John Deere Z910A Z920A Z925A Z925A EFI Z930A Z950A Z960A & Z970A ZTrak Service Manual – PDF DOWNLOAD
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John Deere Z910A Z920A Z925A Z925A EFI Z930A Z950A Z960A & Z970A ZTrak Service Manual – PDF DOWNLOAD
Introduction
Foreword :
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction.
- At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines.
- They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
TABLE OF CONTENTS:
John Deere Z910A Z920A Z925A Z925A EFI Z930A Z950A Z960A & Z970A ZTrak Service Manual – PDF DOWNLOAD
Contents...................................................................................... 3 General Information....................................................................... 5 Safety................................................................................ 7 Recognize Safety Information...................................................... 7 Understand Signal Words........................................................... 7 Follow Safety Instructions........................................................ 7 Practice Safe Maintenance......................................................... 8 Use Proper Tools.................................................................. 8 Handle Fluids Safely—Avoid Fires.................................................. 9 Drain Gasoline When Storing Machine............................................... 9 Prevent Acid Burns................................................................ 10 Prevent Battery Explosions........................................................ 10 Handling Batteries Safely......................................................... 11 Prepare for Emergencies........................................................... 11 Park Machine Safely............................................................... 12 Support Machine Properly.......................................................... 12 Wear Protective Clothing.......................................................... 12 Work in Clean Area................................................................ 13 Service Machines Safely........................................................... 13 Work In Ventilated Area........................................................... 13 Illuminate Work Area Safely....................................................... 14 Replace Safety Signs.............................................................. 14 Use Proper Lifting Equipment...................................................... 14 Service Tires Safely.............................................................. 15 Dispose of Waste Properly......................................................... 15 Protect Against High Pressure Spray............................................... 16 Live With Safety.................................................................. 16 General Specifications................................................................ 17 Service Recommendations for O-Ring Boss Fittings.................................. 17 Service Recommendations For Flat Face O-Ring Seal Fittings........................ 18 Metric Cap Screw Torque Values—Grade 7............................................ 18 Metric Bolt and Screw Torque Values............................................... 19 Unified Inch Bolt and Screw Torque Values......................................... 20 Fuel and Lubricant.................................................................... 21 Gasoline Engine Oil............................................................... 21 Oil Filters....................................................................... 21 Gasoline Fuel for 4-Cycle Engines................................................. 21 Transmission and Hydraulic Oil.................................................... 22 Grease............................................................................ 22 Mixing of Lubricants.............................................................. 23 Alternative and Synthetic Lubricants.............................................. 23 Lubricant Storage................................................................. 23 Machine Specifications................................................................ 25 Serial Number Locations........................................................... 25 Engine Repair, Kawasaki................................................................... 29 General Repair FX651V, FX730V, FX751V, FX801V, and FX850V............................. 31 Summary of References............................................................. 31 Service Equipment and Tools....................................................... 31 Other Material.................................................................... 31 Specifications.................................................................... 32 Replace Fuel Filter............................................................... 39 Remove and Install Fuel Pump...................................................... 39 Remove and Install Throttle Cable................................................. 40 Remove and Install Choke Cable.................................................... 41 Remove and Install Muffler........................................................ 42 Remove and Install Engine......................................................... 43 Service Air Cleaner............................................................... 45 Remove and Install Air Cleaner Assembly........................................... 46 Remove Governor Lever Arm......................................................... 47 Install Governor Lever Arm........................................................ 47 Remove and Install Carburetor..................................................... 48 Clean and Inspect Carburetor...................................................... 50 Check Float Level................................................................. 52 Remove and Install Crankcase Breather............................................. 52 Remove and Install Ignition Coil.................................................. 53 Remove and Install Flywheel....................................................... 54 Remove and Install Stator......................................................... 54 Remove and Install Rocker Arm Cover............................................... 55 Remove Rocker Arm and Push Rod.................................................... 55 Install Rocker Arm and Push Rod................................................... 56 Remove Cylinder Head.............................................................. 57 Disassemble and Assemble Cylinder Head............................................ 58 Inspect Cylinder Head............................................................. 59 Install Cylinder Head............................................................. 59 Inspect Valve Guides.............................................................. 61 Analyze Valves.................................................................... 61 Recondition Valve Seats........................................................... 63 Lap Valves........................................................................ 65 Remove and Inspect Governor Shaft................................................. 65 Install Governor Shaft............................................................ 66 Remove Oil Pump................................................................... 66 Inspect Oil Pump.................................................................. 68 Install Oil Pump.................................................................. 69 Disassemble and Assemble Governor................................................. 71 Remove and Install Camshaft and Tappets........................................... 72 Inspect Camshaft and Tappets...................................................... 73 Remove and Disassemble Piston and Connecting Rod.................................. 75 Inspect Piston.................................................................... 76 Inspect Connecting Rod............................................................ 79 Assemble and Install Piston and Connecting Rod.................................... 79 Check Piston Ring End Gap......................................................... 82 Remove and Install Crankshaft..................................................... 83 Inspect Crankshaft................................................................ 83 Replace Crankshaft Oil Seal....................................................... 85 Deglaze Cylinder Bore............................................................. 86 Resize Cylinder Bore.............................................................. 87 Analyze Crankshaft and Connecting Rod Wear........................................ 87 Remove and Install Starting Motor................................................. 88 Disassemble and Assemble Starting Motor........................................... 89 Inspect Starting Motor............................................................ 90 Repair FX651V and FX730V.............................................................. 93 Summary of References............................................................. 93 Specifications.................................................................... 93 Remove and Install Throttle Control Plate (FX651V, FX730V)........................ 93 Repair Carburetor (FX651V, FX730V)................................................ 94 Remove Intake Manifold (FX651V, FX730V)...........................................101 Install Intake Manifold (FX651V, FX730V)..........................................102 Remove and Install Blower Housing (FX651V, FX730V)................................102 Remove Rocker Arm and Push Rod (FX651V, FX730V)...................................104 Install Rocker Arm and Push Rod (FX651V, FX730V)..................................104 Remove Crankcase Cover (FX651V, FX730V)...........................................105 Install Crankcase Cover (FX651V, FX730V)..........................................105 Repair FX751V, FX801V, and FX850V.....................................................107 Summary of References.............................................................107 Specifications....................................................................107 Remove and Install Throttle Control Plate (FX751V, FX801V, FX850V)................108 Carburetor Repair (FX751V, FX801V, FX850V)........................................109 Remove Intake Manifold (FX751V, FX801V, FX850V)...................................116 Install Intake Manifold (FX751V, FX801V, FX850V)..................................116 Remove and Install Blower Housing (FX751V, FX801V, FX850V)........................117 Remove and Install Oil Cooler (FX751V, FX801V, FX850V)............................119 Remove and Install Rocker Arm Assembly (FX751V, FX801V, FX850V)...................119 Remove Crankcase Cover (FX751V, FX801V, FX850V)...................................120 Install Crankcase Cover (FX751V, FX801V, FX850V)..................................121 Repair FX921V and FX1000V.............................................................123 Summary of References.............................................................123 Specifications....................................................................124 Replace Fuel Filter (FX921V, FX1000V).............................................128 Remove and Install Fuel Pump (FX921V, FX1000V)....................................129 Remove and Install Throttle Cable (FX921V, FX1000V)...............................129 Remove and Install Choke Cable (FX921V, FX1000V)..................................130 Remove and Install Muffler (FX921V, FX1000V)......................................131 Remove and Install Engine (FX921V, FX1000V).......................................132 Service Air Cleaner (FX921V, FX1000V).............................................134 Remove and Install Air Cleaner Assembly (FX921V, FX1000V).........................135 Remove and Install Throttle Control Plate (FX921V, FX1000V).......................136 Remove and Install Carburetor (FX921V, FX1000V)...................................137 Carburetor Repair (FX921V, FX1000V)...............................................139 Clean and Inspect Carburetor (FX921V, FX1000V)....................................146 Check Float Level (FX921V, FX1000V)...............................................148 Remove Intake Manifold (FX921V, FX1000V)..........................................148 Install Intake Manifold (FX921V, FX1000V).........................................149 Remove and Install Crankcase Breather (FX921V, FX1000V)...........................150 Remove Breather Baffle (FX921V, FX1000V)..........................................151 Install Breather Baffle (FX921V, FX1000V).........................................152 Remove and Install Blower Housing (FX921V, FX1000V)...............................153 Remove and Install Ignition Coils (FX921V, FX1000V)...............................155 Remove and Install Flywheel (FX921V, FX1000V).....................................155 Remove and Install Stator (FX921V, FX1000V).......................................156 Remove and Install Oil Cooler (FX921V, FX1000V)...................................157 Remove and Install Rocker Arm Cover (FX921V, FX1000V).............................157 Remove and Install Rocker Arm Assembly (FX921V, FX1000V)..........................158 Inspect Rocker Arm and Push Rod (FX921V, FX1000V).................................159 Remove Cylinder Head (FX921V, FX1000V)............................................160 Disassemble and Assemble Cylinder Head (FX921V, FX1000V)..........................160 Inspect Cylinder Head and Valve Guides (FX921V, FX1000V)..........................161 Analyze Valves (FX921V, FX1000V)..................................................162 Recondition Valve Seats (FX921V, FX1000V).........................................164 Lap Valves (FX921V, FX1000V)......................................................166 Install Cylinder Head (FX921V, FX1000V)...........................................167 Remove Crankcase Cover (FX921V, FX1000V)..........................................168 Install Crankcase Cover (FX921V, FX1000V).........................................168 Remove and Inspect Governor Shaft (FX921V, FX1000V)...............................170 Install Governor Shaft (FX921V, FX1000V)..........................................170 Disassemble and Inspect Oil Pump (FX921V, FX1000V)................................171 Assemble Oil Pump (FX921V, FX1000V)...............................................174 Disassemble and Assemble Governor (FX921V, FX1000V)...............................175 Remove and Install Camshaft and Tappets (FX921V, FX1000V).........................177 Inspect Camshaft and Tappets (FX921V, FX1000V)....................................178 Remove and Disassemble Piston and Connecting Rod (FX921V, FX1000V)................180 Inspect Piston (FX921V, FX1000V)..................................................181 Inspect Connecting Rod (FX921V, FX1000V)..........................................184 Assemble and Install Piston and Connecting Rod (FX921V, FX1000V)..................184 Check Piston Ring End Gap (FX921V, FX1000V).......................................187 Remove and Install Crankshaft (FX921V, FX1000V)...................................187 Inspect Crankshaft (FX921V, FX1000V)..............................................188 Replace Oil Seal (FX921V, FX1000V)................................................189 Deglaze Cylinder Bore (FX921V, FX1000V)...........................................190 Resize Cylinder Bore (FX921V, FX1000V)............................................191 Analyze Crankshaft and Connecting Rod Wear (FX921V, FX1000V)......................191 Remove and Install Starting Motor (FX921V, FX1000V)...............................192 Disassemble and Assemble Starting Motor (FX921V, FX1000V).........................193 Inspect Starting Motor (FX921V, FX1000V)..........................................194 Engine Repair, Kohler EFI.................................................................198 Repair................................................................................199 Summary of References.............................................................199 Essential or Recommended Tools....................................................199 Service Equipment and Tools.......................................................200 Specifications....................................................................201 Remove Engine (EFI)...............................................................207 Install Engine (EFI)..............................................................209 Remove and Install Air Cleaner Element (EFI)......................................210 Remove and Install Air Cleaner Assembly (EFI).....................................210 Remove and Install Muffler (EFI)..................................................211 Remove and Install Grass Screen (EFI).............................................213 Remove and Install Throttle Control Panel Assembly (EFI)..........................214 Remove and Install External Governor Controls (EFI)...............................216 Remove and Install Oil Cooler (EFI)...............................................217 Remove and Install Oil Separator (EFI)............................................217 Remove Blower Housing and Outer Baffle (EFI)......................................218 Install Blower Housing and Outer Baffle (EFI).....................................222 Remove Inner Baffles and Breather Cover (EFI).....................................226 Install Inner Baffles and Breather Cover (EFI)....................................226 Remove Intake Manifold (EFI)......................................................228 Install Intake Manifold (EFI).....................................................229 Remove Lift Fuel Pump (EFI).......................................................230 Install Lift Fuel Pump (EFI)......................................................230 Remove and Install Fuel Pump Module (EFI).........................................231 Remove Fuel Injector (EFI)........................................................233 Install Fuel Injector (EFI).......................................................234 Remove and Install Throttle Body (EFI)............................................234 Remove and Install Throttle Position Sensor TPS (EFI).............................236 Remove and Install Electronic Control Module ECM (EFI)............................237 Remove and Install Oxygen Sensor (EFI)............................................237 Remove and Install Ignition Coil (EFI)............................................238 Remove and Install Oil Temperature Sensor (EFI)...................................238 Remove and Install Crankshaft Position Sensor (EFI)...............................238 Remove and Install Manifold Absolute Pressure (MAP) Sensor (EFI)..................239 Remove and Install Intake Air Sensor (EFI)........................................240 Remove and Install Oil Sentry Switch (EFI)........................................241 Remove and Install Voltage Regulator/Rectifier (EFI)..............................241 Remove and Install Starting Motor (EFI)...........................................242 Disassemble Starting Motor (EFI)..................................................243 Starting Motor Armature (EFI).....................................................245 Assemble Starting Motor (EFI).....................................................246 Remove Valve Cover (EFI)..........................................................248 Install Valve Cover (EFI).........................................................249 Remove Cylinder Head (EFI)........................................................250 Install Cylinder Head (EFI).......................................................250 Inspect Cylinder Head (EFI).......................................................252 Remove and Install Rocker Arms (EFI)..............................................252 Remove and Install Valves and Springs (EFI).......................................254 Inspect Valves (EFI)..............................................................254 Recondition Valve Seats (EFI).....................................................255 Lap Valves (EFI)..................................................................256 Inspect Push Rods (EFI)...........................................................256 Inspect Valve Guides (EFI)........................................................257 Inspect Hydraulic Valve Lifters (EFI).............................................257 Inspect Crankcase Breather Reed Valve (EFI).......................................258 Remove and Install Flywheel (EFI).................................................258 Remove and Install Stator (EFI)...................................................260 Remove Oil Pan (EFI)..............................................................261 Install Oil Pan (EFI).............................................................261 Remove and Install Oil Pan Crankshaft Seal (EFI)..................................262 Remove and Install Governor.......................................................263 Remove Governor Cross Shaft (EFI).................................................264 Install Governor Cross Shaft (EFI)................................................265 Remove and Install Oil Pump (EFI).................................................266 Remove Camshaft (EFI).............................................................267 Install Camshaft (EFI)............................................................267 Inspect Cam Shaft (EFI)...........................................................268 Camshaft End Play (EFI)...........................................................269 Remove Piston (EFI)...............................................................269 Disassemble Piston (EFI)..........................................................270 Inspect Piston Pin (EFI)..........................................................271 Inspect Piston (EFI)..............................................................271 Assemble Piston (EFI).............................................................272 Measure Piston Ring End Gap (EFI).................................................273 Piston Ring Side Clearance (EFI)..................................................273 Measure Piston to Bore (EFI)......................................................274 Install Piston (EFI)..............................................................275 Remove and Install Crankcase Crankshaft Oil Seal (EFI)............................275 Inspect Block (EFI)...............................................................276 Deglaze Cylinder Bore (EFI).......................................................276 Measure Crankshaft and Connecting Rod (EFI).......................................277 Electrical Repair.........................................................................279 Component Location....................................................................281 Summary of References.............................................................281 Electrical Components (All Except EFI)............................................281 Instrument Cluster................................................................282 Wire Harness—Standard (Z910A, Z920A, Z925A, Z930A, Z950A) (SN -020000)................283 Summary of References.............................................................283 W1 Main Harness (SN -020000)......................................................284 W1 Main Harness Legend (SN -020000)...............................................287 W1 Main Harness Wire Codes (SN -020000)...........................................288 W2 Engine Harness (SN -020000)....................................................288 W4 Ignition Coil Harness (SN -020000).............................................289 W8 Headlight Wire Harness (SN -020000)............................................290 Wire Harness—Standard (Z910A, Z920A, Z925A, Z930A, Z950A) (SN 020001- )...............291 Summary of References.............................................................291 W1 Main Harness (SN 020001-)......................................................292 W1 Main Harness Legend (SN 020001-)...............................................295 W1 Main Harness Wire Codes (SN 020001-)...........................................296 W2 Engine Harness (SN 020001-)....................................................296 W4 Ignition Coil Harness (SN 020001-).............................................297 W8 Headlight Harness (SN 020001-).................................................298 Wire Harness—EFI Only (Z925A) (SN 020001- )...........................................299 Summary of References.............................................................299 W1 Main Harness (Z925A EFI).......................................................300 W1 Main Harness Legend (Z925A EFI)................................................303 W1 Main Harness Wire Codes (Z925A EFI)............................................304 W2 Engine Harness (Z925A EFI).....................................................306 W2 Engine Harness Wire Codes (Z925A EFI)..........................................309 W3 Engine Harness Adapter (Z925A EFI).............................................310 W8 Headlight Harness (Z925A EFI)..................................................311 ECM Connector Pinout..............................................................312 ECM Signal and Pinout Table.......................................................312 Wire Harness—Convenience Package (Z930A, Z950A, Z960A, Z970A).........................313 Summary of Reference..............................................................313 W1 Main Harness (Z930A, Z950A, Z960A, Z970A)......................................314 W1 Main Harness Legend (Z930A, Z950A, Z960A, Z970A)...............................317 W1 Main Harness Wire Codes (Z930A, Z950A, Z960A, Z970A)...........................318 W2 Engine Harness (Z930A, Z950A, Z960A, Z970A)....................................319 W4 Ignition Coil Harness (Z930A, Z950A, Z960A, Z970A).............................319 W5 Fuel Shut Off Solenoid Harness (Z930A, Z950A, Z960A, Z970A)....................319 W6 Lift Switch Harness (Z930A, Z950A, Z960A, Z970A)...............................320 W7 PTO Stop Switch Harness (Z930A, Z950A, Z960A, Z970A)...........................321 W8 Headlight Harness (Z930A, Z950A, Z960A, Z970A).................................322 Power Train Repair........................................................................323 Component Location....................................................................325 Summary of References.............................................................325 Power Train Components............................................................325 Tension Arm Components............................................................326 Transaxle Components..............................................................327 Transaxle Components Legend.......................................................328 Brake System Components...........................................................329 Brake System Components Legend....................................................330 Repair................................................................................331 Summary of References.............................................................331 Specifications....................................................................331 Remove and Install Traction Drive Belt............................................332 Remove and Install Steering Linkage Assembly......................................332 Remove and Install Traction Drive Belt Tension Arm Assembly.......................333 Remove and Install Control Damper.................................................334 Remove and Install Both Transaxles................................................334 Remove and Install Right or Left Transaxle........................................336 Remove and Install Fan Assembly...................................................338 Disassemble Transaxle.............................................................338 Assemble Transaxle................................................................352 Attachments Repair........................................................................363 Component Location....................................................................365 Summary of References.............................................................365 48 Inch Deck Components...........................................................365 54 Inch Deck Components...........................................................366 54 Inch Deck M.O.D. Components....................................................367 60 Inch Deck Components...........................................................368 60 Inch Deck M.O.D. Components....................................................369 72 Inch Deck Components...........................................................370 Spindles and Sheaves Components...................................................371 Spindles and Sheaves Components Legend............................................372 Idlers and Sheaves Components.....................................................373 Idlers and Sheaves Components Legend..............................................374 Anti-Scalp Wheel Components.......................................................375 Mulch-On-Demand Deck Linkage Components...........................................376 Mulch-On-Demand Deck Linkage Components Legend....................................377 Deck Lift With Pedal Components...................................................378 Mower Deck Lift Assist Components.................................................379 Mower Deck Lift Linkage Components................................................380 Repair................................................................................381 Summary of References.............................................................381 Specifications....................................................................381 Remove and Install Mower Deck.....................................................382 Remove and Install Mower Belt Shields.............................................383 Remove Mower Drive Belt...........................................................384 Install Mower Drive Belt..........................................................385 Check and Replace Mower Blades....................................................386 Sharpen and Balance Blades........................................................386 Remove and Install Spindle Assembly...............................................387 Disassemble Spindle...............................................................389 Spindle Cross Section.............................................................390 Assemble Spindle..................................................................391 Remove and Install PTO Clutch.....................................................392 Repair (Optional MCS).................................................................395 Summary of References.............................................................395 Specifications....................................................................395 Remove MCS Drive Sheave and Spacer................................................395 Install MCS Drive Sheave and Spacer...............................................396 Remove Primary Drive Belt.........................................................396 Install Primary Drive Belt........................................................397 Remove Secondary Drive Belt.......................................................398 Install Secondary Drive Belt......................................................398 Disassemble Blower................................................................399 Assemble Blower...................................................................402 Miscellaneous Repair......................................................................405 Wheels................................................................................407 Summary of References.............................................................407 Specifications....................................................................407 Remove and Install Front Caster Wheels............................................407 Repair Caster Wheel...............................................................408 Remove and Install Caster Wheel Yoke..............................................408 Adjust Front Caster Shimmy........................................................409 Remove and Install Rear Drive Wheels..............................................409 Operators Station.....................................................................411 Summary of References.............................................................411 Specifications....................................................................411 Remove and Install Seat Platform..................................................411 Repair Seat Platform..............................................................412 Remove and Install Suspended Seat.................................................413 Repair Suspended Seat Platform....................................................416 Remove and Install Control Console Cover..........................................417 Remove and Install Control Console Bracket........................................417 Roll Over Protective Structure (ROPS).................................................423 Summary of References.............................................................423 Specifications....................................................................423 Remove and Install Roll Over Protective Structure (ROPS)..........................423 Miscellaneous.........................................................................425 Summary of References.............................................................425 Specifications....................................................................425 Remove and Install Height-of-Cut (HOC) Assembly...................................425 Remove and Install Fuel Tank......................................................427 Remove and Install Grille.........................................................429 Engine Diagnosis, Tests, and Adjustments, Kawasaki........................................432 Component Location....................................................................433 Summary of References.............................................................433 Engine Block Components (FX651V, FX730V)..........................................434 Engine Block Components (FX751V, FX801V, FX850V)..................................436 Engine Block Components (FX921V, FX1000V).........................................438 Carburetor Components (FX651V, FX730V)............................................440 Carburetor Components (FX751V, FX801V, FX850V)....................................441 Carburetor Components (FX921V, FX1000V)...........................................442 Valves and Governor Components (FX651V, FX730V)...................................443 Valves and Governor Components (FX751V, FX801V, FX850V)...........................445 Valves and Piston Components (FX921V, FX1000V)....................................448 Theory of Operation...................................................................451 Summary of References.............................................................451 Engine Oil Flow Chart.............................................................451 Lubrication System Operation......................................................452 Governor Operation................................................................452 Crankcase Breather Operation......................................................453 Automatic Compression Release (ACR) Operation.....................................455 Cooling System Operation..........................................................456 Carburetor Operation..............................................................456 Ignition Operation................................................................458 Diagnosis.............................................................................459 Diagnose Engine Does Not Crank....................................................459 Diagnose Engine Does Not Crank................................................459 Diagnose Engine Cranks But Will Not Start.........................................460 Diagnose Engine Cranks But Will Not Start.....................................460 Diagnose Engine Hard to Start.....................................................461 Diagnose Engine Hard to Start.................................................461 Diagnose Engine Runs Erratically..................................................463 Diagnose Engine Runs Erratically..............................................463 Diagnose Engine Dies After Running................................................465 Diagnose Engine Dies After Running............................................465 Diagnose Engine Malfunctions At Low RPM...........................................465 Diagnose Engine Malfunctions At Low RPM.......................................465 Diagnose Engine Malfunctions At High RPM..........................................466 Diagnose Engine Malfunctions At High RPM......................................467 Diagnose Excessive Oil Consumption................................................467 Diagnose Excessive Oil Consumption............................................467 Diagnose Low Oil Pressure.........................................................468 Diagnose Low Oil Pressure.....................................................468 Diagnose Engine Overheats.........................................................469 Diagnose Engine Overheats.....................................................469 Diagnose Excessive Fuel Consumption...............................................470 Diagnose Excessive Fuel Consumption...........................................470 Diagnose Contamination In Crankcase...............................................471 Diagnose Contamination In Crankcase...........................................471 Diagnose Starting Motor...........................................................472 Starting Motor Does Not Rotate................................................472 Starting Motor Rotates Slowly.................................................473 Tests and Adjustments.................................................................475 Summary of References.............................................................475 Service Equipment and Tools.......................................................475 Specifications....................................................................477 Check and Adjust Choke Cable (FX651V, FX730V).....................................478 Check and Adjust Choke Cable (FX751V, FX801V, FX850V).............................480 Check and Adjust Choke Cable (FX921V, FX1000V)....................................480 Check and Adjust Throttle Cable (FX651V, FX730V)..................................481 Check and Adjust Throttle Cable (FX751V, FX801V, FX850V)..........................482 Check and Adjust Throttle Cable (FX921V, FX1000V).................................483 Adjust Static Governor Linkage (FX651V, FX730V)...................................484 Adjust Static Governor Linkage (FX921V, FX1000V)..................................484 Adjust Slow Idle Speed (FX651V, FX730V)...........................................485 Adjust Slow Idle Speed (FX751V, FX801V, FX850V)...................................486 Adjust Slow Idle Speed (FX921V, FX1000V)..........................................487 Adjust Fast Idle Speed (FX651V, FX730V)...........................................488 Adjust Fast Idle Speed (FX751V, FX801V, FX850V)...................................489 Adjust Fast Idle Speed (FX921V, FX1000V)..........................................489 Check and Adjust Fan Screen.......................................................490 Check and Adjust Valve Clearance (FX651V, FX730V, FX751V, FX801V, FX850V).........490 Check and Adjust Valve Clearance (FX921V, FX1000V)................................492 Check and Adjust Ignition Coil Air Gap............................................494 Test Cylinder Compression.........................................................495 Test Cylinder Leak-Down...........................................................496 Test Engine Oil Pressure..........................................................498 Test Fuel Pump....................................................................499 Crankcase Vacuum Test.............................................................500 Adjust Spark Plug Gap.............................................................500 Engine Diagnosis, Tests, and Adjustments, Kohler..........................................501 Theory of Operation...................................................................503 Summary of References.............................................................503 General Engine Operation..........................................................503 Air Intake System.................................................................503 Cooling System....................................................................503 Lubrication System................................................................503 Crankcase Breather System.........................................................503 Engine Control Module (ECM).......................................................504 Fuel System.......................................................................504 Throttle Body.....................................................................504 Governor System...................................................................505 Ignition System...................................................................505 Diagnosis.............................................................................507 Engine Troubleshooting............................................................507 Tests and Adjustments.................................................................513 Summary of References.............................................................513 Service Equipment and Tools.......................................................513 Specifications....................................................................513 Adjust Governor...................................................................514 Adjust Low Idle Speed.............................................................515 Adjust Spark Plug Gap.............................................................516 Test Cylinder Leak-Down...........................................................516 Test Fuel Pump, Pulse.............................................................517 Test Fuel Pump, Module............................................................518 Adjust Crankshaft Position Sensor Air Gap.........................................520 Test Fuel Injector and Wires......................................................521 Test Starter Solenoid.............................................................523 Electrical Diagnosis, Tests, and Adjustments..............................................526 Theory of Operation...................................................................527 Summary of References.............................................................527 Charging Circuit Operation........................................................527 Cranking Circuit Operation........................................................528 Run Circuit Operation.............................................................531 PTO Clutch Circuit Operation......................................................534 Engine Oil Pressure and Hour Meter Circuit Operation..............................536 Lift Circuit Operation (Z950A, Z960A, Z970A)......................................538 Headlight Circuit Operation.......................................................540 Theory of Operation (EFI).............................................................541 Summary of References.............................................................541 Control Units (ECU and ECM).......................................................541 Engine Control Module and General Sensor Circuit Operation........................542 On Board Diagnostics..............................................................543 Malfunction Indicator Light (MIL) Operation.......................................543 Crankshaft Position Sensor Operation..............................................544 Throttle Position Sensor (TPS) Operation..........................................544 Oil Temperature Sensor Operation..................................................544 Intake Air Temperature Sensor Operation...........................................545 Oxygen Sensor Operation...........................................................545 Manifold Absolute Pressure (MAP) Sensor Operation.................................545 Fuel Injector Operation...........................................................546 Ignition Coil Operation...........................................................546 Fuel Pump Operation...............................................................546 Diagnosis.............................................................................547 Electronic Control Unit (ECU) Diagnostic Codes....................................547 Electronic Control Unit (ECU) Switch Input Codes..................................548 Diagnose Charging Circuit.........................................................548 Procedure A...................................................................548 Diagnose Cranking Circuit.........................................................550 Procedure A...................................................................550 Diagnose Run Circuit..............................................................555 Procedure A - Run Circuit.....................................................555 Procedure B - Ignition Shutoff Circuit (Except EFI)...........................559 Diagnose PTO Clutch Circuit.......................................................560 Procdeure A...................................................................560 Diagnose Engine Oil Pressure Circuit..............................................564 Procedure A...................................................................564 Diagnose Hour Meter Circuit.......................................................567 Procedure A...................................................................567 Diagnose Lift Circuit.............................................................569 Procedure A...................................................................569 Diagnose Headlight Circuit........................................................572 Procedure A...................................................................572 Engine Diagnostic Test Codes (EFI)....................................................575 Engine Control Module (ECM) Diagnostic Test Codes.................................575 0031 — Diagnostic Test Code.......................................................575 0032 — Diagnostic Test Code.......................................................576 0107 — Diagnostic Test Code.......................................................576 0108 — Diagnostic Test Code.......................................................576 0112 — Diagnostic Test Code.......................................................576 0113 — Diagnostic Test Code.......................................................577 0117 — Diagnostic Test Code.......................................................577 0118 — Diagnostic Test Code.......................................................577 0122 — Diagnostic Test Code.......................................................577 0123 — Diagnostic Test Code.......................................................578 0131 — Diagnostic Test Code.......................................................578 0132 — Diagnostic Test Code.......................................................578 0171 — Diagnostic Test Code.......................................................579 0172 — Diagnostic Test Code.......................................................579 0174 — Diagnostic Test Code.......................................................580 0201 — Diagnostic Test Code.......................................................580 0202 — Diagnostic Test Code.......................................................580 0230 — Diagnostic Test Code.......................................................580 0232 — Diagnostic Test Code.......................................................581 0336 — Diagnostic Test Code.......................................................581 0337 — Diagnostic Test Code.......................................................581 0351 — Diagnostic Test Code.......................................................581 0352 — Diagnostic Test Code.......................................................582 0562 — Diagnostic Test Code.......................................................582 0563 — Diagnostic Test Code.......................................................582 61 — Diagnostic Test Code.........................................................582 Tests and Adjustments.................................................................583 Summary of References.............................................................583 Essential or Recommended Tools....................................................583 Service Equipment and Tools.......................................................583 Specifications....................................................................584 Ground Circuit Test...............................................................585 Battery Voltage and Specific Gravity Tests........................................586 Battery Charge....................................................................587 Battery Load Test.................................................................587 Test Regulated Voltage Output.....................................................588 Test Unregulated Voltage Output...................................................588 Test Stator.......................................................................589 Test Starting Motor Solenoid......................................................589 Test Starting Motor Amperage Draw.................................................590 Spark Test........................................................................591 Fuse Test.........................................................................591 Diode Test........................................................................591 Key Switch Test...................................................................592 Park Brake Switch Test............................................................592 Seat Switch Test..................................................................593 Lift Switch Test..................................................................593 Test Headlight Switch.............................................................594 PTO Switch Test...................................................................594 PTO Stop Switch Test..............................................................595 PTO Clutch Test...................................................................595 Relay Test........................................................................596 Ignition Coil Test (Except EFI)...................................................596 Fuel Shutoff Solenoid Test........................................................597 Oil Pressure Switch Test..........................................................598 Tests and Adjustments (EFI)...........................................................599 Summary of References.............................................................599 Specifications....................................................................599 EFI Crankshaft Position Sensor Test...............................................599 EFI Throttle Position Sensor Test.................................................600 EFI Engine Oil Temperature Sensor Test............................................601 EFI Intake Air Temperature Sensor Test............................................601 EFI Manifold Absolute Pressure Sensor Test........................................602 EFI Oxygen Sensor Test............................................................602 EFI Fuel Injector Electrical Test.................................................603 EFI Ignition Coil Test............................................................603 EFI Fuel Pump Module Electrical Test..............................................604 EFI ECM Diagnostic Code Retrieval.................................................604 EFI ECM Reset and TPS Learn Procedures............................................605 Wiring Schematics.....................................................................607 Schematic Legend, Z910A, Z920A, Z925A, and Z930A (SN -020000).....................607 Main Schematic, Z910A, Z920A, Z925A, and Z930A (SN -020000).......................608 Schematic Legend, Z950A (SN -020000), Z960A, Z970A................................611 Main Schematic, Z950A (SN -020000), Z960A and Z970A...............................612 Schematic Legend, Z910A, Z920A, Z925A (Except EFI), Z930A, Z950A (SN 020001-).....615 Main Schematic, Z910A, Z920A, Z925A (Except EFI), Z930A and Z950A (SN 020001-)....616 Schematic Legend, Z925A (EFI Only), (SN 020001-)..................................619 Main Schematic, Z925A (EFI Only) (SN 020001-).....................................620 Engine Wiring (W2) - Z925A EFI....................................................625 Connector Information.................................................................627 WEATHER PACK™ Connector - Removal.................................................627 WEATHER PACK™ Connector - Replacement.............................................628 WEATHER PACK™ Connector Terminal..................................................628 METRI-PACK™ Connector.............................................................629 METRI-PACK™ Terminal - Replacement................................................631 Power Train Diagnosis, Tests, and Adjustments.............................................635 Theory of Operation...................................................................637 Summary of References.............................................................637 Transaxle Operation...............................................................638 Brake System Operation............................................................639 Diagnosis.............................................................................641 Diagnose System Fails to Build Pressure...........................................641 Diagnose System Fails to Build Pressure.......................................641 Diagnose Machine Will Not Drive Straight..........................................642 Diagnose Machine Will Not Drive Straight......................................642 Diagnose Machine Will Not Reach Maximum Speed.....................................643 Diagnose Machine Will Not Reach Maximum Speed.................................643 Diagnose Machine Will Not Move When Controls Are Engaged..........................644 Diagnose Machine Will Not Move When Controls Are Engaged......................644 Diagnose Jerky or Erratic Operation...............................................646 Diagnose Jerky or Erratic Operation...........................................646 Diagnose Sluggish Operation Under Load............................................648 Diagnose Sluggish Operation Under Load........................................648 Diagnose Excessive Noise..........................................................650 Diagnose Excessive Noise......................................................650 Tests and Adjustments.................................................................653 Summary of References.............................................................653 Bleed Hydrostatic System..........................................................653 Adjust Tracking and Speed.........................................................654 Check and Adjust Neutral Creep....................................................655 Check and Align Motion Control Levers.............................................657 Check and Adjust Park Brake.......................................................657 Attachments Diagnosis, Tests, and Adjustments.............................................661 Theory of Operation...................................................................663 Summary of References.............................................................663 Mulch On Demand (M.O.D.) Operation................................................664 PTO Clutch Operation..............................................................667 Diagnosis.............................................................................669 Diagnose Mower System.............................................................669 Diagnose Mower System.........................................................669 Diagnose Mower System (Engine Running)............................................672 Diagnose Mower System (Engine Running)........................................672 Diagnose Mower Deck Will Not Run..................................................673 Diagnose Mower Deck Will Not Run..............................................673 Diagnose Mower Deck Vibrates......................................................674 Diagnose Mower Deck Vibrates..................................................674 Diagnose Mower Cuts Unevenly......................................................676 Diagnose Mower Cuts Unevenly..................................................676 Diagnose Poor Mulching (M.O.D. Deck)..............................................677 Diagnose Poor Mulching (M.O.D. Deck)..........................................677 Diagnose Excessive Noise..........................................................678 Diagnose Excessive Noise......................................................678 Diagnose PTO Clutch...............................................................679 Diagnose PTO Clutch...........................................................679 Diagnose Clutch Slips.............................................................680 Diagnose Clutch Slips.........................................................680 Diagnose Noisy Clutch or Vibration................................................682 Diagnose Noisy Clutch or Vibration............................................682 Tests and Adjustments.................................................................685 Summary of References.............................................................685 Service Equipment and Tools.......................................................685 Specifications....................................................................685 Adjust Mower Deck Cutting Height..................................................686 Adjust and Level Mower Deck.......................................................687 Adjust Mower Deck Anti-Scalp Wheels...............................................689 Adjust Deck Lift Spring Tension...................................................689 Adjust Mulch-On-Demand and Mower Deck Linkage.....................................690 Check and Adjust PTO Air Gap......................................................692 Adjust MCS Blower Primary Belt Tension............................................693 Adjust MCS Blower Secondary Belt Tension..........................................693 Adjust Dump-From-Seat Hopper Linkage..............................................693 Break-In PTO Clutch...............................................................694 Service Tools and Kits....................................................................695 Service Tools and Kits................................................................697 Essential or Recommended Tools....................................................697 Kits..............................................................................698 Page Number................................................................................... 3 Section 10................................................................................ 5 Group 05.............................................................................. 7 Group 10.............................................................................. 17 Group 15.............................................................................. 21 Group 20.............................................................................. 25 Section 20................................................................................ 29 Group 05.............................................................................. 31 Group 10.............................................................................. 93 Group 15..............................................................................107 Group 25..............................................................................123 Section 25................................................................................198 Group 05..............................................................................199 Section 30................................................................................279 Group 10..............................................................................281 Group 20..............................................................................283 Group 30..............................................................................291 Group 40..............................................................................299 Group 50..............................................................................313 Section 40................................................................................323 Group 10..............................................................................325 Group 20..............................................................................331 Section 50................................................................................363 Group 10..............................................................................365 Group 20..............................................................................381 Group 30..............................................................................395 Section 60................................................................................405 Group 10..............................................................................407 Group 20..............................................................................411 Group 30..............................................................................423 Group 40..............................................................................425 Section 220...............................................................................432 Group 05..............................................................................433 Group 10..............................................................................451 Group 15..............................................................................459 Group 20..............................................................................475 Section 225...............................................................................501 Group 10..............................................................................503 Group 15..............................................................................507 Group 20..............................................................................513 Section 230...............................................................................526 Group 10..............................................................................527 Group 15..............................................................................541 Group 20..............................................................................547 Group 25..............................................................................575 Group 30..............................................................................583 Group 35..............................................................................599 Group 40..............................................................................607 Group 50..............................................................................627 Section 240...............................................................................635 Group 10..............................................................................637 Group 20..............................................................................641 Group 30..............................................................................653 Section 250...............................................................................661 Group 10..............................................................................663 Group 20..............................................................................669 Group 30..............................................................................685 Section 299...............................................................................695 Group 10..............................................................................697
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