John Deere™ Z910A Z920A Z925A Z925A EFI Z930A Z950A Z960A & Z970A ZTrak Service Manual

Description

John Deere Z910A Z920A Z925A Z925A EFI Z930A Z950A Z960A & Z970A ZTrak Service Manual – PDF DOWNLOAD

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DESCRIPTION:

John Deere Z910A Z920A Z925A Z925A EFI Z930A Z950A Z960A & Z970A ZTrak Service Manual – PDF DOWNLOAD

Introduction
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. 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.

TABLE OF CONTENTS:

John Deere Z910A Z920A Z925A Z925A EFI Z930A Z950A Z960A & Z970A ZTrak Service Manual – PDF DOWNLOAD

Contents......................................................................................  3
	General Information.......................................................................  5
		Safety................................................................................  7
			Recognize Safety Information......................................................  7
			Understand Signal Words...........................................................  7
			Follow Safety Instructions........................................................  7
			Practice Safe Maintenance.........................................................  8
			Use Proper Tools..................................................................  8
			Handle Fluids Safely—Avoid Fires..................................................  9
			Drain Gasoline When Storing Machine...............................................  9
			Prevent Acid Burns................................................................ 10
			Prevent Battery Explosions........................................................ 10
			Handling Batteries Safely......................................................... 11
			Prepare for Emergencies........................................................... 11
			Park Machine Safely............................................................... 12
			Support Machine Properly.......................................................... 12
			Wear Protective Clothing.......................................................... 12
			Work in Clean Area................................................................ 13
			Service Machines Safely........................................................... 13
			Work In Ventilated Area........................................................... 13
			Illuminate Work Area Safely....................................................... 14
			Replace Safety Signs.............................................................. 14
			Use Proper Lifting Equipment...................................................... 14
			Service Tires Safely.............................................................. 15
			Dispose of Waste Properly......................................................... 15
			Protect Against High Pressure Spray............................................... 16
			Live With Safety.................................................................. 16
		General Specifications................................................................ 17
			Service Recommendations for O-Ring Boss Fittings.................................. 17
			Service Recommendations For Flat Face O-Ring Seal Fittings........................ 18
			Metric Cap Screw Torque Values—Grade 7............................................ 18
			Metric Bolt and Screw Torque Values............................................... 19
			Unified Inch Bolt and Screw Torque Values......................................... 20
		Fuel and Lubricant.................................................................... 21
			Gasoline Engine Oil............................................................... 21
			Oil Filters....................................................................... 21
			Gasoline Fuel for 4-Cycle Engines................................................. 21
			Transmission and Hydraulic Oil.................................................... 22
			Grease............................................................................ 22
			Mixing of Lubricants.............................................................. 23
			Alternative and Synthetic Lubricants.............................................. 23
			Lubricant Storage................................................................. 23
		Machine Specifications................................................................ 25
			Serial Number Locations........................................................... 25
	Engine Repair, Kawasaki................................................................... 29
		General Repair FX651V, FX730V, FX751V, FX801V, and FX850V............................. 31
			Summary of References............................................................. 31
			Service Equipment and Tools....................................................... 31
			Other Material.................................................................... 31
			Specifications.................................................................... 32
			Replace Fuel Filter............................................................... 39
			Remove and Install Fuel Pump...................................................... 39
			Remove and Install Throttle Cable................................................. 40
			Remove and Install Choke Cable.................................................... 41
			Remove and Install Muffler........................................................ 42
			Remove and Install Engine......................................................... 43
			Service Air Cleaner............................................................... 45
			Remove and Install Air Cleaner Assembly........................................... 46
			Remove Governor Lever Arm......................................................... 47
			Install Governor Lever Arm........................................................ 47
			Remove and Install Carburetor..................................................... 48
			Clean and Inspect Carburetor...................................................... 50
			Check Float Level................................................................. 52
			Remove and Install Crankcase Breather............................................. 52
			Remove and Install Ignition Coil.................................................. 53
			Remove and Install Flywheel....................................................... 54
			Remove and Install Stator......................................................... 54
			Remove and Install Rocker Arm Cover............................................... 55
			Remove Rocker Arm and Push Rod.................................................... 55
			Install Rocker Arm and Push Rod................................................... 56
			Remove Cylinder Head.............................................................. 57
			Disassemble and Assemble Cylinder Head............................................ 58
			Inspect Cylinder Head............................................................. 59
			Install Cylinder Head............................................................. 59
			Inspect Valve Guides.............................................................. 61
			Analyze Valves.................................................................... 61
			Recondition Valve Seats........................................................... 63
			Lap Valves........................................................................ 65
			Remove and Inspect Governor Shaft................................................. 65
			Install Governor Shaft............................................................ 66
			Remove Oil Pump................................................................... 66
			Inspect Oil Pump.................................................................. 68
			Install Oil Pump.................................................................. 69
			Disassemble and Assemble Governor................................................. 71
			Remove and Install Camshaft and Tappets........................................... 72
			Inspect Camshaft and Tappets...................................................... 73
			Remove and Disassemble Piston and Connecting Rod.................................. 75
			Inspect Piston.................................................................... 76
			Inspect Connecting Rod............................................................ 79
			Assemble and Install Piston and Connecting Rod.................................... 79
			Check Piston Ring End Gap......................................................... 82
			Remove and Install Crankshaft..................................................... 83
			Inspect Crankshaft................................................................ 83
			Replace Crankshaft Oil Seal....................................................... 85
			Deglaze Cylinder Bore............................................................. 86
			Resize Cylinder Bore.............................................................. 87
			Analyze Crankshaft and Connecting Rod Wear........................................ 87
			Remove and Install Starting Motor................................................. 88
			Disassemble and Assemble Starting Motor........................................... 89
			Inspect Starting Motor............................................................ 90
		Repair FX651V and FX730V.............................................................. 93
			Summary of References............................................................. 93
			Specifications.................................................................... 93
			Remove and Install Throttle Control Plate (FX651V, FX730V)........................ 93
			Repair Carburetor (FX651V, FX730V)................................................ 94
			Remove Intake Manifold (FX651V, FX730V)...........................................101
			Install Intake Manifold (FX651V, FX730V)..........................................102
			Remove and Install Blower Housing (FX651V, FX730V)................................102
			Remove Rocker Arm and Push Rod (FX651V, FX730V)...................................104
			Install Rocker Arm and Push Rod (FX651V, FX730V)..................................104
			Remove Crankcase Cover (FX651V, FX730V)...........................................105
			Install Crankcase Cover (FX651V, FX730V)..........................................105
		Repair FX751V, FX801V, and FX850V.....................................................107
			Summary of References.............................................................107
			Specifications....................................................................107
			Remove and Install Throttle Control Plate (FX751V, FX801V, FX850V)................108
			Carburetor Repair (FX751V, FX801V, FX850V)........................................109
			Remove Intake Manifold (FX751V, FX801V, FX850V)...................................116
			Install Intake Manifold (FX751V, FX801V, FX850V)..................................116
			Remove and Install Blower Housing (FX751V, FX801V, FX850V)........................117
			Remove and Install Oil Cooler (FX751V, FX801V, FX850V)............................119
			Remove and Install Rocker Arm Assembly (FX751V, FX801V, FX850V)...................119
			Remove Crankcase Cover (FX751V, FX801V, FX850V)...................................120
			Install Crankcase Cover (FX751V, FX801V, FX850V)..................................121
		Repair FX921V and FX1000V.............................................................123
			Summary of References.............................................................123
			Specifications....................................................................124
			Replace Fuel Filter (FX921V, FX1000V).............................................128
			Remove and Install Fuel Pump (FX921V, FX1000V)....................................129
			Remove and Install Throttle Cable (FX921V, FX1000V)...............................129
			Remove and Install Choke Cable (FX921V, FX1000V)..................................130
			Remove and Install Muffler (FX921V, FX1000V)......................................131
			Remove and Install Engine (FX921V, FX1000V).......................................132
			Service Air Cleaner (FX921V, FX1000V).............................................134
			Remove and Install Air Cleaner Assembly (FX921V, FX1000V).........................135
			Remove and Install Throttle Control Plate (FX921V, FX1000V).......................136
			Remove and Install Carburetor (FX921V, FX1000V)...................................137
			Carburetor Repair (FX921V, FX1000V)...............................................139
			Clean and Inspect Carburetor (FX921V, FX1000V)....................................146
			Check Float Level (FX921V, FX1000V)...............................................148
			Remove Intake Manifold (FX921V, FX1000V)..........................................148
			Install Intake Manifold (FX921V, FX1000V).........................................149
			Remove and Install Crankcase Breather (FX921V, FX1000V)...........................150
			Remove Breather Baffle (FX921V, FX1000V)..........................................151
			Install Breather Baffle (FX921V, FX1000V).........................................152
			Remove and Install Blower Housing (FX921V, FX1000V)...............................153
			Remove and Install Ignition Coils (FX921V, FX1000V)...............................155
			Remove and Install Flywheel (FX921V, FX1000V).....................................155
			Remove and Install Stator (FX921V, FX1000V).......................................156
			Remove and Install Oil Cooler (FX921V, FX1000V)...................................157
			Remove and Install Rocker Arm Cover (FX921V, FX1000V).............................157
			Remove and Install Rocker Arm Assembly (FX921V, FX1000V)..........................158
			Inspect Rocker Arm and Push Rod (FX921V, FX1000V).................................159
			Remove Cylinder Head (FX921V, FX1000V)............................................160
			Disassemble and Assemble Cylinder Head (FX921V, FX1000V)..........................160
			Inspect Cylinder Head and Valve Guides (FX921V, FX1000V)..........................161
			Analyze Valves (FX921V, FX1000V)..................................................162
			Recondition Valve Seats (FX921V, FX1000V).........................................164
			Lap Valves (FX921V, FX1000V)......................................................166
			Install Cylinder Head (FX921V, FX1000V)...........................................167
			Remove Crankcase Cover (FX921V, FX1000V)..........................................168
			Install Crankcase Cover (FX921V, FX1000V).........................................168
			Remove and Inspect Governor Shaft (FX921V, FX1000V)...............................170
			Install Governor Shaft (FX921V, FX1000V)..........................................170
			Disassemble and Inspect Oil Pump (FX921V, FX1000V)................................171
			Assemble Oil Pump (FX921V, FX1000V)...............................................174
			Disassemble and Assemble Governor (FX921V, FX1000V)...............................175
			Remove and Install Camshaft and Tappets (FX921V, FX1000V).........................177
			Inspect Camshaft and Tappets (FX921V, FX1000V)....................................178
			Remove and Disassemble Piston and Connecting Rod (FX921V, FX1000V)................180
			Inspect Piston (FX921V, FX1000V)..................................................181
			Inspect Connecting Rod (FX921V, FX1000V)..........................................184
			Assemble and Install Piston and Connecting Rod (FX921V, FX1000V)..................184
			Check Piston Ring End Gap (FX921V, FX1000V).......................................187
			Remove and Install Crankshaft (FX921V, FX1000V)...................................187
			Inspect Crankshaft (FX921V, FX1000V)..............................................188
			Replace Oil Seal (FX921V, FX1000V)................................................189
			Deglaze Cylinder Bore (FX921V, FX1000V)...........................................190
			Resize Cylinder Bore (FX921V, FX1000V)............................................191
			Analyze Crankshaft and Connecting Rod Wear (FX921V, FX1000V)......................191
			Remove and Install Starting Motor (FX921V, FX1000V)...............................192
			Disassemble and Assemble Starting Motor (FX921V, FX1000V).........................193
			Inspect Starting Motor (FX921V, FX1000V)..........................................194
	Engine Repair, Kohler EFI.................................................................198
		Repair................................................................................199
			Summary of References.............................................................199
			Essential or Recommended Tools....................................................199
			Service Equipment and Tools.......................................................200
			Specifications....................................................................201
			Remove Engine (EFI)...............................................................207
			Install Engine (EFI)..............................................................209
			Remove and Install Air Cleaner Element (EFI)......................................210
			Remove and Install Air Cleaner Assembly (EFI).....................................210
			Remove and Install Muffler (EFI)..................................................211
			Remove and Install Grass Screen (EFI).............................................213
			Remove and Install Throttle Control Panel Assembly (EFI)..........................214
			Remove and Install External Governor Controls (EFI)...............................216
			Remove and Install Oil Cooler (EFI)...............................................217
			Remove and Install Oil Separator (EFI)............................................217
			Remove Blower Housing and Outer Baffle (EFI)......................................218
			Install Blower Housing and Outer Baffle (EFI).....................................222
			Remove Inner Baffles and Breather Cover (EFI).....................................226
			Install Inner Baffles and Breather Cover (EFI)....................................226
			Remove Intake Manifold (EFI)......................................................228
			Install Intake Manifold (EFI).....................................................229
			Remove Lift Fuel Pump (EFI).......................................................230
			Install Lift Fuel Pump (EFI)......................................................230
			Remove and Install Fuel Pump Module (EFI).........................................231
			Remove Fuel Injector (EFI)........................................................233
			Install Fuel Injector (EFI).......................................................234
			Remove and Install Throttle Body (EFI)............................................234
			Remove and Install Throttle Position Sensor TPS (EFI).............................236
			Remove and Install Electronic Control Module ECM (EFI)............................237
			Remove and Install Oxygen Sensor (EFI)............................................237
			Remove and Install Ignition Coil (EFI)............................................238
			Remove and Install Oil Temperature Sensor (EFI)...................................238
			Remove and Install Crankshaft Position Sensor (EFI)...............................238
			Remove and Install Manifold Absolute Pressure (MAP) Sensor (EFI)..................239
			Remove and Install Intake Air Sensor (EFI)........................................240
			Remove and Install Oil Sentry Switch (EFI)........................................241
			Remove and Install Voltage Regulator/Rectifier (EFI)..............................241
			Remove and Install Starting Motor (EFI)...........................................242
			Disassemble Starting Motor (EFI)..................................................243
			Starting Motor Armature (EFI).....................................................245
			Assemble Starting Motor (EFI).....................................................246
			Remove Valve Cover (EFI)..........................................................248
			Install Valve Cover (EFI).........................................................249
			Remove Cylinder Head (EFI)........................................................250
			Install Cylinder Head (EFI).......................................................250
			Inspect Cylinder Head (EFI).......................................................252
			Remove and Install Rocker Arms (EFI)..............................................252
			Remove and Install Valves and Springs (EFI).......................................254
			Inspect Valves (EFI)..............................................................254
			Recondition Valve Seats (EFI).....................................................255
			Lap Valves (EFI)..................................................................256
			Inspect Push Rods (EFI)...........................................................256
			Inspect Valve Guides (EFI)........................................................257
			Inspect Hydraulic Valve Lifters (EFI).............................................257
			Inspect Crankcase Breather Reed Valve (EFI).......................................258
			Remove and Install Flywheel (EFI).................................................258
			Remove and Install Stator (EFI)...................................................260
			Remove Oil Pan (EFI)..............................................................261
			Install Oil Pan (EFI).............................................................261
			Remove and Install Oil Pan Crankshaft Seal (EFI)..................................262
			Remove and Install Governor.......................................................263
			Remove Governor Cross Shaft (EFI).................................................264
			Install Governor Cross Shaft (EFI)................................................265
			Remove and Install Oil Pump (EFI).................................................266
			Remove Camshaft (EFI).............................................................267
			Install Camshaft (EFI)............................................................267
			Inspect Cam Shaft (EFI)...........................................................268
			Camshaft End Play (EFI)...........................................................269
			Remove Piston (EFI)...............................................................269
			Disassemble Piston (EFI)..........................................................270
			Inspect Piston Pin (EFI)..........................................................271
			Inspect Piston (EFI)..............................................................271
			Assemble Piston (EFI).............................................................272
			Measure Piston Ring End Gap (EFI).................................................273
			Piston Ring Side Clearance (EFI)..................................................273
			Measure Piston to Bore (EFI)......................................................274
			Install Piston (EFI)..............................................................275
			Remove and Install Crankcase Crankshaft Oil Seal (EFI)............................275
			Inspect Block (EFI)...............................................................276
			Deglaze Cylinder Bore (EFI).......................................................276
			Measure Crankshaft and Connecting Rod (EFI).......................................277
	Electrical Repair.........................................................................279
		Component Location....................................................................281
			Summary of References.............................................................281
			Electrical Components (All Except EFI)............................................281
			Instrument Cluster................................................................282
		Wire Harness—Standard (Z910A, Z920A, Z925A, Z930A, Z950A) (SN -020000)................283
			Summary of References.............................................................283
			W1 Main Harness (SN -020000)......................................................284
			W1 Main Harness Legend (SN -020000)...............................................287
			W1 Main Harness Wire Codes (SN -020000)...........................................288
			W2 Engine Harness (SN -020000)....................................................288
			W4 Ignition Coil Harness (SN -020000).............................................289
			W8 Headlight Wire Harness (SN -020000)............................................290
		Wire Harness—Standard (Z910A, Z920A, Z925A, Z930A, Z950A) (SN 020001- )...............291
			Summary of References.............................................................291
			W1 Main Harness (SN 020001-)......................................................292
			W1 Main Harness Legend (SN 020001-)...............................................295
			W1 Main Harness Wire Codes (SN 020001-)...........................................296
			W2 Engine Harness (SN 020001-)....................................................296
			W4 Ignition Coil Harness (SN 020001-).............................................297
			W8 Headlight Harness (SN 020001-).................................................298
		Wire Harness—EFI Only (Z925A) (SN 020001- )...........................................299
			Summary of References.............................................................299
			W1 Main Harness (Z925A EFI).......................................................300
			W1 Main Harness Legend (Z925A EFI)................................................303
			W1 Main Harness Wire Codes (Z925A EFI)............................................304
			W2 Engine Harness (Z925A EFI).....................................................306
			W2 Engine Harness Wire Codes (Z925A EFI)..........................................309
			W3 Engine Harness Adapter (Z925A EFI).............................................310
			W8 Headlight Harness (Z925A EFI)..................................................311
			ECM Connector Pinout..............................................................312
			ECM Signal and Pinout Table.......................................................312
		Wire Harness—Convenience Package (Z930A, Z950A, Z960A, Z970A).........................313
			Summary of Reference..............................................................313
			W1 Main Harness (Z930A, Z950A, Z960A, Z970A)......................................314
			W1 Main Harness Legend (Z930A, Z950A, Z960A, Z970A)...............................317
			W1 Main Harness Wire Codes (Z930A, Z950A, Z960A, Z970A)...........................318
			W2 Engine Harness (Z930A, Z950A, Z960A, Z970A)....................................319
			W4 Ignition Coil Harness (Z930A, Z950A, Z960A, Z970A).............................319
			W5 Fuel Shut Off Solenoid Harness (Z930A, Z950A, Z960A, Z970A)....................319
			W6 Lift Switch Harness (Z930A, Z950A, Z960A, Z970A)...............................320
			W7 PTO Stop Switch Harness (Z930A, Z950A, Z960A, Z970A)...........................321
			W8 Headlight Harness (Z930A, Z950A, Z960A, Z970A).................................322
	Power Train Repair........................................................................323
		Component Location....................................................................325
			Summary of References.............................................................325
			Power Train Components............................................................325
			Tension Arm Components............................................................326
			Transaxle Components..............................................................327
			Transaxle Components Legend.......................................................328
			Brake System Components...........................................................329
			Brake System Components Legend....................................................330
		Repair................................................................................331
			Summary of References.............................................................331
			Specifications....................................................................331
			Remove and Install Traction Drive Belt............................................332
			Remove and Install Steering Linkage Assembly......................................332
			Remove and Install Traction Drive Belt Tension Arm Assembly.......................333
			Remove and Install Control Damper.................................................334
			Remove and Install Both Transaxles................................................334
			Remove and Install Right or Left Transaxle........................................336
			Remove and Install Fan Assembly...................................................338
			Disassemble Transaxle.............................................................338
			Assemble Transaxle................................................................352
	Attachments Repair........................................................................363
		Component Location....................................................................365
			Summary of References.............................................................365
			48 Inch Deck Components...........................................................365
			54 Inch Deck Components...........................................................366
			54 Inch Deck M.O.D. Components....................................................367
			60 Inch Deck Components...........................................................368
			60 Inch Deck M.O.D. Components....................................................369
			72 Inch Deck Components...........................................................370
			Spindles and Sheaves Components...................................................371
			Spindles and Sheaves Components Legend............................................372
			Idlers and Sheaves Components.....................................................373
			Idlers and Sheaves Components Legend..............................................374
			Anti-Scalp Wheel Components.......................................................375
			Mulch-On-Demand Deck Linkage Components...........................................376
			Mulch-On-Demand Deck Linkage Components Legend....................................377
			Deck Lift With Pedal Components...................................................378
			Mower Deck Lift Assist Components.................................................379
			Mower Deck Lift Linkage Components................................................380
		Repair................................................................................381
			Summary of References.............................................................381
			Specifications....................................................................381
			Remove and Install Mower Deck.....................................................382
			Remove and Install Mower Belt Shields.............................................383
			Remove Mower Drive Belt...........................................................384
			Install Mower Drive Belt..........................................................385
			Check and Replace Mower Blades....................................................386
			Sharpen and Balance Blades........................................................386
			Remove and Install Spindle Assembly...............................................387
			Disassemble Spindle...............................................................389
			Spindle Cross Section.............................................................390
			Assemble Spindle..................................................................391
			Remove and Install PTO Clutch.....................................................392
		Repair (Optional MCS).................................................................395
			Summary of References.............................................................395
			Specifications....................................................................395
			Remove MCS Drive Sheave and Spacer................................................395
			Install MCS Drive Sheave and Spacer...............................................396
			Remove Primary Drive Belt.........................................................396
			Install Primary Drive Belt........................................................397
			Remove Secondary Drive Belt.......................................................398
			Install Secondary Drive Belt......................................................398
			Disassemble Blower................................................................399
			Assemble Blower...................................................................402
	Miscellaneous Repair......................................................................405
		Wheels................................................................................407
			Summary of References.............................................................407
			Specifications....................................................................407
			Remove and Install Front Caster Wheels............................................407
			Repair Caster Wheel...............................................................408
			Remove and Install Caster Wheel Yoke..............................................408
			Adjust Front Caster Shimmy........................................................409
			Remove and Install Rear Drive Wheels..............................................409
		Operators Station.....................................................................411
			Summary of References.............................................................411
			Specifications....................................................................411
			Remove and Install Seat Platform..................................................411
			Repair Seat Platform..............................................................412
			Remove and Install Suspended Seat.................................................413
			Repair Suspended Seat Platform....................................................416
			Remove and Install Control Console Cover..........................................417
			Remove and Install Control Console Bracket........................................417
		Roll Over Protective Structure (ROPS).................................................423
			Summary of References.............................................................423
			Specifications....................................................................423
			Remove and Install Roll Over Protective Structure (ROPS)..........................423
		Miscellaneous.........................................................................425
			Summary of References.............................................................425
			Specifications....................................................................425
			Remove and Install Height-of-Cut (HOC) Assembly...................................425
			Remove and Install Fuel Tank......................................................427
			Remove and Install Grille.........................................................429
	Engine Diagnosis, Tests, and Adjustments, Kawasaki........................................432
		Component Location....................................................................433
			Summary of References.............................................................433
			Engine Block Components (FX651V, FX730V)..........................................434
			Engine Block Components (FX751V, FX801V, FX850V)..................................436
			Engine Block Components (FX921V, FX1000V).........................................438
			Carburetor Components (FX651V, FX730V)............................................440
			Carburetor Components (FX751V, FX801V, FX850V)....................................441
			Carburetor Components (FX921V, FX1000V)...........................................442
			Valves and Governor Components (FX651V, FX730V)...................................443
			Valves and Governor Components (FX751V, FX801V, FX850V)...........................445
			Valves and Piston Components (FX921V, FX1000V)....................................448
		Theory of Operation...................................................................451
			Summary of References.............................................................451
			Engine Oil Flow Chart.............................................................451
			Lubrication System Operation......................................................452
			Governor Operation................................................................452
			Crankcase Breather Operation......................................................453
			Automatic Compression Release (ACR) Operation.....................................455
			Cooling System Operation..........................................................456
			Carburetor Operation..............................................................456
			Ignition Operation................................................................458
		Diagnosis.............................................................................459
			Diagnose Engine Does Not Crank....................................................459
				Diagnose Engine Does Not Crank................................................459
			Diagnose Engine Cranks But Will Not Start.........................................460
				Diagnose Engine Cranks But Will Not Start.....................................460
			Diagnose Engine Hard to Start.....................................................461
				Diagnose Engine Hard to Start.................................................461
			Diagnose Engine Runs Erratically..................................................463
				Diagnose Engine Runs Erratically..............................................463
			Diagnose Engine Dies After Running................................................465
				Diagnose Engine Dies After Running............................................465
			Diagnose Engine Malfunctions At Low RPM...........................................465
				Diagnose Engine Malfunctions At Low RPM.......................................465
			Diagnose Engine Malfunctions At High RPM..........................................466
				Diagnose Engine Malfunctions At High RPM......................................467
			Diagnose Excessive Oil Consumption................................................467
				Diagnose Excessive Oil Consumption............................................467
			Diagnose Low Oil Pressure.........................................................468
				Diagnose Low Oil Pressure.....................................................468
			Diagnose Engine Overheats.........................................................469
				Diagnose Engine Overheats.....................................................469
			Diagnose Excessive Fuel Consumption...............................................470
				Diagnose Excessive Fuel Consumption...........................................470
			Diagnose Contamination In Crankcase...............................................471
				Diagnose Contamination In Crankcase...........................................471
			Diagnose Starting Motor...........................................................472
				Starting Motor Does Not Rotate................................................472
				Starting Motor Rotates Slowly.................................................473
		Tests and Adjustments.................................................................475
			Summary of References.............................................................475
			Service Equipment and Tools.......................................................475
			Specifications....................................................................477
			Check and Adjust Choke Cable (FX651V, FX730V).....................................478
			Check and Adjust Choke Cable (FX751V, FX801V, FX850V).............................480
			Check and Adjust Choke Cable (FX921V, FX1000V)....................................480
			Check and Adjust Throttle Cable (FX651V, FX730V)..................................481
			Check and Adjust Throttle Cable (FX751V, FX801V, FX850V)..........................482
			Check and Adjust Throttle Cable (FX921V, FX1000V).................................483
			Adjust Static Governor Linkage (FX651V, FX730V)...................................484
			Adjust Static Governor Linkage (FX921V, FX1000V)..................................484
			Adjust Slow Idle Speed (FX651V, FX730V)...........................................485
			Adjust Slow Idle Speed (FX751V, FX801V, FX850V)...................................486
			Adjust Slow Idle Speed (FX921V, FX1000V)..........................................487
			Adjust Fast Idle Speed (FX651V, FX730V)...........................................488
			Adjust Fast Idle Speed (FX751V, FX801V, FX850V)...................................489
			Adjust Fast Idle Speed (FX921V, FX1000V)..........................................489
			Check and Adjust Fan Screen.......................................................490
			Check and Adjust Valve Clearance (FX651V, FX730V, FX751V, FX801V, FX850V).........490
			Check and Adjust Valve Clearance (FX921V, FX1000V)................................492
			Check and Adjust Ignition Coil Air Gap............................................494
			Test Cylinder Compression.........................................................495
			Test Cylinder Leak-Down...........................................................496
			Test Engine Oil Pressure..........................................................498
			Test Fuel Pump....................................................................499
			Crankcase Vacuum Test.............................................................500
			Adjust Spark Plug Gap.............................................................500
	Engine Diagnosis, Tests, and Adjustments, Kohler..........................................501
		Theory of Operation...................................................................503
			Summary of References.............................................................503
			General Engine Operation..........................................................503
			Air Intake System.................................................................503
			Cooling System....................................................................503
			Lubrication System................................................................503
			Crankcase Breather System.........................................................503
			Engine Control Module (ECM).......................................................504
			Fuel System.......................................................................504
			Throttle Body.....................................................................504
			Governor System...................................................................505
			Ignition System...................................................................505
		Diagnosis.............................................................................507
			Engine Troubleshooting............................................................507
		Tests and Adjustments.................................................................513
			Summary of References.............................................................513
			Service Equipment and Tools.......................................................513
			Specifications....................................................................513
			Adjust Governor...................................................................514
			Adjust Low Idle Speed.............................................................515
			Adjust Spark Plug Gap.............................................................516
			Test Cylinder Leak-Down...........................................................516
			Test Fuel Pump, Pulse.............................................................517
			Test Fuel Pump, Module............................................................518
			Adjust Crankshaft Position Sensor Air Gap.........................................520
			Test Fuel Injector and Wires......................................................521
			Test Starter Solenoid.............................................................523
	Electrical Diagnosis, Tests, and Adjustments..............................................526
		Theory of Operation...................................................................527
			Summary of References.............................................................527
			Charging Circuit Operation........................................................527
			Cranking Circuit Operation........................................................528
			Run Circuit Operation.............................................................531
			PTO Clutch Circuit Operation......................................................534
			Engine Oil Pressure and Hour Meter Circuit Operation..............................536
			Lift Circuit Operation (Z950A, Z960A, Z970A)......................................538
			Headlight Circuit Operation.......................................................540
		Theory of Operation (EFI).............................................................541
			Summary of References.............................................................541
			Control Units (ECU and ECM).......................................................541
			Engine Control Module and General Sensor Circuit Operation........................542
			On Board Diagnostics..............................................................543
			Malfunction Indicator Light (MIL) Operation.......................................543
			Crankshaft Position Sensor Operation..............................................544
			Throttle Position Sensor (TPS) Operation..........................................544
			Oil Temperature Sensor Operation..................................................544
			Intake Air Temperature Sensor Operation...........................................545
			Oxygen Sensor Operation...........................................................545
			Manifold Absolute Pressure (MAP) Sensor Operation.................................545
			Fuel Injector Operation...........................................................546
			Ignition Coil Operation...........................................................546
			Fuel Pump Operation...............................................................546
		Diagnosis.............................................................................547
			Electronic Control Unit (ECU) Diagnostic Codes....................................547
			Electronic Control Unit (ECU) Switch Input Codes..................................548
			Diagnose Charging Circuit.........................................................548
				Procedure A...................................................................548
			Diagnose Cranking Circuit.........................................................550
				Procedure A...................................................................550
			Diagnose Run Circuit..............................................................555
				Procedure A - Run Circuit.....................................................555
				Procedure B - Ignition Shutoff Circuit (Except EFI)...........................559
			Diagnose PTO Clutch Circuit.......................................................560
				Procdeure A...................................................................560
			Diagnose Engine Oil Pressure Circuit..............................................564
				Procedure A...................................................................564
			Diagnose Hour Meter Circuit.......................................................567
				Procedure A...................................................................567
			Diagnose Lift Circuit.............................................................569
				Procedure A...................................................................569
			Diagnose Headlight Circuit........................................................572
				Procedure A...................................................................572
		Engine Diagnostic Test Codes (EFI)....................................................575
			Engine Control Module (ECM) Diagnostic Test Codes.................................575
			0031 — Diagnostic Test Code.......................................................575
			0032 — Diagnostic Test Code.......................................................576
			0107 — Diagnostic Test Code.......................................................576
			0108 — Diagnostic Test Code.......................................................576
			0112 — Diagnostic Test Code.......................................................576
			0113 — Diagnostic Test Code.......................................................577
			0117 — Diagnostic Test Code.......................................................577
			0118 — Diagnostic Test Code.......................................................577
			0122 — Diagnostic Test Code.......................................................577
			0123 — Diagnostic Test Code.......................................................578
			0131 — Diagnostic Test Code.......................................................578
			0132 — Diagnostic Test Code.......................................................578
			0171 — Diagnostic Test Code.......................................................579
			0172 — Diagnostic Test Code.......................................................579
			0174 — Diagnostic Test Code.......................................................580
			0201 — Diagnostic Test Code.......................................................580
			0202 — Diagnostic Test Code.......................................................580
			0230 — Diagnostic Test Code.......................................................580
			0232 — Diagnostic Test Code.......................................................581
			0336 — Diagnostic Test Code.......................................................581
			0337 — Diagnostic Test Code.......................................................581
			0351 — Diagnostic Test Code.......................................................581
			0352 — Diagnostic Test Code.......................................................582
			0562 — Diagnostic Test Code.......................................................582
			0563 — Diagnostic Test Code.......................................................582
			61 — Diagnostic Test Code.........................................................582
		Tests and Adjustments.................................................................583
			Summary of References.............................................................583
			Essential or Recommended Tools....................................................583
			Service Equipment and Tools.......................................................583
			Specifications....................................................................584
			Ground Circuit Test...............................................................585
			Battery Voltage and Specific Gravity Tests........................................586
			Battery Charge....................................................................587
			Battery Load Test.................................................................587
			Test Regulated Voltage Output.....................................................588
			Test Unregulated Voltage Output...................................................588
			Test Stator.......................................................................589
			Test Starting Motor Solenoid......................................................589
			Test Starting Motor Amperage Draw.................................................590
			Spark Test........................................................................591
			Fuse Test.........................................................................591
			Diode Test........................................................................591
			Key Switch Test...................................................................592
			Park Brake Switch Test............................................................592
			Seat Switch Test..................................................................593
			Lift Switch Test..................................................................593
			Test Headlight Switch.............................................................594
			PTO Switch Test...................................................................594
			PTO Stop Switch Test..............................................................595
			PTO Clutch Test...................................................................595
			Relay Test........................................................................596
			Ignition Coil Test (Except EFI)...................................................596
			Fuel Shutoff Solenoid Test........................................................597
			Oil Pressure Switch Test..........................................................598
		Tests and Adjustments (EFI)...........................................................599
			Summary of References.............................................................599
			Specifications....................................................................599
			EFI Crankshaft Position Sensor Test...............................................599
			EFI Throttle Position Sensor Test.................................................600
			EFI Engine Oil Temperature Sensor Test............................................601
			EFI Intake Air Temperature Sensor Test............................................601
			EFI Manifold Absolute Pressure Sensor Test........................................602
			EFI Oxygen Sensor Test............................................................602
			EFI Fuel Injector Electrical Test.................................................603
			EFI Ignition Coil Test............................................................603
			EFI Fuel Pump Module Electrical Test..............................................604
			EFI ECM Diagnostic Code Retrieval.................................................604
			EFI ECM Reset and TPS Learn Procedures............................................605
		Wiring Schematics.....................................................................607
			Schematic Legend, Z910A, Z920A, Z925A, and Z930A (SN -020000).....................607
			Main Schematic, Z910A, Z920A, Z925A, and Z930A (SN -020000).......................608
			Schematic Legend, Z950A (SN -020000), Z960A, Z970A................................611
			Main Schematic, Z950A (SN -020000), Z960A and Z970A...............................612
			Schematic Legend, Z910A, Z920A, Z925A (Except EFI), Z930A, Z950A (SN 020001-).....615
			Main Schematic, Z910A, Z920A, Z925A (Except EFI), Z930A and Z950A (SN 020001-)....616
			Schematic Legend, Z925A (EFI Only), (SN 020001-)..................................619
			Main Schematic, Z925A (EFI Only) (SN 020001-).....................................620
			Engine Wiring (W2) - Z925A EFI....................................................625
		Connector Information.................................................................627
			WEATHER PACK™ Connector - Removal.................................................627
			WEATHER PACK™ Connector - Replacement.............................................628
			WEATHER PACK™ Connector Terminal..................................................628
			METRI-PACK™ Connector.............................................................629
			METRI-PACK™ Terminal - Replacement................................................631
	Power Train Diagnosis, Tests, and Adjustments.............................................635
		Theory of Operation...................................................................637
			Summary of References.............................................................637
			Transaxle Operation...............................................................638
			Brake System Operation............................................................639
		Diagnosis.............................................................................641
			Diagnose System Fails to Build Pressure...........................................641
				Diagnose System Fails to Build Pressure.......................................641
			Diagnose Machine Will Not Drive Straight..........................................642
				Diagnose Machine Will Not Drive Straight......................................642
			Diagnose Machine Will Not Reach Maximum Speed.....................................643
				Diagnose Machine Will Not Reach Maximum Speed.................................643
			Diagnose Machine Will Not Move When Controls Are Engaged..........................644
				Diagnose Machine Will Not Move When Controls Are Engaged......................644
			Diagnose Jerky or Erratic Operation...............................................646
				Diagnose Jerky or Erratic Operation...........................................646
			Diagnose Sluggish Operation Under Load............................................648
				Diagnose Sluggish Operation Under Load........................................648
			Diagnose Excessive Noise..........................................................650
				Diagnose Excessive Noise......................................................650
		Tests and Adjustments.................................................................653
			Summary of References.............................................................653
			Bleed Hydrostatic System..........................................................653
			Adjust Tracking and Speed.........................................................654
			Check and Adjust Neutral Creep....................................................655
			Check and Align Motion Control Levers.............................................657
			Check and Adjust Park Brake.......................................................657
	Attachments Diagnosis, Tests, and Adjustments.............................................661
		Theory of Operation...................................................................663
			Summary of References.............................................................663
			Mulch On Demand (M.O.D.) Operation................................................664
			PTO Clutch Operation..............................................................667
		Diagnosis.............................................................................669
			Diagnose Mower System.............................................................669
				Diagnose Mower System.........................................................669
			Diagnose Mower System (Engine Running)............................................672
				Diagnose Mower System (Engine Running)........................................672
			Diagnose Mower Deck Will Not Run..................................................673
				Diagnose Mower Deck Will Not Run..............................................673
			Diagnose Mower Deck Vibrates......................................................674
				Diagnose Mower Deck Vibrates..................................................674
			Diagnose Mower Cuts Unevenly......................................................676
				Diagnose Mower Cuts Unevenly..................................................676
			Diagnose Poor Mulching (M.O.D. Deck)..............................................677
				Diagnose Poor Mulching (M.O.D. Deck)..........................................677
			Diagnose Excessive Noise..........................................................678
				Diagnose Excessive Noise......................................................678
			Diagnose PTO Clutch...............................................................679
				Diagnose PTO Clutch...........................................................679
			Diagnose Clutch Slips.............................................................680
				Diagnose Clutch Slips.........................................................680
			Diagnose Noisy Clutch or Vibration................................................682
				Diagnose Noisy Clutch or Vibration............................................682
		Tests and Adjustments.................................................................685
			Summary of References.............................................................685
			Service Equipment and Tools.......................................................685
			Specifications....................................................................685
			Adjust Mower Deck Cutting Height..................................................686
			Adjust and Level Mower Deck.......................................................687
			Adjust Mower Deck Anti-Scalp Wheels...............................................689
			Adjust Deck Lift Spring Tension...................................................689
			Adjust Mulch-On-Demand and Mower Deck Linkage.....................................690
			Check and Adjust PTO Air Gap......................................................692
			Adjust MCS Blower Primary Belt Tension............................................693
			Adjust MCS Blower Secondary Belt Tension..........................................693
			Adjust Dump-From-Seat Hopper Linkage..............................................693
			Break-In PTO Clutch...............................................................694
	Service Tools and Kits....................................................................695
		Service Tools and Kits................................................................697
			Essential or Recommended Tools....................................................697
			Kits..............................................................................698
Page Number...................................................................................  3
	Section 10................................................................................  5
		Group 05..............................................................................  7
		Group 10.............................................................................. 17
		Group 15.............................................................................. 21
		Group 20.............................................................................. 25
	Section 20................................................................................ 29
		Group 05.............................................................................. 31
		Group 10.............................................................................. 93
		Group 15..............................................................................107
		Group 25..............................................................................123
	Section 25................................................................................198
		Group 05..............................................................................199
	Section 30................................................................................279
		Group 10..............................................................................281
		Group 20..............................................................................283
		Group 30..............................................................................291
		Group 40..............................................................................299
		Group 50..............................................................................313
	Section 40................................................................................323
		Group 10..............................................................................325
		Group 20..............................................................................331
	Section 50................................................................................363
		Group 10..............................................................................365
		Group 20..............................................................................381
		Group 30..............................................................................395
	Section 60................................................................................405
		Group 10..............................................................................407
		Group 20..............................................................................411
		Group 30..............................................................................423
		Group 40..............................................................................425
	Section 220...............................................................................432
		Group 05..............................................................................433
		Group 10..............................................................................451
		Group 15..............................................................................459
		Group 20..............................................................................475
	Section 225...............................................................................501
		Group 10..............................................................................503
		Group 15..............................................................................507
		Group 20..............................................................................513
	Section 230...............................................................................526
		Group 10..............................................................................527
		Group 15..............................................................................541
		Group 20..............................................................................547
		Group 25..............................................................................575
		Group 30..............................................................................583
		Group 35..............................................................................599
		Group 40..............................................................................607
		Group 50..............................................................................627
	Section 240...............................................................................635
		Group 10..............................................................................637
		Group 20..............................................................................641
		Group 30..............................................................................653
	Section 250...............................................................................661
		Group 10..............................................................................663
		Group 20..............................................................................669
		Group 30..............................................................................685
	Section 299...............................................................................695
		Group 10..............................................................................697

JOHN DEERE™ Z910A Z920A Z925A Z925A EFI Z930A Z950A Z960A & Z970A ZTRAK SERVICE MANUAL:

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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