TECHNICAL MANUAL - John Deere JS25, JS35, JS45 Walk Behind Rotary Mower TM103619

TM103619

April 2009

DCG

INTRODUCTION Introduction

Safety

Manual Description This technical manual is written for an experienced t e c h n i c i a n a n d c o n t a i n s s e c t i o n s t hSpecifications a t a r e s p e cand i f i cInformation ally for this product. It is a part of a total product support program.

The manual is organized so that all the information on a p a r t i c u l a r s y s t e m i s k e p t t o g e t h e r . Engine T h e o(JS25 r d e r& oJS35) f grouping as follows: •Table

of

Contents

•Specifications

and

•Identification

Numbers

•Tools

and

Information

Materials

•Component

Location

•Schematics

and

•Theory

of

•Operation •

is

Electrical

Harnesses

Operation and

Engine (JS45)

Power Train (Gear)

Diagnostics

Diagnostics

•Tests

and

•

Repair

•

Other

Miscellaneous

Adjustments

Note: Depending on the particular section or system being covered, not all of the above groups may be used.

The bleed tabs for the pages of each section will align the sections listed on this page. Page numbering is consecutive from the beginning of the Safety section through the last section.

with

We appreciate your input on this manual. If you find any errors or want to comment on the layout of the manual please contact us.

All information, illustrations and specifications in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT© 2009 Deere & Co. John Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHT© 2008

Introduction

For the full PDF version of this manual, Please click on the above download PDF button.

SAFETY Replace Safety Signs

Safety Recognize Safety Information

MIF

Replace missing or damaged safety machine operator’s manual for cor placement.

MIF

This is the safety-alert symbol.

When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Understand Signal Words

A signal word - DANGER, WARNING, used with the safety-alert symbol. most serious hazards.

DANGER or WARNING safety signs a specific hazards. General precautio CAUTION safety signs. CAUTION als p r e c a Messages utions and safe Special safety messages in this manual.

Y o u r m a n u a l c o n t a i n s s p e c i a l m e ssages to bring attention servicing to potential safety concerns, machine damage as well as p r al p c ft u i cl e Fluids he o sp . e r a t i n g a n d s e r v i c i n g Handle inform a t i Safely o n . P- lAvoid e a s eFires read all the information carefully to avoid injury and machine Be Prepared For Emergencies damage.

Follow

recommended

c Caution: Avoid Injury! This symbol and text

highlight potential hazards or death to the operator or bystanders that may occur if the hazards or procedures are ignored.

Important: Avoid Damage! This text is used to tell the operator of actions or conditions that might result in damage to the machine.

MIF

Note: General information is given throughout the manual that may help the operator in the operation or service of the machine.

•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 ipnr ce isns eu rr ai zt e t ue rr es . e do rc opnutna ci n •Make of

sure

trash,

debris.

•Do not can

machine

grease,

store

ignite

oily

and

is

clean

and rags;

they

burn

spontaneously.

•Be prepared if a fire starts.

Safety - 1 •Keep a first aid kit and fire extinguisher handy.

•Keep

emergency

numbers

for

SAFETY Use Care In Handling and Servicing Batteries

Wear Protective Clothing

MIF MIF

Wear close fitting clothing appropriate to the job.

and

sa

Prevent Battery Explosions olo op ne gn e df l ea xmp eo sauwr ae y t o l o u d n o i s e • K e e p s p a r k s , l i g h t e d m a t c h e s , aPnr d h eeaxr pi n f r o m t h e t o p o f b a t t e r y . B a t t e r y l og sa ss oc fa n l ogd. eW . ear a suitable he such as earmuffs or earplugs to pr • N e v e r c h e c k b a t t e r y c h a r g e b y op bl aj e cc i nt igo n a am c tm f o r t a b l e l o b leet aol r oubnj e co across the posts. Use a volt-meter or hydrometer.

Operating equipment safely requir •Do not charge a frozen battery; it may explode. Warm operator. Do not wear radio or mu battery to 16°C (60°F). operating machine.

Prevent Acid Burns • S u l f u r i c a c i d i n b a t t e r y e l e c t r o Parking l y t e i Safely s poisonous. It is strong enough to burn skin, eat holes in clothing, and c a u s e b l i n d n e s s i f s p l a s h e d i n t o1 . eS yt eo sp. m a c h i n e o n a l e v e l 2.Disengage blade.

Avoid acid burns by: •Filling

w e l l - v e n t i3 l . aS tt eo dp ae rnega i. n e .

R re m p r o t e c t i o n a n d r u b4b. e g loovvee sk .e y , i f

batteries

•Wearing

eye

in

surface,

a

your

machine

is

e

.W f ol yr t ee n igs i na ed da endd. a l l m o v i n g p w h e n5 e l eaci tt r o leave the operator’s station.

•Avoiding spilling or dripping electrolyte.

6.Close fuel shut-off valve, if your •Use proper jump start procedure.

•Avoiding

If

breathing

fumes

you

spill

acid

on

•Flush

your

skin

with

•Apply

baking

•Flush

your

•Get If

eyes

medical

acid

•Drink

is

soda

or

with

Service Machines Safely

water. lime

to

water

for

attention

help 10

neutralize -

15

the

acid.

minutes.

immediately.

swallowed:

large

amounts

•Then drink milk vegetable oil.

•Get

yourself:

medical

of

of

water

magnesia,

attention

or

milk.

beaten

eggs,

or MIF

immediately.

Tie long hair behind your head. Do scarf, loose clothing, or necklace machine tools or moving parts. If caught, severe injury could result Remove rings and other jewelry to and entanglement in moving parts

Safety

-

2

SAFETY Use Proper Tools

Illuminate Work Area Safely

m ai n k n adr e a a d e q u a t U s e t o o l s a p p r o p r i a t e t o t h e w o rI lkl . u M ka e ts eh i yf o t ut ro owl os r a t as b f eo twy e lr i gt o ho t l fs o r w o r k i n g i p r o c e d u r e s c a n c r e a t e s a f e t y h a pz o ard . l Ue s se a p e o tshe en ibnugl b i s e n o n l y t o l o o s e n t h r e a d e d p a r t s a nmda cf ah si n t ee n. eMr sa .k eF os ru rl o accidentall a n d t i g h t e n i n g h a r d w a r e , u s e t hTeh e c o hr o r et c fti l sa i m z ee nt to oo lf s .a n DO i l lm ed o sr t oe inl e. r s .

N O T u s e U . S . m e a s u r e m e n t t o o l ss p on e t fr ui ce l f a Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications.

Work In Ventilated Area

Work in Clean Area Before starting a job: 1.Clean work

area

and

machine.

2.Make

sure

necessary job. on

you

tools

3.Have

the

to

have

all

do

your

right

parts

MIF

hand.

Support Machine Properly and Use Proper all instructions Lifting Equipment

Engine exhaust fumes can cause si necessary to run an engine in an e the exhaust fumes from the area w extension.

4.Read

thoroughly; shor tcuts.

do

not

attempt

If you do not have an exhaust pipe doors and get outside air into the

Warning: California Proposition 65 Warning

Gasoline engine exhaust from this chemicals known to the State of C birth defects, or other reproductiv

Diesel engine exhaust and some of known to the State of California to o n a l i f t e d m a cdhe if ne ec tos r, a tn tda co ht m h ee rn tr ,e p r o d u c t i v e h a the machine or attachment.

MIF

If you must work securely support

Do not support the machine on cinder blocks, hollow tiles, Remove Paint Before Welding or Heating or props that may crumble under continuous load. Do not t il ay l lbyy t ao xj iacc kf u w o r k u n d e r a m a c h i n e t h a t i s s u Ap vpooi rdt epdo ts eonl e . mes and c a n b e g e n e r a t e d w h e n p aint is he Follow recommended procedures in this manual. soldering, or using a torch. Do all L i f t i n g h e a v y c o m p o n e n t s i n c o r rveecnt tl iy l ac taend caar ue sa e. D s ei sv p eo r es e o f p a i n t a

i n j u r y o r m a c h i n e d a m a g e . F o l l o Rwe m r eocvoem pma ei n td ebde f o r e w e l d i n g o r h e p r o c e d u r e f o r r e m o v a l a n d i n s t a gl lr ai n t ido np aoi fn tc ,o m a vpooi n d e bn rt es a it nh i tnhge t h e d respirator. If you use solvent or p manual. stripper with soap and water befo solvent or paint stripper containe Using High Pressure Washers material from area. Allow fumes to b /eef loer ce t rwi e l dl i n g o r h e a t i n g D i r e c t i n g p r e s s u r i z e d w a t e r a t eml ei n cu t rt oe ns i c ca components or connectors, bearings, hydraulic seals, fuel injection pumps or other sensitive parts and components may cause product malfunctions. Reduce pressure and spray at a 45 to 90 degree angle.

Safety

-

3

SAFETY

Check the MSDS before you start a hazardous chemical. That way you the risks are and how to do the job procedures and recommended equi

Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers.

Inhaled asbestos fibers may cause lung cancer.

Components

in

products

Dispose of Waste Properly

Improperly disposing of waste can environment and ecology. Potentia with John Deere equipment include coolant, brake fluid, filters, and ba containers when draining fluids. D beverage containers that may misl drinking from them. Do not pour w down a drain, or into any water sou proper way to recycle or dispose of environmental or recycling center, dealer.

that

may contain asbestos fibers a a rn ed bl ir na ikneg paasds se, mbbr lai ke es , bcal nu dt c h plates,

and

some

gaskets.

The

asbestos used in these c ud a l il n y fs oo umned i no m a pr oe ns e i nn tos r i ss e ua sl e way.

Normal

handling

is

not

hazardous as long as airborne d u ts t g ce on ne tr aa it ne idn. g a s b e s t o s i s no

Avoid Injury From Rotating Blades and

A void Augers use

creating

dust.

compressed

air

Live with Safety

Never

for

cleaning.

A m vaot iedr i ba rl ucs ohni n t ag i no irn g g r ai ns d b ie ns g tos.

When servicing, wear an approved respirator. A special v cuum c l e ae n er is ra ea MIF s cb oe m s tm o se .n d If d n otto c l e a n a v a i l a b l e , a p p l y a m i s t o f o l ile K e e p h a n d s a n d f e e t a w a y wi h o o fr f wpaot w ee r r o tn o t sh ee r vmi c ae t e, rl iua bl r i c a t e a u g e r s o r P T O s h a f t s. . K e e p c o n t an i nd ienr gs aa swbaeys tf o b r os m the a ry es at a .

machine is running. Shut or remove mower blades,

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems.

Install all guards and shields.

Handle Chemical Products Safely

MIF

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, 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.

Safety

MIF

-

4

SPECIFICATIONS AND INFORMATION TABLE OF CONTENTS Table of Contents Specifications

and

Information

Fastener Torques..............................................7 Metric Fastener Torque Values......................7 Inch Fastener Torque Values.........................8 Metric Fastener Torque Value - Grade 7 (Special).........................................................9 General Information..........................................9 Gasoline .........................................................9 Gasoline Storage..........................................10 4 - Cycle Gasoline Engine Oil......................10 Break-In Engine Oil - 4-Cycle Gasoline........10 Alternative Lubricants...................................11 Synthetic Lubricants.....................................11 Lubricant Storage.........................................11 Mixing of Lubricants.....................................11 Grease..........................................................11 Serial Number Locations...............................12 Machine Product Identification Number.......12 Engine Serial Number..................................12

Specifications

and

Information

Table

of

Contents

SPECIFICATIONS AND INFORMATION FASTENER TORQUES Fastener Torques

Metric Fastener Torque Values 4.8

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

10

12

10

5 5

12.9

10

10

5

Property Class and Nut Marking s

12.9

8.8

12

Property Class and Head Marking s

10

10

12

MIF

Class

4.8Class

Lubricated SIZE

N•m

M6

4.8

M8

12

aDry

lb-ft

3.5

8.8

6

or

9.8Class

aLubricated

N•m

4.5

9

lb-ft

6.5

8.5

15

11

22

16

8.5 20

12.9

aDry

aLubricated

lb-ft

N•m

lb-ft

17

15

N•m

11

28

10.9Class

13

32

9.5

24

40

30

11.5

37

19

47

N•m

lb-ft

N•m

14.5

35

17

29

21

43

32

55

40

63

M12

40

29

50

37

75

55

95

70

110

80

M14

63

47

80

60

120

150

110

175

M16

100

73

M18

135

100

175

M20

190

140

240

180

375

275

475

350

530

400

675

500

625

460

800

M22

260

190

330

250

510

375

650

475

725

540

925

675

850

625

1075

M24

330

250

425

310

650

475

825

600

925

675

1150

850

1075

800

135

M27

490

360

625

450

950

700

1200

875

1700

1250

1600

115

M30

675

490

850

625

1300

950

1650

1200

M33

900

675

1150

850

1750

1300

M36

1150

850

1450

1075

2250

these

hand

torque

DO

NOT

use

92

190

125

140

260

240

195

175

330

75

55

140

105

130

95

130

225

165

205

150

260

109

275

200

350

225

320

240

400

250

60

28

lb-ft

aD

23

125

80

N•m

aLubricated

M10

88

47

12

aDry

375

2200

1650

275

1350

2850

values

if

a

165

350

1000

1350

2500

2100

70

475

1850

1650

95

440

2300

1850

3200

120

560

1700

3150

2350

different

325

torque

41

2150

2350

4050

300

5

1

2900

3000

37

values

s

value or tightening procedure is given for a specific head. application. Torque values listed are for general use only Tighten toothed or serrated-type lock nuts to the full torque and include a ±10% variance factor. Check tightness of value. fasteners periodically. DO NOT use air powered wrenches. a “Lubricated” means coated with a lubricant such as Shear bolts are designed to fail under predetermined loads. engine oil, or fasteners with phosphate and oil coatings.

Always replace shear bolts with identical grade.

“Dry” means plain or zinc plated (yellow dichromate Fasteners should be replaced with the same grade. Make Specificat sR ue rf e r St h- r eG a2 d0 s0 .a r e c l e a n a n d t h a t y o u p r o p e r l y s t a r t e r feans ct ee :n e JD thread engagement. This will prevent them from failing when tightening.

When

bolt

and

nut

Specifications

combination and

fasteners

Information

are

Fastener

used,

torque

Torques

-

7

SPECIFICATIONS AND INFORMATION FASTENER TORQUES Inch Fastener Torque Values 8

5.2

5.1

5

1 or 2b

SAE Gra de and Head Markings

8.2

No Marks

5

2

SAE Gra de and Nut Markings

8

No Marks

MIF

Grade

1Grade

Lubricated SIZE 1/4

3.7

5/16

14

7/16

22

9/16

lb-ft

36

5/8

67

3/4

120

87

7/8

190

140

1

50

7

9

15

25

18

16

27

20

35

26

44

33

35

53

45 62

150

9.5

20

31

85

lb-ft

11

20

60

N•m

15

22

39

N•m

44

67

5.5

32

50

55

N•m

13.5

10

28

21

26

50

36

35 63

lb-ft 17

80

58

100

75

63

110

80

120

90

150

115

125

90

155

115

175

130

225

70

105

78

135

100

170

125

215

160

215

190

140

240

175

300

225

375

280

140

240

175

490

360

lb-ft

N•m

12.5

52

95

190

N•m

aD

46

56

175

aLubricated

70

85

41

12

aDry

75

110

240

26

8.2

lb-ft

9

12

or

aLubricated

7.5

6

8

aDry

4.5

13

42

5.2Grade

3.5

17

25

or

lb-ft

7

28

5.1

N•m

10

16

48

4.7

5,

aLubricated

5.5

10

33

aDry

2.8

7.7

3/8

1/2

N•m

2bGrade

625

160

160 300

425

450

225

310

700

550

500

400

875

65

290

210

360

270

290

210

360

270

725

540

925

675

1050

750

1300

97

1-1/8

470

300

510

375

470

300

510

375

900

675

1150

850

1450

1075

18

1-1/4

570

425

725

530

570

425

725

530

1300

950

1-3/8

750

550

950

700

750

550

950

700

1700

1250

1-1/2

1000

725

1250

DO

NOT

use

these

925 hand

990

725

torque

1250

930

values

if

2250 a

1650

1200

2150

1650

different

2050

1550

2850

2700

2100

torque

1500

200

3600

head.

vTai lguhet eonr tt o i go ht h t ee nd i no g r sp er ro rcaet de ud r- et y ips e g li ov ce kn nf o u rt s a t so p tehc ei f if cu l l t o r q u e application. Torque values listed are for general use only value. and include a ±10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches.a “Lubric engine oil, or fasteners with phosphate and oil coatings.

Shear bolts are designed to fail under predetermined loads.

“Dry” means plain or zinc plated (yellow dichromate Always replace shear bolts with identical grade.

Specification JDS117) without any lubrication.

Fasteners should be replaced with the same grade. Make b “Grade 2” applies for hex cap screws (Not Hex Bolts) up sure fastener threads are clean and that you properly start to 152 mm (6 in.) long. “Grade 1” applies for hex cap thread engagement. This will prevent them from failing screws over 152 mm (6 in.) long, and for all other types of when tightening. bolts and screws of any length.

When bolt and nut combination fasteners are used, torque Reference: JDS - G200 values should be applied to the NUT instead of the bolt Specifications

and

Information

Fastener

Torques

-

8

SPECIFICATIONS AND INFORMATION GENERAL INFORMATION Metric Fastener Torque Value - Grade 7 (Special) Steel or Gray Iron Torque

Aluminum Torque

N•m

N•m

M6

(lb-

(lb-

M8

ft)

M10

(8)

(6)

M12

24

19

M14

(18)

(14)

M16

52

41

(38)

(30)

88

70

(65)

(52)

138

111

(102)

(82)

224

179

(165)

(132)

Size

11

ft)

General Information Gasoline

8

mif

c Caution: Avoid Injury! Fuel vapors are explosive and flammable:

•Shut engine off and allow to cool before filling fuel tank.

•Do not smoke while handling fuel.

•Keep fuel away from flames or sparks.

•Fill fuel tank outdoors or in well ventilated area.

•Clean up spilled fuel immediately.

•Use clean approved non-metal container to prevent static electric discharge.

•Use clean approved plastic funnel without screen or filter to prevent static electric discharge.

•Loosen fuel cap slowly to release pressure and to keep fuel from escaping around the cap.

To

avoid

•DO

NOT

engine

damage:

mix

with

oil

gasoline

•ONLY use clean, fresh unleaded gasoline with an octane rating (anti-knock index) of 87 or higher •fill

gas

tank

prevent tank •keep

at

the

end

condensation

up

with

of

from

specified

each

day's

forming

service

operation

inside

a

t

partia

intervals

Use of alternative oxygenated, gasohol blended, u gasoline is acceptable as long as: •the ethyl or grain alcohol blends DO NOT exceed by volume or •methyl tertiary exceed

15%

by

Specifications

butyl

ether

(MTBE)

blends

DO

NOT

volume and

Information

General

Informatio

SPECIFICATIONS AND INFORMATION GENERAL INFORMATION

c Caution: Avoid Injury! California Proposition 65 Warning: Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

SAE 5W-30 -40 -22

-4

14

32

50

68

86

1 0 41 2 2

-40 -30

-20

-10

F

10

20

30

40

0

Gasoline Storage

50

SAE 10W-30

C SAE 30

Important: Avoid Damage! Keep all dirt, scale, water or other foreign material out of gasoline.

Keep gasoline stored in a safe, protected area. Storage of g a s o l i n e i n a c l e a n , p r o p e r l y m a rBreak-In k e d ( “Engine U N L EOil AD ED - 4-Cycle Gasoline GASOLINE”) POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. DO Important: Avoid Damage! ONLY use a quality breakNOT use de-icers to attempt to remove water from gasoline in oil in rebuilt or remanufactured engines for the or depend on fuel filters to remove water from gasoline. first 5 hours (maximum) of operation. DO NOT use Use a water separator installed in the storage tank outlet. oils with heavier viscosity weights than SAE 5W-30, BE SURE to properly discard unstable or contaminated these oils will not allow rebuilt or remanufactured gasoline. When storing machine or gasoline, it is engines to break-in properly. recommended that you add John Deere Gas Stabilizer or an equivalent to the gasoline. BE og l l oJ w T hSeU fRoEl l to ow if n o hdn i rDe ec et ir oe n os i l i s on container and to properly discard empty container.

•BREAK - IN ENGINE OIL.

PR

John Deere BREAK - IN ENGINE OIL special additives for aluminum and to allow the power cylinder compo Use the appropriate oil viscosity based on the expected air liners as well) to “wear-in” while p temperature range during the period between components, valve train and gears, recommended oil changes. Operating outside of these Engine rebuild instructions should recommended oil air temperature ranges may cause determine if special requirements premature engine failure.

4 - Cycle Gasoline Engine Oil

The

following

John

Deere

oil

is

•TORQ - GARD SUPREME® - SAE 30;

oE hF n E DR eReErDe : B R E A K - I N E N G I N E O I L PJ R recommended for non-John Deere e and cast iron types.

•TORQ - GARD SUPREME® - SAE 10W-30.

The following John Deere oil is als T h e f o l l o w i n g J o h n D e e r e o i l s a r •TORQ e a l s- GARD o r eSUPREME® c o m m e- SAE n d 5W-30. ed, based on their specified temperature range: If the above recommended John De •TURF - GARD® - SAE 10W-30; available, use a break-in engine oi specification during the first 5 hou •PLUS - 4® - SAE 10W-30. operation: Other oils may be used if above John Deere oils are not •SAE 5W-30 - API Service Classifica available, provided they meet one of the following specifications: •SAE •SAE •SAE

C l a s s i f i Important: cation S J o rDamage! h i g h eAfter r; Avoid the break-in period, use the John Deere oil that is recommended 10W-30 - API Service Classifications SJ or higher; for this engine.

30 - API Service Classification SJ or higher.

5W-30

-

API

Service

Specifications

and

Information

General

Informatio

SPECIFICATIONS AND INFORMATION GENERAL INFORMATION Grease BREAK-IN OIL -40 -22

-4

14

-40 -30

-20

-10

32

50

68

86

1 0 41 2 2

F

10

20

30

40

50

0 SAE 5W-30 C

Important: Avoid Damage! Use recommended John Deere greases to avoid component failure and premature wear.

The recommended John Deere greases are effective within an average air temperature range of -29 to 135 degrees C (-20 to 275 degrees F).

If operating outside that temperature range, contact your Servicing dealer for a special-use grease.

Alternative Lubricants

The following greases are preferred:

Use of alternative lubricants could cause reduced life of the component.

•John

If

alternative

lubricants

to

be

is

used,

it

are

Deere

Polyurea •John not

SD

Grease

Deere

Lithium

Multi-Purpose Multi-Purpose

Complex

using

HD

Grease

any

of

If the

preferred greases, be sure to rSynthetic ecomm ended Lubricants tS h a t t h e f a c t o r y f i l l b e yo ni trt coh h tnihc y rb ts h ue ig e e u s e du si en aJ o h n D e e r e e q u i p m e n t w gl yl ur be rmi co av ne tds bme af o gena e r a l a l l -q pu ui rr e p o seen tgsr e a s e it fo tahneyy aml teeertn ta ht iev ea pl p l i c a b l t h na cne Nr Le G I g r am de No.2 u b r i c a ne t .p e r f owri m ( i n d u s t r y c l a s s i f i c a t i o n a n d / o r mr ial ti ti n a rg y. s p e c i f i c a t i o n ) a s shown in this manual.

Wet or high speed conditions The recommended air temperature limits and service or e qa ui n i rt ea i un seed oaf s a s h sp l u b r i c a n t c h a n g e i n t e r v a l s s h o u lm d aby e r m oe w cni a l i n t h e o p e r a t o r ’ s m a n u a l , u n l e s s u os teh g erw i s e s t a t e d o n . e Ca ol en rt af co tr y o u r S c ieanatgi odn i ne fr ov ri m . lubricant label.

Avoid

mixing

different

brands,

grades,

or

types

of

oil.

Oil

manufacturers blend additives in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

Lubricant Storage All machines operate at top efficiency only when clean lubricants are used. Use clean storage containers to handle all lubricants. Store them in an area protected from dust, moisture, and other contamination. Store drums on their sides. Make sure all containers are properly marked as to their contents. Dispose of all old, used containers and their contents properly.

Mixing of Lubricants In general, avoid mixing different brands or types of lubricants. Manufacturers blend additives in their lubricants to meet certain specifications and performance requirements. Mixing different lubricants can interfere with the proper functioning of these additives and lubricant properties which will downgrade their intended specified performance.

Specifications

and

Information

General

Information

-

11

SPECIFICATIONS AND INFORMATION SERIAL NUMBER LOCATIONS •

Serial Number Locations

Engine

Serial

Number

is

located

Machine Product Identification Number JS25

PIN

(100001-)

JS35

PIN

(100001-)

JS45

PIN

(100001-)

If you need to contact an Authorized Service Center for information on servicing, always provide the product model and identification numbers.

You will need to locate the model and serial number for the machine and for the engine of your machine and record the information in the spaces provided below.

When ordering parts or submitting a warranty claim, it is IMPORTANT that the machine product identification number (PIN) and component serial numbers are included.

The location of the PIN and component serial numbers are shown.

B A

MX40230

•Machine Serial mower deck.

Specifications

Number

and

is

located

Information

on

Serial

left-hand

Number

side

of

Locations

-

12

o

ENGINE - JS25 & JS35 TABLE OF CONTENTS Table of Contents

Repair .............................................................. 40 Engine Cover Removal...................... ..........40 Fuel Tank Removal and Specifications.................................................15 Engine Installation............41 Specifications.............

Engine Blower Housing ......................15 Removal and Fuel............................

Installation................. .................................. ..................................

15 Electrical . 41 Engine Removal Specifications............. and . . . . . . . . . . . . . . . . . . .

1 5 R e p a i r Installation.................

Component Location......................................18 Specifications.............

42 Carburetor Removal .......................15 and Torque Installation...........44 Specifications.............

Carburetor ......................16 Inspection...................

Theory S p eofc Operation.......................................22 ial Equipment Or ...............45 Tools.........................1 Carburetor Base Plate 7 Other Removal and Materials.....................

Installation................. ........................17 .................................. . 46 Intake Manifold Component Location Removal and Installation....46 Muffler Removal and General....................18 Installation.................

C P iosm t op no naenndt VL ao lcvaetsi .o. n . . 1 -9 47 Bi-Metallic Coil Component Location Removal......................

Diagnosis.........................................................29 ........48 Governor Lever Carburetor................2 Removal and Tests and Adjustments..................................33 Installation...48 0 Ignition Module A i r I n t a k e C o m p o n e n t L 1 ocation....................2 Removal and Installation....48 Cooling Alternator Removal and Installation.............48 System........................

Starter Interlock Switch Removal and ....................22 Installation.................

C ra n ek m c a. .s. e B r. e. . a. .t . h. .e. r. . . . . . . ..................................

S y s t . . . . .

22 . 49 Starter Motor Lubrication Removal and Installation.......49 System........................

Flywheel Removal and ...............22 Installation..............4 C r e. s. .s . i. o. .n. . .R. .e. l. e 9 Crankcase Breather S yo smt p em . . a. .s . e. . 2 2 Removal and Fuel Inspection System........................ .................................. . . . . . . . . . . . . . . . . . . . . . . E. n . . g2i 2n e - J S 2 5 &. . J. .S . 3. 5. . T. .a. b. .l .e . .o. f. C o n t e n t s - 51 03 Crankcase Breather C o .r . . M O ap rebr u a rt e i ot n . . a. .i .n. . .C. .i .r . c2 u2 i t Installation.................

Governor Engine

-

JS25

&

JS35

ENGINE - JS25 & JS35 SPECIFICATIONS Specifications Engine Specifications Engine: Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Briggs & Stratton Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675 Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air cooled (4 cycle) Valve Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . Flat Head Valves in Cylinder Block Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 cc (11.59 cu in.)

Engine Governed Speed . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3400 ± 100 rpm Cylinder Bore (Nominal) . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.26 mm (2.688 in.)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.80 mm (2.040 in.)

Lubrication Type. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Splash System Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 L (20 U.S. oz) Oil Fill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Top/left of engine Air Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . Dry Replaceable w/Foam - Dual Element Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fixed Speed

Fuel Fuel System: Type Required. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . Unleaded Gasoline, 85 Minimum Octane Fuel Tank Capacity. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 L (2.1 qt) Carburetor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Float-type CARB/EPA Certified Choke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . used in California

Electrical Specifications Ignition: Armature Air Gap . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 - 0.25 mm (0.006 - 0.010 in.)

Stator Air Gap (JS35) (SN -100000). . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 - 0.25 mm (0.006 - 0.010 in.)

Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electronic Spark plug (resistor). . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RJ19LM Champion Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.076 mm (0.030 in.)

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . Recoil with compression release (Electric on JS35).

Repair Specifications Connecting Rod: Crankpin Bore (ID) . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 27.95 - 27.93 mm (1.100 - 1.010 in.)

Crankpin Bore (Reject Size) . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.98 mm (1.102 in.)

Piston Pin Bore (ID) . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 15.89 - 15.90 mm (0.626 - 0.626 in.)

Piston Pin Bore (Reject Size) . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.93 mm (0.627 in.)

Engine

-

JS25

&

JS35

Specifications

-

15

ENGINE - JS25 & JS35 SPECIFICATIONS Crankshaft: Out-of Round (Maximum) . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.013 mm (0.001 in.)

PTO End (Reject Size) . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.92 mm (1.060 in.)

Crankpin (Reject Size) . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.86 mm (1.097 in.)

Flywheel End (Reject Size) . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.17 mm (0.873 in.)

Crankshaft End Play. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.76 mm (0.002 - 0.030 in.)

Camshaft: Gear Journal (Reject Size). . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.65 mm (0.498 in.)

Lobes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .Replace If Lobes Are Pitted Or Galled Cylinder: Piston Bore ID (Reject Size) . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.29 mm (2.689 in.)

Crankcase: Cam End Bores. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.80 mm (0.504 in.)

PTO End Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.05 mm (1.065 in.) . . .mm . (0.878 . . . in.) . . . . . . . . . . . . . . . . . . . .

Flywheel End Bore. . . . . . . . . . . . . . . . . . . . . . . . 22.30 Piston: Pin Diameter (Reject Size). . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.85 mm (0.624 in.)

Pin Bore (Maximum). . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.90 mm (0.626 In.) Compression Ring End Gap (Reject Size). . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.89 mm (0.035 in.)

Oil Ring End Gap (Reject Size) . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 mm (0.045 in.)

Valves: Intake Valve Clearance. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 - 0.18 mm (0.005 - 0.007 In.) Exhaust Valve Clearance. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.23 - 0.28 mm (0.009 - 0.011 In.) Valve Guide Reject Size. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.60 mm (0.260 In.) Valve Seats: Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46° Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31° Minimum Width. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.79 mm (0.031 in.)

Blade Brake Clutch Brake Pad Thickness (Minimum) . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)

Torque Specifications Torques (Alphabetical) Flywheel Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 N•m (60 lb-ft) Carburetor Mount. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (89 lb-in.)

Connecting Rod Cap Screw . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 N•m (100 lb-in.)

Cylinder Head Cap Screw . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.8 - 18 N•m (140 - 160 lb-in.)

Engine to Mower Deck Cap Screws . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 ± 14 N•m (40 ± 10 lb-ft) Intake Manifold Cap Screw . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 N•m (120 lb-in.)

Blade Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - 61 N•m (35 - 45 lb-ft) Muffler Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (89 lb-in.)

Engine

-

JS25

&

JS35

Specifications

-

16

.

.

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