Service

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 non road engine repair establishment or individual. Warranty repairs must be performed by an authorized John Deere dealer.

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.

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.

Avoid Fumes

c CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the engine.

Do not run an engine in an enclosed area without adequate ventilation.

· Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

· Allow fresh outside air into the work area to clear the exhaust fumes out.

Engine Oil

MIF

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

The following John Deere oils are preferred:

· TORQ-GARD SUPREME® (SAE 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)

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

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

· SAE 30-API Service Classification SC or higher

Checking Engine Oil

c CAUTION: Avoid injury! Before you check or add oil:

· Stop engine. Let it cool.


IMPORTANT: Avoid damage! Change oil after first 5 hours of operation.

1. Park mower on level surface and stop engine.

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2. Turn oil dipstick (A) 1/4 turn counterclockwise and remove from the filler tube.

3. Wipe dipstick off with a clean cloth.

4. Install dipstick. Turn oil dipstick (A) 1/4 turn clockwise and tighten.


IMPORTANT: Avoid damage! If oil level is below ADD mark, Do not run engine.

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5. Remove dipstick. Check oil level. Oil should be between ADD and FULL marks shown on dipstick, not above FULL mark.

6. Add oil if necessary.

7. 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.

· Engine may be hot. Use caution to avoid burns to the hands.

· Fuel is highly flammable. To prevent fuel spillage from occurring, drain fuel from tank before tipping mower to drain oil.


IMPORTANT: Avoid damage! · Change oil after first 5 hours of operation. · Change oil while engine is warm. · If mower is not operated 25 hours during the mowing season, change oil before storing mower. · Help prevent air cleaner damage and hard starting, turn mower onto the left side when servicing.

1. Park mower on a level surface.

2. Drain fuel from tank or run engine until fuel tank is empty or near empty.

3. Stop engine and disconnect spark plug wire.

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4. Turn oil dipstick (A) 1/4 turn counterclockwise and remove from the oil filler tube.

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5. Insert a plastic drain tube firmly inside oil filler tube opening (B).


IMPORTANT: Avoid damage! To help prevent air cleaner damage and hard starting: · Turn mower on its left side.

6. Place a drain pan on the left side of the mower.

7. Turn mower onto its left side.

8. Allow engine oil to drain from the dipstick filler tube location into the drain pan.

9. After oil has drained, return mower to an upright position.

10. Remove plastic drain tube.

11. Clean area around filler tube.


IMPORTANT: Avoid damage! Do not fill oil beyond FULL mark. Oil capacity for a dry engine is 590 ml (20 oz). You may not need to put in entire amount when you change oil. Check oil level with dipstick.

12. Add oil through dipstick filler tube. Check oil level and continue to add oil to FULL mark.

· To check oil level, wipe dipstick, install dipstick and tighten, then remove dipstick and read level.

13. Install and tighten dipstick.

14. Connect spark plug wire.

Checking and Cleaning Air Cleaner Element

1. Park machine safely. (See Parking Safely in the Safety Section.)

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine and components will be hot if the engine has been running. Allow the engine to cool before servicing.

2. Let engine cool.

3. Disconnect spark plug wire.

4. Clean dirt and debris from the air cleaner cover.

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5. Loosen screws (A), and remove cover.

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6. Inspect the foam precleaner (B) without removing it. If the foam precleaner is dirty:

a. Remove it from the filter carefully, leaving the paper element in the air cleaner housing.

b. Wash precleaner in a solution of warm water and liquid detergent.

c. Rinse precleaner thoroughly. Squeeze out excess water in a dry cloth until precleaner is completely dry.


IMPORTANT: Avoid damage! Dirt and debris can enter the engine through a damaged filter element. · Do not wash paper element. · Do not attempt to clean paper element by tapping against another object. · Do not use pressurized air to clean element. · Replace element only if it is very dirty, damaged or the seal is cracked.

7. Inspect the paper element without removing it. If the paper element is damaged or dirty, remove and replace it with a new element.

8. Clean air cleaner base carefully, preventing any dirt from falling into carburetor.

9. Install foam precleaner onto paper element and install into air cleaner base.

10. Close cover and tighten screws. Do not overtighten.

Cleaning and Gapping Spark Plug

c CAUTION: Avoid injury! Before you remove spark plug:

· Stop engine. Let engine cool.

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1. Disconnect spark plug wire (A). Remove spark 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: 0.51 mm (0.02 in.).

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

6. Connect wire.

Cleaning Engine Cooling Fins

c CAUTION: Avoid injury! Before you clean fins:

· Stop engine.

· Let it cool.

· Wear eye protection to guard against flying debris.


IMPORTANT: Avoid damage! Keep fins clean or engine may overheat.

1. Park mower on level surface and stop engine.

2. Let engine cool.

3. Disconnect spark plug wire.

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4. Clean fins (A) with brush, rag, or compressed air.

5. Blow compressed air under shroud (B).

Cleaning Drive Belt and Transmission Area (JS61, JS63 and JS63C)

c CAUTION: Avoid injury! Before you remove shield:

· Stop engine. Let it cool.

· Do not operate mower without belt shield in place.

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1. Remove hardware (A) and belt shield (B).

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2. Remove control cables (C) from belt shield notch (D).

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

4. Slide control cable into belt shield notch.

5. Install belt shield.

Checking and Replacing Drive Belt

c CAUTION: Avoid injury! Before removing belt shield:

· Prevent burns by allowing engine to cool.

· Disconnect spark plug wire.

· Wear protective gloves when service is performed within the mower blade area.

· Do not operate mower without shield.

1. Stop engine and disconnect spark plug wire.

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2. Remove hardware (A) and belt shield (B).

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3. Remove control cables (C) from belt shield notch (D).

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4. Inspect belt (E) for excessive wear or damage.

To Replace Drive Belt (JS61):

NOTE: On model JS61 only, the anti-rotation bracket must be removed prior to pushing the drive sheave forward to remove the drive belt.

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Picture Note: View is from underside of differential.

1. Remove cap screw (F) and anti-rotation bracket.

c CAUTION: Avoid injury! Wear protective eyewear when removing belt from drive sheave. Tension spring may come loose.

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2. Push drive sheave (G) forward to relieve spring tension on belt.

NOTE: Tension spring (H) may come loose when belt is removed.

3. Remove belt from drive sheave.

4. Move belt into underside of mower deck.

5. Turn mower onto its left side.

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6. Remove drive belt (E) from blade sheave (I).

7. Install new drive belt to blade sheave.

8. Lower mower.

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9. Insert belt through deck opening (J).

10. Install tension spring (K) if removed.

11. Check that drive belt is installed on engine sheave.

12. Push drive sheave (G) forward and install belt to sheave.

13. Install anti-rotation bracket and secure with cap screw.

14. Slide control cables into belt shield notch.

15. Install belt shield and connect spark plug wire.

To Replace Drive Belt (JS63 and JS63C):

c CAUTION: Avoid injury! Wear protective eyewear when removing belt from drive sheave. Tension spring may come loose.

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1. Push down on front of drive sheave (F) to relieve spring tension on belt (E) and remove drive belt.

NOTE: Tension spring (G) may come loose when drive belt is removed. Install after you replace belt.

2. Move belt through deck opening (H) into underside of mower deck.

3. Turn mower on its left side.

c CAUTION: Avoid injury! Mower blades are sharp. Always wear gloves when handling mower blades or working near blades.

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4. Remove drive belt (E) from blade sheave (I) and mower blade.

5. Install new drive belt over mower blade and onto blade sheave.

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6. Insert belt back through deck opening (H).

7. Return mower to upright position.

8. Install tension spring (G) if removed.

9. Push down on front of drive sheave (F) and install belt on sheave.

10. Slide control cables into belt shield notch.

11. Install drag flap and belt shield with screws.

Adjusting Transmission Cable (JS63 and JS63C)

c CAUTION: Avoid injury! Help prevent bodily injury. Before removing belt shield:

· Stop engine and wait for all moving parts to stop.

· Prevent burns by allowing engine to cool.

· Disconnect spark plug wire.

· Wear protective gloves when service is performed within the mower blade area.

· Do not operate mower without belt shield.

1. Park mower on level surface and stop engine.

2. Disconnect spark plug wire.

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3. Remove screws (A), belt shield (B), and drag flap (C).

c CAUTION: Avoid injury! Wear protective eye wear when removing belt from drive sheave. Tension spring may come loose.

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4. Remove control cables (D) from belt shield notch (E).

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5. Push down on front of drive sheave (F) to relieve spring tension on belt and remove drive belt (G).

6. Remove E-clip (H) and drive sheave.

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7. Measure the clutch spring length (I) in the relaxed position. Record this value.

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8. Engage the traction clutch lever (at handle bar) and measure the spring length in the extended position (J).

· The spring extension length (the difference between I and J measurements) must be 10 mm (0.390 in.).

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9. Use 8 mm wrench to loosen (but not remove) cable mount bracket capscrews (K) to adjust spring extension.

NOTE: For transmission clutch to operate properly, there must be a certain amount of spring pressure or the transmission will slip and not drive the wheels.

M96827

10. Slide bracket (L) distance needed to obtain 10 mm (0.390 in.) spring extension length (difference between length of relaxed spring and length of extended spring). Tighten capscrews.

11. Repeat steps 7-8 to verify 10 mm (0.390 in.) spring extension length.

12. Install cables through notch in belt shield.

13. Install drag flap and belt shield with screws.

14. Connect spark plug wire.

15. Start engine and check that transmission is operating properly.

NOTE: Make sure transmission immediately disengages when traction clutch lever is released.

16. If transmission does not disengage when lever is released, reduce spring extension length and check that transmission is operating properly.

Lubricating Drive Shaft Hub Bushings (JS61, JS63 and JS63C)

Service Interval: Lubricate drive shaft hub bushings every 25 hours or once a year.

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1. Remove hardware (A) and belt shield (B).

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2. Remove control cable (C) from belt shield notch (D).

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3. Tilt mower slightly to one side. Lubricate driveshaft hub bushing (E) with a few drops of light weight motor oil. Repeat procedure for other side.

4. Slide control cables (C) into belt shield notch (D).

5. Install belt shield.

Grease

MIF

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.

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

Lubricate Mower Axles

Front Axle (JS60H)

1. Tip mower to one side to elevate mower wheels slightly off the ground. Use a wood block to keep side of mower in a raised position.

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2. Insert screwdriver in slot (A) to remove plastic hubcap (B).

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3. Remove locknut (C).

4. Remove wheel from each axle.

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5. Apply a light coating of grease to axle (D).

6. Install wheel, hardware and hubcap.

7. Lower mower.

8. Repeat procedure on other side of mower.

Rear Axle (JS60H)

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Rear wheels are equipped with sealed bearings (A). Do not lubricate the rear axles.

Rear Axle (JS61, JS63, JS63C)

1. Tip mower to one side to raise mower wheels slightly off ground. Use wood blocks to keep side of mower raised.

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2. Remove hubcap and locknut (A).

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3. Apply a light coating of multi-purpose grease to each axle (B).

4. Install wheels, hardware and hubcaps.

5. Lower mower. Repeat procedure for other rear wheel.

Greasing Caster Wheel Spindle (JS63C)

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1. Grease caster wheel spindle hole (A) with multi-purpose grease.

2. Repeat for other castor wheel.

Cleaning Caster Wheel Pin (JS63C)

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1. Remove cover (A) on caster wheel.

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2. Clean dirt from around and on pin and spring (B).

3. Install cover.

Servicing Mower Blades

c CAUTION: Avoid injury! Service blade safely.

· Disconnect spark plug wire to prevent accidental startup.

· Mower blades are sharp. Always wear gloves when handling or working near blades.


IMPORTANT: Avoid damage! To help prevent air cleaner damage and hard starting: · Turn mower on its left side.

NOTE: Sharpened edges on blade tips must face upward when installing blade.

Removing Mower Blades

M87085

1. Remove bolt (A), washer and blade.

2. Inspect blade; sharpen, balance or replace blade as necessary.

Installing Mower Blades

1. Lubricate bolt threads lightly with a general purpose grease or oil to prevent rusting and seizing.

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

Sharpening Blades

c CAUTION: Avoid injury! Mower blades are dangerous!

· Always wear gloves while working on blades.

· Always wear safety eye protection when grinding.

· Sharpen blade with grinder, hand file or electric blade sharpener

MIF

· Keep original bevel (A) when you grind.

· Blade should have 0.40 mm (1/64 in.) cutting edge (B).

· Balance blades before installing.

Balancing Blades

c CAUTION: Avoid injury! Mower blades are sharp. Always wear gloves when handling mower blades or working near blades.

1. Remove and clean blade.

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2. Put blade (A) on a nail in vise. Turn blade to horizontal position.

3. Check balance. If blade is not balanced, the heavy end of blade will drop.

4. Grind bevel of heavy end. Do not change bevel.

5. Install blade, washer, and bolt. Tighten bolt to 75 N·m (55 lb-ft).

Cleaning Fuel Cap Vents

c CAUTION: Avoid injury! Before you remove cap:

· Stop engine. Let it cool.

· Do not smoke.

1. Remove cap.

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2. Check two vents (A) under metal ring and vent in top, center of cap.

3. Clean cap and vents in nonflammable solvent. Let cap dry.

4. Install the cap.

Filling Fuel Tank

c CAUTION: Avoid injury! Fuel vapors are explosive and flammable:

· Shut engine off before filling fuel tank.

· Do not smoke while handling fuel.

· Keep fuel away from flames or sparks

· Fill fuel tank outdoors or in well ventilated area.

· Clean up spilled fuel immediately.

· Use clean approved non-metal container to prevent static electric discharge.

· Use clean approved plastic funnel without screen or filter to prevent static electric discharge.


IMPORTANT: Avoid damage! Dirt and water in fuel can cause engine damage: · Clean dirt and debris from the fuel tank opening. · Use clean, fresh, stabilized fuel. · Fill the fuel tank at the end of each day's operation to keep condensation out of the fuel tank. · Use a non-metallic funnel with a plastic mesh strainer when filling the fuel tank or container.

Use regular grade 87 octane unleaded fuel.

Add John Deere fuel stabilizer to fuel before using it in your machine to prevent engine damage due to stale fuel. Follow directions on stabilizer container.

1. Stop engine. If engine is hot let it cool several minutes before you add fuel.

2. Remove grass clippings and other trash from tank area.

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3. Remove fuel cap (A).

4. Fill tank with fresh fuel only to bottom of filler neck.

5. Install fuel cap.

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