MANUAL - JOHN DEERE Z915B/E Z920M/R Z925M Z930M/R Z945M Z950M/R Z960M/R Z970R MOWER TM127619

Z915B, Z920M, Z925M EFI, Z930M, Z930M EFI, Z950M, Z920R, Z930R, Z950R, Z960R, Z970R ZTrak™ Mowers Diagnostic and Repair TECHNICAL MANUAL ZTrak B/M/R Series Mower models Z915B, Z920M, Z925M EFI, Z930M EFI, Z920R, Z930R, Z950R, Z960R, Z970R, Z950M TM127619 21APR15 (ENGLISH)

John Deere Commercial and Consumer Equipment Lawn and Garden

TM127619-TECHNICAL MANUAL

(g) by Belgreen v2.1

Table of contents FOREWORD Section 10 - GENERAL INFORMATION Group 05 - Safety Group 10 - General Specifications Group 15 - Fuel and Lubricant Group 40 - Machine Specifications Section 20 - ENGINE REPAIR, KAWASAKI Group 05 - General Repair FX730V, FX801V, FX850V, and FX1000V Group 10 - Repair FX730V Group 15 - Repair FX801V and FX850V Group 20 - Repair FX1000V Section 25 - ENGINE REPAIR, KOHLER Group 05 - Repair CV740 and CV742 Group 10 - Repair ECV740 and ECV749 Section 30 - ELECTRICAL REPAIR Group 10 - Component Location Group 20 - Wire Harness, B Series Group 25 - Wire Harness, M Series Group 30 - Wire Harness, R Series Group 40 - Engine Harnesses and Options Group 50 - General Repair Section 40 - POWER TRAIN REPAIR Group 05 - Repair Section 50 - ATTACHMENTS REPAIR Group 10 - Component Location Group 20 - Repair Section 60 - MISCELLANEOUS REPAIR Group 10 - Wheels Group 20 - Operators Station Group 30 - Roll Over Protective Structure (ROPS) Group 40 - Miscellaneous Section 220 - ENGINE DIAGNOSIS, TESTS, AND ADJUSTMENTS, KAWASAKI Group 05 - Component Location Group 10 - Theory of Operation Group 15 - Diagnosis Group 20 - Tests and Adjustments Section 225 - ENGINE DIAGNOSIS, TESTS, AND ADJUSTMENTS, KOHLER Group 10 - Theory of Operation Group 20 - Diagnosis CV740 and CV742 Group 25 - Diagnosis ECV740 and ECV749 Group 30 - Tests and Adjustments CV740 and CV742 Group 35 - Tests and Adjustments ECV740 and ECV749 Section 230 - ELECTRICAL DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 05 - Specifications and Information Group 10 - Theory of Operation Group 15 - Theory of Operation (EFI) Group 20 - Diagnosis Group 25 - Engine Diagnostic Codes (EFI) Group 30 - Tests and Adjustments Group 35 - Tests (EFI) Group 40 - Wiring Schematics Group 50 - Connectors <- Go to Global Table of contents

TM127619-TECHNICAL MANUAL

TM127619-TECHNICAL MANUAL

(g) by Belgreen v2.1

Section 240 - POWER TRAIN DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 05 - Component Location Group 10 - Theory of Operation Group 20 - Diagnosis Group 30 - Tests and Adjustments Section 250 - ATTACHMENTS DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 10 - Theory of Operation Group 20 - Diagnosis Group 30 - Tests and Adjustments Section 299 - SERVICE TOOLS AND KITS Group 10 - Essential or Recommended Tools

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TM127619-TECHNICAL MANUAL

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TM127619-TECHNICAL MANUAL

GENERAL INFORMATION

(g) by Belgreen v2.0

Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.

Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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Section 10 page 1

TM127619-TECHNICAL MANUAL

TM127619-TECHNICAL MANUAL

(g) by Belgreen v2.1

Section 10 - GENERAL INFORMATION Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 1 Practice Safe Maintenance ................................................................................................................... 3 Use Proper Tools ................................................................................................................................... 3 Handle Fluids Safely—Avoid Fires ......................................................................................................... 4 Drain Gasoline When Storing Machine ................................................................................................. 4 Handling Batteries Safely ..................................................................................................................... 5 Prepare for Emergencies ...................................................................................................................... 7 Park Machine Safely ............................................................................................................................. 7 Support Machine Properly .................................................................................................................... 7 Wear Protective Clothing ...................................................................................................................... 9 Work in Clean Area ............................................................................................................................... 9 Service Machines Safely ..................................................................................................................... 10 Work In Ventilated Area ...................................................................................................................... 10 Illuminate Work Area Safely ............................................................................................................... 10 Replace Safety Signs .......................................................................................................................... 11 Use Proper Lifting Equipment ............................................................................................................. 11 Follow Tire Recommendations ............................................................................................................ 12 Dispose of Waste Properly .................................................................................................................. 12 Protect Against High Pressure Spray .................................................................................................. 13 Live With Safety ................................................................................................................................. 13 Group 10 - General Specifications ....................................................................................................... 14 Service Recommendations for O-Ring Boss Fittings ........................................................................... 14 Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 16 Metric Cap Screw Torque Values—Grade 7 ........................................................................................ 17 Metric Bolt and Screw Torque Values ................................................................................................. 18 Unified Inch Bolt and Screw Torque Values ........................................................................................ 19 Group 15 - Fuel and Lubricant ............................................................................................................. 20 Gasoline Engine Oil ............................................................................................................................. 20 Reduce Engine Oil Consumption ......................................................................................................... 22 Oil Filters ............................................................................................................................................ 23 Gasoline Fuel for 4-Cycle Engines ...................................................................................................... 23 Transmission and Hydraulic Oil .......................................................................................................... 24 Grease ................................................................................................................................................ 24 Mixing of Lubricants ........................................................................................................................... 25 Alternative and Synthetic Lubricants .................................................................................................. 25 Lubricant Storage ............................................................................................................................... 26 Group 40 - Machine Specifications ...................................................................................................... 27 Machine Specifications ....................................................................................................................... 27 Machine Identification Number Locations ........................................................................................... 27 Machine Identification Number Location ............................................................................................ 28 Engine Serial Number ......................................................................................................................... 28

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TM127619-TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION

Group 05: Safety

Group 05 - Safety Recognize Safety Information

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.

Understand Signal Words

Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards.

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

CAUTION also calls attention to safety messages in this manual.

Follow Safety Instructions

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Section 10 page 1

TM127619-TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION

Group 05: Safety

Safety Messages Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition.

Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator′s manual.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

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Section 10 page 2

TM127619-TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION

Group 05: Safety

Practice Safe Maintenance

Keep Area Clean Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts.

Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Use Proper Tools

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Section 10 page 3

TM127619-TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION

Group 05: Safety

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.

Handle Fluids Safely—Avoid Fires

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.

Drain Gasoline When Storing Machine

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Section 10 page 4

TM127619-TECHNICAL MANUAL