GZD 15 HD LD WSM en

WORKSHOP MANUAL
GZD15
KiSC issued 04, 2006 A

TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism,
service and maintenance of GZD15. It is divided into two parts, "Mechanism" and "Servicing" for each section.
B Mechanism
Information on the features and new mechanisms are described. This information should be understood before
proceeding with troubleshooting, disassembling and servicing.
B Servicing
The heading "General" includes general precautions, check and maintenance and special tools. Other section,
there are troubleshooting, 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.
December 2003
KUBOTA Corporation 2003

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GZD15, WSM 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.
A Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
A Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
A Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
A Indicates that equipment or property damage could result if instructions are not followed.
A Gives helpful information.
0000000752E
BEFORE SERVICING AND REPAIRING
A Read all instructions and safety instructions in this
manual and on your machine safety decals.
A Clean the work area and machine.
A Park the machine on a firm and level ground, and set
the parking brake.
A Lower the implement to the ground.
A Stop the engine, and remove the key
A Disconnect the battery negative cable
A Hang a "DO NOT OPERATE" tag in operator
station.
0000000753E
SAFETY STARTING
A Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
A Do not alter or remove any part of machine safety
system.
A Before starting the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
A Never start the engine while standing on ground.
Start the engine only from operator's seat.
0000000754E

1
SAFETY WORKING
A Do not work on the machine while under the
influence of alcohol, medication, or other substances
or while fatigued.
A Wear close fitting clothing and safety equipment
appropriate to the job.
A Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
A When servicing is performed together by two or
more persons, take care to perform all work safely.
A Do not work under the machine that is supported
solely by a jack. Always support the machine by
safety stands.
A Do not touch the rotating or hot parts while the
engine is running.
A Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise,
hot water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
A Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic or
fuel lines. Tighten all connections before applying
pressure.
0000000755E
AVOID FIRES
A Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
A To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
A Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
A Make sure that no fuel has been spilled on the
engine.
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2
VENTILATE WORK AREA

A 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.
0000000757E
PREVENT ACID BURNS

A Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
0000000758E
DISPOSE OF FLUIDS PROPERLY

A Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when
disposing of oil, fuel, coolant, electrolyte and other
harmful waste.
0000000759E
PREPARE FOR EMERGENCIES

A Keep a first aid kit and fire extinguisher handy at all
times.
A Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
0000000760E

3
SAFETY DECALS
The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not
on the machine, replace it. The decal part number is listed in the parts list.

4

5

6
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7
GZD15, WSM SPECIFICATIONS
SPECIFICATIONS
Model GZD15-LD GZD15-HD
Maximum gross power 11.2 kW (15 HP) *1
Model Z602-GZD15
Type Indirect injection. Vertical, water-cooled, 4-cycle diesel engine
Number of cylinder 2
Bore and stroke 72.0 x 73.6 mm (2.83 x 2.90 in.)
Total displacement 599 (36.6 cu.in.)
Rated revolution 3000 rpm
Combustion chamber Spherical type (E-TVCS)
Fuel injection pump Bosh MD type mini pump
Governor Centrifugal ball mechanical governor
Injection nozzle Bosh throttle type
Injection timing 0.30 to 0.33 rad. (17 to 19 ) before T.D.C.

Engine
Injection order 1-2
Injection pressure 13.73 MPa (140 , 1990 psi)
Lubricating system Forced lubrication by gear pump
Cooling system Pressurized radiator, forced circulation with water pump
API Service classification CD, CE or CF,

below 0 (32 ) : SAE 10W, 10W-30 or 10W-40,
Lubricating oil
0 to 25 (32 to 77 ) : SAE 20, 10W-30 or 10W-40,
above 25 (77 ) :SAE 30, 10W-30 or 10W-40
Starting system Electrical starter (12 V, 1.1 kW)
Battery 65D23L (12V, 52A.H. at 5H.R.)
No.2-D Diesel fuel (ASTM D975)

Fuel
[No. 1-D diesel fuel, if temperature is below -10 (14 )]
Fuel tank 20 L (5.3 U.S.gals, 4.4 lmp.gals)
Engine crankcase 2.1 L (2.2 U.S.qts, 1.8 lmp.qts)
Engine coolant 1.4 L (1.5 U.S.qts, 1.2 lmp.qts)
Recovery tank 0.25 L (0.26 U.S.qts., 0.22 Imp.qts.)

Capacities
Transmission case & rear axle gear case (RH
10.0 L (10.6 U.S.qts., 8.8 Imp.qts.)
& LH)
Front PTO case 0.13 L (0.14 U.S.gals, 0.11 lmp.gals)
Mower gear case oil 0.15 L (0.16 U.S.qts, 0.13 lmp.qts)
Front 15 x 6.0 - 6 (4 PR) Rib

Tyres
Rear 20 x 10.0 - 12 (4 PR) Turf
Forward 0 to 13.5 km/h (0 to 8.4 mph)

Traveling speeds
Reverse 0 to 10.0 km/h (0 to 6.3 mph)
NOTE:
*1 Manufacture's estimate
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8
GZD15, WSM SPECIFICATIONS
Model GZD15-LD GZD15-HD
Overall length (with grass collector) 2785 mm (109.7 in.)
Overall width (with mower) 1195 mm (47.1 in.)
Overall height (without ROPS) 1115 mm (43.9 in.) 1345 mm (53.0 in.)
Dimensions
Wheel base 1285 mm (50.6 in.)
Front 815 mm (32.1 in.)

Tread
Rear 950 mm (37.4 in.), 850 mm (32.7 in.)
510 kg (1124.6 lbs) / with 40 in. 540 kg (1190.7 lbs) / with 40 in.
Weight (with mower deck and grass collector))
mower deck mower deck
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9
GZD15, WSM DIMENSIONS
DIMENSIONS

10
GZD15, WSM DIMENSIONS
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11
G GENERAL

CONTENTS
1. IDENTIFICATION ................................................................................................................G-1
2. GENERAL PRECAUTIONS................................................................................................G-2
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING......................G-3
[1] WIRING..............................................................................................................................G-3
[2] BATTERY ..........................................................................................................................G-5
[3] FUSE .................................................................................................................................G-5
[4] CONNECTOR....................................................................................................................G-5
[5] HANDLING OF CIRCUIT TESTER....................................................................................G-6
4. LUBRICANTS, FUEL AND COOLANT .............................................................................G-7
5. TIGHTENING TORQUES ...................................................................................................G-9
[1] GENERAL USE SCREWS, BOLTS AND NUTS ..........................................................G-9
[2] METRIC SCREWS, BOLTS AND NUTS .......................................................................G-9
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH
UNC OR UNF THREADS .............................................................................................G-10
[4] PLUGS.............................................................................................................................G-10
6. MAINTENANCE.................................................................................................................G-11
7. CHECK AND MAINTENANCE ........................................................................................G-13
[1] DAILY CHECK ................................................................................................................G-13
[2] CHECK POINTS OF INITIAL 50 HOURS ...................................................................G-19
[3] CHECK POINT OF INITIAL 100 HOURS ...................................................................G-24
[4] CHECK POINTS OF EVERY 50 HOURS ...................................................................G-25
[5] CHECK POINTS OF EVERY 100 HOURS .................................................................G-30
[6] CHECK POINT OF EVERY 150 HOURS ...................................................................G-34
[9] CHECK POINTS OF EVERY 1 YEAR ........................................................................G-36
[10] CHECK POINTS OF EVERY 2 YEARS......................................................................G-39
[11] OTHERS ..........................................................................................................................G-40
8. SPECIAL TOOLS .............................................................................................................G-50
[1] SPECIAL TOOLS FOR ENGINE .....................................................................................G-50
[2] SPECIAL TOOLS FOR MACHINE ...............................................................................G-56

GZD15, WSM GENERAL
1. IDENTIFICATION
When contacting your local KUBOTA distributor, always specify
engine serial number (3), machine serial number (2), mower serial
number (4) and hour meter reading.
(1) Machine Identification Plate (4) Mower Serial Number
(2) Machine Serial Number (5) Mower Identification Plate
(3) Engine Serial Number
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G-1
GZD15, WSM GENERAL
2. GENERAL PRECAUTIONS
A During disassembly, carefully arrange removed parts in a
clean area to prevent confusion later. Screws, bolts and nuts
should be installed in their original position to prevent
reassembly errors.
A When special tools are required, use KUBOTA genuine
special tools. Special tools which are not frequently used
should be made according to the drawings provided.
A Before disassembling or servicing electrical wires, always
disconnect the ground cable from the battery first.
A Remove oil and dirt from parts before measuring.
A Use only KUBOTA genuine parts for parts replacement to
maintain machine performance and to assure safety.
A 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.
A When reassembling external snap rings or internal snap rings,
they must be positioned so that sharp edge faces against the
direction from which a force is applied. See the figure left side.
A When inserting spring pins, their splits must face the direction
from which a force is applied. See the figure left side.
A To prevent damage to the hydraulic system, use only specified
fluid or equivalent.
(1) Grease (A) External Snap Ring
(2) Force (B) Internal Snap Ring
(3) Sharp Edge
(4) Axial Force
(5) Rotating Movement
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G-2
GZD15, WSM GENERAL
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS

AND WIRING
To ensure safety and prevent damage to the machine and
surrounding equipment, heed the following precautions in
handling electrical parts and wiring.
A Check electrical wiring for damage and loosened

connection every year. To this end, educate the customer
to do his or her own check and at the same time
recommend the dealer to perform periodic check for a fee.
A Do not attempt to modify or remodel any electrical parts
and wiring.
A When removing the battery cables, disconnect the
negative cable first. When installing the battery cables,
connect the positive cable first.
(1) Negative Terminal (2) Positive Terminal
0000000613E
[1] WIRING
A Securely tighten wiring terminals.
(1) Correct (2) Incorrect
(Securely Tighten) (Loosening Leads to Faulty
Contact)
0000000614E
A Do not let wiring contact dangerous part.

(1) Dangerous Part (3) Wiring (Correct)
(2) Wiring (Incorrect) (4) Dangerous Part
0000000615E
A Securely insert grommet.

(1) Grommet (A) Correct
(B) Incorrect
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G-3
GZD15, WSM GENERAL
A Securely clamp, being careful not to damage wiring.

(1) Clamp (3) Clamp
*Wind Clamp Spirally (4) Welding Dent
(2) Wire Harness
0000000617E
A Clamp wiring so that there is no twist, unnecessary sag, or

excessive tension, except for movable part, where sag be
required.
(1) Wiring (A) Correct
(2) Clamp (B) Incorrect
0000000618E
A In installing a part, take care not to get wiring caught by it.

(1) Wiring (A) Incorrect
0000000619E
A After installing wiring, check protection of terminals and

clamped condition of wiring, only connect battery.
(1) Cover
*Securely Install Cover
0000000620E

G-4
GZD15, WSM GENERAL
[2] BATTERY
A Take care not to confuse positive and negative terminal posts.
A When removing battery cables, disconnect negative cable
first. When installing battery cables, check for polarity and
connect positive cable first.
A Do not install any battery with capacity other than is specified
(Ah).
A After connecting cables to battery terminal posts, apply high
temperature grease to them and securely install terminal
covers on them.
A Do not allow dirt and dust to collect on battery.
A Take care not to let battery liquid spill on your skin and
clothes. If contaminated, wash it off with water
immediately.
A Before recharging the battery, remove it from the
machine.
A Before recharging, remove cell caps.
A Do recharging in a well-ventilated place where there is no
open flame nearby, as hydrogen gas and oxygen are
formed.
0000000621E
[3] FUSE
A Use fuses with specified capacity.
Neither too large or small capacity fuse is acceptable.
A Never use steel or copper wire in place of fuse.
A Do not install working light, radio set, etc. on machine which is
not provided with reserve power supply.
A Do not install accessories if fuse capacity of reserve power
supply is exceeded.
(1) Fuse (2) Fusible Link
0000000622E
[4] CONNECTOR
A For connector with lock, push lock to separate.
(A) Push
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G-5
GZD15, WSM GENERAL
A In separating connectors, do not pull wire harnesses.

A Hold connector bodies to separate.
(A) Correct (B) Incorrect
0000000624E
A Use sandpaper to remove rust from terminals.

A Repair deformed terminal. Make certain there is no terminal
being exposed or displaced.
(1) Exposed Terminal (3) Sandpaper
(2) Deformed Terminal (4) Rust
0000000625E
A Make certain that there is no female connector being too open.

(A) Correct (B) Incorrect
0000000626E
[5] HANDLING OF CIRCUIT TESTER

A Use tester correctly following manual provided with tester.
A Check for polarity and range.
0000000628E

G-6
GZD15, WSM GENERAL
4. LUBRICANTS, FUEL AND COOLANT

Capacity
No. Place Lubricants, fuel and coolant
GZD15-LD GZD15-HD
20 L No. 2-D diesel fuel
1 Fuel tank 5.3 U.S.gals. No. 1-D diesel fuel if temperature is below
4.4 lmp.gals. -10 (14 )
1.4 L
Cooling
1.5 U.S.qts.
system
1.2 lmp.qts.
2 Coolant Fresh clean water with anti-freeze
0.25 L
Recovery
0.26 U.S.qts.
tank
0.22 lmp.qts.
Engine oil: API service classification CD, CE or CF
2.1 L
Below 0 (32 ) : SAE10W, 10W-30 or 10W-40
3 Engine crankcase 2.2 U.S.qts.
0 to 25 (32 to 77 ) : SAE20, 10W-30 or 10W-40
1.8 lmp.qts.
Above 25 (77 ) : SAE30, 10W-30 or 10W-40
Transmission case and 10.0 L
4 rear axle gear case 2.6 U.S.gals.
(RH and LH) 2.2 lmp.gals.
0.15 L
5 Mower gear box 0.16 U.S.qts. KUBOTA UDT or SUPER UDT fluid**
0.13 Imp.qts.
0.13 L
6 Front PTO case 0.14 U.S.qts.
0.11 Imp.qts.
*Oil amount when the oil level is at the upper of the oil level gauge.
**KUBOTA original transmission hydraulic fluid.
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G-7
GZD15, WSM GENERAL
Greasing, oiling (Machine)

No. Place No. of greasing point Capacity Type of grease
7 Motion control lever boss 2
8 Centre pin 1
9 King pin 2 SAE multi-purpose type
Until grease overflows
10 Front wheel 2 grease
11 Front PTO drive shaft 2

12 Engine universal joint 1
13 Motion control lever
14 Seat adjuster
15 Hydraulic lift pedal Moderate amount oil Oil
16 Cable
17 Grass collector link
Greasing (Mower)
18 Universal joint 3 SAE multi-purpose type
Until grease overflows
19 Two spindle shafts 2 grease
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G-8
GZD15, WSM GENERAL
5. TIGHTENING TORQUES
[1] GENERAL USE SCREWS, BOLTS AND NUTS
Screws, bolt and nuts whose tightening torque are not specified in this Workshop Manual should be tightened
according to the table below.
Indication on top of
No-grade or 4T 7T 9T
bolt
Material of bolt SS400, S20C S43C, S48C SCr435, SCM435
Material of
Ordinariness Aluminum Ordinariness Aluminum Ordinariness
opponent part
Unit
ft-lbs ft-lbs ft-lbs ft-lbs ft-lbs
Diameter
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 1.25 9.05
M6
to to to to to to to to to to to to to to to
(6 mm, 0.24 in.)
9.31 0.95 6.87 8.82 0.90 6.50 11.2 1.15 8.31 8.82 0.90 6.50 14.2 1.45 10.4
17.7 1.8 13.1 16.7 1.7 12.3 23.6 2.4 17.4 17.7 1.8 13.1 29.5 3.0 21.7
M8
(8 mm, 0.31 in.)
20.5 2.1 15.1 19.6 2.0 14.4 27.4 2.8 20.2 20.5 2.1 15.1 34.3 3.5 25.3
39.3 4.0 29.0 31.4 3.2 23.2 48.1 4.9 35.5 39.3 4.0 29.0 60.9 6.2 44.9
M10
(10 mm, 0.39 in.)
45.1 4.6 33.2 34.3 3.5 25.3 55.8 5.7 41.2 44.1 4.5 32.5 70.6 7.2 52.0
62.8 6.4 46.3 77.5 7.9 57.2 62.8 6.4 46.3 103 10.5 76.0
M12
to to to to to to to to to to to to
(12 mm, 0.47 in.)
72.5 7.4 53.5 90.2 9.2 66.5 72.5 7.4 53.5 117 12.0 86.7
108 11.0 79.6 124 12.6 91.2 167 17.0 123
M14
to to to to to to to to to
(14 mm, 0.55 in.)
125 12.8 92.5 147 15.0 108 196 20.0 144
167 17.0 123 197 20.0 145 260 26.5 192

M16
(16 mm, 0.63 in.)
191 19.5 141 225 23.0 166 304 31.0 224
246 25.0 181 275 28.0 203 344 35.0 254

M18
(18 mm, 0.71 in.)
284 29.0 209 318 32.5 235 402 41.0 296
334 34.0 246 368 37.5 272 491 50.0 362

M20
(20 mm, 0.79 in.)
392 40.0 289 431 44.0 318 568 58.0 419
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[2] METRIC SCREWS, BOLTS AND NUTS
Property class 8.8 Property class 10.9

Grade
Unit
Nominal ft-lbs ft-lbs
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
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G-9
GZD15, WSM GENERAL
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR

UNF THREADS
SAE GR.5 SAE GR.8

Grade
Unit
Norminal ft-lbs ft-lbs
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
0000001414E
[4] PLUGS
Material of opponent part
Shape Size Ordinariness Aluminum
ft-lbs 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
Tapered
screw 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 57.9
Straight G1/4 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3

screw
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
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G-10
GZD15, WSM GENERAL
6. MAINTENANCE
Period Indication on hour meter Refer-
After
No. ence
50 100 150 200 250 300 350 400 450 500 550 600 since
Item page
every
1 Engine oil Change G-19
100Hr
every
2 Engine oil filter Replace G-20
200Hr
Transmission and
every
3 Rear axle gear case Change G-21
200Hr
(RH and LH) fluid
Transmission oil every

4 Replace G-20
filter 200Hr
Transmission every
5 Clean G-23
strainer 200Hr
every
Check G-29
50Hr
6 Front PTO case fluid
every
Change G-29
150Hr
every
7 Front axle pivot Adjust G-24 *2
200Hr
every
8 Safety device Check G-25
50Hr
every
9 Oiling - G-28
50Hr
Greasing every
10 - G-27
(without mower) 50Hr
every
Check G-26
50Hr
11 Mower gear box oil
every
Change G-34
150Hr
every
Clean G-26 *1
50Hr
12 Air cleaner element
every
Replace G-36
1 year
every
13 Battery condition Check G-32
50Hr
every
14 Fan belt Adjust G-31
100Hr
every
15 Parking brake Adjust G-31 *2
100Hr
every
Check G-30
100Hr
16 Fuel filter element
every
Replace G-36 *2
400Hr
every
Check G-30
100Hr
17 Fuel line
every
Replace G-39 *2
2 years
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G-11
GZD15, WSM GENERAL
Period Indication on hour meter Refer-

After
No. ence
50 100 150 200 250 300 350 400 450 500 550 600 since
Item page
every
Check G-35
Radiator hose and 200Hr
18
clamp every
Replace G-39 *2
2 years
every
Check G-35
200Hr
19 Hydraulic hose
every
Replace G-39 *2
2 years
every
20 Radiator Clean G-37
1 year
every
21 Coolant Change G-37
1 year
every
22 Mower gear box seal Replace G-39 *2
2 years
23 Fuel system Bleed G-42
24 Fuse Replace Service G-40

as
25 Blade Replace required G-41
26 Mower belt Replace G-42
A The jobs indicated by must be done initially.

A *1: This maintenance should be done daily more often in dusty condition than in normal conditions.
Suggested cleaning interval is every 100 hours in normal conditions.
A *2: These items should be serviced by an authorized KUBOTA Distributor, unless the owner has the
proper tools and is mechanically proficient.
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G-12
GZD15, WSM GENERAL
7. CHECK AND MAINTENANCE
A Be sure to check and service the machine on a flat place with engine shut off, the parking brake on and
chock the wheels.
0000001417E
[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
A Check areas where previous trouble was experienced.

A Walk around the machine.
1. Tire pressure, wear and damage
2. Oil and water leak
3. Engine oil level
4. Transmission fluid level
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
A Mower
1. Oil leak
2. Make sure blade cap screws are tight.
3. Check blades for wear or damage.
4. Check all hardware.
5. Make sure all pins are in place.
6. Mower deck cleaning
7. Greasing
A While sitting in the operator's seat,

1. Motion control lever
2. Parking brake
A 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 abnormal noise and vibration.
0000001418E

G-13
GZD15, WSM GENERAL
Checking Engine Oil Level
A Always stop the engine and remove the key before

checking oil.
1. Check engine oil before starting and 5 minutes or more after
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 (A) Upper Level
(2) Oil Level Dipstick (B) Lower Level
0000001422E

G-14
GZD15, WSM GENERAL
Checking Amount of Fuel and Refueling
A Handle fuel carefully. If the engine is running, do not fill

the fuel tank. If engine is hot, let engine cool several
minutes before adding fuel.
Do not smoke while filling the fuel tank or servicing the
fuel system. Fill fuel tank only to bottom of filler neck.
Check the fuel level. Take care that the fuel tank does not
become empty.
20L
Fuel tank capacity 5.3 U.S.gals.
4.4 Imp.gals.
A Use Diesel Fuel Only.

1. Use No.2 diesel fuel.
2. Use No.1 diesel fuel if the temperature is below -10 .
3. Always use a strainer when refueling to prevent fuel injection
pump contamination.
A No.2-D is a distillate fuel of lower volatility for engines in

industrial and heavy mobile service.
(SAE J313 JUN87)
Grade of Diesel Fuel Oil according to ASTM D975
Water and Carbon Residue
Flash point Sediment, on, 10 percent Ash, weight %
volume % Residuum %
Min Max Max Max
52 0.05 0.35 0.01
Distillation
Viscosity Kinematics cSt Viscosity Saybolt, SUS
Temperatures 90%
or /S at 40 at 100
Point
Min Max Min Max Min Max
282 338 1.9 4.1 32.6 40.1
Sulfur, weight Copper strip Corrosion Cetane Number
Max Max Min
0.50 No.3 40
(1) Fuel Gauge E: Empty

F: Full
0000001667E

G-15
GZD15, WSM GENERAL
Checking and Cleaning Radiator to Prevent Overheating
A Be sure to stop the engine and remove the key before

cleaning.
Daily or after every 5 hours 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 screen and remove 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 it off the screen with hand. Check the radiator
screen from time to time if grass accumulates.
6. If the dust or chaff has accumulated inside of the panel,
remove the radiator screen and clean inside completely.
After cleaning, replace the radiator screens properly.
A When assembling the panel screen, be sure to fit it in the

runners.
(1) Panel Screen (2) Radiator Screen
0000001423E
Checking Tyre Pressure
A Do not attempt to mount a tyre on a rim. This should be

done by a qualified person with the proper equipment.
A Always maintain the correct tyre pressure.
Inflation pressure in front tyres rises quickly when using
compressed air.
Do not inflate tyres above the recommended pressure
shown in the Operatorís Manual.
A Do not use tyres larger than specified.

B Inflation Pressure
Though the inflation pressure is factory-set to the prescribed
level, it naturally drops slowly in the course of time. Thus, check
it and inflate as necessary.
Recommended Inflation
Tyre Sizes
Pressure
207 kPa
Front 15 x 6.0-6, 4PR Rib
(2.1 , 30 psi)
140 kPa
Rear 20 x 10.00-8, 4PR Turf
(1.4 , 20 psi)
(1) Ground (A) Insufficient

(B) Normal
(C) Excessive
0000001419E
G-16
GZD15, WSM GENERAL
Checking Transmission Fluid Level

1. Park the machine on a flat surface, lower the implement to the
ground and shut off engine and remove the key.
2. Open the hood and detach the engine side cover (L.H.).
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 notches. If the level is too low, add new
oil to the prescribed level at the oil inlet. (See page G-7.)
A If oil level is low, do not run engine.

(1) Oil Level Dipstick (A) Oil level is acceptable within
this range.
0000001420E
Checking Coolant Level
A 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 that the coolant level is between 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 leakage, add anti-freeze and water in the specified
mixing ratio up to the full level. (See page G-7.)
A If the radiator cap has to be removed, follow the caution

above and securely retighten the cap.
A Use clean, distilled water and anti-freeze to fill the
recovery tank.
(1) Recovery Tank (A) FULL
(B) LOW
0000001421E

G-17
GZD15, WSM GENERAL
Lubricating Grease Nipple

greasing.
1. Apply grease to the following location as figures.
(1) Engine Universal Joint (3) Front PTO Drive Shaft
(2) Mower Universal (4) Spindle Shaft
0000001424E

G-18
GZD15, WSM GENERAL
[2] CHECK POINTS OF INITIAL 50 HOURS

Changing Engine Oil
A Be sure to stop the engine before changing oil.

1. Raise the grass collector from the machine.
2. Remove the spring (1) connecting the cover duct (2) and the
mower deck (3).
3. Remove the bolts (5) and duct (4).
4. To change the used oil, remove the drain plug at the bottom of
the engine and drain the oil completely. The used oil can be
drained out more easily if the engine is warm.
5. Fill with the new oil up to the upper notch on the dipstick (7).
6. To check the oil level, remove the dipstick (7), wipe it clean,
insert it and draw it out again. Check to see that the oil level
is between two marks.
A When using an oil of different manufacture or viscosity

from the previous one, remove all of the oid oil.
A Never mix two different type of oil.
A Use the proper SAE engine oil according to ambient
temperatures.
Refer to "LUBRICANTS, FUEL AND COOLANT".
(See page G-7.)
2.1 L
Engine oil capacity 2.2 U.S.qts.
1.8 lmp.qts
(1) Spring (5) Bolt

(2) Cover Duct (6) Drain Plug
(3) Mower Deck (7) Oil Level Dipstick
(4) Duct
A: Upper Level
B: Lower Level
0000001425E

G-19
GZD15, WSM GENERAL
Replacing Engine Oil Filter Cartridge
A Be sure to stop the engine before changing the oil filter

cartridge.
A 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.
A 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
0000001426E
Replacing Transmission Oil Filter Cartridge
A Be sure to stop the engine before changing the oil filter

cartridge.
A Allow transmission case to cool down sufficiently; oil can
be hot and may cause burns.
1. The transmission oil filter cartridge (1) must be changed every
300 service hours.
2. Remove the oil filter cartridge (1) 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. Tighten the filter quickly until it contacts the mounting surface.
Tighten filter by hand an additional 1/2 turn only.
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.
A To prevent serious damage to hydraulic system, the

replacement filter must be a highly efficient, 10 filter.
Use only a genuine KUBOTA filter or its equivalent.
(1) Transmission Oil Filter (2) Screw
Cartridge
0000001427E

G-20
GZD15, WSM GENERAL
Changing Transmission and Rear Axle Gear Case (RH and LH)
Fluid
A 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.
Remove the clamp and hose (2) from L shape adaptor (3) at
the rear axle gear case (RH & LH) bottom and drain rear axle
gear case (RH & LH) fluid.
3. After draining, disassembling and clean the strainer and
change the oil filter cartridge. After reassembling, fill with UDT
or SUPER UDT hydraulic transmission fluid, or its equivalent.
4. Remove the filler plug (5) of the both rear axle gear cases.
Fill with the new oil up to the plug port. After filling, reinstall the
filler plug.
5. Remove the oil plug and breather cup (6), and fill with the new
oil.
6. After running the engine for a few minutes, stop it and check
the oil level again; add oil to the prescribed level.
A 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.)
A Operate only at low RPM's immediately after changing the
transmission fluid and filter cartridge.
Keep the engine at medium speed for a few minutes to
insure proper lubrication of all parts so there is no
damage to transmission.
A 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.
A Do not mix different brands oil together.
10.0 L
Transmission case and rear axle gear case (RH
2.6 U.S.qts.
and LH) fluid
2.2 Imp.qts.
(1) Drain Plug (3) L Shape Adaptor

(2) Hose
0000001429E

G-21
GZD15, WSM GENERAL
Changing Transmission and Rear Axle Gear Case (RH and LH)
Fluid (Continued)
(4) Rear Axle Gear Case (A) Oil level acceptable within
(5) Oil Filler Plug this range
(6) Oil Plug and Breather Cup
(7) Dipstick
(8) Transmission Oil Filter
0000001430E

G-22
GZD15, WSM GENERAL
Cleaning Transmission Strainer

When changing the transmission fluid, disassemble and rinse
the strainer with nonflammable solvent to completely clean off
filings.
Check O-ring (3), replace if damaged, cracked or hardened.
When reassembling be careful not to damage the parts.
A 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 (3) O-ring
(2) Suction Line
0000001431E

G-23
GZD15, WSM GENERAL
[3] CHECK POINT OF INITIAL 100 HOURS

Adjusting Front Axle Rocking Force
1. Lift the front axle (1).
2. Measure the front axle rocking force with a push-pull gauge.
3. If the measurement is not within the factory specifications,
adjust with the slotted nut (2).
4. Set the centre pin setting spring pin (4) to the centre pin (3).
(When reassembling)
Grease nipple of centre pin should be installed to upside
9.8 to 147.1
Front axle rocking force Factory spec. 1.0 to 15
7.2 to 108.5 ft-lbs
(1) Front Axle (4) Centre Pin Setting Spring Pin

(2) Slotted Nut (5) Grease Nipple
(3) Centre Pin
0000001428E

G-24
GZD15, WSM GENERAL
[4] CHECK POINTS OF EVERY 50 HOURS

Checking Safety Device
A Do not allow anyone near the machine while testing.

A If the machine does not pass one of the following tests, do
not operate the machine.
A Sit on operator's seat for all tests except for Test 1.
B 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.
B Test 2 (OPERATOR ON THE SEAT)
1. Do not set the parking brake. (Release it from test 1.)
3. Set the motion control levers (3) to the "NEUTRAL LOCK"
position.
3. Grasp the motion control levers (3) and move then inward from
"NEUTRAL LOCK" position to "NEUTRAL" position and
then release the levers.
2. Shift the PTO lever (4) to "ENGAGE" (ON) position.
3. Grasp the motion control levers (3) and move then inward from
1. Start the engine.
2. Do not set the parking brake.
4. Grasp the motion control levers and move then inward from
5. Stand up. (Do not get off the machine.)
6. The engine must shut off.
(1) Brake Pedal (4) PTO Lever
(2) Parking Brake Pedal (5) Key Switch
(3) Motion Control Lever
0000001432E

G-25
GZD15, WSM GENERAL
Checking Safety Device (Continued)

B Test 6 (OPERATOR NOT ON THE SEAT)
2. Do not set the parking brake.
3. Shift the PTO lever to "ENGAGE" (ON) position.
4. Stand up. (Do not get off the machine.)
5. The engine must shut off.
(1) Brake Pedal (4) PTO Lever
(2) Parking Brake Pedal (5) Key Switch
(3) Motion Control Lever
0000001433E
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 element, use clean and dry
compressed air on the inside of the element. Air pressure
should not exceed 205 kPa (2.1 , 30 psi).
A Operating in dusty conditions requires more frequent

maintenance.
A Align the arrow marks when reinstalling the air cleaner
cover.
(1) Air Cleaner Cover (2) Air Cleaner Element
0000001434E
Checking Mower Gear Box Oil Level

checking oil.
1. Park the machine on a flat surface and lower the mower to the
ground.
To check the oil level, loosen check plug bolt and check to see
that the oil level is just below the oil filler plug (1).
If the level is too low, add new oil to the prescribed level at the
oil inlet. (See page G-7.)
(1) Oil Filler Plug
0000001435E

G-26
GZD15, WSM GENERAL
Lubricating All Grease Nipple

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

greasing.
(1) Centre Pin (3) Front Wheel (LH, RH)
(2) King Pin (LH, RH) (4) Motion Control Lever Boss
(LH, RH)
0000001436E

G-27
GZD15, WSM GENERAL
Oiling
1. Apply oil to the following position as figures.

greasing.
(Reference)
A Grass container control cables (6) shown below are adopted
to GZD15-HD(E). (Serial No. : Below 10736).
(1) Motion Control Lever (LH, RH) (4) Front Link

(2) Seat Adjuster (5) Hydraulic Lift Pedal (Oil)
(3) Throttle Cable (Oil) (6) Grass Container Control
Cables (for HD) (Oil)
0000001437E

G-28
GZD15, WSM GENERAL
Oiling (Continued)
1. Apply oil to the following position as figures.

greasing.
(Reference)
A Grass container control cables (6) shown below are adopted
to GZD15-HD(E). (Serial No. : Below 10736).
(1) Grass Collector Link (Oil) (3) Grass Collector Control Cables
(2) Grass Collector Link (for HD, (for HD) (Oil)
LH, RH ) (Oil)
0000001438E
Checking Front PTO Case Oil Level

checking oil.
1. Park the machine on a flat surface and lower the mower to the
ground.
To check the oil level, loosen check plug bolt (2) and 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
inlet.
(See page G-7.)
(1) Drain Plug (Bolt) (2) Check Plug (Bolt)
0000001439E

G-29
GZD15, WSM GENERAL

Changing Engine Oil
1. See page G-19.
0000001441E
Checking Fuel Lines And Fuel Filter
A Be sure to stop the engine and remove the key when

attempting to make the following checks and changes.
A 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 connections should be checked annually or every
100 service hours, whichever comes first.
1. The fuel lines is made of rubber and ages regardless of service
period.
2. If the fuel line and clamps are found damages or deteriorated,
replace them.
3. Check fuel filter, if it is clogged by debris, and replace it.
A 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 taken 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 (3) Fuel Filter
(2) Fuel Line (4) Fuel Pump
0000001442E

G-30
GZD15, WSM GENERAL
Checking Fan Drive Belt Tension

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, securely tighten the bolts.
Moderate belt tension:

The belt should deflect approx. 10 mm (0.4 in.) when the centre
of the belt is depressed with finger pressure of 98 N (10 kgf, 22
lbs).
Approx. 10 mm
Fan belt tension (A) Factory spec.
0.4 in.
A When replacing fan belt, be careful not to catch it on the

cap under the water pump. See the illustration to the left.
(1) Tension Belt A: Fan Belt Tension
(2) Alternator 10 mm (0.4 in.)
(3) Adjustment bolt
0000001443E
Adjusting Parking Brake
A Stop the engine and chock the wheels before checking or

adjusting.
A Park the machine on a hard and level surface.
A Wrong adjustment may cause machine damage.

B Check
1. Apply parking brake and check the length (A) of the brake
spring (2).
2. If it is not correct, turn the lock nut (3) in the desireddirection
until the proper length is achieved.
B Check on the slope
1. Place the machine on the under 17 ramp.
2. Apply the parking brake fully.
3. Place the motion control levers in "NEUTRAL LOCK"
position and shut off the engine.
4. Check that the machine does not move.
A For parking brake test purposes only use 17 ramp.

27 mm
Brake spring length (A) Factory spec.
1.06 in.
(1) Brake Pedal A: Brake Spring Length

(2) Brake Spring B: "Under 17 "
(3) Lock Nut
0000001444E

G-31
GZD15, WSM GENERAL
Checking Battery Condition
A Never remove the vent cap while the engine is running.

A Keep electrolyte away from eyes, hands and clothes. If
you are spattered with it, wash it away completely with
water immediately and get medical attention.
A 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 (1) is weak, the engine will be difficult to start and
the lights will become dim. It is important to check the battery (1)
periodically.
B How to read the indicator
Check the battery condition by reading the indicator (2).
State of indicator display
Specific gravity of electrolyte and quality of electrolyte are both

Green
in good condition.
Black Needs changing battery.
White Needs changing battery.
(1) Battery (2) Indicator
0000001440E

G-32
GZD15, WSM GENERAL
B Battery Charging
A 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.
A When charging the battery, ensure the vent caps are
securely in place. (If equipped)
A When disconnecting the cable from the battery, start with
the negative terminal first.
When connecting the cable to the battery, start with the
positive terminal first.
A Never check battery charge by placing a metal object
across the posts.
Use a voltmeter or hydrometer.
1. 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.
2. A boost charge is only for emergencies. It will partially charge
the battery at a high rate and in a short time.
When using a boost-charged battery, it is necessary to
recharge the battery as early as possible.
Failure to do this will shorten the battery's service life.
3. The battery is charged if the indicator display turns green from
black.
4. When exchanging an old battery for a new one, use battery of
equal specification shown in Table 1.
[Table 1]
Battery Type Volts (V) Capacity at 5H.R (A.H)
65D23L 12 52
[Table 2]
Battery voltage Reference state of charge
12.6 100% (Full charge)
12.4 75%
12.2 50%
12.0 25%
11.8 0%
(1) Battery
0000001445E
B Direction for Storage

1. When storing the machine for a long period, remove the
battery from machine, adjust the electrolyte to the proper level
and store in a dry place out of direct sunlight.
2. The battery self-discharges while it is stored.
Recharge it once every three months in hot seasons and once
every six months in cold seasons.
0000001446E

G-33
GZD15, WSM GENERAL
[6] CHECK POINT OF EVERY 150 HOURS

Changing Mower Gear Box Oil

changing the oil.
1. To drain the used oil, remove the oil filler plug (1) at the mower
gear box, tilt the mower deck and drain the oil completery into
the oil pan.
2. After draining, reinstall the oil filler plug (1).
3. Fill with the new oil up to the filler plug port.
(See page G-7.)
4. After filling, reinstall the oil filler plug (1).
0.15 L
Mower gear box oil capacity 0.16 U.S.qts.
0.13 Imp.qts.
(1) Oil Filler Plug
0000001447E

Replacing Engine Oil Filter Cartridge
1. See page G-20.
0000001448E
Changing Transmission and Rear Axle Case Fluid

1. See page G-21.
0000001449E
Replacing Transmission Oil Filter Cartridge

1. See page G-20.
0000001450E

G-34
GZD15, WSM GENERAL
Checking Radiator Hose and Clamp
A Check to see if the radiator hoses are properly fixed every

200 hours of operation or 6 months, whichever comes
first.
1. If clamp bands (2) are loose or water 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.
A Take the following actions in the event the coolant

temperature be nearly or more than the boiling point, what
is called "Overheating".
A Park the machine in a safe place and keep the engine
unloaded idling.
A Don't stop the engine suddenly, but stop it after about 5
minutes of unloaded idling
A Keep yourself well away from the machine for further 10
minutes or while the steam is blown out.
A 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
0000001451E
Checking Hydraulic Hose

checking and replacing hydraulic hose.
A Allow transmission case to cool down sufficiently; oil can
be hot and may cause burns.
1. Check to see that all lines 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) Hydraulic Hose (2) Mower Lift Cylinder Hose
0000001452E

1. See page G-24.
0000001453E

G-35
GZD15, WSM GENERAL

Replacing Fuel Filter
1. Disconnect the fuel hoses and loosen the filter band to replace
the fuel filter (2).
A If the fuel line is removed, be sure to properly bleed the

fuel system. (See page G-42.)
(1) Pipe Clamps (3) Fuel Filter
(2) Fuel Line (4) Fuel Pump
0000001455E
[9] CHECK POINTS OF EVERY 1 YEAR

Replacing Air Cleaner Element
1. Remove the air cleaner element (2) once a year.
A The air cleaner uses a dry element, never apply oil.

A Do not run the engine with filter element removed.
A 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.
A 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 (3) Evacuator Valve
(2) Air Cleaner Element
0000001456E

G-36
GZD15, WSM GENERAL
Flushing Cooling System and Changing Coolant
A 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 cock and install the
drain plug.
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 engine and let cool. Check coolant level of recovery
tank (2) and add coolant if necessary.
A Do not start engine without coolant.

A Use clean, fresh water and anti-freeze to fill the radiator
and recovery tank.
A When the anti-freeze is mixed with water, the anti-freeze
mixing ratio must be less than 50 %.
A Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
A Refer to "LUBRICANTS, FUEL AND COOLANT" (See
page G-7.)
1.4 L
Cooling system 1.5 U.S.qts.
1.2 Imp.qts.
Coolant capacity
0.25 L
Recovery tank 0.26 U.S.qts.
0.22 Imp.qts.
(1) Radiator Cap A: FULL

(2) Recovery Tank B: LOW
(3) Drain Plug
(4) Clamp
0000001457E

G-37
GZD15, WSM GENERAL
Flushing Cooling System and Changing Coolant (Continued)

B Anti-Freeze
If it freezes, coolant can damage the cylinders and radiator. If
the ambient temperature falls below 0 or before a long-term
storage, let out cooling water completely, or mix fresh water with
long-life coolant and fill the radiator and reserve tank with the
mixture.
1. Long-life coolant (hereafter LLC) comes in several types. Use
ethylene glycol (EG) type for this engine.
2. Before employing LLC-mixed cooling water, fill the radiator
with fresh water and empty it again. Repeat this procedure 2
or 3 times to clean up the inside.
3. Mixing the LLC
Put the LLC in cooling water in the percentage (%) for a target
temperature. When mixing, stir it up well, and then fill into the
radiator.
4. The procedure for the mixing of water and anti-freeze differs
according to the make of the anti-freeze and the ambient
temperature. Refer to SAE J1034 standard, more specifically
also to SAE J814c.
A When the anti-freeze is mixed with water, the anti-freeze

mixing ratio must be less than 50%.
5. Adding the LLC
(1) Add only water if the mixture reduces in amount by
evaporation.
(2) If there is a mixture leak, add the LLC the same
manufacture and type in the same mixture percentage.
*Never add any long-life coolant of different manufacture.
(Different brands may have different additive components, and
the engine may fail to perform as specified.)
6. When the LLC is mixed, do not employ any radiator cleaning
agent. The LLC contains anti-corrosive agent. If mixed with
the cleaning agent, sludge may build up, adversely affecting
the engine parts.
7. Kubota's genuine long-life coolant has a service life of 2 years.
Be sure to change the coolant every 2 years.
A The above data represent industry standards that

necessitate a minimum glycol content in the concentrated
anti-freeze.
A When the coolant level drops due to evaporation, add
water only to keep the anti-freeze mixing ratio less than
50%. In case of leakage, add anti-freeze and water in the
specified mixing ratio before filling in to the radiator.
(1) Radiator Cap A: FULL
(2) Recovery Tank B: LOW
(3) Drain Plug
(4) Clamp
0000001458E

G-38
GZD15, WSM GENERAL
[10]CHECK POINTS OF EVERY 2 YEARS

Replacing Hydraulic Hose
1. Replace the hose.
Refer to "Checking Hydraulic Hose". (See page G-35.)
0000001459E
Replacing Fuel Lines

1. Replace the fuel line.
Refer to "Checking Fuel Lines and Fuel Filter". (See page G-
30.)
0000001460E
Replacing Radiator Hose

1. Replace the hoses and clamps.
Refer to "Checking Radiator Hose and Hose Clamp". (See
page G-35.)
0000001461E
Replacing Mower Gear Box Oil Seals
1. Replace the mower gear box oil seals (1), (2).
Refer to "Disassembling Gear Box Assembly".
(See page 6-S8.)
(1) Oil Seal (2) Oil Seal
0000001462E

G-39
GZD15, WSM GENERAL
[11]OTHERS
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 blow, replace with a new one of the
same capacity.
3. Open hood.
4. Remove the blow fuse.
5. Place a new fuse of the same capacity in position.
A 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.
B Protected Circuit
Fuse No.
Capacity (A) Protected circuit
(ID Label)
20A Engine stop
15A Charge system
1 15A Aux. outlet
15A Main system
10A Control system
Check circuit against wrong battery

2 Slow blow fuse 30A
connection.
(1) Fuse (2) Slow Blow Fuse
0000001463E

G-40
GZD15, WSM GENERAL
Checking and Replacing Mower Blade
A Be sure to stop the engine and remove the key.

A Blades may be sharp. When you handle blades, wear
heavy gloves or wrap end of blade with a rag.
B Checking Blade
1. The blade cutting edges should be kept sharp at all times.
Sharpen the cutting edges, if they resemble blade (b).
Replace the blades if they appear similar to blade (c).
B Replacing Blade
1. Remove the mower deck from the machine and turn it over to
expose the blades.
2. Wedge a block of wooden block (1) between the blade and
mower housing as illustrated.
3. The blade screws (2) have right hand threads, turn
counterclockwise to loosen.
The blade screw (2) has left hand threads, turn clockwise to
loosen.
A Use the proper size box or socket wrench to tighten or

loosen the blade mounting bolt.
4. To sharpen the blades yourself, clamp the blade securely in a
vise.
Use a large mill file and file along the original bevel until sharp.
5. To check the blade for balance, place a small rod though the
centre hole. If the blade is not balanced, file the heavy side of
the blade until balance is achieved.
6. To attach blades, be sure to install the 2-cup washers between
the blade and bolt head.
98.0 to 117.6
Tightening torque Mower blade screw 10.0 to 12.0
72.0 to 86.8 ft-lbs
(1) Wooden Block (a) New Blade

(2) Mower Blade Screw (b) Worn Blade
(3) Mower Blade (c) Cracked Blade
(4) Spindle Holder
(5) 2-cup Washers A: Loosen
(6) Spindle Guard B: Tighten
(7) Collar C: 30 mm (1-3/16 in.)
0000001464E

G-41
GZD15, WSM GENERAL
Replacing Mower Belt

1. Remove the mower deck from the machine.
2. Remove the left and right hand shield (4), (6) from the mower
deck.
3. Clean around the pulleys to remove the belt (3) from the
pulleys. Slip the belt (3) over the top of the left side pulley.
4. Remove the both brackets which mounts the gear box to the
mower deck.
5. To install a new belt, reverse the above procedure.
A When attaching the bracket, tighten the reamer belt first.

39.2 to 44.1
Tightening torque Bracket mounting screw 4.0 to 4.5
8.8 to 9.9 ft-lbs
(1) Reamer Bolt (4) Left Hand Shield

(2) Reamer Bolt, Nut (5) Mower Gear Box
(3) Belt (6) Right Hand Shield
0000001465E
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 (1) to work and pump air out of the
fuel system.
3. Start the engine and run for about 30 seconds, and then stop
the engine.
(1) Fuel Pump
0000001466E

G-42
GZD15, WSM GENERAL
Adjusting Motion Control Lever, HST "NEUTRAL"

A If it is necessary to run engine in an enclosed area, use a
gas tight exhaust pipe extension to remove the fumes.
A Always try to work in a well-ventilated area.
A Lift up and secure with jack stands or blocking the rear of
the machine, do not run the machine while adjusting.
Remove rear wheels.
A Do not adjust only one of the following adjustment;
exclude "SPEED CONTROL LEVER POSITION".
They are relation each other.
A Right and left motion control levers can be adjusted

independently.
B HST "NEUTRAL" Adjustment
1. Lift-up and secure with jack stands or blocking the rear of the
machine frame.
2. Remove both rear wheels.
3. Place the motion control lever (1) in the "NEUTRAL LOCK"
position (A).
4. Pull the lever of seat frame, then raise and latch the seat
assembly.
5. Remove the connector from the seat safety switch, then
temporarily install a jumper wire across the terminal in the
connector of the wiring harness.
A Do not operate the machine with a jumper wire.

6. Loosen the lock nut (3) of the motion control rod (2).
Adjust the motion control rod (2) until axle rotation stops.
7. Tighten the lock nut (3).
Place the motion control lever (1) to the reverse position, and
move them to the forward slowly.
8. Place the lever in the "NEUTRAL LOCK" position (A), and
check the rear axle does not rotate.
If the axle have not stopped rotating, adjust the "HST
NEUTRAL" again.
9. After adjustment, be sure to stop the engine immediately.
(1) Motion Control Lever (3) Lock Nut
(2) Motion Control Rod A: "NEUTRAL LOCK" position
0000001467E

G-43
GZD15, WSM GENERAL
Adjusting Motion Control Lever, Reverse Return Position

Remove rear wheels.

independently.
B Reverse RETURN Position Adjustment
machine frame.
2. Remove both rear wheels.
3. Start the engine, and run at maximum speed.
4. Place the motion control lever (1) in the "NEUTRAL" position
(B).
5. Pull the motion control lever (1) to the reverse maximum
position and release the lever.
6. Check if the axle rotate or not.
7. If the axle rotate, loosen the lock nut and adjust the reverse
return spring bolt length so that the axle does not rotate.
8. Lock the nut.
9. Check the lever return position again.
If it is not correct, adjust again.
10. Adjust other side "REVERSE RETURN POSITION" equally.
11. After adjustment, be sure to stop the engine immediately.
(1) Motion Control Lever A: "REVERSE" position
(2) Return Spring B: "NEUTRAL" position
0000001468E

G-44
GZD15, WSM GENERAL
Adjusting Motion Control Lever, Maximum Speed (Forward)

Remove rear wheels.

independently.
B Maximum Speed (Forward)
machine frame.
2. After starting the engine, keep the engine speeds to the
maximum.
3. Place the motion control lever (1) in the "MAXIMUM
(FORWARD)" position.
4. Check both rear wheels rotation with a digital speed meter.
5. If the rear tyre rotation is not within the factory specification,
adjust the adjusting bolt.
Rear wheel rotation 140 to 160 rpm at engine
Factory Spec.
(Forward and Reverse) max. speed
(1) Motion Control lever (3) Speed Set Bolt

(2) Lock Nut
0000001469E

G-45
GZD15, WSM GENERAL
Aligning Motion Control Lever

B Checking the alignment
1. Check the gap (A) and space (B) between the levers, at the
maximum forward position.
Gap (A): 0 to 2 mm (0 to 0.08 in.)
Recommendation
Space (B): 10 to 20 mm (0.4 to 0.8 in.)
If positions of the motion control levers (1) are unequal, an

adjustment is necessary.
B Aligning the motion control levers
1. Stop the engine and apply the parking brake.
2. Loosen the nut and remove the boot (2).
Lever position (High and Low)
3. Remove the bolts (3) and select the motion control lever
position, high or low.
Lever alignment (Right and left)
4. Loosen the bolts (3).
5. Slide both levers forward or reward to desired position within
tab slots until levers are aligned.
6. Tighten the bolts (3).
A If the ends of the levers strike against each other while in

the "NEUTRAL" position, move the levers outward to the
"NEUTRAL LOCK" position and carefully bend them
outward.
Move them back to the "NEUTRAL" Position and check
for the recommended space.
(1) Motion COntrol Lever A: Gap
(2) Boot B: Space
(3) Bolts
0000001470E

G-46
GZD15, WSM GENERAL
Adjusting Mower Deck Level (Side-to-Side)

A Apply the parking brake.
A Disengage PTO (OFF).
A Stop the engine, remove the key and remove the mower u-
joint while checking or adjusting the level of the mower
deck.
A Check the machine tyre pressure.

Inflate tyres to the correct pressure. (See page G-16.)
B Checking level (Side-to-Side)
A Mower deck anti-scalp rollers should not contact the

ground.
1. Raise the mower deck to the transport position. (Also the top
end.)
2. Turn the cutting height set dial to the 3 in. cutting height
position.
3. Lower the mower deck.
4. Position the right mower blade (1) in the Side-to-Side position.
5. Measure from outside blade tip to the level surface with a short
ruler or leveling gauge.
Reference
Height of the blade at 80 mm
Factory spec.
the concrete surface 3.0 in.
A There is a difference of the blade height between on the

concrete and ground.
6. Check that the left side blade is same height.
The difference between both measurements should be less
than 3 mm (0.1 in.).
7. If the Side-to-Side adjustment is not within the given tolerance,
adjustment necessary.
(1) Blade A: Side
(2) Cutting Height Fine Turning
Bolt
(3) Lock Nut
0000001471E

G-47
GZD15, WSM GENERAL
Adjusting Mower Deck Level (Side-to-Side) (Continued)

B Adjusting level (Side-to-Side)
1. Raise up the mower deck to the transport position. (Also the
top end.)
position.
3. place 51 mm (2.0 in.) height wood blocks under each side of
the mower deck.
5. Position mower blade (1) in the Side-to-Side position.
6. Loosen the lock nuts of the right side of the machine.
7. Adjust the cutting height fine turning bolts to set 80 mm height.
8. Lock the nuts.
9. Adjust the left side equally.
10. Check the side-to-side level and if it is not level, adjustment
necessary.
(1) Blade A: Side
(2) Cutting Height Fine Turning
Bolt
(3) Lock Nut
0000001478E

G-48
GZD15, WSM GENERAL
Adjusting Mower Deck Level (Front-to-Rear)

A Engage the parking brake.
A Disengage PTO (OFF).
A Stop the engine, remove the key and remove the mower u-
joint while checking or adjusting the level of the mower
deck.
A Check the machine tyre pressure.

Inflate tyres to the correct pressure. (See page G-16.)
B Checking level (Front-to-Rear)

ground.
1. Raise the mower deck to the transport position. (Also the top
end.)
position.
4. Position the right mower blade in the Front-to-Rear position.
5. Measure from the right front blade tip to the level surface with
a short ruler or leveling gauge.
6. Turn the blade 180 and measure from right rear blade tip to
the level surface.
7. Check that the left side blade has the same dimension.
The difference between both measurement should be less
than 6 mm (0.24 in.).
Front side must be lower than rear side.
8. If the Front-to-Rear adjustment is not within the given
tolerance, adjustment necessary.
B Adjusting level (Front-to-Rear)
top end.)
position.
3. Place 51 mm (2.0 in.) height wood blocks under each side of
the mower deck.
5. Loosen the lock nuts of the front side of the machine.
6. Adjust the cutting height fine turning bolts to set 80 mm (3.0
in.) height.
7. Lock the nuts.
A The difference between both measurements should be

less than 6 mm. Front side must be lower than read side.
8. Check the front-to-rear level and if it is not level, adjustment
necessary.
(1) Blade A: Front Cutting Height
(2) Cutting Height Fine Turning Bolt B: Rear Cutting Height
(3) Lock Nut
0000001472E
G-49
GZD15, WSM GENERAL
8. SPECIAL TOOLS
[1] SPECIAL TOOLS FOR ENGINE
Special Use Puller Set
Code No : 07916-09032
Application : Use exclusively for pulling out bearing, gears and
other parts with ease.
0000000677E
Piston Ring Compressor

Code No : 07909-32111
Application : Use exclusively for pushing in the piston with
piston rings into the cylinder.
0000000678E
Piston Ring Tool

Code No : 07909-32121
Application : Use exclusively for removing or installing the
piston ring with ease.
0000000679E
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 (7) Adaptor F
(2) L Joint (8) Adaptor G
(3) Adaptor A (9) Adaptor H
(4) Adaptor B (10) Adaptor I
(5) Adaptor C (11) Adaptor J
(6) Adaptor E
0000000680E

G-50
GZD15, WSM GENERAL
Oil Pressure Tester

Code No : 07916-32032
Application : Use to measure lubricating oil pressure.
(1) Gauge (5) Adaptor 2
(2) Cable (6) Adaptor 3
(3) Threaded Joint (7) Adaptor 4
(4) Adaptor 1 (8) Adaptor 5
0000000681E
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.) 38.0 mm (1.496 in.)
31.6 mm (1.244 in.) 41.3 mm (1.626 in.)
35.0 mm (1.378 in.) 50.8 mm (2.000 in.)
0000000682E
Radiator Tester
Code No : 07909-31551
Application : Use to check of radiator cap pressure, and leaks
from cooling system.
Remarks : Adaptor (1) BANZAI Code No. RCT-2A-30S.
0000000815E
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 (2.56 to 11.81 in.)
0000000684E

G-51
GZD15, WSM GENERAL
Flywheel Puller
Code No : 07916-32011
Application : Use to loosen and tighten the flywheel screw.
0000001473E
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 , 0 to 7000 psi)
0000000685E
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.)
0000000686E
Red Check
Code No : 07909-31371
Application : Use to check cracks on cylinder head, cylinder
block, etc..
0000000687E

G-52
GZD15, WSM GENERAL
A 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.)
B 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. (0.263 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.)
0000001474E

G-53
GZD15, WSM GENERAL
Injection Pump Pressure Tester

Application : Use to check fuel tightness of injection pumps.
Pressure gauge full scale : More than 29.4 MPa (300 , 4267
A
psi)
B Copper gasket
C Flange (Material : Steel)
D Hex. nut 27 mm (1.06 in.) across the plat
E Injection Pipe
F PF 1/2
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 to11.99 mm dia. (0.4713 to 0.4721 in.dia.)
P PF 1/2
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 x P1.5
a Adhesive application
b Fillet welding on the enter circumference
0000000693E

G-54
GZD15, WSM GENERAL
Bushing Replacing Tools

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 (0.7835 to 0.7854 in.)
E 21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)
F 25 mm (0.79 in.)
a 6.3 (250 .)
b 6.3 (250 .)
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 dia. (0.8622 to 0.8642 in. dia.)
F 25 mm (0.98 in.)
a 6.3 (250 .)
b 6.3 (250 .)
0000001476E
Crankshaft Bearing 1 Replacing Tool
Application : Use to press out and press fit the crankshaft
bearing 1.
[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. (2.68 in. dia.)
H 39.90 to 39.95 mm dia. (1.5709 to 1.5728 in. dia.)
0000001477E

G-55
GZD15, WSM GENERAL
[2] SPECIAL TOOLS FOR MACHINE

Relief Valve Pressure Tester
Code No : 07916-50045
Application : This allows easy measurement of relief set
pressure.
(1) Gauge (07916-50322) (6) Adaptor C (PS3/8)
(2) Cable (07916-50331) (07916-50371)
(3) Threaded Joint (7) Adaptor D (PT1/8)
(07916-50401) (07916-50381)
(4) Threaded Joint (8) Adaptor E (PS3/8)
(07916-50341) (07916-50392)
(5) Adaptor B (M18 x P1.5) (9) Adaptor F (PF1/2)
(07916-50361) (07916-62601)
(10) Adaptor 58 (PT1/4)
(07916-52391)
0000000705E

G-56
1 ENGINE

CONTENTS
1. ENGINE BODY .................................................................................................................1-M1
[1] HALF-FLOATING HEAD COVER ..................................................................................1-M1
[2] GEAR CASE ...................................................................................................................1-M1
[3] OIL PAN..........................................................................................................................1-M2
2. LUBRICATING SYSTEM ..................................................................................................1-M3
3. COOLING SYSTEM .........................................................................................................1-M4
4. FUEL SYSTEM.................................................................................................................1-M5
[1] FUEL LINE ......................................................................................................................1-M5

GZD15, WSM ENGINE
1. ENGINE BODY
[1] HALF-FLOATING HEAD COVER
The rubber packing is fitting in to maintain the head
cover 0.5 mm or so off the cylinder head. This
arrangement helps reduce noise coming from the
cylinder head.
(1) Cylinder Head Cover (2) Rubber Packing
0000005017E
[2] GEAR CASE

The engine has a gear case where the cooling fins are
set up around the oil passage. Therefore, the
temperature of engine oil is decreased by the wind
generated by the cooling fan.
(1) Cooling Fins
0000005018E

1-M1
GZD15, WSM ENGINE
[3] OIL PAN

The oil pan is expanded under the gear case.
Therefore, the height of the engine can be lowered more
than so far while securing a necessary amount of oil.
(1) Gear Case (3) Crank Case
(2) Oil Pan
0000005019E

1-M2
GZD15, WSM ENGINE
2. LUBRICATING SYSTEM
(1) Rocker Arm
(2) Oil Pressure Switch
(3) Rocker Arm Shaft
(4) Valve
(5) Idle Gear
(6) Crankshaft
(7) Oil Pump
(8) Oil Strainer
(9) Relief Valve
(10) Push Rod
(11) Tappet
(12) Camshaft
(13) Piston
(14) Connecting Rod
(15) Oil Filter Cartridge
This engine's lubricating system consists of oil strainer (8), oil pump (7), relief valve (9), oil filter cartridge (15) and
oil pressure switch (2).
The oil pump sucks lubricating oil from the oil pan through the oil strainer and the oil flows down to the filter
cartridge, where it is further filtered. Then the oil is forced to crankshaft (6), connecting rods (14), idle gear (5),
camshaft (12) and rocker arm shaft (3) to lubricate each part.
Some part of oil, splashed by the crankshaft or leaking and dropping from gaps of each part, lubricates these parts:
piston (13), cylinders, small ends or connecting rods, tappets (11), push rods (10), inlet and exhaust valves (4) and
timing gears.
0000000937E

1-M3
GZD15, WSM ENGINE
3. COOLING SYSTEM
(1) Radiator
(2) Water Pump
(3) Cooling Fan
(4) Thermostat
(5) Cylinder Head
(6) Cylinder Block
The cooling system consists of a radiator (1), a centrifugal water pump (2), a cooling fan (3) and a thermostat (4).
The coolant is cooled through the radiator core, and the cooling fan (3) set behind the radiator (1) pushes cooling
air through the radiator core to improve cooling.
The water pump receives water from the radiator or from the cylinder head and force it into the cylinder block.
The thermostat opens or closes according to the water temperature. When the water temperature is high, the
thermostat opens to allow the water to flow from the cylinder head to the radiator. When the water temperature is
low, the thermostat close to flow the water only to the water pump.
0000000938E

1-M4
GZD15, WSM ENGINE
4. FUEL SYSTEM
[1] FUEL LINE
(1) Injection Nozzle

(2) Fuel Overflow Pipe
(3) Fuel Tank
(4) Fuel Filter
(5) Fuel Feed Pump
(6) Fuel Filter
(7) Injection Pump
(8) Injection Pipe
Fuel from the fuel tank (3) passes through the fuel filter (4), and then enters the injection pump (7) after impurities
such as dirt, water, etc. are removed.
The fuel pressurized by the injection pump to the opening pressure (13.73 to 14.71 MPa, 140 to 150 , 1990
to 2133 psi), of the injection nozzle (1) is injected into the combustion chamber.
Part of the fuel fed to the injection nozzle (1) lubricates the moving parts of the needle valve inside the nozzle, then
returns to the fuel tank through the fuel overflow pipe (2) from the upper part of the nozzle holder.
0000000939E

1-M5
CONTENTS
1. TROUBLESHOOTING....................................................................................................... 1-S1
2. SERVICING SPECIFICATIONS ....................................................................................... 1-S4
3. TIGHTENING TORQUES ................................................................................................. 1-S9
4. CHECKING, DISASSEMBLING AND SERVICING ...................................................... 1-S10
[1] SEPARATING ENGINE ................................................................................................ 1-S10
(1) Draining Coolant and Engine Oil ........................................................................... 1-S10
[2] ENGINE BODY ............................................................................................................. 1-S16
(1) Checking and Adjusting......................................................................................... 1-S16
(2) Disassembling and Assembling............................................................................. 1-S19
(3) Servicing................................................................................................................ 1-S32
[3] LUBRICATING SYSTEM .............................................................................................. 1-S50
(1) Checking................................................................................................................ 1-S50
(2) Servicing................................................................................................................ 1-S51
[4] COOLING SYSTEM...................................................................................................... 1-S52
[5] FUEL SYSTEM ............................................................................................................. 1-S55

GZD15, WSM ENGINE
1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
Engine Does Not Start A No fuel Replenish fuel G-15
A Air in the fuel system Bleed G-42
A Water in the fuel system Change fuel and G-30, 42
repair or replace fuel
system
A Fuel pipe clogged Clean G-30
A Fuel filter clogged Change G-36
A Excessively high viscosity of fuel or engine oil Use specified fuel G-7
at low temperature or engine oil
A Fuel with low cetane number Use specified G-7
fuel
A Fuel leak due to loose injection pipe retaining Tighten retaining nut 1-S24
nut
A Incorrect injection timing Adjust 1-S56
A Fuel camshaft worn Replace
A Injection nozzle clogged Repair or replace 1-S59
A Injection pump malfunctioning Replace
A Seizure of crankshaft, camshaft, piston, Repair or replace
cylinder or bearing
A Compression leak from cylinder Replace head gasket, 1-S16
tighten cylinder head
screw, glow plug and
nozzle holder
A Improper valve timing Correct or replace 1-S25
timing gear
A Piston ring and cylinder worn Replace 1-S42, S49
A Excessive valve clearance Adjust 1-S18
(Starter Does Not A Battery discharged Charge G-32, 33
Run)
A Starter malfunctioning Repair or replace 5-S13 to S15
A Main switch malfunctioning Repair or replace
A Safety switches malfunctioning Adjust or replace 5-S10 to S11
A Wiring disconnected Connect

1-S1
GZD15, WSM ENGINE
Reference
Page
Engine Revolution Is A Fuel filter clogged or dirty Replace G-36
Not Smooth
A Air cleaner clogged Clean or replace G-26, 36
A Fuel leak due to loose injection pipe retaining Tighten retaining nut 1-S24
nut
A Injection pump malfunctioning Replace
A Incorrect nozzle injection pressure Adjust 1-S59
A Injection nozzle stuck or clogged Repair or replace 1-S59
A Governor malfunctioning Repair
Either White or Blue A Excessive engine oil Reduce to specified G-19
Exhaust Gas Is level
Observed
A Piston ring and cylinder worn or stuck Repair or replace 1-S42, S49
A Deficient compression Adjust top clearance 1-S17
Either Black or Dark A Overload Reduce the load
Gray Exhaust Gas Is
A Low grade fuel used Use specified fuel G-7
Observed
A Fuel filter clogged Replace G-36
A Air cleaner clogged Clean or replace G-26, 36
A Deficient nozzle injection Repair or replace 1-S59
nozzle
Deficient Output A Incorrect injection timing Adjust 1-S56
A Engine's moving parts seem to be seizing Repair or replace
A Uneven fuel injection Replace injection
pump
nozzle
A Compression leak Replace head gasket, 1-S16, S21,
tighten cylinder head S22
screw, glow plug and
nozzle holder
Excessive Lubricant A Piston ring's gap facing the same direction Shift ring gap 1-S28
Oil Consumption direction
A Oil ring worn or stuck Replace 1-S42
A Piston ring groove worn Replace piston 1-S42
A Valve stem and valve guide worn Replace 1-S33
A Oil leaking due to defective seals or packing Replace
Fuel Mixed into A Injection pump's plunger worn Replace injection
Lubricant Oil pump
nozzle
A Injection pump broken Replace

1-S2
GZD15, WSM ENGINE
Reference
Page
Water Mixed into A Head gasket defective Replace
Lubricant Oil
A Cylinder block or cylinder head flawed Replace
Low Oil Pressure A Engine oil insufficient Replenish
A Oil strainer clogged Clean
A Oil filter cartridge clogged Replace G-20
A Relief valve stuck with dirt Clean
A Relief valve spring weaken or broken Replace
A Excessive oil clearance of crankshaft bearing Replace 1-S46 to S48
A Excessive oil clearance of crankpin bearing Replace 1-S45
A Excessive oil clearance of rocker arm Replace 1-S4
A Oil passage clogged Clean
A Different type of oil Use specified type of G-7
oil
A Oil pump defective Repair or replace 1-S50, S51
High Oil Pressure A Different type of oil Use specified type of G-7
oil
A Relief valve defective Replace
Engine Overheated A Engine oil insufficient Replenish G-7
A Fan belt broken or tensioned improperly Replace or adjust G-31, 1-S52
A Coolant insufficient Replenish G-7
A Radiator net and radiator fin clogged with dust Clean
A Inside of radiator corroded Clean or replace G-37
A Coolant flow route corroded Clean or replace G-35, 37
A Radiator cap defective Replace 1-S53
A Radiator hose damaged Replace G-35
A Overload running Reduce the load
A Head gasket defective Replace
A Unsuitable fuel used Use specified fuel G-7
0000001479E

1-S3
GZD15, WSM ENGINE
2. SERVICING SPECIFICATIONS
ENGINE BODY
Item Factory Specification Allowable Limit
Compression Pressure 3.53 to 4.02 MPa 2.55 MPa
36.0 to 41.0 26.0
512 to 583 psi 370 psi
Variance Among
10 % or less
Cylinder
Top Clearance 0.50 to 0.70 mm
0.0197 to 0.0276 in.
Valve Clearance (Cold) 0.145 to 0.185 mm
0.00571 to 0.00728 in.
Cylinder Head Surface Flatness 0.05 mm
0.0020 in.
Valve Recessing (Intake and Exhaust) -0.10 to 0.10 mm 0.30 mm
-0.0039 to 0.0039 in. 0.0118 in.
Valve Stem to Valve Guide Clearance 0.030 to 0.057 mm 0.10 mm
0.00118 to 0.00224 in. 0.0039 in.
Valve Stem 5.968 to 5.980 mm
(O.D.) 0.23496 to 0.23543 in.
Valve Guide 6.010 to 6.025 mm
(I.D.) 0.23661 to 0.23720 in.
Valve Face Angle 0.785 rad.
45
Valve Seat Angle 0.785 rad.
45
Width 2.12 mm
0.0835 in.
Valve Spring Free Length 31.3 to 31.8 mm 28.4 mm
1.232 to 1.252 in. 1.118 in.
Tilt 1.2 mm
0.047 in.
Setting Load / 64.7 N / 27.0 mm 54.9 N / 27.0 mm
Setting Length 6.6 kgf / 27.0 mm 5.6 kgf / 27.0 mm
14.6 lbs / 1.063 in. 12.3 lbs / 1.063 in.
Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.045 mm 0.15 mm
0.00063 to 0.00177 in. 0.0059 in.
Rocker Arm Shaft 10.473 to 10.484 mm
(O.D.) 0.41232 to 0.41276 in.
Rocker Arm 10.500 to 10.518 mm
(I.D.) 0.41339 to 0.41410 in.
0000001400E

1-S4
GZD15, WSM ENGINE
ENGINE BODY (Continued)

Push Rod Alignment 0.25 mm
0.0098 in.
Tappet to Tappet Guide Bore Oil Clearance 0.016 to 0.052 mm 0.10 mm
0.00063 to 0.00205 in. 0.0039 in.
Tappet 17.966 to 17.984 mm
(O.D.) 0.70732 to 0.70803 in.
Tappet Guide Bore 18.000 to 18.018 mm
(I.D.) 0.70866 to 0.70937 in.
Timing Gear Crank Gear to Idle 0.043 to 0.124 mm 0.15 mm
Gear (Backlash) 0.00169 to 0.00488 in. 0.0059 in.
Idle Gear to Cam 0.047 to 0.123 mm 0.15 mm
Gear (Backlash) 0.00185 to 0.00484 in. 0.0059 in.
Idle Gear to
0.046 to 0.124 mm 0.15 mm
Injection Pump
0.00181 to 0.00488 in. 0.0059 in.
Gear (Backlash)
Crank Gear to Oil
0.041 to 0.123 mm 0.15 mm
Pump Drive Gear
0.00161 to 0.00484 in. 0.0059 in.
(Backlash)
Idle Gear Side Clearance 0.20 to 0.51 mm 0.80 mm
0.0079 to 0.0201 in. 0.0315 in.
Camshaft Side Clearance 0.15 to 0.31 mm 0.50 mm
0.0059 to 0.0122 in. 0.0197 in.
Alignment 0.01 mm
0.0004 in.
Cam Height (Intake 26.88 mm 26.83 mm
and Exhaust) 1.0583 in. 1.0563 in.
Camshaft Journal to Cylinder Block Bore Oil Clearance 0.050 to 0.091 mm 0.15 mm
0.00197 to 0.00358 in. 0.0059 in.
Camshaft Journal 32.934 to 32.950 mm
(O.D.) 1.29661 to 1.29724 in.
Cylinder Block Bore 33.000 to 33.025 mm
(I.D.) 1.29921 to 1.30020 in.
Idle Gear Shaft to Idle Gear Bushing Oil Clearance 0.020 to 0.084 mm 0.10 mm
0.00079 to 0.00331 in. 0.0039 in.
Idle Gear Shaft 19.967 to 19.980 mm
(O.D.) 0.78610 to 0.78661 in.
Idle Gear Bushing 20.000 to 20.051 mm
(I.D.) 0.78740 to 0.78941 in.
0000001401E

1-S5
GZD15, WSM ENGINE

Piston Pin Bore I.D. 20.000 to 20.013 mm 20.05 mm
0.78740 to 0.78791 in. 0.7894 in.
Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.038 mm 0.10 mm
0.00055 to 0.00150 in. 0.0039 in.
Piston Pin 20.002 to 20.011 mm
(O.D.) 0.78748 to 0.78783 in.
Small End Bushing 20.025 to 20.040 mm
(I.D.) 0.78839 to 0.78897 in.
Piston Pin to Small End Bushing Oil Clearance 0.015 to 0.075 mm 0.15 mm
(Spare Parts) 0.00059 to 0.00295 in. 0.0059 in.
Small End Bushing 20.026 to 20.077 mm
(I.D.) 0.78845 to 0.79043 in.
Piston Ring Gap Top Ring 0.20 to 0.35 mm 1.25 mm
0.0079 to 0.0138 in. 0.0492 in.
Second Ring 0.35 to 0.50 mm 1.25 mm
0.0138 to 0.0197 in. 0.0492 in.
Oil Ring 0.20 to 0.35 mm 1.25 mm
0.0079 to 0.0138 in. 0.0492 in.
Piston Ring to Piston Ring Groove Second Ring 0.090 to 0.120 mm 0.15 mm
(Clearance) 0.00354 to 0.00472 in. 0.0059 in.
Oil Ring 0.04 to 0.08 mm 0.15 mm
(Clearance) 0.0016 to 0.0031 in. 0.0059 in.
Connecting Rod Alignment 0.05 mm
0.0020 in.
Crankshaft Side Clearance 0.15 to 0.31 mm 0.50 mm
0.0059 to 0.0122 in. 0.0197 in.
Alignment 0.02 mm
0.0008 in.
Crankpin to Crankpin Bearing Oil Clearance 0.020 to 0.051 mm 0.15 mm
0.00079 to 0.00201 in. 0.0059 in.
Crankpin 33.959 to 33.975 mm
(O.D.) 1.33697 to 1.33760 in.
Crankpin Bearing 33.995 to 34.010 mm
(I.D.) 1.33893 to 1.33898 in.
0000001402E

1-S6
GZD15, WSM ENGINE

Crankshaft Journal to Crankshaft Bearing 1 Oil Clearance 0.034 to 0.106 mm 0.20 mm
0.00134 to 0.00417 in. 0.0079 in.
Crankshaft Journal 43.934 to 43.950 mm
(O.D.) 1.72968 to 1.73031 in.
Crankshaft Bearing 43.984 to 44.040 mm
1 (I.D.) 1.73165 to 1.73386 in.
(Flywheel Side) 0.00110 to 0.00232 in. 0.0079 in.
(O.D.) 1.72968 to 1.73031 in.
2 (I.D.) 1.73142 to 1.73201 in.
(Intermediate) 0.00110 to 0.00232 in. 0.0079 in.
(O.D.) 1.72968 to 1.73031 in.
3 (I.D.) 1.73142 to 1.73201 in.
Cylinder Liner I.D. 72.000 to 72.019 mm 72.169 mm
[Standard] 2.83464 to 2.83539 in. 2.84129 in.
Cylinder Liner I.D. 72.500 to 72.519 mm 72.669 mm
[Oversize : 0.25 mm (0.0098 in.)] 2.85433 to 2.85507 in. 2.86098 in.
0000001403E
LUBRICATING SYSTEM
Engine Oil Pressure At Idle Speed More than 49 kPa
0.5
7 psi
At Rated Speed 196 to 441 kPa 147 kPa
2.0 to 4.5 1.5
28 to 64 psi 21 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 Clearance 0.075 to 0.135 mm
0.00295 to 0.00531 in.
0000001404E

1-S7
GZD15, WSM ENGINE
COOLING SYSTEM
Fan Belt Tension Approx. 10 mm / 98 N
0.4 in. / 98 N
(10 kgf, 22 lbs)
Thermostat Valve Opening
69.5 to 72.5
Temperature
157.1 to 162.5
(At Beginning)
Valve Opening
85
Temperature
185
(Opened Completely)
Radiator Cap Pressure Falling Time 10 seconds or more
88 59 kPa
0.9 0.6
13 9 psi
Radiator Weak Leakage Test No leaks at specified
Pressure pressure
157 kPa
1.6
23 psi
0000001405E
FUEL SYSTEM
Injection Pump Injection Timing 0.30 to 0.33 rad.
(17 to 19 )
before T.D.C.
Pump Element Fuel Tightness 13.7 MPa
140
1990 psi
Delivery Valve Fuel Tightness 10 seconds 5 seconds
13.7 12.7 MPa 13.7 12.7 MPa
140 130 140 130
1990 1849 psi 1990 1849 psi
Fuel Injection Nozzle Injection Pressure 13.73 to 14.71 MPa
140 to 150
1991 to 2134 psi
Valve Seat When the pressure is
Tightness 12.75 MPa
(130 , 1849 psi),
the valve seat must be
fuel tightness
0000001406E

1-S8
GZD15, WSM ENGINE
Tightening torques of screws and nuts on the table below are especially specified.
(For general use screws and nuts : See page G-9.)
Item Size x Pitch ft-lbs
Under cover mounting screw and nut M6 x 1 7.8 to 8.8 0.8 to 0.9 5.8 to 6.5
Front coupling mounting screw M8 x 1.25 23.5 to 27.4 2.4 to 2.8 17.3 to 20.2
Engine mounting nut M8 x 1.25 23.5 2.4 17.3
Cushion mounting nut M8 x 1.25 23.5 2.4 17.3
Air cleaner stay screw M8 x 1.25 23.5 to 27.4 2.4 to 2.8 17.4 to 20.3
Engine support screw M10 x 1.25 48.0 to 55.9 4.9 to 5.7 35.4 to 41.2
*Cylinder head cover screw M6 x 1 6.86 to 11.3 0.7 to 1.15 5.1 to 8.3
Injection pipe retaining nut M12 x 1.5 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3
Overflow pipe retaining nut M12 x 1.5 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1
Nozzle holder assembly M20 x 1.5 49.0 to 68.6 5.0 to 7.0 36.2 to 50.6
Glow plug M8 x 1 7.85 to 14.7 0.8 to 1.5 5.8 to 10.8
*Rocker arm bracket screw M6 x 1 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3
*Cylinder head screw M8 x 1.25 37.3 to 42.2 3.8 to 4.3 27.5 to 31.1
*Fan drive pulley screw M12 x 1.5 98.0 to 107.8 10.0 to 11.0 72.3 to 79.5
*Idle gear shaft mounting screw M6 x 1 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3
*Connecting rod screw M7 x 0.75 26.5 to 30.4 2.7 to 3.1 19.5 to 22.4
*Flywheel screw M10 x 1.25 53.9 to 58.8 5.5 to 6.0 39.8 to 43.4
Bearing case cover mounting screw M6 x 1 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3
*Main bearing case screw 2 M7 x 1 26.5 to 30.4 2.7 to 3.1 19.5 to 22.5
*Main bearing case screw 1 M6 x 1 12.7 to 15.7 1.3 to 1.6 9.37 to 11.6
Nozzle holder - 34.3 to 39.2 3.5 to 4.0 25.3 to 28.9
Oil pressure switch PT 1/8 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5
A In removing and applying the screws and nuts marked with "*", a pneumatic wrench or similar
pneumatic tool, if employed, must be used with enough care not to get them seized.
A For "*" marked screws and nuts on the table, apply engine oil to their threads and seats before
tightening.
A The letter "M" in Size x Pitch means that the screw 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.
0000001698E

1-S9
GZD15, WSM ENGINE
4. CHECKING, DISASSEMBLING AND SERVICING

[1] SEPARATING ENGINE
(1) Draining Coolant and Engine Oil
Draining Coolant
A Never open the radiator cap while operating or

immediately 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. Open the radiator drain plug (2), and remove radiator cap to
completely drain the coolant.
2. After all coolant is drained, clamp the drain plug.
(When refilling coolant)
1. Fill with coolant up to the "FULL" mark on the recovery tank
(3).
2. Start and operate the engine for a few minutes.
3. Stop the engine and let cool.
4. Check coolant level of recovery tank (3) and add coolant if
necessary.
1.65 L
Capacity (with
Coolant 1.76 U.S.qts.
recovery tank)
1.42 Imp.qts.
(1) Clamp (3) Recovery Tank

(2) Drain Plug
0000001480E
Draining Engine Oil
1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine.
3. Remove the drain plug (1) to drain oil.
4. After draining, screw in the drain plug (1).
(When refilling)
A Fill the engine oil up to the upper line on the dipstick (3).
A Never mix two different type of oil.

A Use the proper SAE Engine Oil according to ambient
temperature.
Refer to "LUBRICANTS, FUEL AND COOLANT". (See
page G-7.)
2.1 L
Engine Oil Capacity 2.20 U.S.qts.
1.85 Imp.qts.
(1) Drain Plug (3) Dipstick

(2) Oil Inlet Plug
0000001481E

1-S10
GZD15, WSM ENGINE
Battery
A When disconnecting the battery cables, disconnect the

negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
1. Disconnect the negative cable (2) from the battery (1).
2. Disconnect the positive cable (3) from the battery (1).
(1) Battery (3) Positive Cable
(2) Negative Cable
0000001482E
Under Cover
1. Remove the right and the left under cover (1).
(1) Under Cover (2) Bonnet
0000001483E
Bonnet
1. Remove the bonnet (1).
(When reassembling)
7.8 to 8.8
Tightening torque Bonnet mounting screw 0.8 to 0.9
5.8 to 6.5 ft-lbs
(1) Bonnet (2) Bonnet Mounting Screw
0000001484E
Grass Collector Base

1. Disconnect the grass collector dump cylinder hoses on right
side.
2. Remove the pins (2) on both sides.
3. Separate the grass collector base (1).
(1) Grass Collector Base (2) Pin
0000001668E

1-S11
GZD15, WSM ENGINE
Seat, Rear Floor Cover and Radiator Shutter Plate

1. Remove the seat (1) with seat stay (2).
2. Remove the front radiator net (3).
3. Remove the screw (4) and rear floor cover (3).
4. Remove the screw.
5. Disconnect the radiator shutter plate (6) from the machine.
(1) Seat (4) Rear Floor Cover
(2) Seat Stay (5) Screw
(3) Front Radiator Net (6) Radiator Shutter Plate
0000001669E

1-S12
GZD15, WSM ENGINE
Wiring Harness and Accelerating Wire

1. Disconnect the wiring harness, connector and clamps shown
in the picture.
2. Before disconnecting accelerating wire, check the length "L"
shown in the picture.
3. Disconnect the accelerating wire from the engine.
(When reassembling)
1. Adjust the length "L" of accelerating wire.
2. Lock the nut securely.
(1) Pin (7) ST Terminal
(2) Nut (8) B Terminal
(3) Stop Solenoid Connector (9) Plastic Clamp
(4) Glow Plug Terminal Nut (11) Accelerating Wire
(5) Thermo Sensor
(6) Oil Switch L: Length
0000001670E
Fuel Hoses
1. Disconnect the overflow hose (1).
2. Disconnect the fuel hose (3).
(1) Overflow Hose (3) Fuel Hose
(2) Fuel Filter
0000001671E

1-S13
GZD15, WSM ENGINE
Front Coupling
1. Remove the front coupling mounting screws (1).
2. Disconnect the front coupling (2) from engine.
(When reassembling)
23.5 to 27.4
Front coupling mounting
Tightening torque 2.4 to 2.8
screw
17.4 to 20.3 ft-lbs
(1) Screw (2) Front Coupling
0000001672E
Engine Mounting Supports

1. Hang and support the engine with chain block.
2. Remove the engine mounting support screws (1).
3. Disconnect the left and the right engine mounting support from
the engine.
(When reassembling)
31.4 to 34.3
Engine mounting
support screw
23.1 to 25.3 ft-lbs
(1) Screw (2) Engine Mounting Support
0000001673E

1-S14
GZD15, WSM ENGINE
Engine Assembly
1. Lift and separate the engine assembly (1) from the machine
body.
2. Attach the engine stands for safety.
(When reassembling the engine)
1. Connect the front coupling (2).
2. Check the wiring harness (3) and fuel pipes (4), and
accelerating wire (5) as shown in picture.
3. Check the hydraulic oil cooler (6) as shown in picture.
(1) Engine Assembly (4) Fuel Pipe
(2) Front Coupling (5) Accelerating Wire
(3) Wiring Harness (6) Hydraulic Oil Cooler
0000001674E

1-S15
GZD15, WSM ENGINE
[2] ENGINE BODY

(1) Checking and Adjusting
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. Engage the parking brake.
6. Set a compression tester (Code No. 07909-30208) with the
adaptor (Adaptor H, code No. 07909-31231) to the nozzle
hole.
7. While cranking the engine with the starter, measure the
compression pressure.
8. Repeat steps 6 and 7 for each cylinder.
9. If the measurement 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.
10. If the compression pressure is still less than the allowable limit,
check the top clearance, valve clearance and cylinder head.
11. If the compression pressure increases after applying oil, check
the cylinder wall and piston rings.
A Check the compression pressure with the specified valve

clearance.
A Always use a fully charged battery for performing this
test.
A Variances in cylinder compression values should be
under 10 %.
3.53 to 4.02 MPa
Factory spec. 36 to 41
512 to 583 psi
Compression pressure
2.55 MPa
Allowable limit 26
370 psi
0000001485E

1-S16
GZD15, WSM ENGINE
Top Clearance
1. Remove the cylinder head. (Do not attempt to remove the
cylinder head gasket.).
2. Move the piston up, and stick a strip of fuse [1.5 mm dia.
(0.059 in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the
piston head at three positions with grease so as to avoid the
intake and exhaust valves and the combustion chamber ports.
3. Lower the piston, and install the cylinder head and tighten the
cylinder head screws to the specified torque.
4. Turn the flywheel until the piston exceeds its top dead centre.
5. Remove the cylinder head, and measure the thickness of the
squeezed fuses.
check the oil clearance between the crankpin and crankpin
bearing and between the piston pin and small end bushing.
A After checking the top clearance, be sure to assemble the

cylinder head with a new cylinder head gasket.
0.50 to 0.70 mm
Top clearance Factory spec.
0.0197 to 0.0276 in.
37.3 to 42.2
Tightening torque Cylinder head screw 3.8 to 4.3
27.5 to 31.1 ft-lbs
(1) Fuse
0000001683E

1-S17
GZD15, WSM ENGINE
Valve Clearance
A The valve clearance must be checked and adjusted when

engine is cold.
1. Remove the cylinder head cover (1) and the glow plugs.
2. Align the "1TC" mark (2) on the flywheel and alignment
marking plate (3) so that the No. 1 piston comes to the
compression top dead centre.
3. Check the following valve clearance marked with " " using a
thickness gauge.
[When No.1 piston is at the compression top dead centre
position]
Cylinder No. No.1 No.2
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 (2) on the flywheel and alignment marking plate (3) on
the rear end plate so that the No.1 piston comes to the overlap
position.
6. Check the following valve clearance marked with " " using a
thickness gauge.
[When No.1 piston is at the overlap position]

Cylinder No. No.1 No.2
Intake valve
Exhaust valve
7. If the clearance is not within the factory specifications, adjust

with the adjusting screw.
Intake and exhaust 0.145 to 0.185 mm
Factory spec.
valve clearance (Cold) 0.00571 to 0.00728 in.
A The sequence of cylinder numbers is given as No.1 and

No.2 starting from the gear case side.
A After adjusting the valve clearance, secure the adjusting
screw with the lock nut.
(1) Cylinder Head Cover A: Gear Case Side
(2) "1TC" Mark 1: No.1 Cylinder
(3) Alignment Marking Plate 2: No.2 Cylinder
0000001486E

1-S18
GZD15, WSM ENGINE
(2) Disassembling and Assembling
(A) Cylinder Head, Valves and Oil Pan

Radiator, Dynamo, Fan Belt and Muffler
1. Disconnect the radiator hoses and separate the radiator (1)
with recovery tank (2) from engine assembly.
2. Remove the cooling fan (9) and fan pulley.
3. Remove the dynamo (3) and fan belt (4).
4. Remove the muffler (5).
5. Remove the starter (6).
6. Disconnect the inlet pipe (7), air cleaner (8).
7. Remove the stop solenoid (10).
(When reassembling)
A Check to see that there are no cracks on the fan belt surface.
A After reassembling the fan belt, be sure to adjust the fan

belt tension.
48.0 to 55.9
Tightening torque Muffler 4.9 to 5.7
35.4 to 41.2 ft-lbs
(1) Radiator (6) Starter

(2) Recovery Tank (7) Inlet Pipe
(3) Dynamo (8) Air Cleaner
(4) Fan Belt (9) Cooling Fan
(5) Muffler (10) Stop Solenoid
0000001487E
Cylinder Head Cover
1. Remove the head cover screws (1).
2. Remove the cylinder head cover (2).
(When reassembling)
A Check to see if the cylinder head cover gasket is not defective.
6.86 to 11.3
Cylinder head cover
screw
5.1 to 8.3 ft-lbs
(1) Head Cover Screws (2) Cylinder Head Cover
0000001488E
Injection Pipes
1. Loosen the screw on the pipe clamp (1).
2. Detach the injection pipes (2).
(When reassembling)
A Sent compressed air into the pipes to blow out dust. Then,
reassemble the pipes in the reverse order.
24.5 to 34.3
Injection pipe retaining
nut
18.1 to 25.3 ft-lbs
(1) Pipe Clamp (2) Injection Pipe
0000001490E

1-S19
GZD15, WSM ENGINE
Nozzle Holder Assembly and Glow Plug

1. Remove the overflow pipe (1).
2. Remove the nozzle holder assemblies (2).
3. Remove the copper gasket (5) and the heat seal (6).
4. Remove the lead (3) from the glow plugs (4).
5. Remove the glow plugs (4).
(When reassembling)
A Replace the copper gasket and heat seal with new one.
19.6 to 24.5
Overflow pipe retaining
2.0 to 2.5
nut
14.5 to 18.1 ft-lbs
49.0 to 68.6
Tightening torque Nozzle holder assembly 5.0 to 7.0
36.2 to 50.6 ft-lbs
7.85 to 14.7
Glow plug 0.8 to 1.5
5.8 to 10.8 ft-lbs
(1) Overflow Pipe (4) Glow Plug

(2) Nozzle Holder Assembly (5) Copper Gasket
(3) Lead (6) Heat Seal
0000001489E
Rocker Arm and Push Rod
1. Remove the rocker arm bracket screws (1).
2. Detach the rocker arm assembly (2).
3. Remove the push rods (3).
(When reassembling)
A When putting the push rods (3) onto the tappets (4), check to
see if their ends are properly engaged with the dimples.
A After installing the rocker arm, be sure to adjust the valve

clearance.
9.8 to 11.3
Rocker arm bracket
screw
7.2 to 8.3 ft-lbs
(1) Rocker Arm Bracket screws (3) Push Rod

(2) Rocker Arm Assembly (4) Tappet
0000001491E

1-S20
GZD15, WSM ENGINE
Cylinder Head
1. Loosen the pipe clamp, and remove the water return pipe.
2. Remove the cylinder head screw in the order of (j) to (a).
3. Lift up the cylinder head to detach.
4. Remove the cylinder head gasket and O-ring (1).
(When reassembling)
A Replace the cylinder head gasket with a new one.
A Securely fit the O-ring (1) to the pipe pin.
A Tighten the cylinder head screws after applying sufficient oil.
A Tighten the cylinder head screws diagonal sequence starting
from the centre.
A Tighten them uniformly, or the head may deform in the long
run.
A Retighten the cylinder head screws after running the engine
for 30 minutes.
37.3 to 42.2
Tightening torque Cylinder head screw 3.8 to 4.3
27.5 to 31.1 ft-lbs
(j) to (a): To Loosen (1) O-ring

(a) to (j): To Tighten
0000001684E
Tappets
1. Remove the tappets (1) from the crankcase.
(When reassembling)
A Visually check the contact between tappets and cams for
proper rotation. If defect is found, replace tappets.
A Before installing the tappets, apply engine oil thinly around
them.
A Do not change the combination of tappet and tappet

guide.
(1) Tappet
0000000854E

1-S21
GZD15, WSM ENGINE
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 spring retainer (4), valve spring (5) and
valve stem seal (6).
4. Remove the valve (7).
(When reassembling)
A Wash the valve stem seal and valve guide hole, and apply
engine oil sufficiently.
A After installing the valve spring collets, lightly tap the stem to
assure proper fit with a plastic hammer.
A Do not change the combination of valve and valve guide.

(1) Valve Spring Replacer (5) Valve Spring
(2) Valve Cap (6) Valve Stem Seal
(3) Valve Spring Collet (7) Valve
(4) Valve Spring Retainer
0000000855E

1-S22
GZD15, WSM ENGINE
Oil Pan and Oil Strainer

1. Remove the oil pan mounting screws (1).
2. Remove the oil pan (2) by lightly tapping the rim of the pan with
a wooden hammer.
3. Remove the oil strainer (3).
(When reassembling)
A After cleaning the oil strainer, check to see that the filter mesh
in clean, and install it.
A Visually check the O-ring (4), apply engine oil, and install it.
A Securely fit the O-ring to the oil strainer.
A To avoid uneven tightening, tighten oil pan mounting screws in
diagonal order from the centre.
A Using the hole (5) numbered "2", install the oil strainer by
mounting screw.
A Scrape off the old adhesive completely. Wipe the sealing

surface clean. Now apply new adhesive 3 to 5 mm (0.12 to
0.20 in.) thick all over the contact surface. Apply the
adhesive also on the centre of the flange as well as on the
inner wall of each screw hole.
A Cut the nozzle of the "liquid gasket" (Three Bond 1207D or
equivalent) container at its second notch. Apply "liquid
gasket" 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) Oil Pan Mounting Screw (4) O-ring
(2) Oil Pan (5) Hole
(3) Oil Strainer
0000001685E

1-S23
GZD15, WSM ENGINE
(B) Timing Gear, Camshaft and Fuel Camshaft

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 governor spring (4).
3. Disconnect the governor spring (4) and remove the speed
control plate (2).
(When reassembling)
A Hook the governor spring (4) to the governor lever (5) first and
install the speed control plate (2).
A Be sure to place the copper washers underneath two screws
(1). (Two screws (1) in the upper of the speed control plate
(2).)
A Position the slot (9) on the fork lever just under the slot (8) on
the crankcase.
A Insert the injection pump (3) so that the control rod (7) should
be pushed by the idling adjusting 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).
A The sealant is applied to both sides of the soft metal

gasket shim. The liquid gasket is not required for
assembling.
A Addition or reduction of shim (0.05 mm, 0.0020 in.) delays
or advances the injection timing by approx. 0.0087 rad.
(0.5 )
A In disassembling and replacing, be sure to use the same
number of new gasket shims with the same thickness.
(1) Screws and Copper Washers (6) Idling Adjusting Spring
(2) Speed Control Plate (7) Control Rod
(3) Injection Pump (8) Slot (Crankcase Side)
(4) Governor Spring (9) Slot (Fork Lever Side)
(5) Governor Lever (10) Pin
0000000858E
Fan Drive Pulley
1. Secure the flywheel to keep it from turning.
2. Remove the fan drive pulley screw.
3. Draw out the fan drive pulley with a puller.
(When reassembling)
A Install the pulley to the crankshaft, aligning the mark (1) on
them.
A Apply engine oil to the fan drive pulley retaining screws. And
tighten them.
98.0 to 107.8
Tightening torque Fan drive pulley screw 10.0 to 11.0
72.3 to 79.5 ft-lbs
(1) Alignment Mark
0000000859E

1-S24
GZD15, WSM ENGINE
Gear Case
1. Remove the screw (1) of inside the gear case and outside
screws.
2. Disconnect the start spring (2) from the fork lever 1.
3. Remove the gear case (3).
(When reassembling)
A Apply a liquid gasket (Three Bond 1215 or equivalent) to both
sides of the gear case gasket.
A Be sure to set three O-rings inside the gear case.
(1) Screw (Inside) (3) Gear Case
(2) Start Spring
0000000860E
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)
A Apply engine oil to the idle gear shaft mounting screw. And
tighten them.
A Install the idle gear, aligning the mark on the gears referring to
the figure.
9.8 to 11.3
Idle gear shaft mounting
screw
7.2 to 8.3 ft-lbs
(1) Idle Gear (3) External Snap Ring

(2) Idle Gear Collar
0000000861E

1-S25
GZD15, WSM ENGINE
Fuel Camshaft
1. Remove the screws and draw out the camshaft with the gear
on it.
2. Remove the retaining plate (1).
3. Remove the screws, then draw out the injection pump gear (3)
and fuel camshaft (2) with the governor fork assembly.
(When reassembling)
A Hook the governor spring (7) to the fork lever 2 (6) as shown
in the figure before installing the fork lever assembly to the
crankcase.
(1) Retaining Plate (5) Fork Lever 1
(2) Fuel Camshaft (6) Fork Lever 2
(3) Injection Pump Gear (7) Governor Spring
(4) Governor Sleeve
0000000862E
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 crankshaft oil slinger (2).
4. Remove the crankshaft gear (1) with a puller.
(When reassembling)
A Install the collar (4) after aligning the marks on the gear. (See
the photo at "Idle Gear".).
(1) Crankshaft Gear (4) Crankshaft Collar
(2) Crankshaft Oil Slinger (5) Oil Pump
(3) O-ring (6) Oil Pump Gear
0000000863E
(C) Piston and Connecting Rod

Connecting Rod
1. Remove the connecting rod caps (1).
(When reassembling)
A Align the marks (a) with each other. (Face the marks toward
the injection pump.).
A 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 rod screw won't be screwed in smoothly,
clean the threads.
If the connecting rod screw is still hard to screw in, replace it.
26.5 to 30.4
Tightening torque Connecting rod screw 2.7 to 3.1
19.5 to 22.4 ft-lbs
(1) Connecting Rod Cap (a) Mark
0000000865E

1-S26
GZD15, WSM ENGINE
Pistons
1. Turn the flywheel and bring the piston to top dead centre.
2. Draw out the piston upward by lightly tapping it from the
bottom of the crankcase with the grip of a hammer.
3. Draw out the other piston in the same method as above.
(When reassembling)
A Before inserting the piston into the cylinder, apply enough
engine oil to the piston.
A When inserting the piston into the cylinder, face the mark on
the connecting rod to the injection pump.
A Do not change the combination of cylinder and piston.

Make sure of the position of each piston by marking. For
example, mark "1" on the No.1 piston.
A When installing the piston into the cylinder, place the
gaps of all the piston rings as shown in the figure.
A Carefully insert the pistons using a piston ring
compressor (1). Otherwise, their chrome-plated section
may be scratched, causing trouble inside the cylinder.
(1) Piston Ring Compressor (a) 0.785 rad. (45 )
(A) Top Ring Gap (b) 0.785 rad. (45 )
(B) Second Ring Gap (c) 1.57 rad. (90 )
(C) Oil Ring Gap
(D) Piston Pin Hole
0000001686E

1-S27
GZD15, WSM ENGINE
Piston Ring and Connecting Rod

1. Remove the piston rings using a piston ring tool (Code No.
07909-32121).
2. Remove the piston pin (7), and separate the connecting rod
(6) from the piston (5).
(When reassembling)
A When installing the ring, assemble the rings so that the
manufacturer's mark (12) near the gap faces the top of the
piston.
A When installing the oil ring onto the piston, place the expander
joint (10) on the opposite side of the oil ring gap (11).
A Apply engine oil to the piston pin.
A When installing the connecting rod to the piston, immerse the
piston in 80 (176 ) oil for 10 to 15 minutes and insert the
piston pin to the piston.
A When installing the connecting rod to the piston, align the
mark (8) on the connecting rod to the fan-shaped concave (9).
A Select the connecting rod and crankpin bearing that have their
I.D. colour (A) and (B) just the same.
A Mark the same number on the connecting rod and the

piston so as not to change the combination.
(1) Top Ring (9) Fan-Shaped Concave
(2) Second Ring (10) Expander Joint
(3) Oil Ring (11) Oil Ring Gap
(4) Piston Pin Snap Ring (12) Manufacturer's Mark
(5) Piston
(6) Connecting Rod (A) Connecting Rod I.D. Colour
(7) Piston Pin :(Yellow, Brown and Blue)
(8) Mark (B) Crankpin Bearing I.D. Colour
:(Yellow, Brown and Blue)
0000001687E

1-S28
GZD15, WSM ENGINE
(D) Crankshaft
Flywheel
1. Secure the flywheel to keep it from turning.
2. Remove all flywheel screws (1) and then remove the flywheel
(2).
(When reassembling)
A Align the "1TC" mark (a) on the outer surface of the flywheel
horizontally with the alignment marking plate (b). Now fit the
flywheel in position.
A Apply engine oil to the threads and the undercut surface of the
flywheel screw and fit the screw.
53.9 to 58.8
Tightening torque Flywheel screw 5.5 to 6.0
39.8 to 43.4 ft-lbs
(1) Flywheel Screw (a) 1TC Mark

(2) Flywheel (b) Alignment Marking Plate
0000001492E
Bearing Case Cover
1. Remove the bearing case cover mounting screws. First,
remove inside screws (1) and then outside screws (2).
2. Remove the bearing case cover (6).
(When reassembling)
A Fit the bearing case gasket (3) and the bearing case cover
gasket (4) with correct directions.
A Install the bearing case cover (6) to position the casting mark
"UP" (a) on it upward.
A Apply engine oil to the oil seal (5) lip and take care that it is not
rolled when installing.
A Tighten the bearing case cover mounting screws with even
force on the diagonal line.
9.8 to 11.3
Bearing case cover
mounting screw
7.2 to 8.3 ft-lbs
(1) Bearing Case Cover Mounting (5) Oil Seal

Screw (Inside) (6) Bearing Case Cover
(2) Bearing Case Cover Mounting
Screw (Outside) (a) Top Mark "UP"
(3) Bearing Case Gasket (b) Upside
(4) Beairng Case Cover Gasket
0000000870E

1-S29
GZD15, WSM ENGINE
Crankshaft Assembly
1. Remove the main bearing case screw 2 (1).
2. Pull out the crankshaft assembly.
(When reassembling)
A Clean the oil passage of the crankshaft with compressed air.
A Apply oil to the main bearing case screw 2 (1).
A Install the crankshaft assembly, aligning the screw hole of
main bearing case with the screw hole of crankcase.
26.5 to 30.4
Main bearing case
screw 2
19.5 to 22.4 ft-lbs
(1) Main Bearing Case Screw 2
0000000871E

1-S30
GZD15, WSM ENGINE
Main Bearing Case Assembly

1. Remove the two main bearing case screws 1 (1), and remove
the main bearing case assembly 1 (2), being careful with
crankshaft bearing 3 (4) (5).
2. Remove the main bearing case assembly (3) as above. Keep
in mind, however, that the thrust bearing (8) is installed in the
main bearing case assembly (3).
(When reassembling)
A Clean the oil passage in the main bearing cases.
A Apply clean engine oil on the bearings.
A Install the main bearing case assemblies in original positions.
(Refer to the figure.)
A For the combination of the I.D. mark (b) of the main bearing
case assembly 1 (2) and the I.D. colour (c) of the crankshaft
bearing 3 (4) (5), refer to the table below.
Main Bearing case assembly I.D. mark (b) Crankshaft bearing I.D. colour (c)
S Yellow
M Brown
L Blue
A Be careful not to confuse the top and bottom of the crankshaft

bearing 3 (4) (5).
(Install the bearing with the oil groove (d) up.)
A Match the alignment numbers (a) on the main bearing case.
A Do the same for the main bearing case assembly (3) too.
A When installing the main bearing case 1, face the mark
"FLYWHEEL" to the flywheel.
A Install the thrust bearing with its oil groove facing outward.
A Confirm that the main bearing case moves smoothly after
tightening the main bearing case screw 1 to the specified
torque.
12.7 to 15.7
Main bearing case
screw 1
9.4 to 11.6 ft-lbs
(1) Main Bearing Case Screw 1 (a) Alignment Number

(2) Main Bearing Case Assembly 1 (b) I.D. Mark
(3) Main Bearing Case Assembly (c) I.D. Colour
(4) Crankshaft Bearing 3 (d) Oil Groove
(Upper, with oil groove)
(5) Crankshaft Bearing 3 (Lower)
(6) Crankshaft Bearing 2
(Upper, with oil groove)
(7) Crankshaft Bearing 2 (Lower)
(8) Thrust Bearing
0000001675E

1-S31
GZD15, WSM ENGINE
(3) Servicing
(A) Cylinder Head and Valves

Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head's four sides and two
diagonals as shown in the figure.
3. Measure the clearance with a thickness gauge.
4. If the measurement exceeds the allowable limit, correct it with
a surface grinder.
A Do not place the straightedge on the combustion

chamber.
A Be sure to check the valve recessing after correcting.
Cylinder head surface 0.05 mm
Allowable limit
flatness 0.0020 in.
0000000874E
Cylinder Head Flaw

1. Prepare an air spray red check (Code No. 07909-31371).
2. Clean the surface of the cylinder head with the detergent (2).
3. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.
4. Wash away the red permeative liquid on the cylinder head
surface with the detergent (2).
5. Spray the cylinder head surface with the white developer (3).
6. If flawed, it can be identified as red marks.
(1) Red Permetive Liquid (3) White Developer
(2) Detergent
0000000875E

1-S32
GZD15, WSM ENGINE
Valve Recessing
1. Clean the cylinder head surface, valve face and valve seat.
2. Insert the valve into the valve guide.
3. Measure the valve recessing with a depth gauge.
4. If the measurement exceeds the allowable limit, replace the
valve.
5. If it still exceeds the allowable limit after replacing the valve,
correct the valve seat face of the cylinder head with a valve
seat cutter (Code No. 07909-33102) or valve seat grinder.
6. Then, correct the cylinder head surface with a surface grinder,
or replace the cylinder head.
0.10 (protrusion) to
0.10 (recessing) mm
Factory spec.
Valve recessing (Intake 0.0039 (protrusion) to
and Exhaust) 0.0039 (recessing) in.
0.30 (recessing) mm
Allowable limit
0.0118 (recessing) in.
(1) Cylinder Head Surface (A) Recessing

(B) Protrusion
0000000876E
Clearance between Valve Stem and Valve Guide

1. Remove carbon from the valve guide section.
2. Measure the valve stem O.D. with an outside micrometer.
3. Measure the valve guide I.D. with a small hole gauge, and
calculate the clearance.
4. If the clearance exceeds the allowable limit, replace the
valves. If it still exceeds the allowable limit, replace the valve
guide.
0.030 to 0.057 mm
Clearance between Factory spec.
0.00118 to 0.00224 in.
valve stem and valve
guide 0.10 mm
Allowable limit
0.0039 in.
5.968 to 5.980 mm
Valve stem O.D. Factory spec.
0.23496 to 0.23543 in.
6.010 to 6.025 mm
Valve guide I.D. Factory spec.
0.23661 to 0.23720 in.
0000000877E

1-S33
GZD15, WSM ENGINE
Replacing Valve Guide

(When removing)
1. Press out the used valve guide using a valve guide replacing
tool.
(When installing)
1. Clean a new valve guide and valve guide bore, and apply
engine oil to them.
2. Press in a new valve guide using a valve guide replacing tool.
3. Ream precisely the I.D. of the valve guide to the specified
dimension.
Valve guide I.D. (Intake 6.010 to 6.025 mm
Factory spec.
and Exhaust) 0.2366 to 0.2372 in.
A Do not hit the valve guide with a hammer during

replacement.
(A) When removing (B) When installing
0000000878E
Valve Seating
1. Coat the valve face lightly with prussian blue and put the valve
on its seat to check the contact.
2. If the valve does not seat all the way around the valve seat or
the valve contact is less than 70 %, correct the valve seating
as follows.
3. If the valve contact does not comply with the reference value,
replace the valve or correct the contact of valve seating.
2.12 mm
Valve seat width Factory spec.
0.0835 in.
(1) Correct (3) Incorrect

(2) Incorrect
0000000879E

1-S34
GZD15, WSM ENGINE
Correcting Valve and Valve Seat
A Before correcting the valve and seat, check the valve

stem and the I.D. of valve guide section, and repair them
if necessary.
A After correcting the valve seat, be sure to check the valve
recessing.
1) Correcting Valve
1. Correct the valve with a valve refacer.
0.785 rad.
Valve face angle Factory spec.
45
2) Correcting Valve Seat

1. Slightly correct the seat surface with a 0.785 rad. (45 ) valve
seat cutter (Code No. 07909-33102).
2. Fitting the valve, check the contact position of the valve face
and seat surface with prussian blue. (Visual check) [ If the
valve has been used for a long period, the seat tends to come
in contact with the upper side of the valve face.]
3. Grind the upper surface of the seat with a 0.262 rad. (15 )
valve seat cutter until the valve seat touches to the centre of
the valve face (so that a equals b as shown in the figure)
4. Grind the seat with a 0.785 rad. (45 ) valve seat cutter again,
and visually recheck the contact between the valve and seat.
5. Repeat steps 3 and 4 until the correct contact is achieved.
6. Continue lapping until the seated rate becomes more than 70
% of the total contact area.
0.785 rad.
Valve seat angle Factory spec.
45
(a) Identical Dimensions (A) Check Contact

(b) Valve Seat Width (B) Correct Seat Width
(c) 0.262 rad. (15 ) (C) Check Contact
(d) 0.262 rad. (15 )
(e) 0.785 rad. (45 )
0000001688E
Valve Lapping
1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve onto its
seat with a valve flapper or screwdriver.
3. After lapping the valve, wash the compound away and apply
oil, then repeat valve lapping with oil.
4. Apply prussian blue to the contact surface to check the seated
rate. If it is less than 70 %, repeat valve lapping again.
A When valve lapping is performed, be sure to check the

valve recessing and adjust the valve clearance after
assembling the valve.
0000000881E

1-S35
GZD15, WSM ENGINE
Free Length and Tilt of Valve Spring

1. Measure the free length (A) of valve spring with vernier
calipers. If the measurement is less than the allowable limit,
replace it.
2. Put the valve spring on a surface plate, place a square on the
side of the valve spring.
3. Check to see if the entire side is in contact with the square.
Rotate the valve spring and measure the maximum tilt (B).
If the measurement exceeds the allowable limit, replace it.
4. Check the entire surface of the valve spring for scratches.
If there is any defect, replace it.
31.3 to 31.8 mm
Factory spec.
1.232 to 1.252 in.
Free length (A)
28.4 mm
Allowable limit
1.118 in.
1.2 mm
Tilt (B) Allowable limit
0.047 in.
(A) Free Length (B) Tilt
0000001676E
Valve Spring Setting Load
1. Place the valve spring on a tester and compress it to the same
length it is actually compressed in the engine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
64.7 N / 27.0 mm
Factory spec. 6.6 kgf / 27.0 mm
Setting load / Setting 14.6 lbs / 1.063 in.
length 54.9 N / 27.0 mm
Allowable limit 5.6 kgf / 27.0 mm
12.3 lbs / 1.063 in.
0000000883E
Oil Clearance between Rocker Arm and Rocker Arm Shaft
1. Measure the rocker arm shaft O.D. with an outside
micrometer.
2. Measure the rocker arm I.D. with an inside micrometer, and
then calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
rocker arm and measure the oil clearance again. If it still
exceeds the allowable limit, replace also the rocker arm shaft.
0.016 to 0.045 mm
Oil clearance between Factory spec.
0.00063 to 0.00177 in.
rocker arm and rocker
arm shaft 0.15 mm
Allowable limit
0.0059 in.
10.473 to 10.484 mm
Rocker arm shaft O.D. Factory spec.
0.41232 to 0.41276 in.
10.500 to 10.518 mm
Rocker arm I.D. Factory spec.
0.41339 to 0.41410 in.
0000000884E

1-S36
GZD15, WSM ENGINE
Push Rod Alignment

1. Place the push rod on V blocks.
2. Measure the push rod alignment.
push rod.
0.25 mm
Push rod alignment Allowable limit
0.0098 in.
0000000885E
Oil Clearance between Tappet and Tappet Guide Bore

1. Measure the tappet O.D. with an outside micrometer.
2. Measure the I.D. of the tappet guide bore with a cylinder
gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit or the tappet is
damaged, replace the tappet.
0.016 to 0.052 mm
0.00063 to 0.00205 in.
tappet and tappet guide
bore 0.10 mm
Allowable limit
0.0039 in.
17.966 to 17.984 mm
Tappet O.D. Factory spec.
0.70732 to 0.70803 in.
18.000 to 18.018 mm
Tappet guide bore I.D. Factory spec.
0.70866 to 0.70937 in.
0000000886E

1-S37
GZD15, WSM ENGINE
(B) Timing Gear, Camshaft and Fuel Camshaft

Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating
gear.
3. If the backlash exceeds the allowable limit, check the oil
clearance of the shafts and the gear.
4. If the oil clearance is not proper, replace the gear.
0.043 to 0.124 mm
Factory spec.
Backlash between idle 0.00169 to 0.00488 in.
gear and crank gear 0.15 mm
Allowable limit
0.0059 in.
0.047 to 0.123 mm
Factory spec.
Backlash between idle 0.00185 to 0.00484 in.
gear and cam gear 0.15 mm
Allowable limit
0.0059 in.
0.046 to 0.124 mm
Backlash between idle Factory spec.
0.00185 to 0.00488 in.
gear and injection pump
gear 0.15 mm
Allowable limit
0.0059 in.
0.041 to 0.123 mm
Backlash between oil Factory spec.
0.00120 to 0.00484 in.
punp drive gear and
crank gear 0.15 mm
Allowable limit
0.0059 in.
0000000888E
Idle Gear Side Clearance
1. Set a dial indicator with its tip on the idle gear.
2. Measure the side clearance by moving the idle gear to the
front and rear.
idle gear collar.
0.20 to 0.51 mm
Factory spec.
0.0079 to 0.0201 in.
Idle gear side clearance
0.80 mm
Allowable limit
0.0315 in.
0000000889E
Camshaft Side Clearance
1. Set a dial indicator with its tip on the camshaft.
2. Measure the side clearance by moving the cam gear to the
front and rear.
camshaft stopper.
0.15 to 0.31 mm
Factory spec.
Camshaft side 0.0059 to 0.0122 in.
clearance 0.50 mm
Allowable limit
0.0197 in.
0000000890E

1-S38
GZD15, WSM ENGINE
Camshaft Alignment
1. Support the camshaft with V blocks on the surface plate at
both end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the camshaft alignment.
camshaft.
0.01 mm
Camshaft alignment Allowable limit
0.0004 in.
0000000891E
Cam Height
1. Measure the height of the cam at its highest point with an
outside micrometer.
2. If the measurement is less than the allowable limit, replace the
camshaft.
26.88 mm
Factory spec.
Cam height of intake 1.0583 in.
and exhaust 26.83 mm
Allowable limit
1.0563 in.
0000000892E
Oil Clearance of Camshaft Journal

1. Measure the camshaft journal O.D. with an outside
micrometer.
2. Measure the cylinder block bore I.D. for camshaft with a
cylinder gauge, and calculate the oil clearance.
camshaft.
0.050 to 0.091 mm
Factory spec.
Oil clearance of 0.00197 to 0.00358 in.
camshaft journal 0.15 mm
Allowable limit
0.0059 in.
32.934 to 32.950 mm
Camshaft journal O.D. Factory spec.
1.29661 to 1.29724 in.
Camshaft bearing I.D.

33.000 to 33.025 mm
(Cylinder block bore Factory spec.
1.29921 to 1.30020 in.
I.D.)
0000000893E

1-S39
GZD15, WSM ENGINE
Oil Clearance between Idle Gear Shaft and Idle Gear Bushing
1. Measure the idle gear shaft O.D. with an outside micrometer.
2. Measure the idle gear bushing I.D. with an inside micrometer,
and calculate the oil clearance.
bushing.
4. If it still exceeds the allowable limit, replace the idle gear shaft.
0.020 to 0.084 mm
0.00079 to 0.00331 in.
idle gear shaft and idle
gear bushing 0.10 mm
Allowable limit
0.0039 in.
19.967 to 19.980 mm
Idle gear shaft O.D. Factory spec.
0.78610 to 0.78661 in.
20.000 to 20.051 mm
Idle gear bushing I.D. Factory spec.
0.78740 to 0.78941 in.
0000000894E
Replacing Idle Gear Bushing

(When removing)
1. Press out the used idle gear bushing using an idle gear
bushing replacing tool.
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Press in a new bushing using an idle gear bushing replacing
tool, until it is flush with the end of the idle gear.
(A) When removing (B) When installing
0000000895E
(C) Piston and Connecting Rod

Piston Pin Bore I.D.
1. Measure the piston pin bore I.D. in both the horizontal and
vertical directions with a cylinder gauge.
piston.
20.000 to 20.013 mm
Factory spec.
0.78740 to 0.78791 in.
Piston pin bore I.D.
20.05 mm
Allowable limit
0.7894 in.
0000000897E

1-S40
GZD15, WSM ENGINE
Oil Clearance between Piston Pin and Small End Bushing

1. Measure the piston pin O.D. where it contacts the bushing with
an outside micrometer.
2. Measure the small end bushing I.D. with an inside micrometer,
and calculate the oil clearance.
bushing. If it still exceeds the allowable limit, replace the
piston pin.
0.014 to 0.038 mm
0.00055 to 0.00150 in.
piston pin and small end
bushing 0.10 mm
Allowable limit
0.0039 in.
20.002 to 20.011 mm
Piston pin O.D. Factory spec.
0.78748 to 0.78783 in.
20.025 to 20.040 mm
Small end bushing I.D. Factory spec.
0.78839 to 0.78897 in.
0000000898E
Replacing Small End Bushing
(When removing)
1. Press out the used bushing using a small end bushing
replacing tool.
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil
to them.
2. Insert a new bushing onto the tool and press-fit it with a press
so that the seam (1) of bushing positions as shown in the
figure, until it is flush with the connecting rod.
3. Drill a hole to the bushing with aligning the oil hole (2) of
connecting rod. (Refer to the figure.)
A Be sure to chamfer the oil hole circumference with an oil

stone.
0.015 to 0.075 mm
0.00059 to 0.00295 in.
piston pin and small end
bushing (Spare parts) 0.15 mm
Allowable limit
0.0059 in.
Small end bushing I.D. 20.026 to 20.077 mm

Factory spec.
(Spare parts) 0.78845 to 0.79043 in.
(1) Seam (A) When removing

(2) Oil Hole (B) When installing
(a) 0.785 rad. (45 )
0000000899E

1-S41
GZD15, WSM ENGINE
Piston Ring Gap

1. Insert the piston ring into the lower part of the cylinder (the
least worn out part) with piston.
2. Measure the ring gap with a thickness gauge.
piston ring.
Factory 0.20 to 0.35 mm
spec. 0.0079 to 0.0138 in.
Top ring
Allowable 1.25 mm
limit 0.0492 in.

Second spec. 0.0138 to 0.0197 in.
Piston ring gap
ring Allowable 1.25 mm
limit 0.0492 in.

spec. 0.0079 to 0.0138 in.
Oil ring
Allowable 1.25 mm
limit 0.0492 in.
0000000900E
Clearance between Piston Ring and Piston Ring Groove
1. Clean the rings and the ring grooves, and install each ring in
its groove.
2. Measure the clearance between the ring and the groove with
a thickness gauge.
3. If the clearance exceeds the allowable limit, replace the piston
ring.
4. If the clearance still exceeds the allowable limit with new ring,
replace the piston.
Second spec. 0.00354 to 0.00472 in.
ring Allowable 0.15 mm
Clearance between limit 0.0059 in.
piston ring and piston
ring groove Factory 0.04 to 0.08 mm
spec. 0.0016 to 0.0031 in.
Oil ring
Allowable 0.15 mm
limit 0.0059 in.
0000000901E

1-S42
GZD15, WSM ENGINE
Connecting Rod Alignment

1. Remove the crankpin bearing, and install the connecting rod
cap.
2. Install the piston pin in the connecting rod.
3. Install the connecting rod on the connecting rod alignment tool
(Code No. 07909-31661).
4. Put a gauge over the piston pin, and move it against the face
plate.
5. If the gauge does not fit squarely against the face plate,
measure the space between the pin of the gauge and the face
plate.
connecting rod.
Space between gauge 0.05 mm
Allowable limit
pin face plate 0.0020 in.
0000000902E

1-S43
GZD15, WSM ENGINE
(D) Crankshaft
Crankshaft Side Clearance
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the
front and rear.
thrust bearings.
4. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an oversize one referring to the
table and figure.
0.15 to 0.31 mm
Factory spec.
Crankshaft side 0.0059 to 0.0122 in.
clearance 0.50 mm
Allowable limit
0.0197 in.
(Reference)
A Oversize thrust bearing
Oversize Bearing Code Number Marking
0.2 mm Thrust bearing 1 02 15261-23950 020 OS

0.008 in. Thrust bearing 2 02 15261-23970 020 OS
0.4 mm Thrust bearing 1 04 15261-23960 040 OS

0.016 in. Thrust bearing 2 04 15261-23980 040 OS
A Oversize dimensions of crankshaft journal

0.2 mm 0.4 mm
Oversize
0.008 in. 0.016 in.
23.40 to 23.45 mm 23.80 to 23.85 mm

Dimension A
0.9134 to 0.9154 in. 0.9213 to 0.9232 in.
46.1 to 46.3 mm 46.3 to 46.5 mm

Dimension B
1.815 to 1.823 in. 1.823 to 1.831 in.
1.8 to 2.2 mm radius 1.8 to 2.2 mm radius

Dimension C
0.071 to 0.087 in. radius 0.071 to 0.087 in. radius
(0.8-S)
The crankshaft journal must be fine-finished to higher than
0000000904E
Crankshaft Alignment
1. Support the crankshaft with V blocks on the surface plate at
both end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the crankshaft alignment.
crankshaft.
0.02 mm
Crankshaft alignment Allowable limit
0.0008 in.
0000000905E

1-S44
GZD15, WSM ENGINE
Oil Clearance between Crankpin and Crankpin Bearing

1. Clean the crankpin and crankpin bearing.
2. Put a strip of plastigage (Code No.: 07909-30241) on the
centre of the crankpin.
3. Install the connecting rod cap and tighten the connecting rod
screws to the specified torque, and remove the cap again.
4. Measure the amount of the flattening with the scale, and get
the oil clearance.
crankpin bearing.
6. If the same size bearing is useless because of the crankpin
wear, replace it with an undersize one referring to the table
and figure.
A Never insert the plastigage into the crankpin oil hole.

A Be sure not to move the crankshaft while the connecting
rod screws are tightened.
0.020 to 0.051 mm
0.00079 to 0.00201 in.
crankpin and crankpin
bearing 0.15 mm
Allowable limit
0.0059 in.
33.959 to 33.975 mm
Crankpin O.D. Factory spec.
1.33697 to 1.33760 in.
33.995 to 34.010 mm
Crankpin bearing I.D. Factory spec.
1.33893 to 1.33898 in.
(Reference)
A Undersize crankpin bearing
Undersize Bearing Code Number Marking
0.2 mm
Crankpin bearing 02 15861-22970 020 US
0.008 in.
0.4 mm
Crankpin bearing 04 15861-22980 040 US
0.016 in.
A Undersize dimensions of crankpin

0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.

Dimension A
4 mm dia. 4 mm dia.
Dimension B
0.16 in. dia. 0.16 in. dia.
33.759 to 33.775 mm dia. 33.559 to 33.575 mm dia.

Dimension C
1.32910 to 1.32973 in. dia. 1.32112 to 1.32185 in. dia.
(0.8-S)
The crankpin must be fine-finished to higher than
0000001689E

1-S45
GZD15, WSM ENGINE
Oil Clearance between Crankshaft Journal and Crankshaft

Bearing 1
1. Measure the O.D. of the crankshaft front journal with an
outside micrometer.
2. Measure the I.D. of the crankshaft bearing 1 with an inside
micrometer, and calculate the oil clearance.
crankshaft bearing 1.
journal wear, replace it with an undersize one referring to the
table and figure.
0.034 to 0.106 mm
0.00134 to 0.00417 in.
crankshaft journal and
crankshaft bearing 1 0.20 mm
Allowable limit
0.0079 in.
43.934 to 43.950 mm
Crankshaft journal O.D. Factory spec.
1.72968 to 1.73031 in.
Crankshaft bearing 1 43.984 to 44.040 mm

Factory spec.
I.D. 1.73165 to 1.73386 in.
(Reference)
A Undersize crankshaft bearing 1
0.2 mm
Crankshaft bearing 1 02 1G460-23910 020 US
0.008 in.
0.4 mm
Crankshaft bearing 1 04 1G460-23920 040 US
0.016 in.
A Undersize dimensions of crankshaft journal

0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.

Dimension A
4 mm dia. 4 mm dia.
Dimension B
0.16 in. dia. 0.16 in. dia.
43.734 to 43.750 mm dia. 43.534 to 43.550 mm dia.

Dimension C
1.72181 to 1.72244 in. dia. 1.71394 to 1.7147 in. dia.
(0.8-S)
0000005610E

1-S46
GZD15, WSM ENGINE
Replacing Crankshaft Bearing 1

(When removing)
1. Press out the used crankshaft bearing 1 using a crankshaft
bearing 1 replacing tool.
(When installing)
1. Clean a new crankshaft bearing 1 and crankshaft journal bore,
and apply engine oil to them.
2. Using a crankshaft bearing 1 replacing tool, press in a new
bearing 1 (2) so that its seam (1) directs toward the exhaust
manifold side. (See figure.)
0.0 to 0.3 mm
Dimension (A) Factory spec.
0.0 to 0.0118 in.
(1) Seam (3) Cylinder Block

(2) Crankshaft Bearing 1
0000000908E
Bearing 2 (Crankshaft Bearing 3)
1. Put a strip of plastigage (Code No. 07909-30241) on the
centre of the journal.
2. Install the bearing case and tighten the bearing case screws 1
to the specified torque, and remove the bearing case again.
3. Measure the amount of the flattening with the scale, and get
the oil clearance.
crankshaft bearing 2 (crankshaft bearing 3).
journal wear, replace it with an undersize one referring to the
table and figure.
A Be sure not to move the crankshaft while the bearing case

screws are tightened.
Oil clearance between 0.028 to 0.059 mm
Factory spec.
crankshaft journal and 0.00110 to 0.00232 in.
crankshaft bearing 2 0.20 mm
(Crankshaft bearing 3) Allowable limit
0.0079 in.
Crankshaft journal O.D. 43.934 to 43.950 mm

Factory spec.
(Flywheel side) 1.72968 to 1.73031 in.

Factory spec.
I.D. 1.73142 to 1.73201 in.
Crankshaft journal O.D. 43.934 to 43.950 mm

Factory spec.
(Intermediate) 1.72968 to 1.73031 in.

Factory spec.
I.D. 1.73142 to 1.73201 in.
0000001690E

1-S47
GZD15, WSM ENGINE

Bearing 2 (Crankshaft Bearing 3) (Continued)
(Reference)
A Undersize crankshaft bearing 2 and 3
Crankshaft bearing 2 02 15694-23930

020 US
0.2 mm Crankshaft bearing 2F 02 1G460-07530
0.008 in. Crankshaft bearing 3 02 1G460-07580
020 US
Crankshaft bearing 3F 02 1G460-07630
Crankshaft bearing 2 04 15694-23940

040 US
0.4 mm Crankshaft bearing 2F 04 1G460-07540
0.016 in. Crankshaft bearing 3 04 1G460-07590
040 US
Crankshaft bearing 3F 04 1G460-07640
A Undersize dimensions of crankshaft journal

0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.

Dimension A
4 mm dia. 4 mm dia.
Dimension B
0.16 in. dia. 0.16 in. dia.
43.734 to 43.750 mm dia. 43.534 to 43.550 mm dia.

Dimension C
1.72181 to 1.72244 in. dia. 1.71394 to 1.7147 in. dia.
43.734 to 43.750 mm dia. 43.534 to 43.550 mm dia.

Dimension D
1.72181 to 1.72244 in. dia. 1.71394 to 1.7147 in. dia.
(0.8-S)
0000000910E

1-S48
GZD15, WSM ENGINE
(E) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.'s.
2. Get the difference (Maximum wear) between the maximum
and the minimum I.D.'s.
3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension. (Refer to "Correcting Cylinder".)
4. Visually check the cylinder wall for scratches. If deep
scratches are found, the cylinder should be bored. (Refer to
"Correcting Cylinder".)
72.000 to 72.019 mm
Factory spec.
2.83464 to 2.83539 in.
Cylinder I.D.
72.169 mm
Allowable limit
2.84129 in.
(A) Top (a) Right-angled to Piston Pin

(B) Middle (b) Piston Pin Direction
(C) Bottom (Skirt)
0000001678E
Correcting Cylinder
1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
72.500 to 72.519 mm
Factory spec.
Cylinder I.D. 2.85433 to 2.85507 in.
[Oversize] 72.669 mm
Allowable limit
2.86098 in.
Horn to 1.2 to 2.0 m Rmax.

Finishing
(0.000047 to 0.000079 in. Rmax.)
2. Replace the piston and piston rings with oversize ones.

Oversize Part Name Code Number Marking
0.25 mm Piston 1G460-21900 025

0.0098 in. Piston ring assembly 1G460-21090 025
A When the oversize cylinder is worn beyond the allowable

limit, replace the cylinder block with a new one.
(1) Cylinder I.D. (2) Cylinder I.D. [Oversize]
[Before Correction]
0000000913E

1-S49
GZD15, WSM ENGINE
[3] LUBRICATING SYSTEM

(1) Checking
Engine Oil Pressure
1. Remove the engine oil pressure switch, and set an oil
pressure tester (Code No.: 07916-32032).
2. Start the engine. After warming up, measure the oil pressure
of both idling and rated speeds.
3. If the oil pressure is less than the allowable limit, check the
following.
A Engine oil insufficient.
A Oil pump defective
A Oil strainer clogged
A Oil filter cartridge clogged
A Oil gallery clogged
A Excessive oil clearance
A Foreign matter in the relief valve
More than 49 kPa
At idle Factory
0.5
speed spec.
7 psi
196 to 441 kPa

Factory
Engine oil pressure 2.0 to 4.5
spec.
At rated 28 to 64 psi
speed 147 kPa
Allowable
1.5
limit
21 psi
(When reassembling)
A After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
0000000914E

1-S50
GZD15, WSM ENGINE
(2) Servicing
Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and
the outer rotor with a thickness gauge.
2. If the clearance exceeds the factory specifications, replace the
oil pump rotor assembly.
0.03 to 0.14 mm
Rotor lobe clearance Factory spec.
0.0012 to 0.0055 in.
0000000915E
Clearance between Outer Rotor and Pump Body

1. Measure the clearance between the outer rotor and the pump
body with a thickness gauge.
Clearance between
0.07 to 0.15 mm
outer rotor and pump Factory spec.
0.0028 to 0.0059 in.
body
0000000916E
Clearance between Rotor and Cover

1. Put a strip of plastigage (Code No. 07909-30241) onto the
rotor face with grease.
2. Install the cover and tighten the screws.
3. Remove the cover carefully, and measure the amount of the
flattening with the scale and get the clearance.
Clearance between 0.075 to 0.135 mm
Factory spec.
rotor and cover 0.00295 to 0.00531 in.
0000000918E

1-S51
GZD15, WSM ENGINE
[4] COOLING SYSTEM

Fan Belt Tension
1. Measure the deflection (A), depressing the belt halfway
between the fan drive pulley and dynamo pulley at specified
force (98 N, 10 kgf, 22 lbs).
loosen the dynamo mounting screws and relocate the dynamo
to adjust.
Approx. 10 mm
Deflection (A) Factory spec.
0.4 in.
0000001679E
Fan Belt Damage and Wear

1. Check the fan belt for damage.
2. If the fan belt is damaged, replace it.
3. Check if the fan belt is worn and sunk in the pulley groove.
4. If the fan belt is nearly worn out and deeply sunk in the pulley
groove, replace it.
(A) Good (B) Bad
0000000920E
Thermostat Valve Opening Temperature

1. Suspend the thermostat in the water by a string with its end
inserted between the valve and seat.
2. Heating the water gradually, read the temperature when the
valve opens and leaves the string.
3. Continue heating and read the temperature when the valve
opens approx. 8 mm (0.315 in.).
replace the thermostat.
Thermostat's valve 69.5 to 72.5
Factory spec.
opening temperature 157.1 to 162.5
Temperature at which
85
thermostat completely Factory spec.
185
opens
0000000921E

1-S52
GZD15, WSM ENGINE
A When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled
down. Otherwise, hot water way gush out, scalding nearby people.
0000000922E
Radiator Cap Air Leakage
1. Set a radiator tester (1) and adaptor (2) (BANZAI Code No.:
RCT-2A-30S) on the radiator cap.
2. Apply the specified pressure (88 kPa, 0.9 , 13 psi), and
measure the time for the pressure to fall to 59 kPa (0.6
, 9 psi).
3. If the measurement is less than the factory specification,
replace the radiator cap.
More than 10 seconds for
pressure fall from
Pressure falling time Factory spec. 88 to 59 kPa
(from 0.9 to 0.6
from 13 to 9 psi)
(1) Radiator Tester (2) Adaptor
0000000923E
Radiator Water Leakage
1. Pour a specified amount of water into the radiator.
2. Set a radiator tester (1) (Code No. 07909-31551) and an
adaptor (2) (BANZAI Code No.: RCT-2A-30S) and raise the
water pressure to the specified pressure.
3. Check the radiator for water leaks.
4. For water leak from the pinhole, repair with the radiator
cement. When water leak is excessive, replace the radiator.
157 kPa
Radiator water leakage
Factory spec. 1.6
test pressure
23 psi
(1) Radiator Tester (2) Adaptor
0000000924E

1-S53
GZD15, WSM ENGINE

Thermostat Assembly
1. Remove the thermostat cover mounting screws, and remove
the thermostat cover (1).
2. Remove the thermostat assembly (3).
(When reassembling)
A Apply a liquid gasket (Three Bond 1215 or equivalent) only at
the thermostat cover side of the gasket (2).
(1) Thermostat Cover (3) Thermostat Assembly
(2) Thermostat Cover Gasket
0000000925E
Water Pump Assembly

1. Loosen the dynamo mounting screws, and remove the fan
belt.
2. Remove the fan and fan pulley.
3. Remove the water pump assembly from the gear case cover.
4. Remove the water pump flange (1).
5. Press out the water pump shaft (2) with the impeller (5) on it.
6. Remove the impeller from the water pump shaft.
7. Remove the mechanical seal (4).
(When reassembling)
A Apply a liquid gasket (Three Bond 1215 or equivalent) to the
both sides of gasket.
A Replace the mechanical seal with new one.
(1) Water Pump Flange (4) Mechanical Seal
(2) Water Pump Shaft (5) Impeller
(3) Water Pump Body
0000000926E

1-S54
GZD15, WSM ENGINE
[5] FUEL SYSTEM

(A) Engine Revolution

Adjusting Engine Revolution
1. Keep the throttle lever (1) to "A" position of the stay.
2. Adjust the accelerating wire so that engine speeds control
lever (5) contacts to the engine speeds limit bolt (6) at 3400
rpm engine revolution.
3. Tighten the lock nut (4) of the accelerating wire (3).
Engine revolution at "A"
position of throttle lever Factory spec. 3400 rpm
stay
(1) Throttle Lever A: Engine Revolution

(2) Stay Adjustment Position
(3) Accelerating Wire B: Throttle Lever Usual
(4) Lock Nut Operation Position
(5) Engine Speeds Control Lever F: Front Side
(6) Engine Speeds Limit Bolt
0000001682E

1-S55
GZD15, WSM ENGINE
(B) Injection Pump

Injection Timing
1. Remove the injection pipes.
2. Remove the engine stop solenoid.
3. Turn the flywheel counterclockwise (facing the flywheel) until
fuel flows from the delivery valve holder.
4. Continue to turn the flywheel slowly, and stop it as soon as the
fuel level at the tip of the delivery valve holder begins to
increase.
5. Check to see if the timing angle lines on the flywheel is aligned
with the alignment mark (2).
6. If the injection timing is out of adjustment, readjust the timing
with shims.
0.30 to 0.33 rad. (17 to 19 )
Injection timing Factory spec.
before T.D.C.
A The sealant is applied to both sides of the shim (soft metal

gasket shim). The liquid gasket is not required for
assembling.
A Shims are available in thickness of 0.20 mm (0.0079 in.),
0.25 mm (0.0098 in.) and 0.30 mm (0.0118 in.). Combine
these shims for adjustments.
A Addition or reduction of shim (0.05 mm, 0.0020 in.) delays
or advances the injection timing by approx. 0.0087 rad.
(0.5 ).
A In disassembling and replacing the injection pump, be
sure to use the same number of new shims with the same
thickness.
A Refer to figure below to check the thickness of the shims.
(1) Timing Line (4) Two-holes:
(2) Alignment Mark 0.20 mm (0.0079 in.)
(3) Shim (Soft Metal Gasket Shim) (5) One-holes:
0.25 mm (0.0098 in.)
(6) Without hole:
0.30 mm (0.0118 in.)
0000000928E

1-S56
GZD15, WSM ENGINE
Fuel Tightness of Pump Element

2. Remove the injection pipes and glow plugs.
3. Install the injection pump pressure tester to the injection pump.
4. Install the injection nozzle (1) jetted with the proper injection
pressure to the injection pump pressure tester (2). (Refer to
the figure.)
5. Set the speed control lever to the maximum speed position.
6. Run the starter to increase the pressure.
7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
13.7 MPa
Fuel tightness of pump
Allowable limit 140
element
1990 psi
A Never try to disassemble the injection pump assembly.

For repairs, you are strongly requested to contact a
Kubota-authorized pump service shop.
(1) Injection Nozzle (3) Protection Cover for Jetted Fuel
(2) Injection Pump Pressure Tester
0000001407E

1-S57
GZD15, WSM ENGINE
Fuel Tightness of Delivery Valve

2. Remove the injection pipes and glow plugs.
3. Set a pressure tester to the fuel injection pump.
4. Install the injection nozzle (1) jetted with the proper injection
pressure to the injection pump pressure tester (2).
5. Run the starter to increase the pressure.
6. Stop the starter when the fuel jets from the injection nozzle.
After that, turn the flywheel by the hand and raise the pressure
to approx. 13.7 MPa (140 , 1990 psi).
7. Now turn the flywheel back about half a turn (to keep the
plunger free). Maintain the flywheel at this position and clock
the time taken for the pressure to drop from 13.7 to 12.7 MPa
(from 140 to 130 , from 1990 to 1849 psi).
8. Measure the time needed to decrease the pressure from 13.7
to 12.7 MPa (from 140 to 130 , from 1990 to 1849 psi).
9. If the measurement is less than allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
10 seconds
13.7 12.7 MPa
Factory spec.
140 130
Fuel tightness of 1990 1849 psi
delivery valve 5 seconds
13.7 12.7 MPa
Allowable limit
140 130
1990 1849 psi
A Never try to disassemble the injection pump assembly.

For repairs, you are strongly requested to contact a
Kubota-authorized pump service shop.
(1) Injection Nozzle (3) Protection Cover for Jetted Fuel
(2) Injection Pump Pressure Tester
0000001408E

1-S58
GZD15, WSM ENGINE
(C) Injection Nozzle
A Check the injection pressure and condition after confirming that there is nobody standing in the
direction the fume goes.
A If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood
poisoning may be caused.
0000000932E
Nozzle Spraying Condition
1. Set the injection nozzle to a nozzle tester (Code No. 07909-
31361), and check the nozzle spraying condition.
2. If the spraying condition is defective, replace the nozzle piece.
(a) Good (b) Bad
0000000933E
Fuel Injection Pressure

31361).
2. Slowly move the tester handle to measure the pressure at
which fuel begins jetting out from the nozzle.
replace the adjusting washer (1) in the nozzle holder to adjust
it.
13.73 to 14.71 MPa
Fuel injection pressure Factory spec. 140 to 150
1991 to 2134 psi
(Reference)
A Pressure variation with 0.01 mm (0.0004 in.) difference of
adjusting washer thickness.
Approx. 235 kPa (2.4 , 34 psi)
(1) Adjusting Washer
0000000934E

1-S59
GZD15, WSM ENGINE
Valve Seat Tightness

31361).
2. Raise the fuel pressure, and keep at 12.75 MPa (130 ,
1849 psi) for 10 seconds.
3. If any fuel leak is found, replace the nozzle piece.
No fuel leak at
12.75 MPa
Valve seat tightness Factory spec.
130
1849 psi
0000000935E
Nozzle Holder
1. Secure the nozzle retaining nut (7) with a vise.
2. Remove the nozzle holder (1), and take out parts inside.
(When reassembling)
A Assemble the nozzle in clean fuel oil.
A Install the push rod (4), noting its direction.
A After assembling the nozzle, be sure to adjust the fuel injection
pressure.
34.3 to 39.2
Nozzle holder 3.5 to 4.0
25.3 to 28.9 ft-lbs
19.6 to 24.5
Tightening torque Overflow pipe nut 2.0 to 2.5
14.5 to 18.1 ft-lbs
49.0 to 68.6
Nozzle holder assembly 5.0 to 7.0
36.2 to 50.6 ft-lbs
(1) Nozzle Holder (5) Distance Piece

(2) Adjusting Washer (6) Nozzle Piece
(3) Nozzle Spring (7) Nozzle Retaining Nut
(4) Push Rod
0000000936E

1-S60
2 TRANSAXLE

CONTENTS
1. STRUCTURE.....................................................................................................................2-M1
2. TRAVELLING SYSTEM....................................................................................................2-M2
[1] HYDROSTATIC TRANSMISSION ..................................................................................2-M2
(1) Structure ..................................................................................................................2-M2
(2) Pump and Motor ......................................................................................................2-M3
(3) Check and High Pressure Relief Valve ...................................................................2-M4
(4) Oil Flow....................................................................................................................2-M5
(5) Power Trains Operation...........................................................................................2-M6
(6) Motion Control Linkage............................................................................................2-M7
(7) Final Reduction Gear Section..................................................................................2-M8
(8) PTO System ............................................................................................................2-M9
(9) Brake .....................................................................................................................2-M12

GZD15, WSM TRANSAXLE
1. STRUCTURE
(1) PTO Section (3) Hydrostatic Transmission (4) Brake Section (5) Final Reduction Gear
(2) Bevel Gear Section Section
0000001601E

2-M1
2. TRAVELLING SYSTEM
[1] HYDROSTATIC TRANSMISSION
(1) Structure
(1) Trunnion Arm (6) Piston (11) Cylinder (Motor) (16) Pump Shaft
(2) Swashplate (7) Motor Shaft (12) Centre Section (17) Check Valve
(3) Cradle Bearing (8) Ball Bearing (13) Bush (18) High Pressure Relief Valve
(4) Ball Bearing (9) Thrust Ball Bearing (14) Piston Spring (19) Check Valve Spring
(5) Thrust Ball Bearing (10) Piston (Motor) (15) Cylinder Block (Pump) (20) Relief Valve Spring
A: From Oil Filter
The hydrostatic transmission consists of variable displacement piston pump, fixed displacement piston motor and
valve system.
0000001602E

2-M2
(2) Pump and Motor
(1) Piston (2) Cylinder (3) Oil (A) Pump

(B) Motor
(a) Swashplate
Pump and motor cylinder, each containing pistons, are connected by lines. Cylinders and lines are filled with oil.
Pistons ride against swashplates located in pump and motor.
In the pump, as the cylinder rotates, pistons move across the sloping face of swashplate and slide in or out of their
cylinder bores. The oil, forced out by the pump pistons, causes the motor pistons to slide out of their cylinder bores.
In the motor, sliding out of the cylinder and moving across the sloping face of swashplate, the pistons rotate the
cylinder.
0000001603E

2-M3
(3) Check and High Pressure Relief Valve

The check and high-pressure relief valve consists of
pressure poppet (2), check valve seat (1), relief valve
spring (3), spring guide (4) and check valve spring (5).
The valve is used to prevent an overload that would
happen at a quick start, sudden stop or even during
usual running. This valve doubles as a check valve.
The check and high-pressure relief valves are laid out
facing each other as shown in the figure.
In neutral, both valves are opened and charging oil
enters into the main oil circuit through the valves. (A)
At normal operation, the check valve in the high-
pressure side is closed and it pushes and opens the
other one. An excessive charge flow goes through the
charge relief valve into HST housing. (B)
The check and high-pressure relief valve along the
high-pressure line serves as a high-pressure relief
valve. If the pressure exceeds a high-pressure limit
level, the pressure poppet opens itself against the relief
valve spring (3) force and opens the valve seat that is
located between the check valve seat (1) and the
pressure poppet (2). Now the flow goes from P3 to P1
and P2. (C)
If the P3 pressure drops, the relief valve spring forces
the valve seat closed against the pressure. The high-
pressure oil at P3 does not flow to P1 any longer.
As discussed above, the check and high-pressure
relief valve protects engines, pumps, motors, gears and
even the machine itself from overload.
Oil Temperature Valve operation pressure
18.5 to 22.5 MPa

50 to 60 (122 to 140 ) 189 to 230
2683 to 3263 psi
(1) Check Valve Seat (A) In Neutral (Stop)

(2) Pressure Poppet (B) When Check Valve
(3) Relief Valve Spring Activating (Normal
(4) Spring Guide Operation)
(5) Check Valve Spring (C) When High Pressure
(6) Valve Plug Relief Valve Activating
P1: Oil Charge Port
P2: HST Reverse Port
P3: HST Forward Port
0000001604E

2-M4
(4) Oil Flow
(1) Oil Strainer (5) Regulator Valve (8) Check and High Pressure (11) Swashplate
(2) Transmission Case (6) PTO Clutch Relief Valve (12) Piston
(3) Hydraulic Pump (7) Oil Filter Cartridge (9) Lubricating Orifice (13) Cylinder Block (Motor)
(4) Control Valve (10) Cylinder Block (Pump)
The pump and motor are joined in a closed hydraulic loop and most of oil circulates within the main oil circuit. A
little oil lubricates and oozes out from the clearance between the moving parts of the case. Then oil in the main oil
circuit of the HST needs to be supplied a want.
The charge oil is sent to the HST housing after the control valve and oil filter pass with the hydraulic pump.
The charge oil aids smooth operation of pistons for pump and motor. And overflow oil from HST housing return to
the transmission case.
0000001605E

2-M5
(5) Power Trains Operation
(1) Check and Relief Valve (1)-3 Neutral Orifice (4) Pump (7) Paper Filter
(with Neutral Orifice) (2) Motor (5) Hydraulic Pump (8) Regulator Valve
(1)-1 Relief Valve (3) Lubricating Orifice (6) Control Valve (9) PTO Clutch
(1)-2 Check Valve
B NEUTRAL
With the motion control levers in the NEUTRAL position, the piston springs in the pump block in the pumps force
the swash plates to a position that is parallel to the pump body. With the swash plates parallel to the pump body,
the pistons do not reciprocate in the cylinder block, they merely rotate, and no oil is being drawn in or discharged
from the pump. The machine is in a zero displacement position and the machine remains stationary.
Oil returning from the HST housing and hydraulic pump is directed through the regulating valve before returning
to the transmission case.
B Forward
As the motion control levers are pushed forward, the swash plates in the pumps move from the neutral position
(parallel to the pump body) to a forward angle position. Piston springs inside the cylinder bores force the pistons
against the swash plates.
As the cylinder block rotates, the pistons follow the contour of the swash plate, moving outward, drawing oil into
their bores. As the cylinder block continues to rotate, the pistons are forced into their bores, discharging oil under
pressure.
High-pressure oil from the pumps is routed to the motors, driving the machine forward.
B Reverse
Reverse operation is accomplished by reversing the angle applied to the pump swash plates, reversing the flow
of high-pressure oil to the motors.
0000001606E

2-M6
(6) Motion Control Linkage

The motion control lever (1) and the trunnion shaft of
variable swashplate are linked with the speed shaft (4),
speed control rod (5) and the speed change arm (7). As
the motion control lever (1) is pushed, the swashplate
rotates and forward travelling speed increases. Pulling
the motion control lever (1) increases reverse speed.
A neutral position can be requested by the thing to
operate the motion control lever (1). Moreover, it is
possible to fix to a neutral position by putting the motion
control lever (1) in the neutral slot (3). The motion
control lever (1) is pushed by the speed limit bolt's (2)
working when the motion control lever (1) is removed
from the neutral slot (3). As the result, the machine
synchronizes with the movement of the motion control
lever (1) and begins to move slowly. (The machine is
set like this.) The damper connected to the speed shaft
(4) restricts the movement of the linkage to prevent
abrupt operation or reversing.
B Steering
The Zero-Turn Mower does not have a separate
steering system. Steering is accomplished by varying
the wheel motor speeds. This gives the machine a zero-
turn capability.
As the control levers are moved to a full left turn
position, the right hydraulic pump is moved to the full-
speed forward position and the left pump is moved to
the full-speed reverse position. This will allow the
machine to pivot around its center.
(1) Motion Control Lever (5) Speed Control Rod
(2) Speed Limit Bolt (6) HST
(3) Neutral Slot (7) Speed Change Arm
(4) Speed Shaft A: Front Side
0000001607E

2-M7
(7) Final Reduction Gear Section

As for this machine, power is transmitted from the 8T
gear (1) on the HST motor shaft to the rear axle (5)
through 23T gear (2), 7T gear (3) and 48T gear (4).
(1) 8T Gear (4) 48T Gear
(2) 23T Gear (5) Rear Axle
(3) 7T Gear
0000001608E

2-M8
(8) PTO System
B PTO Clutch and Valve
(1) PTO Clutch Pack (6) PTO Clutch Shaft (11) 33T Gear A: From Hydraulic Pump
(1) PTO Clutch Valve (7) PTO Brake Plate (12) PTO Clutch Plate B: To Hydrostatic
(3) Control Valve (8) PTO Clutch Case (13) PTO Brake Disc Transmission
(4) Oil Filter (9) 26T Gear (HST Shaft) (14) 28T Gear
(5) Regulator Valve (10) PTO Clutch Disk
The GZD series equipped with hydraulic independent PTO clutch (wet multi-plates type). Therefore, the engine
power could engage or disengage to the PTO shaft (6) without stopping the machine movement.
The PTO clutch pack (1) has five clutch discs (10), five clutch plates (12), pressure plate, clutch piston and so on.
The clutch piston is actuated by hydraulic oil flow from the hydraulic pump through the regulator valve (5).
0000001609E

2-M9
B Regulator Valve
This machine is controlled with the regulator valve so
that the oil sent from the hydraulic pump may become
the setting pressure. And the oil flows into PTO clutch
and hydrostatic transmission.
(Reference)
A Regulator valve setting pressure:
0.5 to 0.6 MPa
5.1 to 6.1
72.5 to 87.0 psi
(1) Poppet (A) From Hydraulic Pump
(2) Spring (B) To Hydrostatic
(3) Plug Transmission
(4) Circlip (C) To Transmission Case
0000001610E
B PTO Clutch "Engaged"
The PTO clutch valve has two oil passing holes. One
hole is a direct line hole and it faces to the relief valve.
The other hole is 90 angle hole and it faces through
the transmission case to the PTO clutch shaft.
When the PTO clutch lever is set at the "Engaged"
position, the PTO clutch valve (1) rotates, two holes of
the clutch valve (1) are connected to the PTO clutch
pack (5).
Oil entering the PTO clutch pack (5) pushes the clutch
piston to engage the clutch pack.
(Reference)
(1) PTO Clutch Valve (A) Regulator Valve Port
(2) Delivery Pipe (B) To Transmission Case
(3) Oil Filter and PTO Clutch Shaft
(4) Regulator Valve
(5) PTO Clutch Pack
(6) PTO Clutch Shaft
0000001611E

2-M10
B PTO Clutch "Disengaged"

When the PTO clutch lever is set at the
"Disengaged" position, the PTO clutch valve (1)
rotates and close the oil passage to the PTO clutch pack
(5). The oil in the PTO clutch pack (5) drained into the
transmission case. Thus the clutch piston (2) is pushed
back by the spring (9).
When the piston is pushed back, the piston pushes
the brake pressure plate so as to stop the rotation and
drag of the PTO clutch shaft (6).
(1) PTO Clutch Valve (A) Regulator Valve Port
(2) Delivery Pipe (B) To Transmission Case
(3) Oil Filter and PTO Clutch Shaft
(4) Regulator Valve
(5) PTO Clutch Pack
(6) PTO Clutch Shaft
(7) PTO Brake Disc
0000001612E

2-M11
(9) Brake
Brake system is composed of brake pedal, brake
pedal arm (1), brake shaft, parking brake lock lever (2),
brake return spring (3), brake rod (4) located at the
machine front side and brake arm (5), brake lever (6),
actuator (7), balls (8), actuator plate (9), friction plates
(10), brake disks (11), brake plates (12) (14) located at
the machine transmission rear side.
As the parking brake lock pedal is pressed and the
parking brake lock lever (2) is pushed, the brake will be
applied and locked.
When the parking brake is released, the brake can be
released if the parking brake lever is pulled back.
To prevent the brake from dragging when the parking
brake is applied, this machine is designed so that the
engine may stop if the brake pedal is not released within
few seconds after the engine is started.
(1) Brake Pedal Arm (8) Ball
(2) Parking Brake Lock Lever (9) Actuator Plate
(3) Brake Return Spring (10) Friction Plate
(4) Brake Rod (11) Brake Disc
(5) Brake Arm (12) Brake Plate
(6) Brake Lever (13) HST Motor Shaft
(7) Actuator (14) Brake Plate
0000001613E

2-M12
CONTENTS
4. CHECKING AND ADJUSTING ........................................................................................ 2-S5
5. DISASSEMBLING AND ASSEMBLING ........................................................................ 2-S11
[1] SEPARATING TRANSAXLE ........................................................................................ 2-S11
[2] SEPARATING FRONT PTO CASE ............................................................................ 2-S22
6. SERVICING ..................................................................................................................... 2-S24
[1] HYDROSTATIC TRANSMISSION ................................................................................ 2-S24
[2] TRANSMISSION CASE ................................................................................................ 2-S26

1. TROUBLESHOOTING
Reference
Symptom Probable Causes Solution
Page
Machine Will Not Stop A Improper neutral adjustment Adjust neutral 2-S6
in Neutral Position
A Improper speed control rod adjustment Adjust 2-S6
Machine Jerky and A Transmission oil insufficient Replenish 2-S11
Noisy When Starting
A Air entering from suction pipe Retighten
A Oil strainer clogged Clean G-23
A Transmission oil filter cartridge clogged Replace G-20
A Hydrostatic transmission defective Replace 2-S17 to S19
Loss of Power A Control linkage defective Repair or replace
A Transmission oil insufficient Replenish 2-S11
A Hydraulic pump defective Replace 2-S16
A Hydrostatic transmission defective Replace 2-S17 to S19
System Operates in A Check valve defective Replace 2-S24
One Direction Only
A Control linkage defective
System Operating Hot A Transmission oil insufficient Replenish 2-S11
A Overload working
Noise from A Transmission oil insufficient Replenish 2-S11
Transmission
A Gear worn Replace
A Improper backlash between 19T spiral bevel Adjust 2-S27
gear and spiral bevel gear
A Bearing worn Replace 2-S26
0000001615E
TRAVELLING GEAR SHIFT SECTION
Reference
Symptom Probable Causes Solution
Page
Noise from A Transmission oil insufficient Refill 2-S11
Transmission
A Gear worn or broken Replace
A Bearings worn Replace 2-S26
0000001616E

2-S1
PTO SECTION
PTO Clutch Slip A Operating pressure is low Check 2-S10

A PTO clutch valve malfunctioning Repair or replace 2-S20
A Clutch disc or drive plate excessively worn Replace 2-S20
PTO Shaft Does Not A PTO clutch malfunctioning Repair or replace 2-S20
Rotate
PTO Clutch Operating A Transmission oil improper or insufficient Refill G-7, G-21
Pressure Is Low
A Regulator valve malfunctioning Replace 2-M10
PTO Clutch Drags A Brake plate excessively worn Replace 2-S20
A Clutch spring weaken or broken Replace 2-S20
A Deformation of pressure plate or steel plate Replace 2-S20
0000001617E
PARKING BRAKE SECTION
Brake Drags A Brake spring play too small Adjust G-31, 2-S5
A Brake return spring weaken or broken Replace
Poor Braking Force A Brake spring play excessive Adjust G-31, 2-S5
A Brake disc worn Replace 2-S21
0000001618E

2-S2
Brake Spring Length at Parking Setting length 27 mm
1.06 in.
Regulator Valve Setting pressure 0.5 to 0.6 MPa
5.1 to 6.1
72.5 to 87.0 psi
PTO Clutch Operating pressure 0.98 to 1.08 MPa
10.0 to 11.0
142.3 to 156.6 psi
Check and High Pressure Relief Valve Relief valve setting 18.5 to 22.5 MPa
pressure 189 to 230
2683 to 3263 psi
Maximum Speed at Maximum Engine rpm Wheel rotation 140 to 160 rpm
Motion Control Lever Alignment Gap 0 to 2 mm
0 to 0.08 in.
Space 10 to 20 mm
0.4 to 0.8 in.
19T Bevel Gear to Spiral Bevel Gear Backlash 0.15 to 0.30 mm
0.0059 to 0.0118 in.
0000001619E

2-S3
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 ft-lbs
Motion control lever mounting bolt and nut 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2
Hydrostatic transmission mounting screw 39.3 to 44.1 4.0 to 4.5 28.9 to 32.5
Rear wheel mounting nut 48.0 to 56.0 4.9 to 5.7 35.4 to 41.2
Universal joint mounting screw 26.0 to 28.0 2.7 to 2.9 19.2 to 20.7
Transaxle and rear axle case mounting screw
M12 7T Aluminum 62.7 to 72.5 6.4 to 7.4 46.3 to 53.5
M10 7T Aluminum 39.3 to 44.1 4.0 to 4.5 28.9 to 32.5
M12 7T 77.5 to 90.2 7.9 to 9.2 57.2 to 66.5
M10 7T 48.0 to 55.9 4.9 to 5.7 35.4 to 41.2
Hydraulic pump housing mounting screw 17.7 to 20.5 1.8 to 2.1 13.1 to 15.1
Centre cover mounting screw 39.3 to 44.1 4.0 to 4.5 28.9 to 32.5
Centre section mounting hex. socket head screw 17.7 to 20.5 1.8 to 2.1 13.1 to 15.1
Check valve plug 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3
Check and high pressure relief valve plug 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3
0000001620E

2-S4
4. CHECKING AND ADJUSTING

Adjusting Parking Brake
A Stop the engine and chock the wheels before checking or

adjusting.
A Wrong adjustment may cause machine damage.

B Check
1. Apply parking brake and check the length (A) of the brake
spring (2).
2. If it is not correct, turn the lock nut (3) in the desireddirection
until the proper length is achieved.
B Check on the slope
1. Place the machine on the under 17 ramp.
2. Apply the parking brake fully.
3. Place the motion control levers in "NEUTRAL LOCK"
position and shut off the engine.
4. Check that the machine does not move.
A For parking brake test purposes only use 17 ramp.

27 mm
Brake spring length (A) Factory spec.
1.06 in.
(1) Brake Pedal A: Brake Spring Length

(2) Brake Spring B: "Under 17 "
(3) Lock Nut
0000001444E
Checking Neutral
1. Park machine safely.
2. Set the motion control levers are in the NEUTRAL position.
3. Move the PTO lever to OFF position and apply the parking
brake.
4. Sit on the seat and start the engine.
5. Move the throttle lever to Max. speed position.
6. Release the parking brake.
7. Check whether the drive wheels move or not.
8. If movements is noted, perform adjustment as follows.
0000001621E

2-S5
Adjusting Neutral

exclude !MOTION CONTROL LEVER POSITION".
They are relative each other.
1. Turn key switch to OFF position.
2. Apply the parking brake.
3. Set the motion control levers (1) to Neutral lock position.
4. Remove the set knobs of seat frame, then raise and latch the
seat assembly.
temporarily install a jumper wire across the terminals in the
6. Raise the rear of machine and block up so that rear wheel can
rotate freely.
7. Loosen the lock nuts from the ball joints on the two rods.
10. Release the parking brake.
11. Adjust the speed control rod (2) length by rotating the double
nuts on the rod appropriate direction until the rear wheel does
not rotate.
12. The left rod assembly controls left wheel and the right rod
assembly controls right wheel.
13. Repeat on opposite side of unit, tighten lock nuts (3) securely
against ball joint.
14. Shut off the machine. Remove jumper wire from wire harness
connector and plug connector or into seat safety switch.
A The right and left motion control lever (1) can be adjusted
independently.
(2) Speed Control Rod
0000001622E

2-S6
Adjusting Maximum Speed

exclude "MOTION CONTROL LEVER POSITION".
They are relative each other.
1. Turn key switch to OFF position.
2. Apply the parking brake.
3. Set the motion control lever (1) to Neutral lock position.
4. Remove the set knobs of seat frame, then raise and latch the
seat assembly.
temporarily install a jumper wire across the terminals in the
6. Remove the boots.
7. Raise the rear of machine and block up so that rear wheel can
rotate freely.
10. Push the motion control lever (1) to the front until the speed set
bolt (2) comes into contact with the stopper plate.
A At this time, the thing that the speed set bolt (2) touches
the stopper plate is.
11. Measure the rotations of rear wheel.
loosen the lock nut (3) and adjust the length of speed set bolt
(2).
Rear wheel max. 140 to 160 rpm at engine
Factory spec.
rotation max.
A The right and left speed set bolt can be adjusted

independently.
(2) Speed Set Bolt
0000001623E

2-S7
Checking Motion Control Lever Alignment
A When checking, park the tractor on flat ground, apply the

parking brake.
1. Check the gap (A) and space (B) between the motion control
levers, at the maximum forward position.
If positions of the motion control levers are unequal, an
adjustment is necessary.
When adjusting alignment
1. Stop the engine and apply the parking brake.
2. Loosen the nut and remove the boot (1).
B Lever position (High or Low)
1. Remove the screw (2) and select the motion control lever
position, high or low.
2. Tighten the screw (2) and install the boot (1).
B Lever alignment (Right and Left)
1. Loosen the screws (2).
2. Slide both motion control levers forward or rearward to desired
position within tab slots until levers are aligned.
3. Tighten the screws (2).
0 to 2 mm
Gap (A)
0 to 0.08 in.
Factory spec.
10 to 20 mm
Space (B)
0.4 to 0.8 in.
A If the ends of the levers strike against each other while in

the "NEUTRAL" position, move the levers outward to the
"NEUTRAL LOCK" position and carefully bend them
outward.
Move them back to the "NEUTRAL" position and check for
the recommended space.
(1) Boot (A) Gap
(2) Motion Control Lever Mounting (B) Space
Screw
0000001624E

2-S8
Checking Hydrostatic Transmission
A When checking, park the machine on flat ground, apply

the parking brake.
A Sit on operatorís seat for checking.
1. After worming up the machine, apply the parking brake and set
the stop wood (chock) to the rear wheels.
2. Remove the plug (2) (3) from the centre section of the HST
and set the HST adaptor. Then install the pressure gauge.
A Note that the allen wrench does not come off firmly
because the plug is not loose hard. Otherwise, the plug
(1) might be damaged, and the plug not be loosened.
3. The safety switch for motion control lever is temporarily turned
on, and the state which can be checked is made.
6. Grasp the motion control lever and move then inward from
"NEUTRAL LOCK" position and then slowly push forward.
And measure the pressure of HST.
7. At this time, if pressure rise to 12.3 MPa (125 , 1779
psi), it is assumed OK.
A If pressure exceeds 18.5 to 22.5 MPa (189 to 230 ,

2683 to 3263 psi), rear wheel can not be locked with
parking brake. Please fix the rear wheel hub with the stick
etc., prevent the rear wheel rotating, and measure the
pressure at time.
8. At this time, if pressure does not rise to 12.3 MPa (125
, 1779 psi), repair or replace the HST.
(Reference)
Check and high 18.5 to 22.5 MPa
pressure relief valve Factory spec. 189 to 230
pressure 2683 to 3263 psi
A When the check and high pressure relief valve pressure is

measured, the relief valve is not operated continuously
for 5 seconds or more. Otherwise, HST might to break.
(1) Centre Section (3) Plug (Reverse Side)
(2) Plug (Forward Side)
0000001625E

2-S9
PTO Clutch Operating Pressure (Hydrostatic Transmission

Charge Pressure)
A When checking, park the machine on flat ground, apply

the parking brake.
1. Remove the plug (1) as a check port, then install the adaptor
cable and pressure gauge.
2. Start the engine and set at maximum speed.
3. At this time, read the pressure gauge.
4. If the pressure is not within the factory specifications, check
the regulator valve and related hydraulic components.
5. If the relief valve and related hydraulic components are good,
replace the relief valve spring with a new one.
0.98 to 1.08 MPa
PTO clutch operating
Factory spec. 10.0 to 11.0
pressure
142.3 to 156.6 psi
Condition
A Engine speed.....Maximum
A Oil temperature.....50 to 60 (122 to 140 )
(1) Plug (Check Port) (3) Delivery Pipe
(2) PTO Clutch Valve (4) Oil Filter
0000001626E
Checking Parking Brake

1. See page G-31.
0000001627E

2-S10
5. DISASSEMBLING AND ASSEMBLING

[1] SEPARATING TRANSAXLE
Draining Transmission Fluid
A Be sure to stop the engine before checking and 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.
Remove the clamp and hose (4) from L shape adaptor (5) at
the rear axle gear case (RH & LH) bottom and drain rear axle
gear case (RH & LH) fluid.
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.
A 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.).
A Never work the tractor immediately after changing the
transmission oil. Keeping the engine at medium speed
for a few minutes prevents damage to the transmission.
A Do not mix different brands oil together.
10.0 L
Transmission case and rear axle gear
2.6 U.S.gals.
case (RH and LH) capacity
2.2 Imp.gals.
(1) Drain Plug (4) Hose

(2) Oil Plug and Breather Cap (5) L Shape Adaptor
(3) Dipstick
0000001628E
Battery
A When disconnecting the battery cables, disconnect the

negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
1. Disconnect the negative cable (2) from the battery.
2. Disconnect the positive cable (1) from the battery.
(1) Positive Cable (2) Negative Cable
0000001629E
Removing Engine
1. See "ENGINE" Section.
0000001630E

2-S11
Removing Rear Frame

1. Disconnect the grass collector wiring harness (3) connector.
2. Remove the universal joint (6).
3. Remove the rear frame mounting screws (2).
4. Remove the rear frame (1).
(When reassembling)
1. Check the hydraulic hoses, wiring harness, fuel hose and
accelating wire as shown in the picture.
48.1 to 55.9
Rear frame mounting
bolt
35.4 to 41.2 ft-lbs
(1) Rear Frame (4) Accelating Wire

(2) Rear Frame Mounting Bolt (5) Fuel Hose
(3) Wiring Harness (6) Universal Joint
0000001631E
Removing Oil Cooler

1. Remove the oil cooler (1).
(1) Oil Cooler
0000001632E

2-S12
Removing High Dump Cylinder Frame, Hydraulic Hoses and

Fenders
1. Remove the high dump wiring from cylinder frame.
2. Remove the cylinder pin (1).
3. Disconnect the hydraulic hoses (3) from hydraulic control
valve.
4. Remove the mounting bolts on right and left side.
5. Remove the right and left fender.
48.1 to 55.9
High dump cylinder
frame mounting bolt
35.4 to 41.2 ft-lbs
(1) Cylinder Pin (3) Hydraulic Hose

(2) Frame Mounting Bolt (4) Fender
0000001633E
Removing Hydraulic Control Valve

1. Remove the control valve stay nut (1).
2. Disconnect the hydraulic linkage from machine body.
3. Remove the stay (2) with hydraulic control valve (3).
(1) Nut (3) Hydraulic Control Valve
(2) Stay
0000001634E
Removing Front Engine Mounting Frame

1. Remove the bolts (1).
2. Remove the front engine mounting frame (2).
3. Remove the pin (4).
4. Remove the brake spring (5) and brake rod (3).
(When reassembling)
48.1 to 55.9
Front engine mounting
frame bolt
35.4 to 41.2 ft-lbs
(1) Bolt (4) Pin

(2) Front Engine Mounting Frame (5) Brake Spring
(3) Brake Rod
0000001635E

2-S13
Fuel Tank
1. Disconnect the fuel hose (2).
2. Remove the fuel tank (1).
(1) Fuel Tank (2) Fuel Hose
0000001636E
Removing Upper Frame and Connection Plate

1. Disconnect the HST rods (2).
2. Remove the upper frame mounting bolt.
3. Remove the upper frame (1).
4. Remove the connection plate bolts (3).
5. Remove the connection plate.
(1) Upper Frame (3) Bolt
(2) HST Rod
0000001637E

2-S14
Separating the Transaxle Assembly

1. Raise up the transaxle (1) and support the machine frame (2)
with rigid jacks.
2. Disconnect the brake rod and HST rods.
3. Remove the rear wheels.
4. Remove the mounting screws.
5. Separate the transaxle (1) to rear side.
(When reassembling)
1. Using a screw driver (3), and attach the transaxle (1) to the
machine frame (2).
Clearance between 0 mm
Factory spec.
transaxle and frame (L) 0 in.
77.5 to 90.2
Transaxle assembly
7.9 to 9.2
mounting screw
57.2 to 66.5 ft-lbs
Tightening torque
48.0 to 56.0
Rear wheel mounting
4.9 to 5.7
nut
35.4 to 41.2 ft-lbs
(1) Transaxle Assembly L: Clearance between Transaxle

(2) Frame and Frame
(3) Screw Driver
0000001638E

2-S15
Hydraulic Pipes, Hoses, Transaxle Cover and Hydraulic Pump

1. Remove the delivery hose and pipe as an unit.
2. Remove the hydraulic pipes and hoses.
3. Remove the bolts and the transaxle cover (4) as an unit.
4. Remove the hydraulic pump (5).
(When reassembling)
A Take care not to damage the O-rings.
A When removing hydraulic hoses from cover (4) do not

damage the circlips.
(1) Pipe (4) Transaxle Cover
(2) Hose (5) Hydraulic Pump
(3) Bolt
0000001639E
Rear Axle Case

1. Remove the rear axle case assembly (RH) (1).
2. Remove the rear axle case assembly (LH) (2).
(When reassembling)
39.3 to 44.1
Rear axle assembly
mounting screw
28.9 to 32.5 ft-lbs
(1) Rear Axle Case Assembly (RH) (9) Shim

(2) Rear Axle Case Assembly (LH) (10) 23T Gear
(3) 48T Bevel Gear (11) Axle
(4) Shim (12) Oil Seal
(5) Side Case (13) Axle Case
(6) Shim (14) Ball Bearing
(7) 7T Gear Shaft (15) External Circlip
(8) Shim
0000001640E

2-S16
Hydrostatic Transmission Assembly

1. Remove the hydrostatic transmission assembly (LH), (RH) (1)
(2) from transmission case.
(When reassembling)
A Apply oil to the O-rings and take care not to damage them.
Hydrostatic 39.3 to 44.1
Tightening torque transmission mounting 4.0 to 4.5
screw 28.9 to 32.5 ft-lbs
(1) Hydrostatic Transmission (3) Identification Plate (LH)

Assembly (LH) (4) Identification Plate (RH)
(2) Hydrostatic Transmission
Assembly (RH)
0000001641E
Centre Section and Check and High Pressure Relief Valve
Assembly
1. Remove the centre section mounting hex. socket head
screws.
2. Tap the centre section (1) with soft hammer and separate the
centre section (1) from the HST housing.
3. Remove the plug (3) and draw out the spring (3) and check
and high pressure relief valve assembly (2).
(When reassembling)
A Cover the splines of each shaft with thin tape to protect the
sealing lip of the oil seals.
A Place a new gasket on the HST housing.
A Take care not to damage the O-ring on the plug.
A Take care not to damage the surface of cylinder blocks,

pistons and centre section.
Centre section 17.7 to 20.5
Tightening torque mounting hex. socket 1.8 to 2.1
head screw 13.1 to 15.1 ft-lbs
Check and high 24.5 to 34.3

Tightening torque pressure relief valve 2.5 to 3.5
plug 18.1 to 25.3 ft-lbs
(1) Centre Section (3) Spring

(2) Check and High Pressure Relief (4) Plug
Valve Assembly
0000001642E

2-S17
Cylinder Block Assembly and Thrust Ball Bearing

1. Lay the housing on its side.
2. Slide out the cylinder block assembly (pump) (5).
3. Slide out the cylinder block assembly (motor) (6) with the
motor shaft.
4. Remove the thrust ball bearing (4).
A Take care not to damage the surface of the cylinder

blocks
(When reassembling)
A Apply clean fluid to the surface of cylinder block.
A After installing the cylinder block assembly, check it to rotate
lightly.
1. Using robber band (12), and install cylinder block (pump) (5)
and cylinder block (motor) (6).
(1) Hydrostatic Transmission Case (7) Hydrostatic Transmission Case
(LH) (RH)
(2) Thrust Plate (8) Centre Section (RH)
(3) Pump Shaft (9) Joint Shaft
(4) Thrust Ball Bearing (10) Shim
(5) Cylinder Block Assembly (11) 19T Bevel Gear
(Pump) (12) Robber Band
(6) Cylinder Block Assembly
(Motor)
0000001643E
Swashplate, Thrust Ball Bearing, Crandle Bearing and Thrust

Washer
1. Remove the swashplate (4) from the housing.
2. Remove the thrust plates (1), thrust bearing (2) from the
swashplate (4).
3. Remove the swashplate bearings (5) from the housing.
(When reassembling)
A Apply clean fluid to the thrust washer and thrust plate.
(1) Thrust Plate (5) Swashplate Bearing
(2) Thrust Bearing (6) Pump Shaft
(3) Slot Guide (7) Motor Shaft
(4) Swashplate
0000001644E

2-S18
Pump Shaft and Motor Shaft

1. Remove the oil seal (7) and internal snap ring (8).
2. Tap the pump shaft (1) with a plastic hammer slightly to side
out it from the housing with the ball bearing (9).
3. Remove the internal snap ring (5) and the oil seal (3).
4. Tap the motor shaft (2) with a plastic hammer slightly to side
out if from the housing with ball bearing (10).
(When reassembling)
A Replace the oil seal with a new one.
A Wrap the pump shaft with a thin plastic or cellophane tape to
prevent damage to new seal lip during installation.
(1) Pump Shaft (6) Shim
(2) Motor Shaft (7) Oil Seal
(3) Oil Seal (8) Internal CIrclip
(4) Shim (9) Bearing
(5) Internal Circlip (10) Bearing
0000001645E
Input Shaft, PTO Clutch Shaft and PTO Counter Shaft
1. Remove the front PTO cover with hydraulic pump.
2. Remove the input shaft (1).
3. Remove the hydraulic pump shaft (2), the idle shaft (3), PTO
clutch shaft (4), the idle shaft (5), and the front PTO shaft (6).
(When reassembling)
A Clean the housing surface. Apply the liquid gasket.
17.7 to 20.5
Tightening torque Front PTO Cover 1.8 to 2.1
13.1 to 15.1 ft-lbs
(1) Input Shaft (4) PTO Clutch Shaft

(2) Hydraulic Pump Shaft (5) Idle Shaft
(3) Idle Shaft (6) Front PTO Shaft
0000001646E

2-S19
Disassembling PTO Clutch Assembly

1. Remove the bearing (6) and 33T/28T gear (10).
2. Remove the internal snap ring (12), then remove the pressure
plate (13), clutch disc (4) and clutch plate (22).
3. Remove the external snap ring (3), spring collar (4) and clutch
spring (15).
4. Remove the piston (17) and the clutch case (1).
5. Remove the brake plate (18) and brake disc (5).
(When reassembling)
A Apply transmission oil to the O-rings (23) and take care not to
damage it.
(1) Clutch Case (13) Pressure Plate
(2) PTO Clutch Shaft (14) Clutch Disc
(3) External Snap RIng (15) Clutch Spring
(4) Spring Collar (16) External Circlip
(5) Blake Disk (17) Piston
(6) Bearing (18) Brake Plate
(7) Clutch Ring (19) Brake Plate
(8) Collar (20) External Snap Ring
(9) Needle Bearing (21) Bearing
(10) 33T/28T Gear (22) Clutch Plate
(11) Thrust Collar (23) O-ring
(12) Internal Snap Ring
0000001647E
PTO Clutch Lever
1. Remove the external snap ring (2) and PTO clutch lever (1).
(When reassembling)
(1) PTO Clutch Lever (3) O-ring
(2) External Snap Ring
0000001648E

2-S20
Removing Brake Assembly

1. Remove the brake cover bolts.
2. Remove the brake assembly (1) from housing.
3. Remove the bolts (3) and remove brake case (9) from brake
cover (11).
4. Remove the internal snap ring (4).
5. Remove the brake discs (6) and brake plates (5) from brake
case (9).
(When reassembling)
1. Apply grease on the balls (8) not to let the ball drop.
2. Install the brake lever front end to the actuator groove firmly.
3. Install the thick brake plates to the internal snap ring sides.
4. After installing brake assembly (1), install HST (LH and RH) to
housing.
(1) Brake Assembly (7) Actuator Plate
(2) Housing (8) Ball
(3) Bolt (9) Brake Case
(4) Internal Snap Ring (10) Actuator
(5) Brake Plate (11) Brake Lever
(6) Brake Disc
0000001649E
Removing Arm and Spring
1. Remove the nut (1) from the front axle side.
2. Remove the plane washers (2) and spring (3).
3. Remove the snap pin and brake shaft.
4. Remove the brake lock lever (7).
5. Remove the brake arm (6).
(When reassembling)
1. When reassembling the brake spring (3), adjust the brake
spring length (L).
2. When parking the parking brake, adjust the brake spring
length (L).
Brake spring length at 27 mm
Factory spec.
parking (L) 1.06 in.
(1) Nut (5) Brake Rod

(2) Plane Washer (6) Brake Arm
(3) Brake Spring (7) Brake Lock Lever
(4) Plane Washer L: Brake Spring Length
0000001650E

2-S21
[2] SEPARATING FRONT PTO CASE

Removing Front Axle
See "FRONT AXLE" Section.
0000001651E
Moving Front PTO Shaft Spline Boss
1. Detach the external circlip (1) from the outer spline boss (3).
2. Move the outer spline boss (3) to the rear side.
3. Take the balls (8) from inner spline boss (2).
4. Move the inner spline boss (2) to the rear side.
5. Move the rear side spline boss (7) as the front side spline
boss.
(When reassembling)
1. Apply grease to the balls (8) not to drop.
(1) Front Axle Case (5) Front PTO Shaft
(2) Inner Spline Boss (6) External Circlip
(3) Outer Spline Boss (7) Spline Boss
(4) External Circlip (8) Ball
0000001652E
Removing Front PTO Case

1. Remove the bolts (2).
2. Remove the front PTO case (1) from machine body.
(1) Front PTO Case (2) Bolt
0000001653E

2-S22
Draining Front PTO Case Oil

1. Remove the drain bolt (1).
2. Drain the oil from front PTO case (2).
0.13 L
Front PTO case oil 0.14 U.S.qts.
0.11 Imp.qts.
(1) Drain Bolt (3) Breezer

(2) Front PTO Case
0000001654E
Disassembling Front PTO Case

1. Open the front PTO case carefully with a screw driver.
(When reassembling)
1. Clean the front PTO case surface.
2. Apply the liquid gasket on the cleaned case surface.
3. Tighten the front PTO case bolts.
17.7 to 20.5
Tightening torque Front PTO case bolt 1.8 to 2.1
13.1 to 15.1 ft-lbs
(1) Front PTO Case (Front) (5) Front PTO Case (Rear)
(2) Bearing (6) Bearing
(3) 30T Front PTO Gear Shaft (7) 25T USA Gear Shaft
(4) Bearing (8) Bearing
0000001655E

2-S23
6. SERVICING
[1] HYDROSTATIC TRANSMISSION
Centre Section
1. Check the surface (1) of centre section for scratches or wear.
If deep scratch or excessive wear is found, replace the
hydrostatic transmission assembly.
(1) Surface
0000001691E
Check and High Pressure Relief Valve

1. Check the valves (3) for scratches and damage.
2. Check the spring (2) for breakage and wear.
3. If anything are unusual, replace the valve and spring.
(1) Plug (3) Valve
(2) Spring
0000001656E
Cylinder Block Assembly

1. Check the cylinder block (1) and pistons (2) for scratches and
wear.
2. If scratch or worn, replace the cylinder block assembly.
3. Check that the piston (2), spring (3) are in each cylinder bore.
4. Check the pistons for their free movement in the cylinder block
bores.
5. If the piston or the cylinder block is scored, replace the cylinder
block assembly.
6. Check the polished face (4) of cylinder block for scoring.
7. If scored, replace the cylinder block assembly.
A Do not interchange pistons between pump and motor

cylinder block. Pistons and cylinder blocks are matched.
(1) Cylinder Block (3) Spring
(2) Piston (4) Polished Face
0000001657E

2-S24
Thrust Washer, Thrust Ball Bearing and Thrust Plate

1. Check the thrust ball bearing (3) for scratches and excessive
wear.
2. If worn, replace.
3. Check the thrust plate (4) for scratches and excessive wear.
4. If worn or scored, replace.
(1) Pump Shaft (3) Thrust Ball Bearing
(2) Thrust Washer (4) Thrust Plate
0000001658E
Pump Shaft
1. Check the seal surface (4), the bearing surface and the ball
bearing (2).
2. If the shaft is rough or grooved, replace it.
3. If the ball bearing is worn, replace it.
(1) Pump Shaft (4) Shim
(2) Ball Bearing (5) Oil Seal
(3) Seal Surface (6) Internal Snap Ring
0000001659E
Bushing and Oil Seal

1. Check the oil seals for damage.
2. Check the bushes (1) for wear.
3. If the oil seal and needle bearings are worn or damaged,
replace them.
(1) Bush
0000001660E

2-S25
[2] TRANSMISSION CASE

Checking Bearing
1. Hold the inner race, and push and pull the outer race in all
directions to check for wear and roughness.
2. Apply transmission fluid to the bearing, and hold the inner
race. Then, turn the outer race to check rotation.
3. If there is any defect, replace it.
0000001019E
Backlash and Tooth Contact between 19T Spiral Gear (A) and
19T Spiral Gear (B)
1. Measure the backlash between the 19T spiral gear (A) (1) and
19T spiral gear (B) (2).
2. When the backlash is too large, decrease the number of shims
at the side of the 19T spiral gear (A) (1), and add the shims at
the opposite side. When the backlash is too small, decrease
the number of shims at the side of the differential case, and
add the shims at the opposite side.
3. Adjust the backlash properly by repeating the above
procedure.
4. Apply red lead lightly over several teeth at three positions
equally spaced on the hypoid ring gear.
5. Turn the 19T spiral gear (B) (2) by input shaft while pressing a
wooden piece against the periphery of the bevel gear.
6. Check the tooth contact, if not proper, adjust according to the
following instruction.
Backlash between 19T
0.15 to 0.30 mm
spiral gear (A) and 19T Factory spec.
0.0059 to 0.0118 in.
spiral gear (B)
More than 25 % red lead

Tooth contact Factory spec. contact area on the gear
tooth surface
the center of tooth contact

The position of tooth
Factory spec. at 3/10 of the entire width
contact point
from the small end
(1) 19T Spiral Gear (A) (4) Shim

(2) 19T Spiral Gear (B) (5) Input Shaft
(3) Shim
0000001661E

2-S26
Correcting of Tooth Contact

1. Proper contact.
A No adjustment.
0000001662E
2. Correcting of the heel contact (A) and shallow contact (B).

A It is confirmed whether there is a shim (2).
A The 19T spiral gear (1) can be moved to backward by doing to
add the shim (2) when the thickness of the shim is not proper.
A And place the 19T spiral gear (4) side shim to the shim (2) to
move the 19T spiral gear (1) outside.
A Repeat above until the proper tooth contact and backlash are
achieved.
0000001663E
3. Correcting of the toe contact (C) and deep contact (D).

A It is confirmed whether there is a shim (2).
A The 19T spiral gear (1) can be moved to forward by removing
the shim (2) if there is a shim. (The shim (2) is not put when
there is no shim.)
A And place the shim (3) side to the 19T spiral gear (2) side shim
to move the 19T spiral gear inside.
A Repeat above until the proper tooth contact and backlash are
achieved.
(1) 19T Spiral Gear A: Heel Contact
(2) Shim B: Shallow Contact
(3) Shim C: Toe Contact
(4) 19T Spiral Gear D: Deep Contact
0000001664E

2-S27
Backlash and Tooth Contact of Rear Axle Case Gear

1. Measure the backlash between the 48T gear (1) and the 7T
gear shaft (5).
2. When the backlash is too large, decrease the number of shims
at the side of 7T gear shaft (5), and add the shim at the 48T
gear side.
When the backlash is too small, add the number of shims at
the 7T gear shaft (5), and decrease the number of shims at the
48T gear side.
Backlash between 7T 0.15 to 0.30 mm
Factory spec.
gear and 48T gear 0.0059 to 0.0118 in.
(1) 48T Gear (5) 7T Gear Shaft

(2) Shim (6) Shim
(3) Rear Axle SIde Case (7) Shim
(4) Shim (8) 23T Gear
0000001665E

2-S28
3 FRONT AXLE

CONTENTS
1. STRUCTURE.....................................................................................................................3-M1

GZD15, WSM FRONT AXLE
1. STRUCTURE
(1) Tyre (5) Pin (9) Locking Nut (1/2-20 UNF) (12) Spring Washer
(2) Front Axle Assembly (6) Snap Pin (10) Centre Pin Setting Pin (13) Centre Pin
(3) Bolt (7) Wheel Bracket (11) Slotted Nut (14) Grease Nipple
(4) Wheel Collar (8) Bolt (1/2-20 x 8.5)
The front axle is constructed as shown above. The shape of the front axle is relatively simple, and the front axle is
supported at its centre with the center pin (12), so that steering operation is stable even on uneven grounds in a grass
field.
0000001493E

3-M1
CONTENTS
4. CHECKING, DISASSEMBLING AND SERVICING ........................................................ 3-S4
[1] CHECKING AND ADJUSTING ...................................................................................... 3-S4
[2] DISASSEMBLING AND ASSEMBLING......................................................................... 3-S5
(1) Separating Floor Cover and Front Axle ................................................................... 3-S5
(2) Disassembling Front Wheel and Wheel Bracket ..................................................... 3-S7

1. TROUBLESHOOTING
Reference
Page
Front Wheels Wander A Clearance between center pin and front axle Replace
to Right or Left excessive
A Force of the bolt which tighten the wheel Adjust 3-S7
bracket has become down.
A Clearance between front axle and front axle Adjust 3-S4
support excessive
0000001498E

3-S1
Axle Rocking Force 1 to 15
9.8 to 147.1
0000001499E

3-S2
Item ft-lbs
Wheel bolt and lock nut 20 to 25 2.04 to 2.55 14.75 to 18.44
Wheel bracket lock bolt 45 to 55 4.59 to 5.61 33.19 to 40.57
0000001500E

3-S3

[1] CHECKING AND ADJUSTING
1. Lift the front axle (1).
2. Measure the front axle rocking force with a push-pull gauge.
adjust with the slottle nut (2).
4. Set the centre pin setting spring pin (4) to the centre pin (3).
(When reassembling)
Grease nipple of centre pin should be installed to upside.
9.8 to 147.1
Front axle rocking force Factory spec. 1.0 to 15
7.2 to 108.5 ft-lbs
(1) Front Axle (4) Centre Pin Setting Spring Pin

(2) Slotted Nut (5) Grease Nipple
(3) Centre Pin
0000001501E

3-S4
[2] DISASSEMBLING AND ASSEMBLING

(1) Separating Floor Cover and Front Axle
Removing Motion Control Lever
1. After removing seat with seat bracket, remove the motion
control lever (1).
(1) Motion Control Lever (3) Screw
(2) Screw (4) Floor Cover
0000001502E
Removing Brake Pedal and Hydraulic Lift Pedal

1. Remove the brake pedal (1) and hydraulic lift pedal (2).
(1) Brake Pedal (3) Screw
(2) Hydraulic Lift Pedal (4) Screw
0000001503E
Removing Front Weight

1. Remove screws (2) and nuts (3).
2. Remove front weight from machine.
(When reassembling)
45.0 to 55.0
Front weight mounting
screw and nut
33.2 to 40.6 ft-lbs
(1) Front Weight (3) Nut (with spring washer and

(2) Screw (with spring washer and plane washer)
plane washer)
0000001504E

3-S5
Removing Floor Sheet Cover

1. Remove screws (2) under the floor sheet cover (1).
2. Remove the floor sheet cover (1).
3. Remove the front weight bracket (3).
(1) Floor Sheet Cover (4) Lift Cylinder Stay
(2) Screw (5) Front Axle
(3) Front Weight Bracket
0000001505E
Separating Front Axle

1. Remove the lift cylinder stay (3).
2. Lift up the machine and support the machine right side and left
side frame with rigid jacks.
3. Remove the set spring.
4. Loosen the slotted nut (4).
5. Remove the centre pin (2) from the front axle (1).
6. Separate the front axle (1) from the machine slowly.
(When assembling)
Check the front axle rocking force. (See page 3-S4.)
(1) Front Axle (3) Lift Cylinder Stay
(2) Centre Pin (4) Slotted Nut
0000001506E

3-S6
(2) Disassembling Front Wheel and Wheel Bracket

Removing the Front Wheel
1. Inspect tyre and wheel for wear or damage. Replace tyre as
an assembly.
(When reassembling)
20 to 25
Front wheel mounting
bolt and locking nut
14.75 to 18.44 ft-lbs
(1) Bolt (4) Oil Seal

(2) Locking Nut (5) Spacer
(3) Taper Roller Bearing (6) Sleeve
0000001507E
Removing the Wheel Bracket
1. Remove the bolt (1).
2. Remove the wheel bracket (4).
3. Inspect all parts for wear or damage. Replace the parts as
needed.
(When reassembling)
45 to 55
Tightening torque Wheel Bracket Bolt 4.59 to 5.61
33.19 to 40.57 ft-lbs
(1) Bolt (4) Front Axle

(2) Collar (5) Wheel Bracket
(3) Bush
0000001508E

3-S7
4 HYDRAULIC SYSTEM

CONTENTS
1. HYDRAULIC CIRCUIT .....................................................................................................4-M1
2. HYDRAULIC PUMP..........................................................................................................4-M2
3. HYDRAULIC CONTROL VALVE .....................................................................................4-M3
4. LIFT CYLINDER .............................................................................................................4-M11
[1] MOWER LIFT CYLINDER ...........................................................................................4-M11
[2] GRASS COLLECTOR LIFT CYLINDER AND GRASS COLLECTOR
DUMP CYLINDER ........................................................................................................4-M12
5. MOWER LINKAGE .........................................................................................................4-M13
6. GRASS COLLECTOR CONTROL MECHANISM.........................................................4-M14
[1] COMPARISON OF HIGH DUMP AND LOW DUMP GRASS COLLECTOR .........4-M14
[2] GRASS COLLECTOR CONTROL MECHANISM .......................................................4-M15

GZD15, WSM HYDRAULIC SYSTEM
1. HYDRAULIC CIRCUIT
(1) PTO Clutch (5) Grass Collector Lift (8) Grass Collector Dumping (13) Regulator Valve
(2) PTO Clutch Valve Cylinder (LH) Control Valve (14) Oil Filter
(3) Hydraulic Control Valve (6) Grass Collector Dump (9) Mower Lifting Control Valve (15) HST (LH)
Assembly Cylinder (10) Check Valve (16) HST (RH)
(4) Grass Collector Lift (7) Grass Collector Lifting (11) Relief Valve (17) Hydraulic Pump
Cylinder (RH) Control Valve (12) Mower Lift Cylinder (18) Oil Strainer
The hydraulic system of this machine is composed of a hydraulic pump (17), control valve assembly (3), grass
collector lift cylinder (4), (5) and other components.
This system has the following functions.
Oil is supplied by hydraulic pump (17) which is driven by engine.
Power from the input shaft (pump shaft) is distributed right and left with the bevel gears and drives each hydrostatic
transmission (15), (16).
Moreover, oil from the hydraulic pump (17) is sent to the transmission centre case through the control valve. On
the other hand, oil is regulated with the regulator valve (13) to constant pressure and sent to the hydrostatic
transmission (15), (16) and PTO clutch (1).
0000001566E

4-M1
2. HYDRAULIC PUMP
The hydraulic pump is composed of the casing (1),
cover (6), side plate (4), and two spur gears (drive (2)
and driven gear (3) )that are in mesh.
Hydraulic pump is driven by the pump drive shaft in
the transmission case.
Maximum displacement is as follows.
Displacement Engine speed Condition
14.5 L/min.
3.8 U.S.gal/min. At 3000 rpm at no load
3.2 Imp.gal/min.
(1) Casing (4) Side Plate

(2) Drive Gear (5) Double Ring
(3) Driven Gear (6) Cover
0000001567E

4-M2
3. HYDRAULIC CONTROL VALVE

GZD15's hydraulic control system consists of control
levers (or pedal), rod, hydraulic control valve (1),
hydraulic hoses, cylinders and other components.
Filtered oil is forced out by the hydraulic pump to the
control valve (1) through the delivery pipe.
The movement of grass collector lifting control valve,
grass collector dumping control valve or mower lifting
control valve switch the oil flow, and the oil is channeled
to the grass collector lift cylinder, grass collector dump
cylinder, or mower lift cylinder, or returned to the
transmission case through the return pipe.
(1) Control Valve Body P: Pump Port
(2) Spool (Mower Lift T: Tank Port
Cylinder) PB: Power beyond port
(3) Spool (Grass Collector A1: A1 Port
Lift Cylinder) A2: A2 Port
(4) Spool (Grass Collector A3: A3 Port
Dump Cylinder) B2: B2 Port
(5) Relief Valve B3: B3 Port
0000001568E

4-M3
B Mower Lift Cylinder "NEUTRAL"

1) Since the hydraulic lift pedal is not pushed, the
spool (2) is not pushed in and is not pulled out from the
control valve(1).
2) High-pressured oil is forced through "C" port to the
second and the third spool port in the control valve (1).
3) Oil passage between the spool (2) and the control
valve (1) is not formed. Hydraulic oil from the mower lift
cylinder is kept in delivery hose and in the control valve
(1).
4) While the control valve keeps "NEUTRAL"
position, mower does not lower down.
(1) Control Valve (2) Spool
0000001569E
B Mower Lift Cylinder "LIFT"
1) When the hydraulic lift pedal is pushed to the
"LIFT" position, the spool (2) is pushed into the control
valve (1).
valve (1) is formed. High-pressured oil delivered from
"P" port is forced through the orifice (3) of the spool (2)
to "A1" port.
3) Since the oil is forced through the mower delivery
hose to the mower lift cylinder, the mower is lifted up.
(1) Control Valve (3) Orifice
(2) Spool
0000001570E
B Mower Lift Cylinder "DOWN"
1) When the hydraulic lift pedal is pushed to the
"DOWN" position, the spool (2) is pushed out from the
control valve (1).
2) High-pressure oil delivered from the hydraulic
pump is forced to the second and the third spool ports.
3) Oil passage between the spool "A1" port side and
the control valve (1) is formed.
Oil in the mower lift cylinder is returned though "A1"
port and the spool orifice (3) to "T" port.
4) While the hydraulic lift pedal is pushed to the
"DOWN" position, the mower is lowering down with its
weight.
(2) Spool
0000001571E

4-M4
Grass collector dump cylinder is a double action type.

Grass collector dump cylinder is connected to the
control valve "A2" and "B2" ports with the hydraulic
hoses.
B Grass Collector Dump Cylinder "NEUTRAL"
1) When the control lever is set to the "NEUTRAL"
position, the spool (2) is stopped.
2) High-pressured oil is forced out from "B" port to
"C" port.
valve (1) is not formed in both "A2" and "B2" port sides.
Hydraulic oil from the grass collector dump cylinder is
kept in the delivery hoses and in the control valve (1).
4) While the control lever is kept to the "NEUTRAL"
position, the grass collector is not opened and closed.
0000001572E
B Grass Collector Dump Cylinder "OPEN"
1) When the control lever is set to "OPEN" position,
the spool (2) is pushed into the control valve (1).
2) In "A2" port side, oil passage between the spool
(2) and the control valve (1) is formed.
"P" port and "A2" port are connected through orifice (2)
of the spool (1).
High-pressured oil is forced out from "P" port to "A2"
port and grass collector dump cylinder.
3) In "B2" port side, oil passage between the spool
"B2" port is connected to "PB" port. Since oil in the
grass collector dump cylinder is returned to the "PB"
port, grass collector is opened.
4) While the control lever is kept to the "OPEN"
position, the grass collector is opened.
(2) Spool
0000001573E

4-M5
B Grass Collector Dump Cylinder "CLOSE"

1) When the control lever is set to the "CLOSE"
position, the spool (2) is pushed out from the control
valve (1).
2) In "A2" port side, oil passage between "A2" port
and "PB" port is formed.
Oil in "A2" port is returned to "PB" port.
3) In "B2" port, oil passage between the spool (2) and
the control valve (1) is formed, and high-pressured oil is
forced out from "P" port to "B2" port. Since this oil is
forced out to the grass collector dump cylinder, the
grass collector is closed.
4) While the control lever is kept to the "CLOSE"
position, the grass collector is closed.
(2) Spool
0000001574E

4-M6
Grass collector lift cylinder is a double action type.

Grass collector lift cylinder is connected to the control
valve "A3" and "B3" ports with the hydraulic hoses.
B Grass Collector Lift Cylinder "NEUTRAL"
1) When the control lever is set to the "NEUTRAL"
position, the spool (2) is stopped.
2) High-pressured oil is forced out from "B" port to
"C" port.
valve (1) is not formed in both "A3" and "B3" port sides.
Hydraulic oil from the grass collector lift cylinder (lift and
right side) is kept in the delivery hoses and in the control
valve (1).
4) While the control lever is kept to the "NEUTRAL"
position, the grass collector lift cylinder does not lift up
and lower down.
0000001575E
B Grass Collector Lift Cylinder "LIFT"
1) When the control lever is set to "LIFT" position, the
spool (2) is pushed into the control valve (1).
2) In "A3" port side, oil passage between the spool
"P" port and "A3" port are connected through orifice (3)
of the spool (2).
High-pressured oil is forced out from "P" port to "A3"
port and grass collector lift cylinder.
3) In "B3" port side, oil passage between the spool
"B3" port is connected to "PB" port. Since oil from
"B3" port flows to "PB" port, the grass collector lift
cylinder (left and right) is lifted up.
4) While the control lever is kept to the "LIFT"
position, the grass collector is lifted up.
(2) Spool
0000001576E

4-M7
B Grass Collector Lift Cylinder "DOWN"

1) When the control lever is set to the "DOWN"
position, the spool (2) is pushed out from the control
valve (1).
2) In "A3" port side, oil passage between "A3" port
and "PB" port is formed.
Oil in "A2" port is returned to "PB" port.
3) In "B3" port, oil passage between the spool (2) and
the control valve (1), and high-pressured oil is forced out
from "P" port to "B3" port. Since this oil is forced out to
the grass collector lift cylinder (left and right side), the
grass collector is down.
4) While the control lever is kept to the "DOWN"
position, the grass collector is lowered down.
(2) Spool
0000001577E

4-M8
B Relief Valve
The implement control system circuit has a relief
valve to restrict the maximum pressure in the circuit.
The relief valve is located in the hydraulic control valve
assembly.
The relief valve is the adjusting screw with damping
effect.
Among direct acting relief valves, this type is suited to
higher pressure and has large capacity. Furthermore,
this type is free from unstable operation, such as
chattering, which occurs often in direct acting relief
valves.
As shown in the figure, the valve is attached to the
control valve body.
When the oil pressure in the circuit is lower than the
setting pressure of the relief valve, the relief valve is not
operated and the oil fed to the relief valve from the
hydraulic pump flows into the implement control valve.
As the oil pressure in the circuit increases, so does
the pressure in the chamber. When the pressure rises
above the valve setting and overcomes the spring force,
the valve opens. Oil then flows out to PB port,
preventing any further rise in pressure. The valve
closes again when enough oil is released to drop
pressure below the valve setting.
(Reference)
A Relief valve setting pressure:
10.79 to 11.77 MPa
110 to 120
1566 to 1708 psi
A Engine speed: Maximum
A Oil temperature:
50 to 60
122 to 140
(1) Control Valve P: Pump Port
(2) Valve T: Tank Port
(3) Washer PB: PB Port
(4) Spring
(5) Nut
(6) Adjusting Screw
0000001578E

4-M9
B Check Valve
The implement control system circuit has a check
valve to prevent the oil leak in the circuit. The check
valve is located in the hydraulic control valve assembly.
The check valve is the spring type.
As shown in the figure, the valve is attached to the
control valve body.
After starting the engine, hydraulic oil pressure in the
control valve increases.
This oil pressure from pump port pushes and opens
the check valve (2).
The oil is delivered to the each spool to control the oil
flows such as the mower lift and the grass collector lift
and dump.
On the other hand, after stopping the engine,
hydraulic oil pressure in the control valve decreases.
The oil pressure from the spool side pushed and close
the check valve.
And the check valve prevents the oil to leak from oil
circuit such as the mower lift cylinder, and the grass
collector cylinder.
(1) Control Valve P: Pump Port
(2) Valve
(3) Spring
0000001579E

4-M10
4. LIFT CYLINDER
[1] MOWER LIFT CYLINDER
(1) Tube End

(2) Snap Ring
(3) Cylinder Tube
(4) Packing
(5) Scraper
(6) Piston Rod
The lift cylinder consists of the tube end (1), cylinder tube (3), piston rod (6) and other parts as shown in the figure
above.
This cylinder is single acting type.
0000001580E

4-M11
[2] GRASS COLLECTOR LIFT CYLINDER AND GRASS COLLECTOR

DUMP CYLINDER
(1) Piston Rod (3) Cylinder Tube (5) Nut B: Rod O.D.
(2) Head (4) Piston A: Cylinder I.D. C: Stroke
The cylinder consists of a head (2), cylinder tube (3), piston rod (1), piston (4) and other parts as shown in the figure
above.
This is single-rod double acting cylinder in which the reciprocating motion of the piston is controlled by hydraulic
force applied to both of its ends.
Cylinder Specifications
Grass Collector Lift Cylinder Grass Collector Dump Cylinder
Cylinder tube I.D. (A) 40 mm (1.57 in.)
Rod O.D. (B) 20 mm (0.79 in.)
Stroke (C) 368 mm (14.49 in.) 93 mm (3.66 in.)
0000001581E

4-M12
5. MOWER LINKAGE
(1) Mower Lift Pedal (4) Lift Rod (8) Front Link (12) Lift Link Shaft
(2) Cutting Height Adjusting (5) Control Valve (9) Cam Arm (13) Rear Arm
Dial (6) Lift Cylinder (10) Mower (14) Rear Link
(3) Lift Rod (7) Delivery Hose (11) Adjusting Cam (15) Link Retainer
The mower rear link (14) and rear arm (13) are linked with lift link (2), (12), lift link rear (3), (10) lift link shaft (12)
and mower lift arm (6).
As the hydraulic control pedal (1) moves to up position, front link (8) is raised and lift link shaft (12) is rotated to pull
the rear link (14) to upward. As a result, mower (10) are lifted.
The cutting height adjusting dial (2) adjusts cutting height of mower by rotating the adjusting cam (11). The position
of mower rear link (14) are adjusted by changing the lift rod (4).
0000001582E

4-M13
6. GRASS COLLECTOR CONTROL MECHANISM

[1] COMPARISON OF HIGH DUMP AND LOW DUMP GRASS COLLECTOR
Item High Dump Low Dump

Lift Base O
Lift Arm O
Lift Cylinder O
Lift Cylinder Hose O
Restriction Wire O
O O
Bag Base
Fixed to lift arm Fixed to machine frame
Dump Cylinder O O
O O
Bag Cover
Fixed to lift arm Fixed to machine frame
Grass Collector O O
O: Equipped, : None
High dump and low dump grass collector mainly differs in the items shown in the table.
As shown in the table, the structure of the low dump is simpler than the high dump.
In this WSM, "Mechanism" and "Servicing" of high dump grass collector are mainly written in "HYDRAULICS"
section.
0000001583E

4-M14
[2] GRASS COLLECTOR CONTROL MECHANISM

B Grass Collector Lifting and Lowing Mechanism
Grass collector lift arm (2) is connected with two lift
cylinders (3).
When the grass collector control lever (1) is set to the
"UP" (A) position, hydraulic oil is delivered to the lift
cylinders (3).
The lift cylinders (3) are extended and lift the lift arms
(2). And grass collector is lifted up.
When the grass collector control lever (1) is set to the
"DOWN" (B) position, hydraulic oil is delivered to the lift
cylinders (3). The lift cylinders (3) are shortened and
lowers the lift arms. And grass collector (5) is lowered
down.
B Grass Collector Dumping and Closing
Mechanism
After lifting up the grass collector, the restriction wire
connected to the lift arm (right side) opens the guide
located at the grass collector control lever (1).
After that, this control lever (1) is set to the "DUMP"
(C) position, hydraulic oil is delivered to the dump
cylinder (4).
The dump cylinder is shortened.
The grass collector is opened.
When the control lever (1) is set to the "CLOSED" (D)
position, the dump cylinder (4) is extended. And the
grass collector is closed.
(1) Grass Collector Control A: UP
Lever B: DOWN
(2) Lift Arm C: DUMP
(3) Lift Cylinder D: CLOSE
(4) Dump Cylinder N: NEUTRAL
(5) Grass Collector
0000001584E

4-M15
CONTENTS
[1] HYDRAULIC CONTROL VALVE AND PUMP ............................................................. 4-S4
(1) Checking and Adjusting (GZD15-HD(E) Serial No. : Below 10736) ........................ 4-S4
(2) Disassembling and Assembling............................................................................... 4-S6
[2] MOWER LIFT CYLINDER ............................................................................................. 4-S8
[3] GRASS COLLECTOR LIFT CYLINDER ....................................................................... 4-S9
[4] GRASS COLLECTOR DUMP CYLINDER.................................................................. 4-S11

1. TROUBLESHOOTING
Reference
Page
Mower Does Not Rise A Control valve malfunctioning Repair or replace 4-S6, S7
A Lift cylinder damaged Replace 4-S8
A Relief valve spring damaged Replace 4-S6
A Relief valve setting pressure too low Adjust 4-S5
A Hydraulic pump defective Replace
A Oil strainer clogged Clean or replace G-23
A Suction pipe loosened or broken Repair or replace
A Suction pipe O-ring damaged Replace
A Insufficient transmission oil Refill G-17, 21
A Mower lifting linkage between mower lift pedal Adjust linkage
and mower lift lever is not proper
Mower Does Not A Control valve malfunctioning Repair or replace 4-S6, S7
Lower
Mower Drops by Its A Lift cylinder worn or damaged Replace 4-S10
Weight
A Control valve malfunctioning Replace 4-S6, S7
Grass Collector Does A Control valve malfunctioning Repair or replace 4-S6, S7
Not Rise
A Lift cylinder damaged Replace 4-S8
Not Lower
A Lift cylinder damaged Repair 4-S10
Grass Collector Drops A Lift cylinder worn or damaged Replace 4-S10
By Its Weight
A Control valve malfunctioning Replace 4-S6, S7

4-S1
Reference
Page
Not Dump
A Lift cylinder damaged Repair 4-S10, S11
A Lift arm wire adjustment is not proper Adjust the length of lift 4-S4
arm wire
Not Close
A Lift cylinder damaged Repair 4-S10, S11
A Lift arm wire adjustment is not proper Adjust the length of lift 4-S4
arm wire
0000001585E

4-S2
Relief Valve (Control Valve) Setting Pressure 10.79 to 11.77 MPa
110 to 120
1560 to 1708 psi
0000001586E

4-S3

[1] HYDRAULIC CONTROL VALVE AND PUMP
(1) Checking and Adjusting (GZD15-HD(E) Serial No. : Below 10736)
Adjusting Length of Lift Arm Wire
2. Lift up the grass collector and keep it at horizontal as shown in
the picture.
3. Adjust the length of the lift arm wire so that the control lever
can be shifted from "LIFT" position (A) to "DUMP" position
(B).
4. If the wire adjustment is not proper, the control lever can not
be shifted, or the control lever can be shifted at the lowest
position.
5. After adjusting the wire adjustment, check whether the control
lever operates smoothly.
Length of lift arm wire 8.5 mm
Reference value
adjustment (L) 0.33 in.
Length of lift arm wire 6.0 mm

Reference value
adjustment (M) 0.24 in.
(1) Grass Collector Wire A: "LIFT" Position

(2) Nut B: "DUMP" Position
(3) Control Lever L: Length of Lift Arm WIre
Adjustment (Lift Cylinder
Side)
M: Length of Lift Arm Wire
Adjustment (Control Lever
Side)
0000001587E

4-S4
Relief Valve Setting Pressure

1. Disconnect the lift cylinder delivery hose (5).
2. Install the adaptor (3) and hydraulic pressure gauge (4) to lift
cylinder adaptor (2). And install the delivery hose (5) to the
adaptor (3).
3. Start the engine and set at maximum speed.
4. Move the control lever (6) to "DOWN" position to operate the
relief valve and read the gauge.
5. If the pressure is not within the factory specifications, adjust
the relief valve adjusting screw (8).
10.79 to 11.77 MPa
Relief valve setting
Factory spec. 110 to 120
pressure
1566 to 1708 psi
Condition
A Engine Speed.....Maximum
A Oil temperature.....50 to 60
122 to 140
(1) Lift Cylinder T: Tank Port
(2) Lift Cylinder Adaptor P: Pump Port
(3) Adaptor PB Power Beyond Port
(4) Hydraulic Pressure Gauge
(5) Hydraulic Delivery Hose
(6) Control Lever
(7) Control Valve
(8) Relief Valve Adjusting Screw
0000001588E

4-S5

Removing Control Valve
A Since clearance between hydraulic hoses is very narrow.

Thin and narrow open-end spanner 17-19 mm is required.
1. Remove the nuts (1).
2. Remove the control valve and bracket as a unit.
3. Remove the control valve (2) with the control valve adaptor
(3).
4. Remove the control valve adaptor (3) from the control valve
(2).
(When reassembling)
A Take care not to damage the hydraulic hoses.
A Install the adaptors, the hydraulic hoses and pipes to the
control valve as the picture and the illustration.
(1) Nut A1-B3: Control Valve Port
(2) Control Valve PL: Plug
(3) Adaptor S: Straight Adaptor
(4) Hydraulic Hose L: L Type Adaptor
(5) Hydraulic Pipe T: T Type Adaptor
0000001589E
Relief Valve
1. Unscrew the lock nut (2) and the relief adjusting screw (1) from
the control valve (7).
2. Remove the washer (5) spring (4) and valve (6).
(When reassembling)
A Take care not to damage the O-ring (3).
A After reassembling the relief valve, be sure to adjust its

setting pressure. (See page 4-S5.)
(1) Adjusting Screw (5) Spring
(2) Lock Nut (6) Valve
(3) O-ring (7) Control Valve
(4) Washer
0000001590E

4-S6
Spool Cover and Spool

1. Unscrew the valve cover mounting screws (1) and remove the
valve cover (2) from the control valve rear side.
2. Remove the screws (4) and plate (3) from the control valve
front side.
3. Unscrew the screws (12).
4. Pull out the spool (7).
(When reassembling)
A Visually inspect the spool for signs of scoring or damage. If
defects are found, replace it.
A Correctly insert the spool (7) to the original groove of the
control valve.
(1) Screw (7) Spool
(2) Cover (8) Collar
(3) Plate (9) Spring Guide
(4) Screw (10) Spring
(5) Back-up Ring (11) Washer
(6) O-ring (12) Screw
0000001591E
Removing Check Valve

1. Removing the plug (1) from control valve (5).
2. Remove the spring (3) and valve (4).
3. Check and clean the valve (4) and the spring (3)
(When reassembling)
(1) Plug (4) Valve
(2) O-ring (5) Control Valve
(3) Spring
0000001592E

4-S7
Removing Relief Valve

1. Remove the internal snap ring (5) from housing case (6).
2. Remove the plug (4).
3. Remove the spring (2) and valve (1).
4. Check and clean the valve (1) and spring (2).
(When reassembling)
A After reassembling the relief valve, be sure to adjust its

setting pressure. (See page "TRANSAXLE" Section.)
(1) Valve (4) Plug
(2) Spring (5) Internal Snap Ring
(3) O-ring (6) Housing Case
0000001593E
[2] MOWER LIFT CYLINDER

Removing Mower Lift Cylinder
1. Disconnect the cylinder hose (4) from the lift cylinder (3).
2. Remove the clevis pins (2) and remove the lift cylinder (3).
3. Check the oil leaks from lift cylinder.
4. If the oil leaks are found, change the cylinder as an assembly.
(When reassenbling)
A Note the direction of the adaptor (5).
A Use hydraulic thread sealer on the taper thread of adaptor (5),
(4).
(1) Pin (4) Cylinder Hose
(2) Clevis Pin (5) Adaptor
(3) Lift Cylinder
0000001595E

4-S8
Disassembling Mower Linkage

(1) Grip
(2) Lift Rod
(3) Cam
(4) Retain Spring Plate
(5) Mower Front Link
(6) Lift Shaft
(7) Rear Boss
(8) Rear Arm
(9) Mower Rear Link
(10) Hinge Pin
(11) Hinge Spring
(12) Mower Link Retainer
0000001596E
1.Remove the grip (1).

2.Remove the lift rod (2).
3.Remove the cam (3).
4.Remove the mower rear link (9) and the rear arm (8).
5.Remove the rear boss (7) and the lift shaft (6).
(When reassembling)
A Apply grease around the rear boss (7).
A Do not damage the retain spring plate (4).
0000001597E
[3] GRASS COLLECTOR LIFT CYLINDER

Removing Grass Collector Lift Cylinder
1. Disconnect the hydraulic hoses (5) from the adaptors (4).
2. Remove the pins (1) and the clevis pins (2).
3. Remove the lift cylinder (3) from the machine.
(When reassembling)
A Note the directions the adaptor (4).
(1) Pin (4) Adaptor
(2) Clevis Pin (5) Hydraulic Hose
(3) Lift Cylinder
0000001598E

4-S9
Disassembling Lift Cylinder

1. Remove the head (2) with a wrench.
2. Remove the piston rod (1) from the cylinder tube (3).
3. Remove the nut (6) and piston (5) from the piston rod (1).
4. Remove the head (2) from piston rod (1).
5. Remove the O-rings (7) (8) and back-up rings from the head
(2).
6. Remove the O-ring (9) (10) and back-up ring (11) from the
piston (5).
(When reassembling)
A Take care not to damage the O-ring (7), (8), (9), (10) and back-
up rings (11).
(1) Piston Rod (7) O-ring
(2) Head (8) O-ring
(3) Cylinder Tube (9) O-ring
(4) Adaptor (10) O-ring
(5) Piston (11) Back-up Ring
(6) Nut
0000001594E

4-S10
[4] GRASS COLLECTOR DUMP CYLINDER

Removing Grass Collector Dump Cylinder
1. Remove the grass collector (1) from the machine.
2. Disconnect the hydraulic hoses (2) from the dump cylinder (3).
3. Remove the pin (4) and the clevis pin from the machine.
4. Remove the dump cylinder from the machine.
(When reassembling)
A Note the hydraulic hoses arrangement.
A Install and band the hydraulic hoses with plastic bands to
move smoothly.
(1) Grass Collector (4) Pin
(2) Hydraulic Hose (5) Clevis Pin
(3) Dump Cylinder (6) Grass Collector Base
0000001599E
Disassembling Grass Collector Dump Cylinder

1. Refer to grass collector lift cylinder. (See page 4-S10.)
0000001600E

4-S11
5 ELECTRICAL SYSTEM

CONTENTS
1. WIRING DIAGRAM...........................................................................................................5-M1
2. STARTING SYSTEM ........................................................................................................5-M4
[1] STARTER ........................................................................................................................5-M7
[2] GLOW PLUG ..................................................................................................................5-M8
[3] SAFETY SWITCH (LIMIT SWITCH) .............................................................................5-M8
[4] FUEL PUMP ...................................................................................................................5-M9
[5] ENGINE STOP SOLENOID...........................................................................................5-M9
3. CHARGING SYSTEM.....................................................................................................5-M10
[1] AC DYNAMO ................................................................................................................5-M11
[2] REGULATOR.................................................................................................................5-M11
[3] EASY CHECKER (TM) ................................................................................................5-M12

GZD15, WSM ELECTRICAL SYSYTEM
1. WIRING DIAGRAM
Colour of Wiring
W......White WB.....White / Black RY......Red / Yellow

R.......Red GB....Green / Black YW.......Yellow / White
L.......Blue OrL.....Orange / Blue BW.......Black / White
P.......Pink YB......Yellow / Black BR.......Black / Red
B......Black BrR......Brown / Red GW.......Green / White
G.....Green WR......White / Red YR.......Yellow / Red
Or......Orange WY.....White / Yellow YL.......Yellow / Blue
BY......Black / Yellow RW.....Red / White
0000001509E

5-M1
0000001510E

5-M2
0000001511E

5-M3
2. STARTING SYSTEM
When the main switch is turned to the PREHEAT position, the terminal B is connected to the terminals G and ACC.
The glow plugs become red-hot, and the preheat indicator lamp also lights on while preheating.
When the main switch is then turned to the START position with the safety switches on, the terminal B is connected
to the terminals ST and ACC. Consequently, battery current flows to the starter motor and start the engine.
The main switch automatically returns to the ON position, the terminal B is connected only to the terminal ACC,
thereby causing the starting circuit to be opened, stopping the starter motor.
When the main switch turned from the ON position to the OFF position, the fuel cut-off solenoid moves the fuel
injection pump control rack to the "No Fuel Injection" position and stop the engine.
0000001513E

5-M4
Table 1. Engine Stop and Start Control
Switch and
Engine Remarks Switch Position
Control
Motion Forward and
Control Lever Reverse:OFF, ON ON ON ON ON ON ON ON
Switch Neutral:ON
Engaged:OFF
PTO Switch ON ON ON ON ON ON ON ON
Disengaged:ON
Engaged:ON
Brake Switch ON ON ON ON OFF OFF OFF OFF
Released:OFF
On Seat:OFF
Seat Switch ON ON OFF OFF ON ON OFF OFF
Off Seat:ON
Closed and
Grass
Down:ON
Collector ON OFF ON OFF ON OFF ON OFF
Open and Lift
Switch
Up:OFF
Engine Stop:
Engine Stop Running Running Running Running Running Running Stop Stop
Solenoid ON
Not Not Not Not Not Not
Engine Start Start Start
Start Start Start Start Start Start
Engine is started when the motion control lever (L, R) is set to "NEUTRAL" position, PTO lever is set to "OFF"
position, operator is sitting on the operator's seat and the brake pedal is depressed. In other cases, engine is not
started.
Switch and
Control
Motion Forward and
Control Lever Reverse:OFF, ON ON ON ON ON ON ON ON
Switch Neutral:ON
Engaged:OFF
PTO Switch OFF OFF OFF OFF OFF OFF OFF OFF
Disengaged:ON
Engaged:ON
Released:OFF
On Seat:OFF
Off Seat:ON
Closed and
Grass
Down:ON
Open and Lift
Switch
Up:OFF
Engine Stop:
Engine Stop Running Stop Stop Stop Running Stop Stop Stop
Solenoid ON
Not Not Not Not Not Not Not Not
Engine Start
Start Start Start Start Start Start Start Start

5-M5
Switch and
Control
Motion Forward and
Control Lever Reverse:OFF, OFF OFF OFF OFF OFF OFF OFF OFF
Switch Neutral:ON
Engaged:OFF
PTO Switch ON ON ON ON ON ON ON ON
Disengaged:ON
Engaged:ON
Released:OFF
On Seat:OFF
Off Seat:ON
Closed and
Grass
Down:ON
Open and Lift
Switch
Up:OFF
Engine Stop:
Engine Stop Running Running Stop Stop Running Running Stop Stop
Solenoid ON
Engine Start
Switch and
Control
Motion Forward and
Control Lever Reverse:OFF, OFF OFF OFF OFF OFF OFF OFF OFF
Switch Neutral:ON
Engaged:OFF
PTO Switch OFF OFF OFF OFF OFF OFF OFF OFF
Disengaged:ON
Engaged:ON
Released:OFF
On Seat:OFF
Off Seat:ON
Closed and
Grass
Down:ON
Open and Lift
Switch
Up:OFF
Engine Stop:
Engine Stop Running Stop Stop Stop Running Stop Stop Stop
Solenoid ON
Engine Start
0000001692E

5-M6
[1] STARTER
(1) Housing
(2) Magnetic Switch
(3) Overrunning Clutch
(4) Drive Lever
(5) Internal Gear
(6) Gear Shaft
(7) Planetary Gear
(8) Armature Shaft
(9) Yoke
(10) Brush Holder
(11) Rear End Holder
The reduction system is used planetary gears, and the speed of gear shaft (6) is reduced to approximately one fifth
of the armature shaft (8).
0000001514E

5-M7
[2] GLOW PLUG

This plug is a two-material type QGS (Quick Glow
System) for quick temperature rise, and has self-
controlling function as well as excellent durability.
The heater (4) connected in series to the heater (3),
which also functions as the resistor, is incorporated in
the sheath tube (1) of the super glow plug.
The resistance of this heater (3) cum resistor is small
when the temperature is low, while the resistance
becomes large when the temperature rises.
Therefore, because sufficient current is flown to the
heater (4) during the initial period of energization, the
temperature rises quickly and the resistance grows with
the rise in the temperature of the resistor, the flowing
current is reduces to prevent the heater (4) from being
heated.
The ignition point is in the area of 2 to 3 mm (0.079 to
0.118 in.) from the tip of the plug in order to reduce its
projection into the combustion chamber.
(1) Sheath Tube (a) Glow Plug Temperature
(2) Insulation Powder ( )
(3) Heater also functioning as (b) Current (A)
as a Resistor (c) Time (Sec.)
(4) Heater
(5) Super Glow Plug
(6) Conventional Quick-
heating type Glow Plug
(7) Glow Plug Current
0000001515E
[3] SAFETY SWITCH (LIMIT SWITCH)

The safety switch prevents current from flowing to the
starter when the safety switches are not depressed.
This is to ensure safe starting or stopping.
The safety switches are located on five (parking brake
lever, motion control lever, operator's seat, PTO lever
and grass collector) different positions.
0000001516E

5-M8
[4] FUEL PUMP

An electro magnetic fuel pump uses a transistor that
causes the pump to start pumping fuel when the main
switch is turned to the "ON" position.
Therefore, fuel is supplied to the fuel injection pump
regardless of engine speed. This pump is driven by the
battery. It can therefore be operated even with the
engine being stopped.
A: Inlet B: Outlet
0000001517E
[5] ENGINE STOP SOLENOID

The timer relay is provided to actuate the engine stop
solenoid approx. 10 seconds to stop after the main
switch is turned from ON position to OFF position.
Flowing of the battery current into the coil while the
timer relay contact point is closed attracts the plunger to
actuate the stop lever of the injection pump. When the
battery current stops, the plunger is returned to the
original position by the spring.
A: ON B: OFF
0000001518E

5-M9
3. CHARGING SYSTEM
The charging system supplies electric power for various electrical devices and also charges the battery while the
engine runs.
It consists of a AC dynamo and a regulator.
0000001519E

5-M10
[1] AC DYNAMO
The dynamo is an 8-8 pole rotating magnet type
generator. It is simple in construction, consisting of a
stator and rotor. The rotor is made up of eight
permanent magnet pole pieces assembled on a shaft
and rotates on the center of the stator around which
eight electromagnetic coils are provided for.
This dynamo produces higher voltage in slow speed
rotation, and charges electric current to the battery
during engine idling.
0000001520E
[2] REGULATOR
The regulator performs rectification and voltage
regulation.
The regulator converts AC into DC which flows
through the power consuming circuits and the battery,
and also charges the battery.
If however, the battery voltage exceeds a certain
level, the DC current is cut off from the charging circuit
to prevent overcharging.
0000001521E

5-M11
[3] EASY CHECKER (TM)

To check the conditions of the machine easily before and during operation, easy checker combination of lamps on
the easy checker board is provided.
0000001531E
B Indication Items
(1) Electrical Charge Lamp
If the alternator is not charging the battery, the
warning lamp in the Easy Checker (TM) will come on.
If this should happen during operation, check the
electrical charging system.
(2) Coolant Temperature Lamp
If this warning light comes on during operation, take
the actions according to "Checking and Cleaning
Radiator to Prevent Overheating".
(3) Engine Oil Pressure Lamp
If the oil pressure in the engine goes below the
prescribed level, the warning lamp in the Easy Checker
(TM) will come on.
If this should happen during operation, stop the
engine immediately and check level of engine oil.
(1) Electrical Charge Lamp (3) Engine Oil Pressure
(2) Coolant Temperature Lamp
Lamp (4) Pre-heat Indicator Lamp
0000001522E
B Oil Pressure Switch
While oil pressure is high and the force applied to the
diaphragm (2) is large than the spring tension, the
terminal contact (1) is open separated from the body
contact (3). If the pressure drops below approx. 49 kPa
(0.5 , 7.1 psi), the contact closes.
(1) Terminal Contact (3) Body Contact
(2) Diaphragm
0000001523E

5-M12
CONTENTS
[1] BATTERY ........................................................................................................................ 5-S5
(1) Checking.................................................................................................................. 5-S5
[2] STARTING SYSTEM ...................................................................................................... 5-S6
(1) Checking.................................................................................................................. 5-S6
(3) Servicing................................................................................................................ 5-S13
[3] CHARGING SYSTEM................................................................................................... 5-S16
(1) Checking................................................................................................................ 5-S16
(3) Servicing................................................................................................................ 5-S17

GZD15, WSM ELECTRICAL SYSTEM
1. TROUBLESHOOTING
Reference
Page
All Electrical A Battery discharged or defective Recharge or replace G-32, G-33
Equipments Do Not
A Battery positive cable disconnected or Repair or replace 5-S5
Operate
improperly connected
A Battery negative cable disconnected or Repair or replace 5-S5
improperly connected
A Slow blow fuse blown Replace
Fuse Blown A Short-circuited Repair or replace
Frequently
0000001525E
BATTERY
Battery Discharges A Battery defective Replace 5-S5

Too Quickly
A Dynamo defective Repair or replace 5-S17
A IC Regulator defective Replace
A Wiring harness disconnected or improperly Repair or replace
connected (between battery positive terminal
and regulator B terminal)
A Cooling fan belt slipping Adjust tension G-31
0000001526E
STARTING SYSTEM
Reference
Page
Starter Motor Does A Battery discharged or defective Recharge or replace G-32, G-33,
Not Operate 5-S5
A Slow blow fuse blown (30A) Replace G-40
A Safety switch defective Repair or replace 5-S10, S11
connected (between main switch ST terminal
and safety switches, between safety switches
and starter motor, between battery positive
terminal and starter motor)
A Starter motor defective Repair or replace 5-S13 to S15
A Main switch defective Replace 5-S6 to S7

5-S1
Reference
Page
Engine Does Not Stop A Fuse blown (15 A) Replace G-40
When Main Switch is
Turned OFF
connected (between main switch ACC
terminal and engine stop solenoid)
A Engine stop solenoid defective Replace 5-S12
A Combination box defective Replace
Engine Does Not Start A Engine stop solenoid defective Replace 5-S12
A Combination box defective Replace
0000001527E
CHARGING SYSTEM
Charging Lamp Does A Fuse blown (15 A) Replace G-40

Not Light When Main
Switch Is Turned ON
connected (between main switch ACC
terminal and panel board, between panel
board and dynamo)
A Regulator defective Replace 5-S16
Charging Lamp Does A Wiring harness disconnected or improperly Repair or replace
Not Go Off When connected (between main switch B terminal
Engine Is Running and dynamo, between panel board and
dynamo)
A Regulator defective Replace 5-S16
0000001528E

5-S2
Battery Voltage More than 12 V
Potential Difference Less than 0.1 V
Glow Plug Resistance Approx. 0.9
Starter Commutator 30.0 mm 29.0 mm
(O.D.) 1.181 in. 1.142 in.
Commutator
Less than 0.02 mm 0.05 mm
(Difference of
0.0008 in. 0.0020 in.
O.D.'s)
Mica 0.50 to 0.80 mm 0.20 mm
(Undercut) 0.0197 to 0.0315 in. 0.0079 in.
Brush 14.0 mm 9.0 mm
(Length) 0.551 in. 0.354 in.
AC Dynamo Charging Current / 14 to 15 A /
Dynamo Speed 5200 (rpm)
Charging Voltage / 14 to 15 V /
Dynamo Speed 5200 (rpm)
0000001529E

5-S3
Item ft-lbs
Starter (B terminal nut) 5.9 to 11.8 0.6 to 1.2 4.3 to 8.7
AC dynamo (Stator nut) 39.2 to 44.1 4.0 to 4.5 28.9 to 32.5
0000001530E

5-S4
A To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the
negative cable is attached to the negative terminal.
A Never remove the battery cap while the engine is running.
A Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away
completely with water immediately.
A Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.
A If the machine is to be operated for a short time without battery (using a slave battery for starting), use
additional current (lights) while engine is running and insulate terminal of battery. If this advice is
disregarded, damage to alternator and regulator may result.
0000001139E
[1] BATTERY
(1) Checking
Battery Voltage
1. Stop the engine and turn the main switch off.
2. Connect the COM (-) lead of the voltmeter to the battery's
negative terminal post (2) and the (+) lead to the positive
terminal post (1), and measure the battery voltage.
3. If the battery voltage is less than the factory specification,
check the battery specific gravity and recharge the battery.
Battery voltage Factory spec. More than 12 V
(1) Positive Terminal Post (2) Negative Terminal Post
0000001693E
Battery Terminal Connection
1. Turn the main switch on, and turn on the head light.
2. Measure the voltage with a voltmeter across the battery's
positive terminal post and the cable terminal, and the voltage
across the battery's negative terminal post and the chassis.
3. If the measurement exceeds the factory specification, clean
the battery terminal posts and cable clamps, and tighten them
firmly.
Potential difference Factory spec. Less than 0.1 V
0000001141E

5-S5
[2] STARTING SYSTEM

(1) Checking
(A) Safety Switches

Method of Inspecting Each Control
A defective location can be judge by checking function of each
safety switch one by one as shown in the table below.
(Reference)
A Type of Safety Switch
Parking Brake Pedal......Normal Close
Motion Control Lever.....Normal Open
PTO Lever....................Normal Open
Operator's Seat............Normal Open
Grass Collector............Normal Open
A Engine starting condition
Engine is started when the motion control lever (L, R) is set to
"NEUTRAL" position, PTO lever is set to "OFF" position,
operator is sitting on the operator's seat and the brake pedal is
depressed. In other cases, engine is not started.
(1) Parking Brake Pedal (4) PTO Lever
(2) Motion Control Lever (LH) (5) Operator's Seat
(3) Motion COntrol Lever (RH) (6) Key Switch
0000001533E
(B) Main Switch

Connector Voltage
1. Disconnect the main seitch connector (1) from the main switch
(2).
2. Measure the voltage with a voltmeter across the main switch
connector B (Red) terminal and chassis.
3. If the voltage differs from the battery voltage (11 to 14 V), the
wiring harness is faulty.
Connector B terminal
Voltage Approx. battery voltage
- chassis
(1) Main Switch Connector (2) Main Switch
0000001535E

5-S6
Main Switch Continuity

1) Main Switch Key at OFF Position
1. Set the main switch OFF position.
2. Measure the resistance with an ohmmeter across the B
terminal and the ACC terminal, B terminal and G terminal, B
terminal and ST terminal.
3. If infinity is not indicated, the contacts of the main switch are
faulty.
B terminal - ACC terminal
Resistance B terminal - G terminal Infinity
B terminal - ST terminal
2) Main Switch Key at ON Position

1. Set the main switch ON position.
terminal and the ACC terminal.
3. If 0 ohm is not indicated, the B - ACC contact of the main
switch are faulty.
Resistance B terminal - ACC terminal 0
3) Main Switch Key at PREHEAT Position

1. Set and hold the main switch key at the PREHEAT position.
terminal and the G terminal, and measure the resistance
across the B terminal and the ACC terminal.
3. If 0 ohm is not indicated, these contacts of the main switch are
faulty.
Resistance 0
B terminal - G terminal
4) Main Switch Key at START Position

1. Set and hold the main switch key at the START position.
terminal and the ACC terminal, across the B terminal and the
G terminal, and across the B terminal and the ST terminal.
3. If 0 ohm is not indicated, these contacts of the main switch are
faulty.
Resistance B terminal - G terminal 0
B terminal - ST terminal
(1) B Terminal (3) G Terminal

(2) ACC Terminal (4) ST Terminal
0000001536E

5-S7
(C) Starter
Motor Test
A Secure the starter to prevent it from jumping up and down

while testing the motor.
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable and the leads from the
starter.
3. Remove the starter from the engine.
4. Disconnect the connecting lead (2) from the starter C terminal
(1).
5. Connect a jumper lead from the connecting lead (2) to the
battery positive terminal post.
6. Connect a jumper lead momentarily between the starter motor
housing and the battery negative terminal post.
7. If the motor does not run, check the motor.
(1) C Terminal (2) Connecting Lead
0000001148E
Magnet Switch Test (Pull-in, Holding Coils)
A Preparate a 6 V battery for the test, and each test should

be carried out for 3 to 5 seconds.
1) Checking Pull-in Coil
1. Connect jumper lead from the battery's negative terminal post
to the C terminal.
2. The plunger should be attracted strongly when a jumper lead
is connected from the battery positive terminal to the S
terminal.
2) Checking Holding Coil
1. Connect jumper leads from the battery's negative terminal
post to the body and the battery's positive terminal post to the
S terminal.
2. Push the plunger in by hand and release it. Then, the plunger
should remain being attracted.
0000001149E

5-S8
(D) Glow Plug

Lead Terminal Voltage
1. Disconnect the wiring lead (1) from the glow plug (2) after
turning the main switch off.
2. Turn the main switch key to the "PREHEAT" position, and
measure the voltage between the lead terminal and the
chassis.
3. Turn the main switch key to the "START" position, and
measure the voltage with a voltmeter between the lead
terminal and the chassis.
4. If the voltage at either position differs from the battery voltage,
the wiring harness or main switch is faulty.
Main switch key at
Approx. battery voltage
Voltage(Lead "PREHEAT"
terminal - Chassis) Main switch key at
Approx. battery voltage
"START"
(1) Wiring Lead (Positive) (2) Glow Plug
0000001151E
Glow Plug Continuity
1. Disconnect the lead from the glow plugs.
2. Measure the resistance with an ohmmeter between the glow
plug terminal and the chassis.
3. If 0 ohm is indicated, the screw at the tip of the glow plug and
the housing are short-circuited.
4. If the factory specification is not indicated, the glow plug is
faulty.
Glow plug resistance Factory spec. Approx. 0.9
0000001152E

5-S9
(E) Safety Switch

Operator's Seat Switch Continuity
1. Remove the operator's switch leads (2).
2. Connect the circuit tester to the operator's switch connectors
(2).
3. Measure the resistance between connectors (2).
4. If the operator's switch (1) is defective, replace it.
When switch push is
0
Resistance (Across pushed
switch terminal) When switch push is
Infinity
released
(1) Operator's Seat Switch (2) Lead
0000001540E
Brake Pedal Switch
1. Remove the brake switch leads (3).
2. Connect the circuit tester to the brake switch leads (3).
3. Measure the resistance between leads (3).
4. If the brake switch (2) is defective, replace it.
When switch push is
Resistance (Across Infinity
pushed
brake pedal switch
terminal) When switch push is
0
released
(1) Brake Pedal (3) Lead

(2) Brake Switch
0000001541E
PTO Lever Switch
1. Remove the PTO lever switch leads (3).
2. Connect the circuit tester to the PTO lever switch leads (3).
4. If the PTO lever switch (2) is defective, replace it.
When switch push is
Resistance (Across Infinity
pushed
PTO lever switch
terminal) When switch push is
0
released
(1) PTO Lever (3) Lead

(2) PTO Lever Switch
0000001542E

5-S10
Motion Control Lever Switch (Left and Right)

1. Remove the motion control lever switch leads (3).
2. Connect the circuit tester to the motion control lever switch
leads (3).
4. If the motion control lever switch (2) is defective, replace it.
When switch push is
Resistance (Across 0
pushed
motion control lever
switch) When switch push is
Infinity
released
(1) Motion Control Lever (3) Lead

(2) Motion Control Lever Switch
0000001543E
Grass Collector Switch
1. Remove the grass collector switch leads (2).
2. Connect the circuit tester to the grass collector switch
connectors.
3. Measure the resistance between connectors.
4. If the grass collector switch (1) is defective, replace it.
When switch push is
Resistance(Across 0
pushed
grass collector
switch) When switch push is
Infinity
released
(1) Grass Collector Switch (2) Lead
0000001544E
(F) Fuel Pump

Connector Voltage
1. Disconnect the 2P connector from the fuel pump (1).
2. Turn the main switch key to the "ON" position, and measure
the voltage with a voltmeter between the main wire harness
side connector (2) terminals.
3. Connect the positive lead to the Red/Blue lead.
Connect the negative lead to the black lead.
4. If the voltage differs from the battery voltage, the wiring
harness or main switch is faulty.
Between connector
Voltage Approx. battery voltage
terminals
(1) Fuel Pump (3) Fuel Pump Side Connector

(2) Main Wire Harness Side
Connector
0000001545E

5-S11
Fuel Pump Continuity

1. Disconnect the 2P connector from the fuel pump (1).
2. Check the continuity between the fuel pump side connector (2)
terminals with an ohmmeter.
3. If it does not conduct, the fuel pump is faulty.
(1) Fuel Pump (2) Fuel Pump Side Connector
0000001546E
(G) Engine Stop Solenoid

Engine Stop Solenoid Test
1. Disconnect the 1P connector from the engine stop solenoid.
2. Remove the engine stop solenoid from the engine.
3. Connect the jumper leads from the battery positive terminal to
the 1P connector, and from the battery negative terminal to the
engine stop solenoid body.
4. If the solenoid plunger is not attracted, the engine stop
solenoid is faulty.
(1) Battery (12 V)
0000001163E
(H) Thermo Switch

Connector Voltage
1. Disconnect the 1P connector from the thermo switch (1).
2. Turn the main switch key to the "ON" position, and measure
the voltage with a voltmeter between the connector terminal
and the chassis.
3. If a certain voltage is not indicated, the wiring harness or
coolant temperature a gauge is faulty.
Voltage (Connector A certain voltage is
Factory spec.
terminal - Chassis) indicated
(1) Thermo Switch
0000001696E
Thermo Switch Continuity
1. Disconnect the 1P connector, and remove the thermo switch.
2. Using an ohmmeter, check for continuity between the switch
terminal and the chassis as shown in the figure.
3. If infinity is indicated at temperature over factory
specifications, the switch is faulty.
120 to 126
Working temperature Factory spec.
248.0 to 258.8
(A) ON (C) 116 (240.8 ) or more

(B) OFF (D) 120 to 126
(248.0 to 258.8 )
0000001697E
5-S12
(1) Magnetic Switch

Mounting Nut
(2) Housing
(3) Magnetic Switch
(4) C Terminal Nut
(5) Shaft Assembly
(6) Drive Lever
(7) Overrunning Clutch
(8) Connecting Lead
(9) Mounting Screw
(10) Armature
(11) Yoke
(12) Brush Holder
(13) Rear End Frame
(14) Through Bolt
1. Unscrew the C terminal nut (4), and disconnect the connecting lead (8).
2. Unscrew the magnetic switch mounting nuts (1), and remove the magnetic switch (3) from the housing (2).
3. Unscrew the through bolts (14) and mounting screw (9), and remove the rear end frame (13).
4. Remove the brush from the brush holder while holding the spring up.
5. Remove the brush holder (12).
6. Draw out the armature (10) and yoke (11) from the housing.
7. Draw out the shaft assembly (5) with the drive lever (6) and overrunning clutch (7) from the housing.
(When reassembling)
5.9 to 11.8
Tightening torque C Terminal Nut 0.6 to 1.2
4.3 to 8.7 ft-lbs
0000001167E
(3) Servicing
Overrunning Clutch
1. Inspect the pinion for wear or damage.
2. If there is any defect, replace the overrunning clutch assembly.
3. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking
direction.
4. If the pinion slips or does not rotate in the both directions,
replace the overrunning clutch assembly.
0000001168E

5-S13
Commutator and Mica

1. Check the contact face of the commutator for wear, and grind
the commutator with emery paper if it is slightly worn.
2. Measure the commutator O.D. with an outside micrometer at
several points.
3. If the minimum O.D. is less than the allowable limit, replace the
armature.
4. If the difference of the O.D.'s exceeds the allowable limit,
correct the commutator on a lathe to the factory specification.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct it with a
saw blade and chamfer the segment edges.
30.0 mm
Factory spec.
1.181 in.
Commutator O.D.
29.0 mm
Allowable limit
1.142 in.
Less than 0.02 mm

Factory spec.
0.0008 in.
Difference of O.D.'s
0.05 mm
Allowable limit
0.0020 in.
0.50 to 0.80 mm
Factory spec.
0.0197 to 0.0315 in.
Mica undercut
0.20 mm
Allowable limit
0.0079 in.
(1) Segment (a) Correct

(2) Undercut (b) incorrect
(3) Mica
0000001169E
Brush Wear
1. If the contact face of the brush is dirty or dusty, clean it with
emery paper.
2. Measure the brush length (A) with vernier calipers.
3. If the length is less than the allowable limit, replace the yoke
assembly and brush holder.
14.0 mm
Factory spec.
0.551 in.
Brush length (A)
9.0 mm
Allowable limit
0.354 in.
0000001170E

5-S14
Brush Holder
1. Check the continuity across the brush holder and the holder
support with an ohmmeter.
2. If it conducts, replace the brush holder.
0000001171E
Armature Coil
1. Check the continuity across the commutator and armature coil
core with an ohmmeter.
2. If it conducts, replace the armature.
3. Check the continuity across the segments of the commutator
with an ohmmeter.
4. If it does not conduct, replace the armature.
0000001172E
Field Coil
1. Check the continuity across the lead (1) and brush (2) with an
ohmmeter.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with an
ohmmeter.
4. If it conducts, replace the yoke assembly.
(1) Lead (3) Yoke
(2) Brush
0000001173E

5-S15
[3] CHARGING SYSTEM

(1) Checking
Battery Charging Current
1. After starting the engine, disconnect the battery positive cord
(+), and connect an ammeter and voltmeter. Then switch on
all electrical loads (such as head lights) and measure the
charging current.
A Connect an ammeter only after starting the engine.

A When the electrical loads is considerably low or the
battery is fully charged, the specified reading may not be
obtained.
Current 14 to 15 A
Factory spec. Voltage 14 to 15 V
Dynamo speed 5200 (rpm)
(1) Battery Positive Cord
0000001174E
Continuity across Regulator's Terminals

1. Remove the regulator.
2. Check with a tester whether the regulator is in optimum
condition or not.
B Check Table
A Use a high-resistance type tester as far as possible.

A The judgement should be as below table. "ON" if the
indictor moves, otherwise "OFF".
Tester + Cord colours
terminal
Tester Blue Black Blue Green Yellow Red
- terminal
Blue (1) OFF OFF OFF OFF ON
Black (2) OFF OFF OFF OFF OFF
Cord Blue (3) OFF OFF OFF OFF ON

colours Green(4) OFF OFF OFF OFF OFF
Yellow (5) ON ON ON OFF ON
Red (6) OFF OFF OFF OFF OFF
(1) Blue (4) Green

(2) Black (5) Yellow
(3) Blue (6) Red
0000001548E

5-S16

Stator
1. Remove the nut (3) and separate the stator comp. (4).
2. Unscrew the screws (1) and remove the stator (2).
(When reassembling)
39.2 to 44.1
Tightening torque Nut 4.0 to 4.5
28.9 to 32.5 ft-lbs
(1) Screw (3) Nut

(2) Stator (4) Stator Comp.
0000001176E
Rotor
1. Tap out the shaft (1) from the rotor (3).
(When reassembling)
A Take care the direction of the collar (4), the flat side should
face to the pulley (2) side
(1) Shaft (4) Collar
(2) Pulley (5) Bearings
(3) Rotor (6) Collar
0000001177E
(3) Servicing
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
0000001178E

5-S17
6 MOWER

CONTENTS
1. POWER TRANSMISSION................................................................................................6-M1
2. LIFTING MECHANISM .....................................................................................................6-M2

GZD15, WSM MOWER
1. POWER TRANSMISSION
(1) Front PTO Shaft (4) Mower Gear (7) 17T Spiral Gear (9) Blade Shaft
(2) Front PTO Case (5) Mower Blade (8) 18T Spiral Gear (10) Transmission Case
(3) Mower PTO Shaft (6) Input Shaft
The power is transmitted from transmission case to blades as follows.

Front PTO Shaft (1) Front PTO Case (2) Mower PTO Shaft (3) Input Shaft (6) 17T Spiral Gear (7)
18T Spiral Gear (8) Blade Shaft (9) Mower Blade (5)
0000001549E

6-M1
GZD15, WSM MOWER
2. LIFTING MECHANISM
(1) Mower Lift Pedal (4) Control Valve (7) Front Link (10) Rear Link
(2) Delivery Hose (5) Mower Lift Cylinder (8) Cam Arm (11) Link Retainer
(3) Mower Lift Rod (6) Front Arm (9) Lift Rod
Mower lifting is performed by the hydraulic system on the machine.

For avoiding danger, the mower should be kept lifting when traveling. When the mower lift pedal is moved to "LIFT"
position, the front link (7) are risen with front arm (6) by the mower lift cylinder (5).
Therefore, front link (7) connected with the cam arm (8) are lifted at the same time.
As this link system is a parallel linkage, the mower can be kept parallel at every position.
A Never operate mower in transport position.
0000001550E

6-M2
CONTENTS
4. CHECKING, DISASSEMBLING AND ASSEMBLING .................................................... 6-S4
[1] CHECKING AND ADJUSTING ...................................................................................... 6-S4
[2] DISASSEMBLING AND ASSEMBLING......................................................................... 6-S6

GZD15, WSM MOWER
1. TROUBLESHOOTING
Reference
Page
Blade Does Not Turn A PTO system malfunctioning Check transmission
A Broken mower belt Replace mower belt G-42
Blade Speed Is Slow A Loosen mower belt Replace mower belt G-42, 6-S8,
or tension spring S9
A Clogged grass Remove grass
A Flattened out or worn cup washer Replace cup washer 6-S7
A Engine rpm too low Mow at full throttle,
check and reset
engine rpm
Cutting Is Poor A Worn or bent mower blade Sharpen or replace G-41
mower blade
A Loosen mower blade screw Retighten mower G-41, 6-S7
blade screw
A Cutting height improper Adjust cutting height 6-S5
A Ground speed too fast Slow-down
A Low wheel inflation Add air to correct
A Anti-scalp rollers not adjusted correctly Adjust anti-scalp 6-S4
rollers
Mower Is Not Lifted A Broken linkage system Replace linkage
system
A Trouble of hydraulic system Check hydraulic 4-S6 to S8
system
0000001551E

6-S1
GZD15, WSM MOWER
Pinion Shaft (without Mower Belt) Turning Torque Less than 0.7
0.07
0.52 ft-lbs
Bevel Gears in Gear Box Backlash 0.13 to 0.25 mm 0.40 mm
0.0051 to 0.0098 in. 0.157 in.
Front Tip of Blade to Rear Tip of Blade Difference 0 to 6.0 mm
0 to 0.24 in.
Left Tip of Blade to Right Tip of Blade Difference Less than 3 mm
0.1181 in.
0000001552E

6-S2
GZD15, WSM MOWER
Item ft-lbs
Mower blade screw 98 to 118 10.0 to 12.0 72.3 to 86.8
Gear box screw 23.5 to 27.4 2.4 to 2.8 17.4 to 20.2
Gear box mounting screw (Standard type / Reamer type) 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2
Pulley holder mounting screw (Standard type / Reamer
48.1 to 55.9 4.9 to 5.7 35.4 to 41.2
type)
0000001553E

6-S3
GZD15, WSM MOWER
4. CHECKING, DISASSEMBLING AND ASSEMBLING

[1] CHECKING AND ADJUSTING
Adjusting Anti-scalp Rollers
A he flattest cut can be achieved by having the anti-scalp

rollers adjusted off the ground.
Check anti-scalp roller adjustments each time the mower
deck cutting height is changed.
It is recommended that all the anti-scalp rollers be kept off
the ground to minimize scuffing.
1. Check the machine wheel pressure.
Inflate wheels to the correct pressure. (See table below.)
Tyre Size Inflation Pressure
Front Wheel (15 x 6.0-6, 4PR Rib) 270 kPa, 2.1 , 30 psi
Rear Wheel (20 x 10.00-8, 4PR Turf) 140 kPa, 1.4 , 20 psi

3. Raise up the mower deck to the transport position.
(Also the top end of the lift.)
4. Turn the cutting height control dial to adjust height.
0000001554E

6-S4
GZD15, WSM MOWER
Adjusting Left and Right Cutting Height

1. Wheel pressure must be correct.
top end).
3. Turn the cutting height set dial (1) to the 3 in. (76 mm) cutting
height position.
4. Place 2 in. (51 mm) height wood blocks under each side of the
mower deck.
Anti-scalp rollers must not rest on the wood block.
6. Position mower blade in the Side-to-Side position.
7. Loosen the lock nuts (4) of the right side of the machine.
8. Adjust the cutting height fine tuning bolts (3) to set 80 mm (3
1/8 in.) height.
Front and rear side bolts must be adjusted.
9. Lock the nuts.
10. Adjust the left side equally.
11. Measure the heights of left blade and right blade from the
ground surface and calculate the difference.
12. If the difference between left tip and right tip of blade is not
within the factory specification, adjust the length of cutting
height fine tuning bolt (3).
Difference between left Less than 3 mm
Factory spec.
tip and right tip of blade 0.12 in.
(1) Cutting Height Control Dial (A) Blade Height

(2) Hydraulic Control Pedal (H) Length of Cutting Height Fine
(3) Cutting Height Fine Tuning Bolt Tuning Bolt
(4) Lock Nut
0000001555E

6-S5
GZD15, WSM MOWER
Adjusting Front and Rear Cutting Height

ground.
1. Wheel pressure must be correct.
top end).
3. Turn the cutting height set dial (1) to the 3 in. cutting height
position.
4. Position the right mower blade in the Front-to-Right position.
6. Loosen the lock nuts (4) of the front side of the machine.
7. Adjust the cutting height fine tuning bolts (3) to set 80 mm (3
1/8 in.) height.
8. Lock the nuts (4).
9. Adjust the other side equally.
10. Measure the heights of blade (A) and (B) from the ground
surface and calculate the difference.
11. If the difference between front tip and rear tip of blade is not
within the factory specification, adjust the length H of cutting
height fine tuning bolt with lock nut (4). The height of rear
blade tip (B) should be bigger than the front.
Difference ((B) - (A))
0 to 6.0 mm
((B) (A)) between front Factory spec.
0 to 0.24 in.
tip and rear tip of blade
(1) Cutting Height Control Dial (H) Length of Cutting Height Fine
(2) Hydraulic Control Lever Tuning Bolt
(3) Cutting Height Fine Tuning Bolt (A) Height of Blade Tip (Front)
(4) Lock Nut (B) Height of Blade Tip (Rear)
0000001556E
[2] DISASSEMBLING AND ASSEMBLING

Universal Joint and Belt Covers
1. Remove the left and right belt covers (2), (3) and (4).
2. Remove the universal joint (1).
(1) Universal Joint (3) Belt Cover
(2) Belt Cover (4) Belt Cover
0000001557E

6-S6
GZD15, WSM MOWER
Mower Blades (Left Blade and Right Blades)

1. Turn over the mower.
2. Unscrew the mower blade screw (1), and remove the blade
boss (6), two cup washers (2), mower blade (3) and dust cover
(4).
A To remove the blade securely, wedge a block of wood

between one blade and the mower deck in such position
that it will hold the blade safely while loosing or tightening
the blade screw.
(When reassembling)
A Be sure to assemble the two cup washers between the mower
blade and the mower blade screw.
A Make sure the cup washer is not flattened out or worn,

causing blade to slip easily.
Replace two cup washers if either is damaged.
98 to 118
Tightening torque Mower blade screw 10.0 to 12.0
72.3 to 86.8 ft-lbs
(1) Mower Blade Screw A: Loosen

(2) Cup Washer
(3) Mower Blade
(4) Dust Cover
(5) External Snap Ring
(6) Blade Boss
(7) Collar
0000001558E
Blade Boss
1. Remove the external snap ring (1).
2. Remove the blade boss (2).
(1) External Snap Ring (4) Pulley Holder
(2) Blade Boss (5) Bolt
(3) Reamer Bolt
0000001559E

6-S7
GZD15, WSM MOWER
Gear Box and Mower Belt

1. Turn over the mower.
2. Remove the mower belt (1) from the tension pulley (5).
3. Unscrew the left and right gear box mounting screws (3), (4)
and remove the gear box (2) from the mower deck.
(When reassembling)
A Install the reamer screws (3) at their original positions as
shown in the figure.
48.1 to 55.9
Gear box mounting
screw
35.4 to 41.2 ft-lbs
(1) Mower Belt (5) Gear Box Mounting Screw

(2) Tension Spring (Reamer Screw)
(3) Tension Pulley (6) Bolt and Nut
(4) Gear Box (7) Gear Box Mounting Screw
0000001560E
Disassembling Gear Box

1. Unscrew the drain plug, and drain the gear box oil.
2. Remove the pulley (with a puller).
3. Remove the gear box.
4. Open the gear box.
5. Remove the input shaft (1) and the blade shaft (2).
6. Disassemble the input shaft (1) and the blade shaft (2).
(When reassembling)
A Replace the oil seals (5) and gear box caps with new ones.
A Check the backlash and turning torque.
If not proper, adjust with the shims.
A After cleaning dirty and gear box oil and the gear box surface,
apply the liquid gasket.
A Reassemble the gear box shaft correctly as a picture.
23.5 to 27.4
Tightening torque Gear box screw 2.4 to 2.8
17.4 to 20.2 ft-lbs
(1) Input Shaft (7) Shim

(2) Blade Shaft (8) Shim
(3) Oil Seal (9) Drain Plug
(4) Plug
(5) Oil Seal A: Correct Assembly
(6) Shim B: Wrong Assembly
0000001561E

6-S8
GZD15, WSM MOWER
Tension Arm and Pulley

1. Pull the tension arm (2) and the tension arm spring (1).
2. Remove the mower belt (6).
3. Remove the tension arm spring (1) from tension arm (2).
4. Remove the tension arm bolt (3).
5. Remove the tension arm (2).
6. Remove the pulley bolt (4).
7. Remove the pulley (5) from mower deck.
(1) Tension Arm Spring (4) Pulley Bolt
(2) Tension Arm (5) Pulley
(3) Tension Arm Bolt (6) Mower Belt
0000001563E
Pulley Holder (RH)
After removing the blade (1) and the pulley (16), unscrew the
pulley holder screws (11).
1. Remove the holder (12).
2. Remove the oil seal (5), the internal snap ring (6), the blade
shaft etc..
(When reassembling)
A Replace the oil seals (5), (15) with new ones.
48.1 to 55.9
Tightening torque Pulley holder screw 4.9 to 5.7
35.4 to 41.2 ft-lbs
(1) Blade (10) Blade Shaft

(2) Dust Cover (11) Screw
(3) External Snap Ring (12) Pulley Holder
(4) Blade Boss (13) Extension Pipe
(5) Oil Seal (14) Grease Nipple
(6) Internal Snap Ring (15) Oil Seal
(7) Bearing (16) Pulley
(8) Collar (17) Collar
(9) Bearing
0000001562E

6-S9
GZD15, WSM MOWER
Backlash between Bevel Gears

1. Place fuses on the teeth of the 17T spiral gear (6).
2. Tighten the gear case bolts temporarily. And assembly the
gear case temporarily for checking gear backlash.
3. Turn the pinion shaft.
4. Open the gear box. Take out the fuses, and measure the
thickness of fuses with an outside micrometer. (Backlash
equal thickness of fuse)
5. If the backlash exceeds the allowable limit, adjust with shims
(5), (7), (9).
0.13 to 0.25 mm
Factory spec.
Backlash between bevel 0.0051 to 0.0098 in.
gears 0.40 mm
Allowable limit
0.157 in.
(Reference)
A Thickness of adjusting shims (5), (7) and (9) :
0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
(1) Input Shaft (6) 17T Spiral Gear
(2) Blade Shaft (7) Shim
(3) Mower Gear Case (RH) (8) Bearing
(4) Bearing (9) Shim
(5) Shim (10) Oil Seal
0000001565E

6-S10
GZD15, WSM MOWER
Turning Torque of Pinion Shaft

1. Remove the mower belt, and reassemble the gear box to the
mower deck.
2. Wind a string around the input shaft and set a spring balance
(or push-pull gauge) to the tip of the string, and then slowly pull
the spring balance horizontally to measure the turning force.
3. If the measurement exceeds the factory specification, check
the bearing and gears and adjust the adjusting shims (4), (6),
(8).
Less than 0.7
Turning torque Factory spec. 0.07
0.52 ft-lbs
(Reference)
A Thickness of adjusting shims (4), (6) and (8) :
0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
(1) Input Shaft (6) Adjusting Shim
(2) Blade Shaft (7) Bearing
(3) Bearing (8) Adjusting Shim
(4) Adjsting Shim (9) Oil Seal
(5) 17T Spiral Gear
0000001564E

6-S11
EDITOR:
KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.
64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN
PHONE : (81)72-241-1129
FAX : (81)72-245-2484
E-mail : ksos-pub@kubota.co.jp
Printed in Japan 2006. 03, S, EI, EI, e Code No.9Y011-15231

KUBOTA Corporation 2003. 03, S, EI, EI, e

GZD 15 HD LD WSM en

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WORKSHOP MANUAL

KiSC issued 04, 2006 A

KUBOTA Corporation 2003

KiSC issued 04, 2006 A

A Gives helpful information.

KiSC issued 04, 2006 A

KiSC issued 04, 2006 A

VENTILATE WORK AREA

PREVENT ACID BURNS

DISPOSE OF FLUIDS PROPERLY

PREPARE FOR EMERGENCIES

KiSC issued 04, 2006 A

KiSC issued 04, 2006 A

KiSC issued 04, 2006 A

KiSC issued 04, 2006 A

KiSC issued 04, 2006 A

Maximum gross power 11.2 kW (15 HP) *1

Type Indirect injection. Vertical, water-cooled, 4-cycle diesel engine

Bore and stroke 72.0 x 73.6 mm (2.83 x 2.90 in.)

Total displacement 599 (36.6 cu.in.)

Rated revolution 3000 rpm

Combustion chamber Spherical type (E-TVCS)

Fuel injection pump Bosh MD type mini pump

Governor Centrifugal ball mechanical governor

Injection nozzle Bosh throttle type

Injection timing 0.30 to 0.33 rad. (17 to 19 ) before T.D.C.

Injection pressure 13.73 MPa (140 , 1990 psi)

Lubricating system Forced lubrication by gear pump

Cooling system Pressurized radiator, forced circulation with water pump

API Service classification CD, CE or CF,

Starting system Electrical starter (12 V, 1.1 kW)

Battery 65D23L (12V, 52A.H. at 5H.R.)

No.2-D Diesel fuel (ASTM D975)

Fuel tank 20 L (5.3 U.S.gals, 4.4 lmp.gals)

Engine crankcase 2.1 L (2.2 U.S.qts, 1.8 lmp.qts)

Engine coolant 1.4 L (1.5 U.S.qts, 1.2 lmp.qts)

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

Front PTO case 0.13 L (0.14 U.S.gals, 0.11 lmp.gals)

Mower gear case oil 0.15 L (0.16 U.S.qts, 0.13 lmp.qts)

Front 15 x 6.0 - 6 (4 PR) Rib

Forward 0 to 13.5 km/h (0 to 8.4 mph)

KiSC issued 04, 2006 A

Model GZD15-LD GZD15-HD

Overall length (with grass collector) 2785 mm (109.7 in.)

Overall width (with mower) 1195 mm (47.1 in.)

Front 815 mm (32.1 in.)

KiSC issued 04, 2006 A

KiSC issued 04, 2006 A

KiSC issued 04, 2006 A

KiSC issued 04, 2006 A

KiSC issued 04, 2006 A

KiSC issued 04, 2006 A

KiSC issued 04, 2006 A

3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS

A Check electrical wiring for damage and loosened

A Do not let wiring contact dangerous part.

A Securely insert grommet.

KiSC issued 04, 2006 A

A Securely clamp, being careful not to damage wiring.

A Clamp wiring so that there is no twist, unnecessary sag, or

A In installing a part, take care not to get wiring caught by it.

A After installing wiring, check protection of terminals and