Kubota ZD221 Zero Turn Mower Service Manual Repair

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 under the 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, or immediately after stopping. Otherwise, hot water will spout out from radiator. Only remove radiator cap when cool enough to touch with bare hands. Slowly loosen the cap to first stop to relieve pressure before removing completely. • 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, or any other components 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 1BDABCQAP093A (4) Part No. K3271-6587-0 1BDABCYAP064A 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 1BDABDEAP025A 5

ZD221, WSM SAFETY INSTRUCTIONS (1) Part No. K3271-6583-0 1 BDABCYAP066A (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 ...........--- :.. ./ 1BDABCYAP067 A (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 1 BDABCQAP124A (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 I Total 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

Kubota ZD221 Zero Turn Mower Service Manual Repair

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