Product Services InformationINSTALLATION INSTRUCTIONS

(Includes English, French, German, Spanish and Italian)

M152773

H4

Garden Tractor

X465, X475, X485, X495, X575, X585, X595

CAB HEATER KITLitho in U.S.A.

BM21510, BM21480

Parts in Kit

MX31148

MX20903

NOTE: For machines with diesel engines which have the oil filter cooler line (A) routing to the upper side of the thermostat housing, contact your John Deere dealer for DTAC solution. For all other machines with diesel engines, and all machines with gasoline engines, follow these installation instructions.

Qty Parts In Kit

1 Heater, with Wire and Bullet Connectors (A)

1 Heater Hose, 5/8 in. diameter (B)

1Red and Black Wires, with Bullet Connectors (C)

1 Inline Fuse Holder (D)

1 8 Amp Fuse (E)

2 Nylon Washer, 16mm (F)

2 Nylon Washer, 12mm (G)

3 Loom Clamp (H)

B

R

S

XY

Z

C

D

QKL M N O

T

U V W

J

A

E

GF HI

P

3 Self-Tapping Screws (I)

1 Hose Clamp (J)

1 Heater Switch (K)

1 Butt Connector (L)

3 Female Push-On Connector (M)

1 Bullet Connector, Female (N)

3 Ring Terminal, 5/16 in. (O)

2 5/8 in. Y-Fitting (black plastic) (P)

1 Wire Loom (Q)

1 Switch Bracket, with Screws (R)

7 Tie Strap, Medium (S)

1Universal Heater Adapter (with Hex Adapter) (T)

1 NPT Nipple, 3/8 in. (U)

1 Tee Fitting, 1 x 5/8 x 1 in. (V)

1 Inline Shut-Off Valve (W)

2 Hose Grommet (X)

2 Hose Clamp, 1-1/2 in. (Y)

12 Hose Clamp, 1 in. (Z)

Qty Parts In Kit

A

John Deere Worldwide Consumer & Commercial Equipment DivisionLitho in U.S.A. English - 1 M152773 H4 (9/13/04)

Retain these installation instructions with the machine operator’s manual.

Parking Safely

1. Stop machine on a level surface, not on a slope.

2. Disengage mower blades or any other attachments.

3. Lower attachments to the ground.

4. Lock the park brake.

5. Stop the engine.

6. Remove the key.

7. Wait for engine and all moving parts to stop before you leave the operator’s seat.

8. Close fuel shut-off valve, if your machine is equipped.

9. Disconnect the negative battery cable or remove the spark plug wire (for gasoline engines) before servicing the machine.

Prepare Machine

1. Park machine safely.

2. Open the engine cover and allow the engine to cool.

3. Remove air cleaner.

4. Confirm that engine is cool, then loosen radiator cap, open radiator drain valve and drain coolant into a clean container for later use.

Install Hose Grommets

MX31149

1. Remove plastic plugs (A) from existing holes at base of left front leg.

MX14162

2. Push grommets (B) completely into holes from the outside.

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Allow the engine to cool before servicing or working near the engine and components.

A

B

2 M152773 H4

Install Heater Switch Bracket (For Installation Without Switch Panel/Fuse Block Kit

NOTE: If the switch panel/fuse block kit is installed at the same time as the heater kit, the heater switch and bracket should not be installed.

MX16354

1. Position switch bracket (A) on top of heater housing (B) midway between the left (C) and middle screws at the rear of the housing.

MX16355

Picture Note: Top view of heater.

2. Position bracket (A) at back edge of heater housing (B) with bracket slots (D) facing to the rear.

3. Make a mark in each slot approximately 9.5 mm (3/8 in.) from the rear of the housing.

4. Drill a 2 mm (5/64 in.) hole at each mark for the switch mounting screws.

5. Install screws, adjust bracket if necessary and tighten.

Install Heater

MX14382

1. Remove the two rear screws (B) from the left side of the heater housing.

2. Align holes in heater housing with holes in bracket (A) on the left side frame and install with original screws.

MX14164

3. Remove shipping plugs (C), if equipped, from both supply and return tubes of heater unit.

Install Universal Heater Adapter

NOTE: Use thread tape or thread compound on threaded adapter components as necessary to prevent coolant leaks.

1. Confirm that engine is cool, then loosen radiator cap, open radiator drain valve and drain coolant into a clean container for later use.

AB

C

A

B D

A

B

C

3 M152773 H4

MX14168

Picture Note: Diesel engine sending unit.

MX14271

Picture Note: Gasoline engine sending unit.

2. Disconnect coolant temperature sending unit wiring lead (A), remove sending unit (B) and copper washer (C).

MX16353

Picture Note: Diesel engine shown, with two 12 mm nylon washers.

3. Install a 16 mm nylon washer (D) and hex adapter (E) into temperature sending unit port and tighten.

4. Install a 12 mm nylon washer (F) onto male thread of universal heater adapter (G), thread universal heater adapter into hex adapter and tighten.

• The crosshole in adapter must be properly aligned for installation of the NPT nipple (H). If alignment is not

correct on diesel engine, remove universal adapter, add an additional 12 mm nylon washer and tighten.

5. Install 3/8 in. NPT nipple into middle port of the adapter and tighten.

6. Install original temperature sending unit (B), 16 mm nylon washer (D) and original copper washer into end port of the adapter and tighten.

7. Connect temperature sending unit wiring lead.

Install Heater Hoses and Inline Shut-Off Valve (Diesel Engine)

MX14319

1. Connect one end of the supplied heater hose (A) to the left side (supply) tube on the heater and fasten with a 1 in. hose clamp (B).

MX14176

2. Route the hose (A) through the left side hose grommet (C), under the corner of the footrest (D) and up along the side of the engine, next to the oil filler tube, to the 3/8 in. NPT nipple.

3. Cut the hose, install on the nipple and fasten with a 1 in. hose clamp.

A

B

C

BA

D

E

G

H

DF

B

A

A

CD

4 M152773 H4

MX14175

4. Determine suitable position for inline shut-off valve (D).

5. Cut hose, install valve and fasten with two 1 in. hose clamps (B).

6. Connect one end of the remaining section of heater hose to the right side (return) tube at the heater and fasten with a 1 in. hose clamp.

MX14210

7. Route the hose (E) through the remaining hose grommet in the left front leg, under the footrest parallel to the supply hose and over the top of the frame (F).

MX20901

8. Remove the lower radiator hose (G) and cut for installation of 1 x 5/8 x 1 in. tee fitting (H) in area shown.

Remove 16mm (5/8 in.) long section from one end of hose to make room for the fitting.

9. Assemble the fitting to hose sections and secure with 1-1/2 in. hose clamps. Connect return hose to tee fitting with 1 in. hose clamp.

Install Heater Hoses and Inline Shut-Off Valve (Gasoline Engine)

MX14319

1. Connect one end of the supplied heater hose (A) to the left side (supply) tube on the heater and secure with a 1 in. hose clamp (B).

MX14176

2. Route the hose (A) through the left side hose grommet (C), under the corner of the footrest (D) and up against the radiator shroud.

3. Install the air cleaner.

D

B

E

F

G

H

B

A

A

CD

5 M152773 H4

MX14275

Picture Note: Air cleaner intake hose removed for clarity.

4. Route the hose against the shroud and toward the other side of the engine, under the upper radiator hose (E), then over the upper radiator hose to the 3/8 in. NPT nipple (F) and secure with a 1 in. hose clamp.

MX14276

5. Secure the hose at the top corner of the shroud with a P-clip (G). Secure the hose clamp to the shroud using an existing cap screw (H) and locknut.

6. Install the inline shut-off valve (I) by cutting the hose mid-way between the P-clip and the bottom of the radiator shroud, inserting the valve and securing with 1 in. hose clamps.

MX14277

Picture Note: Tee fitting shown with heater return hose (N) connected.

7. Locate the formed hose (J) that connects the water pump outlet (K) and the thermostat housing inlet (L), mark the hose where the tee fitting (M) should be installed and remove the hose.

8. Cut the hose at the mark, removing an additional 16 mm (5/8 in.) long section to accommodate the fitting.

9. Assemble the fitting (M) to the hose sections, connect hose to thermostat housing and water pump, and secure with 1-1/2 in. hose clamps. Finished installation should appear as shown.

10.Connect one end of the remaining section of heater hose (N) to the right side (return) tube at the heater and secure with a 1 in. hose clamp.

MX14210

11.Route the hose through the remaining hose grommet in the left front leg, under the footrest parallel to the supply hose and over the top of the frame (O).

E

F

I

G

H

K

L

J

M

N

NO

6 M152773 H4

MX14184

Picture Note: View from under vehicle equipped with four wheel drive. Hose routing along frame bracket (P) is the same for all configurations.

12.Route the hose (N) back and down to the front side of the arched frame bracket (P), across and through a cluster of hydraulic lines (Q), then directly up to the tee fitting (M) installed earlier in the lower radiator elbow hose. Secure with a 1 in. hose clamp.

13.Secure the hose to the frame bracket (P) with a tie strap (R) to prevent it from sagging when hot and being damaged by other moving parts.

MX14264

14.Using an existing hole (S) in the machine frame as an anchor point, use a tie strap (R) to secure the return hose (N) away from the motor mount (T) to prevent damage from pinching or abrasion.

15.Use remaining tie straps to secure hoses away from moving parts.

Route and Connect Wiring (Without Switch Panel/Fuse Block Kit)

NOTE: Removal of hood is recommended for better access to components.

1. Confirm that negative battery cable is removed from battery before beginning electrical installation.

NOTE: The terminal marked C on the back of the switch is not a ground terminal and is not used for this application.

MX14211

Picture Note: Side and rear views of heater switch. The terminal identification letters are clearly marked on the back of the switch.

2. Cut bullet connectors off the ends of the red and orange heater wires and install a female push-on connector on each wire.

3. Connect the red wire to the L (low speed) switch terminal and the orange wire to the H (high speed) switch terminal.

4. Cut the bullet connector off the end of the supplied red wire (power lead), install a female push-on connector and connect to the B (power) terminal on the heater switch. Do not route the wire further at this time.

5. Install the rotary switch (A) from the rear of the hole in the switch bracket and tighten in place with the supplied nut (B), then firmly push the knob (C) onto the shaft.

M

Q

N

P

R

N

S

R

N

T

A

A

B

C

7 M152773 H4

MX16357

6. To ensure that there is an adequate ground, connect one end of supplied black wire to an existing screw on the heater housing (D) with a 5/16 in. ring terminal (E).

MX16358

7. Route the red wire (power lead) and the black wire (ground) down the left side frame (F) and over to the corner of the footrest near the engine. Use wire loom (G), loom clamps (H) and self-tapping screws (I) to secure as needed.

MX31189

Picture Note: Typical routing depicted, diesel engine shown. Gasoline engine will differ slightly. Wires are encased in wire loom (G) and tie straps are installed.

8. Route the wires/wire loom (G) from the corner of the footrest (J), over to the engine.

9. Bundle wires/wire loom (G) with an existing wiring harness (K) and route the black/ground wire to the battery.

MX14225

10.Route the black/ground wire (L) up along the side of the battery shield (M) to the negative battery terminal.

11.Cut to length and install a 5/16 in. ring terminal (E).

12.Connect the ring terminal to the negative battery terminal clamp bolt using the existing nut.

13.Install wire loom where appropriate for protection and secure as necessary with tie straps.

14.Route the red power lead to the starter.

D

E

HF

G

HI

IMPORTANT: Avoid damage! To minimize risk of fire, do not bundle electrical wires to any of the fuel lines for support.

G

K

J

L

E

M

8 M152773 H4

NOTE: The starters for the diesel and gasoline engines are located on opposite sides of the engine block. In each case, route the power lead along an existing harness to the starter and connect as noted below.

MX14239

15.Cut the inline fuse wire (N) in the middle of the loop. Install a butt connector (O) on one end of the wire, a 5/16 in. ring terminal (E) on the other end of the wire and install provided fuse.

MX14214

16.Connect the ring terminal end of the inline fuse wire (N) to the starter terminal (P). Connect the open end of the red power lead to the butt connector on the inline fuse wire.

17.Connect battery cable and test switch operation.

Route and Connect Wiring (With Switch Panel/Fuse Block Kit)

1. Install switch panel/fuse block kit according to directions included with that kit before proceeding.

NOTE: Removal of hood is recommended for better access to components.

2. Confirm that negative battery cable is removed from battery before beginning electrical installation.

3. Connect the male bullet connector on the red heater motor wire to the female bullet connector on one end of the supplied red wire. Route the wire to the side frame, then through the switch panel wire loom to the back of the switch panel. Allow generous extra length for slack, then cut the wire.

4. Attach a female bullet connector to one end of the remaining supplied red wire and connect it to the male bullet connector on the orange heater motor wire. Route the wire to the side frame, then accompanying the other motor lead wire through the switch panel wire loom to the back of the switch panel.

MX16359

5. To ensure that there is an adequate ground, connect one end of the supplied black wire to an existing screw on the heater housing (A) with a 5/16 in. ring terminal (B).

6. Route the wire to the side frame, then through the switch panel wire loom to the back of the switch panel, together with the red and orange motor wires.

7. Refer to the instruction included with the switch panel/fuse block kit for final wiring connections to the panel.

Complete Installation and Test Heater

1. Fully open the inline shut-off valve in the supply hose to allow unrestricted coolant flow to the heater.

2. Temporarily remove the two mounting screws retaining heater and carefully lower heater to floorboard (with hoses connected). This will aid in purging air from the heater unit while adding coolant.

3. Backfill heater hoses and bleed all air from system.

IMPORTANT: Avoid damage! The power lead is always hot. Make sure that the heater switch is off when not in use to prevent battery drain.

N

N

EO

N

P

A

B

9 M152773 H4

4. Fill radiator with coolant saved from earlier step, adding new coolant as needed. Install radiator pressure cap and ensure that the radiator overflow tank is filled to the proper level.

5. Mount heater and secure with screws removed earlier.

6. Start the engine and check for coolant leaks. Repair any leaks before operating.

7. Run engine to operating temperature, turn on heater switch and check for heater function. Stop engine and allow to cool.

8. Check coolant level, and add if necessary.

Inline Shut-Off Valve Operation

An inline shut-off valve is used for both diesel and gasoline engine applications to control coolant flow to the heater unit to generate less heat within the cab in warm weather. Turning the valve screw fully clockwise closes the valve, counter-clockwise opens the valve.

The inline shut-off valve should be open for normal heating operation. This allows coolant to flow through the heater unit. Closing the valve directly shuts off flow to the heater.

10 M152773 H4