workshop manual gr2100ec2

WORKSHOP MANUAL

GR2100EC2

KiSC issued 04, 2007 A

TO THE READER

This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KUBOTA GR2100EC2. It is divided into three parts, “General”, “Mechanism” and “Servicing”.

■

General

Information on the product identification, the general precautions, maintenance check list, check and maintenance and special tools are described.

■

Mechanism

Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing.

■

Servicing

Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting, disassembling and assembling, and servicing which cover procedures, precautions, factory specification and allowable limits.

All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication.

The right is reserved to make changes in all information at any time without notice.

Due to covering many models of this manual, information or picture being used, have not been specified as one model.

July 2006

© KUBOTA Corporation 2006


GR2100EC2, 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.

DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

■

IMPORTANT : Indicates that equipment or property damage could result if instructions are not followed.

■

NOTE : Gives helpful information.

BEFORE SERVICING AND REPAIRING

• Read all instructions and safety instructions in this manual and on your machine safety decals.

• Clean the work area and machine.

• Park the machine on a firm and level ground, and set the parking brake.

• Lower the implement to the ground.

• Stop the engine, and remove the key.

• Disconnect the battery negative cable.

• Hang a “DO NOT OPERATE” tag in operator station.

1


GR2100EC2, WSM

2

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.

• Never start the engine while standing on ground.

Start the engine only from operator’s seat.

SAFETY WORKING

• Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued.

• Wear close fitting clothing and safety equipment appropriate to the job.

• Use tools appropriate to the work. Makeshift tools, parts, and procedures are not recommended.

• When servicing is performed together by two or more persons, take care to perform all work safely.

• Do not work under the machine that is supported solely by a jack. Always support the machine by safety stands.

• Do not touch the rotating or hot parts while the engine is running.

• Never remove the radiator cap while the engine is running, or immediately after stopping. Otherwise, hot water will spout out from radiator. Only remove radiator cap when cool enough to touch with bare hands. Slowly loosen the cap to first stop to relieve pressure before removing completely.

• Escaping fluid (fuel or hydraulic oil) under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or fuel lines.

Tighten all connections before applying pressure.

AVOID FIRES

• Fuel is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in your working area.

• To avoid sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last.

• Battery gas can explode. Keep sparks and open flame away from the top of battery, especially when charging the battery.

• Make sure that no fuel has been spilled on the engine.


GR2100EC2, 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.

3

PREVENT ACID BURNS

• Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, clothing and cause blindness if splashed into eyes. Keep electrolyte away from eyes, hands and clothing. If you spill electrolyte on yourself, flush with water, and get medical attention immediately.

DISPOSE OF FLUIDS PROPERLY

• Do not pour fluids into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, electrolyte and other harmful waste.

PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher handy at all times.

• Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone.


GR2100EC2, 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.

4


GR2100EC2, WSM

SAFETY INSTRUCTIONS

5


GR2100EC2, WSM

SAFETY INSTRUCTIONS

6


GR2100EC2, WSM

SPECIFICATIONS

SPECIFICATIONS

Engine

Maker

Model

Type

Fuel

Model

Number of cylinders

Bore and stroke

Total displacement

Engine gross power (DIN)

Rated revolution

Battery

Starting system

Lubrication system

Cooling system

Capacities

Dimensions

Fuel tank

Engine crankcase (with filter)

Engine coolant (with recovery tank)

Transmission case

Front axle case

Overall length (with grass catcher)

Overall width

Overall height

Wheel base

Tread

Front

Rear

Weight (without mower and grass catcher)

Tires

Front

Rear

Traveling system

Steering

Transmission

Brake

Traveling speed

Forward

Reverse

Clutch

PTO system

PTO brake

NOTE: *Manufacture's estimate

The company reserves the right to change the specifications without notice.

GR2100EC2

KUBOTA

D782-E2-GX

Indirect injection. Vertical, water-cooled, 4-cycle diesel

3

67 x 73.6 mm (2.64 x 2.90 in.)

778 cm

3

(47.46 cu.in.)

15.6 kW (20.9 HP)

50 r/s [3000 min

-1

(rpm)]

51R (12 V, 450CCA)

Cell starter (with glow plug)

Forced lubrication by trochoidal pump

Pressurized radiator, forced circulation with water pump

Diesel fuel No.2-D [above -10

°

C (14

°

F)],

Diesel fuel No.1-D [below -10

°

C (14

°

F)]

18 L (4.8 U.S.gals, 4.0 lmp.gals)

2.8 L (2.96 U.S.qts., 2.46 lmp.qts.)

2.35 L (2.48 U.S.qts., 2.07 lmp.qts.)

3.4 L (0.90 U.S.gals., 0.75 lmp.gals.)

1.9 L (0.50 U.S.gals., 0.42 lmp.gals.)

2880 mm (113.4 in.)

1280 mm (50.4 in.)

1230 mm (48.4 in.)

1280 mm (50.4 in.)

825 mm (32.5 in.)

800 mm (31.5 in.)

360 kg (794 lbs)

16 x 7.50 - 8, 4PR

23 x 10.50 - 12, 4PR

Full hydraulic power steering (Gear Steer)

Hydrostatic transmission

Internal expanding brake

0.0 to 10.0 km/h (0.0 to 6.2 mph)

0.0 to 5.0 km/h (0.0 to 3.1 mph)

Mechanical wet multi discs

Wet multi discs

W1028280


7

GR2100EC2, WSM

Mower

Model

Cutting width

Cutting height

Adjustment of cutting height

Mounting method

Weight (Approx.)

Dimensions

Total length

Total width

Total height

Discharge direction

Gear box oil

SPECIFICATIONS

RCK48GREC2

1219 mm (48.0 in.)

25 to 102 mm (1 to 4 in.)

Dial gauge

Quick joint, Parallel linkage

80 kg (176 lbs)

871 mm (34.3 in.)

1270 mm (50.0 in.)

305 mm (12.0 in.)

Rear

0.40 L (0.42 U.S.qts, 0.35 Imp.qts)

W1030594

Model

Container capacity

Grass catcher

Weight (Approx.)

NOTE: *Manufacture's estimate

The company reserves the right to change the specifications without notice.

GCK450GREC2

450 L (118.9 U.S.gals, 99.0 Imp.gals)

50 kg (110 lbs)

W1031306

8


GR2100EC2, WSM

DIMENSIONS

DIMENSIONS

9


G

GENERAL


GENERAL

CONTENTS

1. IDENTIFICATION............................................................................................. G-1

2. GENERAL PRECAUTIONS ............................................................................ G-2

3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .. G-3

[1] WIRING...................................................................................................... G-3

[2] BATTERY................................................................................................... G-5

[3] FUSE.......................................................................................................... G-5

[4] CONNECTOR ............................................................................................ G-5

[5] HANDLING OF CIRCUIT TESTER......................................................... G-7

4. LUBRICANTS, FUEL AND COOLANT ......................................................... G-8

5. TIGHTENING TORQUES ............................................................................... G-9

[1] GENERAL USE SCREWS, BOLT AND NUTS ..................................... G-9

[2] METRIC SCREWS, BOLTS AND NUTS ............................................... G-9

[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC

OR UNF THREADS ............................................................................... G-10

[4] PLUGS ..................................................................................................... G-10

6. MAINTENANCE CHECK LIST ..................................................................... G-11

7. CHECK AND MAINTENANCE ..................................................................... G-13

[1] DAILY CHECK ........................................................................................ G-13

[2] CHECK POINTS OF EVERY 50 HOURS ........................................... G-19

[3] CHECK POINTS OF EVERY 100 HOURS ......................................... G-27



[6] CHECK POINT OF EVERY 400 HOURS ........................................... G-35

[7] CHECK POINT OF 1500 HOURS........................................................ G-36

[8] CHECK POINTS OF EVERY 1 YEAR ................................................ G-36

[9] CHECK POINTS OF EVERY 2 YEARS.............................................. G-39

[10]OTHERS .................................................................................................. G-39

8. SPECIAL TOOLS .......................................................................................... G-43

[1] SPECIAL TOOLS FOR ENGINE .......................................................... G-43

[2] SPECIAL TOOLS FOR TRACTOR....................................................... G-50

9. TIRES............................................................................................................. G-54

[1] TIRE PRESSURE ................................................................................... G-54

[2] TREAD ..................................................................................................... G-54

10. IMPLEMENT LIMITATIONS.......................................................................... G-55


GR2100EC2, WSM

1. IDENTIFICATION

G GENERAL

When contacting your local KUBOTA distributor, always specify engine serial number (2), machine serial number (1), mower serial number (3) and hour meter reading.

(1) Machine Serial Number

(2) Engine Serial Number

(3) Mower Serial Number

(4) Hour Meter

W1010662

G-1


GR2100EC2, WSM G GENERAL

2. GENERAL PRECAUTIONS

• During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. 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.

• Before disassembling or servicing electrical wires, always disconnect the ground cable from the battery first.

• Remove oil and dirt from parts before measuring.

• Use only KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety.

• Gaskets and O-rings must be replaced during reassembly. Apply grease to new O-rings or oil seals before assembling. See the figure left side.

• When reassembling external snap rings or internal snap rings, they must be positioned so that sharp edge faces against the direction from which a force is applied. See the figure left side.

• When inserting spring pins, their splits must face the direction from which a force is applied. See the figure left side.

• To prevent damage to the hydraulic system, use only specified fluid or equivalent.

(1) Grease

(2) Force

(3) Sharp Edge

(4) Axial Force

(5) Rotating Movement

(A) External Snap Ring

(B) Internal Snap Ring

W1011487

G-2



3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS

AND WIRING

To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring.

■

IMPORTANT

• Check electrical wiring for damage and loosened connection every year. To this end, educate the customer to do his or her own check and at the same time recommend the dealer to perform periodic check for a fee.

• Do not attempt to modify or remodel any electrical parts and wiring.

• When removing the battery cables, disconnect the negative cable first. When installing the battery cables, connect the positive cable first.

(1) Negative Terminal (2) Positive Terminal

W1014000

[1] WIRING

• Securely tighten wiring terminals

(1) Correct (Securely Tighten) (2) Incorrect (Loosening Leads to Faulty

Contact)

W1012010

• Do not let wiring contact dangerous part.

(1) Dangerous Part

(2) Wiring (Incorrect)

(3) Wiring (Correct)

(4) Dangerous Part

W1016619

• Securely insert grommet.

(1) Grommet

(A) Correct

(B) Incorrect

W1017242


G-3


• Securely clamp, being careful not to damage wiring.

(1) Clamp

•Wind Clamp Spirally

(2) Wire Harness

(3) Clamp

(4) Welding Dent

W1017829

• Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.

(1) Wiring

(2) Clamp

(A) Correct

(B) Incorrect

W1018301

• In installing a part, take care not to get wiring caught by it.

(1) Wiring

(A) Incorrect

W1018801

• After installing wiring, check protection of terminals and clamped condition of wiring, only connect battery.

(1) Cover

•Securely Install Cover

W1019331

G-4


GR2100EC2, WSM

[2] BATTERY

[3] FUSE

[4] CONNECTOR

G GENERAL

• 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).

• After connecting cables to battery terminal posts, apply high temperature grease to them and securely install terminal covers on them.

• Do not allow dirt and dust to collect on battery.

CAUTION

• Take care not to let battery liquid spill on your skin and clothes. If contaminated, wash it off with water immediately.

• Before recharging the battery, remove it from the machine.

• Before recharging, remove cell caps.

• Do recharging in a well-ventilated place where there is no open flame nearby, as hydrogen gas and oxygen are formed.

W1012584

• Use fuses with specified capacity.

Neither too large or small capacity fuse is acceptable.

• Never use steel or copper wire in place of fuse.

• Do not install working light, radio set, etc. on machine which is not provided with reserve power supply.

• Do not install accessories if fuse capacity of reserve power supply is exceeded.

(1) Fuse (2) Fusible Link

W1021306

• For connector with lock, push lock to separate.

(A) Push

W1022218

G-5



• In separating connectors, do not pull wire harnesses.

• Hold connector bodies to separate.

(A) Correct (B) Incorrect

W1023039

• Use sandpaper to remove rust from terminals.

• Repair deformed terminal. Make certain there is no terminal being exposed or displaced.

(1) Exposed Terminal

(2) Deformed Terminal

(3) Sandpaper

(4) Rust

W1023383

• Make certain that there is no female connector being too open.

(A) Correct (B) Incorrect

W1023675

• Make certain plastic cover is large enough to cover whole connector.

(1) Cover

(A) Correct

(B) Incorrect

W1023937

G-6



[5] HANDLING OF CIRCUIT TESTER

• Use tester correctly following manual provided with tester.

• Check for polarity and range.

W1025166

G-7



4. LUBRICANTS, FUEL AND COOLANT

No.

1

2

Place

Fuel tank

Cooling system with recovery tank

Capacity

18 L

4.8 U.S.gals.

4.0 lmp.gals.

2.35 L

2.48 U.S.qts.

2.07 lmp.qts.

Lubricants, fuel and coolant

No. 2-D diesel fuel

No. 1-D diesel fuel if temperature is below

-10

°

C (14

°

F)

Fresh clean water with anti-freeze

3 Engine crankcase

2.8 L

2.96 U.S.qts.

2.46 lmp.qts.

Engine oil: API service CD, CE or CF

Below 0

°

C (32

°

F) : SAE10W, 10W-30 or 10W-40

0 to 25

°

C (32 to 77

°

F) : SAE20, 10W-30 or 10W-

40

Above 25

°

C (77

°

F) : SAE30, 10W-30 or 10W-40

4

5

6

Transmission case

Front axle case

Mower gear box

3.3 L

0.87 U.S.gals.

0.73 lmp.gals.

1.9 L

0.50 U.S.gals.

0.42 lmp.gals.

0.40 L

0.42 U.S.qts.

0.35 lmp.qts.

Greasing

No. of greasing points

1

No.

11

12

Place

7

Engine transmission universal joint

King pin 8

9 Center pin

10 Glide Steer bolt

Glise Steer rear arm

Speed control pedal shaft

13 Mower link

14 Seat adjuster

15 Cable

16 PTO lever

–

17 Hydraulic lift lever

18

Grass catcher hinge

19

[Mower]

Spindle shafts

20 Tension arm

21

Mower universal joint

1

* KUBOTA original transmission hydraulic fluid.

3

2

–

–

–

–

–

–

2

2

2

2

KUBOTA UDT or SUPER UDT fluid*

SAE90 gear oil

(API service classification : more than GL-3)

Capacity

Until grease overflows

Moderate amount

Until grease overflows

Moderate amount

Type of grease

SAE multi-purpose type grease

Engine oil

SAE multi-purpose type grease

Engine oil


G-8


5. TIGHTENING TORQUES

[1] GENERAL USE SCREWS, BOLT AND NUTS

Screws, bolt and nuts whose tightening torque are not specified in this Workshop Manual should be tightened according to the table below.

Indication on top of bolt

Material of bolt

Material of opponent part

Unit

Diameter

N·m kgf·m

No-grade or 4T

SS400, S20C

Ordinariness ft-lbs N·m

Aluminum kgf·m ft-lbs N·m kgf·m

7T

S43C, S48C

Ordinariness ft-lbs N·m

Aluminum kgf·m ft-lbs

SCr435, SCM435

Ordinariness

N·m

9T kgf·m ft-lbs

M6

(6 mm, 0.24 in.)

M8

(8 mm, 0.31 in.)

M10

(10 mm, 0.39 in.)

M12

(12 mm, 0.47 in.)

M14

(14 mm, 0.55 in.)

M16

(16 mm, 0.63 in.)

M18

(18 mm, 0.71 in.)

M20

(20 mm, 0.79 in.)

7.85

to

9.31

17.7

to

20.5

39.3

to

45.1

62.8

to

72.5

108 to

125

167 to

191

246 to

284

334 to

392

0.80

to

0.95

1.8

to

2.1

4.0

to

4.6

6.4

to

7.4

11.0

to

12.8

17.0

to

19.5

25.0

to

29.0

34.0

to

40.0

5.79

to

6.87

13.1

to

15.1

29.0

to

33.2

46.3

to

53.5

181 to

209

246 to

289

79.6

to

92.5

123 to

141

7.85

to

8.82

16.7

to

19.6

31.4

to

34.3

–

–

–

–

–

0.80

to

0.90

1.7

to

2.0

3.2

to

3.5

–

–

–

–

–

5.79

to

6.50

12.3

to

14.4

23.2

to

25.3

–

–

–

–

–

9.81

to

11.2

23.6

to

27.4

48.1

to

55.8

77.5

to

90.2

124 to

147

197 to

225

275 to

318

368 to

431

1.00

to

1.15

2.4

to

2.8

4.9

to

5.7

7.9

to

9.2

12.6

to

15.0

20.0

to

23.0

28.0

to

32.5

37.5

to

44.0

7.24

to

8.31

17.4

to

20.2

35.5

to

41.2

57.2

to

66.5

91.2

to

108

145 to

166

203 to

235

272 to

318

39.3

to

44.1

62.8

to

72.5

7.85

to

8.82

17.7

to

20.5

–

–

–

–

4.0

to

4.5

6.4

to

7.4

0.80

to

0.90

1.8

to

2.1

–

–

–

–

29.0

to

32.5

46.3

to

53.5

5.79

to

6.50

13.1

to

15.1

–

–

–

–

12.3

to

14.2

29.5

to

34.3

60.9

to

70.6

103 to

117

167 to

196

260 to

304

344 to

402

491 to

568

17.0

to

20.0

26.5

to

31.0

35.0

to

41.0

50.0

to

58.0

6.2

to

7.2

10.5

to

12.0

1.25

to

1.45

3.0

to

3.5

123 to

144

192 to

224

254 to

296

362 to

419

44.9

to

52.0

76.0

to

86.7

9.05

to

10.4

21.7

to

25.3

W1034542

[2] METRIC SCREWS, BOLTS AND NUTS

Property class 8.8

Property class 10.9

Grade

Unit

Nominal

Diameter

M 8

M 10

M 12

M 14

M 16

N·m

23.6 to 27.4

48.1 to 55.8

77.5 to 90.1

124.0 to 147.0

196.0 to 225.0

kgf·m

2.4 to 2.8

4.9 to 5.7

7.9 to 9.2

12.6 to 15.0

20.0 to 23.0

ft-lbs

17.4 to 20.2

35.5 to 41.2

57.2 to 66.5

91.2 to 108.0

145.0 to 166.0

N·m

29.4 to 34.3

60.8 to 70.5

103.0 to 117.0

167.0 to 196.0

260.0 to 303.0

kgf·m

3.0 to 3.5

6.2 to 7.2

10.5 to 12.0

17.0 to 20.0

26.5 to 31.0

ft-lbs

21.7 to 25.3

44.9 to 52.1

76.0 to 86.8

123.0 to 144.0

192.0 to 224.0

W1016172


G-9


[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR

UNF THREADS

SAE GR.5

SAE GR.8

Grade

Unit

Nominal

Diameter

5/16

3/8

1/2

9/16

5/8

N·m kgf·m

23.1 to 27.8

47.5 to 57.0

108.5 to 130.2

149.2 to 179.0

203.4 to 244.1

2.35 to 2.84

4.84 to 5.82

11.07 to 13.29

15.22 to 18.27

20.75 to 24.91

ft-lbs

17.0 to 20.5

35.0 to 42.0

80.0 to 96.0

110.0 to 132.0

150.0 to 180.0

N·m

32.5 to 39.3

61.0 to 73.2

149.2 to 179.0

217.0 to 260.4

298.3 to 358.0

kgf·m

3.31 to 4.01

6.22 to 7.47

15.22 to 18.27

22.14 to 26.57

30.44 to 36.53

ft-lbs

24.0 to 29.0

45.0 to 54.0

110.0 to 132.0

160.0 to 192.0

220.0 to 264.0

W1022485

[4] PLUGS

Material of opponent part

Shape

Tapered screw

Straight screw

Size

R1/8

R1/4

R3/8

R1/2

G1/4

G3/8

G1/2

N·m

12.7 to 21.6

24.5 to 44.1

49.0 to 88.3

58.8 to 107.9

24.5 to 34.3

61.8 to 82.4

49.0 to 88.3

Ordinariness kgf·m

1.3 to 2.2

2.5 to 4.5

5.0 to 9.0

6.0 to 11.0

2.5 to 3.5

6.3 to 8.4

5.0 to 9.0

ft-lbs

9.4 to 15.9

18.1 to 32.5

36.2 to 65.1

43.4 to 79.6

18.1 to 25.3

45.6 to 60.8

36.2 to 65.1

N·m

12.7 to 19.6

24.5 to 34.3

49.0 to 58.8

58.8 to 78.5

–

–

–

Aluminum kgf·m

1.3 to 2.0

2.5 to 3.5

5.0 to 6.0

6.0 to 8.0

–

–

–

ft-lbs

9.4 to 15.4

18.1 to 25.4

36.2 to 43.4

43.4 to 57.9

–

–

–

0000001666E

G-10



6. MAINTENANCE CHECK LIST

■

IMPORTANT

• The jobs indicated by

★

must be done initially.

• *1 : This maintenance should be done daily more often in dusty conditions than in normal conditions.

Suggested cleaning interval is every 100 hours in normal conditions.

Period

Indication on hour meter (Hr)

No.

After since

Important

Reference page

Item

50 100 150 200 250 300 350 400 450 500 550 600

1 Engine oil

2 Engine oil filter

3

Transmission and

Front axle cases fluid

4 Transmission oil filter

5 Transmission strainer

6 Front axle pivot

7

Safety device

8

Oiling

9 Greasing

10

Mower gear box oil

11

Air cleaner element

12

Battery condition

13

Brake

14

Fan drive belt tension

15

Fuel filter element

Change

★

Replace

★

Change

Replace

★

Clean

Adjust

Check

–

–

Check

Change

✩

Clean

Replace

Check

Adjust

Adjust

Check

Replace

✩

✩

✩

✩

✩

✩

✩

★

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

★

✩

★

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩

✩ every

100 hr every

200 hr every

200 hr every

50 hr every

1 year every

50 hr every

100 hr every

100 hr every

100 hr every

400 hr every

50 hr every

50 hr every

50 hr every

150 hr every

200 hr every

200 hr every

200 hr every

50 hr

*1

G-27

G-30

G-31,

G-33

G-32

G-32

G-35

G-19

G-22

G-21

G-20

G-29

G-20

G-36

G-25

G-28

G-29

G-28

G-35

W1035769

G-11



No.

16

17

18

19

20

Fuel injection nozzle

(Injection pressure)

21

Radiator

22

23

24

25

26

27

Period

Item

Fuel line

Hydraulic hose

Radiator hose and clamp

Intake air line

Coolant

Mower gear box oil seal

Fuel system

Fuse

Blade

Mower belt

Check

Replace

Check

Replace

Check

Replace

Check

Replace

Check

Clean

Change

Replace

Bleed

Replace

Replace

Replace

Indication on hour meter (Hr)

50 100 150 200 250 300 350 400 450 500 550 600

After since

Important

Reference page

✩ ✩

✩

✩

✩

✩ ✩

✩

✩

✩

✩ ✩

✩

✩

✩ every

100 hr every

2 years every

200 hr every

2 years every

200 hr every

2 years every

200 hr every

2 years every

1500 hr every

1 year every

1 year every

2 years

G-28

G-39

G-34

G-34

G-32

G-39

G-35

G-39

G-39

G-36

G-36

G-39

Service as required

G-42

G-39

G-41

G-42

W1045250

G-12


GR2100EC2, WSM

7. CHECK AND MAINTENANCE

G GENERAL

CAUTION

• Be sure to check and service the machine on a flat place with engine shut off, the parking brake on and chock the wheels.

[1] DAILY CHECK

To prevent trouble from occurring, it is important to know the condition of the machine. Check the following items before starting.

Checking

• Walk around the machine.

1. Tire pressure, wear and damage

2. Oil and water leak

3. Engine oil level

4. Transmission fluid level

5. Coolant level in the recovery tank

6. Damage of machine body, tightness of all bolts and nuts

7. Radiator screen

8. Panel screen

9. Brake play

10.Fuel level

11.Check air cleaner element

• Mower

1. Oil leak

2. Make sure blade cap screws are tight.

3. Blades for wear or damage.

4. Check all hardware.

5. Make sure all pins are in place.

6. Mower deck cleaning

7. Greasing

• While sitting in the operator's seat

1. Speed control pedal and brake pedal

2. Brake

• Turning the key switch "ON"

1. Performance of the easy checker light.

• Starting the engine

1. Color of the exhaust fumes

2. Safety start switch, seat safety control and another safety devices.

3. Check for abnormal noise and vibration.

• Others

1. Check the areas where previous troubles were experienced.

G-13



Checking Engine Oil Level

CAUTION

• Always stop the engine and remove the key before checking oil.

1. Check engine oil before starting and 5 minutes or more after the engine has stopped.

2. Wipe dipstick (2) area clean.

3. To check the oil level, remove the dipstick (2), wipe it clean, reinsert it, and draw it out again. Check to see that the oil level is between the two notches.

4. Add new oil to the prescribed level at the oil inlet (1) if necessary.

5. When using a different brand or viscosity oil from the previous one, remove all of the old oil and oil filter. Never mix two different types of oil.

6. Use the proper Engine Oil SAE according to the ambient temperatures. (Refer to “4. LUBRICANTS, FUEL AND

COOLANT” in this section.)

(1) Engine Oil Inlet

(2) Oil Level Dipstick

A : Upper Level

B : Lower Level

W1029428

G-14



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. Fill fuel tank only to bottom of filler neck.

Check the fuel level. Take care that the fuel tank does not become empty.

Fuel tank capacity

18 L

4.8 U.S.gals.

4.0 Imp.gals.

■

IMPORTANT

• Use Diesel Fuel Only.

1. Use No.2-D diesel fuel.

2. Use No.1-D diesel fuel if the temperature is below -10

°

C (14

°

F).

3. Always use a strainer when refueling to prevent fuel injection pump contamination.

■

NOTE

• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service.

(SAE J313 JUN87)

Grade of Diesel Fuel Oil according to ASTM D975

Flash point

°

C

Min

52

Water and

Sediment, volume %

Max

0.05

Carbon Residue on, 10 percent

Residuum %

Max

0.35

Ash, weight %

Max

0.01

Distillation

Temperatures

°

C 90%

Point

Min Max

282 338

Sulfur, weight

Max

0.50

(1) Fuel Cap

Kinematics Viscosity cSt or mm

2

/S at 40

°

C

Min

1.9

Max

4.1

Copper strip Corrosion

Max

No.3

Saybolt Viscosity, SUS at 100

°

F

Min

32.6

Max

40.1

Cetane Number

Min

40

W1030533

G-15



Checking and Cleaning Radiator to Prevent Overheating

CAUTION

• Be sure to stop the engine and remove the key before cleaning.

Daily or after every 5 hours of operation, check to be sure the radiator screen (2) and radiator core are clean. Dirt or chaff on the radiator screen (2) or radiator core decrease cooling performance.

1. Remove the radiator screen (2) and panel screen (1) and remove all foreign material.

2. Remove the dust from between the fins and the tube.

3. Tighten the fan drive belt as necessary. For this, refer to

"CHECK POINT EVERY 100 HOURS".

4. If scale forms in the tube, clean with the scale inhibitor or its equivalent.

5. Each time the panel screen (1) is covered with grass during operation, rub it off the screen with hand. Check the radiator screen (2) from time to time if grass accumulates.

6. If the dust or chaff has accumulated inside of the panel, remove the radiator screen (2) and clean inside completely.

After cleaning, reinstall the radiator screen (2) properly.

■

NOTE

• When assembling the panel screen (1), be sure to fit it to panel with no clearance at the bottom.

(1) Panel Screen (2) Radiator Screen

W1033765

G-16



Checking Tire Pressure

WARNING

• Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment.

• Always maintain the correct tire pressure.

Do not inflate tires above the recommended pressure.

• Inflation pressure in front tires rises quickly when using compressed air.

CAUTION

• Never operate machine with a loose rim, wheel or axle.

• Whenever bolts are loosened, retighten to specified torque.

• Check all bolts frequently and keep them tightened.

■

Inflation Pressure

Though the inflation pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time. Thus, check it every day and inflate as necessary.

Front

Rear

Tire Sizes

16 x 7.50-8, 4PR

23 x 10.50-12, 4PR

Recommended Inflation

Pressure

200 kPa

(2.0 kgf/cm

2

, 29 psi)

140 kPa

(1.4 kgf/cm

2

, 20 psi)

(1) Ground

(A) Insufficient

(B) Normal

(C) Excessive

W1034256

Checking Transmission Fluid Level

1. Park the machine on a flat surface, lower the implement to the ground and shut off engine and remove the key.

2. Raise the operator's seat.

3. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to see that the oil level lies between the two notches. If the level is too low, add new oil to the prescribed level at the oil inlet. (See page G-8.)

■

IMPORTANT

• If oil level is low, do not run engine.

(1) Oil Level Dipstick

A : Oil level is acceptable within this range.

W1035093

G-17



Checking Coolant Level

CAUTION

• Do not remove the radiator cap when the engine is hot.

Loosen cap slightly, to the stop, to relieve any excess pressure before removing cap completely.

Check the coolant level daily both the radiator and the recovery tank (4) before starting engine.

1. Remove the radiator cap (1) and check to see that the coolant level is just below the fill port.

2. Check to see that the coolant level is between the "FULL" and

"LOW" marks of recovery tank (4).

3. When the coolant level drops due to evaporation, add water only up to just below the fill port of the radiator and the full level of the recovery tank (4).

In case of leakage, add coolant and water in the specified mixing ratio up to the full level. (Refer to “Flushing Cooling System

and Changeing Coolant” of “7. CHECK AND

MAINTENANCE” in this section.)

■

IMPORTANT

• If the radiator cap has to be removed, follow the caution above and securely retighten the cap.

• Use clean, distilled coolant and water to fill the radiator and recovery tank.

(1) Radiator Cap

(2) Overflow Pipe

(3) Recovery Tank Cap

(4) Recovery Tank

A : FULL

B : LOW

W1035624

Greasing

CAUTION

• Be sure to stop the engine and remove the key before greasing.

(1) Spindle Shaft

(2) Tension Arm

(3) Mower Universal Joint (Apply grease on the spline shaft)

W1036873

G-18



[2] CHECK POINTS OF EVERY 50 HOURS

Checking Safety Device

CAUTION

• Do not allow anyone near the machine while testing.

• If the machine does not pass one of the following tests, do not operate the machine.

1. Check the following tests before operating the mower. Sit on the operator's seat for all tests.

■

Safety Start Control 1

1. Depress the brake pedal (3) fully.

2. Engage the PTO lever (4).

3. Turn the key switch (2) to the "START" position.

4. The engine should not crank.

■

Safety Start Control 2

1. Disengage the PTO lever (4).

2. Release the brake pedal (3).

3. Turn the key to the "START" position.

4. The engine should not crank.

■

Seat Safety Control 1

1. Run the engine at half throttle.


3. Stand up. (Do not get off the machine.)

4. Engine should shut off.

■

Seat Safety Control 2


2. Disengage the PTO lever (4).

3. Release the brake pedal (3).

4. Stand up. (Do not get off the machine.)


■

PTO Safety Control 1

1. Dismount the grass container (6) from the platform.




■




3. Dump the grass from grass container (6).


■


1. Open the top cover (5).




(1) Throttle Lever

(2) Key Switch

(3) Brake Pedal

(4 PTO lever

(5) Top Cover

(6) Grass container

W1013056

G-19



Cleaning Air Cleaner Element

1. The air cleaner uses a dry element, never apply oil.

2. Do not touch the filter element except where cleaning is required.

To clean the element, use clean and dry compressed air on the inside of the element. Air pressure should not exceed 205 kPa

(2.1 kgf/cm

2

, 30 psi).

■

NOTE

• Operating in dusty conditions requires more frequent maintenance.

• Align the arrow marks when reinstalling the air cleaner cover.

(1) Air Cleaner Cover (2) Air Cleaner Element

W1038722

Checking Mower Gear Box Oil Level

CAUTION

• Always stop the engine and remove the key before checking oil.

1. Park the machine on a flat surface and lower the mower to the ground.

To check the oil level, loosen check plug (1) bolt and check to see that the oil level is just below the oil check plug (1) port.

If the level is too low, add new oil to the prescribed level at the oil filling plug (2). (Refer to “4. LUBRICUNTS, FUEL AND


(1) Check Plug (2) Oil Filling Plug

W1039488

G-20



Lubricating All Grease Nipple

1. Apply grease to the following locations as shown the figures.

CAUTION

• Be sure to stop the engine and remove the key before greasing.

(1) Engine Transmission Universal Joint

(2) Center Pin

(3) King Pin Support

(4) Glide Steer Bolt

(5) Glide Steer Rear Arm

W1040070

G-21



Oiling

1. Apply oil to the following location as shown the figures.

CAUTION

• Be sure to stop the engine and remove the key before oiling.

(1) Mower Universal Joint

(2) Speed Control Shaft (RH)

(3) Speed Control Shaft (LH)

(4) Seat Adjuster

(5) Throttle Cable

W1040344

G-22



Oiling (Continued)


CAUTION


(1) Around Hole of Mower Link

(2) Around Pin

(3) Pivot of Mower Link

(4) Pivot of Lift Arm

(5) Front Link

(6) Top Cover Lock Lever

(7) Frame Shaft

(8) Top Cover Hinge

(9) Arm Bracket

W1040745

G-23





CAUTION


(1) Quick Clean Lever

(2) PTO Lever (Fulcrum)

(3) Hydraulic Lift Lever (Fulcrum)

(4) Link Fulcrum

W1028368

G-24





CAUTION


(1) Glide Steer Wire

W1041255

Checking Battery Condition

DANGER

• To avoid the possibility of battery explosion:

For the refillable type battery, follow the instructions below.

• Do not use or charge the refillable type battery if the fluid

level is below the LOWER (lower limit level) mark. Otherwise, the battery component parts may prematurely deteriorate, which may shorten the battery's service life or cause an explosion. Check the fluid level regularly and add distilled water as required so that the fluid level is between the

UPPER and LOWER levels.

CAUTION

• Never remove the vent plugs 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.

• Wear eye protection and rubber gloves when working around battery.

1. Mishandling the battery shortens the service life and adds to maintenance costs.

2. The original battery is maintenance free type battery, but need some servicing. If the battery is weak, the engine is difficult to start and the lights become dim. It is important to check the battery periodically.

(1) Battery

W1041496

G-25



■

Battery Charging

DANGER

• When the battery is being activated, hydrogen and oxygen

gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.

CAUTION

• When charging the battery, ensure the vent caps are securely in place (if equipped).

• When disconnecting the cable from the battery, start with the negative terminal first.

When connecting the cable to the battery, start with the positive terminal first.

• Never check battery charge by placing a metal object across the posts.

Use a voltmeter or hydrometer

(For accessible maintainable type batteries with removable vent caps.)

1. Make sure each electrolyte (3) level is to the bottom of vent wells

(4), if necessary add distilled water in a well-ventilated area.

2. The water in the electrolyte (3) evaporates during recharging.

Liquid shortage damages the battery. Excessive liquid spills over and damages the machine.

3. To slow charge the battery, connect the battery positive terminal to the charger positive terminal and the negative to the negative, then recharge in the standard fashion.

4. A boost charge is only for emergencies. It will partially charges the battery at a high rate and in a short time.

When using a boost-charged battery, it is necessary to recharge the battery as early as possible.

Failure to do this will shorten the battery's service life.

5. When the specific gravity of electrolyte (3) become between 1.27

and 1.29 charge has completed.

6. When exchanging an old battery into new one, use battery of equal specification shown in "SPECIFICATIONS".

(1) Lowest Level

(2) Highest Level

(3) Electrolyte

(4) Vent Well

(5) Separator

W1041690

G-26



■

Battery Charging (Continued)

(For non-accessible maintenance-free type batteries.)

Maintenance-free, non-accessible batteries are designed to eliminate the need to add water. Yet the volume of electrolyte (3) above plates may eventually become depleted due to abnormal conditions such as high heat or improper regulator setting. Use a voltmeter to check the state of charge. (See reference chart below to determine if charging is necessary.)

Battery voltage

12.6

12.4

12.2

12.0

Reference state of charge

100 % (Full charge)

75 %

50 %

25 %

11.8

0 %

■

Direction for Storage

1. When storing the machine for long periods of time, remove the battery from machine, adjust the electrolyte (3) to the proper level and store in a dry place out of direct sunlight.

2. The battery self-discharges while it is stored.

Recharge it once every three months in hot seasons and once every six months in cold seasons.

(1) Lowest Level

(2) Highest Level

(3) Electrolyte

(4) Vent Well

(5) Separator

W1041987


Changing Engine Oil

CAUTION

• Be sure to stop the engine and remove the key before changing the oil.

• Allow engine to cool down sufficiently; oil can be hot and may cause burns.

1. To change the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely. The used oil can be drained out more easily if the engine is warm.

2. Fill with the new oil up to the upper notch on the dipstick.

3. To check the oil level. Remove the dipstick, wipe it clean, insert it and draw it out again. Check to see the oil level is between the two marks.

Engine oil capacity

2.8 L

2.96 U.S.qts

2.46 Imp.qts

(1) Drain Plug

W1042588

G-27



Checking Fuel Line and Fuel Filter

CAUTION

• Be sure to stop the engine and remove the key when attempting to make the following checks and changes.

• Never fail to check the fuel lines periodically. The fuel lines are subject to wear and aging. Fuel may leak out onto the running engine, causing a fire.

The fuel line connections should be checked annually or every

100 service hours, whichever comes first.

1. The fuel line (2) is made of rubber and ages regardless of service period.

2. If the fuel line (2) and clamps (1) are found to be damaged or deteriorated, replace them.

3. Check fuel filter (3), if it is clogged by debris or contaminated with water, replace it.

■

IMPORTANT

• When the fuel line is disconnected for maintenance or repair, close both ends of the fuel line with a piece of clean cloth or paper to prevent dust and dirt from entering. In addition, particular care must be take not to admit dust and dirt into the fuel pump. Entrance of even a small amount of dust or dirt cause premature wear and malfunction of the fuel pump and injector components.

(1) Pipe Clamp

(2) Fuel Line

(3) Fuel Filter

W1042817

Checking Brake

CAUTION

• When making adjustments, park the machine on a flat area, block wheels, stop the engine and remove the key.

1. Correct play ranges from 15 to 25 mm (0.59 to 0.98 in.). If it is not correct, loosen the lock nut (2) and turn the nut (3) in the desired direction until the proper play is achieved. After adjustment, retighten lock nut securely.

Play (A) Factory spec.

15 to 25 mm

0.59 to 0.98 in.

(1) Brake Pedal

(2) Lock Nut

(3) Nut

(4) Spring

W1043637

G-28



Checking Fan Drive Belt Tension

CAUTION

• Be sure to stop the engine and remove the key before checking belt tension.

1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley (1) and dynamo pulley (2) at specified force

(98 N, 10 kgf, 22 lbs).

2. If the measurement is not within the factory specifications, loosen the dynamo mounting screws and relocate the dynamo to adjust.

Deflection (A) Factory spec.

7 to 9 mm

0.28 to 0.35 in.

(1) Fan Drive Pulley (2) Dynamo Pulley

W1044388


Changing Mower Gear Box Oil

CAUTION

• Be sure to stop the engine and remove the key before changing the oil.

1. To drain the used oil, remove the oil filler plug (1) at the mower gear box, tilt the mower deck and drain the oil completely into the oil pan.

2. Fill with the new oil. (Refer to “4. LUBRICANTS, FUEL AND


3. After filling, reinstall the oil filler plug (1).

Mower gear box oil capacity

0.40 L

0.42 U.S.qts.

0.35 Imp.qts.

(1) Oil Filler Plug (2) Drain Plug

W1044642

G-29




Replacing Engine Oil Filter Cartridge

CAUTION

• Be sure to stop the engine and remove the key before changing the oil filter cartridge.

• Allow engine to cool down sufficiently, oil can be hot and may cause burns.

1. The oil filter cartridge (1) must be changed every 200 service hours.

2. Apply a slight coat of oil onto the rubber gasket of new cartridge.

3. Tighten the filter quickly until it contacts the mounting surface.

Tighten filter by hand an additional 1/2 turn only.

4. After the cartridge has been replaced, the engine oil level normally lowers a little. Add engine oil to proper level. Check for oil leaks around filter gasket.

■

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

W1045046

G-30



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.

The fluid in the transmission case is also used for the hydrostatic drive system.

1. To drain the transmission oil, place oil pan underneath the transmission case and remove the drain plug (2) at the bottom of the transmission case.

2. After draining, disassemble and clean the strainer (5) and change the oil filter cartridge (7). After reassembling, fill with UDT or

SUPER UDT hydrostatic transmission fluid, or its equivalent.

3. Remove the oil plug and fill with the new oil.

4. After running the engine for a few minutes, stop it and check the oil level again; add oil to the prescribed level.

■

IMPORTANT

• Operate only at low rpm immediately after changing the transmission fluid and filter cartridge.

Keep the engine at medium speed for a few minutes to insure proper lubrication of all parts so that there is no damage to transmission.

• Do not engage PTO before checking the oil level.

Transmission fluid capacity

3.4 L

0.90 U.S.gals

0.75 Imp.gals

(1) Suction Pipe

(2) Drain Plug

(3) O-ring (Small)

(4) O-ring (Large)

(5) Strainer

(6) Boss

(7) Transmission Oil Filter Cartridge

(8) Dipstick

A : Oil level is acceptable within this range

W1045178

G-31



Cleaning Transmission Strainer

When changing the transmission fluid, disassemble and rinse the strainer with nonflammable solvent to completely clean off filings.

Check O-rings (2), (3), replace if damaged, cracked or hardened.

When reassembling be careful not to damage the parts.

■

NOTE

• Since the fine filings in the oil can damage the precision component parts of the hydraulic system, the end of the suction line is provided with an oil strainer.

(1) Suction Pipe

(2) O-ring (Small)

(3) O-ring (Large)

(4) Strainer

(5) Boss

W1045507

Replacing Transmission Oil Filter Cartridge

CAUTION

• Be sure to stop the engine before changing the oil filter cartridge.


1. The transmission oil filter cartridge (1) must be changed every

300 service hours.

2. Remove the grass container and clean the area indicated.

3. Remove the oil filter cartridge (1) with the filter wrench.

4. Lightly tighten the screw (2) by using a screwdriver.

5. Apply a slight coat of oil onto the cartridge gasket.

6. Tighten the filter quickly until it contacts the mounting surface.

Tighten filter by hand an additional 1/2 turn only.

7. Assemble the cover and mount the grass container.

8. After the new cartridge has been replaced, the transmission fluid level normally lowers a little. Add fluid to proper level. Check for oil leaks around filter gasket.

■

IMPORTANT

• To prevent serious damage to hydraulic system, the replacement filter must be a highly efficient, 10

μ

m filter.

Use only a genuine KUBOTA filter or its equivalent.

(1) Transmission Oil Filter Cartridge (2) Screw

W1046228

Checking Radiator Hose and Hose Clamp

Check to see if radiator hoses are properly fixed every 200 hours of operation or six months, whichever comes first.

1. If hose clamps are loose or water leaks, tighten bands securely.

2. Replace hoses (2) and tighten hose clamps securely, if radiator hoses (2) are swollen, hardened or cracked.

(1) Radiator Core (2) Radiator Hose

W1046941

G-32



Changing Front Axle Case Oil

1. Park the machine on a firm, flat and level surface.

2. To drain the used oil, remove the right and left drain plugs (3) and filling plug (2) at the front axle case and drain the oil completely into the oil pan.

3. After draining, reinstall the drain plugs (3).

4. Remove the right or left breather plugs (1).

5. Fill with the new oil up to the upper notch on the dipstick (2).

■

IMPORTANT

• After ten minutes, check the oil level again: add oil to prescribed level.

6. After filling reinstall the filling plug (2) and breather plugs (1).

Front axle case fluid capacity

1.9 L

0.50 U.S.gals

0.42 Imp.gals

(1) Breather Plug

(2) Filling Plug with Dipstick

(3) Drain Plug


W1047178

G-33



Checking Hydraulic Hose

CAUTION

• Be sure to stop the engine and remove the key before checking and replacing hydraulic case.


Check to see if hydraulic hoses are properly fixed every 200 hours of operation.

1. Check to see that all lines and hose clamps are tight and not damaged.

2. If hoses and clamps are found worn or damaged, replace or repair them at once.

(1) Power Steering Hose RH

(2) Power Steering Hose LH

(3) Mower Lift Cylinder Hose

W1047766

G-34



Adjusting Front Axle Pivot

1. Jack up the front of machine.

2. Measurement the clearance between the front axle bracket (1) and frame (5).

3. If the measurement exceeds the factory specification, adjust the front axle bracket mounting screw and nut (4).

4. If the vibration in the front wheel does not stop after adjustment, remove one shim (2) (3) and tighten the front axle bracket mounting screw and nut (4) with a specified torque.

Clearance between front axle bracket and frame

"A"

Factory spec.

81 to 83 mm

3.19 to 3.26 in.

Tightening torque

(1) Front Axle Bracket

(2) Shim

(3) Shim

Front axle bracket mounting screw and nut

48.1 to 55.9 N·m

4.9 to 5.7 kgf·m

35.5 to 41.2 ft-lbs

(4) Front Axle Bracket Mounting Nut

(5) Frame

A : Clearance

W1048078

Checking Intake Air Line

1. Check to see that hose (1) and clamps (2) are tight and not damaged.

2. If hose (1) and clamps (2) are hound worm or damaged, replace or repair them at once.

(1) Hose (2) Clamp

W1029557

[6] CHECK POINT OF EVERY 400 HOURS

Replacing Fuel Filter

1. Disconnect the fuel hoses and loosen the filter band to replace the fuel filter (3).

■

NOTE

• If the fuel line is removed, be sure to properly bleed the fuel system. (Refer to “Bleeding Fuel System” of “7. CHECK

AND MAINTENANCE” in this section.)

(1) Pipe Clamps

(2) Fuel Line

(3) Fuel Filter

W1048746

G-35



[7] CHECK POINT OF 1500 HOURS

Checking Fuel Injection Nozzle (Injection Pressure)

1. Check the fuel injection nozzle.

Refer to “[1] CHECKING AND ADJUSTING” of “4.

CHECKING, DISASSEMBLING AND SERVICING” at “1.

ENGINE” section.

W1030281

[8] CHECK POINTS OF EVERY 1 YEAR

Replacing Air Cleaner Element

1. Change the element once a year.

W1048957

Flushing Cooling System and Changing Coolant

CAUTION

• Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Stop the engine and let cool down.

2. To drain the coolant, remove the clamp and the hose, and remove the radiator cap. The radiator cap must be removed to completely drain the coolant.

3. After all coolant is drained, install the hose with the clamp.

4. Fill with clean water and cooling system cleaner.

5. Follow directions of the cleaner instruction.

6. After flushing, fill with clean water and anti-freeze until the coolant level is just below the fill port on the radiator. Install the radiator cap securely.

7. Fill with coolant up to "FULL" mark on the recovery tank.

8. Start and operate the engine for a few minutes.

9. Stop the engine and let cool. Check coolant level of recovery tank (2) and add coolant if necessary.

■

IMPORTANT

• Do not start engine without coolant.

• Use clean, fresh water and anti-freeze to fill the radiator and recovery tank.

• When the anti-freeze is mixed with water, the anti-freeze mixing ratio must be less than 50 %.

• Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

• Refer to "4. LUBRICANTS, FUEL AND COOLANT" at this section.

Coolant capacity (with recovery tank)

2.35 L

2.48 U.S.qts.

2.07 Imp.qts.

(1) Clamp

(2) Recovery Tank

(3) Recovery Tank Cap

a : FULL b : LOW

W1049126

G-36



Flushing Cooling System and Changing Coolant (Continued)

■

Anti-Freeze

CAUTION

• When using anti-freeze, put on some protection such as rubber gloves (Anti-freeze contains poison.).

• If should drink anti-freeze, throw up at once and take medical attention.

• When anti-freeze comes in contact with the skin or clothing, wash it off immediately.

• Do not mix different types of anti-freeze. The mixture can produce chemical reaction causing harmful substances.

• Anti-freeze is extremely flammable and explosive under certain conditions. Keep fire and children away from antifreeze.

• When draining fluids from the engine, place some container underneath the engine body.

• Do not pour waste onto the grounds, down a drain, or into any water source.

• Also, observe the relevant environmental protection regulations when disposing of anti-freeze.

If it freezes, coolant can damage the cylinders and radiator. If the ambient temperature falls below 0

°

C or before a long-term storage, let out coolant completely, or mix fresh water with long-life coolant and fill the radiator and reserve tank with the mixture.

1. Long-life coolant (hereafter LLC) comes in several types. Use ethylene glycol (EG) type for this engine.

2. Before employing LLC-mixed coolant, fill the radiator with fresh water and empty it again. Repeat this procedure 2 or 3 times to clean up the inside.

3. Mixing the LLC

Put the LLC in coolant in the percentage (%) for a target temperature. When mixing, stir it up well, and then fill into the radiator.

4. The procedure for the mixing of water and anti-freeze differs according to the make of the anti-freeze and the ambient temperature. Refer to SAE J1034 standard, more specifically also to SAE J814c.

W1049548

G-37



Flushing Cooling System and Changing Coolant (Continued)

■

IMPORTANT

• When the anti-freeze is mixed with water, the anti-freeze mixing ratio must be less than 50%.

Vol %

Anti-freeze

40

Freezing Point

°

C (

°

F)

-24 (-12)

Boiling Point*

°

C (

°

F)

106 (222)

50 -37 (-34) 108 (226)

*At 0.1013 MPa (760 mmHg) pressure (atmospheric). A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.

1. Adding the LLC

(1) Add only water if the mixture reduces in amount by evaporation.

(2) If there is a mixture leak, add the LLC the same manufacture and type in the same mixture percentage.

*Never add any long-life coolant of different manufacture.

(Different brands may have different additive components, and the engine may fail to perform as specified.)

2. When the LLC is mixed, do not employ any radiator cleaning agent. The LLC contains anti-corrosive agent. If mixed with the cleaning agent, sludge may build up, adversely affecting the engine parts.

3. Kubota's genuine long-life coolant has a service life of 2 years.

Be sure to change the coolant every 2 years.

■

NOTE

• The above data represent industry standards that necessitate a minimum glycol content in the concentrated anti-freeze.

• When the coolant level drops due to evaporation, add water only to keep the anti-freeze mixing ratio less than 50%. In case of leakage, add anti-freeze and water in the specified mixing ratio before filling in to the radiator.

W1049970

G-38



[9] CHECK POINTS OF EVERY 2 YEARS

Replacing Fuel Lines

1. Replace the fuel line.

Refer to "Checking Fuel Lines and Fuel Filter" of “7. CHECK

AND MAINTENANCE” in this section.

W1050439

Replacing Radiator Hose

1. Replace hoses and clap bands every 2 years or earlier if checked and found that hoses are swollen, hardened or cracked.

W1050634

Replacing Intake Air Line

1. Replace the intake air line.

Refer to "Checking intake Air Lines" of “7. CHECK AND

MAINTENANCE” in this section.

W1030580

Replacing Mower Gear Box Oil Seals

1. Replace the mower gear box oil seals.

Refer to “[3] DISASSEMBLING AND ASSEMBLING” of “4.


MOWER” section.

W1050704

[10] OTHERS

Replacing Fuses

1. Open the hood.

2. Remove the blown fuse.

3. Place a new 3 A or 10 A or 15 A or 30 A or 40 A fuse in position.

■

IMPORTANT

• Never "jump" the fuse with wire or foil, or install a larger capacity fuse than is recommended.

■

Protected circuit

Fuse No. (ID Label)

E/G STOP (a)

(1) IG/M (b)

OPC (c)

(2) –

Capacity (A)

15

10

3

Slow blow fuse 40

Protected circuit

Engine stop timer relay

Fuel pump, head light, etc.

OPC

Check circuit against wrong battery connection

(1) Fuse Location (2) Slow Blow Fuse

W1050999

G-39



Replacing Bulbs

(A) Replacement of the head light bulb

1. Open the hood.

2. Turn bulb socket to remove socket from head light housing.

3. Push bulb down and turn one quarter turn to remove bulb from the socket.

4. Install new bulb to the socket.

5. Install the socket in housing.

6. Close the hood.

Head light bulb 12V - 24 W

(B) Replacement of the indicator light bulb

1. Open the hood.

2. Turn bad bulb socket to the left. And remove it.

3. Pull bulb from the socket.

4. Push new bulb into the socket.

5. Install the socket.

6. Close the hood.

Indicator light bulb

14.0 rated voltage / 0.27

AMP/2 MSCP

W1051306

G-40



Checking and Replacing Mower Blade

CAUTION

• Be sure to stop the engine and remove the key.

• Blades may be sharp. When you handle blades, wear heavy gloves or wrap end of blade with a rag.

■

Checking Blade

1. The blade cutting edges should be kept sharp at all times.

Sharpen the cutting edges, if they resemble blade (b). Replace the blades if they appear similar to blade (c).

■

Replacing Blade

1. Remove the mower deck from the machine and turn it over to expose the blades (4).

2. Wedge a block of wood (1) between the blade (4) and mower housing as illustrated.

3. The blade bolt (2) has right hand threads, turn counterclockwise to loosen.

The blade bolt (2) has left hand threads, turn clockwise to loosen.

■

NOTE

• Use the proper size box or socket wrench to tighten or loosen the blade mounting bolt.

4. To sharpen the blades yourself, clamp the blade securely in a vise.

Use a large mill file and file along the original bevel until sharp.

5. To check the blade for balance, place a small rod though the centre hole. If the blade is not balanced, file the heavy side of the blade until balance is achieved.

6. To attach blades (4), be sure to install the spring plate (5) between the blade (4) and bolt (2) head.

Tightening torque Blade mounting bolt

88.0 to 117.6 N·m

8.98 to 11.99 kgf·m

65.0 to 86.7 ft-lbs

(1) Block

(2) Blade Bolt

(3) Spindle Holder

(4) Blade

(5) Spring Plate

(6) Cover

(a) New Blade

(b) Worn Blade

(c) Cracked Blade

A : Loosen

W1052103

G-41



Replacing Mower Belt

1. Remove the left and right belt covers from the mower deck.

2. Disconnect the universal joint from the gear box (2).

3. Clean around the gear box (2).

4. Remove the mower belt RH (3) from the tension pulley (4).

5. Remove the mower belt LH (1) from the left side blade pulley (5).

6. Remove the gear box stays (7) (8).

7. Remove the mower belts (1) (3) from the center blade pulley.

Tightening torque

Gear box mounting screw

LH (Reamer)


RH

Gear box stay mounting screw LH (Reamer)

Gear box stay mounting screw RH

77.5 to 90.2 N·m

7.9 to 9.2 kgf·m

57.2 to 66.5 ft-lbs

77.5 to 90.2 N·m

7.9 to 9.2 kgf·m

57.2 to 66.5 ft-lbs

77.5 to 90.2 N·m

7.9 to 9.2 kgf·m

57.2 to 66.5 ft-lbs

48.1 to 55.8 N·m

4.9 to 5.7 kgf·m

35.5 to 41.2 ft-lbs

(1) Mower Belt LH

(2) Gear Box

(3) Mower Belt RH

(4) Tension Pulley

(5) Left Side Blade Pulley

(6) Gear Box Mounting Screw LH

(Reamer)

(7) Gear Box Stay LH

(8) Gear Box Stay RH

(9) Gear Box Stay Mounting Screw RH

(10) Gear Box Mounting Screw RH

(11) Gear Box Stay Mounting Screw LH

(Reamer)

W1053326

Bleeding Fuel System

Air must be removed:

1. When the fuel filter or lines are removed.

2. When tank is completely empty.

3. After the machine has not been used for a long period of time.

Bleeding procedure is as follows:

1. Fill the fuel tank with fuel.

2. Start the engine and run for about 30 seconds, and then stop the engine.

W1054074

G-42



8. SPECIAL TOOLS

[1] SPECIAL TOOLS FOR ENGINE

Special Use Puller Set

Code No.: 07916-09032

Application: Use exclusively for pulling out bearing, gears and other parts with ease.

W1054230

Piston Ring Compressor

Code No.: 07909-32111

Application: Use exclusively for pushing in the piston with piston rings into the cylinder.

W1054311

Piston Ring Tool

Code No.: 07909-32121

Application: Use exclusively for removing or installing the piston ring with ease.

W1054371

Diesel Engine Compression Tester

Code No.: 07909-30208 (Assembly) 07909-31251 (G)

07909-30934 (A to F) 07909-31271 (I)

07909-31211 (E and F)

07909-31231 (H)

07909-31281 (J)

Application: Use to measure diesel engine compression and diagnostics of need for major overhaul.

(1) Gauge

(2) L Joint

(3) Adaptor A

(4) Adaptor B

(5) Adaptor C

(6) Adaptor E

(7) Adaptor F

(8) Adaptor G

(9) Adaptor H

(10) Adaptor I

(11) Adaptor J

W1054428


G-43


Diesel Engine Compression Tester (for Glow Plug)

Code No.: 07909-39081 (Assembly) 07909-31301 (L)

07909-31291 (K) 07909-31311 (M)

Application: Use to measure diesel engine compression and diagnostics of need for major overhaul.

(1) Gauge

(2) L Joint

(3) Adaptor K

(4) Adaptor L

(5) Adaptor M

W1054772

Oil Pressure Tester

Code No.: 07916-32032

Application: Use to measure lubricating oil pressure.

(1) Gauge

(2) Cable

(3) Threaded Joint

(4) Adaptor 1

(5) Adaptor 2

(6) Adaptor 3

(7) Adaptor 4

(8) Adaptor 5

W1055056

Valve Seat Cutter

Code No.: 07909-33102

Application: Use to reseat valves.

Angle: 0.785 rad (45

°

)

0.262 rad (15

°

)

Diameter: 28.6 mm (1.126 in.)

31.6 mm (1.244 in.)

35.0 mm (1.378 in.)

38.0 mm (1.496 in.)

41.3 mm (1.626 in.)

50.8 mm (2.000 in.)

W1055258

Radiator Tester

Code No.: 07909-31551

Application: Use to check of radiator cap pressure, and leaks from cooling system.

Remarks: Adaptor (1) BANZAI Code No. RCT-2A-30S.

W1055581

G-44



Connecting Rod Alignment Tool

Code No.: 07909-31661

Application: Use to check the connecting rod alignment.

Applicable: Connecting rod big end I.D.

Range 30 to 75 mm (1.18 to 2.95 in.) dia.

Connecting rod length

65 to 300 mm (2.56 to 11.81 in.)

W1055652

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

2

, 0 to 7000 psi)

W1055750

Plastigage

Code No.: 07909-30241

Application: Use to check the oil clearance between crankshaft and bearing, etc..

Measuring: Green.....0.025 to 0.076 mm (0.001 to 0.003 in.)

Range Red.........0.051 to 0.152 mm (0.002 to 0.006 in.)

Blue.........0.102 to 0.229 mm (0.004 to 0.009 in.)

W1055861

Red Check

Code No.: 07909-31371

Application: Use to check cracks on cylinder head, cylinder block, etc..

W1055928

G-45



R

S

T

U

P

Q

V a b

L

M

J

K

N

O

D

E

B

C

F

G

H

I

Injection Pump Pressure Tester

Application: Use to check fuel tightness of injection pumps.

A

Pressure gauge full scale :

More than 29.4 MPa (300 kgf/cm

2

, 4267 psi)

Copper gasket

Flange (Material : Steel)

Hex. nut 27 mm (1.06 in.) across the plat

Retaining nut

PF 1/2

5 mm (0.20 in.)

17 mm dia. (0.67 in.dia.)


1.0 mm (0.039 in.)


6.10 to 6.20 mm dia. (0.2402 to 0.2441 in.dia.)

8 mm (0.31 in.)

4 mm (0.16 in.)

11.97 to11.99 mm dia. (0.4713 to 0.4721 in.dia.)

PF 1/2

23 mm (0.91 in.)

17 mm (0.67 in.)

4 mm (0.16 in.)

12.00 to 12.02 mm dia. (0.4724 to 0.4732 in.dia.)

100 mm (3.94 in.)

M12 x P1.5

Adhesive application

Fillet welding on the enter circumference

W1050289

G-46



Valve Guide Replacing Tool

Application: Use to press out and press fit the valve guide.

C

D

E

A

B

H

I

F

G

J

K

L

C1

C2

C0.3

20 mm dia. (0.79 in. dia.)

9.96 to 9.98 mm dia. (0.3921 to 0.3929 in. dia.)

5.5 to 5.7 mm dia. (0.2165 to 0.2244 in. dia.)

220 mm (8.66 in.)

80 mm (3.15 in.)

40 mm (1.58 in.)

25 mm dia. (0.98 in. dia.)

5 mm (0.197 in.)

6.0 to 6.1 mm dia. (0.236 to 0.240 in. dia.)

18 mm dia. (0.71 in. dia.)

10.6 to 10.7 mm dia. (0.417 to 0.421 in. dia.)

6.9 to 7.1 mm dia. (0.272 to 0.280 in. dia.)

Chamfer 1.0 mm (0.039 in.)



W1025017

G-47



Bushing Replacing Tools

Application: Use to press out and to press fit the bushing.

1. For small end bushing

E

F

C1

C2

A

B

C

D

C0.3

a b

C

D

E

A

B

F

C1

C2

145 mm (5.71 in.)

20 mm (0.79 in.)

100 mm (3.94 in.)

19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)

21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)

25 mm dia. (0.98 in. dia.)



C0.3

a b


6.3

μ m (248

μ in.)

6.3

μ m (248

μ in.)

2. For idle gear bushing

150 mm (5.91 in.)

23 mm (0.91 in.)

100 mm (3.94 in.)

19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)

21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)

25 mm dia. (0.98 in. dia.)




6.3

μ m (248

μ in.)

6.3

μ m (248

μ in.)

W12358870

G-48



Flywheel Stopper

Application: Use to loosen and tighten the flywheel screw.

C

D

E

A

B

200 mm (7.87 in.)

20 mm (0.79 in.)

30 mm (1.18 in.)

8 mm (0.31 in.)

10 mm dia. (0.39 in. dia.)

W12365478

Crankshaft Bearing 1 Replacing Tool

Application: Use to press out and press fit the crankshaft bearing 1.

[Press Out]

A

135 mm (5.31 in.)

F

G

H

B

C

D

E

72 mm (2.83 in.)

40 mm radius (1.57 in. radius)

10 mm (0.39 in.)

22 mm (0.87 in.)

20 mm dia. (0.79 in. dia.)

47.90 to 47.95 mm dia. (1.8858 to 1.8878 in. dia.)

43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)

[Press Fit]

A

130 mm (5.12 in.)

D

E

F

G

H

B

C

72 mm (2.83 in.)

40 mm radius (1.57 in. radius)

9 mm (0.35 in.)

24 mm (0.95 in.)

20 mm dia. (0.79 in. dia.)

68 mm dia. (2.68 in. dia.)

39.90 to 39.95 mm dia. (1.5709 to 1.5728 in. dia.)

W78965412

G-49



[2] SPECIAL TOOLS FOR TRACTOR

Relief Valve Pressure Tester

Code No.: 07916-50045

Application: This allows easy measurement of relief set pressure.

(1) Gauge (07916-50322)

(2) Cable (07916-50331)

(3) Threaded Joint (07916-50401)

(4) Threaded Joint (07916-50341)

(5) Adaptor B (M18 x P1.5)

(07916-50361)

(6) Adaptor C (PS3/8) (07916-50371)

(7) Adaptor D (PT1/8) (07916-50381)

(8) Adaptor E (PS3/8) (07916-50392)

(9) Adaptor F (PF1/2) (07916-62601)

(10) Adaptor 58 (PT1/4) (07916-52391)

W1026741

Hydrostatic Transmission Tester and HST Adaptor Set

Code No.: 07916-52040 (Hydrostatic Transmission Tester)

07916-53072 (HST Adaptor Set)

Application: This allows easy measurement of hydrostatic transmission pressure.

(1) Hydrostatic Transmission Tester

(07916-52040)

(2) Gasket (04714-00200)

(3) Connector 3 (07916-51331)

(4) Vacuum Gauge (07916-51331)

(5) Pressure Gauge (Low Pressure)

(07916-51301)

(6) Pressure Gauge (High Pressure) (in

Relief Valve Set Pressure Tester)

(07916-50321)

(7) HN Tube (in Relief Valve Set

Pressure Tester) (07916-50331)

(8) Valve Seat Driver (07916-60841)

(9) Connector 1 (07916-60811)

(10) Connector 2 (07916-60821)

(11) Long Connector (07916-60831)

(12) Adaptor 1 (07916-52621)

(13) Adaptor 2 with Collar

(07916-52632)

(14) Adaptor 3 with Collar

(07916-52642)

(15) HST Adaptor Set (07916-53072)

W1023682

G-50


GR2100EC2, WSM

HST Relief Pressure Gauge Adaptors

1. Adaptor 1

G GENERAL

A

B

P

Q

R

S

T

U

L

M

N

O

J

K

V

W

C0.5

R0.4

R0.1

E

F

C

D

G

H

I

5.94 to 6.00 mm dia.

(0.234 to 0.236 in. dia.)

8.165 to 8.187 mm dia.

(0.3215 to 0.3223 in. dia.)

8.4 mm dia. (0.3307 in. dia.)

8.2 mm (0.32 in.)

14.2 mm (0.55905 in.)

7.6 to 8.0 mm (0.30 to 0.31 in.)

2.3 mm (0.09055 in.)

2.0 to 2.2 mm (0.079 to 0.087 in.)

15° (0.26 rad.)

M8

3 mm dia. drill (0.12 in. dia. drill)

Rc1/16

120° (2.09 rad.)

11.8 to 11.9 mm (0.465 to 0.469 in.)

12.2 mm (0.480 in.)

2 mm (0.079 in.)

3 mm (0.118 in.)

8 mm (0.31496 in.)

2 mm (0.079 in.)

2 mm (0.079 in.)

17.4625 mm dia. (0.6875 in. dia.)

7.7 mm (0.303 in.)

10.7 mm (0.421 in.)


Radius 0.4 mm (0.016 in.)


W1014589

G-51


GR2100EC2, WSM

2. Adaptor 2

G GENERAL

Q

C1

C0.2

R0.4

R0.2

C

D

E

F

G

A

B

H

I

J

K

L

M

N

O

P

3. Adaptor Lever

E

F

R1.2

R1

A

B

C

D

9.7 to 10.3 mm (0.382 to 0.406 in.)

1 mm (0.0472 in.)

10.6 to 10.9 mm (0.417 to 0.429 in.)

100 mm (3.94 in.)

12 mm (0.47 in.)

2 mm (0.08 in.)


Radius 1 mm (0.039 in.)

10 mm (0.394 in.)

3 mm (0.1181 in.)

2.0 to 2.4 mm (0.079 to 0.094 in.)

3 mm (0.12 in.)

5.8 mm (0.23 in.)

1.5 mm (0.06 in.)

9 mm dia. (0.35 in. dia.)

8.200 to 8.215 mm dia.

(0.3228 to 0.3234 in. dia.)

9.2 mm dia. (0.16 in. dia.)

12.16 to 12.29 mm dia.

(0.4787 to 0.4839 in. dia.)

17.6 to 17.8 mm dia.

(0.693 to 0.701 in. dia.)

30° (0.52 rad.)

9/16-18UNF

M8

1.5 mm (0.059 in.)

10.3 to 10.5 mm

(0.4055 to 0.4134 in.)

120° (2.09 rad.)

Chamfer 1 mm (0.039 in.)




W1067375

W1015898

Short Neck Wrench

A

B

C

D

R6.4

90 mm (3.543 in.)

7 to 8 mm (0.28 to 0.31 in.)

14 mm (0.551 in.)

6.35 mm (0.25 in.)


W1068021

G-52


GR2100EC2, WSM

PTO Brake Assembling Template

■

NOTE

• The thickness of this is 1.0 mm (0.039 in.)

M

N

K

L

O

P

Q

R

U

V

S

T

C1

G

H

I

J

E

F

A

B

C

D

76.5 mm (3.01 in.)

33.5 mm (1.32 in.)

67.9 to 68.1 mm (2.67 to 2.68 in.)

25.4 to 25.6 mm (1.00 to 1.01 in.)

57.4 to 57.6 mm (2.26 to 2.27 in.)

21.4 to 21.6 mm (0.843 to 0.850 in.)

15mm (0.59 in.)

115 mm (4.53 in.)

103.4 to 103.6 mm (4.071 to 4.078 in.)

47.4 to 47.6 mm (1.866 to 1.874 in.)

44.9 to 45.1 mm (1.77 to 1.78 in.)

15.4 to 15.6 mm (0.607 to 0.614 in)

83.6 to 84.1 mm dia. (3.30 to 3.31 in. dia.)

72.15 to 72.45 mm dia. (2.841 to 2.852 in. dia.)

4.9 mm (0.19 in.)

33.9 to 34.1 mm (1.33 to 1.34 in.)

5.3 to 5.7 mm (0.21 to 0.22 in.)

11.7 to 11.9 mm (0.461 to 0.468 in.)

2.3536 to 2.3588 rad (134.85 to 135.15

°

)

1.569 to 1.573 ra (89.85 to 90.15

°

)

0.4338 to 0.4389 rad (24.85 to 25.15

°

)

6 X 8.2 mm dia. (6 X 0.32 in. dia.)


G GENERAL

W1207119

G-53



9. TIRES

[1] TIRE PRESSURE

CAUTION

• Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment.

• Always maintain the correct tire pressure.

Do not inflate tires above the recommended pressure as shown below.

■

IMPORTANT

• Do not use tires larger than specified.

Front

Rear

Tire sizes

16 x 7.50-8, 4PR

23 x 10.50-12, 4PR

Inflation pressure

200 kPa (2.0 kgf/cm

2

, 29 psi)

140 kPa (1.4 kgf/cm

2

, 20 psi)

Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time.

Thus, check it everyday and inflate as necessary.

[2] TREAD

The tread can not be adjusted.

■

IMPORTANT

• Do not turn discs to obtain wider tread.

• Always attach tires as shown in the drawing.

• If not attached as illustrated, transmission parts may be damaged.

■

NOTE

• Use the tapered bolts for wheels with beveled or tapered holes.

Front

16 x 7.50 - 8, 4PR

Rear

23 x 10.50 - 12, 4PR

A : 825 mm (32.5 in.) B : 800 mm (31.5 in.)

G-54



10. IMPLEMENT LIMITATIONS

The KUBOTA Machine has been thoroughly tested for proper performance with implements sold or approved by

KUBOTA. Use of implements which are not sold or approved by KUBOTA and which exceed the maximum specifications listed below, or which are otherwise unfit for use with the KUBOTA Machine may result in malfunctions or failures of the machine, damage to other property and injury to the operator or others. [Any malfunctions or failures of the machine resulting from use with improper implements are not covered by the warranty.]

Front axle Wf

300 kg (661 lbs)

Maximum axle loading weight

Rear axle Wr

500 kg (1102 lbs)

Total gross weight

700 kg (1543 lbs)

G-55


1

ENGINE


MECHANISM

CONTENTS

1. ENGINE BODY ............................................................................................. 1-M1

[1] HALF-FLOATING HEAD COVER .......................................................... 1-M1

[2] CLOSED BREATHER............................................................................. 1-M1

2. LUBRICATING SYSTEM .............................................................................. 1-M2

3. COOLING SYSTEM ...................................................................................... 1-M3

4. FUEL SYSTEM ............................................................................................. 1-M2

[1] FUEL LINE .............................................................................................. 1-M4


GR2100EC2, WSM

1. ENGINE BODY

[1] HALF-FLOATING HEAD COVER

ENGINE

The rubber packing is fitting in to maintain the head cover 0.5 mm (0.02 in.) or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head.

(1) Cylinder Head Cover (2) Rubber Packing

W1012749

[2] CLOSED BREATHER

Closed breather system has been adopted to prevent the release of blowby gas into the atmosphere.

After its oil content is filtered by oil shield (4), the blowby gas is fed back to the intake manifold through breather valve (3) to be used for re-combustion.

(1) Breather Hose

(2) Cylinder Head Cover

(3) Breather Valve

(4) Oil Shield

(5) Rubber Packing

W1012858

1-M1


GR2100EC2, WSM

2. LUBRICATING SYSTEM

ENGINE

(1) Rocker Arm

(2) Oil Pressure Switch

(3) Rocker Arm Shaft

(4) Valve

(5) Idle Gear

(6) Crankshaft

(7) Oil Pump

(8) Oil Strainer

(9) Relief Valve

(10) Push Rod

(11) Tappet

(12) Camshaft

(13) Piston

(14) Connecting Rod

(15) Oil Filter Cartridge

W1013007

This engine's lubricating system consists of oil strainer (8), oil pump (7), relief valve (9), oil filter cartridge (15) and oil pressure switch (2).

The oil pump sucks lubricating oil from the oil pan through the oil strainer and the oil flows down to the filter cartridge, where it is further filtered. Then the oil is forced to crankshaft (6), connecting rods (14), idle gear (5), camshaft (12) and rocker arm shaft (3) to lubricate each part.

Some part of oil, splashed by the crankshaft or leaking and dropping from gaps of each part, lubricates these parts: piston (13), cylinders, small ends or connecting rods, tappets (11), push rods (10), inlet and exhaust valves (4) and timing gears.

1-M2


GR2100EC2, WSM

3. COOLING SYSTEM

ENGINE

(1) Radiator

(2) Water Pump

(3) Cooling Fan

(4) Thermostat

(5) Cylinder Head

(6) Cylinder Block

W1013330

The cooling system consists of a radiator (1), a centrifugal water pump (2), a cooling fan (3) and a thermostat (4).

The coolant is cooled through the radiator core, and the cooling fan (3) set behind the radiator (1) pushes cooling air through the radiator core to improve cooling.

The water pump receives water from the radiator or from the cylinder head and force it into the cylinder block.

The thermostat opens or closes according to the water temperature. When the water temperature is high, the thermostat opens to allow the water to flow from the cylinder head to the radiator. When the water temperature is low, the thermostat close to flow the water only to the water pump.

1-M3


GR2100EC2, WSM

4. FUEL SYSTEM

[1] FUEL LINE

ENGINE

(1) Injection Nozzle

(2) Fuel Overflow Pipe

(3) Fuel Tank

(4) Fuel Filter

(5) Fuel Feed Pump

(6) Fuel Filter

(7) Injection Pump

(8) Injection Pipe

W1013581

Fuel from the fuel tank (3) passes through the fuel filter (4), and then enters the injection pump (7) after impurities such as dirt, water, etc. are removed.

The fuel pressurized by the injection pump to the opening pressure (13.73 to 14.71 MPa, 140 to 150 kgf/cm

2

, 1990 to 2133 psi), of the injection nozzle (1) is injected into the combustion chamber.

Part of the fuel fed to the injection nozzle (1) lubricates the moving parts of the needle valve inside the nozzle, then returns to the fuel tank through the fuel overflow pipe (2) from the upper part of the nozzle holder.

1-M4


SERVICING

CONTENTS

1. TROUBLESHOOTING ....................................................................................1-S1

2. SERVICING SPECIFICATIONS ....................................................................1-S4

3. TIGHTENING TORQUES ..............................................................................1-S9

4. CHECKING, DISASSEMBLING AND SERVICING....................................1-S10

[1] CHECKING AND ADJUSTING .............................................................1-S10

(1) Engine Body......................................................................................1-S10

(2) Lubricating System ...........................................................................1-S13

(3) Cooling System .................................................................................1-S13

(4) Fuel System ......................................................................................1-S16

[2] PREPARATION ......................................................................................1-S20

(1) Separating Engine ............................................................................1-S20

[3] DISASSEMBLING AND ASSEMBLING................................................1-S24

(1) Cylinder Head and Valves ................................................................1-S24

(2) Oil Pan, Timing Gears, Camshaft and Fuel Camshaft ......................1-S27

(3) Pistons and Connecting Rods...........................................................1-S32

(4) Crankshaft.........................................................................................1-S34

(5) Waterpump .......................................................................................1-S37

(6) Injection Nozzle.................................................................................1-S38

[4] SERVICING ............................................................................................1-S38

(1) Cylinder Head and Valve ..................................................................1-S38

(2) Timing Gear, Camshaft and Fuel Camshaft .....................................1-S45

(3) Piston and Connecting Rod ..............................................................1-S47

(4) Crankshaft.........................................................................................1-S51

(5) Cylinder .............................................................................................1-S55

(6) Oil Pump ...........................................................................................1-S56


GR2100EC2, WSM ENGINE

1. TROUBLESHOOTING

Symptom

Engine Does Not

Start

(Starter Does Not

Run)

Probable Cause Solution

No fuel

Air in the fuel system

Water in the fuel system

Replenish fuel

Bleed

Change fuel and repair or replace fuel system

Clean Fuel pipe clogged

Fuel filter clogged

Excessively high viscosity of fuel or engine oil at low temperature

Change

Use specified fuel or engine oil

Fuel with low cetane number Use specified fuel

Fuel leak due to loose injection pipe retaining nut Tighten retaining nut

Incorrect injection timing

Fuel camshaft worn

Injection nozzle clogged

Injection pump malfunctioning

Seizure of crankshaft, camshaft, piston, cylinder or bearing

Compression leak from cylinder

Adjust

Replace

Repair or replace

Replace

Repair or replace

Improper valve timing

Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder

Correct or replace timing gear

Replace Piston ring and cylinder worn

Excessive valve clearance

Battery discharged

Starter malfunctioning

Main switch malfunctioning

PTO switch defective

Brake switch defective

Seat switch defective

Slow blow fuse blown

Wiring disconnected

Adjust

Charge

Repair or replace

Replace

Replace

Replace

Replace

Replace

Connect

Reference

Page

G-8

G-42

G-15, 39

G-28

G-28, 35

G-8

G-8

1-S24

1-S16

–

1-S38

1-S28

–

1-S10

1-S30

1-S49, 55

1-S12

G-25

7-S18

7-S6, 7

7-S10

7-S10

7-S11

G-39

–

W1014322


1-S1


Symptom

Engine Revolution Is

Not Smooth

Either White or Blue

Exhaust Gas Is

Observed

Either Black or Dark

Gray Exhaust Gas Is

Observed

Deficient Output

Excessive Lubricant

Oil Consumption

Fuel Mixed into

Lubricant Oil


Fuel filter clogged or dirty

Air cleaner clogged

Replace

Clean or replace

Fuel leak due to loose injection pipe retaining nut Tighten retaining nut

Injection pump malfunctioning Replace

Incorrect nozzle injection pressure

Injection nozzle stuck or clogged

Adjust

Repair or replace

Governor malfunctioning

Excessive engine oil

Repair

Reduce to specified level

Piston ring and cylinder worn or stuck


Deficient compression

Overload

Low grade fuel used

Fuel filter clogged

Air cleaner clogged

Deficient nozzle injection


Engine's moving parts seem to be seizing

Uneven fuel injection

Repair or replace

Adjust

Adjust top clearance

Reduce the load

Use specified fuel

Replace

Clean or replace

Repair or replace nozzle

Adjust

Repair or replace


Compression leak

Piston ring's gap facing the same direction

Oil ring worn or stuck

Piston ring groove worn

Valve stem and valve guide worn

Oil leaking due to defective seals or packing

Injection pump's plunger worn


Injection pump broken

Replace injection pump


Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder

Shift ring gap direction

Replace

Replace piston

Replace

Replace

Replace injection pump


Replace

Reference

Page

G-28, 35

G-20, 36

1-S24

1-S28

1-S19

1-S38

–

G-8, 14

1-S49, 55

1-S16

1-S11

–

G-8

G-35

G-20, 36

1-S38

1-S16

–

1-S28

1-S38

1-S10

1-S32

1-S33

1-S32, 49

1-S27, 40

–

1-S28

1-S38

1-S28

W1011327

1-S2


GR2100EC2, WSM

Symptom

Water Mixed into

Lubricant Oil

Low Oil Pressure

High Oil Pressure

Engine Overheated

Probable Cause

Head gasket defective

Cylinder block or cylinder head flawed

Engine oil insufficient

Oil strainer clogged

Oil filter clogged

Relief valve stuck with dirt

Relief valve spring weaken or broken

Excessive oil clearance of crankshaft bearing

Excessive oil clearance of crankpin bearing

Excessive oil clearance of rocker arm

Oil passage clogged

Different type of oil

Oil pump defective

Different type of oil

Relief valve defective


Fan belt broken or tensioned improperly

Coolant insufficient

Radiator net and radiator fin clogged with dust

Inside of radiator corroded

Coolant flow route corroded

Radiator cap defective

Radiator hose damaged

Overload running

Head gasket defective


Unsuitable fuel used

ENGINE

Solution

Replace

Replace

Replenish

Clean

Replace

Clean

Replace

Replace

Replace

Replace

Clean

Use specified type of oil

Repair or replace

Use specified type of oil

Replace

Replenish

Replace or adjust

Reference

Page

1-S26

–

G-8, 14

–

G-30

–

–

1-S53, 54

1-S52

1-S43

–

G-8

1-S31

G-8

Replenish

Clean

Clean or replace

Clean or replace

Replace

Replace

Reduce the load

Replace

Adjust

Use specified fuel

–

G-8

G-29,

1-S13

G-8

–

G-36

G-36

1-S15

G-32

–

1-S26

1-S16

G-8

W1011747

1-S3


GR2100EC2, WSM

2. SERVICING SPECIFICATIONS

ENGINE BODY

Item

Compression Pressure –

Variance Among

Cylinder

Factory Specification

2.84 to 3.24 MPa

29.0 to 33.0 kgf/cm

2

412 to 469 psi

–

Top Clearance

Valve Clearance (Cold)

Cylinder Head Surface

Valve Recessing (Intake and Exhaust)

Valve Stem to Valve Guide

Valve Seat

Valve Face

Valve Spring

Flatness

Clearance

Valve Stem

(O.D.)

Valve Guide

(I.D.)

Width

Angle

Angle

Free Length

Tilt

0.50 to 0.70 mm

0.0197 to 0.0276 in.

0.145 to 0.185 mm

0.00571 to 0.00728 in.

–

-0.10 to 0.10 mm

-0.0039 to 0.0039 in.

0.030 to 0.057 mm

0.00118 to 0.00224 in.

5.968 to 5.980 mm

0.23496 to 0.23543 in.

6.010 to 6.025 mm

0.23661 to 0.23720 in.

2.12 mm

0.0835 in.

0.785 rad

45

°

0.785 rad

45

°

31.3 to 31.8 mm

1.232 to 1.252 in.

–

Rocker Arm to Rocker Arm Shaft

Push Rod

Setting Load

Setting Length

Oil Clearance

Rocker Arm Shaft

(O.D.)

Rocker Arm

(I.D.)

Alignment

64.7 N

6.6 kgf

14.6 lbs

27.0 mm

1.063 in.

0.016 to 0.045 mm

0.00063 to 0.00177 in.

10.473 to 10.484 mm

0.41232 to 0.41276 in.

10.500 to 10.518 mm

0.41339 to 0.41410 in.

–

ENGINE

Allowable Limit

2.26 MPa

23.0 kgf/cm

2

327 psi

10 % or less

–

–

–

28.4 mm

1.118 in.

1.2 mm

0.047 in.

54.9 N

5.6 kgf

12.3 lbs

–

0.15 mm

0.0059 in.

–

0.05 mm

0.0020 in.

0.30 mm

0.0118 in.

0.10 mm

0.0039 in.

–

–

–

–

–

0.25 mm

0.0098 in.

W1013874


1-S4

GR2100EC2, WSM

ENGINE BODY (Continued)

Tappet to Tappet Guide

Timing Gear

Idle Gear

Camshaft

Piston Pin Bore

Item

Camshaft Journal to Cylinder Block Bore

Idle Gear Shaft to Idle Gear Bushing

ENGINE

Clearance

Tappet

(O.D.)

Tappet Guide Bore

(I.D.)

Idle Gear to Crank

Gear

(Backlash)

Idle Gear to Cam

Gear

(Backlash)

Idle Gear to

Injection Pump

Gear

(Backlash)

Oil Pump Drive

Gear to Crank

Gear

(Backlash)

Side Clearance


0.016 to 0.052 mm

0.00063 to 0.00205 in.

17.966 to 17.984 mm

0.70732 to 0.70803 in.

18.000 to 18.018 mm

0.70866 to 0.70937 in.

0.043 to 0.124 mm

0.00169 to 0.00488 in.

0.047 to 0.123 mm

0.00185 to 0.00484 in.

0.046 to 0.124 mm

0.00185 to 0.00488 in.

0.041 to 0.123 mm

0.00161 to 0.00484 in.

Side Clearance

Alignment

0.20 to 0.51 mm

0.0079 to 0.0201 in.

0.15 to 0.31 mm

0.0059 to 0.0122 in.

–

Cam Height

(Intake and

Exhaust)

Oil Clearance

26.88 mm

1.0583 in.

Camshaft Journal

(O.D.)

Cylinder Block

Bore

(I.D.)

Oil Clearance

0.050 to 0.091 mm

0.00197 to 0.00358 in.

32.934 to 32.950 mm

1.29661 to 1.29724 in.

33.000 to 33.025 mm

1.29921 to 1.30020 in.

Idle Gear Shaft

(O.D.)

Idle Gear Bushing

(I.D.)

I.D.

0.020 to 0.084 mm

0.00079 to 0.00331 in.

19.967 to 19.980 mm

0.78610 to 0.78661 in.

20.000 to 20.051 mm

0.78740 to 0.78941 in.

20.000 to 20.013 mm

0.78740 to 0.78791 in.

Allowable Limit

0.10 mm

0.0039 in.

–

–

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.80 mm

0.0315 in.

0.50 mm

0.0197 in.

0.01 mm

0.0004 in.

26.83 mm

1.0563 in.

0.15 mm

0.0059 in.

–

–

0.10 mm

0.0039 in.

–

–

20.05 mm

0.7894 in.

W1012561

1-S5


GR2100EC2, WSM


(Spare Parts)

Piston Ring Gap

Connecting Rod

Crankshaft

Item

Piston Pin to Small End Bushing

Piston Pin to Small End Bushing

Piston Pin to Piston Ring Groove

ENGINE

Oil Clearance

Piston Pin

(O.D.)

Small End Bushing

(I.D.)

Oil Clearance

Small End Bushing

(I.D.)

Top Ring

Second Ring

Oil Ring

Second Ring

(Clearance)

Oil Ring

(Clearance)

Alignment


0.014 to 0.038 mm

0.00055 to 0.00150 in.

20.002 to 20.011 mm

0.78748 to 0.078783 in.

20.025 to 20.040 mm

0.78839 to 0.78897 in.

0.015 to 0.075 mm

0.00059 to 0.00295 in.

20.026 to 20.077 mm

0.78845 to 0.79043 in.

0.15 to 0.30 mm

0.0059 to 0.0118 in.

0.30 to 0.45 mm

0.0118 to 0.0177 in.

0.15 to 0.30 mm

0.0059 to 0.0118 in.

0.090 to 0.120 mm

0.00354 to 0.00472 in.

0.04 to 0.08 mm

0.0016 to 0.0031 in.

–

Allowable Limit

0.10 mm

0.0039 in.

–

–

0.15 mm

0.0059 in.

–

Side Clearance

Alignment

0.15 to 0.31 mm

0.0059 to 0.0122 in.

–

1.20 mm

0.0472 in.

1.20 mm

0.0472 in.

1.20 mm

0.0472 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.05 mm

0.0020 in.

0.50 mm

0.0197 in.

0.02 mm

0.0008 in.

0.15 mm

0.0059 in.

–

Crankpin to Crankpin Bearing Oil Clearance

Crankpin

(O.D.)

Crankpin Bearing

(I.D.)

Oil Clearance Crankshaft Journal to Crankshaft Bearing

1

Crankshaft Journal

(O.D.)

Crankshaft

Bearing 1

(I.D.)

Oil Clearance Crankshaft Journal to Crankshaft Bearing

2

(Flywheel Side)

Crankshaft Journal

(O.D.)

Crankshaft

Bearing 2

(I.D.)

0.020 to 0.051 mm

0.00079 to 0.00201 in.

33.959 to 33.975 mm

1.33697 to 1.33760 in.

33.995 to 34.010 mm

1.33893 to 1.33898 in.

0.034 to 0.106 mm

0.00134 to 0.00417 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.984 to 40.040 mm

1.57417 to 1.57638 in.

0.028 to 0.059 mm

0.00110 to 0.00232 in.

43.934 to 43.950 mm

1.72968 to 1.73031 in.

43.978 to 43.993 mm

1.73142 to 1.73201 in.

–

0.20 mm

0.0079 in.

–

–

0.20 mm

0.0079 in.

–

–

W1012878

1-S6


GR2100EC2, WSM


Item

Crankshaft Journal to Crankshaft Bearing

3

(Intermediate)

Oil Clearance

Cylinder Liner

Crankshaft Journal

(O.D.)

Crankshaft

Bearing 3

(I.D.)

I.D.


0.028 to 0.059 mm

0.00110 to 0.00232 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.978 to 39.993 mm

1.57394 to 1.57453 in.

Cylinder Liner

(Oversize)

I.D.

67.000 to 67.019 mm

2.63779 to 2.63854 in.

67.250 to 67.269 mm

2.64764 to 2.64839 in.

ENGINE

Allowable Limit

0.20 mm

0.0079 in.

–

–

67.169 mm

2.6445 in.

67.419 mm

2.65429 in.

W1013251

LUBRICATING SYSTEM

Engine Oil Pressure At Idle Speed –

Oil Pump

At Rated Speed

Inter Rotor to

Outer Rotor

(Clearance)

Outer Rotor to

Pump Body

(O.D.)

Inter Rotor to

Cover

(I.D.)

More than 49 MPa

0.5 kgf/cm

2

7 psi

196 to 441 MPa

2.0 to 4.5 kgf/cm

2

28 to 64 psi

0.03 to 0.14 mm

0.0012 to 0.0055 in.

0.07 to 0.15 mm

0.0028 to 0.0059 in.

0.075 to 0.135 mm

0.00295 to 0.00531 in.

147 MPa

1.5 kgf/cm

2

21 psi

–

–

–

W1013973

1-S7


GR2100EC2, WSM

COOLING SYSTEM

Fan Belt

Thermostat

Item

Radiator Cap

Radiator

FUEL SYSTEM

Injection Pump

Pump Element

Delivery Valve

Fuel Injection Nozzle

ENGINE

Tension

Valve Opening

Temperature

(At Beginning)

Valve Opening

Temperature

(Opened

Completely)

Pressure Falling

TIme


7 to 9 mm / 98 N

0.28 to 0.35 in. / 98N

(10 kgf, 22 lbs)

69.5 to 72.5

°

C

157.1 to 162.5

°

F

85

°

C

185

°

F

Allowable Limit

–

–

–

Water Leakage

Test Pressure

10 seconds or more

88

→

59 kPa

0.9

→

0.6 kgf/cm

2

13

→

9 psi

No leak at specified pressure

157 kPa

1.6 kgf/cm

2

23 psi

–

–

W1013687

Injection Timing 0.28 to 0.31 rad

(16 to 18

°

) before T.D.C.

–

–

Fuel Tightness

Fuel Tightness

140

10 seconds

13.73

→

→

1991

12.75 MPa

130 kgf/cm

→

1849 psi

2

Injection Pressure

Valve Seat

Tightness

13.73 to 14.71 MPa

140 to 150 kgf/cm

2

1991 to 2134 psi

When the pressure is

12.75 MPa

(130 kgf/cm

2

, 1849 psi), the valve seat must be fuel tightness

13.7 MPa

140 kgf/cm

2

1991 psi

5 seconds

13.73

→

12.75 MPa

140

→

130 kgf/cm

2

1991

→

1849 psi

–

–

W1013792

1-S8




Tightening torques of screws and nuts on the table below are especially specified.

(For general use screws and nuts : Refer to “5. TIGHTNING TORQUES” at “G. GENERAL” section.)

Item

Front coupling mounting screw

Engine mounting nut

Air cleaner stay screw

Engine support screw

*Cylinder head cover screw

Injection pipe retaining nut

Overflow pipe retaining nut

Nozzle holder assembly

Glow plug

*Rocker arm bracket screw

*Cylinder head screw

*Fan drive pulley screw

*Idle gear shaft mounting screw

*Connecting rod screw

*Flywheel screw

Bearing case cover mounting screw

*Main bearing case screw 2

*Main bearing case screw 1

Nozzle holder

Oil pressure switch

Size x Pitch

M8 x 1.25

M8 x 1.25

M8 x 1.25

M10 x 1.25

M6 x 1.0

M12 x 1.5

M12 x 1.5

M20 x 1.5

M8 x 1.0

M6 x 1.0

M8 x 1.25

M12 x 1.5

M6 x 1.0

M7 x 0.75

M10 x 1.25

M6 x 1.0

M7 x 1.0

M6 x 1.0

N·m

23.5 to 27.4

23.5

23.5 to 27.4

48.1 to 55.9

6.86 to 11.3

24.5 to 34.3

19.6 to 24.5

49.0 to 68.6

7.85 to 14.7

9.8 to 11.3

37.3 to 42.2

98.0 to 107.8

9.8 to 11.3

26.5 to 30.4

53.9 to 58.8

9.8 to 11.3

26.5 to 30.4

12.7 to 15.7

34.3 to 39.2

14.7 to 19.6

kgf·m

2.4 to 2.8

2.4

2.4 to 2.8

4.9 to 5.7

0.7 to 1.15

2.5 to 3.5

2.0 to 2.5

5.0 to 7.0

0.8 to 1.5

1.00 to 1.15

3.8 to 4.3

10.0 to 11.0

1.00 to 1.15

2.7 to 3.1

5.5 to 6.0

1.00 to 1.15

2.7 to 3.1

1.3 to 1.6

3.5 to 4.0

1.5 to 2.0

ft-lbs

17.4 to 20.3

17.4

17.4 to 20.3

35.4 to 41.2

5.1 to 8.3

18.1 to 25.3

14.5 to 18.1

36.2 to 50.6

5.8 to 10.8

7.2 to 8.3

27.5 to 31.1

72.3 to 79.5

7.2 to 8.3

19.5 to 22.4

39.8 to 43.4

7.2 to 8.3

19.5 to 22.4

9.4 to 11.6

25.3 to 28.9

10.8 to 14.5

PT1/8

■

NOTE

• In removing and applying the screws and nuts marked with "*", a pneumatic wrench or similar pneumatic tool, if employed, must be used with enough care not to get them seized.

• For "*" marked screws and nuts on the table, apply engine oil to their threads and seats before tightening.

• The letter "M" in Size x Pitch means that the screw or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads.

W1013236

1-S9



4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING

(1) Engine Body

Compression Pressure

1. Run the engine until it is warmed up.

2. Stop the engine.

3. Disconnect the 2P connector from the fuel pump.

4. Remove the air cleaner, the muffler and all injection nozzles.

5. Disconnect the accelerator wire.

6. Engage the parking brake.

7. Set a compression tester (Code No.: 07909-30208) with the adaptor (Adaptor H, Code No.: 07909-31231) to the nozzle hole.

8. While cranking the engine with the starter, measure the compression pressure.

9. Repeat steps 7 and 8 for each cylinder.

10.If the measurement is below the allowable limit, apply a small amount of oil to the cylinder wall through the nozzle hole and measure the compression pressure again.

11.If the compression pressure is still less than the allowable limit, check the top clearance, valve clearance and cylinder head.

12.If the compression pressure increases after applying oil, check the cylinder wall and piston rings.

■

NOTE

• Check the compression pressure with the specified valve clearance.

• Always use a fully charged battery for performing this test.

• Variances in cylinder compression values should be under

10 %.

Compression pressure

Factory spec.

Allowable limit

2.84 to 3.24 MPa

29.0 to 33.0 kgf/cm

2

412 to 469 psi

2.26 MPa

23.0 kgf/cm

2

327psi

W1010662

1-S10



Top Clearance

1. Remove the cylinder head. (Do not attempt to remove the cylinder head gasket.).

2. Move the piston up, and stick a strip of fuse [1.5 mm dia. (0.059

in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the piston head at three positions with grease so as to avoid the intake and exhaust valves and the combustion chamber ports.

3. Lower the piston, and install the cylinder head and tighten the cylinder head screws to the specified torque.

4. Turn the flywheel until the piston exceeds its top dead center.

5. Remove the cylinder head, and measure the thickness of the squeezed fuses.

6. If the measurement is not within the factory specifications, check the oil clearance between the crankpin and crankpin bearing and between the piston pin and small end bushing.

■

NOTE

• After checking the top clearance, be sure to assemble the cylinder head with a new cylinder head gasket.

Top clearance Factory spec.

0.50 to 0.70 mm

0.0197 to 0.0276 in.

Tightening torque Cylinder head screw

37.3 to 42.2 N·m

3.8 to 4.3 kgf·m

27.5 to 31.1 ft-lbs

(1) Fuse

W1015675

1-S11



Checking Valve Clearance

■

IMPORTANT

• The valve clearance must be checked and adjusted when engine is cold.

1. Remove the cylinder head cover (1) and the glow plugs.

2. Align the "1TC" mark (2) on the flywheel and alignment mark (3) on the rear end plate so that the No. 1 piston comes to the compression top dead center.

3. Check the following valve clearance marked with "

★

" using a thickness gauge.

4. If the clearance is not within the factory specifications, adjust with the adjusting screw.

5. Then turn the flywheel 6.28 rad (360

°

), and align the "1TC" mark

(2) on the flywheel and alignment mark (3) on the rear end plate so that the No.1 piston comes to the overlap position.

6. Check the following valve clearance marked with "

✩

" using a thickness gauge.

Cylinder No.

Intake valve

No.1

★

No.2

✩

No.3

★

Exhaust valve

★ ★ ✩

★

: When No.1 piston is at the compression top dead center position.

✩

: When No.1 piston is at the overlap position.

7. If the clearance is not within the factory specifications, adjust with the adjusting screw.

Intake and exhaust valve clearance (Cold)

Factory spec.

0.145 to 0.185 mm

0.00571 to 0.00728 in.

■

NOTE

• The sequence of cylinder numbers is given as No.1, No.2

and No.3 starting from the gear case side.

• After adjusting the valve clearance, secure the adjusting screw with the lock nut.

(1) Cylinder Head Cover

(2) "1TC" Mark

(3) Alignment Mark

A : Gear Case Side

W1016777

1-S12


GR2100EC2, WSM

(2) Lubricating System

(3) Cooling System

ENGINE

Engine Oil Pressure

1. Remove the engine oil pressure switch, and set an oil pressure tester (Code No.: 07916-32032).

2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.

3. If the oil pressure is less than the allowable limit, check the following.

• Engine oil insufficient.

• Oil pump defective

• Oil strainer clogged

• Oil filter cartridge clogged

• Oil gallery clogged

• Excessive oil clearance

• Foreign matter in the relief valve

At idle speed

Factory spec.

More than 49 kPa

0.5 kgf/cm

2

7 psi

Engine oil pressure

At rated speed

Factory spec.

Allowabl e limit

196 to 441 kPa

2.0 to 4.5 kgf/cm

2

28 to 64 psi

147 kPa

1.5 kgf/cm

2

21 psi

(When reassembling)

• After checking the engine oil pressure, tighten the engine oil pressure switch to the specified torque.

W1028313

Checking Fan Drive Belt Tension

CAUTION

• Be sure to stop the engine and remove the key before checking belt tension.

1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley (1) and dynamo pulley (2) at specified force

(98 N, 10 kgf, 22 lbs).

2. If the measurement is not within the factory specifications, loosen the dynamo mounting screws and relocate the dynamo to adjust.

Deflection (A) Factory spec.

7 to 9 mm

0.28 to 0.35 in.

(1) Fan Drive Pulley (2) Dynamo Pulley

W1020731

1-S13



Fan Belt Damage and Wear

1. Check the fan belt for damage.

2. If the fan belt is damaged, replace it.

3. Check if the fan belt is worn and sunk in the pulley groove.

4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.

(A) Good (B) Bad

W1021898

Thermostat Valve Opening Temperature

1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat.

2. Heating the water gradually, read the temperature when the valve opens and leaves the string.

3. Continue heating and read the temperature when the valve opens approx. 6 mm (0.236 in.).

4. If the measurement is not within the factory specifications, replace the thermostat.

Thermostat's valve opening temperature

Temperature at which thermostat completely opens

Factory spec.

Factory spec.

69.5 to 72.5

°

C

157.1 to 162.5

°

F

85

°

C

185

°

F

W1023486

1-S14



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 Cap Air Leakage

1. Set a radiator tester (1) and adaptor (2) (BANZAI Code No.: RCT-

2A-30S) on the radiator cap.

2. Apply the specified pressure 88 kPa, (0.9 kgf/cm

2

, 13 psi), and measure the time for the pressure to fall to 59 kPa (0.6 kgf/cm

2

,

9 psi).

3. If the measurement is less than the factory specification, replace the radiator cap.

Pressure falling time Factory spec.

More than 10 seconds for pressure fall from

88 to 59 kPa

(from 0.9 to 0.6 kgf/cm

2 from 13 to 9 psi)

(1) Radiator Tester (2) Adaptor

W1023993

Radiator Water Leakage

1. Pour a specified amount of water into the radiator.

2. Set a radiator tester (1) (Code No.: 07909-31551) and an adaptor

(2) (BANZAI Code No.: RCT-2A-30S) and raise the water pressure to the specified pressure.

3. Check the radiator for water leaks.

4. For water leak from the pinhole, repair with the radiator cement.

When water leak is excessive, replace the radiator.

Radiator water leakage test pressure

Factory spec.

157 kPa

1.6 kgf/cm

2

23 psi

(1) Radiator Tester (2) Adaptor

W1024517

1-S15


GR2100EC2, WSM

(4) Fuel System

ENGINE

Injection Timing

1. Remove the injection pipes.

2. Remove the engine stop solenoid.

3. Turn the flywheel counterclockwise (facing the flywheel) until fuel flows from the delivery valve holder.

4. Continue to turn the flywheel slowly, and stop it as soon as the fuel level at the tip of the delivery valve holder begins to increase.

5. Check to see if the timing angle lines on the flywheel is aligned with the alignment mark (2).

6. If the injection timing is out of adjustment, readjust the timing with shims.

Injection timing Factory spec.

0.28 to 0.31 rad

(16 to 18

°

) before T.D.C.

■

NOTE

• The sealant is applied to both sides of the shim (soft metal gasket shim). The liquid gasket is not required for assembling.

• Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25

mm (0.0098 in.) and 0.30 mm (0.0118 in.). Combine these shims for adjustments.

• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5

°

).

• In disassembling and replacing the injection pump, be sure to use the same number of new shims with the same thickness.

• Refer to figure below to check the thickness of the shims.

(1) Timing Line

(2) Alignment Mark

(3) Shim (Soft Metal Gasket Shim)

(4) Two-holes : 0.20 mm (0.0079 in.)

(5) One-holes : 0.25 mm (0.0098 in.)

(6) Without hole : 0.30 mm (0.0118 in.)

W1019047

1-S16



Fuel Tightness of Pump Element


2. Remove the injection pipes and glow plugs.

3. Install the injection pump pressure tester to the injection pump.

4. Install the injection nozzle (1) jetted with the proper injection pressure to the injection pump pressure tester (2). (Refer to the figure.)

5. Set the speed control lever to the maximum speed position.

6. Run the starter to increase the pressure.

7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.

Fuel tightness of pump element

Allowable limit

13.7 MPa

140 kgf/cm

2

1991 psi

■

NOTE

• Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.


(2) Injection Pump Pressure Tester

(3) Protection Cover for Jetted Fuel

W1027828

1-S17



Fuel Tightness of Delivery Valve


2. Remove the injection pipes and glow plugs.

3. Set a pressure tester to the fuel injection pump.

4. Install the injection nozzle (1) jetted with the proper injection pressure to the injection pump pressure tester (2).

5. Run the starter to increase the pressure.

6. Stop the starter when the fuel jets from the injection nozzle.

After that, turn the flywheel by the hand and raise the pressure to approx. 13.73 MPa (140 kgf/cm

2

, 1991 psi).

7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13.73 to 12.75 MPa (from 140 to 130 kgf/cm

2

, from 1991 to 1849 psi).

8. Measure the time needed to decrease the pressure from 13.73 to

12.75 MPa (from 140 to 130 kgf/cm

2

, from 1991 to 1849 psi).

9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.

Fuel tightness of delivery valve

Factory spec.

Allowable limit

10 seconds

13.73

→

12.75 MPa

140

→

130 kgf/cm

1991

→

1849 psi

2

5 seconds

13.73

→

12.75 MPa

140

→

130 kgf/cm

1991

→

1849 psi

2

■

NOTE

• Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.


(2) Injection Pump Pressure Tester

(3) Protection Cover for Jetted Fuel

W1028381

1-S18



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.

Nozzle Spraying Condition

1. Set the injection nozzle to a nozzle tester (Code No.: 07909-

31361), and check the nozzle spraying condition.

2. If the spraying condition is defective, replace the nozzle piece.

(a) Good (b) Bad

W1028951

Fuel Injection Pressure


31361).

2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.

3. If the measurement is not within the factory specifications, replace the adjusting washer (1) in the nozzle holder to adjust it.

Fuel injection pressure Factory spec.

(Reference)

• Pressure variation with 0.01 mm (0.0004 in.) difference of adjusting washer thickness.

Approx. 235 kPa (2.3 kgf/cm

2

, 34 psi)

(1) Adjusting Washer

13.73 to 14.71 MPa

140 to 150 kgf/cm

2

1991 to 2134 psi

W1029328

1-S19


GR2100EC2, WSM

[2] PREPARATION

(1) Separating Engine

ENGINE

Valve Seat Tightness


31361).

2. Raise the fuel pressure, and keep at 12.75 MPa (130 kgf/cm

2

,

1849 psi) for 10 seconds.

3. If any fuel leak is found, replace the nozzle piece.

Valve seat tightness Factory spec.

No fuel leak at

12.75 MPa

130 kgf/cm

2

1849 psi

W1030468

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. Open the radiator drain plug (2), and remove radiator cap (1) to completely drain the coolant.

2. After all coolant is drained, close the drain plug (2).

Coolant

Capacity (with recovery tank)

2.35 L

2.48 U.S.qts.

2.07 Imp.qts.

(1) Radiator Cap (2) Drain Plug

W1018574

1-S20



Draining Engine Oil

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. Remove the drain plug (1) to drain oil.

4. After draining, screw in the drain plug (1).

(When refilling)

• Fill the engine oil up to the upper line on the dipstick (3).

■

IMPORTANT

• Never mix two different type of oil.

• Use the proper SAE Engine Oil according to ambient temperature.

Refer to "4. LUBRICANTS, FUEL AND COOLANT" at "G.

GENERAL" section.

Engine Oil Capacity

2.8 L

2.96 U.S.qts.

2.46 Imp.qts.

(1) Drain Plug

(2) Oil Inlet

(3) Dipstick

A : Upper Level

B : Lower Level

W1032108

Battery

CAUTION

• When disconnecting the battery cables, disconnect the negative cable from the battery first. When connecting, connect the positive cable to the battery first.

1. Open the bonnet.

2. Remove the radiator net.

3. Disconnect the negative cable (1) from the battery.

4. Disconnect the positive cable (2) from the battery and remove the battery (3).

(1) Negative Cable

(2) Positive Cable

(3) Battery

W1033344

1-S21



Bonnet and Side Bonnet

1. Disconnect the connectors (5) from the head light.

2. Remove the wire harness (4) from the bonnet.

3. Remove the bonnet (1) with bonnet bracket (2).

4. Remove the side bonnet (3).

(1) Bonnet

(2) Bonnet Bracket

(3) Side Bonnet

(4) Wire Harness

(5) Connector

W1033805

Air Cleaner, Muffler, Fuel Hose and Wire Harness

1. Remove the air cleaner (1) and muffler (2).

2. Disconnect the fuel hoses (3).

3. Disconnect the accelerator wire (4).

4. Disconnect the wire harness (5).

(1) Air Cleaner

(2) Muffler

(3) Fuel Hose

(4) Accelerator Wire

(5) Wire Harness

W1034150

1-S22



Engine Assembly

1. Remove the radiator stopper snap pins (2).

2. Disconnect the front coupling (5).

3. Separate the engine assembly (6) with radiator from the frame

(3).


Tightening torque

Front coupling mounting screw

Engine mounting nut

23.5 to 27.4 N·m

2.4 to 2.8 kgf·m

17.4 to 20.3 ft-lbs

23.5 N·m

2.4 kgf·m

17.4 ft-lbs

(1) Radiator Stopper

(2) Radiator Stopper Snap Pin

(3) Frame

(4) Joint Pin

(5) Front Coupling

(6) Engine Assembly

W1034766

1-S23



[3] DISASSEMBLING AND ASSEMBLING

(1) Cylinder Head and Valves

Dynamo, Fan Belt and Radiator

1. Disconnect the radiator hoses and separate the radiator (1) with recovery tank (2) from engine assembly.

2. Remove the cooling fan (9) and fan pulley.

3. Remove the dynamo (3) and fan belt (4).

4. Remove the starter (6).

5. Disconnect the air cleaner stay (8) and engine stop solenoid.

6. Remove the wire bracket.

7. Remove the engine support LH (7) and RH (5).


• Check to see that there are no cracks on the belt surface.

■

IMPORTANT

• After reassembling the fan belt, be sure to adjust the fan belt tension.

Tightening torque

Air cleaner stay screw

Engine support screw

23.5 to 27.4 N·m

2.4 to 2.8 kgf·m

17.4 to 20.3 ft-lbs

48.1 to 55.9 N·m

4.9 to 5.7 kgf·m

35.4 to 41.2 ft-lbs

(1) Radiator

(2) Recovery Tank

(3) Dynamo

(4) Fan Belt

(5) Engine Support RH

(6) Starter

(7) Engine Support LH

(8) Air Cleaner Stay

(9) Cooling Fan

W1030916

Cylinder Head Cover

1. Remove the head cover screws (1).

2. Remove the cylinder head cover (2).


• Check to see if the cylinder head cover gasket is not defective.

Tightening torque Cylinder head cover screw

6.86 to 11.3 N·m

0.7 to 1.15 kgf·m

5.1 to 8.3 ft-lbs

(1) Head Cover Screws (2) Cylinder Head Cover

W1037527

Injection Pipes

1. Loosen the screw on the pipe clamp (1).

2. Detach the injection pipes (2).


• Sent compressed air into the pipes to blow out dust. Then, reassemble the pipes in the reverse order.

Tightening torque Injection pipe retaining nut

24.5 to 34.3 N·m

2.5 to 3.5 kgf·m

18.1 to 25.3 ft-lbs

(1) Pipe Clamp (2) Injection Pipe

W1038271

1-S24



Nozzle Holder Assembly and Glow Plugs

1. Remove the overflow pipe (1).

2. Remove the nozzle holder assemblies (2).

3. Remove the copper gasket (5) and the heat seal (6).

4. Remove the lead (3) from the glow plugs (4).

5. Remove the glow plugs (4).


• Replace the copper gasket and heat seal with new one.

Tightening torque



Glow plug

19.6 to 24.5 N·m

2.0 to 2.5 kgf·m

14.5 to 18.1 ft-lbs

49.0 to 68.6 N·m

5.0 to 7.0 kgf·m

36.2 to 50.6 ft-lbs

7.85 to 14.7 N·m

0.8 to 1.5 kgf·m

5.8 to 10.8 ft-lbs

(1) Overflow Pipe

(2) Nozzle Holder Assembly

(3) Lead

(4) Glow Plug

(5) Copper Gasket

(6) Heat Seal

W1038500

Rocker Arm and Push Rods

1. Remove the rocker arm bracket screws.

2. Detach the rocker arm assembly (1).

3. Remove the push rods (2).


• When putting the push rods (2) onto the tappets (3), check to see if their ends are properly engaged with the dimples.

■

IMPORTANT

• After installing the rocker arm, be sure to adjust the valve clearance.

Tightening torque Rocker arm bracket screw

9.8 to 11.3 N·m

1.00 to 1.15 kgf·m

7.2 to 8.3 ft-lbs

(1) Rocker Arm Assembly

(2) Push Rod

(3) Tappet

W1039359

1-S25



Cylinder Head

1. Loosen the pipe clamp, and remove the water return pipe.

2. Remove the cylinder head screw in the order of (n) to (a).

3. Lift up the cylinder head to detach.

4. Remove the cylinder head gasket and O-ring (1).


• Replace the cylinder head gasket with a new one.

• Securely fit the O-ring (1) to the pipe pin.

• Tighten the cylinder head screws after applying sufficient oil.

• Tighten the cylinder head screws diagonal sequence starting from the centre.

• Tighten them uniformly, or the head may deform in the long run.

• Retighten the cylinder head screws after running the engine for

30 minutes.

Tightening torque Cylinder head screw

37.3 to 42.2 N·m

3.8 to 4.3 kgf·m

27.5 to 31.1 ft-lbs

(1) O-ring

(n) to (a) :To Loosen

(a) to (n) :To Tighten

W1040055

Tappets

1. Remove the tappets (1) from the crankcase.


• Visually check the contact between tappets and cams for proper rotation. If defect is found, replace tappets.

• Before installing the tappets, apply engine oil thinly around them.

■

IMPORTANT

• Do not change the combination of tappet and tappet guide.

(1) Tappet

W1041259

1-S26



Valves

1. Remove the valve caps (2).

2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1).

3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6).

4. Remove the valve (7).


• Wash the valve stem seal and valve guide hole, and apply engine oil sufficiently.

• After installing the valve spring collets, lightly tap the stem to assure proper fit with a plastic hammer.

■

IMPORTANT

• Do not change the combination of valve and valve guide.

(1) Valve Spring Replacer

(2) Valve Cap

(3) Valve Spring Collet

(4) Valve Spring Retainer

(5) Valve Spring

(6) Valve Stem Seal

(7) Valve

W1041807

(2) Oil Pan, Timing Gears, Camshaft and Fuel Camshaft

Oil Pan and Oil Strainer

1. Remove the oil pan mounting screws (5).

2. Remove the oil pan (4) by lightly tapping the rim of the pan with a wooden hammer.

3. Remove the oil strainer (3).


• After cleaning the oil strainer, check to see that the filter mesh in clean, and install it.

• Visually check the O-ring (1), apply engine oil, and install it.

• Securely fit the O-ring to the oil strainer.

• To avoid uneven tightening, tighten oil pan mounting screws in diagonal order from the center.

• Using the hole (6) numbered "3", install the oil strainer by mounting screw.

■

IMPORTANT

• Scrape off the old adhesive completely. Wipe the sealing surface clean. Now apply new adhesive 3 to 5 mm (0.12 to

0.20 in.) thick all over the contact surface. Apply the adhesive also on the center of the flange as well as on the inner wall of each bolt hole.

• Cut the nozzle of the "liquid gasket" (Three Bond 1207D or equivalent) container at its second notch. Apply "liquid gasket" about 5 mm (0.20 in.) thick.

Within 20 minutes after the application of fluid sealant, reassemble the components. Wait then for about 30 minutes, and pour oil in the crankcase.

(1) O-ring

(2) Screw

(3) Oil Strainer

(4) Oil Pan

(5) Oil Pan Mounting Screws

(6) Hole

W1036246

1-S27



Injection Pump and Speed Control Plate

1. Remove the socket head screws and nuts, and remove the injection pump (3).

2. Remove the screws and separate the speed control plate (2), taking care not to damage the governor spring (4).

3. Disconnect the governor spring (4) and remove the speed control plate (2).


• Hook the governor spring (4) to the governor lever (5) first and install the speed control plate (2).

• Be sure to place the copper washers underneath two screws (1).

(Two screws (1) in the upper of the speed control plate (2).)

• Position the slot (9) on the fork lever just under the slot (8) on the crankcase.

• Insert the injection pump (3) so that the control rod (7) should be pushed by the idling adjusting spring (6) at its end and the pin

(10) on the rod engages with the slot (9) on the fork lever (as shown in the figure).

■

NOTE

• The sealant is applied to both sides of the soft metal gasket shim. The liquid gasket is not required for assembling.

• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5

°

).

• In disassembling and replacing, be sure to use the same number of new gasket shims with the same thickness.

(1) Screws and Copper Washers

(2) Speed Control Plate

(3) Injection Pump

(4) Governor Spring

(5) Governor Lever

(6) Idling Adjusting Spring

(7) Control Rod

(8) Slot (Crankcase Side)

(9) Slot (Fork Lever Side)

(10) Pin

W1043814

Fan Drive Pulley

1. Secure the flywheel to keep it from turning.

2. Remove the fan drive pulley screw.

3. Draw out the fan drive pulley with a puller.


• Install the pulley to the crankshaft, aligning the mark (1) on them.

• Apply engine oil to the fan drive pulley retaining screws. And tighten them.

Tightening torque Fan drive pulley screw

98.0 to 107.8 N·m

10.0 to 11.0 kgf·m

72.3 to 79.5 ft-lbs

(1) Alignment Mark

W1045048

1-S28



Gear Case

1. Remove the screw (1) of inside the gear case and outside screws

(6).

2. Disconnect the start spring (2) from the fork lever 1.

3. Remove the gear case (3).


• Apply a liquid gasket (Three Bond 1215 or equivalent) to both sides of the gear case gasket (4).

• Be sure to set three O-rings (5) inside the gear case.

(1) Screw (Inside)

(2) Start Spring

(3) Gear Case

(4) Gear Case Gasket

(5) O-rings

(6) Screw

W1045996

1-S29



Idle Gear

1. Remove the external snap ring (3), the collar (2) and the idle gear

(1).

2. Remove the idle gear shaft mounting screws (4).

3. Remove the idle gear shaft (5).


• Apply engine oil to the idle gear shaft mounting screw (4). And tighten them.

• Install the idle gear, aligning the mark (6) on the gears referring to the photo.

Tightening torque

Idle gear shaft mounting screw

9.8 to 11.3 N·m

1.00 to 1.15 kgf·m

7.2 to 8.3 ft-lbs

(1) Idle Gear

(2) Idle Gear Collar

(3) External Snap Ring

(4) Idle Gear Shaft Mounting Screw

(5) Idle Gear Shaft

(6) Alignment Mark

W1046512

Camshaft

1. Remove the camshaft mounting screws (1) and draw out the camshaft with gear (2) on it.


• When install the camshaft, apply engine oil to the camshaft journals.

• Apply engine oil to the camshaft mounting screws. And tighten them.

(1) Camshaft Mounting Screw (2) Camshaft Gear

W1048169

1-S30



Fuel Camshaft

1. Remove the retaining plate (1).

2. Remove the fork lever holder mounting screws (8), then draw out the injection pump gear (3) and fuel camshaft (2) with the governor fork assembly.


• Hook the governor spring (7) to the fork lever 2 (6) as shown in the figure before installing the fork lever assembly to the crankcase.

(1) Retaining Plate

(2) Fuel Camshaft

(3) Injection Pump Gear

(4) Governor Sleeve

(5) Fork Lever 1

(6) Fork Lever 2

(7) Governor Spring

(8) Fork Lever Holder Mounting Screw

W1048670

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 crankshaft oil slinger (2).

4. Remove the crankhshaft gear (1).


• Install the collar (4) after aligning the marks on the gears. (See the figure at "Idle Gear".)

(1) Crankshaft Gear

(2) Crankshaft Oil Slinger

(3) O-ring

(4) Crankshaft Collar

(5) Oil Pump

(6) Oil Pump Gear

W1049311

1-S31


GR2100EC2, WSM

(3) Pistons and Connecting Rods

ENGINE

Connecting Rods

1. Remove the connecting rod caps (1).


• Align the marks (a) with each other. (Face the marks toward the injection pump.).

• Apply engine oil to the connecting rod screws and lightly screw it in by hand, then tighten it to the specified torque.

If the connecting rod screw won't be screwed in smoothly, clean the threads.

If the connecting rod screw is still hard to screw in, replace it.

Tightening torque Connecting rod screw

26.5 to 30.4 N·m

2.7 to 3.1 kgf·m

19.5 to 22.4 ft-lbs

(1) Connecting Rod Cap

(a) Mark

W1042376

Pistons

1. Turn the flywheel and bring the piston to top dead center.

2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer.

3. Draw out the other piston in the same method as above.


• Before inserting the piston into the cylinder, apply enough engine oil to the piston.

• When inserting the piston into the cylinder, face the mark on the connecting rod to the injection pump.

■

IMPORTANT

• Do not change the combination of cylinder and piston. Make sure of the position of each piston by marking. For example, mark "1" on the No.1 piston.

• When installing the piston into the cylinder, place the gaps of all the piston rings as shown in the figure.

• Carefully insert the pistons using a piston ring compressor

(1). Otherwise, their chrome-plated section may be scratched, causing trouble inside the cylinder.

(1) Piston Ring Compressor

(A) Top Ring Gap

(B) Second Ring Gap

(C) Oil Ring Gap

(D) Piston Pin Hole

(a) 0.785 rad (45

°

)

(b) 0.785 rad (45

°

)

(c) 1.57 rad (90

°

)

W1051250

1-S32



Piston Ring and Connecting Rod

1. Remove the piston rings using a piston ring tool (Code No.:

07909-32121).

2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5).


• When installing the ring, assemble the rings so that the manufacturer's mark (12) near the gap faces the top of the piston.

• When installing the oil ring onto the piston, place the expander joint (10) on the opposite side of the oil ring gap (11).

• Apply engine oil to the piston pin.

• When installing the connecting rod to the piston, immerse the piston in 80

°

C (176

°

F) oil for 10 to 15 minutes and insert the piston pin to the piston.

• When installing the connecting rod to the piston, align the mark

(8) on the connecting rod to the fan-shaped concave (9).

■

NOTE

• Mark the same number on the connecting rod and the piston so as not to change the combination.

(1) Top Ring

(2) Second Ring

(3) Oil Ring

(4) Piston Pin Snap Ring

(5) Piston

(6) Connecting Rod

(7) Piston Pin

(8) Mark

(9) Fan-Shaped Concave

(10) Expander Joint

(11) Oil Ring Gap

(12) Manufacturer's Mark

W1052645

1-S33


GR2100EC2, WSM

(4) Crankshaft

ENGINE

Flywheel

1. Secure the flywheel to keep it from turning using a flywheel stopper. (Refer to "[1] SPECIAL TOOLS FOR ENEGINE" of

"8. SPECIAL TOOLS" at "G. GENERAL" section.)

2. Remove all flywheel screws (1) and then remove the flywheel (2).


• Set the No. 1 crankpin at the top dead center (T.D.C.).

• Align the "1TC" mark (a) on the outer surface of the flywheel horizontally with the alignment mark (b) on the rear end plate.

• Apply engine oil to the threads and the undercut surface of the flywheel screw and fit the screw.

Tightening torque Flywheel screw

53.9 to 58.8 N·m

5.5 to 6.0 kgf·m

39.8 to 43.4 ft-lbs

(1) Flywheel Screw

(2) Flywheel

(a) 1TC Mark

(b) Alignment Mark

W1049787

Bearing Case Cover

1. Remove the bearing case cover mounting screws. First, remove inside screws (1) and then outside screws (2).

2. Remove the bearing case cover (6).


• Fit the bearing case gasket (3) and the bearing case cover gasket

(4) with correct directions.

• Install the bearing case cover (6) to position the casting mark

"UP" (a) on it upward.

• Apply engine oil to the oil seal (5) lip and take care that it is not rolled when installing.

• Tighten the bearing case cover mounting screws with even force on the diagonal line.

Tightening torque

Bearing case cover mounting screw

9.8 to 11.3 N·m

1.00 to 1.15 kgf·m

7.2 to 8.3 ft-lbs

(1) Bearing Case Cover Mounting Screw

(Inside)

(2) Bearing Case Cover Mounting Screw

(Outside)

(3) Bearing Case Gasket

(4) Bearing Case Cover Gasket

(5) Oil Seal

(6) Bearing Case Cover

(a) Top Mark "UP"

(b) Upside

W1054786

1-S34



Crankshaft Assembly

1. Remove the main bearing case screw 2 (1).

2. Turn the crankshaft to set the crankpin of the third cylinder to the bottom dead center. Then draw out the crankshaft until the crankpin of the second cylinder comes to the center of the third cylinder.

3. Turn the crankshaft by 2.09 rad (120

°

) counterclockwise to set the crankpin of second cylinder to the bottom dead center. Draw out the crankshaft until the crankpin of the first cylinder comes to the center of the third cylinder.

4. Repeat the above steps to draw out all the crankshaft.


• Clean the oil passage of the crankshaft with compressed air.

• Install the crankshaft assembly, aligning the screw hole of main bearing case screw 2 with the screw hole of crankcase.

• When tightening the main bearing case screw 2 (1), apply oil to it and screw by hand before tightening the specific torque. If not smooth to screw by hand, align the screw holes between the crankcase and the main bearing case.

Tightening torque Main bearing case screw 2

26.5 to 30.4 N·m

2.7 to 3.1 kgf·m

19.5 to 22.4 ft-lbs

(1) Main Bearing Case Screw 2

W1055087

1-S35



Main Bearing Case Assembly

1. Remove the two main bearing case screws 1 (9), and remove the main bearing case assembly 1 (1), being careful with crankshaft bearing 3 (4) (5).

2. Remove the main bearing case assembly 2 (2) and the main bearing case assembly (3) as above. Keep in mind, however, that the thrust bearing (8) is installed in the main bearing case assembly (3).


• Clean the oil passage in the main bearing cases.

• Apply clean engine oil on the bearings.

• Install the main bearing case assemblies in original positions.

Since diameters of main bearing cases vary, install them in order to marking (b) from the gear case side. (Refer to the figure.)

• Be careful not to confuse the top and bottom of the crankshaft bearing 3 (4) (5).

(Install the bearing with the oil groove (c) up.)

• Match the alignment numbers (a) on the main bearing case assembly 1.

• Do the same for the main bearing case assembly 2 (2) and the main bearing case assembly (3) too.

• When installing the main bearing case 1 and 2, face the mark

"FLYWHEEL" to the flywheel.

• Install the thrust bearing (8) with its oil groove facing outward.

• Confirm that the main bearing case moves smoothly after tightening the main bearing case screw 1 to the specified torque.

Tightening torque Main bearing case screw 1

12.7 to 15.7 N·m

1.3 to 1.6 kgf·m

9.4 to 11.6 ft-lbs

(1) Main Bearing Case Assembly 1

(2) Main Bearing Case Assembly 2

(3) Main Bearing Case Assembly

(4) Crankshaft Bearing 3

(Upper, with oil groove)

(5) Crankshaft Bearing 3 (Lower)


(Upper, with oil groove)

(7) Crankshaft Bearing 2 (Lower)

(8) Thrust Bearing

(9) Main Bearing Case Screw 1

(a) Alignment Number

(b) Marking (1 or 2)

(c) Oil Groove

W1028669

1-S36


GR2100EC2, WSM

(5) Waterpump

ENGINE

Thermostat Assembly

1. Remove the thermostat cover mounting screws, and remove the thermostat cover (1).

2. Remove the thermostat assembly (3).


• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (2).

(1) Thermostat Cover

(2) Thermostat Cover Gasket

(3) Thermostat Assembly

W1056475

Water Pump Assembly

1. Loosen the dynamo mounting screws, and remove the fan belt.

2. Remove the fan and fan pulley.

3. Remove the water pump assembly from the gear case cover.

4. Remove the water pump flange (1).

5. Press out the water pump shaft (2) with the impeller (5) on it.

6. Remove the impeller from the water pump shaft.

7. Remove the mechanical seal (4).


• Apply a liquid gasket (Three Bond 1215 or equivalent) to the both sides of gasket.

• Replace the mechanical seal with new one.

(1) Water Pump Flange

(2) Water Pump Shaft

(3) Water Pump Body

(4) Mechanical Seal

(5) Impeller

W1056777

1-S37


GR2100EC2, WSM

(6) Injection Nozzle

[4] SERVICING

(1) Cylinder Head and Valve

ENGINE

Nozzle Holder

1. Secure the nozzle retaining nut (7) with a vise.

2. Remove the nozzle holder (1), and take out parts inside.


• Assemble the nozzle in clean fuel oil.

• Install the push rod (4), noting its direction.

• After assembling the nozzle, be sure to adjust the fuel injection pressure.

Tightening torque

Nozzle holder



34.3 to 39.2 N·m

3.5 to 4.0 kgf·m

25.3 to 28.9 ft-lbs

19.6 to 24.5 N·m

2.0 to 2.5 kgf·m

14.5 to 18.1 ft-lbs

49.0 to 68.6 N·m

5.0 to 7.0 kgf·m

36.2 to 50.6 ft-lbs

(1) Nozzle Holder

(2) Adjusting Washer

(3) Nozzle Spring

(4) Push Rod

(5) Distance Piece

(6) Nozzle Piece

(7) Nozzle Retaining Nut

W1057030

Cylinder Head Surface Flatness

1. Clean the cylinder head surface.

2. Place a straightedge on the cylinder head's four sides and two diagonal lines as shown in the figure.

3. Measure the clearance with a thickness gauge.

4. If the measurement exceeds the allowable limit, correct it with a surface grinder.

■

IMPORTANT

• Do not place the straightedge on the combustion chamber.

• Be sure to check the valve recessing after correcting.

Cylinder head surface flatness

Allowable limit

0.05 mm

0.0020 in.

W1029458

1-S38



Cylinder Head Flaw

1. Prepare an air spray red check (Code No.: 07909-31371).

2. Clean the surface of the cylinder head with the detergent (2).

3. Spray the cylinder head surface with the red permeative liquid

(1). Leave it five to ten minutes after spraying.

4. Wash away the red permeative liquid on the cylinder head surface with the detergent (2).

5. Spray the cylinder head surface with the white developer (3).

6. If flawed, it can be identified as red marks.

(1) Red Permetive Liquid

(2) Detergent

(3) White Developer

W1061890

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.

5. If it still exceeds the allowable limit after replacing the valve, replace the cylinder head.

Valve recessing (Intake and Exhaust)

Factory spec.

Allowable limit

0.10 (protrusion) to

0.10 (recessing) mm

0.0039 (protrusion) to

0.0039 (recessing) in.

0.30 (recessing) mm

0.0118 (recessing) in.

(1) Cylinder Head Surface

(A) Recessing

(B) Protrusion

W1063434

1-S39



Clearance between Valve Stem and Valve Guide

1. Remove carbon from the valve guide section.

2. Measure the valve stem O.D. with an outside micrometer.

3. Measure the valve guide I.D. with a small hole gauge, and calculate the clearance.

4. If the clearance exceeds the allowable limit, replace the valves.

If it still exceeds the allowable limit, replace the valve guide.

Clearance between valve stem and valve guide

Factory spec.

Allowable limit

0.030 to 0.057 mm

0.00118 to 0.00224 in.

0.10 mm

0.0039 in.

Valve stem O.D.

Valve guide I.D.

Factory spec.

Factory spec.

5.968 to 5.980 mm

0.23496 to 0.23543 in.

6.010 to 6.025 mm

0.23661 to 0.23720 in.

W1065896

Replacing Valve Guide


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.

3. Ream precisely the I.D. of the valve guide to the specified dimension.

Valve guide I.D. (Intake and Exhaust)

Factory spec.

6.010 to 6.025 mm

0.23661 to 0.23720 in.

■

IMPORTANT

• Do not hit the valve guide with a hammer during replacement.

(A) When removing (B) When installing

W1067592

1-S40



Valve Seating

1. Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact.

2. If the valve does not seat all the way around the valve seat or the valve contact is less than 70 %, correct the valve seating as follows.

3. If the valve contact does not comply with the reference value, replace the valve or correct the contact of valve seating.

Valve seat width Factory spec.

2.12 mm

0.0835 in.

(1) Correct

(2) Incorrect

(3) Incorrect

W1069999

1-S41



Correcting Valve and Valve Seat

■

NOTE

• Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary.

• After correcting the valve seat, be sure to check the valve recessing.

1) Correcting Valve

1. Correct the valve with a valve refacer.

Valve face angle Factory spec.

0.785 rad

45

°

2) Correcting Valve Seat

1. Slightly correct the seat surface with a 0.785 rad (45

°

) valve seat cutter (Code No.: 07909-33102).

2. Fitting the valve, check the contact position of the valve face and seat surface with prussian blue. (Visual check) [If the valve has been used for a long period, the seat tends to come in contact with the upper side of the valve face.]

3. Grind the upper surface of the seat with a 0.262 rad (15

°

) valve seat cutter until the valve seat touches to the center of the valve face (so that (a) equals (b) as shown in the figure).

4. Grind the seat with a 0.785 rad (45

°

) valve seat cutter again, and visually recheck the contact between the valve and seat.

5. Repeat steps 3 and 4 until the correct contact is achieved.

6. Continue lapping until the seated rate becomes more than 70 % of the total contact area.

Valve seat angle Factory spec.

0.785 rad

45

°

(1) Valve Seat Cutter

(A) Check Contact

(B) Correct Seat Width

(C) Correct Seat Surface

(D) Check Contact

(a) Identical Dimensions

(b) Valve Seat Width

(c) 0.262 rad (15

°

)

(d) 0.785 rad (45

°

)

W1071641

Valve Lapping

1. Apply compound evenly to the valve lapping surface.

2. Insert the valve into the valve guide. Lap the valve onto its seat with a valve flapper or screwdriver.

3. After lapping the valve, wash the compound away and apply oil, then repeat valve lapping with oil.

4. Apply prussian blue to the contact surface to check the seated rate. If it is less than 70 %, repeat valve lapping again.

■

IMPORTANT

• When valve lapping is performed, be sure to check the valve recessing and adjust the valve clearance after assembling the valve.

W1075772

1-S42



Free Length and Tilt of Valve Spring

1. Measure the free length (A) of valve spring with vernier calipers.

If the measurement is less than the allowable limit, replace it.

2. Put the valve spring on a surface plate, place a square on the side of the valve spring.

3. Check to see if the entire side is in contact with the square.

Rotate the valve spring and measure the maximum tilt (B).

If the measurement exceeds the allowable limit, replace it.

4. Check the entire surface of the valve spring for scratches.

If there is any defect, replace it.

Free length (A)

Factory spec.

Allowable limit

31.3 to 31.8 mm

1.232 to 1.252 in.

28.4 mm

1.118 in.

Tilt (B) Allowable limit

1.2 mm

0.047 in.

(A) Free Length (B) Tilt

W1076767

Valve Spring Setting Load

1. Place the valve spring on a tester and compress it to the same length it is actually compressed in the engine.

2. Read the compression load on the gauge.

3. If the measurement is less than the allowable limit, replace it.

Setting load / Setting length

Factory spec.

Allowable limit

64.7 N / 27.0 mm

6.6 kgf / 27.0 mm

14.6 lbs / 1.063 in.

54.9 N / 27.0 mm

5.6 kgf / 27.0 mm

12.3 lbs / 1.063 in.

W1078655

Oil Clearance between Rocker Arm and Rocker Arm Shaft

1. Measure the rocker arm shaft O.D. with an outside micrometer.

2. Measure the rocker arm I.D. with an inside micrometer, and then calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit, replace the rocker arm and measure the oil clearance again. If it still exceeds the allowable limit, replace also the rocker arm shaft.

Oil clearance between rocker arm and rocker arm shaft

Factory spec.

Allowable limit

0.016 to 0.045 mm

0.00063 to 0.00177 in.

0.15 mm

0.0059 in.

Rocker arm shaft O.D.

Rocker arm I.D.

Factory spec.

Factory spec.

10.473 to 10.484 mm

0.41232 to 0.41276 in.

10.500 to 10.518 mm

0.41339 to 0.41410 in.

W1079717

1-S43



Push Rod Alignment

1. Place the push rod on V blocks.

2. Measure the push rod alignment.

3. If the measurement exceeds the allowable limit, replace the push rod.

Push rod alignment Allowable limit

0.25 mm

0.0098 in.

W1080781

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.

Oil clearance between tappet and tappet guide bore

Factory spec.

Allowable limit

0.016 to 0.052 mm

0.00063 to 0.00205 in.

0.10 mm

0.0039 in.

Tappet O.D.

Tappet guide bore I.D.

Factory spec.

Factory spec.

17.966 to 17.984 mm

0.70732 to 0.70803 in.

18.000 to 18.018 mm

0.70866 to 0.70937 in.

W1081727

1-S44



(2) Timing Gear, Camshaft and Fuel Camshaft

Timing Gear Backlash

1. Set a dial indicator (lever type) with its tip on the gear tooth.

2. Move the gear to measure the backlash, holding its mating gear.

3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear.

4. If the oil clearance is proper, replace the gear.

Backlash between idle gear and crank gear

Factory spec.

Allowable limit

0.043 to 0.124 mm

0.00169 to 0.00488 in.

0.15 mm

0.0059 in.

Backlash between idle gear and cam gear

Factory spec.

Allowable limit

Backlash between idle gear and injection pump gear

Factory spec.

Allowable limit

0.047 to 0.123 mm

0.00185 to 0.00484 in.

0.15 mm

0.0059 in.

0.046 to 0.124 mm

0.00185 to 0.00488 in.

0.15 mm

0.0059 in.

Backlash between oil pump drive gear and crank gear

Factory spec.

Allowable limit

0.041 to 0.123 mm

0.00161 to 0.00484 in.

0.15 mm

0.0059 in.

W1083879

Idle Gear Side Clearance

1. Set a dial indicator with its tip on the idle gear.

2. Measure the side clearance by moving the idle gear to the front and rear.

3. If the measurement exceeds the allowable limit, replace the idle gear collar.

Idle gear side clearance

Factory spec.

Allowable limit

0.20 to 0.51 mm

0.0079 to 0.0201 in.

0.80 mm

0.0315 in.

W1085756

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 front and rear.

3. If the measurement exceeds the allowable limit, replace the camshaft stopper.

Camshaft side clearance

Factory spec.

Allowable limit

0.15 to 0.31 mm

0.0059 to 0.0122 in.

0.50 mm

0.0197 in.

W1086822

1-S45



Camshaft Alignment

1. Support the camshaft with V blocks on the surface plate at both end journals.

2. Set a dial indicator with its tip on the intermediate journal.

3. Measure the camshaft alignment.

4. If the measurement exceeds the allowable limit, replace the camshaft.

Camshaft alignment Allowable limit

0.01 mm

0.0004 in.

W1087575

Cam Height

1. Measure the height of the cam at its highest point with an outside micrometer.

2. If the measurement is less than the allowable limit, replace the camshaft.

Cam height of intake and exhaust

Factory spec.

Allowable limit

26.88 mm

1.0583 in.

26.83 mm

1.0563 in.

W1087827

Oil Clearance of Camshaft Journal

1. Measure the camshaft journal O.D. with an outside micrometer.

2. Measure the cylinder block bore I.D. for camshaft with a cylinder gauge, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit, replace the camshaft.

Oil clearance of camshaft journal

Factory spec.

Allowable limit

0.050 to 0.091 mm

0.00197 to 0.00358 in.

0.15 mm

0.0059 in.

Camshaft journal O.D.

Camshaft bearing I.D.

(Cylinder block bore

I.D.)

Factory spec.

Factory spec.

32.934 to 32.950 mm

1.29661 to 1.29724 in.

33.000 to 33.025 mm

1.29921 to 1.30020 in.

W1088079

1-S46



Oil Clearance between Idle Gear Shaft and Idle Gear Bushing

1. Measure the idle gear shaft O.D. with an outside micrometer.

2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit, replace the bushing.

4. If it still exceeds the allowable limit, replace the idle gear shaft.

Oil clearance between idle gear shaft and idle gear bushing

Factory spec.

Allowable limit

0.020 to 0.084 mm

0.00079 to 0.00331 in.

0.10 mm

0.0039 in.

Idle gear shaft O.D.

Idle gear bushing I.D.

Factory spec.

Factory spec.

19.967 to 19.980 mm

0.78610 to 0.78661 in.

20.000 to 20.051 mm

0.78740 to 0.78941 in.

W1089665

Replacing Idle Gear Bushing

(When removing)

1. Press out the used idle gear bushing using an idle gear bushing replacing tool.


1. Clean a new idle gear bushing and idle gear bore, and apply engine oil to them.

2. Press in a new bushing using an idle gear bushing replacing tool, until it is flush with the end of the idle gear.

(A) When removing (B) When installing

W1029657

(3) Piston and Connecting Rod

Piston Pin Bore I.D.

1. Measure the piston pin bore I.D. in both the horizontal and vertical directions with a cylinder gauge.

2. If the measurement exceeds the allowable limit, replace the piston.

Piston pin bore I.D.

Factory spec.

Allowable limit

20.000 to 20.013 mm

0.78740 to 0.78791 in.

20.05 mm

0.7894 in.

W1092645

1-S47



Oil Clearance between Piston Pin and Small End Bushing

1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer.

2. Measure the small end bushing I.D. with an inside micrometer, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit, replace the bushing. If it still exceeds the allowable limit, replace the piston pin.

Oil clearance between piston pin and small end bushing

Factory spec.

Allowable limit

0.014 to 0.038 mm

0.00055 to 0.00150 in.

0.10 mm

0.0039 in.

Piston pin O.D.

Small end bushing I.D.

Factory spec.

Factory spec.

20.002 to 20.011 mm

0.78748 to 0.78783 in.

20.025 to 20.040 mm

0.78839 to 0.78897 in.

W1093458

Replacing Small End Bushing

(When removing)

1. Press out the used bushing using a small end bushing replacing tool.


1. Clean a new small end bushing and bore, and apply engine oil to them.

2. Insert a new bushing onto the tool and press-fit it with a press so that the seam (1) of bushing positions as shown in the figure, until it is flush with the connecting rod.

3. Drill a hole to the bushing with aligning the oil hole (2) of connecting rod. (Refer to the figure.)

■

NOTE

• Be sure to chamfer the oil hole circumference with an oil stone.

Oil clearance between piston pin and small end bushing (Spare parts)

Factory spec.

Allowable limit

0.015 to 0.075 mm

0.00059 to 0.00295 in.

0.15 mm

0.0059 in.

Small end bushing I.D.

(Spare parts)

(1) Seam

(2) Oil Hole

Factory spec.

20.026 to 20.077 mm

0.78845 to 0.79043 in.

(A) When removing

(B) When installing

(a) 0.785 rad (45

°

)

W1094644

1-S48



Piston Ring Gap

1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with piston.

2. Measure the ring gap with a thickness gauge.

3. If the measurement exceeds the allowable limit, replace the piston ring.

Piston ring gap

Top ring

Second ring

Factory spec.

Allowable limit

Factory spec.

Allowable limit

0.15 to 0.30 mm

0.0059 to 0.0118 in.

1.20 mm

0.0472 in.

0.30 to 0.45 mm

0.0118 to 0.0177 in.

1.20 mm

0.0472 in.

Factory spec.

0.15 to 0.30 mm

0.0059 to 0.0118 in.

Oil ring

Allowable limit

1.20 mm

0.0472 in.

W1027478

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 thickness gauge.

3. If the clearance exceeds the allowable limit, replace the piston ring.

4. If the clearance still exceeds the allowable limit with new ring, replace the piston.

Clearance between piston ring and piston ring groove

Second ring

Oil ring

Factory spec.

Allowable limit

Factory spec.

Allowable limit

0.090 to 0.120 mm

0.00354 to 0.00472 in.

0.15 mm

0.0059 in.

0.04 to 0.08 mm

0.0016 to 0.0031 in.

0.15 mm

0.0059 in.

W1097828

1-S49



Connecting Rod Alignment

1. Remove the crankpin bearing, and install the connecting rod cap.

2. Install the piston pin in the connecting rod.

3. Install the connecting rod on the connecting rod alignment tool

(Code No.: 07909-31661).

4. Put a gauge over the piston pin, and move it against the face plate.

5. If the gauge does not fit squarely against the face plate, measure the space between the pin of the gauge and the face plate.

6. If the measurement exceeds the allowable limit, replace the connecting rod.

Space between gauge pin face plate

Allowable limit

0.05 mm

0.0020 in.

W1099126

1-S50


GR2100EC2, WSM

(4) Crankshaft

ENGINE

Crankshaft Side Clearance

1. Set a dial indicator with its tip on the end of the crankshaft.

2. Measure the side clearance by moving the crankshaft to the front and rear.

3. If the measurement exceeds the allowable limit, replace the thrust bearings.

4. If the same size bearing is useless because of the crankshaft journal wear, replace it with an oversize one referring to the table and figure.

Crankshaft side clearance

Factory spec.

Allowable limit

0.15 to 0.31 mm

0.0059 to 0.0122 in.

0.50 mm

0.0197 in.

(Reference)

• Oversize thrust bearing

Oversize

0.2 mm

0.008 in.

Bearing

Thrust bearing 1 02

Thrust bearing 2 02

Code Number

15261-23950

15261-23970

0.4 mm

0.016 in.

Thrust bearing 1 04 15261-23960

Thrust bearing 2 04 15261-23980

• Oversize dimensions of crankshaft journal

Marking

020 OS

020 OS

040 OS

040 OS

Oversize

Dimension A

0.2 mm

0.008 in.

23.40 to 23.45 mm

0.9134 to 0.9154 in.

0.4 mm

0.016 in.

23.80 to 23.85 mm

0.9213 to 0.9232 in.

Dimension B

Dimension C

46.1 to 46.3 mm

1.815 to 1.823 in.

1.8 to 2.2 mm radius

0.071 to 0.087 in. radius

46.3 to 46.5 mm

1.823 to 1.831 in.



(0.8-S)

The crankshaft journal must be fine-finished to higher than

∇∇∇∇

W1029838

Crankshaft Alignment

1. Support the crankshaft with V blocks on the surface plate at both end journals.

2. Set a dial indicator with its tip on the intermediate journal.

3. Measure the crankshaft alignment.

4. If the measurement exceeds the allowable limit, replace the crankshaft.

Crankshaft alignment Allowable limit

0.02 mm

0.0008 in.

W1100855

1-S51



Oil Clearance between Crankpin and Crankpin Bearing

1. Clean the crankpin and crankpin bearing.

2. Put a strip of plastigage (Code No.: 07909-30241) on the centre of the crankpin.

3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.

4. Measure the amount of the flattening with the scale, and get the oil clearance.

5. If the oil clearance exceeds the allowable limit, replace the crankpin bearing.

6. If the same size bearing is useless because of the crankpin wear, replace it with an undersize one referring to the table and figure.

■

NOTE

• Never insert the plastigage into the crankpin oil hole.

• Be sure not to move the crankshaft while the connecting rod screws are tightened.

Oil clearance between crankpin and crankpin bearing

Factory spec.

Allowable limit

0.020 to 0.051 mm

0.00079 to 0.00201 in.

0.15 mm

0.0059 in.

Crankpin O.D.

Crankpin bearing I.D.

Factory spec.

Factory spec.

33.959 to 33.975 mm

1.33697 to 1.33760 in.

33.995 to 34.010 mm

1.33893 to 1.33898 in.

(Reference)

• Undersize crankpin bearing

Undersize

0.2 mm

0.008 in.

Bearing

Crankpin bearing 02

Code Number

15861-22970

0.4 mm

0.016 in.

Crankpin bearing 04

• Undersize dimensions of crankpin

15861-22980

Marking

020 US

040 US

Undersize

Dimension A

0.2 mm

0.008 in.



0.4 mm

0.016 in.



Dimension B

Dimension C

4 mm dia.

0.16 in. dia.

33.759 to 33.775 mm dia.

1.32910 to 1.32973 in. dia.

4 mm dia.

0.16 in. dia.

33.559 to 33.575 mm dia.

1.32112 to 1.32185 in. dia.

(0.8-S)

The crankpin must be fine-finished to higher than

∇∇∇∇

W1101115

1-S52



Oil Clearance between Crankshaft Journal and Crankshaft

Bearing 1

1. Measure the O.D. of the crankshaft front journal with an outside micrometer.

2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit, replace the crankshaft bearing 1.

4. If the same size bearing is useless because of the crankshaft journal wear, replace it with an undersize one referring to the table and figure.

Oil clearance between crankshaft journal and crankshaft bearing 1

Factory spec.

Allowable limit

0.034 to 0.106 mm

0.00134 to 0.00417 in.

0.20 mm

0.0079 in.

Crankshaft journal O.D.

Factory spec.

Crankshaft bearing 1

I.D.

Factory spec.

(Reference)

• Undersize crankshaft bearing 1

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.984 to 40.040 mm

1.57417 to 1.57638 in.

Undersize

0.2 mm

0.008 in.

Bearing

Crankshaft bearing 1 02

Code Number

15861-23910

0.4 mm

0.016 in.

Crankshaft bearing 1 04 15861-23920

• Undersize dimensions of crankshaft journal

Marking

020 US

040 US

Undersize

Dimension A

0.2 mm

0.008 in.



0.4 mm

0.016 in.



Dimension B

5 mm dia.

0.20 in. dia.

5 mm dia.

0.20 in. dia.

Dimension C

39.734 to

39.750 mm dia.

1.56433 to

1.56496 in. dia.

39.534 to

39.550 mm dia.

1.55646 to

1.55709 in. dia.

(0.8-S)

The crankshaft must be fine-finished to higher than

∇∇∇∇

W1103180

1-S53



Replacing Crankshaft Bearing 1

(When removing)

1. Press out the used crankshaft bearing 1 using a crankshaft bearing 1 replacing tool. (Refer to "SPECIAL TOOLS".)


1. Clean a new crankshaft bearing 1 and crankshaft journal bore, and apply engine oil to them.

2. Using a crankshaft bearing 1 replacing tool, press in a new bearing 1 (2) so that its seam (1) directs toward the exhaust manifold side. (See figure.)

Dimension (A) Factory spec.

0.0 to 0.3 mm

0.0 to 0.0118 in.

(1) Seam


(3) Cylinder Block

(A) Dimension

W1104511


Bearing 2 (Crankshaft Bearing 3)

1. Put a strip of plastigage (Code No.: 07909-30241) on the center of the journal.

2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again.

3. Measure the amount of the flattening with the scale, and get the oil clearance.

4. If the oil clearance exceeds the allowable limit, replace the crankshaft bearing 2 (crankshaft bearing 3).

5. If the same size bearing is useless because of the crankshaft journal wear, replace it with an undersize one referring to the table and figure.

■

NOTE

• Be sure not to move the crankshaft while the bearing case screws are tightened.

Oil clearance between crankshaft journal and crankshaft bearing 2

(Crankshaft bearing 3)

Factory spec.

Allowable limit

0.028 to 0.059 mm

0.00110 to 0.00232 in.

0.20 mm

0.0079 in.


(Flywheel side)


I.D.

Factory spec.

Factory spec.


(Intermediate)


I.D.

Factory spec.

Factory spec.

43.934 to 43.950 mm

1.72968 to 1.73031 in.

43.978 to 43.993 mm

1.73142 to 1.73201 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.978 to 39.993 mm

1.57394 to 1.57453 in.

W1105735

1-S54


GR2100EC2, WSM

(5) Cylinder

ENGINE


Bearing 2 (Crankshaft Bearing 3) (Continued)

(Reference)

• Undersize crankshaft bearing 2 and 3

Undersize

0.2 mm

0.008 in.

0.4 mm

0.016 in.

Bearing





Code Number

15694-23930

15861-23860

15694-23940

15861-23871

• Undersize dimensions of crankshaft journal

Marking

020 US

020 US

040 US

040 US

Undersize

Dimension A

Dimension B

Dimension C

0.2 mm

0.008 in.



3 mm dia.

0.12 in. dia.

39.734 to 39.750 mm dia.

1.56433 to 1.56496 in. dia.

0.4 mm

0.016 in.



3 mm dia.

0.12 in. dia.

39.534 to 39.550 mm dia.

1.55646 to 1.55709 in. dia.

Dimension D

43.734 to 43.750 mm dia.

1.72181 to 1.72244 in. dia.

43.534 to 43.550 mm dia.

1.71394 to 1.7147 in. dia.

(0.8-S)

The crankpin must be fine-finished to higher than

∇∇∇∇

W1107529

Cylinder Wear

1. Measure the I.D. of the cylinder at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.'s.

2. Get the difference (Maximum wear) between the maximum and the minimum I.D.'s.

3. If the wear exceeds the allowable limit, bore and hone to the oversize dimension. (Refer to "Correcting Cylinder".)

4. Visually check the cylinder wall for scratches. If deep scratches are found, the cylinder should be bored. (Refer to "Correcting

Cylinder".)

Cylinder I.D.

Factory spec.

Allowable limit

67.000 to 67.019 mm

2.63779 to 2.63854 in.

67.169 mm

2.6445 in.

(A) Top

(B) Middle

(C) Bottom (Skirt)

(a) Right-angled to Piston Pin

(b) Piston Pin Direction

W1030293

1-S55


GR2100EC2, WSM

(6) Oil Pump

ENGINE

Correcting Cylinder

1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension.

Cylinder I.D.

[Oversize]

Finishing

Factory spec.

67.250 to 67.269 mm

2.64764 to 2.64839 in.

Allowable limit

67.419 mm

2.65429 in.

Horn to 1.2 to 2.0

μ m Rmax.

∇∇∇∇

(0.000047 to 0.000079 in. Rmax.)

2. Replace the piston and piston rings with oversize ones.

Oversize

0.25 mm

0.0098 in.

Part Name

Piston

Piston ring assembly

Code Number

1E051-21900

16853-21090

Marking

025

025

■

NOTE

• When the oversize cylinder is worn beyond the allowable limit, replace the cylinder block with a new one.

(1) Cylinder I.D. [Before Correction] (2) Cylinder I.D. [Oversize]

W1109116

Rotor Lobe Clearance

1. Measure the clearance between lobes of the inner rotor and the outer rotor with a thickness gauge.

2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.

Rotor lobe clearance Factory spec.

0.03 to 0.14 mm

0.0012 to 0.0055 in.

W1030553

Clearance between Outer Rotor and Pump Body

1. Measure the clearance between the outer rotor and the pump body with a thickness gauge.


Clearance between outer rotor and pump body

Factory spec.

0.07 to 0.15 mm

0.0028 to 0.0059 in.

W1110485

1-S56



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.


Clearance between rotor and cover

Factory spec.

0.075 to 0.135 mm

0.00295 to 0.00531 in.

W1110562

1-S57


2

TRANSAXLE


MECHANISM

CONTENTS

1. STRUCTURE ................................................................................................. 2-M1

2. TRAVELLING SYSTEM ................................................................................ 2-M2

[1] HYDROSTATIC TRANSMISSION .......................................................... 2-M2

(1) Structure ............................................................................................ 2-M2

(2) Oil Flow .............................................................................................. 2-M3

(3) Operation ........................................................................................... 2-M4

(4) By-pass Valve .................................................................................... 2-M7

(5) Control Linkage .................................................................................. 2-M8

[2] GLIDE STEER SECTION ...................................................................... 2-M9

(1) General .............................................................................................. 2-M9

(2) Operation ......................................................................................... 2-M11

[3] FRONT WHEEL DRIVE SECTION ..................................................... 2-M12

3. MOWER PTO SYSTEM ............................................................................. 2-M13

[1] MOWER PTO CLUTCH ....................................................................... 2-M13

4. OTHERS ...................................................................................................... 2-M15

[1] HYDRAULIC PUMP SECTION ............................................................ 2-M15


GR2100EC2, WSM

1. STRUCTURE

TRANSAXLE

(1) Hydraulic Pump Section

(2) Input Shaft

(3) Front Wheel Drive Section

(4) Bevel Gear Section

(5) Glide Steer Section

(6) Hydrostatic Transmission

(7) Rear Axle Section

(8) Mower PTO Section

The transaxle of this machine is constructed as shown above. This machine is equipped with left and right clutches in transaxle.

2-M1


GR2100EC2, WSM

2. TRAVELLING SYSTEM

[1] HYDROSTATIC TRANSMISSION

(1) Structure

TRANSAXLE

(1) Check and High Pressure

Relief Valve

(2) Trunnion Arm

(3) Center Section

(4) Cylinder Block (Pump)

(5) Piston Spring

(6) Piston

(7) Spring (Cylinder Block)

(8) Washer

(9) Thrust Ball Bearing

(10) Swashplate

(11) Cradle Bearing

(12) Ball Bearing

(13) Oil Seal

(14) Pump Shaft

(15) Ball Bearing

(16) Oil Seal

(17) Motor Shaft


(19) Cylinder Block (Motor)

(20) By-pass Plug

(21) By-pass Spool

(22) By-pass Spring

(23) Journal Bearing

(24) Oil Seal

(25) Journal Bearing

(26) Oil Seal

Hydrostatic Transmission (HST) consists of a variable displacement piston pump, a fixed displacement piston motor, two check and high pressure relief valves (1) and a by-pass valve.

The pump and motor have five pistons (6) in their own cylinder block (4), (19).

The discharge rate of the HST is 10 cm

3

/rev. (0.61 cu.in./rev.).

With the speed change pedal connecting to the trunnion arm (2) in HST via a link mechanism, the speed change pedal permits simple operation of the machine, starting, stopping and increasing or decreasing speed.

2-M2


GR2100EC2, WSM

(2) Oil Flow

TRANSAXLE

(1) Pump


Relief Valve (Forward)

(3) Filter Cartridge

(4) HST Relief Valve

(5) Hydraulic Control Valve

Assembly

(6) Hydraulic Pump

(7) Main Relief Valve

(8) Motor

(9) By-pass Valve


Relief Valve (Reverse)

(11) Lubricating Orifice


A : From Power Steering

Controller

B : To Power Steering Controller

C: To Mower Lift Cylinder

The closed oil-hydraulic loop connects between the pump (1) and the motor (8) in HST.

Oil from the hydraulic pump (1) flows through the hydraulic control valve assembly (5) to the power steering controller. Then the oil flows back from the power steering controller to the hydraulic control valve assembly (5), and further flows through the filter cartridge (3).

The HST relief valve (4) provides the functionality of a charge relief valve. Therefore, the oil passed through the filter cartridge is routed to HST as charge oil.

Overflow oil from the HST housing flows back to the transaxle.

2-M3


GR2100EC2, WSM

(3) Operation

■

Neutral

TRANSAXLE



(3) Power Steering Controller

(4) Control Valve


(6) Mower Lift Cylinder


Assembly

(8) Hydraulic Pump

(9) Swashplate







(14) Piston

(15) Cylinder Block (Mower)

(16) By-pass Valve

(17) Transaxle Case

(18) Oil Strainer

Engine revolution rotates the pump shaft via the universal joint.

Being engaged with each other, the pump shaft and the cylinder block (10) in the pump rotate together.

With the speed change pedal in the neutral position, the swashplate (9) in the pump is at right angles to the pump pistons.

The pump pistons rotate with the pump cylinder block (10) without reciprocating motion.

At this time, since the pump pistons do not generate pressure, no pressure is transmitted to the motor pistons, thus causing neither rotation of the motor cylinder block (15) nor that of the motor shaft engaged with it.

Thus the machine is stationary.

2-M4


GR2100EC2, WSM

■

Forward

TRANSAXLE




(4) Control Valve




Assembly

(8) Hydraulic Pump

(9) Swashplate







(14) Piston


(16) By-pass Valve

(17) Transaxle Case

(18) Oil Strainer

Stepping on the speed change pedal to the forward position inclines the HST trunnion arm, causing the pump swashplate (9) to incline as shown in the figure.

The pump pistons rotate with the pump cylinder block (10) while reciprocating.

At this time, the pump pistons generate pressure by reciprocating motion. The pressure generated is transmitted to the motor pistons (Port B - Port D).

Pressure from the port D thrusts the motor pistons to the surface of the inclined thrust ball bearing, causing them to slide on the inclined surface.

This causes the motor cylinder block (15) and the motor shaft engaged with it to rotate.

This causes the machine to move forward. The inclination of the pump swashplate (9) determines the motor shaft speed.

2-M5


GR2100EC2, WSM

■

Reverse

TRANSAXLE




(4) Control Valve




Assembly

(8) Hydraulic Pump

(9) Swashplate







(14) Piston


(16) By-pass Valve

(17) Transaxle Case

(18) Oil Strainer

Stepping on the speed change pedal to the reverse position inclines the HST trunnion arm in the direction opposite to that at moving forward, causing the pump swashplate (9) to incline as shown in the figure.

The pump pistons rotate with the pump cylinder block (10) while reciprocating.

At this time, the pump pistons generate pressure by reciprocating motion. The pressure generated is transmitted to the motor pistons (Port A - Port C).

Pressure from the port C thrusts the motor pistons to the surface of the inclined thrust ball bearing, causing them to slide on the inclined surface.

This causes the motor cylinder block (15) and the motor shaft engaged with it to rotate.

This causes the machine to move reverse. The inclination of the pump swashplate (9) determines the motor shaft speed.

2-M6


GR2100EC2, WSM

(4) By-pass Valve

TRANSAXLE

Normally, when the engine is stopped, the pump shaft and pump cylinder block engaged with it do not rotate.

Thus, the motor shaft does not rotate.

However, pressing the by-pass valve in the center section permits moving the machine with human power while the engine is stopped. The following paragraphs describe this mechanism:

Pressing the by-pass valve connects the forward and reverse loops in the center section. This allows oil to flow between the forward and reverse loops through the bypass valve to rotate only the motor cylinder block.

This means that pressing the by-pass valve while the engine is stopped, that is, while the pump shaft is not rotating, permits rotating the motor shaft engaged with the motor cylinder block.

(1) By-pass Spring

(2) By-pass Spool

(3) By-pass Plug

W1014625

2-M7


GR2100EC2, WSM

(5) Control Linkage

TRANSAXLE

(1) Speed Change Pedal

(2) Speed Change Rod

(3) Speed Change Plate

(4) Neutral Arm

(5) Neutral Spring (6) Speed Control Arm

The speed change pedal (1) and the trunnion arm of variable swashplate are linked with the speed change rod (2), speed change plate (3) and the speed control arm (6). As the front of the pedal is depressed, the swashplate rotates and forward travelling speed increases. Depressing the rear end increases reverse speed.

The speed control arm (6) is returned to neutral position by the neutral arm (4) and the tension of neutral spring

(5). At the same time, the swashplate is returned to neutral, when the pedal is released.

2-M8


GR2100EC2, WSM

[2] GLIDE STEER SECTION

(1) General

TRANSAXLE

This machine is equipped with the Glide Steer system.

On turning, the Glide Steer system provides a mechanism that allows a turf-friendly minimum turn by driving the front wheels and the rear wheel on the outside of the turn at the same time.

(1) Differential Gear (Front)

(2) Steering Clutch

A : Engage

B : Disengage

W1014878

This machine has left and right steering clutches (1) in the rear transaxle.

The clutch lever (2) is connected to the king pin support on the front axle with the wire (3). When turning left or right, the wire connecting to the king pin support on the front axle disengages only the steering clutch of the turn side. This shuts off driving power to the rear wheel on the inside of the turn.

On the other hand, the rear wheel on the outside of the turn has driving power.

(1) Steering Clutch

(2) Clutch Lever

(3) Wire

W1019672

2-M9


GR2100EC2, WSM TRANSAXLE

The following paragraphs describe how the machines equipped with normal 4WD and the Glide Steer turn.

■

For Normal 4WD

The machine with four wheels has a wheel base.

Because of this, turning the machine creates a difference in the length of tracks made by the differential gears in the front axle and in the rear axle.

Assuming that the average speeds of the right and left front wheels and of the right and left rear wheels are equal to those of the differential gears in the frontaxle and in the rear axle, respectively.

Also assuming that the speeds of the differential gears in the front axle and in the rear axle are the same, the right and left rear wheels will free-spin by the difference in the length of tracks, causing damage to turf.

A large steering angle of the front axle results in a shorter turning radius of the machine. But a larger steering angle makes an even larger difference in the length of tracks made by differential gears in the front axle and in the rear axle.

Therefore, on a minimum turn, the right and left rear wheels will have more free-spins, causing greater damage to turf.


(2) Differential Gear (Rear)

A : Track made by Differential

Gear (Front)

B : Track made by Differential

Gear (Rear)

W1015161

■

For Glide Steer System

In the Glide Steer system, driving power is transmitted only to the right and left front wheels and the rear wheel on the outside of the turn. The rear wheel on the inside of the turn does not receive driving power.

Assuming that the speeds of the differential gear in the front axle and of the rear wheel on the outside of the turn are the same.

At this time, even with a larger steering angle of the front axle, the difference in the length of tracks made by the differential gear in the front axle and the rear wheel on the outside of the turn is smaller than 4WD.

Therefore, on a minimum turn, the right and left rear wheels will have fewer free-spins, thus providing a turnfriendly mechanism.


(2) Steering Clutch (Engaged)

(3) Steering Clutch (Disengaged)

A : Track made by Differential

Gear (Front)

B : Track made by Rear Wheel on Outside of Turn

W1015290

2-M10


GR2100EC2, WSM

(2) Operation

TRANSAXLE

■

On Going Straight

On going straight, the right and left steering clutches in transaxle are engaged to transmit driving power to the right and left rear wheels. At this time, all four wheels drive the machine.

Spring tension pushes the spline boss (4) in the steering clutch toward the inside of the machine, which eliminates the clearance between clutch disc and friction plate, causing friction necessary to transmit driving power.

The spline boss (4) is engaged with 42T gear shaft (5)

(for right wheels, with right drive shaft). The clutch case

(3) is engaged with the 11T gear shaft (2).

Driving power is transmitted to the 42T gear shaft (5).

Then the driving power is transmitted to the right and left rear wheels as follows.

• Rear wheel (LH) :

42T gear shaft (5)

→

Spline boss (4)

→

Clutch case

(3)

→

11T gear shaft (2)

→

65T gear shaft (1)

→

Rear wheel (LH)

• Rear wheel (RH) :

42T gear shaft (5)

→

Right drive shaft

→

Spline boss

→

Clutch case

→

11T gear shaft

→

65T gear shaft

→

Rear wheel (RH)

(1) 65T Gear Shaft

(2) 11T Gear Shaft

(3) Clutch Case

(4) Spline Boss

(5) 42T Gear Shaft

W1015418

■

On Turning Right or Left

On turning right or left, the steering clutch on the inner side of the turn is disengaged. No driving power is transmitted to the rear wheels on the inside of the turn.

At this time, right and left front wheels and the rear wheel on the outside of the turn drive the machine.

When the front wheels are turned by steering wheel rotation, the king pin support in the direction of turn pulls the wire, and then the wire rotates the clutch lever (2).

The clutch lever (2) pushed the spline boss (1) via the clutch collar (3). This creates clearance between clutch disc and friction plate (4), causing no friction, thus shutting off driving power.

The steering clutch becomes disengaged when the steering wheel rotates to reach a front axle steering angle from 0.17 to 0.44 rad (10 to 25 degree).

(1) Spline Boss

(2) Clutch Lever

(3) Clutch Collar

(4) Clutch Disc and Friction Plate

W1016494

2-M11


GR2100EC2, WSM

[3] FRONT WHEEL DRIVE SECTION

TRANSAXLE

This machine always has the front axle driven.

Driving power is transmitted to the front axle as follows :

Motor shaft (3)

→

15T gear (4)

→

29T gear (2)

→

Front wheel drive shaft (1)

(1) Front Wheel Drive Shaft

(2) 29T Gear

(3) Motor Shaft

(4) 15T Gear

W1016638

2-M12


GR2100EC2, WSM

3. MOWER PTO SYSTEM

[1] MOWER PTO CLUTCH

TRANSAXLE

The mower PTO clutch is equipped with mechanical independent clutches of wet multi-plates type.

The PTO shaft (1) is engaged with the spline boss (3).

The clutch case (5) is engaged with the 24T gear (6).

Normally, spring (8) tension pushes the spline boss

(3) in the PTO clutch toward the front side of the machine, which creates clearance between clutch disc and friction plate (4), causing no friction.

Thus, no driving power is transmitted between spline boss (3) and clutch case (5), that is, no driving power is transmitted to the PTO shaft (1).

(1) PTO Shaft

(2) Clutch Lever

(3) Spline Boss


(5) Clutch Case

(6) 24T Gear

(7) 19T-2 Gear

(8) Spring

(9) Brake Disc and Friction Plate

(10) Thrust Collar

W1016747

■

PTO "Engaged"

When the PTO lever is set at the "Engaged" position, the clutch lever (2) connected to the PTO lever via a link mechanism rotates to the rear side of the machine.

The clutch lever pushes the spline boss (3) toward the rear side of the machine via the thrust collar (10), which eliminates the clearance between the clutch disc and friction plate (4), causing friction necessary to transmit driving power.

This allows driving power to be transmitted as follows:

19T-2 Gear (7)

→

24T Gear (6)

→

Clutch Case (5)

→

Spline Boss (3)

→

PTO Shaft (1)

(1) PTO Shaft

(2) Clutch Lever

(3) Spline Boss


(5) Clutch Case

(6) 24T Gear

(7) 19T-2 Gear

(8) Spring


(10) Thrust Collar

W1016963

2-M13



■

PTO "Disengaged"

When the PTO lever is set at the "Disengaged" position, the clutch lever (2) connected to the PTO lever via a link mechanism rotates to the front side of the machine.

Spring (8) tension pushes the spline boss (3) toward the front side of the machine, which creates clearance between the clutch disc and friction plate (4), causing no friction.

This eliminates the clearance between brake discs and friction plate (9), causing friction.

Driving power to the PTO shaft (1) is thus shut off and brake engages to prevent the PTO shaft (1) from freespinning.

(1) PTO Shaft

(2) Clutch Lever

(3) Spline Boss


(5) Clutch Case

(6) 24T Gear

(7) 19T-2 Gear

(8) Spring


(10) Thrust Collar

W1017152

2-M14


GR2100EC2, WSM

4. OTHERS

[1] HYDRAULIC PUMP SECTION

TRANSAXLE

The hydraulic pump (1) is mounted on the transaxle case.

The power to drive the hydraulic pump (1) is transmitted as follows :

Input shaft (4)

→

25T gear (3) on input shaft

→

Hydraulic pump gear shaft (2)

(1) Hydraulic Pump

(2) Hydraulic Pump Gear Shaft

(3) 25T Gear

(4) Input Shaft

W1017301

2-M15


SERVICING

CONTENTS




4. CHECKING, DISASSEMBLING AND SERVICING......................................2-S6

[1] CHECKING AND ADJUSTING ...............................................................2-S6

[2] PREPARATION ......................................................................................2-S11

(1) Separating Transaxle ........................................................................2-S11

(2) Separating Hydrostatic Transmission ...............................................2-S20


(1) Hydrostatic Transmission..................................................................2-S25

(2) Transaxle Case .................................................................................2-S27

(3) PTO Clutch .......................................................................................2-S35

[4] SERVICING ............................................................................................2-S40

(1) Hydrostatic Transmission..................................................................2-S40

(2) Transaxle Case .................................................................................2-S42




Symptom

System Will Not

Operate in Either

Direction

Vibration and Noise

Probable Cause

Oil level is low

Control linkage defective (Speed change pedal to speed control arm)

Charge pressure is too low

Oil filter cartridge clogged

HST relief valve defective

Hydraulic pump defective

Check and high pressure relief valve defective

By-pass valve defective

HST component parts defective

Oil level is low









Solution

Fill oil to proper level

Repair control linkage

Replace oil filter cartridge

Replace HST relief valve

Replace hydraulic pump

Replace check and high pressure relief valve

Replace by-pass valve

Replace HST assembly









Reference

Page

G-8, 2-S13

2-S7, 18

G-32

6-S15

6-S11

2-S26

2-S26

2-S24

G-8, 2-S13

2-S7, 18

G-32

6-S15

6-S11

2-S26

2-S26

2-S24

W1014322

2-S1



Symptom

Less of Power

Oil Heat Over

Machine Will Not

Stop in Neutral

Position

System Operates in

One Direction Only


Oil level is low









Oil level is low

Excessive machine load










Reduce machine load










Improper adjustment of neutral arm holder shaft Adjust





Reference

Page

G-8, 2-S13

2-S7, 18

G-32

6-S15

6-S11

2-S26

2-S26

2-S24

G-8, 2-S13

–

G-32

6-S15

6-S11

2-S7, 18

2-S6

2-S7, 18

2-S26

W1092336

2-S2



BEVEL GEAR SECTION

Symptom

Excessive or

Unusual Noise at All

Time

Noise while Turning


Reference

Page

2-S45 Improper backlash between 11T bevel gear and

17T-13T gear shaft

Bearing worn

Insufficient or improper type of transmission fluid used

Bearing worn

Adjust

Replace –

Replenish or change G-8, 2-S13

Replace –

W1014322

GLIDE STEER SECTION

The Driving Power is not Transmitted to

Rear Wheel at the

Time of Going

Straight

Steering clutch disc worn

Friction plate worn

Clutch spring weaken or broken

Improper adjustment of wire

Replace

Replace

Replace

Adjust

Replace

2-S34, 44

2-S34, 44

2-S43

2-S19,

4-S5

2-S34

The Driving Power to

Rear Wheel on inside of Turn is not Shut

Off at the Time of

Turning

Steering clutch disc and friction plate are agglutinated

Improper adjustment of wire

Wire broken

Adjust

Replace

2-S19,

4-S5

2-S17,

4-S7

W1011581

MOWER PTO SECTION

PTO Clutch Slip

Improper length of PTO rod spring

PTO rod spring weaken or broken

Clutch disc or friction plate excessively worn

Adjust

Replace

Replace

PTO Shaft Does Not

Rotate

PTO Clutch Drags

PTO clutch malfunctioning

Bearing broken

Brake plate excessive worn

Clutch spring weaken or broken

Deformation of plate

Repair or replace

Replace

Replace

Replace

Replace

2-S16

2-S16

2-S28,

42,43

2-S28 to 31

2-S28

2-S28, 43

2-S28, 43

2-S28, 43

W1011680

2-S3


GR2100EC2, WSM


Item

HST Relief Valve

(Oil temperature at 50

°

C, 122

°

F)

Setting Pressure

High Relief Pressure Setting Pressure

PTO Clutch Disc

Pressure Plate

Friction Plate 1

Friction Plate 2

Clutch Spring

PTO Brake Disc 1

PTO Brake Disc

Brake Friction Plate 1

Brake Friction Plate 2

Clutch Spline Plate

Steering Clutch Disc

Friction Plate

Clutch Plate

11T Bevel Gear Shaft to 17T-13T Gear

Shaft

Thickness

Thickness

Thickness

Thickness

Thickness

Backlash

Thickness

Thickness

Thickness

Thickness

Free Length

Thickness

Thickness

Thickness

TRANSAXLE


0.9 to 1.1 MPa

9.2 to 11.2 kgf/cm

2

130.6 to 159.5 psi

18.5 to 22.2 MPa

189 to 226 kgf/cm

2

2684 to 3263 psi

1.3 to 1.5 mm

0.051 to 0.059 in.

1.55 to 1.65 mm

0.061 to 0.065 in.

1.55 to 1.65 mm

0.061 to 0.065 in.

0.75 to 0.85 mm

0.030 to 0.034 in.

45 mm

1.77 in.

2.85 to 3.05 mm

0.11 to 0.12 in.

3.3 to 3.5 mm

0.13 to 0.14 in.

1.75 to 1.85 mm

0.069 to 0.073 in.

0.95 to 1.05 mm

0.037 to 0.041 in.

0.75 to 0.85 mm

0.030 to 0.033 in.

1.3 to 1.5 mm

0.051 to 0.059 in.

0.75 to 0.85 mm

0.030 to 0.033 in.

1.55 to 1.65 mm

0.061 to 0.065 in.

0.10 to 0.30 mm

0.0039 to 0.0012 in.

Allowable Limit

–

–

0.80 mm

0.031 in.

0.70 mm

0.028 in.

1.2 mm

0.047 in.

0.70 mm

0.028 in.

1.50 mm

0.059 in.

–

1.2 mm

0.047 in.

1.50 mm

0.059 in.

1.50 mm

0.059 in.

0.70 mm

0.028 in.

42 mm

1.65 in.

2.75 mm

0.108 in.

3.0 mm

0.118 in.

1.60 mm

0.063 in.

W1013874


2-S4



Tightening torques of screws, bolts and nuts on the table below are especially specified.

(For general use screws, bolts and nuts : Refer to “5. TIGHTNING TORQUES” at “G. GENERAL” section.)

Item

Brake plate mounting screw

Universal joint mounting screw

Power steering pipe mounting nut

Rear wheel mounting nut

Transaxle mounting screw

Hydrostatic transmission mounting screw

Hydrostatic transmission mounting screw 2

Center section mounting hex. socket head screw

By-pass valve plug

Check valve plug

Hydraulic pump mounting screw

PTO clutch assembly mounting screw

Transaxle case screw

N·m

35 to 40

9.8 to 11.3

20.0 to 25.0

77.5 to 90.2

48.1 to 55.8

23.5 to 27.5

17.7 to 20.6

17.7 to 20.6

15.0

30.0

17.7 to 20.6

17.7 to 20.6

7.8 to 8.8

kgf·m

3.47 to 4.07

1.00 to 1.15

2.04 to 2.54

7.91 to 9.19

4.9 to 5.7

2.4 to 2.8

1.8 to 2.1

1.8 to 2.1

1.53

3.06

1.8 to 2.1

1.8 to 2.1

0.8 to 0.9

ft-lbs

25.1 to 29.5

7.23 to 8.33

14.76 to 18.43

57.2 to 66.5

35.5 to 41.2

17.3 to 20.3

13.1 to 15.2

13.1 to 15.2

11.1

22.1

13.1 to 15.2

13.1 to 15.2

5.8 to 6.5

W1012736

2-S5





Adjustment of HST Neutral Position

1. Lift up the front and rear of the machine, and support it with disassembling jacks.

2. Remove the left rear wheel.

3. Start the engine, and set at approx. 1500 to 3000 min

-1

(rpm).

4. Loosen the holder shaft mounting screw (3).

5. Rotate the holder shaft (2) counterclockwise so that the rear wheels turn forward.

6. Then rotate it clockwise until the rear wheels stop completely.

7. Put a mark on the neutral arm (1). (Position B)

8. Rotate the holder shaft (2) clockwise so that the rear wheels turn in reverse.

9. Then rotate it counterclockwise until the rear wheels stop completely.

10.Put a mark on the neutral arm (1). (Position A)

11.Set the holder shaft (2) where it is right in the center between position A and B and tighten the holder shaft mounting screw (3) firmly.

This means the hydrostatic transaxle is fully in neutral. (Position

C)

WARNING

• Use buddy system in adjusting the neutral position.

• One of you should sit on the operator's seat, adjust the engine rpm and step on the speed change pedal. The other should adjust the neutral position.

(1) Neutral Arm

(2) Holder Shaft

(3) Holder Shaft Mounting Screw

W1010662

2-S6



Speed Change Pedal Restriction

■

NOTE

• This adjustment should be performed after completing the adjustment of neutral.

1. Set the speed change pedal (1) to "NEUTRAL" position, and apply the parking brake.

2. Check that the pin (3) of speed change pedal lock with the brake pedal arm (2).

3. If it is improper, adjust the length (A) with the rod end (4) on speed change rod.

4. Then adjust the length (B) with adjusting nut (6) on speed change rod (5).

(Reference)

• Length (A) : 20 mm (0.79 in.)

• Length (B) : 16 to 20 mm (0.63 to 0.78 in.)


(2) Brake Pedal Arm

(3) Pin

(4) Rod End


(6) Adjusting Nut

W1030319

Adjusting Maximum Speed

■

NOTE

• This adjustment should be performed after completing the adjustment of neutral.

[Forward]

1. Loose the lock nut (2) of adjusting screw.

2. Adjust the length (A) with the adjusting screw (1).

(Reference)

• Length (A) : 12 to 15 mm (0.48 to 0.59 in.)

• Traveling speed : 9.0 to 10.0 km/h (5.6 to 6.2 mph)

[Reverse]

1. Loose the lock nut (3) of adjusting screw.

2. Adjust the length (B) with the adjusting screw (4).

(Reference)

• Length (B) : 12 to 13 mm (0.48 to 0.51 in.)

• Traveling speed : 4.0 to 5.0 km/h (2.5 to 3.1 mph)

(1) Adjusting Screw

(2) Lock Nut

(3) Lock Nut

(4) Adjusting Screw

W1019368

2-S7



HST Relief Pressure

CAUTION

• When checking, park the machine on level ground, apply the parking brake.

• This checking should be performed after completing the adjustment of neutral.

1. Remove the plug (Rc 1/8) (1) from the hydraulic control valve assembly.

2. Install the adaptor, thread joint, cable and pressure gauge.

3. Start the engine and run engine speed at maximum speed.

4. Read the pressure gauge to measure the HST relief pressure.

5. If the measurement is not within the factory specification, check the HST relief valve and related hydraulic components.

HST relief pressure Factory spec.

0.9 to 1.1 MPa

9.2 to 11.2 kgf/cm

2

130.6 to 159.5 psi

Condition

• Engine Speed : Maximum

• Oil Temperature : 50

°

C (122

°

F)

(1) Plug

W1016179

2-S8



HST High Relief Pressure

CAUTION


1. Remove the hexagon socket head plug from P1 (1) or P2 (2), using the short neck hexagon wrench. (Refer to "8. SPECIAL

TOOLS" at "G. GENERAL" section.)

2. Install the O-ring (3) to the adaptor 2 (Refer to "8. SPECIAL

TOOLS" at "G. GENERAL" section) (4). Then, install the adaptor

2 (4) to P1 (1) or P2 (2), manually first and then using an adaptor lever (Refer to "8. SPECIAL TOOLS" at "G. GENERAL" section).

3. Install the O-ring (5) to the adaptor 1 (Refer to "8. SPECIAL

TOOLS" at "G. GENERAL" section) (6). Then, install the adaptor

1 (6) to the adaptor 2 (4), so that the surface "b" of adaptor 1 (6) lightly contacts the surface "a" of adaptor 2 (4).

■

NOTE

• If the adaptor 1 (6) cannot be installed to the adaptor 2 (4) due to interference with the filter case, adjust a mounting position of the filter case (8) to expand clearance "A", by loosening the filter case mounting screws (7) and the hose clamp (9) and turning the filter case (8) clockwise.

• After adjusting a mounting position of the filter case (8), retighten the filter case mounting screws (7) and return the hose clamp (9) to a normal position.

(1) P1 Port (Reverse)

(2) P2 Port (Forward)

(3) O-ring (SAE J515 #6 (Tube OD 3/8))

(4) Adaptor 2

(5) O-ring (P/N 04811-10060)

(6) Adaptor 1

(7) Filter Case Mounting Screw

(8) Filter Case

(9) Hose Clamp

(10) Hose

A : Clearance between the filter case and the bottom of center section.

W1042793

2-S9



HST High Relief Pressure (Continued)

4. Adjust direction of the port (2) by rotating the adaptor 1 (1) counterclockwise seen from underneath, so that the pressure gauge adaptor can be installed on the port (2). However, do not rotate the adapter 1 (1) more than one rotation.

5. Install the adaptor of pressure gauge to the port (2) of adaptor 1 with seal tape. Then install the cable and pressure gauge.

6. Start the engine and run it at maximum speed.

7. Depress the speed change pedal to forward or reverse, and read the pressure gauge to measure the high relief pressure.

8. If the measurement is not same as factory specification, check the high pressure relief valve and related hydraulic components.

HST High relief pressure Factory spec.

18.5 to 22.2 MPa

189 to 226 kgf/cm

2

2684 to 3263 psi

■

IMPORTANT

• To keep a good fit between the adaptor 1 (1) and the adaptor

2, do not rotate the adaptor 1 (1) while measuring.

• Measure quickly so that the high pressure relief valve may not be in operation more than 10 seconds.

■

NOTE

• When installing the adaptor 1 (1), adaptor 2 and hexagon socket head plug, take care not to damage the O-rings.

Condition

• Engine Speed : Maximum Speed

• Oil Temperature : 50

°

C (122 °F)

(1) Adaptor 1 (2) Port

W1051999

2-S10


GR2100EC2, WSM

[2] PREPARATION

(1) Separating Transaxle

TRANSAXLE

Dismounting Mower

1. Refer to “[2] PREPARATION” of “4. CHECKING,

DISASSEMBLING AND SERVICING” at “9. MOWER” section.

W1023014

Dismounting the Container

CAUTION

• Park the machine on a firm and level ground.

• Stop the engine, and remove the key.

1. Open the top cover (1) with the top cover lock lever (2).

2. Place the grass container lift lever (3) on the container lock plate

(5).

3. As shown in the figure, while lifting the rear end of the grass container (4), dismount the grass container (4).

(When remounting)

• Open the top cover (1).

• Place the grass container lift lever (3) on the frame lock plate (6).

• While lifting the rear end of the grass container (4), hook the grass container (4) onto the frame shaft so that a clearance “L” is about 0 to 50 mm.

• Lock the grass container (4) by inserting the grass container lift lever (3) between the container lock plate (5) and the frame lock plate (6).

• Close the top cover (1).

(Reference)

• Clearance “L” : 0 to 50 mm (0 to 2.0 in.)

(1) Top Cover

(2) Top Cover Lock Lever

(3) Grass Container Lift Lever

(4) Grass Container

(5) Container Lock Plate

(6) Frame Lock Plate

W1012898

2-S11



Discharge Duct

1. Remove the filter cover (1) and the duct plate (3).

2. Disconnect the connector (5) from the grass container full switch

(4).

3. Remove the discharge duct (2).

(1) Filter Cover

(2) Discharge Duct

(3) Duct Plate

(4) Grass Container Full Switch

(5) Connector

W1012965

Container Base

1. Disconnect the couplers (1) from the relays (2).

2. Disconnect the connector (4).

3. Remove the container base (3).

(1) Coupler

(2) Relay

(3) Container Base

(4) Connector

[A] Left Side

[B] Right Side

W1013019

2-S12



Draining Transmission Fluid

1. Start the engine. Push the mower lift lever and lower the mower link.

2. Place an oil pan under the transaxle.

3. Remove the drain plug (2).

4. Remove the strainer (5) to completely drain the transmission fluid.

5. After draining, clean the strainer (5) and reinstall it.


• Remove the filling plug with the dipstick, and fill the new transmission fluid to H level on the dipstick.

• Start the engine, and perform the following operations. However, absolutely avoid engaging the PTO lever during this operation.

1) Depress the speed change pedal alternately to the forward side and reverse side in order to move the machine forward and backward.

2) Rotate the steering wheel to the right and left to turn the front wheels right and left.

3) Operate the mower lift lever in order to make the mower deck go up and down.

4) During the operation described above, check to see if no oil leakage from the transaxle assembly and each hydraulic pipe is found.

• At least 5 minutes after stopping the engine, check the oil level again, using the dipstick.

• If the oil level is lower than the H level indicated on the dipstick, fill the oil tank with transmission fluid additionally up to the H level.

• Perform the above-mentioned operation again. And confirm that the oil level is not low level.

• Disconnect the universal joint of mower deck from the PTO shaft.

Shift the PTO lever to "Engage" position, and check to see if the

PTO shaft rotates quickly without abnormal noise. Next, shift the

PTO lever to the "Disengage" position, and check to see if the

PTO shaft stops operation quickly without abnormal noise.

■

IMPORTANT

• Park the machine on level ground.

• Use the KUBOTA UDT or SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system.



• Do not mix different bland oil together.

Transmission fluid Capacity

3.4 L

0.90 U.S.gals

0.75 Imp.gals

(1) Suction Pipe

(2) Drain Plug

(3) O-ring (Small)

(4) O-ring (Large)

(5) Strainer

(6) Boss


H : Highest Level

L : Lowest Level

W1033631

2-S13



Battery

CAUTION


1. Open the bonnet.




(1) Negative Cable

(2) Positive Cable

(3) Battery

W1036278

Seat

1. Remove the snap pin (2).

2. Remove the seat (1).

(1) Seat (2) Snap Pin

W1037658

Fender

1. Remove the lever grips (1) and cutting height control dial (6).

2. Remove the speed change pedal (7).

3. Remove the seat base (2).

4. Peel the step sheet (8) halfway.

5. Remove the fuel cap (4).

6. Remove the fender (5).

(1) Lever Grip

(2) Seat Base

(3) Fender Mounting Screw

(4) Fuel Cap

(5) Fender

(6) Cutting Height Control Dial


(8) Step Sheet

W1038685

2-S14


GR2100EC2, WSM

Fuel Tank

1. Drain the fuel.

2. Disconnect the fuel hoses.

3. Remove the fuel tank (1).

(1) Fuel Tank

TRANSAXLE

W1040558

2-S15



PTO Rod Spring

1. Remove the two nuts (2) (3) and spring (4).


1. Assemble a fuel tank, a seat base and a fender.

2. Setting the PTO lever at "Disengaged" position and lifting the

PTO arm (5) slightly by hands directly, the upper side of PTO arm

(5) and lower nut (6) on the upper side of PTO rod (1) make contact, and there is no play between them. Keeping this position, be sure to tighten the two nuts (6) (7) on the upper side of this PTO rod (1).

3. Assembly temporarily the spring (4) and two nuts (2) (3) to the

PTO rod (1). After this, set the PTO lever at "Engaged" position, and then be sure to tighten two nuts (2) (3) on the lower side of

PTO rod (1) so that the spring length (L2) reaches the specified value.

■

IMPORTANT

• After completing above assembling / adjustment, repeat the motion several times to set the PTO lever at "Disengaged" and "Engaged" position. Then, finally set the PTO lever at

"Engaged" position. Be sure to check that the upper side of

PTO arm (5) and the lower sides of two nuts (6) (7) on the upper side of PTO rod (1) are making no contact.

Spring length (L2) Factory spec.

68 mm

2.68 in.

(Reference)

• Length (L1) : 115 to 118 mm (4.53 to 4.64 in.)

• Length (L3) : 38 to 40 mm (1.50 to 1.57 in.)

(1) PTO Rod

(2) Nut

(3) Nut

(4) Spring

(5) PTO Arm

(6) Nut

(7) Nut

(A) "Disengaged" Position

(B) "Engaged" Position

W1041404

2-S16



Beam

1. Disconnect the connector from the PTO switch (1).

2. Remove the spring (2) from the PTO lever (3).

3. Remove the PTO rod.

4. Remove the filling pipe (4).

5. Remove the hose clamp (7) of breather hose (6).

6. Remove the beam (5).


• After assembling the beam, fix the breather hose (6) to the beam

(5) with the hose clamp horizontally along the beam (5).

(1) PTO Switch

(2) Spring

(3) PTO Lever

(4) Filling Pipe

(5) Beam

(6) Breather Hose

(7) Hose clamp

W1045354

Brake Rod

1. Disconnect the brake rod 1 (6).

2. Remove the lock nut (1), plain washers (2) and brake spring (3).

3. Remove the brake plate (5).

4. Remove the brake rod 2 (4) and brake rod 1 (6).


■

IMPORTANT

• After assembling the brake rod 1, 2 (4), (6) and brake spring

(3), be sure to adjust the brake pedal free travel. (Refer to "4.

CHECKING, DISASSEMBLING AND SERVICING" at "4.

BRAKE" section.)

Tightening torque

Brake plate mounting screw

35 to 40 N·m

3.47 to 4.07 kgf·m

25.1 to 29.5 lbf·ft

(1) Lock Nut

(2) Plain Washer

(3) Brake Spring

(4) Brake Rod 2

(5) Brake Plate

(6) Brake Rod 1

W1047606

2-S17



Speed Control Plate

1. Remove the split pin (2), and disconnect the speed change plate

(1) and speed control arm (3).

2. Separate the speed change plate (1) and speed change rod (4).


■

IMPORTANT

• After assembling the speed change plate (1) and speed change rod (4), be sure to adjust the speed change pedal restriction. (Refer to "[1] CHECKING AND ADJUSTING" in this section.)

(1) Speed Change Plate

(2) Split Pin

(3) Speed Control Arm


(5) Lock Nut

W1049508

Universal Joint

1. Remove the universal joint mounting screw (1).

2. Disconnect the universal joint (2).


• Apply grease to the splines of the universal joint.

Tightening torque

Universal joint mounting screw

9.8 to 11.3 N·m

1.00 to 1.15 kgf·m

7.23 to 8.33 lbf·ft

(1) Universal Joint Mounting Screw (2) Universal Joint

W1051194

Front Wheel Drive Shaft

1. Remove the bearing holder (1).

2. Disconnect the front wheel drive shaft (2) and spline boss (3) from transaxle.


• Install the spline boss (3) a shown in figure.

(1) Bearing Holder

(2) Front Wheel Drive Shaft

(3) Spline Boss

(4) O-ring

(a) Groove

F : Front

R : Rear

W1052501

2-S18



Glide Steer Wire

1. Remove the rue ring pin (1).

2. Loose the adjusting nut (3).

3. Disconnect the Glide Steer wire (4) and wire stay (2).


• Adjust the length (A) with adjusting nut (3) on the Glide Steer wire

(4).

(Reference)

• Length (A) : 10 to 12 mm (0.40 to 0.47 in.)

(1) Rue Ring Pin

(2) Wire Stay

(3) Adjusting Nut


W1054099

Power Steering Pipe, Cylinder Hose and Rear Wheel

1. Disconnect the power steering pipes (1) (2).

2. Disconnect the cylinder hose (4) from the control valve.

3. Remove the rear wheel (3).


Tightening torque

Power steering pipe

Cylinder hose

Rear wheel mounting nut

20.0 to 25.0 N·m

2.04 to 2.54 kgf·m

14.76 to 18.43 lbf·ft

24.0 to 28.0 N·m

2.45 to 2.85 kgf·m

17.7 to 20.6 lbf·ft

77.5 to 90.2 N·m

7.91 to 9.19 kgf·m

57.2 to 66.5 lbf·ft

(1) Power Steering Pipe

(To Power Steering Controller)

(2) Power Steering Pipe

(From Power Steering Controller)

(3) Rear Wheel

(4) Cylinder Hose

Separating Transmission

1. Remove the transaxle mounting screws (2).

2. Separate the transaxle (1) from the frame.


Tightening torque Transaxle mounting screw

48.1 to 55.8 N·m

4.9 to 5.7 kgf·m

35.5 to 41.2 lbf·ft

W1055625

(1) Transaxle (2) Transaxle Mounting Screw

W1057771

2-S19



(2) Separating Hydrostatic Transmission

Speed Control Arm, Neutral Spring, Cooling Fan and Others

1. Remove the neutral spring (2).

2. Remove the speed control arm (1).

3. Remove the cooling fan (4).

4. Remove the breather hoses (3).

5. Remove the return springs (5) (11), wire stays (8) and Glide Steer levers (7) (9).

6. Remove the spring stays (6) (10).


■

NOTE

• When reinstall the set screw (13) (for the speed control arm), apply the liquid lock (Three Bond 1324 or its equivalent) to the screw.

• Before reconnecting the breather hoses to breather ports, clean the breather ports and the inside of breather hose.

• When reconnecting the breather hoses to breather ports, set the hose clamp at 1 to 2 mm (0.04 to 0.08 in.) from the hose end.

• Fix the breather hose (3) with a cord clamp (15) so that the breather hose (3) does not contact with the cooling fan shaft (14).

In this case, wind the cord clamp (15) around the breather hose

(3) in the direction indicated by the arrow mark shown in the figure.

• Fix the breather hose (3) on the neutral arm holder (12) with the clamp as shown in the figure.

Tightening torque

Set screw for speed control arm

17.7 to 20.6 N·m

1.81 to 2.10 kgf·m

13.1 to 15.1 lbf·ft

(1) Speed Control Arm

(2) Neutral Spring

(3) Breather Hose

(4) Cooling Fan

(5) Return Spring

(6) Spring Stay

(7) Glide Steer Lever

(8) Wire Stay

(9) Glide Steer Lever

(10) Spring Stay

(11) Return Spring

(12) Neutral Arm Holder

(13) Set Screw

(14) Cooling Fan Shaft

(15) Cord Clamp

W1033712

2-S20



Suction Filter Case

1. Remove the hose (3).

2. Remove the suction filter case (1) with the suction pipe 2 (2).

3. Remove the suction pipe 2 (2) from the suction filter case (1).

4. Remove the boss (7) and strainer (6) from the suction filter case

(1).


• After cleaning the strainer (6), install it in the suction filter case

(1).

• Install the boss (7) that sets two O-rings (5) in the suction filter case (1).

• After setting the O-ring (4) in the suction pipe 2 (2), install the suction pipe 2 (2) in the suction filter case (1).

• After setting the O-ring (9) in the transaxle case (8), install the suction filter case (1) in the transaxle case (8).

Tightening torque

Suction pipe 2 mounting screw

Suction filter case mounting screw

7.8 to 8.8 N·m

0.80 to 0.89 kgf·m

5.8 to 6.4 lbf·ft

7.8 to 8.8 N·m

0.80 to 0.89 kgf·m

5.8 to 6.4 lbf·ft

(1) Suction Filter Case

(2) Suction Pipe 2

(3) Hose

(4) O-ring (Small)

(5) O-ring (Large)

(6) Strainer

(7) Boss

(8) Transaxle Case

(9) O-ring

W1048370

2-S21



Suction Pipe and Control Valve Pipe

1. Remove the drain hose (5).

2. Remove the joint bolts (8) (14), and disconnect the suction pipe

1 (7) and control valve pipe (1) from the hydraulic pump (11).


• Replace all copper gaskets (9) (10) (12) (13) with new one.

• Install all copper gaskets (9) (10) (12) (13) in original position.

• After temporarily assembling the control valve pipe (1) to the control valve (2) first, reconnect the control valve pipe (1) to the hydraulic pump (11) with the joint bolt (14).

• Reconnect the suction pipe 1 (7) so that it is straight with the hose and suction pipe 2.

• When reconnecting the drain hose (5) to the transaxle and control valve (2), set the hose clamps (4) (6) at the position shown in the figure.

Control valve pipe retaining nut

24 to 28 N·m

2.5 to 2.8 kgf·m

18 to 20 lbf·ft

Tightening torque Joint bolt (8) (14)

Hose clamp for drain hose

(4) (6)

32 to 36 N·m

3.3 to 3.6 kgf·m

24 to 26 lbf·ft

1.0 to 1.2 N·m

0.11 to 0.12 kgf·m

0.74 to 0.88 lbf·ft

(Reference)

• Distance (A) : 1.0 to 2.0 mm (0.04 to 0.08 in.)

• Distance (B) : 5.0 mm (0.2 in.)

(1) Control Valve Pipe


(Filter Bracket)


(4) Hose Clamp

(5) Drain Hose

(6) Hose Clamp

(7) Suction Pipe 1

(8) Joint Bolt

(9) Copper Gasket (Thick Type)

(10) Copper Gasket (Thin Type)

(11) Hydraulic Pump



(14) Joint Bolt

W1029668

2-S22



Neutral Arm Holder and Filter Bracket

1. Remove the neutral arm holder mounting screws (M8) (2).

2. Remove the hydraulic control valve assembly (4) with the neutral arm holder (3).

3. Remove the charge pipe (6).


■

NOTE

• Apply the oil to two O-rings (5) on the charge pipe (6). Insert the charge pipe (6) straight into the charge port (7) while taking care not to damage the O-ring. Next, insert the hydraulic control valve assembly (4) straight into the charge pipe (6).

(1) Neutral Arm


Mounting Screws (M8)


(4) Hydraulic Control Assembly

(5) O-ring

(6) Charge Pipe

(7) Charge Port

W1059835

2-S23



Brake Assembly

1. Remove the brake assembly (1).

2. Remove the external snap ring (2). And pull out the brake drum

(3).


• Apply liquid gasket (Three Bond 1208D or equivalent) to joint face of brake assembly and hydrostatic transmission thinly.

• Tighten the brake assembly mounting screws (4) while pushing up the brake arm lever (5) by the hand.

Tightening torque

Brake Assembly Mounting

Screw

7.8 to 8.8 N·m

0.80 to 0.89 kgf·m

5.8 to 6.4 lbf·ft

(1) Brake Assembly


(3) Brake Drum

(4) Brake Assembly Mounting Screw

(5) Brake Arm Lever

W1061965

Hydrostatic Transmission Assembly

1. Remove the hydrostatic transmission assembly (1).


• Apply the liquid gasket (Three Bond 1208D or equivalent) to joint face of the hydrostatic transmission assembly (1).

• Cover the splines of front drive shaft with thin tape to protect the sealing lip of the oil seal.

■

NOTE

• When reassembling the hydrostatic transmission assembly, insert the drain pipe (3) in the hole (2) surely so as not to drop out it.

Tightening torque

Hydrostatic transmission mounting screw

Hydrostatic transmission mounting screw 2

23.5 to 27.5 N·m

2.4 to 2.8 kgf·m

17.3 to 20.3 lbf·ft

17.7 to 20.6 N·m

1.8 to 2.1 kgf·m

13.1 to 15.2 lbf·ft

(1) Hydrostatic Transmission Assembly

(2) Hole

(3) Drain Pipe

(4) Hydrostatic Transmission Mounting

Screw 2

W1063079

2-S24




(1) Hydrostatic Transmission

15T Gear, 34T Gear and Bevel Gear Shaft

1. Remove the external snap ring (5). And pull out the 15T gear (2).

2. Remove the 34T gear (3) with front drive shaft (1).

3. Remove the bevel gear shaft (4).

(1) Front Drive Shaft

(2) 15T Gear

(3) 34T Gear

(4) Bevel Gear Shaft


(6) Shim

W1064346

Center Section

1. Remove the center section mounting hex. socket head screws.

2. Tap the center section (1) with soft hammer and separate the center section (1) from the HST housing (2).


• Cover the splines of each shaft with thin tape to protect the sealing lip of the oil seals.

• Place a new gasket on the HST housing.

■

NOTE

• Take care not to damage the surface of cylinder blocks, pistons and center section.

Tightening torque

Center section mounting hex. socket head screw

17.7 to 20.6 N·m

1.8 to 2.1 kgf·m

13.1 to 15.2 lbf·ft

(1) Center Section (2) HST Housing

W1030586

2-S25



By-pass Valve

1. Remove the plug (4) and draw out the by-pass spool (2) and spring (1).


• Take care not to damage the O-ring (3) on the plug (4).

Tightening torque By-pass valve plug

15.0 N·m

1.53 kgf·m

11.1 lbf·ft

(1) Spring

(2) By-pass Spool

(3) O-ring

(4) Plug

W1066388

Check and High Pressure Relief Valve

1. Remove the plugs (1), (8).

2. Draw out the springs (3), (6).

3. Draw out the check and high pressure relief valves (4) (5).


• Take care not to damage the O-rings (2), (7) on the plugs (1), (8).

Tightening torque

Check and high pressure relief valve plug

30.0 N·m

3.06 kgf·m

22.1 lbf·ft

(1) Plug

(2) O-ring

(3) Spring

(4) Check and High Pressure Relief

Valve (Reverse)


Valve (Forward)

(6) Spring

(7) O-ring

(8) Plug

W1069382

Cylinder Block Assembly and Thrust Ball Bearing

1. Remove the cylinder block assembly (pump side) (1), spring (2) and washer (3).

2. Remove the cylinder block assembly (motor side) (5).

3. Remove the thrust ball bearing (4).


• Apply clean transmission oil to thrust ball bearing, cylinder block and piston.

■

NOTE

• Take care not to damage the surface of cylinder blocks and pistons.

(1) Cylinder Block Assembly

(Pump Side)

(2) Spring

(3) Washer


(5) Cylinder Block Assembly

(Motor Side)

W1070297

2-S26


GR2100EC2, WSM

(2) Transaxle Case

TRANSAXLE

Swashplate, Pump Shaft and Motor Shaft

1. Remove the swashplate (2) and thrust ball bearing (1) from the

HST housing.

2. Remove the internal snap ring (5), and tap out the pump shaft (3) and oil seal (4).

3. Remove the internal snap ring (6) and the oil seal (7).

4. Remove the internal snap ring (8), and tap out the motor shaft

(10).

■

NOTE

• When removing the oil seal (7), take care not to damage the

HST housing.


• Apply clean transmission oil to thrust ball bearing (1).


(2) Swashplate

(3) Pump Shaft

(4) Oil Seal

(5) Internal Snap Ring


(7) Oil Seal



(10) Motor Shaft

W1071054

Cradle Bearing, Slot Guide and Trunnion Arm

1. Remove the slot guide (2) and trunnion arm (3).

2. Remove the cradle bearings (1) from the HST housing.


• Apply clean transmission oil to the cradle bearings (1) and trunnion arm.

• Fasten down the cradle bearing to the HST housing.

(1) Cradle Bearing

(2) Slot Guide

(3) Trunnion Arm

W1072233

Hydraulic Pump

1. Unscrew the hydraulic pump mounting screws (2).

2. Remove the hydraulic pump (1).


Tightening torque


17.7 to 20.6 N·m

1.8 to 2.1 kgf·m

13.1 to 15.2 lbf·ft

(1) Hydraulic Pump (2) Hydraulic Pump Mounting Screw

W1072904

2-S27



Disassembling PTO Clutch Assembly

1. Remove the PTO cover assembly (1) with the brake disc and friction plate, PTO clutch assembly (3) and 24T gear (2) from the transaxle case.

2. Remove the ball bearing (4) from the transaxle case.

3. Remove the 24T gear (2), PTO clutch assembly (3), brake disc and friction plate (5) from PTO shaft (6).

4. While pressing the PTO clutch assembly (3), turn the clutch case

(7) clockwise. Then, separate the clutch case (7) and the spline boss (12) with clutch disc and friction plate (13).

5. Remove the thrust needle bearing (8), thrust collar (9), collar (10) and spring (11).

6. Remove the external snap ring (14), clutch disc and friction plate

(13) from the spline boss (12).


Tightening torque

PTO cover assembly mounting screw

17.7 to 20.6 N·m

1.81 to 2.10 kgf·m

13.1 to 15.2 lbf·ft

(1) PTO Cover Assembly

(2) 24T Gear

(3) PTO Clutch Assembly

(4) Ball Bearing


(6) PTO Shaft

(7) Clutch Case

(8) Thrust Needle Bearing

(9) Thrust Collar

(10) Collar

(11) Spring

(12) Spline Boss



W1073892

2-S28



Disassembling PTO Cover Assembly

1. Pull out the PTO shaft (1) from PTO clutch cover (5) until external snap ring (3) touches clutch lever (4).

2. Tap out the PTO shaft (1) while opening the external snap ring

(3) with external snap ring pliers.

3. Remove the thrust collar (2) from PTO shaft (1).

4. Remove the ball bearing (6) and oil seal (7) from the PTO clutch cover (5).

(1) PTO Shaft

(2) Thrust Collar


(4) Clutch Lever

(5) PTO Clutch Cover

(6) Ball Bearing

(7) Oil Seal

W1101571

2-S29



Assembling PTO Clutch Assembly

■

NOTE

• When assembling the PTO clutch assembly to the transaxle assembly installed in the machine, refer to “(4) PTO Clutch” in this section.

1. Place the transaxle case so that the front side faces upward. And fix it lightly.

2. Install the ball bearing (1) with the sealed face inside as shown in the figure.

3. Install the 24T gear (6) in the clutch case (7). Install the collar (4) in the clutch case (7), noting its direction.

4. Install the thrust needle bearing (5), thrust collar (3) and PTO shaft (2) in the clutch case (7) as shown in the figure.

5. Install the clutch disc and friction plate (9) and external snap ring

(8) in the spline boss (10).

6. Install the spring (11) in the PTO shaft (2). Install the spline boss

(10) which assembles the clutch disc and friction plate in PTO shaft (2).

7. Turn the clutch case (7) clockwise while pushing spline boss (10), and lock the spline boss (10) which assembles clutch disc and friction plate to the clutch case (7).

8. Install the brake discs (13), (15) and friction plate (12), (14) in the spline boss (10).

■

IMPORTANT

• Do not change the arrangement of the brake discs (13), (15) and brake friction plates (12), (14).

■

NOTE

• Thickness of the brake friction plate 1 (12) is greater than that of the friction plate 2 (14).

• The brake disc 1 (15) has the facing only in one side.

(1) Ball Bearing

(2) PTO Shaft

(3) Thrust Collar

(4) Collar

(5) Thrust Needle Bearing

(6) 24T Gear

(7) Clutch Case



(10) Spline Boss

(11) Spline

(12) Brake Friction Plate 1

(13) Brake Disc


(15) Brake Disc 1

W1027948

2-S30



Assembling PTO Clutch Assembly (Continued)

1. Take out the PTO shaft from the spline boss carefully.

2. Install the PTO clutch assembly (3) which assembles the 24T gear, spline boss, brake disc and friction plate in the transaxle case.

■

NOTE

• Align the tangs (1) of the brake friction plate with the grooves (2) of transaxle case.

3. Install the PTO cover assembly (4) in the transaxle case while inserting the PTO shaft in the spline boss.

■

NOTE

• Apply the liquid gasket (Three Bond 1208D or equivalent) to joint face of PTO cover and transaxle case.

• Install the PTO cover assembly (4) while confirming that tangs (1) of brake friction plate do not come off from the grooves (2) of transaxle case. (See (A) in the figure.)

• Tighten the PTO cover assembly mounting screws evenly.

4. After installing the PTO cover assembly (4) in the transaxle case, push up the PTO lever, and ensure that the PTO shaft rotates smoothly.

Tightening torque

PTO cover assembly mounting screw

17.7 to 20.6 N·m

1.81 to 2.10 kgf·m

13.1 to 15.1 lbf·ft

(1) Tang

(2) Groove



W1028675

Beam and Wire Lever

1. Remove the wire levers (1) (3) and beam (2) from the transaxle case.

(1) Wire Lever

(2) Beam

(3) Wire Lever

W1076842

2-S31



Transaxle Case

1. Remove the transaxle case screws (2).

2. Separate the front side of transaxle case (1).


• Apply the liquid gasket (Three Bond 1208D or its equivalent) without any break along the sealing groove on the front side of transaxle case : the coating width and height should be 2 mm and

1.5 mm, respectively.

• Also apply the liquid gasket on the grooves around holes (A) shown in the figure.

■

NOTE

• Apply the liquid gasket thinly to both front and rear sides only in the oil seal receiving part (B) of rear axle. Be sure to remove extra liquid gasket therefrom if present.

• Do not apply the liquid gasket on the oil passage (C) shown in the figure.

• Install the transaxle case screws (2) in the direction shown in figure.

• Tighten all screws by the hand. Then, tighten the screws located at the circled positions (D) first with tightening torques. Next, tighten the remaining screws with tightening torque.

Tightening torque Transaxle case screw

9.80 to 11.3N·m

1.00 to 1.15 kgf·m

7.23 to 8.33 lbf·ft

(1) Transaxle Case (Front Side)

(2) Transaxle Case Screw

(3) Transaxle Case (Rear Side)

F : Front Side

R : Rear Side

A : Liquid Gasket Application Portion

B : Oil Seal Receiving Part

C : Oil Passage

D : Screws Which Tightened First with Tightening Torque

W1077380

2-S32



Pump Drive Gear, Input Shaft, 19T-2 Gear and 17T-13T Gear

Shaft

1. Remove the pump drive gear (1) and input shaft (2).

2. Remove the intermediate shaft (3) and 19T-2 gear (4) with collars

(7) and needle bearing (8).

3. Remove the 17T-13T gear shaft (5).


■

NOTE

• Install the two external snap rings (6) on intermediate shaft

(3) by shifting each mating portion by 180 degrees.

• Install the collars (7) so that the faces with oil grooves of collars (7) are directed to the 19T-2 gear (4).

(1) Pump Drive Gear

(2) Input Shaft

(3) Intermediate Shaft

(4) 19T-2 Gear

(5) 17T-13T Gear Shaft


(7) Collar

(8) Needle Bearing

W1078418

Steering Clutch, Clutch Lever, 11T Gear Shaft, 42T Gear Shaft and Drive Shaft

1. Remove the steering clutches (2) (8), clutch levers (3) (5), 11T gear shafts (1) (9), 42T gear shaft (4) and drive shaft (10) from transaxle case.

(1) 11T Gear Shaft (LH)

(2) Steering Clutch (LH)

(3) Clutch Lever (LH)

(4) 42T Gear Shaft

(5) Clutch Lever (RH)

(6) Thrust Collar

(7) Spacer

(8) Steering Clutch (RH)

(9) 11T Gear Shaft (RH)

(10) Drive Shaft

(11) Thrust Collar

(12) Spacer

W1079532

2-S33



Disassembling Steering Clutch

1. Remove the internal snap ring (1).

2. Remove the clutch plate (2) and spline boss (5) with clutch disc and friction plate (3) from the steering clutch case (10).

3. Remove the spacer (7), spring (8) and clutch collar (9).

4. Remove the clutch disc and the friction plate (3), clutch spline (4) and external snap ring (6) from spline boss (5).


(2) Clutch Plate


(4) Clutch Spline Plate

(5) Spline Boss


(7) Spacer

(8) Spring

(9) Clutch Collar

(10) Steering Clutch Case

W1080248

Rear Axle

1. Remove the rear axle assembly (1) from the transaxle case.

2. Remove the bush (10) from 65T gear shaft (9).

3. Unscrew the lock nut (2), and remove the rear wheel hub (4).

4. Remove the oil seal (5), bush (6) and collar (7) and external snap ring (8) from 65T gear shaft (9).


• When installing the rear wheel hub (4) to the rear axle, apply the molybdenum disulphide (Three Bond 1901 or equivalent) to the splines of rear axle.

• Install the belleville washer (3), noting its direction as shown in the figure.

• When install the rear axle in the rear side of transaxle case (11), direct the splits (A) of bushes to the front side. Next, draw the bushes (6) (10) in the direction indicated by the arrow as shown in the figure.

Tightening torque Lock Nut

100 to 120 N·m

10.2 to 12.2 kgf·m

73.0 to 88.5 lbf·ft

(1) Rear Axle Assembly

(2) Lock Nut

(3) Belleville Washer

(4) Rear Wheel Hub

(5) Oil Seal

(6) Bush

(7) Collar


(9) 65T Gear Shaft

(10) Bush

(11) Transaxle Case (Rear Side)

A : Split of Bush

W1080885

2-S34



(3) PTO Clutch

■

Sepatating PTO Cover Assembly with PTO Clutch Assembly and Transaxle Assembly installed in the machine.


1. Refer to “ [2] PREPARATION” of “4. CHECKING,


W1058584


1. Refer to “ [2] PREPARATION” of “4. CHECKING,

DISASSEMBLING AND SERVICING” in this section.

W1058727

Separating PTO Cover Assembly with PTO Clutch Assembly

1. Remove the two nuts (4), (5) and spring (6).

2. Pull out the PTO cover assembly (1) with PTO clutch (8) slowly.

■

NOTE

• If PTO cover assembly (1) sticks to the transaxle case (7), move the PTO arm (2) up and down.

■

IMPORTANT

• When pulling out the PTO cover assembly (1) with PTO clutch, check if any parts remain inside the transaxle case

(7).


(2) PTO Arm

(3) PTO Rod

(4) Nut

(5) Nut

(6) Spring

(7) Transaxle Case

(8) Ball Bearing

(9) 24T Gear

(10) PTO Clutch


W1058792

2-S35



■

Reinstalling PTO Cover Assembly with PTO Clutch to the Transaxle Assembly installed in the machine.

Pre-Assembly PTO Cover Assembly

1. Separate the PTO cover assembly (1) and PTO clutch assembly

(3) with brake disc and friction plate (2).

2. Install the PTO cover assembly (1) in the template (7) with the six flange bolts and nuts (6).

3. Apply there dots of liquid gasket (Three Bond 1208D or equivalent) on the places (A) shown in figure of the brake friction plate 1 (4).

■

NOTE

• Thickness of the brake friction plate 1 (4) is greater than that of the brake friction plate 2 (5).

4. Then, attach the brake friction plate 1 to the PTO cover assembly

(1) installed in the template (7).

5. After confirming the brake friction plate 1 (4) is fixed to the PTO cover assembly (1), remove the template (7) from the PTO cover assembly (1).

■

IMPORTANT

• After attaching the brake friction plate 1 (4) to the PTO cover assembly (1), do not attempt to move the PTO arm.






(6) Flange Bolt and Nut

(7) Template (Refer to “8.SPECIAL

TOOLS” at “G. GENERAL” section)

A : Liquid Gasket Application Portion

W1059133

2-S36



Installation of PTO Cover Assembly with PTO Clutch Assembly

1. Clean the mating surface of the transaxle case (3) and PTO cover assembly.

2. Tighten the stud bolts (1) at three locations shown in figure by hand.

■

NOTE

• The shorter thread length side of stud bolt (1) must be screwed into the transaxle case (3).

3. Install the ball bearing (2) with the sealed face inside as shown in figure.

4. Apply the liquid gasket (Three Bond 1208D or equivalent) a long the sealing groove (5) on the PTO cover assembly (4).

5. Install the brake discs, brake friction plate 2 (6), PTO clutch assembly (7) and 24T gear (8) to the PTO cover assembly (4).

6. Align the tangs of brake friction plate 1 and 2. (See (A) in figure.)

■

NOTE

• After aligning the tangs of brake friction plate 1 and 2, do not attempt to rotate the PTO shaft.

7. Insert the PTO rod (10) to the hole (11) or PTO arm (9).

Then, install the PTO cover assembly (4) with PTO clutch (7) to the transaxle case (3).

(1) Stud Bolt

(2) Ball Bearing

(3) Transaxle Case


(5) Sealing Groove



(8) 24T Gear

(9) PTO Arm

(10) PTO Rod

(11) Hole

A : Aligument of the tangs of Brake

Friction Plate 1 and 2

W1059496

2-S37




(Continued)

1. Align the bolt holes of PTO Cover Assembly (3) with the stud bolts (1). Then slide the PTO cover assembly (3) slowly in direction of arrow in figure.

2. When the distance (A) is 15 to 16 mm (0.59 to 0.62 in.), the PTO cover assembly (3) would be blocked from sliding.

In this case, push the PTO cover assembly (3) softly while slightly turning the PTO shaft (2).

3. When the distance (A) is 8.0 to9.0 mm (0.32 to 0.35in.), the PTO cover assembly (3) may be blocked from sliding again because the tangs (6) of brake friction plate do not align with the grooves

(4) of transaxle case.

In this case, slightly pull out the PTO shaft (2), and turn the brake friction plate 2 with a minus screwdriver so that the tangs (6) of it align with the grooves (4) of transaxle case.

■

NOTE

• Do not touch the liquid gasket applied on the PTO cover assembly (3).

4. When the tangs (6) of brake friction plate 2 align with the grooves of transaxle case, further push the PTO cover assembly (3).

If the PTO cover assembly (3) is installed correctly, the distance

(A) should become 5.0 mm (0.20 in.) or less.

5. Install the PTO cover mounting bolts in three remained bolt holes.

And tighten them slowly and evenly until the PTO cover assembly

(3) contacts to the transaxle case.

6. Remove the stud bolts (1), and replace with the PTO cover mounting bolts. Then tighten all bolts with the specific torque.

7. Check the following movement of PTO shaft (2) while raising the

PTO arm (8).

Movement of PTO Shaft (2)

1

Position of PTO Arm (8)

Within a play from the lowest position

2

Range where clutch spring resistance is felt

3 PTO Arm is the highest position

Can Not be turned by hand

Can be turned by hand

Can Not be turned by hand

Tightening torque

(1) Stud bolt

(2) PTO Shaft


(4) Groove

PTO Cover Mounting Bolt

17.7 to 20.5 N·m

1.80 to 2.10 kgf·m

13.1 to 15.1 lbf·ft

(5) Transaxle Case

(6) Tang

(7) PTO Cover Mounting Bolt

(8) PTO Arm

W1060090

2-S38




(Continued)

1. Install the PTO rod spring (1). (Refer to “PTO Rod Spring” of “[2]

PREPARATION” in this section.)

2. Remove the filling plug with the dipstick (5), and fill the new transmission fluid to H level on the dipstick.

3. Start the engine, and perform the following operations. However, absolutely avoid engaging the PTO lever during this operation.

1) Depress the speed change pedal alternately to the forward side and reverse side in order to move the machine forward and backward.




4. At least 5 minutes after stopping the engine, check the oil level again, using the dipstick.

5. If the oil level is lower than the H level indicated on the dipstick, fill the oil tank with transmission fluid additionally up to the H level.

6. Perform the above-mentioned operation again. And confirm that the oil level is not low level.

7. Disconnect the universal joint of mower deck form the PTO shaft.

Shaft the PTO lever to “Engage” position, and check to see if the


PTO lever to the “Disengage” position, and check to see if the


■

IMPORTANT


• Use the KUBOTA UDT or SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system. Refer to

“4. LUBRICANTS, FUEL AND COOLANT” at “G. GENERAL” section.



3.4 L

0.90 U.S.gals

0.75 Imp.gals

(1) PTO ROd Spring

(2) Nut

(3) Nut

(4) PTO Rod

(5) Filling Plug With Dipstick

W1061134

2-S39


GR2100EC2, WSM

[4] SERVICING

(1) Hydrostatic Transmission

TRANSAXLE

Center Section

1. Check the surfaces (1) of center section for scratches or wear.

2. If deep scratch or excessive wear is found, replace the hydrostatic transmission assembly.

(1) Surface

W1081511

Check and High Pressure Relief Valve

1. Check the check and high pressure relief valves (4) (5) for scratches and damage.

2. Check the springs (3) (6) for breakage and wear.

3. If anything unusual, replace the check and high pressure relief valve assembly.

(1) Plug

(2) O-ring

(3) Spring


Valve (Reverse)


Valve (Forward)

(6) Spring

(7) O-ring

(8) Plug

W1083138

By-pass Valve

1. Check the by-pass spool (3) and spring (4).

2. If defects are found, replace them.

(1) Plug

(2) O-ring

(3) By-pass Spool

(4) Spring

W1083603

2-S40



Cylinder Block Assembly

1. Check the cylinder blocks (4) and pistons (3) for scratches and wear.

2. If scratch or worn, replace the cylinder block assembly.

3. Check that the piston (3) and spring (2) are in each cylinder bore.

4. Check the pistons for their free movement in the cylinder block bores.

5. If the piston or the cylinder block is scored, replace the cylinder block assembly.

6. Check the polished face (1) of cylinder block for scoring.

7. If scored, replace the cylinder block assembly.

■

IMPORTANT

• Do not interchange pistons between pump and motor cylinder block. Pistons and cylinder blocks are matched.

(1) Polished Face

(2) Spring

(3) Piston

(4) Cylinder Block

W1106099

Thrust Ball Bearing

1. Check the thrust ball bearing (1) for scratches and excessive wear.

2. If the thrust ball bearing (1) is worn, replace it.


W1086562

Pump Shaft

1. Check the seal surface (1), the bearing surface (2) and the ball bearing (3).

2. If the shaft is rough or grooved, replace it.

3. If the ball bearing is worn, replace it.

(1) Seal Surface

(2) Bearing Surface

(3) Ball Bearing

W1086914

2-S41



Bushing and Oil Seal

1. Check the oil seals (1) for damage.

2. Check the bushings (2) for wear.

3. If the oil seals and bushings are worn or damaged, replace them.

(1) Oil Seal (2) Bushing

W1087089

(2) Transaxle Case

Checking Bearing

1. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness.

2. Apply transmission fluid to the bearing, and hold the inner race.

Then, turn the outer race to check rotation.

3. If there is any defect, replace it.

W1087327

PTO Clutch Disc Wear

1. Measure the thickness of PTO clutch disc with vernier calipers.

2. If the thickness is less than the allowable limit, replace it.

Thickness of PTO clutch disc

Factory spec.

Allowable limit

1.3 to 1.5 mm

0.051 to 0.059 in.

1.2 mm

0.047 in.

W1087562

2-S42



Pressure Plate and Friction Plate Wear

1. Measure the thickness of pressure plate and friction plate 1, 2 with vernier calipers.


Thickness of pressure plate

Factory spec.

Allowable limit

1.55 to 1.65 mm

0.061 to 0.065 in.

1.50 mm

0.059 in.

Thickness of friction plate 1

Thickness of friction plate 2

Factory spec.

Allowable limit

Factory spec.

Allowable limit

1.55 to 1.65 mm

0.061 to 0.065 in.

1.50 mm

0.059 in.

0.75 to 0.85 mm

0.030 to 0.034 in.

0.70 mm

0.028 in.

W1087721

Clutch Spring Free Length

1. Measure the free length of spring with vernier calipers.

2. If the measurement is less than the allowable limit, replace it.

Clutch spring free length

Factory spec.

Allowable limit

45 mm

1.77 in.

42 mm

1.65 in.

W1088067

PTO Brake Disc Wear

1. Measure the thickness of PTO brake disc with a vernier caliper.


PTO brake disc 1 thickness

Factory spec.

Allowable limit

2.85 to 3.05 mm

0.11 to 0.12 in.

2.75 mm

0.108 in.

PTO brake disc thickness

Factory spec.

Allowable limit

3.3 to 3.5 mm

0.13 to 0.14 in.

3.00 mm

0.118 in.

W1088290

2-S43



Friction Plate Wear

1. Measure the thickness of brake friction plate 1, 2 with vernier calipers.


Thickness of brake friction plate 1

Factory spec.

Allowable limit

1.75 to 1.85 mm

0.069 to 0.073 in.

1.60 mm

0.063 in.

Thickness of brake friction plate 2

Factory spec.

Allowable limit

0.95 to 1.05 mm

0.037 to 0.041 in.

0.80 mm

0.031 in.

W1088453

Clutch Spline Plate Wear

1. Measure the thickness of clutch spline plate with vernier calipers.


Thickness of clutch spline plate

Factory spec.

Allowable limit

0.75 to 0.85 mm

0.030 to 0.033 in.

0.70 mm

0.028 in.

W1088611

Steering Clutch Disc Wear

1. Measure the thickness of steering clutch disc with vernier calipers.


Thickness of steering clutch disc

Factory spec.

Allowable limit

1.3 to 1.5 mm

0.051 to 0.059 in.

1.2 mm

0.047 in.

W1088927

Friction Plate and Clutch Plate

1. Measure the thickness of friction plate and clutch plate with vernier calipers.


Thickness of friction plate

Factory spec.

Allowable limit

0.75 to 0.85 mm

0.030 to 0.033 in.

0.70 mm

0.028 in.

Thickness of clutch plate

Factory spec.

Allowable limit

1.55 to 1.65 mm

0.061 to 0.065 in.

1.50 mm

0.059 in.

W1089129

2-S44



Backlash between 11T Bevel Gear Shaft and 17T-13T Gear

Shaft

1. Stick a strip of fuse the three spots on the 11T bevel gear shaft

(3) with grease.

2. Reassemble the hydrostatic transmission and transaxle case.

3. Fix the transaxle case, and push the by-pass valve.

4. Turn the motor shaft.

5. Remove the 11T bevel gear shaft (3), and measure the thickness of the fuses with an outside micrometer.

Backlash between 11T bevel gear shaft and

17T-13T gear shaft

Factory spec.

0.10 to 0.30 mm

0.0039 to 0.012 in.

(Reference)

• Thickness of adjusting shims

For 11T bevel gear shaft (4) : 0.2 mm (0.008 in.)

0.3 mm (0.012 in.)

0.5 mm (0.020 in.)

For 17T-13T gear shaft (LH) (1) : 0.2 mm (0.008 in.)

0.3 mm (0.012 in.)

0.5 mm (0.020 in.)

For 17T-13T gear shaft (RH) (5) :0.2 mm (0.008 in.)

0.3 mm (0.012 in.)

0.5 mm (0.020 in.)

• Tooth contact : More than 35 %

(1) Shim (for 17T-13T Gear Shaft (LH))

(2) 17T-13T Gear Shaft

(3) 11T Bevel Gear Shaft

(4) Shim (for 11T Bevel Gear Shaft)

(5) Shim (for 17T-13T Gear Shaft (RH))

W1106788

2-S45


3

BRAKES


SERVICING

CONTENTS






[2] DISASSEMBLING AND ASSEMBLING..................................................3-S4

(1) Pedal System Component ..................................................................3-S4

(2) Brake Assembly ..................................................................................3-S8


GR2100EC2, WSM


Symptom

Insufficient Braking

Force

Brake Drags

Heavy Brakes

Probable Cause

Brake pedal free travel excessive

Brake shoe worn

Brake drum worn

Grease or oil on brake shoe

Brake pedal free travel too small

Brake spring weaken or broken

Brake pedal rusted

Brake cam lever rusted

BRAKES

Solution

Adjust

Replace

Replace

Replace

Adjust

Replace

Repair or replace

Replace

Reference

Page

3-S4

3-S8

3-S8

3-S8

3-S4

3-S8

3-S8

3-S8

W1014322

3-S1


GR2100EC2, WSM


Item

Brake Pedal Free Travel


15 to 25 mm

0.59 to 0.98 in.

BRAKES

Allowable Limit

–

W1013874

3-S2


GR2100EC2, WSM BRAKES




Item

Steering wheel mounting nut

Power steering hose mounting nut

Steering support mounting screw

Pedal system component mounting nut

N·m

20 to 25

24.0 to 28.0

48.1 to 55.8

48.1 to 55.8

kgf·m

2.0 to 2.5

2.45 to 2.85

4.9 to 5.7

4.9 to 5.7

ft-lbs

14.8 to 18.4

17.71 to 20.65

35.5 to 41.2

35.5 to 41.2

W1012736

3-S3





Brake Pedal Free Travel

CAUTION

• Stop the engine, remove the key, and chock the wheels before checking brake pedal.

1. Release the parking brake.

2. Loosen the lock nut (1).

3. Adjust the brake spring (2) length (A) so that the brake pedal free travel (B) is from 15 to 25 mm (0.59 to 0.98 in.).

4. Retighten the lock nut (1).

Brake pedal free travel

(B)

Factory spec.

15 to 25 mm

0.59 to 0.98 in.

(Reference)

• Brake spring length (A) : 73 to 74 mm (2.87 to 2.91 in.)

(1) Lock Nut (2) Brake Spring

W1010662


(1) Pedal System Component




W1011726

Dismounting Container


DISASSEMBLING AND SERVICING” at “2. TRANSAXLE” section

W1013516

Battery

CAUTION


1. Open the bonnet.




(1) Negative Cable

(2) Positive Cable

(3) Battery

W1013611


3-S4


Discharge Duct



(4).


(1) Filter Cover

(2) Discharge Duct

(3) Duct Plate


(5) Connector

W1012965

Container Base




(1) Coupler

(2) Relay

(3) Container Base

(4) Connector

[A] Left Side

[B] Right Side

W1012680

3-S5



Seat




W1014606

Fender







(1) Lever Grip

(2) Seat Base


(4) Fuel Cap

(5) Fender



(8) Step Sheet

W1014948

Steering Wheel, Side Bonnet and Panel

1. Remove the steering wheel (1).


3. Remove the accelerator lever grip.

4. Remove the indicator lamps.

5. Disconnect the connectors for the KRA system switch (4), main switch (5) and hour meter (6).

6. Remove the fuse box (7) from the steering support.

7. Remove the panel (2).


Tightening torque


20 to 25 N·m

2.0 to 2.5 kgf·m

14.8 to 18.4 lbf-ft

(1) Steering Wheel

(2) Panel

(3) Side Bonnet

(4) KRA System Switch

(5) Main Switch

(6) Hour Meter

(7) Fuse Box

W1015321

3-S6



Separating Engine


DISASSEMBLING AND SERVICING” at “1. ENGINE” section.

W1016481

Steering Support Assembly

1. Disconnect the power steering hose (1) (2) (3) (4).

2. Disconnect the connectors for the timer relay, regulator and buzzer unit.

3. Disconnect the accelerator wire (6).

4. Separate the steering support assembly (5).


• Be sure to connect the power steering hose to their original position, and tighten them to the specified torque.

Tightening torque


Steering support mounting screw

24.0 to 28.0 N·m

2.45 to 2.85 kgf·m

17.71 to 20.65 lbf-ft

48.1 to 55.8 N·m

4.9 to 5.7 kgf·m

35.5 to 41.2 lbf-ft

(1) Cylinder Hose LH

(2) Cylinder Hose RH

(3) Return Hose

(4) Delivery Hose

(5) Steering Support

(6) Accelerator Wire

A : Bottom View

P : Pump Port

(Connected to Delivery Hose)

T : Tank Port

(Connected to Return Hose)

L : L Port

(Connected to Cylinder RH)

R : R Port

(Connected to Cylinder LH) a : Right from Operator b : Front

W1016566

Brake Rod and Speed Change Rod

1. Disconnect the brake rod 1 (1) from the pedal system component.

2. Disconnect the speed change rod (2) from the pedal system component.

(1) Brake Rod 1 (2) Speed Change Rod

W1017520

3-S7



Pedal System Component

1. Remove the parking lock spring (1).

2. Remove the pedal system component mounting nuts (2).

3. Separate the pedal system component (3) from frame.


Tightening torque

Pedal system component mounting nut

48.1 to 55.8 N·m

4.9 to 5.7 kgf·m

35.5 to 41.2 lbf-ft

(1) Parking Lock Spring

(2) Pedal System Component Mounting

Nut

(3) Pedal System Component

W1017756

(2) Brake Assembly

Brake Assembly

1. Remove the lock nut (1), plain washers (2) and brake spring (3).

2. Remove the brake plate (5).

3. Remove the brake rod 2 (4).

4. Remove the brake assembly (6).

5. Remove the external snap ring (7).

6. Pull out the brake drum (8).


• Apply liquid gasket (Three Bond 1208D or equivalent) to joint face of the brake assembly.

• Tighten the brake assembly mounting screws (7) while pushing up the brake arm lever (10) by the hand.

■

NOTE

• After assembling the brake assembly, be sure to adjust the brake pedal free travel ( Refer to “[1] CHECKING AND

ADJUSTING” of “4. CHECKING, DISASSEMBLING AND

SERVICING” in this section).

Tightening torque

Brake Assembly Mounting

Screw

7.8 to 8.8 N·m

0.80 to 0.89 kgf·m

5.8 to 6.4 lbf-ft

(1) Lock Nut

(2) Plain Washer

(3) Brake Spring

(4) Brake Assembly

(5) Brake Rod 2

(6) Brake Plate

(7) Brake Assembly Mounting Screw


(9) Brake Drum

(10) Brake Arm Lever

W1012172

3-S8


4

FRONT AXLE


MECHANISM

CONTENTS

1. STRUCTURE ................................................................................................. 4-M1


GR2100EC2, WSM

1. STRUCTURE

FRONT AXLE


(2) Front Axle Case (Front Side)

(3) Differential Gear Assembly

(4) Differential Pinion Shaft

(5) Differential Pinion Gear

(6) Differential Yoke Shaft, RH

(7) Differential Side Gear

(8) Bevel Gear

(9) Bevel Pinion Shaft

(10) Differential Yoke Shaft, LH

(11) Front Axle Case (Rear Side)

(12) 10T Bevel Gear

(13) 15T Bevel Gear

(14) 35T Bevel Gear

(15) Front Gear Case Cover

(16) Front Axle Shaft


(18) Pipe

(19) Front Gear Case

W1012645

The front axle of this machine is constructed as shown above. Power is transmitted from the transmission through the propeller shaft to the bevel pinion shaft (9), then to the bevel gear (8) and to the differential side gear (7).

The power through the differential side gear is transmitted to the differential yoke shaft (6), (10), and to the bevel gear shaft (17) through the 10T bevel gear (12) and 15T bevel gear (13).

The revolution is greatly reduced by the bevel gear shaft (17) and 35T bevel gear (14), then the power is transmitted to the front axle shaft (16).

The differential system allows each wheel to rotate at a different speed to make turning easier.

4-M1


SERVICING

CONTENTS






[2] PREPARATION ........................................................................................4-S6

(1) Separating Front Axle Assembly.........................................................4-S6


(1) Front Axle Assembly ...........................................................................4-S9

[4] SERVICING ............................................................................................4-S12


GR2100EC2, WSM


Symptom

Front Wheels

Wander to Right or

Left

Front Wheels Can

Not Be Driven

Noised


Tire pressure uneven Adjust

Improper toe-in adjustment (improper alignment) Adjust

Tie-rod end loose

Air sucked in power steering circuit

Front wheel driving gears in front axle gear case broken

Universal joint broken

Front wheel drive gears in transmission broken

Front differential gear broken

Tighten

Bleed

Replace

Replace

Replace

Gear backlash excessive

Oil insufficient

Replace

Adjust or replace

Replenish

Bearings damaged or broken

Gears damaged or broken

Replace

Replace

FRONT AXLE

Reference

Page

G-54

4-S4

4-S9

–

4-S9

4-S7

2-S25

4-S11, 12

4-S13 to 15

4-S6

–

–

W1014322

4-S1


GR2100EC2, WSM


Front Wheel Alignment

Item

Toe-in

Differential Gear Case to Differential Side

Gear

Clearance

Differential Gear

Case

(I.D.)

Differential Side

Gear

(O.D.)

Clearance Differential Pinion Shaft to Differential

Pinion

Differential Pinion

Shaft

(O.D.)

Differential Pinion

(I.D.)

Backlash Differential Pinion Gear to Differential Side

Gear

Bevel Pinion Shaft to Bevel Gear Backlash

10T Bevel Gear to 15T Bevel Gear Backlash


0 to 5 mm

0.00 to 0.20 in.

0.040 to 0.082 mm

0.00157 to 0.00323 in.

19.500 to 19.521 mm

0.76772 to 0.76854 in.

19.439 to 19.460 mm

0.76532 to 0.76614 in.

0.025 to 0.055 mm

0.00098 to 0.00217 in.

9.960 to 9.975 mm

0.39212 to 0.39272 in.

10.000 to 10.015 mm

0.39370 to 0.39429 in.

0.1 to 0.3 mm

0.004 to 0.012 in.

0.1 to 0.3 mm

0.004 to 0.012 in.

0.1 to 0.3 mm

0.004 to 0.012 in.

FRONT AXLE

Allowable Limit

–

0.17 mm

0.0067 in.

–

–

0.25 mm

0.0096 in.

–

–

–

–

–

W1013874

4-S2


GR2100EC2, WSM FRONT AXLE




Item

Power steering cylinder hose

Front wheel mounting screw

Front axle bracket mounting screw

Tie-rod slotted nut

King pin support mounting nut

Front gear case cover mounting screw

Front axle case screw

N·m

24.0 to 28.0

108.5 to 130.2

48.1 to 55.9

17.7 to 34.3

19.6 to 25.5

17.7 to 20.6

9.8 to 11.3

kgf·m

2.45 to 2.85

11.07 to 13.29

4.9 to 5.7

1.8 to 3.5

2.0 to 2.6

1.8 to 2.1

1.00 to 1.15

ft-lbs

17.71 to 20.65

80 to 96

35.5 to 41.2

13.0 to 25.3

14.4 to 18.8

13.0 to 15.1

7.23 to 8.33

W1012736

4-S3





Toe-in

1. Inflate the tires to the specified pressure.

2. Turn the front wheels straight ahead.

3. Measure the toe-in (B-A).

4. If the measurement is not within the factory specifications, adjust the tie-rod length.

Toe-in (B-A) Factory spec.

0 to 5 mm

0.00 to 0.20 in.

(A) Wheel to Wheel Distance at Front

(B) Wheel to Wheel Distance at Rear

(C) Front

W1010662

Toe-in Adjusting

1. Loosen the lock nuts (1).

2. Turn the tie-rod (2) until to be factory specification.

3. Tighten the lock nuts (1).

(1) Lock Nut (2) Tie-rod

W1014949

4-S4



Adjusting Glide Steer

CAUTION


• Stop the engine and remove the key.

■

NOTE

• This adjustment should be performed after completing the adjustment of toe-in.

1. Lift up the machine while kept parallel, and support it with disassembling jacks.

2. To fix the front axle, wedge the wooden blocks between the frame and the front axle.

3. Turn the front wheels straight ahead position.

4. Using the steering wheel, make adjustments so that the length of the right and left steering cylinder tubes becomes equal to each other. Measure the length of the steering cylinder tubes at that time. (This measurement result shall be “L1(a)”.)

5. Confirm that the left and right rear wheels do not rotate manually.

6. Select “L1(b)” from “L1(a)” given by “4” by using TABLE 1 shown below

7. Turn the steering wheel to left or right slowly.

8. When the rear wheel in the side to which the steering wheel is turned is rotated manually, measure the length of the steering cylinder tube.

9. If the measurement result given in “8” is not within the range of

“L1(b)” selected in “6”, adjusting the length of the glide steer wire boot (L2) with the lock nut.

■

NOTE

• The length of the steering cylinder tube (L1 (b)) when the rear wheel is rotaed manually must not exceed 94.9 mm

(3.74 in.).

• This adjustment should be carried out only when the front wheel is turned in the right-turn direction (or the left-turn direction) from the going-straight direction.

[TABLE 1]

L1(a)

L1(b)

68.0 mm

2.68 in.

90.1 to 92.9 mm

3.55 to 3.66 in.

68.5 mm

2.70 in.

90.6 to 93.4 mm

3.57 to 3.68 in.

69.0 mm

2.72 in.

91.1 to 93.9 mm

3.59 to 3.70 in.

69.5 mm

2.74 in.

91.6 to 94.4 mm

3.61 to 3.72 in.

70.0 mm

2.76 in.

92.1 to 94.9 mm

3.63 to 3.74 in.

L1 :Length of the Steering Cylinder

Tube

L1 (a) :“L1” when the front wheels are in the position in the goingstraight direction

L1 (b) :“L1” when the right (or left) rear wheel is rotaed manualluy by turning the front wheels in the right (or left) direction

L2 :Length of Glide Steer wire boot

W1015126

4-S5



[2] PREPARATION

(1) Separating Front Axle Assembly




W1016436

Draining Front Axle Case Oil

1. Place the oil pans underneath the front axle case.

2. Remove the both right and left hand side drain plugs (3) and filling plug with dipstick (2) to drain the oil.

3. After draining, reinstall the drain plugs (3).

(When re-filling)

• When re-filling, remove the right and left breather plugs (1).

• Fill the oil up to the upper line on the filling plug with dipstick (2).

■

IMPORTANT

• After ten minutes, check the oil level again, add oil to prescribed level.

• Use KUBOTA UDT or SUPER UDT fluid. Refer to "4.

LUBRICANTS, FUEL AND COOLANT" at "G. GENERAL" section.

Front axle case fluid capacity

1.9 L

0.50 U.S.gals

0.42 Imp.gals

(1) Breather Plug


(3) Drain Plug


W1014629

Battery

CAUTION


1. Open the bonnet.




(1) Negative Cable

(2) Positive Cable

(3) Battery

W1016814

4-S6








(1) Bonnet

(2) Bonnet Bracket

(3) Side Bonnet

(4) Wire Harness

(5) Connector

W1018035

Power Steering Hose

1. Disconnect the power steering cylinder hoses (1).


Tightening torque


24.0 to 28.0 N·m

2.45 to 2.85 kgf·m

17.71 to 20.65 ft-lbs

(1) Power Steering Cylinder Hose

W1018215


1. Turn the steering wheel to left or right.

2. Disconnect the Glide Steer wire (3) on the opposite side to which the steering wheel is turned from the king pin support (2).

3. Remove the Glide Steer wire (3) from the wire holder (1).


• Adjust the Glide Steer. (Refer to “[1] CHECKING AND

ADJUSTING” of “4. CHECKING, DISASSEMBLING AND

SERVICING” in this section.)

(1) Wire Holder



W1018684

Front Wheel and Joint Cover

1. Lift up the front side of machine and place the disassembling stand under the front axle frame.

2. Remove the front wheels.

3. Remove the joint cover mounting screws and slide the joint cover

(1).


Tightening torque


108.5 to 130.2 N·m

11.07 to 13.29 kgf·m

80 to 96 ft-lbs

(1) Joint Cover (2) Universal Joint

W1018894

4-S7



Power Steering Cylinder Holder

1. Unscrew the power steering cylinder holder mounting screws (2).

2. Remove the power steering cylinder holder (1).


• Reinstall the Glide Steer wire (3) as shown in the figure.

(1) Power Steering Cylinder Holder


Mounting Screw

(3) Glider Steer Wire

(4) Front Axle Assembly

(5) Power Steering Cylinder

W1019057

Front Axle Assembly

1. Support the front axle assembly (1) so as not to drop out.

2. Remove the front axle bracket (2).

3. Separate the front axle assembly (1) from the frame.


• Apply the grease to center pin of front axle assembly.

• Reinstall the shims (4), (6) and collar (5) on the front axle bracket retaining screw (3) as shown in the figure.

Tightening torque

Front axle bracket

Mounting Screw

48.1 to 55.9 N·m

4.9 to 5.7 kgf·m

35.5 to 41.2 ft-lbs



(3) Front Axle Bracket Retaining Screw

(4) Shim

(5) Collar

(6) Shim

W1019299

4-S8




(1) Front Axle Assembly

Power Steering Cylinder

1. Remove the cotter pin and remove the slotted nut for tie-rod (1).

2. Remove the power steering cylinder mounting screws and remove the power steering cylinder (2) with tie-rod.


■

NOTE

• Tighten the slotted nut to 17.7 N·m (1.8 kgf·m, 13 ft-lbs). If the slot and pin hole do not meet, tighten the nut until they do meet, and install the cotter pin.

• Be sure to split the cotter pin like an anchor.

Tightening torque Tie-rod slotted nut

17.7 to 34.3 N·m

1.8 to 3.5 kgf·m

13.0 to 25.3 ft-lbs

(1) Tie-rod (2) Power Steering Cylinder

W1019533

Front Gear Case Assembly

1. Remove the king pin support (1).

2. Remove the front gear case assembly (2).


• Do not interchange left and right front gear case assembles.

Tightening torque

King pin support mounting nut

19.6 to 25.5 N·m

2.0 to 2.6 kgf·m

14.4 to 18.8 ft-lbs

(1) King Pin Support (2) Front Gear Case

W1020557

Front Gear Case Cover

1. Remove the front gear case cover (1) with bevel gear (3).


• Take care not to damage the O-ring (4).

• Install the front gear case cover (1) to position the square mark

(2) on it upward.

Tightening torque

Front gear case cover mounting screw

17.7 to 20.6 N·m

1.8 to 2.1 kgf·m

13.0 to 15.1 ft-lbs

(1) Front Case Cover

(2) Square Mark

(3) Bevel Gear

(4) O-ring

W1020837

4-S9


GR2100EC2, WSM

35T Bevel Gear and Front Axle

1. Remove the 35T bevel gear (1).

2. Remove the collar (2).

3. Tap out the front axle shaft (3).

(1) 35T Bevel Gear

(2) Collar

(3) Front Axle Shaft

FRONT AXLE

W1021672

Front Gear Case

1. Remove the oil seal (1) and the ball bearing (2).

2. Remove the internal snap ring (3).

3. Remove the ball bearing (4).

4. Remove the bevel gear shaft (5) with ball bearing.

(1) Oil Seal

(2) Ball Bearing


(4) Ball Bearing


(6) Front Gear Case

W1021957

Front Axle Case

1. Separate the front axle case to front side (1) and rear side (2).


• Apply liquid gasket (Three Bond 1208D or equivalent) to joint face of the front axle case.

• Install the front axle case screw (3), noting its direction as shown in the figure.

• Tentatively tighten the front axle case screws (3) at intervals of every other one to join the front-side and rear-side front axle cases (1), (2). Then tighten all front axle case screws (3) with a specified tightening torque.

Tightening torque Front axle case screw

9.8 to 11.3 N·m

1.00 to 1.15 kgf·m

7.23 to 8.33 ft-lbs

(1) Front Axle Case (Front Side)

(2) Front Axle Case (Rear Side)

(3) Front Axle Case Screw

W1022133

4-S10



Bevel Pinion Shaft

1. Remove the bevel pinion shaft (4) from the rear side of front axle case (2).

2. Remove the oil seal (1).

(1) Oil Seal

(2) Front Axle Case (Real Side)

(3) Shim


W1022320

15T Bevel Gear

1. Remove the pipe (1).

2. Remove the ball bearing (3) and 15T bevel gear (4).

(1) Pipe

(2) Shim

(3) Ball Bearing

(4) 15T Bevel Gear

W1022499

10T Bevel Gear and Differential Gear Assembly

1. Remove the 10T bevel gears (1), (8) with bearing.

2. Remove the differential yoke shafts (3), (6).

3. Remove the differential gear assembly (4).

(1) 10T Bevel Gear (LH)

(2) Shim

(3) Differential Yoke Shaft (LH)

(4) Differential Gear Assembly

(5) Shim

(6) Differential Yoke Shaft (RH)

(7) Shim

(8) 10T Bevel Gear (RH)

W1022655

4-S11


GR2100EC2, WSM

[4] SERVICING

FRONT AXLE

Differential Gear Assembly

1. Remove the bevel gear (10).

2. Remove the bearings (5), (9) with the puller.


4. Remove the differential pinion shaft (7).

5. Remove the differential pinion gears (3), differential side gears

(4) and shims (2).

■

NOTE

• Arrange the parts to know their original position.


• Apply molybdenum disulfide (Three Bond 1901 or equivalent) to the inner circumferential surface of differential pinion gears (3), differential side gears (4) and shims (2).

• Install the steel ball (1) in a specified position of the differential gear case (6) as shown in the figure.

(1) Steel Ball

(2) Shim

(3) Differential Pinion Gear

(4) Differential Side Gear

(5) Bearing

(6) Differential Gear Case

(7) Differential Pinion Shaft


(9) Bearing

(10) Bevel Gear

W1014840

Clearance between Differential Gear Case and Differential Side

Gear

1. Measure the differential side gear boss O.D..

2. Measure the differential case bore I.D., and calculate the clearance.

3. If the clearance exceeds the allowable limit, replace faulty parts.

Clearance between differential gear case and differential side gear

Factory spec.

Allowable limit

0.040 to 0.082 mm

0.00157 to 0.00323 in.

0.17 mm

0.0067 in.

Differential gear case bore I.D.

Differential side gear

O.D.

Factory spec.

Factory spec.

19.500 to 19.521 mm

0.76772 to 0.76854 in.

19.439 to 19.460 mm

0.76532 to 0.76614 in.

W1023578

4-S12



Clearance between Differential Pinion Shaft and Differential

Pinion Gear

1. Measure the differential pinion shaft O.D..

2. Measure the differential pinion gear I.D., and calculate the clearance.

3. If the clearance exceeds the allowable limit, replace faulty parts.

Clearance between differential pinion shaft and differential pinion gear

Factory spec.

Allowable limit

0.025 to 0.055 mm

0.00098 to 0.00217 in.

0.25 mm

0.0096 in.

Differential pinion shaft

O.D.

Differential pinion gear

I.D.

Factory spec.

Factory spec.

9.960 to 9.975 mm

0.39212 to 0.39272 in.

10.000 to 10.015 mm

0.39370 to 0.39429 in.

W1024742

Backlash between Differential Pinion Gear and Differential Side

Gear

1. Set a dial gauge (lever type) on a tooth of the differential pinion gear.

2. Fix the differential side gear, and move the differential pinion gear to measure the backlash.

3. If the measurement exceeds the factory specifications, adjust with the differential pinion gears shims.

Backlash between differential pinion gear and differential side gear

Factory spec.

0.1 to 0.3 mm

0.004 to 0.012 in.

(Reference)

• Thickness of adjusting shims:

For pinion gear : 2.3 mm (0.091 in.), 2.5 mm (0.098 in.)

2.7 mm (0.106 in.), 2.9 mm (0.114 in.)

W1015159

4-S13



Backlash between Bevel Pinion Shaft and Bevel Gear

1. Stick a strip of fuse to three spots on the bevel gear (3) with grease.

2. Fix the front side and rear side of front axle case.

3. Turn the bevel pinion shaft.

4. Separate the front axle case to front side and rear side.

5. Remove the bevel gear (3), and measure the thickness of the fuses with an outside micrometer.

6. If the backlash is not within the factory specifications, adjust with shims (1), (4).

Backlash between bevel pinion shaft and bevel gear

Factory spec.

0.1 to 0.3 mm

0.004 to 0.012 in.

(Reference)


For Bevel pinion shaft (1) :0.5 mm (0.020 in.), 0.8 mm (0.031 in.)

1.0 mm (0.039 in.), 1.2 mm (0.047 in.)

1.4 mm (0.055 in.)

For Bevel gear (4) :0.6 mm (0.024 in.), 0.8 mm (0.031 in.)

1.2 mm (0.039 in.), 1.2 mm (0.047 in.)

1.4 mm (0.055 in.)

(1) Shim


(3) Bevel Gear

(4) Shim

W1025529

4-S14



Backlash between 10T Bevel Gear and 15T Bevel Gear

1. Stick a strip of fuse to three spots on the 15T bevel gear (2) with grease.

2. Fix the front side and rear side of front axle case.

3. Install the front gear case in front axle case.

4. Turn the axle.

5. Remove the front gear case, and separate the front axle case to front side and rear side.

6. Remove the 15T bevel gear (2), and measure the thickness of the fuses with an outside micrometer.

7. If the backlash is not within the factory specifications, adjust with shims (1), (4).

Backlash between 10T bevel gear and 15T bevel gear

Factory spec.

0.1 to 0.3 mm

0.004 to 0.012 in.

(Reference)


For 15T Bevel gear (1):0.6 mm (0.024 in.), 0.8 mm (0.031 in.)

1.0 mm (0.039 in.), 1.2 mm (0.047 in.)

1.4 mm (0.055 in.)

For 10T Bevel gear (4):0.6 mm (0.024 in.), 0.8 mm (0.031 in.)

1.0 mm (0.039 in.), 1.2 mm (0.047 in.)

1.4 mm (0.055 in.)

(1) Shim

(2) 15T Bevel Gear

(3) 10T Bevel Gear

(4) Shim

W1025842

4-S15


5

STEERING


MECHANISM

CONTENTS

1. HYDRAULIC CIRCUIT .................................................................................. 5-M1

2. STEERING CONTROLLER .......................................................................... 5-M2

3. STEERING CYLINDER................................................................................. 5-M4


GR2100EC2, WSM

1. HYDRAULIC CIRCUIT

STEERING


Assembly

(2) Hydraulic Pump

(3) Oil Strainer

(4) Steering Controller

(5) Steering Cylinder

A : To HST

B : To Mower Lift Cylinder

This machine is provided with a full hydrostatic power steering.

In the full hydrostatic power steering, the steering controller (4) is connected to the steering cylinder (5) with only the hydraulic piping. Accordingly, it does not have mechanical transmitting parts such as steering gear, pitman arm, drag link, etc. Therefore, it is simple in construction. This steering system consists of the oil strainer (3), hydraulic pump (2), hydraulic control valve assembly (1), steering controller (4), steering cylinder (5), etc..

The oil is supplied to the steering controller (4) through the hydraulic control valve assembly (1) by the hydraulic pump (2). With the steering wheel at neutral, the oil returns through the steering controller (4) to the hydraulic control valve assembly (1). Turn the steering wheel, and just a required amount of oil is sent to the steering cylinder (5). The oil at the side opposite to the cylinder flows back to the hydraulic control valve assembly (1).

5-M1


GR2100EC2, WSM

2. STEERING CONTROLLER

STEERING

The steering controller consists of a control valve (3) and a metering device (2).

■

Control Valve

The control valve is a rotating spool type.

When the steering wheel is not turned, the position of the spool (6) and sleeve (8) is kept neutral by the centering spring (7). This causes the forming of a

"Neutral" oil circuit.

When the steering wheel is turned either clockwise or counterclockwise, the position of the spool and sleeve changes in relation to the centering spring. This allows the forming of a "Right Turning" or "Left Turning" oil circuit. At the same time, the gear pump (Metering device) rotates with the spool and sends the oil to the cylinder corresponding to the rotation of the steering wheel.

■

Metering Device

An oil, sent from the hydraulic pump to the steering cylinder, passes through the metering device (2).

Namely, when the rotor is driven, two chambers suck in oil due to volumetric change in the pup chambers formed between the rotor (11) and the stator (12), while oil is discharged from other two chambers. On the other hand, rotation of the steering wheel is directly transmitted to the rotor through the spool (6), drive shaft (9), etc.

Accordingly, the metering device serves to supply the steering cylinder with oil, amount of which corresponds to the rotation of the steering wheel. The wheels are thus turned by the angle corresponding to the rotation of the steering wheel.

When the engine stops or the hydraulic pump malfunctions, the metering device functions as a manual trochoid pump, which makes manual steering possible.


(2) Metering Device

(3) Control Valve

(4) Steering Cylinder

(5 Check Valve

(6) Spool

(7) Centering Spring

(8) Sleeve

(9) Drive Shaft

(10) Distributor Plate

(11) Rotor

(12) Stator

P : P Port (From Hydraulic

Control Valve Assembly)

T : T Port (To Hydraulic


W1012852


5-M2

GR2100EC2, WSM STEERING

■

Relief Valve

The relief valve (1) is located in the steering controller. It controls the maximum pressure of the power steering system.

Its setting pressure is as follows.

8.3 to 8.8 MPa

84.6 to 89.7 kgf/cm

2

1204 to 1276 psi

(1) Relief Valve

P : P Port (From Hydraulic


T : T Port (To Hydraulic


W1013242

5-M3


GR2100EC2, WSM

3. STEERING CYLINDER

STEERING

(1) Rod

(2) Wiper Ring


(4) Guide

(5) O-ring

(6) Seal Ring

(7) Center Piston

(8) Piston O-ring


(10) Cylinder Tube

(11) Rod O-ring

The steering cylinder is single piston both rod double-acting type. This steering cylinder is installed parallel to the front axle and connected to tie-rods.

The tie-rods connected to both knuckle arm guarantees equal steering movement to both front wheels.

The steering cylinder provide force in both directions. Depending upon direction the steering wheel is turned pressure oil enters at one end of the cylinder to extend, or the other end to retract it, thereby turning front wheel of the tractor.

5-M4


SERVICING

CONTENTS






[2] PREPARATION ........................................................................................5-S5

(1) Separating Power Steering Controller ................................................5-S5

(2) Separating Power Steering Cylinder ...................................................5-S8


(1) Power Steering Cylinder ...................................................................5-S11


GR2100EC2, WSM


Symptom

Cannot Be Steered

Hard Steering

Probable Cause

Steering controller malfunctioning

Hose broken

Power steering oil improper

Steering Force

Fluctuates

Hydraulic pump malfunctioning



Air sucked in pump due to lack of oil

Air sucked in pump from suction circuit


Steering Wheel Turns

Spontaneously When

Released

Front Wheels

Wander to Right and

Left

Oil Temperature

Increases Rapidly




Insufficient bleeding

Cylinder malfunctioning

Improper toe-in adjustment

Tire pressure uneven

Cylinder hoses connected in reverse

Wheels Are Turned to a Direction

Opposite to Steering

Direction

Steering Wheel Turns

Idle in Manual

Steering

Noise

Insufficient bleeding

Air sucked in due to lack of oil



Steering controller (relief valve) malfunctioning

Solution

Replace

Replace

Change with specified oil

Replace

Replace

Replace

Replenish

Repair

Replace

Replace

Replenish

Repair

Bleed

Replace

Adjust

Inflate

Repair

Bleed

Replenish

Replenish

Repair

Replace

STEERING

Reference

Page

5-S8

5-S8

G-8, 31

6-S11

5-S8

5-S8

G-8, 17

6-S7, 11

5-S8

5-S8

G-8, 17

6-S7, 11

–

5-S11

4-S4

G-54

5-S8

–

G-8, 17

G-8, 17

6-S7, 11

5-S8

W1014322

5-S1


GR2100EC2, WSM


Item

Steering Wheel Play


30 to 70 mm

0.79 to 1.18 in.

STEERING

Allowable Limit

–

W1013874

POWER STEERING BODY

Relief Valve Operating

Pressure

8.3 to 8.8 MPa

84.6 to 89.7 kgf/cm

2

1204 to 1276 psi

–

W1011454

5-S2






Item



Power steering cylinder hose nut


Front axle bracket mounting screw

Tie-rod slotted nut

Tie-rod screw

N·m

20 to 25

24.0 to 28.0

24.0 to 28.0

108.5 to 130.2

48.1 to 55.9

17.7 to 34.3

74 to 84

kgf·m

2.0 to 2.5

2.45 to 2.85

2.45 to 2.85

11.07 to 13.29

4.9 to 5.7

1.8 to 3.5

7.5 to 8.6

ft-lbs

14.8 to 18.4

17.71 to 20.65

17.71 to 20.65

80 to 96

35.5 to 41.2

13.0 to 25.3

54.6 to 61.9

W1012736

5-S3





Steering Wheel Play

1. Turn the front wheels straight ahead.

2. Rotate the steering wheel lightly by hand, and measure the play.

3. If the measurement exceeds the factory specifications, replace the steering shaft and sector gear.

Steering wheel play Factory spec.

30 to 70 mm

0.79 to 1.18 in.

W1010662

Relief Valve Operating Pressure

CAUTION


1. Disconnect the power steering hose (1) L (or R) from steering controller, and set a pressure gauge.

2. Start the engine and set at maximum speed.

3. Fully turn the steering wheel to the left (or right) to check the feeling which the steering wheel lightly locks. Read the relief valve operating pressure when the steering wheel to the abovementioned lock position.

■

NOTE

• After set a pressure gauge, be sure to bleed air.

• Note that the pressure value changes by the pump action of the power steering controller when the steering operation is continued after the steering wheel is lightly locked and accurate relief valve pressure cannot be measured.

(Reference)

• Hose and adaptor size: 9/16-18 UNF.

Relief valve operating pressure

Factory spec.

8.3 to 8.8 MPa

84.6 to 89.7 kgf/cm

2

1204 to 1276 psi

(1) Power Steering Hose

W1013292

5-S4



[2] PREPARATION

(1) Separating Power Steering Controller




W1014016

Dismounting Container


DISASSEMBLING AND SERVICING” at “2. TRANSAXLE” section.

W1014145

Battery

CAUTION


1. Open the bonnet.




(1) Negative Cable

(2) Positive Cable

(3) Battery

W1014023

5-S5



Discharge Duct



(4).


(1) Filter Cover

(2) Discharge Duct

(3) Duct Plate


(5) Connector

W1012965

Container Base




(1) Coupler

(2) Relay

(3) Container Base

(4) Connector

[A] Left Side

[B] Right Side

W1013744

5-S6


GR2100EC2, WSM

Seat




STEERING

W1015242

Fender







(1) Lever Grip

(2) Seat Base


(4) Fuel Cap

(5) Fender



(8) Step Sheet

W1015581

Steering Wheel, Side Bonnet and Panel

1. Remove the steering wheel (1).


3. Remove the accelerator lever grip.

4. Disconnect the connectors for hour meter, main switch (4) and light switch.

5. Remove the indicator lamps (5).

6. Remove the fuse box (6) from the steering support.

7. Remove the panel (2).


Tightening torque


20 to 25 N·m

2.0 to 2.5 kgf·m

14.8 to 18.4 ft-lbs

(1) Steering Wheel

(2) Panel

(3) Side Bonnet

(4) Main Switch

(5) Indicator Lamp

(6) Fuse Box

W1015949

5-S7



Steering Controller

1. Disconnect the power steering hoses (1), (2), (3), (4).

2. Remove the steering controller mounting screws and remove the steering controller (5).


• Be sure to connect the power steering hoses to their original position, and tighten them to the specified torque.

Tightening torque


24.0 to 28.0 N·m

2.45 to 2.85 kgf·m

17.71 to 20.65 ft-lbs

(1) Cylinder Hose LH

(2) Cylinder Hose RH

(3) Return Hose

(4) Delivery Hose


A : Bottom View

P : Pump Port (Connect to Delivery

Hose)

T : Tank Port (Connect to Return

Hose)

L : L Port (Connect to Cylinder RH)

R : R Port (Connect to Cylinder LH) a : Right from Operator b : Front

W1017056

(2) Separating Power Steering Cylinder



DISASSEMBLING AND SERVICING” at “8. MOWER” section

W1018278

Battery

CAUTION


1. Open the bonnet.




(1) Negative Cable

(2) Positive Cable

(3) Battery

W1018648

5-S8








(1) Bonnet

(2) Bonnet Bracket

(3) Side Bonnet

(4) Wire Harness

(5) Connector

W1019214

Power Steering Hose

1. Disconnect the power steering cylinder hoses (1).


Tightening torque


24.0 to 28.0 N·m

2.45 to 2.85 kgf·m

17.71 to 20.65 ft-lbs

(1) Power Steering Cylinder Hose

W1019448


1. Turn the steering wheel to left or right.

2. Disconnect the Glide Steer wire (3) on the opposite side to which the steering wheel is turned from the king pin support (2).

3. Remove the Glide Steer wire (3) from the wire holder (1).


• Adjust the Glide Steer. (Refer to “[1] CHECKING,

ADJUSTING” of “4. CHECKING, DISASSEMBLING AND

SERVICING” at “4. FRONT AXLE” section.)

(1) Wire Holder



W1020250

Front Wheel and Joint Cover

1. Lift up the front side of machine and place the disassembling stand under the front axle frame.

2. Remove the front wheels.

3. Remove the joint cover mounting screws and slide the joint cover

(1).


Tightening torque


108.5 to 130.2 N·m

11.07 to 13.29 kgf·m

80 to 96 ft-lbs

(1) Joint Cover (2) Universal Joint

W1020516

5-S9



Power Steering Cylinder Holder

1. Unscrew the power steering cylinder holder mounting screws (2).

2. Remove the power steering cylinder holder (1).


• Reinstall the Glide Steer wire (3) as shown in the figure.



Mounting Screw

(3) Glider Steer Wire


(5) Power Steering Cylinder

W1020685

Front Axle Assembly

1. Support the front axle assembly (1) so as not to drop out.

2. Remove the front axle bracket (2).

3. Separate the front axle assembly (1) from the frame.


• Apply the grease to center pin of front axle assembly.

• Reinstall the shims (4), (6) and collar (5) on the front axle bracket retaining screw (3) as shown in the figure.

Tightening torque

Front axle bracket

Mounting Screw

48.1 to 55.9 N·m

4.9 to 5.7 kgf·m

35.5 to 41.2 ft-lbs



(3) Front Axle Bracket Retaining Screw

(4) Shim

(5) Collar

(6) Shim

W1020915

5-S10



Power Steering Cylinder

1. Remove the cotter pin and remove the slotted nut for tie-rod (1).

2. Remove the power steering cylinder mounting screws and remove the power steering cylinder (2) with tie-rod.


■

NOTE

• Tighten the slotted nut to 17.7 N·m (1.8 kgf·m, 13 ft-lbs). If the slot and pin hole do not meet, tighten the nut until they do meet, and install the cotter pin.

• Be sure to split the cotter pin like an anchor.

Tightening torque Tie-rod slotted nut

17.7 to 34.3 N·m

1.8 to 3.5 kgf·m

13.0 to 25.3 ft-lbs

(1) Tie-rod (2) Power Steering Cylinder

W1021151


(1) Power Steering Cylinder

Power Steering Cylinder and Tie-rod

1. Remove the cylinder hose adaptors (2), (3).

2. Remove the tie-rods (1), (4) from piston rod (6).

3. Remove the external snap rings (5).


• Be sure to install the hose adaptors (2), (3) as shown figure left.

• After reassembling the tie-rod, be sure to adjust the toe-in.

(Refer to “[1] CHECKING AND ADJUSTING” of “4.


FRONT AXLE” section.)

• Apply liquid lock to the thread of piston rod (6).

Tightening torque Tie-rod screw

74 to 84 N·m

7.5 to 8.6 kgf·m

54.6 to 61.9 ft-lbs

(1) Tie-rod RH

(2) Hose Adaptor RH

(3) Hose Adaptor LH

(4) Tie-rod LH


(6) Piston Rod

(7) Cylinder

A : Front

W1021401

5-S11


6

HYDRAULIC SYSTEM


MECHANISM

CONTENTS

1. HYDRAULIC CIRCUIT .................................................................................. 6-M1

2. HYDRAULIC PUMP ...................................................................................... 6-M2

3. HYDRAULIC CONTROL VALVE ................................................................. 6-M3

[1] MOWER LIFT CIRCUIT ......................................................................... 6-M4

[2] HST RELIEF VALVE.............................................................................. 6-M8

4. MOWER LIFT CYLINDER ........................................................................... 6-M9

5. MOWER LINKAGE ..................................................................................... 6-M10


GR2100EC2, WSM

1. HYDRAULIC CIRCUIT

HYDRAULIC SYSTEM





Assembly



(7) Check Valve

(8) Control Valve

(9) Hydraulic Pump

(10) Oil Strainer


The hydraulic system of this machine is composed of a hydraulic pump (9), hydraulic control valve assembly (4), mower lift cylinder (6) and other components.

This system has the following functions.

1. The oil is supplied by the hydraulic pump (9) which is driven by pump drive shaft in the transaxle case. As the pump drive shaft is engaged with the input shaft which connected to the propeller shaft, the hydraulic pump (9) starts running when engine is started.

2. The hydraulic pump forces out the oil to the hydraulic control valve assembly (4), steering controller (5) and hydrostatic transmission (1).

6-M1


GR2100EC2, WSM

2. HYDRAULIC PUMP

HYDRAULIC SYSTEM

The hydraulic pump is composed of the casing (1), cover (5), side plate (3), drive gear (2) and driven gear

(8).

Hydraulic pump is driven by the pump drive shaft in the transaxle case.

Maximum displacement is as follows.

Engine speed Condition Displacement

10.4 L/min.

2.75 U.S.gal/min.

2.29 Imp.gal/min.

At 3000 min

-1

(rpm) at no load

(1) Casing

(2) Drive Gear

(3) Side Plate

(4) O-ring

(5) Cover

(6) Oil Seal


(8) Driven Gear

W1013073

6-M2


GR2100EC2, WSM

3. HYDRAULIC CONTROL VALVE

HYDRAULIC SYSTEM

(1) Check Valve



(4) Spool (for Control Valve)

P : Pump Port

T : Tank Port (To Transaxle

Case)

T1 :Tank Port (To T Port)

C : Cylinder Port

PS1 : Power Steering Port (To

Power Steering Controller)

PS2 : Power Steering Port (From


F1 :Filter Port

(To Filter Cartridge)

F2 :Filter Port

(From Filter Cartridge)

H : HST Port (To HST)

Hydraulic control valve assembly is composed of control valve, main relief valve (3), HST relief valve (2) and check valve (1).

The oil from hydraulic pump is faced into control valve. The spool (4) is rotated by hydraulic lift lever via a link mechanism and oil from hydraulic pump is changed flow direction by the spool (4).

6-M3


GR2100EC2, WSM

[1] MOWER LIFT CIRCUIT

■

Neutral

HYDRAULIC SYSTEM

(1) Check Valve


(3) Spool

(4) Passage

P : Pump Port

T : Tank Port

(To Transaxle Case)





The oil is forced into the hydraulic control valve assembly through P port.

When the hydraulic lift lever is set to the "NEUTRAL" position, the spool (3) keeps still its original position. The oil flows through passage (4) in spool to PS1 port, then flows to power steering controller.

Since the oil does not flow through passage (4) in spool to check valve (1), C port is closed by check valve (1).

Therefore, the oil in mower lift cylinder does not flow out through C port and the mower maintains its position.

6-M4


GR2100EC2, WSM

■

Lift

HYDRAULIC SYSTEM

(1) Check Valve


(3) Spool

(4) Passage

P : Pump Port

T : Tank Port






When the hydraulic lift lever is set to the "LIFT" position, the spool (3) is rotated counter clockwise in view of left side of the machine.

The oil flows through passage (4) in spool to check valve (1), and opens the check valve (1).

The oil flows through C port to mower lift cylinder. Therefore, the mower is lifted.

While the hydraulic lift lever is set to the "LIFT" position, the oil does not flow through passage (4) in spool to PS1 port.

6-M5


GR2100EC2, WSM

■

Overload

HYDRAULIC SYSTEM

(1) Check Valve


(3) Spool

(4) Passage

P : Pump Port

T : Tank Port





Power Steering Controller

If the pressure between P port and C port exceeds the main relief valve setting pressure (9.5 to 11.0 MPa, 97 to

112 kgf/cm

2

, 1378 to 1595 psi) while the hydraulic lift lever is set to "LIFT" position, the main relief valve (2) opens.

Then, the oil flows out through the main relief valve (2) to PS1 port, preventing any further rise in pressure.

6-M6


GR2100EC2, WSM

■

Down

HYDRAULIC SYSTEM

(1) Check Valve

(2) Flat Face


(4) Spool

(5) Passage

P : Pump Port

T : Tank Port






When the hydraulic lift lever is set to "DOWN" position, the spool (4) is rotated clockwise in view of left side of the machine.

The oil does not flow through passage in spool (4) to check valve (1). However, the check valve (1) is pushed by flat face (2) of spool and opened. The oil in mower lift cylinder is forced out through C port to T port by the weight of the mower, causing the mower to lower. The oil forced out returns the transaxle case.

6-M7


GR2100EC2, WSM

[2] HST RELIEF VALVE

HYDRAULIC SYSTEM


P : Pump Port

T : Tank Port




PS2 : Power Steering Port (From


F1 :Filter Port

(To Filter Cartridge)

F2 :Filter Port

(From Filter Cartridge)

H : HST Port (To HST)

The oil flows through PS1 port to the power steering controller, and then returns to the hydraulic control valve through PS2 port. The oil in PS2 port is regulated the setting pressure (0.9 to 1.1 MPa, 9.2 to 11.2 kgf/cm

2

, 130.6 to

159.5 psi) by HST relief valve (1). Then, the oil flows through F1 port to the filter cartridge. The oil passes through the filter cartridge, and is supplied through H port as the charge oil to HST.

Therefore, the HST relief valve (1) provides the functionality of a charge relief valve.

The oil that is relieved by HST relief valve (1) passes in the valve poppet, and flows through T port to the transaxle case.

6-M8


GR2100EC2, WSM

4. MOWER LIFT CYLINDER

HYDRAULIC SYSTEM

(1) Cylinder Tube

(2) Snap Ring

(3) Cylinder Rod

(4) Packing

(5) Scraper

W1014609

The mower lift cylinder consists of cylinder tube (1), cylinder rod (3) and other parts as shown in the figure above.

This cylinder is single acting type.

6-M9


GR2100EC2, WSM

5. MOWER LINKAGE

HYDRAULIC SYSTEM

(1) Rear Link


(3) Adjusting Cam

(4) Cutting Height Adjusting Dial

(5) Cutting Height Fine Turning

Bolt

(6) Lift Link Shaft

(7) Lift Link

W1014740

The rear link (1) and lift link shaft (6) are linked with the lift link (7).

As the hydraulic lift lever is set to the "LIFT" position, the mower lift cylinder (2) is extended and the lift link shaft

(6) is rotated to pull the lift link (7). As a result, mower is lifted.

The cutting height adjusting dial (4) adjusts the cutting height of mower by rotating the adjusting cam (3).

The level of mower deck is adjusted by adjusting the cutting height fine tuning bolt length (5).

6-M10


SERVICING

CONTENTS






[2] PREPARATION ........................................................................................6-S5

(1) Separating Hydraulic Control Valve and Hydraulic Pump...................6-S5

(2) Mower Lift Cylinder ...........................................................................6-S12


(1) Hydraulic Control Valve Assembly ....................................................6-S15

(2) Mower Lift Linkage ............................................................................6-S16


GR2100EC2, WSM


Symptom Probable Cause

Mower Does Not Rise

Control valve malfunctioning

Lift cylinder damaged

Main Relief valve spring damaged

Main Relief valve setting pressure too low


Oil strainer clogged

Insufficient transmission oil


Mower Does Not

Lower

Mower Drops by Its

Weight

Lift cylinder worn or damaged


HYDRAULIC SYSTEM

Solution

Repair or replace

Replace

Replace

Adjust

Replace

Clean or replace

Refill

Repair or replace

Replace

Replace

Reference

Page

6-S15

6-S14

6-S15

6-S4

6-S11

G-32

G-8, 17

6-S15

6-S14

6-S15

W1014322

6-S1


GR2100EC2, WSM


Item

Main Relief Valve Setting Pressure


9.5 to 11.0 MPa

97 to 112 kgf/cm

2

1378 to 1595 psi

HYDRAULIC SYSTEM

Allowable Limit

–

W1013874

6-S2


GR2100EC2, WSM HYDRAULIC SYSTEM




Item

Bolt joint


Adaptor

Drain pipe mounting screw

Joint pipe

N·m

24.5 to 34.3

17.7 to 20.6

20.0 to 25.0

5.0 to 7.0

20.0 to 25.0

kgf·m

2.50 to 3.49

1.8 to 2.1

2.04 to 2.54

0.51 to 0.71

2.04 to 2.54

ft-lbs

18.1 to 25.2

13.1 to 15.2

14.8 to 18.4

3.69 to 5.16

14.8 to 18.4

W1012736

6-S3





Main Relief Valve Setting Pressure

1. Remove the cylinder hose (1) form the mower lift cylinder.

2. Install the adaptor and pressure gauge.

3. Start the engine and set at maximum speed.

4. Move the hydraulic lift lever to the "LIFT" position to operate the main relief valve and read the gauge.

5. If the pressure is not within the factory specifications, adjust with the adjusting shims (3).

Main relief valve setting pressure

Factory spec.

9.5 to 11.0 MPa

97 to 112 kgf/cm

2

1378 to 1595 psi

Condition

• Engine speed........ Maximum

• Oil temperature ..... 45 to 55

°

C

113 to 131

°

F

(Reference)

• Thickness of shim : 0.1 mm (0.004 in.)

0.2 mm (0.008 in.)

0.4 mm (0.016 in.)

(1) Cylinder Hose


(3) Shim

W1010662

6-S4



[2] PREPARATION

(1) Separating Hydraulic Control Valve and Hydraulic Pump




W1013656

Discharge Duct



(4).


(1) Filter Cover

(2) Discharge Duct

(3) Duct Plate


(5) Connector

W1012965

6-S5



Container Base




(1) Coupler

(2) Relay

(3) Container Base

(4) Connector

[A] Left Side

[B] Right Side

W1013777

6-S6




1. Start the engine. Push the mower lift lever and lower the mower link.

2. Place an oil pan under the transaxle.

3. Remove the drain plug (2).

4. Remove the strainer (5) to completely drain the transmission fluid.

5. After draining, clean the strainer (5) and reinstall it.


• Remove the filling plug with the dipstick, and fill the new transmission fluid to H level on the dipstick.

• Start the engine, and perform the following operations. However, absolutely avoid engaging the PTO lever during this operation.

1) Depress the speed change pedal alternately to the "forward" side and "reverse" side in order to move the machine forward and backward.




• At least 5 minutes after stopping the engine, check the oil level again, using the dipstick.

• If the oil level is lower than the level H indicated on the dipstick, fill the oil tank with transmission fluid additionally up to the H level.

• Perform the above-mentioned operation again. And confirm that the oil level is not low level.

• Disconnect the universal joint of mower deck from the PTO shaft.

Shift the PTO lever to "Engage" position, and check to see if the


PTO lever to the "Disengage" position, and check to see if the


■

IMPORTANT


• Use the KUBOTA UDT or SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system.





3.4 L

0.90 U.S.gals

0.75 Imp.gals

(1) Suction Pipe

(2) Drain Plug

(3) O-ring (Small)

(4) O-ring (Large)

(5) Strainer

(6) Boss


H : Highest Level

L : Lowest Level

W1016321

6-S7



Seat




W1016597

Fender







(1) Lever Grip

(2) Seat Base


(4) Fuel Cap

(5) Fender



(8) Step Sheet

W1017169

Fuel Tank

1. Drain the fuel.

2. Disconnect the fuel hoses.

3. Remove the fuel tank (1).

(1) Fuel Tank

W1017898

6-S8



Beam

1. Disconnect the connector from the PTO switch (1).

2. Remove the spring (2) from the PTO lever (3).

3. Remove the PTO rod.

4. Remove the filling pipe (4).

5. Remove the hose clamp (7) of breather hose (6).

6. Remove the beam (5).


• After assembling the beam, fix the breather hose (6) to the beam

(5) with the hose clamp (7) horizontally along the beam (5).

(1) PTO Switch

(2) Spring

(3) PTO Lever

(4) Filling Pipe

(5) Beam

(6) Breather Hose

(7) Hose clamp

W1016678

6-S9



Hydraulic Control Valve Assembly

1. Disconnect the brake rod 1 (1) and brake plate (2).

2. Remove the brake plate (2) from neutral arm holder.

3. Remove the filter cartridge (3), breather hose (5) and neutral arm holder (4).

4. Disconnect the power steering pipes (7) (8) and drain hose (10).

5. Remove the control valve pipe (6).

6. Disconnect the cylinder hose (9).

7. Remove the hydraulic control valve assembly (11).


• Apply the oil to two O-rings (15) on the charge pipe (16). Insert the charge pipe (16) straight into the charge part (17) while taking care not to damage the O-ring. Next, insert the hydraulic control valve assembly (11) straight into the charge pipe (16).

• Replace the copper gaskets (13), (14) with new one.

• Install the copper gaskets (13), (14) in original position.

• After temporarily assembling the control valve pipe (6) to the hydraulic control valve assembly (11) first, reconneet the control valve pipe (6) to the hydraulic pump (20) with the joint bolt (12).

• When reconnecting the drain hose (10) to the transaxle and hydraulic control valve assembly (11), set the hose clamps (18),

(19) at the position shown in figure.

Control valve pipe retaining nut

24 to 28 N·m

2.5 to 2.8 kgf·m

18 to 20 lbf-ft

Tightening torque Joint bolt (12)

Hose clamp for drain hose

(18), (19)

32 to 36 N·m

3.3 to 3.6 kgf·m

24 to 26 lbf-ft

1.0 to 1.2 N·m

0.11 to 0.12 kgf·m

0.74 to 0.88 lbf-ft

(Reference)

• Distance (A) : 1.0 to 2.0 mm (0.01 to 0.08 in.)

• Distance (B) : 5.0 mm (0.2 in.)

(1) Brake Rod 1

(2) Brake Plate

(3) Filter cartridge


(5) Breather Hose

(6) Control Valve Pipe

(7) Power Steering Pipe (To Power

Steering Unit Controller)

(8) Power Steering Pipe (From Power

Steering Unit Controller)

(9) Cylinder Hose

(10) Drain Hose

(11) Hydraulic Control Valve Assembly

(12) Joint Bolt



(15) O-ring

(16) Chrge Pipe

(17) Charge Port

(18) Hose Clamp

(19) Hose Clamp

(20) Hydraulic pipe

W1018628

6-S10



Hydraulic Pump

1. Remove the hydraulic pump (2) with the suction pipe 1 (4).

2. Unscrew the joint bolt (6), and remove the suction pipe 1 (4) from the hydraulic pump (2).


• Replace the copper gaskets (3), (5) with new one.

• Install the copper gaskets (3), (5) in original position.

Tightening torque


Joint bolt

17.7 to 20.6 N·m

1.81 to 2.10 kgf·m

13.1 to 15.1 lbf-ft

40.0 to 45.0 N·m

4.08 to 4.58 kgf·m

29.5 to 33.1 lbf-ft

(1) Hydraulic Pump Mounting Screw

(2) Hydraulic Pump


(4) Suction Pipe 1

(5) Copper Gasket (Thinck Type)

(6) Joint Bolt

W1022621

6-S11


GR2100EC2, WSM

(2) Mower Lift Cylinder

HYDRAULIC SYSTEM




W1023561

Discharge Duct



(4).


(1) Filter Cover

(2) Discharge Duct

(3) Duct Plate


(5) Connector

W1014908

6-S12



Container Base




(1) Coupler

(2) Relay

(3) Container Base

(4) Connector

[A] Left Side

[B] Right Side

W1014483

Seat




W1024426

Fender







(1) Lever Grip

(2) Seat Base


(4) Fuel Cap

(5) Fender



(8) Step Sheet

W1018480

6-S13



Mower Lift Cylinder

1. Disconnect the cylinder hose (2) from the mower lift cylinder (1).

2. Remove the both side of lift link (4) from the lift shaft (3).

3. Remove the clevis pins (6) (8), and remove the mower lift cylinder

(1).


(2) Cylinder Hose

(3) Lift Shaft

(4) Lift Link

(5) Rue Ring Pin

(6) Clevis Pin

(7) Rue Ring

(8) Clevis Pin

(9) Adaptor

(10) Plain Washer

W1028095

6-S14




(1) Hydraulic Control Valve Assembly

Adaptor and Filter Joint

1. Remove the adaptors (2) (3).

2. Unscrew the drain pipe mounting screw, and remove the drain pipe (4).

3. Remove the joint pipe (1).

4. Remove the filter joint (5).


Tightening torque

Adaptor

Drain pipe mounting screw

Joint pipe

20.0 to 25.0 N·m

2.04 to 2.54 kgf·m

14.8 to 18.4 lbf-ft

5.0 to 7.0 N·m

0.51 to 0.71 kgf·m

3.69 to 5.16 lbf-ft

20.0 to 25.0 N·m

2.04 to 2.54 kgf·m

14.8 to 18.4 lbf-ft

(1) Joint Pipe

(2) Adaptor

(3) Adaptor

(4) Drain Pipe

(5) Filter Joint

W1014649

Main Relief valve

1. Remove the plug (1).

2. Draw out the shims (3), spring (4), poppet (5) and valve seat (6).



■

IMPORTANT

• After reassembling the main relief valve, be sure to adjust the main relief valve setting pressure (Refer to “[1]

CHECKING AND ADJUSTING” of “4. CHECKING,

DISASSEMBLING AND SERVICING” in this section).

(1) Plug

(2) O-ring

(3) Shim

(4) Spring

(5) Poppet

(6) Valve Seat

W1029422

HST Relief Valve

1. Remove the plug (4).

2. Draw out the spring (2) and poppet (1).



(1) Poppet

(2) Spring

(3) O-ring

(4) Plug

W1029997

6-S15


GR2100EC2, WSM

(2) Mower Lift Linkage

Check Valve

1. Remove the cylinder hose adaptor (1).

2. Draw out the spring (3) and poppet (4).



(1) Cylinder Hose Adaptor

(2) O-ring

(3) Spring

(4) Poppet

HYDRAULIC SYSTEM

W1030474

(1) Screw

(2) Lock Nut

(3) Rear Link LH

(4) Clevis Pin

(5) Lift Link LH

(6) Rue Ring

(7) Rue Ring

(8) Lock Nut

(9) Plate Spring

(10) Adjusting Cam

(11) Cutting Height Adjusting Rod

(12) Cutting Height Adjusting Dial

Knob

(13) Rue Ring

(14) Lift Link RH

(15) Rue Ring

(16) Clevis Pin

(17) Rear Link RH

(18) Lock Nut

(19) Screw

W1030787

1. Dismount the mower. (Refer to “[2] PREPARATION” of “4.


MOWER” section.)

2. Remove the fender. (Refer to “[2] PREPARATION” of “4.


TRANSAXLE” section.)

3. Remove the screws (1), (19) and lock nuts (2), (18), and pull out the rue rings (6), (13).

4. Remove the rear link LH (3) and RH (17).

5. Pull out the rue rings (7), (15) and remove the clevis pins (4), (16).

6. Remove the lift link LH (5) and RH (14).

7. Remove the cutting height adjusting dial knob (12).

8. Remove the plate spring (9).

9. Unscrew the lock nut (8), and remove the cutting height adjusting rod (11) and adjusting cam (10).

W1031554

6-S16


7

ELECTRICAL SYSTEM


MECHANISM

CONTENTS

1. WIRING DIAGRAM ....................................................................................... 7-M1

2. STARTING SYSTEM .................................................................................... 7-M3

3. CHARGING SYSTEM ................................................................................... 7-M4

4. LIGHTING SYSTEM ..................................................................................... 7-M5



GR2100EC2, WSM

Color of Wiring

W .......... White

R ........... Red

L ........... Blue

P ........... Pink

B ........... Black

Br .......... Brown

Sb ......... Sky Blue

WR ........... White / Red

WY ........... White / Yellow

RB ............ Red / Black

RW ............ Red / White

RG ............ Red / Green

RY ............. Red / Yellow

BW ......... Black / White

BR .......... Black / Red

GW ........ Green / White

YR .......... Yellow / Red

YL .......... Yellow / Blue

LW ......... Blue / White

ELECTRICAL SYSTEM

W1019456

7-M2


GR2100EC2, WSM

2. STARTING SYSTEM

ELECTRICAL SYSTEM

(1) Battery

(2) Body Earth

(3) Starter Motor

(4) Glow Plug

(5) Engine Stop Solenoid

(6) Body Earth

(7) Engine Stop Time Relay

(8) Fuel Feed Pump

(9) Slow Blow Fuse (40 A)

(10) Fuse (15 A)

(11) Seat Switch

(12) Grass Container Open Switch

(13) Grass Container Open Relay

(14) Diode (3 A)

(15) Top Cover Open Switch

(16) Brake Switch

(17) Fuse (3 A)

(18) Fuse (10 A)

(19) Main Switch

(20) Hour Meter

(21) Glow Plug Lamp

(22) PTO Switch

When the main switch is turned to the PREHEAT position, the terminal BAT is connected to the terminals GLOW and ON. The glow plugs become red-hot, and the glow plug (preheat indicator) lamp also lights on while preheating.

When the main switch is then turned to the START position with the brake switch on and PTO switch on, the terminal BAT is connected to the terminals START and ON. Consequently, battery current flows to the starter motor and start the engine.

The main switch automatically returns to the ON position, the terminal BAT is connected only to the terminal ON, thereby causing the starting circuit to be opened, stopping the starter motor.

When the main switch turned from the ON position to the OFF position, the engine stop solenoid moves the fuel injection pump control rack to the "No Fuel Injection" position and stop the engine.

This machine equipped the operator presence control (OPC) system which automatically stops the engine when operator stands from the seat while shifting the PTO lever.

With the PTO lever shifted to the “ENGAGE” position, the engine of this machine stops automatically when the cover of the grass container is opened, the grass container is opened or dismounted.

7-M3


GR2100EC2, WSM

3. CHARGING SYSTEM

ELECTRICAL SYSTEM

(1) Battery

(2) Body Earth

(3) Body Earth

(4) Dynamo


(6) Regulator

(7) Main Switch

(8) Fuse (10 A)

(9) Charge Lamp

(10) Hour Meter

The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs.

It consists of a dynamo (4) and a regulator (6).

7-M4


GR2100EC2, WSM

4. LIGHTING SYSTEM

ELECTRICAL SYSTEM

(1) Battery

(2) Body Earth

(3) Thermo Switch

(4) Oil Switch

(5) Body Earth

(6) Dynamo

(7) Regulator


(9) Main Switch

(10) Fuse (10 A)

(11) Fuse (3 A)

(12) PTO Switch


(14) Buzzer Relay

(15) Buzzer

(16) Thermo Lamp

(17) Grass Container Full Lamp

(18) Oil Pressure Lamp

(19) Charge Lamp

(20) Easy Checker

(21) Head Light Switch

(22) Head Light

(23) Hour Meter

The lighting system consists of main switch, head light switch, head lights, etc..

The grass container full lamp in the easy checker lights when the grass container is filled while shifting the PTO lever. And the buzzer rings.

7-M5


SERVICING

CONTENTS






(1) Battery.................................................................................................7-S6

(2) Main Switch.........................................................................................7-S6

(3) Starter .................................................................................................7-S8

(4) Glow Plug............................................................................................7-S9

(5) Safety Switch ....................................................................................7-S10

(6) Operator Presence Control (OPC) Switch ........................................7-S11

(7) Fuel Pump.........................................................................................7-S12

(8) Engine Stop Solenoid .......................................................................7-S12

(9) Time Relay........................................................................................7-S13

(10)Charging System ..............................................................................7-S14

(11)Lighting System ................................................................................7-S15

(12)Coolant Temperature Sensor ...........................................................7-S16

(13)Grass Container Full Switch .............................................................7-S17


(1) Starter ...............................................................................................7-S18

(2) Dynamo.............................................................................................7-S19

[3] SERVICING ............................................................................................7-S20

(1) Starter ...............................................................................................7-S20

(2) Dynamo.............................................................................................7-S22


GR2100EC2, WSM


Symptom

All Electrical

Equipments Do Not

Operate

Fuse Blown

Frequently

Probable Cause

Battery discharged or defective

Battery positive cable disconnected or improperly connected

Battery negative cable disconnected or improperly connected

Slow blow fuse blown (40 A)

Short-circuited

BATTERY

Battery Discharges

Too Quickly

Battery defective

Dynamo defective

Regulator defective

Wiring harness disconnected or improperly connected (between battery positive terminal and regulator B terminal)

Cooling fan belt slipping

ELECTRICAL SYSTEM

Solution

Recharge or replace

Repair or replace

Reference

Page

G-25,

1-S21

–

Repair or replace

Replace

Repair or replace

–

G-39

–

W1014322

Replace

Repair or replace

Replace

Repair or replace

1-S21

7-S19

–

–

Adjust tension G-29

W1011677

7-S1


GR2100EC2, WSM ELECTRICAL SYSTEM

STARTING SYSTEM


Starter Motor Does

Not Operate


Engine Does Not

Stop When Main

Switch is Turned OFF

Engine Does Not

Start


Wiring harness disconnected or improperly connected (between main switch ST terminal and safety switches, between safety switches and starter motor, between battery positive terminal and starter motor)

Starter motor defective

Main switch defective

Seat switch defective

Brake switch defective

PTO switch defective

Grass container open switch defective

Fuse blown (15 A)

Wiring harness disconnected or improperly connected (between main switch ACC terminal and engine stop solenoid)

Engine stop solenoid defective

Timer relay defective

Engine stop solenoid defective

Timer relay defective

Solution

Recharge or replace

Replace

Repair or replace

Repair or replace

Replace

Replace

Replace

Replace

Replace

Replace

Repair or replace

Replace

Replace

Replace

Replace

Reference

Page

G-25,

1-S21

G-39

–

7-S18

7-S6

7-S11

7-S10

7-S10

7-S11

G-39

–

7-S12

7-S13

7-S12

7-S13

W1012286

CHARGING SYSTEM

Charging Lamp Does

Not Light when Main

Switch is Turned ON

Charging Lamp Does

Not Go Off When

Engine is Running

Fuse blown (15 A)

Bulb blown

Wiring harness disconnected or improperly connected (between main switch ACC terminal and regulator connector terminal (yellow), between regulator connector terminal (green) and charge lamp)

Regulator defective

Dynamo defective

Regulator defective

Replace

Replace

Repair or replace

Replace

Repair or replace

Replace

G-39

G-40

–

–

7-S19

–

W1012454

7-S2



LIGHTING SYSTEM

Symptom Probable Cause Solution

Head Light Does Not

Light

Glow Plug Lamp

Does Not Light When

Main Switch Is in

Pre-heat Position

Fuse blown (10 A)

Bulb blown

Wiring harness disconnected or improperly connected (between main switch ACC terminal and head light switch, between head light switch and head light)


Replace

Replace

Repair or replace

Recharge or replace

Replace

Repair or replace

Oil Pressure Lamp

Lights Up When

Engine Is Running

Oil Pressure Lamp

Does Not Light When

Main Switch Is

Turned ON and

Engine Is Not

Running

Thermo Lamp Does

Not Light When Main

Switch Is Turned ON and Engine Is Not

Running


Wiring harness disconnected or improperly connected (between main switch G terminal and glow plug lamp, between glow plug lamp and glow plugs)

Main switch defective

Bulb blown

Engine oil pressure too low


Oil pressure switch defective

Short circuit between oil pressure switch lead and chassis

Fuse blown (10 A)

Bulb blown

Oil pressure switch defective

Wiring harness disconnected or improperly connected (between main switch ACC terminal and oil pressure lamp, between oil pressure lamp and oil pressure switch)

Fuse blown (10 A)

Bulb blown

Thermo switch defective

Wiring harness disconnected or improperly connected (between main switch ACC terminal and thermo lamp, between thermo lamp and thermo switch)

Replace

Replace

Repair engine

Replenish

Replace

Repair

Replace

Replace

Replace

Repair or replace

Replace

Replace

Replace

Repair or replace

Reference

Page

G-39

G-40

–

G-25,

1-S21

G-39

–

7-S6

G-40

–

G-8, 14

7-S15

–

G-39

G-40

7-S15

–

G-39

G-40

7-S16

–

W1012630

7-S3


GR2100EC2, WSM


Item

Battery

Glow Plug

Head Light Switch

Starter

Voltage

Potential

Difference

Resistance

Resistance OFF

Resistance ON

Commutator

(O.D.)

Commutator

(Difference of

O.D.)

Mica

(Undercut)

Brush

(Length)

0.50 to 0.80 mm

0.0197 to 0.0315 in.

16.0 mm

0.630 in.

ELECTRICAL SYSTEM


More than 12 V

Less than 0.1 V

Approx. 0.9

Ω

Infinity

0

Ω

28.0 mm

1.102 in.

Less than 0.05 mm

0.002 in.

Allowable Limit

–

–

–

–

–

27.0 mm

1.063 in.

0.4 mm

0.016 in.

0.20 mm

0.0079 in.

10.5 mm

0.413 in.

W1013874

7-S4






Item

Starter (C terminal nut)

Dynamo (stator nut)

N·m

5.9 to 11.8

39.2 to 44.1

kgf·m

0.6 to 1.2

4.0 to 4.5

ft-lbs

4.3 to 8.7

28.9 to 32.5

W1012736

7-S5





(1) Battery

Battery Voltage

1. Stop the engine and turn the main switch off.

2. Connect the COM (-) lead of the voltmeter to the battery's negative terminal post (2) and the (+) lead to the positive terminal post (1), and measure the battery voltage.

3. If the battery voltage is less than the factory specification, check the battery specific gravity and recharge the battery.

Battery voltage Factory spec.

More than 12 V

(1) Positive Terminal Post (2) Negative Terminal Post

W1010662

Battery Terminal Connection

1. Turn the main switch on, and turn on the head light.

2. Measure the voltage with a voltmeter across the battery's positive terminal post and the cable terminal, and the voltage across the battery's negative terminal post and the chassis.

3. If the measurement exceeds the factory specification, clean the battery terminal posts and cable clamps, and tighten them firmly.

Potential difference Factory spec.

Less than 0.1 V

W1024780

(2) Main Switch

Main Switch

1. Open the bonnet.

2. Disconnect the 4P connector and remove the main switch (1).

3. Perform the following checks.

(1) Main Switch

W1026639

Connector Voltage

1. Measure the voltage with a voltmeter across the connector B

(red) terminal and chassis.

2. If the voltage differs from the battery voltage (11 to 14 V), the wiring harness is faulty.

Voltage

Connector B (Red) terminal - chassis

Approx. battery voltage

(1) Connector

W1029729


7-S6


Main Switch Continuity

1) Main Switch Key at OFF Position

1. Set the main switch OFF position.

2. Measure the resistance with an ohmmeter across the B terminal and the ACC terminal, B terminal and ST terminal, B terminal and G terminal.

3. If infinity is not indicated, the contacts of the main switch are faulty.

Resistance

B terminal - ACC terminal

B terminal - ST terminal Infinity

B terminal - G terminal

2) Main Switch Key at ON Position

1. Set the main switch ON position.

2. Measure the resistance with an ohmmeter across the B terminal and the ACC terminal.

3. If 0 ohm is not indicated, the B - ACC contact of the main switch are faulty.

Resistance B terminal - ACC terminal 0

Ω

3) Main Switch Key at PREHEAT Position

1. Set and hold the main switch key at the PREHEAT position.

2. Measure the resistance with an ohmmeter across the B terminal and the G terminal, and measure the resistance across the B terminal and the ACC terminal.

3. If 0 ohm is not indicated, these contacts of the main switch are faulty.


Resistance 0

Ω


4) Main Switch Key at START Position

1. Set and hold the main switch key at the START position.

2. Measure the resistance with an ohmmeter across the B terminal and the G terminal, across the B terminal and the ST terminal, and across the B terminal and the ACC terminal.

3. If 0 ohm is not indicated, these contacts of the main switch are faulty.

Resistance


B terminal - ST terminal


0

Ω

(1) G Terminal

(2) ACC Terminal

(3) ST Terminal

(4) B Terminal

W1014027

7-S7


GR2100EC2, WSM

(3) Starter

ELECTRICAL SYSTEM

Motor Test

CAUTION

• Secure the starter to prevent it from jumping up and down while testing the motor.

1. Disconnect the battery negative cable from the battery.

2. Disconnect the battery positive cable and the leads from the starter.

3. Remove the starter from the engine.

4. Disconnect the connecting lead (2) from the starter C terminal

(1).

5. Connect a jumper lead from the connecting lead (2) to the battery positive terminal post.

6. Connect a jumper lead momentarily between the starter motor housing and the battery negative terminal post.

7. If the motor does not run, check the motor.

(1) C Terminal (2) Connecting Lead

W1014498

Starter Magnet Switch Test (Pull-in, Holding Coils)

■

NOTE

• Preparate a 6 V battery for the test, and each test should be carried out for 3 to 5 seconds.

1) Checking Pull-in Coil

1. Connect jumper lead from the battery's negative terminal post to the C terminal.

2. The plunger should be attracted strongly when a jumper lead is connected from the battery positive terminal to the S terminal.

2) Checking Holding Coil

1. Connect jumper leads from the battery's negative terminal post to the body and the battery's positive terminal post to the S terminal.

2. Push the plunger in by hand and release it. Then, the plunger should remain being attracted.

W1042396

7-S8


GR2100EC2, WSM

(4) Glow Plug

ELECTRICAL SYSTEM

Lead Terminal Voltage

1. Disconnect the wiring lead (1) from the glow plug (2) after turning the main switch off.

2. Turn the main switch key to the "PREHEAT" position, and measure the voltage between the lead terminal and the chassis.

3. Turn the main switch key to the "START" position, and measure the voltage with a voltmeter between the lead terminal and the chassis.

4. If the voltage at either position differs from the battery voltage, the wiring harness or main switch is faulty.

Voltage (Lead terminal - Chassis)

Main switch key at

"PREHEAT"

Main switch key at

"START"



(1) Wiring Lead (Positive) (2) Glow Plug

W1046568

Glow Plug Continuity

1. Disconnect the lead from the glow plugs.

2. Measure the resistance with an ohmmeter between the glow plug terminal and the chassis.

3. If 0 ohm is indicated, the screw at the tip of the glow plug and the housing are short-circuited.

4. If the factory specification is not indicated, the glow plug is faulty.

Glow plug resistance Factory spec.

Approx. 0.9

Ω

W1049909

7-S9


GR2100EC2, WSM

(5) Safety Switch

ELECTRICAL SYSTEM

PTO Switch

1. Remove the battery.

2. Remove the fender.

3. Disconnect the connector from PTO switch (1).

4. Measure the resistance with an ohmmeter between the terminals.

5. If the PTO switch (1) is defective, replace it.

Resistance (between terminal a and b)

Resistance (between terminal c and d)

When plunger is pushed

When plunger is released



0

Ω

Infinity

0

Ω

Infinity

(1) PTO Switch

(2) PTO Lever

a to d :Switch Terminal

W1015458

Brake Switch


2. Remove the fender.

3. Disconnect the connector from brake switch (1).

4. Measure the resistance with an ohmmeter between the terminals.

5. If the brake switch (1) is defective, replace it.

Resistance (between terminal a and b)

Resistance (between terminal c and d)





0

Ω

Infinity

0

Ω

Infinity

(1) Brake Switch

a to d :Switch Terminal

W1056044

7-S10



Top Cover and Grass Container Open Switch


2. Remove the open switches (1), (2).

3. Measure the resistance with an ohmmeter between the saety switch terminals.

4. If the switches ae defective, replace it.

Resistance (between switch terminals)



0

Ω

Infinity

(1) Top Cover Open Switch (2) Grass Container Open Switch

W1058438

(6) Operator Presence Control (OPC) Switch

OPC Switch (Seat Switch)


2. Remove the OPC switch (1).

3. Measure the resistance with an ohmmeter between the OPC switch terminals.

4. If the OPC switch is defective, replace it.




0

Ω

Infinity

(1) OPC Switch (Seat Switch)

W1065033

7-S11


GR2100EC2, WSM

(7) Fuel Pump

ELECTRICAL SYSTEM

Connector Voltage


2. Turn the main switch key to the "ON" position, and measure the voltage with a voltmeter between the connector terminals.

3. If the voltage differs from the battery voltage, the wiring harness or main switch is faulty.

Voltage

Between connector terminals


W1067315

Fuel Pump Continuity


2. Check the continuity between the connector terminals with an ohmmeter.

3. If it does not conduct, the fuel pump is faulty.

W1070507

(8) Engine Stop Solenoid

Engine Stop Solenoid Test

1. Disconnect the 1P connector from the engine stop solenoid.

2. Remove the engine stop solenoid from the engine.

3. Connect the jumper leads from the battery positive terminal to the

1P connector, and from the battery negative terminal to the engine stop solenoid body.

4. If the solenoid plunger is not attracted, the engine stop solenoid is faulty.

(1) Battery (12 V)

W1072136

7-S12


GR2100EC2, WSM

(9) Time Relay

ELECTRICAL SYSTEM

Timer Relay Connector Voltage

1. Disconnect the connector from the timer relay after turning the main switch off.

2. Measure the voltage with a voltmeter across the connector terminal 4 and chassis.

3. Turn the main switch on, and measure the voltage across the connector terminal 3 and chassis.

4. If these voltages differ from the battery voltage, the wiring harness or main switch is faulty.

Voltage

Connector terminal 4 - chassis

Connector terminal 3 - chassis



(1) Timer Relay

W1073684

Test of Timer Relay

1. Remove the timer relay from the machine.

2. Connect jumper leads across the battery positive terminal and the timer relay terminal 3, and across the battery positive terminal and the timer relay terminal 4.

3. Connect jumper leads across the battery negative terminal and the timer relay terminal 2, and across the battery negative terminal and the bulb terminal.

4. Connect jumper lead across the timer relay terminal 1 and the bulb terminal.

5. The bulb lights up when disconnecting a jumper lead from the terminal 3 arid goes off 6 to 13 seconds late, the timer relay is proper.

(1) Timer Relay

(2) Load (Lamp)

(3) Battery (12V)

W1074866

7-S13


GR2100EC2, WSM

(10) Charging System

ELECTRICAL SYSTEM

No-load Dynamo Output

1. Disconnect the lead wires from the dynamo.

2. Start the engine and operate the dynamo at the rated speed.

3. Measure the output voltage with a volt meter.

4. If the measurement is not within the specified values, replace the dynamo.

No-load output Factory spec.

AC 20 V or more

W1048417

Regulation Voltage

CAUTION

• To avoid personal injury, do not touch the rotating or hot parts while the engine is running.

■

NOTE

• Before performing this checking, make sure that the no-load dynamo output is proper.

• Complete the charging circuit with fully charged battery.

1. Rum the engine at the rated speed.

2. Keeping the coupler (2) of regulator being connected, measure the voltage with a volt meter (5) across the terminal blue (a) and terminal blue (c). (Refer to figure (A).)

3. If the measurement is not within the specified value, replace the wire harness between the dynamo (4) and regulator (1).

4. If the measurement is within the specified value, measure the voltage with a volt meter (6) across the terminal red (f) and chassis. (Refer to figure (B).)

5. If the measurement is not within specified value, replace the regulator (1).

Voltage

Terminal blue (a) -

Terminal blue (c)

Terminal red (f) -

Chassis

AC 20 V or more

DC 14 to 15 V

(1) Regulator

(2) Coupler

(3) Battery

(4) Dynamo

(5) Volt Meter (AC)

(6) Volt Meter (DC)

a : Terminal Blue b : Terminal Black c : Terminal Blue d : Terminal Green e : Terminal Yellow f : Terminal Red

W1015722

7-S14


GR2100EC2, WSM

(11) Lighting System

ELECTRICAL SYSTEM

Head Light Switch Continuity

1. Disconnect the wiring leads from head light switch and remove it.

2. Measure the resistance with an ohmmeter across the head light switch terminals in each position.

3. If the resistance differs from the factory specifications, the head light switch is faulty.

Resistance

Factory spec.

OFF

ON

Infinity

0

Ω

(1) Head Light Switch

W1018288

Engine Oil Pressure Lamp

1. Disconnect the lead from the engine oil pressure switch after turning the main switch OFF.

2. Turn the main switch ON and connect a jumper lead from the lead to the chassis.

3. If the engine oil pressure indicator lamp does not light, the wiring harness is faulty.

(1) Engine Oil Pressure Switch

(a) From Oil Pressure Lamp

W1078559

7-S15



Engine Oil Pressure Switch Continuity

1. Measure the resistance with an ohmmeter across the switch terminal and the chassis.

2. If 0 ohm is not indicated in the normal state, the switch is faulty.

3. If infinity is not indicated at pressure over 4.9 kPa (0.5 kgf/cm

2

, 7 psi), the switch is faulty.

In normal state 0

Ω

Resistance (Switch terminal -Chassis)

At pressure over approx. 4.9 kPa(0.5 kgf/cm

2

, 7 psi)

Infinity

(1) Engine Oil Pressure Switch

W1079305

(12) Coolant Temperature Sensor

Coolant Temperature Sensor

1) Connector Voltage

1. Disconnect the 1P connector from the thermo switch (1).

2. Turn the main switch key to the "ON" position, and measure the voltage with a voltmeter between the connector terminal and the chassis.

3. If a certain voltage is not indicated, the wiring harness is faulty.

Voltage (Connector terminal - Chassis)

Factory spec.

A certain voltage is indicated

2) Thermo Switch Continuity

1. Disconnect the 1P connector, and remove the thermo switch.

2. Using an ohmmeter, check for continuity between the switch terminal and the chassis.

3. If infinity is indicated at temperature over factory specifications, the switch is faulty.

Working temperature Factory spec.

120 to 126

°

C

248.0 to 258.8

°

F

(1) Thermo Switch

(A) ON

(B) OFF

(C) 120 to 126

°

C (248.0 to 258.8

°

F)

(D) 116

°

C (240.8

°

F) or more

W1018760

7-S16


GR2100EC2, WSM

(13) Grass Container Full Switch

ELECTRICAL SYSTEM

Grass Container Full Switch Continuity


2. Dismount the grass container.

3. Remove the filter cover.


(2).

5. Measure the resistance with an ohmmeter between the grass container full switch terminals.

6. If the grass container full switch is defective, replace it.


When the diaphragm of switch is pushed

When the diaphragm of switch is released

0

Ω

Infinity

(1) Connector


(3) Diaphragm

W1018321

Buzzer

1. Remove the air intake net.

2. Disconnect the lead from buzzer (1).

3. Connect the jumper lead between the battery positive terminal and terminal 1 of connector.

4. Connect the jumper lead between the battery negative terminal and terminal 2 of connector.

5. If the buzzer does not whistle, replace it.

(1) Buzzer

1 : Terminal 1

2 : Terminal 2

W1019703

7-S17


GR2100EC2, WSM


(1) Starter

ELECTRICAL SYSTEM

(1) Sleeve Bearing

(2) Bushing

(3) Starter Drive Housing

(4) Drive Lever

(5) Magnet Switch

(6) Yoke

(7) Connecting Lead

(8) Through Bolt

(9) Rear End Frame

(10) Bushing

(11) Brush

(12) Brush Holder

(13) Brush Spring

(14) Brush

(15) Washer

(16) Armature

(17) Overrunning Clutch

W1088772

1. Disconnect the connecting lead (7).

2. Remove the magnetic switch (5).

3. Remove the rear end frame (9).

4. Remove the brush (11) from brush holder (12).

5. Remove the brush holder (12).

6. Draw out the yoke (6) from the starter drive housing (3).

7. Draw out the armature (16) with the drive lever (4).

■

NOTE

• Do not damage to the brush and commutator.


• Apply grease to spline teeth of the armature, bushing, pinion gear of the overrunning clutch and armature shaft.

Tightening torque C Terminal Nut

5.9 to 11.8 N·m

0.6 to 1.2 kgf·m

4.3 to 8.7 ft-lbs

W1090524

7-S18


GR2100EC2, WSM

(2) Dynamo

ELECTRICAL SYSTEM

Stator

1. Remove the nut (3) and separate the stator comp. (4).

2. Unscrew the screws (1) and remove the stator (2).


Tightening torque Nut

39.2 to 44.1 N·m

4.0 to 4.5 kgf·m

28.9 to 32.5 ft-lbs

(1) Screw

(2) Stator

(3) Nut

(4) Stator Comp.

W1019232

Rotor

1. Tap out the shaft (1) from the rotor (3).


• Take care the direction of the collar (4), the flat side should face to the pulley (2) side.

(1) Shaft

(2) Pulley

(3) Rotor

(4) Collar

(5) Bearings

(6) Collar

W1091209

7-S19


GR2100EC2, WSM

[3] SERVICING

(1) Starter

ELECTRICAL SYSTEM

Overrunning Clutch

1. Inspect the pinion for wear or damage.

2. If there is any defect, replace the overrunning clutch assembly.

3. Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction.

4. If the pinion slips or does not rotate in the both directions, replace the overrunning clutch assembly.

W1020620

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.

3. If the minimum O.D. is less than the allowable limit, replace the armature.

4. If the difference of the O.D.'s exceeds the allowable limit, correct the commutator on a lathe to the factory specification.

5. Measure the mica undercut.

6. If the undercut is less than the allowable limit, correct it with a saw blade and chamfer the segment edges.

Commutator O.D.

Factory spec.

Allowable limit

28.0 mm

1.102 in.

27.0 mm

1.063 in.

Difference of O.D.'s

Factory spec.

Allowable limit

Less than 0.05 mm

0.002 in.

0.4 mm

0.016 in.

Mica undercut

(1) Segment

(2) Undercut

(3) Mica

Factory spec.

Allowable limit

(a) Correct

(b) incorrect

0.50 to 0.80 mm

0.0197 to 0.0315 in.

0.20 mm

0.0079 in.

W1020149

7-S20



Brush Wear

1. If the contact face of the brush is dirty or dusty, clean it with emery paper.

2. Measure the brush length (A) with vernier calipers.

3. If the length is less than the allowable limit, replace the yoke assembly and brush holder.

Brush length (A)

Factory spec.

Allowable limit

16.0 mm

0.630 in.

10.5 mm

0.413 in.

W1092955

Brush Holder

1. Check the continuity across the brush holder and the holder support with an ohmmeter.

2. If it conducts, replace the brush holder.

W1103725

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.

4. If it does not conduct, replace the armature

W1093613

7-S21



Field Coil

1. Check the continuity across the lead (1) and brush (2) with an ohmmeter.

2. If it does not conduct, replace the yoke assembly.

3. Check the continuity across the brush (2) and yoke (3) with an ohmmeter.

4. If it conducts, replace the yoke assembly.

(1) Lead

(2) Brush

(3) Yoke

W1094039

(2) Dynamo

Bearing

1. Check the bearing for smooth rotation.

2. If it does not rotate smoothly, replace it.

W1095635

7-S22


8

MOWER


MECHANISM

CONTENTS

1. POWER TRANSMISSION ............................................................................ 8-M1

2. LIFTING MECHANISM ................................................................................. 8-M2


GR2100EC2, WSM

1. POWER TRANSMISSION

MOWER


(2) Mower Belt (Left Side)

(3) Gear Box

(4) Mower Belt (Right Side)

(5) Right Side Blade Pulley

(6) Universal Joint

(7) Blade Shaft (Left Side)

(8) Left Side Blade

(9) 21T Spiral Gear

(10) Input Shaft

(11) 16T Spiral Gear

(12) Center Blade Pulley


(14) Center Blade

(15) Right Side Blade

(16) Blade Shaft (Right Side)

The power is transmitted from transaxle case to blades as follows.

■

Center Blade

PTO Shaft

→

Universal Joint (6)

→

Input Shaft (10)

→

21T Spiral Gear (9)

→

16T Spiral Gear (11)

→

Bevel Gear

Shaft (13)

→

Center Blade (14).

■

Left Side Blade

PTO Shaft

→

Universal Joint (6)

→

Input Shaft (10)

→

21T Spiral Gear (9)

→


→

Bevel Gear

Shaft (13)

→

Center Blade Pulley (12)

→

Mower Belt (Left Side) (2)

→

Left Side Blade Pulley (1)

→

Blade Shaft (Left

Side) (7)

→

Left Side Blade (8).

■

Right Side Blade

PTO Shaft

→

Universal Joint (6)

→

Input Shaft (10)

→

21T Spiral Gear (9)

→


→

Bevel Gear

Shaft (13)

→

Center Blade Pulley (12)

→

Mower Belt (Right Side) (4)

→

Right Side Blade Pulley (5)

→

Blade Shaft

(Right Side) (16)

→

Right Side Blade (15).

8-M1


GR2100EC2, WSM

2. LIFTING MECHANISM

MOWER

(1) Lift Cylinder

(2) Lift Link Shaft

(3) Hydraulic Lift Lever (4) Lift Link (5) Rear Link

The lifting of mower is performed by the hydraulic system on the machine.

For avoiding danger, the mower should be kept lifting when traveling. When the hydraulic lift lever (3) is moved to

"LIFT" position, the lift links (4) are risen with lift link shaft (2) by the oil pressure of hydraulic system.

Therefore, rear links (5) are lifted at the same time.

CAUTION

• Never operate mower in transport position.

8-M2


SERVICING

CONTENTS






(1) Adjusting Anti-Scalp Rollers................................................................8-S4

(2) Adjusting Left and Right Cutting Height ..............................................8-S5

[2] PREPARATION ........................................................................................8-S6

(1) Dismounting Mower ............................................................................8-S6


(1) Mower .................................................................................................8-S8

[4] SERVICING ............................................................................................8-S14

(1) Gear Box ...........................................................................................8-S14


GR2100EC2, WSM



Blade Does Not Turn

PTO system malfunctioning

Mower belt broken

Blade Speed is Slow

Mower belt loosen

Grass clogged

Cup washer flattened or worn

Engine rpm too low

Cutting is Poor

Mower is Not Lifted

Mower blade worn or bent

Mower blade screw loosen

Cutting height improper

Ground speed too fast

Tire pressure uneven

Anti-scalp rollers not adjusted correctly

Linkage system broken

Trouble of hydraulic system

MOWER

Solution

Check transmission

Replace mower belt

Replace mower belt of tension spring

Remove grass

Replace cup washer

Mow at full throttle, check and reset engine rpm

Sharpen or replace mower blade

Retighten mower blade screw

Adjust cutting height

Slow-down

Adjust

Adjust anti-scalp rollers

Replace linkage system

Check hydraulic system

Reference

Page

–

8-S9

8-S9

–

8-S8

–

G-42, 8-S8

8-S8

8-S5

–

G-54

8-S4

6-S14

–

W1014322

8-S1


GR2100EC2, WSM


Item

Left Tip of Blade to Right Tip of Blade Difference

Front Tip of Blade to Rear Tip of Blade

21T Spiral Gear to 16T Spiral Gear

Difference

Backlash


Less than 3 mm

0.1181 in.

Less than 5 mm

0.20 in.

0.13 to 0.25 mm

0.0051 to 0.0098 in.

MOWER

Allowable Limit

–

–

0.40 mm

0.157 in.

W1013874

8-S2


GR2100EC2, WSM MOWER




Item

Mower blade screw

Gear box mounting screw LH (Reamer)

Gear box mounting screw RH

Gear box stay mounting screw LH (Reamer)


Center Blade pulley holder mounting screw

Pulley mounting nut (Right side)

Pulley mounting nut (Left side)

Pulley holder mounting screw

Tension pulley mounting screw and nut (Right side)

Tension pulley mounting screw and nut (Left side)

Tension arm mounting screw (Only left side) and nut

N·m

88.0 to 117.6

77.5 to 90.2

77.5 to 90.2

77.5 to 90.2

48.1 to 55.8

77.5 to 90.2

88.0 to 117.6

103 to 118

77.5 to 90.2

108.5 to 130

47.5 to 57.0

77.5 to 90.2

kgf·m

8.98 to 11.99

7.9 to 9.2

7.9 to 9.2

7.9 to 9.2

4.9 to 5.7

7.9 to 9.2

8.98 to 11.99

10.5 to 12.0

7.9 to 9.2

11.07 to 13.29

4.84 to 5.82

7.9 to 9.2

ft-lbs

65.0 to 86.7

57.2 to 66.5

57.2 to 66.5

57.2 to 66.5

35.5 to 41.2

57.2 to 66.5

65.0 to 86.7

76.0 to 87.0

57.2 to 66.5

80.0 to 96.0

35.0 to 42.0

57.2 to 66.5

W1012736

8-S3





(1) Adjusting Anti-Scalp Rollers

Adjusting Anti-scalp Rollers

■

IMPORTANT

• The flattest cut can be achieved by having the anti-scalp rollers adjusted off the ground.

Check anti-scalp roller adjustments each time the mower deck cutting height is changed.

It is recommended that all the anti-scalp rollers be kept off the ground to minimize scuffing.

1. Check the machine wheel pressure.

Inflate wheels to the correct pressure. (See table below.)

Front wheel

Rear wheel

Inflation Pressure

200 kPa, 2.0 kgf/cm

2

, 29 psi

140 kPa, 1.4 kgf/cm

2

, 20 psi

2. Start the engine.

3. Raise up the mower deck to the transport position.

(Also the top end of the lift.)

4. Turn the cutting height control dial to adjust height.

5. Lower the mower deck.

■

Front side anti-scalp roller

6. Adjust height H of the rear side anti-scalp roller to one of four positions to approximately 19 mm (0.75 in.) between rollers and ground. Adjust both side rollers to the same height.

7. Install the roller with attaching hardware.

■

Rear side anti-scalp roller

8. Adjust height H of the front side anti-scalp roller to one of seven positions to approximately 19 mm (0.75 in.) between rollers and ground. Adjust both side rollers to the same height.

9. Install the roller with attaching hardware.

H : Height 19 mm (0.75 in.)

W1010662

8-S4



(2) Adjusting Left and Right Cutting Height

Adjusting Left and Right Cutting Height

1. Park the machine on level surface.

2. Wheel pressure must be correct.

3. Raise up the mower deck to the transport position. (Also the top end.)

4. Turn the cutting height control dial (1) to the "3" position.

5. Place 51 mm (2 in.) height wood blocks under each side of the mower deck.

Anti-scalp rollers must not rest on the wood block.

6. Lower the mower deck.

7. Adjust the left side equally.

8. Measure the heights of blade (L) and (R) from the ground surface and calculate the difference.

9. If the difference between left tip and right tip of blade is not within the factory specification, adjust the length of cutting height fine tuning bolt (2).

Difference (L) - (R) between left tip and right tip of blade

Factory spec.

Less than 3 mm

0.1181 in.

(Reference)

• Length of cutting height fine tuning bolt (H) :

46 to 54 mm (1.812 to 2.125 in.)


(2) Cutting Height Fine Tuning Bolt

(3) Lock Nut

(L) Left Blade Measurement Position

(R) Right Blade Measurement

Position

A : Blade Height

W1012730

8-S5



Adjusting Parallel Linkage

1. Park the machine on a level surface.

2. Wheel pressure must be correct.

3. Adjust the cutting height so that blade is level.

4. Position mower blade in the Front-to-Rear position.

5. Measure the height of blade X and Y from the ground surface and calculate the difference.

6. If the difference between front tip and rear tip of blade is not within the factory specification, adjust the length "L" of front link with lock nut (1).

Difference (X - Y) between front tip and rear tip of blade

Factory spec.

Less than 5 mm

0.20 in.

(Reference)

• L : 26 to 28 mm (1.0 to 1.1 in.)

(1) Lock Nut

X : Height of Blade Tip (Front)

Y : Height of Blade Tip (Rear)

W1016020

[2] PREPARATION

(1) Dismounting Mower

Cutting Height Adjusting Dial

1. Park the machine on level ground, and stop the engine.

2. Set the cutting height adjusting dial (1) to "1" position.

3. Set the front anti-scalp rollers at the top position.

4. Lower the mower deck on level ground by hydraulic lift lever (2).

(1) Cutting Height Adjusting Dial (2) Hydraulic Lift Lever

W1016542

Front Link

1. Pull the lever fulcrum fixing pin (2) and turn it counterclockwise to lock.

2. Push down the link fixing lever (1).

3. Remove the front link (3) from the mower deck.


• When attach the front link, make sure the length of the front link.

(1) Link Fixing Lever

(2) Lever Fulcrum Fixing Pin

(3) Front Link

W1013194

8-S6



Rear Link and Universal Joint

1. Disconnect the rotate plate rod (1).

2. Disconnect the rear link (2) from the mower deck, pulling the Lpins (3).

3. Disconnect the universal joint (4) from the PTO shaft.

4. Raise the mower lift lever and lock in the raised position.


• Apply grease to the spline of PTO shaft.

• Slide the universal joint back and front to make sure the universal joint is locked securely.

• When attach the rear links, make sure the length of the rear links.

(1) Rotate Plate Rod

(2) Rear Link

(3) L-pin

(4) Universal Joint

W1016771


1. Turn the front wheel to the right.

2. Pull out the mower deck to the left.

W1017139

8-S7




(1) Mower

Mower Blades

1. Turn over the mower.

2. Unscrew the mower blade screw (1), and remove the plate spring

(2), mower blade (3) and dust cover (4).

■

NOTE

• To remove the blade securely, wedge a block of wood between one blade and the mower deck in such position that it will hold the blade safely while loosing or tightening the blade screw.


• Be sure to assemble the plate spring (2) between the mower blade (3) and the mower blade screw (1).

■

IMPORTANT

• Make sure the cup washer is not flattened out or worn, causing blade to slip easily.

Replace two cup washers if either is damaged.

Tightening torque Mower blade screw

88.0 to 117.6 N·m

8.98 to 11.99 kgf·m

65.0 to 86.7 ft-lbs

(1) Mower Blade Screw

(2) Plate Spring

(3) Mower Blade

(4) Dust Cover

A : Loosen

W1013639

8-S8



Mower Belt

1. Remove the left and right belt covers from the mower deck.

2. Disconnect the universal joint from the gear box (2).

3. Clean around the gear box (2).

4. Remove the mower belt RH (3) from the tension pulley (4).

5. Remove the mower belt LH (1) from the left side blade pulley (5).

6. Remove the gear box stays (7), (8).

7. Remove the mower belts (1), (3) from the center blade pulley.

Tightening torque


LH (reamer)


RH

Gear box stay mounting screw LH (reamer)


77.5 to 90.2 N·m

7.9 to 9.2 kgf·m

57.2 to 66.5 ft-lbs

77.5 to 90.2 N·m

7.9 to 9.2 kgf·m

57.2 to 66.5 ft-lbs

77.5 to 90.2 N·m

7.9 to 9.2 kgf·m

57.2 to 66.5 ft-lbs

48.1 to 55.8 N·m

4.9 to 5.7 kgf·m

35.5 to 41.2 ft-lbs

(1) Mower Belt LH

(2) Gear Box

(3) Mower Belt RH

(4) Tension Pulley


(6) Gear Box Mounting Screw LH

(Reamer)

(7) Gear Box Stay LH

(8) Gear Box Stay RH

(9) Gear Box Stay Mounting Screw RH

(10) Gear Box Mounting Screw RH

(11) Gear Box Stay Mounting Screw LH

(Reamer)

W1017452

Gear Box


2. Pull out the gear box (1) with the center blade pulley (2).

3. Remove the spline boss (5).

4. Unscrew the center blade pulley holder mounting screws (3).

5. Remove the pulley holder (4).

Tightening torque

Center blade pulley holder mounting screw

77.5 to 90.2 N·m

7.9 to 9.2 kgf·m

57.2 to 66.5 ft-lbs

(1) Gear Box


(3) Center Blade Pulley Holder

Mounting Screw

(4) Pulley Holder

(5) Spline Boss


W1018241

8-S9



Disassembling Mower Gear Box Assembly

1. Unscrew the drain plug (17), and drain gear case oil.

2. Remove the center blade pulley (1) with a puller, and remove the feather key (3) on the bevel gear shaft (4).

3. Remove the gear case caps (13), (22).

4. Remove the internal snap ring (21) and shims (20).

5. Tap out the input shaft (9) with the ball bearing (19), and external snap ring (12).

6. Remove the 21T spiral gear (11).

7. Remove the oil seal (5), internal snap ring (6), shims (7) and ball bearing (8).

8. Remove the external snap ring (14), and draw out the bevel gear shaft (4).

9. Remove the 16T spiral gear (15), ball bearing (16), shims (18) and oil seal (2).


• Replace the oil seals (2), (5) and gear case caps (13), (22) with new ones.

• Apply grease to the spline of input shaft and of bevel gear shaft.

■

IMPORTANT

• Use the specified gear box oil.

• Refer to "4. LUBRICANTS, FUEL AND COOLANT" at "G.


Mower gear case oil Capacity

0.40 L

0.42 U.S.qts

0.35 Imp.qts

■

NOTE

• While tapping out the input shaft (9) from the gear case (23), set the mating portion of external snap ring (12) on input shaft upward.


(2) Oil Seal

(3) Feather Key


(5) Oil Seal


(7) Shim

(8) Ball Bearing

(9) Input Shaft

(10) Plug



(13) Case Cap



(16) Ball Bearing

(17) Drain Plug

(18) Shim

(19) Ball Bearing

(20) Shim


(22) Case Cap

(23) Gear Case

W1018833

8-S10



Disassembling Center Blade Pulley Holder

1. Remove the center blade pulley holder mounting screws (1).

2. Separate the center blade puller holder from the mower deck.

3. Remove the lower oil seal (7).

4. Remove the internal snap ring (6), ball bearing (5) and center collar (4).

5. Remove the upper oil seal (2).


• Apply grease to the bearing and oil seal lips.

• Apply grease to the inside of center collar.

• Replace the oil seals with new ones.

• Be sure to pay attention to how to assemble lower oil seal.

• Apply liquid gasket (Three Bond 1208D or its equivalent) to the face of center pulley holder.

Tightening torque

Center blade pulley holder mounting screw

77.5 to 90.2 N·m

7.9 to 9.2 kgf·m

57.2 to 66.5 ft-lbs

(1) Center Blade Holder Mounting

Screw

(2) Upper Oil Seal

(3) Center Blade Pulley Holder

(4) Center Collar

(5) Ball Bearing

(6) Internal Snap RIng

(7) Lower Oil Seal

W1019754

8-S11


GR2100EC2, WSM

Disassembling Side Blade Pulley Holder

MOWER

(1) Grease Nipple

(2) Pulley Mounting Nut

(3) Pulley

(4) Oil Seal

(5) Ball Bearing

(6) Pulley Holder Mounting Nut

(7) Pulley Holder

(8) Pulley Holder Mounting

Screw

(9) Collar

(10) Ball Bearing

(11) Oil Seal

(12) Blade Shaft

(13) Feather Key

A : Right Side Blade Pulley

Holder

B : Left Side Blade Pulley

Holder

W1020402

1. Remove the grease nipple (1).

2. Unscrew the pulley mounting nut (2), and remove the pulley (3) and feather key (13) (only right side).

3. Tap out the blade shaft (12).

4. Remove the pulley holder (7) from the mower deck.

5. Remove the oil seal (4), (11).

6. Remove the ball bearings (5), (10) and collar (9).

Tightening torque

Pulley mounting nut

(Right side)

Pulley mounting nut

(Left side)

Pulley holder mounting screw

88.0 to 117.6 N·m

8.98 to 11.99 kgf·m

65.0 to 86.7 ft-lbs

103 to 118 N·m

10.5 to 12.0 kgf·m

76.0 to 87.0 ft-lbs

77.5 to 90.2 N·m

7.9 to 9.2 kgf·m

57.2 to 66.5 ft-lbs

W1020643

8-S12



Disassembling Tension Pulley

1. Remove the spring from the tension arm (9).

2. Remove the tension arm mounting nut (4) and screw (12) (only left side).

3. Remove the tension arm assembly, tension collar (3) and plate

(11) (only right side).

4. Remove the tension pulley mounting screw (8) and nut (7).

5. Remove the tension pulley (5) and the tension cover (6) from the tension arm (9).


• Apply grease to the tension collar (3).

Tightening torque

Tension pulley mounting screw and nut (Right side)

Tension pulley mounting screw and nut (Left side)

Tension arm mounting screw (Only left side) and nut

108.5 to 130.2 N·m

11.07 to 13.29 kgf·m

80.0 to 96.0 ft-lbs

47.5 to 57.0 N·m

4.84 to 5.82 kgf·m

35.0 to 42.0 ft-lbs

77.5 to 90.2 N·m

7.9 to 9.2 kgf·m

57.2 to 66.5 ft-lbs

(1) Grease Nipple

(2) Shim

(3) Tension Collar

(4) Tension Arm Mounting Nut

(5) Tension Pulley

(6) Tension Cover

(7) Tension Pulley Mounting Nut

(8) Tension Pulley Mounting Screw

(9) Tension Arm

(10) Mower Deck

(11) Plate

(12) Tension Arm Screw

A : Right Side Tension Pulley

B : Left Side Tension Pulley

W1020693

8-S13


GR2100EC2, WSM

[4] SERVICING

(1) Gear Box

MOWER

Backlash between 21T Spiral Gear and 16T Spiral Gear

1. Remove the 21T spiral gear (2) from gear box.

2. Stick the strip of fuse on the 21T spiral gear (2) with grease.

3. Reassemble the gear box.

4. Turn the input shaft (4).

5. Take out the fuses, and measure the thickness of fuses with an outside micrometer. (Backlash equal thickness of fuse.)

6. If the backlash exceeds the allowable limit, adjust with shims (1),

(3), (6).

Backlash between 21T spiral gear and 16T spiral gear

Factory spec.

Allowable limit

0.13 to 0.25 mm

0.0051 to 0.0098 in.

0.40 mm

0.0157 in.

(Reference)

• Thickness of adjusting shims for 21T spiral gear (1), (3) : 0.2 mm (0.0079 in.),

0.3 mm (0.0118 in.) for 16T spiral gear (6) : 0.1 mm (0.0039 in.),

0.2 mm (0.0079 in.)

(1) Shim

(2) 21T Spiral Gear

(3) Shim

(4) Input Shaft

(5) 16T Spiral Gear

(6) Shim

W1014084

8-S14


EDITOR:

KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.

64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN

PHONE : (81)72-241-1129

FAX : (81)72-245-2484

E-mail : [email protected]

KUBOTA Corporation

Printed in Japan 2007. 03, S, EI, EI, e Code No.9Y011-15571

2006. 07, S, EI, EI, e

workshop manual gr2100ec2

WORKSHOP MANUAL

BEFORE SERVICING AND REPAIRING

SAFETY STARTING

SAFETY WORKING

AVOID FIRES

VENTILATE WORK AREA

PREVENT ACID BURNS

DISPOSE OF FLUIDS PROPERLY

PREPARE FOR EMERGENCIES

GENERAL

[1] WIRING

[2] BATTERY

[3] FUSE

[4] CONNECTOR

[5] HANDLING OF CIRCUIT TESTER

[1] GENERAL USE SCREWS, BOLT AND NUTS

[2] METRIC SCREWS, BOLTS AND NUTS

[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR

UNF THREADS

[4] PLUGS

[1] DAILY CHECK

[2] CHECK POINTS OF EVERY 50 HOURS

[3] CHECK POINTS OF EVERY 100 HOURS

[4] CHECK POINTS OF EVERY 150 HOURS

[5] CHECK POINTS OF EVERY 200 HOURS

[6] CHECK POINT OF EVERY 400 HOURS

[7] CHECK POINT OF 1500 HOURS

[8] CHECK POINTS OF EVERY 1 YEAR

[9] CHECK POINTS OF EVERY 2 YEARS

[10] OTHERS

[1] SPECIAL TOOLS FOR ENGINE

[2] SPECIAL TOOLS FOR TRACTOR

[1] TIRE PRESSURE

[2] TREAD

ENGINE

[1] HALF-FLOATING HEAD COVER

[2] CLOSED BREATHER

[1] FUEL LINE

[1] CHECKING AND ADJUSTING

(1) Engine Body

(2) Lubricating System

(3) Cooling System

(4) Fuel System

[2] PREPARATION

(1) Separating Engine

[3] DISASSEMBLING AND ASSEMBLING

(1) Cylinder Head and Valves

(2) Oil Pan, Timing Gears, Camshaft and Fuel Camshaft

(3) Pistons and Connecting Rods

(4) Crankshaft

(5) Waterpump

(6) Injection Nozzle

[4] SERVICING

(1) Cylinder Head and Valve

(2) Timing Gear, Camshaft and Fuel Camshaft

(3) Piston and Connecting Rod

(4) Crankshaft

(5) Cylinder

(6) Oil Pump

TRANSAXLE

[1] HYDROSTATIC TRANSMISSION

(1) Structure

(2) Oil Flow

(3) Operation

(4) By-pass Valve

(5) Control Linkage

[2] GLIDE STEER SECTION

(1) General

(2) Operation

[3] FRONT WHEEL DRIVE SECTION

[1] MOWER PTO CLUTCH

[1] HYDRAULIC PUMP SECTION

[1] CHECKING AND ADJUSTING

[2] PREPARATION

(1) Separating Transaxle

(2) Separating Hydrostatic Transmission

[3] DISASSEMBLING AND ASSEMBLING

(1) Hydrostatic Transmission

(2) Transaxle Case