Page 1 WORKSHOP MANUAL ZD1511 KiSC issued 11, 2016 A...
Page 2 All illustrations, photographs and specifications contained in this manual are of the newest information available at the time of publication. Kubota reserves the right to change all information at any time without notice. Since this manual includes many models, information or illustrations and photographs can show more than one model.
Page 3: Table Of Contents
CONTENTS 1. INFORMATION SAFETY FIRST..............................1-1 1. Safety first..............................1-1 2. Before you start service ..........................1-2 3. Start safely..............................1-2 4. Operate safely ............................1-2 5. Protect against high pressure spray ......................1-3 6. Avoid hot exhaust .............................1-3 7. Exhaust filter cleaning ..........................1-3 8.
Page 4 3.1 Adjusting front axle pivot ......................... 2-24 4. Check point of initial 400 hours ......................2-25 4.1 Changing transmission fluid and rear axle gear case oil (R.H. and L.H.) ........2-25 5. Check points of every 50 hours ......................2-26 5.1 Checking engine start system ......................
Page 5 17.3 Replacing mower blade......................... 2-49 17.4 Replacing mower belt........................2-50 17.5 Bleeding fuel system ........................2-51 SPECIAL TOOLS.............................2-53 1. Special tools for engine .......................... 2-53 1.1 Diesel engine compression tester (for nozzle hole) ................ 2-53 1.2 Diesel engine compression tester (for glow plug hole) ..............2-53 1.3 Oil pressure tester ...........................
Page 6 5.3 Function of Diesel Particulate Filter (DPF) ..................3-17 5.4 Definition of temperature sensor ..................... 3-17 5.5 Definition of differential pressure sensor ..................3-18 SERVICING ..............................3-19 1. Troubleshooting for engine ........................3-19 2. Servicing specifications for engine ......................3-23 3. Tightening torques for engine ......................... 3-27 4.
Page 7 6.1.7 Checking valve seating ......................3-63 6.1.8 Correcting valve ........................3-63 6.1.9 Correcting valve seat ......................3-64 6.1.10 Checking valve lapping ......................3-64 6.1.11 Checking free length and tilt of valve spring ................. 3-65 6.1.12 Checking valve spring setting load ..................3-65 6.1.13 Checking oil clearance between rocker arm and rocker arm shaft ........
Page 8 MECHANISM ..............................4-1 1. Structure of transaxle ..........................4-1 1.1 Hydraulic transmission section......................4-2 1.1.1 Hydrostatic transmission......................4-2 1.1.2 HST oil flow..........................4-4 1.1.3 Power transmission operation ....................4-5 1.1.4 Pump and motor ........................4-7 1.1.5 Check and high pressure relief valve..................4-8 1.1.6 Hydrostatic control linkage......................
Page 9 5.1.22 Removing speed control rods ....................4-35 5.1.23 Removing hydraulic lift rod ....................4-35 5.1.24 Removing PTO lever assembly .................... 4-36 5.1.25 Removing cutting height adjusting gear................4-36 5.1.26 Removing ROPS ........................4-37 5.1.27 Removing rear wheel ......................4-37 5.1.28 Removing parking brake ....................... 4-37 5.1.29 Separating transaxle assembly.....................
Page 10 5.5.8 Removing parking brake ......................4-57 5.6 Disassembling speed lever ......................4-57 5.6.1 Removing the battery......................4-57 5.6.2 Removing step and center step ....................4-58 5.6.3 Removing seat assembly......................4-58 5.6.4 Removing fenders........................4-58 5.6.5 Removing speed lever assembly .................... 4-59 6.
Page 11 5. Disassembling and assembling ......................6-12 5.1 Hydraulic control valve ........................6-12 5.1.1 Draining transmission fluid...................... 6-12 5.1.2 Removing PTO clutch link, cylinder hose, oil cooler pipe and HST charge pipes ....6-13 5.1.3 Removing PTO clutch lever, delivery pipe, pipe fitting, universal joint and PTO shaft oil seal 6-14 5.1.4 Removing center case front cover assembly ................
Page 12 4. Checking and adjusting .......................... 7-22 4.1 Battery .............................7-22 4.1.1 Checking battery voltage ......................7-22 4.1.2 Checking battery terminal connection..................7-22 4.1.3 Checking battery specific gravity .................... 7-22 4.2 Starting system ..........................7-23 4.2.1 Checking main switch continuity ..................... 7-23 4.2.2 Testing starter motor .......................
Page 13 6.2.6 Checking rectifier ........................7-44 6.2.7 Checking IC regulator continuity ..................... 7-44 8. MOWER MECHANISM ..............................8-1 1. Power flow of mower ..........................8-1 SERVICING ...............................8-3 1. Troubleshooting for mower ........................8-3 2. Servicing specifications for mower ......................8-4 3. Tightening torques for mower ........................8-5 4.
Page 14 ZD1511 KiSC issued 11, 2016 A...
Page 15: Information
INFORMATION KiSC issued 11, 2016 A...
Page 16: Safety First
SAFETY FIRST 1. Safety first 1. INFORMATION SAFETY FIRST 1. Safety first This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you try to repair or use this unit.
Page 17: Before You Start Service
SAFETY FIRST 1. INFORMATION 2. Before you start service 2. Before you start service 4. Operate safely • Read all instructions and safety instructions in this manual and on your machine safety decals. • Clean the work area and machine. •...
Page 18: Protect Against High Pressure Spray
SAFETY FIRST 5. Protect against high pressure spray 1. INFORMATION 6. Avoid hot exhaust loosen the cap to release the pressure before you remove it fully. • Released fluid (fuel or hydraulic oil) under pressure can cause damage to the skin and cause serious injury.
Page 19: Prevent A Fire
SAFETY FIRST 1. INFORMATION 8. Prevent a fire 8. Prevent a fire 10. Discard fluids correctly • Fuel is very flammable and explosive under some • Do not discard fluids on the ground, down the drain, conditions. Do not smoke or let flames or sparks in into a stream, pond, or lake.
Page 20: Prepare For Emergencies
SAFETY FIRST 12. Prepare for emergencies 1. INFORMATION 12. Prepare for emergencies • Keep a first aid kit and fire extinguisher ready at all times. • Keep the emergency contact telephone numbers near your telephone at all times. ZD1511 KiSC issued 11, 2016 A...
Page 21 SAFETY FIRST 1. INFORMATION ZD1511 KiSC issued 11, 2016 A...
Page 22: Safety Decals
SAFETY DECALS 1. INFORMATION SAFETY DECALS The 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. ZD1511 KiSC issued 11, 2016 A...
Page 23 SAFETY DECALS 1. INFORMATION ZD1511 KiSC issued 11, 2016 A...
Page 24 SAFETY DECALS 1. INFORMATION ZD1511 KiSC issued 11, 2016 A...
Page 25 SAFETY DECALS 1. INFORMATION 1-10 ZD1511 KiSC issued 11, 2016 A...
Page 26 SAFETY DECALS 1. INFORMATION 1-11 ZD1511 KiSC issued 11, 2016 A...
Page 27: Care Of Danger, Warning And Caution Labels
SAFETY DECALS 1. INFORMATION 1.Care of danger, warning and caution labels 1. Care of danger, warning and caution labels • Keep danger, warning and caution labels clean and free from obstructing material. • Clean danger, warning and caution labels with soap and water, dry with a soft cloth.
Page 28: Specifications
SPECIFICATIONS 1. INFORMATION SPECIFICATIONS (Specifications and design subject to change without notice) Model ZD1511LF Model V1505-T Maximum engine kW (HP) 23.0 (30.8) power (Gross) Type Liquid-cooled Number of cylinders Bore and stroke mm (in.) 78 x 78.4 (3.07 x 3.09) Total displacement (cu.
Page 29 Min. turning radius mm (in.) 0 (0) Revolution 1 speed (2570 rpm at 2500 engine rpm) Drive system Shaft drive, KUBOTA 10 tooth involute spline Clutch type Wet multi disks PTO brake Wet single disk Manufacturer's estimate, SAE J1940 At 2500 engine rpm Oil amount when the oil level is at the upper level.
Page 30: Dimensions
DIMENSIONS 1. INFORMATION DIMENSIONS 1-15 ZD1511 KiSC issued 11, 2016 A...
Page 31 1. INFORMATION 1-16 ZD1511 KiSC issued 11, 2016 A...
Page 32: General
GENERAL KiSC issued 11, 2016 A...
Page 33: Identification
IDENTIFICATION 2. GENERAL IDENTIFICATION • Identify serial numbers for machine, engine and mower. (1) Machine identification plate (3) ROPS serial number (2) Machine serial number (1) Engine serial number (1) Mower identification plate (2) Mower serial number ZD1511 KiSC issued 11, 2016 A...
Page 34 2. GENERAL ZD1511 KiSC issued 11, 2016 A...
Page 35: General Precautions
• Remove oil and dirt from parts before you measure. • Use only KUBOTA genuine parts for replacement to keep the machine performance and to make sure of safety.
Page 36 2. GENERAL ZD1511 KiSC issued 11, 2016 A...
Page 37: Identifying Cylinder Number
IDENTIFYING CYLINDER NUMBER 2. GENERAL IDENTIFYING CYLINDER NUMBER The cylinder numbers of KUBOTA diesel engine are designated as shown in the figure. The sequence of cylinder numbers is No. 1, No. 2, No. 3 and No. 4 and it starts from the gear case side.
Page 38 2. GENERAL ZD1511 KiSC issued 11, 2016 A...
Page 39: Handling Precautions For Electrical Parts And Wiring
HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING 1.Handling of wiring 2. GENERAL HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING IMPORTANT • Check electrical wiring damage loosened connection every year. To this end, educate the customer to do his or her own check and at the same time recommend the dealer to perform periodic check for a fee.
Page 40: Handling Of Battery
HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING 2. GENERAL 2.Handling of battery (1) Clamp (Wind clamp spirally) (4) Welding dent (1) Cover (Securely install cov- (2) Wire harness (3) Clamp • Clamp wiring so that there is no twist, unnecessary 2.
Page 41: Handling Of Fuse
HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING 3.Handling of fuse 2. GENERAL 3. Handling of fuse (A) Correct (B) Incorrect • Use sandpaper to remove rust from terminals. (1) Fuse (3) Slow blow fuse • Repair deformed terminal. Make certain there is no (2) Fusible link terminal being exposed or displaced.
Page 42: Handling Of Circuit Tester
HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING 2. GENERAL 5.Handling of circuit tester (An example) W/R: Red stripe on white color Color of wiring Color code Black Brown Green Gray Gy or Gr Blue Light green (1) Cover (B) Incorrect (A) Correct Orange Pink...
Page 43: Lubricants, Fuel And Coolant
2. GENERAL LUBRICANTS, FUEL AND COOLANT IMPORTANT • To prevent serious damage to hydraulic system, use only KUBOTA genuine fluid or its equivalent. NOTE Fuel • Cetane number of 45 is minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20 (-4 ) or elevations above 1500 m (5000 ft).
Page 44 Oil amount when the oil level is at the upper level of the oil level gauge. The product name of KUBOTA genuine UDT fluid may be different from that in the Operator's Manual depending on countries or territories. Biodiesel Fuel (BDF) B0-B5 Biodiesel fuels (BDF): mixed diesel fuels containing 5% or less biodiesel can be utilized under the following conditions.
Page 45 8. The Kubota Warranty, as specified in the Owner's Warranty Information Guide, only covers problems in product materials and workmanship. Accordingly, any problems that may arise due to the use of poor quality fuels that fail to meet the above requirements, whether biodiesel or mineral oil based, are not covered by the Kubota Warranty. Routine handling: 1.
Page 46 2. GENERAL 2-14 ZD1511 KiSC issued 11, 2016 A...
Page 47: Tightening Torques
TIGHTENING TORQUES 1.General use screws, bolts and nuts 2. GENERAL TIGHTENING TORQUES 1. General use screws, bolts and nuts Indica- tion on No-grade or 4T top of bolt Indica- tion on No-grade or 4T top of Materi- al of oppo- Ordinariness Aluminum Ordinariness...
Page 48: Metric Screws, Bolts And Nuts
TIGHTENING TORQUES 2. GENERAL 3.Metric screws, bolts and nuts 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 22 to 25 48 to 55...
Page 49: Maintenance Check List
• The jobs indicated by ★ must be done initially. • 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 50 2. GENERAL Service interval After Reference Item since page 100 150 200 250 300 350 400 450 500 550 600 Transmission oil and 2-25 every 400 Rear axle gear case Change ★ (RH & LH) fluid every 400 2-37 16 Hydraulic oil filter Replace ☆...
Page 51: Check And Maintenance
CHECK AND MAINTENANCE 1.Daily check 2. GENERAL CHECK AND MAINTENANCE 1. Daily check • Always stop the engine and remove the key before checking oil. 1.1 Checking the machine 1. Check engine oil before starting and 5 minutes or To prevent trouble from occurring, it is important to more after the engine has stopped.
Page 52: Checking Transmission Fluid Level
CHECK AND MAINTENANCE 2. GENERAL 1.Daily check • Allow the transmission case to cool down IMPORTANT sufficiently when cleaning its surface. • Use diesel fuel only. • Do not permit dirt or trash or water to get into IMPORTANT the fuel system. •...
Page 53: Checking And Cleaning Radiator To Prevent Overheating
CHECK AND MAINTENANCE 1.Daily check 2. GENERAL 1. Remove the radiator cap and check to see that the on the radiator screen, hood screen or radiator coolant level is just below the fill port. decrease cooling performance. 2. Check to see that the coolant level is between the 1.
Page 54: Checking And Cleaning Dpf Muffler And Its Surroundings
CHECK AND MAINTENANCE 2. GENERAL 1.Daily check 1.7 Checking and cleaning DPF muffler and its surroundings WARNING To avoid serious injury or death: • Before checking or cleaning the DPF muffler, stop the engine and wait long enough until it is cooled down.
Page 55: Check Points Of Initial 50 Hours
• Allow engine to cool down sufficiently; oil can element of recommended type must be used. be hot and may cause burns. Use only a genuine KUBOTA filter or its equivalent. IMPORTANT • When using oil of different manufacture or 1.
Page 56: Replacing Hst Transmission Oil Filter
IMPORTANT • To prevent serious damage or premature failure 1. Lift up and securely block the front of the machine. to the hydraulic system, use only a KUBOTA 2. Measure the clearance (L) between the front axle genuine filter. (4) and front axle support (3).
Page 57: Check Point Of Initial 400 Hours
CHECK AND MAINTENANCE 4.Check point of initial 400 hours 2. GENERAL 3. If the measurement exceeds the allowable limit, • Allow transmission case cool down remove the set spring and adjust the end play by sufficiently; oil can be hot and may cause slotted nut (1).
Page 58: Check Points Of Every 50 Hours
CHECK AND MAINTENANCE 2. GENERAL 5.Check points of every 50 hours 3. Fill with UDT, SUPER UDT hydrostatic transmission fluid or its equivalent up to the upper line of the gauge. (1) Parking brake lock pedal (3) Key switch (2) Motion control lever (4) PTO lever Test 1 (Operator not on the seat) (1) Oil level dipstick...
Page 59: Checking Opc System
• If the machine does not pass one of the 5. After checking, reinstall the oil inlet plug with gauge following tests, do not operate the machine. See correctly. your local KUBOTA Dealer. (1) Drain plug (A) Oil level is acceptable within (1) Parking brake lock pedal...
Page 60 CHECK AND MAINTENANCE 2. GENERAL 5.Check points of every 50 hours 1. Apply a grease to the following position as figures. (1) Parking brake lock pedal 2. When you put grease to the machine universal joint, (1) King pin (L.H., R.H.) (3) Front wheel (L.H., R.H.) (2) Center pin remove the L-plate.
Page 61: Check Points Of Every 100 Hours
CHECK AND MAINTENANCE 6.Check points of every 100 hours 2. GENERAL 6. Check points of every 100 RELATED PAGE hours 11.1 Replacing air cleaner primary element and secondary element on page 2-38 6.1 Cleaning air cleaner primary element 6.2 Checking fuel filter WARNING To avoid serious injury or death: WARNING...
Page 62: Adjusting Fan Belt Tension
CHECK AND MAINTENANCE 2. GENERAL 6.Check points of every 100 hours 5. Check fuel filter, if it is clogged by debris or contaminated with water, replace it. (1) Tension bolt (A) 10 mm (0.4 in.) (2) Alternator (3) Adjustment bolt Moderate belt tension: Approx.
Page 63: Adjusting Parking Brake
CHECK AND MAINTENANCE 6.Check points of every 100 hours 2. GENERAL 6.4 Adjusting parking brake WARNING To avoid serious injury or death: • Park the machine on a hard and level surface. • Stop the engine and chock the wheels before checking or adjusting.
Page 64: Greasing Mower Link Bushing
CHECK AND MAINTENANCE 2. GENERAL 6.Check points of every 100 hours 6.7 Checking battery condition DANGER To avoid the possibility of battery explosion: refillable type battery, follow instructions below. • Do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark.
Page 65: Charging Battery
CHECK AND MAINTENANCE 6.Check points of every 100 hours 2. GENERAL • When connecting the cables to the battery, start NOTE with the positive terminal first. • The factory-installed battery is of non-refillable • Never check battery charge by placing a metal type.
Page 66: Check Point Of Every 150 Hours
CHECK AND MAINTENANCE 2. GENERAL 7.Check point of every 150 hours 8. Check points of every 200 Battery voltage Reference state of charge hours 12.6 100% (Full charge) 8.1 Changing engine oil 12.4 12.2 WARNING 12.0 To avoid serious injury or death: 11.8 •...
Page 67: Replacing Hst Transmission Oil Filter
5. After the new cartridge has been replaced, the element of recommended type must be used. transmission fluid level normally lowers a little. Add Use only a genuine KUBOTA filter or its fluid to proper level. Check for oil leaks around filter equivalent.
Page 68: Check Points Of Every 400 Hours
CHECK AND MAINTENANCE 2. GENERAL 9.Check points of every 400 hours 3. If the measurement exceeds the allowable limit, • Allow transmission case cool down remove the set spring and adjust the end play by sufficiently; oil can be hot and may cause slotted nut (1).
Page 69: Replacing Hydraulic Filter
• Never fail to check the fuel lines periodically. • To prevent serious damage or premature failure The fuel lines are subject to wear and age. Fuel to the hydraulic system, use only a KUBOTA may leak out onto the running engine, causing a genuine filter.
Page 70: Check Points Of Every 800 Hours
1 year 11.1 Replacing air cleaner primary element and secondary element IMPORTANT • To prevent serious damage to the engine, use only a Kubota genuine filter. • Pull out the tabs only when replacing the secondary element. 2-38 ZD1511...
Page 71: Check Point Of Every 1500 Hours
CHECK AND MAINTENANCE 12.Check point of every 1500 hours 2. GENERAL 13. Check points of every 2000 [How to remove the secondary element] 1. Pull out the two tabs of the secondary element hours or 2 years using a suitable tool (e.g. Flat-blade screwdriver) as shown in the figure.
Page 72: Anti-Freeze
(2) Radiator hose freeze. (1) Drain valve NOTE • Always use a 50/50 mix of long-life coolant and 4.6 L clean soft water in KUBOTA engines. Radiator 4.9 U.S.qts 4.0 Imp.qts Coolant capaci- 1. Long-Life Coolant (hereafter LLC) comes in several 1.1 L...
Page 73: Check Point Of Every 3000 Hours
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 2 years.
Page 74: Check Points Of Every 1 Year
CHECK AND MAINTENANCE 2. GENERAL 15.Check points of every 1 year [Radial clearance] lines, be sure to relieve all pressure. Before applying pressure to the system, make sure all connections are tight and that lines, pipes, and hoses are not damaged. 1.
Page 75: Checking Fuel Lines
CHECK AND MAINTENANCE 15.Check points of every 1 year 2. GENERAL 2. Replace radiator hoses (2) and tighten hose clamps securely, if radiator hoses (2) are swollen, hardened or cracked. (1) Fuel valve 3. The fuel line is made of rubber and ages regardless of service period.
Page 76: Checking Intake Air Line
CHECK AND MAINTENANCE 2. GENERAL 15.Check points of every 1 year 15.5 Checking intake air line WARNING To avoid serious injury or death: • Be sure to stop the engine and remove the key before checking intake air line. 1. Check to see that hoses and hose clamps are tight and not damaged.
Page 77: Replacing Radiator Hose
CHECK AND MAINTENANCE 16.Check point of every 4 years 2. GENERAL connections are tight and that lines, pipes, and hoses are not damaged. 1. Check to see that all lines 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 78: Replacing Intake Air Line
CHECK AND MAINTENANCE 2. GENERAL 16.Check point of every 4 years 16.4 Replacing intake air line 2. Close the fuel valves to both fuel tanks R.H. and L.H. WARNING To avoid serious injury or death: • Be sure to stop the engine and remove the key before checking intake air line.
Page 79: Replacing Mower Gear Box Seals
CHECK AND MAINTENANCE 16.Check point of every 4 years 2. GENERAL 16.5 Replacing mower gear box seals 1. Replace the mower gear box oil seals (1), (2) if damaged. (1) Oil seal (2) Oil seal RELATED PAGE 5.5 Disassembling gear box on page 8-9 16.6 Replacing engine breather hose 1.
Page 80: Others
CHECK AND MAINTENANCE 2. GENERAL 17.Others 17. Others 17.1 Replacing fuses IMPORTANT • Before replacing a blown fuse, determine why the fuse blew and make any necessary repairs. Failure to follow this procedure may result in serious damage to the electrical system. •...
Page 81: Checking Mower Blade
CHECK AND MAINTENANCE 17.Others 2. GENERAL Protected circuit Fuse No. (ID label) Capacity Protected circuit Capacity Protected circuit (12) Control system (20A) (Work light) Diag tool (13) Seat compressor 10 A (14) 10 A Alternator Meter (Glow) Fuel pump Solenoid valve Engine run (ACC) Fuse box 10 A...
Page 82: Replacing Mower Belt
CHECK AND MAINTENANCE 2. GENERAL 17.Others IMPORTANT • The blade bolts have right hand threads. Turn them counterclockwise to loosen. • To prolong the service life of the blades, reposition them as shown in the figure to the right periodically. NOTE •...
Page 83: Bleeding Fuel System
CHECK AND MAINTENANCE 17.Others 2. GENERAL (When reassembling) 77.6 to 90.2 N⋅m Tightening tor- Bracket mounting 8.00 to 9.20 kgf⋅m bolt 57.1 to 66.5 lbf⋅ft 17.5 Bleeding fuel system IMPORTANT Air must be removed: 1. When the fuel filter or lines are removed. 2.
Page 84 CHECK AND MAINTENANCE 2. GENERAL 17.Others 2-52 ZD1511 KiSC issued 11, 2016 A...
Page 85: Special Tools For Engine
SPECIAL TOOLS 1.Special tools for engine 2. GENERAL SPECIAL TOOLS 1. Special tools for engine 1.2 Diesel engine compression tester (for glow plug hole) 1.1 Diesel engine compression tester (for nozzle hole) Use to measure diesel engine compression and diagnosis of need for major overhaul. Use to measure diesel engine compression and diagnosis of need for major overhaul.
Page 86: Injection Pump Pressure Tester
SPECIAL TOOLS 2. GENERAL 1.Special tools for engine Code No. Pressure gauge full scale: • 07916-32032 More than 29.42 MPa (300.0 kgf/cm , 4267 psi) 1.4 Injection pump pressure tester PF 1/2 Copper gasket Use to check fuel tightness of injection pumps. Flange (Material: Steel) NOTE •...
Page 87: Bushing Replacing Tool
SPECIAL TOOLS 1.Special tools for engine 2. GENERAL 1.6 Bushing replacing tool Use to press out and press fit the bushing. NOTE • The special tools are not provided, so make them referring to the figure. For small end bushing 157 mm (6.18 in.) 24 mm (0.94 in.) 120 mm (4.72 in.)
Page 88: Flywheel Stopper
SPECIAL TOOLS 2. GENERAL 1.Special tools for engine 1.7 Flywheel stopper [Press out] Use to loosen and tighten the flywheel screw. 135 mm (5.31 in.) NOTE 72 mm (2.8 in.) • The special tools are not provided, so make 40 mm radius (1.6 in. radius) them referring to the figure.
Page 89: Crank Sleeve Setter
SPECIAL TOOLS 1.Special tools for engine 2. GENERAL Chamfer 1.0 mm (0.039 in.) 73.90 to 74.00 mm dia. (2.910 (1) Auxiliary socket for pushing to 2.913 in. dia.) 130 mm (5.12 in.) 69.80 to 69.90 mm dia. (2.748 to 2.751 in. dia.) 112 mm (4.41 in.) 30 mm dia.
Page 90 SPECIAL TOOLS 2. GENERAL 1.Special tools for engine (2) Sleeve guide 42 mm (1.7 in.) 12 mm (0.47 in.) 30 mm (1.2 in.) M10 × Pitch 1.25 2.0 mm (0.079 in.) 10 mm (0.39 in.) 2.0 mm (0.079 in.) 17.90 to 17.95 mm dia. (0.7048 to 0.7066 in.
Page 91: Rotation Sensor Signal Interface Unit
SPECIAL TOOLS 1.Special tools for engine 2. GENERAL 1.11 Rotation sensor signal interface unit Use for reading rotation sensor signal. NOTE • This special tool is not provided, so make it referring to the figure. (1) 9 V battery (5) Clip (Red) (a) +9 V (e) Signal (2) Switch...
Page 92: Special Tools For Machine
SPECIAL TOOLS 2. GENERAL 2.Special tools for machine 2. Special tools for machine 80.0 mm (3.15 in.) 2.1 Relief valve pressure tester 20 mm (0.79 in.) 60.0 mm (2.36 in.) This allows easy measurement of relief set pressure. Code No. G 1/4 ×...
Page 93: 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 94 2. GENERAL 2-62 ZD1511 KiSC issued 11, 2016 A...
Page 95: Engine
ENGINE KiSC issued 11, 2016 A...
Page 96: Mechanism
MECHANISM 1. Engine body 3. ENGINE MECHANISM 1. Engine body 1.1 Function of cylinder block The cylinder block is the main housing of engine. (1) Breather hose (4) Oil shield (2) Cylinder head cover (5) Rubber packing (3) Breather valve 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 97: Function Of Piston
MECHANISM 3. ENGINE 1. Engine body 1.4 Function of piston hardened cast iron. To reduce the wear on the ring, they are often plated with chrome on their contact The piston creates the forces for the suction, faces, or are coated their contact faces with compression, power and exhaust cycles.
Page 98: Function Of Crankshaft
MECHANISM 1. Engine body 3. ENGINE 1.7 Function of crankshaft journal and cam sections are chilled to resist wear. One intake and one exhaust cam is provided for each The crankshaft converts the up-and-down motion of the cylinder. The journal diameters are large to permit pistons into rotary motion.
Page 99: Function Of Flywheel
MECHANISM 3. ENGINE 1. Engine body 1.10 Function of flywheel set obliquely to the axis of rotation to rotate smoothly and reduce noise. The crankshaft is the hub around A flywheel is a rotating mechanical device that is used which other parts of the engine can be timed and to store rotational energy.
Page 100: Lubricating System
MECHANISM 2. Lubricating system 3. ENGINE 2. Lubricating system 2.1 Overview of lubricating system (1) Rocker arm (5) Idle gear (9) Relief valve (13) Piston (2) Oil pressure switch (6) Crankshaft (10) Push rod (14) Connecting rod (3) Rocker arm shaft (7) Oil pump (11) Tappet (15) Oil filter cartridge...
Page 101 MECHANISM 3. ENGINE 2. Lubricating system The oil pump sucks lubricating oil from the oil pan through the oil strainer and the oil flows down to the filter cartridge, where it is further filtered. Then the oil is forced to crankshaft (6), connecting rods (14), idle gear (5), camshaft (12) and rocker arm shaft (3) to lubricate each part.
Page 102: Function Of Oil Strainer
MECHANISM 2. Lubricating system 3. ENGINE 2.2 Function of oil strainer 2.4 Function of oil filter The oil strainer strains large particles from the oil. The oil filter is responsible for filtering impurities from the oil. (1) Oil strainer (2) Mesh screen The strainer (1) has a mesh screen (2) suitable for straining large particles from the oil and yet passes a sufficient quantity of oil to the inlet side of the oil pump.
Page 103: Function Of Relief Valve
MECHANISM 3. ENGINE 2. Lubricating system 2.5 Function of relief valve The relief valve prevents the damage of the lubricating system due to high oil pressure. (1) Spring (3) Gasket (2) Poppet (4) Plug The relief valve prevents the damage of the lubricating system due to high oil pressure.
Page 104: Cooling System
The cooling system cools the engine while it is running to prevent overheating and maintain a proper operating temperature. KUBOTA engines are used pressurized forced-circulation type. This system consists of a radiator (1), water pump (2), cooling fan (3), thermostat (4) and coolant temperature sensor (some models). The coolant is cooled through the radiator core, and the fan set behind the radiator pulls cooling air through the core to improve cooling.
Page 105 MECHANISM 3. ENGINE 3. Cooling system the bottom bypass system to improve the cooling performance of radiator and the three step valve opening type thermostat to reduce thermal shock radically. 3-10 ZD1511 KiSC issued 11, 2016 A...
Page 106: Function Of Water Pump
(2) and fins (3) at a right angle to the tubes. KUBOTA engines use corrugated fin type core which has a right weight and high heat transfer rate. Radiators are usually made of copper or brass.
Page 107: Fuel System
MECHANISM 3. ENGINE 4. Fuel system 4. Fuel system 4.3 Function of fuel feed pump An electromagnetic fuel feed pump is used when a fuel 4.1 Overview of fuel system tank is positioned below the pump of the engine. (1) Injection nozzle (5) Fuel feed pump Fuel in Fuel out...
Page 108: Function Of Injection Nozzle
MECHANISM 4. Fuel system 3. ENGINE 4.4 Function of injection nozzle 4.5 Function of fuel tank A fuel tank is a safe container for flammable fluids. (1) Fuel tank A fuel tank (1) is a safe container for flammable fluids. 4.6 Definition of electronic governor The actuator (1) and rack sensor (2) are placed on either side of the injection pump (3) control rack.
Page 109 MECHANISM 3. ENGINE 4. Fuel system (1) Actuator (3) Injection pump (2) Rack sensor (4) Control rack pin 3-14 ZD1511 KiSC issued 11, 2016 A...
Page 110: Reformer And After Treatment Devices
MECHANISM 5. Reformer and after treatment devices 3. ENGINE 5. Reformer and after treatment devices 5.1 Definition of reformer The reformer (1) is a Diesel Particulate Filter (DPF) regeneration device that is not dependent on the combustion method. Fuel (e) and air (primary air (b)) are supplied to the reformer (1) placed in the reforming catalyst generating reformer gas (a).
Page 111 MECHANISM 3. ENGINE 5. Reformer and after treatment devices [A] Exhaust gas temperature 250 ℃ or more If the exhaust temperature is higher than 250 ℃, the reformer gas (a) reacts exothermically with the DOC, raises the exhaust temperature generating a temperature in the DPF enabling regeneration and removes the Particulate Matter (PM) through combustion (normal regeneration).
Page 112: Definition Of Diesel Oxidation Catalyst (Doc)
MECHANISM 5. Reformer and after treatment devices 3. ENGINE 5.2 Definition of Diesel Oxidation Catalyst (DOC) An oxidizing catalyst positioned in front of the Diesel Particulate Filter (DPF) step that uses reformer gas to actively regenerate the DPF. (1) Diesel Particulate Filter (DPF) 5.4 Definition of temperature sensor The temperature sensor is a sensor that measures the...
Page 113: Definition Of Differential Pressure Sensor
MECHANISM 3. ENGINE 5. Reformer and after treatment devices 5.5 Definition of differential pressure sensor The differential pressure sensor is a sensor that detects the pressure differential between the atmosphere and the exhaust gas. (1) Differential pressure sensor 3-18 ZD1511 KiSC issued 11, 2016 A...
Page 114: Servicing
SERVICING 1. Troubleshooting for engine 3. ENGINE SERVICING 1. Troubleshooting for engine Refer- Probable cause and checking Symptom Solution ence procedure page Engine does not start 1. No fuel Replenish fuel 2-19 2. Air in fuel system Vent air 2-51 3.
Page 115 SERVICING 3. ENGINE Refer- Probable cause and checking Symptom Solution ence procedure page Engine revolution is not smooth 1. Fuel filter clogged or dirty Replace 2-37 2. Air cleaner clogged Clean or replace 2-29 3. Fuel leak due to loose injec- Tighten retaining nut 3-44 tion pipe retaining nut...
Page 116 SERVICING 3. ENGINE Refer- Probable cause and checking Symptom Solution ence procedure page Deficient output 7. Air leak from compressor dis- Repair or replace 2-41 charge side 8. Air cleaner dirty or clogged Clean or replace 2-29 9. Compressor wheel turning Replace turbocharger assembly 3-43 heavily...
Page 117 SERVICING 3. ENGINE Refer- Probable cause and checking Symptom Solution ence procedure page Engine overheated 1. Engine oil insufficient Replenish 2-23 2. Fan belt broken or elongated Replace or adjust 2-30 3. Coolant insufficient Replenish 2-39 4. Radiator net and radiator fin Clean 2-21 clogged with dust...
Page 118: Servicing Specifications For Engine
SERVICING 2.Servicing specifications for engine 3. ENGINE 2. Servicing specifications for engine Engine body Item Factory specification Allowable limit Cylinder head surface Flatness — 0.005 mm 0.002 in. Top clearance 0.55 to 0.75 mm — 0.022 to 0.029 in. Compression pressure 3.14 to 3.53 MPa 2.26 MPa 32.0 to 36.0 kgf/cm...
Page 119 SERVICING 3. ENGINE Item Factory specification Allowable limit • Tappet O.D. 19.959 to 19.980 mm — 0.78579 to 0.78661 in. Camshaft Side clearance 0.070 to 0.22 mm 0.30 mm 0.0028 to 0.0086 in. 0.012 in. Alignment — 0.01 mm 0.0004 in. Cam height Intake 28.80 mm...
Page 120 SERVICING 3. ENGINE Item Factory specification Allowable limit Piston pin bore I.D. 22.000 to 22.013 mm 22.03 mm 0.86615 to 0.86665 in. 0.8673 in. Piston ring to piston ring groove • Second ring Clearance 0.0850 to 0.122 mm 0.20 mm 0.00335 to 0.00480 in.
Page 121 SERVICING 3. ENGINE Item Factory specification Allowable limit Cylinder Liner I.D. 78.000 to 78.019 mm 78.15 mm 3.0709 to 3.0716 in. 3.077 in. Cylinder (oversize) 78.500 to 78.519 mm 78.65 mm 3.0906 to 3.0912 in. 3.096 in. Lubricating system Item Factory specification Allowable limit Engine oil pressure...
Page 122: Tightening Torques For Engine
SERVICING 3.Tightening torques for engine 3. ENGINE 3. Tightening torques for engine Tightening torques of screws, bolts and nuts on the table below are especially specified. NOTE • For the screws, bolts and nuts with the mark "*", apply engine oil to their threads and seats before you tighten.
Page 123 SERVICING 3. ENGINE Dimension × Item N⋅m kgf⋅m lbf⋅ft Pitch Alternator's pulley nut — 58.4 to 78.9 5.95 to 8.05 43.1 to 58.2 Drain plug with copper gasket M12 × 1.25 33 to 37 3.3 to 3.8 24 to 27 Drain plug with rubber coated gasket M22 ×...
Page 124: Checking And Adjusting
SERVICING 4.Checking and adjusting 3. ENGINE 4. Checking and adjusting 9. If compression pressure increases after applying oil, check the cylinder wall and piston 4.1 Engine body rings. 4.1.1 Checking compression pressure 4.1.2 Checking valve clearance NOTE • Check the compression pressure with the IMPORTANT specified valve clearance.
Page 125: Lubricating System
SERVICING 3. ENGINE 4.Checking and adjusting 1. Remove the cylinder head cover and the glow 49 kPa plugs. At idle speed Allowable limit 0.50 kgf/cm 7.1 psi 2. Align the “1TC” mark (1) on the flywheel and alignment mark (2) on the rear end plate so that the 197 to No.
Page 126: Checking Radiator Cap Air Leakage
SERVICING 4.Checking and adjusting 3. ENGINE 2. If the fan belt is damaged, replace it. (1) Radiator tester (2) Adapter 2. Apply the specified pressure, and measure the time (A) Good (B) Bad for the pressure to fall. 3. Check if the fan belt is worn and sunk in the pulley 3.
Page 127: Checking Thermostat Valve Opening Temperature
SERVICING 3. ENGINE 4.Checking and adjusting 2. Set a radiator tester (1) and an adaptor (2) and 4. If the measurement is not within the factory raise the water pressure to the specified pressure. specifications, replace the thermostat. Thermostat's valve opening tempera- 69.5 to 72.5 ℃...
Page 128: Checking Fuel Tightness Of Pump Element
(1) Timing line (6) One-hole: (2) Alignment mark 0.25 mm (0.0098 in.) requested to contact a Kubota-authorized pump (4) Shim (Soft metal gasket (7) Without hole: service shop. shim) 0.30 mm (0.012 in.) (5) Two-holes: (8) Three-holes: 1.
Page 129: Checking Fuel Tightness Of Delivery Valve
• Check nozzle injection pressure requested to contact a Kubota-authorized pump condition after you make sure that there is service shop. nobody standing in the direction the fume goes. If the fume from the nozzle directly contacts the 1. Remove the solenoid.
Page 130: Checking Valve Seat Tightness
SERVICING 4.Checking and adjusting 3. ENGINE 1. Set the injection nozzle to a nozzle tester. human body, cells may be destroyed and blood poisoning may be caused. 2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.
Page 131: Disassembling And Assembling
SERVICING 3. ENGINE 5.Disassembling and assembling 2. Start and warm up the engine for approx. 5 minutes. 3. Place an oil pan underneath the engine. (1) Drain plug 4. Remove the drain plug (1) to drain oil and drain the oil completely.
Page 132: Draining Coolant
SERVICING 5.Disassembling and assembling 3. ENGINE • Use the proper SAE Engine Oil according to 4. Remove the radiator cap (1) to completely drain the ambient temperatures. coolant. 5. After all coolant is drained, close the engine coolant drain valve (4). 6.7 L Engine oil Capacity...
Page 133: Removing Dpf Cover
SERVICING 3. ENGINE 5.Disassembling and assembling 5.1.7 Removing air cleaner assembly 2. Remove the bonnet (1). 1. Disconnect air cleaner hose from turbocharger (1). (1) Bonnet (1) Air cleaner hose (turbo- (4) Air cleaner assembly charger) 5.1.5 Removing DPF cover 2.
Page 134: Disconnecting Engine Wiring Harness
SERVICING 5.Disassembling and assembling 3. ENGINE 5.1.8 Disconnecting engine wiring harness 1. Disconnect each wiring connector. • DPF harness connector (1) • Water temperature sensor (2) • Doser fuel pump connector (3) • Engine stop solenoid connector (4) • Blower connectors (5) •...
Page 135: Disconnecting Engine Fuel Hoses
SERVICING 3. ENGINE 5.Disassembling and assembling 5.1.9 Disconnecting engine fuel hoses 1. Turn off fuel cut off valve (1). 2. Disconnect fuel hose from engine (2). 3. Disconnect fuel hose from doser fuel pump (3). 4. Remove fuel filter assembly (4). (2) Rear engine stopper 5.1.11 Removing universal joint from engine...
Page 136: Disconnecting Radiator Assembly
SERVICING 5.Disassembling and assembling 3. ENGINE 5.1.12 Disconnecting radiator assembly 1. Remove the oil cooler mounting bolts (1). (6) Center radiator plate 4. Remove radiator bracket mounting bolts (7), (8). (1) Oil cooler mounting bolts (3) Oil cooler (2) Oil cooler clips 2.
Page 137: Separating The Engine
SERVICING 3. ENGINE 5.Disassembling and assembling 5. Remove upper radiator hose (9). (When reassembling) (9) Upper radiator hose • Apply grease to the all splines on the drive shaft. 23.5 to 27.5 N⋅m Tightening tor- Engine mounting 5.1.13 Separating the engine 2.40 to 2.80 kgf⋅m 17.4 to 20.3 lbf⋅ft 1.
Page 138 SERVICING 5.Disassembling and assembling 3. ENGINE 5. Remove the starter (3). 3. Disconnect the pipe band (2). 4. Remove the double flare pipe 1-1, the double flare pipe 1-2, and the double flare pipe 2 from the doser flange (3). 5.
Page 139: Cylinder Head And Valve
SERVICING 3. ENGINE 5.Disassembling and assembling 5.2.2 Cylinder head and valve 5.2.2.3 Removing nozzle holder assembly and glow plug 5.2.2.1 Removing cylinder head cover (1) Breather hose (3) Cylinder head cover (2) Cylinder head cover screw 1. Disconnect the breather hose (1). (1) Overflow pipe (3) Glow plug 2.
Page 140 SERVICING 5.Disassembling and assembling 3. ENGINE 5.2.2.5 Removing rocker arm and push rod Overflow pipe re- taining nut 20 to 24 N⋅m Serial No.: 2.0 to 2.5 kgf⋅m Below 15 to 18 lbf⋅ft BTZ999 Overflow pipe re- taining nut 35 to 39 N⋅m Serial No.: 3.5 to 4.0 kgf⋅m Tightening tor-...
Page 141 SERVICING 3. ENGINE 5.Disassembling and assembling 5.2.2.6 Removing cylinder head and (When reassembling) cylinder head gasket NOTE • Do not use O-ring on the pin pipe. • It is not necessary to retighten the cylinder head screw and to readjust valve clearance after engine warmed up.
Page 142: Removing Valves
SERVICING 5.Disassembling and assembling 3. ENGINE 5.2.2.8 Removing valves 2. Remove the thermostat assembly (4). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (3). 5.2.3 Gear case and timing gears 5.2.3.1 Removing injection pump NOTE •...
Page 143 SERVICING 3. ENGINE 5.Disassembling and assembling (1) Aligning mark • Apply engine oil to the fan drive pulley retaining screw. And tighten it. 236 to 245 N⋅m Tightening tor- Fan drive pulley 24.0 to 25.0 kgf⋅m screw 174 to 180 lbf⋅ft (1) Gear case (e) Bolt length = 68 mm (2.7 in.) (a) Bolt length = 45 mm (1.8 in.)
Page 144 SERVICING 5.Disassembling and assembling 3. ENGINE 5.2.3.4 Removing cam gear, idle gear 1, 2 and governor gear (1) Fuel cam gear (9) Fuel camshaft (2) Alignment mark (10) Ball bearing (3) Cam gear (11) External snap ring (4) Idle gear 1 (12) Governor shaft (5) Crank gear (13) Set screw...
Page 145: Piston And Connecting Rod
SERVICING 3. ENGINE 5.Disassembling and assembling 5.2.4.2 Removing connecting rod • Check the governor shaft for smooth rotation. 5.2.4 Piston and connecting rod 5.2.4.1 Removing oil pan and oil strainer (for standard oil pan) 1. Remove the connecting rod cap. (When reassembling) •...
Page 146: Removing Pistons
SERVICING 5.Disassembling and assembling 3. ENGINE 5.2.4.3 Removing pistons (1) Piston ring compressor • Before inserting the piston into the cylinder, apply 1. Turn the flywheel and bring the piston to top dead enough engine oil to the piston. center. •...
Page 147: Flywheel And Crankshaft
SERVICING 3. ENGINE 5.Disassembling and assembling 5.2.5 Flywheel and crankshaft 5.2.5.1 Removing 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). (12) Manufacturer's mark •...
Page 148 SERVICING 5.Disassembling and assembling 3. ENGINE • Tighten the bearing case cover mounting screws with even force on the diagonal line. 10.8 to 12.2 N⋅m Tightening tor- Bearing case cov- 1.10 to 1.25 kgf⋅m er mounting screw 7.96 to 9.04 lbf⋅ft 5.2.5.3 Removing crankshaft assembly IMPORTANT •...
Page 149 SERVICING 3. ENGINE 5.Disassembling and assembling 5.2.5.4 Removing main bearing case (When reassembling) assembly (5) Main bearing case screw 1 (b) Marking (“A”, “B”, “C”) (a) Alignment number (c) Oil groove • Clean the oil passage in the main bearing cases. •...
Page 150: Alternator
SERVICING 5.Disassembling and assembling 3. ENGINE 5.2.6 Alternator 5.2.6.1 Disassembling alternator (1) Pulley (4) Bearing (7) Bearing (10) IC regulator (2) Drive end frame (5) Retainer plate (8) Rear end frame (11) Brush holder (3) Stator (6) Rotor (9) Rectifier (12) Rear end cover 1.
Page 151 SERVICING 3. ENGINE 5.Disassembling and assembling (When reassembling) 58.4 to 78.9 N⋅m Tightening torque Pulley nut 5.95 to 8.05 kgf⋅m 43.1 to 58.2 lbf⋅ft 3-56 ZD1511 KiSC issued 11, 2016 A...
Page 152: Starter
SERVICING 5.Disassembling and assembling 3. ENGINE 5.2.7 Starter 5.2.7.1 Disassembling starter (Electromagnetic drive type) NOTE • Do not damage to the brush and commutator. 3-57 ZD1511 KiSC issued 11, 2016 A...
Page 153 SERVICING 3. ENGINE 5.Disassembling and assembling (1) Solenoid switch mounting nut (8) Snap ring (15) Brake spring (22) Through bolt (2) Starter drive housing (9) Overrunning clutch (16) Brake shoe (a) Joint of solenoid switch (3) Drive lever (10) Armature (17) End frame cap (b) Bushing (4) Gasket...
Page 154 SERVICING 5.Disassembling and assembling 3. ENGINE 9. Draw out the armature (10) with the drive lever (3). (When reassembling) • Apply grease (DENSO.CO.LTD. No. 50 or equivalent) to the parts indicated in the figure. 5.88 to 11.8 N⋅m Tightening torque B terminal nut 0.600 to 1.20 kgf⋅m 4.34 to 8.70 lbf⋅ft...
Page 155: Servicing
SERVICING 3. ENGINE 6.Servicing 5. Remove the brush from the brush holder while holding the spring up. 6. Remove the brush holder (9). 7. Draw out the armature (5) from the yoke (4). 8. Remove the housing (13). 9. Remove the idle gear (7) and the overrunning clutch (6). 10.
Page 156: Checking Cylinder Head Flaw
SERVICING 6.Servicing 3. ENGINE 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 five to ten minutes after spraying. 4. Wash away the red permeative liquid on the cylinder head surface with the detergent (2).
Page 157: Checking Clearance Between Valve Stem And Valve Guide
SERVICING 3. ENGINE 6.Servicing 6.1.6 Replacing valve guide 5. If it still exceeds the allowable limit after replacing the valve, replace the cylinder head. NOTE • Do not hit the valve guide with a hammer during 6.1.5 Checking clearance between valve replacement.
Page 158: Checking Valve Seating
SERVICING 6.Servicing 3. ENGINE 6.1.7 Checking valve seating 1. Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact. (1) Correct (3) Incorrect (2) Incorrect 2. If the valve does not seat all the way around the valve seat or the valve contact is less than 70%, correct the valve seating as follows.
Page 159: Correcting Valve Seat
SERVICING 3. ENGINE 6.Servicing 6.1.9 Correcting valve seat 1.0 rad 60° Valve seat an- Factory speci- NOTE fication 0.79 rad • Before correcting the valve seat, check the 45° valve stem and the I.D. of valve guide section, and repair them if necessary. 2.
Page 160: Checking Free Length And Tilt Of Valve Spring
SERVICING 6.Servicing 3. ENGINE 6.1.11 Checking free length and tilt of valve 2. Read the compression load on the gauge. spring 3. If the measurement is less than the allowable limit, replace it. 117.4 N / 31.0 mm Factory specifi- 11.97 kgf / 31.0 mm cation 26.39 lbf / 1.22 in.
Page 161: Checking Push Rod Alignment
SERVICING 3. ENGINE 6.Servicing 6.1.14 Checking push rod alignment Factory specifi- 0.020 to 0.062 mm Oil clearance be- cation 0.00079 to 0.0024 in. tween tappet and 0.07 mm tappet guide bore Allowable limit 0.003 in. 6.2 Timing gears, camshaft and governor gear 6.2.1 Checking timing gear backlash 1.
Page 162: Checking Idle Gear 1 And 2 Side Clearance
SERVICING 6.Servicing 3. ENGINE 6.2.2 Checking idle gear 1 and 2 side 6.2.4 Checking camshaft alignment clearance 1. Support the camshaft with V blocks on the surface 1. Set a dial indicator with its tip on the idle gear. plate at both end journals. 2.
Page 163: Checking Oil Clearance Of Camshaft Journal
SERVICING 3. ENGINE 6.Servicing 2. If the measurement is less than the allowable limit, 3. If the oil clearance exceeds the allowable limit, replace the camshaft. replace the camshaft. Factory specifi- 28.80 mm Factory specifi- 0.050 to 0.091 mm cation 1.134 in.
Page 164: Replacing Idle Gear Bushing
SERVICING 6.Servicing 3. ENGINE 6.2.8 Replacing idle gear bushing Factory specifi- 22.000 to 22.013 mm cation 0.86615 to 0.86665 in. Piston pin bore I.D. 22.03 mm Allowable limit 0.8673 in. 6.3.2 Checking oil clearance between piston pin and small end bushing (A) When removing (B) When installing (When removing)
Page 165: Replacing Small End Bushing
SERVICING 3. ENGINE 6.Servicing 6.3.3 Replacing small end bushing 6.3.4 Checking 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. 2.
Page 166: Checking Clearance Between Piston Ring And Piston Ring Groove
SERVICING 6.Servicing 3. ENGINE 3. If the measurement exceeds the allowable limit, 1. Clean the rings and the ring grooves, and install replace the piston ring. each ring in its groove. 2. Measure the clearance between the ring and the 0.15 to groove with a feeler gauge or depth gauge.
Page 167: Checking Crankshaft Alignment
SERVICING 3. ENGINE 6.Servicing 4. If the same size bearing is useless because of the Crankshaft align- 0.02 mm Allowable limit crankshaft journal wear, replace it with an oversize ment 0.0008 in. one referring to the table and figure. (Reference) 6.4.3 Checking oil clearance between crankpin and crankpin bearing NOTE...
Page 168: Checking Oil Clearance Between Crankshaft Journal And Crankshaft Bearing 1
SERVICING 6.Servicing 3. ENGINE 6. If the same size bearing is useless because of the crankpin wear, replace it with an undersize one referring to the table and figure. (Reference) Crankshaft journal Factory specifi- 47.934 to 47.950 mm O.D. cation 1.8872 to 1.8877 in.
Page 169: Replacing Crankshaft Bearing 1
SERVICING 3. ENGINE 6.Servicing 4. If the same size bearing is useless because of the crankshaft journal wear, replace it with an undersize one referring to the table and figure. (Reference) (1) Seam (A) Dimension (2) Crankshaft bearing 1 (3) Cylinder block Factory specifi- 0 to 0.3 mm Dimension (A)
Page 170: Replacing Crankshaft Sleeve
SERVICING 6.Servicing 3. ENGINE 1. Put a strip of plastigauge on the center of the Undersize dimensions of crankshaft journal journal. 0.20 mm 0.40 mm Undersize 2. Install the bearing case and tighten the baring case 0.0079 in. 0.016 in. screws 1 to the specified torque, and remove the 2.3 to 2.7 mm radi- 2.3 to 2.7 mm radi-...
Page 171: Cylinder
SERVICING 3. ENGINE 6.Servicing (1) Crankshaft sleeve (3) Auxiliary socket for pushing (A) Top (a) Right-angled to piston pin (2) Sleeve guide (4) Crankshaft (B) Middle (b) Piston pin direction (C) Bottom (Skirt) 1. Remove the used crankshaft sleeve. 2. Get the difference (maximum wear) between the 2.
Page 172: Correcting Cylinder
SERVICING 6.Servicing 3. ENGINE 6.5.2 Correcting cylinder 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly. Rotor lobe clear- Factory specifi- 0.060 to 0.18 mm ance cation 0.0024 to 0.0071 in. 6.6.2 Checking clearance between outer (1) Cylinder I.D.
Page 173: Checking Clearance Between Rotor And Cover
SERVICING 3. ENGINE 6.Servicing 6.6.3 Checking clearance between rotor and cover [A] Electromagnetic drive type [B] Planetary gear reduction type 1. Check the pinion and if worn or damage, replace 1. Put a strip of plastigauge onto the rotor face with the clutch assembly.
Page 174: Checking Brush Wear
SERVICING 6.Servicing 3. ENGINE 2. Measure the commutator O.D. with an outside Gear reduction type micrometer at several points. Less than Factory specifi- 0.02 mm cation Difference of 0.0008 in. O.D.'s 0.05 mm Allowable limit 0.002 in. 5. Measure the mica undercut. 6.
Page 175: Checking Brush Holder
SERVICING 3. ENGINE 6.Servicing 3. If the length is than the allowable limit, replace the yoke assembly and brush holder. Factory specifi- 16.0 mm cation 0.630 in. Brush length (A) 10.5 mm Allowable limit 0.413 in. 6.7.4 Checking brush holder 1.
Page 176: Alternator
SERVICING 6.Servicing 3. ENGINE 6.8 Alternator 6.8.3 Checking rotor 6.8.1 Checking bearing 1. Check the bearing for smooth rotation. 1. Measure the resistance across the slip rings. 2. If the resistance is not the factory specification, replace it. 2. If it does not rotate smoothly, replace it. Factory specifi- Resistance 2.9 Ω...
Page 177: Checking Brush Wear
SERVICING 3. ENGINE 6.Servicing 6.8.5 Checking brush wear 2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction. 1. Measure the brush length with vernier calipers. 2. If the measurement is less than allowable limit, replace it.
Page 178: Transaxle
TRANSAXLE KiSC issued 11, 2016 A...
Page 179: Mechanism
MECHANISM 1. Structure of transaxle 4. TRANSAXLE MECHANISM 1. Structure of transaxle Transmission consists of bevel gear section (1) hydrostatic transmission (3), brake section (4), final reduction gear section (5), and PTO section (2). Power from engine is transmitted through transmission to mower and rear wheels. (1) Bevel gear section (3) Hydrostatic transmission (5) Final reduction gear section...
Page 180: Hydraulic Transmission Section
MECHANISM 4. TRANSAXLE 1. Structure of transaxle 1.1 Hydraulic transmission section 1.1.1 Hydrostatic transmission 1.1.1.1 Function of hydrostatic transmission Hydrostatic transmissions transmit all power hydraulically, using hydraulic fluid as the power distribution system. It works by converting energy harnessed from the movement of fluid through hydraulic pumps to the drive train of a vehicle.
Page 181 MECHANISM 1. Structure of transaxle 4. TRANSAXLE (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) (8) Cylinder block (pump) (13) Needle bearing (18) Relief valve spring (4) Center section...
Page 182: Hst Oil Flow
MECHANISM 4. TRANSAXLE 1. Structure of transaxle 1.1.2 HST oil flow 1.1.2.1 Structure of HST oil flow (1) Oil strainer (5) Regulator valve (8) Check and high pressure relief (11) Swashplate (2) Transmission case (6) PTO clutch valve (12) Piston (3) Hydraulic pump (7) Oil filter cartridge (9) Lubricating orifice...
Page 183: Power Transmission Operation
MECHANISM 1. Structure of transaxle 4. TRANSAXLE 1.1.3 Power transmission operation 1.1.3.1 Structure of power transmission operation (1) Check and high pressure relief (4) Neutral orifice (8) Lubricating orifice (12) Orifice (to rear axle case) valve (5) Oil filter (9) Pump (2) High pressure relief valve (6) Regulator valve (10) Hydraulic pump...
Page 184 MECHANISM 4. TRANSAXLE 1. Structure of transaxle 1.1.3.2 Neutral With the control levers in the neutral position, the piston springs in the pump block in the pumps force the swash plates to a position that is parallel to the pump body. With the swash plates parallel to the pump body, the pistons do not reciprocate in the cylinder block, they merely rotate, and no oil is being drawn in or...
Page 185: Pump And Motor
MECHANISM 1. Structure of transaxle 4. TRANSAXLE 1.1.4 Pump and motor 1.1.4.1 Structure of pump and motor Pump and motor cylinder, each containing pistons, are connected by lines. Cylinders and lines are filled with oil. Pistons ride against swashplates located in pump and motor. Diameter of pump cylinder block is smaller than motor cylinder block.
Page 186: Check And High Pressure Relief Valve
MECHANISM 4. TRANSAXLE 1. Structure of transaxle 1.1.4.2 Function of pump and motor 1.1.5.2 Function of check and high pressure relief valve In the pump, as the cylinder rotates, pistons move across the sloping face of swashplate and slide in or out of their cylinder bores.
Page 187 MECHANISM 1. Structure of transaxle 4. TRANSAXLE limit level, the pressure poppet opens itself against the relief valve spring (3) force and opens the valve seat that is located between the check valve seat (2) and the pressure poppet (1). Now the flow goes from P1 to P2 and P3.
Page 188: Hydrostatic Control Linkage
MECHANISM 4. TRANSAXLE 1. Structure of transaxle 1.1.6 Hydrostatic control linkage 1.1.6.1 Function of hydrostatic control linkage The motion control lever (1) and the trunnion shaft of variable swash-plate are linked with the speed control rod (3) and the trunnion arm (2). As the motion control lever (1) is pushed, the swash-plate rotates and forward traveling speed increases.
Page 189: Final Reduction Gear Section
MECHANISM 1. Structure of transaxle 4. TRANSAXLE 1.2 Final reduction gear section 1.2.1 Function of final reduction gear A combination of gears used to reduce the input speed to a lower output speed. As for this machine, power is transmitted from the gear on the brake shaft (1) to the rear axle (3) through 70T gear (2).
Page 190: Pto Section
MECHANISM 4. TRANSAXLE 1. Structure of transaxle 1.3 PTO section 1.3.1 Structure of PTO (1) PTO valve lever (9) Hydraulic pump (17) Center case, front cover (D) From hydraulic pump to valve (2) Regulator valve (10) Center case, rear cover (18) PTO shaft lever (3) PTO brake plate...
Page 191: Pto Clutch "Disengaged
MECHANISM 1. Structure of transaxle 4. TRANSAXLE 1.3.2 PTO clutch "Disengaged" the clutch pack pushes the clutch piston (4) to engage the clutch pack. After starting the engine, when the PTO clutch lever is set at the "Disengaged" position, the hole (9) of PTO valve lever (1) dose not face to hydraulic pump port.
Page 192: Function Of Regulator Valve
MECHANISM 4. TRANSAXLE 1. Structure of transaxle 1.3.4 Function of regulator valve (1) Poppet To transmission case (2) Spring (3) Plug From hydraulic pump to oil filter cartridge, PTO clutch and hydrostatic transmis- sion This machine is controlled with the regulator valve so that the oil sent from the hydraulic pump may become the setting pressure.
Page 193: Parking Brake Section
MECHANISM 1. Structure of transaxle 4. TRANSAXLE 1.4 Parking brake section 1.4.1 Function of parking brake The parking brake is usually used to keep the vehicle stationary and prevent machine roll back while machine is not in use. The parking brake consists of brake pedal (1), parking lock pedal (2), brake pedal return spring (3), brake shaft (4), brake rods (5), brake arms (7) and brake assemblies (6).
Page 194: Bevel Gear Section
MECHANISM 4. TRANSAXLE 1. Structure of transaxle 1.5 Bevel gear section 1.5.1 Function of bevel gears (1) Bevel gears (2) Transmission case (3) Input shaft Bevel gears are gears where the axes of the two shafts intersect and the tooth-bearing faces of the gears themselves are conically shaped.
Page 195: Servicing
SERVICING 1. Troubleshooting for transaxle 4. TRANSAXLE SERVICING 1. Troubleshooting for transaxle Refer- Probable cause and checking Symptom Solution ence procedure page Vehicle will not stop in neutral 1. Improper neutral adjustment Adjust Neutral 4-20 position 2. Improper speed control rod Adjust 4-20 adjustment...
Page 196: Servicing Specifications For Transaxle
SERVICING 4. TRANSAXLE 2. Servicing specifications for transaxle 2. Servicing specifications for transaxle Item Factory specifications Allowable limit Regulator valve (HST Charge Re- Setting pressure 0.75 to 0.95 MPa — lief Valve) at engine speed: 7.7 to 9.6 kgf/cm 3000 min (rpm) 110 to 130 psi PTO clutch at engine speed:...
Page 197: Tightening Torques For Transaxle
SERVICING 3. Tightening torques for transaxle 4. TRANSAXLE 3. Tightening torques for transaxle Tightening torques of screws, bolts and nuts on the table below are especially specified. Dimension × Item N⋅m kgf⋅m lbf⋅ft Pitch Motion control lever mounting bolt and nut —...
Page 198: Checking And Adjusting
SERVICING 4. TRANSAXLE 4. Checking and adjusting 4. Checking and adjusting 4.1 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 199: Checking Motion Control Lever Neutral Position
SERVICING 4. Checking and adjusting 4. TRANSAXLE 16. After taking steps 12. and 14. above, fix the speed control rod (2) length at the midpoint between the two position. 17. Adjust a speed control rod (2) length to be the center of the HST neutral range.
Page 200: Adjusting Motion Control Lever Operating Force
SERVICING 4. TRANSAXLE 4. Checking and adjusting 4.4 Adjusting motion control lever operating force IMPORTANT • Adjust the dampers after adjusting HST neutral. • Adjusting the motion control lever force will affect the maneuverability. • For adjustment of L.H. and R.H., use the same hole location.
Page 201: Adjusting Maximum Speed
SERVICING 4. Checking and adjusting 4. TRANSAXLE 4.6 Adjusting maximum speed 6. Remove the motion control lever cover (1). 7. Raise the rear of machine and block up so that rear wheel can rotate freely. WARNING 8. Start the engine. To avoid serious injury or death: 9.
Page 202: Checking Pto Clutch Operating Pressure (Hydrostatic Transmission Charge Pressure)
SERVICING 4. TRANSAXLE 4. Checking and adjusting If the operation pressure does not rises to 17.0 MPa (173 kgf/cm , 2470 psi), repair or replace the HST. 4.8 Checking PTO clutch operating pressure (hydrostatic transmission charge pressure) WARNING To avoid serious injury or death: •...
Page 203: Adjusting Parking Brake
SERVICING 4. Checking and adjusting 4. TRANSAXLE If the pressure is not within the factory specifications, check the regulator valve and related hydraulic components. 4.9 Adjusting parking brake WARNING To avoid serious injury or death: • Park the machine on a hard and level surface. •...
Page 204: Disassembling And Assembling
SERVICING 4. TRANSAXLE 5. Disassembling and assembling (When refilling) (A) Under 17° ramp 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.
Page 205: Draining Coolant
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 3. After draining reinstall the drain plugs (2). (4) Oil filling plug and breather (A) Oil level acceptable within this range. (1) Transmission oil filter (3) Rear axle gear case L.H. (5) Dipstick (2) Drain plug 12.1 L (When refilling)
Page 206: Removing The Battery
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 1. Remove the battery cover (1). 2. Disconnect the negative cable (3) from the battery. 3. Disconnect the positive cable (2) from the battery. 4. Remove the battery. (1) Battery cover (3) Negative cable (2) Positive cable 5.1.5 Removing the bonnet 1.
Page 207: Removing Rear Engine Frame
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 5.1.6 Removing rear engine frame 3. Remove air cleaner stay bolts (3). 4. Remove air cleaner assembly (4). 1. Remove rear engine frame (1). (2) Air cleaner hose (blower) (4) Air cleaner assembly (1) Rear engine frame (3) Air cleaner stay bolts 5.1.7 Removing DPF cover...
Page 208: Disconnecting Engine Wiring Harness
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 5.1.9 Disconnecting engine wiring harness 1. Disconnect each wiring connector. • DPF harness connector (1) • Water temperature sensor (2) • Doser fuel pump connector (3) • Engine stop solenoid connector (4) • Blower connectors (5) •...
Page 209: Disconnecting Engine Fuel Hoses
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 5.1.10 Disconnecting engine fuel hoses 1. Turn off fuel cut off valve (1). 2. Disconnect fuel hose from engine (2). 3. Disconnect fuel hose from doser fuel pump (3). 4. Remove fuel filter assembly (4). (2) Rear engine stopper 5.1.12 Removing universal joint from engine...
Page 210: Disconnecting Radiator Assembly
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 5.1.13 Disconnecting radiator assembly 1. Remove the oil cooler mounting bolts (1). (6) Center radiator plate 4. Remove radiator bracket mounting bolts (7), (8). (1) Oil cooler mounting bolts (3) Oil cooler (2) Oil cooler clips 2.
Page 211: Separating The Engine
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 5. Remove upper radiator hose (9). (When reassembling) (9) Upper radiator hose • Apply grease to the all splines on the drive shaft. 23.5 to 27.5 N⋅m Tightening tor- Engine mounting 5.1.14 Separating the engine 2.40 to 2.80 kgf⋅m 17.4 to 20.3 lbf⋅ft 1.
Page 212: Removing Fuel Stabilizer
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 2. Remove the seat assembly (1). 2. Disconnect regeneration switches (2). 3. Remove fender L.H. (3). (1) Seat assembly (1) LCD panel (3) Fender (L.H.) (2) Regeneration switches 5.1.17 Removing fuel stabilizer 4. Remove mower cutting height adjusting dial (4). 1.
Page 213: Removing Radiator
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 3. Remove oil cooler (3). (1) Fuel gauge (3) Fuel hose (2) Fuel cutoff switch (1) Oil cooler bolts (3) Oil cooler 4. Remove fuel tank L.H. (4). (2) Oil cooler clips 5. Remove fuel tank R.H. (5). 5.1.20 Removing radiator 1.
Page 214: Removing Pto Lever Assembly
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 2. Remove hydraulic lift rod (2). (1) Dial rod (2) Cutting height adjusting gear (1) Hydraulic lift hose (2) Hydraulic lift rod 5.1.24 Removing PTO lever assembly 1. Remove spring (1). 2. Remove PTO link (2). 3.
Page 215: Removing Rops
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 5.1.26 Removing ROPS • When tightening ROPS mounting bolts (6), begin with right bolt tighten counterclockwise two laps. 77.4 to 90.2 N⋅m Tightening tor- ROPS mounting 7.90 to 9.19 kgf⋅m screw (M12) 57.1 to 66.5 lbf⋅ft 5.1.27 Removing rear wheel 1.
Page 216: Separating Transaxle Assembly
SERVICING 4. TRANSAXLE 5. Disassembling and assembling between pump shaft and the pump drive shaft RELATED PAGE easy. 6.4 Adjusting parking brake on page 2-31 5.1.29 Separating transaxle assembly 1. Remove the rear axle gear case mounting bolts (1). (1) Rear axle gear case mount- ing bolts 2.
Page 217: Removing Pto Clutch Shaft Assembly And Pump Gear Shaft
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 5.2.2 Removing PTO clutch shaft assembly and pump gear shaft (1) HST pipe (4) Center case front cover (2) PTO clutch lever (5) PTO shaft oil seal (3) Delivery pipe (6) Plate (1) Input shaft assembly (3) Pump shaft assembly (2) PTO clutch shaft assembly 1.
Page 218: Removing Pto Clutch Lever
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 5.2.5 Removing PTO clutch lever 5.2.7 Removing input shaft, spiral bevel gear and joint shaft 1. Remove the lever stopper and remove the PTO clutch lever (2). (1) Internal snap ring (3) Joint shaft assembly (2) Shim (4) Spiral bevel gear (1) Center case front cover...
Page 219: Draining Transmission Fluid
SERVICING 5. Disassembling and assembling 4. TRANSAXLE (When refilling) 3. After draining reinstall the drain plugs (2). (2) Dipstick (A) Upper level (1) Transmission oil filter (3) Rear axle gear case L.H. (3) Engine oil range (B) Lower level (2) Drain plug IMPORTANT (When refilling) •...
Page 220: Draining Coolant
SERVICING 4. TRANSAXLE 5. Disassembling and assembling (4) Oil filling plug and breather (A) Oil level acceptable within (1) Radiator cap (3) Lower radiator hose this range. (2) Recovery tank (4) Engine coolant drain valve (5) Dipstick 1. Stop the engine and let cool down. 2.
Page 221: Removing The Bonnet
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 1. Remove the battery cover (1). 2. Disconnect the negative cable (3) from the battery. 3. Disconnect the positive cable (2) from the battery. 4. Remove the battery. (1) DPF cover 5.3.7 Removing rear engine frame 1.
Page 222: Disconnecting Engine Wiring Harness
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 4. Remove air cleaner assembly (4). (2) Air cleaner hose (blower) (4) Air cleaner assembly (3) Air cleaner stay bolts 5.3.9 Disconnecting engine wiring harness 1. Disconnect each wiring connector. • DPF harness connector (1) •...
Page 223: Disconnecting Engine Fuel Hoses
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 5.3.11 Removing engine stoppers 5. Disconnect all ground cables (14). 1. Remove front engine stoppers (1) on both sides of engine. (1) Front engine stopper 2. Remove rear engine stoppers (2) on both sides of engine.
Page 224: Disconnecting Radiator Assembly
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 2. Remove universal joint (2). (1) Universal joint mounting bolts (engine) (2) Universal joint (When reassembling) • Apply grease to the all splines on the drive shaft. 26.0 to 28.0 N⋅m Tightening tor- Universal joint 2.70 to 2.90 kgf⋅m mounting bolt...
Page 225: Separating The Engine
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 4. Remove radiator bracket mounting bolts (7), (8). (1) Engine mounting nuts L.H. (2) Engine mounting nuts R.H. 3. Attach hoist to engine. (7) Radiator bracket mounting (8) Radiator bracket mounting bolt L.H. bolt R.H.
Page 226: Removing Radiator
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 3. Remove oil cooler (3). (When reassembling) • Replace the PTO shaft oil seal with new one. 5.3.18 Removing center case rear cover and PTO clutch shaft assembly NOTE • At this point, the input shaft (3) must be pulled out to prevent interference between the PTO clutch case and the gear.
Page 227: Disassembling Pto Clutch Assembly
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 5.4 Disassembling hydrostatic 5.3.19 Disassembling PTO clutch assembly transmission and rear axle gear case assembly 5.4.1 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 228: Removing The Battery
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 5.4.2 Removing the battery • It takes time to pour the oil from the transmission case to the rear axle case R.H. and L.H. Pour the regulated amount of oil slowly. WARNING • Use only multi-grade transmission oil. Use of To avoid serious injury or death: other oils may damage the transmission of •...
Page 229: Removing Parking Brake
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 5.4.6 Separating hydrostatic transmission 2. Remove the rear wheels (1). and rear axle gear case assembly NOTE • The hydrostatic transmission and rear axle gear case assembly is very heavy. Be very careful in handling.
Page 230: Removing Rear Axle Gear Case
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 5.4.7 Removing rear axle gear case 1. Remove the rear axle gear case (1). (1) Center section (When reassembling) (1) Rear axle gear case Center section 25 to 29 N⋅m Tightening tor- mounting hex. 2.6 to 3.0 kgf⋅m (When reassembling) socket head screw...
Page 231: Removing Cylinder Block Assembly And Thrust Ball Bearing
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 5.4.10 Removing cylinder block assembly and thrust ball bearing NOTE • Be careful not to damage the surface of the cylinder blocks. (1) Swashplate 5.4.12 Removing slot guide and cradle bearing (1) Cylinder block assembly (3) Cylinder block assembly (Pump) (Motor)
Page 232: Removing Pump Shaft
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 5.4.13 Removing pump shaft (1) Transmission oil filter (3) Rear axle gear case L.H. (2) Drain plug (1) Pump shaft (3) Ball bearing (2) External snap ring (4) Internal snap ring (When refilling) 1.
Page 233: Removing The Battery
SERVICING 5. Disassembling and assembling 4. TRANSAXLE (1) Battery cover (3) Negative cable (2) Positive cable 5.5.3 Removing step and center step 1. Remove the step center (1). 2. Remove the front mask (2). 3. Remove the step (3). (4) Oil filling plug and breather (A) Oil level acceptable within this range.
Page 234: Removing Parking Brake
SERVICING 4. TRANSAXLE 5. Disassembling and assembling (When reassembling) 109 to 131 N⋅m Tightening tor- Rear wheel mount- 11.1 to 13.3 kgf⋅m ing screw 80.3 to 96.1 lbf⋅ft 5.5.5 Removing parking brake 1. Remove parking brake return plate (1). 2. Remove parking brake spring (2). 3.
Page 235: Removing Rear Axle
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 5.5.7 Removing rear axle 5.5.8 Removing parking brake (1) Internal snap ring (3) Brake disc (2) Friction plate 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).
Page 236: Removing Step And Center Step
SERVICING 4. TRANSAXLE 5. Disassembling and assembling 4. Remove the battery. (1) Seat assembly (1) Battery cover (3) Negative cable (2) Positive cable 5.6.4 Removing fenders 1. Disconnect LCD panel (1). 5.6.2 Removing step and center step 2. Disconnect regeneration switches (2). 1.
Page 237: Removing Speed Lever Assembly
SERVICING 5. Disassembling and assembling 4. TRANSAXLE 7. Remove fender R.H. (7). (1) Surface (4) Mower cutting height adjust- (6) Lever grips ing dial (7) Fender (R.H.) 6.1.2 Checking check and high pressure (5) Key switch relief valve 5.6.5 Removing speed lever assembly 1.
Page 238: Checking Thrust Washer, Thrust Ball Bearing And Thrust Plate
SERVICING 4. TRANSAXLE 6. Servicing 6.1.5 Checking pump shaft (1) Cylinder block (3) Spring (2) Piston (4) Polished face (1) Pump shaft (3) Bearing surface (2) Ball bearing 1. Check the cylinder blocks (1) and pistons (2) for scratches and wear. 1.
Page 239: Transmission Case
SERVICING 6. Servicing 4. TRANSAXLE 6.2 Transmission case Backlash between 19T bevel gear Factory specifi- 0.25 to 0.30 mm 6.2.1 Checking bearing and 18T bevel cation 0.0099 to 0.011 in. gear 3. Adjust the backlash properly by repeating the above procedure.
Page 240: Pto Clutch
SERVICING 4. TRANSAXLE 6. Servicing Proper contact • Make sure that whether there is a shim (5). • The 18T bevel gear (6) can be moved to backward by removing the shim (5) if there is a shim. (The shim (5) is not put when there is no shim.) •...
Page 241: Brake
SERVICING 6. Servicing 4. TRANSAXLE 6.4 Brake 6.4.1 Checking brake discs, friction plates and actuator 1. Check the surface of the brake discs (2), friction plates (1) and actuator (3). If excessive wear is found, replace it to a new one. (1) Friction plate (3) Actuator (2) Brake disc...
Page 242 SERVICING 4. TRANSAXLE 6. Servicing 4-64 ZD1511 KiSC issued 11, 2016 A...
Page 243: Front Axle
FRONT AXLE KiSC issued 11, 2016 A...
Page 244: Mechanism
MECHANISM 1. Structure of front axle 5. FRONT AXLE MECHANISM 1. Structure of front axle (1) Taper roller bearing (5) Center pin (2) Wheel bracket (6) Cap (3) Front axle (7) Taper roller bearing (4) Slotted nut 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...
Page 245 MECHANISM 5. FRONT AXLE ZD1511 KiSC issued 11, 2016 A...
Page 246: Servicing
SERVICING 1. Troubleshooting for front axle 5. FRONT AXLE SERVICING 1. Troubleshooting for front axle Refer- Probable cause and checking Symptom Solution ence procedure page Front wheels wander to right or 1. Clearance between center pin Check the clearance and replace left and front axle excessive the center pin or front axle...
Page 247: Servicing Specifications For Front Axle
SERVICING 5. FRONT AXLE 2.Servicing specifications for front axle 2. Servicing specifications for front axle Item Factory specifications Allowable limit Front axle end play Clearance 0 to 0.2 mm 0.5 mm 0 to 0.008 in. 0.02 in. ZD1511 KiSC issued 11, 2016 A...
Page 248: Tightening Torques For Front Axle
SERVICING 3. Tightening torques for front axle 5. FRONT AXLE 3. Tightening torques for front axle Dimension x Item N⋅m kgf⋅m lbf⋅ft Pitch Wheel bolt and lock nut － 20 to 25 2.1 to 2.5 15 to 18 Wheel bracket lock nut 45 to 55 4.6 to 5.6 34 to 40...
Page 249: Checking And Adjusting
SERVICING 5. FRONT AXLE 4.Checking and adjusting 4. Checking and adjusting 5. Disassembling and assembling 4.1 Adjusting front axle pivot 5.1 Separating front wheel and wheel bracket 5.1.1 Removing the front wheel 1. Lift up and secure machine with jack stands. 2.
Page 250: Separating Front Axle Assembly
SERVICING 5. Disassembling and assembling 5. FRONT AXLE 5.2 Separating front axle assembly 3. Inspect all parts for wear or damage. Replace the parts as needed. 5.2.1 Removing the battery WARNING To avoid serious injury or death: • When disconnecting battery cables, disconnect the negative cable from the battery...
Page 251 SERVICING 5. FRONT AXLE 5.Disassembling and assembling 2. Remove the cotter pin and clevis pin (4). 3. Remove the connecting plate (3). 4. Lift up and secure with jack stands or blocking the front of machine frame. 5. Remove the center pin (1), and separate the front axle assembly (5).
Page 252: Hydraulic System
HYDRAULIC SYSTEM KiSC issued 11, 2016 A...
Page 253: Mechanism
MECHANISM 1. Function of hydraulic circuit 6. HYDRAULIC SYSTEM MECHANISM 1. Function of hydraulic circuit The hydraulic system of this machine is composed of a hydraulic pump (10), control valve (6), hydraulic cylinder (4) and other components. This system has the following functions. Oil is supplied by hydraulic pump (10) which is driven by engine. Power from the input shaft (pump shaft) is distributed right and left with the bevel gears and drives each hydrostatic transmission (12).
Page 254: Hydraulic Pump
MECHANISM 6. HYDRAULIC SYSTEM 2. Hydraulic pump 2. Hydraulic pump (1) Control valve To PTO clutch From hydraulic pump To hydrostatic transmission (1) Casing (4) Drive gear (2) Driven gear (5) Side plate (3) Cover 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.
Page 255: Neutral Position
MECHANISM 3. Definition of hydraulic control valve 6. HYDRAULIC SYSTEM 3.1 Neutral position 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. The oil sent to the mower-lifting cylinder is interrupted by the spool (3).
Page 256: Lift And Overloaded
MECHANISM 6. HYDRAULIC SYSTEM 3. Definition of hydraulic control valve 3.2 Lift and overloaded The oil flowing from the pump flows through a hydraulic circuit, which is switched over by the spool (3), and is sent to the mower-lifting cylinder (2). When the mower is lifted, the relief valve (6) also operates. As a result, the oil passing through the relief valve (6) is always sent to the PTO valve and HST charge circuit.
Page 257: Down Position
MECHANISM 3. Definition of hydraulic control valve 6. HYDRAULIC SYSTEM 3.3 Down position 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. The mower-lifting cylinder circuit, which has been interrupted by the spool, is returned to the transmission center case by the pressed-in spool, and a new circuit if formed.
Page 258: Function Of Lift Cylinder
MECHANISM 6. HYDRAULIC SYSTEM 4. Function of lift cylinder 4. Function of lift cylinder The lift cylinder consists of the cylinder (4), piston rod (1) and other parts as shown in the figure. This cylinder is single acting type. (1) Piston rod (3) Packing (5) Snap ring (2) Scraper...
Page 259: Function Of Mower Linkage
MECHANISM 5. Function of mower linkage 6. HYDRAULIC SYSTEM 5. Function of mower linkage CAUTION • Never operate mower in transport position. The lifting of mower is performed by the hydraulic system on the machine. Front arm (7) and lift shaft are linked with horizon plate (6). When the position control lever is moved to LIFT position, the lift shaft (4) is risen by the oil pressure of hydraulic system.
Page 260 MECHANISM 6. HYDRAULIC SYSTEM ZD1511 KiSC issued 11, 2016 A...
Page 261: Servicing
SERVICING 1. Troubleshooting for hydraulic system 6. HYDRAULIC SYSTEM SERVICING 1. Troubleshooting for hydraulic system Refer- Probable cause and checking Symptom Solution ence procedure page Mower does not rise 1. Control valve malfunctioning Check and repair or replace 6-12, 6-15 2.
Page 262: Servicing Specifications For Hydraulic System
SERVICING 6. HYDRAULIC SYSTEM 2.Servicing specifications for hydraulic system 2. Servicing specifications for hydraulic system Item Factory specifications Allowable limit Relief Valve (Control Valve) at en- Setting pressure 5.5 to 7.0 MPa — gine speed: 1600 min (rpm) 56 to 71 kgf/cm 800 to 1000 psi 6-10 ZD1511...
Page 263: Tightening Torques For Hydraulic System
SERVICING 3. Tightening torques for hydraulic system 6. HYDRAULIC SYSTEM 3. Tightening torques for hydraulic system NOTE • Tightening torques of screws, bolts and nuts on the table below are especially specified. Dimension × Item N⋅m kgf⋅m lbf⋅ft Pitch Center case front cover mounting screw —...
Page 264: Checking And Adjusting
SERVICING 6. HYDRAULIC SYSTEM 4.Checking and adjusting 4. Checking and adjusting 4.1 Checking relief valve setting pressure 1. Remove the plug (2) from the front cover of transmission center case. 2. Install the adapter (3/8 in., straight thread), hose and pressure gauge. 3.
Page 265: Removing Pto Clutch Link, Cylinder Hose, Oil Cooler Pipe And Hst Charge Pipes
SERVICING 5. Disassembling and assembling 6. HYDRAULIC SYSTEM 3. After draining reinstall the drain plugs (2). (4) Oil filling plug and breather (A) Oil level acceptable within this range. (1) Transmission oil filter (3) Rear axle gear case L.H. (5) Dipstick (2) Drain plug 12.1 L (When refilling)
Page 266: Removing Pto Clutch Lever, Delivery Pipe, Pipe Fitting, Universal Joint And Pto Shaft Oil Seal
SERVICING 6. HYDRAULIC SYSTEM 5.Disassembling and assembling 6. Disconnect the lift cylinder hose (5). (1) Tape 2. Remove the center case front cover mounting (1) PTO clutch link (5) Lift cylinder hose (2) Lift rod (6) HST pipe screw, and separate the center case and center (3) Oil cooler pipe case front cover.
Page 267: Removing Lift Shaft And Arm
SERVICING 5. Disassembling and assembling 6. HYDRAULIC SYSTEM 5.1.5 Removing lift shaft and arm (1) Hydraulic control valve (When reassembling) Hydraulic control 18 to 20 N⋅m Tightening tor- valve mounting 1.8 to 2.1 kgf⋅m screw 13 to 15 lbf⋅ft 5.1.7 Removing spool 1.
Page 268: Removing Relief Valve
SERVICING 6. HYDRAULIC SYSTEM 5.Disassembling and assembling 5.1.8 Removing relief valve 1. Remove the plug (1), and remove the shims (2), spring (3), poppet (4) and valve seat (5). (1) Drain plug 4. Remove the drain plug (1) to drain oil and drain the oil completely.
Page 269: Draining Transmission Fluid
SERVICING 5. Disassembling and assembling 6. HYDRAULIC SYSTEM • It takes time to pour the oil from the 6.7 L transmission case to the rear axle case R.H. and Engine oil Capacity 7.1 U.S.qts 5.9 Imp.qts L.H. Pour the regulated amount of oil slowly. •...
Page 270: Draining Coolant
SERVICING 6. HYDRAULIC SYSTEM 5.Disassembling and assembling 5.2.3 Draining coolant 5.2.4 Removing the battery WARNING WARNING To avoid serious injury or death: To avoid serious injury or death: • Never open the radiator cap while operating or • When disconnecting battery cables, immediately after stopping.
Page 271: Removing Rear Engine Frame
SERVICING 5. Disassembling and assembling 6. HYDRAULIC SYSTEM 5.2.6 Removing rear engine frame 3. Remove air cleaner stay bolts (3). 4. Remove air cleaner assembly (4). 1. Remove rear engine frame (1). (2) Air cleaner hose (blower) (4) Air cleaner assembly (1) Rear engine frame (3) Air cleaner stay bolts 5.2.7 Removing DPF cover...
Page 272: Disconnecting Engine Wiring Harness
SERVICING 6. HYDRAULIC SYSTEM 5.Disassembling and assembling 5.2.9 Disconnecting engine wiring harness 1. Disconnect each wiring connector. • DPF harness connector (1) • Water temperature sensor (2) • Doser fuel pump connector (3) • Engine stop solenoid connector (4) • Blower connectors (5) •...
Page 273: Disconnecting Engine Fuel Hoses
SERVICING 5. Disassembling and assembling 6. HYDRAULIC SYSTEM 5.2.10 Disconnecting engine fuel hoses 1. Turn off fuel cut off valve (1). 2. Disconnect fuel hose from engine (2). 3. Disconnect fuel hose from doser fuel pump (3). 4. Remove fuel filter assembly (4). (2) Rear engine stopper 5.2.12 Removing universal joint from engine...
Page 274: Disconnecting Radiator Assembly
SERVICING 6. HYDRAULIC SYSTEM 5.Disassembling and assembling 5.2.13 Disconnecting radiator assembly 1. Remove the oil cooler mounting bolts (1). (6) Center radiator plate 4. Remove radiator bracket mounting bolts (7), (8). (1) Oil cooler mounting bolts (3) Oil cooler (2) Oil cooler clips 2.
Page 275: Separating The Engine
SERVICING 5. Disassembling and assembling 6. HYDRAULIC SYSTEM 5. Remove upper radiator hose (9). (When reassembling) (9) Upper radiator hose • Apply grease to the all splines on the drive shaft. 23.5 to 27.5 N⋅m Tightening tor- Engine mounting 5.2.14 Separating the engine 2.40 to 2.80 kgf⋅m 17.4 to 20.3 lbf⋅ft 1.
Page 276: Removing Radiator
SERVICING 6. HYDRAULIC SYSTEM 5.Disassembling and assembling 5.2.16 Removing radiator 1. Remove radiator assembly (1). (1) Hydraulic pump assembly (4) Casing (2) Side plate (5) Driven gear (3) Drive gear (1) Radiator assembly (When reassembling) • Be careful not to damage the O-ring. •...
Page 277: Electrical System
ELECTRICAL SYSTEM KiSC issued 11, 2016 A...
Page 278: Mechanism
MECHANISM 1. Electrical circuit of starting system 7. ELECTRICAL SYSTEM MECHANISM 1. Electrical circuit of starting system ZD1511 KiSC issued 11, 2016 A...
Page 279: Electrical Circuit Of Charging System And Easy Checker
MECHANISM ™ 2. Electrical circuit of charging system and Easy Checker 7. ELECTRICAL SYSTEM ™ 2. Electrical circuit of charging system and Easy Checker ZD1511 KiSC issued 11, 2016 A...
Page 280: Electrical Circuit Of Gauge System
MECHANISM 3. Electrical circuit of gauge system 7. ELECTRICAL SYSTEM 3. Electrical circuit of gauge system ZD1511 KiSC issued 11, 2016 A...
Page 281: Electrical Connector Chart
MECHANISM 7. ELECTRICAL SYSTEM 4. Electrical connector chart 4. Electrical connector chart ZD1511 KiSC issued 11, 2016 A...
Page 282: Reading Electrical Circuit Diagrams
MECHANISM 5. Reading electrical circuit diagrams 7. ELECTRICAL SYSTEM 5. Reading electrical circuit diagrams 5.1 How to read wiring diagram Electrical wiring chart symbols for harnesses and wires (Example) Contents of illustra- Item Reference tion Name of part STARTER RELAY Wire specification code All use (common) Wire size...
Page 283 MECHANISM 7. ELECTRICAL SYSTEM 5. Reading electrical circuit diagrams Color of wiring Color code Black Green Blue Pink White Yellow Brown Gray Light green Orange Sky blue ZD1511 KiSC issued 11, 2016 A...
Page 284 MECHANISM 5. Reading electrical circuit diagrams 7. ELECTRICAL SYSTEM Unit symbol (1) Variable (11) Heating element (22) Auto resetting b-Contact (33) ON (2) Non-linear variable (12) Condenser (23) Auto-resetting a-Contact (34) START (auto reset) (3) Fixed setting (13) Electrolytic capacitor (24) Relay coil (A) New symbol (4) Step variable...
Page 285: Layout Of Connector Diagrams
MECHANISM 7. ELECTRICAL SYSTEM 5. Reading electrical circuit diagrams 5.2 Layout of connector diagrams Connector arrangement sequence Depiction of connectors NOTE • In principle, the connector locking part is shown on the top side. • Female connector terminal numbers start from 1 in the top right corner, looking at the connecting face. •...
Page 286: Precautions On Handling Electrical Connectors
MECHANISM 5. Reading electrical circuit diagrams 7. ELECTRICAL SYSTEM 5.3 Precautions on handling electrical connectors 1. When disconnecting connectors, grasp the body of the connector and pull it out; do not pull on the wiring harness. If the connector is the locking type, release the lock and then pull to disconnect. 2.
Page 287: Starting System
MECHANISM 7. ELECTRICAL SYSTEM 6. Starting system 6. Starting system When current is applied to the winding (energized) (10), a magnetic field pushes the contact lever (8) and 6.1 Function of relay normally open terminal is connected. 6.2 Function of starter (1) Front bracket (6) Gear shaft (2) Drive lever...
Page 288: Function Of Glow Plug
MECHANISM 6. Starting system 7. ELECTRICAL SYSTEM 6.3 Function of glow plug 6.4 Function of safety switch (1) Sheath tube (6) Conventional quick-heating (1) Parking brake switch (3) Seat switch (2) Insulation powder type glow plug (2) Motion control lever switch (4) PTO lever switch (3) Heater also functioning as a (7) Glow plug current...
Page 289: Function Of Fuel Pump
MECHANISM 7. ELECTRICAL SYSTEM 6. Starting system 6.5 Function of fuel pump 7. Charging system 7.1 Function of alternator Inlet Outlet An electromagnetic 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 (1) Pulley (8) Spring supplied to the fuel injection pump regardless of engine...
Page 290: Service Code Display
MECHANISM 7. Charging system 7. ELECTRICAL SYSTEM • If the engine stalled with some remaining in the fuel tank R.H., close the fuel valve of fuel tank L.H. and you can operate. If the fuel in the tank goes below the prescribed level, ™...
Page 291: Gauge System
MECHANISM 7. ELECTRICAL SYSTEM 8. Gauge system As the float lowers, the resistance of the variable resistor varies. The relation between the amount of fuel and the resistance is as follows. E (Remaining fuel of approx. 5.0 L, 1.32 U.S.gals, 1.10 Imp.gals) 1 to 5 Ω...
Page 292: Function Of Oil Pressure Switch
MECHANISM 8. Gauge system 7. ELECTRICAL SYSTEM Characteristics of Thermistor Resistance of VR: Temperature Condition 40 ℃ (104 ℉) 1.14 kΩ 80 ℃ (176 ℉) 0.32 kΩ 100 ℃ (212 ℉) 0.19 kΩ 120 ℃ (248 ℉) 0.12 kΩ When galvanometer shows 0 (Zero). Condition Setting Value 54.945 to 55.055 W...
Page 293 MECHANISM 7. ELECTRICAL SYSTEM 8. Gauge system 7-16 ZD1511 KiSC issued 11, 2016 A...
Page 294: Servicing
SERVICING 1. Troubleshooting for electrical system 7. ELECTRICAL SYSTEM SERVICING 1. Troubleshooting for electrical system Refer- Probable cause and checking Symptom Solution ence procedure page All Electrical Equipments Do Not 1. Battery discharged or dam- Recharge or replace 2-33 Operate aged Blade Speed Is Slow 2.
Page 295 SERVICING 7. ELECTRICAL SYSTEM Refer- Probable cause and checking Symptom Solution ence procedure page Engine Does Not Stop When 1. Fuse blown (20 A) Replace 2-48 Main Switch Is Turned OFF 2. Wiring harness disconnected Repair or replace or improperly connected (be- Electri- tween main switch AC terminal cal Dia-...
Page 296 SERVICING 7. ELECTRICAL SYSTEM Refer- Probable cause and checking Symptom Solution ence procedure page Coolant Temperature Gauge 3. Wiring harness disconnected Repair or replace panel Does Not Function or improperly connected Electri- (between coolant temperature cal Dia- gauge and coolant temperature gram sensor) 7-19...
Page 297: Servicing Specifications For Electrical System
SERVICING 7. ELECTRICAL SYSTEM 2.Servicing specifications for electrical system 2. Servicing specifications for electrical system Item Factory specifications Allowable limit Battery) Voltage More than 12 V － Potential Difference Less than 0.1 V － Glow Plug Resistance Approx. 0.9 Ω －...
Page 298: Tightening Torques For Electrical System
SERVICING 3.Tightening torques for electrical system 7. ELECTRICAL SYSTEM 3. Tightening torques for electrical system NOTE • Tightening torques of screws, bolts and nuts on the table below are especially specified. • The alphabet "M" in Dimension × Pitch shows that the screw, bolt or nut dimensions are in the metric system.
Page 299: Checking And Adjusting
SERVICING 7. ELECTRICAL SYSTEM 4.Checking and adjusting 4. Checking and adjusting Potential differ- Factory specifi- Less than 0.1 V ence cation 4.1 Battery 4.1.1 Checking battery voltage 4.1.3 Checking battery specific gravity NOTE • Hold the hydrometer tube vertical without removing it from the electrolyte.
Page 300: Starting System
SERVICING 4.Checking and adjusting 7. ELECTRICAL SYSTEM 2. When the electrolyte temperature differs from that 2. Measure the resistance with an ohmmeter across at which the hydrometer was calibrated, correct the the B terminal and the ACC terminal, B terminal specific gravity reading following the formula and ST terminal, B terminal and G terminal.
Page 301: Testing Starter Motor
SERVICING 7. ELECTRICAL SYSTEM 4.Checking and adjusting 4.2.2 Testing starter motor 7. If the motor does not run, starter is failure. Repair or replace the starter. CAUTION 4.2.3 Testing magnetic switch • Secure the starter to prevent it from jumping up and down while testing the motor.
Page 302: Checking Magnet Switch Continuity
SERVICING 4.Checking and adjusting 7. ELECTRICAL SYSTEM 4.2.4 Checking magnet switch continuity 1. Check the continuity across the C terminal (1) and the B terminal (2) with a circuit tester, pushing in the plunger. (1) C terminal [B] Gear reduction type (2) B terminal [A] Electromagnetic drive type 2.
Page 303: Opc (Operator Presence Control) System
SERVICING 7. ELECTRICAL SYSTEM 4.Checking and adjusting 4.3 OPC (Operator Presence Control) system 4.3.1 Checking OPC system (1) Parking brake lock pedal (2) Motion control lever (3) Key switch (4) PTO lever 7-26 ZD1511 KiSC issued 11, 2016 A...
Page 304 SERVICING 4.Checking and adjusting 7. ELECTRICAL SYSTEM 1. A damaged location can be judged by checking the function of each safety switch one by one as shown in the table below. State of set such as operation levers Control operation Motion con- Motion con- Engine start...
Page 305: Checking Opc Continuity
SERVICING 7. ELECTRICAL SYSTEM 4.Checking and adjusting 4.3.2 Checking OPC continuity Main switch Voltage (Lead ter- key at PRE- Approx. battery voltage minal -Chassis) HEAT 4.4.2 Checking glow plug continuity (1) Parking brake lock pedal (3) PTO lever (2) Motion control lever (4) Operator seat Resistance (Across When switch push...
Page 306: Checking Glow Plug (Heater) Continuity
SERVICING 4.Checking and adjusting 7. ELECTRICAL SYSTEM 4.5 Fuel pump 2. Measure the resistance with a circuit tester between the glow plug terminal and the engine body. 4.5.1 Checking fuel pump connector 3. If the factory specification is not indicated, glow plug voltage is faulty.
Page 307: Engine Stop Solenoid
SERVICING 7. ELECTRICAL SYSTEM 4.Checking and adjusting 4.6 Engine stop solenoid RELATED PAGE 5.2.6.1 Disassembling alternator on page 3-55 4.6.1 Engine stop solenoid test ™ 4.8 Easy Checker 4.8.1 Checking engine oil pressure lamp (1) Solenoid 1. Remove the solenoid (1) from the engine. 2.
Page 308: Checking Horn Wiring Harness
SERVICING 4.Checking and adjusting 7. ELECTRICAL SYSTEM 4.8.2 Checking horn wiring harness 1. Disconnect the connector. 2. Remove the rack sensor. 3. Measure the resistance with a circuit tester between terminal 2 and terminal 3. (1) Meter panel (3) Coolant temperature sensor (2) Wiring harness connector (4) Terminal 12 1.
Page 309: Checking Blower
SERVICING 7. ELECTRICAL SYSTEM 4.Checking and adjusting 4.9.2 Checking blower 2. Check the continuity between the terminal 1 (4) and terminal 2 (3), terminal 1 (4) and terminal 3 (2) and 1. Disconnect the connectors. terminal 2 (3) and terminal 3 (2) with a circuit tester. (1) Motor connector (1) Blower flow pressure sensor (4) Terminal 1...
Page 310: Checking Temperature Sensor
SERVICING 4.Checking and adjusting 7. ELECTRICAL SYSTEM 4.9.6 Checking doser fuel pump 2. Check the continuity between the terminal 1 (2) and terminal 2 (3), terminal 1 (2) and terminal 3 (4) and terminal 2 (3) and terminal 3 (4) with a circuit tester. 1.
Page 311: Checking Engine Oil Pressure Switch Continuity
SERVICING 7. ELECTRICAL SYSTEM 4.Checking and adjusting 4.9.7 Checking engine oil pressure switch 4.9.8 Checking fuel level sensor continuity (1) Fuel level sensor (F) Full (E) Empty (1) Engine oil pressure switch Sensor Continuity 1. Measure the resistance with an ohmmeter across 1.
Page 312: Checking Coolant Temperature Sensor Voltage
SERVICING 4.Checking and adjusting 7. ELECTRICAL SYSTEM 4.9.9 Checking coolant temperature sensor 4.9.10 Checking coolant temperature voltage sensor continuity (1) Coolant temperature sensor (a) From temperature gauge (1) Coolant temperature sensor 1. Disconnect the lead from the coolant temperature Sensor continuity sensor after turning the main switch OFF.
Page 313: Relays
SERVICING 7. ELECTRICAL SYSTEM 4.Checking and adjusting 4.10 Relays 4. Measure the resistance with an ohmmeter across all: 4.10.1 Checking relay a. Terminal 2 (2) to terminal 1 (5) b. Terminal 5 (1) to terminal 4 (3) c. Terminal 5 (1) to terminal 3 (4) d.
Page 314: Disassembling And Assembling
SERVICING 5.Disassembling and assembling 7. ELECTRICAL SYSTEM 5. Disassembling and assembling 5.1 Disassembling starter (Electromagnetic drive type) NOTE • Do not damage to the brush and commutator. 7-37 ZD1511 KiSC issued 11, 2016 A...
Page 315 SERVICING 7. ELECTRICAL SYSTEM 5.Disassembling and assembling (1) Solenoid switch mounting nut (8) Snap ring (15) Brake spring (22) Through bolt (2) Starter drive housing (9) Overrunning clutch (16) Brake shoe (a) Joint of solenoid switch (3) Drive lever (10) Armature (17) End frame cap (b) Bushing (4) Gasket...
Page 316: Disassembling Alternator
SERVICING 5.Disassembling and assembling 7. ELECTRICAL SYSTEM 9. Draw out the armature (10) with the drive lever (3). (When reassembling) • Apply grease (DENSO.CO.LTD. No. 50 or equivalent) to the parts indicated in the figure. 5.88 to 11.8 N⋅m Tightening torque B terminal nut 0.600 to 1.20 kgf⋅m 4.34 to 8.70 lbf⋅ft...
Page 317: Servicing
SERVICING 7. ELECTRICAL SYSTEM 6.Servicing 6. Remove the rectifier (9). 7. Remove the rear end frame (8). 8. Press out the rotor (6) from drive end frame (2). 9. Remove the retainer plate (5). 10. Press out the bearing (4) from drive end frame (2) with a press and jig. 11.
Page 318: Checking Brush Wear
SERVICING 6.Servicing 7. ELECTRICAL SYSTEM 2. Measure the commutator O.D. with an outside Gear reduction type micrometer at several points. Less than Factory specifi- 0.02 mm cation Difference of 0.0008 in. O.D.'s 0.05 mm Allowable limit 0.002 in. 5. Measure the mica undercut. 6.
Page 319: Checking Brush Holder
SERVICING 7. ELECTRICAL SYSTEM 6.Servicing 3. If the length is than the allowable limit, replace the yoke assembly and brush holder. Factory specifi- 16.0 mm cation 0.630 in. Brush length (A) 10.5 mm Allowable limit 0.413 in. 6.1.4 Checking brush holder 1.
Page 320: Charging System
SERVICING 6.Servicing 7. ELECTRICAL SYSTEM 6.2 Charging system 6.2.3 Checking rotor 6.2.1 Checking bearing 1. Check the bearing for smooth rotation. 1. Measure the resistance across the slip rings. 2. If the resistance is not the factory specification, replace it. 2.
Page 321: Checking Brush Wear
SERVICING 7. ELECTRICAL SYSTEM 6.Servicing 6.2.5 Checking brush wear 2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction. 1. Measure the brush length with vernier calipers. 2.
Page 322: Mower
MOWER KiSC issued 11, 2016 A...
Page 323: Mechanism
MECHANISM 1. Power flow of mower 8. MOWER MECHANISM 1. Power flow of mower The power is transmitted from mid-PTO to blades as follows. (1) Center pulley (3) 19T bevel gear (5) Outer pulley From PTO shaft (2) 15T bevel gear (RCK60P-1200Z) (6) Mower belt (RCK60RP-1200Z)
Page 324 MECHANISM 8. MOWER ZD1511 KiSC issued 11, 2016 A...
Page 325: Servicing
SERVICING 1. Troubleshooting for mower 8. MOWER SERVICING 1. Troubleshooting for mower Refer- Probable cause and checking Symptom Solution ence procedure page Blade does not turn 1. PTO system malfunctioning Check transmission 4-24, 4-40 2. Broken mower belt Replace mower belt Blade speed is slow 1.
Page 326: Servicing Specifications For Mower
SERVICING 8. MOWER 2.Servicing specifications for mower 2. Servicing specifications for mower Item Factory specifications Allowable limit Pinion Shaft (without Mower Belt) Turning Force Less than 118 N － 12.0 kgf 26.5 lbf Turning Torque Less than 1.5+N⋅m － 0.15 kgf⋅m 1.1 lbf⋅ft Bevel Gears in Gear Box Backlash...
Page 327: Tightening Torques For Mower
SERVICING 3. Tightening torques for mower 8. MOWER 3. Tightening torques for mower NOTE • Tightening torques of screws, bolts and nuts on the table below are especially specified. Dimension × Item N⋅m kgf⋅m lbf⋅ft Pitch Mower blade screw 102.9 to 117.6 10.50 to 11.99 75.90 to 86.73 －...
Page 328: Checking And Adjusting
SERVICING 8. MOWER 4.Checking and adjusting 4. Checking and adjusting Inflation pressure 4.1 Adjusting anti-scalp rollers Front wheel Rear wheel 83 kPa (0.84 kgf/cm , 12 psi) WARNING 2. Start the engine. To avoid serious injury or death: 3. Raise up the mower deck to the transport position. •...
Page 329: Adjusting Front And Rear Cutting Height
SERVICING 4. Checking and adjusting 8. MOWER 4. Place 51 mm (2 in.) height wood blocks under each • Apply the parking brake. side of the mower deck. • Disengage PTO (OFF). Anti-scalp rollers must not rest on the wood block. •...
Page 330: Disassembling And Assembling
SERVICING 8. MOWER 5.Disassembling and assembling 9. Check the front-to-rear level and if it is not level, adjustment is necessary. (A) Loosen 1. Turn over the mower. (A) Height of blade tip (Front) (B) Height of blade tip (Rear) 2. Remove the mower blade bolt (5), and remove the spline boss (4), two cup washers (3), mower blade 5.
Page 331: Removing Blade Boss
SERVICING 5. Disassembling and assembling 8. MOWER 5.3 Removing blade boss (When reassembling) • Install the reamer bolts at their original positions as shown in the figure. 77.4 to 90.2 N⋅m Tightening tor- Gear box mount- 7.90 to 9.19 kgf⋅m ing bolt 57.1 to 66.5 lbf⋅ft 5.5 Disassembling gear box...
Page 332: Disassembling Center Pulley Holder
SERVICING 8. MOWER 5.Disassembling and assembling 10. Remove the bevel gear (9) with ball bearing (10). (1) Gear box bolt (8) Center pulley holder bolt (2) Gear box stay R.H. (9) Collar (3) Gear box stay L.H. (10) Ball bearing (4) Gear box reamer bolt (11) Internal snap ring (1) Oil seal...
Page 333: Checking Turning Torque Of Pinion Shaft
SERVICING 5. Disassembling and assembling 8. MOWER 3. Remove the external snap ring (34) on the left 167 to 190 N⋅m Outer pulley blade shaft (29). 17.0 to 19.3 kgf⋅m mounting nut 123 to 140 lbf⋅ft 4. Remove the spline boss (33) and oil seal (32). Tightening tor- 5.
Page 334: Checking Backlash Between Bevel Gears
SERVICING 8. MOWER 5.Disassembling and assembling 3. If measurement exceeds factory (Reference) specification, check the bearings and gears. 0.20 mm (0.0079 in.) Thickness of adjusting shims (1), (5) Less than 0.30 mm (0.012 in.) 118 N Turning force 0.10 mm (0.0039 in.) 12.0 kgf Thickness of adjusting shims 26.5 lbf...
Page 335 INDEX blade shaft disassembling............ 8-10 acid burns blower prevent..............1-4 checking.............7-32 actuator blower flow pressure sensor checking.............4-63 checking.............7-32 air blower bolts................. 2-15 removing............3-43 bonnet air cleaner removing........3-37,4-28,4-43,6-18 removing........3-38,4-29,4-43,6-19 brake discs air cleaner primary element checking.............4-63 cleaning..............2-29 brush replacing............2-38 checking wear......
Page 336 clamp cylinder head checking.............2-42 checking flaw............. 3-61 closed breather checking surface flatness........3-60 function..............3-1 removing............3-46 color of wiring.............7-5 cylinder head cover commutator removing............3-44 checking.............3-78,7-40 cylinder head gasket connecting rod removing............3-46 checking alignment..........3-70 cylinder hose function..............3-2 removing............
Page 337 electronic governor fire................1-4 definition.............3-13 fluids correctly emergencies discarding.............1-4 preparation............1-5 flywheel engine function..............3-4 separating........3-42,4-33,4-47,6-23 removing............3-52 servicing specifications........3-23 flywheel stopper............2-56 tightening torques..........3-27 friction plates troubleshooting..........3-19 checking.............4-63 engine breather hose front axle checking.............2-44 servicing specifications........5-4 replacing............
Page 338 fuse replacing............2-44 handling............... 2-9 hydraulic lift rod fuses removing............4-35 replacing............2-48 hydraulic pump............6-2 removing............6-24 hydraulic system servicing specifications........6-10 gauge system tightening torques..........6-11 electrical circuit............ 7-3 troubleshooting............ 6-9 gear box hydrostatic control linkage disassembling............8-9 function.............. 4-10 gear box oil level hydrostatic transmission changing............
Page 339 mower linkage function..............6-7 lead terminal voltage checking.............7-28 left cutting height needle bearing adjusting...............8-6 checking.............4-60 lift................6-4 neutral lift cylinder adjusting.............4-20 function..............6-6 checking.............4-20 lift shaft neutral position............6-3 removing............6-15 nozzle lubricants..............2-11 checking spraying condition.......3-34 lubricating system nozzle heat seal overview...............3-5 removing............
Page 340 pinion shaft radiator checking turning torque........8-11 checking water leakage........3-31 pipe fitting disconnecting......3-41,4-32,4-46,6-22 removing............6-14 function...............3-11 piston removing..........4-35,4-48,6-24 function..............3-2 radiator cap piston pin checking air leakage.......... 3-31 checking bore I.D..........3-69 function...............3-11 piston pin and small end bushing radiator hose checking oil clearance........3-69 checking.............2-42...
Page 341 rotor and cover thermostat valve checking clearance..........3-78 checking opening temperature......3-32 thrust ball bearing checking.............4-60 removing............4-53 safety decals.............. 1-7 thrust plate safety first..............1-1 checking.............4-60 safety switch thrust washer function...............7-11 checking.............4-60 screws..............2-15 timing gear seat assembly checking backlash..........3-66 removing............ 4-33,4-58 timing gears service code display..........7-13 function..............
Page 342 valve stem and valve guide checking clearance..........3-62 valves removing............3-47 water pump function...............3-11 wheel bracket removing.............. 5-6 wiring color..............2-10 handling............... 2-7 handling precaution..........2-7 VIII ZD1511 KiSC issued 11, 2016 A...
Page 343 FUSE_BOX FUSE_BOX STARTER SWITCH, ASSY CONTROL_SYSTEM/DIAG_TOOL M014 AVSS 0.5 Or/L MiniFuses STARTER_SW TO_(MAIN_S) TO_(STARTER_M) S003 M009 AVS 3.0 FUSE_BOX RACK_POSITION_SENSOR TO_(MAIN_S) TO_(STARTER_M) S004 M011 M011 M020 AVSS 0.85 TO_(MAIN_S) TO_(STARTER_M) AUX_POWER S006 M027 MiniFuses M140 AVSS 2.0 TO_(MAIN_S) TO_(STARTER_M) S007 M025 AVS 3.0 ALT/FUEL_PUMP/SOLE_VALVE AUXILIARY_POWER(CA)
Page 344 Editor : Farm and Industrial 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 : ks_g.ksos-pub@kubota.com Printed in Japan 2016. 11, S, EI, EI, engusa Code No.9Y111-13850 KUBOTA Corporation...

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