John Deere Z225 Z245 Z235 Z255 EZtrak Mower Workshop Service Repair Manual TM112919 PDF - MJODTM112919.zip
This is a full workshop service and repair guide, complete with electrical wiring schematics, covering John Deere's residential riding mowers—the Z225, Z245, Z235, and Z255 EZtrak models. It contains everything needed to service, troubleshoot, and maintain these machines to the same standard as trained technicians.
Inside the John Deere EZtrak Z225, Z245, Z235, and Z255 service and repair manual, you'll find:
* 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
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)