Kubota GR1600EC Instruction manual

GR1600EC
WORKSHOP MANUAL
KiSC issued 04, 2006 A

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".
Information on the product identification, the general precautions, maintenance check list, check and maintenance
and special tools are described.
Information on the construction and function are included. This part should be understood before proceeding with
troubleshooting, disassembling and servicing.
Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting,
disassembling and assembling, and servicing which cover procedures, precautions, factory specifications 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.
KUBOTA Corporation 2005
BGeneral
BMechanism
BServicing
February 2005
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GR1600EC, WSM SAFETY INSTRUCTIONS
1
BEFORE SERVICING AND REPAIRING
ARead all instructions and safety instructions in this
manual and on your machine safety decals.
AClean the work area and machine.
APark the machine on a firm and level ground, and set
the parking brake.
ALower the implement to the ground.
AStop the engine, and remove the key
ADisconnect the battery negative cable
AHang a "DO NOT OPERATE" tag in operator
station.
SAFETY STARTING
ADo not start the engine by shorting across starter
terminals or bypassing the safety start switch.
ADo not alter or remove any part of machine safety
system.
ABefore starting the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
ANever start the engine while standing on ground.
Start the engine only from operator's seat.
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.
AIndicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
AIndicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
AIndicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
AIndicates that equipment or property damage could result if instructions are not followed.
AGives helpful information.
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GR1600EC, WSM SAFETY INSTRUCTIONS
2
SAFETY WORKING
ADo not work on the machine while under the
influence of alcohol, medication, or other substances
or while fatigued.
AWear close fitting clothing and safety equipment
appropriate to the job.
AUse tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
AWhen servicing is performed together by two or
more persons, take care to perform all work safely.
ADo not work under the machine that is supported
solely by a jack. Always support the machine by
safety stands.
ADo not touch the rotating or hot parts while the
engine is running.
ANever 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.
AEscaping 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
AFuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
ATo avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
ABattery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
AMake sure that no fuel has been spilled on the
engine.
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GR1600EC, WSM SAFETY INSTRUCTIONS
3
VENTILATE WORK AREA
AIf 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
ASulfuric 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
ADo 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
AKeep a first aid kit and fire extinguisher handy at all
times.
AKeep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
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GR1600EC, WSM SAFETY INSTRUCTIONS
4
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.
SAFETY DECALS
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GR1600EC, WSM SAFETY INSTRUCTIONS
5
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GR1600EC, WSM SAFETY INSTRUCTIONS
6
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GR1600EC, WSM SPECIFICATIONS
7
SPECIFICATIONS
Model GR1600EC
Engine
Maker KUBOTA
Model Z482-E2-GX
Type Indirect injection. Vertical, water-cooled, 4-cycle diesel
Number of cylinders 2
Bore and stroke 67 x 68 mm (2.64 x 2.68 in.)
Total displacement 479 (29.9 cu.in.)
Engine gross power (DIN) 10.0 kW (13.4 HP)
Rated revolution 53.3 r/s [3200 (rpm)]
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
Fuel Diesel fuel No.2-D [above -10 (14 )],
Diesel fuel No.1-D [below -10 (14 )]
Capacities
Fuel tank 18 L (4.8 U.S.gals, 4.0 lmp.gals)
Engine crankcase (with filter) 1.2 L (1.27 U.S.qts., 1.06 lmp.qts.)
Engine coolant (with recovery tank) 2.15 L (2.27 U.S.qts., 1.89 lmp.qts.)
Transmission case 2.7 L (0.71 U.S.gals., 0.59 lmp.gals.)
Dimensions
Overall length (with grass catcher) 2460 mm (96.9 in.)
Overall width 1110 mm (43.7 in.)
Overall height 1190 mm (46.9 in.)
Wheel base 1280 mm (50.4 in.)
Tread Front 750 mm (29.5 in.)
Rear 800 mm (31.5 in.)
Weight (without mower and grass catcher) 310 kg (684 lbs)
Traveling system
Tires Front 15 x 6.00 - 6, 4PR
Rear 20 x 10.00 - 8, 4PR
Steering Manual (Sector gear type)
Transmission Hydrostatic transmission
Brake Internal expanding brake
Differential Bevel gear
Traveling speed 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)
PTO system 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.
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GR1600EC, WSM SPECIFICATIONS
8
Model RCK42GR
Mower
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)
Dimensions
Total length 965 mm (38.0 in.)
Total width 1110 mm (43.7 in.)
Total height 295 mm (11.6 in.)
Discharge direction Rear
Gear box oil 0.33 L (0.35 U.S.qts, 0.29 Imp.qts)
Model GCK350GR
Grass catcher Container capacity 350 L (92.5 U.S.gals, 77.0 Imp.gals)
Weight (Approx.) 40 kg (88.2 lbs)
NOTE: *Manufacture's estimate
The company reserves the right to change the specifications without notice.
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GR1600EC, WSM DIMENSIONS
9
DIMENSIONS
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KiSC issued 04, 2006 A

GGENERAL
KiSC issued 04, 2006 A

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
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-25
[4] CHECK POINT OF EVERY 150 HOURS...................................................................G-27
[5] CHECK POINTS OF EVERY 200 HOURS.................................................................G-28
[6] CHECK POINT OF EVERY 400 HOURS...................................................................G-31
[7] CHECK POINTS OF EVERY 1 YEAR........................................................................G-31
[8] CHECK POINTS OF EVERY 2 YEARS......................................................................G-34
[9] OTHERS..........................................................................................................................G-35
8. SPECIAL TOOLS .............................................................................................................G-38
[1] SPECIAL TOOLS FOR ENGINE ..................................................................................G-38
[2] SPECIAL TOOLS FOR MACHINE ...............................................................................G-45
9. TIRES................................................................................................................................G-46
[1] TIRE PRESSURE...........................................................................................................G-46
[2] TREAD.............................................................................................................................G-46
10.IMPLEMENT LIMITATIONS .............................................................................................G-47
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GR1600EC, WSM GENERAL
G-1
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 (4) Hour Meter
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GR1600EC, WSM GENERAL
G-2
2. GENERAL PRECAUTIONS
ADuring 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.
AWhen special tools are required, use KUBOTA genuine
special tools. Special tools which are not frequently used
should be made according to the drawings provided.
ABefore disassembling or servicing electrical wires, always
disconnect the ground cable from the battery first.
ARemove oil and dirt from parts before measuring.
AUse only KUBOTA genuine parts for parts replacement to
maintain machine performance and to assure safety.
AGaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
See the figure left side.
AWhen 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.
AWhen inserting spring pins, their splits must face the direction
from which a force is applied. See the figure left side.
ATo prevent damage to the hydraulic system, use only specified
fluid or equivalent.
(1) Grease (A) External Snap Ring
(2) Force (B) Internal Snap Ring
(3) Sharp Edge
(4) Axial Force
(5) Rotating Movement
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GR1600EC, WSM GENERAL
G-3
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.
ACheck 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.
ADo not attempt to modify or remodel any electrical parts
and wiring.
AWhen removing the battery cables, disconnect the
negative cable first. When installing the battery cables,
connect the positive cable first.
[1] WIRING
ASecurely tighten wiring terminals.
ADo not let wiring contact dangerous part.
ASecurely insert grommet.
(1) Negative Terminal (2) Positive Terminal
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(1) Correct (2) Incorrect
(Securely Tighten) (Loosening Leads to Faulty
Contact)
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(1) Dangerous Part (3) Wiring (Correct)
(2) Wiring (Incorrect) (4) Dangerous Part
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(1) Grommet (A) Correct
(B) Incorrect
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GR1600EC, WSM GENERAL
G-4
ASecurely clamp, being careful not to damage wiring.
AClamp wiring so that there is no twist, unnecessary sag, or
excessive tension, except for movable part, where sag be
required.
AIn installing a part, take care not to get wiring caught by it.
AAfter installing wiring, check protection of terminals and
clamped condition of wiring, only connect battery.
(1) Clamp (3) Clamp
*Wind Clamp Spirally (4) Welding Dent
(2) Wire Harness
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(1) Wiring (A) Correct
(2) Clamp (B) Incorrect
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(1) Wiring (A) Incorrect
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(1) Cover
*Securely Install Cover
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GR1600EC, WSM GENERAL
G-5
[2] BATTERY
ATake care not to confuse positive and negative terminal posts.
AWhen removing battery cables, disconnect negative cable
first. When installing battery cables, check for polarity and
connect positive cable first.
ADo not install any battery with capacity other than is specified
(Ah).
AAfter connecting cables to battery terminal posts, apply high
temperature grease to them and securely install terminal
covers on them.
ADo not allow dirt and dust to collect on battery.
ATake care not to let battery liquid spill on your skin and
clothes. If contaminated, wash it off with water
immediately.
ABefore recharging the battery, remove it from the
machine.
ABefore recharging, remove cell caps.
ADo recharging in a well-ventilated place where there is no
open flame nearby, as hydrogen gas and oxygen are
formed.
[3] FUSE
AUse fuses with specified capacity.
Neither too large or small capacity fuse is acceptable.
ANever use steel or copper wire in place of fuse.
ADo not install working light, radio set, etc. on machine which is
not provided with reserve power supply.
ADo not install accessories if fuse capacity of reserve power
supply is exceeded.
[4] CONNECTOR
AFor connector with lock, push lock to separate.
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(1) Fuse (2) Fusible Link
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(A) Push
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GR1600EC, WSM GENERAL
G-6
AIn separating connectors, do not pull wire harnesses.
AHold connector bodies to separate.
AUse sandpaper to remove rust from terminals.
ARepair deformed terminal. Make certain there is no terminal
being exposed or displaced.
AMake certain that there is no female connector being too open.
AMake certain plastic cover is large enough to cover whole
connector.
(A) Correct (B) Incorrect
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(1) Exposed Terminal (3) Sandpaper
(2) Deformed Terminal (4) Rust
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(A) Correct (B) Incorrect
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(1) Cover (A) Correct
(B) Incorrect
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GR1600EC, WSM GENERAL
G-7
[5] HANDLING OF CIRCUIT TESTER
AUse tester correctly following manual provided with tester.
ACheck for polarity and range.
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