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 customer’s 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

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 oils are preferred:

• John Deere TURF-GARD®

• John Deere PLUS-4®

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


IMPORTANT: Avoid damage! Failure to check the oil level regularly could lead to serious engine problems if oil level is out of the operating range: • Check oil level before operating. • Check oil level when the engine is cold and not running. • Keep oil level between the dipstick marks. • Shut off engine before adding oil.

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.)

2. Allow engine to cool.

3. Clean area around dipstick prior to removing it.

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4. Remove the oil fill cap / dipstick (A); wipe with clean cloth to remove oil.

5. Insert the oil fill cap / dipstick into the oil fill tube and thread the dipstick in completely.

6. Remove oil fill cap / dipstick and check oil level; oil level should be between the ADD and FULL marks

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• If oil is low, add oil to bring oil level no higher than the FULL mark on dipstick.

• If oil level is above the FULL mark, drain to proper level.

7. Install and tighten oil fill cap / dipstick.

Changing Engine Oil and Filter

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Keep hands and body away from hot surfaces when servicing or working near the engine and components.


IMPORTANT: Avoid damage! Change the oil more often if the vehicle is used in extreme conditions: • Extremely dusty conditions. • Frequent slow or low-speed operation. • Frequent short trips.

1. Run engine to warm oil.

2. Park machine safely on a level surface. (See Parking Safely in the SAFETY section.)

3. Put container under oil drain area.

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4. Remove plug (A) and allow oil to drain.

5. After oil drains, remove oil filter and discard.

6. Install plug.

7. Apply a film of clean engine oil on gasket of new filter.

8. Install filter. Turn filter clockwise until gasket makes contact with mounting surface. Tighten 1/2 to 3/4 turn after gasket contact.

9. Clean area around the oil dipstick.

10. Unscrew and remove the dipstick.

11. Add oil.

12. Install and tighten dipstick.

13. Start engine and run at slow throttle for approximately two minutes. Check for leaks around filter and drain plug.

14. Stop engine.

15. Check oil level:

• Remove and wipe dipstick clean with a rag.

• Install dipstick but do not screw onto threads.

• Remove dipstick. Check oil level on dipstick; oil level should be between the ADD and FULL marks. Add oil if needed.

16. Install dipstick and tighten.

Cleaning Engine Air Intake Screen and Fan

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.

• Reduce compressed air pressure to 210 kPa (30 psi).


IMPORTANT: Avoid damage! The engine is air-cooled and requires a large amount of air intake when running. Reduced air intake can cause overheating: • Keep air intake screen and cooling fins clean. • Keep covers and screens in place.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

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2. Remove outer air intake screen (A) and clean with a rag, brush or compressed air.

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3. Clean inner screen (B) with a rag, brush or compressed air.

4. Clean fan with rag, brush or compressed air.

5. Install outer screen.

Checking and Replacing Air Cleaner Element


IMPORTANT: Avoid damage! Dirt and debris can enter the engine when removing the air cleaner elements. Service elements only at prescribed intervals.

1. Park the machine safely. (See Parking Safely in the SAFETY section.)

2. Clean dirt and debris from air cleaner cover.

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3. Open air cleaner cover (A) and release latch (B).


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.

4. Inspect foam precleaner (C) without removing it.

5. If the foam precleaner is dirty:

• Remove filter carefully.

• Wash precleaner in warm water with detergent.

• Rinse precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water, and allow precleaner to air dry.

• Saturate the precleaner with new engine oil, Squeeze out all excess oil.

6. Remove and inspect paper filter element (D). Replace with new element only if damaged or dirty. If dirty:

• Remove foam precleaner and discard the paper filter element.

• Install foam precleaner onto new paper filter element.

7. Clean area around carburetor very carefully, preventing any dirt or debris from falling into it.

8. Install foam precleaner onto paper filter element.

9. Close air cleaner cover.

Checking Spark Plugs

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


IMPORTANT: Avoid damage! Do not clean spark plug area with spark plug removed.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Clean area around both spark plugs.

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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.

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5. Check and adjust spark plug gap (B) to 0.76 mm (0.030 in.).

6. Install spark plugs.

• Tighten to 22 N•m (16 ft-lb).

7. Install both spark plug wires.

Cleaning Engine Area


IMPORTANT: Avoid damage! To ensure proper cooling, keep the engine cooling fins and surrounding area clean at all times. Operating the engine with obstructed cooling fins could cause engine damage due to overheating.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

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2. Remove two rear hex head screws (A).

3. Remove fuel pump mounting hardware (B) but do not disconnect fuel lines.

4. Raise operator seat.

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5. Remove two hex head screws (C) from the back of engine and two from the side (D).

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6. Lift shroud from engine.

7. Clean debris from:

• Fan area (C).

• Engine cooling fins.

• Cylinder head cooling fins (D).

• Area between engine and machine frame.

8. Install shroud and hardware.

9. Lower seat.

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

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

• Do not smoke while handling fuel.

• Keep fuel away from flames or sparks.

• Shut off engine before servicing.

• Cool engine before servicing.

• Work in a well-ventilated area.

• Clean up spilled fuel immediately.


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 (towards the engine) for proper operation.

NOTE: Change fuel filter when fuel is low.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Allow engine to cool.

3. Place a drain pan under hoses to catch any fuel that may be left in the hoses.

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4. Disconnect fuel hose (A) from the outlet side of the fuel filter (B), and drain gasoline into a properly marked container.

5. Remove the fuel filter from the inlet fuel hose (C). Discard filter.

6. Install new fuel filter.

• Make sure fuel filter is installed with arrow pointing in direction of fuel flow.

7. Connect hoses to new fuel filter.

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