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Kubota G5200 Troubleshooting

The Kubota G5200 garden tractor manufactured from 1984 to 1990. The Kubota G5200 is powered by Kubota D600 vertical 3-cylinder water-cooled diesel engine with a rated power of 14 hp (10.4 kW) at 3200 rev/min.

The Kubota G5200 is fitted with a 3-range hydrostatic transmission with infinite forward and reverse gears and foot travel speed control. Maximum forward speed - 6.5 mph (10.5 kph), max. reverse speed - 3.2 mph (5.1 kph). The Kubota G5200 is equipped with a manual steering system, disc type brakes, 15x6.50-8 front tires, and 23x10.5-12 rear tires. The wheelbase is 47.2 in (1190 mm).

The tractor is compatible with the following attachments: 40", 44" and 48" mid-mount 3-blade mower decks, 38", 46" front-mount snowblowers, and 46" or 48" front blades.

Diesel Engine Troubleshooting
Engine will not start or hard to start
Plugged fuel filter - Clean the filter or install new filter element
No fuel supply from the tank - Open the fuel supply valve
Water, dirt, or air in fuel system - Drain, flush, fill, and bleed system
Faulty or dirty injectors - Inspect fuel injectors and replace if necessary
Fuel injection pump malfunctioning - Change pump or rebuild it
Engine has low compression - Check cylinder block and replace worn parts
Diesel stalls while running
Engine is not fully warmed up - Warm up the engine as required
Fuel lines leaking air - Tighten clamps, change faulty pipes
Irregular fuel injection - Adjust fuel injection timing
Fuel filter is dirty - Change filter element
Clogged fuel injectors - Service or change fuel injectors
Engine starts and stops
Fuel injection pump timing is incorrect - Fuel injection pump timing adjustment needs to be corrected
Plugged fuel filter - Clean the filter element
Fuel injector nozzles fault - Replace fuel injector nozzles
Fuel injection pump is not operating properly - Repair or install new pump
Clogged air cleaner element - Change or replace air cleaner element
Engine stalls while idling
Improperly adjusted low idle speed - Correct low idle settings
Defective fuel injection pump - Replace or rebuild injection pump
Damaged or clogged injector nozzles - Change or clean injector nozzles
Excessive valve clearance - Correct valve clearance
Engine is overheated
Low engine coolant - Add the coolant. Inspect the system for leaks
Cooling system is clogged or cooling components are defective - Flush cooling system or replace faulty parts
Lack of engine oil - Fill the crankcase with engine oil
Worn fan belt or unadjusted belt tension - Adjust as required or change belt
Thermostat failure - Check and replace if required
Diesel power loss
Fuel injectors are damaged or dirty - Check fuel injectors and replace if required
Uneven fuel injection pressure - Adjust pressure to proper level
Air filter element clogging - Replace or clean the air filter element
Oil filter element is dirty - Clean or change engine oil filter
Diesel engine overloaded - Reduce load on the engine
Valve clearance is out of adjustment - Correct valve clearance needs to be set
Wrong adjustment of low idle speed - Adjustment required
Fuel hoses or pipes clogging - Clean fuel system hoses and pipes
Poor engine compression: Worn or damaged valves - Have valves replaced
Engine noise or knocking
Timing of fuel injection pump is wrong - Fuel injection pump timing adjustment needs to be corrected
Clogged or damaged injector nozzles - Inspect injector nozzles and change if required
Engine oil insufficient - Fill up the engine oil
Low coolant temperature - Warm up the engine as required
Worn crankshaft or main bearings - Replace crankshaft or bearings
Piston rings are worn or broken - Replace the piston rings as required
Flywheel bolts are loose - Bolts need to be tightened
Engine consuming too much oil
External oil leaks: Worn seals or gaskets - Install new components
Wrong oil viscosity - Use oil of correct viscosity
Worn or stuck piston rings - Change piston rings
Worn valve stems and valve guides - Replace defective valves
Pistons or cylinder liners are scuffed - Inspect liners and pistons, replace as necessary

Hydrostatic Transmission Troubleshooting
HST transmission is excessively noisy
Speed control pedal linkage is damaged or out of adjustment - Adjust or install new linkage
Transmission is under excessive load - Reduce transmission load
Fluid is contaminated or fluid level is insufficient - Top up to proper level or change transmission fluid
Defective or worn transmission parts - Change or repair defective parts
Shifting is hard
Shift linkage is loose or broken - Service or change the linkage
Hydrostatic pump is seized or faulty - Repair or change pump
Damaged or unadjusted transmission shift control components - Adjust correctly or replace
Loss of power
Low oil level - Check transmission oil level and add oil as required
Worn or damaged drive sheave - Replace sheave
Shift linkage is damaged or unadjusted - Change or adjust linkage
Worn or out of adjustment speed control linkage - Adjust or install new linkage
Transmission leakage
Transmission gaskets or seals are damaged - Replace seals or gaskets
Final drive shaft is leaking - Install new shaft seals
Transmission housing is cracked - Replace housing or transmission assembly

Mower Deck Troubleshooting
Excessive mower vibration
Drive sheave of mower deck is dirty or worn - Clean or replace sheave
Drive belt is defective or loose - Change belt or adjust belt tension
Mower blades are warped or not balanced - Change or balance blades
Blade mounting bolts are loose - Bolts should be tightened
Discharge chute regular clogging
Mowing speed is too high - Operate at slower speed
Tall grass - Must be set to low cutting height
Engine rpm is too low - Adjust throttle to full opening
Low cutting height - Must be set to high cutting height
Improper drive belt installation - Check drive belt for correct installation
Uncut grass when mowing
Deck is plugged with grass - Need to clean the mower deck
Not sharp blades - Need to sharpen the blades
Worn or defective blades - Blades must be changed
Ground speed is too fast - Use a lower speed
Cutting level is too low - Change cutting height adjustment
Full bagger - Empty the bagger
Blades are scalping the grass
Bumpy or not smooth lawn - Lawn leveling required
Cutting level is too low - Use correct cutting height
Fast mowing speed - Select a slower speed
Mower deck is not leveled properly - Level the deck properly
Worn or bent blades - Blades need to be replaced
Incorrect tire pressure - Inflate tires correctly
Mower deck to cut unevenly
Tires are not properly inflated - Need to inflate tires
Improper mower deck level - Level the deck properly
Blades are not sharp - Sharpen the blades
Blades are worn or damaged - Replace the blades
Deck is plugged with grass - Inspect and clean cutting deck
Broken mower deck shell - Replace or rebuild mower deck
Mower spindle is loose or defective - Install new spindle or repair it

Electrical Troubleshooting
Battery does not charge
Electrical cable connections are loose or corroded - Tighten or service connections
Battery terminal connectors are faulty - Terminal connectors should be replaced
Dead cell in battery - Battery change required
Starter cranks slow
Low battery output - Battery needs to be recharged
Battery does not hold charge - Service charging system or replace battery
Corroded battery terminals or disconnected wires - Check wiring and clean or replace terminals
Starter doesn't crank
Battery is drained or defective - Charge or change the battery
Wiring harness is disconnected or improperly connected - Check wiring harness and connect as required
Low battery capacity - Battery is drained, charge it
Spark plug gapped improperly or faulty - Clean, gap or replace spark plug
Starter motor or solenoid is damaged - Replace solenoid or repair starter



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