Kubota G21HD Workshop Manual

Category
Lawnmowers
Type
Workshop Manual

This manual is also suitable for

G21LD,G21HD
WORKSHOP MANUAL
KiSC issued 08, 2007 A
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of G21LD and G21HD. It is
divided into three parts, “General”, “Mechanism” and “Servicing”.
General
Information on the product identification, the general precautions, maintenance
check list, check and maintenance and special tools are described.
Mechanism
Information on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.
Refer to Diesel Engine Mechanism Workshop Manual (Code No. 9Y021-01874) for
the one which has not been described to this workshop manual.
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.
June 2005
© KUBOTA Corporation 2005
KiSC issued 08, 2007 A
1
G21LD · G21HD, WSM
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
BEFORE SERVICING AND REPAIRING
Read all instructions and safety instructions in this
manual and on your machine 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 aDO NOT OPERATE” tag in operator
station.
SAFETY FIRST
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.
KiSC issued 08, 2007 A
2
G21LD · G21HD, WSM
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) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
AVOID FIRES
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 battery, especially when
charging the battery.
Make sure that no fuel has been spilled on the engine.
KiSC issued 08, 2007 A
3
G21LD · G21HD, WSM
SAFETY INSTRUCTIONS
VENTILATE WORK AREA
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.
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
DISPOSE OF FLUIDS PROPERLY
Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when disposing
of oil, fuel, coolant, electrolyte and other harmful
waste.
PREPARE FOR EMERGENCIES
Keep a first aid kit and fire extinguisher handy at all
times.
Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
KiSC issued 08, 2007 A
4
G21LD · G21HD, WSM
SAFETY INSTRUCTIONS
The following safety decals are installed on the machine.
If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in
the parts list.
SAFETY DECALS
KiSC issued 08, 2007 A
5
G21LD · G21HD, WSM
SAFETY INSTRUCTIONS
KiSC issued 08, 2007 A
6
G21LD · G21HD, WSM
SAFETY INSTRUCTIONS
KiSC issued 08, 2007 A
7
G21LD · G21HD, WSM
SAFETY INSTRUCTIONS
KiSC issued 08, 2007 A
8
G21LD · G21HD, WSM
SPECIFICATIONS
SPECIFICATIONS
W1028929
Model G21LD G21HD
Maximum gross power 15.6 kw (21 HP)
Engine
Model D782-E2-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
3
(47.48 cu.in.)
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
Injection timing 0.28 to 0.31 rad (16° to 18°) before T.D.C.
Injection order 1-2-3
Injection pressure 13.73 MPa (140 kgf/cm
2
, 1991 psi)
Compression ratio 24 : 1
Lubricating system Forced Iubrication by gear pump
Cooling system Pressurized radiator, forced circulation with water pump
Lubricating oil API Service classification CC or CD, Below 0°C (32 °F) : SAE 10W or 10W-30, 0 to 25 °C
(32 °F to 77 ° F) : SAE 20 or 10W-30, Above 25 °C (77 °F) : SAE 30 or 10W-30
Starting system Electric starter (12 V, 1.0 kW)
Battery 51R (12V, 450CCA)
Fuel No.2-D diesel fuel (ASTM D975)
[No.1-D diesel fuel, if temperature is below - 10 °C (14 °F)]
Capacities
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)
4.5L (4.75 U.S.qts., 3.96 Imp.qts.) 6.0L (6.34 U.S.qts., 5.28 Imp.qts.)
Mower gear case oil 0.40L (0.42 U.S.qts., 0.35 Imp.qts.)
Tires
Front 16 × 6.50-8 (4PR) Turf
Rear 23 × 10.5-12 (4PR) Turf
Traveling
speeds
Forward 0 to 15.0 km/h (0 to 9.3 mph)
Reverse 0 to 6.0 km/h (0 to 3.8 mph)
Dimensions
Overall length
(with grass collector)
2930 mm (115.4 in.) 2990 mm (117.7 in.)
Overall width (with mower) 1280 mm (50.4 in.)
Overall height 1280 mm (50.4 in.) 1450 mm (57.1 in.)
Wheel base 1280 mm (50.4 in.)
Treads
Front 825 mm (32.5 in.)
Rear 780 mm (30.7 in.)
Weight (Without mower deck and grass
collector)
440 kg (970 lbs) 510 kg (1124 lbs)
PTO Shaft drive
PTO clutch Belt tension
Revolution (PTO speed) 2576 min
-1
(rpm)
PTO brake Available
KiSC issued 08, 2007 A
9
G21LD · G21HD, WSM
SPECIFICATIONS
The company reserves the right to chage the specifications without notice
W1030228
Model G21LD G21HD
Steering Electric power steering (EPS)
Transmission Hydrostatic transmission
Brake Internal expanding brake
Mower Model RCK48G18-PRO
Total length 900 mm (35.4 in.)
Total width 1280 mm (50.4 in.)
Total height 315 mm (12.4 in.)
Mounting method Quick joint, parallel linkage
Adjustment of cutting height Dial gauge
Cutting width 1219 mm (48.0 in.)
Cutting height 25 to 102 mm (1.0 to 4.0 in.)
Number of blades 3
Weight (Approx.) 95 kg (209 lbs)
Discharge direction Rear side
Grass
collector
Model GCK500 GCK500HD
Container capacity 500 L (132 U.S.gals, 110 Imp.gals)
Weight (Approx.) 30 kg (66 Ibs) 60 kg (132 Ibs)
Dumping height 1750 mm (68.9 in.)
KiSC issued 08, 2007 A
10
G21LD · G21HD, WSM
DIMENSIONS
DIMENSIONS
KiSC issued 08, 2007 A
11
G21LD · G21HD, WSM
DIMENSIONS
KiSC issued 08, 2007 A
G GENERAL
KiSC issued 08, 2007 A
CONTENTS
GENERAL
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-6
4. LUBRICANTS, FUEL AND COOLANT ......................................................... G-7
5. TIGHTENING TORQUES ............................................................................... G-8
[1] GENERAL USE SCREWS, BOLTS AND NUTS................................... G-8
[2] METRIC SCREWS, BOLTS AND NUTS ............................................... G-8
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC
OR UNF THREADS................................................................................. G-9
6. MAINTENANCE CHECK LIST..................................................................... G-10
7. CHECK AND MAINTENANCE..................................................................... G-12
[1] DAILY CHECK........................................................................................ G-12
[2] CHECK POINTS OF INITIAL 50 HOURS........................................... G-21
[3] CHECK POINTS OF EVERY 50 HOURS........................................... G-23
[4] CHECK POINTS OF EVERY 100 HOURS......................................... G-29
[5] CHECK POINT OF EVERY 150 HOURS ......................................... G-32
[6] CHECK POINTS OF EVERY 200 HOURS........................................ G-32
[7] CHECK POINTS OF EVERY 300 HOURS......................................... G-34
[8] CHECK POINT OF EVERY 500 HOURS ........................................... G-35
[9] CHECK POINT OF EVERY 1500 HOURS ......................................... G-36
[10]CHECK POINT OF EVERY 3000 HOURS ......................................... G-36
[11]CHECK POINTS OF EVERY 1 YEAR................................................ G-37
[12]CHECK POINTS OF EVERY 2 YEARS.............................................. G-40
[13]OTHERS.................................................................................................. G-43
8. SPECIAL TOOLS.......................................................................................... G-44
[1] SPECIAL TOOLS FOR ENGINE .......................................................... G-44
[2] SPECIAL TOOLS FOR MACHINE........................................................ G-50
9. IMPLEMENT LIMITATIONS.......................................................................... G-55
KiSC issued 08, 2007 A
G-1
G21LD · G21HD, WSM
G GENERAL
1. IDENTIFICATION
W1010714
(1) Engine Serial Number
(2) Machine Serial Number
(3) Mower Serial Number
(4) Hour Meter
KiSC issued 08, 2007 A
G-2
G21LD · G21HD, WSM
G GENERAL
2. GENERAL PRECAUTIONS
During disassembly, carefully arrange removed parts in a clean
area to prevent confusion later. Screws, bolts and nuts should be
installed in their original position to prevent reassembly errors.
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.
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 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.
When inserting spring pins, their splits must face the direction
from which a force is applied. See the figure left side.
To prevent damage to the hydraulic system, use only specified
fluid or equivalent.
W1010904
(1) Grease
(2) Force
(3) Sharp Edge
(4) Axial Force
(5) Rotating Movement
(A) External Snap Ring
(B) Internal Snap Ring
KiSC issued 08, 2007 A
G-3
G21LD · G21HD, WSM
G GENERAL
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS
AND WIRING
To ensure safety and prevent damage to the machine and
surrounding equipment, heed the following precautions in handling
electrical parts and wiring.
IMPORTANT
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.
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.
W1011114
[1] WIRING
Securely tighten wiring terminals.
W1011216
Do not let wiring contact dangerous part.
W1011313
Securely insert grommet.
W1011388
(1) Negative Terminal (2) Positive Terminal
(1) Correct
(Securely tighten)
(2) Incorrect
(Loosening leads to faulty contact)
(1) Dangerous Part
(2) Wiring (Incorrect)
(3) Wiring (Correct)
(4) Dangerous Part
(1) Grommet (A) Correct
(B) Incorrect
KiSC issued 08, 2007 A
G-4
G21LD · G21HD, WSM
G GENERAL
Securely clamp, being careful not to damage wiring.
W1011458
Clamp wiring so that there is no twist, unnecessary sag, or
excessive tension, except for movable part, where sag be
required.
W1011587
In installing a part, take care not to get wiring caught by it.
W1011670
After installing wiring, check protection of terminals and clamped
condition of wiring, only connect battery.
W1011735
(1) Clamp
• Wind Clamp Spirally
(2) Wire Harness
(3) Clamp
(4) Welding Dent
(1) Wiring
(2) Clamp
(A) Correct
(B) Incorrect
(1) Wiring (A) Incorrect
(1) Cover
• Securely Install Cover
KiSC issued 08, 2007 A
G-5
G21LD · G21HD, WSM
G GENERAL
[2] BATTERY
Take care not to confuse positive and negative terminal posts.
When removing battery cables, disconnect negative cable first.
When installing battery cables, check for polarity and connect
positive cable first.
Do not install any battery with capacity other than is specified
(Ah).
After connecting cables to battery terminal posts, apply high
temperature grease to them and securely install terminal covers
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 well-ventilated place where there is no
open flame nearby, as hydrogen gas and oxygen are formed.
W1011816
[3] FUSE
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.
W1012092
[4] CONNECTOR
For connector with lock, push lock to separate.
W1012211
In separating connectors, do not pull wire harnesses.
Hold connector bodies to separate.
W1012272
(1) Fuse (2) Slow Blow Fuse
(A) Push
(A) Correct (B) Incorrect
KiSC issued 08, 2007 A
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Kubota G21HD Workshop Manual

Category
Lawnmowers
Type
Workshop Manual
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