, Disassembling And Assembling

    GR1600EC2, WSM MOWER 4. CHECKING, DISASSEMBLING AND ASSEMBLING [1] CHECKING AND ADJUSTING (1) Adjusting Anti-scalp Rollers Adjusting Anti-scalp Rollers IMPORTANT • The flattest cut can be achieved by having the anti-scalp rollers adjusted off the ground. Check anti-scalp roller adjustments each time the mower deck cutting height is changed.

  • Page 233: Adjusting Left And Right Cutting Height

    GR1600EC2, 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.)

  • Page 234: Preparation

    GR1600EC2, 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 235 GR1600EC2, 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.

  • Page 236: Disassembling And Assembling

    GR1600EC2, WSM MOWER [3] DISASSEMBLING AND ASSEMBLING (1) Mower Mower Blades (Left Blade and Right Blades) 1. Turn over the mower. 2. Unscrew the mower blade screw (1), and remove the shim (2), two cup washers (3), mower blade (4) and dust cover (6).
  • Page 237 GR1600EC2, WSM MOWER Disassembling Gear Box 1. Unscrew the drain plug (10), and drain the gear box oil. 2. Unscrew the pulley mounting screw (1), and remove the pulley (3). 3. Remove the case cover (15). 4. Remove the shim (14) and 18T spiral gear (12) with ball bearing (13).
  • Page 238 GR1600EC2, WSM MOWER Disassembling Pulley Holder 1. Remove the grease nipple (12). 2. Unscrew the pulley mounting nut (11), and remove the pulley (10). 3. Tap out the blade shaft (1). 4. Remove the pulley holder (6) from the mower deck.

  • Page 239: Mower Lift Linkage

    GR1600EC2, WSM MOWER (2) Mower Lift Linkage (1) Screw (2) Gas Spring Mounting Nut (3) Lock Nut (4) Rear Link LH (5) Clevis Pin (6) Lift Link LH (7) Rue Ring (8) Rue Ring (9) Gas Spring Mounting Nut (10) Gas Spring...

  • Page 240: Servicing

    GR1600EC2, WSM MOWER [4] SERVICING (1) Gear Box Backlash between 17T Spiral Gear and 18 Spiral Gear 1. Remove the 18T spiral gear (6) from gear box. 2. Stick the strip of fuse the 18T spiral gear (6) with grease.
  • Page 241 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 KUBOTA Corporation Printed in Japan 2006. 07, S, EI, EI, e...

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