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
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)
