Service Electrical
Battery Warning
WARNING: Battery posts, terminals and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
Service the Battery Safely
Service and repair manual CD NEW. Service & Maintenance. Fully printable. Just print section you need or just use it on your laptop or your tablet pc. Using Indicator Light - Model Z520A Using the PTO Using the Throttle Lever Using the Hour Meter. John Deere Quality Service Record Record Service Dates. Introduction Thank You for Purchasing a John Deere Product. Using Your Operator’s Manual.
c CAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode: • Do not smoke or have open flame near battery. • Wear eye protection and gloves. • Do not allow direct metal contact across battery posts. • Remove negative cable first when disconnecting. • Install negative cable last when connecting. |
Checking the Battery (Sealed Batteries)
NOTE: Do not attempt to open, add fluid or service battery. Any attempt to do so will void warranty.
• Keep battery and terminals clean.
• Keep battery bolts tight.
• Keep small vent holes open.
IMPORTANT: Avoid damage! This battery comes fully charged. If the machine is not used by the service expiration date indicated on the battery, charge the battery. |
• Recharge, if necessary, at 6-10 amperes for 1 hour.
Cleaning Battery and Terminals
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Disconnect and remove battery.
3. Wash battery with solution of four tablespoons of baking soda to one gallon of water. Be careful not to get the soda solution into the cells.
4. Rinse the battery with plain water and dry.
5. Clean terminals and battery cable ends with wire brush until bright.
6. Install battery.
7. Attach cables to battery terminals using washers and nuts.
8. Apply spray lubricant to terminal to prevent corrosion.
Using Booster Battery
c CAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode: • Do not smoke or have open flame near battery. • Wear eye protection and gloves. • Do not jump start or charge a frozen battery. Warm battery to 16°C (60°F). • Do not connect the negative (-) booster cable to the negative (-) terminal of the discharged battery. Connect at a good ground location away from the discharged battery. |
M71044
A - Booster Battery
B - Disabled Vehicle Battery
1. Connect positive (+) booster cable to booster battery (A) positive (+) post (C).
2. Connect the other end of positive (+) booster cable to the disabled vehicle battery (B) positive (+) post (D).
3. Connect negative (–) booster cable to booster battery negative (–) post (E).
IMPORTANT: Avoid damage! Electric charge from booster battery can damage machine components. Do not install negative booster cable to machine frame. Install only to the engine block. Install negative booster cable away from moving parts in the engine compartment, such as belts and fan blades. |
4. Connect the other end (F) of negative (–) booster cable to a metal part of the disabled machine engine block away from battery.
5. Start the engine of the disabled machine and run machine for several minutes.
6. Carefully disconnect the booster cables in the exact reverse order: negative cable first and then the positive cable.
Replacing Fuses
IMPORTANT: Avoid damage! When replacing fuses, be sure the replacement fuse has the same fuse rating and is installed in the correct location. Failure to do so could result in damage to the electrical harness and/or electrical components. |
NOTE: The fuses are located on the left side of the engine compartment next to the starter.
The Z510A has one 20-amp system fuse.
The Z520A has two fuses, one 20-amp system fuse and one 30-amp deck lift fuse.
MX25969
Picture Note: Z510A shown. Z520A is similar.
1. Remove cover (A) from fuse holder (B) and remove fuse.
2. Check metal clip in fuse window and discard fuse if clip is broken.
3. Install new fuse and place cover back onto fuse holder.
Diagnostic Light Check - Model Z520A Only
The electronic control unit provides a diagnostic light to help the operator identify operational and electrical problems by flashing a diagnostic code.
Diagnostic “Real Time” Codes
1. Park machine safely. (See Park Safely in SAFETY section.)
NOTE: The operator can be seated on the machine or standing next to the machine.
2. Turn the key to the START position and release key to RUN mode.
MX24914
TCU24274
Picture Note: Diagnostic code label is located on right side console beside operator’s seat.
3. If engine starter does not engage, use the diagnostic light (A) and diagnostic codes (B) to diagnose the problem.
• BRAKE NOT ENGAGED (1-2) diagnostic code: one flash, a short pause and two additional flashes. This code sequence indicates that the park brake switch has not been activated. Lock park brake to start engine.
• STARTER THERMAL PROTECT MODE (2-5) diagnostic code: two flashes, a short pause and five additional flashes. This code sequence indicates that the module has started a 60-second cool-down period to prevent the starting motor from overheating. Turn key switch to OFF position and let the starting motor cool down for at least 60 seconds before attempting to re-start engine.
4. Once the unit has started and/or while operating the machine, the following codes may occur:
• PTO/MOW ENGAGED (1-3) diagnostic code: one flash, a short pause and three additional flashes. This code sequence can occur under the following conditions:
NOTE: For safety, the PTO will not engage with the park brake locked.
a. When getting out of the seat while operating the machine with the PTO engaged.
NOTE: This will cause the control module to disable the PTO system.
b. Applying the park brake while operating the machine with the PTO engaged.
NOTE: For safety, the PTO will not engage without the operator in the seat.
c. Standing next to a running, parked machine and the operator attempts to engage the PTO by turning ON the PTO (knob) switch.
• This code can be reset by turning OFF the PTO (knob) switch.
• OVER VOLTAGE (3-1) diagnostic code: three flashes, a short pause and one additional flash. This code sequence indicates that the electronic control unit has detected a voltage higher than normal in the electrical system. If the problem is severe, the control unit may disable the PTO output to the PTO clutch. Check electrical wiring for loose connections, specifically the battery positive and negative, starter, and frame ground on engine block.
• WEAK BATTERY OR STARTER SYSTEM ISSUE (3-3) diagnostic code: three flashes, a short pause and three additional flashes. This code sequence indicates that the battery may have become too weak to turn the starter motor or that the electronic control module has detected an excessive current draw. Recharge the battery. If this does not remove the code, check that all starter circuit harness connections are secure and not “shorted” to ground.
• OUTPUT FAULT DETECTED (3-7) diagnostic code: three flashes, a short pause and seven additional flashes. This code sequence indicates that the electronic control module has detected an electrical problem in the engine wiring harness. The control module’s internal “resettable” fuse had tripped to protect the system. This will remain tripped until the fault is removed. Check engine wiring harness for pinched or frayed wires.
5. Refer to the troubleshooting section for additional diagnostic codes. If further diagnostic assistance is needed, refer to the Technical Manual or consult your John Deere distributor.
Diagnostic Test Mode
This is a troubleshooting mode that can be used to check the integrity of the switches, sensors, wiring, and hardware of the control module. The diagnostic information is generated in the control module and displayed through a flashing diagnostic code on the display module. Please refer to the troubleshooting section of this manual for more information.
I have a Z520A, and what i thought was a dying battery has actually turned out to be a more difficult problem to solve. The symptoms are that if I put a fully charged, new battery in the mower, it starts and runs fine. But within a few hours, the hydraulic deck control starts not working, and eventually the mower deck shuts off and will restart and rub only for a second or two. Finally, if I shut the engine down, I have to jump it to restart it.
So this must be either the charging system or maybe the voltage regulator? But I have no idea really where to start in terms of narrowing the source of the problem and any help would be appreciated.
Oh, by the way when I run the diagnostic i get 3-2, 'low voltage condition'.
Any guidance on how to definitively diagnose & repair this would be great, esp as my nearest dealer just closed up shop.
Thanks,
billy