Service Engine

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

TS1412

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

The following oil is preferred:

· John Deere PLUS-4®

Other oils may be used if they meet one the following:

· API Service Classification SG

· API Service Classification SF

· CCMC Specification G4

Oils meeting Military Specification MIL-L-46167B may be used as arctic oils.

Checking Engine Oil Level

1. Park Front Mower on a level surface.

2. Check engine oil when oil is cold.

3. Lift hood.

M39490

4. Remove dipstick (A). Wipe dipstick with a clean rag.

5. Install dipstick.

M72321

6. Remove dipstick. Check oil level on dipstick.

7. Oil must be between FULL mark "H" and LOW mark "L" on dipstick.

8. If oil level is low, remove oil filler cap.


IMPORTANT: Avoid damage! If oil level is at or below "L" mark, DO NOT run engine.

M38327

9. Add oil to bring oil level no higher then the "F" mark on dipstick. (See ENGINE OIL in this section for correct oil.)

10. Install dipstick.

11. Install and tighten oil filler cap.

12. Lower hood.

Changing Engine Oil And Filter

1. Park Front Mower on a level surface.

2. Run engine a few minutes to warm oil.

3. STOP engine.

4. Remove key.

5. ENGAGE service-park brake.

M38337

6. Remove drain plug. Drain oil in pan.

7. While oil is draining, change oil filter.

8. Lift hood.

M39488

9. Put a drain pan under filter (A).

10. Remove filter using a filter wrench. Turn filter counterclockwise.

11. Apply a film of clean engine oil on seal of new filter.

12. Install filter. Turn filter until seal contacts mounting surface. Then turn filter BY HAND 1/2 turn more.

13. Install and tighten drain plug.

14. Remove filler cap. Add approximately 2.3 L (2.5 qt) of oil. (See Engine Oils in this section for correct oil.)

M39490

15. Remove dipstick (B) to check oil level. Add oil only to mark "H" on dipstick.

16. Install filler cap.

M72321

NOTE: Mark "L" is low oil level on dipstick.

17. Start engine and run at slow speed for 2 minutes. Check for leaks around filter and drain plug.

18. STOP engine. Check oil level.

19. Install dipstick. Lower hood.

Checking Air Restriction Indicator

· DO NOT replace primary element unless air restriction indicator shows 635 mm (25 in) vacuum.

· DO NOT replace secondary element unless air restriction indicator shows 500 mm (20 in) vacuum after primary element is replaced.

M62860

· It is normal for air restriction indicator (A) to show at least 380 mm (15 in) vacuum after primary element is replaced.

Cleaning Air Intake Screen And Radiator

1. Raise hood.

M38329

2. Loosen three wing nuts (A) to remove screen.

M38330

3. Clean screen with a brush or compressed air.

4. Clean air intake screen and radiator cooling fins using compressed air or a brush.

5. Install screen.

M38667

6. Tighten nuts.

Service Cooling System Safely

c CAUTION: Avoid injury! Explosive release of fluids from pressurized cooling system can cause serious burns:

· Shut off engine.

· Only remove filler cap when radiator is cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

Engine Coolant

Use ethylene glycol base coolant. These coolants usually have labels stating "For Automobile and Light Duty Service." These products are also often labeled for use in aluminum engines. Check container label before using.


IMPORTANT: Avoid damage! To prevent engine damage, DO NOT use pure antifreeze or more than 50% antifreeze in the cooling system. DO NOT mix or add any other type additives to the cooling system.

Mix approximately 50 percent antifreeze with 50 percent distilled or deionized water. This mixture will provide freeze protection to -37 degrees C (-34 degrees F).

Certain geographical areas may require lower temperature protection. See the label on your antifreeze container or consult your John Deere dealer to obtain the latest information and recommendations.

The recommended antifreeze provides:

· Adequate heat transfer.

· Corrosion-resistant environment within the cooling system.

· Compatibility with cooling system hose and seal material.

· Protection during cold and hot weather operations.

Checking Coolant Level

c CAUTION: Avoid injury! To avoid personal injury, do not remove radiator cap unless the engine is cool.

· Wrap hand with a rag.

· Turn cap slowly to the stop.

· Release all pressure before you remove cap.


IMPORTANT: Avoid damage! To prevent engine damage: · DO NOT operate engine without coolant. · DO NOT pour coolant into the radiator when the engine is hot. · To prevent engine overheating, never exceed more than 50 percent antifreeze in cooling system.

1. Lift hood.

M39491

2. Coolant level must be 25-51 mm (1-2 in) in recovery tank (A).

3. If coolant is low, remove coolant recovery tank cap.

4. Add 50 percent ethylene glycol (without stop-leak additive) antifreeze and 50 percent water to proper level.

5. Install and tighten coolant recovery tank cap.

6. Clean debris from air intake screen and radiator. (See Cleaning Air Intake Screen And Radiator in this section.)

7. Check condition of hoses. Check for leaks or loose connections.

Draining Cooling System

c CAUTION: Avoid injury! To prevent personal injury:

· Do not remove radiator cap unless engine is cool.

· Wrap hand with a rag.

· Turn cap slowly to the stop.

· Release call pressure before you remove cap.

1. STOP engine. Let engine cool.

2. Lift hood.

3. Slowly remove radiator cap.

M38346

4. Open radiator petcock (A). Drain coolant into a bucket.

M38347

5. Loosen block drain (B) one or two turns and drain coolant from engine block.

6. After all coolant has drained, close radiator petcock and tighten block drain.

7. Flush cooling system. (See Flushing Cooling System this section.)

Flushing Cooling System

c CAUTION: Avoid injury! Explosive release of fluids from pressurized cooling system can cause serious burns:

· Shut off engine.

· Only remove filler cap when cool enough to touch with bare hands.

· Slowly loosen cap to first stop to relieve all pressure before removing completely.


IMPORTANT: Avoid damage! To prevent engine damage, DO NOT pour water into a hot engine. DO NOT operate engine without coolant.

M39493

1. Fill cooling system with clean water and John Deere Cooling System Cleaner, or John Deere Cooling System Quick Flush or an equivalent. Follow directions on can.

2. Install and tighten radiator cap.

3. Start and run engine until it reaches operating temperature.

4. Drain cooling system immediately before rust and dirt settle.

5. Close radiator petcock.

M39491

6. Remove and clean recover tank (A).

7. Install tank after cleaning.

8. Fill cooling system. (See Filling Cooling System this section.)

Filling Cooling System


IMPORTANT: Avoid damage! To prevent engine damage, DO NOT use straight antifreeze or more than 50% antifreeze in the cooling system. DO NOT mix or add any other type additives to the cooling system. Cooling system capacity is 3.5 L (3.8 U.S. qt.)

1. For cold weather:

· Use a solution of only low silicate ethylene glycol antifreeze (without a stop-leak additive) and clean, soft water.

· A chart on the antifreeze container tells how much antifreeze to use for freeze protection needed in your area.

2. When operating engine in extremely cold temperatures, see your John Deere dealer for information on arctic operation.

3. For temperatures above freezing, fill cooling system with clean, soft water and John Deere Engine Coolant Conditioner.

4. John Deere Cooling System Sealer or its equivalent may be added to the radiator to seal leaks. Do not use any other additives in the cooling system.

5. Install and tighten radiator cap.

6. Run engine until it reaches operating temperature.

7. STOP engine.

8. After engine cools, check coolant level in recovery tank. Level should be approximately 25-51 mm (1-2 in).

9. Remove cap to add coolant, if necessary.

10. Check condition of coolant system hoses. Install new hoses, if necessary.

11. Tighten hose clamps, if necessary.

Adjusting Carburetor

NOTE: The 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 is in neutral ("N") and the PTO switch is in the OFF position. 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.

Replacing Primary Element


IMPORTANT: Avoid damage! DO NOT clean primary element. · DO NOT replace primary element unless air restriction indicator shows 635mm (25 in).

1. STOP engine and lift hood.

M62859

2. Remove wing nut (A) and cover (B).

M62860

3. Remove and discard wing nut and washer (C).

4. Remove and discard old primary element (D).

5. Wipe dirt from inside of cannister with a soft cloth.

6. Install new primary element.

7. Install new wing nut and washer.

8. Tighten wing nut.

9. Install old cover with washer and wing nut.

10. Tighten wing nut.

11. Depress reset button (E) on air restriction indicator (F) and then release to reset.

12. Start engine and allow it to run a minute at maximum speed.

13. STOP engine and check air restriction indicator. If indicator shows 500 mm (20 in) or more vacuum, replace secondary element.

Replacing Secondary Element


IMPORTANT: Avoid damage! DO NOT clean secondary element. · Replace secondary element only every third primary element change. · Every two years, OR · When air restriction indicator shows 500 mm (20 in) vacuum after replacing primary element.

1. Remove primary element. (See Replacing Primary Element in this section.)

M62861

2. Remove wing nut (A) and secondary element (B).

3. Install new secondary element.

4. Install washer and wing nut.

5. Tighten wing nut


IMPORTANT: Avoid damage! It is normal for air restriction indicator to show at least 380 mm (15 in) vacuum, after primary element is replaced.

M62859

6. Install new primary element. (See Replacing Primary Element this section.)

7. Install washer and wing nut.

8. Tighten wing nut.

9. Install cover (C).

10. Install wing nut (D).

11. Tighten wing nut.

12. Close hood.

Cleaning And Gapping Spark Plugs

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

· Stop engine.

· Wait until engine is cool.

1. Lift hood.

2. Disconnect spark plug wires from spark plugs.

M40535

3. Remove spark plugs.

4. Clean spark plugs carefully with a wire brush.

5. Inspect spark plugs for:

· Cracked porcelain.

· Pitted or damaged electrodes.

· Other wear or damage.

NOTE: In Canada, replace spark plugs with resistor-type plugs only.

6. Replace spark plugs as necessary.

M33906

7. Check plug gap with a wire feeler gauge.

8. Gap must be 0.76 mm ( 0.030 in.).

9. To change gap, move the outer electrode toward the center electrode.

10. Install and tighten spark plugs to 20 N·m (15 lb-ft).

11. Connect spark plug wires.

12. Lower hood.

Changing Fuel Filter

c CAUTION: Avoid injury! Keep cigarettes, sparks, and flames away from fuel system. Make sure engine is cool to the touch.

1. Stop engine.

2. Remove key.

3. Lift hood.

NOTE: Some models fuel filter is located as shown in photo. Other models fuel filter is located under seat.

M40536

4. Loosen and slide hose clamps (A) away from filter (B).

5. Remove filter from hoses.

6. Remove screw (C) to remove filter.

7. Install new filter with screw and connect hoses to filter.

8. Slide clamps against filter and tighten clamps.

Checking PTO Belt Tension

M40157

1. The end of plastic gauge (A) must be aligned with ends of springs (B) for proper belt tension.

2. Loosen nuts (C). Tighten nuts (D) equally to get proper belt tension.

3. Tighten nuts (C) against nuts (D).

4. Check PTO belts for wear damage; replace if necessary.

Grease

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

TS1417

The following greases are preferred:

· John Deere MOLY HIGH TEMPERATURE EP GREASE

· John Deere HIGH TEMPERATURE EP GREASE

· John Deere GREASE-GARDTM

Other greases may be used if they meet one of the following:

· SAE Multipurpose EP Grease with a maximum of 5% molybdenum disulfide

· SAE Multipurpose EP Grease

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

Lubricating Engine Driveshaft

M38335

Lubricate U-Joint fitting (A) with one or two shots of John Deere Multipurpose Grease or equivalent.

Lubricating PTO Shaft Bearing


IMPORTANT: Avoid damage! Check Attachment Operator Manual for servicing requirements and service at the same time as servicing the mower.

M38664

Lubricate fitting (A) on PTO shaft bearing with one or two shots of John Deere Multipurpose Grease or equivalent.