John Deere X495 and X595 Lawn and Garden Tractors North American Technical Manual TM2024 01FEB05

Table of Contents
Fastener Torques……………………………………….9
Metric Fastener Torque Values………………….9
Inch Fastener Torque Values…………………..10
O-Ring Seal Service Recommendations ……11
Face Seal Fittings With Inch Stud Ends
Torque………………………………………………….11
Face Seal Fittings With Metric Stud Ends
Torque………………………………………………….12
O-ring Face Seal Fittings…………………………13
O-Ring Boss Fittings ………………………………13
Straight Fitting or Special Nut Torques ……..14
Metric Fastener Torque Value – Grade 7
(Special) ……………………………………………….14
General Information………………………………….14
Diesel Fuel ……………………………………………14
Diesel Fuel Lubricity……………………………….14
Diesel Fuel Storage………………………………..15
4 – Cycle Diesel Engine Oil………………………15
Break-In Engine Oil – Diesel…………………….15
Hydrostatic Transmission and Hydraulic Oil.16
Gear Case Oil………………………………………..16
Gear Transmission Grease ……………………..16
Alternative Lubricants……………………………..17
Synthetic Lubricants ……………………………….17
Anti-Corrosion Grease…………………………….17
Mower Spindle Grease……………………………17
Lubricant Storage…………………………………..17
Mixing of Lubricants ……………………………….17
Oil Filters ………………………………………………18
Coolant Specifications……………………………..18
Diesel Engine Coolant…………………………….18
Diesel Engine Coolant Drain Interval ………..18
Serial Number Locations ………………………….19
Product Serial Number ……………………………19
Diesel Engine Serial Number Location………19
Engine – Diesel 3TNE74
Table of Contents
Specifications ………………………………………….23
General…………………………………………………23
Repair Specifications………………………………23
Tests and Adjustment Specifications ………..29
Operational Tests …………………………………..29
Tightening Torques ………………………………..30
Other Materials………………………………………30
Theory of Operation …………………………………31
Cooling System Theory of Operation ………..31
Lubrication System Theory of Operation……32
Fuel System Theory of Operation …………….33
Air System Theory of Operation……………….34
Component Location………………………………..35
Diesel Engine Component Location ………….35
Fuel System Component Location ……………36
Diagnostics ……………………………………………..37
Engine Troubleshooting ………………………….37
Diagnostic Table…………………………………….43
Tests and Adjustments …………………………….45
Cylinder Compression Test ……………………..45
Throttle Cable Adjustment……………………….45
Slow Idle Adjustment………………………………46
Valve Clearance Adjustment ……………………46
Valve Lift Check …………………………………….48
Fuel Injection System Tests …………………….48
Fuel Injection Nozzle Test……………………….49
Injection Pump Timing (EPA Engines) ………51
Thermostat Test …………………………………….51
Water Pump/Alternator Drive Belt
Adjustment ……………………………………………52
Radiator Bubble Test………………………………52
Cooling System Pressure Test…………………53
Radiator Cap Pressure Test…………………….53
Engine Oil Pressure Test ………………………..53
Fuel Transfer Pump Pressure Test …………..54
Fuel Transfer Pump Flow Test…………………55
Fuel System Air Bleeding………………………..55
Air Restriction Indicator Test ……………………56
Repair………………………………………………………57
Fan/Alternator Belt Removal and
Installation …………………………………………….57
Fuel Filter Removal and Installation ………….58
Air Cleaner Disassembly, Inspection and
Assembly………………………………………………58
Rocker Arm Cover Removal and
Installation……………………………………………. 59
Rocker Arm and Push Rods …………………… 60
Radiator Removal and Installation…………… 62
Cylinder Head Removal and Installation…… 64
Muffler Removal and Installation …………….. 65
Intake Manifold Removal and Installation…. 65
Exhaust Manifold Removal and Installation. 65
Engine Removal and Installation …………….. 66
Cylinder Head Recondition…………………….. 68
Crankshaft Oil Seals……………………………… 72
Timing Gear Cover ……………………………….. 73
Camshaft End Play Check……………………… 74
Timing Gear Backlash Check …………………. 74
Idler Gear…………………………………………….. 75
Camshaft Followers………………………………. 76
Camshaft …………………………………………….. 76
Oil Pan and Strainer …………………………….. 80
Connecting Rod Side Play Check……………. 80
Crankshaft End Play Check …………………… 81
Connecting Rod Bearing Clearance Check . 81
Crankshaft Main Bearing Clearance Check. 82
Piston-To-Cylinder Head Clearance ………… 82
Piston and Connecting Rod Repair …………. 83
Cylinder Bore……………………………………….. 88
Crankshaft and Main Bearings ……………….. 89
Flywheel Removal and Installation ………….. 92
Engine Back Plate ………………………………… 92
Timing Gear Housing…………………………….. 92
Oil Pump……………………………………………… 93
Oil Pressure Regulating Valve………………… 95
Coolant Temperature Switch ………………….. 95
Thermostat Removal and Installation ………. 95
Water Pump…………………………………………. 96
Fuel Transfer Pump………………………………. 97
Fuel Injection Nozzle …………………………….. 97
Fuel Injection Pump…………………………….. 100
Fuel Shutoff Solenoid Removal and
Installation………………………………………….. 104
Fuel Control and Governor Linkage……….. 105
Table of Contents
Specifications ………………………………………..109
General……………………………………………….109
Repair Specifications…………………………….109
Tests and Adjustment Specifications ………114
Operational Tests …………………………………114
Tightening Torques ………………………………115
Other Materials…………………………………….115
Theory of Operation ……………………………….116
Cooling System Theory of Operation ………116
Lubrication System Theory of Operation….117
Fuel System Theory of Operation …………..118
Air System Theory of Operation……………..119
Component Location………………………………120
Diesel Engine Component Location ………..120
Fuel System Component Location ………….121
Diagnostics ……………………………………………122
Engine Troubleshooting ………………………..122
Diagnostic Table…………………………………..128
Tests and Adjustments …………………………..130
Cylinder Compression Test ……………………130
Throttle Cable Adjustment……………………..130
Slow Idle Adjustment…………………………….131
Valve Clearance Adjustment ………………….131
Valve Lift Check …………………………………..133
Fuel Injection System Tests …………………..133
Fuel Injection Nozzle Test……………………..134
Injection Pump Static Timing Check ……….136
Thermostat Test …………………………………..137
Water Pump/Alternator Drive Belt Adjustment .
138
Radiator Bubble Test…………………………….138
Cooling System Pressure Test……………….139
Radiator Cap Pressure Test…………………..139
Engine Oil Pressure Test ………………………140
Fuel Transfer Pump Pressure Test …………140
Fuel Transfer Pump Flow Test ……………….141
Fuel System Air Bleeding………………………141
Air Restriction Indicator Test ………………….141
Repair…………………………………………………….143
Fan/Alternator Belt Removal and
Installation …………………………………………..143
Fuel Filter Removal and Installation ………..143
Air Cleaner Disassembly, Inspection and
Assembly…………………………………………….144
Rocker Arm Cover Removal and
Installation………………………………………….. 145
Rocker Arm and Push Rods …………………. 145
Radiator Removal and Installation…………. 148
Cylinder Head Removal and Installation…. 150
Muffler Removal and Installation …………… 151
Exhaust Manifold Removal and
Installation………………………………………….. 151
Engine Removal and Installation …………… 151
Cylinder Head Recondition…………………… 153
Crankshaft Oil Seals……………………………. 157
Timing Gear Cover ……………………………… 158
Camshaft End Play Check……………………. 159
Timing Gear Backlash Check ……………….. 159
Idler Gear…………………………………………… 160
Camshaft Followers…………………………….. 161
Camshaft …………………………………………… 161
Oil Pan and Strainer …………………………… 165
Connecting Rod Side Play Check………….. 165
Crankshaft End Play Check …………………. 166
Connecting Rod Bearing Clearance Check166
Crankshaft Main Bearing Clearance
Check………………………………………………… 167
Piston-To-Cylinder Head Clearance ………. 167
Piston and Connecting Rod Repair ……….. 168
Cylinder Bore……………………………………… 173
Crankshaft and Main Bearings ……………… 174
Flywheel Removal and Installation ………… 177
Engine Back Plate ………………………………. 177
Timing Gear Housing…………………………… 177
Oil Pump …………………………………………… 178
Coolant Temperature Switch ………………… 180
Thermostat Removal and Installation …….. 180
Water Pump……………………………………….. 180
Fuel Transfer Pump…………………………….. 181
Fuel Injection Nozzle …………………………… 182
Fuel Injection Pump…………………………….. 184
Fuel Shutoff Solenoid Removal and
Installation………………………………………….. 186
Fuel Control and Governor Linkage
Inspection ………………………………………….. 186
Table of Contents
General Information………………………………..191
Reading Electrical Schematics……………….191
Theory Of Operation Information…………….192
Diagnostic Information…………………………..192
Wire Color Abbreviation Chart………………..192
Common Circuit Tests…………………………..193
Conductors For 12 Volt Circuits ……………..193
Specifications ………………………………………..194
General Specifications ………………………….194
Test and Adjustment Specifications ………..195
Other Materials…………………………………….195
Component Location………………………………196
X495 and X595 Diesel…………………………..196
Diesel Engine ………………………………………198
Instrument Panel ………………………………….199
Schematics and Harnesses …………………….200
Schematic And Wiring Harness Legend…..200
Main Electrical Schematic (SN -30000)……202
Instrument Panel Electrical Schematic
(SN -30000)…………………………………………206
W1 Main Wiring Harness (SN -30000)…….207
Main Electrical Schematic (SN 30001- )…..209
Control Panel Electrical Schematic
(SN 30001-)…………………………………………213
W1 Main Wiring Harness (SN 30001-)…….214
W2 Headlight Wiring Harness ………………..216
W3 Rear Wiring Harness……………………….216
W4 PTO Option Wiring Harness …………….216
W1 Main Wiring Harness Color Codes
(SN -30000)…………………………………………217
W1 Main Wiring Harness Color Codes
(SN 30001-)…………………………………………219
W2 Headlight Wiring Harness Color
Codes…………………………………………………220
W3 Rear Wiring Harness Color Codes…….220
W4 PTO Option Wiring Harness Color
Codes…………………………………………………220
Operation and Diagnostics ……………………..221
Power Circuit Operation ………………………..221
Power Circuit Electrical Schematic………….222
Power Circuit Diagnosis ………………………..224
Cranking Circuit Operation …………………….230
Cranking Circuit Electrical Schematic ……..231
Cranking Circuit Diagnosis …………………….232
arging Circuit Operation …………………… 235
Charging Circuit Electrical Schematic…….. 236
Charging Circuit Diagnosis …………………… 237
Glow Plug Circuit Operation …………………. 240
Glow Plug Circuit Electrical Schematic…… 241
Glow Plug Circuit Diagnosis …………………. 242
Fuel Supply Circuit Operation……………….. 245
Fuel Supply Circuit Electrical Schematic … 246
Fuel Supply Circuit Diagnosis……………….. 247
PTO Circuit Operation …………………………. 249
PTO Circuit Electrical Schematic…………… 250
PTO Circuit Diagnosis …………………………. 252
PTO Overtemp Circuit Operation ………….. 257
PTO Overtemp Circuit Schematic………….. 258
PTO Overtemp Circuit Diagnosis…………… 259
Instrument Panel Circuit Operation………… 262
Instrument Panel Circuit Electrical Schematic
(SN -30000) ……………………………………….. 264
Electrical Panel Circuit Electrical Schematic
(SN 30001-) ……………………………………….. 265
Instrument Panel Circuit Diagnosis………… 266
Lights Circuit Operation ……………………….. 269
Lights Circuit Electrical Schematic
(SN -30000) ……………………………………….. 270
Lights Circuit Electrical Schematic
(SN 30001-) ……………………………………….. 271
Lights Circuit Diagnosis ……………………….. 272
Tests and Adjustments …………………………. 275
Common Circuit Test…………………………… 275
Ground Circuit Test……………………………… 275
Battery Voltage and Specific Gravity Test . 276
Battery – Charge …………………………………. 277
Battery – Load Test ……………………………… 277
Unregulated Voltage Test…………………….. 278
Stator Resistance Test ………………………… 278
Regulated Amperage and Voltage Test….. 279
Starting Motor Condition………………………. 279
Starting Motor System Test ………………….. 280
Starter Solenoid Test…………………………… 281
Starting Motor Amp Draw Test ……………… 282
Starting Motor No-load Amperage and
RPM Test…………………………………………… 282
Windings Test…………………………………….. 283
Starter Armature Test ………………………….. 284
Control/Fuse Module Test ……………………. 284
Engine Coolant Temperature Sensor Test 286
Engine Oil Pressure Switch Test …………… 286
Lights Switch Test……………………………….. 287
PTO/RIO Switch Test……………………………287
Relay Test …………………………………………..288
Seat Switch Test ………………………………….289
Brake Switch Test and Adjustment …………289
Service Timer Reset Switch (SN -30000)…290
Fuse Test ……………………………………………290
Instrument Panel Light Test …………………..290
PTO Solenoid Test……………………………….291
Rear PTO Switch Test (optional)…………….292
Diode Test…………………………………………..293
Fuel Tank Sensor Test ………………………….293
Air Restriction Indicator Test ………………….294
Power Train – Hydrostatic
Table of Contents
Specifications ………………………………………..297
General Specifications ………………………….297
Test And Adjustment Specifications………..297
Repair Specifications…………………………….297
Special or Essential Tools……………………..298
Other Materials…………………………………….298
Component Location………………………………299
Hydrostatic Power Train ………………………..299
Final Drive (MFWD)………………………………301
Front Axle Gear Case (MFWD) ………………302
Front Axle Assembly (MFWD)………………..304
Rear PTO Gear Case Assembly …………….305
MFWD Output Shaft……………………………..307
Foot Pedals and Linkage……………………….309
Theory of Operation ……………………………….311
Center Section and Directional Control
Valves – Reverse System Operation ……….311
Transaxle Oil Flow System Operation……..314
External Power Train System Operation….317
Transaxle Internal System Operation………318
Rear PTO Component Location and
Operation (Option)………………………………..322
540 Rear PTO ……………………………………..323
Diagnostics ……………………………………………324
Hydrostatic Transmission Diagnosis ……….324
Mid-PTO System Diagnosis …………………..326
Transaxle Diagnosis……………………………..326
Hydrostatic Transmission Test ……………….327
Mid-PTO System Test…………………………..329
Transaxle Test……………………………………..330
Tests and Adjustments …………………………..331
Hydraulic Oil Warm-Up Procedure………….331
Charge Pump Pressure Test………………….331
Charge Pump Flow and Pressure Test –
At Charge Pump…………………………………..332
Mid-PTO Engagement Pressure and Brake
Test ……………………………………………………334
Transaxle Neutral Adjustment ………………..335
Transaxle Control Linkage Adjustment ……336
Transaxle Linkage Full Forward
Adjustment ………………………………………….337
Cruise Control Linkage Check and
Adjustment …………………………………………337
Repair…………………………………………………… 339
Foot Control Linkage Removal and
Installation………………………………………….. 339
Shift Lever Linkage (MFWD) Removal and
Installation………………………………………….. 341
Oil Cooler Removal and Installation ………. 342
Control Arm and Damper Removal and
Installation …………………………………………. 343
Differential Lock Linkage Inspection ………. 344
Charge Pump Removal and Installation …. 345
Charge Pump Disassembly and Assembly 345
Directional Control Valves ……………………. 346
Hydrostatic Pressure Relief Valve (45 Loader)
Installation………………………………………….. 347
Drive Shaft Removal and Installation …….. 348
PTO Solenoid Valve ……………………………. 349
PTO Relief Valve Removal and
Installation………………………………………….. 350
PTO Relief Valve Disassembly, Inspection
and Assembly …………………………………….. 350
PTO Brake Removal and Installation……… 351
PTO Brake Disassembly, Inspection and
Assembly …………………………………………… 352
PTO Drive Train (Mid-PTO) Removal and
Installation …………………………………………. 353
PTO Drive Train (Mid and Rear PTO)
Removal and Installation ……………………… 354
Rear PTO Removal and Installation ………. 357
Transaxle Removal and Installation……….. 360
Differential Lock Shaft Disassembly and
Assembly …………………………………………… 362
Differential (2-Wheel Drive) Disassembly
and Assembly …………………………………….. 363
Differential (MFWD) Disassembly and
Assembly …………………………………………… 364
PTO Clutch Disassembly, Inspection and
Assembly …………………………………………… 365
MFWD Output Shaft Removal and
Installation………………………………………….. 366
Hydrostatic Transmission 2-WD and
MFWD ………………………………………………. 369
Hydrostatic Pump Inspection………………… 376
Transaxle Disassembly………………………… 377
Transaxle (Right Cover) Disassembly and
Assembly …………………………………………… 380
Transaxle Case – Inspection…………………. 381
Transaxle Assembly ……………………………. 381
Rear Axle Assembly Removal and
Installation …………………………………………..383
Rear Axle Assembly – Disassembly and
Assembly…………………………………………….384
Final Drive Cover Removal and
Installation – (MFWD) ……………………………385
Final Drive Housing Removal and
Installation – (MFWD) ……………………………387
Spindle Housing – (MFWD) ……………………389
Drive Shaft Removal and Installation –
(MFWD)………………………………………………390
Mechanical Front Wheel Drive Removal
and Installation – (MFWD) …………………….390
Differential Input Housing – (MFWD) ……….391
Front Axle Housing Disassembly and
Assembly…………………………………………….393
Specifications ………………………………………..397
General Specifications ………………………….397
Test and Adjustment Specifications ………..397
Repair Torque Specifications …………………398
Special or Essential Tools……………………..398
Other Materials…………………………………….398
Schematics…………………………………………….399
Hydraulic Schematic – Power Train …………399
Component Location………………………………400
Hydraulic System …………………………………400
Operation and Diagnostics ……………………..401
Hydraulic System …………………………………401
Hydraulic Control Valve Operation –
Neutral………………………………………………..402
Hydraulic Control Valve Operation –
Raise ………………………………………………….403
Hydraulic Control Valve Operation –
Float …………………………………………………..404
Hydraulic Control Valve Operation –
Regen…………………………………………………405
Lift Cylinder Shut-off Valve – Optional ……..406
Hydraulic Diagnostics……………………………406
Preliminary Hydraulic System Inspection…408
Hydraulic System Tests…………………………409
Tests and Adjustments …………………………..410
Hydraulic Oil Warm-Up Procedure………….410
Charge Pump Pressure and Flow Quick
Test at Couplers…………………………………..410
Charge Pump Pressure Test………………….411
Lift Cylinder Leakage Test……………………..413
Control Valve Leakage Test …………………..414
Repair…………………………………………………….414
Hydraulic Control Valve Removal and
Installation …………………………………………..414
Hydraulic Control Valve…………………………415
Lift Cylinder Removal and Installation……..416
Hydraulic Control Levers and Linkage …….417
Specifications ………………………………………..421
General Specifications ………………………….421
Test and Adjustment Specifications ………..421
Repair Specifications…………………………….421
Special or Essential Tools……………………..421
Component Location………………………………422
Steering Components – Front Wheel Steer 422
Steering Components – All Wheel Steer…..423
Steering Components – All Wheel Steer
Rear Axle…………………………………………….424
Theory of Operation ……………………………….425
Steering System Operation ……………………425
Steering Valve Operation – Neutral …………426
Steering Valve Operation – Turning…………427
Steering Valve Operation – Manual …………428
Diagnostics ……………………………………………429
Steering Diagnosis ……………………………….429
Steering System Tests ………………………….430
Steering Link Checks ……………………………430
Tests and Adjustments …………………………..431
Hydraulic Oil Warm-Up Procedure………….431
Steering Valve and Cylinder Leakage Test 431
Toe-In Adjustment Front Wheels…………….432
Toe-In Adjustment All Wheel Steering …….433
Repair…………………………………………………….434
Steering Column Removal and Installation 434
Steering Valve Removal and Installation …435
Steering Valve Disassembly and
Assembly…………………………………………….437
Steering Cylinder Removal and
Installation …………………………………………..440
Front Axle Removal and Installation………..440
Front Axle Disassembly and Assembly……441
Rear Steering Linkage – AWS ………………..443
Steering Intermediate Linkage – AWS……..445
Front and Rear Pivots …………………………..446
Specifications ………………………………………..451
General Specifications ………………………….451
Test and Adjustment Specifications ………..451
Repair Specifications…………………………….451
Special or Essential Tools……………………..451
Other Materials…………………………………….451
Component Location………………………………452
Brake System Component Location………..452
Brake/Differential Linkage (Exploded)……..453
Theory of Operation ……………………………….454
Brake System Operation ……………………….454
Diagnostics ……………………………………………455
Brakes ………………………………………………..455
Tests and Adjustments …………………………..457
Brake/Differential Linkage Adjustment …….457
Repair…………………………………………………….459
Brake/Differential Linkage Removal and
Installation …………………………………………..459
Brakes Removal and Installation…………….461
Table of Contents
Specifications ………………………………………..465
General Specifications ………………………….465
Torque and Repair Specifications …………..467
Diagnostics ……………………………………………469
48, 54 and 62-Inch Mower Deck Diagnosis469
45 Loader Diagnosis …………………………….472
Tests and Adjustments …………………………..473
Adjusting Cutting Height (48C, 54C, and
62C Mower Deck)…………………………………473
Adjusting Mower Deck Wheels……………….473
Mower Deck Level Check and Adjustment.474
Adjusting Mower Level Side-to-Side ……….474
Adjusting Mower Level Front-to-Rear………475
Adjusting Latch Rod ……………………………..476
Cylinder Leakage Test ………………………….476
45 Loader Lubrication……………………………476
Repair…………………………………………………….477
Cleaning Grass and Debris From Machine 477
Mower Deck Belt and Shield Removal and
Installation …………………………………………..477
Mower Deck Blade Removal and
Installation …………………………………………..479
Mower Deck Blade – Sharpen ………………..480
Mower Deck Blade – Balance …………………480
48C Mower Deck Spindle Removal and
Installation …………………………………………..480
Idlers…………………………………………………..482
Jacksheave …………………………………………483
54C Mower Deck Spindle Removal and
Installation …………………………………………..483
Jacksheave …………………………………………485
Idlers…………………………………………………..486
62C Mower Deck Spindle Removal and
Installation …………………………………………..486
Mower Deck Drive Shaft Removal and
Installation …………………………………………..488
Mower Deck Drive Shaft Repair ……………..489
Mower Deck Gearbox Removal and
Installation …………………………………………..490
Mower Deck Gearbox Repair…………………492
General Information………………………………. 493
Reading Electrical Schematics ……………… 493
Operation and Diagnostics …………………… 494
Diagnostic Information…………………………. 494
Wire Color Abbreviation Chart………………. 494
Common Circuit Tests …………………………. 494
Conductors For 12 Volt Circuits…………….. 495
Identification Numbers………………………….. 496
Generator…………………………………………… 496
Alternator …………………………………………… 496
Component Location…………………………….. 497
Generator…………………………………………… 497
Alternator Components………………………… 498
Control Panel……………………………………… 499
Generator Gear Box Components…………. 500
Schematics and Harnesses …………………… 501
Wiring Harness Legend ……………………….. 501
Connectors ………………………………………… 501
Standard Electrical Schematic………………. 502
Operation and Diagnostics ……………………. 504
Generator Circuit Operation………………….. 504
Generator Circuit Diagnosis………………….. 504
Tests and Adjustments …………………………. 506
Generator Stator Test………………………….. 506
Generator Rotor Test…………………………… 507
Ground Fault Circuit Interrupter (GFCI)
Checks………………………………………………. 507
Generator Ground Test………………………… 508
Repair…………………………………………………… 508
Stator Excitation Field Restoration ………… 508
PTO Shield Removal and Installation …….. 509
Generator Removal and Disassembly……. 509
Gear Case Removal and Disassembly…… 509
Rotor Bearing Removal and Installation …. 511
Rotor Fan Removal and Installation ………. 511
Generator Assembly and Installation……… 512
Control Panel Removal and Installation….. 513
Specifications ………………………………………..517
Repair Specifications…………………………….517
Other Materials…………………………………….517
Repair…………………………………………………….518
Fender Deck Removal and Installation ……518
Fuel Tank Removal and Installation ………..519
Fuel Pump/Fuel Gauge Sensor Removal
and Installation …………………………………….520
Headlights Adjustment …………..