Kubota G2160, G2160-R48S, G2460G Workshop Manual
WORKSHOP MANUAL
KiSC issued 11, 2006 A
TRACTOR
G2160,G2160-R48S,G2460G
TO THE READER
KiSC issued 11, 2006 A
This WORKSHOP MANUAL has been prepa re d to provi de se rvi cing per sonnel with
information on the mechanism, service and maintenance of KUBOTA G2160. It is
divided into two parts, “MECHANISM” and “SERVICING” for each section except
“ENGINE” section.
■ MECHANISM
Information on the construction and function are included. This information should be
understood before proceeding with troubleshooting, disassembling and servicing.
■ SERVICING
The heading “GENERAL” includes general precautions, check and maintenance and
special tools. Other section, there are troubleshooting, servicing specification lists,
checking and adjusting, disassembling and assembling, and servicing which cover
procedures, precautions, factory specifications and allowable limits.
All information il lustr ati ons an d spec i fic ati ons c ont ain ed i n th is man ual ar e b ased 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.
December 2000
© KUBOTA Corporation 2000
G2160, WSM
SAFETY FIRST
KiSC issued 11, 2006 A
SAFETY INSTRUCTIONS
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.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
■ IMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
■ NOTE : Gives helpful information.
BEFORE SERVICING AND REPAIRING
• Read all instructions and safety instructions in this
manual and on your generator safety decals.
• Clean the work area and machine.
• Park the machine on a firm and level ground, and set
the parking brake.
• Lower the implement to the ground.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “DO NOT OPERATE” tag in operator
station.
1
G2160, WSM
KiSC issued 11, 2006 A
SAFETY INSTRUCTIONS
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Do not alter or remove any part of machine safety
system.
• Before starting the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
• Never start the engine while standing on ground.
Start the engine only from operator’s seat.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication , or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not work under the machine that is supported
solely by a jack. Always support the machine by
safety stands.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) un der pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of b attery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.
2
G2160, WSM
KiSC issued 11, 2006 A
SAFETY INSTRUCTIONS
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated . Neve r run the eng ine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
PREVENT ACID BURNS
• Sulfuric acid in batte ry electrolyte is poisonou s. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
DISPOSE OF FLUIDS PROPERLY
• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental prot ectio n regulati ons whe n disp osing
of oil, fuel, coolant, electrolyte and other harmful
waste.
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extingui sher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
3
G2160, WSM
KiSC issued 11, 2006 A
SAFETY INSTRUCTIONS
SAFETY DECALS
● The following safety decals are installed on the machine.
If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is
listed in the parts list.
4
G2160, WSM
KiSC issued 11, 2006 A
SAFETY INSTRUCTIONS
5
G2160, WSM
KiSC issued 11, 2006 A
SAFETY INSTRUCTIONS
6
G2160, WSM
KiSC issued 11, 2006 A
SAFETY INSTRUCTIONS
7
G2160, WSM
KiSC issued 11, 2006 A
SPECIFICATIONS
Model G2160
Maximum gross power 15.6 kW (21 HP)
Model D782-E-G21
Type Indirect injection, vertical, water cooled, 4-cycle diesel engine
Number of cylinders 3
Bore and stroke 67.0 × 73.6 mm (2.64 × 2.90 in.)
Total displacement 778 cm
Rated revolution 3000 rpm
Combustion chamber Spherical type (E-TVCS)
Fuel injection pump Bosch MD type mini pump
Governor Centrifugal ball mechanical governor
Injection nozzle Bosch throttle type
Engine
Capacities
Tires
Travelling
speeds
Dimensions
Weight (Without mower deck and grass
collecter)
PTO Belt drive
PTO clutch Belt tension
Revolution (PTO speed) 2576 rpm
PTO brake Available
Injection timing 0.33 to 0.37 rad. (19° to 21°) before T.D.C.
Injection order 1-2-3
Injection pressure 13.73 MPa (140 kgf/cm
Compression ratio 23 : 1
Lubricating system Forced Iubrication by gear pump
Cooling system Pressurized radiator, forced circulation with water pump
Lubricating oil API Service classification CCor CD, Below 0°C (32 °F) : SAE 10W or 10W-30, 0 to 25 °C
Starting system Electric starter (12 V, 1.0 kW)
Battery 51R (12V, 450CCA)
Fuel No.2-D Diesel fuel (ASTM D975)
Fuel tank 22L (5.8U.S.gals., 4.8 lmp. gals.)
Engine crankcase 2.8L (2.95 U.S.qts., 2.4 Imp.qts.)
Engine coolant 2.1L (2.2 U.S.qts., 1.8 Imp.qts.)
Recovery tank 0.25 L (0.26 U.S.qts., 0.22 Imp.qts.)
Transmission (Including
HST and cylinder)
Mower gear case oil 0.40L (0.42 U.S.qts., 0.35 Imp.qts.)
Front 16 × 6.50-8 (4PR) Turf
Rear 23 × 10.5-12 (4PR) Turf
Forward 0 to 15.0 km/h (0 to 9.3 mph)
Reverse 0 to 6.0 km/h (0 to 3.8 mph)
Overall length 1885 mm (74.2 in.)
Overall width (With mower) 1843 mm (72.6 in.)
Overall height 1280 mm (50.4 in.)
Wheel base 1290 mm (50.8 in.)
Treads
Front 825 mm (32.5 in.)
Rear 780 mm (30.7 in.)
(32 °F to 77 ° F) : SAE 20 or 10W-30, Above 25 °C (77 °F) : SAE 30 or 10W-30
[No.1-D diesel fuel, if temperature is below - 10 °C (14 °F)]
4.5L (4.75 U.S.qts., 3.86 Imp.qts.)
3
(47.48 cu.in.)
430 kg (948 lbs)
2
, 1990 psi)
SPECIFICATIONS
W1028929
8
G2160, WSM
KiSC issued 11, 2006 A
Model G2160
Steering Electric power steering (EPS)
Transmission Hydrostatic transmission
Brake Internal expanding brake
Model RCK54-24G RCK60B-24G
Total length 946 mm (37.2 in.) 992 mm (39.1 in.)
Total width 1690 mm (66.5 in.) 1843 mm (72.5 in.)
Total height 273 mm (10.7 in.)
Mounting method Quick joint, parallel linkage
Mower
The company reserves the right to change the specifications without notice.
Adjustment of cutting height Dial gauge
Cutting width 1372 mm (54 in.) 1524 mm (60 in.)
Cutting height 25 to 102 mm (1.0 to 4.0 in.)
Number of blades 3
Weight (Approx.) 95 kg (209 lbs) 110 kg (243 lbs)
Discharge Right side
SPECIFICATIONS
W1030228
9
G2160, WSM
KiSC issued 11, 2006 A
DIMENSIONS
DIMENSIONS
10
G GENERAL
KiSC issued 11, 2006 A
GENERAL
KiSC issued 11, 2006 A
CONTENTS
1. FEATURES......................................................................................................G-1
2. IDENTIFICATION............................................................................................. G-2
3. GENERAL PRECAUTIONS ............................................................................ G-3
4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING..G-4
[1] WIRING...................................................................................................... G-4
[2] BATTERY................................................................................................... G-6
[3] FUSE.......................................................................................................... G-6
[4] CONNECTOR............................................................................................ G-6
[5] HANDLING OF CIRCUIT TESTER......................................................... G-7
5. LUBRICANTS, FUEL AND COOLANT ......................................................... G-8
6. 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
7. MAINTENANCE CHECK LIST..................................................................... G-11
8. CHECK AND MAINTENANCE............... ...... ....... ......................................... G-12
[1] DAILY CHECK........................................................................................ G-12
[2] CHECK POINTS OF INITIAL 50 HOURS........................................... G-17
[3] CHECK POINTS OF EVERY 50 HOURS........................................... G-19
[4] CHECK POINTS OF EVERY 100 HOURS......................................... G-23
[5] CHECK POINTS OF EVERY 150 HOURS ....................................... G-25
[6] CHECK POINTS OF EVERY 200 HOURS........................................ G-25
[7] CHECK POINTS OF EVERY 300 HOURS......................................... G-26
[8] CHECK POINTS OF EVERY 500 HOURS......................................... G-27
[9] CHECK POINTS OF EVERY 1 YEAR ................................................ G-28
9. SPECIAL TOOLS.......................................................................................... G-33
[1] SPECIAL TOOLS FOR ENGINE .......................................................... G-33
[2] SPECIAL TOOLS FOR MACHINE........................................................ G-39
10. IMPLEMENT LIMITATIONS.......................................................................... G-43
G2160, WSM
KiSC issued 11, 2006 A
1. FEATURES
G GENERAL
1. E-TVCS engine
2. Front PTO (option)
3. Rugged ladder type chassis
4. Low-noise, high-performance mower
5. Large-capacity fuel tank
6. Hydraulic mower lift
G-1
G2160, WSM
KiSC issued 11, 2006 A
2. IDENTIFICATION
G GENERAL
When contacting your local KUBOTA distributor, always specify
engine serial numb er (1), machine seria l number (2), mower ser ial
number (3) and hour meter reading.
(1) Engine Serial Number
(2) Machine Serial Number
(3) Mower Serial Number
(4) Hour Meter
W1010714
G-2
G2160, WSM
KiSC issued 11, 2006 A
3. GENERAL PRECAUTIONS
• During disasse mbly, care fully arrang e removed pa rts in a clean
area to prevent confusion later. Screws, bolts and nuts should be
installed in their original position to prevent reassembly errors.
• When special tools are requir ed, use KUBOTA ge nuine special
tools. Special tools which are not frequently used should be
made according to the drawings provided.
• Before disassembling or servicing electrical wires, always
disconnect the ground cable from the battery first.
• Remove oil and dirt from parts before measuring.
• Use only KUBOTA genuine parts for parts replacement to
maintain machine performance and to assure safety.
• Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
See the figure left side.
• When reassemblin g external snap rings or internal snap rings,
they must be po sitioned so that sharp edge fa ces against the
direction from which a force is applied. See the figure left side.
• When inserting sp ring pins, their splits must face the direct ion
from which a force is applied. See the figure left side.
• To prevent dama ge to the hydrauli c system, use only s pecified
fluid or equivalent.
(1) Grease
(2) Force
(3) Sharp Edge
(4) Axial Force
(5) Rotating Movement
G GENERAL
(A) External Snap Ring
(B) Internal Snap Ring
W1010904
G-3
G2160, WSM
IMPORTANT■
KiSC issued 11, 2006 A
G GENERAL
4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS
AND WIRING
To ensure safety and prevent damage to the machine and
surrounding equipm ent, heed the fo llowing prec autions in hand ling
electrical parts and wiring.
• Check electrical wiring for damage and loosened
connection every year. To this end, educate the customer to
do his or her own check an d at the same time recommend
the dealer to perform periodic check for a fee.
• Do not attempt to modify or remodel any electrical parts and
wiring.
• When removing the battery cables, disconnect the negative
cable first. When installing the battery cables, connect the
positive cable first.
(1) Negative Terminal (2) Positive Terminal
W1011114
[1] WIRING
• Securely tighten wiring terminals.
(1) Correct
(Securely tighten)
(2) Incorrect
(Loosening leads to faulty contact)
W1011216
• Do not let wiring contact dangerous part.
(1) Dangerous Part
(2) Wiring (Incorrect)
(3) Wiring (Correct)
(4) Dangerous Part
• Securely insert gro mm et.
(1) Grommet (A) Correct
(B) Incorrect
W1011313
W1011388
G-4
G2160, WSM
KiSC issued 11, 2006 A
G GENERAL
• Securely clamp, being careful not to damage wiring.
(1) Clamp
• Wind Clamp Spirally
(2) Wire Harness
(3) Clamp
(4) Welding Dent
W1011458
• Clamp wiring so that there is no twist, unnecessary sag, or
excessive tension, except for movable part, where sag be
required.
(1) Wiring
(2) Clamp
(A) Correct
(B) Incorrect
W1011587
• In installing a part, take care not to get wiring caught by it.
(1) Wiring (A) Incorrect
W1011670
• After installing wiring, check protection of terminals and clamped
condition of wiring, only connect battery.
(1) Cover
• Securely Install Cover
W1011735
G-5
G2160, WSM
KiSC issued 11, 2006 A
[2] BATTERY
[3] FUSE
G GENERAL
• Take care not to confuse positive and negative terminal posts.
• When removing battery cables, disconnec t negative cable first.
When installing battery cables, check for polarity and connect
positive cable first.
• Do not inst all any battery with capacity other th an is specified
(Ah).
• After connecting cables to battery terminal posts, apply high
temperature greas e to them and se curely instal l term inal co vers
on them.
• Do not allow dirt and dust to collect on battery.
CAUTION
• Take care not to let battery liquid spill on your skin and
clothes. If contaminated, wash it off with water immediately.
• Before recharging the battery, remove it from the machine.
• Before recharging, remove cell caps.
• Do recharging in a we ll-ventilated place where there is no
open flame nearby, as hydrogen gas and oxygen are formed.
W1011816
[4] CONNECTOR
• Use fuses with specified capacity.
Neither too large or small capacity fuse is acceptable.
• Never use steel or copper wire in place of fuse.
• Do not install working light, radio set, etc. on machine which is not
provided with reserve power supply.
• Do not install accessories if fuse capacity of reserve power
supply is exceeded.
(1) Fuse (2) Slow Blow Fuse
W1012092
• For connector with lock, push lock to separate.
(A) Push
W1012211
• In separating connectors, do not pull wire harnesses.
• Hold connector bodies to separate.
(A) Correct (B) I ncorrect
W1012272
G-6
G2160, WSM
KiSC issued 11, 2006 A
G GENERAL
• Use sandpaper to remove rust from terminals.
• Repair deformed terminal. Make certain there is no terminal
being exposed or displaced.
(1) Exposed Terminal
(2) Deformed Terminal
(3) Sandpaper
(4) Rust
W1012346
• Make certain that there is no female connector being too open.
(A) Correct (B) Incorrect
W1012430
• Make certain plastic cover is large enough to cover whole
connector.
(1) Cover (A) Correct
[5] HANDLING OF CIRCUIT TESTER
• Use tester correctly following manual provided with tester.
• Check for polarity and range.
(B) Incorrect
W1054624
W1012684
G-7
G2160, WSM
KiSC issued 11, 2006 A
5. LUBRICANTS, FUEL AND COOLANT
G GENERAL
Place
1Fuel
Cooling
system
2 Coolant
Recovery
tank
3 Engine crankcase
Transmission (Including
4
HST & cylinder)
5 Mower gear case
King pin (Left and right)
Center pin
PTO tension arm
6
Universal joint
Side blade shaft
Center blade shaft
Mower tension arm
Speed control pedal shaft
Lift lever shaft
Brake pedal shaft
7
PTO lever fulcrum
Anti-scalp roller
Speed control link
Accelerator cable
Capacity
G2160
22 L
5.8 U.S.gals
4.8 Imp.gals
2.1 L
2.2 U.S.qts
1.8 Imp.qts
0.25 L
0.26 U.S.qts
0.22 Imp.qts
2.8 L
2.95 U.S.qts
2.4 Imp.qts
4.5 L
4.75 U.S.qts
3.86 Imp.qts
0.40 L
0.42 U.S.qts
0.35 Imp.qts
Until grease overflows SAE multipurpose type grease
Moderate amount Oil or spray type grease
[ASTM D975]
No. 2-D diesel fuel
No. 1-D diesel fuel if temperature is below
−10 °C (14 °F)
Fresh clean water (soft water) with anti-freeze
Engine oil : MIL-L-46152, MIL-L-2104C,
API Service Classification
CC or CD
Below 0 °C (32 °F) : SAE10W or 10W-30
0 to 25 °C (32 to 77 °F): SAE20 or 10W-30
Above 25 °C (77 °F): SAE30 or 10W- 30
KUBOTA UDT or SUPER UDT fluid
SAE #90 gear oil
Lubricants
G-8
G2160, WSM
KiSC issued 11, 2006 A
G GENERAL
6. TIGHTENING TORQUES
[1] GENERAL USE SCREWS, BOLTS AND NUTS
Screws, bolts, and nuts whose tightening torques are not specified in this Workshop Manual should be
tightened according to the table below.
Indication on top of
bolt
Material of bolt SS400, S20C S43C, S48C
Material of opponent
part
Unit
Diameter
M6
(6 mm, 0.24 in.)
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
M14
(14 mm, 0.55 in.)
M16
(16 mm, 0.63 in.)
M18
(18 mm, 0.71 in.)
M20
(20 mm, 0.79 in.)
No-grade or 4T 7T 9T
SCr435,
SCM435
Ordinariness Aluminum Ordinariness Aluminum Ordinariness
N·m kgf·m ft-lbs N·m kgf·m ft-lbs N·m kgf·m ft-lbs N·m kgf·m ft-lbs N·m kgf·m ft-lbs
7.85
0.80
5.79
7.85
0.80
5.79
9.81
1.00
7.24
7.85
0.80
5.79
12.3
to
9.31
17.7
to
20.5
39.3
to
45.1
62.8
to
72.5
108
to
125
167
to
191
246
to
284
334
to
392
to
0.95
1.8
to
2.1
4.0
to
4.6
6.4
to
7.4
11.0
to
12.8
17.0
to
19.5
25.0
to
29.0
34.0
to
40.0
to
6.87
13.1
to
15.1
29.0
to
33.2
46.3
to
53.5
79.6
to
92.5
123
to
141
181
to
209
246
to
289
to
to
to
8.82
0.90
6.50
16.7
19.6
31.4
34.3
1.7
12.3
to
to
2.0
3.2
to
3.5
–––
–––
–––
–––
–––
to
14.4
23.2
to
to
25.3
to
11.2
23.6
to
27.4
48.1
to
55.8
77.5
to
90.2
124
to
147
197
to
225
275
to
318
368
to
431
to
1.15
2.4
to
2.8
4.9
to
5.7
7.9
to
9.2
12.6
to
15.0
20.0
to
23.0
28.0
to
32.5
37.5
to
44.0
to
8.31
17.4
to
20.2
35.5
to
41.2
57.2
to
66.5
91.2
to
108
145
to
166
203
to
235
272
to
318
to
to
to
8.82
0.90
6.50
17.7
20.5
39.3
44.1
62.8
72.5
1.8
13.1
to
to
2.1
4.0
to
4.5
6.4
to
7.4
–––
–––
–––
–––
to
15.1
29.0
to
to
32.5
46.3
to
to
53.5
to
14.2
29.5
to
34.3
60.9
to
70.6
103
to
117
167
to
196
260
to
304
344
to
402
491
to
568
1.25
to
1.45
3.0
to
3.5
6.2
to
7.2
10.5
to
12.0
17.0
to
20.0
26.5
to
31.0
35.0
to
41.0
50.0
to
58.0
W1034542
9.05
to
10.4
21.7
to
25.3
44.9
to
52.0
76.0
to
86.7
123
to
144
192
to
224
254
to
296
362
to
419
[2] METRIC SCREWS, BOLTS AND NUTS
Grade
Unit
Nominal
Diameter
M 8 23.6 to 27.4 2.4 to 2.8 17.4 to 20.2 29.4 to 34.3 3.0 to 3.5 21.7 to 25.3
M 10 48.1 to 55.8 4.9 to 5.7 35.5 to 41.2 60.8 to 70.5 6.2 to 7.2 44.9 to 52.1
M 12 77.5 to 90.1 7.9 to 9.2 57.2 to 66.5 103.0 to 117.0 10.5 to 12.0 76.0 to 86.8
M 14 124.0 to 147.0 12.6 to 15.0 91.2 to 108.0 167.0 to 196.0 17.0 to 20.0 123.0 to 144.0
M 16 196.0 to 225.0 20.0 to 23.0 145.0 to 166.0 260.0 to 303.0 26.5 to 31.0 192.0 to 224.0
Property class 8.8 Property class 10.9
N·m kgf·m ft-lbs N·m kgf·m ft-lbs
W1016172
G-9
G2160, WSM
KiSC issued 11, 2006 A
G GENERAL
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR
UNF THREADS
Grade
Unit
Nominal 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
3/8 47.5 to 57.0 4.84 to 5.82 35.0 to 42.0 61.0 to 73.2 6.22 to 7.47 45.0 to 54.0
1/2 108.5 to 130.2 11.07 to 13.29 80.0 to 96.0 149.2 to 179.0 15.22 to 18.27 110.0 to 132.0
9/16 149.2 to 179.0 15.22 to 18.27 110.0 to 132.0 217.0 to 260.4 22.14 to 26.57 160.0 to 192.0
5/8 203.4 to 244.1 20.75 to 24.91 150.0 to 180.0 298.3 to 358.0 30.44 to 36.53 220.0 to 264.0
SAE GR.5 SAE GR.8
N·m kgf·m ft-lbs N·m kgf·m ft-lbs
W1022485
G-10
G2160, WSM
IMPORTANT■
KiSC issued 11, 2006 A
7. MAINTENANCE CHECK LIST
G GENERAL
Period
No.
Item
1 Tires Check ✩ Every 50 Hr G-19
2 Batte ry condition Check ✩✩✩✩✩Every 100 Hr G-24
3 Engine oil Change ★✩ ✩✩✩ ✩Every 100 Hr G-17
4 Engine oil filter cartridge Change ★✩✩Every 200 Hr G-18
5 Transmission fluid Change ✩✩Every 300 Hr G-26
6 Transmission oil filter cartridge Replace ★✩ ✩Every 300 Hr G-18
7 Transmission oil strainer Clean ✩✩Every 300 Hr G-27
Hydraulic hose
8
Fuel lines
9
10 Fuel filter
11 Radiator hose and clamp
Check ✩✩ Every 200 Hr G-26
Replace Every 2 Years* G-30
Check ✩✩✩✩✩Every 100 Hr G-23
Replace
Check ✩✩✩✩✩Every 100 Hr G-23
Replace
Check ✩✩ Every 200 Hr G-25
Replace
Every 50 Hr
50 100 150 200 300 400 450 500 After
1
1
1
Hour meter reading
Reference
page
Every 2 Years* G-30
✩ Every 500 Hr G-27
Every 2 Years* G-30
12 Radiator core Clean ✩✩✩✩✩Every 100 Hr** G-23
13 Cooling system Clean Every 1 Year G -28
14 Coolant Change Every 1 Year G -28
15 Air cleaner element
16 Fan belt tension Adjust ✩ G-20
17 Front PT O belt tension Adjust ✩*** G-22
18 Brake play Adjust
19 Greasing – ✩ G-20
20 Mower gear box oil Change ★✩✩✩Every 150 Hr G-18
21 Mower gear box oil seal Replace Every 2 Years* G-31
★ : The maintenance indicated by ★ must be d one initially.
* : Replace only if necessary.
** : This maintenance should be done more often in dusty conditions than in normal conditions.
*** : Initial elongat ion of the front PTO belt may occur prior to 25 hours. Adjust the tension spring len gth as needed to maintain belt
tension.
1
: These items should be serviced by an authorized KUBOTA Dealer, unless the owner has the proper tools and is mechanically
proficient.
Clean ✩** G-21
Replace Every 1 Year** G-28
1
✩ G-19
W1035769
G-11
G2160, WSM
KiSC issued 11, 2006 A
G GENERAL
8. CHECK AND MAINTENANCE
CAUTION
• Be sure to check and serv ice the machine on a flat p lace with engine shut off, the parking brake on and
chock the wheels.
[1] DAILY CHECK
To prevent trouble from o cc uri ng, it is im por ta nt t o k now the co ndi ti on o f th e m ac hin e. Chec k th e fo ll owin g i tem s
before starting.
Checking
• Check areas where previous trouble was experienced.
• Walk around the machine.
1. Oil and water leak
2. Engine oil level
3. Coolant level in the recovery tank
4. Damage of machine body, tightness of all bolts and nuts
5. Radiator screen
6. Panel screen
7. Air cleaner
8. Oiling
•Mower
1. Make sure blade bolts are tight.
2. Check blades for wear or damage.
3. Check all hardware.
4. Make sure all pins are in place.
• While sitting in the operator’s seat,
1. Speed control pedal
2. Brake pedal
3. Parking brake
• Turning the key switch “ON”
1. Head lights
• Starting the engine,
1. Color of the exhaust fumes
2. If either of safety start switch and seat safety control do not operate properly, contact your KUBOTA Dealer
immediately.
3. Check for abnormal noise and vibration.
4. Check Easy checker
TM
.
G-12
G2160, WSM
■
KiSC issued 11, 2006 A
G GENERAL
Checking Engine Oil Level
CAUTION
• To avoid personal injury : Always stop the engine and
remove the key before checking oil.
1. Check engine oil before starti ng and 5 minut es or more afte r the
engine has stopped.
2. Wipe dipstick area clean.
3. To check the oil level, remove the dipstick (2), wipe it clean,
replace it, and draw it out again. Check to see that the oil level is
between the two notches.
4. Add new oil to the prescribed level at the oil port if necessary.
IMPORTANT
• Use the specified engine oil.
Refer to “LUBRICANTS, FUEL AND COOLING WATER”.
(See page G-8)
• When using new oil of a different maker or viscosity from the
previous one, drain all used oil.
Never mix two different types of oil.
(1) Oil Inlet Plug
(2) Dipstick
(A) Upper Level
(B) Lower Level
W1021025
G-13
G2160, WSM
IMPORTANT■
NOTE■
KiSC issued 11, 2006 A
G GENERAL
Checking Amount of Fuel and Refueling
CAUTION
• Handle fuel carefully. If the engine is running, do not fill the
fuel tank. If engine is hot, let engine cool several minutes
before adding fuel. Do not smoke while filling the fuel tank
or servicing the fuel system. Fill fuel tank only to bottom of
filler neck.
1. Check the fuel leve l.
2. Take care that the fuel tank does not become empty.
Fuel tank capacity 22 L (5.8 U.S.gal.)
• Use diesel fuel only
1. Use No.2 diesel fuel.
2. Use No.1 diesel fuel if the temperature is below –10 °C (14 °F).
3. Always use a strainer when refueling to prevent fuel injection
pump contamination.
• No.2-D is a distillate fuel of lower volatility for engines in
industrial and heavy mobile service.
(SAE J313 JUN87)
Grade of diesel fuel oil according to ASTM D975
Flash Point
°C (°F)
Min Max Max Max
52
(125)
Water and
Sediment,
volume %
0.05 0.35 0.01
Carbon Residue
on, 10 percent
Residuum, %
Ash, weight %
Distillation
Temperatures
°C (°F)
90 % Point
Min Max Min Max Min Max Max Max Min
282
(540)
338
(640)
Viscosity
Kinematic
cSt or mm
at 40 °C
1.9 4.1 32.6 40.1 0.50 No.3 40
Viscosity
2
saybolt,
/s
SUS
at 100 °F
Sulfur,
weight
%
Copper
strip
Corrsion
Catane
Number
W1021324
G-14
G2160, WSM
IMPORTANT■
NOTE■
KiSC issued 11, 2006 A
G GENERAL
Radiator Screen and Panel Screen
Daily or after every 5 hours of operation, c heck to be sure the
radiator screen (1) and p anel sc reen (2) are clean . Dirt or c haff on
the radiator screen (1) or radiator core decrease cooling
performance.
1. Remove the radiator screen (1) and remove all foreign material.
2. Remove the dust from between the fins and the tube.
3. If scale forms in the tube, clean with scale inhibitor or its
equivalent.
4. Each time the panel screen is covered with grass during
operation, wipe off the screen with hand. Check the radiator
screen (1) from time to time if grass often gets on it.
5. If dust or chaff is accumulated inside of the panel, clean the
inside of the panel.
• Be sure to stop the engine before cleaning the radiator
screen.
(1) Radiator Screen (2) Panel Screen
W1022263
Retightening Mower Blade Screw
CAUTION
• To avoid injury, always handle the mower blade with care.
1. Dismount the mower and turn it over to expose the mower
blades.
2. Wedge a woode n block (1) sec urely between the mower blade
and mower deck.
3. Retighten the mower blade screw to the specified torque.
4. If the mower blade screw (2) is worn or broken, replace it.
88.2 to 117.6 N·m
Tightening torque Mower blade screw
9.0 to 12.0 kgf·m
65.1 to 86.8 ft-lbs
(1) Wooden Block
(2) Mower Blade Screw
(A) “LOOSEN”
(B) “TIGHTEN”
W1022525
Checking Mower Blade
1. Check the cutting edge of mower blade.
2. Sharpen the cutti ng edg es , if the mo wer b lad es are as s hown in
figure (2).
3. Replace the mower blades, if they are as shown in figure (3).
• To sharpen the mower blades by yourself, clamp the mower
blade securely in a vise and use a la rge mill file along the
original bevel.
• To balance the mower blade, place a small rod through the
center hole and check to see if the blade balances
evenly.File heavy side of the blade until it balance out even.
(1) New Blade
(2) Worn Blade
(3) Cracked Blade
W1022841
G-15
G2160, WSM
■
KiSC issued 11, 2006 A
G GENERAL
Oiling
CAUTION
• Be sure to stop the engine and remove the key before oiling.
Oil the following points before starting.
NOTE
• Oil these points on both sides of the machine.
1. Apply oil to the following points.
(1) Link Fulcrum
(2) PTO Lever (Fulcrum) and PTO cable
(3) Front PTO Cable
(4) Brake Pedal
(5) Seat Adjuster
(6) Speed Control Pedal Shaft
(7) Throttle Cable
(8) Mower Univerdsl Joint
(9) Front Link
W1030315
G-16
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