Kubota ZD221-48 Instruction manual

ZD221, WSM
SAFETY INSTRUCTIONS
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 attempt to repair or use
this unit.
A DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in
death
or serious injury.
A WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
A CAUTION : Indicates a
potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
• IMPORTANT :
Indicates that equipment or property damage could result if instructions are not
followed.
• NOTE : Gives
helpful information .
BEFORE SERVICING AND REPAIRING
o 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 firm and level ground. and set
the parking brake.
• Lower the implement to the ground.
o Stop the engine. and remove the key.
o Disconnect the battery negative cable.
• Hang a
''~O NOT OPERATE" tag in operator
station.
1

ZD221 , WSM
SAFETY INSTRUCTIONS
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Do not alter or remove any part of machine safety
system.
• Before starting the engine, make sure that all shift
levers are
in neutral positions or in disengaged
positions.
• Never start the engine while standing
on ground.
Start the engine only from operator's seat.
SAFETY WORKING
• Do not work on the machine while underthe influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not work under the machine that is supported
solely 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, orimmediately 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.
• Escaping 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.
• Do not open high-pressure fuel system.
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt repair
fuel lines, sensors, orany othercomponents between
the high-pressure fuel pump and injectors
on engines
with high pressure common rail fuel system.
• High voltage exceeding 100 V is generated
in the
ECU, and
is applied to the injector.
Pay sufficient caution
to electric shock when
performing work activities.
2

ZD221, WSM
SAFETY INSTRUCTIONS
•
+ -
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions.
Do not smoke or allow flames or
sparks
in your working area.
• To avoid sparks from
an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top
of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.
VENTILATE WORK AREA
• If 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
• Sulfuric 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
• 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.
3

ZD221 , WSM
SAFETY INSTRUCTIONS
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
4

ZD221. WSM
SAFETY INSTRUCTIONS
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.
(2) Part No. K3271-6585-1
(3) Part No. K3271-6581-0
(1) Part No. K3181-6585-0
1 BDABCQAP093A
(4) Part No. K3271-6587-0
1 BDABCYAP064A
I 3GZAAAKCP001 A
1BDABCYAP065A
(5) Part No. K3131-6568-1
ACAUTION
\NIlen Engine IS running
do
not open thiS cover
1BDABDEAP024A
(6) Part No. K3131-6569-1
A PRECAUCION
Nunca abra el capo mlentras el
motor esta
en funClonamlento
1 BDABDEAP025A
5

ZD221, WSM
SAFETY INSTRUCTIONS
(1) Part No. K3271-6583-0
1BDABCYAP066A
(3) Part No. K3181-6587-2
Gasoline No fire
fuel only
it
~
LOW SULFUR FUEL
OR ULTRA LOW
: SULFUR FUEL ONLY
COMBUSTIBLE CON
BAJO CONTENIDO
DE AZUFRE 0
COMBUSTIBLE CON
CONTENIOO ULTRABAJO
DE AZUFRE SOLAMENTE
1BDAIATAPOO1A
3GZAAAKCP002A
(2) Part No. K3271-6532-0
[r~tiQ-.U T-IO-N-r-: A-P-R-EC-A-UCION' ...
l~Jn·)I:t3:t41~il •
ESCAPE CALIENTE
........... --- :.. ./
1BDABCYAP067A
(4) Part No. K3181-2481-1
...:1.=..BD::.oA.:.;;:B;.::C.:;;.QA;.;;;P...:1.;;;;;22A;;;..;;... _________ --'
6

ZD221 , WSM
SAFETY INSTRUCTIONS
(1) Part No. K3181-6564-0 (2) Part No. K3181-6563-0 (3) Part No. K3181-6566-0 (4) Part No. K3181-6565-0
AWARNING
AADVERTENCIA
[ 1'~ I [
l?~ I
~4
~4
1BDABCQAP100A
1BDABCQAP134A
3GZAAAKCP003A
7

ZD221 , WSM
SAFETY INSTRUCTIONS
1BDABCQAP124A
(1) Part No. K3181-6115-1
DANGER I POISON
· SHIELD EYES
EXPLOSIVEGASES can cause blindness
or injury.
· NO SPARKS I FLAMES I SMOKING
· SULFURIC ACID can cause blindness or
servere burns.
· Flush eyes immediately with water.
· Get medical help fast.
(2) Part No. K3111-6591-1
Do not get your hands close to fan belt. (3) Part
No. K3181-6586-1
Do not get your hands close
to engine fan and fan belt.
1BDABCOAP10SA
1BDABCOAP1Q7A
3GZAAAKCP004A
8

ZD221 , WSM
SAFETY INSTRUCTIONS
(1) Part No. KS681-7312-0 (2) Part No. KS681-7311-0
(3) Part No. KS681-7310-0
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 replaced component.
5. Mount new danger, warning and caution labels by applying on a clean dry surface and pressing any
bubbles to outside edge.
3GZAAAKCPOOSA
9

ZD221 , WSM
SPECIFICATIOI\lS
SPECIFICATIONS
Model ZD221-48 I
Z022i·54
Model D782-E3-ZD-1
Maximum engine power
(Gross) 15.7 kW
(21 HP)'1
Type Liquid-cooled
Number
of cylinders 3
Bore and stroke
67 x 73.6 mm
(2.64 x 2.90 in.)
Engine ITotal displacement 778
cm
3 (47.5 cu.in.)
Rated revolution 3200 min-1(rpm)
Fuel Diesel fuel
No.1 [below - 10°C (14 OF)]
Diesel fuel No.2 [above
10°C (14 OF)]
Starter Electric starter with battery, glow plug, 12 V, 1.0 kW
Lubrication Forced lubrication by gear pump
Cooling Liquid with pressurized radiator
Battery
51 R (12 V, RC : 70 min, CCA: 450 A)
Fuel tank 23 L
(6.1 U.S.gals, 5.1 Imp.gals)
Engine crankcase 3.5 L
(with filter) (3.70 U.S.qts, 3.08 Imp.qts)
Capacities Engine coolant 1.2 L
(1.27 U.S.qts, 1.06 Imp.qts)
Recovery tank 0.25 L (0.26 U.S.qts, 0.22 Imp.qts)
Transmission including rear
axle gear case 7.5 L (7.9 U.S.qts, 6.60 Imp.qts)'3
Overall length 2130 mm (83.9 in.)
erall width Without mower
ck
1210 mm (47.7 in.)
Overall With ROPS
upright 1775 mm (69.9 in.)
Dimensions height With ROPS
folded 1320 mm (51.9 in.)
Wheelbase
1295 mm (51.0 in.)
Minimum ground clearance 130 mm (5.12 in.)
with 54 in., with
48 in.
Front 860 mm (33.9 in.)
Tread Rear 930 mm (36.3 in.)
NOTE: Specifications and design subject to change without notice.
'1 : Manufacurer's estimate
'2 : At 3200 min-1 (rpm)
*3: Oil amount when the oil level is at the upper level.
10

ZD221 WSM
Model ZD221-48 ZD221-54
Weight (with Mower Deck) 545
kg (1202 Ibs) with 48 in. 555
kg (1224 Ibs) with 54 in.
Tires Front 13 x 5.0-6 (4PR) Rib
Rear 23 x 10.5-12 (4PR) Turf
Travelling Forward o
to 14.5 km/h (0 to 9.0 mph)'2
Travelling speeds Reverse oto 8.0 km/h (0 to 5.0 mph)'2
system Steering 2-Hand levers
Transmission 2-Hydrostatic transmission with gear
Parking brake Wet multi discs I foot applied, released
Min. turning radius omm (0 in.)
Revolution 1 speed (2530 rpm at 3200 engine rpm)
Shaft drive, KUBOTA
10 tooth in involute spline
PTO
~
Wet multi discs
IPTO brake Wet single disc
NOTE: Specifications and design subject to change without notice.
'1 : Manufacurer's estimate
'2: At 3200 min-1 (rpm)
'3 : Oil amount when the oil level is at the upper level. W1030228
Model RCK48P·222Z RCK54P-227Z
PRO
commercial
deck
(fabricated
deck)
Suitable machine ZD221
Mounting method Quick joint, parallel linkage
Adjustment
of cutting height Dial gauge
Cutting width 1225 mm (48 in.) 1375 mm (54 in.)
Cutting height 25 to 127 mm (1.0 to 5.0 in.)
Weight (approx.) 106
kg (234Ibs) 119 kg (262 Ibs)
Blade spindle speed 64.8 rls (3890 min-1(rpm))'l 58.0 rls (3480 min-1 (rpm))'1
Blade tip velocity 86.4 m/s (17000 fpm)'1 86.6 m/s (17000
fpm)'l
Blade length 424 mm (16.7 in.) 475 mm (18.7 in.)
Number
of blades 3
Dimensions
Total length 880 mm (34.6 in.) 925 mm (36.4 in.)
Total width 1552 mm (61.1 in.) 1710 mm (67.3 in.)
Total height 340 mm (13.3 in.) 340 mm (13.3 in.)
NOTE: Specifications and design subject to change without notice.
*1 : Engine max. revolution. W1036076
11

Vol
G>
N
»
»
»
-n
'"
I'
"'0
0
0
»
~
~
Vol
0
->.
N
I~
CD
Vol
<0
::;.
1320 mm (51.9 in.) ,
I
775 mm (69.9 in.)
N
<0
{J1
3
3
U1
~
10
860 mm (33.9 in.)
"I
I I
,
IF'
"
-
I"
,
RCK48P-222Z : 1552 mm (61.1 in.)
RCK54P-227Z: 1710 mm (67.3 in.)
930 mm (36.3 in.)
-I
1210 mm (47.7 in.)
C N
0
N
N
3: -
~
-
:.:i!
m
(/)
Z
~
CJ)
-
0
Z
CJ)
o
~
m
z
(j)
(5
Z
(j)

GENERAL
CONTENTS
1. IDENTIFiCATION............................................................................................. G-1
2. GENERAL PRECAUTIONS ............................................................................ G-2
3. CYLINDER NYMBER.......................................................................................G-2
4. 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
5. LUBRICANTS, FUEL AND COOLANT ......................................................... G-7
6. TIGHTENING TORQUES ............................................................................. G-10
[1] GENERAL USE SCREWS, BOLTS AND NUTS................................. G-10
[2] STUD BOLTS.......................................................................................... G-10
[3] METRIC SCREWS, BOLTS AND NUTS .............................................
G-11
[4] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC
OR UNF THREADS ...............................................................................
G-11
[5) PLUGS..................................................................................................... G-11
7. MAINTENANCE CHECK LlST..................................................................... G-12
8. CHECK AND MAINTENANCE..................................................................... G-14
[1] DAILY CHECK ........................................................................................G-14
[2] CHECK POINTS OF INITIAL
50 HOURS ........................................... G-18
[3] CHECK POINT
OF INITIAL 400 HOURS ........................................... G-20
[4] CHECK POINTS OF EVERY
50 HOLIRS ........................................... G-23
[5] CHECK POINTS OF EVERY 100 HOURS ......................................... G-29
[6] CHECK POINTS OF EVERY 150 HOURS......................................... G-34
[7] CHECK POINTS OF EVERY 200 HOURS......................................... G-34
[8] CHECK POINT OF EVERY 400 HOURS ........................................... G-38
[9] CHECK POINT OF EVERY 1500 HOURS .......................................... G-39
[10]CHECK POINTS OF EVERY 3000 HOLIRS ....................................... G-40
[11]CHECK POINTS OF EVERY 1 YEAR ................................................
G-41
[12]CHECK POINT OF EVERY 2 YEARS ................................................ G-44
[13]OTHERS ..................................................................................................G-46
9. SPECIAL TOOLS.......................................................................................... G-49
[1] SPECIAL TOOLS FOR ENGINE .......................................................... G-49
[2) SPECIAL TOOLS FOR MACHINE........................................................ G-55
10. IMPLEMENT LIMITATIONS.......................................................................... G-56

ZD221 , WSM
G GENERAL
1. IDENTIFICATION
3GZAAAKOP002A
[8]
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 [A] RCK48P
(2) Machine Serial Number [8] RCK54P
(3) Engine Serial Number
(4) Mower Serial Number
(5) Mower Identification Plate
(6) ROPS Serial Number W1010714
13GZAAAKOP003A
G-1

ZD221, WSM
G GENERAL
2. GENERAL PRECAUTIONS
(1 )
(A) (8)
(3)
(4)
qopO
(5)
3TMABABOP005A
3. CYLINDER NYMBER
3EEACAA1P067A
• During 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.
• When special tools are required, use
KUBaT A genuine special
tools. Special tools which are not frequently used should be
made according to the drawings provided.
Before disassembling
or servicing electrical wires. always
disconnect the ground cable from the battery first.
• Remove oil and dirt from parts before measuring.
• Use only
KUBaT A genuine parts for parts replacement to
maintain machine performance and to assure safety.
• Gaskets and a-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 is applied. See the figure left side.
• When inserting spring pins, their splits must face the direction
from which a force is applied. See the figure left side.
• To prevent damage to the hydraulic system, use only specified
fluid
or equivalent.
(1) Grease (A) External Snap Ring
(2) Force (8) Internal Snap Ring
(3) Sharp Edge
(4) Axial Force
(5) Rotating Movement
W1010904
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.
W1011077
G-2

ZD221. WSM
G GENERAL
4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS
AND WIRING
To ensure safety and prevent damage to the machine and
(1 ) surrounding equipment, heed the following precautions
in handling
electrical parts and wiring.
• IMPORTANT
• Check electrical
wlrmg 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.
• Do
not attempt to mOdify or remodel any electrical parts and
wiring.
3TMABABOP006A • When
removing the battery cables, disconnect the negative
cable first. When
installing the battery cables, connect the
positive cable first.
(1) Negative Terminal (2) Positive Terminal
W1011114
[1] WIRING
• Securely tighten wiring terminals.
(1) Correct (2) Incorrect
(Securely tighten) (Loosening leads to faulty contact)
W1011216
(1 )
3TMABABOP007A
(4)
3TMABABOP008A
(A)
(8)
• Do not let wiring contact dangerous part.
(1) Wiring (Correct) (3) Dangerous Part
(2) Wiring (Incorrect) (4) Dangerous Part
W1011313
• Securely insert grommet.
(1) Grommet (A)
Correct
(8) Incorrect
W1011388
3TMABABOP009A
G-3

ZD221 , WSM G GENERAL
• Securely clamp, being careful not to damage wiring.
(1) Clamp (3) Clamp
(2)
• Wind Clamp Spirally (4) Welding Dent
(2) Wire Harness
W1011458
3TMABABOP010A
(1) (2)
(A)
(8)
3TMABABOP011A (1)
(2)
(A)
(1)
3TMABABOP012A
(1)
3TMABABOP013A
Clamp wiring so that there is no twist, unnecessary sag, or
excessive tension, except for movable part, where sag be
required.
(1) Wiring (A) Correct
(2) Clamp
(8) Incorrect
W1011587
• In installing a part, take care not to get wiring caught by it.
(1) Wiring (A) Incorrect
W1011670
• After installing wiring, check protection of terminals and clamped
condition
of wiring, only connect battery.
(1) Cover
• Securely Install Cover
W1011735
G-4

ZD221, WSM G GENERAL
[2] BATTERY
3TMABABOP006B
[3] FUSE
(1 )
(2)
3TMABABOP014A
[4] CONNECTOR
(A)
• Take care not to confuse positive and negative terminal posts.
• When removing battery cables, disconnect negative cable first.
When installing battery cables, check for polarity and connect
positive cable first.
• Do not install any battery with capacity other than is specified
(Ah).
• After connecting cables to battery terminal posts, apply high
temperature grease to them and securely install terminal covers
on them.
• Do not allow dirt and dust to collect
on battery.
A CAUTION
• Take care not to let battery liquid spill on your skin and
clothes.
If contaminated, wash it off 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
• Use fuses with specified capacity.
Neithertoo large
or small capacity fuse is acceptable.
• Never use steel or copper wire
in place of fuse.
• Do notinstall working light, radio set, etc. on machine which is not
provided with reserve power supply.
• Do not install accessories if fuse capacity
of reserve power
supply is exceeded.
(1) Fuse (2) Slow Blow Fuse
W1012092
• For connector with lock, push lock to separate.
(A) Push
W1012211
3TMABABOP015A •
In separating connectors, do not pull wire harnesses.
(8)
• Hold connector bodies to separate.
(A) Correct
(B) Incorrect
W1012272
3TMABABOP016A
G-5

ZD221, WSM G
GENERAL
(3)1_--~-'~141
(1 )
~ (8)
,.
3TMABABOPO18A
• Use sandpaper to remove rust from terminals.
• Repair deformed terminal. Make certain there
is no terminal
being exposed or displaced.
(1) Exposed Terminal (3) Sandpaper
(2) Bend Terminal (4) Rust W1012346
• Make certain that there is no female connector being too open.
(A) Correct
(8) Incorrect
W1012430
3TMABABOP020A
[5] HANDLING OF CIRCUIT TESTER
• Use tester correctly following manual provided with tester.
• Check for polarity and range. W1012684
G-6