JOHN DEERE Z355R MOWER TM140319 PDF MANUAL

Z335E, Z335M, Z345M, Z345R, Z355E, Z355R, Z375R ZTrak Mower (SN: 010001-)

TECHNICAL MANUAL Z335E, Z335M, Z345M, Z345R, Z355E, Z355R, Z375R ZTrak Mower (SN: 010001-) TM140319 01DEC18 (ENGLISH)

John Deere Power Products

Introduction Foreword routine failures quickly.

Operation and tests sections help you identify the majority of

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.

Technical Manuals are concise guides for specific machines.

They are on-the-job guides containing only the vital information CAUTION:needed for diagnosis, analysis, testing, and repair.

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 DX,TMIFC-19-20140415 and tests. Repair sections tell how to repair the components.

TM140319 (01.12.2018)

Z335E, Z335M, Z345M, Z345R, Z355E, Z355R, Z375R ZTrak Mower

Contents 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 - Engine Twin Cylinder

Section 30 - Electrical Repair Group 10 - Component Location Group 20 - Wiring Harnesses

Section 40 - Power Train Repair Group 10 - Component Location Group 20 - Repair

Section 50 - Attachments Repair Group 10 - Component Location Group 20 - Repair

Section 60 - Miscellaneous Repair Group 10 - Component Location Group 20 - Repair

Section 220 - Engine Diagnosis, Tests, and

TM140319 (01.12.2018)

Adjustments

Group 10 - Diagnosis Group 20 - Tests and Adjustments

Section 230 - Electrical Diagnosis, Tests, and Adjustments Group 10 - Theory of Operation

Group 20 - Diagnosis Group 30 - Tests and Adjustments Group 40 - Wiring Schematics Group 50 - Connectors

Section 240 - Power Train Diagnosis, Tests, and Adjustments Group 10 - Theory of Operation

Group 20 - Diagnosis Group 30 - Tests and Adjustments

Section 250 - Attachments Diagnosis, Tests, and Adjustments Group 10 - Diagnosis Group 20 - Tests and Adjustments

Section 299 - Service Tools and Kits Group 10 - Service Tools

Z335E, Z335M, Z345M, Z345R, Z355E, Z355R, Z375R ZTrak Mower

Section 10

General Information Page

Contents

Page

Group 05 - Safety Recognize Safety Information...............................10-05-1 Understand Signal Words......................................10-05-1 Follow Safety Instructions......................................10-05-1 Practice Safe Maintenance....................................10-05-2 Use Proper Tools...................................................10-05-2 Handle Fluids Safely - Avoid Fires........................10-05-2 Drain Gasoline When Storing Machine.................10-05-3 Handling Batteries Safely......................................10-05-3 Prepare for Emergencies.......................................10-05-4 Park Machine Safely..............................................10-05-4 Support Machine Properly.....................................10-05-4 Wear Protective Clothing.......................................10-05-4 Work in Clean Area...............................................10-05-5 Service Machines Safely.......................................10-05-5 Work In Ventilated Area.........................................10-05-5 Illuminate Work Area Safely..................................10-05-5 Replace Safety Signs............................................10-05-6 Use Proper Lifting Equipment................................10-05-6 Follow Tire Recommendations..............................10-05-6 Decommissioning - Proper Recycling and Disposal 10-056 of Fluids and Components.............................

Protect Against High Pressure Spray....................10-05-7

Live With Safety.................................................... 10-05-7 Group 10 - General Specifications Metric Cap Screw Torque Values - Grade 7..........

Metric Bolt and Screw Torque Values....................

Unified Inch Bolt and Screw Torque Values..........

Group 15 - Fuel and Lubricants

10-10-1 10-10-2 10-10-3 10-15-1 10-15-1 10-15-1

Summary of References........................................

10-15-1 Gasoline Engine Oil...............................................

10-15-2 Oil Filters...............................................................

10-15-2 Gasoline Fuel for 4 - Cycle Engines......................

10-15-2 Transaxle Oil.........................................................

10-15-2 Grease...................................................................

10-15-2 Mower Spindle Grease..........................................

10-15-2 Mixing of Lubricants..............................................

10-15-4 Alternative and Synthetic Lubricants.....................

10-15-4 Lubricant Storage..................................................

Gasoline and Engine Storage...............................

Carburetor Cleaning..............................................

Carburetor Cleaning Methods...............................

Group 20 - Machine Specifications

10-15-6 10-20-1 10-20-2

Machine Specifications..........................................

Product Identification Number Location................

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Safety

Group 05 Safety Recognize Safety Information

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.

Understand Signal Words

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.

TS187-19: Signal Words

DX,SIGNAL-19-20161005

Follow Safety Instructions

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.

Therecanbeadditionalsafetyinformationcontainedonpartsand components sourced from suppliers that isnot 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.

TS201-UN: Safety Messages

DX,READ-19-20090616

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Safety

Practice Safe Maintenance

TS218-UN: 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 away 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.

Falling while cleaning or working at height can cause serious injury. Use a ladder or platform to easily reach each location. Use sturdy and secure footholds and handholds.

DX,SERV-19-20170228

Use Proper Tools

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

Handle Fluids Safely—Avoid Fires

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

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Safety

Drain Gasoline When Storing Machine

TS227-UN: Storing Gasoline

Gasoline stored in fuel tank can explode.

Never store equipment with gasoline in the tank inside a building where fumes may reach an open flame or spark.

Always drain gasoline from fuel tank and carburetor bowl when storing machine. Allow engine to cool before storing.

DX,STORE2-19-19900126

Handling Batteries Safely

TS203-UN: Caution

Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

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

Always remove grounded (-) battery clamp first and replace grounded clamp last.

Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid hazards by:

Filling batteries in a well-ventilated area Wearing eye protection and rubber gloves Avoiding use of air pressure to clean batteries Avoiding breathing fumes when electrolyte is added Avoiding spilling or dripping electrolyte Using correct battery booster or charger procedure.

TS204-UN: Caution

If acid is spilled on skin or in eyes:

Flush skin with water.

Apply baking soda or lime to help neutralize the acid.

Flush 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 qt.).

Get medical attention immediately.

Battery posts, terminals, and related accessories WARNING: contain lead and lead compounds, chemicals known to the State of California cause cancer and reproductive harm. Wash hands aftertohandling.

DX,WW,BATTERIES-19-20101202

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Safety

Prepare for Emergencies

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

Park Machine Safely

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 station.

in operator DX,PARK-19-19900604

Support Machine Properly

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

Wear Protective Clothing

TS206-UN: Protective Clothing

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

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Safety

Work in Clean Area

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

Service Machines Safely

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

Work In Ventilated Area

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

Illuminate Work Area Safely

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

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

Safety

Replace Safety Signs

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

Use Proper Lifting Equipment

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

Follow Tire Recommendations

H111235-UN: Read OM

Keep your machine in proper working order.

Use only prescribed tire sizes with correct ratings and inflate to the pressure specified in this manual.

Use of other than prescribed tires may decrease stability, affect steering, result in premature tire failure, or cause other durability or safety issues.

DX,TIRE,INFO-19-20140519

Decommissioning—Proper Recycling TS1133-UN: Recycle Waste Safety and environmental stewardship measures must be taken and Disposal of Fluids and into account when decommissioning a machine and/or component. These measures include the following: Components 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.

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Safety 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 in other than specially designed incinerators may be prohibited by law and could result in exposure to harmful fumes or ashes.

Protect Against High Pressure Spray

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

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

Live With Safety

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

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General Specifications

Group 10 General Specifications Metric Cap Screw Torque Values— Grade 7 NOTE: When bolting aluminum parts, specified in table.

tighten to 80% of

torque

Size

N˙m (lb-ft)

M6

9.5—12.2

(7—9)

M8

20.3—27.1

(15—20)

M1

47.5—54.2

(35—40)

0

81.4—94.9

(60—70)

M1

128.8—146.4

(95—108)

2

210.2—240

(155—177)

M1 4

CED,OUO1085,12-19-20000731

M1 6

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General Specifications

Metric Bolt and Screw Torque Values

TS1670-UN: Metric Bolt and Screw

Class 4.8Class 8.8 or 9.8Class 10.9Class 12.9 Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means 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 Sizephosphate and oillubrication, orphosphate and oillubrication, orphosphate and oillubrication, orphosphate and oillubrication, or coatings, or M20 andM6 to M18coatings, or M20 andM6 to M18coatings, or M20 andM6 to M18coatings, or M20 andM6 to M18 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.]

N˙m

lb.-in.

N˙m lb.-in.

N˙m

lb.-in.

N˙m lb.-in.

N˙m

lb.-in.

N˙m lb.-in.

N˙m

lb.-in.

N˙m lb.-in.

M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172 N˙m lb.-ft.

N˙m lb.-ft.

N˙m

lb.-ft.

N˙m lb.-ft.

M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35 N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.

M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70 N˙m lb.-ft.

M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120 M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190 M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300 M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410 M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580 M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800 M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000 M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475 M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000 M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500 Torque values listed are for general use only, based on the strength of the bolt or

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with screw. DO NOT use these values if a different torque value or tightening identical property class. Replace fasteners with the same or higher property class. If higher procedure is given for a specific application. For stainless steel fasteners or for property class fasteners are used, tighten these to the strength of the original. Make sure nuts on U-bolts, see the tightening instructions for the specific application. Tighten fastener threads are clean and that you properly start thread engagement. When possible, plastic insert or crimped steel type lock nuts by turning the nut to the dry torque lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, shown in the chart, unless different instructions are given for the specific unless different instructions are given for the specific application. application.

DX,TORQ2-19-20110112

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General Specifications

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 SAE Grade 1SAE Grade 5, 5.1 or 5.2SAE Grade 8 or 8.2 hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length.]

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.]

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-ft.

N˙m

lb.-ft.

5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26 N˙m lb.-ft. N˙mlb.-ft.

3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46 N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.

7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74 N˙m lb.-ft.

1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115 9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165 5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225 3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400 7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640 1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960 1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350 1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920 1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500 1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 Torque values listed are for general use only, based on the strength of the bolt or screw.

Replace fasteners with the same or higher grade. If higher grade fasteners are DO NOT use these values if a different torque value or tightening procedure is given for a used, tighten these to the strength of the original. Make sure fastener threads are specific application. For plastic insert or crimped steel type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application. or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless Shear bolts are designed to fail under predetermined loads. Always replace shear bolts different instructions are given for the specific application. with identical grade.

clean and that you properly start thread engagement. When possible, lubricate plain

DX,TORQ1-19-20110112

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Fuel and Lubricants

Group 15 Fuel and Lubricants Summary of References

Mixing of Lubricants Alternative and Synthetic Lubricants Lubricant Storage Carburetor Cleaning Carburetor Cleaning Methods

Gasoline Engine Oil Oil Filters Gasoline Fuel for 4-Cycle Engines Transaxle Oil Grease

OUMX258,0000DDF-19-20160503

Use oil viscosity based on the expected air temperature range during the period between oil changes.

Gasoline Engine Oil

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™ John Plus-50™ II one or more of the following: Other oils mayDeere be used if they meet 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 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

DX,ENOIL2-19-20150720

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

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

recommended.

Stabilizer (or equivalent) at the specified concentration.

Fuel blends of unleaded gasoline with a maximum 10% ethanol or 15% MTBE (methyl tertiary-butyl ether) are also acceptable.

When storing fuel, add John Deere Gasoline Conditioner and IMPORTANT: DO NOT use methanol or fuel blends that contain methanol.

Avoid spilling fuel. Gasoline can damage plastic and painted

CAUTION: surfaces.

Reduce the risk of fire. Handle fuel carefully. DO NOT fill DO NOT mix oil with gasoline. 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.

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Fuel and Lubricants JD Hy-Gard™ may be used if oil is unavailable.

Transaxle Oil

Hy-Gard is a trademark of Deere & Company

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The transaxles are filled at the factory. Do not mix oil types.

The following oil is preferred:

10W-30 Oil Other greases may be used if above preferred John Deere grease is not available, provided they meet the following

Grease specification: IMPORTANT:

John Deere Standard JDM J13E4, NLGIto Grade Use recommended John Deere greases avoid2.component failure and premature wear.

Use the following grease based on the air temperature range.

Operating outside of the recommended grease air temperature twice as often until all old grease is purged from the system. range may cause premature failures.

Not all grease types are compatible; John Deere does not recommend mixing greases. If using any product other than the recommended grease in service, purge any remaining grease fromthesystempriortoapplication.Ifthisisnotpractical,grease

The following John Deere grease is PREFERRED:

GREASE-GARD™ Premium Plus John Deere Multi-Purpose HD Lithium Complex Grease

MXAL36820-UN: Air Temp Range

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Other greases may be used if they meet or exceed the following

Mower Spindle Grease specification:

Thispremium,multi-purposegreaseisspeciallyformulatedasaJohn Deere Standard JDM J13E4, NLGI Grade 2. high-temperature, extreme-pressure grease, especially effective in rolling contact applications.

The following water resistant grease ispreferred:

Multi-Purpose SD Polyurea Grease - TY6341.

The following multi-purpose grease may also be used:

-

Multi-Purpose HD Lithium Complex Grease TY24416.

MXAL36820-UN: Air Temperature Range

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Mixing different oils can interfere with the proper functioning of

Mixing of and Lubricants these additives degrade lubricant performance.

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

Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.

Conditions in certain geographical areas may require lubricant The temperature limits and service intervals shown in this manual recommendations different from those printed in this manual.apply to both conventional and synthetic lubricants.

Some John Deere brand coolants and lubricants may not be Re-refined base stock products may be used if the finished available in your location.lubricant meets the performance requirements.

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Consult your John Deere dealer to obtain information and recommendations.

Lubricant StorageUse clean containers to handle all lubricants.

Store lubricants and containers in an area protected from dust, Your equipment can operate at top efficiency only when clean moisture, and other contamination. Store containers on their side lubricants are used.to avoid water and dirt accumulation.

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Fuel and Lubricants Make certain that all containers are properly marked to identify Properly dispose of all old containers and any residual lubricant their contents. they may contain.

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Fuel and Lubricants 1.Change engine oil and filter while engine is warm.

Gasoline and Engine Storage 2.Service air filter if necessary.

Fuel:3.Clean debris from engine air intake screen.

Ifyouhavebeenusing‘StabilizedFuel”,addstabilizedfueltotank4.On gas engines: until the tank is full. a. Remove spark plugs. Put 30 mL (1 oz.) of clean engine oil in cylinder(s).

NOTE:

b.Install spark plugs, but do not connect spark plug wires.

Filling the fuel tank reduces the amount of air in the fuel c. Crank the engine five or six times to allow oil to be tank and helps reduce deterioration of fuel.distributed.

5.Clean the engine and engine compartment.

6.Remove battery.

If you are not using‘Stabilized Fuel”:

7. Clean the battery and battery posts. Check the electrolyte 1.Park machine safely in a well-ventilated area.level, if the battery is not maintenance free.

8.Close fuel shutoff valve, if machine is equipped.

2. NOTE:

9.Store the battery in a cool, dry place where it will not freeze.

Try to anticipate the last time the machine will be used 10. NOTE: for the season so very little fuel is left in the fuel tank.

The stored battery should be charged every 90 days.

Turn on engine and allow to run until it runs out of fuel.

3.For machines with a key switch, turn key to off position.Charge the battery.

4. Mixfreshfuelandfuelstabilizerinseparatecontainer.Follow stabilizer instructions for mixing.IMPORTANT: 11. Prolonged exposure to sunlight could damage the hood 5.Fill tank with stabilized fuel. surface. Store the machine inside or use a cover if 6.Runengineforafewminutestoallowfuelmixturetostored outside. circulate through carburetor on gas engine or fuel injectors on gas engine or diesel engine.

Store the machine in a dry, protected place. If machine is Engine:stored outside, put a waterproof cover over it.

Engine storage procedure should be used when machine is not OUMX258,000062C-19-20121018 to be used for longer than 60 days.

Carburetor Cleaning3.Determineifcarburetorisrepairable,excessivecorrosion may determine this is not practical.

Debris, corrosion, rust, or varnish can build up in the internal air/ 4. If repairable, clean any remaining dirt and old gaskets from fuelpassages.Manytimesthecontaminationislocatedinanthe carburetor. area of the carburetor that is not visible. In most cases proper cleaning can resolve these issues.The preferred method of cleaning is to use an ultrasonic cleaner.

Carburetors and carburetor components can be cleaned by using IMPORTANT: Wires and metal instruments should not be used. Light one of several types of commercial cleaning methods: aerosol damageordepositsonthesurfaceofthefloatvalveseatcan be sprays, caustic dip tanks, and ultrasonic cleaners. removed using a cotton swab with a mild abrasive such as toothpaste or 800 grit lapping compound.

NOTE:

Some cleaning chemicals may be flammable and have toxic fumes. Always follow the chemical manufacturer’s recommendations. Always wear personal protection gear such as safety glasses protective gloves and work in a well ventilated area. Do not use drill or hard wire to clean carburetor passage ways.

Manual. Keep the following in mind:

Carburetor Assembly When the carburetor is ready for assembly, lay out all the necessary components on a clean surface. Be aware that even clean shop rags may contain dirt and metal shavings. Assemble the carburetor in accordance with the instructions in the Technical

Cleaning ProcedureCheckthethrottleshaftforexcessiveplayor movement and any signs of binding.

Always follow the solvent manufacturer’s recommendations for material compatibility because some solvents may attack metal,

Never use oil on the throttle shaft because it attracts

plastic or rubber components.dirtwhichcancauseprematurewearofthethrottle shaft seals.

1. Clean debris off the outside of the carburetor before If the throttle shaft was removed use new screws disassembly.and follow the service manual torque specifications.

2. Completely disassemble the carburetor per the instructions Always check the float and float valve for binding in the Technical Manual and visually inspect.with the float valve installed in its proper position.

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Fuel and Lubricants Replacement of all gaskets and seals is necessary when servicing any carburetor.

Inspect the carburetor insulator for damage and replace if necessary. Be sure to install the insulator using the correct orientation.

Clean and flush the complete fuel system.

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Fuel lines must be replaced if they are brittle, cracked, excessively soft or damaged.

Replace the fuel filter and air filter after cleaning the carburetor.

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Fuel and Lubricants carburetor passages in the opposite direction of the air and fuel flow (into the smallest passages to flush debris out of the larger passages). This will prevent debris lodging in difficult to clean

Carburetor Cleaning Methods Ultrasonic Cleaning Systemsareas.

UltrasoniccleanersuseenvironmentallyfriendlycleaningsolutionAerosol Cleaner and sound waves to penetrate deep into carburetor passages.

Heating the solution is an option on ultrasonic cleaners that Personal safety, environmental concerns and cleaning significantly increases the effectiveness of the system. Ultrasonic effectiveness make this method the least desirable. This method cleaner systems work by creating sound wave pulses that are can be used on carburetor components that may be damaged transmitted through a cleaning solution. Manufactures of by caustic cleaners (rubber seals or other non-metallic ultrasonic cleaners claim the pulses create small bubbles that components). When cleaning with aerosol sprays, it is always loosen and pulverizes contaminates. Select a chemical solution best to spray in the opposite direction of the air/fuel circuit (into that is designed specifically for carburetor cleaning.thesmallestpassagestoflushdebrisoutofthelargerpassages).

This will prevent debris lodging in difficult to clean areas.

Generally, chemicals will need to be diluted with water prior to use. When choosing a chemical, consider dilution rates to help determine which chemical is the most cost effective. Consider

disposal of cleaning solution before ordering chemicals. Check CAUTION: with local authorities on recommended disposal methods before Vapors from solvents can be explosive and flammable. disposing of any cleaning solution. Ultrasonic cleaners come in Follow the instructions on the container label for safe use manysizes.Most5.7—7.6L(1.5-2gal.)tankswillbesufficientof the solvent. for carburetors used by John Deere gas engines.

IfanUltrasonicCleanerisused,placecarburetorinandrunforWork in a well-ventilated area.

30minutesat43.4°C(110°F)inthepropersolutionmix.IftheWear protective clothing when handling solvent. solutionistoostrongorthecarburetorisleftinthecleanerfortooDo not smoke while handling solvents. long, the aluminum body will have a residue on the surface from Keep solvent away from flames or sparks the aluminum oxidizing.

Rinse the parts in water and dry with compressed air (up to 210 kPa [30 psi]).Caustic Dip Tanks Caustic dip tanks use aggressive chemicals to dissolve carbon based contamination. This method is effective for most carburetor

CAUTION:cleaning needs.

Compressed air can cause debris to fly a long distanceRotatingthepartsinthetankwillensurethecleaningsolution

flushes out any air pockets left in the passages. Follow the

Clear work area of bystandersrecommendationonthecleanerforsubmersiontimes.

Wear eye protection when using compressed air for Disadvantages of the caustic dip tanks are that some carburetor cleaning purposes.parts may be damaged if left in solution too long.

Reduce compressed air pressure to 210 kPa (30 Personal safety and chemical disposal are additional concerns. psi). Because the chemical is caustic, exposure may cause injury or cleaners are considered hazardous waste.

Wash off and blow ports out in carburetor body, fuel transfe tubes, and discharge port. Blow compressed air r throug h

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