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WSM ZD1511
Kubota WSM ZD1511 Manuals
Manuals and User Guides for Kubota WSM ZD1511. We have
1
Kubota WSM ZD1511 manual available for free PDF download: Workshop Manual
Kubota WSM ZD1511 Workshop Manual (344 pages)
Brand:
Kubota
| Category:
Lawn Mower
| Size: 19 MB
Table of Contents
Table of Contents
3
Information
15
Safety First
16
Before You Start Service
17
Start Safely
17
Operate Safely
17
Protect against High Pressure Spray
18
Avoid Hot Exhaust
18
Exhaust Filter Cleaning
18
Prevent a Fire
19
Keep a Good Airflow in the Work Area
19
Discard Fluids Correctly
19
Prevent Acid Burns
19
Prepare for Emergencies
20
Safety Decals
22
Care of Danger, Warning and Caution Labels
27
Specifications
28
Dimensions
30
General
32
Identification
33
General Precautions
35
Identifying Cylinder Number
37
Handling Precautions for Electrical Parts and Wiring
39
Handling of Wiring
39
Handling of Battery
40
Handling of Fuse
41
Handling of Connector
41
Handling of Circuit Tester
42
Color of Wiring
42
Lubricants, Fuel and Coolant
43
Tightening Torques
47
General Use Screws, Bolts and Nuts
47
Stud Bolts
47
Metric Screws, Bolts and Nuts
48
American Standard Screws, Bolts and Nuts with UNC or UNF Threads
48
Plugs
48
Maintenance Check List
49
Check and Maintenance
51
Daily Check
51
Checking the Machine
51
Checking Engine Oil Level
51
Checking Amount of Fuel and Refueling
51
Checking Transmission Fluid Level
52
Checking Coolant Level
52
Checking and Cleaning Radiator to Prevent Overheating
53
Checking and Cleaning DPF Muffler and Its Surroundings
54
Checking Tire Pressure
54
Greasing (Mower)
54
Check Points of Initial 50 Hours
55
Changing Engine Oil
55
Replacing Engine Oil Filter
55
Replacing HST Transmission Oil Filter
56
Check Point of Initial 100 Hours
56
Adjusting Front Axle Pivot
56
Check Point of Initial 400 Hours
57
Changing Transmission Fluid and Rear Axle Gear Case Oil (R.H. and L.H.)
57
Check Points of Every 50 Hours
58
Checking Engine Start System
58
Checking OPC System
59
Checking Gear Box Oil Level
59
Greasing
59
Check Points of Every 100 Hours
61
Cleaning Air Cleaner Primary Element
61
Checking Fuel Filter
61
Adjusting Fan Belt Tension
62
Adjusting Parking Brake
63
Check on Slope
63
Greasing Mower Link Bushing
64
Checking Battery Condition
64
Charging Battery
65
Check Point of Every 150 Hours
66
Changing Gear Box Oil Level
66
Changing Engine Oil
66
Replacing Engine Oil Filter
66
Replacing HST Transmission Oil Filter
67
Adjusting Front Axle Pivot
67
Check Points of Every 400 Hours
68
Changing Transmission Fluid and Rear Axle Gear Case Oil (R.H. and L.H.)
68
Replacing Hydraulic Filter
69
Replacing Fuel Filter
69
Check Points of Every 800 Hours
70
Adjusting Engine Valve Clearance
70
Check Points of Every 1000 Hours or 1 Year
70
Replacing Air Cleaner Primary Element and Secondary Element
70
Check Point of Every 1500 Hours
71
Checking Fuel Injection Nozzle Pressure
71
Check Points of Every 2000 Hours or 2 Years
71
Flushing Cooling System and Changing Coolant
71
Anti-Freeze
72
Check Point of Every 3000 Hours
73
Checking Injection Pump
73
Checking Turbocharger
73
Check Points of Every 1 Year
74
Checking Exhaust Manifold
74
Checking Hydraulic Hose
74
Checking Radiator Hose and Clamp
74
Checking Fuel Lines
75
Checking Intake Air Line
76
Checking Mower Gear Box Seals
76
Checking Engine Breather Hose
76
Check Point of Every 4 Years
76
Replacing Hydraulic Hose
76
Replacing Radiator Hose
77
Replacing Fuel Lines
77
Replacing Intake Air Line
78
Replacing Mower Gear Box Seals
79
Replacing Engine Breather Hose
79
Others
80
Replacing Fuses
80
Checking Mower Blade
81
Replacing Mower Blade
81
Replacing Mower Belt
82
Bleeding Fuel System
83
Special Tools for Engine
85
Diesel Engine Compression Tester (for Nozzle Hole)
85
Diesel Engine Compression Tester (for Glow Plug Hole)
85
Oil Pressure Tester
85
Injection Pump Pressure Tester
86
Valve Guide Replacing Tool
86
Bushing Replacing Tool
87
Flywheel Stopper
88
Crankshaft Bearing 1 Replacing Tool
88
Crank Sleeve Setter
89
Rotation Sensor Signal Interface Unit
91
Special Tools for Machine
92
Relief Valve Pressure Tester
92
HST Relief Valve Adapter
92
Implement Limitations
93
Engine
95
Mechanism
96
Engine Body
96
Function of Cylinder Block
96
Function of Closed Breather
96
Function of Half-Floating Head Cover
96
Function of Piston
97
Function of Piston Ring
97
Function of Connecting Rod
97
Function of Crankshaft
98
Function of Camshaft
98
Function of Rocker Arm
98
Function of Flywheel
99
Function of Timing Gears
99
Definition of Engine Control System
99
Lubricating System
100
Overview of Lubricating System
100
Function of Oil Strainer
102
Function of Oil Pump
102
Function of Oil Filter
102
Function of Relief Valve
103
Function of Oil Pressure Switch
103
Cooling System
104
Overview of Cooling System
104
Function of Water Pump
106
Function of Radiator
106
Function of Radiator Cap
106
Fuel System
107
Overview of Fuel System
107
Function of Fuel Filter
107
Function of Fuel Feed Pump
107
Function of Injection Nozzle
108
Function of Fuel Tank
108
Definition of Electronic Governor
108
Reformer and after Treatment Devices
110
Definition of Reformer
110
Definition of Diesel Oxidation Catalyst (DOC)
112
Function of Diesel Particulate Filter (DPF)
112
Definition of Temperature Sensor
112
Definition of Differential Pressure Sensor
113
Servicing
114
Troubleshooting for Engine
114
Servicing Specifications for Engine
118
Tightening Torques for Engine
122
Checking and Adjusting
124
Engine Body
124
Checking Compression Pressure
124
Checking Valve Clearance
124
Lubricating System
125
Checking Engine Oil Pressure
125
Cooling System
125
Checking Fan Belt Tension
125
Checking Fan Belt Damage and Wear
125
Checking Radiator Cap Air Leakage
126
Checking Radiator Water Leakage
126
Checking Thermostat Valve Opening Temperature
127
Fuel System
127
Checking Injection Timing
127
Checking Fuel Tightness of Pump Element
128
Checking Fuel Tightness of Delivery Valve
129
Checking Nozzle Spraying Condition
129
Checking Fuel Injection Pressure
129
Checking Valve Seat Tightness
130
Removing Nozzle Holder
130
Disassembling and Assembling
131
Separating Engine
131
Draining Engine Oil
131
Draining Coolant
132
Removing the Battery
132
Removing the Bonnet
132
Removing DPF Cover
133
Removing Rear Engine Frame
133
Removing Air Cleaner Assembly
133
Disconnecting Engine Wiring Harness
134
Disconnecting Engine Fuel Hoses
135
Removing Engine Stoppers
135
Removing Universal Joint from Engine
135
Disconnecting Radiator Assembly
136
Separating the Engine
137
Disassembling the Engine
137
External Components
137
Cylinder Head and Valve
139
Removing Valves
142
Gear Case and Timing Gears
142
Piston and Connecting Rod
145
Removing Pistons
146
Flywheel and Crankshaft
147
Alternator
150
Starter
152
Servicing
155
Cylinder Head and Valve
155
Checking Top Clearance
155
Checking Cylinder Head Surface Flatness
155
Checking Cylinder Head Flaw
156
Checking Valve Recessing
156
Checking Clearance between Valve Stem and Valve Guide
157
Replacing Valve Guide
157
Checking Valve Seating
158
Correcting Valve
158
Correcting Valve Seat
159
Checking Valve Lapping
159
Checking Free Length and Tilt of Valve Spring
160
Checking Valve Spring Setting Load
160
Checking Oil Clearance between Rocker Arm and Rocker Arm Shaft
160
Checking Push Rod Alignment
161
Checking Oil Clearance between Tappet and Tappet Guide Bore
161
Timing Gears, Camshaft and Governor Gear
161
Checking Timing Gear Backlash
161
Checking Idle Gear 1 and 2 Side Clearance
162
Checking Camshaft Side Clearance
162
Checking Camshaft Alignment
162
Checking Cam Height
162
Checking Oil Clearance of Camshaft Journal
163
Checking Oil Clearance between Idle Gear Shaft 1 and 2 and Idle Gear Bushing
163
Replacing Idle Gear Bushing
164
Piston and Connecting Rod
164
Checking Piston Pin Bore I.D
164
Checking Oil Clearance between Piston Pin and Small End Bushing
164
Replacing Small End Bushing
165
Checking Connecting Rod Alignment
165
Checking Piston Ring Gap
165
Checking Clearance between Piston Ring and Piston Ring Groove
166
Crankshaft
166
Checking Crankshaft Side Clearance
166
Checking Crankshaft Alignment
167
Checking Oil Clearance between Crankpin and Crankpin Bearing
167
Checking Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1
168
Replacing Crankshaft Bearing 1
169
Checking Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3)
169
Replacing Crankshaft Sleeve
170
Cylinder
171
Checking Cylinder Wear
171
Correcting Cylinder
172
Oil Pump
172
Checking Rotor Lobe Clearance
172
Checking Clearance between Outer Rotor and Pump Body
172
Checking Clearance between Rotor and Cover
173
Starter
173
Checking Overrunning Clutch
173
Checking Commutator and Mica
173
Checking Brush Wear
174
Checking Brush Holder
175
Checking Armature Coil
175
Checking Field Coil
175
Alternator
176
Checking Bearing
176
Checking Stator
176
Checking Rotor
176
Checking Slip Ring
176
Checking Brush Wear
177
Checking Rectifier
177
Checking IC Regulator Continuity
177
Transaxle
178
Mechanism
179
Structure of Transaxle
179
Hydraulic Transmission Section
180
HST Oil Flow
182
Power Transmission Operation
183
Pump and Motor
185
Check and High Pressure Relief Valve
186
Hydrostatic Control Linkage
188
Final Reduction Gear Section
189
Function of Final Reduction Gear
189
PTO Section
190
Structure of PTO
190
PTO Clutch "Disengaged
191
PTO Clutch "Engaged
191
Function of Regulator Valve
192
Parking Brake Section
193
Function of Parking Brake
193
Bevel Gear Section
194
Function of Bevel Gears
194
Servicing
195
Troubleshooting for Transaxle
195
Servicing Specifications for Transaxle
196
Tightening Torques for Transaxle
197
Checking and Adjusting
198
Checking Neutral
198
Adjusting Neutral
198
Checking Motion Control Lever Neutral Position
199
Adjusting Motion Control Lever Operating Force
200
Checking Motion Control Lever Alignment
200
Adjusting Maximum Speed
201
Checking High Pressure Relief Valve Pressure
201
Checking PTO Clutch Operating Pressure (Hydrostatic Transmission Charge Pressure)
202
Adjusting Parking Brake
203
Check on Slope
203
Disassembling and Assembling
204
Separating Transaxle Assembly
204
Draining Engine Oil
204
Draining Transmission Fluid
204
Draining Coolant
205
Removing the Battery
206
Removing the Bonnet
206
Removing Rear Engine Frame
207
Removing DPF Cover
207
Removing Air Cleaner Assembly
207
Disconnecting Engine Wiring Harness
208
Disconnecting Engine Fuel Hoses
209
Removing Engine Stoppers
209
Removing Universal Joint from Engine
209
Disconnecting Radiator Assembly
210
Separating the Engine
211
Removing Step and Center Step
211
Removing Seat Assembly
211
Removing Fuel Stabilizer
212
Removing Fenders
212
Removing Oil Cooler
212
Removing Radiator
213
Removing Fuel Tanks
213
Removing Speed Control Rods
213
Removing Hydraulic Lift Rod
213
Removing PTO Lever Assembly
214
Removing Cutting Height Adjusting Gear
214
Removing ROPS
215
Removing Rear Wheel
215
Removing Parking Brake
215
Separating Transaxle Assembly
216
Disassembling Transaxle Center Case
216
Removing Center Case Rear Cover
216
Removing PTO Clutch Shaft Assembly and Pump Gear Shaft
217
Removing Center Case
217
Removing Regulator Valve (HST Charge Pressure Relief Valve)
217
Removing PTO Clutch Lever
218
Separating Hydrostatic Transmission and Rear Axle Gear Case Assembly
218
Removing Input Shaft, Spiral Bevel Gear and Joint Shaft
218
Disassembling PTO Clutch Shaft Assembly
218
Draining Engine Oil
218
Draining Transmission Fluid
219
Draining Coolant
220
Removing the Battery
220
Removing the Bonnet
221
Removing DPF Cover
221
Removing Rear Engine Frame
221
Removing Air Cleaner Assembly
221
Disconnecting Engine Wiring Harness
222
Disconnecting Engine Fuel Hoses
223
Removing Engine Stoppers
223
Removing Universal Joint from Engine
223
Disconnecting Radiator Assembly
224
Separating the Engine
225
Removing Oil Cooler
225
Removing Radiator
226
Disconnecting Universal Joint and Removing PTO Shaft Oil Seal
226
Removing Center Case Rear Cover and PTO Clutch Shaft Assembly
226
Disassembling PTO Clutch Assembly
227
Disassembling Hydrostatic Transmission and Rear Axle Gear Case Assembly
227
Draining Transmission Fluid
227
Removing the Battery
228
Removing Step and Center Step
228
Removing Rear Wheels
228
Removing Parking Brake
229
Separating Hydrostatic Transmission and Rear Axle Gear Case Assembly
229
Removing Rear Axle Gear Case
230
Removing Center Section (Port Block)
230
Removing Check and High Pressure Relief Valve Assembly
230
Removing Cylinder Block Assembly and Thrust Ball Bearing
231
Removing Swashplate
231
Removing Slot Guide and Cradle Bearing
231
Removing Pump Shaft
232
Disassembling Rear Axle Case
232
Draining Transmission Fluid
232
Removing the Battery
233
Removing Step and Center Step
233
Removing Rear Wheels
233
Removing Parking Brake
234
Removing Rear Axle Gear Case
234
Removing Rear Axle
235
Removing Parking Brake
235
Disassembling Speed Lever
235
Removing the Battery
235
Removing Step and Center Step
236
Removing Seat Assembly
236
Removing Fenders
236
Removing Speed Lever Assembly
237
Servicing
237
Hydrostatic Transmission
237
Checking Center Section
237
Checking Check and High Pressure Relief Valve
237
Checking Cylinder Block Assembly
237
Checking Thrust Washer, Thrust Ball Bearing and Thrust Plate
238
Checking Pump Shaft
238
Checking Bush and Needle Bearing
238
Transmission Case
239
Checking Bearing
239
Checking Backlash and Tooth Contact between 16T or 18T Bevel Gear and 19T Bevel Gear
239
Correcting of Tooth Contact
239
PTO Clutch
240
Checking PTO Clutch Discs
240
Brake
241
Checking Brake Discs, Friction Plates and Actuator
241
Front Axle
243
Mechanism
244
Structure of Front Axle
244
Servicing
246
Troubleshooting for Front Axle
246
Servicing Specifications for Front Axle
247
Tightening Torques for Front Axle
248
Checking and Adjusting
249
Adjusting Front Axle Pivot
249
Disassembling and Assembling
249
Separating Front Wheel and Wheel Bracket
249
Removing the Front Wheel
249
Removing the Wheel Bracket
249
Separating Front Axle Assembly
250
Removing the Battery
250
Removing Step and Center Step
250
Hydraulic System
252
Mechanism
253
Function of Hydraulic Circuit
253
Hydraulic Pump
254
Definition of Hydraulic Control Valve
254
Neutral Position
255
Lift and Overloaded
256
Down Position
257
Function of Lift Cylinder
258
Function of Mower Linkage
259
Servicing
261
Troubleshooting for Hydraulic System
261
Servicing Specifications for Hydraulic System
262
Tightening Torques for Hydraulic System
263
Checking and Adjusting
264
Checking Relief Valve Setting Pressure
264
Disassembling and Assembling
264
Hydraulic Control Valve
264
Draining Transmission Fluid
264
Removing PTO Clutch Link, Cylinder Hose, Oil Cooler Pipe and HST Charge Pipes
265
Removing PTO Clutch Lever, Delivery Pipe, Pipe Fitting, Universal Joint and PTO Shaft Oil Seal
266
Removing Lift Shaft and Arm
267
Removing Hydraulic Control Valve
267
Removing Spool
267
Removing Relief Valve
268
Hydraulic Pump
268
Draining Engine Oil
268
Draining Transmission Fluid
269
Draining Coolant
270
Removing the Battery
270
Removing the Bonnet
270
Removing Rear Engine Frame
271
Removing DPF Cover
271
Removing Air Cleaner Assembly
271
Disconnecting Engine Wiring Harness
272
Disconnecting Engine Fuel Hoses
273
Removing Engine Stoppers
273
Removing Universal Joint from Engine
273
Disconnecting Radiator Assembly
274
Separating the Engine
275
Removing Oil Cooler
275
Removing Radiator
276
Disassembling Hydraulic Pump
276
Electrical System
277
Mechanism
278
Electrical Circuit of Starting System
278
Electrical Circuit of Charging System and Easy Checker
279
Electrical Circuit of Gauge System
280
Electrical Connector Chart
281
Reading Electrical Circuit Diagrams
282
How to Read Wiring Diagram
282
Layout of Connector Diagrams
285
Precautions on Handling Electrical Connectors
286
Starting System
287
Function of Relay
287
Function of Starter
287
Function of Glow Plug
288
Function of Safety Switch
288
Function of Fuel Pump
289
Function of Engine Stop Solenoid
289
Charging System
289
Function of Alternator
289
Function of Easy Checker
289
Service Code Display
290
Gauge System
291
Function of Fuel Level Sensor
291
Function of Coolant Temperature Sensor
291
Function of Oil Pressure Switch
292
Servicing
294
Troubleshooting for Electrical System
294
Servicing Specifications for Electrical System
297
Tightening Torques for Electrical System
298
Checking and Adjusting
299
Battery
299
Checking Battery Voltage
299
Checking Battery Terminal Connection
299
Checking Battery Specific Gravity
299
Starting System
300
Checking Main Switch Continuity
300
Testing Starter Motor
301
Testing Magnetic Switch
301
Checking Magnet Switch Continuity
302
OPC (Operator Presence Control) System
303
Checking OPC System
303
Checking OPC Continuity
305
Glow Plug
305
Checking Lead Terminal Voltage
305
Checking Glow Plug Continuity
305
Checking Glow Plug (Burner) Continuity
305
Checking Glow Plug (Heater) Continuity
306
Fuel Pump
306
Checking Fuel Pump Connector Voltage
306
Checking Fuel Pump Continuity
306
Engine Stop Solenoid
307
Engine Stop Solenoid Test
307
Charging System
307
Alternator on Unit Test
307
Easy Checker
307
Checking Engine Oil Pressure Lamp
307
Checking Horn Wiring Harness
308
Engine Control System
308
Checking Rack Sensor Continuity
308
Checking Blower
309
Checking Blower Flow Pressure Sensor
309
Checking Differential Pressure Sensor
309
Checking Temperature Sensor
310
Checking Doser Fuel Pump
310
Checking Engine Oil Pressure Switch Continuity
311
Checking Fuel Level Sensor
311
Checking Coolant Temperature Sensor Voltage
312
Checking Coolant Temperature Sensor Continuity
312
Relays
313
Checking Relay
313
Disassembling and Assembling
314
Disassembling Starter (Electromagnetic Drive Type)
314
Disassembling Alternator
316
Servicing
317
Starter
317
Checking Overrunning Clutch
317
Checking Commutator and Mica
317
Checking Brush Wear
318
Checking Brush Holder
319
Checking Armature Coil
319
Checking Field Coil
319
Charging System
320
Checking Bearing
320
Checking Stator
320
Checking Rotor
320
Checking Slip Ring
320
Checking Brush Wear
321
Checking Rectifier
321
Checking IC Regulator Continuity
321
Mower
322
Mechanism
323
Power Flow of Mower
323
Servicing
325
Troubleshooting for Mower
325
Servicing Specifications for Mower
326
Tightening Torques for Mower
327
Checking and Adjusting
328
Adjusting Anti-Scalp Rollers
328
Adjusting Left and Right Cutting Height
328
Adjusting Front and Rear Cutting Height
329
Disassembling and Assembling
330
Removing Universal Joint and Belt Covers
330
Removing Mower Blades (Center Blade and Outer Blades)
330
Removing Blade Boss
331
Removing Mower Belt
331
Disassembling Gear Box
331
Disassembling Center Pulley Holder
332
Disassembling Outer Pulley and Blade Shaft
332
Checking Turning Torque of Pinion Shaft
333
Checking Backlash between Bevel Gears
334
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