JOHN DEERE F910 (01) PDF MANUAL

JOHN DEERE F910 (01) PDF SUMMARY:

What manuals are included as part of the total service support program?

FOS Manuals-reference, Technical Manuals-machine service, and Component Manuals-component service are included.

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What do FOS Manuals cover?

FOS Manuals cover basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic types of failures and their causes. FOS Manuals are for training new personnel and for reference by experienced technicians.

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What are Technical Manuals?

Technical Manuals are concise service guides for specific machines. Technical manuals are on-the-job guides containing only the vital information needed by an experienced service technician.

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What are Component Technical Manuals?

Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand alone manuals covering multiple machine applications.

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What are the features of this technical manual?

• John Deere ILLUSTRUCTION format emphasizing illustrations and concise instructions in easy-to-use modules.
• Emphasis on diagnosis, analysis, and testing so you can understand the problem and correct it.
• Diagnostic information presented with the most logical and easiest to isolate problems first to help you identify the majority of routine failures quickly.
• Step-by-step instructions for teardown and assembly.
• Summary listing at the beginning of each group of all applicable specifications, wear tolerances, torque values, essential tools, and materials needed to do the job.
• An emphasis throughout on safety-so you do the job right without getting hurt.

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What should you do when you see the safety symbol?

Follow the safety message to avoid personal injury.

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What should you do to avoid fire hazards?

• Be prepared if an accident or fire should occur. Know where the first aid kit and the fire extinguishers are located-know how to use them.
• Do not smoke while you fill the fuel tank, service fuel system or handle highly flammable material.
• Do not remove fuel cap or add fuel to tank when engine is hot or running. Allow engine to cool for several minutes.
• Do not use open pans of gasoline or diesel fuel for cleaning parts. Use good commercial, nonflammable solvents.
• Provide adequate ventilation when charging batteries.
• Do not check battery charge by placing metal objects across the posts.
• Do not allow sparks or open flame near batteries.
• Do not smoke near battery.
• Never check fuel or battery electrolyte with an open flame.
• Never use an open flame to look for leaks anywhere on the equipment.
• Never use an open flame as light anywhere on or around the equipment.
• When preparing engine for storage, remember that inhibitor is volatile and therefore dangerous. Seal and tape openings after adding the inhibitor. Keep container tightly closed when not in use.
• Inspect electrical wiring for worn or frayed insulation. Install new wiring if wires are damaged.

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What should you understand about machine operation?

Only qualified people should operate the machine. Carefully read the PDF and manuals furnished with attachments. Learn the location and purpose of all controls, instruments, indicators, and labels.

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What type of clothing should you wear?

Wear fairly tight clothing and safety equipment.

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How do you protect against noise?

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable uncomfortable loud noises.

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How do you avoid high-pressure fluids?

Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.

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How do you start the engine safely?

• Avoid possible injury or death from machine runaway.
• Do not start the engine by shorting across starter terminals.
• Before you start the engine:
  • Sit on the operators seat.
  • Move hydrostatic control lever to “STOP” position.
  • Engage the park brake.
  • Lower equipment to the ground.

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How do you operate the machine safely?

• Before you move any equipment, be sure all persons are away from the machine.
• When the machine is operating, ONLY the operator should be on it.
• Keep operating area level.

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What should you understand about correct service?

• Be sure you understand a service procedure before you work on the machine.
• Unauthorized modifications to the machine may impair the function and/ or safety and affect machine life.
• If it is necessary to make checks with the engine running, ALWAYS USE TWO PEOPLE-with the operator at the controls, able to see the person doing the checking.

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How do you service tires safely?

• Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious injury or death.
• Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Have it done by your John Deere dealer or a qualified tire repair service.
• When sealing tire beads on rims, never exceed 35 psi (241 kPa) (2.4 bar) or maximum inflation pressures specified by tire manufacturers for mounting tires. Inflation beyond this maximum pressure may break the bead, or even the rim, with dangerous explosive force. If both beads are not seated when the maximum recommended pressure is reached, deflate, reposition tire, relubricate bead and reinflate.
• Detailed tire mounting instructions, including necessary safety precautions, are contained in John Deere Fundamentals of Service (FOS) Manual 55, Tires and Tracks, available through your John Deere dealer. Such information is also available from the Rubber Manufacturers Association and from tire manufacturers.

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How do you prepare the machine for repair?

1. Move hydrostatic control lever to “STOP” position.
2. Disengage PTO’s.
3. Lower all equipment to the ground.
4. Engage park brake.
5. Stop the engine.
6. Remove key.
7. Operate all hydraulic control levers to release hydraulic pressure in the system.
8. Before you leave the operator’s seat, wait for engine and attachment parts to stop moving.

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What type of fuel is recommended?

Unleaded fuel is recommended. Regular leaded gasoline with an anti-knock index of 87 or higher may be used. Do not use gasoline that has been stored for a long period of time. Use of gasohol is acceptable as long as the ethyl alcohol blend does not exceed 10 percent. Unleaded gasohol is preferred over leaded gasohol.

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How do you handle fuel?

Handle fuel carefully. If the engine is hot or running, do not fill the fuel tank. Do not smoke while you fill the fuel tank or service the fuel system. Fill fuel tank only to bottom of filter neck.

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How should fuel be stored?

Keep fuel in a clean container in a protected area. Water and sediment must be removed before fuel gets to the engine. Do not use de-icers to remove water from fuel. Do not depend on fuel filters to remove water. If possible, install a water separator at the storage tank outlet.

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What should you do if the tractor is either stored or used during the winter?

Add TY6295 John Deere Gasoline Storage Stabilizer or an equivalent to the fuel. Follow directions on can.

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What kind of engine oil is recommended?

John Deere TORO-GUARD SUPREME® engine oil is recommended. If other oils are used, they must be premium quality engine oils meeting performance requirements of API Service Classification SD, SE, SE/CC, or SF. Quality engine oils are blended, so additives are neither required nor recommended. Some increase in oil consumption may be expected when SAE 5W-20 oil is used and to check oil level frequently.

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What kind of transmission-hydraulic oil is recommended?

John Deere All-Weather Hydrostatic Fluid is recommended. If other fluid is used, it must be a type “F” Automotive Automatic Transmission Fluid.

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What kind of general purpose grease is recommended?

John Deere Multi-Purpose Grease is recommended. If other greases are used, use SAE Multi-purpose Grease or SAE Multi-purpose Grease containing 3 to 5 per cent molybdenum disulfide. At temperatures below -22°F (—30°C), use arctic greases such as those meeting Military Specification MIL-G-10924C.

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What should you do for cold weather operation?

Additional information on cold weather operation is available from your John Deere dealer.

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What should you do for lubricant storage?

Your machine can operate at top efficiency only if clean lubricants are used. Use clean containers to handle all lubricants. Store them in an area protected from dust, moisture, and other contamination. Store drums on their sides.

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What is important to do when working on machines or components that are covered by warranty?

It is IMPORTANT that you include the tractor Product Identification Number and the component serial number on the warranty claim form.

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What should you see in component manual CTM-2 for complete repair information on the Onan engine?

See the component manual for instructions on the following subjects:

• Air Cleaner and Breather
• Intake Manifold and Cylinder Heads
• Intake and Exhaust Valves
• Flywheel
• Camshaft
• Connecting Rods and Pistons
• Crankshaft and Main Bearings
• Lubrication System
• Governor
• Carburetor
• Stator and Regulator-Rectifier
• Starter
• Breaker Points, Condenser and Ignition Coil

These groups include: Disassembly, Inspection, Repair, and Assembly.

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How do you disconnect wiring and throttle cable for engine removal?

1. Park tractor safely.
2. Disconnect battery negative (-) cable.
3. Move fuel valve to no fuel position.
4. Slide clamp (A) back to disconnect fuel pump inlet hose (B).
5. Disconnect wiring harness connector ©.
6. Disconnect electric PTO clutch wiring lead.
7. Remove nut (A) to disconnect starter cable (B).
8. Loosen cap screw (A), clamp (B), and screw © to disconnect choke cable (D).
9. Loosen cap screw (E) and clamp (F) to disconnect throttle cable (G).

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How do you disconnect the driveshaft and oil lines for engine removal?

1. Loosen lock nuts to release spring tension. Remove two belts (A) from PTO pulley (B).
2. Pull pin and remove belts from electric PTO clutch ©.
3. Loosen three wing nuts to remove air intake screen.
4. Remove four nuts and cap screws. Move oil cooler from the driveshaft area.
5. Hold driveshaft using a screwdriver. Remove four cap screws to disconnect driveshaft.
6. Disconnect engine oil lines. Close opening with caps or plugs to prevent dirt from entering engine oil system.

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How do you remove the engine?

1. Fasten engine to a hoist using a load-positioning sling.
2. If necessary, remove drain plug (A) to drain engine oil. After engine oil is completely drained, install and tighten drain plug.
3. Remove four cap screws to disconnect engine oil base from tractor frame.
4. Pull the engine rearward until flywheel shroud is clear from blower shroud ©. Carefully lift the engine out of tractor.

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How do you install the engine?

1. Fasten engine to a hoist using a load-positioning sling.
2. Carefully lower the engine until the oil drain plug can be installed in frame hole.
3. Push the engine forward until flywheel shroud is in blower shroud ©. Install engine.
4. Install lock washer on cap screw under PTO pulley. Install four cap screws into engine oil base. Tighten cap screws to 39 ± 4 N·m (348 ± 35 lb-in.).

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How do you connect the driveshaft and oil lines after engine installation?

1. Connect and tighten engine oil lines.
2. Connect driveshaft and fasten with four cap screws.
3. Hold driveshaft using a screwdriver. Tighten cap screws to 27 ± 3 N·m (240 ± 27 lb-in.).
4. Fasten oil cooler to bulkhead wall with four cap screws and nuts.
5. Install air intake screen and tighten wing nuts.
6. Install two belts (A) on electric PTO clutch ©. Install pin and push wire loop over electric PTO clutch bracket.
7. Install belts on PTO pulley (B).
8. Tighten nuts (D) until springs (E) are 21 mm (0.8 in.) long. Tighten lock nuts (F).

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How do you connect the wiring and throttle cable after engine installation?

1. Install throttle cable (G) in bottom hole of throttle control lever.
2. Move throttle handle to fast idle position. Tighten cap screw (E) and clamp (F).
3. Connect choke cable (D) to choke linkage.
4. Push choke knob down. Hold choke linkage upward (choke plate open). Tighten screw ©, cap screw (A), and clamp (B).
5. Connect starter cable (8) and fasten with nut (A).
6. Connect electric PTO clutch wiring lead.
7. Connect wiring harness connector ©.
8. Connect fuel pump inlet hose (B) and fasten with clamp (A).
9. Connect battery negative ( – ) cable.
10. Fill engine crankcase with proper oil to proper level.
11. Adjust fast idle and slow idle. (See Section 220).

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How do you remove the muffler?

1. Park tractor safely.
2. Disconnect battery negative ( – ) cable.
3. Remove six cap screws to remove lift brackets (A) and exhaust pipe shrouds (B).
4. Remove four nuts to remove muffler clamps.
5. Remove two cap screws (A} and nuts to disconnect exhaust pipe shroud bracket (8) and electric PTO clutch bracket ©.
6. Remove two cap screws (D) to remove muffler. Inspect muffler for cracks, holes, or damage.

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How do you install the muffler?

1. Install muffler on exhaust pipes. Install and tighten two cap screws (D).
2. Install electric PTO clutch bracket © under muffler bracket and exhaust pipe shroud bracket (B) on top of muffler bracket. Install two cap screws (A) and tighten nuts.
3. Install muffler clamps. Install and tighten four nuts.
4. Install exhaust pipe shrouds (8), lift brackets (A), and fasten with six cap screws. Tighten lift bracket cap screws to 11 ± 3 N·m (97 ± 27 lb-in.).
5. Connect battery negative (-) cable.

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How do you remove the fuel pump?

1. Turn reserve fuel lever to OFF position.
2. Disconnect left spark plug wire.
3. Disconnect stator leads (A) and battery lead (B) from voltage regulator.
4. Remove three cap screws on F930; two cap screws on F910. Remove manifold cover.
5. For F930 only, remove cap screw.
6. For F930, bend shroud for access to impulse line connection to fuel pump. For F910, loosen coil clamp screw (A) and push coil inward to clear shroud. Bend shroud for access to impulse line connection to fuel pump.
7. Loosen clamps and disconnect hoses (A) and (B) from fuel pump.
8. Remove oil cooler screen.
9. Remove two nuts (A). Loosen two nuts (B).
10. Raise bulkhead slightly for access to remove two screws.
11. Pull impulse hose from back to remove fuel pump.

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How do you repair the fuel pump?

1. Remove two screws to disassemble fuel pump.
2. Wash parts in solvent. Inspect for cracks and deterioration. Replace with new parts where necessary. Always replace gaskets. Check and clean the small diaphragm air bleed hole in the pump base (A).
3. Assemble fuel pump in the order shown. Be sure the parts are positioned so that the indexing tabs align with the base and cover.

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How do you install the fuel pump?

1. Connect impulse line (A) to fuel pump. Fasten with hose clamp.
2. Fasten pump with two screws. Raise bulkhead slightly for access.
3. Install two nuts (A). Tighten nuts (A) and (B).
4. Install oil cooler screen.
5. Connect fuel supply line (A) to inlet of fuel pump. Connect filter line (B) to outlet. Fasten lines with clamps.
6. For F930, bend engine shroud down into place. For F910, bend engine shroud down into place. Pull coil outward and rotate it to its original position; then tighten screw (A).
7. For F930 only, install cap screw.
8. Install manifold cover. Fasten with three cap screws on F930; two, cap screws on F910.
9. Connect stator wires (A) to “AC” terminals on voltage regulator.
10. Connect red-on-white battery lead (B) to “B+” terminal.
11. Connect spark plug lead.
12. Turn reserve fuel lever to ON position.

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How do you remove the left fuel tank?

1. Park machine safely. Disconnect negative (-) battery cable.
2. Turn reserve fuel lever to OFF position.
3. Remove as much fuel as possible from the tank to reduce weight. Put it in a suitable container.
4. Disconnect fuel line (A).
5. Remove two nuts (8).
6. Remove nut © and lift wire retainer from stud.
7. Remove nut (D). Remove ground wire terminal and external-internal lock washer.
8. Hold fuel tank and bracket. Remove two bolts (A) from under tank. Lift bracket and tank from stud bolts.
9. Remove any remaining fuel.

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How do you remove the right fuel tank?

1. Park machine safely. Disconnect negative (-) battery cable.
2. Turn reserve fuel lever to OFF position.
3. Remove as much fuel as possible from the tank to reduce weight. Put it in a suitable container.
4. Remove five cap screws (early units) or three cap screws (later units) to remove fender.
5. Disconnect fuel line (A).
6. Remove four nuts (B).
7. Hold fuel tank and bracket. Remove two bolts (A) from under tank. Lift bracket and tank from stud bolts.
8. Remove any remaining fuel.

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How do you repair fuel tank fittings?

1. Loosen clamp. Turn fitting counter-clockwise to remove it.
2. Pull screen strainer out of hose. Clean and inspect screen and hose for deterioration. Replace as necessary.

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How do I check the fuel cap vent?

Be sure it is open. Use a small piece of wire to unplug vent hole.

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What should I check the fuel cap for and what should I do if it is defective?

Check fuel cap for cracks which could cause fuel leakage. Replace cap if cracked or broken.

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How do I replace the ground cable?

Loosen clamp. Pull filler neck from tank. Remove push nut (A) to replace ground cable.

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What is the caution when replacing the ground cable?

Be sure ground cable is securely installed in filler neck to prevent fuel explosion.

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How do I replace the ground clip?

Slide ground clip (B) off vent tube to replace it.

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What should I check the fuel tank for and what should I do if it is defective?

Check fuel tank for cracks, holes or worn spots. Replace tank if defective.

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How do I clean the fuel tank?

Wash fuel tank out with a small amount of fuel to remove any debris.

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How do I install the filler neck and ground cable assembly?

Install filler neck and ground cable assembly (A). Fasten with clamp.

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How do I install the ground clip?

Install ground clip (Bl with teeth pointing upward.

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How do I install the screen, hose, and fuel fitting assembly?

Install screen, hose, and fuel fitting assembly ©. Turn clockwise to tighten then fasten with a clamp.

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How do I install the foam pads on the right-side fuel tank?

Install foam pads (D) as shown for right-side fuel tank.

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Where should I place the foam pads for the left fuel tank?

Place on opposite side for left fuel tank.

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How do I install the fuel tanks?

1. Place washers (A) on four stud bolts.
   • NOTE: Washers are used as spacers to permit attaching nuts to tighten fully on the threads.
2. Install fuel tank supports (B). Fasten with cap screws.
   • NOTE: On earlier units, the supports are not used because the fuel tank bracket is fastened directly to the frame.

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How do I install the left fuel tank?

1. Install fuel tank and bracket on stud bolts with tank resting on supports.
2. Push bracket and tank toward frame and tighten two nuts (B).
3. Install wire retainer and fasten with nut ©.
4. Install external-internal lock washer and ground wire terminal. Fasten with nut (D).
5. Connect fuel line. Fasten with clamp (A).
6. Install bolts and nuts (A). Tighten bolts until fuel tank is held firmly against frame.

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What should I do on earlier units when installing the left fuel tank?

NOTE: On some earlier units, the fuel tank bracket is fastened directly to the frame. Push the bracket and tank firmly against frame; then tighten bolts.

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How do I install the right fuel tank?

1. Install fuel tank and bracket on stud bolts with tank resting on supports.
2. Push bracket and tank toward frame. Tighten four nuts (B).
3. Connect fuel line. Fasten with clamp (A).

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What is the note about F910 with right fuel tank only?

F910 with right fuel tank only has two fuel lines. Be sure to connect marked line to marked fitting.

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What should I do on earlier units when installing the right fuel tank?

NOTE- On some earlier units, the fuel tank bracket is fastened directly to the frame. Push the bracket and tank firmly against frame; then tighten bolts.

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How do I finish the fuel tank installation?

1. Install fender. Fasten with three or five cap screws.
2. Turn reserve fuel lever to ON position.
3. Connect negative (-) battery cable to battery.

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How do I replace the fuel filter?

1. Slide clamps back on fuel hoses to remove fuel filter (A).
   • NOTE: The words “IN” and “OUT” are stamped on the filter. Install the filter with the “IN” port to the fuel pump hose and the “OUT” port to the inlet hose to the carburetor.
2. Install filter. Connect and fasten fuel hoses to filter with clamps.

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How do I replace the fuel valve?

1. Slide hose clamp back and remove line (A) from fuel tank fitting. (F930 and F910 with auxiliary fuel tank.)

2. Remove nut and washer (B) from fuel valve.

3. Remove valve assembly from fender.

4. Slide clamps back to disconnect fuel lines from valve.

5. Install new valve and connect fuel lines.

   • On machines with two fuel tanks, connect:
     • A-Short line-to-left fuel tank
     • B-line-to-fuel pump
     • C-Line-to-right fuel tank
   • On machines with right fuel tank only, connect:
     • A-Line-to-reserve tube on tank fitting
     • B-Line-to-fuel pump
     • C-Line-to-main pick up tube on tank fitting

6. Install valve in fender. Fasten with washer and nut. Be sure center position of valve handle is pointing forward, then tighten nut.

7. Connect fuel line to left tank, if equipped.

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How do I remove the electric PTO clutch?

1. Park machine safely.
2. Loosen lock nuts to release spring tension. Remove two belts (A) from pulley (B).
3. Pull pin and remove belts from electric PTO clutch ©. Inspect belts for cracks or excessive wear. Replace both belts as a set if either one is defective.
4. Disconnect PTO clutch lead (A).
5. Remove cap screw (B) and two washers.
6. Slide clutch off shaft and lower it between tie rod and engine mount. Electric PTO clutch has no service parts. Replace the entire clutch if it is defective.

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What is the caution when removing the electric PTO clutch?

To avoid burns from the hot muffler, DO NOT attempt to remove PTO clutch until muffler is cool to the touch.

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What is the note about removing the electric PTO clutch?

Turn steering wheel until steering tie rod clears PTO clutch when removing clutch.

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How do I install the electric PTO clutch?

1. Install key in PTO shaft.
2. lift PTO clutch between tie rod and engine mount. Slide clutch onto shaft.
3. Install small washer, large washer, and cap screw (8). Tighten cap screw to 35 ± 3.5 N·m (310 ± 30 lb-in.).
4. Connect clutch lead (A).
5. Install two belts (A) on electric PTO clutch ©. Install pin and push wire loop over PTO clutch bracket.
6. Install belts on PTO pulleys (B).
7. Tighten nuts (D) until springs (E) are 21 mm (0.8 in.) long. Tighten lock nuts (F).

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How do I remove the charge pump?

1. Park tractor safely.
2. Disconnect battery ground cable.
3. Loosen three wing nut to remove air intake screen.
4. Remove four nuts and cap screws. Move oil cooler out of the drive shaft area.
5. Remove four cap screws to remove drive shaft.
6. Remove two cap screws to remove charge pump.
7. Remove pin (A). Inspect pin for straightness and rounded ends. Replace if necessary.
8. Inspect machined surface (B) of transmission for severe scoring. If scoring is noted replace transmission.

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What are the important notes when removing the charge pump?

• IMPORTANT: DO NOT damage oil cooler fins when working in the drive shaft area.
• NOTE: If necessary loosen hardware and disconnect spring to move blower shrouding (A) to get enough clearance to remove driveshaft.
• CAUTION: To avoid injury from escaping hydraulic oil under pressure, relieve the pressure in the system by stopping the engine and operating all hydraulic control valves.
• NOTE: Transmission is removed for clarity of photograph only.

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How do I disassemble the charge pump?

1. Remove inner ring and rotor ring (A).
2. Remove O-ring (B).
3. Inspect gerotor set.
4. Remove seal.
5. Remove bearing.
6. Inspect housing for wear or damage. If necessary replace entire charge pump.

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How do I inspect the gerotor set?

• Inspect inner ring key way for damage or shear pin debris.
• Inspect rotor ring (A) for cracks or signs of scoring on the outer edge.

If any component is worn or damaged the gerotor set must be replaced.

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How do I assemble the charge pump?

1. Clean and dry all parts.
2. Apply clean transmission oil on all internal parts.
3. Install bearing. Drive bearing into housing until it is flush with surface using a 1-1 /8 in. driver disk.
4. Install oil seal. Install seal with lip of seal (spring side) toward inside of housing using a 1-5/8 in. driver disk.
5. Install O-ring. Apply petroleum jelly to seal and housing to hold O-ring in its groove.
6. Install rotor ring (A) and inner ring. The gerotor set must spin freely in housing.

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How do I install the charge pump?

1. Clean and dry all parts. Machined surface (B) must be clean.
2. Apply clean transmission oil on all internal parts.
3. Install pin (A). Apply petroleum jelly to pin and shaft to prevent pin from moving during installation of charge pump.
4. Apply petroleum jelly to lip of oil seal and splined end of shaft.
5. Carefully install charge pump onto shaft. Turn pump until flat side of casting is on relief valve side.
6. Align large keyway in inner ring with shear pin in shaft.
7. Install cap screws and tighten to 70 ± 5 N·m (600 ± 25 lb-in.).
8. Install splined end of drive shaft on transmission shaft and fasten other end to engine with cap screws. Hold driveshaft and tighten cap screws.
9. Attach oil cooler to bulkhead wall with four nuts and cap screws.
10. Install air intake screen and tighten wing nuts.
11. Connect battery ground cable.
12. Bleed hydraulic system.

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What are the important notes when installing the charge pump?

• NOTE: Transmission is removed for clarity of photograph only.
• IMPORTANT: Do not damage seal when installing charge pump on shaft.
• NOTE: If blower shrouding (A) was moved to remove or install the driveshaft, it should be moved back to seal the blower housing. Tighten nuts and fasten spring.
• IMPORTANT: Do not damage oil cooler fins when working in the driveshaft area.

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How do I remove the charge relief valve?

1. Park tractor safely.
2. Disconnect battery ground cable.
3. Remove plug.
4. Remove shims (A) if equipped, spring and valve.
5. Inspect valve and housing for wear or damage. Valve must slide freely in bore. Replace parts a required.

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What is the important note when removing the charge relief valve?

If relief valve is being disassembled to be cleaned, the same number and thicknesses of shims must be installed when assembled.

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How do I install and adjust the charge relief valve?

1. Clean and dry all parts.
2. Apply clean transmission oil on valve.
3. Install valve and spring into housing bore.
4. Install the required amount of shims (A), from shim pack, until the charge relief valve opening pressure is 930 ± 310 kPa (135 ± 45 psi). After assembling the charge relief valve, test opening pressure.
5. Install and tighten plug.
6. Connect battery ground cable.

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What is the important note when installing the charge relief valve?

If relief valve was disassembled to be cleaned, the same number and thicknesses of shims must be Installed.

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How do I remove the implement relief valve?

1. Park machine safely. Disconnect battery negative ( – ) cable.
2. Remove two bolts (A). Move hydraulic reservoir to the side, if equipped.
3. Remove plug.
4. Remove shims (A) if equipped, spring and valve.
5. Inspect valve and housing for wear or damage. Valve must slide freely in bore. Replace parts as necessary.

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What is the important note when removing the implement relief valve?

If relief valve Is being disassembled to be cleaned, the same number and thicknesses of shims must be installed when assembled.

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How do I install and adjust the implement relief valve?

1. Clean and dry all parts.
2. Apply clean transmission oil on valve.
3. Install valve and spring into housing bore.
4. Install the required amount of shims (A), from shim pack, until the implement relief valve opening pressure is 6200 ± 340 kPa (900 ± 50 psi). After assembling the implement relief valve, test opening pressure.
5. Install and tighten plug.
6. Install hydraulic reservoir, if equipped. Fasten it with two bolts.
7. Connect battery negative (- ) cable.

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What is the important note when installing the implement relief valve?

If relief valve was disassembled to be cleaned, the same number and thicknesses of shims must be Installed.

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How do I remove the transmission?

1. Park machine safely.
2. Disconnect battery negative ( – ) cable.
3. Remove plug from differential to drain transmission oil.
4. Loosen three wing nuts to remove air intake screen.
5. Remove four nuts and cap screws. Move oil cooler out of the driveshaft area.
6. Remove four cap screws to remove driveshaft.
7. For units with hand-operated speed control, remove nut and cap screw to disconnect control linkage (A).
8. Remove two bolts (A). Move hydraulic reservoir to the side, if equipped.
9. Disconnect hydraulic lines (A and B).
10. Close all openings with caps and plugs to keep dirt out of the hydraulic system.
11. Remove cotter pin and headed pin (A). Disconnect dampening cylinder.
12. Remove cap screw (B) to remove tubing clamp.
13. Loosen clamp ©. Disconnect hose.
14. Cut tie band (D).
15. Remove bolt (E). Turn bracket to clear support.
16. Remove two cap screws and washers (F).
17. Remove four bolts (G) to remove differential support (H).
18. Remove nut (A) to disconnect drive link.
19. Remove bolt and roller (B).
20. Lift plate ©. Pull link (D) to disconnect it from rod (E).
21. Remove four cap screws (A) and spacers (B) to remove transmission.
22. Remove fittings (A).
23. Remove safety wire and roll pin (B) to remove control lever.

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What are the important notes when removing the transmission?

• IMPORTANT: Do not damage oil cooler fins when working in the drive shaft area.
• NOTE If necessary loosen hardware and disconnect spring to move blower shrouding (A) to get enough clearance to remove driveshaft.
• CAUTION: To avoid injury from escaping hydraulic oil under pressure, relieve the pressure in the system by stopping the engine and operating all hydraulic control valves.
• NOTE: Items A and E are not on early units with hand-operated speed control.
• NOTE Steps 18, 19, and 20 apply to units with foot-operated speed control only.

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How do I disassemble the transmission cover?

1. Thoroughly clean outside surface of transmission using a steam cleaner or diesel fuel.
2. Install transmission on a bench fixture.
3. Remove charge pump (B).
4. Remove implement relief valve (D).
5. Remove charge relief valve ©.
6. Remove filter (A).
7. Remove two plugs and O-rings (A).
8. Remove two check valves.
9. Remove O-ring, backup ring (B), and O-ring (A).
10. Internal valve © must move freely inside check valve.
11. Remove four pipe plugs.
12. Remove snap ring to remove output shaft drive gear.
13. LOOSEN eight cap screws (do not remove). Remove transmission from bench fixture.
14. Put transmission on work bench and remove eight cap screws, center section and gasket (A).
15. Remove valve plates (A and B). If it is necessary to pry valve plates loose from center section, use a wooden dowel and pry only at dowel pin grooves.
16. Inspect bearing plates.
17. Inspect both bearings in center section, replace if necessary.
18. Install center section in bench fixture and remove bearing using a 2-jaw puller and a slide hammer.

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What are the important notes when disassembling the transmission cover?

• NOTE: This disassembly procedure is for the Lawn and Garden Tractors and Front mower hydrostatic transmission. The differences are noted.
• NOTE Originally equipped 420 and 430 Lawn and Garden Tractor transmissions do not have manually operated check valves. If check valves have been replaced; service replacements will have manually operated check valves.
• IMPORTANT: Do not disassemble the transmission any further while in the bench fixture.
• IMPORTANT: Do not allow internal parts to fall when removing center section.
• IMPORTANT: Do not nick or scratch lapped or ma­chined surfaces of the center section, valve plates or cylinder blocks.

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How should the bearing plates be inspected?

Bearing plates should be flat, free of all nicks, burrs, scratches and erosion around the ports. The bronze metal should show no scoring, smearing or be discolored. NOTE: Scoring is indicated by fine scratches or grooves cut into the plate. When these scratches can be detected by feel, finger nail or lead pencil, the plate should be replaced.

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How do I disassemble the pump and motor?

1. Remove motor and pump cylinder blocks.
2. Inspect cylinder block assemblies.
3. Remove and inspect all pistons.
4. Remove and inspect both piston retainers.
5. Inspect both cylinder blocks.
6. Remove pump and motor thrust plates using a brass O-ring pick.
7. Inspect thrust plates. Check plates for scoring and smeared bronze material.

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What are the important notes when disassembling the pump and motor?

• IMPORTANT: Do not nick or scratch lapped surface of cylinder blocks.
• IMPORTANT: Do not interchange pistons between motor and pump cylinder blocks. Pistons and cylinder blocks are matched.

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What do I check the barrel for when inspecting all pistons?

Check barrel (B) for scoring, discoloration, or any signs of separation of slippers.

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What do I check the slipper for when inspecting all pistons?

Check slipper (A) for scoring, smearing, rolled edges and a full 360° free rotation on barrel.

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What do I check the lubrication hole for when inspecting all pistons?

Check lubrication hole © for blockage. Clean with compressed air.

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What should I do if any component of the piston is damaged?

If any component of the piston is damaged, the cylinder block assembly must be replaced.

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What do I check the retainer for when inspecting both piston retainers?

Check retainer for flatness, nicks, burrs and discoloration.

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What do I check the area around piston slippers for when inspecting both piston retainers?

Check area around piston slippers (A) for scoring.

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What should I do if any part of the piston retainer is damaged?

If any part of the piston retainer is damaged, the cylinder block assembly must be replaced.

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What do I check the ball guide area for when inspecting both cylinder blocks?

Check ball guide area (A) for scoring, wear and damage.

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What do I check the nine cylinder bores for when inspecting both cylinder blocks?

Check nine cylinder bores (B) for burrs and scoring.

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What do I check the lapped surface for when inspecting both cylinder blocks?

Check lapped surface © for wear and damage.

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What do I check the spring assembly for when inspecting both cylinder blocks?

Check spring assembly (D) for damage and free movement.

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What should I do if any part of the cylinder block is damaged?

If any part of the cylinder block is damaged, the cylinder block assembly must be replaced.

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What is the important note about thrust plates and swashplates?

Do not scratch machined surfaces of thrust plates or swashplates.

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How do I disassemble the pump and motor housing?

1. Remove snap ring and washer (A) from both trunion shafts.
2. Push top of swashplate © down until it contacts the stops in the housing.
3. Drive pin (B) until it bottoms in housing.
4. Drive two pins (D) until the lower one bottoms in housing.
5. Turn swashplate to the neutral position. Pins should fall into housing.
6. Repeat the above steps to remove second pin (D).
7. Remove control shaft (E) and trunion shaft (A) to remove swashplate.
8. Inspect swashplate and motor housing (F).
9. Remove pump shaft.
10. Inspect bearing, replace if necessary.
11. Remove bearing using a 1 in. driver disk (A), bearing puller attachment and a press.
12. Remove three seals from housing.
13. Inspect both trunion bearings, replace if necessary.
14. Drive bearings through housing using a 13/ 16 in. driver disk (A).
15. Remove motor shaft and bearing. Using a 1-in. driver disk (A), and a press.
16. Inspect bearing, replace if necessary.
17. Remove bearing using a 1 in. driver disk (A), bearing puller attachment and a press.

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What are the important notes when disassembling the pump and motor housing?

• IMPORTANT: Pump shaft and bearing assembly could restrict movement of swashplate. Full swashplate movement Is approximately 25 mm (1 in.) in each direction. If neces­sary tap shaft with a soft faced hammer.
• IMPORTANT: DO NOT drive pins after they bottom. Housing damage will result.
• IMPORTANT: Be sure to hold shaft while removing bearing.
• IMPORTANT: Be sure to hold shaft and bearing when removing from housing.

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How do I assemble the pump and motor housing?

1. Push motor shaft into bearing until it is on the shaft shoulder using a 1 in. driver disk (A), bearing puller attachment, and a press 6.
2. Push motor shaft assembly into housing until bearing is at the bottom of bore using a 1-7 / 16 in. driver disk (A), socket (B) and a donut type disk © and a press.
3. Install housing on bench fixture.
4. Install two needle bearings. Drive bearings into hous­ ing until they are flush with surface using a 1-in. driver disk (A).
5. Install three oil seals. Install seal with lip of seal (spring side) toward inside of housing using a 1-7 /16 in. driver disk (A).
6. Push pump shaft into bearing until it is on the shaft shoulder using a 1-in. driver disk (A) bearing puller attachment and a press.
7. Install pump shaft.
8. Install swashplate ©, control shaft (E), and shaft (A).
9. Drive pin (B) into swashplate and shaft until pin is about 6 mm (1 / 4 in.) below swashplate surface.
10. Drive two pins (D) into swashplate and control shaft until top pin is about 6 mm (1 / 4 in.) below swashplate surface.
11. Install washer (A) and snap ring on both trunion shafts.
12. Remove housing from bench fixture.

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What are the important notes when assembling the pump and motor housing?

• NOTE: This assembly procedure is for the lawn and Garden Tractor and Front mower hydrostatic transmissions. The differences are noted.
• IMPORTANT: To prevent bearing damage, press only on outer race of bearing when install­ing motor shaft assembly.
• NOTE: There will be approximately 5 mm (3/16 in.) of the bearing race above the mounting surface.
• IMPORTANT: Pump shaft and bearing assembly could restrict movement of swashplate. Full swashplate movement is approximately 25 mm (1 in.) in each direction. If neces­sary tap shaft with a soft faced hammer to seat bearing.

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How do I assemble the pump and motor?

1. Put clean John Deere All-Weather Hydrostatic Fluid or an equivalent on all internal parts.
2. Install pump and motor thrust plates.
3. Install pistons and piston retainer.
4. Install pump and motor cylinder blocks.

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What are the important notes when assembling the pump and motor?

• IMPORTANT: Do not nick or scratch lapped surface of cylinder blocks.
• IMPORTANT: Piston-to-Bore relationship need not be maintained; keep pump and motor components separate, they are not interchangeable.

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How do I assemble the transmission cover?

1. Install two needle bearings. Drive bearings into housing until they are approximately 3 mm (7 /64 in.) above the surface of the housing using a 5/8 in. driver disk (A).
2. Put clean hydrostatic oil on valve plates and housing surface.
3. Install pump valve plate (B) and motor valve plate (A) over the protruding bearings and align slots in plates with pins in housing.
4. Install center section and gasket (A) on housing and install eight cap screws. Tighten cap screws evenly.
5. Install transmission in bench fixture.
6. Tighten cap screws to 35 ± 5 N·m (330 ± 30 lb-in.).
7. Install gear on motor shaft (output shaft). Install snap ring.
8. Install and tighten four pipe plugs.
9. Install O-ring (A), backup ring (8) and O-ring. Internal valve © must move freely.
10. Install and tighten two check valves.
11. Install two plugs and O-ring (A).
12. Install new filter (A).
13. Install charge relief valve ©.
14. Install implement relief valve (D).
15. Install charge pump (B).

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What are the important notes when assembling the transmission cover?

• IMPORTANT: Do not nick or scratch lapped or ma­chined surfaces of the center section, valve plates or cylinder block.
• IMPORTANT: PUMP VALVE PLATE has TWO slotted ports (D). MOTOR VALVE PLATE has FOUR slotted ports. ©.
• IMPORTANT: Use extreme care when assembling the center section, valve plates and cylinder block to avoid dropping, nicking or scratching lapped surfaces.
• NOTE Center section will seem springy, this is because the springs inside the cylinder blocks are being compressed.
• IMPORTANT: Check for proper internal assembly by slowly rotating pump, motor and control shaft while tightening cap screws.

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How do I install the transmission?

1. Install fittings (A). Tighten fittings to 24 N·m (215 lb-in.).
2. Install control lever. Fasten with roll pin (B) and safety wire.
3. Install transmission. Fasten transmis­sion with four cap screws (B) and spacers ©. Tighten cap screws to 45 ± 5 N·m (415 ± 50 lb-in.).

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What is the note when installing the transmission on units with foot-operated speed controls?

For units with foot-operated speed controls, install switch mounting plate (A).