Kubota ZD1600 Series User manual

OPERATOR'S MANUAL
MANUAL DEL OPERADOR
1BNGU00001A01
ZD1611LF
ZD1611RLF
ZD1611RL
MODELS
MODELOS
English, Spanish (U.S.A.)
Code No.
Código n° K3452-7126-1
©2022 Kubota Corporation
PRINTED IN U.S.A.
IMPRESO EN E.E.U.U.
READ AND SAVE THIS MANUAL
LEA Y CONSERVE ESTE MANUAL
ZD1611LF·ZD1611RLF·ZD1611RL
BA . K . 1 - 1 . - . AK

OPERATOR'S MANUAL
READ AND SAVE THIS MANUAL
MODELS ZD1611LF
ZD1611RLF
ZD1611RL
1BNGU00001A01

ABBREVIATION LIST
Abbreviations
API
ASTM
fpm
HST
m/s
PTO
RH/LH
ROPS
rpm
r/s
SAE
Definitions
American Petroleum Institute
American Society for Testing and Materials, USA
Feet Per Minute
Hydrostatic Transmission
Meters Per Second
Power Take Off
Right-hand and left-hand sides are determined by facing in
the direction of forward travel
Roll-Over Protective Structures
Revolutions Per Minute
Revolutions Per Second
Society of Automotive Engineers
California Proposition 65
WARNING
Engine exhaust, some of its constituents,
certain vehicle components and fluids,
contain or emit chemicals known to the
State of California to cause cancer and birth
defects or other reproductive harm.
Canadian Electromagnetic Compatibility (EMC):
This machine complies with Industry Canada ICES-002.

UNIVERSAL SYMBOLS
As a guide to the operation of your machine, various universal symbols have been utilized on the instruments and
controls. The symbols are shown below with an indication of their meaning.
Safety alert symbol
Diesel fuel
Fuel-level
Parking brake
Engine-STOP
Preheat
Engine-RUN
Starter control
Power take-off clutch control-OFF
position (disengaged)
Power take-off clutch control-ON
position (engaged)
Cutting height
Mower-LOWERED position
Mower-RAISED position
FAST
SLOW
Engine speed control
Battery
Oil pressure
Coolant temperature
Regeneration
Regeneration INHIBIT (switch)
Regeneration (switch)
PARKED regeneration
Master system warning
Engine - warning

CONTENTS
SAFE OPERATION......................................................................................................................7
SERVICING OF MACHINE........................................................................................................21
DEALER SERVICE............................................................................................................................................. 21
WARRANTY........................................................................................................................................................ 22
SCRAPPING THE MACHINE ............................................................................................................................. 22
SPECIFICATIONS......................................................................................................................23
SPECIFICATION TABLE..................................................................................................................................... 23
IMPLEMENT LIMITATIONS.......................................................................................................25
INSTRUMENT PANEL AND CONTROLS .................................................................................26
INSTRUMENT PANEL, SWITCHES AND HAND CONTROLS .......................................................................... 26
MOWER.............................................................................................................................................................. 27
MOWER MOUNTING.................................................................................................................28
MOUNTING THE MOWER DECK ...................................................................................................................... 28
ADJUSTING THE MOWER ................................................................................................................................ 29
DISMOUNTING THE MOWER DECK ................................................................................................................ 29
INSTALLING PARTS TO THE MOWER ............................................................................................................. 30
1. Installation of skid ...................................................................................................................................... 30
2. Installation of gauge wheel ........................................................................................................................ 30
3. Installation of bolt (adjuster) ...................................................................................................................... 31
OPERATING THE ENGINE .......................................................................................................32
EXHAUST AFTERTREATMENT DEVICES........................................................................................................ 32
1. Diesel particulate filter (DPF) muffler......................................................................................................... 32
2. Handling points.......................................................................................................................................... 33
2.1 Fuel .................................................................................................................................................... 33
2.2 Engine oil ........................................................................................................................................... 33
2.3 Prohibition of unnecessary short-time operation................................................................................ 33
2.4 Regeneration...................................................................................................................................... 33
DPF REGENERATION PROCESS..................................................................................................................... 33
1. Tips on diesel particulate filter (DPF) regeneration ................................................................................... 34
1.1 Avoid prolonged idling if possible....................................................................................................... 34
1.2 Necessary conditions for “Regeneration”........................................................................................... 34
1.3 Other notes ........................................................................................................................................ 34
2. Operating procedure for auto regeneration mode ..................................................................................... 35
2.1 PM warning level and required procedures........................................................................................ 37
3. Operating procedure for regeneration inhibit mode................................................................................... 41
4. Operating procedure for parked regeneration ........................................................................................... 42
GETTING ON AND OFF THE MACHINE SAFELY............................................................................................. 44
STARTING THE ENGINE ................................................................................................................................... 44
1. Key switch ................................................................................................................................................. 46
STOPPING THE ENGINE................................................................................................................................... 46
CHECK DURING OPERATING .......................................................................................................................... 46
1. Easy Checker™ ........................................................................................................................................ 46
LCD MONITOR................................................................................................................................................... 47
1. Fuel gauge................................................................................................................................................. 47
2. Coolant temperature gauge....................................................................................................................... 47
3. Hour meter, tachometer............................................................................................................................. 48
4. Service code display.................................................................................................................................. 48
5. Overheat alarm.......................................................................................................................................... 48
6. Fuel gauge, warning indicator and fuel valve ............................................................................................ 48
COLD WEATHER STARTING............................................................................................................................. 49
ZD1611LF,ZD1611RLF,ZD1611RL
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WARMING UP THE ENGINE ............................................................................................................................. 49
1. Warm-up and transmission oil in the low temperature range .................................................................... 49
JUMP STARTING ............................................................................................................................................... 49
OPERATING THE MACHINE ....................................................................................................51
OPERATING A NEW MACHINE......................................................................................................................... 51
1. Changing lubricating oil for new machine.................................................................................................. 51
2. Engine break-in ......................................................................................................................................... 51
3. Machine break-in ....................................................................................................................................... 51
OPERATING THE FOLDABLE ROPS................................................................................................................ 52
1. Folding the ROPS...................................................................................................................................... 52
2. Raising the ROPS to the upright position .................................................................................................. 52
3. Adjusting the foldable ROPS ..................................................................................................................... 53
STARTING THE MACHINE ................................................................................................................................ 53
1. Operator's seat .......................................................................................................................................... 53
2. Seat belt .................................................................................................................................................... 54
3. Hydraulic lift control pedal ......................................................................................................................... 55
4. Accelerator lever........................................................................................................................................ 55
5. Parking brake pedal................................................................................................................................... 55
6. Motion control lever ................................................................................................................................... 56
6.1 Stop position of the motion control lever ............................................................................................ 56
6.2 Operating position of the motion control lever.................................................................................... 56
6.3 Re-start on slopes .............................................................................................................................. 58
STOPPING THE MACHINE................................................................................................................................ 58
FRONT AXLE...................................................................................................................................................... 58
1. Fixing the front axle ................................................................................................................................... 58
2. Oscillating the front axle ............................................................................................................................ 59
PARKING THE MACHINE .................................................................................................................................. 59
ACCESSORY...................................................................................................................................................... 59
1. 12 V electric power socket......................................................................................................................... 59
TRANSPORTING THE MACHINE...................................................................................................................... 60
1. Transporting the machine on a suitable trailer........................................................................................... 60
2. Transporting the machine by driving.......................................................................................................... 61
OPTIONAL EQUIPMENT.................................................................................................................................... 61
OPERATING THE MOWER .......................................................................................................62
MOWING TIPS.................................................................................................................................................... 62
ADJUSTING THE CUTTING HEIGHT................................................................................................................ 62
1. Cutting height reference chart ................................................................................................................... 64
OPERATING THE MOWER................................................................................................................................ 65
1. PTO lever................................................................................................................................................... 65
2. Starting the machine.................................................................................................................................. 65
TREATMENT OF MOWER DECK INSIDE SKID................................................................................................ 65
1. Removing skids ......................................................................................................................................... 66
PREVENTING GRASS CLIPPINGS AND DUST FROM SCATTERING............................................................ 66
1. Rubber plates installation .......................................................................................................................... 66
TIRES AND WHEELS................................................................................................................68
TIRES.................................................................................................................................................................. 68
1. Inflation pressure ....................................................................................................................................... 68
WHEELS............................................................................................................................................................. 68
1. Removing the front caster wheels ............................................................................................................. 68
2. Installing the front caster wheels ............................................................................................................... 69
PERIODIC SERVICE .................................................................................................................70
OPENING THE HOOD, FRONT COVER AND STEP ........................................................................................ 70
1. Hood .......................................................................................................................................................... 70
2. Front cover ................................................................................................................................................ 70
3. Step ........................................................................................................................................................... 70
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ZD1611LF,ZD1611RLF,ZD1611RL

RAISING AND LOWERING THE OPERATOR'S SEAT...................................................................................... 70
TILTING UP THE MACHINE............................................................................................................................... 71
OPENING THE LEVER GUIDE .......................................................................................................................... 72
LIFT-UP POINT................................................................................................................................................... 72
1. Front side:.................................................................................................................................................. 73
2. Rear side: .................................................................................................................................................. 73
LUBRICANTS, FUEL AND COOLANT ............................................................................................................... 74
1. Biodiesel fuel (BDF)................................................................................................................................... 76
DAILY CHECK .................................................................................................................................................... 77
1. Checking the engine oil level..................................................................................................................... 78
2. Checking the amount of fuel and refueling ................................................................................................ 78
3. Checking water separator.......................................................................................................................... 79
4. Checking transmission oil level ................................................................................................................. 80
5. Checking coolant level............................................................................................................................... 80
6. Checking and cleaning radiator screen and hood screen ......................................................................... 81
7. Checking and cleaning inside of the hood and around the mower belt to avoid fire hazard ..................... 81
8. Checking and cleaning DPF muffler and its surroundings......................................................................... 82
9. Checking the tire pressure......................................................................................................................... 82
9.1 Inflation pressure................................................................................................................................ 82
10. Checking movable parts .......................................................................................................................... 82
11. Cleaning cut grass in the bottom cover.................................................................................................... 82
12. Lubricating all grease fittings ................................................................................................................... 83
MAINTENANCE.........................................................................................................................84
SERVICE INTERVALS........................................................................................................................................ 84
PERIODIC SERVICE CHART LABEL ................................................................................................................ 86
EVERY 50 HOURS............................................................................................................................................. 87
1. Checking the engine start system ............................................................................................................. 87
2. Checking the OPC system ........................................................................................................................ 87
3. Checking gear box oil level........................................................................................................................ 88
4. Greasing .................................................................................................................................................... 89
EVERY 100 HOURS........................................................................................................................................... 90
1. Cleaning air cleaner primary element........................................................................................................ 90
2. Adjusting fan drive belt tension.................................................................................................................. 91
3. Adjusting parking brake ............................................................................................................................. 92
3.1 Checking brake spring ....................................................................................................................... 92
3.2 Check on the slope ............................................................................................................................ 93
4. Greasing .................................................................................................................................................... 93
5. Checking the battery condition .................................................................................................................. 93
5.1 Non accessible maintenance free type batteries ............................................................................... 94
5.2 Checking the battery voltage.............................................................................................................. 94
5.3 How to read indicator ......................................................................................................................... 94
5.4 Charging the battery........................................................................................................................... 94
5.5 Storing the battery.............................................................................................................................. 95
EVERY 150 HOURS........................................................................................................................................... 95
1. Changing gear box oil................................................................................................................................ 95
EVERY 200 HOURS........................................................................................................................................... 97
1. Changing engine oil................................................................................................................................... 97
2. Replacing the engine oil filter .................................................................................................................... 97
3. Replacing transmission oil filter (HST) ...................................................................................................... 97
4. Adjusting front axle pivot ........................................................................................................................... 98
EVERY 400 HOURS........................................................................................................................................... 98
1. Changing transmission oil and rear axle gear case oil (RH and LH)......................................................... 98
2. Replacing hydraulic oil filter....................................................................................................................... 99
3. Replacing water separator element......................................................................................................... 100
4. Replacing fuel filter .................................................................................................................................. 101
EVERY 800 HOURS......................................................................................................................................... 101
1. Adjusting engine valve clearance ............................................................................................................ 101
ZD1611LF,ZD1611RLF,ZD1611RL
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EVERY 1000 HOURS OR EVERY 1 YEAR...................................................................................................... 101
1. Replacing air cleaner primary element and secondary element.............................................................. 101
EVERY 1500 HOURS....................................................................................................................................... 101
1. Checking fuel injection nozzle (injection pressure).................................................................................. 101
2. Checking EGR cooler .............................................................................................................................. 101
EVERY 2000 HOURS OR EVERY 2 YEARS ................................................................................................... 101
1. Flushing cooling system and changing coolant ....................................................................................... 101
2. Antifreeze ................................................................................................................................................ 102
EVERY 3000 HOURS....................................................................................................................................... 103
1. Checking injection pump ......................................................................................................................... 103
2. Checking turbo charger ........................................................................................................................... 103
3. Checking EGR system ............................................................................................................................ 103
4. Checking supply pump ............................................................................................................................ 103
EVERY 3000 HOURS TO 6000 HOURS .......................................................................................................... 103
1. Cleaning DPF muffler .............................................................................................................................. 103
EVERY 1 YEAR ................................................................................................................................................ 104
1. Checking exhaust manifold ..................................................................................................................... 104
2. Checking fuel lines .................................................................................................................................. 104
3. Checking radiator hose and clamp .......................................................................................................... 104
4. Checking hydraulic hoses........................................................................................................................ 104
5. Checking intake air line ........................................................................................................................... 105
6. Checking engine breather hose............................................................................................................... 105
7. Checking mower gear box oil seal........................................................................................................... 105
EVERY 4 YEARS.............................................................................................................................................. 105
1. Replacing hydraulic hoses....................................................................................................................... 105
2. Replacing the fuel lines ........................................................................................................................... 105
3. Replacing engine breather hose.............................................................................................................. 105
4. Replacing radiator hose........................................................................................................................... 105
5. Replacing mower gear box oil seal.......................................................................................................... 105
6. Replacing intake air line .......................................................................................................................... 105
SERVICE AS REQUIRED................................................................................................................................. 106
1. Replacing fuses ....................................................................................................................................... 106
2. Bleeding fuel system ............................................................................................................................... 107
3. Checking and replacing blades ............................................................................................................... 108
4. Replacing the mower belt ........................................................................................................................ 109
ADJUSTMENT......................................................................................................................... 111
MOTION CONTROL LEVER .............................................................................................................................111
1. HST neutral ..............................................................................................................................................111
2. Maximum speed (forward)........................................................................................................................111
3. Adjusting the motion control lever operating strength ..............................................................................111
4. Motion control lever alignment................................................................................................................. 112
4.1 Checking the alignment.................................................................................................................... 112
4.2 Aligning the motion control levers .................................................................................................... 112
MOWER DECK LEVEL..................................................................................................................................... 112
1. Anti-scalp rollers ...................................................................................................................................... 112
2. Leveling the mower deck (side-to-side)................................................................................................... 113
2.1 Checking the level (side-to-side)...................................................................................................... 113
2.2 Adjusting the level (side-to-side) ...................................................................................................... 114
3. Leveling the mower deck (front-to-rear) .................................................................................................. 114
3.1 Checking level (front-to-rear) ........................................................................................................... 115
3.2 Adjusting the level (front-to-rear)...................................................................................................... 115
GENERAL TIGHTENING TORQUE SPECIFICATION ..................................................................................... 117
STORAGE................................................................................................................................118
STORING THE MACHINE................................................................................................................................ 118
REMOVING THE MACHINE FROM STORAGE............................................................................................... 118
TROUBLESHOOTING.............................................................................................................120
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ZD1611LF,ZD1611RLF,ZD1611RL