Kubota GZD15 Instruction manual

GZD15
WORKSHOP MANUAL
KiSC issued 04, 2006 A

TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism,
service and maintenance of GZD15. It is divided into two parts, "Mechanism" and "Servicing" for each section.
Information on the features and new mechanisms are described. This information should be understood before
proceeding with troubleshooting, disassembling and servicing.
The heading "General" includes general precautions, check and maintenance and special tools. Other section,
there are troubleshooting, checking and adjusting, disassembling and assembling, and servicing which cover
procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on the latest product information
available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
KUBOTA Corporation 2003
BMechanism
BServicing
December 2003
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KiSC issued 04, 2006 A

GZD15, WSM SAFETY INSTRUCTIONS
1
BEFORE SERVICING AND REPAIRING
ARead all instructions and safety instructions in this
manual and on your machine safety decals.
AClean the work area and machine.
APark the machine on a firm and level ground, and set
the parking brake.
ALower the implement to the ground.
AStop the engine, and remove the key
ADisconnect the battery negative cable
AHang a "DO NOT OPERATE" tag in operator
station.
SAFETY STARTING
ADo not start the engine by shorting across starter
terminals or bypassing the safety start switch.
ADo not alter or remove any part of machine safety
system.
ABefore starting the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
ANever start the engine while standing on ground.
Start the engine only from operator's seat.
This symbol, the industry's "Safety Alert Symbol" is used throughout this manual and on labels on the machine
itself to warn of the possibility of personal injury. Read these instructions carefully.It is essential that you read the
instructions and safety regulations before you attempt to repair or use this unit.
AIndicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
AIndicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
AIndicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
AIndicates that equipment or property damage could result if instructions are not followed.
AGives helpful information.
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GZD15, WSM SAFETY INSTRUCTIONS
2
SAFETY WORKING
ADo not work on the machine while under the
influence of alcohol, medication, or other substances
or while fatigued.
AWear close fitting clothing and safety equipment
appropriate to the job.
AUse tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
AWhen servicing is performed together by two or
more persons, take care to perform all work safely.
ADo not work under the machine that is supported
solely by a jack. Always support the machine by
safety stands.
ADo not touch the rotating or hot parts while the
engine is running.
ANever 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 completely.
AEscaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic or
fuel lines. Tighten all connections before applying
pressure.
AVOID FIRES
AFuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
ATo avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
ABattery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
AMake sure that no fuel has been spilled on the
engine.
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GZD15, WSM SAFETY INSTRUCTIONS
3
VENTILATE WORK AREA
AIf the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains
poisonous carbon monoxide.
PREVENT ACID BURNS
ASulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into 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
ADo 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 EMERGENCIES
AKeep a first aid kit and fire extinguisher handy at all
times.
AKeep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
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GZD15, WSM SAFETY INSTRUCTIONS
4
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
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GZD15, WSM SAFETY INSTRUCTIONS
5
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6
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GZD15, WSM SAFETY INSTRUCTIONS
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GZD15, WSM SPECIFICATIONS
8
SPECIFICATIONS
Model GZD15-LD GZD15-HD
Maximum gross power 11.2 kW (15 HP) *1
Engine
Model Z602-GZD15
Type Indirect injection. Vertical, water-cooled, 4-cycle diesel engine
Number of cylinder 2
Bore and stroke 72.0 x 73.6 mm (2.83 x 2.90 in.)
Total displacement 599 (36.6 cu.in.)
Rated revolution 3000 rpm
Combustion chamber Spherical type (E-TVCS)
Fuel injection pump Bosh MD type mini pump
Governor Centrifugal ball mechanical governor
Injection nozzle Bosh throttle type
Injection timing 0.30 to 0.33 rad. (17 to 19 ) before T.D.C.
Injection order 1-2
Injection pressure 13.73 MPa (140 , 1990 psi)
Lubricating system Forced lubrication by gear pump
Cooling system Pressurized radiator, forced circulation with water pump
Lubricating oil
API Service classification CD, CE or CF,
below 0 (32 ) : SAE 10W, 10W-30 or 10W-40,
0 to 25 (32 to 77 ) : SAE 20, 10W-30 or 10W-40,
above 25 (77 ) :SAE 30, 10W-30 or 10W-40
Starting system Electrical starter (12 V, 1.1 kW)
Battery 65D23L (12V, 52A.H. at 5H.R.)
Fuel No.2-D Diesel fuel (ASTM D975)
[No. 1-D diesel fuel, if temperature is below -10 (14 )]
Capacities
Fuel tank 20 L (5.3 U.S.gals, 4.4 lmp.gals)
Engine crankcase 2.1 L (2.2 U.S.qts, 1.8 lmp.qts)
Engine coolant 1.4 L (1.5 U.S.qts, 1.2 lmp.qts)
Recovery tank 0.25 L (0.26 U.S.qts., 0.22 Imp.qts.)
Transmission case & rear axle gear case (RH
& LH) 10.0 L (10.6 U.S.qts., 8.8 Imp.qts.)
Front PTO case 0.13 L (0.14 U.S.gals, 0.11 lmp.gals)
Mower gear case oil 0.15 L (0.16 U.S.qts, 0.13 lmp.qts)
Tyres Front 15 x 6.0 - 6 (4 PR) Rib
Rear 20 x 10.0 - 12 (4 PR) Turf
Traveling speeds Forward 0 to 13.5 km/h (0 to 8.4 mph)
Reverse 0 to 10.0 km/h (0 to 6.3 mph)
NOTE:
*1 Manufacture's estimate
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KiSC issued 04, 2006 A

GZD15, WSM SPECIFICATIONS
9
Model GZD15-LD GZD15-HD
Dimensions
Overall length (with grass collector) 2785 mm (109.7 in.)
Overall width (with mower) 1195 mm (47.1 in.)
Overall height (without ROPS) 1115 mm (43.9 in.) 1345 mm (53.0 in.)
Wheel base 1285 mm (50.6 in.)
Tread Front 815 mm (32.1 in.)
Rear 950 mm (37.4 in.), 850 mm (32.7 in.)
Weight (with mower deck and grass collector)) 510 kg (1124.6 lbs) / with 40 in.
mower deck 540 kg (1190.7 lbs) / with 40 in. mower deck
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GZD15, WSM DIMENSIONS
10
DIMENSIONS
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GZD15, WSM DIMENSIONS
11
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GGENERAL
KiSC issued 04, 2006 A

CONTENTS
1. IDENTIFICATION................................................................................................................G-1
2. GENERAL PRECAUTIONS................................................................................................G-2
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING......................G-3
[1] WIRING..............................................................................................................................G-3
[2] BATTERY ..........................................................................................................................G-5
[3] FUSE .................................................................................................................................G-5
[4] CONNECTOR....................................................................................................................G-5
[5] HANDLING OF CIRCUIT TESTER....................................................................................G-6
4. LUBRICANTS, FUEL AND COOLANT.............................................................................G-7
5. TIGHTENING TORQUES...................................................................................................G-9
[1] GENERAL USE SCREWS, BOLTS AND NUTS ..........................................................G-9
[2] METRIC SCREWS, BOLTS AND NUTS.......................................................................G-9
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH
UNC OR UNF THREADS .............................................................................................G-10
[4] PLUGS.............................................................................................................................G-10
6. MAINTENANCE.................................................................................................................G-11
7. CHECK AND MAINTENANCE ........................................................................................G-13
[1] DAILY CHECK................................................................................................................G-13
[2] CHECK POINTS OF INITIAL 50 HOURS...................................................................G-19
[3] CHECK POINT OF INITIAL 100 HOURS...................................................................G-24
[4] CHECK POINTS OF EVERY 50 HOURS...................................................................G-25
[5] CHECK POINTS OF EVERY 100 HOURS.................................................................G-30
[6] CHECK POINT OF EVERY 150 HOURS...................................................................G-34
[7] CHECK POINTS OF EVERY 200 HOURS.................................................................G-34
[8] CHECK POINTS OF EVERY 400 HOURS.................................................................G-36
[9] CHECK POINTS OF EVERY 1 YEAR........................................................................G-36
[10] CHECK POINTS OF EVERY 2 YEARS......................................................................G-39
[11] OTHERS..........................................................................................................................G-40
8. SPECIAL TOOLS .............................................................................................................G-50
[1] SPECIAL TOOLS FOR ENGINE.....................................................................................G-50
[2] SPECIAL TOOLS FOR MACHINE ...............................................................................G-56
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GZD15, WSM GENERAL
G-1
1. IDENTIFICATION When contacting your local KUBOTA distributor, always specify
engine serial number (3), machine serial number (2), mower serial
number (4) and hour meter reading.
(1) Machine Identification Plate (4) Mower Serial Number
(2) Machine Serial Number (5) Mower Identification Plate
(3) Engine Serial Number
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GZD15, WSM GENERAL
G-2
2. GENERAL PRECAUTIONS
ADuring disassembly, carefully arrange removed parts in a
clean area to prevent confusion later. Screws, bolts and nuts
should be installed in their original position to prevent
reassembly errors.
AWhen special tools are required, use KUBOTA genuine
special tools. Special tools which are not frequently used
should be made according to the drawings provided.
ABefore disassembling or servicing electrical wires, always
disconnect the ground cable from the battery first.
ARemove oil and dirt from parts before measuring.
AUse only KUBOTA genuine parts for parts replacement to
maintain machine performance and to assure safety.
AGaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
See the figure left side.
AWhen reassembling external snap rings or internal snap rings,
they must be positioned so that sharp edge faces against the
direction from which a force is applied. See the figure left side.
AWhen inserting spring pins, their splits must face the direction
from which a force is applied. See the figure left side.
ATo prevent damage to the hydraulic system, use only specified
fluid or equivalent.
(1) Grease (A) External Snap Ring
(2) Force (B) Internal Snap Ring
(3) Sharp Edge
(4) Axial Force
(5) Rotating Movement
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GZD15, WSM GENERAL
G-3
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS
AND WIRING To ensure safety and prevent damage to the machine and
surrounding equipment, heed the following precautions in
handling electrical parts and wiring.
ACheck electrical wiring for damage and loosened
connection every year. To this end, educate the customer
to do his or her own check and at the same time
recommend the dealer to perform periodic check for a fee.
ADo not attempt to modify or remodel any electrical parts
and wiring.
AWhen removing the battery cables, disconnect the
negative cable first. When installing the battery cables,
connect the positive cable first.
[1] WIRING
ASecurely tighten wiring terminals.
ADo not let wiring contact dangerous part.
ASecurely insert grommet.
(1) Negative Terminal (2) Positive Terminal
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(1) Correct (2) Incorrect
(Securely Tighten) (Loosening Leads to Faulty
Contact)
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(1) Dangerous Part (3) Wiring (Correct)
(2) Wiring (Incorrect) (4) Dangerous Part
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(1) Grommet (A) Correct
(B) Incorrect
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GZD15, WSM GENERAL
G-4
ASecurely clamp, being careful not to damage wiring.
AClamp wiring so that there is no twist, unnecessary sag, or
excessive tension, except for movable part, where sag be
required.
AIn installing a part, take care not to get wiring caught by it.
AAfter installing wiring, check protection of terminals and
clamped condition of wiring, only connect battery.
(1) Clamp (3) Clamp
*Wind Clamp Spirally (4) Welding Dent
(2) Wire Harness
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(1) Wiring (A) Correct
(2) Clamp (B) Incorrect
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(1) Wiring (A) Incorrect
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(1) Cover
*Securely Install Cover
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GZD15, WSM GENERAL
G-5
[2] BATTERY
ATake care not to confuse positive and negative terminal posts.
AWhen removing battery cables, disconnect negative cable
first. When installing battery cables, check for polarity and
connect positive cable first.
ADo not install any battery with capacity other than is specified
(Ah).
AAfter connecting cables to battery terminal posts, apply high
temperature grease to them and securely install terminal
covers on them.
ADo not allow dirt and dust to collect on battery.
ATake care not to let battery liquid spill on your skin and
clothes. If contaminated, wash it off with water
immediately.
ABefore recharging the battery, remove it from the
machine.
ABefore recharging, remove cell caps.
ADo recharging in a well-ventilated place where there is no
open flame nearby, as hydrogen gas and oxygen are
formed.
[3] FUSE
AUse fuses with specified capacity.
Neither too large or small capacity fuse is acceptable.
ANever use steel or copper wire in place of fuse.
ADo not install working light, radio set, etc. on machine which is
not provided with reserve power supply.
ADo not install accessories if fuse capacity of reserve power
supply is exceeded.
[4] CONNECTOR
AFor connector with lock, push lock to separate.
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(1) Fuse (2) Fusible Link
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(A) Push
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