JD K Series LIQUID-COOLED Engine Workshop Service Manual

COMPONENT TECHNICAL MANUAL Litho in U.S.A John Deere Lawn & Grounds Care Division John Deere K Series Liquid-cooled Engines CTM39 (Oct93) Replaces CTM39 (28JAN91)

INTRODUCTION 4/7/95 1 - 1 This component technical manual is written for an experienced technician. It covers recommended repair procedures, starting with the engine removed from the machine and on a workbench or engine stand. Some components may be serviced in the machine. Determine the repair procedure before removing the engine. Use this manual in conjunction with the machine technical manual. It is a part of a total product support program. Use the Fundamental Of Service (FOS) manual as reference for fundamentals of service and basic theory of operation. The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows: • Table of Contents • Safety • Specifications • Theory of Operation • Repair Note: Depending on the particular section or system being covered, not all of the above groups may be used. Each section will be identified with a symbol rather than a number. The pages within a section will be consecutively numbered. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. We appreciate your input on this manual. To help, there are postage paid post cards included at the back. If you find any errors or want to comment on the layout of the manual please fill out one of the cards and mail it back to us. COPYRIGHT © 1993 JOHN DEERE HORICON WORKS Horicon, Wisconsin All rights reservedl Information Specifications and Intake, Muffler & Breather Cylinder Head & Valves Camshaft, Crankshaft & Lubrication System Cooling System Electrical System Component Analysis Fuel System & Governor Safety Miscellaneous Cylinder Block, Pistons & Rods Troubleshooting Flywheel

SAFETY 1 - 2 4/7/95 HANDLE FLUIDS SAFELY-AVOID FIRES • BE PREPARED FOR EMERGENCIES When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. TS227 TS291 HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment. • DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer. TS1133 TS1132

SAFETY 4/7/95 1 - 3 USE SAFE SERVICE PROCEDURES • WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate for the job. 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 or uncomfortable loud noises. . • SERVICE MACHINES SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. • USE PROPER TOOLS Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications. TS228 TS206 • WORK IN CLEAN AREA • Before starting a job 1. Clean work area and machine: 2. Make sure you have all necessary tools to do your job. 3. Have the right parts on hand. 4. Read all instructions thoroughly; do not attempt shortcuts. • ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. • WORK IN VENTILATED AREA Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area. TS220

SAFETY 1 - 4 4/7/95 • REMOVE PAINT BEFORE WELDING OR HEATING Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. • AVOID HARMFUL ASBESTOS DUST Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer. Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated. Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area. REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement. TS201 LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields. TS231

CONTENTS SPECIFICATIONS & INFORMATION 4/7/95 2 - 1 CONTENTS Page SPECIFICATIONS & INFORMATION BASIC ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE MODEL CONFIGURATION CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ENGINE SERIAL NUMBER PLATE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CARBURETOR SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TEST & ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 5 REPAIR SPECIFICACATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FD440V/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 METRIC TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 GASOLINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 FUEL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SYNTHETIC LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 FD440V/501V/590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 INTERNAL ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

NOTES SPECIFICATIONS & INFORMATION 2 - 2 4/7/95

SPECIFICATIONS & INFORMATION 4/7/95 2 - 3 BASIC ENGINE SPECIFICATIONS ENGINE APPLICATIONS NOTE: Refer to the engine application chart to identify product-model/engine type-model relationship. Lawn Tractors Machine Engine Model No. LX178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD440V - AS00 LX188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD501V - AS00 Lawn And Garden Tractors 285 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS00 285 w/Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS01 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS00 425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS02 445 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS01 Front Mowers F911 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS00 F725 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS03 Golf And Turf Equipment 1800 Utility Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS04 2243 Professional Greensmower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS02 2653 Professional Utility Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS04 6X4 Gator Utility Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS11 ENGINE FD440V AS00 FD501V AS00 FD590V- AS00/02 FD590V- AS03 FD620D AS04/11 FD620D ASO2 FD620D AS00/01 HORSEPOWER 11.1 kW (15 HP) 12.6kW (17 HP) 13.4 kW (18 HP) 14.9kW (20 HP) 13.4 kW (18 HP) 14.9kW (20 HP) 16.4 kW (22 HP) CYLINDER 2 2 2 2 2 2 2 CYCLE 4 4 4 4 4 4 4 BORE 67 mm (2.64 in.) 67 mm (2.64 in.) 74 mm (2.90 in.) 74 mm (2.90 in.) 76 mm (2.99 in.) 76 mm (2.99 in. 76 mm (2.99 in. STROKE 62 mm (2.44 in.) 62 mm (2.44 in.) 68 mm (2.66 in.) 68 mm (2.66 in.) 68 mm (2.66 in.) 68 mm (2.66 in.) 68 mm (2.66 in.) DISPLACEMENT 437 cm 3 (26.7 cu. in.) 437 cm 3 (26.7 cu. in.) 585 cm 3 (35.7 cu. in.) 585 cm 3 (35.7 cu. in.) 617 cm 3 (35.7 cu. in.) 617 cm 3 (35.7 cu. in.) 617 cm 3 (35.7 cu. in.)

SPECIFICATIONS & INFORMATION 2 - 4 4/7/95 ENGINE MODEL CONFIGURATION CHANGES FD590V The following is a list of the major differences between the model configurations of the FD590V-AS00 through the FD590V-AS03. • The FD590V-AS00 is the first configuration used and its first application was in the 285 Lawn and Garden Tractor. • FD590V-AS01 was converted to a electronic fuel injection system. The carburetor was replaced by a throttle body and a water temperature sensor was added. • FD590V-AS02 engine is used in the 2243 Triplex Professional Greensmower. • FD590V-AS03 is used in the F725 Front Mower. The power was increased from 18 to 20 horsepower. To obtain the higher horsepower the following components were changed: • A larger redesigned intake manifold • The cylinder head induction passage and combustion chamber was redesigned. • A larger carburetor is used. NOTE: The FD440V, FD501V and FD590V are vertical shaft engines. The FD620D is a horizontal shaft engine. FD620D The differences in horsepower are due to the following: • rpm that the engine must run for the application. • the efficiencies of fuel injection on the FD620 - AS01. ENGINE SERIAL NUMBER PLATE LOCATIONS NOTE: Refer to the engine model designation on the engine serial number plate to identify repair information covered in the Component Technical Manual FD440V/FD501V/FD590V: The engine serial number (A) is located on the side of the cooling air duct. FD620D: The engine serial number (A) is located on the crankcase cover. M53952 M53953

TEST & ADJUSTMENT SPECIFICATIONS SPECIFICATIONS & INFORMATION 4/7/95 2 - 5 CARBURETOR SERIAL NUMBER LOCATIONS FD440V/FD501V/FD590V: The carburetor serial number (A) is located on the top of carburetor. M53957 FD620D: The carburetor serial number (A) is located on the side of carburetor. M53958 TEST & ADJUSTMENT SPECIFICATIONS Engine: Oil pressure sensor activates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 kPa (14.2 psi) Oil pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 kPa (40 psi) Oil filter bypass valve opening pressure . . . . . . . . . . . 78.5—117.5 kPa (11.4—17.1 psi) Cylinder compression pressure (minimum) . . . . . . . . . . . . . . . . . . . . 1171 kPa (170 psi) Maximum compression pressure variation between cylinders . . . . . . . . 138 kPa (20 psi) Crankcase vacuum (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1 in.) water Intake and exhaust valve clearance (cold) . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.01 in.) Intake and exhaust valve adjustment interval . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 hrs. Valve clearance adjusting nut torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in) Fuel/Air System: Fuel Pump Minimum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 ml (3.5 oz) in 15 seconds Minimum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 kPa (1.5 psi) Carburetor SLOW idle mixture screw initial setting . . . . . . . . . . . . . . . . . . . . . . . . . 1 Turn Carburetor SLOW idle stop screw setting . . . . . . . . . . . . . . . 50 rpm less than throttle control arm SLOW idle stop screw setting Throttle Cable Throttle control arm SLOW idle stop screw setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1175+25 / -50 rpm Throttle control arm FAST idle stop screw setting . . . . . . . . . . . . . . . . . . 3650 ± 75 rpm Air Restriction Indicator Normal restriction vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . .102—178 mm (4—7 in.) Maximum restriction vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 mm (15 in.) Fuel Tank Check valve opening pressure (maximum) . . . . . . . . . . . . . . . . . . . . . . 3 kPa (0.4 psi) Cooling System: Radiator cap Maximum test pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 kPa (17 psi) Minimum pressure after 15 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi) Opening pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–96 kPa (12–14 psi) Minimum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 kPa (11 psi) Thermostat Begin-to-open temperature . . . . . . . . . . . . . . . . . . . . . . . approximately 63°C (145°F) Full-open temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 80°C (176°F) Full-closed temperature . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 63°C (145°F)

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JD K Series LIQUID-COOLED Engine Workshop Service Manual

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