Kubota WSM ZD1211 Instruction manual

ZD1211,ZD1211R,
ZD1211L,ZD1211RL
WORKSHOP MANUAL
KiSC issued 06, 2017 A

TO THE READER
This Workshop Manual tells the servicing personnel about the mechanism, servicing and
maintenance of the ZD1211, ZD1211R, ZD1211L, ZD1211RL. It contains 4 parts: "Information",
"General", "Mechanism" and "Servicing".
Information
This section primarily contains information below.
• Safety First
• Safety Decal
• Specifications
• Dimensions
General
This section primarily contains information below.
• Engine Identification
• Model Identification
• General Precautions
• Maintenance Check List
• Check and Maintenance
• Special Tools
Mechanism
This section contains information on the structure and the function of the unit. Before you continue
with the subsequent sections, make sure that you read this section.
Refer to the latest version of Workshop Manual (Code No. 9Y021-01870 / 9Y021-18200) for the
diesel engine / tractor mechanism that this workshop manual does not include.
Servicing
This section primarily contains information below.
• Troubleshooting
• Servicing Specifications
• Tightening Torques
• Checking, Disassembling and Servicing
All illustrations, photographs and specifications contained in this manual are of the newest
information available at the time of publication.
KUBOTA reserves the right to change all information at any time without notice.
Since this manual includes many models, information or illustrations and photographs can show
more than one model.
November, 2015
© KUBOTA Corporation 2015
KiSC issued 06, 2017 A
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Record of Revisions
For pdf, use search function {Search word} to find all the revised locations.
Last digit
of the
Code No.
Issue
month Main Revised Point and Corrective Measures {Search word} Reference
Page
12016.07 Updated Specifications
Added Error Code Display
Updated Torque for Gearbox mounting bolt
I-8,
I-9,
I-10
5-M16
6-S13
22016.07 Updated Maintenance Chart
• Added Engine valve clearance
Updated Greasing Points
G-14
G-9
32017.06 Updated "Battery for storage" contents G-31
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I INFORMATION
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CONTENTS
1. SAFETY FIRST .............................................................................................................................. I-1
2. SAFETY DECALS .......................................................................................................................... I-4
3. SPECIFICATIONS.......................................................................................................................... I-8
4. DIMENSIONS ............................................................................................................................... I-10
INFORMATION
KiSC issued 06, 2017 A
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INFORMATION
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
I-1
1. SAFETY FIRST
WSM000001INI0001US1
BEFORE YOU START SERVICE
• Read all instructions and safety instructions in this
manual and on your machine safety decals.
• Clean the work area and machine.
• Park the machine on a stable and level ground, and
set the parking brake.
• Lower the implement to the ground.
• Stop the engine, then remove the key.
• Disconnect the battery negative cable.
• Hang a "DO NOT OPERATE" tag in the operator
station.
WSM000001INI0010US0
START SAFELY
• Do not do the procedures below when you start the
engine.
– short across starter terminals
– bypass the safety start switch
• Do not alter or remove any part of machine safety
system.
• Before you start the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
• Do not start the engine when you stay on the ground.
Start the engine only from operator's seat.
WSM000001INI0015US0
SAFETY FIRST
• This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the
machine itself to warn of the possibility of personal injury. Read these instructions carefully.
• It is essential that you read the instructions and safety regulations before you try to repair or use this
unit.
DANGER
• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
• Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate
injury.
IMPORTANT
• Indicates that equipment or property damage could result if instructions are not followed.
NOTE
• Gives helpful information.
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INFORMATION
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
I-2
OPERATE SAFELY
• Do not use the machine after you consume alcohol
or medication or when you are tired.
• Put on applicable clothing and safety equipment.
• Use applicable tools only. Do not use alternative
tools or parts.
• When 2 or more persons do servicing, make sure
that you do it safely.
• Do not operate below the machine that only a jack
holds. Always use a safety stand to hold the
machine.
• Do not touch the hot parts or parts that turn when the
engine operates.
• Do not remove the radiator cap when the engine
operates, or immediately after it stops. If not, hot
water can spout out from the radiator. Only remove
the radiator cap when it is at a sufficiently low
temperature to touch with bare hands. Slowly loosen
the cap to release the pressure before you remove it
fully.
• Released fluid (fuel or hydraulic oil) under pressure
can cause damage to the skin and cause serious
injury. Release the pressure before you disconnect
hydraulic or fuel lines. Tighten all connections before
you apply the pressure.
• Do not open a fuel system under high pressure.
The fluid under high pressure that stays in fuel lines
can cause serious injury. Do not disconnect or repair
the fuel lines, sensors, or any other components
between the fuel pump and injectors on engines with
a common rail fuel system under high pressure.
• Put on an applicable ear protective device (earmuffs
or earplugs) to prevent injury against loud noises.
• Be careful about electric shock. The engine
generates a high voltage of more than DC100 V in
the ECU and is applied to the injector.
WSM000001INI0012US0
PREVENT A FIRE
• Fuel is very flammable and explosive under some
conditions. Do not smoke or let flames or sparks in
your work area.
• To prevent sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
• The battery gas can cause an explosion. Keep the
sparks and open flame away from the top of battery,
especially when you charge the battery.
• Make sure that you do not spill fuel on the engine.
WSM000001INI0005US0
KiSC issued 06, 2017 A
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INFORMATION
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
I-3
KEEP A GOOD AIRFLOW IN THE WORK AREA
• If the engine is in operation, make sure that the area
has good airflow. Do not operate the engine in a
closed area. The exhaust gas contains poisonous
carbon monoxide.
WSM000001INI0006US0
PREVENT ACID BURNS
• Keep electrolyte away from your eyes, hands and
clothing. Sulfuric acid in battery electrolyte is
poisonous and it can burn your skin and clothing and
cause blindness. If you spill electrolyte on yourself,
clean yourself with water, and get medical aid
immediately.
WSM000001INI0008US0
DISCARD FLUIDS CORRECTLY
• Do not discard fluids on the ground, down the drain,
into a stream, pond, or lake. Obey related
environmental protection regulations when you
discard oil, fuel, coolant, electrolyte and other
dangerous waste.
WSM000001INI0007US0
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher ready at all
times.
• Keep the emergency contact telephone numbers
near your telephone at all times.
WSM000001INI0009US0
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INFORMATION
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
I-4
2. SAFETY DECALS
The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not
on the machine, replace it. The decal part number is listed in the parts list.
WSM000001INI0013US0
9Y1211344INI0001US0
KiSC issued 06, 2017 A
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INFORMATION
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
I-5
9Y1211344INI0002US0
KiSC issued 06, 2017 A
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INFORMATION
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
I-6
9Y1211344INI0003US0
KiSC issued 06, 2017 A

INFORMATION
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
I-7
9Y1211344INI0004US0
CARE OF DANGER, WARNING AND CAUTION LABELS
1. Keep danger, warning and caution labels clean and free from obstructing material.
2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth.
3. Replace damaged or missing danger, warning and caution labels with new labels.
4. If a component with danger, warning and caution label(s) affixed is replaced with new part, make sure new label(s)
is (are) attached in the same location(s) as the replace component.
5. Mount new danger, warning and caution labels by applying on a clean dry surface and pressing any bubbles to
outside edge.
9Y1211344INI0005US0
KiSC issued 06, 2017 A

INFORMATION
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
I-8
3. SPECIFICATIONS
(Specifications and design subject to change without notice)
NOTE
• *1: Manufacturer's estimate, SAE J1940
• *2: At 3000 engine rpm [ZD1211, ZD1211R, ZD1211L, ZD1211RL]
• *3: Oil amount when the oil level is at the upper level.
9Y1211344INI0006US0
Model ZD1211 ZD1211R ZD1211L ZD1211RL
Engine
Model D1105
Maximum engine power (Gross) 18.5 kw (24.5 HP) (*1) (*2)
Type Liquid-cooled
Number of cylinders 3
Bore and stroke 78 × 78.4 mm (3.07 × 3.09 in.)
Total displacement 1123 cm3 (68.5 cu.in.)
Rated revolution 3000 min-1 (rpm)
Low idling revolution 1400 to 1500 min-1 (rpm)
Fuel Diesel fuel No. 1 [below −10 °C (14 °F)]
Diesel fuel No. 2 [above −10 °C (14 °F)]
Starter Electric starter with battery, glow plug, 12 V, 1.2 kW
Lubrication Forced lubrication by gear pump
Cooling Liquid with pressurized radiator
Battery SMF51R (12 V, RC:80 min, CCA:430 A)
Capacities
Fuel tank 49 L (12.9 U.S.gals., 11 Imp.gals.)
Engine crankcase
(with filter) 3.9 L (4.1 U.S.qts., 3.4 Imp.qts.)
Engine coolant 3.5 L (3.70 U.S.qts., 3.1 Imp.qts.)
Recovery tank 0.25 L (0.26 U.S.qts., 0.22 Imp.qts.)
Transmission case including rear
axle gear case 12.1 L (12.8 U.S.qts., 10.6 Imp.qts.) (*3)
Dimensions
Overall length 2260 mm (89.0 in.) 2380 mm (93.7 in.)
Overall width without mower deck 1510 mm (54.9 in.) 1540 mm (60.6 in.)
Overall
height
With ROPS upright 2000 mm (78.7 in.)
With ROPS folded 1640 mm (64.6 in.)
Wheel base 1440 mm (56.7 in.) 1560 mm (61.4 in.)
Minimum ground clearance 135 mm (5.31 in.)
W/60"
135 mm (5.31 in.)
W/72"
Tread Front 1064 mm (41.9 in.) 1250 mm (49.2 in.)
Rear 1210 mm (47.6 in.)
Weight
(W/O FUEL, W/MOWER DECK)
760 kg (1676 lbs)
with 60"
765 kg (1687 lbs)
with 60"
790 kg (1742 lbs)
with 72"
805 kg (1775 lbs)
with 72"
Travelling
system
Tires Front 15 × 6.0 - 6
(Semi-pneumatic Non Flat Tire) Smooth
Rear 26 × 12.0 - 16 (4PR) Turf low profile tire
Travelling
speeds
Forward 0 to 10.6 mph (0 to 17.0 km/h) (*2)
Reverse 0 to 5.3 mph (0 to 8.5 km/h) (*2)
Steering 2-Hand levers
Transmission 2 - HST w / Gear
Parking brake Wet multi disk / Foot applied, released
Min. turning radius 0 mm (0 in.)
PTO
Revolution 1 speed (2540 rpm at 3000 engine rpm)
Drive system Shaft drive, KUBOTA 10 tooth involute spline
Clutch type Wet multi disks
PTO brake Wet multi disks
KiSC issued 06, 2017 A

INFORMATION
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
I-9
*1: Engine Max rpm
9Y1211344INI0007US0
Model RCK60P-1200Z RCK60RP-1200Z RCK72P-1200Z RCK72RP-1200Z
PRO Com-
mercial
Deck
(Fabri-
cated deck)
Suitable machine ZD1211 ZD1211R ZD1211L ZD1211RL
Mounting method Quick joint, Parallel linkage
Adjustment of cutting height Dial gauge
Cutting width 1524 mm (60.0 in.) 1829 mm (72.0 in.)
Cutting height 25 to 127 mm (1.0 to 5.0 in.)
Weight (Approx.) 140 kg (306 lbs) 145 kg (320 lbs) 165 kg (364 lbs) 160 kg (353 lbs)
Blade spindle speed 55.9 r/s
(3355 rpm) *1
52.4 r/s
(3145 rpm) *1 46.7 r/s (2800 rpm) *1
Blade tip velocity 92 m/s
(18050 fpm) *1
86 m/s
(16900 fpm) *1
92 m/s
(18100 fpm) *1
91 m/s
(18000 fpm) *1
Blade length 523 mm (20.6 in.) 625 mm (24.6 in.)
Number of blades 3
Mower gear box capacity
0.5 L
(0.53 U.S.qts.,
0.4 Imp.qts.)
0.4 L
(0.42 U.S.qts.,
0.4 Imp.qts.)
0.5 L
(0.53 U.S.qts.,
0.4 Imp.qts.)
0.4 L
(0.42 U.S.qts.,
0.4 Imp.qts.)
Dimensions
Total length 974 mm (38.4 in.) 1000 mm (39.4 in.) 1162 mm (45.8 in.) 1155 mm (45.5 in.)
Total width 1876 mm (73.9 in.) 1600 mm (63.0 in.) 2180 mm (85.8 in.) 1910 mm (75.2 in.)
Total height 426 mm (16.8 in.) 420 mm (16.5 in.) 421 mm (16.6 in.) 413 mm (16.3 in.)
KiSC issued 06, 2017 A

INFORMATION
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
I-10
4. DIMENSIONS
9Y1211344INI0008US0
KiSC issued 06, 2017 A

G GENERAL
KiSC issued 06, 2017 A

CONTENTS
1. IDENTIFICATION ......................................................................................................................... G-1
2. GENERAL PRECAUTIONS.......................................................................................................... G-2
3. CYLINDER NYMBER ................................................................................................................... G-3
4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .................................... G-4
[1] WIRING .................................................................................................................................. G-4
[2] BATTERY ............................................................................................................................... G-6
[3] FUSE ...................................................................................................................................... G-6
[4] CONNECTOR ........................................................................................................................ G-6
[5] HANDLING OF CIRCUIT TESTER ........................................................................................ G-7
[6] COLOR OF WIRING ..............................................................................................................G-8
5. LUBRICANTS, FUEL AND COOLANT......................................................................................... G-9
6. TIGHTENING TORQUES........................................................................................................... G-12
[1] GENERAL USE SCREWS, BOLTS AND NUTS .................................................................. G-12
[2] STUD BOLTS ....................................................................................................................... G-12
[3] METRIC SCREWS, BOLTS AND NUTS.............................................................................. G-13
[4] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF
THREADS ............................................................................................................................ G-13
[5] PLUGS ................................................................................................................................. G-13
7. MAINTENANCE CHECK LIST ................................................................................................... G-14
8. CHECK AND MAINTENANCE ................................................................................................... G-16
[1] DAILY CHECK...................................................................................................................... G-16
[2] CHECK POINTS OF INITIAL 50 HOURS ............................................................................ G-22
[3] CHECK POINT OF INITIAL 100 HOURS ............................................................................. G-23
[4] CHECK POINT OF INITIAL 400 HOURS ............................................................................. G-24
[5] CHECK POINTS OF EVERY 50 HOURS ............................................................................ G-25
[6] CHECK POINTS OF EVERY 100 HOURS .......................................................................... G-29
[7] CHECK POINTS OF EVERY 150 HOURS .......................................................................... G-34
[8] CHECK POINTS OF EVERY 200 HOURS .......................................................................... G-34
[9] CHECK POINT OF EVERY 400 HOURS............................................................................. G-35
[10]CHECK POINTS OF EVERY 1000 HOURS OR EVERY 1 YEAR ....................................... G-35
[11]CHECK POINTS OF EVERY 1500 HOURS ........................................................................ G-36
[12]CHECK POINTS OF EVERY 2000 HOURS OR EVERY 2 YEARS..................................... G-36
[13]CHECK POINTS OF EVERY 3000 HOURS ........................................................................ G-39
[14]CHECK POINTS OF EVERY 1 YEAR.................................................................................. G-39
[15]CHECK POINT OF EVERY 4 YEARS.................................................................................. G-40
[16]OTHERS............................................................................................................................... G-41
9. SPECIAL TOOLS ....................................................................................................................... G-45
[1] SPECIAL TOOLS FOR ENGINE.......................................................................................... G-45
[2] SPECIAL TOOLS FOR MACHINE ....................................................................................... G-53
10. IMPLEMENT LIMITATIONS ....................................................................................................... G-54
GENERAL
KiSC issued 06, 2017 A

GENERAL
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
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.
9Y1211344GEG0001US0
(1) Machine Identification Plate
(2) Machine Serial Number
(3) ROPS Serial Number
(4) Engine Serial Number
(5) Mower Identification Plate
(6) Mower Serial Number
[A] RCK60P, RCK72P
[B] RCK60R, RCK72R
KiSC issued 06, 2017 A

GENERAL
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
G-2
2. GENERAL PRECAUTIONS
• When you disassemble, carefully put the parts in a clean area
to make it easy to find the parts. You must install the screws,
bolts and nuts in their initial position to prevent the reassembly
errors.
• When it is necessary to use special tools, use KUBOTA special
tools. Refer to the drawings when you make special tools that
you do not use frequently.
• Before you disassemble or repair machine, make sure that you
always disconnect the ground cable from the battery first.
• Remove oil and dirt from parts before you measure.
• Use only KUBOTA genuine parts for replacement to keep the
machine performance and to make sure of safety.
• You must replace the gaskets and O-rings when you assemble
again. Apply grease (1) to new O-rings or oil seals before you
assemble.
• When you assemble the external or internal circlips, make sure
that the sharp edge (3) faces against the direction from which
force (2) is applied.
• When inserting spring pins, their splits must face the direction
from which a force is applied. See the figure on the left side.
• To prevent damage to the hydraulic system, use only specified
fluid or equivalent.
WSM000001GEG0092US0
(1) Grease
(2) Force
(3) Sharp Edge
(4) Axial Force
(5) Rotating Movement
(A) External Circlip
(B) Internal Circlip
KiSC issued 06, 2017 A

GENERAL
ZD1211, ZD1211R, ZD1211L, ZD1211RL, WSM
G-3
3. CYLINDER NYMBER
The cylinder numbers of KUBOTA diesel engine are designated
as shown in the figure.
The sequence of cylinder numbers is given as No.1, No.2 and
No.3 starting from the gear case side.
9Y1211344GEG0002US0
KiSC issued 06, 2017 A