Kubota GZD15 Workshop Manual
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Kubota GZD15 Workshop Manual

Kubota GZD15 Workshop Manual

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WORKSHOP MANUAL
GZD15
KiSC issued 04, 2006 A

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Summary of Contents for Kubota GZD15

  • Page 1 WORKSHOP MANUAL GZD15 KiSC issued 04, 2006 A...
  • Page 2 TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of GZD15. It is divided into two parts, "Mechanism" and "Servicing" for each section. B Mechanism Information on the features and new mechanisms are described. This information should be understood before proceeding with troubleshooting, disassembling and servicing.
  • Page 3 GZD15, WSM SAFETY INSTRUCTIONS This symbol, the industry's "Safety Alert Symbol" is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully.It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit.
  • Page 4 GZD15, WSM SAFETY INSTRUCTIONS SAFETY WORKING A Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued. A Wear close fitting clothing and safety equipment appropriate to the job. A Use tools appropriate to the work. Makeshift tools, parts, and procedures are not recommended.
  • Page 5 GZD15, WSM SAFETY INSTRUCTIONS VENTILATE WORK AREA A If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.

  • Page 6: Safety Decals

    GZD15, WSM SAFETY INSTRUCTIONS SAFETY DECALS The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list. KiSC issued 04, 2006 A...
  • Page 7 GZD15, WSM SAFETY INSTRUCTIONS KiSC issued 04, 2006 A...
  • Page 8 GZD15, WSM SAFETY INSTRUCTIONS KiSC issued 04, 2006 A...
  • Page 9 GZD15, WSM SAFETY INSTRUCTIONS 0000001495E KiSC issued 04, 2006 A...

  • Page 10: Specifications

    GZD15, WSM SPECIFICATIONS SPECIFICATIONS Model GZD15-LD GZD15-HD Maximum gross power 11.2 kW (15 HP) *1 Model Z602-GZD15 Type Indirect injection. Vertical, water-cooled, 4-cycle diesel engine Number of cylinder Bore and stroke 72.0 x 73.6 mm (2.83 x 2.90 in.) Total displacement (36.6 cu.in.)
  • Page 11 GZD15, WSM SPECIFICATIONS Model GZD15-LD GZD15-HD Overall length (with grass collector) 2785 mm (109.7 in.) Overall width (with mower) 1195 mm (47.1 in.) Overall height (without ROPS) 1115 mm (43.9 in.) 1345 mm (53.0 in.) Dimensions Wheel base 1285 mm (50.6 in.) Front 815 mm (32.1 in.)
  • Page 12 GZD15, WSM DIMENSIONS DIMENSIONS KiSC issued 04, 2006 A...
  • Page 13 GZD15, WSM DIMENSIONS 0000001694E KiSC issued 04, 2006 A...
  • Page 14 GENERAL KiSC issued 04, 2006 A...

  • Page 15: Table Of Contents

    CONTENTS 1. IDENTIFICATION ........................G-1 2. GENERAL PRECAUTIONS....................G-2 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING......G-3 [1] WIRING..........................G-3 [2] BATTERY ..........................G-5 [3] FUSE ..........................G-5 [4] CONNECTOR........................G-5 [5] HANDLING OF CIRCUIT TESTER..................G-6 4. LUBRICANTS, FUEL AND COOLANT ................G-7 5. TIGHTENING TORQUES ....................G-9 [1] GENERAL USE SCREWS, BOLTS AND NUTS ............G-9 [2] METRIC SCREWS, BOLTS AND NUTS ...............G-9 [3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH...

  • Page 16: Identification

    GZD15, WSM GENERAL 1. IDENTIFICATION When contacting your local KUBOTA distributor, always specify engine serial number (3), machine serial number (2), mower serial number (4) and hour meter reading. (1) Machine Identification Plate (4) Mower Serial Number (2) Machine Serial Number...

  • Page 17: General Precautions

    A Remove oil and dirt from parts before measuring. A Use only KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety. A Gaskets and O-rings must be replaced during reassembly.

  • Page 18: Handling Precautions For Electrical Parts And Wiring

    GZD15, WSM GENERAL 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring. A Check electrical wiring for damage and loosened connection every year.
  • Page 19 GZD15, WSM GENERAL A Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp *Wind Clamp Spirally (4) Welding Dent (2) Wire Harness 0000000617E A Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.

  • Page 20: Battery

    GZD15, WSM GENERAL [2] BATTERY A Take care not to confuse positive and negative terminal posts. A When removing battery cables, disconnect negative cable first. When installing battery cables, check for polarity and connect positive cable first. A Do not install any battery with capacity other than is specified (Ah).

  • Page 21: Handling Of Circuit Tester

    GZD15, WSM GENERAL A In separating connectors, do not pull wire harnesses. A Hold connector bodies to separate. (A) Correct (B) Incorrect 0000000624E A Use sandpaper to remove rust from terminals. A Repair deformed terminal. Make certain there is no terminal being exposed or displaced.

  • Page 22: Lubricants, Fuel And Coolant

    2.6 U.S.gals. (RH and LH) 2.2 lmp.gals. 0.15 L Mower gear box 0.16 U.S.qts. KUBOTA UDT or SUPER UDT fluid** 0.13 Imp.qts. 0.13 L Front PTO case 0.14 U.S.qts. 0.11 Imp.qts. *Oil amount when the oil level is at the upper of the oil level gauge.
  • Page 23 GZD15, WSM GENERAL Greasing, oiling (Machine) Place No. of greasing point Capacity Type of grease Motion control lever boss Centre pin King pin SAE multi-purpose type Until grease overflows grease Front wheel Front PTO drive shaft Engine universal joint Motion control lever...

  • Page 24: Tightening Torques

    GZD15, WSM GENERAL 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolt and nuts whose tightening torque are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of No-grade or 4T...

  • Page 25: American Standard Screws, Bolts And Nuts With Unc Or Unf Threads

    GZD15, WSM GENERAL [3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS SAE GR.5 SAE GR.8 Grade Unit Norminal ft-lbs ft-lbs Diameter 5/16 23.1 to 27.8 2.35 to 2.84 17.0 to 20.5 32.5 to 39.3 3.31 to 4.01 24.0 to 29.0...

  • Page 26: Maintenance

    GZD15, WSM GENERAL 6. MAINTENANCE Period Indication on hour meter Refer- After ence since Item page every Engine oil Change G-19 100Hr every Engine oil filter Replace G-20 200Hr Transmission and every Rear axle gear case Change G-21 200Hr (RH and LH) fluid...
  • Page 27 A *1: This maintenance should be done daily more often in dusty condition than in normal conditions. Suggested cleaning interval is every 100 hours in normal conditions. A *2: These items should be serviced by an authorized KUBOTA Distributor, unless the owner has the proper tools and is mechanically proficient.

  • Page 28: Check And Maintenance

    GZD15, WSM GENERAL 7. CHECK AND MAINTENANCE A Be sure to check and service the machine on a flat place with engine shut off, the parking brake on and chock the wheels. 0000001417E [1] DAILY CHECK To prevent trouble from occurring, it is important to know the condition of the machine. Check the following items before starting.
  • Page 29 GZD15, WSM GENERAL Checking Engine Oil Level A Always stop the engine and remove the key before checking oil. 1. Check engine oil before starting and 5 minutes or more after the engine has stopped. 2. Wipe dipstick area clean.
  • Page 30 GZD15, WSM GENERAL Checking Amount of Fuel and Refueling A Handle fuel carefully. If the engine is running, do not fill the fuel tank. If engine is hot, let engine cool several minutes before adding fuel. Do not smoke while filling the fuel tank or servicing the fuel system.
  • Page 31 GZD15, WSM GENERAL Checking and Cleaning Radiator to Prevent Overheating A Be sure to stop the engine and remove the key before cleaning. Daily or after every 5 hours of operation, check to be sure the radiator screen and radiator core are clean. Dirt or chaff on the radiator screen or radiator core decrease cooling performance.
  • Page 32 GZD15, WSM GENERAL Checking Transmission Fluid Level 1. Park the machine on a flat surface, lower the implement to the ground and shut off engine and remove the key. 2. Open the hood and detach the engine side cover (L.H.).
  • Page 33 GZD15, WSM GENERAL Lubricating Grease Nipple A Be sure to stop the engine and remove the key before greasing. 1. Apply grease to the following location as figures. (1) Engine Universal Joint (3) Front PTO Drive Shaft (2) Mower Universal...

  • Page 34: Check Points Of Initial 50 Hours

    GZD15, WSM GENERAL [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil A Be sure to stop the engine before changing oil. 1. Raise the grass collector from the machine. 2. Remove the spring (1) connecting the cover duct (2) and the mower deck (3).
  • Page 35 Check for oil leaks around filter gasket. A To prevent serious damage to hydraulic system, the replacement filter must be a highly efficient, 10 filter. Use only a genuine KUBOTA filter or its equivalent. (1) Transmission Oil Filter (2) Screw Cartridge...
  • Page 36 GZD15, WSM GENERAL Changing Transmission and Rear Axle Gear Case (RH and LH) Fluid A Be sure to stop the engine before changing the transmission fluid 1. Place an oil pan underneath the transmission case. 2. Remove the drain plugs (1) at the bottom of the transmission case and drain the oil completely.
  • Page 37 GZD15, WSM GENERAL Changing Transmission and Rear Axle Gear Case (RH and LH) Fluid (Continued) (4) Rear Axle Gear Case (A) Oil level acceptable within (5) Oil Filler Plug this range (6) Oil Plug and Breather Cup (7) Dipstick (8) Transmission Oil Filter...
  • Page 38 GZD15, WSM GENERAL Cleaning Transmission Strainer When changing the transmission fluid, disassemble and rinse the strainer with nonflammable solvent to completely clean off filings. Check O-ring (3), replace if damaged, cracked or hardened. When reassembling be careful not to damage the parts.

  • Page 39: Check Point Of Initial 100 Hours

    GZD15, WSM GENERAL [3] CHECK POINT OF INITIAL 100 HOURS Adjusting Front Axle Rocking Force 1. Lift the front axle (1). 2. Measure the front axle rocking force with a push-pull gauge. 3. If the measurement is not within the factory specifications, adjust with the slotted nut (2).

  • Page 40: Check Points Of Every 50 Hours

    GZD15, WSM GENERAL [4] CHECK POINTS OF EVERY 50 HOURS Checking Safety Device A Do not allow anyone near the machine while testing. A If the machine does not pass one of the following tests, do not operate the machine.
  • Page 41 GZD15, WSM GENERAL Checking Safety Device (Continued) B Test 6 (OPERATOR NOT ON THE SEAT) 1. Start the engine. 2. Do not set the parking brake. 3. Shift the PTO lever to "ENGAGE" (ON) position. 4. Stand up. (Do not get off the machine.) 5.
  • Page 42 GZD15, WSM GENERAL Lubricating All Grease Nipple 1. Apply a grease to the following position as figures. A Be sure to stop the engine and remove the key before greasing. (1) Centre Pin (3) Front Wheel (LH, RH) (2) King Pin (LH, RH)
  • Page 43 A Be sure to stop the engine and remove the key before greasing. (Reference) A Grass container control cables (6) shown below are adopted to GZD15-HD(E). (Serial No. : Below 10736). (1) Motion Control Lever (LH, RH) (4) Front Link (2) Seat Adjuster...
  • Page 44 A Be sure to stop the engine and remove the key before greasing. (Reference) A Grass container control cables (6) shown below are adopted to GZD15-HD(E). (Serial No. : Below 10736). (1) Grass Collector Link (Oil) (3) Grass Collector Control Cables (2) Grass Collector Link (for HD,...

  • Page 45: Check Points Of Every 100 Hours

    GZD15, WSM GENERAL [5] CHECK POINTS OF EVERY 100 HOURS Changing Engine Oil 1. See page G-19. 0000001441E Checking Fuel Lines And Fuel Filter A Be sure to stop the engine and remove the key when attempting to make the following checks and changes.
  • Page 46 GZD15, WSM GENERAL Checking Fan Drive Belt Tension A Be sure to stop the engine and remove the key before checking belt tension. 1. If the fan drive belt becomes loose, the engine may overheat. 2. To adjust, loosen bolts and turn the alternator to tighten the belt.
  • Page 47 GZD15, WSM GENERAL Checking Battery Condition A Never remove the vent cap while the engine is running. A Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately and get medical attention.
  • Page 48 GZD15, WSM GENERAL B Battery Charging A When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.

  • Page 49: Check Point Of Every 150 Hours

    GZD15, WSM GENERAL [6] CHECK POINT OF EVERY 150 HOURS Changing Mower Gear Box Oil A Be sure to stop the engine and remove the key before changing the oil. 1. To drain the used oil, remove the oil filler plug (1) at the mower gear box, tilt the mower deck and drain the oil completery into the oil pan.
  • Page 50 GZD15, WSM GENERAL Checking Radiator Hose and Clamp A Check to see if the radiator hoses are properly fixed every 200 hours of operation or 6 months, whichever comes first. 1. If clamp bands (2) are loose or water leaks, tighten clamp band (2) securely.

  • Page 51: Check Points Of Every 400 Hours

    GZD15, WSM GENERAL [8] CHECK POINTS OF EVERY 400 HOURS Replacing Fuel Filter 1. Disconnect the fuel hoses and loosen the filter band to replace the fuel filter (2). A If the fuel line is removed, be sure to properly bleed the fuel system.
  • Page 52 GZD15, WSM GENERAL Flushing Cooling System and Changing Coolant A Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. 1. Stop the engine and let cool down.
  • Page 53 7. Kubota's genuine long-life coolant has a service life of 2 years. Be sure to change the coolant every 2 years. A The above data represent industry standards that necessitate a minimum glycol content in the concentrated anti-freeze.

  • Page 54: Check Points Of Every 2 Years

    GZD15, WSM GENERAL [10]CHECK POINTS OF EVERY 2 YEARS Replacing Hydraulic Hose 1. Replace the hose. Refer to "Checking Hydraulic Hose". (See page G-35.) 0000001459E Replacing Fuel Lines 1. Replace the fuel line. Refer to "Checking Fuel Lines and Fuel Filter". (See page G- 30.)

  • Page 55: Others

    GZD15, WSM GENERAL [11]OTHERS Replacing Fuses 1. The electrical system is protected from potential damage by fuses. A blown fuse indicates that there is an overload or short somewhere in the electrical system. 2. If any of the fuses should blow, replace with a new one of the same capacity.
  • Page 56 GZD15, WSM GENERAL Checking and Replacing Mower Blade A Be sure to stop the engine and remove the key. A Blades may be sharp. When you handle blades, wear heavy gloves or wrap end of blade with a rag. B Checking Blade 1.
  • Page 57 GZD15, WSM GENERAL Replacing Mower Belt 1. Remove the mower deck from the machine. 2. Remove the left and right hand shield (4), (6) from the mower deck. 3. Clean around the pulleys to remove the belt (3) from the pulleys.
  • Page 58 GZD15, WSM GENERAL Adjusting Motion Control Lever, HST "NEUTRAL" A Park the machine on a hard and level surface. A If it is necessary to run engine in an enclosed area, use a gas tight exhaust pipe extension to remove the fumes.
  • Page 59 GZD15, WSM GENERAL Adjusting Motion Control Lever, Reverse Return Position A Park the machine on a hard and level surface. A If it is necessary to run engine in an enclosed area, use a gas tight exhaust pipe extension to remove the fumes.
  • Page 60 GZD15, WSM GENERAL Adjusting Motion Control Lever, Maximum Speed (Forward) A Park the machine on a hard and level surface. A If it is necessary to run engine in an enclosed area, use a gas tight exhaust pipe extension to remove the fumes.
  • Page 61 GZD15, WSM GENERAL Aligning Motion Control Lever B Checking the alignment 1. Check the gap (A) and space (B) between the levers, at the maximum forward position. Gap (A): 0 to 2 mm (0 to 0.08 in.) Recommendation Space (B): 10 to 20 mm (0.4 to 0.8 in.) If positions of the motion control levers (1) are unequal, an adjustment is necessary.
  • Page 62 GZD15, WSM GENERAL Adjusting Mower Deck Level (Side-to-Side) A Park the machine on a hard and level surface. A Apply the parking brake. A Disengage PTO (OFF). A Stop the engine, remove the key and remove the mower u- joint while checking or adjusting the level of the mower deck.
  • Page 63 GZD15, WSM GENERAL Adjusting Mower Deck Level (Side-to-Side) (Continued) B Adjusting level (Side-to-Side) 1. Raise up the mower deck to the transport position. (Also the top end.) 2. Turn the cutting height set dial to the 3 in. cutting height position.
  • Page 64 GZD15, WSM GENERAL Adjusting Mower Deck Level (Front-to-Rear) A Park the machine on a hard and level surface. A Engage the parking brake. A Disengage PTO (OFF). A Stop the engine, remove the key and remove the mower u- joint while checking or adjusting the level of the mower deck.

  • Page 65: Special Tools

    GZD15, WSM GENERAL 8. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Special Use Puller Set Code No : 07916-09032 Application : Use exclusively for pulling out bearing, gears and other parts with ease. 0000000677E Piston Ring Compressor Code No :...
  • Page 66 GZD15, WSM GENERAL Oil Pressure Tester Code No : 07916-32032 Application : Use to measure lubricating oil pressure. (1) Gauge (5) Adaptor 2 (2) Cable (6) Adaptor 3 (3) Threaded Joint (7) Adaptor 4 (4) Adaptor 1 (8) Adaptor 5...
  • Page 67 GZD15, WSM GENERAL Flywheel Puller Code No : 07916-32011 Application : Use to loosen and tighten the flywheel screw. 0000001473E Nozzle Tester Code No : 07909-31361 Application : Use to check the fuel injection pressure and spray pattern of nozzle.
  • Page 68 GZD15, WSM GENERAL A The following special tools are not provided, so make them referring to the figure. Valve Guide Replacing Tool Application : Use to press out and press fit the valve guide. 20 mm dia. (0.79 in. dia.) 9.96 to 9.98 mm dia.
  • Page 69 GZD15, WSM GENERAL Injection Pump Pressure Tester Application : Use to check fuel tightness of injection pumps. Pressure gauge full scale : More than 29.4 MPa (300 , 4267 psi) Copper gasket Flange (Material : Steel) Hex. nut 27 mm (1.06 in.) across the plat...
  • Page 70 GZD15, WSM GENERAL Bushing Replacing Tools Application : Use to press out and to press fit the bushing. 1. For small end bushing 145 mm (5.71 in.) 20 mm (0.79 in.) 100 mm (3.94 in.) 19.90 to 19.95 mm (0.7835 to 0.7854 in.) 21.90 to 21.95 mm dia.

  • Page 71: Special Tools For Machine

    GZD15, WSM GENERAL [2] SPECIAL TOOLS FOR MACHINE Relief Valve Pressure Tester Code No : 07916-50045 Application : This allows easy measurement of relief set pressure. (1) Gauge (07916-50322) (6) Adaptor C (PS3/8) (2) Cable (07916-50331) (07916-50371) (3) Threaded Joint...
  • Page 72 ENGINE KiSC issued 04, 2006 A...
  • Page 73 CONTENTS 1. ENGINE BODY .........................1-M1 [1] HALF-FLOATING HEAD COVER ..................1-M1 [2] GEAR CASE ........................1-M1 [3] OIL PAN..........................1-M2 2. LUBRICATING SYSTEM ....................1-M3 3. COOLING SYSTEM ......................1-M4 4. FUEL SYSTEM.........................1-M5 [1] FUEL LINE ........................1-M5 KiSC issued 04, 2006 A...

  • Page 74: Engine Body

    GZD15, WSM ENGINE 1. ENGINE BODY [1] HALF-FLOATING HEAD COVER The rubber packing is fitting in to maintain the head cover 0.5 mm or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head. (1) Cylinder Head Cover...

  • Page 75: Oil Pan

    GZD15, WSM ENGINE [3] OIL PAN The oil pan is expanded under the gear case. Therefore, the height of the engine can be lowered more than so far while securing a necessary amount of oil. (1) Gear Case (3) Crank Case...

  • Page 76: Lubricating System

    GZD15, WSM ENGINE 2. LUBRICATING SYSTEM (1) Rocker Arm (2) Oil Pressure Switch (3) Rocker Arm Shaft (4) Valve (5) Idle Gear (6) Crankshaft (7) Oil Pump (8) Oil Strainer (9) Relief Valve (10) Push Rod (11) Tappet (12) Camshaft...

  • Page 77: Cooling System

    GZD15, WSM ENGINE 3. COOLING SYSTEM (1) Radiator (2) Water Pump (3) Cooling Fan (4) Thermostat (5) Cylinder Head (6) Cylinder Block The cooling system consists of a radiator (1), a centrifugal water pump (2), a cooling fan (3) and a thermostat (4).

  • Page 78: Fuel System

    GZD15, WSM ENGINE 4. FUEL SYSTEM [1] FUEL LINE (1) Injection Nozzle (2) Fuel Overflow Pipe (3) Fuel Tank (4) Fuel Filter (5) Fuel Feed Pump (6) Fuel Filter (7) Injection Pump (8) Injection Pipe Fuel from the fuel tank (3) passes through the fuel filter (4), and then enters the injection pump (7) after impurities such as dirt, water, etc.
  • Page 79 CONTENTS 1. TROUBLESHOOTING....................... 1-S1 2. SERVICING SPECIFICATIONS ..................1-S4 3. TIGHTENING TORQUES ....................1-S9 4. CHECKING, DISASSEMBLING AND SERVICING ............1-S10 [1] SEPARATING ENGINE ....................1-S10 (1) Draining Coolant and Engine Oil ................1-S10 [2] ENGINE BODY ......................1-S16 (1) Checking and Adjusting..................1-S16 (2) Disassembling and Assembling................

  • Page 80: Troubleshooting

    GZD15, WSM ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not Start A No fuel Replenish fuel G-15 A Air in the fuel system Bleed G-42 A Water in the fuel system Change fuel and G-30, 42...
  • Page 81 GZD15, WSM ENGINE Reference Symptom Probable Cause Solution Page A Fuel filter clogged or dirty Engine Revolution Is Replace G-36 Not Smooth A Air cleaner clogged Clean or replace G-26, 36 A Fuel leak due to loose injection pipe retaining...
  • Page 82 GZD15, WSM ENGINE Reference Symptom Probable Cause Solution Page A Head gasket defective Water Mixed into Replace Lubricant Oil A Cylinder block or cylinder head flawed Replace A Engine oil insufficient Low Oil Pressure Replenish A Oil strainer clogged Clean...

  • Page 83: Servicing Specifications

    GZD15, WSM ENGINE 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Compression Pressure 3.53 to 4.02 MPa 2.55 MPa 36.0 to 41.0 26.0 512 to 583 psi 370 psi Variance Among 10 % or less Cylinder Top Clearance 0.50 to 0.70 mm...
  • Page 84 GZD15, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Push Rod Alignment 0.25 mm 0.0098 in. Tappet to Tappet Guide Bore Oil Clearance 0.016 to 0.052 mm 0.10 mm 0.00063 to 0.00205 in. 0.0039 in. Tappet 17.966 to 17.984 mm (O.D.)
  • Page 85 GZD15, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Piston Pin Bore I.D. 20.000 to 20.013 mm 20.05 mm 0.78740 to 0.78791 in. 0.7894 in. Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.038 mm 0.10 mm 0.00055 to 0.00150 in.
  • Page 86 GZD15, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing 1 Oil Clearance 0.034 to 0.106 mm 0.20 mm 0.00134 to 0.00417 in. 0.0079 in. Crankshaft Journal 43.934 to 43.950 mm (O.D.) 1.72968 to 1.73031 in.
  • Page 87 GZD15, WSM ENGINE COOLING SYSTEM Item Factory Specification Allowable Limit Fan Belt Tension Approx. 10 mm / 98 N 0.4 in. / 98 N (10 kgf, 22 lbs) Thermostat Valve Opening 69.5 to 72.5 Temperature 157.1 to 162.5 (At Beginning)

  • Page 88: Tightening Torques

    GZD15, WSM ENGINE 3. TIGHTENING TORQUES Tightening torques of screws and nuts on the table below are especially specified. (For general use screws and nuts : See page G-9.) Item Size x Pitch ft-lbs Under cover mounting screw and nut M6 x 1 7.8 to 8.8...

  • Page 89: Checking, Disassembling And Servicing

    GZD15, WSM ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] SEPARATING ENGINE (1) Draining Coolant and Engine Oil Draining Coolant A Never open the radiator cap while operating or immediately after stopping. Otherwise, hot water will spout out from the radiator.
  • Page 90 GZD15, WSM ENGINE Battery A When disconnecting the battery cables, disconnect the negative cable from the battery first. When connecting, connect the positive cable to the battery first. 1. Disconnect the negative cable (2) from the battery (1). 2. Disconnect the positive cable (3) from the battery (1).
  • Page 91 GZD15, WSM ENGINE Seat, Rear Floor Cover and Radiator Shutter Plate 1. Remove the seat (1) with seat stay (2). 2. Remove the front radiator net (3). 3. Remove the screw (4) and rear floor cover (3). 4. Remove the screw.
  • Page 92 GZD15, WSM ENGINE Wiring Harness and Accelerating Wire 1. Disconnect the wiring harness, connector and clamps shown in the picture. 2. Before disconnecting accelerating wire, check the length "L" shown in the picture. 3. Disconnect the accelerating wire from the engine.
  • Page 93 GZD15, WSM ENGINE Front Coupling 1. Remove the front coupling mounting screws (1). 2. Disconnect the front coupling (2) from engine. (When reassembling) 23.5 to 27.4 Front coupling mounting Tightening torque 2.4 to 2.8 screw 17.4 to 20.3 ft-lbs (1) Screw...
  • Page 94 GZD15, WSM ENGINE Engine Assembly 1. Lift and separate the engine assembly (1) from the machine body. 2. Attach the engine stands for safety. (When reassembling the engine) 1. Connect the front coupling (2). 2. Check the wiring harness (3) and fuel pipes (4), and accelerating wire (5) as shown in picture.

  • Page 95: Engine Body

    GZD15, WSM ENGINE [2] ENGINE BODY (1) Checking and Adjusting Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Disconnect the 2P connector from the fuel pump. 4. Remove the air cleaner, the muffler and all injection nozzles.
  • Page 96 GZD15, WSM ENGINE Top Clearance 1. Remove the cylinder head. (Do not attempt to remove the cylinder head gasket.). 2. Move the piston up, and stick a strip of fuse [1.5 mm dia. (0.059 in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the piston head at three positions with grease so as to avoid the intake and exhaust valves and the combustion chamber ports.
  • Page 97 GZD15, WSM ENGINE Valve Clearance A The valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover (1) and the glow plugs. 2. Align the "1TC" mark (2) on the flywheel and alignment marking plate (3) so that the No.

  • Page 98: Disassembling And Assembling

    GZD15, WSM ENGINE (2) Disassembling and Assembling (A) Cylinder Head, Valves and Oil Pan Radiator, Dynamo, Fan Belt and Muffler 1. Disconnect the radiator hoses and separate the radiator (1) with recovery tank (2) from engine assembly. 2. Remove the cooling fan (9) and fan pulley.
  • Page 99 GZD15, WSM ENGINE Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe (1). 2. Remove the nozzle holder assemblies (2). 3. Remove the copper gasket (5) and the heat seal (6). 4. Remove the lead (3) from the glow plugs (4).
  • Page 100 GZD15, WSM ENGINE Cylinder Head 1. Loosen the pipe clamp, and remove the water return pipe. 2. Remove the cylinder head screw in the order of (j) to (a). 3. Lift up the cylinder head to detach. 4. Remove the cylinder head gasket and O-ring (1).
  • Page 101 GZD15, WSM ENGINE Valves 1. Remove the valve caps (2). 2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1). 3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6).
  • Page 102 GZD15, WSM ENGINE Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws (1). 2. Remove the oil pan (2) by lightly tapping the rim of the pan with a wooden hammer. 3. Remove the oil strainer (3).
  • Page 103 GZD15, WSM ENGINE (B) Timing Gear, Camshaft and Fuel Camshaft Injection Pump and Speed Control Plate 1. Remove the socket head screws and nuts, and remove the injection pump (3). 2. Remove the screws and separate the speed control plate (2), taking care not to damage the governor spring (4).
  • Page 104 GZD15, WSM ENGINE Gear Case 1. Remove the screw (1) of inside the gear case and outside screws. 2. Disconnect the start spring (2) from the fork lever 1. 3. Remove the gear case (3). (When reassembling) A Apply a liquid gasket (Three Bond 1215 or equivalent) to both sides of the gear case gasket.
  • Page 105 GZD15, WSM ENGINE Fuel Camshaft 1. Remove the screws and draw out the camshaft with the gear on it. 2. Remove the retaining plate (1). 3. Remove the screws, then draw out the injection pump gear (3) and fuel camshaft (2) with the governor fork assembly.
  • Page 106 GZD15, WSM ENGINE Pistons 1. Turn the flywheel and bring the piston to top dead centre. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer. 3. Draw out the other piston in the same method as above.
  • Page 107 GZD15, WSM ENGINE Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool (Code No. 07909-32121). 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) A When installing the ring, assemble the rings so that the manufacturer's mark (12) near the gap faces the top of the piston.
  • Page 108 GZD15, WSM ENGINE (D) Crankshaft Flywheel 1. Secure the flywheel to keep it from turning. 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) A Align the "1TC" mark (a) on the outer surface of the flywheel horizontally with the alignment marking plate (b).
  • Page 109 GZD15, WSM ENGINE Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly. (When reassembling) A Clean the oil passage of the crankshaft with compressed air. A Apply oil to the main bearing case screw 2 (1).
  • Page 110 GZD15, WSM ENGINE Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (1), and remove the main bearing case assembly 1 (2), being careful with crankshaft bearing 3 (4) (5). 2. Remove the main bearing case assembly (3) as above. Keep in mind, however, that the thrust bearing (8) is installed in the main bearing case assembly (3).

  • Page 111: Servicing

    GZD15, WSM ENGINE (3) Servicing (A) Cylinder Head and Valves Cylinder Head Surface Flatness 1. Clean the cylinder head surface. 2. Place a straightedge on the cylinder head's four sides and two diagonals as shown in the figure. 3. Measure the clearance with a thickness gauge.
  • Page 112 GZD15, WSM ENGINE Valve Recessing 1. Clean the cylinder head surface, valve face and valve seat. 2. Insert the valve into the valve guide. 3. Measure the valve recessing with a depth gauge. 4. If the measurement exceeds the allowable limit, replace the valve.
  • Page 113 GZD15, WSM ENGINE Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them. 2. Press in a new valve guide using a valve guide replacing tool.
  • Page 114 GZD15, WSM ENGINE Correcting Valve and Valve Seat A Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. A After correcting the valve seat, be sure to check the valve recessing.
  • Page 115 GZD15, WSM ENGINE Free Length and Tilt of Valve Spring 1. Measure the free length (A) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring.
  • Page 116 GZD15, WSM ENGINE Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. 0.25 mm Push rod alignment Allowable limit 0.0098 in.
  • Page 117 GZD15, WSM ENGINE (B) Timing Gear, Camshaft and Fuel Camshaft Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear.
  • Page 118 GZD15, WSM ENGINE Camshaft Alignment 1. Support the camshaft with V blocks on the surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Measure the camshaft alignment. 4. If the measurement exceeds the allowable limit, replace the camshaft.
  • Page 119 GZD15, WSM ENGINE Oil Clearance between Idle Gear Shaft and Idle Gear Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance.
  • Page 120 GZD15, WSM ENGINE Oil Clearance between Piston Pin and Small End Bushing 1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer. 2. Measure the small end bushing I.D. with an inside micrometer, and calculate the oil clearance.
  • Page 121 GZD15, WSM ENGINE Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with piston. 2. Measure the ring gap with a thickness gauge. 3. If the measurement exceeds the allowable limit, replace the piston ring.
  • Page 122 GZD15, WSM ENGINE Connecting Rod Alignment 1. Remove the crankpin bearing, and install the connecting rod cap. 2. Install the piston pin in the connecting rod. 3. Install the connecting rod on the connecting rod alignment tool (Code No. 07909-31661).
  • Page 123 GZD15, WSM ENGINE (D) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings.
  • Page 124 GZD15, WSM ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage (Code No.: 07909-30241) on the centre of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
  • Page 125 GZD15, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance.
  • Page 126 GZD15, WSM ENGINE Replacing Crankshaft Bearing 1 (When removing) 1. Press out the used crankshaft bearing 1 using a crankshaft bearing 1 replacing tool. (When installing) 1. Clean a new crankshaft bearing 1 and crankshaft journal bore, and apply engine oil to them.
  • Page 127 GZD15, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) (Continued) (Reference) A Undersize crankshaft bearing 2 and 3 Undersize Bearing Code Number Marking Crankshaft bearing 2 02 15694-23930 020 US Crankshaft bearing 2F 02 1G460-07530 0.2 mm...
  • Page 128 GZD15, WSM ENGINE (E) Cylinder Cylinder Wear 1. Measure the I.D. of the cylinder at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.'s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.'s.

  • Page 129: Lubricating System

    GZD15, WSM ENGINE [3] LUBRICATING SYSTEM (1) Checking Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester (Code No.: 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.

  • Page 130: Servicing

    GZD15, WSM ENGINE (2) Servicing Rotor Lobe Clearance 1. Measure the clearance between lobes of the inner rotor and the outer rotor with a thickness gauge. 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.

  • Page 131: Cooling System

    GZD15, WSM ENGINE [4] COOLING SYSTEM (1) Checking and Adjusting Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and dynamo pulley at specified force (98 N, 10 kgf, 22 lbs). 2. If the measurement is not within the factory specifications, loosen the dynamo mounting screws and relocate the dynamo to adjust.
  • Page 132 GZD15, WSM ENGINE A When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water way gush out, scalding nearby people. 0000000922E Radiator Cap Air Leakage 1. Set a radiator tester (1) and adaptor (2) (BANZAI Code No.: RCT-2A-30S) on the radiator cap.
  • Page 133 GZD15, WSM ENGINE (2) Disassembling and Assembling Thermostat Assembly 1. Remove the thermostat cover mounting screws, and remove the thermostat cover (1). 2. Remove the thermostat assembly (3). (When reassembling) A Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (2).
  • Page 134 GZD15, WSM ENGINE [5] FUEL SYSTEM (1) Checking and Adjusting (A) Engine Revolution Adjusting Engine Revolution 1. Keep the throttle lever (1) to "A" position of the stay. 2. Adjust the accelerating wire so that engine speeds control lever (5) contacts to the engine speeds limit bolt (6) at 3400 rpm engine revolution.
  • Page 135 GZD15, WSM ENGINE (B) Injection Pump Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid. 3. Turn the flywheel counterclockwise (facing the flywheel) until fuel flows from the delivery valve holder. 4. Continue to turn the flywheel slowly, and stop it as soon as the fuel level at the tip of the delivery valve holder begins to increase.
  • Page 136 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. 13.7 MPa...
  • Page 137 8. Measure the time needed to decrease the pressure from 13.7 to 12.7 MPa (from 140 to 130 , from 1990 to 1849 psi). 9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. 10 seconds 13.7 12.7 MPa...
  • Page 138 GZD15, WSM ENGINE (C) Injection Nozzle A Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. A If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
  • Page 139 GZD15, WSM ENGINE Valve Seat Tightness 1. Set the injection nozzle to a nozzle tester (Code No. 07909- 31361). 2. Raise the fuel pressure, and keep at 12.75 MPa (130 1849 psi) for 10 seconds. 3. If any fuel leak is found, replace the nozzle piece.
  • Page 140 TRANSAXLE KiSC issued 04, 2006 A...
  • Page 141 CONTENTS 1. STRUCTURE........................2-M1 2. TRAVELLING SYSTEM....................2-M2 [1] HYDROSTATIC TRANSMISSION ..................2-M2 (1) Structure ........................2-M2 (2) Pump and Motor ......................2-M3 (3) Check and High Pressure Relief Valve ..............2-M4 (4) Oil Flow........................2-M5 (5) Power Trains Operation...................2-M6 (6) Motion Control Linkage....................2-M7 (7) Final Reduction Gear Section..................2-M8 (8) PTO System ......................2-M9 (9) Brake ........................2-M12 KiSC issued 04, 2006 A...

  • Page 142: Structure

    GZD15, WSM TRANSAXLE 1. STRUCTURE (1) PTO Section (3) Hydrostatic Transmission (4) Brake Section (5) Final Reduction Gear (2) Bevel Gear Section Section 0000001601E KiSC issued 04, 2006 A 2-M1...

  • Page 143: Travelling System

    GZD15, WSM TRANSAXLE 2. TRAVELLING SYSTEM [1] HYDROSTATIC TRANSMISSION (1) Structure (1) Trunnion Arm (6) Piston (11) Cylinder (Motor) (16) Pump Shaft (2) Swashplate (7) Motor Shaft (12) Centre Section (17) Check Valve (3) Cradle Bearing (8) Ball Bearing (13) Bush...

  • Page 144: Pump And Motor

    GZD15, WSM TRANSAXLE (2) Pump and Motor (1) Piston (2) Cylinder (3) Oil (A) Pump (B) Motor (a) Swashplate 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.

  • Page 145: Check And High Pressure Relief Valve

    GZD15, WSM TRANSAXLE (3) Check and High Pressure Relief Valve The check and high-pressure relief valve consists of pressure poppet (2), check valve seat (1), relief valve spring (3), spring guide (4) and check valve spring (5). The valve is used to prevent an overload that would happen at a quick start, sudden stop or even during usual running.

  • Page 146: Oil Flow

    GZD15, WSM TRANSAXLE (4) Oil Flow (1) Oil Strainer (5) Regulator Valve (8) Check and High Pressure (11) Swashplate (2) Transmission Case (6) PTO Clutch Relief Valve (12) Piston (3) Hydraulic Pump (7) Oil Filter Cartridge (9) Lubricating Orifice (13) Cylinder Block (Motor)

  • Page 147: Power Trains Operation

    GZD15, WSM TRANSAXLE (5) Power Trains Operation (1) Check and Relief Valve (1)-3 Neutral Orifice (4) Pump (7) Paper Filter (with Neutral Orifice) (2) Motor (5) Hydraulic Pump (8) Regulator Valve (1)-1 Relief Valve (3) Lubricating Orifice (6) Control Valve...

  • Page 148: Motion Control Linkage

    GZD15, WSM TRANSAXLE (6) Motion Control Linkage The motion control lever (1) and the trunnion shaft of variable swashplate are linked with the speed shaft (4), speed control rod (5) and the speed change arm (7). As the motion control lever (1) is pushed, the swashplate rotates and forward travelling speed increases.

  • Page 149: Final Reduction Gear Section

    GZD15, WSM TRANSAXLE (7) Final Reduction Gear Section As for this machine, power is transmitted from the 8T gear (1) on the HST motor shaft to the rear axle (5) through 23T gear (2), 7T gear (3) and 48T gear (4).

  • Page 150: Pto System

    GZD15, WSM TRANSAXLE (8) PTO System B PTO Clutch and Valve (1) PTO Clutch Pack (6) PTO Clutch Shaft (11) 33T Gear A: From Hydraulic Pump (1) PTO Clutch Valve (7) PTO Brake Plate (12) PTO Clutch Plate B: To Hydrostatic...
  • Page 151 GZD15, WSM TRANSAXLE B Regulator Valve This machine is controlled with the regulator valve so that the oil sent from the hydraulic pump may become the setting pressure. And the oil flows into PTO clutch and hydrostatic transmission. (Reference) A Regulator valve setting pressure: 0.5 to 0.6 MPa...
  • Page 152 GZD15, WSM TRANSAXLE B PTO Clutch "Disengaged" When the PTO clutch lever is set at the "Disengaged" position, the PTO clutch valve (1) rotates and close the oil passage to the PTO clutch pack (5). The oil in the PTO clutch pack (5) drained into the transmission case.

  • Page 153: Brake

    GZD15, WSM TRANSAXLE (9) Brake Brake system is composed of brake pedal, brake pedal arm (1), brake shaft, parking brake lock lever (2), brake return spring (3), brake rod (4) located at the machine front side and brake arm (5), brake lever (6),...
  • Page 154 CONTENTS 1. TROUBLESHOOTING....................... 2-S1 2. SERVICING SPECIFICATIONS ..................2-S3 3. TIGHTENING TORQUES ....................2-S4 4. CHECKING AND ADJUSTING ..................2-S5 5. DISASSEMBLING AND ASSEMBLING ................ 2-S11 [1] SEPARATING TRANSAXLE ..................2-S11 [2] SEPARATING FRONT PTO CASE ................2-S22 6. SERVICING ........................2-S24 [1] HYDROSTATIC TRANSMISSION ................

  • Page 155: Troubleshooting

    GZD15, WSM TRANSAXLE 1. TROUBLESHOOTING Reference Symptom Probable Causes Solution Page A Improper neutral adjustment Machine Will Not Stop Adjust neutral 2-S6 in Neutral Position A Improper speed control rod adjustment Adjust 2-S6 A Transmission oil insufficient Machine Jerky and...
  • Page 156 GZD15, WSM TRANSAXLE PTO SECTION A Operating pressure is low PTO Clutch Slip Check 2-S10 A PTO clutch valve malfunctioning Repair or replace 2-S20 A Clutch disc or drive plate excessively worn Replace 2-S20 A PTO clutch malfunctioning PTO Shaft Does Not...

  • Page 157: Servicing Specifications

    GZD15, WSM TRANSAXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Brake Spring Length at Parking Setting length 27 mm 1.06 in. Regulator Valve Setting pressure 0.5 to 0.6 MPa 5.1 to 6.1 72.5 to 87.0 psi PTO Clutch Operating pressure 0.98 to 1.08 MPa...
  • Page 158 GZD15, WSM TRANSAXLE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9) Item ft-lbs Motion control lever mounting bolt and nut 17.7 to 20.6...

  • Page 159: Checking And Adjusting

    GZD15, WSM TRANSAXLE 4. CHECKING AND ADJUSTING Adjusting Parking Brake A Stop the engine and chock the wheels before checking or adjusting. A Park the machine on a hard and level surface. A Wrong adjustment may cause machine damage. B Check 1.
  • Page 160 GZD15, WSM TRANSAXLE Adjusting Neutral A Park the machine on a hard and level surface. A If it is necessary to run engine in an enclosed area, use a gas tight exhaust pipe extension to remove the fumes. A Always try to work in a well-ventilated area.
  • Page 161 GZD15, WSM TRANSAXLE Adjusting Maximum Speed A Park the machine on a hard and level surface. A If it is necessary to run engine in an enclosed area, use a gas tight exhaust pipe extension to remove the fumes. A Always try to work in a well-ventilated area.
  • Page 162 GZD15, WSM TRANSAXLE Checking Motion Control Lever Alignment A When checking, park the tractor on flat ground, apply the parking brake. 1. Check the gap (A) and space (B) between the motion control levers, at the maximum forward position. If positions of the motion control levers are unequal, an adjustment is necessary.
  • Page 163 GZD15, WSM TRANSAXLE Checking Hydrostatic Transmission A When checking, park the machine on flat ground, apply the parking brake. A Sit on operatorís seat for checking. 1. After worming up the machine, apply the parking brake and set the stop wood (chock) to the rear wheels.
  • Page 164 GZD15, WSM TRANSAXLE PTO Clutch Operating Pressure (Hydrostatic Transmission Charge Pressure) A When checking, park the machine on flat ground, apply the parking brake. 1. Remove the plug (1) as a check port, then install the adaptor cable and pressure gauge.

  • Page 165: Disassembling And Assembling

    GZD15, WSM TRANSAXLE 5. DISASSEMBLING AND ASSEMBLING [1] SEPARATING TRANSAXLE Draining Transmission Fluid A Be sure to stop the engine before checking and changing the transmission fluid. 1. Place an oil pan underneath the transmission case. 2. Remove the drain plugs (1) at the bottom of the transmission case and drain the oil completely.
  • Page 166 GZD15, WSM TRANSAXLE Removing Rear Frame 1. Disconnect the grass collector wiring harness (3) connector. 2. Remove the universal joint (6). 3. Remove the rear frame mounting screws (2). 4. Remove the rear frame (1). (When reassembling) 1. Check the hydraulic hoses, wiring harness, fuel hose and accelating wire as shown in the picture.
  • Page 167 GZD15, WSM TRANSAXLE Removing High Dump Cylinder Frame, Hydraulic Hoses and Fenders 1. Remove the high dump wiring from cylinder frame. 2. Remove the cylinder pin (1). 3. Disconnect the hydraulic hoses (3) from hydraulic control valve. 4. Remove the mounting bolts on right and left side.
  • Page 168 GZD15, WSM TRANSAXLE Fuel Tank 1. Disconnect the fuel hose (2). 2. Remove the fuel tank (1). (1) Fuel Tank (2) Fuel Hose 0000001636E Removing Upper Frame and Connection Plate 1. Disconnect the HST rods (2). 2. Remove the upper frame mounting bolt.
  • Page 169 GZD15, WSM TRANSAXLE Separating the Transaxle Assembly 1. Raise up the transaxle (1) and support the machine frame (2) with rigid jacks. 2. Disconnect the brake rod and HST rods. 3. Remove the rear wheels. 4. Remove the mounting screws.
  • Page 170 GZD15, WSM TRANSAXLE Hydraulic Pipes, Hoses, Transaxle Cover and Hydraulic Pump 1. Remove the delivery hose and pipe as an unit. 2. Remove the hydraulic pipes and hoses. 3. Remove the bolts and the transaxle cover (4) as an unit.
  • Page 171 GZD15, WSM TRANSAXLE Hydrostatic Transmission Assembly 1. Remove the hydrostatic transmission assembly (LH), (RH) (1) (2) from transmission case. (When reassembling) A Apply oil to the O-rings and take care not to damage them. Hydrostatic 39.3 to 44.1 Tightening torque transmission mounting 4.0 to 4.5...
  • Page 172 GZD15, WSM TRANSAXLE Cylinder Block Assembly and Thrust Ball Bearing 1. Lay the housing on its side. 2. Slide out the cylinder block assembly (pump) (5). 3. Slide out the cylinder block assembly (motor) (6) with the motor shaft. 4. Remove the thrust ball bearing (4).
  • Page 173 GZD15, WSM TRANSAXLE Pump Shaft and Motor Shaft 1. Remove the oil seal (7) and internal snap ring (8). 2. Tap the pump shaft (1) with a plastic hammer slightly to side out it from the housing with the ball bearing (9).
  • Page 174 GZD15, WSM TRANSAXLE Disassembling PTO Clutch Assembly 1. Remove the bearing (6) and 33T/28T gear (10). 2. Remove the internal snap ring (12), then remove the pressure plate (13), clutch disc (4) and clutch plate (22). 3. Remove the external snap ring (3), spring collar (4) and clutch spring (15).
  • Page 175 GZD15, WSM TRANSAXLE Removing Brake Assembly 1. Remove the brake cover bolts. 2. Remove the brake assembly (1) from housing. 3. Remove the bolts (3) and remove brake case (9) from brake cover (11). 4. Remove the internal snap ring (4).

  • Page 176: Separating Front Pto Case

    GZD15, WSM TRANSAXLE [2] SEPARATING FRONT PTO CASE Removing Front Axle See "FRONT AXLE" Section. 0000001651E Moving Front PTO Shaft Spline Boss 1. Detach the external circlip (1) from the outer spline boss (3). 2. Move the outer spline boss (3) to the rear side.
  • Page 177 GZD15, WSM TRANSAXLE Draining Front PTO Case Oil 1. Remove the drain bolt (1). 2. Drain the oil from front PTO case (2). 0.13 L Front PTO case oil 0.14 U.S.qts. 0.11 Imp.qts. (1) Drain Bolt (3) Breezer (2) Front PTO Case...

  • Page 178: Servicing

    GZD15, WSM TRANSAXLE 6. SERVICING [1] HYDROSTATIC TRANSMISSION Centre Section 1. Check the surface (1) of centre section for scratches or wear. If deep scratch or excessive wear is found, replace the hydrostatic transmission assembly. (1) Surface 0000001691E Check and High Pressure Relief Valve 1.
  • Page 179 GZD15, WSM TRANSAXLE Thrust Washer, Thrust Ball Bearing and Thrust Plate 1. Check the thrust ball bearing (3) for scratches and excessive wear. 2. If worn, replace. 3. Check the thrust plate (4) for scratches and excessive wear. 4. If worn or scored, replace.

  • Page 180: Transmission Case

    GZD15, WSM TRANSAXLE [2] TRANSMISSION CASE Checking Bearing 1. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness. 2. Apply transmission fluid to the bearing, and hold the inner race.
  • Page 181 GZD15, WSM TRANSAXLE Correcting of Tooth Contact 1. Proper contact. A No adjustment. 0000001662E 2. Correcting of the heel contact (A) and shallow contact (B). A It is confirmed whether there is a shim (2). A The 19T spiral gear (1) can be moved to backward by doing to add the shim (2) when the thickness of the shim is not proper.
  • Page 182 GZD15, WSM TRANSAXLE Backlash and Tooth Contact of Rear Axle Case Gear 1. Measure the backlash between the 48T gear (1) and the 7T gear shaft (5). 2. When the backlash is too large, decrease the number of shims at the side of 7T gear shaft (5), and add the shim at the 48T gear side.

  • Page 183: Front Axle

    FRONT AXLE KiSC issued 04, 2006 A...
  • Page 184 CONTENTS 1. STRUCTURE........................3-M1 KiSC issued 04, 2006 A...
  • Page 185 GZD15, WSM FRONT AXLE 1. STRUCTURE (1) Tyre (5) Pin (9) Locking Nut (1/2-20 UNF) (12) Spring Washer (2) Front Axle Assembly (6) Snap Pin (10) Centre Pin Setting Pin (13) Centre Pin (3) Bolt (7) Wheel Bracket (11) Slotted Nut...
  • Page 186 CONTENTS 1. TROUBLESHOOTING....................... 3-S1 2. SERVICING SPECIFICATIONS ..................3-S2 3. TIGHTENING TORQUES ....................3-S3 4. CHECKING, DISASSEMBLING AND SERVICING ............3-S4 [1] CHECKING AND ADJUSTING ..................3-S4 [2] DISASSEMBLING AND ASSEMBLING................. 3-S5 (1) Separating Floor Cover and Front Axle ..............3-S5 (2) Disassembling Front Wheel and Wheel Bracket .............

  • Page 187: Troubleshooting

    GZD15, WSM FRONT AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Clearance between center pin and front axle Front Wheels Wander Replace to Right or Left excessive A Force of the bolt which tighten the wheel Adjust 3-S7 bracket has become down.

  • Page 188: Servicing Specifications

    GZD15, WSM FRONT AXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Axle Rocking Force 1 to 15 9.8 to 147.1 0000001499E KiSC issued 04, 2006 A 3-S2...
  • Page 189 GZD15, WSM FRONT AXLE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9) Item ft-lbs Wheel bolt and lock nut 20 to 25 2.04 to 2.55...

  • Page 190: Checking, Disassembling And Servicing

    GZD15, WSM FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Adjusting Front Axle Rocking Force 1. Lift the front axle (1). 2. Measure the front axle rocking force with a push-pull gauge. 3. If the measurement is not within the factory specifications, adjust with the slottle nut (2).

  • Page 191: Disassembling And Assembling

    GZD15, WSM FRONT AXLE [2] DISASSEMBLING AND ASSEMBLING (1) Separating Floor Cover and Front Axle Removing Motion Control Lever 1. After removing seat with seat bracket, remove the motion control lever (1). (1) Motion Control Lever (3) Screw (2) Screw...
  • Page 192 GZD15, WSM FRONT AXLE Removing Floor Sheet Cover 1. Remove screws (2) under the floor sheet cover (1). 2. Remove the floor sheet cover (1). 3. Remove the front weight bracket (3). (1) Floor Sheet Cover (4) Lift Cylinder Stay...

  • Page 193: Disassembling Front Wheel And Wheel Bracket

    GZD15, WSM FRONT AXLE (2) Disassembling Front Wheel and Wheel Bracket Removing the Front Wheel 1. Inspect tyre and wheel for wear or damage. Replace tyre as an assembly. (When reassembling) 20 to 25 Front wheel mounting Tightening torque 2.04 to 2.55 bolt and locking nut 14.75 to 18.44 ft-lbs...

  • Page 194: Hydraulic System

    HYDRAULIC SYSTEM KiSC issued 04, 2006 A...
  • Page 195 CONTENTS 1. HYDRAULIC CIRCUIT .....................4-M1 2. HYDRAULIC PUMP......................4-M2 3. HYDRAULIC CONTROL VALVE ..................4-M3 4. LIFT CYLINDER ......................4-M11 [1] MOWER LIFT CYLINDER ...................4-M11 [2] GRASS COLLECTOR LIFT CYLINDER AND GRASS COLLECTOR DUMP CYLINDER ......................4-M12 5. MOWER LINKAGE ......................4-M13 6. GRASS COLLECTOR CONTROL MECHANISM............4-M14 [1] COMPARISON OF HIGH DUMP AND LOW DUMP GRASS COLLECTOR ..4-M14 [2] GRASS COLLECTOR CONTROL MECHANISM ............4-M15 KiSC issued 04, 2006 A...

  • Page 196: Hydraulic Circuit

    GZD15, WSM HYDRAULIC SYSTEM 1. HYDRAULIC CIRCUIT (1) PTO Clutch (5) Grass Collector Lift (8) Grass Collector Dumping (13) Regulator Valve (2) PTO Clutch Valve Cylinder (LH) Control Valve (14) Oil Filter (3) Hydraulic Control Valve (6) Grass Collector Dump...

  • Page 197: Hydraulic Pump

    GZD15, WSM HYDRAULIC SYSTEM 2. HYDRAULIC PUMP The hydraulic pump is composed of the casing (1), cover (6), side plate (4), and two spur gears (drive (2) and driven gear (3) )that are in mesh. Hydraulic pump is driven by the pump drive shaft in the transmission case.

  • Page 198: Hydraulic Control Valve

    GZD15, WSM HYDRAULIC SYSTEM 3. HYDRAULIC CONTROL VALVE GZD15's hydraulic control system consists of control levers (or pedal), rod, hydraulic control valve (1), hydraulic hoses, cylinders and other components. Filtered oil is forced out by the hydraulic pump to the control valve (1) through the delivery pipe.
  • Page 199 GZD15, WSM HYDRAULIC SYSTEM B Mower Lift Cylinder "NEUTRAL" 1) Since the hydraulic lift pedal is not pushed, the spool (2) is not pushed in and is not pulled out from the control valve(1). 2) High-pressured oil is forced through "C" port to the second and the third spool port in the control valve (1).
  • Page 200 GZD15, WSM HYDRAULIC SYSTEM Grass collector dump cylinder is a double action type. Grass collector dump cylinder is connected to the control valve "A2" and "B2" ports with the hydraulic hoses. B Grass Collector Dump Cylinder "NEUTRAL" 1) When the control lever is set to the "NEUTRAL"...
  • Page 201 GZD15, WSM HYDRAULIC SYSTEM B Grass Collector Dump Cylinder "CLOSE" 1) When the control lever is set to the "CLOSE" position, the spool (2) is pushed out from the control valve (1). 2) In "A2" port side, oil passage between "A2" port and "PB"...
  • Page 202 GZD15, WSM HYDRAULIC SYSTEM Grass collector lift cylinder is a double action type. Grass collector lift cylinder is connected to the control valve "A3" and "B3" ports with the hydraulic hoses. B Grass Collector Lift Cylinder "NEUTRAL" 1) When the control lever is set to the "NEUTRAL"...
  • Page 203 GZD15, WSM HYDRAULIC SYSTEM B Grass Collector Lift Cylinder "DOWN" 1) When the control lever is set to the "DOWN" position, the spool (2) is pushed out from the control valve (1). 2) In "A3" port side, oil passage between "A3" port and "PB"...
  • Page 204 GZD15, WSM HYDRAULIC SYSTEM B Relief Valve The implement control system circuit has a relief valve to restrict the maximum pressure in the circuit. The relief valve is located in the hydraulic control valve assembly. The relief valve is the adjusting screw with damping effect.
  • Page 205 GZD15, WSM HYDRAULIC SYSTEM B Check Valve The implement control system circuit has a check valve to prevent the oil leak in the circuit. The check valve is located in the hydraulic control valve assembly. The check valve is the spring type.

  • Page 206: Lift Cylinder

    GZD15, WSM HYDRAULIC SYSTEM 4. LIFT CYLINDER [1] MOWER LIFT CYLINDER (1) Tube End (2) Snap Ring (3) Cylinder Tube (4) Packing (5) Scraper (6) Piston Rod The lift cylinder consists of the tube end (1), cylinder tube (3), piston rod (6) and other parts as shown in the figure above.

  • Page 207: Grass Collector Lift Cylinder And Grass Collector Dump Cylinder

    GZD15, WSM HYDRAULIC SYSTEM [2] GRASS COLLECTOR LIFT CYLINDER AND GRASS COLLECTOR DUMP CYLINDER (1) Piston Rod (3) Cylinder Tube (5) Nut B: Rod O.D. (2) Head (4) Piston A: Cylinder I.D. C: Stroke The cylinder consists of a head (2), cylinder tube (3), piston rod (1), piston (4) and other parts as shown in the figure above.

  • Page 208: Mower Linkage

    GZD15, WSM HYDRAULIC SYSTEM 5. MOWER LINKAGE (1) Mower Lift Pedal (4) Lift Rod (8) Front Link (12) Lift Link Shaft (2) Cutting Height Adjusting (5) Control Valve (9) Cam Arm (13) Rear Arm Dial (6) Lift Cylinder (10) Mower...

  • Page 209: Grass Collector Control Mechanism

    GZD15, WSM HYDRAULIC SYSTEM 6. GRASS COLLECTOR CONTROL MECHANISM [1] COMPARISON OF HIGH DUMP AND LOW DUMP GRASS COLLECTOR Item High Dump Low Dump Lift Base Lift Arm Lift Cylinder Lift Cylinder Hose Restriction Wire Bag Base Fixed to lift arm...

  • Page 210: Grass Collector Control Mechanism

    GZD15, WSM HYDRAULIC SYSTEM [2] GRASS COLLECTOR CONTROL MECHANISM B Grass Collector Lifting and Lowing Mechanism Grass collector lift arm (2) is connected with two lift cylinders (3). When the grass collector control lever (1) is set to the "UP" (A) position, hydraulic oil is delivered to the lift cylinders (3).
  • Page 211 2. SERVICING SPECIFICATIONS ..................4-S3 3. CHECKING, DISASSEMBLING AND SERVICING ............4-S4 [1] HYDRAULIC CONTROL VALVE AND PUMP ............. 4-S4 (1) Checking and Adjusting (GZD15-HD(E) Serial No. : Below 10736) ......4-S4 (2) Disassembling and Assembling................4-S6 [2] MOWER LIFT CYLINDER ..................... 4-S8 (1) Disassembling and Assembling................

  • Page 212: Troubleshooting

    GZD15, WSM HYDRAULIC SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Control valve malfunctioning Mower Does Not Rise Repair or replace 4-S6, S7 A Lift cylinder damaged Replace 4-S8 A Relief valve spring damaged Replace 4-S6 A Relief valve setting pressure too low...
  • Page 213 GZD15, WSM HYDRAULIC SYSTEM Reference Symptom Probable Cause Solution Page A Control valve malfunctioning Grass Collector Does Repair or replace 4-S6, S7 Not Dump A Lift cylinder damaged Repair 4-S10, S11 A Relief valve spring damaged Replace 4-S6 A Relief valve setting pressure too low...

  • Page 214: Servicing Specifications

    GZD15, WSM HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Relief Valve (Control Valve) Setting Pressure 10.79 to 11.77 MPa 110 to 120 1560 to 1708 psi 0000001586E KiSC issued 04, 2006 A 4-S3...

  • Page 215: Checking, Disassembling And Servicing

    HYDRAULIC SYSTEM 3. CHECKING, DISASSEMBLING AND SERVICING [1] HYDRAULIC CONTROL VALVE AND PUMP (1) Checking and Adjusting (GZD15-HD(E) Serial No. : Below 10736) Adjusting Length of Lift Arm Wire 1. Start the engine. 2. Lift up the grass collector and keep it at horizontal as shown in the picture.
  • Page 216 GZD15, WSM HYDRAULIC SYSTEM Relief Valve Setting Pressure 1. Disconnect the lift cylinder delivery hose (5). 2. Install the adaptor (3) and hydraulic pressure gauge (4) to lift cylinder adaptor (2). And install the delivery hose (5) to the adaptor (3).

  • Page 217: Disassembling And Assembling

    GZD15, WSM HYDRAULIC SYSTEM (2) Disassembling and Assembling Removing Control Valve A Since clearance between hydraulic hoses is very narrow. Thin and narrow open-end spanner 17-19 mm is required. 1. Remove the nuts (1). 2. Remove the control valve and bracket as a unit.
  • Page 218 GZD15, WSM HYDRAULIC SYSTEM Spool Cover and Spool 1. Unscrew the valve cover mounting screws (1) and remove the valve cover (2) from the control valve rear side. 2. Remove the screws (4) and plate (3) from the control valve front side.

  • Page 219: Mower Lift Cylinder

    GZD15, WSM HYDRAULIC SYSTEM Removing Relief Valve 1. Remove the internal snap ring (5) from housing case (6). 2. Remove the plug (4). 3. Remove the spring (2) and valve (1). 4. Check and clean the valve (1) and spring (2).

  • Page 220: Grass Collector Lift Cylinder

    GZD15, WSM HYDRAULIC SYSTEM Disassembling Mower Linkage (1) Grip (2) Lift Rod (3) Cam (4) Retain Spring Plate (5) Mower Front Link (6) Lift Shaft (7) Rear Boss (8) Rear Arm (9) Mower Rear Link (10) Hinge Pin (11) Hinge Spring...
  • Page 221 GZD15, WSM HYDRAULIC SYSTEM Disassembling Lift Cylinder 1. Remove the head (2) with a wrench. 2. Remove the piston rod (1) from the cylinder tube (3). 3. Remove the nut (6) and piston (5) from the piston rod (1). 4. Remove the head (2) from piston rod (1).

  • Page 222: Grass Collector Dump Cylinder

    GZD15, WSM HYDRAULIC SYSTEM [4] GRASS COLLECTOR DUMP CYLINDER (1) Disassembling and Assembling Removing Grass Collector Dump Cylinder 1. Remove the grass collector (1) from the machine. 2. Disconnect the hydraulic hoses (2) from the dump cylinder (3). 3. Remove the pin (4) and the clevis pin from the machine.

  • Page 223: Electrical System

    ELECTRICAL SYSTEM KiSC issued 04, 2006 A...
  • Page 224 CONTENTS 1. WIRING DIAGRAM......................5-M1 2. STARTING SYSTEM ......................5-M4 [1] STARTER ........................5-M7 [2] GLOW PLUG ........................5-M8 [3] SAFETY SWITCH (LIMIT SWITCH) ................5-M8 [4] FUEL PUMP ........................5-M9 [5] ENGINE STOP SOLENOID...................5-M9 3. CHARGING SYSTEM.....................5-M10 [1] AC DYNAMO ........................5-M11 [2] REGULATOR.........................5-M11 [3] EASY CHECKER (TM) ....................5-M12 KiSC issued 04, 2006 A...

  • Page 225: Wiring Diagram

    GZD15, WSM ELECTRICAL SYSYTEM 1. WIRING DIAGRAM Colour of Wiring W..White WB..White / Black RY..Red / Yellow R..Red GB..Green / Black YW..Yellow / White L..Blue OrL..Orange / Blue BW..Black / White P..Pink YB..Yellow / Black BR..Black / Red B..Black BrR..Brown / Red GW..Green / White...
  • Page 226 GZD15, WSM ELECTRICAL SYSYTEM 0000001510E KiSC issued 04, 2006 A 5-M2...
  • Page 227 GZD15, WSM ELECTRICAL SYSYTEM 0000001511E KiSC issued 04, 2006 A 5-M3...

  • Page 228: Starting System

    GZD15, WSM ELECTRICAL SYSYTEM 2. STARTING SYSTEM When the main switch is turned to the PREHEAT position, the terminal B is connected to the terminals G and ACC. The glow plugs become red-hot, and the preheat indicator lamp also lights on while preheating.
  • Page 229 GZD15, WSM ELECTRICAL SYSYTEM Table 1. Engine Stop and Start Control Switch and Engine Remarks Switch Position Control Motion Forward and Control Lever Reverse:OFF, Switch Neutral:ON Engaged:OFF PTO Switch Disengaged:ON Engaged:ON Brake Switch Released:OFF On Seat:OFF Seat Switch Off Seat:ON...
  • Page 230 GZD15, WSM ELECTRICAL SYSYTEM Table 3. Engine Stop and Start Control Switch and Engine Remarks Switch Position Control Motion Forward and Control Lever Reverse:OFF, Switch Neutral:ON Engaged:OFF PTO Switch Disengaged:ON Engaged:ON Brake Switch Released:OFF On Seat:OFF Seat Switch Off Seat:ON...

  • Page 231: Starter

    GZD15, WSM ELECTRICAL SYSYTEM [1] STARTER (1) Housing (2) Magnetic Switch (3) Overrunning Clutch (4) Drive Lever (5) Internal Gear (6) Gear Shaft (7) Planetary Gear (8) Armature Shaft (9) Yoke (10) Brush Holder (11) Rear End Holder The reduction system is used planetary gears, and the speed of gear shaft (6) is reduced to approximately one fifth of the armature shaft (8).

  • Page 232: Glow Plug

    GZD15, WSM ELECTRICAL SYSYTEM [2] GLOW PLUG This plug is a two-material type QGS (Quick Glow System) for quick temperature rise, and has self- controlling function as well as excellent durability. The heater (4) connected in series to the heater (3), which also functions as the resistor, is incorporated in the sheath tube (1) of the super glow plug.

  • Page 233: Fuel Pump

    GZD15, WSM ELECTRICAL SYSYTEM [4] FUEL PUMP An electro magnetic fuel pump uses a transistor that causes the pump to start pumping fuel when the main switch is turned to the "ON" position. Therefore, fuel is supplied to the fuel injection pump regardless of engine speed.

  • Page 234: Charging System

    GZD15, WSM ELECTRICAL SYSYTEM 3. CHARGING SYSTEM The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs. It consists of a AC dynamo and a regulator. 0000001519E KiSC issued 04, 2006 A...

  • Page 235: Ac Dynamo

    GZD15, WSM ELECTRICAL SYSYTEM [1] AC DYNAMO The dynamo is an 8-8 pole rotating magnet type generator. It is simple in construction, consisting of a stator and rotor. The rotor is made up of eight permanent magnet pole pieces assembled on a shaft and rotates on the center of the stator around which eight electromagnetic coils are provided for.

  • Page 236: Easy Checker (Tm)

    GZD15, WSM ELECTRICAL SYSYTEM [3] EASY CHECKER (TM) To check the conditions of the machine easily before and during operation, easy checker combination of lamps on the easy checker board is provided. 0000001531E B Indication Items (1) Electrical Charge Lamp If the alternator is not charging the battery, the warning lamp in the Easy Checker (TM) will come on.
  • Page 237 CONTENTS 1. TROUBLESHOOTING....................... 5-S1 2. SERVICING SPECIFICATIONS ..................5-S3 3. TIGHTENING TORQUES ....................5-S4 4. CHECKING, DISASSEMBLING AND SERVICING ............5-S5 [1] BATTERY ........................5-S5 (1) Checking........................5-S5 [2] STARTING SYSTEM ...................... 5-S6 (1) Checking........................5-S6 (2) Disassembling and Assembling................5-S13 (3) Servicing........................

  • Page 238: Troubleshooting

    GZD15, WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A Battery discharged or defective All Electrical Recharge or replace G-32, G-33 Equipments Do Not A Battery positive cable disconnected Repair or replace 5-S5 Operate improperly connected A Battery...
  • Page 239 GZD15, WSM ELECTRICAL SYSTEM Reference Symptom Probable Cause Solution Page A Fuse blown (15 A) Engine Does Not Stop Replace G-40 When Main Switch is A Wiring harness disconnected or improperly Repair or replace Turned OFF connected (between main switch...

  • Page 240: Servicing Specifications

    GZD15, WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Battery Voltage More than 12 V Potential Difference Less than 0.1 V Glow Plug Resistance Approx. 0.9 Starter Commutator 30.0 mm 29.0 mm (O.D.) 1.181 in. 1.142 in.
  • Page 241 GZD15, WSM ELECTRICAL SYSTEM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9) Item ft-lbs Starter (B terminal nut) 5.9 to 11.8 0.6 to 1.2...

  • Page 242: Checking, Disassembling And Servicing

    GZD15, WSM ELECTRICAL SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING A To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal. A Never remove the battery cap while the engine is running.

  • Page 243: Starting System

    GZD15, WSM ELECTRICAL SYSTEM [2] STARTING SYSTEM (1) Checking (A) Safety Switches Method of Inspecting Each Control A defective location can be judge by checking function of each safety switch one by one as shown in the table below. (Reference) A Type of Safety Switch Parking Brake Pedal..Normal Close...
  • Page 244 GZD15, WSM ELECTRICAL SYSTEM Main Switch Continuity 1) Main Switch Key at OFF Position 1. Set the main switch OFF position. 2. Measure the resistance with an ohmmeter across the B terminal and the ACC terminal, B terminal and G terminal, B terminal and ST terminal.
  • Page 245 GZD15, WSM ELECTRICAL SYSTEM (C) Starter Motor Test A Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable and the leads from the starter.
  • Page 246 GZD15, WSM ELECTRICAL SYSTEM (D) Glow Plug Lead Terminal Voltage 1. Disconnect the wiring lead (1) from the glow plug (2) after turning the main switch off. 2. Turn the main switch key to the "PREHEAT" position, and measure the voltage between the lead terminal and the chassis.
  • Page 247 GZD15, WSM ELECTRICAL SYSTEM (E) Safety Switch Operator's Seat Switch Continuity 1. Remove the operator's switch leads (2). 2. Connect the circuit tester to the operator's switch connectors (2). 3. Measure the resistance between connectors (2). 4. If the operator's switch (1) is defective, replace it.
  • Page 248 GZD15, WSM ELECTRICAL SYSTEM Motion Control Lever Switch (Left and Right) 1. Remove the motion control lever switch leads (3). 2. Connect the circuit tester to the motion control lever switch leads (3). 3. Measure the resistance between leads (3).
  • Page 249 GZD15, WSM ELECTRICAL SYSTEM Fuel Pump Continuity 1. Disconnect the 2P connector from the fuel pump (1). 2. Check the continuity between the fuel pump side connector (2) terminals with an ohmmeter. 3. If it does not conduct, the fuel pump is faulty.

  • Page 250: Disassembling And Assembling

    GZD15, WSM ELECTRICAL SYSTEM (2) Disassembling and Assembling (1) Magnetic Switch Mounting Nut (2) Housing (3) Magnetic Switch (4) C Terminal Nut (5) Shaft Assembly (6) Drive Lever (7) Overrunning Clutch (8) Connecting Lead (9) Mounting Screw (10) Armature (11) Yoke...
  • Page 251 GZD15, WSM ELECTRICAL SYSTEM Commutator and Mica 1. Check the contact face of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points.
  • Page 252 GZD15, WSM ELECTRICAL SYSTEM Brush Holder 1. Check the continuity across the brush holder and the holder support with an ohmmeter. 2. If it conducts, replace the brush holder. 0000001171E Armature Coil 1. Check the continuity across the commutator and armature coil core with an ohmmeter.

  • Page 253: Charging System

    GZD15, WSM ELECTRICAL SYSTEM [3] CHARGING SYSTEM (1) Checking Battery Charging Current 1. After starting the engine, disconnect the battery positive cord (+), and connect an ammeter and voltmeter. Then switch on all electrical loads (such as head lights) and measure the charging current.

  • Page 254: Disassembling And Assembling

    GZD15, WSM ELECTRICAL SYSTEM (2) Disassembling and Assembling Stator 1. Remove the nut (3) and separate the stator comp. (4). 2. Unscrew the screws (1) and remove the stator (2). (When reassembling) 39.2 to 44.1 Tightening torque 4.0 to 4.5 28.9 to 32.5 ft-lbs...
  • Page 255 MOWER KiSC issued 04, 2006 A...
  • Page 256 CONTENTS 1. POWER TRANSMISSION....................6-M1 2. LIFTING MECHANISM .....................6-M2 KiSC issued 04, 2006 A...
  • Page 257 GZD15, WSM MOWER 1. POWER TRANSMISSION (1) Front PTO Shaft (4) Mower Gear (7) 17T Spiral Gear (9) Blade Shaft (2) Front PTO Case (5) Mower Blade (8) 18T Spiral Gear (10) Transmission Case (3) Mower PTO Shaft (6) Input Shaft The power is transmitted from transmission case to blades as follows.

  • Page 258: Lifting Mechanism

    GZD15, WSM MOWER 2. LIFTING MECHANISM (1) Mower Lift Pedal (4) Control Valve (7) Front Link (10) Rear Link (2) Delivery Hose (5) Mower Lift Cylinder (8) Cam Arm (11) Link Retainer (3) Mower Lift Rod (6) Front Arm (9) Lift Rod Mower lifting is performed by the hydraulic system on the machine.
  • Page 259 CONTENTS 1. TROUBLESHOOTING....................... 6-S1 2. SERVICING SPECIFICATIONS ..................6-S2 3. TIGHTENING TORQUES ....................6-S3 4. CHECKING, DISASSEMBLING AND ASSEMBLING ............ 6-S4 [1] CHECKING AND ADJUSTING ..................6-S4 [2] DISASSEMBLING AND ASSEMBLING................. 6-S6 KiSC issued 04, 2006 A...

  • Page 260: Troubleshooting

    GZD15, WSM MOWER 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page A PTO system malfunctioning Blade Does Not Turn Check transmission A Broken mower belt Replace mower belt G-42 A Loosen mower belt Blade Speed Is Slow Replace mower belt...

  • Page 261: Servicing Specifications

    GZD15, WSM MOWER 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Pinion Shaft (without Mower Belt) Turning Torque Less than 0.7 0.07 0.52 ft-lbs Bevel Gears in Gear Box Backlash 0.13 to 0.25 mm 0.40 mm 0.0051 to 0.0098 in.
  • Page 262 GZD15, WSM MOWER 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-9) Item ft-lbs Mower blade screw 98 to 118 10.0 to 12.0 72.3 to 86.8...

  • Page 263: Checking, Disassembling And Assembling

    GZD15, WSM MOWER 4. CHECKING, DISASSEMBLING AND ASSEMBLING [1] CHECKING AND ADJUSTING Adjusting Anti-scalp Rollers A he flattest cut can be achieved by having the anti-scalp rollers adjusted off the ground. Check anti-scalp roller adjustments each time the mower deck cutting height is changed.
  • Page 264 GZD15, WSM MOWER Adjusting Left and Right Cutting Height 1. Wheel pressure must be correct. 2. Raise up the mower deck to the transport position. (Also the top end). 3. Turn the cutting height set dial (1) to the 3 in. (76 mm) cutting height position.

  • Page 265: Disassembling And Assembling

    GZD15, WSM MOWER Adjusting Front and Rear Cutting Height A Mower deck anti-scalp rollers should not contact the ground. 1. Wheel pressure must be correct. 2. Raise up the mower deck to the transport position. (Also the top end). 3. Turn the cutting height set dial (1) to the 3 in. cutting height position.
  • Page 266 GZD15, WSM MOWER Mower Blades (Left Blade and Right Blades) 1. Turn over the mower. 2. Unscrew the mower blade screw (1), and remove the blade boss (6), two cup washers (2), mower blade (3) and dust cover (4). A To remove the blade securely, wedge a block of wood...
  • Page 267 GZD15, WSM MOWER Gear Box and Mower Belt 1. Turn over the mower. 2. Remove the mower belt (1) from the tension pulley (5). 3. Unscrew the left and right gear box mounting screws (3), (4) and remove the gear box (2) from the mower deck.
  • Page 268 GZD15, WSM MOWER Tension Arm and Pulley 1. Pull the tension arm (2) and the tension arm spring (1). 2. Remove the mower belt (6). 3. Remove the tension arm spring (1) from tension arm (2). 4. Remove the tension arm bolt (3).
  • Page 269 GZD15, WSM MOWER Backlash between Bevel Gears 1. Place fuses on the teeth of the 17T spiral gear (6). 2. Tighten the gear case bolts temporarily. And assembly the gear case temporarily for checking gear backlash. 3. Turn the pinion shaft.
  • Page 270 GZD15, WSM MOWER Turning Torque of Pinion Shaft 1. Remove the mower belt, and reassemble the gear box to the mower deck. 2. Wind a string around the input shaft and set a spring balance (or push-pull gauge) to the tip of the string, and then slowly pull the spring balance horizontally to measure the turning force.
  • Page 271 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ksos-pub@kubota.co.jp Printed in Japan 2006. 03, S, EI, EI, e Code No.9Y011-15231 KUBOTA Corporation 2003.

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