jd 325_335_345 service manual

325, 335 and 345 Lawn and Garden TractorsSerial No. (70001 - )

TECHNICAL MANUALJohn Deere Worldwide Commercial and Consumer Equipment Division TM1760 (28May99)

Litho in U.S.A

M82901

INTRODUCTIONThis technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program.

Safety Specifications and General Information Engine325 (FH531V) Engine335 (FH601V) Engine345 (FD611V) Electrical Power Train (Hydrostatic) Steering325

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 General Diagnostic Information Specifications Electrical Wiring Harness Legend Component Location System Schematic Wiring Harness Troubleshooting Chart Theory of Operation Diagnostics Tests & Adjustments 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 groups and pages within a section will be consecutively numbered.

Steering335/345 Brakes Hydraulics

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.

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.

Attachments Miscellaneous

COPYRIGHT 1999 Deere and Co. John Deere Worldwide Commercial and Consumer Equipment Division Horicon, WI All rights reserved

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SAFETY

RECOGNIZE SAFETY INFORMATION

HANDLE FLUIDS SAFELY-AVOID FIRES Be Prepared For Emergencies

This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe servicing practices.

Understand Signal WordsA signal wordDANGER, WARNING, or CAUTIONis used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

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.

REPLACE SAFETY SIGNS

Replace missing or damaged safety signs. See the machine operators manual for correct safety sign placement.

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SAFETY

USE CARE IN HANDLING AND SERVICING BATTERIES

USE CARE AROUND HIGHPRESSURE FLUID LINES Avoid High-pressure Fluids

Prevent Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16C (60F). Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid injury from escaping fluid under pressure by stopping the engine and relieving pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid acid burns by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 10_15 minutes. 4. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately.

Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

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SAFETY

USE SAFE SERVICE PROCEDURES Wear Protective Clothing

Park Machine Safely

Wear close fitting clothing and safety equipment appropriate to 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. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

Before working on the machine: 1. Lower all equipment to the ground. 2. Stop the engine and remove the key. 3. Disconnect the battery ground strap. 4. Hang a DO NOT OPERATE tag in operator station.

Support Machine Properly And Use Proper Lifting Equipment

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.

If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual.

Use Proper ToolsUse 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.

Work In Clean AreaBefore 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.

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SAFETY

Using High Pressure WashersDirecting pressurized water at electronic/electrical components or connectors, bearings, hydraulic seals, fuel injection pumps or other sensitive parts and components may cause product malfunctions. Reduce pressure and spray at a 45 to 90 degree angle.

Avoid Harmful Asbestos DustAvoid 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.

Illuminate Work Area SafelyIlluminate 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

SERVICE TIRES SAFELY

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.

WARNING: California Proposition 65Warning: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

Remove Paint Before Welding Or HeatingAvoid 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.

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SAFETY

AVOID INJURY FROM ROTATING BLADES, AUGERS AND PTO SHAFTS

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 ProperlyImproperly 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.

Keep hands and feet away while machine is running. Shut off power to service, lubricate or remove mower blades, augers or PTO shafts.

SERVICE COOLING SYSTEM SAFELY

LIVE WITH SAFETY

Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off machine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

HANDLE CHEMICAL PRODUCTS SAFELY

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

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SPECIFICATIONS AND INFORMATION

CONTENTS

CONTENTSPage

VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3ENGINE- 325. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE- 335. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE- 345. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PTO DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 IMPLEMENT LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 MOWER ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 WEIGHTS AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 METRIC FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INCH FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 O-RING SEAL SERVICE RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FACE SEAL FITTINGS WITH INCH STUD ENDS TORQUE . . . . . . . . . . . . . . . . . . . 9 FACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUE . . . . . . . . . . . . . . . . 10 O-RING FACE SEAL FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 O-RING BOSS FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

GASOLINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124CYCLE ENGINES NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4CYCLE ENGINES EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144CYCLE GASOLINE ENGINE OIL NORTH AMERICA. . . . . . . . . . . . . . . . . . . . . 14 4CYCLE GASOLINE ENGINE OIL EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 BREAKIN ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 HYDROSTATIC TRANSMISSION AND HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . 16 ANTI-CORROSION GREASE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SYNTHETIC LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 MIXING OF LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 CHASSIS GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18GASOLINE ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 GASOLINE ENGINE COOLANT DRAIN INTERVAL. . . . . . . . . . . . . . . . . . . . . . . . . 18

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19MACHINE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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CONTENTS


Page ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CARBURETOR SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 HYDROSTATIC TRANSMISSION SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . 20

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6/16/99


VEHICLE SPECIFICATIONS

VEHICLE SPECIFICATIONS ENGINE- 325Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere K Series, Air Cooled Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH531V Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Natural Horsepower (SAEJ1940). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.4 kW (18 hp) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494 cm3 (30 cu in.) Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 mm (2.68 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 mm (2.68 in.) Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3:1 Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 75 rpm Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3400 50 rpm Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overhead Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . Dual Stage Paper Air Filter and Foam Precleaner Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame Engine Oil Capacity With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 L (1.8 U.S. qt) Without Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L (1.6 U.S. qt)

ENGINE- 335Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere K Series, Air Cooled Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH601V Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Natural Horsepower (SAEJ1940). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.9 kW (20 hp) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675 cm3 (41.2 cu in.) Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.2 mm (2.96 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 mm (2.99 in.) Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1:1 Slow Idle (Governed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 75 rpm Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3400 50 rpm Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overhead Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . Dual Stage Paper Air Filter and Foam Precleaner Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame Engine Oil Capacity With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 L (1.8 U.S. qt) Without Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L (1.6 U.S. qt)

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ENGINE- 345Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Deere K Series, Liquid Cooled Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD611V Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Natural Horsepower (SAEJ1940). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.9 kW (20 hp) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, V-twin Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585 cm3 (35.7 cu in.) Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 mm (2.900 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 mm (2.700 in.) Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7:1 Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 75 rpm Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3400 50 rpm Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overhead Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Coolant Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 L (3.3 qt) Air Cleaner . . . . . . . . . . . . . . . . . . . . Dual Stage Paper Air Filter and Foam Precleaner Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame Engine Oil Capacity With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 U.S. qt) Without Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 L (1.8 U.S. qt)

FUEL SYSTEMFuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Fuel Tank Capacity (Total). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2 L (3.50 U.S. gal) Fuel (min. octane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded gasoline, 87 octane Fuel Pump Location 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On Right-Hand Side of Engine 335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On Right-Hand Side of Engine 345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On Front of Engine Fuel Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diaphragm Vacuum Pulse Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Float-Type Side Draft Carburetor Fuel Shut-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Fuel Line Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replaceable, In-line Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Translucent Fuel Tank

ELECTRICALIgnition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electronic Type of Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Shift Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Alternator Charging Capacity: 325/335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 amp Regulated 345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 amp Regulated Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BCI Group 51 Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC Electrolyte Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt) Battery Cold Cranking amps at -17.8 C (0 F) . . . . . . . . . . . . . . . . . . . . . . . . .500 amps Battery Reserve Capacity at 26.7 C (80 F) . . . . . . . . . . . . . . . . . . . . . . . . . 90 minutes

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5/27/99



Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Incandescent, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Halogen Bulbs, Optional) Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Pressure, Battery Charge Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345 only Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hourmeter Ignition Interlock Switches. . . . . . . . . . . .Neutral Start, Operator Presence, Brake Pedal

PTO DRIVEType. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Belt Clutch Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Mounted, Electric

POWER TRAINDrive Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Traction Drive . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic, Twin Touch Foot Control Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic, Piston Type Transmission Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kanzaki K70A Transmission Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 L (4.7 qts) Transmission Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Double V-Belt Transmission Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable Internal Cartridge Fan Blade Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 in. Diameter Axle Type/Wheel Hubs . . . . . . . . . . . . . . . . . . . . . . . Straight with Separate 5-Bolt Hubs Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward Travel, Lever on Dash Travel Speeds at Full rpm Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 011.2 km/h (07 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06.4 km/h (04 mph)

STEERINGType: 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual, Sealed Gearbox 335/345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power, Hydraulic, Front Wheels Tilt Wheel (All tractors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Position

BRAKESLocation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Wet Disk, Single Pedal Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Pedal Lock Lever

HYDRAULICSSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift (325) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift and Steering (335/345) Lift Control Valve Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical, Spool Valve Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Under Tunnel Cover Cutting Unit Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Cylinder Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Micron, Replaceable, In-Line

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IMPLEMENT LIFTLift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic with Depth Stop Lift Lever Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Right-Hand Side of Dash Cutting Heights (Independent of Lifts). . . . . . . . 12.7143.3 mm (6.35 mm increments) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5004.500 in. (0.250 in. increments)Note: Heights may only be set while lift is in raised position.

MOWER ATTACHMENTSCutting Unit Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt

WEIGHTS AND DIMENSIONSNet Weight (less attachments and fuel) 325/335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291.2 kg (642 lbs) 345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317.1 kg (699 lbs) Mower Deck Weight 38-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 kg (95 lbs) 44-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 kg (108 lbs) 48-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 kg (125 lbs) 54-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 kg (140 lbs) Wheel Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 m (47.9 in.) Tread Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.74 m (29 in.) Turning Radius (inside rear wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.64 m (25 in.) Overall Length (w/ 7 bushel rear bagger) . . . . . . . . . . . . . . . . . . . . . . 1.84 m (72.25 in.) Overall Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 m (43.6 in.) Overall Width (without attachments) . . . . . . . . . . . . . . . . . . . . 1.01.1 m (3941.5 in.) With 38-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33 m (52.60 in.) With 44-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 m (45.70 in.) With 48-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52 m (60 in.) With 54-Inch Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68 m (66 in.)

WHEELS AND TIRESFront . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 x 6.50-8.00, 2PR, Turf Inflation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6997 kPa (1015 psi) Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 x 10.50-12.00, Turf Inflation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5569 kPa (810 psi) Optional Tires: Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 x 6.50-8.00, 4PR, Turf Inflation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6997 kPa (1015 psi) Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 x 10.50-12.00, Bar Inflation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5569 kPa (810 psi)

(Specifications and design subject to change without notice.)

2-6

5/27/99



METRIC FASTENER TORQUE VALUES4.8 Property Class and Head Markings 8.8 9.8 10.9 12.9

4.8 4.8 5 5

8.8 8.8 10 10

9.8 9.8

10.910.9

12.9 12.9 12 1212

12.9

Property Class and Nut Markings

10 1010

5

10

TS1163

Class 4.8 Lubricated SIZE M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 Nm 4.8 12 23 40 63 100 135 190 260 330 490 675 900 1150a

Class 8.8 or 9.8 Drya

Class 10.9 Drya

Class 12.9 Drya

Lubricated lb-ft 4.5 11 21 37 60 92 125 180 250 310 450 625 850 1075 Nm 9 22 43 75 120 190 260 375 510 650 950 1300 1750 2250

a

Lubricated lb-ft 8.5 20 40 70 110 175 250 350 475 600 875 1200 1650 2100 Nm 13 32 63 110 175 275 375 530 725 925 1350 1850 2500 3200

a

Lubricateda lb-ft 12 30 60 105 165 225 350 500 675 850 1250 1700 2350 3000 Nm 15 37 75 130 205 320 440 625 850 1075 1600 2150 2900 3750 lb-ft 11.5 28 55 95 150 240 325 460 625 800 1150 1600 2150 2750

Drya Nm 19 47 95 165 260 400 560 800 1075 1350 2000 2700 3700 4750 lb-ft 14.5 35 70 120 190 300 410 580 800 1000 1500 2000 2750 3500

lb-ft 3.5 8.5 17 29 47 73 100 140 190 250 360 490 675 850

Nm 6 15 29 50 80 125 175 240 330 425 625 850 1150 1450

lb-ft 6.5 16 32 55 88 140 195 275 375 475 700 950 1300 1650

Nm 11 28 55 95 150 240 330 475 650 825 1200 1650 2200 2850

lb-ft 9.5 24 47 80 130 200 275 400 540 675 1000 1350 1850 2350

Nm 17 40 80 140 225 350 475 675 925 1150 1700 2300 3150 4050

DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only and include a 10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same class. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.Lubricated means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. Dry means plain or zinc plated (yellow dichromate - Specification JDS117) without any lubrication.Reference: JDSG200.a

5/27/99

2-7



INCH FASTENER TORQUE VALUESSAE Grade and Head Markings 1 or 2b No Marks 5 5.1 5.2 8 8.2

2 SAE Grade and Nut Markings No Marks

5

8

TS1162

Grade 1 Lubricateda SIZE 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 Nm 3.7 7.7 14 22 33 48 67 120 190 290 470 570 750 1000 lb-ft 2.8 5.5 10 16 25 36 50 87 140 210 300 425 550 725 Drya Nm 4.7 10 17 28 42 60 85 150 240 360 510 725 950 1250 lb-ft 3.5 7 13 20 31 45 62 110 175 270 375 530 700 925

Grade 2b Lubricateda Nm 6 12 22 35 53 75 105 190 190 290 470 570 750 990 lb-ft 4.5 9 16 26 39 56 78 140 140 210 300 425 550 725 Drya Nm 7.5 15 27 44 67 95 135 240 240 360 510 725 950 1250 lb-ft 5.5 11 20 32 50 70 100 175 175 270 375 530 700 930

Grade 5, 5.1 or 5.2 Lubricateda Nm 9.5 20 35 55 85 125 170 300 490 725 900 1300 1700 2250 lb-ft 7 15 26 41 63 90 125 225 360 540 675 950 1250 1650 Drya Nm 12 25 44 70 110 155 215 375 625 925 1150 1650 2150 2850 lb-ft 9 18 33 52 80 115 160 280 450 675 850 1200 1550 2100

Grade 8 or 8.2 Lubricateda Nm 13.5 28 50 80 120 175 215 425 700 1050 1450 2050 2700 3600 lb-ft 10 21 36 58 90 130 160 310 500 750 1075 1500 2000 2650 Drya Nm 17 35 63 100 150 225 300 550 875 1300 1850 2600 3400 4550 lb-ft 12.5 26 46 75 115 160 225 400 650 975 1350 1950 2550 3350

DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only and include a 10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same grade. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt head.

Tighten toothed or serrated-type lock nuts to the full torque value.Lubricated means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. Dry means plain or zinc plated (yellow dichromate - Specification JDS117) without any lubrication.a

Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm (6-in.) long. Grade 1 applies for hex cap screws over 152 mm (6-in.) long, and for all other types of bolts and screws of any length.Reference: JDSG200.

b

2-8

5/27/99



O-RING SEAL SERVICE RECOMMENDATIONS FACE SEAL FITTINGS WITH INCH STUD ENDS TORQUEStud End Tube Nut

Stud Straight and Tube Nut Locknut

Swivel Nut Tube Nut Stud End 90 Adjustable Stud Elbow 90 Swivel Elbow and Tube Nut

Bulkhead Union and Bulkhead LOCKNUT

Nominal Tube O.D./Hose I.D. Metric Tube O.D. mm Inch Tube O.D. Dash Size -3 6 8 10 12 16 22 25 32 38 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24

Face Seal Tube/Hose End Thread Size Tube Nut/ Swivel Nut Torque Nm lb-ft Bulkhead Locknut Torque Nm lb-ft

O-ring Stud Ends Thread Size in. 3/8-24 Straight Fitting or Locknut Torque Nm 8 12 16 24 46 62 102 122 142 190 217 lb-ft 6 9 12 18 34 46 75 90 105 140 160

in. 0.188 0.250 0.312 0.375 0.500 0.625 0.750 0.875 1.000 1.25 1.50

mm 4.76 6.35 7.94 9.52 12.70 15.88 19.05 22.22 25.40 31.75 38.10

in.

9/16-18 11/16-16 13/16-16 1-14 1-3/16-12 1-3/16-12 1-7/16-12 1-11/16-12 2-12

16 24 50 69 102 102 142 190 217

12 18 37 51 75 75 105 140 160

12 24 46 62 102 102 142 190 217

9 18 34 46 75 75 105 140 160

7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1-1/16-12 1-3/16-12 1-5/16-12 1-5/8-12 1-7/8-12

NOTE: Torque tolerance is + 15 minus 20%.

5/27/99

2-9



FACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUEStud End Tube Nut

Groove For Metric Identification Stud Straight and Tube Nut Groove For Metric Identification Bulkhead Union and Bulkhead LOCKNUT

Swivel Nut Locknut Tube Nut Stud End 90 Swivel Elbow and Tube Nut

90 Adjustable Stud Elbow

Nominal Tube O.D./Hose I.D. Metric Tube O.D. mm 6 8 10 12 16 22 25 28 32 38 -20 -24 1.25 1.50

Face Seal Tube/Hose End Tube Nut/ Bulkhead Swivel Locknut Nut Torque Torque

O-ring Stud Ends, Straight Fitting or Locknut Thread Size Steel or Aluminum Hex Gray Iron Torque Size Torque mm Nm lb-ft Nm lb-ft 17 19 22 24 27 32 36 41 46 50 55 158 176 190 217 116 130 140 160 71 79 85 98 52 58 63 72 21 33 41 50 69 102 15.5 24 30 37 51 75 9 15 18 21 28 46 6.6 11 13 15 21 34

Inch Tube O.D.

Thread Size

Hex Size

Dash Size -4 -5 -6 -8 -10 -12 -14 -16

in. 0.250 0.312 0.375

mm 6.35 7.94

in. 9/16-18

mm Nm lb-ft Nm lb-ft 17 16 12 12 9

mm M12X1.5 M14X1.5

9.52

11/16-16 13/16-16 1-14

22 24 30 36 36 41 50 60

24 50 69 102 102

18 37 51 75 75

24 46 62 102 102

18 34 46 75 75

M16X1.5 M18X1.5 M22X1.5 M27X2 M30X2 M33X2 M38X2 M42X2 M48X2

0.500 12.70 0.625 15.88

0.750 19.05 1-3/16-12 0.875 22.22 1-3/16-12 1.000 25.40 1-7/16-12 31.75 1-11/16-12 38.10 2-12

142 105 142 105 190 140 190 140 217 160 217 160

NOTE: Torque tolerance is + 15 minus 20%.

2-10

5/27/99


VEHICLE SPECIFICATIONS.

O-RING FACE SEAL FITTINGSSealing Surface

Special Nut

Special Washer

Angle Fitting

O-ring Sealing Surface

1. Inspect the fitting sealing surfaces. They must be free of dirt or defects. 2. Inspect the O-ring. It must be free of damage or defects. 3. Lubricate O-rings and install into groove using petroleum jelly to hold in place. 4. Push O-ring into the groove with plenty of petroleum jelly so O-ring is not displaced during assembly. 5. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 6. Tighten fitting or nut to torque value shown on the chart per dash size stamped on the fitting. Do not allow hoses to twist when tightening fittings.

3. For angle fittings, loosen special nut and push special washer against threads so O-ring can be installed into the groove of fitting. 4. Turn fitting into the boss by hand until special washer or washer face (straight fitting) contacts boss face and O-ring is squeezed into its seat. 5. To position angle fittings, turn the fitting counterclockwise a maximum of one turn. 6. Tighten straight fittings to torque value shown on chart. For angle fittings, tighten the special nut to value shown in the chart while holding body of fitting with a wrench. STRAIGHT FITTING OR SPECIAL NUT TORQUE Thread Size 3/8-24 UNF 7/16-20 UNF 1/2-20 UNF 9/16-18 UNF Torquea Nm 8 12 16 24 46 62 102 122 142 190 217 lb-ft (6) (9) (12) (18) (34) (46) (75) (90) (105) (140) (160) Number of Flatsb 2 2 2 2 2 1-1/2 1 1 3/4 3/4 1/2

O-RING BOSS FITTINGS1. Inspect boss O-ring boss seat. It must be free of dirt and defects. If repeated leaks occur, inspect for defects with a magnifying glass. Some raised defects can be removed with a slip stone.Groove

O-ring

3/4-16 UNF 7/8-14 UNF 1-1/16-12 UN 1-3/16-12 UN 1-5/16-12 UN 1-5/8-12 UN

2. Put hydraulic oil or petroleum jelly on the O-ring. Place electrical tape over the threads to protect Oring from nicks. Slide O-ring over the tape and into the groove of fitting. Remove tape.

1-7/8-12 UN

a. Torque tolerance is 10 percent. b. To be used if a torque wrench cannot be used. After tightening fitting by hand, put a mark on nut or boss; then tighten special nut or straight fitting the number of flats shown.

5/27/99

2-11

GASOLINE SPECIFICATIONS


GASOLINE SPECIFICATIONS 4CYCLE ENGINES NORTH AMERICA

c CAUTIONGasoline is HIGHLY FLAMMABLE, handle it with care. DO NOT refuel machine while: indoors, always fill gas tank outdoors; machine is near an open flame or sparks; engine is running, STOP engine; engine is hot, allow it to cool sufficiently first; smoking.

STOP ENGINE

NO HOT ENGINE

NO SMOKING

Help prevent fires: fill gas tank to bottom of filler neck only; NO STATIC ELECTRIC NO OPEN FLAME be sure fill cap is tight after fueling; DISCHARGE OR SPARK clean up any gas spills IMMEDIATELY; keep machine clean and in good repairfree of excess grease, oil, debris, and faulty or damaged parts; any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light. To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling: ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter. To avoid engine damage: DO NOT mix oil with gasoline; ONLY use clean, fresh unleaded gasoline with an octane rating (anti-knock index) of 87 or higher; fill gas tank at the end of each day's operation to help prevent condensation from forming inside a partially filled tank; keep up with specified service intervals. Use of alternative oxygenated, gasohol blended, unleaded gasoline is acceptable as long as: the ethyl or grain alcohol blends DO NOT exceed 10% by volume or methyl tertiary butyl ether (MTBE) blends DO NOT exceed 15% by volume.

c WARNINGCalifornia Proposition 65 Warning: Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

GASOLINE STORAGEIMPORTANT: Keep all dirt, scale, water or other foreign material out of gasoline. Keep gasoline stored in a safe, protected area. Storage of gasoline in a clean, properly marked (UNLEADED GASOLINE) POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. DO NOT use de-icers to attempt to remove water from gasoline or depend on fuel filters to remove water from gasoline. Use a water separator installed in the storage tank outlet. BE SURE to properly discard unstable or contaminated gasoline. When storing unit or gasoline, it is recommended that you add John Deere Gasoline Conditioner and Stabilizer (TY15977) or an equivalent to the gasoline. BE SURE to follow directions on container and to properly discard empty container.5/27/99

IMPORTANT: DO NOT use METHANOL gasolines because METHANOL is harmful to the environment and to your health.

2-12


GASOLINE SPECIFICATIONS

4CYCLE ENGINES EUROPE

c CAUTIONGasoline is HIGHLY FLAMMABLE, handle it with care. DO NOT refuel machine while: indoors, always fill gas tank outdoors; machine is near an open flame or sparks; engine is running, STOP engine; engine is hot, allow it to cool sufficiently first; smoking.

STOP ENGINE

NO HOT ENGINE

NO SMOKING

Help prevent fires: fill gas tank to bottom of filler neck only; NO STATIC ELECTRIC NO OPEN FLAME be sure fill cap is tight after fueling; DISCHARGE OR SPARK clean up any gas spills IMMEDIATELY; keep machine clean and in good repairfree of excess grease, oil, debris, and faulty or damaged parts; any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light. To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling: ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter.

To avoid engine damage: DO NOT mix oil with gasoline; ONLY use clean, fresh unleaded gasoline with an octane rating (anti-knock index) of 87 or higher; fill gas tank at the end of each day's operation to help prevent condensation from forming inside a partially filled tank; keep up with specified service intervals. Use of alternative oxygenated, gasohol blended, unleaded gasoline is acceptable as long as: the ethyl or grain alcohol blends DO NOT exceed 10% by volume or methyl tertiary butyl ether (MTBE) blends DO NOT exceed 15% by volume.

GASOLINE STORAGEIMPORTANT: Keep all dirt, scale, water or other foreign material out of gasoline. Keep gasoline stored in a safe, protected area. Storage of gasoline in a clean, properly marked (UNLEADED GASOLINE) POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. DO NOT use de-icers to attempt to remove water from gasoline or depend on fuel filters to remove water from gasoline. Use a water separator installed in the storage tank outlet. BE SURE to properly discard unstable or contaminated gasoline. When storing unit or gasoline, it is recommended that you add John Deere Gasoline Conditioner and Stabilizer (TY15977) or an equivalent to the gasoline. BE SURE to follow directions on container and to properly discard empty container.

IMPORTANT: DO NOT use METHANOL gasolines because METHANOL is harmful to the environment and to your health.

5/27/99

2-13

LUBRICANTS


LUBRICANTS 4CYCLE GASOLINE ENGINE OIL NORTH AMERICAUse the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure. The following John Deere oils are PREFERRED: PLUS4SAE 10W-40; TORQGARD SUPREMESAE 5W-30. The following John Deere oils are also recommended, based on their specified temperature range: 10W-30; PLUS4SAE 10W-30; TORQGARD SUPREMESAE 30. Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: SAE 10W-40API Service Classification SG or higher; SAE 5W-30API Service Classification SG or higher; SAE 10W-30API Service Classification SG or higher; SAE 30API Service Classification SC or higher. TURFGARDSAE

4CYCLE GASOLINE ENGINE OIL EUROPEUse the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure. The following John Deere oils are PREFERRED: TORQGARD SUPREMESAE 10W-40; UNIGARDSAE 10W-40; TORQGARD SUPREMESAE 5W-30; UNIGARDSAE 5W-30. The following John Deere oils are also recommended, based on their specified temperature range: TORQGARD SUPREMESAE 10W-30; UNIGARDSAE 10W-30; TORQGARD SUPREMESAE 30; UNIGARDSAE 30. Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: CCMC Specification G4 or higher.

SAE 10W-40

SAE 30

SAE 10W-40

SAE 30

SAE 5W-30

SAE 10W-30

PREFERREDAIR TEMPERATURE M58275


2-14

SAE 5W-30

5/27/99

SAE 10W-30


LUBRICANTS

BREAKIN ENGINE OILIMPORTANT: ONLY use a quality break-in oil in rebuilt or remanufactured engines for the first 5 hours (maximum) of operation. DO NOT use oils with heavier viscosity weights than SAE 5W-30 or oils meeting specifications API SG or SH, these oils will not allow rebuilt or remanufactured engines to break-in properly.BREAK-IN OIL

The following John Deere oil is PREFERRED: BREAKIN ENGINE OIL. John Deere BREAKIN ENGINE OIL is formulated with special additives for aluminum and cast iron type engines to allow the power cylinder components (pistons, rings, and liners as well) to wear-in while protecting other engine components, valve train and gears, from abnormal wear. Engine rebuild instructions should be followed closely to determine if special requirements are necessary.

PREFERRED John Deere BREAKIN ENGINE OIL is also recommended for non-John Deere engines, both aluminum and cast iron types. The following John Deere oil is also recommended as a break-in engine oil: TORQGARD SUPREMESAE 5W-30. If the above recommended John Deere oils are not available, use a break-in engine oil meeting the following specification during the first 5 hours (maximum) of operation: SAE 5W-30API Service Classification SE or higher. SAE 5W-30CCMC Specification G4 or higher. IMPORTANT: After the break-in period, use the John Deere oil that is recommended for this engine.AIR TEMPERATURE M58275

John Deere Dealers: You may want to cross-reference the following publications to recommend the proper oil for your customers: Module DX,ENOIL4 in JDSG135; Section 530, Lubricants & Hydraulics, of the John Deere Merchandise Sales Guide; Lubrication Sales Manual PI7032.

OIL FILTERSIMPORTANT: Filtration of oils is critical to proper lubrication performance. Always change filters regularly. The following John Deere oil filters are PREFERRED: AUTOMOTIVE AND LIGHT TRUCK ENGINE OIL FILTERS. Most John Deere filters contain pressure relief and anti-drainback valves for better engine protection. Other oil filters may be used if above recommended John Deere oil filters are not available, provided they meet the following specification: ASTB Tested In Accordance With SAE J806.

SAE 5W-30

5/27/99

2-15

LUBRICANTS


HYDROSTATIC TRANSMISSION AND HYDRAULIC OILIMPORTANT: ONLY use a quality SAE 10W-30 SYNTHETIC engine oil in this transmission. Mixing of two viscosity grade oils is NOT RECOMENDED. DO NOT use BIOHYGARD in this transmission. The following John Deere transmission and hydraulic oil is PREFERRED: John Deere Low Viscosity HY-GARD J20D. Other oils may be used if above recommended John Deere oils are not available. Use only oils that meet one of the following specifications: John Deere Standard JDM J20D; John Deere Standard JDM J20C. CCMC Specifications G4 or higher. Use the appropriate oil viscosity based on these air temperature ranges. Operating outside of these recommended oil air temperature ranges may cause premature hydrostatic transmission failure.

Deere Merchandise Sales Guide; Lubrication Sales Manual PI7032. Use only oils that meet the following specifications: API Service Classifications SG or higher.

ANTI-CORROSION GREASE SPECIFICATIONSThis anti-corrosion grease is formulated to provide the best protection against absorbing moisture, which is one of the major causes of corrosion. This grease is also superior in its resistance to separation and migration. The following anti-corrosion grease is PREFERRED: DuBois MPG-2 Multi-Purpose Polymer GreaseM79292. Other greases may be used if they meet or exceed the following specifications: John Deere Standard JDM J13A2, NLGI Grade 1.

JDM J20D

JDM J20C

JDM J13A2 NLGI Grade 1

AIR TEMPERATURE

M58275


John Deere Dealers: You may want to cross-reference the following publications to recommend the proper oil for your customers: Module DX,ENOIL2 in JDSG135; Section 530, Lubricants & Hydraulics, of the John

2-16

5/27/99


LUBRICANTS

ALTERNATIVE LUBRICANTSConditions in certain geographical areas outside the United States and Canada may require different lubricant recommendations than the ones printed in this technical manual or the operator's manual. Consult with your John Deere Dealer, or Sales Branch, to obtain the alternative lubricant recommendations. IMPORTANT: Use of alternative lubricants could cause reduced life of the component. If alternative lubricants are to be used, it is recommended that the factory fill be thoroughly removed before switching to any alternative lubricant.

CHASSIS GREASEUse the following grease based on the air temperature range. Operating outside of the recommended grease air temperature range may cause premature failures. IMPORTANT: ONLY use a quality grease in this application. DO NOT mix any other greases in this application. DO NOT use any BIOGREASE in this application. The following John Deere grease is PREFERRED: NON-CLAY HIGH-TEMPERATURE EP GREASEJDM J13E4, NLGI Grade 2. GREASEGARDJDM J13E4, NLGI Grade 2. Other greases may be used if above preferred John Deere grease is not available, provided they meet the following specification: John Deere Standard JDM J13E4, NLGI Grade 2.

SYNTHETIC LUBRICANTSSynthetic lubricants may be used in John Deere equipment if they meet the applicable performance requirements (industry classification and/or military specification) as shown in this manual. The recommended air temperature limits and service or lubricant change intervals should be maintained as shown in the operators manual. Avoid mixing different brands, grades, or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

LUBRICANT STORAGEAll machines operate at top efficiency only when clean lubricants are used. Use clean storage containers to handle all lubricants. Store them in an area protected from dust, moisture, and other contamination. Store drums on their sides. Make sure all containers are properly marked as to their contents. Dispose of all old, used containers and their contents properly.

MIXING OF LUBRICANTSIn general, avoid mixing different brands or types of lubricants. Manufacturers blend additives in their lubricants to meet certain specifications and performance requirements. Mixing different lubricants can interfere with the proper functioning of these additives and lubricant properties which will downgrade their intended specified performance.

JDM J13E4 NLGI Grade 2

AIR TEMPERATURE

M58275

John Deere Dealers: You may want to cross-reference the following publications to recommend the proper grease for your customers: Module DX,GREA1 in JDSG135; Section 530, Lubricants & Hydraulics, of the John Deere Merchandise Sales Guide; Lubrication Sales Manual P17032.

5/27/99

2-17

COOLANT SPECIFICATIONS


COOLANT SPECIFICATIONS GASOLINE ENGINE COOLANTThe engine cooling system when filled with a proper dilution mixture of anti-freeze and deionized or distilled water provides year-round protection against corrosion, cylinder or liner pitting, and winter freeze protection down to 37C (34F). ONLY use a quality Automobile and Light Duty Engine Service ethylene glycol base coolant, meeting the following specification: The following John Deere coolant is PREFERRED: PRE-DILUTED DIESEL ENGINE ANTI-FREEZE/ SUMMER COOLANT (TY16036). ASTM D3306 (JDM H24C1). This coolant satisfies specifications for Automobile and Light Duty Engine Service and is safe for use in John Deere Lawn and Grounds Care/Golf and Turf Division equipment, including aluminum block gasoline engines and cooling systems. The above preferred pre-diluted anti-freeze provides: adequate heat transfer corrosion-resistant chemicals for the cooling system compatibility with cooling system hose and seal material protection during extreme cold and extreme hot weather operations chemically pure water for better service life compliance with ASTM D4656 (JDM H24C2) specifications If above preferred pre-diluted coolant is not available, the following John Deere concentrate is recommended: DIESEL ENGINE ANTI-FREEZE/SUMMER COOLANT CONCENTRATE (TY16034).

high qualityclean, clear, potable water (low in chloride and hardnessTable 1) is generally acceptable. DO NOT use salt water. Deionized or distilled water is ideal to use. Coolant that is not mixed to these specified levels and water purity can cause excessive scale, sludge deposits, and increased corrosion potential.

Water QualityProperty Total Solids, Maximum Total Hardness, Max. Chloride (as Cl), Max. Sulfate (as SO4), Max. Requirements 340 ppm (20 grns/gal) 170 ppm (10 grns/gal) 40 ppm (2.5 grns/gal) 100 ppm (5.8 grns/gal)

Mix 50 percent anti-freeze concentrate with 50 percent distilled or deionized water. This mixture and the prediluted mixture (TY16036) will protect the cooling system down to -37C(-34F) and up to 108C (226F). Certain geographical areas may require lower air temperature protection. See the label on your antifreeze container or consult your John Deere dealer to obtain the latest information and recommendations.

GASOLINE ENGINE COOLANT DRAIN INTERVALWhen using John Deere Pre-Diluted (TY16036) Automobile and Light Duty Engine Service coolants, drain and flush the cooling system and refill with fresh coolant mixture every 36 months or 3,000 hours of operation, whichever comes first. When using John Deere Concentrate (TY16034) Automobile and Light Duty Engine Service coolants, drain and flush the cooling system and refill with fresh coolant mixture every 24 months or 2,000 hours of operation, whichever comes first. If above John Deere Automobile and Light Duty Engine Service coolants are not being used; drain, flush, and refill the cooling system according to instructions found on product container or in equipment operators manual or technical manual.

If either of above recommended engine coolants are available use any Automobile and Light Duty Engine Service ethylene glycol base coolant, meeting the following specification: ASTM D3306 (JDM H24C1). Read container label completely before using and follow instructions as stated. IMPORTANT: To prevent engine damage, DO NOT use pure anti-freeze or less than a 50% antifreeze mixture in the cooling system. DO NOT mix or add any additives/conditioners to the cooling system in Lawn and Grounds Care/Golf and Turf Division equipment. Water used to dilute engine coolant concentrate must be of

2-18

5/27/99


SERIAL NUMBER LOCATION

SERIAL NUMBER LOCATIONWhen ordering parts or submitting a warranty claim, it is IMPORTANT that the machine product identification number and component serial numbers are included. The location of the machine identification number and component serial numbers are shown.

CARBURETOR SERIAL NUMBER

MACHINE IDENTIFICATION NUMBER

325 (FH531V)

M82830

M82994

ENGINE SERIAL NUMBERM99822A

335 (FH601V)

325/335 (FH531V/FH601V)

M95470

345 (FD611V)

M53957

345 (FD611V)

M95471

5/27/99

2-19

SERIAL NUMBER LOCATION


HYDROSTATIC TRANSMISSION SERIAL NUMBER

M82993

2-20

5/27/99

KAWASKAI FH531V ENGINE

CONTENTS

CONTENTSPage

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TEST AND ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . 8 ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . 9 ENGINE TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 STARTING MOTOR TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . 14

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15THROTTLE CABLE CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CHOKE PLATE CHECK AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 GOVERNOR STATIC ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SLOW IDLE SPEED ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 FAST IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 VALVE CLEARANCE, CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 18 CYLINDER COMPRESSION PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CRANKCASE VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SPARK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SPARK PLUG GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24THROTTLE CONTROL LEVER AND CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ENGINE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 MUFFLER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 AIR CLEANER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CARBURETOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 CARBURETOR COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 CARBURETOR DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FUEL PUMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 BLOWER HOUSING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 30 FLYWHEEL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 BREATHER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ROCKER ARM REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 CYLINDER HEAD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33 CYLINDER HEAD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 ANALYZE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 RECONDITION VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 LAP VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6/16/99

3-1

CONTENTS CONTINUED

KAWASKAI FH531V ENGINE

CRANKCASE COVER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ANALYZE PISTON RING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ANALYZE PISTON WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ANALYZE CRANKSHAFT AND CONNECTING ROD WEAR . . . . . . . . . . . . . . . . . CAMSHAFT AND TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT OIL SEALS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER BLOCK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DEGLAZE CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESIZE CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL FILTER MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GOVERNOR INSPECTION AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . GOVERNOR SHAFT INSPECTION AND REPLACEMENT. . . . . . . . . . . . . . . . . . . STATOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARMATURE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NO-LOAD AMPERAGE DRAW AND RPM TEST . . . . . . . . . . . . . . . . . . . . . . . . . .

37 38 42 43 44 44 46 47 48 48 48 49 50 51 51 51 52 52 52 55

3-2

6/16/99

KAWASAKI FH531V ENGINE

SPECIFICATIONS

SPECIFICATIONSMake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere K Series, Air Cooled Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH531V Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Natural Horsepower (SAEJ1940) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.4 kW (18 hp) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494 cm3 (30 cu in.) Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 mm (2.68 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 mm (2.68 in.) Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3:1 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overhead Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . Dual Stage Paper Air Filter and Foam Precleaner Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame

TEST AND ADJUSTMENT SPECIFICATIONSSlow Idle (Governed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 75 rpm Throttle stop screw setting . . . . . . . . . . . . . . . . . . 100 rpm lower than governed setting Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3400 50 rpm Minimum Cylinder Compression Pressure . . . . . . . . . . . . . . . . . . . . . . 483 kPa (71 psi) Valve Clearance (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Valve Adjustment Screw Jam Nut Torque . . . . . . . . . . . . . . . . . . . . . . 9 Nm (79 lb-in.) Valve Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm (53 lb-in.) Minimum Exhaust Valve ACR Movement . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Minimum Crankcase Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 cm (10 in.) water Minimum Engine Oil Pressure: Fast Idle (3400 50 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 kPa (45 psi) Slow Idle (1550 75 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 kPa (35 psi) Fuel Pump Minimum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 kPa (0.90 psi) Fuel Pump Minimum Flow. . . . . . . . . . . . . . . . . . 65 ml/15 seconds (2.2 oz/15 seconds) Ignition Coil Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.250.35 mm (0.0100.014 in.) Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (177 lb-in.)

REPAIR SPECIFICATIONSEngine Oil Capacity Without Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L (1.6 U.S. qt) With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 L (1.8 U.S. qt) Engine Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 16 Nm (144 lb-in.) Breather Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.0400.080 in.) Valve Adjustment Screw Jam Nut Torque . . . . . . . . . . . . . . . . . . . . . . 9 Nm (79 lb-in.) Valve Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm (53 lb-in.) Flywheel Screen Minimum Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.059 in.) Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Nm (127 lb-ft) Rocker Arm Assembly Minimum Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.94 mm (0.509 in.) Maximum Bearing ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.07 mm (0.515 in.) Maximum Push Rod Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)5/28/99

3-3

REPAIR SPECIFICATIONS


Cylinder Head and Valves Cap Screw Torque in Sequence (Lubricated) Initial Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Nm (124 lb-in.) Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Nm (221 lb-in.) Cylinder Head Flatness (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Maximum Valve Guide ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.07 mm (0.278 in.) Valve Seating Surface. . . . . . . . . . . . . . . . . . . . . . . . . . 1.101.46 mm (0.0430.057 in.) Minimum Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.50 mm (1.476 in.) Minimum Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in.) Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) Valve Guide Installation Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 mm (0.370 in.) Finished Valve Guide ID. (Reamed) . . . . . . . . . . . . . . . 7.007.02 mm (0.2750.276 in.) Valve Seat and Face Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090.22 mm (0.0040.009 in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (230 lb-in.) Oil Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm (200 lb-in.) Piston Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (177 lb-in.) Maximum Ring Groove Side Clearance Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.17 mm (0.007 in.) Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Minimum Pin OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.98 mm (0.865 in.) Maximum Pin Bore OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.04 mm (0.868 in.) Piston OD Standard Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . 88.8388.86 mm (3.4883.498 in.) Oversize Piston 0.50 mm (0.020 in.) . . . . . . . . . . . 89.3389.36 mm (3.5173.518 in.) Cylinder Bore ID Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.9889.00 mm (3.5033.504 in.) Wear Limit (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.08 mm (3.507 in.) 0.50 mm (0.020 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.4889.50 mm (3.5233.527 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Maximum) 89.58 mm (3.527 in.) Connecting Rod Maximum Crankshaft Bearing ID Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.07 mm (1.617 in.) Undersized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.56 mm (1.597 in.) Maximum Piston Pin Bearing ID . . . . . . . . . . . . . . . . . . . . . . . . . 22.06 mm (0.868 in.) Piston Rings Minimum Ring Thickness (Top and Second Rings) . . . . . . . . . . . 1.94 mm (0.076 in.) Minimum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) Maximum Ring End Gap Compression Rings (Top and Second) . . . . . . . . . . . . . . . . . . . . . 0.90 mm (0.035 in.) Oil Ring Side Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 mm (0.051 in.) Camshaft Minimum End Journal OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.91 mm (0.823 in.) Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.10 mm (1.461 in.) Maximum Bearing ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.08 mm (0.830 in.) Reciprocating Balancer Support Shaft Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Nm (65 lb-in.) Link Rod Minimum Journal OD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.94 mm (2.281 in.) Maximum Small End ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.06 mm (0.475 in.) Maximum Large End ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.15 mm (2.289 in.)

3-4

5/28/99


SERVICE PARTS KITS

Balancer Weight Maximum Bearing ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.027 in.) Bushing Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.) Support Shaft Minimum Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.93 mm (1.021 in.) Crankshaft Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Minimum Main Bearing Journal OD . . . . . . . . . . . . . . . . . . . . . . 37.90 mm (1.492 in.) Minimum Connecting Rod Journal OD Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.93 mm (1.611 in.) Undersized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.43 mm (1.591 in.) Maximum Crankcase Cover Plain Bearing ID . . . . . . . . . . . . . . . . . 38.06 mm (1.498 in.) PTO Side Oil Seal Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.) Oil Pump Minimum Rotor Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.63 mm (0.497 in.) Maximum Rotor Shaft Bearing ID . . . . . . . . . . . . . . . . . . . . . . . . 12.76 mm (0.502 in.) Outer Rotor Minimum Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.92 mm (0.391 in.) Minimum OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.47 mm (1.596 in.) Outer Rotor Bearing Minimum Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 mm (0.401 in.) Maximum ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.77 mm (1.605 in.) Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . 19.00 mm (0.750 in.) Governor Governor Mounting Shaft Height. . . . . . . . . . . . . . . . 32.232.8 mm (1.2671.291 in.) Governor Lever Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Nm (69 lb-in.) Armature with Coil Resistance between primary lead and core . . . . . . . . . . . . . . . . . . . .0.480.72 ohms Resistance between plug cap and core . . . . . . . . . . . . . . . . . . . . . 10.916.3 Kohms Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) Starting Motor Maximum Amperage (No Load) . . . . . . . . . . . . . . . . . . . . . . . . 50 amps at 5000 rpm Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 mm (0.413 in.) Wire Connection to Solenoid Nut Torque . . . . . . . . . . . . . . . . . . . . 9.8 Nm (84 lb-in.)

SERVICE PARTS KITSThe following kits are available through your parts catalog: Carburetor Repair Kit Gasket Kit Carburetor Repair Kit Piston Ring Kit Oversized Pistons Oversized Piston Ring Kit Starting Motor Brush Kit Starting Motor Stopper Kit Oil Pump Kit

5/28/99

3-5

SPECIAL OR ESSENTIAL TOOLS


SPECIAL OR ESSENTIAL TOOLSNOTE: Order tools according to information given in the U.S. SERVICE-GARD Catalog or in the European Microfiche Tool Catalog (MTC).RECOMMENDED TOOLS Number JT05719 JDM59 JT05698 8741-F66 JT05703 JT05699 JT03344 JT03338 JT03017 JDG356 D-05351ST JDM70 JDG504 JT05712 Name Hand-Held Digital Tachometer Compression Gauge U-Tube Manometer Plug Barb Fitting Line Pressure Gauge Assembly 90 Elbow Fitting Hose Assembly Pressure Gauge Spark Tester Valve Spring Compressor Valve Guide Driver Tool Current Gun Use Used to check idle speed and starter performance. Used to check engine compression. Used to check engine crankcase vacuum. Used to connect U-tube manometer to engine for Crankcase Vacuum Test. Used to read engine oil pressure when performing Engine Oil Pressure Test. Used to connect pressure gauge to engine. Used to check fuel pump performance. Used to check overall condition of ignition system. Used to remove and install valve springs. Used to replace valve guide bushings. Used to check starting motor performance.

OTHER MATERIALSNumber M79292 Name MPG-2 Multipurpose Grease SCOTCH-BRITE Abrasive Sheets/Pads Valve Guide Cleaner Stanisol (or Kerosene) Prussian Blue Compound Lithium Base Grease Zinc Oxide/Wood Alcohol Mineral Spirits Valve Lap Compound T43512 / TY9473 / 242 TY15130 / 395 Thread Lock and Sealer (Medium Strength) LOCTITE Form-in-Place Gasket Pipe Sealant with TEFLON

Use Apply to engine crankshaft Clean cylinder head Clean valve guides Finish ream valve guides Check valve seat contact Pack oil seals Check block for cracks Clean armature Lap valves Apply to threads of throttle and choke plate screws Rocker arm cover mating surfaces Apply to threads of oil pressure switch

MPG-2 is a registered trademark of DuBois USA. LOCTITE is a registered trademark of the Loctite Corp. SCOTCH-BRITE is a registered trademark of the 3M Co. TEFLON is a registered trademark of DuPont

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5/28/99


COMPONENT LOCATION

COMPONENT LOCATION ENGINE COMPONENTSIgnition Modules Blower Housing Screen Blower Fan Flywheel Stator

Dipstick

Rocker Arm Cover

Oil Pressure Switch Oil Filter Crankcase

Spark Plug Throttle Control Panel Throttle and Choke Linkage Governor Linkage Drain PlugM95399

LEFT SIDE

Vacuum Hose Fuel Pump Air Cleaner Housing

Air Cleaner Cover

Carburetor Inlet Hose

Carburetor

Fuel Shutoff Starting Motor Voltage Regulator/RectifierM95400

Rocker Arm Cover Spark Plug

RIGHT SIDE

5/28/99

3-7

TROUBLESHOOTING


TROUBLESHOOTING ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHARTEngine surges, or has uneven or uncontrolled rpm. Exhaust smoke black or uses too much fuel. Engine will not stay running, runs rough, or irregularly. Excessive engine noise or vibration. 5/28/99 Engine cranks but will not start or starts hard. Lack of fuel in carburetor.

Engine stalls frequently.

Engine has low power.

Problem or Symptom

Engine has low oil pressure.

Exhaust smoke blue or has excessive oil consumption.

Engine will not crank.

Engine has no spark.

Check or SolutionSpark plug fouled, defective, or gap not correct. Incorrect spark plug. Defective ignition components. Starter worn. Cranking rpm too slow. Fuel filter or line restricted. Fuel pump weak, restricted, or leaking. Fuel stale, contains water, or wrong type. Fuel pump not operating. Air filter element(s) plugged, oil soaked, or restricted. Choke, throttle, or governor linkage misadjusted. Carburetor misadjusted. Carburetor worn, contaminated with debris or varnish. Passages plugged. Wrong jets. Carburetor, intake manifold, or cylinder head gaskets leaking or damaged. Low compression from worn piston, rings, cylinder, valves or warped head. Valve clearance incorrect. Burned or warped valves and seats. Defective springs.

3-8

Engine overheats.

Engin

jd 325_335_345 service manual

Documents

safety specifications

safety messages

safetyalert symbol

safety use care

warning safety signs

caution safety signs

damaged safety signs

battery electrolyte