Kubota ZD21-EC, Workshop Manual

Page 1: ...ZD21N EC ZD21 EC ZD28 EC WORKSHOP MANUAL ZERO TURN MOWER KiSC issued 09 2006 A ...

Page 2: ...ing disassembling and servicing Servicing The heading GENERAL includes general precautions check and maintenance and special tools Other section there are troubleshooting servicing specification lists checking and adjusting disassembling and assembling and servicing which cover procedures precautions factory specifications and allowable limits All information illustrations and specifications conta...

Page 3: ...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 DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous sit...

Page 4: ...by a jack Always support the machine by safety stands Do not touch the rotating or hot parts while the engine is running Never remove the radiator cap while the engine is running or immediately after stopping Otherwise hot water will spout out from radiator Only remove radiator cap when cool enough to touch with bare hands Slowly loosen the cap to first stop to relieve pressure before removing com...

Page 5: ...to eyes Keep electrolyte away from eyes hands and clothing If you spill electrolyte on yourself flush with water and get medical attention immediately DISPOSE OF FLUIDS PROPERLY Do not pour fluids into the ground down a drain or into a stream pond or lake Observe relevant environmental protection regulations when disposing of oil fuel coolant electrolyte and other harmful waste PREPARE FOR EMERGEN...

Page 6: ...AFETY INSTRUCTIONS 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 SAFETY DECALS KiSC issued 09 2006 A ...

Page 7: ...5 ZD21N EC ZD21 EC ZD28 EC WSM SAFETY INSTRUCTIONS KiSC issued 09 2006 A ...

Page 8: ...6 ZD21N EC ZD21 EC ZD28 EC WSM SAFETY INSTRUCTIONS KiSC issued 09 2006 A ...

Page 9: ... C 32 F SAE 10W or 10W 30 0 to 25 C 32 F to 77 F SAE 20 or 10W 30 Above 25 C 77 F SAE 30 or 10W 30 Starting system Electric starter 12 V 1 1 kW Battery 51 R 12 V 450 CCA Fuel No 2 D Diesel fuel ASTM D975 No 1 D diesel fuel if temperature is below 10 C 14 F Capacities Fuel tank 30 L 5 8 U S gals 4 8 lmp gals Engine crankcase 3 5 L 3 7 U S qts 3 1 Imp qts 3 4 L 3 6 U S qts 3 0 Imp qts Engine coolant...

Page 10: ... at 3200 engine rpm 1 speed 2540 rpm at 3000 engine rpm PTO brake Wet single disc Steering 2 Hand levers Transmission 2 Hydrostatic transmission with gear Brake Internal expanding shoe Hand Model RCK54 21NZ EC RCK54 21NZ EC RCK60 28Z EC RCK72 28Z EC Mower Suitable machine ZD21N EC ZD21N EC ZD28 EC Mounting method Quick joint parallel linkage Adjustment of cutting height Dial gauge Cutting width 13...

Page 11: ...9 ZD21N EC ZD21 EC ZD28 EC WSM DIMENSIONS DIMENSIONS KiSC issued 09 2006 A ...

Page 12: ...G GENERAL KiSC issued 09 2006 A ...

Page 13: ...F THREADS G 10 5 PLUGS G 10 6 MAINTENANCE CHECK LIST G 11 7 CHECK AND MAINTENANCE G 13 1 DAILY CHECK G 13 2 CHECK POINTS OF INITIAL 50 HOURS G 17 3 CHECK POINT OF INITIAL 100 HOURS G 19 4 CHECKING POINTS OF INITIAL 200 HOURS G 20 5 CHECK POINTS OF EVERY 50 HOURS G 22 6 CHECK POINTS OF EVERY 100 HOURS G 26 7 CHECK POINTS OF EVERY 150 HOURS G 31 8 CHECK POINTS OF EVERY 200 HOURS G 31 9 CHECK POINTS ...

Page 14: ...l KUBOTA distributor always specify engine serial number 3 machine serial number 2 mower serial number 4 and hour meter reading W1010714 1 Machine Identification Plate 2 Machine Serial Number 3 Engine Serial Number 4 Mower Serial Number 5 Mower Identification Plate KiSC issued 09 2006 A ...

Page 15: ...ing Use only KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety Gaskets and O rings must be replaced during reassembly Apply grease to new O rings or oil seals before assembling See the figure left side When reassembling external snap rings or internal snap rings they must be positioned so that sharp edge faces against the direction from which a force i...

Page 16: ...ler to perform periodic check for a fee Do not attempt to modify or remodel any electrical parts and wiring When removing the battery cables disconnect the negative cable first When installing the battery cables connect the positive cable first W1011114 1 WIRING Securely tighten wiring terminals W1011216 Do not let wiring contact dangerous part W1011313 Securely insert grommet W1011388 1 Negative ...

Page 17: ...art where sag be required W1011587 In installing a part take care not to get wiring caught by it W1011670 After installing wiring check protection of terminals and clamped condition of wiring only connect battery W1011735 1 Clamp Wind Clamp Spirally 2 Wire Harness 3 Clamp 4 Welding Dent 1 Wiring 2 Clamp A Correct B Incorrect 1 Wiring A Incorrect 1 Cover Securely Install Cover KiSC issued 09 2006 A...

Page 18: ...f with water immediately Before recharging the battery remove it from the machine Before recharging remove cell caps Do recharging in a well ventilated place where there is no open flame nearby as hydrogen gas and oxygen are formed W1011816 3 FUSE Use fuses with specified capacity Neither too large or small capacity fuse is acceptable Never use steel or copper wire in place of fuse Do not install ...

Page 19: ...terminal being exposed or displaced W1012346 Make certain that there is no female connector being too open W1012430 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provided with tester Check for polarity and range W1012684 1 Exposed Terminal 2 Bend Terminal 3 Sandpaper 4 Rust A Correct B Incorrect KiSC issued 09 2006 A ...

Page 20: ...ts 3 3 Imp qts Fresh clean water soft water with anti freeze Recovery tank 0 25 L 0 26 U S qts 0 22 Imp qts 3 Engine crankcase 3 5 L 3 7 U S qts 3 1 Imp qts 3 4 L 3 6 U S qts 3 0 Imp qts Engine oil API Service Classification CC or CD Below 0 C 32 F SAE10W 10W 30 or 10W 40 0 to 25 C 32 to 77 F SAE20 10W 30 or 10W 40 Above 25 C 77 F SAE30 10W 30 or 10W 40 4 Transmission case 3 2 L 3 4 U S qts 2 8 Im...

Page 21: ... purpose type grease 8 Speed control lever 2 9 Center pin 1 10 King pin 2 11 Front wheel 2 12 Front lift arm 2 13 Universal joint 3 14 Seat adjuster 2 15 Throttle cable 2 Moderate amount Engine oil Greasing Mower 16 Universal joint 3 Until grease overflows SAE multi purpose type grease 17 Three spindle shafts 3 18 Belt tension pulley 1 19 Belt tension pivot 1 KiSC issued 09 2006 A ...

Page 22: ... to 4 6 29 0 to 33 2 31 4 to 34 3 3 2 to 3 5 23 2 to 25 3 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 39 3 to 44 1 4 0 to 4 5 29 0 to 32 5 60 9 to 70 6 6 2 to 7 2 44 9 to 52 0 M12 12 mm 0 47 in 62 8 to 72 5 6 4 to 7 4 46 3 to 53 5 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 62 8 to 72 5 6 4 to 7 4 46 3 to 53 5 103 to 117 10 5 to 12 0 76 0 to 86 7 M14 14 mm 0 55 in 108 to 125 11 0 to 12 8 79 6 to 92 5 124 to 147...

Page 23: ...o 2 84 17 0 to 20 5 32 5 to 39 3 3 31 to 4 01 24 0 to 29 0 3 8 47 5 to 57 0 4 84 to 5 82 35 0 to 42 0 61 0 to 73 2 6 22 to 7 47 45 0 to 54 0 1 2 108 5 to 130 2 11 07 to 13 29 80 0 to 96 0 149 2 to 179 0 15 22 to 18 27 110 0 to 132 0 9 16 149 2 to 179 0 15 22 to 18 27 110 0 to 132 0 217 0 to 260 4 22 14 to 26 57 160 0 to 192 0 5 8 203 4 to 244 1 20 75 to 24 91 150 0 to 180 0 298 3 to 358 0 30 44 to...

Page 24: ...e every 200 hr G 21 4 Transmission oil filter Replace every 200 hr G 18 5 Transmission strainer Clean every 200 hr G 20 6 Rear axle gear case RH LH fluid Change every 200 hr G 21 7 Front axle pivot Adjust every 200 hr G 19 8 Safety device Check every 50 hr G 22 9 Greasing without mower every 50 hr G 24 10 Mower gear box oil Check every 150 hr G 26 Change every 150 hr 11 Air cleaner element Clean e...

Page 25: ... 2 years 18 Hydraulic hose Check every 200 hr G 31 Replace every 2 years 19 Intake air line Check every 200 hr G 32 Replace every 2 years 2 20 Motion control lever pivot Adjust every 200 hr G 32 21 Radiator Clean every 1 year G 34 22 Coolant Change every 1 year G 34 23 Mower gear box oil seal Replace every 2 years G 36 24 Fuel system Bleed Service as required G 38 25 Fuse Replace G 37 26 Blade Rep...

Page 26: ...id level 5 Coolant level in the recovery tank 6 Damage of machine body tightness of all bolts and nuts 7 Radiator screen 8 Panel screen 9 Brake play 10 Air cleaner 11 Fuel level 12 Oiling Mower 1 Oil leak 2 Make sure blade cap screws are tight 3 Check blades for wear or damage 4 Check all hardware 5 Make sure all pins are in place 6 Mower deck cleaning 7 Greasing While sitting in the operator s se...

Page 27: ...550 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 Raise and lock the operator s seat 3 To check the oil level draw out the dipstick wipe it clean replace it and draw it out again Check to see that the oil level lies between the two notches If the level is too low add new oil to the prescribed level ...

Page 28: ...istilled water and anti freeze to fill the recovery tank W1042377 Checking Engine Oil Level CAUTION To avoid personal injury 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 3 To check the oil level remove the dipstick wipe it clean replace it and draw it out again Check to...

Page 29: ...section 4 If scale forms in the tube clean with the scale inhibitor or its equivalent 5 Each time the panel screen is covered with grass during operation rub it off the screen with hand Check the radiator screen from time to time if grass accumulates 6 If the dust or chaff has accumulated inside of the panel remove the radiator screen and clean inside completely After cleaning replace the radiator...

Page 30: ...pletely 4 Screw in the drain plug 1 5 Fill new oil up to upper line on the dipstick 3 IMPORTANT When using an oil of different manufacture or viscosity from the previous one remove all of the old oil Never mix two different type of oil Use the proper SAE engine oil according to ambient temperatures Refer to LUBRICANTS FUEL AND COOLANT See page G 7 W1030749 Engine oil capacity ZD21N ZD21 3 5 L 3 7 ...

Page 31: ... Replacing Transmission Oil Filter Cartridge CAUTION Be sure to stop the engine before changing the oil filter cartridge Allow transmission case to cool down sufficiently oil can be hot and may cause burns 1 The oil filter cartridge must be changed every 300 service hours 2 Remove the oil filter cartridge with the filter wrench 3 Lightly tighten the screw 2 by using a screwdriver 4 Apply a slight ...

Page 32: ...spring 5 and adjust the end play by slotted nut 1 When reassembling NOTE When fastening the center pin 4 tighten the nut 1 so that the front axle maybe oscillated smoothly by hand W1053511 Tightening torque Center pin lock nut Slotted nut 40 to 80 N m 4 08 to 8 16 kgf m 29 50 to 59 00 ft lbs Front axle end play A Factory spec 0 to 0 2 mm 0 to 0 008 in Allowable limit 0 5 mm 0 02 in 1 Slotted Nut 2...

Page 33: ...BRICANTS FUEL AND COOLANT See page G 7 Never work the machine immediately after changing the transmission oil Keeping the engine at medium speed for a few minutes prevents damage to the transmission Do not mix different brands oil together W1048918 Cleaning Transmission Strainer When changing the transmission fluid disassemble and rinse the strainer with nonflammable solvent to completely clean of...

Page 34: ...ter running the engine for a few minutes stop it and check the oil level again if low add oil to prescribed level IMPORTANT Use only multi grade transmission oil Use of other oils may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 7 Never work the machine immediately after changing the transmission oil Keeping the engine at medium speed for a few minute...

Page 35: ...ing brake 2 Shift the PTO lever 4 to DISENGAGE OFF position 3 Grasp the motion control levers 3 and move then inward from NEUTRAL LOCK position to NEUTRAL position and then release the levers 4 Turn the key switch 5 to START position 5 The engine must not crank Test 4 OPERATOR ON THE SEAT 1 Securely set the parking brake 2 Shift the PTO lever 4 to ENGAGE ON position 3 Grasp the motion control leve...

Page 36: ... position to NEUTRAL position and then release the levers 5 Stand up Do not get off the machine 6 The engine must shut off Test 7 OPERATOR ON THE SEAT 1 Start the engine 2 Do not set the parking brake 3 Shift the PTO lever 4 to ENGAGE ON position 4 Stand up Do not get off the machine 5 The engine must shut off W1032761 1 Parking Brake Lock Pedal 2 Parking Brake Release Lever 3 Motion Control Lever...

Page 37: ...ion as figures CAUTION To avoid personal injury Be sure to stop the engine and remove the key before greasing W1034228 1 King Pin LH RH 2 Center Pin 3 Front Wheel LH RH 4 Front Lift Arm LH RH 5 Motion Control Levers LH RH 6 Motion Control Lever Boss LH RH 7 Seat Adjuster KiSC issued 09 2006 A ...

Page 38: ...Greasing Continued 1 Apply a grease to the following position as figures CAUTION To avoid personal injury Be sure to stop the engine and remove the key before greasing W1035206 1 Machine Universal Joint 2 Throttle Cable Oil KiSC issued 09 2006 A ...

Page 39: ... see that the oil level is just below the check plug port If the level is too low add new oil to the prescribed level at the oil inlet See page G 7 W1054012 6 CHECK POINTS OF EVERY 100 HOURS Checking Battery Condition CAUTION Never remove the vent cap while the engine is running Keep electrolyte away from eyes hands and clothes If you are spattered with it wash it away completely with water immedi...

Page 40: ...arge the battery connect the battery positive terminal to the charger positive terminal and the negative to the negative then recharge in the standard fashion 4 A boost charge is only for emergencies It will partially charge the battery at a higher rate and in a short time When using a boost charged battery it is necessary to recharge the battery as soon as possible Failure to do this will shorten...

Page 41: ... prevent dust and dirt from entering In addition particular care must be taken not to admit dust and dirt into the fuel pump Entrance of dust and dirt causes malfunction of the fuel pump and injector components W1034725 Changing Engine Oil 1 See page G 17 W1034674 Adjusting Fan Belt Tension CAUTION Be sure to stop the engine and remove the key before checking belt tension 1 If the fan drive belt b...

Page 42: ...osition 2 Be sure to chock the rear wheels 3 Apply the parking brake to the notch 4 Check the length of the brake springs on both sides 5 Release the parking brake 6 Pull the brake rod fully forward by hand and hold 7 Check the brake spring play 8 If these dimensions are not correct adjust Proper brake spring length at the first notch B 56 mm 2 2 in Proper brake spring play C 1 0 to 2 0 mm 0 04 to...

Page 43: ...he same dimension Check the play of parking brake lock pedal 1 Place the motion control levers to NEUTRAL LOCK position 2 Be sure to chock the rear wheels 3 Release the parking brake completely 4 Check that parking brake release lever moves at the same time as the parking brake lock pedal is depressed 5 If parking brake release lever does not move momentarily adjust Adjustment of parking brake loc...

Page 44: ...an the boiling point what is called Overheating Park the machine in a safe place and keep the engine unloaded idling Don t stop the engine suddenly but stop it after about 5 minutes of unloaded idling Keep yourself well away from the machine for further 10 minutes or while the steam is blown out Checking that there gets no danger such as burning get rid of the causes of overheating and then start ...

Page 45: ...ceeded remove the fender and retighten the nut 3 to specified torque NOTE If the motion control lever pivot bolt 2 is maladjusted motion control may be difficult W1063124 Checking Intake Air Line 1 Check to see that hoses and hose clamps are tight and not damaged 2 If hoses and clamps are found worn or damaged replace or repair them at once W1037686 Lever free travel A Factory spec 2 to 15 mm 0 08...

Page 46: ...lement 2 once a year IMPORTANT The air cleaner uses a dry element never apply oil Do not run the engine with filter element removed Be sure to refit the air cleaner cover 1 as shown in the figure If the air cleaner cover 1 is improperly fitted evacuator valve 3 will not function and dust will adhere to the element If it is loose dust and dirt may be sucked in wearing down the cylinder and piston r...

Page 47: ...stall the radiator cap 1 securely 7 Fill with coolant up to FULL mark on the recovery tank 8 Start and operate the engine for a few minutes 9 Stop the engine and let cool Check coolant level of recovery tank 2 and add coolant if necessary IMPORTANT Do not start engine without coolant Use clean fresh water and anti freeze to fill the radiator and recovery tank When the anti freeze is mixed with wat...

Page 48: ... Mix the anti freeze with water and then fill in to the radiator At 101 kPa 760 mmHg pressure atmospheric A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system NOTE The above date represent industry standards that necessitate a minimum glycol content in the concentrates anti freeze When the coolant level drops due to...

Page 49: ...ator Hose and Hose Clamp See page G 31 W1067436 Replacing Fuel Lines 1 Replace the fuel line Refer to Checking Fuel Lines and Fuel Filter See page G 28 W1082371 Replacing Intake Air Line 1 Replace the intake air line Refer to Checking Intake Air Line See page G 32 W1037080 Replacing Mower Gear Box Seals 1 Replace the mower gear box oil seals 1 2 Refer to Disassembling Gear Box Assembly See page 6 ...

Page 50: ...jury always handle the mower blade with care 1 Tilt up the mower and turn it over to expose the mower blades 2 Wedge a wooden block 1 securely between the mower blade and mower deck 3 Retighten the mower blade screw to the specified torque 4 If the mower blade screw 2 is worn or broken replace it NOTE The screw of the red painted mower blade is of inverse helical type W1022525 FUSE NO ID LABEL CAP...

Page 51: ...essively Replace the 2 cup washers if either is damaged W1022841 Replacing Mower Belt 1 Remove the mower deck from the machine 2 Remove the left and right hand shield from the mower deck 3 Clean around the gear box 4 Remove the belt from the tension pulley 5 Remove the right hand bracket which mounts the gear box to the mower deck and slip the belt over the top of the gear box 6 To install a new b...

Page 52: ...nder W1048361 Piston Ring Tool Code No 07909 32121 Application Use exclusively for removing or installing the piston ring with ease W1048421 Diesel Engine Compression Tester Code No 07909 30208 Assembly 07909 31251 G 07909 30934 A to F 07909 31271 I 07909 31211 E and F 07909 31281 J 07909 31231 H Application Use to measure diesel engine compression and diagnostics of need for major overhaul W10484...

Page 53: ...551 Application Use to check of radiator cap pressure and leaks from cooling system Remarks Adapter 1 BANZAI Code No RCT 2A 30S W1049045 Connecting Rod Alignment Tool Code No 07909 31661 Application Use to check the connecting rod alignment Applicable Connecting rod big end I D range 30 to 75 mm 1 18 to 2 95 in dia Connecting rod length 65 to 300 mm 2 57 to 11 81 in W1049118 Flywheel Puller Code N...

Page 54: ... No 07909 31371 Application Use to check cracks on cylinder head cylinder block etc W1050024 NOTE 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 W1050106 A 20 mm dia 0 79 in dia B 9 96 to 9 98 mm dia 0 3921 to 0 3929 in dia C 5 5 to 5 7 mm dia 0 2165 to 0 2244 in dia D 200 mm 7 ...

Page 55: ... the plat E Injection pipe F PF1 2 G 5 mm 0 20 in H 17 mm dia 0 67 in dia I 8 mm dia 0 31 in dia J 1 0 mm 0 039 in K 17 mm dia 0 67 in dia L 6 10 to 6 20 mm dia 0 2402 to 0 2441 in dia M 8 mm 0 31 in N 4 mm 0 16 in O 11 97 to 11 99 mm dia 0 4713 to 0 4721 in dia P PF1 2 Q 23 mm 0 91 in R 17 mm 0 67 in S 4 mm 0 16 in T 12 00 to 12 02 mm dia 0 4724 to 0 4732 in dia U 100 mm 3 94 in V M12 P1 5 a Adhe...

Page 56: ...854 in dia E 21 90 to 21 95 mm dia 0 8622 to 0 8642 in dia F 25 mm dia 0 98 in dia a 6 3 μ m 250 μ in b 6 3 μ m 250 μ in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in A 150 mm 5 91 in B 20 mm 0 79 in C 100 mm 3 94 in D 19 90 to 19 95 mm 0 7835 to 0 7854 in E 21 90 to 21 95 mm 0 8622 to 0 8642 in F 25 mm 0 98 in a 6 3 μ m 250 μ in b 6 3 μ m 250 μ in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0...

Page 57: ...mm 5 31 in B 72 mm 2 83 in C 1 57 rad 40 D 10 mm 0 39 in E 22 mm 0 87 in F 20 mm dia 0 79 in dia G 48 90 to 48 95 mm dia 1 9251 to 1 9271 in dia H 43 90 to 43 95 mm dia 1 7283 to 1 7303 in dia A 130 mm 5 12 in B 72 mm 2 83 in C 1 57 rad 40 D 9 mm 0 35 in E 24 mm 0 95 in F 20 mm dia 0 79 in dia G 68 mm dia 0 79 in dia H 39 90 to 39 95 mm dia 1 5709 to 1 5728 in dia KiSC issued 09 2006 A ...

Page 58: ...040355 1 Gauge 07916 50322 2 Cable 07916 50331 3 Threaded Joint 07916 50401 4 Threaded Joint 07916 50341 5 Adaptor B M18 P1 5 07916 50361 6 Adaptor C PS3 8 07916 50371 7 Adaptor D PT1 8 07916 50381 8 Adaptor E PS3 8 07916 50392 9 Adaptor F PF1 2 07916 62601 10 Adaptor 58 PT1 4 07916 52391 A 80 mm 3 15 in B 20 mm 0 79 in C 60 mm 2 36 in D G 1 4 15 mm 0 59 in E 12 mm 0 47 in F 13 mm dia 0 51 in dia ...

Page 59: ...1 ENGINE KiSC issued 09 2006 A ...

Page 60: ...CONTENTS MECHANISM 1 FUEL SYSTEM 1 M1 1 GOVERNOR 1 M1 KiSC issued 09 2006 A ...

Page 61: ...oked to a thrust lever and holds the control rack in the direction of the increase Fork lever 2 7 and the floating lever are installed in fork lever 1 6 with the fork lever shaft 2 The max torque limitation 3 device limits the amount of the fuel exhalation at the overload with the torque pin 0000004865E At Rated Operation When the engine is running the fork lever 2 7 and the floating lever 8 are m...

Page 62: ...ply with the help of the torque spring tension The fuel supply increases C in relation to the degree of the torque pin motion thus preventing the engine speed from dropping At the time the maximum torque limiter 3 prevents superfluous fuel supply and suppresses the generation of black smoke W1013813 3 Max Torque Limiter 4 Start Spring 6 Fork Lever 1 7 Fork Lever 2 8 Floating Lever 9 Torque Pin 10 ...

Page 63: ...16 4 TIGHTENING TORQUES 1 S17 5 CHECKING DISASSEMBLING AND SERVICING 1 S19 1 SEPARATING ENGINE 1 S19 1 Disassembling and Assembling 1 S19 2 ENGINE BODY 1 S25 1 Checking and Adjusting 1 S25 2 Disassembling and Assembling 1 S28 3 Servicing 1 S42 3 LUBRICATING SYSTEM 1 S66 1 Checking 1 S66 2 Servicing 1 S66 4 COOLING SYSTEM 1 S68 1 Checking and Adjusting 1 S68 2 Disassembling and Assembling 1 S70 5 F...

Page 64: ...witch defective Motion control lever switch defective Seat switch defective Wiring harness disconnected Replenish fuel Bleed fuel system Change fuel and replace fuel system Clean fuel pipe Replace fuel filter Use specified fuel or engine oil Use specified fuel Tighten retaining nut Adjust injection timing Replace fuel camshaft Clean injection nozzle Repair or replace injection pump Replace cranksh...

Page 65: ...gs 1 S 39 S65 1 S71 Either Black or Dark Gray Exhaust Gas Is Observed Overload Low grade fuel used Fuel filter clogged Air cleaner clogged Deficient nozzle injection Lessen load Use specified fuel Replace fuel filter Clean or replace air cleaner element Repair or replace nozzle G 33 G 28 1 S29 S74 Deficient Output Incorrect injection timing Engine s moving parts seem to be seized Uneven fuel injec...

Page 66: ...ge clogged Relief valve stuck with dirt Relief valve spring weaken or broken Excessive oil clearance of crankshaft bearing Excessive oil clearance of crankpin bearing Excessive oil clearance of rocker arm Oil passage clogged Different type of oil Oil pump defective Replenish engine oil Clean oil strainer Change engine oil filter cartridge Clean or replace relief valve Replace relief valve spring R...

Page 67: ...nt flow route corroded Radiator cap defective Overload running Head gasket defective Incorrect injection timing Unsuitable fuel used Replenish engine oil Replace fan belt or adjust fan belt tension Replenish coolant Clean radiator net and radiator fin Clean inside of radiator or replace radiator Clean or replace coolant flow route Replace radiator cap Loosen load Replace head gasket Adjust injecti...

Page 68: ...ld 0 145 to 0 185 mm 0 00571 to 0 00728 in Valve Seat Width 2 12 mm 0 0835 in Valve Seat Angle 0785 rad 45 Valve Face Angle 0785 rad 45 Valve Recessing 0 10 to 0 10 mm 0 0039 to 0 0039 in 0 3 mm 0 0118 in Valve Stem to Valve Guide Valve Stem Valve Guide Clearance O D I D 0 030 to 0 057 mm 0 00118 to 0 00224 in 5 968 to 5 980 mm 0 23496 to 0 23543 in 6 010 to 6 025 mm 0 23661 to 0 23720 in 0 10 mm ...

Page 69: ...0 518 mm 0 41339 to 0 41410 in 0 15 mm 0 0059 in Push Rod Alignment 0 25 mm 0 0098 in Tappet to Guide Tappet Tappet Guide Clearance O D I D 0 016 to 0 052 mm 0 00063 to 0 00205 in 17 966 to 17 984 mm 0 70732 to 0 70803 in 18 000 to 18 018 mm 0 70866 to 0 70937 in 0 10 mm 0 0039 in Camshaft Side Clearance 0 15 to 0 31 mm 0 0059 to 0 0122 in 0 50 mm 0 0197 in Camshaft Alignment 0 01 mm 0 0004 in Cam...

Page 70: ...9 980 mm 0 78610 to 0 78661 in 20 000 to 20 051 mm 0 78740 to 0 78941 in 0 10 mm 0 0039 in Idle Gear Side Clearance 0 13 to 0 49 mm 0 0051 to 0 0193 in 0 60 mm 0 0236 in Piston Pin Bore I D 20 000 to 20 013 mm 0 78740 to 0 78791 in 20 05 mm 0 7894 in Piston Ring Clearance Second Ring Oil Ring 0 090 to 0 120 mm 0 00354 to 0 00472 in 0 04 to 0 08 mm 0 0016 to 0 0031 in 0 15 mm 0 0059 in 0 15 mm 0 00...

Page 71: ...79 in Crankshaft Journal to Crankshaft Bearing 3 Intermediate Crankshaft Journal Crank bearing 3 Oil Clearance O D I D 0 028 to 0 059 mm 0 00110 to 0 00232 in 39 934 to 39 950 mm 1 57221 to 1 57284 in 39 978 to 39 993 mm 1 57394 to 1 57453 in 0 20 mm 0 0079 in Crankpin and Crankpin Bearing Crankpin Crankpin Bearing Oil Clearance O D I D 0 020 to 0 051 mm 0 00079 to 0 00201 in 33 959 to 33 975 mm 1...

Page 72: ...0 0055 in Outer Rotor to Pump Body Clearance 0 07 to 0 15 mm 0 0028 to 0 0059 in Inner Rotor to Cover End Clearance 0 075 to 0 135 mm 0 00295 to 0 00531 in Thermostat Valve Opening Temperature At Beginning Valve Opening Temperature Opened Completely 80 5 to 83 5 C 176 9 to 182 3 F 95 C 203 F Radiator Water Tightness Water tightness at specified pressure 137 kPa 1 4 kgf cm2 20 psi Radiator Cap Air ...

Page 73: ... C Pump Element Fuel Tightness 14 7 MPa 150 kgf cm2 2130 psi Delivery Valve Fuel Tightness 5 seconds 14 7 13 7 MPa 150 140 kgf cm2 2130 1990 psi Fuel Injection Nozzle Injection Pressure 13 7 to 14 7 MPa 140 to 150 kgf cm2 1990 to 2130 psi Nozzle Valve Seat Fuel Tightness When the pressure is 12 7 MPa 130 kgf cm2 1850 psi the valve seat must be fuel tightness KiSC issued 09 2006 A ...

Page 74: ...mm 0 0057 to 0 0072 in Valve Seat Width 2 12 mm 0 0835 in Valve Seat Angle Intake Angle Exhaust 1 047 rad 60 0 785 rad 45 Valve Face Angle Intake Angle Exhaust 1 047 rad 60 0 785 rad 45 Valve Recessing 0 05 to 0 15 mm 0 0020 to 0 0059 in 0 40 mm 0 0157 in Valve Stem to Valve Guide Valve Stem Valve Guide Clearance O D I D 0 035 to 0 065 mm 0 0014 to 0 0026 in 6 960 to 6 975 mm 0 2740 to 0 2746 in 7...

Page 75: ...039 in Push Rod Alignment 0 25 mm 0 0098 in Tappet to Tappet Guide Tappet Tappet Guide Clearance O D I D 0 020 to 0 062 mm 0 00079 to 0 00244 in 19 959 to 19 980 mm 0 78579 to 0 78661 in 20 000 to 20 021 mm 0 78740 to 0 78823 in 0 07 mm 0 0028 in Camshaft Side Clearance 0 07 to 0 22 mm 0 0028 to 0 0087 in 0 30 mm 0 0118 in Camshaft Alignment 0 01 mm 0 0004 in Cam Height Intake Exhaust 28 80 mm 1 1...

Page 76: ...e O D I D 0 020 to 0 054 mm 0 0008 to 0 0021 in 25 967 to 25 980 mm 1 0223 to 1 0228 in 26 000 to 26 021 mm 1 0236 to 1 0244 in 0 10 mm 0 0039 in Piston Pin Bore I D 22 000 to 22 013 mm 0 8661 to 0 8667 in 22 03 mm 0 8673 in Piston Ring Clearance Second Ring Oil Ring 0 095 to 0 112 mm 0 0037 to 0 0044 in 0 02 to 0 06 mm 0 0008 to 0 0022 in 0 20 mm 0 0079 in 0 15 mm 0 0059 in Ring Gap Top Ring and ...

Page 77: ...to 1 89091 in 0 20 mm 0 0079 in Crankpin to Crankpin Bearing Crankpin Crankpin Bearing Oil Clearance O D I D 0 029 to 0 091 mm 0 00114 to 0 00358 in 39 959 to 39 975 mm 1 57319 to 1 57382 in 40 004 to 40 050 mm 1 57496 to 1 57677 in 0 20 mm 0 0079 in Crankshaft Journal to Crankshaft Bearing 3 Crankshaft Journal Crankshaft Bearing 3 Oil Clearance O D I D 0 034 to 0 098 mm 0 00134 to 0 00386 in 51 9...

Page 78: ... Rotor to Pump Body Clearance 0 100 to 0 180 mm 0 0039 to 0 0071 in Rotor to Cover Clearance 0 025 to 0 075 mm 0 0010 to 0 0029 in Thermostat Valve Opening Temperature At Beginning Valve Opening Temperature Opened Completely 80 5 to 83 5 C 176 9 to 182 3 F 95 C 203 F Radiator Water Leakage Test Pressure No leaks at 137 kPa 1 4 kgf cm2 20 psi Radiator Cap Pressure Falling Time 10 seconds or more fo...

Page 79: ...s 10 seconds or more for pressure falling from 14 7 to 13 7 MPa from 150 to 140 kgf cm2 from 2133 to 1990 psi 5 seconds for pressure falling from 14 7 to 13 7 MPa from 150 to 140 kgf cm2 from 2133 to 1990 psi Fuel Injection Nozzle Injection Pressure 13 73 to 14 71 MPa 140 to 150 kgf cm2 1991 to 2133 psi Fuel Injection Nozzle Valve Seat Valve Seat Tightness When the pressure is 12 75 MPa 130 kgf cm...

Page 80: ... 7 to 2 9 4 9 to 5 7 2 4 to 2 8 1 8 to 2 1 7 2 to 10 1 19 2 to 20 7 35 4 to 41 2 17 4 to 20 3 13 0 to 15 2 Cylinder head screw Cylinder head cover cap nut Injection pipe retaining nut Nozzle holder assembly Overflow pipe assembly retaining nut nozzle Glow plug Rocker arm bracket nut Fan drive pulley retaining screw Idle gear shaft mounting screw Connecting rod screw Flywheel bolt Main bearing case...

Page 81: ...w Injection pipe retaining nut Main bearing case screw 1 Main bearing case screw 2 Nozzle holder Nozzle holder assembly Oil pressure switch Overflow pipe assembly retaining nut Rocker arm bracket nut M10 1 25 M6 1 0 M8 1 0 M7 1 0 M10 1 25 M14 1 5 M10 1 25 M8 1 0 M6 1 0 M12 1 5 M8 1 25 M9 1 25 M20 1 5 PT 1 8 M12 1 5 M7 1 0 48 1 to 55 9 9 8 to 11 3 41 2 to 46 1 6 9 to 8 8 63 7 to 68 6 235 4 to 245 2...

Page 82: ...lug 1 to drain oil 5 After draining screw in the drain plug 1 When refilling Fill the engine oil up to the upper line on the dipstick 3 IMPORTANT Never mix two different type of oil Use the proper SAE Engine Oil according to ambient temperatures Refer to LUBRICANTS FUEL AND COOLANT See page G 7 W1019220 Engine oil Capacity D782 ZD21N ZD21 3 5 L 3 7 U S qts 3 1 Imp qts D1105 ZD28 3 4 L 3 6 U S qts ...

Page 83: ...move the radiator coolant drain plug 3 and engine coolant drain plug 4 to drain the coolant 3 Remove the radiator cap 1 to completely drain the coolant 4 After all coolant is drained close the drain plugs W1019510 Coolant capacity ZD21N ZD21 Radiator 2 6 L 2 7 U S qts 2 3 lmp qts ZD28 Radiator 3 8 L 4 0 U S qts 3 3 lmp qts Recovery tank 0 25 L 0 26 U S qts 0 22 lmp qts 1 Radiator Cap 2 Recovery Ta...

Page 84: ...p pin and bonnet mounting screw then remove the bonnet 1 2 Remove the rear bumper 2 W1019921 Panel Screen Shutter Plate and Others 1 Disconnect the wire harness 1 and positive cable 2 battery side first 2 Disconnect the accelerator wire 3 3 Disconnect the fuel hoses 4 4 Remove the panel screen 5 and shutter plate 6 IMPORTANT When disconnecting the fuel hoses be careful not to let the fuel spill ou...

Page 85: ...r 7 5 Remove the starter 11 6 Disconnect the inlet pipe 2 air cleaner 1 and air cleaner stay 5 7 Remove the wire bracket 8 Remove the engine support LH 12 and RH 6 When reassembling Check to see that there are no cracks on the belt surface IMPORTANT After reassembling the fan belt be sure to adjust the fan belt tension Tightening torque Universal joint mounting screw 26 0 to 28 0 N m 2 7 to 2 9 kg...

Page 86: ... and muffler 8 5 Remove the panel screen 6 IMPORTANT When disconnecting the fuel hoses be careful not to let the fuel spill out the hoses Engine Disassembly 1 Remove the universal joint mounting screws 2 2 Disconnect the universal joint 3 from fun drive pulley 3 Remove the engine mounting nuts 4 Separate the engine with the radiator from the frame take care not to damage the radiator When reassemb...

Page 87: ...cleaner stay 3 6 Remove the wire bracket 7 Remove the engine support LH 9 and RH 4 When reassembling Check to see that there are no cracks on the belt surface IMPORTANT After reassembling the fan belt be sure to adjust the fan belt tension Tightening torque Engine support mounting screw 48 1 to 55 9 N m 4 9 to 5 7 kgf m 35 4 to 41 2 ft lbs 1 Radiator 2 Cooling Fan 3 Air Cleaner Stay 4 Engine Suppo...

Page 88: ...ylinder 10 If the measurement is below the allowable limit apply a small amount of oil to the cylinder wall through the nozzle hole and measure the compression pressure again 11 If the compression pressure is still less than the allowable limit check the top clearance valve clearance and cylinder head 12 If the compression pressure increases after applying oil check the cylinder wall and piston ri...

Page 89: ...e crank shaft until the piston exceeds its top dead center 5 Remove the cylinder head and measure the thickness of the squeezed fuses 6 If the measurement is not within the factory specifications check the oil clearance of between the crankpin and crankpin bearing and between the piston pin and small end bushing NOTE After checking the top clearance be sure to assemble the cylinder head with a new...

Page 90: ...ign the 1TC mark 1 on the flywheel and alignment mark 2 on the rear end plate so that the No 1 piston comes to the overlap position 6 Check the following valve clearance marked with using a feeler gauge When No 1 piston comes to the overlap position 7 If the clearance is not within the factory specifications adjust with the adjusting screw NOTE The sequence of cylinder numbers is given as No 1 No ...

Page 91: ... reassembling Check to see if the cylinder head cover gasket is not defective Apply engine oil to the cylinder head cover cap nuts And tighten them W10147380 Injection Pipes 1 Loosen the screws on the pipe clamps 1 2 Detach the injection pipes 2 When reassembling Blow out dust from the pipes with compressed air Then reassemble the pipes in the reverse order W10150780 Tightening torque Engine suppo...

Page 92: ...r Arm and Push Rod 1 Remove the rocker arm bracket nuts 2 Detach the rocker arm assembly 1 3 Remove the push rods 2 When reassembling When putting the push rods 2 onto the tappets 3 check to see if their ends are properly engaged with the grooves IMPORTANT After installing the rocker arm be sure to adjust the valve clearance Apply engine oil to the rocker arm bracket nuts And tighten them W1015581...

Page 93: ...from the crankcase When reassembling Before installing the tappets apply engine oil thinly around them IMPORTANT Mark the cylinder number to the tappets to prevent interchanging W1027457 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 4 Remove...

Page 94: ... as shown in the figure NOTE The sealant is applied to both sides of the soft metal gasket shim The liquid gasket is not required for assembling Addition or reduction of shim 0 05 mm 0 0020 in delays or advances the injection timing by approx 0 0087 rad 0 5 In disassembling and replacing be sure to use the same number of new gasket shims with the same thickness W10167080 Fan Drive Pulley 1 Set the...

Page 95: ... Remove the external snap ring 3 the collar 2 and the idle gear 1 2 Remove the idle gear shaft mounting screws 3 Remove the idle gear shaft When reassembling Install the idle gear aligning the mark on the gears referring to the figure Apply engine oil to the idle gear shaft mounting screws And tighten them W1028418 1 Screw 2 Start Spring 3 Gear Case 4 Gear Case Gasket 5 O rings Tightening torque I...

Page 96: ...ring 3 after aligning the marks on the gears See the figure at Idle Gear Install the crankshaft collar 4 after installing the gear case cover W10180290 C Timing Gears Fuel Camshaft and Camshaft D1105 E2 ZD Fan Drive Pulley 1 Set the stopper to the flywheel 2 Remove the fan drive pulley screw 1 3 Draw out the fan drive pulley 2 with a puller When reassembling Install the fan drive pulley to the cra...

Page 97: ...55 mm 2 17 in D 59 mm 2 32 in E 68 mm 2 68 in F 80 mm 3 15 in G Nut W1035535 Engine Stop Solenoid 1 Remove the engine stop solenoid 1 When reassembling Apply a thin coat of liquid type gasket Three Bond 1215 or equivalent to both surfaces of the solenoid s cover packing Confirm the convex part of the flange of the engine stop solenoid has fitted into the hole and then fasten the bolts W1035740 Spe...

Page 98: ...The sealant is applied to both sides of the soft metal gasket shim The liquid gasket is not required for assembling Addition or reduction of shim 0 05 mm 0 0020 in delays or advances the injection timing by approx 0 0087 rad 0 5 In disassembling and replacing be sure to use the same number or new gasket shims with the same thickness W1035956 Fuel Camshaft 1 Remove the fuel camshaft stopper 2 2 Dra...

Page 99: ...l its tapered part contacts the circumferential end of the ball bearing W1036385 Camshaft and Idle Gear 1 Remove the external snap ring and then remove the idle gear 4 2 Remove the camshaft stopper mounting screw and pull out the camshaft 6 When reassembling When installing the idle gear be sure to align the alignment marks a b c on the gears Securely fit the external snap ring and stopper W103698...

Page 100: ...20 in thick Within 20 minutes after the application of fluid sealant reassemble the components Wait then for about 30 minutes and pour oil in the crankcase W10265670 Connecting Rod Cap 1 Remove the connecting rod screws from connecting rod cap 2 Remove the connecting rod caps When reassembling Align the marks a with each other Face the marks toward the injection pump Apply engine oil to the connec...

Page 101: ...bination of cylinder and piston Make sure of the position of each piston by marking For example mark 1 on the No 1 piston When inserting the piston into the cylinder place the gap of the compression ring 1 on the opposite side of the combustion chamber and stagger the gaps of the compression ring 2 and oil ring making a right angle from the gap of the compression ring 1 Carefully insert the piston...

Page 102: ...posite side of the oil ring gap 11 Apply engine oil to the piston pin When installing the piston pin immerse the piston in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin to the piston When installing the connecting rod to the piston align the mark 8 on the connecting rod to the fan shaped concave 9 IMPORTANT Mark the same number on the connecting rod and the piston so as not to chan...

Page 103: ...directions Apply liquid type gasket Three Bond 1215 or its equivalent to both sides of a new bearing case cover gasket Install the bearing case cover to position the casting mark 1 on it upward D782 Install the bearing case cover to position the casting mark UP on it upward D1105 Apply engine oil to the oil seal lip and take care that it is not rolled when installing Tighten the bearing case cover...

Page 104: ...ove the main bearing case assemblies 1 5 2 1 When reassembling Clean the oil passage in the main bearing case Apply clean engine oil on the crankshaft bearing 2 and thrust bearings Install the main bearing case assemblies in the original positions Since diameters of main bearing case vary install them in order of makings 1 2 from the gear case side When installing the main bearing case assemblies ...

Page 105: ...re to check the valve recessing after correcting W10301620 Cylinder Head Flaw 1 Prepare an air spray red check Code No 07909 31371 2 Clean the surface of the cylinder head with detergent 2 3 Spray the cylinder head surface with the red permeative liquid 1 Leave it five to ten minutes after spraying 4 Wash away the red permeative liquid on the cylinder head surface with the detergent 2 5 Spray the ...

Page 106: ... limit replace the valves If it still exceeds the allowable limit replace the valve guide D782 D1105 W10311740 Valve recessing Factory spec 0 10 protrusion to 0 10 recessing mm 0 0039 protrusion to 0 0039 recessing in Allowable limit 0 30 recessing mm 0 0118 recessing in Valve recessing Factory spec 0 05 protrusion to 0 15 recessing mm 0 0020 protrusion to 0 0059 recessing in Allowable limit 0 40 ...

Page 107: ... Valve Seating 1 Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact 2 If the valve does not seat all the way around the valve seat or the valve contact is less than 70 correct the valve seating as follows 3 If the valve contact does not comply with the reference valve replace the valve or correct the contact of valve seating W1033143 Valve guide I D I...

Page 108: ... 0 785 rad 45 valve seat cutter again and visually recheck the contact between the valve and seat 5 Repeat steps 3 and 4 until the correct contact is achieved 6 Continue lapping until the seated rate becomes more than 70 of the total contact area W10319540 Valve Lapping 1 Apply compound evenly to the valve lapping surface 2 Insert the valve into the valve guide Lap the valve onto its seat with a v...

Page 109: ... valve spring on a tester and compress it to the same length it is actually compressed the engine 2 Read the compression load on the gauge 3 If the measurement is less than the allowable limit replace it D782 D1105 W11177330 Free length A Factory spec 31 3 to 31 8 mm 1 232 to 1 252 in Allowable limit 28 4 mm 1 118 in Tilt B Allowable limit 1 2 mm 0 047 in Free length A Factory spec 37 0 to 37 5 mm...

Page 110: ...gnment 3 If the measurement exceeds the allowable limit replace the push rod W11220210 Oil clearance between rocker arm and rocker arm shaft Factory spec 0 016 to 0 045 mm 0 00063 to 0 00177 in Allowable limit 0 15 mm 0 0059 in Rocker arm shaft O D Factory spec 10 473 to 10 484 mm 0 41232 to 0 41276 in Rocker arm I D Factory spec 10 500 to 10 518 mm 0 41339 to 0 41410 in Oil clearance between rock...

Page 111: ...e between tappet and tappet guide bore Factory spec 0 016 to 0 052 mm 0 00063 to 0 00205 in Allowable limit 0 10 mm 0 0039 in Tappet O D Factory spec 17 966 to 17 984 mm 0 70732 to 0 70803 in Tappet guide bore I D Factory spec 18 000 to 18 018 mm 0 70866 to 0 70937 in Oil clearance between tappet and tappet guide bore Factory spec 0 020 to 0 062 mm 0 00079 to 0 00244 in Allowable limit 0 07 mm 0 0...

Page 112: ...m 0 0059 in Backlash between idle gear and injection pump gear Factory spec 0 046 to 0 124 mm 0 00185 to 0 00488 in Allowable limit 0 15 mm 0 0059 in Backlash between oil pump drive gear and crank gear Factory spec 0 041 to 0 123 mm 0 00161 to 0 00484 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and crank gear Factory spec 0 032 to 0 115 mm 0 00120 to 0 00453 in Allowable limit ...

Page 113: ... 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 W11312720 Idle gear side clearance Factory spec 0 13 to 0 49 mm 0 0051 to 0 0199 in Allowable limit 0 60 mm 0 0236 in Idle gear side clearance Factory sp...

Page 114: ...n Allowable limit 26 83 mm 1 0563 in Cam height of intake Factory spec 28 80 mm 1 1339 in Allowable limit 28 75 mm 1 1319 in Cam height of exhaust Factory spec 29 00 mm 1 1417 in Allowable limit 28 95 mm 1 1398 in Oil clearance of camshaft journal Factory spec 0 050 to 0 091 mm 0 00197 to 0 00358 in Allowable limit 0 15 mm 0 0059 in Camshaft journal O D Factory spec 32 934 to 32 950 mm 1 29661 to ...

Page 115: ...and apply engine oil to them 2 Press in a new brushing using an idle gear bushing replacing tool until it is flush with the end of the idle gear W11373220 Oil clearance between idle gear shaft and idle gear bushing Factory spec 0 020 to 0 084 mm 0 00079 to 0 00331 in Allowable limit 0 10 mm 0 0039 in Idle gear shaft O D Factory spec 19 967 to 19 980 mm 0 78610 to 0 78661 in Idle gear bushing I D F...

Page 116: ...n pin D782 D1105 W11420110 Piston pin bore I D Factory spec 20 000 to 20 013 mm 0 78740 to 0 78791 in Allowable limit 20 05 mm 0 7894 in Piston pin bore I D Factory spec 22 000 to 22 013 mm 0 86614 to 0 86665 in Allowable limit 22 03 mm 0 8673 in Oil clearance between piston pin and small end bushing Factory spec 0 014 to 0 038 mm 0 00055 to 0 00150 in Allowable limit 0 10 mm 0 0039 in Piston pin ...

Page 117: ... an oil stone W11437590 Piston Ring Gap 1 Insert the piston ring into the lower part of the cylinder the least worn out part with a piston ring compressor and piston 2 Measure the ring gap with a feeler gauge 3 If the measurement exceeds the allowable limit replace the piston ring D782 D1105 W11466710 1 Seam 2 Oil Hole A When Removing B When Installing a 0 785 rad 45 Piston ring gap Factory spec T...

Page 118: ...he connecting rod on the connecting rod alignment tool Code No 07909 31661 4 Put a gauge over the piston pin and move it against the face plate 5 If the gauge does not fit squarely against the face plate measure the space between the pin of the gauge and the face plate 6 If the measurement exceeds the allowable limit replace the connecting rod W11499650 Clearance between piston ring and piston rin...

Page 119: ...61 040 OS Thrust bearing 2 04 15261 23981 040 OS Oversize Bearing Code Number Marking 0 2 mm 0 008 in Thrust bearing 1 02 15521 23950 020 OS Thrust bearing 2 02 19202 23970 020 OS 0 4 mm 0 016 in Thrust bearing 1 04 15521 23960 040 OS Thrust bearing 2 04 19202 23980 040 OS Oversize 0 2 mm 0 008 in 0 4 mm 0 016 in Dimension A 23 40 to 23 45 mm 0 9134 to 0 9154 in 23 80 to 23 85 mm 0 9213 to 0 9232 ...

Page 120: ...place the crankpin bearing 6 If the same size bearing is useless because of the crankpin wear replace it with an undersize one referring to the table and the figure NOTE Never insert the plastigage into the crankpin oil hole Be sure not to move the crankshaft while the connecting rod screws are tightened D782 D1105 W11625390 Crankshaft alignment Allowable limit 0 02 mm 0 0008 in Oil clearance betw...

Page 121: ...08 in 0 4 mm 0 016 in A 2 3 to 2 7 mm radius 0 091 to 0 106 in radius 2 3 to 2 7 mm radius 0 091 to 0 106 in radius B 4 mm dia 0 16 in dia 4 mm dia 0 16 in dia C 33 759 to 33 775 mm dia 1 32910 to 1 32973 in dia 33 559 to 33 575 mm dia 1 32122 to 1 32185 in dia 0 8 S The crankpin must be fine finished to higher than Undersize Dimension 0 2 mm 0 008 in 0 4 mm 0 016 in A 2 8 to 3 2 mm radius 0 1102 ...

Page 122: ...eferring to the table and the figure D782 D1105 W10323470 Oil Clearance between crankshaft journal and crankshaft bearing 1 Factory spec 0 034 to 0 106 mm 0 00134 to 0 00417 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory spec 39 934 to 39 950 mm 1 57221 to 1 57284 in Crankshaft bearing 1 I D Factory spec 39 984 to 40 040 mm 1 57417 to 1 57638 in Oil Clearance between crankshaf...

Page 123: ...n 0 2 mm 0 008 in 0 4 mm 0 016 in A 1 8 to 2 2 mm radius 0 071 to 0 087 in radius 1 8 to 2 2 mm radius 0 071 to 0 087 in radius B 5 mm dia 0 20 in dia 5 mm dia 0 20 in dia C 39 734 to 39 750 mm dia 1 56433 to 1 56496 in dia 39 534 to 39 550 mm dia 1 55646 to 1 55709 in dia 0 8 S The crankshaft journal must be fine finished to higher than Undersize Dimension 0 2 mm 0 008 in 0 4 mm 0 016 in A 2 3 to...

Page 124: ...n installing 1 Clean a new crankshaft bearing 1 and crankshaft journal bore and apply engine oil to them 2 Using a crankshaft bearing 1 replacing tool press in a new bearing 1 2 so that its seam 1 directs toward the exhaust manifold side See figure W10342000 Dimension A Factory spec 0 to 0 3 mm 0 to 0 012 in 1 Seam 2 Crankshaft Bearing 1 3 Cylinder Block KiSC issued 09 2006 A ...

Page 125: ...o 0 059 mm 0 00110 to 0 00232 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Intermediate Factory spec 39 934 to 39 950 mm 1 57221 to 1 57284 in Crankshaft bearing 3 I D Factory spec 39 978 to 39 993 mm 1 57394 to 1 57453 in Crankshaft journal O D Flywheel side Factory spec 43 978 to 43 993 mm 1 73142 to 1 73201 in Crankshaft bearing 2 I D Factory spec 43 984 to 44 026 mm 1 73165 to 1...

Page 126: ... 0 2 mm 0 008 in 0 4 mm 0 016 in A 1 8 to 2 2 mm radius 0 071 to 0 087 in radius 1 8 to 2 2 mm radius 0 071 to 0 087 in radius B 3 mm dia 0 12 in dia 3 mm dia 0 12 in dia C 39 734 to 39 750 mm dia 1 56433 to 1 56496 in dia 39 534 to 39 550 mm dia 1 55646 to 1 55709 in dia D 43 734 to 43 750 mm dia 1 72181 to 1 72244 in dia 43 534 to 43 550 mm dia 1 71394 to 1 71457 in dia 0 8 S The crankshaft jour...

Page 127: ...size dimension Refer to Correcting Cylinder 4 Visually check the cylinder wall for scratches If deep scratches are found the cylinder should be bored Refer to Correcting Cylinder D782 D1105 W10360060 Cylinder liner I D Factory spec 67 000 to 67 019 mm 2 63779 to 2 63854 in Allowable limit 67 169 mm 2 64444 in Cylinder liner I D Factory spec 72 000 to 72 019 mm 2 83464 to 2 83539 in Allowable limit...

Page 128: ...g Hone to 1 2 to 2 0 μ R max 0 0472 to 0 0787 in R max Oversized cylinder liner I D Factory spec 72 500 to 72 519 mm 2 85433 to 2 85507 in Allowable limit 72 669 mm 2 86098 in Finishing Hone to 1 2 to 2 0 μ R max 0 0472 to 0 0787 in R max Oversize Part Name Code Number Marking 0 25 mm 0 0098 in Piston 16851 21900 025 OS Piston ring assembly 16851 21090 025 OS Oversize Part Name Code Number Marking...

Page 129: ... lobes of the inner rotor and the outer rotor with a feeler gauge 2 If the clearance exceeds the factory specifications replace the oil pump rotor assembly W10378950 Clearance between Outer Rotor and Pump Body 1 Measure the clearance between the outer rotor and the pump body with a feeler gauge 2 If the clearance exceeds the factory specifications replace the oil pump rotor assembly W10381420 Engi...

Page 130: ... tighten the screws 3 Remove the cover carefully and measure the amount of the flattening with the scale and get the clearance 4 If the clearance exceeds the factory specifications replace oil pump rotor assembly W10382660 Clearance between rotor and cover Factory spec D782 0 075 to 0 135 mm 0 00295 to 0 00531 in D1105 0 025 to 0 075 mm 0 0010 to 0 0029 in KiSC issued 09 2006 A ...

Page 131: ...t is not within the factory specifications loosen the alternator mounting screws and relocate the alternator to adjust W10384280 Fan Belt Damage and Wear 1 Check the fan belt for damage 2 If the fan belt is damaged replace it 3 Check if the fan belt is worn and sunk in the pulley groove 4 If the fan belt is nearly worn out and deeply sunk in the pulley groove replace it W10385490 Deflection A Fact...

Page 132: ...ssure to fall to 59 kPa 0 6 kgf cm2 9 psi 3 If the measurement is less than the factory specification replace the radiator cap W1054156 C Thermostat Thermostat Valve Opening Temperature 1 Suspend the thermostat in the water by a string with its end inserted between the valve and seat 2 Heating the water gradually read the temperature when the valve opens and leaves the string 3 Continue heating an...

Page 133: ...ove the fan belt 2 Remove the fan and fan pulley 3 Remove the water pump assembly from the gear case cover 4 Remove the water pump flange 1 5 Press out the water pump shaft 2 with the impeller 5 on it 6 Remove the impeller from the water pump shaft 2 7 Remove the mechanical seal 4 When reassembling Apply a liquid gasket Three Bond 1215 or equivalent to the both sides of gasket Replace the mechanic...

Page 134: ...ng is out of adjustment readjust the timing with shims 3 NOTE The sealant is applied to both sides of the shim soft metal gasket shim The liquid gasket is not required for assembling Shims are available in thickness of 0 20 mm 0 0079 in 0 25 mm 0 0098 in and 0 30 mm 0 0118 in Combine these shims for adjustments Addition or reduction of shim 0 05 mm 0 0020 in delays or advances the injection timing...

Page 135: ...ve 1 Remove the bonnet and air cleaner 2 Remove the muffler 3 Remove the injection pipes and glow plugs 4 Install the injection pump pressure tester to the fuel injection pump 5 Set the throttle lever to the maximum engine speed 6 Turn the flywheel and raise the pressure to approx 14 7 MPa 150 kgf cm2 2130 psi 7 Now turn the flywheel back about half a turn to keep the plunger free Maintain the fly...

Page 136: ... move the tester handle to measure the pressure at which fuel begins to jet out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer 1 in the nozzle holder to adjust it Reference Pressure variation with 0 025 mm 0 001 in difference of adjusting washer thickness Approx 59 kPa 0 6 kgf cm2 8 5 psi W10408820 Valve Seat Tightness 1 Set the injection...

Page 137: ...rod 4 noting its direction After assembling the nozzle be sure to adjust the fuel injection pressure W10415210 Tightening torque Nozzle holder 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 ft lbs Overflow pipe nut 19 6 to 24 5 N m 2 0 to 2 5 kgf m 14 5 to 18 1 ft lbs Nozzle holder assembly 49 0 to 68 6 N m 5 0 to 7 0 kgf m 36 2 to 50 6 ft lbs 1 Nozzle Holder 2 Adjusting Washer 3 Nozzle Spring 4 P...

Page 138: ...2 TRANSAXLE KiSC issued 09 2006 A ...

Page 139: ...HYDROSTATIC TRANSMISSION 2 M2 1 Structure 2 M2 2 Pump and Motor 2 M3 3 Check Valve and High Pressure Relief Valve 2 M4 4 Oil Flow 2 M5 5 Power Trains Operation 2 M7 6 Control Linkage 2 M8 7 Final Reduction Gear Section 2 M9 8 PTO System 2 M10 KiSC issued 09 2006 A ...

Page 140: ...2 M1 ZD21N EC ZD21 EC ZD28 EC WSM TRANSAXLE 1 STRUCTURE 1 Hydrostatic Transmission 2 PTO Section 3 Final Reduction Gear Section 4 Parking Brake Section 5 Bevel Gear Section KiSC issued 09 2006 A ...

Page 141: ...iston motor and valve system 1 Lubricating Orifice 2 Bearing 3 Pump Shaft 4 Motor Shaft 5 Center Section 6 Cradle Bearing 7 Slot Guide 8 Trunnion Arm 9 Cylinder Block Pump 10 Swashplate 11 Ball Bearing 12 Thrust Ball Bearing 13 Piston Spring 14 Thrust Ball Bearing 15 Cylinder Block Motor 16 Check Valve Spring 17 Relief Valve Spring 18 Check Valve 19 High Pressure Relief Valve KiSC issued 09 2006 A...

Page 142: ...the cylinder rotates pistons move across the sloping face of swashplate and slide in or out of their cylinder bores The oil forced out by the pump pistons causes the motor pistons to slide out of their cylinder bores In the motor sliding out of the cylinder and moving across the sloping face of swashplate the pistons rotate the cylinder 1 Swashplate 2 Piston 3 Cylinder 4 Oil 5 Cylinder 6 Piston 7 ...

Page 143: ...the high pressure line serves as a high pressure relief valve If the pressure exceeds a high pressure limit level the pressure poppet opens itself against the relief valve spring 3 force and opens the valve seat that is located between the check valve seat 1 and the pressure poppet 2 Now the flow goes from P1 to P2 and P3 C If the P1 pressure drops the relief valve spring forces the valve seat clo...

Page 144: ...upplied a want The charge oil is sent to the HST housing after the control valve and oil filter pass with the hydraulic pump The charge oil aids smooth operation of pistons for pump and motor And overflow oil from HST housing return to the transmission case 1 Oil Strainer 2 Transmission Case 3 Hydraulic Pump 4 Control Valve 5 Regulator Valve 6 PTO Clutch 7 Oil Filter Cartridge 8 Check and High Pre...

Page 145: ...d after that the cooled oil is sent to the control valve The oil is sent to the HST housing by passing the oil filter after pressure is controlled with the regulator valve The charge oil aids smooth operation of pistons for pump and motor And overflow oil from HST housing return to the transmission case 1 Oil Strainer 2 Transmission Case 3 Hydraulic Pump 4 Oil Cooler 5 Control Valve 6 Regulator Va...

Page 146: ...d the swash plates in the pumps move from the neutral position parallel to the pump body to a forward angle position Piston springs inside the cylinder bores force the pistons against the swash plates As the cylinder block rotates the pistons follow the contour of the swash plate moving outward drawing oil into their bores As the cylinder block continues to rotate the pistons are forced into their...

Page 147: ...control lever 1 is removed from the neutral slot 6 As the result the machine synchronizes with the movement of the motion control lever 1 and begins to move slowly The machine is set like this The damper connected to the speed shaft 5 restricts the movement of the linkage to prevent abrupt operation or reversing Steering The Zero Turn Mower does not have a separate steering system Steering is acco...

Page 148: ...ear Section As for this machine power is transmitted from the 12T gear 1 on the HST motor shaft to the rear axle 5 through 53T gear 14T gear shaft and 57T gear W1013563 1 12T Gear 2 53T Gear 3 14T Gear Shaft Brake Shaft 4 57T Gear 5 Rear Axle KiSC issued 09 2006 A ...

Page 149: ...ch plates 7 pressure plate clutch piston 9 and so on The clutch piston 9 is actuated by hydraulic oil flow from the hydraulic pump through regulator valve 5 1 34T Gear ZD21N ZD21 33T Gear ZD28 2 Input Shaft 3 43T Gear ZD21N ZD21 39T Gear ZD28 4 Oil Filter Cartridge 5 Regulator Valve 6 Rear Cover 7 Clutch Plate 8 Transmission Case 9 Piston 10 PTO Brake Disc 11 PTO Shaft 12 PTO Brake Plate 13 Clutch...

Page 150: ...ose the oil passage to the PTO clutch pack The oil in the PTO clutch pack drained into the transmission case 5 Thus the clutch piston 2 is pushed back by the spring 9 When the piston 2 is pushed back the piston push to the brake pressure plate 1 so as to stop the rotation and drag of the PTO shaft 4 W1014560 1 Poppet 2 Spring 3 Plug A From Hydraulic Pump B To Hydrostatic Transmission C To Transmis...

Page 151: ... 1 is lifted up the brake will be applied and locked When the parking brake is released the brake can be released if the parking brake lever is pulled back To prevent the brake from dragging when the parking brake is applied this machine is designed so that the engine may stop if the parking brake lever 1 is not released within few seconds after the engine is started 1 Parking Brake Lever 2 Parkin...

Page 152: ...RVICING 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 6 SERVICING 2 S22 1 HYDROSTATIC TRANSMISSION 2 S22 2 TRANSMISSION CASE 2 S24 KiSC issued 09 2006 A ...

Page 153: ...ective Transmission oil insufficient Oil strainer clogged Transmission oil filter cartridge clogged Hydraulic pump defective Hydrostatic transmission defective Repair or replace Replenish Clean Replace Replace Replace 2 S11 G 20 G 18 2 S18 2 S15 System Operates in One Direction Only Check valve defective Control linkage defective Replace 2 S16 System Operating Hot Transmission oil insufficient Oil...

Page 154: ...S18 2 S17 PTO Shaft Does Not Rotate PTO clutch malfunctioning Repair or replace 2 S17 PTO Clutch Operating Pressure Is Low Transmission oil improper or insufficient Regulator valve malfunctioning Replenish or change Check or replace 2 S10 2 S18 PTO Clutch Drags Brake plate excessively worn Clutch spring weaken or broken Deformation of pressure plate or steel plate Replace Replace Replace 2 S17 2 S...

Page 155: ...0 kgf cm2 71 2 to 99 6 psi Creeping Speed At Maximum Engine rpm Wheel rotation 8 to 10 rpm Check and High Pressure Relief Valve Relief valve setting pressure 28 4 to 29 4 MPa 290 to 300 kgf cm2 4125 to 4269 psi Maximum Speed At Maximum Engine rpm Wheel rotation 148 to 150 rpm Motion control lever Alignment Gap 0 to 2 mm 0 to 0 08 in Space 10 to 20 mm 0 4 to 0 8 in 16T Bevel Gear to 19T Bevel Gear ...

Page 156: ...Aluminum M12 7T M10 7T Hydraulic pump housing mounting screw Center cover mounting screw Center section mounting hex socket head screw Check and high pressure relief valve plug 17 7 to 20 6 39 3 to 44 1 48 0 to 56 0 26 0 to 28 0 62 7 to 72 5 39 3 to 44 1 77 5 to 90 2 48 0 to 55 9 17 7 to 20 5 39 3 to 44 1 17 7 to 20 5 24 5 to 34 3 1 8 to 2 1 4 0 to 4 5 4 9 to 5 7 2 7 to 2 9 6 4 to 7 4 4 0 to 4 5 7...

Page 157: ...y the parking brake 3 Set the motion control levers 2 to Neutral lock position 4 Remove the set knobs of seat frame then raise and latch the seat assembly 5 Remove the connector from the seat safety switch then temporarily install a jumper wire across the terminals in the connector of the wiring harness 6 Raise the rear of machine and block up so that rear wheel can rotate freely 7 Loosen the lock...

Page 158: ...wiring harness 6 Raise the rear of machine and block up so that rear wheel can rotate freely 7 Start the engine 8 Move the throttle lever to Max speed position 9 Release the parking brake 10 Pull the motion control lever 3 to reverse maximum position from NEUTRAL position and release the motion control lever 3 11 Measure the wheel rotation 12 Loosen the lock nut 1 and adjust the creep speed contro...

Page 159: ...emove the connector from the seat safety switch then temporarily install a jumper wire across the terminals in the connector of the wiring harness 6 Remove the motion control lever boots 1 7 Raise the rear of machine and block up so that rear wheel can rotate freely 8 Start the engine 9 Move the throttle lever to Max speed position 10 Push the motion control lever 2 to the front until the speed se...

Page 160: ...select the motion control lever position high or low 4 Tighten the screw 2 and install the boot 1 Lever alignment Right and Left 3 Loosen the screws 2 4 Slide both motion control levers forward or rearward to desired position within tab slots until levers are aligned 5 Tighten the screws 2 NOTE If the ends of the levers strike against each other while in the NEUTRAL position move the levers outwar...

Page 161: ...ax speed position 6 Grasp the motion control lever and move then inward from NEUTRAL LOCK position to position and then slowly push forward And measure the pressure of HST 7 At this time if pressure rise to 19 6 MPa 200 kgf cm2 2845 psi it is assumed OK NOTE If pressure exceeds 29 4 MPa 300 kgf cm2 4269 psi rear wheel can not be locked with parking brake Please fix the rear wheel hub with the stic...

Page 162: ...Start the engine and set at maximum speed 3 At this time read the pressure gauge 4 If the pressure is not within the factory specifications check the regulator valve and related hydraulic components Condition Engine speed Maximum Oil temperature 45 to 55 C 113 to 131 F W1014889 Checking Parking Brake 1 See page G 29 W1015239 PTO clutch operating pressure Factory spec 0 50 to 0 69 MPa 5 0 to 7 0 kg...

Page 163: ...r oils may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 7 Never work the tractor immediately after changing the transmission oil Keeping the engine at medium speed for a few minutes prevents damage to the transmission Do not mix different brands oil together W1015312 Battery CAUTION When disconnecting the battery cables disconnect the negative cable f...

Page 164: ...he fender LH 3 5 Remove the cutting height adjusting knob 7 and center frame 6 6 Disconnect the seat safety switch and then remove the seat assembly with seat frame 5 W1015356 Fuel Tank 1 Disconnect the lead wire 1 from fuel level sensor and fuel hoses 2 from the fuel tank 2 Remove the fuel tank 3 W1015458 1 Motion control lever LH 2 Fuel Tank Cap 3 Fender LH 4 Boot LH 5 Seat Frame 6 Center Frame ...

Page 165: ...s and clevis pins from both yokes 6 6 Remove the rue rings and dampers from both speed control shafts 5 7 Remove the connecting plate 4 8 Remove the upper frame 9 W1015520 Universal Joint ZD21N ZD21 1 Remove the universal joint mounting screws from engine side When reassembling W1015713 1 Wire Harness 2 Regulator 3 Combination Box 4 Connecting Plate 5 Speed Control Shaft 6 Yoke 7 Speed Control Rod...

Page 166: ...e both brake rods 3 Raise the rear of machine and block up 4 Remove the rear wheels 5 Hold the transaxle assembly with chain and crane 6 Remove the transaxle assembly 1 mounting screws and separate it When reassembling W1015817 Tightening torque Universal joint mounting screw 26 0 to 28 0 N m 2 7 to 2 9 kgf m 19 2 to 20 7 ft lbs 1 Propeller Shaft 2 Delivery Pipe 3 Oil Cooler 4 Delivery Hose Tighte...

Page 167: ...ge the O rings The direction of the 12T gear is noted Flat face to hydrostatic transmission side W1016171 Hydrostatic Transmission Assembly 1 Remove the hydrostatic transmission assembly 1 from transmission case When reassembling Apply oil to the O rings and take care not to damage them W1017377 1 Delivery Pipe 2 O ring 3 Coller 4 Delivery Hose Tightening torque Rear axle assembly mounting screw 3...

Page 168: ...der blocks pistons and center section W1017500 Check Valve and High Pressure Relief Valve Assembly 1 Remove the plug 1 and draw out the spring 2 and Check and high pressure relief valve assembly 3 When reassembling Take care not to damage the O ring on the plug W1017728 Tightening torque Center section mounting hex socket head screw 17 7 to 20 5 N m 1 8 to 2 1 kgf m 13 1 to 15 1 ft lbs 1 Center Se...

Page 169: ...fluid to the surface of cylinder block After installing the cylinder block assembly check it to rotate lightly Swashplate 1 Remove the spring 5 and external snap ring 2 Remove the swashplate 1 from the housing 3 Remove the thrust plate 4 thrust ball bearing 3 and thrust washer 2 from the Swashplate When reassembling Apply clean fluid to the thrust washer and thrust plate 1 Cylinder Block Assembly ...

Page 170: ...w seal lip during installation W1031231 Suction Hose Hydraulic Pump and Center Cover Assembly 1 Remove the suction hose 1 and hydraulic pump 2 2 Remove the center cover assembly 3 and separate the PTO clutch assembly 4 from center cover When reassembling Take care not to damage the O rings W1016333 1 Cradle Bearing 2 Slot Guide 3 Trunnion Arm 1 Ball Bearing 2 Internal Snap Ring 3 Oil Seal 4 Pump S...

Page 171: ... the bearing 4 and external snap ring 5 then remove the brake plate 6 and brake disc 7 6 Tap out the behind of piston 10 from clutch case 8 When reassembling Apply transmission oil to the O rings 18 D ring 9 and seal rings and take care not to damage it W1017183 1 Bearing 2 43T Gear 3 PTO Clutch Shaft 4 Bearing 5 External Snap Ring 6 Brake Plate 7 Brake Disc 8 Clutch Case 9 D ring 10 Piston 11 Clu...

Page 172: ...O rings W1016683 Input Shaft and Bevel Gears 1 Remove the internal snap ring and 19T bevel gear with bearing 2 Remove the internal snap ring and joint shaft with bearing 3 Remove the 16T bevel gear and input shaft assembly 1 When reassembling IMPORTANT Adjust the backlash and the tooth contact after assembling the 19T and 16T bevel gears W1016759 1 Center Cover Assembly 2 Poppet 3 Spring 4 Plug 5 ...

Page 173: ...ve the rear wheel and brake rod 3 3 Remove the brake cover 1 with brake shoes 4 Remove the external snap ring and brake drum 4 5 Inspect all parts for wear or damage Replace the parts as needed When reassembling When the brake cover is assembled the brake cover keeps the same as the pull of the brake lever 2 and making the brake and is assembled The brake shoes are prevented being biased NOTE Afte...

Page 174: ...ring 3 are in each cylinder bore 4 Check the pistons for their free movement in the cylinder block bores 5 If the piston or the cylinder block is scored replace the cylinder block assembly 6 Check the polished face 4 of cylinder block for scoring 7 If scored replace the cylinder block assembly IMPORTANT Do not interchange pistons between pump and motor cylinder block Pistons and cylinder blocks ar...

Page 175: ...aft is rough or grooved replace it 3 If the ball bearing is worn replace it W1019162 Bearing and Oil Seal 1 Check the oil seals for damage 2 Check the bearings 1 for wear 3 If the oil seal and needle bearings are worn or damaged replace them W1019539 1 Ball Bearing 2 Oil Seal 3 Bearing Surface 4 Seal Surface 1 Bearing KiSC issued 09 2006 A ...

Page 176: ...mall decrease the number of shims in the side of the differential case and insert the removed shims in the opposite side 3 Adjust the backlash properly by repeating the above procedure 4 Apply red lead lightly over several teeth at three positions equally spaced on the hypoid ring gear 5 Turn the 16T bevel gear by input shaft while pressing a wooden piece against the periphery of the bevel gear 6 ...

Page 177: ... the shim 4 to move the 19T bevel gear outside Repeat above until the proper tooth contact and backlash are achieved W1028716 3 Correcting of the toe contact and deep contact It is confirmed whether there is a shim 3 The 16T bevel gear 5 can be moved to forward by removing the shim 3 if there is a shim The shim 3 is not put when there is no shim And place the shim 4 side to the 19T bevel gear 2 si...

Page 178: ...3 FRONT AXLE KiSC issued 09 2006 A ...

Page 179: ...CONTENTS MECHANISM 1 STRUCTURE 3 M1 KiSC issued 09 2006 A ...

Page 180: ...ont axle is relatively simple and the front axle is supported at its center with the center pin 8 so that steering operation is stable even on uneven grounds in a grass field 1 Cap 2 Taper Roller Bearing 3 Taper Roller Bearing 4 Wheel Bracket 5 Lift Up Adjuster 6 Front Axle 7 Slotted Nut 8 Center Pin KiSC issued 09 2006 A ...

Page 181: ...S1 2 SERVICING SPECIFICATIONS 3 S2 3 TIGHTENING TORQUES 3 S3 4 CHECKING DISASSEMBLING AND SERVICING 3 S4 1 CHECKING AND ADJUSTING 3 S4 2 DISASSEMBLING AND ASSEMBLING 3 S5 1 Separating Front Wheel and Wheel Bracket 3 S5 KiSC issued 09 2006 A ...

Page 182: ...lution Reference Page Front Wheels Wander to Right or Left Clearance between center pin and front axle excessive Force of the lock nut which tighten the wheel bracket has become down Clearance between front axle and front axle support excessive Replace Adjust Adjust 3 S5 3 S4 KiSC issued 09 2006 A ...

Page 183: ...21N EC ZD21 EC ZD28 EC WSM FRONT AXLE 2 SERVICING SPECIFICATIONS W1013874 Item Factory Specification Allowable Limit Front Axle End Play Clearance 0 to 0 2 mm 0 to 0 008 in 0 5 mm 0 02 in KiSC issued 09 2006 A ...

Page 184: ...below are especially specified For general use screws bolts and nuts See page G 9 W1012736 Item N m kgf m ft lbs Wheel bolt and lock nut Wheel bracket lock nut Center pin lock nut slotted nut 20 to 25 45 to 55 40 to 80 2 04 to 2 55 4 59 to 5 61 4 08 to 8 16 14 75 to 18 44 33 19 to 40 57 29 50 to 59 00 KiSC issued 09 2006 A ...

Page 185: ...he set spring 5 and adjust the end play by slotted nut 1 When reassembling NOTE When fastening the center pin 4 tighten the nut 1 so that the front axle may be oscillated smoothly by hand W1011206 Tightening torque Center pin lock nut Slotted nut 40 to 80 N m 4 08 to 8 16 kgf m 29 50 to 59 00 ft lbs Front axle end play A Factory spec 0 to 0 2 mm 0 to 0 008 in Allowable limit 0 5 mm 0 02 in 1 Slott...

Page 186: ...ar or damage Replace the parts as needed When reassembling Do not mistake the direction when reassembling the plate spring 3 taper roller bearing 4 6 and oil seal 7 W1011557 Tightening torque Front wheel mounting bolt and locking nut 20 to 25 N m 2 04 to 2 55 kgf m 14 75 to 18 44 ft lbs 1 Bolt 2 Locking Nut 3 Taper Roller Bearing 4 Oil Seal 5 Spacer 6 Sleeve Tightening torque Locking nut tightenin...

Page 187: ...4 HYDRAULIC SYSTEM KiSC issued 09 2006 A ...

Page 188: ...CONTENTS MECHANISM 1 HYDRAULIC CIRCUIT 4 M1 2 HYDRAULIC PUMP 4 M2 3 HYDRAULIC CONTROL VALVE AND VALVE ADAPTOR 4 M3 4 LIFT CYLINDER 4 M6 5 MOWER LINKAGE 4 M7 KiSC issued 09 2006 A ...

Page 189: ...eft with the bevel gears and drives each hydrostatic transmission 12 Moreover oil from the hydraulic pump 10 is sent to the transmission center case through the control valve On the other hand oil is regulated with the regulator valve 9 to constant pressure and sent to the hydrostatic transmission 12 and PTO clutch 1 1 PTO Clutch 2 PTO Clutch Valve 3 Hydraulic Control Valve Assembly 4 Hydraulic Cy...

Page 190: ...ngine is a trochoid pump Inside the pump body the 6 lobe inner rotor 2 is eccentrically engaged with the 7 lobe outer rotor 1 The inner rotor is driven by the input shaft which in turn rotate the outer rotor W1012820 1 Outer Rotor 2 Inner Rotor 3 Pump Case 4 Input Shaft KiSC issued 09 2006 A ...

Page 191: ... by the hydraulic pump to the control valve 3 through the delivery pipe 2 The control valve switches the oil flow and oil is channeled to the lift cylinder 6 or returned to the transmission case hydrostatic transmission charge line through the return pipe 1 Return Pipe 2 Delivery Pipe 3 Control Valve 4 Control Valve Adaptor 5 Cylinder Hose 6 Lift Cylinder A From Hydraulic Pump B To Transmission Ca...

Page 192: ...ver 7 is set to LIFT position the spool 2 moves to the right to form a lifting circuit Pressure fed oil goes through the clearance between the valve body 3 and spool 2 and is fed to the lift cylinder to lift the mower through the C port 9 and control valve adaptor 5 with orifice 4 1 Valve Cover 2 Spool 3 Valve Body 4 Orifice 5 Control Valve Adaptor 6 Relief Cover 7 Control Lever 8 R Return Port 9 ...

Page 193: ... lift cylinder is forced out by the weight of the mower and returns to the hydrostatic transmission to lower the mower as shown in the figure Oil pressure fed from the hydraulic pump goes through the clearance between the valve body 3 and spool 2 and then flows to the hydrostatic transmission through the R port 8 and control valve adaptor 5 1 Spool 2 Control Valve Adaptor 3 R Return Port 4 Relief ...

Page 194: ...INDER W1014031 The lift cylinder consists of the tube end 1 cylinder tube 3 piston rod 6 and other parts as shown in the figure above This cylinder is single acting type 1 Tube End 2 Snap Ring 3 Cylinder Tube 4 Packing 5 Scraper 6 Piston Rod KiSC issued 09 2006 A ...

Page 195: ...1 is extended and lift shaft 3 is rotated to pull the rear arm 5 rearward As a result mower is lifted The cutting height adjusting dial 2 adjusts cutting height of mower by rotating the adjusting cam 6 The level of mower deck is adjusted by adjusting the cutting height fine tuning bolt length 7 1 Lift Cylinder 2 Cutting Height Adjusting Dial 3 Lift Shaft 4 Front Arm 5 Rear Arm 6 Adjusting Cam 7 Cu...

Page 196: ...PECIFICATIONS 4 S2 3 CHECKING DISASSEMBLING AND SERVICING 4 S3 1 HYDRAULIC CONTROL VALVE PUMP AND CYLINDER 4 S3 1 Checking and Adjusting 4 S3 2 Disassembling and Assembling 4 S3 2 LIFT CYLINDER 4 S5 1 Disassembling and Assembling 4 S5 KiSC issued 09 2006 A ...

Page 197: ...mp defective Oil strainer clogged Suction pipe loosened or broken Suction pipe O ring damaged Insufficient transmission oil Repair or replace Replace Replace Adjust Replace Clean or replace Repair or replace Replace Refill 4 S4 4 S5 4 S4 4 S3 2 S18 G 20 2 S15 2 S15 G 20 Mower Does Not Lower Control valve malfunctioning Repair or replace 4 S3 Mower Drops by Its Weight Lift cylinder worn or damaged ...

Page 198: ... ZD28 EC WSM HYDRAULIC SYSTEM 2 SERVICING SPECIFICATIONS W1013874 Item Factory Specification Allowable Limit Relief Valve Control Valve Setting Pressure 3 14 to 3 73 MPa 32 to 38 kgf cm2 455 to 540 psi KiSC issued 09 2006 A ...

Page 199: ... in 0 8 mm 0 0315 in W1011441 2 Disassembling and Assembling Removing Control Valve 1 Remove the control lever 2 Disconnect the return pipe and hydraulic hose from control valve 3 Remove the eye joint bolt from control valve then remove the control valve and bracket as a unit 4 Remove the control valve adaptor mounting screws 4 and remove the control valve 2 with the control valve adaptor 3 5 Remo...

Page 200: ...nd remove the gasket 2 stopper spring 3 and steel ball 4 4 Flatten the lock washer 11 and unscrew the valve guide arm mounting screw 12 5 Remove the control lever 8 and valve guide arm 10 When reassembling Visually inspect the spool for signs of scoring or damage If defects are found replace it Replace the valve cover gasket 14 with a new one Take care not to damage the O ring 9 Correctly insert t...

Page 201: ...r spring 4 5 Remove the cutting height adjusting dial knob 1 6 Remove the nut and remove the adjusting cam 3 and cutting height adjusting rod 2 When height by mower is lifted become insufficient ZD28 1 Because the mower linkages are worn out and correct height was not able to be obtained the adjustment coller 11 is built in 2 6 35 mm 0 25 in mower lifts high by changing the position of the adjusti...

Page 202: ...5 ELECTRICAL SYSTEM KiSC issued 09 2006 A ...

Page 203: ...lug 5 M8 3 SAFETY SWITCH LIMIT SWITCH 5 M8 4 FUEL PUMP 5 M9 5 ENGINE STOP SOLENOID 5 M9 6 COOLANT TEMPERATURE SWITCH 5 M9 3 CHARGING SYSTEM 5 M10 1 AC DYNAMO 5 M11 2 REGULATOR 5 M11 3 EASY CHECKER 5 M12 4 GAUGES 5 M13 1 FUEL QUANTITY 5 M13 2 COOLANT TEMPERATURE 5 M14 KiSC issued 09 2006 A ...

Page 204: ...5 M1 ZD21N EC ZD21 EC ZD28 EC WSM ELECTRICAL SYSTEM 1 WIRING DIAGRAM ZD21N ZD21 KiSC issued 09 2006 A ...

Page 205: ...5 M2 ZD21N EC ZD21 EC ZD28 EC WSM ELECTRICAL SYSTEM ZD28 KiSC issued 09 2006 A ...

Page 206: ...5 M3 ZD21N EC ZD21 EC ZD28 EC WSM ELECTRICAL SYSTEM ZD21N ZD21 KiSC issued 09 2006 A ...

Page 207: ...5 M4 ZD21N EC ZD21 EC ZD28 EC WSM ELECTRICAL SYSTEM ZD28 KiSC issued 09 2006 A ...

Page 208: ... safety switches on the terminal 30 is connected to the terminals 50 and AC Consequently battery current flows to the starter motor and start the engine The main switch automatically returns to the ON position the terminal 30 is connected only to the terminal AC thereby causing the starting circuit to be opened stopping the starter motor When the main switch turned from the ON position to the OFF ...

Page 209: ...ches on the terminal 30 is connected to the terminals 50 and AC Consequently battery current flows to the starter motor and start the engine The main switch automatically returns to the ON position the terminal 30 is connected only to the terminal AC thereby causing the starting circuit to be opened stopping the starter motor When the main switch turned from the ON position to the OFF position the...

Page 210: ...d planetary gears and the speed of gear shaft 6 is reduced to approximately one fifth of the armature shaft 8 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 KiSC issued 09 2006 A ...

Page 211: ...the resistance grows with the rise in the temperature of the resistor the flowing current is reduces to prevent the heater 4 from being heated The ignition point is in the area of 2 to 3 mm 0 079 to 0 118 in from the tip of the plug in order to reduce its projection into the combustion chamber W1013021 3 SAFETY SWITCH LIMIT SWITCH The safety switch prevents current from flowing to the starter when...

Page 212: ...sition Flowing of the battery current into the coil while the timer relay contact point is closed attracts the plunger to actuate the stop lever of the injection pump When the battery current stops the plunger is returned to the original position by the spring W1013394 6 COOLANT TEMPERATURE SWITCH The coolant temperature switch is installed to the water flange of engine and its tip is in touch wit...

Page 213: ... WSM ELECTRICAL SYSTEM 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 KiSC issued 09 2006 A ...

Page 214: ...tromagnetic coils are provided for This dynamo produces higher voltage in slow speed rotation and charges electric current to the battery during engine idling W1013535 2 REGULATOR The regulator performs rectification and voltage regulation The regulator converts AC into DC which flows through the power consuming circuits and the battery and also charges the battery If however the battery voltage e...

Page 215: ...arging system is not functioning properly this lamp illuminates 3 Pre heat Indicator Lamp When the key switch is in the Pre heat position the pre heat indicator lamp illuminates W1013747 Oil Pressure Switch While oil pressure is high and the force applied to the diaphragm 2 is larger than the spring tension the terminal contact 1 is open separated from the body contact 3 If the pressure drops belo...

Page 216: ... temperature detection 1 FUEL QUANTITY Fuel Level Sensor The remaining fuel quantity is detected by the fuel level sensor installed in the fuel tank and indicated on the fuel gauge For detection a float and a resistor are used As the float lowers the resistance of the variable resistor varies The relation between the amount of fuel and the resistance is as follows W1013985 F 1 2 E Remaining fuel o...

Page 217: ...t contains a thermistor 4 whose electrical resistance decreases as the temperature increases Current varies with changes in the coolant temperature and the increases or decreases in the current move the pointer of gauge W1014123 Characteristics of Thermistor Temperature Resistance 50 C 122 F 153 9 Ω 80 C 176 F 51 9 Ω 100 C 212 F 27 4 Ω 120 C 248 F 16 1 Ω 1 Terminal 2 Insulator 3 Body 4 Thermistor ...

Page 218: ...SERVICING 5 S5 1 BATTERY 5 S5 1 Checking 5 S5 2 STARTING SYSTEM 5 S7 1 Checking 5 S7 2 Disassembling and Assembling 5 S12 3 Servicing 5 S12 3 CHARGING SYSTEM 5 S15 1 Checking 5 S15 2 Disassembling and Assembling 5 S15 3 Servicing 5 S16 4 LIGHTING SYSTEM 5 S17 1 Checking 5 S17 5 GAUGES 5 S18 1 Checking 5 S18 KiSC issued 09 2006 A ...

Page 219: ...ipping Replace Repair or replace Replace Repair or replace Adjust tension 5 S15 G 28 Starter Motor Does Not Operate Battery discharged or defective Slow blow fuse blown Safety switch defective Wiring harness disconnected or improperly connected between main switch 50 terminal and safety switches between safety switches and starter motor between battery positive terminal and starter motor Starter m...

Page 220: ...disconnected or improperly connected between main switch 30 terminal and dynamo between panel board and dynamo Dynamo defective Regulator defective Repair or replace Repair or replace Replace 5 S15 Fuel Gauge Does Not Function Fuel gauge defective Fuel level sensor defective Wiring harness disconnected or improperly connected between fuel gauge and fuel level sensor Replace Replace Repair or repla...

Page 221: ...low Plug Resistance Approx 0 9 Ω Starter Commutator Mica Brush O D Difference of O D s Undercut Length 30 0 mm 1 181 in Less than 0 02 mm 0 0008 in 0 50 to 0 80 mm 0 0197 to 0 0315 in 14 0 mm 0 551 in 29 0 mm 1 142 in 0 05 mm 0 0020 in 0 20 mm 0 0079 in 9 0 mm 0 354 in AC Dynamo Charging Current Dynamo Speed Charging Voltage Dynamo Speed 14 to 15 A 5200 rpm 14 to 15 V 5200 rpm KiSC issued 09 2006 ...

Page 222: ...es of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page G 9 W1012736 Item N m kgf m ft lbs Starter B terminal nut AC dynamo Stator nut 5 9 to 11 8 39 2 to 44 1 0 6 to 1 2 4 0 to 4 5 4 3 to 8 7 28 9 to 32 5 KiSC issued 09 2006 A ...

Page 223: ...this advice is disregarded damage to alternator and regulator may result 1 BATTERY 1 Checking Battery Voltage 1 Stop the engine and turn the main switch off 2 Connect the COM lead of the voltmeter to the battery s negative terminal post and the lead to the positive terminal post and measure the battery voltage 3 If the battery voltage is less than the factory specification check the battery specif...

Page 224: ... and hold the hydrometer at eye level The hydrometer reading must be taken at the highest electrolyte level Reference Specific gravity slightly varies with temperature To be exact the specific gravity decreases by 0 0007 with an increase of 1 C 0 0004 with an increase of 1 F in temperature and increases by 0 0007 with a decreases of 1 C 0 0004 with a decrease of 1 F Therefore using 20 C 68 F as a ...

Page 225: ...released at combination 3 the parking brake safety switch is bad 3 If the engine starts in combination 4 when the PTO lever is ON position the PTO lever switch is bad 4 If the engine starts in combinations 5 and 6 when the motion control lever is a Operating position the motion control lever safety switch is bad Moreover the engine stops if the parking lever is not released within two seconds afte...

Page 226: ...n 1 Set and hold the main switch key at the PREHEAT position 2 Measure the resistance with an ohmmeter across the 30 terminal and the 19 terminal and measure the resistance across the 30 terminal and the AC terminal 3 If 0 ohm is not indicated these contacts of the main switch are faulty 4 Main Switch Key at START Position 1 Set and hold the main switch key at the START position 2 Measure the resi...

Page 227: ... 2 The plunger should be attracted strongly when a jumper lead is connected from the battery positive terminal to the S terminal 2 Checking Holding Coil 1 Connect jumper leads from the battery s negative terminal post to the body and the battery s positive terminal post to the S terminal 2 Push the plunger in by hand and release it Then the plunger should remain being attracted W1018490 D Glow Plu...

Page 228: ...Continuity 1 Remove the safety switch leads 2 Connect the circuit tester to the safety switch leads 3 Measure the resistance between leads 4 If the safety switch is defective replace it W1019187 Glow plug resistance Factory spec Approx 0 9 Ω Resistance Across switch terminal Speed control lever PTO lever Operator seat When switch push is pushed 0 Ω When switch push is released Infinity Resistance ...

Page 229: ...el pump 2 Check the continuity between the connector terminals with an ohmmeter 3 If it does not conduct the fuel pump is faulty W1019534 G Engine Stop Solenoid Engine Stop Solenoid Test 1 Disconnect the 1P connector from the engine stop solenoid 2 Remove the engine stop solenoid from the engine 3 Connect the jumper leads from the battery positive terminal to the 1P connector and from the battery ...

Page 230: ...e shaft assembly 5 with the drive leverr 6 and overrunning clutch 7 from the housing 3 Servicing Overrunning Clutch 1 Inspect the pinion for wear or damage 2 If there is any defect replace the overrunning clutch assembly 3 Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction 4 If the pinion slips or does not rotate in the both dir...

Page 231: ... Wear 1 If the contact face of the brush is dirty or dusty clean it with emery paper 2 Measure the brush length A with vernier calipers 3 If the length is less than the allowable limit replace the yoke assembly and brush holder W1022961 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 W1023089 Commutator O...

Page 232: ...ity across the segments of the commutaor with an ohmmeter 4 If it does not conduct replace the armature W1023212 Field Coil 1 Check the continuity across the lead 1 and brush 2 with an ohmmeter 2 If it does not conduct replace the yoke assembly 3 Check the continuity across the brush 2 and yoke 3 with an ohmmeter 4 If it conducts replace the yoke assembly W1023312 1 Lead 2 Brush 3 Yoke KiSC issued...

Page 233: ...ot Check Table NOTE Type to use a high resistance tester as far as possible The judgement should be as below table ON if the indicator moves otherwise OFF W1023600 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 W1024139 Current Factory spec 14 to 15 A Voltage 14 to 15 V Dynamo speed 5200 rpm 1...

Page 234: ...hen reassembling Take care the direction of the collar 4 the flat side should face to the pulley 2 side W1024281 3 Servicing Bearing 1 Check the bearing for smooth rotation 2 If it does not rotate smoothly replace it W1024489 1 Shaft 2 Pulley 3 Rotor 4 Collar 5 Bearings 6 Collar KiSC issued 09 2006 A ...

Page 235: ...h OFF 2 Turn the main switch ON and connect a jumper lead from the lead to the chassis 3 If the engine oil pressure indicator lamp does not light the wiring harness is faulty W1024686 Engine Oil Pressure Switch Continuity 1 Measure the resistance with an ohmmeter across the switch terminal and the chassis 2 If 0 ohm is not indicated in the normal state the switch is faulty 3 If infinity is not ind...

Page 236: ... Temperature Gauge Operation 1 Remove the under panel 2 Turn the main switch to ON position Measure the voltage with a voltmeter across the I terminal 3 and GND terminal 2 of the gauge 3 If approx battery voltage is indicated the ignition and ground lead connections are good 4 Turn the main switch to OFF position Connect a jumper lead between S terminal 1 and GND terminal 2 of the gauge 5 Turn the...

Page 237: ...6 ROTARY MOWER KiSC issued 09 2006 A ...

Page 238: ...CONTENTS MECHANISM 1 POWER TRANSMISSION 6 M1 2 LIFTING MECHANISM 6 M2 KiSC issued 09 2006 A ...

Page 239: ...Shaft 1 Universal Joint 2 Pinion Shaft 4 Bevel Gear 3 Bevel Gear 5 Bevel Gear Shaft 10 Center Pulley 11 Mower Belt 9 Outer Pulley 7 Blade Shaft 8 Outer Blade 6 1 PTO Shaft 2 Universal Joint 3 19T Bevel Gear RCK54 18T Bevel Gear RCK60 17T Bevel Gear RCK72 4 Pinion Shaft 5 16T Bevel Gear RCK54 17T Bevel Gear RCK60 18T Bevel Gear RCK72 6 Outer Blade 7 Outer Pulley 8 Blade Shaft 9 Mower Belt 10 Bevel ...

Page 240: ...r is moved to LIFT position the rear arm 3 are risen with lift shaft 2 by the oil pressure of hydraulic system Therefore front arm 5 connected with the horizon plate 4 are lifted at the same time As this link system is a parallel linkage the mower can be kept parallel at every position CAUTION Never operate mower in transport position 1 Lift Cylinder 2 Lift Shaft 3 Rear Arm 4 Horizon Plate 5 Front...

Page 241: ...ING 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 S7 KiSC issued 09 2006 A ...

Page 242: ...spring Remove grass Replace cup washer Mow at full throttle check and reset engine rpm G 38 6 S7 Cutting Is Poor Worn or bent mower blade Loosen mower blade screw Cutting height improper Ground speed too fast Low wheel inflation Anti scalp rollers not adjusted correctly Sharpen or replace mower blade Retighten mower blade screw Adjust cutting height Slow down Add air to correct Adjust anti scalp r...

Page 243: ...ning Force Turning Torque Less than 117 7 N 12 0 kgf 26 5 lbs Less than 1 47 N m 0 15 kgf m 1 08 ft lbs Bevel Gears in Gear Box Backlash 0 13 to 0 25 mm 0 0051 to 0 0098 in 0 4 mm 0 157 in Front Tip of Blade to Rear Tip of Blade Difference 0 to 6 0 mm 0 to 0 24 in Left Tip of Blade to Right Tip of Blade Difference Less than 3 mm 0 1181 in KiSC issued 09 2006 A ...

Page 244: ...6 Item N m kgf m ft lbs Mower blade screw Gear box mounting screw Standard type Reamer type Center pulley holder screw Standard type Reamer type Outer pulley mounting nut Pulley holder mounting screw 98 1 to 117 7 77 6 to 90 2 77 6 to 90 2 166 7 to 186 3 77 4 to 90 2 10 0 to 12 0 8 0 to 9 2 8 0 to 9 2 17 0 to 19 0 7 9 to 9 2 72 3 to 86 8 57 1 to 66 5 57 1 to 66 5 123 0 to 137 4 57 1 to 66 5 KiSC i...

Page 245: ...rt position Also the top end of the lift 4 Turn the cutting height control dial to adjust height 5 Lower the mower deck W1020280 Rear side anti scalp roller 6 Adjust height H of the rear side anti scalp roller to one of four positions to approximately 19 mm 0 75 in between rollers and ground Adjust both side rollers to the same height 7 Install the roller with attaching hardware W1020905 Front sid...

Page 246: ...ht fine tuning bolts 3 to set 80 mm 3 1 8 in height Front and rear side bolts must be adjusted 9 Lock the nuts 10 Adjust the left side equally 11 Measure the heights of blade L and R from the ground surface and calculate the difference 12 If the difference between left tip and right tip of blade is not within the factory specification adjust the length of cutting height fine tuning bolt 3 W1011016...

Page 247: ...oth front side bolts 3 must be adjusted 8 Lock the nuts 4 9 Adjust the other side equally 10 Measure the heights of blade A and B from the ground surface and calculate the difference 11 If the difference between front tip and rear tip of blade is not within the factory specification adjust the length H of cutting height fine tuning bolt with lock nut 4 The height of rear blade tip B should be bigg...

Page 248: ... it will hold the blade safely while loosing or tightening the blade screw When reassembling Be sure to assemble the two cup washers between the mower blade and spline boss IMPORTANT Make sure the cup washer is not flattened out or worn causing blade to slip easily Replace two cup washers if either is damaged W1012667 Blade Boss 1 Remove the external snap ring 2 2 Remove the blade boss 1 W1012871 ...

Page 249: ...aring 13 9 Remove the external snap ring 8 and draw out the bevel gear shaft 22 10 Remove the bevel gear 9 with ball bearing 10 When reassembling Replace the oil seals 1 20 and gear box caps 7 18 with new ones Check the backlash and turning torque If not proper adjust with the shims 3 11 and 14 See page S6 11 W1018511 Tightening torque Gear box mounting screw 77 6 to 90 2 N m 8 0 to 9 2 kgf m 57 1...

Page 250: ... prevent the incline the gear box Tighten the reamer screws 9 to the gear box first then tighten the reamer screws 10 to the center pulley holder 12 with specified torque Tighten the gear box screws 6 to the gear box then tighten the center pulley holder screws 5 with specified torque See page 6 S8 for tightening torque of gear box screw W1013720 Tightening torque Center pulley holder screw Standa...

Page 251: ...embling Replace the oil seals 32 24 14 and 6 with new ones Tightening torque Outer pulley mounting nut 166 7 to 186 3 N m 17 0 to 19 0 kgf m 123 0 to 137 4 ft lbs Pulley holder mounting screw 77 4 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 ft lbs 1 Grease Nipple 2 Outer Pulley Mounting Nut 3 Spring Washer 4 Plain Washer 5 Outer Pulley Right 6 Oil Seal 7 Internal Snap Ring 8 Ball Bearing 9 Blade Sha...

Page 252: ...ar 2 on the pinion shaft 5 3 Turn the pinion shaft 4 Take out the fuses and measure the thickness of fuses with an outside micrometer Backlash equal thickness of fuse 5 If the backlash exceeds the allowable limit adjust with shims 1 4 6 Reference Thickness of adjusting shims 1 4 0 2 mm 0 0079 in 0 3 mm 0 0118 in Thickness of adjusting shims 6 0 1 mm 0 0039 in 0 2 mm 0 0079 in W1020126 Turning forc...

Page 253: ...ode No 9Y011 15151 2002 03 S EI EI e KUBOTA Corporation EDITOR KUBOTA FARM INDUSTRIAL MACHINERY SERVICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72 245 2484 E mail ksos pub kubota co jp ...