John Deere X465 X475 X485 X575 & X585 TM2023 Garden Tractors Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere X465 X475 X485 X575 & X585 TM2023 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 X465 X475 X485 X575 & X585 TM2023 Garden Tractors Service Manual – PDF DOWNLOAD
TM2023 X465, X575, X485, X575 and X585 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....................................................................... 7 Using High Pressure Washers.............................................................. 7 Illuminate Work Area Safely.............................................................. 7 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..................................................................... 8 Avoid Injury From Rotating Blades, Augers And PTO Shafts................................. 9 Service Cooling System Safely............................................................ 9 Handle Chemical Products Safely.......................................................... 9 Dispose of Waste Properly................................................................ 9 Live With Safety......................................................................... 9 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 Gasoline............................................................................. 18 Gasoline Storage..................................................................... 19 4 - Cycle Gasoline Engine Oil........................................................ 19 Break-In Engine Oil - 4-Cycle Gasoline............................................... 20 Hydrostatic Transmission and Hydraulic Oil........................................... 20 Gear Case Oil........................................................................ 21 Gear Transmission Grease............................................................. 22 Alternative Lubricants............................................................... 22 Synthetic Lubricants................................................................. 22 Lubricant Storage.................................................................... 22 Mixing of Lubricants................................................................. 22 Oil Filters.......................................................................... 22 Coolant Specifications................................................................... 23 Gasoline Engine Coolant.............................................................. 23 Gasoline Engine Coolant Drain Interval............................................... 23 Serial Number Locations.................................................................. 24 Product Serial Number................................................................ 24 Gasoline Engine Serial Number Location............................................... 24 Engine - Gas (Air-Cooled).................................................................... 25 Table of Contents........................................................................ 25 Specifications........................................................................... 27 General Specifications............................................................... 27 Tests & Adjustments Specifications................................................... 27 Repair Specifications................................................................ 28 Torque Specifications (Alphabetical)................................................. 29 Special or Required Tools............................................................ 30 Component Location....................................................................... 31 Engine - 21 HP (FH641D).............................................................. 31 Theory of Operation...................................................................... 32 Carburated Engine Fuel and Air System Operation...................................... 32 Governor Operation................................................................... 32 Lubrication System Operation......................................................... 33 Troubleshooting.......................................................................... 34 Engine Troubleshooting Guide......................................................... 34 Engine Runs Erratically/Loss Of Power................................................ 35 Starting Motor Troubleshooting Guide................................................. 35 Diagnostics.............................................................................. 37 Diagnostic Table..................................................................... 37 Tests and Adjustments.................................................................... 39 Throttle Cable Adjustment............................................................ 39 Choke Adjustment..................................................................... 39 Governor Adjustment.................................................................. 40 Low Idle Speed Adjustment............................................................ 40 High Idle Speed Adjustment........................................................... 40 Compression Test..................................................................... 41 Valve Clearance Adjustment........................................................... 42 Crankcase Vacuum Test................................................................ 43 Fuel Flow Test....................................................................... 44 Oil Pressure Test.................................................................... 45 Spark Test........................................................................... 46 Engine Repair............................................................................ 46 Fuel Pump Removal and Installation................................................... 46 Fuel Pump/Fuel Filter Inspection..................................................... 47 Air Cleaner - Removal/Inspection/Installation........................................ 47 Carburetor Removal and Installation.................................................. 48 Carburetor Disassembly/Assembly...................................................... 49 Carburetor Clean/Inspect/Rebuild:.................................................... 54 Intake Manifold Removal and Installation............................................. 54 Muffler Removal and Installation..................................................... 55 Engine Removal and Installation...................................................... 56 Cylinder Head Removal and Installation............................................... 59 Push Rod and Rocker Arm Removal and Installation..................................... 61 Valve Train Removal and Installation................................................. 62 Piston Removal and Installation...................................................... 63 Inspect Piston and Cylinder.......................................................... 65 Cylinder Bore Honing................................................................. 68 Cylinder Bore Resizing............................................................... 68 Crankcase Cover Removal and Installation............................................. 69 Crankcase Cover Inspection........................................................... 71 Governor Assembly Removal/Replacement................................................ 71 Governor Assembly Inspection......................................................... 73 Camshaft/Tappet Removal and Installation............................................. 73 Camshaft Disassembly/Inspection...................................................... 74 Crankshaft Removal/Replacement....................................................... 76 Crankshaft Inspection................................................................ 77 Connecting Rod Inspection............................................................ 78 Breather Valve Removal and Installation.............................................. 79 Breather Valve Inspection............................................................ 80 Oil Pump Removal and Installation.................................................... 80 Oil Pump Inspection.................................................................. 81 Oil Pickup Removal and Installation.................................................. 82 Oil Screen Inspection/Cleaning....................................................... 82 Flywheel Removal and Installation.................................................... 83 Stator Coil Inspection............................................................... 85 Ignition Coil Removal and Installation............................................... 85 Starting Motor Removal and Installation.............................................. 86 Starting Motor Solenoid Tests........................................................ 86 Starting Motor Test.................................................................. 87 Starter Motor Disassembly/Assembly................................................... 87 Starting Motor Inspection............................................................ 90 Engine - Gas (Liquid-Cooled)................................................................. 93 Table of Contents........................................................................ 93 Specifications........................................................................... 95 General Specifications............................................................... 95 Tests and Adjustments Specifications................................................. 96 Repair Specifications................................................................ 96 Torque Specifications (Alphabetical)................................................. 97 Special or Required Tools............................................................ 98 Component Location....................................................................... 99 Engine - 23 HP (FD671D).............................................................. 99 Engine - 25 HP (FD711D)..............................................................100 Theory of Operation......................................................................101 Cooling System Operation.............................................................101 Fuel and Air System Operation........................................................102 Fuel Injection Air System Components and Operation 25 HP - (FD711D)..................102 Fuel Pressure Regulator Operation - FD711D...........................................103 Governor Operation...................................................................103 Lubrication System Operation.........................................................104 Throttle Body Operation - 25 HP (FD711D).............................................105 Diagnostics..............................................................................106 Engine Diagnosis.....................................................................106 Engine Tests.........................................................................110 Tests and Adjustments....................................................................112 Throttle Lever Adjustment............................................................112 Throttle Cable Adjustment............................................................113 Choke Adjustment - 23 HP (FD671D)....................................................113 Governor Adjustment..................................................................113 Low Idle Speed Adjustment............................................................114 High Idle Speed Adjustment...........................................................115 Compression Test.....................................................................115 Valve Clearance Adjustment...........................................................116 Crankcase Vacuum Test................................................................117 Engine Oil Pressure Test.............................................................118 Fuel Pump Flow Test for Carburetor - 23 HP (FD671D)..................................119 Fuel Pump Pressure Test for Carburetor - 23 HP (FD671D)..............................119 Fuel Pump Pressure Test For Fuel Injection - 25 HP (FD711D)..........................120 Bleed Fuel System - 25 HP (FD711D)...................................................121 Fan Belt Tension Adjustment..........................................................121 Radiator Bubble Test.................................................................122 Radiator Cap Pressure Test...........................................................122 Thermostat Test......................................................................122 Cooling System Test..................................................................124 Repair...................................................................................124 Thermostat Removal and Installation..................................................124 Fan Belt Removal and Installation....................................................125 Cooling Fan and Bracket Removal and Installation.....................................126 Coolant Pump Removal and Installation................................................126 Radiator Removal and Installation....................................................128 Muffler Removal and Installation.....................................................131 Air Cleaner Removal and Installation.................................................132 Carburetor Removal and Installation - 23 HP (FD671D).................................133 Throttle Body Removal and Installation - 25 HP (FD711D)..............................135 Fuel Injector Removal and Installation - 25 HP (FD711D)..............................136 Fuel Pressure Regulator Removal and Installation - 25 HP (FD711D)....................137 Cylinder Head Removal and Installation...............................................138 Intake Manifold Removal and Installation - 23 HP (FD671D)............................139 Intake Manifold Removal and Installation - 25 HP (FD711D)............................140 Starting Motor Removal and Installation..............................................142 Starter Motor Disassembly and Assembly...............................................142 Starting Motor Inspection............................................................144 Engine Removal and Installation......................................................147 Flywheel Removal and Installation....................................................150 Push Rod/Rocker Arm Removal and Installation.........................................151 Valve Train Removal and Installation.................................................153 Crankcase Cover Removal and Installation.............................................154 Crankcase Cover Inspection...........................................................155 Governor Assembly Removal and Installation...........................................156 Piston Removal and Installation......................................................158 Inspect Piston and Cylinder..........................................................161 Cylinder Bore Honing.................................................................164 Cylinder Bore Resizing...............................................................164 Camshaft/Tappet Removal and Installation.............................................165 Camshaft Disassembly and Inspection..................................................166 Crankshaft Removal and Replacement...................................................167 Crankshaft Inspection................................................................167 Connecting Rod Inspection............................................................169 Breather Valve Removal and Installation..............................................170 Oil Pump Removal and Installation....................................................170 Oil Pump Inspection..................................................................171 Oil Screen Removal and Installation..................................................173 Electrical...................................................................................175 Table of Contents........................................................................175 General Information......................................................................179 Reading Electrical Schematics........................................................179 Theory of Operation Information......................................................180 Diagnostic Information...............................................................180 Wire Color Abbreviation Chart........................................................180 Common Circuit Tests.................................................................181 Conductors For 12 Volt Circuits......................................................181 Specifications...........................................................................182 General Specifications...............................................................182 Test and Adjustment Specifications...................................................182 Repair Specifications................................................................183 Special or Essential Tools...........................................................184 Other Materials......................................................................184 Component Location.......................................................................185 Right Side...........................................................................185 Left Side............................................................................186 Engine Components (FH641D)...........................................................187 Engine Components (FD671D)...........................................................188 Engine Components (FD711D EFI).......................................................189 Instrument Panel.....................................................................190 Schematics and Harnesses.................................................................191 Schematic and Wiring Harness Legend - X465, X475 and X575............................191 Schematic And Wiring Harness Legend - X485 and X585..................................192 Electrical Schematic - X465 (1 of 3).................................................195 Electrical Schematic - X465 (2 of 3).................................................196 Electrical Schematic - X465 (3 of 3).................................................197 Electrical Schematic - X475 and X575 (1 of 3)........................................198 Electrical Schematic - X475 and X575 (2 of 3)........................................199 Electrical Schematic - X475 and X575 (3 of 3)........................................200 Electrical Schematic - X485 and X585 (1 of 4)........................................201 Electrical Schematic - X485 and X585 (2 of 4)........................................202 Electrical Schematic - X485 and X585 (3 of 4)........................................203 Electrical Schematic - X485 and X585 (4 of 4)........................................204 W1 Main Wiring Harness - X465 (1 of 2)...............................................205 W1 Main Wiring Harness - X465 (2 of 2)...............................................206 W2, W6 and W7 Engine Wiring Harnesses - X465.........................................207 W1 Main Wiring Harness - X475 and X575 (1 of 2)......................................208 W1 Main Wiring Harness - X475 and X575 (2 of 2)......................................209 W2 Engine Wiring Harness - X475 and X575.............................................210 W1 Main Wiring Harness - X485 and X585 (1 of 2)......................................211 W1 Main Wiring Harness - X485 and X585 (2 of 2)......................................212 W2 Engine Wiring Harness - X485 and X585.............................................213 W2 Engine Wiring Harness Circuit Schematic - X485 and X585...........................214 W3 Headlight Wiring Harness..........................................................215 W4 Rear Wiring Harness...............................................................215 W5 PTO Option Wiring Harness.........................................................215 W1 Main Wiring Harness Color Codes - X465............................................216 W1 Main Wiring Harness Color Codes - X475 and X575...................................217 W1 Main Wiring Harness Color Codes - X485 and X585...................................218 W2 Engine Wiring Harness Color Codes - X475 and X575.................................219 W2 Engine Wiring Harness Color Codes - X485 and X585.................................220 W3 Headlight Wiring Harness Color Codes..............................................220 W4 Rear Wiring Harness Color Codes...................................................220 W5 PTO Option Wiring Harness Color Codes.............................................220 Operation and Diagnostics................................................................221 Power Circuit Operation - X465.......................................................221 Power Circuit Wiring Schematic - X465................................................222 Power Circuit Operation - X475 and X575..............................................224 Power Circuit Electrical Schematic - X475 and X575...................................225 Power Circuit Diagnosis - X465, X475 and X575........................................227 Power Circuit Operation - X485 and X585..............................................230 Power Circuit Electrical Schematic - X485 and X585...................................232 Power Circuit Diagnosis - X485 and X585..............................................235 Cranking Circuit Operation - All Models..............................................239 Cranking Circuit Electrical Schematic - All Models...................................240 Cranking Circuit Diagnosis - All Models..............................................241 Charging Circuit Operation - All Models..............................................243 Charging Circuit Electrical Schematic - All Models...................................244 Charging Circuit Diagnosis - All Models..............................................245 Ignition Circuit Operation - X465, X475 and X575.....................................247 Ignition Circuit Electrical Schematic - X465, X475 and X575..........................248 Ignition Circuit Diagnosis - X465, X475 and X575.....................................250 Ignition Circuit Operation - X485 and X585...........................................253 Ignition Circuit Electrical Schematic - X485 and X585................................254 Ignition Circuit Diagnosis - X485 and X585...........................................257 PTO/RIP Circuit Operation - All Models...............................................263 PTO Circuit Electrical Schematic - All Models........................................265 PTO Circuit Diagnosis - All Models...................................................267 Instrument Panel Circuit Operation - All Models......................................270 Instrument Panel Circuit Electrical Schematic - All Models (SN -30000)...............272 Instrument Panel Circuit Schematic - All Models (SN 30001-)..........................273 Instrument Panel Circuit Diagnosis - All Models......................................274 Lights Circuit Operation - All Models................................................276 Lights Circuit Electrical Schematic - All Models.....................................277 Lights Circuit Diagnosis - All Models................................................278 Fuel Pump and Fuel Shutoff Circuit Operation - X465, X475 and X575...................280 Fuel Pump and Fuel Shutoff Circuit Electrical Schematic - X465, X475 and X575........281 Fuel Pump and Fuel Shutoff Circuit Diagnosis - X465, X475 and X575...................283 Fuel Pump and Fuel Injector Circuit Operation - X485 and X585........................286 Fuel Pump and Fuel Injector Circuit Electrical Schematic - X485 and X585.............287 Fuel Pump and Fuel Injector Circuit Diagnosis - X485 and X585........................290 Fuel Injection Sensor and Diagnostic Circuit Operation - X485 and X585...............294 Fuel Injection Sensor and Diagnostic Circuit Electrical Schematic - X485 and X585....295 Fuel Injection Sensor and Diagnostic Circuit Diagnosis - X485 and X585...............298 Tests and Adjustments....................................................................302 Common Circuit Tests.................................................................302 Ground Circuit Tests.................................................................302 Battery Voltage and Specific Gravity Test............................................303 Battery - Charge.....................................................................304 Battery - Load Test..................................................................304 Regulated Amperage and Voltage Test..................................................305 Regulated Voltage Test...............................................................306 Voltage Regulator/Rectifier Test - X465..............................................306 Unregulated Voltage Test - X465......................................................307 Unregulated Voltage Test - X475, X575, X485, and X585................................307 Stator Resistance Test...............................................................308 Starting Motor Condition.............................................................308 Starter Solenoid Test................................................................309 Starting Motor Amp Draw Test.........................................................309 Starting Motor No-load Amperage and RPM Test.........................................310 Field Windings Test..................................................................310 Starter Armature Test................................................................311 Ignition Interlock Test..............................................................312 Engine Coolant Temperature Sensor Test - X475, X575, X485, and X585..................314 Engine Oil Pressure Switch Test......................................................315 Lights Switch Test...................................................................315 PTO/RIP Switch Test..................................................................316 Relay Test...........................................................................316 Seat Switch Test.....................................................................317 Brake Switch Test and Adjustment.....................................................317 RIO Switch Test......................................................................318 RIO Switch Adjustment................................................................318 Service Timer Reset Switch (SN -30000)...............................................319 Fuse Test............................................................................319 Instrument Panel Light Test..........................................................320 PTO Solenoid Test....................................................................321 PTO Switch Test (optional)...........................................................321 Fuel Shutoff Solenoid Test - X465, X475 and X575.....................................322 Diode Test...........................................................................323 Fuel Tank Sensor Test................................................................323 Fuel Injector Test - X485 and X585...................................................324 Fuel Injection Module Test - X485 and X585...........................................324 Vacuum Pressure Sensor Test - X485 and X585..........................................325 Air Temperature Sensor Test - X485 and X585..........................................326 Coolant Temperature Sensor Test - X485 and X585......................................326 Spark Plug Gap Test..................................................................327 Spark Plug Gap Adjustment............................................................327 Ignition Coil Test...................................................................328 Spark Test...........................................................................328 Repair...................................................................................329 Ignition Coil Replacement............................................................329 Stator Replacement...................................................................330 Power Train - Hydrostatic....................................................................331 Table of Contents........................................................................331 Specifications...........................................................................333 General Specifications...............................................................333 Test And Adjustment Specifications...................................................333 Repair Specifications................................................................333 Special or Essential Tools...........................................................334 Other Materials......................................................................334 Component Location.......................................................................335 Hydrostatic Power Train..............................................................335 Final Drive (MFWD)...................................................................337 Front Axle Gear Case (MFWD)..........................................................338 Front Axle Assembly (MFWD)...........................................................340 Rear PTO Gear Case Assembly..........................................................341 MFWD Output Shaft....................................................................343 Theory of Operation......................................................................344 Center Section and Directional Control Valves - Reverse System Operation.............344 Transaxle Oil Flow System Operation..................................................347 External Power Train System Operation................................................350 Transaxle Internal System Operation..................................................351 Rear PTO Component Location and Operation - Optional.................................355 540 Rear PTO.........................................................................356 Diagnostics..............................................................................357 Hydrostatic Transmission Diagnosis...................................................357 Mid-PTO System Diagnosis.............................................................359 Transaxle Diagnosis..................................................................359 Hydrostatic Transmission Test........................................................360 Mid-PTO System Test..................................................................362 Transaxle Test.......................................................................363 Tests and Adjustments....................................................................364 Hydraulic Oil Warm-Up Procedure......................................................364 Charge Pump Pressure Test............................................................364 Charge Pump Flow and Pressure Test - At Charge Pump..................................365 Mid-PTO Engagement Pressure and Brake Test...........................................367 Transaxle Neutral Adjustment.........................................................368 Transaxle Control Linkage Adjustment.................................................369 Transaxle Linkage Full Forward Adjustment............................................370 Cruise Control Linkage Check and Adjustment..........................................370 Repair...................................................................................372 Foot Control Linkage Removal and Installation........................................372 Shift Lever Linkage (MFWD) Removal and Installation..................................375 Oil Cooler Removal and Installation..................................................376 Control Arm and Damper Removal and Installation......................................378 Differential Lock Linkage Inspection.................................................379 Charge Pump Removal and Installation.................................................379 Charge Pump Disassembly and Assembly.................................................380 Directional Control Valves...........................................................381 Hydrostatic Pressure Relief Valve (45 Loader) Installation...........................382 Drive Shaft Removal and Installation.................................................382 PTO Solenoid Valve...................................................................383 PTO Relief Valve Removal and Installation............................................385 PTO Relief Valve Disassembly, Inspection and Assembly................................385 PTO Brake Removal and Installation...................................................385 PTO Brake Disassembly, Inspection and Assembly.......................................386 PTO Drive Train (Mid-PTO) Removal and Installation...................................387 PTO Drive Train (Mid and Rear PTO) Removal and Installation..........................388 Rear PTO Removal and Installation....................................................391 Transaxle Removal and Installation...................................................394 Differential Lock Shaft Disassembly and Assembly.....................................396 Differential (2-Wheel Drive) Disassembly and Assembly................................397 Differential (MFWD) Disassembly and Assembly.........................................398 PTO Clutch Disassembly, Inspection and Assembly......................................399 MFWD Output Shaft Removal and Installation...........................................400 Hydrostatic Transmission 2-WD and MFWD...............................................403 Hydrostatic Pump Inspection..........................................................410 Transaxle Disassembly................................................................411 Transaxle (Right Cover) Disassembly and Assembly.....................................414 Transaxle Case Inspection............................................................415 Transaxle Assembly...................................................................415 Rear Axle Assembly (Two Wheel Steer Models) Removal and Installation.................417 Rear Axle Assembly (Two Wheel Steer Models) Disassembly and Assembly.................418 Rear Axle Assembly (All Wheel Steer) Removal and Installation........................419 Rear Axle Assembly (All Wheel Steer) Disassembly and Assembly........................420 Knuckle Assembly (All Wheel Steer) Removal and Installation..........................421 Knuckle Housing Disassembly and Assembly.............................................421 Final Drive Cover Removal and Installation - (MFWD)..................................422 Final Drive Housing Removal and Installation - (MFWD)................................424 Spindle Housing - (MFWD).............................................................426 Drive Shaft Removal and Installation - (MFWD)........................................427 Mechanical Front Wheel Drive Removal and Installation - (MFWD).......................427 Differential Input Housing - (MFWD)..................................................429 Front Axle Housing Disassembly and Assembly..........................................430 Hydraulics...................................................................................433 Table of Contents........................................................................433 Specifications...........................................................................435 General Specifications...............................................................435 Test and Adjustment Specifications...................................................435 Repair Torque Specifications.........................................................436 Special or Essential Tools...........................................................436 Other Materials......................................................................436 Schematics...............................................................................437 Hydraulic Schematic - Power Train....................................................437 Component Location.......................................................................438 Hydraulic System.....................................................................438 Operation and Diagnostics................................................................439 Hydraulic System.....................................................................439 Hydraulic Control Valve Operation - Neutral..........................................440 Hydraulic Control Valve Operation - Raise............................................441 Hydraulic Control Valve Operation - Float............................................442 Hydraulic Control Valve Operation - Regen............................................443 Lift Cylinder Shut-off Valve - Optional..............................................444 Hydraulic Diagnostics................................................................444 Preliminary Hydraulic System Inspection..............................................446 Hydraulic System Tests...............................................................447 Tests and Adjustments....................................................................448 Hydraulic Oil Warm-Up Procedure......................................................448 Charge Pump Pressure and Flow Quick Test at Couplers.................................448 Charge Pump Pressure Test............................................................449 Lift Cylinder Leakage Test...........................................................451 Control Valve Leakage Test...........................................................451 Repair...................................................................................452 Hydraulic Control Valve Removal and Installation.....................................452 Hydraulic Control Valve..............................................................453 Lift Cylinder Removal and Installation...............................................454 Hydraulic Control Levers and Linkage.................................................455 Steering.....................................................................................457 Table of Contents........................................................................457 Specifications...........................................................................459 General Specifications...............................................................459 Test and Adjustment Specifications...................................................459 Repair Specifications................................................................459 Special or Essential Tools...........................................................459 Component Location.......................................................................460 Steering Components - Front Wheel Steer..............................................460 Steering Components - All Wheel Steer................................................461 Steering Components - All Wheel Steer Rear Axle......................................462 Theory of Operation......................................................................463 Steering System Operation............................................................463 Steering Valve Operation - Neutral...................................................464 Steering Valve Operation - Turning...................................................465 Steering Valve Operation - Manual....................................................466 Diagnostics..............................................................................467 Steering Diagnosis...................................................................467 Steering System Tests................................................................468 Steering Link Checks.................................................................468 Tests and Adjustments....................................................................469 Hydraulic Oil Warm-Up Procedure......................................................469 Steering Valve and Cylinder Leakage Test.............................................469 Toe-In Adjustment Front Wheels.......................................................470 Toe-In Adjustment All Wheel Steering.................................................471 Repair...................................................................................472 Steering Column Removal and Installation.............................................472 Steering Valve Removal and Installation..............................................473 Steering Valve Disassembly and Assembly..............................................475 Steering Cylinder Removal and Installation...........................................478 Front Axle Removal and Installation..................................................478 Front Axle Disassembly and Assembly..................................................479 Rear Steering Linkage - All Wheel Steering...........................................481 Steering Intermediate Linkage - AWS..................................................483 Front and Rear Pivots................................................................484 Brakes.......................................................................................487 Table of Contents........................................................................487 Specifications...........................................................................489 General Specifications...............................................................489 Test and Adjustment Specifications...................................................489 Repair Specifications................................................................489 Special or Essential Tools...........................................................489 Other Materials......................................................................489 Component Location.......................................................................490 Brake System Component Location......................................................490 Brake/Differential Linkage (Exploded)................................................491 Theory of Operation......................................................................492 Brake System Operation...............................................................492 Diagnostics..............................................................................493 Brakes...............................................................................493 Tests and Adjustments....................................................................495 Brake/Differential Linkage Adjustment................................................495 Repair...................................................................................497 Brake/Differential Linkage Removal and Installation..................................497 Brakes Removal and Installation......................................................499 Attachments..................................................................................501 Table of Contents........................................................................501 Specifications...........................................................................503 General Specifications...............................................................503 Torque and Repair Specifications.....................................................505 Diagnostics..............................................................................507 48, 54 and 62-Inch Mower Deck Diagnosis..............................................507 45 Loader Diagnosis..................................................................510 Tests and Adjustments....................................................................511 Adjusting Cutting Height (48C, 54C, and 62C Mower Deck)..............................511 Adjusting Mower Deck Wheels..........................................................511 Mower Deck Level Check and Adjustment................................................512 Adjusting Mower Level Side-to-Side...................................................512 Adjusting Mower Level Front-to-Rear..................................................513 Adjusting Latch Rod..................................................................514 Cylinder Leakage Test................................................................514 45 Loader Lubrication................................................................514 Repair...................................................................................515 Cleaning Grass and Debris From Machine...............................................515 Mower Deck Belt and Shield Removal and Installation..................................515 Mower Deck Blade Removal and Installation............................................517 Mower Deck Blade - Sharpen...........................................................518 Mower Deck Blade - Balance...........................................................518 48C Mower Deck Spindle Removal and Installation......................................518 Idlers...............................................................................520 Jacksheave...........................................................................521 54C Mower Deck Spindle Removal and Installation......................................521 Jacksheave...........................................................................523 Idlers...............................................................................524 62C Mower Deck Spindle Removal and Installation......................................524 Mower Deck Drive Shaft Removal and Installation......................................526 Mower Deck Drive Shaft Repair........................................................527 Mower Deck Gearbox Removal and Installation..........................................528 Mower Deck Gearbox Repair............................................................530 General Information......................................................................531 Reading Electrical Schematics........................................................531 Operation and Diagnostics............................................................532 Diagnostic Information...............................................................532 Wire Color Abbreviation Chart........................................................532 Common Circuit Tests.................................................................532 Conductors For 12 Volt Circuits......................................................533 Identification Numbers...................................................................534 Generator............................................................................534 Alternator...........................................................................534 Component Location.......................................................................535 Generator............................................................................535 Alternator Components................................................................536 Control Panel........................................................................537 Generator Gear Box Components........................................................538 Schematics and Harnesses.................................................................539 Wiring Harness Legend................................................................539 Connectors...........................................................................539 Standard Electrical Schematic........................................................540 Operation and Diagnostics................................................................542 Generator Circuit Operation..........................................................542 Generator Circuit Diagnosis..........................................................542 Tests and Adjustments....................................................................544 Generator Stator Test................................................................544 Generator Rotor Test.................................................................545 Ground Fault Circuit Interrupter (GFCI) Checks.......................................545 Generator Ground Test................................................................546 Repair...................................................................................546 Stator Excitation Field Restoration..................................................546 PTO Shield Removal and Installation..................................................547 Generator Removal and Disassembly....................................................547 Gear Case Removal and Disassembly....................................................547 Rotor Bearing Removal and Installation...............................................549 Rotor Fan Removal and Installation...................................................549 Generator Assembly and Installation..................................................550 Control Panel Removal and Installation...............................................551 Miscellaneous................................................................................553 Table of Contents........................................................................553 Specifications...........................................................................555 Repair Specifications................................................................555 Other Materials......................................................................555 Repair...................................................................................556 Fender Deck Removal and Installation.................................................556 Fuel Tank Removal and Installation...................................................557 Fuel Pump/Fuel Gauge Sensor Removal and Installation.................................558 Headlights Adjustment................................................................559 Lift Linkage Removal and Installation................................................560 Hood Removal and Installation........................................................563 Instrument Panel Removal and Installation............................................564 Front Wheel Removal and Installation.................................................565 Rear Wheel Removal and Installation..................................................565 Index........................................................................................567 Numerics.................................................................................567 A........................................................................................567 B........................................................................................567 C........................................................................................567 D........................................................................................568 E........................................................................................568 F........................................................................................571 G........................................................................................572 H........................................................................................572 I........................................................................................572 K........................................................................................572 L........................................................................................572 M........................................................................................572 O........................................................................................573 P........................................................................................573 R........................................................................................573 S........................................................................................574 T........................................................................................574 U........................................................................................575 V........................................................................................575 W........................................................................................575
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V