John Deere Garden Tractors X465 X475 X485 X575 & X585 Technical Manual – PDF DOWNLOAD

Description

John Deere Garden Tractors X465 X475 X485 X575 & X585 Technical Manual – PDF DOWNLOAD

DESCRIPTION:

John Deere Garden Tractors X465 X475 X485 X575 & X585 Technical Manual – PDF DOWNLOAD

INTRODUCTION:

Manual Description
This technical manual is written for an experienced
technician and contains sections that are specifically for
this product. It is a part of a total product support program.
The manual is organized so that all the information on a
particular system is kept together. The order of grouping is
as follows:
• Table of Contents
• Specifications and Information
• Identification Numbers
• Tools and Materials
• Component Location
• Schematics and Harnesses
• Theory of Operation
• Operation and Diagnostics
• Diagnostics
• Tests and Adjustments
• Repair
• Other

TABLE OF CONTENTS:

John Deere Garden Tractors X465 X475 X485 X575 & X585 Technical Manual – PDF DOWNLOAD

TM2023 X465, X575, X485, X575 and X585 Garden Tractors……………………………………. 1
Introduction……………………………………………………………………… 3
Safety…………………………………………………………………………… 5
Recognize Safety Information……………………………………………………. 5
Understand Signal Words………………………………………………………… 5
Replace Safety Signs…………………………………………………………… 5
Handle Fluids Safely – Avoid Fires………………………………………………. 5
Use Care In Handling And Servicing Batteries……………………………………… 5
Prevent Battery Explosions……………………………………………………… 6
Prevent Acid Burns…………………………………………………………….. 6
Wear Protective Clothing……………………………………………………….. 6
Use Care Around High-pressure Fluid Lines………………………………………… 6
Service Machines Safely………………………………………………………… 7
Use Proper Tools………………………………………………………………. 7
Park Machine Safely……………………………………………………………. 7
Support Machine Properly and Use Proper Lifting Equipment………………………….. 7
Work In Clean Area…………………………………………………………….. 7
Using High Pressure Washers…………………………………………………….. 7
Illuminate Work Area Safely…………………………………………………….. 7
Work In Ventilated Area………………………………………………………… 8
Warning: California Proposition 65 Warning……………………………………….. 8
Remove Paint Before Welding or Heating…………………………………………… 8
Avoid Harmful Asbestos Dust…………………………………………………….. 8
Service Tires Safely…………………………………………………………… 8
Avoid Injury From Rotating Blades, Augers And PTO Shafts…………………………… 9
Service Cooling System Safely…………………………………………………… 9
Handle Chemical Products Safely…………………………………………………. 9
Dispose of Waste Properly………………………………………………………. 9
Live With Safety………………………………………………………………. 9
Specifications & Information……………………………………………………….. 11
Table of Contents……………………………………………………………… 11
Fastener Torques………………………………………………………………. 13
Metric Fastener Torque Values……………………………………………….. 13
Inch Fastener Torque Values…………………………………………………. 14
O-Ring Seal Service Recommendations……………………………………………… 15
Face Seal Fittings With Inch Stud Ends Torque…………………………………. 15
Face Seal Fittings With Metric Stud Ends Torque……………………………….. 16
O-Ring Face Seal Fittings…………………………………………………… 17
O-Ring Boss Fittings……………………………………………………….. 17
Straight Fitting or Special Nut Torques………………………………………. 18
Metric Fastener Torque Value – Grade 7 (Special)………………………………. 18
General Information……………………………………………………………. 18
Gasoline………………………………………………………………….. 18
Gasoline Storage…………………………………………………………… 19
4 – Cycle Gasoline Engine Oil……………………………………………….. 19
Break-In Engine Oil – 4-Cycle Gasoline……………………………………….. 20
Hydrostatic Transmission and Hydraulic Oil……………………………………. 20
Gear Case Oil……………………………………………………………… 21
Gear Transmission Grease……………………………………………………. 22
Alternative Lubricants……………………………………………………… 22
Synthetic Lubricants……………………………………………………….. 22
Lubricant Storage………………………………………………………….. 22
Mixing of Lubricants……………………………………………………….. 22
Oil Filters……………………………………………………………….. 22
Coolant Specifications…………………………………………………………. 23
Gasoline Engine Coolant…………………………………………………….. 23
Gasoline Engine Coolant Drain Interval……………………………………….. 23
Serial Number Locations………………………………………………………… 24
Product Serial Number………………………………………………………. 24
Gasoline Engine Serial Number Location……………………………………….. 24
Engine – Gas (Air-Cooled)………………………………………………………….. 25
Table of Contents……………………………………………………………… 25
Specifications………………………………………………………………… 27
General Specifications……………………………………………………… 27
Tests & Adjustments Specifications…………………………………………… 27
Repair Specifications………………………………………………………. 28
Torque Specifications (Alphabetical)…………………………………………. 29
Special or Required Tools…………………………………………………… 30
Component Location…………………………………………………………….. 31
Engine – 21 HP (FH641D)…………………………………………………….. 31
Theory of Operation……………………………………………………………. 32
Carburated Engine Fuel and Air System Operation……………………………….. 32
Governor Operation…………………………………………………………. 32
Lubrication System Operation………………………………………………… 33
Troubleshooting……………………………………………………………….. 34
Engine Troubleshooting Guide………………………………………………… 34
Engine Runs Erratically/Loss Of Power………………………………………… 35
Starting Motor Troubleshooting Guide…………………………………………. 35
Diagnostics…………………………………………………………………… 37
Diagnostic Table…………………………………………………………… 37
Tests and Adjustments………………………………………………………….. 39
Throttle Cable Adjustment…………………………………………………… 39
Choke Adjustment…………………………………………………………… 39
Governor Adjustment………………………………………………………… 40
Low Idle Speed Adjustment…………………………………………………… 40
High Idle Speed Adjustment………………………………………………….. 40
Compression Test…………………………………………………………… 41
Valve Clearance Adjustment………………………………………………….. 42
Crankcase Vacuum Test………………………………………………………. 43
Fuel Flow Test…………………………………………………………….. 44
Oil Pressure Test………………………………………………………….. 45
Spark Test………………………………………………………………… 46
Engine Repair…………………………………………………………………. 46
Fuel Pump Removal and Installation…………………………………………… 46
Fuel Pump/Fuel Filter Inspection…………………………………………….. 47
Air Cleaner – Removal/Inspection/Installation…………………………………. 47
Carburetor Removal and Installation………………………………………….. 48
Carburetor Disassembly/Assembly……………………………………………… 49
Carburetor Clean/Inspect/Rebuild:……………………………………………. 54
Intake Manifold Removal and Installation……………………………………… 54
Muffler Removal and Installation…………………………………………….. 55
Engine Removal and Installation……………………………………………… 56
Cylinder Head Removal and Installation……………………………………….. 59
Push Rod and Rocker Arm Removal and Installation………………………………. 61
Valve Train Removal and Installation…………………………………………. 62
Piston Removal and Installation……………………………………………… 63
Inspect Piston and Cylinder…………………………………………………. 65
Cylinder Bore Honing……………………………………………………….. 68
Cylinder Bore Resizing……………………………………………………… 68
Crankcase Cover Removal and Installation……………………………………… 69
Crankcase Cover Inspection………………………………………………….. 71
Governor Assembly Removal/Replacement………………………………………… 71
Governor Assembly Inspection………………………………………………… 73
Camshaft/Tappet Removal and Installation……………………………………… 73
Camshaft Disassembly/Inspection……………………………………………… 74
Crankshaft Removal/Replacement………………………………………………. 76
Crankshaft Inspection………………………………………………………. 77
Connecting Rod Inspection…………………………………………………… 78
Breather Valve Removal and Installation………………………………………. 79
Breather Valve Inspection…………………………………………………… 80
Oil Pump Removal and Installation……………………………………………. 80
Oil Pump Inspection………………………………………………………… 81
Oil Pickup Removal and Installation………………………………………….. 82
Oil Screen Inspection/Cleaning………………………………………………. 82
Flywheel Removal and Installation……………………………………………. 83
Stator Coil Inspection……………………………………………………… 85
Ignition Coil Removal and Installation……………………………………….. 85
Starting Motor Removal and Installation………………………………………. 86
Starting Motor Solenoid Tests……………………………………………….. 86
Starting Motor Test………………………………………………………… 87
Starter Motor Disassembly/Assembly…………………………………………… 87
Starting Motor Inspection…………………………………………………… 90
Engine – Gas (Liquid-Cooled)……………………………………………………….. 93
Table of Contents……………………………………………………………… 93
Specifications………………………………………………………………… 95
General Specifications……………………………………………………… 95
Tests and Adjustments Specifications…………………………………………. 96
Repair Specifications………………………………………………………. 96
Torque Specifications (Alphabetical)…………………………………………. 97
Special or Required Tools…………………………………………………… 98
Component Location…………………………………………………………….. 99
Engine – 23 HP (FD671D)…………………………………………………….. 99
Engine – 25 HP (FD711D)……………………………………………………..100
Theory of Operation…………………………………………………………….101
Cooling System Operation…………………………………………………….101
Fuel and Air System Operation………………………………………………..102
Fuel Injection Air System Components and Operation 25 HP – (FD711D)………………102
Fuel Pressure Regulator Operation – FD711D…………………………………….103
Governor Operation………………………………………………………….103
Lubrication System Operation…………………………………………………104
Throttle Body Operation – 25 HP (FD711D)………………………………………105
Diagnostics……………………………………………………………………106
Engine Diagnosis……………………………………………………………106
Engine Tests……………………………………………………………….110
Tests and Adjustments…………………………………………………………..112
Throttle Lever Adjustment……………………………………………………112
Throttle Cable Adjustment……………………………………………………113
Choke Adjustment – 23 HP (FD671D)…………………………………………….113
Governor Adjustment…………………………………………………………113
Low Idle Speed Adjustment……………………………………………………114
High Idle Speed Adjustment…………………………………………………..115
Compression Test……………………………………………………………115
Valve Clearance Adjustment…………………………………………………..116
Crankcase Vacuum Test……………………………………………………….117
Engine Oil Pressure Test…………………………………………………….118
Fuel Pump Flow Test for Carburetor – 23 HP (FD671D)…………………………….119
Fuel Pump Pressure Test for Carburetor – 23 HP (FD671D)…………………………119
Fuel Pump Pressure Test For Fuel Injection – 25 HP (FD711D)……………………..120
Bleed Fuel System – 25 HP (FD711D)……………………………………………121
Fan Belt Tension Adjustment………………………………………………….121
Radiator Bubble Test………………………………………………………..122
Radiator Cap Pressure Test…………………………………………………..122
Thermostat Test…………………………………………………………….122
Cooling System Test…………………………………………………………124
Repair………………………………………………………………………..124
Thermostat Removal and Installation…………………………………………..124
Fan Belt Removal and Installation…………………………………………….125
Cooling Fan and Bracket Removal and Installation……………………………….126
Coolant Pump Removal and Installation…………………………………………126
Radiator Removal and Installation…………………………………………….128
Muffler Removal and Installation……………………………………………..131
Air Cleaner Removal and Installation………………………………………….132
Carburetor Removal and Installation – 23 HP (FD671D)……………………………133
Throttle Body Removal and Installation – 25 HP (FD711D)…………………………135
Fuel Injector Removal and Installation – 25 HP (FD711D)…………………………136
Fuel Pressure Regulator Removal and Installation – 25 HP (FD711D)………………..137
Cylinder Head Removal and Installation………………………………………..138
Intake Manifold Removal and Installation – 23 HP (FD671D)……………………….139
Intake Manifold Removal and Installation – 25 HP (FD711D)……………………….140
Starting Motor Removal and Installation……………………………………….142
Starter Motor Disassembly and Assembly………………………………………..142
Starting Motor Inspection……………………………………………………144
Engine Removal and Installation………………………………………………147
Flywheel Removal and Installation…………………………………………….150
Push Rod/Rocker Arm Removal and Installation…………………………………..151
Valve Train Removal and Installation………………………………………….153
Crankcase Cover Removal and Installation………………………………………154
Crankcase Cover Inspection…………………………………………………..155
Governor Assembly Removal and Installation…………………………………….156
Piston Removal and Installation………………………………………………158
Inspect Piston and Cylinder………………………………………………….161
Cylinder Bore Honing………………………………………………………..164
Cylinder Bore Resizing………………………………………………………164
Camshaft/Tappet Removal and Installation………………………………………165
Camshaft Disassembly and Inspection…………………………………………..166
Crankshaft Removal and Replacement……………………………………………167
Crankshaft Inspection……………………………………………………….167
Connecting Rod Inspection……………………………………………………169
Breather Valve Removal and Installation……………………………………….170
Oil Pump Removal and Installation…………………………………………….170
Oil Pump Inspection…………………………………………………………171
Oil Screen Removal and Installation…………………………………………..173
Electrical………………………………………………………………………..175
Table of Contents………………………………………………………………175
General Information…………………………………………………………….179
Reading Electrical Schematics………………………………………………..179
Theory of Operation Information………………………………………………180
Diagnostic Information………………………………………………………180
Wire Color Abbreviation Chart………………………………………………..180
Common Circuit Tests………………………………………………………..181
Conductors For 12 Volt Circuits………………………………………………181
Specifications…………………………………………………………………182
General Specifications………………………………………………………182
Test and Adjustment Specifications……………………………………………182
Repair Specifications……………………………………………………….183
Special or Essential Tools…………………………………………………..184
Other Materials…………………………………………………………….184
Component Location……………………………………………………………..185
Right Side…………………………………………………………………185
Left Side………………………………………………………………….186
Engine Components (FH641D)…………………………………………………..187
Engine Components (FD671D)…………………………………………………..188
Engine Components (FD711D EFI)……………………………………………….189
Instrument Panel……………………………………………………………190
Schematics and Harnesses………………………………………………………..191
Schematic and Wiring Harness Legend – X465, X475 and X575……………………….191
Schematic And Wiring Harness Legend – X485 and X585…………………………….192
Electrical Schematic – X465 (1 of 3)………………………………………….195
Electrical Schematic – X465 (2 of 3)………………………………………….196
Electrical Schematic – X465 (3 of 3)………………………………………….197
Electrical Schematic – X475 and X575 (1 of 3)………………………………….198
Electrical Schematic – X475 and X575 (2 of 3)………………………………….199
Electrical Schematic – X475 and X575 (3 of 3)………………………………….200
Electrical Schematic – X485 and X585 (1 of 4)………………………………….201
Electrical Schematic – X485 and X585 (2 of 4)………………………………….202
Electrical Schematic – X485 and X585 (3 of 4)………………………………….203
Electrical Schematic – X485 and X585 (4 of 4)………………………………….204
W1 Main Wiring Harness – X465 (1 of 2)………………………………………..205
W1 Main Wiring Harness – X465 (2 of 2)………………………………………..206
W2, W6 and W7 Engine Wiring Harnesses – X465…………………………………..207
W1 Main Wiring Harness – X475 and X575 (1 of 2)………………………………..208
W1 Main Wiring Harness – X475 and X575 (2 of 2)………………………………..209
W2 Engine Wiring Harness – X475 and X575………………………………………210
W1 Main Wiring Harness – X485 and X585 (1 of 2)………………………………..211
W1 Main Wiring Harness – X485 and X585 (2 of 2)………………………………..212
W2 Engine Wiring Harness – X485 and X585………………………………………213
W2 Engine Wiring Harness Circuit Schematic – X485 and X585………………………214
W3 Headlight Wiring Harness………………………………………………….215
W4 Rear Wiring Harness………………………………………………………215
W5 PTO Option Wiring Harness…………………………………………………215
W1 Main Wiring Harness Color Codes – X465……………………………………..216
W1 Main Wiring Harness Color Codes – X475 and X575……………………………..217
W1 Main Wiring Harness Color Codes – X485 and X585……………………………..218
W2 Engine Wiring Harness Color Codes – X475 and X575……………………………219
W2 Engine Wiring Harness Color Codes – X485 and X585……………………………220
W3 Headlight Wiring Harness Color Codes……………………………………….220
W4 Rear Wiring Harness Color Codes……………………………………………220
W5 PTO Option Wiring Harness Color Codes………………………………………220
Operation and Diagnostics……………………………………………………….221
Power Circuit Operation – X465……………………………………………….221
Power Circuit Wiring Schematic – X465…………………………………………222
Power Circuit Operation – X475 and X575……………………………………….224
Power Circuit Electrical Schematic – X475 and X575……………………………..225
Power Circuit Diagnosis – X465, X475 and X575………………………………….227
Power Circuit Operation – X485 and X585……………………………………….230
Power Circuit Electrical Schematic – X485 and X585……………………………..232
Power Circuit Diagnosis – X485 and X585……………………………………….235
Cranking Circuit Operation – All Models……………………………………….239
Cranking Circuit Electrical Schematic – All Models……………………………..240
Cranking Circuit Diagnosis – All Models……………………………………….241
Charging Circuit Operation – All Models……………………………………….243
Charging Circuit Electrical Schematic – All Models……………………………..244
Charging Circuit Diagnosis – All Models……………………………………….245
Ignition Circuit Operation – X465, X475 and X575……………………………….247
Ignition Circuit Electrical Schematic – X465, X475 and X575……………………..248
Ignition Circuit Diagnosis – X465, X475 and X575……………………………….250
Ignition Circuit Operation – X485 and X585…………………………………….253
Ignition Circuit Electrical Schematic – X485 and X585…………………………..254
Ignition Circuit Diagnosis – X485 and X585…………………………………….257
PTO/RIP Circuit Operation – All Models………………………………………..263
PTO Circuit Electrical Schematic – All Models………………………………….265
PTO Circuit Diagnosis – All Models……………………………………………267
Instrument Panel Circuit Operation – All Models………………………………..270
Instrument Panel Circuit Electrical Schematic – All Models (SN -30000)……………272
Instrument Panel Circuit Schematic – All Models (SN 30001-)……………………..273
Instrument Panel Circuit Diagnosis – All Models………………………………..274
Lights Circuit Operation – All Models…………………………………………276
Lights Circuit Electrical Schematic – All Models……………………………….277
Lights Circuit Diagnosis – All Models…………………………………………278
Fuel Pump and Fuel Shutoff Circuit Operation – X465, X475 and X575……………….280
Fuel Pump and Fuel Shutoff Circuit Electrical Schematic – X465, X475 and X575……..281
Fuel Pump and Fuel Shutoff Circuit Diagnosis – X465, X475 and X575……………….283
Fuel Pump and Fuel Injector Circuit Operation – X485 and X585……………………286
Fuel Pump and Fuel Injector Circuit Electrical Schematic – X485 and X585………….287
Fuel Pump and Fuel Injector Circuit Diagnosis – X485 and X585……………………290
Fuel Injection Sensor and Diagnostic Circuit Operation – X485 and X585……………294
Fuel Injection Sensor and Diagnostic Circuit Electrical Schematic – X485 and X585….295
Fuel Injection Sensor and Diagnostic Circuit Diagnosis – X485 and X585……………298
Tests and Adjustments…………………………………………………………..302
Common Circuit Tests………………………………………………………..302
Ground Circuit Tests………………………………………………………..302
Battery Voltage and Specific Gravity Test……………………………………..303
Battery – Charge……………………………………………………………304
Battery – Load Test…………………………………………………………304
Regulated Amperage and Voltage Test…………………………………………..305
Regulated Voltage Test………………………………………………………306
Voltage Regulator/Rectifier Test – X465……………………………………….306
Unregulated Voltage Test – X465………………………………………………307
Unregulated Voltage Test – X475, X575, X485, and X585…………………………..307
Stator Resistance Test………………………………………………………308
Starting Motor Condition…………………………………………………….308
Starter Solenoid Test……………………………………………………….309
Starting Motor Amp Draw Test…………………………………………………309
Starting Motor No-load Amperage and RPM Test…………………………………..310
Field Windings Test…………………………………………………………310
Starter Armature Test……………………………………………………….311
Ignition Interlock Test……………………………………………………..312
Engine Coolant Temperature Sensor Test – X475, X575, X485, and X585………………314
Engine Oil Pressure Switch Test………………………………………………315
Lights Switch Test………………………………………………………….315
PTO/RIP Switch Test…………………………………………………………316
Relay Test…………………………………………………………………316
Seat Switch Test……………………………………………………………317
Brake Switch Test and Adjustment……………………………………………..317
RIO Switch Test…………………………………………………………….318
RIO Switch Adjustment……………………………………………………….318
Service Timer Reset Switch (SN -30000)………………………………………..319
Fuse Test………………………………………………………………….319
Instrument Panel Light Test………………………………………………….320
PTO Solenoid Test…………………………………………………………..321
PTO Switch Test (optional)…………………………………………………..321
Fuel Shutoff Solenoid Test – X465, X475 and X575……………………………….322
Diode Test…………………………………………………………………323
Fuel Tank Sensor Test……………………………………………………….323
Fuel Injector Test – X485 and X585……………………………………………324
Fuel Injection Module Test – X485 and X585…………………………………….324
Vacuum Pressure Sensor Test – X485 and X585……………………………………325
Air Temperature Sensor Test – X485 and X585……………………………………326
Coolant Temperature Sensor Test – X485 and X585………………………………..326
Spark Plug Gap Test…………………………………………………………327
Spark Plug Gap Adjustment……………………………………………………327
Ignition Coil Test………………………………………………………….328
Spark Test…………………………………………………………………328
Repair………………………………………………………………………..329
Ignition Coil Replacement……………………………………………………329
Stator Replacement………………………………………………………….330
Power Train – Hydrostatic…………………………………………………………..331
Table of Contents………………………………………………………………331
Specifications…………………………………………………………………333
General Specifications………………………………………………………333
Test And Adjustment Specifications……………………………………………333
Repair Specifications……………………………………………………….333
Special or Essential Tools…………………………………………………..334
Other Materials…………………………………………………………….334
Component Location……………………………………………………………..335
Hydrostatic Power Train……………………………………………………..335
Final Drive (MFWD)………………………………………………………….337
Front Axle Gear Case (MFWD)………………………………………………….338
Front Axle Assembly (MFWD)…………………………………………………..340
Rear PTO Gear Case Assembly………………………………………………….341
MFWD Output Shaft…………………………………………………………..343
Theory of Operation…………………………………………………………….344
Center Section and Directional Control Valves – Reverse System Operation………….344
Transaxle Oil Flow System Operation…………………………………………..347
External Power Train System Operation…………………………………………350
Transaxle Internal System Operation…………………………………………..351
Rear PTO Component Location and Operation – Optional……………………………355
540 Rear PTO……………………………………………………………….356
Diagnostics……………………………………………………………………357
Hydrostatic Transmission Diagnosis……………………………………………357
Mid-PTO System Diagnosis…………………………………………………….359
Transaxle Diagnosis…………………………………………………………359
Hydrostatic Transmission Test………………………………………………..360
Mid-PTO System Test…………………………………………………………362
Transaxle Test……………………………………………………………..363
Tests and Adjustments…………………………………………………………..364
Hydraulic Oil Warm-Up Procedure………………………………………………364
Charge Pump Pressure Test……………………………………………………364
Charge Pump Flow and Pressure Test – At Charge Pump…………………………….365
Mid-PTO Engagement Pressure and Brake Test…………………………………….367
Transaxle Neutral Adjustment…………………………………………………368
Transaxle Control Linkage Adjustment………………………………………….369
Transaxle Linkage Full Forward Adjustment……………………………………..370
Cruise Control Linkage Check and Adjustment……………………………………370
Repair………………………………………………………………………..372
Foot Control Linkage Removal and Installation………………………………….372
Shift Lever Linkage (MFWD) Removal and Installation…………………………….375
Oil Cooler Removal and Installation…………………………………………..376
Control Arm and Damper Removal and Installation………………………………..378
Differential Lock Linkage Inspection………………………………………….379
Charge Pump Removal and Installation………………………………………….379
Charge Pump Disassembly and Assembly………………………………………….380
Directional Control Valves…………………………………………………..381
Hydrostatic Pressure Relief Valve (45 Loader) Installation………………………382
Drive Shaft Removal and Installation………………………………………….382
PTO Solenoid Valve………………………………………………………….383
PTO Relief Valve Removal and Installation……………………………………..385
PTO Relief Valve Disassembly, Inspection and Assembly…………………………..385
PTO Brake Removal and Installation……………………………………………385
PTO Brake Disassembly, Inspection and Assembly…………………………………386
PTO Drive Train (Mid-PTO) Removal and Installation……………………………..387
PTO Drive Train (Mid and Rear PTO) Removal and Installation……………………..388
Rear PTO Removal and Installation…………………………………………….391
Transaxle Removal and Installation……………………………………………394
Differential Lock Shaft Disassembly and Assembly……………………………….396
Differential (2-Wheel Drive) Disassembly and Assembly…………………………..397
Differential (MFWD) Disassembly and Assembly…………………………………..398
PTO Clutch Disassembly, Inspection and Assembly………………………………..399
MFWD Output Shaft Removal and Installation…………………………………….400
Hydrostatic Transmission 2-WD and MFWD………………………………………..403
Hydrostatic Pump Inspection………………………………………………….410
Transaxle Disassembly……………………………………………………….411
Transaxle (Right Cover) Disassembly and Assembly……………………………….414
Transaxle Case Inspection……………………………………………………415
Transaxle Assembly………………………………………………………….415
Rear Axle Assembly (Two Wheel Steer Models) Removal and Installation……………..417
Rear Axle Assembly (Two Wheel Steer Models) Disassembly and Assembly……………..418
Rear Axle Assembly (All Wheel Steer) Removal and Installation……………………419
Rear Axle Assembly (All Wheel Steer) Disassembly and Assembly……………………420
Knuckle Assembly (All Wheel Steer) Removal and Installation……………………..421
Knuckle Housing Disassembly and Assembly………………………………………421
Final Drive Cover Removal and Installation – (MFWD)…………………………….422
Final Drive Housing Removal and Installation – (MFWD)…………………………..424
Spindle Housing – (MFWD)…………………………………………………….426
Drive Shaft Removal and Installation – (MFWD)………………………………….427
Mechanical Front Wheel Drive Removal and Installation – (MFWD)…………………..427
Differential Input Housing – (MFWD)…………………………………………..429
Front Axle Housing Disassembly and Assembly……………………………………430
Hydraulics………………………………………………………………………..433
Table of Contents………………………………………………………………433
Specifications…………………………………………………………………435
General Specifications………………………………………………………435
Test and Adjustment Specifications……………………………………………435
Repair Torque Specifications…………………………………………………436
Special or Essential Tools…………………………………………………..436
Other Materials…………………………………………………………….436
Schematics…………………………………………………………………….437
Hydraulic Schematic – Power Train…………………………………………….437
Component Location……………………………………………………………..438
Hydraulic System……………………………………………………………438
Operation and Diagnostics……………………………………………………….439
Hydraulic System……………………………………………………………439
Hydraulic Control Valve Operation – Neutral……………………………………440
Hydraulic Control Valve Operation – Raise……………………………………..441
Hydraulic Control Valve Operation – Float……………………………………..442
Hydraulic Control Valve Operation – Regen……………………………………..443
Lift Cylinder Shut-off Valve – Optional……………………………………….444
Hydraulic Diagnostics……………………………………………………….444
Preliminary Hydraulic System Inspection……………………………………….446
Hydraulic System Tests………………………………………………………447
Tests and Adjustments…………………………………………………………..448
Hydraulic Oil Warm-Up Procedure………………………………………………448
Charge Pump Pressure and Flow Quick Test at Couplers……………………………448
Charge Pump Pressure Test……………………………………………………449
Lift Cylinder Leakage Test…………………………………………………..451
Control Valve Leakage Test…………………………………………………..451
Repair………………………………………………………………………..452
Hydraulic Control Valve Removal and Installation……………………………….452
Hydraulic Control Valve……………………………………………………..453
Lift Cylinder Removal and Installation………………………………………..454
Hydraulic Control Levers and Linkage………………………………………….455
Steering………………………………………………………………………….457
Table of Contents………………………………………………………………457
Specifications…………………………………………………………………459
General Specifications………………………………………………………459
Test and Adjustment Specifications……………………………………………459
Repair Specifications……………………………………………………….459
Special or Essential Tools…………………………………………………..459
Component Location……………………………………………………………..460
Steering Components – Front Wheel Steer……………………………………….460
Steering Components – All Wheel Steer…………………………………………461
Steering Components – All Wheel Steer Rear Axle………………………………..462
Theory of Operation…………………………………………………………….463
Steering System Operation……………………………………………………463
Steering Valve Operation – Neutral……………………………………………464
Steering Valve Operation – Turning……………………………………………465
Steering Valve Operation – Manual…………………………………………….466
Diagnostics……………………………………………………………………467
Steering Diagnosis………………………………………………………….467
Steering System Tests……………………………………………………….468
Steering Link Checks………………………………………………………..468
Tests and Adjustments…………………………………………………………..469
Hydraulic Oil Warm-Up Procedure………………………………………………469
Steering Valve and Cylinder Leakage Test………………………………………469
Toe-In Adjustment Front Wheels……………………………………………….470
Toe-In Adjustment All Wheel Steering………………………………………….471
Repair………………………………………………………………………..472
Steering Column Removal and Installation………………………………………472
Steering Valve Removal and Installation……………………………………….473
Steering Valve Disassembly and Assembly……………………………………….475
Steering Cylinder Removal and Installation…………………………………….478
Front Axle Removal and Installation…………………………………………..478
Front Axle Disassembly and Assembly…………………………………………..479
Rear Steering Linkage – All Wheel Steering…………………………………….481
Steering Intermediate Linkage – AWS…………………………………………..483
Front and Rear Pivots……………………………………………………….484
Brakes……………………………………………………………………………487
Table of Contents………………………………………………………………487
Specifications…………………………………………………………………489
General Specifications………………………………………………………489
Test and Adjustment Specifications……………………………………………489
Repair Specifications……………………………………………………….489
Special or Essential Tools…………………………………………………..489
Other Materials…………………………………………………………….489
Component Location……………………………………………………………..490
Brake System Component Location………………………………………………490
Brake/Differential Linkage (Exploded)…………………………………………491
Theory of Operation…………………………………………………………….492
Brake System Operation………………………………………………………492
Diagnostics……………………………………………………………………493
Brakes…………………………………………………………………….493
Tests and Adjustments…………………………………………………………..495
Brake/Differential Linkage Adjustment…………………………………………495
Repair………………………………………………………………………..497
Brake/Differential Linkage Removal and Installation…………………………….497
Brakes Removal and Installation………………………………………………499
Attachments……………………………………………………………………….501
Table of Contents………………………………………………………………501
Specifications…………………………………………………………………503
General Specifications………………………………………………………503
Torque and Repair Specifications……………………………………………..505
Diagnostics……………………………………………………………………507
48, 54 and 62-Inch Mower Deck Diagnosis……………………………………….507
45 Loader Diagnosis…………………………………………………………510
Tests and Adjustments…………………………………………………………..511
Adjusting Cutting Height (48C, 54C, and 62C Mower Deck)…………………………511
Adjusting Mower Deck Wheels………………………………………………….511
Mower Deck Level Check and Adjustment…………………………………………512
Adjusting Mower Level Side-to-Side……………………………………………512
Adjusting Mower Level Front-to-Rear…………………………………………..513
Adjusting Latch Rod…………………………………………………………514
Cylinder Leakage Test……………………………………………………….514
45 Loader Lubrication……………………………………………………….514
Repair………………………………………………………………………..515
Cleaning Grass and Debris From Machine………………………………………..515
Mower Deck Belt and Shield Removal and Installation…………………………….515
Mower Deck Blade Removal and Installation……………………………………..517
Mower Deck Blade – Sharpen…………………………………………………..518
Mower Deck Blade – Balance…………………………………………………..518
48C Mower Deck Spindle Removal and Installation………………………………..518
Idlers…………………………………………………………………….520
Jacksheave…………………………………………………………………521
54C Mower Deck Spindle Removal and Installation………………………………..521
Jacksheave…………………………………………………………………523
Idlers…………………………………………………………………….524
62C Mower Deck Spindle Removal and Installation………………………………..524
Mower Deck Drive Shaft Removal and Installation………………………………..526
Mower Deck Drive Shaft Repair………………………………………………..527
Mower Deck Gearbox Removal and Installation……………………………………528
Mower Deck Gearbox Repair……………………………………………………530
General Information…………………………………………………………….531
Reading Electrical Schematics………………………………………………..531
Operation and Diagnostics……………………………………………………532
Diagnostic Information………………………………………………………532
Wire Color Abbreviation Chart………………………………………………..532
Common Circuit Tests………………………………………………………..532
Conductors For 12 Volt Circuits………………………………………………533
Identification Numbers………………………………………………………….534
Generator………………………………………………………………….534
Alternator…………………………………………………………………534
Component Location……………………………………………………………..535
Generator………………………………………………………………….535
Alternator Components……………………………………………………….536
Control Panel………………………………………………………………537
Generator Gear Box Components………………………………………………..538
Schematics and Harnesses………………………………………………………..539
Wiring Harness Legend……………………………………………………….539
Connectors…………………………………………………………………539
Standard Electrical Schematic………………………………………………..540
Operation and Diagnostics……………………………………………………….542
Generator Circuit Operation………………………………………………….542
Generator Circuit Diagnosis………………………………………………….542
Tests and Adjustments…………………………………………………………..544
Generator Stator Test……………………………………………………….544
Generator Rotor Test………………………………………………………..545
Ground Fault Circuit Interrupter (GFCI) Checks…………………………………545
Generator Ground Test……………………………………………………….546
Repair………………………………………………………………………..546
Stator Excitation Field Restoration…………………………………………..546
PTO Shield Removal and Installation…………………………………………..547
Generator Removal and Disassembly…………………………………………….547
Gear Case Removal and Disassembly…………………………………………….547
Rotor Bearing Removal and Installation………………………………………..549
Rotor Fan Removal and Installation……………………………………………549
Generator Assembly and Installation…………………………………………..550
Control Panel Removal and Installation………………………………………..551
Miscellaneous……………………………………………………………………..553
Table of Contents………………………………………………………………553
Specifications…………………………………………………………………555
Repair Specifications……………………………………………………….555
Other Materials…………………………………………………………….555
Repair………………………………………………………………………..556
Fender Deck Removal and Installation………………………………………….556
Fuel Tank Removal and Installation……………………………………………557
Fuel Pump/Fuel Gauge Sensor Removal and Installation……………………………558
Headlights Adjustment……………………………………………………….559
Lift Linkage Removal and Installation…………………………………………560
Hood Removal and Installation………………………………………………..563
Instrument Panel Removal and Installation……………………………………..564
Front Wheel Removal and Installation………………………………………….565
Rear Wheel Removal and Installation…………………………………………..565
Index…………………………………………………………………………….567
Numerics………………………………………………………………………567
A…………………………………………………………………………….567
B…………………………………………………………………………….567
C…………………………………………………………………………….567
D…………………………………………………………………………….568
E…………………………………………………………………………….568
F…………………………………………………………………………….571
G…………………………………………………………………………….572
H…………………………………………………………………………….572
I…………………………………………………………………………….572
K…………………………………………………………………………….572
L…………………………………………………………………………….572
M…………………………………………………………………………….572
O…………………………………………………………………………….573
P…………………………………………………………………………….573
R…………………………………………………………………………….573
S…………………………………………………………………………….574
T…………………………………………………………………………….574
U…………………………………………………………………………….575
V…………………………………………………………………………….575
W…………………………………………………………………………….575

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