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
KiSC issued 04, 2007 A
SAFETY INSTRUCTIONS
GR2100EC2, WSM
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
KiSC issued 04, 2007 A
SAFETY INSTRUCTIONS
GR2100EC2, WSM
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.
2
KiSC issued 04, 2007 A
SAFETY INSTRUCTIONS
GR2100EC2, WSM
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
PREVENT ACID BURNS
• 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.
3
KiSC issued 04, 2007 A
SAFETY INSTRUCTIONS
GR2100EC2, WSM
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
KiSC issued 04, 2007 A
SAFETY INSTRUCTIONS
GR2100EC2, WSM
5
KiSC issued 04, 2007 A
SAFETY INSTRUCTIONS
GR2100EC2, WSM
6
KiSC issued 04, 2007 A
SPECIFICATIONS
GR2100EC2, WSM
SPECIFICATIONS
Model
GR2100EC2
Maker
KUBOTA
Model
D782-E2-GX
Type
Indirect injection. Vertical, water-cooled, 4-cycle diesel
Number of cylinders
3
Bore and stroke
67 x 73.6 mm (2.64 x 2.90 in.)
778 cm3 (47.46 cu.in.)
Total displacement
Engine
Engine gross power (DIN)
15.6 kW (20.9 HP)
50 r/s [3000 min-1 (rpm)]
Rated revolution
Battery
51R (12 V, 450CCA)
Starting system
Cell starter (with glow plug)
Lubrication system
Forced lubrication by trochoidal pump
Cooling system
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)]
Fuel
Fuel tank
Capacities
Dimensions
18 L (4.8 U.S.gals, 4.0 lmp.gals)
Engine crankcase (with filter)
2.8 L (2.96 U.S.qts., 2.46 lmp.qts.)
Engine coolant (with recovery tank)
2.35 L (2.48 U.S.qts., 2.07 lmp.qts.)
Transmission case
3.4 L (0.90 U.S.gals., 0.75 lmp.gals.)
Front axle case
1.9 L (0.50 U.S.gals., 0.42 lmp.gals.)
Overall length (with grass catcher)
2880 mm (113.4 in.)
Overall width
1280 mm (50.4 in.)
Overall height
1230 mm (48.4 in.)
Wheel base
Tread
1280 mm (50.4 in.)
Front
825 mm (32.5 in.)
Rear
800 mm (31.5 in.)
Front
16 x 7.50 - 8, 4PR
Rear
23 x 10.50 - 12, 4PR
Weight (without mower and grass catcher)
Tires
360 kg (794 lbs)
Steering
Traveling system
Full hydraulic power steering (Gear Steer)
Transmission
Hydrostatic transmission
Brake
Traveling speed
PTO system
Internal expanding brake
Forward
0.0 to 10.0 km/h (0.0 to 6.2 mph)
Reverse
0.0 to 5.0 km/h (0.0 to 3.1 mph)
Clutch
Mechanical wet multi discs
PTO brake
Wet multi discs
NOTE: *Manufacture's estimate
The company reserves the right to change the specifications without notice.
W1028280
7
KiSC issued 04, 2007 A
SPECIFICATIONS
GR2100EC2, WSM
Model
RCK48GREC2
Cutting width
1219 mm (48.0 in.)
Cutting height
25 to 102 mm (1 to 4 in.)
Adjustment of cutting height
Mower
Dial gauge
Mounting method
Quick joint, Parallel linkage
Weight (Approx.)
80 kg (176 lbs)
Dimensions
Total length
871 mm (34.3 in.)
Total width
1270 mm (50.0 in.)
Total height
305 mm (12.0 in.)
Discharge direction
Rear
Gear box oil
0.40 L (0.42 U.S.qts, 0.35 Imp.qts)
W1030594
Model
Grass catcher
GCK450GREC2
Container capacity
450 L (118.9 U.S.gals, 99.0 Imp.gals)
Weight (Approx.)
50 kg (110 lbs)
NOTE: *Manufacture's estimate
The company reserves the right to change the specifications without notice.
W1031306
8
KiSC issued 04, 2007 A
DIMENSIONS
GR2100EC2, WSM
DIMENSIONS
9
KiSC issued 04, 2007 A
G
GENERAL
KiSC issued 04, 2007 A
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
[4] CHECK POINTS OF EVERY 150 HOURS ......................................... G-29
[5] CHECK POINTS OF EVERY 200 HOURS ......................................... G-30
[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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
1. IDENTIFICATION
When contacting your local KUBOTA distributor, always specify
engine serial number (2), machine serial number (1), mower serial
number (3) and hour meter reading.
(1) Machine Serial Number
(2) Engine Serial Number
(3) Mower Serial Number
(4) Hour Meter
W1010662
G-1
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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)
(2)
(3)
(4)
(5)
Grease
Force
Sharp Edge
Axial Force
Rotating Movement
(A) External Snap Ring
(B) Internal Snap Ring
W1011487
G-2
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
• 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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
[2] BATTERY
• Take care not to confuse positive and negative terminal posts.
• When removing battery cables, disconnect negative cable first.
When installing battery cables, check for polarity and connect
positive cable first.
• Do not install any battery with capacity other than is specified
(Ah).
• 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
[3] FUSE
• 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
[4] CONNECTOR
• For connector with lock, push lock to separate.
(A) Push
W1022218
G-5
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
• 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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
[5] HANDLING OF CIRCUIT TESTER
• Use tester correctly following manual provided with tester.
• Check for polarity and range.
W1025166
G-7
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
4. LUBRICANTS, FUEL AND COOLANT
No.
Place
Capacity
Lubricants, fuel and coolant
1
Fuel tank
18 L
4.8 U.S.gals.
4.0 lmp.gals.
No. 2-D diesel fuel
No. 1-D diesel fuel if temperature is below
-10 °C (14 °F)
2
Cooling system
with recovery tank
2.35 L
2.48 U.S.qts.
2.07 lmp.qts.
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 10W40
Above 25 °C (77 °F) : SAE30, 10W-30 or 10W-40
4
Transmission case
3.3 L
0.87 U.S.gals.
0.73 lmp.gals.
5
Front axle case
1.9 L
0.50 U.S.gals.
0.42 lmp.gals.
6
Mower gear box
0.40 L
0.42 U.S.qts.
0.35 lmp.qts.
KUBOTA UDT or SUPER UDT fluid*
SAE90 gear oil
(API service classification : more than GL-3)
Greasing
No.
Place
No. of greasing points
Engine
transmission
universal joint
1
7
8
King pin
2
9
Center pin
2
10
Glide Steer bolt
2
11
Glise Steer rear
arm
2
12
Speed control
pedal shaft
–
13
Mower link
–
14
Seat adjuster
–
15
Cable
–
16
PTO lever
–
17
Hydraulic lift lever
–
18
Grass catcher
hinge
–
Capacity
Type of grease
Until grease overflows
SAE multi-purpose
type grease
Moderate amount
Engine oil
Until grease overflows
SAE multi-purpose
type grease
[Mower]
19
Spindle shafts
3
20
Tension arm
2
21
Mower universal
joint
1
Moderate amount
Engine oil
* KUBOTA original transmission hydraulic fluid.
G-8
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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
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.)
No-grade or 4T
7T
SS400, S20C
Ordinariness
9T
S43C, S48C
Aluminum
Ordinariness
SCr435, SCM435
Aluminum
Ordinariness
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
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
79.6
to
92.5
123
to
141
181
to
209
246
to
289
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
–
–
–
5.79
to
6.50
13.1
to
15.1
29.0
to
32.5
46.3
to
53.5
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
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
0.80
to
0.90
1.8
to
2.1
4.0
to
4.5
6.4
to
7.4
–
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
7.85
to
8.82
17.7
to
20.5
39.3
to
44.1
62.8
to
72.5
–
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
–
–
–
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
1.25
to
1.45
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
35.0
to
41.0
50.0
to
58.0
9.05
to
10.4
21.7
to
25.3
44.9
to
52.0
76.0
to
86.7
123
to
144
192
to
224
254
to
296
362
to
419
W1034542
[2] METRIC SCREWS, BOLTS AND NUTS
Property class 8.8
Property class 10.9
Grade
Unit
Nominal
Diameter
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
M8
23.6 to 27.4
2.4 to 2.8
17.4 to 20.2
29.4 to 34.3
3.0 to 3.5
21.7 to 25.3
M 10
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
60.8 to 70.5
6.2 to 7.2
44.9 to 52.1
M 12
77.5 to 90.1
7.9 to 9.2
57.2 to 66.5
103.0 to 117.0
10.5 to 12.0
76.0 to 86.8
M 14
124.0 to 147.0
12.6 to 15.0
91.2 to 108.0
167.0 to 196.0
17.0 to 20.0
123.0 to 144.0
M 16
196.0 to 225.0
20.0 to 23.0
145.0 to 166.0
260.0 to 303.0
26.5 to 31.0
192.0 to 224.0
W1016172
G-9
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR
UNF THREADS
SAE GR.5
SAE GR.8
Grade
Unit
Nominal
Diameter
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
5/16
23.1 to 27.8
2.35 to 2.84
17.0 to 20.5
32.5 to 39.3
3.31 to 4.01
24.0 to 29.0
3/8
47.5 to 57.0
4.84 to 5.82
35.0 to 42.0
61.0 to 73.2
6.22 to 7.47
45.0 to 54.0
1/2
108.5 to 130.2
11.07 to 13.29
80.0 to 96.0
149.2 to 179.0
15.22 to 18.27
110.0 to 132.0
9/16
149.2 to 179.0
15.22 to 18.27
110.0 to 132.0
217.0 to 260.4
22.14 to 26.57
160.0 to 192.0
5/8
203.4 to 244.1
20.75 to 24.91
150.0 to 180.0
298.3 to 358.0
30.44 to 36.53
220.0 to 264.0
W1022485
[4] PLUGS
Material of opponent part
Shape
Tapered
screw
Straight
screw
Size
Ordinariness
Aluminum
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
R1/8
12.7 to 21.6
1.3 to 2.2
9.4 to 15.9
12.7 to 19.6
1.3 to 2.0
9.4 to 15.4
R1/4
24.5 to 44.1
2.5 to 4.5
18.1 to 32.5
24.5 to 34.3
2.5 to 3.5
18.1 to 25.4
R3/8
49.0 to 88.3
5.0 to 9.0
36.2 to 65.1
49.0 to 58.8
5.0 to 6.0
36.2 to 43.4
R1/2
58.8 to 107.9
6.0 to 11.0
43.4 to 79.6
58.8 to 78.5
6.0 to 8.0
43.4 to 57.9
G1/4
24.5 to 34.3
2.5 to 3.5
18.1 to 25.3
–
–
–
G3/8
61.8 to 82.4
6.3 to 8.4
45.6 to 60.8
–
–
–
G1/2
49.0 to 88.3
5.0 to 9.0
36.2 to 65.1
–
–
–
0000001666E
G-10
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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
No.
Indication on hour meter (Hr)
50
100
✩
150
200
250
300
350
400
450
500
550
600
Item
Engine oil
Change
★
2
Engine oil filter
Replace
★
3
Transmission and
Front axle cases fluid
Change
4
Transmission oil filter
Replace
5
Transmission strainer
Clean
6
Front axle pivot
Adjust
7
Safety device
Check
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
8
Oiling
–
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
9
Greasing
–
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
Check
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
10
Mower gear box oil
Change
✩
Clean
✩
11
✩
★
★
✩
✩
1
✩
✩
✩
✩
✩
★
✩
✩
✩
✩
✩
★
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
Air cleaner element
Replace
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
12
Battery condition
Check
13
Brake
Adjust
✩
✩
✩
✩
✩
✩
14
Fan drive belt tension
Adjust
✩
✩
✩
✩
✩
✩
Check
✩
✩
✩
✩
✩
✩
15
Fuel filter element
✩
Replace
ReferAfter Imporence
since tant
page
every
100 hr
every
200 hr
G-27
G-30
every
200 hr
every
200 hr
every
200 hr
every
200 hr
every
50 hr
every
50 hr
every
50 hr
every
50 hr
every
150 hr
every
50 hr
every
1 year
every
50 hr
every
100 hr
every
100 hr
every
100 hr
every
400 hr
G-31,
G-33
G-32
G-32
G-35
G-19
G-22
G-21
G-20
G-29
*1
G-20
G-36
G-25
G-28
G-29
G-28
G-35
W1035769
G-11
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
Period
No.
Indication on hour meter (Hr)
50
100
150
200
250
300
350
400
450
500
550
600
Item
Check
16
✩
✩
✩
✩
✩
✩
Fuel line
Replace
Check
17
✩
✩
✩
Hydraulic hose
Replace
Check
18
✩
✩
✩
Radiator hose and clamp
Replace
Check
19
✩
✩
Intake air line
Replace
20
Fuel injection nozzle
(Injection pressure)
Check
21
Radiator
Clean
22
Coolant
Change
23
Mower gear box oil seal
Replace
24
Fuel system
Bleed
25
Fuse
Replace
26
Blade
Replace
27
Mower belt
Replace
✩
ReferAfter Imporence
since tant
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
G-42
Service
as required
G-39
G-41
G-42
W1045250
G-12
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
7. CHECK AND MAINTENANCE
CAUTION
• Be sure to check and service the machine on a flat place with engine shut off, the parking brake on and
chock the wheels.
[1] DAILY CHECK
To prevent trouble from occurring, it is important to know the condition of the machine. Check the following items
before starting.
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
Checking Engine Oil Level
•
1.
2.
3.
4.
5.
6.
CAUTION
Always stop the engine and remove the key before checking
oil.
Check engine oil before starting and 5 minutes or more after the
engine has stopped.
Wipe dipstick (2) area clean.
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.
Add new oil to the prescribed level at the oil inlet (1) if necessary.
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.
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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.
18 L
4.8 U.S.gals.
4.0 Imp.gals.
Fuel tank capacity
■
•
1.
2.
3.
IMPORTANT
Use Diesel Fuel Only.
Use No.2-D diesel fuel.
Use No.1-D diesel fuel if the temperature is below -10 °C (14 °F).
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
Water and
Sediment,
volume %
Flash point °C
Carbon Residue
on, 10 percent
Residuum %
Ash, weight %
Min
Max
Max
Max
52
0.05
0.35
0.01
Distillation
Temperatures °C 90%
Point
Kinematics Viscosity
cSt or mm2/S at 40 °C
Saybolt Viscosity, SUS
at 100 °F
Min
Max
Min
Max
Min
Max
282
338
1.9
4.1
32.6
40.1
Sulfur, weight
Copper strip Corrosion
Cetane Number
Max
Max
Min
0.50
No.3
40
(1) Fuel Cap
W1030533
G-15
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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.
•
•
•
■
Tire Sizes
Recommended Inflation
Pressure
Front
16 x 7.50-8, 4PR
200 kPa
(2.0 kgf/cm2, 29 psi)
Rear
23 x 10.50-12, 4PR
140 kPa
(1.4 kgf/cm2, 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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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)
(2)
(3)
(4)
Radiator Cap
Overflow Pipe
Recovery Tank Cap
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
[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.
2. Engage the PTO lever (4).
3. Stand up. (Do not get off the machine.)
4. Engine should shut off.
■ Seat Safety Control 2
1. Run the engine at half throttle.
2. Disengage the PTO lever (4).
3. Release the brake pedal (3).
4. Stand up. (Do not get off the machine.)
5. Engine should shut off.
■ PTO Safety Control 1
1. Dismount the grass container (6) from the platform.
2. Run the engine at half throttle.
3. Engage the PTO lever (4).
4. Engine should shut off.
■ PTO Safety Control 2
1. Run the engine at half throttle.
2. Engage the PTO lever (4).
3. Dump the grass from grass container (6).
4. Engine should shut off.
■ PTO Safety Control 3
1. Open the top cover (5).
2. Run the engine at half throttle.
3. Engage the PTO lever (4).
4. Engine should shut off.
(1) Throttle Lever
(2) Key Switch
(3) Brake Pedal
(4 PTO lever
(5) Top Cover
(6) Grass container
W1013056
G-19
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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/cm2, 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
COOLANT” in this section.)
(1) Check Plug
(2) Oil Filling Plug
W1039488
G-20
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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 (4) Glide Steer Bolt
(2) Center Pin
(5) Glide Steer Rear Arm
(3) King Pin Support
W1040070
G-21
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
Oiling (Continued)
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)
(2)
(3)
(4)
(5)
Around Hole of Mower Link
Around Pin
Pivot of Mower Link
Pivot of Lift Arm
Front Link
(6)
(7)
(8)
(9)
Top Cover Lock Lever
Frame Shaft
Top Cover Hinge
Arm Bracket
W1040745
G-23
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
Oiling (Continued)
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) Quick Clean Lever
(2) PTO Lever (Fulcrum)
(3) Hydraulic Lift Lever (Fulcrum)
(4) Link Fulcrum
W1028368
G-24
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
Oiling (Continued)
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) 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.
•
•
•
1.
2.
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.
Mishandling the battery shortens the service life and adds to
maintenance costs.
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
■ 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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
■ 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
Reference state of charge
12.6
100 % (Full charge)
12.4
75 %
12.2
50 %
12.0
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
[3] CHECK POINTS OF EVERY 100 HOURS
Changing Engine Oil
•
•
1.
2.
3.
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.
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.
Fill with the new oil up to the upper notch on the dipstick.
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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)
(1) Brake Pedal
(2) Lock Nut
Factory spec.
15 to 25 mm
0.59 to 0.98 in.
(3) Nut
(4) Spring
W1043637
G-28
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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.
(1) Fan Drive Pulley
7 to 9 mm
0.28 to 0.35 in.
(2) Dynamo Pulley
W1044388
[4] CHECK POINTS OF EVERY 150 HOURS
Changing Mower Gear Box Oil
•
1.
2.
3.
CAUTION
Be sure to stop the engine and remove the key before
changing the oil.
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.
Fill with the new oil. (Refer to “4. LUBRICANTS, FUEL AND
COOLANT” in this section.)
After filling, reinstall the oil filler plug (1).
Mower gear box oil capacity
(1) Oil Filler Plug
0.40 L
0.42 U.S.qts.
0.35 Imp.qts.
(2) Drain Plug
W1044642
G-29
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
[5] CHECK POINTS OF EVERY 200 HOURS
Replacing Engine Oil Filter Cartridge
•
•
1.
2.
3.
4.
■
•
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.
The oil filter cartridge (1) must be changed every 200 service
hours.
Apply a slight coat of oil onto the rubber gasket of new cartridge.
Tighten the filter quickly until it contacts the mounting surface.
Tighten filter by hand an additional 1/2 turn only.
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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
(1)
(2)
(3)
(4)
(5)
(6)
Suction Pipe
Drain Plug
O-ring (Small)
O-ring (Large)
Strainer
Boss
3.4 L
0.90 U.S.gals
0.75 Imp.gals
(7) Transmission Oil Filter Cartridge
(8) Dipstick
A : Oil level is acceptable within this
range
W1045178
G-31
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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.
• Allow transmission case to cool down sufficiently; oil can be
hot and may cause burns.
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 μm 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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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) Breather Plug
(2) Filling Plug with Dipstick
(3) Drain Plug
1.9 L
0.50 U.S.gals
0.42 Imp.gals
A : Oil level is acceptable within this
range
W1047178
G-33
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
Checking Hydraulic Hose
CAUTION
• Be sure to stop the engine and remove the key before
checking and replacing hydraulic case.
• Allow transmission case to cool down sufficiently; oil can be
hot and may cause burns.
Check to see if hydraulic hoses are properly fixed every 200
hours of operation.
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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"
Tightening torque
(1) Front Axle Bracket
(2) Shim
(3) Shim
Factory spec.
Front axle bracket
mounting screw and nut
81 to 83 mm
3.19 to 3.26 in.
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
[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)
(1) Clamp
(2) Recovery Tank
(3) Recovery Tank Cap
2.35 L
2.48 U.S.qts.
2.07 Imp.qts.
a : FULL
b : LOW
W1049126
G-36
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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
Freezing Point
Boiling Point*
°C (°F)
°C (°F)
40
-24 (-12)
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
[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.
CHECKING, DISASSEMBLING AND SERVICING” at “8.
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)
(1)
Capacity (A)
Protected circuit
E/G STOP (a)
15
Engine stop timer relay
IG/M (b)
10
Fuel pump, head light, etc.
OPC (c)
3
(2)
–
(1) Fuse Location
OPC
Slow blow fuse 40
Check circuit against
wrong battery connection
(2) Slow Blow Fuse
W1050999
G-39
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
Checking and Replacing Mower Blade
•
•
■
1.
■
1.
2.
3.
■
•
4.
5.
6.
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
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
Remove the mower deck from the machine and turn it over to
expose the blades (4).
Wedge a block of wood (1) between the blade (4) and mower
housing as illustrated.
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.
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.
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.
To attach blades (4), be sure to install the spring plate (5)
between the blade (4) and bolt (2) head.
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
Block
Blade Bolt
Spindle Holder
Blade
Spring Plate
Cover
Blade mounting bolt
88.0 to 117.6 N·m
8.98 to 11.99 kgf·m
65.0 to 86.7 ft-lbs
(a) New Blade
(b) Worn Blade
(c) Cracked Blade
A : Loosen
W1052103
G-41
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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.
Gear box 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
Gear box mounting screw
RH
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.2 to 66.5 ft-lbs
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
Gear box stay mounting
screw RH
48.1 to 55.8 N·m
4.9 to 5.7 kgf·m
35.5 to 41.2 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
Mower Belt LH
Gear Box
Mower Belt RH
Tension Pulley
Left Side Blade Pulley
Gear Box Mounting Screw LH
(Reamer)
(7)
(8)
(9)
(10)
(11)
Gear Box Stay LH
Gear Box Stay RH
Gear Box Stay Mounting Screw RH
Gear Box Mounting Screw RH
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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)
07909-31281 (J)
07909-31231 (H)
Application: Use to measure diesel engine compression and
diagnostics of need for major overhaul.
(1)
(2)
(3)
(4)
(5)
(6)
Gauge
L Joint
Adaptor A
Adaptor B
Adaptor C
Adaptor E
(7)
(8)
(9)
(10)
(11)
Adaptor F
Adaptor G
Adaptor H
Adaptor I
Adaptor J
W1054428
G-43
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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)
(2)
(3)
(4)
Gauge
Cable
Threaded Joint
Adaptor 1
(5)
(6)
(7)
(8)
Adaptor 2
Adaptor 3
Adaptor 4
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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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/cm2, 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
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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/cm2, 4267 psi)
B
Copper gasket
C
Flange (Material : Steel)
D
Hex. nut 27 mm (1.06 in.) across the plat
E
Retaining nut
F
PF 1/2
G
5 mm (0.20 in.)
H
17 mm dia. (0.67 in.dia.)
I
8 mm dia. (0.31 in.dia.)
J
1.0 mm (0.039 in.)
K
17 mm dia. (0.67 in.dia.)
L
6.10 to 6.20 mm dia. (0.2402 to 0.2441 in.dia.)
M
8 mm (0.31 in.)
N
4 mm (0.16 in.)
O
11.97 to11.99 mm dia. (0.4713 to 0.4721 in.dia.)
P
PF 1/2
Q
23 mm (0.91 in.)
R
17 mm (0.67 in.)
S
4 mm (0.16 in.)
T
12.00 to 12.02 mm dia. (0.4724 to 0.4732 in.dia.)
U
100 mm (3.94 in.)
V
M12 x P1.5
a
Adhesive application
b
Fillet welding on the enter circumference
W1050289
G-46
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
Valve Guide Replacing Tool
Application: Use to press out and press fit the valve guide.
A
20 mm dia. (0.79 in. dia.)
B
9.96 to 9.98 mm dia. (0.3921 to 0.3929 in. dia.)
C
5.5 to 5.7 mm dia. (0.2165 to 0.2244 in. dia.)
D
220 mm (8.66 in.)
E
80 mm (3.15 in.)
F
40 mm (1.58 in.)
G
25 mm dia. (0.98 in. dia.)
H
5 mm (0.197 in.)
I
6.0 to 6.1 mm dia. (0.236 to 0.240 in. dia.)
J
18 mm dia. (0.71 in. dia.)
K
10.6 to 10.7 mm dia. (0.417 to 0.421 in. dia.)
L
6.9 to 7.1 mm dia. (0.272 to 0.280 in. dia.)
C1
Chamfer 1.0 mm (0.039 in.)
C2
Chamfer 2.0 mm (0.079 in.)
C0.3
Chamfer 0.3 mm (0.012 in.)
W1025017
G-47
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
Bushing Replacing Tools
Application: Use to press out and to press fit the bushing.
1. For small end bushing
A
145 mm (5.71 in.)
B
20 mm (0.79 in.)
C
100 mm (3.94 in.)
D
19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)
E
21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)
F
25 mm dia. (0.98 in. dia.)
C1
Chamfer 1.0 mm (0.039 in.)
C2
Chamfer 2.0 mm (0.079 in.)
C0.3
Chamfer 0.3 mm (0.012 in.)
a
6.3 μm (248 μin.)
b
6.3 μm (248 μin.)
2. For idle gear bushing
A
150 mm (5.91 in.)
B
23 mm (0.91 in.)
C
100 mm (3.94 in.)
D
19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)
E
21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)
F
25 mm dia. (0.98 in. dia.)
C1
Chamfer 1.0 mm (0.039 in.)
C2
Chamfer 2.0 mm (0.079 in.)
C0.3
Chamfer 0.3 mm (0.012 in.)
a
6.3 μm (248 μin.)
b
6.3 μm (248 μin.)
W12358870
G-48
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
Flywheel Stopper
Application: Use to loosen and tighten the flywheel screw.
A
200 mm (7.87 in.)
B
20 mm (0.79 in.)
C
30 mm (1.18 in.)
D
8 mm (0.31 in.)
E
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.)
B
72 mm (2.83 in.)
C
40 mm radius (1.57 in. radius)
D
10 mm (0.39 in.)
E
22 mm (0.87 in.)
F
20 mm dia. (0.79 in. dia.)
G
47.90 to 47.95 mm dia. (1.8858 to 1.8878 in. dia.)
H
43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)
[Press Fit]
A
130 mm (5.12 in.)
B
72 mm (2.83 in.)
C
40 mm radius (1.57 in. radius)
D
9 mm (0.35 in.)
E
24 mm (0.95 in.)
F
20 mm dia. (0.79 in. dia.)
G
68 mm dia. (2.68 in. dia.)
H
39.90 to 39.95 mm dia. (1.5709 to 1.5728 in. dia.)
W78965412
G-49
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
[2] SPECIAL TOOLS FOR TRACTOR
Relief Valve Pressure Tester
Code No.: 07916-50045
Application: This allows easy measurement of relief set pressure.
(1)
(2)
(3)
(4)
(5)
Gauge (07916-50322)
Cable (07916-50331)
Threaded Joint (07916-50401)
Threaded Joint (07916-50341)
Adaptor B (M18 x P1.5)
(07916-50361)
(6)
(7)
(8)
(9)
(10)
Adaptor C (PS3/8) (07916-50371)
Adaptor D (PT1/8) (07916-50381)
Adaptor E (PS3/8) (07916-50392)
Adaptor F (PF1/2) (07916-62601)
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)
(9)
(10)
(11)
(12)
(13)
Valve Seat Driver (07916-60841)
Connector 1 (07916-60811)
Connector 2 (07916-60821)
Long Connector (07916-60831)
Adaptor 1 (07916-52621)
Adaptor 2 with Collar
(07916-52632)
(14) Adaptor 3 with Collar
(07916-52642)
(15) HST Adaptor Set (07916-53072)
W1023682
G-50
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
HST Relief Pressure Gauge Adaptors
1. Adaptor 1
A
5.94 to 6.00 mm dia.
(0.234 to 0.236 in. dia.)
B
8.165 to 8.187 mm dia.
(0.3215 to 0.3223 in. dia.)
C
8.4 mm dia. (0.3307 in. dia.)
D
8.2 mm (0.32 in.)
E
14.2 mm (0.55905 in.)
F
7.6 to 8.0 mm (0.30 to 0.31 in.)
G
2.3 mm (0.09055 in.)
H
2.0 to 2.2 mm (0.079 to 0.087 in.)
I
15° (0.26 rad.)
J
M8
K
3 mm dia. drill (0.12 in. dia. drill)
L
Rc1/16
M
120° (2.09 rad.)
N
11.8 to 11.9 mm (0.465 to 0.469 in.)
O
12.2 mm (0.480 in.)
P
2 mm (0.079 in.)
Q
3 mm (0.118 in.)
R
8 mm (0.31496 in.)
S
2 mm (0.079 in.)
T
2 mm (0.079 in.)
U
17.4625 mm dia. (0.6875 in. dia.)
V
7.7 mm (0.303 in.)
W
10.7 mm (0.421 in.)
C0.5
Chamfer 0.5 mm (0.020 in.)
R0.4
Radius 0.4 mm (0.016 in.)
R0.1
Radius 0.1 mm (0.004 in.)
W1014589
G-51
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
2. Adaptor 2
A
10 mm (0.394 in.)
B
3 mm (0.1181 in.)
C
2.0 to 2.4 mm (0.079 to 0.094 in.)
D
3 mm (0.12 in.)
E
5.8 mm (0.23 in.)
F
1.5 mm (0.06 in.)
G
9 mm dia. (0.35 in. dia.)
H
8.200 to 8.215 mm dia.
(0.3228 to 0.3234 in. dia.)
I
9.2 mm dia. (0.16 in. dia.)
J
12.16 to 12.29 mm dia.
(0.4787 to 0.4839 in. dia.)
K
17.6 to 17.8 mm dia.
(0.693 to 0.701 in. dia.)
L
30° (0.52 rad.)
M
9/16-18UNF
N
M8
O
1.5 mm (0.059 in.)
P
10.3 to 10.5 mm
(0.4055 to 0.4134 in.)
Q
120° (2.09 rad.)
C1
Chamfer 1 mm (0.039 in.)
C0.2
Chamfer 0.2 mm (0.008 in.)
R0.4
Radius 0.4 mm (0.016 in.)
R0.2
Radius 0.2 mm (0.008 in.)
W1067375
3. Adaptor Lever
A
9.7 to 10.3 mm (0.382 to 0.406 in.)
B
1 mm (0.0472 in.)
C
10.6 to 10.9 mm (0.417 to 0.429 in.)
D
100 mm (3.94 in.)
E
12 mm (0.47 in.)
F
2 mm (0.08 in.)
R1.2
R1
Radius 1.2 mm (0.047 in.)
Radius 1 mm (0.039 in.)
W1015898
Short Neck Wrench
A
90 mm (3.543 in.)
B
7 to 8 mm (0.28 to 0.31 in.)
C
14 mm (0.551 in.)
D
6.35 mm (0.25 in.)
R6.4
Radius 6.4 mm (0.252 in.)
W1068021
G-52
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
PTO Brake Assembling Template
■ NOTE
• The thickness of this is 1.0 mm (0.039 in.)
A
76.5 mm (3.01 in.)
B
33.5 mm (1.32 in.)
C
67.9 to 68.1 mm (2.67 to 2.68 in.)
D
25.4 to 25.6 mm (1.00 to 1.01 in.)
E
57.4 to 57.6 mm (2.26 to 2.27 in.)
F
21.4 to 21.6 mm (0.843 to 0.850 in.)
G
15mm (0.59 in.)
H
115 mm (4.53 in.)
I
103.4 to 103.6 mm (4.071 to 4.078 in.)
J
47.4 to 47.6 mm (1.866 to 1.874 in.)
K
44.9 to 45.1 mm (1.77 to 1.78 in.)
L
15.4 to 15.6 mm (0.607 to 0.614 in)
M
83.6 to 84.1 mm dia. (3.30 to 3.31 in. dia.)
N
72.15 to 72.45 mm dia. (2.841 to 2.852 in. dia.)
O
4.9 mm (0.19 in.)
P
33.9 to 34.1 mm (1.33 to 1.34 in.)
Q
5.3 to 5.7 mm (0.21 to 0.22 in.)
R
11.7 to 11.9 mm (0.461 to 0.468 in.)
S
2.3536 to 2.3588 rad (134.85 to 135.15°)
T
1.569 to 1.573 ra (89.85 to 90.15°)
U
0.4338 to 0.4389 rad (24.85 to 25.15°)
V
6 X 8.2 mm dia. (6 X 0.32 in. dia.)
C1
Chamfer 1.0 mm (0.039 in.)
W1207119
G-53
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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.
Tire sizes
Inflation pressure
Front
16 x 7.50-8, 4PR
200 kPa (2.0 kgf/cm2, 29 psi)
Rear
23 x 10.50-12, 4PR
140 kPa (1.4 kgf/cm2, 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
Rear
16 x 7.50 - 8, 4PR
23 x 10.50 - 12, 4PR
A : 825 mm (32.5 in.)
B : 800 mm (31.5 in.)
G-54
KiSC issued 04, 2007 A
G GENERAL
GR2100EC2, WSM
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.]
Maximum axle loading weight
Front axle Wf
Rear axle Wr
Total gross weight
300 kg (661 lbs)
500 kg (1102 lbs)
700 kg (1543 lbs)
G-55
KiSC issued 04, 2007 A
1
ENGINE
KiSC issued 04, 2007 A
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
1. ENGINE BODY
[1] HALF-FLOATING HEAD COVER
The rubber packing is fitting in to maintain the head
cover 0.5 mm (0.02 in.) or so off the cylinder head. This
arrangement helps reduce noise coming from the
cylinder head.
(1) Cylinder Head Cover
(2) Rubber Packing
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
2. LUBRICATING SYSTEM
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Rocker Arm
Oil Pressure Switch
Rocker Arm Shaft
Valve
Idle Gear
Crankshaft
Oil Pump
Oil Strainer
Relief Valve
Push Rod
Tappet
Camshaft
Piston
Connecting Rod
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
3. COOLING SYSTEM
(1)
(2)
(3)
(4)
(5)
(6)
Radiator
Water Pump
Cooling Fan
Thermostat
Cylinder Head
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
4. FUEL SYSTEM
[1] FUEL LINE
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Injection Nozzle
Fuel Overflow Pipe
Fuel Tank
Fuel Filter
Fuel Feed Pump
Fuel Filter
Injection Pump
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/cm2, 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
KiSC issued 04, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................1-S1
SERVICING SPECIFICATIONS ....................................................................1-S4
TIGHTENING TORQUES ..............................................................................1-S9
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
1. TROUBLESHOOTING
Symptom
Engine Does Not
Start
(Starter Does Not
Run)
Probable Cause
Reference
Page
Solution
No fuel
Replenish fuel
G-8
Air in the fuel system
Bleed
G-42
Water in the fuel system
Change fuel and
repair or replace fuel
system
Fuel pipe clogged
Clean
Fuel filter clogged
Change
Excessively high viscosity of fuel or engine oil at
low temperature
Use specified fuel
or engine oil
G-8
Fuel with low cetane number
Use specified
fuel
G-8
Fuel leak due to loose injection pipe retaining nut
Tighten retaining nut
1-S24
Incorrect injection timing
Adjust
1-S16
Fuel camshaft worn
Replace
Injection nozzle clogged
Repair or replace
1-S38
Injection pump malfunctioning
Replace
1-S28
Seizure of crankshaft, camshaft, piston, cylinder
or bearing
Repair or replace
Compression leak from cylinder
Replace head
gasket,
tighten cylinder head
screw, glow plug and
nozzle holder
1-S10
Improper valve timing
Correct or replace
timing gear
1-S30
Piston ring and cylinder worn
Replace
Excessive valve clearance
Adjust
1-S12
Battery discharged
Charge
G-25
Starter malfunctioning
Repair or replace
7-S18
Main switch malfunctioning
Replace
7-S6, 7
PTO switch defective
Replace
7-S10
Brake switch defective
Replace
7-S10
Seat switch defective
Replace
7-S11
Slow blow fuse blown
Replace
G-39
Wiring disconnected
Connect
–
G-15, 39
G-28
G-28, 35
–
–
1-S49, 55
W1014322
1-S1
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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
Probable Cause
Solution
Reference
Page
Fuel filter clogged or dirty
Replace
G-28, 35
Air cleaner clogged
Clean or replace
G-20, 36
Fuel leak due to loose injection pipe retaining nut
Tighten retaining nut
1-S24
Injection pump malfunctioning
Replace
1-S28
Incorrect nozzle injection pressure
Adjust
1-S19
Injection nozzle stuck or clogged
Repair or replace
1-S38
Governor malfunctioning
Repair
Excessive engine oil
Reduce to specified
level
Piston ring and cylinder worn or stuck
Repair or replace
Incorrect injection timing
Adjust
1-S16
Deficient compression
Adjust top clearance
1-S11
Overload
Reduce the load
Low grade fuel used
Use specified fuel
G-8
Fuel filter clogged
Replace
G-35
Air cleaner clogged
Clean or replace
G-20, 36
Deficient nozzle injection
Repair or replace
nozzle
1-S38
Incorrect injection timing
Adjust
1-S16
Engine's moving parts seem to be seizing
Repair or replace
–
Uneven fuel injection
Replace injection
pump
1-S28
Deficient nozzle injection
Repair or replace
nozzle
1-S38
Compression leak
Replace head
gasket, tighten
cylinder head screw,
glow plug and nozzle
holder
1-S10
Piston ring's gap facing the same direction
Shift ring gap
direction
1-S32
Oil ring worn or stuck
Replace
1-S33
Piston ring groove worn
Replace piston
1-S32, 49
Valve stem and valve guide worn
Replace
1-S27, 40
Oil leaking due to defective seals or packing
Replace
–
Injection pump's plunger worn
Replace injection
pump
1-S28
Deficient nozzle injection
Repair or replace
nozzle
1-S38
Injection pump broken
Replace
1-S28
–
G-8, 14
1-S49, 55
–
W1011327
1-S2
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Symptom
Probable Cause
Reference
Page
Solution
Water Mixed into
Lubricant Oil
Head gasket defective
Replace
1-S26
Cylinder block or cylinder head flawed
Replace
–
Low Oil Pressure
Engine oil insufficient
Replenish
Oil strainer clogged
Clean
Oil filter clogged
Replace
Relief valve stuck with dirt
Clean
–
Relief valve spring weaken or broken
Replace
–
Excessive oil clearance of crankshaft bearing
Replace
1-S53, 54
Excessive oil clearance of crankpin bearing
Replace
1-S52
Excessive oil clearance of rocker arm
Replace
1-S43
Oil passage clogged
Clean
Different type of oil
Use specified type of
oil
Oil pump defective
Repair or replace
Different type of oil
Use specified type of
oil
Relief valve defective
Replace
Engine oil insufficient
Replenish
Fan belt broken or tensioned improperly
Replace or adjust
Coolant insufficient
Replenish
Radiator net and radiator fin clogged with dust
Clean
Inside of radiator corroded
Clean or replace
G-36
Coolant flow route corroded
Clean or replace
G-36
Radiator cap defective
Replace
1-S15
Radiator hose damaged
Replace
G-32
Overload running
Reduce the load
Head gasket defective
Replace
1-S26
Incorrect injection timing
Adjust
1-S16
Unsuitable fuel used
Use specified fuel
High Oil Pressure
Engine Overheated
G-8, 14
–
G-30
–
G-8
1-S31
G-8
–
G-8
G-29,
1-S13
G-8
–
–
G-8
W1011747
1-S3
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
2. SERVICING SPECIFICATIONS
ENGINE BODY
Item
Factory Specification
Allowable Limit
2.84 to 3.24 MPa
29.0 to 33.0 kgf/cm2
412 to 469 psi
2.26 MPa
23.0 kgf/cm2
327 psi
–
10 % or less
0.50 to 0.70 mm
0.0197 to 0.0276 in.
–
0.145 to 0.185 mm
0.00571 to 0.00728 in.
–
–
0.05 mm
0.0020 in.
-0.10 to 0.10 mm
-0.0039 to 0.0039 in.
0.30 mm
0.0118 in.
Clearance
0.030 to 0.057 mm
0.00118 to 0.00224 in.
0.10 mm
0.0039 in.
Valve Stem
(O.D.)
5.968 to 5.980 mm
0.23496 to 0.23543 in.
–
Valve Guide
(I.D.)
6.010 to 6.025 mm
0.23661 to 0.23720 in.
–
Width
2.12 mm
0.0835 in.
–
Angle
0.785 rad
45 °
–
Valve Face
Angle
0.785 rad
45 °
–
Valve Spring
Free Length
31.3 to 31.8 mm
1.232 to 1.252 in.
28.4 mm
1.118 in.
–
1.2 mm
0.047 in.
Setting Load
64.7 N
6.6 kgf
14.6 lbs
54.9 N
5.6 kgf
12.3 lbs
Setting Length
27.0 mm
1.063 in.
–
Oil Clearance
0.016 to 0.045 mm
0.00063 to 0.00177 in.
0.15 mm
0.0059 in.
Rocker Arm Shaft
(O.D.)
10.473 to 10.484 mm
0.41232 to 0.41276 in.
–
Rocker Arm
(I.D.)
10.500 to 10.518 mm
0.41339 to 0.41410 in.
–
–
0.25 mm
0.0098 in.
Compression Pressure
–
Variance Among
Cylinder
Top Clearance
Valve Clearance (Cold)
Cylinder Head Surface
Flatness
Valve Recessing (Intake and Exhaust)
Valve Stem to Valve Guide
Valve Seat
Tilt
Rocker Arm to Rocker Arm Shaft
Push Rod
Alignment
W1013874
1-S4
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
ENGINE BODY (Continued)
Item
Factory Specification
Allowable Limit
Clearance
0.016 to 0.052 mm
0.00063 to 0.00205 in.
0.10 mm
0.0039 in.
Tappet
(O.D.)
17.966 to 17.984 mm
0.70732 to 0.70803 in.
–
Tappet Guide Bore
(I.D.)
18.000 to 18.018 mm
0.70866 to 0.70937 in.
–
Idle Gear to Crank
Gear
(Backlash)
0.043 to 0.124 mm
0.00169 to 0.00488 in.
0.15 mm
0.0059 in.
Idle Gear to Cam
Gear
(Backlash)
0.047 to 0.123 mm
0.00185 to 0.00484 in.
0.15 mm
0.0059 in.
Idle Gear to
Injection Pump
Gear
(Backlash)
0.046 to 0.124 mm
0.00185 to 0.00488 in.
0.15 mm
0.0059 in.
Oil Pump Drive
Gear to Crank
Gear
(Backlash)
0.041 to 0.123 mm
0.00161 to 0.00484 in.
0.15 mm
0.0059 in.
Idle Gear
Side Clearance
0.20 to 0.51 mm
0.0079 to 0.0201 in.
0.80 mm
0.0315 in.
Camshaft
Side Clearance
0.15 to 0.31 mm
0.0059 to 0.0122 in.
0.50 mm
0.0197 in.
–
0.01 mm
0.0004 in.
26.88 mm
1.0583 in.
26.83 mm
1.0563 in.
Oil Clearance
0.050 to 0.091 mm
0.00197 to 0.00358 in.
0.15 mm
0.0059 in.
Camshaft Journal
(O.D.)
32.934 to 32.950 mm
1.29661 to 1.29724 in.
–
Cylinder Block
Bore
(I.D.)
33.000 to 33.025 mm
1.29921 to 1.30020 in.
–
Oil Clearance
0.020 to 0.084 mm
0.00079 to 0.00331 in.
0.10 mm
0.0039 in.
Idle Gear Shaft
(O.D.)
19.967 to 19.980 mm
0.78610 to 0.78661 in.
–
Idle Gear Bushing
(I.D.)
20.000 to 20.051 mm
0.78740 to 0.78941 in.
–
I.D.
20.000 to 20.013 mm
0.78740 to 0.78791 in.
20.05 mm
0.7894 in.
Tappet to Tappet Guide
Timing Gear
Alignment
Cam Height
(Intake and
Exhaust)
Camshaft Journal to Cylinder Block Bore
Idle Gear Shaft to Idle Gear Bushing
Piston Pin Bore
W1012561
1-S5
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
ENGINE BODY (Continued)
Item
Piston Pin to Small End Bushing
Piston Pin to Small End Bushing
(Spare Parts)
Piston Ring Gap
Piston Pin to Piston Ring Groove
Factory Specification
Allowable Limit
Oil Clearance
0.014 to 0.038 mm
0.00055 to 0.00150 in.
0.10 mm
0.0039 in.
Piston Pin
(O.D.)
20.002 to 20.011 mm
0.78748 to 0.078783 in.
–
Small End Bushing
(I.D.)
20.025 to 20.040 mm
0.78839 to 0.78897 in.
–
Oil Clearance
0.015 to 0.075 mm
0.00059 to 0.00295 in.
0.15 mm
0.0059 in.
Small End Bushing
(I.D.)
20.026 to 20.077 mm
0.78845 to 0.79043 in.
–
Top Ring
0.15 to 0.30 mm
0.0059 to 0.0118 in.
1.20 mm
0.0472 in.
Second Ring
0.30 to 0.45 mm
0.0118 to 0.0177 in.
1.20 mm
0.0472 in.
Oil Ring
0.15 to 0.30 mm
0.0059 to 0.0118 in.
1.20 mm
0.0472 in.
Second Ring
(Clearance)
0.090 to 0.120 mm
0.00354 to 0.00472 in.
0.15 mm
0.0059 in.
Oil Ring
(Clearance)
0.04 to 0.08 mm
0.0016 to 0.0031 in.
0.15 mm
0.0059 in.
–
0.05 mm
0.0020 in.
0.15 to 0.31 mm
0.0059 to 0.0122 in.
0.50 mm
0.0197 in.
–
0.02 mm
0.0008 in.
Oil Clearance
0.020 to 0.051 mm
0.00079 to 0.00201 in.
0.15 mm
0.0059 in.
Crankpin
(O.D.)
33.959 to 33.975 mm
1.33697 to 1.33760 in.
–
Crankpin Bearing
(I.D.)
33.995 to 34.010 mm
1.33893 to 1.33898 in.
–
Oil Clearance
0.034 to 0.106 mm
0.00134 to 0.00417 in.
0.20 mm
0.0079 in.
Crankshaft Journal
(O.D.)
39.934 to 39.950 mm
1.57221 to 1.57284 in.
–
Crankshaft
Bearing 1
(I.D.)
39.984 to 40.040 mm
1.57417 to 1.57638 in.
–
Oil Clearance
0.028 to 0.059 mm
0.00110 to 0.00232 in.
0.20 mm
0.0079 in.
Crankshaft Journal
(O.D.)
43.934 to 43.950 mm
1.72968 to 1.73031 in.
–
Crankshaft
Bearing 2
(I.D.)
43.978 to 43.993 mm
1.73142 to 1.73201 in.
–
Connecting Rod
Alignment
Crankshaft
Side Clearance
Alignment
Crankpin to Crankpin Bearing
Crankshaft Journal to Crankshaft Bearing
1
Crankshaft Journal to Crankshaft Bearing
2
(Flywheel Side)
W1012878
1-S6
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
ENGINE BODY (Continued)
Item
Factory Specification
Allowable Limit
Oil Clearance
0.028 to 0.059 mm
0.00110 to 0.00232 in.
0.20 mm
0.0079 in.
Crankshaft Journal
(O.D.)
39.934 to 39.950 mm
1.57221 to 1.57284 in.
–
Crankshaft
Bearing 3
(I.D.)
39.978 to 39.993 mm
1.57394 to 1.57453 in.
–
Cylinder Liner
I.D.
67.000 to 67.019 mm
2.63779 to 2.63854 in.
67.169 mm
2.6445 in.
Cylinder Liner
(Oversize)
I.D.
67.250 to 67.269 mm
2.64764 to 2.64839 in.
67.419 mm
2.65429 in.
Crankshaft Journal to Crankshaft Bearing
3
(Intermediate)
W1013251
LUBRICATING SYSTEM
Engine Oil Pressure
Oil Pump
–
At Idle Speed
More than 49 MPa
0.5 kgf/cm2
7 psi
At Rated Speed
196 to 441 MPa
2.0 to 4.5 kgf/cm2
28 to 64 psi
147 MPa
1.5 kgf/cm2
21 psi
Inter Rotor to
Outer Rotor
(Clearance)
0.03 to 0.14 mm
0.0012 to 0.0055 in.
–
Outer Rotor to
Pump Body
(O.D.)
0.07 to 0.15 mm
0.0028 to 0.0059 in.
–
Inter Rotor to
Cover
(I.D.)
0.075 to 0.135 mm
0.00295 to 0.00531 in.
–
W1013973
1-S7
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
COOLING SYSTEM
Item
Factory Specification
Allowable Limit
7 to 9 mm / 98 N
0.28 to 0.35 in. / 98N
(10 kgf, 22 lbs)
–
Fan Belt
Tension
Thermostat
Valve Opening
Temperature
(At Beginning)
69.5 to 72.5 °C
157.1 to 162.5 °F
–
Valve Opening
Temperature
(Opened
Completely)
85 °C
185 °F
–
Radiator Cap
Pressure Falling
TIme
10 seconds or more
88 → 59 kPa
0.9 → 0.6 kgf/cm2
13 → 9 psi
–
Radiator
Water Leakage
Test Pressure
No leak at specified
pressure
157 kPa
1.6 kgf/cm2
23 psi
–
W1013687
FUEL SYSTEM
Injection Pump
Injection Timing
0.28 to 0.31 rad
(16 to 18 °)
before T.D.C.
–
Pump Element
Fuel Tightness
–
13.7 MPa
140 kgf/cm2
1991 psi
Delivery Valve
Fuel Tightness
10 seconds
13.73 → 12.75 MPa
140 → 130 kgf/cm2
1991 → 1849 psi
5 seconds
13.73 →
12.75 MPa
140 →
130 kgf/cm2
1991 → 1849 psi
Fuel Injection Nozzle
Injection Pressure
13.73 to 14.71 MPa
140 to 150 kgf/cm2
1991 to 2134 psi
–
When the pressure is
12.75 MPa
(130 kgf/cm2, 1849 psi),
the valve seat must be
fuel tightness
–
Valve Seat
Tightness
W1013792
1-S8
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
3. TIGHTENING TORQUES
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
Size x Pitch
N·m
kgf·m
ft-lbs
Front coupling mounting screw
M8 x 1.25
23.5 to 27.4
2.4 to 2.8
17.4 to 20.3
Engine mounting nut
M8 x 1.25
23.5
2.4
17.4
Air cleaner stay screw
M8 x 1.25
23.5 to 27.4
2.4 to 2.8
17.4 to 20.3
Engine support screw
M10 x 1.25
48.1 to 55.9
4.9 to 5.7
35.4 to 41.2
*Cylinder head cover screw
M6 x 1.0
6.86 to 11.3
0.7 to 1.15
5.1 to 8.3
Injection pipe retaining nut
M12 x 1.5
24.5 to 34.3
2.5 to 3.5
18.1 to 25.3
Overflow pipe retaining nut
M12 x 1.5
19.6 to 24.5
2.0 to 2.5
14.5 to 18.1
Nozzle holder assembly
M20 x 1.5
49.0 to 68.6
5.0 to 7.0
36.2 to 50.6
Glow plug
M8 x 1.0
7.85 to 14.7
0.8 to 1.5
5.8 to 10.8
*Rocker arm bracket screw
M6 x 1.0
9.8 to 11.3
1.00 to 1.15
7.2 to 8.3
*Cylinder head screw
M8 x 1.25
37.3 to 42.2
3.8 to 4.3
27.5 to 31.1
*Fan drive pulley screw
M12 x 1.5
98.0 to 107.8
10.0 to 11.0
72.3 to 79.5
*Idle gear shaft mounting screw
M6 x 1.0
9.8 to 11.3
1.00 to 1.15
7.2 to 8.3
*Connecting rod screw
M7 x 0.75
26.5 to 30.4
2.7 to 3.1
19.5 to 22.4
*Flywheel screw
M10 x 1.25
53.9 to 58.8
5.5 to 6.0
39.8 to 43.4
Bearing case cover mounting screw
M6 x 1.0
9.8 to 11.3
1.00 to 1.15
7.2 to 8.3
*Main bearing case screw 2
M7 x 1.0
26.5 to 30.4
2.7 to 3.1
19.5 to 22.4
*Main bearing case screw 1
M6 x 1.0
12.7 to 15.7
1.3 to 1.6
9.4 to 11.6
34.3 to 39.2
3.5 to 4.0
25.3 to 28.9
14.7 to 19.6
1.5 to 2.0
10.8 to 14.5
Nozzle holder
Oil pressure switch
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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 %.
Factory spec.
2.84 to 3.24 MPa
29.0 to 33.0 kgf/cm2
412 to 469 psi
Allowable limit
2.26 MPa
23.0 kgf/cm2
327psi
Compression pressure
W1010662
1-S10
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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
Tightening torque
Factory spec.
Cylinder head screw
0.50 to 0.70 mm
0.0197 to 0.0276 in.
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.
No.1
No.2
No.3
Intake valve
★
✩
★
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
(2) Lubricating System
Engine Oil Pressure
1. Remove the engine oil pressure switch, and set an oil pressure
tester (Code No.: 07916-32032).
2. Start the engine. After warming up, measure the oil pressure of
both idling and rated speeds.
3. 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
Engine oil pressure
At rated
speed
Factory
spec.
More than 49 kPa
0.5 kgf/cm2
7 psi
Factory
spec.
196 to 441 kPa
2.0 to 4.5 kgf/cm2
28 to 64 psi
Allowabl
e limit
147 kPa
1.5 kgf/cm2
21 psi
(When reassembling)
• After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
W1028313
(3) Cooling System
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)
(1) Fan Drive Pulley
Factory spec.
7 to 9 mm
0.28 to 0.35 in.
(2) Dynamo Pulley
W1020731
1-S13
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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
Factory spec.
69.5 to 72.5 °C
157.1 to 162.5 °F
Temperature at which
thermostat completely
opens
Factory spec.
85 °C
185 °F
W1023486
1-S14
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.: RCT2A-30S) on the radiator cap.
2. Apply the specified pressure 88 kPa, (0.9 kgf/cm2, 13 psi), and
measure the time for the pressure to fall to 59 kPa (0.6 kgf/cm2,
9 psi).
3. If the measurement is less than the factory specification, replace
the radiator cap.
Pressure falling time
(1) Radiator Tester
Factory spec.
More than 10 seconds for
pressure fall from
88 to 59 kPa
(from 0.9 to 0.6 kgf/cm2
from 13 to 9 psi)
(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
(1) Radiator Tester
Factory spec.
157 kPa
1.6 kgf/cm2
23 psi
(2) Adaptor
W1024517
1-S15
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
(4) Fuel System
Injection Timing
1. Remove the injection pipes.
2. Remove the engine stop solenoid.
3. Turn the flywheel counterclockwise (facing the flywheel) until fuel
flows from the delivery valve holder.
4. Continue to turn the flywheel slowly, and stop it as soon as the
fuel level at the tip of the delivery valve holder begins to increase.
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Fuel Tightness of Pump Element
1. Remove the engine stop solenoid.
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/cm2
1991 psi
■ NOTE
• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.
(1) Injection Nozzle
(2) Injection Pump Pressure Tester
(3) Protection Cover for Jetted Fuel
W1027828
1-S17
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Fuel Tightness of Delivery Valve
1. Remove the engine stop solenoid.
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/cm2, 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/cm2, 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/cm2, 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.
Factory spec.
10 seconds
13.73 → 12.75 MPa
140 → 130 kgf/cm2
1991 → 1849 psi
Allowable limit
5 seconds
13.73 → 12.75 MPa
140 → 130 kgf/cm2
1991 → 1849 psi
Fuel tightness of
delivery valve
■ NOTE
• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.
(1) Injection Nozzle
(2) Injection Pump Pressure Tester
(3) Protection Cover for Jetted Fuel
W1028381
1-S18
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.: 0790931361), 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
1. Set the injection nozzle to a nozzle tester (Code No.: 0790931361).
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.
13.73 to 14.71 MPa
140 to 150 kgf/cm2
1991 to 2134 psi
(Reference)
• Pressure variation with 0.01 mm (0.0004 in.) difference of
adjusting washer thickness.
Approx. 235 kPa (2.3 kgf/cm2, 34 psi)
(1) Adjusting Washer
W1029328
1-S19
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Valve Seat Tightness
1. Set the injection nozzle to a nozzle tester (Code No.: 0790931361).
2. Raise the fuel pressure, and keep at 12.75 MPa (130 kgf/cm2,
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/cm2
1849 psi
W1030468
[2] PREPARATION
(1) Separating Engine
Draining Coolant
CAUTION
• Never open the radiator cap while operating or immediately
after stopping. Otherwise, hot water will spout out from the
radiator. Wait for more than ten minutes to cool the radiator,
before opening the cap.
1. 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
(1) Radiator Cap
Capacity (with
recovery tank)
2.35 L
2.48 U.S.qts.
2.07 Imp.qts.
(2) Drain Plug
W1018574
1-S20
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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
(1) Drain Plug
(2) Oil Inlet
(3) Dipstick
2.8 L
2.96 U.S.qts.
2.46 Imp.qts.
Capacity
A : Upper Level
B : Lower Level
W1032108
Battery
•
1.
2.
3.
4.
CAUTION
When disconnecting the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
Open the bonnet.
Remove the radiator net.
Disconnect the negative cable (1) from the battery.
Disconnect the positive cable (2) from the battery and remove the
battery (3).
(1) Negative Cable
(2) Positive Cable
(3) Battery
W1033344
1-S21
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Engine Assembly
1. Remove the radiator stopper snap pins (2).
2. Disconnect the front coupling (5).
3. Separate the engine assembly (6) with radiator from the frame
(3).
(When reassembling)
Front coupling mounting
screw
23.5 to 27.4 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
Engine mounting nut
23.5 N·m
2.4 kgf·m
17.4 ft-lbs
Tightening torque
(1) Radiator Stopper
(2) Radiator Stopper Snap Pin
(3) Frame
(4) Joint Pin
(5) Front Coupling
(6) Engine Assembly
W1034766
1-S23
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
[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).
(When reassembling)
• 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.
Air cleaner stay screw
23.5 to 27.4 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
Engine support screw
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.4 to 41.2 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
(5)
Radiator
Recovery Tank
Dynamo
Fan Belt
Engine Support RH
(6)
(7)
(8)
(9)
Starter
Engine Support LH
Air Cleaner Stay
Cooling Fan
W1030916
Cylinder Head Cover
1. Remove the head cover screws (1).
2. Remove the cylinder head cover (2).
(When reassembling)
• Check to see if the cylinder head cover gasket is not defective.
Tightening torque
(1) Head Cover Screws
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
(2) Cylinder Head Cover
W1037527
Injection Pipes
1. Loosen the screw on the pipe clamp (1).
2. Detach the injection pipes (2).
(When reassembling)
• Sent compressed air into the pipes to blow out dust. Then,
reassemble the pipes in the reverse order.
Tightening torque
(1) Pipe Clamp
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
(2) Injection Pipe
W1038271
1-S24
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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).
(When reassembling)
• Replace the copper gasket and heat seal with new one.
Tightening torque
Overflow pipe retaining nut
19.6 to 24.5 N·m
2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
Nozzle holder assembly
49.0 to 68.6 N·m
5.0 to 7.0 kgf·m
36.2 to 50.6 ft-lbs
Glow plug
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 reassembling)
• 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
(1) Rocker Arm Assembly
(2) Push Rod
9.8 to 11.3 N·m
1.00 to 1.15 kgf·m
7.2 to 8.3 ft-lbs
(3) Tappet
W1039359
1-S25
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Cylinder Head
1. Loosen the pipe clamp, and remove the water return pipe.
2. Remove the cylinder head screw in the order of (n) to (a).
3. Lift up the cylinder head to detach.
4. Remove the cylinder head gasket and O-ring (1).
(When reassembling)
• 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
(1) O-ring
Cylinder head screw
37.3 to 42.2 N·m
3.8 to 4.3 kgf·m
27.5 to 31.1 ft-lbs
(n) to (a) :To Loosen
(a) to (n) :To Tighten
W1040055
Tappets
1. Remove the tappets (1) from the crankcase.
(When reassembling)
• 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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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).
(When reassembling)
• 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)
(2)
(3)
(4)
Valve Spring Replacer
Valve Cap
Valve Spring Collet
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).
(When reassembling)
• 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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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).
(When reassembling)
• 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)
(2)
(3)
(4)
(5)
Screws and Copper Washers
Speed Control Plate
Injection Pump
Governor Spring
Governor Lever
(6)
(7)
(8)
(9)
(10)
Idling Adjusting Spring
Control Rod
Slot (Crankcase Side)
Slot (Fork Lever Side)
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.
(When reassembling)
• 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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Gear Case
1. Remove the screw (1) of inside the gear case and outside screws
(6).
2. Disconnect the start spring (2) from the fork lever 1.
3. Remove the gear case (3).
(When reassembling)
• Apply a liquid gasket (Three Bond 1215 or equivalent) to both
sides of the gear case gasket (4).
• 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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Idle Gear
1. Remove the external snap ring (3), the collar (2) and the idle gear
(1).
2. Remove the idle gear shaft mounting screws (4).
3. Remove the idle gear shaft (5).
(When reassembling)
• Apply engine oil to the idle gear shaft mounting screw (4). And
tighten them.
• Install the idle gear, aligning the mark (6) on the gears referring
to the photo.
Tightening torque
Idle gear shaft mounting
screw
(1) Idle Gear
(2) Idle Gear Collar
(3) External Snap Ring
9.8 to 11.3 N·m
1.00 to 1.15 kgf·m
7.2 to 8.3 ft-lbs
(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 reassembling)
• 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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Fuel Camshaft
1. Remove the retaining plate (1).
2. Remove the fork lever holder mounting screws (8), then draw out
the injection pump gear (3) and fuel camshaft (2) with the
governor fork assembly.
(When reassembling)
• Hook the governor spring (7) to the fork lever 2 (6) as shown in
the figure before installing the fork lever assembly to the
crankcase.
(1)
(2)
(3)
(4)
Retaining Plate
Fuel Camshaft
Injection Pump Gear
Governor Sleeve
(5)
(6)
(7)
(8)
Fork Lever 1
Fork Lever 2
Governor Spring
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).
(When reassembling)
• 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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
(3) Pistons and Connecting Rods
Connecting Rods
1. Remove the connecting rod caps (1).
(When reassembling)
• 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
(1) Connecting Rod Cap
26.5 to 30.4 N·m
2.7 to 3.1 kgf·m
19.5 to 22.4 ft-lbs
(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.
(When reassembling)
• 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)
(A)
(B)
(C)
(D)
Piston Ring Compressor
Top Ring Gap
Second Ring Gap
Oil Ring Gap
Piston Pin Hole
(a) 0.785 rad (45 °)
(b) 0.785 rad (45 °)
(c) 1.57 rad (90 °)
W1051250
1-S32
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Piston Ring and Connecting Rod
1. Remove the piston rings using a piston ring tool (Code No.:
07909-32121).
2. Remove the piston pin (7), and separate the connecting rod (6)
from the piston (5).
(When reassembling)
• When installing the ring, assemble the rings so that the
manufacturer's mark (12) near the gap faces the top of the piston.
• 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)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Top Ring
Second Ring
Oil Ring
Piston Pin Snap Ring
Piston
Connecting Rod
Piston Pin
Mark
(9)
(10)
(11)
(12)
Fan-Shaped Concave
Expander Joint
Oil Ring Gap
Manufacturer's Mark
W1052645
1-S33
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
(4) Crankshaft
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).
(When reassembling)
• 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
53.9 to 58.8 N·m
5.5 to 6.0 kgf·m
39.8 to 43.4 ft-lbs
Flywheel screw
(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).
(When reassembling)
• 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
(1) Bearing Case Cover Mounting Screw
(Inside)
(2) Bearing Case Cover Mounting Screw
(Outside)
(3) Bearing Case Gasket
(4) Bearing Case Cover Gasket
9.8 to 11.3 N·m
1.00 to 1.15 kgf·m
7.2 to 8.3 ft-lbs
(5) Oil Seal
(6) Bearing Case Cover
(a) Top Mark "UP"
(b) Upside
W1054786
1-S34
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.
(When reassembling)
• 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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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).
(When reassembling)
• 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
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Main bearing case screw 1
Main Bearing Case Assembly 1
Main Bearing Case Assembly 2
Main Bearing Case Assembly
Crankshaft Bearing 3
(Upper, with oil groove)
Crankshaft Bearing 3 (Lower)
Crankshaft Bearing 2
(Upper, with oil groove)
Crankshaft Bearing 2 (Lower)
Thrust Bearing
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
(a) Alignment Number
(b) Marking (1 or 2)
(c) Oil Groove
W1028669
1-S36
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
(5) Waterpump
Thermostat Assembly
1. Remove the thermostat cover mounting screws, and remove the
thermostat cover (1).
2. Remove the thermostat assembly (3).
(When reassembling)
• 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).
(When reassembling)
• 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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
(6) Injection Nozzle
Nozzle Holder
1. Secure the nozzle retaining nut (7) with a vise.
2. Remove the nozzle holder (1), and take out parts inside.
(When reassembling)
• 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
(1)
(2)
(3)
(4)
Nozzle Holder
Adjusting Washer
Nozzle Spring
Push Rod
Nozzle holder
34.3 to 39.2 N·m
3.5 to 4.0 kgf·m
25.3 to 28.9 ft-lbs
Overflow pipe retaining nut
19.6 to 24.5 N·m
2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
Nozzle holder assembly
49.0 to 68.6 N·m
5.0 to 7.0 kgf·m
36.2 to 50.6 ft-lbs
(5) Distance Piece
(6) Nozzle Piece
(7) Nozzle Retaining Nut
W1057030
[4] SERVICING
(1) Cylinder Head and Valve
Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head's four sides and two
diagonal 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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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)
(1) Cylinder Head Surface
Factory spec.
0.10 (protrusion) to
0.10 (recessing) mm
0.0039 (protrusion) to
0.0039 (recessing) in.
Allowable limit
0.30 (recessing) mm
0.0118 (recessing) in.
(A) Recessing
(B) Protrusion
W1063434
1-S39
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.
0.030 to 0.057 mm
0.00118 to 0.00224 in.
Allowable limit
0.10 mm
0.0039 in.
Valve stem O.D.
Factory spec.
5.968 to 5.980 mm
0.23496 to 0.23543 in.
Valve guide I.D.
Factory spec.
6.010 to 6.025 mm
0.23661 to 0.23720 in.
W1065896
Replacing Valve Guide
(When reassembling)
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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
(1) Correct
(2) Incorrect
Factory spec.
2.12 mm
0.0835 in.
(3) Incorrect
W1069999
1-S41
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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
(1)
(A)
(B)
(C)
(D)
Valve Seat Cutter
Check Contact
Correct Seat Width
Correct Seat Surface
Check Contact
Factory spec.
(a)
(b)
(c)
(d)
0.785 rad
45 °
Identical Dimensions
Valve Seat Width
0.262 rad (15 °)
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.
Factory spec.
31.3 to 31.8 mm
1.232 to 1.252 in.
Allowable limit
28.4 mm
1.118 in.
Allowable limit
1.2 mm
0.047 in.
Free length (A)
Tilt (B)
(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.
Factory spec.
64.7 N / 27.0 mm
6.6 kgf / 27.0 mm
14.6 lbs / 1.063 in.
Allowable limit
54.9 N / 27.0 mm
5.6 kgf / 27.0 mm
12.3 lbs / 1.063 in.
Setting load / Setting
length
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.
0.016 to 0.045 mm
0.00063 to 0.00177 in.
Allowable limit
0.15 mm
0.0059 in.
Rocker arm shaft O.D.
Factory spec.
10.473 to 10.484 mm
0.41232 to 0.41276 in.
Rocker arm I.D.
Factory spec.
10.500 to 10.518 mm
0.41339 to 0.41410 in.
W1079717
1-S43
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.
0.016 to 0.052 mm
0.00063 to 0.00205 in.
Allowable limit
0.10 mm
0.0039 in.
Tappet O.D.
Factory spec.
17.966 to 17.984 mm
0.70732 to 0.70803 in.
Tappet guide bore I.D.
Factory spec.
18.000 to 18.018 mm
0.70866 to 0.70937 in.
W1081727
1-S44
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
(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.
Factory spec.
0.043 to 0.124 mm
0.00169 to 0.00488 in.
Allowable limit
0.15 mm
0.0059 in.
Factory spec.
0.047 to 0.123 mm
0.00185 to 0.00484 in.
Allowable limit
0.15 mm
0.0059 in.
Backlash between idle
gear and injection pump
gear
Factory spec.
0.046 to 0.124 mm
0.00185 to 0.00488 in.
Allowable limit
0.15 mm
0.0059 in.
Backlash between oil
pump drive gear and
crank gear
Factory spec.
0.041 to 0.123 mm
0.00161 to 0.00484 in.
Allowable limit
0.15 mm
0.0059 in.
Backlash between idle
gear and crank gear
Backlash between idle
gear and cam gear
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.
Factory spec.
0.20 to 0.51 mm
0.0079 to 0.0201 in.
Allowable limit
0.80 mm
0.0315 in.
Idle gear side clearance
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.
0.15 to 0.31 mm
0.0059 to 0.0122 in.
Allowable limit
0.50 mm
0.0197 in.
W1086822
1-S45
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.
26.88 mm
1.0583 in.
Allowable limit
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.
Factory spec.
0.050 to 0.091 mm
0.00197 to 0.00358 in.
Allowable limit
0.15 mm
0.0059 in.
Camshaft journal O.D.
Factory spec.
32.934 to 32.950 mm
1.29661 to 1.29724 in.
Camshaft bearing I.D.
(Cylinder block bore
I.D.)
Factory spec.
33.000 to 33.025 mm
1.29921 to 1.30020 in.
Oil clearance of
camshaft journal
W1088079
1-S46
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.
0.020 to 0.084 mm
0.00079 to 0.00331 in.
Allowable limit
0.10 mm
0.0039 in.
Idle gear shaft O.D.
Factory spec.
19.967 to 19.980 mm
0.78610 to 0.78661 in.
Idle gear bushing I.D.
Factory spec.
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.
(When installing)
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.
Factory spec.
20.000 to 20.013 mm
0.78740 to 0.78791 in.
Allowable limit
20.05 mm
0.7894 in.
Piston pin bore I.D.
W1092645
1-S47
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.
0.014 to 0.038 mm
0.00055 to 0.00150 in.
Allowable limit
0.10 mm
0.0039 in.
Piston pin O.D.
Factory spec.
20.002 to 20.011 mm
0.78748 to 0.78783 in.
Small end bushing I.D.
Factory spec.
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.
(When installing)
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)
Small end bushing I.D.
(Spare parts)
(1) Seam
(2) Oil Hole
Factory spec.
0.015 to 0.075 mm
0.00059 to 0.00295 in.
Allowable limit
0.15 mm
0.0059 in.
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.
Top ring
Piston ring gap
Second
ring
Oil ring
Factory
spec.
0.15 to 0.30 mm
0.0059 to 0.0118 in.
Allowable
limit
1.20 mm
0.0472 in.
Factory
spec.
0.30 to 0.45 mm
0.0118 to 0.0177 in.
Allowable
limit
1.20 mm
0.0472 in.
Factory
spec.
0.15 to 0.30 mm
0.0059 to 0.0118 in.
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.
Second
ring
Clearance between
piston ring and piston
ring groove
Oil ring
Factory
spec.
0.090 to 0.120 mm
0.00354 to 0.00472 in.
Allowable
limit
0.15 mm
0.0059 in.
Factory
spec.
0.04 to 0.08 mm
0.0016 to 0.0031 in.
Allowable
limit
0.15 mm
0.0059 in.
W1097828
1-S49
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
(4) Crankshaft
Crankshaft Side Clearance
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the front
and rear.
3. If the measurement exceeds the allowable limit, replace the
thrust bearings.
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.
0.15 to 0.31 mm
0.0059 to 0.0122 in.
Allowable limit
0.50 mm
0.0197 in.
(Reference)
• Oversize thrust bearing
Oversize
Bearing
Code Number
Marking
0.2 mm
0.008 in.
Thrust bearing 1 02
15261-23950
020 OS
Thrust bearing 2 02
15261-23970
020 OS
0.4 mm
0.016 in.
Thrust bearing 1 04
15261-23960
040 OS
Thrust bearing 2 04
15261-23980
040 OS
• Oversize dimensions of crankshaft journal
Oversize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
23.40 to 23.45 mm
0.9134 to 0.9154 in.
23.80 to 23.85 mm
0.9213 to 0.9232 in.
Dimension B
46.1 to 46.3 mm
1.815 to 1.823 in.
46.3 to 46.5 mm
1.823 to 1.831 in.
Dimension C
1.8 to 2.2 mm radius
0.071 to 0.087 in. radius
1.8 to 2.2 mm radius
0.071 to 0.087 in. radius
(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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.
0.020 to 0.051 mm
0.00079 to 0.00201 in.
Allowable limit
0.15 mm
0.0059 in.
Crankpin O.D.
Factory spec.
33.959 to 33.975 mm
1.33697 to 1.33760 in.
Crankpin bearing I.D.
Factory spec.
33.995 to 34.010 mm
1.33893 to 1.33898 in.
(Reference)
• Undersize crankpin bearing
Undersize
Bearing
Code Number
Marking
0.2 mm
0.008 in.
Crankpin bearing 02
15861-22970
020 US
0.4 mm
0.016 in.
Crankpin bearing 04
15861-22980
040 US
• Undersize dimensions of crankpin
Undersize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
2.3 to 2.7 mm radius
0.091 to 0.106 in. radius
2.3 to 2.7 mm radius
0.091 to 0.106 in. radius
Dimension B
4 mm dia.
0.16 in. dia.
4 mm dia.
0.16 in. dia.
Dimension C
33.759 to 33.775 mm dia.
1.32910 to 1.32973 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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.
0.034 to 0.106 mm
0.00134 to 0.00417 in.
Allowable limit
0.20 mm
0.0079 in.
Crankshaft journal O.D.
Factory spec.
39.934 to 39.950 mm
1.57221 to 1.57284 in.
Crankshaft bearing 1
I.D.
Factory spec.
39.984 to 40.040 mm
1.57417 to 1.57638 in.
(Reference)
• Undersize crankshaft bearing 1
Undersize
Bearing
Code Number
Marking
0.2 mm
0.008 in.
Crankshaft bearing 1 02
15861-23910
020 US
0.4 mm
0.016 in.
Crankshaft bearing 1 04
15861-23920
040 US
• Undersize dimensions of crankshaft journal
Undersize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
1.8 to 2.2 mm radius
0.071 to 0.087 in. radius
1.8 to 2.2 mm radius
0.071 to 0.087 in. radius
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
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Replacing Crankshaft Bearing 1
(When removing)
1. Press out the used crankshaft bearing 1 using a crankshaft
bearing 1 replacing tool. (Refer to "SPECIAL TOOLS".)
(When installing)
1. Clean a new crankshaft bearing 1 and crankshaft journal bore,
and apply engine oil to them.
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)
(1) Seam
(2) Crankshaft Bearing 1
(3) Cylinder Block
Factory spec.
0.0 to 0.3 mm
0.0 to 0.0118 in.
(A) Dimension
W1104511
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 2 (Crankshaft Bearing 3)
1. Put a strip of plastigage (Code No.: 07909-30241) on the center
of the journal.
2. Install the bearing case and tighten the bearing case screws 1 to
the specified torque, and remove the bearing case again.
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.
Factory spec.
0.028 to 0.059 mm
0.00110 to 0.00232 in.
Allowable limit
0.20 mm
0.0079 in.
Crankshaft journal O.D.
(Flywheel side)
Factory spec.
43.934 to 43.950 mm
1.72968 to 1.73031 in.
Crankshaft bearing 2
I.D.
Factory spec.
43.978 to 43.993 mm
1.73142 to 1.73201 in.
Crankshaft journal O.D.
(Intermediate)
Factory spec.
39.934 to 39.950 mm
1.57221 to 1.57284 in.
Crankshaft bearing 3
I.D.
Factory spec.
39.978 to 39.993 mm
1.57394 to 1.57453 in.
Oil clearance between
crankshaft journal and
crankshaft bearing 2
(Crankshaft bearing 3)
W1105735
1-S54
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 2 (Crankshaft Bearing 3) (Continued)
(Reference)
• Undersize crankshaft bearing 2 and 3
Undersize
Bearing
Code Number
Marking
0.2 mm
0.008 in.
Crankshaft bearing 2 02
15694-23930
020 US
Crankshaft bearing 3 02
15861-23860
020 US
0.4 mm
0.016 in.
Crankshaft bearing 2 04
15694-23940
040 US
Crankshaft bearing 3 04
15861-23871
040 US
• Undersize dimensions of crankshaft journal
Undersize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
1.8 to 2.2 mm radius
0.071 to 0.087 in. radius
1.8 to 2.2 mm radius
0.071 to 0.087 in. radius
Dimension B
3 mm dia.
0.12 in. dia.
3 mm dia.
0.12 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.
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
(5) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.'s.
2. Get the difference (Maximum wear) between the maximum and
the minimum I.D.'s.
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".)
Factory spec.
67.000 to 67.019 mm
2.63779 to 2.63854 in.
Allowable limit
67.169 mm
2.6445 in.
Cylinder I.D.
(A) Top
(B) Middle
(C) Bottom (Skirt)
(a) Right-angled to Piston Pin
(b) Piston Pin Direction
W1030293
1-S55
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
Correcting Cylinder
1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
Cylinder I.D.
[Oversize]
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 μm Rmax.
∇∇∇∇
(0.000047 to 0.000079 in. Rmax.)
Finishing
2. Replace the piston and piston rings with oversize ones.
Oversize
Part Name
Code Number
Marking
0.25 mm
0.0098 in.
Piston
1E051-21900
025
Piston ring assembly
16853-21090
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
(6) Oil Pump
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.
2. If the clearance exceeds the factory specifications, replace the oil
pump rotor assembly.
Clearance between
outer rotor and pump
body
Factory spec.
0.07 to 0.15 mm
0.0028 to 0.0059 in.
W1110485
1-S56
KiSC issued 04, 2007 A
ENGINE
GR2100EC2, WSM
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.
4. If the clearance exceeds the factory specifications, replace the oil
pump rotor assembly.
Clearance between rotor
and cover
Factory spec.
0.075 to 0.135 mm
0.00295 to 0.00531 in.
W1110562
1-S57
KiSC issued 04, 2007 A
2
TRANSAXLE
KiSC issued 04, 2007 A
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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
1. STRUCTURE
(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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
2. TRAVELLING SYSTEM
[1] HYDROSTATIC TRANSMISSION
(1) Structure
(1) Check and High Pressure
Relief Valve
(2) Trunnion Arm
(3) Center Section
(4) Cylinder Block (Pump)
(5) Piston Spring
(6) Piston
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Spring (Cylinder Block)
Washer
Thrust Ball Bearing
Swashplate
Cradle Bearing
Ball Bearing
Oil Seal
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Pump Shaft
Ball Bearing
Oil Seal
Motor Shaft
Thrust Ball Bearing
Cylinder Block (Motor)
By-pass Plug
(21)
(22)
(23)
(24)
(25)
(26)
By-pass Spool
By-pass Spring
Journal Bearing
Oil Seal
Journal Bearing
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 cm3/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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
(2) Oil Flow
(1) Pump
(2) Check and High Pressure
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
(10) Check and High Pressure
Relief Valve (Reverse)
(11) Lubricating Orifice
(12) Hydrostatic Transmission
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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
(3) Operation
■ Neutral
(1)
(2)
(3)
(4)
(5)
(6)
Filter Cartridge
HST Relief Valve
Power Steering Controller
Control Valve
Main Relief Valve
Mower Lift Cylinder
(7) Hydraulic Control Valve
Assembly
(8) Hydraulic Pump
(9) Swashplate
(10) Cylinder Block (Pump)
(11) Lubricating Orifice
(12) Check and High Pressure
Relief Valve (Reverse)
(13) Check and High Pressure
Relief Valve (Forward)
(14)
(15)
(16)
(17)
(18)
Piston
Cylinder Block (Mower)
By-pass Valve
Transaxle Case
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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
■ Forward
(1)
(2)
(3)
(4)
(5)
(6)
Filter Cartridge
HST Relief Valve
Power Steering Controller
Control Valve
Main Relief Valve
Mower Lift Cylinder
(7) Hydraulic Control Valve
Assembly
(8) Hydraulic Pump
(9) Swashplate
(10) Cylinder Block (Pump)
(11) Lubricating Orifice
(12) Check and High Pressure
Relief Valve (Reverse)
(13) Check and High Pressure
Relief Valve (Forward)
(14)
(15)
(16)
(17)
(18)
Piston
Cylinder Block (Mower)
By-pass Valve
Transaxle Case
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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
■ Reverse
(1)
(2)
(3)
(4)
(5)
(6)
Filter Cartridge
HST Relief Valve
Power Steering Controller
Control Valve
Main Relief Valve
Mower Lift Cylinder
(7) Hydraulic Control Valve
Assembly
(8) Hydraulic Pump
(9) Swashplate
(10) Cylinder Block (Pump)
(11) Lubricating Orifice
(12) Check and High Pressure
Relief Valve (Reverse)
(13) Check and High Pressure
Relief Valve (Forward)
(14)
(15)
(16)
(17)
(18)
Piston
Cylinder Block (Mower)
By-pass Valve
Transaxle Case
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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
(4) By-pass Valve
Normally, when the engine is stopped, the pump shaft
and pump cylinder block engaged with it do not rotate.
Thus, the motor shaft does not rotate.
However, pressing the by-pass valve in the center
section permits moving the machine with human power
while the engine is stopped. 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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
(5) Control Linkage
(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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
[2] GLIDE STEER SECTION
(1) General
This machine is equipped with the Glide Steer
system.
On turning, the Glide Steer system provides a
mechanism that allows a turf-friendly minimum turn by
driving the front wheels and the rear wheel on the outside
of the turn at the same time.
(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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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.
(1) Differential Gear (Front)
(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.
(1) Differential Gear (Front)
A : Track made by Differential
(2) Steering Clutch (Engaged)
Gear (Front)
(3) Steering Clutch (Disengaged) B : Track made by Rear Wheel
on Outside of Turn
W1015290
2-M10
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
(2) Operation
■ 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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
[3] FRONT WHEEL DRIVE SECTION
This machine always has the front axle driven.
Driving power is transmitted to the front axle as follows :
Motor shaft (3) → 15T gear (4) → 29T gear (2) →
Front wheel drive shaft (1)
(1) Front Wheel Drive Shaft
(2) 29T Gear
(3) Motor Shaft
(4) 15T Gear
W1016638
2-M12
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
3. MOWER PTO SYSTEM
[1] MOWER PTO CLUTCH
The mower PTO clutch is equipped with mechanical
independent clutches of wet multi-plates type.
The PTO shaft (1) is engaged with the spline boss (3).
The clutch case (5) is engaged with the 24T gear (6).
Normally, spring (8) tension pushes the spline boss
(3) in the PTO clutch toward the front side of the
machine, which creates clearance between clutch disc
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)
(2)
(3)
(4)
(5)
PTO Shaft
(6)
Clutch Lever
(7)
Spline Boss
(8)
Clutch Disc and Friction Plate (9)
Clutch Case
(10)
24T Gear
19T-2 Gear
Spring
Brake Disc and Friction Plate
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)
(2)
(3)
(4)
(5)
PTO Shaft
(6)
Clutch Lever
(7)
Spline Boss
(8)
Clutch Disc and Friction Plate (9)
Clutch Case
(10)
24T Gear
19T-2 Gear
Spring
Brake Disc and Friction Plate
Thrust Collar
W1016963
2-M13
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
■ 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)
(2)
(3)
(4)
(5)
PTO Shaft
(6)
Clutch Lever
(7)
Spline Boss
(8)
Clutch Disc and Friction Plate (9)
Clutch Case
(10)
24T Gear
19T-2 Gear
Spring
Brake Disc and Friction Plate
Thrust Collar
W1017152
2-M14
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
4. OTHERS
[1] HYDRAULIC PUMP SECTION
The hydraulic pump (1) is mounted on the transaxle
case.
The power to drive the hydraulic pump (1) is
transmitted as follows :
Input shaft (4) → 25T gear (3) on input shaft →
Hydraulic pump gear shaft (2)
(1) Hydraulic Pump
(2) Hydraulic Pump Gear Shaft
(3) 25T Gear
(4) Input Shaft
W1017301
2-M15
KiSC issued 04, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................2-S1
SERVICING SPECIFICATIONS ....................................................................2-S4
TIGHTENING TORQUES ..............................................................................2-S5
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
[3] DISASSEMBLING AND ASSEMBLING................................................2-S25
(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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
1. TROUBLESHOOTING
Solution
Reference
Page
Oil level is low
Fill oil to proper level
G-8, 2-S13
Control linkage defective (Speed change pedal
to speed control arm)
Repair control
linkage
Charge pressure is too
low
Oil filter cartridge
clogged
Replace oil filter
cartridge
G-32
HST relief valve
defective
Replace HST relief
valve
6-S15
Hydraulic pump
defective
Replace hydraulic
pump
6-S11
Check and high pressure relief valve defective
Replace check and
high pressure relief
valve
2-S26
By-pass valve defective
Replace by-pass
valve
2-S26
HST component parts defective
Replace HST
assembly
2-S24
Oil level is low
Fill oil to proper level
Control linkage defective (Speed change pedal
to speed control arm)
Repair control
linkage
Charge pressure is too
low
Oil filter cartridge
clogged
Replace oil filter
cartridge
G-32
HST relief valve
defective
Replace HST relief
valve
6-S15
Hydraulic pump
defective
Replace hydraulic
pump
6-S11
Check and high pressure relief valve defective
Replace check and
high pressure relief
valve
2-S26
By-pass valve defective
Replace by-pass
valve
2-S26
HST component parts defective
Replace HST
assembly
2-S24
Symptom
System Will Not
Operate in Either
Direction
Vibration and Noise
Probable Cause
2-S7, 18
G-8, 2-S13
2-S7, 18
W1014322
2-S1
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
Solution
Reference
Page
Oil level is low
Fill oil to proper level
G-8, 2-S13
Control linkage defective (Speed change pedal
to speed control arm)
Repair control
linkage
Charge pressure is too
low
Oil filter cartridge
clogged
Replace oil filter
cartridge
G-32
HST relief valve
defective
Replace HST relief
valve
6-S15
Hydraulic pump
defective
Replace hydraulic
pump
6-S11
Check and high pressure relief valve defective
Replace check and
high pressure relief
valve
2-S26
By-pass valve defective
Replace by-pass
valve
2-S26
HST component parts defective
Replace HST
assembly
2-S24
Oil level is low
Fill oil to proper level
Excessive machine load
Reduce machine
load
–
Oil filter cartridge
clogged
Replace oil filter
cartridge
G-32
HST relief valve
defective
Replace HST relief
valve
6-S15
Hydraulic pump
defective
Replace hydraulic
pump
6-S11
Symptom
Less of Power
Oil Heat Over
Probable Cause
Charge pressure is too
low
Machine Will Not
Stop in Neutral
Position
Control linkage defective (Speed change pedal
to speed control arm)
Repair control
linkage
Improper adjustment of neutral arm holder shaft
Adjust
System Operates in
One Direction Only
Control linkage defective (Speed change pedal
to speed control arm)
Repair control
linkage
Check and high pressure relief valve defective
Replace check and
high pressure relief
valve
2-S7, 18
G-8, 2-S13
2-S7, 18
2-S6
2-S7, 18
2-S26
W1092336
2-S2
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
BEVEL GEAR SECTION
Reference
Page
Symptom
Probable Cause
Excessive or
Unusual Noise at All
Time
Improper backlash between 11T bevel gear and
17T-13T gear shaft
Adjust
Bearing worn
Replace
Insufficient or improper type of transmission fluid
used
Replenish or change
Bearing worn
Replace
Noise while Turning
Solution
2-S45
–
G-8, 2-S13
–
W1014322
GLIDE STEER SECTION
The Driving Power is Steering clutch disc worn
not Transmitted to
Friction plate worn
Rear Wheel at the
Clutch spring weaken or broken
Time of Going
Straight
Improper adjustment of wire
The Driving Power to
Rear Wheel on inside
of Turn is not Shut
Off at the Time of
Turning
Replace
2-S34, 44
Replace
2-S34, 44
Replace
2-S43
Adjust
2-S19,
4-S5
Steering clutch disc and friction plate are
agglutinated
Replace
2-S34
Improper adjustment of wire
Adjust
2-S19,
4-S5
Wire broken
Replace
2-S17,
4-S7
W1011581
MOWER PTO SECTION
PTO Clutch Slip
Improper length of PTO rod spring
Adjust
2-S16
PTO rod spring weaken or broken
Replace
2-S16
Clutch disc or friction plate excessively worn
Replace
2-S28,
42,43
PTO Shaft Does Not
Rotate
PTO clutch malfunctioning
Repair or replace
Bearing broken
Replace
2-S28
PTO Clutch Drags
Brake plate excessive worn
Replace
2-S28, 43
Clutch spring weaken or broken
Replace
2-S28, 43
Deformation of plate
Replace
2-S28, 43
2-S28 to 31
W1011680
2-S3
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
2. SERVICING SPECIFICATIONS
Item
Factory Specification
Allowable Limit
HST Relief Valve
(Oil temperature at 50 °C, 122 °F)
Setting Pressure
0.9 to 1.1 MPa
9.2 to 11.2 kgf/cm2
130.6 to 159.5 psi
–
High Relief Pressure
Setting Pressure
18.5 to 22.2 MPa
189 to 226 kgf/cm2
2684 to 3263 psi
–
PTO Clutch Disc
Thickness
1.3 to 1.5 mm
0.051 to 0.059 in.
1.2 mm
0.047 in.
Pressure Plate
Thickness
1.55 to 1.65 mm
0.061 to 0.065 in.
1.50 mm
0.059 in.
Friction Plate 1
Thickness
1.55 to 1.65 mm
0.061 to 0.065 in.
1.50 mm
0.059 in.
Friction Plate 2
Thickness
0.75 to 0.85 mm
0.030 to 0.034 in.
0.70 mm
0.028 in.
Clutch Spring
Free Length
45 mm
1.77 in.
42 mm
1.65 in.
PTO Brake Disc 1
Thickness
2.85 to 3.05 mm
0.11 to 0.12 in.
2.75 mm
0.108 in.
PTO Brake Disc
Thickness
3.3 to 3.5 mm
0.13 to 0.14 in.
3.0 mm
0.118 in.
Brake Friction Plate 1
Thickness
1.75 to 1.85 mm
0.069 to 0.073 in.
1.60 mm
0.063 in.
Brake Friction Plate 2
Thickness
0.95 to 1.05 mm
0.037 to 0.041 in.
0.80 mm
0.031 in.
Clutch Spline Plate
Thickness
0.75 to 0.85 mm
0.030 to 0.033 in.
0.70 mm
0.028 in.
Steering Clutch Disc
Thickness
1.3 to 1.5 mm
0.051 to 0.059 in.
1.2 mm
0.047 in.
Friction Plate
Thickness
0.75 to 0.85 mm
0.030 to 0.033 in.
0.70 mm
0.028 in.
Clutch Plate
Thickness
1.55 to 1.65 mm
0.061 to 0.065 in.
1.50 mm
0.059 in.
11T Bevel Gear Shaft to 17T-13T Gear
Shaft
Backlash
0.10 to 0.30 mm
0.0039 to 0.0012 in.
–
W1013874
2-S4
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
3. TIGHTENING TORQUES
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
N·m
kgf·m
ft-lbs
35 to 40
3.47 to 4.07
25.1 to 29.5
9.8 to 11.3
1.00 to 1.15
7.23 to 8.33
Power steering pipe mounting nut
20.0 to 25.0
2.04 to 2.54
14.76 to 18.43
Rear wheel mounting nut
77.5 to 90.2
7.91 to 9.19
57.2 to 66.5
Transaxle mounting screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
Hydrostatic transmission mounting screw
23.5 to 27.5
2.4 to 2.8
17.3 to 20.3
Hydrostatic transmission mounting screw 2
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2
Center section mounting hex. socket head screw
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2
By-pass valve plug
15.0
1.53
11.1
Check valve plug
30.0
3.06
22.1
Hydraulic pump mounting screw
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2
PTO clutch assembly mounting screw
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2
7.8 to 8.8
0.8 to 0.9
5.8 to 6.5
Brake plate mounting screw
Universal joint mounting screw
Transaxle case screw
W1012736
2-S5
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Adjustment of HST Neutral Position
1. Lift up the front and rear of the machine, and support it with
disassembling jacks.
2. Remove the left rear wheel.
3. Start the engine, and set at approx. 1500 to 3000 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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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.)
(1) Speed Change Pedal
(2) Brake Pedal Arm
(3) Pin
(4) Rod End
(5) Speed Change Rod
(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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
HST Relief Pressure
•
•
1.
2.
3.
4.
5.
CAUTION
When checking, park the machine on level ground, apply the
parking brake.
This checking should be performed after completing the
adjustment of neutral.
Remove the plug (Rc 1/8) (1) from the hydraulic control valve
assembly.
Install the adaptor, thread joint, cable and pressure gauge.
Start the engine and run engine speed at maximum speed.
Read the pressure gauge to measure the HST relief pressure.
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/cm2
130.6 to 159.5 psi
Condition
• Engine Speed : Maximum
• Oil Temperature : 50 °C (122 °F)
(1) Plug
W1016179
2-S8
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
HST High Relief Pressure
•
1.
2.
3.
■
•
•
(1)
(2)
(3)
(4)
(5)
(6)
CAUTION
When checking, park the machine on level ground, apply the
parking brake.
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.)
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).
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.
P1 Port (Reverse)
(7) Filter Case Mounting Screw
P2 Port (Forward)
(8) Filter Case
O-ring (SAE J515 #6 (Tube OD 3/8)) (9) Hose Clamp
Adaptor 2
(10) Hose
O-ring (P/N 04811-10060)
A : Clearance between the filter case
Adaptor 1
and the bottom of center section.
W1042793
2-S9
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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/cm2
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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
[2] PREPARATION
(1) Separating 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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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.
(When refilling)
• 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.
Refer to "4. LUBRICANTS, FUEL AND COOLANT" at "G.
GENERAL" section.
• Do not mix different bland oil together.
Transmission fluid
(1)
(2)
(3)
(4)
(5)
Suction Pipe
Drain Plug
O-ring (Small)
O-ring (Large)
Strainer
Capacity
3.4 L
0.90 U.S.gals
0.75 Imp.gals
(6) Boss
(7) Filling Plug with Dipstick
H : Highest Level
L : Lowest Level
W1033631
2-S13
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
Battery
•
1.
2.
3.
4.
CAUTION
When disconnecting the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
Open the bonnet.
Remove the radiator net.
Disconnect the negative cable (1) from the battery.
Disconnect the positive cable (2) from the battery and remove the
battery (3).
(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)
(2)
(3)
(4)
Lever Grip
Seat Base
Fender Mounting Screw
Fuel Cap
(5)
(6)
(7)
(8)
Fender
Cutting Height Control Dial
Speed Change Pedal
Step Sheet
W1038685
2-S14
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
Fuel Tank
1. Drain the fuel.
2. Disconnect the fuel hoses.
3. Remove the fuel tank (1).
(1) Fuel Tank
W1040558
2-S15
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
PTO Rod Spring
1. Remove the two nuts (2) (3) and spring (4).
(When reassembling)
1. Assemble a fuel tank, a seat base and a fender.
2. Setting the PTO lever at "Disengaged" position and lifting the
PTO arm (5) slightly by hands directly, the upper side of PTO arm
(5) and lower nut (6) on the upper side of PTO rod (1) make
contact, and there is no play between them. 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)
(2)
(3)
(4)
(5)
PTO Rod
Nut
Nut
Spring
PTO Arm
(6) Nut
(7) Nut
(A) "Disengaged" Position
(B) "Engaged" Position
W1041404
2-S16
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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).
(When reassembling)
• After assembling the beam, fix the breather hose (6) to the beam
(5) with the hose clamp horizontally along the beam (5).
(1)
(2)
(3)
(4)
PTO Switch
Spring
PTO Lever
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).
(When reassembling)
■ 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
(1) Lock Nut
(2) Plain Washer
(3) Brake Spring
Brake plate mounting
screw
35 to 40 N·m
3.47 to 4.07 kgf·m
25.1 to 29.5 lbf·ft
(4) Brake Rod 2
(5) Brake Plate
(6) Brake Rod 1
W1047606
2-S17
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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).
(When reassembling)
■ 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
(4) Speed Change Rod
(5) Lock Nut
W1049508
Universal Joint
1. Remove the universal joint mounting screw (1).
2. Disconnect the universal joint (2).
(When reassembling)
• Apply grease to the splines of the universal joint.
Tightening torque
Universal joint mounting
screw
(1) 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
(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.
(When reassembling)
• Install the spline boss (3) a shown in figure.
(1)
(2)
(3)
(4)
Bearing Holder
Front Wheel Drive Shaft
Spline Boss
O-ring
(a) Groove
F : Front
R : Rear
W1052501
2-S18
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
Glide Steer Wire
1. Remove the rue ring pin (1).
2. Loose the adjusting nut (3).
3. Disconnect the Glide Steer wire (4) and wire stay (2).
(When reassembling)
• 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
(4) Glide Steer Wire
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).
(When reassembling)
Tightening torque
Power steering pipe
20.0 to 25.0 N·m
2.04 to 2.54 kgf·m
14.76 to 18.43 lbf·ft
Cylinder hose
24.0 to 28.0 N·m
2.45 to 2.85 kgf·m
17.7 to 20.6 lbf·ft
Rear wheel mounting nut
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
W1055625
Separating Transmission
1. Remove the transaxle mounting screws (2).
2. Separate the transaxle (1) from the frame.
(When reassembling)
Tightening torque
(1) Transaxle
Transaxle mounting screw
48.1 to 55.8 N·m
4.9 to 5.7 kgf·m
35.5 to 41.2 lbf·ft
(2) Transaxle Mounting Screw
W1057771
2-S19
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
(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).
(When reassembling)
■ 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
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Speed Control Arm
Neutral Spring
Breather Hose
Cooling Fan
Return Spring
Spring Stay
Glide Steer Lever
Wire Stay
Set screw for speed
control arm
(9)
(10)
(11)
(12)
(13)
(14)
(15)
17.7 to 20.6 N·m
1.81 to 2.10 kgf·m
13.1 to 15.1 lbf·ft
Glide Steer Lever
Spring Stay
Return Spring
Neutral Arm Holder
Set Screw
Cooling Fan Shaft
Cord Clamp
W1033712
2-S20
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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).
(When reassembling)
• 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).
Suction pipe 2 mounting
screw
7.8 to 8.8 N·m
0.80 to 0.89 kgf·m
5.8 to 6.4 lbf·ft
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
Tightening torque
(1)
(2)
(3)
(4)
(5)
Suction Filter Case
Suction Pipe 2
Hose
O-ring (Small)
O-ring (Large)
(6)
(7)
(8)
(9)
Strainer
Boss
Transaxle Case
O-ring
W1048370
2-S21
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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).
(When reassembling)
• 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.
Tightening torque
Control valve pipe
retaining nut
24 to 28 N·m
2.5 to 2.8 kgf·m
18 to 20 lbf·ft
Joint bolt (8) (14)
32 to 36 N·m
3.3 to 3.6 kgf·m
24 to 26 lbf·ft
Hose clamp for drain hose
(4) (6)
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
(2) Hydraulic Control Valve
(Filter Bracket)
(3) Oil Filter Cartridge
(4) Hose Clamp
(5) Drain Hose
(6) Hose Clamp
(7) Suction Pipe 1
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Joint Bolt
Copper Gasket (Thick Type)
Copper Gasket (Thin Type)
Hydraulic Pump
Copper Gasket (Thin Type)
Copper Gasket (Thick Type)
Joint Bolt
W1029668
2-S22
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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).
(When reassembling)
■ 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
(2) Neutral Arm Holder
Mounting Screws (M8)
(3) Neutral Arm Holder
(4) Hydraulic Control Assembly
(5) O-ring
(6) Charge Pipe
(7) Charge Port
W1059835
2-S23
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
Brake Assembly
1. Remove the brake assembly (1).
2. Remove the external snap ring (2). And pull out the brake drum
(3).
(When reassembling)
• 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
(1) Brake Assembly
(2) External Snap Ring
(3) Brake Drum
7.8 to 8.8 N·m
0.80 to 0.89 kgf·m
5.8 to 6.4 lbf·ft
(4) Brake Assembly Mounting Screw
(5) Brake Arm Lever
W1061965
Hydrostatic Transmission Assembly
1. Remove the hydrostatic transmission assembly (1).
(When reassembling)
• 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.
Hydrostatic transmission
mounting screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.3 to 20.3 lbf·ft
Hydrostatic transmission
mounting screw 2
17.7 to 20.6 N·m
1.8 to 2.1 kgf·m
13.1 to 15.2 lbf·ft
Tightening torque
(1) Hydrostatic Transmission Assembly
(2) Hole
(3) Drain Pipe
(4) Hydrostatic Transmission Mounting
Screw 2
W1063079
2-S24
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
[3] DISASSEMBLING AND ASSEMBLING
(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
(5) External Snap Ring
(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).
(When reassembling)
• 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
(1) Center Section
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
(2) HST Housing
W1030586
2-S25
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
By-pass Valve
1. Remove the plug (4) and draw out the by-pass spool (2) and
spring (1).
(When reassembling)
• Take care not to damage the O-ring (3) on the plug (4).
Tightening torque
By-pass valve plug
(1) Spring
(2) By-pass Spool
15.0 N·m
1.53 kgf·m
11.1 lbf·ft
(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).
(When reassembling)
• Take care not to damage the O-rings (2), (7) on the plugs (1), (8).
Tightening torque
(1)
(2)
(3)
(4)
Check and high pressure
relief valve plug
Plug
O-ring
Spring
Check and High Pressure Relief
Valve (Reverse)
30.0 N·m
3.06 kgf·m
22.1 lbf·ft
(5) Check and High Pressure Relief
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).
(When reassembling)
• 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
(4) Thrust Ball Bearing
(5) Cylinder Block Assembly
(Motor Side)
W1070297
2-S26
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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.
(When reassembling)
• Apply clean transmission oil to thrust ball bearing (1).
(1)
(2)
(3)
(4)
(5)
Thrust Ball Bearing
Swashplate
Pump Shaft
Oil Seal
Internal Snap Ring
(6)
(7)
(8)
(9)
(10)
Internal Snap Ring
Oil Seal
Internal Snap Ring
External Snap Ring
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.
(When reassembling)
• 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
(2) Transaxle Case
Hydraulic Pump
1. Unscrew the hydraulic pump mounting screws (2).
2. Remove the hydraulic pump (1).
(When reassembling)
Tightening torque
(1) Hydraulic Pump
Hydraulic pump mounting
screw
17.7 to 20.6 N·m
1.8 to 2.1 kgf·m
13.1 to 15.2 lbf·ft
(2) Hydraulic Pump Mounting Screw
W1072904
2-S27
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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).
(When reassembling)
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
(7)
PTO cover assembly
mounting screw
PTO Cover Assembly
24T Gear
PTO Clutch Assembly
Ball Bearing
Brake Disc and Friction Plate
PTO Shaft
Clutch Case
(8)
(9)
(10)
(11)
(12)
(13)
(14)
17.7 to 20.6 N·m
1.81 to 2.10 kgf·m
13.1 to 15.2 lbf·ft
Thrust Needle Bearing
Thrust Collar
Collar
Spring
Spline Boss
Clutch Disc and Friction Plate
External Snap Ring
W1073892
2-S28
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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)
(2)
(3)
(4)
PTO Shaft
Thrust Collar
External Snap Ring
Clutch Lever
(5) PTO Clutch Cover
(6) Ball Bearing
(7) Oil Seal
W1101571
2-S29
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Ball Bearing
PTO Shaft
Thrust Collar
Collar
Thrust Needle Bearing
24T Gear
Clutch Case
External Snap Ring
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Clutch Disc and Friction Plate
Spline Boss
Spline
Brake Friction Plate 1
Brake Disc
Brake Friction Plate 2
Brake Disc 1
W1027948
2-S30
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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
(1) Tang
(2) Groove
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
(3) PTO Clutch Assembly
(4) PTO Cover Assembly
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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
Transaxle Case
1. Remove the transaxle case screws (2).
2. Separate the front side of transaxle case (1).
(When reassembling)
• 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
(1) Transaxle Case (Front Side)
(2) Transaxle Case Screw
(3) Transaxle Case (Rear Side)
F:
R:
A:
B:
C:
D:
9.80 to 11.3N·m
1.00 to 1.15 kgf·m
7.23 to 8.33 lbf·ft
Front Side
Rear Side
Liquid Gasket Application Portion
Oil Seal Receiving Part
Oil Passage
Screws Which Tightened First
with Tightening Torque
W1077380
2-S32
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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).
(When reassembling)
■ 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)
(2)
(3)
(4)
Pump Drive Gear
Input Shaft
Intermediate Shaft
19T-2 Gear
(5)
(6)
(7)
(8)
17T-13T Gear Shaft
External Snap Ring
Collar
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)
(2)
(3)
(4)
(5)
(6)
11T Gear Shaft (LH)
Steering Clutch (LH)
Clutch Lever (LH)
42T Gear Shaft
Clutch Lever (RH)
Thrust Collar
(7)
(8)
(9)
(10)
(11)
(12)
Spacer
Steering Clutch (RH)
11T Gear Shaft (RH)
Drive Shaft
Thrust Collar
Spacer
W1079532
2-S33
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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).
(1)
(2)
(3)
(4)
(5)
Internal Snap Ring
Clutch Plate
Clutch Disc and Friction Plate
Clutch Spline Plate
Spline Boss
(6)
(7)
(8)
(9)
(10)
External Snap Ring
Spacer
Spring
Clutch Collar
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 reassembling)
• 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
(1)
(2)
(3)
(4)
(5)
(6)
Rear Axle Assembly
Lock Nut
Belleville Washer
Rear Wheel Hub
Oil Seal
Bush
100 to 120 N·m
10.2 to 12.2 kgf·m
73.0 to 88.5 lbf·ft
Lock Nut
(7)
(8)
(9)
(10)
(11)
A:
Collar
External Snap Ring
65T Gear Shaft
Bush
Transaxle Case (Rear Side)
Split of Bush
W1080885
2-S34
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
(3) PTO Clutch
■ Sepatating PTO Cover Assembly with PTO Clutch Assembly and Transaxle Assembly installed in the
machine.
Dismounting Mower
1. Refer to “ [2] PREPARATION” of “4. CHECKING,
DISASSEMBLING AND SERVICING” at “8. MOWER” section.
W1058584
Draining Transmission Fluid
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).
(1)
(2)
(3)
(4)
(5)
(6)
PTO Cover Assembly
PTO Arm
PTO Rod
Nut
Nut
Spring
(7)
(8)
(9)
(10)
(11)
Transaxle Case
Ball Bearing
24T Gear
PTO Clutch
Brake Disc and Friction Plate
W1058792
2-S35
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
■ 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.
(1)
(2)
(3)
(4)
(5)
PTO Cover Assembly
Brake Disc and Friction Plate
PTO Clutch Assembly
Brake Friction Plate 1
Brake Friction Plate 2
(6) Flange Bolt and Nut
(7) Template (Refer to “8.SPECIAL
TOOLS” at “G. GENERAL” section)
A : Liquid Gasket Application Portion
W1059133
2-S36
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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)
(2)
(3)
(4)
(5)
(6)
Stud Bolt
Ball Bearing
Transaxle Case
PTO Cover Assembly
Sealing Groove
Brake Friction Plate 2
(7) PTO Clutch Assembly
(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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
Installation of PTO Cover Assembly with PTO Clutch Assembly
(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).
Position of PTO Arm (8)
Movement of PTO Shaft (2)
1
Within a play from the lowest
position
Can Not be turned by hand
2
Range where clutch spring
resistance is felt
Can be turned by hand
3
PTO Arm is the highest position
Can Not be turned by hand
Tightening torque
(1)
(2)
(3)
(4)
PTO Cover Mounting Bolt
Stud bolt
PTO Shaft
PTO Cover Assembly
Groove
(5)
(6)
(7)
(8)
17.7 to 20.5 N·m
1.80 to 2.10 kgf·m
13.1 to 15.1 lbf·ft
Transaxle Case
Tang
PTO Cover Mounting Bolt
PTO Arm
W1060090
2-S38
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
Installation of PTO Cover Assembly with PTO Clutch Assembly
(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.
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.
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 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. Refer to
“4. LUBRICANTS, FUEL AND COOLANT” at “G. GENERAL”
section.
• Do not mix different bland oil together.
Transmission fluid
(1) PTO ROd Spring
(2) Nut
(3) Nut
Capacity
3.4 L
0.90 U.S.gals
0.75 Imp.gals
(4) PTO Rod
(5) Filling Plug With Dipstick
W1061134
2-S39
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
[4] SERVICING
(1) Hydrostatic Transmission
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)
(2)
(3)
(4)
Plug
O-ring
Spring
Check and High Pressure Relief
Valve (Reverse)
(5) Check and High Pressure Relief
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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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.
(1) Thrust Ball Bearing
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
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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.
1.3 to 1.5 mm
0.051 to 0.059 in.
Allowable limit
1.2 mm
0.047 in.
W1087562
2-S42
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
Pressure Plate and Friction Plate Wear
1. Measure the thickness of pressure plate and friction plate 1, 2
with vernier calipers.
2. If the thickness is less than the allowable limit, replace it.
Thickness of pressure
plate
Thickness of friction
plate 1
Thickness of friction
plate 2
Factory spec.
1.55 to 1.65 mm
0.061 to 0.065 in.
Allowable limit
1.50 mm
0.059 in.
Factory spec.
1.55 to 1.65 mm
0.061 to 0.065 in.
Allowable limit
1.50 mm
0.059 in.
Factory spec.
0.75 to 0.85 mm
0.030 to 0.034 in.
Allowable limit
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.
Factory spec.
45 mm
1.77 in.
Allowable limit
42 mm
1.65 in.
Clutch spring free length
W1088067
PTO Brake Disc Wear
1. Measure the thickness of PTO brake disc with a vernier caliper.
2. If the thickness is less than the allowable limit, replace it.
PTO brake disc 1
thickness
PTO brake disc
thickness
Factory spec.
2.85 to 3.05 mm
0.11 to 0.12 in.
Allowable limit
2.75 mm
0.108 in.
Factory spec.
3.3 to 3.5 mm
0.13 to 0.14 in.
Allowable limit
3.00 mm
0.118 in.
W1088290
2-S43
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
Friction Plate Wear
1. Measure the thickness of brake friction plate 1, 2 with vernier
calipers.
2. If the thickness is less than the allowable limit, replace it.
Thickness of brake
friction plate 1
Thickness of brake
friction plate 2
Factory spec.
1.75 to 1.85 mm
0.069 to 0.073 in.
Allowable limit
1.60 mm
0.063 in.
Factory spec.
0.95 to 1.05 mm
0.037 to 0.041 in.
Allowable limit
0.80 mm
0.031 in.
W1088453
Clutch Spline Plate Wear
1. Measure the thickness of clutch spline plate with vernier calipers.
2. If the thickness is less than the allowable limit, replace it.
Thickness of clutch
spline plate
Factory spec.
0.75 to 0.85 mm
0.030 to 0.033 in.
Allowable limit
0.70 mm
0.028 in.
W1088611
Steering Clutch Disc Wear
1. Measure the thickness of steering clutch disc with vernier
calipers.
2. If the thickness is less than the allowable limit, replace it.
Thickness of steering
clutch disc
Factory spec.
1.3 to 1.5 mm
0.051 to 0.059 in.
Allowable limit
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.
2. If the thickness is less than the allowable limit, replace it.
Thickness of friction
plate
Factory spec.
0.75 to 0.85 mm
0.030 to 0.033 in.
Allowable limit
0.70 mm
0.028 in.
Factory spec.
1.55 to 1.65 mm
0.061 to 0.065 in.
Allowable limit
1.50 mm
0.059 in.
Thickness of clutch plate
W1089129
2-S44
KiSC issued 04, 2007 A
TRANSAXLE
GR2100EC2, WSM
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
KiSC issued 04, 2007 A
3
BRAKES
KiSC issued 04, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................3-S1
SERVICING SPECIFICATIONS ....................................................................3-S2
TIGHTENING TORQUES ..............................................................................3-S3
CHECKING, DISASSEMBLING AND SERVICING......................................3-S4
[1] CHECKING AND ADJUSTING ...............................................................3-S4
[2] DISASSEMBLING AND ASSEMBLING..................................................3-S4
(1) Pedal System Component ..................................................................3-S4
(2) Brake Assembly ..................................................................................3-S8
KiSC issued 04, 2007 A
BRAKES
GR2100EC2, WSM
1. TROUBLESHOOTING
Symptom
Insufficient Braking
Force
Brake Drags
Heavy Brakes
Probable Cause
Solution
Reference
Page
Brake pedal free travel excessive
Adjust
3-S4
Brake shoe worn
Replace
3-S8
Brake drum worn
Replace
3-S8
Grease or oil on brake shoe
Replace
3-S8
Brake pedal free travel too small
Adjust
3-S4
Brake spring weaken or broken
Replace
3-S8
Brake pedal rusted
Repair or replace
3-S8
Brake cam lever rusted
Replace
3-S8
W1014322
3-S1
KiSC issued 04, 2007 A
BRAKES
GR2100EC2, WSM
2. SERVICING SPECIFICATIONS
Item
Brake Pedal
Free Travel
Factory Specification
Allowable Limit
15 to 25 mm
0.59 to 0.98 in.
–
W1013874
3-S2
KiSC issued 04, 2007 A
BRAKES
GR2100EC2, WSM
3. TIGHTENING TORQUES
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
N·m
kgf·m
ft-lbs
20 to 25
2.0 to 2.5
14.8 to 18.4
Power steering hose mounting nut
24.0 to 28.0
2.45 to 2.85
17.71 to 20.65
Steering support mounting screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
Pedal system component mounting nut
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
Steering wheel mounting nut
W1012736
3-S3
KiSC issued 04, 2007 A
BRAKES
GR2100EC2, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Brake Pedal Free Travel
CAUTION
• Stop the engine, remove the key, and chock the wheels
before checking brake pedal.
1. Release the parking brake.
2. Loosen the lock nut (1).
3. 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
[2] DISASSEMBLING AND ASSEMBLING
(1) Pedal System Component
Dismounting Mower
1. Refer to “[2] PREPARATION” of “4. CHECKING,
DISASSEMBLING AND SERVICING” at “8. MOWER” section.
W1011726
Dismounting Container
1. Refer to “[2] PREPARATION” of “4. CHECKING,
DISASSEMBLING AND SERVICING” at “2. TRANSAXLE”
section
W1013516
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
W1013611
3-S4
KiSC issued 04, 2007 A
BRAKES
GR2100EC2, WSM
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
W1012680
3-S5
KiSC issued 04, 2007 A
BRAKES
GR2100EC2, WSM
Seat
1. Remove the snap pin (2).
2. Remove the seat (1).
(1) Seat
(2) Snap Pin
W1014606
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)
(2)
(3)
(4)
Lever Grip
Seat Base
Fender Mounting Screw
Fuel Cap
(5)
(6)
(7)
(8)
Fender
Cutting Height Control Dial
Speed Change Pedal
Step Sheet
W1014948
Steering Wheel, Side Bonnet and Panel
1. Remove the steering wheel (1).
2. Remove the side bonnet (3).
3. Remove the accelerator lever grip.
4. 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).
(When reassembling)
Tightening torque
(1)
(2)
(3)
(4)
Steering Wheel
Panel
Side Bonnet
KRA System Switch
Steering wheel mounting
nut
20 to 25 N·m
2.0 to 2.5 kgf·m
14.8 to 18.4 lbf-ft
(5) Main Switch
(6) Hour Meter
(7) Fuse Box
W1015321
3-S6
KiSC issued 04, 2007 A
BRAKES
GR2100EC2, WSM
Separating Engine
1. Refer to “[2] PREPARATION” of “4. CHECKING,
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).
(When reassembling)
• Be sure to connect the power steering hose to their original
position, and tighten them to the specified torque.
Power steering hose
mounting nut
24.0 to 28.0 N·m
2.45 to 2.85 kgf·m
17.71 to 20.65 lbf-ft
Steering support mounting
screw
48.1 to 55.8 N·m
4.9 to 5.7 kgf·m
35.5 to 41.2 lbf-ft
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
Cylinder Hose LH
Cylinder Hose RH
Return Hose
Delivery Hose
Steering Support
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
KiSC issued 04, 2007 A
BRAKES
GR2100EC2, WSM
Pedal System Component
1. Remove the parking lock spring (1).
2. Remove the pedal system component mounting nuts (2).
3. Separate the pedal system component (3) from frame.
(When reassembling)
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
(3) Pedal System Component
(2) Pedal System Component Mounting
Nut
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).
(When reassembling)
• 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
(1)
(2)
(3)
(4)
(5)
Lock Nut
Plain Washer
Brake Spring
Brake Assembly
Brake Rod 2
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
(6) Brake Plate
(7) Brake Assembly Mounting Screw
(8) External Snap Ring
(9) Brake Drum
(10) Brake Arm Lever
W1012172
3-S8
KiSC issued 04, 2007 A
4
FRONT AXLE
KiSC issued 04, 2007 A
MECHANISM
CONTENTS
1. STRUCTURE ................................................................................................. 4-M1
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
1. STRUCTURE
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
King Pin Support
Front Axle Case (Front Side)
Differential Gear Assembly
Differential Pinion Shaft
Differential Pinion Gear
Differential Yoke Shaft, RH
Differential Side Gear
Bevel Gear
Bevel Pinion Shaft
Differential Yoke Shaft, LH
Front Axle Case (Rear Side)
10T Bevel Gear
15T Bevel Gear
35T Bevel Gear
Front Gear Case Cover
Front Axle Shaft
Bevel Gear Shaft
Pipe
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
KiSC issued 04, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................4-S1
SERVICING SPECIFICATIONS ....................................................................4-S2
TIGHTENING TORQUES ..............................................................................4-S3
CHECKING, DISASSEMBLING AND SERVICING......................................4-S4
[1] CHECKING AND ADJUSTING ...............................................................4-S4
[2] PREPARATION ........................................................................................4-S6
(1) Separating Front Axle Assembly.........................................................4-S6
[3] DISASSEMBLING AND ASSEMBLING..................................................4-S9
(1) Front Axle Assembly ...........................................................................4-S9
[4] SERVICING ............................................................................................4-S12
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
1. TROUBLESHOOTING
Symptom
Front Wheels
Wander to Right or
Left
Front Wheels Can
Not Be Driven
Noised
Probable Cause
Solution
Reference
Page
Tire pressure uneven
Adjust
G-54
Improper toe-in adjustment (improper alignment)
Adjust
4-S4
Tie-rod end loose
Tighten
4-S9
Air sucked in power steering circuit
Bleed
Front wheel driving gears in front axle gear case
broken
Replace
4-S9
Universal joint broken
Replace
4-S7
Front wheel drive gears in transmission broken
Replace
2-S25
Front differential gear broken
Replace
4-S11, 12
Gear backlash excessive
Adjust or replace
Oil insufficient
Replenish
Bearings damaged or broken
Replace
–
Gears damaged or broken
Replace
–
–
4-S13 to 15
4-S6
W1014322
4-S1
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
2. SERVICING SPECIFICATIONS
Item
Factory Specification
Allowable Limit
0 to 5 mm
0.00 to 0.20 in.
–
Front Wheel Alignment
Toe-in
Differential Gear Case to Differential Side
Gear
Clearance
0.040 to 0.082 mm
0.00157 to 0.00323 in.
0.17 mm
0.0067 in.
Differential Gear
Case
(I.D.)
19.500 to 19.521 mm
0.76772 to 0.76854 in.
–
Differential Side
Gear
(O.D.)
19.439 to 19.460 mm
0.76532 to 0.76614 in.
–
Clearance
0.025 to 0.055 mm
0.00098 to 0.00217 in.
0.25 mm
0.0096 in.
Differential Pinion
Shaft
(O.D.)
9.960 to 9.975 mm
0.39212 to 0.39272 in.
–
Differential Pinion
(I.D.)
10.000 to 10.015 mm
0.39370 to 0.39429 in.
–
Differential Pinion Shaft to Differential
Pinion
Differential Pinion Gear to Differential Side
Gear
Backlash
0.1 to 0.3 mm
0.004 to 0.012 in.
–
Bevel Pinion Shaft to Bevel Gear
Backlash
0.1 to 0.3 mm
0.004 to 0.012 in.
–
10T Bevel Gear to 15T Bevel Gear
Backlash
0.1 to 0.3 mm
0.004 to 0.012 in.
–
W1013874
4-S2
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
3. TIGHTENING TORQUES
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
N·m
kgf·m
ft-lbs
Power steering cylinder hose
24.0 to 28.0
2.45 to 2.85
17.71 to 20.65
Front wheel mounting screw
108.5 to 130.2
11.07 to 13.29
80 to 96
Front axle bracket mounting screw
48.1 to 55.9
4.9 to 5.7
35.5 to 41.2
Tie-rod slotted nut
17.7 to 34.3
1.8 to 3.5
13.0 to 25.3
King pin support mounting nut
19.6 to 25.5
2.0 to 2.6
14.4 to 18.8
Front gear case cover mounting screw
17.7 to 20.6
1.8 to 2.1
13.0 to 15.1
9.8 to 11.3
1.00 to 1.15
7.23 to 8.33
Front axle case screw
W1012736
4-S3
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Toe-in
1. Inflate the tires to the specified pressure.
2. Turn the front wheels straight ahead.
3. Measure the toe-in (B-A).
4. If the measurement is not within the factory specifications, adjust
the tie-rod length.
Toe-in (B-A)
Factory spec.
(A) Wheel to Wheel Distance at Front
(B) Wheel to Wheel Distance at Rear
0 to 5 mm
0.00 to 0.20 in.
(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
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
Adjusting Glide Steer
•
•
■
•
1.
2.
3.
4.
5.
6.
7.
8.
9.
■
•
•
CAUTION
Park the machine on level ground.
Stop the engine and remove the key.
NOTE
This adjustment should be performed after completing the
adjustment of toe-in.
Lift up the machine while kept parallel, and support it with
disassembling jacks.
To fix the front axle, wedge the wooden blocks between the
frame and the front axle.
Turn the front wheels straight ahead position.
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)”.)
Confirm that the left and right rear wheels do not rotate manually.
Select “L1(b)” from “L1(a)” given by “4” by using TABLE 1 shown
below
Turn the steering wheel to left or right slowly.
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.
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)
68.0 mm
2.68 in.
68.5 mm
2.70 in.
69.0 mm
2.72 in.
69.5 mm
2.74 in.
70.0 mm
2.76 in.
L1(b)
90.1 to 92.9
mm
3.55 to 3.66
in.
90.6 to 93.4
mm
3.57 to 3.68
in.
91.1 to 93.9
mm
3.59 to 3.70
in.
91.6 to 94.4
mm
3.61 to 3.72
in.
92.1 to 94.9
mm
3.63 to 3.74
in.
L1 :Length of the Steering Cylinder
L1 (b) :“L1” when the right (or left)
Tube
rear wheel is rotaed manualluy by
L1 (a) :“L1” when the front wheels are
turning the front wheels in the
in the position in the goingright (or left) direction
straight direction
L2 :Length of Glide Steer wire boot
W1015126
4-S5
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
[2] PREPARATION
(1) Separating Front Axle Assembly
Dismounting Mower
1. Refer to “[2] PREPARATION” of “4. CHECKING,
DISASSEMBLING AND SERVICING” at “8. MOWER” section.
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) Breather Plug
(2) Filling Plug with Dipstick
(3) Drain Plug
1.9 L
0.50 U.S.gals
0.42 Imp.gals
A : Oil level is acceptable within this
range
W1014629
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
W1016814
4-S6
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
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
W1018035
Power Steering Hose
1. Disconnect the power steering cylinder hoses (1).
(When reassembling)
Tightening torque
Power steering cylinder
hose
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
Glide Steer Wire
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).
(When reassembling)
• Adjust the Glide Steer. (Refer to “[1] CHECKING AND
ADJUSTING” of “4. CHECKING, DISASSEMBLING AND
SERVICING” in this section.)
(1) Wire Holder
(2) King Pin Support
(3) Glide Steer Wire
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).
(When reassembling)
Tightening torque
(1) Joint Cover
Front wheel mounting
screw
108.5 to 130.2 N·m
11.07 to 13.29 kgf·m
80 to 96 ft-lbs
(2) Universal Joint
W1018894
4-S7
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
Power Steering Cylinder Holder
1. Unscrew the power steering cylinder holder mounting screws (2).
2. Remove the power steering cylinder holder (1).
(When reassembling)
• Reinstall the Glide Steer wire (3) as shown in the figure.
(1) Power Steering Cylinder Holder
(2) 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.
(When reassembling)
• 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
(1) Front Axle Assembly
(2) Front Axle Bracket
(3) Front Axle Bracket Retaining Screw
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.5 to 41.2 ft-lbs
(4) Shim
(5) Collar
(6) Shim
W1019299
4-S8
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
[3] DISASSEMBLING AND ASSEMBLING
(1) Front Axle Assembly
Power Steering Cylinder
1. Remove the cotter pin and remove the slotted nut for tie-rod (1).
2. Remove the power steering cylinder mounting screws and
remove the power steering cylinder (2) with tie-rod.
(When reassembling)
■ 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
(1) Tie-rod
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
(2) Power Steering Cylinder
W1019533
Front Gear Case Assembly
1. Remove the king pin support (1).
2. Remove the front gear case assembly (2).
(When reassembling)
• Do not interchange left and right front gear case assembles.
Tightening torque
(1) King Pin Support
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
(2) Front Gear Case
W1020557
Front Gear Case Cover
1. Remove the front gear case cover (1) with bevel gear (3).
(When reassembling)
• 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
(1) Front Case Cover
(2) Square Mark
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
(3) Bevel Gear
(4) O-ring
W1020837
4-S9
KiSC issued 04, 2007 A
FRONT AXLE
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
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
(3) Internal Snap Ring
(4) Ball Bearing
(5) Bevel Gear Shaft
(6) Front Gear Case
W1021957
Front Axle Case
1. Separate the front axle case to front side (1) and rear side (2).
(When reassembling)
• 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
(1) Front Axle Case (Front Side)
(2) Front Axle Case (Rear Side)
9.8 to 11.3 N·m
1.00 to 1.15 kgf·m
7.23 to 8.33 ft-lbs
(3) Front Axle Case Screw
W1022133
4-S10
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
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
(4) Bevel Pinion Shaft
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)
(2)
(3)
(4)
10T Bevel Gear (LH)
Shim
Differential Yoke Shaft (LH)
Differential Gear Assembly
(5)
(6)
(7)
(8)
Shim
Differential Yoke Shaft (RH)
Shim
10T Bevel Gear (RH)
W1022655
4-S11
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
Differential Gear Assembly
1. Remove the bevel gear (10).
2. Remove the bearings (5), (9) with the puller.
3. Remove the external snap ring (8).
4. Remove the differential pinion shaft (7).
5. Remove the differential pinion gears (3), differential side gears
(4) and shims (2).
■ NOTE
• Arrange the parts to know their original position.
(When reassembling)
• 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)
(2)
(3)
(4)
(5)
Steel Ball
Shim
Differential Pinion Gear
Differential Side Gear
Bearing
(6)
(7)
(8)
(9)
(10)
Differential Gear Case
Differential Pinion Shaft
External Snap Ring
Bearing
Bevel Gear
W1014840
[4] SERVICING
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.
Factory spec.
0.040 to 0.082 mm
0.00157 to 0.00323 in.
Allowable limit
0.17 mm
0.0067 in.
Differential gear case
bore I.D.
Factory spec.
19.500 to 19.521 mm
0.76772 to 0.76854 in.
Differential side gear
O.D.
Factory spec.
19.439 to 19.460 mm
0.76532 to 0.76614 in.
Clearance between
differential gear case
and differential side gear
W1023578
4-S12
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
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.
Factory spec.
0.025 to 0.055 mm
0.00098 to 0.00217 in.
Allowable limit
0.25 mm
0.0096 in.
Differential pinion shaft
O.D.
Factory spec.
9.960 to 9.975 mm
0.39212 to 0.39272 in.
Differential pinion gear
I.D.
Factory spec.
10.000 to 10.015 mm
0.39370 to 0.39429 in.
Clearance between
differential pinion shaft
and differential pinion
gear
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
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
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)
• Thickness of adjusting shims:
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
(2) Bevel Pinion Shaft
(3) Bevel Gear
(4) Shim
W1025529
4-S14
KiSC issued 04, 2007 A
FRONT AXLE
GR2100EC2, WSM
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)
• Thickness of adjusting shims:
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
KiSC issued 04, 2007 A
5
STEERING
KiSC issued 04, 2007 A
MECHANISM
CONTENTS
1. HYDRAULIC CIRCUIT .................................................................................. 5-M1
2. STEERING CONTROLLER .......................................................................... 5-M2
3. STEERING CYLINDER................................................................................. 5-M4
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
1. HYDRAULIC CIRCUIT
(1) Hydraulic Control Valve
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
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
2. STEERING CONTROLLER
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.
(1)
(2)
(3)
(4)
(5
(6)
(7)
(8)
(9)
Steering Controller
Metering Device
Control Valve
Steering Cylinder
Check Valve
Spool
Centering Spring
Sleeve
Drive Shaft
(10) Distributor Plate
(11) Rotor
(12) Stator
P : P Port (From Hydraulic
Control Valve Assembly)
T : T Port (To Hydraulic
Control Valve Assembly)
W1012852
5-M2
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
■ 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/cm2
1204 to 1276 psi
(1) Relief Valve
P : P Port (From Hydraulic
Control Valve Assembly)
T : T Port (To Hydraulic
Control Valve Assembly)
W1013242
5-M3
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
3. STEERING CYLINDER
(1) Rod
(2) Wiper Ring
(3) Internal Snap Ring
(4) Guide
(5) O-ring
(6) Seal Ring
(7) Center Piston
(8) Piston O-ring
(9) External Snap 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
KiSC issued 04, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................5-S1
SERVICING SPECIFICATIONS ....................................................................5-S2
TIGHTENING TORQUES ..............................................................................5-S3
CHECKING, DISASSEMBLING AND SERVICING......................................5-S4
[1] CHECKING AND ADJUSTING ...............................................................5-S4
[2] PREPARATION ........................................................................................5-S5
(1) Separating Power Steering Controller ................................................5-S5
(2) Separating Power Steering Cylinder ...................................................5-S8
[3] DISASSEMBLING AND ASSEMBLING................................................5-S11
(1) Power Steering Cylinder ...................................................................5-S11
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
1. TROUBLESHOOTING
Symptom
Cannot Be Steered
Probable Cause
Solution
Reference
Page
Steering controller malfunctioning
Replace
5-S8
Hose broken
Replace
5-S8
Power steering oil improper
Change with
specified oil
Hydraulic pump malfunctioning
Replace
6-S11
Steering controller malfunctioning
Replace
5-S8
Steering controller malfunctioning
Replace
5-S8
Air sucked in pump due to lack of oil
Replenish
G-8, 17
Air sucked in pump from suction circuit
Repair
6-S7, 11
Steering Wheel Turns
Spontaneously When
Released
Steering controller malfunctioning
Replace
5-S8
Front Wheels
Wander to Right and
Left
Steering controller malfunctioning
Replace
5-S8
Air sucked in pump due to lack of oil
Replenish
G-8, 17
Air sucked in pump from suction circuit
Repair
6-S7, 11
Insufficient bleeding
Bleed
–
Cylinder malfunctioning
Replace
5-S11
Improper toe-in adjustment
Adjust
4-S4
Tire pressure uneven
Inflate
G-54
Wheels Are Turned
to a Direction
Opposite to Steering
Direction
Cylinder hoses connected in reverse
Repair
5-S8
Steering Wheel Turns
Idle in Manual
Steering
Insufficient bleeding
Bleed
–
Air sucked in due to lack of oil
Replenish
G-8, 17
Noise
Air sucked in pump due to lack of oil
Replenish
G-8, 17
Air sucked in pump from suction circuit
Repair
6-S7, 11
Steering controller (relief valve) malfunctioning
Replace
Hard Steering
Steering Force
Fluctuates
Oil Temperature
Increases Rapidly
G-8, 31
5-S8
W1014322
5-S1
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
2. SERVICING SPECIFICATIONS
Item
Steering Wheel
Play
Factory Specification
Allowable Limit
30 to 70 mm
0.79 to 1.18 in.
–
W1013874
POWER STEERING BODY
Relief Valve
Operating
Pressure
8.3 to 8.8 MPa
84.6 to 89.7 kgf/cm2
1204 to 1276 psi
–
W1011454
5-S2
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
3. TIGHTENING TORQUES
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
N·m
kgf·m
ft-lbs
20 to 25
2.0 to 2.5
14.8 to 18.4
Power steering hose mounting nut
24.0 to 28.0
2.45 to 2.85
17.71 to 20.65
Power steering cylinder hose nut
24.0 to 28.0
2.45 to 2.85
17.71 to 20.65
108.5 to 130.2
11.07 to 13.29
80 to 96
Front axle bracket mounting screw
48.1 to 55.9
4.9 to 5.7
35.5 to 41.2
Tie-rod slotted nut
17.7 to 34.3
1.8 to 3.5
13.0 to 25.3
74 to 84
7.5 to 8.6
54.6 to 61.9
Steering wheel mounting nut
Front wheel mounting screw
Tie-rod screw
W1012736
5-S3
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Steering Wheel Play
1. Turn the front wheels straight ahead.
2. Rotate the steering wheel lightly by hand, and measure the play.
3. If the measurement exceeds the factory specifications, replace
the steering shaft and sector gear.
Steering wheel play
Factory spec.
30 to 70 mm
0.79 to 1.18 in.
W1010662
Relief Valve Operating Pressure
CAUTION
• When checking, park the machine on level ground, apply the
parking brake.
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/cm2
1204 to 1276 psi
(1) Power Steering Hose
W1013292
5-S4
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
[2] PREPARATION
(1) Separating Power Steering Controller
Dismounting Mower
1. Refer to “[2]
PREPARATION” of “4.
CHECKING,
DISASSEMBLING AND SERVICING” at “8. MOWER” section.
W1014016
Dismounting Container
1. Refer to “[2]
PREPARATION” of “4.
CHECKING,
DISASSEMBLING AND SERVICING” at “2. TRANSAXLE”
section.
W1014145
Battery
•
1.
2.
3.
4.
CAUTION
When disconnecting the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
Open the bonnet.
Remove the radiator net.
Disconnect the negative cable (1) from the battery.
Disconnect the positive cable (2) from the battery and remove the
battery (3).
(1) Negative Cable
(2) Positive Cable
(3) Battery
W1014023
5-S5
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
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
W1013744
5-S6
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
Seat
1. Remove the snap pin (2).
2. Remove the seat (1).
(1) Seat
(2) Snap Pin
W1015242
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)
(2)
(3)
(4)
Lever Grip
Seat Base
Fender Mounting Screw
Fuel Cap
(5)
(6)
(7)
(8)
Fender
Cutting Height Control Dial
Speed Change Pedal
Step Sheet
W1015581
Steering Wheel, Side Bonnet and Panel
1. Remove the steering wheel (1).
2. Remove the side bonnet (3).
3. Remove the accelerator lever grip.
4. Disconnect the connectors for hour meter, main switch (4) and
light switch.
5. Remove the indicator lamps (5).
6. Remove the fuse box (6) from the steering support.
7. Remove the panel (2).
(When reassembling)
Tightening torque
(1) Steering Wheel
(2) Panel
(3) Side Bonnet
Steering wheel mounting
nut
20 to 25 N·m
2.0 to 2.5 kgf·m
14.8 to 18.4 ft-lbs
(4) Main Switch
(5) Indicator Lamp
(6) Fuse Box
W1015949
5-S7
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
Steering Controller
1. Disconnect the power steering hoses (1), (2), (3), (4).
2. Remove the steering controller mounting screws and remove the
steering controller (5).
(When reassembling)
• Be sure to connect the power steering hoses to their original
position, and tighten them to the specified torque.
Tightening torque
(1)
(2)
(3)
(4)
(5)
Cylinder Hose LH
Cylinder Hose RH
Return Hose
Delivery Hose
Steering Controller
Power steering hose
mounting nut
24.0 to 28.0 N·m
2.45 to 2.85 kgf·m
17.71 to 20.65 ft-lbs
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
Dismounting Mower
1. Refer to “[2]
PREPARATION” of “4.
CHECKING,
DISASSEMBLING AND SERVICING” at “8. MOWER” section
W1018278
Battery
•
1.
2.
3.
4.
CAUTION
When disconnecting the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
Open the bonnet.
Remove the radiator net.
Disconnect the negative cable (1) from the battery.
Disconnect the positive cable (2) from the battery and remove the
battery (3).
(1) Negative Cable
(2) Positive Cable
(3) Battery
W1018648
5-S8
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
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
W1019214
Power Steering Hose
1. Disconnect the power steering cylinder hoses (1).
(When reassembling)
Tightening torque
Power steering cylinder
hose
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
Glide Steer Wire
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).
(When reassembling)
• Adjust the Glide Steer.
(Refer to “[1]
CHECKING,
ADJUSTING” of “4. CHECKING, DISASSEMBLING AND
SERVICING” at “4. FRONT AXLE” section.)
(1) Wire Holder
(2) King Pin Support
(3) Glide Steer Wire
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).
(When reassembling)
Tightening torque
(1) Joint Cover
Front wheel mounting
screw
108.5 to 130.2 N·m
11.07 to 13.29 kgf·m
80 to 96 ft-lbs
(2) Universal Joint
W1020516
5-S9
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
Power Steering Cylinder Holder
1. Unscrew the power steering cylinder holder mounting screws (2).
2. Remove the power steering cylinder holder (1).
(When reassembling)
• Reinstall the Glide Steer wire (3) as shown in the figure.
(1) Power Steering Cylinder Holder
(2) Power Steering Cylinder Holder
Mounting Screw
(3) Glider Steer Wire
(4) Front Axle Assembly
(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.
(When reassembling)
• 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
(1) Front Axle Assembly
(2) Front Axle Bracket
(3) Front Axle Bracket Retaining Screw
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.5 to 41.2 ft-lbs
(4) Shim
(5) Collar
(6) Shim
W1020915
5-S10
KiSC issued 04, 2007 A
STEERING
GR2100EC2, WSM
Power Steering Cylinder
1. Remove the cotter pin and remove the slotted nut for tie-rod (1).
2. Remove the power steering cylinder mounting screws and
remove the power steering cylinder (2) with tie-rod.
(When reassembling)
■ 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
(1) Tie-rod
17.7 to 34.3 N·m
1.8 to 3.5 kgf·m
13.0 to 25.3 ft-lbs
(2) Power Steering Cylinder
W1021151
[3] DISASSEMBLING AND ASSEMBLING
(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).
(When reassembling)
• 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.
CHECKING, DISASSEMBLING AND SERVICING” at “4.
FRONT AXLE” section.)
• Apply liquid lock to the thread of piston rod (6).
Tightening torque
(1)
(2)
(3)
(4)
(5)
Tie-rod RH
Hose Adaptor RH
Hose Adaptor LH
Tie-rod LH
External Snap Ring
74 to 84 N·m
7.5 to 8.6 kgf·m
54.6 to 61.9 ft-lbs
Tie-rod screw
(6) Piston Rod
(7) Cylinder
A : Front
W1021401
5-S11
KiSC issued 04, 2007 A
6
HYDRAULIC SYSTEM
KiSC issued 04, 2007 A
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
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
1. HYDRAULIC CIRCUIT
(1) Hydrostatic Transmission
(2) Oil Filter Cartridge
(3) HST Relief Valve
(4) Hydraulic Control Valve
Assembly
(5) Steering Controller
(6) Mower Lift Cylinder
(7) Check Valve
(8) Control Valve
(9) Hydraulic Pump
(10) Oil Strainer
(11) Main Relief Valve
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
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
2. HYDRAULIC PUMP
The hydraulic pump is composed of the casing (1),
cover (5), side plate (3), drive gear (2) and driven gear
(8).
Hydraulic pump is driven by the pump drive shaft in
the transaxle case.
Maximum displacement is as follows.
Displacement
10.4 L/min.
2.75 U.S.gal/min.
2.29 Imp.gal/min.
(1)
(2)
(3)
(4)
Casing
Drive Gear
Side Plate
O-ring
Engine speed
At 3000 min-1 (rpm)
(5)
(6)
(7)
(8)
Condition
at no load
Cover
Oil Seal
Internal Snap Ring
Driven Gear
W1013073
6-M2
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
3. HYDRAULIC CONTROL VALVE
(1)
(2)
(3)
(4)
Check Valve
HST Relief Valve
Main Relief Valve
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
F1 :Filter Port
Power Steering Controller)
(To Filter Cartridge)
PS2 : Power Steering Port (From F2 :Filter Port
Power Steering Controller)
(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
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
[1] MOWER LIFT CIRCUIT
■ Neutral
(1)
(2)
(3)
(4)
Check Valve
Main Relief Valve
Spool
Passage
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)
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
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
■ Lift
(1)
(2)
(3)
(4)
Check Valve
Main Relief Valve
Spool
Passage
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)
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
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
■ Overload
(1)
(2)
(3)
(4)
Check Valve
Main Relief Valve
Spool
Passage
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
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/cm2, 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
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
■ Down
(1)
(2)
(3)
(4)
(5)
Check Valve
Flat Face
Main Relief Valve
Spool
Passage
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)
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
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
[2] HST RELIEF VALVE
(1) HST Relief Valve
P : Pump Port
T : Tank Port
(To Transaxle Case)
PS1 : Power Steering Port (To
F1 :Filter Port
Power Steering Controller)
(To Filter Cartridge)
PS2 : Power Steering Port (From F2 :Filter Port
Power Steering Controller)
(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/cm2, 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
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
4. MOWER LIFT CYLINDER
(1)
(2)
(3)
(4)
(5)
Cylinder Tube
Snap Ring
Cylinder Rod
Packing
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
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
5. MOWER LINKAGE
(1)
(2)
(3)
(4)
(5)
Rear Link
Mower Lift Cylinder
Adjusting Cam
Cutting Height Adjusting Dial
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
KiSC issued 04, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................6-S1
SERVICING SPECIFICATIONS ....................................................................6-S2
TIGHTENING TORQUES ..............................................................................6-S3
CHECKING, DISASSEMBLING AND SERVICING......................................6-S4
[1] CHECKING AND ADJUSTING ...............................................................6-S4
[2] PREPARATION ........................................................................................6-S5
(1) Separating Hydraulic Control Valve and Hydraulic Pump...................6-S5
(2) Mower Lift Cylinder ...........................................................................6-S12
[3] DISASSEMBLING AND ASSEMBLING................................................6-S15
(1) Hydraulic Control Valve Assembly ....................................................6-S15
(2) Mower Lift Linkage............................................................................6-S16
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
1. TROUBLESHOOTING
Symptom
Mower Does Not Rise
Probable Cause
Solution
Reference
Page
Control valve malfunctioning
Repair or replace
6-S15
Lift cylinder damaged
Replace
6-S14
Main Relief valve spring damaged
Replace
6-S15
Main Relief valve setting pressure too low
Adjust
6-S4
Hydraulic pump defective
Replace
6-S11
Oil strainer clogged
Clean or replace
G-32
Insufficient transmission oil
Refill
Mower Does Not
Lower
Control valve malfunctioning
Repair or replace
6-S15
Mower Drops by Its
Weight
Lift cylinder worn or damaged
Replace
6-S14
Control valve malfunctioning
Replace
6-S15
G-8, 17
W1014322
6-S1
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
2. SERVICING SPECIFICATIONS
Item
Main Relief Valve
Setting Pressure
Factory Specification
Allowable Limit
9.5 to 11.0 MPa
97 to 112 kgf/cm2
1378 to 1595 psi
–
W1013874
6-S2
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
3. TIGHTENING TORQUES
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
N·m
kgf·m
ft-lbs
Bolt joint
24.5 to 34.3
2.50 to 3.49
18.1 to 25.2
Hydraulic pump mounting screw
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2
Adaptor
20.0 to 25.0
2.04 to 2.54
14.8 to 18.4
5.0 to 7.0
0.51 to 0.71
3.69 to 5.16
20.0 to 25.0
2.04 to 2.54
14.8 to 18.4
Drain pipe mounting screw
Joint pipe
W1012736
6-S3
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Main Relief Valve Setting Pressure
1. Remove the cylinder hose (1) form the mower lift cylinder.
2. Install the adaptor and pressure gauge.
3. Start the engine and set at maximum speed.
4. 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/cm2
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
(2) Hydraulic Control Valve
(3) Shim
W1010662
6-S4
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
[2] PREPARATION
(1) Separating Hydraulic Control Valve and Hydraulic Pump
Dismounting Container
1. Refer to “[2]
PREPARATION” of “4.
CHECKING,
DISASSEMBLING AND SERVICING” at “2. TRANSAXLE”
section.
W1013656
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
6-S5
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
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
W1013777
6-S6
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
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.
(When refilling)
• 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 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 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.
Refer to "4. LUBRICANTS, FUEL AND COOLANT" at "G.
GENERAL" section.
• Do not mix different bland oil together.
Transmission fluid
(1)
(2)
(3)
(4)
(5)
Suction Pipe
Drain Plug
O-ring (Small)
O-ring (Large)
Strainer
Capacity
3.4 L
0.90 U.S.gals
0.75 Imp.gals
(6) Boss
(7) Filling Plug with Dipstick
H : Highest Level
L : Lowest Level
W1016321
6-S7
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
Seat
1. Remove the snap pin (2).
2. Remove the seat (1).
(1) Seat
(2) Snap Pin
W1016597
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)
(2)
(3)
(4)
Lever Grip
Seat Base
Fender Mounting Screw
Fuel Cap
(5)
(6)
(7)
(8)
Fender
Cutting Height Control Dial
Speed Change Pedal
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
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
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).
(When reassembling)
• After assembling the beam, fix the breather hose (6) to the beam
(5) with the hose clamp (7) horizontally along the beam (5).
(1)
(2)
(3)
(4)
PTO Switch
Spring
PTO Lever
Filling Pipe
(5) Beam
(6) Breather Hose
(7) Hose clamp
W1016678
6-S9
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
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).
(When reassembling)
• 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.
Tightening torque
Control valve pipe
retaining nut
24 to 28 N·m
2.5 to 2.8 kgf·m
18 to 20 lbf-ft
Joint bolt (12)
32 to 36 N·m
3.3 to 3.6 kgf·m
24 to 26 lbf-ft
Hose clamp for drain hose
(18), (19)
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)
(2)
(3)
(4)
(5)
(6)
(7)
Brake Rod 1
Brake Plate
Filter cartridge
Neutral Arm Holder
Breather Hose
Control Valve Pipe
Power Steering Pipe (To Power
Steering Unit Controller)
(8) Power Steering Pipe (From Power
Steering Unit Controller)
(9) Cylinder Hose
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Drain Hose
Hydraulic Control Valve Assembly
Joint Bolt
Copper Gasket (Thick Type)
Copper Gasket (Thin Type)
O-ring
Chrge Pipe
Charge Port
Hose Clamp
Hose Clamp
Hydraulic pipe
W1018628
6-S10
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
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).
(When reassembling)
• Replace the copper gaskets (3), (5) with new one.
• Install the copper gaskets (3), (5) in original position.
Hydraulic pump mounting
screw
17.7 to 20.6 N·m
1.81 to 2.10 kgf·m
13.1 to 15.1 lbf-ft
Joint bolt
40.0 to 45.0 N·m
4.08 to 4.58 kgf·m
29.5 to 33.1 lbf-ft
Tightening torque
(1) Hydraulic Pump Mounting Screw
(2) Hydraulic Pump
(3) Copper Gasket (Thin Type)
(4) Suction Pipe 1
(5) Copper Gasket (Thinck Type)
(6) Joint Bolt
W1022621
6-S11
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
(2) Mower Lift Cylinder
Dismounting Container
1. Refer to “[2]
PREPARATION” of “4.
CHECKING,
DISASSEMBLING AND SERVICING” at “2. TRANSAXLE”
section.
W1023561
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
W1014908
6-S12
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
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
W1014483
Seat
1. Remove the snap pin (2).
2. Remove the seat (1).
(1) Seat
(2) Snap Pin
W1024426
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)
(2)
(3)
(4)
Lever Grip
Seat Base
Fender Mounting Screw
Fuel Cap
(5)
(6)
(7)
(8)
Fender
Cutting Height Control Dial
Speed Change Pedal
Step Sheet
W1018480
6-S13
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
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).
(1)
(2)
(3)
(4)
(5)
Mower Lift Cylinder
Cylinder Hose
Lift Shaft
Lift Link
Rue Ring Pin
(6)
(7)
(8)
(9)
(10)
Clevis Pin
Rue Ring
Clevis Pin
Adaptor
Plain Washer
W1028095
6-S14
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
[3] DISASSEMBLING AND ASSEMBLING
(1) Hydraulic Control Valve Assembly
Adaptor and Filter Joint
1. Remove the adaptors (2) (3).
2. Unscrew the drain pipe mounting screw, and remove the drain
pipe (4).
3. Remove the joint pipe (1).
4. Remove the filter joint (5).
(When reassembling)
Tightening torque
(1) Joint Pipe
(2) Adaptor
(3) Adaptor
Adaptor
20.0 to 25.0 N·m
2.04 to 2.54 kgf·m
14.8 to 18.4 lbf-ft
Drain pipe mounting screw
5.0 to 7.0 N·m
0.51 to 0.71 kgf·m
3.69 to 5.16 lbf-ft
Joint pipe
20.0 to 25.0 N·m
2.04 to 2.54 kgf·m
14.8 to 18.4 lbf-ft
(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).
(When reassembling)
• Take care not to damage the O-ring (2).
■ 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).
(When reassembling)
• Take care not to damage the O-ring (3).
(1) Poppet
(2) Spring
(3) O-ring
(4) Plug
W1029997
6-S15
KiSC issued 04, 2007 A
HYDRAULIC SYSTEM
GR2100EC2, WSM
Check Valve
1. Remove the cylinder hose adaptor (1).
2. Draw out the spring (3) and poppet (4).
(When reassembling)
• Take care not to damage the O-ring (2).
(1) Cylinder Hose Adaptor
(2) O-ring
(3) Spring
(4) Poppet
W1030474
(2) Mower Lift Linkage
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Screw
Lock Nut
Rear Link LH
Clevis Pin
Lift Link LH
Rue Ring
Rue Ring
Lock Nut
Plate Spring
Adjusting Cam
Cutting Height Adjusting Rod
Cutting Height Adjusting Dial
Knob
Rue Ring
Lift Link RH
Rue Ring
Clevis Pin
Rear Link RH
Lock Nut
Screw
W1030787
1. Dismount the mower. (Refer to “[2] PREPARATION” of “4.
CHECKING, DISASSEMBLING AND SERVICING” at “8.
MOWER” section.)
2. Remove the fender. (Refer to “[2] PREPARATION” of “4.
CHECKING, DISASSEMBLING AND SERVICING” at “2.
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
KiSC issued 04, 2007 A
7
ELECTRICAL SYSTEM
KiSC issued 04, 2007 A
MECHANISM
CONTENTS
1.
2.
3.
4.
WIRING DIAGRAM ....................................................................................... 7-M1
STARTING SYSTEM .................................................................................... 7-M3
CHARGING SYSTEM ................................................................................... 7-M4
LIGHTING SYSTEM ..................................................................................... 7-M5
KiSC issued 04, 2007 A
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
Color of Wiring
W .......... White
WR ........... White / Red
BW ......... Black / White
R ........... Red
WY ........... White / Yellow
BR .......... Black / Red
L ........... Blue
RB ............ Red / Black
GW ........ Green / White
P ........... Pink
RW ............ Red / White
YR .......... Yellow / Red
B ........... Black
RG ............ Red / Green
YL .......... Yellow / Blue
Br .......... Brown
RY ............. Red / Yellow
LW ......... Blue / White
Sb ......... Sky Blue
W1019456
7-M2
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
2. STARTING SYSTEM
(1)
(2)
(3)
(4)
(5)
(6)
Battery
Body Earth
Starter Motor
Glow Plug
Engine Stop Solenoid
Body Earth
(7)
(8)
(9)
(10)
(11)
(12)
Engine Stop Time Relay
Fuel Feed Pump
Slow Blow Fuse (40 A)
Fuse (15 A)
Seat Switch
Grass Container Open Switch
(13)
(14)
(15)
(16)
(17)
Grass Container Open Relay
Diode (3 A)
Top Cover Open Switch
Brake Switch
Fuse (3 A)
(18)
(19)
(20)
(21)
(22)
Fuse (10 A)
Main Switch
Hour Meter
Glow Plug Lamp
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
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
3. CHARGING SYSTEM
(1) Battery
(2) Body Earth
(3) Body Earth
(4) Dynamo
(5) Slow Blow Fuse (40 A)
(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
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
4. LIGHTING SYSTEM
(1)
(2)
(3)
(4)
(5)
(6)
Battery
Body Earth
Thermo Switch
Oil Switch
Body Earth
Dynamo
(7)
(8)
(9)
(10)
(11)
(12)
Regulator
Slow Blow Fuse (40 A)
Main Switch
Fuse (10 A)
Fuse (3 A)
PTO Switch
(13)
(14)
(15)
(16)
(17)
(18)
Grass Container Full Switch
Buzzer Relay
Buzzer
Thermo Lamp
Grass Container Full Lamp
Oil Pressure Lamp
(19)
(20)
(21)
(22)
(23)
Charge Lamp
Easy Checker
Head Light Switch
Head Light
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
KiSC issued 04, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................7-S1
SERVICING SPECIFICATIONS ....................................................................7-S4
TIGHTENING TORQUES ..............................................................................7-S5
CHECKING, DISASSEMBLING AND SERVICING......................................7-S6
[1] CHECKING AND ADJUSTING ...............................................................7-S6
(1) Battery.................................................................................................7-S6
(2) Main Switch.........................................................................................7-S6
(3) Starter .................................................................................................7-S8
(4) Glow Plug............................................................................................7-S9
(5) Safety Switch ....................................................................................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
[2] DISASSEMBLING AND ASSEMBLING................................................7-S18
(1) Starter ...............................................................................................7-S18
(2) Dynamo.............................................................................................7-S19
[3] SERVICING ............................................................................................7-S20
(1) Starter ...............................................................................................7-S20
(2) Dynamo.............................................................................................7-S22
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
1. TROUBLESHOOTING
Symptom
All Electrical
Equipments Do Not
Operate
Fuse Blown
Frequently
Probable Cause
Reference
Page
Solution
Battery discharged or defective
Recharge or replace
G-25,
1-S21
Battery positive cable disconnected or
improperly connected
Repair or replace
–
Battery negative cable disconnected or
improperly connected
Repair or replace
–
Slow blow fuse blown (40 A)
Replace
Short-circuited
Repair or replace
G-39
–
W1014322
BATTERY
Battery Discharges
Too Quickly
Battery defective
Replace
1-S21
Dynamo defective
Repair or replace
7-S19
Regulator defective
Replace
–
Wiring harness disconnected or improperly
connected (between battery positive terminal
and regulator B terminal)
Repair or replace
–
Cooling fan belt slipping
Adjust tension
G-29
W1011677
7-S1
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
STARTING SYSTEM
Symptom
Starter Motor Does
Not Operate
Engine Does Not
Stop When Main
Switch is Turned OFF
Engine Does Not
Start
Probable Cause
Solution
Reference
Page
Battery discharged or defective
Recharge or replace
G-25,
1-S21
Slow blow fuse blown (40 A)
Replace
G-39
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)
Repair or replace
–
Starter motor defective
Repair or replace
7-S18
Main switch defective
Replace
7-S6
Seat switch defective
Replace
7-S11
Brake switch defective
Replace
7-S10
PTO switch defective
Replace
7-S10
Grass container open switch defective
Replace
7-S11
Fuse blown (15 A)
Replace
G-39
Wiring harness disconnected or improperly
connected (between main switch ACC terminal
and engine stop solenoid)
Repair or replace
Engine stop solenoid defective
Replace
7-S12
Timer relay defective
Replace
7-S13
Engine stop solenoid defective
Replace
7-S12
Timer relay defective
Replace
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)
Replace
G-39
Bulb blown
Replace
G-40
Wiring harness disconnected or improperly
connected (between main switch ACC terminal
and regulator connector terminal (yellow),
between regulator connector terminal (green)
and charge lamp)
Repair or replace
–
Regulator defective
Replace
–
Dynamo defective
Repair or replace
Regulator defective
Replace
7-S19
–
W1012454
7-S2
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
LIGHTING SYSTEM
Symptom
Head Light Does Not
Light
Glow Plug Lamp
Does Not Light When
Main Switch Is in
Pre-heat Position
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
Probable Cause
Reference
Page
Solution
Fuse blown (10 A)
Replace
G-39
Bulb blown
Replace
G-40
Wiring harness disconnected or improperly
connected (between main switch ACC terminal
and head light switch, between head light switch
and head light)
Repair or replace
Battery discharged or defective
Recharge or replace
G-25,
1-S21
Slow blow fuse blown (40 A)
Replace
G-39
Wiring harness disconnected or improperly
connected (between main switch G terminal and
glow plug lamp, between glow plug lamp and
glow plugs)
Repair or replace
Main switch defective
Replace
7-S6
Bulb blown
Replace
G-40
Engine oil pressure too low
Repair engine
Engine oil insufficient
Replenish
Oil pressure switch defective
Replace
Short circuit between oil pressure switch lead
and chassis
Repair
Fuse blown (10 A)
Replace
G-39
Bulb blown
Replace
G-40
Oil pressure switch defective
Replace
7-S15
Wiring harness disconnected or improperly
connected (between main switch ACC terminal
and oil pressure lamp, between oil pressure
lamp and oil pressure switch)
Repair or replace
Fuse blown (10 A)
Replace
G-39
Bulb blown
Replace
G-40
Thermo switch defective
Replace
7-S16
Wiring harness disconnected or improperly
connected (between main switch ACC terminal
and thermo lamp, between thermo lamp and
thermo switch)
Repair or replace
–
–
–
G-8, 14
7-S15
–
–
–
W1012630
7-S3
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
2. SERVICING SPECIFICATIONS
Item
Factory Specification
Allowable Limit
Voltage
More than 12 V
–
Potential
Difference
Less than 0.1 V
–
Glow Plug
Resistance
Approx. 0.9 Ω
–
Head Light Switch
Resistance OFF
Infinity
–
Resistance ON
0Ω
–
Commutator
(O.D.)
28.0 mm
1.102 in.
27.0 mm
1.063 in.
Commutator
(Difference of
O.D.)
Less than 0.05 mm
0.002 in.
0.4 mm
0.016 in.
Mica
(Undercut)
0.50 to 0.80 mm
0.0197 to 0.0315 in.
0.20 mm
0.0079 in.
16.0 mm
0.630 in.
10.5 mm
0.413 in.
Battery
Starter
Brush
(Length)
W1013874
7-S4
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
3. TIGHTENING TORQUES
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
Starter (C terminal nut)
Dynamo (stator nut)
N·m
kgf·m
ft-lbs
5.9 to 11.8
0.6 to 1.2
4.3 to 8.7
39.2 to 44.1
4.0 to 4.5
28.9 to 32.5
W1012736
7-S5
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Battery
Battery Voltage
1. Stop the engine and turn the main switch off.
2. Connect the COM (-) lead of the voltmeter to the battery's
negative terminal post (2) and the (+) lead to the positive terminal
post (1), and measure the battery voltage.
3. If the battery voltage is less than the factory specification, check
the battery specific gravity and recharge the battery.
Battery voltage
Factory spec.
(1) Positive Terminal Post
More than 12 V
(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
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
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.
B terminal - ACC terminal
Resistance
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
0Ω
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
B terminal - G terminal
B terminal - ACC terminal
0Ω
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.
B terminal - G terminal
Resistance
B terminal - ST terminal
0Ω
B terminal - ACC terminal
(1) G Terminal
(2) ACC Terminal
(3) ST Terminal
(4) B Terminal
W1014027
7-S7
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
(3) Starter
Motor Test
CAUTION
• Secure the starter to prevent it from jumping up and down
while testing the motor.
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable and the leads from the
starter.
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
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
(4) Glow Plug
Lead Terminal Voltage
1. Disconnect the wiring lead (1) from the glow plug (2) after turning
the main switch off.
2. Turn the main switch key to the "PREHEAT" position, and
measure the voltage between the lead terminal and the chassis.
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"
Approx. battery voltage
Main switch key at
"START"
Approx. battery voltage
(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
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
(5) Safety Switch
PTO Switch
1. Remove the battery.
2. Remove the fender.
3. Disconnect the connector from PTO switch (1).
4. Measure the resistance with an ohmmeter between the
terminals.
5. If the PTO switch (1) is defective, replace it.
Resistance (between
terminal a and b)
Resistance (between
terminal c and d)
(1) PTO Switch
(2) PTO Lever
When plunger is
pushed
0Ω
When plunger is
released
Infinity
When plunger is
pushed
0Ω
When plunger is
released
Infinity
a to d :Switch Terminal
W1015458
Brake Switch
1. Remove the battery.
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)
(1) Brake Switch
When plunger is
pushed
0Ω
When plunger is
released
Infinity
When plunger is
pushed
0Ω
When plunger is
released
Infinity
a to d :Switch Terminal
W1056044
7-S10
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
Top Cover and Grass Container Open Switch
1. Remove the battery.
2. Remove the open switches (1), (2).
3. Measure the resistance with an ohmmeter between the saety
switch terminals.
4. If the switches ae defective, replace it.
Resistance (between
switch terminals)
When plunger is
pushed
0Ω
When plunger is
released
Infinity
(1) Top Cover Open Switch
(2) Grass Container Open Switch
W1058438
(6) Operator Presence Control (OPC) Switch
OPC Switch (Seat Switch)
1. Remove the battery.
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.
Resistance (between
switch terminals)
When plunger is
pushed
0Ω
When plunger is
released
Infinity
(1) OPC Switch (Seat Switch)
W1065033
7-S11
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
(7) Fuel Pump
Connector Voltage
1. Disconnect the 2P connector from the fuel pump.
2. Turn the main switch key to the "ON" position, and measure the
voltage with a voltmeter between the connector terminals.
3. If the voltage differs from the battery voltage, the wiring harness
or main switch is faulty.
Voltage
Between connector
terminals
Approx. battery voltage
W1067315
Fuel Pump Continuity
1. Disconnect the 2P connector from the fuel pump.
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
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
(9) Time Relay
Timer Relay Connector Voltage
1. Disconnect the connector from the timer relay after turning the
main switch off.
2. Measure the voltage with a voltmeter across the connector
terminal 4 and chassis.
3. Turn the main switch on, and measure the voltage across the
connector terminal 3 and chassis.
4. If these voltages differ from the battery voltage, the wiring
harness or main switch is faulty.
Voltage
Connector
terminal 4 - chassis
Approx. battery voltage
Connector
terminal 3 - chassis
Approx. battery voltage
(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
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
(10) Charging System
No-load Dynamo Output
1. Disconnect the lead wires from the dynamo.
2. Start the engine and operate the dynamo at the rated speed.
3. Measure the output voltage with a volt meter.
4. If the measurement is not within the specified values, replace the
dynamo.
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
(1)
(2)
(3)
(4)
(5)
(6)
Regulator
Coupler
Battery
Dynamo
Volt Meter (AC)
Volt Meter (DC)
Terminal blue (a) Terminal blue (c)
AC 20 V or more
Terminal red (f) Chassis
DC 14 to 15 V
a:
b:
c:
d:
e:
f:
Terminal Blue
Terminal Black
Terminal Blue
Terminal Green
Terminal Yellow
Terminal Red
W1015722
7-S14
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
(11) Lighting 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
Infinity
ON
0Ω
(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
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
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/cm2, 7
psi), the switch is faulty.
Resistance (Switch
terminal -Chassis)
In normal state
0Ω
At pressure over
approx. 4.9 kPa(0.5
kgf/cm2, 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
(1) Thermo Switch
Factory spec.
(A)
(B)
(C)
(D)
120 to 126 °C
248.0 to 258.8 °F
ON
OFF
120 to 126 °C (248.0 to 258.8 °F)
116 °C (240.8 °F) or more
W1018760
7-S16
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
(13) Grass Container Full Switch
Grass Container Full Switch Continuity
1. Remove the battery.
2. Dismount the grass container.
3. Remove the filter cover.
4. Disconnect the connector (1) from the grass container full switch
(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.
Resistance (between
switch terminals)
When the diaphragm
of switch is pushed
0Ω
When the diaphragm
of switch is released
Infinity
(1) Connector
(2) Grass Container Full Switch
(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
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
[2] DISASSEMBLING AND ASSEMBLING
(1) Starter
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Sleeve Bearing
Bushing
Starter Drive Housing
Drive Lever
Magnet Switch
Yoke
Connecting Lead
Through Bolt
Rear End Frame
Bushing
Brush
Brush Holder
Brush Spring
Brush
Washer
Armature
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.
(When reassembling)
• 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
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
(2) Dynamo
Stator
1. Remove the nut (3) and separate the stator comp. (4).
2. Unscrew the screws (1) and remove the stator (2).
(When reassembling)
Tightening torque
(1) Screw
(2) Stator
Nut
39.2 to 44.1 N·m
4.0 to 4.5 kgf·m
28.9 to 32.5 ft-lbs
(3) Nut
(4) Stator Comp.
W1019232
Rotor
1. Tap out the shaft (1) from the rotor (3).
(When reassembling)
• 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
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
[3] SERVICING
(1) Starter
Overrunning Clutch
1. Inspect the pinion for wear or damage.
2. If there is any defect, replace the overrunning clutch assembly.
3. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking direction.
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.
Factory spec.
28.0 mm
1.102 in.
Allowable limit
27.0 mm
1.063 in.
Factory spec.
Less than 0.05 mm
0.002 in.
Allowable limit
0.4 mm
0.016 in.
Factory spec.
0.50 to 0.80 mm
0.0197 to 0.0315 in.
Allowable limit
0.20 mm
0.0079 in.
Commutator O.D.
Difference of O.D.'s
Mica undercut
(1) Segment
(2) Undercut
(3) Mica
(a) Correct
(b) incorrect
W1020149
7-S20
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
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.
Factory spec.
16.0 mm
0.630 in.
Allowable limit
10.5 mm
0.413 in.
Brush length (A)
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
KiSC issued 04, 2007 A
ELECTRICAL SYSTEM
GR2100EC2, WSM
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
KiSC issued 04, 2007 A
8
MOWER
KiSC issued 04, 2007 A
MECHANISM
CONTENTS
1. POWER TRANSMISSION ............................................................................ 8-M1
2. LIFTING MECHANISM ................................................................................. 8-M2
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
1. POWER TRANSMISSION
(1)
(2)
(3)
(4)
Left Side Blade Pulley
Mower Belt (Left Side)
Gear Box
Mower Belt (Right Side)
(5)
(6)
(7)
(8)
Right Side Blade Pulley
Universal Joint
Blade Shaft (Left Side)
Left Side Blade
(9)
(10)
(11)
(12)
21T Spiral Gear
Input Shaft
16T Spiral Gear
Center Blade Pulley
(13)
(14)
(15)
(16)
Bevel Gear Shaft
Center Blade
Right Side Blade
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) → 16T Spiral Gear (11) → 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) → 16T Spiral Gear (11) → 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
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
2. LIFTING MECHANISM
(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
KiSC issued 04, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................8-S1
SERVICING SPECIFICATIONS ....................................................................8-S2
TIGHTENING TORQUES ..............................................................................8-S3
CHECKING, DISASSEMBLING AND SERVICING......................................8-S4
[1] CHECKING AND ADJUSTING ...............................................................8-S4
(1) Adjusting Anti-Scalp Rollers................................................................8-S4
(2) Adjusting Left and Right Cutting Height ..............................................8-S5
[2] PREPARATION ........................................................................................8-S6
(1) Dismounting Mower ............................................................................8-S6
[3] DISASSEMBLING AND ASSEMBLING..................................................8-S8
(1) Mower .................................................................................................8-S8
[4] SERVICING ............................................................................................8-S14
(1) Gear Box ...........................................................................................8-S14
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
1. TROUBLESHOOTING
Symptom
Blade Does Not Turn
Blade Speed is Slow
Cutting is Poor
Mower is Not Lifted
Probable Cause
Reference
Page
Solution
PTO system malfunctioning
Check transmission
–
Mower belt broken
Replace mower belt
8-S9
Mower belt loosen
Replace mower belt
of tension spring
8-S9
Grass clogged
Remove grass
Cup washer flattened or worn
Replace cup washer
Engine rpm too low
Mow at full throttle,
check and reset
engine rpm
–
Mower blade worn or bent
Sharpen or replace
mower blade
G-42, 8-S8
Mower blade screw loosen
Retighten mower
blade screw
8-S8
Cutting height improper
Adjust cutting height
8-S5
Ground speed too fast
Slow-down
Tire pressure uneven
Adjust
G-54
Anti-scalp rollers not adjusted correctly
Adjust anti-scalp
rollers
8-S4
Linkage system broken
Replace linkage
system
6-S14
Trouble of hydraulic system
Check hydraulic
system
–
–
8-S8
–
W1014322
8-S1
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
2. SERVICING SPECIFICATIONS
Item
Factory Specification
Allowable Limit
Left Tip of Blade to Right Tip of Blade
Difference
Less than 3 mm
0.1181 in.
–
Front Tip of Blade to Rear Tip of Blade
Difference
Less than 5 mm
0.20 in.
–
21T Spiral Gear to 16T Spiral Gear
Backlash
0.13 to 0.25 mm
0.0051 to 0.0098 in.
0.40 mm
0.157 in.
W1013874
8-S2
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
3. TIGHTENING TORQUES
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
N·m
kgf·m
ft-lbs
Mower blade screw
88.0 to 117.6
8.98 to 11.99
65.0 to 86.7
Gear box mounting screw LH (Reamer)
77.5 to 90.2
7.9 to 9.2
57.2 to 66.5
Gear box mounting screw RH
77.5 to 90.2
7.9 to 9.2
57.2 to 66.5
Gear box stay mounting screw LH (Reamer)
77.5 to 90.2
7.9 to 9.2
57.2 to 66.5
Gear box stay mounting screw RH
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
Center Blade pulley holder mounting screw
77.5 to 90.2
7.9 to 9.2
57.2 to 66.5
Pulley mounting nut (Right side)
88.0 to 117.6
8.98 to 11.99
65.0 to 86.7
Pulley mounting nut (Left side)
103 to 118
10.5 to 12.0
76.0 to 87.0
Pulley holder mounting screw
77.5 to 90.2
7.9 to 9.2
57.2 to 66.5
Tension pulley mounting screw and nut (Right side)
108.5 to 130
11.07 to 13.29
80.0 to 96.0
Tension pulley mounting screw and nut (Left side)
47.5 to 57.0
4.84 to 5.82
35.0 to 42.0
Tension arm mounting screw (Only left side) and nut
77.5 to 90.2
7.9 to 9.2
57.2 to 66.5
W1012736
8-S3
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Adjusting Anti-Scalp Rollers
Adjusting Anti-scalp Rollers
■ IMPORTANT
• The flattest cut can be achieved by having the anti-scalp
rollers adjusted off the ground.
Check anti-scalp roller adjustments each time the mower
deck cutting height is changed.
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.)
Inflation Pressure
Front wheel
200 kPa, 2.0 kgf/cm2, 29 psi
Rear wheel
140 kPa, 1.4 kgf/cm2, 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
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
(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.)
(1) Cutting Height Control Dial
(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
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
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 reassembling)
• 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
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
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.
(When reassembling)
• 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
Dismounting Mower
1. Turn the front wheel to the right.
2. Pull out the mower deck to the left.
W1017139
8-S7
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
[3] DISASSEMBLING AND ASSEMBLING
(1) Mower
Mower Blades
1. Turn over the mower.
2. Unscrew the mower blade screw (1), and remove the plate spring
(2), mower blade (3) and dust cover (4).
■ 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.
(When reassembling)
• 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
(1)
(2)
(3)
(4)
Mower Blade Screw
Plate Spring
Mower Blade
Dust Cover
Mower blade screw
88.0 to 117.6 N·m
8.98 to 11.99 kgf·m
65.0 to 86.7 ft-lbs
A : Loosen
W1013639
8-S8
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
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.
Gear box 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
Gear box mounting screw
RH
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.2 to 66.5 ft-lbs
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
Gear box stay mounting
screw RH
48.1 to 55.8 N·m
4.9 to 5.7 kgf·m
35.5 to 41.2 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
Mower Belt LH
Gear Box
Mower Belt RH
Tension Pulley
Left Side Blade Pulley
Gear Box Mounting Screw LH
(Reamer)
(7)
(8)
(9)
(10)
(11)
Gear Box Stay LH
Gear Box Stay RH
Gear Box Stay Mounting Screw RH
Gear Box Mounting Screw RH
Gear Box Stay Mounting Screw LH
(Reamer)
W1017452
Gear Box
1. Remove the external snap ring (6).
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
(1) Gear Box
(2) Center Blade Pulley
(3) 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
(4) Pulley Holder
(5) Spline Boss
(6) External Snap Ring
W1018241
8-S9
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
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).
(When reassembling)
• 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.
GENERAL" section.
Mower gear case oil
0.40 L
0.42 U.S.qts
0.35 Imp.qts
Capacity
■ 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.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Center Blade Pulley
Oil Seal
Feather Key
Bevel Gear Shaft
Oil Seal
Internal Snap Ring
Shim
Ball Bearing
Input Shaft
Plug
21T Spiral Gear
External Snap Ring
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Case Cap
External Snap Ring
16T Spiral Gear
Ball Bearing
Drain Plug
Shim
Ball Bearing
Shim
Internal Snap Ring
Case Cap
Gear Case
W1018833
8-S10
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
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).
(When reassembling)
• 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
(1) Center Blade Holder Mounting
Screw
(2) Upper Oil Seal
(3) Center Blade Pulley Holder
(4) Center Collar
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.2 to 66.5 ft-lbs
(5) Ball Bearing
(6) Internal Snap RIng
(7) Lower Oil Seal
W1019754
8-S11
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
Disassembling Side Blade Pulley Holder
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
A:
B:
Grease Nipple
Pulley Mounting Nut
Pulley
Oil Seal
Ball Bearing
Pulley Holder Mounting Nut
Pulley Holder
Pulley Holder Mounting
Screw
Collar
Ball Bearing
Oil Seal
Blade Shaft
Feather Key
Right Side Blade Pulley
Holder
Left Side Blade Pulley
Holder
W1020402
1.
2.
3.
4.
5.
6.
Remove the grease nipple (1).
Unscrew the pulley mounting nut (2), and remove the pulley (3) and feather key (13) (only right side).
Tap out the blade shaft (12).
Remove the pulley holder (7) from the mower deck.
Remove the oil seal (4), (11).
Remove the ball bearings (5), (10) and collar (9).
Pulley mounting nut
(Right side)
Tightening torque
88.0 to 117.6 N·m
8.98 to 11.99 kgf·m
65.0 to 86.7 ft-lbs
Pulley mounting nut
(Left side)
103 to 118 N·m
10.5 to 12.0 kgf·m
76.0 to 87.0 ft-lbs
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
W1020643
8-S12
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
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).
(When reassembling)
• Apply grease to the tension collar (3).
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Tension pulley mounting
screw and nut (Right side)
108.5 to 130.2 N·m
11.07 to 13.29 kgf·m
80.0 to 96.0 ft-lbs
Tension pulley mounting
screw and nut (Left side)
47.5 to 57.0 N·m
4.84 to 5.82 kgf·m
35.0 to 42.0 ft-lbs
Tension arm mounting
screw (Only left side) and
nut
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.2 to 66.5 ft-lbs
Grease Nipple
Shim
Tension Collar
Tension Arm Mounting Nut
Tension Pulley
Tension Cover
Tension Pulley Mounting Nut
Tension Pulley Mounting Screw
(9)
(10)
(11)
(12)
Tension Arm
Mower Deck
Plate
Tension Arm Screw
A : Right Side Tension Pulley
B : Left Side Tension Pulley
W1020693
8-S13
KiSC issued 04, 2007 A
MOWER
GR2100EC2, WSM
[4] SERVICING
(1) Gear Box
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.
0.13 to 0.25 mm
0.0051 to 0.0098 in.
Allowable limit
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
KiSC issued 04, 2007 A
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 : ksos-pub@kubota.co.jp
KUBOTA Corporation
Printed in Japan 2007. 03, S, EI, EI, e
2006. 07, S, EI, EI, e
Code No.9Y011-15571
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