Operation and tests sections help you identify the majority of
quickly.
This manual is written for an experienced technician. Essential Information is organized in groups for the various components tools required in performing certain service work are identified in requiring service instruction. At the beginning of each group are this manual and are recommended for use.summarylistingsofallapplicableessentialtools,service equipment and tools, other materials needed to do the job,
Live with safety: Read the safety messages in the introduction of service parts kits, specifications, wear tolerances, and torque this manual and the cautions presented throughout the text of the values. manual.
CAUTION:needed for diagnosis, analysis, testing, and repair.
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information
This is the safety-alert symbol. When you see this symbol on the Fundamental service information is available from other sources machine or in this manual, be alert to the potential for personal covering basic theory of operation, fundamentals of injury. troubleshooting, general maintenance, and basic type of failures and their causes.
Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.
DX,TMIFC-19-20140415
Section 10 - General Information
Group 05 - Safety
Group 10 - General Specifications
Group 15 - Fuel and Lubricants
Group 20 - Machine Specifications
Section 20 - Engine Repair
Group 10 - Repair and Adjustments
Section 30 - Electrical Repair
Group 10 - Wiring Harnesses
Group 20 - Wiring Harnesses, Kits
Section 40 - Power Train Repair
Group 10 - Transmission
Group 15 - Axles and Drive Shaft
Group 20 - Mechanical Four Wheel Drive
Section 50 - Steering and Brake Repair
Group 10 - Steering
Group 20 - Brakes
Section 60 - Miscellaneous Repair
Group 10 - Wheels
Group 15 - Hood, Cargo Box, and Bumper
Group 20 - Miscellaneous
Section 70 - Operator ` s Station Repair
Section 220 - Engine Operation, Tests, and Adjustments
Group 10 - Component Location
Group 20 - Diagnosis
Group 25 - Tests and Adjustments
Section 230 - Electrical Operation, Tests,
Group 05 - General Information
Group 10 - Component Location
Group 15 - Theory of Operation
Group 30 - Wiring Schematics
Group 50 - Tests and Adjustments
Group 55 - Connector Information
Section 240 - Control Unit Operation, Tests, anGd ro A u d p j1u0stmThe e n o t r s y ofOperation
Service Tires Safely...............................................
Stay Clear of Rotating Drivelines...........................
Recognize Safety Information
Understand Signal Words
TS187-19:
Replace Safety Signs
T81389-UN: Safety-alert symbol
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating practices.
DX,ALERT-19-19980929
DANGER; The signal word DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING; The signal word WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION; The signal word CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION may also be used to alert against unsafe practices associated with events which could lead to personal injury.
A signal word DANGER, WARNING, or CAUTION is used withthesafety-alertsymbol.DANGERidentifiesthemostserious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safetysigns.CAUTIONalsocallsattentiontosafetymessagesin this manual.
DX,SIGNAL-19-20161005
TS201-UN: Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.
DX,SIGNS1-19-19900604
Signal Words
Handle Fluids Safely Avoid Fires
Prepare for Emergencies
Prevent Battery Explosions
TS227-UN: Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn spontaneously.
DX,FLAME-19-19980929
TS291-UN: First Aid Kit
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
DX,FIRE2-19-19930303
TS204-UN: Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
DX,SPARKS-19-19930303
Prevent Acid Burns
Wear Protective Clothing
Avoid High-Pressure Fluids
X9811-UN: High Pressure
Inspect hydraulic hoses periodically–at least once per year–for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage.
TS203-UN: Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.
Avoid the hazard by:
Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte.
Use proper jump start procedure.
If you spill acid on yourself:
Flush your skin with water.
Apply baking soda or lime to help neutralize the acid. Flush your eyes with water for 15 30 minutes. Get medical attention immediately.
If acid is swallowed:
Do not induce vomiting.
Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).
Get medical attention immediately.
TS206-UN: Protective Clothing
DX,POISON-19-19930421
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.
DX,WEAR-19-19900910
Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.
DX,FLUID-19-20111012
Avoid Heating Near Pressurized Fluid Lines
Service Machines Safely
Use Proper Tools
Park Machine Safely
TS953-UN: Flammable Spray
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.
DX,TORCH-19-20041210
TS228-UN: Moving Parts
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
DX,LOOSE-19-19900604
TS779-UN: Proper Tools
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
DX,REPAIR-19-19990217
TS230-UN: Remove the Key
Before working on the machine:
Lower all equipment to the ground. Stop the engine and remove the key. Disconnect the battery ground strap. Hang a "DO NOT OPERATE" tag in operator station.
DX,PARK-19-19900604
Support Machine Properly
Use Proper Lifting Equipment
Work in Clean Area
Protect Against High Pressure Spray
TS229-UN: Support Properly
Always lower the attachment or implement to the ground before youworkonthemachine.Iftheworkrequiresthatthemachineor attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.
When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual.
DX,LOWER-19-20000224
TS226-UN: Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.
DX,LIFT-19-19900604
T6642EJ-UN: Clean Work Area
Before starting a job:
Clean work area and machine.
Make sure you have all necessary tools to do your job.
Have the right parts on hand.
Read all instructions thoroughly; do not attempt shortcuts.
DX,CLEAN-19-19900604
TS1343-UN: High Pressure Spray
Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body.
If an accident occurs, see a doctor immediately. Any high pressure spray injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar withthistypeofinjuryshouldreferenceaknowledgeablemedical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
DX,SPRAY-19-19920416
Illuminate Work Area Safely
Work In Ventilated Area
Remove Heating Paint Before Welding or
TS220-UN: Toxic Fumes
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
TS223-UN: Work Area Safely
Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
DX,LIGHT-19-19900604
TS220-UN: Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. Ifyoudonothaveanexhaustpipeextension,openthedoorsand get outside air into the area.
DX,AIR-19-19990217
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT-19-20020724
Avoid Harmful Asbestos Dust
Service Tires Safely
Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers are brakepads, brakebandandlining assemblies, clutch plates, and somegaskets.Theasbestosusedinthesecomponentsisusually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos.
Keep bystanders away from the area.
TS211-UN: Explosive Tire and Rim Parts
DX,DUST-19-19910315
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.
Wheninflatingtires,useaclip-onchuckandextensionhoselong enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
DX,RIM-19-19900824
TS220-UN: Asbestos Dust
Stay Clear of Rotating Drivelines
Service Cooling System Safely
Safety
Entanglement in rotating driveline can cause serious injury or death.
Keep tractor master shield and driveline shields in place at all times. Make sure rotating shields turn freely.
Only use power take-off driveshafts with adequate guards and shields.
Wear close fitting clothing. Stop the engine and be sure that PTO driveline is stopped before making adjustments, connections, or cleaning out PTO driven equipment.
Do not install any adapter device between the tractor and the primary implement PTO driveshaft that will allow a 1000 rpm tractorshafttopowera540rpmimplementatspeedshigherthan 540 rpm.
Do not install any adapter device that results in a portion of the rotating implement shaft, tractor shaft, or the adapter to be unguarded. The tractor master shield shall overlap the end of the splined shaft and the added adaptor device as outlined in the table.
The angle at which the primary implement PTO driveshaft can be inclined may be reduced depending on the shape and size of the tractor master shield and the shape and size of the guard of the primary implement PTO driveshaft.
Do not raise implements high enough to damage the tractor master shield or guard of primary implement PTO driveshaft. Detach the PTO driveline shaft if it is necessary to increase implement height. (See Attching/Detaching PTO Driveline)
When using Type 3/4 PTO, inclination and turning angles may be reduced depending on type of PTO master shield and coupling rails.
TS281-UN: Cooling System
Explosive release of fluids from pressurized cooling system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
DX,RCAP-19-19900604
TS1644-UN: Rotating Drivelines
Decommissioning Proper Recycling and Disposal of Fluids and Components
TS1133-UN: Recycle Waste
Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:
Use appropriate tools and personal protective equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials.
Follow instructions for specialized components. Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems.
Handle Chemical Products Safely
Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately.
Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers.
Do not pour waste fluids onto the ground, down a drain, or into any water source.
Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid); filters; batteries; and, other substances or parts. Burning of flammable fluids or components inotherthanspeciallydesignedincineratorsmaybe prohibited by law and could result in exposure to harmful fumes or ashes.
Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape.
Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely.
Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste.
DX,DRAIN-19-20150601
TS1132-UN: Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipmentincludesuchitemsaslubricants,coolants,paints,and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)
DX,MSDS,NA-19-19930303
TS231-19: Safety Systems
Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.
DX,LIVE-19-19920925
Live With Safety
Group 10 General Specifications
Service Recommendations for O-Ring Boss Fittings
Straight Fitting
TCT008637-UN: Straight Fitting LEGEND:
A-Straight Boss Fitting
B-Straight Stud and Tube Nut
1. Inspect O-ring boss seat for dirt or defects.
2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.
Angle Fitting
TCT008638-UN: Angle Fitting
LEGEND:
A-Locknut
B-Washer
C-Head-End of Fitting
1. Inspect O-ring boss seat for dirt or defects.
2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape.
3. Back-off locknut (A) and back-up washer (B) completely to head-end (C) of fitting.
4. Turn fitting into threaded boss until back-up washer contacts face of boss.
5. Turn fitting head-end counterclockwise to proper index (maximum of one turn).
6. NOTE:
Do not allow hoses to twist when tightening fittings.
Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value.
STUD END O-RING SEAL TORQUE FOR STRAIGHT AND ADJUSTABLE FITTINGS*
TCT008639-UN: Flat Face Fittings LEGEND: A-O-ring B-Nut
1. Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects.
2. Lubricate O-ring (A) and install into groove using petroleum jelly to hold in place.
Metric Grade 7 Cap Screw Torque Values—
NOTE:
When bolting aluminum parts, tighten to 80% of torque specified in table.
Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place.
Unlessspecifiedotherwise,tightenfittingornut(B)totorque value shown on the chart. Do not allow hoses to twist when tightening fittings, use backup wrench on straight hose couplings.
Boltcoated with a lubricantplain or zinccoated with a lubricantplain or zinccoated with a lubricantplain or zinccoated with a lubricantplain or zinc orsuch as engine oil,plated withoutsuch as engine oil,plated withoutsuch as engine oil,plated withoutsuch as engine oil,plated without Screwfasteners withanyfasteners withanyfasteners withanyfasteners withany c Soizaetpinhgoss ,pohraMte2a0nadnodiMllu6btroicMat1io8nco , oatripnhgoss, pohr aMte20anadndoMill6ubtoricMa1ti8ocno,aotrinpghso,soprhMat2e0aannddoMil6lutboriMca1t8iocno,aotirnpghso , soprhMa2te0aannddMoil6lutborMica1t8ion, or larger fasteners withfasteners withlarger fasteners withfasteners withlarger fasteners withfasteners withlarger fasteners withfasteners with JDM F13C, F13F or F13JJDM F13B,JDM F13C, F13F or F13JJDM F13B,JDM F13C, F13F or F13JJDM F13B,JDM F13C, F13F or F13JJDM F13B, zinc flake coating.]F13E or F13Hzinc flake coating.]F13E or F13Hzinc flake coating.]F13E or F13Hzinc flake coating.]F13E or F13H zinc flakezinc flakezinc flakezinc flake coating.] coating.] coating.] coating.]
Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening Shear
pro c pe drtuyrecliassgsifvaentefonrearssapreecuifsiceda,ptpiglihcatetinonheFsoertsotainlestsresntegethl f oafstheeneorrsigoinrafol.rMake sure nfausttseonnerUt-hbroelatds,ssaeretchleatnigahntedntihnagtinyosturupcrotipoenrslyfosrtathrtetshpreacidfiecnagpapgliecmateionnt.WTihge h n te p nossible, lpulbasritcicatienspelartinorocrrziimncpepdlastetedeflatsytpeenelorcskonthuetsrtbhyatnulroncinkgntuhtes,nwuttoelthbeoldtsryotrowrqhueeelnuts, s u h nolewsnsidniftfheerecnhtainrts,turuncletisosndsifafreeregnivteinnsftorrutchtieonspseacrieficgiavpenplficoarttihoen.specific
application.
Unified Inch Bolt and Screw Torque Values
TS1671-UN: Unified Inch Bolt and Screw
SAE Grade 2 [Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hAexEcGarpadsecr1eSwAsEoGvreard6ein5,5(1.152om5m.2) long, and for all other types of bolts and screws of any length.]
S r SAE Grade 8 or 8.2
Bolt Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry or [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means Screwcoated with a lubricantplain or zinccoated with aplain or zinccoated with aplain or zinccoated with a lubricantplain or zinc
Sizesuch as engine oil,plated withoutlubricant such asplated withoutlubricant such asplated withoutsuch as engine oil,plated without fasteners withanyengine oil, fastenersanyengine oil, fastenersanyfasteners withany phosphate and oillubrication, orwith phosphate andlubrication, orwith phosphate andlubrication, orphosphate and oillubrication, or coatings, or 7/8 in. and1/4 to 3/4 in.oil coatings, or 7/8 in.1/4 to 3/4 in.oil coatings, or 7/8 in.1/4 to 3/4 in.coatings, or 7/8 in. and1/4 to 3/4 in. larger fasteners withfasteners withand larger fastenersfasteners withand larger fastenersfasteners withlarger fasteners withfasteners with JDM F13C, F13F or F13JJDM F13B,with JDM F13C, F13FJDM F13B,with JDM F13C, F13FJDM F13B,JDM F13C, F13F or F13JJDM F13B, zinc flake coating.]F13E or F13Hor F13J zinc flakeF13E or F13Hor F13J zinc flakeF13E or F13Hzinc flake coating.]F13E or F13H zinc flakecoating.]zinc flakecoating.]zinc flakezinc flake coating.] coating.] coating.] coating.]
1-1/8
1-1/4
1-1/2
Torque values listed are for general use only, based on the strength of the bolt or screw. RDeOpNlaOcTe u fa s s etethnesrse w vaitlhuethseifsaadmifefeorrehnitgthoerqr ugreavdaeluIef o hrigthigehrtgernaidneg f p a r s o t c e endeurrseairegiven for a u sp s edci,fticigahptepnlictahteiosen.tFootrhpelsatsrteicnginthseorfttohrecorirmigpineadl.sMteaekletyspuerelofcakstneuntesr,tfhoresatadisnalersessteelclean and that you properly start thread engagement. When possible, lubricate plain f o a r s ztiennceprsla,toerdfofarsntuetnseorsnoUt-hbeorlths,asneleocthkenutitgsh,twenhieneglibnoslttrsucotriownhsefeolrntuhtes,supnelceifsiscapplication.dSihffeearrebnotlitnssatrruecdtieosnigsnaerde gtoivfeanilfuonrdtheer psrpeedceiftiecrampipnleicdaltoioands. Always replace shear bolts
with identical grade.
Gasoline Engine Oil
Turf-Gard is a trademark of Deere & Company
Plus-4 is a trademark of Deere & Company
Plus-50 is a trademark of Deere & Company
TS1734-UN: Oil Viscosities for Air Temperature Ranges
Group 15 Fuel and Lubricants
Use oil viscosity based on the expected air temperature range during the period between oil changes.
Using single viscosity grade oils such as SAE 30 or SAE 40 can reduce oil consumption in air cooled engines.
John Deere Turf-Gard™ is preferred.
The following oils are also recommended:
John Deere Plus-4™
OtheroilsJoh m n ay Deer e b u e se Pdluifsth5 e 0 y ™ m I e Ietoneormoreofthefollowing:
ILSAC GF-5
API Service Category SN
API Service Category SM
API Service Category SL
API Service Category SJ
ACEA Oil Sequence A5
ACEA Oil Sequence A3
ACEA Oil Sequence A1
ACEA Oil Sequence C4
ACEA Oil Sequence C3
ACEA Oil Sequence C2
ACEA Oil Sequence C1
Oil FiltersAlways change filters regularly as specified in this manual.
Use filters meeting John Deere performance specifications.
Filtration of oils is critical to proper operation and lubrication.DX,FILT-19-19960318
DX,ENOIL2-19-20150720
Gasoline Fuel for 4-Cycle EnginesRefueloutdoors.DONOTsmokewhileyoufillthefueltank
or service the fuel system. Store fuel in properly identified
Useunleadedgasolinewithaminimumoctaneratingof87AKIpolyethylene containers. (anti-knock index) or 90 RON (research octane number).
Gasoline fuels specified to EN 228 or ASTM D4814 are
When storing fuel, add John Deere Gasoline Conditioner and recommended. Stabilizer (or equivalent) at the specified concentration.
IMPORTANT:
Fuel blends of unleaded gasoline with a maximum 10% ethanol or 15% MTBE (methyl tertiary-butyl ether) are also acceptable.
CAUTION:
Reduce the risk of fire. Handle fuel carefully. DO NOT fill the fuel tank when the engine is running or hot. Stop engine and allow it to cool for several minutes before filling fuel tank. Fill fuel tank only to the bottom of the filler neck.
DO NOT use methanol or fuel blends that contain methanol. Avoid spilling fuel. Gasoline can damage plastic and painted surfaces.
DO NOT mix oil with gasoline.
DX,FUEL2-19-20130515
Transmission and Hydraulic Oil
Grease
icant performance.
TS1739-UN: Oils for Air Temperature Ranges
Use oil viscosity based on the expected air temperature range during the period between oil changes.
The following oils are preferred:
John Deere Hy-Gard™
John Deere Low Viscosity Hy-Gard™
Other oils may be used if they meet one of the following:
John Deere Standard JDM J20C
John Deere Standard JDM J20D
Use John Deere Bio Hy-Gard™ II oil when a biodegradable fluid is required. [Bio Hy-Gard II meets or exceeds the minimum biodegradability of 80% within 21 days according to CECL-33-T-82 test method. Bio Hy-Gard II should not be mixed with mineral oils, because this reduces the biodegradability and makes proper oil recycling impossible.]
Hy-Gard is a trademark of Deere & Company
Bio Hy-Gard is a trademark of Deere & Company
DX,ANTI-19-20160825
TS1673-UN: Greases for Air Temperature Ranges
Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval.
John Deere SD Polyurea Grease is preferred.
The following greases are also recommended:
John Deere HD Lithium Complex Grease
John Deere HD Water Resistant Grease
John Deere GREASE-GARD™
Other greases may be used if they meet the following:
NLGI Performance Classification GC-LB
IMPORTANT:
Some types of grease thickeners are not compatible with others. Consult your grease supplier before mixing different types of grease.
GREASE-GARD is a trademark of Deere & Company
DX,GREA1-19-20110414
Mixing different oils can interfere with the proper functioning of
In general, avoid mixing different brands or types of oil. Oil ConsultyourJohnDeeredealertoobtainspecificinformationand manufacturers blend additives in their oils to meet certain recommendations. specifications and performance requirements.DX,LUBMIX-19-19960318
Alternative and Synthetic Lubricants
Consult your John Deere dealer to obtain information and recommendations.
Conditions in certain geographical areas may require lubricant Synthetic lubricants may be used if they meet the performance recommendations different from those printed in this manual.requirements as shown in this manual.
Some John Deere brand coolants and lubricants may not be Thetemperaturelimitsandserviceintervalsshowninthismanual available in your location.apply to both conventional and synthetic lubricants.
Fuel and Lubricants
Re-refined base stock products may be used if the finished lubricant meets the performance requirements.
Summary of References
Remove and Install Engine
Remove and Install Valve Cover
Remove and Install Timing Belt
Remove and Install Water Pump
Remove and Install Cylinder Head
Remove and Install Intake Manifold
Remove and Install Exhaust Manifold
Recondition Cylinder Head
Remove and Install Oil Pan and Strainer
Remove and Install Oil Pump
Remove and Install Crankshaft Front Oil Seal
Remove and Install Camshafts
Check Crankshaft Main Bearing Clearance
Check Connecting Rod Bearing Clearance
Check Connecting Rod Side Play
Remove and Install Piston and Connecting Rod
Disassemble and Assemble Piston and Connecting Rod
Inspect Piston and Connecting Rod Bore Cylinder
Remove and Install Crankshaft and Main Bearings
Inspect Crankshaft
Remove and Install Crankshaft Rear Oil Seal
Remove and Install Alternator
Remove and Install Starting Motor
Replace Fuel Injector
Replace Exhaust Gas Oxygen Sensor
Replace Knock Sensor
Replace Camshaft Position Sensor
Replace Crankshaft Position Sensor
Replace Intake Manifold Pressure and Temperature Sensor
Replace Throttle Body
OUMX068,000141B-19-20180213
Machine Specifications
Machine Specifications
NOTE:
Specifications and design subject to change without notice.
(27 mph)
(30 mph)
(2.618 in.)
Deere Plus-4™ or John Deere TURF-
StarterSolenoid Shift
BatteryBCI Group U1
Group 20
Machine Specifications
Cold Cranking Amps @-18° C (0° F)480 amps
Charging System (@ Output at 1900 rpm)36 amps
Charging System (Rated Output at 6000 rpm)75 amps
Charging System Static Draw5 mA
Power Train:
Drive Belt Width (3N1o7m5inmam l) (1.25in.)
EDnricvleotsruarine
Clutch Engagement1350 rpm
Clutch Disengagement1250 rpm
Transmission OilHy-Gard™ J20C or J20D (Cold Weather)
EMFWD OilLow Viscosity Hy-Gard™ J20C
Steering:
TypeRack and Pinion
Brakes:
TypeAll Wheel Hydraulic Disc
Capacities:
Fuel Tank20.1 L (5.3 gal)
Crankcase (with Filter)2.2 L (2.3 qt.)
Transmission4.3 L (4.5 qt.)
EMFWD Front
6 D6if0femre Lnt(i2a2 l oz.)
Dimensions:
2 Passenger4 Passenger
Width (overall)1.5 m (59. 3 in.)
Length (with bumper)2.8 7 m (113.0 in.)
Height (with OPS)1.89 m (74.4 in.)
Ground Clearance26.7 cm (11.0 in.)
Plus-4 is a trademark of Deere & Company
TURF-GARD is a trademark of Deere & Company
Hy-Gard is a trademark of Deere & Company
Product Identification Number Location
Group 10 - Repair
Summary of References........................................
(E5x4halbus-tftM)anifold to Exhaust Pipe NutsTorque
0.08 mm
(C0yl0in0d3eirnH.)eadFlatnessOut-of-Flat
0.8 1.2 mm
(I0nt0a3ke1 Va0lv0e4F7aicne.)MarginThickness 0.8
1.2 mm
(E0xh0a3u1s t 0Va0lv4e7Finac)e MarginThickness
0.75 mm
(V0al0v3e0Fiance) MarginWearLimitThickness
Inner Rotor-to-Outer Rotor Wear Limit
Crankshaft Pulley Cap Screw
Timing Belt Tensioner Cap Screw
Intake Camshaft
Exhaust Camshaft
Camshaft End Play (Max)
Camshaft Bearing Cap Screw
Intake Cam Front Journal
Intake Cam 2, 3 & 4th Journals
Exhaust Cam Front Journal
Exhaust Cam 2, 3 & 4th Journals
Main Bearing Cap Screw
Crankshaft Main Bearing
Crankshaft Main Bearing Wear Limit
Connecting Rod Cap Screw
Connecting Rod Bearing Oil
Connecting Rod Bearing Wear Limit
Connecting Rod Side Play
Connecting Rod Side Play Wear Limit
Connecting Rod Nut
Connecting Rod Bearing Clearance
Connecting Rod Bearing
Connecting Rod Bearing Wear Limit
Crankshaft Connecting Rod Journal
Piston Ring Groove Side Clearance
Top Piston Ring
Top Piston Ring (Max)
Second Piston Ring
Second Piston Ring (Max)
Piston Ring End Gap
Top Ring
Top Ring Wear Limit
Second Ring
Second Ring Wear Limit
Oil Control Ring
Oil Control Ring Wear Limit
Piston Pin Clearance
Piston Pin-to-Bore
Piston Pin-to-Bore Wear Limit
Cylinder Bore (Max)
Clearance (0.010 in.)
0.05 0.18 mm
(C0le.0a0ra2n c0e.007in.)
0.35 mm
Clearance (0.014 in.)
98 N·m
Torque (72 lb.-ft.)
25 N·m
Torque (18 lb.-ft.)
0.1 0.17 mm
(E0nd00P4la y0.007in.)
0.1 0.173 mm
(E0nd00P4la y0.007 in.) 0.18 mm
End Play (0.007 in.)
(T8o0rq±u9elb.-in.)
9±1 N·m
25.97 mm
OD (1.022 in.)
22.97 mm
OD (0.904 in.)
29.967 mm
OD (1.18 in.)
22.97 mm
OD (0.904 in.)
78 N·m
Torque (58 lb.-ft.)
0.020 0.072 mm
(C0le.0a0ra0n8c e0.0028 in.) 0.15 mm
Clearance (0.006 in.)
40 N·m
Torque (30 lb.-ft.)
0.020 0.044 mm
(C0le.0a0ra1n c0e.002in.) 0.07 mm
Clearance (0.003 in.)
0.15 0.24 mm
(E0nd00P6la y0.009 in.) 0.30 mm
End Play (0.012 in.)
40 N·m
Torque (30 lb.-ft.)
0.020 0.044 mm
(C0le.0a0ra0n8c e0.002 in.) 0.07 mm
Clearance (0.003 in.)
36.984 37 mm
(O1D.456 1.457in.)
0.03 0.06 mm
(C0le.0a0ra1n c0e.002in.) 0.12 mm
Clearance (0.005 in.)
0.03 0.06 mm
(C0le.0a0ra1n c0e.002in.) 0.11 mm
Clearance (0.004 in.)
0.25 0.40 mm
(G0a.0p10 0.016in.)
(G0a.0p14 0.020
Second Pass
Final Pass
Crankshaft
Crankshaft Connecting Rod Journal
(T1o8rqlbue-ft.) 48 N·m (T3o6rqlbue-ft.)
70.5 N·m (T5o2rqlbue-ft.)
Radial0.03 mm Runout(0.001 in.)
Essential or Recommended Tools
NOTE:
Order tools from the SERVICEGARD™ Catalog.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable only from the SERVICEGARD™ Catalog.
Service Equipment and Tools
NOTE:
Order tools according to information given in the SERVICEGARD™ Catalog. Some tools may be available from a local supplier.
Ridge Reamer JT07277
Removes ridge from top of cylinder bore.
Valve Spring Compressor JDG10981
Used to compress valve springs.
SERVICEGARD is a trademark of Deere & Company OUMX068,0000088-19-20131118
Other Material
Number Name
PM38609 (U.S.) (U.S.)
PM37469 (Canada) (U.S.)
7G6a4sk9e(tLoctite®) (U.S.)
TGYa1sk5e1t30(U.S.)
545 ( Loctite®) (U.S.)
Form-in-Place
Form-in-Place
Red 0.050 0.15 mmPlastigage (0.002-0.006 in.) (U.S.)Plastigage®
TY12130 (U.S.)
J20D (U.S.)Hy-Gard
Form-in-Place Gasket Sealer
Use
Applied to mating surfaces of oil pan and engine block.
Applied to mating surfaces of cylinder head.
Apply to threads of camshaft sprocket bolt.
Used to check main bearing clearances.
Used to measure main bearing clearance.
Apply to mating surface of engine block for oil seal case
Apply to transmission flange
Use to fill park brake assembly
Loctite is a trademark of Henkel Corporation Plastigage is a trademark of Perfect Circle Corporation OUMX068,0000089-19-20141112
Crankshaft Main Bearing Journal
Crankshaft Main Bearing
Crankshaft Main Bearing Wear Limit
Oil Seal Case Cap Screws
Flywheel Mounting Cap Screw
OUMX068,0000206-19-20141112
RECOMMENDED TOOLS, as noted, are suggested to perform the job correctly. Some tools may be available from local suppliers or may be fabricated.
Clutch Removal Tool JDG11200
Separates Primary Clutch from Engine Crankshaft
Oil Seal Protector JDG10978
Used to protect oil seal.
Intake Valve Seal Installer JDG10979
Use to install intake valve stem oil seals.
Exhaust Valve Seal Installer JDG10980
Used to install exhaust valve stem oil seals.
Socket JDG10982
Used to remove and install exhaust gas oxygen sensor.
Valve Stem Seal Protector JDG10984
Used to protect valve stem seals when installing on valve.
SERVICEGARD is a trademark of Deere & Company
OUMX068,0000087-19-20131028
Remove bolts (F) from driveshaft bearing.
LEGEND:
Alternator and Water Pump Belt Cover
A-Bolts (2 Used)
B-Alternator and Water Pump Belt Cover
LEGEND:
G-Coolant Hose
H-Coolant Hose
I- Bolt and Nut (2 Used)
J-Ignition Coil (3 Used)
K-Coolant temperature Sensor
Disconnect two coolant hoses (G) and (H).
Remove two bolts and nuts (I) securing the exhaust pipe to the exhaust manifold.
CAUTION:
Avoid Injury! USE CAUTION AROUND MOVING PARTS. STOP engine. Remove ignition key. Wait for all moving parts to STOP.
1 Park vehicle safely. Remove cargo box.
2 Disconnect negative ( )cable from the battery.12. Remove two bolts (A). Remove alternator and water pump belt cover (B).
LEGEND:
C-Drain Plug
D-Cap Screw
E-Coupling
F-Bolts (2 Used)
Place a coolant drain pan under engine. Loosen radiator cap and remove plug (C) from water pump to drain coolant from engine. 13.
6. Remove drive shaft retaining cap screw (D) and slide coupling (E) forward to disconnect from transmission.
Mark and disconnect connectors to ignition coils (J).
Disconnect coolant temperature sensor (K).
CAUTION:
Avoid Injury! Gasoline is flammable. DO NOT SMOKE. Always work in a well-ventilated area away from open flame or spark-producing equipment, including equipment that utilizes pilot lights.
Mark fuel injector connectors (N) to correspond with the cylinder number to aid in reassembly and disconnect fuel injector wiring.
Disconnect camshaft position sensor (O).
LVAL22463-UN: Connections at Side of Engine
LEGEND:
P-Clip
Q-Jam Nut
R-Intake Manifold Temperature and Pressure Sensor
S-Knock Sensor
T-Exciter Wire
U-Spring Cotter and Pin
Remove clip (P) from throttle cable end and loosen nut (Q).
Disconnect throttle cable and move aside.
Disconnect wire from intake manifold temperature and pressure sensor (R).
Disconnect wire from knock sensor (S).
Disconnect positive (+) battery cable and exciter wire (T) from starting motor solenoid.
Remove spring cotter and pin (U) from transmission shift cable yoke.
V-Snorkel Tube
W-Clutch Cover
Remove snorkel tube (V) and clutch cover (W).
Fan and Clutch Retaining Bolt LEGEND:
X-Drive Belt
Y-Clutch Retaining Bolt
Z-Fan
Remove drive belt (X).
Remove clutch retaining bolt (Y) and fan (Z).
21.
22.
23.
LVAL22464-UN: Snorkel Tube and Clutch Cover LEGEND:
LVAL22465-UN:
LEGEND:
aa-JDG11200 Clutch Removal Tool
Install JDG11200 Clutch Removal Tool(aa). Hold clutch and tighten tool until clutch pops off tapered shaft.
LEGEND:
ab-Driven Clutch Retaining Bolt
Remove driven clutch retaining bolt (ab) and slide clutch off shaft.
26. NOTE:
Keep track of different bolt lengths and locations for reassembly purposes.
LEGEND:
ac-Crankshaft Position Sensor
Disconnect crankshaft position sensor (ac).
Mark location of inner clutch enclosure bolts (arrows) to aid in reassembly. Bolts are not all the same length. Remove all bolts securing inner clutch enclosure to engine and transmission.
LEGEND:
ad-Bolt (3 Used)
ae-Transmission Mount
af-Bolt (2 Used)
ag-Mount
Remove three bolts (ad) around transmission mount (ae) and two bolts (af) securing mount (ag) to engine backplate. Remove mount.
24. LVAL22466-UN: Clutch
27.
LVAL22468-UN: Inner Clutch Enclosure
25. LVAL22467-UN: Driven Clutch Retaining Bolt
28.
LVAL22469-UN: Transmission Mount
29. LVAL22470-UN: Clutch Stub Shaft
LEGEND:
ah-Bolt (4 Used)
Remove four bolts (ah) remove shaft. from the clutch stub shaft and
30.
LVAL22471-UN: Crankshaft Position Sensor
LEGEND:
ai-Bolt (2 Used)
aj-Crankshaft Position Sensor
ak-Bolt (6 Used)
Remove two bolts (ai) securing crankshaft position sensor (aj) and remove sensor.
Clean exhaust pipe and exhaust manifold flanges of any old gasket material. Install a new manifold gasket.
Install exhaust manifold flange bolts and nuts and tighten to specifications.
Item Measurement Specification
E7x3hNaumst Pipe to Manifold Nut TorqueTorque
(54 lb.-ft.)
Connect all engine wiring harness connectors.
Attach throttle cable to throttle lever and adjust cable. (SeeAdjust Throttle Cable.)
Connect coolant hoses. Check condition of hoses and replace as necessary.
Attach ground wire to engine bracket.
Attach battery positive (+) cable and solenoid exciter wire to starting motor solenoid.
Connect fuel line.
NOTE:
Oil level should be at full mark with the cap screwed tight while the engine is cold. To make sure level is correct, start engine and run at 4500 rpm for one minute. Stop engine and check oil level.
Fill engine to proper level with oil of correct specifications. Fill coolant to correct level. (SeeFill and Bleed Coolant System.)
Attach negative ( )cable to battery. OUMX068,0000068-19-20141112
