Kubota ZD1511 Zero Turn Mower Service Manual
344 pages · Publication 9Y111-13850
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- Models
- ZD1511
- Manual type
- Service Manual
- Pages
- 344
- Publication
- 9Y111-13850
- Condition
- Brand new
What's inside
From the manual's own table of contents: 53 sections, 556 entries. See sample pages (PDF, 778 KB)
SAFETY FIRST11 topics
- Before you start service
- Start safely
- Operate safely
- Protect against high pressure spray
- Avoid hot exhaust
- Exhaust filter cleaning
- Prevent a fire
- Keep a good airflow in the work area
- Discard fluids correctly
- Prevent acid burns
- Prepare for emergencies
SAFETY DECALS1 topic
- Care of danger, warning and caution labels
SPECIFICATIONS
DIMENSIONS
IDENTIFICATION
GENERAL PRECAUTIONS
IDENTIFYING CYLINDER NUMBER
HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING6 topics
- Handling of wiring
- Handling of battery
- Handling of fuse
- Handling of connector
- Handling of circuit tester
- Color of wiring
LUBRICANTS, FUEL AND COOLANT
TIGHTENING TORQUES5 topics
- General use screws, bolts and nuts
- Stud bolts
- Metric screws, bolts and nuts
- American standard screws, bolts and nuts with UNC or UNF threads
- Plugs
MAINTENANCE CHECK LIST
CHECK AND MAINTENANCE16 topics
- Daily check
- Checking the machine
- Checking engine oil level
- Checking amount of fuel and refueling
- Checking transmission fluid level
- Checking coolant level
- Checking and cleaning radiator to prevent overheating
- Checking and cleaning DPF muffler and its surroundings
- Checking tire pressure
- Greasing (Mower)
- Check points of initial 50 hours
- Changing engine oil
- Replacing engine oil filter
- Replacing HST transmission oil filter
- Check point of initial 100 hours
- Adjusting front axle pivot
Check point of initial 400 hours1 topic
- Changing transmission fluid and rear axle gear case oil (R.H. and L.H.)
Check points of every 50 hours4 topics
- Checking engine start system
- Checking OPC system
- Checking gear box oil level
- Greasing
Check points of every 100 hours8 topics
- Cleaning air cleaner primary element
- Checking fuel filter
- Adjusting fan belt tension
- Adjusting parking brake
- Check on slope
- Greasing mower link bushing
- Checking battery condition
- Charging battery
Check point of every 150 hours1 topic
- Changing gear box oil level
Check points of every 200 hours3 topics
- Changing engine oil
- Replacing engine oil filter
- Replacing HST transmission oil filter
Check points of every 400 hours2 topics
- Replacing hydraulic filter
- Replacing fuel filter
Check points of every 800 hours1 topic
- Adjusting engine valve clearance
Check points of every 1000 hours or 1 year1 topic
- Replacing air cleaner primary element and secondary element
Check point of every 1500 hours1 topic
- Checking fuel injection nozzle pressure
Check points of every 2000 hours or 2 years2 topics
- Flushing cooling system and changing coolant
- Anti-freeze
Check point of every 3000 hours2 topics
- Checking injection pump
- Checking turbocharger
Check points of every 1 year7 topics
- Checking exhaust manifold
- Checking hydraulic hose
- Checking radiator hose and clamp
- Checking fuel lines
- Checking intake air line
- Checking mower gear box seals
- Checking engine breather hose
Show all 53 sections
Check point of every 4 years6 topics
- Replacing hydraulic hose
- Replacing radiator hose
- Replacing fuel lines
- Replacing intake air line
- Replacing mower gear box seals
- Replacing engine breather hose
Others5 topics
- Replacing fuses
- Checking mower blade
- Replacing mower blade
- Replacing mower belt
- Bleeding fuel system
SPECIAL TOOLS15 topics
- Special tools for engine
- Diesel engine compression tester (for nozzle hole)
- Diesel engine compression tester (for glow plug hole)
- Oil pressure tester
- Injection pump pressure tester
- Valve guide replacing tool
- Bushing replacing tool
- Flywheel stopper
- Crankshaft bearing 1 replacing tool
- Governor gear holder bushing replacing tool
- Crank sleeve setter
- Rotation sensor signal interface unit
- Special tools for machine
- Relief valve pressure tester
- HST relief valve adapter
IMPLEMENT LIMITATIONS
MECHANISM38 topics
- Engine body
- Function of cylinder block
- Function of closed breather
- Function of half-floating head cover
- Function of piston
- Function of piston ring
- Function of connecting rod
- Function of crankshaft
- Function of camshaft
- Function of rocker arm
- Function of flywheel
- Function of timing gears
- Definition of engine control system
- Lubricating system
- Overview of lubricating system
- Function of oil strainer
- Function of oil pump
- Function of oil filter
- Function of relief valve
- Function of oil pressure switch
- Cooling system
- Overview of cooling system
- Function of water pump
- Function of radiator
- Function of radiator cap
- Fuel system
- Overview of fuel system
- Function of fuel filter
- Function of fuel feed pump
- Function of injection nozzle
- Function of fuel tank
- Definition of electronic governor
- Reformer and after treatment devices
- Definition of reformer
- Definition of Diesel Oxidation Catalyst (DOC)
- Function of Diesel Particulate Filter (DPF)
- Definition of temperature sensor
- Definition of differential pressure sensor
SERVICING
Troubleshooting for engine
Servicing specifications for engine
Tightening torques for engine
Checking and adjusting19 topics
- Engine body
- Checking compression pressure
- Checking valve clearance
- Lubricating system
- Checking engine oil pressure
- Cooling system
- Checking fan belt tension
- Checking fan belt damage and wear
- Checking radiator cap air leakage
- Checking radiator water leakage
- Checking thermostat valve opening temperature
- Fuel system
- Checking injection timing
- Checking fuel tightness of pump element
- Checking fuel tightness of delivery valve
- Checking nozzle spraying condition
- Checking fuel injection pressure
- Checking valve seat tightness
- Removing nozzle holder
Disassembling and assembling22 topics
- Separating engine
- Draining engine oil
- Draining coolant
- Removing the battery
- Removing the bonnet
- Removing DPF cover
- Removing rear engine frame
- Removing air cleaner assembly
- Disconnecting engine wiring harness
- Disconnecting engine fuel hoses
- Removing engine stoppers
- Removing universal joint from engine
- Disconnecting radiator assembly
- Separating the engine
- Disassembling the engine
- External components
- Cylinder head and valve
- Gear case and timing gears
- Piston and connecting rod
- Flywheel and crankshaft
- Alternator
- Starter
Servicing61 topics
- Cylinder head and valve
- Checking top clearance
- Checking cylinder head surface flatness
- Checking cylinder head flaw
- Checking valve recessing
- Checking clearance between valve stem and valve guide
- Replacing valve guide
- Checking valve seating
- Correcting valve
- Correcting valve seat
- Checking valve lapping
- Checking free length and tilt of valve spring
- Checking valve spring setting load
- Checking oil clearance between rocker arm and rocker arm shaft
- Checking push rod alignment
- Checking oil clearance between tappet and tappet guide bore
- Timing gears, camshaft and governor gear
- Checking timing gear backlash
- Checking idle gear 1 and 2 side clearance
- Checking camshaft side clearance
- Checking camshaft alignment
- Checking cam height
- Checking oil clearance of camshaft journal
- Checking oil clearance between idle gear shaft 1 and 2 and idle gear bushing
- Replacing idle gear bushing
- Piston and connecting rod
- Checking piston pin bore I.D
- Checking oil clearance between piston pin and small end bushing
- Replacing small end bushing
- Checking connecting rod alignment
- Checking piston ring gap
- Checking clearance between piston ring and piston ring groove
- Crankshaft
- Checking crankshaft side clearance
- Checking crankshaft alignment
- Checking oil clearance between crankpin and crankpin bearing
- Checking oil clearance between crankshaft journal and crankshaft bearing 1
- Replacing crankshaft bearing 1
- Replacing crankshaft sleeve
- Cylinder
- Checking cylinder wear
- Correcting cylinder
- Oil pump
- Checking rotor lobe clearance
- Checking clearance between outer rotor and pump body
- Checking clearance between rotor and cover
- Starter
- Checking overrunning clutch
- Checking commutator and mica
- Checking brush wear
- Checking brush holder
- Checking armature coil
- Checking field coil
- Alternator
- Checking bearing
- Checking stator
- Checking rotor
- Checking slip ring
- Checking brush wear
- Checking rectifier
- Checking IC regulator continuity
Structure of transaxle18 topics
- Hydraulic transmission section
- Hydrostatic transmission
- HST oil flow
- Power transmission operation
- Pump and motor
- Check and high pressure relief valve
- Hydrostatic control linkage
- Final reduction gear section
- Function of final reduction gear
- PTO section
- Structure of PTO
- PTO clutch "Disengaged
- PTO clutch "Engaged
- Function of regulator valve
- Parking brake section
- Function of parking brake
- Bevel gear section
- Function of bevel gears
Troubleshooting for transaxle
Servicing specifications for transaxle
Tightening torques for transaxle110 topics
- Checking neutral
- Adjusting neutral
- Checking motion control lever neutral position
- Adjusting motion control lever operating force
- Checking motion control lever alignment
- Adjusting maximum speed
- Checking high pressure relief valve pressure
- Checking PTO clutch operating pressure (hydrostatic transmission charge pressure)
- Separating transaxle assembly
- Draining engine oil
- Draining transmission fluid
- Draining coolant
- Removing the battery
- Removing the bonnet
- Removing rear engine frame
- Removing DPF cover
- Removing air cleaner assembly
- Disconnecting engine wiring harness
- Disconnecting engine fuel hoses
- Removing engine stoppers
- Removing universal joint from engine
- Disconnecting radiator assembly
- Separating the engine
- Removing step and center step
- Removing seat assembly
- Removing fuel stabilizer
- Removing fenders
- Removing oil cooler
- Removing radiator
- Removing fuel tanks
- Removing speed control rods
- Removing hydraulic lift rod
- Removing PTO lever assembly
- Removing cutting height adjusting gear
- Removing ROPS
- Removing rear wheel
- Removing parking brake
- Separating transaxle assembly
- Disassembling transaxle center case
- Removing center case rear cover
- Removing PTO clutch shaft assembly and pump gear shaft
- Removing center case front cover
- Removing regulator valve (HST charge pressure relief valve)
- Removing PTO clutch lever
- Separating hydrostatic transmission and rear axle gear case assembly
- Removing input shaft, spiral bevel gear and joint shaft
- Disassembling PTO clutch shaft assembly
- Draining engine oil
- Draining transmission fluid
- Draining coolant
- Removing the battery
- Removing the bonnet
- Removing DPF cover
- Removing rear engine frame
- Removing air cleaner assembly
- Disconnecting engine wiring harness
- Disconnecting engine fuel hoses
- Removing engine stoppers
- Removing universal joint from engine
- Disconnecting radiator assembly
- Separating the engine
- Removing oil cooler
- Removing radiator
- Disconnecting universal joint and removing PTO shaft oil seal
- Removing center case rear cover and PTO clutch shaft assembly
- Disassembling PTO clutch assembly
- Disassembling hydrostatic transmission and rear axle gear case assembly
- Draining transmission fluid
- Removing the battery
- Removing step and center step
- Removing rear wheels
- Removing parking brake
- Separating hydrostatic transmission and rear axle gear case assembly
- Removing rear axle gear case
- Removing center section (Port block)
- Removing check and high pressure relief valve assembly
- Removing cylinder block assembly and thrust ball bearing
- Removing swashplate
- Removing slot guide and cradle bearing
- Removing pump shaft
- Disassembling rear axle case
- Draining transmission fluid
- Removing the battery
- Removing step and center step
- Removing rear wheels
- Removing parking brake
- Removing rear axle gear case
- Removing rear axle
- Removing parking brake
- Disassembling speed lever
- Removing the battery
- Removing step and center step
- Removing seat assembly
- Removing fenders
- Removing speed lever assembly
- Hydrostatic transmission
- Checking center section
- Checking check and high pressure relief valve
- Checking cylinder block assembly
- Checking thrust washer, thrust ball bearing and thrust plate
- Checking pump shaft
- Checking bush and needle bearing
- Transmission case
- Checking bearing
- Checking backlash and tooth contact between 16T or 18T bevel gear and 19T bevel gear
- Correcting of tooth contact
- PTO clutch
- Checking PTO clutch discs
- Brake
- Checking brake discs, friction plates and actuator
Structure of front axle
Troubleshooting for front axle
Servicing specifications for front axle
Tightening torques for front axle7 topics
- Separating front wheel and wheel bracket
- Removing the front wheel
- Removing the wheel bracket
- Separating front axle assembly
- Removing the battery
- Removing step and center step
- Separating front axle assembly
Function of hydraulic circuit
Hydraulic pump
Definition of hydraulic control valve3 topics
- Neutral position
- Lift and overloaded
- Down position
Function of lift cylinder
Function of mower linkage
Troubleshooting for hydraulic system
Servicing specifications for hydraulic system
Tightening torques for hydraulic system1 topic
- Checking relief valve setting pressure
viii126 topics
- Disassembling and assembling
- Hydraulic control valve
- Draining transmission fluid
- Removing PTO clutch link, cylinder hose, oil cooler pipe and HST charge pipes
- Removing center case front cover assembly
- Removing lift shaft and arm
- Removing hydraulic control valve
- Removing spool
- Removing relief valve
- Hydraulic pump
- Draining engine oil
- Draining transmission fluid
- Draining coolant
- Removing the battery
- Removing the bonnet
- Removing rear engine frame
- Removing DPF cover
- Removing air cleaner assembly
- Disconnecting engine wiring harness
- Disconnecting engine fuel hoses
- Removing engine stoppers
- Removing universal joint from engine
- Disconnecting radiator assembly
- Separating the engine
- Removing oil cooler
- Removing radiator
- Disassembling hydraulic pump
- Electrical circuit of starting system
- Electrical circuit of charging system and Easy Checker ™
- Electrical circuit of gauge system
- Electrical connector chart
- Reading electrical circuit diagrams
- How to read wiring diagram
- Layout of connector diagrams
- Precautions on handling electrical connectors
- Starting system
- Function of relay
- Function of starter
- Function of glow plug
- Function of safety switch
- Function of fuel pump
- Function of engine stop solenoid
- Charging system
- Function of alternator
- Function of Easy Checker ™
- Service code display
- Gauge system
- Function of fuel level sensor
- Function of coolant temperature sensor
- Function of oil pressure switch
- Troubleshooting for electrical system
- Servicing specifications for electrical system
- Tightening torques for electrical system
- Battery
- Checking battery voltage
- Checking battery terminal connection
- Checking battery specific gravity
- Starting system
- Checking main switch continuity
- Testing starter motor
- Testing magnetic switch
- Checking magnet switch continuity
- OPC (Operator Presence Control) system
- Checking OPC system
- Checking OPC continuity
- Glow plug
- Checking lead terminal voltage
- Checking glow plug continuity
- Checking glow plug (burner) continuity
- Checking glow plug (heater) continuity
- Fuel pump
- Checking fuel pump connector voltage
- Checking fuel pump continuity
- Engine stop solenoid
- Engine stop solenoid test
- Charging system
- Alternator on unit test
- Easy Checker ™
- Checking engine oil pressure lamp
- Checking horn wiring harness
- Engine control system
- Checking rack sensor continuity
- Checking blower
- Checking blower flow pressure sensor
- Checking differential pressure sensor
- Checking temperature sensor
- Checking doser fuel pump
- Checking engine oil pressure switch continuity
- Checking fuel level sensor
- Checking coolant temperature sensor voltage
- Checking coolant temperature sensor continuity
- Relays
- Checking relay
- Disassembling starter (Electromagnetic drive type)
- Disassembling alternator
- Starter
- Checking overrunning clutch
- Checking commutator and mica
- Checking brush wear
- Checking brush holder
- Checking armature coil
- Checking field coil
- Checking bearing
- Checking stator
- Checking rotor
- Checking slip ring
- Checking brush wear
- Checking rectifier
- Checking IC regulator continuity
- Power flow of mower
- Troubleshooting for mower
- Servicing specifications for mower
- Tightening torques for mower
- Checking and adjusting
- Adjusting anti-scalp rollers
- Adjusting left and right cutting height
- Adjusting front and rear cutting height
- Removing universal joint and belt covers
- Removing mower blades (center blade and outer blades)
- Removing blade boss
- Removing mower belt
- Disassembling gear box
- Disassembling center pulley holder
- Disassembling outer pulley and blade shaft
- Checking turning torque of pinion shaft
- Checking backlash between bevel gears
Inside this manual
Real pages from this service manual (344 pages). Open the sample pages (PDF, 777 KB)
- Specifications, page 121: Factory specification
- Troubleshooting, page 261: 1. Troubleshooting for hydraulic system
- Diagram, page 286: 5.3 Precautions on handling electrical connectors
- Color page: Oil cooler bolts
- Color page: Seat assembly
- Foldout diagram (color): MECHANISM
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 344 pages
Quantity one is the manual described above.
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