Kubota GR1600EC Workshop Manual

WORKSHOP MANUAL

KiSC issued 04, 2006 A

GR1600EC

TO THE READER

KiSC issued 04, 2006 A

This Workshop Manual has been prepared to provide servicing personn el with information on the mechanism,
service and maintenance of KUBOTA GR1600EC. It is divided into three parts, "General", "Mechanism" and
"Servicing".

B General

Information on the product identification, the general precautions, maintenance check list, check and maintenance
and special tools are described.

B Mechanism

Information on the construction and function are included. This part should be understood before proceeding with
troubleshooting, disassembling and servicing.

B Servicing

Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting,
disassembling and assembling, and servicing which cover procedures, precautions, factory specifications and
allowable limits.

All information illustrations and specifications contained in this manual are based on the latest product information
available at the time of publication.

The right is reserved to make changes in all information at any time without notice.

Due to covering many models of thi s manual, informa tion or picture b eing used ha ve not been specif ied as one
model.

February 2005

KUBOTA Corporation 2005

0000009635E

GR1600EC, WSM SAFETY INSTRUCTIONS

KiSC issued 04, 2006 A

This symbol, the indu stry's "Saf ety Alert Symbol " is used throu ghout this ma nual and on labe ls on the mach ine
itself to warn of the possibility of per sonal injur y. Read these inst ructions care fully.It is essen tial that you read the
instructions and safety regulations before you attempt to repair or use this unit.

A Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

A Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

A Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

A Indicates that equipment or property damage could result if instructions are not followed.

A Gives helpful information.

BEFORE SERVICING AND REPAIRING
A Read all instruc tions and safety instructions in this

manual and on your machine safety decal s .

A Clean the work area and machine.
A Park the machine on a firm and level ground, and set

the parking brake.

A Lower the implement to the ground.
A Stop the engine, and remove the key
A Disconnect the battery negative cable
A Hang a "DO NOT OPERATE" tag in operator

station.

SAFETY STARTING
A Do not start the engine by shorting across starter

terminals or bypassing the safety start switch.

A Do not alter or remove any part of machine safety

system.

A Before starting the engine, make sure that all s hift

levers are in neutral positions or in disengaged
positions.

A Never start the engine while standing on ground.

Start the engine only from operator's seat.

0000000752E

0000000753E

0000000754E

1

GR1600EC, WSM SAFETY INSTRUCTIONS

KiSC issued 04, 2006 A

SAFETY WORKING
A Do not work on the machine while under the

influence of alcohol, medication, or other substances
or while fatigued.

A Wear close fitting clothing and safety equipment

appropriate to the job.

A Use tools appropriate to the wo rk. Makeshift tools,

parts, and procedures are not recommended.

A When servicing is performed together by two or

more persons, take care to perform all work safely.

A Do not work under the machine that is supported

solely by a jack. Always support the machine by
safety stands.

A Do not touch the rotating or hot parts while the

engine is running.

A Never remove the radiator cap while the e ngine 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 loos en the cap to fi rst stop to re lieve
pressure be fore removing completely.

A Escaping fluid (fue l or hydraulic oil ) under pressure

can penetrate the skin causing serious injury.
Relieve pressure before disconnect ing hydraulic or
fuel lines. Tighten all connections before applying
pressure.

0000000755E

AVOID FIRES
A Fuel is extremely flammable and explosive under

certain condit ions. Do not smoke or al low fla mes or
sparks in your working area.

A To avoid sparks from an accidental short circuit,

always disconnect the battery negative cable first
and connect it last.

A Battery gas can explode. Keep sparks and open

flame away from the top of bat tery, esp ecially when
charging the battery.

A Make sure that no fuel has been spilled on the

engine.

0000000756E

2

GR1600EC, WSM SAFETY INSTRUCTIONS

KiSC issued 04, 2006 A

VENTILATE WORK AREA
A If the engine must be running to do some work, make

sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains
poisonous carbon monoxide.

0000000757E

PREVENT ACID BURNS
A Sulfuric acid in battery elec trolyte is poiso nous. 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.

0000000758E

DISPOSE OF FLUIDS PROPERLY
A Do not pour fluids in to the ground, down a drain, or

into a stream, pond, or lake. Observe relevant
environmental protection regulations when
disposing of oil, fuel, cool ant, electrolyte and other
harmful waste.

0000000759E

PREPARE FOR EMERGENCIES
A Keep a first aid k it and fire ex tingu isher h andy at all

times.

A Keep emergency numbers for doctors, ambulance

service, hospital and fire department near your
telephone.

0000000760E

3

GR1600EC, WSM SAFETY INSTRUCTIONS

KiSC issued 04, 2006 A

SAFETY DECALS

The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not

on the machine, replace it. The decal part number is listed in the parts list.

0000009636E

4

GR1600EC, WSM SAFETY INSTRUCTIONS

KiSC issued 04, 2006 A

0000009633E

5

GR1600EC, WSM SAFETY INSTRUCTIONS

KiSC issued 04, 2006 A

0000009634E

6

GR1600EC, WSM SPECIFICATIONS

KiSC issued 04, 2006 A

SPECIFICATIONS

Model GR1600EC
Maker KUBOTA
Model Z482-E2-GX
Type Indirect injection. Vertical, water-cooled, 4-cycle diesel
Number of cylinders 2
Bore and stroke 67 x 68 mm (2.64 x 2.68 in.)
Total displacement 479 (29.9 cu.in.)

Engine

Capacities

Dimensions

Weight (without mower and grass catcher) 310 kg (684 lbs)

Traveling system

PTO system

Engine gross power (DIN) 10.0 kW (13.4 HP)
Rated revolution 53.3 r/s [3200 (rpm)]
Battery 51R (12 V, 450CCA)
Starting system Cell starter (with glow plug)
Lubrication system Forced lubrication by trochoidal pump
Cooling system Pressurized radiator, forced circulation with water pump

Fuel

Fuel tank 18 L (4.8 U.S.gals, 4.0 lmp.gals)
Engine crankcase (with filter) 1.2 L (1.27 U.S.qts., 1.06 lmp.qts.)
Engine coolant (with recovery tank) 2.15 L (2.27 U.S.qts., 1.89 lmp.qts.)
Transmission case 2.7 L (0.71 U.S.gals., 0.59 lmp.gals.)
Overall length (with grass catcher) 2460 mm (96.9 in.)
Overall width 1110 mm (43.7 in.)
Overall height 1190 mm (46.9 in.)
Wheel base 1280 mm (50.4 in.)

Tread

Tires

Steering Manual (Sector gear type)
Transmission Hydrostatic transmission
Brake Internal expanding brake
Differential Bevel gear

Traveling speed

Clutch Mechanical wet multi discs
PTO brake Wet multi discs

Front 750 mm (29.5 in.)
Rear 800 mm (31.5 in.)

Front 15 x 6.00 - 6, 4PR
Rear 20 x 10.00 - 8, 4PR

Forward 0.0 to 10.0 km/h (0.0 to 6.2 mph)
Reverse 0.0 to 5.0 km/h (0.0 to 3.1 mph)

Diesel fuel No.2-D [above -10 (14 )],
Diesel fuel No.1-D [below -10 (14 )]

NOTE: *Manufacture's estimate
The company reserves the right to change the specifications without notice.

0000009637E

7

GR1600EC, WSM SPECIFICATIONS

KiSC issued 04, 2006 A

Model RCK42GR
Cutting width 1067 mm (42.0 in.)
Cutting height 25 to 102 mm (1 to 4 in.)
Adjustment of cutting height Dual gauge
Mounting method Quick joint, Parallel linkage

Mower

Grass catcher

NOTE: *Manufacture's estimate
The company reserves the right to change the specifications without notice.

Weight (Approx.) 75 kg (165 lbs)

Total length 965 mm (38.0 in.)

Dimensions

Discharge direction Rear
Gear box oil 0.33 L (0.35 U.S.qts, 0.29 Imp.qts)

Model GCK350GR
Container capacity 350 L (92.5 U.S.gals, 77.0 Imp.gals)
Weight (Approx.) 40 kg (88.2 lbs)

Total width 1110 mm (43.7 in.)
Total height 295 mm (11.6 in.)

0000009638E

8

GR1600EC, WSM DIMENSIONS

KiSC issued 04, 2006 A

DIMENSIONS

0000009634E

9

KiSC issued 04, 2006 A

G GENERAL

CONTENTS

KiSC issued 04, 2006 A

1. IDENTIFICATION................................................................................................................G-1

2. GENERAL PRECAUTIONS................................................................................................G-2

3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING......................G-3

[1] WIRING..............................................................................................................................G-3

[2] BATTERY ..........................................................................................................................G-5

[3] FUSE .................................................................................................................................G-5

[4] CONNECTOR....................................................................................................................G-5

[5] HANDLING OF CIRCUIT TESTER.................................................................................G-7

4. LUBRICANTS, FUEL AND COOLANT.............................................................................G-8

5. TIGHTENING TORQUES...................................................................................................G-9

[1] GENERAL USE SCREWS, BOLTS AND NUTS ..........................................................G-9

[2] METRIC SCREWS, BOLTS AND NUTS.......................................................................G-9

[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF

THREADS........................................................................................................................G-10

[4] PLUGS.............................................................................................................................G-10

6. MAINTENANCE CHECK LIST ........................................................................................ G-11

7. CHECK AND MAINTENANCE ........................................................................................G-13

[1] DAILY CHECK..... ............................................................. ..............................................G-13

[2] CHECK POINTS OF EVERY 50 HOURS...................................................................G-19

[3] CHECK POINTS OF EVERY 100 HOURS.................................................................G-25

[4] CHECK POINT OF EVERY 150 HOURS ...................................................................G-27

[5] CHECK POINTS OF EVERY 200 HOURS.................................................................G-28

[6] CHECK POINT OF EVERY 400 HOURS ...................................................................G-31

[7] CHECK POINTS OF EVERY 1 YEAR........................................................................G-31

[8] CHECK POINTS OF EVERY 2 YEARS......................................................................G-34

[9] OTHERS..........................................................................................................................G-35

8. SPECIAL TOOLS .............................................................................................................G-38

[1] SPECIAL TOOLS FOR ENGINE..................................................................................G-38

[2] SPECIAL TOOLS FOR MACHINE ...............................................................................G-45

9. TIRES................................................................................................................................G-46

[1] TIRE PRESSURE...........................................................................................................G-46

[2] TREAD.............................................................................................................................G-46

10.IMPLEMENT LIMITATIONS .............................................................................................G-47

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

1. IDENTIFICATION

When contacting your local KUBOTA distributor, always specify
engine serial number (2), machine serial number (1), mower serial
number (3) and hour meter reading.

(1) Machine Serial Number (3) Mower Serial Number
(2) Engine Serial Number (4) Hour Meter

0000009540E

G-1

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

2. GENERAL PRECAUTIONS

A During disassembly, carefully arrange removed parts in a

clean area to prevent conf usion late r. Screws, bolts and nuts
should be installed in their original position to prevent
reassembly errors.

A When special tools are required, use KUBOTA genuine

special tools. Special tools which are not frequently used
should be made according to the drawings provided.

A Before disassembling or servicing electrical wires, always

disconnect the ground cable from the battery first.

A Remove oil and dirt from parts before measuring.
A Use only KUBOTA genuine parts for parts replacement to

maintain machine performance and to assure safety.

A Gaskets and O-rings must be replaced during reassembly.

Apply grease to new O -rings or oil seals b efore assembling.
See the figure left side.

A When reassembling external snap rings or internal snap rings

, they must be positioned so that sharp edge faces against the
direction from which a force is applied. See the figure left side.

A When inserting spring pins, their splits must face the direction

from which a force is applied. See the figure left side.

A To prevent damage to t he hydraul ic system, u se only sp ecified

fluid or equivalent.

(1) Grease (A) External Snap Ring
(2) Force (B) Internal Snap Ring
(3) Sharp Edge
(4) Axial Force
(5) Rotating Movement

0000000612E

G-2

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS
AND WIRING

To ensure safety and prevent damage to the machine and
surrounding equipment, heed the following precautions in
handling electrical parts and wiring.

A Check electrical wiring for damage and loosened

connection every year. To this end, educate the customer
to do his or her own check and at the same time
recommend the dealer to perform periodic check for a fee.

A Do not attempt to modify or remodel any electrical parts

and wiring.

A 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

0000000613E

[1] WIRING

A Securely tighten wiring terminals.

(1) Correct (2) Incorrect

(Securely Tighten) (Loosening Leads to Faulty

Contact)

A Do not let wiring contact dangerous part.

(1) Dangerous Part (3) Wiring (Correct)
(2) Wiring (Incorrect) (4) Dangerous Part

A Securely insert grommet.

(1) Grommet (A) Correct

(B) Incorrect

0000000614E

0000000615E

0000000616E

G-3

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

A Securely clamp, being careful not to damage wiring.

(1) Clamp (3) Clamp

*Wind Clamp Spirally (4) Welding Dent

(2) Wire Harness

0000000617E

A Clamp wiring so that there is no twist, unnecessary sag, or

excessive tension, except for movable part, where sag be
required.

(1) Wiring (A) Correct
(2) Clamp (B) Incorrect

0000000618E

A In installing a part, take care not to get wiring caught by it.

(1) Wiring (A) Incorrect

0000000619E

A After installing wiring, check protection of terminals and

clamped condition of wiring, only connect battery.

(1) Cover

*Securely Install Cover

0000000620E

G-4

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

[2] BATTERY

A Take care not to confuse positive and negative terminal posts.
A When removing battery cables, disconnect negative cable

first. When installing battery cables, check for polarity and
connect positive cable first.

A Do not install an y b atte ry wi th ca pac it y o the r than is s pe ci fie d

(Ah).

A After connecting cab les to battery terminal posts, apply high

temperature grease to them and securely install terminal
covers on them.

A Do not allow dirt and dust to collect on battery.

A Take care not to let battery liquid spill on your skin and

clothes. If contaminated, wash it off with water
immediately.

A Before recharging the battery, remove it from the

machine.

A Before recharging, remove cell caps.
A Do recharging in a well-ventilated place where there is no

open flame nearby, as hydrogen gas and oxygen are
formed.

[3] FUSE

[4] CONNECTOR

0000000621E

A Use fuses with specified capacity.

Neither too large or small capacity fuse is acceptable.

A Never use steel or copper wire in place of fuse.
A Do not install working light, radio set, etc. on machine which is

not provided with reserve powe r suppl y.

A Do not install accessories if fuse capacity of reserve power

supply is exceeded.

(1) Fuse (2) Fusible Link

0000000622E

A For connector with lock, push lock to separate.

(A) Push

0000000623E

G-5

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

A In separating connectors, do not pull wire harnesses.
A Hold connector bodies to separate.

(A) Correct (B) Incorrect

0000000624E

A Use sandpaper to remove rust from terminals.
A Repair deformed termin al. Make certain th ere is no terminal

being exposed or displaced.

(1) Exposed Terminal (3) Sandpaper
(2) Deformed Terminal (4) Rust

0000000625E

A Make certain that there is no female connector being too open.

(A) Correct (B) Incorrect

0000000626E

A Make certain plastic cover is large enough to cover whole

connector.

(1) Cover (A) Co r rect

(B) Incorrect

0000000627E

G-6

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

[5] HANDLING OF CIRCUIT TESTER

A Use tester correctly following manual provided with tester.
A Check for polarity and range.

0000000628E

G-7

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

4. LUBRICANTS, FUEL AND COOLANT

No. Place Capacity Lubricants, fuel and coolant

18 L

1 Fuel tank

Cooling system with

2

recovery tank

3 Engine crankcase

4 Transmission case

5 Mower gear box

No. Place No. of greasing points Capacity Type of grease

Engine transmission

6

universal joint

4.8 U.S.gals.

4.0 lmp.gals.

2.15 L

2.27 U.S.qts.

1.89 lmp.qts.

1.2 L

1.27 U.S.qts.

1.06 lmp.qts.

2.7 L

0.71 U.S.gals.

0.59 lmp.gals.

0.33 L

0.35 U.S.qts.

0.29 lmp.qts.

Greasing

1

No. 2-D diesel fuel
No. 1-D diesel fuel if temperature is below

-10 (14 )

Fresh clean water with anti-freeze

Engine oil: API service CD, CE or CF
Below 0 (32 ) : SAE10W, 10W-30 or 10W-40
0 to 25 (32 to 77 ) : SAE20, 10W-30 or 10W-40
Above 25 (77 ) : SAE30, 10W-30 or 10W-40

KUBOTA UDT or SUPER UDT fluid*

SAE90 gear oil
(API service classification : more than GL-3)

Until grease overflows

SAE multi-purpose type

grease7 King pin 2
8 Center pin
9 Speed control pedal shaft

10 Mower link
11 Seat adjuster
12 Cable
13 PTO lever
14 Hydraulic lift lever
15 Grass catcher hinge

[Mower]
16 Spindle shafts 2
17 Tension arm 1
18 Mower universal joint 1 Moderate amount Engine oil

*KUBOTA original transmission hydraulic fluid.

Moderate amount Engine oil

Until grease overflows

SAE multi-purpose type
grease

0000009541E

G-8

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

5. TIGHTENING TORQUES

[1] GENERAL USE SCREWS, BOLTS AND NUTS

Screws, bolt and n uts whose tightening torque are n ot specified in this Workshop M anual should be tightened

according to the table below.

Indication on top of

bolt

Material of bolt SS400, S20C S43C, S48C SCr435, SCM435

Material of

opponent part

Unit
Diameter

M6

(6 mm, 0.24 in.)

M8

(8 mm, 0.31 in.)

M10

(10 mm, 0.39 in.)

M12

(12 mm, 0.47 in.)

M14

(14 mm, 0.55 in.)

M16

(16 mm, 0.63 in.)

M18

(18 mm, 0.71 in.)

M20

(20 mm, 0.79 in.)

7.85
to

9.31

17.7
to

20.5

39.3
to

45.1

62.8
to

72.5

108

to

125
167

to

191
246

to

284
334

to

392

No-grade or 4T 7T 9T

Ordinariness Aluminum Ordinariness Aluminum Ordinariness

ft-lbs ft-lbs ft-lbs ft-lbs ft-lbs

0.80

5.79

7.85

0.80

5.79

9.81

1.00

7.24

7.85

0.80

5.79

12.3

to

0.95

1.8
to

2.1

4.0
to

4.6

6.4
to

7.4

11.0
to

12.8

17.0
to

19.5

25.0
to

29.0

34.0
to

40.0

to

6.87

13.1
to

15.1

29.0
to

33.2

46.3
to

53.5

79.6
to

92.5

123

to

141
181

to

209
246

to

289

to

8.82

16.7
to

19.6

31.4
to

34.3

to

0.90

1.7
to

2.0

3.2
to

3.5

to

6.50

12.3
to

14.4

23.2
to

25.3

to

11.2

23.6
to

27.4

48.1
to

55.8

77.5
to

90.2

124

to

147
197

to

225
275

to

318
368

to

431

to

1.15

2.4
to

2.8

4.9
to

5.7

7.9
to

9.2

12.6
to

15.0

20.0
to

23.0

28.0
to

32.5

37.5
to

44.0

to

8.31

17.4
to

20.2

35.5
to

41.2

57.2
to

66.5

91.2
to

108
145

to

166
203

to

235
272

to

318

to

8.82

17.7
to

20.5

39.3
to

44.1

62.8
to

72.5

to

0.90

1.8
to

2.1

4.0
to

4.5

6.4
to

7.4

to

6.50

13.1
to

15.1

29.0
to

32.5

46.3
to

53.5

to

14.2

29.5
to

34.3

60.9
to

70.6

103

to

117
167

to

196
260

to

304
344

to

402
491

to

568

1.25
to

1.45

3.0
to

3.5

6.2
to

7.2

10.5
to

12.0

17.0
to

20.0

26.5
to

31.0

35.0
to

41.0

50.0
to

58.0

9.05
to

10.4

21.7
to

25.3

44.9
to

52.0

76.0
to

86.7

123

to

144
192

to

224
254

to

296
362

to

419

[2] METRIC SCREWS, BOLTS AND NUTS

Unit
Nominal
Diameter

0000001412E

Grade

M8 23.6 to 27.4 2.4 to 2.8 17.4 to 20.2 29.4 to 34.3 3.0 to 3.5 21.7 to 25.3
M10 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
M12 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
M14 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
M16 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

ft-lbs ft-lbs

Property class 10.9

0000001413E

G-9

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR

UNF THREADS

Grade

Unit
Norminal
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 11 0.0 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

[4] PLUGS

Shape Size

Tapered

screw

Straight

screw

SAE GR.5 SAE GR.8

ft-lbs ft-lbs

0000001414E

Material of opponent part

Ordinariness Aluminum

ft-lbs ft-lbs

R1/8 12.7 to 21.6 1.3 to 2.2 9.4 to 15.9 12.7 to 19.6 1.3 to 2.0 9.4 to 15.4
R1/4 24.5 to 44.1 2.5 to 4.5 18.1 to 32.5 24.5 to 34.3 2.5 to 3.5 18.1 to 25.4
R3/8 49.0 to 88.3 5.0 to 9.0 36.2 to 65.1 49.0 to 58.8 5.0 to 6.0 36.2 to 43.4
R1/2 58.8 to 107.9 6.0 to 11.0 43.4 to 79.6 58.8 to 78.5 6.0 to 8.0 43.4 to 57.9
G1/4 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3
G3/8 61.8 to 82.4 6.3 to 8.4 45.6 to 60.8

G1/2 49.0 to 88.3 5.0 to 9.0 36.2 to 65.1

0000001666E

G-10

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

6. MAINTENANCE CHECK LIST

A The jobs indicated by must be done initially.
A *1 : This maintenance should be done daily more often in dusty conditions than in normal conditions.

Suggested cleaning interval is every 100 hours in normal conditions.

Period

No.

Item

1 Engine oil Change

2 Engine oil filter Replace

3 Transmission fluid Change

4 Transmission oil filter Replace

5 Transmission strainer Clean

6 Front axle pivot Adjust

7 Safety device Check

8 Oiling -

9 Greasing -

Check

10 Mower gear box oil

Change

Clean

11 Air cleaner element

Replace

12 Battery condition Check

13 Brake Adjust

14 Fan drive belt tension Adjust

Check

15 Fuel filter element

Replace

Indication on hour meter (Hr )

50 100 150 200 250 300 350 400 450 500 550 600

After

since

every

100 hr

every

200 hr

every

200 hr

every

200 hr

every

200 hr

every

200 hr

every

50 hr

every

50 hr

every

50 hr

every

50 hr

every

150 hr

every

50 hr

every 1

year

every

50 hr

every

100 hr

every

100 hr

every

100 hr

every

400 hr

Ref-

Im-

por-

ence

tant

page

G-25

G-28

G-29

G-30

G-30

G-31

G-19

G-21

G-20

G-20

G-27

*1 G-20

G-31

G-23

G-26

G-27

G-26

G-31

er-

G-11

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

Period

No.

Item

Check

16 Fuel line

Replace

Radiator hose and

17

clamp

18 Radiator core Check

19 Radiator Clean

20 Coolant Change

21 Mower gear box oil seal Replace

22 Fuel system Bleed
23 Fuse Replace G-35
24 Blade Replace G-36
25 Mower belt Replace G-37

Check

Replace

50 100 150 200 250 300 350 400 450 500 550 600

Indication on hour meter (Hr )

After

since

every

100 hr

every 2

years
every

200 hr

every 2

years
every

200 hr

every 1

year

every 1

year

every 2

years

Ser­vice

as re-

quired

Im­por­tant

Ref-

er­ence
page

G-26

G-34

G-30

G-34

G-30

G-32

G-32

G-34

G-37

0000009542E

G-12

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

7. CHECK AND MAINTENANCE

A Be sure to check and service the machine on a flat place with engine shut off, the parking brake on and

chock the wheels.

0000001417E

[1] DAILY CHECK

To prevent trouble from occurring, it is important to know the condition of the machine. Check the following items

before starting.

Checking

A Check areas where previous trouble was experienced.
A Walk around the machine.

1. Tire pressure, wear and damage

2. Oil and water leak

3. Engine oil level

4. Transmission fluid level

5. Coolant level in the recovery tank

6. Damage of machine body, tightness of all bolts and nuts

7. Radiator screen

8. Panel screen

9. Brake play

10.Fuel level

11.Check air cleaner element
A Mower

1. Oil leak

2. Make sure blade cap screws are tight.

3. Blades for wear or damage.

4. Check all hardware.

5. Make sure all pins are in place.

6. Mower deck cleaning

7. Greasing
A While sitting in the operator's seat,

1. Speed control pedal and brake pedal

2. Brake
A Turning the key switch "ON"

1. Performance of the easy checke r lig ht.
A Starting the engine

1. Color of the exhaust fumes

2. Safety start switch, seat safety control and another safety devices.

3. Check for abnormal noise and vibration.
A Others

1. Check the areas where previous troubles were experienced.

0000009543E

G-13

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

Checking Engine Oil Level

A Always stop the engine and remove the key before

checking oil.

1. Check engine oil before start ing and 5 m inutes or mo re after
the engine has stopped.

2. Wipe dipstick (2) area clean.

3. To check the oil level, remove th e dipstick (2), wi pe it clean,
reinsert i t, and dr aw it ou t again . Check t o see th at the oi l level
is between the two notches.

4. Add new oil to the prescribed level at the oil inlet (1) if
necessary.

5. When using a different brand or viscosity oil from the previous
one, remove all of the old oil and oil filter. Never mix two
different types of oil.

6. Use the proper Engine Oil SAE according to the ambient
temperatures. (See page G-8.)

(1) Engine Oil Inlet A : Upper Level
(2) Oil Level Dipstick B : Lower Level

0000009548E

G-14

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

Checking Am ount of Fuel and Refueling

A Handle fuel carefully. If the engine is running, do not fill

the fuel tank. If engine is hot, let engine cool several
minutes before adding fuel.
Do not smoke while filling the fuel tank or servicing the
fuel system. Fill fuel tank only to bottom of filler neck.

Check the fuel level. Take care that the fuel tank does not

become empty.

Fuel tank capacity

18 L

4.8 U.S.gals.

4.0 Imp.gals.

A Use Diesel Fuel Only.

1. Use No.2-D diesel fuel.

2. Use No.1-D diesel f uel if the temperat ure is below -10 (14

).

3. Always use a strainer whe n refueling to prevent fu el injectio n
pump contamination.

A 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

Min Max Max Max

52 0.05 0.35 0.01

Distillation

Temperatures 90%

Point
MinMaxMinMaxMinMax
282 338 1.9 4.1 32.6 40.1

Sulfur, weight Copper strip Corrosion Cetane Number

Max Max Min

0.50 No.3 40

(1) Fuel Cap

Water and
Sediment,

volume %

Kinematics Viscosity

cSt or /S at 40

Carbon Residue

on, 10 percent

Residuum %

Saybolt Viscosity, SUS

Ash, weight %

at 100

0000009549E

G-15

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

Checking and Cleaning Radiator to Prevent Overheating

A Be sure to stop the engine and remove the key before

cleaning.

Daily or after every 5 ho urs of operation, check to be sure the
radiator screen (2) and radiator core are clean. Dirt or chaff on the
radiator screen (2) or radiator core decrease cooling
performance.

1. Remove the radiator screen (2) and panel screen (1) and

remove all foreign material.

2. Remove the dust from between the fins and the tube.

3. Tighten the fan drive belt as necessary. For this, refer to

"CHECK POINT EVERY 1 00 HOURS".

4. If scale forms in the tube, clean wi th the scale inhi bitor or its

equivalent.

5. Each time the pan el screen (1) is cover ed with grass durin g

operation, rub it off the screen with han d. Check the radiator
screen (2) from time to time if grass accumulates.

6. If the dust or chaff has accumulated inside of the panel,

remove the radiator screen (2) and clean inside completely.
After cleaning, reinstall the radiator screen (2) properly.

A When assembling th e pane l scre en (1), be s ure to fit it to

panel with no clearance at the bottom.

(1) Panel Screen (2) Radiator Screen

0000009550E

G-16

GR1600EC, WSM GENERAL

KiSC issued 04, 2006 A

Checking Tire Pressure

A Do not attempt to mount a tire on a rim. This should be

done by a qualified person with the proper equipment.

A Always maintain the correct tire pressure.

Do not inflate tires above the recommended pressure.

A Inflation pressure in front tire s rises quickly when using

compressed air.

A Never operate machine with a loose rim, wheel or axle.
A Whenever bolts are loosened, retighten to specified

torque.

A Check all bolts frequently and keep them tightened.
B Inflation Pressure

Though the inflation pres sure is factory-set to the prescribed
level, it natur al ly d rop s s low ly i n t he course of time. Th us , check
it every day and inflate as necessary.

Tire Sizes

Front 15 x 6.0-6, 4PR

Rear 20 x 10.00-8, 4PR

Recommended Inflation

Pressure

200 kPa

(2.0 , 29 psi)

140 kPa

(1.4 , 20 psi)

(1) Ground (A) Insufficient

(B) Normal
(C) Excessive

0000009551E

Checking Transmission Fluid Level

1. Park the machine on a flat surface, lower the implement to the

ground and shut off engine and remove the key.

2. Raise the operator's seat.

3. To check the oil le ve l, draw out th e dipsti ck ( 1), wipe it cl ean,

reinsert i t, and dr aw it ou t again . Check t o see th at the oi l level
lies between the two notc hes . If th e l eve l i s too l ow, a dd ne w
oil to the prescribed level at the oil inlet. (See page G-8.)

A If oil level is low, do not run engine.

(1) Oil Level Dipstick A : Oil level is acceptable within

this range.

0000009552E

G-17