Page 1 WORKSHOP MANUAL ProFields = ZD1211 with RCK60P-1200Z Deck (60”) ZD1211,ZD1211R, ZD1211L,ZD1211RL KiSC issued 06, 2017 A...
Page 2 TO THE READER This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of the ZD1211, ZD1211R, ZD1211L, ZD1211RL. It contains 4 parts: "Information", "General", "Mechanism" and "Servicing". Information This section primarily contains information below. • Safety First •...
Page 3 Record of Revisions For pdf, use search function {Search word} to find all the revised locations. Last digit Issue Reference of the Main Revised Point and Corrective Measures {Search word} month Page Code No. 2016.07 Updated Specifications I-8, I-9, I-10 Added Error Code Display 5-M16 Updated Torque for Gearbox mounting bolt...
Page 4 INFORMATION KiSC issued 06, 2017 A...
Page 5 INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 2. SAFETY DECALS .......................... I-4 3. SPECIFICATIONS.......................... I-8 4. DIMENSIONS ..........................I-10 KiSC issued 06, 2017 A...
Page 6: Safety First
INFORMATION ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. SAFETY FIRST 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.
Page 7 INFORMATION ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM OPERATE SAFELY • Do not use the machine after you consume alcohol or medication or when you are tired. • Put on applicable clothing and safety equipment. • Use applicable tools only. Do not use alternative tools or parts.
Page 8 INFORMATION ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM KEEP A GOOD AIRFLOW IN THE WORK AREA • If the engine is in operation, make sure that the area has good airflow. Do not operate the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.
Page 9: Safety Decals
INFORMATION ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 2. 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.
Page 10 INFORMATION ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 9Y1211344INI0002US0 KiSC issued 06, 2017 A...
Page 11 INFORMATION ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 9Y1211344INI0003US0 KiSC issued 06, 2017 A...
Page 12 INFORMATION ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 9Y1211344INI0004US0 CARE OF DANGER, WARNING AND CAUTION LABELS 1. Keep danger, warning and caution labels clean and free from obstructing material. 2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth.
Page 13: Specifications
(Specifications and design subject to change without notice) NOTE • *1: Manufacturer's estimate, SAE J1940 • *2: At 3000 engine rpm [ZD1211, ZD1211R, ZD1211L, ZD1211RL] • *3: Oil amount when the oil level is at the upper level. 9Y1211344INI0006US0 KiSC issued 06, 2017 A...
Page 14 INFORMATION ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Model RCK60P-1200Z RCK60RP-1200Z RCK72P-1200Z RCK72RP-1200Z Suitable machine ZD1211 ZD1211R ZD1211L ZD1211RL Mounting method Quick joint, Parallel linkage Adjustment of cutting height Dial gauge Cutting width 1524 mm (60.0 in.) 1829 mm (72.0 in.) Cutting height 25 to 127 mm (1.0 to 5.0 in.)
Page 15: Dimensions
INFORMATION ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 4. DIMENSIONS 9Y1211344INI0008US0 I-10 KiSC issued 06, 2017 A...
Page 16 GENERAL KiSC issued 06, 2017 A...
Page 17: Table Of Contents
GENERAL CONTENTS 1. IDENTIFICATION ......................... G-1 2. GENERAL PRECAUTIONS......................G-2 3. CYLINDER NYMBER ........................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 ..................
Page 18: Identification
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. IDENTIFICATION When contacting your local KUBOTA distributor, always specify engine serial number (3), machine serial number (2), mower serial number (4) and hour meter reading. (1) Machine Identification Plate [A] RCK60P, RCK72P (2) Machine Serial Number...
Page 19: General Precautions
• When it is necessary to use special tools, use KUBOTA special tools. Refer to the drawings when you make special tools that you do not use frequently.
Page 20: Cylinder Nymber
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 3. CYLINDER NYMBER The cylinder numbers of KUBOTA diesel engine are designated as shown in the figure. The sequence of cylinder numbers is given as No.1, No.2 and No.3 starting from the gear case side.
Page 21: Handling Precautions For Electrical Parts And Wiring
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, obey the following precautions in handling electrical parts and wiring. IMPORTANT • Check electrical wiring for damage and loosened connection every year.
Page 22 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp (Wind Clamp Spirally) (4) Welding Dent (2) Wire Harness WSM000001GEG0067US0 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.
Page 23: Battery
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [2] BATTERY • Be careful not to confuse positive and negative terminal posts. • When you remove battery cables, disconnect negative cable first. When you install battery cables, check for polarity and connect positive cable first.
Page 24: Handling Of Circuit Tester
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make sure that there is no terminal being exposed or displaced. (1) Exposed Terminal (3) Sandpaper (2) Deformed Terminal (4) Rust WSM000001GEG0075US0 •...
Page 25: Color Of Wiring
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [6] COLOR OF WIRING • Colors of wire are specified to the color codes. • This symbol of "/" shows color with stripe (s). (An example) Red stripe on white color: W/R Color of wiring...
Page 26: Lubricants, Fuel And Coolant
• *1 Oil amount when the oil level is at the upper level of the oil level gauge. • *2 The product name of KUBOTA genuine UDT fluid may be different from that in the Operator's Manual depending on countries or territories.
Page 27 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Greasing Place No. of greasing point Capacity Type of grease King Pin Until grease overflows • Multipurpose EP2 Grease (NLGI Grade Center pin No.2) Front wheel Rear mower link bushing Front mower link bushing...
Page 28 ZD1211, ZD1211R, ZD1211L, ZD1211RL — Transmission Oil • KUBOTA Super UDT-2: For an enhanced ownership experience, we highly recommend Super UDT-2 to be used instead of standard hydraulic/transmission fluid. Super UDT-2 is a proprietary KUBOTA formulation that deliveries superior performance and protection in all operating conditions.
Page 29: Tightening Torques
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 6. TIGHTENING TORQUES Tighten screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual according to the table below. WSM000001GEG0116US0 [1] GENERAL USE SCREWS, BOLTS AND NUTS Indication on top of bolt...
Page 30: Metric Screws, Bolts And Nuts
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [3] METRIC SCREWS, BOLTS AND NUTS Grade Property class 8.8 Property class 10.9 Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft 24 to 27 2.4 to 2.8 18 to 20 30 to 34 3.0 to 3.5...
Page 31: Maintenance Check List
*7: The initial 100 hours should not be a replacement cycle. • The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the U.S.EPA non-road emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction.
Page 32 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Service Interval Refer- After Item ence since 50 100 150 200 250 300 350 400 450 500 550 600 page every 17 Hydraulic oil filter Replace G-35 400 Hr every 18 Engine valve clearance...
Page 33: Check And Maintenance
• Starting the engine 1. Color of the exhaust fumes 2. Safety systems. If either of these do not operate properly, contact your local KUBOTA Dealer immediately. 3. Check for abnormal noise and vibration. • Others 1. Check the areas where previous trouble was experienced.
Page 34 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking Tire Pressure WARNING To avoid personal injury: • Do not try to mount a tire on a rim. This should be done by a qualified person with the proper equipment. • Always keep the correct tire pressure.
Page 35 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking Coolant Level WARNING To avoid serious injury: • Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.
Page 36 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking Amount of Fuel and Refueling CAUTION To avoid personal injury: • 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.
Page 37 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking and Cleaning Radiator to Prevent Overheating WARNING To avoid serious injury: • Engine components can get extremely hot from operation. To prevent severe burns, do not touch these areas while the engine is running, or immediately after it is turned off.
Page 38 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Greasing (Mower) CAUTION To avoid personal injury: • Be sure to stop the engine and remove the key before greasing. 1. Apply grease to the following position as figures. (1) Mower Universal Joint [A] RCK60P, RCK72P...
Page 39: Check Points Of Initial 50 Hours
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil WARNING To avoid serious injury: • Be sure to stop the engine and remove the key before changing the oil. • Allow engine to cool down sufficiently; oil can be hot and may cause burns.
Page 40: Check Point Of Initial 100 Hours
Add fluid to proper level. Check for oil leaks around filter gasket. IMPORTANT • To prevent serious damage or premature failure to the hydraulic system, use only a KUBOTA genuine filter. (1) HST Transmission Oil Filter (2) Gasket Cartridge...
Page 41: Check Point Of Initial 400 Hours
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [4] CHECK POINT OF INITIAL 400 HOURS Changing Transmission Fluid and Rear Axle Gear Case Oil (RH and LH) WARNING To avoid serious injury: • Be sure to stop the engine and remove the key before changing or checking the oil.
Page 42: Check Points Of Every 50 Hours
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [5] CHECK POINTS OF EVERY 50 HOURS Checking Engine Start System WARNING To avoid serious injury: • Do not allow anyone near the machine while testing. • If the machine does not pass one of the following tests, do not operate the machine.
Page 43 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking OPC System The OPC (Operator Presence Control) system in your machine are designed to protect you while operating. Please check these OPC system periodically. It is recommended to check the OPC system before daily operation.
Page 44 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Greasing 1. Apply a grease to the following position as figures. WARNING To avoid serious injury: • Be sure to stop the engine and remove the key before greasing. IMPORTANT • Put grease into front wheel until grease overflows from both ends of the front wheel.
Page 45 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (Continued) 1. Apply a grease to the following position as figures. WARNING To avoid serious injury: • Be sure to stop the engine and remove the key before greasing. (7) Seat Adjuster 9Y1211344GEG0024US0 Oiling...
Page 46: Check Points Of Every 100 Hours
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [6] CHECK POINTS OF EVERY 100 HOURS Cleaning Air Cleaner Primary Element WARNING To avoid serious injury: • Be sure to stop engine and remove the key before cleaning air cleaner element. 1. Remove the air cleaner cover and primary element.
Page 47 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking Battery Condition DANGER To avoid the possibility of battery explosion: For the refillable type battery, follow the instructions below. • Do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark.
Page 48 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 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.
Page 49 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking Fuel Lines and Fuel Filter WARNING To avoid serious injury: • 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 periodically. The fuel lines are subject to wear and age.
Page 50 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Adjusting Parking Brake WARNING To avoid serious injury: • Park the machine on a hard and level surface. • Stop the engine and chock the wheels before checking or adjusting. IMPORTANT • Wrong adjustment may cause machine damage.
Page 51: Check Points Of Every 150 Hours
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Check on the slope 1. Place the machine on a 17 ° ramp. 2. Apply the parking brake. 3. Place the motion control levers in "NEUTRAL LOCK" position and shut off the engine. 4. Check that the machine does not move.
Page 52: Check Point Of Every 400 Hours
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [9] CHECK POINT OF EVERY 400 HOURS Replacing Fuel Filter 1. See page G-32. 9Y1211344GEG0043US0 Changing Transmission Fluid and Rear Axle Gear Case Oil (RH and LH) 1. See page G-24. 9Y1211344GEG0044US0 Replacing Hydraulic Oil Filter WARNING •...
Page 53: Check Points Of Every 1500 Hours
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [11] CHECK POINTS OF EVERY 1500 HOURS Checking Fuel Injection Nozzle (Injection Pressure) 1. See page 1-S18. 9Y1211344GEG0047US0 [12] CHECK POINTS OF EVERY 2000 HOURS OR EVERY 2 YEARS Flushing Cooling System and Changing Coolant...
Page 54 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (Continued) Anti-Freeze WARNING To avoid serious injury: • When using anti-freeze, put on some protection such as rubber gloves. (Anti-freeze contains poison.) • If someone drank anti-freeze, seek immediate medical help. Do NOT make a person throw up unless told to do so by poison control or a health care professional.
Page 55 The LLC contains anti-corrosive agent. If mixed with the cleaning agent, sludge may build up, adversely affecting the engine parts. 7. Kubota's genuine long-life coolant has a service life of 2 years. Be sure to change the coolant every 2000 hours or every 2 years whichever comes faster.
Page 56: Check Points Of Every 3000 Hours
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [13] CHECK POINTS OF EVERY 3000 HOURS Checking Injection Pump 1. See page 1-S16. 9Y1211344GEG0049US0 [14] CHECK POINTS OF EVERY 1 YEAR Checking Radiator Hose and Clamp WARNING To avoid serious injury: • Be sure to stop the engine and remove the key before checking radiator hose and clamps.
Page 57: Check Point Of Every 4 Years
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking Intake Air Line 1. Check to see that hoses and hose clamps are tight and not damaged. 2. If hoses and clamps are found worn or damaged, replace or repair them at once.
Page 58: Others
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Replacing Mower Gear Box Seals 1. Replace the mower gear box oil seals (1), (2). Refer to "Disassembling Gear Box Assembly". (See page 6-S14.) (1) Oil Seal (2) Oil Seal 9Y1211344GEG0059US0 Replacing Engine Breather Hose 1.
Page 59 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking Mower Blade WARNING To avoid serious injury: • Be sure to stop the engine and remove the key. • Blades may be sharp. When you handle blades, wear heavy gloves or wrap end of blade with a rag.
Page 60 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Replacing Mower Blades WARNING To avoid serious injury: • Be sure to stop the engine and remove the key. • Blades may be sharp. When you handle blades, wear heavy gloves or wrap end of blade with a rag.
Page 61 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Replacing Mower Belt 1. Remove the mower deck from the machine. 2. Remove the left and right hand shield from the mower deck. 3. Clean around the gear box. 4. Remove the belt from the tension pulley.
Page 62: Special Tools
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 9. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Special Use Puller Set Code No. • 07916-09032 Application • Use exclusively to pull out bearing, gears and other parts with ease. WSM000001GEG0011US0 Piston Ring Compressor Code No.
Page 63 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Oil Pressure Tester Code No. • 07916-32032 Application • Use to measure lubricating oil pressure. (1) Gauge (5) Adaptor 2 (2) Cable (6) Adaptor 3 (3) Threaded Joint (7) Adaptor 4 (4) Adaptor 1...
Page 64: Measuring Range
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Nozzle Tester Code No. • 07909-31361 Application • Use to check the fuel injection pressure and spray pattern of nozzle. Measuring range • 0 to 50 MPa (0 to 500 kgf/cm , 0 to 7200 psi)
Page 65 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM NOTE • The following special tools are not provided, so make them referring to the figure. 9Y1211344GEG0066US0 Valve Guide Replacing Tool Application • Use to press out and press fit the valve guide. D782-E3-ZD, D902-E3/E4 20 mm dia.
Page 66 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Injection Pump Pressure Tester Application • Use to check fuel tightness of injection pumps. Pressure gauge full scale: More than 29.4 MPa (300 kgf/cm , 4267 psi) Copper gasket Flange (Material: Steel) Hex. nut 27 mm (1.06 in.) across the plat...
Page 67 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Bushing Replacing Tool [For D782-E3, D902-E3/E4]] Application • Use to press out and press fit the bushing. 1. For small end bushing 145 mm (5.71 in.) 20 mm (0.79 in.) 100 mm (3.94 in.) 19.90 to 19.95 mm dia.
Page 68 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Bushing Replacing Tool [For D1005-E3/E4, D1105-E4-ZD, D1305-E3] 1. For small end bushing 157 mm (6.18 in.) 24 mm (0.94 in.) 120 mm (4.72 in.) 21.8 to 21.9 mm dia. (0.859 to 0.862 in. dia.) 24.8 to 24.9 mm dia.
Page 69 GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Crankshaft Bearing 1 Replacing Tool Application • Use to press out and press fit the crankshaft bearing 1. [Press Out] D1005-E3/E4 D782-E3 D902-E3/E4 D1105-E4 D1305-E3 135 mm (5.31 in.) 72 mm (2.8 in.) 40 mm (1.6 in.) 10 mm dia.
Page 70: Special Tools For Machine
GENERAL ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Governor Gear Holder Bushing Replacing Tool [For D1005-E3/E4, D1105-E4] Application • Use to press out and press fit the governor gear holder bushing. C1: Chamfer 1.0 mm (0.039 in.) 73.90 to 74.00 mm dia. (2.910 to 2.913 in. dia.) 69.80 to 69.90 mm dia.
Page 71: Implement Limitations
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 10. IMPLEMENT LIMITATIONS The KUBOTA Machine has been thoroughly tested for proper performance with implements sold or approved by KUBOTA. Use with implements below may result in malfunctions or failures of the machine, damage to other property and injury to the operator or others.
Page 72 ENGINE KiSC issued 06, 2017 A...
Page 73 MECHANISM CONTENTS 1. ENGINE BODY........................... 1-M1 [1] CLOSED BREATHER ......................1-M1 [2] GOVERNOR......................... 1-M2 2. LUBRICATING SYSTEM......................1-M4 3. COOLING SYSTEM ........................1-M5 4. FUEL SYSTEM........................... 1-M6 KiSC issued 06, 2017 A...
Page 74: Engine Body
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. ENGINE BODY [1] CLOSED BREATHER Closed breather system has been adopted to prevent the release of blow-by gas into the atmosphere. After its oil content is filtered by oil shield (4), the blow by gas in fed back to the intake manifold through breather valve (3) to be used for re-combustion.
Page 75: Governor
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [2] GOVERNOR Injection pump performance is closely related to the engine performance, and in many ways, the function of an injection pump depends on the governor connected to the pump. A governor performs an important role in saving fuel while allowing the engine run smoothly.
Page 76 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (Overloaded Operation) The amount of the movement of the fork lever assembly is limited with the fuel limitation bolt (10) and can not be moved in the direction of the fuel increase. As overload reduces the centrifugal force of the...
Page 77: Lubricating System
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 2. LUBRICATING SYSTEM (1) Rocker Arm (2) Oil Pressure Switch (3) Rocker Arm Shaft (4) Valve (5) Idle Gear (6) Crankshaft (7) Oil Pump (8) Oil Strainer (9) Relief Valve (10) Push Rod (11) Tappet...
Page 78: Cooling System
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 3. COOLING SYSTEM (1) Radiator (2) Water Pump (3) Cooling Fan (4) Thermostat (5) Cylinder Head (6) Cylinder Head The cooling system consists of a radiator (1), a centrifugal water pump (2), a cooling fan (3) and a thermostat (4).
Page 79: Fuel System
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 4. FUEL SYSTEM (1) Injection Nozzle (2) Fuel Overflow Pipe (3) Fuel Tank (4) Fuel Filter (5) Fuel Feed Pump (6) Fuel Filter (7) Injection Pump (8) Injection Pipe Fuel from the fuel tank (3) passes through the fuel filter (4), and then enters the injection pump (7) after impurities such as dirt, water, etc.
Page 80 SERVICING CONTENTS 1. TROUBLESHOOTING.........................1-S1 2. SERVICING SPECIFICATIONS ....................1-S4 3. TIGHTENING TORQUES......................1-S10 4. CHECKING, DISASSEMBLING AND SERVICING ..............1-S11 [1] CHECKING AND ADJUSTING....................1-S11 (1) Engine Body ........................1-S11 (2) Lubricating System ......................1-S13 (3) Cooling System ......................1-S13 (4) Fuel System........................1-S15 [2] SEPARATING ENGINE.......................1-S20 [3] DISASSEMBLING AND ASSEMBLING ................1-S25 (1) D1105-E4 ........................1-S25 [4] SERVICING .........................1-S37 (1) Cylinder Head and Valves .....................1-S37...
Page 81: Troubleshooting
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. TROUBLESHOOTING Probable Cause and Reference Symptom Solution Checking Procedure Page Engine Does Not 1. No fuel Fill fuel G-9, G-19 Start 2. Air in the fuel system Vent air G-44 3. Water in the fuel system...
Page 82 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Probable Cause and Reference Symptom Solution Checking Procedure Page Engine Revolution Is 1. Fuel filter clogged or dirty Replace G-32, G-44 Not Smooth 2. Air cleaner clogged Clean or replace G-29 3. Fuel leak due to loose...
Page 83 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Probable Cause and Reference Symptom Solution Checking Procedure Page Water Mixed into 1. Head gasket damaged Replace 1-S27 Lubricant Oil 2. Cylinder block or cylinder Replace 1-S37, head flawed 1-S38 Low Oil Pressure 1. Engine oil insufficient...
Page 84: Servicing Specifications
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Valve Clearance (Cold) 0.145 to 0.185 mm – 0.00571 to 0.00728 in. Compression Pressure 3.73 to 4.11 MPa 2.26 MPa 38.1 to 41.9 kgf/cm 23.0 kgf/cm...
Page 85 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Item Factory Specification Allowable Limit Push Rod Alignment – 0.25 mm 0.0098 in. Tappet to Tappet Guide Clearance 0.020 to 0.062 mm 0.07 mm 0.00079 to 0.0024 in. 0.003 in. • Tappet O.D. 19.959 to 19.980 mm –...
Page 86 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Item Factory Specification Allowable Limit Piston Pin to Small End Bushing Clearance 0.014 to 0.038 mm 0.15 mm 0.00056 to 0.0014 in. 0.0059 in. • Piston Pin O.D. 22.002 to 22.011 mm – 0.86622 to 0.86657 in.
Page 87 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing 2 Oil Clearance 0.034 to 0.095 mm 0.20 mm 0.0014 to 0.0037 in. 0.0079 in. • Crankshaft Journal O.D. 47.934 to 47.950 mm –...
Page 88 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed 68 kPa – 0.69 kgf/cm 9.9 psi At Rated Speed 294 to 441 kPa 147 kPa 3.00 to 4.49 kgf/cm 1.50 kgf/cm 42.7 to 63.9 psi...
Page 89 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Item Factory Specification Allowable Limit Injection Nozzle Valve Seat Valve Seat When the pressure is – Tightness 12.75 MPa (130.0 kgf/cm 1849 psi), the valve seat must be fuel tightness. 9Y1211344ENS0002US0 1-S9 KiSC issued 06, 2017 A...
Page 90: Tightening Torques
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 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 "6. TIGHTENING TORQUES" on page G-12.) Item Size × Pitch N·m...
Page 91: Checking, Disassembling And Servicing
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Remove the air cleaner, the muffler and all glow plugs.
Page 92 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Valve Clearance IMPORTANT • 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 (a) so that the No.
Page 93: Lubricating System
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester. 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
Page 94 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove.
Page 95: Fuel System
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Thermostat Valve Opening Temperature 1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat. 2. Heating the water gradually, read the temperature when the valve opens and leaves the string.
Page 96 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. 13.73 MPa...
Page 97 12.75 MPa (140.0 to 130.0 kgf/cm , 1991 to 1849 psi). 9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. 10 seconds 13.73 → 12.75 MPa Factory specification 140.0 →...
Page 98 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Fuel Injection Pressure 1. Set the injection nozzle to a nozzle tester. 2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle. 3. If the measurement is not within the factory specification, replace the adjusting washer (1) in the nozzle holder to adjust it.
Page 99 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and remove parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil. • Install the push rod (4), noting its direction.
Page 100: Separating Engine
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [2] SEPARATING ENGINE 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.
Page 101 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 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 10 minutes to cool the radiator, before opening the cap.
Page 102 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Bonnet 1. Remove the bonnet mounting bolts (1). 2. Remove the bonnet (2). (1) Bonnet Mounting Bolts (2) Bonnet 9Y1211344ENS0024US0 Fan Shroud, Electric Wiring and Others 1. Disconnect the wiring connectors for engine stop solenoid, glow plug, coolant temperature sensor, engine oil pressure switch and dynamo.
Page 103 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Separating Engine 1. Raise seat. 2. Remove ROPS connecting plate. 3. Remove universal joint mounting screws (1). 4. Disconnect universal joint (2) from Fan drive pulley. 5. Remove engine mounting nuts. 6. Separate the engine.
Page 104 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Dynamo, Fan Belt and Muffler 1. Remove the radiator hoses (1), (4). 2. Remove the cooling fan (2) and fan pulley. 3. Remove the dynamo (9) and fan belt. 4. Remove the muffler (6).
Page 105: Disassembling And Assembling
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [3] DISASSEMBLING AND ASSEMBLING (1) D1105-E4 [A] Cylinder Head and Valve Cylinder Head Cover 1. Disconnect the breather hose (1). 2. Remove the cylinder head cover screw (2). 3. Remove the cylinder head cover (3).
Page 106 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Nozzle Heat Seal Service Removal Procedure IMPORTANT • Use a plus (phillips head) screw driver (1) of which diameter is bigger than the heat seal hole (Approx. 6 mm (1/4 in.)). 1. Drive screw driver (1) lightly into the heat seal hole.
Page 107 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Cylinder Head and Cylinder Head Gasket 1. Loosen the pipe clamps (1), and remove the water return pipe (2). 2. Remove the cylinder head screw in the order of "n" to "a" and remove the cylinder head.
Page 108 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 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 spring retainer (4), valve spring (5) and valve stem seal (6).
Page 109 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Gear Case 1. Remove the fuel feed pump. 2. Remove the gear case. (When reassembling) • Grease thinly to the oil seal, and install it, ensuring the lip does not come off. (1) Gear Case Bolt Length = 45 mm (1.8 in.)
Page 110 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Injection Pump 1. Disconnect the start spring (4) on the thrust lever side (5). 2. Align the control rack pin (2) with the notch (1) on the crankcase, and remove the injection pump (3).
Page 111 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Cam Gear, Idle Gear 1 and Governor Gear 1. Remove the idle gear 1 (4). 2. Remove the fuel camshaft stopper (7). 3. Draw out the injection pump gear (1) with fuel camshaft (8).
Page 112 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [C] Piston and Connecting Rod Oil Pan and Oil Strainer (for Standard Oil Pan) 1. Remove the oil pan mounting screws (5). 2. Remove the oil pan (4). 3. Remove the oil strainer (3).
Page 113 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Pistons 1. Turn the flywheel and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer.
Page 114 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) • When installing the ring, assemble the rings so that the manufacturer's mark (12) near the gap faces the top of the piston.
Page 115 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [D] Flywheel and Crankshaft Flywheel 1. Secure the flywheel to keep it from turning, using a flywheel stopper. 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) • Align the "1TC" mark (a) on the outer surface of the flywheel horizontally with the alignment mark (b) on the rear end plate.
Page 116: Crankshaft Assembly
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly. IMPORTANT • Be careful to protect crankshaft bearing 1 from scratches, caused by the crank gear, etc.. (Wrap the gear in vinyl tape, etc.)
Page 117: Servicing
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [4] SERVICING (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head. 2. With the piston at TDC, use grease to attach three or four plastigauges (1) of 5.0 to 7.0 mm (0.20 to 0.27 in.) long to the crown of the piston;...
Page 118 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it 5 to 10 minutes after spraying.
Page 119 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (See page "SPECIAL TOOLS".) (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them.
Page 120 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Correcting Valve and Valve Seat NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
Page 121 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Free Length and Tilt of Valve Spring 1. Measure the free length (B) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring.
Page 122: Timing Gears, Camshaft And Governor Gear
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. 0.25 mm Push rod alignment Allowable limit 0.0098 in.
Page 123 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Idle Gear and Idle Gear 1 Side Clearance 1. Set a dial indicator with its tip on the idle gear. 2. Measure the side clearance by moving the idle gear to the front and rear.
Page 124 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with a cylinder gauge, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the camshaft.
Page 125: Piston And Connecting Rod
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (3) Piston and Connecting Rod 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.
Page 126: Connecting Rod Alignment
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Connecting Rod Alignment NOTE • Since the I.D. of the connecting rod small end bushing is the basis of this check, check bushing for wear beforehand. 1. Install the piston pin into the connecting rod.
Page 127: Crankshaft
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Clearance between Piston ring and Piston Ring Groove 1. Clean the rings and the ring grooves, and install each ring in its groove. 2. Measure the clearance between the ring and the groove with a feeler gauge or depth gauge.
Page 128: Crankshaft Alignment
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Crankshaft Alignment 1. Support the crankshaft with V blocks on the surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Measure the crankshaft alignment.
Page 129 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance.
Page 130 ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) 1. Put a strip of plastigauge on the center of the journal. 2. Install the bearing case and tighten the baring case screws 1 to the specified torque, and remove the bearing case again.
Page 131: Cylinder
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Replacing Crankshaft Sleeve 1. Remove the used crankshaft sleeve. 2. Set the sleeve guide (2) to the crankshaft. 3. Heat a new sleeve to a temperature between 150 and 200 °C (302 and 392 °F), and fix the sleeve to the crankshaft as shown in figure.
Page 132: Oil Pump
ENGINE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Correcting Cylinder (Oversize) 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. 78.500 to 78.519 mm Factory specification 3.0906 to 3.0912 in. Oversized cylinder liner I.D.
Page 133 TRANSAXLE KiSC issued 06, 2017 A...
Page 134 MECHANISM CONTENTS 1. STRUCTURE..........................2-M1 2. TRAVELLING SYSTEM......................2-M2 [1] HYDROSTATIC TRANSMISSION ..................2-M2 (1) Structure ......................... 2-M2 (2) Check Valve and High Pressure Relief Valve ..............2-M3 (3) Oil Flow........................... 2-M4 (4) Power Trains Operation....................2-M5 (5) Control Linkage ......................2-M6 (6) Final Reduction Gear Section..................
Page 135: Structure
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. STRUCTURE (1) Bevel Gear Section (3) Hydrostatic Transmission (4) Brake Section (5) Final Reduction Gear Section (2) PTO Section Transmission consists of bevel gear section (1) hydrostatic transmission (3), brake section (4), final reduction gear section (5), and PTO section (2).
Page 136: Travelling System
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 2. TRAVELLING SYSTEM [1] HYDROSTATIC TRANSMISSION (1) Structure (1) Lubricating Orifice (6) Slot Guide (11) Swashplate (16) Cylinder Block (Motor) (2) Pump Shaft (7) Cradle Bearing (12) Piston (Motor) (17) Check Valve Spring (3) Brake Shaft (8T)
Page 137: Check Valve And High Pressure Relief Valve
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (2) Check Valve and High Pressure Relief Valve The check and high-pressure relief valve consists of pressure poppet (2), check valve seat (1), relief valve spring (3), spring guide (4) and check valve spring (5).
Page 138: Oil Flow
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (3) Oil Flow (1) Transmission Case (5) Regulator Valve (9) Cylinder Block (Pump) (13) Cylinder Block (Motor) (2) Hydraulic Pump (6) PTO Clutch (10) Lubricating Orifice (14) Check and High Pressure (3) Oil Filter Cartridge...
Page 139: Power Trains Operation
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (4) Power Trains Operation (1) Check and High Pressure (4) Oil Cooler (7) Neutral Orifice (10) Pump Relief Valve (5) Motor (8) Check Valve (11) Suction Oil Filter (2) Oil Filter (6) Lubricating Orifice...
Page 140: Control Linkage
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (5) Control Linkage (1) Motion Control Lever (3) Speed Limit Spring (4) Speed Control Rod (5) Trunnion Arm (2) Speed Shaft The motion control lever (1) and the trunnion shaft of variable swashplate are linked with the speed shaft (2), speed control rod (4) and the trunnion arm (5).
Page 141: Final Reduction Gear Section
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (6) Final Reduction Gear Section As for this machine, power is transmitted from the 8T gear on the brake shaft (1) to the rear axle (4) through 53T gear (3), 19T gear shaft (2) and 49T gear (5).
Page 142: Pto System
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (7) PTO System PTO Clutch and Valve (1) PTO Valve Lever (9) Hydraulic Pump (17) Center Case, Front Cover From Hydraulic Pump (2) Regulator Valve (10) Center Case, Rear Cover (18) PTO Shaft From Hydraulic Pump to...
Page 143 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM PTO Clutch "Engaged" (1) PTO Clutch Valve (2) Poppet (3) Center Case, Front Cover (4) Brake Pressure Plate (5) Center Case (6) Center Case, Rear Cover (7) Clutch Gear (8) Spring (9) Clutch Piston...
Page 144 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM PTO Clutch "Disengaged" (1) PTO Clutch Valve (2) Poppet (3) Center Case, Front Cover (4) Brake Pressure Plate (5) Center Case (6) Center Case, Rear Cover (7) Clutch Gear (8) Spring (9) Clutch Piston...
Page 145: Parking Brake
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (8) Parking Brake (1) Brake Pedal (5) Brake Rod (8) Brake Spring (11) Brake Disk (2) Parking Lock Pedal (6) Brake Assembly (9) Ball (12) Brake Plate (3) Brake Pedal Return Spring (7) Brake Arm...
Page 146 SERVICING CONTENTS 1. TROUBLESHOOTING.........................2-S1 2. SERVICING SPECIFICATIONS ....................2-S3 3. TIGHTENING TORQUES......................2-S4 4. CHECKING AND ADJUSTING....................2-S5 5. DISASSEMBLING AND ASSEMBLING ..................2-S14 [1] SEPARATING TRANSAXLE ASSEMBLY................2-S14 [2] DISASSEMBLING TRANSAXLE CENTER CASE ..............2-S21 [3] DISASSEMBLING PTO CLUTCH SHAFT ASSEMBLY ............2-S23 [4] DISASSEMBLING HYDROSTATIC TRANSMISSION AND REAR AXLE GEAR CASE ASSEMBLY .........................2-S28 [5] DISASSEMBLING REAR AXLE GEAR CASE ..............2-S33 [6] DISASSEMBLING SPEED LEVER ASSEMBLY ..............2-S36...
Page 147: Troubleshooting
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. TROUBLESHOOTING Probable Cause and Reference Symptom Solution Checking Procedure Page Vehicle Will Not Stop 1. Improper neutral Adjust neutral 2-S6 in Neutral Position adjustment 2. Improper speed control Adjust 2-S6 rod adjustment Vehicle Jerky and 1.
Page 148 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM TRAVELLING GEAR SHIFT SECTION Probable Cause and Reference Symptom Solution Checking Procedure Page Noise from 1. Transmission oil Refill 2-S14 Transmission insufficient 2. Gear worn or broken Replace 2-S21 3. Bearings worn Replace –...
Page 149: Servicing Specifications
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Regulator Valve (HST Charge Relief Valve) Setting Pressure 0.75 to 0.95 MPa – at engine speed: 3000 min (rpm) 7.7 to 9.6 kgf/cm 110 to 130 psi...
Page 150: Tightening Torques
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 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 "6. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m...
Page 151: Checking And Adjusting
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 4. CHECKING AND ADJUSTING Checking Neutral 1. Park machine safely. 2. Set the motion control levers are in the NEUTRAL position. 3. Move the PTO lever to OFF position and apply the parking brake.
Page 152 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Adjusting Neutral WARNING To avoid serious injury: • Park the machine on a hard and level surface. • If it is necessary to run engine in an enclosed area, use a gas tight exhaust pipe extension to remove the fumes.
Page 153 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking Motion Control Lever Neutral Position WARNING To avoid serious injury: • Park the machine on a firm and level surface. • If it is necessary to run engine in an enclosed area, use a gas tight exhaust pipe extension to remove the fumes.
Page 154 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Adjusting Maximum Speed WARNING To avoid serious injury: • Park the machine on a hard and level surface. • If it is necessary to run engine in an enclosed area, use a gas tight exhaust pipe extension to remove the fumes.
Page 155 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking Motion Control Lever Alignment WARNING To avoid serious injury: • Park the machine on a firm and level surface. • Stop the engine, remove the key and apply the parking brake. 1. Check the gap (A) and space (B) between the motion control levers, at the maximum forward position.
Page 156 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking Hydrostatic Transmission CAUTION • When checking, park the machine on flat ground, apply the parking brake. • Sit on operator's seat for checking. 1. After warming up the machine, apply the parking brake and set the stop wood (chock) to the rear wheels.
Page 157 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM PTO Clutch Operating Pressure (Hydrostatic Transmission Charge Pressure) WARNING To avoid serious injury: • When checking, park the tractor on flat ground, apply the parking brake. • Be careful when engaging PTO. 1. Remove the plug (1), then install the adaptor (2) cable and pressure gauge.
Page 158 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking and Adjusting Parking Brake WARNING To avoid serious injury: • Park the machine on a hard and level surface. • Stop the engine and chock the wheels before checking or adjusting. IMPORTANT • Wrong adjustment may cause machine damage.
Page 159 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Checking Parking Brake on the Slope 1. Place the machine on a 17 ° ramp A. 2. Apply the parking brake. 3. Place the motion control levers in "NEUTRAL LOCK" position and shut off the engine.
Page 160: Disassembling And Assembling
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 5. DISASSEMBLING AND ASSEMBLING [1] SEPARATING TRANSAXLE ASSEMBLY Draining Transmission Fluid CAUTION To avoid personal injury: • 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.
Page 161 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 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 10 minutes to cool the radiator, before opening the cap.
Page 162 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Bonnet 1. Remove the bonnet mounting bolts (1). 2. Remove the bonnet (2). (1) Bonnet Mounting Bolts (2) Bonnet 9Y1211344ENS0024US0 Fan Shroud, Electric Wiring and Others 1. Disconnect the wiring connectors for engine stop solenoid, glow plug, coolant temperature sensor, engine oil pressure switch and dynamo.
Page 163 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Separating Engine 1. Raise seat. 2. Remove ROPS connecting plate. 3. Remove universal joint mounting screws (1). 4. Disconnect universal joint (2) from Fan drive pulley. 5. Remove engine mounting nuts. 6. Separate the engine.
Page 164 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Seat Assembly and Fender 1. Raise the seat and disconnect the wiring connector for safety switch. 2. Remove the seat assembly (1) with seat base. 3. Disconnect LCD Panel. 4. Remove RH and LH fuel vapor hose guards (2).
Page 165 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Fuel Tank 1. Disconnect the wiring connectors for fuel gauge (1). 2. Switch off fuel flow by turning fuel cut off switches (2) (one on each tank). 3. Remove fuel hoses (3). 4. Remove fuel hoses (5).
Page 166 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM ROPS, Rear Wheel and Others 1. Remove the oil cooler pipes (2). 2. Remove the ROPS upper, and remove the ROPS lower (LH) (1) and ROPS lower (RH) (3). 3. Remove the universal joint (4) from the transaxle.
Page 167: Disassembling Transaxle Center Case
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [2] DISASSEMBLING TRANSAXLE CENTER CASE Center Case Rear Cover 1. Remove the oil filter cartridge (1). 2. Remove the delivery pipe (3). 3. Remove the center case rear cover (4). NOTE • Make sure to remove the hex. socket head screw hidden behind the filter cartridge (1) •...
Page 168 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Regulator Valve (HST Charge Pressure Relief Valve) 1. Remove the plug (3). 2. Remove the spring (2) and poppet (1). (1) Poppet (3) Plug (2) Spring 9Y1211344TXS0027US0 PTO Clutch Lever 1. Remove the lever stopper and remove the PTO clutch lever (2).
Page 169: Disassembling Pto Clutch Shaft Assembly
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [3] DISASSEMBLING PTO CLUTCH SHAFT ASSEMBLY Draining Transmission Fluid CAUTION To avoid personal injury: • 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.
Page 170 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 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 10 minutes to cool the radiator, before opening the cap.
Page 171 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Fan Shroud, Electric Wiring and Others 1. Disconnect the wiring connectors for engine stop solenoid, glow plug, coolant temperature sensor, engine oil pressure switch and dynamo. 2. Remove the positive cable (9) from starter motor.
Page 172 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Oil Cooler, Radiator, Universal Joint and Others 1. Remove the ROPS connecting upper plate (1). 2. Remove the oil cooler (2). 3. Remove the radiator (3). 4. Remove the universal joint (4). 5. Remove the oil cooler pipes (5).
Page 173 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Center Case Rear Cover and PTO Clutch Shaft Assembly 1. Disconnect the delivery pipe (1). 2. Remove the center case rear cover (2). 3. Remove the pump shaft assembly (5). 4. Remove the PTO clutch shaft assembly (4).
Page 174: Disassembling Hydrostatic Transmission And Rear Axle Gear Case Assembly
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [4] DISASSEMBLING HYDROSTATIC TRANSMISSION AND REAR AXLE GEAR CASE ASSEMBLY Draining Transmission Fluid CAUTION To avoid personal injury: • Be sure to stop the engine and remove the key before changing or checking the oil.
Page 175 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Battery WARNING To avoid serious injury: • When disconnecting the battery cables, disconnect the negative cable from the battery first. When connecting, connect the positive cable to the battery first. 1. Remove the battery cover (1).
Page 176 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Hydrostatic Transmission and Rear Axle Gear Case Assembly NOTE • The hydrostatic transmission and rear axle gear case assembly weighs approximately 35 kg (77 lbs). Be very careful in handling. 1. Loosen the HST delivery pipe. Remove the hydrostatic transmission mounting screws.
Page 177 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Check and High Pressure Relief Valve Assembly 1. Remove the plug (1) and draw out the spring (2) and check and high pressure relief valve assembly (3). (When reassembling) • Be careful not to damage the O-ring on the plug.
Page 178 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Pump Shaft 1. Remove the external snap ring (2). 2. Tap the pump shaft (1) with a plastic hammer slightly to side out it from the housing with the ball bearing (3). 3. Remove the internal snap ring (4) and bearing (3).
Page 179: Disassembling Rear Axle Gear Case
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [5] DISASSEMBLING REAR AXLE GEAR CASE Draining Transmission Fluid CAUTION To avoid personal injury: • 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.
Page 180 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Battery WARNING To avoid serious injury: • When disconnecting the battery cables, disconnect the negative cable from the battery first. When connecting, connect the positive cable to the battery first. 1. Remove the battery cover (1).
Page 181 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Removing Rear Axle Gear Case 1. Remove the rear axle gear case mounting screws. 2. Separate the rear axle gear case assembly (1) and center section (2). (When reassembling) • Apply to liquid gasket (Three Bond 1208D or equivalent) to the joint face of the rear axle gear case and center section.
Page 182: Disassembling Speed Lever Assembly
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Parking Brake 1. Remove the internal snap ring (1), friction plates (2) and brake discs (3). 2. Remove the external snap ring (4), brake cam (5) and balls (6). (When reassembling) • Align splines of brake shaft and brake discs (3).
Page 183 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Seat Assembly and Fender 1. Raise the seat and disconnect the wiring connector for safety switch. 2. Remove the seat assembly (1) with seat base. 3. Disconnect LCD Panel. 4. Remove RH and LH fuel vapor hose guards (2).
Page 184: Servicing
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 6. SERVICING [1] HYDROSTATIC TRANSMISSION Center Section 1. Check the surface (1) of center section for scratches or wear. If deep scratch or excessive wear is found, replace the hydrostatic transmission assembly. (1) Surface...
Page 185 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Pump Shaft 1. Check the bearing surface (3) and the ball bearing (2). 2. If the shaft is rough or grooved, replace it. 3. If the ball bearing is worn, replace it. (1) Pump Shaft...
Page 186: Transmission Case
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [2] TRANSMISSION CASE Checking Bearing 1. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness. 2. Apply transmission fluid to the bearing, and hold the inner race.
Page 187 TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Correcting of Tooth Contact 1. Proper contact • No adjustment. 2. Correcting of the heel contact and shallow contact • Make sure that whether there is a shim (5). • The 18T bevel gear (6) can be moved to backward by doing to add the shim (5) when not is.
Page 188: Pto Clutch
TRANSAXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [3] PTO CLUTCH Checking PTO Clutch Discs 1. Check the surface of the pressure plate (1), PTO clutch discs (2) and PTO clutch plates (3). 2. If excessive wear is found, replace it to a new one.
Page 189: Front Axle
FRONT AXLE KiSC issued 06, 2017 A...
Page 190 MECHANISM CONTENTS 1. STRUCTURE..........................3-M1 KiSC issued 06, 2017 A...
Page 191 FRONT AXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. STRUCTURE (1) Cap (3) Taper Roller Bearing (5) Center Pin (7) Slotted Nut (2) Taper Roller Bearing (4) Wheel Bracket (6) Front Axle (8) Lift Up Adjuster The front axle is constructed as shown above. The shape of the front axle is relatively simple, and the front axle is supported at its center with the center pin (5), so that steering operation is stable even on uneven grounds in a grass field.
Page 192 SERVICING CONTENTS 1. TROUBLESHOOTING.........................3-S1 2. SERVICING SPECIFICATIONS ....................3-S2 3. TIGHTENING TORQUES......................3-S3 4. CHECKING, DISASSEMBLING AND SERVICING ..............3-S4 [1] CHECKING AND ADJUSTING....................3-S4 [2] DISASSEMBLING AND ASSEMBLING ................3-S5 (1) Separating Front Wheel and Wheel Bracket ..............3-S5 (2) Separating Front Axle Assembly ..................3-S6 KiSC issued 06, 2017 A...
Page 193: Troubleshooting
FRONT AXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. TROUBLESHOOTING Probable Cause and Reference Symptom Solution Checking Procedure Page Front Wheels Wander 1. Clearance between center Check the clearance and replace the 3-S6 to Right or Left pin and front axle...
Page 194: Servicing Specifications
FRONT AXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Front Axle End Play Clearance 0 to 0.2 mm 0.5 mm 0 to 0.008 in. 0.02 in. 9Y1211344FAS0002US0 3-S2 KiSC issued 06, 2017 A...
Page 195: Tightening Torques
FRONT AXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 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 "6. TIGHTENING TORQUES" on page G-12.) Item N·m...
Page 196: Checking, Disassembling And Servicing
FRONT AXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Adjusting Front Axle Pivot 1. Lift up and securely block the front of the machine. 2. Measure the clearance (A) between the front axle (4) and front axle support (3).
Page 197: Disassembling And Assembling
FRONT AXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [2] DISASSEMBLING AND ASSEMBLING (1) Separating Front Wheel and Wheel Bracket Remove the Front Wheel 1. Inspect all parts for wear or damage. Replace the parts as needed. (When reassembling) • Apply grease to grease fittings. (See page G-9.) 20 to 25 N·m...
Page 198: Separating Front Axle Assembly
FRONT AXLE ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (2) Separating Front Axle Assembly Battery WARNING To avoid serious injury: • When disconnecting the battery cables, disconnect the negative cable from the battery first. When connecting, connect the positive cable to the battery first.
Page 199: Hydraulic System
HYDRAULIC SYSTEM KiSC issued 06, 2017 A...
Page 200 MECHANISM CONTENTS 1. HYDRAULIC CIRCUIT ....................... 4-M1 2. HYDRAULIC PUMP........................4-M2 3. HYDRAULIC CONTROL VALVE....................4-M3 4. LIFT CYLINDER ......................... 4-M6 KiSC issued 06, 2017 A...
Page 201: Hydraulic Circuit
HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. HYDRAULIC CIRCUIT (1) PTO Clutch (4) Hydraulic Cylinder (7) Oil Filter (10) Hydraulic Pump (2) PTO Clutch Valve (5) Relief Valve (8) Regulator Valve (11) Oil Filter (3) Hydraulic Control Valve (6) Control Valve...
Page 202: Hydraulic Pump
HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 2. HYDRAULIC PUMP The hydraulic pump consists of the casing (1), cover (3), side plate (5), and two spur gears (drive gear (4) and driven gear (2)) that are in mesh. Hydraulic pump is driven by the pump drive shaft in the transmission case.
Page 203: Hydraulic Control Valve
HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 3. HYDRAULIC CONTROL VALVE hydraulic system composed transmission case (oil tank), cushion oil filter, hydraulic pump, control valve, hydraulic cylinder and etc.. The new series product is provided with a built-in control valve in the case.
Page 204 HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Neutral (1) To PTO Clutch and Hydrostatic Transmission (2) C (Cylinder) Port (3) Spool (4) P (Pump) Port (5) Valve Body (6) Relief Valve The oil sent from the pump passes through a gap between the spool (3) and the valve body (5), through the regulator valve, and then flows to the PTO valve and HST charge circuit.
Page 205 HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Down (1) To PTO Clutch and Hydrostatic Transmission (2) Spool (3) C (Cylinder) Port (4) P (Pump) Port (5) Valve Body (6) Relief Valve Drain directly to the Transmission Center Case The oil sent from the pump passes through a gap between the spool (2) and the valve body (5), through the regulator valve, and then the oil flows to the PTO valve and HST charge circuit.
Page 206: Lift Cylinder
HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 4. LIFT CYLINDER (1) Piston Rod (2) Scraper (3) Packing (4) Cylinder (5) Snap Ring The lift cylinder consists of the cylinder (4), piston rod (1) and other parts as shown in the figure above.
Page 207 SERVICING CONTENTS 1. TROUBLESHOOTING.........................4-S1 2. SERVICING SPECIFICATIONS ....................4-S2 3. TIGHTENING TORQUES......................4-S3 4. CHECKING, DISASSEMBLING AND SERVICING ..............4-S4 [1] HYDRAULIC CONTROL VALVE, PUMP AND CYLINDER...........4-S4 (1) Checking and Adjusting....................4-S4 (2) Disassembling and Assembling the Hydraulic Control Valve ..........4-S5 (3) Disassembling and Assembling the Hydraulic Pump ............4-S9 KiSC issued 06, 2017 A...
Page 208: Troubleshooting
HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. TROUBLESHOOTING Probable Cause and Reference Symptom Solution Checking Procedure Page Mower Does Not Rise 1. Control valve Check and repair or replace 4-S4, 4-S7 malfunctioning 2. Lift cylinder damaged Check and replace 6-S8 3.
Page 209: Servicing Specifications
HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Relief Valve (Control Valve) Setting Pressure 5.5 to 7.0 MPa – at engine speed: 1600 min (rpm) 56 to 71 kgf/cm 800 to 1000 psi...
Page 210: Tightening Torques
HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 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 "6. TIGHTENING TORQUES" on page G-12.) Item N·m...
Page 211: Checking, Disassembling And Servicing
HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] HYDRAULIC CONTROL VALVE, PUMP AND CYLINDER (1) Checking and Adjusting Relief Valve Setting Pressure 1. Remove the plug (2) from the front cover of transmission center case.
Page 212: Disassembling And Assembling The Hydraulic Control Valve
HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (2) Disassembling and Assembling the Hydraulic Control Valve Draining Transmission Fluid CAUTION To avoid personal injury: • Be sure to stop the engine and remove the key before changing or checking the oil.
Page 213 HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM PTO Clutch Link, Cylinder Hose, Oil Cooler Pipe and HST Charge Pipes 1. Remove the seat and seat base assembly. 2. Remove the PTO clutch link (1). 3. Remove the lift rod (2).
Page 214 HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Lift Shaft and Arm 1. Remove the lift arm (1). 2. Remove the oil seal (3). 3. Remove the internal snap ring (4). 4. Remove the lift shaft (5) with ball bearings and remove the arm (2).
Page 215 HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Relief Valve 1. Remove the plug (1), and remove the shims (2), spring (3), poppet (4) and valve seat (5). (When reassembling) • Be careful not to damage the O-ring on plug. 49 to 68 N·m...
Page 216: Disassembling And Assembling The Hydraulic Pump
HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (3) Disassembling and Assembling the Hydraulic Pump Draining Transmission Fluid CAUTION To avoid personal injury: • 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.
Page 217 HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 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 10 minutes to cool the radiator, before opening the cap.
Page 218 HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Fan Shroud, Electric Wiring and Others 1. Disconnect the wiring connectors for engine stop solenoid, glow plug, coolant temperature sensor, engine oil pressure switch and dynamo. 2. Remove the positive cable (9) from starter motor.
Page 219 HYDRAULIC SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Oil Cooler, Radiator and Removing Hydraulic Pump 1. Remove the ROPS connecting plate upper (1). 2. Remove the oil cooler (2). 3. Remove the radiator (3). 4. Remove the hydraulic pump (4). (When reassembling) 24 to 27 N·m...
Page 220: Electrical System
ELECTRICAL SYSTEM KiSC issued 06, 2017 A...
Page 221 MECHANISM CONTENTS 1. ELECTRICAL DIAGRAM......................5-M1 2. ELECTRICAL CONNECTOR CHART ..................5-M2 3. READING THE ELECTRICAL CIRCUIT DIAGRAMS ..............5-M3 [1] HOW TO READ WIRING DIAGRAM..................5-M3 [2] LAYOUT OF CONNECTOR DIAGRAMS ................5-M6 (1) Main Layout ........................5-M6 [3] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS ........5-M6 4.
Page 223: Electrical Connector Chart
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 2. ELECTRICAL CONNECTOR CHART 9Y1211344ELM0020US0 5-M2 KiSC issued 06, 2017 A...
Page 224: Reading The Electrical Circuit Diagrams
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 3. READING THE ELECTRICAL CIRCUIT DIAGRAMS [1] HOW TO READ WIRING DIAGRAM Electrical Wiring Chart Symbols for Harnesses and Wires Item (Example) Contents of illustration Reference Name of part STARTER RELAY Wire specification code...
Page 225 ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Colors of Wiring Color of wiring Color code Black Green Blue Pink White Yellow Brown Gray Light Green Orange Sky Blue (Ex.) 1.25-Y/R means : 1.25 : Wire size (mm Y : Base color (yellow) R : Stripe color (red) •...
Page 226 ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Unit Symbol (1) Variable (10) Potentiometer with Sliding (19) Two-Way Breakdown Diode (28) Horn (2) Non-Linear Variable Contact (20) Coil (29) Speaker (3) Fixed Setting (11) Heating Element (21) a-Contact (30) AC Voltage Source...
Page 227: Layout Of Connector Diagrams
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [2] LAYOUT OF CONNECTOR DIAGRAMS (1) Main Layout Connector Arrangement Sequence In alphabetical order downwards from top left, and then to column next right. 9Y1211344ELM0027US0 Depiction of Connectors In principle, the connector locking part is shown on the top side.
Page 228: Starting System
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 4. STARTING SYSTEM (1) Battery (4) Starter Relay (7) Seat (10) OPC (2) Starter (5) Neutral (R) (8) Parking Brake (11) Glow Plug (3) Slow Blow (6) Neutral (L) (9) PTO When the main switch is turned to the PREHEAT position, the terminal B is connected to the terminals G and ACC.
Page 229: Relay
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [1] RELAY Relay Relay (1) basically consists of relay winding (5) and mechanical contact points (9). Current flowing from switch to relay winding (5) cause "ON (Close)" or "OFF (Open)" of mechanical contact points (9).
Page 230: Starter
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [2] STARTER (1) Housing (2) Magnetic Switch (3) Overrunning Clutch (4) Drive Lever (5) Internal Gear (6) Gear Shaft (7) Planetary Gear (8) Armature Shaft (9) Yoke (10) Brush Holder (11) Rear End Holder The reduction system uses planetary gears (7), and the speed of gear shaft (6) is reduced to approximately one fifth of the armature shaft (8).
Page 231: Glow Plug
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [3] GLOW PLUG This plug is a two-material type QGS (Quick Glow System) quick temperature rise, self-controlling function as well as excellent durability. The heater (4) connected in series to the heater (3), which also functions as the resistor, is incorporated in the sheath tube (1) of the super glow plug.
Page 232: Fuel Pump
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [5] FUEL PUMP An electro magnetic fuel pump uses a transistor that causes the pump to start pumping fuel when the main switch is turned to the "ON" position. Therefore, fuel is supplied to the fuel injection pump regardless of engine speed.
Page 233: Charging System And Easy Checker
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 5. CHARGING SYSTEM AND EASY CHECKER™ (1) Battery (3) Regulator (4) Dynamo (5) Meter Panel (2) Starter The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs.
Page 234: Ac Dynamo
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [1] AC DYNAMO The dynamo is an 8-8 pole rotating magnet type generator. It is simple in construction, consisting of a stator and rotor. The rotor is made up of eight permanent magnet pole pieces assembled on a shaft and rotates on...
Page 235: Easy Checker
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [3] EASY CHECKER™ If the warning lamps of the Easy Checker (TM) come on during operation, immediately stop the engine, and find the cause as shown below. Never operate the machine while Easy Checker (TM) lamp is on.
Page 236 ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (Continued) IMPORTANT • When the fuel warning lamp lights up, refuel the tank as soon as possible. If the machine runs out of fuel and stalls, the engine and its components may be damaged.
Page 237 ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Error Code Display If something is wrong with the power train, the master system warning indicator starts blinking and the error code shown below is displayed on the LCD monitor, indicating the location of the trouble.
Page 238: Gauges
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 6. GAUGES (1) Battery (5) Neutral (L) (9) Regulator (13) Fuel Sensor (2) Starter (6) PTO (10) Solenoid Relay (14) Temperature Coolant Sensor (3) Slow Blow Fuse (7) Parking Brake (11) Horn (15) Oil Pressure Sensor...
Page 239: Fuel Quantity
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [1] FUEL QUANTITY Fuel Level Sensor The remaining fuel quantity is detected by the fuel level sensor installed in the fuel tank and indicated on the fuel gauge. For detection, a float and a resistor are used.
Page 240 ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Oil Pressure Switch While oil pressure is high and the force applied to the diaphragm (2) is larger than the spring tension, the terminal contact (1) is open separated from the body contact (3). If the pressure drops below approx. 49 kPa (0.5 kgf/cm...
Page 241 SERVICING CONTENTS 1. TROUBLESHOOTING.........................5-S1 2. SERVICING SPECIFICATIONS ....................5-S4 3. TIGHTENING TORQUES......................5-S5 4. CHECKING, DISASSEMBLING AND SERVICING ..............5-S6 [1] CHECKING..........................5-S6 (1) Battery ..........................5-S6 (2) Safety Switches .......................5-S8 (3) Main Switch ........................5-S9 (4) Starter..........................5-S10 (5) Glow Plug ........................5-S10 (6) Safety Switch.........................5-S11 (7) Fuel Pump ........................5-S12 (8) Engine Stop Solenoid ....................5-S12 (9) Charging System ......................5-S12 (10)Easy Checker™...
Page 242: Troubleshooting
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. TROUBLESHOOTING Probable Cause and Reference Symptom Solution Checking Procedure Page All Electrical 1. Battery discharged or Recharge or replace G-30 Equipments Do Not damaged Operate 2. Battery positive cable Repair or replace...
Page 243 ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM STARTING SYSTEM Probable Cause and Reference Symptom Solution Checking Procedure Page Starter Motor Does 1. Battery discharged or Recharge or replace G-30 Not Operate damaged 2. Slow blow fuse blown Replace G-41 3. Safety switch damaged...
Page 244 ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM CHARGING SYSTEM Probable Cause and Reference Symptom Solution Checking Procedure Page Charging Lamp Does 1. Fuse blown (15 A) Replace G-41 Not Light When Main 2. Wiring harness Repair or replace 5-M1 Switch Is Turned ON...
Page 245: Servicing Specifications
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Battery Voltage More than – 12 V Potential Less than – Difference 0.1 V Glow Plug Resistance Approx. 0.9 Ω – Starter • Commutator O.D.
Page 246: Tightening Torques
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 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 "6. TIGHTENING TORQUES" on page G-12.) Item N·m...
Page 247: Checking, Disassembling And Servicing
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 4. CHECKING, DISASSEMBLING AND SERVICING CAUTION • To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal.
Page 248 ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).
Page 249: Safety Switches
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (2) Safety Switches Method of Inspecting Each Control A damaged location can be judge by checking function of each safety switch one by one as shown in the table below. (Reference) • Type of Safety Switch...
Page 250: Main Switch
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (3) Main Switch Main Switch Continuity 1) Main Switch Key at OFF Position 1. Set the main switch OFF position. 2. Measure the resistance with an ohmmeter across the B terminal and the ACC terminal, B terminal and ST terminal, B terminal and G terminal.
Page 251: Starter
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (4) Starter Motor Test CAUTION • Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable and the leads from the starter.
Page 252: Safety Switch
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Glow Plug Continuity 1. Disconnect the lead from the glow plugs. 2. Measure the resistance with an ohmmeter between the glow plug terminal and the chassis. 3. Check each glow plug. 4. If 0 ohm is indicated, the screw at the tip of the glow plug and the housing are short-circuited.
Page 253: Fuel Pump
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (7) Fuel Pump Connector Voltage 1. Disconnect the 2P connector from the fuel pump. 2. Turn the main switch key to the "ON" position, and measure the voltage with a voltmeter between the connector terminals.
Page 254 ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Regulation Voltage WARNING To avoid serious injury • To avoid personal injury, do not touch the rotating or hot parts while the engine is running. NOTE • Before performing this checking, make sure that the no-load dynamo output is proper.
Page 255: Easy Checker
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (10) Easy Checker™ Charge Lamp (Charging Circuit) 1. Turn main switch OFF. 2. Remove the under panel. 3. Disconnect the 6P connector from the regulator. 4. Turn the main switch ON. 5. Connect a jumper lead from the wiring harness connector terminal (Black) to the chassis.
Page 256: Gauges
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (11) Gauges Fuel Level Sensor 1) Sensor Continuity 1. Remove the fuel level sensor from the fuel tank. 2. Measure the resistance with an ohmmeter across the sensor terminal and its body. 3. If the reference values are not indicated, the sensor is faulty.
Page 257: Cooling System
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (12) Cooling System Horn Wiring Harness 1. Turn the main switch OFF. 2. Raise seat. 3. Disconnect the meter panel (1) from the wiring harness connector (2). 4. Turn the main switch ON.
Page 258 ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Relay (Horn, Solenoid and Starter) 1. Disconnect the connector from relay (6) after turning the main switch off. 2. Remove the relay from bracket. 3. Measure the resistance with an ohmmeter across the terminal 2 (2) to terminal 1 (5), terminal 5 (1) to terminal 4 (3) and terminal 5 (1) to terminal 3 (4).
Page 259: Disassembling And Assembling
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [2] DISASSEMBLING AND ASSEMBLING (1) Starter (1) Magnetic Switch Mounting (2) Housing (3) Magnetic Switch (4) C Terminal Nut (5) Shaft Assembly (6) Drive Lever (7) Overrunning Clutch (8) Connecting Lead (9) Mounting Screw...
Page 260: Servicing
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [3] SERVICING (1) Starter Overrunning Clutch 1. Inspect the pinion for wear or damage. 2. If there is any problem, replace the overrunning clutch assembly. 3. Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction.
Page 261 ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Brush Holder 1. Check the continuity across the brush holder and the holder support with an ohmmeter. 2. If it conducts, replace the brush holder. 9Y1211344ELS0033US0 Armature Coil 1. Check the continuity across the commutator and armature coil core with an ohmmeter.
Page 262: Charging System
ELECTRICAL SYSTEM ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (2) Charging System Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. 9Y1211344ELS0036US0 5-S21 KiSC issued 06, 2017 A...
Page 263 MOWER KiSC issued 06, 2017 A...
Page 264 MECHANISM CONTENTS 1. POWER TRANSMISSION......................6-M1 2. MOWER LINKAGE ........................6-M2 KiSC issued 06, 2017 A...
Page 265: Power Transmission
MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. POWER TRANSMISSION (1) Center Pulley (3) 19T Bevel Gear (4) Pinion Shaft (9) Blade Shaft (2) 15T Bevel Gear (RCK60P-1200Z) (5) Outer Pulley (10) Outer Blade (RCK60P-1200Z) 18T Bevel Gear (6) Mower Belt...
Page 266: Mower Linkage
MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 2. MOWER LINKAGE (1) Cutting Height Adjusting Dial (2) Dial Cam Gear (3) Lift Cylinder (4) Lift Shaft (5) Adjusting Cam (6) Horizon Plate (7) Front Arm The lifting of mower is performed by the hydraulic system on the machine.
Page 267 SERVICING CONTENTS 1. TROUBLESHOOTING.........................6-S1 2. SERVICING SPECIFICATIONS ....................6-S2 3. TIGHTENING TORQUES......................6-S3 4. CHECKING, DISASSEMBLING AND ASSEMBLING ..............6-S4 [1] CHECKING AND ADJUSTING....................6-S4 [2] DISASSEMBLING AND ASSEMBLING ................6-S8 (1) Lifting Linkage .........................6-S8 (2) Mower Deck........................6-S11 KiSC issued 06, 2017 A...
Page 268: Troubleshooting
MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 1. TROUBLESHOOTING Probable Cause and Reference Symptom Solution Checking Procedure Page Blade Does Not Turn 1. PTO system Check transmission 2-S11, malfunctioning 2-S23, 2-S42 2. Broken mower belt Replace mower belt 6-S13 Blade Speed Is Slow 1.
Page 269: Servicing Specifications
MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Pinion Shaft (without Mower Belt) Turning Force Less than – 117.7 N 12.0 kgf 26.5 lbf Turning Torque Less than – 1.47 N·m 0.15 kgf·m 1.08 lbf·ft...
Page 270 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 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 "6. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m...
Page 271: Checking, Disassembling And Assembling
MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM 4. CHECKING, DISASSEMBLING AND ASSEMBLING [1] CHECKING AND ADJUSTING Adjusting Anti-scalp Rollers WARNING To avoid serious injury: • Park the machine on a firm and level surface. • Apply the parking brake. • Stop the engine and remove the key.
Page 272 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (Continued) (Reference) • Set position for recommended ground clearance 19 mm (0.75 in.). Anti-scalp roller cutting height adjusting chart The number of collars Ground clearance mm Position of bolts under the boss (Ref.) Rear anti-scalp roller...
Page 273 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Adjusting Left and Right Cutting Height WARNING To avoid serious injury: • Park the machine on a firm and level surface. • Engage the parking brake. • Disengage PTO. • Stop the engine, remove the key and remove the mower universal joint while checking or adjusting the level of the mower deck.
Page 274 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Adjusting Front and Rear Cutting Height WARNING To avoid serious injury: • Park the machine on a firm and level surface. • Engage the parking brake. • Disengage PTO. • Stop the engine, remove the key and remove the mower universal joint while checking or adjusting the level of the mower deck.
Page 275: Disassembling And Assembling
MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM [2] DISASSEMBLING AND ASSEMBLING (1) Lifting Linkage Removing Lift Cylinder 1. Disconnect the cylinder hose (1). 2. Remove the clevis pin top (3). 3. Remove the clevis pin bottom (4). 4. Remove the lift cylinder (2) with cylinder hose (1).
Page 276 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Dial Cam Gear 1. Remove RH and LH fender. 2. Remove bonnet lock assembly (2). 3. Remove cam rod (1). 4. Remove dial cam gear assembly (3). 5. Remove dial cam gears (4). 6. Remove dial cam nut (5).
Page 277 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Mower Linkage 1. Remove mower deck. 2. Remove RH and LH link plates (1). 3. Remove RH and LH joint plates (2). 4. Remove rear lift link (3). 5. Remove front lift link (4).
Page 278: Mower Deck
MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM (2) Mower Deck Mower 1. Raise seat and disconnect PTO Shaft (1). 2. Start engine and set mower at lowest cutting position. 3. Turn off engine. 4. Remove clevis pins (2) from mounting links LH and RH.
Page 279 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Universal Joint and Belt Covers 1. Remove the universal joint (1). 2. Remove the left and right belt covers (2), (3). (1) Universal Joint [A] RCK60P (2) Belt Cover (Left) RCK72P (3) Belt Cover (Right)
Page 280 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Blade Boss 1. Remove the external snap ring (2). 2. Remove the blade boss (1). (1) Blade Boss (2) External Snap Ring 9Y1211344MOS0013US0 Gear Box and Mower Belt 1. Remove the mower deck from the machine.
Page 281 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Disassembling Gear Box 1. Remove the drain plug, and drain the gear box oil. 2. Remove the center pulley (23) with a puller, and remove the feather key (24) on the bevel gear shaft.
Page 282 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Center Pulley Holder 1. Remove the center pulley holder screws (8) and reamer screws (7). 2. Remove the upper oil seal (5) and lower oil seal (12). 3. Remove the internal snap ring (11) and ball bearing (10).
Page 283 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Outer Pulley and Blade Shaft 1. Remove the outer pulley mounting nut (19), and remove the outer pulley (22) and feather key (18). 2. Remove the pulley holder mounting bolts (28), and separate the left pulley holder (27) from the mower deck.
Page 284 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Turning Torque of Pinion Shaft 1. Remove the mower belt, and reassemble the gear box to the mower deck. 2. Wind a string around the pinion shaft and set a spring balance (or push-pull gauge) to the tip of the string, and then slowly pull the spring balance horizontally to measure the turning force.
Page 285 MOWER ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM Backlash between Bevel Gears 1. Remove the gear box cap (3). 2. Attach plastigauge on the bevel gear (4) on the pinion shaft (2). 3. Turn the pinion shaft (2). 4. Remove the plastigauge, and measure the plastigauge.
Page 286 : Farm Machinery International Service Department Address 64, Ishizu-Kitamachi, Sakai-Ku, Sakai-City, Osaka, 590-0823, Japan Phone +81- 72-241-1129 +81- 72-245-2484 E-mail : kbt_g.ag-sv@kubota.com Printed in Japan 2017. 06, S, EI, EI, engusa Code No.9Y111-13443 KUBOTA Corporation 2015. 11, S, EI, EI, engusa...

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