Kubota G2160 Workshop Manual

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WORKSHOP MANUAL

TRACTOR

G2160,G2160-R48S,G2460G

KiSC issued 11, 2006 A

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Troubleshooting

Summary of Contents for Kubota G2160

Page 1 WORKSHOP MANUAL TRACTOR G2160,G2160-R48S,G2460G KiSC issued 11, 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 G2160. It is divided into two parts, “MECHANISM” and “SERVICING” for each section except “ENGINE” section. MECHANISM Information on the construction and function are included.
Page 3 G2160, 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 G2160, 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 G2160, 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
G2160, 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 11, 2006 A...
Page 7 G2160, WSM SAFETY INSTRUCTIONS KiSC issued 11, 2006 A...
Page 8 G2160, WSM SAFETY INSTRUCTIONS KiSC issued 11, 2006 A...
Page 9 G2160, WSM SAFETY INSTRUCTIONS KiSC issued 11, 2006 A...
Page 10 G2160, WSM SPECIFICATIONS SPECIFICATIONS Model G2160 Maximum gross power 15.6 kW (21 HP) Model D782-E-G21 Type Indirect injection, vertical, water cooled, 4-cycle diesel engine Number of cylinders 67.0 × 73.6 mm (2.64 × 2.90 in.) Bore and stroke Total displacement 778 cm (47.48 cu.in.)
Page 11 G2160, WSM SPECIFICATIONS Model G2160 Steering Electric power steering (EPS) Transmission Hydrostatic transmission Brake Internal expanding brake Model RCK54-24G RCK60B-24G Total length 946 mm (37.2 in.) 992 mm (39.1 in.) Total width 1690 mm (66.5 in.) 1843 mm (72.5 in.) Total height 273 mm (10.7 in.)
Page 12 G2160, WSM DIMENSIONS DIMENSIONS KiSC issued 11, 2006 A...
Page 13 GENERAL KiSC issued 11, 2006 A...
Page 14: Table Of Contents
GENERAL CONTENTS 1. FEATURES ...................... G-1 2. IDENTIFICATION..................... G-2 3. GENERAL PRECAUTIONS ................G-3 4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .. G-4 [1] WIRING...................... G-4 [2] BATTERY....................G-6 [3] FUSE......................G-6 [4] CONNECTOR .................... G-6 [5] HANDLING OF CIRCUIT TESTER............G-7 5.
Page 15: Features
G2160, WSM G GENERAL 1. FEATURES 1. E-TVCS engine 2. Front PTO (option) 3. Rugged ladder type chassis 4. Low-noise, high-performance mower 5. Large-capacity fuel tank 6. Hydraulic mower lift KiSC issued 11, 2006 A...
Page 16: Identification
G2160, WSM G GENERAL 2. IDENTIFICATION When contacting your local KUBOTA distributor, always specify engine serial number (1), machine serial number (2), mower serial number (3) and hour meter reading. (1) Engine Serial Number (3) Mower Serial Number (2) Machine Serial Number...
Page 17: General Precautions
Screws, bolts and nuts should be installed in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.
Page 18: Handling Precautions For Electrical Parts And Wiring
G2160, WSM G GENERAL 4. 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 19 G2160, WSM G GENERAL • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp • Wind Clamp Spirally (4) Welding Dent (2) Wire Harness W1011458 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.
Page 20: Battery
G2160, 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 21: Handling Of Circuit Tester
G2160, WSM G GENERAL • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make certain there is no terminal being exposed or displaced. (1) Exposed Terminal (3) Sandpaper (2) Deformed Terminal (4) Rust W1012346 • Make certain that there is no female connector being too open.
Page 22: Lubricants, Fuel And Coolant
0 to 25 °C (32 to 77 °F): SAE20 or 10W-30 Above 25 °C (77 °F): SAE30 or 10W-30 4.5 L Transmission (Including 4.75 U.S.qts KUBOTA UDT or SUPER UDT fluid HST & cylinder) 3.86 Imp.qts 0.40 L Mower gear case 0.42 U.S.qts...
Page 23: Tightening Torques
G2160, WSM G GENERAL 6. 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 24: American Standard Screws, Bolts And Nuts With Unc Or Unf Threads
G2160, WSM G GENERAL [3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS Grade SAE GR.5 SAE GR.8 Unit N·m kgf·m ft-lbs N·m kgf·m ft-lbs Nominal Diameter 5/16 23.1 to 27.8 2.35 to 2.84 17.0 to 20.5 32.5 to 39.3...
Page 25: Maintenance Check List
*** : Initial elongation of the front PTO belt may occur prior to 25 hours. Adjust the tension spring length as needed to maintain belt tension. : These items should be serviced by an authorized KUBOTA Dealer, unless the owner has the proper tools and is mechanically proficient.
Page 26: Check And Maintenance
1. Head lights • Starting the engine, 1. Color of the exhaust fumes 2. If either of safety start switch and seat safety control do not operate properly, contact your KUBOTA Dealer immediately. 3. Check for abnormal noise and vibration.
Page 27 G2160, WSM G GENERAL Checking Engine Oil Level CAUTION • To avoid personal injury : Always stop the engine and remove the key before checking oil. 1. Check engine oil before starting and 5 minutes or more after the engine has stopped.
Page 28 G2160, 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 G2160, WSM G GENERAL Radiator Screen and Panel Screen Daily or after every 5 hours of operation, check to be sure the radiator screen (1) and panel screen (2) are clean. Dirt or chaff on the radiator screen (1) or radiator core decrease cooling performance.
Page 30 G2160, WSM G GENERAL Oiling CAUTION • Be sure to stop the engine and remove the key before oiling. Oil the following points before starting. NOTE • Oil these points on both sides of the machine. 1. Apply oil to the following points.
Page 31: Check Points Of Initial 50 Hours
G2160, WSM G GENERAL (10) Around the hole of the Mower Link (12) Pivot of Mower Link (11) Around the Link (13) Pivot of Liftarm W1066546 [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil CAUTION • Be sure to stop the engine before changing oil.
Page 32 IMPORTANT • To prevent serious damage to hydraulic system, the replacement filter must be a highly efficient, 10 μm filter. Use only a genuine KUBOTA filter or its equivalent. (1) Transmission Oil Filter Cartridge (2) Screw W1031068 Changing Mower Gear Box Oil 1.
Page 33: Check Points Of Every 50 Hours
G2160, WSM G GENERAL [3] CHECK POINTS OF EVERY 50 HOURS Checking Tire Pressure 1. Check the wear and damage or tires. 2. Check the tire pressure. 3. If insufficient, add air. If excessive, reduce air. 200 kPa Front 2.0 kgf/cm...
Page 34 G2160, WSM G GENERAL Adjusting Fan Belt Tension CAUTION • Be sure to stop the engine and remove the key before checking belt tension. 1. If the fan drive belt becomes loose, the engine may overheat. 2. To adjust, loosen bolts and turn the alternator to tighten the belt.
Page 35 G2160, WSM G GENERAL (8) Grease Nipple (Balance Shaft) (RCK60B-24G Only) (9) Tension Lever W1045060 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.
Page 36 G2160, WSM G GENERAL Checking and Adjusting Front PTO Belt Tension CAUTION • Always stop the engine, set the parking brake, remove the key, and disengage the PTO lever before working on the front PTO. If the front PTO belts slip when the PTO is operating under load, check the front PTO belt tension and adjust the tension spring length, as explained below.
Page 37: Check Points Of Every 100 Hours
G2160, WSM G GENERAL [4] CHECK POINTS OF EVERY 100 HOURS Changing Engine Oil 1. See page G-17. W1034674 Checking Fuel Lines And Fuel Filter CAUTION • Be sure to stop the engine and remove the key when attempting to make the following checks and changes.
Page 38 G2160, WSM G GENERAL Checking Battery Condition CAUTION • Never remove the vent cap while the engine is running. Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately and get medical attention.
Page 39: Check Points Of Every 150 Hours
G2160, WSM G GENERAL 5. When the specific gravity of electrolyte reaches 1.27 to 1.29, charge has completed. 6. When exchanging an old battery with new one, use a battery of equal specification shown in “SPECIFICATIONS”. (For non-accessible maintenance-free type batteries.)
Page 40: Check Points Of Every 300 Hours
G2160, WSM G GENERAL Checking Hydraulic Hose CAUTION • Be sure to stop the engine and remove the key before checking and replacing hydraulic hose. • Allow transmission case to cool down sufficiently; oil can be hot and may cause burns.
Page 41: Check Points Of Every 500 Hours
G2160, WSM G GENERAL Changing Transmission Oil Filter Cartridge 1. See page G-18. W1036964 Cleaning Transmission Oil Strainer CAUTION • Be sure to stop the engine and remove the key before cleaning the transmission oil strainer. • Allow transmission case to cool down sufficiently; oil can be hot and may cause burns.
Page 42: Check Points Of Every 1 Year
G2160, WSM G GENERAL [9] CHECK POINTS OF EVERY 1 YEAR Replacing Air Cleaner Element 1. Remove the air cleaner element (2) once a year. IMPORTANT • The air cleaner uses a dry element, never apply oil. • Do not run the engine with filter element removed.
Page 43 G2160, WSM G GENERAL Flushing Cooling System and Changing Coolant (Continued) Anti-Freeze If cooling water freezes, the cylinders and radiator can be damaged. It is necessary, if the ambient temperature falls below 0 °C (32 °F), to remove cooling water mix it with anti-freeze and full the radiator with it.
Page 44 G2160, WSM G GENERAL Replacing Fuel Line 1. Replace the fuel hoses (1) and hose clamps (2). Refer to “Checking Fuel Line”. (See page G-23.) (1) Fuel Hose (2) Hose Clamp W1038053 Replacing Radiator Hose and Clamp Band 1. Replace the radiator hoses (1) and clamp bands (2).
Page 45 G2160, WSM G GENERAL Replacing Mower Gear Box Seals 1. Replace the mower gear box oil seals (1), (2). Refer to “Disassembling Gear Box Assembly” (See page 9- S11). (1) Oil Seal (2) Oil Seal W1038357 Replacing Fuses 1. The electrical system is protected from potential damage by fuses.
Page 46 G2160, WSM G GENERAL Replacing Bulbs (A) Replacing the head light bulb 1. Open hood. 2. Turn bulb socket to remove socket from headlight housing. 3. Push bulb down and turn one quarter turn to remove bulb from the socket.
Page 47: Special Tools
G2160, WSM G GENERAL 9. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Special Use Puller Set Code No: 07916-09032 Application: Use exclusively for pushing out bearing, gears and other parts with ease. W1048293 Piston Ring Compressor Code No: 07909-32111 Application: Use exclusively for pushing in the piston with piston rings into the cylinder.
Page 48 G2160, WSM G GENERAL Oil Pressure Tester Code No: 07916-32032 Application: Use to measure lubricating oil pressure. (1) Gauge (5) Adaptor 2 (2) Cable (6) Adaptor 3 (3) Threaded Joint (7) Adaptor 4 (4) Adaptor 1 (8) Adaptor 5 W1048722...
Page 49 G2160, WSM G GENERAL Nozzle Tester Code No: 07909-31361 Application: Use to check the fuel injection pressure and spray pattern of nozzle. Measuring: 0 to 50 MPa range (0 to 500 kgf/cm , 0 to 7000 psi) W1049783 Plastigage Code No:...
Page 50 G2160, 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 51 G2160, WSM G GENERAL Bushing Replacing Tool Application: Use to press out and to press fit the bushing. 1. For small end bushing 145 mm (5.71 in.) 20 mm (0.79 in.) 100 mm (3.94 in.) 19.90 to 19.95 mm dia.
Page 52 G2160, WSM G GENERAL Crankshaft Bearing 1 Replacing Tool Application: Use to press out and to press fit the crankshaft bearing [Press Out] 135 mm (5.31 in.) 72 mm (2.83 in.) 40° (1.57 rad) 10 mm (0.39 in.) 22 mm (0.87 in.) 20 mm dia.
Page 53: Special Tools For Machine
G2160, WSM G GENERAL [2] SPECIAL TOOLS FOR MACHINE Steering Wheel Puller Code No: 07916-51090 Application: Use for removing the steering wheel without damaging the steering shaft. W1051779 Toe-in Gauge Code No: 07909-31681 Application: This allows easy measurement of toe-in for all machine models.
Page 54 G2160, WSM G GENERAL NOTE • The following special tool is not provided, so make it referring to the figure. Steering Wheel Puller Adaptor Application: Use for removing the steering wheel with steering wheel 22 mm (0.87 in.) 116 mm (4.57 in.) 64 mm (2.52 in.)
Page 55 G2160, WSM G GENERAL Adaptor Bolt for HST Application: Use for checking the charge relief valve setting pressure. 26 mm (1.02 in.) 0.4 mm (0.02 in.) 18 mm (0.71 in.) 0.5 mm (0.02 in.) 15 mm (0.59 in.) 15 mm (0.59 in.) 30 mm (1.18 in.)
Page 56 G2160, WSM G GENERAL Adaptor for Control Valve Application: Use for checking the main relief valve setting pressure. 40 mm (1.57 in.) 4.5 mm dia. (0.18 in. dia.) 18 mm (0.71.) 9 mm dia. (0.18 in. dia.) 6 mm (0.24 in.) RP 1/4 thread depth 15 mm (0.59 in.)
Page 57 G2160, WSM G GENERAL Flange for Control Valve 1. Use for checking the relief valve setting pressure. NOTE • When using , attach with following parts. 1. O-ring: 04811-10240 2. O-ring: 04811-10600. RP 1/4 5 mm dia. (0.20 in. dia.) 14.5 mm dia.
Page 58: Implement Limitations
KUBOTA. Use of implements which exceed the maximum loading weight listed below, or which are not recommended for use with the KUBOTA Machine may result in malfunctions or failures of the machine, damage to other property and injury to the operator or others.
Page 59 ENGINE KiSC issued 11, 2006 A...
Page 60 SERVICING CONTENTS 1. TROUBLESHOOTING ..................1-S1 2. SERVICING SPECIFICATIONS ..............1-S5 [1] ENGINE BODY ..................1-S5 [2] LUBRICATING SYSTEM .................1-S9 [3] COOLING SYSTEM.................1-S9 [4] FUEL SYSTEM ..................1-S10 3. TIGHTENING TORQUES ................1-S11 4. CHECKING, DISASSEMBLING AND SERVICING........1-S12 [1] SEPARATING ENGINE .................1-S12 (1) Disassembling and Assembling ............1-S12 [2] ENGINE BODY ..................1-S17 (1) Checking and Adjusting ..............1-S17 (2) Disassembling and Assembling ............1-S20...
Page 61: Troubleshooting
G2160, WSM ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not • No fuel Replenish fuel. – Start • Air in the fuel system Bleed fuel system. – • Water in the fuel system Change fuel and –...
Page 62 G2160, WSM ENGINE Reference Symptom Probable Cause Solution Page Engine Revolution Is • Fuel filter clogged or dirty Replace fuel filter. G-27 Not Smooth • Air cleaner clogged Clean or replace air G-28 cleaner element. • Fuel leak due to loose injection pipe retaining Tighten retaining nut.
Page 63 G2160, WSM ENGINE Reference Symptom Probable Cause Solution Page Fuel Mixed into • Injection pump's plunger worn Replace pump 1-S52 Lubricant Oil element or injection pump. • Deficient nozzle injection Repair or replace 1-S51 nozzle. 1-S52 • Injection pump broken...
Page 64 G2160, WSM ENGINE Reference Symptom Probable Cause Solution Page Engine Overheated • Engine oil insufficient Replenish engine oil. G-17 • Fan belt broken or tensioned improperly Replace fan belt or G-20 adjust fan belt 1-S48 tension. • Cooling water insufficient Replenish cooling –...
Page 65: Servicing Specifications
G2160, WSM ENGINE 2. SERVICING SPECIFICATIONS [1] ENGINE BODY Cylinder Head Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.05 mm 0.0020 in. Top Clearance 0.50 to 0.70 mm – 0.0197 to 0.0276 in. Compression Pressure 2.84 to 3.24 MPa 2.26 MPa...
Page 66 G2160, WSM ENGINE Valve Spring Item Factory Specification Allowable Limit Free Length 31.3 to 31.8 mm 28.4 mm 1.232 to 1.252 in. 1.118 in. Setting Load / Setting Length 64.7 N / 27.0 mm 54.9 N / 27.0 mm 6.6 kgf / 27.0 mm 5.6 kgf / 27.0 mm...
Page 67 G2160, WSM ENGINE Timing Gear Item Factory Specification Allowable Limit Timing Gear Backlash Crank Gear- Idle Gear 0.043 to 0.124 mm 0.15 mm 0.00169 to 0.00488 in. 0.0059 in. Idle Gear-Cam Gear 0.047 to 0.123 mm 0.15 mm 0.00185 to 0.00484 in.
Page 68 G2160, WSM ENGINE Crankshaft Item Factory Specification Allowable Limit Crankshaft Runout – 0.04 mm 0.0016 in. Oil Clearance between Crankshaft Journal and Crankshaft 0.034 to 0.106 mm 0.20 mm Bearing 1 0.00134 to 0.00417 in. 0.0079 in. Crankshaft Journal O.D.
Page 69: Lubricating System
G2160, WSM ENGINE [2] LUBRICATING SYSTEM Oil Pump Item Factory Specification Allowable Limit Engine Oil Pressure 98 kPa – At Idle Speed 1.0 kgf/cm 14 psi At Rated Speed 196 to 441 kPa 98 kPa 2.0 to 4.5 kgf/cm 1.0 kgf/cm...
Page 70: Fuel System
G2160, WSM ENGINE [4] FUEL SYSTEM Injection Pump Item Factory Specification Allowable Limit Injection Timing 0.31 to 0.34 rad (19.0 to – 21.0 °) Before T.D.C. Fuel Tightness of Pump Element – 14.7 MPa 150 kgf/cm 2130 psi Fuel Tightness of Delivery Valve –...
Page 71: Tightening Torques
G2160, WSM ENGINE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9.) Item Size x Pitch N·m kgf·m ft-lbs M6 × 1.0 Starter M terminal nut 9.8 to 13.7...
Page 72: Checking, Disassembling And Servicing
G2160, WSM ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] SEPARATING ENGINE (1) Disassembling and Assembling Dismount Mower 1. See to “MOWER” section. W1019171 Draining Engine Oil 1. Park the machine on level ground. 2. Start and warm up the engine for approx. 5 minutes.
Page 73 G2160, WSM ENGINE Draining Coolant CAUTION • Never open the radiator cap while operating or immediately after stopping. Otherwise, hot water will spout out from the radiator. Wait for more than ten minutes to cool the radiator, before opening the cap.
Page 74 G2160, WSM ENGINE Wiring 1. Disconnect the tie (1) from the alternator, and remove the PTO cable (3) and wiring (2). 2. Disconnect 2P connector (5) and wiring (4) from the alternator. 3. Disconnect 1P connector (8) from the oil pressure switch.
Page 75 G2160, WSM ENGINE Muffler, Wiring, Accelerator and Hose 1. Remove the muffler mounting screws (1), (7). 2. Remove the muffler (2). 3. Disconnect 1P connector (5) from the coolant temperature sensor. 4. Disconnect the wiring (3) from the glow plug.
Page 76 G2160, WSM ENGINE Separating Engine 1. Pull out the hairpin cotters from the radiator. 2. Remove the engine mounting nuts, and support the engine with an engine lift hook and hoist. 3. Separate the engine with the radiator from the frame, taking care not to damage the radiator.
Page 77: Engine Body
G2160, WSM ENGINE [2] ENGINE BODY (1) Checking and Adjusting Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Disconnect the 2P connector from the fuel pump. 4. Remove the air cleaner, the muffler and all injection nozzles.
Page 78 G2160, WSM ENGINE Top Clearance 1. Remove the cylinder head (Do not attempt to remove the cylinder head gasket completely). 2. Bring the piston to its top dead center fasten 1.5 mm dia. 5 to 7 mm long fuse wires to 3 to 4 spots on the piston top with grease so as to avoid the intake and exhaust valves and the combustion chamber ports.
Page 79 G2160, WSM ENGINE Valve Clearance IMPORTANT • The valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover and the glow plugs. 2. Align the “1TC” mark (1) on the flywheel and alignment mark (2) on the rear end plate so that the No.
Page 80: Disassembling And Assembling
G2160, WSM ENGINE (2) Disassembling and Assembling (A) Cylinder Head and Valves External Components 1. Remove the air cleaner stay (5). 2. Remove the water pipe 1 (2), water pipe 2 (7) and radiator (8) with the recovery tank. 3. Remove the alternator (9) and fan belt (10).
Page 81 G2160, WSM ENGINE Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe assembly (5). 2. Remove the nozzle holder assemblies (2) using a 21 mm deep socket wrench. 3. Remove the copper gasket and heat seal (3). 4. Remove the lead (4) from the glow plugs.
Page 82 G2160, WSM ENGINE Cylinder Head 1. Loosen the pipe clamp, and remove the water return pipe. 2. Remove the cylinder head bolt in the order of (14) to (1). 3. Lift up the cylinder head to detach. 4. Remove the cylinder head gasket and O-ring.
Page 83 G2160, WSM ENGINE (B) Timing Gears and Camshaft Injection Pump and Speed Control Plate 1. Remove the socket head screws and nuts, and remove the injection pump (3). 2. Remove the screws and separate the speed control plate (2), taking care not to damage the spring (4).
Page 84 G2160, WSM ENGINE Gear Case 1. Remove the screw (1). 2. Disconnect the start spring (2) in the speed control plate mounting hole. 3. Remove the gear case (3). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) to both sides of the gear case gasket (4).
Page 85 G2160, WSM ENGINE Fuel Camshaft 1. Remove the screws and draw out the camshaft with the gear on 2. Remove the retaining plate (1). 3. Remove the screws, then draw out the injection pump gear (2) and fuel camshaft (3) with the governor fork assembly.
Page 86 G2160, WSM ENGINE (C) Connecting Rod and Piston Oil Pan and Oil Strainer 1. Remove the oil pan (4). 2. Remove the oil strainer (3). (When reassembling) • Install the oil strainer, using care not to damage the O-ring (1).
Page 87 G2160, WSM ENGINE Piston 1. Turn the flywheel and bring the No.1 piston to the top dead center. 2. Pull out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer.
Page 88 G2160, WSM ENGINE Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Put the casting mark (↑) (8) on the piston as shown in figure. 3. Remove the piston pin (1), and separate the connecting rod (7) from the piston (2).
Page 89 G2160, WSM ENGINE (D) Crankshaft Flywheel 1. Lock the flywheel not to turn using flywheel stopper. 2. Remove the flywheel screws, except for two which must be loosened and left as they are. 3. Set a flywheel puller (Code No: 07916-32011), and remove the flywheel.
Page 90 G2160, WSM ENGINE Crankshaft 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly. (When reassembling) • Install the crankshaft sub assembly, aligning the screw hole of main bearing case 2 with the screw hole of cylinder block.
Page 91: Servicing
G2160, WSM ENGINE (3) Servicing (A) Cylinder Head and Valve Cylinder Head Surface Flatness 1. Clean the cylinder head surface. 2. Place a straightedge on the cylinder head’s four sides and two diagonal as shown in the figure. 3. Measure the clearance with a feeler gauge.
Page 92 G2160, WSM ENGINE Valve Recessing 1. Clean the cylinder head surface, valve face and valve seat. 2. Insert the valve into the valve guide. 3. Measure the valve recessing with a depth gauge. 4. If the measurement exceeds the allowable limit, replace the valve.
Page 93 G2160, WSM ENGINE Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them. 2. Press in a new valve guide using a valve guide replacing tool.
Page 94 G2160, WSM ENGINE Correcting Valve and Valve Seat NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of the valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
Page 95 G2160, WSM ENGINE Free Length and Tilt of Valve Spring 1. Measure the free length (A) of valve spring with venire 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 96 G2160, WSM ENGINE Oil Clearance between Tappet and Tappet Guide Bore 1. Measure the tappet O.D. with an outside micrometer. 2. Measure the I.D. of the tappet guide bore with a cylinder gauge, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit or the tappet is damaged, replace the tappet.
Page 97 G2160, WSM ENGINE Camshaft Side Clearance 1. Set a dial indicator with its tip on the camshaft. 2. Measure the side clearance by moving the cam gear to the font and rear. 3. If the measurement exceeds the allowable limit, replace the camshaft stopper.
Page 98 G2160, 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 99 G2160, 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 100 G2160, WSM ENGINE Clearance between Piston Ring and Piston Ring Groove 1. Clean the rings and the ring grooves, and install each ring in its groove. 2. Measure the clearance between the ring and the groove with a feeler gauge.
Page 101 G2160, WSM ENGINE Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the main bearing case assembly.
Page 102 G2160, 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 103 G2160, 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 104 G2160, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 1. Put a strip of plastigage (Code No. 07909-30241) on the center of the journal. 2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again.
Page 105 G2160, WSM ENGINE Cylinder Wear 1. Measure thecylinder liner I.D. at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.’s 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.’s 3.
Page 106: Lubricating System
G2160, WSM ENGINE [3] LUBRICATING SYSTEM (1) Checking Engine Oil Pressure 1. Remove the engine oil pressure switch, and set a oil pressure tester (Code No. 07916-32032). (Adapter screw size : PT 1/8) 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
Page 107 G2160, 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 108: Cooling System
G2160, WSM ENGINE [4] COOLING SYSTEM (1) Checking and Adjusting (A) Fan Belt Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and alternator pulley at specified force (98 N, 10 kgf, 22 lbs).
Page 109 G2160, WSM ENGINE (B) Radiator CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people. Radiator Water Leakage 1. Pour a specified amount of water into the radiator.
Page 110: Disassembling And Assembling
G2160, WSM ENGINE (2) Disassembling and Assembling 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 111: Fuel System
G2160, WSM ENGINE [5] FUEL SYSTEM (1) Checking and Adjusting (A) Injection Pump Injection Timing 1. Remove the bonnet and air cleaner. 2. Remove the muffler. 3. Remove the injection pipes and glow plugs. 4. Engage the parking brake. 5. Set the throttle lever to the maximum engine speed.
Page 112 G2160, WSM ENGINE Fuel Tightness of Pump Element 1. Remove the bonnet and air cleaner. 2. Remove the muffler. 3. Disconnect the accelerator wire. 4. Remove the air cleaner stay. 5. Remove the injection pipes and glow plugs. 6. Install the air cleaner stay.
Page 113 G2160, WSM ENGINE (B) Injection Nozzle CAUTION • Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
Page 114: Disassembling And Assembling
G2160, WSM ENGINE (2) Disassembling and Assembling (A) Injection Nozzle Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil.
Page 115 TRANSMISSION AND REAR AXLE KiSC issued 11, 2006 A...
Page 116 MECHANISM CONTENTS 1. STRUCTURE ....................2-M1 2. HYDROSTATIC TRANSMISSION ..............2-M2 [1] STRUCTURE ................... 2-M2 [2] OIL FLOW ....................2-M3 [3] BY-PASS VALVE ..................2-M4 [4] CHARGE PUMP ..................2-M5 KiSC issued 11, 2006 A...
Page 117: Structure
G2160, WSM TRANSMISSION AND REAR AXLE 1. STRUCTURE (1) Hydrostatic Transmission (2) Gear Section (3) Rear Axle Section (4) Differential Gear Section Section W1013364 KiSC issued 11, 2006 A 2-M1...
Page 118: Hydrostatic Transmission
G2160, WSM TRANSMISSION AND REAR AXLE 2. HYDROSTATIC TRANSMISSION [1] STRUCTURE (1) Charge Relief Valve (9) Piston Assembly (17) Needle Bearing (25) Thrust Ball Bearing (2) Charge Pump Housing (10) Thrust Plate (18) By-pass Valve (26) Slot Guide (3) Charge Pump Spacer...
Page 119: Oil Flow
G2160, WSM TRANSMISSION AND REAR AXLE [2] OIL FLOW (1) Drain Hose (4) Oil Filter Cartridge (6) Drain Hose (8) Suction Pipe (2) Rear Axle Case (5) Control Valve Adaptor (7) Rear Axle Case (9) Drain Pipe (3) Control Valve 1.
Page 120: By-Pass Valve
G2160, WSM TRANSMISSION AND REAR AXLE [3] BY-PASS VALVE (1) Center Section (3) Check Valve (5) By-Pass Valve (7) Orifice (2) Pump Shaft (4) Motor Shaft (6) Check Valve (8) Orifice The by-pass valve (5) is used to connect the two sides of the closed loop in the center section (1).
Page 121: Charge Pump
G2160, WSM TRANSMISSION AND REAR AXLE [4] CHARGE PUMP (1) Charge Relief Valve (5) O-ring (9) Needle Bearing (13) Dowel Pin (2) Charge Pump Housing (6) Gerotor (10) Internal Snap Ring (14) Drive Pin (3) O-ring (7) Dowel Pin (11) Oil Seal...
Page 122 SERVICING CONTENTS 1. TROUBLESHOOTING ..................2-S1 [1] HYDROSTATIC TRANSMISSION ............2-S1 [2] TRANSMISSION..................2-S3 2. SERVICING SPECIFICATIONS ..............2-S4 3. TIGHTENING TORQUES ................2-S5 4. CHECKING, DISASSEMBLING AND SERVICING.........2-S6 [1] CHECKING AND ADJUSTING ...............2-S6 [2] DISASSEMBLING AND ASSEMBLING..........2-S8 (1) Separating Transmission ..............2-S8 (2) Separating Hydrostatic Transmission ..........2-S13 (3) Separating Transmission ..............2-S14 (4) Disassembling Transmission ............2-S14 (5) Disassembling Rear Axle ..............2-S20...
Page 123: Troubleshooting
G2160, WSM TRANSMISSION AND REAR AXLE 1. TROUBLESHOOTING [1] HYDROSTATIC TRANSMISSION KiSC issued 11, 2006 A 2-S1...
Page 124 G2160, WSM TRANSMISSION AND REAR AXLE KiSC issued 11, 2006 A 2-S2...
Page 125: Transmission
G2160, WSM TRANSMISSION AND REAR AXLE [2] TRANSMISSION KiSC issued 11, 2006 A 2-S3...
Page 126: Servicing Specifications
G2160, WSM TRANSMISSION AND REAR AXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Charge Relief Valve Setting pressure 0.32 to 0.41 MPa – 3.3 to 4.2 kgf/cm 47 to 60 psi Transmission Fluid Capacity 4.5 L – (Including HST and Cylinder) 4.75 U.S.qts...
Page 127: Tightening Torques
G2160, WSM TRANSMISSION AND REAR AXLE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9.) Item N·m kgf·m ft-lbs Cam mounting nut 39.2 to 45.1...
Page 128: Checking, Disassembling And Servicing
G2160, WSM TRANSMISSION AND REAR AXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Adjusting Neutral 1. Block the front wheels with stoppers, and lift up the rear of machine with a jack. 2. Remove the left rear wheel.
Page 129 G2160, WSM TRANSMISSION AND REAR AXLE Pedal Stopper (Adjusting Maximum Forward and Reverse Travelling Speed) NOTE • This adjustment should be performed after completing the adjustment of neutral. [Forward Operation] 1. Loosen the lock nut (3) and screw back the adjusting screw (2).
Page 130: Disassembling And Assembling
G2160, WSM TRANSMISSION AND REAR AXLE [2] DISASSEMBLING AND ASSEMBLING (1) Separating Transmission (A) Dismounting Mower Dismounting Mower 1. See to "MOWER" section. W1013684 Draining Transmission Fluid 1. Place an oil pan underneath the drain plug (1). 2. Remove the drain plug (1).
Page 131 G2160, WSM TRANSMISSION AND REAR AXLE (C) Separating Fender Seat 1. Disconnect the 2P connector (3) from the seat switch and fuse (4). 2. Remove the seat support mounting lock nut (1). 3. Remove the screws (5). 4. Remove the seat with seat support.
Page 132 G2160, WSM TRANSMISSION AND REAR AXLE Separating Fender 1. Remove the speed change pedal. 2. Peel the step sheet (1) halfway. 3. Remove the step support mounting screws (2). 4. Remove the step support (5) and rubber bushing (6). 5. Remove the fuel cap (4).
Page 133 G2160, WSM TRANSMISSION AND REAR AXLE Brake spring, Brake Rod and Speed Change Plate 1. Remove the lock nut (5), plane washers (3), and brake spring (4). 2. Remove the brake rod (2). 3. Remove the speed change plate (1) from the speed control arm.
Page 134 G2160, WSM TRANSMISSION AND REAR AXLE Separating Transmission 1. Remove the universal joint mounting screws. 2. Disconnect the universal joint. 3. Remove the rear axle case mounting screws. 4. Separating the transmission from the frame. (When reassembling) • Apply grease to the splines of universal joint.
Page 135: Separating Hydrostatic Transmission
G2160, WSM TRANSMISSION AND REAR AXLE Separating Hydrostatic Transmission Neutral Arm, Speed Control Arm and Hydraulic Pipes 1. Remove the neutral spring (10). 2. Remove the neutral arm assembly mounting screws (11). 3. Remove the neutral arm assembly (9). 4. Remove the speed control arm set screw (4).
Page 136: Separating Transmission
G2160, WSM TRANSMISSION AND REAR AXLE (3) Separating Transmission Separating Control Valve Assembly 1. Remove the control valve assembly stay mounting screw (4). 2. Separating the control valve assembly (1) from the transmission. 3. Remove the collar (3) and O-ring (2) on the front cover.
Page 137 G2160, WSM TRANSMISSION AND REAR AXLE Charge Pump Housing and Charge Pump Spacer 1. Remove the charge pump housing mounting hex. socket head screws (4). 2. Remove the charge pump housing (5). 3. Remove the O-ring (6) from the housing.
Page 138 G2160, WSM TRANSMISSION AND REAR AXLE Center Section 1. Remove the center section mounting hex. socket head screws. 2. Lift the center section off the housing. 3. Remove the gasket. 4. Draw out the dowel pins. NOTE • Take care not to damage the surface of the center section and cylinder blocks.
Page 139 G2160, WSM TRANSMISSION AND REAR AXLE Cylinder Block Assembly and Thrust Ball Bearing 1. Lay the housing on its side. 2. Slide out the cylinder bloke assembly (pump) (1). 3. Slide out the cylinder block assembly (motor) (3) with the motor shaft (2).
Page 140 G2160, WSM TRANSMISSION AND REAR AXLE Swashplate 1. Remove the swashplate (1) from the housing. 2. Remove the thrust plate (4), thrust roller bearing (3) and thrust washer (2) from the Swashplate. (When reassembling) • Apply clean fluid to the thrust washer and thrust plate.
Page 141 G2160, WSM TRANSMISSION AND REAR AXLE Trunnion Arm and Journal Bearing 1. Remove the trunnion arm (1). 2. Pry the oil seal (3) off with a screwdriver. 3. Press out the journal bearing (2). (When reassembling) • Apply clean field to the journal bearing.
Page 142: Disassembling Rear Axle
G2160, WSM TRANSMISSION AND REAR AXLE Brake Shaft, Idle Gear Shaft and Bevel Pinion Shaft 1. Separate the front cover (1) from the transmission case (5). 2. Remove the brake shaft assembly. 3. Remove the idle gear shaft assembly. 4. Remove the external snap ring (12).
Page 143: Disassembling Differential Gear Case
G2160, WSM TRANSMISSION AND REAR AXLE (6) Disassembling Differential Gear Case Differential Gear 1. Remove the 20T spiral bevel gear (5) with ball bearing (6) and ball bearing (9) by puller. 2. Tap out the spring pin (10) from 20T bevel gear side.
Page 144: Servicing
G2160, WSM TRANSMISSION AND REAR AXLE [3] SERVICING (1) Hydostatic Transmission Auxiliary Pump 1. Check the charge pump housing (2) and the gerotor assembly (1) for scratches and wear. 2. If scratch or worn, replace the charge pump complete assembly.
Page 145 G2160, WSM TRANSMISSION AND REAR AXLE Center Section 1. Check the surface of center section (1) for scratches and wear. 2. If scratch or wear, replace the HST assembly. 3. Check the needle bearing (2) for wear. 4. If worn, replace the needle bearing.
Page 146: Transmission
G2160, WSM TRANSMISSION AND REAR AXLE Charge Relief Valve 1. Check the charge relief cone and the seat in the auxiliary pump housing for damage. 2. Check the spring for breakage and wear. 3. If anything unusual, replace them. (1) Charge Relief Cone...
Page 147 G2160, WSM TRANSMISSION AND REAR AXLE Backlash between Differential Pinion and Differential Side Gear 1. Set a dial gauge (lever type) on a tooth of the differential pinion. 2. Fix the differential side gear, and move the differential pinion to measure the backlash.
Page 148 BRAKE KiSC issued 11, 2006 A...
Page 149 SERVICING CONTENTS 1. TROUBLESHOOTING ..................3-S1 2. SERVICING SPECIFICATIONS ..............3-S1 3. TIGHTENING TORQUES ................3-S1 4. CHECKING, DISASSEMBLING AND SERVICING.........3-S2 [1] CHECKING AND ADJUSTING ...............3-S2 [2] DISASSEMBLING AND ASSEMBLING..........3-S2 (1) Parking Brake ..................3-S2 (2) Brake Assembly ..................3-S6 [3] SERVICING ....................3-S7 KiSC issued 11, 2006 A...
Page 150: Troubleshooting
G2160, WSM BRAKE 1. TROUBLESHOOTING 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit −1.0 to 0.0 mm Brake Spring to Plane Washer Clearance – −0.04 to 0.00 in. Brake Lining Thickness 9.0 mm 7.5 mm 0.35 in. 0.30 in. Brake Drum I.D.
Page 151: Checking, Disassembling And Servicing
G2160, WSM BRAKE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Brake Pedal Play 1. Keep the brake return spring (1) off position. 2. Keep the brake pedal in return position. 3. Gently press the tip of the transaxle’s brake actuating arm (5) toward the pedal.
Page 152 G2160, WSM BRAKE Parking Lock Pedal 1. Remove the parking lock pedal mounting nut (2). 2. Remove the parking lock pedal (1) from the brake lock. (When reassembling) IMPORTANT • Using the oval hole, make such adjustment that the parking lock pedal be kept out of contact with the panel over the entire stroke.
Page 153 G2160, WSM BRAKE Separating Panel 1. Remove the speed change pedal. 2. Peel the step sheet (2) halfway. 3. Remove the panel mounting screws (1). 4. Separate the panel (3). (When reassembling) • Clean up the step sheet and the step. Apply instantaneous adhesive on the step sheet as shown in the figure.
Page 154 G2160, WSM BRAKE Cutting Height Adjusting Dial 1. Lift the mower to the highest position. 2. Remove the cam mounting nut (1). 3. Remove the cutting height adjusting dial, plane washer and cam (2). (When reassembling) • Apply grease to the outside of cam.
Page 155: Brake Assembly
G2160, WSM BRAKE Separating Pedal System Complete 1. Remove the return spring (3). 2. Pull out the cotter pin (7). 3. Remove the brake rod 2 (6) and plain washer. 4. Disconnect 4P connector (5) from the brake switch (4).
Page 156 G2160, WSM BRAKE [3] SERVICING Brake Lining Wear 1. Measure the brake lining thickness with vernier caliper. 2. If the measurement is less than the allowable limit, replace the brake shoes. 9.0 mm Factory spec. 0.35 in. Brake lining thickness 7.5 mm...
Page 157: Front Axle
FRONT AXLE KiSC issued 11, 2006 A...
Page 158: Servicing
SERVICING CONTENTS 1. TROUBLESHOOTING ..................4-S1 2. SERVICING SPECIFICATIONS ..............4-S1 3. TIGHTENING TORQUES ................4-S1 4. CHECKING, DISASSEMBLING AND SERVICING.........4-S2 [1] CHECKING AND ADJUSTING ...............4-S2 [2] DISASSEMBLING AND ASSEMBLING..........4-S3 (1) Separating Front Axle Assembly............4-S3 (2) Disassembling Front Axle ..............4-S4 (3) Disassembling Front Axle Support Assembly ........4-S5 [3] SERVICING ....................4-S5 KiSC issued 11, 2006 A...
Page 159: Troubleshooting
G2160, WSM FRONT AXLE 1. TROUBLESHOOTING 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Front Wheel Alignment Toe-in 0 to 10 mm – 0 to 0.394 in. Front Axle End Play 0.1 to 0.4 mm 1.0 mm 0.004 to 0.016 in.
Page 160: Checking, Disassembling And Servicing
G2160, WSM FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Toe-in 1. Inflate the front tires to the specified pressure. 2. Turn the front wheels straight ahead, and measure the toe-in (B- 3. If the measurement is not within the factory specifications, change the tie-rod length to adjust.
Page 161: Disassembling And Assembling
G2160, WSM FRONT AXLE [2] DISASSEMBLING AND ASSEMBLING (1) Separating Front Axle Assembly Dismount Mower 1. See to “MOWER” section. W1011444 Battery and Bonnet 1. Turn the main switch off. 2. Remove the radiator screen (2). 3. Disconnect the negative cable (1) from the battery.
Page 162: Disassembling Front Axle
G2160, WSM FRONT AXLE Separating Front Axle Assembly 1. Remove the rod end mounting nut (1). 2. Support the frame with jacks. 3. Remove the front axle support mounting screws (3). 4. Draw out the front axle support assembly (2) forward.
Page 163: Disassembling Front Axle Support Assembly
G2160, WSM FRONT AXLE Knuckle Arm and Kingpin 1. Remove the knuckle arm mounting bolt (3), spring washer and nut (5). 2. Remove the knuckle arm (4) and the kingpin (L.H.) (6). 3. Remove the external snap ring (1) and kingpin (R.H.) (2).
Page 164 STEERING KiSC issued 11, 2006 A...
Page 165 MECHANISM CONTENTS 1. SYSTEM CONFIGURATION ................. 5-M1 2. CONSTRUCTION AND FUNCTION OF MAIN COMPONENTS ....5-M2 [1] POWER STEERING ASSEMBLY............5-M2 (1) Construction of Power Steering Assembly......... 5-M2 (2) Torque Sensor ................... 5-M3 (3) Motor ....................5-M4 [2] EPS CONTROLLER ................5-M5 (1) Basic Control..................
Page 166: System Configuration
G2160, WSM STEERING 1. SYSTEM CONFIGURATION (1) Power Steering Assembly A : Engine Revolution Signal D : Battery (2) Power Steering Gear Case (Oil Switch) E : EPS Controller B : Warning Lamp F : Steering Torque Signal C : Connector for Servicing G : Motor Driving Current The steering system employs an electric power steering (EPS).
Page 167: Construction And Function Of Main Components
G2160, WSM STEERING 2. CONSTRUCTION AND FUNCTION OF MAIN COMPONENTS [1] POWER STEERING ASSEMBLY (1) Construction of Power Steering Assembly The power steering assembly is mainly composed of an input shaft (1), output shaft (in the gear case side) (5),...
Page 168: Torque Sensor
G2160, WSM STEERING (2) Torque Sensor Construction The torque sensor senses the steering power and rotating direction, convert them into a voltage signal and outputs the signal to the EPS controller. The torque sensor section is composed of a slider (3), detecting ring and detecting coil (4) (slider and detecting ring are combined).
Page 169: Motor
G2160, WSM STEERING (3) Motor The motor is installed on the steering column (4). It is composed of a worm gear (1) and direct current motor (3). The worm gear (1) is engaged with the helical gear of the worm wheel (2), reducing and transmitting the motor revolution to the worm wheel.
Page 170: Eps Controller
G2160, WSM STEERING [2] EPS CONTROLLER The EPS controller detects an electric signal from the oil switch, activates the system after the engine starting and controls the motor according to an input signal from the torque sensor. The EPS controller has a self-diagnosis function.
Page 171: Failure Diagnosis Function
G2160, WSM STEERING Failure Diagnosis Function The EPS controller monitors the input/output data and motor driving current. If an abnormal condition occurs in the system, the EPS controller stops the system and makes the warning lamp go on. In this case, the normal manual steering operation is applied and the abnormal condition is coded and stored in the failure diagnosis circuit.
Page 172 SERVICING CONTENTS 1. CAUTIONARY INSTRUCTIONS BEFORE STARTING FAILURE DIAGNOSIS ....................5-S1 2. TROUBLESHOOTING ..................5-S2 [1] TROUBLESHOOTING BASED ON EACH SYMPTOM ......5-S2 [2] TROUBLESHOOTING BASED ON ERROR CODE ......5-S6 (1) Error code 02 ..................5-S6 (2) Error code 03 ..................5-S7 (3) Error code 05 ..................5-S7 (4) Error code 06 ..................5-S8 (5) Error code 11 ..................5-S8 (6) Error code 12 and 13 ................5-S9...
Page 173: Cautionary Instructions Before Starting Failure Diagnosis
G2160, WSM STEERING 1. CAUTIONARY INSTRUCTIONS BEFORE STARTING FAILURE DIAGNOSIS 1. Self-diagnosis function The EPS controller has a self-diagnosis function. If the EPS controller detects an abnormal condition in the system, it performs the following. • Making the warning lamp go on.
Page 174: Troubleshooting
G2160, WSM STEERING 2. TROUBLESHOOTING [1] TROUBLESHOOTING BASED ON EACH SYMPTOM KiSC issued 11, 2006 A 5-S2...
Page 175 G2160, WSM STEERING KiSC issued 11, 2006 A 5-S3...
Page 176 G2160, WSM STEERING KiSC issued 11, 2006 A 5-S4...
Page 177 G2160, WSM STEERING KiSC issued 11, 2006 A 5-S5...
Page 178: Troubleshooting Based On Error Code
G2160, WSM STEERING [2] TROUBLESHOOTING BASED ON ERROR CODE (1) Error code 02 [EPS System Troubleshooting Procedure] KiSC issued 11, 2006 A 5-S6...
Page 179: Error Code 03
G2160, WSM STEERING (2) Error code 03 (3) Error code 05 KiSC issued 11, 2006 A 5-S7...
Page 180: Error Code 06
G2160, WSM STEERING (4) Error code 06 (5) Error code 11 KiSC issued 11, 2006 A 5-S8...
Page 181: Error Code 12 And 13
G2160, WSM STEERING (6) Error code 12 and 13 (7) Error code 15 KiSC issued 11, 2006 A 5-S9...
Page 182: Error Code 17
G2160, WSM STEERING (8) Error code 17 (9) Error code 19 and 22 KiSC issued 11, 2006 A 5-S10...
Page 183: Error Code 23
G2160, WSM STEERING (10) Error code 23 KiSC issued 11, 2006 A 5-S11...
Page 184: Error Code 32
G2160, WSM STEERING (11) Error code 32 (12) Error code 34 KiSC issued 11, 2006 A 5-S12...
Page 185: Error Code 35
G2160, WSM STEERING (13) Error code 35 KiSC issued 11, 2006 A 5-S13...
Page 186: Servicing Specifications
G2160, WSM STEERING 3. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Steering Wheel Play Less than 15 mm – Less than 0.59 in. Throttle Lever Operating Force 30 to 50 N – 3.1 to 5.1 kgf 66 to 110 lbs...
Page 187: Checking, Disassembling And Servicing
G2160, WSM STEERING 5. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Warning Lamp Checking of EPS System When the main switch is set to the ON position (B), the EPS controller detects the voltage signal from the oil switch (1) and makes the warning lamp (2) glow for 5 seconds.
Page 188 G2160, WSM STEERING Checking of Warning Lamp • The fail-safe codes recorded in the controller start flashing in the ascending order. (There may be just one code.) • After one cycle of the flashing codes, there is a longer period of no-flash time.
Page 189: Torque Sensor Cable
G2160, WSM STEERING (2) Torque Sensor Cable Checking Torque Sensor Cable 1. Keep the main switch at ON position (B) and disconnect the 1P connector (1) from the oil switch. Check to see if the power steering system works. (Do not start the engine.) 2.
Page 190: Torque Sensor 3P Connector
G2160, WSM STEERING (3) Torque Sensor 3P Connector Checking Torque Sensor 3P Connector IMPORTANT • While disassembling, handle the power steering assembly, controller and wire harness with enough care. disconnect the steering wheel, be sure to use the steering wheel puller (1) and puller adaptor (2), never any hammer.
Page 191: Torque Sensor 3P Connector Terminal
G2160, WSM STEERING (4) Torque sensor 3P Connector Terminal Checking the Resistance of the Torque Sensor 3 Connector Terminal 1. Using a circuit tester, measure the terminal resistance between the red and black wires, as well as that between the white and black wires of torque sensor 3P connector (1).
Page 192: Wire Harness
G2160, WSM STEERING Wire Harness Checking the Torque Sensor Connectors for Poor Contact 1. Check the torque sensor 3P connector (1) and related parts for the following defects. - Terminal off position - Terminal deformed or crushed - Female terminal too open: Improper connection (6)
Page 193: Checking Voltage
G2160, WSM STEERING (6) Checking Voltage Checking the Battery Terminal Voltage 1. Measure the voltage between the positive (+) and negative (-) battery terminals (1), (2). 2. If the voltage is out of factory specification, recharge the battery and go to the following checking.
Page 194 G2160, WSM STEERING Checking 16P and 4P Connectors to EPS Controller 1. Disconnect the steering wheel with the steering wheel puller (1) and puller adaptror (2) carefully. Do not use any hammer. 2. Detach panel and make the following check. with the main switch at ON position (do not start the engine), measure the voltages between following terminals.
Page 195: Error Codes And Defective Sections
G2160, WSM STEERING Checking Continuity between the Torque Sensor 3P Connector and EPS Controller 16P Connector 1. Using a circuit tester, check continuity between the terminals. Refer to the figure below. Resistance 0 Ω Factory spec. (between same color terminal) ∞...
Page 196: Steering Wheel Play
G2160, WSM STEERING (8) Steering Wheel Play Steering Wheel Play 1. Turn the front wheels straight ahead. 2. Rotate the steering wheel lightly by hand, and measure the play. 3. If the measurement exceeds the factory specification, replace the steering shaft and sector gear.
Page 197: Disassembling And Assembling
G2160, WSM STEERING [2] DISASSEMBLING AND ASSEMBLING (1) Separating Power Steering Assembly and EPS Controller Battery and Bonnet 1. Turn the main switch off. 2. Remove the radiator screen (1). 3. Disconnect the negative cable from the battery. 4. Disconnect the 1P connectors (3) from the head light (2).
Page 198 G2160, WSM STEERING Steering Wheel 1. Remove the grip of the throttle lever (1). 2. Remove the steering pad and remove the steering wheel mounting nut. 3. Remove the steering wheel using the steering wheel puller (Code. No. 07916-51090) and steering wheel puller adaptor.
Page 199 G2160, WSM STEERING Wiring and EPS controller 1. Disconnect 2P connector (4) from the motor. 2. Disconnect 3P connector from the torque sensor. 3. Disconnect 4P connector (1) and 16P connector (2) from the EPS controller. 4. Remove the EPS controller (3).
Page 200: Power Steering Gear Case
G2160, WSM STEERING Power Steering Gear Case Power Steering Gear Case 1. Remove the rod end mounting nut. 2. Remove the rod end (1). 3. Remove the power steering gear case mounting screws (4). 4. Remove the power steering gear case (3) with the rod end.
Page 201: Servicing
G2160, WSM STEERING [3] SERVICING EPS Controller Right and Left Steering Force Setting at Neutral Position IMPORTANT • If this setting procedure is wrongly taken, the neutral position cannot be programmed in the controller. To take the procedure over again, be sure to go back to Setting Method No.
Page 202 G2160, WSM STEERING Erasing Fail Safe History IMPORTANT • Do not start the engine while erasing. • If the code erasing procedure is wrongly taken, the code cannot be erased. To take the procedure over again, go back to Setting Method No. 3 (with the main switch at OFF and the service connector fit in position).
Page 203 G2160, WSM STEERING Checking of Steering Mechanical System Checking of Power Steering Assembly 1. Remove the steering wheel. 2. Remove the power steering assembly. 3. Remove the universal joint. 4. Install the power steering assembly. 5. Attach a torque wrench to the steering shaft.
Page 204 G2160, WSM STEERING Checking EPS Controller for Trouble 1. To see if the EPS controller is in trouble, disconnect the 4P (5) and 16P (6) connectors from the controller. Without the controller, set the main switch to “ON” position (B) and see if the IG/M fuse (10A) (3) blows out.
Page 205: Hydraulic System
HYDRAULIC SYSTEM KiSC issued 11, 2006 A...
Page 206 MECHANISM CONTENTS 1. HYDRAULIC CIRCUIT (LOW DUMP)............6-M1 2. RELIEF VALVE ..................... 6-M2 3. CONTROL VALVE ..................6-M2 [1] MOWER LIFTING CIRCUIT..............6-M2 KiSC issued 11, 2006 A...
Page 207 G2160, WSM HYDRAULIC SYSTEM 1. HYDRAULIC CIRCUIT (LOW DUMP) (1) Transmission Case (7) Valve (for Grass Collector A : Up (c) Up (2) Oil Strainer Cylinder) B : Down (d) Down (3) Charge Pump (8) Filter Relief Valve (a) Open...
Page 208: Relief Valve
G2160, WSM HYDRAULIC SYSTEM 2. RELIEF VALVE This machine is equipped with two direct-acting relief valves (11), (12). The main relief valve (12) serves to control the pressures of the mower lift cylinder and grass collector cylinder and to protect the entire hydraulic system against damage.
Page 209 SERVICING CONTENTS 1. TROUBLESHOOTING ..................6-S1 2. SERVICING SPECIFICATIONS ..............6-S1 3. TIGHTENING TORQUES ................6-S2 4. CHECKING, DISASSEMBLING AND SERVICING.........6-S3 [1] CONTROL VALVE ..................6-S3 (1) Checking and Adjusting ..............6-S3 (2) Disassembling and Assembling ............6-S5 [2] CYLINDER ....................6-S9 (1) Disassembling and Assembling ............6-S9 [3] MOWER LIFT LINKAGE .................6-S10 (1) Checking and Adjusting ..............6-S10 (2) Disassembling and Assembling ............6-S10...
Page 210: Troubleshooting
G2160, WSM HYDRAULIC SYSTEM 1. TROUBLESHOOTING 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Main Relief Valve Setting Pressure 2.94 to 3.43 MPa – 30.0 to 35.0 kgf/cm 426 to 497 psi Filter Relief Valve Setting Pressure 1.96 to 2.45 MPa –...
Page 211 G2160, 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 N·m kgf·m ft-lbs Cam mounting nut 39.2 to 45.1 4.0 to 4.6...
Page 212: Checking, Disassembling And Servicing
G2160, WSM HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CONTROL VALVE (1) Checking and Adjusting Main Relief Valve Setting Pressure CAUTION • When checking, park the tractor on flat ground, apply the parking brake. 1. Disconnect the cylinder hose from the mower lift cylinder.
Page 213 G2160, WSM HYDRAULIC SYSTEM Filter Relief Valve Setting Pressure CAUTION • When checking, park the tractor on flat ground, apply the parking brake. 1. Remove the oil filter cartridge. 2. Set the flange for control valve (see page G-42), O-rings, thread joint (Code No.: 07916-50341), cable (Code No.: 07916-50331),...
Page 214 G2160, WSM HYDRAULIC SYSTEM (2) Disassembling and Assembling (A) Separating Control Valve Dismount Mower 1. See to “MOWER” section. W1011842 Draining Transmission Fluid 1. Place an oil pan underneath the drain plug (1). 2. Remove the drain plug (1). 3. Remove the oil inlet plug (2) to completely drain the transmission fluid.
Page 215 G2160, WSM HYDRAULIC SYSTEM Cutting Height Adjusting Dial 1. Lift the mower to the highest position. 2. Remove the cam mounting nut (1). 3. Remove the cutting height adjusting dial, plain washer and cam (2). (When reassembling) • Apply grease to the outside of cam.
Page 216: Control Valve
G2160, WSM HYDRAULIC SYSTEM Separating Control Valve Assembly 1. Remove the Mower lift lever from the control valve assembly. 2. Remove the stopper plate (5). 3. Remove the suction pipe (4) with the oil strainer. 4. Disconnect the hydraulic hoses (2), (6) from the drain pipe (7).
Page 217 G2160, WSM HYDRAULIC SYSTEM Relief Valve 1. Remove the bolt (1). 2. Remove the shims (3), washer with rubber (2), spring (4) and steel ball (5). 3. Remove the plug (10). 4. Remove the shims (9), O-ring (6), spring (8) and poppet (7).
Page 218: Disassembling And Assembling
G2160, WSM HYDRAULIC SYSTEM [2] CYLINDER (1) Disassembling and Assembling (A) Mower Lift Cylinder Separating Mower Lift Cylinder 1. Disconnect the mower lift cylinder hose (2). 2. Pull out the cotter pins (4). 3. Separate the mower lift cylinder (3) from the frame.
Page 219: Mower Lift Linkage
G2160, WSM HYDRAULIC SYSTEM [3] MOWER LIFT LINKAGE (1) Checking and Adjusting Clearance between Rear Link and Frame Stopper 1. Lift the rear link assembly (1) to the highest position. 2. Measure the clearance (L) between the rear link assembly and frame stopper (2).
Page 220 PTO SYSTEM KiSC issued 11, 2006 A...
Page 221 SERVICING CONTENTS 1. TROUBLESHOOTING ..................7-S1 2. SERVICING SPECIFICATIONS ..............7-S2 3. CHECKING, DISASSEMBLING AND SERVICING.........7-S3 [1] CHECKING AND ADJUSTING ...............7-S3 [2] DISASSEMBLING AND ASSEMBLING..........7-S5 [3] SERVICING ....................7-S6 KiSC issued 11, 2006 A...
Page 222: Troubleshooting
G2160, WSM PTO SYSTEM 1. TROUBLESHOOTING KiSC issued 11, 2006 A 7-S1...
Page 223: Servicing Specifications
G2160, WSM PTO SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit PTO Clutch Spring Length 88.0 to 89.0 mm – 3.47 to 3.54 in. Tension Arm to Tip of Adjusting Screw Clearance 3.0 to 4.0 mm – 0.12 to 0.16 in.
Page 224: Checking, Disassembling And Servicing
G2160, WSM PTO SYSTEM 3. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING PTO Belt Tension 1. Place the machine on level ground, and stop the engine. 2. Set the PTO clutch lever to “ENGAGE” position. 3. Measure the length (L) of PTO clutch spring (2).
Page 225 G2160, WSM PTO SYSTEM Adjusting Belt Stay 1. Place the machine on level ground, and stop the engine. 2. Set the PTO clutch lever to “ENGAGE” position. 3. Measure the clearance (L) between the belt stay (3) and front PTO belt (1).
Page 226: Disassembling And Assembling
G2160, WSM PTO SYSTEM [2] DISASSEMBLING AND ASSEMBLING Battery and Bonnet 1. Turn the main switch off. 2. Remove the radiator screen (1). 3. Disconnect the negative cable from the battery. 4. Disconnect the 1P connectors (3) from the head light (2).
Page 227: Servicing
G2160, WSM PTO SYSTEM [3] SERVICING Clearance between Tension Collar and Tension Arm Bushing 1. Measure the tension collar O.D. with an outside micrometer. 2. Measure the tension arm bushing I.D. with an inside micrometer, and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace the tension arm bushing.
Page 228 ELECTRICAL SYSTEM KiSC issued 11, 2006 A...
Page 229 MECHANISM CONTENTS 1. WIRING DIAGRAM ..................8-M1 [1] WIRING DIAGRAM (with KRA system) ..........8-M1 [2] WIRING DIAGRAM (without KRA system) .......... 8-M3 2. KRA (Kubota Reverse Awareness) SYSTEM (If Equipped)......8-M5 KiSC issued 11, 2006 A...
Page 230: Wiring Diagram
G2160, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM [1] WIRING DIAGRAM (with KRA system) KiSC issued 11, 2006 A 8-M1...
Page 231 G2160, WSM ELECTRICAL SYSTEM KiSC issued 11, 2006 A 8-M2...
Page 232: Wiring Diagram (Without Kra System)
G2160, WSM ELECTRICAL SYSTEM [2] WIRING DIAGRAM (without KRA system) KiSC issued 11, 2006 A 8-M3...
Page 233 G2160, WSM ELECTRICAL SYSTEM KiSC issued 11, 2006 A 8-M4...
Page 234: Kra (Kubota Reverse Awareness) System (If Equipped)
(3) KRA system Relay Unit (6) Stop Solenoid Tractor is configured with a KRA (Kubota Reverse Awareness) system to prevent the operator from attempting to mow in reverse. However, the operator may choose to override the system by pushing an override switch on panel board.
Page 235 G2160, WSM ELECTRICAL SYSTEM PTO LEVER AND SPEED CONTROL PEDAL MOVEMENT The operation equipment PTO lever Speed control pedal Seat Neutral The condition Disengage Engage Reverse Occupied Forward The operation of the switch Push Free Free Push Push The condition of contact in electrical...
Page 236 G2160, WSM ELECTRICAL SYSTEM KRA system Operating Mode “Operating mode” is set up as follows: 1. Start the engine. 2. Set the throttle lever to the “FAST” position (A). 3. Push down the PTO lever to the “ENGAGED” position. (1) Throttle Lever (A) “FAST”...
Page 237 G2160, WSM ELECTRICAL SYSTEM The above electrical circuit is a circuit at the position of speed control pedal to “NEUTRAL” or “FORWARD”. Condition 1: First, PTO lever is selected “ENGAGED” position. At this moment, electrical circuit between main switch and PTO switch is cut off.
Page 238 G2160, WSM ELECTRICAL SYSTEM KRA system Override Mode “Override mode” is set up as follows: 1. Start and run the engine at 1/4 throttle. 2. Engage the PTO lever. 3. Push the KRA system override switch. 4. The KRA system lamp flashes.
Page 239 G2160, WSM ELECTRICAL SYSTEM The above electrical circuit is a circuit at the position of “Override mode” resetting. Condition: Disengage the PTO lever. Current from main switch flows to KRA system through PTO switch. Speed control pedal position is free. Operator can always select the speed control pedal to “FORWARD” and “NEUTRAL”.
Page 240 SERVICING CONTENTS 1. TROUBLESHOOTING ..................8-S1 2. SERVICING SPECIFICATIONS ..............8-S9 3. TIGHTENING TORQUES ................8-S10 4. CHECKING, DISASSEMBLING AND SERVICING........8-S11 [1] BATTERY....................8-S11 (1) CHECKING ..................8-S11 [2] STARTING SYSTEM ................8-S12 (1) CHECKING ..................8-S12 (2) Main Switch..................8-S12 (3) Starter ....................8-S14 (4) Glow Plug..................8-S15 (5) DISASSEMBLING AND ASSEMBLING..........8-S16 (6) Starter ....................8-S16 (7) SERVICING ..................8-S17 (8) Starter ....................8-S17...
Page 241: Troubleshooting
G2160, WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING KiSC issued 11, 2006 A 8-S1...
Page 242 G2160, WSM ELECTRICAL SYSTEM KiSC issued 11, 2006 A 8-S2...
Page 243 G2160, WSM ELECTRICAL SYSTEM KiSC issued 11, 2006 A 8-S3...
Page 244 G2160, WSM ELECTRICAL SYSTEM KiSC issued 11, 2006 A 8-S4...
Page 245 G2160, WSM ELECTRICAL SYSTEM KiSC issued 11, 2006 A 8-S5...
Page 246 G2160, WSM ELECTRICAL SYSTEM KiSC issued 11, 2006 A 8-S6...
Page 247 G2160, WSM ELECTRICAL SYSTEM KiSC issued 11, 2006 A 8-S7...
Page 248 G2160, WSM ELECTRICAL SYSTEM KiSC issued 11, 2006 A 8-S8...
Page 249: Servicing Specifications
G2160, WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS BATTERY Item Factory Specification Allowable Limit Battery Voltage More than 12 V – Potential difference Less than 0.1 V – W1010878 STARTER Commutator O.D. 28.0 mm 27.0 mm 1.102 in. 1.063 in. Difference of Less than 0.02 mm...
Page 250 G2160, 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 • M terminal nut 9.8 to 13.7...
Page 251: Checking, Disassembling And Servicing
G2160, WSM ELECTRICAL SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING CAUTION • To avoid accidental short circlet, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal. • Never remove the battery cap while the engine is running.
Page 252: Starting System
G2160, WSM ELECTRICAL SYSTEM [2] STARTING SYSTEM CHECKING (1) Main Switch Connector Voltage 1. Open the bonnet. 2. Disconnect the 4P connector from the main switch. 3. Measure the voltage with a voltmeter between the connector terminal and chassis. 4. If the voltage differs from battery voltage, the wiring harness is faulty.
Page 253 G2160, WSM ELECTRICAL SYSTEM Main Switch Continuity 1. Open the bonnet. 2. Disconnect the 4P connector from the main switch. 3. Remove the main switch from the panel. 4. Measure the resistance with an ohmmeter across the connector terminals when the main switch key is set at “A” position.
Page 254: Starter
G2160, WSM ELECTRICAL SYSTEM (2) Starter M Terminal Voltage 1. Measure the voltage with a voltmeter between the M terminal and the chassis. 2. If the voltage differs from the battery voltage, the battery’s positive cable or the battery negative cable is faulty.
Page 255: Glow Plug
G2160, WSM ELECTRICAL SYSTEM (3) Glow Plug Lead Terminal Voltage 1. Disconnect the 1P connector (1) from the glow plug (2) after turning the main switch off. 2. Turn the main switch key to the “PREHEAT” position, and measure the voltage between the lead terminal and the chassis.
Page 256: Disassembling And Assembling
G2160, WSM ELECTRICAL SYSTEM DISASSEMBLING AND ASSEMBLING (1) Starter Disassembling Starter (1) Magnetic Switch Mounting Nut (2) Housing (3) Magnetic Switch (4) C Terminal Nut (5) Shaft Assembly (6) Overrunning Clutch (7) Drive Lever (8) Connecting Lead (9) Through Bolt...
Page 257: Servicing
G2160, WSM ELECTRICAL SYSTEM SERVICING (1) Starter Commutator and Mica 1. Check the contact face of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points.
Page 258 G2160, WSM ELECTRICAL SYSTEM Armature Coil 1. Check the continuity across the commutator and armature coil core with an ohmmeter. 2. If it conducts, replace the armature. 3. Check the continuity across the segments of the commutator with an ohmmeter.
Page 259: Engine Key Switch Shut-Off System
G2160, WSM ELECTRICAL SYSTEM [3] ENGINE KEY SWITCH SHUT-OFF SYSTEM CHECKING Timer Relay Connector Voltage 1. Disconnect the connector from the timer relay after turning the main switch off. 2. Measure the voltage with a voltmeter across the connector 4 terminal and chassis.
Page 260: Charging System
G2160, WSM ELECTRICAL SYSTEM [4] CHARGING SYSTEM CHECKING (1) Alternator Alternator 1. Disconnect the 2P connector (3) from alternator (2) after tuning the main switch OFF. 2. Perform the following checkings. (1) B Terminal (3) 2P Connector (2) Alternator W1017030 Connector Voltage 1.
Page 261: Disassembling And Assembling
G2160, WSM ELECTRICAL SYSTEM DISASSEMBLING AND ASSEMBLING (1) Alternator Pulley 1. Secure the hexagonal end of the pulley shaft with a double- ended ratchet wrench as shown in the figure, loosen the pulley nut with a socket wrench and remove it.
Page 262 G2160, WSM ELECTRICAL SYSTEM Rear End Frame 1. Unscrew the two nuts and two screws holding the drive end frame and the rear end frame(1). 2. Remove the rear end frame (1) (1) Rear End Frame W1018366 Rotor 1. Press out the rotor (1) from drive end frame (3).
Page 263: Servicing
G2160, WSM ELECTRICAL SYSTEM SERVICING (1) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. W1018966 Stator 1. Measure the resistance across each lead of the stator coil with an ohmmeter.
Page 264: Electrical Equipment
G2160, WSM ELECTRICAL SYSTEM Rectifier 1. Check the continuity across each diode of rectifier with an analog ohmmeter. Conduct the test in the (R × 1) setting. 2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction.
Page 265: Thermo Switch
G2160, WSM ELECTRICAL SYSTEM (2) Thermo Switch Connector Voltage 1. Disconnect the 1P connector from the thermo switch (1). 2. Turn the main switch key to the “ON” position, and measure the voltage with a voltmeter between the connector terminal and the chassis.
Page 266: Head Light Switch
G2160, WSM ELECTRICAL SYSTEM (4) Head Light Switch Connector Voltage 1. Disconnect the 1P connectors from the head light switch (1). 2. Turn the main switch key to the “ON” position, and measure the voltage with a voltmeter between the connector terminal (Red / White) and the chassis.
Page 267: Brake Switch
G2160, WSM ELECTRICAL SYSTEM (5) Brake Switch Brake Switch 1) Connector Voltage 1. Turn the main switch off. 2. Disconnect the 4P connectors from the brake switch (1). 3. Set the PTO clutch lever at “DISENGAGE” position. 4. Turn the main switch to “ON” position.
Page 268: Pto Switch
G2160, WSM ELECTRICAL SYSTEM (6) PTO Switch PTO Switch 1) Connector Voltage 1. Turn the main switch off. 2. Disconnect the 4P connector from the PTO switch (1). 3. Turn the main switch to “ON” position. 4. Measure the voltage with a voltmeter across the connector 3 terminal and chassis.
Page 269: Fuel Switch
G2160, WSM ELECTRICAL SYSTEM (8) Fuel Switch Fuel Switch Continuity 1. Disconnect the 2P connector from the fuel switch. 2. Using an ohmmeter, check for continuity between the connector terminals. There should be continuity when the fuel in the tank is empty, and no continuity when the fuel in the tank is full.
Page 270: Kra System (If Equipped)
G2160, WSM ELECTRICAL SYSTEM [6] KRA SYSTEM (If Equipped) (1) Reverse Switch Adjusting of Reverse Switch Gap (1) Pedal System Comp. (2) Reverse Switch Lever (3) Parking Lock Spring (4) Reverse Switch Plate (5) Reverse Switch W1030362 1. Check and adjust gap between reverse switch (5) and reverse switch lever (2).
Page 271: Kra System Unit (Harness Connector Side)
G2160, WSM ELECTRICAL SYSTEM (2) KRA system Unit (Harness connector side) KRA system Unit Connector Battery Voltage 1. Turn the main switch to “ON” position. But do not start the engine. 2. Measure voltage with a voltmeter. Voltage Factory spec.
Page 272 MOWER KiSC issued 11, 2006 A...
Page 273 SERVICING CONTENTS 1. TROUBLESHOOTING ..................9-S1 2. SERVICING SPECIFICATIONS ..............9-S2 3. TIGHTENING TORQUES ................9-S3 4. CHECKING, DISASSEMBLING AND SERVICING.........9-S4 [1] CHECKING AND ADJUSTING ...............9-S4 [2] DISMOUNTING AND MOUNTING ............9-S8 [3] DISASSEMBLING AND ASSEMBLING..........9-S10 [4] SERVICING ....................9-S15 KiSC issued 11, 2006 A...
Page 274: Troubleshooting
G2160, WSM MOWER 1. TROUBLESHOOTING KiSC issued 11, 2006 A 9-S1...
Page 275: Servicing Specifications
G2160, WSM MOWER 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Front Tip of Blade to Rear Tip of Blade Difference Less than 5 mm – 0.20 in. Left Tip of Blade to Right Tip of Blade Difference Less than 4 mm –...
Page 276 G2160, 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 Reamer bolt 77.4 to 90.2 7.9 to 9.2...
Page 277: Checking, Disassembling And Servicing
G2160, WSM MOWER 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Checking Mower Blade 1. Check the cutting edge of mower blade. 2. Sharpen the cutting edges, if the mower blades are as shown in figure (2). 3. Replace the mower blades, if they are as shown in figure (3).
Page 278 G2160, WSM MOWER Adjusting the Parallel Linkage 1. Park the machine on a level surface. 2. Make sure the mower blades are level in the way mentioned below. Then tighten the lock nuts securely. Adjust (L) of front rinks with lock nut so that (A) is 0∼5 mm (0∼0.2 in.).
Page 279 G2160, WSM MOWER Adjusting Left and Right Cutting Height 1. Mount the mower to the machine, and place the machine on a level ground. 2. Set the cutting height to “2” position. 3. Measure the heights (L), (R) of the blade.
Page 280 G2160, WSM MOWER Adjusting Cutting Height 1. To set the cutting height, pull the mower lift lever backward to raise the mower deck to the top position. Turn the cutting height control dial to adjust height. 2. Set the anti-scalp roller’s height as shown to keep clearance between rollers and ground more than 6 mm (0.24 in.).
Page 281: Dismounting And Mounting
G2160, WSM MOWER [2] DISMOUNTING AND MOUNTING Anti-scalp Rollers and Cutting Height Adjusting Dial 1. Park the machine on level ground, and stop the engine. 2. Set the front anti-scalp rollers sideways and at the topmost position. 3. Set the cutting height adjusting dial to “1” position, and down the mower.
Page 282 G2160, WSM MOWER Dismounting Mower 1. Turn the front wheel to the left. 2. Pull out the mower deck to the right. 3. Return wheels to straight ahead position. 4. Reset the front anti-scalp rollers to straight ahead position. (A) LEFT...
Page 283: Disassembling And Assembling
G2160, WSM MOWER [3] DISASSEMBLING AND ASSEMBLING Universal Joint and Covers 1. Remove the universal joint. 2. Remove the left and right hand covers (1), (2). (When reassembling) • Apply grease to the splines and grease nipples of the universal joint.
Page 284 G2160, WSM MOWER Gear Box and Mower Belt 1. Turn over the mower. 2. Remove the mower belt (1) from the tension pulley (6). 3. Unscrew the left and right gear box mounting screws (3), (4) and remove the gear box (2) from the mower deck.
Page 285 G2160, WSM MOWER Center Pulley Holder 1. Unscrew the center pulley holder screws (2), (14) and / center pulley nuts (10), (15). 2. Remove the upper oil seal (6) and lower oil seal (5). 3. Remove the internal snap ring (4) and ball bearing (3).
Page 286 G2160, WSM MOWER Outer Pulley and Blade Shaft 1. Unscrew the outer pulley mounting nut (21), and remove the outer pulley (27). 2. Unscrew the pulley holder mounting nut (29) and remove the left pulley holder (35), 3. Remove the oil seal (37) and tap out the left blade shaft (38) with the ball bearings (36), (32) taking care not to damage the grease nipple (20).
Page 287 G2160, WSM MOWER Balancer 1. Unscrew the lock nut (3) both side. 2. Remove the plane washer (4) and balancer spring (2). 3. Unscrew the center pin bolt (6). 4. Remove the center pin (5) and balancer plate (1). (When reassembling) •...
Page 288: Servicing
G2160, WSM MOWER [4] SERVICING Turning Torque of Pinion Shaft 1. Remove the mower belt, and reassemble the gear box to the mower deck. 2. Wind a string around the pinion shaft and set a spring balance (or push-pull gauge) to the tip of the string, and then slowly pull the spring balance horizontally to measure the turning force.
Page 289 G2460G (Supplement) Printed in Japan 2001.02, S, EI, EI, e 97897-15041 KiSC issued 11, 2006 A...
Page 290 CONTENTS SAFETY INSTRUCTIONS..................P-1 SPECIFICATIONS ....................P-6 1. GENERAL .....................PG-1 2. ENGINE Servicing...................... P1-S1 3. ELECTRICAL SYSTEM Mechanism ....................P8-M1 Servicing...................... P8-S1 KiSC issued 11, 2006 A...
Page 291 G2160 are explained separately in two items, “Mechanism” and “Servicing” for each section. Gasoline engine is mounted on G2460G. And G2460G’s body is basically same as G2160’s body. As for the items which are not explained in this section, refer to G2160 Workshop Manual (9Y021-15044). Mechanism Information on the construction and function in all sections except “General”...
Page 292 G2460G, 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 293 G2460G, 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 294 G2460G, 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. PREVENT ACID BURNS •...
Page 295 G2460G, 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 11, 2006 A...
Page 296 G2460G, WSM SAFETY INSTRUCTIONS KiSC issued 11, 2006 A...
Page 297 G2460G, WSM SPECIFICATIONS SPECIFICATIONS Model G2460G Maximum gross power 15.6 kW (21 HP) Model WG752-ES-24G Type Vertical, water cooled, 4-cycle gasoline engine Number of cylinders 68.0 × 68.0 mm (2.68 × 2.68 in.) Bore and stroke Total displacement 740 cm (45.2 cu.in.) Rated revolution 3000 rpm...
Page 298 G2460G, WSM G GENERAL 1. FEATURES 1. Gasoline engine 2. Front PTO (option) 3. Rugged ladder type chassis 4. Low-noise, high-performance mower 5. Large-capacity fuel tank 6. Hydraulic mower lift KiSC issued 11, 2006 A PG-1...
Page 299 0 to 25 °C (32 to 77 °F): SAE20 or 10W-30 2.3 Imp.qts Above 25 °C (77 °F): SAE30 or 10W-30 4.5 L Transmission (Including 4.75 U.S.qts KUBOTA UDT or SUPER UDT fluid HST and cylinder) 3.86 Imp.qts 0.40 L Mower gear case 0.42 U.S.qts SAE #90 gear oil 0.35 Imp.qts...
Page 300 *** : Initial elongation of the front PTO belt may occur prior to 25 hours. Adjust the tension spring length as needed to maintain belt tension. : These items should be serviced by an authorized KUBOTA Dealer, unless the owner has the proper tools and is mechanically proficient.
Page 301 G2460G, WSM G GENERAL 4. 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 Checking Engine Oil Level CAUTION •...
Page 302 G2460G, WSM G GENERAL Retightening Mower Blade Screw CAUTION • To avoid injury, always handle the mower blade with care. 1. Dismount the mower and turn it over to expose the mower blades. 2. Wedge a wooden block (1) securely between the mower blade and mower deck.
Page 303 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 W1030950 KiSC issued 11, 2006 A PG-6...
Page 304 G2460G, WSM G GENERAL [3] CHECK POINTS OF EVERY 100 HOURS Checking Fuel Lines And Fuel Filter CAUTION • Be sure to stop the engine and remove the key when attempting to make the following checks and changes. • Never fail to check the fuel lines periodically. The fuel lines are subject to wear and age.
Page 305 G2460G, WSM G GENERAL Checking Spark Plugs 1. Lift hood. 2. Remove the spark plug wire from spark plug (1). 3. Use a spark plug wrench to remove plug (1). NOTE • This engine is equipped with resistor-type spark plugs. 4.
Page 306 G2460G, WSM G GENERAL Battery Charging DANGER To avoid serious injury or death : • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.
Page 307 G2460G, WSM G GENERAL [4] CHECK POINTS OF EVERY 200 HOURS Checking Radiator Hose and Clamp NOTE • Check to see if the radiator hoses are properly fixed every 200 hours of operation or 6 months, whichever comes first. 1. If clamp bands (2) are loose or water leaks, tighten clamp band (2) securely.
Page 308 G2460G, WSM G GENERAL [6] CHECK POINTS OF EVERY 1 YEAR Flushing Cooling System and Changing Coolant CAUTION • Never open radiator cap when engine is hot. • When opening, loosen cap slightly to the stop to relieve any excess pressure before removing radiator cap completely. 1.
Page 309 G2460G, WSM G GENERAL Replacing Radiator Hose and Clamp Band 1. Replace the radiator hoses (1) and clamp bands (2). (1) Radiator Hose (2) Clamp Band W1038188 Replacing Fuses 1. The electrical system is protected from potential damage by fuses. A blown fuse indicates that there is an overload or short somewhere in the electrical system.
Page 310 G2460G, WSM G GENERAL Replacing Bulbs (A) Replacing the head light bulb 1. Open hood. 2. Turn bulb socket to remove socket from headlight housing. 3. Push bulb down and turn one quarter turn to remove bulb from the socket. 4.
Page 311 G2460G, WSM G GENERAL 5. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Timing Light Application : Use to adjust the ignition timing. W1024318 Auxiliary Socket for Fixing Crankshaft Sleeve Code No: 07916-34041 Application: Use exclusively for fixing the crankshaft sleeve. W1041415 Air Cooled Compression Tester Code No:...
Page 312 • Distributor is tamper resistant ; the ignition timing adjustment screw has been covered after adjustment at the factory. So, except the authorized KUBOTA dealers, you CAN NOT adjust the ignition timing. The special tool is only for using in order to recover the factory original adjustment. So, without any reason, adjustment, disassembly and assembly for Emission Parts MUST NOT be done.
Page 313 G2460G, WSM ENGINE 1. GENERAL [1] ENGINE IDENTIFICATION When contacting your local KUBOTA dealer, always specify the engine serial number. NOTE • The serial number is marked on specified position shown in the figure. Engine Serial Number The engine serial number is an identified number for the engine.
Page 314 The content of the label is approved officially by EPA / CARB. W1091012 Tamper Resistance KUBOTA corporation provides safeguards for the parts where never to be adjusted, and is approved by EPA / CARB for the purpose of this engine to be in compliance with EPA / CARB Emission Regulations through its useful life.
Page 315 G2460G, WSM ENGINE 2. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Excessive Vibration • Loosen engine mounting nuts Retighten mounting P1-S16 nuts. Engine Will Not • Engine jammed Check engine to find – Crank trouble and repair. • Battery discharged Check battery PG-8 specific gravity, and...
Page 316 G2460G, WSM ENGINE Reference Symptom Probable Cause Solution Page Engine Cranks at • No fuel Replenish fuel. – Normal Speed but • Water or dirt in fuel system Replace fuel and – Does Not Start repair fuel system. • Fuel pipe or fuel filter clogged or damaged Clean or replace fuel PG-10 pipe or fuel filter.
Page 317 G2460G, WSM ENGINE Reference Symptom Probable Cause Solution Page Either Black or Dark • Overload Lessen load. – Gray Exhaust Gas Is • Low grade fuel used Use specified fuel. PG-2 Observed • Fuel filter clogged Replace fuel filter. PG-7, 10 •...
Page 318 G2460G, WSM ENGINE Reference Symptom Probable Cause Solution Page High Oil Pressure • Different type of oil Use specified type of PG-2 oil. • Relief valve defective Replace relief valve. – Engine Overheated • Engine oil insufficient Replenish engine oil. PG-2, 4 •...
Page 319 G2460G, WSM ENGINE 3. SERVICING SPECIFICATIONS [1] ENGINE BODY Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.05 mm 0.0020 in. Top Clearance (Serial No.: above 1A0001) 0.85 to 1.30 mm – 0.0335 to 0.0512 in. (Serial No.: below YY8644) 1.45 to 1.75 mm –...
Page 320 G2460G, WSM ENGINE Engine Body (Continued) Item Factory Specification Allowable Limit Valve Spring Free Length 31.3 to 31.8 mm 28.4 mm 1.23 to 1.25 in. 1.12 in. Setting Load 64.7 N 54.9 N 6.6 kgf 5.6 kgf 14.6 lbs 12.3 lbs Setting Length 27.0 mm 27.0 mm...
Page 321 G2460G, WSM ENGINE Engine Body (Continued) Item Factory Specification Allowable Limit Timing Gear Crank Gear to Idle Gear Backlash 0.043 to 0.124 mm 0.15 mm 0.00169 to 0.00488 in. 0.0059 in. Idle Gear to Cam Gear Backlash 0.047 to 0.123 mm 0.15 mm 0.00185 to 0.00484 in.
Page 322 G2460G, WSM ENGINE Engine Body (Continued) Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Oil Clearance 0.034 to 0.106 mm 0.20 mm Bearing 1 0.00134 to 0.00417 in. 0.0079 in. Crankshaft Journal O.D. 39.934 to 39.950 mm – 1.57221 to 1.57284 in. Crankshaft Bearing 1 I.D.
Page 323 G2460G, WSM ENGINE [2] LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed More than 69 kPa – 0.7 kgf/cm 10 psi At Rated Speed 196 to 441 kPa 69 kPa 2.0 to 4.5 kgf/cm 0.7 kgf/cm 28 to 64 psi 10 psi Inner Rotor to Outer Rotor...
Page 324 G2460G, WSM ENGINE 4. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9.) Item Size x Pitch N·m kgf·m ft-lbs M6 × 1.0 Starter M terminal nut 9.8 to 13.7 1.0 to 1.4...
Page 325 G2460G, WSM ENGINE 5. CHECKING, DISASSEMBLING AND SERVICING [1] SEPARATING ENGINE (1) Disassembling and Assembling Dismount Mower 1. See to “MOWER” section. W1019171 Draining Engine Oil 1. Park the machine on level ground. 2. Start and warm up the engine for approx. 5 minutes. 3.
Page 326 G2460G, WSM ENGINE Draining Coolant CAUTION • Never open the radiator cap while operating or immediately after stopping. Otherwise, hot water will spout out from the radiator. Wait for more than ten minutes to cool the radiator, before opening the cap. 1.
Page 327 G2460G, WSM ENGINE Wiring 1. Remove the PTO cable (2) and wiring (1). 2. Disconnect 2P connector (3) and wiring (4) from the alternator. 3. Disconnect 1P connector (6) from the oil pressure switch. 4. Disconnect 1P connector (8) and wiring (7) from the starter. 5.
Page 328 G2460G, WSM ENGINE Separating Engine 1. Pull out the hairpin cotters from the radiator. 2. Remove the engine mounting nuts, and support the engine with an engine lift hook and hoist. 3. Separate the engine with the radiator from the frame, taking care not to damage the radiator.
Page 329 G2460G, WSM ENGINE [2] ENGINE BODY (1) Checking and Adjusting Compression Pressure 1. After warming up the engine, stop it and remove the air cleaner, the muffler and all spark plugs. 2. Install a compression tester (Code No: 07909-30251) for gasoline engines to spark plug hole.
Page 330 G2460G, WSM ENGINE Valve Clearance IMPORTANT • The valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover and the glow plugs. 2. Align the “1TC” mark on the flywheel and alignment mark on the rear end plate so that the No.
Page 331 G2460G, WSM ENGINE Closed Breather 1. Disconnect the breather hose (1). (1) Closed Breather Hose (3) Air Cleaner Flange (2) Closed Breather Assembly (4) Head Cover W1045993 Ignition Cords, Inlet Manifold and Cylinder Head Cover 1. Remove the spark plug cap and the spark plug (1). 2.
Page 332 G2460G, WSM ENGINE (B) Cylinder Head and Valves Rocker Arm Assembly and Push Rod 1. Remove the rocker arm bracket mounting nuts, and remove the rocker arm assembly (1). 2. Remove the push rods (2). (When reassembling) • Insert the push rods into the tappets securely. •...
Page 333 G2460G, WSM ENGINE Valves 1. Remove the valve caps (2). 2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1). 3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6).
Page 334 CARB SOREs (Small Off Road Engines) emission regulations are made tamper resistant, so that operators, users or unauthorized KUBOTA repair shops can not easily tamper with the adjustments. • If the ignition timing has to be adjusted, remove the tamper resistance from the distributor mounting screw.
Page 335 G2460G, WSM ENGINE (When reassembling) NOTE • When placing the distributor over the distributor drive shaft, make sure that the distributor drive groove is horizontal when No. 1 cylinder is at its T.D.C.. At this time, the mating mark should be at the bottom. 1.
Page 336 G2460G, WSM ENGINE Fan Drive Pulley 1. Set the stopper to the flywheel. 2. Remove the fan drive pulley retaining screw. 3. Draw out the fan drive pulley with a puller. (When reassembling) • Install the pulley to the crankshaft, aligning the aligning marks (1) on them.
Page 337 G2460G, WSM ENGINE Oil Pump and Crankshaft Gear 1. Remove the oil pump gear (6). 2. Remove the oil pump (5). 3. Remove the collar (4), O-ring (3) and oil slinger (2). 4. Remove the crankshaft gear (1) with a puller. (When reassembling) •...
Page 338 G2460G, WSM ENGINE Bearing Case Cover 1. Remove the bearing case cover mounting screws. First, remove inside screws (6) and then outside screws (3). 2. Screw two removed screws into the screw hole of bearing case cover (5) to remove it. IMPORTANT •...
Page 339 G2460G, WSM ENGINE [3] FUEL SYSTEM (1) Checking and Adjusting (A) Governor Adjusting Governor 1. Loosen the governor lever nut (3). 2. Set the throttle valve to the fully “open” position (A) with the governor lever (1), turn the groove on the governor lever shaft (2) fully clockwise with a screwdriver (to open the governor completely), and then tighten the nut (3) in this position.
Page 340 G2460G, WSM ENGINE Adjusting Engine Speed 1. Warm up the engine at a medium speed for 10 to 15 minutes. 2. Engine speed is adjusted to approx. 1500 rpm by the speed control lever (3). 3. Throttle valve (1) is closed by hand and the rpm of the engine is adjusted with the throttle adjust screw (2) to 1200 rpm (1100 to 1300 rpm).
Page 341 G2460G, WSM ENGINE (2) Carburetor (A) Altitude Compensation Kit (Engine Serial No.: Above 1A0001) Main Jet and Pilot Jet 1. Remove the carburetor. 2. Loosen the drain screw (3) to let fuel out. 3. Remove the gasoline solenoid (6). 4. Remove the main jet (5). 5.
Page 342 G2460G, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM AND ELECTRICAL CIRCUIT [1] WIRING DIAGRAM KiSC issued 11, 2006 A P8-M1...
Page 343 G2460G, WSM ELECTRICAL SYSTEM KiSC issued 11, 2006 A P8-M2...
Page 344 G2460G, WSM ELECTRICAL SYSTEM [2] ELECTRICAL CIRCUIT KiSC issued 11, 2006 A P8-M3...
Page 345 G2460G, WSM ELECTRICAL SYSTEM KiSC issued 11, 2006 A P8-M4...
Page 346 G2460G, WSM ELECTRICAL SYSTEM 1. SERVICING SPECIFICATIONS SPARK PLUG Item Factory Specification Allowable Limit Spark Plug Gap 1.0 to 1.1 mm – 0.039 to 0.043 in. W1027540 IGNITION COIL 1.3 to 1.6 Ω Primary Coil Resistance – Secondary Coil Resistance 10.7 to 14.5 kΩ...
Page 347 G2460G, WSM ELECTRICAL SYSTEM 2. CHECKING AND SERVICING [1] SPARK PLUG AND IGNITION COIL CHECKING Spark Test 1. Remove the spark plug, put it inside the high voltage cord cap firmly, and then ground the threaded section to the engine body (not to painted or resin parts).
Page 348 G2460G, WSM ELECTRICAL SYSTEM [2] SOLENOID CHECKING Fuel Cut Off Solenoid 1. Disconnect the connector. 2. Measure the resistance with an ohmmeter between the connector terminals. 3. If the factory specification is not indicated the solenoid is faulty. Approx. 38 Ω Resistance Factory spec.
Page 349 G2160-R48S (Supplement) Use this workshop manual together with Workshop Manual for G2160 issued already. Printed in Japan 2001.03, S, EI, EI, e Code No. 97897-15042 KiSC issued 11, 2006 A...
Page 350 CONTENTS SAFETY INSTRUCTIONS..................Q1 SPECIFICATIONS ....................Q6 DIMENSIONS ......................Q8 1. GENERAL ....................QG-1 [1] FEATURES ..................... QG-1 [2] IDENTIFICATION..................QG-2 [3] LUBRICANTS, FUEL AND COOLANT ..........QG-3 [4] MAINTENANCE CHECK LIST ............. QG-4 [5] CHECK AND MAINTENANCE ............. QG-5 2.
Page 351 TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KUBOTA G2160-R48S. It is divided into two parts, “Mechanism” and “Servicing” for each section except “ENGINE” section. Mechanism Information on the construction and function are included.
Page 352: Safety Instructions
G2160-R48S, 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 11, 2006 A...
Page 353 G2160-R48S, WSM SAFETY INSTRUCTIONS KiSC issued 11, 2006 A...
Page 354 G2160-R48S, WSM SAFETY INSTRUCTIONS KiSC issued 11, 2006 A...
Page 355 G2160-R48S, WSM SAFETY INSTRUCTIONS KiSC issued 11, 2006 A...
Page 356: Specifications
G2160-R48S, WSM SPECIFICATIONS SPECIFICATIONS Model G2160-R48S Maximum gross power 15.6 kW (21 HP) Model D782-E-G21 Type Indirect injection, vertical, water cooled, 4-cycle diesel engine Number of cylinders 67.0 × 73.6 mm (2.64 × 2.90 in.) Bore and stroke Total displacement 778 cm (47.48 cu.in.)
Page 357 G2160-R48S, WSM SPECIFICATIONS Model G2160-R48S Steering Electric power steering (EPS) Transmission Hydrostatic transmission Brake Internal expanding brake Model RCK48R-21G Total length 938 mm (36.9 in.) Total width 1690 mm (66.5 in.) Total height 255 mm (10.0 in.) Mounting method Quick joint, parallel linkage...
Page 358: Dimensions
G2160-R48S, WSM DIMENSIONS DIMENSIONS KiSC issued 11, 2006 A...
Page 359: General
G2160-R48S, WSM G GENERAL 1. GENERAL [1] FEATURES 1. E-TVCS engine 2. Front PTO (option) 3. Rugged ladder type chassis 4. Low-noise, high-performance mower 5. Large-capacity fuel tank 6. Hydraulic mower lift 7. Large-capacity grass collector bag KiSC issued 11, 2006 A...
Page 360: Identification
G2160-R48S, WSM G GENERAL [2] IDENTIFICATION When contacting your local KUBOTA distributor, always specify engine serial number (1), machine serial number (2), mower serial number (3) and hour meter reading. (1) Engine Serial Number (3) Mower Serial Number (2) Machine Serial Number...
Page 361: Lubricants, Fuel And Coolant
0 to 25 °C (32 to 77 °F): SAE20 or 10W-30 Above 25 °C (77 °F): SAE30 or 10W-30 4.5 L Transmission (Including 4.75 U.S.qts. KUBOTA UDT or SUPER UDT fluid HST & cylinder) 3.86 Imp.qts. 0.40 L Mower gear case 0.42 U.S.qts.
Page 362: Maintenance Check List
**** : Initial elongation of the front PTO belt may occur prior to 25 hours. Adjust the tension spring length as needed to maintain belt tension. : These items should be serviced by an authorixed KUBOTA Dealer, unless the owner has the proper tools and is mechanically proficient.
Page 363: Check And Maintenance
G2160-R48S, WSM G GENERAL [5] 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 Oiling CAUTION • Be sure to stop the engine and remove the key before oiling.
Page 364 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 W1013443...
Page 365 G2160-R48S, WSM G GENERAL (3) Check Points of Every 50 Hours Adjusting Brake Play CAUTION • When making adjustments, park the machine on a flat area, block wheels, stop engine and remove the key. 1. If brake play is not correct, loose the lock nut (2) and turn the nut (3) in the desired direction until the proper play is achieved.
Page 366 G2160-R48S, WSM G GENERAL (5) Check Points of Every 300 Hours Changing Transmission Fluid CAUTION • Be sure to stop the engine and remove the key before changing or checking the oil. • Allow transmission case to cool down sufficiently; oil can be hot and may cause burns 1.
Page 367 G2160-R48S, WSM G GENERAL (6) Check Points of Every 1 Year Replacing Grass Hopper Net 1. Remove the knob nut (1) from top of grass hopper cover. 2. Remove plastic cover (2) from hopper 3. Remove the 2 clevis pins, 2 cotter-pins (3), 2 flange bolts and the height adjust stay (4) from the top of hopper frame.
Page 368 KUBOTA. Use of implements which exceed the maximum loading weight listed below, or which are not recommended for use with the KUBOTA Machine may result in malfunctions or failures of the machine, damage to other property and injury to the operator or others.
Page 369 G2160-R48S, WSM TRANSMISSION AND REAR AXLE 2. TRANSMISSION AND REAR AXLE [1] MECHANISM (1) Hydrostatic Transmission Oil Flow (1) Drain Hose (4) Oil Filter Cartridge (6) Drain Hose (8) Suction Pipe (2) Rear Axle Case (5) Control Valve Adaptor (7) Rear Axle Case...
Page 370 G2160-R48S, WSM TRANSMISSION AND REAR AXLE [2] SERVICING (1) Tightening Torque 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 Cam mounting nut 39.2 to 45.1...
Page 371: Transmission And Rear Axle
G2160-R48S, WSM TRANSMISSION AND REAR AXLE Discharging Plate and Discharge Duct 1. Remove the discharging plate (1). 2. Remove the discharge duct (3) from the platform (5). (1) Discharging Plate (4) M8 Bolt (2) M6 Bolt (5) Platform (3) Discharge Duct...
Page 372 G2160-R48S, WSM TRANSMISSION AND REAR AXLE (B) Separating Platform Connector, PTO Clutch Return Cable and Cylinder Hose 1. Disconnect the 2P connector (3) from the grass collector switch. 2. Remove the wiring (2) from the platform. 3. Disconnect the PTO clutch return cable (4).
Page 373: Mechanism
G2160-R48S, WSM HYDRAULIC SYSTEM 6. HYDRAULIC SYSTEM [1] MECHANISM (1) Hydraulic Circuit (1) Transmission Case (7) Valve (for Grass Collector (12) Grass Collector Cylinder (a) Open (2) Oil Strainer Cylinder) A: Close (b) Close (3) Charge Pump (8) Filter Relief Valve...
Page 374 G2160-R48S, WSM HYDRAULIC SYSTEM (2) Grass Collector Dumping Circuit Suppose that the mower lifting spool (spool 1) (1) is in the neutral position. Neutral The oil coming from port P flows to port T1. Port A and B that are connected with the grass collector cylinder are kept closed by the spool 2 (for grass collector cylinder) (2).
Page 375 G2160-R48S, WSM HYDRAULIC SYSTEM Close Move the grass collector dumping lever to the “DOWN” position, and the spool 2 (for grass collector cylinder) (1) is activated in the direction shown in the figure. The oil coming from port P flows through port A into the grass collector cylinder.
Page 376 G2160-R48S, WSM HYDRAULIC SYSTEM (3) Grass Collector Cylinder (1) Nut (3) Cylinder Tube (5) Piston Rod B: Rod O.D. (2) Piston (4) Head A: Cylinder I.D. C: Stroke The grass collector cylinder consists of a head (4), cylinder tube (3), piston rod (5), piston (2), and other parts as shown in the above figure.
Page 377: Servicing
G2160-R48S, WSM HYDRAULIC SYSTEM [2] SERVICING (1) Troubleshooting KiSC issued 11, 2006 A Q6-S2...
Page 378 G2160-R48S, WSM HYDRAULIC SYSTEM (2) Servicing Specifications Item Factory Specification Allowable Limit Main relief valve Setting Pressure 2.94 to 3.43 MPa – 30.0 to 35.0 kgf/cm 426 to 497 psi Filter Relief valve Setting Pressure 1.96 to 2.45 MPa –...
Page 379 G2160-R48S, WSM HYDRAULIC SYSTEM (B) Disassembling Control Valve Adaptor, Plug and Spool 1. Remove adaptors. 2. Remove the plug. 3. Draw out the spool assembly. (When reassembling) • Take care not to damage the O-rings. • Install the adaptors as shown in the figure.
Page 380 G2160-R48S, WSM HYDRAULIC SYSTEM (C) Separating Grass Collector Cylinder Separating Grass Collector Cylinder 1. Remove the cylinder cover (3). 2. Pull out the cotter pins (2), (4). 3. Separate the grass collector cylinder (1) from the platform. 4. Remove the adaptors (5), (6) from the grass collector cylinder.
Page 381 G2160-R48S, WSM HYDRAULIC SYSTEM Cylinder Head, Piston and Nut 1. Secure the rod end in a vise. 2. Unscrew the cylinder piston mounting lock nut (4). 3. Remove the piston (3) and cylinder head (2) from the piston rod (1).
Page 382: Pto System
G2160-R48S, WSM PTO SYSTEM 7. PTO SYSTEM [2] SERVICING (1) Adjusting PTO Clutch Return Cable Adjusting PTO Clutch Return Cable 1. Place the machine on level ground, and stop the engine. 2. Set the PTO clutch lever to “ENGAGE” position.
Page 383: Electrical System
G2160-R48S, WSM ELECTRICAL SYSTEM 8. ELECTRICAL SYSTEM [1] MECHANISM (1) Wiring Diagram KiSC issued 11, 2006 A Q8-M1...
Page 384 G2160-R48S, WSM ELECTRICAL SYSTEM KiSC issued 11, 2006 A Q8-M2...
Page 385: Servicing
G2160-R48S, WSM ELECTRICAL SYSTEM [2] SERVICING (1) Servicing Specification GRASS CLLECTOR SWITCH Item Factory Specification Allowable Limit Resistance between the terminals in pushing switch 0 ohm – W1010640 (2) Grass Collector Switch Grass Collector 1. Disconnect the grass collector switch (1) from the wiring harness.
Page 386: Mower
G2160-R48S, WSM MOWER 9. MOWER [2] SERVICING (1) 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 Reamer bolt 77.4 to 90.2...
Page 387 G2160-R48S, WSM MOWER Adjusting Front and Rear Cutting Height 1. Mount the mower to the machine, and place the vehicle on a level ground. 2. Set the cutting height to “2” position. 3. Measure the heights (F), (R) of the blade.
Page 388 G2160-R48S, WSM MOWER Adjusting Left and Right Cutting Height 1. Mount the mower to the machine, and place the machine on a level ground. 2. Set the cutting height to “2” position. 3. Measure the heights (L), (R) of the blade.
Page 389 G2160-R48S, WSM MOWER Mower Blade (Center Blade and Outer Blades) 1. Turn over the mower. 2. Remove the mower blade screw (1). 3. Remove the spring plate (2), blade (3) and dust cover (4). 4. Remove the external snap ring (5) on the bevel gear shaft (only center blade).
Page 390 G2160-R48S, WSM MOWER Mower Belt, Gear Case and Center Pulley Holder 1. Turn over the mower. 2. Remove the tension springs (7), (9). 3. Remove the mower belts (1), (6). 4. Remove the RH case stay (5). 5. Remove the reamer bolts (2), (3).
Page 391 G2160-R48S, WSM MOWER Side Blade Pulley Holder Assembly 1. Remove the side blade pulley mounting nut (2). 2. Remove the side blade pulley (3), feather key (7) (only right side blade pulley) and grease nipple (1) from the blade shaft (6).
Page 392 G2160-R48S, WSM MOWER Disassembling LH Tension Pulley 1. Remove the tension spring from the tension arm (10). 2. Remove the tension arm mounting bolt (5) and nut (1). 3. Remove the tension arm assembly, tension collar (2) and plate (4).
Page 393 G2160-R48S, WSM MOWER Backlash between Bevel Gears 1. Remove the gear case cap (2). 2. Place fuses the 21T bevel gear (3) on the pinion shaft. 3. Turn the pinion shaft. 4. Take out the fuses, and measure the thickness of fuses with an outside micrometer.
Page 394 G2160-R48S, WSM MOWER Clearance between Tension Collar and Tension Arm Bushing 1. Measure the tension collar O.D. with an outside micrometer. 2. Measure the tension arm bushing I.D. with an inside micrometer, and calculate the clearance. 3. If the clearance exceeds the factory specification, replace them.
Page 395 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. 05, S, EI, EI, e Code No.9Y011-15044 KUBOTA Corporation 2001.

This manual is also suitable for:

G2160-r48s G2460g

Kubota G2160 Workshop Manual

General

1 Features

2 Identification

3 General Precautions

4 Handling Precautions for Electrical Parts and Wiring

5 Lubricants, Fuel and Coolant

6 Tightening Torques

7 Maintenance Check List

8 Check and Maintenance

9 Special Tools

10 Implement Limitations

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Tightening Torques

4 Checking, Disassembling and Servicing

Mechanism

1 Structure

2 Hydrostatic Transmission

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Tightening Torques

4 Checking, Disassembling and Servicing

Servicing

Servicing

Mechanism

1 System Configuration

2 Construction and Function of Main Components

Servicing

1 Cautionary Instructions before Starting Failure Diagnosis

2 Troubleshooting

3 Servicing Specifications

5 Checking, Disassembling and Servicing

6 Servicing

Servicing

1 Troubleshooting

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Checking, Disassembling and Servicing

Mechanism

1 Wiring Diagram

2 KRA (Kubota Reverse Awareness) SYSTEM (if Equipped)

Servicing

1 Troubleshooting

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Servicing

1 Troubleshooting

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Q G2160-R48S (Supplement)

Safety Instructions

Specifications

Dimensions

Transmission and Rear Axle

Pto System

Electrical System

Mower

Quick Links

Chapters

Troubleshooting

Related Manuals for Kubota G2160

Summary of Contents for Kubota G2160