Service

Service Intervals

Service Record

Engine Warranty Maintenance Statement

Maintenance, repair, or replacement of the emission control devices and systems on this engine, which are being done at the customers expense, may be performed by any nonroad engine repair establishment or individual. Warranty repairs must be performed by an authorized John Deere dealer.

Avoid Fumes

c CAUTION: Avoid injury! Engine exhaust fumes can cause sickness or death: · If it is necessary to run an engine in an enclosed area, use an exhaust pipe extension to remove the fumes. · Always try to work in a well ventilated area.

Engine Oil

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

The following John Deere oils are preferred:

· PLUS-4® (SAE 10W-40)

· TORQ-GARD SUPREME®
(SAE 5W-30)

The following John Deere oils are also recommended, based on their specified temperature range:

· TURF-GARD® (SAE 10W-30)

· PLUS-4® (SAE 10W-30)

· TORQ-GARD SUPREME®
(SAE 30)

Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications:

· SAE 10W-40-API Service Classification SG or higher

· SAE 5W-30-API Service Classification SG or higher

· SAE 10W-30-API Service Classification SG or higher

· SAE 30-API Service Classification SC or higher

Checking Engine Oil Level

c CAUTION: Avoid injury! Before you check or add oil, STOP engine. Let it cool.

M61458

1. Stop engine. Put mower on a level surface.

2. Remove dipstick and wipe it with a clean cloth.

3. Install dipstick. DO NOT TIGHTEN, LET THREADS REST ON TOP OF TUBE.

M61459

4. Remove dipstick. Check oil level. Oil level MUST BE between ADD and FULL marks. If not, pour oil into dipstick tube to bring level to FULL mark (A).

5. Install and tighten dipstick.

Changing Engine Oil

c CAUTION: Avoid injury! Used oil may harm environment and people if it is dumped on the ground or into a drain or a body of water. Call your local Recycling Center or John Deere dealer to learn how to recycle used oil.

NOTE: An oil filter kit is available for some models at your John Deere dealer. If you install kit, change oil every 50 hours.

M62532

1. Install drain hose (included with mower) on oil drain fitting.

2. Turn fitting to the left to open drain. Drain oil into a container.

3. Tighten fitting. Remove hose.

4. Pour 0.6 L (20 oz) oil into dipstick tube.

5. Install dipstick. DO NOT TIGHTEN IT: LET THREADS REST ON TOP OF TUBE.

6. Check oil level. If necessary, add oil to bring level to the FULL MARK.

7. Install and tighten dipstick.

Changing Oil Filter (Optional-not available on all Models)

c CAUTION: Avoid injury! A used oil filter may harm environment and people if it is dumped on the ground or into a drain or a body of water. Call your local Recycling Center or John Deere dealer to learn how to dispose of a used oil filter. Before you remove filter: STOP engine. Let it cool.

M61553

1. Drain oil.

2. Remove filter by turning it to the left.

3. Apply a film of clean engine oil to new filter gasket.

4. Install filter by turning filter to the right until gasket contacts filter base. Tighten filter by hand 3/4 turn more.

5. Pour new oil into dipstick tube.

6. Run engine and check for leaks around filter.

7. STOP engine. Check oil level.

8. Install and tighten dipstick.

Cleaning Air Cleaner Foam Element

c CAUTION: Avoid injury! Before you remove elements: · STOP engine. Let it cool.

M61461

1. Clean cover and area around it. Remove cover (A).

2. Remove foam element (B) from paper element (C).

3. Wash foam element in non-flammable solvent or warm water-detergent solution.

4. Rinse element. Let it dry.

5. Put 10-15 drops of clean engine oil on element. Squeeze element to distribute oil.

6. Inspect paper element. Install elements and cover.

Replacing Paper Element

c CAUTION: Avoid injury! Before you work on engine: · STOP engine. Let it cool.

M61461

1. Clean cover and area around it. Remove cover (A).

2. Remove foam element (B) from paper element (C).

3. Inspect paper element.

4. Replace an element:

· That is oily or sooty.

· With a break, hole, or damaged seal.

· If engine performance is poor.

5. Install elements and cover.

Cleaning and Gapping Spark Plug

c CAUTION: Avoid injury! Before you remove plug: · STOP engine. Let it cool.

M61522

1. Disconnect spark plug wire (A). Remove plug (B).

2. Carefully wire brush carbon from plug. Do not clean it with abrasives in a machine.

3. Inspect plug for damage. Replace damaged plug.

4. Adjust gap to 0.76 mm (0.030 in.).

5. Install and tighten plug to 20 N·m (15 lb-ft).

6. Connect wire.

Cleaning Cooling Fins

M60977

Clean fins with a brush, rag, or compressed air.

Also, blow compressed air under the shroud.

Adjusting Throttle Cable

M61465

1. Push throttle lever to the FAST r position.

2. Loosen screw (B).

3. Adjust cable cover (C) until holes (D) are in line.

4. Tighten screw.

Adjusting Choke

M61465

1. Adjust throttle cable.

2. Turn screw (B) (under plate) to the right until lever (C) begins to move. If lever moves when you first turn screw, back off screw and start Step 2 again.

3. Push throttle lever to the CHOKE k position.

4. Move lever (C) back and forth. There should be no free play. If necessary, repeat Step 2.

Adjusting Carburetor

NOTE: Carburetor is calibrated by the engine manufacturer and should not require any adjustments.

If engine is operated at altitudes above 1829 m
(6,000 ft), some carburetors may require a special high altitude main jet. See your John Deere dealer.

Possible engine surging will occur at high rpm when the transmission and the blades are disengaged. This is a normal condition due to the emission control system.

If engine is hard to start or runs rough, check the TROUBLESHOOTING section of this manual.

After performing the checks in the troubleshooting section and your engine is still not performing correctly, contact your John Deere dealer.

Adjusting Traction Clutch

c CAUTION: Avoid injury! Do not operate mower without belt shield. Before you adjust clutch: · STOP engine. Let it cool. · Keep people and pets away from mower. · Keep hands and tools away from belt area when engine is running.

NOTE: Adjust clutch before 50 hours if mower slows as it goes uphill.

1. Remove knob (A) and shield(B).

M62533

2. Loosen nut (C).

3. Turn nut (D) down 6 mm (1/4 in.).

4. Tighten nut (C).

5. Start engine.

6. ENGAGE traction clutch lever to check clutch action.

M62535

7. If clutch needs more tension, repeat Steps 2 and 3.

8. Make sure pulley (E) does not turn when engine is running and clutch lever is DISENGAGED. If pulley turns when engine is running, traction clutch cable is adjusted too tight.

9. STOP engine.

Adjusting Blade Brake Clutch

c CAUTION: Avoid injury! Do not operate mower unless belt shield is in place.

NOTE: Blade should stop within 3 seconds after you release blade stop lever. If not, adjust clutch.

1. Put blade engagement lever on handlebar all the way to the rear.

M62536

2. To adjust cable:

· Remove belt shield.

· Loosen nut (A).

· Pull threaded fitting to rear to remove all cable slack.

· Turn nut (B) against deck fork.

M60985

· Tighten nut (A).

· Make sure there is tension on cable (C), but that it is not too loose or too tight. This will give maximum blade brake clutch engagement.

· Install shield.

Grease

Use grease based on the expected air temperature range during the service interval.

The following greases are preferred:

· John Deere Moly High Temperature EP Grease.

· John Deere High Temperature EP Grease.

· John Deere GREASE-GARD.

Other greases may be used are:

· SAE Multipurpose EP Grease with 3 to 5 percent molybdenum disulfide.

· SAE Multipurpose EP Grease.

TS1417

· Greases meeting Military Specification MIL-G-10924C may be used as arctic grease.

Lubricate Rear Axle Bearings

NOTE: Adjust mower height indicator until zerk is easy to get grease gun on.

M61549

1. Wipe grease fittings clean.

2. Lubricate bearing (A) on each side with one shot of John Deere Multipurpose Grease or an equivalent.

Cleaning Mower

c CAUTION: Avoid injury! Before you clean mower: · STOP engine. Let engine cool. · Disconnect spark plug wire. · Turn mower onto its RIGHT side to clean under the deck.

Clean engine and top of the deck.

Check and clean cooling fins, if necessary.

Grass clippings can build up in belt and transmission area. If necessary, remove belt shield and clean this area. DO NOT spray the transmission with water. (See Clean Belt and Transmission Area in this section.)

If you operate the mower in dusty conditions, clean air cleaner foam element.

Remove mulch plug. Spray under the deck with water under pressure to remove corrosive lawn chemicals and grass buildup. DO NOT spray the transmission with water. (See IMPORTANT information.)

Remove and shake bag to remove clippings.

If bag is caked with grass on the inside, use water under pressure to clean bag. Direct water from outside to inside of bag.

Clean grass clippings that may build up between the wheels and the mower deck.

Cleaning Fuel Cap Vent

M61468

1. Remove cap (A).

2. Remove rubber vent (B) from cap.

3. Clean cap and vent in an nonflammable solvent.

4. Install vent and cap.

Cleaning Belt and Transmission Area

c CAUTION: Avoid injury! Before you remove shield: · STOP engine. Let it cool. · DO NOT operate mower without belt shield.

M62533

1. Remove knob (A) and shield (B).

2. Remove clippings from belt area and top of the transmission.

M62534

3. Install shield.

Blade Oil

John Deere TORQ-GARD SUPREME® or John Deere
PLUS 4® engine oil is recommended for lubricating cutting blades. If other oils are used, they must be premium quality engine oils meeting performance requirements of:

· API Service Classification SG or SF.

Check Blade

c CAUTION: Avoid injury! Service blade safely: · STOP engine. Let it cool. · Disconnect spark plug wire. · Wear gloves or wrap blade with a rag.

NOTE: Wing on blade tip MUST point up.

M61462

CHECK BLADE:

· Replace damaged blade.

· Tighten Bolts (A) to 75 N·m (55 lb-ft).

· Sharpen dull blade. (See Sharpening Blade in this section.)

TO REMOVE BLADE:

· Remove bolts (A) and blade.

Sharpening Blade

c CAUTION: Avoid injury! Wear gloves and goggles when sharpening, balancing or installing blade.

M61830

Sharpen blade: Keep original bevel (A).

Balance and Install Blade

M61524

1. Clean blade. Put it on a nail in vise or on a wall. Heavy end of blade will drop. Grind bevel of heavy end. Do not change bevel.

2. Install blade, washers (cup-side against blade), and bolts.

3. Tighten bolts to 75 N·m (55 lb-ft).

Charging the Battery (JE75)

NOTE: If battery is not used for an extended time, you may have to charge it.

NOTE: The battery can be charged by running the engine or by using the battery charger.

M61558

1. Disconnect battery wire connector (A) from engine wire connector (B).

2. Connect charger cord connector (C) to battery wire connector.

3. Plug charger (D) into a 115-volt house receptacle. For a new or discharged battery: Charge battery 24-36 hours.

4. Unplug cord from house receptacle, then from battery.

5. Connect battery wire connector to engine wire connector.

Removing the Battery (JE75)

NOTE: If battery becomes permanently damaged, it can be removed and replaced.

If the battery is not used for an extended time, you may need to charge it. (See Charging the Battery in this section).

62533

1. Remove knob (A) and shield (B).

c CAUTION: Avoid injury! To avoid injury from electric shock: · Battery must ALWAYS have wire connectors and boot properly installed on terminals during installation or removal. · Never check battery charge by placing a metal object across the terminal post.

M61558

2. Disconnect battery wire connector (C) from engine wire connector (D).

M63535

3. Using a 10 mm wrench, loosen lock nut (E) and rotate battery retainer (G) away from the battery.

M63434

4. Remove battery.

Handle Fuel Safely

c CAUTION: Avoid injury! Handle fuel with care, it is highly flammable: · DO NOT refuel machine while you smoke, when machine is near an open flame or sparks, or when engine is running. STOP engine. · Fill fuel tank outdoors. · Prevent fires: clean oil, grease and dirt from machine. Clean up spilled fuel immediately. · Do not store machine with fuel in tank in a building where fumes may reach an open flame or spark. · To prevent fire and explosion caused by static electric discharge, while you fill tank, use a non-metal fuel container. If you use a funnel, MAKE SURE it is PLASTIC. Avoid using a funnel which has a metal screen or filter. · Use only clean oil and fuel and clean approved containers and funnels. · Store oil and fuel in an area protected from dust, moisture and other contamination. · DO NOT use METHANOL gasolines. METHANOL is harmful to the environment and to your health.

Filling Fuel Tank

· Use only clean, fresh, unleaded regular grade gasoline.

· Remove any trash from top of fuel tank drain area.

· Never use fuel that is stale or has been stored for a long period of time:

Warm Weather: Maximum 60 days.

Cold Weather: Maximum of 90 days.

· Fill fuel tank at the end of each day's operation. This helps to keep condensation out of fuel tank.

Oxygenated Fuel

Oxygenates (either ethanol or MTBE) are added to the gasoline. If you use the oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement.

The following are the EPA approved percentages of fuel oxygenates:

ETHANOL (Ethyl or Grain Alcohol): You may use gasoline containing up to 10 percent ethanol by volume.

MTBE (Methyl Tertiary Butyl Ether): You may use gasoline containing up to 15 percent MTBE by volume.

Filling Fuel Tank (Continued)

M60978

1. Remove fuel cap (A).

2. DO NOT fill tank to top; fuel can expand.

3. Fasten fuel cap.

4. Wipe off any spilled fuel.