John Deere Z525E Z535M Z540M Z535R and Z540R ZTrak Mowers Technical Manual TM140419 21JUN23

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
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, Flat
Remove and Install Air Cleaner, Oval
Replace Fuel Filter
Cleaning Engine Screen Guard
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
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 48A and 54A
60HC Deck Components
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
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
Adjust Throttle and Choke Cable, V-Twin
Governor Static Adjustment, V-Twin
Governor Dynamic Adjustment, 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
Engine Idles, Does Not Run Properly At Wide Open Throttle (WOT)
Fuel
Fuel Line
Fuel Solenoid
Main Jet
Needle Valve
Air Filter
Choke Plate
Carburetor
Main Jet
(continued)
Fuel System
Float Bowl
Engine Does Not Idle Properly
Float Bowl
Float
Pilot Jet and Passages
Fuel
Fuel Line
Fuel Solenoid
Main Jet
Needle Valve
Air Filter
Choke Plate
Carburetor
Main Jet
(continued)
Fuel System
Float Bowl
Engine Does Not Idle Properly
Float Bowl
Float
Pilot Jet and Passages
Engine Cranks But Will Not Start
Engine Will Not Crank
Battery
Battery Cables
Starting Motor
Fuel Solenoid
Cranking Check
Engine
Fuel
Choke
Spark
Engine
Engine Will Not Crank
Battery
Battery Cables
Starting Motor
Fuel Solenoid
Cranking Check
Engine
Fuel
Choke
Spark
Engine
Starter Rotates Slowly
Starter Solenoid
Machine Conditions
Battery
Battery Cables
Key Switch
Engine
Battery
Battery Cables
Starting Motor
Engine
Starter Solenoid
Machine Conditions
Battery
Battery Cables
Key Switch
Engine
Battery
Battery Cables
Starting Motor
Engine
Group 50 – Tests and Adjustments
Summary of References
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
Switched Power
Starting Motor Solenoid
Key Switch
Start Relay
Voltage Regulator
Key Switch (connected)
PTO Switch
Hourmeter Connector
Left Neutral Switch
Park Brake Switch
Light Switch (option)
Starting Motor Solenoid
Key Switch
Start Relay
Voltage Regulator
Key Switch (connected)
PTO Switch
Hourmeter Connector
Left Neutral Switch
Park Brake Switch
Light Switch (option)
Test Procedure C:
Interlock relay circuit test
(continued)
Key switch circuit test
(continued)
Start relay circuit test
(continued)
(continued)
Interlock relay circuit test
(continued)
Key switch circuit test
(continued)
Start relay circuit test
(continued)
(continued)
Test Procedure A:
PTO circuit test
(continued)
PTO circuit test
(continued)
Test Procedure B:
Hour meter circuit power test
(continued)
(continued)
Hour meter circuit signal test
(continued)
Hour meter circuit power test
(continued)
(continued)
Hour meter circuit signal test
(continued)
Test Procedure B
Battery
Stator Connector
Battery
Stator Connector
Test Procedure C:
Key Switch Circuit Test
(continued)
Park Brake and Neutral Switch Circuit Test
(continued)
(continued)
(continued)
(continued)
PTO Switch, Seat Switch, and Interlock Relay Circuit Test
(continued)
(continued)
(continued)
(continued)
(continued)
(continued)
(continued)
(continued)
(continued)
(continued)
Key Switch Circuit Test
(continued)
Park Brake and Neutral Switch Circuit Test
(continued)
(continued)
(continued)
(continued)
PTO Switch, Seat Switch, and Interlock Relay Circuit Test
(continued)
(continued)
(continued)
(continued)
(continued)
(continued)
(continued)
(continued)
(continued)
(continued)
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
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 Check
Fan
Drive Belt
Idler Tensioning Spring
Sheaves and Idlers, Belt Traction Drive System
(continued)
Transaxle Housing Exterior
(continued)
Park Brakes
Axles
Tires, Wheels, and Axles
(continued)
(continued)
Engine Performance
Stroking Control Arm: (Lack of Forward or Reverse Speed)
Fan
Drive Belt
Idler Tensioning Spring
Sheaves and Idlers, Belt Traction Drive System
(continued)
Transaxle Housing Exterior
(continued)
Park Brakes
Axles
Tires, Wheels, and Axles
(continued)
(continued)
Engine Performance
Stroking Control Arm: (Lack of Forward or Reverse Speed)
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
Procedure
Checks
(continued)
(continued)
Checks
(continued)
(continued)
Procedure
Checks
(continued)
(continued)
Checks
(continued)
(continued)
Procedure
Checks
(continued)
(continued)
(continued)
(continued)
Checks
(continued)
(continued)
(continued)
(continued)
Procedure
Checks
(continued)
(continued)
Checks
(continued)
(continued)
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
Service Equipment and Tools