Complete service repair manual with electrical wiring diagrams for John Deere Riding Lawn Residential Mowers Z225, Z245, Z235, Z255 EZtrak, with all the workshop information to maintain, diagnose, repair, and service like professional mechanics.

John Deere Riding Lawn Residential Mowers Z225, Z245, Z235, Z255 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.

tm112919 - Z225, Z245 EZtrak Mower (S.N. 100001-)Z235, Z255 EZtrak Mower (S.N. 130001- ) Technical Manual.pdf
tm112919 - Z225, Z245 EZtrak Mower (S.N. 100001-)Z235, Z255 EZtrak Mower (S.N. 130001- ) Technical Manual.epub

Total Pages: 1,064 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
   Foreword
   General Information
      Safety
      General Specifications
      Fuel and Lubricants
      Machine Specifications
   Single Cylinder Engine Repair
      Engine Single Cylinder
   V-Twin Engine Repair
      Repair Engine V-Twin
   Electrical Repair
      Component Location
      Wiring Harness
   Power Train Repair
      Component Location
      Repair
   Attachments Repair
      Component Location
      Repair
   Miscellaneous Repair
      Component Location
      Repair
   Single Cylinder Diagnosis, Tests, and Adjustments
      Diagnosis
      Tests and Adjustments
   V-Twin Engine Diagnosis, Tests, and Adjustments
      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
      Diagnosis
      Tests and Adjustments
   Attachments Diagnosis, Tests, and Adjustments
      Diagnosis
      Tests and Adjustments
   Service Tools and Kits
      Service Tools

tm112919 - Z225, Z245 EZtrak Mower (S.N. 100001-)Z235, Z255 EZtrak Mower (S.N. 130001- )

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

Follow Tire Recommendations

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

Summary of References

Gasoline Engine Oil

Oil Filters

Gasoline Fuel for 4-Cycle Engines

Transaxle 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 Z225 and Z245 (S.N. -130000)

Machine Specifications Z235 and Z255 (S.N. 130001- )

Product Identification Number Location (S.N. -130000)

Product Identification Number Location (S.N. 130001- )

Section 20: Single Cylinder Engine Repair

Group 10: Engine Single Cylinder

Summary of References

Specifications

Service Equipment and Tools

Remove and Install Upper Blower Housing

Service Air Cleaner

Remove Carburetor

Install Carburetor

Disassemble Carburetor

Inspect Carburetor

Assemble Carburetor

Service Breather Valve

Remove Engine

Install Engine

Remove Cylinder Head

Install Cylinder Head

Inspect and Repair Cylinder Head

Remove Valves

Reface Valves

Install Valves

Remove and Install Governor

Piston and Rings

Inspect Cylinder Bore

Hone Cylinder Bore

Clean Cylinder Bore

Resize Cylinder Bore

Inspect Piston and Connecting Rod

Assemble and Install Connecting Rod and Piston

Remove and Install Flywheel

Remove and Install Stator

Remove Crankshaft

Remove Balance System

Install Balance System

Install Crankshaft and Cam Gear

Inspect Magneto and Cam Bearing

Inspect PTO Journal

Inertia Starting Motor Components

Remove and Install Starting Motor

Disassemble Inertia Starting Motor

Assemble Inertia Starting Motor

Replace Inertia Pinion Gear

Section 30: V-Twin Engine Repair

Group 10: Repair Engine V-Twin

Summary of References

Specifications

Essential or Recommended Tools

Service Equipment and Tools

Remove and Install Air Cleaner (S.N. -130000)

Remove and Install Air Cleaner (S.N. 130001- )

Remove and Install Upper Blower Housing (S.N. -130000)

Remove and Install Upper Blower Housing (S.N. 130001- )

Remove Single Barrel Carburetor

Install Single Barrel Carburetor

Disassemble Single Barrel Carburetor

Inspect Single Barrel Carburetor

Assemble Single Barrel Carburetor

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 40: Electrical Repair

Group 10: Component Location

Summary of References

Electrical Component Location (S.N. -130000)

Electrical Component Location (S.N. 130001-170000)

Electrical Component Location (S.N. 170001- )

Group 20: Wiring Harness

Summary of References

Wiring Harness Legend

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

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

W1 Main Wiring Harness (S.N. 120001-130000)

W1 Main Wiring Harness Color Codes (S.N. 120001-130000)

W1 Main Wiring Harness (S.N. 130001-170000)

W1 Main Wiring Harness Color Codes (S.N. 130001-170000)

W1 Main Wiring Harness (S.N. 170001- )

W1 Main Wiring Harness Color Codes (S.N. 170001- )

W2 Engine Wiring Harness

W3 Lighting Kit Wiring Harness (S.N. -130000)

W3 Lighting Kit Wiring Harness (S.N. 130001- )

Section 50: Power Train Repair

Group 10: Component Location

Summary of References

Power Train Components (S.N. -130000)

Power Train Components (S.N. 130001- )

Control Linkage Components (S.N. -130000)

Control Linkage Components (S.N. 130001- )

Transaxle Components (S.N. -130000)

Transaxle Components (S.N. 130001- )

Fan Pulley (S.N. -130000)

Fan Pulley (S.N. 130001- )

Transaxle Mounts (S.N. -130000)

Transaxle Mounts (S.N. 130001- )

Group 20: Repair

Summary of References

Specifications

Disassemble Park Brake (S.N. -130000)

Inspect Park Brake (S.N. -130000)

Assemble Park Brake (S.N. -130000)

Remove Traction Belt (S.N. -130000)

Install Traction Belt (S.N. -130000)

Remove Traction Belt (S.N. 130001- )

Install Traction Belt (S.N. 130001- )

Remove and Install Transaxle (S.N. -130000)

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

Replace Neutral Return Shaft Seal

Replace Transaxle Hub Nut

Section 60: Attachments Repair

Group 10: Component Location

Summary of References

Deck and Lift Components, 42C (S.N. -130000)

Deck and Lift Components, 42C (S.N. 130001- )

Deck and Lift Components, 48TD (S.N. -130000)

Deck and Lift Components, 48TD (S.N. 130001- )

Deck Spindles and Sheaves, 42C (S.N. -130000)

Deck Spindles and Sheaves, 42C (S.N. 130001- )

Deck Spindles and Sheaves, 48TD

Deck Lift Assembly Components (S.N. -130000)

Deck Lift Assembly Components (S.N. 130001- )

Spindle Section, 42 and 48 Decks MY09

Spindle Section, 42 and 48 Decks MY10—

Group 20: Repair

Summary of References

Specifications

Install Mounting Post Bracket to Machine (S.N. -130000)

Install Bagger Chute

Remove Bagger Chute

Install Weight Kit

Remove Mower Deck (42C) (S.N. -130000)

Install Mower Deck (42C) (S.N. -130000)

Remove Mower Deck (42C) (S.N. 130001- )

Install Mower Deck (42C) (S.N. 130001- )

Remove Mower Deck (48TD) (S.N. -130000)

Install Mower Deck (48TD) (S.N. -130000)

Remove Mower Deck (48TD) (S.N. 130001- )

Install Mower Deck (48TD) (S.N. 130001- )

Replace Mower Drive Belt (42C) (S.N. -130000)

Replace Mower Drive Belt (42C) (S.N. 130001- )

Replace Mower Drive Belt (48TD)

Remove and Install Mower Blade

Sharpen and Balance Blades

Disassemble Spindle, 42 and 48 Inch

Assemble Spindle, 42 and 48 Inch

Section 70: Miscellaneous Repair

Group 10: Component Location

Summary of References

Fuel System Components (S.N. -130000)

Fuel System Components (S.N. 130001-170000)

Fuel System Components (S.N. 170001- )

Park Brake Components (S.N. -130000)

Park Brake Components (S.N. 130001- )

Muffler and Heat Shield, Single Cylinder

Muffler and Heat Shield, V-Twin (S.N. -120000)

Muffler and Heat Shield, V-Twin (S.N. 120001-130000)

Muffler and Heat Shield, V-Twin (S.N. 130001- )

Seat and Pan Components (S.N. -130000)

Seat and Pan Components (S.N. 130001- )

Group 20: Repair

Summary of References

Specifications

Remove and Install Seat (S.N. -130000)

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

Remove and Install Control Console (S.N. -130000)

Remove and Install Control Panel (S.N. -130000)

Repair Park Brake (S.N. -130000)

Repair Park Brake (S.N. 130001- )

Remove and Install Foot Plate (S.N. -130000)

Remove and Install Foot Plate (S.N. 130001- )

Remove Engine Guards (S.N. -130000)

Remove Engine Guards (S.N. 130001- )

Front Caster Wheels (S.N. -130000)

Front Caster Wheels (S.N. 130001- )

Section 220: Single Cylinder Diagnosis, Tests, and Adjustments

Group 10: Diagnosis

Diagnose Engine Starting (Single Cylinder)

Diagnose Carburetor, Air, Fuel (Single Cylinder)

Engine Will Not Crank (Single Cylinder)

Engine Cranks But Will Not Start (Single Cylinder)

Engine Runs Erratically (Single Cylinder)

Engine Runs Then Dies (Single Cylinder)

Engine Backfires or Misses (Single Cylinder)

Engine Overheats (Single Cylinder)

Engine Has Loss of Power (Single Cylinder)

Group 20: Tests and Adjustments

Summary of References

Specifications

Service Equipment and Tools

Adjust Throttle and Choke Cable

Test Fuel Shutoff Solenoid

Adjust Governor - Static

Adjust Governor - Dynamic

Adjust Governed Idle

Adjust Low Idle

Adjust Valve Clearance

Adjust Armature Air Gap

Test Crankcase Vacuum

Test Cylinder Leakdown

Section 230: V-Twin Engine Diagnosis, Tests, and Adjustments

Group 10: 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 20: Tests and Adjustments

Summary of References

Specifications

Service Equipment and Tools

Adjust Throttle and Choke Cable, V-Twin

Test Fuel Shutoff Solenoid, V-Twin

Adjust Governor - Static, V-Twin

Adjust Governor - Dynamic, V-Twin (S.N. -130000)

Adjust Governor - Dynamic, V-Twin (S.N. 130001- )

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 240: 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)

PTO Circuit Operation (S.N. -120000)

Charging Circuit Operation (S.N. -120000)

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

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

Power Circuit Operation (S.N. 120001-130000)

Cranking Circuit Operation (S.N. 120001-130000)

Ignition Interlock Circuit Operation (S.N. 120001-130000)

Fuel Shutoff Circuit Operation (S.N. 120001-130000)

PTO Circuit Operation (S.N. 120001-130000)

Charging Circuit Operation (S.N. 120001-130000)

Headlight Circuit Operation (option) (S.N. 120001-130000)

Hour Meter Circuit Operation (S.N. 120001-130000)

Power Circuit Operation (S.N. 130001- )

Cranking Circuit Operation (S.N. 130001- )

Ignition Interlock Circuit Operation (S.N. 130001- )

Fuel Shutoff Circuit Operation (S.N. 130001- )

PTO Circuit Operation (S.N. 130001- )

Charging Circuit Operation (S.N. 130001- )

Headlight Circuit Operation (option) (S.N. 130001- )

Hour Meter Circuit Operation (S.N. 130001- )

Low Fuel Light Circuit Operation (S.N. 170001- )

Group 20: Diagnosis

Diagnose Power Circuit (S.N. -120000)

Diagnose Cranking Circuit (S.N. -120000)

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

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

Diagnose PTO Circuit (S.N. -120000)

Diagnose Charging Circuit (S.N. -120000)

Diagnose Headlight Circuit (S.N. -120000)

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

Diagnose Power Circuit (S.N. 120001-130000)

Diagnose Cranking Circuit (S.N. 120001-130000)

Diagnose Ignition Interlock Circuit (S.N. 120001-130000)

Diagnose Fuel Shutoff Circuit (S.N. 120001-130000)

Diagnose PTO Circuit (S.N. 120001-130000)

Diagnose Charging Circuit (S.N. 120001-130000)

Diagnose Headlight Circuit (S.N. 120001-130000)

Diagnose Hour Meter Circuit (S.N. 120001-130000)

Diagnose Power Circuit (S.N. 130001- )

Diagnose Cranking Circuit (S.N. 130001- )

Diagnose Ignition Interlock Circuit (S.N. 130001- )

Diagnose Fuel Shutoff Circuit (S.N. 130001- )

Diagnose PTO Circuit (S.N. 130001- )

Diagnose Charging Circuit (S.N. 130001- )

Diagnose Headlight Circuit (S.N. 130001- )

Diagnose Hour Meter Circuit (S.N. 130001- )

Diagnose Low Fuel Light Circuit (S.N. 170001- )

Group 30: Tests and Adjustments

Summary of References

Specifications

Service Equipment and Tools

Ground Circuit Test

Battery Voltage and Specific Gravity Tests

Battery Charge

Battery Load Test

Spark Test

Regulated Voltage Test

Regulated Amperage Test

Starting Motor Amperage Draw Test: Loaded, B&S

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

Stator Output Test, B&S

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

Seat Switch Test

Headlight Switch (S.N. -130000)

Headlight Switch (S.N. 130001- )

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. 120001-130000)

Main Electrical Schematic (S.N. 130001-170000)

Main Electrical Schematic (S.N. 170001- )

Group 50: Connector Information

Summary of References

Load Center (S.N. -120000)

Load Center (S.N. 120001-130000)

Load Center (S.N. 130001- )

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 Harness Connector, C3F (W1 Main Harness) (S.N. 130001- )

Headlight Harness Connector, C3M (W3 Light Kit Harness) (S.N. 130001- )

Headlight Connector

Power Connector (S.N. 130001- )

Engine Connector

PTO Clutch Connector

Start Relay Connectors

Regulator/Rectifier Connectors

Section 250: Power Train Diagnosis, Tests, and Adjustments

Group 20: Theory of Operation

Summary of References

Drive Operation (S.N. -130000)

Drive Operation (S.N. 130001- )

Transaxle Operation

Group 30: 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 40: Tests and Adjustments

Summary of References

Specifications

Adjust Tracking

Adjust Neutral Creep (S.N. -130000)

Adjust Neutral Creep (S.N. 130001- )

Adjust Return To Neutral (RTN)

Adjust Motion Control Levers

Adjust Park Brake (S.N. -130000)

Adjust Park Brake (S.N. 130001- )

Purge Transaxle Hydraulic System

Section 260: Attachments Diagnosis, Tests, and Adjustments

Group 20: Diagnosis

Mower Blade Does Not Rotate

Mower Deck Vibrates

Mower Deck Cuts Unevenly or with Striping

Mower Belt Slips or Jumps Off Sheaves

Group 30: Tests and Adjustments

Summary of References

Specifications

Adjust Mower Wheels (S.N. -130000)

Adjust Mower Wheels (S.N. 130001- )

Adjust Mower Level

Section 299: Service Tools and Kits

Group 10: Service Tools

Service Equipment and Tools

John Deere Riding Lawn Residential Mowers Z225, Z245, Z235, Z255 EZtrak Technical Service Manual (TM112919)