6.2
Updated
Servicing Cooling System
Draining Cooling System
Park machine safely. (See Parking Safely in the Safety section.)
Allow engine to cool.
Raise operator seat.
Slowly open radiator cap to the first stop to release all pressure.
TCT015954-UN: Radiator Drain HosePlace a suitable container below the radiator drain hose (A) located between engine and right rear tire.
TCT015953-UN: Radiator drainOpen the radiator drain (B) on the bottom of the radiator. Drain coolant into container. Close radiator drain after all coolant has drained from the radiator.
Flush the cooling system.
Flushing Cooling System
Drain cooling system and add John Deere Cooling System Cleaner, or John Deere Cooling System Quick Flush or equivalent. Fill system with clean water. Follow directions on can.
Install and tighten radiator cap.
Start and run engine until it reaches operating temperature.
Stop engine.
Open radiator drain valve. Drain cooling system immediately before rust and dirt settle.
Close radiator drain valve.
Fill cooling system with clean water and repeat flushing until system is clean.
Drain system and fill with coolant.
Filling Cooling System
IMPORTANT:
Avoid Damage! Using incorrect coolant mixture can damage the radiator:
Do not operate engine with plain water.
Do not exceed a 50% mixture of coolant and water.
Aluminum engine blocks and radiators require approved ethylene-glycol based antifreeze.
With engine and cooling system cool, open radiator cap to the first stop to release all pressure. Press down on cap slightly and turn counterclockwise to remove.
Fill cooling system.
Cooling system capacity is as follows:
Item
Measurement
Specification
Cooling System
Z994R
Capacity
7.1 L (7.5 qt)
Certain geographical areas may require lower temperature protection. See the label on your antifreeze container or consult your John Deere dealer to obtain the latest information and recommendations.
John Deere Cooling System Sealer or its equivalent may be added to the radiator to seal leaks. Do not use any other additives in the cooling system.
Start engine and watch coolant level in radiator. Add coolant if necessary to bring coolant level up to filler neck.
Install and tighten radiator cap. Run engine until at operating temperature.
Stop engine and allow to cool down.
Add coolant, if necessary, to the coolant recovery tank.
Check condition of hoses and clamps. Check for leaks or loose connections.
Coolant recovery tank is used to catch overflow from radiator, and will remain about half full during operation. Coolant will flow back into radiator as needed after system cools.
Servicing Fuel Filter
Avoid Injury! Fuel vapors are explosive and flammable:
Do not smoke while handling fuel.
Keep fuel away from flames or sparks.
Shut off engine before servicing.
Cool engine before servicing.
Work in a well-ventilated area.
Clean up spilled fuel immediately.
Change filter when fuel level is low.
Checking
Park machine safely. (See Parking Safely in the Safety section.)
Allow engine to cool.
Open engine cover.
TCT015944-UN: Fuel filter sediment bowlLocate the fuel filter sediment bowl (A) on the left side of the engine. Look for water in the sediment bowl indicated by the red float ring being lifted off the bottom.
Cleaning and Replacing
Close fuel shutoff valve (B) by turning to the horizontal position.
Unscrew collar (C) to remove bowl and filter. Discard filter.
Clean bowl and install new filter.
Install bowl and collar. Tighten collar hand tight.
Open fuel shutoff valve by turning lever to vertical position (shown).
Prime fuel system using primer lever on the fuel pump.
Start engine and check for leaks.
Priming Fuel System
NOTE:
It may be necessary to prime the fuel system after running out of fuel or changing the fuel filter.
Make sure that the machine is on a level surface, not a slope.
Turn off PTO switch.
Lower attachments to the ground.
Lock the park brake.
Remove the key.
TCT015945-UN: Electric boost pump is located under the seat on the left side of machine.Turn key switch to RUN position for 2 minutes prior to starting engine. The fuel pump (A) will pressurize the fuel and remove any air in the system. Start engine. If engine will not start, repeat previous step.
Checking and Adjusting Alternator Belt
Avoid Injury! Rotating parts can catch fingers, loose clothing, or long hair. Wait for engine and all moving parts to stop before leaving operator’s station to adjust or service machine.
Checking Belt Tension
Park machine safely. (See Parking Safely in the Safety section.)
Allow engine to cool.
TCT015938-UN: Engine Access GrillRemove cap screws (A) on each side of machine. Remove and set aside engine access grill (B).
TCT015951-UN: Pulley CoverRemove three cap screws (C) and pulley cover (D).
TCT015947-UN: Alternator beltCheck alternator belt (E). Inspect belt for excessive wear, damage, or stretching while mounted on engine.
Apply finger pressure to the belt approximately halfway between the alternator and water pump pulleys at (E). Belt should deflect the specified distance. Adjust if too tight or too loose.
Item
Measurement
Specification
Alternator Belt
Deflection
10-15 mm (3/8-1/2 in.)
Adjusting Belt Tension
Loosen adjustment bolt (F).
Loosen alternator mounting bolt (G).
Apply outward pressure to the alternator housing.
Tighten adjustment bolt (F) and mounting bolt (G).
Check belt tension.
Reinstall pulley cover and engine grille.
Replacing Alternator Belt
CAUTION: Avoid Injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Allow the engine to cool before servicing or working near the engine and components.
Park machine safely. (See Parking Safely in the Safely section.)
Allow engine to cool.
Open engine cover.
TCT015938-UN: Engine Access GrillRemove cap screws (A) on each side of machine. Remove and set aside engine access grill (B).
TCT015951-UN: Pulley CoverRemove three cap screws (C) and pulley cover (D). NOTE:
It may be necessary to remove alternator adjustment bolt to loosen belt enough for it to come off of pulleys.
TCT015952-UN: Alternator BoltsLoosen adjustment bolt (E) and alternator mounting bolt (F). Push alternator in towards the engine to loosen alternator belt tension.
Remove the worn alternator belt (G) from the machine.
Install new belt onto the engine and alternator pulleys.
Adjust alternator belt tension.
Close engine cover.
Engine
-: Model Z994
Engine Model Number..............Yanmar 3TNV80F |
Engine Type..............4-Cycle, 3-Cylinder, In-Line Diesel |
Displacement..............1.267 L (77.3 in³) |
Bore..............80 mm (3.15 in) |
Stroke..............84 mm (3.31 in) |
Engine RPM/Slow Idle..............1725 +/- 100 RPM |
Engine RPM/Fast Idle..............3385 +/- 50 RPM |
Valve Clearance..............0.15—0.25 mm (0.006—0.010 in) |
Cooling..............Liquid Cooled |
Injection Type..............Indirect |
Air Cleaner..............Dry, Replaceable Dual Element |
Starting Aid..............Glow Plugs |
Z994R
Changing Gearbox Oil
CAUTION: Avoid Injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Allow the engine to cool before servicing or working near the engine and components.
IMPORTANT:Avoid Damage! Change the oil more often if the vehicle is used in extreme conditions:
Dusty conditions.
Frequent slow or low-speed operation.
Frequent short trips.
Run engine to warm oil.
Park machine safely on a level surface. (See Parking Safely in the Safety section.)
Put container under oil drain area.
TCT016133-UN: Remove GrilleRemove two cap screws (A) on both sides of grille. Remove grille (B) from machine.
TCT016134-UN: Remove Guard and CoverRemove four cap screws (C), guard (D), and cover (E) from machine.
TCT016018-UN: Remove PlugsRemove the fill plug (F) and clean the magnet of any metallic debris. Remove drain plug (G) and allow oil to drain into container.
Clean magnet of any metallic debris.
After oil drains, install drain plug. Tighten drain plug to specification.
Item
Measurement
Specification
Gearbox Drain Plug
Torque
28—33 N·m (20—24 lb·ft)
Using a funnel, fill the gearbox with 335—435 mL (11.3—14.7 oz) of 80W90 GL5 Gearbox Oil.
Install the fill plug. Tighten the fill plug to specification.
Item
Measurement
Specification
Gearbox Fill Plug
Torque
28—33 N·m
(20—24 lb·ft)Clean for any oil spilled during the process.
Reinstall cover, guard, grille, and exhaust guard.
Using Indicator Lights
Hourmeter (A) will display number of hours machine has run.
Engine Coolant Temperature Indicator (B) will glow if engine temperature becomes excessive. Stop engine and determine cause.
Deck lift and PTO functions will be disabled whenever the Engine Coolant Temperature indicator is illuminated.
Battery Discharge Indicator (C) will glow when alternator is not producing adequate voltage. Stop engine and determine cause.
Hydraulic Oil Temperature Indicator (D) will glow when hydraulic oil temperature is high and deck lift and PTO functions will stop. Let hydraulic oil temperature cool by allowing engine to idle under a no-load situation. This keeps the oil flowing through the oil cooler and cools the oil. Check oil level and make sure oil cooler coils are clean. Continued operation may cause higher temperatures, resulting in damage.
PTO function will be disabled whenever the Hydraulic Oil Temperature indicator is illuminated.
Engine Glow Plug Indicator Light (E) will glow when key switch is turned to the run position. After approximately 3 to 15 seconds the light will go out.
Diagnostic Indicator Light (F) will flash a diagnostic code to help the operator identify operational and electrical problems. (See Diagnostics in this section.)
Engine Oil Pressure Indicator (G) will glow when engine oil pressure is low. If lamp glows when engine is running, stop engine immediately. (See your John Deere distributor.)
Adjusting Seat Position
Sit on operator seat.
TCT013977-UN: Adjusting SeatAdjust seat position: Sit in seat.
Push and hold the seat adjustment lever (A) to middle of seat.
Slide forward or backward to desired position.
Release lever.
TCT013978-UN: Adjust Seat ComfortGlideSeat ComfortGlide™ feature: Sit on seat.
Push on lever (A) to outside of seat to allow seat glide.
Push lever to middle of seat to disengage glide feature.
If glide position does not disengage, rise off seat and push lever to middle of seat.
Release lever.
Adjusting Ride Comfort
TCT014246-UN: Adjusting suspension
TCT014247-UN: Lumbar supportAdjust seat weight adjuster knob (A) to the operator’s weight. Turn knob (B) to the desired seat back position.
Turn lever (C) to desired lumbar support position.
Setting Mower Deck Cutting Height
Avoid Injury! Rotating blades are dangerous and can cut fingers and toes. Stop engine, lock the park brake, and wait for blade to stop rotating before adjusting cutting height.
Cutting height can be adjusted from approximately 25 to 139 mm (1 to 5-1/2 in.). Each increment on the knob adjusts the height-of-cut (HOC) approximately 6 mm (1/4 in).
The deck can also be raised and locked in a transport position, to provide maximum ground clearance when moving the machine from one area to another.
Adjusting
Park machine safely. (See Parking Safely in the Safety section.)
Disengage PTO.
Stop engine and lock park brake.
Raise mower deck using deck lift pedal.
TCT012780-UN: Setting Mower Deck Cutting HeightWith the deck in raised position, adjust height of cut knob (A) to align cut height to the index mark (B). Release pedal to lower deck to desired setting.
Transport Lock
The deck can be locked in a transport position to give maximum ground clearance when the machine is moved to and from various work sites.
The transport lock should always be used if the deck needs to be in the transport position for more than 12 seconds.
The transport lock function allows the deck to be returned to the previous Height of Cut after being in the transport position.
Park machine safely. (See Parking Safely in the Safety section.)
Disengage PTO.
Stop engine and lock park brake.
Raise mower deck using deck lift pedal.
With the deck in raised position, rotate knob (C) counterclockwise into the transport lock position.
Release pedal to lower deck to transport setting.
Release Transport Lock
Raise mower deck using deck lift pedal.
Rotate transport lock knob clockwise. Knob will release to off position.
Release pedal to lower deck to previous height of cut setting.
Testing PTO Switch
Sit on the operator seat.
Lock the park brake.
Push front of PTO switch down to engage.
Turn key switch to the start position.
Result: The engine will not crank.
Using the Park Brake
Avoid Injury! Children or bystanders may attempt to move or operate an unattended machine.
Always lock the park brake and remove the key before leaving the machine unattended.
TCT014259-UN: PedalTo lock the park brake, press park brake pedal (A) fully down. To unlock the park brake, press park brake release (B) with your heel.
Using the PTO
Engage PTO:
NOTE:
The PTO will be disabled and not engage if the key switch is in the RUN and/or START position for 10 seconds or longer and the engine has not been started. Turn the key switch to the OFF position and then to the START position and start the engine within 10 seconds to allow the PTO to engage.
Move throttle lever to the 1/2 or 3/4 fast position.
Push front of PTO switch down to engage mower deck.
Move throttle lever forward to the fast position for mowing.
Disengage PTO:
Push back of PTO switch down.
Engaging Mower
Avoid Injury! Clear mowing area of all bystanders when operating this machine. Thrown objects could cause serious injury or death.
Keep hands and feet away from blades and discharge opening.
Do not mow in reverse unless absolutely necessary.
Avoid Damage! To help prevent damage to the PTO clutch:
• Do not engage PTO with throttle in the fast position.
Adjust the height of cut knob to the desired cutting height and lower the deck.
Start engine.
Move throttle lever to the 1/2–3/4 throttle position.
Unlock park brake.
Move both motion control levers to the neutral position.
Push down front of PTO switch to engage mower deck.
Move throttle lever to the fast position.
NOTE:
The travel speed and turn rate will vary with the amount that the control levers are moved.
Push motion control levers forward slowly. Mow at a safe travel speed.
To stop machine motion, move both motion control levers in the opposite direction of motion until machine comes to a stop.
Changing Transmission Oil and Filters
Avoid Injury! Escaping fluid under high pressure can penetrate the skin and cause serious injury. Avoid the hazard by relieving pressure before connecting hydraulic or other lines. Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
• If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. In the United States and Canada only, this information may be obtained by calling 1-800-822-8262.
Avoid Damage! Contamination of hydraulic fluid could cause transmission damage or failure. Do not open oil reservoir cap unless absolutely necessary.
Severe or unusual conditions may require a more frequent service interval.
Park machine safely. (See Parking Safely in the Safety section.)
Allow engine and transmission oil reservoir to cool.
Place drain pan under both transmissions.
IMPORTANT:
Avoid Damage! Do not use chlorinated solvents or high pressure water to clean grass and debris from filter caps.
TCT016519-UN: Clean area around each filter capClean area around each filter cap (A). Remove filter cap (A) and filter from each transmission. Discard filters.
Allow transmission oil to drain into a drain pan.
Apply a film of clean oil on gasket of each new transmission filter.
TCAL43541-UN: Install new filter into each transmissionInstall new filter into each transmission, with spring end (B) facing filter cap (C). Replace O-ring (D) on the filter cap.
Install filter cap (removed earlier) and tighten to specification.
Item
Measurement
Specification
Filter Cap
Torque
7.3 - 12.3 N·m (5.4 - 9 lb·ft)
Use a safe lifting device to raise the drive wheel off the ground. Support with jackstands.
Lift operator seat and lock into position.
Fill reservoir until oil level is between MIN and MAX marks on reservoir.
On both transmissions, pull the bypass levers back to the open position.
Rotate each drive tire by hand 1 full revolution forward and backward.
Check and fill reservoir until oil level is between MIN and MAX marks on reservoir.
Lower seat.
Start engine.
Allow engine to idle for 1 minute at low idle.
Push both motion control levers to full forward and hold for 5 seconds. Pull both control levers to full reverse and hold for 5 seconds. Repeat two additional times.
Stop the engine.
Push the bypass levers forward to the closed position.
Use a safe lifting device to raise the drive wheels off the ground. Remove the jackstands.
CAUTION: Avoid Injury! Help prevent serious bodily injury. Remain alert to other people and the surroundings when operating the machine.
Start the engine.
Move throttle lever to the 3/4 high idle position.
Unlock park brake.
Run engine in full throttle for 5 minutes and then cycle motion control levers forward and rearward several times. Check for leaks around filters.
Stop the engine. Check oil level. Add oil as necessary.
Checking and Adjusting Park Brake
Check Procedure—Brake Engaged
TCT005196-UN: Park MachineStop the machine on a maximum of 17° slope. Lock park brake.
Results
If adjusted properly, the brakes must prevent the wheels from turning. If wheels turn, perform adjustment procedure.
Check Procedure—Brake Released
Park machine safely. (See Parking Safely in the Safety section.)
Start engine.
Unlock park brake.
Move both control levers forward.
Results
If the brakes are adjusted properly, the drive wheels turn freely and the machine begins to travel forward. Adjust the brakes if needed.
If the brakes are over-tightened, an audible hydrostatic whine occurs and the machine moves slowly. Adjust the brakes if needed.
Park Brake Adjustment
IMPORTANT:
Avoid Damage! Right and left brakes must be adjusted evenly to ensure maximum brake performance and prevent uneven brake wear.
A park brake that is adjusted too tightly could damage the transmission or cause premature brake wear.
NOTE:Perform adjustment if neutral interlock system adequately restrains controls in neutral, but brake does not hold on slope.
Park machine safely. (See Parking Safely in the Safety section.)
Lock park brake.
CAUTION: Avoid Injury! The machine can fall or slip from an unsafe lifting device or supports.
• Use a safe lifting device rated for the load to be lifted.
• Lower machine onto jack-stands or other stable supports and block wheels before servicing.
IMPORTANT:Avoid Damage! Do not use rear grille as a lift point; using the grille could damage the frame.
Lift rear of the machine using a safe lifting device.
Measure the gap (A) between the two washers (B).
Tighten or loosen the brake equalizer adjustment nut (C) on the park brake actuator rod (D) so that the gap (A) between the two washers meets specification:
Item
Measurement
Specification
Park Brake Washer Gap
Length
27—29 mm
(1-1/16—1-9/64 in.)Test park brake.
Neutral Interlock Adjustment
NOTE:
Perform adjustment only if neutral interlock system does not adequately lock control sticks in neutral, or if brake or steering system has been disassembled.
Park machine safely. (See Parking Safely in the Safety section.)
Unlock park brake.
Back off the brake equalizer adjustment nut (A) to end of threaded rod, but do not remove.
Lock park brake.
Move control levers to the neutral lock position.
TCT005199-UN: Nuts
TCT005200-UN: Control lever removed for clarity.
TCT005201-UN: Cam and Control SurfaceLoosen nuts (B). Adjust (shorten) turnbuckle (C) until cam (D) is fully engaged under the control pivot wedge (E).
When adjusted properly, cam (D) and control surface (F) are parallel.
Verify that the control handle moves freely in and out of the slot in the frame before tightening nuts.
Adjust the equalizer nut. (See Park Brake Adjustment.)
Move control levers out to the neutral lock position.
TCT005202-UN: Set ScrewAdjust control set screw (G) until you notice the control lever begin to move forward in the control slot. Move control lever in and out to verify that it is not binding with the frame slot. Engage and release park brake.
NOTE:
Do not pull pedal back manually.
If the brake pedal binds or does not fully release, back off the set screw one flat. Check pedal again for binding. If the pedal still binds, back off the right-hand set screw by one flat. Repeat as necessary.
Replacing Fuses
Avoid Damage! When replacing fuses, be sure the replacement fuse has the same fuse rating and is installed in the correct location. Failure to do so could result in damage to the electrical harness and/or electrical components.
Park machine safely. (See Parking Safely in the Safety section.)
Raise and secure operator seat.
TCT016515-UN: Load Center and Console CoverRemove load center cover (A) to access fuses, relays, diode, and resistor. Remove covers (B) to access radiator fan and main system fuses.
Remove flange head cap screw (C), four cap screws (D), and console (E) to access radiator fan relay.
TCT016516-UN: Radiator Fan RelayDisconnect wiring harness connector (F) and remove flange nut (G) to replace radiator fan relay (H). Install radiator fan relay to console cover with the flange nut and connect to wiring harness. Reinstall console cover to the machine.
TCT016437-UN: Load Center ComponentsLEGEND: A - Diode, PTO ClutchB - Fuse, 10AC - Fuse, 5AD - Resistor, 68 ΩE - Relay, PTO ClutchF - Relay, StarterG - Relay, Fuel Pull-inH - Relay, Glow PlugIdentify and replace load center components with correct replacement components as needed. Reinstall load center cover.
TCT016517-UN: Radiator Fan and System FusesLEGEND: A - Radiator Fan Fuse, 50AB - Main System Fuse, 125AIdentify and replace radiator fan fuse (A) or main system fuse (B) as needed. Remove two flange nuts and fuse from machine.
Install new fuse with flange nuts. Tighten nuts to 4.5 N·m (39.8 lb·ft).
Reinstall covers.
Lower operator seat.
Drive Clutch Adjustment Procedure
If drive clutch has worn to the extent that the existing air-gap is too large to allow for complete clutch engagement, the brake shim can be removed to restore air gap and allow the clutch to continue to function properly.
Verify that proper voltage and current are supplied to the clutch before proceeding.
Clean out any debris from under and around the entire clutch assembly.
TCAL43573-UN: Loosen both M6 brake mounting boltsLoosen both M6 brake mounting bolts (A) 1/2 to 1 full turn.
TCAL43574-UN: Using needle nose pliers, or by hand, take hold of the tab and remove shimUsing needle nose pliers, or by hand, take hold of the tab and remove shim (B) (do not discard shim until proper clutch function has been confirmed).
TCAL43575-UN: Using a pneumatic line, blow out any debris from under the brake poleUsing a pneumatic line (C), blow out any debris from under the brake pole and around the aluminum spacers. Tighten each M6 brake mounting bolts (A) to specification
Item
Measurement
Specification
Brake Mounting Bolts
Torque
13 N·m (115 lb-in.)
TCAL43576-UN: Using a 0.010 thick feeler gage
TCAL43577-UN: Using a 0.010 thick feeler gageUsing a 0.010 thick feeler gage (D), verify that a gap is present between the rotor and armature face on both sides of the brake pole as shown above. If the gap is less than 0.010, then reinstall the shim. Consult your local John Deere Dealer for service.
If sufficient gap is present, then proceed to safety check outlined below.
Perform safety check:
Observe deck from position on mower seat with engine running to be certain deck is not engaged with PTO switch off and clutch off. From same position, engage and disengage the PTO switch ten consecutive times to ensure proper function of the clutch.
If clutch still does not engage, then consult your local John Deere Dealer for service.
Diagnostic Real-Time Codes (with key in RUN position)
For further assistance with all Diagnostic Codes, refer to the Technical Manual and/or consult your John Deere dealer.
-: Electrical System “Interlock” Violations
Electrical System “Interlock” Violations | |||
Real-Time Diagnostic Trouble Code Description | Diagnostic Code | Notes | Action Required to Remove Code: |
Brake Not Locked | 1 - 2 | This code can occur under the following conditions: 1. When the engine is trying to be started without the brake pedal locked. NOTE: Machine automatically shuts down if the following occurs: 2. When the engine is running and operator gets out of seat without the brake locked. | • Verify that the Park brake is locked. |
PTO/Mow Engaged | 1 - 3 | NOTE: This causes the PTO to be disabled. This code occurs only when getting out of the seat while operating the machine with the PTO engaged. | NOTE: For Safety, the PTO can not be engaged with the park brake locked or with the operator out of the seat. • Turn key switch to the OFF position. |
Crank Time Exceeded (20 second limit) | 2 - 4 | This code lets the operator know the maximum cranking time of 20 seconds per crank has been exceeded. | • Return the key to the OFF or RUN |
Starter Thermal Protect Mode, 60-second Cool- Down Needed | 2 - 5 | This code indicates that the module has started a 60- second cool-down period to prevent the starter from overheating. | • Turn the key switch to the OFF position and let the starter cool down for at least 60 seconds before making another attempt to start the engine. |
Over Temperature, Engine or Hydraulic System | 2 - 6 | This code indicates engine coolant or hydraulic oil has exceeded high temperature limits. | Turn the key switch to the OFF position and let the machine cool down before further operation. |
Engine Oil Pressure Low, PTO Disabled (Z900R Series Only) | 2 - 7 | This code indicates that the internal engine oil pressure is low and to eliminate any extra load on the engine, the vehicle control unit shuts down the PTO circuit. The PTO is disabled and not engaged if the key switch is in the RUN and/or START position for 10 seconds or longer and the engine has not been started. Turn the key switch to the OFF position and then to the START position and start the engine within 10 seconds to allow the PTO to engage. | • Turn the key switch to the OFF position • Check oil level in the engine. • Check oil pressure sender on the engine. • Check the harness wires from the oil pressure sender to the vehicle control unit, insure good connections. |
-: Electrical System 'Fault' Violations
Electrical System 'Fault' Violations | |||
NOTE: For All “Fault” codes it is important to first check battery, starter, and ground connections. | |||
| |||
Electrical System Diagnostic Trouble Code Description | Diagnostic Code | Notes | Action Required to Remove Code: |
Over Voltage | 3 - 1 | This code indicates that the vehicle control unit has detected a voltage higher than normal in the electrical charging system. At 15 V the code is set. At 16 V or greater the PTO is disengaged | • Inspect the electrical harness for loose connections, specifically the battery positive and negative, starter, and frame ground (on engine block). |
Low Voltage | 3 - 2 | This code will let the operator know that the battery is being depleted. Code sets when voltage level drops below 9 V. | • Check charging system connections. |
Starter Output Problem | 4 -1 | This code indicates a failed coil (low impedance), a short-to-ground condition in the wiring harness, or an output circuit failure internal to the module. This condition causes the output transistor to shut down to protect the module from over-current or over-temperature conditions. | • Inspect system wiring for short to ground condition. |
Fuel Pull Output Problem | 4 - 2 | This code indicates a failed coil (low impedance), a short-to-ground condition in the wiring harness, or an output circuit failure internal to the module. This condition causes the output transistor to shut down to protect the module from overcurrent or overtemp conditions. | • Inspect system wiring for short to ground condition. |
Glow Plug Output Problem | 4 - 3 | This code indicates a failed coil (low impedance), a short-to-ground condition in the wiring harness, or an output circuit failure internal to the module. This condition causes the output transistor to shut down to protect the module from overcurrent or overtemp conditions. | • Inspect system wiring for short to ground condition. |
Fuel Hold Output Failure | 4 - 4 | This code indicates that the fuel hold output circuit has failed internal to the module. | |
PTO Output Error | 4 - 5 | This code indicates that the PTO output circuit has failed internal to the module. | |
Starter Output Error | 5 - 1 | This code is only displayed if the key switch is in the start position. The code indicates that the output has detected an open circuit. | Inspect system wiring for an open circuit. |
Fuel Pull Output Error | 5 - 2 | This code indicates that output has detected an open circuit | Inspect system wiring for an open circuit. |
Glow Plug Output Error | 5 - 3 | This code indicates that output has detected an open circuit | Inspect system wiring for an open circuit. |
Fuel Hold Output Error | 5 - 4 | This code indicates that output has detected an open circuit or a short to power condition. | Inspect system wiring for shorted or open condition. |
Fuel Hold Output Overload | 5 - 5 | An over-current or over-temperature condition has been detected (solenoid has failed short or conductor is shorted to ground). | Inspect system wiring for shorted condition. |
PTO Circuit Open | 5 - 6 | This code indicates that an open circuit exists between the PTO output from the module and the clutch coil ground. | • Turn the key switch to the OFF position. • Inspect for a poor connection between switch contacts in the PTO switch, or an intermittent/open circuit in the harness connections between the module and the PTO clutch, or an open circuit in the PTO clutch coil winding. |
PTO Output Overload | 5 - 7 | An over-current or over-temperature condition has been detected (solenoid has failed short or conductor is shorted to ground). | Inspect system wiring for shorted condition. |
Cooling Fan Relay Output Error | 6 - 1 | This code indicates that output has detected an open circuit or a short to power condition. | Inspect system wiring for shorted or open condition. |
Cooling Fan Relay Output Overload | 6 - 2 | An over-current or over-temperature condition has been detected (solenoid has failed short or conductor is shorted to ground). | Inspect system wiring for shorted condition. |
Cooling Fan Relay Output Failure | 6 - 3 | Cooling fan relay output circuit has failed internal to the module | |
Diagnostic Test Mode Codes (with machine OFF)
This mode is used to check the integrity of the switches, sensors, wiring, and hardware of the vehicle control unit. Diagnostic information is generated in the vehicle control unit and displayed through a flashing code on the display module (next to the wrench icon).
Do not rotate the key past RUN to START mode during these three cycles.
Before entering the Diagnostic Test Mode, it is best to turn off all switch INPUTS (that is, brake not locked, PTO switch not in the on position, operator not in seat, and so on). Once all the INPUTS are off, the operator can enter the Diagnostic Test Mode by cycling the key switch quickly from OFF to RUN exactly three times. On the third cycle, leave the key in the RUN mode.
Upon entering the Diagnostic Test Mode, the vehicle control unit performs an automatic diagnostic check. If there are no system FAULTS and all the INPUTS are not detected, the display flashes a 1-1 Code.
See the chart below for instructions on how to remove the Fault/Input Codes in order to achieve a 1-1 Display.
-: Fault/Input Codes
Diagnostic Test Mode Code | Fault/Input Code Description | Action Needed to Remove Unwanted Codes: |
3 - 1 | Battery Voltage High | • Inspect electrical harness for loose connections, specifically the battery positive and negative, the starter, and frame ground (on the engine block). |
3 - 2 | Battery Voltage Low | • Check battery, starter, and ground connections. • Check charging system connections. |
1 - 2 | Key switch to START | Verify that key switch is in RUN mode not START. |
1 - 3 | PTO (Knob) Switch Input ON | Turn OFF switch (knob in the down position). |
1 - 4 | Brake Switch Input ON | Unlock the brake pedal, check brake switch for engagement. |
1 - 5 | Seat Switch Input ON | De-activate seat switch (operator not in seat). |
-: Fault/Input Codes
Diagnostic Test Mode Code | Fault/Input Code Description | Action Needed to Generate the Code: |
2 - 2 | Engine Oil Pressure Switch ON (I.E. Closed) | Disconnect the harness connector at the oil pressure switch on the engine. |
4 - 1 | Radiator Tank Temperature Switch Input is On. | Disconnect and jump the tank temperature switch. |
4 - 2 | OVERTEMP Switch Input is ON | Disconnect switch at the engine and jump connector to ground. |
Once the 1-1 Code has been achieved, the following steps are performed to complete the Diagnostic Test Mode.
-: Diagnostic Codes
Actions Required to Verify Electrical Functionality NOTE: INPUT actions can be performed in any order. | INPUT Description | Diagnostic Test Mode |
Turn the KEYSWITCH to the START position. The 1-2 Code should flash. Return to RUN position. | Key switch to START | 1 - 2 |
Pull the knob to activate the PTO switch. The 1-3 code should flash. Return PTO to OFF position. | PTO (Knob) Switch Input ON | 1 - 3 |
Activate the BRAKE pedal. The 1-4 code should flash. De-activate the pedal. | Brake Switch Input ON | 1 - 4 |
Sit on seat to activate the SEAT switch. The 1-5 code should flash. Get out of the seat. | Seat Switch Input ON | 1 - 5 |
Requires removal of the harness connector at the oil pressure switch on the engine. This condition generates the code. | Harness connection to the oil pressure switch is working. | 2 - 2 |
If the Diagnostic Test Mode Codes cannot be achieved when applying the INPUT Actions listed above, inspect the applicable wiring harness connections and switch, or contact your local John Deere Dealer for further assistance or part replacement.
Mower
-: Mower
Discharge Chute Plugged | • Grass is wet - ground speed may need to be adjusted. • Raise cutting height. • Run engine at fast idle. • Ground speed too fast for conditions. • Correct installation of deck drive belt. • Incorrect blade. | |
Mower Deck Vibrates | • Run engine at fast throttle. • Loose hardware. • Check/replace deck drive belt. • Blade bolts are loose. • Blade not in pilot when installed. • Ground speed too fast for conditions. • Blades are bent or worn. • Sharpen and balance blades. • Remove belt shields and clean debris from pulleys. • Check pulleys for proper alignment or damage. | |
Mower Deck Belt Breaks | • Blade rake (Front-to-Rear adjustment) not within specifications. • Debris on deck or lodged in deck drive system. Clean as required. • Belt guide damaged or out of alignment. See Replacing Mower Deck Drive Belt, Installing Deck Drive Belt in the Service Mower Section. • Ground speed too fast for conditions. | |
Mower Blades Do Not Engage | • Deck drive belt slipping or broken, check belt for wear and replace if necessary. • Deck belt tension spring not installed or broken. • PTO switch failure. • Clutch air gap too large. Remove shim. • Fuse is blown. • Loose electrical connections. | |
Mower Deck Does Not Lift or Lower Easily | • Check lift assist spring settings. Adjust for more or less assistance when lifting. See Adjusting Deck Lift Spring Tension in the Operating Section. • Excessive debris build up. | |
Mower Deck Does Not Engage Transport Lock | • Inspect lift bushings and adjust manual lift link. | |
Mower Mows Unevenly | • Mower deck not properly leveled. • Ground speed too fast for conditions. • Run engine at fast throttle. • Reduce ground speed when making turns. • Sharpen or replace blades. • Change mowing pattern. • Check air pressure in all traction unit tires. | |
Poor Quality Cut | • Clean debris build-up from underside of deck. • Check blades for sharpness and damage. • Check discharge chute for damage. • Change blades. • Run engine at fast throttle. • Mowing too fast for grass conditions. | |
Mower Blade Stop Time Excessive | • Clutch air gap too large. Remove shim. | |
Mulch-On-Demand Baffles Are Out of Timing or System Not Mowing Correctly | • Adjust linkage for gate. | |
Mulch-On-Demand Handle Loose | • Check linkage adjustments. • Check gate bushings for wear. | |
Mulch-On-Demand Material Dispersion | • Check linkage adjustments. • Check gate bushings for wear. • Adjust and/or remove chamber separator baffles. • Clean debris build-up from underside of deck. • Check blades for sharpness and damage. • Check discharge chute for damage. • Change blades. • Run engine at fast throttle. • Mowing too fast for grass conditions. |
Steering and Brakes
-: Steering and Brakes
Steering..............Dual Control Levers |
Brakes..............Hydraulic |
Park Brake..............Foot Pedal - Internal Wet Disk |
Tires
-: Tires
Front..............13 x 6.5-6 |
Rear..............24 x 12-12 |
Inflation Front..............N/A - semi-pneumatics |
Inflation Rear..............83 kPa (12 psi) |
Recommended Lubricants
-: Recommended Lubricants
Engine Oil.............. Torq-Gard™ OR Plus-50™ II |
Hydraulic Oil..............HY-GARD™ J20C |
Grease..............John Deere Multi-Purpose HD Lithium Complex Grease |
Gearbox Oil..............80W90 GL5 |
(Specifications and design subject to change without notice.) |
WARNING
Keep Rollover Protective Structure fully extended
Do not jump if machine tips
Use seat belt
When structure must be down
DO NOT use seat belt
Drive with extra care
CAUTION
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear suitable hearing protection.
DANGER
To avoid injury to children, stop mower when children are near. Do not mow in reverse. Look behind when backing. Never carry riders, especially children.
DANGER
To avoid injury from tipover, drive across slopes, not up and down. If machine stops going uphill, stop blades and back down slowly.
CAUTION
Avoid equipment fires.
Accumulation of grass, leaves and other debris on or near hot or moving parts can cause a fire.
Inspect machine before, during, and after use.
Shut off engine and allow machine to cool before cleaning.
Inspect and clean the entire machine and pay special attention to these locations:
Muffler and exhaust system
Engine and engine screens
Top of mower deck and under shields
Lifting Machine
CAUTION: Avoid Injury! The machine can fall or slip from an unsafe lifting device or supports.
• Use a safe lifting device rated for the load to be lifted.
• Lower machine onto jack stands or other stable supports and block wheels before servicing.
IMPORTANT:Avoid Damage! Place jack stands under frame, not under transmission or engine, when raising or supporting machine.
Park machine safely. (See Parking Safely in the Safety section.)
TCT016514-UN: Safely lift rear of machineSafely lift rear of the machine at bar (A). Place jack stands or other stable supports near lift locations. If only lifting rear of machine, block front wheels remaining on ground to avoid movement of the machine.
TCT016418-UN: Safely lift front of machineSafely lift front of the machine at bottom of plates (B). Place jack stands or other stable supports near lift locations. If only lifting front of machine, block rear wheels remaining on ground to avoid movement of the machine.
To lower the machine, lift front and/or rear of machine, and remove jack stands or supports. Lower machine.
Removing and Installing Battery
Removal
Park machine safely. (See Parking Safely in the Safety section.)
Raise and secure operator seat.
TCT016416-UN: BatteryDisconnect negative (-) battery cable (A). Remove red cover (B), and disconnect positive (+) battery cable (C).
Remove cap screw (D) and battery hold down (E).
Remove battery from the machine.
Installation
Installation is done in the reverse order of removal.
Clean all electrical connections.
Tighten cables, install red cover on positive (+) cable, and battery hold down with the cap screw.
Checking and Aligning Motion Control Levers
Check Alignment
Park machine safely. (See Parking Safely in the Safety section.)
Move both motion control levers forward.
Check levers for equal alignment. If positions of control levers are unequal, an adjustment is necessary.
Alignment Procedure
TCT016413-UN: Loosen locknutsLoosen locknuts (A). Slide both left and right motion control levers forward or rearward to desired position on the control arm until levers are aligned.
NOTE:
The control lever height can also be adjusted using this procedure. There are two height settings on the control arms.
Tighten locknuts.
Cleaning Debris From Traction Drive System
Avoid Injury! Compressed air can cause debris to fly a long distance.
• Clear work area of bystanders.
• Wear eye protection when using compressed air for cleaning purposes.
• Reduce compressed air pressure to 210 kPa (30 psi).
Avoid Damage! To ensure proper cooling, keep the transmission cooling fins and surrounding area clean at all times. Operating the machine with obstructed cooling fins could cause transmission damage due to overheating.
Park machine safely. (See Parking Safely in the Safety section.)
Lift operator seat and lock into position.
IMPORTANT:
Avoid Damage! Do not use chlorinated solvents or high pressure water to clean grass and debris from transmission fan, cooling fins and reservoir.
TCT016412-UN: Clean cooling fins around exteriorClean cooling fins around the exterior of transmissions and fans (A) with a rag, brush, or compressed air. Clean transmission fan screens (B).
Moving Machine by Hand (Using the Bypass Pump Release Valves)
Avoid Injury! When the bypass valve is open, the machine will have unrestricted motion.
• Do not open the bypass valve when the machine is stopped on an incline to prevent it from going downhill out of control.
Avoid Damage! Transmission damage may occur if the machine is towed or moved incorrectly:
• Move machine by hand only.
• Do not use another vehicle to move machine.
• Do not tow machine.
Both bypass pump release valves must be fully closed (pushed inward towards rear of machine) during normal vehicle operation.
When the machine needs to be moved without starting the engine, use the bypass pump release valves:
Lock the park brake.
TCT016411-UN: Left side shownOn both transmissions pull the bypass levers (A) forward (towards the front of the machine) to the open position. Unlock park brake.
Push machine to desired location. Due to hydraulic system drag, machine will move slowly.
Lock park brake.
Push both bypass levers (A) back (towards the rear of the machine) to the closed position.
Raising and Lowering Operator Seat
Raising the Seat
Park machine safely. (See Parking Safely in the Safety section.)
Stand on the side of the machine. Lift seat (A) by lifting seat latch (B).
TCT016407-UN: Seat rodSlide seat rod (C) through the bracket cutout (D). Set the seat rod in the lower cutout of the bracket.
Lowering the Seat
Stand on the side of the machine.
Push seat forward slightly and reset seat rod into the top slide of the frame cutout.
Lower seat and return vehicle into service.
Raising and Lowering ROPS
Avoid Injury! Always wear seat belt when operating machine with folding Roll-Over Protective Structure (ROPS) in upright position. Do not jump from machine if machine tips.
If ROPS must be folded to operate in a low clearance area, do not use seat belt. Raise ROPS and use seat belt as soon as conditions permit.
Park machine safely. (See Parking Safely in the Safety section.)
TCT016408-UN: ROPS hingeRemove spring pin (A) from the drilled pin (B) on left and right sides of ROPS. Remove drilled pin from left and right sides of ROPS.
CAUTION: Avoid Injury! Fingers and hands can be pinched or crushed. Be aware of potential pinch points and keep hands away.
TCT016409-UN: ROPS loweredPull ROPS rearward to lowered position (C). Install drilled pins and spring pins back into holes in ROPS to secure in place.
Placing ROPS into Intermediate Position
When a Material Collection System attachment is installed, the ROPS cannot be fully lowered. If the ROPS must be lowered, place it into the intermediate position.
With the spring pins and drilled pins removed, lower the upper ROPS (A) rearward and install drilled pins (B) and spring locking pins to secure position.
Repeat for the other side of ROPS.
Diagnostics
Diagnostic functions are provided by the electronic control module to help diagnose problems starting the engine.
The following conditions must be met to energize the starter solenoid and engage the starter motor:
Park brake locked.
Mow-transport lever in the transport position.
Motion control levers are in the neutral position.
Key switch in the START position.
If engine does not turn over, hold the key in the START position, the diagnostic indicator light (A) on the indicator light module will begin to flash a diagnostic code.
If any codes are flashing other than the ones described on the diagnostic code label or listed below, refer to the Technical Manual or consult your John Deere distributor.
• Code 1-2 (One pulse followed by a short pause by two pulses). Indicates that the park brake switch has not been activated during an attempted engine start or while the engine is idled with the operator out of the seat. Lock park brake to start engine.
• Code 1-3 (One pulse followed by a short pause followed by three pulses). Indicates that there was an attempted start with the PTO turned on. Turn PTO switch OFF before attempting to start.
This code will also flash if the machine and PTO are running with the brake released and the operator leaves the seat. The engine and PTO will stop. Turn PTO switch OFF.
Engaging the starter, without engine start, is limited by the controller to a total time of 60 seconds.
• Code 2-5 (Two pulses followed by a short pause followed by five pulses). Indicates that the control module has started a 60-second cool-down period to prevent the starter from overheating. Turn key switch to OFF position and let the starter cool down for at least 60 seconds before making another attempt to start engine.
• Code 2-7 (Two pulses followed by a short pause followed by six pulses). Indicates that engine oil has exceeded the low-pressure limit. Park machine and check engine oil level. (See Checking Engine Oil Level in the Service Engine section.)
• Code 3-1 (Three pulses followed by a short pause followed by one pulse). Indicates that there is over voltage within the electrical system. The PTO may disengage when this code flashes. Check electrical wiring for loose connections, specifically the battery positive and negative, starter, and frame ground on the engine block.
• Code 3-3 (Three pulses followed by a short pause followed by three pulses). Indicates a low voltage condition within the electrical system. Recharge the battery. If this does not remove the code, check that all starter circuit harness connections are secure and not “shorted” to ground.
• Code 3-7 (Three pulses followed by a short pause followed by seven pulses). Indicates that the control unit has detected an electrical problem in the engine wiring harness. The control unit’s internal “resettable” fuse tripped to protect the system. This will remain tripped until the fault is removed. Check engine wiring harness for pinched or frayed wires.
Engine
-: Engine
If | Check |
Engine Will Not Start Or Is Hard To Start | Check diagnostic light. Motion control levers not in the “neutral lock” position. Park brake lever not in the proper position. Operator not on seat. Key switch not in proper position. PTO engaged. Stale or improper fuel / fuel level Plugged fuel filter. Plugged air intake filter. Blown fuse. Electrical problem - dead battery. Fuel system on water or air. |
Engine Runs Rough or Stalls | Plugged fuel filter. Plugged air intake system. Fuel cap vent dirty. Stale or improper fuel / fuel level. Dirty or faulty fuel injectors. |
Engine Knocks | Engine oil level low. Reduce load. (Slower ground speed.) Fuel is bad. Fill tank with fresh fuel, correct cetane. Idle speed too slow. Water in fuel system Clogged air filter |
Engine Overheats | Clean grille, radiator screen, or radiator cooling fins. Low oil level. Do not operate at low idle. Operate at high idle. Plugged air intake filter. Operating at too fast ground speed for conditions. Defective thermostat, water temperature indicator, or sender. |
Engine Lacks Power | Reduce load. Plugged air intake system. Plugged fuel filter. Improper type of fuel. Drain tank and fill with correct fuel. Clean cooling fins to help prevent overheating. |
Engine Uses Too Much Oil | Find and correct oil leaks. Incorrect engine oil. Plugged oil filter. Plugged air intake filter. Worn piston rings or cylinder walls. |
Low Oil Pressure | Engine oil level low. Plugged oil filter. Improper type of oil. Oil leaks. |
Engine Emits White Smoke | Improper type of fuel. Low engine temperature. |
Engine Emits Black Or Gray Exhaust Smoke | Improper type of fuel. Plugged air intake system. Operating at too fast ground speed for conditions. |
High Fuel Consumption | Improper type of fuel. Plugged air intake system. Operating at too fast ground speed for conditions. Restricted air intake system. Plugged crankcase vent tube or baffle. |
Mounting and Dismounting Machine Safely
When mounting and dismounting the machine, do so from the left side of the machine using the step (A) or the foot plate (B). Park machine safely before dismounting. (See Parking Safely in the Safety section.) Do not mount or dismount the machine from the front.
Keep the foot plate clean.
Checking and Adjusting Neutral Creep
Avoid Injury! Do not attempt this adjustment unless you are a qualified and properly trained technician. Improper adjustment can result in an unsafe machine.
Checking Motion Control Linkages
Park machine safely. (See Parking Safely in the Safety section.)
Raise rear of machine only enough for rear tires to rotate freely.
CAUTION: Avoid Injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.
• Move the machine to an outside area before running the engine.
• Do not run an engine in an enclosed area without adequate ventilation.
• Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.
• Allow fresh outside air into the work area to clear the exhaust fumes out.
Start engine.
Set throttle lever to the fast position.
Unlock park brake.
If the rear drive wheels begin to creep, an adjustment is required.
Adjusting Motion Control Linkages
Perform adjustments with rear tires off the ground just enough so wheels can rotate.
Stop engine and lock park brake.
Move both motion control levers (A) to the neutral lock position. Sit on seat.
Start engine.
CAUTION: Avoid Injury! Use extreme caution when adjusting for neutral creep. Drive wheels are free to spin when machine is raised off the floor and the engine is started.
Do not have engine running any longer than necessary to do adjustment. Shut off engine and remove key as soon as possible after adjustment is made.
Set throttle to high idle position.
Unlock park brake.
Locate left and right motion control linkage adjustment points (B).
Be sure that the right motion control linkage is in the neutral lock position. The right drive wheel must not turn. If it does turn, adjust the motion control linkage.
TCT016531-UN: Front plate shown removed for clarity.Adjust nut (C) on end of motion control linkage. If the wheel is spinning in forward direction, turn nut clockwise to bring wheel to a stop.
If the wheel is spinning in reverse direction, turn nut counterclockwise to bring wheel to a stop.
Move the right motion control lever completely forward and rearward in the slot and then back to the neutral lockout position.
The drive wheels will slow down to +/- 4 rpm. If the drive wheels are rotating faster than +/- 4 rpm, repeat previous step.
Repeat procedure to adjust the left motion control linkage.
Drive wheels should not rotate when in neutral lock position.
Stop engine.
Move both motion control levers to the neutral lock position.
Lock park brake.
Dismount from the machine.
Lower machine.
Adjusting Tracking
If the machine does not track in a straight line while going forward, adjust the tracking:
Park machine safely. (See Parking Safely in the Safety section.)
TCT016532-UN: Turn the adjusting screw as requiredTurn the adjusting screw as required: If machine tracks to right, turn adjusting screw (A) clockwise one rotation.
If machine tracks to left, turn adjusting screw (A) counterclockwise one rotation.
Test vehicle for the proper tracking.
Repeat the steps 2 and 3 as necessary to adjust the tracking.
Return vehicle to service.
Checking and Adjusting Motion Control Levers Gap
Checking Alignment
Park machine safely. (See Parking Safely in the Safety section.)
TCT016533-UN: Move motion control levers inward to neutral positionMove motion control levers (A) inward to neutral position. If the ends of the levers strike against each other while in the neutral position an adjustment is needed.
Adjustment Procedure
TCT016534-UN: Loosen jam nutsLoosen jam nuts (B). Tighten left and right adjustment bolts (C) slightly to increase gap between handles. See the recommended gap specification for motion control levers.
Item
Measurement
Specification
Motion Control Levers
Gap
6—19 mm
(1/4—3/4 in)Tighten jam nuts to hold adjustment bolts in place.
Removing and Installing Foot Plate
Avoid Injury! Always operate the mower with the foot plate installed. Operating with the foot plate removed can cause serious injury.
Removing Foot Plate
Park machine safely. (See Parking Safely in the Safety section.)
TCT016576-UN: Rotate foot plate up using handlesRotate foot plate up using handles (A). Remove foot plate.
Installing Foot Plate
Place tabs (B) of the foot plate into slots in frame.
Lower foot plate.
Checking ROPS Hardware
Park machine safely. (See Parking Safely in the Safety section.)
NOTE:
When tightening ROPS hardware, tighten the bolt head side and not the nut.
TCT016577-UN: Check ROPS HardwareTighten the four ROPS attaching bolts (A) on each side of ROPS to specification. Item
Measurement
Specification
ROPS Attaching Bolts
Torque
115 N·m
(85 lb·ft)
Adjusting Footrests
NOTE:
The face of footrest is angled for comfort and is marked with a raised line to aid in getting both footrests oriented the same way. Marks can either be both up or down depending on preference.
Orient footrest to desired angle for comfort.
TC100256-UN: FootrestPlace footrest (A) in desired opening of toe board. Avoid interference with foot brake or deck lift pedal. Install bolts (B), washers and locknuts (C). Tighten to:
Item
Measurement
Specification
Foot Rest Bolt
Torque
20 N·m (15 lb·ft)
Repeat for the other footrest.
Safety Label Location (Machine)
Safety Label Location (Mower)
Safety Label Location (Mower)
Cleanout Areas
Inspect and clean the entire machine and pay special attention to these locations:
Muffler and exhaust system (A).
Engine and engine screens (B).
Slots into the rear chassis frame above the TZT transmission (C).
Battery compartment (D).
Top of the mower deck and under shields (E).
Debris enclosure or chute of the rear discharge deck (F).
Daily Operating Checklist
□ Test safety systems.
□ Clean grass and debris from the operator station foot platform.
□ Remove grass and debris from the operator platform, air intake screen, engine compartment, transmissions, fans, traction drive belt, and muffler area.
□ Remove grass and debris from machine and mower deck.
□ Clean debris from radiator inlet screens.
□ Remove mower deck belt shields. Clean grass and debris from belt area.
□ Check all belts for damage or cracking.
□ Make sure that all necessary guards and shields are safely and securely attached. Check for loose, missing, or damaged parts.
□ Check mower level, cutting height, and blades.
□ Check engine oil level.
□ Check transmission oil level.
□ Check for oil leaks.
□ Check fuel level.
□ Check engine air filter indicator.
□ Check wheel bolt torque. Tighten if necessary.
□ Check tire air pressure. Check tires for damage or cracking.
□ Test park brake.
□ Check and adjust motion control linkages.
□ Check for loose, damaged, or missing parts.
□ Check battery.
□ Remove belt shields from the mower deck and clean any grass or debris from around belts and sheaves (viper rear discharge deck).
□ Raise seat platform and open the engine cover and remove grass and debris from the engine compartment.
Stopping Engine
CAUTION: Children or bystanders may attempt to move or operate an unattended machine.
Always lock the park brake and remove the key before leaving the machine unattended.
Move the motion control levers to the neutral lock position.
Lock park brake.
Turn key switch to STOP position.
Remove key.
Mowing Tips
Mow grass with throttle lever in the full fast/mow position.
Mow grass when it is dry.
Keep mower deck and discharge chute clean.
Properly level mower deck for a smooth cut.
Avoid damaging grass by slipping or skidding machine drive wheels. Practice smooth control lever movements.
When performing sharp turns, do not allow inside the machine drive wheel to stop and twist on grass.
Keep mower blades sharp. Dull blades tear the grass; tips of grass will then turn brown.
Adjust cutting height to fit the conditions:
Normal mowing - adjust to remove only 1/3 of the grass at a time
Tall or wet grass - Mow twice. Cut grass at half desired height, then cut at desired height.
Mow grass often. Short grass clippings will decay quickly.
Adjust travel speed to match mowing conditions (see Mowing Travel Speeds):
Travel at slow speed when you mow thick, tall grass,
Make sharp turns or trim around objects. NOTE:
When the mower is traveling uphill it is necessary to reduce travel speed in order to maintain adequate engine rpm for satisfactory cut quality. This necessity for slower travel speed uphill may be more pronounced with the addition of attachments, such as with MCS.
Use a different mowing pattern each time you mow.
Overlap mowing paths 50 - 100 mm (2 - 4 in).
Drive over ridges and through shallow ditches straight-on, not at an angle.
Service Intervals
Before Each Use
Check engine oil.
Check hydraulic oil.
Check for leaks.
Inspect tires and check air pressure.
Check safety interlock system.
Check brake system.
Check air filtration system.
Check for loose, missing, or damaged parts.
Check all safety guards and shields.
Check belts.
Check pedals and/or steering control.
Check seat belt.
Check engine coolant.
After Each Use
Check / fill fuel.
Clean debris from machine.
Clean debris from cooling system.
Clean debris from the traction drive system.
Clean debris from mower and/or attachment drive systems.
Clean debris from viper rear discharge debris enclosure.
Clean debris from the underside of the mower deck.
Check mower deck drive belts.
Check mower blades.
Lubricate machine after washing. (See Service Lubrication for grease points)
Break In (After First 8 Hours)
Check and tighten wheel hardware.
Every 50 Hours
Lubricate deck spindles.
Every 100 Hours
Check drive belt tension.
Inspect mower deck drive belt.
Check and clean cooling fins and engine oil cooler (if equipped).
Clean and check battery.
Every 250 Hours
Change engine oil and filter.
Break-In (After First 300 Hours)
Change transmission oil and filters.
Change gearbox oil.
Every 300 Hours
Replace primary air cleaner element.
Every 500 Hours
Change transmission oil and filters. (Every 500 h after 300 h initial break-in).
Check torque on ROPS hardware.
Replace fuel filter.
Replace secondary air cleaner element.
Lubricate front caster wheel pivots.
Change gearbox oil. (Every 500 h after 300 h initial break-in).
Every 1000 Hours or Yearly
Check engine coolant freeze point.
Check and adjust valve clearance.
Every 1500 Hours
Check fuel injectors.
Every 2000 Hours or 24 Months
Change engine coolant and thermostat.
Lubricating Deck Spindles
Removal of belt shields and foot plate is not necessary to lubricate the spindles.
Lubricate one mower deck spindle grease fitting (A), located in the center of the deck.
Lubricate two mower deck spindle grease fittings (B).
Operating Mulch-On-Demand Mower Deck (MOD) If Equipped
Adjusting Spring Tension
Only check if there are issues with the force when opening or closing baffles. Also check spring tension if the system is popping out of mulch/side discharge while mowing.
Park machine safely. (See Parking Safely in the Safety section.)
To adjust linkages, put deck in lowest position.
Put handle in mulch position.
TCT011894-UN: Tension SpringMeasure tension spring. To adjust: Loosen nuts (A).
Measure distance between outside of washers. Measurement (B) is 83 mm (3.3 in).
Tighten nuts (A).
Adjust Handle Position
To adjust the handle position, adjust the turnbuckle (B) by loosening nuts then turning turnbuckle.
Park machine safely. (See Parking Safely in the Safety section.)
TCT011895-UN: TurnbuckleLoosen two nuts (A). Adjust turnbuckle (B) for handle position.
Tighten nuts (A).
Adjusting Discharge Baffle
Adjusting the discharge baffle helps with reducing windrowing in mulch mode.
Park machine safely. (See Parking Safely in the Safety section.)
TCT011751-UN: Adjusting Discharge Baffle
TCT011752-UN: Baffle GapLoosen two nuts (A). Adjust turnbuckle (B) until the gap (C) is closed.
Tighten nuts (A).
Adjusting Baffle Timing
If the baffles are out of timing, or the system is not mowing correctly, check the following:
Put system in Mulch Mode.
TCT011904-UN: Baffle TimingLoosen two nuts (A) slightly on each clamp for each baffle (B). Slide baffle closed until the baffle hits the stop. Tighten nuts to 39 N·m (29 lb·ft). Check discharge baffle gap and adjust if needed. (See “Adjusting Discharge Baffle” in this section.)
Removing and Installing Mower Deck Belt Shields
Avoid Injury! Help prevent serious personal injury. Do not operate the mower without the belt shields installed.
Removing Belt Shields
Park machine safely. (See Parking Safely in the Safety section.)
Lower mower deck to the lowest cutting height position.
APY37079-UN: Left Side ShownDisengage belt shield (A) from grommet (B). Remove belt shield (A).
Slide belt shield towards outside of the deck to remove.
Repeat steps for the other shield.
Installing Belt Shields
Slide belt shield (A) into position under frame.
Engage the grommet (B) with a belt shield (A).
Repeat steps for the other shield.
Removing and Installing Rear Drive Wheels
Avoid Injury! The machine can fall or slip from an unsafe lifting device or supports.
• Use a safe lifting device rated for the load to be lifted.
• Lower machine onto jack stands or other stable supports and block wheels before servicing.
Removing:
Park machine safely. (See Parking Safely in the Safety section.)
APY37080-UN: Rear Right Side Wheel ShownSlightly loosen four wheel nuts (A). Lift machine with a safe lifting device. (See Lifting Machine in the Service Miscellaneous section.)
Remove wheel nuts.
Remove wheel.
Installing:
Install new wheel.
Install and tighten the wheel nuts in a star pattern until recommended torque value is reached.
Tighten nuts to specification.
Item
Measurement
Specification
Wheel Nuts
Torque
100 N·m
(75 lb·ft)
NOTE:Do not overtighten.
Lower machine.
NOTE:Check wheel hardware tightness often during the first 100 hours of operation after installing the wheel.
Operating Mulch-On-Demand Mower Deck (MOD) If Equipped
To Mulch:
APY37081-UN: Lever position forward (closed) for mulch position.Push deck mode lever (A) forward for the mulch position.
To Side Discharge:
APY37082-UN: Lever position rearward (open) for side discharge position.Pull deck mode lever (A) rearward for side discharge mode.
Adjusting Chamber Separators
Depending on mowing conditions, chamber separators can be adjusted, or removed, to improve performance when mulching or side discharging.
Move chamber separators in the forward position (B) for best mulching performance; they should be in the rearward position (A) or removed when side discharging. However, any combination of chamber separators placements can be used at the customer's discretion.
Chamber separators are slotted (C) for ease of adjustment.
To Adjust or Remove Chamber Separators:
Park machine safely. (See Parking Safely in the Safety section.)
Raise the mower deck to the highest position.
Raise front of the machine with a safe lifting device. (See Lifting Machine in the Service Miscellaneous section.)
TCT011900-UN: Chamber separatorsLoosen M6 locknut (A). NOTE:
If chamber separators are removed, store M6 locknut and M6 carriage bolt with chamber separators for later use.
Move chamber separators (B) in, out, or remove as required.
Secure with M6 locknut.
Repeat as necessary for second chamber separators.
Replacing Mower Deck Drive Belt
Removing Deck Drive Belt
Park machine safely. (See Parking Safely in the Safety section.)
Lower mower deck to the lowest cutting height position.
Remove belt shields.
Remove the foot plate.
TCT016422-UN: Deck removed for better view.Remove the spring (A) from stud (B) using spring puller. Loosen the hardware (C) from the idler arm guide and spindle belt guide (D). Move belt guide (D) out of the alignment slot and rotate it away from the pulley.
Remove belt (E) from the deck pulleys.
TCT016423-UN: Remove beltRemove belt (F) from the PTO drive pulley (G) and through the window of the cross frame member (H).
Installing Deck Drive Belt
TC102081-UN: Deck removed for better view.Route drive belt around mower deck sheaves as shown in inset (A). Make sure that there are no twists in the belt. Make sure the idler arm guide (B) is in the alignment slot and fully seated. Tighten the guide hardware.
Install belt through the window of the cross frame member and onto the PTO drive pulley.
Make sure that the spring is in the right orientation - long end toward (C). Hook short end on spring hook (D).
Install the foot plate.
Adjust mower deck to a desired cutting height.
Record Identification Numbers
ZTrak™ Z994R
PIN (060001—)
If you need to contact an authorized service center for information on servicing, always provide the product model and serial number.
You need to locate the product identification number (PIN) for the machine and engine serial number. Record the information in the following spaces:
DATE OF PURCHASE:
_________________________________________
DEALER NAME:
_________________________________________
DEALER PHONE:
_________________________________________
PRODUCT IDENTIFICATION NUMBER (A):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
ENGINE SERIAL NUMBER (B):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
Adjusting Deck Lift Spring Tension
Deck lift spring tension is adjusted at the factory. If the effort required to raise or lower the mower deck is not satisfactory, an adjustment may be necessary.
Check Spring Tension
Park machine on a hard, level surface.
Stop engine and lock park brake.
Raise the mower deck to the transport position.
Lift operator seat and lock into position.
TCT014261-UN: Spring LengthMeasure length (A).
Machines without Material Collection System Installed:
-: Machines without Material Collection System Installed:
Deck | Recommended Factory Setting |
60 inch | 41 mm (1.61 in) |
60 inch - Rear Discharge | 41 mm (1.61 in) |
60 inch - Mulch on Demand | 31 mm (1.22 in) |
72 inch - Rear Discharge | 39 mm (1.54 in) |
72 inch | 43 mm (1.70 in) |
Machines with Material Collection System Installed:
-: Machines with Material Collection System installed:
Deck | Recommended Factory Setting |
60 inch | 78 mm (3.07 in) |
60 inch - Mulch on Demand | 65 mm (2.17 in) |
72 inch | 77 mm (3.07 in) |
Adjust Spring Tension
Do not over tension the deck lift spring. If the spring is compressed too tightly, the mower deck floats too freely.
Decrease deck lift spring tension if operating in rough terrain.
While Looking from Rear of Machine:
Turn hex nut (B) clockwise to increase deck lift spring.
Turn hex nut (B) counterclockwise to decrease deck lift spring tension.
Dimensions
-: Dimensions
Wheel Base..............1.42 m (56 in) |
Overall Height (ROPS Down)..............1.19 m (47 in) |
Overall Height (ROPS Up)..............1.85 m (73 in) |
Overall Length..............2.25 m (88 in) |
Overall Width (60 inch Side Discharge Deck) |
Chute Up..............1.68 m (66 in) |
Chute Down..............1.88 m (74 in) |
Overall Width (60 inch Rear Discharge Deck) |
Width..............1.61 m (64 in) |
Overall Width (72 inch Side Discharge Deck) |
Chute Up..............1.95 m (77 in) |
Chute Down..............2.18 m (86 in) |
Overall Width (72 inch Rear Discharge Deck) |
Width..............1.92 m (76 in) |
Weight
Weight of machine depends on seat option. Weight ranges cover all seat options.
-: Weight
60 in - Side Discharge..............781-785 kg (1721-1731 lb) |
60 in - Rear Discharge..............776-794 kg (1711-1750 lb) |
60 in - Mulch on Demand..............790-801 kg (1741-1766 lb) |
72 in - Side Discharge..............797-808 kg (1757-1782 lb) |
72 in - Rear Discharge..............803-821 kg (1771-1810 lb) |
Emission System Warranty
YANMAR POWER TECHNOLOGY CO., LTD. EMISSION CONTROL SYSTEM WARRANTY - USA ONLY
Your Warranty Rights and Obligations:
The California Air Resources Board (CARB), the United State Environmental Protection Agency (EPA) and YANMAR POWER TECHNOLOGY CO., LTD. hereafter referred to as YANMAR, are pleased to explain the emission control system warranty on your 2022, 2023, or 2024 model year industrial compression-ignition engine. California-certified, new off-road compression-ignition engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards. In the remaining forty-nine (49) states, new non-road compression-ignition engines must be designed, built, and equipped to meet the United States EPA emissions standards. YANMAR must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine.
Your emission control system may include parts such as the fuel injection system, the air induction system, the electronic control system, EGR (Exhaust Gas Recirculation) system and the exhaust gas after treatment (diesel particulate filter system, urea SCR system). Also included may be hoses, belts, connectors, and other emission-related assemblies.
Where a warrantable condition exists, YANMAR will repair your off-road compression-ignition engine at no charge to you including diagnosis, parts and labor.
Manufacturer’s Warranty Period:
2022, 2023, or 2024 model year off-road compression-ignition engines are warranted for the periods listed below. If any emission-related part on your engine is found to be defective during the applicable warranty period, the part will be repaired or replaced by YANMAR.
-: Warranty Period
If your engine is certified as | And its maximum power is | And its rated speed is | Then its warranty period is |
Variable speed or constant speed | kW <19 | Any speed | 1,500 hours or two (2) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of two (2) years. |
Constant speed | 19 ≤ kW <37 | 3000 rpm or higher | 1,500 hours or two (2) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of two (2) years. |
Constant speed | 19 ≤ kW <37 | Less than 3,000 rpm | 3,000 hours or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years. |
Variable speed | 19 ≤ kW <37 | Any speed | 3,000 hours or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years. |
Variable speed or constant speed | kW ≥ 37 | Any speed | 3,000 hours or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years. |
Warranty Coverage:
This warranty is transferable to each subsequent purchaser for the duration of the warranty period. YANMAR recommends that repair or replacement of any warranted part will be performed at an authorized YANMAR dealer.
Warranted parts not scheduled for replacement as required maintenance in the owner’s manual shall be warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in the owner’s manual are warranted for the period of time prior to the first scheduled replacement. Any warranted parts scheduled for replacement as required maintenance that are repaired or replaced under warranty shall be warranted for the remaining period of time prior to the first scheduled replacement. Any part not scheduled for replacement that is repaired or replaced under warranty shall be warranted for the remaining warranty period.
During the warranty period, YANMAR is liable for damages to other engine components caused by the failure of any warranted part during the warranty period.
Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine, and shall not reduce YANMAR’s warranty obligations. Add-on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or modified parts shall be grounds for disallowing a warranty.
Warranted Parts:
This warranty covers engine components that are a part of the emission control system of the engine as delivered by YANMAR to the original retail purchaser. Such components may include the following:
(A) Fuel injection system (including Altitude compensation system)
(B) Cold start enrichment system
(C) Intake manifold and Air intake throttle valve
(D) Turbocharger systems
(E) Exhaust manifold and exhaust throttle valve
(F) Positive crankcase ventilation system
(G) Charge Air Cooling systems
(H) Exhaust Gas Recirculation (EGR) systems
(I) Exhaust gas after treatment (Diesel Particulate Filter (DPF) system, urea SCR system)
(J) Electronic Control units, sensors, solenoids and wiring harnesses used in above systems
(K) Hoses, belts, connectors and assemblies used in above systems
(L) Emission Control Information Labels
Since emissions related parts may vary slightly between models, certain models may not contain all of these parts and other models may contain the functional equivalents.
Exclusions:
Failures other than those arising from defects in material or workmanship are not covered by this warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance, or use of non-recommended fuels and lubricating oils; accident-caused damage and replacement of expendable items made in connection with scheduled maintenance. YANMAR disclaims any responsibility for incidental or consequential such as loss of time, inconvenience, loss of use of equipment/engine or commercial loss.
Owner’s Warranty Responsibilities:
As the off-road compression-ignition engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. YANMAR recommends that you retain all documentation, including receipts, covering maintenance on your off-road compression-ignition engine, but YANMAR cannot deny warranty solely for the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.
YANMAR may deny your warranty coverage if your off-road compression-ignition engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with CARB and EPA emissions requirements.
You are responsible for initiating the warranty process. You are responsible for presenting your engine to an authorized YANMAR dealer or distributor as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible. If you have any questions regarding your warranty rights and responsibilities, or would like information on the nearest YANMAR dealer or authorized service center, you should contact YANMAR America Corporation.
Website: https://www.yanmar.com
E-mail: CS_support@yanmar.com
Toll free telephone number: 1-800-872-2867, 1-855-416-7091
What the Emergency Stationary Type Engine Owner must Do:
The engines for emergency stationary type generators certified by Federal Law (40 CFR Part60) are limited to emergency use only, and the operation for maintenance checks and verification test for functions is required. The total operating hours for maintenance and verification test for functions should not exceed 100 hours per year. However, there is no limitation on the operating hours for emergency use. Keep a log of the number of hours the engine is operated for both emergency use and non-emergency use. Also, note the reason for the operation.
Emission System Warranty
YANMAR POWER TECHNOLOGY CO., LTD. LIMITED EMISSION CONTROL SYSTEM WARRANTY - USA ONLY
Your Warranty Rights and Obligations:
The California Air Resources Board (CARB), the United State Environmental Protection Agency (EPA) and YANMAR POWER TECHNOLOGY CO., LTD. hereafter referred to as YANMAR, are pleased to explain the emission control system warranty on your 2023, 2024, or 2025 model year compression-ignition engine. In California, new heavy-duty off-road engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. In the remaining forty nine (49) states, new non-road compression-ignition engines must be designed, built and equipped to meet the United States EPA emissions standards. YANMAR must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine.
Your emission control system may include parts such as the fuel injection system, the air induction system, the electronic control system, EGR (Exhaust Gas Recirculation) system and the exhaust gas after treatment (diesel particulate filter system, urea SCR system). Also included may be hoses, belts, connectors, and other emission-related assemblies.
Where a warrantable condition exists, YANMAR will repair your heavy-duty off-road compression-ignition engine at no charge to you including diagnosis, parts and labor.
Manufacturer’s Warranty Period:
2023, 2024, or 2025 model year heavy-duty off-road compression-ignition engines are warranted for the periods listed below. If any emission-related part on your engine is defective, the part will be repaired or replaced by YANMAR.
-: Warranty Period
If your engine is certified as | And its maximum power is | And its rated speed is | Then its warranty period is |
Variable speed or constant speed | kW <8 | Any speed | 2,000 hours or two (2) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of two (2) years. |
Variable speed or constant speed | 8<=kW<19 | Any speed | 2,000 hours or two (2) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of two (2) years. |
Constant speed | 19 <=kW <37 | 3000 rpm or higher | 2,000 hours or two (2) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of two (2) years. |
Constant speed | 19 <=kW <37 | Less than 3,000 rpm | 3,000 hours or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years. |
Variable speed | 19 <=kW <37 | Any speed | 3,000 hours or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years. |
Variable speed or constant speed | kW ≥ 37 | Any speed | 3,000 hours or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years. |
Warranty Coverage:
This warranty is transferable to each subsequent purchaser for the duration of the warranty period. YANMAR recommends that repair or replacement of any warranted part will be performed at an authorized YANMAR dealer.
Warranted parts not scheduled for replacement as required maintenance in the owner’s manual shall be warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in the owner’s manual are warranted for the period of time prior to the first scheduled replacement. Any warranted parts scheduled for replacement as required maintenance that are repaired or replaced under warranty shall be warranted for the remaining period of time prior to the first scheduled replacement. Any part not scheduled for replacement that is repaired or replaced under warranty shall be warranted for the remaining warranty period.
During the warranty period, YANMAR is liable for damages to other engine components caused by the failure of any warranted part during the warranty period.
Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine, and shall not reduce YANMAR’s warranty obligations. Add-on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or modified parts shall be grounds for disallowing a warranty.
Warranted Parts:
This warranty covers engine components that are a part of the emission control system of the engine as delivered by YANMAR to the original retail purchaser. Such components may include the following:
Fuel injection system (including Altitude compensation system)
Cold start enrichment system
Intake manifold and Air intake throttle valve
Turbocharger systems
Exhaust manifold and exhaust throttle valve
Positive crankcase ventilation system
Charge Air Cooling systems
Exhaust Gas Recirculation (EGR) systems
Exhaust gas after treatment (Diesel Particulate Filter (DPF) system, urea SCR system)
Electronic Control units, sensors, solenoids and wiring harnesses used in above systems
Hoses, belts, connectors and assemblies used in above systems
Emission Control Information Labels
Since emissions related parts may vary slightly between models, certain models may not contain all of these parts and other models may contain the functional equivalents.
Exclusions:
Failures other than those arising from defects in material or workmanship are not covered by this warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance, or use of non-recommended fuels and lubricating oils; accident-caused damage and replacement of expendable items made in connection with scheduled maintenance. YANMAR disclaims any responsibility for incidental or consequential such as loss of time, inconvenience, loss of use of equipment/engine or commercial loss.
Owner’s Warranty Responsibilities:
As the off-road compression-ignition engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. YANMAR recommends that you retain all documentation, including receipts, covering maintenance on your off-road compression-ignition engine, but YANMAR cannot deny warranty solely for the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.
As the off-road engine owner, you should however be aware that YANMAR may deny your warranty coverage if your off-road compression-ignition engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with CARB and EPA emissions requirements.
You are responsible for initiating the warranty process. The ARB and EPA suggest that you present your off-road engine to a YANMAR dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible. If you have any questions regarding your warranty rights and responsibilities, you should contact YANMAR America Corporation. If you would like to find the nearest YANMAR dealer or authorized service center, you should contact YANMAR America Corporation.
Website: https://www.yanmar.com
E-mail: CS_support@yanmar.com
Toll free telephone number: 1-800-872-2867, 1-855-416-7091
What the Emergency Stationary Type Engine Owner must Do:
The engines for emergency stationary type generators certified by Federal Law (40 CFR Part 60) are limited to emergency use only, and the operation for maintenance checks and verification test for functions is required. The total operating hours for maintenance and verification test for functions should not exceed 100 hours per year. However, there is no limitation on the operating hours for emergency use. Keep a log of the number of hours the engine is operated for both emergency use and non-emergency use. Also, note the reason for the operation.
YANMAR POWER TECHNOLOGY CO., LTD. EMISSION CONTROL SYSTEM WARRANTY - USA ONLY
Your warranty rights and obligations:
The California Air Resources Board (CARB), the United States Environmental Protection Agency (EPA) and YANMAR POWER TECHNOLOGY CO., LTD., hereafter referred to as YANMAR, are pleased to explain the emission control system warranty on your 2020, 2021, or 2022 model year industrial compression-ignition engine. California-certified, new off-road compression-ignition engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. In the remaining forty nine (49) states, new non-road compression-ignition engines must be designed, built and equipped to meet the United States EPA emissions standards. YANMAR must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine.
Your emission control system may include parts such as the fuel injection system, the air induction system, the electronic control system, EGR (Exhaust Gas Recirculation) system and the exhaust gas aftertreatment (diesel particulate filter system, urea SCR system). Also included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, YANMAR will repair your off-road compression-ignition engine at no charge to you including diagnosis, parts and labor.
Manufacturer’s warranty period:
2020, 2021, or 2022 model year off-road compression-ignition engines are warranted for the periods listed below. If any emission-related part on your engine is found to be defective during the applicable warranty period, the part will be repaired or replaced by YANMAR.
-: Warranty Period
If your engine is certified as | And its maximum power is | And its rated speed is | Then its warranty period is |
Variable speed or constant speed | kW < 8 | Any speed | 2,000 hours or two (2) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of two (2) years. |
Variable speed or constant speed | 8 ≤ kW < 19 | Any speed | 2,000 hours or two (2) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of two (2) years. |
Constant speed | 19 ≤ kW <37 | 3,000 rpm or higher | 2,000 hours or two (2) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of two (2) years. |
Constant speed | 19 ≤ kW <37 | Less than 3,000 rpm | 3,000 hours or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years. |
Variable speed | 19 ≤ kW <37 | Any speed | 3,000 hours or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years. |
Variable speed or constant speed | kW ≥ 37 | Any speed | 3,000 hours or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years. |
Warranty coverage:
This warranty is transferable to each subsequent purchaser for the duration of the warranty period. YANMAR recommends that repair or replacement of any warranted part will be performed at an authorized YANMAR dealer.
Warranted parts not scheduled for replacement as required maintenance in the owner's manual shall be warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in the owner's manual are warranted for the period of time prior to the first scheduled replacement. Any warranted parts scheduled for replacement as required maintenance that are repaired or replaced under warranty shall be warranted for the remaining period of time prior to the first scheduled replacement. Any part not scheduled for replacement that is repaired or replaced under warranty shall be warranted for the remaining warranty period.
During the warranty period, YANMAR is liable for damages to other engine components caused by the failure of any warranted part during the warranty period.
Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine, and shall not reduce YANMAR's warranty obligations. Add-on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or modified parts shall be grounds for disallowing a warranty.
Warranted parts:
This warranty covers engine components that are a part of the emission control system of the engine as delivered by YANMAR to the original retail purchaser. Such components may include the following:
(A) Fuel injection system (including Altitude compensation system)
(B) Cold start enrichment system
(C) Intake manifold and Air intake throttle valve
(D) Turbocharger systems
(E) Exhaust manifold and exhaust throttle valve
(F) Positive crankcase ventilation system
(G) Charge Air Cooling systems
(H) Exhaust Gas Recirculation (EGR) systems
(I) Exhaust gas after treatment (Diesel Particulate Filter (DPF) system, urea SCR system)
(J) Electronic Control units, sensors, solenoids and wiring harnesses used in above systems
(K) Hoses, belts, connectors and assemblies used in above systems
(L) Emission Control Information Labels
Since emissions related parts may vary slightly between models, certain models may not contain all of these parts and other models may contain the functional equivalents.
Exclusions:
Failures other than those arising from defects in material or workmanship are not covered by this warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance, or use of non-recommended fuels and lubricating oils; accident-caused damage and replacement of expendable items made in connection with scheduled maintenance. YANMAR disclaims any responsibility for incidental or consequential damages such as loss of time, inconvenience, loss of use of equipment/engine or commercial loss.
Owner’s warranty responsibilities:
As the off-road compression-ignition engine owner, you are responsible for the performance of the required maintenance listed in your operation manual. YANMAR recommends that you retain all documentation, including receipts, covering maintenance on your off-road compression-ignition engine, but YANMAR cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
YANMAR may deny your warranty coverage if your off-road compression-ignition engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with CARB and EPA emissions requirements.
You are responsible for initiating the warranty process. You are responsible for presenting your engine to an authorized YANMAR dealer or distributor as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.
If you have any questions regarding your warranty rights and responsibilities, or would like information on the nearest YANMAR dealer or authorized service center, you should contact YANMAR America Corporation.
Website: https://www.yanmar.com
E-mail: CS_support@yanmar.com
Toll free telephone number: 1-800-872-2867, 1-855-416-7091
What the emergency stationary type engine owner must do:
The engines for emergency stationary type generators certified by Federal Law (40 CFR Part60) are limited to emergency use only, and the operation for maintenance checks and verification test for functions is required. The total operating hours for maintenance and verification test for functions should not exceed 100 hours per year. However, there is no limitation on the operating hours for emergency use. Keep a log of the number of hours the engine is operated for both emergency use and non-emergency use. Also, note the reason for the operation.
Proposition 65 Warning
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
If this product contains a gasoline engine:
⚠WARNING
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
The State of California requires the above two warnings.
NOTE:MX52301,0002004-19-20180820CAUTION: NOTE:MX52301,0002005-19-20180820MX52301,0002006-19-20180607CAUTION: MX52301,0002007-19-20180820MX52301,0002008-19-20180607GB36814,0000176-19-20200929TCT015971-UN: Z994RLEGEND: A - Park Brake PedalB - Park Brake Lock PedalC - Deck Raise PedalD - MOD LeverE - Right Motion Control LeverF - Height of Cut / Transport Lock KnobG - HourmeterH - Engine Speed Control LeverI - Ignition Key SwitchJ - PTO Engagement SwitchK - Fuel Tank CapL - Fuel Level GaugeM - Left Motion Control LeverMX52301,000200E-19-20180611MX52301,0002063-19-20180820TCAL43729-UN: Using Indicator LightsNOTE:NOTE:MX52301,0002065-19-20180711ComfortGlide is a trademark of Deere & Company
MX00654,00001CC-19-20180804MX00654,00001CD-19-20180804CAUTION: MX00654,00001CE-19-20180820MX00654,00001CF-19-20180816CAUTION: MX00654,00001D0-19-20180807MX00654,00001D1-19-20180804CAUTION: IMPORTANT:MX00654,00001D2-19-20180807CAUTION: IMPORTANT:MX00654,00001D3-19-20180820TCT005197-UN: Gap Between WashersTCT005198-UN: Brake Equalizer NutMX00654,00001D4-19-20180820IMPORTANT:MX00654,00001D5-19-20180820NOTE:MX00654,00001D6-19-20180804NOTE:MX00654,00001D7-19-20190228NOTE:MX00654,00001D8-19-20190228MX00654,00001D9-19-20180804MX00654,00001DC-19-20180805MX00654,00001DD-19-20180805Torq-Gard is a trademark of Deere & Company
Plus-50 is a trademark of Deere & Company
MX00654,00001DF-19-20180817TCT016400-UN: Avoid CrushingMX52301,00020B1-19-20180806TCT016401-UN: Hearing ProtectionMX52301,00020B2-19-20180806TCT016402-UN: Avoid InjuryMX52301,00020B3-19-20180806TCT016403-UN: Avoid TippingMX52301,00020B4-19-20180806TCT016404-UN: Prevent Equipment FiresMX52301,00020B5-19-20180806MX52301,00020B6-19-20180820MX52301,00020B7-19-20180820MX52301,00020BA-19-20180820CAUTION: IMPORTANT:MX52301,00020BB-19-20180820CAUTION: IMPORTANT:NOTE:MX52301,00020BC-19-20180816TCT016406-UN: SeatMX52301,00020BE-19-20180820CAUTION: NOTE:TCT016410-UN: ROPS intermediate positionMX52301,00020BD-19-20180820TCT016513-UN: Diagnostic indicator lightTCT016512-UN: Diagnostic code label (B) is located on right side console beside operator’s seat.NOTE:MX52301,00020DF-19-20180820MX52301,00020E0-19-20180816TCT016518-UN: Mounting and DismountingMX52301,00020E2-19-20180820CAUTION: NOTE:MX52301,00020E3-19-20180820MX52301,00020E4-19-20180820MX52301,00020E5-19-20180820CAUTION: MX52301,00020E6-19-20180820MX52301,00020E8-19-20180820MX00654,00003A2-19-20190618TC100924-UN: Complete text of safety label messages can be found following this illustration.LEGEND: A - CAUTION - TCU24659B - DANGER - TCU37848C - CAUTION - UC14930D - WARNING - TCU39704E - WARNING (Spanish) - TCU39705F - CAUTION - TCU39706G - CAUTION - UC14932H - WARNING - M134406I - WARNING - TCU25390J - DANGER - TCU37849K - CAUTION (Spanish) - TCU24660MX00654,00003BA-19-20190705APY35732-UN: 60 in Rear Discharge Deck ShownLEGEND: A - DANGER - M131739B - WARNING - TCU51051C - WARNING - TCU24465D - WARNING - DMU211432APY37074-UN: 60 in Side Discharge Deck ShownLEGEND: A - DANGER - M131739B - WARNING - TCU24465C - WARNING - TCU51051D - DANGER - M137637E - DANGER - TCU33341SR99263,000032F-19-20200608APY37075-UN: 60 in Rear Discharge Deck ShownLEGEND: A - Rotating Blades - TCU31483B - Rotating Belt - TCU31482C - Rotating Belt - TCU31701APY37076-UN: 60 in Side Discharge Deck ShownLEGEND: A - Rotating Blades - TCU31483B - Rotating Belt - TCU31482C - Rotating Belt - TCU31701D - Thrown Objects - TCU18996E - Rotating Blade/Thrown Object - M173018BVVMSIT,000037D-19-20200608APY37078-UN: 60 in Rear Discharge Deck Model ShownAPY37077-UN: 60 in Side Discharge Deck Model ShownBVVMSIT,000037E-19-20200609BVVMSIT,000037F-19-20200609BVVMSIT,0000380-19-20200612BVVMSIT,0000381-19-20200609BVVMSIT,0000382-19-20200609NOTE:TCAL43497-UN: Lubricate the spindles.BVVMSIT,0000383-19-20200609NOTE:NOTE:NOTE:NOTE:BVVMSIT,0000384-19-20200612CAUTION: BVVMSIT,0000385-19-20200612CAUTION: BVVMSIT,0000386-19-20200609TCT011893-UN: Chamber Separators Performance AdjustmentThe Mulch-On-Demand Mower Decks are equipped with two adjustable chamber separators that can be used to control grass flow between blades. BVVMSIT,000038A-19-20200610MX00654,0000508-19-20220120TCT015912-UN: model numberZTrak is a trademark of Deere & Company
H2AC9Y3,000000E-19-20220413NOTE:NOTE:NOTE:H2AC9Y3,000000F-19-20220310H2AC9Y3,0000010-19-20220310NOTE:H2AC9Y3,0000011-19-20220310MK71445,0000418-19-20220502mk71445,1679915954842-19-20230330mk71445,1681748727253-19-20230418 CALIFORNIA
![[DA] ACME CPG](https://sprcdn-assets.sprinklr.com/1436/a7d6e3dd-fbc7-4292-a20c-e8f9964348e5-1036124649.png)
