Kubota ZD25F Zero Turn Mower Complete Workshop Service Repair Manual

GENERAL CONTENTS 1. IDENTIFiCATION ............................................................................................. G-1 2. GENERAL PRECAUTIONS ............................................................................ G-2 3. 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 4. LUBRICANTS, FUEL AND COOLANT ......................................................... G-7 5. TIGHTENING TORQUES ............................................................................... G-9 [1] GENERAL USE SCREWS, BOLTS AND NUTS................................... G-9 [2] STUD BOL TS ............................................................................................ G-9 [3] METRIC SCREWS, BOLTS AND NUTS ............................................. G-10 [4] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS .......................................................... G-10 [5] PLUGS ..................................................................................................... G-1 0 6. MAINTENANCE CHECK LIST ..................................................................... G-11 7. CHECK AND MAINTENANCE ..................................................................... G-12 [1] DAILY CHECK ........................................................................................ G-12 [2] CHECK POINTS OF INITIAL 50 HOURS ........................................... G-17 [3] CHECK POINT OF INITIAL 100 HOURS ........................................... G-18 [4] CHECKING POINTS OF INITIAL 200 HOURS ................................... G-19 [5] CHECK POINTS OF EVERY 50 HOURS ........................................... G-21 [6] CHECK POINTS OF EVERY 100 HOURS ......................................... G-25 [7] CHECK POINTS OF EVERY 150 HOURS ......................................... G-30 [8] CHECK POINTS OF EVERY 200 HOURS ......................................... G-30 [9] CHECK POINTS OF EVERY 400 HOURS ......................................... G-32 [10]CHECK POINTS OF EVERY 1 YEAR ................................................ G-32 [11]CHECK POINT OF EVERY 2 YEARS ................................................ G-35 [12]OTHERS .................................................................................................. G-36 8. SPECIAL TOOLS .......................................................................................... G-38 [1] SPECIAL TOOLS FOR ENGINE .......................................................... G-38 [2] SPECIAL TOOLS FOR MACHINE ........................................................ G-44

ZD25F, WSM G GENERAL 1. IDENTIFICATION / ~/ ~\ 3GZAAAFOPOO"2<A-'--< 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 (4) Mower Serial Number (2) Machine Serial Number (5) Mower Identification Plate (3) Engine Serial Number W1010714 G-1

ZD25F, WSM G GENERAL 2. GENERAL PRECAUTIONS (1 ) (A) (8) (2) (2) (3) qop (4) ~Q 3TMABABOPOO5A • 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 KUBOTA 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 KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety. • Gaskets and O-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 W1 01 0904 G-2

WSM 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING (1 ) 3TMABABOP006A [1] WIRING 3TMABABOP007 A (4) 3TMABABOP008A (A) (8) (1 ) ~ To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring . • IMPORTANT • Check electrical wiring 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. • 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 • Securely tighten wiring terminals. (1) Correct (2) Incorrect (Securely tighten) (Loosening leads to faulty contact) • Do not let wiring contact dangerous part. (1) Dangerous Part (2) Wiring (Incorrect) (3) Wiring (Correct) (4) Dangerous Part • Securely insert grommet. (1) Grommet (A) Correct (8) Incorrect W1011216 W1011313 W1011388 G-3

ZD25F, WSM G GENERAL • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clarnp • Wind Clamp Spirally (4) Welding Dent (2) Wire Harness W1011458 (2) 3TMABABOP010A (1 ) (2) (A) (8) . 3TMABABOP011 A (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 Wl011670 • After installing wiring, check protection of terminals and clamped condition of wiring. only connect battery. (1) Cover • Securely Install Cover W1011735 G·4

ZD25F, WSM G GENERAL [2] BATTERY 3TMABABOP006B [3] FUSE 3TMABABOP014A (2) [4] CONNECTOR 3TMABABOP015A (8) 3TMABABOP016A • 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. Neither too large or small capacity fuse is acceptable. • Never use steel or copper wire in place of fuse. • Do not install 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 Wl012211 • In separating connectors, do not pull wire harnesses. • Hold connector bodies to separate. (A) Correct (8) Incorrect W1012272 G-5

Z~25F, WSM G GENERAL (3)1___ ~ __ '~(4) (1 ) ~ (8) ,. 3TMABABOP018A • 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

ZD25F, WSM G GENERAL 4. LUBRICANTS, FUEL AND COOLANT No. Place Capacity Lubricants, fuel and coolant ZD25F 1 Fuel 30 L 7.9 U.S.gals. 6.6 Imp.gals. No. 2-D diesel fuel No. 1-D diesel fuel if temperature is below-10 °C (14 OF) 2 Coolant Cooling system 4.0 L 4.2 U.S.qts. 3.5 Imp.qts. Fresh clean water (soft water) with anti- freeze Recovery tank 0.25 L 0.26 U.S.qts. 0.22 Imp.qts. 3 Engine crankcase 3.4 L" 3.6 U.S.qts. 3.0 Imp.qts. Engine oil: API Service Classification CC or CD Below 0 °C (32 OF) : SAE10W, 10W-30 or 10W-40 o to 25°C (32 to 77 OF) : SAE20, 10W-30 or 10W-40 Above 25°C (77 OF) : SAE30, 10W-30 or 10W-40 4 Transmission case 3.2 L 3.4 U.S.qts. 2.8 Imp.qts. KUBOTA UDT or SUPER UDT fluid,,1 5 Transmission case with filter and hose 4.0 L 4.2 U.S.qts. 3.5 Imp.qts. 6 Rear axle case 1.8 Leach 1.9 U.S.qts. each 1.6 Imp.qts. each KUBOTA UDT or SUPER UDT fluid*1 or SAE 80 . 90 gear oil 7 Mower gear case 0.40 L 0.42 U.S.qts. 0.35 Imp.qts. SAE 90 gear oil G-7

ZD25F, WSM G GENERAL i Greasing, oiling (Machine) No. Place No. of greasing point Capacity Type of grease 8 Motion control lever boss 2 9 Motion control lever 2 10 Center pin 1 11 King pin 2 Multi-purpose grease Until grease overflows NLGI-2 or NLGI-1 12 Front wheel 2 (GC-LB) 13 Front lift arm 2 14 Universal jOint 3 15 Seat adjuster 2 I 16 Throttle cable 2 Moderate amount Engine oil i Greasing (Mower) 17 Universal joint 3 18 Three spindle shafts 3 19 Belt tension pulley 1 20 Belt tension pivot 1 Multi-purpose grease Until grease overflows NLGI-2 or NLGI-1 21 Front anti-scalp roller 2 (GC-LB) (pro deck) 22 Front anti-scalp roller 2 pivot boss (pro deck) * Oil amount when the oil level is at the upper level of the oil level gauge . • IMPORTANT • To prevent serious damage to hydraulic systems, use only KUBOTA genuine fluid or its equivalent. • NOTE • Engine Oil : Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE Engine Oil according to the ambient temperatures as shown above . • Transmission oil (KUBOTA SUPER UOT *1): The oil used to lubricate the transmission is also used as hydraulic fluid. To insure proper operation of the hydraulic system and complete lubrication of the transmission, it is important that a multi-grade transmission fluid be used in this system. We recommend the use of KUBOTA UOT or SUPER UOT fluid for optimum protection and performance. Do not mix different brands together. • Indicated capacity of water and oil are manufacture's estimate. G-8

Kubota ZD25F Zero Turn Mower Complete Workshop Service Repair Manual

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