Complete service repair manual with Electrical Wiring Diagrams for John Deere ZTrak Riding Lawn Mowers Z525E, Z535M, Z540M, Z535R, Z540R, with all the workshop information to maintain, test, repair, service like professional mechanics.

John Deere ZTrak Riding Lawn Mowers Z525E, Z535M, Z540M, Z535R, Z540R workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TM140419 - John Deere Z525E, Z535M, Z540M, Z535R, Z540R ZTrak Riding Lawn Mower Technical Manual.PDF
TM140419 - John Deere Z525E, Z535M, Z540M, Z535R, Z540R ZTrak Riding Lawn Mower Technical Manual.EPUB

Total Pages: 760 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   General Information
      Safety
      General Specifications
      Fuel and Lubricants
      Machine Specifications
   Engine Repair Briggs & Stratton
      Engine Repair
   Engine Repair Kawasaki
      Engine Repair
      Starting Motor Repair
   Electrical Repair
      Component Location
      Wiring Harnesses
   Power Train Repair
      Component Location
      Repair
   Attachments Repair
      Component Location
      Repair
   Miscellaneous Repair
      Component Location
      Repair
   Engine Diagnosis, Tests, and Adjustments V-Twin
      General Information
      Diagnosis
      Tests and Adjustments
   Engine Diagnosis, Tests, and Adjustments Kawasaki
      Component Location
      General Information
      Theory of Operation
      Diagnosis
      Tests and Adjustments
   Electrical Diagnosis, Tests, and Adjustments
      Theory of Operation
      Diagnosis
      Tests and Adjustments
      Wiring Schematics
      Connectors
   Power Train Diagnosis, Tests, and Adjustments
      Theory of Operation
      Diagnosis
      Tests and Adjustments
   Attachments Diagnosis, Tests, and Adjustments
      Diagnosis
      Tests and Adjustments
   Service Tools and Kits
      Service Tools

tm140419 - Z525E, Z535M, Z540M, Z535R, Z540R ZTrak Mower (S.N. 010001-)

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Practice Safe Maintenance

Use Proper Tools

Handle Fluids Safely—Avoid Fires

Drain Gasoline When Storing Machine

Handling Batteries Safely

Prepare for Emergencies

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Follow Tire Recommendations

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Protect Against High Pressure Spray

Live With Safety

Group 10: General Specifications

Metric Cap Screw Torque Values—Grade 7

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Group 15: Fuel and Lubricants

Summary of References

Gasoline Engine Oil

Oil Filters

Gasoline Fuel for 4-Cycle Engines

Transaxle Oil

Grease

Mower Spindle Grease

Mixing of Lubricants

Alternative and Synthetic Lubricants

Lubricant Storage

Gasoline and Engine Storage

Carburetor Cleaning

Carburetor Cleaning Methods

Group 20: Machine Specifications

Machine Specifications Z525E, Z535M, Z540M

Machine Specifications Z535R, Z540R

Product Identification Number Location

Section 20: Engine Repair Briggs & Stratton

Group 10: Engine Repair

Summary of References

Specifications

Remove Engine

Install Engine

Remove Upper Blower Housing

Install Upper Blower Housing

Changing Engine Oil and Filter

Cleaning Air Intake Screen and Engine Fins

Cleaning Engine Shroud

Remove and Install Air Cleaner, Oval

Replace Fuel Filter

Cleaning Engine Screen Guard

Remove Single Barrel Carburetor

Install Single Barrel Carburetor

Single Barrel Carburetor Components

Disassemble Single Barrel Carburetor

Assemble Single Barrel Carburetor

Remove Two Barrel Carburetor

Install Two Barrel Carburetor

Repair Two Barrel Carburetor

Remove Cylinder Air Guides

Install Cylinder Air Guides

Remove Cylinder Head

Install Cylinder Head

Inspect and Repair Cylinder Head

Remove Valve

Inspect and Repair Valve

Lap Valves

Install Valve

Remove Piston, Rings and Rod

Check Piston Ring End Gap

Inspect Piston and Rod

Assemble Piston and Rod

Install Piston and Rod

Inspect Cylinder Bore

Hone Cylinder Bore

Clean Cylinder Bore

Resize Cylinder Bore

Remove Flywheel

Install Flywheel

Remove and Install Stator

Remove and Inspect Crankshaft and Camshaft

Crankshaft and Camshaft Component Location

Install Crankshaft and Camshaft

Inspect Magneto Bearing

Inspect PTO and Cam Bearing

Service Breather Valve

Remove Oil Pump

Install Oil Pump

Inertia Starting Motor Components

Remove and Install Starting Motor

Disassemble Inertia Starting Motor

Assemble Inertia Starting Motor

Replace Inertia Pinion Gear

Section 25: Engine Repair Kawasaki

Group 10: Engine Repair

Summary of References

Specifications

Replace Fuel Filter, FS730V

Remove and Install Fuel Pump, FS730V

Remove and Install Muffler, FS730V

Remove Engine, FS730V

Install Engine, FS730V

Remove and Install Carburetor, FS730V

Disassemble and Assemble Carburetor, FS730V

Remove and Install Intake Manifold, FS730V

Remove and Install Crankcase Breather, FS730V

Remove and Install Blower Housing, FS730V

Remove and Install Ignition Coil, FS730V

Remove and Install Flywheel, FS730V

Remove and Install Stator, FS730V

Remove and Install Rocker Arm Cover, FS730V

Remove and Install Rocker Arm and Push Rod, FS730V

Inspect Rocker Arm and Push Rod, FS730V

Remove Cylinder Head, FS730V

Disassemble and Assemble Cylinder Head, FS730V

Install Cylinder Head, FS730V

Inspect Cylinder Head and Valves, FS730V

Analyze Valves, FS730V

Recondition Valve Seats, FS730V

Lap Valve, FS730V

Remove and Install Crankcase Cover, FS730V

Crankcase Cover Disassemble, Inspect, and Assemble, FS730V

Disassemble and Assemble Governor, FS730V

Remove and Install Camshaft and Tappets, FS730V

Inspect Camshaft and Tappets, FS730V

Remove Piston and Connecting Rod, FS730V

Disassemble Piston and Connecting Rod, FS730V

Inspect Piston and Connecting Rod, FS730V

Check Piston Ring End Gap, FS730V

Assemble and Install Piston and Connecting Rod, FS730V

Analyze Piston Ring Wear, FS730V

Analyze Piston Wear, FS730V

Remove and Install Crankshaft, FS730V

Crankshaft Inspection, FS730V

Check Connecting Rod-to-Crankshaft Clearance, FS730V

Inspect Crankshaft and Connecting Rod Wear, FS730V

Replace Oil Seal, FS730V

Deglaze Cylinder Bore, FS730V

Resize Cylinder Bore, FS730V

Group 20: Starting Motor Repair

Summary of References

Remove and Install Starting Motor, FS730V

Disassemble and Assemble Starting Motor, FS730V

Inspect Starting Motor, FS730V

Section 30: Electrical Repair

Group 10: Component Location

Wiring Harness (Z525E, Z535M, Z535R)

Wiring Harness (Z540M, Z540R)

Group 20: Wiring Harnesses

Summary of References

Main Wiring Harness, Z525E, Z535M, Z535R

Main Wiring Harness Color Codes, Z525E, Z535M, Z535R

Main Wiring Harness, Z540M, Z540R

Main Wiring Harness Color Codes, Z540M, Z540R

Engine Wiring Harness, Z525E, Z535M, Z535R

Engine Wiring Harness, Z540M, Z540R

Light Harness

Section 40: Power Train Repair

Group 10: Component Location

Summary of References

Transmission Serviceable Components

Transaxle Mount Components

Pulleys and Drive Belt

Group 20: Repair

Summary of References

Other Material

Remove and Install Traction Drive Belt

Remove and Install Transaxle

Drain and Replace Transaxle Oil

Replace Input Shaft Seal

Replace Bypass Seal

Replace Axle Seal

Replace Control Shaft Seal

Replace Brake Lever Seal

Remove and Install Transaxle Case Plug

Section 50: Attachments Repair

Group 10: Component Location

Mower Deck Components 48 Accel Deep and 54 Accel Deep

48HC and 54HC Decks Similar to 60HC

62C Deck Components

Spindles and Sheaves Components (60HC Deck)

Spindles and Sheaves Components (62C Deck)

Idlers and Sheaves Components (60HC Deck)

Idlers and Sheaves Components (62C Deck)

Anti-Scalp Wheel Components (60HC Deck)

Anti-Scalp Wheel Components (62C Deck)

Spindle Section, 54C and 62C

Group 20: Repair

Summary of References

Remove and Install Mower Blades

Sharpen and Balance Blades

Disassemble Spindle, 48A and 54A Mower Decks

Assemble Spindle, 48A and 54A Mower Decks

Disassemble Spindle, 48HC, 54HC, and 62HC Mower Decks

Assemble Spindle, 48HC, 54HC, and 62HC Mower Decks

Disassemble Spindle, 60C Mower Deck

Assemble Spindle, 60C Mower Deck

Remove and Install Mower Deck Foot Plate

Remove and Install Mower Deck Shields

Remove Mower Deck (48A, 48HC, 54A, 54HC, 60HC and 62C)

Install Mower Deck (48A, 48HC, 54A, 54HC, 60HC and 62C)

Replace Mower Drive Belt (48A, 48HC, 54A, 54HC, 60HC and 62C)

Section 60: Miscellaneous Repair

Group 10: Component Location

Summary of References

Fuel System Components

Park Brake Components

Muffler and Heat Shield

Seat, Pan, and Arms Components

Steering System Components

Platform and Frame Components

Lift Linkage

Group 20: Repair

Summary of References

Remove and Install Foot Plate

Front Caster Wheels

Remove and Install Rear Wheel Assembly

Remove and Install Seat

Remove and Install Park Brake

Remove and Install Engine Guard

Remove and Install Battery

Section 220: Engine Diagnosis, Tests, and Adjustments V-Twin

Group 20: General Information

Diagnose Carburetor Air and Fuel

Carburetor Diagnostic Inspection

Cleaning Carburetors

Cleaning Methods

Fuel

Group 40: Diagnosis

Diagnose Engine Starting, V-Twin

Diagnose Carburetor, Air and Fuel, V-Twin

Engine Will Not Crank, V-Twin

Engine Cranks But Will Not Start, V-Twin

Engine Runs Erratically, V-Twin

Engine Runs Then Dies, V-Twin

Engine Backfires or Misses, V-Twin

Engine Overheats, V-Twin

Engine Has Loss of Power, V-Twin

Group 50: Tests and Adjustments

Summary of References

Specifications

Service Equipment and Tools

Adjust Throttle Cable, V-Twin

Adjust Choke Cable, V-Twin

Governor Static Adjustment, V-Twin

Governor Dynamic Adjustment, V-Twin

Fuel Pump Test, V-Twin

Test Crankcase Vacuum, V-Twin

Test Cylinder Leakdown, V-Twin

Test Cylinder Balance, V-Twin

Adjust Armature Air Gap, V-Twin

Adjust Valve Clearance, V-Twin

Test Engine Oil Pressure, V-Twin

Section 225: Engine Diagnosis, Tests, and Adjustments Kawasaki

Group 10: Component Location

Engine Block

Valves and Governor

Group 20: General Information

Cleaning Carburetors

Cleaning Methods

Fuel

Group 30: Theory of Operation

Engine Oil Flow Chart

Lubrication System Operation

Governor Operation

Crankcase Breather Operation

Automatic Compression Release (ACR) Operation

Cooling System Operation

Ignition System Operation

Carburetor Operation

Group 40: Diagnosis

Kawasaki, Diagnose Carburetor Air and Fuel

Kawasaki, Diagnose Carburetor

Kawasaki, Diagnose Starting

Kawasaki, Diagnose Starting Motor

Group 50: Tests and Adjustments

Summary of References

Specifications

Check and Adjust Choke, FS730V

Check and Adjust Throttle Cable, FS730V

Adjust Governor Static, FS730V

Adjust Low Idle, FS730V

Adjust High Idle, FS730V

Cylinder Compression Test, FS730V

Cylinder Leak-Down Test, FS730V

Check and Adjust Valve Clearance, FS730V

Fan Screen Check and Adjust, FS730V

Ignition Coil Air Gap Check and Adjust, FS730V

Test Spark, FS730V

Spark Plug Gap Adjust, FS730V

Test Engine Oil Pressure, FS730V

Test Fuel Pump, FS730V

Test Crankcase Vacuum, FS730V

Section 230: Electrical Diagnosis, Tests, and Adjustments

Group 10: Theory of Operation

Summary of References

Power Circuit Operation

Cranking Circuit Operation

PTO Circuit Operation

Hour Meter Circuit Operation

Charging Circuit Operation

Interlock Circuit Operation

Group 20: Diagnosis

Diagnose Power Circuit

Diagnose Cranking Circuit

Diagnose PTO Circuit

Diagnose Hour Meter Circuit

Diagnose Charging Circuit

Diagnose Ignition Interlock Circuit

Group 30: Tests and Adjustments

Summary of References

Common Circuit Tests

Ground Circuit Test

Charge Battery

Battery Load Test

Spark Test

Starting Motor Amperage Draw Test: Loaded, B&S

Starting Motor Amperage Draw Test: No Load, B&S

Starting Motor Amperage Draw Test: Loaded, Kawasaki

Starting Motor Amperage Draw Test: No-Load, Kawasaki

Test Starting Solenoid, Kawasaki

Stator Output Test, B&S

Stator Output Test, Kawasaki

Flywheel Stator Magnets Test

Flywheel Ignition Magnet Test

Diode Test

PTO Switch Test

Electric PTO Clutch Test

Key Switch Test

Relay Test

Fuel Shutoff Solenoid Test, B&S

Fuel Shutoff Solenoid Test, Kawasaki

Seat Switch Test

Fuse Test

Headlight Switch Test

Park Brake and Neutral Switch Test

Group 40: Wiring Schematics

Main Electrical Schematic (Z525E, Z535M, Z535R)

Main Electrical Schematic (Z540M, Z540R)

Group 50: Connectors

Summary of References

Load Center

Hour Meter Connector

Key Switch Connector

Left Handle Neutral Switch Connector

Right Handle Neutral Switch Connector

Park Brake Switch Connector

Seat Switch Connector

PTO Switch Connector

Light Switch Connector

Light Harness Connector

Engine Connector

PTO Clutch Connector

Start Relay Connectors

Regulator/Rectifier Connectors

Section 240: Power Train Diagnosis, Tests, and Adjustments

Group 10: Theory of Operation

Summary of References

Drive Operation

Transaxle Operation

Group 20: Diagnosis

Transaxle Checks

Machine Does Not Achieve Full Speed

Machine Will Not Move

Noisy Operation

Wheel Will Not Rotate

Wheel Rotates One Direction Only

Group 30: Tests and Adjustments

Summary of References

Checking and Adjusting Neutral Creep

Adjusting Tracking

Checking and Replacing Transaxle/Transmission Drive Belt

Section 250: Attachments Diagnosis, Tests, and Adjustments

Group 10: Diagnosis

Mower Blade Does Not Rotate

Mower Deck Vibrates

Mower Deck Cuts Unevenly or with Striping

Mower Belt Slips or Jumps Off Sheaves

Group 20: Tests and Adjustments

Summary of References

Adjusting Cutting Height

Adjust Mower Level

Adjusting Mower Wheels

Adjust Mower Drive Belt Tension

Section 299: Service Tools and Kits

Group 10: Service Tools

Essential or Recommended Tools

Service Equipment and Tools

Other Material

John Deere ZTrak Riding Lawn Mowers Z525E, Z535M, Z540M, Z535R, Z540R Service Technical Manual (TM140419)