Complete service manual with electrical wiring diagrams for John Deere Residential Mowers Z625, Z645, Z655, and Z665 EZtrak, with workshop information to maintain, diagnose repair, and service like professional mechanics.

John Deere Residential Mowers Z625, Z645, Z655, and Z665 EZtrak 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.

TM113119 - John Deere Residential Mowers Z625, Z645, Z655, and Z665 EZtrak Technical Manual (Diagnostics and Repair).PDF
TM113119 - John Deere Residential Mowers Z625, Z645, Z655, and Z665 EZtrak Technical Manual (Diagnostics and Repair).EPUB

Total Pages: 965 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle/iPad/iPhone/Android.
Language: English

MAIN SECTIONS
Foreword
   General Information
      Safety
      General Specifications
      Fuel and Lubricants
      Machine Specifications
   Engine Repair B&S
      Repair Engine Twin Cylinder
   Engine Repair Kawasaki
      Engine Repair
      Starting Motor Repair
   Electrical Repair
      Component Location
      Wiring Harness
   Power Train Repair
      Component Location (S.N. -130000)
      Component Location (S.N. 130001- )
      Repair (S.N. -130000)
      Repair (S.N. 130001- )
   Attachments Repair
      Component Location
      Repair
   Miscellaneous Repair
      Component Location
      Repair
   Engine Diagnosis, Tests, and Adjustments B&S
      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
      Connector Information
   Power Train Diagnosis, Tests, and Adjustments
      Theory of Operation (S.N. -130000)
      Theory of Operation (S.N. 130001- )
      Diagnosis (S.N. -130000)
      Diagnosis (S.N. 130001- )
      Tests and Adjustments (S.N. -130000)
      Tests and Adjustments (S.N. 130001- )
   Attachments Diagnosis, Tests, and Adjustments
      Diagnosis
      Tests and Adjustments
   Miscellaneous Tests and Adjustments
      Tests and Adjustments
   Service Tools and Kits
      Service Tools

tm113119 - Z625, Z645, Z655, and Z665 EZtrak™ Mower

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

Prevent Acid Burns

Prevent Battery Explosions

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

Service Tires Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Protect Against High Pressure Spray

Live With Safety

Group 10: General Specifications

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

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

Gasoline Engine Oil

Oil Filters

Gasoline Fuel for 4-Cycle Engines

Transmission and Hydraulic Oil

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 (S.N. -130000)

Machine Specifications (S.N. 130001-150000 )

Machine Specifications (S.N. 150001-170000)

Machine Specifications (S.N. 170001- )

Product Identification Number Location

Section 20: Engine Repair B&S

Group 10: Repair Engine Twin Cylinder

Summary of References

Essential or Recommended Tools

Service Equipment and Tools

Specifications

Remove and Install Blower Housing

Remove and Install Air Cleaner

Remove Two Barrel Carburetor

Install Two Barrel Carburetor

Repair Two Barrel Carburetor

Assemble Two Barrel Carburetor

Remove Engine (S.N. -130000)

Install Engine (S.N. -130000)

Remove Engine (S.N. 130001-)

Install Engine (S.N. 130001-)

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

Disassemble and Assemble Starting Motor

Inspect Starting Motor

Section 30: Electrical Repair

Group 10: Component Location

Electrical Component Location

Group 20: Wiring Harness

Summary of References

Wiring Harness Legend (S.N. -120000)

W1 Main Wiring Harness (S.N. -120000)

W1 Main Wiring Harness Color Codes (S.N. -120000)

Wiring Harness Legend (S.N. 120001- )

W1 Main Wiring Harness (S.N. 120001-150000)

W1 Main Wiring Harness Color Codes (S.N. 120001-150000)

W1 Main Wiring Harness (S.N. 150001- )

W1 Main Wiring Harness Color Codes (S.N. 150001- )

W2 Engine Wiring Harness

W3 Lighting Kit Wiring Harness

Section 40: Power Train Repair

Group 10: Component Location (S.N. -130000)

Summary of References

Control Linkage Components (S.N. -130000)

Hydraulic System Components (S.N. -130000)

Hydrostatic Pump Components (S.N. -130000)

Hydrostatic Pump Components Legend (S.N. -130000)

Hydraulic Reservoir Components (S.N. -130000)

Group 15: Component Location (S.N. 130001- )

Summary of References

Control Linkage Components (S.N. 130001- )

Transmission Serviceable Components (S.N. 130001- )

Group 20: Repair (S.N. -130000)

Summary of References

Other Material

Specifications

Replace Transmission Drive Belt (S.N. -130000)

Change Hydraulic Oil and Filter (S.N. -130000)

Remove and Install Wheel Motor (S.N. -130000)

Remove Hydrostatic Pump (S.N. -130000)

Install Hydrostatic Pump (S.N. -130000)

Disassemble Hydrostatic Pump (S.N. -130000)

Assemble Hydrostatic Pump (S.N. -130000)

Group 25: Repair (S.N. 130001- )

Summary of References

Other Material

Drain and Replace Transaxle Oil (S.N. 130001- )

Remove and Install Transaxle (S.N. 130001- )

Remove and Install Traction Drive Belt (S.N. 130001- )

Replace Input Shaft Seal (S.N. 130001- )

Replace Bypass Seal (S.N. 130001- )

Replace Axle Seal (S.N. 130001- )

Replace Control Shaft Seal (S.N. 130001- )

Replace Brake Lever Seal (S.N. 130001- )

Remove and Install Transaxle Case Plug (S.N. 130001- )

Section 50: Attachments Repair

Group 10: Component Location

Summary of References

Deck and Lift Assembly

Deck Lift Control and Linkage

Deck 48HC Legend

Deck 48HC

Deck Shields—48HC Deck

Deck 54HC Legend

Deck 54HC

Deck Shields—54HC

Deck 60HC Legend

Deck 60HC

Deck Shields—60HC Deck

Spindle Section

Group 20: Repair

Summary of References

Specifications

Remove Mower Blades

Install Mower Blades

Remove Mower Deck

Install Mower Deck

Replace Mower Drive Belt (48HC and 54HC)

Replace Mower Drive Belt (60HC)

Remove and Install Deck Lift Assist Spring

Sharpen Mower Blades

Balance Mower Blades

Disassemble Mower Deck Spindle

Assemble Mower Deck Spindle

Repair Mower Deck Idlers

Section 60: Miscellaneous Repair

Group 10: Component Location

Summary of References

Park Brake Components (S.N. -130000)

Park Brake Components (S.N. 130001- )

Seat and Pan Components

Fuel Tank and Line Components (S.N. -130000)

Fuel Tank and Line Components (S.N. 130001- )

Muffler and Heat Shield—Z645, Z655 (S.N. -120000)

Muffler and Heat Shield—Z645, Z655 (S.N. 120001- )

Muffler and Heat Shield—Z665 (S.N. -150000)

Muffler and Heat Shield—Z665 (S.N. 150001-)

Group 20: Repair

Summary of References

Specifications

Remove Engine Guards

Remove and Install Control Console

Remove and Install Seat

Remove and Install Seat Platform

Remove and Install Control Panel

Remove and Install Foot Plate

Front Caster Wheels

Repair Park Brake (S.N. 130001- )

Section 220: Engine Diagnosis, Tests, and Adjustments B&S

Group 10: Diagnosis

B&S V-Twin, Diagnose Engine Starting

B&S V-Twin, Diagnose Carburetor, Air and Fuel

B&S V-Twin, Engine Will Not Crank

B&S V-Twin, Engine Cranks But Will Not Start

B&S V-Twin, Engine Runs Erratically

B&S V-Twin, Engine Runs Then Dies

B&S V-Twin, Engine Backfires or Misses

B&S V-Twin, Engine Overheats

B&S V-Twin, Engine Has Loss of Power

Group 20: Tests and Adjustments

Summary of References

Specifications

Service Equipment and Tools

Adjust Throttle and Choke Cable, V-Twin

Adjust Governor - Static, V-Twin

Adjust Governor - Dynamic, 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

Intake and Carburetor Components

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 (S.N. -120000)

Cranking Circuit Operation (S.N. -120000)

Ignition Interlock Circuit Operation (S.N. -120000)

Fuel Shutoff Circuit Operation (S.N. -120000)

Charging Circuit Operation (S.N. -120000)

PTO Circuit Operation (S.N. -120000)

Hour Meter Circuit Operation (S.N. -120000)

Headlight Circuit Operation (option) (S.N. -120000)

Power Circuit Operation (S.N. 120001-150000)

Cranking Circuit Operation (S.N. 120001-150000)

PTO Circuit Operation (S.N. 120001-150000)

Hour Meter Circuit Operation (S.N. 120001-150000)

Interlock Circuit Operation (S.N. 120001-150000)

Charging Circuit Operation (S.N. 120001-150000)

Fuel Shutoff Circuit Operation (S.N. 120001-150000)

Headlight Circuit Operation (option) (S.N. 120001-150000)

Power Circuit Operation (S.N. 150001- )

Cranking Circuit Operation (S.N. 150001- )

PTO Circuit Operation (S.N. 150001- )

Hour Meter Circuit Operation (S.N. 150001- )

Interlock Circuit Operation (S.N. 150001- )

Charging Circuit Operation (S.N. 150001- )

Fuel Shutoff Circuit Operation (S.N. 150001- )

Headlight Circuit Operation (option) (S.N. 150001- )

Group 20: Diagnosis

Diagnose Power Circuit (S.N. -120000)

Diagnose Ignition Interlock Circuit (S.N. -120000)

Diagnose Fuel Shutoff Circuit (S.N. -120000)

Diagnose Cranking Circuit (S.N. -120000)

Diagnose PTO Circuit (S.N. -120000)

Diagnose Charging Circuit (S.N. -120000)

Diagnose Hour Meter Circuit (S.N. -120000)

Diagnose Headlight Circuit (S.N. -120000)

Diagnose Power Circuit (S.N. 120001-150000)

Diagnose Ignition Interlock Circuit (S.N. 120001-150000)

Diagnose Fuel Shutoff Circuit (S.N. 120001-150000)

Diagnose Cranking Circuit (S.N. 120001-150000)

Diagnose PTO Circuit (S.N. 120001-150000)

Diagnose Charging Circuit (S.N. 120001-150000)

Diagnose Hour Meter Circuit (S.N. 120001-150000)

Diagnose Headlight Circuit (S.N. 120001-150000)

Diagnose Power Circuit (S.N. 150001- )

Diagnose Ignition Interlock Circuit (S.N. 150001- )

Diagnose Fuel Shutoff Circuit (S.N. 150001- )

Diagnose Cranking Circuit (S.N. 150001- )

Diagnose PTO Circuit (S.N. 150001- )

Diagnose Charging Circuit (S.N. 150001- )

Diagnose Hour Meter Circuit (S.N. 150001- )

Diagnose Headlight Circuit (S.N. 150001- )

Group 30: Tests and Adjustments

Summary of References

Essential or Recommended Tools

Service Equipment and Tools

Specifications

Ground Circuit Test

Battery Voltage and Specific Gravity Tests

Battery Charge

Battery Load Test

Spark Test

Regulated Voltage Test

Regulated Amperage Test

Voltage Regulator/Rectifier Test, Kawasaki

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

Start Relay Test

Relay Test

Fuel Shutoff Solenoid Test, B&S

Fuel Shutoff Solenoid Test, Kawasaki

Seat Switch Test

Headlight Switch Test

Park Brake and Neutral Switch Test

Group 40: Wiring Schematics

Summary of References

Schematic Legend

Main Electrical Schematic (S.N. -120000)

Main Electrical Schematic (S.N. 120001-150000)

Main Electrical Schematic (S.N. 150001- )

Group 50: Connector Information

Summary of References

Load Center (S.N. -120000)

Load Center (S.N. 120001-150000)

Load Center (S.N. 150001- )

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

Headlight 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 (S.N. -130000)

Summary of References

Power Train Operation (S.N. -130000)

Hydraulic Schematic (S.N. -130000)

Group 15: Theory of Operation (S.N. 130001- )

Summary of References

Drive Operation (S.N. 130001- )

Transaxle Operation (S.N. 130001- )

Group 20: Diagnosis (S.N. -130000)

Diagnose System Fails to Build Pressure (S.N. -130000)

Diagnose Machine Will Not Drive Straight (S.N. -130000)

Diagnose Machine Will Not Reach Maximum Speed (S.N. -130000)

Diagnose Machine Will Not Move When Controls Are Engaged (S.N. -130000)

Diagnose Jerky or Erractic Operation (S.N. -130000)

Diagnose Sluggish Operation Under Load (S.N. -130000)

Group 25: Diagnosis (S.N. 130001- )

Transaxle Checks (S.N. 130001- )

Machine Does Not Achieve Full Speed (S.N. 130001- )

Machine Will Not Move (S.N. 130001- )

Noisy Operation (S.N. 130001- )

Wheel Will Not Rotate (S.N. 130001- )

Wheel Rotates One Direction Only (S.N. 130001- )

Group 30: Tests and Adjustments (S.N. -130000)

Summary of References

Service Equipment and Tools

Specifications

Check and Adjust Speed Control Lever Neutral Position (S.N. -130000)

Adjust Motion Control Levers (S.N. -130000)

Adjust Tracking (S.N. -130000)

Using the Bypass Valves (S.N. -130000)

Bleed Hydraulic System (S.N. -130000)

Removing Hydraulic Lock (S.N. -130000)

Test Hydraulic Pump Flow (S.N. -130000)

Group 35: Tests and Adjustments (S.N. 130001- )

Summary of References

Adjust Tracking (S.N. 130001- )

Adjust Neutral Creep (S.N. 130001- )

Adjust Motion Control Levers (S.N. 130001- )

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

Specifications

Adjust Mower Wheels

Adjust Mower Level

Mower Drive Belt Tension

Section 260: Miscellaneous Tests and Adjustments

Group 10: Tests and Adjustments

Summary of References

Specifications

Adjust Park Brake (S.N. -130000)

Adjust Park Brake (S.N. 130001- )

Section 299: Service Tools and Kits

Group 10: Service Tools

Essential or Recommended Tools

Service Equipment and Tools