Kubota ZD21N-EC, ZD21-EC, ZD28-EC Workshop Manual

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Page 1

WORKSHOP MANUAL

KiSC issued 09, 2006 A

ZERO TURN MOWER

ZD21N-EC,ZD21-EC,ZD28-EC

Page 2

TO THE READER

KiSC issued 09, 2006 A

This WORKSHOP MANUAL has been prepared to provide servicing personnel with information on th e mechan ism, ser vice an d mai ntenance of Z D21N-EC, Z D21- EC an d ZD28-EC KUBOTA ZD Series Zero Turn Mower. It is divided into two parts, “MECHANISM” and “SERVICING” for each section except “ENGINE” section.

■ Mechanism

Information on the cons truction and fu nction are inclu ded. This info rmation shoul d be understood before proceeding with troubleshooting, disassembling and servicing.

■ Servicing

The heading “GENERAL” includes general precautions, check and maintenance and special tools. Other section, there are troubleshooting, servicing specification lists, checking and adjusting, disassembling and assembling, and servicing which cover procedures, precautions, factory specifications and allowable limits.

All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication.

The right is reserved to make changes in all information at any time without notice.

April 2004

Page 3

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

SAFETY FIRST

KiSC issued 09, 2006 A

SAFETY INSTRUCTIONS

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.

DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in

death or serious injury.

WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury.

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

• 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.

• Stop the engine, and remove the key.

• Disconnect the battery negative cable.

• Hang a “DO NOT OPERATE” tag in operator station.

Page 4

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

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 appr opriate to the work. Mak eshift 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 fr om 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) un der pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or fuel lines. Tighten all connections before applying pressure.

AVOID FIRES

• Fuel is extremely flammable and explosive under certain condition s. Do not smoke or allow flames o r 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 b attery, especially when charging the battery.

• Mark sure that no fuel has been spilled on the engine.

Page 5

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

SAFETY INSTRUCTIONS

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 electr olyte is po isonous. 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 prot ectio n regulati ons whe n disp osing of oil, fuel, coolant, electrolyte and other harmful waste.

PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extingui sher handy at all times.

• Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone.

Page 6

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

SAFETY INSTRUCTIONS

SAFETY DECALS

· The following safety decals are installed on the machine. If a decal becomes dama ged , il legib le or is no t o n t he ma chin e, repla ce i t. Th e de cal p art nu mb er is list ed in the parts list.

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ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

SAFETY INSTRUCTIONS

Page 8

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

SAFETY INSTRUCTIONS

Page 9

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

SPECIFICATIONS

Model ZD21N-EC ZD21-EC ZD28-EC

Maximum gross power (SAE) 15.7 kW (21 HP)*

Model D782-E-XFM5 D1105-E2-ZD Type Indirect injection, vertical, water cooled, 4-cycle diesel engine Number of cylinders 3 Bore and stroke 67.0 × 73.6 mm (2.64 × 2.90 in.) 78.0 × 78.4 mm

Total displacement 778 cm Rated revolution 3200 rpm 3000 rpm Combustion chamber Spherical type (E-TVCS) Fuel injection pump Bosch MD type mini pump Governor Centrifugal ball mechanical governor

Engine

Injection nozzle Bosch throttle type Injection timing 0.33 to 0.37 rad (19° to 21°) before T.D.C. Injection order 1-2-3 Injection pressure 13.73 MPa (140 kgf/cm Lubricating system Forced Iubrication by gear pump Cooling system Pressurized radiator, forced circulation with water pump

Lubricating oil

Starting system Electric starter (12 V, 1.1 kW) Battery 51 R (12 V, 450 CCA)

Fuel Fuel tank 30 L (5.8 U.S.gals., 4.8 lmp.gals.)

Engine crankcase 3.5 L (3.7 U.S.qts., 3.1 Imp.qts.) Engine coolant

Capacities

Recovery tank 0.25 L (0.26 U.S.qts., 0.22 Imp.qts.) Transmission (Including

HST and cylinder) Rear axle gear case 1.8 L (1.9 U.S.qts., 1.6 Imp.qts.)*2 each Mower gear case oil 0.40 L (0.42 U.S.qts., 0.35 Imp.qts.)

Tires

Travelling speeds

Front 15 × 6.0-6 (4PR) Rib Rear 23 × 10.5-12 (4PR) Turf 24 × 12.0-12 (4PR) Turf

Forward

Reverse

NOTE: *1 Manufacturer’s estimate

Oil amount when the oil level is at the upper level.

At 3200 engine rpm

At 3000 engine rpm

API Service classification CC or CD, Below 0 °C (32 °F) : SAE 10W or 10W-30, 0 to 25 °C

(32 °F to 77 ° F) : SAE 20 or 10W-30, Above 25 °C (77 °F) : SAE 30 or 10W-30

[No. 1-D diesel fuel, if temperature is below – 10 °C (14 °F)]

2.6 L (2.7 U.S.qts., 2.3 Imp.qts.)

0 to 14.5 km/h

(0 to 9.0 mph)*

0 to 8.0 km/h

(0 to 5.0 mph)*

(47.5 cu.in.) 1123 cm3 (68.5 cu.in.)

No. 2-D Diesel fuel (ASTM D975)

4.0 L (4.2 U.S.qts., 3.5 Imp.qts.)*

0 to 15.0 km/h

(0 to 9.3 mph)*

0 to 8.3 km/h

(0 to 5.2 mph)*

, 1990 psi)

SPECIFICATIONS

20.9 kW (28 HP)*

(3.07 × 309 in.)

3.4 L

(3.6 U.S.qts., 3.0 Imp.qts.)

3.8 L

(4.0 U.S.qts., 3.3 Imp.qts.)

0 to 15.0 km/h

(0 to 9.3 mph)*

0 to 8.3 km/h

(0 to 5.2 mph)*

W1028929

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ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

Model ZD21N-EC ZD21-EC ZD28-EC

Overall length 2040 mm (80.3 in.) 2260 mm (90.0 in.) Overall width (Without mower)

Dimensions

Weight (With mower deck)

PTO Shaft drive KUBOTA 10 tooth in spline PTO clutch Wet multi discs Revolution (PTO speed)

PTO brake Wet single disc Steering 2-Hand levers Transmission 2-Hydrostatic transmission with gear Brake Internal expanding shoe / Hand

The company reserves the right to change the specifications without notice.

Overall height Wheel base 1250 mm (49.2 in.) 1365 mm (53.7 in.)

Treads

Front 975 mm (38.4 in.) 1065 mm (41.9 in.) Rear 1080 mm (42.5 in.) 1150 mm (45.3 in.)

1328 mm (52.3 in.) 1451 mm (57.1 in.) 1178 mm (46.4 in.) 1193 mm (47.0 in.)

570 kg (1256.6 lbs) / With

560 kg (1234.8 lbs) / With

54" mower deck

1 speed (2530 rpm at 3200 engine rpm)

60" mower deck

SPECIFICATIONS

652 kg (1437.7 lbs) / With

60" mower deck

676 kg (1490.6 lbs) / With

72” mower deck

1 speed (2540 rpm at 3000 engine rpm)

W1031261

Model RCK54-21NZ-EC RCK54-21NZ-EC RCK60-28Z-EC RCK72-28Z-EC

Suitable machine ZD21N-EC ZD21N-EC ZD28-EC Mounting method Quick joint, parallel linkage Adjustment of cutting height Dial gauge Cutting width 1372 mm (54.0 in.) 1524 mm (60.0 in.) 1829 mm (72.0 in.) Cutting height 25 to 127 mm (1.0 to 5.0 in.) Weight (Approx.) 103 kg (227 lbs) 120 kg (265 lbs) 150 kg (331 lbs) Blade spindle speed 50.1 r/s (3006 rpm) 44.6 r/s (2676 rpm) 44.8 r/s (2688 rpm) 40.0 r/s (2400 rpm)

Mower

The company reserves the right to change the specifications without notice.

Blade tip velocity 74.7 m/s

(14701 fpm) Blade length 475 mm (18.7 in.) 523 mm (20.6 in.) 625 mm (24.6 in.) Number of blades 3

Total length 985 mm (38.8 in.) 1025 mm (40.4 in.) 1095 mm (43.1 in.)

Dimensions

Discharge Right side

Total width 1690 mm (60.5 in.) 1845 mm (72.6 in.) 2245 mm (88.4 in.) Total height 300 mm (11.8 in.)

73.4 m/s

(14445 fpm)

73.6 m/s

(14484 fpm)

78.5 m/s

(15449 fpm)

W1029898

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ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

DIMENSIONS

Page 12

G GENERAL

KiSC issued 09, 2006 A

Page 13

GENERAL

KiSC issued 09, 2006 A

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 BOLTS............................................................................................ 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-10

6. MAINTENANCE CHECK LIST..................................................................... G-11

7. CHECK AND MAINTENANCE......... ...... ...... ....................................... ....... .. G-13

[1] DAILY CHECK........................................................................................ G-13

[2] CHECK POINTS OF INITIAL 50 HOURS........................................... G-17

[3] CHECK POINT OF INITIAL 100 HOURS ........................................... G-19

[4] CHECKING POINTS OF INITIAL 200 HOURS................................... G-20

[5] CHECK POINTS OF EVERY 50 HOURS........................................... G-22

[6] CHECK POINTS OF EVERY 100 HOURS......................................... G-26

[7] CHECK POINTS OF EVERY 150 HOURS......................................... G-31

[8] CHECK POINTS OF EVERY 200 HOURS......................................... G-31

[9] CHECK POINTS OF EVERY 400 HOURS......................................... G-33

[10]CHECK POINTS OF EVERY 1 YEAR................................................ G-33

[11]CHECK POINT OF EVERY 2 YEARS ................................................ G-36

[12]OTHERS .................................................................................................. G-37

8. SPECIAL TOOLS.......................................................................................... G-39

[1] SPECIAL TOOLS FOR ENGINE .......................................................... G-39

[2] SPECIAL TOOLS FOR MACHINE........................................................ G-45

Page 14

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

1. IDENTIFICATION

G GENERAL

When contacting your loca l KUBOTA distr ibutor, alway s specify engine serial num ber (3), machine serial number (2 ), mower serial number (4) and hour meter reading.

(1) Machine Identification Plate (2) Machine Serial Number (3) Engine Serial Number

(4) Mower Serial Number (5) Mower Identification Plate

W1010714

G-1

Page 15

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

2. GENERAL PRECAUTIONS

• During disa ssembly, ca refully ar range removed parts in a cle an area to prevent confusion later. Screws, bolts and nuts should be installed in their original position to prevent reassembly errors.

• When special tools are requi red, use KUBOT A genuine speci al 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 reassem bling external snap rings or inte rnal 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 insert ing spring pins, their splits must face the direction from which a force is applied. See the figure left side.

• To prevent dam age to the hydraulic s ystem, use only sp ecified fluid or equivalent.

(1) Grease (2) Force (3) Sharp Edge (4) Axial Force (5) Rotating Movement

G GENERAL

(A) External Snap Ring (B) Internal Snap Ring

W1010904

G-2

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ZD21N-EC, ZD21-EC, ZD28-EC, WSM

IMPORTANT■

KiSC issued 09, 2006 A

G GENERAL

3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING

To ensure safety and prevent damage to the machine and surrounding equipm ent, heed the following pr ecautions in handling electrical parts and wiring.

• 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 s ame 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 th e ba tter y cab le s, dis co nn ect t he n egat ive cable first. When in stalling the b attery cables, c onnect the positive cable first.

(1) Negative Terminal (2) Positive Terminal

W1011114

[1] WIRING

• Securely t ighten wiring terminals.

(1) Correct

(Securely tighten)

(2) Incorrect

(Loosening leads to faulty contact)

W1011216

• Do not let wiring contact dangerous part.

(1) Wiring (Correct) (2) Wiring (Incorrect)

(3) Dangerous Part (4) Dangerous Part

• Securely insert grommet.

(1) Grommet (A) Co rrect

(B) Incorrect

W1011313

W1011388

G-3

Page 17

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

• Securely clamp, being careful not to damage wiring.

(1) Clamp

• Wind Clamp Spirally

(2) Wire Harness

(3) Clamp (4) Welding Dent

W1011458

• Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.

(1) Wiring (2) Clamp

(A) Correct (B) 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

Page 18

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

[2] BATTERY

[3] FUSE

G GENERAL

• Take care not to confuse positive and negative terminal posts.

• When removing b attery cables, disconnect negative cable first. When installing battery cables, check for polarity and connect positive cable first.

• Do not install a ny battery with capacity other than is specified (Ah).

• After connecting cables to battery terminal posts, apply high temperature grease to them a nd sec urely in stall t erminal covers on them.

• Do not allow dirt and dust to collect on battery.

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

[4] CONNECTOR

• 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

W1012211

• In separating connectors, do not pull wire harnesses.

• Hold connector bodies to separate.

(A) Correct (B) Incorrect

W1012272

G-5

Page 19

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

• Use sandpaper to remove rust from terminals.

• Repair deformed terminal. Make certain there is no terminal being exposed or displaced.

(1) Exposed Terminal (2) Bend Terminal

(3) Sandpaper (4) Rust

W1012346

• Make certain that there is no female connector being too open.

(A) Correct (B) Incorrect

W1012430

[5] HANDLING OF CIRCUIT TESTER

• Use tester correctly following manual provided with tester.

• Check for polarity and range .

W1012684

G-6

Page 20

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

4. LUBRICANTS, FUEL AND COOLANT

G GENERAL

No. Place

1Fuel

Cooling system

2Coolant

Recovery tank

3 Engine crankcase

4 T ransmission case

Transmission case with

filter & hose

6 Rear axle case

7 Mower gear case

* Oil amount when the oil level is the upper of the oil level gauge. ** KUBOTA original transmission hydraulic fluid

ZD21N-EC ZD21-EC ZD28-EC

2.7 U.S.qts.

2.3 Imp.qts.

3.7 U.S.qts.

3.1 Imp.qts.

Capacity

30 L

7.9 U.S.gals.

6.6 Imp.gals.

2.6 L

4.0 U.S.qts.

3.3 Imp.qts.

0.25 L

0.26 U.S.qts.

0.22 Imp.qts.

3.5 L*

3.6 U.S.qts.

3.0 Imp.qts.

3.2 L

3.4 U.S.qts.

2.8 Imp.qts.

4.0 L

4.2 U.S.qts.

3.5 Imp.qts.

1.8 L each

1.9 U.S.qts. each

1.6 Imp.qts. each

0.40 L

0.42 U.S.qts.

0.35 Imp.qts.

3.8 L

3.4 L*

Lubricants, fuel and coolant

No. 2-D diesel fuel No. 1-D diesel fuel if temperature is below – 10 °C (14 °F)

Fresh clean water (soft water) with anti-freeze

Engine oil : API Service Classification CC or CD Below 0 °C (32 °F) : SAE10W, 10W-30 or 10W-40 0 to 25 °C (32 to 77 °F): SAE20, 10W-30 or 10W-40 Above 25 °C (77 °F): SAE30, 10W30 or 10W-40

KUBOTA UDT or SUPER UDT fluid**

G-7

Page 21

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

Greasing, oiling (Machine)

No. Place No. of greasing point Capacity Type of grease

7 Speed control lever boss 2 8 Speed control lever 2 9 Center pin 1

10 King pin 2

Until grease overflows

11 Front wheel 2

SAE multi-purpose type grease

12 Front lift arm 2 13 Universal joint 3 14 Seat adjuster 2 15 Throttle cable 2 Moderate amount Engine oil

Greasing (Mower)

16 Universal joint 3 17 Three spindle shafts 3

Until grease overflows

18 Belt tension pulley 1

SAE multi-purpose type grease

19 Belt tension pivot 1

G-8

Page 22

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

5. TIGHTENING TORQUES

[1] GENERAL USE SCREWS, BOLTS AND NUTS

Screws, bolts and nu ts whose tightening torques are not speci fied in t his Worksh op Manual should b e tightened

according to the table below.

Indication on top of

bolt

Material of bolt SS400, S20C S43C, S48C

Material of opponent

part

Unit Diameter

(6 mm, 0.24 in.)

(8 mm, 0.31 in.)

M10

(10 mm, 0.39 in.)

M12

(12 mm, 0.47 in.)

M14

(14 mm, 0.55 in.)

M16

(16 mm, 0.63 in.)

M18

(18 mm, 0.71 in.)

M20

(20 mm, 0.79 in.)

No-grade or 4T 7T 9T

SCr435,

SCM435

Ordinariness Aluminum Ordinariness Aluminum Ordinariness

N·m kgf·m ft-lbs N·m kgf·m ft-lbs N·m kgf·m ft-lbs N·m kgf·m ft-lbs N·m kgf·m ft-lbs

7.85

0.80

5.79

7.85

0.80

5.79

9.81

1.00

7.24

7.85

0.80

5.79

12.3

9.31

17.7 to

20.5

39.3 to

45.1

62.8 to

72.5

108

125 167

191 246

284 334

392

0.95

1.8 to

2.1

4.0 to

4.6

6.4 to

7.4

11.0 to

12.8

17.0 to

19.5

25.0 to

29.0

34.0 to

40.0

6.87

13.1 to

15.1

29.0 to

33.2

46.3 to

53.5

79.6 to

92.5

123

141 181

209 246

289

8.82

0.90

6.50

16.7

19.6

31.4

34.3

1.7

12.3

2.0

3.2

3.5

–––

14.4

23.2

25.3

11.2

23.6 to

27.4

48.1 to

55.8

77.5 to

90.2

124

147 197

225 275

318 368

431

1.15

2.4 to

2.8

4.9 to

5.7

7.9 to

9.2

12.6 to

15.0

20.0 to

23.0

28.0 to

32.5

37.5 to

44.0

8.31

17.4 to

20.2

35.5 to

41.2

57.2 to

66.5

91.2 to

108 145

166 203

235 272

318

8.82

0.90

6.50

17.7

20.5

39.3

44.1

62.8

72.5

1.8

13.1

2.1

4.0

4.5

6.4

7.4

–––

15.1

29.0

32.5

46.3

53.5

14.2

29.5 to

34.3

60.9 to

70.6

103

117 167

196 260

304 344

402 491

568

1.25 to

1.45

3.0 to

3.5

6.2 to

7.2

10.5 to

12.0

17.0 to

20.0

26.5 to

31.0

35.0 to

41.0

50.0 to

58.0

W1034542

9.05 to

10.4

21.7 to

25.3

44.9 to

52.0

76.0 to

86.7

123

144 192

224 254

296 362

419

[2] STUD BOLTS

Material of opponent

part

Unit Diameter

(8 mm, 0.31 in.)

M10

(10 mm, 0.39 in.)

M12

(12 mm, 0.47 in.)

Ordinariness Aluminum

N·m kgf·m ft-lbs N·m kgf·m ft-lbs

11.8 to

15.6

24.6 to

31.3

29.5 to

49.0

1.2 to

1.6

2.5 to

3.2

3.0 to

5.0

8.68

8.82

11.5

18.1

23.1

21.7

36.1

11.8

19.7

25.4

31.4 3.2 23.1

0.90 to

1.2

2.0 to

2.6

6.51 to

8.67

14.5 to

18.8

W10481390

G-9

Page 23

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

[3] METRIC SCREWS, BOLTS AND NUTS

G GENERAL

Grade

Unit

Nominal Diameter

M8 23.6 to 27.4 2.4 to 2.8 17.4 to 20.2 29.4 to 34.3 3.0 to 3.5 21.7 to 25.3 M10 48.1 to 55.8 4.9 to 5.7 35.5 to 41.2 60.8 to 70.5 6.2 to 7.2 44.9 to 52.1 M12 77.5 to 90.1 7.9 to 9.2 57.2 to 66.5 103.0 to 117.0 10.5 to 12.0 76.0 to 86.8 M14 124.0 to 147.0 12.6 to 15.0 91.2 to 108.0 167.0 to 196.0 17.0 to 20.0 123.0 to 144.0 M16 196.0 to 225.0 20.0 to 23.0 145.0 to 166.0 260.0 to 303.0 26.5 to 31.0 192.0 to 224.0

N·m kgf·m ft-lbs N·m kgf·m ft-lbs

Property class 8.8 Property class 10.9

0000001413E

[4] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR

UNF THREADS

Grade

Unit Nominal Diameter

5/16 23.1 to 27.8 2.35 to 2.84 17.0 to 20.5 32.5 to 39.3 3.31 to 4.01 24.0 to 29.0

3/8 47.5 to 57.0 4.84 to 5.82 35.0 to 42.0 61.0 to 73.2 6.22 to 7.47 45.0 to 54.0

1/2 108.5 to 130.2 11.07 to 13.29 80 .0 to 96.0 149 .2 to 179.0 15.22 to 18.27 110.0 to 132.0 9/16 149.2 to 179.0 15 .22 to 18.27 110.0 to 132.0 217.0 to 260.4 22.14 to 26.57 160.0 to 192.0

5/8 203.4 to 244.1 20.75 to 24.91 150.0 to 180.0 298.3 to 358.0 30.44 to 36.53 220.0 to 264.0

N·m kgf·m ft-lbs N·m kgf·m ft-lbs

SAE GR.5 SAE GR.8

0000001414E

[5] PLUGS

Shape Size

Tapered

screw

Straight

screw

Material of opponent part

Ordinariness Aluminum

N·m kgf·m ft-lbs N·m kgf·m ft-lbs

R1/8 12.7 to 21.6 1.3 to 2.2 9.4 to 15.9 12.7 to 19.6 1.3 to 2.0 9.4 to 15.4 R1/4 24.5 to 44.1 2.5 to 4.5 18.1 to 32.5 24.5 to 34.3 2.5 to 3.5 18.1 to 25.4 R3/8 49.0 to 88.3 5.0 to 9.0 36.2 to 65.1 49.0 to 58.8 5.0 to 6.0 36.2 to 43.4

R1/2 58.8 to 107.9 6.0 to 11.0 43.4 to 79.6 58.8 to 78.5 6.0 to 8.0 43.4 to 57.4 G1/4 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3 – – – G3/8 61.8 to 82.4 6.3 to 8.4 45.6 to 60.8 – – –

G1/2 49.0 to 88.3 5.0 to 9.0 36.2 to 65.1 – – –

0000001666E

G-10

Page 24

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

IMPORTANT■

KiSC issued 09, 2006 A

6. MAINTENANCE CHECK LIST

G GENERAL

Period

No.

Items

1 Engine oil Change ★✩✩✩✩✩✩

2 Engine oil filter Replace ★✩✩✩

Transmission

fluid Transmission oil

filter Transmission

strainer Rear axle gear

case (RH & LH) fluid

7 Front axle pivot Adjust ★✩✩✩

8 Safety device Check ✩✩✩✩✩✩✩✩✩✩✩✩

Greasing

(without mower)

Mower gear box

oil

Air cleaner

element

12 Battery condition Check ✩✩✩✩✩✩

13 Fan belt Adjust ✩✩✩✩✩✩

14 Parking brake Adjust ✩✩✩✩✩✩

Fuel filter

element

16 Fuel line

Change ★✩✩

Replace ★✩✩✩

Clean ★✩✩

Change ★✩✩

Check ✩✩✩✩✩✩✩✩✩✩✩✩

Change ✩✩✩✩

Clean ✩✩✩✩✩✩✩✩✩✩✩✩

Replace

Check ✩✩✩✩✩✩

Replace ✩

Check ✩✩✩✩✩✩

Replace

50 100 150 200 250 300 350 400 450 500 550 600

– ✩✩✩✩✩✩✩✩✩✩✩✩

Service interval

After

since

every

100 hr

every

200 hr

every

200 hr

every

200 hr

every

200 hr

every

200 hr

every

200 hr

every

50 hr

every

50 hr

every

150 hr

every

150 hr

every

50 hr

every

1 year

every

100 hr

every

100 hr

every

100 hr

every

100 hr

every

400 hr

every

100 hr

every

2 years

*1 G-26

Reference

page

G-17

G-18

G-21

G-18

G-20

G-21

G-19

G-22

G-24

G-26

–

G-26

G-28

G-29

G-28

G-33

G-28

–

W1037757

• The jobs indicated by ★ must be done initially.

* Suggested cleaning interval is every 100 hours in normal conditions.

This maintenance should be done daily more often in dusty condition than in normal conditions.

G-11

Page 25

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

Period

No.

Items

Radiator hose

and clamp

18 Hydraulic hose

19 Intake air line

Motion control

lever pivot

21 Radiator Clean

22 Coolant Change

Mower gear box

oil seal 24 Fuel system Bleed 25 Fuse Replac e G-37 26 Blade Replace G-38 27 Mower belt Replace G-38

Check ✩✩✩

Replace

Check ✩✩✩

Replace

Check ✩✩✩

Replace

Adjust ✩✩✩

Replace

50 100 150 200 250 300 350 400 450 500 550 600

Service interval

After

since

every

200 hr

every

2 years

every

200 hr

every

2 years

every

200 hr

every

2 years

every

200 hr

every

1 year

every

1 year

every

2 years

Service

required

Reference

page

G-31

G-32

G-34

G-36

G-38

W1063926

–

■ IMPORTANT

Replace if necessary.

G-12

Page 26

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

7. CHECK AND MAINTENANCE

CAUTION

• Be sure to check and service the machine o n a flat place with en gine shut off, the pa rking brake on and chock the wheels.

[1] DAILY CHECK

To prevent trouble from occurring, it is important to know the condition of the machine. Check the following items

before starting.

Checking

• Check areas where previous trouble was experienced.

• Walk around the machine.

1. Tire pressure, wear and damage

2. Oil and water leak

3. Engine oil level

4. Transmission fluid le vel

5. Coolant level in the recovery tank

6. Damage of machine body, tightness of all bolts and nuts

7. Radiator screen

8. Panel screen

9. Brake play

10.Air cleaner

11.Fuel level

12.Oiling

•Mower

1. Oil leak

2. Make sure blade cap screws are tight.

3. Check blades for wear or damage.

4. Check all hardwar e.

5. Make sure all pins are in place.

6. Mower deck cleaning

7. Greasing

• While sitting in the operator’s seat,

1. Motion contr ol lever

2. Parking brake

• Turning the key switch “ON”

1. Performance of the easy checker light

• Starting the engine,

1. Color of the exhaust fumes

2. Safety start switch, seat safety control and another safety control and another safety devices.

3. Check for abnorma l nois e and vi br ati on.

G-13

Page 27

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

IMPORTANT■

KiSC issued 09, 2006 A

G GENERAL

Checking Tire Pressure

WARNING

To avoid personal injury:

• Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment.

• Always maintain the correct tire pressure. Inflation pressure in front tires rises quickly when using compressed air. Do not inflate tires above the r ecommended pressure shown in the Operator’s Manual.

IMPORTANT

• Do not use tires larger than specified.

■ Inflation Pressure

Though the inflation pressure is factory-set to the prescribed

level, it naturally drops slowly in the cours e of time. Thus, check it and inflate as necessary.

Tire Sizes

Front 15 × 6.0-6, 4PR Rib

23 × 10.5-12, 4PR Turf

Rear

24 × 12.0-12, 4PR Turf

Recommended Inflation

Pressure

207 kPa

140 kPa

, 30 psi)

, 20 psi)

(2.1 kgf/cm

(1.4 kgf/cm

(1) Ground (A) Insufficient

(B) Normal (C) Excessive

W1041550

Checking Transmission Fluid Level

1. Park the mach ine on a flat surface, lower the imp lement to the ground and shut off engine and remove the key.

2. Raise and lock the operator’s seat.

3. To check the oil level, draw out the dipstick, wipe it clean, replace it, and draw it out again. Check to see that the oil level lies between the two not ches. If the level is to o low, add ne w oil to the prescribed level at the oil inlet. (See page G-7.)

• If oil level is low, do not run engine.

(1) Oil Level Dipstick (2) Oil Plug and Breather Cup

(A) Oil level is acceptable within this

range.

W1041984

G-14

Page 28

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

KiSC issued 09, 2006 A

G GENERAL

Checking Coolant Level

CAUTION

To avoid personal injury:

• Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Check to see t hat the coola nt level is b etween the “FULL” and “LOW” marks of recovery tank.

2. When the coolant level drops due to evaporation, add water only up to the full level of the recovery tank. In case of leaka ge, add anti-freeze and water in the specified mixing ratio up to the full level. (See page G-7.)

IMPORTANT

• If the radiator cap has to be removed, follow the caution above and securely retighten the cap.

• Use clean, distilled water a nd anti-freeze t o fill the r ecovery tank.

(1) Recovery Tank (A) FULL

(B) LOW

W1042377

Checking Engine Oil Level

CAUTION

To avoid personal injury:

• Always stop the engine and remove the key before checking oil.

1. Check engine oil before starti ng and 5 minut es or more afte r the engine has stopped.

2. Wipe dipstick area clean.

3. To check the oil level, remove the dipstick, wipe it clean, replace it, and draw it out again. Check to see that the oil level is between the two notches.

4. Add new oil to the prescribed level at the oil port if necessary.

5. When using a different brand or viscosity oil from the previous one, remove all of the old oil and oil filter. Never mix two different types of oil.

6. Use the proper Engine Oil SAE according to the ambient temperatures. (See page G-7.)

(1) Engine Oil Port (2) Oil Level Dipstick

(A) Upper Level (B) Lower Level

W1042659

G-15

Page 29

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

KiSC issued 09, 2006 A

G GENERAL

Checking and Cleaning Radiator to Prevent Overheating

CAUTION

To avoid personal injury:

• Be sure to stop the engine and remove the key before cleaning.

Daily or after every 5 hour s of operation, check to be sure the

radiator screen and radiator core are clean. Dirt or chaff on the radiator screen or radiator core decrease cooling performance.

1. Remove the radiator screen and panel sc reen and remo ve all foreign material.

2. Remove the dust from between the fins and the tube.

3. Tighten the fan drive belt as necessary. For this, refer to “EVERY 100 HOURS” in Maintenance section.

4. If scale forms in the tube, clean with the scale inhibitor or its equivalent.

5. Each time the panel screen is covered with grass during operation, rub i t off the screen with hand. Check the radiator screen from time to time if grass accumulates.

6. If the dust or chaff h as acc umula ted inside of the panel , remove the radiator screen and clean inside completely. After cleaning, replace the radiator screens properly.

NOTE

• When assembling the panel screen, be sure to fit it in the runners.

(1) Panel Screen (2) Radiator Screen

W1043048

Greasing (Mower)

CAUTION

To avoid personal injury:

• Be sure to stop the engine and remove the key before greasing.

1. Apply grease to the following position as figures.

(1) Mower Universal Joint (2) Spindle Shaft

(3) Belt Tension Pulley (4) Belt Tension Pivot

W1043490

G-16

Page 30

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

KiSC issued 09, 2006 A

[2] CHECK POINTS OF INITIAL 50 HOURS

Changing Engine Oil

CAUTION

• Be sure to stop the engine before changing oil.

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. To drain the used o il, r emove the drai n plug (1) at t he botto m of the engine and drain the oil completely.

4. Screw in the drain plug (1).

5. Fill new oil up to upper line on the dipstick (3).

IMPORTANT

• When using an oil of different manufacture or viscosity from the previous one, remove all of the old oil.

• Never mix two different type of oil.

• Use the proper SAE engine oil according to ambient temperatures. Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page G-7.)

Engine oil capacity

ZD21N ZD21

ZD28

G GENERAL

3.5 L

3.7 U.S.qts.

3.1 Imp.qts.

3.4 L

3.6 U.S.qts.

3.0 Imp.qts.

(1) Drain Plug (2) Oil Inlet Plug (3) Dipstick

(A) Upper Level (B) Lower Level

W1030749

G-17

Page 31

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

IMPORTANT■

KiSC issued 09, 2006 A

G GENERAL

Replacing Engine Oil Filter Cartridge

CAUTION

• Be sure to stop the engine before changing the oil filter cartridge.

• Allow engine to cool down sufficiently, oil can be hot and may cause burns.

1. Remove the engine oil filter cartridge (1) with the filter wrench.

2. Apply a slight coat of oil onto the rubber gasket of new cartridge.

3. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

4. After the cartridge has been replaced, the engine oil level normally lowers a little. Add engine oil to proper level. Check for oil leaks around filter gasket.

IMPORTANT

• To prevent serious damage to the engine, element of recommended type must be used. Use only a genuine KUBOTA filter or its equivalent.

(1) Engine Oil Filter Cartridge

W1030949

Replacing Transmission Oil Filter Cartridg e

CAUTION

• Be sure to stop the engine before changing the oil filter cartridge.

• Allow transmission case to cool down sufficiently; oil can be hot and may cause burns.

1. The oil filter cartridge must be changed every 300 service hours.

2. Remove the oil filter cartridge with the filter wrench.

3. Lightly tighten the screw (2) by using a screwdriver.

4. Apply a slight coat of oil onto the cartridge gasket.

5. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

6. After the new cartridge has been replaced, the transmission fluid level normally lowers a little. Add fluid to proper level. Check for oil leaks around filter gasket.

• To prevent serious damage to hydraulic system, the replacement filter must be a highly efficient, 10 μm filter. Use only a genuine KUBOTA filter or its equivalent.

(1) Transmission Oil Filter Cartridge (2) Screw

W1031068

G-18

Page 32

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

NOTE■

KiSC issued 09, 2006 A

[3] CHECK POINT OF INITIAL 100 HOURS

Adjusting Front Axle Pivot

1. Lift up and securely block the front of the machine.

2. Measure the clearance (A) between the front axle (3) and front axle support (2).

3. If the measurement exceed s the allowable limi t, remove the set spring (5) and adjust the end play by slotted nut (1).

(When reassembling)

Tightening torque

• When fastening the center pin (4), tighten the nut (1) so that the front axle maybe oscillated smoothly by hand.

Front axle end play (A)

Center pin lock nut (Slotted nut)

Factory spec.

Allowable limit

G GENERAL

40 to 80 N·m

4.08 to 8.16 kgf·m

29.50 to 59.00 ft-lbs

0 to 0.2 mm 0 to 0.008 in.

0.5 mm

0.02 in.

(1) Slotted Nut (2) Front Axle Support (3) Front Axle (4) Center Pin (5) Set Spring

(A) Front Axle End Play

W1053511

G-19

Page 33

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

KiSC issued 09, 2006 A

[4] CHECKING POINTS OF INITIAL 200 HOURS

Changing Transmission Fluid

CAUTION

• Be sure to stop the engine before changing the transmission fluid.

1. Place an oil pan underneath the transmission case.

2. Remove the drain plugs (1) at the bottom of the transmission case and drain the oil completely.

3. After draining, screw in the drain plug.

4. Fill new oil from filling port after removing the filling plug (3) up to the upper notch on the dipstick.

5. After running the engine for a few minutes, stop it and check the oil level again, if low, add oil to prescribed level.

IMPORTANT

• Use only multi-grade transmission oil. Use of other oils may damage the transmission or hydraulic system. Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page G-7.)

• Never work the machine immediately after changing the transmission oil. Keeping the engine at medium speed for a few minutes prevents damage to the transmiss ion.

• Do not mix different brands oil together.

Transmission fluid capacity

G GENERAL

4.0 L

4.2 U.S.qts.

3.5 Imp.qts.

(1) Drain Plug (2) Transmission Strainer (3) Oil Plug and Breather Cup (4) Dipstick

(A) Oil level acceptable within this

range.

W1048918

Cleaning Transmission Strainer

When changing the transmission fluid, disassemble and rinse the

strainer with nonflammable solvent to completely clean off filings.

Check O-rings (3), replace if damaged, cracked or hardened. When reassembling be careful not to damage the parts.

NOTE

• Since the fine filings in the oil can damage the precision component parts of the hydraulic system, the end of the suction line is provided with an oil strainer.

(1) Strainer (2) Suction Line

(3) O-ring

W1049356

G-20

Page 34

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

KiSC issued 09, 2006 A

G GENERAL

Changing Rear Axle Case Oil (RH & LH)

CAUTION

• Be sure to s top the engine be fore ch anging t he transm ission fluid.

1. Place an oil pan underneath the rear axle gear case.

2. Remove the drain plugs (1) at the bottom of the transmission case and drain the oil completely.

3. After draining, screw in the drain plug.

4. Fill new oil from filling port after removing the filling plug (2) up to the upper line of the gauge.

5. After running the engine for a few minutes, stop it and check the oil level again, if low, add oil to prescribed level.

IMPORTANT

• Use only multi-grade transmission oil. Use of other oils may damage the transmission or hydraulic system. Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page G-7.)

• Never work the machine immediately after changing the transmission oil. Keeping the engine at medium speed for a few minutes prevents damage to the transmission.

• Do not mix different brands oil together.

Rear axle case oil capacity

1.8 L each

1.9 U.S.qts. each

1.6 Imp.qts. each

(1) Drain Plug (2) Filling Plug with Gauge

(A) Upper Level (B) Lower Level

W1049491

G-21

Page 35

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

IMPORTANT■

KiSC issued 09, 2006 A

[5] CHECK POINTS OF EVERY 50 HOURS

Checking Safety Device

CAUTION

To avoid personal injury:

• Do not allow anyone near the machine while testing.

• If the machine does not pass one of the following tests, do not operate the machine.

• Sit on operator’s seat for all tests except for Test 1.

■ Test 1 (OPERATOR NOT ON THE SEAT)

1. Securely set the parking brake.

2. Shift the PTO lever (4) to “DISENGAGE” (OFF) position.

3. Set the motion control levers (3) to the “NEUTRAL LOCK” position.

4. Turn the key switch (5) to “START” position.

5. The engine must not crank.

■ Test 2 (OPERATOR ON THE SEAT)

1. Do not set the parking brake. (Release it from test 1.)

2. Shift the PTO lever (4) to “DISENGAGE” (OFF) position.

3. Set the motion control levers (3) to the “NEUTRAL LOCK” position.

4. Turn the key switch (5) to “START” position.

5. The engine must not crank.

■ Test 3 (OPERATOR ON THE SEAT)

1. Securely set the parking brake.

2. Shift the PTO lever (4) to “DISENGAGE” (OFF) position.

3. Grasp the moti on control levers (3) an d move then inward from “NEUTRAL LOCK” position to “NEUTRAL” positio n and then release the levers.

4. Turn the key switch (5) to “START” position.

5. The engine must not crank.

■ Test 4 (OPERATOR ON THE SEAT)

1. Securely set the parking brake.

2. Shift the PTO lever (4) to “ENGAGE” (ON) position.

3. Grasp the moti on control levers (3) an d move then inward from “NEUTRAL LOCK” position to “NEUTRAL” positio n and then release the levers.

4. Turn the key switch (5) to “START” position.

5. The engine must not crank.

■ Test 5 (OPERATOR ON THE SEAT)

1. Start the engine.

2. Keeps the parking brake securely set.

3. Shift the PTO lever (4) to “DISENGAGE” (OFF) position.

4. Grasp the moti on control levers (3) an d move then inward from “NEUTRAL LOCK” position to “NEUTRAL” positio n and then release the levers.

5. The engine must shut off after a short time delay.

G GENERAL

• For this test only, the engine will shut off in a few seconds.

(1) Parking Brake Lock Pedal (2) Parking Brake Release Lever (3) Motion Control Lever

(4) PTO Lever (5) Key Switch

G-22

Page 36

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

■ Test 6 (OPERATOR ON THE SEAT)

1. Start the engine.

2. Do not set the parking brake.

3. Shift the PTO le ve r (4) to “DISENGAGE” (OFF) position.

4. Grasp the mot ion control levers (3) a nd move t hen inward from “NEUTRAL LOCK” position to “NEUTRAL” position and then release the levers.

5. Stand up. (Do not get off the machine.)

6. The engine must shut off.

■ Test 7 (OPERATOR ON THE SEAT)

1. Start the engine.

2. Do not set the parking brake.

3. Shift the PTO le ve r (4) to “ENGAGE” (ON) position.

4. Stand up. (Do not get off the machine.)

5. The engine must shut off.

(1) Parking Brake Lock Pedal (2) Parking Brake Release Lever (3) Motion Control Lever

(4) PTO Lever (5) Key Switch

W1032761

G-23

Page 37

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

Greasing

1. Apply a grease to the following position as figures.

CAUTION

To avoid personal injury:

• Be sure to stop the engine and remove the key before greasing.

(1) King Pin (LH · RH) (2) Center Pin (3) Front Wheel (LH · RH) (4) Front Lift Arm (LH · RH)

(5) Motion Control Levers (LH · RH) (6) Motion Control Lever Boss

(LH · RH)

(7) Seat Adjuster

W1034228

G-24

Page 38

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

Greasing (Continued)

1. Apply a grease to the following position as figures.

CAUTION

To avoid personal injury:

• Be sure to stop the engine and remove the key before greasing.

(1) Machine Universal Joint (2) Throttle Cable (Oil)

W1035206

G-25

Page 39

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

NOTE■

KiSC issued 09, 2006 A

G GENERAL

Cleaning Air Cleaner Element

1. The air cleaner uses a dry element, never apply oil.

2. Do not touch the filter element except where cleaning is required. To clean the elemen t, use cle an and dry co mpress ed air on the inside of the eleme nt. Air pres sure shou ld not exce ed 205 kPa

(2.1 kgf/cm

, 30 psi).

• Operating in dusty conditions requires more frequent maintenance.

• Align the arrow marks when reinstalling the air cleaner cover.

(1) Air Cleaner Cover (2) Air Cleaner Element

W1053698

Checking Gear Box Oil Level

CAUTION

To avoid personal injury:

• Always stop the engine and remove the key before checking oil.

1. Park the machin e on a flat surface and lower the mower to the ground. To check the o il level, loosen che ck plug bolt an d check to see that the oil level is just below the check plug port. If the level is too low, add new oil to the prescribed level at the oil inlet. (See page G-7.)

(1) Drain Plug (Bolt) (2) Check Plug (Bolt)

(3) Oil Filler Plug

W1054012

[6] CHECK POINTS OF EVERY 100 HOURS

Checking Battery Condition

CAUTION

• Never remove the vent cap while the engine is running.

(1)

Keep electrolyte away from eye s, hand s and clot hes . If you are spattered with it, wash it away completely with water immediately and get medical attention.

• Wear eye protection and rubber gloves when working around battery.

Mishandling the battery shortens the service life and adds to

maintenance costs.

The original battery is a maintenance-free, non accessible type

battery.

If the battery is weak, the engine wi ll be difficult to sta rt and the

lights will become dim. It is important to check the battery periodically.

(1) Battery

W1083097

G-26

Page 40

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

■ Battery Charging

DANGER

To avoid serious injury or death:

• When the battery is being activated, hydrogen and oxygen

gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.

CAUTION

• When charging battery, ensure that the vent caps are securely in place (if equipped).

• When disconnecting the cables from the battery, start with the negative terminal first. When connecting the cables to the battery, start with the positive terminal first.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

(For accessible main tainable t ype ba tteries w ith re movable v ent caps.)

1. Make sure each ele ctr o ly te le ve l i s at th e bo ttom of ve nt wel ls, i f necessary add distilled water in a well-ventilated area.

2. The water in the electrolyte evaporates during recharging. Liquid shortage damages the battery. Exc essive liquid s pills over and damages the machine body.

3. To slow charge the battery, connect the battery positive terminal to the charger positive terminal and the negative to the negative, then recharge in the standard fashion.

4. A boost charge is only for emergencies. It will partially charge the battery at a higher rate and in a short time. When using a boost-charged battery, it is necessary to recharge the battery as soon as possible. Failure to do this will shorten the battery’s service life.

5. When the specific gravity of electrolyte reaches 1.27 to 1.29, charge has completed.

6. When exchanging an old battery with new o ne, use a b attery o f equal specification shown in “SPECIFICATIONS”. (For non-accessible maintenance-free type batteries.) Maintenance-free, non-accessible batteries are designed to eliminate the need to add water. Yet the volu me of electrolyte above plates may even tually becom e depleted d ue to abnor mal conditions such a s hi gh heat or imp roper reg ulator s etting . Use a voltmeter to check the state of charge. (See reference chart to determine if charging is necessary.)

Battery voltage Reference state of change

12.6 100 % (Full charge)

12.4 75 %

12.2 50 %

12.0 25 %

11.8 0 %

(1) Vent well (2) Separator (3) Electrolyte

G-27

(A) Highest Level (B) Lowest Level

W1035046

Page 41

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

IMPORTANT■

KiSC issued 09, 2006 A

G GENERAL

Checking Fuel Lines And Fuel Filter

CAUTION

• Be sure to stop the engine and remove the key when attempting to make the following checks and changes.

• Never fail to check the fuel lines periodically. The fuel lines are subject to wear and age. Fuel may leak out onto the running engine, causing a fire.

The fuel line con nections should be checked annually o r every

100 service hours, whichever comes first.

1. The fuel lines is made of rubber and ages regardl ess of service period.

2. If the fuel line and clamps are found damages or deteriorat ed, replace them.

3. Check fuel filter, if it is clogged by debris, and replace it.

IMPORTANT

• When the fuel line is disconnected for maintenance or repair, close both ends of the fuel line with a piece of clean cloth or paper to prevent dust and dirt from entering. In addition, particular care must be take n not to admit dust and dirt into the fuel pump. Entrance of dust and dirt causes malfunction of the fuel pump and injector components.

(1) Pipe Clamps (2) Fuel Line

(3) Fuel Filter (4) Fuel Pump

W1034725

Changing Engine Oil

1. See page G-17.

W1034674

Adjusting Fan Belt Tension

CAUTION

• Be sure to stop the engine and remove the key before checking belt tension.

1. If the fan drive belt becomes loose, the engine may overheat.

2. To adjust, loosen bolts and turn the alternator to tighten the belt.

3. After adjustment, sec urel y tighten the bol ts.

Moderate belt tension:

The belt deflect app rox. 10 mm (0.4 in .) when the center of the

belt is depressed with finger pressure of 98 N (10 kgf, 22 lbs).

Fan belt tension (A) Factory spec.

Approx. 10 mm

0.4 in.

• When replacing fan belt, be careful not to catch it on the cap under the water pump. See the illustration to the left.

(1) Cap (2) Tension bolt

(3) Alternator (4) Adjustment bolt

G-28

Page 42

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

KiSC issued 09, 2006 A

G GENERAL

Checking Parking Brake

CAUTION

To avoid personal injury:

• Stop the engine and chock the wheels before checking or adjusting.

• Park the machine on a hard and level surface. IMPORTANT

• Wrong adjustment may cause machine damage.

■ Check

1. Place the motion control levers to “NEUTRAL LOCK” position.

2. Be sure to chock the rear wheels.

3. Apply the parking brake to the notch.

4. Check the length of the brake springs on both sides.

Proper brake spring length at the first notch (B)

56 mm

2.2 in.

5. Release the parking brake.

6. Pull the brake rod fully forward by hand and hold.

7. Check the brake spring play.

Proper brake spring play (C)

1.0 to 2.0 mm

0.04 to 0.08 in.

8. If these dimensions are not correct, adjust.

(1) Brake Rod (A) Notch

(B) Parking Brake Spring Length (C) Brake Spring Play (D) Pull the Brake Rod

G-29

Page 43

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

NOTE■

KiSC issued 09, 2006 A

G GENERAL

■ Adjustment of brake spring play

1. Place the motion control lever to “NEUTRAL LOCK” position.

2. Be sure to chock the rear wheels.

3. Release the parking brake.

4. Loosen the lock nuts.

5. Pull the brake rod fully forward by hand and hold.

6. Tighten the nut to the correct space between the end of the spring and the plain washer.

7. Lock the nuts.

8. Adjust the other side spring to the same dimension.

■ Adjustment of brake length

1. Place the motion control lever to “NEUTRAL LOCK” position.

2. Apply the parking brake to the notch.

3. Loosen the lock nuts.

4. Adjust the spring length to the recommendation.

5. Lock the nuts.

6. Check the brake spring play to the recommendation. If there is no play, adjust the brake spring play again.

7. Adjust the other side spring to the same dimension.

■ Check the play of parking brake lock pedal

1. Place the motion control levers to “NEUTRAL LOCK” position.

2. Be sure to chock the rear wheels.

3. Release the parking brake completely.

4. Check that pa rking brake rel ease lever moves at the sa me time as the parking brake lock pedal is depressed.

5. If parking brake release lever does not move momentarily, adjust.

■ Adjustment of parking brake lock pedal play

1. Place the motion control lever to “NEUTRAL LOCK” position.

2. Be sure to chock the rear wheels.

3. Release the parking brake completely.

4. Loosen the lock nuts (1).

5. Adjust bolt (2) just to eliminate parking brake lock pedal play then lock the nut (1) to secure.

W1036954

■ Check on the slope

1. Place the machine on a 17° ramp.

2. Apply the parking brake.

3. Place the motion control levers in “NEUTRAL LOCK” position and shut off the engine.

4. Check that the machine does not move.

• For parking brake test purposes only use 17° ramp.

(1) Nut (2) Bolt

(E) Under 17° Ramp

G-30

W1037508

Page 44

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

NOTE■

KiSC issued 09, 2006 A

[7] CHECK POINTS OF EVERY 150 HOURS

Changing Mower Gear Box Oil

1. See page G-26.

[8] CHECK POINTS OF EVERY 200 HOURS

Adjusting Front Axle Pivot

1. See page G-19.

Checking Radiator Hose and Clamp

• Check to see if the radiator hos es are properly fi xed every 200 hours of operation or 6 months, whichever comes first.

1. If clamp bands ( 2) are loo se or w ater leaks , tighten clamp band (2) securely.

2. Replace radiator hoses (1) and tighten clamp bands (2) securely, if radiator hoses (1) are swollen, hardened or cracked. Replace radiator hoses (1) and clamp bands (2) every 2 years or earlier if checked and found that hoses are swollen, hardened or cracked.

G GENERAL

W1036280

W1036862

• Take the following actions in the event the coolant temperature be nearly or more than the boiling point, what is called “Overheating”.

• Park the machine in a safe place and keep the engine unloaded idling.

• Don’t stop the engine suddenly, but stop it after about 5 minutes of unloaded idling

• Keep yourself well away from the machine for further 10 minutes or while the steam is blown out.

• Checking that there gets no danger such as burning, get rid of the causes of overheating and then start the engine again.

(1) Radiator Hose (2) Clamp Band

W1036392

Changing Engine Oil Filter Cartridge

1. See page G-18.

W1061492

Replacing Transmission Oil Filter Cartridge

1. See page G-18.

W1061793

Checking Hydraulic Hose

CAUTION

To avoid personal injury:

• Be sure to stop the engine and remove the key before checking and replacing hydraulic hose.

• Allow transmission case to cool down sufficiently; oil can be hot and may cause burns.

1. Check to see the hose is tight and not damaged.

2. If the worn or damaged of the hose is found, replace it..

(1) Mower Lift Cylinder Hose

W1036641

G-31

Page 45

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

NOTE■

KiSC issued 09, 2006 A

G GENERAL

Adjusting the Motion Control Lever Pivot

CAUTION

To avoid personal injury:

• Be sure to stop the engine and set the parking brake t o “ON” before checking.

Lever free travel (A) Factory spec.

2 to 15 mm

0.08 to 0.59 in.

1. Set the motion control lever (1) in the “NEUTRAL” position.

2. Slightly move the lever back and forth and measure the free travel at the top of lever stroke.

3. If the free travel limits are exceeded, remove the fender and retighten the nut (3) to specified torque.

• If the motion control lever pivot bolt (2) is maladjusted, motion control may be difficult.

Tightening torque Pivot bolt

18.6 to 20.6 N·m

1.9 to 2.1 kgf·m

13.7 to 15.2 ft-lbs

(1) Motion Control Lever (2) Bolt (3) Nut

(A) Free Travel

W1063124

Checking Intake Air Line

1. Check to see that hoses and hose clamps are tight and not damaged.

2. If hoses and clamps are found worn or damaged, replace or repair them at once.

(1) Hose (2) Clamp

W1037686

G-32

Page 46

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

IMPORTANT■

KiSC issued 09, 2006 A

[9] CHECK POINTS OF EVERY 400 HOURS

Replacing Fuel Filter

1. Disconnect the fuel hoses and loosen the f ilter band to replace the fuel filter (2).

NOTE

• If the fuel line is removed, be sure to properly bleed the fuel system. (See page G-38.)

(1) Fuel Pump (2) Fuel Filter

G GENERAL

W1037174

[10] CHECK POINTS OF EVERY 1 YEAR

Replacing Air Cleaner Element

1. Remove the air cleaner element (2) once a year.

• The air cleaner uses a dry element, never apply oil.

• Do not run the engine with filter element removed.

• Be sure to refit the air cleaner cover (1) as shown in the figure. If the air cleaner cover (1) is improperly fitted, evacuator valve (3) will not function and dust will adhere to the element.

• If it is loose, dust and dirt may be sucked in, wearing down the cylinder and piston rings earlier and thereby resulting in poor power output.

(1) Air Cleaner Cover (2) Air Cleaner Element

(3) Evacuator Valve

W1037268

G-33

Page 47

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

KiSC issued 09, 2006 A

G GENERAL

Flushing Cooling System and Changing Coolant

CAUTION

• Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain plug (3) and remove the radiator cap (1) . The radiator cap (1) must be removed to completely drain the coolant.

3. After all coolant is drained, close the drain plug (3).

4. Fill with clean water and cooling system cleaner.

5. Follow directions of the cleaner instruction.

6. After flushing, fill with clean water and anti-freeze until the coolant level is just below the port. Install the radiator cap (1) securely.

7. Fill with coolant up to “FULL” mark on the recovery tank.

8. Start and operate the engine for a few minutes.

9. Stop the en gine and let cool. Check cool ant level of recovery tank (2) and add coolant if necessary.

IMPORTANT

• Do not start engine without coolant.

• Use clean, fresh water and anti-freeze to fill the radiator and recovery tank.

• When the anti-freeze is mixed with water, the anti-freeze mixing ratio must be less than 50 %.

• Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

• Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page G-7.)

2.6 L

2.7 U.S.qts.

2.3 Imp.qts.

3.8 L

4.0 U.S.qts.

3.3 Imp.qts.

0.25 L

0.26 U.S.qts.

0.22 Imp.qts.

Coolant capacity

Cooling system

Recovery tank

ZD21N ZD21

ZD28

ZD21N ZD21 ZD28

(1) Radiator Cap (2) Recovery Tank (3) Drain Plug (4) Drain Cock

G-34

(A) FULL (B) LOW

W1037402

Page 48

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

NOTE■

KiSC issued 09, 2006 A

G GENERAL

Flushing Cooling System and Changing Coolant (Continued)

■ Anti-Freeze

If coolant freezes, the cylinders and radiator can be damaged. It is necessary, if the ambient temperature falls below 0 °C (32 °F), to remove coolant mix it with anti-freeze and full the radiator with it.

1. There are two types of anti-fr eeze availab le; use the perma nent type (PT) for this engine.

2. Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh water and draining it a few times.

3. The procedure for mixing of water and anti-freeze differs according to the maker of the anti-freeze and the ambient temperature, basicall y should be referred to SAE J1034, more specially also to SAE J814c.

4. Mix the anti-freeze with water, and then fill in to the radiator.

Vol % Antifreeze

40 – 24 – 12 106 222 50 – 37 – 34 108 226

Freezing Point Boiling Point*

°C °F °C °F

* At 101 kPa (760 mmHg) pressure (atmospheric). A higher boiling point is obt ained by usin g a radiator pressure cap which permits the development of pressure within the cooling system.

• The above date represent industry standards that necessitate a minimum glycol con tent in the concentrates anti-freeze.

• When the coolant level drops due to evaporation, add water only. In case o f leakage, add anti-freeze and water in the specified mixing ratio.

• Anti-freeze absorb s moist ure. Kee p un used a nti-f re ez e in a tightly sealed container.

• Do not use radiator cleaning agents when anti-freeze has been added to the coolant. (Anti-freeze contains an anticorrosive agent, which will react with the radiato r cleaning agent forming sludge which will affect the engine parts.)

W1037674

G-35

Page 49

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

[11] CHECK POINT OF EVERY 2 YEARS

Replacing Hydraulic Hose

1. Replace the hose. Refer to “Checking Hydraulic Hose” . (See page G-31.)

Replacing Radiator Hose

1. Replace the hoses and clamps. Refer to “Checking Radiator Hos e and Hose Clamp”. (See page G-31.)

Replacing Fuel Lines

1. Replace the fuel line. Refer to “Checking Fuel Lines and Fuel Filter”. (See page G-

28.)

Replacing Intake Air Line

1. Replace the intake air line. Refer to “Checking Intake Air Line”. (See page G-32.)

Replacing Mower Gear Box Seals

1. Replace the mower gear box oil seals (1), (2). Refer to “Disassembling Gea r Box Asse mbly”. ( Se e pa ge 6 S8.)

(1) Oil Seal (2) Oil Seal

G GENERAL

W1067327

W1067436

W1082371

W1037080

W1038357

G-36

Page 50

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

IMPORTANT■

NOTE■

KiSC issued 09, 2006 A

[12] OTHERS

G GENERAL

Replacing Fuses

1. The electrical system is protected from potential damage by fuses. A blown fuse indicates that there is an overload or short somewhere in the electrical system.

2. If any of the fuses should blo w, replace with a new one of the same capacity.

• Before replacing a blown fuse, determine why the fuse blew and make any necessary repairs. Failure to follow this procedure may result in serious damage to the electrical system.

■ Protected Circuit

FUSE NO.

(ID LABEL)

2 Slow blow fuse 40 A

(1) Fuse (2) Slow Blow Fuse

CAPACITY

(A) 20A Engine stop 15A Charge system 15A Aux. outlet 15A Main system 10A Control system

Check circuit against wrong battery connection

Protected circuit

W1038470

Retightening Mower Blade Screw

CAUTION

• To avoid injury, always handle the mower blade with care.

1. Tilt up the mower and turn it over to expose the mower blades.

2. Wedge a woode n block (1) sec urely between the mower blade and mower deck.

3. Retighten the mower blade screw to the specified torque.

4. If the mower blade screw (2) is worn or broken, replace it.

• The screw of the red-painted mower blade is of inverse helical type.

Tightening torque Mower blade screw

(1) Wooden Block (2) Mower Blade Screw

(A) Loosen (B) Tighten

98.0 to 117.6 N·m

10.0 to 12.0 kgf·m

72.0 to 86.8 ft-lbs

W1022525

G-37

Page 51

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NOTE■

KiSC issued 09, 2006 A

G GENERAL

Checking Mower Blade and Replacing Mower Blade

1. Check the cutting edge of mower blade.

2. Sharpen the cu tting edge s, if the mower blades ar e as shown in figure (2).

3. Replace the mower blades, if they are as shown in figure (3).

• To sharpen the mower blades by yourself, clamp the mower blade securely in a vise a nd use a large mill file along the original bevel.

• To balance the mower blade, place a small rod through the center hole and check to see if the blade balances evenly. File heavy side of the blade until it balance out even.

4. Tilt up the mower deck.

5. Wedge a wooden block s ecurel y bet ween th e mowe r blad e and mower deck or use a box wrench ove r the pulley nut to prevent the spindle from rotating while removing the blade bolts; then loosen the blade bolts.

6. Pass the sp line boss through th e blade (5) and 2 cup wa shers (6), and tighten the bolt (8).

• Make sure that the cup w asher is not flatten ed out or wor n; this cause blade to slip excessively. Replace the 2 cup washers if either is damaged.

(1) New Blade (2) Worn Blade (3) Cracked Blade (4) Spindle Holder (5) Blade

(6) 2 Cup Washers (7) Lock Washer (8) Bolt

(A) 30 mm (1-3/16 in.)

W1022841

Replacing Mower Belt

1. Remove the mower deck from the machine.

2. Remove the left and right hand shield from the mower deck.

3. Clean around the gear box.

4. Remove the belt from the tension pulley.

5. Remove the right hand bracket which mounts the gear box to the mower deck and slip the belt over the top of the gear box.

6. To install a new belt, reverse the above procedure.

27.6 to 90.2 N·m

Tightening torque Bracket mounting screw

8.0 to 9.2 kgf·m

57.1 to 66.5 ft-lbs

(1) Tension Pulley (2) Bracket (RH)

(3) Belt

W1069194

Bleeding Fuel System Air must be removed:

1. When the fuel filter or lines are removed.

2. When tank is completely empty.

3. After the tractor has not been used for a long period of time.

Bleeding procedure is as follows:

1. Fill the fuel tank with fuel.

2. Turn the key switch to “ON” position for about 30 seconds. Doing so allows fuel pump to work and pump air out of the fu el system.

3. Start the engine and run for about 30 seconds, and then stop the engine.

(1) Fuel Pump

W1069400

G-38

Page 52

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

8. SPECIAL TOOLS

[1] SPECIAL TOOLS FOR ENG INE

Special Use Puller Set

Code No: 07916-09032 Application: Use exclusively for pushing out bearing, gears and

Piston Ring Compressor

Code No: 07909-32111 Application: Use exclusively for pushing in the piston with piston

G GENERAL

other parts with ease.

W1048293

rings into the cylinder.

W1048361

Piston Ring Tool

Code No: 07909-32121 Application: Use exclusively for removing or installing the piston ring

with ease.

W1048421

Diesel Engine Compression Tester

Code No: 07909-30208 (Assembly) 07909-31251 (G)

07909-30934 (A to F) 07909-31271 (I) 07909-31211 (E and F) 07909-31281 (J) 07909-31231 (H)

Application: Use to measure diesel engine compression and

diagnostics of need for major overhaul.

(1) Gauge (2) L Joint (3) Adaptor A (4) Adaptor B (5) Adaptor C (6) Adaptor E

(7) Adap tor F (8) Adap tor G

(9) Adap tor H (10) Adaptor I (11) Adaptor J

W1048481

G-39

Page 53

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

Oil Pressure Tester

Code No: 07916-32032 Application: Use to measure lubricating oil pressure.

(1) Gauge (2) Cable (3) Threaded Joint (4) Adaptor 1

(5) Adaptor 2 (6) Adaptor 3 (7) Adaptor 4 (8) Adaptor 5

W1048722

Valve Seat Cutter

Code No: 07909-33102 Application: Use to reseat valves. Angle: 0.785 rad (45 °)

0.262 rad (15 °)

Diameter: 28.6 mm (1.126 in.)

31.6 mm (1.244 in.)

35.0 mm (1.378 in.)

38.0 mm (1.496 in.)

41.3 mm (1.626 in.)

50.8 mm (2.000 in.)

W1048944

Radiator Tester

Code No: 07909-31551 Application: Use to check of radiator cap press ure, and l eaks from

cooling system.

Remarks: Adapter (1) BANZAI Code No. RCT-2A-30S

W1049045

Connecting Rod Alignment Tool

Code No: 07909-31661 Application: Use to check the connecting rod alignment. Applicable: Connecting rod big end I.D. range 30 to 75 mm (1.18 to 2.95 in.) dia.

Connecting rod length 65 to 300 mm (2.57 to 11.81 in.)

W1049118

Flywheel Puller

Code No: 07916-32011 Application: Use exclusively for removing the flywheel with ease.

W1049723

G-40

Page 54

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

NOTE■

KiSC issued 09, 2006 A

G GENERAL

Nozzle Tester

Code No: 07909-31361 Application: Use to check the fuel injection pressure and spray

pattern of nozzle.

Measuring: 0 to 50 MPa

range (0 to 500 kgf/cm

, 0 to 7000 psi)

W1049783

Plastigage

Code No: 07909-30241 Application: Use to check the oil clearance between crankshaft and

bearing, etc..

Measuring: Green.....0.025 to 0.076 mm (0.001 to 0.003 in.)

range Red........0.051 to 0.152 mm (0.002 to 0.006 in.)

Blue.......0.102 to 0.229 mm (0.004 to 0.009 in.)

W1049942

Red Check

Code No: 07909-31371 Application: Use to check cracks on cylinder head , cylinder block,

etc..

• The following special tools are not provided, so make them referring to the figure. Valve Guide Replacing Tool

Application: Use to press out and press fit the valve guide.

A 20 mm dia. (0.79 in. dia.)

9.96 to 9.98 mm dia.

(0.3921 to 0.3929 in. dia.) C 5.5 to 5.7 mm dia. (0.2165 to 0.2244 in. dia.) D 200 mm (7.87 in.) E 80 mm (3.15 in.) F 40 mm (1.58 in.) G 15 mm (0.59 in.) H 5 mm (0.197 in.)

I 6.0 to 6.1 mm dia. (0.236 to 0.240 in. dia.)

J 18 mm dia. (0.71 in. dia.) K 10.6 to 10.7 mm dia. (0.417 to 0.421 in. dia.) L 7 mm (0.276 in.)

C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.012 in.)

W1050024

W1050106

G-41

Page 55

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

Injection Pump Pressure Tester

Application: Use to check fuel tightness of injection pumps.

Pressure gauge full scale: More than

29.4 MPa (300 kgf/cm B Copper gasket C Flange (Material: Steel) D Hex. nut 27 mm (1.06 in.) across the plat E Injection pipe FPF1/2 G 5 mm (0.20 in.) H 17 mm dia. (0.67 in. dia.)

I 8 mm dia. (0.31 in. dia.)

J 1.0 mm (0.039 in.) K 17 mm dia. (0.67 in. dia.) L 6.10 to 6.20 mm dia. (0.2402 to 0.2441 in. dia.) M 8 mm (0.31 in.) N 4 mm (0.16 in.) O 11.97 to 11.99 mm dia. (0.4713 to 0.4721 in. dia.) PPF1/2 Q 23 mm (0.91 in.) R 17 mm (0.67 in.) S 4 mm (0.16 in.) T 12.00 to 12.02 mm dia. (0.4724 to 0.4732 in. dia.) U 100 mm (3.94 in.) V M12 × P1.5 a Adhesive application b Fillet welding on the enter circumference

, 4267 psi)

W1050289

G-42

Page 56

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

Bushing Replacing Tool

Application: Use to press out and to press fit the bushing.

1. For small end bushing

A 145 mm (5.71 in.) B 20 mm (0.79 in.) C 100 mm (3.94 in.) D 19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.) E 21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.) F 25 mm dia. (0.98 in. dia.) a6.3 μ m (250 μ in.)

b6.3 μ m (250 μ in.) C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.)

2. For idle gear bushing

A 150 mm (5.91 in.)

B 20 mm (0.79 in.)

C 100 mm (3.94 in.)

D 19.90 to 19.95 mm (0.7835 to 0.7854 in.)

E 21.90 to 21.95 mm (0.8622 to 0.8642 in.)

F 25 mm (0.98 in.)

a6.3 μ m (250 μ in.)

b6.3 μ m (250 μ in.) C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.)

W1050660

Flywheel Stopper

Application: Use to loosen and tighten the flywheel screw.

A 200 mm (7.87 in.)

B 30 mm (1.18 in.)

C 20 mm (0.79 in.)

D 15 mm (0.59 in.)

E 15 mm (0.59 in.)

G 8 mm (0.31 in.)

F 10 mm dia. (0.39 in. dia.)

W1050819

G-43

Page 57

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

G GENERAL

Crankshaft Bearing 1 Replacing Tool

Application: Use to press out and to press fit the crankshaft bearing

[Press Out]

A 135 mm (5.31 in.) B 72 mm (2.83 in.) C 1.57 rad (40°) D 10 mm (0.39 in.) E 22 mm (0.87 in.) F 20 mm dia. (0.79 in. dia.) G 48.90 to 48.95 mm dia. (1.9251 to 1.9271 in. dia.) H 43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)

[Press Fit]

A 130 mm (5.12 in.) B 72 mm (2.83 in.) C 1.57 rad (40°) D 9 mm (0.35 in.) E 24 mm (0.95 in.) F 20 mm dia. (0.79 in. dia.) G 68 mm dia. (0.79 in. dia.) H 39.90 to 39.95 mm dia. (1.5709 to 1.5728 in. dia.)

W1051113

G-44

Page 58

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

[2] SPECIAL TOOLS FOR MA CHIN E

Relief Valve Pressure Tester

Code No: 07916-50045 Application: This allows easy measurement of relief set pressure.

(1) Gauge (07916-50322) (2) Cable (07916-50331) (3) Threaded Joint (07916-50401) (4) Threaded Joint (07916-50341) (5) Adaptor B (M18 × P1.5)

(07916-50361)

HST Relief Valve Adaptor

Application: This adaptor is used to measure the HST relief valve

A 80 mm (3.15 in.)

B 20 mm (0.79 in.)

C 60 mm (2.36 in.)

D G 1/4 × 15 mm (0.59 in.)

E 12 mm (0.47 in.)

F 13 mm dia. (0.51 in. dia.)

GG 1/4

H 3 mm dia. (0.118 in. dia.)

I 19 mm (0.75 in.)

C1 Chamfer 1.0 mm (0.039 in.)

G GENERAL

(6) Adap tor C (PS3/8) (07916-50371) (7) Adap tor D (PT1/8) (07916-50381) (8) Adap tor E (PS 3 /8) (07916-50392) (9) Adap tor F (PF1/2) (07916-62601)

(10) Adaptor 58 (PT1/4) (07916-52391)

W1051907

pressure.

W1040355

G-45

Page 59

1 ENGINE

KiSC issued 09, 2006 A

Page 60

MECHANISM

KiSC issued 09, 2006 A

CONTENTS

1. FUEL SYSTEM ............................................................................................. 1-M1

[1] GOVERNOR ............................................................................................1-M1

Page 61

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

1. FUEL SYSTEM

[1] GOVERNOR

ENGINE

The governor s ystem is a mechanic al governor that

used the flyweight (1).

The flyweight (1) is mounted on the governor shaft

that rotates at the same speed as the crankshaft.

Because the feature o f thi s mec han is m ta ke s ou t the engine rotational speed dir ectly as a centrif ugal forc e of weight, the speed control that the change in the eng ine rotational speed is sensitively transmitted to fork lever comp (A) and accuracy is high is enabled.

The fork lever assembly of this engine is composed of fork lever 1 (6), fork leve r 2 (7), and t he floati ng lever (8). A thrust lever is i nstalled in fork lever 1. The gove rnor spring (5) is hooked to fork lever 2 (7).

The floating leve r (8) ins talls the torque pin (9) of the output drop prevention at the overload . The star t spring (4) is hooked to a thrust lever, and holds the control rack in the direction of the increase.

Fork lever 2 (7) and the floa ting lever ar e install ed in fork lever 1 (6) with the fork lever shaft (2). The max. torque limitatio n (3) device lim its the amount of the fuel exhalation at the overload with the torque pin.

(1) Flyweight (2) Fork Lever Shaft (3) Max. Torque Limitation (4) Start Spring (5) Governor Spring

(6) Fork Lever 1 (7) Fork Lever 2 (8) Floating Lever (9) Torque Pin

(A) Fork Lev e r Co m p

0000004865E

■ At Rated Operation

When the engine is ru nning, the fork lever 2 (7) and the floating leve r (8) ar e mov ing with t he for k lever 1 (6) due to the tension of the governor spring (5).

During the time, the torque pin (9) is pressed into the floating lever by cen trifu gal forc e of the go vernor weigh t (1).

The fork lever 2 (7) comes in contact with the fuel limitation bolt (10), and th e fuel injection pump s upplies necessary fuel for rated operation.

(3) Max Torque Limiter (6) Fork Lever 1 (7) Fork Lever 2

(8) Floating Lever

(10) Fuel Limitation Bolt

0000004866E

1-M1

Page 62

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

ENGINE

■ Overloaded Operation

The amount of the mo ve men t of the fork lever co mp. is limited with the fuel limi tation b olt (10 ) and can no t be moved in the direction of the fuel increase.

As overload reduces the centrifugal force of the governor weight, which is pressing the torque pin (9) into the floating lever (8), the torque pin pushes the fork lever 1 (6) in the way to in cr ea se the fuel supply with the he lp of the torque spring tension.

The fuel supply increases (C) in relation to the degree of the torque pin motion, thus preventing the engine speed from dropping.

At the time, the maximum to rque limiter (3) pr events superfluous fuel supp ly and suppresses the gener ation of black smoke.

(3) Max. Torque Limiter (4) Start Spring (6) Fork Lever 1 (7) Fork Lever 2 (8) Floating Lever (9) Torque Pin

(10) Fuel Limitation Bolt

(A) Distance Where Rack

Moves (Amount of a fuel increase at overload)

(B) The Max. Torque Limiter

Worked (C) Increase of Fuel (D) Distance t o Which Torque

Pin (9) Pushes Fork Lever 1

(6) Out

W1013813

1-M2

Page 63

SERVICING

KiSC issued 09, 2006 A

CONTENTS

1. TROUBLESHOOTING....................................................................................1-S1

2. SERVICING SPECIFICATIONS[D782-E-XFM5] ...........................................1-S5

[1] ENGINE BODY ........................................................................................1-S5

[2] LUBRICATING SYSTEM ............................... ...... ....... ...... ....... ...... ....... ...1-S9

[3] COOLING SYSTEM.................................................................................1-S9

[4] FUEL SYSTEM ....................................... ....... ...... ....... ...........................1-S10

3. SERVICING SPECIFICATIONS[D1105-E2-ZD] ..........................................1-S11

[1] ENGINE BODY ......................................................................................1-S11

[2] LUBRICATING SYSTEM ............................... ...... ....... ...... ....... ...... ....... .1-S15

[3] COOLING SYSTEM...............................................................................1-S15

[4] FUEL SYSTEM ....................................... ....... ...... ....... ...........................1-S16

4. TIGHTENING TORQUES ............................. ....... ...... ....... ...... ....... ...... ....... .1-S17

5. CHECKING, DISASSEMBLING AND SERVICING.....................................1-S19

[1] SEPARATING ENGINE .......................... ....... ...... ....... ...... ....... ...... ....... .1-S19

(1) Disassembling and Assembling ........................................................1-S19

[2] ENGINE BODY ......................................................................................1-S25

(1) Checking and Adjus ti ng ..................... ....................................... ....... .1-S25

(2) Disassembling and Assembling ........................................................1-S28

(3) Servicing ...........................................................................................1-S42

[3] LUBRICATING SYSTEM ............................... ...... ....... ...... ....... ...... ....... .1-S66

(1) Checking ...........................................................................................1-S66

(2) Servicing ...........................................................................................1-S66

[4] COOLING SYSTEM...............................................................................1-S68

(1) Checking and Adjus ti ng ..................... ....................................... ....... .1-S68

(2) Disassembling and Assembling ........................................................1-S70

[5] FUEL SYSTEM ....................................... ....... ...... ....... ...........................1-S71

(1) Checking and Adjus ti ng ..................... ....................................... ....... .1-S71

(2) Disassembling and Assembling ........................................................1-S74

Page 64

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

1. TROUBLESHOOTING

ENGINE

Symptom Probable Cause Solution

Engine Does Not Start

(Starter Does Not Run)

• No fuel

• Air in the fuel system

• Water in the fuel system

• Fuel pipe clogged

• Fuel filter clogged

• Excessively high viscosity of fuel or engine oil at low temperature

• Fuel with low cetane number

• Fuel leak due to l oos e inj ect ion pip e ret a ini ng nut

• Incorrect injec tio n timi ng

• Fuel camshaft worn

• Injection nozzle clogged

• Injection pump malfunctioning

• Seizure of crankshaft, camshaft, piston, cylinder or bearing

• Compression leak from cylinder

• Improper valve timing

• Piston ring and cylinder worn

• Excessive valve clearance

• Battery discharged

• Starter malfunctioning

• Slow blow fuse blown

• Main switch malfunctioning

• PTO switch defective

• Parking brake switch defective

• Motion control lever switch defective

• Seat switch defective

• Wiring harness disconnected

Replenish fuel Bleed fuel system Change fuel and replace fuel system Clean fuel pipe Replace fuel filter Use specified fuel or engine oil Use specified fuel Tigh ten retaining nut

Adjust injection timing Replace fuel camshaft Clean injection nozzle Repair or replace injection pump Replace crankshaft, camshaft, piston, cylinder or bearing Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder Correct valve timing Replace pi ston ring and bore oversize cylinder Adjust valve clearance

Charge battery Repair or replace starter Replace slow blow fuse Repair or replace main switch Replace PTO switch Replace brake switch Replace reverse switch or adjust reverse switch gap Replace seat switch Connect wiring harness

Reference Page

– – –

–

G-33

G-7 G-7

1-S28 1-S71

1-S33, S35

1-S74 1-S31, S35 1-S39, S40

1-S30

1-S32, S36 1-S39, S65

1-S27

G-27

5-S12

G-37 5-S8

5-S10

–

W1066187

1-S1

Page 65

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

ENGINE

Symptom Probable Cause Solution

Engine Revolution Is Not Smooth

• Fuel filter clogged or dirty

• Air cleaner clogged

Replace fuel filter Clean or replace air cleaner element.

• Fuel leak due to loose injection pipe retaining

Tighten retaining nut

nut

• Injection pump malfunctioning

Repair or replace injection pump

• Incorrect nozzle injection pressure

Adjust nozzle injection pressure

• Injection nozzle stuck or clogged

Repair or replace injection nozzle

Either White or Blue Exhaust Gas Is Observed

• Governor malfunctioning

• Excessive engine oil

• Piston ring and cylinder worn or stock

Repair governor Reduce to specified

engine oil level Repair piston ring and bore oversize piston

• Incorrect injection timing

Adjust injection timing

• Deficient compression

Replace each bearings

Either Black or Dark Gray Exhaust Gas Is Observed

•Overload

• Low grade fuel used

• Fuel filter clogged

• Air cleaner clogged

Lessen load Use specified fuel Replace fuel filter Clean or replace air cleaner element

• Deficient nozzle injection

Repair or replace nozzle

Deficient Output • Incorrect injection timing

Adjust injection timing

• Engine's moving parts seem to be seized.

Repair or replace engine’s moving parts

• Uneven fuel injection

Repair or replace injection pump

• Deficient nozzle injection

Repair or replace nozzle

• Compression leak from cylinder

Replace head gasket, tighten cylinder head screws, glow plugs and nozzle holders.

Excessive Lubricant Oil Consumption

• Piston ring’s gap facing the same direction

• Oil ring worn or stuck

• Piston ring groove worn

• Valve stem and valve guide worn

Shift ring gap direction Replace oil ring Replace piston Replace valve and valve guide

• Oil leaking due to defective seals or packing

Replace defective seals or packing

Reference Page

G-33 G-26

1-S28

1-S31, S35

1-S73

1-S29, S74

– –

1-S-39,S65

1-S71

–

– G-33 G-28

1-S29, S74

1-S71

–

1-S31, S35 1-S29, S74

1-S30

1-S39 1-S39

1-S39

1-S30, S44

–

W1010717

1-S2

Page 66

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

ENGINE

Symptom Probable Cause Solution

Fuel Mixed into Lubricant Oil

• Injection pump’s plunger worn

Replace pump element or injection pump

• Deficient nozzl e inj ec tio n

Repair or replace nozzle

• Injection pump broken

Replace injection pump

Water Mixed into Lubricant Oil

• Head gasket defectiv e

• Cylinder block or cylinder head flawed

Replace head gasket Replace cylinder block or cylinder head

Low Oil Pressure • Engine oil insufficient

• Oil strainer clogged

• Engine oil filter cartridge clogged

Replenish engine oil Clean oil strainer Change engine oil filter cartridge

• Relief valve stuck with dirt

Clean or replace relief valve

• Relief valve spring weaken or broken

Replace relief valve spring

• Excessive oil clearance of crankshaft bearing

Replace main bearings, metals or crankshaft

• Excessive oil clearance of crankpin bearing

Replace crankpin bearings

• Excessive oil clearance of rocker arm

Replace rock er arms, rocker arm brackets or rocker arm shaft.

• Oil passage clogged

• Different type of oil

Clean oil passage Use specified type of oil

• Oil pump defective

Repair or replace oil pump

High Oil Pressure • Different type of oil

Use specified type of oil

• Relief valve defective

Replace relief valve

Reference Page

1-S31, S35

1-S29, S74 1-S31, S35

1-S30

–

G-17 G-20 G-18

– –

1-S41

1-S37 1-S29

– –

1-S66

– –

W1012734

1-S3

Page 67

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

ENGINE

Symptom Probable Cause Solution

Engine Overheated • Engine oil insufficient

• Fan belt broken or tensioned improperly

Replenish engine oil Replace fan belt or adjust fan belt tension

• Coolant insufficient

• Radiator net and radiator fin clogged with dust

• Inside of radiator corroded

Replenish coolant Clean radiator net and radiator fin Clean inside of radiator or replace radiator

• Coolant flow route corroded

Clean or replace coolant flow route

• Radiator cap defective

• Overload running

• Head gasket defective

• Incorrect injection timing

Replace radiator cap Loosen load Replace head gasket Adjust injection timing

• Unsuitable fuel used

Use specified fuel

Reference Page

G-17 G-28

– –

G-16

G-34

–

– 1-S30 1-S71

–

W1013908

1-S4

Page 68

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

2. SERVICING SPECIFICATIONS [D782-E-XFM5]

[1] ENGINE BODY

Item Factory Specification Allowable Limit

Cylinder Head Surface Flatness – 0.05 mm

0.0020 in.

Top Clearance 0.50 to 0.70 mm

0.0197 to 0.0276 in.

Compression Pressure

2.84 to 3.24 MPa

29.0 to 33.0 kgf/cm 412 to 469 psi

–

2.26 MPa

23.0 kgf/cm 327 psi

ENGINE

Variance among Cylinders

Valve Clearance (Cold) 0.145 to 0.185 mm

0.00571 to 0.00728 in.

Valve Seat Width 2.12 mm

Valve Seat Angle 0785 rad

Valve Face Angle 0785 ra d

Valve Recessing – 0.10 to 0.10 mm

– 0.0039 to 0.0039 in.

Valve Stem to Valve Guide

Valve Stem

Valve Guide

Valve Timing (Intake Valve) Open

Clearance

O.D.

I.D.

0.030 to 0.057 mm

0.00118 to 0.00224 in.

5.968 to 5.980 mm

0.23496 to 0.23543 in.

6.010 to 6.025 mm

0.23661 to 0.23720 in.

–

0.0835 in.

45°

0.35 rad (20°) before T.D.C.

10 % or less

–

0.3 mm

0.0118 in.

0.10 mm

0.0039 in.

–

– –

Valve Timing (Exhaust Valve) Open

1-S5

0785 rad (45°)

after B.D.C.

0.89 rad (50°) before B.D.C.

0.26 rad (15°) after T.D.C.

–

W1013874

Page 69

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Valve Spring Free Length

31.3 to 31.8 mm

1.232 to 1.252 in.

ENGINE

28.4 mm

1.118 in.

Setting Load

Setting Length

Tilt

64.7 N

6.6 kgf

14.6 lbs

27.0 mm

1.063 in. –

54.9 N

5.6 kgf

12.3 lbs

27.0 mm

1.063 in.

1.2 mm

0.047 in.

Rocker Arm Shaft to Rocker Arm

Rocker Arm Shaft

Clearance

O.D.

0.016 to 0.045 mm

0.00063 to 0.00177 in.

10.473 to 10.484 mm

0.15 mm

0.0059 in. –

0.41232 to 0.41276 in.

Rocker Arm

I.D.

10.500 to 10.518 mm

–

0.41339 to 0.41410 in.

Push Rod Alignment – 0.25 mm

0.0098 in.

Tappet to Guide

Tappet

Clearance

O.D.

0.016 to 0.052 mm

0.00063 to 0.00205 in.

17.966 to 17.984 mm

0.10 mm

0.0039 in. –

0.70732 to 0.70803 in.

Tappet Guide

I.D.

18.000 to 18.018 mm

–

0.70866 to 0.70937 in.

Camshaft Side Clearance 0.15 to 0.31 mm

0.0059 to 0.0122 in.

0.50 mm

0.0197 in.

Camshaft Alignment – 0.01 mm

0.0004 in.

Cam Height Intake and

Exhaust

Camshaft

Camshaft Journal

Oil Clearance

O.D.

26.88 mm

1.0583 in.

0.050 to 0.091 mm

0.00197 to 0.00358 in.

32.934 to 32.950 mm

26.83 mm

1.0563 in.

0.15 mm

0.0059 in. –

1.29661 to 1.29724 in.

Camshaft Bearing

I.D.

33.000 to 33.025 mm

–

1.29921 to 1.30020 in.

W1014987

1-S6

Page 70

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

ENGINE BODY (Continued)

Timing Gear Crank Gear to Idle Gear

ENGINE

Item Factory Specification Allowable Limit

Backlash

0.043 to 0.124 mm

0.00169 to 0.00488 in.

0.15 mm

0.0059 in.

Idle Gear to Cam Gear

Backlash

0.047 to 0.123 mm

0.00185 to 0.00484 in.

Idle Gear to Injection Pump Gear

Backlash

0.046 to 0.124 mm

0.00185 to 0.00488 in.

Crank Gear to Oil Pump Drive Gear

Backlash

0.041 to 0.123 mm

0.00161 to 0.00484 in.

Idle Gear Shaft to Idle Gear Bushing

Clearance

0.020 to 0.084 mm

0.00079 to 0.00331 in.

Idle Gear Shaft

O.D.

19.967 to 19.980 mm

0.78610 to 0.78661 in.

Idle Gear Bushing

I.D.

20.000 to 20.051 mm

0.78740 to 0.78941 in.

Idle Gear Side Clearance 0.13 to 0.49 mm

0.0051 to 0.0193 in.

Piston Pin Bore I.D. 20.000 to 20.013 mm

0.78740 to 0.78791 in.

Piston Ring Clearance Second Ring

0.090 to 0.120 mm

0.00354 to 0.00472 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.10 mm

0.0039 in. –

–

0.60 mm

0.0236 in.

20.05 mm

0.7894 in.

0.15 mm

0.0059 in.

Oil Ring

Piston Ring Gap Top Ring and

Second Ring Oil Ring

0.04 to 0.08 mm

0.0016 to 0.0031 in.

0.25 to 0.40 mm

0.0059 to 0.0118 in.

0.15 to 0.30 mm

0.0118 to 0.0177 in.

0.15 mm

0.0059 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

Connecting Rod Alignment – 0.05 mm

0.0020 in.

Piston Pin to Small End Bushi ng

Piston Pin

Clearance

O.D.

0.014 to 0.038 mm

0.00055 to 0.00150 in.

20.002 to 20.011 mm

0.10 mm

0.0039 in. –

0.78748 to 0.78783 in.

Small End Bushing

I.D.

20.025 to 20.040 mm

0.78839 to 0.78897 in.

–

W1013874

1-S7

Page 71

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Crankshaft Alignment – 0.02 mm

0.0008 in.

Crankshaft Journal to Crankshaft Bearing 1

Oil Clearance

0.034 to 0.106 mm

0.00134 to 0.00417 in.

0.20 mm

0.0079 in.

ENGINE

Crankshaft Journal

Crankshaft Bearing 1

Crankshaft Journal to Crankshaft Bearing 2 (Flywheel Side)

Crankshaft Journal

Crankshaft Bearing 2

Crankshaft Journal to Crankshaft Bearing 3 (Intermediate)

Crankshaft Journal

Crank bearing 3

Crankpin and Crankpin Bearing

O.D.

I.D.

Oil Clearance

O.D.

I.D.

Oil Clearance

O.D.

I.D.

Oil Clearance

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.984 to 40.040 mm

1.57417 to 1.57638 in.

0.028 to 0.059 mm

0.00110 to 0.00232 in.

43.978 to 43.993 mm

1.73142 to 1.73201 in.

43.984 to 44.026 mm

1.73165 to 1.73331 in.

0.028 to 0.059 mm

0.00110 to 0.00232 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.978 to 39.993 mm

1.57394 to 1.57453 in.

0.020 to 0.051 mm

0.00079 to 0.00201 in.

–

0.20 mm

0.0079 in. –

–

0.20 mm

0.0079 in. –

–

0.15 mm

0.0059 in.

Crankpin

O.D.

33.959 to 33.975 mm

1.33697 to 1.33760 in.

Crankpin Bearing

I.D.

33.995 to 34.010 mm

1.33839 to 1.33898 in.

Crankshaft (D722) Side Clearance 0.15 to 0.25 mm

0.0059 to 0.0098 in.

Crankshaft (D782) Side Clearance 0.15 to 0.31 mm

0.0059 to 0.0122 in.

Cylinder Liner I.D. 67.000 to 67.019 mm

2.63779 to 2.63854 in.

Cylinder [Oversize: 0.25 mm (0.0098 in.)]

I.D. 67.250 to 67.269 mm

2.64764 to 2.64839 in.

–

0.50 mm

0.0197 in.

0.50 mm

0.0197 in.

67.169 mm

2.64444 in.

67.419 mm

2.70739 in.

W1017094

1-S8

Page 72

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

[2] LUBRICATING SYSTEM

Item Factory Specification Allowable Limit

Engine Oil Pressure At Idle Speed

More than 49 kPa

0.5 kgf/cm

7 psi

ENGINE

–

At Rated Speed

196 to 441 kPa

2.0 to 4.5 kgf/cm 28 to 64 psi

Inner Rotor to Outer Rotor Clearance 0.03 to 0.14 mm

0.0012 to 0.0055 in.

Outer Rotor to Pump Body Clearance 0.07 to 0.15 mm

0.0028 to 0.0059 in.

Inner Rotor to Cover End Clearance 0.075 to 0.135 mm

0.00295 to 0.00531 in.

[3] COOLING SYSTEM

Thermostat Valve Opening

Temperature (At Beginning)

Valve Opening Temperature (Opened Completely)

Radiator Water Tightness Water tightness at

Radiator Cap Air Leakage 10 seconds or more

Fan Belt Tension Approx. 10 mm (0.4 in.)

80.5 to 83.5 °C

176.9 to 182.3 °F

95 °C

203 °F

specified pressure

137 kPa

1.4 kgf/cm

, 20 psi

88 → 59 kPa

0.9 → 0.6 kgf/cm

13 → 9 psi

deflection at 98 N

(10 kgf, 22 lbs) of force

1.5 kgf/cm

27 psi

–

147 kPa

W1017384

–

W1017547

1-S9

Page 73

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

[4] FUEL SYSTEM

Item Factory Specification Allowable Limit

Injection Pump Injection Timing 0.33 to 0.37 rad

19.0 to 21.0° before T.D.C.

Pump Element Fuel Tightness – 14.7 MPa

Delivery Valve Fuel Tightness – 5 seconds

14.7 → 13.7 MPa

150 →140 kgf/cm

2130 → 1990 psi

Fuel Injection Nozzle Injection Pressure 13.7 to 14.7 MPa

140 to 150 kgf/cm

1990 to 2130 psi

Nozzle Valve Seat Fuel Tightness When the pressure is

12.7 MPa

(130 kgf/cm

, 1850 psi),

the valve seat must be

fuel tightness.

–

150 kgf/cm

2130 psi

–

ENGINE

W1013874

1-S10

Page 74

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

3. SERVICING SPECIFICATIONS [D1105-E2-ZD]

[1] ENGINE BODY

Item Factory Specification Allowable Limit

Cylinder Head Surface Flatness – 0.05 mm

0.0020 in.

Top Clearance 0.55 to 0.70 mm

0.0217 to 0.0276 in.

Compression Pressure (When Cranking with Starting Motor)

2.84 to 3.24 MPa 29 to 33 kgf/cm

412 to 469 psi

–

2.26 MPa

23 kgf/cm

327 psi

ENGINE

Variance among Cylinders

Valve Clearance (Cold) 0.145 to 0.185 mm

0.0057 to 0.0072 in.

Valve Seat Width 2.12 mm

Valve Seat Angle (Intake)

Angle (Exhaust)

Valve Face Angle (Intake)

Angle (Exhaust)

Valve Recessing – 0.05 to 0.15 mm

– 0.0020 to 0.0059 in.

Valve Stem to Valve Guide

Valve Stem

Clearance

O.D.

0.035 to 0.065 mm

0.0014 to 0.0026 in.

6.960 to 6.975 mm

0.2740 to 0.2746 in.

–

0.0835 in.

1.047 rad 60°

0.785 rad 45°

1.047 rad 60°

0.785 rad 45°

10 % or less

–

0.40 mm

0.0157 in.

0.10 mm

0.0039 in. –

Valve Guide

Valve Timing (Intake Valve) Open

Valve Timing (Exhaust Valve) Open

I.D.

1-S11

7.010 to 7.025 mm

0.27599 to 0.27657 in.

0.24 rad (14°) before T.D.C.

0.52 rad (30°) after B.D.C.

0.96 rad (55°)

before B.D.C.

0.24 rad (14°)

after T.D.C.

–

W1015702

Page 75

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Valve Spring Free Length

37.0 to 37.5 mm

1.457 to 1.476 in.

ENGINE

36.5 mm

1.437 in.

Setting Load

Setting Length

117.6 N

12.0 kgf

26.4 lbs

31.0 mm

100.0 N

10.2 kgf

22.5 lbs –

1.220 in.

Tilt

–

1.0 mm

0.039 in.

Rocker Arm Shaft to Rocker Arm

Rocker Arm Shaft

Clearance

O.D.

0.016 to 0.045 mm

0.0006 to 0.0018 in.

11.973 to 11.984 mm

0.10 mm

0.0039 in. –

0.4714 to 0.4718 in.

Rocker Arm

I.D.

12.000 to 12.018 mm

–

0.4724 to 0.4732 in.

Push Rod Alignment – 0.25 mm

0.0098 in.

Tappet to Tappet Guide

Tappet

Clearance

O.D.

0.020 to 0.062 mm

0.00079 to 0.00244 in.

19.959 to 19.980 mm

0.07 mm

0.0028 in. –

0.78579 to 0.78661 in.

Tappet Guide

I.D.

20.000 to 20.021 mm

–

0.78740 to 0.78823 in.

Camshaft Side Clearance 0.07 to 0.22 mm

0.0028 to 0.0087 in.

0.30 mm

0.0118 in.

Camshaft Alignment – 0.01 mm

0.0004 in.

Cam Height Intake

Exhaust

Camshaft Journal to Cylinder Block Bore

Camshaft Journal

Oil Clearance

O.D.

28.80 mm

1.1339 in.

29.00 mm

1.1417 in.

0.05 to 0.09 mm

0.0020 to 0.0036 in.

35.934 to 35.950 mm

28.75 mm

1.1319 in.

28.95 mm

1.1398 in.

0.15 mm

0.0059 in. –

1.4147 to 1.4154 in.

Cylinder Block Bore

I.D.

36.000 to 36.025 mm

–

1.4173 to 1.4183 in.

W1016974

1-S12

Page 76

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

ENGINE BODY (Continued)

Timing Gear

Crank Gear to Idle Gear

ENGINE

Item Factory Specification Allowable Limit

Backlash

0.032 to 0.115 mm

0.0013 to 0.0045 in.

0.15 mm

0.0059 in.

Idle Gear to Cam Gear

Backlash

0.036 to 0.114 mm

0.0014 to 0.0045 in.

Idle Gear to Injection Pump Gear

Backlash

0.034 to 0.116 mm

0.0013 to 0.0046 in.

Injection Pump Gear to Governor Gear

Backlash

0.032 to 0.118 mm

0.0013 to 0.0046 in.

Idle Gear Side Clearance 0.20 to 0.51 mm

0.0079 to 0.0200 in.

Idle Gear Shaft to Gear Bushing

Clearance

0.020 to 0.054 mm

0.0008 to 0.0021 in.

Idle Gear Shaft

O.D.

25.967 to 25.980 mm

1.0223 to 1.0228 in.

Gear Bushing

I.D.

26.000 to 26.021 mm

1.0236 to 1.0244 in.

Piston Pin Bore I.D. 22.000 to 22.013 mm

0.8661 to 0.8667 in.

Piston Ring Clearance Second Ring

0.095 to 0.112 mm

0.0037 to 0.0044 in

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.8 mm

0.0315 in.

0.10 mm

0.0039 in. –

–

22.03 mm

0.8673 in.

0.20 mm

0.0079 in.

Oil Ring

Ring Gap Top Ring and

Second Ring Oil Ring

0.02 to 0.06 mm

0.0008 to 0.0022 in.

0.30 to 0.45 mm

0.0118 to 0.0177 in.

0.25 to 0.40 mm

0.0098 to 0.0157 in.

0.15 mm

0.0059 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

Connecting Rod Alignment – 0.05 mm

0.0020 in.

Piston Pin to Small End Bushi ng

Piston Pin

Clearance

O.D.

0.014 to 0.038 mm

0.00055 to 0.00150 in.

22.002 to 22.011 mm

0.15 mm

0.0059 in. –

0.86622 to 0.86657 in.

Small End Bushing

I.D.

22.025 to 22.040 mm

–

0.86713 to 0.86771 in.

Crankshaft Alignment – 0.02 mm

0.0008 in.

W1019055

1-S13

Page 77

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Crankshaft Journal to Crankshaft Bearing 1

Oil Clearance

0.034 to 0.114 mm

0.00134 to 0.00449 in.

ENGINE

0.20 mm

0.0079 in.

Crankshaft Journal

Crankshaft Bearing 1

Crankshaft Journal to Crankshaft Bearing 2

Crankshaft Journal

Crankshaft Bearing 2

Crankpin to Crankpin Bearing

Crankpin

Crankpin Bearing

Crankshaft Journal to Crankshaft Bearing 3

O.D.

I.D.

Oil Clearance

O.D.

I.D.

Oil Clearance

O.D.

I.D.

Oil Clearance

47.934 to 47.950 mm

1.88717 to 1.88779 in.

47.984 to 48.048 mm

1.88913 to 1.89165 in.

0.034 to 0.095 mm

0.00134 to 0.00374 in.

47.934 to 47.950 mm

1.88716 to 1.88779 in.

47.984 to 48.029 mm

1.88913 to 1.89091 in.

0.029 to 0.091 mm

0.00114 to 0.00358 in.

39.959 to 39.975 mm

1.57319 to 1.57382 in.

40.004 to 40.050 mm

1.57496 to 1.57677 in.

0.034 to 0.098 mm

0.00134 to 0.00386 in.

–

0.20 mm

0.0079 in. –

–

0.20 mm

0.0079 in. –

–

0.20 mm

0.0079 in.

Crankshaft Journal

O.D.

51.921 to 51.940 mm

2.04413 to 2.04488 in.

Crankshaft Bearing 3

I.D.

51.974 to 52.019 mm

2.04622 to 2.04799 in.

Crankshaft Side Clearance 0.15 to 0.31 mm

0.0059 to 0.0122 in.

Cylinder [Standard]

Cylinder [Oversize: 0.5 mm (0.0197 in.)]

I.D. 78.000 to 78.019 mm

3.0709 to 3.716 in.

I.D. 78.500 to 78.519 mm

3.0906 to 3.0912 in.

–

0.50 mm

0.0197 in.

78.169 mm

3.0775 in.

78.319 mm

3.0834 in.

W1022700

1-S14

Page 78

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

[2] LUBRICATING SYSTEM

Item Factory Specification Allowable Limit

Engine Oil Pressure At Idle Speed

More than 49 kPa

0.5 kgf/cm

7 psi

ENGINE

–

At Rated Speed

196 to 441 kPa

2.0 to 4.5 kgf/cm 36 to 64 psi

Inner Rotor to Outer Rotor Clearance 0.06 to 0.18 mm

0.0024 to 0.0071 in.

Outer Rotor to Pump Body Clearance 0.100 to 0.180 mm

0.0039 to 0.0071 in.

Rotor to Cover Clearance 0.025 to 0.075 mm

0.0010 to 0.0029 in.

[3] COOLING SYSTEM

Thermostat Valve Opening

Temperature (At Beginning)

Valve Opening Temperature (Opened Completely)

Radiator Water Leakage

Test Pressure

Radiator Cap Pressure Falling

Time

Fan Belt Tension Approx. 10 mm (0.4 in.)

80.5 to 83.5 °C

176.9 to 182.3 °F

95 °C

203 °F

No leaks at

137 kPa

1.4 kgf/cm

20 psi

10 seconds or mo re f or

pressure falling from

88 to 59 kPa

from 0.9 to 0.6 kgf/cm

from 13 to 9 psi

deflection at 98 N

(10 kgf, 22 lbs) of force

1.5 kgf/cm

27 psi

–

147 kPa

W1017384

–

W1017547

1-S15

Page 79

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

[4] FUEL SYSTEM

Item Factory Specification Allowable Limit

Injection Pump Injection Timing 0.33 to 0.37 rad

19.0 to 21.0° before T.D.C.

Pump Element Fuel Tightness – 14.7 MPa

Delivery Valve Fuel Tightness 10 seconds or more for

pressure falling

from 14.7 to 13.7 MPa

from 150 to 140 kgf/cm

from 2133 to 1990 psi

Fuel Injection Nozzle Injection Pressure 13.73 to 14.71 MPa

140 to 150 kgf/cm

1991 to 2133 psi

Fuel Injection Nozzle Valve Seat Valve Seat

Tightness

When the pressure is

12.75 MPa

(130 kgf/cm

, 1849 psi),

the valve seat must be

fuel tightness.

–

150 kgf/cm

2133 psi

5 seconds for

from 14.7 to

13.7 MPa

from 150 to

140 kgf/cm

from 2133 to

1990 psi

–

ENGINE

W1013874

1-S16

Page 80

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

NOTE■

KiSC issued 09, 2006 A

4. TIGHTENING TORQUES

Tightening torques of screws, bolts and nuts on the table below are especially specified.

(For general use screws, bolts and nuts : See page G-9.)

Item Size × Pitch N·m kgf·m ft-lbs

Starter M terminal nut Universal joint mounting screw Engine support mounting screw Engine mounting nut Cushion mounting nut

[D782-E-XFM5]

Cylinder head screw * Cylinder head cover cap nut Injection pipe retaining nut Nozzle holder assembly Overflow pipe assembly retaining nut (nozzle) Glow plug * Rocker arm bracket nut * Fan drive pulley retaining screw * Idle gear shaft mounting screw * Connecting rod screw * Flywheel bolt * Main bearing case screw 2 * Main bearing case screw 1

(D782) Oil pressure switch Nozzle holder

M6 × 1.0

M8 × 1.25

M10 × 1.25

M8 × 1.25 M8 × 1.25

M8 × 1.25

M6 × 1.0 M12 × 1.5 M20 × 1.5 M12 × 1.5

M8 × 1.0

M6 × 1.0 M12 × 1.5

M6 × 1.0 M7 × 0.75

M10 × 1.25

M7 × 1.0 M8 × 1.25

M6 × 1.0

PT 1/8

9.8 to 13.7

26.0 to 28.0

48.1 to 55.9

23.5 to 27.5

17.6 to 20.6

37.2 to 42.1

3.9 to 5.9

24.5 to 34.3

49.0 to 68.6

19.6 to 24.5

7.8 to 14.7

9.8 to 11.3

117.6 to 127.4

9.8 to 11.3

26.5 to 30.4

53.9 to 58.8

26.5 to 30.4

23.5 to 27.5

12.7 to 15.7

14.7 to 19.6

34.3 to 39.2

1.0 to 1.4

2.7 to 2.9

4.9 to 5.7

2.4 to 2.8

1.8 to 2.1

3.8 to 4.3

0.4 to 0.6

2.5 to 3.5

5.0 to 7.0

2.0 to 2.5

0.8 to 1.5

1.00 to 1.15

12.0 to 13.0

1.00 to 1.15

2.7 to 3.1

5.5 to 6.0

2.7 to 3.1

2.4 to 2.8

1.3 to 1.6

1.5 to 2.0

3.5 to 4.0

ENGINE

7.2 to 10.1

19.2 to 20.7

35.4 to 41.2

17.4 to 20.3

13.0 to 15.2

W1026185

28.0 to 31.7

2.9 to 4.3

18.1 to 25.3

36.2 to 50.6

14.5 to 18.1

5.8 to 10.8

7.2 to 8.3

86.8 to 94.0

7.2 to 8.3

19.5 to 22.4

39.8 to 43.4

19.5 to 22.4

17.4 to 20.3

9.4 to 11.6

10.8 to 14.5

25.3 to 28.9

• In removing and applying the bolts and nuts marked with “ * ”, a pneumatic wrench or similar pneumatic tool, if employed, must be used with enough care not to get them sized.

• For * marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening.

• The letter “M” in Size × Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads.

W1013236

1-S17

Page 81

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

NOTE■

KiSC issued 09, 2006 A

ENGINE

[D1105-E2-ZD]

Item Size × Pitch N·m kgf·m ft-lbs

Air cleaner stay nut * Bearing case cover screw Connecting rod screw * Cylinder head cover cap nut * Cylinder head screw * Fan drive pulley screw * Flywheel Glow plug * Idle gear shaft mounting screw Injection pipe retaining nut * Main bearing case screw 1 * Main bearing case screw 2 Nozzle holder Nozzle holder assembly * Oil pressure switch Overflow pipe assembly retaining nut * Rocker arm bracket nut

M10 × 1.25

M6 × 1.0 M8 × 1.0 M7 × 1.0

M10 × 1.25

M14 × 1.5

M10 × 1.25

M8 × 1.0

M6 × 1.0 M12 × 1.5 M8 × 1.25 M9 × 1.25

M20 × 1.5

PT 1/8

M12 × 1.5

M7 × 1.0

48.1 to 55.9

9.8 to 11.3

41.2 to 46.1

6.9 to 8.8

63.7 to 68.6

235.4 to 245.2

53.9 to 58.8

7.8 to 14.7

9.8 to 11.3

24.5 to 34.3

29.4 to 34.3

49.0 to 53.9

34.3 to 39.2

49.0 to 68.6

14.7 to 19.6

19.6 to 24.5

21.6 to 26.5

4.9 to 5.7

1.00 to 1.15

4.2 to 4.7

0.7 to 0.9

6.5 to 7.0

24.0 to 25.0

5.5 to 6.0

0.8 to 1.5

1.00 to 1.15

2.5 to 3.5

3.0 to 3.5

5.0 to 5.5

3.5 to 4.0

5.0 to 7.0

1.5 to 2.0

2.0 to 2.5

2.2 to 2.7

35.4 to 41.2

7.2 to 8.3

30.4 to 34.0

5.1 to 6.5

47.0 to 50.6

173.6 to 180.8

39.8 to 43.4

5.8 to 10.8

7.2 to 8.3

18.1 to 25.3

21.7 to 25.3

36.2 to 39.8

25.3 to 28.9

36.2 to 50.6

10.8 to 14.5

14.5 to 18.1

15.9 to 19.5

• In removing and applying the bolts and nuts marked with “ * ”, a pneumatic wrench or similar pneumatic tool, if employed, must be used with enough care not to get them sized.

• For * marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening.

W1026768

1-S18

Page 82

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

IMPORTANT■

KiSC issued 09, 2006 A

5. CHECKING, DISASSEMBLING AND SERVICING

[1] SEPARATING ENGINE

(1) Disassembling and Assembling

Draining Engine Oil

1. Park the machine on level ground.

2. Start and warm up the engine for approx. 5 minutes.

3. Place an oil pan underneath the engine.

4. Remove the drain plug (1) to drain oil.

5. After draining, screw in the drain plug (1).

(When refilling)

• Fill the engine oil up to the upper line on the dipstick (3).

D782 (ZD21N ·

Engine oil Capacity

ZD21)

D1105 (ZD28)

• Never mix two different type of oil.

• Use the proper SAE Engine Oil according to ambient temperatures. Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page G-7.)

(1) Drain Plug (2) Oil Inlet Plug (3) Dipstick

(A) Upper Level (B) Lower Level

3.5 L

3.7 U.S.qts.

3.1 Imp.qts.

3.4 L

3.6 U.S.qts.

3.0 Imp.qts.

ENGINE

W1019220

1-S19

Page 83

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

KiSC issued 09, 2006 A

ENGINE

Draining Coolant

CAUTION

• Never open the radiat or cap while operating or immedi ately after stopping. Otherwise, hot water will spout out from the radiator. Wait for more than ten minutes to cool the radiator, before opening the cap.

1. Stop the engine and let cool down.

2. Remove the radiator coolant drain plu g (3) and engine cool ant drain plug (4) to drain the coolant.

3. Remove the radiator cap (1) to completely drain the coolant.

4. After all coolant is drained , close the dr ain plugs.

2.6 L

2.7 U.S.qts.

2.3 lmp.qts.

3.8 L

4.0 U.S.qts.

3.3 lmp.qts

0.25 L

0.26 U.S.qts.

0.22 lmp.qts

Coolant capacity

ZD21N ZD21

ZD28 Radiator

—

Radiator

Recovery tank

(1) Radiator Cap (2) Recovery Tank (3) Radiator Coolant Drain Plug (4) Engine Coolant Drain Cock

(A) Upper Level (B) Lower Level

W1019510

1-S20

Page 84

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

KiSC issued 09, 2006 A

[ZD21N · ZD21]

ENGINE

Battery

CAUTION

• When disconnecting the battery cables, disconnect the negative cable from the battery first. When connecting, connect the positive cable to the battery first.

1. Remove the battery cover (1).

2. Disconnect the negative cable (3) from the battery.

3. Disconnect the positive cable (2) from the battery.

(1) Battery Cover (2) Positive Cable

(3) Negative Cable

W1019788

Bonnet and Rear Bumper

1. Remove the snap p in and bon net m ountin g screw , then r emove the bonnet (1).

2. Remove the rear bumper (2).

(1) Bonnet (2) Bumper

W1019921

Panel Screen, Shutter Plate and Others

1. Disconnect the wire har ness (1) and positive cable (2) battery side first.

2. Disconnect the accelerator wire (3).

3. Disconnect the fuel hoses (4).

4. Remove the panel screen (5) and shutter plate (6).

IMPORTANT

• When disconnecting the fuel hoses, be careful not to let the fuel spill out the hoses.

(1) Wire Harness (2) Positive Cable (3) Accelerator Wire

(4) Fuel Hose (5) Panel Screen (6) Shutter Plate

W1033201

1-S21

Page 85

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

IMPORTANT■

KiSC issued 09, 2006 A

ENGINE

Engine Disassembly

1. Remove the universal joint mounting screws (1).

2. Disconnect the universal joint (2) from fun drive pulley.

3. Pull out the snap pins from the radiator.

4. Remove the engine mounting nuts.

5. Separate the engine with th e radiator from the frame, take c are not to damage the radiator.

(When reassembling)

• Apply grease to the all splines on the drive shaft.

Universal joint mounting screw

Tightening torque

Engine mounting nut

(1) Universal Joint Mounting Screw (2) Universal Joint

26.0 to 28.0 N·m

2.7 to 2.9 kgf·m

19.2 to 20.7 ft-lbs

23.5 to 27.5 N·m

2.4 to 2.8 kgf·m

17.4 to 20.3 ft-lbs

W1033679

Dynamo, Fan Belt and Muffler

1. Disconnect t he r ad iator hos es an d s epa ra te th e radi ato r (3) with recovery tank (8) from engine assembly.

2. Remove the co oling fan (4 ) and fan pulley .

3. Remove the dynamo (9) and fan belt (10).

4. Remove the muffler (7).

5. Remove the starter (11).

6. Disconnect th e inlet p ipe (2), ai r cleane r (1) and air cl eaner stay (5).

7. Remove the wire bracket.

8. Remove the engine support LH (12) and RH (6).

(When reassembling)

• Check to see that there are no cracks on the belt surface.

• After reassembling the fan belt, be sure to adjust the fan belt tension.

48.1 to 55.9 N·m

4.9 to 5.7 kgf·m

35.4 to 41.2 ft-lbs

Tightening torque

(1) Air Cleaner (2) Inlet Pipe (3) Radiator (4) Cooling Fan (5) Air Cleaner Stay (6) Engine Support RH

Engine support mounting screw

(7) Muffler (8) Recovery Tank

(9) Dynam o (10) Fan Belt (11) Starter (12) Engine Support LH

1-S22

Page 86

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

■

KiSC issued 09, 2006 A

[ZD28]

ENGINE

Battery and Bonnet

CAUTION

• When disconnecting the battery cables, disconnect the negative cable from the battery first. When connecting, connect the positive cable to the battery first.

1. Remove the battery cover (1).

2. Disconnect the negative cable (3) from the battery.

3. Disconnect the positive cable (2) from the battery.

4. Remove the snap p in and bon net m ountin g screw , then r emove the bonnet (4).

(1) Battery Cover (2) Positive Cable

(3) Negative Cable (4) Bonnet

Panel Screen, Shutter Plate and Others

1. Disconnect the glow plug and stop solenoide harness (1) and positive cable (2) battery side first.

2. Disconnect the accelerator wire (3) and fuse box from shutter plate (5).

3. Disconnect the fuel hoses (4).

4. Remove the air cleaner (7) and muffler (8).

5. Remove the panel screen (6).

IMPORTANT

• When disconnecting the fuel hoses, be careful not to let the fuel spill out the hoses.

(1) Wire Harness (2) Positive Cable (3) Accelerator Wire (4) Fuel Hose

(5) Shutter Plate (6) Panel Screen (7) Air Cleaner (8) Muffler

Engine Disassembly

1. Remove the universal joint mounting screws (2).

2. Disconnect the universal joint (3) from fun drive pulley.

3. Remove the engine mounting nuts.

4. Separate the engin e with the ra diator from the frame, take ca re not to damage the radiator.

(When reassembling)

• Apply grease to the all splines on the drive shaft.

Universal joint mounting screw

Tightening torque

Engine mounting nut

(1) Oil Cooler (2) Universal Joint Mounting Screw

(3) Universal Joint

26.0 to 28.0 N·m

2.7 to 2.9 kgf·m

19.2 to 20.7 ft-lbs

23.5 to 27.5 N·m

2.4 to 2.8 kgf·m

17.4 to 20.3 ft-lbs

1-S23

Page 87

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

IMPORTANT■

KiSC issued 09, 2006 A

ENGINE

Dynamo, Fan Belt and Muffler

1. Disconnect t he r ad iator hos es an d s epa ra te th e radi ato r (1) with recovery tank (5) from engine assembly.

2. Remove the co oling fan (2 ) and fan pulley .

3. Remove the dynamo (6) and fan belt (7).

4. Remove the starter (8).

5. Remove the air cleaner stay (3).

6. Remove the wire bracket.

7. Remove the engine support LH (9) and RH (4).

(When reassembling)

• Check to see that there are no cracks on the belt surface.

• After reassembling the fan belt, be sure to adjust the fan belt tension.

48.1 to 55.9 N·m

4.9 to 5.7 kgf·m

35.4 to 41.2 ft-lbs

Tightening torque

Engine support mounting screw

(1) Radiator (2) Cooling Fan (3) Air Cleaner Stay (4) Engine Support RH (5) Recovery Tank

(6) Dynamo (7) Fan Belt (8) Starter (9) Engine Support LH

1-S24

Page 88

ZD21N-EC, ZD21-EC, ZD28-EC, WSM

NOTE■

KiSC issued 09, 2006 A

[2] ENGINE BODY

(1) Checking and Adjusting

ENGINE

Compression Pressure

1. Run the engine until it is warmed up.

2. Stop the engine.

3. Disconnect the 2P connector from the fuel pump.

4. Remove the air cleaner, the muffler and all injection nozzles.

5. Disconnect the accelerator wire.

6. Engage the parking brake.

7. Set a compression tester (Code No. 07909-30208) with the adaptor (Adaptor H, Code No. 07909-31231) to the nozzle hole.

8. While cranking the engine with the starter, measure the compression pressure.

9. Repeat steps 7 and 8 for each cylinder.

10.If the measurem ent is below the allowable limit, apply a small amount of oil to the cylinder wall through the nozzle hole and measure the compression pressure again.

11.If the compres sion pressure is still less than the allowabl e limit, check the top clearance, valve clearance and cylinder head.

12.If the c ompression pressu re increases after a pplying oil, check the cylinder wall and piston rings.

• Check the compression pressure with the specified valve clearance.

• Always use a fully charged battery for performing this test.

• Variances in cylinder compression values should be under 10 %.

Compression pressure

Factory spec.

Allowable limit

2.84 to 3.24 MPa

29.0 to 33.0 kgf/cm 412 to 469 psi

2.26 MPa

23.0 kgf/cm 327 psi

W1022478

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NOTE■

KiSC issued 09, 2006 A

ENGINE

Top Clearance

1. Remove the cylinder head (Do not attempt to remove the cylinder head gasket completely).

2. Bring the pis ton to its top dead cente r fasten 1 .5 mm dia. 5 to 7 mm long fuse wires to 3 to 4 sp ots on the piston top wi th gr ease so as to avoid the intake and exhaust valves and the combustion chamber ports.

3. Bring t he piston to its middle positio n, install the cylinder head, and tighten the cylinder head screws to specification. (Head gasket must be changed to new one.)

4. Turn the crank shaft until the piston exceeds its top dead center.

5. Remove the cylinder head, and measure the thickness of the squeezed fuses.

6. If the measurement is not within the factory specifications, check the oil clearanc e of between the crankpin and crankpin bea ring and between the piston pin and small end bushing.

• After checking the t op clearance, be sure to assemble the cylinder head with a new cylinder head gasket.

0.50 to 0.70 mm

0.0197 to 0.0276 in.

0.55 to 0.70 mm

0.0217 to 0.276 in.

Top clearance

Factory spec.

D782

D1105

Tightening torque

(1) Fuse

Cylinder head screw

D782

D1105

37.2 to 42.1 N·m

3.8 to 4.3 kgf·m

28.0 to 31.7 ft-lbs

63.7 to 68.6 N·m

6.5 to 7.0 kgf·m

47.0 to 50.6 ft-lbs

W10107670

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IMPORTANT■

NOTE■

KiSC issued 09, 2006 A

ENGINE

Valve Clearance

• The valve clearance must be checked and adjusted when engine is cold.

1. Remove the cylinder head cover and the glow plugs.

2. Align the “1TC” m ark ( 1) on the flywheel and alignment mark (2) on the rear end plate so that the No. 1 piston comes to the compression top dead center.

3. Check the following valve clearance marked with “★” using a feeler gauge.

[When No. 1 piston comes to the compression top dead center]

Cylinder No. No. 1 No. 2 No. 3 Intake valve ★★ Exhaust valve ★★

4. If the clearance is not within the factory specifications, adjust with the adjusting screw.

5. Then turn the flywheel 6.28 rad (360°), and align the “1TC” mark (1) on the flywheel and alig nment mark (2) on the rear end pl ate so that the No. 1 piston comes to the overlap position.

6. Check the following valve clearance marked with “✩” using a feeler gauge.

[When No. 1 piston comes to the overlap position]

Cylinder No. No. 1 No. 2 No. 3 Intake valve ✩ Exhaust valve ✩

7. If the clearance is not within the factory specifications, adjust with the adjusting screw.

Intake and exhaust valve clearance (Cold)

Factory spec.

0.145 to 0.185 mm

0.00571 to 0.00728 in.

• The sequence of cylinder numbers is given as No. 1, No. 2 and No. 3 starting from the gear case side.

• After adjusting the valve clearance, secure the adjusting screw with the lock nut.

(1) “1TC” Mark (2) Alignment Mark

A : Gear Case Side

W10113200

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IMPORTANT■

KiSC issued 09, 2006 A

(2) Disassembling and Assembling (A) Cylinder Head and Valves

ENGINE

Dynamo, Fan Belt and Muffler

1. Disconnect t he r ad iator hos es an d s epa ra te th e radi ato r (3) with recovery tank (8) from engine assembly.

2. Remove the co oling fan (4 ) and fan pulley .

3. Remove the dynamo (9) and fan belt (10).

4. Remove the muffler (7).

5. Remove the starter (11).

6. Disconnect th e inlet p ipe (2), ai r cleane r (1) and air cl eaner stay (5).

7. Remove the wire bracket.

8. Remove the engine support LH (12) and RH (6).

(When reassembling)

• Check to see that there are no cracks on the belt surface.

• After reassembling the fan belt, be sure to adjust the fan belt tension.

48.1 to 55.9 N·m

4.9 to 5.7 kgf·m

35.4 to 41.2 ft-lbs

Tightening torque

Engine support mounting screw

(1) Air Cleaner (2) Inlet Pipe (3) Radiator (4) Cooling Fan (5) Air Cleaner Stay (6) Engine Support RH

(7) Muffler (8) Recovery Tank

(9) Dynam o (10) Fan Belt (11) Starter (12) Engine Support LH

W1024919

Cylinder Head Cover

1. Remove the head cover cap nuts.

2. Remove the cylinder head cover.

(When reassembling)

• Check to see if the cylinder head cover gasket is not defective.

• Apply engine oil to the cylinder head cover cap nuts. And tighten them.

3.9 to 5.9 N·m

0.4 to 0.6 kgf·m

2.9 to 4.3 ft-lbs

6.9 to 8.8 N·m

0.7 to 0.9 kgf·m

5.1 to 6.5 ft-lbs W10147380

Tightening torque

D782

Cylinder head cover cap nut

D1105

Injection Pipes

1. Loosen the screws on the pipe clamps (1).

2. Detach the injection pipes (2).

(When reassembling)

• Blow out dust from the pipes with compressed air. Then reassemble the pipes in the reverse order.

Tightening torque Injection pipe retaining nut

24.5 to 34.3 N·m

2.5 to 3.5 kgf·m

18.1 to 25.3 ft-lbs

(1) Pipe Clamp (2) Injection Pipe

W10150780

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■

IMPORTANT■

KiSC issued 09, 2006 A

ENGINE

Nozzle Holder Assembly and Glow Plug

1. Remove the overflow pipe assembly (5).

2. Remove the nozzle holder assembl ies (2) using a 21 mm d eep socket wrench.

3. Remove the copper gasket and heat seal (3).

4. Remove the lead (4) from the glow plugs.

5. Remove the glow plugs (1).

(When reassembling)

• Replace the copper gasket and heat seal with new one.

49.0 to 68.6 N·m

Tightening torque

Nozzle holder assembly

Overflow pipe assembly retaining nut

Glow plug

5.0 to 7.0 kgf·m

36.2 to 50.6 ft-lbs

19.6 to 24.5 N·m

2.0 to 2.5 kgf·m

14.5 to 18.1 ft-lbs

7.8 to 14.7 N·m

0.8 to 1.5 kgf·m

5.8 to 10.8 ft-lbs

(1) Glow Plug (2) Nozzle Holder Assembly (3) Heat Seal

(4) Lead (5) Overflow Pipe Assembly

W10259700

Removal Procedure for Nozzle Heat Seal Service

IMPORTANT

• Use a plus (phillips head) screw driver (1) that has a Dia. bigger than the heat seal hole (Approx. 6 mm) 1/4 in..

1. Drive a screw driver (1) lightly into the heat seal hole.

2. Turn a screw driver three or four times each way.

3. While turning the s crew driver, slowly pull the he at seal (4) out together with the copper gasket ( 3).

4. If the heat seal drops, repeat the above procedure.

(1) Screw driver (Plus) (2) Nozzle Holder

(3) Copper Gasket (4) Heat Seal

W10154410

Rocker Arm and Push Rod

1. Remove the rocker arm bracket nuts.

2. Detach the rocker arm assembly (1).

3. Remove the push rods (2).

(When reassembling)

• When putting the push rods (2) onto the tappets (3), check to see if their ends are properly engaged with the grooves.

• After installing the rocker arm, be sure to a djust the valve clearance.

• Apply engine oil to the rocker arm bracket nuts. And tighten them.

9.8 to 11.3 N·m

1.00 to 1.15 kgf·m

7.2 to 8.3 ft-lbs

21.6 to 26.5 N·m

2.2 to 2.7 kgf·m

15.9 to 19.5 ft-lbs

W10155810

Tightening torque

(1) Rocker Arm Assembly (2) Push Rod

Rocker arm bracket nut

D782

D1105

(3) Tappet

1-S29

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NOTE■

IMPORTANT■

KiSC issued 09, 2006 A

ENGINE

Cylinder Head

1. Loosen the pipe clamp, and remove the water return pipe.

2. Remove the cylinder head bolt in the order of (14) to (1).

3. Lift up the cylinder head to detach.

4. Remove the cylinder head gasket and O-ring for carbon sheet gasket.

(When reassembling)

• Replace the cylinder head gasket with a new one.

• Securely fit the O-ring for carbon sheet gasket to the pipe pin.

• Tighten the cylinder head bolts after applying sufficient oil.

• Tighten the cylinder head bolts in diagonal sequence starting from the center. (Refer to figure left.)

• Tighten them uniforml y, or the cylinder head may deform in the long run.

• Retighten the cy linde r head bol ts after r un nin g the eng ine for 30 minutes.

• To Loosen : 14 to 1

• To Tighten : 1 to 14

37.2 to 42.1 N·m

Tightening torque

D782

Cylinder head screw

D1105

3.8 to 4.3 kgf·m

28.0 to 31.7 ft-lbs

63.7 to 68.6 N·m

6.5 to 7.0 kgf·m

47.0 to 50.6 ft-lbs W10159710

Tappets

1. Remove the tappets (1) from the crankcase.

(When reassembling)

• Before installing the tappets, apply engine oil thinly around them.

• Mark the cylinder number to the tappets to prevent interchanging.

(1) Tappet

W1027457

Valves

1. Remove the valve caps (2).

2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1).

3. Remove the valve spri ng retain er (4 ), valve spri ng (5) an d valv e stem seal (6).

4. Remove the valve (7).

(When reassembling)

• Wash the va lve s tem and valve g uid e h ole , an d apply engine oi l sufficiently.

• After installing the valve spring collets, lightly tap the stem to assure proper fit with a plastic hammer.

• Don’t cha nge the co mbination of valve a nd valve guide.

(1) Valve Spring Replacer (2) Valve Cap (3) Valve Spring Collet (4) Valve Spring Retainer

(5) Valve Spring (6) Valve Stem Seal (7) Valve

W10162820

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KiSC issued 09, 2006 A

(B) Timing Gears, Fuel Camshaft and Camshaft

[D782-E-XFM5]

Injection Pump and Speed Control Plate

1. Remove the socket head screws and nuts, and remove the injection pump (3).

2. Remove the screws and separate the speed control plate (2), taking care not to damage the spring (4).

3. Disconnect the spring (4) and remove the speed control plate (2).

(When reassembling)

• Hook the spring (4) to the lever (5) first and install the speed control plate (2).

• Be sure to place the copper washers underneath two screws (1) (as shown in the figure).

• Position the slot (9) on the fork lever just under the slot (8) on the crankcase.

• Insert the injection pump (3) so that the control rod (7) should be pushed by the spring (6) at its end and the pin (10) on the rod engages with the slot (9) on the fork lever (as shown in the figure).

NOTE

• The sealant is applied to both sides of the soft metal gasket shim. The liquid gasket is not required for assembling.

• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5°).

• In disassembling and replacing, be sure to use the same number of new gasket shims with the same thickness.

(1) Screws and Copper Washers (2) Speed Control Plate (3) Injection Pump (4) Spring (5) Lever

ENGINE

(6) Spring (7) Control Rod (8) Slot (Crankcase Side) (9) Slot (Fork Lever Side)

(10) Pin

W10167080

Fan Drive Pulley

1. Set the stopper to the flywheel.

2. Remove the fan drive pulley retaining screw.

3. Draw out the fan drive pulley with a puller.

(When reassembling)

• Install the pulley to the crankshaft, aligning the mark (1) on them.

• Apply engine oil to the fan drive pulley retaining screws. And tighten them.

Tightening torque

(1) Aligning Mark

Fan drive pulley retaining screw

117.6 to 127.4 N·m

12.0 to 13.0 kgf·m

86.8 to 94.0 ft-lbs

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KiSC issued 09, 2006 A

ENGINE

Gear Case

1. Remove the screw (1).

2. Disconnect the start spring (2) in the speed control plate mounting hole.

3. Remove the gear case (3).

(When reassembling)

• Apply a liquid gas ket (Three Bond 1215 or equivalent) to both sides of the gear case gasket (4).

• Be sure to set three O-rings (5) inside the gear case.

(1) Screw (2) Start Spring (3) Gear Case

(4) Gear Case Gasket (5) O-rings

W10174840

Idle Gear

1. Remove the external snap ring (3), the collar (2) and the idle gear (1).

2. Remove the idle gear shaft mounting screws.

3. Remove the idle gear shaft.

(When reassembling)

• Install the idl e gear, aligning th e mark on the gears r eferring to the figure.

• Apply engine oil to the idle gear shaft mounting screws. And tighten them.

Tightening torque

(1) Idle Gear (2) Idle Gear Collar

Idle gear shaft mounting screw

(3) External Snap Ring

9.8 to 11.3 N·m

1.00 to 1.15 kgf·m

7.2 to 8.3 ft-lbs

W1028418

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KiSC issued 09, 2006 A

ENGINE

Fuel Camshaft

1. Remove the screws and d ra w out t he c amshaft with the gear on it.

2. Remove the retaining plate (1).

3. Remove the screws, then dra w out the injection pump gear (2) and fuel camshaft (3) with the governor fork assembly.

(When reassembling)

• Hook the spring to the fork lever 2 (4) as sh own in the figure before installing the fork lever assembly to the crankcase.

(1) Retaining Plate (2) Injection Pump Gear (3) Fuel Camshaft

(4) Fork Lever 2 (5) Fork Lever 1 (6) Governor Sleeve

W10178820

Oil Pump and Crankshaft Gear

1. Remove the oil pump gear (6).

2. Remove the oil pump (5).

3. Remove the collar (4), O-ring (3) and oil slinger (2).

4. Remove the crankshaft gear (1) with a puller.

(When reassembling)

• Install the oil slinger (2) and O-ring (3) after aligning the marks on the gears. (See the figure at “Idle Gear”.)

• Install the crankshaft collar (4) after installing the gear case cover.

(1) Crankshaft Gear (2) Crankshaft Oil Slinger (3) O-ring

(4) Crankshaft Collar (5) Oil Pump (6) Oil Pump Gear

W10180290

[D1105-E2-ZD]

Fan Drive Pulley

1. Set the stopper to the flywheel.

2. Remove the fan drive pulley screw (1).

3. Draw out the fan drive pulley (2) with a puller.

(When reassembling)

• Install the fan drive pulley to the cranksha ft, aligning the marks (3) on them.

Tightening torque

(1) Fan Drive Pulley Screw (2) Fan Drive Pulley

Fan drive pulley retaining screw

(3) Aligning Mark

235.4 to 245.2 N·m

24.0 to 25.0 kgf·m

173.6 to 180.8 ft-lbs

W1035250

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KiSC issued 09, 2006 A

ENGINE

Water Pump

1. Remove the water pump flange.

(When reassembling)

• Before installing the water pump flange gasket, apply liquid gasket (Three Bond 1215 or equivalent) to the both side.

W1035410

Gear Case

1. Remove the gear case.

2. Remove the crankshaft collar and O-rings.

(When reassembling)

• Replace the gear case gasket with a new one.

• Be sure to set the O-ring on the crankshaft.

• Apply a thin f ilm of engine oil to the oil se al, and inst all it, n oting the lip come off.

• Length of the gear case mounting screws. (Refer to the figure.) A : 45 mm (1.77 in.) B : 50 mm (1.97 in.) C : 55 mm (2.17 in.) D : 59 mm (2.32 in.) E : 68 mm (2.68 in.) F : 80 mm (3.15 in.) G : Nut

W1035535

Engine Stop Solenoid

1. Remove the engine stop solenoid (1).

(When reassembling)

• Apply a thin coat of liquid-type gasket (Three Bond 1215 or equivalent) to both surfaces of the solenoid’s cover packing.

• Confirm the convex part of the flange of the engine stop solenoid has fitted into the hole, and then fasten the bolts.

(1) Engine Stop Solenoid

W1035740

Speed Control Plate

1. Remove the s pee d control plate and governor lever (1) fro m the governor springs 1 (2).

(When reassembling)

• Securely catch the governor spring on the governor lever as shown in the figure.

• Apply a liquid gas ket (Three Bond 1215 or equivalent) to both sides of the speed control plate gas ket .

(1) Governor Lever (2) Governor Spring 1

W1035848

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NOTE■

KiSC issued 09, 2006 A

ENGINE

Injection Pump

1. Remove the injection pump mounting screws and nuts.

2. Disconnect the start spring (4) on the thrust lever side (5).

3. Align the control rack pin (2) with the notch (1) on the crankcase, and remove the injection pump (3).

4. Remove the injection pump shims.

5. In principle, the injection pump should not be disassembled.

(When reassembling)

• When installing the injection pump, insert the control rack pin (2) firmly into the groove (6) of the thrust lever of fork lever.

• The sealant is applied to both sides of the soft metal gasket shim. The liquid gasket is not required for assembling.

• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5°).

• In disassembling and replacing, be sure to use the same number or new gasket shims with the same thickness.

(1) Notch (2) Control Rack Pin (3) Injection Pump

(4) Start Spring (5) Thrust Lever (6) Groove

W1035956

Fuel Camshaft

1. Remove the fuel camshaft stopper (2).

2. Draw out the fuel camshaft (3) and injection pump gear (1).

(When reassembling)

• Apply engine oil thinly to the fuel camshaft before installation.

(1) Injection Pump Gear (2) Fuel Camshaft Stopper

(3) Fuel Camshaft

W1036263

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IMPORTANT■

KiSC issued 09, 2006 A

ENGINE

Governor Shaft

1. Remove the pump cover.

2. Remove the external snap ring (1) from the governor shaft (2).

3. Pull out the governor shaft (2).

(When reassembling)

• Make sure assembling the external snap ring of the governor shaft.

• Check the governor shaft for smooth rotation.

• When replacing the ball bearing of governor shaft, securely fit the ball bearing (3) to the crankc ase, apply an adhesive (Three Bond 1324B or equivalent) to the set screw (4), and fasten the screw until its tapered part contacts the circumferential end of the ball bearing.

(1) External Snap Ring (2) Governor Shaft

(3) Ball Bearing (4) Set Screw

W1036385

Camshaft and Idle Gear

1. Remove the external snap ring, a nd then remove the idle gear (4).

2. Remove the camshaft stopper m ounting s crew, and pu ll out the camshaf t (6).

(When reassembling)

• When installing the idle gear, be sure to align the alignment marks (a), (b), (c) on the gears.

• Securely fit the external snap ring and stoppe r.

(1) Injection Pump Gear (2) Governor Gear (3) Crank Gear (4) Idle Gear (5) Cam Gear (6) Camshaft

(a) Alignment Mark

(Idle Gear and Cam Gear)

(b) Alignment Mark

(Idle Gear and Crank Gear)

(Idle Gear and Injection Pump Gear)

W1036981

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IMPORTANT■

KiSC issued 09, 2006 A

(D) Connecting Rod and Piston

ENGINE

Oil Pan and Oil Strainer

1. Remove the oil pan (4).

2. Remove the oil strainer (3).

(When reassembling)

• Install the oil strainer, using care not to damage the O-ring (1).

• Using the hole (6) numbered “3”, install the oil strainer by mounting screw.

• Apply liquid gask et (Three B ond 1270 D or 1270C ) to the oil pan as shown in the figure.

• Scrape off the old adhesive completely. Wipe the sealing surface clean using waste cloth soaked with gasoline. Now apply new adhesive 3 to 5 mm (0.12 to 0.20 in.) thick all over the contact surface. App ly the adhesive also on the center of the flange as wel l as on the inne r w all o f each bolt hole.

• Cut the nozzl e of t he “f luid sealan t” co ntain er at i ts se cond notch. Apply “fluid sealant” about 5 mm (0.20 in.) thick. Within 20 minutes after the application of fluid sealant, reassemble the components. Wait then for about 30 minutes, and pour oil in the crankcase.

(1) O-ring (2) Screw (3) Oil Strainer (4) Oil Pan

(5) Oil Pan Mounting Screws (6) Hole (7) Fluid sealant

W10265670

Connecting Rod Cap

1. Remove the connecting rod screws from connecting rod cap.

2. Remove the connecting rod caps.

(When reassembling)

•Align the marks (a) with each other. (Face the marks toward the injection pump.)

• Apply engine oil to the connecting rod screws and lightly screw it in by hand, then tighten it to the specified torque. If the connecting ro d screw won’t be screwed in smo othl y , cl ean the threads. If the connecting rod screw is still hard to screw in, replace it.

• Do not change the combination of crankpin bearing and connecting rod.

26.5 to 30.4 N·m

2.7 to 3.1 kgf·m

19.5 to 22.4 ft-lbs

41.2 to 46.1 N·m

4.2 to 4.7 kgf·m

30.4 to 34.0 ft-lbs

W10275480

Tightening torque

(a) Mark

D782

Connecting rod screw

D1105

1-S37