Service Engine
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.
Avoid Fumes
Engine Oil
Use oil viscosity based on the expected air temperature range during the period between oil changes.
The following oils are preferred:
The following oils are also recommended, based on their specified temperature range:
Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications:
· API Service Classification SF, SG, SH or SJ
Checking Engine Oil Level
NOTE: Check oil twice a day if you run engine over 4 hours in a day.
Make sure engine is cold when checking engine oil level.
1. Park machine safely. (See Parking Safely in the SAFETY section.)
3. Clean area around dipstick prior to removing it.
4. Remove dipstick (A). Wipe it clean.
6. Remove dipstick and check oil level. Oil level should be between "low" (B) and "high" (C) marks on dipstick.
· If oil is low, add oil to bring oil level no higher than the "H" high mark on dipstick.
· If oil level is above the "H" high mark, drain to proper level.
IMPORTANT: Avoid damage! To prevent extensive engine wear or damage, always maintain the proper engine oil level. Never operate the engine with the oil level below the add mark or over the full mark. |
Changing Engine Oil and Filter
IMPORTANT: Avoid damage! Change the oil more often if the machine is used in extreme conditions: |
2. Park machine safely. (See Parking Safely in the SAFETY section.)
3. Connect an appropriate size hose to drain tube (A) and place container under hose.
5. Allow oil to drain into an oil drain pan.
6. After oil drains, close drain valve and remove hose.
7. Connect an appropriate size drain hose to bottom side of funnel (C) and route through hole in frame.
8. Put container under drain hose.
9. Remove oil filter (D). Turn filter counterclockwise to remove.
10. Apply a film of clean engine oil on gasket of new filter.
11. Install filter. Turn filter clockwise until gasket makes contact with mounting surface. Tighten 1/2 to 3/4 turn after gasket contact. Remove drain hose.
12. Clean area around the oil fill cap (E) and oil dipstick tube (F).
13. Unscrew and remove the oil fill cap.
14. Add approximately 2.0 L (2.1 qt) of oil.
15. Install and tighten oil fill cap.
16. Start engine and run at slow idle for approximately two minutes. Check for leaks around filter and drain plug.
· Remove and wipe oil dipstick clean with a rag.
· Remove dipstick and check oil level. Oil level must be between the "low" (G) and "high" (H) marks on dipstick. Add oil if needed.
Cleaning Pump Drive Belt Compartment
c CAUTION: Avoid injury! Compressed air can cause debris to fly a long distance.
· Clear work area of bystanders. · Wear eye protection when using compressed air for cleaning purposes. |
1. Park machine safely. (See Parking Safely in the SAFETY section.)
3. Clear any debris from belt compartment area.
Cleaning Radiator Screens and Fins
|
c CAUTION: Avoid injury! Compressed air can cause debris to fly a long distance.
· Clear work area of bystanders. · Wear eye protection when using compressed air for cleaning purposes. |
1. Park machine safely. (See Parking Safely in the SAFETY section.)
3. Lift and secure operator seat in the raised position.
4. Lift primary screen (A) to remove and clean.
5. Lift secondary screen (B) to remove and clean.
6. Remove dirt and debris from radiator and radiator fins (C).
7. Install secondary and primary screens.
Cleaning Air Intake Screen and Pump Drive Belt Compartment
|
c CAUTION: Avoid injury! Compressed air can cause debris to fly a long distance.
· Clear work area of bystanders. · Wear eye protection when using compressed air for cleaning purposes. |
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Lift and secure operator seat in the raised position.
3. Remove grass and debris from pump drive belt compartment (A).
4. Clean air intake screen (B) with a rag, brush or compressed air.
Checking and Cleaning Canister Style Air Cleaner Elements
IMPORTANT: Avoid damage! Dirt and debris can enter the engine when removing the air cleaner elements. Service elements only at prescribed intervals. |
Servicing Primary Air Cleaner Element
1. Park the machine safely. (See Park Safely in the SAFETY section.)
3. Release latches (A) and remove air cleaner canister cover (B).
NOTE: Inspect secondary air cleaner element. Replace if necessary.
4. Remove and discard primary element (C). Replace with new primary element.
5. Install air cleaner canister cover with rubber dust unloading valve pointing downward.
Servicing Secondary Air Cleaner Element
1. Remove primary air cleaner element.
2. Remove and discard secondary air cleaner element (D). Install new secondary element.
3. Install primary air cleaner element.
4. Install air cleaner canister cover.
Checking Spark Plugs
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Clean area around both spark plugs.
3. Disconnect the spark plug wire (A) from each plug.
4. Remove and inspect spark plugs:
· Clean each plug and check for damage, replace if necessary.
· If plugs are in good condition, check gap.
5. Check and adjust spark plug gap (B) to 0.75 mm (0.030 in.).
· Tighten to 22 N·m (16 ft-lb).
7. Install both spark plug wires.
Removing and Installing Engine Cover
1. Remove radiator primary screen.
2. Remove locking nut (A) retaining engine cover to the bottom of the air filter housing.
3. Remove two locking nuts (B) retaining the cover to the radiator support.
4. Spread front of cover to clear the mounting studs. Roll engine cover rearward and lift from machine. Clean debris from engine area or repair as necessary.
5. Installation is done in the reverse of removal.
· Do not overtighten the retaining nuts.
Adjusting Carburetor
NOTE: Carburetor is calibrated by the engine manufacturer and is not adjustable.
If engine is operated at altitudes above 1829 m (6,000 ft), some carburetors may require a special high altitude main jet. See your authorized dealer.
If engine is hard to start or runs rough, check the TROUBLESHOOTING section of this manual.
Possible engine surging will occur at high throttle with transmission in "N" neutral and mower engagement lever disengaged. This is a normal condition due to the emission control system.
After performing the checks in the troubleshooting section and your engine is still not performing correctly, contact your authorized dealer.
Replacing Fuel Filter
IMPORTANT: Avoid damage! Incorrect installation of fuel filter may cause engine damage. Install the filter with the arrow pointing in the direction of fuel flow for proper operation. |
NOTE: Change filter when fuel level is low.
1. Park machine safely. (See Parking Safely in the SAFETY section.)
Picture Note: Model 797 Shown. 777 is Similar.
3. Slide hose clamps (A) away from fuel filter (B).
4. Place a drain pan under hoses to catch any fuel that may be left in the hoses.
5. Disconnect hoses from fuel filter.
· Make sure fuel filter is installed with arrow pointing in direction of fuel flow.
7. Connect hoses to new fuel filter.
Service Cooling System Safely
Recommended Engine Coolant
The following John Deere coolants are preferred:
· COOL-GARD® PRE-DILUTED SUMMER COOLANT (TY16036).
· COOL-GARD® CONCENTRATED SUMMER COOLANT (TY16034).
If neither of the recommended coolants is available, use a glycol base coolant that meets the following specification:
Check container label before using to be sure it has the appropriate specifications for your machine. Use coolant with conditioner or add conditioner to coolant before using.
If using concentrate, mix approximately 50 percent antifreeze with 50 percent distilled or deionized water before adding to cooling system. 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. Never exceed the maximum dilution rate for the coolant you are using. Exceeding the maximum rate will greatly reduce the coolant effectiveness.
Checking Radiator Hoses and Clamps
1. Park the machine safely. (See Parking Safely in the Safety section.)
3. Check hoses for cracks or damage.
5. Replace hoses and clamps as necessary.
Checking Coolant Level
1. Park machine safely. (See Parking Safely in the SAFETY section.)
3. Check recovery tank (A) coolant level:
· Coolant level should be at or slightly above the lower line (B) with the coolant cold.
4. Remove recovery tank cap (C), if necessary, to add coolant.
5. Add pre-diluted coolant or specified ratio of antifreeze and water.
6. Install and tighten recovery tank cap.
Servicing Cooling System
Draining Cooling System
1. Park machine safely. (See Parking Safely in the SAFETY section.)
3. Remove radiator primary screen (A).
4. Slowly open radiator cap (B) to the first stop to release all pressure.
5. Close radiator cap tightly.
6. Place a drain pan with at least 3 L (3.17 qt) capacity under the engine coolant drain (C). Remove engine coolant drain plug from thermostat housing.
7. When coolant has drained from the recovery tank, remove radiator cap.
8. After all coolant has drained, install engine coolant drain plug.
Flushing Cooling System
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 the can.
2. Install and tighten radiator cap.
3. Start and run engine until it reaches operating temperature.
5. Slowly loosen radiator cap to the first stop to release pressure. Remove radiator cap ONLY after all pressure has been released.
6. Remove engine coolant drain plug.
7. Drain cooling system immediately before rust and dirt settles.
8. Install drain plug. Fill system with clean water and repeat steps 3-7.
9. Install engine coolant drain plug and fill cooling system with correct coolant.
Filling Cooling System
NOTE: John Deere COOL-GARD coolant is recommended when adding new coolant to the cooling system.
Follow the directions on the container for correct mixture ratio.
2. Fill cooling system. Cooling system capacity is 2.7 L (2.9 qt).
3. Install and tighten radiator cap.
4. Run engine until it reaches operating temperature.
6. Check recovery tank coolant level:
· Coolant level should be at the lower line (A) on the recovery tank when the engine is cold.
7. Remove cap (B) from recovery tank to add coolant if necessary.