Kubota GR1600EC Workshop Manual
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Kubota GR1600EC Workshop Manual

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WORKSHOP MANUAL
GR1600EC
KiSC issued 04, 2006 A

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Questions and answers

John Bowbyes
February 21, 2025

ENGINE WONT TURN OFF,SAFETY SWITCHES NON FUNCTIONALsOLENOID OK ,TIMER RELAY REPLACED ALL TO NO AVAIL

0
1 comments:
Mr. Anderson
February 21, 2025

If the engine on a Kubota GR1600EC does not turn off despite the solenoid being functional and the timer relay being replaced, possible causes could include:

1. Faulty Wiring or Connections – Check for damaged or loose wiring between the timer relay, solenoid, and ignition switch.
2. Ignition Switch Malfunction – A defective ignition switch may not be sending the correct signal to stop the engine.
3. Grounding Issue – Poor grounding can prevent the stop solenoid from functioning correctly. Ensure all ground connections are clean and secure.
4. Fuel Shutoff Mechanism Failure – If the solenoid is not cutting off fuel properly, inspect the fuel shutoff system for blockages or mechanical failure.

Verifying these components should help identify the issue.

This answer is automatically generated

0
Dado
April 9, 2025

May I know what is the measurement of the GR1600EC deck belt?

0
1 comments:
Mr. Anderson
April 10, 2025

The measurement of the Kubota GR1600EC deck belt is not provided in the given context.

This answer is automatically generated

0

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Summary of Contents for Kubota GR1600EC

  • Page 1 WORKSHOP MANUAL GR1600EC KiSC issued 04, 2006 A...
  • Page 2 TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KUBOTA GR1600EC. It is divided into three parts, "General", "Mechanism" and "Servicing". B General Information on the product identification, the general precautions, maintenance check list, check and maintenance and special tools are described.
  • Page 3 GR1600EC, WSM SAFETY INSTRUCTIONS This symbol, the industry's "Safety Alert Symbol" is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully.It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit.
  • Page 4 GR1600EC, WSM SAFETY INSTRUCTIONS SAFETY WORKING A Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued. A Wear close fitting clothing and safety equipment appropriate to the job. A Use tools appropriate to the work. Makeshift tools, parts, and procedures are not recommended.
  • Page 5 GR1600EC, WSM SAFETY INSTRUCTIONS VENTILATE WORK AREA A If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.

  • Page 6: Safety Decals

    GR1600EC, WSM SAFETY INSTRUCTIONS SAFETY DECALS The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list. 0000009636E...
  • Page 7 GR1600EC, WSM SAFETY INSTRUCTIONS 0000009633E KiSC issued 04, 2006 A...
  • Page 8 GR1600EC, WSM SAFETY INSTRUCTIONS 0000009634E KiSC issued 04, 2006 A...

  • Page 9: Specifications

    GR1600EC, WSM SPECIFICATIONS SPECIFICATIONS Model GR1600EC Maker KUBOTA Model Z482-E2-GX Type Indirect injection. Vertical, water-cooled, 4-cycle diesel Number of cylinders Bore and stroke 67 x 68 mm (2.64 x 2.68 in.) Total displacement (29.9 cu.in.) Engine gross power (DIN) 10.0 kW (13.4 HP)
  • Page 10 GR1600EC, WSM SPECIFICATIONS Model RCK42GR Cutting width 1067 mm (42.0 in.) Cutting height 25 to 102 mm (1 to 4 in.) Adjustment of cutting height Dual gauge Mounting method Quick joint, Parallel linkage Weight (Approx.) 75 kg (165 lbs) Mower Total length 965 mm (38.0 in.)
  • Page 11 GR1600EC, WSM DIMENSIONS DIMENSIONS 0000009634E KiSC issued 04, 2006 A...
  • Page 12 GENERAL KiSC issued 04, 2006 A...

  • Page 13: Table Of Contents

    CONTENTS 1. IDENTIFICATION ........................G-1 2. GENERAL PRECAUTIONS....................G-2 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING......G-3 [1] WIRING..........................G-3 [2] BATTERY ..........................G-5 [3] FUSE ..........................G-5 [4] CONNECTOR........................G-5 [5] HANDLING OF CIRCUIT TESTER.................G-7 4. LUBRICANTS, FUEL AND COOLANT ................G-8 5. TIGHTENING TORQUES ....................G-9 [1] GENERAL USE SCREWS, BOLTS AND NUTS ............G-9 [2] METRIC SCREWS, BOLTS AND NUTS ...............G-9 [3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF...

  • Page 14: Identification

    GR1600EC, WSM GENERAL 1. IDENTIFICATION When contacting your local KUBOTA distributor, always specify engine serial number (2), machine serial number (1), mower serial number (3) and hour meter reading. (1) Machine Serial Number (3) Mower Serial Number (2) Engine Serial Number...

  • Page 15: General Precautions

    A Remove oil and dirt from parts before measuring. A Use only KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety. A Gaskets and O-rings must be replaced during reassembly.

  • Page 16: Handling Precautions For Electrical Parts And Wiring

    GR1600EC, WSM GENERAL 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring. A Check electrical wiring for damage and loosened connection every year.
  • Page 17 GR1600EC, WSM GENERAL A Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp *Wind Clamp Spirally (4) Welding Dent (2) Wire Harness 0000000617E A Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.

  • Page 18: Battery

    GR1600EC, WSM GENERAL [2] BATTERY A Take care not to confuse positive and negative terminal posts. A When removing battery cables, disconnect negative cable first. When installing battery cables, check for polarity and connect positive cable first. A Do not install any battery with capacity other than is specified (Ah).
  • Page 19 GR1600EC, WSM GENERAL A In separating connectors, do not pull wire harnesses. A Hold connector bodies to separate. (A) Correct (B) Incorrect 0000000624E A Use sandpaper to remove rust from terminals. A Repair deformed terminal. Make certain there is no terminal being exposed or displaced.

  • Page 20: Handling Of Circuit Tester

    GR1600EC, WSM GENERAL [5] HANDLING OF CIRCUIT TESTER A Use tester correctly following manual provided with tester. A Check for polarity and range. 0000000628E KiSC issued 04, 2006 A...

  • Page 21: Lubricants, Fuel And Coolant

    1.06 lmp.qts. Above 25 ) : SAE30, 10W-30 or 10W-40 2.7 L Transmission case 0.71 U.S.gals. KUBOTA UDT or SUPER UDT fluid* 0.59 lmp.gals. 0.33 L SAE90 gear oil Mower gear box 0.35 U.S.qts. (API service classification : more than GL-3) 0.29 lmp.qts.

  • Page 22: Tightening Torques

    GR1600EC, WSM GENERAL 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolt and nuts whose tightening torque are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of No-grade or 4T...

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

    GR1600EC, WSM GENERAL [3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS SAE GR.5 SAE GR.8 Grade Unit Norminal ft-lbs ft-lbs Diameter 5/16 23.1 to 27.8 2.35 to 2.84 17.0 to 20.5 32.5 to 39.3 3.31 to 4.01 24.0 to 29.0...

  • Page 24: Maintenance Check List

    GR1600EC, WSM GENERAL 6. MAINTENANCE CHECK LIST A The jobs indicated by must be done initially. A *1 : This maintenance should be done daily more often in dusty conditions than in normal conditions. Suggested cleaning interval is every 100 hours in normal conditions.
  • Page 25 GR1600EC, WSM GENERAL Indication on hour meter (Hr) Ref- Period After por- since ence Item tant page every Check G-26 100 hr Fuel line every 2 Replace G-34 years every Check G-30 200 hr Radiator hose and clamp every 2...

  • Page 26: Check And Maintenance

    GR1600EC, WSM GENERAL 7. CHECK AND MAINTENANCE A Be sure to check and service the machine on a flat place with engine shut off, the parking brake on and chock the wheels. 0000001417E [1] DAILY CHECK To prevent trouble from occurring, it is important to know the condition of the machine. Check the following items before starting.
  • Page 27 GR1600EC, WSM GENERAL Checking Engine Oil Level A Always stop the engine and remove the key before checking oil. 1. Check engine oil before starting and 5 minutes or more after the engine has stopped. 2. Wipe dipstick (2) area clean.
  • Page 28 GR1600EC, WSM GENERAL Checking Amount of Fuel and Refueling A Handle fuel carefully. If the engine is running, do not fill the fuel tank. If engine is hot, let engine cool several minutes before adding fuel. Do not smoke while filling the fuel tank or servicing the fuel system.
  • Page 29 GR1600EC, WSM GENERAL Checking and Cleaning Radiator to Prevent Overheating A Be sure to stop the engine and remove the key before cleaning. Daily or after every 5 hours of operation, check to be sure the radiator screen (2) and radiator core are clean. Dirt or chaff on the...
  • Page 30 GR1600EC, WSM GENERAL Checking Tire Pressure A Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment. A Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure.
  • Page 31 GR1600EC, WSM GENERAL Checking Coolant Level A Do not remove the radiator cap when the engine is hot. Loosen cap slightly, to the stop, to relieve any excess pressure before removing cap completely. Check the coolant level daily both the radiator and the recovery tank (4) before starting engine.

  • Page 32: Check Points Of Every 50 Hours

    GR1600EC, WSM GENERAL [2] CHECK POINTS OF EVERY 50 HOURS Checking Safety Device A Do not allow anyone near the machine while testing. A If the machine does not pass one of the following tests, do not operate the machine.
  • Page 33 GR1600EC, WSM GENERAL Cleaning Air Cleaner Element 1. The air cleaner uses a dry element, never apply oil. 2. Do not touch the filter element except where cleaning is required. To clean the element, use clean and dry compressed air on the inside of the element. Air pressure should not exceed 205 kPa (2.1...
  • Page 34 GR1600EC, WSM GENERAL Oiling 1. Apply oil to the following location as figures. A Be sure to stop the engine and remove the key before oiling. (1) Mower Universal Joint (4) Seat Adjuster (2) Speed Control Shaft (RH) (5) Throttle Cable...
  • Page 35 GR1600EC, WSM GENERAL Oiling (Continued) 1. Apply oil to the following location as figures. A Be sure to stop the engine and remove the key before oiling. (1) Around Hole of Mower Link (5) Front Link (2) Around Pin (6) Grass Catcher Hinge...
  • Page 36 GR1600EC, WSM GENERAL Checking Battery Condition A To avoid the possibility of battery explosion: For the refillable type battery, follow the instructions below. A Do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark.
  • Page 37 GR1600EC, WSM GENERAL B Battery Charging A When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.

  • Page 38: Check Points Of Every 100 Hours

    GR1600EC, WSM GENERAL B Battery Charging (Continued) (For non-accessible maintenance-free type batteries.) Maintenance-free, non-accessible batteries are designed to eliminate the need to add water. Yet the volume of electrolyte (3) above plates may eventually become depleted due to abnormal conditions such as high heat or improper regulator setting. Use a voltmeter to check the state of charge.
  • Page 39 GR1600EC, WSM GENERAL Checking Fuel Line and Fuel Filter A Be sure to stop the engine and remove the key when attempting to make the following checks and changes. A Never fail to check the fuel lines periodically. The fuel lines are subject to wear and aging.

  • Page 40: Check Point Of Every 150 Hours

    GR1600EC, WSM GENERAL Checking Fan Drive Belt Tension A Be sure to stop the engine and remove the key before checking belt tension. 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley (1) and dynamo pulley (2) at specified force (98 N, 10 kgf, 22 lbs).

  • Page 41: Check Points Of Every 200 Hours

    A To prevent serious damage to the engine, element of recommended type must be used. Use only a genuine KUBOTA filter or its equivalent. (1) Engine Oil Filter Cartridge 0000009569E KiSC issued 04, 2006 A...
  • Page 42 GR1600EC, WSM GENERAL Changing Transmission Fluid A Be sure to stop the engine and remove the key before changing or checking the oil. A Allow transmission case to cool down sufficiently; oil can be hot and may cause burns. The fluid in the transmission case is also used for the hydrostatic drive system.
  • Page 43 Check for oil leaks around filter gasket. A To prevent serious damage to hydraulic system, the replacement filter must be a highly efficient, 10 filter. Use only a genuine KUBOTA filter or its equivalent. (1) Transmission Oil Filter (2) Screw Cartridge...

  • Page 44: Check Point Of Every 400 Hours

    GR1600EC, WSM GENERAL Adjusting Front Axle Pivot 1. Jack up the front of machine. 2. Tighten the center pin locking nut (1) with specified torque. 3. Measure the clearance between the front axle frame (2) and anti-vibration bolt (3). 4. If the measurement exceeds the factory specification, adjust the anti-vibration bolt.
  • Page 45 GR1600EC, WSM GENERAL Flushing Cooling System and Changing Coolant A Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. 1. Stop the engine and let cool down.
  • Page 46 GR1600EC, WSM GENERAL Flushing Cooling System and Changing Coolant (Continued) B Anti-Freeze A When using anti-freeze, put on some protection such as rubber gloves (Anti-freeze contains poison.). A If should drink anti-freeze, throw up at once and take medical attention.

  • Page 47: Check Points Of Every 2 Years

    3. Kubota's genuine long-life coolant has a service life of 2 years. Be sure to change the coolant every 2 years. A The above data represent industry standards that necessitate a minimum glycol content in the concentrated anti-freeze.

  • Page 48: Others

    GR1600EC, WSM GENERAL Replacing Mower Gear Box Oil Seals 1. Replace the mower gear box oil seals. Refer to "Disassembling Gear Box". (See page 7-S9.) 0000009582E [9] 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.
  • Page 49 GR1600EC, WSM GENERAL Checking and Replacing Mower Blade A Be sure to stop the engine and remove the key. A Blades may be sharp. When you handle blades, wear heavy gloves or wrap end of blade with a rag. B Checking Blade 1.
  • Page 50 GR1600EC, WSM GENERAL Replacing Mower Belt 1. Remove the mower deck from the machine. 2. Remove the left and right hand shield (4), (6) from the mower deck. 3. Clean around the pulleys to remove the belt (3) from the pulleys.

  • Page 51: Special Tools

    GR1600EC, WSM GENERAL 8. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Special Use Puller Set Code No : 07916-09032 Application : Use exclusively for pulling out bearing, gears and other parts with ease. 0000000677E Piston Ring Compressor Code No :...
  • Page 52 GR1600EC, WSM GENERAL Diesel Engine Compression Tester (for Glow Plug) Code No : 07909-39081 (Assembly) 07909-31301 (L) 07909-31291 (K) 07909-31311 (M) Application : Use to measure diesel engine compression and diagnostics of need for major overhaul. (1) Gauge (4) Adaptor L...
  • Page 53 GR1600EC, WSM GENERAL Connecting Rod Alignment Tool Code No : 07909-31661 Application : Use to check the connecting rod alignment. Applicable : Connecting rod big end I.D. range 30 to 75 mm (1.18 to 2.95 in.) dia. Connecting rod length 65 to 300 mm (2.56 to 11.81 in.)
  • Page 54 GR1600EC, WSM GENERAL Injection Pump Pressure Tester Application : Use to check fuel tightness of injection pumps. Pressure gauge full scale : More than 29.4 MPa (300 , 4267 psi) Copper gasket Flange (Material : Steel) Hex. nut 27 mm (1.06 in.) across the plat...
  • Page 55 GR1600EC, WSM GENERAL Valve Guide Replacing Tool Application : Use to press out and press fit the valve guide. 20 mm dia. (0.79 in. dia.) 9.96 to 9.98 mm dia. (0.3921 to 0.3929 in. dia.) 5.5 to 5.7 mm dia. (0.2165 to 0.2244 in. dia.) 220 mm (8.66 in.)
  • Page 56 GR1600EC, WSM GENERAL Bushing Replacing Tools Application : Use to press out and to press fit the bushing. 1. For small end bushing 145 mm (5.71 in.) 20 mm (0.79 in.) 100 mm (3.94 in.) 19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.) 21.90 to 21.95 mm dia.
  • Page 57 GR1600EC, WSM GENERAL Crankshaft Bearing 1 Replacing Tool Application : Use to press out and press fit the crankshaft bearing 1. [Press Out] 135 mm (5.31 in.) 72 mm (2.83 in.) 40 mm radius (1.57 in. radius) 10 mm (0.39 in.) 22 mm (0.87 in.)

  • Page 58: Special Tools For Machine

    GR1600EC, WSM GENERAL [2] SPECIAL TOOLS FOR MACHINE Relief Valve Pressure Tester Code No : 07916-50045 Application : This allows easy measurement of relief set pressure. (1) Gauge (07916-50322) (6) Adaptor C (PS3/8) (2) Cable (07916-50331) (07916-50371) (3) Threaded Joint...

  • Page 59: Tires

    GR1600EC, WSM GENERAL 9. TIRES [1] TIRE PRESSURE A Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment. A Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure as shown below.

  • Page 60: Implement Limitations

    KUBOTA. Use of implements which are not sold or approved by KUBOTA and which exceed the maximum specifications listed below, or which are otherwise unfit for use with the KUBOTA Machine may result in malfunctions or failures of the machine, damage to other property and injury to the operator or others. [Any malfunctions or failures of the machine resulting from use with improper implements are not covered by the warranty.]...
  • Page 61 ENGINE KiSC issued 04, 2006 A...
  • Page 62 CONTENTS 1. ENGINE BODY .........................1-M1 [1] HALF-FLOATING HEAD COVER ..................1-M1 [2] CLOSED BREATHER.....................1-M1 2. LUBRICATING SYSTEM ....................1-M2 3. COOLING SYSTEM ......................1-M3 4. FUEL SYSTEM.........................1-M4 [1] FUEL LINE ........................1-M4 KiSC issued 04, 2006 A...

  • Page 63: Engine Body

    GR1600EC, WSM ENGINE 1. ENGINE BODY [1] HALF-FLOATING HEAD COVER The rubber packing is fitting in to maintain the head cover 0.5 mm (0.02 in.) or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head.

  • Page 64: Lubricating System

    GR1600EC, WSM ENGINE 2. LUBRICATING SYSTEM (1) Rocker Arm (2) Oil Pressure Switch (3) Rocker Arm Shaft (4) Valve (5) Idle Gear (6) Crankshaft (7) Oil Pump (8) Oil Strainer (9) Relief Valve (10) Push Rod (11) Tappet (12) Camshaft...

  • Page 65: Cooling System

    GR1600EC, WSM ENGINE 3. COOLING SYSTEM (1) Radiator (2) Water Pump (3) Cooling Fan (4) Thermostat (5) Cylinder Head (6) Cylinder Block The cooling system consists of a radiator (1), a centrifugal water pump (2), a cooling fan (3) and a thermostat (4).

  • Page 66: Fuel System

    GR1600EC, WSM ENGINE 4. FUEL SYSTEM [1] FUEL LINE (1) Injection Nozzle (2) Fuel Overflow Pipe (3) Fuel Tank (4) Fuel Filter (5) Fuel Feed Pump (6) Fuel Filter (7) Injection Pump (8) Injection Pipe Fuel from the fuel tank (3) passes through the fuel filter (4), and then enters the injection pump (7) after impurities such as dirt, water, etc.
  • Page 67 CONTENTS 1. TROUBLESHOOTING....................... 1-S1 2. SERVICING SPECIFICATIONS ..................1-S4 3. TIGHTENING TORQUES ....................1-S9 4. CHECKING, DISASSEMBLING AND SERVICING ............1-S10 [1] CHECKING AND ADJUSTING ..................1-S10 (1) Engine Body ......................1-S10 (2) Lubricating System ....................1-S13 (3) Cooling System ..................... 1-S13 (4) Fuel System......................

  • Page 68: Troubleshooting

    GR1600EC, WSM ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not Start A No fuel Replenish fuel A Air in the fuel system Bleed G-37 A Water in the fuel system Change fuel and G-26, 34 repair or replace fuel...
  • Page 69 GR1600EC, WSM ENGINE Reference Symptom Probable Cause Solution Page A Fuel filter clogged or dirty Engine Revolution Is Replace G-26, 31 Not Smooth A Air cleaner clogged Clean or replace G-20 A Fuel leak due to loose injection pipe retaining...
  • Page 70 GR1600EC, WSM ENGINE Reference Symptom Probable Cause Solution Page A Head gasket defective Water Mixed into Replace 1-S25 Lubricant Oil A Cylinder block or cylinder head flawed Replace A Engine oil insufficient Low Oil Pressure Replenish G-8, 14 A Oil strainer clogged...

  • Page 71: Servicing Specifications

    GR1600EC, WSM ENGINE 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Compression Pressure 2.84 to 3.24 MPa 2.26 MPa 29.0 to 33.0 23.0 412 to 469 psi 327 psi Variance Among 10 % or less Cylinder Top Clearance 0.50 to 0.70 mm...
  • Page 72 GR1600EC, WSM ENGINE Item Factory Specification Allowable Limit Tappet to Tappet Guide Clearance 0.016 to 0.052 mm 0.10 mm 0.00063 to 0.00205 in. 0.0039 in. Tappet 17.966 to 17.984 mm (O.D.) 0.70732 to 0.70803 in. Tappet Guide Bore 18.000 to 18.018 mm (I.D.)
  • Page 73 GR1600EC, WSM ENGINE Item Factory Specification Allowable Limit Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.038 mm 0.10 mm 0.00055 to 0.00150 in. 0.0039 in. Piston Pin 20.002 to 20.011 mm (O.D.) 0.78748 to 0.078783 in. Small End Bushing 20.025 to 20.040 mm...
  • Page 74 GR1600EC, WSM ENGINE Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing 3 Oil Clearance 0.028 to 0.051 mm 0.20 mm (Intermediate) 0.00110 to 0.00201 in. 0.0079 in. Crankshaft Journal 39.934 to 39.950 mm (O.D.) 1.57221 to 1.57284 in.
  • Page 75 GR1600EC, WSM ENGINE COOLING SYSTEM Item Factory Specification Allowable Limit Fan Belt Tension 7 to 9 mm / 98 N 0.28 to 0.35 in. / 98N (10 kgf, 22 lbs) Thermostat Valve Opening 80.5 to 83.5 Temperature 176.9 to 182.3...
  • Page 76 GR1600EC, WSM ENGINE 3. TIGHTENING TORQUES Tightening torques of screws and nuts on the table below are especially specified. (For general use screws and nuts : See page G-9.) Item Size x Pitch ft-lbs Front coupling mounting screw M8 x 1.25 23.5 to 27.4...

  • Page 77: Checking, Disassembling And Servicing

    GR1600EC, WSM ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Disconnect the 2P connector from the fuel pump. 4. Remove the air cleaner, the muffler and all injection nozzles.
  • Page 78 GR1600EC, WSM ENGINE Top Clearance 1. Remove the cylinder head. (Do not attempt to remove the cylinder head gasket.). 2. Move the piston up, and stick a strip of fuse [1.5 mm dia. (0.059 in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the piston head at three positions with grease so as to avoid the intake and exhaust valves and the combustion chamber ports.
  • Page 79 GR1600EC, WSM ENGINE Valve Clearance A The valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover (1) and the glow plugs. 2. Align the "1TC" mark (2) on the flywheel and alignment mark (3) on the rear end plate so that the No.

  • Page 80: Lubricating System

    GR1600EC, WSM ENGINE (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester (Code No.: 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
  • Page 81 GR1600EC, WSM ENGINE Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.
  • Page 82 GR1600EC, WSM ENGINE A When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people. 0000000922E Radiator Cap Air Leakage 1. Set a radiator tester (1) and adaptor (2) (BANZAI Code No.: RCT-2A-30S) on the radiator cap.

  • Page 83: Fuel System

    GR1600EC, WSM ENGINE (4) Fuel System Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid. 3. Turn the flywheel counterclockwise (facing the flywheel) until fuel flows from the delivery valve holder. 4. Continue to turn the flywheel slowly, and stop it as soon as the fuel level at the tip of the delivery valve holder begins to increase.
  • Page 84 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. 13.7 MPa...
  • Page 85 12.75 MPa (from 140 to 130 , from 1991 to 1849 psi). 9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. 10 seconds 13.73 12.75 MPa Factory spec.
  • Page 86 GR1600EC, WSM ENGINE A Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. A If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.

  • Page 87: Preparation

    GR1600EC, WSM ENGINE Valve Seat Tightness 1. Set the injection nozzle to a nozzle tester (Code No. 07909- 31361). 2. Raise the fuel pressure, and keep at 12.75 MPa (130 1849 psi) for 10 seconds. 3. If any fuel leak is found, replace the nozzle piece.
  • Page 88 GR1600EC, WSM ENGINE Draining Engine Oil 1. Start and warm up the engine for approx. 5 minutes 2. Place an oil pan underneath the engine. 3. Remove the drain plug (1) to drain oil. 4. After draining, screw in the drain plug (1).
  • Page 89 GR1600EC, WSM ENGINE Bonnet and Side Bonnet 1. Disconnect the connectors (5) from the head light. 2. Remove the wire harness (4) from the bonnet. 3. Remove the bonnet (1) with bonnet bracket (2). 4. Remove the side bonnet (3).

  • Page 90: Disassembling And Assembling

    GR1600EC, WSM ENGINE Engine Assembly 1. Remove the radiator retaining snap pins (1). 2. Disconnect the front coupling (2). 3. Separate the engine assembly (3) with radiator from the frame (4). (When reassembling) 23.5 to 27.4 Front coupling mounting 2.4 to 2.8 screw 17.4 to 20.3 ft-lbs...
  • Page 91 GR1600EC, WSM ENGINE Cylinder Head Cover 1. Remove the head cover screws (1). 2. Remove the cylinder head cover (2). (When reassembling) A Check to see if the cylinder head cover gasket is not defective. 6.86 to 11.3 Cylinder head cover Tightening torque 0.7 to 1.15...
  • Page 92 GR1600EC, WSM ENGINE Rocker Arm and Push Rod 1. Remove the rocker arm bracket screws (1). 2. Detach the rocker arm assembly (2). 3. Remove the push rods (3). (When reassembling) A When putting the push rods (3) onto the tappets (4), check to see if their ends are properly engaged with the dimples.
  • Page 93 GR1600EC, WSM ENGINE Tappets 1. Remove the tappets (1) from the crankcase. (When reassembling) A Visually check the contact between tappets and cams for proper rotation. If defect is found, replace tappets. A Before installing the tappets, apply engine oil thinly around them.

  • Page 94: Timing Gear, Camshaft And Fuel Camshaft

    GR1600EC, WSM ENGINE (2) Timing Gear, Camshaft and Fuel Camshaft Injection Pump and Speed Control Plate 1. Remove the socket head screws and nuts, and remove the injection pump (3). 2. Remove the screws and separate the speed control plate (2), taking care not to damage the governor spring (4).
  • Page 95 GR1600EC, WSM ENGINE Gear Case 1. Remove the screw (1) of inside the gear case and outside screws (6). 2. Disconnect the start spring (2) from the fork lever 1. 3. Remove the gear case (3). (When reassembling) A Apply a liquid gasket (Three Bond 1215 or equivalent) to both sides of the gear case gasket (4).
  • Page 96 GR1600EC, WSM ENGINE Idle Gear 1. Remove the external snap ring (3), the collar (2) and the idle gear (1). 2. Remove the idle gear shaft mounting screws (4). 3. Remove the idle gear shaft (5). (When reassembling) A Apply engine oil to the idle gear shaft mounting screw (4). And tighten them.
  • Page 97 GR1600EC, WSM ENGINE Fuel Camshaft 1. Remove the retaining plate (1). 2. Remove the fork lever holder mounting screws (8), then draw out the injection pump gear (3) and fuel camshaft (2) with the governor fork assembly. (When reassembling) A Hook the governor spring (7) to the fork lever 2 (6) as shown in the figure before installing the fork lever assembly to the crankcase.
  • Page 98 GR1600EC, WSM ENGINE Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws (5). 2. Remove the oil pan (4) by lightly tapping the rim of the pan with a wooden hammer. 3. Remove the oil strainer (3).

  • Page 99: Piston And Connecting Rod

    GR1600EC, WSM ENGINE (3) Piston and Connecting Rod Connecting Rods 1. Remove the connecting rod caps (1). (When reassembling) A Align the marks (a) with each other. (Face the marks toward the injection pump.). A Apply engine oil to the connecting rod screws and lightly screw it in by hand, then tighten it to the specified torque.
  • Page 100 GR1600EC, WSM ENGINE Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool (Code No. 07909-32121). 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) A When installing the ring, assemble the rings so that the manufacturer's mark (12) near the gap faces the top of the piston.

  • Page 101: Crankshaft

    GR1600EC, WSM ENGINE (4) Crankshaft Flywheel 1. Secure the flywheel to keep it from turning using a flywheel stopper. (Refer to "SPECIAL TOOLS".) 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) A Set the No. 1 crankpin at the top dead center (T.D.C.).
  • Page 102 GR1600EC, WSM ENGINE Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly. (When reassembling) A Clean the oil passage of the crankshaft with compressed air. A Apply oil to the main bearing case screw 2 (1).
  • Page 103 GR1600EC, WSM ENGINE Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (1), and remove the main bearing case assembly 1 (2), being careful with crankshaft bearing 3 (4), (5). 2. Remove the main bearing case assembly (3) as above. Keep in mind, however, that the thrust bearing (8) is installed in the main bearing case assembly (3).

  • Page 104: Water Pump

    GR1600EC, WSM ENGINE (5) Water Pump Thermostat Assembly 1. Remove the thermostat cover mounting screws, and remove the thermostat cover (1). 2. Remove the thermostat assembly (3). (When reassembling) A Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (2).

  • Page 105: Injection Nozzle

    GR1600EC, WSM ENGINE (6) Injection Nozzle Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) A Assemble the nozzle in clean fuel oil. A Install the push rod (4), noting its direction.
  • Page 106 GR1600EC, WSM ENGINE Cylinder Head Flaw 1. Prepare an air spray red check (Code No. 07909-31371). 2. Clean the surface of the cylinder head with the detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying.
  • Page 107 GR1600EC, WSM ENGINE Clearance between Valve Stem and Valve Guide 1. Remove carbon from the valve guide section. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. with a small hole gauge, and calculate the clearance.
  • Page 108 GR1600EC, WSM ENGINE Valve Seating 1. Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact. 2. If the valve does not seat all the way around the valve seat or the valve contact is less than 70 %, correct the valve seating as follows.
  • Page 109 GR1600EC, WSM ENGINE Correcting Valve and Valve Seat A Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. A After correcting the valve seat, be sure to check the valve recessing.
  • Page 110 GR1600EC, WSM ENGINE Free Length and Tilt of Valve Spring 1. Measure the free length (A) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring.
  • Page 111 GR1600EC, WSM ENGINE Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. 0.25 mm Push rod alignment Allowable limit 0.0098 in.

  • Page 112: Timing Gear, Camshaft And Fuel Camshaft

    GR1600EC, WSM ENGINE (2) Timing Gear, Camshaft and Fuel Camshaft Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear.
  • Page 113 GR1600EC, WSM ENGINE Camshaft Alignment 1. Support the camshaft with V blocks on the surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Measure the camshaft alignment. 4. If the measurement exceeds the allowable limit, replace the camshaft.

  • Page 114: Piston And Connecting Rod

    GR1600EC, WSM ENGINE Oil Clearance between Idle Gear Shaft and Idle Gear Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance.
  • Page 115 GR1600EC, WSM ENGINE Oil Clearance between Piston Pin and Small End Bushing 1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer. 2. Measure the small end bushing I.D. with an inside micrometer, and calculate the oil clearance.
  • Page 116 GR1600EC, WSM ENGINE Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with piston. 2. Measure the ring gap with a thickness gauge. 3. If the measurement exceeds the allowable limit, replace the piston ring.
  • Page 117 GR1600EC, WSM ENGINE Connecting Rod Alignment 1. Remove the crankpin bearing, and install the connecting rod cap. 2. Install the piston pin in the connecting rod. 3. Install the connecting rod on the connecting rod alignment tool (Code No. 07909-31661).

  • Page 118: Crankshaft

    GR1600EC, WSM ENGINE (4) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings.
  • Page 119 GR1600EC, WSM ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage (Code No.: 07909-30241) on the centre of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
  • Page 120 GR1600EC, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance.
  • Page 121 GR1600EC, WSM ENGINE Replacing Crankshaft Bearing 1 (When removing) 1. Press out the used crankshaft bearing 1 using a crankshaft bearing 1 replacing tool. (Refer to "SPECIAL TOOLS".) (When installing) 1. Clean a new crankshaft bearing 1 and crankshaft journal bore, and apply engine oil to them.

  • Page 122: Cylinder

    GR1600EC, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) (Continued) (Reference) A Undersize crankshaft bearing 2 and 3 Undersize Bearing Code Number Marking Crankshaft bearing 2 02 15694-23930 020 US 0.2 mm 0.008 in.

  • Page 123: Oil Pump

    GR1600EC, WSM ENGINE Correcting Cylinder 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. 67.250 to 67.269 mm Factory spec. 2.64764 to 2.64839 in. Cylinder I.D. [Oversize] 67.419 mm Allowable limit 2.65429 in.
  • Page 124 GR1600EC, WSM ENGINE Clearance between Rotor and Cover 1. Put a strip of plastigage (Code No. 07909-30241) onto the rotor face with grease. 2. Install the cover and tighten the screws. 3. Remove the cover carefully, and measure the amount of the flattening with the scale and get the clearance.
  • Page 125 TRANSMISSION KiSC issued 04, 2006 A...
  • Page 126 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) Charge Pump ......................2-M7 (5) By-pass Valve......................2-M7 (6) Control Linkage .......................2-M8 [2] MOWER PTO SYSTEM....................2-M9 (1) Mower PTO Clutch ....................2-M9 KiSC issued 04, 2006 A...

  • Page 127: Structure

    GR1600EC, WSM TRANSAXLE 1. STRUCTURE (1) Hydraulic Transmission (2) Mower PTO Section (3) Differential Gear Section (4) Rear Axle Section Section 0000009178E KiSC issued 04, 2006 A 2-M1...

  • Page 128: Travelling System

    GR1600EC, WSM TRANSAXLE 2. TRAVELLING SYSTEM [1] HYDROSTATIC TRANSMISSION (1) Structure (1) Check Valve (8) Piston (15) Oil Seal (22) By-pass Plug (2) Trunnion Arm (9) Spring (Cylinder Block) (16) Pump Shaft (23) By-pass Spool (3) Charge Relief Valve (10) Washer...

  • Page 129: Oil Flow

    GR1600EC, WSM TRANSAXLE (2) Oil Flow (1) Pump (4) Filter Cartridge (7) Lubricating Orifice (9) Neutral Orifice (2) Charge Pump (5) Motor (8) Check Valve (Reverse) (10) Charge Relief Valve (3) Check Valve (Forward) (6) By-pass Valve The closed oil-hydraulic loop connects between the pump (1) and the motor (5) in HST.

  • Page 130: Operation

    GR1600EC, WSM TRANSAXLE (3) Operation B Neutral (1) Cylinder Block (Pump) (5) Lubricating Orifice (8) Transaxle Case (11) Charge Relief Valve (2) Swashplate (6) Check Valve (Forward) (9) Oil Strainer (12) Filter Cartridge (3) Piston (7) By-pass Valve (10) Check Valve (Reverse)
  • Page 131 GR1600EC, WSM TRANSAXLE B Forward (1) Cylinder Block (Pump) (5) Lubricating Orifice (8) Transaxle Case (11) Charge Relief Valve (2) Swashplate (6) Check Valve (Forward) (9) Oil Strainer (12) Filter Cartridge (3) Piston (7) By-pass Valve (10) Check Valve (Reverse)
  • Page 132 GR1600EC, WSM TRANSAXLE B Reverse (1) Cylinder Block (Pump) (5) Lubricating Orifice (8) Transaxle Case (11) Charge Relief Valve (2) Swashplate (6) Check Valve (Forward) (9) Oil Strainer (12) Filter Cartridge (3) Piston (7) By-pass Valve (10) Check Valve (Reverse)

  • Page 133: Charge Pump

    GR1600EC, WSM TRANSAXLE (4) Charge Pump The charge pump revolves in combination with pump shaft to draw oil from the transaxle case, and feed oil to the charge circuit. The charge pump is necessary to make up for leakage from the pump and motor, preventing system.

  • Page 134: Control Linkage

    GR1600EC, WSM TRANSAXLE (6) Control Linkage (1) Speed Change Pedal (3) Speed Change Plate (5) Neutral Spring (6) Speed Control Arm (2) Speed Change Rod (4) Neutral Arm The speed change pedal (1) and the trunnion arm of variable swashplate are linked with the speed change rod (2), speed change plate (3) and the speed control arm (6).

  • Page 135: Mower Pto System

    GR1600EC, WSM TRANSAXLE [2] MOWER PTO SYSTEM (1) Mower PTO Clutch The mower PTO clutch is equipped with mechanical independent clutches of wet multi-plates type. The PTO shaft (1) is engaged with the spline boss (3). The clutch case (5) is engaged with the 24T gear (6).
  • Page 136 GR1600EC, WSM TRANSAXLE B PTO "Disengaged" When the PTO lever is set at the "Disengaged" position, the clutch lever (2) connected to the PTO lever via a link mechanism rotates to the front side of the machine. Spring (8) tension pushes the spline boss (3) toward...
  • Page 137 CONTENTS 1. TROUBLESHOOTING....................... 2-S1 2. SERVICING SPECIFICATIONS ..................2-S4 3. TIGHTENING TORQUES ....................2-S5 4. CHECKING, DISASSEMBLING AND SERVICING ............2-S6 [1] CHECKING AND ADJUSTING ..................2-S6 [2] PREPARATION ....................... 2-S9 (1) Separating Transaxle ....................2-S9 [3] DISASSEMBLING AND ASSEMBLING............... 2-S16 (1) Hydrostatic Transmission ..................

  • Page 138: Troubleshooting

    GR1600EC, WSM TRANSAXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Oil level is low System Will Not Fill oil to proper level G-8, 2-S11 Operate in Either A Control linkage defective (Speed change pedal Repair control linkage 2-S7, 15...
  • Page 139 GR1600EC, WSM TRANSAXLE A Oil level is low Less of Power Fill oil to proper level G-8, 2-S11 A Control linkage defective (Speed change pedal Repair control linkage 2-S7, 15 to speed control arm) A Charge pressure is A Oil filter cartridge...
  • Page 140 GR1600EC, WSM TRANSAXLE DIFFERENTIAL GEAR SECTION Reference Symptom Probable Cause Solution Page A Improper backlash between 11T bevel gear Excessive or Unusual Adjust 2-S35 Noise at All Time and 17T-13T gear shaft A Improper backlash between differential pinion Adjust 2-S34...

  • Page 141: Servicing Specifications

    GR1600EC, WSM TRANSAXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Charge Relief Valve Setting Pressure 0.3 to 0.5 MPa (Oil temperature at 50 , 122 3.1 to 5.1 43.5 to 72.5 psi PTO Clutch Disc Thickness 1.3 to 1.5 mm 1.2 mm...
  • Page 142 GR1600EC, WSM TRANSAXLE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9) Item ft-lbs Brake plate mounting screw 34 to 40 3.47 to 4.07...

  • Page 143: Checking, Disassembling And Servicing

    GR1600EC, WSM TRANSAXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Adjustment of HST Neutral Position 1. Block the front wheels with stoppers, and lift up the rear of machine with a jack. 2. Remove the left rear wheel.
  • Page 144 GR1600EC, WSM TRANSAXLE Speed Change Pedal Restriction A This adjustment should be performed after completing the adjustment of neutral. 1. Set the speed change pedal (1) to "NEUTRAL" position, and apply the parking brake. 2. Check that the pin (3) of speed change pedal lock with the brake pedal arm (2).
  • Page 145 GR1600EC, WSM TRANSAXLE Charge Relief Pressure A When checking, park the machine on level ground, apply the parking brake. A This checking should be performed after completing the adjustment of neutral. 1. Remove the hexagon socket head plug (9/16-18 UNF) from P1 (1) or P2 (2).

  • Page 146: Preparation

    GR1600EC, WSM TRANSAXLE [2] PREPARATION (1) Separating Transaxle Dismounting Mower 1. See page 7-S6. ("Mower" Section) 0000009311E Dismounting the Container A Park the machine on a firm and level ground. A Stop the engine, and remove the key. 1. Grip the grass container lock handle (2) with the handle (3).
  • Page 147 GR1600EC, WSM TRANSAXLE Container Base 1. Disconnect the couplers (1) from the relays. 2. Disconnect the connectors (2). 3. Open the switch cover (6). And disconnect the connector (4) from the grass container full switch (5). 4. Remove the discharge duct (3).
  • Page 148 A After running the engine for few minutes, stop the engine and check the oil level again, if low, add oil to prescribed level. A Use the KUBOTA UDT or SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system.
  • Page 149 GR1600EC, WSM TRANSAXLE Seat 1. Remove two snap pins (2), (4). 2. Remove the seat (1) and seat plate (3). (1) Seat (3) Seat Plate (2) Snap Pin (4) Snap Pin 0000009319E Fender 1. Remove the speed change pedal (5).
  • Page 150 GR1600EC, WSM TRANSAXLE PTO Rod Spring 1. Remove the two nuts (2) (3) and spring (4). (When reassembling) 1. Assemble a fuel tank, a seat base and a fender. 2. Setting the PTO lever at "Disengaged" position and lifting the...
  • Page 151 GR1600EC, WSM TRANSAXLE Beam 1. Disconnect the connector from the PTO switch (1). 2. Remove the spring (2) from the PTO lever (3). 3. Remove the PTO rod 4. Remove the filling pipe (4). 5. Remove the beam (5). (1) PTO Switch...
  • Page 152 GR1600EC, WSM TRANSAXLE Speed Control Plate 1. Remove the rue ring pin (2), and disconnect the speed change plate (1) and speed control arm (3). 2. Separate the speed change plate (1) and speed change rod (4). A After assembling the speed change plate (1) and speed change rod (4), be sure to adjust the speed change pedal restriction (see page 2-S7).

  • Page 153: Disassembling And Assembling

    GR1600EC, WSM TRANSAXLE [3] DISASSEMBLING AND ASSEMBLING (1) Hydrostatic Transmission Speed Control Arm, Neutral Spring, Cooling Fan and Others 1. Remove the neutral spring (2). 2. Remove the speed control arm (1). 3. Remove the cooling fan (3). 4. Remove the breather hoses (4).
  • Page 154 GR1600EC, WSM TRANSAXLE Brake Assembly 1. Remove the brake assembly (1). 2. Remove the external snap ring (2). And pull out the brake drum (3). (1) Brake Assembly (3) Brake Drum (2) External Snap Ring 0000009335E Hydrostatic Transmission Assembly 1. Remove the hydrostatic transmission assembly (1).
  • Page 155 GR1600EC, WSM TRANSAXLE 15T Gear, 34T Gear and Bevel Gear Shaft 1. Remove the external snap ring (4). And pull out the 15T gear (1) and 34T gear (2). 2. Remove the bevel gear shaft (3). (1) 15T Gear (4) External Snap Ring...
  • Page 156 GR1600EC, WSM TRANSAXLE Center Section 1. Remove the center section mounting hex. socket head screws. 2. Tap the center section (1) with soft hammer and separate the center section (1) from the HST housing (2). (When reassembling) A Cover the splines of each shaft with thin tape to protect the sealing lip of the oil seals.
  • Page 157 GR1600EC, WSM TRANSAXLE 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).

  • Page 158: Transaxle Case

    GR1600EC, WSM TRANSAXLE (2) Transaxle Case Speed Control Arm, Neutral Spring, Cooling Fan and Others 1. Remove the neutral spring (2). 2. Remove the speed control arm (1). 3. Remove the cooling fan (3). 4. Remove the breather hoses (4).
  • Page 159 GR1600EC, WSM TRANSAXLE Brake Assembly 1. Remove the brake assembly (1). 2. Remove the external snap ring (2). And pull out the brake drum (3). (1) Brake Assembly (3) Brake Drum (2) External Snap Ring 0000009335E Hydrostatic Transmission Assembly 1. Remove the hydrostatic transmission assembly (1).
  • Page 160 GR1600EC, WSM TRANSAXLE PTO Clutch Assembly 1. Remove the PTO clutch assembly (1) and the ball bearing (2) from the transaxle case. (When reassembling) A Install the ball bearing (2) with the sealed face inside. A Align the tangs (4) of PTO brake friction plate with the slots (3) of transaxle case.
  • Page 161 GR1600EC, WSM TRANSAXLE Disassembling PTO Clutch Assembly 1. Remove the 24T gear (1), clutch (2), brake disc and friction plate (3) from PTO shaft (4). 2. While pressing the clutch (2), turn the clutch case (5) clockwise. Then, separate the clutch case (5) and the spline boss (9) with clutch disc and friction plate (10).
  • Page 162 GR1600EC, WSM TRANSAXLE Disassembling PTO Clutch Assembly (Continued) 1. Pull out the PTO shaft (1) from PTO clutch cover (5) until external snap ring (3) touches clutch lever (4). 2. Tap out the PTO shaft (1) while opening the external snap ring (3) with external snap ring pliers.
  • Page 163 GR1600EC, WSM TRANSAXLE Transaxle Case 1. Remove the transaxle case screws (2). 2. Separate the rear side of transaxle case (1). (When reassembling) A Apply liquid gasket (Three Bond 1208D or equivalent) to joint face of the transaxle case. A Install the transaxle case screws (2) in the direction shown in figure.
  • Page 164 GR1600EC, WSM TRANSAXLE Input Shaft, 19T-2 Gear and 17T-13T Gear Shaft 1. Remove the input shaft (1). 2. Remove the intermediate shaft (2) and 19T-2 gear (3) with collars (6) and needle bearing (7). 3. Remove the 17T-13T gear shaft (4).
  • Page 165 GR1600EC, WSM TRANSAXLE Rear Differential Gear Assembly 1. Remove the 42T gear mounting screws (1). 2. Remove the 42T gear (2) and differential side gear (3). 3. Remove the differential pinion shaft (6). 4. Remove the differential pinion gears (5), differential side gear (7) and shims (4).

  • Page 166: Servicing

    GR1600EC, WSM TRANSAXLE [4] SERVICING (1) Hydrostatic Transmission Charge Pump 1. Check the charge pump housing (1) and gerotor assembly (2) for scratches and wear. 2. If scratch or worn, replace the charge pump assembly. (1) Charge Pump Housing (2) Gerotor Assembly...
  • Page 167 GR1600EC, WSM TRANSAXLE By-pass Valve 1. Check the by-pass spool (3) and spring (4). 2. If defects are found, replace them. (1) Plug (3) By-pass Spool (2) O-ring (4) Spring 0000009358E Cylinder Block Assembly 1. Check the cylinder blocks (4) and pistons (3) for scratches and wear.

  • Page 168: Transaxle Case

    GR1600EC, WSM TRANSAXLE 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...
  • Page 169 GR1600EC, WSM TRANSAXLE 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. 1.55 to 1.65 mm Factory spec.
  • Page 170 GR1600EC, WSM TRANSAXLE 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. 1.75 to 1.85 mm Factory spec. 0.069 to 0.073 in.
  • Page 171 GR1600EC, WSM TRANSAXLE Clearance between Differential Pinion Gear and Differential Pinion Shaft 1. Measure the differential pinion gear (1) I.D.. 2. Measure the differential pinion shaft (2) O.D., and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace faulty parts.
  • Page 172 GR1600EC, WSM TRANSAXLE Backlash between 11T Bevel Gear Shaft and 17T-13T Gear Shaft 1. Stick a strip of fuse the three spots on the 11T bevel gear shaft (3) with grease. 2. Reassemble the hydrostatic transmission and transaxle case. 3. Fix the transaxle case, and push the by-pass valve.
  • Page 173 BRAKES KiSC issued 04, 2006 A...
  • Page 174 CONTENTS 1. TROUBLESHOOTING....................... 3-S1 2. SERVICING SPECIFICATIONS ..................3-S2 3. TIGHTENING TORQUES ....................3-S3 4. CHECKING, DISASSEMBLING AND SERVICING ............3-S4 [1] CHECKING AND ADJUSTING ..................3-S4 [2] DISASSEMBLING AND ASSEMBLING................. 3-S4 (1) Pedal System Component..................3-S4 (2) Brake Assembly....................... 3-S8 KiSC issued 04, 2006 A...

  • Page 175: Troubleshooting

    GR1600EC, WSM BRAKES 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Brake pedal free travel excessive Insufficient Braking Adjust 3-S4 Force A Brake shoe worn Replace 3-S8 A Brake drum worn Replace 3-S8 A Grease or oil on brake shoe...

  • Page 176: Servicing Specifications

    GR1600EC, WSM BRAKES 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Brake Pedal Free Travel 15 to 25 mm 0.59 to 0.98 in. 0000009613E KiSC issued 04, 2006 A 3-S2...
  • Page 177 GR1600EC, WSM BRAKES 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9) Item ft-lbs Steering wheel mounting nut 20 to 25 2.0 to 2.5...

  • Page 178: Checking, Disassembling And Servicing

    GR1600EC, WSM BRAKES 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Brake Pedal Free Travel A Stop the engine, remove the key, and chock the wheels before checking brake pedal. 1. Release the parking brake. 2. Loosen the lock nut (1).
  • Page 179 GR1600EC, WSM BRAKES Container Base 1. Disconnect the couplers (1) from the relays. 2. Disconnect the connectors (2). 3. Open the switch cover (6). And disconnect the connector (4) from the grass container full switch (5). 4. Remove the discharge duct (3).
  • Page 180 GR1600EC, WSM BRAKES Steering Wheel, Side Bonnet and Panel 1. Remove the steering wheel (1). 2. Remove the side bonnet (3). 3. Remove the accelerator lever grip. 4. Disconnect the connectors for hour meter (4), main switch (5) and light switch.
  • Page 181 GR1600EC, WSM BRAKES 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...

  • Page 182: Brake Assembly

    GR1600EC, WSM BRAKES (2) Brake Assembly Brake Assembly 1. Remove the lock nut (1), plain washers (2) and brake spring (3). 2. Remove the brake plate (6). 3. Remove the brake rod 2 (5). 4. Remove the brake assembly (4).

  • Page 183: Front Axle

    FRONT AXLE KiSC issued 04, 2006 A...
  • Page 184 CONTENTS 1. TROUBLESHOOTING....................... 4-S1 2. SERVICING SPECIFICATIONS ..................4-S2 3. TIGHTENING TORQUES ....................4-S3 4. CHECKING, DISASSEMBLING AND SERVICING ............4-S4 [1] CHECKING AND ADJUSTING ..................4-S4 [2] PREPARATION ....................... 4-S4 (1) Separating Front Axle Assembly ................4-S4 [3] DISASSEMBLING AND ASSEMBLING................. 4-S6 (1) Front Axle Assembly....................

  • Page 185: Troubleshooting

    GR1600EC, WSM FRONT AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Tire pressure uneven Front Wheels Wander Adjust to Right or Left A Improper toe-in Replace tie-rod 4-S4, 6 A Kingpin worn Replace front axle 4-S5 assembly A Center pin collar worn...

  • Page 186: Servicing Specifications

    GR1600EC, WSM FRONT AXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Front Wheel Alignment Toe-in 1 to 10 mm 0.04 to 0.39 in. Front Axle Frame to Anti-vibration Bolt Clearance 0.3 to 0.5 mm 0.012 to 0.020 in. Center Pin to Center Pin Collar Clearance 0.109 to 0.200 mm...
  • Page 187 GR1600EC, WSM FRONT AXLE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9) Item ft-lbs Center pin locking nut 77.4 to 90.2 7.9 to 9.2...

  • Page 188: Checking, Disassembling And Servicing

    GR1600EC, WSM FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Toe-in 1. Inflate the tires to the specified pressure. 2. Turn the front wheels straight ahead. 3. Measure the toe-in (B-A). 4. If the measurement is not within the factory specifications, replace the tie-rod.
  • Page 189 GR1600EC, WSM FRONT AXLE Bonnet and Side Bonnet 1. Disconnect the connectors (5) from the head light. 2. Remove the wire harness (4) from the bonnet. 3. Remove the bonnet (1) with bonnet bracket (2). 4. Remove the side bonnet (3).

  • Page 190: Disassembling And Assembling

    GR1600EC, WSM FRONT AXLE [3] DISASSEMBLING AND ASSEMBLING (1) Front Axle Assembly Tie-rod 1. Remove the tie-rod mounting locking nut (1). 2. Remove the tie-rod (2). (When reassembling) 49.9 to 54.2 Tie-rod mounting Tightening torque 5.09 to 5.53 locking nut 36.8 to 40.0 ft-lbs...
  • Page 191 STEERING KiSC issued 04, 2006 A...
  • Page 192 CONTENTS 1. TROUBLESHOOTING....................... 5-S1 2. SERVICING SPECIFICATIONS ..................5-S2 3. TIGHTENING TORQUES ....................5-S3 4. CHECKING, DISASSEMBLING AND SERVICING ............5-S4 [1] CHECKING AND ADJUSTING ..................5-S4 [2] PREPARATION ....................... 5-S4 (1) Separating Steering Support Assembly..............5-S4 [3] DISASSEMBLING AND ASSEMBLING................. 5-S7 (1) Steering Support Assembly ..................

  • Page 193: Troubleshooting

    GR1600EC, WSM STEERING 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Steering shaft and sector gear broken Cannot Steer Replace 5-S6, 7 A Steering linkage broken Replace 5-S6 A Tire pressure uneven Hard Steering Adjust A Improper alignment of front wheels...

  • Page 194: Servicing Specifications

    GR1600EC, WSM STEERING 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Steering Wheel Play 30 to 70 mm 0.79 to 1.18 in. 0000009619E KiSC issued 04, 2006 A 5-S2...
  • Page 195 GR1600EC, WSM STEERING 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9) Item ft-lbs Steering wheel mounting nut 20 to 25 2.0 to 2.5...

  • Page 196: Checking, Disassembling And Servicing

    GR1600EC, WSM STEERING 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Steering Wheel Play 1. Turn the front wheels straight ahead. 2. Rotate the steering wheel lightly by hand, and measure the play. 3. If the measurement exceeds the factory specifications, replace the steering shaft and sector gear.
  • Page 197 GR1600EC, WSM STEERING Container Base 1. Disconnect the couplers (1) from the relays. 2. Disconnect the connectors (2). 3. Open the switch cover (6). And disconnect the connector (4) from the grass container full switch (5). 4. Remove the discharge duct (3).
  • Page 198 GR1600EC, WSM STEERING Steering Wheel, Side Bonnet and Panel 1. Remove the steering wheel (1). 2. Remove the side bonnet (3). 3. Remove the accelerator lever grip. 4. Disconnect the connectors for hour meter (4), main switch (5) and light switch.

  • Page 199: Disassembling And Assembling

    GR1600EC, WSM STEERING [3] DISASSEMBLING AND ASSEMBLING (1) Steering Support Assembly Steering Shaft and Sector Gear 1. Remove the shaft retainer (4). 2. Remove the sector gear mounting screw (5), and remove the sector gear (8). 3. Remove the steering bearing (1) and ball bearing (3).

  • Page 200: Electrical System

    ELECTRICAL SYSTEM KiSC issued 04, 2006 A...
  • Page 201 CONTENTS 1. WIRING DIAGRAM......................6-M1 2. STARTING SYSTEM ......................6-M3 3. CHARGING SYSTEM.......................6-M4 4. LIGHTING SYSTEM ......................6-M5 KiSC issued 04, 2006 A...

  • Page 202: Wiring Diagram

    GR1600EC, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM 0000009632E KiSC issued 04, 2006 A 6-M1...
  • Page 203 GR1600EC, WSM ELECTRICAL SYSTEM Color of Wiring W..White WR..White / Red BW..Black / White R..Red WY..White / Yellow BR..Black / Red L..Blue RB..Red / Black GW..Green / White P..Pink RW..Red / White YR..Yellow / Red B..Black RG..Red / Green YL..Yellow / Blue Br..Brown...

  • Page 204: Starting System

    GR1600EC, WSM ELECTRICAL SYSTEM 2. STARTING SYSTEM (1) Battery (7) Engine Stop Time Relay (12) Grass Container Open (16) Fuse (3 A) (2) Body Earth (8) Fuel Feed Pump Switch (17) Fuse (10 A) (3) Starter Motor (9) Slow Blow Fuse (40 A)

  • Page 205: Charging System

    GR1600EC, WSM ELECTRICAL SYSTEM 3. CHARGING SYSTEM (1) Battery (4) Dynamo (7) Main Switch (9) Charge Lamp (2) Body Earth (5) Slow Blow Fuse (40 A) (8) Fuse (10 A) (10) Hour Meter (3) Body Earth (6) Regulator The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs.

  • Page 206: Lighting System

    GR1600EC, WSM ELECTRICAL SYSTEM 4. LIGHTING SYSTEM (1) Battery (7) Regulator (13) Grass Container Full (18) Oil Pressure Lamp (2) Body Earth (8) Slow Blow Fuse (40 A) Switch (19) Charge Lamp (3) Thermo Switch (9) Main Switch (14) Buzzer Relay...
  • Page 207 CONTENTS 1. TROUBLESHOOTING....................... 6-S1 2. SERVICING SPECIFICATIONS ..................6-S4 3. TIGHTENING TORQUES ....................6-S5 4. CHECKING, DISASSEMBLING AND SERVICING ............6-S6 [1] CHECKING AND ADJUSTING ..................6-S6 (1) Battery ........................6-S6 (2) Main Switch ......................6-S8 (3) Starter........................6-S10 (4) Glow Plug ......................6-S11 (5) Safety Switch......................

  • Page 208: Troubleshooting

    GR1600EC, WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Battery discharged or defective All Electrical Recharge or replace G-24, 1-S21 Equipments Do Not A Battery positive cable disconnected Repair or replace Operate improperly connected A Battery...
  • Page 209 GR1600EC, WSM ELECTRICAL SYSTEM STARTING SYSTEM Reference Symptom Probable Cause Solution Page A Battery discharged or defective Starter Motor Does Recharge or replace G-24, 1-S21 Not Operate A Slow blow fuse blown (40 A) Replace G-35 A Wiring harness disconnected or improperly...
  • Page 210 GR1600EC, WSM ELECTRICAL SYSTEM LIGHTING SYSTEM Reference Symptom Probable Cause Solution Page A Fuse blown (10 A) Head Light Does Not Replace G-35 Light A Bulb blown Replace G-35 A Wiring harness disconnected or improperly Repair or replace connected (between...

  • Page 211: Servicing Specifications

    GR1600EC, WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Battery Voltage More than 12 V Potential Difference Less than 0.1 V Glow Plug Resistance Approx. 0.9 Head Light Switch Resistance OFF Infinity Resistance ON Starter Commutator 28.0 mm 27.0 mm...
  • Page 212 GR1600EC, WSM ELECTRICAL SYSTEM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9) Item ft-lbs Starter (C terminal nut) 5.9 to 11.8 0.6 to 1.2...

  • Page 213: Checking, Disassembling And Servicing

    GR1600EC, WSM ELECTRICAL SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Battery Battery Voltage 1. Stop the engine and turn the main switch off. 2. Connect the COM (-) lead of the voltmeter to the battery's negative terminal post (2) and the (+) lead to the positive terminal post (1), and measure the battery voltage.
  • Page 214 GR1600EC, WSM ELECTRICAL SYSTEM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).

  • Page 215: Main Switch

    GR1600EC, WSM ELECTRICAL SYSTEM (2) Main Switch Main Switch 1. Open the bonnet. 2. Disconnect the 4P connector and remove the main switch (1). 3. Perform the following checks. (1) Main Switch 0000009471E Connector Voltage 1. Measure the voltage with a voltmeter across the connector B (red) terminal and chassis.
  • Page 216 GR1600EC, WSM ELECTRICAL SYSTEM Main Switch Continuity 1) Main Switch Key at OFF Position 1. Set the main switch OFF position. 2. Measure the resistance with an ohmmeter across the B terminal and the ACC terminal, B terminal and ST terminal, B terminal and G terminal.

  • Page 217: Starter

    GR1600EC, WSM ELECTRICAL SYSTEM (3) Starter Motor Test A Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable and the leads from the starter.

  • Page 218: Glow Plug

    GR1600EC, WSM ELECTRICAL SYSTEM (4) Glow Plug Lead Terminal Voltage 1. Disconnect the wiring lead (1) from the glow plug (2) after turning the main switch off. 2. Turn the main switch key to the "PREHEAT" position, and measure the voltage between the lead terminal and the chassis.

  • Page 219: Safety Switch

    GR1600EC, WSM ELECTRICAL SYSTEM (5) Safety Switch PTO Switch 1. Remove the battery. 2. Remove the fender. 3. Disconnect the connector from the PTO switch (1). 4. Measure the resistance with an ohmmeter between the terminals. 5. If the PTO switch is defective, replace it.

  • Page 220: Operator Presence Control (Opc) Switch

    GR1600EC, WSM ELECTRICAL SYSTEM Grass Container Open Switch 1. Remove the battery. 2. Dismount the grass container. 3. Disconnect the safety switch (1) lead. 4. Measure the resistance with an ohmmeter between the saety switch terminals. 5. If the safety switch is defective, replace it.

  • Page 221: Fuel Pump

    GR1600EC, WSM ELECTRICAL SYSTEM (7) Fuel Pump Connector Voltage 1. Disconnect the 2P connector from the fuel pump. 2. Turn the main switch key to the "ON" position, and measure the voltage with a voltmeter between the connector terminals. 3. If the voltage differs from the battery voltage, the wiring harness or main switch is faulty.

  • Page 222: Time Relay

    GR1600EC, WSM ELECTRICAL SYSTEM (9) Time Relay Timer Relay Connector Voltage 1. Disconnect the connector from the timer relay after turning the main switch off. 2. Measure the voltage with a voltmeter across the connector terminal 4 and chassis. 3. Turn the main switch on, and measure the voltage across the connector terminal 3 and chassis.

  • Page 223: Lighting System

    GR1600EC, WSM ELECTRICAL SYSTEM Regulating Voltage 1. Complete the charging circuit with a fully charged battery and run the engine speed at the rated speed. 2. Measure the battery voltage with a volt meter. 3. If the measurement is not within the specified values, replace the regulator.
  • Page 224 GR1600EC, WSM ELECTRICAL SYSTEM Engine Oil Pressure Lamp 1. Disconnect the lead from the engine oil pressure switch after turning the main switch OFF. 2. Turn the main switch ON and connect a jumper lead from the lead to the chassis.

  • Page 225: Coolant Temperature Sensor

    GR1600EC, WSM ELECTRICAL SYSTEM (12)Coolant Temperature Sensor Coolant Temperature Sensor 1) Connector Voltage 1. Disconnect the 1P connector from the thermo switch (1). 2. Turn the main switch key to the "ON" position, and measure the voltage with a voltmeter between the connector terminal and the chassis.
  • Page 226 GR1600EC, WSM ELECTRICAL SYSTEM Buzzer 1. Remove the air intake net. 2. Disconnect the lead from buzzer (1). 3. Connect the jumper lead between the battery positive terminal and terminal 1 of connector. 4. Connect the jumper lead between the battery negative terminal and terminal 2 of connector.

  • Page 227: Disassembling And Assembling

    GR1600EC, WSM ELECTRICAL SYSTEM [2] DISASSEMBLING AND ASSEMBLING (1) Starter (1) Sleeve Bearing (2) Bushing (3) Starter Drive Housing (4) Drive Lever (5) Magnet Switch (6) Yoke (7) Connecting Lead (8) Through Bolt (9) Rear End Frame (10) Bushing (11) Brush...

  • Page 228: Dynamo

    GR1600EC, WSM ELECTRICAL SYSTEM (2) Dynamo Stator 1. Remove the nut (3) and separate the stator comp. (4). 2. Unscrew the screws (1) and remove the stator (2). (When reassembling) 39.2 to 44.1 Tightening torque 4.0 to 4.5 28.9 to 32.5 ft-lbs...

  • Page 229: Servicing

    GR1600EC, WSM ELECTRICAL SYSTEM [3] SERVICING (1) Starter Overrunning Clutch 1. Inspect the pinion for wear or damage. 2. If there is any defect, replace the overrunning clutch assembly. 3. Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction.
  • Page 230 GR1600EC, WSM ELECTRICAL SYSTEM Brush Wear 1. If the contact face of the brush is dirty or dusty, clean it with emery paper. 2. Measure the brush length (A) with vernier calipers. 3. If the length is less than the allowable limit, replace the yoke assembly and brush holder.

  • Page 231: Dynamo

    GR1600EC, WSM ELECTRICAL SYSTEM Field Coil 1. Check the continuity across the lead (1) and brush (2) with an ohmmeter. 2. If it does not conduct, replace the yoke assembly. 3. Check the continuity across the brush (2) and yoke (3) with an ohmmeter.
  • Page 232 MOWER KiSC issued 04, 2006 A...
  • Page 233 CONTENTS 1. POWER TRANSMISSION....................7-M1 2. LIFTING MECHANISM .....................7-M2 KiSC issued 04, 2006 A...
  • Page 234 GR1600EC, WSM MOWER 1. POWER TRANSMISSION (1) Center Pulley (4) 18T Spiral Gear (7) Mower Belt (9) Blade Shaft (2) Output Shaft (5) Input Shaft (8) Universal Joint (10) Blade (3) 17T Spiral Gear (6) Outer Pulley The power is transmitted from transmission case to blades as follows.

  • Page 235: Lifting Mechanism

    GR1600EC, WSM MOWER 2. LIFTING MECHANISM (1) Lift Link LH (4) Lift Link Shaft (7) Cutting Height Adjusting (9) Lift Link RH (2) Rear Link LH (5) Mower Lift Lever Dial (10) Rear Link RH (3) Gas Spring (6) Lift Link (8) Adjusting Cam The rear link RH (10) and mower lift lever (5) are linked with lift link RH (9) and lift link (6).
  • Page 236 CONTENTS 1. TROUBLESHOOTING....................... 7-S1 2. SERVICING SPECIFICATIONS ..................7-S2 3. TIGHTENING TORQUES ....................7-S3 4. CHECKING, DISASSEMBLING AND ASSEMBLING ............ 7-S4 [1] CHECKING AND ADJUSTING ..................7-S4 (1) Adjusting Anti-scalp Rollers..................7-S4 (2) Adjusting Left and Right Cutting Height..............7-S5 [2] PREPARATION .......................
  • Page 237 GR1600EC, WSM MOWER 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A PTO system malfunctioning Blade Does Not Turn Check transmission A Mower belt broken Replace mower belt 7-S8 A Mower belt loosen Blade Speed Is Slow Replace mower belt...

  • Page 238: Servicing Specifications

    GR1600EC, WSM MOWER 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Left Tip of Blade to Right Tip of Blade Difference Less than 6 mm 0.24 in. Front Tip of Blade to Rear Tip of Blade Difference Less than 5 mm 0.20 in.
  • Page 239 GR1600EC, WSM MOWER 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9) Item ft-lbs Mower blade screw 98 to 118 10.0 to 12.0 72.3 to 86.8...

  • Page 240: Checking, Disassembling And Assembling

    GR1600EC, WSM MOWER 4. CHECKING, DISASSEMBLING AND ASSEMBLING [1] CHECKING AND ADJUSTING (1) Adjusting Anti-scalp Rollers Adjusting Anti-scalp Rollers A The flattest cut can be achieved by having the anti-scalp rollers adjusted off the ground. Check anti-scalp roller adjustments each time the mower deck cutting height is changed.

  • Page 241: Adjusting Left And Right Cutting Height

    GR1600EC, WSM MOWER (2) Adjusting Left and Right Cutting Height Adjusting Left and Right Cutting Height 1. Park the machine on level surface. 2. Wheel pressure must be correct. 3. Raise up the mower deck to the transport position. (Also the top end.)

  • Page 242: Preparation

    GR1600EC, WSM MOWER Adjusting Parallel Linkage 1. Park the machine on a level surface. 2. Wheel pressure must be correct. 3. Adjust the cutting height so that blade is level. 4. Position mower blade in the Front-to-Rear position. 5. Measure the height of blade X and Y from the ground surface and calculate the difference.
  • Page 243 GR1600EC, WSM MOWER Rear Link and Universal Joint 1. Disconnect the rotate plate rod (1). 2. Disconnect the rear link (2) from the mower deck, pulling the L-pins (3). 3. Disconnect the universal joint (4) from the PTO shaft. 4. Raise the mower lift lever and lock in the raised position.

  • Page 244: Disassembling And Assembling

    GR1600EC, WSM MOWER [3] DISASSEMBLING AND ASSEMBLING (1) Mower Mower Blades (Left Blade and Right Blades) 1. Turn over the mower. 2. Unscrew the mower blade screw (1), and remove the shim (2), two cup washers (3), mower blade (4) and dust cover (6).
  • Page 245 GR1600EC, WSM MOWER Disassembling Gear Box 1. Unscrew the drain plug (10), and drain the gear box oil. 2. Unscrew the pulley mounting screw (1), and remove the pulley (3). 3. Remove the case cover (15). 4. Remove the shim (14) and 18T spiral gear (12) with ball bearing (13).
  • Page 246 GR1600EC, WSM MOWER Disassembling Pulley Holder 1. Remove the grease nipple (12). 2. Unscrew the pulley mounting nut (11), and remove the pulley (10). 3. Tap out the blade shaft (1). 4. Remove the pulley holder (6) from the mower deck.

  • Page 247: Mower Lift Linkage

    GR1600EC, WSM MOWER (2) Mower Lift Linkage (1) Screw (2) Gas Spring Mounting Nut (3) Lock Nut (4) Rear Link LH (5) Clevis Pin (6) Lift Link LH (7) Rue Ring (8) Rue Ring (9) Gas Spring Mounting Nut (10) Gas Spring...

  • Page 248: Servicing

    GR1600EC, WSM MOWER [4] SERVICING (1) Gear Box Backlash between 17T Spiral Gear and 18T Spiral Gear 1. Remove the 18T spiral gear (6) from gear box. 2. Stick the strip of fuse the 18T spiral gear (6) with grease.
  • Page 249 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ksos-pub@kubota.co.jp Printed in Japan 2006. 03, S, EI, EI, e Code No.9Y011-15402 KUBOTA Corporation 2005.

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