JOHN DEERE AG & TURF DIVISION M166319 H2 John Deere EZtrak OMM166319 H2 OPERATOR’S MANUAL North American Version Printed in U.S.A.
INTRODUCTION c WARNING: The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Introduction Thank You for Purchasing a John Deere Product We appreciate having you as a customer and wish you many years of safe and satisfied use of your machine. California Proposition 65 Warning Using Your Operator’s Manual This manual is an important part of your machine and should remain with the machine when you sell it.
PRODUCT IDENTIFICATION DEALER NAME: _________________________________________ DEALER PHONE: _________________________________________ B A MX50271 Product Identification Number (A): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ Engine Serial Number: On engine valve cover(s). __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ Transaxle Serial Numbers (B): S/N tag on forward side of each transaxle housing.
SAFETY LABELS Safety Label Location Safety Labels B A C E D MX51445 DANGER identifies the most serious hazards. The operator’s manual also explains any potential safety hazards whenever necessary in special safety messages that are identified with the word, CAUTION, and the safety-alert symbol. Picture Note: Z235 model shown.
SAFETY LABELS Label M167706 Avoid Injury • Remove key CAUTION Avoid equipment fires. Accumulation of grass, leaves and other debris on or near hot or moving parts can cause a fire. Inspect machine before, during and after use. Shut off engine and allow machine to cool before cleaning. For clean-out locations refer to service label. WARNING To avoid injury from loaded spring M146577 • To avoid injury from loaded spring, read operator’s manual before changing attachments.
SAFETY LABELS Warning M159705 • Sulfuric acid can cause blindness or severe burns. • Flush eyes immediately with water. Get medical help fast. • Keep out of reach of children. Do not tip. • Do not open battery! DANGER M128699 M159705 M128699 Picture Note: Located on battery Picture Note: This label is required and installed on machines sold in California. This label may also be installed on machines sold in other locations.
SAFETY LABELS DANGER M162849 Prevent Equipment Fires M162849 M165708 • Make sure that children stay clear of mower at all times when the engine is running. • Clean and inspect the entire machine. • Stay a safe distance from the machine. • Carefully read Operator’s Manual Machine Cleanout section for details. WARNING M162849 Avoid Injury From Getting Caught in Belts and Blades M160860 M160860 • Stay clear of belts. M162849 • Do not operate mower without shields.
SAFETY Avoid Injury From Rotating Blades - M118041 Safety Operating Safely This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death. M118041 • Do not put hands or feet under or into mower when engine is running. • Do not operate mower without discharge chute or entire grass catcher in place.
SAFETY counterweights. 2. Disengage mower blades. • Inspect machine before you operate. Be sure hardware is tight. Repair or replace damaged, badly worn, or missing parts. Be sure guards and shields are in good condition and fastened in place. Make any necessary adjustments before you operate. 3. Move motion control levers out to the Start/Shutdown position. • Before using, always visually inspect to see that the blades, blade bolts and the mower assembly are not worn and damaged.
SAFETY • Keep children indoors, out of the mowing area, and in the watchful eye of a responsible adult, other than the operator, when a mower is being operated. changes in speed or direction, which could cause the ride-on mower to roll over. • Stay alert to the presence of children. Never assume that children will remain where you last saw them. Turn the machine off if a child enters the work area.
SAFETY Operating Near Hazards A • Total towed weight must not exceed combined weight of pulling machine, ballast and operator. Use counterweights or wheel weights as described in the attachment or pulling machine operator’s manual. B • Excessive towed load can cause loss of traction and loss of control on slopes. Reduce towed weight when operating on slopes. • Never allow children or others in or on towed equipment. C • Use only approved hitches.
SAFETY Prevent Fires Grasscatcher components are subject to wear, damage, and deterioration which could expose moving parts or allow objects to be thrown. • Besides routine maintenance, one of the best ways to keep your John Deere equipment running efficiently and to reduce fire risk is to regularly remove debris buildup from the machine. • Mower blades are sharp. Wrap the blade or wear gloves, and use extra care when servicing them. Only replace blades. Never straighten or weld them.
MACHINE CLEANOUT outdoors and provide adequate ventilation. • Clean up spilled fuel immediately. If fuel is spilled on clothing, change clothing immediately. If fuel is spilled near machine, do not attempt to start the engine but move the machine away from the area of spillage. Avoid creating any source of ignition until fuel vapors have dissipated. • Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or other appliance.
MACHINE CLEANOUT D C H MX51441 c.Top of mower deck, under shields (C), including spindle and belt area (D). MX51464 F E G I MX50275 d.On or near transaxles (E) and belt drives and fins (F). e.In and around cross-strap bracket (G). MX51681 f. Under the seat (H), including the battery (I) and wiring harness. • Excess lubrication or fuel/oil leaks or spills on the machine can also serve as collection sites for debris.
ASSEMBLY Assembly Charge and Connect Battery c CAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode: • Do not smoke or have open flame near battery. • Wear eye protection and gloves. • Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. • Do not jump start or charge a frozen battery. Warm battery to 16°C (60°F). 1. Remove and discard the red positive (+) protective cap from the positive (+) battery terminal.
OPERATING - CONTROLS Operator Station Controls Operating - Controls F C E B D A G I K L J H MX51462, MX51463 Key Description Key Description A Left Motion Control Lever H Fuel Tank Cap B Headlight (If equipped) I Ignition Key Switch C Park Brake Lever J Hourmeter D Deck Height Pin K Mower Engagement Switch E Mower Deck Lift Lever L Throttle/Choke Control Lever F Mower Deck Lift Pedal (If Equipped) G Right Motion Control Lever Operating - Controls - 15
OPERATING Adjusting Seat Operating Daily Operating Checklist ❏ Test safety systems. ❏ Check fuel level. (See SERVICE MISCELLANEOUS section, Using A Proper Fuel and Stabilizer) ❏ Check engine oil level. ❏ Remove grass and debris from engine compartment and muffler area, and on top of mower deck, before and after operating machine. ❏ Clean air intake screen. ❏ Check area below machine for leaks. MX51837 Avoid Damage to Plastic and Painted Surfaces 1. Tip seat forward.
OPERATING A B B A MIF MX50270 2. Pull upward on mower deck lift lever (A) and pull lever towards center of machine to lock in raised position. 3. Insert the pin (B) in the proper hole for the desired height of cut. Picture Note: A convenient leveling gauge (A) (AM130907) is available from your dealer. a.Position mower blades as follows and measure from each outside blade tip (B) to the level surface. 4.
OPERATING Adjusting Mower Wheels D c CAUTION: Avoid injury! Rotating blades are dangerous. Before adjusting or servicing mower: • Disconnect spark plug wire(s) or battery negative (-) cable to prevent engine from starting accidently. • Always wear gloves when handling mower blades or working near blades. MX4896a a.Turn right blade (D) so blade tip points straight forward.
OPERATING Testing Safety Systems 5. Try to start engine. Result: Engine must not crank. If engine cranks, there is a problem with your safety interlock circuit. Testing Seat Switch 1. Park machine safely. (See Parking Safely in the SAFETY Section.) 2. First test: a.Lock park brake. b.Start engine. c.Move throttle lever up to maximum engine speed. d.Engage mower. e.Raise up off seat. Do not get off machine. Result: Engine and mower blades should stop.
OPERATING Using Park Brake c Using the Motion Control Levers c CAUTION: Avoid injury! Children or bystanders may attempt to move or operate an unattended machine. Always lock the park brake and remove the key before leaving the machine unattended. Setting Park Brake 1. Raise park brake lever to lock park brake. CAUTION: Avoid injury! Learn use of the motion control levers and practice at half throttle until becoming proficient and comfortable with the operation of the machine.
OPERATING Neutral Position smoothly, slowly move the levers toward neutral. Reverse Travel C D B B MX51452 • Machine speed, motion, and direction can be controlled when the engine is running, motion control levers are in the neutral position (C), and the park brake (D) is unlocked. MX51454 • To stop the machine for an emergency, move the motion control levers quickly back to the neutral position. 1.
OPERATING C D D C MX51456 MX51458 2. To turn sharply to the left, push right control lever (C) forward and pull left control lever (D) rearward at the same time. 2. To turn sharply to the right, push left control lever (D) forward and pull right control lever (C) rearward at the same time. Right Turn Starting the Engine c CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.
OPERATING Engaging Mower c IMPORTANT: Avoid damage! Transmission damage may occur if the machine is towed or moved incorrectly: • Move machine by hand only. CAUTION: Avoid injury! Clear mowing area of all bystanders when operating this machine. Thrown objects could cause serious injury or death. Keep hands and feet away from blades and discharge opening. Do not mow in reverse unless absolutely necessary. • Do not use another vehicle to move machine. • Do not tow machine.
OPERATING Unplugging Mower, Bagger, or Material Collection System 5. Start engine. 6. Run at full throttle. 7. Engage mower blades. c 8. Flush water under deck for approximately one minute. CAUTION: Avoid injury! Do not attempt to unplug 9. Disengage mower blades. attachment with machine running. 10. Stop engine. • Rotating blades are dangerous. Shut off the engine and remove the key before getting off the seat to inspect the machine and attachment. 11.
SERVICE INTERVALS Mowing Tips • Mow grass with throttle lever in the full fast / mow position. • Mow grass when it is dry. • Keep mower deck and discharge chute clean. • Mow with sharp blades. A • Properly level mower deck for a smooth cut. • Mow grass frequently. • Use a travel speed that fits the conditions: • Mow tall or wet grass twice. Cut grass at half desired height – then cut at desired height. A • Travel slow when mowing tall or thick grass.
SERVICE LUBRICATION Every 50 Hours or Annually 42C Mower Deck • Change engine oil. • Change engine oil filter. • Lubricate mower deck spindles. A Every 100 Hours or Annually A • Replace spark plugs. • Replace air filter element(s). • Replace fuel filter. • Check mower belt. • Sharpen / replace mower blades. • Clean underside of deck. • Check tire pressure. • Clean engine cooling fins. MX43836 • If there is debris that cannot be blown out, remove blower housing for complete cleaning.
SERVICE ENGINE Avoid Fumes operation. Lubricating Front Caster Spindles c c CAUTION: Avoid injury! To avoid injury, Do not lubricate CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death. Do not run an engine in an enclosed area, such as a garage, even with doors or windows opened. machine while the engine is running. Move the machine to an outside area before running the engine.
SERVICE ENGINE IMPORTANT: Avoid damage! Dirt and contamination can enter engine when checking oil level. Clean area around dipstick before loosening or removing. A A C B MX50272 3. Remove dipstick (A). Wipe with clean cloth. 4. Install and tighten dipstick. MX50272 5. Remove dipstick. 6. Check oil level on dipstick. Oil must be between ADD and FULL marks. 3. Clean area around dipstick (A) to prevent debris from falling into crankcase. 7.
SERVICE ENGINE Cleaning Air Intake Screen and Engine Fins c C A B CAUTION: Avoid injury! Compressed air can cause debris to fly a long distance. • Clear work area of bystanders. D • Wear eye protection when using compressed air for cleaning purposes. C • Reduce compressed air pressure to 210 kPa (30 psi). E IMPORTANT: Avoid damage! An obstructed air intake screen can cause engine damage due to overheating.
SERVICE ENGINE IMPORTANT: Avoid damage! Dirt and debris can enter the engine through a damaged filter element: H • Do not wash paper element. • Do not attempt to clean paper element by tapping against another object. • Do not use pressurized air to clean element. I • Replace element only if it is very dirty, damaged or the seal is cracked. NOTE: During filter cartridge removal, any material or foreign object that enters the air intake must be removed before replacement of the cartridge. C MX38389 8.
SERVICE ENGINE Replacing Fuel Filter c CAUTION: Avoid injury! Fuel vapors are explosive and flammable: • Do not smoke while handling fuel. • Keep fuel away from flames or sparks. • Shut off engine before servicing. A • Cool engine before servicing. • Work in a well-ventilated area. • Clean up spilled fuel immediately. NOTE: Change filter when fuel is low. MX51683 2. Disconnect spark plug wire (A) on each side of engine. 1. Park machine safely. (See Parking Safely in the SAFETY section). 2.
SERVICE TRANSMISSION C B A C B C D A E MX51831 a.Remove two bolts (A) and steering arm (B). MX51833 1. Locate rotating screen guard (A) at top of engine. b.Raise seat and disconnect wiring harness connector (C) from seat switch. c.Remove two L-pins (D) to remove seat. 2. Remove screw (B), press in tabs (C) and lift off guard (A). d.Remove seven push retainers from style panel (E) and remove style panel. 3. Clean guard and flywheel cover of debris. 4. Install guard after cleaning.
SERVICE TRANSMISSION A B A MX50275 C Picture Note: View from front of machine. MX51689 2. Adjust tracking with the 13 mm socket on the free end of the deck height adjustment lock pin (A) as follows: NOTE: Tracking bolts limit top forward speed. If both levers hit against the tracking bolts, turn both bolts counterclockwise equal amounts until only one bolt contacts the lever. This will achieve maximum forward speed. • If machine tracks to the left, turn tracking bolt (B) clockwise.
SERVICE MOWER Removing and Installing Mower Deck Foot Plate D F I B F c C CAUTION: Avoid injury! Always operate the mower with the foot plate installed. Operating with the foot plate removed can cause serious injury. E Removing Foot Plate 1. Park machine safely. (See Parking Safely in the SAFETY section.) A G A MX51687 B Picture Note: Components viewed from bottom. 3. Disconnect electric clutch wiring connector (A) from main wiring harness connector.
SERVICE MOWER H B I J A C MX51442 MX51443 7. Remove locking clip (H) and, remove stud end (I) from front draft bracket (J). 4. Remove lock pin, push handle to its lowest position (A) and install pin (B) just above lever to lock deck in lowered position. 5. Remove bolt (C) to remove foot plate. c CAUTION: Avoid injury! Component is spring-assisted and under tension. Injury can occur if spring-assisted component is released suddenly. K 6. Disconnect mower drive belt: MX51441 8.
SERVICE MOWER E B F A G MX51440 MX51443 7. Remove locking clip (E), and remove stud end (F) from front draft bracket (G).. 4. Remove lock pin, push handle (A) to its lowest position and install pin (B) just above lever to lock deck in lowered position. 5. Remove foot plate. c CAUTION: Avoid injury! Component is spring-assisted and under tension. Injury can occur if spring-assisted component is released suddenly. H 6. Disconnect mower drive belt: C MX51441 8.
SERVICE MOWER belt out of V-sheave to allow more belt slack for installation of belt onto clutch. 5. Slide mower deck under machine. c CAUTION: Avoid injury! Component is spring-assisted and under tension. Injury can occur if spring-assisted component is released suddenly. B C A H I MX51443 6. Remove lock pin, push handle (A) to its lowest position and install pin (B) just above lever to lock deck in lowered position. MX51685 10. Connect mower drive belt: 7. Remove bolt (C) to remove foot plate.
SERVICE MOWER NOTE: Left and right spindle sheaves are hidden by belt covers. Failure to seat belt properly on sheaves may result in belt damage. • Install 3/8-inch ratchet onto square hole (G) in tension arm and rotate clockwise to release tension on belt, while installing mower belt onto center spindle sheave (H). Make sure belt is properly seated on all sheaves. A 8. Install foot plate. Replacing Mower Drive Belt (42 Inch Mower) 1. Park machine safely. (See Parking Safely in SAFETY section.) 2.
SERVICE MOWER 8. Install and tighten bolt (C) on belt guide. E D F C G MX38099 Picture Note: Shown without sheave for clarity only. 9. Make sure belt guide (E) is indexed properly into hole (F) on tension arm (G). MX39749 • Loosen nut (C) and bolt (D) on sheaves, and remove belt from all sheaves. 5. Inspect belt for wear or damage; replace as necessary. 10. Tighten sheave hardware to 47 N•m (35 lb-ft). 11. Make sure belt is properly seated on all sheaves, and install right and left belt shields. 6.
SERVICE ELECTRICAL Checking for Bent Mower Blades c K CAUTION: Avoid injury! Blades are sharp. Always wear gloves when handling blades or working near blades. C Replace blades if defective. Never straighten or weld them. 1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Raise mower deck to highest position to access blades. B A MX37886 Picture Note: 42 inch deck shown. • Loosen and remove nut (A), washer (B), and blade (C). 5.
SERVICE ELECTRICAL c 3. Apply general purpose grease or silicone spray to terminals to help prevent corrosion. CAUTION: Avoid injury! The battery produces a flammable 4. Slide red cover over positive battery terminal. 5. Install battery compartment cover. and explosive gas. The battery may explode: 6. Lower operator seat. • Do not smoke or have open flame near battery. • Wear eye protection and gloves. Cleaning Battery and Terminals • Do not allow direct metal contact across battery posts. 1.
SERVICE MISCELLANEOUS IMPORTANT: Avoid damage! Electric charge from booster battery can damage machine components. Do not install negative booster cable to machine frame. Install only to the engine block. or environmental conditions and, over time, may affect your machine’s operation. Fill machine fuel tank at the end of the day. Filling Fuel Tank Install negative booster cable away from moving parts in the engine compartment, such as belts and fan blades. 4.
SERVICE MISCELLANEOUS Checking Tire Pressure c CAUTION: Avoid injury! The machine can fall or slip from an unsafe lifting device or supports. • Use a safe lifting device rated for the load to be lifted. • Lower machine onto jack stands or other stable supports and block wheels before servicing. NOTE: Remove any material collection system attachments prior to lifting machine.
SERVICE MISCELLANEOUS 7. Remove wheel assembly (E). c CAUTION: Avoid injury! Explosive separation of tire and rim F parts is possible when they are serviced incorrectly: G • Do not attempt to mount a tire without the proper equipment and experience to perform the job. 5. Take wheel assembly to an authorized service dealer for repairs. Installing 1. Install wheel assembly with valve stem to the outside. 2. Tighten wheel nuts evenly in alternating sequence until snug. 3.
TROUBLESHOOTING Repairing Deep Scratches (bare metal or primer showing): IF CHECK 1. Clean area to be repaired with rubbing alcohol or mineral spirits. 2. Use paint stick with factory-matched colors available from your authorized dealer to fill scratches. Follow directions included on paint stick for use and for drying. Engine Runs Unevenly Cooling fins plugged. Loose electrical connections. Choke or throttle cable sticking. 3. Smooth out surface using an automotive polishing compound.
TROUBLESHOOTING Electrical IF CHECK Starter Does Not Work Or Will Not Turn Engine Park brake not locked. IF CHECK Patches Of Grass Uncut Travel speed too fast. Mower deck needs cleaning. Mower is engaged. Battery terminals are corroded. Belt Slipping Motion control levers not in Start/ Shutdown position. Blown fuse. Belt tension is incorrect. Too Much Vibration Debris on mower deck or in sheaves. Damaged drive belt. Defective key switch Damaged sheaves or sheaves out of alignment.
STORAGE 6. Run engine for a few minutes to allow fuel mixture to circulate through carburetor on gas engine or fuel injectors on diesel engine. Storage Engine: Storing Safety c Engine storage procedure should be used when vehicle is not to be used for longer than 60 days. 1. Change engine oil and filter while engine is warm. CAUTION: Avoid injury! Fuel vapors are explosive and 2. Service air filter if necessary. flammable.
SPECIFICATIONS Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1821 mm (72 in.) Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 kg (590 lb) Magneto Air Gap . . . . . . . . . . . . . . . . . . . . .20 - .30 mm (.
WARRANTY applicable U.S. Environmental Protection Agency regulations under 40 CFR Parts 1054 and 1060: and, Warranty Product Warranty Product warranty is provided as part of John Deere’s support program for customers who operate and maintain their equipment as described in this manual. Engine related warranties stated in this manual refer only to emissionsrelated parts and components of your engine.
WARRANTY is determined from the Warranty Code printed at the top of the battery and chart below. Installation costs are not covered by warranty after 90 days from the date of purchase. Ignition System: • Spark plugs. • Magneto or electronic ignition system. THIS WARRANTY DOES NOT COVER • Spark advance/retard system. A. Breakage of the container, cover, or terminals. Exhaust System: B. Depreciation or damage caused by lack of reasonable and necessary maintenance or by improper maintenance.
INDEX Hourmeter, Using ...................................................................................20 Index I Identification Numbers, Record ................................................................1 K A Air Cleaner Elements (Twin Cylinder), Checking and Cleaning ............ 30 Air Intake Screen, Cleaning ................................................................... 29 B Bagger, Unplugging ...............................................................................
GETTING QUALITY SERVICE Park Brake, Using .................................................................................. 20 Parts Catalog ......................................................................................... 50 Parts, Replacement ........................................................................ 50, 51 Plastic And Painted Surfaces, Avoid Damage To .................................. 16 R Replacement Parts .........................................................................
SERVICE RECORD Service Record Record Service Dates Oil Change Oil Filter Change (If Equipped) Lubricate Machine Air Cleaner Element Check/ Clean Service Record - 53 Fuel Filter Change
SERVICE RECORD Service Record - 54
SERVICE RECORD Service Record - 55
