John Deere Mowers X495 & X595 TM2024 Garden Tractors Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere Mowers X495 & X595 TM2024 Garden Tractors Service Manual – PDF DOWNLOAD
Manual Description:
This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program.
The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows:
• Table of Contents
• Specifications and Information
• Identification Numbers
• Tools and Materials
• Component Location
• Schematics and Harnesses
• Theory of Operation
• Operation and Diagnostics
• Diagnostics
• Tests and Adjustments
• Repair
• Other
- The bleed tabs for the pages of each section will align with the sections listed on this page. Page numbering is consecutive from the beginning of the Safety section through the last section.
- We appreciate your input on this manual. If you find any errors or want to comment on the layout of the manual please contact us.
TABLE OF CONTENTS:
John Deere Mowers X495 & X595 TM2024 Garden Tractors Service Manual – PDF DOWNLOAD
TM2024 X495 and X595 Garden Tractors.................................................... 1 Introduction........................................................................ 3 Safety.............................................................................. 5 Recognize Safety Information.................................................... 5 Understand Signal Words......................................................... 5 Replace Safety Signs............................................................ 5 Handle Fluids Safely - Avoid Fires.............................................. 5 Use Care In Handling and Servicing Batteries.................................... 5 Prevent Battery Explosions...................................................... 6 Prevent Acid Burns.............................................................. 6 Wear Protective Clothing........................................................ 6 Use Care Around High-pressure Fluid Lines....................................... 6 Service Machines Safely......................................................... 7 Use Proper Tools................................................................ 7 Park Machine Safely............................................................. 7 Support Machine Properly and Use Proper Lifting Equipment....................... 7 Work In Clean Area.............................................................. 8 Using High Pressure Washers..................................................... 8 Illuminate Work Area Safely..................................................... 8 Work In Ventilated Area......................................................... 8 Warning: California Proposition 65 Warning...................................... 8 Remove Paint Before Welding or Heating.......................................... 8 Avoid Harmful Asbestos Dust..................................................... 8 Service Tires Safely............................................................ 9 Avoid Injury From Rotating Blades, Augers and PTO Shafts........................ 9 Service Cooling System Safely................................................... 9 Handle Chemical Products Safely................................................. 9 Dispose Of Waste Properly....................................................... 10 Live With Safety................................................................ 10 Specifications & Information........................................................ 11 Table of Contents............................................................... 11 Fastener Torques................................................................ 13 Metric Fastener Torque Values............................................... 13 Inch Fastener Torque Values................................................. 14 O-Ring Seal Service Recommendations............................................. 15 Face Seal Fittings With Inch Stud Ends Torque............................... 15 Face Seal Fittings With Metric Stud Ends Torque............................. 16 O-ring Face Seal Fittings................................................... 17 O-Ring Boss Fittings........................................................ 17 Straight Fitting or Special Nut Torques..................................... 18 Metric Fastener Torque Value - Grade 7 (Special)............................ 18 General Information............................................................. 18 Diesel Fuel................................................................. 18 Diesel Fuel Lubricity....................................................... 18 Diesel Fuel Storage......................................................... 19 4 - Cycle Diesel Engine Oil................................................. 19 Break-In Engine Oil - Diesel................................................ 19 Hydrostatic Transmission and Hydraulic Oil.................................. 20 Gear Case Oil............................................................... 21 Gear Transmission Grease.................................................... 21 Alternative Lubricants...................................................... 21 Synthetic Lubricants........................................................ 22 Anti-Corrosion Grease....................................................... 22 Mower Spindle Grease........................................................ 22 Lubricant Storage........................................................... 22 Mixing of Lubricants........................................................ 22 Oil Filters................................................................. 23 Coolant Specifications.......................................................... 23 Diesel Engine Coolant....................................................... 23 Diesel Engine Coolant Drain Interval........................................ 24 Serial Number Locations......................................................... 24 Product Serial Number....................................................... 24 Diesel Engine Serial Number Location........................................ 24 Engine - Diesel..................................................................... 25 Table of Contents............................................................... 25 Specifications.................................................................. 27 General..................................................................... 27 Repair Specifications....................................................... 27 Tests and Adjustment Specifications......................................... 33 Operational Tests........................................................... 33 Tightening Torques.......................................................... 34 Other Materials............................................................ 34 Theory of Operation............................................................. 35 Cooling System Theory of Operation.......................................... 35 Lubrication System Theory of Operation...................................... 36 Fuel System Theory of Operation............................................. 37 Air System Theory of Operation.............................................. 38 Component Location.............................................................. 39 Diesel Engine Component Location............................................ 39 Fuel System Component Location.............................................. 40 Diagnostics..................................................................... 41 Engine Troubleshooting...................................................... 41 Diagnostic Table............................................................ 47 Tests and Adjustments........................................................... 49 Cylinder Compression Test................................................... 49 Throttle Cable Adjustment................................................... 49 Slow Idle Adjustment........................................................ 50 Valve Clearance Adjustment.................................................. 50 Valve Lift Check............................................................ 52 Fuel Injection System Tests................................................. 52 Fuel Injection Nozzle Test.................................................. 53 Injection Pump Timing (EPA Engines)......................................... 55 Thermostat Test............................................................. 55 Water Pump/Alternator Drive Belt Adjustment................................. 56 Radiator Bubble Test........................................................ 56 Cooling System Pressure Test................................................ 57 Radiator Cap Pressure Test.................................................. 57 Engine Oil Pressure Test.................................................... 57 Fuel Transfer Pump Pressure Test............................................ 58 Fuel Transfer Pump Flow Test................................................ 59 Fuel System Air Bleeding.................................................... 59 Air Restriction Indicator Test.............................................. 60 Repair.......................................................................... 61 Fan/Alternator Belt Removal and Installation................................ 61 Fuel Filter Removal and Installation........................................ 62 Air Cleaner Disassembly, Inspection and Assembly............................ 62 Rocker Arm Cover Removal and Installation................................... 63 Rocker Arm and Push Rods.................................................... 64 Radiator Removal and Installation........................................... 66 Cylinder Head Removal and Installation...................................... 68 Muffler Removal and Installation............................................ 69 Intake Manifold Removal and Installation.................................... 69 Exhaust Manifold Removal and Installation................................... 69 Engine Removal and Installation............................................. 70 Cylinder Head Recondition................................................... 72 Crankshaft Oil Seals........................................................ 76 Timing Gear Cover........................................................... 77 Camshaft End Play Check..................................................... 78 Timing Gear Backlash Check.................................................. 78 Idler Gear.................................................................. 79 Camshaft Followers.......................................................... 80 Camshaft.................................................................... 80 Oil Pan and Strainer........................................................ 84 Connecting Rod Side Play Check.............................................. 84 Crankshaft End Play Check................................................... 85 Connecting Rod Bearing Clearance Check...................................... 85 Crankshaft Main Bearing Clearance Check..................................... 86 Piston-To-Cylinder Head Clearance........................................... 86 Piston and Connecting Rod Repair............................................ 87 Cylinder Bore............................................................... 92 Crankshaft and Main Bearings................................................ 93 Flywheel Removal and Installation........................................... 96 Engine Back Plate........................................................... 96 Timing Gear Housing......................................................... 96 Oil Pump.................................................................... 97 Oil Pressure Regulating Valve............................................... 99 Coolant Temperature Switch.................................................. 99 Thermostat Removal and Installation......................................... 99 Water Pump..................................................................100 Fuel Transfer Pump..........................................................101 Fuel Injection Nozzle.......................................................101 Fuel Injection Pump.........................................................104 Fuel Shutoff Solenoid Removal and Installation..............................108 Fuel Control and Governor Linkage...........................................109 Electrical..........................................................................111 Table of Contents...............................................................111 General Information.............................................................113 Reading Electrical Schematics...............................................113 Theory Of Operation Information.............................................114 Diagnostic Information......................................................114 Wire Color Abbreviation Chart...............................................114 Common Circuit Tests........................................................115 Conductors For 12 Volt Circuits.............................................115 Specifications..................................................................116 General Specifications......................................................116 Test and Adjustment Specifications..........................................117 Other Materials.............................................................117 Component Location..............................................................118 X495 and X595 Diesel........................................................118 Diesel Engine...............................................................120 Instrument Panel............................................................121 Schematics and Harnesses........................................................122 Schematic And Wiring Harness Legend.........................................122 Main Electrical Schematic (1 of 4 SN -30000)................................124 Main Electrical Schematic (2 of 4 SN -30000)................................125 Main Electrical Schematic (3 of 4 SN -30000)................................126 Main Electrical Schematic (4 of 4 SN -30000)................................127 Instrument Panel Electrical Schematic (SN -30000)...........................128 W1 Diesel Main Wiring Harness (1 of 2 SN -30000)............................129 W1 Diesel Main Wiring Harness (2 of 2 SN -30000)............................130 Main Electrical Schematic (1 of 4 SN 30001-)................................131 Main Electrical Schematic (2 of 4 SN 30001-)................................132 Main Electrical Schematic (3 of 4 SN 30001-)................................133 Main Electrical Schematic (4 of 4 SN 30001-)................................134 Control Panel Electrical Schematic (SN 30001-)..............................135 W1 Diesel Main Wiring Harness (1 of 2 SN 30001-)............................136 W1 Diesel Main Wiring Harness (2 of 2 SN 30001-)............................137 W2 Headlight Wiring Harness.................................................138 W3 Rear Wiring Harness......................................................138 W4 PTO Option Wiring Harness................................................138 W1 Main Wiring Harness Color Codes (SN -30000)..............................139 W1 Main Wiring Harness Color Codes (SN 30001-)..............................141 W2 Headlight Wiring Harness Color Codes.....................................142 W3 Rear Wiring Harness Color Codes..........................................142 W4 PTO Option Wiring Harness Color Codes....................................142 Operation and Diagnostics.......................................................143 Power Circuit Operation.....................................................143 Power Circuit Electrical Schematic..........................................144 Power Circuit Diagnosis.....................................................146 Cranking Circuit Operation..................................................152 Cranking Circuit Electrical Schematic.......................................153 Cranking Circuit Diagnosis..................................................154 Charging Circuit Operation..................................................157 Charging Circuit Electrical Schematic.......................................158 Charging Circuit Diagnosis..................................................159 Glow Plug Circuit Operation.................................................162 Glow Plug Circuit Electrical Schematic......................................163 Glow Plug Circuit Diagnosis.................................................164 Fuel Supply Circuit Operation...............................................167 Fuel Supply Circuit Electrical Schematic....................................168 Fuel Supply Circuit Diagnosis...............................................169 PTO Circuit Operation.......................................................171 PTO Circuit Electrical Schematic............................................172 PTO Circuit Diagnosis.......................................................174 PTO Overtemp Circuit Operation..............................................179 PTO Overtemp Circuit Schematic..............................................180 PTO Overtemp Circuit Diagnosis..............................................181 Instrument Panel Circuit Operation..........................................184 Instrument Panel Circuit Electrical Schematic (SN -30000)...................186 Electrical Panel Circuit Electrical Schematic (SN 30001-)...................187 Instrument Panel Circuit Diagnosis..........................................188 Lights Circuit Operation....................................................191 Lights Circuit Electrical Schematic (SN -30000).............................192 Lights Circuit Electrical Schematic (SN 30001-).............................193 Lights Circuit Diagnosis....................................................194 Tests and Adjustments...........................................................197 Common Circuit Test.........................................................197 Ground Circuit Test.........................................................197 Battery Voltage and Specific Gravity Test...................................198 Battery - Charge............................................................199 Battery - Load Test.........................................................199 Unregulated Voltage Test....................................................200 Stator Resistance Test......................................................200 Regulated Amperage and Voltage Test.........................................201 Starting Motor Condition....................................................201 Starting Motor System Test..................................................202 Starter Solenoid Test.......................................................203 Starting Motor Amp Draw Test................................................204 Starting Motor No-load Amperage and RPM Test................................204 Windings Test...............................................................205 Starter Armature Test.......................................................206 Control/Fuse Module Test....................................................206 Engine Coolant Temperature Sensor Test......................................208 Engine Oil Pressure Switch Test.............................................208 Lights Switch Test..........................................................209 PTO/RIO Switch Test.........................................................210 Relay Test..................................................................210 Seat Switch Test............................................................211 Brake Switch Test and Adjustment............................................211 Service Timer Reset Switch (SN -30000)......................................212 Fuse Test...................................................................212 Instrument Panel Light Test.................................................212 PTO Solenoid Test...........................................................213 Rear PTO Switch Test (optional).............................................214 Diode Test..................................................................215 Fuel Tank Sensor Test.......................................................215 Air Restriction Indicator Test..............................................216 Power Train - Hydrostatic...........................................................217 Table of Contents...............................................................217 Specifications..................................................................219 General Specifications......................................................219 Test And Adjustment Specifications..........................................219 Repair Specifications.......................................................219 Special or Essential Tools..................................................220 Other Materials.............................................................220 Component Location..............................................................221 Hydrostatic Power Train.....................................................221 Final Drive (MFWD)..........................................................223 Front Axle Gear Case (MFWD).................................................224 Front Axle Assembly (MFWD)..................................................226 Rear PTO Gear Case Assembly.................................................227 MFWD Output Shaft...........................................................229 Foot Pedals and Linkage.....................................................231 Theory of Operation.............................................................233 Center Section and Directional Control Valves - Reverse System Operation....233 Transaxle Oil Flow System Operation.........................................236 External Power Train System Operation.......................................239 Transaxle Internal System Operation.........................................240 Rear PTO Component Location and Operation (Option)..........................244 540 Rear PTO................................................................245 Diagnostics.....................................................................246 Hydrostatic Transmission Diagnosis..........................................246 Mid-PTO System Diagnosis....................................................248 Transaxle Diagnosis.........................................................248 Hydrostatic Transmission Test...............................................249 Mid-PTO System Test.........................................................251 Transaxle Test..............................................................252 Tests and Adjustments...........................................................253 Hydraulic Oil Warm-Up Procedure.............................................253 Charge Pump Pressure Test...................................................253 Charge Pump Flow and Pressure Test - At Charge Pump.........................254 Mid-PTO Engagement Pressure and Brake Test..................................256 Transaxle Neutral Adjustment................................................257 Transaxle Control Linkage Adjustment........................................258 Transaxle Linkage Full Forward Adjustment...................................259 Cruise Control Linkage Check and Adjustment.................................259 Repair..........................................................................261 Foot Control Linkage Removal and Installation...............................261 Shift Lever Linkage (MFWD) Removal and Installation.........................263 Oil Cooler Removal and Installation.........................................264 Control Arm and Damper Removal and Installation.............................265 Differential Lock Linkage Inspection........................................266 Charge Pump Removal and Installation........................................267 Charge Pump Disassembly and Assembly........................................267 Directional Control Valves..................................................268 Hydrostatic Pressure Relief Valve (45 Loader) Installation..................269 Drive Shaft Removal and Installation........................................270 PTO Solenoid Valve..........................................................271 PTO Relief Valve Removal and Installation...................................272 PTO Relief Valve Disassembly, Inspection and Assembly.......................272 PTO Brake Removal and Installation..........................................273 PTO Brake Disassembly, Inspection and Assembly..............................274 PTO Drive Train (Mid-PTO) Removal and Installation..........................275 PTO Drive Train (Mid and Rear PTO) Removal and Installation.................276 Rear PTO Removal and Installation...........................................279 Transaxle Removal and Installation..........................................282 Differential Lock Shaft Disassembly and Assembly............................284 Differential (2-Wheel Drive) Disassembly and Assembly.......................285 Differential (MFWD) Disassembly and Assembly................................286 PTO Clutch Disassembly, Inspection and Assembly.............................287 MFWD Output Shaft Removal and Installation..................................288 Hydrostatic Transmission 2-WD and MFWD......................................291 Hydrostatic Pump Inspection.................................................298 Transaxle Disassembly.......................................................299 Transaxle (Right Cover) Disassembly and Assembly............................302 Transaxle Case - Inspection.................................................303 Transaxle Assembly..........................................................303 Rear Axle Assembly Removal and Installation.................................305 Rear Axle Assembly - Disassembly and Assembly...............................306 Final Drive Cover Removal and Installation - (MFWD).........................307 Final Drive Housing Removal and Installation - (MFWD).......................309 Spindle Housing - (MFWD)....................................................311 Drive Shaft Removal and Installation - (MFWD)...............................312 Mechanical Front Wheel Drive Removal and Installation - (MFWD)..............312 Differential Input Housing - (MFWD).........................................313 Front Axle Housing Disassembly and Assembly.................................315 Hydraulics..........................................................................317 Table of Contents...............................................................317 Specifications..................................................................319 General Specifications......................................................319 Test and Adjustment Specifications..........................................319 Repair Torque Specifications................................................320 Special or Essential Tools..................................................320 Other Materials.............................................................320 Schematics......................................................................321 Hydraulic Schematic - Power Train...........................................321 Component Location..............................................................322 Hydraulic System............................................................322 Operation and Diagnostics.......................................................323 Hydraulic System............................................................323 Hydraulic Control Valve Operation - Neutral.................................324 Hydraulic Control Valve Operation - Raise...................................325 Hydraulic Control Valve Operation - Float...................................326 Hydraulic Control Valve Operation - Regen...................................327 Lift Cylinder Shut-off Valve - Optional.....................................328 Hydraulic Diagnostics.......................................................328 Preliminary Hydraulic System Inspection.....................................330 Hydraulic System Tests......................................................331 Tests and Adjustments...........................................................333 Hydraulic Oil Warm-Up Procedure.............................................333 Charge Pump Pressure and Flow Quick Test at Couplers........................333 Charge Pump Pressure Test...................................................334 Lift Cylinder Leakage Test..................................................336 Control Valve Leakage Test..................................................337 Repair..........................................................................337 Hydraulic Control Valve Removal and Installation............................337 Hydraulic Control Valve.....................................................338 Lift Cylinder Removal and Installation......................................339 Hydraulic Control Levers and Linkage........................................340 Steering............................................................................341 Table of Contents...............................................................341 Specifications..................................................................343 General Specifications......................................................343 Test and Adjustment Specifications..........................................343 Repair Specifications.......................................................343 Special or Essential Tools..................................................343 Component Location..............................................................344 Steering Components - Front Wheel Steer.....................................344 Steering Components - All Wheel Steer.......................................345 Steering Components - All Wheel Steer Rear Axle.............................346 Theory of Operation.............................................................347 Steering System Operation...................................................347 Steering Valve Operation - Neutral..........................................348 Steering Valve Operation - Turning..........................................349 Steering Valve Operation - Manual...........................................350 Diagnostics.....................................................................351 Steering Diagnosis..........................................................351 Steering System Tests.......................................................352 Steering Link Checks........................................................352 Tests and Adjustments...........................................................353 Hydraulic Oil Warm-Up Procedure.............................................353 Steering Valve and Cylinder Leakage Test....................................353 Toe-In Adjustment Front Wheels..............................................354 Toe-In Adjustment All Wheel Steering........................................355 Repair..........................................................................356 Steering Column Removal and Installation....................................356 Steering Valve Removal and Installation.....................................357 Steering Valve Disassembly and Assembly.....................................359 Steering Cylinder Removal and Installation..................................362 Front Axle Removal and Installation.........................................362 Front Axle Disassembly and Assembly.........................................363 Rear Steering Linkage - All Wheel Steering..................................365 Steering Intermediate Linkage - AWS.........................................367 Front and Rear Pivots.......................................................368 Brakes..............................................................................371 Table of Contents...............................................................371 Specifications..................................................................373 General Specifications......................................................373 Test and Adjustment Specifications..........................................373 Repair Specifications.......................................................373 Special or Essential Tools..................................................373 Other Materials.............................................................373 Component Location..............................................................374 Brake System Component Location.............................................374 Brake/Differential Linkage (Exploded).......................................375 Theory of Operation.............................................................376 Brake System Operation......................................................376 Diagnostics.....................................................................377 Brakes......................................................................377 Tests and Adjustments...........................................................379 Brake/Differential Linkage Adjustment.......................................379 Repair..........................................................................381 Brake/Differential Linkage Removal and Installation.........................381 Brakes Removal and Installation.............................................383 Attachments.........................................................................385 Table of Contents...............................................................385 Specifications..................................................................387 General Specifications......................................................387 Torque and Repair Specifications............................................389 Diagnostics.....................................................................391 48, 54 and 62-Inch Mower Deck Diagnosis.....................................391 45 Loader Diagnosis.........................................................394 Tests and Adjustments...........................................................395 Adjusting Cutting Height (48C, 54C, and 62C Mower Deck).....................395 Adjusting Mower Deck Wheels.................................................395 Mower Deck Level Check and Adjustment.......................................396 Adjusting Mower Level Side-to-Side..........................................396 Adjusting Mower Level Front-to-Rear.........................................397 Adjusting Latch Rod.........................................................398 Cylinder Leakage Test.......................................................398 45 Loader Lubrication.......................................................398 Repair..........................................................................399 Cleaning Grass and Debris From Machine......................................399 Mower Deck Belt and Shield Removal and Installation.........................399 Mower Deck Blade Removal and Installation...................................401 Mower Deck Blade - Sharpen..................................................402 Mower Deck Blade - Balance..................................................402 48C Mower Deck Spindle Removal and Installation.............................402 Idlers......................................................................404 Jacksheave..................................................................405 54C Mower Deck Spindle Removal and Installation.............................405 Jacksheave..................................................................407 Idlers......................................................................408 62C Mower Deck Spindle Removal and Installation.............................408 Mower Deck Drive Shaft Removal and Installation.............................410 Mower Deck Drive Shaft Repair...............................................411 Mower Deck Gearbox Removal and Installation.................................412 Mower Deck Gearbox Repair...................................................414 General Information.............................................................415 Reading Electrical Schematics...............................................415 Operation and Diagnostics...................................................416 Diagnostic Information......................................................416 Wire Color Abbreviation Chart...............................................416 Common Circuit Tests........................................................416 Conductors For 12 Volt Circuits.............................................417 Identification Numbers..........................................................418 Generator...................................................................418 Alternator..................................................................418 Component Location..............................................................419 Generator...................................................................419 Alternator Components.......................................................420 Control Panel...............................................................421 Generator Gear Box Components...............................................422 Schematics and Harnesses........................................................423 Wiring Harness Legend.......................................................423 Connectors..................................................................423 Standard Electrical Schematic...............................................424 Operation and Diagnostics.......................................................426 Generator Circuit Operation.................................................426 Generator Circuit Diagnosis.................................................426 Tests and Adjustments...........................................................428 Generator Stator Test.......................................................428 Generator Rotor Test........................................................429 Ground Fault Circuit Interrupter (GFCI) Checks..............................429 Generator Ground Test.......................................................430 Repair..........................................................................430 Stator Excitation Field Restoration.........................................430 PTO Shield Removal and Installation.........................................431 Generator Removal and Disassembly...........................................431 Gear Case Removal and Disassembly...........................................431 Rotor Bearing Removal and Installation......................................433 Rotor Fan Removal and Installation..........................................433 Generator Assembly and Installation.........................................434 Control Panel Removal and Installation......................................435 Miscellaneous.......................................................................437 Table of Contents...............................................................437 Specifications..................................................................439 Repair Specifications.......................................................439 Other Materials.............................................................439 Repair..........................................................................440 Fender Deck Removal and Installation........................................440 Fuel Tank Removal and Installation..........................................441 Fuel Pump/Fuel Gauge Sensor Removal and Installation........................442 Headlights Adjustment.......................................................442 Lift Linkage Removal and Installation.......................................443 Hood Removal and Installation...............................................446 Instrument Panel Removal and Installation...................................447 Front Wheel Removal and Installation........................................448 Rear Wheel Removal and Installation.........................................448 Index...............................................................................449 Numerics........................................................................449 A...............................................................................449 B...............................................................................449 C...............................................................................450 D...............................................................................450 E...............................................................................451 F...............................................................................452 G...............................................................................453 H...............................................................................453 I...............................................................................453 L...............................................................................453 M...............................................................................453 O...............................................................................454 P...............................................................................454 R...............................................................................454 S...............................................................................455 T...............................................................................456 U...............................................................................457 V...............................................................................457 W...............................................................................457
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
S.V