John Deere Z645 Zero Turn Mowers Operator’s Manual Instant Download (PIN120001-) (Publication No.OMM168435)

1
JOHN DEERE AG TURF DIVISION
John Deere EZtrak OMM168435 F2
Original Instruction All information,
illustrations and specifications in this manual
are based on the latest information at the time
of publication. The right is reserved to make
changes at any time without notice. COPYRIGHT
2012 Deere Co. John Deere Ag Turf Division
All rights reserved Previous Editions COPYRIGHT
2009, 2010, 2011
2
Introduction
Table of Contents lntroduction....................
..................................................
.......................... 1 Product
ldentification....................................
.............................................
2 Safety LabeIs...................................
..................................................
........ 3 Safety ................................
..................................................
...................... 6 Machine CIeanout
..................................................
.................................
10 AssembIy.......................................
..................................................
........ 11 Operating - ControIs
..................................................
.............................. 13 Operating.......
..................................................
........................................
14 Service lntervaIs..............................
..................................................
...... 24 Service Lubrication.....................
..................................................
........... 25 Service Engine ....................
..................................................
.................. 26 Service Transmission
..................................................
........................... 33 Service
Mower.............................................
............................................
38 Service EIectricaI.............................
..................................................
...... 47 Service MisceIIaneous
..................................................
.......................... 48 TroubIeshooting
..................................................
.....................................
51 Storage........................................
..................................................
.......... 53 Specifications .....................
..................................................
................... 53 DecIaration of Conformity
..................................................
...................... 56 DecIaration of
Conformity .......................................
................................. 57 DecIaration
of Conformity ....................................
.................................... 59
lndex.............................................
..................................................
......... 61 Getting QuaIity Service
..................................................
......................... 62 Service
Record............................................
............................................ 64
Introduction Thank You for Purchasing a John
Deere Product We appreciate having you as a
customer and wish you many years of safe and
satisfied use of your machine.
Using Your Operator's Manual This manuaI is an
important part of your machine and shouId remain
with the machine when you seII it. Reading your
operators manuaI wiII heIp you and others avoid
personaI injury or damage to the machine.
lnformation given in this manuaI wiII provide the
operator with the safest and most effective use
of the machine. Knowing how to operate this
machine safeIy and correctIy wiII aIIow you to
train others who may operate this machine. lf you
have an attachment, use the safety and operating
information in the attachment operators manuaI
aIong with the machine operators manuaI to
operate the attachment safeIy and correctIy. This
manuaI and safety signs on your machine may aIso
be avaiIabIe in other Ianguages (see your
authorized deaIer to order). Sections in your
operators manuaI are pIaced in a specific order
to heIp you understand aII the safety messages
and Iearn the controIs so you can operate this
machine safeIy. You can aIso use this manuaI to
answer any specific operating or servicing
questions. A convenient index Iocated at the end
of this book wiII heIp you to find needed
information quickIy. The machine shown in this
manuaI may differ sIightIy from your machine, but
wiII be simiIar enough to heIp you understand our
instructions. RlGHT-HAND and LEFT-HAND sides are
determined by facing in the direction the machine
wiII traveI when going forward. When you see a
broken Iine (------), the item referred to is
hidden from view. Before deIivering this machine,
your deaIer performed a predeIivery inspection to
ensure best performance.
Machine Use This machine is designed soIeIy for
use in customary Iawn mowing and Iight grounds
care operations. Use in any other way is
considered as contrary to the intended use. This
machine is not intended for use in spraying
operations where hazardous substances may be
used. The manufacturer accepts no IiabiIity for
damage or injury resuIting from this misuse, and
these risks must be borne soIeIy by the user.
CompIiance with and strict adherence to the
conditions of operation, service and repair as
specified by the manufacturer aIso constitute
essentiaI eIements for the intended use. This
machine shouId be operated, serviced and repaired
onIy by persons famiIiar with aII its particuIar
characteristics and acquainted with the reIevant
safety ruIes (accident prevention). The accident
prevention reguIations, aII other generaIIy
recognized reguIations on safety and occupationaI
medicine and the road traffic reguIations must be
observed at aII times. Setting fueI deIivery
beyond pubIished factory specifications or
otherwise overpowering wiII resuIt in Ioss of
warranty protection for this machine. Any
arbitrary modifications carried out on this
machine wiII reIieve the manufacturer of aII
IiabiIity for any resuIting damage or
injury. Special Messages Your manuaI contains
speciaI messages to bring attention to potentiaI
safety concerns, machine damage as weII as
heIpfuI operating and servicing information.
PIease read aII the information carefuIIy to
avoid injury and machine damage.
lntroduction - 1
3
Product Identification
Product ldentification Number (A)
CAUTION Avoid injury! This symbol and text
highlight potential hazards or death to the
operator or bystanders that may occur if the
hazards or procedures are ignored.
Engine Serial Number On engine vaIve covers.
IMPORTANT Avoid damage! This text is used to
tell the operator of actions or conditions that
might result in damage to the machine.
Transaxle Serial Numbers S/N tag at rear of each
transaxIe housing. LEFT SlDE
RlGHT SlDE
Product Identification Record Identification
Numbers Zero Turn Mowers PlN (120001-) lf you
need to contact an Authorized Service Center for
information on servicing, aIways provide the
product modeI and identification numbers. You
wiII need to Iocate the modeI and seriaI number
for the machine, engine and transmission/transaxIe
of your machine and record the information in
the spaces provided beIow. DATE OF PURCHASE
DEALER NAME DEALER PHONE Product
Identification Number
A
MX48925
Product ldentification - 2
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5
Safety Labels
Safety Label Location
Safety Labels
B
A
G
C
D
E
F
MX45981 Picture Note Use label number listed in
table below to locate complete text of safety
label message following this illustration.
E- DANGER M146611 (Z645 only) F- DANGER
M118040 G- CAUTION M165708
Pictorial Safety Signs At severaI important
pIaces on this machine safety signs are affixed
intended to signify potentiaI danger. The hazard
is identified by a pictoriaI in a warning
triangIe. An adjacent pictoriaI provides
information how to avoid personaI injury.
Pictorial labels are required for certain parts
of the world. Your machine may not be equipped
with these labels. A- DANGER-POISON (On
Battery) B- WARNING/DANGER M162849 C- DANGER
M118041 D- DANGER M160860
These safety signs, their pIacement on the
machine and a brief expIanatory text are shown in
this Safety section.
6
Safety Labels
There can be additionaI safety information
contained on parts and components sourced from
suppIiers that is not reproduced in this
operators manuaI. WARNING M162849

• M162849
• Make sure that chiIdren stay cIear of mower at
  aII times when the engine is running.
• Stay a safe distance from the machine.

M162849
Avoid Injury From Rotating Blades - M118041

• This operators manuaI contains important
  information necessary for safe machine operation.
• CarefuIIy read operators manuaI before operating
  machine. Observe aII safety ruIes to avoid
  accidents.
• WARNING M162849
• M118041
• Do not put hands or feet under or into mower when
  engine is running.
• Do not operate mower without discharge chute or
  entire grass catcher in pIace.
• Avoid Injury From Rotating Blades and Thrown
  Objects
• - M118040
• M162849
• Keep safe distance from the machine as Iong as
  the engine is running.
• WARNING M162849

• M118040
• Do not put hands or feet under or into mower when
  engine is running.
• Do not operate mower without discharge chute or
  entire grass catcher in pIace.

• Before mowing, cIear area of objects that may be
  thrown by bIade.
• Stay cIear whiIe engine is running.

• M162849
• Do not drive where machine couId sIip or tip.
  Drive across sIopes, not up and down.

Avoid Injury From Loaded Spring

• Do not drive on sIope with more than a 10º
  incIine.
• DANGER M162849

7
Safety Labels
Avoid Injury From Getting Caught in Belts and
Blades - M160860
M160860
M146611

• Stay cIear of beIts.
• Do not operate mower without shieIds.

• Keep fingers and hands away from pinch point.

• Lock Iift pedaI before changing attachment.
• Read operators manuaI before changing attachment.

Prevent Equipment Fires
M165708

• CIean and inspect the entire machine.
• CarefuIIy read Operators ManuaI Machine CIeanout
  section for detaiIs.
• CE Certification and Specification Label - M160859

M160859 This IabeI on your machine indicates that
this modeI has been certified and is in
compIiance with European Directive 2006/42/EC
(98/37EEC) Standard.
8
Safety

• On muIti-bIaded machines, take care as rotating
  one bIade can cause other bIades to rotate.

• Safety
• Training
• Read the instructions carefuIIy. Be famiIiar with
  the controIs and the proper use of the equipment.

• Operation
• Do not operate the engine in a confined space
  where dangerous carbon monoxide fumes can coIIect.

• The residentiaI zero radius Iawn mower drives
  differentIy than a traditionaI riding mower.
  Learning to operate the controIs smoothIy and
  safeIy wiII take some time.

• Mow onIy in dayIight or in good artificiaI Iight.

• Before attempting to start the engine, disengage
  aII bIade attachment cIutches and shift into
  neutraI.

• Practice operating the residentiaI zero radius
  Iawn mower in a Iarge open area with the bIades
  off. Keep practicing untiI you feeI confident in
  your maneuvering and driving skiIIs.

• Do not use on sIopes of degrees more than
  recommended by the manufacturer.
• Remember there is no such thing as a safe sIope.
  TraveI on grass sIopes requires particuIar care.
  To guard against overturning
• do not stop or start suddenIy when going up or
  downhiII

• Never aIIow chiIdren or peopIe unfamiIiar with
  these instructions to use the Iawnmower. LocaI
  reguIations can restrict the age of the operator.
• OnIy aIIow responsibIe aduIts, who have practiced
  driving the residentiaI zero radius Iawn mower
  and are famiIiar with the instructions to operate
  the machine.
• Never mow whiIe peopIe, especiaIIy chiIdren, or
  pets are nearby.

• engage cIutch sIowIy, aIways keep machine in
  gear, especiaIIy when traveIing downhiII
• machine speeds shouId be kept Iow on sIopes and
  during tight turns

• stay aIert for humps and hoIIows and other hidden
  hazards
• never mow across the face of a sIope, unIess the
  machine is designed for this purpose.

• Keep in mind that the operator or user is
  responsibIe for accidents or hazards occurring to
  other peopIe or their property.
• Do not carry passengers.

• Use care when puIIing Ioads or using heavy
  equipment

• AII drivers shouId seek and obtain professionaI
  and practicaI instruction. Such instruction
  shouId emphasize

• use onIy approved drawbar hitch points

• the need for care and concentration when working
  with ride-on machines.
• controI of a ride-on machine sIiding on a sIope
  wiII not be regained by the appIication of the
  brake.

• Iimit Ioads to those you can safeIy controI

• do not turn sharpIy. Use care when reversing
• use counterweights or wheeI weights when
  suggested in the operators manuaI.

• The main reasons for Ioss of controI are
• insufficient wheeI grip

• Watch out for traffic when crossing or near
  roadways.
• Stop the bIades from rotating before crossing
  surfaces other than grass.

• being driven too fast
• inadequate braking

• Never direct discharge of materiaI toward
  bystanders nor aIIow anyone near the machine
  whiIe in operation.

• the type of machine is unsuitabIe for its task

• Never operate the machine with defective guards,
  or without safety protective devices in pIace.
• Do not change the engine governor settings or
  overspeed the engine. Operating the engine at
  excessive speed can increase the hazard of
  personaI injury.
• Before Ieaving the operators position

• Iack of awareness of the effect of ground
  conditions, especiaIIy sIopes
• incorrect hitching and Ioad distribution.

• Preparation
• WhiIe mowing, aIways wear substantiaI footwear
  and Iong trousers. Do not operate the equipment
  when barefoot or wearing open sandaIs.

• disengage the drive to any attachments and Iower
  them

• change into neutraI and Iock the parking brake
• stop the engine and remove the key.

• ThoroughIy inspect the area where the equipment
  is to be used and remove aII objects which can be
  thrown by the machine.

• WARNlNG-FueI is highIy fIammabIe.

• Disengage drive to attachments, stop the engine,
  disconnect the spark pIug wires and remove the
  ignition key

• store fueI in containers specificaIIy designed
  for this purpose.

• refueI outdoors onIy and do not smoke whiIe
  refueIing.

• before cIearing bIockages or uncIogging chute

• before checking, cIeaning, or working on the
  machine
• after striking a foreign object. lnspect the
  machine for damage and make repairs before
  restarting and operating the equipment
• if the machine starts to vibrate abnormaIIy
  (check immediateIy).

• add fueI before starting the engine. Never remove
  the cap of the fueI tank or add fueI whiIe the
  engine is running or when the engine is hot.

• if fueI is spiIIed, do not attempt to start the
  engine but move the machine away from the area of
  spiIIage and avoid creating any source of
  ignition untiI fueI vapors have dissipated.

• Disengage drive to attachments when transporting
  or not in use.

• repIace aII fueI tank and container caps secureIy.

• Stop the engine and disengage drive to
  attachment
• before refueIing

• RepIace fauIty siIencers.
• Before using, aIways visuaIIy inspect to see that
  the bIades, bIade boIts and cutter assembIy are
  not worn or damaged. RepIace worn or damaged
  bIades and boIts in sets to preserve baIance.

• before removing the grass catcher

9
Safety

• before making height adjustment unIess adjustment
  can be made from the operators position.
• Reduce the throttIe setting during run-out and,
  if the engine is provided with a shut-off vaIve,
  turn the fueI off at the concIusion of mowing.

• any components with stored energy, such as
  hydrauIic components or springs.
• ReIease hydrauIic pressure by Iowering attachment
  or cutting units to the ground or to a mechanicaI
  stop and move hydrauIic controI Ievers back and
  forth.
• Disconnect battery or remove spark pIug (for gas
  engines) before making any repairs. Disconnect
  the negative terminaI first and the positive
  Iast. Reconnect positive first and negative Iast.
• Use care when checking bIades. Wrap the bIades or
  wear gIoves, and use caution when servicing them.
  OnIy repIace bIades. Never straighten or weId
  them.
• Keep hands, feet, cIothing, jeweIry and Iong hair
  away from moving parts. lf possibIe, do not make
  adjustments with the engine running.

• Read, understand and foIIow aII instructions in
  the manuaI and on the machine before starting.

• lnspect machine before you operate. Repair or
  repIace damaged, badIy worn, or missing parts.
  Make any necessary adjustments before you operate.

• Be sure aII drives are in neutraI and parking
  brake is Iocked before starting engine. OnIy
  start engine from the operators position.
• Do not operate mower without discharge chute or
  entire grass catcher in pIace. Never operate with
  the discharge defIector raised, removed, or
  aItered, unIess using a grass catcher.
• Check brake action before you operate. Adjust or
  service brakes as necessary.
• Stop machine if anyone enters the area.

• Charge batteries in an open weII ventiIated area,
  away from spark and fIames. UnpIug charger before
  connecting or disconnecting from battery. Wear
  protective cIothing and use insuIated tooIs.

• Checking Mowing Area
• CIear mowing area of objects that might be
  thrown. Keep peopIe and pets out of mowing area.

• Do not Ieave machine unattended when it is
  running.

• Use care when approaching bIind corners, shrubs,
  trees, or other objects that may obscure vision.

• Low-hanging branches and simiIar obstacIes can
  injure the operator or interfere with

• Use onIy accessories and attachments approved by
  the manufacturer of the machine. Keep safety
  IabeIs visibIe when instaIIing accessories and
  attachments.
• Do not operate machine if you are under the
  infIuence of drugs or aIcohoI.
• Data indicates operators 60 years and above are
  invoIved in a Iarge percentage of riding
  mower-reIated injuries. These operators shouId
  evaIuate their abiIity to operate the riding
  mower safeIy enough to protect themseIves and
  others from serious injury.

mowing operation. Before mowing, identify
potentiaI obstacIes such as Iow-hanging branches,
and trim or remove those obstacIes.

• Study mowing area. Set up a safe mowing pattern.
  Do not mow where traction or stabiIity is
  doubtfuI.
• Test drive area with mower Iowered but not
  running. SIow down when you traveI over rough
  ground.

• Parking Safely
• Stop machine on a IeveI surface, not on a sIope.
• Disengage mower bIades.

• Do not wear radio or music headphones. Safe
  service and operation requires your fuII
  attention.
• Use extra care when Ioading or unIoading the
  machine into a traiIer or truck.

3. Move motion controI Ievers out to the
Start/Shutdown position.

1. Lock the park brake.
2. Stop the engine.

• Maintenance and Storage
• Keep aII nuts, boIts and screws tight to be sure
  the equipment is in safe working condition.
• Never store the equipment with fueI in the tank
  inside a buiIding where fumes can reach an open
  fIame or spark.

1. Remove the key.
2. Wait for engine and aII moving parts to stop
   before you Ieave the operators seat.

• AIIow the engine to cooI before storing in any
  encIosure.
• To reduce the fire hazard, keep the engine,
  siIencer, battery compartment and fueI storage
  area free of grass, Ieaves, or excessive grease.
• Check the grass catcher frequentIy for wear or
  deterioration.

8. Disconnect the negative battery cabIe or
remove the spark pIug wire (for gasoIine engines)
before servicing the machine.
Rotating Blades are Dangerous HELP PREVENT
SERIOUS OR FATAL ACCIDENTS

• RepIace worn or damaged parts for safety.

• lf the fueI tank has to be drained, this shouId
  be done outdoors.
• On muIti-bIaded machines, take care as rotating
  one bIade can cause other bIades to rotate.
• When machine is to be parked, stored or Ieft
  unattended, Iower the cutting means unIess a
  positive mechanicaI Iock in used.

• Rotating bIades can cut off arms and Iegs, and
  throw objects. FaiIure to observe safety
  instructions couId resuIt in serious injury or

death.

• Keep hands, feet and cIothing away from mower
  deck when engine is running.

• Be aIert at aII times, drive forward and in
  reverse carefuIIy. PeopIe, especiaIIy chiIdren
  can move quickIy into the mowing area before you
  know it.

• Use jack stands or Iock service Iatches to
  support components when required. SecureIy
  support any machine eIements that must be raised
  for service work.

• Before backing up, stop mower bIades or
  attachments and Iook down and behind the machine
  carefuIIy, especiaIIy for chiIdren.

• Before servicing machine or attachment, carefuIIy
  reIease pressure from

10
Safety

• Do not mow in reverse.
• Shut off bIades when you are not mowing.

• a sIope.
• Do not mow or operate machine on wet grass. Tires
  may Iose traction. Tires may Iose traction on
  sIopes even though the brakes are functioning
  properIy.

• Park machine safeIy before Ieaving the operators
  station for any reason incIuding emptying the
  grasscatchers or unpIugging the chute.
• The mower bIades shouId stop in approximateIy
  five seconds when the mower is disengaged. lf you
  beIieve that your bIades may not be stopping in
  that period of time, take your machine to your
  authorized deaIer where they can safeIy check and
  service your machine.

• Avoid starting, stopping or turning on a sIope.
  lf the tires Iose traction, disengage the bIades
  and proceed sIowIy, straight down the sIope.

• Keep aII movement on sIopes sIow and graduaI. Do
  not make sudden changes in speed or direction,
  which couId cause the machine to roII over.
• Use extra care whiIe operating machine with
  grasscatchers or other attachments, they can
  affect stabiIity of the machine. Do not use on
  steep sIopes.
• Do not mow near drop-offs, ditches, embankments,
  or bodies of water. The machine couId suddenIy
  roII over if a wheeI goes over the edge or the
  edge caves in.
• Leave at Ieast the width of the machine as a
  safety area between the machine and any safety
  hazard. Mow those areas with a hand-heId trimmer
  or waIk-behind mower.
• FoIIow the manufacturers recommendations for
  wheeI weights or counterweights for added
  stabiIity when operating on sIopes or using front
  or rear mounted attachments. Remove weights when
  not required.
• Drive machine sIowIy and avoid quick stops if
  attachment has been removed for servicing mower
  or machine.

• Protect Children
• Death or serious injury can occur when young
  chiIdren associate having fun with a Iawn mowing
  machine simpIy because someone has given them a
  ride on a machine.

• ChiIdren are attracted to Iawn mowing machines
  and mowing activities. They dont understand the
  dangers of rotating bIades or the fact that the
  operator is unaware of their presence.
• ChiIdren who have been given rides in the past
  may suddenIy appear in the mowing area for
  another ride and be run over or backed over by
  the machine.

• Tragic accidents with chiIdren can occur if the
  operator is not aIert to the presence of
  chiIdren, especiaIIy when a chiId approaches a
  machine from behind. Before and whiIe backing up,
  stop mower bIades and Iook down and behind the
  machine carefuIIy, especiaIIy for chiIdren.

• Keep Riders Off
• OnIy aIIow the operator on the machine. Keep
  riders off.
• Riders on the machine or attachment may be struck
  by foreign objects or thrown off the

• Never carry chiIdren on a machine or attachment,
  even with the bIades off. Do not tow chiIdren in
  a cart or traiIer. They can faII off and be
  seriousIy injured or interfere with safe machine
  operation.

• machine causing serious injury.
• Riders obstruct the operators view resuIting in
  the machine being operated in an unsafe manner.

• Never use the machine as a recreationaI vehicIe
  or to entertain chiIdren.

• Never aIIow chiIdren or an untrained person
  operate the machine. lnstruct aII operators not
  to give chiIdren a ride on the machine or in an
  attachment.

• Towing Loads Safely
• Stopping distance increases with speed and weight
  of towed Ioad. TraveI sIowIy and aIIow extra time
  and distance to stop.

• Keep chiIdren indoors, out of the mowing area,
  and in the watchfuI eye of a responsibIe aduIt,
  other than the operator, when a mower is being
  operated.

• Stay aIert to the presence of chiIdren. Never
  assume that chiIdren wiII remain where you Iast
  saw them. Turn the machine off if a chiId enters
  the work area.

• TotaI towed weight must not exceed combined
  weight of puIIing machine, baIIast and operator.
  Use counterweights or wheeI weights as described
  in the attachment or puIIing machine operators
  manuaI.
• Excessive towed Ioad can cause Ioss of traction
  and Ioss of controI on sIopes. Reduce towed
  weight when operating on sIopes.

• Use extreme care when approaching bIind corners,
  shrubs, trees, or other objects that may bIock
  your view of a chiId.

• Never aIIow chiIdren or others in or on towed
  equipment.
• Use onIy approved hitches. Tow onIy with a
  machine that has a hitch designed for towing. Do
  not attach towed equipment except at the approved
  hitch point.
• FoIIow the manufacturers recommendations for
  weight Iimits for towed equipment and towing on
  sIopes.

• Avoid Tipping
• SIopes are a major factor reIated to
  Ioss-of-controI and tip-over accidents, which can
  resuIt in severe injury or death. Operation on
  aII sIopes requires extra caution.
• Mow across sIopes, not up and down.

• Never mow on any sIope that is more than 10
  degrees, or a sIope that rises more than 3-1/2
  feet within a distance of 20 feet of distance.
• Make a safe choice when operating on sIopes. lf
  you feeI uncomfortabIe on a hiIIside, or if you
  feeI the front of the machine start to creep down
  the sIope, stop mowing immediateIy and proceed
  sIowIy and safeIy down the sIope.

• lf you cannot back up a sIope with a towed Ioad,
  the sIope is too steep to operate on with the
  towed Ioad. Reduce the towed Ioad or do not
  operate.

• Do not turn sharpIy. Use additionaI caution when
  turning or operating under adverse surface
  conditions. Use care when reversing.
• Do not shift to neutraI and coast downhiII.

• lf steering direction cannot be maintained with
  sIight steering corrections, the sIope is too
  steep to mow.
• Watch for hoIes, ruts, bumps, rocks, or other
  hidden objects. Uneven terrain couId overturn the
  machine. TaII grass can hide obstacIes.
• Choose a Iow ground speed so you wiII not have to
  stop or shift whiIe on

11
Safety

• Wear Appropriate Clothing
• AIways wear eye protection when operating the
  machine.

• UnpIug battery charger before connecting or
  disconnecting from the battery. Wear protective
  cIothing and use insuIated tooIs.
• Do not strike the fIywheeI with a hammer or hard
  object because the fIywheeI may Iater shatter
  during operation.

• Wear cIose fitting cIothing and safety equipment
  appropriate for the job.

• lf equipped with hydrauIic Iift - reIease
  hydrauIic pressure by Iowering attachment or
  cutting units to the ground or to a mechanicaI
  stop and move hydrauIic controI Ievers back and
  forth.

• WhiIe operating this machine, aIways wear
  substantiaI footwear and Iong trousers. Do not
  operate the equipment when barefoot or wearing
  open sandaIs.

• Avoid High Pressure Fluids
• HydrauIic hoses and Iines can faiI due to
  physicaI damage, kinks, age, and exposure. Check
  hoses and Iines reguIarIy. RepIace damaged hoses
  and Iines.

• Wear a suitabIe protective device such as
  earpIugs. Loud noise can cause impairment or Ioss
  of hearing.

• Practice Safe Maintenance
• OnIy quaIified, trained aduIts shouId service
  this machine. Understand service procedure before
  doing work.

• HydrauIic fIuid connections can Ioosen due to
  physicaI damage and vibration. Check connections
  reguIarIy. Tighten Ioose connections.

• Escaping fIuid under pressure can penetrate the
  skin causing serious injury. Avoid the hazard by
  reIieving pressure before disconnecting hydrauIic
  or other Iines. Tighten aII connections before
  appIying pressure.
• Search for Ieaks with a piece of cardboard.
  Protect hands and body from high pressure fIuids.
• lf an accident occurs, see a doctor immediateIy.
  Any fIuid injected into the skin must be
  surgicaIIy removed within a few hours or gangrene
  may resuIt. Doctors unfamiIiar with this type of
  injury shouId reference a knowIedgeabIe medicaI
  source. Such information is avaiIabIe from Deere
  Company MedicaI Department in MoIine, lIIinois,
  U.S.A. lnformation may be obtained in the United
  States and Canada onIy by caIIing 1-800-822- 8262.

• Never operate machine in a cIosed area

• where dangerous carbon monoxide fumes can
  coIIect.
• Keep aII nuts and boIts tight, especiaIIy bIade
  attachment boIts, to be sure the equipment is in
  safe working condition.

• Never tamper with safety devices. Check their
  proper operation reguIarIy.
• Keep machine free of grass, Ieaves or other
  debris buiId-up. CIean up oiI or fueI spiIIage
  and remove any fueI-soaked debris. AIIow the
  machine to cooI before storing.
• lf you strike a foreign object, stop and inspect
  the machine. Repair, if necessary, before
  restarting.
• Never make any adjustments or repairs with the
  engine running. Wait for aII movement to stop on
  machine before adjusting, cIeaning or repairing.

• Prevent Fires
• Besides routine maintenance, one of the best ways
  to keep your John Deere equipment running
  efficientIy and to reduce fire risk is to
  reguIarIy remove debris buiIdup from the machine.
• PIease review these recommendations with aII
  operators. See your John Deere deaIer with

• Check grasscatcher components and the discharge
  guard frequentIy and repIace with manufacturers
  recommended parts, when necessary. Grasscatcher
  components are subject to wear, damage, and
  deterioration which couId expose moving parts or
  aIIow objects to be thrown.
• Mower bIades are sharp. Wrap the bIade or wear
  gIoves, and use extra care when servicing them.
  OnIy repIace bIades. Never straighten or weId
  them.

• questions.
• AIways foIIow aII safety procedures posted on the
  machine and in this operator manuaI. Before
  carrying out any inspection or cIeaning, aIways
  shut off engine, set parking brake and remove
  ignition key.
• After operating, aIIow machine to cooI in an open
  area before cIeaning or storing. Do not park
  machine near fIammabIe materiaIs such as wood,
  cIoth or chemicaIs.
• Empty any grasscatcher bags or containers
  compIeteIy before storing.

• Check brake operation frequentIy. Adjust and
  service as required.

• Maintain or repIace safety and instruction
  IabeIs, as necessary.

• On muIti-bIaded machines, take care as rotating
  one bIade can cause other bIades to rotate.

• Keep hands, feet, cIothing, jeweIry, and Iong
  hair away from any moving parts, to prevent them
  from getting caught.
• Lower any attachments to the ground before
  cIeaning or servicing machine. Disengage aII
  power and stop the engine. Lock park brake and
  remove the key. Let machine cooI.
• SecureIy support any machine eIements that must
  be raised for service work. Use jack stands or
  Iock service Iatches to support components when
  needed.
• Disconnect battery or remove spark pIug wire (for
  gasoIine engines) before making any repairs.
  Disconnect negative terminaI first and positive
  Iast. lnstaII positive terminaI first and
  negative Iast.

• Frequency of these inspections and cIeaning wiII
  vary depending on a number of factors incIuding
  operating conditions, machine configuration,
  operating speeds and weather conditions
  particuIarIy dry, hot and windy conditions. When
  you are operating in these conditions, inspect
  and cIean these areas frequentIy throughout the
  day.
• Wind direction, terrain type and moisture content
  of surrounding vegetation can effect where and
  how much debris accumuIates.

• Debris can accumuIate anywhere on the machine,
  especiaIIy on horizontaI surfaces.

• Before servicing machine or attachment, carefuIIy
  reIease pressure from any components with stored
  energy, such as hydrauIic components or springs.
• Keep aII parts in good condition and properIy
  instaIIed. Fix damage immediateIy. RepIace worn
  or broken parts.

• Keeping engine area cIean wiII provide the
  greatest impact on fire prevention. Other areas
  requiring reguIar inspection and cIeaning incIude
  behind wheeI rims, wire harness, hose/Iine
  routings, mowing attachments, etc. Compressed
  air, Ieaf bIowers or high pressured water can
  assist keeping these areas cIean.

• Charge batteries in an open, weII-ventiIated
  area, away from sparks.

12
Machine Cleanout

• eIectric discharge can ignite fueI vapors in an
  ungrounded fueI container.
• Never fiII containers inside a vehicIe or on a
  truck or traiIer bed with a pIastic Iiner. AIways
  pIace containers on the ground away from your
  vehicIe before fueIing.

• Excess Iubrication or fueI/oiI Ieaks or spiIIs on
  the machine can aIso serve as coIIection sites
  for debris. Prompt machine repair and oiI/fueI
  cIeanup wiII minimize the potentiaI for debris
  coIIection and reduced cooIing throughout machine
  Iife.

• Bearing faiIures or overheating can resuIt in a
  fire. To reduce this risk, aIways foIIow the
  instructions in the machine operators manuaI
  regarding Iubrication intervaIs and Iocations.
  Washing the machine whiIe warm may aIso reduce
  bearing Iife and increase potentiaI for premature
  bearing faiIure.
• AIways shut off fueI when storing or transporting
  machine, if the machine has a fueI shutoff.

• Remove fueI-powered equipment from the truck or
  traiIer and refueI it on the ground. lf this is
  not possibIe, then refueI such equipment with a
• portabIe container, rather than from a fueI
  dispenser nozzIe.

• Keep the nozzIe in contact with the rim of the
  fueI tank or container opening at aII times untiI
  the fueIing is compIete. Do not use a nozzIe
  Iock- open device.

• Never overfiII fueI tank. RepIace fueI tank cap
  and tighten secureIy.
• RepIace aII fueI container caps secureIy after
  use.

• Tire Safety
• ExpIosive separation of a tire and rim parts can
  cause serious injury or death
• Do not attempt to mount a tire without the proper
  equipment and experience to perform the job.

• For gasoIine engines, do not use gas with
  methanoI. MethanoI is harmfuI to your heaIth and
  to the environment.

Handling Waste Product and Chemicals Waste
products, such as, used oiI, fueI, cooIant, brake
fIuid, and batteries, can harm the environment
and peopIe

• AIways maintain the correct tire pressure. Do not
  infIate the tires above the recommended pressure.
  Never weId or heat a wheeI and tire assembIy. The
  heat can cause an increase in air pressure
  resuIting in a tire expIosion. WeIding can
  structuraIIy weaken or deform the wheeI.

• Do not use beverage containers for waste fIuids -
  someone may drink from them.

• See your IocaI RecycIing Center or authorized
  deaIer to Iearn how to recycIe or get rid of
  waste products.

• When infIating tires, use a cIip-on chuck and
  extension hose Iong enough to aIIow you to stand
  to one side and NOT in front of or over the tire
  assembIy.
• Check tires for Iow pressure, cuts, bubbIes,
  damaged rims or missing Iug boIts and nuts.

• See your IocaI RecycIing Center or authorized
  deaIer to Iearn how to put your machine out of
  service at the end of the machines service Iife.

• Machine Cleanout
• Prevent Fires
• Besides routine maintenance, one of the best ways
  to keep your John Deere equipment running
  efficientIy and to reduce fire risk is to
  reguIarIy remove debris buiIdup from the machine.
• PIease review these recommendations with aII
  operators. See your John Deere deaIer with
  questions.

• Checking Wheel Hardware
• A serious accident couId occur causing serious
  injury if wheeI hardware is not tight.
• Check wheeI hardware tightness often during the
  first 100 hours of operation.
• WheeI hardware must be tightened to specified
  torque using the proper procedure anytime it is
  Ioosened.

Handling Fuel Safely

• AIways foIIow aII safety procedures posted on the
  machine and in this operator manuaI. Before
  carrying out any inspection or cIeaning, aIways
  shut off engine, set parking brake and remove
  ignition key.
• After operating, aIIow machine to cooI in an open
  area before cIeaning or storing. Do not park
  machine near fIammabIe materiaIs such as wood,
  cIoth or chemicaIs.
• Empty any grasscatcher bags or containers
  compIeteIy before storing.

To avoid personal injury or property damage, use
extreme care in handling fuel. Fuel is extremely
flammable and fuel vapors are explosive

• Extinguish aII cigarettes, cigars, pipes, and
  other sources of ignition.
• Use onIy approved non-metaI, portabIe fueI
  containers. lf using a funneI, make sure it is
  pIastic and has no screen or fiIter.
• Never remove the fueI tank cap or add fueI with
  the engine running. AIIow engine to cooI before
  refueIing.

• Frequency of these inspections and cIeaning wiII
  vary depending on a number of factors incIuding
  operating conditions, machine configuration,
  operating speeds and weather conditions
  particuIarIy dry, hot and windy conditions. When
  you are operating in these conditions, inspect
  and cIean these areas frequentIy throughout the
  day.

• Wind direction, terrain type and moisture content
  of surrounding vegetation can effect where and
  how much debris accumuIates.

• Never add fueI to or drain fueI from the machine
  indoors. Move machine outdoors and provide
  adequate ventiIation.

• Debris can accumuIate anywhere on the machine,
  especiaIIy on horizontaI surfaces.
• Keeping engine area cIean wiII provide the
  greatest impact on fire prevention. Other areas
  requiring reguIar inspection and cIeaning incIude
  behind wheeI rims, wire harness, hose/Iine
  routings, mowing attachments, etc. Compressed
  air, Ieaf bIowers or high pressured water can
  assist keeping these areas cIean.

• CIean up spiIIed fueI immediateIy. lf fueI is
  spiIIed on cIothing, change cIothing immediateIy.
  lf fueI is spiIIed near machine, do not attempt
  to start the engine but move the machine away
  from the area of spiIIage. Avoid creating any
  source of ignition untiI fueI vapors have
  dissipated.
• Never store the machine or fueI container where
  there is an open fIame, spark. or piIot Iight
  such as on a water heater or other appIiance.

• Primary areas that must be inspected and cIeaned
  on the machine
• Prevent fire and expIosion caused by static
  eIectric discharge. Static
• Machine CIeanout - 10

13
Assembly
incIude (See Safety LabeI Section) a.Exhaust
manifoId, muffIer pipe, muffIer and muffIer
shieId.
H G
B A B
MX50272
b.Engine intake screens (A), cooIing fins (B) and
oiI cooIer.
D C

• MX49285
• e.Under the seat and near fuse bIock (G),
  incIuding the battery (H) and wiring harness.
• Excess Iubrication or fueI/oiI Ieaks or spiIIs on
  the machine can aIso serve as coIIection sites
  for debris. Prompt machine repair and oiI/fueI
  cIeanup wiII minimize the potentiaI for debris
  coIIection and reduced cooIing throughout machine
  Iife.

• Bearing faiIures or overheating can resuIt in a
  fire. To reduce this risk, aIways foIIow the
  instructions in the machine operators manuaI
  regarding Iubrication intervaIs and Iocations.
  Washing the machine whiIe warm may aIso reduce
  bearing Iife and increase potentiaI for premature
  bearing faiIure.
• AIways shut off fueI when storing or transporting
  machine, if the machine has a fueI shutoff.

MX48862 c.Top of mower deck, under shieIds (C),
incIuding spindIe and beIt area (D).
F E
Assembly Charge and Connect Battery

• CAUTION Avoid injury! The battery produces a
  flammable and explosive gas. The battery may
  explode
• Do not smoke or have open flame near battery.
• Wear eye protection and gloves.
• Never check battery charge by placing a metal
  object across the posts. Use a voltmeter or
  hydrometer.
• Do not jump start or charge a frozen battery.
  Warm battery to 16C (60F).

MX50275
d.On or near transaxIes (E) and beIt drives and
fins (F).

• Remove and discard the red positive ()
  protective cap from the positive () battery
  terminaI.
• Charge the battery.
• Battery is fuIIy charged at 12.6 voIts.
• Connect positive () battery cabIe to battery.
• Connect negative () battery cabIe.

14
Assembly

• AppIy generaI purpose grease or siIicone spray to
  terminaI to heIp prevent corrosion.
• SIide red cover over positive battery cabIe.
• Install Seat
• Z645 Models

B A C
MX45961 1. Remove rear boIt (A) and discard
pIastic washer from each side of seat bracket (B).

• Loosen front boIt (C) on each side of seat
  bracket.
• Lift seat back to operating position and insert
  boIts removed earIier into hoIes (D) on each side
  of seat.
• Tighten four boIts to 24 Nm (18 Ib-ft).
• Check Tire Pressure
• Check tire pressure. (See Checking Tire Pressure
  in the SERVlCE MlSCELLANEOUS section.)
• Adjust Mower Deck Level (42 and 48)
• Adjust mower deck IeveI. (See Adjusting Mower
  Deck LeveI in the OPERATlNG section.)
• Check Engine Oil Level
• Check engine oiI IeveI. (See Checking Engine OiI
  LeveI in the SERVlCE ENGlNE section.)
• Check Machine Safety System
• Perform safety system check to make sure the
  eIectronic safety interIock circuit is
  functioning properIy. Perform aII tests. (See
  Testing Safety System in the OPERATlNG section.)

15
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Operating - Controls
Operator Station Controls
Operating - Controls
F C A B E D L M K J N F C A B E D L M K J N F C A B E D L M K J N F C A B E D L M K J N G H I
MX48859, MX41661
Key Description Key Description
A Left Motion ControI Lever H Right Motion ControI Lever
B HeadIight (lf equipped) Left avaiIabIe for Z225, Left and Right l FueI Tank Cap
avaiIabIe for Z425, Z645.
C Park Brake Lever (Z225 styIe shown) J lgnition Key Switch
D Seat Adjustment Lever K HeadIight Switch (lf equipped)
E Deck Height Pin L Hourmeter
F Mower Deck Lift Lever M Mower Engagement Switch
G Mower Deck Lift PedaI N ThrottIe/Choke ControI Lever
(Z645 with 48 in. High Capacity deck onIy)
Operating - ControIs - 13
17
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