Kubota G2160, G2160-R48S, G2460G Workshop Manual

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Page 1

WORKSHOP MANUAL

KiSC issued 11, 2006 A

TRACTOR

G2160,G2160-R48S,G2460G

Page 2

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

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G2160, WSM

SAFETY FIRST

KiSC issued 11, 2006 A

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.

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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.

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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.

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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.

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G2160, WSM

KiSC issued 11, 2006 A

SAFETY INSTRUCTIONS

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G2160, WSM

KiSC issued 11, 2006 A

SAFETY INSTRUCTIONS

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G2160, WSM

KiSC issued 11, 2006 A

SAFETY INSTRUCTIONS

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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.)

(47.48 cu.in.)

430 kg (948 lbs)

, 1990 psi)

SPECIFICATIONS

W1028929

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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

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G2160, WSM

KiSC issued 11, 2006 A

DIMENSIONS

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G GENERAL

KiSC issued 11, 2006 A

Page 14

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

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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

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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

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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

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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

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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

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[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

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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

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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

HST & cylinder)

5 Mower gear case

King pin (Left and right) Center pin PTO tension arm

Universal joint Side blade shaft Center blade shaft Mower tension arm Speed control pedal shaft Lift lever shaft Brake pedal shaft

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

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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

(6 mm, 0.24 in.)

(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

9.31

17.7 to

20.5

39.3 to

45.1

62.8 to

72.5

108

125 167

191 246

284 334

392

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

6.87

13.1 to

15.1

29.0 to

33.2

46.3 to

53.5

79.6 to

92.5

123

141 181

209 246

289

8.82

0.90

6.50

16.7

19.6

31.4

34.3

1.7

12.3

2.0

3.2

3.5

–––

14.4

23.2

25.3

11.2

23.6 to

27.4

48.1 to

55.8

77.5 to

90.2

124

147 197

225 275

318 368

431

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

8.31

17.4 to

20.2

35.5 to

41.2

57.2 to

66.5

91.2 to

108 145

166 203

235 272

318

8.82

0.90

6.50

17.7

20.5

39.3

44.1

62.8

72.5

1.8

13.1

2.1

4.0

4.5

6.4

7.4

–––

15.1

29.0

32.5

46.3

53.5

14.2

29.5 to

34.3

60.9 to

70.6

103

117 167

196 260

304 344

402 491

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

144 192

224 254

296 362

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

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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

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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

Fuel lines

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

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.

: 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

✩ G-19

W1035769

G-11

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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

G-12

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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

Page 28

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

(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

saybolt,

SUS

at 100 °F

Sulfur, weight

Copper

strip

Corrsion

Catane

Number

W1021324

G-14

Page 29

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

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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

Page 31

G2160, WSM

IMPORTANT■

KiSC issued 11, 2006 A

G GENERAL

(10) Around the hole of the Mower Link (11) Around the Link

[2] CHECK POINTS OF INITIAL 50 HOURS

Changing Engine Oil

CAUTION

• Be sure to stop the engine before changing oil.

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

2. Place an oil pan underneath the engine.

3. To drain the use d oil, r emove the drai n plug (1) at t he botto m of the engine and drain the oil completely.

4. Screw in the drain plug (1).

5. Fill new oil up to upper line on the dipstick (3).

(12) Pivo t of Mower Link (13) Pivo t of Liftarm

W1066546

• When using an oil of different manufacture or viscosity from the previous one, remove all of the old oil.

• Never mix two different type of oil.

• Use the proper SAE engine oil according to ambient temperatures. Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page G-8)

(1) Drain Plug (2) Oil Inlet Plug (3) Dipstick

(A) Upper Level (B) Lower Level

W1030749

G-17

Page 32

G2160, WSM

■

IMPORTANT■

■

KiSC issued 11, 2006 A

G GENERAL

Replacing Engine Oil Filter Cartridge

CAUTION

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

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

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

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

3. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

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

IMPORTANT

• To prevent serious damage to the engine, element of recommended type must be used. Use only a genuine KUBOTA filter or its equivalent.

W1030949

Replacing Transmission Oil Filter

CAUTION

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

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

1. The oil filter cartridge must be changed every 300 service hours.

2. Remove the oil filter cartridge with the filter wrench.

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

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

5. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

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

• To prevent serious damage to hydraulic system, the replacement filter must be a highly efficient, 10 μm filter. Use only a genuine KUBOTA filter or its equivalent.

(1) Transmission Oil Filter Cartridge (2) Screw

W1031068

Changing Mower Gear Box Oil

1. Dismount the mower, and place the mower on level ground.

2. Remove the oil inlet plug (2).

3. Remove the drain plug (1), and drain the used oil completely.

4. After draining the used oil, reinstall the drain plug (1).

5. Fill with new oil up to the specified level.

IMPORTANT

• Use the proper SAE Gear Oil.

• Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page G-8)

(1) Drain Plug (2) Oil Inlet Plug

W1031440

G-18

Page 33

G2160, WSM

KiSC issued 11, 2006 A

[3] CHECK POINTS OF EVERY 50 HOURS

Checking Tire Pressure

1. Check the wear and damage or tires.

2. Check the tire pressure.

3. If insufficient, add air. If excessive, reduce air.

Tire pressure

CAUTION

• Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure.

(1) Ground (A) Insufficient

Front

Rear

(B) Normal (C) Excessive

200 kPa

2.0 kgf/cm 28 psi

140 kPa

1.4 kgf/cm 20 psi

G GENERAL

W1068933

Adjusting Brake Play

CAUTION

• When making ad just ment s, park t he mach i ne o n a fl at a rea , block wheels, stop engine and remove the key.

1. If brake play is not correct, loose the lock nut (2) and turn the nut (3) in the desired direction until the proper play is achieved.

2. After adjustment, retighten lock nut securely.

Brake play 15 to 25 mm (0.59 to 0.98 in.)

(1) Brake Pedal (2) Lock Nut (3) Nut (4) Spring

(A) Brake Play

W1069219

G-19

Page 34

G2160, WSM

IMPORTANT■

KiSC issued 11, 2006 A

G GENERAL

Adjusting Fan Belt Tension

CAUTION

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

1. If the fan drive belt becomes loose, the engine may overheat.

2. To adjust, loosen bolts and turn the alternator to tighten the belt.

3. After adjustment, sec urel y tighten the bol ts.

Moderate belt tension :

The belt deflect app rox. 10 mm (0.4 in .) when the center of the

belt is depressed with finger pressure of 98 N (10 kgf, 22 lbs).

Fan belt tension Approx. 10mm (0.4 in.)

• When replacing fan belt, be careful not to catch it on the cap under the water pump. See the illustration to the left.

(1) Cap (2) Tension bolt (3) Alternator (4) Adjustment bolt

(A) Approx. 10 mm (0.4 in.)

W1069477

Greasing

CAUTION

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

1. Apply grease to the following points.

(1) King Pin (2) Center Pin (3) Mower Universal Joint (4) Machine Universal Joint (5) Grease Nipple (Spindle Shaft)

(6) Grease Nipple (Belt Tension Pulley) (7) Grease Nipple (Belt Tension Pivot)

W1069765

G-20

Page 35

G2160, WSM

NOTE■

KiSC issued 11, 2006 A

G GENERAL

(8) Grease Nipple (Balance Shaft)

(RCK60B-24G Only)

(9) Tension Lever

W1045060

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, u se clean and dry compr essed air on the inside of the elem ent. Air pre ssure shoul d not exceed 20 5 kPa

(2.1 kgf/cm

, 30 psi).

• Operating in dusty conditions requires frequent

maintenance.

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

W1070714

G-21

Page 36

G2160, WSM

■

KiSC issued 11, 2006 A

G GENERAL

Checking and Adjusting Front PTO Belt Tension

CAUTION

• Always stop the eng ine, set the parking brake, remove the key, and disengage the PTO lever before working on the front PTO.

If the front PTO belts slip when the PTO is operating under load,

check the front PTO belt tension and adjust the tension spring length, as explained below.

1. Engage the PTO lever.

2. Measure tension spring length L.

3. If L is shorter than 87 mm (3.43 in.), adjust it with the tension clutch cable adjusting nut.

• L should be 88 to 90 mm (3.47 to 3.54 in.).

4. After adjustment, tighten the nut securely.

• When replacing the new front P TO belts, L sho uld be 91 to 92 mm (3.58 to 3.62 in.).

IMPORTANT

• When replacing the front PTO belts, be sure to replace the complete set. These belts are a matched set.

Front PTO belt tension (L) 88 to 90 mm (3.47 to 3.54 in.)

W1034175

G-22

Page 37

G2160, WSM

IMPORTANT■

KiSC issued 11, 2006 A

[4] CHECK POINTS OF EVERY 100 HOURS

Changing Engine Oil

1. See page G-17.

Checking Fuel Lines And Fuel Filter

CAUTION

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

• Never fail to check the fuel lines p eriod ic ally . The fuel lines are subject to wear and age. Fuel may leak out onto the running engine, causing a fire.

The fuel line connections should be checked annually or every 100 service hours, whichever comes first.

1. The fuel lines i s made o f rubber a nd ages regardless of servi ce period.

2. If the fuel line and clam ps are found damages or deteriorated , replace them.

3. Check fuel filter, if it is clogged by debris, and replace it.

G GENERAL

W1034674

• When the fuel line is disconnected for maintenance or repair, close both ends of the fuel line with a piece of clean cloth or paper to prevent dust and dirt from entering. In addition, particular care must be taken not to admit dust and dirt into the fuel pump. Entrance of dust and dirt causes malfunction of the fuel pump.

(1) Pipe Clamps (2) Fuel Line

(3) Fuel Filter

W1034725

Checking Radiator Core

CAUTION

• Be sure to stop the engine before removing the screen.

1. Remove the radiator screen (1).

2. Check the radiator core (2) for the dust and chaff.

3. If the dust or chaff is accumlated, clean the radiator core completely. After cleaning, place the screens properly.

(1) Radiator Screen (2) Radiator Core

W1034897

G-23

Page 38

G2160, WSM

KiSC issued 11, 2006 A

G GENERAL

Checking Battery Condition

CAUTION

• Never remove the vent cap while the engine is running. Keep electrolyte away from eye s, hand s and clot hes . If you are spattered with it, wash it away completely with water immediately and get medical attention.

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

Mishandling the battery shortens the service life and adds to maintenance costs. The original battery is a maintenance-free, non accessible type battery. If the battery is weak, the engine wi ll be difficult to sta rt and the lights will become dim. It is important to check the battery periodically.

(1) Battery

W1035046

Battery Charging

DANGER

To avoid serious injury or death :

• When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.

CAUTION

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

• When disconnect ing the cables fro m the battery, start with the negative terminal first. When connecting the cables to the battery, start with the positive terminal first.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

(For accessible maintainable type batteries with removable vent

caps.)

(1) Vent well (2) Separator (3) Electrolyte

(A) HIGHEST LEVEL (B) LOWEST LEVEL

1. Make sure each electrolyte level is at the bottom of vent wells, if necessary add distilled water in a well-ventilated area.

2. The water in the electrolyte evaporates during recharging. Liquid shortage damage s the battery . Excessiv e liquid s pills over a nd damages the machine body.

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

4. A boost charge is only for emergencies. It will partially charge the battery at a higher rate and in a short time. When using a boost-charged battery, it is necessary to recharge the battery as soon as possible. Failure to do this will shorten the battery’s service life.

W1062448

G-24

Page 39

G2160, WSM

NOTE■

KiSC issued 11, 2006 A

5. When the specific gravity of electrolyte reaches 1.27 to 1.29, charge has completed.

6. When exchang ing an old battery with new o ne, use a b attery o f equal specification shown in “SPECIFICATIONS”. (For non-accessible maintenance-free type batteries.) Maintenance-free, non-accessible batteries are designed to eliminate the need to add water. Yet the volu me of electrolyte above plates may even tually becom e depleted d ue to abnor mal conditions such a s hi gh heat or imp roper reg ulator s etting . Use a voltmeter to check the state of charge. (See reference chart to determine if charging is necessary.)

[5] CHECK POINTS OF EVERY 150 HOURS

Changing Mower Gear Box Oil

1. See page G-18.

[6] CHECK POINTS OF EVERY 200 HOURS

Changing Engine Oil Fiter Cartridge

1. See page G-18.

Checking Radiator Hose and Clamp

G GENERAL

W1064359

W1036280

W1036341

• Check to see if the radiator hos es are properly fi xed every 200 hours of operation or 6 months, whichever comes first.

1. If clamp bands ( 2) are l oose or w ater leaks , tighten clamp band (2) securely.

2. Replace radiator hoses (1) and tighten clamp bands (2) securely, if radiator hoses (1) are swollen, hardened or cracked. Repalce radiator hoses (1) and clamp bands (2) every 2 years or earlier if checked and found that hoses are swollen, hardened or cracked.

• Take the following actions in the event the coolant temperature be nearly or more than the boiling point, what is called “Overheating”.

• Park the machine in a safe place and keep the engine unloaded idling.

• Don’t stop the engine suddenly, but stop it after about 5 minutes of unloaded idling

• Keep yourself well away from the machine for further 10 minutes or while the steam is belown out.

• Checking that there gets no danger such as burning, get rid of the causes of overheating and then start the engine again.

(1) Radiator Hose (2) Clamp Band

W1036392

G-25

Page 40

G2160, WSM

■

KiSC issued 11, 2006 A

Checking Hydraulic Hose

CAUTION

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

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

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

1. Check to s ee that all lines and hose clamps ar e tight and not damaged.

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

(1) Mower Lift Cylinder Hose

[7] CHECK POINTS OF EVERY 300 HOURS

Changing Transmission Fluid

CAUTION

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

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

G GENERAL

W1036641

1. Place the machine on level ground.

2. Remove the drain plug (1) and oil inlet plug (2), and drai n the used oil completely.

3. After draining the oil, reinstall the drain plug (1).

4. Fill with ne w oil up to the uppe r level (A) o n the oi l lev el dip stick (3).

5. After drain ing, disass emble and cl ean the stra iners and chan ge the oil filter cartridge. After reassembling, fill with UDT or SUPER UDT hydraulic transmission fluid, or its equivalent.

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

IMPORTANT

• Operate only at low RPM’s immediately after changing the transmission fluid and filter cartridge. Keep the engine at medium speed for a few minutes to insure proper lubrication of all parts so there is no damage to transmission.

(1) Drain Plug (2) Oil Inlet Plug (3) Oil Level Dipstick

(A) Upper Level (B) Lower Lev e l

W1036772

G-26

Page 41

G2160, WSM

KiSC issued 11, 2006 A

G GENERAL

Changing Transmission Oil Filter Cartridge

1. See page G-18.

W1036964

Cleaning Transmission Oil Strainer

CAUTION

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

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

1. Remove 2-M8 bolts.

2. Remove the suction pipe (1) with O ring (2).

3. Clean completely the oil strainer (3) with kerosene.

4. Install the suction pipe (1) with O ring (2).

5. Install the bolts.

(1) Suction Pipe (2) O-ring

(3) Oil Strainer

W1037015

[8] CHECK POINTS OF EVERY 500 HOURS

Replacing Fuel Filter

1. Replace the fuel filters (1).

(1) Fuel Filter

W1037174

G-27

Page 42

G2160, WSM

IMPORTANT■

KiSC issued 11, 2006 A

[9] CHECK POINTS OF EVERY 1 YEAR

Replacing Air Cleaner Element

1. Remove the air cleaner element (2) once a year.

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

• Do not run the engine with filter element removed.

• Be sure to refit the air cleaner cover (1) as shown in the figure. If the air cleaner cover (1) is improperly fitted, evacuator valve (3) will not function and dust will adhere to the element.

• If it is loose, dust and dirt may be sucked in, wearing down the cylinder and piston rings earlier and thereby resulting in poor power output.

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

Flushing Cooling System and Changing Coolant

CAUTION

• Never open radiator cap when engine is hot.

• When opening, loosen cap slightly to the stop to relieve any excess pressure before removing radiator cap completely.

G GENERAL

(3) Evacuator Valve

W1037268

1. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain plug (3) and engine drain plug (4) and rem ove t he ra diator cap (1). The r adiato r cap (1) must be removed to completely drain the coolant.

3. After all coolant is drained, fill with clean water and cooling system cleaner.

4. Follow directions of the cleaner instruction.

5. After flushing, fill with clean water and anti-freeze until the coolant level is just below the port.

6. Fill with cle an water and anti-fr eeze upper lev el of the recovery tank (2).

7. Start and operate the engine for few minutes.

8. Stop the engine. Check coolant level and add coolant if necessary.

9. Install the radiator cap (1) securely.

• Do not start engine without coolant.

• Use clean, fresh water and anti-freeze to fill the radiator and recovery tank. Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page G-8)

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

• Securely tighten the radiator cap (1). If the cap is loose or improperly fitted, water may lead out and the engine could overheat.

(1) Radiator Cap (2) Recovery Tank (3) Radiator Drain Plug (4) Engine Drain Plug

(A) Highest Level (B) Lowest Level

W1037402

G-28

Page 43

G2160, WSM

NOTE■

KiSC issued 11, 2006 A

G GENERAL

Flushing Cooling System and Changing Coolant (Continued)

■ Anti-Freeze

If cooling water freezes, the cylinders and radiator can be damaged. It is necessary, if the ambient temperature falls below 0 °C (32 °F), to remove c ooling wa ter mix it with anti-freez e and full the radiator with it.

1. There are two types of anti- freeze availab le; use the perma nent type (PT) for this engine.

2. Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh water and draining it a few times.

3. The procedure for mixing of water and anti-freeze differs according to the maker of the anti-freeze and the ambient temperature, basicall y should be referred to SAE J1034, more specially also to SAE J814c.

4. Mix the anti-freeze with water, and then fill in to the rediator.

Vol % Antifreeze

40 -24 -12 106 222 50 -37 -34 108 226

Freezing Point Boilling Point*

°C °F °C °F

* At 101 kPa (760 mmHg) pressure (atmospheric). A higher boiling point is obt ained by usin g a radiator pressure cap which permits the development of pressure within the cooling system.

• The above date represent industry standards that necessitate a minimum glycol con tent in the concentrates anti-freeze.

• When the cooling water level drops due to evaporation, add water only. In case o f leakag e, add anti-f reeze an d water in the specified mixing ratio.

• Anti-freeze absorb s moist ure. Kee p un used a nti-f re ez e in a tightly sealed container.

• Do not use radiator cleaning agents when anti-freeze has been added to the cooling water. (Anti-freeze contains an anti-corrosive agent, which will react with the radiator cleaning agent forming sludge which will affect the engine parts.)

W1037674

G-29

Page 44

G2160, WSM

KiSC issued 11, 2006 A

G GENERAL

Replacing Fuel Line

1. Replace the fuel hoses (1) and hose clamps (2). Refer to “Checking Fuel Line”. (See page G-23.)

(1) Fuel Hose (2) Hose Clamp

W1038053

Replacing Radiator Hose and Clamp Band

1. Replace the radiator hoses (1) and clamp bands (2). Refer to “Checking Radiator Hose and Hose Clamp” . (See page G-25.)

(1) Radiator Hose (2) Clamp Band

W1038187

Replacing Hydraulic Hoses

1. Replace hydr aulic hoses ( 1) and clamp bands every 2 year s or ealier if checke d and found that hydraulic hos es ( 1) a re swo llen, hardened or cracked.

(1) Hydraulic Hose

W1038289

G-30

Page 45

G2160, WSM

IMPORTANT■

KiSC issued 11, 2006 A

G GENERAL

Replacing Mower Gear Box Seals

1. Replace the mower gear box oil seals (1), (2). Refer to “Disassembling Gear Box A ssembly” (See page 9S11).

(1) Oil Seal (2) Oil Seal

W1038357

Replacing Fuses

1. The electrical system is protected from potential damage by fuses. A blown fuse indicates that there is an overload or short somewhere in the electrical system.

2. If any of the fuses should blo w, replace with a new one of the same capacity.

• Before replacing a blown fuse, determine why the fuse blew and make any necessary repairs. Failure to follow this procedure may result in serious damage to the electrical system.

■ Protected Circuit

FUSE NO. (ID LABEL)

1 (a) EPS MT 30

(b) E/G STOP 15 Engine stop timer relay (c) IG/M 10

(d) OPC 3 Engine running circuit

2 – Slow blow fuse 40

3 – 3 KRA system

CAPACITY

(A)

Protected circuit

Electric power steering moter circuit

Fuel pump, head light, power steering control unit, etc.

Check circuit against wrong battery connection

(1) Fuse (2) Slow Blow Fuse

G-31

(3) KRA system Fuse

W1038470

Page 46

G2160, WSM

KiSC issued 11, 2006 A

G GENERAL

Replacing Bulbs (A) Replacing the head light bulb

1. Open hood.

2. Turn bulb socket to remove socket from headlight housing.

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

4. Install new bulb to the socket.

5. Install the socket in housing.

6. Close hood.

Head light bulb Capacity

1.04A / 12.8 Rated voltage

(B) Replacing the indicator light bulb

1. Open hood.

2. Turn bad bulb socket to the left.

3. Pull bulb from the socket.

4. Push new bulb into the socket.

5. Install the socket.

6. Close hood.

Indicator light bulb Capacity

0.27A / 14.0 Rated voltage

W1047730

G-32

Page 47

G2160, WSM

KiSC issued 11, 2006 A

9. SPECIAL TOOLS

[1] SPECIAL TOOL S FOR ENG INE

Special Use Puller Set

Code No: 07916-09032 Application: Use exclusively for pushing out bearing, gears and

Piston Ring Compressor

Code No: 07909-32111 Application: Use exclusively for pushing in the piston with piston

G GENERAL

other parts with ease.

W1048293

rings into the cylinder.

W1048361

Piston Ring Tool

Code No: 07909-32121 Application: Use exclusively for removing or installing the piston ring

with ease.

W1048421

Diesel Engine Compression Tester

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

07909-30934 (A to F) 07909-31271 (I) 07909-31211 (E and F) 07909-31281 (J) 07909-31231 (H)

Application: Use to measure diesel engine compression and

diagnostics of need for major overhaul.

(1) Gauge (2) L Joint (3) Adaptor A (4) Adaptor B (5) Adaptor C (6) Adaptor E

(7) Adaptor F (8) Adaptor G

(9) Adaptor H (10) Adaptor I (11) Adaptor J

W1048481

G-33

Page 48

G2160, WSM

KiSC issued 11, 2006 A

G GENERAL

Oil Pressure Tester

Code No: 07916-32032 Application: Use to measure lubricating oil pressure.

(1) Gauge (2) Cable (3) Threaded Joint (4) Adaptor 1

(5) Adaptor 2 (6) Adaptor 3 (7) Adaptor 4 (8) Adaptor 5

W1048722

Valve Seat Cutter

Code No: 0 790 9- 331 02 Application: Use to reseat valves. Angle: 0.785 rad (45 °)

0.262 rad (15 °)

Diameter: 28.6 mm (1.126 in.)

31.6 mm (1.244 in.)

35.0 mm (1.378 in.)

38.0 mm (1.496 in.)

41.3 mm (1.626 in.)

50.8 mm (2.000 in.)

W1048944

Radiator Tester

Code No: 07909-31551 Application: Use to check of radiator cap press ure, and l eaks from

cooling system.

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

W1049045

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 (2.57 to 11.81 in.)

W1049118

Flywheel Puller

Code No: 07916-32011 Application: Use exclusively for removing the flywheel with ease.

W1049723

G-34

Page 49

G2160, WSM

NOTE■

KiSC issued 11, 2006 A

G GENERAL

Nozzle Tester

Code No: 07909-31361 Application: Use to check the fuel injection pressure and spray

pattern of nozzle.

Measuring: 0 to 50 MPa

range (0 to 500 kgf/cm

, 0 to 7000 psi)

W1049783

Plastigage

Code No: 07909-30241 Application: Use to check the oil clearance between crankshaft and

bearing, etc..

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

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

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

W1049942

Red Check

Code No: 07909-31371 Application: Use to check cracks on cylinder head , cylinder block,

etc..

• The following special tools are not provided, so make them referring to the figure. Valve Guide Replacing Tool

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

A 20 mm dia. (0.79 in. dia.) B 9.96 to 9.98 mm dia. (0.3921 to 0.3929 in. dia.) C 5.5 to 5.7 mm dia. (0.2165 to 0.2244 in. dia.) D 200 mm (7.87 in.) E 80 mm (3.15 in.) F 40 mm (1.58 in.)

G 15 mm (0.59 in.)

H 5 mm (0.197 in.)

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

J 18 mm dia. (0.71 in. dia.) K 10.6 to 10.7 mm dia. (0.417 to 0.421 in. dia.) L 7 mm (0.276 in.)

C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.012 in.)

W1050024

W1050106

G-35

Page 50

G2160, WSM

KiSC issued 11, 2006 A

G GENERAL

Injection Pump Pressure Tester

Application: Use to check fuel tightness of injection pumps.

A B Copper gasket

C Flange (Material: Steel) D Hex. nut 27 mm (1.06 in.) across the plat E Injection pipe F PF1/2 G 5 mm (0.20 in.) H 17 mm dia. (0.67 in. dia.)

I 8 mm dia. (0.31 in. dia.) J 1.0 mm (0.039 in.) K 17 mm dia. (0.67 in. dia.)

M 8 mm (0.31 in.)

N 4 mm (0.16 in.)

P PF1/2 Q 23 mm (0.91 in.) R 17 mm (0.67 in.) S 4 mm (0.16 in.)

T U 100 mm (3.94 in.)

V M12 × P1.5 a Adhesive application b F illet welding on the enter circumference

Pressure gauge full scale: More than

29.4 MPa (300 kgf/cm

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

11.97 to 11.99 mm dia. (0.4713 to 0.4721 in. dia.)

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

, 4267 psi)

W1050289

G-36

Page 51

G2160, WSM

KiSC issued 11, 2006 A

G GENERAL

Bushing Replacing Tool

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

1. For small end bushing

A 145 mm (5.71 in.) B 20 mm (0.79 in.) C 100 mm (3.94 in.)

E F 25 mm dia. (0.98 in.dia.)

a 6.3 μm (250μin.)

b 6.3 μm (250μin.)

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

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

2. For idle gear bushing

A 150 mm (5.91 in.) B 20 mm (0.79 in.) C 100 mm (3.94 in.)

E F 25 mm (0.98 in.)

a 6.3 μm (250μin.)

b 6.3 μm (250μin.)

19.90 to 19.95 mm (0.7835 to 0.7854 in.)

21.90 to 21.95 mm (0.8622 to 0.8642 in.)

Flywheel Stopper

Application: Use to loosen and tighten the flywheel screw.

A 200 mm (7.87 in.) B 30 mm (1.18 in.) C 20 mm (0.79 in.) D 15 mm (0.59 in.) E 15 mm (0.59 in.)

G 8 mm (0.31 in.)

F 10 mm dia. (0.39 in. dia.)

W1050660

W1050819

G-37

Page 52

G2160, WSM

KiSC issued 11, 2006 A

G GENERAL

Crankshaft Bearing 1 Replacing Tool

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

[Press Out]

A 135 mm (5.31 in.) B 72 mm (2.83 in.) C 40° (1.57 rad) D 10 mm (0.39 in.) E 22 mm (0.87 in.) F 20 mm dia. (0.79 in.dia.)

48.90 to 48.95 mm dia. (1.9251 to 1.9271 in. dia.)

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

[Press Fit]

A 130 mm (5.12 in.) B 72 mm (2.83 in.) C 40° (1.57 rad) D 9 mm (0.35 in.) E 24 mm (0.95 in.) F 20 mm dia. (0.79 in.dia.) G 68 mm dia. (0.79 in. dia.)

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

W1051113

G-38

Page 53

G2160, WSM

KiSC issued 11, 2006 A

[2] SPECIAL TOOL S FOR MA CHINE

Steering Wheel Puller

Code No: 07916-51090 Application: Use for removing the steering wheel without damaging

Toe-in Gauge

Code No: 07909-31681 Application: This allows easy measurement of toe-in for all machine

G GENERAL

the steering shaft.

W1051779

models.

W1051843

Relief Valve Pressure Tester

Code No: 07916-50045 Application: This allows easy measurement of relief set pressure.

(1) Gauge (07916-50322) (2) Cable (07916-50331) (3) Threaded Joint (07916-50401) (4) Threaded Joint (07916-50341) (5) Adaptor B (M18 × P1.5) (07916-50361)

(6) Adaptor C (PS3/8) (07916-50371) (7) Adaptor D (PT1/8) (07916-50381) (8) Adaptor E (PS3/8) (07916-50392) (9) Adaptor F (PF1/2) (07916-62601)

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

W1051907

Pressure Gauge 50

Code No: 07916-52961 Application: This pressure gauge is used to measure the low oil

pressure.

W1052218

G-39

Page 54

G2160, WSM

NOTE■

KiSC issued 11, 2006 A

• The following special tool is not provided, so make it referring to the figure.

Steering Wheel Puller Adaptor

G GENERAL

Application: Use for removing the steering wheel with steering wheel

A 22 mm (0.87 in.) F 116 mm (4.57 in.) B 64 mm (2.52 in.) G 5 mm (0.20 in.) C 11 mm (0.43 in.) H 9.5 mm (0.38 in.) D 32 mm (1.26 in.) I 3 mm (0.12 in.) E 20 mm (0.79 in.) J 5 mm (0.20 in.)

G-40

Page 55

G2160, WSM

KiSC issued 11, 2006 A

Adaptor Bolt for HST

Application: Use for checking the charge relief valve setting pressure.

A 26 mm (1.02 in.) K 0.4 mm (0.02 in.) B 18 mm (0.71 in.) L 0.5 mm (0.02 in.) C 15 mm (0.59 in.) M 15 mm (0.59 in.) D 30 mm (1.18 in.) N G 3/8 E RP 1/4 O Chamfer 1 mm (0.04 in.) F 22 mm (0.87 in.) P 8 mm (0.31 in.) dia. drill thru

G 10 mm (0.39 in.) Q 10 mm dia. (0.39 in. dia.) H 0.8 mm (0.03 in.) R 16.8 mm dia. (0.66 in. dia.)

I 46.5 mm (1.83 in.) S 24.5 mm dia. (0.96 IN. dia.)

J 17 mm (0.67 in.)

G GENERAL

Chamfer 0.5 mm (0.02 in.) (Both ends)

G-41

Page 56

G2160, WSM

KiSC issued 11, 2006 A

Adaptor for Control Valve

Application: Use for checking the main relief valve setting pressure.

A 40 mm (1.57 in.) I 4.5 mm dia. (0.18 in. dia.) B 18 mm (0.71.) J 9 mm dia. (0.18 in. dia.) C 6 mm (0.24 in.) K RP 1/4 thread depth 15 mm (0.59 in.)

D 3 mm (0.12 in.) L 0.5 mm (0.02 in.) E 3 mm (0.12 in.) M 7/16-20 SAE 37 ° flare F 0.785 rad (45 °) N 21 mm (0.83 in.) G 0.523 rad (30 °) O 24.2 mm (0.95 in.) H 0.645 rad (37 °)

G GENERAL

Drill depth 20 mm (0.79 in.)

G-42

Page 57

G2160, WSM

■

KiSC issued 11, 2006 A

Flange for Control Valve

1. Use for checking the relief valve setting pressure.

NOTE

• When using , attach with following parts.

1. O-ring: 04811-102 40

2. O-ring: 04811-106 00.

G GENERAL

A RP 1/4 N 5 mm dia. (0.20 in. dia.) B 14.5 mm dia. (0.59 in. dia.) O 2.70 to 2.95 mm (0.106 to 0.116 in.) C 2.09 rad (120 °) P 2.09 rad (120 °) D 20 mm (0.79 in.) Q 20 mm dia. (0.79 in. dia.) E 3/4-16 UNF R 23.95 to 24.00 mm dia.

(0.9429 to 0.9449 in. dia.)

F Chamfer 1mm (0.04 in.) S 63.00 to 63.05 mm dia.

G 38 mm (1.50 in.) T 76 mm dia. (2.99 in. dia.) H 18 mm (0.71 in.) U R 0.5 mm (0.02 in.)

I 15 mm (0.59 in.) V 1.4 to 1.5 mm (0.055 to 0.059 in.)

J 1.4 to 1.5 mm (0.055 to 0.059 in.) W 2.70 to 2.95 mm (0.106 to 0.116 in.) K Chamfer 1mm (0.04 in.) X R 0.5mm (0.02 in.) L R 0.5 mm (0.02 in.) Y 20 mm (0.79 in.) M R 0.5 mm (0.02 in.) Z 26 mm (1.02 in.)

(2.4803 to 2.4823 in. dia.)

G-43

Page 58

G2160, WSM

KiSC issued 11, 2006 A

G GENERAL

10.IMPLEMENT LIMITATIONS

The KUBOTA Machi ne has be en thor oughl y tes ted for pr oper perform ance with im plemen ts sold or ap proved b y KUBOTA. Use of implements which exceed the maximum loading weight listed below, or which are not recommended for use with the KUBOTA Machi ne may r esult in mal functions or failures of the machine, damage to o ther prop erty and injury to the operator or others. (Any malfunctions or fai lures of the machine resulting from use with impr oper implements are not covered by the warranty.)

Maximum axle loading weight

Front axle

G2160 350 kg (772 lbs) 550 kg (1213 lbs) 700 kg (1540 lbs)

Rear axle

Wry

Total gross machine

weight

W1054384

G-44

Page 59

KiSC issued 11, 2006 A

1 ENGINE

Page 60

SERVICING

KiSC issued 11, 2006 A

CONTENTS

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

2. SERVICING SPECIFICATIONS ....................................................................1-S5

[1] ENGINE BODY ........................................................................................1-S5

[2] LUBRICATING SYSTEM ............................... ...... ....... ...... ....... ...... ....... ...1-S9

[3] COOLING SYSTEM.................................................................................1-S9

[4] FUEL SYSTEM ....................................... ....... ...... ..................................1-S10

3. TIGHTENING TORQUES ............................. ....... ...... ....... ...... ....... ...... ....... .1-S11

4. CHECKING, DISASSEMBLING AND SERVICING.....................................1-S12

[1] SEPARATING ENGINE .......................... ....... ...... ....... ...... ....... ...... ....... .1-S12

(1) Disassembling and Assembling........................................................1-S12

[2] ENGINE BODY ......................................................................................1-S17

(1) Checking and Adjus ti ng ..................... .............................................. .1-S17

(2) Disassembling and Assembling........................................................1-S20

(3) Servicing ...........................................................................................1-S31

[3] LUBRICATING SYSTEM ............................... ...... ....... ...... ....... ...... ....... .1-S46

(1) Checking ...........................................................................................1-S46

(2) Servicing ...........................................................................................1-S46

[4] COOLING SYSTEM...............................................................................1-S48

(1) Checking and Adjus ti ng ..................... .............................................. .1-S48

(2) Disassembling and Assembling........................................................1-S50

[5] FUEL SYSTEM ....................................... ....... ...... ..................................1-S51

(1) Checking and Adjus ti ng ..................... .............................................. .1-S51

(2) Disassembling and Assembling........................................................1-S54

Page 61

G2160, WSM

KiSC issued 11, 2006 A

1. TROUBLESHOOTING

ENGINE

Symptom Probable Cause Solution

Engine Does Not Start

• No fuel

• Air in the fuel system

• Water in the fuel system

• Fuel pipe clogged

• Fuel filter clogged

• Excessively high viscosity of fuel or engine oil at low temperature

• Fuel with low cetane number

• Fuel leak due to l oos e inj ect ion pip e ret a ini ng nut

• Incorrect injec tio n timi ng

• Fuel camshaft worn

• Injection nozzle clogged

• Injection pump malfunctioning

• Seizure of crankshaft, camshaft, piston, cylinder or bearing

• Compression leak from cylinder

• Improper valve timing

• Piston ring and cylinder worn

• Excessive valve clearance

Replenish fuel. Bleed fuel system. Change fuel and replace fuel system. Clean fuel pipe. Replace fuel filter. Use specified fuel or engine oil. Use specified fuel. Tigh ten retaining nut.

Adjust injection timing. Replace fuel camshaft. Clean injection nozzle. Repair or replace injection pump. Replace crankshaft, camshaft, piston, cylinder or bearing. Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder. Correct valve timing. Replace pi ston ring and bore oversize cylinder. Adjust valve clearance.

Reference Page

– – –

–

G-27

G-8 G-8

1-S54 1-S51 1-S25 1-S53 1-S52 1-S28

1-S30 1-S21

1-S22

1-S51 1-S28 1-S30 1-S45 1-S19

(Starter Does Not Run)

• Battery discharged

• Starter malfunctioning

• Slow blow fuse blown

• Main switch malfunctioning

• PTO switch defective

• Brake switch defective

• Reverse switch defective

• Seat switch defective

• Wiring harness disconnected

1-S1

Charge battery. Repair or replace starter Replace slow blow fuse. Repair or replace main switch. Replace PTO switch. Replace brake switch. Replace reverse switch or adjust reverse switch gap. Replace seat switch. Connect wiring harness.

G-24

8-S16

– 8-S12 8-S28

8-S27 8-S30

8-S28

–

W1066187

Page 62

G2160, WSM

KiSC issued 11, 2006 A

ENGINE

Symptom Probable Cause Solution

Engine Revolution Is Not Smooth

• Fuel filter clogged or dirty

• Air cleaner clogged

Replace fuel filter. Clean or replace air cleaner element.

• Fuel leak due to loose injection pipe retaining

Tighten retaining nut.

nut

• Injection pump malfunctioning

Repair or replace injection pump.

• Incorrect nozzle injection pressure

Adjust nozzle injection pressure.

• Injection nozzle stuck or clogged

Repair or replace injection nozzle.

Either White or Blue Exhaust Gas Is Observed

• Governor malfunctioning

• Excessive engine oil

• Piston ring and cylinder worn or stock

Repair governor.

Reduce to specified engine oil level. Repair piston ring and bore oversize piston.

• Incorrect injection timing

Adjust injection timing.

Either Black or Dark Gray Exhaust Gas Is Observed

• Deficient compression

•Overload

• Low grade fuel used

• Fuel filter clogged

• Air cleaner clogged

Adjust top clearance Lessen load.

Use specified fuel. Replace fuel filter. Clean or replace air cleaner element.

• Deficient nozzle injection

Repair or replace nozzle

Deficient Output • Incorrect injection timing

Adjust injection timing.

• Engine's moving parts seem to be seized.

Repair or replace engine’s moving parts.

• Uneven fuel injection

Repair or replace injection pump.

• Deficient nozzle injection

Repair or replace nozzle.

• Compression leak from cylinder

Replace head gasket, tighten cylinder head screws, glow plugs and nozzle holders.

Excessive Lubricant Oil Consumption

• Piston ring's gap facing the same direc tion

• Oil ring worn or stuck

• Piston ring groove worn

• Valve stem and valve guide worn

Shift ring gap direction. Replace oil ring. Replace piston. Replace valve stem and valve guide.

• Oil leaking due to defective seals or packing

Replace defective seals or packing.

Reference Page

G-27

G-28 1-S20 1-S23 1-S53 1-S53 1-S23

1-S25

–

1-S28 1-S30 1-S45 1-S51

1-S18

– –

G-27

G21 G28

1-S53

1-S51

–

1-S53 1-S53 1-S21

1-S22

1-S27 1-S28 1-S28 1-S28 1-S33

–

W1010717

1-S2

Page 63

G2160, WSM

KiSC issued 11, 2006 A

ENGINE

Symptom Probable Cause Solution

Fuel Mixed into Lubricant Oil

• Injection pump's plunger worn

Replace pump element or injection pump.

• Deficient nozzl e inj ec tio n

Repair or replace nozzle.

• Injection pump broken

Replace injection pump.

Water Mixed into Lubricant Oil

• Head gasket defectiv e

• Cylinder block or cylinder head flawed

Replace head gasket. Replace cylinder block or cylinder head.

Low Oil Pressure • Engine oil insufficient

• Oil strainer clogged

• Engine oil filter cartridge clogged

Replenish engine oil. Clean oil strainer. Change engine oil filter cartridge.

• Relief valve stuck with dirt

• Relief valve spring weaken or broken

Replace relief valve. Replace relief valve spring.

• Excessive oil clearance of crankshaft bearing

Replace main bearings, metals or crankshaft.

• Excessive oil clearance of crankpin bearing

Replace crankpin bearings.

• Excessive oil clearance of rocker arm

Replace rock er arms, rocker arm brackets or rocker arm shaft.

• Oil passage clogged

• Different type of oil

Clean oil passage. Use specified type of oil.

• Oil pump defective

Repair or replace o il pump.

High Oil Pressure • Different type of oil

Use specified type of oil.

• Relief valve defective

Replace relief valve.

Reference Page

1-S52

1-S51 1-S52 1-S52

1-S22 1-S22

G-17 G-27 G-18

1-S46

–

1-S43 1-S44

1-S42 1-S35

– –

1-S46 1-S47

–

1-S46

W1012734

1-S3

Page 64

G2160, WSM

KiSC issued 11, 2006 A

ENGINE

Symptom Probable Cause Solution

Engine Overheated • Engine oil insufficient

• Fan belt broken or tensioned improperly

Replenish engine oil. Replace fan belt or adjust fan belt tension.

• Cooling water insufficient

Replenish cooling water.

• Radiator net and radiator fin clogged with dust

• Inside of radiator corroded

Clean radiator net and radiator fin. Clean inside of radiator or replace radiator.

• Cooling water flow route corroded

Clean or replace cooling water flow route.

• Radiator cap defective

• Overload running

• Head gasket defective

Replace radiator cap. Loosen load. Replace head gasket.

• Incorrect injection timing

Adjust injection timing.

• Unsuitable fuel used

Use specified fuel.

Reference Page

G-17 G-20

1-S48

– –

G-28

1-S49

– 1-S19 1-S22 1-S51

–

W1013908

1-S4

Page 65

G2160, WSM

KiSC issued 11, 2006 A

2. SERVICING SPECIFICATIONS

[1] ENGINE BODY

Cylinder Head

Item Factory Specification Allowable Limit

Cylinder Head Surface Flatness – 0.05 mm

0.0020 in.

Top Clearance 0.50 to 0.70 mm

0.0197 to 0.0276 in.

Compression Pressure 2.84 to 3.24 MPa

29.0 to 33.0 kgf/cm

412 to 469 psi

Variance Among Cylinders – 10 % or less

Valves

Valve Clearance (Cold) 0.145 to 0.185 mm

0.00571 to 0.00728 in.

Valve Seat Width 2.12 mm

0.0835 in.

Valve Seat Angle 0.79 rad

45°

Valve Face Angle 0.79 rad

45°

Valve Recessing −0.10 to 0.10 mm

−0.0039 to 0.0039 in.

Clearance between Valve Stem and Valve Guide

0.030 to 0.057 mm

0.00118 to 0.00224 in.

–

2.26 MPa

23.0 kgf/cm 327 psi

–

0.3 mm

0.0118 in.

0.10 mm

0.0039 in.

ENGINE

W1013874

Valve Stem O.D.

5.968 to 5.980 mm

0.23496 to 0.23543 in.

Valve Guide I.D.

6.010 to 6.025 mm

0.23661 to 0.23720 in.

Valve Timing

Intake Valve Open 0.35 rad (20°)

before T.D.C.

Close 0.79 rad (45°)

after B.D.C.

Exhaust Valve Open 0.89 rad (50°)

before B.D.C.

Close 0.26 rad (15°)

after T.D.C.

–

W1014656

–

W1013874

1-S5

Page 66

G2160, WSM

KiSC issued 11, 2006 A

Valve Spring

Item Factory Specification Allowable Limit

Free Length 31.3 to 31.8 mm

1.232 to 1.252 in.

Setting Load / Setting Length 64.7 N / 27.0 mm

6.6 kgf / 27.0 mm

14.6 lbs / 1.063 in.

28.4 mm

1.118 in.

54.9 N / 27.0 mm

5.6 kgf / 27.0 mm

12.3 lbs / 1.063 in.

Tilt – 1.2 mm

0.047 in.

Rocker Arm

Clearance between Rocker Arm Shaft and Rocker Arm

0.016 to 0.045 mm

0.00063 to 0.00177 in.

0.15 mm

0.0059 in.

ENGINE

W1014987

Rocker Arm Shaft O.D.

10.473 to 10.484 mm

–

0.41232 to 0.41276 in.

Rocker Arm I.D.

10.500 to 10.518 mm

–

0.41339 to 0.41410 in.

Push Rod

Push Rod Runout – 0.50 mm

0.0196 in.

Tappet

Clearance between Tappet and Guide

Tappet O.D.

0.016 to 0.052 mm

0.00063 to 0.00205 in.

17.966 to 17.984 mm

0.10 mm

0.0039 in. –

0.70732 to 0.70803 in.

Tappet Guide I.D.

18.000 to 18.018 mm

–

0.70866 to 0.70937 in.

Camshaft

Camshaft Side Clearance 0.15 to 0.31 mm

0.0059 to 0.0122 in.

0.50 mm

0.0197 in.

Camshaft Runout – 0.02 mm

0.0008 in.

Cam Height of Intake and Exhaust 26.88 mm

1.0583 in.

Oil Clearance of Camshaft

0.050 to 0.091 mm

0.00197 to 0.00358 in.

26.83 mm

1.0563 in.

0.15 mm

0.0059 in.

W1015094

W1015197

W1013874

Camshaft Journal O.D.

Camshaft Bearing I.D.

1-S6

32.934 to 32.950 mm

1.29661 to 1.29724 in.

33.000 to 33.025 mm

1.29921 to 1.30020 in.

–

W1016577

Page 67

G2160, WSM

KiSC issued 11, 2006 A

Timing Gear

Timing Gear Backlash Crank Gear- Idle Gear

ENGINE

Item Factory Specification Allowable Limit

0.043 to 0.124 mm

0.00169 to 0.00488 in.

0.15 mm

0.0059 in.

Idle Gear-Cam Gear

0.047 to 0.123 mm

0.00185 to 0.00484 in.

Idle Gear-Injection Pump Gear

0.041 to 0.124 mm

0.00161 to 0.00488 in.

Crank Gear-Oil Pump Drive Gear

0.041 to 0.123 mm

0.00161 to 0.00484 in.

Clearance between Idle Gear Shaft and Idle Gear Bushing

0.020 to 0.084 mm

0.00079 to 0.00331 in.

Idle Gear Shaft O.D.

19.967 to 19.980 mm

0.78610 to 0.78661 in.

Idle Gear Bushing I.D.

20.000 to 20.051 mm

0.78740 to 0.78941 in.

Idle Gear Side Clearance 0.20 to 0.51 mm

0.0079 to 0.0201 in.

Piston • Piston Ring

Piston Pin Bore I.D. 20.000 to 20.013 mm

0.78740 to 0.78791 in.

Piston Ring Clearance Second Ring 0.090 to 0.120 mm

0.00354 to 0.00472 in.

Oil Ring 0.04 to 0.08 mm

0.0016 to 0.0031 in.

Piston Ring Gap Top Ring

Oil Ring

0.15 to 0.30 mm

0.0059 to 0.0118 in.

Second Ring 0.30 to 0.45 mm

0.0118 to 0.0177 in.

Oversize of Piston Rings +0.25 mm

+0.0098 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.10 mm

0.0039 in. –

–

0.60 mm

0.0236 in.

W1013874

20.05 mm

0.7894 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in. –

W1016812

Connecting Rod

Connecting Rod Alignment – 0.05 mm

0.0020 in.

Clearance between Piston Pin and Small End Bushing

Piston Pin O.D.

0.014 to 0.038 mm

0.00055 to 0.00150 in.

20.002 to 20.011 mm

0.10 mm

0.0039 in. –

0.78748 to 0.78783 in.

Small End Bushing I.D.

20.025 to 20.040 mm

0.78839 to 0.78897 in.

–

W1016985

1-S7

Page 68

G2160, WSM

KiSC issued 11, 2006 A

Crankshaft

Item Factory Specification Allowable Limit

Crankshaft Runout – 0.04 mm

0.0016 in.

Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1

0.034 to 0.106 mm

0.00134 to 0.00417 in.

0.20 mm

0.0079 in.

ENGINE

Crankshaft Journal O.D.

Crankshaft Bearing 1 I.D.

Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Flywheel Side)

Crankshaft Journal O.D. Crankshaft Bearing 2 I.D.

Oil Clearance between Crankshaft Journal and Crankshaft Bearing 3 (Intermediate)

Crankshaft Journal O.D.

Crank bearing 3 I.D.

Oil Clearance between Crankpin and Crankpin Bearing

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.984 to 40.040 mm

1.57417 to 1.57638 in.

0.034 to 0.092 mm

0.00134 to 0.00362 in.

43.934 to 43.950 mm

1.72969 to 1.73032 in.

43.984 to 44.026 mm

1.73165 to 1.73331 in.

0.034 to 0.092 mm

0.00134 to 0.00362 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.984 to 40.026 mm

1.57417 to 1.57583 in.

0.020 to 0.051 mm

0.00079 to 0.00201 in.

–

0.20 mm

0.0079 in. –

–

0.20 mm

0.0079 in. –

–

0.15 mm

0.0059 in.

Crankpin O.D.

33.959 to 33.975 mm

1.33697 to 1.33760 in.

Crankpin Bearing I.D.

33.995 to 34.010 mm

1.33839 to 1.33898 in.

Crankshaft Side Clearance 0.15 to 0.31 mm

0.0059 to 0.0122 in.

Cylinder Liner

Cylinder Liner I.D. 67.000 to 67.019 mm

2.63779 to 2.63854 in.

Oversized Cylinder Liner I.D. 67.250 to 67.269 mm

2.64764 to 2.64839 in.

–

0.50 mm

0.0197 in.

W1017094

+0.15 mm

0.0059 in.

+0.15 mm

0.0059 in.

W1017278

1-S8

Page 69

G2160, WSM

KiSC issued 11, 2006 A

[2] LUBRICATING SYSTEM

Oil Pump

Item Factory Specification Allowable Limit

Engine Oil Pressure At Idle Speed

98 kPa

1.0 kgf/cm 14 psi

ENGINE

–

At Rated Speed

196 to 441 kPa

2.0 to 4.5 kgf/cm 28 to 64 psi

Clearance between Inner Rotor and Outer Rotor 0.03 to 0.14 mm

0.0012 to 0.0055 in.

Clearance between Outer Rotor and Pump Body 0.07 to 0.15 mm

0.0028 to 0.0059 in.

End Clearance between Inner Rotor and Cover 0.075 to 0.135 mm

0.00295 to 0.00531 in.

[3] COOLING SYSTEM

Thermostat

Thermostat's Valve Opening Temperature 80.5 to 83.5 °C

176.9 to 182.3 °F

Temperature at Which Thermostat Completely Opens 95 °C

203 °F

Radiator

Radiator Water Tightness Water tightness at

specified pressure

147 kPa

1.5 kgf/cm

Radiator Cap Air Leakage 10 seconds or more

88 → 59 kPa

0.9 → 0.6 kgf/cm 13 → 9 psi

Fan Belt Tension Approx.10 mm / 98 N

0.4 in. / 98 N

(10 kgf, 22 lbs)

, 21 psi

98 kPa

1.0 kgf/cm

14 psi

–

W1017384

–

W1017547

–

W1013874

1-S9

Page 70

G2160, WSM

KiSC issued 11, 2006 A

[4] FUEL SYSTEM

Injection Pump

Item Factory Specification Allowable Limit

Injection Timing 0.31 to 0.34 rad (19.0 to

21.0 °) Before T.D.C.

Fuel Tightness of Pump Element – 14.7 MPa

Fuel Tightness of Delivery Valve – 5 seconds

14.7 → 13.7 MPa

150 →140 kgf/cm

2130 → 1990 psi

Injection Nozzle

Fuel Injection Pressure 13.7 to 14.7 MPa

140 to 150 kgf/cm

1990 to 2130 psi

Fuel Tightness of Nozzle Valve Seat When the pressure is

12.7 MPa

(130 kgf/cm

, 1850 psi),

the valve seat must be

fuel tightness.

–

150 kgf/cm

2130 psi

–

ENGINE

W1013874

W1013973

1-S10

Page 71

G2160, WSM

NOTE■

KiSC issued 11, 2006 A

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 Size x Pitch N·m kgf·m ft-lbs

Starter M terminal nut Alternator B terminal nut Glow plug terminal mounting nut Universal joint mounting screw Engine mounting nut Cylinder head bolt * Cylinder head cover cap nut Injection pipe retaining nut Nozzle holder assembly Overflow pipe assembly retaining nut (nozzle) Glow plug * Rocker arm bracket nut * Fan drive pulley retaining screw * Idle gear shaft mounting screw * Connecting rod screw * Flywheel bolt * Main bearing case screw 2 * Main bearing case screw 1 Oil pressure switch Nozzle holder

M6 × 1.0 M6 × 1.0

M8 × 1.25 M8 × 1.25 M8 × 1.25

M6 × 1.0 M12 × 1.5 M20 × 1.5 M12 × 1.5

M8 × 1.0

M6 × 1.0 M12 × 1.5

M6 × 1.0 M7 × 0.75

M10 × 1.25

M7 × 1.0

M6 × 1.0

PT 1/8

9.8 to 13.7

7.8 to 9.3

1.0 to 1.8

23.5 to 27.5

37.2 to 42.1

3.9 to 5.9

24.5 to 34.3

49.0 to 68.6

19.6 to 24.5

7.8 to 14.7

9.8 to 11.3

117.6 to 127.4

9.8 to 11.3

26.5 to 30.4

53.9 to 58.8

26.5 to 30.4

12.7 to 15.7

14.7 to 19.6

34.3 to 39.2

1.0 to 1.4

0.80 to 0.95

0.10 to 0.18

2.4 to 2.8

3.8 to 4.3

0.4 to 0.6

2.5 to 3.5

5.0 to 7.0

2.0 to 2.5

0.8 to 1.5

1.00 to 1.15

12.0 to 13.0

1.00 to 1.15

2.7 to 3.1

5.5 to 6.0

2.7 to 3.1

1.3 to 1.6

1.5 to 2.0

3.5 to 4.0

ENGINE

7.2 to 10.1

5.8 to 6.9

0.74 to 1.33

17.4 to 20.3

28.0 to 31.7

2.9 to 4.3

18.1 to 25.3

36.2 to 50.6

14.5 to 18.1

5.8 to 10.8

7.2 to 8.3

86.8 to 94.0

7.2 to 8.3

19.5 to 22.4

39.8 to 43.4

19.5 to 22.4

9.4 to 11.6

10.8 to 14.5

25.3 to 28.9

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

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

W1013236

1-S11

Page 72

G2160, WSM

■

KiSC issued 11, 2006 A

4. CHECKING, DISASSEMBLING AND SERVICING

[1] SEPARATING ENGINE

(1) Disassembling and Assembling

Dismount Mower

1. See to “MOWER” section.

Draining Engine Oil

1. Park the machine on level ground.

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

3. Place an oil pan underneath the engine.

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

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

(When refilling)

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

2.8 L

Engine oil Capacity

IMPORTANT

• Never mix two different type of oil.

• Use the proper SAE Engine Oil according to ambient temperatures. Refer to "LUBRICANTS, FUEL AND COOLING WATER".(See page G-8.)

(1) Drain Plug (2) Oil Inlet Plug (3) Dipstick

(A) Upper Level (B) Lower Lev e l

2.95 U.S.qts

2.4 lmp.qts

ENGINE

W1019171

W1019220

1-S12

Page 73

G2160, WSM

KiSC issued 11, 2006 A

ENGINE

Draining Coolant

CAUTION

• Never open the radiator cap while operating or immediately after stopping. Otherwise, hot water will spout out from the radiator. Wait for more than ten minutes to cool the radiator, before opening the cap.

1. Stop the engine and let cool down.

2. Remove the radiato r coolant drain plug (3) and engine coolant drain plug (4) to drain the coolant.

3. Remove the radiator cap (1) to completely drain the coolant.

4. After all coolant is drained, close the drain plugs.

Radiator

Coolant Capacity

Recovery tank

2.1 L

2.2 U.S.qts

1.8 lmp.qts

0.25 L

0.26 U.S.qts

0.22 lmp.qts

(1) Radiator Cap (2) Recovery Tank

(3) Radiator Coolant Drain Plug (4) Engine Coolant Drain Plug

W1019510

Battery

CAUTION

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

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

2. Disconnect the positive cable (2) from the battery.

(1) Negative Cable (2) Positive Cable

W1019788

Bonnet and Air Cleaner

1. Disconnect the 1P connectors (3) from the head light (2).

2. Remove the wiring (4) from the bonnet.

3. Remove the bonnet stay mounting screws (6).

4. Remove the bonnet with the bonnet bracket (5) from the frame.

5. Loosen the air cleaner hose clamp.

6. Remove the air cleaner (1) with air cleaner hose.

(1) Air Cleaner (2) Head Light (3) 1P Connectors

(4) Wiring (5) Bonnet Bracket (6) Bonnet Stay Mounting Screws

W1019921

1-S13

Page 74

G2160, WSM

KiSC issued 11, 2006 A

ENGINE

Wiring

1. Disconnect the tie (1) from the al ternator, and rem ove the PTO cable (3) and wiring (2).

2. Disconnect 2P connector (5) and wiring (4) from the alternator.

3. Disconnect 1P connector (8) from the oil pressure switch.

4. Disconnect 1P connector (10) and wiring (9) from the starter.

5. Disconnect the tie (6) from the rear end plate.

6. Disconnect the ground cable (7).

9.8 to 13.7 N·m

Starter M terminal nut

Tightening torque

Alternator B terminal nut

1.0 to 1.4 Kgf·m

7.2 to 10.1 ft-lbs

7.8 to 9.3 N·m

0.80 to 0.95 Kgf·m

5.8 to 6.9 ft-lbs

(1) Tie (2) Wiring (3) PTO Cable (4) Wiring (5) 2P Connector

(6) Tie (7) Ground Cable (8) 1P Connector (9) Wiring

(10) 1P Connector

W1020275

Front Cover and PTO Assembly

1. Remove the front PTO cover.

2. Remove the PTO clutch spring (4), brake spring (7) and retur n spring (6).

3. Remove the belt stay (9).

4. Remove the pulley (10).

5. Remove the front PTO belts (8).

6. Remove the cotter pin and flange bolt (3).

7. Pull out the PTO brake assembly (5) and tension arm (2) with tension pulley.

(When reassembling)

• Apply grease to the tension arm bushings a nd the PTO brake bushing.

• After reassembl ing the PTO cl utch spring, be s ure to adju st the front PTO belt tension. (See page 7-S3)

• After reassembling the belt stay, be sure to adjust the clearance between the belt stay and front PTO belt. (See page 7-S3) Clearance (L) :1.0 to 2.5 mm (0.04 to 0.10 in.)

(1) Cotter Pin (2) Tension Arm (3) Flange Bolt (4) PTO Clutch Spring (5) PTO Brake Assembly

(6) Return Spring (7) Brake Spring (8) Front PTO Belts (9) Belt Stay

(10) Pulley

W1020759

1-S14

Page 75

G2160, WSM

IMPORTANT■

KiSC issued 11, 2006 A

ENGINE

Muffler, Wiring, Accelerator and Hose

1. Remove the muffler mounting screws (1), (7).

2. Remove the muffler (2).

3. Disconnect 1P connector (5) from the coolant temperature sensor.

4. Disconnect the wiring (3) from the glow plug.

5. Disconnect 1P connector (4) from the engine stop solenoid.

6. Disconnect the accelerator wire (6).

7. Loosen the hose clamps.

8. Remove the return hose 1 (8) and fuel hose 1 (9).

9. Disconnect the ground cables (10), (11).

• When disconnecting the fuel hose 1 and return hose 1, be careful not to let the fuel spill out of the hoses.

(When reassembling)

1.0 to 1.8 N·m

0.10 to 0.18 Kgf·m

0.74 to 1.33 ft-lbs

Tightening torque

Glow plug terminal mounting nut

(1) Muffler Mounting Screws (2) Muffler (3) Wiring (4) 1P Connector (5) 1P Connector (6) Accelerator Wire

(7) Muffler Mounting Screw (8) Return Hose 1

(9) Fuel Hose 1 (10) Ground Cable (11) Ground Cable

W1021263

Universal Joint

1. Remove the universal joint mounting screws (1).

2. Disconnect the universal joint (2) from the fun drive pulley.

(When reassembling)

• Apply grease to the all splines on the drive shaft.

Tightening torque

(1) Universal Joint Mounting Screw (2) Universal Joint

Univer s al joint mounting screw

23.5 to 27.5 N·m

2.4 to 2.8 Kgf·m

17.4 to 20.3 ft-lbs

W1021776

1-S15

Page 76

G2160, WSM

KiSC issued 11, 2006 A

ENGINE

Separating Engine

1. Pull out the hairpin cotters from the radiator.

2. Remove th e engi ne mo unting nuts , and supp ort the engine with an engine lift hook and hoist.

3. Separate the engine with the radiator from the frame, taking care not to damage the radiator.

(When reassembling)

• Fit the radiator to the frame, adjusting the clearance between the radiator and the fan as shown in the figure.

23.5 to 27.5 N·m

Tightening torque Engine mounting nut

2.4 to 2.8 Kgf·m

17.4 to 20.3 ft-lbs

(Reference)

9.0 mm

0.35 in.

2.0 mm

0.08 in.

Clearance between fan and radiator

Factory spec.

(1) Fan (2) Radiator

L : Circumferential clearance

between fan and radiator

H : Longitudinal clearance between

fan and radiator

W1021955

1-S16

Page 77

G2160, WSM

NOTE■

KiSC issued 11, 2006 A

[2] ENGINE BODY

(1) Checking and Adjusting

ENGINE

Compression Pressure

1. Run the engine until it is warmed up.

2. Stop the engine.

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

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

5. Disconnect the accelerator wire.

6. Remove the air cleaner stay.

7. Remove the glow plugs and return hose 1.

8. Engage the parking brake.

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

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

11.Repeat steps 9 and 10 for each cylinder.

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

13.If the compres sion pressure is still less than the allowabl e limit, check the top clearance, valve and cylinder head.

14.If the c ompression pressu re increases after a pplying oil, check the cylinder wall and piston rings.

• Check the compression pressure with the specified valve clearance.

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

• Variances in cylinder compression values should be under 10 %.

Compression pressure

Factory spec.

Allowable limit

2.84 to 3.24 MPa

29.0 to 33.0 kgf/cm 412 to 469 psi

2.26 MPa

23.0 kgf/cm 327 psi

W1022478

1-S17

Page 78

G2160, WSM

NOTE■

KiSC issued 11, 2006 A

ENGINE

Top Clearance

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

2. Bring the pis ton to its top dead cente r fasten 1 .5 mm dia. 5 to 7 mm long fuse wires to 3 to 4 sp ots on the piston top wi th gr ease so as to avoid the intake and exhaust valves and the combustion chamber ports.

3. Bring t he piston to its middle positio n, install the cylinder head, and tighten the cylinder head screws to specification. (Head gasket must be changed to new one.)

4. Turn the crank shaft until the piston exceeds its top dead center.

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

6. If the measurement is not within the factory specifications, check the oil clearanc e of between the crankpin and crankpin bea ring and between the piston pin and small end bushing.

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

Top clearance Factory spec.

0.50 to 0.70 mm

0.0197 to 0.0276 in.

Tightening torque Cylinder head bolt

(1) Fuse

37.2 to 42.1 N·m

3.8 to 4.3 kgf·m

28.0 to 31.7 ft-lbs

W10107670

1-S18

Page 79

G2160, WSM

IMPORTANT■

NOTE■

KiSC issued 11, 2006 A

ENGINE

Valve Clearance

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

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

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

3. Check the following valve clearance marked with “✩” using a feeler gauge.

[When No. 1 piston comes to the compression top dead center]

Cylinder No. No.1 No.2 No.3 Intake valve ★★ Exhaust valve ★★

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

5. Then turn the flywheel 6.28 rad (360°), and align the “1TC” mark (1) on the flywheel and alig nment mark (2) on the rear end plate so that the No.1 piston comes to the overlap position.

6. Check the following valve clearance marked with “✩” using a feeler gauge.

[When No. 1 piston comes to the overlap position]

Cylinder No. No.1 No.2 No.3 Intake valve ✩ Exhaust valve ✩

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

Intake and exhaust valve clearance (Cold)

Factory spec.

0.145 to 0.185 mm

0.00571 to 0.00728 in.

• The sequence of cylinder numbers is given as No.1, No.2 and No.3 starting from the gear case side.

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

(1) “1TC” Mark (2) Alignment Mark

A : Gear Case Side

W10113200

1-S19

Page 80

G2160, WSM

IMPORTANT■

KiSC issued 11, 2006 A

(2) Disassembling and Assembling (A) Cylinder Head and Valves

ENGINE

External Components

1. Remove the air cleaner stay (5).

2. Remove the wate r pipe 1 (2), water pipe 2 (7) and radiator (8) with the recovery tank.

3. Remove the alter nato r (9) and fan belt (10).

4. Remove the cooling fan (4 ) and fan pulley .

5. Remove the starter (11).

6. Remove the engine stop solenoid (1).

7. Remove the engine mounting stays (6).

8. Remove the PTO pulley.

(When reassembling)

• Connect the water pipe 1 with the white marking facing upward.

• Connect the water pipe 2 with the yellow marking facing upward.

• Install the engine stop solenoid so that the plunger moves smoothly.

• After reassembling the fan belt, be sure to adjust the fan belt tension. (See page 1-S48)

(1) Engine Stop Solenoid (2) Water Pipe 1 (3) PTO Pulley (4) Cooling Fan (5) Air Cleaner Stay (6) Engine Mounting Stay

(7) Water Pipe 2 (8) Radiator

(9) Alternator (10) Fan Belt (11) Starter

W1024919

Cylinder Head Cover

1. Remove the head cover cap nuts.

2. Remove the cylinder head cover.

(When reassembling)

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

• Apply engine oil to the cylinder head cover cap nuts. And tighten them.

3.9 to 5.9 N·m

0.4 to 0.6 kgf·m

2.9 to 4.3 ft-lbs W10147380

Tightening torque

Cylinder head cover cap nut

Injection Pipes

1. Loosen the screws on the pipe clamps (1).

2. Detach the injection pipes (2).

(When reassembling)

• Blow out dust from the pipes with compressed air. Then reassemble the pipes in the reverse order..

Tightening torque

Injection pipe retaining nut

24.5 to 34.3 N·m

2.5 to 3.5 kgf·m

18.1 to 25.3 ft-lbs

(1) Pipe Clamp (2) Injection Pipe

W10150780

1-S20

Page 81

G2160, WSM

■

IMPORTANT■

KiSC issued 11, 2006 A

ENGINE

Nozzle Holder Assembly and Glow Plug

1. Remove the overflow pipe assembly (5).

2. Remove the nozzle holder assembl ies (2) using a 21 mm deep socket wrench.

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

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

5. Remove the glow plugs (1).

(When reassembling)

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

49.0 to 68.6 N·m

Tightening torque

Nozzle holder assembly

Overflow pipe assembly retaining nut

Glow plug

5.0 to 7.0 kgf·m

36.2 to 50.6 ft-lbs

19.6 to 24.5 N·m

2.0 to 2.5 kgf·m

14.5 to 18.1 ft-lbs

7.8 to 14.7 N·m

0.8 to 1.5 kgf·m

5.8 to 10.8 ft-lbs

(1) Glow Plug (2) Nozzle Holder Assembly (3) Heat Seal

(4) Lead (5) Overflow Pipe Assembly

W10259700

Removal Procedure for Nozzle Heat Seal Service

IMPORTANT

• Use a plus (phillips head) screw driver (1) that has a Dia. bigger than the heat seal hole (Approx. 6 mm) 1/4 in..

1. Drive a screw driver (1) lightly into the heat seal hole.

2. Turn a screw driver three or four times each way.

3. While turning the s crew driver, slowly pull the he at seal (4) out together with the copper gasket (3).

4. If the heat seal drops, repeat the above procedure.

(1) Screw driver (Plus) (2) Nozzle Holder

(3) Copper Gasket (4) Heat Seal

W10154410

Rocker Arm and Push Rod

1. Remove the rocker arm bracket nuts.

2. Detach the rocker arm assembly (1).

3. Remove the push rods (2).

(When reassembling)

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

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

• Apply engine oil to the rocker arm bracket nuts. And tighten them.

Tightening torque Rocker arm bracket nut

(1) Rocker Arm Assembly (2) Push Rod

(3) Tappet

9.8 to 11.3 N·m

1.00 to 1.15 kgf·m

7.2 to 8.3 ft-lbs

W10155810

1-S21

Page 82

G2160, WSM

NOTE■

IMPORTANT■

KiSC issued 11, 2006 A

ENGINE

Cylinder Head

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

2. Remove the cylinder head bolt in the order of (14) to (1).

3. Lift up the cylinder head to detach.

4. Remove the cylinder head gasket and O-ring.

(When reassembling)

• Replace the cylinder head gasket with a new one.

• Securely fit the O-ring to the pipe pin.

• Tighten the cylinder head bolts after applying sufficient oil.

• Tighten the cylinder head bolts in diagonal sequence starting from the center. (Refer to figure left.)

• Tighen them unifo rmly, or the cylinder head m ay deform in the long run.

• Retighten the cy linde r head bol ts after r un nin g the eng ine for 30 minutes.

• To Loosen : 14 to 1

• To Tighten : 1 to 14

37.2 to 42.1 N·m

Tightening torque Cylinder head screw

3.8 to 4.3 kgf·m

28.0 to 31.7 ft-lbs W10159710

Tappets

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

(When reassembling)

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

• Mark the cylinder number to the tappets to prevent interchanging.

(1) Tappet

W1027457

Valves

1. Remove the valve caps (2).

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

3. Remove the valve spri ng retain er (4 ), valve spri ng (5) an d valv e stem seal (6).

4. Remove the valve (7).

(When reassembling)

• Wash the va lve s tem and valve guid e h ole , an d a ppl y engine oil sufficiently.

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

• Don’t cha nge the combination of valve and valve guide.

(1) Valve Spring Replacer (2) Valve Cap (3) Valve Spring Collet (4) Valve Spring Retainer

(5) Valve Spring (6) Valve Stem Seal (7) Valve

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NOTE■

KiSC issued 11, 2006 A

(B) Timing Gears and Camshaft

ENGINE

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 spring (4).

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

(When reassembling)

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

• Be sure to place the copper washers underneath two screws (1) (as shown in the figure).

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

• Insert the injection pump (3) so that the control rod (7) should be pushed by the spring (6) at its end and the pin (10) on the rod engages with the slot (9) on the fork lever (as shown in the figure).

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

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

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

(1) Screws and Copper Washers (2) Speed Control Plate (3) Injection Pump (4) Spring (5) Lever

(6) Spring (7) Control Rod (8) Slot (Crankcase Side) (9) Slot (Fork Lever Side)

(10) Pin

W10167080

Fan Drive Pulley

1. Set the stopper to the flywheel.

2. Remove the fan drive pulley retaining screw.

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

(When reassembling)

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

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

Tightening torque

(1) Aligning Mark

Fan drive pulley retaining screw

117.6 to 127.4 N·m

12.0 to 13.0 kgf·m

86.8 to 94.0 ft-lbs

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ENGINE

Gear Case

1. Remove the screw (1).

2. Disconnect the start spring (2) in the speed control plate mounting hole.

3. Remove the gear case (3).

(When reassembling)

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

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

(1) Screw (2) Start Spring (3) Gear Case

(4) Gear Case Gasket (5) O-rings

W10174840

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.

3. Remove the idle gear shaft.

(When reassembling)

• Install the idl e gear, aligning th e mark on the gears r eferring to the figure.

• Apply engine oil to the idle gear shaft mounting screws. And tighten them.

Tightening torque

(1) Idle Gear (2) Idle Gear Collar

Idle gear shaft mounting screw

(3) External Snap Ring

9.8 to 11.3 N·m

1.00 to 1.15 kgf·m

7.2 to 8.3 ft-lbs

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ENGINE

Fuel Camshaft

1. Remove the screws and d ra w out t he c ams ha ft wit h the gear on it.

2. Remove the retaining plate (1).

3. Remove the screws, then dra w out the injection pump gear (2) and fuel camshaft (3) with the governor fork assembly.

(When reassembling)

• Hook the spring to the fork lever 2 (4) as shown in the figure before installing the fork lever assembly to the crankcase.

(1) Retaining Plate (2) Injection Pump Gear (3) Fuel Camshaft

(4) Fork Lever 2 (5) Fork Lever 1 (6) Governor Sleeve

W10178820

Oil Pump and Crankshaft Gear

1. Remove the oil pump gear (6).

2. Remove the oil pump (5).

3. Remove the collar (4), O-ring (3) and oil slinger (2).

4. Remove the crankshaft gear (1) with a puller.

(When reassembling)

• Install the coll ar after align ing the mar ks on the gear s. (See the figure at “Idle Gear”.)

(1) Crankshaft Gear (2) Crankshaft Oil Slinger (3) O-ring

(4) Crankshaft Collar (5) Oil Pump (6) Oil Pump Gear

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IMPORTANT■

KiSC issued 11, 2006 A

ENGINE

Oil Pan and Oil Strainer

1. Remove the oil pan (4).

2. Remove the oil strainer (3).

(When reassembling)

• Install the oil strainer, using care not to damage the O-ring (1).

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

• Apply liquid gask et (Three Bo nd 1270D or 1270C) to the oil pan as shown in the figure.

• Scrape off the old adhesive completely. Wipe th e sealing surface clean using waste cloth soaked with gasoline. Now apply n e w a d he si v e 3 to 5 mm (0.1 2 t o 0. 2 0 in .) t hi c k a l l over the contact surfac e. Apply the adhesive also on the center of the flange as w ell as on th e inner wa ll of ea ch b olt hole.

• Cut the nozzle of t he “flu id seala nt” c ontain er at it s sec ond notch. Apply “fluid sealant” about 5 mm (0.20 in.) thick. Within 20 minutes after the application of fluid sealant, reassemble the components. Wait then for about 30 minutes, and pour oil in the crankcase.

(1) O-ring (2) Screw (3) Oil Strainer (4) Oil Pan

(5) Oil Pan Mounting Screws (6) Hole (7) Fluid Sealant

W10265670

Connecting Rod Cap

1. Remove the connecting rod screws from connecting rod cap.

2. Remove the conne cti ng rod caps .

(When reassembling)

• Align the marks (a) with each other. ( Face th e m ar ks to ward the injection pump.)

• Apply engine oil to the connecting rod screws and lightly screw it in by hand, then tighten it to the specified torque. If the connecting rod scr ew wo n’t b e s crew ed i n s moo thly, c lean the threads. If the connecting rod screw is still hard to screw in, replace it.

• Do not change the combination of crankpin bearing and connecting rod.

Tightening torque Connecting rod screw

(a) Mark

26.5 to 30.4 N·m

2.7 to 3.1 kgf·m

19.5 to 22.4 ft-lbs

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KiSC issued 11, 2006 A

ENGINE

Piston

1. Turn the flywheel and bring the No.1 piston to the top dead center.

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

(When reassembling)

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

• When inserting the pis ton into the cylinder, fac e the mar k on the connecting rod to the injection pump.

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

• When inserting the piston into the cylinder, place the gap of the compression ring 1 on the opposite side of the combustion chamber and stagger the gaps of the compression ring 2 and oil ring making a right angle from the gap of the compression ring 1.

• Carefully insert the pistons using a piston ring compressor. Otherwise, their chrome-plated section may be scratched, causing trouble inside the cylinder.

(A) Top Ring Gap (B) Second Ring Gap (C) Oil Ring Gap (D) Piston Pin Hole

(a) 0.79 rad (45°) (b) 0.79 rad (45°) (c) 0.79 rad (45°)

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IMPORTANT■

KiSC issued 11, 2006 A

ENGINE

Piston Ring and Connecting Rod

1. Remove the piston rings using a piston ring tool.

2. Put the casting mark (↑) (8) on the piston as shown in figure.

3. Remove the piston pin ( 1), and se parate the conn ecting rod (7) from the piston (2).

(When reassembling)

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

• When installi ng the oil ring o nto the piston, plac e the expander joint (10) on the opposite side of the oil ring gap (11).

• Apply engine oil to the piston pin.

• When installing the piston pin, immerse the piston in 80 °C (176°F) oil for 10 to 15 min utes and insert the pisto n pin to the piston.

• When installi ng the connecti ng rod to the piston, align th e mark (8) on the connecting rod to the casting mark (9).

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

(1) Piston Pin (2) Piston (3) Piston Pin Snap Ring (4) Top Ring (5) Second Ring (6) Oil Ring

(7) Connecting Rod (8) Mark (9) Casting Ma rk

(10) Expander Joint

(11) Oil Ring Gap

(12) Manufact urer’s Mark

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(D) Crankshaft

ENGINE

Flywheel

1. Lock the flywheel not to turn using flywheel stopper.

2. Remove the flywheel screws, except for two which must be loosened and left as they are.

3. Set a flywheel p uller (Code No: 07916 -32011), and rem ove the flywheel.

(When reassembling)

• Apply engine oil to the flywheel screws. And tighten them.

53.9 to 58.8 N·m

Tightening torque Flywheel bolt

5.5 to 6.0 kgf·m

39.8 to 43.4 ft-lbs W1030810

Bearing Case Cover

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

(When reassembling)

• Fit the bearing case gasket (3) and the bearing case cover gasket (4) with correct directions.

• Apply liquid-ty pe gasket (Three Bond 1215 or i ts equivalent) to both sides of a new bearing case cover gas ket .

• Install the bearing case cover to position the casting mark “↑” (1) on it upward.

• Apply engine oil to the oil seal lip and take care that it is not rolled when insta lling.

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

(1) Mark (2) Mark Bearing Case Cover (3) Bearing Case Gasket (4) Bearing Case Cover Gasket

(A) Upside

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ENGINE

Crankshaft

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

2. Pull out the crankshaft assembly.

(When reassembling)

• Install the cranks haft sub assembly, aligning the screw hol e of main bearing case 2 with the screw hole of cylinder block.

• Apply engine oil to the main bearing case screw 2. And tighten it.

26.5 to 30.4 N·m

Tightening torque Main bearing case screw 2

(1) Main Bearing Case Screw 2

2.7 to 3.1 kgf·m

19.5 to 22.4 ft-lbs

W1031360

Main Bearing Case Assembly

1. Remove the two main bearing case screws 1 (3), and remove the main bearing ca se assembly 1 (2), being c ar eful wi th c r ankshaft bearing 2.

2. Remove the main bearing case assembly 2 (1) and 3 (4) as above.

(When reassembling)

• Clean the oil passage in the main bearing case.

• Apply clean engine oil on the bearings.

• Install the main bearing case assemblies in the original positions. Since diameters o f m ain bearing case vary, install them in or de r of makings (1, 2) from the gear case side.

• Match the alignment numbers (1 or 2) on the main bearing case.

• When installi ng the main bearing case 2 a nd 3, face the mark “FLYWHEEL” to the flywheel.

• Apply engine oil to the bearing case screw 1.

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

Tightening torque Bearing case screw 1

(1) Main Bearing Case Assembly 2 (2) Main Bearing Case Assembly 1

(3) Main Bearing Case Screw 1 (4) Main Bearing Case Assembly 3

12.7 to 15.7 N·m

1.3 to 1.6 kgf·m

9.4 to 11.6 ft-lbs

W1031597

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IMPORTANT■

KiSC issued 11, 2006 A

(3) Servicing (A) Cylinder Head and Valve

ENGINE

Cylinder Head Surface Flatness

1. Clean the cylinder head surface.

2. Place a straighte dge on the cylinder head’s fo ur sides and two diagonal as shown in the figure.

3. Measure the clearance with a feeler gauge.

4. If the measuremen t exceed s the allo wable l imit, correct it wi th a surface grinder.

• Do not place the straightedge on the combustion chamber.

• Be sure to check the valve recessing after correcting.

Cylinder head surface flatness

Allowable limit

0.05 mm

0.0020 in. W10301620

Cylinder Head Flaw

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

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

3. Spray the cyl inder head surface with the r ed permeative liquid (1). Leave it five to ten minutes after spraying.

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

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

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

(1) Red Permeative Liquid (2) Detergent

(3) White Developer

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ENGINE

Valve Recessing

1. Clean the cylinder head surface, valve face and valve seat.

2. Insert the valve into the valve guide.

3. Measure the valve recessing with a depth gauge.

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

5. If it still exceeds the allowable limit after replacing the valve, correct the valve seat face of the cylinder head with a valve seat cutter (Code No. 07909-33102) or valve seat grinder.

6. Then, correct the cylinder head surface with a surface grinder, or replace the cylinder head.

0.10 (protrusion) to

Factory spec.

Valve recessing

Allowable limit

0.10 (recessing) mm

0.0039 (protrusion) to

0.0039 (recessing) in.

0.30 (recessing) mm

0.0118 (recessing) in.

(1) Cylinder Head Surface (A) Recessing

(B) Protrusion

W10305870

Clearance between Valve Stem and Valve Guide

1. Remove carbon from the valve guide section.

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

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

4. If the clea rance exceeds t he allowable limit, replace th e valves. If it still exceeds the allowable limit, replace the valve guide.

Clearance between valve stem and valve guide

Valve stem O.D. Factory spec.

Valve guide I.D. Fact ory spec .

Factory spec.

Allowable limit

0.030 to 0.057 mm

0.00118 to 0.00224 in.

0.10 mm

0.0039 in.

5.968 to 5.980 mm

0.23496 to 0.23543 in.

6.010 to 6.025 mm

0.23661 to 0.23720 in. W10311740

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IMPORTANT■

KiSC issued 11, 2006 A

ENGINE

Replacing Valve Guide (When removing)

1. Press out the used valve guide using a valve guide replacing tool.

(When installing)

1. Clean a new valve guide and valve guide bore, and apply engine oil to them.

2. Press in a new valve guide using a valve guide replacing tool.

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

Valve guide I.D. (Intake and exhaust)

Factory spec.

6.010 to 6.025 mm

0.23661 to 0.23720 in.

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

(1) Intake Val ve Guide (2) Exhaust Valve Guide

(A) When Removing (B) When Installing

W10314690

Valve Seating

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

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

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

(1) Correct (2) Incorrect

(3) Incorrect

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NOTE■

IMPORTANT■

KiSC issued 11, 2006 A

ENGINE

Correcting Valve and Valve Seat

• Before correct ing the valve and se at, check the valve stem and the I.D. of the valve guide section, and repair them if necessary.

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

1) Correcting Valve

1. Correct the valve with a valve refacer.

Valve face angle Fact ory spec .

0.79 rad

45.0°

2) Correcting Valve Seat

1. Slightly c orrec t the seat surfa ce wi th a 0.79 rad (45°) valve seat cutter (Code No. 07909-33102).

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

3. Grind the upp er surface of the valve s eat with a 0.26 rad (15°) valve seat cutter until the v alve sea t touc he s to the c ente r of the valve face (so that a equals b as shown in the figure).

4. Grind the se at with a 0 .79 rad (45°) valv e seat cutter again, and visually recheck the contact between the valve and seat.

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

6. Continue l app ing un til th e sea ted r ate be co mes m ore t han 70 % of the total contact area.

Valve seat angle Factory spec .

0.79 rad

14.0°

(a) Identical Dimensions (b) Valve Seat Width (c) 0.26 rad (15°) (d) 0.26 rad (15°) (e) 0.79 rad (45°)

(A) Check Contact (B) Correct Seat Width (C) Check Contact

W10319540

Valve Lapping

1. Apply compound evenly to the valve lapping surface.

2. Insert th e va lv e i nto th e v al ve g uid e. La p the valve onto i ts seat with a valve flapper or screwdriver.

3. After lappi ng the v alv e, wash the compound away and apply oil, then repeat valve lapping with oil.

4. Apply prussi an blue to the contact surfa ce to check the seated rate. If it is less than 70%, repeat valve lapping again.

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

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ENGINE

Free Length and Tilt of Valve Spring

1. Measure the free length (A) of valve spring with venire calipers. If the measurement is less than the allowable limit, replace it.

2. Put the valve spr ing on a surface plate, pl ace a square on the side of the valve spring.

3. Check to see if the entire side is in contact with the square. Rotate the valve spring and measure the maximum tilt (B). If the measurement exceeds the allowable limit, replace it. Check the entire surface of the valve spring for scratches. If there is any defect, replace it.

Tilt (B) Allowable limit

1.2 mm

0.047 in.

Factory spec.

Free length (A)

Allowable limit

31.3 to 31.8 mm

1.232 to 1.252 in.

28.4 mm

1.118 in. W11157830

Valve Spring Setting Load

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

2. Read the compression load on the gauge.

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

64.7 N / 27.0 mm

Factory spec.

Setting load / Setting length

Allowable limit

6.6 kgf / 27.0 mm

14.6 lbs / 1.063 in.

54.9 N / 27.0 mm

5.6 kgf / 27.0 mm

12.3 lbs / 1.063 in. W11177330

Oil Clearance between Rocker Arm and Rocker Arm Shaft

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

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

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

Oil clearance between rocker arm and rocker arm shaft

Factory spec.

Allowable limit

0.016 to 0.045 mm

0.00063 to 0.00177 in.

0.15 mm

0.0059 in.

Rocker arm shaft O.D. Factory spec.

Rocker arm I.D. Factory spec.

10.473 to 10.484 mm

0.41232 to 0.41276 in.

10.500 to 10.518 mm

0.41339 to 0.41410 in. W11199710

Push Rod Runout

1. Place the push rod on V blocks.

2. Measure the push rod runout.

3. If the meas ureme nt exceed s the all owable l imit, re place the push rod.

Push rod runout Allowable limit

0.50 mm

0.0196 in. W11220210

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ENGINE

Oil Clearance between Tappet and Tappet Guide Bore

1. Measure the tappet O.D. with an outside micr ome ter.

2. Measure the I.D. of t he tapp et g ui de b or e w ith a cy linde r gau ge, and calculate the oil clearance.

3. If the oil clear ance exceeds the allowable limit or th e tappet is damaged, replace the tappet.

Oil clearance between tappet and tappet guide bore

Factory spec.

Allowable limit

0.016 to 0.052 mm

0.00063 to 0.00205 in.

0.10 mm

0.0039 in.

Tappet O.D. Factory spec.

Tappet guide bore I.D. Factory spec.

(B) Timing Gears, 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 shaft and the gear.

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

Backlash between idle gear and crank gear

Backlash between idle gear and cam gear

Backlash between idle gear and injection pump gear

Factory spec.

Allowable limit

Factory spec.

Allowable limit

Factory spec.

Allowable limit

17.966 to 17.984 mm

0.70732 to 0.70803 in.

18.000 to 18.018 mm

0.70866 to 0.70937 in. W11231410

0.043 to 0.124 mm

0.00169 to 0.00484 in.

0.15 mm

0.0059 in.

0.047 to 0.123 mm

0.00185 to 0.00484 in.

0.15 mm

0.0059 in.

0.041 to 0.124 mm

0.00161 to 0.00488 in.

0.15 mm

0.0059 in.

Backlash between oil pump drive gear and crank gear

Factory spec.

Allowable limit

0.041 to 0.123 mm

0.00161 to 0.00484 in.

0.15 mm

0.0059 in. W11264830

Idle Gear Side Clearance

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

2. Measure the s ide clearanc e by movi ng the idle gea r to the front and rear.

3. If the measu remen t exceed s th e allo wable lim it, re place the id le gear collar.

Factory spec.

Idle gear side clearance

Allowable limit

0.20 to 0.51 mm

0.0079 to 0.0201 in.

0.60 mm

0.0236 in. W11286770

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ENGINE

Camshaft Side Clearance

1. Set a dial indicator with its tip on the camshaft.

2. Measure the side clearance by moving the cam gear to the font and rear.

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

0.15 to 0.31 mm

0.0059 to 0.0122 in.

0.50 mm

0.0197 in. W11299720

Camshaft side clearance

Factory spec.

Allowable limit

Camshaft Runout

1. Support the camshaft wit h V blocks on the su rface plate at both end journals.

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

3. Measure the camshaft runout.

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

Camshaft runout Allowable limit

0.02 mm

0.0008 in. W11312720

Cam Height

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

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

26.88 mm

1.0583 in.

26.83 mm

1.0563 in. W11324040

Cam height of intake and exhaust

Factory spec.

Allowable limit

Oil Clearance of Camshaft Journal

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

2. Measure the camsha ft bearing I.D. (cylinder blo ck bore I.D.) for camshaft with an inside micrometer. Calculate the oil clearance.

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

Oil clearance of camshaft journal

Camshaft journal O.D. Factory spec.

Camshaft Bearing I.D. (Cylinder block bore I.D.)

Factory spec.

Allowable limit

Factory spec.

0.050 to 0.091 mm

0.00197 to 0.00358 in.

0.15 mm

0.0059 in.

32.934 to 32.950 mm

1.29661 to 1.29724 in.

33.000 to 33.025 mm

1.29921 to 1.30020 in. W11335580

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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 id le gear bushing I.D. with an inside micrometer, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit, replace the bushing. If it still exceeds the allowable limit, replace the idle gear shaft.

Oil clearance between idle gear shaft and idle gear bushing

Factory spec.

Allowable limit

0.020 to 0.084 mm

0.00079 to 0.00331 in.

0.10 mm

0.0039 in.

Idle gear shaft O.D. Factory spec.

Idle gear bushing I.D. Factory spec.

19.967 to 19.980 mm

0.78610 to 0.78661 in.

20.000 to 20.051 mm

0.78740 to 0.78941 in. W11356150

Replacing Idle Gear Bushing (When removing)

1. Press out the used idl e gear bushi ng using an idle gear bushi ng replacing tool.

(When installing)

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

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

(A) When Removing (B) When Installing

W11373220

Piston Pin Bore I.D.

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

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

Factory spec.

Piston pin bore I.D.

Allowable limit

20.000 to 20.013 mm

0.78740 to 0.78791 in.

20.05 mm

0.7894 in. W11406200

1-S38

Page 99

G2160, WSM

NOTE■

KiSC issued 11, 2006 A

ENGINE

Oil Clearance between Piton 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 en d bushing I.D. with an inside micro meter, and calculate the oil clearance.

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

Oil clearance between piston pin and small end bushing

Factory spec.

Allowable limit

0.014 to 0.038 mm

0.00055 to 0.00150 in.

0.10 mm

0.0039 in.

Piston pin O.D. Factory spec.

Small end bushing I.D. Factory spec.

20.002 to 20.011 mm

0.78748 to 0.78783 in.

20.025 to 20.040 mm

0.78839 to 0.78897 in. W11420110

Replacing Small End Bushing (When removing)

1. Press out the used bushing us in g a small end bus hing r epl acing tool.

(When installing)

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

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

3. Drill a hole to the bushing with aligning the oil hole (2) of connecting rod using 4.0 mm dia. (0.157 in. dia.) drill.

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

(1) Seam (2) Oil Hole

(A) When Removing (B) When Installing (a) 0.79 rad (45°)

W11437590

Piston Ring Gap

1. Insert the piston ring in to th e l owe r par t o f the c ylin der (the least worn out part) with a piston ring compressor and piston.

2. Measure the ring gap with a feeler gauge.

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

Piston ring gap

Top ring Oil ring

Second ring

Factory spec.

Allowable limit

Factory spec.

Allowable limit

0.15 to 0.30 mm

0.0059 to 0.0118 in.

1.25 mm

0.0492 in.

0.30 to 0.45 mm

0.0118 to 0.0177 in.

1.25 mm

0.0492 in. W11466710

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Page 100

G2160, WSM

NOTE■

KiSC issued 11, 2006 A

ENGINE

Clearance between Piston Ring and Piston Ring Groove

1. Clean the rin gs and the ring grooves , and inst all each rin g in its groove.

2. Measure th e clearance be tween the ring a nd the groove with a feeler gauge.

3. If the clear ance exceeds the allowable l imit, replace the piston ring.

4. If the clearance still exceeds the allowable limit after replacing the ring, replace the piston.

Clearance between piston ring and piston ring groove

Second ring

Oil ring

Factory spec.

Allowable limit

Factory spec.

Allowable limit

0.090 to 0.120 mm

0.00354 to 0.00472 in.

0.15 mm

0.0059 in.

0.04 to 0.08 mm

0.0016 to 0.0031 in.

0.15 mm

0.0059 in. W11485500

Connecting Rod Alignment

• Since the I.D. of the connecting rod small end bushing is the basis of this check, check the bushing for wear beforehand.

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

2. Install the piston pin in the connecting rod.

3. Install the connecting rod on the connecting rod alignment tool (Code No. 07909-31661).

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

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

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

Space between gauge pin and face plate

Allowable limit

0.05 mm

0.0020 in. W11499650

1-S40