Introduction
Safety Signs
Controls
Operating Machine
Replacement Parts
Service Machine Safely
Service Interval Chart
Service Engine
Service Transmission
Hydrostatic Transmission and Hydraulic Oil
Replacing Transmission Drive Belt
Adjusting Transmission Drive Belt Tension
Adjust Speed Control Neutral Switch Position
Checking Transmission Hydraulic Oil Levels
Checking the Hydrostatic Transmissions
Service-Brakes and Drive Wheels
Service Mower
Service Electrical
Service Miscellaneous
Troubleshooting
Storing Machine
Assembly
Specifications
Warranty
John Deere Service Literature
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Service Transmission
Hydrostatic Transmission and Hydraulic Oil
Use the following oil viscosity based on the air temperature range. Operating outside of the recommended oil air temperature range may cause premature hydrostatic transmission failure.
The following John Deere oils are PREFERRED:
Replacing Transmission Drive Belt
c CAUTION: Avoid injury! Use caution when removing and installing a replacement belt. Possible pinch point between idler pulley and PTO clutch sheave.
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2. Remove the clutch to mower deck drive belt (A). (Refer to removal procedure in the Service-Mower section.)
3. Block mower deck in a raised position while attached to the power unit.
4. Remove six bolts (B) securing the mower deck to the power unit.
5. Separate mower deck and power unit.
6. Lower power unit as shown for easier access and serviceability.
7. Remove belt adjustment hardware (C).
8. Loosen belt tensioning hardware (D) and tension arm assembly (E).
9. Remove transmission belt (F) from transmission sheaves and clutch.
NOTE: Belt tensioning hardware will travel within adjustment slot (G) when tightened.
11. Tighten belt tensioning hardware (D).
12. Install belt adjustment hardware (C). Check drive belt tension and adjust if necessary. (See Adjusting Transmission Drive Belt in this section.)
13. Raise and install power unit to the mower deck.
14. Install the clutch to mower deck drive belt.
15. Install mower deck shield.
Adjusting Transmission Drive Belt Tension
Check transmission drive belt adjustment:
· The recommended belt adjustment setting is accomplished by measuring distance (A) between the back of the washer (B) and the front of the power unit.
· As the drive belt stretches, the distance between washer (B) and the power unit will increase.
· When the distance between washer (B) and the power unit reaches 17 mm (.67 in.) or greater, an adjustment is needed.
· Turn adjustment nut (C) right to increase or left to decrease drive belt tension.
· Adjust to 14-16 mm (.55-.63 in.).
· If necessary, see service label on left side of mower deck frame
Adjusting Neutral Position
Transmission Neutral Adjustment
The speed control lever neutral position is adjustable. Check speed control neutral adjustment:
· Move throttle to the "r" position.
· Pull up steering control levers and engage neutral locks.
· Push speed control lever forward 25 mm (1 in.).
· If drive wheels begin to creep, an adjustment is required.
NOTE: Free-Wheeling levers (A) must be unlatched into position shown prior to making an adjustment.
1. Raise rear of mower so drive wheels are off the ground and support with jack stands.
2. Release brake by loosening fine adjustment jam nut (B).
3. Remove brake cable from slot.
4. Remove spring pin (C) from each short left and right reverse rod (D). Disconnect reverse rods from hand controls.
5. Turn the tracking adjustment knob (E) fully right until it stops.
6. Turn tracking adjustment knob left two full revolutions.
7. Pull speed control lever (F) back to the "Z" position.
8. Loosen both jam nuts (G) on each long control rod (H).
9. Cycle speed control lever fully forward and back 2 times.
10. Push one operator presence bail into a down position. Secure with tape or a rubber band.
12. Set throttle to the "r" position.
13. Run engine for approximately 5 minutes to warm hydraulic fluid.
14. Adjust turnbuckles (I) until power unit drive wheels turn slightly in reverse.
15. Cycle speed control lever fully forward and back 2 times.
· Cycle speed control lever fully forward and back 2 times.
· Check turning motion of the drive wheels.
18. Set throttle lever to the "t" position.
19. Continue process by adjusting the thumb latch neutral position.
Thumb Latch Neutral Adjustment
IMPORTANT: Avoid damage! Transmission Neutral Adjustment sequence must be completed prior to doing this adjustment. |
1. Attach short left and right reverse rods (D) to hand controls with spring pin (C).
2. Push speed control lever to a full forward position.
3. Cycle steering control levers up and down 2 times.
4. Pull up steering control levers and engage both neutral locks.
5. Set throttle lever to the "r" position. Drive wheels should be turning slightly in reverse.
6. Cycle each steering control lever up and down 2 times and engage the neutral locks. Check drive wheel rotation. Wheels should turn slightly in reverse. If not, continue with the adjustment procedure.
7. Repeat steps 1-6 until both drive wheels just start to turn in reverse.
· To increase reverse wheel speed, turn reverse rod end (J) right to shorten.
· To decrease reverse wheel speed, turn reverse rod end (J) left to lengthen.
8. Set throttle lever to the "t" position.
9. Release operator presence bail.
11. Install brake cable. Tighten jam nut (B).
12. Adjust the brakes. (See Adjust Park Brake in the Service-Steering And Brakes section.)
Adjust Speed Control Neutral Switch Position
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c CAUTION: Avoid injury! Exhaust fumes can cause sickness or death. Work in a well ventilated area.
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The position of the machine neutral safety switch (A) is adjustable if necessary.
Test Neutral Switch
· Move the speed control lever to the "Z" position.
· With operator presence bails up, slowly push the speed control lever forward a distance of 16 mm 3 mm (.63 .12 in.).
· If properly adjusted, engine should kill before the wheels start turning.
Adjust Neutral Switch Position
1. Raise rear of mower so drive wheels are off the ground and support with jack stands.
2. Move the speed control lever to the "Z" position. Operator presence bails must be released.
4. Loosen hardware (B) securing neutral safety switch to the left side of the console.
5. Push switch down to the bottom of slot to the point where the switch hardware (B) can slide in the adjustment slot with resistance.
6. Move speed control lever forward until gap between lever and rear of console slot is 16mm (.63 in.).
7. With one hand, tap lightly up on the bottom of switch hardware (B). Have other hand ready to activate operator presence.
8. Move the switch until the engine begins to kill. Activate the operator presence to keep the engine running.
9. Continue to adjust and test the safety switch position until the machine just continues to run without killing the engine with the operator presence released.
10. Carefully tighten the safety switch hardware (B).
11. Pull speed control lever back to the "Z" position.
12. With operator presence released, slowly move the speed control lever forward until the machine begins to kill.
13. Measure gap between speed control lever and rear of console slot. Adjustment is complete if gap measurement is 16mm 3 mm (.63 .12 in.).
14. If further adjustment is required, repeat steps 4-13.
15. Stop engine. Lower machine.
Checking Transmission Hydraulic Oil Levels
Service Interval: Visually check transmission hydraulic oil levels every 100 hours of operation. Hydraulic oil reservoirs (A) exist for each of the two machine transmissions.
NOTE: Check transmission oil levels when oil is cold.
1. Park mower on a level surface. Stop engine.
2. Check each reservoir (A) for the appropriate amount of oil. Oil levels must be maintained between range lines (B).
· If oil is above the lower reservoir fill line, DO NOT open the cap.
· Carefully clean area around reservoir cap.
· Add oil to midpoint of reservoir range lines (B). (See Hydrostatic Transmission and Hydraulic Oil in this section for the proper application.)
· Carefully replace cap and rubber bladder. Rubber bladder must be centered in cap and reservoir.
· Oil levels must be maintained between the high and low range lines (B).
Checking the Hydrostatic Transmissions
The two transmissions in this machine are sealed components. No maintenance is required on these transmissions. If any transmission problems should develop, contact your John Deere Dealer.