John Deere D170, D160, D140, D130, D120 User Manual

...

JOHN DEERE

AG & TURF DIVISION

GX24537 G2

John Deere Tractors

100 Series

OMGX24537 G2

OPERATOR’S MANUAL

North American Ve rsion

Printed in U.S.A.

INTRODUCTION

c WARNING: The Engine Exhaust

from this product conta ins chemicals kno wn

to the State of California to cause cancer,

birth defects or other reproductive harm.

California Proposition 65 Warning

T able of Contents

Introduction................................................................................................ 1

Product Identification.................................................................................1

Safety Labels............................................................................................. 3

Safety ........................................................................................................ 9

Machine Cleanout ................................................................................... 14

Assembly................................................................................................. 16

Operating Controls ..................................................................................18

Operating................................................................................................. 21

Service Intervals...................................................................................... 31

Service Lubrication.................................................................................. 32

Service Engine ........................................................................................33

Service Transmission .............................................................................39

Service Mower.........................................................................................39

Service Electrical..................................................................................... 44

Service Miscellaneous ............................................................................46

Troubleshooting .......................................................................................50

Storage....................................................................................................52

Specifications.......................................................................................... 53

Warranty..................................................................................................55

Index........................................................................................................ 57

Getting Quality Service ........................................................................... 58

Service Record........................................................................................59

Introduction

Thank Yo u for Purchasing a John Deere Product

We appreciate having you as a customer and wish you many years of safe and sat is fie d us e of you r mac hi ne.

Using Your Operator’s Manual

This manual is an important part of your machine and should remain with the machine when you sell it.

Reading your operator’s manual will help you and others avoid personal injury or damage to the machine. Information given in this manual will provide the operator with the safest and most effective use of the machine. Knowing how to operate this machine safely and correctly will allow you to train others who may operate this machine.

This ma nua l and safety si gn s on your mach in e may also be availa ble in other languages (see your authorized dealer to order).

Sections in your operator’s manual are placed in a specific order to help you understand all the safety messages and learn the control s so you can operate this machine safely. You can also use this manual to answer any specific operating or servicing ques tions.

The machine shown in this manual may differ slightly from your machine, but will be similar enough to help you understand our instructions.

RIGHT-HAND and LEFT-HAND si des are determined by facing in the direction the machine w ill travel when going forward. When you see a broken line (------), the item referred to is hidden from view.

Before delivering this machine, your dealer performed a predelivery inspection to ensure best performance.

Special Messages

Your manual contains special messages to bring attention to potential safety concerns, machine damage as well as helpful operating and servicin g information. Please read all the information carefully to avoid injury and machine damage .

c 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.

Original Instruction

All information, illustrations and

specifications in this manual are based on

the latest information at the time of

publicati on. The right is reserved to make

changes at any time without notice.

John Deere Worldwide Commercial and

Consumer Equipment Division

Deere & Co.

Previous Editions

IMPORTANT: Avoid damage! This text is used to tell the operator of actions or conditions that might result in damage to the machine.

NOTE: General information is given throughout the manual that may help the operator in the operation or service of the m achine.

Product Identification

Record Identification Numbers

Lawn Tractors

D105, D110, D120, D130, D140, D160, D170 PIN (D400001-) 49 State PIN (D040001-) California PIN (D070001-) Australia, Canada , Mexico, ROW. If you need to contact an Authoriz ed Service Center for information on

servicing, always provide the prod uct model and ide ntification numbers. You will need to locate the product identification number (PIN) for the

Introduction - 1

PRODUCT IDE NTIFICATION

machin e and engine serial number. Record the information in the spaces prov ided below.

DATE OF PURCHASE: _________________________________________ DEALER NAME: _________________________________________ DEALER PHONE: _________________________________________ PRODUCT IDENTIFICATION NUMBER: __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ ENGINE SERIAL NUMBER: __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

Machine Product Identification Number Location

Engine Seri al Num be r Loca tion

MX25599

Picture Note: Single Cylinder Engines

Picture Note: Located on left side of frame.

MX46486

MX49394

Picture Note: V-Twin Engines

Regist er Your Product and Warranty Onli ne

To register your product through the Internet, simply go to www.JohnDeereWarrantyRegistration.com. Complet ing the information, either online or with the product warranty card, will ensure the customer that their product receives all post sales service and important product infor mation.

Product Identification - 2

Safety Labels

SAFETY LABELS

Safety Label Location (Text)

MX46490

Picture Note: Use label number listed in table below to locate complete text of safety label message following this illustration.

A- WARNING GX22477 B- DANGER/CAUTION M128699 C- W ARNING MX4878 D- DANGER M118610 E- CAUTION M165279

F- WARNING GX23479 G- DANGER GX22477 H- DANGER M89504

Safety Labels - 3

Safety Label Loc a tion (No Text)

SAFETY LABELS

MX46490

Picture Note: Non-text labels are required for certain regions of the world. Your machine may not be equipped with th ese labels. Use label number listed in table below to locate complete text of safety label message following this illustration.

A- WARNING GX24842 B- W ARNING M128484 C- W ARNING M136436 D- WARNING GX24503

E- DANGER M118041 F- WARNING GX21121 G- WARNING GX23479 H- DANGER M148522 I - DAN GER M118040 J- WARNING (Bypass Rod) GX21086

Safety Labels - 4

SAFETY LABELS

Understanding The Machine Safety Labels

The machine safety labels shown in this section are placed in impo rtant areas on your machine to draw atte ntion to potential safety hazards.

On your machine safety labels, the words DANGER, WARNING, and CA UTION are used with this safety-alert symbol. DANGER identifies the most serious hazards.

The operator’s manual also explains any potential safety hazards whenever necessary in special safety messages that are identified with the word, CAUTION, and the safety-alert symbol.

Warning MX4878

MX4878

• Read and follow Operating Instructions before running engine.

• Gasoline is flammable. Allow engine to cool at l east 2 minutes before refueling.

• Engines em it carbon mo nox id e, DO NOT ru n in enclosed area.

DANGER

GX22477

ROTATING BLADES CUT OFF ARMS AND LEGS

• Do not mow when children or others are around.

• Do not mow in reverse.

• Look down and behind before and wh ile backing.

• Never carry childr en even with blad es off.

DANGER M128699

DANGER

M118610

ROTA TING BL ADE

• Do not put ha nd s or feet und er or into mowe r wh en eng ine is runn in g.

DANGER - M89504

M89504

ROTA TING BL ADE

• Do not put ha nd s or feet und er or into mowe r wh en eng ine is runn in g.

THROWN OB JECTS

• Before mowing, clear area of objects that may be thrown by blade.

• Do not operate mower without discharge chute or entire grass catcher in place.

M128699

Picture Note: Located on battery

• Shield eyes, explosive gases can cause blindness or injury.

• No sparks, flames, smoking.

• Sulfuric acid can cause blindness or severe burns.

• Flush eyes immediately with water. Get medical help fast.

• Kee p out of reach of children.

• Do not tip.

• Keep vent caps tight and level.

WARNING

GX22477

AVOID SERIOUS INJURY OR DEATH

• Drive up and down slopes, not across.

• Avoid sudden turns.

• If machine stops going u phill, stop blades and back d own slowly.

• Keep safety devices (guards, shields, and switches) in place and working.

• Remove objects that could be thrown by blades.

• Read operator’s manual.

Safety Labels - 5

SAFETY LABELS

• Remove objects th at can be thrown by blades

• When leaving machine: –Stop engine –Set par k brake –Remove key

DANGER GX23479

WARNING

• Hot sur face

Warning M159705

Prevent Equipment Fires

GX23479

M159705

Picture Note: This label is required and installed on machines sold in California. This label may also be installed on machines sold in other locations.

Oper ation of This Equipment May Create Sparks that Can Start Fires Around Dry Vegetatio n. A Spark Arrestor May be Requ ired. The Operator Should Contact Local Fire Agencies For La ws or Regulations Relating to Fire Prevention Requirements.

M165279

• Avoid equipment fires.

• Accumulation of grass, leaves and other debris on or n ear hot or moving parts can cause a fire.

• Inspect machine before, during, and after use.

• Shut off engine and allow machine to cool before cleaning.

Inspect and clean the entire machine and pay special attention to these lo c ations:

1. Muffler and exhaust system

2. Engine and engine screens

3. Top of mower deck and un der shields

4. On or near transmission

Emission Control System Certification Label

NOTE: Tampering with emission controls and components by unauthorized personnel may result in severe fines or penalties. Emission controls and components can only be adjusted by EPA and/or CARB authorized service centers. Contact your John Deere Retailer concerning emission controls and component questions.

The presence of an emissions label signifies that the engine has been certified with the United States Environmental Protection Agency (EPA) and/or California Air Resources Board (CARB).

The emis sions warranty applies only to those engines marketed by John Deere that have been certified by the EPA and/or CARB; and used in the United States and Can ada in off-road mobil e equipment.

Safety Labels - 6

SAFETY LABELS

Emission Compliance Period

If your engine has the emission compliance category listed on the emissio n control sy s tem ce rtific a tion or air index la be l, thi s in dic a t es the number of operating hours for which the engine has been certified to meet EPA and/or CARB emission requirements. The following table provides the engine compliance period in hours associated with the category found on the cer tifica tio n label.

Agency Category Hours

EPA C 250 EPA B 500 EPA A 1000 CARB Moderate 125 CARB Intermediate 250 CARB Extended 500

Certification

Your mo wer has been certified for compliance with American National Standards Institute B-71.1-2003, “Safety Specifications” for Power Lawn Mowers, Lawn and Garden Tractors, and Lawn Tractors.

Canadian Electromagnetic Compatibility (EMC) Compliance

This spark ignition system complies with Canadian ICES-002.

Pictoria l Safety Signs

At several imp ortan t pl a c es on t hi s ma ch ine safety signs

are affixed intended to signify potential danger. The hazard

is iden tif i ed b y a pi ctor ia l in a w a rnin g tria ng l e. An ad ja ce nt

pictorial provides information how to avoid personal injury. These sa fety signs, the ir pl ac em e nt on the ma ch ine and a bri ef explanatory text are shown in this Safety section.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator’s manual.

Avoid In jury From Rotating Blades - M118041

M118041

• Do not put hands or feet under or into mower when eng ine is running.

• Do not operate mower without discharge chute or entire grass catcher in place.

WARNING M128484

M128484

Avoid Injury From Battery Gases and Acids

• Batteri es conta in e xp losi v e ga se s an d sulf ur ic acid. Us e ex tr em e caut i on when handling battery.

• Read operator’s manual for all safety informa tion before handling battery.

• Use extreme caution when handling battery.

Avoid In jury From Getting Caught in Belt - M136436

Av oi d Inju ry Fr om Rot ati ng Bl ades and Thr own Objec ts

- M118040

M118040

• Do not put ha nd s or feet und er or into mowe r wh en eng ine is runn in g.

• Do not operate mower without discharge chute or entire grass catcher in place.

• Before mowing, clear area of objects that may be thrown by blade.

• Stay clear wh ile engine is runn in g.

Safety Labels - 7

M136436

• Stay clear of belts.

• Do not oper at e mow e r wit ho ut sh ields in plac e.

WARNING GX24503

GX24503

SAFETY LABELS

Clean and inspect the entire machine. Carefully read Operator’s Manual Machine Cleanout section for details.

WARNING GX21121

GX21121

Warning - Hot Surfaces

• Ke ep away from hot surfaces.

WARNING - GX23479

Avoid Injury From Tipping

• In some co nfigurations, do not drive or operate on a slope of more than 10 degree s.

• Refer to the Operating on Slopes section for more information.

• Drive up and down slopes, not across.

• Avoid sudden turns.

Avoid Injury From Rotating Blades and Thrown Objects

M148522

• Do not put hands or feet under or into mower when eng ine is running.

• Keep away from rotating parts. Do not open or remove safety shields while engine is runnin g.

• Thrown O bjects - Before mowing, clear area of objects t hat may be thrown by blade. Do not operate mower without discharge chute or entire grass catcher in place.

• Stay a safe distance from machine.

GX23479

WARNING

• Hot sur face

Avoid Inju ry

GX24842

Picture Note: Located on fenderdeck in front of seat.

Read Operators Manual

• This operator’s manual contains important information necessary for safe machine operation. Observe all safety warnings to avoid accidents.

Keep Children Away From Mower

• Do not mow when children or others are around.

• Do not mow in reverse.

• Look down and behind before and while backing.

• Never carry children even with blades off.

Avoid Injury: Use Transmission Bypass Rod Safely

GX21086

• Carefully read operator’s manual for safe operation of transmission bypass rod.

Safety Labels - 8

SAFETY

Safety

Operating Safely

This cutting machine is capable of amp utating hands and

feet and throwing objects. Failure to observe the following

safety instructions could result in serious injury or death.

• Read, understand and follow all instructions on the machine and in manuals provided, and view safety video, before starting. Be thoroughly familiar with the controls and the proper use of the machine before starting.

• Do not put hands or feet near rotating parts or under the machine. Keep clear of the discharge opening at all times.

• Only allow responsible adults, who are familiar with the instructions, to operate this machine. Local regulations may restrict the age of the operator.

• Clear the area of objects such as rocks, wire and toys which could be thrown by the blades.

• Be sure the area is clear of bystanders befor e operating. Stop machine if anyone enters the area.

• Never carry passengers.

• Do not mow in reverse unless absolutely necessary. Always look down and behi nd befor e an d wh il e ba cki ng.

• Never direct discharged material toward anyone. Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blades when crossing gravel surfaces.

• Do not operate the machine without the entire grasscatcher, discharge guard, or other safety devic es in place and wo rking. Never operate with the discharge deflector raised, removed, or altered, unless using a grasscatcher.

• Slow down before t u rn ing.

• Never leave a running machine unattended. Always turn off blades, lock park brake, stop engine and remove key before dismounting.

• Disengage blades when not mowing. Shut off engine and wait for all parts to com e to a complete stop before cleaning the machine, removing the grasscatcher, or unclogging the discharge chute.

• Operate machine only in daylight or good artificial light.

• Do not operate the machine while under the influence of alcohol or drugs.

• Watch for traffic when operating near or crossing roadways. Stop blades before crossing ro ads or sidewal k s.

• Use extra care whe n loading or unloading the machine into a trailer or truck.

• Always wear safety goggles or safety glasses with side shields when operating machin e.

• Data indicates operators 60 year s and above ar e involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.

• Follow the manufacturer’s recommendation for wheel weights or counterweights.

• Inspect machine before you operate. Be sure hardware is tight. Repair or replace damaged, badly worn, or missing parts. Be sure guards and shields are in good condition and fastened in place. Make any necessary adjust me nts before yo u op erate.

• Before using, always visually inspect to see that the blades, blade bolts

and the m ower assembly are not worn and damaged. Replace worn and damaged blades and bolts in sets to preserve balance.

• Make sure spark plug, m uffler, fu el cap and air cleaner are in place before starting the engine.

• Be sure all drives are in neutral and parking brake is locked before starting engine. Only st art engine from the operator’s position.

• Do not change the engine governor settings or overspeed the engine. Operating the engine at excessive speed can increase the hazard of person al injury.

• If y ou hit an object or if abnormal vibration occurs, stop the machine and inspect it. Make repairs before you operate.

• Use only accessories and attachments approved by the manufacturer of the machine. Keep safety labels visible when installing accessories and attachments.

• Do not wear radio or music head ph on es. Safe service and operation requires your full attention.

• When machine is left unattended, stored, or parked, lower the mower deck unless a positive mechanical lock is used.

Using a Spark Arrestor

The California Public Resources Code, section 4442.5 provides as follows:

No person shall sell, offer for sale, lease, or rent to any person any internal combustion engine subject to Section 4442 or 4443, and not subject to Section 13005 of the Health and Safety Code, unless the person provides a written n ot ic e to t he pu rcha se r o r bai l ee , at th e tim e of sa le or at the t i me of entering into the lease or rental contract, stating that it is a violation of Section 4442 or 4443 to use or operate the en gine on any f orest-covered, brush-covered, or grass-cov ered land unless the engine is eq uipped with a spark arrestor, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire pursuant to Section 4443. Cal. Pub. Res. Code

4442.5. Other states or jurisdictions may have similar laws. A spark arre stor for

your m achine may be available from your auth orized dealer. An installed spark arrestor must be maintained in good working order by the operator.

Checking Mowing Area

• Clear mowing area of objects that might be throw n. Keep people and pets out of mowing area.

• Low-hanging branches and similar obstacles

can injure the operator or interfere with mowing operation. Before mowing, identify potential obstacles such as low-hanging branch es, and trim or r emove those obstacles.

• Study mowing area. Set up a safe mowing pattern. Do not mow where traction or stability is doubtful.

• Test drive area with mower lowered but not running. Slow down when you travel over rough ground.

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.

Safety - 9

SAFETY

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

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

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

Rotating Blades are Dangerous

HELP PREVENT SERIOU S OR FATAL ACCIDENTS:

• Rotating blades can cut off arms and legs, and throw objects. Failure to observe safety instructions could result in serious injury or

death.

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

• Be alert at all times, drive forward and in reverse carefully. People, especially children can move quickly into the mowing area before you know it.

• Before backing up, stop mower blades or attachments and look down and behind the machine carefully, especially for children.

• Do not mow in reverse.

• Shut off blades when you are not m owing.

• Park machi ne safely before leaving the operator’s station for any reason including emptying the grasscatchers or unplugging the chute.

• The mo wer blades should stop in appr oximately f ive seconds when the mower is disengaged. If you believe that your blades may not be stopping in that period of time, take your machine to your authorized dealer where they can safely check and service yo ur machine.

Protect Children

• Death or se rious injury ca n occur when young children associate having fun with a lawn mowing machine simply because someone has given them a ride on a machine.

• Children are attracted to lawn mowing machines and mowing act ivities. They don’t understand the dangers of rotating blades or the fact that the operator is unaware of their presence.

• Children who have been given rides in the past may su ddenly appear in the mo wing area for another ride and be run over or backed over by the machine.

• Tragic accidents with children can occur if the operator is not alert to the presence of children, especially when a child approaches a machine from behind . B efore and while ba cking up, stop mo we r blades and look down and behind the machine carefully, especially for children.

• Never carry children on a machine or attachment, even with the blades off. Do no t t ow c hi ldr en in a cart or t r a ile r. They ca n f al l of f an d b e s er ious ly injured or interfere with safe machine operation.

• Never use the machine as a recreational vehicle or to entertain children.

• Never allow chil dr e n or an untraine d pe r so n op er a te the machin e. Instruct all operat ors not to give children a ride on the machine or in an attachment.

• Ke ep chi l dr en in do or s , out of the mo w ing ar ea , and in t he wat ch ful e y e of a responsible adult, other than the operator, when a mower is being operated.

• Stay alert to the presence of children. Never assume that children will

remain where you last saw them. Turn the machine off if a child enters the work area.

• Use ex treme care when approaching b lind corners, shrubs, trees, or other objects that may block your view of a child.

Operating on Slopes

NOTE: Make a photocopy of this page and cut out angle chart (A) to use for measuring slope angle.

• Slopes ar e a maj or factor relate d t o l oss -of -co nt rol an d t ipo v er ac cide nt s , which can result in severe injury or death. Operation on all slopes requires extra caution.

Identify Slopes for Safe Operation

• Follow safe procedures for operation on slopes. Measure slopes of all moving sites to determine which slopes are safe for mowing with a ride-on mower. Always use common sense and good judgement when performing this survey.

Measuring Slopes

• Sugges ted Method 1: Lay a straight piece of sturdy lumber 1.2 m (4 ft) long on the slope and measu re the angle of the slope with an angle indica tor or protract or level.

• Suggested Method 2: Refer to the slope gauge provided with this manual.

Operate Safely on Slopes

• Exceeding the recommended maximum slope angle increases the risk of rollover accidents that can result in serious injury or death.

• Nev er mow or operate ride-on mower on slope angles greater than 13° with the lawn ride-on mower in its basic configuration. The basic configuration is the ride-on mower with mower deck and not other attachments. (A 13° slope is a slope tha t rises 1.4 m (4.6 ft) over a horizontal distance of 6.1 m (20 ft).)

• When us in g att a c hm en ts, never mow or operate the rid e -o n mow e r on slope ang le s grea t e r th an 10° . Th e ad di tio n of a weather enc lo su re, material collection system, or other attachments will increase the risk of a rollover. (A 10° slope is a slop e that rises 1 m (3.5 ft) over a horizontal distance of 6.1 m (20 ft).)

• On slope angles of 10° or less, the risk of rollover is low, but as the slope angle increases to the recommended maxim um, the risk increases to a medium level.

• Always consider potential turf conditions and slope angles when determining the risk of loss-of-control and tip-ov er accidents.

• Drive slowly when mowing or operating on slopes.

• If you feel uneasy on a hillside, do not mow or operate on it.

• Mow up and down slopes, not across.

• Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the ride-on mower. Tall grass can hide obstacles.

• Drive slowly so you will not have to stop while on a slope.

• Do not mow on wet grass. Tires may lose traction. Tires may slip on slopes even though the brakes are func tioning properly.

• Avoid starting, stopping or turning on a slope. If the tires lose traction, diseng age the PTO and proceed slowly, straight down the slope.

• Keep all movement on slopes slow and gradual. Do not make sudden changes in spee d or dir e ctio n, whi ch co ul d caus e t he ride - on mo w er to r ol l over.

Safe ty - 10

SAFETY

Operating Near Hazards

Picture Note: Example side view of slope and hazards, showing areas (A), (B), and (C).

• Do not mow or operate ma chine in areas adjacent to haza r d s that may cause the machine to roll over. The machine could suddenly lose traction, slide, and/or roll over if a wheel goes over the edge or if the edge breaks away.

• Hazards (A) include but are not limited to:

• Drop-offs, ditches, embankments, or bodies of water.

• Areas of unsafe slope, soft ground, edges along bodies of water, or area with holes, ruts, bumps, or other hidden objects.

• Maint ain a buffer area (B) at least as wid e as the machine between hazards ( A) an d the mo win g a rea (C) . D o not mo w or o per ate th e ma ch ine in the hazard area or buffer area.

• Only mow or operate the machine in the mowing area (C). Do not exceed the recommended slope operating angle. Refer to the "Operate Safely on Slopes" section.

• Use a walk-behind mower or string trimmer in and around areas (A) and (B).

MX51888

MX51667

Keep Riders Off

• Only allo w the op er ator on the mach ine . Ke ep

riders off.

• Riders on the machine or attachment may be

struck by foreign objects or thrown off the

mach in e ca us in g seriou s in jury.

• Riders obstruct the operator’s view resulting in the machine being operated in an unsafe manne r.

Tow ing Loads S afely

• Stopping distance increases with speed and weight of towed load. Travel slowly and allow extra time and distance to stop.

• T otal towed weight must not exceed combined weight of pulling machine, ballas t an d o pe rat o r . Use co un ter we ig ht s or whe el we ig ht s as de scr ibed i n

Safe ty - 11

SAFETY

the attachment or pulling machine operator’s manual.

• Excessive towed load can cause loss of traction an d loss of control on slopes. Reduce towed weight when operating on slopes.

• Never allow children or others in or on tow ed equipment.

• Use on ly approved hitches. Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the approved hi t ch poi nt.

• Follow the manufacturer’s recommendations for weight limits for towed equipment and towing on slopes.

• Towed attachments will increase the risk of rollover. Refer to the “Operating on Slopes” section for more information.

• Do not turn sharply. Use additional caution when turning or operating under adverse surface conditions. Use care when reversing.

• Do not shift to neutral and coast downhill.

Wear Appropriate Clothing

• Always wear eye protection when operating the machine.

• Wear close fitting cl oth in g and safety equipment appropriate for the job.

• Whil e oper a tin g t hi s mac hi ne, al ways wear subs ta nti al f oot we ar an d l ong trousers. Do not ope rate the equipment when barefoot or wearing open sandals.

• Wea r a suitable protective device such as earplugs. Loud noise can cause impairment or loss of hearing.

Driving Safely on Public Roads

Avoid personal injury or death resulting from a collision with another vehicle on public roads:

• Use safety lights and devices. S low moving machin es when driven on public roads are hard to see, especially at night.

• Whenever driving on public roads, use flashing warning lights and turn signals according to local regulations. Extra flashing warning lights may need to be installed.

Practice Safe Maintenance

• Only qualified, trained adults should service this machine. Understand service procedure before doing work.

• Never operate machine in a closed area

where dangerous carbon monox ide fumes can collect.

• Keep all nuts and bolts tight, especially blade attachment bolts, to be sure the equipment is in safe working condition.

• Never tamper wit h safety devices. Check their proper operation r egularly.

• Keep machine free of grass, leaves or other debris build-up. Clean up oil or fuel spillage and remove any fuel-soaked debris. Allow the machine to cool before storing.

• If 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 all mo vement to stop on machine bef ore adjusting, cleaning or r epairing.

• Check grasscatcher components and the discharge guard frequently and replace with manuf acturer’s recommended parts, when necessary. Grass ca tche r co mpo nent s ar e subjec t to wea r , dam ag e , and de te rioration which could expose moving parts or allow objects to be thrown.

• Mower blades are sharp. Wrap the blade or wear gloves, and use extra care when servicing them. Only replace blades. Never straighten or weld them.

• Chec k brake operation frequently. Adjust and servic e as required.

• Maintain or replace safety and instruction labels, as necessary.

• On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.

• Keep hands, feet, clothing, jewelry, and long hair away from any moving parts, to prevent them from getting caught.

• Lower any attachments to the ground before cleaning or servicing machine. Disengage all power and stop th e engine. Lock park brake and remove the key. Let machine cool.

• Securely support any machine elements that must be raised for service work. Use jack stands or lock service latches to support components when needed.

• Disconnect battery or remove spark plug wire (for gasoline engines) before making any repairs. Disconnect negative terminal first and positive last. Install positive terminal first and negative last.

• Before servicing machine or attachment, carefully release pressure from any components with stored energy, such as hydraulic components or springs.

• Keep all parts in good condition and properly installed. Fix damage immediately. Replace wo rn or broken parts.

• Charge batteri es i n an op en , we ll-ventila te d area, away from sparks. Unplug battery charger be fore connecting or disconnecting from the battery. Wear protectiv e clothing and u s e insulated tools.

• Do not str ike the flywheel with a hammer or hard object be cause the flywheel may later shatter during operation.

• If equipped with hydraulic lift - release hydraulic pressure by lowering attachment or cutting units to the ground or to a mechanical stop and move hydraulic control levers back and forth.

Avoid High Pressure Fluids

• Hydraulic hoses and lines can fail due to

physi cal damage, kinks, age, and exposure.

Check hoses and lines regularly. Replace

damaged hoses and line s.

• Hydraulic fluid connections can loosen due to physical damage and vibration. Check connections regularly. Tighten loose connections.

• Escaping fluid under pr essure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconne cting hydraulic or other lines. Tighten all connections before applying pressure.

• Search for leaks with a piece of cardboard. Protect hands a nd 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 s hould refere nce a knowled g ea ble me dical sourc e. S uc h inform a tion is available from D ee r e & Company Medical Department in Moline, Illinois, U.S.A. Information may be obta ined in the United States and Canada only by calling 1-800-822-

8262.

Safe ty - 12

SAFETY

Prevent Fires

• Besides routine maintenance, one of the best ways to keep your John Deere equipment running efficiently and to reduce fire risk is to regularly remove debris buildup from the machine.

• Please review these recommendations with all operators. See your John Deere dealer with

questions.

• Always follow all safety procedures posted on the machine and in this operator manual. Before carrying out any inspection or cleaning, always shut off engine, set parking brak e and remove ignition key.

• After op era ti n g, all o w mac hi ne to coo l in an ope n ar ea be fore cleanin g or storing. Do not park machine near flammable materials such as wood, cloth or chemicals.

• Empty any grasscatcher bags or containers completely before storing.

• Frequency of thes e inspect i on s an d cleanin g will vary de pe nd ing on a number of factors incl ud in g operatin g co nd it i on s, ma chine configurat ion, operating speeds and weather con ditions particularly dry, hot and windy conditions. When you are operating in these conditions, inspect and cl ean these areas frequently throughout the day.

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

• Debris can accumulate anywhere on the machine, especially on horizontal surfaces.

• Ke eping engine ar ea clean will provide the greatest impact on fire prevention. Other are as re qu iring reg ul ar ins p ec t io n an d cl eaning include behind wheel rims, wire harness, hose/line routings, mowing attachments, etc. Compressed air, leaf blowers or high pressured water can assist keeping these areas clean.

• Excess lubrication or fuel/oil leaks or spills on the machine can also serve as collection sites for debris. Prompt machine repair and oil/fuel cleanup will minimize the potential for debris collection and reduced cooling throughout machine life.

• Bearing failures or overheating can result in a fire. To reduc e this risk, always follow the instructions in the machine operator’s manual regarding lubrication intervals and locations. Washing the machine while warm may also reduce bearing life and increase potential for premature bearing failure.

• Always shut off fuel when storing or transpo rting machine, if the machine has a fuel sh utoff.

Handling Fuel Safely

To avoid personal injury or property dama ge, use extre me care in handling fuel. Fuel is extremely flam m able and fue l vapors are explosive:

• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Use only an approved fuel co nt ainer. Use only non-metal, portable fuel containers approved by the Underwriter’s Laboratory (U.L.) or the American Society for Testing & Materials (ASTM). If using a funnel, make sure it is plastic and has no screen or filter.

• Never remove the fuel tank cap or add fuel with the engine running. Allow engine to cool before refueling.

• Never add fuel to or drain fuel from the machine indoors. Move machine

outdoo rs and provid e adequate ventilation.

• Clean up spilled fuel immediately. If fuel is spilled on clothing, change clothing immediately. If fuel is spilled near machine, do not attempt to start the engine but move the machine away from the area of spillage. Avoid creating any source of ignition until fuel vapors have dissipated.

• Nev er store the machine or fuel container where there is an open flame , spark, or pilot light such as on a water heater or other appliance.

• Prevent fire and explosion caused by static electric di scharge. Static electric discharge can ignite fuel v apors in an ung rounded fuel c ontainer.

• Nev er fill containers inside a vehicle or on a truck or tra iler bed with a plasti c liner. Always place containers on the ground away from your vehicle before fueling.

• Remove fuel-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a fuel dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until the fuel ing is complete. Do not use a nozzle lockopen devi ce.

• Never overfill fuel tank. Replace fuel tank cap and tighten securely.

• Replace all fuel container caps securely after use.

• For gasoline engines, do not use gas with methanol. Methanol is harmful to your health and to the en vi ronment .

Tire Safety

Explos ive 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.

• 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 i nfl at i ng ti r es, u se a cl i p-o n c huc k an d e xt e nsi on hose l on g e noug h to allow you to stand to one side and NOT in front of or over the tire assembly.

• Check tires for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

Checking Wheel Hardware

• A serious accident could occur causing serious injury if wheel hardware is not tight.

• Check wheel hardware tightness often during the first 100 hours of operation.

• Wheel hardware must be tightened to specified torque using the proper procedure anytime i t is loosened.

Handling Waste Product and Chemicals

Waste products, such as, used oil, fuel, coolant, brake fluid, and batteries, can harm the environment and people:

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

• See your local Recycling Center or authorized dealer to learn how to recycle or get rid of waste products.

• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and

Safe ty - 13

MAC HINE CLEANOUT

emergency response techniques. The seller of the chemical products used with you r mac h in e is res ponsible for prov iding the MSDS for that product.

Machine Cleanout

Prevent Fires

• Besides routine maintenance, one of the best ways to keep your John Deere equipment running efficiently and to reduce fire risk is to regularly remove debris buildup from the machine.

• Please review these recommendations with all operators. See your John Deere de al er wit h que st ions.

• After op era ti n g, all o w mac hi ne to coo l in an ope n ar ea be fore cleanin g or storing. Do not park machine near flammable materials such as wood, cloth or chemicals.

• Empty any grasscatcher bags or containers completely before storing.

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

• Debris can accumulate anywhere on the machine, especially on horizontal surfaces.

• Primary area s th at mu st be in s pe ct ed an d cl ea ne d on the mach in e include (See Safety Label Section):

Picture Note: Single cylinder shown.

Picture Note: Twin cylinder shown.

a.Exhaust manifold (A), muffler pipe (B), muffler (C) and muffler shield (D).

MX48341

MX48340

Machine Cleanout - 14

MAC HINE CLEANOUT

Picture Note: Single cylinder shown.

c.Top of mower d eck, under shields (G), including spindle (H) and belt areas.

MX49847

MX49849

MX49848

Picture Note: Twin cylinder shown.

b.Engine intake screens (E), cooling fins (F), and oil cooler (if equipped).

MX38694

Picture Note: Shown with wheel removed.

d.On or near transmission (I) and driveline (J).

Machine Cleanout - 15

ASSEMBLY

MX49850

e.Under left side panel near fuse block (K), and all wiring, including the battery (L) and related wiring harnesses (M).

• Always shut off fuel when storing or transpo rting machine, if the machine has a fuel sh utoff.

battery terminal.

3. Charge the battery.

• Battery is fully charged at 12.6 volts.

MX46480

4. Connect positive (+) battery cable (A) to battery.

5. Connect negative (–) battery cable (B).

6. Apply general purpose grease or silicone spray to t erminal to help prevent corrosion.

7. Slide red cover (C) over positive battery cable.

Check Tire Pressure

Check tire pressure. (See Checking Tire Pressure in the SERVICE MISCELLANEOUS section.)

Adjust Mower Deck Level

Adjust mower deck level. (See Adjusting Mower Level in the OPERATING section.)

Check Engine Oil Level

Check engine oil level. (See Checking Engine Oil Level in the SERVICE ENGINE secti on.)

Assembly

Charge and Connect 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.

• Never check battery charge by placing a metal object across

the posts. Use a voltmete r or hydrome ter.

• Do not jump start or charge a frozen battery. Warm battery to 16°C (60°F).

1. Remove and discard the tie strap from the positive (+) battery terminal.

2. Remove and discard the black protective cap from the negative (–)

Assembly - 16

Check Machine Safety System

Perform safety system check to make sure the electronic safety interlock circuit is functioning properly. Perform all tests. (See Testing Safety System in t he OPERATING section.)

Break In Electric Engagement Clutch (If Equipped)

1. Start engine and move ma chine to flat level surface.

ASSEMBLY

MX49386

2. Push throttle lever (A) up to full thro tt le po sitio n.

3. Engage attachment engagement switch (B) and allow mower to run for 10 seconds.

4. Disengage attachment engagement switch and wait 10 seconds.

5. Repeat steps 3 and 4 for 12-15 cycles.

NOTE: Clutch is now properly burnished.

Assembly - 17

Operating Controls

OPERATING CONTROLS

Operator Station Controls (D105)

ABrake Pedal B Park Brake Lo ck Lever C Throttle/Choke Lever D Reverse Implement Option (RIO) Switch E Service Reminder/Hourmeter FKey Switch G Attachment Engagement Lever H Motio n Pedal I Deflector Shield J Transmissi on Shift Lever K Fuel Level Window L Attachment Lift Lever

MX51677

Operating Controls - 18

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